2001 Dakota / Durango Service Manual

GROUP TAB LOCATOR
Introduction
0
Lubrication & Maintenance
2
Suspension
3
Differential & Driveline
5
Brakes
6
Clutch
7
Cooling
8A
Audio
8B
Chime/Buzzer
8E
Electronic Control Modules
8F
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8J
Instrument Cluster
8L
Lamps
8M
Message Systems
8N
Power Systems
8O
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8W
Wiring
9
Engine
11
Exhaust System
13
Frame & Bumpers
14
Fuel System
19
Steering
21
Transmission and Transfer Case
22
Tires/Wheels
23
Body
24
Heating & Air Conditioning
25
Emissions Control
30
New Vehicle Preparation
Component and System Index
Service Manual Comment Forms (Rear of Manual)
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
VECI LABEL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BODY CODE PLATE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT IDENTIFICATION PLATE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INTERNATIONAL SYMBOLS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FASTENER IDENTIFICATION
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FASTENER USAGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
METRIC SYSTEM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE REFERENCES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehi cl e safety certi fi cati on l abel i s attached to
every Dai ml erChrysl er Corporati on vehi cl e. The l abel
certi fi es that the vehi cl e conforms to al l appl i cabl e
Federal Motor Vehi cl e Safety Standards. The l abel
al so l i sts:
Month and year of vehi cl e manufacture.
Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWRs) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
Vehi cl e I denti fi cati on Number (VI N).
Type of vehi cl e.
Type of rear wheel s.
Bar code.
Month, Day and Hour (MDH) of fi nal assembl y.
Pai nt and Tri m codes.
Country of ori gi n.
The l abel i s l ocated on the dri ver-si de door shut-
face (Fi g. 1).
Al l communi cati ons or i nqui ri es regardi ng the
vehi cl e shoul d i ncl ude the Month-Day-Hour and
Vehi cl e I denti fi cati on Number.
Fig. 1 Vehicle Safety Certification Label
AN INTRODUCTION 1
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
attached to the top l eft si de of the i nstrument panel
(Fi g. 2). The VI N contai ns 17 characters that provi de
data concerni ng the vehi cl e. Refer to the decodi ng
chart to determi ne the i denti fi cati on of a vehi cl e.
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1= USA
2 Make B = Dodge
3 Vehicle Type 7 = Truck
4 Gross Vehicle Weight Rating
F = 4001-5000 lbs.
G = 5001-6000 lbs.
H = 6001-7000 lbs.
5 Vehicle Line
G = Dakota
Dakota Sport
Dakota 4x4
L = Dakota
Dakota Sport
Dakota 4x2
6 Series
2 = Dakota
Dakota Sport
Dakota SLT
7 Body Style
2 = Club Cab
A = Quad Cab
6 = Conventional Cab
8 Engine
P = 2.5L
X = 3.9L
N=4.7L
Y = 5.2L
Z = 5.9L
9 Check Digit
10 Model Year 1=2001
11 Assembly Plant S = Warren Truck Assembly
12 Thru 17 Vehicle Build Sequence Assembly Sequence
Fig. 2 Vehicle Identification Number (VIN)
1 - VIN
2 INTRODUCTION AN
VECI LABEL
DESCRIPTION
Al l vehi cl es are equi pped wi th a combi ned VECI
l abel . Thi s l abel i s l ocated i n the engi ne compart-
ment (Fi g. 3).
The VECI l abel contai ns the fol l owi ng:
Engi ne fami l y and di spl acement
Evaporati ve fami l y
Emi ssi on control system schemati c
Certi fi cati on appl i cati on
Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
I dl e speeds (i f adjustabl e)
Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages. These l abel s are per-
manentl y attached and cannot be removed wi thout
defaci ng i nformati on and destroyi ng l abel .
BODY CODE PLATE
DESCRIPTION
LOCATION AND DECODING
A metal body code pl ate i s attached to the fl oor pan
under the passenger seat. Remove the passenger
seat, door si l l scuff pl ate and pul l back the carpet to
access the body code pl ate. There are seven l i nes of
i nformati on on the body code pl ate. Li nes 5, 6, and 7
are not used to defi ne servi ce i nformati on. I nforma-
ti on reads from l eft to ri ght, starti ng wi th l i ne 4 i n
the center of the pl ate to l i ne 1 at the bottom of the
pl ate (Fi g. 4).
The l ast code i mpri nted on a vehi cl e code pl ate wi l l
be fol l owed by the i mpri nted word END. When two
vehi cl e code pl ates are requi red, the l ast avai l abl e
spaces on the fi rst pl ate wi l l be i mpri nted wi th the
l etters CTD (for conti nued).
When a second vehi cl e code pl ate i s necessary, the
fi rst four spaces on each row wi l l not be used because
of the pl ate overl ap.
BODY CODE PLATE LINE 4
DIGITS 1 THROUGH 12
Vehi cl e Order Number
DIGITS 13, 14, AND 15
Open Space
Car Li ne Shel l
AN1 = Dakota 4 X 2
AN5 = Dakota 4 X 4
DIGIT 19
Pri ce Cl ass
L = Dakota (Al l )
DIGITS 20 AND 21
Body Type
31 = Dakota Cl ub Cab (130.9 i n. Wheel Base)
61 = Dakota (111.9 i n. Wheel Base)
62 = Dakota (123.9 i n. Wheel Base)
DIGITS 1, 2, AND 3
Pai nt Procedure
Fig. 3 VECI Label Location
1 - VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL
Fig. 4 Body Code
AN INTRODUCTION 3
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Pri mary Pai nt
Refer to Group 23, Body for col or codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Pai nt
DIGIT 14
Open Space
I nteri or Tri m Code
DIGIT 19
Open Space
Engi ne Code
EPE = 2.5 L 4 cyl . MPI Gasol i ne
EHC = 3.9 L 6 cyl . MPI Gasol i ne
ELF = 5.2 L 8 cyl . MPI Gasol i ne
ELM = 5.9 L 8 cyl . MPI Gasol i ne
DIGITS 1, 2, AND 3
Transmi ssi on Codes
DDK = 5Speed Manual (NVG 1500)
DDQ = 5Speed Manual (AX15)
DDC = 5Speed Manual (NVG 3500)
DGK = 4Speed Automati c (42RE)
DGW = 4Speed Automati c (44RE)
DGT = 4Speed Automati c (46RE)
DIGIT 4
Open Space
DIGIT 5
Market Code
B = I nternati onal
C = Canada
M = Mexi co
U = Uni ted States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number (VI N)
Refer to Vehi cl e I denti fi cati on Number (VI N) para-
graph for proper breakdown of VI N code.
DIGITS 1 THROUGH 6 Body-in-white assembly sequence.
DIGITS 7 THROUGH 9
Open Space
DIGITS 10 THROUGH 12 Cargo box code
XBS = Sweptl i ne
Open Space
EQUIPMENT IDENTIFICATION
PLATE
DESCRIPTION
The Equi pment I denti fi cati on Pl ate (Fi g. 5) i s
l ocated at the l eft, front of the i nner hood panel . The
pl ate l i sts i nformati on concerni ng the vehi cl e as fol -
l ows:
The model .
The wheel base.
The VI N (Vehi cl e I denti fi cati on Number).
The T.O.N. (order number).
The opti onal and speci al equi pment i nstal l ed on
the vehi cl e.
Refer to the i nformati on l i sted on the pl ate when
orderi ng repl acement parts.
DESCRIPTION
The graphi c symbol s i l l ustrated i n the fol l owi ng
I nternati onal Control and Di spl ay Symbol s Chart
(Fi g. 6) are used to i denti fy vari ous i nstrument con-
trol s. The symbol s correspond to the control s and di s-
pl ays that are l ocated on the i nstrument panel .
Fig. 5 Equipment Identification PlateTypical
4 INTRODUCTION AN
BODY CODE PLATE (Continued)
FASTENER IDENTIFICATION
GRADE/CLASS IDENTIFICATION
DESCRIPTION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 10.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on (Fi g. 7)
and Fastener Strength Charts (Fi g. 8).
FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fi gure art, speci fi cati ons and ti ghteni ng torque ref-
erences i n thi s manual are i denti fi ed i n metri c and
SAE format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage al l fasteners (nuts, bol ts, etc.)
for reassembl y. I f the fastener i s not sal vageabl e, a
fastener of equi val ent speci fi cati on must be use.
DESCRIPTION
Most stri pped threaded hol es can be repai red usi ng
a Hel i coi l . Fol l ow the manufacture recommendati on
for appl i cati on and repai r procedures.
Fig. 6 INTERNATIONAL SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
AN INTRODUCTION 5
INTERNATIONAL SYMBOLS (Continued)
Fig. 7 FASTENER IDENTIFICATION
6 INTRODUCTION AN
FASTENER USAGE (Continued)
Fig. 8 FASTENER STRENGTH
AN INTRODUCTION 7
FASTENER USAGE (Continued)
METRIC SYSTEM
DESCRIPTION
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on.
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
Refer to the Metri c Conversi on Chart (Fi g. 9) to
convert torque val ues l i sted i n metri c Newton-
meters (Nm). Al so, use the chart to convert between
mi l l i meters (mm) and i nches (i n.)
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters (Nm) Nm x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (Nm) Nm x 0.7376 = ft-lbs
Inches Hg
(60F)
x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/
Hr. (Km/h)
x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
(Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
8 INTRODUCTION AN
Fig. 9 METRIC CONVERSION CHART
AN INTRODUCTION 9
METRIC SYSTEM (Continued)
TORQUE REFERENCES
DESCRIPTION
I ndi vi dual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Speci fi -
cati ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts (Fi g. 10).
Fig. 10 TORQUE SPECIFICATIONS
10 INTRODUCTION AN
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PARTS & LUBRICANT
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 2
CLASSIFICATION OF LUBRICANTS. . . . . . . . . . 2
FLUID TYPES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLUID FILL/CHECK LOCATIONS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MAINTENANCE SCHEDULES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HOISTING
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12
HOISTING RECOMMENDATIONS. . . . . . . . . . . 12
JUMP STARTING
JUMP STARTING PROCEDURE. . . . . . . . . . . . 12
TOWING
TOWING RECOMMENDATIONS. . . . . . . . . . . . 13
TWO WHEEL DRIVE VEHICLE TOWING . . . . . 14
FOUR WHEEL DRIVE VEHICLE TOWING. . . . . 15
LUBRICATION &
MAINTENANCE
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 2-Door: 83L (22 U.S.
Gallons)****
4-Door: 91L (24 U.S.
Gallons)****
ENGINE OIL - WITH FILTER
2.5L Engine 4.3L (4.5 qts.)
COOLING SYSTEM
2.5L Engine 9.3L (9.8 qts.)***
3.9L Engine 13.3L (14.0 qts.)***
4.7L Engine 12.3L (13.0 qts.)***
5.9L Engine 13.7L (14.6 qts.)***
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8L (4.0 qts)
O-haul Fill - 42RE 9.1-9.5L (19-20 pts)
Service Fill - 46RE 3.8L (4.0 qts)
O-haul Fill - 46RE 9.1-9.5L (19-20 pts)
O-haul Fill - 45RFE 13.33L (28.0 pts)
MANUAL TRANSMISSION
NV3500 2.28L (4.8 pts.)
TRANSFER CASE
NV233 1.18L (2.5 pts.)
NV244 1.35L (2.85 pts.)
FRONT AXLE
C205F 1.66L (3.5 pts.)
REAR AXLE
9 1/4 2.32L (4.9 pts.)**
8 1/4 2.22L (4.7 pts.)**
** When equipped with Trac-lok, include 148 ml (5
oz.) of Friction Modifier.
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
AN LUBRICATION & MAINTENANCE 0 - 1
DESCRIPTION
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
PARTS & LUBRICANT
STANDARD PROCEDURE CLASSIFICATION OF
LUBRICANTS
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used to servi ce a
Dai ml erChrysl er Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range.
SAE 30 = si ngl e grade engi ne oi l .
SAE 10W-30 = mul ti pl e grade engi ne oi l .
Dai ml erChrysl er Corporati on onl y recommends
mul ti pl e grade engi ne oi l s.
API QUALITY CLASSIFICATION This symbol (Fig. 2) on the
front of an oil container means that the oil has been
certified by the American Petroleum Institute (API) to meet
all the lubrication requirements specified by
DailmlerChrysler Corporation.
Refer to Group 9, Engi ne for gasol i ne engi ne oi l
speci fi cati on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti pl e grade gear
l ubri cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
SPECIALIZED LUBRICANTS AND OILS
Some mai ntenance or repai r procedures may
requi re the use of speci al i zed l ubri cants or oi l s. Con-
sul t the appropri ate secti ons i n thi s manual for the
correct appl i cati on of these l ubri cants.
Fig. 1 International Symbols
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCE AN
RECOMMENDATIONS
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar brand parts,
l ubri cants and chemi cal s be used. Mopar provi des
the best engi neered products for servi ci ng Dai ml er-
Chrysl er Corporati on vehi cl es.
FLUID TYPES
DESCRIPTION - FUEL REQUIREMENTS
Your engi ne i s desi gned to meet al l emi ssi ons reg-
ul ati ons and provi de excel l ent fuel economy and per-
formance when usi ng hi gh qual i ty unl eaded regul ar
gasol i ne havi ng an octane rati ng of 87. The routi ne
use of premi um gasol i ne i s not recommended. Under
normal condi ti ons the use of premi um fuel wi l l not
provi de a benefi t over hi gh qual i ty regul ar gasol i nes
and i n some ci rcumstances may resul t i n poorer per-
formance.
Li ght spark knock at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
i mmedi ate servi ce i s requi red. Engi ne damage resul t-
i ng from operati on wi th a heavy spark knock may
not be covered by the new vehi cl e warranty.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng and hesi tati ons. I f you experi -
ence these symptoms, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
Over 40 auto manufacturers worl d-wi de have
i ssued and endorsed consi stent gasol i ne speci fi cati ons
(the Worl dwi de Fuel Charter, WWFC) to defi ne fuel
properti es necessary to del i ver enhanced emi ssi ons,
performance and durabi l i ty for your vehi cl e. We rec-
ommend the use of gasol i nes that meet the WWFC
speci fi cati ons i f they are avai l abl e.
REFORMULATED GASOLINE
Many areas of the country requi re the use of
cl eaner burni ng gasol i ne referred to as reformul at-
ed gasol i ne. Reformul ated gasol i ne contai n oxygen-
ates, and are speci fi cal l y bl ended to reduce vehi cl e
emi ssi ons and i mprove ai r qual i ty.
We strongl y support the use of reformul ated gaso-
l i ne. Properl y bl ended reformul ated gasol i ne wi l l pro-
vi de excel l ent performance and durabi l i ty for the
engi ne and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
oxygenates such as 10% ethanol , MTBE, and ETBE.
Oxygenates are requi red i n some areas of the country
duri ng the wi nter months to reduce carbon monoxi de
emi ssi ons. Fuel s bl ended wi th these oxygenates may
be used i n your vehi cl e.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT i s a manganese-contai ni ng metal l i c addi ti ve
that i s bl ended i nto some gasol i ne to i ncrease octane.
Gasol i ne bl ended wi th MMT provi de no performance
advantage beyond gasol i ne of the same octane num-
ber wi thout MMT. Gasol i ne bl ended wi th MMT
reduce spark pl ug l i fe and reduce emi ssi on system
performance i n some vehi cl es. We recommend that
gasol i nes free of MMT be used i n your vehi cl e. The
MMT content of gasol i ne may not be i ndi cated on the
gasol i ne pump; therefore, you shoul d ask your gaso-
l i ne retai l er whether or not hi s/her gasol i ne contai ns
MMT.
I t i s even more i mportant to l ook for gasol i ne wi th-
out MMT i n Canada because MMT can be used at
l evel s hi gher than al l owed i n the Uni ted States.
MMT i s prohi bi ted i n Federal and Cal i forni a refor-
mul ated gasol i ne.
SULFUR IN GASOLINE
I f you l i ve i n the northeast Uni ted States, your
vehi cl e may have been desi gned to meet Cal i forni a
l ow emi ssi on standards wi th Cl eaner-Burni ng Cal i -
forni a reformul ated gasol i ne wi th l ow sul fur. I f such
fuel s are not avai l abl e i n states adopti ng Cal i forni a
emi ssi on standards, your vehi cl es wi l l operate sati s-
factori l y on fuel s meeti ng federal speci fi cati ons, but
emi ssi on control system performance may be
adversel y affected. Gasol i ne sol d outsi de of Cal i forni a
i s permi tted to have hi gher sul fur l evel s whi ch may
affect the performance of the vehi cl es catal yti c con-
verter. Thi s may cause the Mal functi on I ndi cator
Lamp (MI L), Check Engi ne or Servi ce Engi ne Soon
l i ght to i l l umi nate. We recommend that you try a di f-
ferent brand of unl eaded gasol i ne havi ng l ower sul fur
to determi ne i f the probl em i s fuel rel ated pri or to
returni ng your vehi cl e to an authori zed deal er for
servi ce.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
Al l gasol i ne sol d i n the Uni ted States and Canada
are requi red to contai n effecti ve detergent addi ti ves.
Use of addi ti onal detergents or other addi ti ves i s not
needed under normal condi ti ons.
PARTS & LUBRICANT (Continued)
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicles performance:
The use of l eaded gas i s prohi bi ted by Federal
l aw. Usi ng l eaded gasol i ne can i mpai r engi ne perfor-
mance, damage the emi ssi on control system, and
coul d resul t i n l oss of warranty coverage.
An out-of-tune engi ne, or certai n fuel or i gni ti on
mal functi ons, can cause the catal yti c converter to
overheat. I f you noti ce a pungent burni ng odor or
some l i ght smoke, your engi ne may be out of tune or
mal functi oni ng and may requi re i mmedi ate servi ce.
Contact your deal er for servi ce assi stance.
When pul l i ng a heavy l oad or dri vi ng a ful l y
l oaded vehi cl e when the humi di ty i s l ow and the tem-
perature i s hi gh, use a premi um unl eaded fuel to
hel p prevent spark knock. I f spark knock persi sts,
l i ghten the l oad, or engi ne pi ston damage may resul t.
The use of fuel addi ti ves whi ch are now bei ng
sol d as octane enhancers i s not recommended. Most
of these products contai n hi gh concentrati ons of
methanol . Fuel system damage or vehi cl e perfor-
mance probl ems resul ti ng from the use of such fuel s
or addi ti ves i s not the responsi bi l i ty of Dai ml er-
Chrysl er Corporati on and may not be covered under
the new vehi cl e warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37C (-35F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Mopar Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149C
(300F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37C (-34F). The anti freeze concentrati on
must alwaysbe a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
FLUID TYPES (Continued)
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7C (-90F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicles coolant bottle cap to
identify HOAT or Non-HOAT coolant. Non-HOAT
coolant is green in color.
heads and water pumps requi res speci al corrosi on
protecti on. Onl y Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (gl ycol base cool ant wi th
corrosi on i nhi bi tors cal l ed HOAT, for Hybri d Organi c
mi xed wi th 50% di sti l l ed water to obtai n to obtai n a
freeze poi nt of -37C (-35F). I f i t l oses col or or
becomes contami nated, drai n, fl ush, and repl ace wi th
fresh properl y mi xed cool ant sol uti on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conform to
thi s servi ce grade.
SAE VISCOSITY
cosi ty of engi ne oi l . Use onl y engi ne oi l s wi th mul ti -
pl e vi scosi ti es such as 5W-30 or 10W-30. These are
speci fi ed wi th a dual SAE vi scosi ty grade whi ch i ndi -
cates the col d-to-hot temperature vi scosi ty range.
Sel ect an engi ne oi l that i s best sui ted to your par-
ti cul ar temperature range and vari ati on (Fi g. 4) and
(Fi g. 5).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 6).
Thi s symbol on the front of an oi l contai ner means
that the oi l has been certi fi ed by the Ameri can Petro-
l eum I nsti tute (API ) to meet al l the l ubri cati on
requi rements speci fi ed by Dai ml erChrysl er.
Fig. 4 Temperature/Engine Oil Viscosity
Fig. 5 Temperature/Engine Oil Viscosity
DESCRIPTION - TRANSFER CASE - NV233
Recommended l ubri cant for the NV233 transfer
case i s Mopar ATF +4, type 9602, Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - TRANSFER CASE - NV244
Recommended l ubri cant for the NV244 transfer
case i s Mopar ATF +4, type 9602, Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - AXLE
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
FRONT AXLE
The l ubri cant shoul d have MI L-L-2105C and
API GL 5 qual i ty speci fi cati ons.
Lubri cant i s a thermal l y stabl e SAE 80W-90
gear l ubri cant.
REAR AXLE
The l ubri cant shoul d have MI L-L-2105C and
API GL 5 qual i ty speci fi cati ons.
8 1/4 axl e l ubri cant i s a thermal l y stabl e SAE
80W-90 gear l ubri cant.
9 1/4 axl e l ubri cant i s a thermal l y stabl e SAE
75W-90 gear l ubri cant.
NOTE: Trac-lok equipped axles require a friction
modifier be added to the lubricant.
DESCRIPTION - MANUAL TRANSMISSION
Mopar Manual Transmi ssi on Lubri cant i s the
onl y l ubri cant recommended for use i n the manual
transmi ssi ons.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopar ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d i s the recommended fl ui d for Dai ml er-
Chrysl er automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d when new i s red i n col or. The ATF i s dyed
red so i t can be i denti fi ed from other fl ui ds used i n
the vehi cl e such as engi ne oi l or anti freeze. The red
col or i s not permanent and i s not an i ndi cator of fl ui d
condi ti on. As the vehi cl e i s dri ven, the ATF wi l l begi n
to l ook darker i n col or and may eventual l y become
brown. This is normal. A dark brown/bl ack fl ui d
accompani ed wi th a burnt odor and/or deteri orati on
i n shi ft qual i ty may i ndi cate fl ui d deteri orati on or
transmi ssi on component fai l ure.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous speci al addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on seal ers shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
Fig. 6 Engine Oil Container Standard Notations
FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fl ui d check/fi l l poi nts and l ubri cati on l ocati ons
are l ocated i n each appl i cabl e Secti ons.
DESCRIPTION
Servi ce and mai ntenance procedures for compo-
nents and systems l i sted i n Schedul e A or B can
be found by usi ng the Group Tab Locator i ndex at
the front of thi s manual . I f i t i s not cl ear whi ch
group contai ns the i nformati on needed, refer to the
i ndex at the back of thi s manual .
There are two mai ntenance schedul es that show
proper servi ce based on the condi ti ons that the vehi -
cl e i s subjected to.
Schedul e A, l i sts schedul ed mai ntenance to be
performed when the vehi cl e i s used for general trans-
portati on.
Schedul e B, l i sts mai ntenance i nterval s for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of that schedul e secti on.
Use the schedul e that best descri bes the dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
There are two mai ntenance schedul es that show
proper servi ce for the Dakota.
Fi rst i s Schedul e A. I t l i sts al l the schedul ed
mai ntenance to be performed under normal operat-
i ng condi ti ons.
Second i s Schedul e B. I t i s a schedul e for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of that schedul e.
Use the schedul e that best descri bes the dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
At Each Stop For Gasoline
Check engi ne oi l l evel , add as requi red.
Check wi ndshi el d washer sol vent and add i f
requi red.
Cl ean wi ndshi el d and wi per bl ades as requi red.
Once A Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect battery and cl ean and ti ghten termi nal s
as requi red.
Check fl ui d l evel s of cool ant reservoi r, power
steeri ng and transmi ssi on and add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
I nspect and cl ean wi per bl ades. Repl ace i f
requi red.
At Each Oil Change
I nspect exhaust system.
I nspect brake hoses.
Rotate the ti res at each oi l change i nterval
shown on Schedul e A: (7,500 mi l es) or every other
i nterval shown on Schedul e B (6,000 mi l es).
Check engi ne cool ant l evel , hoses, and cl amps.
EMISSION CONTROL SYSTEM MAINTENANCE
The schedul ed emi ssi on mai ntenance l i sted i n bold
type on the Mai ntenance Schedul es, must be done at
the mi l eage speci fi ed to assure the conti nued proper
functi oni ng of the emi ssi on control system. These,
and al l other mai ntenance servi ces i ncl uded i n thi s
manual , shoul d be done to provi de the best vehi cl e
performance and rel i abi l i ty. More frequent mai nte-
nance may be needed for vehi cl es i n severe operati ng
condi ti ons such as dusty areas and very short tri p
dri vi ng.
FLUID FILL LOCATIONS AND LUBRICATION
POINTS
The fl ui d fi l l /check l ocati ons and l ubri cati on poi nts
are l ocated i n each appl i cabl e group.
SCHEDULE A
7,500 Miles (12 000 km) or at 6 months
Change engi ne oi l .
Repl ace engi ne oi l fi l ter.
Lubri cate front suspensi on bal l joi nts i f
requi red.
I nspect front wheel beari ngs.
I nspect brake l i ni ngs.
Replace engine air cleaner element.
Replace spark plugs.
Drai n and refi l l automati c transmi ssi on fl ui d
and change fi l ter (4.7L onl y).
Drai n and refi l l transfer case fl ui d.
Drai n and refi l l automati c transmi ssi on fl ui d.
Repl ace fi l ter and adjust bands (3.9L, and 5.9L onl y).
requi red.
Fl ush and repl ace engi ne cool ant at 36 months,
regardl ess of mi l eage.
Fl ush and repl ace engi ne cool ant i f not done at
36 months.
Replace ignition cables (2.5L, 3.9L, 5.9L).
Inspect PCV valve, replace as necessary.
(3.9L, 4.7L, and 5.9L)*
I nspect auto tensi on dri ve bel t and repl ace i f
requi red (3.9L, & 5.9L).
I nspect and adjust tensi on on dri ve bel t (2.5L).
requi red.
Repl ace fi l ter and adjust bands (3.9L & 5.9L).
Drai n and refi l l transfer case.
Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
requi red (3.9L, & 5.9L).
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
(3.9L, 4.7L, and 5.9L)*
requi red.
requi red (3.9L, 4.7L, & 5.9L).
30,000 Mi l es (48 000km) or 24 months si nce l ast
change.
requi red (3.9L, 4.7L, & 5.9L).
Repl ace fi l ter and adjust bands (3.9L & 5.9L onl y).
requi red.
30,000 Mi l es (48 000km) or 24 months si nce l ast
change.
Replace ignition cables (2.5L, 3.9L & 5.9L).
MAINTENANCE SCHEDULES (Continued)
(3.9L, 4.7L, and 5.9L)*
requi red (3.9L, 4.7L, & 5.9L).
*Thi s mai ntenance i s recommended by Dai ml er-
Chrysl er Corporati on to the owner but i s not
requi red to mai ntai n the warranty on the PCV val ve.
Thi s mai ntenance i s not requi red i f the bel t was
previ ousl y repl aced.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
SCHEDULE B
Use schedul e B i f the vehi cl e i s usual l y operated
under the fol l owi ng condi ti ons:
Frequent short tri p dri vi ng l ess than 5 mi l es (8
km)
Frequent dri vi ng i n dusty condi ti ons
Trai l er towi ng
Extensi ve i dl i ng
More than 50% of the dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 90F (32C)
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
requi red.
Change rear axl e fl ui d.
Change front axl e fl ui d (4x4).
15,000 Miles (24 000 km)
Inspect engine air cleaner element, replace
as necessary.
18,000 Miles (29 000 km)
Drai n and refi l l manual transmi ssi on fl ui d (3.9L
onl y).
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
requi red.
27,000 miles (43 000 km)
30,000 Miles (48 000 km)
(3.9L, 4.7L and 5.9L)*
I nspect and adjust dri ve tensi on on dri ve bel t
(2.5L).
33,000 Miles (53,000 km)
36,000 Miles (58 000 km)
requi red.
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
as necessary.
48,000 Miles (77 000 km)
requi red.
51,000 Miles (82 000 km)
Fl ush and repl ace engi ne cool ant.
54,000 Miles (86 000 km)
Drai n and refi l l manual transmi ssi on fl ui d (3.9L
onl y).
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
Replace ignition cables.
(3.9L, 4.7L, and 5.9L)*
requi red.
requi red (3.9L & 5.9L).
63,000 Miles (101 000 km)
66,000 Miles (106,000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
requi red.
75,000 Miles (120 000 km)
as necessary.
requi red (3.9L, 4.7L & 5.9L).
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
30,000 mi l es (48 000 km) si nce l ast change.
84,000 Miles (134 000 km)
requi red.
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
(3.9L, 4.7L, and 5.9L)*
requi red (3.9L, 4.7L, & 5.9L).
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
requi red.
99,000 Miles (158 000 km)
Change engi ne oi l
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
as necessary.
requi red (3.9L, 4.7L, & 5.9L).
108,000 Miles (173 000 km)
requi red.
111,000 Miles (178 000 km)
30,000 mi l es (48 000 km) si nce l ast change.
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
Replace ignition cables.
(3.9L, 4.7L, and 5.9L)*
requi red.
requi red (3.9L, 4.7L, & 5.9L).
*Thi s mai ntenance i s recommended by Chrysl er
Corporati on to the customer but i s not requi red to
mai ntai n warranty on the PCV val ve.
Thi s mai ntenance i s not requi red i f the bel t was
previ ousl y repl aced.
Prol onged operati on wi th heavy l oadi ng, espe-
ci al l y i n hot weather, use of vehi cl e for off-the-hi gh-
way operati on, and trai l er towi ng requi re the more
frequent transmi ssi on servi ce i ndi cated wi th a i n
Schedul e B. Perform these servi ces i f the vehi cl e i s
usual l y operated under these condi ti ons.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
HOISTING
STANDARD PROCEDURE HOISTING
RECOMMENDATIONS
FLOOR JACK
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
An axle tube.
Aluminum differential.
A body side sill.
A steering linkage component.
A drive shaft.
The engine or transmission oil pan.
The fuel tank.
A front suspension arm.
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Dakota vehi cl e (Fi g. 7). Support the vehi cl e
i n the rai sed posi ti on wi th jack stands at the front
and rear ends of the frame rai l s.
HOIST
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
CAUTION: DO NOT LET THE REAR WHEELS/AXLE
HANG UNSUPPORTED WHEN THE VEHICLE IS
LIFTED WITH THE PARKING BRAKE APPLIED.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 7).
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
J UMP STARTING
STANDARD PROCEDURE JUMP STARTING
PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
Fig. 7 Correct Vehicle Lifting LocationsTypical
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, park the booster vehi cl e wi thi n cabl e reach.
Turn off al l accessori es, set the parki ng brake, pl ace
the automati c transmi ssi on i n PARK or the manual
transmi ssi on i n NEUTRAL and turn the i gni ti on
OFF.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e (Fi g. 8).
(6) Start the engi ne i n the vehi cl e whi ch has the
booster battery, l et the engi ne i dl e a few mi nutes,
then start the engi ne i n the vehi cl e wi th the di s-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING
STANDARD PROCEDURE TOWING
RECOMMENDATIONS
A vehi cl e equi pped wi th an SAE approved Wheel -
l i ft towi ng devi ce can be used to tow al l Short Bed
DAKOTA vehi cl es. Long Bed vehi cl es must be towed
wi th a Fl at-bed devi ce (Fi g. 9). When towi ng a 4WD
vehi cl e, use tow dol l i es under the opposi te end of the
vehi cl e.
Fig. 8 Jumper Cable Clamp Connections
1 - ENGINE GROUND
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE
4 - POSITIVE JUMPER CABLE
5 - BATTERY POSITIVE CABLE
6 - BATTERY
7 - TEST INDICATOR
Fig. 9 Tow Vehicles With Approved Equipment
J UMP STARTING (Continued)
SAFETY PRECAUTIONS
NOTE: The following safety precautions must be
observed when towing a vehicle.
Secure l oose and protrudi ng parts.
Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl es fuel tank.
Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
Do not attach tow chai ns, T-hooks, or J-hooks to
a bumper, steeri ng l i nkage, dri ve shafts or a non-re-
i nforced frame hol e.
Do not tow a heavi l y l oaded vehi cl e. Damage to
the cab, cargo box or frame may resul t. Use a fl at
bed devi ce to transport a l oaded vehi cl e.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be
sure there i s adequate ground cl earance at the oppo-
si te end of the vehi cl e, especi al l y when towi ng over
rough terrai n or steep ri ses i n the road. I f necessary,
remove the wheel s from the l i fted end of the vehi cl e
and l ower the vehi cl e cl oser to the ground, to
i ncrease the ground cl earance at the opposi te end of
the vehi cl e. I nstal l l ug nuts on wheel attachi ng studs
to retai n brake drums.
RAMP ANGLE
I f a vehi cl e wi th fl at bed towi ng equi pment i s used,
the approach ramp angl e shoul d not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehi cl e i s l ocked and keys are not avai l -
abl e, use a fl at bed haul er. A Sl i ng-type devi ce can be
used on 4WD vehi cl es provi ded all the wheels are
lifted off the ground using tow dollies.
STANDARD PROCEDURE TWO WHEEL DRIVE
VEHICLE TOWING
TOWING-REAR END LIFTED
CAUTION:
Short bed vehicles must be towed with a Wheel-lift
device (Fig. 10) or transported on a flat bed (Fig.
11). Long bed vehicles must be transported on a
flat bed.
2WD vehi cl es can be towed wi th the front wheel s
on the surface for extended di stances at speeds not
exceedi ng 48 km/h (30 mph).
(1) Attach wheel l i ft devi ce to rear wheel s.
(2) Attach safety chai ns to frame rai l s. Route
chai ns so not to i nterfere wi th tai l pi pe when vehi cl e
i s l i fted.
(3) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(4) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(5) Veri fy that steeri ng components are i n good
condi ti on.
(6) Shi ft the transmi ssi on to NEUTRAL.
TOWING-FRONT END LIFTED
When l i fti ng from the front end, al l vehi cl es must
be towed wi th a Wheel -l i ft devi ce or transported on a
fl at bed.
(1) Attach Wheel -l i ft devi ce to front wheel s.
Fig. 10 Short Bed Vehicle TowingTypical
Fig. 11 Long Bed Vehicle TowingTypical
TOWING (Continued)
(2) Attach the safety chai ns to the di sabl ed vehi cl e
at the frame rai l s.
TWO WHEEL DRIVE MANUAL AND AUTOMATIC
TRANSMISSION
Provi ded the transmi ssi on i s operabl e, tow onl y i n
NEUTRAL at speeds not to exceed 30 mph (50
km/h) and di stances l ess than 15 mi l es (25km/h).
I f the vehi cl e i s to be towed more than 15 mi l es,
the propel l er shaft shoul d be di sconnected or pl ace
tow dol l i es under rear wheel s.
STANDARD PROCEDURE FOUR WHEEL
DRIVE VEHICLE TOWING
FOUR WHEEL DRIVE TOWING REAR END LIFTED
CAUTION:
Short bed vehicles must be towed with a Wheel-lift
device (Fig. 10) or transported on a flat bed. Long
bed vehicles must be transported on a flat bed (Fig.
11). When using a Wheel-lift device, all wheels must
be lifted off the ground using tow dollies.
(1) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(2) Attach wheel l i ft devi ce to rear wheel s.
(3) Attach safety chai ns to frame rai l s. Route
chai ns so not to i nterfere wi th tai l pi pe when vehi cl e
i s l i fted.
(5) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(6) Shi ft the transfer case to NEUTRAL.
FOUR WHEEL DRIVE TOWING FRONT END
LIFTED
When l i fti ng from the front end, al l vehi cl es must
be towed wi th a wheel -l i ft devi ce or transported on a
fl at bed.
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(2) Attach wheel l i ft devi ce to front wheel s.
(3) Attach the safety chai ns to the di sabl ed vehi cl e
at the frame rai l s.
(5) Shi ft the transfer case to NEUTRAL.
TOWING (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRONT - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2
PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . . 2
HEIGHT MEASUREMENT 4WD . . . . . . . . . . . . . 3
HEIGHT ADJUSTMENT 4WD . . . . . . . . . . . . . . . 3
CAMBER AND CASTER ADJUSTMENT . . . . . . . 4
CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEEL ALIGNMENT
DESCRIPTION
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe (Fi g. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e forward provi des negati ve caster. Ti l ti ng the
top of the knuckl e rearward provi des posi ti ve caster.
Posi ti ve caster promotes di recti onal stabi l i ty. Thi s
angl e enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns (Fi g. 2).
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Fig. 1 Wheel Alignment Measurements
1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
4 - TOE-IN
AN SUSPENSION 2 - 1
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re (Fi g. 2).
TOE i s the di fference between the l eadi ng i nsi de
edges and trai l i ng i nsi de edges of the front ti res.
Wheel toe posi ti on out of speci fi cati on causes unsta-
bl e steeri ng, uneven ti re wear and steeri ng wheel off-
center. The wheel toe posi ti on i s the final front
wheel al i gnment adjustment (Fi g. 2).
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e (Fi g. 2).
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
INSPECTION
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on and necessary correcti ons must be com-
pl eted. Refer to Suspensi on and Steeri ng System
Di agnosi s Chart for addi ti onal i nformati on.
(1) I nspect ti res for si ze, ai r pressure and tread
wear.
(2) I nspect front wheel beari ngs for wear.
(3) I nspect front wheel s for excessi ve radi al or l at-
eral runout and bal ance.
(4) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(5) I nspect suspensi on components for wear and
noi se.
(6) On 4x4 vehi cl es check suspensi on hei ght.
(7) Road test the vehi cl e.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
3. Lower ball joint (4x4). 3. Gease joint and perform diagnosis and
testing.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
Fig. 2 Wheel Alignment
1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
4 - TOE-IN
2 - 2 WHEEL ALIGNMENT AN
WHEEL ALIGNMENT (Continued)
VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Column coupler binding. 2. Replace coupler.
VEHICLE PULLS TO ONE
SIDE
necessary.
4. Radial tire lead. 4. Rotate or replace tire as necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
7. Ride height 4WD only. 7. Measure and adjust ride height.
STANDARD PROCEDURE - HEIGHT
MEASUREMENT 4WD
The vehi cl e suspensi on hei ght must be measured
and adjusted i f necessary before performi ng wheel
al i gnment on a 4x4 vehi cl e. Al so when front suspen-
si on components have be repl aced. Thi s measure
must be performed wi th the vehi cl e supporti ng i ts
own wei ght and taken on both si des of the vehi cl e.
(1) I nspect ti res for the correct si ze and ai r pres-
sure.
(2) Jounce the front of the vehi cl e.
(3) Measure and record the di stance between the
ground and the center of the l ower suspensi on arm
rear mounti ng bol t head (Fi g. 3).
(4) Measure and record the di stance between the
ground and the center of the front wheel (Fi g. 3).
(5) Subtract the fi rst measurement from the sec-
ond measurement. The di fference between the two
measurement shoul d be 47 mm (1.85 i nches) 3.25
mm (0.125 i nches).
STANDARD PROCEDURE - HEIGHT
ADJUSTMENT 4WD
The vehi cl e suspensi on hei ght must be measured
and adjusted i f necessary before performi ng wheel
al i gnment on a 4x4 vehi cl e. Al so when front suspen-
si on components have be repl aced. Thi s measure
must be performed wi th the vehi cl e supporti ng i ts
own wei ght and taken on both si des of the vehi cl e.
To adjust the vehi cl e hei ght turn the torsi on bar
adjustment bol t CLOCKWI SE to rai se the vehi cl e
and COUNTER CLOCKWI SE to l ower the vehi cl e.
Fig. 3 Height
AN WHEEL ALIGNMENT 2 - 3
CAUTION: ALWAYS raise the vehicle to the correct
suspension height, NEVER lower the vehicle to
obtain the correct suspension height. If the vehicle
suspension height is too high, lower the vehicle
below the height specification. Then raise the vehi-
cle to the correct suspension height specification.
This will insure the vehicle maintains the proper
suspension height.
NOTE: If a height adjustment has been made, per-
form height measurement again on both sides of
the vehicle.
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT
NOTE: 4x4 suspension height measurement must
be performed before alignment.
Camber and caster angl e adjustments i nvol ve
changi ng the posi ti on of the upper suspensi on arm
pi vot bar (Fi g. 4).
NOTE: On 4x2 vehicles use Alignment Tool 8393 for
alignment. The tool attaches to the pivot bar on the
upper control arm.
STANDARD PROCEDURE - CASTER
Movi ng the rear posi ti on of the pi vot bar i n or out,
wi l l change the caster angl e si gni fi cantl y and camber
angl e onl y sl i ghtl y. To mai ntai n the camber angl e
whi l e adjusti ng caster, move the rear of the pi vot bar
i n or out. Then move the front of the pi vot bar
sl i ghtl y i n the opposi te di recti on.
For exampl e, to i ncrease a posi ti ve caster angl e,
move the rear posi ti on of the pi vot bar i nward
(toward the engi ne). Move the front of pi vot bar out-
ward (away from the engi ne) sl i ghtl y unti l the ori gi -
nal camber angl e i s obtai ned.
STANDARD PROCEDURE - CAMBER
Move the front of the pi vot bar i n or out. Thi s wi l l
change the camber angl e si gni fi cantl y and caster
angl e sl i ghtl y.
After adjustment i s made ti ghten the pi vot bar
nuts to proper torque speci fi cati on.
STANDARD PROCEDURE - TOE ADJUSTMENT
The wheel toe posi ti on adjustment i s the fi nal
adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the ti e rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
Fig. 4 Caster & Camber Adjustment-Typical
1 - PIVOT BAR
2 - + CASTER
3 - + CAMBER
4 - UPPER ARM SUSPENSION
2 - 4 WHEEL ALIGNMENT AN
(3) Adjust the wheel toe posi ti on by turni ng the ti e
rod as necessary (Fi g. 5).
(4) Ti ghten the ti e rod jam nut to 75 Nm (55 ft.
l bs.).
(5) Veri fy the speci fi cati ons.
(6) Turn off engi ne.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
VEHICLE WHEEL BASE CASTER ( 0.50) CAMBER ( 0.50)
TOTAL TOE (
0.06)
4x2
111.9 2.99 0.25 0.10
130.9 3.13 0.25 0.10
4x4
111.9 3.16 0.25 0.10
130.9 3.27 0.25 0.10
MAXIMUM RT to LT DIFFERENCE 0.50 0.50 0.06
DAKOTA RT
VEHICLE WHEEL BASE CASTER ( 0.50) CAMBER ( 0.50) TOTAL TOE ( 0.06)
4x2
111.9 3.67 0.34 0.10
130.9 3.81 0.34 0.10
MAXIMUM RT to LT DIFFERENCE 0.50 0.50 0.06
Fig. 5 Toe
1 - JAM NUT
2 - TIE ROD
3 - TIE ROD END
AN WHEEL ALIGNMENT 2 - 5
FRONT - 2WD
TABLE OF CONTENTS
page page
FRONT - 2WD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BUSHINGS - CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HUB / BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
KNUCKLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOWER BALL JOINT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 10
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 10
LOWER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SHOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPRING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STABILIZER BAR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
UPPER BALL JOINT
UPPER BALL JOINT. . . . . . . . . . . . . . . . . . . . . 13
UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT - 2WD
DESCRIPTION - 2WD
The front suspensi on i s desi gned to al l ow each
wheel to adapt to di fferent road surfaces i ndepen-
dentl y. The wheel s are mounted to hub beari ngs on
the cast i ron steeri ng knuckl e spi ndl es. The doubl e-
row hub beari ngs are seal ed and l ubri cated for l i fe.
The steeri ng knuckl es turn (pi vot) on bal l joi nts ri v-
eted to the outboard porti on of the suspensi on arms.
The bal l joi nts are l ubri cated for l i fe.
The 4x2 front suspensi on i s compri sed of (Fi g. 1):
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
Shock absorbers
Coi l spri ngs
Suspensi on arms
Stabi l i zer bar
Jounce/Rebound Bumpers
Steeri ng Knuckl e
Hub/Beari ng
Bal l Joi nts
2 - 6 FRONT - 2WD AN
DESCRIPTION - SUSPENSION ARMS
The upper suspensi on arm bol ts on frame brackets
through the arm pi vot shaft. The frame brackets
have sl otted hol es whi ch al l ow the arms to be
adjusted for caster and camber. Pi vot shaft bushi ngs
are not repl aceabl e.
The l ower suspensi on arms bol t to the l ower frame
brackets and pi vot through bushi ngs, these bushi ngs
The suspensi on arms have l ube for l i fe ri veted bal l
studs. The suspensi on arm travel (jounce) i s l i mi ted
through the use of urethane bumpers. Rebound
travel i s l i mi ted by the shock absorber.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Nm Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut
26 19
Shock Absorber
Lower Bolts
28 21
Lower Suspension Arm
Front Nut
175 130
Rear Nut
108 80
Ball Joint Nut
127 94
Upper Suspension Arm
Pivot Shaft Nuts
167 130
Pivot Shaft to Frame Nuts
210 155
Ball Joint Nut
81 60
Stabilizer Bar
Link Upper Nut
37 27
Stabilizer Bar
Link Ball Stud Nut
47 35
Stabilizer Bar
Retainer Bolts
60 45
Hub/Bearing
Spindle Nut
251 185
Fig. 1 Front Suspension - 4X2
1 - UPPER SUSPENSION ARM
2 - STEERING KNUCKLE
3 - COIL SPRING
4 - LOWER SUSPENSION ARM
5 - STABILIZER BAR
AN FRONT - 2WD 2 - 7
FRONT - 2WD (Continued)
SPECIAL TOOLS
FRONT SUSPENSION
REMOVAL
(1) Remove the control arm from the vehi cl e,(Refer
to 2 - SUSPENSI ON/FRONT/UPPER CONTROL
ARM - REMOVAL).
(2) Mount the control arm securel y i n a vi se.
(3) Remove the nut and washer from the control
arm shaft.
(4) I nstal l the bushi ng tool (Fi g. 2).
(5) Press out the ol d bushi ngs.
INSTALLATION
(1) I nstal l the bushi ng i n the control arm and
i nserted over the shaft.
(2) I nstal l the bushi ng tool (Fi g. 3).
(3) Press the bushi ng i nto the control arm.
(4) I nstal l the washer and nut to the control arm
shaft. Ti ghten the nut to 167 Nm (130 ft. l bs.).
(5) Remove the control arm from the vi se.
(6) I nstal l the control arm i n the vehi cl e, (Refer to
2 - SUSPENSI ON/FRONT/UPPER CONTROL ARM -
I NSTALLATI ON).
Fig. 2 BUSHING REMOVAL
1 - 8441-1
2 - 8441-2
3 - 8441-3
Fig. 3 BUSHING INSTALLATION
1 - 8441-1
2 - 8441-4
Compressor, Coil Spring DD-1278
Remover Ball Joint MB-991113
Remover Ball Joint C-4150A
Puller Tie Rod C-3894-A
HUB / BEARING
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake cal i per, rotor, and ABS wheel
speed sensor i f equi pped, (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/ROTORS - REMOVAL).
(4) Remove hub/beari ng spi ndl e nut and di scard
nut (Fi g. 4).
CAUTION: The hub/bearing spindle nut can not be
re-used.
(5) Sl i de hub/beari ng off spi ndl e.
INSTALLATION
(1) Sl i de hub/beari ng on spi ndl e.
(2) I nstal l new spi ndl e nut and ti ghten to 251
Nm (185 ft. l bs.).
(3) I nstal l brake rotor, cal i per, and ABS wheel
speed sensor i f equi pped, (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/ROTORS - I NSTALLA-
TI ON).
(4) I nstal l wheel and ti re assembl y. (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(5) Remove support and l ower vehi cl e.
KNUCKLE
DESCRIPTION
The knuckl e i s a si ngl e casti ng wi th l egs machi ned
for the upper and l ower bal l joi nts. The knuckl e al so
has machi ned mounti ng l ocati ons for the front brake
cal i pers and hub beari ng.
OPERATION
The steeri ng knuckl e pi vot between the upper and
l ower bal l joi nt. Steeri ng l i nkage attached to the
knuckl e al l ows the vehi cl e to be steered.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl y.
(3) Remove di sc brake cal i per, rotor, shi el d and
ABS speed sensor, (Refer to 5 - BRAKES/HYDRAU-
LI C/MECHANI CAL/ROTORS - REMOVAL).
(4) Remove ti e-rod from steeri ng knuckl e arm,
(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD END -
REMOVAL).
(5) Remove the hub/beari ng. (Refer to 2 - SUS-
PENSI ON/FRONT/HUB / BEARI NG - REMOVAL).
(6) Remove the shock absorber. (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - REMOVAL).
(7) I nstal l Spri ng Compressor DD-1278 up through
the l ower suspensi on arm, coi l spri ng and upper
shock mounti ng hol e (Fi g. 9).
(8) Ti ghten the tool l ower nut to compress the coi l
spri ng.
(9) Remove the l ower bal l joi nt nut and separate
the bal l joi nt from the knuckl e wi th Remover
C-4150A (Fi g. 10).
(10) Remove the upper bal l joi nt nut and separate
MB-991113 (Fi g. 5).
CAUTION: When install Remover MB-991113 to sep-
arate the ball joint, be careful not to damage the
ball joint seal.
(11) Remove steeri ng knuckl e.
INSTALLATION
(1) Posi ti on steeri ng knuckl e on upper and l ower
bal l joi nts and i nstal l nuts. Ti ghten l ower nut to 127
Nm (94 ft. l bs.). Ti ghten upper nut to 81 Nm (60 ft.
l bs.) and i nstal l new cotter pi ns.
(2) Remove the spri ng compressor.
(3) I nstal l the shock absorber. (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - I NSTALLATI ON).
(4) I nstal l the hub/beari ng. (Refer to 2 - SUSPEN-
SI ON/FRONT/HUB / BEARI NG - I NSTALLATI ON).
(5) I nstal l ABS speed sensor, brake dust shi el d,
rotor and cal i per, (Refer to 5 - BRAKES/HYDRAU-
LI C/MECHANI CAL/ROTORS - I NSTALLATI ON).
(6) I nstal l ti e rod to steeri ng knuckl e arm, (Refer
to 19 - STEERI NG/LI NKAGE/TI E ROD END -
I NSTALLATI ON).
Fig. 4 Hub/Bearing
1 - KNUCKLE
2 - HUB/BEARING
3 - SPINDLE NUT
(7) I nstal l the wheel and ti re assembl y. (Refer to
22 - TI RES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(8) Remove support and l ower the vehi cl e
LOWER BALL J OINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
(1) Rai se the front of the vehi cl e. Pl ace safety fl oor
stands under both l ower suspensi on arms as far out-
board as possi bl e. Lower the vehi cl e to al l ow the
stands to support some or al l of the vehi cl e wei ght.
NOTE: The upper suspension arms must not con-
tact the rebound bumpers.
(2) Remove the ti re and wheel assembl i es.
(3) Mount a di al i ndi cator sol i dl y under the l ower
suspensi on arm.
(4) Posi ti on i ndi cator pl unger agai nst the bottom
of the steeri ng knuckl e l ower bal l joi nt boss.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss (Fig. 6).
(5) Posi ti on a pry bar over the top of the upper
suspensi on arm and under the pi vot bar of the upper
suspensi on arm. Pry down on the upper suspensi on
arm and then zero the di al i ndi cator.
(6) Reposi ti on the pry bar under the upper suspen-
si on arm and on top of the frame rai l . Pry up on the
upper suspensi on arm and record the di al i ndi cator
readi ng.
(7) I f the travel exceeds 1.52 mm (0.060 i n.),
repl ace the l ower suspensi on arm.
LOWER CONTROL ARM
REMOVAL
(3) Remove di sc brake cal i per and rotor from steer-
i ng knuckl e, (Refer to 5 - BRAKES/HYDRAULI C/
MECHANI CAL/ROTORS - REMOVAL).
(4) Remove shock absorber. (Refer to 2 - SUSPEN-
SI ON/FRONT/SHOCK - REMOVAL).
(5) Remove stabi l i zer bar l i nk from the l ower sus-
pensi on arm. (Refer to 2 - SUSPENSI ON/FRONT/
STABI LI ZER BAR - REMOVAL).
(6) Remove the coi l spri ng.
(7) Remove l ower suspensi on arm mounti ng bol ts
(Fi g. 7)from the frame mounts and remove the arm.
INSTALLATION
CAUTION: Frame mounting bolts must be installed
to their original location and orientation to avoid
damaging the steering rack boots.
(1) Loosel y attach suspensi on arm to frame
mounts.
(2) I nstal l the coi l spri ng.
Fig. 5 Upper Ball Joint
1 - UPPER BALL JOINT
2 - REMOVER
3 - KNUCKLE
Fig. 6 Lower Ball Joint Boss
1 - BALL JOINT BOSS
3 - DIAL INDICATOR
KNUCKLE (Continued)
(4) I nstal l stabi l i zer bar l i nk to the l ower suspen-
si on arm and ti ghten nut to 47 Nm (35 ft. l bs.)
(Refer to 2 - SUSPENSI ON/FRONT/STABI LI ZER
BAR - I NSTALLATI ON).
(5) I nstal l brake rotor and cal i per, (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
I NSTALLATI ON).
DURE).
(7) Remove support and l ower the vehi cl e.
(8) Ti ghten the front suspensi on arm mounti ng
nut to 175 Nm (130 ft. l bs.) and the rear nut to 108
Nm (80 ft. l bs.).
SHOCK
DESCRIPTION
The top of the l ow-pressure gas charged shock are
bol ted to the frame. The bottom of the shock are
bol ted to the l ower suspensi on arm.
OPERATION
The shock absorbers dampen jounce and rebound
of the vehi cl e over vari ous road condi ti ons.
DIAGNOSIS AND TESTING - SHOCK
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL
(1) Remove the upper shock nut, retai ner and
grommet from the shock absorber stud (Fi g. 8) .
(3) Remove the l ower mounti ng bol ts and remove
shock absorber through the l ower suspensi on arm
(Fi g. 8) .
INSTALLATION
NOTE: Upper shock nut must be replaced or use
Mopar Lock N Seal or Loctite 242 on existing nut.
(1) I nstal l the l ower retai ner (lower retainer is
stamped with a L) and grommet on the shock
absorber stud and extend the shock. I nsert the shock
absorber through the l ower suspensi on arm and
upper mounti ng hol e.
Fig. 7 Lower Suspension Arm
2 - FRAME MOUNTS
Fig. 8 Front Shock Absorber
1 - RETAINER
2 - GROMMET
3 - SHOCK ABSORBER
LOWER CONTROL ARM (Continued)
(2) I nstal l the l ower mounti ng bol ts and ti ghten to
28 Nm (21 ft. l bs.).
(4) I nstal l the upper grommet and retai ner (upper
retainer is stamped with a U) on the shock
absorber stud. I nstal l a new nut or use Mopar Lock
N Seal or Locti te 242 on exi sti ng nut and ti ghten to
26 Nm (19 ft. l bs.).
SPRING
DESCRIPTION
The spri ngs mount between the l ower suspensi on
arms and frame rai l spri ng seats. A rubber i sol ator
seats on top off the spri ng to hel p prevent noi se.
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght.
REMOVAL
(3) Remove the stabi l i zer bar l i nk from the l ower
suspensi on arm. (Refer to 2 - SUSPENSI ON/FRONT/
STABI LI ZER BAR - REMOVAL).
(4) Remove the shock absorber. (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - REMOVAL).
the l ower suspensi on arm, coi l spri ng and upper
shock mounti ng hol e (Fi g. 9).
(6) Ti ghten the tool l ower nut to compress the coi l
spri ng.
(7) Remove the l ower bal l joi nt nut and separate
C-4150A (Fi g. 10).
(8) Loosen the spri ng compressor l ower nut to
rel i eve spri ng tensi on.
(9) Remove the tool and pul l down on the l ower
suspensi on arm to remove the spri ng.
INSTALLATION
NOTE: The ramped or open end of the coil spring is
the bottom of the spring.
(1) Tape the i sol ator pad to the top of the coi l
spri ng. Posi ti on the spri ng i n the l ower suspensi on
arm pocket. Be sure that the coi l spri ng i s seated i n
the pocket.
the l ower suspensi on arm, coi l spri ng upper shock
mounti ng hol e.
(3) Ti ghten the tool nut to compress the coi l
spri ng.
Fig. 9 Spring Compressor
1 - COIL SPRING
3 - SPRING COMPRESSOR
Fig. 10 Lower Ball Joint
1 - LOWER BALL JOINT
2 - REMOVER
SHOCK (Continued)
(4) I nstal l the l ower bal l joi nt i nto the knuckl e and
ti ghten the nut to 127 Nm (94 ft. l bs.). I nstal l cotter
pi n.
(5) Remove the spri ng compressor tool .
(6) I nstal l the stabi l i zer bar l i nk to the l ower sus-
pensi on arm and ti ghten nut to 47 Nm (35 ft. l bs.).
(Refer to 2 - SUSPENSI ON/FRONT/STABI LI ZER
BAR - I NSTALLATI ON).
CEDURE).
STABILIZER BAR
DESCRIPTION
The bar extends across the front undersi de of the
chassi s and mounts on the frame rai l s. Li nks con-
nected the bar to the l ower suspensi on arms. Stabi -
l i zer bar mounts are i sol ated by rubber bushi ngs.
Li nks are i sol ated wi th rubber grommets.
OPERATION
The stabi l i zer bar i s used to mi ni mi ze vehi cl e front
sway duri ng turns. The spri ng steel bar hel ps to con-
trol the vehi cl e body i n rel ati onshi p to the suspen-
si on.
REMOVAL
(2) Remove the upper l i nk nut, retai ner and grom-
met from each l i nk.
(3) Remove the l ower l i nk nut from the l ower sus-
pensi on arm on each si de (Fi g. 11).
(4) Remove the stabi l i zer bar retai ner bol ts and
remove the retai ners and stabi l i zer bar from the
vehi cl e.
(5) Remove the bushi ngs from the stabi l i zer bar.
INSTALLATION
(1) I nstal l the bushi ngs on the stabi l i zer bar.
(2) I nstal l the stabi l i zer bar on the frame and
i nstal l the retai ners and the bol ts.
(3) Ti ghten the bol ts to 60 Nm (45 ft. l bs.).
NOTE: Ensure the bar is center with equal spacing
on both sides.
(4) I nstal l the l i nk l ower retai ner and grommet on
the l i nks.
(5) I nstal l the l i nks i nto the stabi l i zer bar and
l ower suspensi on arm on each si de.
(6) I nstal l the l ower l i nk mounti ng nut and ti ghten
to 47 Nm (35 ft. l bs.).
NOTE: Ensure both link end caps are facing
straight forward.
(7) I nstal l the upper l i nk grommet, retai ner and
nut and ti ghten to 37 Nm (27 ft. l bs.).
UPPER BALL J OINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
(1) Posi ti on a fl oor jack under the l ower suspen-
si on arm. Rai se the wheel and al l ow the ti re to
l i ghtl y contact the fl oor (vehi cl e wei ght rel i eved from
the ti re).
(2) Mount a di al i ndi cator sol i dl y on the upper sus-
pensi on arm.
(3) Posi ti on the i ndi cator pl unger agai nst the
upper bal l joi nt boss of the steeri ng knuckl e.
(4) Grasp the top of the ti re and appl y force i n and
out. Look for movement at the bal l joi nt between the
upper suspensi on arm and steeri ng knuckl e.
(5) I f l ateral movement i s greater than 1.52 mm
(0.060 i n.), repl ace upper suspensi on arm.
UPPER CONTROL ARM
REMOVAL
Fig. 11 Stabilizer Bar
1 - RETAINER
2 - GROMMET
3 - STABILIZER LINK
4 - STABILIZER BAR
SPRING (Continued)
(3) Remove brake hose bracket from the arm.
(4) Posi ti on a hydraul i c jack under the arm and
rai se the jack to unl oad the rebound bumper.
(5) Remove cotter pi n and nut from upper bal l joi nt.
(6) Separate upper bal l joi nt from steeri ng knuckl e
wi th Remover MB-991113 (Fi g. 5).
CAUTION: When installing Remover MB-991113 to
separate the ball joint, be careful not to damage the
ball joint seal.
(7) Remove suspensi on arm pi vot bar mounti ng
nuts and remove suspensi on arm (Fi g. 12).
INSTALLATION
NOTE: Before installation, insure pivot bar adjust-
ment bolts are in their original location (Fig. 12).
(1) Posi ti on suspensi on arm pi vot bar on adjust-
ment bol ts. I nstal l nuts and ti ghten to 210 Nm (155
ft. l bs.).
(2) Posi ti on steeri ng knuckl e on upper bal l joi nt.
Ti ghten the upper bal l joi nt nut to 81 Nm (60 ft.
l bs.) and i nstal l a new cotter pi n.
CEDURE).
(5) Al i gn front end to speci fi cati ons. (Refer to 2 -
SUSPENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
Fig. 12 Upper Suspension Arm
UPPER CONTROL ARM (Continued)
FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 17
LOWER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
KNUCKLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STABILIZER BAR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HUB / BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LOWER BALL JOINT
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 20
UPPER BALL JOINT
UPPER BALL JOINT. . . . . . . . . . . . . . . . . . . . . 21
UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SHOCK
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SHOCK ABSORBERS. . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TORSION BAR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT - 4WD
DESCRIPTION - 4WD
The front suspensi on i s desi gned to al l ow each
wheel to adapt to di fferent road surfaces i ndepen-
dentl y. The wheel s are mounted to hub/beari ngs
uni ts bol ted to cast steeri ng knuckl e. The doubl e-row
hub beari ngs are seal ed and l ubri cated for l i fe. The
steeri ng knuckl es turn (pi vot) on bal l joi nts. The
upper bal l joi nt i s ri veted to the outboard porti on of
the suspensi on arm and l ubri cated for l i fe. The l ower
bal l joi nt i s pressed i nto the l ower suspensi on arm
and requi res l ubri cati on.
The 4x4 front suspensi on i s compri sed of (Fi g. 1):
Shock absorbers
Torsi on-bar spri ngs
Suspensi on arms
Steeri ng knuckl es
Stabi l i zer bar
Jounce/Rebound bumpers
Hub/Beari ng
Bal l Joi nts
Fig. 1 Front Suspension - 4x4
2 - SHOCK ABSORBER
3 - STABILIZER BAR
5 - TORSION BAR
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DESCRIPTION - SUSPENSION ARMS
The upper suspensi on arm bol ts on frame brackets
through the arm pi vot shaft. The frame brackets
have sl otted hol es whi ch al l ow the arms to be
adjusted for caster and camber. Pi vot shaft bushi ngs
The l ower suspensi on arms bol t to the l ower frame
brackets and pi vot through bushi ngs, these bushi ngs
The suspensi on arms have l ube for l i fe ri veted bal l
studs. The suspensi on arm travel (jounce) i s l i mi ted
through the use of urethane bumpers. Rebound
travel i s l i mi ted by the shock absorber.
STANDARD PROCEDURE - LUBRICATION
Peri odi c l ubri cati on of the suspensi on system may
be requi red. Refer to Lubri cati on And Mai ntenance
for the recommended mai ntenance schedul e.
SPECIFICATIONS
TORQUE CHART
Shock Absorber
Upper Nut
26 19
Shock Absorber
Lower Bolts
108 80
Front Bolt
108 80
Rear Bolt
190 140
Ball Joint Nut
183 135
Pivot Shaft Nuts
129 95
Pivot Shaft to Frame Nuts
224 165
Ball Joint Nut
81 60
Stabilizer Bar
Frame Retainer Bolt
108 80
Stabilizer Bar
Frame Retainer Nut
190 140
Stabilizer Bar
Control Arm Retainer Bolts
34 25
Hub/Bearing
olts
166 123
FRONT - 4WD (Continued)
SPECIAL TOOLS
FRONT SUSPENSION
LOWER CONTROL ARM
REMOVAL
(3) Remove the front hal fshaft, (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/HALF SHAFT/AXLE
SHAFT - REMOVAL).
(4) Remove the torsi on bar. (Refer to 2 - SUSPEN-
SI ON/FRONT/TRACK BAR - REMOVAL).
(5) Remove the outer ti e rod from the steeri ng
knuckl e. (Refer to 19 - STEERI NG/LI NKAGE/TI E
ROD END - REMOVAL).
(6) Remove the shock absorber l ower bol t.
(7) Remove the stabi l i zer bar. (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER BAR - REMOVAL).
(8) Remove the cotter pi n and nut from l ower bal l
joi nt. Separate bal l joi nt from the steeri ng knuckl e
wi th Remover C-4150A (Fi g. 2).
(9) Remove the suspensi on arm pi vot bol ts and
suspensi on arm from frame rai l brackets (Fi g. 3).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm at the frame
rai l brackets. I nstal l the pi vot bol ts and nuts.
Ti ghten the nuts fi nger-ti ght.
CAUTION: The ball joint stud taper must be CLEAN
and DRY before installing the knuckle. Clean the
stud taper with mineral spirits to remove dirt and
grease.
(2) I nsert the bal l joi nt i nto steeri ng knuckl e.
I nstal l and ti ghten the retai ni ng nut to 183 Nm (135
ft. l bs.) and i nstal l a new cotter pi n.
(3) I nstal l the torsi on bar. (Refer to 2 - SUSPEN-
SI ON/FRONT/TRACK BAR - I NSTALLATI ON).
Puller Tie Rod C-3894-A
Remover MB-991113
Remover C-4150A
1 - REMOVER
2 - LOWER BALL STUD
Fig. 3 Lower Suspension Arm
1 - PIVOT BOLTS
(4) I nstal l shock absorber l ower bol t and ti ghten to
108 Nm (80 ft. l bs.).
(5) I nstal l the front hal fshaft. (Refer to 3 - DI F-
SHAFT - I NSTALLATI ON).
(6) I nstal l the stabi l i zer bar. (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER BAR - I NSTALLA-
TI ON).
(7) I nstal l the outer ti e rod to the knuckl e. (Refer
I NSTALLATI ON).
(8) Ti ghten the l ower suspensi on front pi vot nut to
108 Nm (80 ft. l bs.). Ti ghten rear pi vot bol t to 190
Nm (140 ft. l bs.).
CEDURE).
(10) Remove the support and l ower the vehi cl e.
(11) Adjust the front suspensi on hei ght and al i gn
i f necessary. (Refer to 2 - SUSPENSI ON/WHEEL
ALI GNMENT - STANDARD PROCEDURE).
KNUCKLE
DESCRIPTION
The knuckl e i s a si ngl e casti ng wi th l egs machi ned
for the upper and l ower bal l joi nts. The knuckl e al so
has machi ned mounti ng l ocati ons for the front brake
cal i pers and hub beari ng.
OPERATION
The steeri ng knuckl e pi vot between the upper and
l ower bal l joi nt. Steeri ng l i nkage attached to the
knuckl e al l ows the vehi cl e to be steered.
REMOVAL
(3) Remove the brake cal i per, rotor, shi el d and
ABS wheel speed sensor i f equi pped. (Refer to 22 -
DURE).
(4) Remove the front hal fshaft, (Refer to 3 - DI F-
SHAFT - REMOVAL).
(5) Remove the ti e rod end nut (Fi g. 4). Separate
the ti e rod from the knuckl e wi th Remover C-3894A.
(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD END -
REMOVAL).
(6) Support the l ower suspensi on arm wi th a
hydraul i c jack and rai se the jack to unl oad the
rebound bumper.
ball joint seal.
(7) Remove the upper bal l joi nt cotter pi n and nut.
Separate the bal l joi nt from the knuckl e wi th
Remover MB-991113 (Fi g. 5).
(8) Remove the l ower bal l joi nt cotter pi n and nut.
Separate the bal l joi nt from the knuckl e wi th
Remover C-4150A (Fi g. 6) and remove the knuckl e.
(9) Remove the hub/beari ng from the steeri ng
knuckl e. (Refer to 2 - SUSPENSI ON/FRONT/HUB /
BEARI NG - REMOVAL).
INSTALLATION
NOTE: When installing hub/bearing with ABS
brakes, position the speed sensor opening towards
the front of the vehicle.
(1) I nstal l the hub/beari ng to the steeri ng knuckl e
and ti ghten the bol ts to 166 Nm (123 ft. l bs.).
Fig. 4 Tie Rod End Puller
1 - TOOL C-3894-A
2 - BALL STUD
3 - SEAL
4 - TIE-ROD END
5 - LOCKNUT
LOWER CONTROL ARM (Continued)
CAUTION: The ball joint stud tapers must be
CLEAN and DRY before installing the knuckle.
Clean the stud tapers with mineral spirits to remove
dirt and grease.
(2) I nstal l the knuckl e onto the upper and l ower
bal l joi nt.
(3) I nstal l the upper and l ower bal l joi nt nuts.
Ti ghten the upper bal l joi nt nut to 81 Nm (60 ft.
l bs.) and the l ower bal l joi nt nut to 183 Nm (135 ft.
l bs.) then i nstal l cotter pi ns. Grease the l ower bal l
joi nt.
(4) Remove the hydraul i c jack from the l ower sus-
pensi on arm.
(5) I nstal l the ti e rod end and ti ghten the nut to
88 Nm (65 ft. l bs.). (Refer to 19 - STEERI NG/LI NK-
AGE/TI E ROD END - I NSTALLATI ON).
(6) I nstal l the front hal fshaft, (Refer to 3 - DI F-
SHAFT - I NSTALLATI ON).
(7) I nstal l the ABS wheel speed sensor i f equi pped
and brake shi el d, rotor and cal i per. (Refer to 5 -
I NSTALLATI ON).
CEDURE).
STABILIZER BAR
DESCRIPTION
The bar extends across the front undersi de of the
chassi s and connects to the frame crossmember. The
ends of the bar mount to the l ower suspensi on arm.
Al l mounti ng poi nts of the stabi l i zer bar are i sol ated
by bushi ngs.
OPERATION
The stabi l i zer bar i s used to mi ni mi ze vehi cl e front
sway duri ng turns. The bar hel ps to mai ntai n a fl at
atti tude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle must
be on a drive on hoist. The vehicle suspension
must be at curb height for stabilizer bar installation.
(1) Remove the stabi l i zer bar retai ner bol ts from
the l ower suspensi on arms (Fi g. 7) and remove the
retai ners.
(2) Remove the stabi l i zer bar retai ner nuts, bol ts
and retai ners from the frame crossmember (Fi g. 7)
and remove the bar.
(3) I f necessary, remove the bushi ngs from the sta-
bi l i zer bar.
INSTALLATION
NOTE: To service the stabilizer bar the vehicle must
be on a drive on hoist. The vehicle suspension
must be at curb height for stabilizer bar installation.
(1) I f removed, i nstal l the bushi ngs on the stabi -
l i zer bar.
(2) Posi ti on the stabi l i zer bar on the frame cross-
member brackets and i nstal l the retai ners and nuts
and bol ts fi nger-ti ght (Fi g. 7).
Fig. 5 Upper Ball Joint
1 - UPPER BALL STUD
2 - REMOVER
1 - REMOVER
2 - LOWER BALL STUD
KNUCKLE (Continued)
NOTE: Check the alignment of the bar to ensure
there is no interference with the either frame rail or
chassis component. Spacing should be equal on
both sides.
(3) I nstal l the stabi l i zer bar to the l ower suspen-
si on arm.
(4) I nstal l the retai ners and bol ts to the l ower sus-
pensi on arm and ti ghten to 34 Nm (25 ft. l bs.).
(5) Ti ghten the frame retai ner nuts to 190 Nm
(140 ft. l bs.).
(6) Ti ghten the frame retai ner bol ts to 108 Nm
(80 ft. l bs.).
HUB / BEARING
REMOVAL
(3) Remove the hal fshaft nut.
(4) Remove the ABS wheel speed sensor i f
equi pped, (Refer to 5 - BRAKES/ELECTRI CAL/
FRONT WHEEL SPEED SENSOR - REMOVAL).
(5) Remove the brake cal i per and rotor, (Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
(6) Remove the hub/beari ng mounti ng bol ts from
the steeri ng knuckl e (Fi g. 8).
(7) Sl i d the hub/beari ng out of the steeri ng
knuckl e and off the hal fshaft.
INSTALLATION
(1) I nstal l the hub/beari ng i nto the steeri ng
knuckl e and ti ghten the bol ts to 166 Nm (123 ft.
l bs.).
(2) I nstal l the brake rotor and cal i per. (Refer to 5 -
I NSTALLATI ON).
(3) I nstal l the ABS wheel speed sensor i f equi pped.
(Refer to 5 - BRAKES/ELECTRI CAL/FRONT
WHEEL SPEED SENSOR - I NSTALLATI ON).
(4) I nstal l the hal fshaft nut and ti ghten to 235
Nm (173 ft. l bs.).
CEDURE).
(6) Remove the support and l ower vehi cl e.
LOWER BALL J OINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
NOTE: If the ball joint is equipped with a lubrication
fitting, grease the joint then road test the vehicle
before performing test.
(1) Rai se the front of the vehi cl e. Pl ace safety fl oor
stands under both l ower suspensi on arms as far out-
board as possi bl e. Lower the vehi cl e to al l ow the
stands to support some or al l of the vehi cl e wei ght.
NOTE: The upper suspension arms must not con-
tact the rebound bumpers.
(2) Remove the ti re and wheel assembl i es.
(3) Mount a di al i ndi cator sol i dl y to the undersi de
of the l ower suspensi on arm.
Fig. 7 Stabilizer Bar
2 - FLAG NUT
3 - STABILIZER BAR
4 - RETAINER
Fig. 8 Hub/Bearing
1 - HUB BEARING
STABILIZER BAR (Continued)
(4) Posi ti on i ndi cator pl unger agai nst the bottom
surface of the steeri ng knuckl e l ower bal l joi nt boss.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss (Fig. 9).
(5) Posi ti on a pry bar over the top of the upper
suspensi on arm and under the pi vot bar of the upper
suspensi on arm. Pry down on the upper suspensi on
arm and then zero the di al i ndi cator.
(6) Reposi ti on the pry bar under the upper suspen-
si on arm and on top of the jounce/rebound bracket.
Pry up on the upper suspensi on arm and record the
di al i ndi cator readi ng.
(7) I f the travel exceeds 1.52 mm (0.060 i n.),
repl ace the l ower control arm.
UPPER BALL J OINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
(1) Posi ti on a fl oor jack under the l ower suspen-
si on arm. Rai se the wheel and al l ow the ti re to
l i ghtl y contact the fl oor (vehi cl e wei ght rel i eved from
the ti re).
(2) Mount a di al i ndi cator sol i dl y on the upper sus-
pensi on arm.
(3) Posi ti on the i ndi cator pl unger agai nst the back
si de of the upper bal l joi nt boss of the steeri ng
knuckl e (Fi g. 10).
(4) Grasp the top of the ti re and pul l outward,
then zero the di al i ndi cator.
(5) Grasp the top of the ti re and push i nward and
record the di al i ndi cator readi ng.
(6) I f l ateral movement i s greater than 1.52 mm
(0.060 i n.), repl ace upper suspensi on arm.
UPPER CONTROL ARM
REMOVAL
(3) Remove brake hose brackets from suspensi on
arm.
(4) Posi ti on hydraul i c jack under l ower suspensi on
arm and rai se jack to unl oad rebound bumper.
(5) Remove shock absorber. (Refer to 2 - SUSPEN-
SI ON/FRONT/SHOCK - REMOVAL).
(6) Remove the cotter pi n and nut from upper bal l
joi nt.
(7) Separate upper bal l joi nt from the steeri ng
knuckl e wi th Remover MB-991113 (Fi g. 11).
ball joint seal.
(8) Remove suspensi on arm pi vot bar bol ts and
remove suspensi on arm (Fi g. 12).
Fig. 9 Lower Ball Joint Boss
1 - BALL JOINT BOSS
3 - DIAL INDICATOR
Fig. 10 Upper Ball Joint Boss
1 - DIAL INDICATOR
2 - BALL JOINT BOSS
LOWER BALL J OINT (Continued)
INSTALLATION
(1) Posi ti on suspensi on arm pi vot bar on mounti ng
bracket. I nstal l bol ts and ti ghten (temporari l y) to 136
Nm (100 ft. l bs.).
(2) I nsert bal l joi nt i n steeri ng knuckl e and
ti ghten bal l joi nt nut to 81 Nm (60 ft. l bs.) then
i nstal l a new cotter pi n.
(3) I nstal l shock absorber. (Refer to 2 - SUSPEN-
SI ON/FRONT/SHOCK - I NSTALLATI ON).
(4) Remove hydraul i c jack.
(5) Attach brake hose brackets to suspensi on arm.
(6) Ti ghten upper suspensi on arm pi vot bol ts to
224 Nm (165 ft. l bs.).
CEDURE).
(9) Al i gn front suspensi on. (Refer to 2 - SUSPEN-
SI ON/WHEEL ALI GNMENT - STANDARD PROCE-
DURE).
SHOCK
DESCRIPTION
The top of the l ow-pressure gas charged shock are
bol ted to the frame. The bottom of the shock are
bol ted to the l ower suspensi on arm.
OPERATION
The shock absorbers dampen jounce and rebound
of the vehi cl e over vari ous road condi ti ons.
DIAGNOSIS AND TESTING - SHOCK
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL
(2) Remove the upper shock absorber nut, retai ner
and grommet (Fi g. 13) .
(3) Remove the l ower bol t and remove the shock
absorber.
Fig. 11 Separate Upper Ball Joint
1 - UPPER BALL STUD
2 - REMOVER
Fig. 12 Upper Suspension Arm
1 - PIVOT BAR BOLT
UPPER CONTROL ARM (Continued)
INSTALLATION
(1) I nstal l the l ower retai ner (lower retainer is
stamped with a L) and grommet on the shock
absorber stud. I nsert the shock absorber through the
frame bracket hol e.
(2) I nstal l the l ower bol t and ti ghten the bol t to
108 Nm (80 ft. l bs.).
(3) I nstal l the upper grommet, retai ner (upper
retainer is stamped with a U) and new nut or use
Mopar Lock N Seal or Locti te 242 on exi sti ng nut,
on the shock absorber stud. Ti ghten nut to 26 Nm
(19 ft. l bs.).
TORSION BAR
DESCRIPTION
The front of the bar mounts to the back si de of the
l ower suspensi on arm. The rear end of the bar i s
mounted i n a anchor that rests i n the frame cross-
member.
OPERATION
The torsi on bars are used to control ri de hei ght
and ri de qual i ty. The vehi cl e hei ght i s adjusted
through an anchor adjustment bol t that i ncreases or
decreases the angl e of the torsi on bar. I ncreasi ng or
decreasi ng the bar angl e changes the angl e of the
suspensi on arms.
REMOVAL
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) Rai se and support the vehi cl e wi th the front
suspensi on hangi ng.
(2) Turn the adjustment bol t countercl ockwi se to
rel ease spri ng l oad (Fi g. 14).
NOTE: Count and record the number of turns for
installation reference.
(3) Remove the adjustment bol t from swi vel .
(4) Remove torsi on bar and anchor. Remove anchor
from torsi on bar.
(5) Remove al l forei gn materi al from torsi on bar
mounti ng i n anchor and suspensi on arm.
(6) I nspect adjustment bol t, beari ng and swi vel for
damage.
Fig. 13 Shock Absorber
1 - NUT
2 - RETAINER
3 - GROMMET
4 - SHOCK
Fig. 14 Torsion Bar
1 - SWIVEL
2 - ANCHOR
3 - BEARING
4 - ADJUSTMENT BOLT
5 - TORSION BAR
SHOCK (Continued)
INSTALLATION
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) I nsert torsi on bar ends i nto anchor and suspen-
si on arm.
(2) Posi ti on anchor and beari ng i n frame cross-
member. I nstal l adjustment bol t through beari ng,
anchor and i nto the swi vel .
(3) Turn adjustment bol t cl ockwi se the recorded
amount of turns.
(4) Lower vehi cl e and adjust the front suspensi on
hei ght. (Refer to 2 - SUSPENSI ON/WHEEL ALI GN-
MENT - STANDARD PROCEDURE).
REMOVAL
(1) Remove the control arm from the vehi cl e.
(Refer to 2 - SUSPENSI ON/FRONT/UPPER CON-
TROL ARM - REMOVAL),(Refer to 2 - SUSPEN-
SI ON/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Mount the control arm securel y i n a vi se.
(3) Remove the nut and washer from the control
arm shaft.
(4) I nstal l the bushi ng tool .
(5) Press out the ol d bushi ngs.
INSTALLATION
(1) I nstal l the bushi ng i n the control arm and
i nserted over the shaft.
(2) I nstal l the bushi ng tool .
(3) Press the bushi ng i nto the control arm.
(4) I nstal l the washer and nut to the control arm
shaft. Torque the nut to 167 Nm (130 ft. l bs.) speci -
fi cati on.
(5) Remove the control arm from the vi se.
(6) I nstal l the control arm i n the vehi cl e. (Refer to
2 - SUSPENSI ON/FRONT/UPPER CONTROL ARM -
I NSTALLATI ON), (Refer to 2 - SUSPENSI ON/
FRONT/LOWER CONTROL ARM - I NSTALLA-
TI ON).
TORSION BAR (Continued)
REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPRING AND SHOCK. . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 26
SHOCK
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPRING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
STABILIZER BAR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR
DESCRIPTION
The rear suspensi on i s compri sed of:
Dri ve Axl e
Shock Absorbers
Stabi l i zer Bar (opti onal )
Leaf Spri ngs
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear.
DIAGNOSIS AND TESTING - SPRING AND
SHOCK
The spri ng eye and shock absorber bushi ngs do not
requi re any type of l ubri cati on. Do not attempt to
stop spri ng bushi ng noi se by l ubri cati ng them.
Grease and mi neral oi l -base l ubri cants wi l l deteri o-
rate the bushi ng rubber.
I f the vehi cl e i s used for severe, off-road operati on,
the spri ngs shoul d be exami ned peri odi cal l y. Check
for broken and shi fted l eafs, l oose and mi ssi ng cl i ps,
and broken center bol ts. Refer to Spri ng and Shock
Absorber Di agnosi s chart bel ow for addi ti onal i nfor-
mati on.
AN REAR 2 - 25
SPRING AND SHOCK ABSORBER
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SPECIFICATIONS
TORQUE CHART
Shock Absorber
Lower Bolt
95 70
Shock Absorber
Upper Bolt
95 70
Stabilizer Bar
Frame Bracket Nuts
54 40
Stabilizer Bar
Link Nuts
54 40
Stabilizer Bar
Retainer Bolts
54 40
Spring U-Bolt Nuts
2WD
149 110
Spring U-Bolt Nuts
4WD
149 110
Spring
Eye Nut
163 120
Spring
Shackle Nuts
163 120
Jounce Bumper
Bolts
61 45
SHOCK
DESCRIPTION
The top of the shock absorbers are bol ted to the
body crossmember. The bottom of the shocks are
bol ted to the axl e brackets. The axl e brackets are
staggered one ahead of the axl e and one befi nd.
OPERATION
Ri de control i s accompl i shed through the use of
dual -acti on shock absorbers. The shocks dampen the
jounce and rebound as the vehi cl e travel s over vari -
ous road condi ti ons.
2 - 26 REAR AN
REAR (Continued)
REMOVAL
(1) Rai se vehi cl e and support rear axl e.
(2) Remove shock absorber l ower nut and bol t from
the axl e bracket (Fi g. 1).
(3) Remove shock absorber upper nut and bol t
from the frame bracket and remove the shock
absorber.
INSTALLATION
(1) I nstal l shock absorber and upper mounti ng bol t
and nut. Ti ghten nut to 95 Nm (70 ft. l bs.).
(2) I nstal l shock absorber i nto the axl e bracket.
I nstal l the bol t and nut and ti ghten nut to 95 Nm
(70 ft. l bs.).
(3) Remove axl e support and l ower vehi cl e.
SPRING
DESCRIPTION
The 4x2 rear suspensi on system uses a 4-l eaf two
stage or 5-l eaf si ngl e stage spri ngs and a sol i d dri ve
axl e. The 4x4 rear suspensi on system uses onl y a
4-l eaf two stage spri ng and sol i d dri ve axl e. The for-
ward end of the spri ngs are mounted to the body rai l
hangers through rubber bushi ngs. The rearward end
of the spri ngs are attached to the body by the use of
shackl es. The spri ng and shackl es use rubber bush-
i ngs. The bushi ng hel p to i sol ate road noi se.
OPERATION
The spri ngs control ri de qual i ty and mai ntai n vehi -
cl e ri de hei ght. The shackl es al l ow the spri ngs to
change thei r l ength as the vehi cl e moves over vari ous
road condi ti ons.
REMOVAL
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of the
rear axle. Use care to avoid bending the side rail
flange.
(1) Rai se the vehi cl e at the frame.
(2) Use a hydraul i c jack to rel i eve the axl e wei ght.
(3) Remove the wheel and ti re assembl i es.
(4) Remove the nuts, the U-bol ts and spri ng pl ate
from the axl e (Fi g. 2) and (Fi g. 3) .
(5) Remove the nut and bol t from the spri ng front
eye.
(6) Remove the nut and bol t that attaches the
spri ng shackl e to the rear frame bracket.
(7) Remove the spri ng from the vehi cl e.
(8) Remove the shackl e from the spri ng.
Fig. 1 Shock Absorber
1 - SHOCK ABSORBER
2 - MOUNTING BOLT
3 - MOUNTING BOLT
Fig. 2 Leaf Spring - 4x2
1 - JOUNCE BUMPER
2 - SHACKLE
3 - PLATE
4 - LEAF SPRING
AN REAR 2 - 27
SHOCK (Continued)
INSTALLATION
CAUTION: The rear of the vehicle must be lifted only
with a jack or hoist. The lift must be placed under the
frame rail crossmember located aft of the rear axle.
Use care to avoid bending the side rail flange.
(1) I nstal l the spri ng shackl e on the spri ng fi nger
ti ght.
(2) Posi ti on the spri ng on the rear axl e pad. Make sure
the spri ng center bol t i s i nserted i n the pad l ocati ng hol e.
(3) Al i gn front spri ng eye wi th the bol t hol e i n the
front frame bracket. I nstal l the spri ng eye bol t and
nut and ti ghten the spri ng eye nut fi nger-ti ght.
(4) Al i gn spri ng shackl e eye wi th the bol t hol e i n
the rear frame bracket. I nstal l the bol t and nut and
ti ghten the spri ng shackl e eye nut fi nger-ti ght.
(5) I nstal l the spri ng seat (4x4 onl y), U-bol ts,
spri ng pl ate and nuts.
(6) Ti ghten the U-bol t nuts to 149 Nm (110 ft. l bs.).
(7) I nstal l the wheel and ti re assembl i es. (Refer to
CEDURE).
(8) Remove the support stands from under the
frame rai l s. Lower the vehi cl e unti l the spri ngs are
supporti ng the wei ght of the vehi cl e.
(9) Ti ghten the spri ng eye pi vot bol t nut and al l
shackl e nuts to 163 Nm (120 ft. l bs.).
STABILIZER BAR
DESCRIPTION
The stabi l i zer bar (opti onal ) extends across the
undersi de of the vehi cl e and i s bol ted to the top of
the axl e. Li nks at the end of the bar are bol ted to
frame brackets.
OPERATION
The stabi l i zer bar i s used to mi ni mi ze vehi cl e body
rol l . The spri ng steel bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
REMOVAL
(2) Remove nuts and bol ts from the l i nks at the
stabi l i zer bar.
(3) Remove stabi l i zer bar retai ner bol ts and retai n-
ers (Fi g. 4).
(4) Remove stabi l i zer bar and repl ace worn,
cracked or di storted bushi ngs.
(5) Remove l i nks upper mounti ng nuts and bol ts
and remove l i nks.
INSTALLATION
(1) I nstal l the stabi l i zer bar and center i t wi th
equal spaci ng on both si des. I nstal l stabi l i zer bar
retai ners and ti ghten bol ts to 54 Nm (40 ft. l bs.).
(2) I nstal l l i nk i nto frame brackets and the stabi -
l i zer bar. I nstal l mounti ng nuts and bol ts.
(4) Ti ghten stabi l i zer l i nk nuts to 54 Nm (40 ft. l bs.).
Fig. 3 Leaf Spring - 4x4
1 - SHACKLE
2 - JOUNCE BUMPER
3 - SEAT
4 - PLATE
5 - LEAF SPRING
Fig. 4 Stabilizer Bar Mounting
1 - STABILIZER BAR
2 - LINK
3 - RETAINER
2 - 28 REAR AN
SPRING (Continued)
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT AXLE - C205F . . . . . . . . . . . . . . . . . . . . . 22
REAR AXLE - 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . 47
REAR AXLE - 9 1/4 . . . . . . . . . . . . . . . . . . . . . . . 78
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PROPELLER SHAFT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PROPELLER SHAFT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTER BEARING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PROPELLER SHAFT
DESCRIPTION
A propel l er shaft (Fi g. 1), (Fi g. 2), and (Fi g. 3) i s
the shaft whi ch connects the transmi ssi on/transfer
case to the axl e di fferenti al . Thi s i s the l i nk through
whi ch the engi ne power i s transmi tted to the axl e.
The propel l er shaft i s desi gned and bui l t wi th the
yoke l ugs i n l i ne wi th each other whi ch i s cal l ed zero
phasi ng. Thi s desi gn produces the smoothest runni ng
condi ti on, an out-of-phase shaft can cause a vi bra-
ti on.
Tubul ar propel l er shafts are bal anced by the man-
ufacturer wi th wei ghts spot wel ded to the tube.
Use the exact repl acement parts when i nstal l i ng
the propel l er shafts. The use of the correct repl ace-
ment parts hel ps to ensure safe operati on. Al l fasten-
ers must be torqued to the speci fi ed val ues for safe
operati on.
Fig. 1 FRONT PROPELLER SHAFT
1 - PROPELLER SHAFT
2 - CONSTANT VILOCITY JOINT
3 - COMPANION FLANGE
4 - BOLT
AN DIFFERENTIAL & DRIVELINE 3 - 1
Fig. 2 Rear Propeller Shaft with Center Bearing
1 - REAR AXLE
2 - REAR PROPELLER SHAFT
3 - TRANSMISSION EXTENSION HOUSING
4 - CENTER BEARING
Fig. 3 Rear Propeller Shaft
1 - REAR AXLE
3 - TRANSMISSION EXTENSION HOUSING
3 - 2 PROPELLER SHAFT AN
PROPELLER SHAFT (Continued)
Al so make al i gnment reference marks (Fi g. 4)on
the propel l er shaft yoke and axl e, or transmi ssi on,
yoke pri or to servi ci ng. Thi s hel ps to el i mi nate possi -
bl e vi brati on.
CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
OPERATION
The propel l er shaft must operate through con-
stantl y changi ng rel ati ve angl es between the trans-
mi ssi on and axl e. I t must al so be capabl e of changi ng
l ength whi l e transmi tti ng torque. The axl e ri des sus-
pended by spri ngs i n a fl oati ng moti on. The propel l er
shaft must be abl e to change operati ng angl es when
goi ng over vari ous road surfaces. Thi s i s accom-
pl i shed through uni versal joi nts/constant vi l oci ty
joi nt, whi ch permi t the propel l er shaft to operate at
di fferent angl es. The sl i p joi nts (or yokes) permi t con-
tracti on or expansi on.
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.
CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The speci-
fied torque must always be applied when tightening
the fasteners.
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
(Refer to 22 - TI RES/WHEELS - DI AGNOSI S AND
TESTI NG)
Brake drums that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. (Refer to 5 - BRAKES
- DI AGNOSI S AND TESTI NG)
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
Fig. 4 Reference Marks on Yokes
1 - REFERENCE MARKS
AN PROPELLER SHAFT 3 - 3
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.
1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws and
tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.
3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of
balance.
7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.
9) Re-index propeller shaft, test, and
evaluate.
10) Excessive drive pinion gear shaft
runout.
10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180 relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90 apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 5).
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 6) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/2 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 7).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt and undercoati ng from
the propel l er shaft surface where the di al i ndi cator
wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the
shaft tube for tube lengths over 30 inches. For
tube lengths under 30 inches, the maximum
allowed runout is 0.020 in. (0.50 mm) for the full
length of the tube.
STANDARD PROCEDURES
To accuratel y check dri vel i ne al i gnment, rai se and
support the vehi cl e at the axl es as l evel as possi bl e.
Al l ow the wheel s and propel l er shaft to turn.
(1) Remove any external beari ng snap ri ngs, i f
equi pped, from uni versal joi nt so protractor base si ts
fl at.
(2) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng i s faci ng downward.
NOTE: Always make measurements from front to
rear and from the same side of the vehicle.
Fig. 5 Clamp Screw At Position 1
1 - CLAMP
2 - SCREWDRIVER
Fig. 6 Two Clamp Screws At The Same Position
Fig. 7 Clamp Screws Separated
1 -
1
2 INCH
(3) Pl ace I ncl i nometer 7663 (J-23498A) on yoke
beari ng (A) paral l el to the shaft (Fi g. 8). Center bub-
bl e i n si ght gl ass and record measurement.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(4) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng paral l el to the shaft
(Fi g. 9). Center bubbl e i n si ght gl ass and record mea-
surement. Thi s measurement can al so be taken at
the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(5) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n Transmi ssi on Output Operati ng Angl e.
(6) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng paral l el to the
shaft (Fi g. 10). Center bubbl e i n si ght gl ass and
record measurement.
This measurement will give you the pinion
shaft or Input Yoke Angle (B).
(7) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
11)for addi ti onal i nformati on.
Good cancel l ati on of Ujoi nt operati ng angl es
(wi thi n 1).
Operati ng angl es l ess than 3.
At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
TWO-PIECE PROPELLER SHAFT
The procedure to measure the propel l er shaft
angl es i nvol ved wi th a two-pi ece (Fi g. 12) propel l er
shaft i s the same as those for a one-pi ece propel l er
shaft.
Fig. 8 Front (Output) Angle Measurement (A)
1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
Fig. 9 Propeller Shaft Angle Measurement (C)
1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
Fig. 10 Rear (Input) Angle Measurement (B)
1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
Fig. 11 Universal Joint Angle Example
1 - 4.9Angle (C)
2 - 3.2Angle (B)
3 - Input Yoke
4 - 3.0Angle (A)
5 - Output Yoke
Fig. 12 Universal Joint Angle Two-Piece Shaft
1 - YOKES MUST BE IN SAME PLANE
SPECIFICATIONS
PROPELLER SHAFT
Center Bearing Bolts 68 50 -
Transfer Case Flange
Bolts
30.5 22.5 -
Companion Flange Bolts 108 80 -
SPECIAL TOOLS
PROPELLER SHAFT
PROPELLER SHAFT - FRONT
REMOVAL
(1) Posi ti on transmi ssi on and transfer case to thei r
neutral posi ti ons. Rai se and support vehi cl e. Remove
ski d pl ate, i f equi pped.
(2) Mark a l i ne across the transfer case fl ange and
C/V for i nstal l ati on reference.
(3) Mark a l i ne across the propel l er shaft fl ange
yoke and front axl e compani on fl ange for i nstal l ati on
reference.
(4) Remove compani on fl ange bol ts (Fi g. 13).
(5) Remove transfer case fl ange bol ts and remove
propel l er shaft.
INSTALLATION
(1) I nstal l propel l er shaft wi th wi th al l reference
marks al i gned.
(2) Loosel y i nstal l bol ts to C/V and transfer case
compani on fl ange.
(3) I nstal l bol ts to compani on fl ange and fl ange
yoke and ti ghten to 108 Nm (80 ft. l bs.).
(4) Ti ghten bol ts to transfer case compani on fl ange
to 30.5 Nm (22.5 ft. l bs.).
(5) I nstal l ski d pl ate, i f equi pped.
(6) Lower vehi cl e and road test to veri fy repai r.
Inclinometer 7663
Bearing Splitter 1130
Installer Bearing 6052
Fig. 13 Front Propeller Shaft
1 - PROPELLER SHAFT
2 - CONSTANT VILOCITY JOINT
4 - BOLT
PROPELLER SHAFT - REAR
REMOVAL
(1) Pl ace the transmi ssi on i nto the Neutral posi -
ti on.
(2) Rai se and support vehi cl e on safety stands.
(3) Mark a l i ne across the axl e compani on fl ange
and fl ange yoke for i nstal l ati on reference.
(4) Mark an outl i ne of the center beari ng on the
support bracket for i nstal l ati on reference, i f
equi pped.
(5) Mark an outl i ne of the heat shi el d on the cen-
ter beari ng for i nstal l ati on reference, i f equi pped.
(6) Remove center beari ng and heat shi el d bol ts, i f
equi pped.
(7) Remove compani on fl ange bol ts.
(8) Sl i de sl i p yoke off of the transmi ssi on, or trans-
fer case, output shaft and remove the propel l er shaft
(Fi g. 14).
INSTALLATION
(1) Sl i de the sl i p yoke onto the transmi ssi on, or
transfer case, output shaft.
(2) Al i gn and i nstal l the center beari ng and heat
shi el d to the support bracket, i f necessary. I nstal l the
bol ts and ti ghten to 68 Nm (50 ft. l bs.).
(3) Al i gn compani on fl ange reference mark wi th
fl ange yoke mark.
(4) I nstal l compani on fl ange bol ts and ti ghten to
108 Nm (80 ft. l bs.).
(5) Lower the vehi cl e.
CENTER BEARING
DESCRIPTION
The two-pi ece propel l er shaft uses a center beari ng
to support the shafts. The beari ng i s used to support
the shafts where they are joi ned together. The bear-
i ng i s i nsul ated i n rubber and i s mounted to the
frame crossmember.
OPERATION
The propel l er shaft center beari ng serves to di vi de
the requi red propel l er shaft l ength i nto two smal l er
shafts, whi ch has several i nherent advantages. Hav-
i ng two short propel l er shafts i nstead of one l ong
shaft decreases the chance of unwanted noi se and
vi brati ons. The shorter shafts are easi er to bal ance
and serve to i ncrease ground cl earance whi l e mai n-
tai ni ng acceptabl e dri vel i ne angl es.
REMOVAL
(1) Remove rear propel l er shaft.
(2) Remove sl i p joi nt boot cl amp and separate the
two hal f-shafts.
(3) Use hammer and punch to tap sl i nger away
from shaft to provi de room for beari ng spl i tter.
(4) Posi ti on Beari ng Spl i tter Tool 1130 between
sl i nger and shaft.
CAUTION: Do not damage shaft spline during
removal of center bearing.
(5) Set shaft i n press and press beari ng off the
shaft.
INSTALLATION
(1) I nstal l new sl i nger on shaft and dri ve i nto posi -
ti on wi th appropri ate i nstal l er tool .
(2) I nstal l new center beari ng on shaft wi th Bear-
i ng I nstal l er Tool 6052. Dri ve on shaft wi th hammer
unti l beari ng i s seated.
(3) Cl ean shaft spl i nes and appl y a coat of mul ti
purpose grease.
(4) Al i gn master spl i nes and sl i de front and rear
hal f-shafts together. Reposi ti on sl i p yoke boot and
i nstal l new cl amp.
(5) I nstal l propel l er shaft i n vehi cl e.
Fig. 14 Propeller Shaft
2 - FLANGE YOKE
CENTER BEARING ADJUSTMENT
Dri ve away shudder i s a vi brati on that occurs at
fi rst accel erati on from a stop. Shudder vi brati on usu-
al l y peaks at the engi nes hi ghest torque output.
Shudder i s a symptom associ ated wi th vehi cl es usi ng
a two-pi ece propel l er shaft. To decrease shudder,
l ower the center beari ng i n 1/8 i nch i ncrements. Use
shi m stock or fabri cated pl ates. Pl ate stock must be
used to mai ntai n compressi on of the rubber i nsul ator
around the beari ng. Do not use washers. Repl ace the
ori gi nal bol ts wi th the appropri ate i ncreased l ength
bol ts.
SINGLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: The following procedure is described for a
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
repl aced as an assembl y.
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 15).
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 16).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 17).
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
Fig. 15 Snap Ring
1 - SNAP RING
Fig. 16 Press Out Bearing
1 - PRESS
2 - SOCKET
CENTER BEARING (Continued)
ASSEMBLY
NOTE: The following procedure is described for a
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 18).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 19). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4to i nstal l the opposi te
beari ng cap. I f the joi nt i s sti ff or bi ndi ng, stri ke the
yoke wi th a soft hammer to seat the needl e beari ngs.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
Fig. 17 Press Out Remaining Bearing
1 - CROSS
2 - BEARING CAP
Fig. 18 Cross In Yoke
1 - CROSS
2 - YOKE
Fig. 19 Install Bearing On Trunnion
1 - BEARING CAP
2 - TRUNNION
SINGLE CARDAN UNIVERSAL J OINTS (Continued)
HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 12
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 14
AXLE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
CV BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
CV JOINT - OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
CV JOINT - INNER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
HALF SHAFT
DESCRIPTION
The two constant vel oci ty (C/V) dri ve shafts are
i denti cal and i nterchangeabl e. They are compri sed of
three major components (Fi g. 1):
An i nner, tri pod C/V joi nt
A short, sol i d i nterconnecti ng shaft
An outer, Rzeppa C/V joi nt wi th stub shaft
The i nner tri pod-joi nts are attached to the axl e
shaft spl i nes (Fi g. 1). The outer joi nt i s spl i ned and
mates wi th the hub beari ng on the knuckl e.
The l ubri cant amounts i ncl uded wi th repl acement
rubber boots are di fferent for i nner and outer C/V
joi nts. Appl y onl y the speci fi ed l ubri cant amount to
each C/V joi nt.
CAUTION: Proper C/V joint boot sealing is critical
for retaining the special lubricant. Prevent foreign
material from entering and contaminating the C/V
joints. Mishandling a C/V drive shaft can cause a
boot to be punctured or damage within the joints.
Always support both ends of the C/V drive shaft
during removal and installation to avoid damage.
When repl aci ng C/V dri ve shaft components,
ensure that onl y exact repl acements parts are
i nstal l ed.
OPERATION
The axl e dri veshafts are l ocated on ei ther si de of
the di fferenti al and transmi ts power to the dri ve
wheel s, whi l e al l owi ng for verti cal movement i n the
vehi cl es suspensi on.
DIAGNOSIS AND TESTING - HALF SHAFT
Check for grease i n the vi ci ni ty of the i nboard tri -
pod joi nt and outboard C/V joi nt; thi s i s a si gn of
i nner or outer joi nt seal boot or seal boot cl amp dam-
age. A l i ght fi l m of grease may appear on the ri ght
i nner tri pod joi nt seal boot; thi s i s consi dered normal
and shoul d not requi re repl acement of the seal boot.
NOISE AND/OR VIBRATION IN TURNS
A cl i cki ng noi se and/or a vi brati on i n turns coul d
be caused by one of the fol l owi ng condi ti ons:
Damaged outer C/V or i nner tri pod joi nt seal
boot or seal boot cl amps. Thi s wi l l resul t i n the l oss
and/or contami nati on of the joi nt grease, resul ti ng i n
i nadequate l ubri cati on of the joi nt.
Noi se may al so be caused by another component
of the vehi cl e comi ng i n contact wi th the dri veshafts.
CLUNKING NOISE DURING ACCELERATION
Thi s noi se may be a resul t of one of the fol l owi ng
condi ti ons:
A torn seal boot on the i nner or outer joi nt of the
dri veshaft assembl y whi ch has al l owed the C/V joi nt
to become damaged.
A l oose or mi ssi ng cl amp on the i nner or outer
joi nt of the dri veshaft assembl y whi ch has al l owed
the C/V joi nt to become damaged.
A damaged or worn dri veshaft C/V joi nt.
SHUDDER OR VIBRATION DURING ACCELERATION
Thi s probl em coul d be a resul t of:
A worn or damaged dri veshaft i nner tri pod joi nt.
A sti cki ng tri pod joi nt spi der assembl y (i nner tri -
pod joi nt onl y).
I mproper wheel al i gnment.
3 - 12 HALF SHAFT AN
Fig. 1 C/V Drive Shaft Components
AN HALF SHAFT 3 - 13
HALF SHAFT (Continued)
VIBRATION AT HIGHWAY SPEEDS
Thi s probl em coul d be a resul t of:
Forei gn materi al (mud, etc.) packed on the back-
si de of the wheel (s).
Out of bal ance front ti res or wheel s.
I mproper ti re and/or wheel runout.
SPECIFICATIONS
HALF SHAFT
Axle Flange Bolts 90 65 -
Axle Nut 244 180 -
SPECIAL TOOLS
SPECTIAL TOOLS
AXLE SHAFT
REMOVAL
(1) Loosen the l ug nuts and hub nut whi l e the
vehi cl e i s on the surface wi th the brakes appl i ed (Fi g.
2).
(3) Remove the ski d pl ate, i f equi pped.
1 - RETAINER & HOUSING ASM
2 - C-CLIP
3 - TRIPOD JOINT SPIDER
4 - SEAL RETAINING CLAMP
5 - INNER BOOT
7 - C/V JOINT OUTER RACE
8 - C/V JOINT CAGE
9 - C/V JOINT INNER RACE
10 - CHROME ALLOY BALL
11 - RACE RETAINING RING
13 - DRIVE AXLE OUTBOARD SEAL
15 - AXLE SHAFT
16 - RETAINING RING
17 - BALL & ROLLER RETAINER
18 - TRIPOD JOINT BALL
19 - NEEDLE ROLLER
Remover Cup L-4518
Remover/Installer C-4124
Fig. 2 Wheel Hub Nut
HALF SHAFT (Continued)
(4) Remove the cotter pi n, nut l ock, and spri ng
washer from the stub shaft (Fi g. 3).
(5) Remove the hub nut and washer from the stub
shaft (Fi g. 4).
(6) Remove the wheel and ti re.
(7) Remove the brake cal i per and rotor, refer to
Group 5 Brakes for procedures.
(8) Remove the ABS wheel speed sensor i f
equi pped. Refer to Group 5 Brakes for procedures.
(9) Remove the bol ts hol di ng the hub beari ng to
the knuckl e.
(10) Remove hub beari ng from axl e dri veshaft and
steeri ng knuckl e.
(11) Support the dri ve shaft at the C/V joi nt hous-
i ngs.
(12) Di sengage the i nner C/V joi nt from the axl e
shaft (Fi g. 5). Posi ti on two pry bars between the
i nner C/V housi ng and the axl e housi ng. Appl y pres-
sure away from the di fferenti al housi ng. Thi s wi l l
di sengage the axl e shaft snap-ri ng from the groove
on the i nsi de of the C/V housi ng.
(13) Remove the dri veshaft from the vehi cl e.
INSTALLATION
(1) I nsert the C/V dri ve shaft stub i nto the hub
beari ng bore of the steeri ng knuckl e.
(2) Appl y a l i ght coati ng of wheel beari ng grease
on the axl e shaft spl i nes.
(3) I nstal l the i nner C/V joi nt onto the axl e shaft
fl ange. Push fi rml y on the shaft unti l the axl e shaft
snap-ri ng engages wi th the groove on the i nsi de of
the joi nt housi ng.
(4) Cl ean hub beari ng bore, axl e dri veshaft spl i nes,
and hub beari ng mati ng surface of al l forei gn mate-
ri al s. Appl y l i ght coati ng of grease to al l mati ng sur-
faces.
(5) I nstal l the hub beari ng to the axl e dri veshaft
and the steeri ng knuckl e.
(6) I nstal l the bol ts to hol d the hub beari ng to the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
the proper torque.
(7) Cl ean al l forei gn materi al from the stub shaft
threads. I nstal l the hub nut and washer.
(8) I nstal l the ABS wheel speed sensor, i f
equi pped. Refer to Group 5, Brakes, for proper proce-
dures.
(9) I nstal l the brake cal i per and rotor. Refer to
Group 5, Brakes, for proper procedures.
(10) Appl y the brakes and ti ghten hub nut to 244
Nm (180 ft. l bs.) torque.
Fig. 3 Cotter Pin, Nut Lock & Spring
1 - SPRING WASHER
2 - HUB NUT
3 - NUT LOCK
4 - COTTER PIN
Fig. 4 Hub Nut & Washer
1 - DRIVE SHAFT
2 - HUB WASHER
3 - HUB NUT
Fig. 5 Front
1 - DRIVESHAFT
2 - FRONT AXLE
AXLE SHAFT (Continued)
(11) I nstal l the spri ng washer, nut l ock and cotter
pi n on the stub shaft (Fi g. 6) .
(12) I nstal l the ski d pl ate, i f equi pped.
(13) I nstal l the wheel and ti re.
CV BOOT
REMOVAL
(1) Remove axl e dri veshaft from vehi cl e.
(2) Remove outer C/V joi nt.
(3) Remove outer C/V joi nt smal l cl amp and
remove boot (Fi g. 7).
(4) Remove i nner C/V joi nt boot cl amps and
remove boot.
INSTALLATION
The l ubri cant amounts i ncl uded wi th repl acement
boots are di fferent for i nner and outer C/V joi nts.
Appl y onl y the speci fi ed l ubri cant amount to each
C/V joi nt.
(1) Cl ean the C/V joi nts and shaft of al l ol d grease
and forei gn matter.
(2) Sl i de the i nner C/V joi nt boot up the shaft and
i nsert the l i p l ocated wi thi n the smal l -di ameter end
of the boot i nto the shaft groove (Fi g. 7).
(3) Retai n the smal l di ameter of the boot on the
shaft wi th a l adder-type cl amp i n the boot groove
(Fi g. 7). Veri fy that the boot and l i p are properl y
posi ti oned on the i ntermedi ate shaft. Posi ti on the
cl amp l ocati ng tabs i n the sl ots and ti ghten the
cl amp.
(4) Compress the cl amp bri dge wi th Remover/I n-
stal l er C-4124. Squeeze the tool handl es to compl ete
the ti ghteni ng of the cl amp (Fi g. 8). Care must be
exercised when using the tool to avoid cutting
through the clamp bridge or damaging the
boot.
(5) Posi ti on the l arge-di ameter end of the boot on
the C/V joi nt housi ng.
(6) After the i nner joi nt boot smal l cl amp i s
i nstal l ed, the i nboard hub must be set to a servi ce
bui l d l ength.
(a) Compress the i nner hub down the connector
shaft.
(b) Use a smal l bl unt dri ft between the l arge
end and the boot seal to rel i eve the pressure.
(c) The di stance edge of the l i p to the edge of the
fl ange shoul d be 181.00 mm (7.13 i n.). Thi s wi l l
el i mi nate excess ai r that can cause a bal l ooni ng
affect and possi bl y cause damage to the boot.
(7) Veri fy that the boot i s not twi sted and that i t i s
correctl y posi ti oned on the housi ng.
Fig. 6 Cotter Pin Installation
1 - COTTER PIN
2 - NUT LOCK
Fig. 7 Boot Retaining
1 - LOCATING SHOULDERS
2 - CLAMPS
Fig. 8 Compressing Clamp Bridge
1 - BOOT CLAMP PLIERS
2 - SLINGER
AXLE SHAFT (Continued)
(8) I nstal l the l arge l adder cl amp on the boot and
secure as done wi th the smal l l adder cl amps (Fi g. 8).
(9) Sl i de the outer C/V joi nt boot smal l cl amp onto
shaft.
(10) Sl i de outer C/V joi nt boot onto shaft and i nto
posi ti on on shaft.
(11) I nstal l smal l cl amp to boot as done above.
(12) I nstal l l arge boot cl amp over outer C/V joi nt.
(13) I nstal l outer C/V joi nt to shaft.
(14) I nstal l l arge boot cl amp to boot and C/V joi nt.
(15) I nstal l the C/V dri veshaft.
CV J OINT - OUTER
REMOVAL
(1) Cl amp shaft i n a vi se (wi th soft jaws) and sup-
port C/V joi nt.
(2) Remove cl amps from the C/V joi nt and di scard.
(3) Sl i de the boot off the outer joi nt and down the
shaft.
(4) Remove l ubri cant to expose the C/V joi nt snap
ri ng.
(5) Open snap ri ng and sl i de the joi nt off the shaft
(Fi g. 9).
(6) Remove sl i nger from the joi nt i f damaged. Use
a brass dri ft and a hammer and tap sl i nger ri ng off
the joi nt.
(7) Mark al i gnment marks on the beari ng hub,
beari ng cage and housi ng wi th dabs of pai nt (Fi g.
10).
(8) Cl amp C/V joi nt i n a verti cal posi ti on i n a i n
soft jawed vi se.
(9) Press down one si de of the beari ng cage/hub to
gai n access to a bal l at the opposi te. I f joi nt i s ti ght,
use a hammer and brass dri ft to l oosen the beari ng
hub. Do not contact the bearing cage with the
drift.
(10) Remove bal l from the beari ng cage (Fi g. 11). I f
necessary, a smal l pry bar can be used to pry the bal l
l oose from the cage.
(11) Repeat step above unti l al l si x bal l s are
removed from the beari ng cage.
Fig. 9 Outer C/V Joint
1 - SNAP RING
2 - SNAP RING GROVE
3 - SNAP RING PLIERS
Fig. 10 Ball Access
1 - ALIGNMENT MARKS
2 - BEARING HUB
3 - BEARING CAGE
4 - HOUSING
Fig. 11 Ball Removal
1 - HOUSING
2 - BEARING HUB
3 - BEARING CAGE
4 - BALL
CV BOOT (Continued)
(12) Move beari ng cage and hub to a verti cal posi -
ti on. Pul l cage upward and out from the housi ng
(Fi g. 12).
(13) Turn beari ng hub 90 i n the beari ng cage.
Al i gn one pai r of the hub l ands wi th the cage wi n-
dows. Rai se and i nsert one of the l ands i nto the adja-
cent cage wi ndow. Remove beari ng hub by rol l i ng i t
out of the cage (Fi g. 13).
INSTALLATION
I f the outer C/V joi nt i s excessi vel y worn, repl ace
the enti re C/V joi nt and boot.
(1) Li ghtl y appl y l ubri cati ng oi l to al l the outer
C/V joi nt components before assembl i ng them.
(2) Al i gn the beari ng hub, cage and housi ng
accordi ng to the al i gnment reference marks.
(3) I nsert one of the beari ng hub l ands i nto a bear-
i ng cage wi ndow. Rol l the hub i nto the cage (Fi g. 14).
Rotate the beari ng hub 90 to compl ete the i nstal l a-
ti on (Fi g. 15).
(4) I nsert beari ng cage/hub i nto the housi ng (Fi g.
16). Rotate the cage/hub 90 to compl ete the i nstal l a-
ti on (Fi g. 17).
(5) Appl y the l ubri cant i ncl uded wi th the repl ace-
ment boot to the bal l raceways. Spread the l ubri cant
equal l y between al l the raceways. One packet of
l ubri cant i s suffi ci ent to l ubri cate the joi nt.
(6) Ti l t beari ng hub and cage and i nstal l the bal l s
i n the raceways (Fi g. 18).
Fig. 12 Bearing Cage & Hub
1 - HOUSING
2 - BALL RACE
3 - BALL CAGE WINDOW
Fig. 13 Bearing Hub
Fig. 14 Bearing Hub
1 - BEARING HUB
2 - BEARING CAGE
Fig. 15 Bearing Cage & Hub
1 - CAGE WINDOWS
2 - SNAP RING
CV J OINT - OUTER (Continued)
(7) Appl y a smal l amount of l ubri cant to i nner
di ameter of sl i nger. Pl ace sl i nger squarel y on the
outer C/V joi nt. Use i nstal l er tool L-4518-1 from tool
set L-4518 and hammer sl i nger onto joi nt unti l i t
seats (Fi g. 19).
CAUTION: Prevent damage to the slinger after
installation or a when a replacement outer C/V joint
is installed.
(8) Posi ti on the smal l -di ameter end of the repl ace-
ment boot on the i nterconnecti ng shaft. Retai n the
boot wi th a repl acement cl amp.
(9) Appl y the requi red amount of l ubri cant to the
outer C/V joi nt and boot.
Fig. 16 Bearing Cage & Hub Installation
1 - BALL RACE
2 - BEARING CAGE WINDOW
3 - CV JOINT HOUSING
Fig. 17 Bearing Cage & Hub Installed In Housing
2 - BEARING HUB LARGE COUNTERBORE OUTWARD
3 - BOOT RETAINING SHOULDER
4 - BEARING HUB SMALL COUNTERBORE INWARD
5 - SLINGER
Fig. 18 Ball
2 - BEARING HUB
3 - BEARING CAGE
4 - BALL
Fig. 19 Slinger Installation
1 - HAMMER
2 - OUTER CV JOINT
3 - SLINGER
4 - INSTALLER
(10) Al i gn the shaft spl i nes to the outer C/V joi nt
spl i nes. Push the outer C/V joi nt unti l the snap ri ng
seats i n the groove (Fi g. 20).
(11) Ensure that the snap ri ng i s properl y seated
i n the housi ng. Pul l the outer C/V joi nt from the
i nterconnecti ng shaft to test.
(12) Pl ace the l arge-di ameter end of the repl ace-
ment boot over the edge of the C/V joi nt housi ng.
Ensure that the boot i s not twi sted.
(13) Retai n the boot on the housi ng wi th a repl ace-
ment retai ni ng cl amps.
CV J OINT - INNER
REMOVAL
(1) Remove the axl e dri veshaft.
(2) Pl ace the C/V joi nt housi ng i n a vi se.
(3) Remove the i nner boot retai ni ng cl amps. Pul l
the i nner boot back onto the i nterconnecti ng shaft.
Di scard the retai ni ng cl amps.
(4) Pul l tri pod and shaft strai ght out from the
i nner C/V joi nt housi ng.
(5) Remove snap ri ng from behi nd the tri pod and
sl i de tri pod toward the center of the shaft (Fi g. 21).
(6) Remove C-cl i p from the end of the shaft (Fi g.
22).
Fig. 20 Outer C/V
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
Fig. 21 Snap Retaining Ring
1 - SNAP RING
2 - TRIPOD JOINT
Fig. 22 Tripod C-Clip
1 - SNAP RING
2 - CHAMFERED EDGE
3 - GROOVE
4 - C-CLIP
5 - TRIPOD
(7) Remove tri pod from the shaft and repl ace boot,
i f necessary.
(8) Remove l ubri cant from the i nteri or of the hous-
i ng and the tri pod.
(9) I nspect needl e beari ng raceways i n the housi ng
and tri pod components for excessi ve wear and dam-
age. Repl ace the tri pod as a uni t onl y i f necessary.
INSTALLATION
(1) Sl i de boot down on shaft for work access.
(2) I nstal l snap ri ng past the ri ng groove. Sl i de the
tri pod onto the end of the shaft. Chamfered end of
tri pod i s adjacent to the C-cl i p groove.
(3) I nstal l C-cl i p and sl i de the tri pod out agai nst
the cl i p. I nstal l the snap ri ng i n the i nner groove. Be
sure the snap ri ng and C-cl i p are seated.
(4) Appl y the requi red quanti ty of l ubri cant to the
housi ng and boot. Coat the i nteri or of the joi nt hous-
i ng and the tri pod.
(5) I nsert and seat the tri pod and shaft i n the
housi ng.
(6) Posi ti on the l arge-di ameter end of the boot over
the edge of the housi ng. I nsert l i p of the boot i nto the
l ocati ng groove at the edge of the housi ng (Fi g. 23).
(7) I nsert smal l l i p onto l ocati ng groove i n shaft.
(8) I nstal l smal l boot cl amp i n the boot groove.
Veri fy that the boot and l i p are properl y posi ti oned
on the shaft. Posi ti on the cl amp l ocati ng tabs i n the
sl ots and ti ghten the cl amp tool (Fi g. 24).
NOTE: Squeeze tool handles to complete tightening
the clamp
(9) Posi ti on the l arge-di ameter end of the boot on
the C/V joi nt housi ng.
(10) After the i nner joi nt boot smal l cl amp i s
i nstal l ed, the i nboard hub must be set to a servi ce
bui l d l ength.
(a) Compress the i nner hub down the connector
shaft.
(b) Use a smal l bl unt dri ft between the l arge
end and the boot seal to rel i eve the pressure.
(c) The di stance edge of the l i p to the edge of the
fl ange shoul d be 181.00 mm (7.13 i n.). Thi s wi l l
el i mi nate excess ai r that can cause a bal l ooni ng
affect and possi bl y cause damage to the boot.
(11) Veri fy that the boot i s not twi sted and that i t
i s correctl y posi ti oned on the housi ng.
(12) I nstal l l arge cl amp on the boot and ti ghten
the cl amp wi th cl amp tool (Fi g. 24).
Fig. 23 Inner C/V Joint Boot
1 - CLAMP
2 - BOOT
3 - CLAMP
4 - SHAFT
5 - TRIPOD JOINT
Fig. 24 Compressing Clamp
1 - CLAMP TOOL
2 - SLINGER
CV J OINT - INNER (Continued)
FRONT AXLE - C205F
TABLE OF CONTENTS
page page
FRONT AXLE - C205F
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 34
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 34
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FRONT AXLE - C205F
DESCRIPTION
The C205F (Corporate 205mm ri ng gear Front)
axl e consi sts of an al umunum center secti on wi th an
axl e tube extendi ng from one si de. The tube i s
pressed i nto the di fferenti al housi ng.
The i ntegral type housi ng, hypoi d gear desi gn has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a fi tti ng for a vent hose used to
rel i eve i nternal pressure caused by vapori zati on and
i nternal expansi on.
The power i s transferred from the axl e through
two constant vel oci ty (C/V) dri ve shafts to the wheel
hubs. The dri ve shafts are i denti cal and i nterchange-
abl e.
The cover provi des a means for i nspecti on and ser-
vi ce wi thout removi ng the axl e from the vehi cl e.
The C205F axl e has the assembl y date and gear
rati o l i sted on a tag. The tag i s attached to the hous-
i ng cover by a cover bol t.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l -
pi n. Di fferenti al beari ng prel oad and ri ng gear
backl ash i s adjusted by the use of shi ms (sel ect thi ck-
ness). The shi ms are l ocated between the di fferenti al
beari ng cups and the axl e housi ng. Pi ni on beari ng
prel oad i s set and mai ntai ned by the use of a col l aps-
i bl e spacer.
OPERATION
The axl e recei ves power from the transfer case
through the front propel l er shaft. The front propel l er
shaft i s connected to the pi ni on gear whi ch rotates
the di fferenti al through the gear mesh wi th the ri ng
gear bol ted to the di fferenti al case. The engi ne power
i s transmi tted to the axl e shafts through the pi ni on
mate and si de gears. The si de gears are spl i ned to
the axl e shafts.
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
3 - 22 FRONT AXLE - C205F AN
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
Check for i nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or out of bal ance wheel s.
Loose wheel l ug nuts.
Worn U-joi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Fig. 1 Differential Operation-Straight Ahead Driving
1 - STRAIGHT AHEAD DRIVING
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 Differential Operation-On Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
AN FRONT AXLE - C205F 3 - 23
FRONT AXLE - C205F (Continued)
Check for l oose or damaged front end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
TESTI NG)
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged) can be caused by:
Hi gh engi ne i dl e speed.
Transmi ssi on shi ft operati on.
Loose engi ne/transmi ssi on/transfer case mounts.
Worn U-joi nts.
Loose spri ng mounts.
Loose pi ni on gear nut and yoke.
Excessi ve ri ng gear backl ash.
Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(3) Remove ski d pl ate support crossmember, i f nec-
essary.
(4) Remove both C/V dri veshafts.
(5) Mark the propel l er shaft, transfer case, and
pi ni on compani on fl ange for i nstal l ati on reference.
(6) Remove the front propel l er shaft.
(7) Remove the axl e vent tube.
(8) Use an adjustabl e and movabl e jack to support
the di fferenti al housi ng.
(9) Remove bol ts hol di ng the axl e to the engi ne
mounts (Fi g. 3).
(10) Remove bol ts hol di ng the axl e to the pi ni on
nose bracket (Fi g. 4).
(11) Lower the jack and housi ng.
(12) Remove the axl e from vehi cl e.
INSTALLATION
(1) Rai se the axl e i nto posi ti on. Loosel y i nstal l the
bol ts and nuts to hol d the axl e to the engi ne mounts
and pi ni on nose bracket.
(2) Ti ghten al l the bol ts fi nger-ti ght, then ti ghten
al l bol ts to 95 Nm (70 ft. l bs.).
(3) I nstal l the axl e vent tube.
(4) Al i gn the reference marks on the propel l er
shaft, transfer case, and pi ni on compani on fl ange.
(5) I nstal l propel l er shaft.
(6) I nstal l the C/V dri veshafts.
(7) I nstal l the ski d pl ate support crossmember, i f
necessary.
(8) I nstal l the ski d pl ate, i f necessary.
(9) Check di fferenti al l ubri cant l evel and add
l ubri cant, i f necessary.
(10) Remove the supports and l ower the vehi cl e.
ADJUSTMENTS
Ri ng gear and pi ni on are suppl i ed as matched sets
onl y. The i denti fyi ng numbers for the ri ng gear and
pi ni on are pai nted onto the pi ni on gear shaft and the
si de of the ri ng gear. A pl us (+) number, mi nus ()
number or zero (0) al ong wi th the gear set sequence
number (01 to 99) i s on each gear. Thi s fi rst number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
marked wi th a (0). The next two numbers are the
sequence number of the gear set. The standard set-
ti ng from the center l i ne of the ri ng gear to the back
face of the pi ni on i s 99.690 mm (3.925 i n.). The stan-
dard depth provi des the best teeth contact pattern.
Refer to Backl ash and Contact Pattern i n thi s secti on
for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
between the rear pi ni on beari ng cone and the pi ni on
gear head. (Fi g. 5).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance marked on both the ori gi nal and repl ace-
ment pi ni on. Add or subtract the thi ckness of the
ori gi nal depth shi ms to compensate for the di fference
i n the depth vari ances. Refer to the Depth Vari ance
charts.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus amount needed.
Note the pai nted number on the shaft of the dri ve
pi ni on (1, 2, 0, +1, +2, etc.). The numbers repre-
sent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
Fig. 3 Axle Mounting
1 - LEFT ENGINE MOUNT
2 - RIGHT ENGINE MOUNT
3 - FRONT AXLE
Fig. 4 Pinion Nose Mounting
1 - PINION NOSE BRACKET
2 - FRONT AXLE
Fig. 5 Adjustment Shim
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
5 - COLLAPSIBLE SPACER
PINION GEAR DEPTH VARIANCE
Original
Pinion
Gear
Depth
Variance
Replacement Pinion Gear Depth Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 8177,
Arbor Di scs 8541 and Di al I ndi cator C-3339 (Fi g. 6).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 8177 and rear pi ni on beari ng onto Screw 6741
(Fi g. 6).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through the
pi ni on beari ng cups (Fi g. 7).
(3) I nstal l front pi ni on beari ng and Cone 6740 onto
the screw hand ti ght (Fi g. 6).
(4) Pl ace Arbor Di scs 8541 on Arbor D-115-3 i n
posi ti on i n the housi ng si de beari ng cradl es (Fi g. 8).
I nstal l di fferenti al beari ng caps on arbor di scs and
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n the housi ng so di al probe and scooter bl ock are
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
tor. Ti ghten di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 9). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
Fig. 6 Pinion Gear Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
marked on the shaft of the pi ni on gear usi ng the
opposi te si gn on the vari ance number. For exampl e, i f
the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
(10) Remove the pi ni on depth gauge components
from the housi ng
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the housi ng. The proper shi m thi ck-
ness can be determi ned usi ng sl i p-fi t Dummy Bear-
i ngs 8398 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before proceedi ng wi th
the di fferenti al beari ng prel oad and gear backl ash
measurements, measure the pi ni on gear depth and
prepare the pi ni on for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on i s i nstal l ed, and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng, starti ng poi nt shi m thi cknesses, and the
prel oad speci fi cati on added together. The gear back-
l ash measurement determi nes the thi ckness of the
shi m used on the ri ng gear si de of the di fferenti al
case. Subtract the gear backl ash shi m thi ckness from
the total overal l shi m thi ckness and sel ect that
amount for the pi ni on si de of the di fferenti al (Fi g.
10).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
Fig. 7 Pinion Height Block
1 - PINION BLOCK
Fig. 8 Gauge Tools In
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
Fig. 9 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
(3) I nstal l Dummy Beari ngs 8398 on di fferenti al
case.
(4) I nstal l di fferenti al case i n the housi ng.
(5) I nsert Dummy Shi ms 8107 (0.118 i n. (3.0 mm))
starti ng poi nt shi ms between both dummy beari ngs
and the housi ng (Fi g. 11).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts.
(7) Usi ng a dead-bl ow hammer to seat the di ffer-
enti al dummy beari ngs to each si de of the di fferenti al
housi ng (Fi g. 12) and (Fi g. 13).
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 14).
(9) Attach Di al I ndi cator C-3339 to post and posi -
ti on di al i ndi cator pl unger on a fl at surface on a ri ng
gear bol t head (Fi g. 14).
(10) Push fi rml y and hol d di fferenti al case to pi n-
i on si de of axl e housi ng (Fi g. 15) and zero di al i ndi -
cator.
(11) Push fi rml y and hol d di fferenti al case to the
ri ng gear si de and record di al i ndi cator readi ng (Fi g.
16).
(12) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi cknesses to determi ne the total shi m
thi ckness necessary to achi eve zero di fferenti al end
pl ay.
(13) Add 0.2 mm (0.008 i n) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms necessary to compress, or prel oad the new
beari ngs when the di fferenti al i s i nstal l ed.
(14) Rotate di al i ndi cator out of the way on pi l ot
stud.
(15) Remove di fferenti al case, dummy beari ngs,
and starti ng poi nt shi ms from the housi ng.
(16) I nstal l the pi ni on i n the axl e housi ng. I nstal l
the compani on fl ange and establ i sh the correct pi ni on
rotati ng torque.
(17) I nstal l di fferenti al case and Dummy Beari ngs
i n axl e housi ng wi th a si ngl e dummy shi m on the
ri ng gear si de of the axl e and ti ghten retai ni ng cap
bol ts.
Fig. 10 Adjustment Shim
3 - RING GEAR
Fig. 11 Shim Starting Point
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
Fig. 12 Seat Pinion Side Dummy Bearing
1 - DEAD-BLOW HAMMER
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 14).
(19) Push and hol d di fferenti al case toward pi ni on.
(20) Zero di al i ndi cator face to poi nter.
(21) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng.
(22) Record di al i ndi cator readi ng.
(23) Subtract 0.05 mm (0.002 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Add the resul ti ng measure-
ment to the thi ckness of the si ngl e starti ng poi nt
shi m. Thi s total i s the thi ckness of shi m requi red to
achi eve proper backl ash.
(24) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(25) Rotate di al i ndi cator out of the way on pi l ot
stud.
Fig. 13 Seat Ring Gear Side Dummy
2 - DEAD-BLOW HAMMER
Fig. 14 Differential Side play
2 - DIFFERENTAIL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 Zero Dial Indicator
1 - CASE TO PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - DIAL INDICATOR
Fig. 16 Read Dial Indicator
1 - DIAL INDICATOR
2 - CASE TO RING GEAR SIDE
(26) Remove di fferenti al case, dummy beari ngs
and dummy shi m from the housi ng.
(27) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(28) I nstal l Spreader W-129-B and Adapter Pl ates
8142-A on the housi ng and spread open enough to
recei ve di fferenti al case.
(29) Pl ace the si de beari ng shi ms i n the di fferen-
ti al housi ng agai nst the housi ng shoul der.
(30) I nstal l the di fferenti al case i n the housi ng.
(31) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(32) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 17).
(33) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Zero di al i ndi cator face to poi nter.
(35) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the di fferenti al housi ng to the
other (Fi g. 18).
(36) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
19)and adjust pi ni on depth and gear backl ash as nec-
essary.
Fig. 17 Ring Gear Backlash
1 - DIAL INDICATOR
Fig. 18 Backlash Shim Adjustment
Fig. 19 Gear Tooth Contact Patterns
SPECIFICATIONS
FRONT AXLE - C205F
AXLE SPECIFICATIONS
Axle Ratio 3.55, 3.92
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Ring Gear Diameter 205 mm (7.562 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Std. Depth 99.69 mm (3.925 in.)
Pinion Bearing Preload - Original Bearings 1-2 Nm (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 17-2.5 Nm (15-22 in. lbs.)
Differential Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Pinion Nut 271-474 200-350 -
SPECIAL TOOLS
SPECIAL TOOLS
Puller C-293-PA
Adapter C-293-42
Adapter C-293-48
Plug C-293-3
Puller C-452
Holder 6719A
Installer C-3972-A
Installer Screw 8112
Cup 8109
Handle C-4171
Installer 8236
Installer D-145
Installer D-145
SPECIAL TOOLS (Continued)
Remover 8401
Remover 8401
Installer 6448
Bearing Remover C-4660
Cup 8150
Installer 5063
Installer 8402
Gauge Block 8177
Pinion Depth Set
Adapter Kit 6987A
AXLE SHAFTS
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(2) Remove the necessary C/V dri veshaft from
vehi cl e.
(4) Cl ean al l forei gn materi al from axl e seal area.
(5) I nstal l Pul l er Adapter 8420-A onto the axl e
shaft.
(6) I nstal l Sl i de Hammer C-3752 to the pul l er
adapter.
(7) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube.
(8) I nspect axl e shaft seal for l eakage or damage.
Repl ace the seal i f there i s any questi on as to i ts con-
di ti on.
(9) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) Push fi rml y on the axl e shaft unti l the axl e
shaft snap-ri ng passes compl etel y through the si de
gear and engages the snap-ri ng groove.
(3) Check the di fferenti al fl ui d l evel and add fl ui d
i f necessary. Refer to Lubri cant i n thi s group for
l ubri cant requi rements.
(4) I nstal l ski d pl ate, i f necessary.
(5) I nstal l C/V dri veshaft.
(6) Lower vehi cl e.
AXLE SHAFT SEALS
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal from the end of the
axl e shaft tube wi th a smal l pry bar.
(3) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l a new axl e shaft seal wi th I nstal l er
8402 and Handl e C-4171.
(3) I nstal l the axl e shaft.
Spreader W-129-B
Guide Pin C-3288-B
Dial Indicator C-3339
Dummy Shim 8107
Dummy Bearing 8398
AXLE BEARINGS
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal and beari ng from
the axl e tube wi th Beari ng Removal Tool C-4660-A.
(3) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 5063
and Handl e C-4171.
(3) I nstal l a new axl e shaft seal wi th I nstal l er
PINION SEAL
REMOVAL
(2) Remove ski d pl ate, i f equi pped.
(3) Remove both C/V dri veshafts.
(4) Mark the propel l er shaft and pi ni on compani on
fl ange for i nstal l ati on reference.
(5) Remove the front propel l er shaft.
(6) Rotate the pi ni on gear three or four ti mes and
veri fy pi ni on rotates smoothl y.
(7) Record rotati ng torque at the pi ni on wi th an
i nch pound torque wrench, for i nstal l ati on reference
(Fi g. 20).
(8) Remove the compani on fl ange wi th Remover
C-452 (Fi g. 21).
(9) Posi ti on Hol der 6719 agai nst the compani on
fl ange and i nstal l a four bol ts and washers i nto the
threaded hol es and ti ghten the bol ts.
(10) Remove the pi ni on nut.
C-452 (Fi g. 21).
(12) Remove pi ni on seal wi th a pry tool or a sl i de
hammer mounted screw.
INSTALLATION
NOTE: Outer perimeter of pinion seal is pre-coated
with a special sealant.
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal .
(2) I nstal l seal wi th I nstal l er C-3972-A and Handl e
C-4171 (Fi g. 22).
(3) I nstal l the compani on fl ange onto the pi ni on
wi th I nstal l er C-3718 and Hol der 6719A.
(4) Posi ti on hol der agai nst the compani on fl ange
and i nstal l four bol ts and washers i nto the threaded
hol es. Ti ghten the bol t and washer so that the hol der
i s hel d to the fl ange.
(5) I nstal l the new pi ni on nut onto the pi ni on shaft
and ti ghten the pi ni on nut unti l there i s zero beari ng
end-pl ay (Fi g. 23).
Fig. 20 Pinion Rotating Torque
2 - INCH POUND TORQUE WRENCH
Fig. 21 Companion Flange Remover
2 - PULLER TOOL
CAUTION: Do not exceed the minimum tightening
torque when installing the companion flange at this
point. Damage to the collapsible spacer or bearings
may result.
(6) Ti ghten the nut to 271 Nm (200 ft. l bs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed.
(7) Rotate and record the axl e rotati ng torque at
the pi ni on shaft usi ng a torque wrench. The rotati ng
torque shoul d be equal to the readi ng recorded dur-
i ng removal pl us an addi ti onal 0.56 Nm (5 i n. l bs.)
(Fi g. 24).
(8) I f the rotati ng torque i s l ow, ti ghten the pi ni on
nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l the proper
rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
(9) I nstal l the propel l er shaft wi th reference marks
al i gned.
(10) Add gear l ubri cant to di fferenti al housi ng i f
necessary.
(11) I nstal l C/V dri veshafts.
(12) I nstal l ski d pl ate, i f equi pped.
DIFFERENTIAL
REMOVAL
(2) Remove the di fferenti al housi ng cover and
al l ow fl ui d to drai n.
(3) Remove the axl e shafts.
Fig. 22 Pinion Seal Installer
1 - HANDLE
2 - INSTALLER
Fig. 23 Companion Flange Holder
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 24 Check Pinion Rotation Torque
PINION SEAL (Continued)
(4) Note di fferenti al beari ng cape reference num-
bers stamped on caps and machi ned fl at on the hous-
i ng. I f reference numbers cannot be found, make new
marks for l ater reference.
(5) Loosen the beari ng cap bol ts.
(6) I nstal l Adapter Pl ates 8142-A onto the axl e
housi ng.
(7) Posi ti on Spreader W-129-B onto the adapter
pl ates and i nstal l the safety hol ddown cl amps.
Ti ghten the tool turnbuckl e fi nger-ti ght.
(8) I nstal l a Pi l ot Stud L-4438 at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(9) Spread the housi ng to remove the di fferenti al
case from the housi ng. Measure the di stance wi th the
di al i ndi cator (Fi g. 25).
CAUTION: Do not spread over 0.34 mm (0.013 in). If
the housing is over-spread, it could be distorted or
damaged.
(10) Remove the di al i ndi cator.
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups and shi ms
remai n i n posi ti on on the di fferenti al beari ngs.
(13) Tag di fferenti al beari ng cups and shi ms to
i ndi cate thei r l ocati on.
(14) Remove spreader from housi ng.
DISASSEMBLY
(1) Remove ri ng gear.
(2) Remove rol l -pi n hol di ng mate shaft i n housi ng.
(3) Remove pi ni on gear mate shaft.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 26).
(5) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the pi ni on mate gears and thrust wash-
ers.
(3) I nstal l the pi ni on gear mate shaft.
(4) Al i gn the hol e i n the pi ni on gear mate shaft
wi th the hol e i n the di fferenti al case.
(5) I nstal l the rol l -pi n i n the di fferenti al case a
punch and hammer (Fi g. 27). Peen the edge of the
rol l -pi n hol e i n the di fferenti al case i n two pl aces
180 apart.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
(7) I nstal l ri ng gear.
Fig. 25 Spread Axle Housing-Typical
1 - DIAL INDICATOR
2 - SPREADER
Fig. 26 Pinion Mate Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
DIFFERENTIAL (Continued)
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are repl aced, Refer to adjustments fore Di fferen-
ti al Beari ng Prel oad and Gear Backl ash procedures.
(1) I nstal l Spreader W-129-B, wi th the Adapter
Pl ates 8142-A, on the axl e and i nstal l the safety
hol ddown cl amps. Ti ghten the tool turnbuckl e fi nger
ti ght.
(2) I nstal l a Pi l ot Stud L-4438 at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(3) Spread the housi ng to i nstal l the di fferenti al
case and prel oad shi ms i n the housi ng. Measure the
di stance wi th the di al i ndi cator.
CAUTION: Do not spread over 0.34 mm (0.013 in). If
the housing is over-spread, it could be distorted or
damaged.
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
di fferenti al beari ng cups remai n i n posi ti on on the
beari ngs and the di fferenti al prel oad shi ms are
seated i n the housi ng. Tap di fferenti al case to ensure
beari ngs cups are seated i n the housi ng.
(6) I nstal l beari ng caps to thei r ori gi nal l ocati ons
and l oosel y i nstal l cap bol ts.
(7) Remove axl e housi ng spreader.
(8) Ti ghten the beari ng cap bol ts to 61 Nm (45 ft.
l bs.).
(9) I nstal l the axl e shafts.
(10) I nstal l the di fferenti al housi ng cover and fi l l
wi th the correct l ubri cant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Remove beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA , Adapters C-293-48 and
Pl ug C-293-3 (Fi g. 28).
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 29).
(2) I nstal l di fferenti al i n axl e housi ng.
Fig. 27 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 28 Differential Bearing Puller
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a vi se wi th soft jaw
(Fi g. 30).
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Dri ve ri ng gear from di fferenti al case wi th a
soft hammer (Fi g. 30).
(5) Mark the compani on yoke and compani on
fl ange for i nstal l ati on reference.
(6) Remove compani on fl ange bol ts and ti e the pro-
pel l er shaft to the vehi cl e underbody.
(7) Rotate the compani on fl ange three or four
ti mes and veri fy fl ange rotates smoothl y.
(8) Record rotati ng torque of the compani on fl ange
wi th an i nch pound torque wrench for i nstal l ati on
reference (Fi g. 31).
(9) I nstal l bol ts i nto two of the threaded hol es i n
the compani on fl ange 180 apart.
fl ange and i nstal l a bol t and washer i nto one of the
remai ni ng threaded hol es. Ti ghten the bol ts so that
the Hol der 6719 i s hel d to the fl ange.
(11) Remove the pi ni on nut.
C-452 (Fi g. 32).
Fig. 29 Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 30 Ring Gear
2 - RING GEAR
3 - RAWHIDE HAMMER
DIFFERENTIAL CASE BEARINGS (Continued)
(13) Remove pi ni on from di fferenti al housi ng (Fi g.
33).
(14) Remove pi ni on seal wi th a pry tool or a sl i de
(15) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(16) Remove front pi ni on beari ng cup wi th
Remover D-103 and Handl e C-4171 (Fi g. 34).
(17) Remove rear beari ng cup from housi ng (Fi g.
35) wi th Remover 8401 and Handl e C-4171.
Fig. 32 Companion Flange Remover
2 - PULLER TOOL
Fig. 33 Remove Pinion
1 - RAWHIDE HAMMER
Fig. 34 Front Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 35 Rear Bearing Cup
1 - DRIVER
2 - HANDLE
PINION GEAR/RING GEAR/TONE RING (Continued)
(18) Remove the col l apsi bl e prel oad spacer (Fi g.
36).
(19) Remove rear pi ni on beari ng wi th Pul l er/Press
C-293-PA and Adapters C-293-42 (Fi g. 37).
(20) Remove depth shi ms from the pi ni on shaft
and record thi ckness of shi ms.
INSTALLATION
matched set. Never replace one gear without replac-
ing the other. If ring and pinion gears or bearings
are replaced, Refer to Adjustments for Pinion Gear
Depth Setting.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of beari ng cup.
(2) I nstal l rear pi ni on beari ng cup wi th I nstal l er
D-145 and Dri ver Handl e C-4171 (Fi g. 38) and veri fy
cup i s seated.
(3) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of beari ng cup.
(4) I nstal l front pi ni on beari ng cup wi th I nstal l er
D-129 and Handl e C-4171 (Fi g. 39) and veri fy cup i s
seated.
(5) I nstal l pi ni on front beari ng and oi l sl i nger i f
equi pped.
Fig. 36 Collapsible Spacer
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 37 Rear Pinion Bearing
1 - SPECIAL TOOL C-293PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
Fig. 38 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
(7) I nstal l pi ni on seal wi th I nstal l er C-3972-A and
Handl e C-4171 (Fi g. 40).
(8) Pl ace the proper thi ckness depth shi m on the
pi ni on shaft.
(9) I nstal l rear beari ng and sl i nger i f equi pped,
onto the pi ni on shaft wi th I nstal l er 6448 (Fi g. 41)and
a press.
(10) I nstal l newcol l apsi bl e prel oad spacer onto the
pi ni on shaft (Fi g. 42).
(11) I nstal l the pi ni on i n the axl e housi ng.
(12) I nstal l the compani on fl ange wi th I nstal l er
C-3718 and Hol der 6719.
(13) I nstal l new pi ni on nut and ti ghten to 271 Nm
(200 ft. l bs.) (Fi g. 43).
(14) Usi ng Hol der 6719 and a torque wrench set at
474 Nm (350 ft. l bs.). Ti ghten pi ni on nut unti l bear-
i ng end pl ay i s taken up.
Fig. 39 Front Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 40 Pinion Seal
1 - HANDLE
2 - INSTALLER
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 42 Collapsible Preload Spacer
2 - SHOULDER
3 - PINION
5 - REAR BEARING
(15) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l desi red rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over-
crushi ng the col l apsi bl e spacer (Fi g. 44). The torque
necessary to rotate the pi ni on shoul d be:
Ori gi nal Beari ngs: 1 to 2.5 Nm (10 to 20 i n.
l bs.)
New Beari ngs: 1.7 to 2.5 Nm (15 to 22 i n. l bs.)
be installed.
(16) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(17) I nvert the di fferenti al case i n the vi se.
(18) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 108 Nm (80 ft. l bs.) (Fi g. 45).
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(19) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
(20) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant.
(21) I nstal l propel l er shaft wti h reference marks
al i gned.
Fig. 43 Pinion Nut
3 - TORQUE WRENCH
Fig. 45 Ring Gear Bolt
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
REAR AXLE - 8 1/4
TABLE OF CONTENTS
page page
REAR AXLE - 8 1/4
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 58
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 59
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC LOK . . . . . . . 67
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR AXLE - 8 1/4
DESCRIPTION
The 8 1/4 i nch axl e housi ngs consi st of a cast i ron
center secti on wi th axl e tubes extendi ng from ei ther
si de. The tubes are pressed i nto and wel ded to the
di fferenti al housi ng to form a one-pi ece axl e housi ng.
The axl es have a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi -fl oati ng axl e
shafts, meani ng vehi cl e l oads are supported by the
axl e shaft and beari ngs. The axl e shafts are retai ned
by C-l ocks i n the di fferenti al si de gears.
The removabl e, stamped steel cover provi des a
means for i nspecti on and servi ce wi thout removi ng
the compl ete axl e from the vehi cl e.
The 8 1/4 axl e have a date tag and a gear rati o tag.
The tags are attached to the di fferenti al housi ng by a
cover bol t.
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer.
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
AXLE IDENTIFICATION
The axl e di fferenti al cover can be used for i denti fi -
cati on of the axl e (Fi g. 1). A tag i s al so attached to
the cover.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
STANDARD DIFFERENTIAL
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 2).
AN REAR AXLE - 8 1/4 3 - 47
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
3). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
TRAC-LOK DIFFERENTIAL
The Trac-l ok cl utches are engaged by two concur-
rent forces. The fi rst bei ng the prel oad force exerted
through Bel l evi l l e spri ng washers wi thi n the cl utch
packs. The second i s the separati ng forces generated
by the si de gears as torque i s appl i ed through the
ri ng gear (Fi g. 4).
The Trac-l ok desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
GEAR NOISE
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
Fig. 1 Differential Cover
1 - DIFFERENTIAL COVER
2 - IDENTIFICATION TAG
3 - PUSH-IN FILL PLUG
4 - DATE TAG
Fig. 2 Differential Operation - Straight Ahead Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 3 Differential Operation - On Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 48 REAR AXLE - 8 1/4 AN
REAR AXLE - 8 1/4 (Continued)
greatl y:
Gear damage.
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
LOW SPEED KNOCK
U-joi nt or by worn si degear thrust washers. A worn
VIBRATION
caused by a:
Worn or out-of-bal ance wheel s.
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
TESTI NG)
Fig. 4 Powr-lok Limited Slip Differential
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
AN REAR AXLE - 8 1/4 3 - 49
DRIVELINE SNAP
i nto gear (or the cl utch engaged), can be caused by:
Worn U-joi nts.
DIAGNOSTIC CHART
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
1. Replace case and inspect gears
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
Avoid erratic use of clutch.
3 - 50 REAR AXLE - 8 1/4 AN
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
and quantity.
wheel/tire.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
2. Improper grade of lubricant. 2. Fill differential with the correct
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
AN REAR AXLE - 8 1/4 3 - 51
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
adjustment.
2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
pinion.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
REMOVAL
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Secure brake drums to the axl e shaft.
(6) Remove the RWAL sensor from the di fferenti al
housi ng, i f necessary. Refer to Brakes for procedures.
(7) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Brakes for procedures.
(8) Di sconnect the parki ng brake cabl es and cabl e
brackets.
(9) Di sconnect the vent hose from the axl e shaft
tube.
(10) Mark the propel l er shaft and compani on
fl ange for i nstal l ati on al i gnment reference.
(11) Remove propel l er shaft.
(12) Di sconnect shock absorbers from axl e.
(13) Remove the spri ng cl amps and spri ng brack-
ets. Refer to Suspensi on for procedures.
(14) Separate the axl e from the vehi cl e.
INSTALLATION
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn to
the l eaf spri ng centeri ng bol ts.
(2) I nstal l spri ng cl amps and spri ng brackets.
Refer to Suspensi on for procedures.
(3) I nstal l shock absorbers and ti ghten nuts to 82
Nm (60 ft. l bs.).
(4) I nstal l RWAL sensor i nto the di fferenti al hous-
i ng. Refer to Brakes for procedures.
(5) I nstal l parki ng brake cabl es, cabl e brackets
and brake drums. Refer to Brakes for procedures.
(6) Connect brake hose to axl e juncti on bl ock.
Refer to Brakes for procedures.
(7) I nstal l axl e vent hose.
(8) I nstal l propel l er shaft wi th reference marks
al i gned. Ti ghten bol ts to 108 Nm (80 ft. l bs.).
(9) I nstal l the wheel s and ti res.
(10) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons for l ubri cant requi rements.
(11) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
ADJUSTMENTS
pi ni on are pai nted onto the pi ni on gear shaft (Fi g. 5)
and the si de of the ri ng gear. A pl us (+) number,
mi nus () number or zero (0) al ong wi th the gear set
sequence number (01 to 99) i s on each gear. Thi s fi rst
number i s the amount (i n thousandths of an i nch)
the depth vari es from the standard depth setti ng of a
pi ni on marked wi th a (0). The next two numbers are
the sequence number of the gear set. The standard
depth provi des the best teeth contact pattern. Refer
to Backl ash and Contact Pattern i n thi s secti on for
addi ti onal i nformati on.
3 - 52 REAR AXLE - 8 1/4 AN
behi nd the rear pi ni on beari ng (Fi g. 6).
vari ance pai nted onto both the ori gi nal and repl ace-
chart.
mi nus the amount needed.
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Original
Pinion
Gear
Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 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
Fig. 5 Pinion ID Numbers
1 - VARIANCE NUMBER
2 - SEQUENCE NUMBER
Fig. 6 Adjustment Shim Locations
3 - PINION BEARING
5 - PINION GEAR
6 - BEARING CUP
AN REAR AXLE - 8 1/4 3 - 53
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 7).
(Fi g. 7).
rear beari ng and screw i nto housi ng through pi ni on
beari ng cups (Fi g. 8).
(3) I nstal l front pi ni on beari ng and Cone-Nut 6740
hand ti ght (Fi g. 7).
(4) Pl ace Arbor Di sc 8541 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 9).
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
Fig. 7 Pinion Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1 - PINION BLOCK
Fig. 9 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
3 - 54 REAR AXLE - 8 1/4 AN
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 7). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator. Ti ghten di al i ndi cator face
l ock screw.
(7) Sl owl y sl i de the di al i ndi cator probe over the
edge of the pi ni on hei ght bl ock.
(Fi g. 10). When di al probe contacts the arbor bar, the
di al poi nter wi l l turn cl ockwi se. Conti nue movi ng the
di al probe to the crest of the arbor bar and record the
hi ghest readi ng. I f the di al i ndi cator can not achi eve
a zero readi ng, the rear beari ng cup or the pi ni on
depth gauge set i s not i nstal l ed correctl y.
marked on the shaft of the pi ni on. For exampl e, i f
BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
The maxi mum ri ng gear backl ash vari ati on i s
0.003 i nch (0.076 mm).
Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
Mai ntai n the gear teeth engaged (meshed) as
marked.
The beari ngs must be seated by rapi dl y rotati ng
the pi ni on gear a hal f turn back and forth.
Do thi s fi ve to ten ti mes each ti me the threaded
adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded
adjuster i nward unti l the di fferenti al beari ng free-
pl ay i s el i mi nated (Fi g. 11). Al l ow some ri ng gear
backl ash (approxi matel y 0.01 i nch/0.25 mm) between
the ri ng and pi ni on gear. Seat the beari ng cups wi th
the procedure descri bed above.
Fig. 10 Pinion Gear Depth
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 11 Threaded Adjuster Tool
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
AN REAR AXLE - 8 1/4 3 - 55
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 12).
Measure the backl ash at 4 posi ti ons (90 degrees
apart) around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.003 to 0.004
i nch (0.076 to 0.102 mm) wi th each adjuster ti ght-
ened to 14 Nm (10 ft. l bs.). Seat the beari ng cups
wi th the procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts to 95
Nm (70 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
Nm (75 ft. l bs.). Seat the beari ng cups wi th the pro-
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 Nm (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.006 to 0.008 i nch (0.15 to 0.203 mm).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 Nm (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 Nm (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 Nm (90 i n. l bs.).
Gear Contact procedure.
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st, and hol d a shop towel around the
tern.
shop towel .
essary.
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
3 - 56 REAR AXLE - 8 1/4 AN
AN REAR AXLE - 8 1/4 3 - 57
SIDE GEAR CLEARANCE
When measuri ng si de gear cl earance, check each
gear i ndependentl y. I f i t necessary to repl ace a si de
gear, repl ace both gears as a matched set.
(1) I nstal l the axl e shafts and C-l ocks and pi ni on
mate shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 14) .
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the axl e shaft i s contacti ng the
pi ni on mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 15). I n some cases, the end of the axl e shaft wi l l
move and contact the mate shaft when the feel er
gauge i s i nserted. The C-l ock i s preventi ng the si de
gear from sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-l ock from the axl e shaft. Use a mi crometer to mea-
sure the thrust washer thi ckness. Record the thi ck-
ness and re-i nstal l the thrust washer. Assembl e the
di fferenti al case wi thout the C-l ock i nstal l ed and re-
measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-l ock was i nstal l ed to
thrust washer thi ckness measured. The sum wi l l
determi ne the requi red thi ckness of the repl acement
thrust washer.
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
SPECIFICATIONS
REAR AXLE - 8 1/4
AXLE SPECIFICATIONS
Axle Ratio 3.21, 3.55, 3.92
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Diameter 209.5 mm (8.25 in.)
Pinion Bearing Preload - New Bearings 1.7-4 Nm (15-35 in. lbs.)
Fig. 14 Side Gear Clearance
1 - FEELER GAUGE
2 - SIDE GEARS
Fig. 15 Side Gear
3 - 58 REAR AXLE - 8 1/4 AN
Pinion Nut Minimum 285 210 -
Adjuster Lock Screw 10 7.5 90
Backing Plate Bolts 65 48 -
SPECIAL TOOLS
8 1/4 AXLE
Puller 6790
Remover 6310
Installer C-4198
Handle C-4171
Installer C-4076-B
Handle C-4735-1
AN REAR AXLE - 8 1/4 3 - 59
SPECIFICATIONS (Continued)
Holder 6719
Puller C-452
Installer C-3718
Adjustment Wrench C-4164
Puller/Press C-293PA
Adapters C-293-48
Adapter Plug SP-3289
Adapters C-293-47
Installer C-4340
Fixture 8138
3 - 60 REAR AXLE - 8 1/4 AN
Installer C-4345
Remover C-4307
Installer C-4308
Installer D-130
Installer 6448
Trac-lok Tools 8140
Trac-lok Tools 6960
Pinion Block 8540
Arbor Discs 8541
Pinion Gauge Set
AN REAR AXLE - 8 1/4 3 - 61
AXLE SHAFTS
REMOVAL
(1) Pl ace the transmi ssi on i n NEUTRAL and rai se
and support vehi cl e.
(3) Remove brake drum (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DRUM - REMOVAL) ..
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Remove the housi ng cover and drai n l ubri cant.
(6) Rotate di fferenti al case to access the pi ni on
shaft l ock screw. Remove l ock screw and pi ni on shaft
from di fferenti al case (Fi g. 16).
(7) Push axl e shaft i nward then remove axl e shaft
C-l ock (Fi g. 17).
(8) Remove axl e shaft bei ng careful l not to damage
shaft beari ng and seal .
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect axl e shaft beari ng contact surface for
si gns of bri nel l i ng, gal l i ng and pi tti ng.
INSTALLATION
l ubri cant. I nsert axl e shaft through seal , beari ng and
engage i t i nto si de gear spl i nes.
aging axle shaft seal lip.
(2) I nsert C-l ock i n end of axl e shaft. Push axl e
shaft outward to seat C-l ock i n si de gear.
(3) I nsert pi ni on shaft i nto di fferenti al case and
through thrust washers and di fferenti al pi ni ons.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 11 Nm (8 ft. l bs.).
(5) I nstal l cover and fi l l wi th gear l ubri cant.
(6) I nstal l brake drum (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DRUM - I NSTALLATI ON)
.
(7) I nstal l wheel and ti re assembl i es.
AXLE SHAFT SEALS
REMOVAL
(2) Remove axl e shaft.
(3) Remove axl e shaft seal from the end of the axl e
tube wi th a smal l pry bar (Fi g. 18).
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l a new axl e seal wi th I nstal l er C-4076-B
and Handl e C-4735-1. When the tool contacts the
axl e tube, the seal i s i nstal l ed to the correct depth.
(3) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(5) Check and fi l l gear l ubri cant.
Fig. 16 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 17 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
3 - 62 REAR AXLE - 8 1/4 AN
AXLE BEARINGS
REMOVAL
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(4) Remove axl e shaft beari ng wi th Beari ng
Removal Tool Set 6310 and Adapter Foot 6310-9 (Fi g.
20).
INSTALLATION
(2) I nstal l the axl e shaft beari ng wi th I nstal l er
C-4198 and Handl e C-4171. Ensure beari ng i s
i nstal l ed strai ght and the tool i s i n contacts wi th the
axl e tube when seati ng the beari ng.
NOTE: Install bearing with part number against the
installer.
(6) Check and fi l l gear l ubri cant.
Fig. 18 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 19 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 20 Axle Shaft Bearing
1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE
AN REAR AXLE - 8 1/4 3 - 63
AXLE SHAFT SEALS (Continued)
PINION SEAL
REMOVAL
(2) Mark the uni versal joi nt, compani on fl ange and
pi ni on shaft for i nstal l ati on reference.
(3) Remove compani on fl ange bol ts and secure the
shaft i n an upri ght posi ti on to prevent damage to the
rear uni versal joi nt.
(5) Remove brake drums to prevent any drag.
(6) Rotate compani on fl ange three or four ti mes
and veri fy fl ange rotates smoothl y.
(7) Measure rotati ng torque of the pi ni on wi th a
i nch pound torque wrench and record the readi ng for
i nstal l ati on reference.
remai ni ng threaded hol es. Ti ghten the bol ts so the
Hol der 6719 i s hel d to the fl ange.
(10) Remove the pi ni on nut and washer.
(11) Remove compani on fl ange wi th Remover
C-452 (Fi g. 21).
(12) Remove pi ni on seal wi th a pry tool or sl i de-
INSTALLATION
NOTE: The outer perimeter of the seal is pre-coated
(2) I nstal l new pi ni on seal wi th I nstal l er C-4076-B
and Handl e C-4735-1 (Fi g. 22)
(3) I nstal l compani on fl ange on the end of the
shaft wi th the reference marks al i gned.
remai ni ng threaded hol es. Ti ghten the bol ts so
(6) I nstal l compani on fl ange on pi ni on shaft wi th
I nstal l er C-3718 and Hol der 6719.
(7) I nstal l the pi ni on washer and a new pi ni on
nut. The convex si de of the washer must face out-
ward.
torque when installing the companion flange retain-
ing nut at this point. Damage to collapsible spacer
or bearings may result.
(8) Hol d compani on fl ange wi th Hol der 6719 and
ti ghten the pi ni on nut to 285 Nm (210 ft. l bs.) (Fi g.
23). Rotate pi ni on several revol uti ons to ensure the
beari ng rol l ers are seated.
(9) Rotate pi ni on wi th an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
Fig. 21 Companion Flange
2 - PULLER
1 - HANDLE
3 - INSTALLER
3 - 64 REAR AXLE - 8 1/4 AN
i ng recorded duri ng removal pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 24).
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed.
(10) I f rotati ng torque i s l ow use Hol der 6719 to
hol d the compani on fl ange (Fi g. 23) and ti ghten pi n-
i on nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l proper
NOTE: The seal replacement is unacceptable if final
pinion nut torque is less than 285 Nm (210 ft. lbs.).
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(11) I nstal l propel l er shaft wi th the i nstal l ati on
reference marks al i gned.
(12) Ti ghten compani on fl ange bol ts to 108 Nm
(80 ft. l bs.).
(13) I nstal l the brake drums.
(14) Check the di fferenti al housi ng l ubri cant l evel .
(15) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
DIFFERENTIAL
REMOVAL
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark the di fferenti al housi ng and beari ng caps
for i nstal l ati on reference (Fi g. 25).
(7) Remove beari ng threaded adjuster l ocks from
each beari ng cap.
(8) Loosen beari ng cap bol ts, them l oosen the
threaded adjusters wi th Wrench C-4164 (Fi g. 26).
(9) Hol d the di fferenti al case whi l e removi ng bear-
i ng caps and adjusters.
(10) Remove the di fferenti al case.
NOTE: Tag bearing cups and threaded adjusters
location, for installation reference.
Fig. 23 Tightening Pinion Nut
3 - TORQUE WRENCH
Fig. 24 Pinion Rotation Torque
AN REAR AXLE - 8 1/4 3 - 65
DISASSEMBLY
(1) Remove pi ni on shaft l ock screw (Fi g. 27).
(2) Remove pi ni on shaft.
di fferenti al pi ni ons and thrust washers (Fi g. 28).
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l di fferenti al pi ni on and thrust washers.
(3) I nstal l the pi ni on shaft.
(4) Al i gn the hol e i n the pi ni on shaft wi th the hol e
i n the di fferenti al case and i nstal l the pi ni on shaft
l ock screw.
Fig. 25 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARKS
4 - BEARING CAP
Fig. 26 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 28 Differential
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
3 - 66 REAR AXLE - 8 1/4 AN
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on. Careful l y posi ti on the assem-
bl ed di fferenti al case i n the housi ng.
(2) I nstal l the di fferenti al beari ng caps i n thei r
ori gi nal l ocati ons (Fi g. 29).
(3) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 Nm (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(4) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
(5) Ti ghten beari ng cap bol ts to 95 Nm (70 ft.l bs).
(6) I nstal l adjuster l ocks on the beari ng caps.
(7) I nstal l axl e shafts.
(8) Appl y a bead of Mopar Si l i cone Rubber Seal ant
or equi val ent to the housi ng cover (Fi g. 30).
Install the housing cover within 5 minutes
after applying the sealant.
(9) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(10) Fi l l di fferenti al wi th gear l ubri cant to bottom
of the fi l l pl ug hol e. Refer to the Lubri cant Speci fi ca-
ti ons for correct quanti ty.
(11) I nstal l the fi l l hol e pl ug.
(14) Trac-l ok di fferenti al equi pped vehi cl es
shoul d be road tested by maki ng 10 to 12 sl ow fi gure-
ei ght turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
DIAGNOSIS AND TESTING - TRAC-LOK
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t
for repai r, drai n, fl ush and refi l l the axl e wi th the
speci fi ed l ubri cant. A contai ner of Mopar Trac-l ok
Lubri cant (fri cti on modi fi er) shoul d be added after
repai r servi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 31).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
Fig. 29 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
4 - BEARING CAP
Fig. 30 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
AN REAR AXLE - 8 1/4 3 - 67
DISASSEMBLY
(1) Cl amp si de gear Hol di ng Fi xture 6965 i n a vi se
and posi ti on the di fferenti al case on the Hol di ng Fi x-
ture (Fi g. 32).
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 33).
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer (Fi g. 34).
(5) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
35).
(6) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(7) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter Di sc C-6960-3 (Fi g. 36) to prevent
adapter from turni ng.
Fig. 31 Trac-lok Test -Typical
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 32 Differential Case Holding Fixture
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 33 Mate Shaft Lock Screw
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 34 Pinion Shaft
2 - SIDE GEAR
3 - DRIFT
3 - 68 REAR AXLE - 8 1/4 AN
DIFFERENTIAL - TRAC-LOK (Continued)
(8) I nstal l Forci ng Screw C-6960-4 and ti ghten
screw to 122 Nm (90 ft. l bs.) maxi mum to compress
Bel l evi l l e spri ngs i n cl utch packs (Fi g. 37).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 38).
Fig. 35 Step Plate
1 - LOWER SIDE GEAR
3 - STEP PLATE
Fig. 36 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED ADAPTER DISC
Fig. 37 Compress Belleville Spring
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
Fig. 38 Pinion Gear Thrust Washer
1 - THRUST WASHER
2 - FEELER GAUGE
AN REAR AXLE - 8 1/4 3 - 69
(10) I nsert Turni ng Bar C-6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 39).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 40).
(16) Remove di fferenti al case from the Hol di ng
Fi xture. Remove si de gear, cl utch pack retai ner and
cl utch pack. Keep pl ates i n correct order duri ng
removal .
ASSEMBLY
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 41).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
Fig. 39 Pinion Gear
1 - PINION GEARS
2 - TURNING BAR
Fig. 40 Side Gear & Clutch Pack
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 41 Clutch Disc Pack
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
3 - 70 REAR AXLE - 8 1/4 AN
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 42). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(4) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
(5) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 43).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 43).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
screw to sl i ghtl y compress cl utch di sc.
(9) Pl ace pi ni on gears i n posi ti on i n si de gears and
veri fy that the pi ni on mate shaft hol e i s al i gned.
(10) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(11) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(12) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
Threaded Adapter.
(14) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(15) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
Fig. 42 Clutch Pack and Side Gear
2 - SIDE GEAR AND CLUTCH PACK
Fig. 43 Clutch Pack and Upper Side Gear
3 - STEP PLATE - C-6960-3
AN REAR AXLE - 8 1/4 3 - 71
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e.
(2) Remove di fferenti al beari ngs from the case
wi th Pul l er/Press C-293-PA and Adapters C-293-48
and Pl ug SP-3289 (Fi g. 44).
INSTALLATION
C-4340 and Handl e C-4171 (Fi g. 45).
(2) I nstal l di fferenti al case i n axl e.
TONE RING
REMOVAL
ing the other.
(1) Remove di fferenti al from the axl e housi ng.
(2) Mark the compani on fl ange and propel l er shaft
for i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from the compani on
fl ange and ti e propel l er shaft to underbody.
(4) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 46).
(5) Remove ri ng gear bol ts from the di fferenti al
case.
(6) Dri ve ri ng gear off the di fferenti al case wi th a
rawhi de hammer (Fi g. 46).
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
Fig. 45 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
3 - 72 REAR AXLE - 8 1/4 AN
remove compani on fl ange nut and washer.
C-452 (Fi g. 47).
(11) Remove pi ni on from housi ng (Fi g. 48).
(13) Remove oi l sl i nger i f equi pped and front pi n-
i on beari ng.
Remover C-4345 and Handl e C4171 (Fi g. 49).
Fig. 46 Ring Gear
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
2 - PULLER
Fig. 48 Pinion Gear
1 - RAWHIDE HAMMER
1 - REMOVER
2 - HANDLE
AN REAR AXLE - 8 1/4 3 - 73
(15) Remove the rear beari ng cup from housi ng
(Fi g. 50) wi th Remover C-4307 and Handl e C4171.
(16) Remove col l apsi bl e prel oad spacer (Fi g. 51).
(17) Remove rear beari ng from pi ni on (Fi g. 52)
wi th Pul l er/Press C-293-PA and Adapters C-293-47.
and record shi m thi ckness.
INSTALLATION
matched set. Do not replace the pinion without
replacing the ring gear. If ring and pinion gears or
bearings are replaced, Refer to Adjustments for Pin-
ion Gear Depth Setting.
(1) Appl y Mopar Door Ease or sti ck l ubri cant to
outsi de surface of beari ng cup.
(2) I nstal l rear pi ni on beari ng cup (Fi g. 53) wi th
I nstal l er C-4308 and Dri ver Handl e C-4171 and ver-
i fy cup i s seated.
(4) I nstal l front pi ni on beari ng cup (Fi g. 54) wi th
I nstal l er D-130 and Handl e C-4171 and veri fy cup i s
seated.
1 - REMOVER
2 - HANDLE
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
3 - 74 REAR AXLE - 8 1/4 AN
(5) I nstal l front pi ni on beari ng and oi l sl i nger i f
equi pped.
l i p of pi ni on seal . I nstal l seal wi th I nstal l er
C-4076B and Handl e C-4735-1 (Fi g. 55).
pi ni on shaft.
(8) I nstal l the rear beari ng and sl i nger i f equi pped,
on the pi ni on (Fi g. 56) wi th I nstal l er 6448 and a
press.
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
Fig. 55 Pinion Seal
1 - HANDLE
3 - INSTALLER
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
AN REAR AXLE - 8 1/4 3 - 75
(9) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l the pi ni on i nto the housi ng (Fi g.
57).
(10) I nstal l compani on fl ange wi th I nstal l er
(13) I nstal l the compani on fl ange washer and a
new nut on the pi ni on and ti ghten the pi ni on nut
unti l there i s zero beari ng end-pl ay.
(14) Ti ghten the nut to 285 Nm (210 ft. l bs.) (Fi g.
58).
be installed.
i ncrements unti l the desi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 59).
(16) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 59). The torque necessary
to rotate the pi ni on shoul d be:
Ori gi nal Beari ngs: 1 to 3 Nm (10 to 20 i n. l bs.).
New Beari ngs: 2 to 5 Nm (15 to 35 i n. l bs.).
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 58 Pinion Nut
2 - HOLDER
3 - TORQUE WRENCH
3 - 76 REAR AXLE - 8 1/4 AN
(17) Posi ti on exci ter ri ng on di fferenti al case.
(18) Usi ng a brass dri ft, sl owl y and evenl y tap the
exci ter ri ng i nto posi ti on.
(19) Posi ti on ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
(22) I nstal l di fferenti al i n housi ng and veri fy gear
mesh and contact pattern.
l ubri cant.
al i gned.
Fig. 59 Pinion
2 - TORQUE WRENCH Fig. 60 Ring Gear Bolts
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
AN REAR AXLE - 8 1/4 3 - 77
REAR AXLE - 9 1/4
TABLE OF CONTENTS
page page
REAR AXLE - 9 1/4
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 90
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 90
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 97
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DIAGNOSIS AND TESTING - TRAC LOK . . . . . . . 99
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 103
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 105
REAR AXLE - 9 1/4
DESCRIPTION
The 9 1/4 I nch axl e housi ngs consi st of a cast i ron
center secti on wi th axl e tubes extendi ng from ei ther
si de. The tubes are pressed i nto and wel ded to the
di fferenti al housi ng to form a one-pi ece axl e housi ng
(Fi g. 1).
The axl es have a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi -fl oati ng axl e
shafts, meani ng vehi cl e l oads are supported by the
axl e shaft and beari ngs. The axl e shafts are retai ned
by C-l ocks i n the di fferenti al si de gears.
The removabl e, stamped steel cover provi des a
means for i nspecti on and servi ce wi thout removi ng
the compl ete axl e from the vehi cl e.
The axl e has a date tag and a gear rati o tag. The
tags are attached to the di fferenti al housi ng by a
cover bol t.
The rear wheel anti -l ock (RWAL) brake speed sen-
sor i s attached to the top, forward exteri or of the di f-
ferenti al housi ng. A seal i s l ocated between the
sensor and the wi re harness connector. The seal must
be i n pl ace when the wi re connector i s connected to
the sensor. The RWAL brake exci ter ri ng i s press-fi t-
ted onto the di fferenti al case agai nst the ri ng gear
fl ange.
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer.
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
The axl e di fferenti al cover can be used for i denti fi -
cati on of the axl e and (Fi g. 2). A rati o tag i s attached
to the di fferenti al cover.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
3 - 78 REAR AXLE - 9 1/4 AN
Fig. 1 9 1/4 Axle
AN REAR AXLE - 9 1/4 3 - 79
GEAR NOISE
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
greatl y:
Gear damage.
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
1 - HUB
2 - AXLE SHAFT
3 - VENT FITTING
5 - CUP
6 - FRONT PINION BEARING CONE
7 - NUT
8 - WASHER
10 - SEAL
11 - AXLE SHAFT
12 - HUB
13 - STUD
14 - BEARING CUP
15 - REAR PINION BEARING CONE
16 - DIFFERENTIAL BEARING
17 - ADJUSTER
18 - LOCK
19 - BOLT
20 - BEARING CAP
21 - CAP BOLT
22 - BEARING CUP
23 - THRUST WASHER
24 - SIDE GEAR
25 - C-LOCK
26 - DIFFERENTIAL POSITIONS
27 - THRUST WASHER
28 - COVER
29 - PLUG
30 - COVER BOLT
31 - WASHER
32 - CLIP
33 - SIDE GEAR
34 - THRUST WASHER
35 - DIFFERENTIAL BEARING CONE
36 - C-LOCK
37 - BOLT
38 - LOCK
39 - BEARING CUP
40 - ADJUSTER
41 - BEARING CUP
42 - BOLT
44 - EXCITER RING
46 - RING GEAR BOLT
47 - RING GEAR
48 - PINION
50 - PRELOAD COLLAPSIBLE SPACER
51 - SEAL
52 - AXLE SHAFT BEARING
53 - AXLE SHAFT TUBE
54 - AXLE TUBE
55 - AXLE SHAFT BEARING
56 - SEAL
Fig. 2 Differential Cover
2 - RATIO TAG
3 - FILL PLUG
3 - 80 REAR AXLE - 9 1/4 AN
BEARING NOISE
faster rate. Dri ve the vehi cl e and l oad the di fferenti al .
I f beari ng noi se occurs, the rear pi ni on beari ng i s the
source of the noi se. I f the beari ng noi se i s heard dur-
i ng a coast, the front pi ni on beari ng i s the source.
Worn or damaged di fferenti al beari ngs usual l y produce
a l ow pi tch noi se. Di fferenti al beari ng noi se i s si mi l ar to
pi ni on beari ng noi se. The pi tch of di fferenti al beari ng
noi se i s al so constant and vari es onl y wi th vehi cl e speed.
LOW SPEED KNOCK
U-joi nt or by worn si degear thrust washers. A worn
VIBRATION
caused by a:
Worn or out-of-bal ance wheel s.
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
TESTI NG)
DRIVELINE SNAP
i nto gear (or the cl utch engaged), can be caused by:
Worn U-joi nts.
DIAGNOSTIC CHART
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct
as necessary.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
AN REAR AXLE - 9 1/4 3 - 81
1. Replace case and inspect gears and
bearings for further damage. Set
differential bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid
excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid
erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential
with the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential
with the correct fluid type and quantity.
wheel/tire.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid
type and quantity.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears
and bearings for possible damage.
3 - 82 REAR AXLE - 9 1/4 AN
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
adjustment.
2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion
depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
pinion.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he proper
specification.
REMOVAL
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Secure brake drums to the axl e shaft.
(6) Remove the RWAL sensor from the di fferenti al
housi ng. Refer to Brakes for procedures.
(7) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Brakes for procedures.
(8) Remove parki ng brake cabl es and cabl e brack-
ets.
(9) Di sconnect the vent hose from the axl e shaft
tube.
(10) Mark propel l er shaft and compani on fl ange
for i nstal l ati on reference.
(12) Remove shock absorbers from axl e.
(13) Remove spri ng cl amps and spri ng brackets.
(14) Separate the axl e from the vehi cl e.
INSTALLATION
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn to
l eaf spri ng centeri ng bol ts.
(2) I nstal l spri ng cl amps and spri ng brackets.
(3) I nstal l shock absorbers and ti ghten nuts to 82
Nm (60 ft. l bs.).
(4) I nstal l RWAL sensor to the di fferenti al hous-
i ng. Refer to Brakes for procedures.
(5) I nstal l parki ng brake cabl es and cabl e brack-
ets.
(6) I nstal l brake drums. Refer to Brakes for proce-
dures.
(7) Connect brake hose to the axl e juncti on bl ock.
Refer to Brakes for procedures.
(8) I nstal l axl e vent hose.
al i gned. I nstal l compani on fl ange bol ts and ti ghten to
108 Nm (80 ft. l bs.).
(10) I nstal l the wheel s and ti res.
(11) Add gear l ubri cant, i f necessary. Refer to
Lubri cant for l ubri cant requi rements.
(12) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
AN REAR AXLE - 9 1/4 3 - 83
ADJUSTMENTS
pi ni on are pai nted onto the pi ni on gear shaft (Fi g. 3)
and the si de of the ri ng gear. A pl us (+) number,
mi nus () number or zero (0) al ong wi th the gear set
sequence number (01 to 99) i s on each gear. Thi s fi rst
number i s the amount (i n thousandths of an i nch)
the depth vari es from the standard depth setti ng of a
pi ni on marked wi th a (0). The next two numbers are
the sequence number of the gear set. The standard
depth provi des the best teeth contact pattern. Refer
to Backl ash and Contact Pattern for addi ti onal i nfor-
mati on.
behi nd the rear pi ni on beari ng. (Fi g. 4).
vari ance pai nted onto both the ori gi nal and repl ace-
chart.
mi nus the amount needed.
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Fig. 3 Pinion ID Number
1 - VARIANCE NUMBER
2 - SEQUENCE NUMBER
Fig. 4 Adjustment Shim Locations
3 - PINION BEARING
5 - PINION GEAR
6 - BEARING CUP
3 - 84 REAR AXLE - 9 1/4 AN
Original
Pinion
Gear
Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 5).
(Fi g. 5).
rear beari ng, and screw i nto the housi ng through
pi ni on beari ng cups (Fi g. 6).
(3) I nstal l front pi ni on beari ng and Cone-Nut 6740
hand ti ght (Fi g. 5).
(4) Pl ace Arbor Di sc 8541 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 7).
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 5). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator. Ti ghten di al i ndi cator face
l ock screw.
(7) Sl owl y sl i de the di al i ndi cator probe over the
edge of the pi ni on hei ght bl ock.
Fig. 5 Pinion Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
AN REAR AXLE - 9 1/4 3 - 85
(Fi g. 8). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Conti nue movi ng
the di al probe to the crest of the arbor bar and record
the hi ghest readi ng. I f the di al i ndi cator can not
achi eve the zero readi ng, the rear beari ng cup or the
pi ni on depth gauge set i s not i nstal l ed correctl y.
marked on the shaft of the pi ni on. For exampl e, i f
BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
The maxi mum ri ng gear backl ash vari ati on i s
0.003 i nch (0.076 mm).
Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
Mai ntai n the gear teeth engaged (meshed) as
marked.
The beari ngs must be seated by rapi dl y rotati ng
the pi ni on gear a hal f turn back and forth.
Do thi s fi ve to ten ti mes each ti me the threaded
adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded
adjuster i nward unti l the di fferenti al beari ng free-
pl ay i s el i mi nated (Fi g. 9). Al l ow some ri ng gear
backl ash (approxi matel y 0.25 mm / 0.01 i nch)
between the ri ng and pi ni on gear. Seat the beari ng
cups wi th the procedure descri bed above.
1 - PINION BLOCK
Fig. 7 Pinion Depth Tools
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
Fig. 8 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
3 - 86 REAR AXLE - 9 1/4 AN
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 10).
Measure the backl ash at 4 posi ti ons (90 degrees
apart) around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.003 to 0.004
i nch (0.076 to 0.102 mm) wi th each adjuster ti ght-
ened to 14 Nm (10 ft. l bs.). Seat the beari ng cups
wi th the procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts 136
Nm (100 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
Nm (75 ft. l bs.). Seat the beari ng cups wi th the pro-
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 Nm (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.006 to 0.008 i nch (0.15 to 0.203 mm).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 Nm (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 Nm (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 Nm (90 i n. l bs.).
Gear Contact procedure.
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st, and hol d a shop towel around the
tern.
shop towel .
essary.
1 - AXLE TUBE
2 - BACKING PLATE
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
AN REAR AXLE - 9 1/4 3 - 87
3 - 88 REAR AXLE - 9 1/4 AN
SIDE GEAR CLEARANCE
When measuri ng si de gear cl earance, check each
gear i ndependentl y. I f i t necessary to repl ace a si de
gear, repl ace both gears as a matched set.
(1) I nstal l the axl e shafts and C-l ocks and pi ni on
mate shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 12) .
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the axl e shaft i s contacti ng the
pi ni on mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 13). I n some cases, the end of the axl e shaft wi l l
move and contact the mate shaft when the feel er
gauge i s i nserted. The C-l ock i s preventi ng the si de
gear from sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-l ock from the axl e shaft. Use a mi crometer to mea-
sure the thrust washer thi ckness. Record the thi ck-
ness and re-i nstal l the thrust washer. Assembl e the
di fferenti al case wi thout the C-l ock i nstal l ed and re-
measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-l ock was i nstal l ed to
thrust washer thi ckness measured. The sum wi l l
determi ne the requi red thi ckness of the repl acement
thrust washer.
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
Fig. 12 Side Gear Clearance
1 - FEELER GAUGE
2 - SIDE GEAR
Fig. 13 Side Gear Calculations
AN REAR AXLE - 9 1/4 3 - 89
SPECIFICATIONS
REAR AXLE - 9 1/4
AXLE SPECIFICATIONS
Axle Ratio 3.21, 3.55, 3.92
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Diameter 235 mm (9.25 in.)
Pinion Bearing Preload - New Bearings 1.7-4 Nm (15-35 in. lbs.)
Pinion Nut Minimum 285 210 -
Adjuster Lock Screw 10 7.5 90
Backing Plate Bolts 65 48 -
SPECIAL TOOLS
SPECIAL TOOLS
Puller, Hub 6790
Remover 6310
Installer C-4198
3 - 90 REAR AXLE - 9 1/4 AN
Handle C-4171
Installer C-4076-B
Handle C-4735-1
Holder 6719
Puller C-452
Installer C-3718
Adjustment Wrench C-4164
Puller/Press C-293PA
Adapters C-293-48
Plug SP-3289
AN REAR AXLE - 9 1/4 3 - 91
Adapters C-293-47
Installer C-4340
Fixture 8138
Installer C-4345
Remover C-4307
Installer C-4308
Installer D-130
Installer 6448
Trac-lok Tools 8140
Trac-lok Tools 6960
3 - 92 REAR AXLE - 9 1/4 AN
AXLE SHAFTS
REMOVAL
(1) Pl ace transmi ssi on i n neutral .
(4) Remove brake drum, refer to Group 5 Brakes
for procedure.
(5) Remove di fferenti al housi ng cover and drai n
l ubri cant.
(6) Rotate di fferenti al case so pi ni on mate shaft
l ock screw i s accessi bl e. Remove l ock screw and pi n-
i on mate shaft from di fferenti al case (Fi g. 14).
(7) Push axl e shaft i nward and remove axl e shaft
C-l ock from the axl e shaft (Fi g. 15).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal i n the axl e tube.
INSTALLATION
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
aging axle shaft seal.
(2) I nsert C-l ock i n end of axl e shaft then push
axl e shaft outward to seat C-l ock i n si de gear.
(3) I nsert pi ni on shaft i nto di fferenti al case and
through thrust washers and di fferenti al pi ni ons.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 11 Nm (8 ft. l bs.).
l ubri cant.
(6) I nstal l brake drum, refer to Group 5 Brakes for
procedures.
(7) I nstal l wheel and ti re.
Pinion Gauge Block 8540
Arbor Discs 8541
Pinion Gauge Set
Fig. 14 Pinion Mate Shaft Lock Screw
1 - LOCK SCREW
Fig. 15 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
AN REAR AXLE - 9 1/4 3 - 93
AXLE BEARINGS
REMOVAL
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310, usi ng
Adapter Foot 6310-9 (Fi g. 17).
INSTALLATION
(2) I nstal l the axl e shaft beari ng wi th I nstal l er
C-4198 and Handl e C-4171 (Fi g. 18). I nstal l the bear-
i ng wi th the beari ng part number agai nst the
i nstal l er. Veri fy the beari ng i n i nstal l ed strai ght and
the tool ful l y contacts the axl e tube when seati ng the
beari ng.
Fig. 16 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 17 Axle Shaft Bearing Tool
1 - AXLE SHAFT TUBE
2 - NUT
3 - GUIDE PLATE
4 - GUIDE
5 - THREADED ROD
6 - ADAPTER
7 - FOOT
Fig. 18 Seal and Bearing Installer
1 - HANDLE
2 - INSTALLER
3 - AXLE TUBE
3 - 94 REAR AXLE - 9 1/4 AN
AXLE SHAFT SEALS
REMOVAL
INSTALLATION
and Handl e C-4735-1 (Fi g. 20). When the tool con-
tacts the axl e tube, the seal i s i nstal l ed to the correct
depth.
PINION SEAL
REMOVAL
(3) Mark the uni versal joi nt, compani on fl ange,
and pi ni on shaft for i nstal l ati on reference.
(4) Remove propel l er shaft from the compani on
fl ange. Secure the propel l er shaft i n an upri ght posi -
ti on to prevent damage to the rear uni versal joi nt.
(5) Remove the brake drums to prevent any drag.
(6) Rotate the compani on fl ange three or four
ti mes.
(7) Record pi ni on rotati ng torque wi th an i nch
poundtorque wrench for i nstal l ati on reference.
(8) I nstal l socket head bol ts i nto two of the
threaded hol es i n the compani on fl ange, 180 apart.
(9) Posi ti on Hol der 6719A agai nst the compani on
fl ange and i nstal l a hex head bol t and washer i nto
one of the remai ni ng threaded hol es. Ti ghten the bol t
and washer so that the Hol der 6719 i s hel d to the
fl ange.
(10) Hol d the fl ange wi th Hol der 6719A and
remove pi ni on nut and washer.
(11) Remove compani on fl ange wi th Remover
C-452 (Fi g. 21).
(12) Remove pi ni on seal wi th pry tool or sl i de-
INSTALLATION
NOTE: The outer perimeter of the seal is pre-coated
(2) I nstal l new pi ni on seal wi th I nstal l er C-3860-A
and Handl e C-4171 (Fi g. 22)
(3) I nstal l compani on fl ange on the end of the
shaft wi th the reference marks al i gned.
the compani on fl ange, 180 apart.
remai ni ng threaded hol es. Ti ghten the bol ts so hol der
i s hel d to the fl ange.
(6) I nstal l compani on fl ange on pi ni on shaft wi th
I nstal l er C-3718 and Hol der 6719.
(7) I nstal l pi ni on washer and a new pi ni on nut.
The convex si de of the washer must face outward.
Fig. 19 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 20 Seal and Bearing Installer
1 - HANDLE
2 - INSTALLER
3 - AXLE TUBE
AN REAR AXLE - 9 1/4 3 - 95
torque when installing the companion flange retain-
ing nut at this point. Damage to collapsible spacer
or bearings may result.
ti ghten the pi ni on nut to 285 Nm (210 ft. l bs.) (Fi g.
23). Rotate pi ni on several revol uti ons to ensure the
beari ng rol l ers are seated.
(9) Rotatepi ni on usi ng an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 24).
2 - PULLER
1 - HANDLE
3 - INSTALLER
Fig. 23 Tightening Pinion Nut
3 - TORQUE WRENCH
Fig. 24 Pinion Rotation Torque
2 - TORQUE WRENCH
3 - 96 REAR AXLE - 9 1/4 AN
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed.
(10) I f rotati ng torque i s l ow, use Hol der 6719 to
hol d the compani on fl ange (Fi g. 23) and ti ghten pi n-
i on nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l proper
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
NOTE: The seal replacement is unacceptable if the
final pinion nut torque is less than 285 Nm (210 ft.
lbs.).
(11) I nstal l propel l er shaft wi th the i nstal l ati on
reference marks al i gned.
(12) Ti ghten the compani on fl ange bol ts to 108
Nm (80 ft. l bs.).
(14) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
(15) Check the di fferenti al housi ng l ubri cant l evel .
DIFFERENTIAL
REMOVAL
(2) Remove fi l l er pl ug from the di fferenti al cover.
(3) Remove the di fferenti al cover and drai n the
l ubri cant.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(6) Remove RWAL/ABS sensor from housi ng.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(7) Mark the di fferenti al housi ng and di fferenti al
beari ng caps for i nstal l ati on reference (Fi g. 25).
(8) Remove beari ng threaded adjuster l ock from
each beari ng cap.
(9) Loosen di fferenti al beari ng cap bol ts.
(10) Loosen di fferenti al beari ng adjusters through
the axl e tubes wi th Wrench C-4164 (Fi g. 26).
(11) Hol d the di fferenti al case whi l e removi ng
beari ng caps and adjusters.
(12) Remove the di fferenti al case.
NOTE: Tag the differential bearing cups and
threaded adjusters to indicate their location.
DISASSEMBLY
(1) Remove pi ni on shaft l ock screw (Fi g. 27).
(2) Remove pi ni on shaft.
di fferenti al pi ni ons and thrust washers (Fi g. 28).
washers.
Fig. 25 Reference Marks
1 - REFERENCE MARKS
2 - REFERENCE MARK
3 - BEARING CAPS
1 - AXLE TUBE
2 - BACKING PLATE
AN REAR AXLE - 9 1/4 3 - 97
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l di fferenti al pi ni on and thrust washers.
(3) I nstal l the pi ni on shaft.
(4) Al i gn the hol e i n the pi ni on shaft wi th the hol e
i n the di fferenti al case and i nstal l the pi ni on shaft
l ock screw.
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on.
(2) I nstal l the di fferenti al assembl y i nto the hous-
i ng.
(3) I nstal l the di fferenti al beari ng caps i n thei r
ori gi nal l ocati ons (Fi g. 29).
(4) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 Nm (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(5) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
NOTE: Be sure that all bearing cap bolts are tight-
ened to their final torque of 136 Nm (100 ft.lbs.)
before proceeding.
(7) Appl y a 1/4 i nch bead of Mopar Si l i cone Rubber
Seal ant or equi val ent to the housi ng cover (Fi g. 30).
Install the housing cover within 5 minutes
after applying the sealant.
(8) I nstal l the cover and any i denti fi cati on tag and
ti ghten cover bol ts to 41 Nm (30 ft. l bs.).
(9) Fi l l di fferenti al wi th l ubri cant to bottom of the
fi l l pl ug hol e. Refer to the Lubri cant Speci fi cati ons
for the correct quanti ty and type.
(10) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 28 Differential
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 29 Bearing Caps
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - ADJUSTER LOCK
4 - BEARING CAP
3 - 98 REAR AXLE - 9 1/4 AN
(11) Trac-l ok di fferenti al equi pped vehi cl es
shoul d be road tested by maki ng 10 to 12 sl ow fi gure-
ei ght turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
DIAGNOSIS AND TESTING - TRAC-LOK
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t
for repai r, drai n, fl ush and refi l l the axl e wi th the
speci fi ed l ubri cant. A contai ner of Mopar Trac-l ok
Lubri cant (fri cti on modi fi er) shoul d be added after
repai r servi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 31).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
DISASSEMBLY
(1) Cl amp si de gear Hol di ng Fi xture 6965 i n a vi se
and posi ti on the di fferenti al case on the Hol di ng Fi x-
ture (Fi g. 32).
Fig. 30 Cover Sealant
1 - SEALANT
Fig. 31 Trac-lok Test -Typical
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 32 Differential Case Holding Fixture
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
AN REAR AXLE - 9 1/4 3 - 99
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 33).
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer (Fi g. 34).
(5) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
35).
(6) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(7) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter Di sc C-6960-1 (Fi g. 36) to prevent
adapter from turni ng.
screw to 122 Nm (90 ft. l bs.) maxi mum to compress
Bel l evi l l e spri ngs i n cl utch packs (Fi g. 37).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 38).
(10) I nsert Turni ng Bar C-6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 39).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
Fig. 33 Mate Shaft Lock Screw
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 34 Mate Shaft
2 - SIDE GEAR
3 - DRIFT
Fig. 35 Step Plate
1 - LOWER SIDE GEAR
3 - STEP PLATE
3 - 100 REAR AXLE - 9 1/4 AN
Fig. 36 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - THREADED ADAPTER DISC
Fig. 37 Compress Belleville Spring
1 - TORQUE WRENCH
2 - FORCING SCREW
Fig. 38 Pinion Gear Thrust Washer
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 39 Differential Pinion Gear
1 - PINION GEARS
2 - TURNING BAR
AN REAR AXLE - 9 1/4 3 - 101
Threaded Adapter.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 40).
(16) Remove di fferenti al case from the Hol di ng
Fi xture. Remove si de gear, cl utch pack retai ner and
cl utch pack. Keep pl ates i n correct order duri ng
removal .
ASSEMBLY
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 41).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 42). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Fig. 40 Side Gear & Clutch Pack
2 - RETAINER
Fig. 41 Clutch Disc Pack
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 42 Clutch Pack & Lower Side Gear
2 - LOWER SIDE GEAR AND CLUTCH PACK
3 - 102 REAR AXLE - 9 1/4 AN
(4) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
(5) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 43).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 43).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
screw to sl i ghtl y compress cl utch di sc.
(9) Pl ace pi ni on gears i n posi ti on i n si de gears and
veri fy that the pi ni on mate shaft hol e i s al i gned.
(10) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(11) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(12) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
Threaded Adapter.
(14) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(15) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove di fferenti al beari ngs from the case
wi th Pul l er/Press C-293-PA and Adapters C-293-47
and Pl ug C-293-3 (Fi g. 44).
INSTALLATION
C-4213 and Handl e C-4171 (Fi g. 45).
(2) I nstal l di fferenti al case i nto housi ng.
Fig. 43 Clutch Pack & Upper Side Gear
1 - UPPER SIDE GEAR AND CLUTCH PACK
3 - STEP PLATE
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
AN REAR AXLE - 9 1/4 3 - 103
TONE RING
REMOVAL
ing the other.
(2) Remove wheel and ti re assembl i es.
(3) Mark compani on fl ange and propel l er shaft for
(4) Di sconnect propel l er shaft from the compani on
fl ange and ti e propel l er shaft to underbody.
(5) Remove axl e shafts.
(6) Remove di fferenti al from the di fferenti al hous-
i ng.
(7) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw protectors. (Fi g. 46).
(8) Remove ri ng gear bol ts from the di fferenti al
case.
(9) Dri ve ri ng gear off the di fferenti al case wi th a
rawhi de hammer (Fi g. 46).
(12) Use Hol der 6719 to hol d compani on fl ange
and remove the compani on fl ange nut and washer.
(13) Remove the compani on fl ange from the pi ni on
wi th Remover C-452 (Fi g. 47).
(14) Remove the pi ni on from housi ng (Fi g. 48).
Fig. 45 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 46 Ring Gear
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
2 - REMOVER
3 - 104 REAR AXLE - 9 1/4 AN
DIFFERENTIAL CASE BEARINGS (Continued)
(16) Remove oi l sl i nger i f equi pped and front pi n-
i on beari ng.
Remover C-4345 and Handl e C4171 (Fi g. 49).
(18) Remove the rear beari ng cup from housi ng
(Fi g. 50) wi th Remover C-4307 and Handl e C4171.
(19) Remove the col l apsi bl e prel oad spacer (Fi g.
51).
(20) Remove rear beari ng from the pi ni on (Fi g. 52)
wi th Pul l er/Press C-293-PA and Adapters C-293-47.
and record shi m thi ckness.
INSTALLATION
matched set. Do not replace the pinion without
replacing the ring gear. If ring and pinion gears or
bearings are replaced, Refer to Adjustments for Pin-
ion Gear Depth Setting.
(2) I nstal l rear pi ni on beari ng cup (Fi g. 53) wi th
I nstal l er C-4308 and Dri ver Handl e C-4171 and ver-
i fy cup i s seated.
(4) I nstal l front pi ni on beari ng cup (Fi g. 54) wi th
I nstal l er D-130 and Handl e C-4171 and veri fy cup i s
seated.
(5) I nstal l front pi ni on beari ng.
Fig. 48 Pinion Gear
1 - RAWHIDE HAMMER
1 - REMOVER
2 - HANDLE
1 - DRIVER
2 - HANDLE
AN REAR AXLE - 9 1/4 3 - 105
l i p of pi ni on seal . I nstal l seal wi th I nstal l er
C-4076B and Handl e C-4735-1 (Fi g. 55).
pi ni on shaft.
(8) I nstal l the rear beari ng on the pi ni on (Fi g. 56)
wi th I nstal l er 6448 and a press.
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
3 - 106 REAR AXLE - 9 1/4 AN
(9) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l the pi ni on i nto the housi ng (Fi g.
57).
(10) I nstal l compani on fl ange wi th I nstal l er
(13) I nstal l the compani on fl ange washer and a
new nut on the pi ni on and ti ghten the pi ni on nut
unti l there i s zero beari ng end-pl ay.
(14) Ti ghten the nut to 285 Nm (210 ft. l bs.) (Fi g.
58).
be installed.
i ncrements unti l the desi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 59).
(16) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 59). The torque necessary
to rotate the pi ni on shoul d be:
Ori gi nal Beari ngs: 1 to 3 Nm (10 to 20 i n. l bs.).
New Beari ngs: 2 to 5 Nm (15 to 35 i n. l bs.).
(17) Posi ti on exci ter ri ng on di fferenti al case.
Fig. 55 Pinion Seal
1 - HANDLE
3 - INSTALLER
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
AN REAR AXLE - 9 1/4 3 - 107
(18) Usi ng a brass dri ft, sl owl y and evenl y tap the
exci ter ri ng i nto posi ti on.
(19) Posi ti on ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
(22) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
l ubri cant.
al i gned.
Fig. 58 Pinion Nut
2 - HOLDER
3 - TORQUE WRENCH
Fig. 59 Pinion
2 - TORQUE WRENCH
Fig. 60 Ring Gear Bolts
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
3 - 108 REAR AXLE - 9 1/4 AN
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 2
BRAKE FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . 5
MANUAL BLEEDING . . . . . . . . . . . . . . . . . . . . . 5
PRESSURE BLEEDING . . . . . . . . . . . . . . . . . . . 5
DOUBLE INVERTED FLARING. . . . . . . . . . . . . . 6
ISO FLARING. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RED BRAKE WARNING INDICATOR SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC/MECHANICAL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE LINES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . 10
BRAKE PADS/SHOES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMBINATION VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DISC BRAKE CALIPERS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DRUM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . 17
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FLUID
BRAKE FLUID CONTAMINATION . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 21
FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MASTER CYLINDER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MASTER CYLINDER/POWER BOOSTER . . . . . 23
MASTER CYLINDER BLEEDING . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PEDAL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
AN BRAKES 5 - 1
POWER BRAKE BOOSTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ROTORS
DISC BRAKE ROTOR. . . . . . . . . . . . . . . . . . . . 26
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
WHEEL CYLINDERS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SUPPORT PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CABLES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PEDAL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
RELEASE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
BRAKES - BASE
DESCRIPTION
Thi s vehi cl e i s equi pped wi th front di sc brakes and
rear drum brakes. The front di sc brakes consi st of
si ngl e pi ston cal i pers and venti l ated rotors. The rear
brakes are dual brake shoe, i nternal expandi ng uni ts
wi th cast brake drums. The parki ng brake mecha-
ni sm i s cabl e operated and connected to the rear
brake secondary shoes. Power brake assi st i s stan-
dard equi pment. A vacuum operated power brake
booster i s used for al l appl i cati ons.
Two anti l ock brake systems are used on thi s vehi -
cl e. A rear wheel anti l ock (RWAL) brake system i s
standard. An al l -wheel anti l ock brake system (ABS)
i s avai l abl e as an opti on.
DESCRIPTION
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET LININGS. BREATHING EXCESSIVE
CONCENTRATIONS OF ASBESTOS FIBERS CAN
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
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. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, wheel cyl i nders, brake drums, rotors, brake
5 - 2 BRAKES - BASE AN
l i nes, master cyl i nder, booster, and parki ng brake
components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the brake reservoi r fl ui d l evel wi l l decrease i n
proporti on to normal l i ni ng wear. Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e to exami ne. System wi l l have to be fl ushed
i f fl ui d i s separated i nto l ayers, or contai ns a sub-
stance other than brake fl ui d. The system seal s
and cups wi l l al so have to be repl aced after fl ush-
i ng. Use cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) Check booster vacuum check val ve and hose.
(7) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
(4) Attempt to stop the vehi cl e wi th the parki ng
brake onl y and note grab, drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per/wheel cyl i nder. I f l eakage i s severe, fl ui d wi l l
be evi dent at or around the l eaki ng component.
I nternal l eakage (seal by-pass) i n the master cyl i n-
der caused by worn or damaged pi ston cups, may
al so be the probl em cause.
An i nternal l eak i n the ABS or RWAL system may
al so be the probl em wi th no physi cal evi dence.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up worn l i ni ngs,
rotors, drums, or rear brakes out of adjustment are
the most l i kel y causes. The proper course of acti on i s
to i nspect and repl ace al l worn component and make
the proper adjustments.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system,
and repl ace thi n drums and substandard qual i ty
brake hoses i f suspected.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve coul d
al so be faul ty.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
AN BRAKES - BASE 5 - 3
BRAKES - BASE (Continued)
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Common causes of brake drag are:
Sei zed or i mproperl y adjusted parki ng brake
cabl es.
Loose/worn wheel beari ng.
Sei zed cal i per or wheel cyl i nder pi ston.
Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
Loose cal i per mounti ng.
Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
Mi s-assembl ed components.
Long booster output rod.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Front brake pul l condi ti on coul d resul t from:
Contami nated l i ni ng i n one cal i per
Sei zed cal i per pi ston
Bi ndi ng cal i per
Loose cal i per
Rusty cal i per sl i de surfaces
I mproper brake shoes
Damaged rotor
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder or proporti oni ng val ve
coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or wheel cyl i nders, worn seal s, dri v-
i ng through deep water puddl es, or l i ni ng that has
become covered wi th grease and gri t duri ng repai r.
Contami nated l i ni ng shoul d be repl aced to avoi d fur-
ther brake probl ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
BRAKE NOISES
Some brake noi se i s common wi th rear drum
brakes and on some di sc brakes duri ng the fi rst few
stops after a vehi cl e has been parked overni ght or
stored. Thi s i s pri mari l y due to the formati on of trace
corrosi on (l i ght rust) on metal surfaces. Thi s l i ght
corrosi on i s typi cal l y cl eared from the metal surfaces
after a few brake appl i cati ons causi ng the noi se to
subsi de.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors and drums can become so scored that repl ace-
ment i s necessary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se. I n addi ti on, worn out,
i mproperl y adjusted, or i mproperl y assembl ed rear
brake shoes can al so produce a thump noi se.
STANDARD PROCEDURES - BRAKE FLUID
LEVEL
Al ways cl ean the master cyl i nder reservoi r and
caps before checki ng fl ui d l evel . I f not cl eaned, di rt
coul d enter the fl ui d.
The fl ui d fi l l l evel i s i ndi cated on the si de of the
master cyl i nder reservoi r (Fi g. 1).
The correct fl ui d l evel i s to the FULL i ndi cator on
the si de of the reservoi r. I f necessary, add fl ui d to the
proper l evel .
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me i n the
fol l owi ng sequence:
(1) Remove reservoi r fi l l er caps and fi l l reservoi r.
(2) I f cal i pers, or wheel cyl i nders were overhaul ed,
open al l cal i per and wheel cyl i nder bl eed screws.
Then cl ose each bl eed screw as fl ui d starts to dri p
from i t. Top off master cyl i nder reservoi r once more
before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 2). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Fig. 1 Master Cylinder Fluid
1 - INDICATOR
2 - RESERVOIR
Bl eed onl y one brake component at a ti me i n the
fol l owi ng sequence:
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system. Use
adapter provi ded wi th the equi pment or Adapter
6921.
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are (Fi g. 3).
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on the tube.
(4) I nsert tube i n fl ari ng tool .
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Ti ghten the tool bar on the tube
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 4).
(9) Ti ghten tool handl e unti l pl ug gauge i s
squarel y seated on jaws of fl ari ng tool . Thi s wi l l start
the i nverted fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are (Fi g. 3).
To make a I SO fl are use an I SO Fl ari ng Tool Ki t.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Remove any burrs from the i nsi de of the tube.
(3) I nstal l tube nut on the tube.
(4) Posi ti on the tube i n the fl ari ng tool fl ush wi th
the top of the tool bar (Fi g. 5). Then ti ghten the tool
bar on the tube.
(5) I nstal l the correct si ze adaptor on the fl ari ng
tool yoke screw.
(6) Lubri cate the adaptor.
Fig. 2 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
Fig. 3 Inverted Flare And ISO Flare
1 - ISO-STYLE FLARE
2 - DOUBLE INVERTED-STYLE FLARE
(7) Al i gn the adaptor and yoke screw over the tube
(Fi g. 5).
(8) Turn the yoke screw i n unti l the adaptor i s
squarel y seated on the tool bar.
Fig. 4 Inverted
Fig. 5 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
SPECIFICATIONS
BASE BRAKES
SPECIFICATIONS
Disc Brake Caliper
Type
Sliding
Disc Brake Caliper
Bore
70 mm (2.75 in.)
Disc Brake Rotor
Type
Ventilated
Disc Brake Rotor
Size
287 x 24 mm (11.3 x
0.944 in.)
Disc Brake Rotor
Max. Runout
0.102 mm (0.004)
Disc Brake Rotor
Max. Thickness Varaition
0.013 mm (0.0005 in.)
Disc Brake Rotor
Min.Rotor Thickness
22.6 mm (0.8898 in.)
Drum Brake
Size
228.6 x 63.5 mm (9 x
2.50 in
Drum Brake
Size
279 x 57 mm (11 x 2.25
in.)
Drum Brake
Max. Runout
0.20 mm (0.008 in.)
Drum Brake
Max. Diameter Variation
0.076 mm (0.003 in.)
Brake Booster
Type
Tandem Diaphragm
TORQUE CHART
Brake Booster
Mounting Nuts
28 250
Master Cylinder
Mounting Nuts
18 160
Caliper
Mounting Pins
30 22
Wheel Cylinder Bolts
1/4-20
15 11
Wheel Cylinder Bolts
5/16-18
22 16
Support Plate
Mounting Bolts/Nuts
64 47
Brake Line Fittings
Master Cylinder
19 170
Brake Line Fittings
Combination Valve
19 170
Brake Line Fittings
Wheel Cylinder
16 145
Brake Hose
Front Fitting
16 145
Brake Hose
Front Bolt
28 250
Brake Hose
Rear Fitting
19 170
SPECIAL TOOLS
BASE BRAKES
RED BRAKE WARNING
INDICATOR SWITCH
DESCRIPTION
A red warni ng l amp i s used for the servi ce brake
porti on of the hydraul i c system. The l amp i s l ocated
i n the i nstrument cl uster.
OPERATION
The red warni ng l i ght al erts the dri ver i f a pres-
sure di fferenti al exi sts between the front and rear
hydraul i c systems or the parki ng brakes are appl i ed.
The l amp i s turned on momentari l y when the i gni -
ti on swi tch i s turn to the on posi ti on. Thi s i s a sel f
test to veri fy the l amp i s operati onal .
HYDRAULIC/MECHANICAL
DESCRIPTION
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
OPERATION
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 6).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
Install Dust Boot 8248
Universal Handle C-4171
Fig. 6 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l attempt to stop the rotors from turni ng and
bri ng the vehi cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g. 7).
When the brakes (and fl ui d pressure) are rel eased,
the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
the amount of seal defl ecti on. General l y the amount
i s just enough to mai ntai n contact between the pi s-
ton and i nboard brake shoe.
BRAKE LINES
DESCRIPTION
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. Doubl e wal l ed
steel tubi ng i s used to connect the master cyl i nder to
the major hydraul i c braki ng components and then to
the fl exi bl e rubber hoses. Doubl e i nverted styl e and
I SO styl e fl ares are used on the brake l i nes.
OPERATION
The hoses and l i nes transmi t the brake fl ui d
hydraul i c pressure to the cal i pers and or wheel cyl -
i nders.
DIAGNOSIS AND TESTING - BRAKE LINE AND
HOSES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. I nspect the hoses
whenever the brake system i s servi ced, at every
engi ne oi l change, or whenever the vehi cl e i s i n for
servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper seal washers at al l cal i per connec-
ti ons. Be sure brake l i ne connecti ons are properl y
made (not cross threaded) and ti ghtened to recom-
mended torque.
BRAKE PADS/SHOES
REMOVAL
(1) Cl ean master cyl i nder reservoi r and fi l l er caps.
(2) Remove reservoi r fi l l er cap and drai n approxi -
matel y 1/4 of fl ui d from reservoi r. Use cl ean sucti on
gun or si mi l ar devi ce to drai n fl ui d.
(4) Remove front wheel and ti re assembl i es.
(5) Bottom cal i per pi stons i n bores wi th l arge
C-cl amp. Posi ti on cl amp frame on rear of cal i per and
cl amp screw on outboard brake shoe.
(6) Wi th a screw dri ver pry up on the cal i per
spri ng and pul l the spri ng out of the cal i per hol es.
(7) Remove cal i per sl i de pi ns.
(8) Remove cal i per, (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- REMOVAL) and brake shoes (Fi g. 8).
Fig. 7 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
HYDRAULIC/MECHANICAL (Continued)
(9) Remove outboard brake shoe (Fi g. 9). Pry one
end of shoe retai ner spri ng away from cal i per. Then
ti l t shoe upward and rotate i t out of cal i per.
(10) Remove i nboard shoe by ti l ti ng shoe outward
unti l retai ner spri ng i s cl ear of cal i per pi ston (Fi g.
10).
(11) Support cal i per wi th wi re from suspensi on
component. Do not al l ow brake hose to support cal i -
per wei ght.
INSTALLATION
(1) Cl ean sl i de surfaces of adapter l edges wi th a
wi re brush. Then l ubri cate surfaces wi th a thi n coat
of hi gh temperature grease.
(2) I nstal l new sl i de pi n bushi ngs i f necessary.
(3) I nstal l i nboard shoe. Be sure retai ner spri ng i s
fi rml y seated i n cal i per pi ston.
(4) I nsert outboard brake shoe i n cal i per (Fi g. 11).
(5) I nsure the outboard shoe retai ner spri ng are
seated i n the cal i per (Fi g. 12).
(6) I nstal l cal i per, (Refer to 5 - BRAKES/HY-
- I NSTALLATI ON) and brake shoes over rotor and
i nto adapter.
(7) I nstal l and ti ghten cal i per sl i de pi ns to 30 Nm
(22 ft. l bs.). Start the slide pins by hand before
tightening. Do not cross thread the pins.
(8) I nstal l cal i per spri ng i nto one cal i per hol e and
under the adapter. Pul l down on the opposi te end of
Fig. 10 Inboard Brake Shoe
1 - CALIPER PISTON
2 - RETAINER SPRING
3 - INBOARD SHOE
Fig. 11 Installing Outboard Shoe
1 - CALIPER
2 - OUTBOARD SHOE
Fig. 8 Removing Caliper Assembly
1 - CALIPER AND BRAKE SHOES
Fig. 9 Outboard Brake Shoe
1 - SHOE SPRING
2 - OUTBOARD SHOE
BRAKE PADS/SHOES (Continued)
the spri ng (Fi g. 13) and hol d the end under the
adapter. Wi th a screw dri ver pry up on the spri ng
(Fi g. 14) to seat the spri ng i nto the other cal i per
hol e.
NOTE: Verify the spring is seated properly into the
caliper holes.
DURE).
(11) Pump brake pedal to seat brake shoes.
(12) Fi l l brake fl ui d reservoi r.
(13) Veri fy a fi rm brake pedal before movi ng vehi -
cl e.
COMBINATION VALVE
DESCRIPTION
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e and must be
repl aced as an assembl y i f di agnosi s i ndi cates thi s i s
necessary.
OPERATION
PRESSURE DIFFERENTIAL VALVE
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
Fig. 12 Outboard Shoe Retainer Spring
1 - SEAT RETAINER SPRING ENDS IN CALIPER
2 - OUTBOARD SHOE
Fig. 13 Caliper Spring
1 - CALIPER
2 - ADAPTER
3 - CALIPER SPRING
Fig. 14 Seat Caliper Spring
1 - SCREWDRIVER
2 - ADAPTER
3 - CALIPER
4 - ADAPTER
5 - CALIPER SPRING
BRAKE PADS/SHOES (Continued)
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs to the
brake system are made.
PROPORTIONING VALVE
The proporti oni ng val ve i s used to bal ance front-
rear brake acti on at hi gh decel erati ons. The val ve
al l ows normal fl ui d fl ow duri ng moderate braki ng.
The val ve onl y control s fl ui d fl ow duri ng hi gh decel -
erati ons brake stops.
DIAGNOSIS AND TESTING - COMBINATION
VALVE
Pressure Differential Switch
(1) Have hel per si t i n dri vers seat to appl y brake
pedal and observe red brake warni ng l i ght.
(2) Rai se vehi cl e on hoi st.
(3) Connect bl eed hose to a rear wheel cyl i nder
and i mmerse hose end i n contai ner parti al l y fi l l ed
wi th brake fl ui d.
(4) Have hel per press and hol d brake pedal to fl oor
and observe warni ng l i ght.
(a) I f warni ng l i ght i l l umi nates, swi tch i s operat-
i ng correctl y.
(b) I f l i ght fai l s to i l l umi nate, check ci rcui t fuse,
bul b, and wi ri ng. The parki ng brake swi tch can be
used to ai d i n i denti fyi ng whether or not the brake
l i ght bul b and fuse i s functi onal . Repai r or repl ace
parts as necessary and test di fferenti al pressure
swi tch operati on agai n.
(5) I f warni ng l i ght sti l l does not i l l umi nate,
swi tch i s faul ty. Repl ace combi nati on val ve assembl y,
bl eed brake system and veri fy proper swi tch and
val ve operati on.
REMOVAL
(1) Di sconnect wi re from the pressure di fferenti al
swi tch.
(2) Di sconnect rear brake l i nes from combi nati on
val ve.
(3) Remove the bol t from the combi nati on val ve
and remove the val ve.
INSTALLATION
(1) I nstal l the combi nati on val ve to the bracket
and ti ghten the mounti ng bol t to 20-27 Nm (15-20 ft.
l bs.). I f vehi cl e i s equi pped wi th ABS brakes ti ghten
the bol t to 10-13 Nm (7-10 ft. l bs.).
(2) I nstal l the brake l i nes to the combi nati on
val ve.
(3) Ti ghten the brake l i ne to 19 Nm (170 i n. l bs.).
(4) Connect the wi re to the pressure di fferenti al
swi tch.
(5) Bl eed brakes system. (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
DISC BRAKE CALIPERS
DESCRIPTION
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
OPERATION
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 15).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
Fig. 15 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
COMBINATION VALVE (Continued)
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l attempt to stop the rotors from turni ng and
bri ng the vehi cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g.
16). When the brakes (and fl ui d pressure) are
rel eased, the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
the amount of seal defl ecti on. General l y the amount
i s just enough to mai ntai n contact between the pi s-
ton and i nboard brake shoe.
REMOVAL
(1) Cl ean master cyl i nder reservoi r and fi l l er caps.
(2) Remove reservoi r fi l l er cap and drai n approxi -
matel y 1/4 of fl ui d from reservoi r. Use cl ean sucti on
gun or si mi l ar devi ce to drai n fl ui d.
(4) Remove front wheel and ti re assembl i es.
(5) Bottom cal i per pi stons i n bores wi th l arge
C-cl amp. Posi ti on cl amp frame on rear of cal i per and
cl amp screw on outboard brake shoe.
(6) Di sconnect brake hose at cal i per. Di scard hose
fi tti ng washers i f worn, or damaged (Fi g. 17).
(7) Wi th a screw dri ver pry up on the cal i per
spri ng and pul l the spri ng out of the cal i per hol es.
(8) Remove cal i per and brake shoes from cal i per.
DISASSEMBLY
(1) Drai n ol d brake fl ui d out of cal i per i nto drai n
pan.
(2) Remove pi ston dust boot (Fi g. 18). Use screw-
dri ver to push boot out of groove.
(3) Pad outboard shoe si de of cal i per i nteri or wi th
a mi ni mum 1 i nch thi ckness of shop towel s (Fi g. 19).
Towel s wi l l prevent pi ston damage when pi ston
comes out of the cal i per bore.
(4) Remove cal i per pi ston wi th short bursts of com-
pressed ai r. Appl y ai r pressure through fl ui d i nl et
port of cal i per (Fi g. 19).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
(5) Remove cal i per pi ston seal wi th wood penci l or
pl asti c tool (Fi g. 20). Do not use metal tool s as they
wi l l scratch pi ston bore.
(6) Remove cal i per sl i de pi n bushi ngs and boots.
Fig. 16 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
Fig. 17 Caliper Brake Hose Connection
1 - CALIPER
2 - FRONT BRAKE HOSE
3 - FITTING WASHERS
DISC BRAKE CALIPERS (Continued)
(7) Remove cal i per bl eed screw and cap.
CLEANING
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Wi pe the cal i per and pi ston
dry wi th l i nt free towel s or use l ow pressure com-
pressed ai r.
CAUTION: Do not use gasoline, kerosene, paint
thinner, or similar solvents. These products may
leave a residue that could damage the piston and
seal.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 21). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
INSTALLATION
(1) I nstal l brake shoes i n cal i per. (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/BRAKE
PADS/SHOES - I NSTALLATI ON).
Fig. 18 Piston Dust Boot
1 - PISTON BOOT DUST
Fig. 19 Caliper Piston
1 - AIR GUN NOZZLE
2 - FLUID INLET PORT
3 - CALIPER PISTON
4 - PADDING MATERIAL (TO PROTECT PISTON)
Fig. 20 Caliper Piston Seal
1 - PISTON SEAL
2 - WOOD PENCIL
(2) I nstal l cal i per and shoes over rotor and i nto
l edges i n steeri ng knuckl e. Be sure ends of brake
shoes are properl y seated on sl i de surfaces of l edges.
(3) I nstal l and ti ghten cal i per sl i de pi ns to 30 Nm
(22 ft. l bs.). Start the slide pins by hand before
tightening. Do not cross thread the pins.
(4) I nstal l cal i per spri ng i nto one cal i per hol e and
under the adapter. Pul l down on the opposi te end of
the spri ng (Fi g. 22) and hol d the end under the
adapter. Wi th a scew dri ver pry up on the spri ng
(Fi g. 23) to seat the spri ng i nto the other cal i per
hol e.
NOTE: Verify the spring is seated properly into the
caliper holes.
(5) I nstal l brake hose to cal i per wi th new seal
washers and ti ghten fi tti ng bol t to 24 Nm (18 ft.
l bs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(6) Bl eed base brake system. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
(7) I nstal l wheel and ti re assembl i es. (Refer to 22 -
DURE).
(8) Remove supports and l ower vehi cl e.
(9) Pump brake pedal to seat brake shoes.
(10) Fi l l brake fl ui d reservoi r.
(11) Veri fy fi rm pedal before movi ng vehi cl e.
Fig. 21 Polishing Piston Bore
1 - SPECIAL HONE
2 - CALIPER
3 - PISTON BORE
Fig. 22 Caliper
1 - CALIPER
2 - ADAPTER
3 - CALIPER SPRING
Fig. 23 Seat Caliper Spring
1 - SCREWDRIVER
2 - ADAPTER
3 - CALIPER
4 - ADAPTER
5 - CALIPER SPRING
DRUM
DESCRIPTION
Drum brakes on al l model s are dual shoe, i nternal
expandi ng uni ts wi th an automati c sel f adjusti ng
mechani sm (Fi g. 24). Ni ne i nch and el even i nch
brakes are used.
OPERATION
When the brake pedal i s depressed hydraul i c pres-
sure pushes the rear wheel cyl i nder pi stons outward.
The wheel cyl i nder push rods then push the brake
shoes outward agai nst the brake drum. When the
brake pedal i s rel eased return spri ngs attached to
the brake shoes pul l the shoes back to there ori gi nal
posi ti on.
DIAGNOSIS AND TESTING - BRAKE DRUM
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s i ndi cated on the drum outer edge.
General l y, a drum can be machi ned to a maxi mum of
1.52 mm (0.060 i n.) oversi ze. Al ways repl ace the
drum i f machi ni ng woul d cause drum di ameter to
exceed the si ze l i mi t i ndi cated on the drum.
BRAKE DRUM RUNOUT
Measure drum di ameter and runout wi th an accu-
rate gauge. The most accurate method of measure-
ment i nvol ves mounti ng the drum i n a brake l athe
and checki ng vari ati on and runout wi th a di al i ndi -
cator.
Vari ati ons i n drum di ameter shoul d not exceed
0.076 mm (0.003 i n.). Drum runout shoul d not exceed
0.20 mm (0.008 i n.) out of round. Machi ne the drum
i f runout or vari ati on exceed these val ues. Repl ace
the drum i f machi ni ng causes the drum to exceed the
maxi mum al l owabl e di ameter.
STANDARD PROCEDURES - BRAKE DRUM
MACHINING
The brake drums can be machi ned on a drum l athe
when necessary. I ni ti al machi ni ng cuts shoul d be l i m-
i ted to 0.12 - 0.20 mm (0.005 - 0.008 i n.) at a ti me as
heavi er feed rates can produce taper and surface
vari ati on. Fi nal fi ni sh cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 i n.) are recommended and wi l l gen-
eral l y provi de the best surface fi ni sh.
Be sure the drum i s securel y mounted i n the l athe
before machi ni ng operati ons. A damper strap shoul d
al ways be used around the drum to reduce vi brati on
and avoi d chatter marks.
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum
outer edge.
CAUTION: Replace the drum if machining will cause
the drum to exceed the maximum allowable diame-
ter.
REMOVAL
(3) Remove cl i p nuts securi ng brake drum to wheel
studs.
(4) Remove drum. I f drum i s di ffi cul t to remove,
remove rear pl ug from access hol e i n support pl ate.
Back-off sel f adjusti ng by i nserti ng a thi n screw-
dri ver i nto access hol e and push l ever away from
adjuster screw star wheel . Then i nsert an adjuster
tool i nto brake adjusti ng hol e rotate adjuster star
wheel to retract brake shoes.
Fig. 24 Brake Assembly
1 - SUPPORT PLATE
2 - RETURN SPRING
3 - ANCHOR PLATE
4 - RETURN SPRING
5 - CABLE GUIDE
6 - PARKING BRAKE LEVER
7 - ADJUSTER CABLE AND SPRING
8 - SHOE RETAINER, SPRING AND PIN
9 - SECONDARY SHOE AND LINING
10 - LEVER SPRING
11 - ADJUSTER LEVER
12 - ADJUSTER SCREW ASSEMBLY
13 - SHOE SPRING
14 - PRIMARY SHOE AND LINING
15 - PARKING BRAKE STRUT AND SPRING
(5) Vacuum brake components to remove brake l i n-
i ng dust.
(6) Remove shoe return spri ngs wi th brake spri ng
pl i er tool (Fi g. 25).
(7) Remove adjuster cabl e. Sl i de cabl e eye off
anchor pi n. Then unhook and remove cabl e from
adjuster l ever.
(8) Remove cabl e gui de from secondary shoe and
anchor pl ate from anchor pi n.
(9) Remove adjuster l ever. Di sengage l ever from
spri ng by sl i di ng l ever forward to cl ear pi vot and
work l ever out from under spri ng.
(10) Remove adjuster l ever spri ng from pi vot.
(11) Di sengage and remove shoe spri ng from brake
shoes.
(12) Di sengage and remove adjuster screw assem-
bl y from brake shoes.
(13) Remove brake shoe retai ners, spri ngs (Fi g. 26).
(14) Remove secondary brake shoe from support
pl ate.
(15) Remove strut and spri ng (Fi g. 26).
(16) Remove parki ng brake l ever retai ni ng cl i p
from the secondary shoe and remove the l ever.
(17) Remove pri mary shoe from support pl ate.
(18) Di sengage parki ng brake l ever from parki ng
brake cabl e.
CLEANING
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate and wheel cyl i nder exteri or, wi th a
water dampened cl oth or wi th brake cl eaner. Do not
use any other cl eani ng agents. Remove l i ght rust and
scal e from the brake shoe contact pads on the sup-
port pl ate wi th fi ne sandpaper.
INSPECTION
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper.
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded.
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
Fig. 25 Shoe Return Springs
1 - SHOE RETURN SPRING
2 - SPECIAL TOOL
(REMOVING AND INSTALLING)
4 - ADJUSTER CABLE
5 - LEVER SPRING
6 - ADJUSTER LEVER
7 - SHOE TO SHOE SPRING
8 - ANTI-RATTLE SPRING
Fig. 26 Shoe Retainers, Springs and Pins
1 - STRUT AND SPRING
2 - SPRING
3 - PIN
4 - RETAINER
6 - TOOL C-4070
DRUM (Continued)
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 27).
INSTALLATION
(1) Cl ean and i nspect i ndi vi dual brake compo-
nents, refer to Cl eani ng and I nspecti on Secti on.
(2) Lubri cate anchor pi n and brake shoe contact
pads on support pl ate wi th hi gh temperature grease
or Lubri pl ate (Fi g. 28).
(3) Lubri cate adjuster screw socket, nut, button
and screw thread surfaces wi th grease or Lubri pl ate.
(4) I nstal l the parki ng brake cabl e to the parki ng
brake l ever.
(5) I nstal l parki ng brake l ever to the secondary
shoe and i nstal l retai ni ng cl i p.
(6) I nstal l pri mary shoe on support pl ate. Secure
shoe wi th new spri ng retai ners and pi n.
(7) I nstal l spri ng on parki ng brake strut and
engage strut i n pri mary.
(8) I nstal l secondary shoe on support pl ate (Fi g.
29). I nsert strut i n shoe and gui de shoe onto anchor
pi n. Temporari l y secure shoe wi th retai ni ng pi n.
(9) I nstal l anchor pl ate and adjuster cabl e eyel et
on support pl ate anchor pi n.
(10) I nstal l cabl e gui de i n secondary shoe and posi -
ti on cabl e i n gui de.
(11) Assembl e adjuster screw (Fi g. 30). Then
i nstal l and adjuster screw between the brake shoes.
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.
(12) I nstal l adjuster l ever and spri ng and connect
adjuster cabl e to l ever.
(13) I nstal l secondary shoe retai ners and spri ng.
(14) I nstal l shoe spri ng. Connect spri ng to second-
ary shoe fi rst. Then to pri mary shoe.
(15) Veri fy adjuster operati on. Pul l adjuster cabl e
upward, cabl e shoul d l i ft l ever and rotate star wheel .
Be sure adjuster l ever properl y engages star wheel
teeth.
(16) Adjust brake shoes to drum wi th brake gauge.
Fig. 29 Brake Shoe Installation
2 - ANCHOR PLATE
3 - ADJUSTER CABLE
4 - SHOE RETAINING PIN
7 - STRUT AND SPRING
Fig. 27 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
Fig. 28 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
DRUM (Continued)
DURE).
ADJUSTMENTS - REAR DRUM BRAKE
The rear drum brakes are equi pped wi th a sel f-ad-
justi ng mechani sm. Under normal ci rcumstances, the
onl y ti me adjustment i s requi red i s when the shoes
are repl aced, removed for access to other parts, or
when one or both drums are repl aced.
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
ADJUSTMENT WITH BRAKE GAUGE
(1) Be sure parki ng brakes are ful l y rel eased.
(2) Rai se rear of vehi cl e and remove wheel s and
brake drums.
(3) Veri fy that l eft and ri ght automati c adjuster
l evers and cabl es are properl y connected.
(4) I nsert brake gauge i n drum. Expand gauge
unti l gauge i nner l egs contact drum braki ng surface.
Then l ock gauge i n posi ti on (Fi g. 31).
(5) Reverse gauge and i nstal l i t on brake shoes.
Posi ti on gauge l egs at shoe centers as shown (Fi g.
32). I f gauge does not fi t (too l oose/too ti ght), adjust
shoes.
(6) Pul l shoe adjuster l ever away from adjuster
screw star wheel .
(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Conti nue adjustment
unti l gauge outsi de l egs are l i ght drag-fi t on shoes.
(8) I nstal l brake drums and wheel s and l ower
vehi cl e.
(9) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
ADJUSTMENT WITH ADJUSTING TOOL
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
Fig. 30 Adjuster Screw
1 - WASHER
2 - SOCKET
3 - STAMPED LETTER
L-LEFT BRAKE
R-RIGHT BRAKE
4 - SCREW THREADS
5 - NUT
6 - BUTTON
Fig. 31 Adjusting Gauge On Drum
1 - BRAKE GAUGE
2 - BRAKE DRUM
Fig. 32 Adjusting Gauge On Brake Shoes
1 - BRAKE GAUGE
2 - BRAKE SHOES
DRUM (Continued)
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 33).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
(7) Push and hol d adjuster l ever away from star
wheel wi th thi n screwdri ver.
(8) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(9) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(10) I nstal l support pl ate access hol e pl ugs.
(11) Adjust parki ng brake cabl e and l ower vehi cl e.
(12) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoi r cap and empty fl ui d i nto
drai n contai ner.
(2) Cl amp cyl i nder body i n vi se wi th brass protec-
ti ve jaws.
(3) Remove pi ns that retai n reservoi r to master
cyl i nder. Use hammer and pi n punch to remove pi ns
(Fi g. 34).
(4) Loosen reservoi r from grommets wi th pry tool
(Fi g. 35).
Fig. 33 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRING
DRUM (Continued)
(5) Remove reservoi r by rocki ng i t to one si de and
pul l i ng free of grommets (Fi g. 36).
(6) Remove ol d grommets from cyl i nder body (Fi g.
37).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate new grommets wi th cl ean brake fl ui d
and I nstal l new grommets i n cyl i nder body (Fi g. 38).
Use fi nger pressure to i nstal l and seat grommets.
Fig. 34 Reservoir Retaining Pins
1 - PIN PUNCH
2 - RESERVOIR
3 - BODY
4 - ROLL PINS
Fig. 35 Loosening Reservoir
1 - PRY TOOL
2 - RESERVOIR
3 - GROMMET
4 - MASTER CYLINDER BODY
Fig. 36 Reservoir Removal
1 - RESERVOIR
2 - GROMMETS
Fig. 37 Grommet Removal
1 - MASTER CYLINDER BODY
2 - GROMMETS
Fig. 38 Grommet Installation
1 - WORK NEW GROMMETS INTO PLACE USING FINGER
PRESSURE ONLY
FLUID RESERVOIR (Continued)
(2) Start reservoi r i n grommets. Then rock reser-
voi r back and forth whi l e pressi ng downward to seat
i t i n grommets.
(3) I nstal l pi ns that retai n reservoi r to cyl i nder
body.
(4) Fi l l and bl eed master cyl i nder on bench before
i nstal l ati on i n vehi cl e.
MASTER CYLINDER
DESCRIPTION
A two-pi ece master cyl i nder i s used on al l model s.
The cyl i nder body contai ni ng the pri mary and sec-
ondary pi stons i s made of al umi num. The removabl e
fl ui d reservoi r i s made of nyl on rei nforced wi th gl ass
fi ber. The reservoi r stores reserve brake fl ui d for the
hydraul i c brake ci rcui ts. The reservoi r i s the onl y
servi ceabl e component.
The fl ui d compartments of the nyl on reservoi r are
i nterconnected to permi t fl ui d l evel equal i zati on.
However, the equal i zati on feature does not affect ci r-
cui t separati on i n the event of a front or rear brake
mal functi on. The reservoi r compartments wi l l retai n
enough fl ui d to operate the functi oni ng hydraul i c ci r-
cui t.
Care must be exerci sed when removi ng/i nstal l i ng
the master cyl i nder connecti ng l i nes. The threads i n
the cyl i nder fl ui d ports can be damaged i f care i s not
exerci sed. Start al l brake l i ne fi tti ngs by hand to
avoi d cross threadi ng.
The cyl i nder reservoi r can be repl aced when neces-
sary. However, the al umi num body secti on of the
master cyl i nder i s not a repai rabl e component.
NOTE: If diagnosis indicates that an internal mal-
function has occurred, the aluminum body section
must be replaced as an assembly.
OPERATION
The master cyl i nder bore contai ns a pri mary and
secondary pi ston. The pri mary pi ston suppl i es
hydraul i c pressure to the front brakes. The secondary
pi ston suppl i es hydraul i c pressure to the rear brakes.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on. I t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y turn off i gni -
ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 39).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 40).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i nto reservoi r (Fi g. 41).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
FLUID RESERVOIR (Continued)
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
REMOVAL
(1) Remove brake l i nes from the master cyl i nder
(Fi g. 42).
(2) Remove mounti ng nuts from the master cyl i n-
der (Fi g. 42).
(3) Remove master cyl i nder.
INSTALLATION
NOTE: If master cylinder is replaced bleed cylinder
before installation.
(1) I nstal l master cyl i nder on booster mounti ng
studs.
(2) I nstal l mounti ng nuts and ti ghten to 18 Nm
(160 i n. l bs.).
Fig. 39 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 40 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 41 Master Cylinder BleedingTypical
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 42 Master Cylinder
1 - MOUNTING NUT
2 - MOUNTING NUT
3 - BRAKE LINES
4 - MASTER CYLINDER
MASTER CYLINDER (Continued)
(3) I nstal l brake l i nes and ti ghten to 19 Nm (170
i n. l bs.)
(4) Fi l l and bl eed base brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
PEDAL
DESCRIPTION
A suspended-type brake pedal i s used. The pedal i s
attached to the pedal support bracket wi th a pi vot
bol t and bushi ngs. The booster push rod i s attached
to the pedal wi th a cl i p. The pedal , bushi ngs, pi vot
pi n and support bracket are al l servi ceabl e compo-
nents.
OPERATION
The brake pedal i s attached to the booster push
rod. When the pedal i s depressed, the pri mary
booster push rod i s depressed whi ch move the booster
secondary rod. The booster secondary rod depress the
master cyl i nder pi ston.
REMOVAL
(1) Remove stop l amp swi tch. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/BRAKE
LAMP SWI TCH - REMOVAL).
(2) Remove cl i p securi ng booster push rod to brake
pedal (Fi g. 43).
(3) Remove pedal pi vot pi n C-cl i p and sl i de pi n out
of support bracket and pedal .
(4) Remove pedal and bushi ngs.
INSTALLATION
(1) Repl ace bushi ngs i f worn or damaged.
(2) Lubri cate pedal bushi ngs and pi vot pi n wi th
Mopar mul ti mi l eage grease, Lubri pl ate, or a si l i cone
grease.
(3) I nstal l bushi ngs i n pedal and posi ti on pedal i n
support.
(4) I nsert pi vot pi n through support and pedal
bushi ngs and i nstal l C-cl i p.
(5) I nstal l booster push rod on brake pedal and
i nstal l push rod retai ner cl i p.
(6) I nstal l stop l amp swi tch. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/BRAKE
LAMP SWI TCH - I NSTALLATI ON).
POWER BRAKE BOOSTER
DESCRIPTION
Al l model s use a tandem di aphragm, power brake
booster.
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an
assembly if diagnosis indicates a malfunction has
occurred.
OPERATION
The booster uni t consi sts of a si ngl e housi ng
di vi ded i nto two by a tandem di aphragm. The outer
edge of the di aphragm i s secured to the housi ng. The
booster push rod, whi ch connects the booster to the
brake pedal and master cyl i nder, i s attached to the
center of the di aphragm. A check val ve i s used i n the
booster outl et connected to the engi ne i ntake mani -
fol d. Power assi st i s generated by uti l i zi ng a combi -
nati on of vacuum and atmospheri c pressure to boost
brake assi st.
REMOVAL
(1) Remove master cyl i nder. (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/MASTER CYLI NDER -
REMOVAL).
(2) Di sconnect vacuum l i nes at booster.
(3) Remove cl i p securi ng booster push rod to brake
pedal (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/PEDAL - REMOVAL). (Fi g. 44).
(4) Remove nuts from booster mounti ng studs (Fi g.
45).
(5) Remove booster, spacer and gaskets from front
cowl panel .
Fig. 43 Brake Pedal Mounting
1 - PEDAL SUPPORT
2 - PIVOT ROD
3 - PEDAL SUPPORT
4 - BRAKE PEDAL
5 - BOOSTER ROD
6 - CLUTCH ROD
7 - CLUTCH PEDAL
8 - BRAKE PEDAL
9 - BOOSTER ROD
MASTER CYLINDER (Continued)
INSTALLATION
(1) Posi ti on spacer and gaskets on booster studs.
(2) Gui de booster studs i nto cowl panel hol es and
seat booster on panel .
(3) I nstal l and ti ghten booster attachi ng nuts to 28
Nm (250 i n. l bs.).
(4) I nstal l booster push rod on brake pedal and
i nstal l cl i p. (Refer to 5 - BRAKES/HYDRAULI C/ME-
CHANI CAL/PEDAL - I NSTALLATI ON).
(5) I nstal l booster check val ve i f removed and con-
nect vacuum hose to check val ve.
(6) I nstal l master cyl i nder. (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/MASTER CYLI NDER -
I NSTALLATI ON).
(7) Fi l l and bl eed brake system. (Refer to 5 -
ROTORS
DIAGNOSIS AND TESTING - DISC BRAKE
ROTOR
The rotor braki ng surfaces shoul d not be refi ni shed
unl ess necessary.
Li ght surface rust and scal e can be removed wi th a
l athe equi pped wi th dual sandi ng di scs. The rotor
surfaces can be restored by machi ni ng i n a di sc brake
l athe i f surface scori ng and wear are l i ght.
Repl ace the rotor under the fol l owi ng condi ti ons:
severel y scored
tapered
hard spots
cracked
bel ow mi ni mum thi ckness
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f machi ni ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
Rotor mi ni mum thi ckness i s usual l y speci fi ed on
the rotor hub. The speci fi cati on i s ei ther stamped or
cast i nto the hub surface.
ROTOR RUNOUT
Check rotor l ateral runout wi th di al i ndi cator
C-3339 (Fi g. 46). Excessi ve l ateral runout wi l l cause
brake pedal pul sati on and rapi d, uneven wear of the
brake shoes. Posi ti on the di al i ndi cator pl unger
approxi matel y 25.4 mm (1 i n.) i nward from the rotor
edge. Maxi mum al l owabl e rotor runout i s 0.102 mm
(0.004 i n.).
ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at 6 to 12 poi nts around
the rotor face (Fi g. 47).
Posi ti on the mi crometer approxi matel y 25.4 mm (1
i n.) from the rotor outer ci rcumference for each mea-
surement.
Thi ckness shoul d not vary by more than 0.013 mm
(0.0005 i n.) from poi nt-to-poi nt on the rotor. Machi ne
or repl ace the rotor i f necessary.
Fig. 44 Booster Rod Clip
1 - BOOSTER ROD
2 - BRAKE PEDAL
3 - CLIP
Fig. 45 Power Brake Booster Mounting
1 - BRAKE BOOSTER
2 - SPACER
3 - FRONT COWL PANEL
4 - BRAKE PEDAL
5 - BRAKE BOOSTER ROD
POWER BRAKE BOOSTER (Continued)
STANDARD PROCEDURES - DISC ROTOR
MACHINING
The di sc brake rotor can be machi ned i f scored or
worn. The l athe must machi ne both si des of the rotor
si mul taneousl y wi th dual cutter heads. The rotor
mounti ng surface must be cl ean before pl aci ng on the
l athe. Equi pment capabl e of machi ni ng onl y one si de
at a ti me may produce a tapered rotor.
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the
vehicles hub/bearing.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
REMOVAL
(3) Remove brake cal i per. (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/DI SC BRAKE CALI -
PERS - REMOVAL).
(4) Remove retai ners on wheel studs and remove
rotor.
INSTALLATION
(1) I nstal l rotor hub and i nstal l retai ners.
(2) I nstal l brake cal i per. (Refer to 5 - BRAKES/HY-
- I NSTALLATI ON).
DURE).
(5) Depress brake pedal several ti me to seat brake
shoes.
WHEEL CYLINDERS
REMOVAL
(2) Remove brake drum.
(3) Di sconnect wheel cyl i nder brake l i ne.
(4) Remove brake shoe return spri ngs and move
shoes out of engagement wi th cyl i nder push rods.
(5) Remove cyl i nder attachi ng bol ts and remove
cyl i nder from support pl ate.
DISASSEMBLY
(1) Remove push rods and boots (Fi g. 48).
(2) Press pi stons, cups and spri ng and expander
out of cyl i nder bore.
(3) Remove bl eed screw.
CLEANING
Cl ean the cyl i nder and pi stons wi th cl ean brake
fl ui d or brake cl eaner onl y. Do not use any other
cl eani ng agents.
Dry the cyl i nder and pi stons wi th compressed ai r.
Do not use rags or shop towel s to dry the cyl i nder
components. Li nt from cl oth materi al wi l l adhere to
the cyl i nder bores and pi stons.
Fig. 46 Checking Rotor Runout And Thickness
Variation
1 - DIAL INDICATOR
Fig. 47 Measuring Rotor Thickness
1 - MICROMETER
2 - ROTOR
ROTORS (Continued)
INSPECTION
I nspect the cyl i nder bore. Li ght di scol orati on and
dark stai ns i n the bore are normal and wi l l not
i mpai r cyl i nder operati on.
The cyl i nder bore can be l i ghtl y pol i shed but onl y
wi th crocus cl oth. Repl ace the cyl i nder i f the bore i s
scored, pi tted or heavi l y corroded. Honi ng the bore to
restore the surface i s not recommended.
I nspect the cyl i nder pi stons. The pi ston surfaces
shoul d be smooth and free of scratches, scori ng and
corrosi on. Repl ace the pi stons i f worn, scored, or cor-
roded. Do attempt to restore the surface by sandi ng
or pol i shi ng.
Di scard the ol d pi ston cups and the spri ng and
expander. These parts are not reusabl e. The ori gi nal
dust boots may be reused but onl y i f they are i n good
condi ti on.
ASSEMBLY
(1) Lubri cate wheel cyl i nder bore, pi stons, pi ston
cups and spri ng and expander wi th cl ean brake fl ui d.
(2) I nstal l fi rst pi ston i n cyl i nder bore. Then
i nstal l fi rst cup i n bore and agai nst pi ston. Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) I nstal l spri ng and expander fol l owed by
remai ni ng pi ston cup and pi ston.
(4) I nstal l boots on each end of cyl i nder and i nsert
push rods i n boots.
(5) I nstal l cyl i nder bl eed screw.
INSTALLATION
(1) Appl y bead of si l i cone seal er around cyl i nder
mounti ng surface of support pl ate.
(2) I nstal l cyl i nder mounti ng bol ts and ti ghten to
20 Nm (15 ft. l bs.).
(3) Connect brake l i ne to cyl i nder.
(4) I nstal l brake shoe return spri ng.
(5) I nstal l brake drum.
DURE).
(7) Bl eed base brake system. (Refer to 5 - BRAKES
SUPPORT PLATE
REMOVAL
(1) Remove wheel and ti re assembl y and brake
drum.
(2) Remove brake shoe assembl y. (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/DRUM -
REMOVAL).
(3) Remove parki ng brake cabl e from parki ng
brake l ever. (Refer to 5 - BRAKES/PARKI NG
BRAKE/CABLES - REMOVAL).
(4) Compress parki ng brake cabl e retai ner tabs.
Then push retai ner and cabl e through and out of
support pl ate.
(5) Di sconnect brake l i ne at wheel cyl i nder.
(6) Remove wheel cyl i nder from support pl ate.
(Refer to 5 - BRAKES/HYDRAULI C/MECHANI CAL/
WHEEL CYLI NDERS - REMOVAL).
(7) Remove axl e shaft, (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(8) Remove bol ts attachi ng support pl ate to axl e
and remove support pl ate.
INSTALLATION
(1) Appl y bead of si l i cone seal er around axl e
mounti ng surface of support pl ate.
(2) I nstal l support pl ate on axl e fl ange. Ti ghten
attachi ng bol ts to 115 Nm (85 ft. l bs.).
(3) Appl y bead of si l i cone seal er around wheel cyl -
i nder mounti ng surface and i nstal l wheel cyl i nder.
(Refer to 5 - BRAKES/HYDRAULI C/MECHANI CAL/
WHEEL CYLI NDERS - I NSTALLATI ON).
(4) I nstal l brake l i ne i n wheel cyl i nder.
(5) I nstal l parki ng brake cabl e i n support pl ate.
(6) I nstal l axl e shaft, (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/REAR AXLE - 9 1/4/AXLE
SHAFTS - I NSTALLATI ON).
(7) Connect parki ng brake cabl e to l ever on sec-
ondary shoe and i nstal l brake shoes on support pl ate.
(8) Adjust brake shoes to drum wi th brake gauge.
Fig. 48 Wheel Cylinder ComponentsTypical
1 - SPRING
2 - CYLINDER
3 - PISTON CLIP
4 - BOOT
5 - PUSH ROD
6 - PISTON
7 - BLEED SCREW
8 - CUP EXPANDERS
WHEEL CYLINDERS (Continued)
(9) I nstal l brake drum and wheel and ti re assem-
bl y. (Refer to 22 - TI RES/WHEELS/WHEELS -
STANDARD PROCEDURE) (Refer to 22 - TI RES/
WHEELS/WHEELS - STANDARD PROCEDURE).
(10) Bl eed brake system. (Refer to 5 - BRAKES -
CABLES
REMOVAL - FRONT PARK BRAKE CABLE
(2) Loosen cabl e adjusti ng nut.
(3) Di sengage front cabl e (Fi g. 49) from cabl e ten-
si oner.
(4) Remove support cabl e from the front cabl e (Fi g.
50).
(6) Remove l eft ki ck panel .
(7) Fol d l eft front edge of fl oor coveri ng rearward
and remove cabl e grommet from fl oor pan (Fi g. 50).
(8) Remove cabl e from park brake pedal assembl y.
(Refer to 5 - BRAKES/PARKI NG BRAKE/PEDAL -
REMOVAL).
(9) Work cabl e and housi ng assembl y up through
fl oor pan.
(10) Remove front cabl e from vehi cl e.
REMOVAL - REAR PARK BRAKE CABLES
(2) Remove the rear wheel and ti re assembl i es.
(3) Loosen tensi oner adjuster nut.
(4) Remove the ri ght cabl e (Fi g. 51) from the
extensi on cabl e.
(5) Remove the ri ght cabl e from the frame cl i p and
pul l the cabl e housi ng through the l eft cabl e connec-
tor.
(6) Remove the l eft cabl e connector from the l eft
cabl e.
(7) Pul l both cabl es (Fi g. 51) through the cabl e
bracket.
(8) Remove the ri ght cabl e mounti ng retai ners
from the from the di fferenti al housi ng.
(9) Remove the brake drums.
(10) Di sconnect each cabl e from park brake l ever.
(11) Compress tabs on each cabl e housi ng retai ner
at the brake support pl ate.
(12) Remove the cabl es from the brake support
pl ates.
INSTALLATION - FRONT PARK BRAKE CABLE
(1) I nsert front cabl e through fl oor pan and i nstal l
grommet.
(2) I nsert cabl e retai ner i nto hol e at bottom of
pedal assembl y bracket and connect cabl e end.
(3) Fol d fl oor coveri ng down and i nstal l ki ck panel .
(5) I nstal l support cabl e to the front cabl e.
(6) Attach front cabl e to tensi oner.
(7) Adjust parki ng brakes.
INSTALLATION - REAR PARK BRAKE CABLES
(1) Push each cabl e housi ng through the brake
support pl ate hol e unti l cabl e housi ng retai ner tabs
l ock i nto pl ace.
NOTE: Pull on the cable housing to ensure it is lock
into place.
Fig. 49 Front Cable & Tensioner
1 - TENSIONER
2 - ADJUSTER NUT
3 - FRONT CABLE
Fig. 50 Support Cable
1 - GROMMET
2 - SUPPORT CABLE
3 - FRONT CABLE
SUPPORT PLATE (Continued)
(2) Pul l back on the end of the cabl e. Then push
the cabl e i n to engage the cabl e i n the park brake
l ever.
NOTE: Pull on the cable end to ensure it is attached
it the park brake lever.
(4) I nstal l ri ght cabl e mounti ng retai ners.
(5) Push the cabl es housi ng through the cabl e
bracket.
(6) I nstal l the l eft cabl e onto the cabl e connector.
(7) Push the ri ght cabl e housi ng through the l eft
cabl e connector and connect the cabl e to the exten-
si on cabl e.
(8) I nstal l the wheel and ti re assembl i es. (Refer to
CEDURE).
(9) Perform park brake adjustment procedure.
(Refer to 5 - BRAKES/PARKI NG BRAKE/CABLES -
ADJUSTMENTS).
PARK BRAKE CABLE TENSIONER
NOTE: Tensioner adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform adjustment only as described in the
following procedure. This is necessary to avoid
faulty park brake operation.
(1) Rai se vehi cl e.
(2) Back off cabl e tensi oner adjusti ng nut at equal -
i zer to create sl ack i n cabl es.
(3) Remove rear wheel /ti re assembl i es. Then
remove brake drums.
(4) Veri fy brakes are i n good condi ti on and operat-
i ng properl y.
(5) Veri fy park brake cabl es operate freel y and are
not bi ndi ng, or sei zed.
(6) Check rear brake shoe adjustment wi th stan-
dard brake gauge.
(7) I nstal l drums and veri fy that drums rotate
freel y wi thout drag.
(8) Rei nstal l wheel /ti re assembl i es after brake
shoe adjustment i s compl ete.
(9) Lower vehi cl e enough for access to park brake
foot pedal . Then ful l y appl y park brakes.
NOTE: Leave park brakes applied until adjustment
is complete.
(10) Rai se vehi cl e agai n.
(11) Mark tensi oner rod 6.35 mm (1/4 i n.) from
edge of tensi oner bracket (Fi g. 52).
(12) Ti ghten adjusti ng nut at equal i zer unti l mark
on tensi oner rod moves i nto al i gnment wi th tensi oner
bracket.
CAUTION: Do not loosen, or tighten the tensioner
adjusting nut for any reason after completing
adjustment.
(13) Lower vehi cl e unti l rear wheel s are 15-20 cm
(6-8 i n.) off shop fl oor.
(14) Rel ease park brake foot pedal and veri fy that
rear wheel s rotate freel y wi thout drag. Then l ower
vehi cl e.
PEDAL
DESCRIPTION
The rear drum brake shoes serve as the parki ng
brakes. The parki ng brakes are operated by a system
of cabl es and l evers attached to the rear brake sec-
ondary shoes.
Fig. 51 Park Brake Cables
1 - CABLE RETAINERS
2 - LEFT CABLE
3 - LEFT CABLE CONNECTOR
4 - EXTENSION CABLE
5 - TENSIONER
6 - FRONT CABLE
7 - FRAME CLIPS
8 - CABLE BRACKET
9 - RIGHT CABLE
CABLES (Continued)
OPERATION
The shoes make contact wi th the brake drum sur-
face by a cabl e and l ever mechani sm attached to the
secondary brake shoe. The front parki ng brake cabl e
i s connected to the parki ng brake pedal and to the
rear cabl es. An i ntermedi ate cabl e i s used on some
vehi cl es to connect the front and rear cabl es.
The parki ng brake pedal assembl y i s mounted on
the dri ver si de cowl panel . The front cabl e i s di rectl y
attached to the assembl y. The pedal assembl y con-
tai ns a spri ng l oaded mechani sm to hol d the pedal i n
the appl i ed posi ti on. A rod and spri ng are used to
rel ease the ratchet mechani sm and return the pedal
to normal posi ti on.
REMOVAL
(1) Remove l eft si de ki ck panel .
(2) Remove brake rel ease rod from pedal assembl y
(Fi g. 53).
(3) Di sconnect brake warni ng l amp swi tch.
(4) Remove front parki ng brake cabl e. (Refer to 5 -
BRAKES/PARKI NG BRAKE/CABLES - REMOVAL).
(5) Remove mounti ng nuts and mounti ng bol t.
(6) Sl i de assembl y rearward off the mounti ng
studs (Fi g. 53).
INSTALLATION
(1) I nstal l assembl y on the mounti ng studs.
(2) I nstal l mounti ng bol t and nuts.
(3) I nstal l front parki ng brake cabl e. (Refer to 5 -
BRAKES/PARKI NG BRAKE/CABLES - I NSTALLA-
TI ON).
(4) Connect brake warni ng l amp swi tch.
(5) I nstal l brake rel ease rod to pedal assembl y.
(6) I nstal l l eft si de ki ck panel .
RELEASE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO - PASSIVE RESTRAINT SYSTEMS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Reach under the dri ver si de outboard end of
the i nstrument panel to access and unsnap the pl as-
ti c retai ner cl i p that secures the park brake rel ease
l i nkage rod to the l ever on the back si de of the park
brake rel ease handl e.
(3) Di sengage the park brake rel ease l i nkage rod
end from the l ever on the back of the park brake
rel ease handl e.
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry one of the park brake
handl e hi nge tabs away from i ts pi vot pi n on the
i nstrument panel (Fi g. 54).
(5) Whi l e pryi ng the park brake rel ease handl e
hi nge tab wi th one hand, use the other hand to pul l
the handl e fi rml y down and away from the pi vot pi n.
(6) Remove the park brake rel ease handl e from the
i nstrument panel .
Fig. 52 Adjustment Mark On Cable Tensioner Rod
1 - CABLE CONNECTOR
2 - ADJUSTER NUT
3 - 6.35MM
(1/4 IN.)
Fig. 53 Parking Brake Pedal Assembly
1 - PARKING BRAKE ASSEMBLY
2 - LEFT COWL PANEL
3 - FRONT CABLE
4 - RELEASE ROD
PEDAL (Continued)
INSTALLATION
BAGS, REFER TO - PASSIVE RESTRAINT SYSTEMS
(1) Posi ti on the park brake rel ease handl e to the
i nstrument panel .
(2) Engage one of the park brake rel ease handl e
hi nge tabs wi th one of the pi vot pi ns on the i nstru-
ment panel .
(3) Al i gn the second park brake rel ease handl e
hi nge tab hi nge over the second pi vot pi n on the
i nstrument panel .
(4) Press fi rml y on the park brake rel ease handl e
over the second hi nge tab unti l i t snaps over the sec-
ond pi vot pi n on the i nstrument panel .
(5) Reach under the dri ver si de outboard end of
the i nstrument panel to access and engage the park
brake rel ease l i nkage rod end from the l ever on the
back of the park brake rel ease handl e.
(6) Snap the pl asti c retai ner cl i p that secures the
park brake rel ease l i nkage rod to the l ever on the
back si de of the park brake rel ease handl e over the
l i nkage rod.
(7) Reconnect the battery negati ve cabl e.
Fig. 54 Park Brake Release Handle Remove/Install
1 - INSERT BETWEEN HINGE TAB AND PIVOT PIN
2 - TRIM STICK
3 - PARK BRAKE RELEASE HANDLE
4 - INSTRUMENT PANEL
RELEASE (Continued)
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . . . 35
REAR WHEEL ANTILOCK. . . . . . . . . . . . . . . . . 35
RWAL SERVICE PRECAUTIONS . . . . . . . . . . . 35
BLEEDING ABS BRAKE SYSTEM. . . . . . . . . . . 36
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 36
FRONT WHEEL SPEED SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REAR WHEEL SPEED SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TONE WHEEL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
RWAL VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
BRAKES - ABS
DESCRIPTION
The anti l ock brake system (ABS) i s an el ectroni -
cal l y operated, al l wheel brake control system.
The system i s desi gned to prevent wheel l ockup
and mai ntai n steeri ng control duri ng peri ods of hi gh
wheel sl i p when braki ng. Preventi ng l ockup i s accom-
pl i shed by modul ati ng fl ui d pressure to the wheel
brake uni ts.
The hydraul i c system i s a three channel desi gn.
The front wheel brakes are control l ed i ndi vi dual l y
and the rear wheel brakes i n tandem (Fi g. 1). The
ABS el ectri cal system i s separate from other el ectri -
cal ci rcui ts i n the vehi cl e. A speci al l y programmed
control l er anti l ock brake uni t operates the system
components.
ABS system major components i ncl ude:
Control l er Anti l ock Brakes (CAB)
Hydraul i c Control Uni t (HCU)
Wheel Speed Sensors (WSS)
ABS Warni ng Li ght
Fig. 1 Antilock Brake System
1 - MASTER CYLINDER AND RESERVOIR
2 - POWER BRAKE BOOSTER
3 - WIRES TO WHEEL SPEED SENSORS
4 - RIGHT REAR WHEEL
5 - LEFT REAR WHEEL
6 - HYDRAULIC BRAKE LINES TO WHEELS
7 - COMBINATION VALVE
8 - HARNESS
9 - RIGHT FRONT WHEEL
10 - LEFT FRONT WHEEL
11 - CAB/HCU
AN BRAKES - ABS 5 - 33
DESCRIPTION
COMPONENT LOCATION FUNCTION
RWAL CONTROLLER Driver side inner fender on a
bracket.
Tests, monitors and controls the
rear brake system.
HYDRAULIC CONTROL UNIT/
RWAL VALVE
Driver side inner fender on a
bracket.
Modulates hydraulic pressure to
rear brakes during an RWAL stop.
REAR WHEEL SPEED SENSOR Top of the rear axle housing. Sends an AC voltage sinewave to
the CAB whose frequency is
proportional to vehicle speed.
EXCITER RING Ring gear inside the differential
housing.
Used to pull the magnetic field
across the wheel speed sensors
windings.
RED BRAKE WARNING LAMP Instrument cluster. Indicator for park brake
engagement, hydraulic brake
malfunction, or RWAL malfunction.
AMBER ABS WARNING LAMP Instrument cluster. Indicator of an RWAL malfunction.
BRAKE WARNING LAMP DIODE Instrument panel harness near the
parking brake switch.
Isolates the park brake switch circuit
from the CAB for proper red brake
warning lamp operation.
ISOLATION AND DUMP VALVE
FUSE
Inside the CAB. Fail-safe device for unwanted
control of the isolation and dump
solenoid/valves
ISOLATION AND DUMP
SOLENOID/VALVES
Inside the HCU/RWAL valve. Used to modulation hydraulic
pressure to the rear brakes during
an RWAL stop.
DESCRIPTION
Rear Wheel Anti l ock (RWAL) brake system i s stan-
dard equi pment. The RWAL brake system i s desi gned
to prevent rear wheel l ock-up under heavy braki ng
condi ti ons on vi rtual l y al l types of road surfaces.
RWAL braki ng i s desi rabl e because a vehi cl e whi ch i s
stopped wi thout l ocki ng the wheel s wi l l retai n di rec-
ti onal stabi l i ty. Thi s al l ows the dri ver to retai n
greater control of the vehi cl e duri ng braki ng.
The RWAL components i ncl ude:
RWAL Val ve
Control l er Anti l ock brake (CAB)
Rear Wheel Speed Sensor (WSS)
OPERATION
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c and dynami c checks occurs at i gni ti on
start up. Duri ng the dynami c check, the CAB bri efl y
cycl es the pump and sol enoi ds to veri fy operati on. An
audi bl e noi se may be heard duri ng thi s sel f check.
Thi s noi se shoul d be consi dered normal .
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
The CAB moni tors wheel speed sensor i nputs con-
ti nuousl y whi l e the vehi cl e i s i n moti on. However,
the CAB wi l l not acti vate any ABS components as
l ong as sensor i nputs i ndi cate normal braki ng.
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
5 - 34 BRAKES - ABS AN
BRAKES - ABS (Continued)
The anti l ock system prevents l ockup duri ng hi gh
sl i p condi ti ons by modul ati ng fl ui d appl y pressure to
the wheel brake uni ts.
Brake fl ui d appl y pressure i s modul ated accordi ng
to wheel speed, degree of sl i p and rate of decel era-
ti on. Sensors at each front wheel convert wheel speed
i nto el ectri cal si gnal s. These si gnal s are transmi tted
to the CAB for processi ng and determi nati on of
wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program.
Two sol enoi d val ves are used i n each anti l ock con-
trol channel . The val ves are al l l ocated wi thi n the
HCU val ve body and work i n pai rs to ei ther i ncrease,
hol d, or decrease appl y pressure as needed i n the
i ndi vi dual control channel s.
The sol enoi d val ves are not stati c duri ng anti l ock
braki ng. They are cycl ed conti nuousl y to modul ate
pressure. Sol enoi d cycl e ti me i n anti l ock mode can be
measured i n mi l l i seconds.
OPERATION
When the brakes are appl i ed, hydraul i c fl ui d i s
routed from the master cyl i nders secondary ci rcui t,
through the combi nati on val ve, to the RWAL val ve.
From there hydraul i c fl ui d i s routed to the rear
brake wheel cyl i nders. The Control l er Anti l ock Brake
moni tors rear wheel speed through the rear wheel
speed sensor. I f a wheel i s about to l ock-up, the CAB
si gnal s the RWAL val ve. The RWAL val ve modul ates
the hydraul i c brake pressure to the rear wheel s to
prevent wheel l ock-up.
NORMAL BRAKING
Duri ng l i ght brake appl i cati on, rear wheel decel er-
ati on i s not suffi ci ent to acti vate the anti l ock system
components. Duri ng a normal stop hydraul i c brake
fl ui d fl ows unrestri cted to the rear wheel cyl i nders to
stop the vehi cl e. The anti l ock sol enoi d val ves are
i nacti ve. The i sol ati on val ve i s open and the dump
val ve i s cl osed al l owi ng normal fl ui d fl ow to the rear
wheel cyl i nders.
REAR WHEEL ANTILOCK BRAKING
I f the CAB senses i mpendi ng rear wheel l ock-up, i t
wi l l energi ze the i sol ati on sol enoi d. Thi s prevents a
further i ncrease of dri ver i nduced brake pressure to
the rear wheel s. I f thi s i ni ti al acti on i s not enough to
prevent rear wheel l ock-up, the CAB wi l l momen-
tari l y energi ze a dump sol enoi d. Thi s opens the
dump val ve to vent a smal l amount of i sol ated rear
brake pressure to an accumul ator. The acti on of fl ui d
movi ng to the accumul ator reduces the i sol ated brake
pressure at the wheel cyl i nders. The dump (pressure
venti ng) cycl e i s l i mi ted to very short ti me peri ods
(mi l l i seconds). The CAB wi l l pul se the dump val ve
unti l rear wheel decel erati on reaches the desi red sl i p
rate programmed i nto the CAB. The system wi l l
swi tch to normal braki ng once wheel l ocki ng tenden-
ci es are no l onger present.
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or EDT with J-1850 is used to diag-
nose the ABS system. For additional information
refer to the Antilock Brake section.
DIAGNOSIS AND TESTING - REAR WHEEL
ANTILOCK
Di agnosi s of base brake condi ti ons whi ch are
mechani cal i n nature shoul d be performed fi rst. Thi s
i ncl udes brake noi se, l ack of power assi st, parki ng
brake, or vehi cl e vi brati on duri ng normal braki ng.
The RWAL brake system performs several sel f-
tests every ti me the i gni ti on swi tch i s turned on and
the vehi cl e i s dri ven. The CAB moni tors the system
i nputs and outputs ci rcui ts to veri fy the system i s
operati ng properl y. I f the CAB senses a mal functi on
i n the system i t wi l l set a DTC i nto memory and tri g-
ger the warni ng l amp.
NOTE: The MDS or EDT with J-1850 is used to diag-
nose the RWAL system.
STANDARD PROCEDURES - RWAL SERVICE
PRECAUTIONS
The RWAL uses an el ectroni c control modul e, the
CAB. Thi s modul e i s desi gned to wi thstand normal
current draws associ ated wi th vehi cl e operati on.
Care must be taken to avoi d overl oadi ng the CAB
ci rcui ts. In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure. These ci rcui ts shoul d onl y be tested
usi ng a hi gh i mpedance mul ti -meter or the DRB
tester as descri bed i n thi s secti on. Power shoul d
never be removed or appl i ed to any control modul e
wi th the i gni ti on i n the ON posi ti on. Before removi ng
or connecti ng battery cabl es, fuses, or connectors,
al ways turn the i gni ti on to the OFF posi ti on.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
STANDARD PROCEDURES - BLEEDING ABS
BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. (Refer to 5 -
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then BLEED BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
(Refer to 5 - BRAKES - STANDARD PROCEDURE).
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
SPECIFICATIONS
TORQUE CHART
ABS Assembly
Bracket bolts
14-15 10-12

ABS Assembly
Mounting Nuts
12

102
ABS Assembly
CAB Screws
4-4.7

36-42
ABS Assembly
Brake Line Fittings
19

170
Controller
Mounting Screws
6 53
RWAL Valve
Mounting Bolt
20-27 15-20
RWAL Valve
Brake Line Fittings
19 170
Wheel Speed Sensor
Mounting Bolt
24 200
Wheel Speed Sensors
Front Sensor Bolt
21 190
Wheel Speed Sensors
Rear Sensor Bolt
22.5 195
FRONT WHEEL SPEED
SENSOR
DESCRIPTION
The ABS brake system uses 3 wheel speed sensors.
A sensor i s mounted to each front steeri ng knuckl es.
The thi rd sensor i s mounted on top of the rear axl e
di fferenti al housi ng.
OPERATION
The WSS consi sts of a magnet surrounded by
wi ndi ngs from a si ngl e strand of wi re. The sensor
sends a smal l AC si gnal to the CAB. Thi s si gnal i s
generated by magneti c i nducti on. The magneti c
i nducti on i s created when a toothed sensor ri ng
(exci ter ri ng or tone wheel ) passes the stati onary
magneti c WSS.
When the ri ng gear i s rotated, the exci ter ri ng
passes the ti p of the WSS. As the exci ter ri ng tooth
approaches the ti p of the WSS, the magneti c l i nes of
force expand, causi ng the magneti c fi el d to cut across
the sensors wi ndi ngs. Thi s, i n turn causes current to
fl ow through the WSS ci rcui t (Fi g. 2) i n one di rec-
ti on. When the exci ter ri ng tooth moves away from
the sensor ti p, the magneti c l i nes of force col l apse
cutti ng the wi ndi ng i n the opposi te di recti on. Thi s
causes the current to fl ow i n the opposi te di recti on.
Every ti me a tooth of the exci ter ri ng passes the ti p
of the WSS, an AC si gnal i s generated. Each AC si g-
nal (posi ti ve to negati ve si gnal or si newave) i s i nter-
preted by the CAB. I t then compares the frequency of
the si newave to a ti me val ue to cal cul ate vehi cl e
speed. The CAB conti nues to moni tor the frequency
to determi ne a decel erati on rate that woul d i ndi cate
a possi bl e wheel -l ocki ng tendency.
The si gnal strength of any magneti c i nducti on sen-
sor i s di rectl y affected by:
Magneti c fi el d strength; the stronger the mag-
neti c fi el d, the stronger the si gnal
Number of wi ndi ngs i n the sensor; more wi nd-
i ngs provi de a stronger si gnal
Exci ter ri ng speed; the faster the exci ter ri ng/
tone wheel rotates, the stronger the si gnal wi l l be
Di stance between the exci ter ri ng teeth and
WSS; the cl oser the WSS i s to the exci ter ri ng/tone
wheel , the stronger the si gnal wi l l be
The rear WSS i s not adjustabl e. A cl earance speci -
fi cati on has been establ i shed for manufacturi ng tol er-
ances. I f the cl earance i s not wi thi n these
speci fi cati ons, then ei ther the WSS or other compo-
nents may be damaged. The cl earance between the
WSS and the exci ter ri ng i s 0.005 0.050 i n.
The assembl y pl ant performs a Rol l s Test on
every vehi cl e that l eaves the assembl y pl ant. One of
the test performed i s a test of the WSS. To properl y
test the sensor, the assembl y pl ant connects test
equi pment to the Data Li nk Connector (DLC). Thi s
connector i s l ocated to the ri ght of the steeri ng col -
umn and attached to the l ower porti on of the i nstru-
ment panel (Fi g. 3). The rol l s test termi nal i s spl i ced
to the WSS ci rcui t. The vehi cl e i s then dri ven on a
set of rol l ers and the WSS output i s moni tored for
proper operati on.
Fig. 2 Operation of the Wheel Speed Sensor
1 - MAGNETIC CORE
2 - CAB
3 - AIR GAP
4 - EXCITER RING
5 - COIL
Fig. 3 Data Link Connector - Typical
1 - 16WAY DATA LINK CONNECTOR
REMOVAL - 4X2
CAUTION: Special bolts are used to attach the front
sensor. The bolts have a special shoulder, thread
length and surface treatment. If the original bolts
must be replaced, use only factory replacement
part. Do not use substitute bolts under any circum-
stances.
(2) Remove bol t attachi ng sensor to the steeri ng
knuckl e (Fi g. 4).
(3) Remove cl amps securi ng sensor wi re to control
arm and i nner fender panel .
(4) I n engi ne compartment, di sconnect sensor wi re
from harness and remove sensor.
REMOVAL - 4X4
bolts. Do not use substitute bolt under any circum-
stances.
(3) Remove brake cal i per and rotor. (Refer to 5 -
REMOVAL).
(4) Remove bol ts attachi ng sensor to hub/beari ng
(Fi g. 5).
(5) Remove cl amps securi ng sensor wi re to control
arm and i nner fender panel .
(6) I n engi ne compartment, di sconnect sensor wi re
and remove sensor.
INSTALLATION - 4X2
part. Do not use substitute bolts under any circum-
stances.
(1) Posi ti on sensor i n the knuckl e and i nstal l sen-
sor attachi ng bol ts. Ti ghten bol ts to 21 Nm (190 i n.
l bs.).
(2) Secure sensor wi re retai ni ng cl amps to control
arm and fender panel .
(3) I n engi ne compartment, connect sensor wi re to
harness connector. Make sure wi re i s routed away
from hot or rotati ng underhood components.
(4) Turn steeri ng wheel back and forth to veri fy
that wi re i s cl ear of steeri ng and suspensi on compo-
nents.
INSTALLATION - 4X4
bolts. Do not use substitute bolt under any circum-
stances.
(1) Gui de sensor wi re around upper control arm.
Fig. 4 Front Wheel Speed Sensor - 4x2
1 - WHEEL SPEED SENSOR
2 - KNUCKLE
3 - MOUNTING BOLT
2 - HUB/BEARING
3 - MOUNTING BOLTS
FRONT WHEEL SPEED SENSOR (Continued)
(2) Posi ti on sensor on hub/beari ng and i nstal l
attachi ng bol ts. Ti ghten bol t to 18-25 Nm (160-220
i n. l bs.).
(3) Secure sensor wi re retai ni ng cl amps to control
arm and fender panel wi th ori gi nal hardware.
(4) I n engi ne compartment, connect sensor wi re to
harness connector. I nsure wi re i s routed away from
hot or rotati ng underhood components.
(5) I nstal l brake rotor and cal i per. (Refer to 5 -
I NSTALLATI ON).
DURE).
(7) Turn steeri ng wheel back and forth to veri fy
that wi re i s cl ear of steeri ng and suspensi on compo-
nents.
REAR WHEEL SPEED SENSOR
REMOVAL
(2) Remove brake l i ne mounti ng nut and remove
the brake l i ne from the sensor stud.
(3) Remove mounti ng stud from the sensor and
shi el d (Fi g. 7).
(4) Remove sensor and shi el d from di fferenti al
housi ng.
(5) Di sconnect sensor wi re harness and remove
sensor.
INSTALLATION
(1) Connect harness to sensor. Be sure seal is
securely in place between sensor and wiring
connector.
(2) I nstal l O-ri ng on sensor (i f removed).
(3) I nsert sensor i n di fferenti al housi ng.
(4) I nstal l sensor shi el d.
(5) I nstal l the sensor mounti ng stud and ti ghten to
24 Nm (200 i n. l bs.).
(6) I nstal l the brake l i ne on the sensor stud and
i nstal l the nut.
TONE WHEEL
DESCRIPTION
The rear Wheel Speed Sensor (WSS) i s mounted i n
the rear di fferenti al housi ng (Fi g. 8).
The exci ter ri ng i s press fi tted onto the di fferenti al
carri er next to the fi nal dri ve ri ng gear (Fi g. 9).
REMOVAL- EXCITER RING
The exci ter ri ng i s mounted on the di fferenti al
case. I f the ri ng i s damaged (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/REAR AXLE - 8 1/4/PI NI ON
GEAR/RI NG GEAR/TONE RI NG - REMOVAL).
REMOVAL - TONE WHEEL
The tone wheel for the front speed sensor i s l ocated
on the hub/beari ng on 2-wheel dri ve model s (Fi g. 10).
On 4-wheel dri ve model s, the tone wheel i s l ocated i n
the hub/beari ng housi ng.
The tone wheel i s not a servi ceabl e component. To
repl ace the tone wheel the hub/beari ng must be
2 - KNUCKLE
3 - MOUNTING BOLT
Fig. 7 Rear Speed Sensor Mounting
FRONT WHEEL SPEED SENSOR (Continued)
repl aced. (Refer to 2 - SUSPENSI ON/FRONT/HUB /
BEARI NG - REMOVAL).
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The hydraul i c control uni t (HCU) consi sts of a
val ve body, pump, two accumul ators and a motor
(Fi g. 11). The assembl y i s mounted on the dri versi de
i nner fender under the hood.
OPERATION
The pump, motor, and accumul ators are combi ned
i nto an assembl y attached to the val ve body. The
accumul ators store the extra fl ui d whi ch had to be
dumped from the brakes. Thi s i s done to prevent the
wheel s from l ocki ng up. The pump provi des the fl ui d
vol ume needed and i s operated by a DC type motor.
The motor i s control l ed by the CAB.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
The val ve body contai ns the sol enoi d val ves. The
val ves modul ate brake pressure duri ng anti l ock brak-
i ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure decrease,
pressure hol d, and pressure i ncrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
PRESSURE DECREASE
The i nl et val ve i s cl osed and the outl et val ve i s
opened duri ng the pressure decrease cycl e.
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
to prevent the dri ver from further i ncreasi ng the
Fig. 8 Rear Wheel Speed Sensor Location
Fig. 9 Exciter Ring Location
1 - EXCITER RING
2 - RING GEAR
Fig. 10 Tone Wheel 4x2
1 - HUB
2 - TONE WHEEL
3 - BEARING
TONE WHEEL (Continued)
brake pressure and l ocki ng the brakes. The CAB
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
PRESSURE HOLD
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
PRESSURE INCREASE
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
REMOVAL
NOTE: If the antilock control assembly needs to be
replaced, the rear axle type and tire revolutions per
mile must be programed into the new CAB. For axle
type refer to Differential and Driveline. For tire rev-
olutions per mile (Refer to 22 - TIRES/WHEELS/
TIRES - SPECIFICATIONS). To program the CAB
refer to the Chassis Diagnostic Manual.
(1) Di sconnect battery negati ve cabl e.
(2) Remove the brake l i nes from HCU (Fi g. 11).
(3) Push the harness connector l ocks to rel ease the
l ocks, (Fi g. 11) then remove the connectors from the
CAB.
(4) Remove the nuts whi ch attaches the assembl y
to the mounti ng bracket (Fi g. 12).
(5) Remove the assembl y from the vehi cl e.
INSTALLATION
NOTE: If the antilock control assembly needs to be
replaced, the rear axle type and tire revolutions per
mile must be programed into the new CAB. For axle
type refer to Differential and Driveline. For tire rev-
olutions per mile (Refer to 22 - TIRES/WHEELS/
TIRES - SPECIFICATIONS). To program the CAB
refer to the Chassis Diagnostic Manual.
(1) I nstal l the anti l ock assembl y i nto the bracket
and ti ghten bol ts to 14-15 Nm (10-12 ft. l bs.).
(2) Connect the CAB harnesses.
(3) Connect the brake l i nes to the HCU. Ti ghten
brake l i ne fi tti ngs to 19 Nm (170 i n. l bs.).
(4) Connect battery.
(5) Bl eed brake system, (Refer to 5 - BRAKES -
Fig. 11 HCU Brake Lines
1 - CAB
2 - BRAKE LINES
3 - HCU
Fig. 12 Mounting Bracket
1 - ANTILOCK CONTROL ASSEMBLY
2 - MOUNTING BRACKET
HCU (HYDRAULIC CONTROL UNIT) (Continued)
RWAL VALVE
DESCRIPTION
The val ve i s l ocated on the dri vers si de i nner
fender under the hood. The val ve modul ates hydrau-
l i c pressure to the rear brakes duri ng an RWAL stop.
OPERATION
I f the CAB senses that rear wheel speed decel era-
ti on i s excessi ve, i t wi l l energi ze an i sol ati on sol enoi d
by provi di ng battery vol tage to the sol enoi d. Thi s
prevents a further i ncrease of dri ver i nduced brake
pressure to the rear wheel s. I f thi s i ni ti al acti on i s
not enough to prevent rear wheel l ock-up, the CAB
wi l l momentari l y energi ze a dump sol enoi d (the CAB
energi zes the dump sol enoi d by provi di ng battery
vol tage to the sol enoi d). Thi s opens the dump val ve
to vent a smal l amount of i sol ated rear brake pres-
sure to an accumul ator. The acti on of fl ui d movi ng to
the accumul ator reduces the i sol ated brake pressure
at the wheel cyl i nders. The dump (pressure venti ng)
cycl e i s l i mi ted to very short ti me peri ods (mi l l i sec-
onds). The CAB wi l l pul se the dump val ve unti l rear
wheel decel erati on matches the desi red sl i p rate pro-
grammed i nto the CAB. The system wi l l swi tch to
normal braki ng once wheel l ocki ng tendenci es are no
l onger present.
A predetermi ned maxi mum number of consecuti ve
dump cycl es can be performed duri ng any RWAL
stop. I f excessi ve dump cycl es occur, a DTC wi l l be
set and stored i n the CAB memory. I f duri ng a RWAL
stop, the dri ver rel eases the brake pedal , the reset
swi tch contacts wi l l open. Thi s si gnal to the CAB i s
an i ndi cati on that pressure has equal i zed across the
RWAL val ve. The CAB wi l l then reset the dump cycl e
counter i n anti ci pati on of the next RWAL stop. Addi -
ti onal l y, any fl ui d stored i n the accumul ator wi l l
force i ts way past the dump val ve, back i nto the
hydraul i c ci rcui t and return to the master cyl i nder.
A fuse i nternal to the CAB, provi des a fai l -safe
devi ce whi ch prevents unwanted control over the i so-
l ati on and dump sol enoi ds. The fuse i s i n seri es wi th
the i sol ati on and dump sol enoi ds output ci rcui ts. I f
the i nternal fuse i s open, the CAB cannot provi de
vol tage to energi ze ei ther sol enoi d and RWAL stops
are prevented. I f the fuse i s open, the braki ng system
wi l l operate normal l y but wi thout anti l ock control
over rear brake pressure.
REMOVAL
(1) Remove RWAL val ve harness connector from
the RWAL control l er.
(2) Remove the brake l i nes from the val ve.
(3) Remove the val ve mounti ng bol t (Fi g. 13) and
remove the val ve from the bracket.
INSTALLATION
(1) Posi ti on the val ve on the bracket and i nstal l
the mounti ng bol t. Ti ghten the mounti ng bol t to
20-27 Nm (15-20 ft. l bs.).
(2) I nstal l the brake l i nes and ti ghten to 19 Nm
(170 i n. l bs.).
(3) I nstal l the RWAL val ve harness connector i nto
the RWAL control l er.
(4) Bl eed base brake system, (Refer to 5 - BRAKES
Fig. 13 RWAL Valve
1 - RWAL VALVE
2 - MOUNTING BOLT
3 - BRAKE LINES
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLUTCH DISC
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLUTCH HOUSING
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLUTCH RELEASE BEARING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PRESSURE PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FLYWHEEL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PILOT BEARING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LINKAGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CLUTCH PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CLUTCH
DESCRIPTION
The cl utch mechani sm consi sts of a fl ywheel , a si n-
gl e, dry-type di sc, and a di aphragm styl e cl utch cover
(Fi g. 1). A hydraul i c l i nkage i s used to operate the
cl utch rel ease beari ng and fork. The fl ywheel i s
bol ted to the rear fl ange of the crankshaft. The
cl utch pressure pl ate i s bol ted to the fl ywheel wi th
the cl utch di sc l ocated between these two compo-
nents. The cl utch system provi des the mechani cal ,
but sti l l easi l y detachabl e, l i nk between the engi ne
and the transmi ssi on. The system i s desi gned to
ensure that the ful l torque output of the engi ne i s
transfered to the transmi ssi on whi l e i sol ati ng the
transmi ssi on from the engi ne fi ri ng pul ses to mi ni -
mi ze concerns such as gear rattl e.
OPERATION
Leverage, cl ampi ng force, and fri cti on are what
make the cl utch work. The di sc serves as the fri cti on
el ement and a di aphragm spri ng and pressure pl ate
provi de the cl ampi ng force. The cl utch pedal , hydrau-
l i c l i nkage, rel ease l ever and beari ng provi de the
l everage.
AN CLUTCH 6 - 1
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . When the cl utch pedal i s
depressed, the sl ave cyl i nder i s operated by the
cl utch master cyl i nder mounted on the dash panel .
The rel ease fork i s actuated by the hydraul i c sl ave
cyl i nder mounted on the transmi ssi on housi ng. The
rel ease beari ng i s operated by a rel ease fork pi voti ng
on a bal l stud mounted i n the transmi ssi on housi ng.
The rel ease beari ng then depresses the pressure
pl ate spri ng fi ngers, thereby rel easi ng pressure on
the cl utch di sc and al l owi ng the engi ne crankshaft to
spi n i ndependentl y of the transmi ssi on i nput shaft
(Fi g. 2).
WARNING
WARNING:: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
DIAGNOSTIC AND TESTING - CLUTCH
A road test and component i nspecti on (Fi g. 3) i s
recommended to determi ne a cl utch probl em.
Duri ng a road test, dri ve the vehi cl e at normal
speeds. Shi ft the transmi ssi on through al l gear
ranges and observe cl utch acti on. I f the cl utch chat-
ters, grabs, sl i ps or does not rel ease properl y, remove
and i nspect the cl utch components. I f the probl em i s
noi se or hard shi fti ng, further di agnosi s may be
needed as the transmi ssi on or another dri vel i ne com-
ponent may be at faul t.
Fig. 1 Engine Powerflow
Fig. 2 Clutch Operation
1 - FLYWHEEL
2 - PRESSURE PLATE FINGERS
3 - PIVOT POINT
4 - RELEASE BEARING PUSHED IN
5 - CLUTCH DISC ENGAGED
6 - CLUTCH DISC ENGAGED
7 - RELEASE BEARING
6 - 2 CLUTCH AN
CLUTCH (Continued)
Fig. 3 Clutch Components And Inspection
AN CLUTCH 6 - 3
CLUTCH (Continued)
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab.
Duri ng i nspecti on, note i f any components are con-
tami nated wi th oi l , hydraul i c fl ui d or water/road
spl ash.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Oi l l eak-
age produces a resi due of oi l on the housi ng i nteri or
and on the cl utch cover and fl ywheel . Heat bui l dup
caused by sl i ppage between the cover, di sc and fl y-
wheel , can someti mes bake the oi l resi due onto the
components. The gl aze-l i ke resi due ranges i n col or
from amber to bl ack.
Road spl ash contami nati on means di rt/water i s
enteri ng the cl utch housi ng due to l oose bol ts, hous-
i ng cracks or through hydraul i c l i ne openi ngs. Dri v-
i ng through deep water puddl es can force water/road
spl ash i nto the housi ng through such openi ngs.
Cl utch fl ui d l eaks are usual l y from damaged sl ave
cyl i nder push rod seal s.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear or damage to one or more cl utch compo-
nents. A vi sual i nspecti on of the rel ease components
wi l l usual l y reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. I tems to l ook for are: l eaks at the cl utch cyl i n-
ders and i nterconnecti ng l i ne; l oose sl ave cyl i nder
bol ts; worn/l oose rel ease fork and pi vot stud; dam-
aged rel ease beari ng; and a worn cl utch di sc, or pres-
sure pl ate.
Normal condensati on i n vehi cl es that are stored or
out of servi ce for l ong peri ods of ti me can generate
enough corrosi on to make the di sc sti ck to the fl y-
wheel , or pressure pl ate. I f thi s condi ti on i s experi -
enced, correcti on onl y requi res that the di sc be
l oosened manual l y through the i nspecti on pl ate open-
i ng.
Engagement probl ems usual l y resul t i n sl i p, chat-
ter/shudder, and noi sy operati on. The pri mary causes
are cl utch di sc contami nati on; cl utch di sc wear; mi s-
al i gnment, or di storti on; fl ywheel damage; or a com-
bi nati on of the foregoi ng. A vi sual i nspecti on i s
requi red to determi ne the part actual l y causi ng the
probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
CLUTCH COVER AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
DIAGNOSIS CHART
The cl utch i nspecti on chart (Fi g. 3) outl i nes i tems
to be checked before and duri ng cl utch i nstal l ati on.
Use the chart as a check l i st to hel p avoi d overl ook-
i ng potenti al probl em sources duri ng servi ce opera-
ti ons.
The di agnosi s charts descri be common cl utch prob-
l ems, causes and correcti on. Faul t condi ti ons are
l i sted at the top of each chart. Condi ti ons, causes and
correcti ve acti on are outl i ned i n the i ndi cated col -
umns.
The charts are provi ded as a conveni ent reference
when di agnosi ng faul ty cl utch operati on.
6 - 4 CLUTCH AN
CLUTCH (Continued)
DIAGNOSIS CHART
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
AN CLUTCH 6 - 5
CLUTCH (Continued)
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging and/or binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
6 - 6 CLUTCH AN
CLUTCH (Continued)
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate,
and/or clutch housing. Correct as
necessary.
SPECIFICATIONS
SPECIFICATIONS - CLUTCH
SPECIFICATIONS
Clutch Diameter 2.5L 232mm (9.13 in.)
Clutch Cover Bolts-2.5L 28 21 -
Clutch Cover Bolts-5/16 23 17 -
Clutch Cover Bolts-3/8 41 30 -
Master Cylinder Reservoir
Screws
5 - 40
Master Cylinder Nuts 54 40 -
Slave Cylinder Nuts 23 17 -
Dust Shield Bolt 12 - 105
AN CLUTCH 6 - 7
CLUTCH (Continued)
Flywheel Bolts-2.5L 95 70 -
Flywheel Bolts-3.9/5.2L 75 55 -
CLUTCH DISC
DESCRIPTION
The cl utch di sc fri cti on materi al i s ri veted to the
di sc hub (Fi g. 4) . The hub bore i s spl i ned for i nstal -
l ati on on the transmi ssi on i nput shaft. The cl utch
di sc has cushi on spri ngs i n the di sc hub to dampen
di sc vi brati ons duri ng appl i cati on and rel ease of the
cl utch.
OPERATION
The cl utch di sc i s hel d onto the surface of the fl y-
wheel by the force exerted by the pressure pl ates
di aphragm spri ng. The fri cti on materi al of the cl utch
di sc then transfers the engi ne torque from the fl y-
wheel and pressure pl ate to the i nput shaft of the
transmi ssi on.
REMOVAL
(2) Remove transmi ssi on and cl utch housi ng as
assembl y. Refer to 21 Transmi ssi on and Transfer
Case for procedures.
(3) I f cl utch cover i s onl y bei ng removed for access
to another component, mark posi ti on of cover on fl y-
wheel wi th smal l punch marks (Fi g. 5).
(4) Loosen cl utch cover bol ts evenl y and i n rotati on
to rel i eve spri ng tensi on. Loosen bol ts a few threads
at a ti me to avoi d warpi ng cover.
(5) Remove cover bol ts, cl utch cover and cl utch
di sc.
INSTALLATION
(1) Cl ean fl ywheel surface wi th sol vent. Scuff sand
surface wi th 120/180 gri t emery cl oth to remove
mi nor scratches and gl azi ng.
(2) Check new cl utch di sc for runout and free oper-
ati on on i nput shaft spl i nes.
(3) Lubri cate crankshaft pi l ot beari ng wi th Mopar
hi gh temperature beari ng grease or equi val ent.
(4) Posi ti on cl utch di sc to fl ywheel .
(5) I nsert al i gnment tool or spare i nput shaft
through cl utch di sc and i nto pi l ot beari ng (Fi g. 6).
(6) Veri fy that di sc hub i s posi ti oned correctl y. The
rai sed porti on of the hub faces away from the fl y-
wheel (Fi g. 7).
(7) Posi ti on cl utch cover over di sc and on fl ywheel .
(8) I nstal l cl utch cover bol ts fi nger ti ght.
Fig. 4 Clutch Disc-Typical
1 - FACING MATERIAL
2 - DAMPER SPRINGS
3 - HUB
Fig. 5 Mark Clutch Cover Position
1 - CLUTCH COVER
2 - PUNCH MARKS
3 - FLYWHEEL
6 - 8 CLUTCH AN
(9) Ti ghten cover bol ts evenl y (and i n rotati on) a
few threads at a ti me. Cover bol ts must be ti ghtened
evenl y and to speci fi ed torque to avoi d di storti ng
cover.
(10) Ti ghten cl utch cover bol ts to fol l owi ng torque:
2.5L bol ts to 28 Nm (21 ft. l bs.).
5/16 i n. bol ts to 23 Nm (17 ft. l bs.).
3/8 i n. bol ts to 41 Nm (30 ft. l bs.).
(11) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease to spl i nes of transmi ssi on i nput shaft
and to rel ease beari ng sl i de surface of front beari ng
retai ner. Do not overl ubri cate shaft spl i nes. Thi s
coul d resul t i n grease contami nati on of di sc.
(12) I nstal l transmi ssi on and cl utch housi ng as
CLUTCH HOUSING
DIAGNOSIS AND TESTING - CLUTCH HOUSING
Cl utch housi ng al i gnment i s i mportant to proper
cl utch operati on. The housi ng mai ntai ns al i gnment
between the crankshaft and transmi ssi on i nput
shaft. Mi sal i gnment can cause cl utch noi se, hard
shi fti ng, i ncompl ete rel ease and chatter. I t can al so
resul t i n premature wear of the pi l ot beari ng, cover
rel ease fi ngers and cl utch di sc. I n severe cases, mi s-
al i gnment can al so cause premature wear of the
transmi ssi on i nput shaft and front beari ng.
Housi ng mi sal i gnment i s general l y caused by
i ncorrect seati ng on the engi ne or transmi ssi on, l oose
housi ng bol ts, mi ssi ng al i gnment dowel s, or housi ng
damage. I nfrequentl y, mi sal i gnment may al so be
caused by housi ng mounti ng surfaces that are not
compl etel y paral l el . Mi sal i gnment can be corrected
wi th shi ms.
REMOVAL
(1) Rai se vehi cl e and support vehi cl e.
(2) Remove transmi ssi on and cl utch housi ng as
(3) Remove rel ease beari ng, rel ease fork and fork
boot from i nput shaft and cl utch housi ng.
(4) Remove bol ts attachi ng cl utch housi ng to trans-
mi ssi on (Fi g. 8).
INSTALLATION
(1) Cl ean mounti ng surfaces of transmi ssi on and
cl utch housi ng. Use a wi re brush i f necessary fol -
l owed by a wax and grease remover, or si mi l ar sol -
vent. Al so cl ean engi ne bl ock surface as wel l .
(2) Posi ti on cl utch housi ng on transmi ssi on and
i nstal l housi ng attachi ng bol ts. Ti ghten A bol ts to 38
Nm (28 ft. l bs.).
(3) I nstal l rel ease fork pi vot bal l stud to housi ng, i f
necessary.
(4) Lubri cate rel ease beari ng bore, rel ease fork
contact surfaces, and rel ease fork pi vot stud wi th
Mopar hi gh temperature beari ng grease. Al so l ubri -
cate transmi ssi on i nput shaft spl i nes, pi l ot hub and
beari ng retai ner sl i de surface wi th l i ght coat of same
grease.
(5) I nstal l rel ease fork, beari ng, and boot i n hous-
i ng. Be sure rel ease fork boot i s properl y seated i n
housi ng.
(6) I nstal l transmi ssi on. Refer to 21 Transmi ssi on
and Transfer Case for proper procedures. Ti ghten the
Fig. 6 Aligning Clutch Disc
1 - FLYWHEEL
2 - CLUTCH COVER AND DISC
3 - CLUTCH DISC ALIGNMENT TOOL
Fig. 7 Clutch Disc Position
1 - DISC
2 - INSPECT THIS SURFACE
3 - CLUTCH COVER
4 - FLYWHEEL SIDE STAMPED ON THIS SURFACE
AN CLUTCH 6 - 9
CLUTCH DISC (Continued)
upper transmi ssi on B bol ts to 75 Nm (55 ft.l bs).
Ti ghten al l l ower transmi ssi on C bol ts to 50 Nm (37
ft.l bs.).
CLUTCH RELEASE BEARING
DESCRIPTION
A conventi onal rel ease beari ng (Fi g. 9) i s used to
engage and di sengage the cl utch pressure pl ate
assembl y. The cl utch rel ease beari ng i s mounted on
the transmi ssi on front beari ng retai ner. The beari ng
i s attached to the rel ease fork, whi ch moves the bear-
i ng i nto contact wi th the cl utch cover di aphragm
spri ng.
OPERATION
The rel ease beari ng i s operated by a rel ease fork i n
the cl utch housi ng. Sl ave cyl i nder force causes the
rel ease l ever to move the rel ease beari ng i nto contact
wi th the di aphragm spri ng. As addi ti onal force i s
appl i ed, the beari ng presses the di aphragm spri ng
fi ngers i nward on the ful crums. Thi s acti on moves
the pressure pl ate rearward rel i evi ng cl amp force on
the di sc. Rel easi ng pedal pressure removes cl utch
hydraul i c pressure. The rel ease beari ng then moves
away from the di aphragm spri ng whi ch al l ows the
pressure pl ate to exert cl ampi ng force on the cl utch
di sc.
REMOVAL
(1) Remove transmi ssi on. Refer to 21 Transmi ssi on
and Transfer Case for procedures.
Fig. 8 Clutch Housing
1 - ENGINE
2 - TRANSMISSION
3 - CLUTCH HOUSING
4 - CLUTCH HOUSING BOLTS
5 - ENGINE
6 - CLUTCH HOUSING
6 - 10 CLUTCH AN
CLUTCH HOUSING (Continued)
(2) Di sconnect rel ease beari ng from fork and
remove beari ng (Fi g. 10).
INSTALLATION
(1) I nspect rel ease beari ng sl i de surface of trans-
mi ssi on front beari ng retai ner. Repl ace retai ner i f
sl i de surface i s scored, worn or cracked.
(2) I nspect rel ease fork and fork pi vot (Fi g. 10). Be
sure pi vot i s secure and i n good condi ti on. Be sure
fork i s not di storted or worn. Repl ace rel ease fork
retai ner spri ng i f bent or damaged i n any way.
(3) Li ghtl y l ubri cate pi l ot beari ng, i nput shaft
spl i nes, beari ng retai ner sl i de surface, fork pi vot and
rel ease fork pi vot surface wi th Mopar hi gh temper-
ature beari ng grease.
(4) I nstal l rel ease fork and beari ng. Veri fy fork
and beari ng are properl y secured.
(5) I nstal l transmi ssi on. Refer to 21 Transmi ssi on
and Transfer Case for procedures.
PRESSURE PLATE
DESCRIPTION
The cl utch pressure pl ate assembl y i s a di aphragm
type wi th a one-pi ece spri ng and mul ti pl e rel ease fi n-
gers (Fi g. 11) . The pressure pl ate rel ease fi ngers are
preset duri ng manufacture and are not adjustabl e.
The assembl y al so contai ns the cover, pressure pl ate,
and ful crum components.
OPERATION
The cl utch pressure pl ate assembl y cl amps the
cl utch di sc agai nst the fl ywheel . When the rel ease
beari ng i s depressed by the shi ft fork, the pressure
exerted on the cl utch di sc by the pressure pl ate
spri ng i s decreased. As addi ti onal force i s appl i ed,
the beari ng presses the di aphragm spri ng fi ngers
i nward on the ful crums. Thi s acti on moves the pres-
sure pl ate rearward rel i evi ng cl amp force on the di sc.
The cl utch di sc i s di sengaged and freewheel i ng at
thi s poi nt.
Fig. 9 Clutch Release Bearing
1 - RELEASE BEARING
2 - RELEASE FORK
Fig. 10 Release Bearing And Fork Mounting
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 Nm (200 IN. LBS.)
6 - SPRING
Fig. 11 Clutch Pressure Plate-Typical
1 - COVER
2 - RELEASE FINGERS
3 - PRESSURE PLATE
AN CLUTCH 6 - 11
CLUTCH RELEASE BEARING (Continued)
FLYWHEEL
DESCRIPTION
The fl ywheel (Fi g. 12) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear around the outer ci rcumference to mesh
wi th the starter to permi t engi ne cranki ng. The rear
face of the fl ywheel serves as the dri vi ng member to
the cl utch di sc.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
DIAGNOSIS AND TESTING - FLYWHEEL
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. However,
mi nor fl ywheel scori ng can be cl eaned up by hand
wi th 180 gri t emery, or wi th surface gri ndi ng equi p-
ment. Remove onl y enough materi al to reduce scor-
i ng (approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal . Ti ghten fl ywheel
bol ts to speci fi ed torque onl y. Overti ghteni ng can di s-
tort the fl ywheel hub causi ng runout.
PILOT BEARING
DESCRIPTION
Vehi cl es equi pped wi th a manual transmi ssi on uti -
l i ze a pi l ot beari ng. Thi s beari ng i s l ocated i n the
back of the engi ne crankshaft. Dependi ng on the type
of engi ne or appl i cati on, the pi l ot beari ng can be a
sol i d soft metal l i c bushi ng or a ful l y caged needl e
beari ng. The pi l ot beari ngs mai n functi ons are to
support the transmi ssi on i nput shaft, mai ntai n
proper al i gnment of the cl utch assembl y and al l ow
the transmi ssi on mai n shaft to rotate at a di fferent
speed than the engi ne mounted crankshaft.
OPERATION
The pi l ot beari ng supports the transmi ssi on i nput
shaft, mai ntai ns proper cl utch assembl y al i gnment
and al l ows the transmi ssi on i nput shaft to rotate at a
di fferent speed (RPM) than the engi ne mounted
crankshaft.
When the cl utch pedal i s depressed (wi th vehi cl e i n
dri ve mode) the cl utch di sc sl ows and stops therefore,
the transmi ssi on i nput shaft sl ows and stops as wel l .
The pi l ot beari ng al l ows the engi ne crankshaft to
conti nue to rotate even though the transmi ssi on
i nput shaft i s stati onary.
REMOVAL
(1) Remove transmi ssi on, transfer case, i f
equi pped, and cl utch housi ng. Refer to 21 Transmi s-
si on and Transfer Case for procedures.
(2) Remove cl utch cover and di sc.
(3) Usi ng a sui tabl e bl i nd hol e pul l er, remove pi l ot
beari ng.
Fig. 12 Flywheel
1 - CRANKSHAFT
2 - RING GEAR
3 - FLYWHEEL
6 - 12 CLUTCH AN
INSTALLATION
(1) Cl ean beari ng bore wi th sol vent and wi pe dry
wi th shop towel .
(2) I nstal l new beari ng wi th cl utch al i gnment tool
(Fi g. 13). Keep beari ng strai ght duri ng i nstal l ati on.
Do not al l ow beari ng to become cocked. Tap beari ng
i nto pl ace unti l fl ush wi th edge of beari ng bore. Do
not recess beari ng.
(3) I nstal l cl utch cover and di sc.
(4) I nstal l cl utch housi ng, transmi ssi on and trans-
fer case, i f equi pped. Refer to 21 Transmi ssi on and
Transfer Case for procedures.
LINKAGE
DESCRIPTION
The hydraul i c l i nkage consi sts of a cl utch master
cyl i nder, reservoi r, a cl utch sl ave cyl i nder and an
i nterconnecti ng fl ui d l i ne (Fi g. 14).
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . The sl ave cyl i nder push rod i s
connected to the cl utch rel ease fork. The master cyl -
i nder i s mounted on the dri ver si de of the dash panel
adjacent to the brake master cyl i nder and booster
assembl y.
The factory i nstal l ed hydraul i c l i nkage has a qui ck
di sconnect at the sl ave cyl i nder. Thi s fi tti ng shoul d
not be di sconnected or tampered wi th. The hydraul i c
l i nkage i s servi ced as an assembl y onl y. The i ndi vi d-
ual components that form the l i nkage assembl y can-
not be overhaul ed or servi ced separatel y.
OPERATION
The cl utch l i nkage uses hydraul i c pressure to oper-
ate the cl utch. Depressi ng the cl utch pedal devel ops
fl ui d pressure i n the cl utch master cyl i nder. Thi s
pressure i s transmi tted to the sl ave cyl i nder through
a connecti ng l i ne. I n turn, the sl ave cyl i nder operates
the cl utch rel ease l ever.
The sl ave cyl i nder has an i ntegral spri ng whi ch
prel oads the rel ease beari ng agai nst the cl utch di a-
phragm fi ngers to mai ntai n zero free-pl ay.
Sl ave cyl i nder force causes the rel ease l ever to
move the rel ease beari ng i nto contact wi th the di a-
phragm spri ng. As addi ti onal force i s appl i ed, the
beari ng presses the di aphragm spri ng fi ngers i nward
on the ful crums. Thi s acti on moves the pressure
pl ate rearward rel i evi ng cl amp force on the di sc.
REMOVAL
NOTE: The hydraulic linkage is serviced as a com-
plete assembly only. The individual components
must not be overhauled or serviced separately.
(2) Remove nuts attachi ng sl ave cyl i nder to cl utch
housi ng (Fi g. 15).
CAUTION: Do not disconnect slave cylinder quick
disconnect. If disconnected hydraulic linkage must
be replaced.
(3) Remove sl ave cyl i nder from housi ng.
(4) Remove hydraul i c fl ui d l i ne cl i p from the l ower
dash panel fl ange.
(6) Remove cl i p hol di ng cl utch master cyl i nder
push rod to cl utch pedal (Fi g. 15).
(7) Sl i de cl utch master cyl i nder push rod off cl utch
pedal pi n.
(8) Di sconnect cl utch pedal posi ti on swi tch connec-
tor from wi ri ng harness.
(9) Remove nuts hol di ng cl utch master cyl i nder to
dash panel .
(10) Veri fy that cap on cl utch master cyl i nder res-
ervoi r i s ti ght to avoi d undue spi l l age duri ng
removal .
(11) Remove screws attachi ng cl utch fl ui d reservoi r
to dash panel .
(12) Pul l cl utch master cyl i nder from dash panel .
(13) Remove hydraul i c l i nkage components from
vehi cl e as an assembl y.
Fig. 13 Pilot Bearing
1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - LETTER SIDE MUST FACE TRANSMISSION
AN CLUTCH 6 - 13
PILOT BEARING (Continued)
INSTALLATION
NOTE: The hydraulic linkage is serviced as a com-
plete assembly only. The individual components
must not be serviced separately.
(1) Ti ghten cap on cl utch fl ui d reservoi r to avoi d
spi l l age duri ng i nstal l ati on.
(2) Posi ti on cyl i nders, connecti ng l i nes and reser-
voi r i n vehi cl e.
(3) I nsert cl utch master cyl i nder i n dash panel .
(4) Posi ti on reservoi r on dash panel and i nstal l
reservoi r screws. Ti ghten screws to 5 Nm (40 i n.
l bs.).
(5) I nstal l nuts that hol d cl utch master cyl i nder to
dash panel . Ti ghten nuts to 54 Nm (40 ft. l bs.).
(6) Appl y l i ght coati ng of grease to the i nner di am-
eter of the master cyl i nder pushrod and the outer
di ameter of the cl utch pedal pi n.
(7) I nstal l cl utch master cyl i nder push rod on
cl utch pedal pi n. Secure rod wi th retai ni ng cl i p.
(8) Connect cl utch pedal posi ti on swi tch connector
from wi ri ng harness.
(10) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure end
of rod i s securel y engaged i n rel ease l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
NOTE: If new clutch linkage is being installed, do
not remove plastic shipping strap from the slave
cylinder push rod. The strap will break on its own
upon first clutch application.
(11) I nstal l and ti ghten sl ave cyl i nder attachi ng
nuts to 23 Nm (200 i n. l bs.).
(12) I nstal l hydraul i c fl ui d l i ne cl i p i nto the hol e i n
the l ower dash panel fl ange.
Fig. 14 Clutch
1 - CLUTCH FLUID RESERVOIR
2 - CLUTCH PEDAL
3 - CLUTCH SAVE CYLINDER
4 - CLUTCH HYDRAULIC LINE
5 - CLUTCH PEDAL
6 - CLUTCH PEDAL POSITION SWITCH CONNECTOR
8 - CLUTCH MASTER CYLINDER
6 - 14 CLUTCH AN
LINKAGE (Continued)
(13) Veri fy that fl ui d l i ne from master cyl i nder to
sl ave cyl i nder i s properl y routed.
CLUTCH PEDAL
REMOVAL
(1) Remove retai ni ng cl i p securi ng push rod on
cl utch pedal (Fi g. 16).
(2) Sl i de push rod off cl utch pedal pi n.
(3) Remove snap ri ng and washer attachi ng cl utch
pedal to the pi vot shaft.
(4) Sl i de pedal off pi vot shaft and remove pedal .
(5) Remove and i nspect bushi ngs i n pedal bore.
Repl ace bushi ngs i f worn or cracked.
INSTALLATION
(1) Lubri cate pedal bushi ngs and shaft wi th a si l i -
cone grease or wi th Mopar mul ti -mi l eage grease.
(2) I nstal l bushi ngs i n pedal bore and on pi n.
(3) I nstal l pedal on pi vot shaft.
(4) Secure pedal on shaft wi th washer and snap
ri ng.
(5) Appl y l i ght coati ng of grease to the i nner di am-
eter of the master cyl i nder push-rod and the outer
di ameter of the cl utch pedal pi n.
(6) Connect push rod to pedal and secure rod wi th
retai ni ng cl i p.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
A cl utch pedal posi ti on swi tch i s i n the starter ci r-
cui t. The swi tch i s l ocated on the cl utch master cyl -
i nder push rod.
Fig. 15 Clutch Hydraulic Linkage
1 - CLUTCH FLUID RESERVOIR
2 - CLUTCH PEDAL
3 - CLUTCH SAVE CYLINDER
5 - CLUTCH PEDAL
6 - CLUTCH PEDAL POSITION SWITCH CONNECTOR
8 - CLUTCH MASTER CYLINDER
AN CLUTCH 6 - 15
LINKAGE (Continued)
OPERATION
The swi tch, whi ch i s i n ci rcui t wi th the starter
sol enoi d, requi res that the cl utch pedal be ful l y
depressed i n order to start the engi ne. Swi tch ci r-
cui try and operati on i s provi ded i n secti on 8
El ectri cal .
Fig. 16 Clutch Pedal
1 - PIVOT ROD
2 - PEDAL SUPPORT
3 - BRAKE PEDAL
4 - BOOSTER ROD
5 - CLUTCH ROD
6 - CLUTCH PEDAL
6 - 16 CLUTCH AN
CLUTCH PEDAL POSITION SWITCH (Continued)
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 5
COOLING SYSTEM - TESTING FOR LEAKS . . . 5
PRELIMINARY CHECKS. . . . . . . . . . . . . . . . . . . 7
DRAINING COOLING SYSTEM 2.5L ENGINE . . 14
REFILLING COOLING SYSTEM 2.5L . . . . . . . . 14
DRAINING COOLING SYSTEM 3.9L/5.9L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REFILLING COOLING SYSTEM 3.9L/5.9L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DRAINING COOLING SYSTEM 4.7L ENGINE . . 15
REFILLING COOLING SYSTEM 4.7L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADDING ADDITIONAL COOLANT . . . . . . . . . . . 16
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . 16
COOLING SYSTEM CLEANING/REVERSE
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 17
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 64
COOLING
DESCRIPTION COOLING SYSTEM FLOW 2. 5L
ENGINE
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
An opti onal factory i nstal l ed maxi mum duty cool -
i ng package i s avai l abl e on most model s. Thi s pack-
age wi l l provi de addi ti onal cool i ng capaci ty for
vehi cl es used under extreme condi ti ons such as
trai l er towi ng i n hi gh ambi ent temperatures (Fi g. 1).
DESCRIPTION COOLING SYSTEM FLOW -
3. 9L/5. 9L ENGINE
vents overheati ng.
trai l er towi ng i n hi gh ambi ent temperatures (Fi g. 2).
AN COOLING 7 - 1
Fig. 1 Engine Cooling System Flow
1 - WATER CONTROL VALVE
2 - TO WATER PUMP
3 - THERMOSTAT HOUSING
4 - RADIATOR CAP
5 - RADIATOR
6 - TO COOLANT RESERVE BOTTLE
7 - TO WATER PUMP
8 - TO HEATER CORE
9 - FROM HEATER CORE
7 - 2 COOLING AN
COOLING (Continued)
1 - HEATER
2 - BYPASS*
3 - CROSSFLOW RADIATOR
AN COOLING 7 - 3
COOLING (Continued)
DESCRIPTION COOLING SYSTEM FLOW 4. 7L
ENGINE
The cool i ng system consi sts of (Fi g. 3):
Radi ator
Cool i ng fan (mechani cal /El ectri cal )
Thermal vi scous fan dri ve
Fan shroud
Radi ator pressure cap
Thermostat
Cool ant reserve/overfl ow system (i ntegral to
upper fan shroud)
Transmi ssi on oi l cool er (i f equi pped wi th an
automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
1 - LH CYL. HEAD
2 - BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD
5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
7 - 4 COOLING AN
COOLING (Continued)
DESCRIPTION HOSE CLAMPS
The cool i ng system uti l i zes both worm dri ve and
spri ng type hose cl amps. I f a spri ng type cl amp
repl acement i s necessary, repl ace wi th the ori gi nal
Mopar equi pment spri ng type cl amp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 4).
OPERATION COOLING SYSTEM
vents overheati ng.
trai l er towi ng i n hi gh ambi ent temperatures.
OPERATION HOSE CLAMPS
The worm type hose cl amp uses a speci fi ed torque
val ue to mai ntai n proper tensi on on a hose connec-
ti on.
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, onl y use constant tensi on cl amp pl i ers
desi gned to compress the hose cl amp.
DIAGNOSIS AND TESTING ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrai n control modul e (PCM) has been
programmed to moni tor certai n cool i ng system com-
ponents:
I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan,
a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cated an actual probl em, a DTC
i s stored. The DTC wi l l be stored i n the PCM mem-
ory for eventual di spl ay to the servi ce techni ci an.
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTCs and to obtai n cool i ng system data,
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
scan tool to erase a DTC. Refer to the appropri ate
Powertrai n Di agnosti c Procedures servi ce i nforma-
ti on for operati on of the DRB scan tool .
DIAGNOSIS AND TESTING COOLING
SYSTEM - TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A l eak detecti on addi ti ve i s avai l abl e through the
parts department that can be added to cool i ng sys-
tem. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). Pour one ounce of addi ti ve i nto
cool i ng system. Pl ace heater control uni t i n HEAT
posi ti on. Start and operate engi ne unti l radi ator
upper hose i s warm to touch. Ai m the commerci al l y
avai l abl e bl ack l i ght tool at components to be
checked. I f l eaks are present, bl ack l i ght wi l l cause
addi ti ve to gl ow a bri ght green col or.
The bl ack l i ght can be used i n conjuncti on wi th a
pressure tester to determi ne i f any external l eaks
exi st (Fi g. 5).
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
AN COOLING 7 - 5
COOLING (Continued)
PRESSURE TESTER METHOD
The engi ne shoul d be at normal operati ng temper-
ature. Recheck the system col d i f cause of cool ant
l oss i s not l ocated duri ng the warm engi ne exami na-
ti on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove radi ator pressure cap from fi l l er
neck and check cool ant l evel . Push down on cap to
di sengage i t from stop tabs. Wi pe i nsi de of fi l l er neck
and exami ne l ower i nsi de seal i ng seat for ni cks,
cracks, pai nt, di rt and sol der resi due. I nspect radi a-
tor-to- reserve/overfl ow tank hose for i nternal
obstructi ons. I nsert a wi re through the hose to be
sure i t i s not obstructed.
I nspect cams on outsi de of fi l l er neck. I f cams are
damaged, seati ng of pressure cap val ve and tester
seal wi l l be affected.
Attach pressure tester (7700 or an equi val ent) to
radi ator fi l l er neck (Fi g. 6) or (Fi g. 7).
Operate tester pump to appl y 103.4 kPa (15 psi )
pressure to system. I f hoses enl arge excessi vel y or
bul ges whi l e testi ng, repl ace as necessary. Observe
gauge poi nter and determi ne condi ti on of cool i ng sys-
tem accordi ng to fol l owi ng cri teri a:
Holds Steady: I f poi nter remai ns steady for two
mi nutes, seri ous cool ant l eaks are not present i n sys-
tem. However, there coul d be an i nternal l eak that
does not appear wi th normal system test pressure. I f
i t i s certai n that cool ant i s bei ng l ost and l eaks can-
not be detected, i nspect for i nteri or l eakage or per-
form I nternal Leakage Test. Refer to I NTERNAL
LEAKAGE I NSPECTI ON.
Fig. 5 Leak Detection Using Black LightTypical
1 - TYPICAL BLACK LIGHT TOOL
Fig. 6 PRESSURE TEST POINT 2.5L ENGINE
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
Fig. 7 PRESSURE TEST POINT 5.2L, 5.9L AND 4.7L
ENGINES
7 - 6 COOLING AN
COOLING (Continued)
Drops Slowly: I ndi cates a smal l l eak or seepage
i s occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect radi ator,
hoses, gasket edges and heater. Seal smal l l eak hol es
wi th a Seal er Lubri cant (or equi val ent). Repai r l eak
hol es and i nspect system agai n wi th pressure
appl i ed.
Drops Quickly: I ndi cates that seri ous l eakage i s
occurri ng. Exami ne system for external l eakage. I f
l eaks are not vi si bl e, i nspect for i nternal l eakage.
Large radi ator l eak hol es shoul d be repai red by a
reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . I f cool ant i s present i n
the pan, i t wi l l drai n fi rst because i t i s heavi er than
oi l . An al ternati ve method i s to operate engi ne for a
short peri od to churn the oi l . After thi s i s done,
remove engi ne di psti ck and i nspect for water gl ob-
ul es. Al so i nspect transmi ssi on di psti ck for water
gl obul es and transmi ssi on fl ui d cool er for l eakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 145 KPA (21 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engi ne wi thout pressure cap on radi ator
unti l thermostat opens. Attach a Pressure Tester to
fi l l er neck. I f pressure bui l ds up qui ckl y i t i ndi cates a
combusti on l eak exi sts. Thi s i s usual l y the resul t of a
cyl i nder head gasket l eak or crack i n engi ne. Repai r
as necessary.
I f there i s not an i mmedi ate pressure i ncrease,
pump the Pressure Tester. Do thi s unti l i ndi cated
pressure i s wi thi n system range of 145 kPa (21 psi ).
Fl uctuati on of gauge poi nter i ndi cates compressi on or
combusti on l eakage i nto cool i ng system.
Because the vehi cl e i s equi pped wi th a catal yti c
converter, do not remove spark pl ug cabl es or short
out cyl i nders to i sol ate compressi on l eak.
I f the needl e on di al of pressure tester does not
fl uctuate, race engi ne a few ti mes to check for an
abnormal amount of cool ant or steam. Thi s woul d be
emi tti ng from exhaust pi pe. Cool ant or steam from
exhaust pi pe may i ndi cate a faul ty cyl i nder head gas-
ket, cracked engi ne cyl i nder bl ock or cyl i nder head.
A conveni ent check for exhaust gas l eakage i nto
cool i ng system i s provi ded by a commerci al l y avai l -
abl e Bl ock Leak Check tool . Fol l ow manufacturers
i nstructi ons when usi ng thi s product.
COMBUSTION LEAKAGE TEST WITHOUT
PRESSURE TESTER
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow thermostat
removal . (Refer to 7 - COOLI NG/ENGI NE/ENGI NE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory dri ve bel t (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - REMOVAL).
Add cool ant to radi ator to bri ng l evel to wi thi n 6.3
mm (1/4 i n) of top of thermostat housi ng.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engi ne and accel erate rapi dl y three ti mes, to
approxi matel y 3000 rpm whi l e observi ng cool ant. I f
i nternal engi ne combusti on gases are l eaki ng i nto
cool i ng system, bubbl es wi l l appear i n cool ant. I f bub-
bl es do not appear, i nternal combusti on gas l eakage
i s not present.
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
PROLONGED I DLE
VERY HI GH AMBI ENT TEMPERATURE
SLI GHT TAI L WI ND AT I DLE
SLOW TRAFFI C
TRAFFI C JAMS
HI GH SPEED OR STEEP GRADES
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
TRAILER TOWING:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maxi mum cool i ng package shoul d have been
ordered wi th vehi cl e i f add-on or after market A/C i s
i nstal l ed. I f not, maxi mum cool i ng system compo-
nents shoul d be i nstal l ed for model i nvol ved per
manufacturers speci fi cati ons.
AN COOLING 7 - 7
COOLING (Continued)
RECENT SERVICE OR ACCIDENT REPAIR:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts. I ncorrect water pump or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to COOLING SYSTEM DIAGNOSIS
CHART BELOW.
These charts are to be used as a qui ck-reference
onl y. Refer to COOLI NG SYSTEM DI AGNOSI S
CHART
COOLING SYSTEM DIAGNOSIS CHART
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
On-Board Diagnostics and DTC
information. Replace thermostat if
necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor
connector. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - SCHEMATIC -
ELECTRICAL) Repair connector if
necessary.
3. Is the temperature gauge
operating OK?
3. Check gauge operation. (Refer to
8 - ELECTRICAL/INSTRUMENT
CLUSTER/ENGINE
TEMPERATURE GAUGE -
DESCRIPTION) . Repair as
necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
reserve/overflow tank and the
radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual
text for WARNINGS and
CAUTIONS associated with
removing the radiator cap.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING) for
procedures.
7 - 8 COOLING AN
COOLING (Continued)
TEMPERATURE GAUGE READS
HIGH OR THE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM THE
COOLING SYSTEM
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair. Refer to Possible
Causes (2-20).
2. Is the temperature gauge reading
correctly?
2. Check gauge. (Refer to 8 -
CLUSTER - SCHEMATIC -
ELECTRICAL) . Repair as
necessary.
3. Is the temperature warning
illuminating unnecessarily?
3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL).
4. Coolant low in coolant reserve/
overflow tank and radiator?
4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.
5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator Cap.
Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant level low in radiator but
not in coolant reserve/overflow
tank. This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools
7. (a) Check condition of radiator
cap and cap seals. Refer to
Radiator Cap in this Group. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tanks hoses for blockage.
Repair as necessary.
AN COOLING 7 - 9
COOLING (Continued)
8. Incorrect coolant concentration 8. Check coolant. (Refer to
LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
9. Coolant not flowing through
system
9. Check for coolant flow at radiator
filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine area
of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris.
(Refer to 7 - COOLING -
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Aftermarket A/C installed
without proper radiator.
12. Install proper radiator.
13. Fuel or ignition system
problems.
13. Refer to 14 - Fuel System or 8 -
Electrical for diagnosis and testing
procedures.
14. Dragging brakes. 14. Check and correct as
necessary. (Refer to 5 - BRAKES -
correct procedures.
15. Bug screen or cardboard is
being used, reducing airflow.
15. Remove bug screen or
cardboard.
16. Thermostat partially or
completely shut.
16. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
REMOVAL) .
17. Viscous fan drive not operating
properly.
17. Check fan drive operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - REMOVAL) .
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
19. Heater core leaking. 19. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING -
Repair as necessary.
7 - 10 COOLING AN
COOLING (Continued)
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
2. Check operation of gauge and
repair if necessary. (Refer to 8 -
CLUSTER - DIAGNOSIS AND
TESTING).
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).
5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.
6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.
7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
REMOVAL).
8. Loose accessory drive belt.
(water pump slipping)
8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
AN COOLING 7 - 11
COOLING (Continued)
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.
2. Check coolant concentration.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.
1. (a) Radiator cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
Replace if necessary
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly.
(Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL)
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing.
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
5. A certain amount of fan noise
may be evident on models
equipped with a thermal viscous fan
drive. Some of this noise is normal.
5. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DESCRIPTION) for an explanation
of normal fan noise.
7 - 12 COOLING AN
COOLING (Continued)
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a Diagnostic trouble Code
(DTC) been set?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
3. Obstructions in heater hose/
fittings
3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.
5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - REMOVAL). If a
slipping belt is detected, (Refer to 7
- COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS
AND TESTING). If heater core
obstruction is detected, (Refer to 24
- HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE -
REMOVAL).
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP
AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or
airflow to blow it away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. (Refer to LUBRICATION &
DESCRIPTION). Adjust coolant
mixture as necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
1. A normal condition. No repair is
necessary.
AN COOLING 7 - 13
COOLING (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE DRAINING COOLING
SYSTEM 2. 5L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
DO NOT remove the radi ator cap when drai ni ng
the cool ant from the reserve/overfl ow tank. Open the
radi ator drai ncock and when the tank i s empty,
remove the radi ator cap. The cool ant does not have
to be removed from the tank unl ess the system i s
bei ng refi l l ed wi th a fresh mi xture.
(1) Drai n the cool ant from the radi ator by l oosen-
i ng the drai ncock.
(2) Drai n cool ant from engi ne bl ock by removi ng
drai n pl ug at l eft rear si de of bl ock (Fi g. 8).
STANDARD PROCEDURE REFILLING
COOLING SYSTEM 2. 5L ENGINE
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s).
(2) Fi l l system usi ng a 50/50 mi xture of water and
anti freeze. Fi l l the radi ator to the top and i nstal l the
radi ator cap. Add suffi ci ent cool ant to the reserve/
overfl ow tank to rai se the l evel to the FULL mark.
(3) Operate the engi ne wi th both the radi ator cap
and reserve/overfl ow tank cap i n pl ace. After the
engi ne has reached the normal operati ng tempera-
ture, shut the engi ne off and al l ow i t to cool .
(4) Add cool ant to the reserve/overfl ow tank as
necessary. Only add coolant when the engine is
cold. Coolant level in a warm engine will be
higher due to thermal expansion.
SYSTEM 3. 9L/5. 9L ENGINE
(1) Remove radi ator pressure cap.
(2) Loosen radi ator petcock.
(3) Remove cyl i nder bl ock drai n pl ugs. Refer to
(Fi g. 9).
STANDARD PROCEDURE REFILLING
COOLING SYSTEM 3. 9L/5. 9L ENGINE
Cl ean cool i ng system pri or to refi l l i ng. (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
Fig. 8 Draining Coolant From Block
1 - EXHAUST MANIFOLD
2 - CYLINDER BLOCK COOLANT DRAIN PLUG
Fig. 9 Cylinder Block Drain Plug5.2L/5.9L Engines
1 - BLOCK DRAIN PLUG
7 - 14 COOLING AN
COOLING (Continued)
(1) I nstal l cyl i nder bl ock drai n pl ugs. Coat the
threads wi th Mopar Thread Seal ant wi th Tefl on.
(2) Cl ose radi ator petcock.
(3) Fi l l cool i ng system wi th a 50/50 mi xture of
water and anti freeze.
(4) Fi l l cool ant reserve/overfl ow tank to FULL
mark on i ndi cator sti ck.
(5) Start and operate engi ne unti l thermostat
opens (upper radi ator hose warm to touch).
(6) I f necessary, add a 50/50 water and anti freeze
mi xture to the cool ant reserve/overfl ow tank. Thi s i s
done to mai ntai n cool ant l evel between the FULL
and ADD marks. The l evel i n the reserve/overfl ow
tank may drop bel ow the ADD mark after three or
four warm-up and cool -down cycl es.
SYSTEM 4. 7L ENGINE
BLOCK DRAIN PLUGS (Fig. 10) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 4. 7L ENGINE
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(2) Remove the cool i ng system bl eed pl ug from the
radi ator upper hose i nl et housi ng. (Fi g. 11)Fi l l system
usi ng a 50/50 mi xture of ethyl ene-gl ycol anti freeze
and l ow mi neral content water, unti l cool ant begai ns
comi ng out of the cool i ng system bl eed hol e. I nstal l
the cool i ng system bl eed pl ug. Fi l l radi ator to top and
i nstal l radi ator cap. Add suffi ci ent cool ant to the
reserve/overfl ow tank to rai se l evel to FULL mark.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th radi ator cap i n pl ace.
(4) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
Fig. 10 Drain Plug4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
Fig. 11 Cooling System Bleed Plug4.7L
1 - COOLING SYSTEM BLEED PLUG
AN COOLING 7 - 15
COOLING (Continued)
When engi ne i s cool i ng down, cool ant wi l l be drawn
i nto the radi ator from the reserve/overfl ow tank.
(5) Add cool ant to reserve/overfl ow tank as neces-
sary. Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion.
STANDARD PROCEDURE ADDING
ADDITIONAL COOLANT
heads and water pumps requi res speci al corrosi on
protecti on. Onl y Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (gl ycol base cool ant wi th
corrosi on i nhi bi tors cal l ed HOAT, for Hybri d Organi c
mi xed wi th 50% di sti l l ed water to obtai n a freeze
poi nt of -37C (-35F). I f i t l oses col or or becomes con-
tami nated, drai n, fl ush, and repl ace wi th fresh prop-
erl y mi xed cool ant sol uti on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
STANDARD PROCEDURE COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections. The coolant level can be
checked at coolant recovery bottle (Fig. 12).
The cool ant reserve/overfl ow system provi des a
qui ck method for determi ni ng cool ant l evel wi thout
removi ng radi ator pressure cap. Wi th engi ne not run-
ni ng, open the cool ant recovery bottl e cap and
remove cool ant l evel i ndi cator di psti ck to observe
cool ant l evel i n cool ant recovery bottl e. The cool ant
l evel shoul d be between ADD and FULL marks. I f
the cool ant l evel i s at or bel ow the ADD mark, fi l l
the recovery bottl e wi th a 50/50 mi xture of anti freeze
and water ONE QUART AT A TI ME. Repeat thi s pro-
cedure unti l the cool ant l evel i s at the FULL mark.
STANDARD PROCEDURE COOLING SYSTEM
CLEANING/REVERSE FLUSHING
CLEANING
Drai n cool i ng system and refi l l wi th water. Run
engi ne wi th radi ator cap i nstal l ed unti l upper radi a-
tor hose i s hot. Stop engi ne and drai n water from
system. I f water i s di rty, fi l l system wi th water, run
engi ne and drai n system. Repeat unti l water drai ns
cl ean.
REVERSE FLUSHING
Reverse fl ushi ng of cool i ng system i s the forci ng of
water through the cool i ng system. Thi s i s done usi ng
ai r pressure i n the opposi te di recti on of normal cool -
ant fl ow. I t i s usual l y onl y necessary wi th very di rty
systems wi th evi dence of parti al pl uggi ng.
REVERSE FLUSHING RADIATOR
Di sconnect radi ator hoses from radi ator i nl et and
outl et. Attach a secti on of radi ator hose to radi ator
bottom outl et fi tti ng and i nsert fl ushi ng gun. Con-
nect a water suppl y hose and ai r suppl y hose to
fl ushi ng gun.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result.
Al l ow radi ator to fi l l wi th water. When radi ator i s
fi l l ed, appl y ai r i n short bl asts. Al l ow radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. Have radi ator cl eaned more
extensi vel y by a radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n cool i ng system. Remove thermostat housi ng
and thermostat. I nstal l thermostat housi ng. Di scon-
nect radi ator upper hose from radi ator and attach
fl ushi ng gun to hose. Di sconnect radi ator l ower hose
Fig. 12 Coolant Recovery Bottle Location
1 - RADIATOR
2 - WASHER FLUID RESERVOIR
3 - COOLANT OVERFLOW/RESERVOIR
4 - FAN SHROUD (UPPER)
5 - SCREW
6 - INTERLOCKING PINS
7 - FAN SHROUD (LOWER)
7 - 16 COOLING AN
COOLING (Continued)
from water pump and attach a l ead-away hose to
water pump i nl et fi tti ng.
CAUTION: On vehicles equipped with a heater water
control valve, be sure heater control valve is closed
(heat off). This will prevent coolant flow with scale
and other deposits from entering heater core.
Connect water suppl y hose and ai r suppl y hose to
fl ushi ng gun. Al l ow engi ne to fi l l wi th water. When
engi ne i s fi l l ed, appl y ai r i n short bl asts, al l owi ng
system to fi l l between ai r bl asts. Conti nue unti l cl ean
water fl ows through the l ead away hose.
Remove l ead away hose, fl ushi ng gun, water sup-
pl y hose and ai r suppl y hose. Remove thermostat
housi ng and i nstal l thermostat. I nstal l thermostat
housi ng wi th a repl acement gasket. Refer to Thermo-
stat Repl acement. Connect radi ator hoses. Refi l l cool -
i ng system wi th correct anti freeze/water mi xture.
Refer to Refi l l i ng the Cool i ng System.
CHEMICAL CLEANING
I n some i nstances, use a radi ator cl eaner (Mopar
Radi ator Kl een or equi val ent) before fl ushi ng. Thi s
wi l l soften scal e and other deposi ts and ai d fl ushi ng
operati on.
CAUTION: Follow manufacturers instructions when
using these products.
SPECIFICATIONS
TORQUE
DESCRIPTION Nm Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
BlockBolts 41 30
Automatic Belt Tensioner
PulleyBolt 61 45
Block HeaterBolt 2 17
Generator/Compressor
Mounting BracketBolts
# 1 and 2 54 40
# 3 40 30
Fan Shroud Mounting
Bolts
6 50
Fan Blade to Fan
DriveBolts
23 17
Idler PulleyBolt 54 40
Lbs. Lbs.
Radiator to SupportBolts 23 200
Thermostat HousingBolts
- All Except 4.7L
23 200
Thermostat HousingBolts
- 4.7L
13 112
Transmission Auxiliary Oil
CoolerBolts 10 90
Upper Radiator Closure
PanelBolts 10 90
Water PumpBolts 40 30
SPECIAL TOOLS
COOLING
Pliers Constant Pressure Hose Clamp6094
Cooling System Pressure Tester7700A
3/8 Quick Connect Release Tool6935
AN COOLING 7 - 17
COOLING (Continued)
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS - 2.5L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BELT TENSIONERS - 3.9L/5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DRIVE BELTS - 2.5L
ACCESSORY DRIVE BELT. . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DRIVE BELTS - 3.9L/5.9L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DRIVE BELTS - 4.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL
(1) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove the pul l ey bol t, bushi ng, pul l ey and
spacer (Fi g. 1).
(3) Remove the tensi oner adjustment bol t and ten-
si oner col l ar (Fi g. 1).
INSTALLATION
(1) Posi ti on tensi oner col l ar and i nstal l the ten-
si oner adjustment bol t.
(2) Posi ti on the spacer, i dl er pul l ey, bushi ng and
bol t.
(3) I nstal l the accessory dri ve bel t (Refer to 7 -
I NSTALLATI ON).
BELT TENSIONERS - 3.9L/5.9L
DESCRIPTION
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. I f speci fi ed tensi on i s not mai ntai ned, bel t
sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate, and greatl y
reduced bel t l i fe.
I t i s not necessary to adjust bel t tensi on on the
3.9L or 5.9L engi nes. These engi nes are equi pped
wi th an automati c bel t tensi oner (Fi g. 2). The ten-
si oner mai ntai ns correct bel t tensi on at al l ti mes.
Due to use of thi s bel t tensi oner, do not attempt to
use a bel t tensi on gauge on 3.9L or 5.9L engi nes.
Fig. 1 Accessory Drive Belt Tensioner2.5L Engine
1 - TENSIONER BRACKET
2 - TENSIONER COLLAR
3 - SPACER
4 - BUSHING
5 - BOLT
6 - IDLER PULLEY
7 - TENSIONER ADJUSTMENT BOLT
7 - 18 ACCESSORY DRIVE AN
OPERATION
The automati c bel t tensi oner mai ntai ns bel t ten-
si on by usi ng i nternal spri ng pressure, a pi voti ng
arm and pul l ey to press agai nst the dri ve bel t.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(1) Remove accessory dri ve bel t. (Refer to 7 -
REMOVAL).
(2) Di sconnect wi ri ng and secondary cabl e from
i gni ti on coi l .
(3) Remove i gni ti on coi l from coi l mounti ng
bracket (two bol ts). Do not remove coi l mounti ng
bracket from cyl i nder head.
(4) Remove tensi oner assembl y from mounti ng
bracket (one nut) (Fi g. 3).
(5) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
INSTALLATION
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
Ti ghten bol t to 61 Nm (45 ft. l bs.) torque.
(2) I nstal l tensi oner assembl y to mounti ng
bracket. An i ndexi ng tab i s l ocated on back of ten-
si oner. Al i gn thi s tab to sl ot i n mounti ng bracket.
Ti ghten nut to 67 Nm (50 ft. l bs.) torque.
(3) Connect al l wi ri ng to i gni ti on coi l .
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.
(4) I nstal l coi l to coi l bracket. I f nuts and bol ts are
used to secure coi l to coi l bracket, ti ghten to 11 Nm
(100 i n. l bs.) torque. I f coi l mounti ng bracket has
been tapped for coi l mounti ng bol ts, ti ghten bol ts to 5
Nm (50 i n. l bs.) torque.
(5) I nstal l dri ve bel t. (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(6) Check bel t i ndexi ng marks (Fi g. 3).
DESCRIPTION
sori es. I f speci fi ed tensi on i s not mai ntai ned, bel t
sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate, and greatl y
reduced bel t l i fe.
Fig. 2 Automatic Belt Tensioner5.2L and 5.9L
Engines
1 - AUTOMATIC TENSIONER
2 - COIL AND BRACKET
3 - SCREW AND WASHER
Fig. 3 Tensioner Indexing Marks and Mounting Nut
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
AN ACCESSORY DRIVE 7 - 19
BELT TENSIONERS - 3.9L/5.9L (Continued)
I t i s not necessary to adjust bel t tensi on on the
4.7L engi ne. These engi nes are equi pped wi th an
automati c bel t tensi oner (Fi g. 4). The tensi oner mai n-
tai ns correct bel t tensi on at al l ti mes. Due to use of
thi s bel t tensi oner, do not attempt to use a bel t ten-
si on gauge on 4.7L engi nes.
OPERATION
The automati c bel t tensi oner mai ntai ns bel t ten-
si on by usi ng i nternal spri ng pressure, a pi voti ng
arm and pul l ey to press agai nst the dri ve bel t.
REMOVAL
On 4.7L engines, the tensioner is equipped
with an indexing tang on back of tensioner and
an indexing stop on tensioner housing. If a new
belt is being installed, tang must be within
approximately 24 mm (.94 inches) of indexing
stop. Belt is considered new if it has been used
15 minutes or less.
I f the above speci fi cati on cannot be met, check for:
The wrong bel t bei ng i nstal l ed (i ncorrect l ength/
wi dth)
Worn beari ngs on an engi ne accessory (A/C com-
pressor, power steeri ng pump, water pump, i dl er pul -
l ey or generator)
A pul l ey on an engi ne accessory bei ng l oose
Mi sal i gnment of an engi ne accessory
Bel t i ncorrectl y routed.
NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minmum tension
indicator. Tensioner travel stops at this point.
REMOVAL).
(2) Remove tensi oner assembl y from mounti ng
bracket (Fi g. 5).
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
INSTALLATION
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
(2) An i ndexi ng sl ot i s l ocated on back of tensi oner.
Al i gn thi s sl ot to the head of the bol t on the front
cover. I nstal l the mounti ng bol t. Ti ghten bol t to 41
Nm (30 ft. l bs.).
(3) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
(4) Check bel t i ndexi ng marks (Fi g. 4).
Fig. 4 Automatic Belt Tensioner
1 - AUTOMATIC TENSIONER ASSEMBLY
Fig. 5 Automatic Belt Tensioner4.7L Engine
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 Nm (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
BELT TENSIONERS - 4.7L (Continued)
DRIVE BELTS - 2.5L
DIAGNOSIS AND TESTING ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 6), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 6). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to ACCESSORY DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
NOISE DIAGNOSIS
Noi ses generated by the accessory dri ve bel t are
most noti ceabl e at i dl e. Before repl aci ng a bel t to
resol ve a noi se condi ti on, i nspect al l of the accessory
dri ve pul l eys for al i gnment, gl azi ng, or excessi ve end
pl ay.
ACCESSORY DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (One or more
ribs has separated from belt
body)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove tips 4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of insufficient
tension
1. Inspect/Replace tensioner if
necessary
2. Belt or pulley exposed to substance
that has reduced friction (belt
dressing, oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or
bearing
4. Belt glazed or hardened from heat
and excessive slippage
4. Replace belt.
Fig. 6 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
GROOVE JUMPING
(Belt does not maintain correct
position on pulley)
1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Pulley(s) not within design tolerance 2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct
problem before new belt is
installed)
1. Incorrect belt tension 1. Replace Inspect/Replace
tensioner if necessary
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component and
belt
NOISE
(Objectionable squeal, squeak,
or rumble is heard or felt while
drive belt is in operation)
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced vibration 5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has
cracked or separated from body
of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at
edges of belt or separated from
belt body)
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt
DRIVE BELTS - 2.5L (Continued)
REMOVAL
sori es. There are di fferent types of adjustment
gauges for checki ng ei ther a serpenti ne or a V-type
bel t. Refer to the i nstructi ons suppl i ed wi th the
gauge. Use the correct gauge when checki ng bel t ten-
si on. Pl ace gauge i n the mi ddl e of the secti on of bel t
bei ng tested (between two pul l eys) to check tensi on.
Do not al l ow the gauge (or gauge adapter) to contact
anythi ng but the bel t.
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey assembl y.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Loosen i dl er pul l ey bol t (Fi g. 7).
(3) Loosen tensi on adjusti ng bol t (Fi g. 7) and
remove accessory dri ve bel t.
BELT SCHEMATICS
The bel t routi ng schemati cs are publ i shed from the
l atest i nformati on avai l abl e at the ti me of publ i ca-
ti on. Vehi cl es not equi pped wi th Power Steeri ng have
an i dl er pul l ey i n pl ace of the power steeri ng pump
pul l ey. If anything differs between these sche-
matics and the Belt Routing Label, use the
schematics on Belt Routing Label. Thi s l abel i s
l ocated i n the engi ne compartment.
Refer to (Fi g. 8) or (Fi g. 9) for correct bel t routi ng,
or refer to Bel t Routi ng Label l ocated i n the vehi cl e
engi ne compartment.
Fig. 7 Power Steering Pump Bracket and Idler
Pulley2.5L
1 - ADJUSTMENT BOLT
2 - IDLER BOLT/ANCHOR BOLT
3 - ACCESSORY DRIVE BELT
Fig. 8 2.5L With A/C
1 - GENERATOR PULLEY
2 - AIR CONDITIONER COMPRESSOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 - WATER PUMP AND FAN PULLEY
6 - IDLER PULLEY
7 - CRANKSHAFT PULLEY
Fig. 9 2.5L Engines Without A/C
2 - IDLER PULLEY
5 - IDLER PULLEY
INSTALLATION
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. Refer to (Fig. 10) or
(Fig. 11) for correct belt routing.
(2) I nstal l new bel t. I nstal l bel t tensi on gauge
C-4162 and ti ghten adjustment bol t (Fi g. 7) unti l bel t
tensi on i s wi thi n speci fi cati on range (Refer to 7 -
ADJUSTMENTS).
(3) Ti ghten i dl er pul l ey bol t and re-check bel t ten-
si on. Adjust i f necessary.
ADJUSTMENT ACCESSORY DRIVE BELT
sori es. There are di fferent types of adjustment
gauges for checki ng ei ther a serpenti ne or a V-type
bel t. Refer to the i nstructi ons suppl i ed wi th the
gauge. Use the correct gauge when checki ng bel t ten-
si on. Pl ace gauge i n the mi ddl e of the secti on of bel t
bei ng tested (between two pul l eys) to check tensi on.
Do not al l ow the gauge (or gauge adapter) to contact
anythi ng but the bel t.
Wi th the engi ne off (not runni ng), vi sual l y i nspect
accessory dri ve bel t for gl azi ng, cracks or chunks
mi ssi ng. Al so i nspect pul l eys for mi sal i gnment or
defects. (Refer to 7 - COOLI NG/ACCESSORY
DRI VE/DRI VE BELTS - DI AGNOSI S AND TEST-
I NG) correct bel t di agnosti c procedures.
Fig. 10 2.5L - With A/C
2 - AIR CONDITIONER COMPRESSOR PULLEY
3 - IDLER PULLEY
6 - IDLER PULLEY
Fig. 11 2.5L Engines - Without A/C
2 - IDLER PULLEY
5 - IDLER PULLEY
ACCESSORY DRIVE BELT TENSION CHART
BELT TENSION
**NEW SERPENTINE
BELT
800-900 N (180-200 lbs.)
USED SERPENTINE
BELT
623-712 N (140-160 lbs.)
**Belt is considered new if it has been used 15
minutes or less.
Specifications for use with a belt tension gauge. Refer
to operating instructions supplied with gauge.
(2) I nstal l bel t tensi on gauge C-4162 and compare
readi ng wi th those i n the Accessory Dri ve Bel t Ten-
si on Chart.
I f tensi on i s wi thi n speci fi cati ons and no adjust-
ment i s needed, remove bel t tensi on gauge C-4162
and connect battery negati ve cabl e.
I f bel t tensi on i s out of speci fi cati on and adjustment
i s necessary, conti nue wi th the fol l owi ng procedure.
(3) Loosen i dl er pul l ey bol t (Fi g. 12).
(4) Adjust tensi on adjusti ng bol t (Fi g. 12) unti l
readi ng i s wi thi n speci fi cati on.
(5) Ti ghten i dl er pul l ey bol t and re-check bel t ten-
si on. Adjust i f necessary.
DRIVE BELTS - 3.9L/5.9L
DRIVE BELT
VISUAL DIAGNOSIS
NOISE DIAGNOSIS
pl ay.
Fig. 12 Power Steering Pump Bracket and Idler
Pulley
1 - ADJUSTING BOLT
2 - IDLER PULLEY BOLT
RIB CHUNKING (One or more ribs
has separated from belt body)
1. Foreign objects imbedded in
pulley grooves.
necessary
4. Sharp or jagged pulley groove
tips
4. Replace pulley. Inspect belt.
BELT SLIPS 1. Belt slipping because of
insufficient tension
necessary
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
(seizure)
bearing
4. Belt glazed or hardened from
heat and excessive slippage
4. Replace belt.
groove
1. Replace belt
2. Replace belt
GROOVE JUMPING
position on pulley)
necessary
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
grooves
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
belt installation
2. Replace belt
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
DRIVE BELTS - 3.9L/5.9L (Continued)
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)
necessary
5. Driven component induced
vibration
5. Locate defective driven
FAILURE
circumference of belt has cracked or
separated from body of belt)
stationary object
fabric to age
2. Replace belt
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
necessary
4. Replace belt
REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
Dri ve bel ts on these engi nes are equi pped wi th a
spri ng l oaded automati c bel t tensi oner (Fi g. 14). Thi s
bel t tensi oner wi l l be used on al l bel t confi gurati ons,
such as wi th or wi thout power steeri ng or ai r condi -
ti oni ng. For more i nformati on, (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/BELT TENSI ONERS -
DESCRI PTI ON).
(1) Attach a socket/wrench to pul l ey mounti ng bol t
of automati c tensi oner (Fi g. 14).
(2) Rotate tensi oner assembl y cl ockwi se (as vi ewed
from front) unti l tensi on has been rel i eved from bel t.
(3) Remove bel t from i dl er pul l ey fi rst.
(4) Remove bel t from vehi cl e.
Fig. 14 Belt Tensioner5.2L/5.9L Gas Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be routed correctly. If not, engine may
overheat due to water pump rotating in wrong
direction. Refer to (Fig. 15) (Fig. 16) for correct
engine belt routing. The correct belt with correct
length must be used.
(1) Posi ti on dri ve bel t over al l pul l eys except i dl er
pul l ey. Thi s pul l ey i s l ocated between generator and
A/C compressor.
(2) Attach a socket/wrench to pul l ey mounti ng bol t
of automati c tensi oner (Fi g. 14).
(3) Rotate socket/wrench cl ockwi se. Pl ace bel t over
i dl er pul l ey. Let tensi oner rotate back i nto pl ace.
Remove wrench. Be sure bel t i s properl y seated on
al l pul l eys.
(4) Check bel t i ndexi ng marks (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/BELT TENSI ONERS -
DESCRI PTI ON).
DRIVE BELTS - 4.7L
DRIVE BELT
VISUAL DIAGNOSIS
Fig. 15 Belt Routing5.2L/5.9L Engines with A/C
2 - A/C PULLEY
3 - POWER STEERING PULLEY
5 - WATER PUMP PULLEY
6 - TENSIONER PULLEY
7 - IDLER PULLEY
Fig. 16 Belt Routing5.2L/5.9L Engines Without A/C
2 - IDLER PULLEY
3 - POWER STEERING PULLEY
6 - TENSIONER PULLEY
NOISE DIAGNOSIS
pl ay.
RIB CHUNKING (One or more
ribs has separated from belt
body)
1. Foreign objects imbedded in pulley
grooves.
necessary
4. Sharp or jagged pulley groove tips 4. Replace pulley. Inspect belt.
BELT SLIPS 1. Belt slipping because of insufficient
tension
necessary
2. Belt or pulley exposed to substance
that has reduced friction (belt
dressing, oil, ethylene glycol)
(seizure)
bearing
4. Belt glazed or hardened from heat
and excessive slippage
4. Replace belt.
groove
1. Replace belt
2. Replace belt
GROOVE JUMPING
position on pulley)
necessary
2. Pulley(s) not within design tolerance 2. Replace pulley(s)
grooves
BELT BROKEN
(Note: Identify and correct
problem before new belt is
installed)
belt installation
2. Replace belt
4. Bracket, pulley, or bearing failure 4. Replace defective component and
belt
NOISE
(Objectionable squeal, squeak,
or rumble is heard or felt while
drive belt is in operation)
necessary
5. Driven component induced vibration 5. Locate defective driven
FAILURE
circumference of belt has
cracked or separated from body
of belt)
stationary object
fabric to age
2. Replace belt
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at
edges of belt or separated from
belt body)
necessary
4. Replace belt
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 18).
INSTALLATION
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Check condi ti on of al l pul l eys.
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 18).
(2) I nstal l new bel t (Fi g. 18). Route the bel t
around al l pul l eys except the i dl er pul l ey. Rotate the
tensi oner arm unti l i t contacts i ts stop posi ti on.
Route the bel t around the i dl er and sl owl y l et the
tensi oner rotate i nto the bel t. Make sure the bel t i s
seated onto al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 19). On 4.7L Engi nes onl y, the
gap between the tang and the housi ng stop ( mea-
surement A ) must not exceed 24 mm (.94 i nches). I f
the measurement exceedes thi s speci fi cati on repl ace
the serpenti ne accessory dri ve bel t.
Fig. 18 Belt Routing4.7L
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
Fig. 19 Accessory Drive Belt Wear Indicator4.7L
Engine
1 - AUTOMATIC TENSIONER ASSEMBLY
ENGINE
TABLE OF CONTENTS
page page
COOLANT RECOVERY CONTAINER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE BLOCK HEATER - 3.9L/5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE BLOCK HEATER - 4.7L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE BLOCK HEATER. . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ENGINE COOLANT THERMOSTAT - 2.5L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ENGINE COOLANT THERMOSTAT - 3.9L/5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ENGINE COOLANT THERMOSTAT - 4.7L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FAN DRIVE VISCOUS CLUTCH - 3.9L/4.7L/5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
RADIATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
RADIATOR COOLANT FLOW CHECK. . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
RADIATOR PRESSURE CAP
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
RADIATOR CAP-TO-FILLER NECK SEAL . . . . . 50
RADIATOR CAP - PRESSURE TESTING . . . . . 50
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
RADIATOR FAN MOTOR
ELECTRIC COOLING FAN . . . . . . . . . . . . . . . . 51
RADIATOR FAN RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
WATER PUMP - 2.5L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
WATER PUMP - 3.9L/5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
WATER PUMP - 4.7L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
RADIATOR FAN - ELECTRIC
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
RADIATOR FAN - VISCOUS
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
WATER PUMP INLET TUBE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 - 32 ENGINE AN
COOLANT RECOVERY
CONTAINER
DESCRIPTION
The cool ant recovery contai neri s i ntegral to the
upper fan shroud assembl y and i s made of hi gh tem-
perature pl asti c (Fi g. 1).
OPERATION
The cool ant recovery contai ner works i n conjunc-
ti on wi th the radi ator pressure cap. I t uti l i zes ther-
mal expansi on and contracti on of cool ant to keep
cool ant free of trapped ai r. I t provi des a vol ume for
expansi on and contracti on of cool ant. I t al so provi des
a conveni ent and safe method for checki ng cool ant
l evel and adjusti ng l evel at atmospheri c pressure.
Thi s i s done wi thout removi ng the radi ator pressure
cap. The system al so provi des some reserve cool ant
to the radi ator to cover mi nor l eaks and evaporati on
or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
ENGINE BLOCK HEATER -
3.9L/5.9L
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An opti onal engi ne bl ock heater i s avai l abl e on al l
model s. The heater i s equi pped wi th a power cord.
The heater i s mounted i n a core hol e of the engi ne
cyl i nder bl ock (i n pl ace of a freeze pl ug) wi th the
heati ng el ement i mmersed i n engi ne cool ant. The
cord i s attached to an engi ne compartment compo-
nent wi th ti e-straps.
The 3.9L and 5.9L gas powered engi ne has the
bl ock heater l ocated on the ri ght si de of engi ne next
to the oi l fi l ter (Fi g. 2).
Fig. 1 Upper Fan Shroud with Integral Coolant
Recovery Container
1 - RADIATOR
5 - SCREW
Fig. 2 Engine Block Heater
1 - FREEZE PLUG HOLE
2 - BLOCK HEATER
3 - SCREW
4 - POWER CORD (120V AC)
5 - HEATING COIL
6 - OIL FILTER
AN ENGINE 7 - 33
OPERATION
The heater warms the engi ne cool ant provi di ng
easi er engi ne starti ng and faster warm-up i n l ow
temperatures. Connecti ng the power cord to a
grounded 110-120 vol t AC el ectri cal outl et wi th a
grounded three wi re extensi on cord provi des the el ec-
tri ci ty needed to heat the el ement..
REMOVAL
(2) Drai n cool ant (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(3) Remove power cord from heater by unpl uggi ng
(Fi g. 3).
(4) Loosen (but do not compl etel y remove) the
screw at center of bl ock heater (Fi g. 3).
(5) Remove bl ock heater by careful l y pryi ng from
si de-to-si de. Note di recti on of heati ng el ement coi l
(up or down). El ement coi l must be i nstal l ed correctl y
to prevent damage.
INSTALLATION
(1) Cl ean and i nspect the bl ock heater hol e.
(2) I nstal l new O-ri ng seal (s) to heater i n gasol i ne
engi nes.
(3) I nsert bl ock heater i nto cyl i nder bl ock.
(4) Wi th heater ful l y seated, ti ghten center screw
to 2 Nm (17 i n. l bs.).
(5) Fi l l cool i ng system wi th recommended cool ant.
(Refer to 7 - COOLI NG - STANDARD PROCE-
DURE).
(6) Start and warm the engi ne.
(7) Check bl ock heater for l eaks.
ENGINE BLOCK HEATER - 4.7L
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An opti onal engi ne bl ock heater (Fi g. 4) i s avai l -
abl e wi th al l model s. The heater i s equi pped wi th a
power cord. The cord i s attached to an engi ne com-
partment component wi th ti e-straps. The heater
warms the engi ne provi di ng easi er engi ne starti ng
and faster warm-up i n l ow temperatures. The heater
i s mounted i n a core hol e of the engi ne cyl i nder bl ock
i n pl ace of a freeze pl ug wi th the heati ng el ement
i mmersed i n engi ne cool ant.
Fig. 3 Engine Block Heater
1 - FREEZE PLUG HOLE
2 - BLOCK HEATER
3 - SCREW
4 - POWER CORD (120V AC)
5 - HEATING COIL
6 - OIL FILTER
Fig. 4 Engine Block Heater4.7L
1 - ENGINE BLOCK HEATER
7 - 34 ENGINE AN
ENGINE BLOCK HEATER - 3.9L/5.9L (Continued)
OPERATION
Connecti ng the power cord to a grounded 110-120
vol t AC el ectri cal outl et wi th a grounded, three wi re
extensi on cord acti vates the heati ng el ement warm-
i ng the engi ne cool ant.
DIAGNOSIS AND TESTING ENGINE BLOCK
HEATER
I f the uni t does not operate (Fi g. 5), possi bl e causes
can be ei ther the power cord or the heater el ement.
Test the power cord for conti nui ty wi th a 110-vol t
vol tmeter or 110-vol t test l i ght. Test heater el ement
conti nui ty wi th an ohmmeter or a 12-vol t test l i ght.
CAUTION: To prevent damage, the power cord must
be secured in its retainer clips and away from any
components that may cause abrasion or damage,
such as linkages, exhaust components, etc.
REMOVAL
(2) Drai n cool ant from radi ator (Refer to 7 -
(4) Remove engi ne cyl i nder bl ock drai n pl ug(s)
l ocated on the si des of cyl i nder bl ock above the oi l
pan rai l (Fi g. 6).
(5) Remove power cord from bl ock heater.
(6) Loosen screw at center of bl ock heater. Remove
heater assembl y (Fi g. 7).
INSTALLATION
(1) Thoroughl y cl ean cyl i nder bl ock core hol e and
bl ock heater seat.
Fig. 5 Engine Block Heater 4.7L Engine
Fig. 6 Drain Plug - 4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
Fig. 7 Engine Block Heater - 4.7L
AN ENGINE 7 - 35
ENGINE BLOCK HEATER - 4.7L (Continued)
(2) I nsert bl ock heater assembl y wi th el ement l oop
poi nti ng at twel ve ocl ock (Fi g. 7).
(3) Wi th bl ock heater ful l y seated, ti ghten center
screw to 2 Nm (17 i n. l bs.) torque.
(4) Refi l l cool i ng system (Refer to 7 - COOLI NG -
(5) Start and warm the engi ne. Check for l eaks.
ENGINE COOLANT
TEMPERATURE SENSOR
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
I njector pul se-wi dth
Spark-advance curves
ASD rel ay shut-down ti mes
I dl e Ai r Control (I AC) motor key-on steps
Pul se-wi dth pri me-shot duri ng cranki ng
O2 sensor cl osed l oop ti mes
Purge sol enoi d on/off ti mes
EGR sol enoi d on/off ti mes (i f equi pped)
Leak Detecti on Pump operati on (i f equi pped)
Radi ator fan rel ay on/off ti mes (i f equi pped)
Target i dl e speed
REMOVAL - 3. 9L/5. 2L/5. 9L
The engi ne cool ant temperature sensor i s i nstal l ed
i nto a water jacket at front of i ntake mani fol d near
rear of generator (Fi g. 8).
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Parti al l y drai n cool i ng system (Refer to 7 -
(2) Di sconnect el ectri cal connector from sensor
(Fi g. 8).
(3) Engines with air conditioning: When
removi ng the connector from sensor, do not pul l
di rectl y on wi ri ng harness. Fabri cate an L-shaped
hook tool from a coat hanger (approxi matel y ei ght
i nches l ong). Pl ace the hook part of tool under the
connector for removal . The connector i s snapped onto
the sensor. I t i s not equi pped wi th a l ock type tab.
(4) Remove sensor from i ntake mani fol d.
REMOVAL - 4. 7L
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR.
The ECT sensor i s l ocated near the front of the
i ntake mani fol d (Fi g. 9).
(2) Di sconnect el ectri cal connector from ECT sen-
sor.
Fig. 8 Engine Coolant Temperature Sensor5.2L/
5.9L EnginesTypical
1 - GENERATOR
2 - A/C COMPRESSOR
3 - ENGINE COOLANT TEMPERATURE SENSOR
4 - ELEC. CONN.
7 - 36 ENGINE AN
ENGINE BLOCK HEATER - 4.7L (Continued)
REMOVAL - 2. 5L
ING THE COOLANT TEMPERATURE SENSOR.
(2) Di sconnect el ectri cal connector from sensor
(Fi g. 10).
(3) Remove sensor from thermostat housi ng.
INSTALLATION - 3. 9L/5. 2L/5. 9L
The engi ne cool ant temperature sensor i s i nstal l ed
i nto a water jacket at front of i ntake mani fol d near
rear of generator (Fi g. 8).
(1) I nstal l sensor.
(2) Ti ghten to 11 Nm (8 ft. l bs.) torque.
(3) Use l ong needl enose pl i ers to connect el ectri cal
connector to sensor. The sensor connector i s symmet-
ri cal (not i ndexed). I t can be i nstal l ed to the sensor
i n ei ther di recti on.
(4) Repl ace any l ost engi ne cool ant (Refer to 7 -
INSTALLATION - 4. 7L
(3) Connect el ectri cal connector to sensor.
ENGINE COOLANT
THERMOSTAT - 2.5L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat (Fi g. 11) on al l gas powered
engi nes i s l ocated beneath the thermostat housi ng at
the front of the i ntake mani fol d.
The thermostat i s a wax pel l et dri ven, reverse pop-
pet choke type.
Fig. 9 Engine Coolant Temperature Sensor4.7L
V8 Engine
1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
3 - MAP SENSOR
4 - INTAKE MANIFOLD
Engines
3 - ELECTRICAL CONNECTOR
AN ENGINE 7 - 37
ENGINE COOLANT TEMPERATURE SENSOR (Continued)
Cool ant l eakage i nto the pel l et contai ner wi l l cause
the thermostat to fai l i n the open posi ti on. Thermo-
stats very rarel y sti ck. Do not attempt to free a ther-
mostat wi th a pryi ng devi ce.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes l onger engi ne
warmup ti me, unrel i abl e warmup performance,
i ncreased exhaust emi ssi ons and crankcase condensa-
ti on that can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
DIAGNOSIS AND TESTING THERMOSTAT
ON-BOARD DIAGNOSTICS
Al l gasoline powered models are equi pped wi th
On-Board Di agnosti cs for certai n cool i ng system com-
ponents. Refer to On-Board Di agnosti cs (OBD) i n the
Di agnosi s secti on of thi s group for addi ti onal i nfor-
mati on. I f the powertrai n control modul e (PCM)
detects l ow engi ne cool ant temperature, i t wi l l record
a Di agnosti c Troubl e Code (DTC) i n the PCM mem-
ory. Do not change a thermostat for l ack of heat as
i ndi cated by the i nstrument panel gauge or by poor
heater performance unl ess a DTC i s present. Refer to
the Di agnosi s secti on of thi s group for other probabl e
causes. For other DTC numbers, (Refer to 25 - EMI S-
SI ONS CONTROL - DESCRI PTI ON).
The DTC can al so be accessed through the DRB
scan tool . Refer to the appropri ate Powertrai n Di ag-
nosti c Procedures i nformati on for di agnosti c i nforma-
ti on and operati on of the DRB scan tool .
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on i s
cl ean, drai n the cool ant i nto a cl ean contai ner for reuse.
(2) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng (Refer to 7 -
(3) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(4) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(5) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 12).
Di scard ol d gasket.
(6) Cl ean the gasket mati ng surfaces.
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(a) Observe the recess groove i n the engi ne cyl -
i nder head (Fi g. 13).
(b) Posi ti on thermostat i nto thi s groove wi th
arrow and ai r bl eed hol e on outer fl ange poi nti ng up.
(2) I nstal l repl acement gasket and thermostat
housi ng.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.
(3) Ti ghten the housi ng bol ts to 20 Nm (15 ft. l bs.)
torque.
(4) I nstal l hoses to thermostat housi ng.
(5) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
(6) Connect battery negati ve cabl e.
Fig. 11 ThermostatTypical
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
5 - SHORT BOLT
7 - 38 ENGINE AN
ENGINE COOLANT THERMOSTAT - 2.5L (Continued)
(7) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture (Refer to 7 -
ENGINE COOLANT
THERMOSTAT - 3.9L/5.9L
DESCRIPTION
The thermostat on the 3.9L and 5.9L gas powered
engi nes i s l ocated beneath the thermostat housi ng at
the front of the i ntake mani fol d (Fi g. 14).
The thermostat i s a wax pel l et dri ven, reverse pop-
pet choke type.
Cool ant l eakage i nto the pel l et contai ner wi l l cause
the thermostat to fai l i n the open posi ti on. Thermo-
stats very rarel y sti ck. Do not attempt to free a ther-
mostat wi th a pryi ng devi ce.
Operati ng wi thout a thermostat causes l onger engi ne
warmup ti me, unrel i abl e warmup performance,
i ncreased exhaust emi ssi ons and crankcase condensa-
ti on that can resul t i n sl udge formati on.
Fig. 12 2.5LThermostat Removal/Installation
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
5 - SHORT BOLT
Fig. 13 Thermostat Recess
1 - GROOVE
Fig. 14 Thermostat5.2L and 5.9L Gas Powered
Engines
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
AN ENGINE 7 - 39
OPERATION
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
I f thermostat i s bei ng repl aced, be sure that
repl acement i s speci fi ed thermostat for vehi cl e model
and engi ne type.
Factory i nstal l ed thermostat housi ngs on 3.9L and
5.9L engi nes are i nstal l ed on a gasket wi th an anti -
sti ck coati ng. Thi s wi l l ai d i n gasket removal and
cl ean-up.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n cool i ng system unti l cool ant l evel i s
bel ow thermostat (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(3) Ai r Condi ti oned vehi cl es: Remove support
bracket (generator mounti ng bracket-to-i ntake mani -
fol d) l ocated near rear of generator (Fi g. 15).
NOTE: On air conditioning equipped vehicles, the
generator must be partially removed.
REMOVAL) (Fi g. 16).
(5) Remove two generator mounti ng bol ts. Do not
remove any wi ri ng at generator. I f equi pped wi th
4WD, unpl ug 4WD i ndi cator l amp wi ri ng harness
(l ocated near rear of generator).
(6) Remove generator. Posi ti on generator to gai n
access for thermostat gasket removal .
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
tongue of constant tension clamps (Fig. 17). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(7) Remove radi ator upper hose cl amp and upper
hose at thermostat housi ng.
(8) Posi ti on wi ri ng harness (behi nd thermostat
housi ng) to gai n access to thermostat housi ng.
thermostat housi ng, gasket and thermostat (Fi g. 18).
Di scard ol d gasket.
INSTALLATION
(1) Cl ean mati ng areas of i ntake mani fol d and
Fig. 15 Generator Support Bracket3.9L and 5.9L
Engine
1 - IDLER PULLEY BUSHING
2 - A/C AND/OR GENERATOR MOUNTING BRACKET
3 - IDLER PULLEY
7 - 40 ENGINE AN
ENGINE COOLANT THERMOSTAT - 3.9L/5.9L (Continued)
(2) I nstal l thermostat (spri ng si de down) i nto
recessed machi ned groove on i ntake mani fol d (Fi g.
18).
(3) I nstal l gasket on i ntake mani fol d and over
thermostat (Fi g. 18).
(4) Posi ti on thermostat housi ng to i ntake mani fol d.
Note the word FRONT stamped on housi ng (Fi g. 19).
For adequate cl earance, thi s must be pl aced towards
front of vehi cl e. The housi ng i s sl i ghtl y angl ed for-
ward after i nstal l ati on to i ntake mani fol d.
(5) I nstal l two housi ng-to-i ntake mani fol d bol ts.
Ti ghten bol ts to 23 Nm (200 i n. l bs.) torque.
(6) I nstal l radi ator upper hose to thermostat hous-
i ng.
drive belt, the belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 20) for correct 3.9L
and 5.9L engine belt routing. The correct belt with
correct length must be used.
(7) Ai r Condi ti oned vehi cl es; I nstal l generator.
Ti ghten bol ts to 41 Nm (30 ft. l bs.).
(8) I nstal l support bracket (generator mounti ng
bracket-to-i ntake mani fol d) (Fi g. 15). Ti ghten bol ts to
54 Nm (40 ft. l bs.) torque.
(9) I nstal l accessory dri ve bel t (Fi g. 16)(Refer to 7 -
I NSTALLATI ON).
(10) Fi l l cool i ng system (Refer to 7 - COOLI NG -
Fig. 16 Automatic Belt Tensioner3.9L and 5.9L
Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
Fig. 17 SPRING CLAMP SIZE LOCATION
1 - SPRING CLAMP SIZE LOCATION
Fig. 18 Thermostat3.9L and 5.9L Engines
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
AN ENGINE 7 - 41
ENGINE COOLANT
THERMOSTAT - 4.7L
DESCRIPTION
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control . On the 4.7L engi ne the thermo-
stat i s desi gned to bl ock the fl ow of the cool ant
bypass journal by 50% i nstead of compl etel y bl ocki ng
the fl ow. Thi s desi gn control s cool ant temperature
more accuratel y (Fi g. 21) .
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
OPERATION
Fig. 19 Thermostat Position5.2L and 5.9L Engines
Fig. 20 Belt Routing5.2L and 5.9L Engines
1 - IDLER PULLEY
4 - IF W/OUT A/C
7 - 42 ENGINE AN
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
I f thermostat i s bei ng repl aced, be sure that
repl acement i s speci fi ed thermostat for vehi cl e model
and engi ne type.
(2) Drai n cool i ng system (Refer to 7 - COOLI NG -
(4) Remove spl ash shi el d.
(5) Remove l ower radi ator hose cl amp and l ower
radi ator hose at thermostat housi ng.
thermostat housi ng and thermostat (Fi g. 22).
INSTALLATION
(1) Cl ean mati ng areas of ti mi ng chai n cover and
(2) I nstal l thermostat (spri ng si de down) i nto
recessed machi ned groove on ti mi ng chai n cover (Fi g.
22).
(3) Posi ti on thermostat housi ng on ti mi ng chai n
cover.
(4) I nstal l two housi ng-to-ti mi ng chai n cover bol ts.
Ti ghten bol ts to 13 Nm (112 i n. l bs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
(5) I nstal l l ower radi ator hose on thermostat hous-
i ng.
(6) I nstal l spl ash shi el d.
(9) Connect negati ve battery cabl e to battery.
Fig. 21 Thermostat Cross Section View 4.7L
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
AN ENGINE 7 - 43
FAN DRIVE VISCOUS CLUTCH
- 3.9L/4.7L/5.9L
DESCRIPTION
CAUTION: Engines equipped with accessory drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
The thermal vi scous fan dri ve (Fi g. 23) and (Fi g.
24) i s a si l i cone-fl ui d-fi l l ed coupl i ng used to connect
the fan bl ades to the water pump shaft. The coupl i ng
al l ows the fan to be dri ven i n a normal manner. Thi s
i s done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
On al l engi nes an el ectri cal cool i ng fan l ocated i n
the fan shroud ai ds i n l ow speed cool i ng, I t i s
desi gned to augment the vi scous fan, However, i t
does not repl ace the vi scous fan.
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t. Thi s
spri ng coi l reacts to the temperature of the radi ator
di scharge ai r. I t engages the vi scous fan dri ve for
hi gher fan speed i f the ai r temperature from the
radi ator ri ses above a certai n poi nt. Unti l addi ti onal
engi ne cool i ng i s necessary, the fan wi l l remai n at a
reduced rpm regardl ess of engi ne speed.
Fig. 22 Thermostat and Thermostat Housing 4.7L
2 - THERMOSTAT LOCATION
3 - THERMOSTAT AND GASKET
Fig. 23 Fan Blade/Viscous Fan Drive
1 - VISCOUS FAN DRIVE
2 - FAN BLADE
7 - 44 ENGINE AN
OPERATION
When suffi ci ent heat i s present, the vi scous fan
dri ve wi l l engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
DIAGNOSIS AND TESTING VISCOUS FAN
DRIVE
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18 to
105C (0 to 220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88 C (190 F).
Fan dri ve engagement shoul d have started to occur
at between 74 to 82 C (165 to 180 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 88 C (190
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57 to
79 C (135 to 175 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
REMOVAL
(2) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to water pump hub shaft
(Fi g. 26). Remove fan bl ade/vi scous fan dri ve assem-
bl y from water pump by turni ng mounti ng nut coun-
tercl ockwi se as vi ewed from front. Threads on
vi scous fan dri ve are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On
Cummi ns Di esel Tool Set number 2017DSP) and Spe-
ci al Tool 6958 Spanner Wrench wi th Adapter Pi ns
8346 can be used to hol d the pul l ey sti l l . (Fi g. 25) to
prevent pul l ey from rotati ng.
Fig. 24 Viscous Fan DriveTypical
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
AN ENGINE 7 - 45
FAN DRIVE VISCOUS CLUTCH - 3.9L/4.7L/5.9L (Continued)
(3) Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
(4) Do not unbol t fan bl ade assembl y (Fi g. 27)from
vi scous fan dri ve at thi s ti me.
(5) Remove upper fan shroud attachi ng hardware
(Fi g. 28).
(6) Remove upper fan shroud and fan bl ade/vi scous
fan dri ve from vehi cl e.
(7) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace vi scous fan dri ve i n hori zon-
tal posi ti on. I f stored hori zontal l y, si l i cone fl ui d i n
the vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
(8) Remove four bol ts securi ng fan bl ade assembl y
to vi scous fan dri ve (Fi g. 27).
Fig. 25 Fan Blade and Viscous Fan Drive Removal
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 - FAN
Fig. 26 Fan Blade/Viscous Fan Drive
1 - FAN AND VISCOUS DRIVE
2 - WATER PUMP THREADED SHAFT
Fig. 27 Viscous Fan Drive and Fan Blade
2 - FAN BLADE
Fig. 28 Upper Fan Shroud Removal/Installation
1 - RADIATOR
2 - ELECTRIC COOLING FAN
3 - UPPER SHROUD AND OVERFLOW BOTTLE
4 - SCREW
5 - LOWER SHROUD
7 - 46 ENGINE AN
INSTALLATION
(1) I nstal l fan bl ade assembl y to vi scous fan dri ve.
Ti ghten bol ts (Fi g. 27) to 23 Nm (17 ft. l bs.) torque.
(2) Posi ti on fan bl ade/vi scous fan dri ve assembl y
and upper shroud i nto vehi cl e.
(3) I nstal l fan shroud retai ni ng screws (Fi g. 29).
(4) I nstal l fan bl ade/vi scous fan dri ve assembl y to
water pump shaft (Fi g. 26).
RADIATOR
DESCRIPTION
The radi ator (Fi g. 30) i s a al umi num cross-fl ow
desi gn wi th hori zontal tubes through the radi ator
core and verti cal pl asti c si de tanks.
OPERATION
The radi ator suppl i es suffi ci ent heat transfer usi ng
the cool i ng fi ns i nterl aced between the hori zontal
tubes i n the radai tor core to cool the engi ne and
automati c transmi ssi on oi l (i f equi pped).
DIAGNOSIS AND TESTING RADIATOR
COOLANT FLOW CHECK
Use the fol l owi ng procedure to determi ne i f cool ant
i s fl owi ng through cool i ng system.
(1) I dl e engi ne unti l operati ng temperature i s
reached. I f upper radi ator hose i s warm to the touch,
thermostat i s openi ng and cool ant i s fl owi ng to radi -
ator.
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER RADIATOR PRESSURE CAP, OPEN RADIA-
TOR CAP SLOWLY TO FIRST STOP. ALLOW ANY
BUILT-UP PRESSURE TO VENT TO THE RESERVE/
OVERFLOW TANK. AFTER PRESSURE BUILD-UP
HAS BEEN RELEASED, REMOVE CAP FROM
FILLER NECK.
(2) Drai n a smal l amount of cool ant from radi ator
unti l ends of radi ator tubes are vi si bl e through fi l l er
neck. I dl e engi ne at normal operati ng temperature. I f
cool ant i s fl owi ng past exposed tubes, cool ant i s ci r-
cul ati ng.
REMOVAL
Fig. 29 Upper Fan Shroud Removal/Installation
1 - RADIATOR
4 - SCREW
5 - LOWER SHROUD
Fig. 30 RadiatorTypical
1 - RADIATOR
2 - A/C CONDENSER (IF EQUIPPED)
3 - TRANSMISSION AUXILIARY OIL COOLER
AN ENGINE 7 - 47
(2) Drai n cool i ng system. (Refer to 7 - COOLI NG -
6094) (Fig. 31). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
(3) Remove hose cl amps (Fi g. 31) and hoses from
radi ator. Di sconnect cool ant reserve/overfl ow tank
hose and washer bottl e el ectri cal connector and hose.
(4) Remove upper fan shroud mounti ng screws Li ft
upper fan shroud assembl y up and out of engi ne com-
partment (Fi g. 33).
(5) Di sconnect transmi ssi on oi l cool er l i nes, (i f
equi pped) (Fi g. 34).
(6) Di sconnect el ectri c cool i ng fan motor connector.
(7) Remove radi ator upper mounti ng screws (Fi g.
35). Li ft radi ator upward and away from vehi cl e. Do
not al l ow cool i ng fi ns of radi ator to contact any other
vehi cl e component. Radi ator fi n damage coul d resul t.
CLEANING
Cl ean radi ator fi ns Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
Fig. 31 Hose Clamp ToolTypical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 32 Clamp Number/Letter Location
1 - CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - HOSE
Fig. 33 Radiator Upper Fan Shroud Removal/
InstallationTypical
1 - RADIATOR
4 - SCREW
5 - LOWER SHROUD
7 - 48 ENGINE AN
RADIATOR (Continued)
INSTALLATION
The radi ator has two i sol ator pi ns on bottom of
both tanks. These fi t i nto al i gnment hol es i n radi ator
l ower support (Fi g. 35).
(1) Posi ti on i sol ator pi ns i nto al i gnment hol es i n
radi ator l ower support.
(2) I nstal l and ti ghten radi ator mounti ng bol ts to
23 Nm (200 i n. l bs.) (Fi g. 35).
(3) I nstal l the transmi ssi on oi l cool er l i nes, (i f
equi pped).
(4) Connect fan motor el ectri cal connector to har-
ness connector.
(5) Posi ti on upper fan shroud onto l ower fan
shroud and radi ator.
(6) I nstal l retai ni ng screws i nto shroud.
(7) I nstal l radi ator hoses. reconnect cool ant
reserve/overfl ow tank hose.
(9) Fi l l cool i ng system. (Refer to 7 - COOLI NG -
RADIATOR PRESSURE CAP
DESCRIPTION
Al l cool i ng systems are equi pped wi th a pressure
cap (Fi g. 36) i n the radi ator upper hose. Thi s cap
rel eases pressure at some poi nt wi thi n a range of
131-to-158 kPa (19-to-23 psi ). The pressure rel i ef
poi nt (i n pounds) i s engraved on top of the cap
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve. Thi s val ve opens when
system pressure reaches the rel ease range of 131-to-
158 kPa (19-to-23 psi ).
A rubber gasket seal s the radi ator fi l l er neck. Thi s
i s done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
OPERATION
A vent val ve i n the center of the cap wi l l remai n
shut as l ong as the cool i ng system i s pressuri zed. As
the cool ant cool s, i t contracts and creates a vacuum
i n cool i ng system. Thi s causes the vacuum val ve to
open and cool ant i n reserve/overfl ow tank to be
drawn through connecti ng hose i nto radi ator. I f the
vacuum val ve i s stuck shut, or overfl ow hose i s
ki nked, radi ator hoses wi l l col l apse on cool -down.
Fig. 34 Transmission Oil Cooler LinesAutomatic
Transmission Only
1 - TRANSMISSION COOLER SUPPLY LINE
2 - TRANSMISSION OIL COOLER RETURN LINE
Fig. 35 Radiator Removal/InstallationTypical
1 - CORE SUPPORT
2 - LOWER ISOLATOR MOUNTS
3 - ISOLATOR PINS
4 - RADIATOR ASSEMBLY
5 - SCREWS
AN ENGINE 7 - 49
RADIATOR (Continued)
DIAGNOSIS AND TESTING RADIATOR
CAP-TO-FILLER NECK SEAL
The pressure cap upper gasket (seal ) pressure
rel i ef can be tested by removi ng overfl ow hose from
radi ator fi l l er neck ni ppl e. Attach hose of pressure
tester tool 7700 (or equi val ent) to ni ppl e. I t wi l l be
necessary to di sconnect hose from i ts adapter for
fi l l er neck. Pump ai r i nto radi ator. The pressure cap
upper gasket shoul d rel i eve at 131 kPa (21 psi ) and
hol d pressure at a mi ni mum of 130 kPa (18.8 psi ).
WARNING: THE WARNING WORDS DO NOT
OPEN HOT ON RADIATOR PRESSURE CAP, ARE
A SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, RADIATOR CAP SHOULD
NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR
UNDER PRESSURE.
Do not remove radi ator cap at any ti me except for
the fol l owi ng purposes:
(1) Check and adjust anti freeze freeze poi nt.
(2) Refi l l system wi th new anti freeze.
(3) Conducti ng servi ce procedures.
(4) Checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER CAP AND WITH-
OUT PUSHING CAP DOWN, ROTATE IT COUNTER-
CLOCKWISE TO FIRST STOP. ALLOW FLUID TO
ESCAPE THROUGH THE COOLANT RESERVE/
OVERFLOW HOSE INTO RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
DIAGNOSIS AND TESTING RADIATOR CAP -
PRESSURE TESTING
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l cap on pressure tester 7700 or an equi v-
al ent (Fi g. 37).
Fig. 36 Radiator Pressure CapTypical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
Fig. 37 Pressure Testing Radiator CapTypical
1 - PRESSURE CAP
7 - 50 ENGINE AN
RADIATOR PRESSURE CAP (Continued)
Operate tester pump to bri ng pressure to 138 kPa
(20 psi ) on gauge. I f pressure cap fai l s to hol d pres-
sure of at l east 131 kPa (19 psi ) repl ace cap. Refer to
fol l owi ng CAUTION.
The pressure cap may test properl y whi l e posi -
ti oned on tool 7700 (or equi val ent). I t may not hol d
pressure or vacuum when i nstal l ed on radi ator. I f so,
i nspect radi ator fi l l er neck and caps top gasket for
damage. Al so i nspect for di rt or di storti on that may
prevent cap from seal i ng properl y.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Use onl y a mi l d soap and water to cl ean the radi -
ator cap. Usi ng any type sol vent may cause damage
to the seal i n the radi ator cap.
INSPECTION
Hol d cap at eye l evel , ri ght si de up. The vent val ve
(Fi g. 29) at bottom of cap shoul d open. I f rubber gas-
ket has swol l en and prevents vent val ve from open-
i ng, repl ace cap.
Hol d cap at eye l evel , upsi de down. I f any l i ght can
be seen between vent val ve and rubber gasket,
repl ace cap. Do not use a replacement cap that
has a spring to hold vent shut. A repl acement cap
must be the type desi gned for a cool ant reserve/over-
fl ow system wi th a compl etel y seal ed di aphragm
spri ng and a rubber gasket. Thi s gasket i s used to
seal to radi ator fi l l er neck top surface. Use of proper
cap wi l l al l ow cool ant return to radi ator.
RADIATOR FAN MOTOR
DIAGNOSIS AND TESTING ELECTRIC
COOLING FAN
The powertrai n control modul e (PCM) wi l l set a
di agnosti c troubl e code (DTC) i n memory i f i t detects
a probl em i n the el ectri c cool i ng fan (Fi g. 38), rel ay
or ci rcui t. Refer to On-Board Di agnosti cs i n 25 -
EMI SSI ONS CONTROL for more i nformati on on
accessi ng a DTC.
nosti c i nformati on for di agnosti c i nformati on and
operati on of the DRB scan tool .
RADIATOR FAN MOTOR INOPERATIVE
Equipment Required:
DRB Scan Tool
Vol t/Ohm meter
Wi ri ng Di agrams
Test Procedure:
(1) I nspect 10A fuse i n juncti on bl ock and 40A
maxi fuse i n PDC (Fi g. 39).
(2) Remove Cool i ng Fan Rel ay from the PDC and
make the fol l owi ng checks at the rel ay connector:
Appl y 12 vol ts (usi ng a fused 14-gauge wi re) to
ci rcui t C25 (rel ay termi nal 87). I f fan does not come
on, check for open i n ci rcui t C25 or Z1. I f ci rcui ts are
o.k., repl ace the cool i ng fan motor.
Wi th the i gni ti on key off check for battery vol t-
age at ci rcui t C28 (rel ay termi nal 30). I f no battery
vol tage present check for open/shorted ci rcui t C28
between the PDC and rel ay.
Wi th the i gni ti on key i n the run posi ti on check
for battery vol tage at ci rcui t F18 (rel ay termi nal 86).
I f no battery vol tage present, check for open/short i n
ci rcui t F18 between the juncti on bl ock and the rel ay.
Fig. 38 Electrical Cooling Fan
1 - RADIATOR
2 - ELECTRIC FAN ASSEMBLY
4 - SCREW
AN ENGINE 7 - 51
RADIATOR PRESSURE CAP (Continued)
I f no probl ems are detected, i nstal l the DRB
(refer to the appropri ate Powertrai n Di agnosti c Pro-
cedures manual for DRB scan tool operati ng i nstruc-
ti ons) and start the engi ne. Cl i p a 12V test l i ght to
the battery posi ti ve termi nal and probe ci rcui t C27
(rel ay termi nal 85). When the engi ne temperature
reaches 110 C (230 F), or A/C i s requested, the test
l i ght shoul d l i ght. I f not, check ci rcui t C27 for open.
I f no probl ems are detected at thi s poi nt, repl ace
the cool i ng fan rel ay.
RADIATOR FAN RELAY
DESCRIPTION
The radi ator cool i ng fan rel ay i s a 5pi n, sol enoi d
type, mi ni -rel ay. I t i s l ocated i n the Power Di stri bu-
ti on Center (PDC). Refer to l abel on PDC cover for
rel ay l ocati on.
OPERATION
The el ectri c radi ator cool i ng fan i s control l ed by
the Powertrai n Control Modul e (PCM) through the
radi ator cool i ng fan rel ay. The PCM wi l l acti vate the
rel ay after recei vi ng i nputs from the engi ne cool ant
temperature sensor and/or an ai r condi ti oni ng on/off
si gnal . Not Equipped With A/C: The rel ay i s ener-
gi zed when cool ant temperature i s above approxi -
matel y 103C (217F). I t wi l l then de-energi ze when
cool ant temperature drops to approxi matel y 98C
(208F). Equipped With A/C: I n addi ti on to usi ng
cool ant temperatures to control cool i ng fan operati on,
the cool i ng fan wi l l al so be engaged when the ai r con-
di ti oni ng system has been acti vated. Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG for addi ti onal
i nformati on.
WATER PUMP - 2.5L
DESCRIPTION
CAUTION: All 2.5L 4-cylinder engines are equipped
with a reverse (counterclockwise) rotating water
pump. REVERSE is stamped or imprinted on the
cover of the viscous fan drive and inner side of the
fan. The letter R is stamped into the back of the
water pump impeller. Engines from previous model
years, depending upon application, may have been
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump or vis-
cous fan drive will cause engine over heating.
Thi s al umi num water pump (Fi g. 40) i s the heart
of the cool i ng system. The water pump i s l ocated at
the front of the cyl i nder bl ock, above the ti mi ng
chai n cover
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
Fig. 39 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
Fig. 40 Water Pump
1 - HEATER HOSE FITTING BORE
2 - WATER PUMP
3 - WATER PUMP HUB
7 - 52 ENGINE AN
RADIATOR FAN MOTOR (Continued)
OPERATION
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t on al l engi nes.
REMOVAL
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
CAUTION: All engines have a reverse (counterclock-
wise) rotating water pump. The letter R is stamped
into the back of the water pump impeller (Fig. 41) to
identify. Engines from previous model years,
depending upon application, may be equipped with
a forward (clockwise) rotating water pump. Installa-
tion of the wrong water pump will cause engine
over heating.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
(2) Drai n the cool i ng system (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE).
(3) Loosen (but do not remove at thi s ti me) the
four fan hub-to-water pump pul l ey mounti ng nuts.
REMOVAL).
(5) Remove power steeri ng pump.
6094) (Fig. 42) SNAP-ON CLAMP TOOL (NUMBER
tongue of constant tension clamps (Fig. 43) . If
(6) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(7) Remove four nuts previ ousl y l oosened and
remove the fan bl ade assembl y and pul l ey.
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
(9) Remove the four pump mounti ng bol ts (Fi g. 44)
and remove pump from vehi cl e. Di scard ol d gasket.
Note that one of the four bol ts i s l onger than the
other bol ts.
Fig. 41 Reverse Rotating Water Pump
1 - R STAMPED INTO IMPELLER
Fig. 42 Hose Clamp Tool Typical
2 - HOSE CLAMP
AN ENGINE 7 - 53
WATER PUMP - 2.5L (Continued)
(10) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer to
the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 23 Nm (200 i n. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) Posi ti on water pump pul l ey to water pump
hub.
(6) I nstal l fan and four nuts to water pump hub.
Ti ghten or nuts to 27 Nm (20 ft. l bs.) torque.
(7) I nstal l power steeri ng pump.
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). You may also refer to the Belt
Routing Label in the vehicle engine compartment.
LATI ON).
(10) Connect battery cabl e to battery.
WATER PUMP - 3.9L/5.9L
DESCRIPTION
The water pump i s l ocated on the engi ne front
cover, and has an i ntegral pul l ey attached (Fi g. 45).
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
3 - TYPICAL HOSE
Fig. 44 Water Pump Remove/Install
1 - HEATER HOSE FITTING
2 - UPPER VENT HOLE
3 - PUMP GASKET
4 - WATER PUMP
5 - LOWER VENT HOLE
6 - LONG BOLT
7 - BOLTS (3) SHORT
7 - 54 ENGINE AN
of a shaft that rotates i n a beari ng pressed i nto the
water pump body. The body has a smal l hol e for ven-
ti l ati on. The water pump seal s are l ubri cated by
anti freeze i n the cool ant mi xture. Addi ti onal l ubri ca-
ti on i s not necessary.
OPERATION
radi ator core, cool i ng system hoses and heater core,
thi s cool ant absorbs the heat generated when the
engi ne i s runni ng. The pump i s dri ven by the engi ne
crankshaft vi a a dri ve bel t.
REMOVAL
The water pump can be removed and i nstal l ed
wi thout di schargi ng the ai r condi ti oni ng system (i f
equi pped).
(3) Do not waste reusabl e cool ant. I f sol uti on i s
is necessary, use only an original equipment clamp
with matching number or letter.
(4) Remove upper radi ator hose cl amp and hose at
radi ator.
(5) The thermal vi scous fan dri ve i s attached
(threaded) to the water pump hub shaft (Fi g. 47).
Remove fan/vi scous fan dri ve assembl y from water
pump by turni ng mounti ng nut countercl ockwi se as
vi ewed from front. Threads on vi scous fan dri ve are
RIGHT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummi ns Di esel Tool
Set number 2017DSP) and Speci al Tool 6958 Span-
ner Wrench wi th Adapter Pi ns 8346 can be used.
Pl ace Speci al Tool 6958 Spanner Wrench onto the
water pump pul l ey wi th Adapter Pi ns 8346 i nserted
i nto the hol es on the pul l ey (Fi g. 46)to prevent pul l ey
from rotati ng. Do not attempt to remove fan/vi scous
fan dri ve assembl y from vehi cl e at thi s ti me.
(6) I f water pump i s bei ng repl aced, do not unbol t
fan bl ade assembl y (Fi g. 47) from thermal vi scous
fan dri ve.
(7) Remove fan shroud attachi ng hardware (two
bol ts at bottom-two cl i ps at top).
(8) Remove fan shroud and fan bl ade/vi scous fan
dri ve assembl y from vehi cl e as a compl ete uni t.
Fig. 45 Water Pump
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
4 - WATER PUMP AND PULLEY
Fig. 46 Viscous Fan Drive Removal / Installation
PINS 8346
2 - FAN
AN ENGINE 7 - 55
WATER PUMP - 3.9L/5.9L (Continued)
(10) Remove the accessory dri ve bel t (Refer to 7 -
REMOVAL).
(11) Remove l ower radi ator hose cl amp and remove
l ower hose at water pump.
(12) Remove heater hose cl amp and heater hose
from heater hose cool ant return tube.
(13) Loosen heater hose cool ant return tube
mounti ng bol t (Fi g. 48) and remove tube from water
pump. Di scard the ol d tube O-ri ng.
(14) Remove seven water pump mounti ng bol ts.
(15) Loosen cl amp at water pump end of bypass
hose (Fi g. 47). Sl i p bypass hose from water pump
whi l e removi ng pump from vehi cl e. Di scard ol d gas-
ket.
CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, Water l eaks from shaft seal , Loose or rough
turni ng beari ng or I mpel l er rubbi ng ei ther the pump
body or ti mi ng chai n case/cover.
INSTALLATION
(1) Cl ean gasket mati ng surfaces.
(2) Usi ng a new gasket, i nstal l water pump to
engi ne as fol l ows: Gui de water pump ni ppl e i nto
bypass hose as pump i s bei ng i nstal l ed. I nstal l water
pump bol ts. Ti ghten water pump mounti ng bol ts to
(3) Posi ti on bypass hose cl amp to bypass hose.
(4) Spi n water pump to be sure that pump i mpel -
l er does not rub agai nst ti mi ng chai n case/cover.
(5) I nstal l a new O-ri ng to the heater hose cool ant
return tube (Fi g. 48). Coat the new O-ri ng wi th anti -
freeze before i nstal l ati on.
(6) I nstal l cool ant return tube and i ts mounti ng
bol t to engi ne (Fi g. 48). Be sure the sl ot i n tube
bracket i s bottomed to mounti ng bol t. Thi s wi l l prop-
erl y posi ti on return tube.
(7) Connect radi ator l ower hose to water pump.
(8) Connect heater hose and hose cl amp to cool ant
return tube.
LATI ON).
(10) Posi ti on fan shroud and fan bl ade/vi scous fan
dri ve assembl y to vehi cl e as a compl ete uni t.
(11) I nstal l fan shroud.
water pump shaft.
Fig. 47 Fan Blade and Viscous Fan Drive
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
4 - WATER PUMP AND PULLEY
Fig. 48 Coolant Return TubeTypical
1 - COOLANT RETURN TUBE
2 - WATER PUMP
3 - TUBE MOUNTING BOLT
4 - O-RING
7 - 56 ENGINE AN
(13) Fi l l cool i ng system. (Refer to 7 - COOLI NG -
WATER PUMP - 4.7L
DESCRIPTION WATER PUMP
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t.
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
Both heater hoses are connected to fi tti ngs on the
ti mi ng chai n front cover. The water pump i s al so
mounted di rectl y to the ti mi ng chai n cover and i s
equi pped wi th a non servi ceabl e i ntegral pul l ey (Fi g.
49).
DESCRIPTION WATER PUMP BYPASS
The 4.7L engi ne uses an i nternal water/cool ant
bypass system. The desi gn uses gal l eri es i n the ti m-
i ng chai n cover to ci rcul ate cool ant duri ng engi ne
warm-up preventi ng the cool ant from fl owi ng
through the radi ator. The thermostat uses a stub
shaft l ocated at the rear of the thermostat (Fi g. 50)
to control fl ow through the bypass gal l ery.
OPERATION
radi ator core, cool i ng system hoses and heater core,
thi s cool ant absorbs the heat generated when the
engi ne i s runni ng. The pump i s dri ven by the engi ne
crankshaft vi a a dri ve bel t.
Fig. 49 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
Fig. 50 Water/Coolant Bypass Flow and Thermostat
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
AN ENGINE 7 - 57
OPERATION WATER PUMP BYPASS
When the thermostat i s i n the cl osed posi ti on the
bypass gal l ery i s not obstructed al l owi ng 100% fl ow.
When the thermostat i s i n the open posi ti on the stub
shaft enters the bypass gal l ery obstructi ng bypass
cool ant fl ow by 50%. Thi s desi gn al l ows the cool ant
to reach operati ng temperature qui ckl y when col d,
whi l e addi ng extra cool i ng duri ng normal tempera-
ture operati on.
REMOVAL
The water pump on 4.7L engi nes i s bol ted di rectl y
to the engi ne ti mi ng chai n case cover.
(3) Remove fan/vi scous fan dri ve assembl y from
water pump (Fi g. 51) (Refer to 7 - COOLI NG/EN-
GI NE/FAN DRI VE VI SCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
is necessary, use only an original equipment clamp
with matching number or letter.
(4) I f water pump i s bei ng repl aced, do not unbol t
fan bl ade assembl y from thermal vi scous fan dri ve.
(5) Remove two fan shroud-to-radi ator screws (Fi g.
52). Di sconnect the cool ant overfl ow hose, wi ndshi el d
washer fl ui d hose and washer pump el ectri cal con-
nector.
Fig. 51 Viscous Fan and Fan Drive 4.7L
PINS 8346
2 - FAN
Fig. 52 Upper Fan Shroud, Coolant reservoir and
Washer Fluid Reservoir
1 - RADIATOR
5 - SCREW
7 - 58 ENGINE AN
(6) Remove upper fan shroud and fan bl ade/vi scous
fan dri ve assembl y from vehi cl e.
(8) Remove accessory dri ve bel t (Fi g. 53) (Refer to
7 - COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(9) Remove l ower radi ator hose cl amp and remove
l ower hose at water pump.
(10) Remove seven water pump mounti ng bol ts
and one stud bol t.
CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(11) Remove water pump and gasket. Di scard gas-
ket.
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, Water l eaks from shaft seal , Loose or rough
turni ng beari ng or I mpel l er rubbi ng ei ther the pump
body or ti mi ng chai n case/cover.
INSTALLATION
The water pump on 4.7L engi nes i s bol ted di rectl y
to the engi ne ti mi ng chai n case cover.
(1) Cl ean gasket mati ng surfaces.
(2) Usi ng a new gasket, posi ti on water pump and
i nstal l mounti ng bol ts as shown. (Fi g. 54). Ti ghten
water pump mounti ng bol ts to 54 Nm (40 ft. l bs.)
torque.
(3) Spi n water pump to be sure that pump i mpel -
l er does not rub agai nst ti mi ng chai n case/cover.
(4) Connect radi ator l ower hose to water pump.
(5) Rel ax tensi on from bel t tensi oner (Fi g. 53).
I nstal l dri ve bel t (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - I NSTALLATI ON).
Fig. 53 Automatic Belt Tensioner4.7L
Fig. 54 Water Pump Installation4.7L
1 - WATER PUMP
AN ENGINE 7 - 59
drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 55) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
(6) Posi ti on upper fan shroud and fan bl ade/vi s-
cous fan dri ve assembl y.
(7) Be sure the upper and l ower porti ons of the fan
shroud are fi rml y connected. Al l ai r must fl ow
through the radi ator.
(8) I nstal l two fan shroud-to-radi ator screws (Fi g.
52).
(9) Be sure of at l east 25 mm (1.0 i nches) between
ti ps of fan bl ades and fan shroud.
water pump shaft (Refer to 7 - COOLI NG/ENGI NE/
FAN DRI VE VI SCOUS CLUTCH - I NSTALLATI ON).
(12) Connect negati ve battery cabl e.
RADIATOR FAN - ELECTRIC
DESCRIPTION
The fan (Fi g. 56) i s el ectri cal l y control l ed by the
powertrai n control modul e (PCM) through the fan
control rel ay. Thi s rel ay i s l ocated i n the power di s-
tri buti on center (PDC) (Fi g. 57). For the l ocati on of
the rel ay wi thi n the PDC, refer to l abel on PDC
cover.
Fig. 55 Belt Routing 4.7L
5 - IDLER PULLEY
6 - TENSIONER
Fig. 56 Electric Fan AssemblyTypical
1 - RADIATOR
2 - ELECTRIC FAN ASSEMBLY
7 - 60 ENGINE AN
OPERATION
The PCM regul ates fan operati on based on i nput
from the engi ne cool ant temperature sensor and vehi -
cl e speed.
The fan i s not energi zed duri ng engi ne cranki ng
regardl ess of the el ectri cal i nput from the engi ne
cool ant temperature sensor. However, i f engi ne oper-
ati ng condi ti ons warrant fan engagement, the fan
wi l l run once engi ne starts.
The fan i s energi zed whenever the engi ne i s run-
ni ng and engi ne cool ant or transmi ssi on oi l sump
temperature i s greater than 104 C (220 F) or ai r
condi ti oni ng head pressure i s greater than 32 kpa
(220 psi )..
The fan wi l l turn off when engi ne cool ant or trans-
mi ssi on oi l sump temperature drops bel ow 102 C
(216 F), or ai r condi ti oni ng head pressure drops to
24.6 kpa (170 psi ).
REMOVAL
I f the fan bl ade i s bent, warped, cracked or dam-
aged i n any way, i t must be repl aced only wi th a
repl acement fan bl ade. Do not attempt to repair a
damaged fan blade.
(2) Di sconnect fan motor wi re connector.
(3) Remove the two fan shroud mounti ng cl i ps con-
necti ng the upper part of fan shroud to the radi ator
(Fi g. 58) .
(4) Remove fan assembl y from radi ator.
INSTALLATION
(1) I nstal l fan assembl y onto the radi ator. Ti ghten
bol ts 5 Nm (45 i n. l bs.).
(2) Connect fan motor wi re connector to harness
connector.
(4) Start engi ne and check fan operati on.
RADIATOR FAN - VISCOUS
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(2) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
(3) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
WATER PUMP INLET TUBE
REMOVAL
WITHOUT AIR CONDITIONING
COOLI NG - STANDARD PROCEDURE).Do not
waste reusabl e cool ant. I f sol uti on i s cl ean, drai n
cool ant i nto a cl ean contai ner for reuse.
Fig. 58 Fan ShroudTypical
1 - RADIATOR
4 - SCREW
5 - LOWER SHROUD
AN ENGINE 7 - 61
RADIATOR FAN - ELECTRIC (Continued)
6094) (Fig. 59). SNAP-ON CLAMP TOOL (NUMBER
(2) Loosen both bypass hose cl amps (Fi g. 59) and
posi ti on to center of hose. Remove hose from vehi cl e.
WITH AIR CONDITIONING
I f equi pped wi th A/C, the generator and A/C com-
pressor al ong wi th thei r common mounti ng bracket
(Fi g. 61) must be parti al l y removed. Removi ng gener-
ator or A/C compressor from thei r mounti ng bracket
i s not necessary. Al so, di schargi ng A/C system i s not
necessary. Do not remove any refri gerant l i nes from
A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRESSURE
EVEN WITH ENGINE OFF. REFER TO REFRIGER-
ANT WARNINGS IN GROUP 24, HEATING AND AIR
CONDITIONING.
COOLI NG - STANDARD PROCEDURE).Do not
waste reusabl e cool ant. I f sol uti on i s cl ean, drai n
cool ant i nto a cl ean contai ner for reuse.
(3) Remove upper radi ator hose cl amp (Fi g. 59)and
hose at radi ator.
(4) Unpl ug wi ri ng harness from A/C compressor.
(5) Remove ai r cl eaner assembl y.
REMOVAL).
(7) The dri ve bel t i dl er pul l ey must be removed to
gai n access to one of A/C compressor/generator
bracket mounti ng bol ts. Remove i dl er pul l ey bol t and
remove i dl er pul l ey (Fi g. 61).
(8) Remove oi l di psti ck tube mounti ng bol t at si de
of A/C-generator mounti ng bracket.
(9) Di sconnect throttl e body cabl es.
Fig. 59 Hose Clamp ToolTypical
2 - HOSE CLAMP
1 - CONSTANT TENSION HOSE CLAMP
3 - HOSE
Fig. 61 GeneratorA/C Compressor Mounting
Bracket
1 - IDLER PULLEY BUSHING
2 - A/C AND/OR GENERATOR MOUNTING BRACKET
3 - IDLER PULLEY
7 - 62 ENGINE AN
WATER PUMP INLET TUBE (Continued)
(10) Remove heater hose cl amp and heater hose
from heater hose cool ant return tube.
(11) Remove heater hose cool ant return tube
mounti ng bol t (Fi g. 62) and remove tube from engi ne.
Di scard the ol d tube O-ri ng.
(12) Remove bracket-to-i ntake mani fol d bol ts (Fi g.
61).
(13) Remove si x bracket bol ts (Fi g. 61).
(14) Li ft and posi ti on generator and A/C compres-
sor (al ong wi th thei r common mounti ng bracket) to
gai n access to bypass hose. A bl ock of wood may be
used to hol d assembl y i n posi ti on.
(15) Loosen and posi ti on both hose cl amps to cen-
ter of bypass hose. Remove hose from vehi cl e.
INSTALLATION
WITHOUT AIR CONDITIONING
(1) Posi ti on bypass hose cl amps (Fi g. 59) to center
of hose.
(2) I nstal l bypass hose to engi ne.
(3) Secure both hose cl amps (Fi g. 59).
WITH AIR CONDITIONING
(1) Posi ti on bypass hose cl amps to center of hose.
(2) I nstal l bypass hose to engi ne.
(3) Secure both hose cl amps (Fi g. 59).
(4) I nstal l generator-A/C mounti ng bracket assem-
bl y to engi ne. Ti ghten bol ts (number 1 and 2 (Fi g.
61) to 54 Nm (40 ft. l bs.) torque. Ti ghten bol ts (num-
ber 3 (Fi g. 61)to 40 Nm (30 ft. l bs.) torque.
(5) I nstal l a new O-ri ng to the heater hose cool ant
return tube (Fi g. 62). Coat the new O-ri ng wi th anti -
freeze before i nstal l ati on.
(6) I nstal l cool ant return tube and i ts mounti ng
bol t to engi ne (Fi g. 62).
(7) Connect throttl e body control cabl es.
(8) I nstal l oi l di psti ck mounti ng bol t.
(9) I nstal l i dl er pul l ey. Ti ghten bol t to 54 Nm (40
ft. l bs.) torque.
(10) I nstal l dri ve bel t (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(11) I nstal l ai r cl eaner assembl y.
(12) I nstal l upper radi ator hose to radi ator.
(13) Connect wi ri ng harness to A/C compressor.
Fig. 62 Coolant Return Tube
1 - COOLANT RETURN TUBE
2 - WATER PUMP
3 - TUBE MOUNTING BOLT
4 - O-RING
AN ENGINE 7 - 63
WATER PUMP INLET TUBE (Continued)
TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FLUSHING COOLERS AND TUBES . . . . . . . . . 64
TRANS COOLER
DESCRIPTION
CAUTION: On in-radiator type oil coolers, if trans-
mission oil cooler is leaking, engine coolant may
enter cooler, or transmission oil may enter engine
cooling system. Both engine cooling system and
transmission oil circuit should be drained, flushed,
and inspected.
There are two types of transmi ssi on oi l cool ers
used. One type of cool er i s the i n-radi ator type or oi l
to cool ant type (Fi g. 1). Thi s type oi l cool er i s not ser-
vi ceabl e. The second type used i s a remote type aux-
i l i ary oi l cool er or oi l to ai r cool er (Fi g. 2). The oi l to
ai r type cool er i s l ocated i n front of the radi ator, and
i s servi ceabl e.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906-B Cool er Fl usher.
WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.11968.
WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
Fig. 1 Oil Flow to Cooler - Top View (Typical)
1 - TRANSMISSION OIL COOLER
2 - AUTOMATIC TRANSMISSION
3 - RETURN LINE
4 - PRESSURE LINE
Fig. 2 Auxiliary Transmission Oil Cooler - Typical
1 - RADIATOR
2 - A/C CONDENSER (IF EQUIPPED)
3 - TRANSMISSION AUXILIARY OIL COOLER
7 - 64 TRANSMISSION AN
(1) Remove cover pl ate fi l l er pl ug on Tool 6906-B.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906-B.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF +4, type 9602, Automati c
Transmi ssi on Fl ui d.
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
AN TRANSMISSION 7 - 65
TRANS COOLER (Continued)
AUDIO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AUDIO SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AMPLIFIER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTENNA BODY & CABLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANTENNA BODY AND CABLE . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RADIO
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RADIO NOISE SUPPRESSION GROUND STRAP
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RADIO NOISE SUPPRESSION GROUND
STRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOTE SWITCHES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOTE SWITCHES . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPEAKER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPEAKER - FRONT DOOR UPPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPEAKER - FRONT DOOR LOWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPEAKER - REAR DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPEAKER - REAR CAB SIDE - CLUB CAB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPEAKER - REAR CAB SIDE - REGULAR CAB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AUDIO
DESCRIPTION
An audi o system i s standard factory-i nstal l ed
equi pment on thi s model , unl ess the vehi cl e i s
ordered wi th an avai l abl e radi o del ete opti on. The
standard equi pment audi o system i ncl udes an
AM/FM/cassette (RAS sal es code) recei ver, and
speakers i n four l ocati ons. Several combi nati ons of
radi o recei vers and speaker systems are offered as
opti onal equi pment on thi s model . The audi o system
uses an i gni ti on swi tched source of battery current so
that the system wi l l onl y operate when the i gni ti on
swi tch i s i n the On or Accessory posi ti ons. The audi o
system i ncl udes the fol l owi ng components:
Antenna
Cl ockspri ng (wi th remote radi o swi tches onl y)
Hi gh-l i ne Central Ti mer Modul e (CTM) (wi th
remote radi o swi tches)
Power ampl i fi er (wi th premi um speaker system
onl y)
Radi o noi se suppressi on components
Radi o recei ver
Remote radi o swi tches (opti onal wi th RAZ radi o
recei ver onl y)
Speakers
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - DESCRI PTI ON). (Refer to 8 - ELECTRI -
CAL/ELECTRONI C CONTROL MODULES/BODY
CONTROL/CENTRAL TI MER MODUL - DESCRI P-
TI ON). For compl ete ci rcui t di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
AN AUDIO 8A - 1
nector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds. Fol l owi ng are general
descri pti ons of the remai ni ng major components i n
the standard and opti onal factory-i nstal l ed audi o sys-
tems.
OPERATION
See the owners manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of each of the avai l abl e audi o systems.
CENTRAL TIMER MODULE
The hi gh-l i ne Central Ti mer Modul e (CTM) can
al so control some features of the audi o system when
the vehi cl e i s equi pped wi th the opti onal RAZ radi o
recei ver and remote radi o swi tches. A hi gh-l i ne CTM
i s used on hi gh-l i ne versi ons of thi s vehi cl e. The
CTM combi nes the functi ons of a chi me/buzzer mod-
ul e, an i ntermi ttent wi pe modul e, an i l l umi nated
entry modul e, a remote keyl ess entry modul e, and a
vehi cl e theft securi ty system modul e i n a si ngl e uni t.
The hi gh-l i ne CTM al so control s and i ntegrates
many of the addi ti onal el ectroni c functi ons and fea-
tures i ncl uded on model s wi th thi s opti on. The RAZ
radi o recei ver wi th a remote radi o swi tch opti on i s
one of the features that the CTM control s. The CTM
i s programmed to send swi tch status messages over
the J1850 data bus to control the vol ume, seek, and
pre-set stati on advance functi ons of the RAZ radi o
recei ver. The CTM moni tors the status of the remote
radi o swi tches l ocated on the steeri ng wheel through
a hard wi red ci rcui t. The CTM then sends the proper
swi tch status messages to the radi o recei ver. The
el ectroni c ci rcui try wi thi n the radi o recei ver responds
to the swi tch status messages i t recei ves by adjusti ng
the radi o setti ngs as requested.
(Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/BODY CONTROL/CENTRAL
TI MER MODUL - DESCRI PTI ON) for more i nforma-
ti on on the hi gh-l i ne CTM. (Refer to 8 - ELECTRI -
CAL/AUDI O/REMOTE SWI TCHES -
DESCRI PTI ON) for more i nformati on on thi s compo-
nent. I n addi ti on, radi o recei vers connected to the
J1850 data bus have several audi o system functi ons
that can be di agnosed usi ng a DRB scan tool . Refer
to the proper Di agnosti c Procedures manual for more
i nformati on on DRB testi ng of the audi o systems.
DIAGNOSIS AND TESTING - AUDIO SYSTEM
BAGS, REFER TO ELECTRICAL, RESTRAINTS
Audio System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO 1. Fuse faulty. 1. Check radio fuses in junction block. Replace faulty
fuses, if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connections. Repair,
if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair
wiring, if required.
4. Ground faulty. 4. Check for continuity between radio chassis and a
known good ground. There should be continuity. Repair
ground, if required.
5. Radio faulty. 5. Refer to Radio in the Diagnosis and Testing section of
this group.
6. Speakers faulty. 6. Refer to Speaker in the Diagnosis and Testing section
of this group.
7. Amplifier faulty (if
equipped).
7. Refer to Speaker in the Diagnosis and Testing section
of this group.
NO DISPLAY 1. Fuse faulty. 1. Check radio fuses in junction block. Replace faulty
fuses, if required.
if required.
8A - 2 AUDIO AN
AUDIO (Continued)
Audio System Diagnosis
this group.
CLOCK WILL NOT KEEP
SET TIME
1. Fuse faulty. 1. Check ignition-off draw fuse. Replace faulty fuse, if
required.
if required.
this group.
POOR RADIO
RECEPTION
1. Antenna faulty. 1. Refer to Antenna in the Diagnosis and Testing section
of this group.
this group.
4. Faulty EMI or RFI
noise suppression.
4. Refer to Radio Frequency Interference in the Diagnosis
and Testing section of this group.
NO/POOR TAPE
OPERATION
1. Faulty tape. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.
2. Remove foreign objects and test operation.
3. Dirty cassette tape
head.
3. Clean head with Mopar Cassette Head Cleaner.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT DISC
OPERATION
1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on
CD.
2. Clean CD and test operation.
3. Condensation on CD
or optics.
3. Allow temperature of vehicle interior to stabilize and
test operation.
4. Faulty CD player. 4. Exchange or replace radio, if required.
AN AUDIO 8A - 3
AUDIO (Continued)
SPECIAL TOOLS
AUDIO SYSTEMS
AMPLIFIER
DESCRIPTION
Model s equi pped wi th the I nfi ni ty premi um
speaker package have a separate power ampl i fi er
uni t. Thi s power ampl i fi er i s rated at 120 watts out-
put. The power ampl i fi er uni t i s mounted to the ri ght
cowl si de i nner panel under the passenger si de end of
the i nstrument panel . The power ampl i fi er uni t can
be accessed for servi ce by removi ng the tri m from the
ri ght cowl si de i nner panel .
The power ampl i fi er uni t shoul d be checked i f
there i s no sound output noted from the speakers.
For di agnosi s of the power ampl i fi er, (Refer to 8 -
ELECTRI CAL/AUDI O/SPEAKER - DI AGNOSI S
AND TESTI NG). The power ampl i fi er cannot be
repai red or adjusted and, i f faul ty or damaged, the
uni t must be repl aced.
OPERATION
The power ampl i fi er recei ves fused battery current
from a fuse i n the Juncti on Bl ock (JB) at al l ti mes.
The i nternal ci rcui try of the power ampl i fi er swi tches
the ampl i fi er on based upon a fused 12 vol t output
si gnal that i s recei ved from the radi o recei ver when-
ever the radi o i s turned on. The power ampl i fi er
recei ves the sound si gnal i nputs for four speaker
channel s from the radi o recei ver, then sends the
ampl i fi ed speaker outputs for each of those channel s
to the si x speakers. For compl ete ci rcui t di agrams,
refer to the appropri ate wi ri ng i nformati on. The wi r-
i ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
DIAGNOSIS AND TESTING - AMPLIFIER
The power ampl i fi er uni t shoul d be checked i f
there i s no sound output noted from the speakers.
For di agnosi s of the power ampl i fi er, (Refer to 8 -
ELECTRI CAL/AUDI O/SPEAKER - DI AGNOSI S
AND TESTI NG) For compl ete ci rcui t di agrams, refer
to the appropri ate wi ri ng i nformati on. The wi ri ng
i nformati on i ncl udes wi ri ng di agrams, proper wi re
and connector repai r procedures, detai l s of wi re har-
ness routi ng and retenti on, connector pi n-out i nfor-
mati on and l ocati on vi ews for the vari ous wi re
REMOVAL
cabl e.
(2) Remove the tri m cover from the ri ght cowl si de
i nner panel . (Refer to 23 - BODY/I NTERI OR/COWL
TRI M COVER - REMOVAL) for the procedures.
(3) Di sconnect the two i nstrument panel wi re har-
ness connectors from the connector receptacl es on the
bottom of the power ampl i fi er.
(4) Remove the three screws that secure the power
ampl i fi er to the ri ght cowl si de i nner panel .
(5) Remove the power ampl i fi er from the ri ght
cowl si de i nner panel .
INSTALLATION
(1) Posi ti on the power ampl i fi er to the ri ght cowl
si de i nner panel .
(2) I nstal l the three screws that secure the ampl i -
fi er to the ri ght cowl si de i nner panel . Ti ghten the
screws to 2 Nm (17 i n. l bs.).
(3) Reconnect the two i nstrument panel wi re har-
ness connectors to the connector receptacl es on the
bottom of the power ampl i fi er.
(4) I nstal l the tri m cover onto the ri ght cowl si de
TRI M COVER - I NSTALLATI ON) for the procedures.
Antenna Nut Wrench C-4816
8A - 4 AUDIO AN
AUDIO (Continued)
ANTENNA BODY & CABLE
DESCRIPTION
Al l model s use a bl ack pai nted fi xed-l ength stai n-
l ess steel rod-type antenna mast, i nstal l ed on the
ri ght front fender of the vehi cl e. The antenna mast
has a spi ral groove cut down i ts l ength to reduce
wi nd noi se. The antenna mast i s connected to the
center wi re of the coaxi al antenna cabl e, and i s not
grounded to any part of the vehi cl e. To el i mi nate
stati c, the antenna base must have a good ground.
The coaxi al antenna cabl e shi el d (the outer wi re
mesh of the cabl e) i s grounded to the antenna base
and the radi o recei ver chassi s.
The antenna coaxi al cabl e has an addi ti onal di s-
connect, l ocated near the outboard si de of the gl ove
box openi ng on the back si de of the l ower i nstrument
panel rei nforcement. Thi s addi ti onal di sconnect
al l ows the i nstrument panel assembl y to be removed
and i nstal l ed wi thout removi ng the radi o recei ver.
The factory-i nstal l ed El ectroni cal l y Tuned Radi os
(ETR) automati cal l y compensate for radi o antenna
tri m. Therefore, no antenna tri mmer adjustment i s
requi red or possi bl e when repl aci ng the radi o
recei ver or the antenna.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to coaxi al shi el d test.
The ohmmeter test l ead connecti ons for each test
are shown i n Antenna Tests (Fi g. 1).
NOTE: This model has a special coating on the
antenna mast which is not electrically conductive.
Remove the antenna mast from the antenna base
before attempting to perform Tests 1 and 2.
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the outboard side of the
glove box opening to the antenna base, and then
from the coaxial cable connection to the radio chas-
sis connection.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from the base. Proceed as fol l ows:
(1) Di sconnect the antenna coaxi al cabl e connector
from the radi o recei ver chassi s and i sol ate. Remove
the antenna mast from the antenna base.
(2) I nsert one ohmmeter test l ead i nto the socket
for the antenna mast i n the center of the antenna
base. Connect the other test l ead to the peri meter of
the antenna base. Check for conti nui ty.
(3) There shoul d be no conti nui ty. I f conti nui ty i s
found, repl ace the faul ty or damaged antenna base
and cabl e assembl y.
TEST 2
Test 2 checks the antenna for an open ci rcui t as
fol l ows:
(1) Di sconnect the antenna coaxi al cabl e connector
from the radi o recei ver chassi s. Remove the antenna
mast from the antenna base.
(2) I nsert one ohmmeter test l ead i nto the socket
for the antenna mast i n the center of the antenna
base. Connect the other test l ead to the center pi n of
the antenna coaxi al cabl e connector.
(3) Conti nui ty shoul d exi st (the ohmmeter shoul d
onl y regi ster a fracti on of an ohm). Hi gh or i nfi ni te
resi stance i ndi cates damage to the base and cabl e
assembl y. Repl ace the faul ty base and cabl e, i f
requi red.
Fig. 1 Antenna Test
AN AUDIO 8A - 5
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. Thi s test shoul d be performed
wi th the battery posi ti ve cabl e removed from the bat-
tery. Di sconnect both battery cabl es, the negati ve
cabl e fi rst. Reconnect the battery negati ve cabl e and
perform the test as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the battery
negati ve termi nal post.
(2) The resi stance shoul d be l ess than one ohm.
(3) I f the resi stance i s more than one ohm, check
the brai ded ground strap(s) connected to the engi ne
and the vehi cl e body for bei ng l oose, corroded, or
damaged. Repai r the ground strap connecti ons, i f
requi red.
TEST 4
Test 4 checks the condi ti on of the ground between
the antenna base and the vehi cl e body as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the outer cri mp
on the antenna coaxi al cabl e connector.
(2) The resi stance shoul d be l ess then one ohm.
(3) I f the resi stance i s more then one ohm, cl ean
and/or ti ghten the antenna base to fender mounti ng
hardware.
REMOVAL
ANTENNA BODY AND CABLE
cabl e.
(2) Remove the tri m cover from the ri ght cowl si de
TRI M COVER - REMOVAL.
(3) Reach under the i nstrument panel outboard of
the gl ove box to access and di sconnect the antenna
coaxi al cabl e connector. Di sconnect the connector by
pul l i ng i t apart whi l e twi sti ng the metal connector
hal ves. Do not pul l on the cabl e.
(4) Di sengage the antenna coaxi al cabl e retai ners
at the ri ght cowl si de i nner panel and i nsi de the
ri ght front fender.
(5) Unscrew the antenna mast from the antenna
body (Fi g. 2).
(6) Remove the antenna cap nut usi ng an antenna
nut wrench (Speci al Tool C-4816) (Fi g. 3).
(7) Remove the antenna adapter from the top of
the fender.
(8) Lower the antenna body through the mounti ng
hol e i n the top of the fender.
(9) Pul l the antenna body and cabl e out through
the openi ng between the ri ght cowl si de outer panel
and the fender through the front door openi ng (Fi g.
4).
(10) Di sengage the antenna coaxi al cabl e grommet
from the hol e i n the ri ght cowl si de outer panel .
(11) Pul l the antenna coaxi al cabl e out of the pas-
senger compartment through the hol e i n the ri ght
cowl si de outer panel .
(12) Remove the antenna body and cabl e from the
vehi cl e.
Fig. 2 Antenna Mast
1 - ANTENNA MAST
2 - ADAPTER
3 - CAP NUT
Fig. 3 Antenna Cap Nut
1 - CAP NUT
2 - ANTENNA ADAPTER
3 - TOOL
8A - 6 AUDIO AN
ANTENNA BODY & CABLE (Continued)
INSTRUMENT PANEL ANTENNA CABLE
cabl e.
the gl ove box to access and di sconnect the antenna
coaxi al cabl e connector. Di sconnect the connector by
pul l i ng i t apart whi l e twi sti ng the metal connector
hal ves. Do not pul l on the cabl e.
(3) Securel y ti e a sui tabl e l ength of cord or twi ne
to the i nstrument panel hal f of the antenna coaxi al
cabl e connector. Thi s cord wi l l be used to pul l or
fi sh the cabl e back i nto posi ti on duri ng i nstal l ati on.
(4) Di sengage the i nstrument panel antenna cabl e
from the retai ner cl i ps on the gl ove box openi ng and
i nstrument panel support.
(5) Remove the radi o recei ver from the i nstrument
panel . (Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
REMOVAL).
(6) Pul l the antenna cabl e out through the radi o
recei ver openi ng i n the i nstrument panel .
(7) Unti e the cord or twi ne from the i nstrument
panel antenna cabl e connector, l eavi ng the cord or
twi ne i n pl ace of the cabl e i n the i nstrument panel .
(8) Remove the antenna cabl e from the i nstrument
panel .
INSTALLATION
ANTENNA BODY AND CABLE
(1) Posi ti on the antenna body and cabl e i n the
openi ng between the ri ght cowl si de outer panel and
the fender through the front door openi ng.
(2) Push the antenna coaxi al cabl e i nto the passen-
ger compartment through the hol e i n the ri ght cowl
si de outer panel .
(3) Engage the antenna coaxi al cabl e grommet i n
the hol e i n the ri ght cowl si de outer panel .
(4) Posi ti on the antenna body through the mount-
i ng hol e i n the top of the fender.
(5) I nstal l the adapter over the antenna body from
the top of the fender.
(6) I nstal l and ti ghten the antenna cap nut usi ng
an antenna nut wrench (Speci al Tool C-4816).
Ti ghten the antenna cap nut to 8 Nm (70 i n. l bs.).
(7) I nstal l and ti ghten the antenna mast onto the
antenna body. Ti ghten the mast to 3.3 Nm (30 i n.
l bs.).
(8) Engage the antenna coaxi al cabl e retai ners at
the ri ght cowl si de i nner panel and i nsi de the ri ght
front fender.
(9) Engage the antenna coaxi al cabl e i n the
retai ner cl i ps on the l ower i nstrument panel support
and the gl ovebox.
the gl ove box to reconnect the antenna coaxi al cabl e
connector.
(11) I nstal l the tri m cover onto the ri ght cowl si de
i nner panel .
INSTRUMENT PANEL ANTENNA CABLE
(1) Ti e the end of the cord or twi ne that was used
duri ng i nstrument panel antenna cabl e removal
securel y to the connector on the end of the antenna
coaxi al cabl e bei ng i nstal l ed i nto the i nstrument
panel . Thi s cord wi l l be used to pul l or fi sh the
cabl e back i nto posi ti on.
(2) Usi ng the cord or twi ne, pul l the antenna cabl e
through the radi o recei ver openi ng from under the
i nstrument panel .
(3) I nstal l the radi o recei ver onto the i nstrument
panel . (Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
I NSTALLATI ON).
(4) Engage the i nstrument panel antenna cabl e to
the retai ner cl i p on the l ower i nstrument panel sup-
port and on the gl ove box openi ng.
(5) Unti e the cord or twi ne from the i nstrument
panel hal f of the antenna coaxi al cabl e connector.
the gl ove box to access and reconnect the antenna
coaxi al cabl e connector.
Fig. 4 Antenna Mounting
1 - ADAPTER
2 - MAST
3 - NUT
4 - ANTENNA BODY AND CABLE
5 - RIGHT FRONT FENDER
6 - RETAINER
7 - GROMMET
AN AUDIO 8A - 7
ANTENNA BODY & CABLE (Continued)
RADIO
DESCRIPTION
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude an AM/FM/cassette (RAS sal es code),
or an AM/FM/CD/cassette/3-band graphi c equal i zer
(RAZ sal es code). The factory-i nstal l ed RAZ sal es
code radi o recei vers can al so communi cate on the
J1850 data bus network through a separate two-way
wi re harness connector. Al l factory-i nstal l ed recei vers
are stereo El ectroni cal l y Tuned Radi os (ETR) and
i ncl ude an el ectroni c di gi tal cl ock functi on.
These radi o recei vers can onl y be servi ced by an
authori zed radi o repai r stati on. See the l atest War-
ranty Pol i ci es and Procedures manual for a current
l i sti ng of authori zed radi o repai r stati ons.
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse that i s removed when the vehi cl e i s
shi pped from the factory. Thi s fuse feeds vari ous
accessori es that requi re battery current when the
i gni ti on swi tch i s i n the Off posi ti on, i ncl udi ng the
cl ock. The I OD fuse i s removed to prevent battery
di scharge duri ng vehi cl e storage.
When removi ng or i nstal l i ng the I OD fuse, i t i s
i mportant that the i gni ti on swi tch be i n the Off posi -
ti on. Fai l ure to pl ace the i gni ti on swi tch i n the Off
posi ti on can cause the radi o di spl ay to become scram-
bl ed when the I OD fuse i s removed and repl aced.
Removi ng and repl aci ng the I OD fuse agai n, wi th the
i gni ti on swi tch i n the Off posi ti on, wi l l correct the
scrambl ed di spl ay condi ti on.
The I OD fuse shoul d be checked i f the radi o or
cl ock di spl ays are i noperati ve. The I OD fuse i s
l ocated i n the juncti on bl ock. Refer to the fuse l ayout
l abel on the back of the i nstrument panel fuse access
panel for I OD fuse i denti fi cati on and l ocati on.
OPERATION
The radi o recei ver operates on fused battery cur-
rent that i s avai l abl e onl y when the i gni ti on swi tch i s
i n the On or Accessory posi ti ons. The el ectroni c di gi -
tal cl ock functi on of the radi o operates on fused bat-
tery current suppl i ed through the I OD fuse,
regardl ess of the i gni ti on swi tch posi ti on.
For more i nformati on on the features, setti ng pro-
cedures, and control functi ons for each of the avai l -
abl e factory-i nstal l ed radi o recei vers, see the owners
manual i n the vehi cl e gl ove box. For compl ete ci rcui t
di agrams, refer to the appropri ate wi ri ng i nforma-
ti on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
grams, proper wi re and connector repai r procedures,
detai l s of wi re harness routi ng and retenti on, connec-
tor pi n-out i nformati on and l ocati on vi ews for the
vari ous wi re harness connectors, spl i ces and grounds.
DIAGNOSIS AND TESTING - RADIO
I f the vehi cl e i s equi pped wi th the opti onal remote
radi o swi tches l ocated on the steeri ng wheel and the
probl em bei ng di agnosed i s rel ated to one of the
symptoms l i sted bel ow, be certai n to check the
remote radi o swi tches and ci rcui ts. (Refer to 8 -
ELECTRI CAL/AUDI O/REMOTE SWI TCHES -
DI AGNOSI S AND TESTI NG) pri or to attempti ng
radi o di agnosi s or repai r.
Stati ons changi ng wi th no remote radi o swi tch
i nput
Radi o memory presets not worki ng properl y
Vol ume changes wi th no remote radi o swi tch
i nput
Remote radi o swi tch buttons taki ng on other
functi ons
CD pl ayer ski ppi ng tracks
Remote radi o swi tch i noperati ve.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
CAUTION: The speaker output of the radio receiver
is a floating ground system. Do not allow any
speaker lead to short to ground, as damage to the
radio receiver may result.
(1) Check the fused B(+) fuse i n the juncti on bl ock.
I f OK, go to Step 2. I f not OK, repai r the shorted ci r-
cui t or component as requi red and repl ace the faul ty
fuse.
(2) Check for battery vol tage at the fused B(+) fuse
i n the juncti on bl ock. I f OK, go to Step 3. I f not OK,
repai r the open fused B(+) ci rcui t to the Power Di s-
tri buti on Center (PDC) as requi red.
(3) Check the fused i gni ti on swi tch output (acc/
run) fuse i n the juncti on bl ock. I f OK, go to Step 4. I f
not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse(s).
(4) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (acc/run) fuse i n the juncti on bl ock. I f OK, go
to Step 5. I f not OK, repai r the open fused i gni ti on
8A - 8 AUDIO AN
swi tch output (acc/run) ci rcui t to the i gni ti on swi tch
as requi red.
(5) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the radi o recei ver from the i nstrument
panel , but do not di sconnect the wi re harness connec-
tors. Check for conti nui ty between the radi o recei ver
chassi s and a good ground. There shoul d be conti nu-
i ty. I f OK, go to Step 6. I f not OK, repai r the open
ground ci rcui t to ground as requi red.
(6) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (acc/run)
ci rcui t cavi ty of the l eft (gray) radi o wi re harness
connector. I f OK, go to Step 7. I f not OK, repai r the
open fused i gni ti on swi tch output (acc/run) ci rcui t to
the juncti on bl ock fuse as requi red.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, repl ace the faul ty radi o recei ver. I f not OK,
repai r the open fused B(+) ci rcui t to the juncti on
bl ock fuse as requi red.
REMOVAL
cabl e.
(2) Remove the cl uster bezel from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL) for the procedures.
(3) Remove the four screws that secure the radi o
recei ver to the i nstrument panel (Fi g. 5).
(4) Pul l the radi o recei ver out from the i nstrument
panel far enough to access the i nstrument panel wi re
harness connectors and the antenna coaxi al cabl e
connector (Fi g. 6).
(5) Di sconnect the i nstrument panel wi re harness
connectors and the antenna coaxi al cabl e connector
from the receptacl es on the rear of the radi o recei ver.
(6) Remove the radi o recei ver from the i nstrument
panel .
INSTALLATION
Fig. 5 Radio Receiver Remove/Install
1 - WIRE HARNESS
2 - RADIO
3 - SCREW
Fig. 6 Radio Receiver Connections - Typical
1 - ANTENNA CABLE
2 - RADIO
3 - INSTRUMENT PANEL WIRING
4 - GROUND WIRE
AN AUDIO 8A - 9
RADIO (Continued)
(1) Posi ti on the radi o recei ver to the i nstrument
panel .
(2) Reconnect the i nstrument panel wi re harness
connectors and the antenna coaxi al cabl e connector
to the receptacl es on the rear of the radi o recei ver.
(3) Posi ti on the radi o recei ver i nto the mounti ng
hol e i n the i nstrument panel .
(4) I nstal l and ti ghten the four screws that secure
the radi o recei ver to the i nstrument panel . Ti ghten
the screws to 2.25 Nm (20 i n. l bs.).
(5) I nstal l the cl uster bezel onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL -
I NSTALLATI ON) for the procedures.
RADIO NOISE SUPPRESSION
GROUND STRAP
DESCRIPTION
Radi o Frequency I nterference (RFI ) and El ectro-
Magneti c I nterference (EMI ) noi se suppressi on i s
accompl i shed pri mari l y through ci rcui try i nternal to
the radi o recei vers. These i nternal suppressi on
devi ces are onl y servi ced as part of the radi o recei ver.
External suppressi on devi ces that are used on thi s
vehi cl e to control RFI or EMI noi se i ncl ude the fol -
l owi ng:
Radi o antenna base ground
Radi o recei ver chassi s ground wi re or strap
Engi ne-to-body ground strap(s)
Exhaust system-to-body ground strap (4.7L
engi nes onl y)
Resi stor-type spark pl ugs
Radi o suppressi on-type secondary i gni ti on wi r-
i ng.
For more i nformati on on the spark pl ugs and sec-
ondary i gni ti on components, refer to ELECTRICAL/
IGNITION CONTROLS.
DIAGNOSIS AND TESTING - RADIO NOISE
SUPPRESSION GROUND STRAP
tors, spl i ces and grounds. I nspect the ground paths
and connecti ons at the fol l owi ng l ocati ons:
Bl ower motor
El ectri c fuel pump
Engi ne-to-body ground strap(s)
Generator
I gni ti on modul e
Radi o antenna base ground
Radi o recei ver chassi s ground wi re or strap
Wi per motor.
I f the source of RFI or EMI noi se i s i denti fi ed as a
component on the vehi cl e (i .e., generator, bl ower
motor, etc.), the ground path for that component
shoul d be checked. I f excessi ve resi stance i s found i n
any ground ci rcui t, cl ean, ti ghten, or repai r the
ground ci rcui ts or connecti ons to ground as requi red
before consi deri ng any component repl acement.
For servi ce and i nspecti on of secondary i gni ti on
components, refer to ELECTRI CAL/I GNI TI ON CON-
TROLS. I nspect the fol l owi ng secondary i gni ti on sys-
tem components:
Di stri butor cap and rotor
I gni ti on coi l
Spark pl ugs
Spark pl ug wi re routi ng and condi ti on.
Reroute the spark pl ug wi res or repl ace the faul ty
components as requi red.
I f the source of the RFI or EMI noi se i s i denti fi ed
as two-way mobi l e radi o or tel ephone equi pment,
check the equi pment i nstal l ati on for the fol l owi ng:
Power connecti ons shoul d be made di rectl y to
the battery, and fused as cl osel y to the battery as
possi bl e.
The antenna shoul d be mounted on the roof or
toward the rear of the vehi cl e. Remember that mag-
neti c antenna mounts on the roof panel can adversel y
affect the operati on of an overhead consol e compass,
i f the vehi cl e i s so equi pped.
The antenna cabl e shoul d be ful l y shi el ded coax-
i al cabl e, shoul d be as short as i s practi cal , and
shoul d be routed away from the factory-i nstal l ed
vehi cl e wi re harnesses whenever possi bl e.
The antenna and cabl e must be careful l y
matched to ensure a l ow Standi ng Wave Rati o
(SWR).
Fl eet vehi cl es are avai l abl e wi th an extra-cost RFI -
suppressed Powertrai n Control Modul e (PCM). Thi s
uni t reduces i nterference generated by the PCM on
some radi o frequenci es used i n two-way radi o com-
muni cati ons. However, thi s uni t wi l l not resol ve com-
pl ai nts of RFI i n the commerci al AM or FM radi o
frequency ranges.
8A - 10 AUDIO AN
RADIO (Continued)
REMOVAL
EXHAUST SYSTEM-TO-BODY GROUND STRAP
(2) Remove the nut and washer that secures the
exhaust system-to-body ground strap eyel et termi nal
to the exhaust pi pe cl amp (Fi g. 7).
(3) Remove the screw that secures the exhaust
system-to-body ground strap eyel et termi nal to the
ri ght body si l l panel .
(4) Di sengage the cl i p that secures the exhaust
system-to-body ground strap from the hol e on the top
of the ri ght frame rai l .
(5) Remove the exhaust system-to-body ground
strap from over the top of the ri ght frame rai l .
REMOVAL
ENGINE-TO-BODY GROUND STRAPS
l eft engi ne-to-body ground strap eyel et termi nal to
the wel d stud on the l eft si de of the l ower pl enum
panel (Fi g. 8).
(2) On 6 and 8 cyl i nder engi nes onl y, remove the
nut and washer that secures the ri ght engi ne-to-body
ground strap eyel et termi nal to the i nboard wel d
stud on the ri ght si de of the l ower pl enum panel (Fi g.
8).
Fig. 7 Exhaust System-To-Body Ground Strap
Remove/Install - Typical
1 - EXHAUST PIPE
2 - SCREW
3 - EXHAUST SYSTEM-TO-BODY GROUND STRAP
4 - RIGHT FRAME RAIL
5 - RIGHT BODY SILL PANEL
6 - CLIP
7 - NUT AND WASHER
8 - CLAMP
Fig. 8 Engine-To-Body Ground Strap Remove/Install
- Typical
1 - WELD STUDS
2 - LEFT GROUND STRAP
3 - NUT AND WASHER (2)
4 - RIGHT GROUND STRAP
AN AUDIO 8A - 11
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)
(3) On 4 cyl i nder engi nes onl y, remove the nut and
washer that secures the l eft engi ne-to-body ground
strap eyel et termi nal to the stud on the l eft rear cor-
ner of the engi ne cyl i nder head (Fi g. 9).
screw that secures the l eft engi ne-to-body ground
strap eyel et termi nal to the rear of the l eft cyl i nder
head (Fi g. 10) or (Fi g. 11).
screw that secures the ri ght engi ne-to-body ground
strap eyel et termi nal to the rear of the ri ght cyl i nder
head (Fi g. 10) or (Fi g. 11).
Fig. 9 Engine-To-Body Ground Strap Remove/Install
1 - LEFT CYLINDER HEAD
2 - STUD
3 - NUT
5 - RIGHT CYLINDER HEAD
6 - SCREW (2)
Fig. 10 Engine-To-Body Ground Strap Remove/
Install - 4.7L Engine Only
1 - TO RIGHT COWL STUD
3 - TO RIGHT FENDER STUD
4 - SCREW
5 - TO TRANSMISSION
6 - TO LEFT COWL STUD
7 - SCREW
8A - 12 AUDIO AN
(6) On 4.7L engi nes onl y, remove the nut and
washer that secures the ri ght engi ne-to-body ground
strap eyel et termi nal and the wi re harness grounds
to the wel d stud on the ri ght front fender wheel house
i nner panel (Fi g. 12).
(7) On 4.7L engi nes onl y, remove the screw and
washer that secures the ri ght engi ne-to-body ground
strap eyel et termi nal to the transmi ssi on at the ri ght
rear corner of the engi ne bl ock (Fi g. 13).
(8) On 3.9L and 5.9L engi nes onl y, remove the nut
and washer that secures the ri ght engi ne-to-body
ground strap eyel et termi nal to the i nboard rear
val ve cover stud of the ri ght cyl i nder head (Fi g. 10).
(9) Remove the engi ne-to-body ground strap(s)
from the engi ne compartment.
INSTALLATION
EXHAUST SYSTEM-TO-BODY GROUND STRAP
(1) Posi ti on the exhaust system-to-body ground
strap over the top of the ri ght frame rai l .
(2) Engage the cl i p that secures the exhaust sys-
tem-to-body ground strap i n the hol e on the top of
the ri ght frame rai l .
(3) I nstal l and ti ghten the screw that secures the
exhaust system-to-body ground strap eyel et termi nal
to the ri ght body si l l panel . Ti ghten the screw to 5.0
Nm (45 i n. l bs.).
(4) Posi ti on the exhaust system-to-body ground
strap eyel et termi nal over the exhaust pi pe cl amp
U-bol t.
2 - TO RIGHT CYLINDER HEAD
3 - TO TRANSMISSION
5 - WIRE HARNESS GROUNDS
6 - WELD STUD
7 - NUT AND WASHER
1 - TO RIGHT FENDER STUD
4 - TRANSMISSION
5 - ENGINE BLOCK
Fig. 13 Left Engine-To-Body Ground Strap
Remove/Install - 4 Cylinder Engine Only
2 - NUT
3 - STUD
4 - ENGINE CYLINDER HEAD
AN AUDIO 8A - 13
(5) I nstal l and ti ghten the nut and washer that
secures the exhaust system-to-body ground strap eye-
l et termi nal to the exhaust pi pe cl amp. Ti ghten the
nut to 27.1 Nm (20 ft. l bs.).
INSTALLATION
ENGINE TO BODY GROUND STRAPS
(1) Posi ti on the engi ne-to-body ground strap(s) i n
the engi ne compartment.
(2) On 3.9L and 5.9L engi nes onl y, posi ti on the
ri ght engi ne-to-body ground strap eyel et termi nal
over the i nboard rear val ve cover stud of the ri ght
cyl i nder head.
(3) On 3.9L and 5.9L engi nes onl y, i nstal l and
ti ghten the nut and washer that secures the ri ght
engi ne-to-body ground strap eyel et termi nal to the
i nboard rear val ve cover stud of the ri ght cyl i nder
head. Ti ghten the nut to 2.8 Nm (25 i n. l bs.).
(4) On 4.7L engi nes onl y, i nstal l and ti ghten the
screw and washer that secures the ri ght engi ne-to-
body ground strap eyel et termi nal to the transmi s-
si on at the ri ght rear corner of the engi ne bl ock.
Ti ghten the screw to 67.8 Nm (50 ft. l bs.).
(5) On 4.7L engi nes onl y, posi ti on the ri ght engi ne-
to-body ground strap eyel et termi nal and the wi re
harness grounds over the wel d stud on the ri ght
front fender wheel house i nner panel .
(6) On 4.7L engi nes onl y, i nstal l and ti ghten the
nut and washer that secures the ri ght engi ne-to-body
ground strap eyel et termi nal and the wi re harness
grounds to the wel d stud on the ri ght front fender
wheel house i nner panel . Ti ghten the nut to 11.8 Nm
(105 i n. l bs.).
(7) On 6 and 8 cyl i nder engi nes onl y, i nstal l and
ti ghten the screw that secures the ri ght engi ne-to-
body ground strap eyel et termi nal to the rear of the
ri ght cyl i nder head. On 3.9L and 5.9L engi nes,
ti ghten the screw to 10.2 Nm (90 i n. l bs.). On 4.7L
engi nes, ti ghten the screw to 10.7 Nm (95 i n. l bs.).
ti ghten the screw that secures the l eft engi ne-to-body
ground strap eyel et termi nal to the rear of the l eft
cyl i nder head. On 3.9L and 5.9L engi nes, ti ghten the
screw to 10.2 Nm (90 i n. l bs.). On 4.7L engi nes,
ti ghten the screw to 10.7 Nm (95 i n. l bs.).
(9) On 4 cyl i nder engi nes onl y, posi ti on the l eft
engi ne-to-body ground strap eyel et termi nal over the
stud on the l eft rear corner of the engi ne cyl i nder
head.
(10) On 4 cyl i nder engi nes onl y, i nstal l and ti ghten
the nut and washer that secures the l eft engi ne-to-
body ground strap eyel et termi nal to the stud on the
l eft rear corner of the engi ne cyl i nder head. Ti ghten
the nut to 2.8 Nm (25 i n. l bs.).
(11) On 6 and 8 cyl i nder engi nes onl y, posi ti on the
ri ght engi ne-to-body ground strap eyel et over the
i nboard wel d stud on the ri ght si de of the l ower pl e-
num panel .
ti ghten the nut and washer that secures the ri ght
engi ne-to-body ground strap eyel et to the i nboard
wel d stud on the ri ght si de of the l ower pl enum
panel . Ti ghten the nut to 9 Nm (80 i n. l bs.).
secures the l eft engi ne-to-body ground strap eyel et to
the wel d stud on the l eft si de of the l ower pl enum
panel . Ti ghten the nut to 9 Nm (80 i n. l bs.).
REMOTE SWITCHES
DESCRIPTION
A remote radi o swi tch opti on i s avai l abl e on model s
equi pped wi th the AM/FM/CD/cassette/3-band
graphi c equal i zer (RAZ sal es code) radi o recei ver and
the hi gh-l i ne Central Ti mer Modul e (CTM). (Refer to
8 - ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/BODY CONTROL/CENTRAL TI MER MODUL
- DESCRI PTI ON) for more i nformati on on thi s com-
ponent.
Two rocker-type swi tches (Fi g. 14) are mounted i n
the si des of the rear (i nstrument panel si de) steeri ng
wheel tri m cover. The swi tch on the l eft spoke i s the
seek swi tch and has seek up, seek down, and preset
stati on advance functi ons. The swi tch on the ri ght
spoke i s the vol ume control swi tch and has vol ume
up, and vol ume down functi ons. The swi tch on the
ri ght spoke al so i ncl udes a mode control that al l ows
the dri ver to sequenti al l y sel ect AM radi o, FM radi o,
cassette pl ayer or CD pl ayer. The two swi tches are
retai ned i n mounti ng hol es l ocated on each si de of
the rear steeri ng wheel tri m cover by four l atches
that are i ntegral to the swi tches.
The remote radi o swi tches share a common steer-
i ng wheel wi re harness wi th the vehi cl e speed control
swi tches. The steeri ng wheel wi re harness i s con-
nected to the i nstrument panel wi re harness through
the cl ockspri ng. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - DESCRI PTI ON) for
more i nformati on on thi s component.
OPERATION
The remote radi o swi tches are resi stor mul ti pl exed
uni ts that are hard wi red to the hi gh-l i ne CTM
through the cl ockspri ng. The CTM moni tors the sta-
tus of the remote radi o swi tches and sends the
proper swi tch status messages on the J1850 data bus
network to the radi o recei ver. The el ectroni c ci rcui try
wi thi n the radi o i s programmed to respond to these
8A - 14 AUDIO AN
remote radi o swi tch status messages by adjusti ng the
radi o setti ngs as requested.
For di agnosi s of the CTM or the J1850 data bus,
the use of a DRB scan tool and the proper Di agnosti c
Procedures manual are recommended. For more
i nformati on on the features and control functi ons for
each of the remote radi o swi tches, see the owners
manual i n the vehi cl e gl ove box. For compl ete ci rcui t
DIAGNOSIS AND TESTING - REMOTE
SWITCHES
(1) Remove the remote radi o swi tch(es) (Fi g. 15)
from the steeri ng wheel .
(2) Use an ohmmeter to check the swi tch resi s-
tances as shown i n the Remote Radi o Swi tch Test
chart. I f the remote radi o swi tch resi stances check
OK, go to Step 3. I f not OK, repl ace the faul ty
swi tch.
REMOTE RADIO SWITCH TEST
SWITCH SWITCH POSITION RESISTANCE
Right
(White)
Neutral 24,000 Ohms
Right
(White)
Volume Up 5,310 Ohms
Right
(White)
Volume Down 9,250 Ohms
Right
(White)
Mode 5 Ohms
Left
(Black)
Seek Up 1,210 Ohms
Left
(Black)
Seek Down 3,350 Ohms
Left
(Black)
Pre-Set Station
Advance
500 Ohms
(3) Check for conti nui ty between the ground ci r-
cui t cavi ty of the remote radi o swi tch wi re harness
connector and a good ground. There shoul d be conti -
Fig. 14 Remote Radio Switches
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
Fig. 15 Remote Radio Switches
1 - WHITE REAR SWITCH
2 - BLACK REAR SWITCH
AN AUDIO 8A - 15
REMOTE SWITCHES (Continued)
nui ty. I f OK, go to Step 4. I f not OK, repai r the open
ground ci rcui t to ground as requi red.
(4) Di sconnect the 18-way wi re harness connector
from the Central Ti mer Modul e (CTM). Check for
conti nui ty between the radi o control mux ci rcui t cav-
i ty of the remote radi o swi tch wi re harness connector
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 5. I f not OK, repai r the shorted radi o
control mux ci rcui t as requi red.
(5) Check for conti nui ty between the radi o control
mux ci rcui t cavi ti es of the remote radi o swi tch wi re
harness connector and the 18-way CTM wi re harness
connector. There shoul d be conti nui ty. I f OK, refer to
the proper Di agnosti c Procedures manual to test the
CTM and the J1850 data bus. I f not OK, repai r the
open radi o control mux ci rcui t as requi red.
REMOVAL
cabl e.
(2) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - REMOVAL) for the
procedures.
(3) Remove the speed control swi tch l ocated on the
same si de of the steeri ng wheel as the remote radi o
swi tch that i s bei ng servi ced. Refer to ELECTRI-
CAL/SPEED CONTROL for the procedures.
(4) Di sconnect the steeri ng wheel wi re harness
connector from the connector receptacl e of the remote
radi o swi tch (Fi g. 16).
(5) Di sengage the four remote radi o swi tch l atches
that secure the swi tch to the i nsi de of the mounti ng
hol e i n the steeri ng wheel rear tri m cover .
(6) From the outsi de of the steeri ng wheel rear
tri m cover, remove the remote radi o swi tch from the
tri m cover mounti ng hol e.
INSTALLATION
(1) Posi ti on the remote radi o swi tch to the mount-
i ng hol e on the outsi de of the steeri ng wheel rear
tri m cover. Be certai n that the connector receptacl e i s
ori ented toward the bottom of the swi tch and poi nted
toward the center of the steeri ng wheel .
(2) Press fi rml y and evenl y on the remote radi o
swi tch unti l each of the swi tch l atches i s ful l y
engaged i n the mounti ng hol e of the steeri ng wheel
rear tri m cover.
(3) Reconnect the steeri ng wheel wi re harness con-
nector to the connector receptacl e of the remote radi o
swi tch.
(4) I nstal l the speed control swi tch onto the steer-
i ng wheel . Refer to ELECTRICAL/SPEED CON-
TROL for the procedures.
(5) I nstal l the dri ver si de ai rbag modul e onto the
steeri ng wheel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - I NSTALLATI ON) for
the procedures.
Fig. 16 Remote Radio Switches Remove/Install
1 - STEERING WHEEL
2 - REMOTE RADIO SWITCH
3 - SPEED CONTROL SWITCH
4 - SCREW (2)
5 - DRIVER SIDE AIRBAG MODULE
6 - SPEED CONTROL SWITCH
7 - REAR TRIM COVER
8 - SCREW (2)
8A - 16 AUDIO AN
REMOTE SWITCHES (Continued)
SPEAKER
DESCRIPTION
STANDARD
The standard equi pment speaker system i ncl udes
speakers i n four l ocati ons. One ful l -range 16.5 centi -
meter (6.50 i nch) di ameter speaker i s l ocated i n each
front door. There i s al so one ful l -range speaker
l ocated i n each rear cab si de panel , 13.3 centi meter
(5.25 i nch) di ameter uni ts for the standard cab mod-
el s, and 16.5 centi meter (6.50 i nch) di ameter uni ts
for the cl ub cab model s. On quad cab model s, the
16.5 centi meter (6.50 i nch) di ameter ful l -range
speaker uni ts are l ocated i n each rear door, i nstead
of i n the cab si de panel .
PREMIUM
The opti onal premi um speaker system features
I nfi ni ty model speakers i n si x l ocati ons. Each of the
standard speakers i n the four speaker stereo system
are repl aced wi th I nfi ni ty model speakers, and an
addi ti onal 6.9 centi meter (2.75 i nch) di ameter I nfi n-
i ty dome tweeter i s mounted hi gh i n the front door
tri m panel s. The premi um speaker system al so
i ncl udes an addi ti onal I nfi ni ty power ampl i fi er. The
total avai l abl e power of the premi um speaker system
i s about 120 watts.
OPERATION
STANDARD
Each of the four ful l -range speakers used i n the
standard speaker system i s dri ven by the ampl i fi er
that i s i ntegral to the factory-i nstal l ed radi o recei ver.
For compl ete ci rcui t di agrams, refer to the appropri -
ate wi ri ng i nformati on. The wi ri ng i nformati on
PREMIUM
The si x I nfi ni ty speakers used i n the premi um
speaker system are al l dri ven by the radi o recei ver
through an I nfi ni ty power ampl i fi er. For compl ete ci r-
cui t di agrams, refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng
di agrams, proper wi re and connector repai r proce-
dures, detai l s of wi re harness routi ng and retenti on,
connector pi n-out i nformati on and l ocati on vi ews for
the vari ous wi re harness connectors, spl i ces and
grounds.
DIAGNOSIS AND TESTING - SPEAKER
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
Turn the radi o recei ver on. Adjust the bal ance and
fader control s to check the performance of each i ndi -
vi dual speaker. Note the speaker l ocati ons that are
not performi ng correctl y. Go to Step 2.
(2) Turn the radi o recei ver off. Turn the i gni ti on
swi tch to the Off posi ti on. Di sconnect and i sol ate the
battery negati ve cabl e. Remove the radi o recei ver
from the i nstrument panel . I f the vehi cl e i s equi pped
wi th the I nfi ni ty speaker package, al so di sconnect
the wi re harness connectors at the power ampl i fi er.
Check both the speaker feed (+) ci rcui t and return ()
ci rcui t cavi ti es for the i noperati ve speaker l ocati on(s)
at the radi o recei ver wi re harness connectors for con-
ti nui ty to ground. I n each case, there shoul d be no
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
shorted speaker feed (+) and/or return () ci rcui t(s) to
the speaker as requi red.
(3) I f the vehi cl e i s equi pped wi th the I nfi ni ty
speaker package, go to Step 6. I f the vehi cl e i s
equi pped wi th the standard speaker system, check
the resi stance between the speaker feed (+) ci rcui t
and return () ci rcui t cavi ti es of the radi o recei ver
wi re harness connectors for the i noperati ve speaker
l ocati on(s). The meter shoul d read between 2 and 28
ohms (speaker resi stance). I f OK, go to Step 4. I f not
OK, go to Step 5.
(4) I nstal l a known good radi o recei ver. Connect
the battery negati ve cabl e. Turn the i gni ti on swi tch
to the On posi ti on. Turn on the radi o recei ver and
test the speaker operati on. I f OK, repl ace the faul ty
radi o recei ver. I f not OK, turn the radi o recei ver off,
turn the i gni ti on swi tch to the Off posi ti on, di scon-
AN AUDIO 8A - 17
nect and i sol ate the battery negati ve cabl e, remove
the test radi o recei ver, and go to Step 5.
(5) Di sconnect the wi re harness connector at the
i noperati ve speaker. Check for conti nui ty between
the speaker feed (+) ci rcui t cavi ti es of the radi o
recei ver wi re harness connector and the speaker wi re
harness connector. Repeat the check between the
speaker return () ci rcui t cavi ti es of the radi o
recei ver wi re harness connector and the speaker wi re
harness connector. I n each case, there shoul d be con-
ti nui ty. I f OK, repl ace the faul ty speaker. I f not OK,
repai r the open speaker feed (+) and/or return () ci r-
cui t(s) as requi red.
(6) For each i noperati ve speaker l ocati on, check for
conti nui ty between the speaker feed (+) ci rcui t cavi -
ti es of the radi o recei ver wi re harness connectors and
the power ampl i fi er wi re harness connectors. Repeat
the check for each i noperati ve speaker l ocati on
between the speaker return () ci rcui t cavi ti es of the
radi o recei ver wi re harness connectors and the power
ampl i fi er wi re harness connectors. I n each case,
there shoul d be conti nui ty. I f OK, go to Step 7. I f not
OK, repai r the open speaker feed (+) and/or return
() ci rcui t(s) as requi red.
(7) Check for conti nui ty between the two ground
ci rcui t cavi ti es of the power ampl i fi er wi re harness
ground ci rcui t(s) to ground as requi red.
(8) Check the power ampl i fi er fuse i n the juncti on
bl ock. I f OK, go to Step 9. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
(9) I nstal l the radi o recei ver. Connect the battery
negati ve cabl e. Check for battery vol tage at the
power ampl i fi er fuse i n the juncti on bl ock. I f OK, go
to Step 10. I f not OK, repai r the open fused B(+) ci r-
cui t to the PDC as requi red.
(10) Check for battery vol tage at the two fused
B(+) ci rcui t cavi ti es of the power ampl i fi er wi re har-
ness connector. I f OK, go to Step 11. I f not OK, repai r
the open fused B(+) ci rcui t(s) to the fuse i n the junc-
ti on bl ock as requi red.
Turn the radi o recei ver on. Check for battery vol tage
at the radi o 12 vol t output ci rcui t cavi ty of the power
ampl i fi er wi re harness connector. I f OK, go to Step
12. I f not OK, repai r the open radi o 12 vol t output
ci rcui t to the radi o recei ver as requi red.
(12) Turn the radi o recei ver off. Turn the i gni ti on
swi tch to the Off posi ti on. Di sconnect and i sol ate the
battery negati ve cabl e. For each i noperati ve speaker
l ocati on, check both the ampl i fi ed feed (+) ci rcui t and
the ampl i fi ed return () ci rcui t cavi ti es of the power
ampl i fi er wi re harness connectors for conti nui ty to
ground. I n each case there shoul d be no conti nui ty. I f
OK, go to Step 13. I f not OK, repai r the shorted
ampl i fi ed feed (+) and/or ampl i fi ed return () ci r-
cui t(s) to the speaker as requi red.
(13) For each i noperati ve speaker l ocati on, check
the resi stance between the ampl i fi ed feed (+) ci rcui t
and the ampl i fi ed return () ci rcui t cavi ti es of the
power ampl i fi er wi re harness connectors. The meter
shoul d read between 2 and 28 ohms (speaker resi s-
tance). I f OK, repl ace the faul ty power ampl i fi er. I f
not OK, go to Step 14.
(14) Di sconnect the speaker wi re harness connec-
tor at the i noperati ve speaker. Check for conti nui ty
between the ampl i fi ed feed (+) ci rcui t cavi ti es of the
speaker wi re harness connector and the power ampl i -
fi er wi re harness connector. Repeat the check
between the ampl i fi ed return () ci rcui t cavi ti es of
the speaker wi re harness connector and the power
ampl i fi er wi re harness connector. I n each case there
shoul d be conti nui ty. I f OK, repl ace the faul ty
speaker. I f not OK, repai r the open ampl i fi ed feed (+)
and/or ampl i fi ed return () ci rcui t(s) as requi red.
SPEAKER - FRONT DOOR
UPPER
REMOVAL
cabl e.
(2) Remove the tri m panel from the front door.
(Refer to 23 - BODY/DOOR - FRONT/TRI M PANEL -
REMOVAL)
(3) Remove the screws that secure the front door
upper speaker to the back of the tri m panel .
(4) Remove the front door upper speaker from the
tri m panel .
INSTALLATION
(1) Posi ti on the front door upper speaker to the
back of the tri m panel .
(2) I nstal l and ti ghten the screws that secure the
front door upper speaker to the tri m panel . Ti ghten
the screws to 1.3 Nm (12 i n. l bs.).
(3) Reconnect the door wi re harness connector to
the front door upper speaker wi re harness connector.
(4) I nstal l the tri m panel onto the front door.
I NSTALLATI ON).
(5) Connect the battery negati ve cabl e.
8A - 18 AUDIO AN
SPEAKER (Continued)
SPEAKER - FRONT DOOR
LOWER
REMOVAL
cabl e.
(2) Remove the tri m panel from the front door.
REMOVAL).
(3) Remove the screws that secure the speaker to
the front door (Fi g. 17).
(4) Pul l the speaker away from the mounti ng hol e
i n the front door i nner panel far enough to access the
wi re harness connector.
(5) Di sconnect the front door wi re harness connec-
tor from the speaker.
(6) Remove the speaker from the front door i nner
panel .
INSTALLATION
(1) Posi ti on the speaker to the front door.
(2) Reconnect the front door wi re harness connec-
tor to the speaker.
(3) Posi ti on the speaker i nto the mounti ng hol e i n
the front door.
speaker to the front door. Ti ghten the screws to 2
Nm (17 i n. l bs.).
(5) I nstal l the tri m panel onto the front door.
I NSTALLATI ON).
SPEAKER - REAR DOOR
REMOVAL
cabl e.
(2) Remove the tri m panel from the rear door.
(Refer to 23 - BODY/DOORS - REAR/TRI M PANEL -
REMOVAL).
(3) Remove the screws that secure the speaker to
the rear door (Fi g. 18).
i n the rear door far enough to access the wi re har-
ness connector.
(5) Di sconnect the rear door wi re harness connec-
tor from the speaker.
(6) Remove the speaker from the rear door.
INSTALLATION
(1) Connect the rear door wi re harness connector
to the speaker.
the rear door i nner panel .
speaker to the rear door. Ti ghten the screws to 3.9
Nm (35 i n. l bs.).
(4) I nstal l the tri m panel onto the rear door. (Refer
to 23 - BODY/DOORS - REAR/TRI M PANEL -
I NSTALLATI ON).
Fig. 17 Front Door Lower Speaker Remove/Install
1 - SPEAKER
2 - SCREW
3 - CONNECTOR
Fig. 18 Rear Door Speaker Remove/Install - Quad
Cab
1 - CONNECTOR
2 - SPEAKER
3 - SCREW (3)
4 - REAR DOOR
AN AUDIO 8A - 19
SPEAKER - REAR CAB SIDE -
CLUB CAB
REMOVAL
cabl e.
(2) Remove the tri m panel from the rear cab si de
i nner panel . (Refer to 23 - BODY/I NTERI OR/QUAR-
TER TRI M PANEL - REMOVAL).
(3) Remove the three screws that secure the
speaker to the rear cab si de i nner panel (Fi g. 19).
i n the rear cab si de i nner panel far enough to access
the wi re harness connector.
(5) Di sconnect the body wi re harness connector
from the speaker connector receptacl e.
(6) Remove the speaker from the rear cab si de
i nner panel .
INSTALLATION
(1) Posi ti on the speaker to the rear cab si de i nner
panel .
(2) Reconnect the body wi re harness connector to
the speaker connector receptacl e.
the rear cab si de i nner panel .
(4) I nstal l and ti ghten the three screws that secure
the speaker to the rear cab si de i nner panel . Ti ghten
the screws to 2 Nm (17 i n. l bs.).
(5) I nstal l the tri m panel onto the rear cab si de
i nner panel . (Refer to 23 - BODY/I NTERI OR/QUAR-
TER TRI M PANEL - I NSTALLATI ON).
SPEAKER - REAR CAB SIDE -
REGULAR CAB
REMOVAL
cabl e.
(2) Remove the tri m panel from the B-pi l l ar.(Refer
to 23 - BODY/I NTERI OR/B-PI LLAR TRI M -
REMOVAL).
(3) Pul l the B-pi l l ar tri m away from the cab si de
panel far enough to access the speaker wi re harness
from the speaker connector receptacl e.
Fig. 19 Rear Cab Side Panel Speaker Remove/Install
- Club Cab
1 - REAR CAB SIDE
2 - WIRE HARNESS CONNECTOR
3 - SPEAKER
4 - SCREW
5 - CLIP
Fig. 20 Rear Cab Side Panel Speaker Remove/Install
- Standard Cab
1 - B-PILLAR TRIM PANEL
2 - SCREW
3 - SPEAKER
8A - 20 AUDIO AN
(5) Remove the two screws that secure the speaker
to the back of the B-pi l l ar tri m.
(6) Remove the speaker from the back of the B-pi l -
l ar tri m.
INSTALLATION
(1) Posi ti on the speaker onto the back of the B-pi l -
l ar tri m.
(2) I nstal l and ti ghten the two screws that secure
the speaker to the back of the B-pi l l ar tri m. Ti ghten
(3) Reconnect the body wi re harness connector to
the speaker connector receptacl e.
(4) I nstal l the tri m panel onto the B-pi l l ar. (Refer
to 23 - BODY/I NTERI OR/B-PI LLAR TRI M -
I NSTALLATI ON).
AN AUDIO 8A - 21
SPEAKER - REAR CAB SIDE - REGULAR CAB (Continued)
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME WARNING SYSTEM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHIME WARNING SYSTEM . . . . . . . . . . . . . . . . 3
CHIME WARNING SYSTEM
DESCRIPTION
A chi me warni ng system i s standard factory-i n-
stal l ed equi pment on thi s model . The chi me warni ng
system uses a si ngl e chi me tone generator that i s
i ntegral to the Central Ti mer Modul e (CTM) to pro-
vi de an audi bl e i ndi cati on of vari ous vehi cl e condi -
ti ons that may requi re the attenti on of the vehi cl e
operator. The chi me warni ng system i ncl udes the fol -
l owi ng major components, whi ch are descri bed i n fur-
ther detai l el sewhere i n thi s servi ce manual :
Central Timer Module - The Central Ti mer
Modul e (CTM) i s l ocated on the cowl si de i nner
panel , bel ow the dri ver si de end of the i nstrument
panel . The CTM contai ns an i ntegral chi me tone gen-
erator, i ntegrated ci rcui try, a central processi ng uni t,
and the programmi ng to provi de al l of the proper
chi me warni ng system features based upon the mon-
i tored i nputs. The CTM ci rcui try moni tors hard
wi red swi tch i nputs as wel l as el ectroni c messages
recei ved from other el ectroni c modul es i n the vehi cl e
over the Programmabl e Communi cati ons I nterface
(PCI ) data bus network.
Door Ajar Switch - Door ajar swi tches are
i ntegral to each door l atch. These swi tches provi de
i nputs to the chi me warni ng system i ndi cati ng
whether a door i s opened or cl osed.
Headlamp Switch - The headl amp swi tch i s
l ocated on the i nstrument panel outboard of the
steeri ng col umn. The headl amp swi tch provi des i nput
to the chi me warni ng system i ndi cati ng whether any
i nteri or or exteri or l i ghti ng i s turned On or Off.
Ignition Switch - A key-i n i gni ti on swi tch i s
i ntegral to the i gni ti on swi tch. The key-i n i gni ti on
swi tch provi des an i nput to the chi me warni ng sys-
tem i ndi cati ng whether a key i s present i n the i gni -
ti on l ock cyl i nder.
Hard wi red ci rcui try connects many of the chi me
warni ng system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system
and to the chi me warni ng system components
through the use of a combi nati on of sol dered spl i ces,
spl i ce bl ock connectors, and many di fferent types of
wi re harness termi nal connectors and i nsul ators.
Refer to the appropri ate wi ri ng i nformati on. The wi r-
wi re and connector repai r procedures, further detai l s
on wi re harness routi ng and retenti on, as wel l as
pi n-out and l ocati on vi ews for the vari ous wi re har-
ness connectors, spl i ces and grounds.
The CTM chi me warni ng system ci rcui try and the
i ntegral chi me tone generator cannot be adjusted or
repai red. I f the CTM or the chi me tone generator are
damaged or faul ty, the CTM uni t must be repl aced.
OPERATION
The chi me warni ng system i s desi gned to provi de
an audi bl e output as an i ndi cati on of vari ous condi -
ti ons that may requi re the attenti on or awareness of
the vehi cl e operator. The chi me warni ng system com-
ponents operate on battery current recei ved through
a fused B(+) fuse i n the Juncti on Bl ock (JB) on a
non-swi tched fused B(+) ci rcui t so that the system
may operate regardl ess of the i gni ti on swi tch posi -
ti on.
The chi me warni ng system provi des an audi bl e
i ndi cati on to the vehi cl e operator under the fol l owi ng
condi ti ons:
Compass Mini-Trip Computer (CMTC)
Reset - The Central Ti mer Modul e (CTM) chi me tone
generator wi l l generate one chi me tone each ti me a
Programmabl e Communi cati ons I nterface (PCI ) data
bus message i s recei ved from the opti onal CMTC
i ndi cati ng that the CMTC data has been reset.
Door Ajar Warning - The CTM chi me tone gen-
erator wi l l generate repeti ti ve chi me tones at a sl ow
rate to announce that a hard wi red i nput from any
door ajar swi tch i ndi cates that a door i s open wi th
the i gni ti on swi tch i n the On posi ti on. The chi mes
wi l l conti nue to sound unti l the al l doors are cl osed
or the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
Fasten Seat Belt Warning - The CTM chi me
tone generator wi l l generate repeti ti ve chi me tones at
AN CHIME/BUZZER 8B - 1
a sl ow rate to announce that a hard wi red i nput from
the seat bel t swi tch to the El ectro-Mechani cal I nstru-
ment Cl uster (EMI C) i ndi cates that the dri ver si de
front seat bel t i s not fastened wi th the i gni ti on
swi tch i n the On posi ti on. Unl ess the dri ver si de
front seat bel t i s fastened the chi mes wi l l conti nue to
sound for a durati on of about seven seconds each
ti me the i gni ti on swi tch i s turned to the On posi ti on,
or unti l the dri ver si de front seat bel t i s fastened,
whi chever occurs fi rst. Thi s chi me tone i s based upon
a PCI data bus chi me request message i nput to the
CTM from the EMI C, but i s not ti ed to the operati on
of the EMI C Seatbel t i ndi cator.
Head/Park/Courtesy Lights-On Warning -
The CTM chi me tone generator wi l l generate repeti -
ti ve chi me tones at a fast rate to announce that hard
wi red i nputs from the dri ver door ajar swi tch, head-
l amp swi tch, and i gni ti on swi tch i ndi cate that the
exteri or or courtesy l amps are turned On wi th the
dri ver si de front door opened and the i gni ti on swi tch
i n the Off posi ti on. The chi mes wi l l conti nue to sound
unti l the exteri or or courtesy l amps are turned Off,
the dri ver si de front door i s cl osed, or the i gni ti on
swi tch i s turned to the On posi ti on, whi chever occurs
fi rst.
Key-In-Ignition Warning - The CTM chi me
a fast rate to announce that hard wi red i nputs from
the dri ver door ajar swi tch, headl amp swi tch, and
i gni ti on swi tch i ndi cate that the key i s i n the i gni ti on
l ock cyl i nder wi th the dri ver si de front door opened
and the i gni ti on swi tch i n the Off posi ti on. The
chi mes wi l l conti nue to sound unti l the key i s
removed from the i gni ti on l ock cyl i nder, the dri ver
si de front door i s cl osed, or the i gni ti on swi tch i s
turned to the On posi ti on, whi chever occurs fi rst.
Overspeed Warning - The CTM chi me tone
generator wi l l generate repeti ti ve chi me tones at a
sl ow rate to announce that a PCI data bus vehi cl e
speed message from the Powertrai n Control Modul e
(PCM) i ndi cates that the vehi cl e speed i s over a pro-
grammed speed val ue. Thi s feature i s onl y enabl ed
on a CTM that has been programmed wi th a Mi ddl e
East Gul f Coast Country (GCC) country code.
Warning Chime Support - The CTM chi me
a sl ow rate to announce that a PCI data bus chi me
request message i nput has been recei ved from the
EMI C or the Ai rbag Control Modul e (ACM). These
chi me tones provi de an audi bl e al ert to the vehi cl e
operator that suppl ements certai n vi sual i ndi cati ons
di spl ayed by the EMI C. Suppl emented i ndi cati ons
i ncl ude the fol l owi ng:
The Ai rbag i ndi cator i s i l l umi nated. The ACM
sends a chi me request to the CTM at the same ti me
i t sends an ai rbag l amp-on request to the EMI C. The
chi mes wi l l conti nue to sound for a durati on of about
four seconds each ti me the i ndi cator i s i l l umi nated or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
The Check Gages i ndi cator i s i l l umi nated. The
EMI C sends a chi me request to the CTM. The chi mes
wi l l conti nue to sound for a durati on of about two
seconds each ti me the i ndi cator i s i l l umi nated or
The Low Cool ant i ndi cator i s i l l umi nated (di e-
sel engi ne onl y). The EMI C sends a chi me request to
the CTM. The chi mes wi l l conti nue to sound for a
durati on of about two seconds each ti me the i ndi cator
i s i l l umi nated or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
The Low Fuel i ndi cator i s i l l umi nated. The
The Low Wash i ndi cator i s i l l umi nated. The
The Trans Temp i ndi cator i s i l l umi nated (auto-
mati c transmi ssi on onl y). The EMI C sends a chi me
request to the CTM. The chi mes wi l l conti nue to
sound for a durati on of about two seconds each ti me
the i ndi cator i s i l l umi nated or unti l the i gni ti on
swi tch i s turned to the Off posi ti on, whi chever occurs
fi rst.
A turn si gnal i ndi cator i s i l l umi nated after the
vehi cl e has surpassed a programmed speed and di s-
tance. The EMI C sends a chi me request to the CTM.
The chi mes wi l l conti nue to sound unti l the turn si g-
nal i s turned Off, or unti l the vehi cl e speed i s
reduced bel ow the programmed l evel , whi chever
occurs fi rst.
The Water-I n-Fuel i ndi cator i s i l l umi nated
(di esel engi ne onl y). The EMI C sends a chi me
request to the CTM. The chi mes wi l l conti nue to
sound for a durati on of about two seconds each ti me
the i ndi cator i s i l l umi nated or unti l the i gni ti on
fi rst.
The CTM provi des chi me servi ce for al l avai l abl e
features i n the chi me warni ng system. The CTM
rel i es upon i ts i nternal programmi ng and hard wi red
i nputs from the door ajar swi tches, the headl amp
swi tch, and the key-i n i gni ti on swi tch (i gni ti on
swi tch) to provi de chi me servi ce for the head/park/
courtesy l i ghts-on remi nder, the key-i n i gni ti on
8B - 2 CHIME/BUZZER AN
CHIME WARNING SYSTEM (Continued)
remi nder, and the door ajar warni ng. The CTM rel i es
upon el ectroni c message i nputs recei ved from other
el ectroni c modul es over the PCI data bus network to
provi de chi me servi ce for al l of the remai ni ng chi me
warni ng system features. Upon recei vi ng the proper
i nputs, the CTM acti vates the i ntegral chi me tone
generator to provi de the audi bl e chi me tone to the
vehi cl e operator. The chi me tone generator i n the
CTM i s capabl e of produci ng a si ngl e short beep and
repeated chi me tones at two di fferent rates, sl ow or
fast. The sl ow chi me rate i s about fi fty chi me tones
per mi nute, whi l e the fast chi me rate i s about 180
chi me tones per mi nute. The i nternal programmi ng
of the CTM determi nes the pri ori ty of each chi me
tone request i nput that i s recei ved, as wel l as the
rate and durati on of each chi me tone that i s to be
generated.
The hard wi red chi me warni ng system i nputs to
the CTM, as wel l as other hard wi red ci rcui ts for thi s
system may be di agnosed and tested usi ng conven-
ti onal di agnosti c tool s and procedures. See the own-
ers manual i n the vehi cl e gl ove box for more
i nformati on on the features provi ded by the chi me
warni ng system.
DIAGNOSIS AND TESTING - CHIME WARNING
SYSTEM
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
ness connectors, spl i ces and grounds. The hard wi red
chi me warni ng system i nputs to the Central Ti mer
Modul e (CTM), as wel l as other hard wi red ci rcui ts
for thi s system may be di agnosed and tested usi ng
conventi onal di agnosti c tool s and procedures.
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CHIME WARNING SYSTEM DIAGNOSIS
DOOR AJAR WARNING
CHIME WITH DOORS
CLOSED
1. Driver or passenger door
ajar switch sense circuit
shorted.
1. Disconnect the door wire harness connector for
the driver door ajar switch or the passenger door
ajar switch (1 switch - standard/club cab, 3
switches - quad cab) and the body wire harness
connector (Connector C2) for the CTM. Check for
continuity between the driver or passenger door
ajar switch sense circuit cavity and a good
ground. There should be no continuity. Repair the
shorted driver or passenger door ajar switch
sense circuit, if required.
2. Faulty driver or passenger
door ajar switch.
2. Check for continuity between the ground circuit
cavity and the driver or passenger door ajar
switch sense circuit cavity of the door ajar switch
pigtail wire connector. There should be no
continuity with the door closed. Replace the faulty
door latch, if required.
NO DOOR AJAR WARNING
CHIME WITH A DOOR
OPENED, BUT OTHER
CHIME FEATURES OK
ajar switch ground circuit
open.
cavity of the door wire harness connector for the
driver or passenger door ajar switch (1 switch -
standard/club cab, 3 switches - quad cab) and a
good ground. If not OK, repair the open ground
circuit to ground as required.
ajar switch sense circuit
open.
2. Check for continuity between the driver or
passenger door ajar switch sense circuit cavities
of the door wire harness connector for the driver
or passenger door ajar switch and the body wire
harness connector (Connector C2) for the CTM.
Repair the open driver or passenger door ajar
switch sense circuit, if required.
3. Faulty driver or passenger
door ajar switch.
cavity and the driver or passenger door ajar
switch sense circuit cavity of the door ajar switch
pigtail wire connector. There should be continuity
with the door opened. Replace the faulty door
latch, if required.
NO KEY-IN IGNITION
WARNING CHIME, BUT
OTHER CHIME FEATURES
OK
1. Ignition switch ground
circuit open.
cavity of the instrument panel wire harness
connector for the ignition switch and a good
ground. Repair the open ground circuit to ground,
if required.
2. Key-in ignition switch
sense circuit open.
2. Check for continuity between the key-in ignition
switch sense circuit cavities of the instrument
panel wire harness connector for the ignition
switch and the instrument panel wire harness
connector (Connector C1) for the CTM. Repair
the open key-in ignition switch sense circuit, if
required.
3. Faulty ignition switch. 3. Check for continuity between the key-in ignition
switch sense circuit terminal and the ground
circuit terminal in the ignition switch connector
receptacle. There should be continuity with the
key in the ignition lock cylinder. Replace the faulty
ignition switch, if required.
KEY-IN IGNITION WARNING
CHIME WITH KEY
REMOVED FROM IGNITION
LOCK CYLINDER
1. Key-in ignition switch
sense circuit shorted.
1. Disconnect the instrument panel wire harness
connector for the ignition switch and the
instrument panel wire harness connector
(Connector C1) for the CTM. Check for continuity
between the key-in ignition switch sense circuit
cavity and a good ground. There should be no
continuity. Repair the shorted key-in ignition
switch sense circuit, if required.
8B - 4 CHIME/BUZZER AN
2. Faulty ignition switch. 2. Check for continuity between the key-in ignition
switch sense circuit terminal and the ground
circuit terminal in the ignition switch connector
receptacle. There should be no continuity with the
key removed from the ignition lock cylinder.
Replace the faulty ignition switch, if required.
NO CHIMES AND OTHER
CTM FEATURES ERRATIC
OR DISABLED
1. CTM ground circuit(s)
open.
1. Check for continuity between the three ground
circuit cavities of the instrument panel wire
harness connector (Connector C1) for the CTM
and a good ground. Repair the open ground
circuit(s), if required.
2. CTM fused B(+) circuit(s)
open.
2. Check for battery voltage at the two fused B(+)
circuit cavities of the headlamp and dash wire
harness connector (Connector C3) for the CTM.
Repair the open fused B(+) circuits, if required.
3. CTM fused ignition switch
output (run-start and/or
run-acc) circuit(s) open.
3. With the ignition switch in the On position,
check for battery voltage at the fused ignition
switch output (run-start and run-acc) circuit
cavities of the instrument panel wire harness
connector (Connector C1) for the CTM. Repair
the open fused ignition switch output circuit(s), if
required.
4. Faulty CTM. 4. Replace the faulty CTM, if required.
NO WARNING CHIME
SUPPORT FEATURES FOR
EMIC AND/OR CMTC, BUT
HARD WIRED CHIMES OK
1. Faulty PCI data bus
communication.
1. Use a DRBIII scan tool to diagnose the PCI
data bus and electronic messaging between the
CTM, EMIC, and CMTC. Refer to the appropriate
diagnostic information. Repair the faulty data bus
or replace the faulty electronic modules, if
required.
NO CHIMES, BUT ALL
OTHER CTM FEATURES OK
1. Faulty CTM. 1. Replace the faulty CTM, if required.
ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
PCM/SKIM PROGRAMMING. . . . . . . . . . . . . . . . 1
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CENTRAL TIMER MODULE . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMMUNICATION
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONTROLLER ANTILOCK BRAKE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DATA LINK CONNECTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWERTRAIN CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION CONTROL MODULE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STANDARD PROCEDURES . . . . . . . . . . . . . . . . . 21
TCM QUICK LEARN. . . . . . . . . . . . . . . . . . . . . 21
TRANSFER CASE CONTROL MODULE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM for a failed driver,
control circuit, or ground circuit, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relays and sole-
noids) and shorted circuits (i.e. pull-ups, drivers,
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has been set.
When a PCM (JTEC) and the SKI M are repl aced
at the same ti me, perform the fol l owi ng steps i n
order:
(1) Program the new PCM (JTEC).
(2) Program the new SKI M.
(3) Repl ace al l i gni ti on keys and program them to
the new SKI M.
PROGRAMMING THE PCM (JTEC)
The SKI S Secret Key i s an I D code that i s uni que
to each SKI M. Thi s code i s programmed and stored
i n the SKI M, the PCM, and the i gni ti on key tran-
sponder chi p(s). When repl aci ng the PCM, i t i s nec-
essary to program the secret key i nto the new PCM
usi ng the DRBI I I scan tool . Perform the fol l owi ng
steps to program the secret key i nto the PCM.
(1) Turn the i gni ti on swi tch to the On posi ti on
(transmi ssi on i n Park/Neutral ).
(2) Use the DRBI I I and sel ect THEFT ALARM,
SKI M, then MI SCELLANEOUS.
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
(5) Sel ect ENTER to update PCM VI N.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition switch to
the ON position for one hour, then enter the correct
PIN. (Ensure all accessories are turned off. Also
monitor the battery state and connect a battery
charger if necessary).
AN ELECTRONIC CONTROL MODULES 8E - 1
(6) Press ENTER to transfer the secret key (the
SKI M wi l l send the secret key to the PCM).
(7) Press Page Back to get to the Sel ect System
menu and sel ect ENGI NE, MI SCELLANEOUS, and
SRI MEMORY CHECK.
(8) The DRBI I I wi l l ask, I s odometer readi ng
between XX and XX? Sel ect the YES or NO button
on the DRBI I I . I f NO i s sel ected, the DRBI I I wi l l
read, Enter Odometer Readi ng (From I .P. odome-
ter). Enter the odometer readi ng from the i nstru-
ment cl uster and press ENTER.
PROGRAMMING THE SKIM
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Program the vehi cl e four-di gi t PI N i nto SKI M.
(5) Sel ect COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, it cannot be changed and the SKIM must be
replaced.
(6) Sel ect YES to update VI N (the SKI M wi l l l earn
the VI N from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM wi l l send the secret key to the SKI M).
(8) Program i gni ti on keys to the SKI M.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle ignition keys will need to be
replaced and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(3) Sel ect PROGRAM I GNI TI ON KEYS.
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
(5) Obtai n i gni ti on keys to be programmed from
the customer (8 keys maxi mum).
(6) Usi ng the DRBI I I , erase al l i gni ti on keys by
sel ecti ng MI SCELLANEOUS, and ERASE ALL CUR-
RENT I GN. KEYS.
(7) Program al l of the i gni ti on keys.
I f i gni ti on key programmi ng i s unsuccessful , the
DRBI I I wi l l di spl ay one of the fol l owi ng messages:
Programming Not Attempted - The DRBI I I
attempts to read the programmed key status and
there are no keys programmed i nto SKI M memory.
Programming Key Failed (Possible Used
Key FromWrong Vehicle) - SKI M i s unabl e to pro-
gram an i gni ti on key transponder due to one of the
fol l owi ng:
The i gni ti on key transponder i s faul ty.
The i gni ti on key transponder i s or has been
al ready programmed to another vehi cl e.
8 Keys Already Learned, Programming Not
Done - The SKI M transponder I D memory i s ful l .
Learned Key In Ignition - The I D for the i gni -
ti on key transponder currentl y i n the i gni ti on l ock
cyl i nder i s al ready programmed i n SKI M memory.
DESCRIPTION
Two versi ons of the Central Ti mer Modul e (CTM)
are avai l abl e on thi s vehi cl e, a base versi on and a
hi gh-l i ne versi on (Fi g. 1). Whi chever versi on of the
CTM the vehi cl e i s equi pped wi th, i t i s conceal ed
behi nd the tri m on the l eft cowl si de i nner panel
bel ow the i nstrument panel , where i t i s secured wi th
three screws. The CTM i s encl osed i n a mol ded pl as-
ti c housi ng wi th three i ntegral external connector
receptacl es that connect i t to the vehi cl e el ectri cal
system through one take out and connector of the
body wi re harness, and two take outs and connectors
Fig. 1 Central Timer Module
1 - CENTRAL TIMER MODULE
2 - COWL SIDE INNER PANEL
3 - SCREW (3)
4 - BODY WIRE HARNESS CONNECTOR
5 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR (2)
8E - 2 ELECTRONIC CONTROL MODULES AN
ELECTRONIC CONTROL MODULES (Continued)
of the i nstrument panel wi re harness. The base ver-
si on of the CTM i s used on base model s of thi s vehi -
cl e. These base model s are not equi pped wi th the
opti onal power l ock system, the Remote Keyl ess
Entry (RKE) system, the Vehi cl e Theft Securi ty Sys-
tem (VTSS), or the remote radi o control s. The hi gh-
l i ne versi on of the CTM i s used on hi gh-l i ne vehi cl es
that are equi pped wi th one or more of those opti ons
not found on base model s.
The CTM uti l i zes i ntegrated ci rcui try and i nforma-
ti on carri ed on the Programmabl e Communi cati ons
I nterface (PCI ) data bus network al ong wi th many
hard wi red i nputs to moni tor many sensor and
swi tch i nputs throughout the vehi cl e. I n response to
those i nputs, the i nternal ci rcui try and programmi ng
of the CTM al l ow i t to suppl y the vehi cl e occupants
wi th audi bl e and vi sual i nformati on, and to control
and i ntegrate many el ectroni c functi ons and features
of the vehi cl e through both hard wi red outputs and
the transmi ssi on of el ectroni c message outputs to
other el ectroni c modul es i n the vehi cl e over the PCI
data bus.
The features that the CTM supports or control s
i ncl ude the fol l owi ng:
Automatic Door Lock - The hi gh-l i ne CTM
provi des an automati c door l ock feature (al so known
as rol l i ng door l ocks). Thi s i s a programmabl e fea-
ture.
Battery Protection - The CTM provi des a bat-
tery saver feature that performs ti med l oad sheddi ng
whenever courtesy, readi ng, vi sor vani ty, center con-
sol e, gl ove box, cargo l amps, or any exteri or l amps
are l eft on wi th the i gni ti on swi tch i n the Off posi -
ti on.
Central Locking - The hi gh-l i ne CTM on vehi -
cl es equi pped wi th the opti onal Vehi cl e Theft Secu-
ri ty System (VTSS) i ncl udes a central l ocki ng/
unl ocki ng feature.
Chimes - Al l versi ons of the CTM provi de chi me
servi ce and beep request servi ce through an i ntegral
chi me tone generator.
Door Lock Inhibit - The hi gh-l i ne CTM pro-
vi des a power door l ock i nhi bi t feature.
Enhanced Accident Response - The hi gh-l i ne
CTM provi des an opti onal enhanced acci dent
response feature. Thi s i s a programmabl e feature.
Exterior Light Features - The CTM provi des
control of park l amps, fog l amps, and headl amps.
Thi s i ncl udes support for opti cal horn (al so known as
fl ash-to-pass), headl amp ti me del ay, cargo l amps,
dayti me runni ng l amps (DRL - Canada onl y), and
battery saver features.
Interior Light Features - The CTM provi des
control of courtesy l amps and dome l amps. Thi s
i ncl udes support for a ti med i l l umi nated entry wi th
fade-to-off, i nteri or l i ghti ng del ay, courtesy i l l umi na-
ti on defeat, and battery saver features.
Intermittent Wipe Control - The CTM pro-
vi des control of the i ntermi ttent wi pe del ay, and
wi pe-after-wash features for the wi per and washer
system.
Panic Mode - The hi gh-l i ne CTM provi des sup-
port for the opti onal RKE system pani c mode i ncl ud-
i ng horn chi rp, headl amp fl ash, and park l amp fl ash
features.
Power Lock Control - The hi gh-l i ne CTM pro-
vi des the opti onal power l ock system features, i ncl ud-
i ng support for the automati c door l ock and door l ock
i nhi bi t modes.
Programmable Features - The CTM provi des
support for certai n programmabl e features.
Remote Keyless Entry - The hi gh-l i ne CTM
provi des the opti onal Remote Keyl ess Entry (RKE)
system features, i ncl udi ng support for the RKE Lock
(wi th opti onal horn chi rp and park l amps fl ash),
Unl ock (wi th opti onal park l amps fl ash), Pani c, and
i l l umi nated entry modes, as wel l as the abi l i ty to be
programmed to recogni ze up to four RKE transmi t-
ters. The RKE horn chi rp, park l amps fl ash features
are programmabl e. On quad cab model s onl y, a dri v-
er-door-onl y unl ock or unl ock-al l -doors feature i s al so
programmabl e.
Remote Radio Switch Interface - The hi gh-
l i ne CTM moni tors and transmi ts the status of the
opti onal remote radi o swi tches on the steeri ng wheel .
Speed Sensitive Intermittent Wipe Control -
The CTM provi des a speed sensi ti ve i ntermi ttent
wi pe feature.
Vehicle Theft Security System- The hi gh-l i ne
CTM provi des control of the opti onal Vehi cl e Theft
Securi ty System (VTSS) features, i ncl udi ng support
for the central l ocki ng/unl ocki ng mode and control of
the Securi ty i ndi cator i n the i nstrument cl uster.
Hard wi red ci rcui try connects the CTM to the el ec-
tri cal system of the vehi cl e. These hard wi red ci rcui ts
are i ntegral to several wi re harnesses, whi ch are
routed throughout the vehi cl e and retai ned by many
di fferent methods. These ci rcui ts may be connected to
each other, to the vehi cl e el ectri cal system and to the
CTM through the use of a combi nati on of sol dered
spl i ces, spl i ce bl ock connectors, and many di fferent
types of wi re harness termi nal connectors and i nsu-
l ators. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, further
detai l s on wi re harness routi ng and retenti on, as wel l
as pi n-out and l ocati on vi ews for the vari ous wi re
Al l versi ons of the CTM for thi s model are servi ced
onl y as a compl ete uni t. Many of the el ectroni c fea-
tures i n the vehi cl e control l ed or supported by the
CENTRAL TIMER MODULE (Continued)
CTM are programmabl e usi ng the DRBI I I scan tool .
I n addi ti on, the CTM software i s Fl ash compati bl e,
whi ch means i t can be reprogrammed usi ng Fl ash
reprogrammi ng procedures. However, i f any of the
CTM hardware components are damaged or faul ty,
the enti re CTM uni t must be repl aced. The hard
wi red i nputs or outputs of al l CTM versi ons can be
di agnosed usi ng conventi onal di agnosti c tool s and
methods; however, for di agnosi s of the CTM or the
PCI data bus, the use of a DRBI I I scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
OPERATION
The mi croprocessor-based Central Ti mer Modul e
(CTM) moni tors many hard wi red swi tch and sensor
i nputs as wel l as those resources i t shares wi th other
el ectroni c modul es i n the vehi cl e through i ts commu-
ni cati on over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. The i nternal pro-
grammi ng and al l of these i nputs al l ow the CTM
mi croprocessor to determi ne the tasks i t needs to
perform and thei r pri ori ti es, as wel l as both the stan-
dard and opti onal features that i t shoul d provi de.
The CTM programmi ng then performs those tasks
and provi des those features through both PCI data
bus communi cati on wi th other el ectroni c modul es
and through hard wi red outputs through a number of
dri ver ci rcui ts, rel ays, and actuators. These outputs
al l ow the CTM the abi l i ty to control numerous acces-
sory systems i n the vehi cl e.
The CTM operates on battery current recei ved
through two fuses i n the Juncti on Bl ock (JB) on two
non-swi tched fused B(+) ci rcui ts, a fused i gni ti on
swi tch output (run-start) ci rcui t, and a fused i gni ti on
swi tch output (run-acc) ci rcui t. Thi s arrangement
al l ows the CTM to provi de some features regardl ess
of the i gni ti on swi tch posi ti on, whi l e other features
wi l l operate onl y wi th the i gni ti on swi tch i n the
Accessory, On, and/or Start posi ti ons. The CTM
recei ves ground through i ts connector and take out of
the i nstrument panel wi re harness on three separate
ground ci rcui ts. Two of these ci rcui ts are grounded
through a take out of the i nstrument panel wi re har-
ness wi th an eyel et termi nal connector that i s
secured by a nut to a ground stud on the l eft i nner
cowl si de panel near the CTM, whi l e the thi rd ci rcui t
i s grounded through a take out of the i nstrument
panel wi re harness wi th an eyel et termi nal connector
that i s secured by a ground screw to the l eft si de of
the fl oor panel transmi ssi on tunnel near the Ai rbag
Control Modul e (ACM).
The CTM moni tors i ts own i nternal ci rcui try as
wel l as many of i ts i nput and output ci rcui ts, and
wi l l store a Di agnosti c Troubl e Code (DTC) i n el ec-
troni c memory for any fai l ure i t detects. These DTCs
can be retri eved and di agnosed usi ng a DRBI I I scan
tool . Refer to the appropri ate di agnosti c i nformati on.
HARD WIRED INPUTS
The hard wi red i nputs to the CTM i ncl ude the fol -
l owi ng:
Cargo l amp swi tch sense
Courtesy l amp swi tch sense
Cyl i nder l ock swi tch sense - hi gh l i ne wi th VTSS
onl y
Dri ver door ajar swi tch sense
Dri ver door swi tch mux - hi gh l i ne wi th power
l ocks onl y
Fog l amp swi tch sense
Front washer pump/motor control
Front wi per park swi tch sense
Fused B(+) (two ci rcui ts)
Fused i gni ti on swi tch output (run-acc)
Fused i gni ti on swi tch output (run-start)
Ground (three ci rcui ts)
Headl amp swi tch off sense
Hi gh beam swi tch output
I nteri or l amp defeat
I ntermi ttent front wi per mode sense
I ntermi ttent front wi per swi tch si gnal
Key-i n i gni ti on swi tch sense
Low beam swi tch output
Park brake swi tch sense
Park l amp swi tch sense
Passenger door ajar swi tch sense
Passenger door swi tch mux - hi gh l i ne wi th
power l ocks onl y
PCI bus ci rcui t
Radi o control mux - hi gh-l i ne wi th remote radi o
swi tches onl y
Washer swi tch sense
Wi per park swi tch sense
Wi per swi tch mode sense
Wi per swi tch mode si gnal
HARD WIRED OUTPUTS
The hard wi red outputs of the CTM i ncl ude the fol -
l owi ng:
Cargo l amp dri ver
Courtesy l amp dri ver
Door l ock rel ay output - hi gh-l i ne wi th power
l ocks onl y
Door unl ock rel ay output - hi gh-l i ne wi th power
l ocks onl y
Dri ver door unl ock rel ay output - quad cab hi gh-
l i ne wi th power l ocks onl y
Fog l amp rel ay control - wi th fog l amps onl y
Front washer pump/motor control
Front wi per park swi tch sense
Front wi per rel ay control
Gl ove box l amp dri ver
Hi gh beam i ndi cator dri ver
Horn rel ay control - hi gh-l i ne wi th power l ocks
onl y
I nteri or l amp dri ver
Left hi gh beam dri ver
Left l ow beam dri ver
Park l amp rel ay control
Ri ght hi gh beam dri ver
Ri ght l ow beam dri ver
VTSS i ndi cator dri ver - hi gh-l i ne wi th VTSS
onl y
MESSAGING
The CTM uses the fol l owi ng messages recei ved
from other el ectroni c modul es over the PCI data bus:
Ai rbag Depl oy (ACM)
Beep request (CMTC)
Chargi ng System Fai l ure (PCM)
Chi me request (EMI C)
Engi ne RPM (PCM)
OK to Arm VTSS (PCM)
Securi ty i ndi cator request (SKI M)
System Vol tage (PCM)
Val i d/I nval i d Key (SKI M)
Vehi cl e Di stance (PCM)
Vehi cl e Speed (PCM)
Vol tage Faul t (PCM)
The CTM provi des the fol l owi ng messages to other
el ectroni c modul es over the PCI data bus:
Door Ajar Status (EMI C)
Park Brake Status (CAB, EMI C, TCM)
Radi o Mode (Radi o)
Radi o Preset Scan (Radi o)
Radi o Seek Down (Radi o)
Radi o Seek Up (Radi o)
Radi o Vol ume Down (Radi o)
Radi o Vol ume Up (Radi o)
DIAGNOSIS AND TESTING - CENTRAL TIMER
MODULE
The hard wi red i nputs to and outputs from the
Central Ti mer Modul e (CTM) may be di agnosed and
tested usi ng conventi onal di agnosti c tool s and meth-
ods. Refer to the appropri ate wi ri ng i nformati on. The
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the CTM. I n
order to obtai n concl usi ve testi ng of the CTM, the
bus network and al l of the el ectroni c modul es that
provi de i nputs to or recei ve outputs from the CTM
must al so be checked. The most rel i abl e, effi ci ent,
and accurate means to di agnose the CTM, the PCI
data bus network, and the el ectroni c modul es that
provi de i nputs to or recei ve outputs from the CTM
requi res the use of a DRBI I I scan tool . Refer to the
appropri ate di agnosti c i nformati on. The DRBI I I
scan tool can provi de confi rmati on that the PCI data
bus network i s functi onal , that al l of the el ectroni c
modul es are sendi ng and recei vi ng the proper mes-
sages over the PCI data bus, and that the CTM i s
recei vi ng the proper hard wi red i nputs and respond-
i ng wi th the proper hard wi red outputs needed to
perform i ts many functi ons.
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
NOTE: The following tests may not prove conclu-
sive in the diagnosis of the Central Timer Module
(CTM). The most reliable, efficient, and accurate
means to diagnose the CTM requires the use of a
DRBIII scan tool. Refer to the appropriate diagnos-
tic information.
(1) Check the fused B(+) fuses (Fuse 3 - 20
ampere, and Fuse 12 - 20 ampere) i n the Power Di s-
tri buti on Center (PDC). I f OK, go to Step 2. I f not
OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse.
(2) Check for battery vol tage at the fused B(+)
fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere)
i n the PDC. I f OK, go to Step 3. I f not OK, repai r the
open B(+) ci rcui t between the PDC and the battery
as requi red.
cabl e. Di sconnect the i nstrument panel wi re harness
connector (Connector C3) for the CTM from the CTM
connector receptacl e. Reconnect the battery negati ve
cabl e. Check for battery vol tage at each of the two
fused B(+) ci rcui t cavi ti es of the i nstrument panel
wi re harness connector (Connector C3) for the CTM.
I f OK, di sconnect and i sol ate the battery negati ve
cabl e, reconnect the i nstrument panel wi re harness
connector (Connector C3) for the CTM to the CTM
connector receptacl e, and go to Step 4. I f not OK,
repai r the open fused B(+) ci rcui t(s) between the
CTM and the PDC as requi red.
(4) Check the fused i gni ti on swi tch output (run-
start) fuse (Fuse 11 - 10 ampere) and the fused i gni -
ti on swi tch output (run-acc) fuse (Fuse 5 - 20
ampere) i n the Juncti on Bl ock (JB). I f OK, go to Step
5. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse(s).
(5) Reconnect the battery negati ve cabl e. Turn the
vol tage at the fused i gni ti on swi tch output (run-start)
fuse (Fuse 11 - 10 ampere) and the fused i gni ti on
swi tch output (run-acc) fuse (Fuse 5 - 20 ampere) i n
the JB. I f OK, go to Step 6. I f not OK, repai r the
open fused i gni ti on swi tch output (run-start) ci rcui t
or fused i gni ti on swi tch output (run-acc) ci rcui t
between the JB and the i gni ti on swi tch as requi red.
Di sconnect the i nstrument panel wi re harness con-
nector (Connector C1) for the CTM from the CTM
cabl e. Turn the i gni ti on swi tch to the On posi ti on.
output (run-start) ci rcui t cavi ty and the fused i gni -
ti on swi tch output (run-acc) cavi ty of the i nstrument
panel wi re harness connector (Connector C1) for the
CTM. I f OK, go to Step 7. I f not OK, repai r the open
fused i gni ti on swi tch output (run-start) ci rcui t or
fused i gni ti on swi tch output (run-acc) ci rcui t between
the CTM and the JB as requi red.
Check for conti nui ty between each of the three
ground ci rcui ts i n the i nstrument panel wi re harness
connector (Connector C1) for the CTM and a good
ground. I n each case there shoul d be conti nui ty. I f
OK, use a DRBI I I scan tool to perform further di ag-
nosi s of the CTM. Refer to the appropri ate di agnosti c
i nformati on. I f not OK, repai r the open ground ci r-
cui t(s) to ground (G207 or G208) as requi red.
REMOVAL
NOTE: Before replacing a Central Timer Module
(CTM), use a DRBIII scan tool to retrieve the cur-
rent settings for the CTM programmable features.
Refer to the appropriate diagnostic information.
These settings should be duplicated in the replace-
ment CTM using the DRBIII scan tool before
returning the vehicle to service.
cabl e.
(2) Remove the tri m from the l eft cowl si de i nner
panel . (Refer to 23 - BODY/I NTERI OR/COWL TRI M
COVER - REMOVAL).
(3) Di sconnect the two i nstrument panel wi re har-
ness connectors and one body wi re harness connector
from the CTM connector receptacl es (Fi g. 2).
(4) Remove the three screws that secure the CTM
to the l eft cowl si de i nner panel .
(5) Remove the CTM from the l eft cowl si de i nner
panel .
Fig. 2 Central Timer Module
1 - CENTRAL TIMER MODULE
2 - COWL SIDE INNER PANEL
3 - SCREW (3)
4 - BODY WIRE HARNESS CONNECTOR
5 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR (2)
INSTALLATION
NOTE: Before replacing a Central Timer Module
(CTM), use a DRBIII scan tool to retrieve the cur-
rent settings for the CTM programmable features.
Refer to the appropriate diagnostic information.
These settings should be duplicated in the replace-
ment high-line/premium CTM using the DRBIII
scan tool before returning the vehicle to service.
(1) Posi ti on the CTM onto the l eft cowl si de i nner
panel (Fi g. 2).
the CTM to the l eft cowl si de i nner panel . Ti ghten
ness connectors and one body wi re harness connector
to the CTM connector receptacl es.
(4) Rei nstal l the tri m onto the l eft cowl si de i nner
panel . (Refer to 23 - BODY/I NTERI OR/COWL TRI M
COVER - I NSTALLATI ON).
COMMUNICATION
DESCRIPTION
The Dai ml erChrysl er Programmabl e Communi ca-
ti on I nterface (PCI ) data bus system i s a si ngl e wi re
mul ti pl ex system used for vehi cl e communi cati ons on
many Dai ml erChrysl er Corporati on vehi cl es. Mul ti -
pl exi ng i s a system that enabl es the transmi ssi on of
several messages over a si ngl e channel or ci rcui t. Al l
Dai ml erChrysl er vehi cl es use thi s pri nci pl e for com-
muni cati on between vari ous mi croprocessor-based
el ectroni c control modul es. The PCI data bus exceeds
the Soci ety of Automoti ve Engi neers (SAE) J1850
Standard for Cl ass B Mul ti pl exi ng.
Many of the el ectroni c control modul es i n a vehi cl e
requi re i nformati on from the same sensi ng devi ce. I n
the past, i f i nformati on from one sensi ng devi ce was
requi red by several control l ers, a wi re from each con-
trol l er needed to be connected i n paral l el to that sen-
sor. I n addi ti on, each control l er uti l i zi ng anal og
sensors requi red an Anal og/Di gi tal (A/D) converter i n
order to read these sensor i nputs. Mul ti pl exi ng
reduces wi re harness compl exi ty, sensor current
l oads and control l er hardware because each sensi ng
devi ce i s connected to onl y one control l er, whi ch
reads and di stri butes the sensor i nformati on to the
other control l ers over the data bus. Al so, because
each control l er on the data bus can access the con-
trol l er sensor i nputs to every other control l er on the
data bus, more functi on and feature capabi l i ti es are
possi bl e.
I n addi ti on to reduci ng wi re harness compl exi ty,
component sensor current l oads and control l er hard-
ware, mul ti pl exi ng offers a di agnosti c advantage. A
mul ti pl ex system al l ows the i nformati on fl owi ng
between control l ers to be moni tored usi ng a di agnos-
ti c scan tool . The Dai ml erChrysl er system al l ows an
el ectroni c control modul e to broadcast message data
out onto the bus where al l other el ectroni c control
modul es can hear the messages that are bei ng sent.
When a modul e hears a message on the data bus
that i t requi res, i t rel ays that message to i ts mi cro-
processor. Each modul e i gnores the messages on the
data bus that are bei ng sent to other el ectroni c con-
trol modul es.
OPERATION
Data exchange between modul es i s achi eved by
seri al transmi ssi on of encoded data over a si ngl e wi re
broadcast network. The wi re col ors used for the PCI
data bus ci rcui ts are yel l ow wi th a vi ol et tracer, or
vi ol et wi th a yel l ow tracer, dependi ng upon the appl i -
cati on. The PCI data bus messages are carri ed over
the bus i n the form of Vari abl e Pul se Wi dth Modu-
l ated (VPWM) si gnal s. The PCI data bus speed i s an
average 10.4 Ki l o-bi ts per second (Kbps). By compar-
i son, the pri or two-wi re Chrysl er Col l i si on Detecti on
(CCD) data bus system i s desi gned to run at 7.8125
Kbps.
The vol tage network used to transmi t messages
requi res bi asi ng and termi nati on. Each modul e on
the PCI data bus system provi des i ts own bi asi ng
and termi nati on. Each modul e (al so referred to as a
node) termi nates the bus through a termi nati ng
resi stor and a termi nati ng capaci tor. There are two
types of nodes on the bus. The domi nant node termi -
nates the bus through a 1 KW resi stor and a 3300 pF
capaci tor. The Powertrai n Control Modul e (PCM) i s
the onl y domi nant node for the PCI data bus system.
A standard node termi nates the bus through an 11
KW resi stor and a 330 pF capaci tor.
The modul es bi as the bus when transmi tti ng a
message. The PCI bus uses l ow and hi gh vol tage l ev-
el s to generate si gnal s. Low vol tage i s around zero
vol ts and the hi gh vol tage i s about seven and one-
hal f vol ts. The l ow and hi gh vol tage l evel s are gener-
ated by means of vari abl e-pul se wi dth modul ati on to
form si gnal s of varyi ng l ength. The Vari abl e Pul se
Wi dth Modul ati on (VPWM) used i n PCI bus messag-
i ng i s a method i n whi ch both the state of the bus
and the wi dth of the pul se are used to encode bi t
i nformati on. A zero bi t i s defi ned as a short l ow
pul se or a l ong hi gh pul se. A one bi t i s defi ned as a
l ong l ow pul se or a short hi gh pul se. A l ow (passi ve)
state on the bus does not necessari l y mean a zero bi t.
I t al so depends upon pul se wi dth. I f the wi dth i s
short, i t stands for a zero bi t. I f the wi dth i s l ong, i t
stands for a one bi t. Si mi l arl y, a hi gh (acti ve) state
does not necessari l y mean a one bi t. Thi s too depends
upon pul se wi dth. I f the wi dth i s short, i t stands for
a one bi t. I f the wi dth i s l ong, i t stands for a zero bi t.
I n the case where there are successi ve zero or one
data bi ts, both the state of the bus and the wi dth of
the pul se are changed al ternatel y. Thi s encodi ng
scheme i s used for two reasons. Fi rst, thi s ensures
that onl y one symbol per transi ti on and one transi -
ti on per symbol exi sts. On each transi ti on, every
transmi tti ng modul e must decode the symbol on the
bus and begi n ti mi ng of the next symbol . Si nce ti m-
i ng of the next symbol begi ns wi th the l ast transi ti on
detected on the bus, al l of the modul es are re-syn-
chroni zed wi th each symbol . Thi s ensures that there
are no accumul ated ti mi ng errors duri ng PCI data
bus communi cati on.
The second reason for thi s encodi ng scheme i s to
guarantee that the zero bi t i s the domi nant bi t on
the bus. When two modul es are transmi tti ng si mul -
taneousl y on the bus, there must be some form of
arbi trati on to determi ne whi ch modul e wi l l gai n con-
trol . A data col l i si on occurs when two modul es are
transmi tti ng di fferent messages at the same ti me.
When a modul e i s transmi tti ng on the bus, i t i s read-
i ng the bus at the same ti me to ensure message
i ntegri ty. When a col l i si on i s detected, the modul e
that transmi tted the one bi t stops sendi ng messages
over the bus unti l the bus becomes i dl e.
Each modul e i s capabl e of transmi tti ng and recei v-
i ng data si mul taneousl y. The typi cal PCI bus mes-
sage has the fol l owi ng four components:
Message Header - One to three bytes i n l ength.
The header contai ns i nformati on i denti fyi ng the mes-
sage type and l ength, message pri ori ty, target mod-
ul e(s) and sendi ng modul e.
Data Byte(s) - Thi s i s the actual message that
i s bei ng sent.
Cyclic Redundancy Check (CRC) Byte - Thi s
byte i s used to detect errors duri ng a message trans-
mi ssi on.
In-Frame Response (IFR) byte(s) - I f a
response i s requi red from the target modul e(s), i t can
be sent duri ng thi s frame. Thi s functi on i s descri bed
i n greater detai l i n the fol l owi ng paragraph.
The I FR consi sts of one or more bytes, whi ch are
transmi tted duri ng a message. I f the sendi ng modul e
requi res i nformati on to be recei ved i mmedi atel y, the
target modul e(s) can send data over the bus duri ng
the ori gi nal message. Thi s al l ows the sendi ng modul e
to recei ve ti me-cri ti cal i nformati on wi thout havi ng to
wai t for the target modul e to access the bus. After
the I FR i s recei ved, the sendi ng modul e broadcasts
an End of Frame (EOF) message and rel eases control
of the bus.
The PCI data bus can be moni tored usi ng the
DRBI I I scan tool . I t i s possi bl e, however, for the bus
to pass al l DRBI I I tests and sti l l be faul ty i f the
vol tage parameters are al l wi thi n the speci fi ed range
and fal se messages are bei ng sent.
CONTROLLER REAR WHEEL
ANTILOCK BRAKE
DESCRIPTION
The Control l er Anti l ock Brakes (CAB) i s a mi cro-
processor whi ch handl es testi ng, moni tori ng and con-
trol l i ng the ABS brake system operati on (Fi g. 3). The
CAB functi ons are:
Perform sel f-test di agnosti cs.
Moni tor the RWAL brake system for proper oper-
ati on.
Control the RWAL val ve sol enoi ds.
Fig. 3 RWAL CAB
1 - RWAL CAB
COMMUNICATION (Continued)
The CAB i s mounted on the top of the hydraul i c
control uni t (Fi g. 4). The CAB operates the ABS sys-
tem and i s separate from other vehi cl e el ectri cal ci r-
cui ts. CAB vol tage source i s through the i gni ti on
swi tch i n the RUN posi ti on.
NOTE: If the CAB needs to be replaced, the rear
axle type and tire revolutions per mile must be pro-
gramed into the new CAB. For axle type refer to
Group 3 Differential and Driveline. For tire revolu-
tions per mile, (Refer to 22 - TIRES/WHEELS/TIRES
- SPECIFICATIONS). To program the CAB refer to
the Chassis Diagnostic Manual.
OPERATION
SYSTEM SELF-TEST
When the i gni ti on swi tch i s turned-on the mi cro-
processor RAM and ROM are tested. I f an error
occurs duri ng the test, a DTC wi l l be set i nto the
RAM memory. However i t i s possi bl e the DTC wi l l
not be stored i n memory i f the error has occurred i n
the RAM modul e were the DTCs are stored. Al so i t
i s possi bl e a DTC may not be stored i f the error has
occurred i n the ROM whi ch si gnal s the RAM to store
the DTC.
The CAB contai ns a sel f check program that i l l u-
mi nates the ABS warni ng l i ght when a system faul t
i s detected. Faul ts are stored i n a di agnosti c program
memory and are accessi bl e wi th the DRB scan tool .
ABS faul ts remai n i n memory unti l cl eared, or
unti l after the vehi cl e i s started approxi matel y 50
ti mes. Stored faul ts are not erased i f the battery i s
di sconnected.
CAB INPUTS
The CAB conti nuousl y moni tors the speed of the
di fferenti al ri ng gear by moni tori ng si gnal s generated
by the rear wheel speed sensor. The CAB determi nes
a wheel l ocki ng tendency when i t recogni zes the ri ng
gear i s decel erati ng too rapi dl y. The CAB moni tors
the fol l owi ng i nputs to determi ne when a wheel l ock-
i ng tendency may exi sts:
Rear Wheel Speed Sensor
Brake Lamp Swi tch
Brake Warni ng Lamp Swi tch
Reset Swi tch
4WD Swi tch (I f equi pped)
CAB OUTPUTS
The CAB control s the fol l owi ng outputs for anti l ock
braki ng and brake warni ng i nformati on:
RWAL Val ve
ABS Warni ng Lamp
Brake Warni ng Lamp
REMOVAL
tions per mile, (Refer to 22 - TIRES/WHEELS/TIRES
- SPECIFICATIONS). To program the CAB refer to
the Chassis Diagnostic Manual.
(1) Push the CAB harness connector l ock to
rel ease the l ock and remove the connector (Fi g. 5)
from the control l er.
(2) Remove the RWAL val ve harness and the pump
motor connectors from the control l er. (Fi g. 6)
(3) Remove the control l er mounti ng screws and
remove the control l er from the mounti ng bracket
(Fi g. 7).
Fig. 4 CAB/HCU
1 - CAB
2 - PUMP WIRING
3 - PUMP MOTOR
4 - HCU
CONTROLLER ANTILOCK BRAKE (Continued)
INSTALLATION
tions per mile refer to Group 22 Tire and Wheels. To
program the CAB refer to the Chassis Diagnostic
Manual.
(1) Posi ti on the control l er on the bracket.
(2) I nstal l the mounti ng screws and ti ghten to 6
Nm (53 i n. l bs).
(3) I nstal l the RWAL val ve harness connector i nto
the control l er.
(4) I nstal l the CAB harness connector i nto the con-
trol l er and push down on the connector l ock.
DATA LINK CONNECTOR
DESCRIPTION
The data l i nk connector i s l ocated at the l ower
edge of the i nstrument panel near the steeri ng col -
umn.
OPERATION
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the Powertrai n Control Modul e (PCM).
Fig. 5 Harness Connector Locks
1 - CONNECTOR LOCK
2 - CAB
Fig. 6 Pump Motor Connector
1 - PUMP MOTOR
2 - PUMP CONNECTOR
Fig. 7 RWAL Controller
1 - CAB CONNECTOR LOCK
2 - RWAL CONNECTOR
3 - MOUNTING SCREWS
CONTROLLER ANTILOCK BRAKE (Continued)
POWERTRAIN CONTROL
MODULE
DESCRIPTION
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 8). The PCM i s
referred to as JTEC.
DESCRIPTION - MODES OF OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The PCM pre-posi ti ons the i dl e ai r control (I AC)
motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Starter motor rel ay
Camshaft posi ti on sensor si gnal
Fig. 8 PCM Location
2 - PCM MOUNTING BOLTS (3)
3 - 32WAY CONNECTORS (3)
4 - COVER
5 - POWERTRAIN CONTROL MODULE (PCM)
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
Battery vol tage
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s i s done i f A/C has been
sel ected by the vehi cl e operator and requested by the
A/C thermostat.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM
recei ves i nputs from:
Battery vol tage
tor)
Battery vol tage
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
Battery vol tage
tor)
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
through the cl utch rel ay. Thi s happens i f A/C has
POWERTRAIN CONTROL MODULE (Continued)
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
Battery vol tage
tor)
trans. onl y)
Vehi cl e speed sensor
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
Battery vol tage
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
DESCRIPTION - 5 VOLT SUPPLIES
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
DESCRIPTION - IGNITION CIRCUIT SENSE
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
trai n Control Modul e (PCM).
DESCRIPTION - POWER GROUNDS
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l (s)
Certai n rel ays/sol enoi ds
Certai n sensors
DESCRIPTION - SENSOR RETURN
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ownoi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
DESCRIPTION - SIGNAL GROUND
Si gnal ground provi des a l ow noi se ground to the
data l i nk connector.
OPERATION
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed and the
brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Camshaft posi ti on sensor si gnal
Data l i nk connecti on for DRB scan tool
Fuel l evel
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
Leak detecti on pump (swi tch) sense (i f equi pped)
Oi l pressure
Output shaft speed sensor
Overdri ve/overri de swi tch
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Transmi ssi on governor pressure sensor
Transmi ssi on temperature sensor
Vehi cl e speed i nputs from ABS or RWAL system
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
CCD bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
Data l i nk connecti on for DRB scan tool
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
Generator l amp (i f equi pped)
I dl e ai r control (I AC) motor
I gni ti on coi l
Leak detecti on pump (i f equi pped)
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
Overdri ve i ndi cator l amp (i f equi pped)
Radi ator cool i ng fan (2.5L engi ne onl y)
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t
Transmi ssi on 34 shi ft sol enoi d
Transmi ssi on rel ay
Transmi ssi on temperature l amp (i f equi pped)
Transmi ssi on vari abl e force sol enoi d
OPERATION - 5 VOLT SUPPLIES
Pri mary 5vol t suppl y:
suppl i es the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
Camshaft Posi ti on (CMP) sensor.
suppl i es a reference vol tage for the Mani fol d
Absol ute Pressure (MAP) sensor.
suppl i es a reference vol tage for the Throttl e
Posi ti on Sensor (TPS) sensor.
Secondary 5vol t suppl y:
oi l pressure sensor.
suppl i es the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
suppl i es the 5 vol t power source to the transmi s-
si on pressure sensor (i f equi pped wi th an RE auto-
mati c transmi ssi on).
OPERATION - IGNITION CIRCUIT SENSE
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the i gni ti on sense ci rcui t and i s used to wake up
the PCM. Vol tage on the i gni ti on i nput can be as l ow
as 6 vol ts and the PCM wi l l sti l l functi on. Vol tage i s
suppl i ed to thi s ci rcui t to power the PCMs 8-vol t reg-
ul ator and to al l ow the PCM to perform fuel , i gni ti on
and emi ssi ons control functi ons.
REMOVAL
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
The PCM i s l ocated i n the engi ne compartment
(Fi g. 9).
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Careful l y unpl ug the three 32way connectors
from PCM.
(4) Remove three PCM mounti ng bol ts and remove
PCM from vehi cl e.
INSTALLATION
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
(1) I nstal l PCM and mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts to 35 Nm (3040 i n. l bs.).
(3) Check pi n connectors i n the PCM and the three
32way connectors for corrosi on or damage. Repai r
as necessary.
(4) I nstal l three 32way connectors.
(5) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(6) I nstal l battery cabl e.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage. I f thi s step i s not done,
a Di agnosti c Troubl e Code (DTC) may be set.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key I mmobi l i zer Modul e (SKI M) i s the
pri mary component of the Sentry Key I mmobi l i zer
System (SKI S) (Fi g. 10). The SKI M i s l ocated on the
ri ght si de of the steeri ng col umn, near the i gni ti on
l ock cyl i nder housi ng and i s conceal ed beneath the
steeri ng col umn shrouds. The mol ded bl ack pl asti c
housi ng for the SKI M has an i ntegral mol ded pl asti c
hal o-l i ke antenna ri ng that extends from one si de.
When the SKI M i s properl y i nstal l ed on the steeri ng
col umn, the antenna ri ng i s ori ented around the ci r-
cumference of the i gni ti on l ock cyl i nder housi ng. A
si ngl e i ntegral connector receptacl e contai ni ng si x
termi nal pi ns i s l ocated on the opposi te end of the
SKI M housi ng from the antenna ri ng. A mol ded pl as-
ti c mounti ng tab that i s i ntegral to the SKI M hous-
i ng has a hol e i n the center through whi ch a screw
passes to secure the uni t to the steeri ng col umn. The
Fig. 9 PCM Location and Mounting
4 - COVER
SKI M i s connected to the vehi cl e el ectri cal system
through a si ngl e take out and connector of the
i nstrument panel wi re harness.
The SKI M cannot be adjusted or repai red. I f faul ty
or damaged, the enti re SKI M uni t must be repl aced.
OPERATION
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a
mi croprocessor. The SKI M transmi ts RF si gnal s to,
and recei ves RF si gnal s from the Sentry Key tran-
sponder through a tuned antenna encl osed wi thi n the
mol ded pl asti c antenna ri ng i ntegral to the SKI M
housi ng. I f thi s antenna ri ng i s not mounted properl y
around the i gni ti on l ock cyl i nder housi ng, communi -
cati on probl ems between the SKI M and the transpon-
der may ari se. These communi cati on probl ems wi l l
resul t i n Sentry Key transponder-rel ated faul ts. The
SKI M al so communi cates over the Programmabl e
Communi cati ons I nterface (PCI ) data bus wi th the
Powertrai n Control Modul e (PCM), the Central
Ti mer Modul e (CTM), and/or the DRBI I I scan tool .
The SKI M retai ns i n memory the I D numbers of
any Sentry Key transponder that i s programmed i nto
i t. A maxi mum of ei ght Sentry Key transponders can
be programmed i nto the SKI M. For added system
securi ty, each SKI M i s programmed wi th a uni que
Secret Key code. Thi s code i s stored i n memory, sent
over the PCI data bus to the PCM, and i s encoded to
the transponder of every Sentry Key that i s pro-
grammed i nto the SKI M. Therefore, the Secret Key
code i s a common el ement that i s found i n every com-
ponent of the Sentry Key I mmobi l i zer System (SKI S).
Another securi ty code, cal l ed a PI N, i s used to gai n
access to the SKI M Secured Access Mode. The
Secured Access Mode i s requi red duri ng servi ce to
perform the SKI S i ni ti al i zati on and Sentry Key tran-
sponder programmi ng procedures. The SKI M al so
stores the Vehi cl e I denti fi cati on Number (VI N) i n i ts
memory, whi ch i t l earns through a PCI data bus
message from the PCM duri ng SKI S i ni ti al i zati on.
I n the event that a SKI M repl acement i s requi red,
the Secret Key code can be transferred to the new
SKI M from the PCM usi ng the DRBI I I scan tool
and the SKI S i ni ti al i zati on procedure. Proper com-
pl eti on of the SKI S i ni ti al i zati on wi l l al l ow the exi st-
i ng Sentry Keys to be programmed i nto the new
SKI M so that new keys wi l l not be requi red. I n the
event that the ori gi nal Secret Key code cannot be
recovered, SKI M repl acement wi l l al so requi re new
Sentry Keys. The DRBI I I scan tool wi l l al ert the
techni ci an duri ng the SKI S i ni ti al i zati on procedure i f
new Sentry Keys are requi red.
When the i gni ti on swi tch i s turned to the On posi -
ti on, the SKI M transmi ts an RF si gnal to the tran-
sponder i n the i gni ti on key. The SKI M then wai ts for
an RF si gnal response from the transponder. I f the
response recei ved i denti fi es the key as val i d, the
SKI M sends a val i d key message to the PCM over
the PCI data bus. I f the response recei ved i denti fi es
the key as i nval i d, or i f no response i s recei ved from
the key transponder, the SKI M sends an i nval i d key
message to the PCM. The PCM wi l l enabl e or di sabl e
engi ne operati on based upon the status of the SKI M
messages. I t i s i mportant to note that the defaul t
condi ti on i n the PCM i s an i nval i d key; therefore, i f
no message i s recei ved from the SKI M by the PCM,
the engi ne wi l l be di sabl ed and the vehi cl e i mmobi -
l i zed after two seconds of runni ng.
The SKI M al so sends securi ty i ndi cator status
messages to the CTM over the PCI data bus to tel l
the CTM how to operate the securi ty i ndi cator. The
CTM then control s the securi ty i ndi cator i n the El ec-
troMechani cal I nstrument Cl uster (EMI C) through a
hard wi red securi ty i ndi cator dri ver ci rcui t. The secu-
ri ty i ndi cator status message from the SKI M tel l s the
CTM to turn the i ndi cator on for about three seconds
each ti me the i gni ti on swi tch i s turned to the On
posi ti on as a bul b test. After compl eti on of the bul b
test, the SKI M sends securi ty i ndi cator status mes-
sages to the CTM to turn the i ndi cator off, turn the
i ndi cator on, or to fl ash the i ndi cator on and off. I f
the securi ty i ndi cator fl ashes or stays on sol i d after
the bul b test, i t si gni fi es a SKI S faul t. I f the SKI M
detects a system mal functi on and/or the SKI S has
become i noperati ve, the securi ty i ndi cator wi l l stay
on sol i d. I f the SKI M detects an i nval i d key or i f a
key transponder-rel ated faul t exi sts, the securi ty
i ndi cator wi l l fl ash. I f the vehi cl e i s equi pped wi th
the Customer Learn transponder programmi ng fea-
Fig. 10 Sentry Key Immobilizer Module
1 - SENTRY KEY IMMOBILIZER MODULE
2 - IGNITION LOCK CYLINDER HOUSING
3 - SCREW
4 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
SENTRY KEY IMMOBILIZER MODULE (Continued)
ture, the SKI M wi l l al so send messages to the CTM
to fl ash the securi ty i ndi cator whenever the Cus-
tomer Learn programmi ng mode i s bei ng uti l i zed.
(Refer to 8 - ELECTRI CAL/VEHI CLE THEFT SECU-
RI TY - STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTCs) i n SKI M memory i f a system
mal functi on i s detected. The SKI M can be di agnosed,
and any stored DTCs can be retri eved usi ng a
DRBI I I scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
REMOVAL
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) I f the vehi cl e i s so equi pped, grasp the ti l t
steeri ng col umn knob fi rml y and pul l i t strai ght rear-
ward to remove i t from the ti l t steeri ng col umn
adjuster mechani sm l ever l ocated on the l eft si de of
the col umn just bel ow the mul ti -functi on swi tch con-
trol stal k.
(4) From bel ow the steeri ng col umn, remove the
two outboard screws that secure the upper shroud to
the l ower shroud.
(5) Push gentl y i nward on both si des of the upper
shroud near the parti ng l i ne between the upper and
l ower shrouds to rel ease the snap features that
secure i t to the l ower shroud.
(6) Remove the upper shroud from the l ower
shroud.
one center screw that secures the l ower shroud to the
steeri ng col umn l ock housi ng.
(8) Remove the l ower shroud from the steeri ng col -
umn.
connector for the Sentry Key I mmobi l i zer Modul e
(SKI M) from the SKI M connector receptacl e (Fi g. 11).
(10) Remove the screw that secures the SKI M to
the steeri ng col umn l ock housi ng.
(11) Di sengage the SKI M antenna ri ng from
around the i gni ti on l ock cyl i nder housi ng.
INSTALLATION
(1) Posi ti on the Sentry Key I mmobi l i zer Modul e
(SKI M) onto the steeri ng col umn wi th the antenna
ri ng ori ented around the i gni ti on l ock cyl i nder hous-
i ng (Fi g. 11).
SKI M to the steeri ng col umn l ock housi ng. Ti ghten
the screw to 2 Nm (20 i n. l bs.).
connector for the SKI M to the SKI M connector recep-
tacl e.
(4) Posi ti on the l ower shroud onto the steeri ng col -
umn.
(5) From bel ow the steeri ng col umn, i nstal l and
ti ghten the one center screw that secures the l ower
shroud to the steeri ng col umn l ock housi ng. Ti ghten
(6) Posi ti on the upper shroud onto the steeri ng col -
umn. I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, be certai n to engage the gearshi ft l ever
gap hi der i nto the openi ngs i n the ri ght si de of the
upper and l ower shrouds.
(7) Al i gn the snap features on the upper shroud
wi th the receptacl es on the l ower shroud and appl y
hand pressure to snap them together.
ti ghten the two screws that secure the upper shroud
to the l ower shroud. Ti ghten the screws to 2 Nm (20
i n. l bs.).
(9) I f the vehi cl e i s so equi pped, al i gn the ti l t
steeri ng col umn knob wi th the ti l t steeri ng col umn
trol stal k and usi ng hand pressure push the knob
fi rml y onto the l ever.
(10) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
I NG COVER - I NSTALLATI ON).
Fig. 11 Sentry Key Immobilizer Module
1 - SENTRY KEY IMMOBILIZER MODULE
2 - IGNITION LOCK CYLINDER HOUSING
3 - SCREW
SENTRY KEY IMMOBILIZER MODULE (Continued)
TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmi ssi on Control Modul e (TCM) i s l ocated
i n the engi ne compartment on the ri ght (passenger)
si de and i s mounted to the radi ator core support (Fi g.
12).
OPERATION
The Transmi ssi on Control Modul e (TCM) i s the
control l i ng uni t for al l el ectroni c operati ons of the
transmi ssi on. The TCM recei ves i nformati on regard-
i ng vehi cl e operati on from both di rect and i ndi rect
i nputs, and sel ects the operati onal mode of the trans-
mi ssi on. Di rect i nputs are hardwi red to, and used
speci fi cal l y by the TCM. I ndi rect i nputs ori gi nate
from other components/modul es, and are shared wi th
the TCM vi a the vehi cl e communi cati on bus.
Some exampl es of direct inputs to the TCM are:
Battery (B+) vol tage
I gni ti on ON vol tage
Transmi ssi on Control Rel ay (Swi tched B+)
Throttl e Posi ti on Sensor
Crankshaft Posi ti on Sensor
Transmi ssi on Range Sensor
Pressure Swi tches
Transmi ssi on Temperature Sensor
I nput Shaft Speed Sensor
Output Shaft Speed Sensor
Li ne Pressure Sensor
Some exampl es of indirect inputs to the TCM
are:
Engi ne/Body I denti fi cati on
Mani fol d Pressure
Target I dl e
Torque Reducti on Confi rmati on
Engi ne Cool ant Temperature
Ambi ent/Battery Temperature
DRB Scan Tool Communi cati on
Based on the i nformati on recei ved from these var-
i ous i nputs, the TCM determi nes the appropri ate
shi ft schedul e and shi ft poi nts, dependi ng on the
present operati ng condi ti ons and dri ver demand.
Thi s i s possi bl e through the control of vari ous di rect
and i ndi rect outputs.
Some exampl es of TCM direct outputs are:
Transmi ssi on Control Rel ay
Sol enoi ds
Torque Reducti on Request
Some exampl es of TCM indirect outputs are:
Transmi ssi on Temperature (to PCM)
PRNDL Posi ti on (to BCM)
I n addi ti on to moni tori ng i nputs and control l i ng
outputs, the TCM has other i mportant responsi bi l i -
ti es and functi ons:
Stori ng and mai ntai ni ng Cl utch Vol ume I ndexes
(CVI )
Stori ng and sel ecti ng appropri ate Shi ft Sched-
ul es
System sel f-di agnosti cs
Di agnosti c capabi l i ti es (wi th DRB scan tool )
NOTE: If the TCM has been replaced, the Quick
Learn Procedure must be performed. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
BATTERY FEED
A fused, di rect battery feed to the TCM i s used for
conti nuous power. Thi s battery vol tage i s necessary
to retai n adapti ve l earn val ues i n the TCMs RAM
(Random Access Memory). When the battery (B+) i s
di sconnected, thi s memory i s l ost. When the battery
(B+) i s restored, thi s memory l oss i s detected by the
TCM and a Di agnosti c Troubl e Code (DTC) i s set.
CLUTCH VOLUME INDEXES (CVI)
An i mportant functi on of the TCM i s to moni tor
Cl utch Vol ume I ndexes (CVI ). CVI s represent the vol -
ume of fl ui d needed to compress a cl utch pack.
The TCM moni tors gear rati o changes by moni tor-
i ng the I nput and Output Speed Sensors. The I nput,
or Turbi ne Speed Sensor sends an el ectri cal si gnal to
the TCM that represents i nput shaft rpm. The Out-
Fig. 12 Transmission Control Module Location
1 - TRANSMISSION CONTROL MODULE
put Speed Sensor provi des the TCM wi th output
shaft speed i nformati on.
By compari ng the two i nputs, the TCM can deter-
mi ne transmi ssi on gear posi ti on. Thi s i s i mportant to
the CVI cal cul ati on because the TCM determi nes
CVI s by moni tori ng how l ong i t takes for a gear
change to occur (Fi g. 13).
Gear rati os can be determi ned by usi ng the DRB
Scan Tool and readi ng the I nput/Output Speed Sen-
sor val ues i n the Moni tors di spl ay. Gear rati o can
be obtai ned by di vi di ng the I nput Speed Sensor val ue
by the Output Speed Sensor val ue.
For exampl e, i f the i nput shaft i s rotati ng at 1000
rpm and the output shaft i s rotati ng at 500 rpm,
then the TCM can determi ne that the gear rati o i s
2:1. I n di rect dri ve (3rd gear), the gear rati o changes
to 1:1. The gear rati o changes as cl utches are appl i ed
and rel eased. By moni tori ng the l ength of ti me i t
takes for the gear rati o to change fol l owi ng a shi ft
request, the TCM can determi ne the vol ume of fl ui d
used to appl y or rel ease a fri cti on el ement.
The vol ume of transmi ssi on fl ui d needed to appl y
the fri cti on el ements are conti nuousl y updated for
adapti ve control s. As fri cti on materi al wears, the vol -
ume of fl ui d need to appl y the el ement i ncreases.
Certai n mechani cal probl ems wi thi n the i nput
cl utch assembl y (broken return spri ngs, out of posi -
ti on snap ri ngs, excessi ve cl utch pack cl earance,
i mproper assembl y, etc.) can cause i nadequate or out-
of-range el ement vol umes. Al so, defecti ve I nput/Out-
put Speed Sensors and wi ri ng can cause these
condi ti ons. The fol l owi ng chart i denti fi es the appro-
pri ate cl utch vol umes and when they are moni tored/
updated:
CLUTCH VOLUMES
Clutch When Updated
Proper Clutch
Volume
L/R
2-1 or 3-1
downshift
45 to 134
2C
3-2 kickdown
shift
25 to 85
OD 2-3 upshift 30 to 100
4C 3-4 upshift 30 to 85
UD
4-3 kickdown
shift
30 to 100
Fig. 13 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
TRANSMISSION CONTROL MODULE (Continued)
SHIFT SCHEDULES
As menti oned earl i er, the TCM has programmi ng
that al l ows i t to sel ect a vari ety of shi ft schedul es.
Shi ft schedul e sel ecti on i s dependent on the fol l ow-
i ng:
Shi ft l ever posi ti on
Throttl e posi ti on
Engi ne l oad
Fl ui d temperature
Software l evel
As dri vi ng condi ti ons change, the TCM appropri -
atel y adjusts the shi ft schedul e. Refer to the fol l ow-
i ng chart to determi ne the appropri ate operati on
expected, dependi ng on dri vi ng condi ti ons.
Schedule Condition Expected Operation
Extreme Cold Oil temperature below -16F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super Cold Oil temperature between -12F and
10F
- Delayed 2-3 upshift
- Early 4-3 coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
Cold Oil temperature between 10F and
36F
-Shift schedule is the same as
Super Cold except that the 2-3
upshifts are not delayed.
Warm Oil temperature between 40F and
80F
- Normal operation (upshift,
kickdowns, and coastdowns)
- No EMCC
Hot Oil temperature between 80F and
240F
- Normal operation (upshift,
kickdowns, and coastdowns)
- Normal EMCC operation
Overheat Oil temperature above 240F or
engine coolant temperature above
244F
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE - TCM QUICK LEARN
The qui ck l earn procedure requi res the use of the
DRB scan tool .
Thi s program al l ows the el ectroni c transmi ssi on
system to recal i brate i tsel f. Thi s wi l l provi de the
proper transmi ssi on operati on. The qui ck l earn pro-
cedure shoul d be performed i f any of the fol l owi ng
procedures are performed:
Transmi ssi on Assembl y Repl acement
Transmi ssi on Control Modul e Repl acement
Sol enoi d Pack Repl acement
Cl utch Pl ate and/or Seal Repl acement
Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
The brakes must be appl i ed
The engi ne speed must be above 500 rpm
The throttl e angl e (TPS) must be l ess than 3
degrees
The shi ft l ever posi ti on must stay i n PARK unti l
prompted to shi ft to overdri ve
The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRB
i ndi cates the procedure i s compl ete
The cal cul ated oi l temperature must be above
60 and bel ow 200
TRANSFER CASE CONTROL
MODULE
DESCRIPTION
The Transfer Case Control Modul e (TCCM) (Fi g.
14) i s a mi croprocessor-based assembl y, control l i ng
the 4X4 transfer case shi ft functi ons vi a the actua-
ti on of a shi ft motor and uti l i zi ng the feedback of a
mode sensor assembl y. Communi cati on i s vi a the PCI
seri al bus. I nputs i ncl ude user sel ectabl e 4X4 modes
that i ncl ude AWD(NV244), 2WD(NV233), 4HI , 4LO,
and Neutral . The l ogi c and dri ver ci rcui try i s con-
tai ned i n a mol ded pl asti c housi ng wi th an embedded
heat-si nk and i s l ocated behi nd the center secti on of
the l ower i nstrument panel , to the ri ght of the steer-
i ng col umn.
OPERATION
The Transfer Case Control Modul e (TCCM) uti l i zes
the i nput from the transfer case mounted mode sen-
sor, the i nstrument panel mounted sel ector swi tch,
and the fol l owi ng i nformati on from the vehi cl es PCI
seri al bus to determi ne i f a shi ft i s al l owed.
Engi ne RPM and Vehi cl e Speed
Di agnosti c Requests
Manual Transmi ssi on and Brake Appl i ed
PRNDL
I gni ti on Status
VI N
Once the TCCM determi nes that a requested shi ft
i s al l owed, i t actuates the bi -di recti onal shi ft motor
as necessary to achi eve the desi red transfer case
operati ng mode. The TCCM al so moni tors the mode
sensor whi l e control l i ng the shi ft motor to determi ne
the status of the shi ft attempt.
Several i tems can cause the requested shi ft not to
be compl eted. I f the TCCM has recogni zed a faul t
(DTC) of some vari ety, i t wi l l begi n operati on i n one
of four Functi onal i ty Level s. These l evel s are:
Level Zero - Normal Operati on.
Level One - Onl y Mode Shi fts Are Al l owed.
Level Two - Onl y Mode Shi fts and Shi fts I nto
LOW Are Al l owed (No Neutral Shi fts Are Al l owed).
Level Three - No Shi fts Are Al l owed
The TCCM can al so be operati ng i n one of three
possi bl e power modes. These power modes are:
Full Power Mode i s the normal operati onal
mode of the modul e. Thi s mode i s achi eved by normal
PCI bus traffi c bei ng present and the i gni ti on bei ng
i n the RUN posi ti on.
Reduced Power Mode wi l l be entered when
the i gni ti on has been powered off. I n thi s state, the
modul e wi l l shut down power suppl i ed to external
devi ces, and to el ectroni c i nterface i nputs and out-
puts. From thi s state the modul e can enter ei ther
Sl eep Mode or Ful l Power Mode. To enter thi s mode,
the modul e must recei ve an i gni ti on message denot-
i ng that the i gni ti on i s off, or not recei ve any mes-
sages for 5 0.5 seconds. To exi t thi s mode, the
modul e must recei ve one i gni ti on message that
denotes that the i gni ti on i s i n the RUN posi ti on.
Fig. 14 Transfer Case Control Module (TCCM)
1 - TRANSFER CASE CONTROL MODULE
Sleep Mode wi l l be entered, from the Reduced
Power Mode, when no PCI traffi c has been sensed for
20 1 seconds. I f duri ng Sl eep Mode the modul e
detects PCI bus traffi c, i t wi l l revert to the Reduced
Power mode whi l e moni tori ng for i gni ti on messages.
I t wi l l remai n i n thi s state as l ong as there i s traffi c
other than run or start messages, and wi l l return to
Sl eep mode i f the bus goes wi thout traffi c for 20 1
seconds.
SHIFT REQUIREMENTS
I f the TCCM i s i n ful l power mode and at functi on-
al i ty l evel zero, i t uses the fol l owi ng cri teri a to deter-
mi ne i f a shi ft i s al l owed.
Mode shifts wi l l be al l owed regardl ess of trans-
mi ssi on gear or vehi cl e speed, whenever the fol l owi ng
condi ti ons are met:
A change i n the Sel ector swi tch state i ndi cates
that a mode shi ft has been requested.
A val i d mode sensor si gnal i s bei ng sensed by
the TCCM.
Proper transmi t/recei ve messages are occurri ng
on the PCI bus.
I gni ti on key swi tch i s i n the RUN posi ti on.
Range shifts wi l l be al l owed onl y i f al l of the fol -
l owi ng condi ti ons are met:
A change i n the Sel ector Swi tch state i ndi cati ng
a range shi ft has been requested.
Transmi ssi on i n NEUTRAL si gnal must be rec-
ogni zed for at l east 1.5 seconds 100 msec.
Proper transmi t/recei ve messages are occurri ng
on the PCI bus.
Cl utch si gnal i s recogni zed for 500 msec 50
msec (Cl utch pedal depressed i f a manual transmi s-
si on).
Vehi cl e speed i s l ess than or equal to 4.8 km/hr
(3 mi l es per hour).
I gni ti on key swi tch i s i n the RUN posi ti on.
the TCCM.
A shift into transfer case Neutral wi l l be
al l owed onl y i f al l of the fol l owi ng condi ti ons are met:
The recessed Neutral Sel ecti on swi tch has been
depressed conti nuousl y for 4.0 seconds 100 msec
whi l e al l shi ft condi ti ons have been conti nuousl y met.
Transmi ssi on i n NEUTRAL si gnal recogni zed
from the bus.
Cl utch si gnal i s recogni zed from the bus (Cl utch
pedal depressed i f a manual transmi ssi on).
Proper message transmi ssi ons/recepti ons are
occurri ng on the PCI bus.
I gni ti on key swi tch i s i n the RUN posi ti on,
engi ne off.
Foot Brake i s appl i ed.
the TCCM.
A shift out of transfer case Neutral wi l l be
al l owed onl y i f al l of the fol l owi ng condi ti ons are met:
The recessed Neutral Sel ecti on swi tch has been
depressed conti nuousl y for 1.0 seconds 100 msec
whi l e al l shi ft condi ti ons have been conti nuousl y met.
Transmi ssi on i n NEUTRAL si gnal recogni zed
from the bus.
Cl utch si gnal i s recogni zed from the bus (Cl utch
pedal depressed i f a manual transmi ssi on).
Proper message transmi ssi ons/recepti ons are
occurri ng on the PCI bus.
I gni ti on key swi tch i s i n the RUN posi ti on,
engi ne off.
Foot Brake i s appl i ed.
the TCCM.
SHIFT SEQUENCES
Once al l the dri ver control l abl e condi ti ons for the
requested shi ft have been met, the TCCM begi ns a
shi ft ti mer wi th a maxi mum durati on of 1 second. I f
the shi ft ti mer expi res before the TCCM recogni zes
to correct mode sensor code, the shi ft i s consi dered to
have been bl ocked. The bl ocked shi ft wi l l i ncrement
the bl ocked shi ft counter by one. The TCCM strategy
for handl i ng bl ocked shi fts wi l l be descri bed l ater.
The process the TCCM performs for the vari ous
shi fts wi l l be descri bed fi rst.
RANGE AND MODE SHIFTS
The process for performi ng al l the range and mode
shi fts are the same. The fol l owi ng steps descri be the
process.
Al l ow ti me for Sel ector Swi tch debounce; 250
msec 50 msec.
Perform di agnosti cs on the motor that wi l l check
for opens/shorts.
Engage the shi ft motor for a maxi mum of 1 sec-
ond 100 msec per D channel transi ti on i n the des-
ti nati on gears di recti on whi l e moni tori ng the mode
sensor channel transi ti ons.
Transmi t a bus message that a transfer case
shi ft i s i n progress.
Di sengage the shi ft motor when the correct
mode sensor code i s recogni zed.
Sol i dl y i l l umi nate the current transfer case posi -
ti ons LED whi l e exti ngui shi ng the source gears
LED.
Transmi t a bus message that the transfer case
shi ft i s compl ete.
I f the desi red mode sensor code i s not recei ved
after the shi ft ti mer expi res (i e. a bl ocked or other
TRANSFER CASE CONTROL MODULE (Continued)
condi ti on exi sts), stop dri vi ng the motor and wai t for
1.5 sec 50 msec. The shi ft motor i s then reversed i n
the di recti on back toward the source gear for up to
0.7 seconds 100msec. The TCCM wai ts for 1.5 sec
50 msec. and repeats the attempt to shi ft to the
desi red posi ti on.
SHIFT OUT OF NEUTRAL
Perform di agnosti cs on the motor that wi l l check
for opens/shorts.
Transmi t a bus message that a transfer case
shi ft i s i n progress.
Engage the shi ft motor for a maxi mum of 1 sec-
ond 100 msec toward the transfer case 4H mode
posi ti on whi l e moni tori ng the mode sensor channel
transi ti ons.
Di sengage the shi ft motor when the correct
mode sensor code i s recogni zed.
Exti ngui sh the Neutral LED.
Transmi t a bus message that the transfer case
shi ft i s compl ete.
after the shi ft ti mer expi res (i e. a bl ocked or other
condi ti on exi sts), stop dri vi ng the motor and wai t for
1.5 sec 50 msec. The shi ft motor i s then reversed i n
the di recti on back toward the source gear for up to
0.7 seconds 100msec. The TCCM wai ts for 1.5 sec
50 msec. and repeats the attempt to shi ft to the
desi red posi ti on.
When the Neutral button i s rel eased, i f the 4H
posi ti on i s the desi red posi ti on, the shi ft i s compl ete.
I l l umi nate the 4H LED.
Otherwi se when the Neutral button i s rel eased,
i f al l of the shi ft requi rements are bei ng met then
engage the shi ft motor towards the desi red posi ti on
for 1 second 100 msec per D channel . (i f requi re-
ments for shi fti ng are not met, i l l umi nate the 4H
LED and fl ash the desti nati on LED as an i ndi cati on
to the dri ver that al l of the dri ver control l abl e shi ft
condi ti ons are not bei ng met) I f thi s requi res another
range or mode shi ft, begi n the range/mode shi ft pro-
cess.
after the shi ft ti mer expi res (i .e. a bl ocked or other
condi ti on exi sts), refer to the secti on on Bl ocked Shi ft
Strategy.
BLOCKED SHIFT STRATEGY
When a shi ft i s commanded, the shi ft motor wi l l be
dri ven towards i ts desti nati on posi ti on, except i n the
case of shi fti ng out of Neutral i f 4L was sel ected (the
transfer case wi l l shi ft to the 4H posi ti on fi rst, before
proceedi ng to 4L). I f the shi ft i s bl ocked on the way
to the desti nati on, the TCCM attempts to dri ve the
motor back to the ori gi nal posi ti on. Thi s process wi l l
be al l owed to occur 5 ti mes before the system stops
tryi ng to achi eve the desi red posi ti on. To re-attempt
the desi red shi ft, the sel ector swi tch wi l l need to be
rotated back to the ori gi nal posi ti on unti l the swi tch
debounce ti mer expi res then a shi ft wi l l need to be
requested agai n. The TCCM wi l l not prevent shi fts
on the basi s of a bl ock i n the desti nati on di recti on
I f the mode sensor posi ti on at the end of the 5th
bl ocked attempt i s at any other between gear code,
dri ve the shi ft motor towards the 4H posi ti on.
For al l bl ocked shi fts i n one di recti on or both di rec-
ti ons (desti nati on gear and reversal target), the sta-
tus of the dri ver control l abl e condi ti ons are al ways
rechecked at the end of the reversal unl ess the mode
sensor i s sti l l i n the Neutral regi on (actual posi ti on
or the between gears posi ti on on ei ther si de). I f the
mode sensor i s i n the Neutral regi on at the expi ra-
ti on of the shi ft ti mer, the TCCM wi l l conti nue to
make the shi ft attempts accordi ng to the bl ocked
shi ft strategy i ndependent of whether or not the
dri ver control l ed condi ti ons are met.
For shi fts out of Neutral , i f al l 5 attempts fai l to
reach the desi red posi ti on (whi ch by defaul t i s 4H)
then the motor wi l l be dri ven to stal l i n the 4H di rec-
ti on. After the 2 second 100 msec dri ve/stal l , the
TCCM wi l l l ook at mode sensor posi ti on. I n the worst
case si tuati on after the 2 second dri ve/stal l operati on,
i f the shi ft motor cannot get to the between gears
posi ti on on the Neutral si de of 4H, the uni t wi l l sti l l
be consi dered to be i n Neutral . The Neutral LED and
Servi ce 4WD l amp wi l l be i l l umi nated. Otherwi se
the motor wi l l be on the correct si de of the rooster
comb and the system wi l l depend on the shi ft detent
poppet to center the sector.
SHIFT REVERSAL TARGETS
I f the shi ft ti mer expi res (1 second per D channel )
and we have not made the desi red posi ti on, al l shi fts
wi l l attempt to return to thei r ori gi nal posi ti on wi th
the excepti ons of:
I f the i ntended shi ft i s goi ng to the Hi gh rai l
from Low and cant make i t, but i t can make the
2WD/4WD posi ti on, we stop at that posi ti on. The
TCCM wi l l not attempt to cross back over Neutral i f
i t does not have to. Thi s means that there was a
bl ock on the fi rst attempt to go to 4H and the trans-
fer case has made i t through Neutral to a known
good channel , then the motor wi l l go back onl y to the
2WD/4WD posi ti on and execute the remai nder of the
attempts from there.
For shi fts out of Neutral , any ti me a shi ft i s
commanded out of Neutral the system needs to get
out. The same scenari o of attempti ng to get out of
Neutral and then returni ng to i t shoul d be fol l owed
for al l of the shi ft attempts. The onl y excepti on i s a
shi ft out of Neutral towards the hi gh si de can be con-
si dered compl ete i f i t can make a between gears
readi ng for the nearest hi gh posi ti on. The TCCM
shoul d never go to Neutral unl ess the dri ver i s com-
mandi ng i t and al l requi red condi ti ons are bei ng met
SHIFT ATTEMPT LIMIT
To protect the transfer case system, the TCCM wi l l
i mpose a l i mi t on the number of shi fts that can occur
over a cal i brated ti me peri od. The system wi l l moni -
tor the number of D channel segment transi ti ons
that occur i n any 30 second ti me peri od. I f the num-
ber of segment transi ti ons i s 30 or greater, the sys-
tem wi l l go i nto a defaul t mode. The defaul t mode of
operati on for shi fti ng i s that the number of al l owed
D channel transi ti ons permi tted to occur wi l l be 3
over each 15 second 100 msec cal i brated wi ndow of
ti me. After 5 mi nutes 100 msec, the motor can be
assumed to have cool ed down and the system wi l l
revert to normal operati on. The fol l owi ng rul es al so
appl y to the shi ft l i mi t:
The attempt l i mi t wi l l not i ncl ude shi fts comi ng
out of Neutral , they wi l l be al l owed regardl ess of the
counter/ti mer.
Any shi ft that i s i n progress when the counter
reaches a maxi mum count i n ti me wi l l be al l owed to
compl ete before the defaul t mode i s entered. D-chan-
nel transi ti ons duri ng thi s peri od wi l l not be counted
towards the defaul t mode l i mi t.
A bl ock, regardl ess of the di recti on, whether
towards desti nati on or back towards reversal target
(shi ft ti mer expi ri ng), wi l l count as a val ue of 2 tran-
si ti ons towards the 30 segment transi ti ons to go i nto
defaul t mode as defi ned above. Current attempt l i mi t
val ues are 30 transi ti ons i n 30 seconds and defaul t
mode val ues are 3 transi ti ons every 15 seconds for 5
mi nutes.
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6
BATTERY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING BATTERY ELECTROLYTE
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . 9
BUILT- IN INDICATOR TEST . . . . . . . . . . . . . . . 11
HYDROMETER TEST. . . . . . . . . . . . . . . . . . . . 12
OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . 13
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IGNITION-OFF DRAW TEST. . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BATTERY HOLDDOWN
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BATTERY CABLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BATTERY CABLES. . . . . . . . . . . . . . . . . . . . . . 20
BATTERY TRAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BATTERY SYSTEM
DESCRIPTION
A si ngl e 12-vol t battery system i s standard factory-
i nstal l ed equi pment on thi s model . Al l of the compo-
nents of the battery system are l ocated wi thi n the
engi ne compartment of the vehi cl e. The servi ce i nfor-
mati on for the battery system i n thi s vehi cl e covers
the fol l owi ng rel ated components, whi ch are covered
i n further detai l el sewhere i n thi s servi ce manual :
Battery - The storage battery provi des a rel i -
abl e means of stori ng a renewabl e source of el ectri cal
energy wi thi n the vehi cl e.
Battery Cable - The battery cabl es connect the
battery termi nal posts to the vehi cl e el ectri cal sys-
tem.
Battery Holddown - The battery hol ddown
hardware secures the battery i n the battery tray i n
Battery Thermal Guard - The battery thermal
guard i nsul ates the battery to protect i t from engi ne
compartment temperature extremes.
Battery Tray - The battery tray provi des a
secure mounti ng l ocati on i n the vehi cl e for the bat-
tery and an anchor poi nt for the battery hol ddown
hardware.
AN ENGINE SYSTEMS 8F - 1
For battery system mai ntenance schedul es and
jump starti ng procedures, see the owners manual i n
the vehi cl e gl ove box. Opti onal l y, refer to Lubri cati on
and Mai ntenance for the proper battery jump start-
i ng procedures. Whi l e battery chargi ng can be consi d-
ered a mai ntenance procedure, the battery chargi ng
procedures and rel ated i nformati on are l ocated i n the
servi ce procedures secti on of thi s servi ce manual .
Thi s was done because the battery must be ful l y-
charged before any battery system di agnosi s or test-
i ng procedures can be performed. Refer to Standard
Procedures for the proper battery chargi ng proce-
dures.
OPERATION
The battery system i s desi gned to provi de a safe,
effi ci ent, rel i abl e and mobi l e means of del i veri ng and
stori ng el ectri cal energy. Thi s el ectri cal energy i s
requi red to operate the engi ne starti ng system, as
wel l as to operate many of the other vehi cl e acces-
sory systems for l i mi ted durati ons whi l e the engi ne
and/or the chargi ng system are not operati ng. The
battery system i s al so desi gned to provi de a reserve
of el ectri cal energy to suppl ement the chargi ng sys-
tem for short durati ons whi l e the engi ne i s runni ng
and the el ectri cal current demands of the vehi cl e
exceed the output of the chargi ng system. I n addi ti on
to del i veri ng, and stori ng el ectri cal energy for the
vehi cl e, the battery system serves as a capaci tor and
vol tage stabi l i zer for the vehi cl e el ectri cal system. I t
absorbs most abnormal or transi ent vol tages caused
by the swi tchi ng of any of the el ectri cal components
or ci rcui ts i n the vehi cl e.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starti ng, and chargi ng systems i n the
vehi cl e operate wi th one another and must be tested
as a si ngl e compl ete system. I n order for the engi ne
to start and the battery to charge properl y, al l of the
components that are used i n these systems must per-
form wi thi n speci fi cati ons. I t i s i mportant that the
battery, starti ng, and chargi ng systems be thoroughl y
tested and i nspected any ti me a battery needs to be
charged or repl aced. The cause of abnormal battery
di scharge, overchargi ng or earl y battery fai l ure must
be di agnosed and corrected before a battery i s
repl aced and before a vehi cl e i s returned to servi ce.
The servi ce i nformati on for these systems has been
separated wi thi n thi s servi ce manual to make i t eas-
i er to l ocate the speci fi c i nformati on you are seeki ng.
However, when attempti ng to di agnose any of these
systems, i t i s i mportant that you keep thei r i nterde-
pendency i n mi nd.
The di agnosti c procedures used for the battery,
starti ng, and chargi ng systems i ncl ude the most
basi c conventi onal di agnosti c methods, to the more
sophi sti cated On-Board Di agnosti cs (OBD) bui l t i nto
the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Chargi ng System for the proper chargi ng system on-
board di agnosti c test procedures.
8F - 2 BATTERY SYSTEM AN
BATTERY SYSTEM (Continued)
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.
1. The battery has an
incorrect size or rating for
this vehicle.
1. Refer to Battery Specifications for the proper
size and rating. Replace an incorrect battery, as
required.
2. The battery is physically
damaged.
2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
3. The battery terminal
connections are loose or
corroded.
3. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
4. The battery is discharged. 4. Determine the battery state-of-charge. Refer to
Standard Procedures for the proper test
procedures. Charge the faulty battery, as
required.
5. The electrical system
ignition-off draw is excessive.
5. Refer to Standard Procedures for the proper
test procedures. Repair the faulty electrical
system, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity. Refer
to Standard Procedures for the test procedures.
Replace the faulty battery, as required.
7. The starting system is
faulty.
7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The charging system is
faulty.
8. Determine if the charging system is performing
to specifications. Refer to Charging System for
the proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
AN BATTERY SYSTEM 8F - 3
BATTERY SYSTEM DIAGNOSIS
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.
1. The battery has an
incorrect size or rating for
this vehicle.
1. Refer to Battery Specifications for the proper
specifications. Replace an incorrect battery, as
required.
2. The battery terminal
connections are loose or
corroded.
2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The generator drive belt is
slipping.
3. Refer to Cooling System for the proper
accessory drive belt diagnosis and testing
procedures. Replace or adjust the faulty
generator drive belt, as required.
4. The electrical system
ignition-off draw is excessive.
4. Refer to Standard Procedures for the proper
test procedures. Repair the faulty electrical
system, as required.
5. The battery is faulty. 5. Determine the battery cranking capacity. Refer
to Standard Procedures for the proper test
procedures. Replace the faulty battery, as
required.
6. The starting system is
faulty.
6. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
7. The charging system is
faulty.
7. Determine if the charging system is performing
to specifications. Refer to Charging System for
the proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
8. Electrical loads exceed the
output of the charging
system.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Slow driving or prolonged
idling with high-amperage
draw systems in use.
9. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.
1. The battery is faulty. 1. Refer to Standard Procedures for the proper
battery charging procedures. Charge or replace
the faulty battery, as required.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
Corroded or l oose battery posts and termi nal
cl amps.
A l oose or worn generator dri ve bel t.
El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw.
A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Chargi ng System for the proper charg-
i ng system di agnosi s and testi ng procedures.
A faul ty or i ncorrect starti ng system component.
Refer to Starti ng System for the proper starti ng sys-
tem di agnosi s and testi ng procedures.
A faul ty or i ncorrect battery. Refer to Standard
Procedures for the proper battery di agnosi s and test-
i ng procedures. Refer to Battery System Speci fi ca-
ti ons for the proper speci fi cati ons.
CLEANING
The fol l owi ng i nformati on detai l s the recommended
cl eani ng procedures for the battery and rel ated com-
ponents. I n addi ti on to the mai ntenance schedul es
found i n thi s servi ce manual and the owners man-
ual , i t i s recommended that these procedures be per-
formed any ti me the battery or rel ated components
must be removed for vehi cl e servi ce.
(1) Cl ean the battery cabl e termi nal cl amps of al l
corrosi on. Remove any corrosi on usi ng a wi re brush
or a post and termi nal cl eani ng tool , and a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on (Fi g. 1).
(2) Cl ean the battery tray and battery hol ddown
hardware of al l corrosi on. Remove any corrosi on
usi ng a wi re brush and a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on. Pai nt any
exposed bare metal .
(3) I f the removed battery i s to be rei nstal l ed,
cl ean the outsi de of the battery case and the top
cover wi th a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on usi ng a sti ff bri stl e
parts cl eani ng brush to remove any aci d fi l m (Fi g. 2).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, refer to Battery Speci fi cati ons for the facto-
ry-i nstal l ed battery speci fi cati ons. Confi rm that the
repl acement battery i s the correct si ze and has the
correct rati ngs for the vehi cl e.
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
(4) Cl ean the battery thermal guard wi th a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on usi ng a sti ff bri stl e parts cl eani ng brush to
remove any aci d fi l m.
(5) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 3).
INSPECTION
The fol l owi ng i nformati on detai l s the recommended
i nspecti on procedures for the battery and rel ated
components. I n addi ti on to the mai ntenance sched-
ul es found i n thi s servi ce manual and the owners
manual , i t i s recommended that these procedures be
performed any ti me the battery or rel ated compo-
nents must be removed for vehi cl e servi ce.
(1) I nspect the battery cabl e termi nal cl amps for
damage. Repl ace any battery cabl e that has a dam-
aged or deformed termi nal cl amp.
(2) I nspect the battery tray and battery hol ddown
hardware for damage. Repl ace any damaged parts.
(3) Sl i de the thermal guard off of the battery case,
i f equi pped. I nspect the battery case for cracks or
other damage that coul d resul t i n el ectrol yte l eaks.
Al so, check the battery termi nal posts for l ooseness.
Batteri es wi th damaged cases or l oose termi nal posts
must be repl aced.
(4) I nspect the battery thermal guard for tears,
cracks, deformati on or other damage. Repl ace any
battery thermal guard that has been damaged.
(5) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. Refer to
Standard Procedures for the proper battery bui l t-i n
i ndi cator test procedures. Al so refer to Standard Pro-
cedures for the proper battery chargi ng procedures.
SPECIFICATIONS
BATTERY
Battery Classifications and Ratings
Part Number
BCI Group Size
Classification
Cold
Cranking
Amperage
Reserve
Capacity
Ampere-Hours
Load Test
Amperage
56027100 27 600 120 Minutes 66 300
56027302 27 750 150 Minutes 75 375
BATTERY
DESCRIPTION
A l arge capaci ty, l ow-mai ntenance storage battery
(Fi g. 4) i s standard factory-i nstal l ed equi pment on
thi s model . Refer to Battery Speci fi cati ons for the
proper speci fi cati ons of the factory-i nstal l ed batteri es
avai l abl e on thi s model . Mal e post type termi nal s
made of a soft l ead materi al protrude from the top of
the mol ded pl asti c battery case to provi de the means
for connecti ng the battery to the vehi cl e el ectri cal
system. The battery posi ti ve termi nal post i s physi -
cal l y l arger i n di ameter than the negati ve termi nal
post to ensure proper battery connecti on. The l etters
POS and NEG are al so mol ded i nto the top of the
battery case adjacent to thei r respecti ve posi ti ve and
negati ve termi nal posts for i denti fi cati on confi rma-
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
ti on. Refer to Battery Cabl es for more i nformati on on
the battery cabl es that connect the battery to the
vehi cl e el ectri cal system.
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups that are connected wi th l ead
straps to the posi ti ve termi nal post, and negati vel y
charged pl ate groups that are connected wi th l ead
straps to the negati ve termi nal post. Each pl ate con-
si sts of a sti ff mesh framework or gri d coated wi th
l ead di oxi de (posi ti ve pl ate) or sponge l ead (negati ve
pl ate). I nsul ators or pl ate separators made of a non-
conducti ve materi al are i nserted between the posi ti ve
and negati ve pl ates to prevent them from contacti ng
or shorti ng agai nst one another. These di ssi mi l ar
metal pl ates are submerged i n a sul furi c aci d and
water sol uti on cal l ed an el ectrol yte.
The factory-i nstal l ed battery has a bui l t-i n test
i ndi cator (hydrometer). The col or vi si bl e i n the si ght
gl ass of the i ndi cator wi l l reveal the battery condi -
ti on. Refer to Standard Procedures for the proper
bui l t-i n i ndi cator test procedures. The factory-in-
stalled low-maintenance battery has non-re-
movable battery cell caps. Water cannot be added
to thi s battery. The battery i s not seal ed and has
vent hol es i n the cel l caps. The chemi cal composi ti on
of the metal coated pl ates wi thi n the l ow-mai nte-
nance battery reduces battery gassi ng and water
l oss, at normal charge and di scharge rates. There-
fore, the battery shoul d not requi re addi ti onal water
i n normal servi ce. Rapi d l oss of el ectrol yte can be
caused by an overchargi ng condi ti on. Be certai n to
di agnose the chargi ng system before returni ng the
vehi cl e to servi ce. Refer to Chargi ng System for the
proper chargi ng system di agnosi s and testi ng proce-
dures.
OPERATION
The battery i s desi gned to store el ectri cal energy i n
a chemi cal form. When an el ectri cal l oad i s appl i ed to
the termi nal s of the battery, an el ectrochemi cal reac-
ti on occurs. Thi s reacti on causes the battery to di s-
charge el ectri cal current from i ts termi nal s. As the
battery di scharges, a gradual chemi cal change takes
pl ace wi thi n each cel l . The sul furi c aci d i n the el ec-
trol yte combi nes wi th the pl ate materi al s, causi ng
both pl ates to sl owl y change to l ead sul fate. At the
same ti me, oxygen from the posi ti ve pl ate materi al
combi nes wi th hydrogen from the sul furi c aci d, caus-
i ng the el ectrol yte to become mai nl y water. The
chemi cal changes wi thi n the battery are caused by
the movement of excess or free el ectrons between the
posi ti ve and negati ve pl ate groups. Thi s movement of
el ectrons produces a fl ow of el ectri cal current
through the l oad devi ce attached to the battery ter-
mi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery i tsel f, the battery di schargi ng process
i s reversed. Chargi ng the battery gradual l y changes
the sul fated l ead pl ates back i nto sponge l ead and
l ead di oxi de, and the water back i nto sul furi c aci d.
Thi s acti on restores the di fference i n the el ectron
charges deposi ted on the pl ates, and the vol tage
potenti al of the battery cel l s. For a battery to remai n
useful , i t must be abl e to produce hi gh-amperage cur-
rent over an extended peri od. A battery must al so be
abl e to accept a charge, so that i ts vol tage potenti al
may be restored.
The battery i s vented to rel ease excess hydrogen
gas that i s created when the battery i s bei ng charged
or di scharged. However, even wi th these vents,
hydrogen gas can col l ect i n or around the battery. I f
hydrogen gas i s exposed to fl ame or sparks, i t may
i gni te. I f the el ectrol yte l evel i s l ow, the battery may
arc i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
Fig. 4 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - TEST INDICATOR
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
BATTERY (Continued)
DIAGNOSIS AND TESTING - BATTERY
The battery must be compl etel y charged and the
top, posts and termi nal cl amps shoul d be properl y
cl eaned and i nspected before di agnosti c procedures
are performed. Refer to Battery System Cl eani ng for
the proper cl eani ng procedures, and Battery System
I nspecti on for the proper battery i nspecti on proce-
dures. Refer to Standard Procedures for the proper
battery chargi ng procedures.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS ARE IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
The condi ti on of a battery i s determi ned by two cri -
teri a:
State-Of-Charge - Thi s can be determi ned by
checki ng the speci fi c gravi ty of the battery el ectrol yte
(bui l t-i n i ndi cator test or hydrometer test), or by
checki ng the battery vol tage (open-ci rcui t vol tage
test).
Cranking Capacity - Thi s can be determi ned
by performi ng a battery l oad test, whi ch measures
the abi l i ty of the battery to suppl y hi gh-amperage
current.
Fi rst, determi ne the battery state-of-charge. Thi s
can be done i n one of three ways. I f the battery has a
bui l t-i n test i ndi cator, perform the bui l t-i n i ndi cator
test to determi ne the state-of-charge. I f the battery
has no bui l t-i n test i ndi cator but does have remov-
abl e cel l caps, perform the hydrometer test to deter-
mi ne the state-of-charge. I f the battery cel l caps are
not removabl e, or a hydrometer i s not avai l abl e, per-
form the open-ci rcui t vol tage test to determi ne the
state-of-charge. Refer to open-ci rcui t vol tage test i n
the Standard Procedures secti on of thi s group.
Second, determi ne the battery cranki ng capaci ty by
performi ng a l oad test. The battery must be charged
before proceedi ng wi th a l oad test i f:
The battery bui l t-i n test i ndi cator has a bl ack or
dark col or vi si bl e.
The temperature corrected speci fi c gravi ty of the
battery el ectrol yte i s l ess than 1.235.
The battery open-ci rcui t vol tage i s l ess than 12.4
vol ts.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
A battery i s ful l y-charged when:
Al l battery cel l s are gassi ng freel y duri ng charg-
i ng.
A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty of the battery el ectrol yte.
Open-ci rcui t vol tage of the battery i s 12.4 vol ts
or greater.
STANDARD PROCEDURE - CHECKING BATTERY
ELECTROLYTE LEVEL
The fol l owi ng procedure can be used to check the
el ectrol yte l evel i n the battery.
(1) Remove the battery caps (Fi g. 5).
(2) Look through the battery cap hol es to deter-
mi ne the l evel of the el ectrol yte i n the battery (Fi g.
6). The el ectrol yte shoul d be approxi matel y 1 centi -
meter above the battery pl ates or unti l the hook
i nsi de the battery cap hol es i s covered.
(3) Add onl y di sti l l ed water unti l the el ectrol yte
l evel i s approx. one centi meter above the pl ates.
BATTERY (Continued)
STANDARD PROCEDURE - BATTERY
CHARGING
Battery chargi ng i s the means by whi ch the bat-
tery can be restored to i ts ful l vol tage potenti al . A
battery i s ful l y-charged when:
Al l of the battery cel l s are gassi ng freel y duri ng
battery chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
Three hydrometer tests, taken at one-hour i nter-
val s, i ndi cate no i ncrease i n the temperature-cor-
rected speci fi c gravi ty of the battery el ectrol yte.
Open-ci rcui t vol tage of the battery i s 12.65 vol ts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C [30 F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
AGE MAY RESULT.
OF THE CELL CAPS IS IN PLACE AND TIGHT
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
Fig. 5 Battery Caps - Export Battery
1 - BATTERY CAP
2 - BATTERY
Fig. 6 Hook Inside Battery Cap Holes - Export
Battery
1 - BATTERY SURFACE COVER
2 - HOOK
BATTERY (Continued)
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
NOTE: Models equipped with the diesel engine
option are equipped with two 12-volt batteries, con-
nected in parallel (positive-to-positive and negative-
to-negative). In order to ensure proper charging of
each battery, these batteries MUST be disconnected
from each other, as well as from the vehicle electri-
cal system, while being charged.
Some battery chargers are equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the battery
charger and the battery from bei ng damaged i f they
are i mproperl y connected. I f the battery state-of-
charge i s too l ow for the pol ari ty-sensi ng ci rcui try to
detect, the battery charger wi l l not operate. Thi s
makes i t appear that the battery wi l l not accept
chargi ng current. See the i nstructi ons provi ded by
the manufacturer of the battery charger for detai l s
on how to bypass the pol ari ty-sensi ng ci rcui try.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. Refer to Standard Procedures for
the proper battery l oad test procedures. I f the battery
wi l l endure a l oad test, return the battery to servi ce.
I f the battery wi l l not endure a l oad test, i t i s faul ty
and must be repl aced.
Cl ean and i nspect the battery hol d downs, tray,
termi nal s, posts, and top before compl eti ng battery
servi ce. Refer to Battery System Cl eani ng for the
proper battery system cl eani ng procedures, and Bat-
tery System I nspecti on for the proper battery system
i nspecti on procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 7). I f the
readi ng i s bel ow ten vol ts, the battery chargi ng cur-
rent wi l l be l ow. I t coul d take some ti me before the
battery accepts a current greater than a few mi l l i am-
peres. Such l ow current may not be detectabl e on the
ammeters bui l t i nto many battery chargers.
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the battery charger and
the battery from bei ng damaged i f they are i mprop-
erl y connected. I f the battery state-of-charge i s too
l ow for the pol ari ty-sensi ng ci rcui try to detect, the
battery charger wi l l not operate. Thi s makes i t
appear that the battery wi l l not accept chargi ng cur-
rent. See the i nstructi ons provi ded by the manufac-
turer of the battery charger for detai l s on how to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e chargi ng
current at vari ous vol tages i s shown i n the Charge
Rate Tabl e. I f the chargi ng current i s sti l l not mea-
surabl e at the end of the chargi ng ti me, the battery
i s faul ty and must be repl aced. I f the chargi ng cur-
rent i s measurabl e duri ng the chargi ng ti me, the bat-
tery may be good and the chargi ng shoul d be
compl eted i n the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Fig. 7 Voltmeter - Typical
BATTERY (Continued)
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast battery charger i s connected to a col d
battery, the current accepted by the battery wi l l be
very l ow at fi rst. As the battery warms, i t wi l l accept
a hi gher chargi ng current rate (amperage).
Charger Capacity - A battery charger that
suppl i es onl y fi ve amperes wi l l requi re a l onger
chargi ng ti me. A battery charger that suppl i es
twenty amperes or more wi l l requi re a shorter charg-
i ng ti me.
State-Of-Charge - A compl etel y di scharged bat-
tery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
The Battery Chargi ng Ti me Tabl e gi ves an i ndi ca-
ti on of the ti me requi red to charge a typi cal battery
at room temperature based upon the battery state-of-
charge and the charger capaci ty.
BATTERY CHARGING TIME TABLE
Charging
Amperage
5 Amps
10
Amps
20 Amps
Open Circuit
Voltage
Hours Charging @ 21C (70
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
An i ndi cator (hydrometer) bui l t i nto the top of the
battery case provi des vi sual i nformati on for battery
testi ng (Fi g. 8). Li ke a hydrometer, the bui l t-i n i ndi -
cator measures the speci fi c gravi ty of the battery
el ectrol yte. The speci fi c gravi ty of the el ectrol yte
reveal s the battery state-of-charge; however, i t wi l l
not reveal the cranki ng capaci ty of the battery. A l oad
test must be performed to determi ne the battery
the proper battery l oad test procedures.
AGE MAY RESULT.
CELL CAPS.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n i ndi cator,
i t i s i mportant that the battery be l evel and have a
cl ean si ght gl ass. Addi ti onal l i ght may be requi red to
vi ew the i ndi cator. Do not use open flame as a
source of additional light.
To read the bui l t-i n i ndi cator, l ook i nto the si ght
gl ass and note the col or of the i ndi cati on (Fi g. 9). The
battery condi ti on that each col or i ndi cates i s
descri bed i n the fol l owi ng l i st:
Fig. 8 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
BATTERY (Continued)
Green - I ndi cates 75% to 100% battery state-of-
charge. The battery i s adequatel y charged for further
testi ng or return to servi ce. I f the starter wi l l not
crank for a mi ni mum of fi fteen seconds wi th a ful l y-
charged battery, the battery must be l oad tested.
Refer to Standard Procedures for the proper battery
l oad test procedures.
Black or Dark - I ndi cates 0% to 75% battery
state-of-charge. The battery i s i nadequatel y charged
and must be charged unti l a green i ndi cati on i s vi si -
bl e i n the si ght gl ass (12.4 vol ts or more), before the
battery i s tested further or returned to servi ce. Refer
to Standard Procedures for the proper battery charg-
i ng procedures. Al so refer to Di agnosi s and Testi ng
for more i nformati on on the possi bl e causes of the
di scharged battery condi ti on.
Clear or Bright - I ndi cates a l ow battery el ec-
trol yte l evel . The el ectrol yte l evel i n the battery i s
bel ow the bui l t-i n i ndi cator. A mai ntenance-free bat-
tery wi th non-removabl e cel l caps must be repl aced i f
the el ectrol yte l evel i s l ow. Water must be added to a
l ow-mai ntenance battery wi th removabl e cel l caps
before i t i s charged. Refer to Standard Procedures for
the proper battery fi l l i ng procedures. A l ow el ectro-
l yte l evel may be caused by an overchargi ng condi -
ti on. Refer to Chargi ng System for the proper
chargi ng system di agnosi s and testi ng procedures.
STANDARD PROCEDURE - HYDROMETER TEST
The hydrometer test reveal s the battery state-of-
charge by measuri ng the speci fi c gravi ty of the el ec-
trol yte. This test cannot be performed on
maintenance-free batteries with non-removable
cell caps. I f the battery has non-removabl e cel l caps,
refer to Di agnosi s and Testi ng for al ternate methods
of determi ni ng the battery state-of-charge.
Speci fi c gravi ty i s a compari son of the densi ty of
the battery el ectrol yte to the densi ty of pure water.
Pure water has a speci fi c gravi ty of 1.000, and sul fu-
ri c aci d has a speci fi c gravi ty of 1.835. Sul furi c aci d
makes up approxi matel y 35% of the battery el ectro-
l yte by wei ght, or 24% by vol ume. I n a ful l y-charged
battery the el ectrol yte wi l l have a temperature-cor-
rected speci fi c gravi ty of 1.260 to 1.290. However, a
speci fi c gravi ty of 1.235 or above i s sati sfactory for
the battery to be l oad tested and/or returned to ser-
vi ce.
AGE MAY RESULT.
CELL CAPS.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. Then
remove the battery cel l caps and check the el ectrol yte
l evel . Add di sti l l ed water i f the el ectrol yte l evel i s
bel ow the top of the battery pl ates. Refer to Battery
System Cl eani ng for the proper battery i nspecti on
procedures.
See the i nstructi ons provi ded by the manufacturer
of the hydrometer for recommendati ons on the cor-
rect use of the hydrometer that you are usi ng.
Remove onl y enough el ectrol yte from the battery cel l
so that the fl oat i s off the bottom of the hydrometer
barrel wi th pressure on the bul b rel eased. To read
the hydrometer correctl y, hol d i t wi th the top surface
of the el ectrol yte at eye l evel (Fi g. 10).
CAUTION: Exercise care when inserting the tip of
the hydrometer into a battery cell to avoid damag-
ing the plate separators. Damaged plate separators
can cause early battery failure.
Fig. 9 Built-In Indicator Sight Glass Chart
BATTERY (Continued)
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at 26.7 C (80
F). When testi ng the speci fi c gravi ty at any other
temperature, a correcti on factor i s requi red. The cor-
recti on factor i s approxi matel y a speci fi c gravi ty
val ue of 0.004, whi ch may al so be i denti fi ed as four
poi nts of speci fi c gravi ty. For each 5.5 C above 26.7
C (10 F above 80 F), add four poi nts. For each 5.5
C bel ow 26.7 C (10 F bel ow 80 F), subtract four
poi nts. Al ways correct the speci fi c gravi ty for temper-
ature vari ati on.
EXAMPLE: A battery i s tested at -12.2 C (10 F)
and has a speci fi c gravi ty of 1.240. Determi ne the
actual speci fi c gravi ty as fol l ows:
(1) Determi ne the number of degrees above or
bel ow 26.7 C (80 F): 26.6 C - -12.2 C =38.8 C
(80 F - 10 F =70 F)
(2) Di vi de the resul t from Step 1 by 5.5 C (10
F): 38.8 C 5.5 C =7 (70 F 10 F =7)
(3) Mul ti pl y the resul t from Step 2 by the temper-
ature correcti on factor (0.004): 7 X 0.004 =0.028
(4) The temperature at testi ng was bel ow 26.7 C
(80 F); therefore, the temperature correcti on factor
i s subtracted: 1.240 - 0.028 =1.212
(5) The corrected speci fi c gravi ty of the battery cel l
i n thi s exampl e i s 1.212.
Test the speci fi c gravi ty of the el ectrol yte i n each
battery cel l . I f the speci fi c gravi ty of al l cel l s i s above
1.235, but the vari ati on between cel l s i s more than
fi fty poi nts (0.050), the battery shoul d be repl aced. I f
the speci fi c gravi ty of one or more cel l s i s l ess than
1.235, charge the battery at a rate of approxi matel y
fi ve amperes. Conti nue chargi ng the battery unti l
three consecuti ve speci fi c gravi ty tests, taken at one-
hour i nterval s, are constant. I f the cel l speci fi c grav-
i ty vari ati on i s more than fi fty poi nts (0.050) at the
end of the charge peri od, repl ace the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235,
and the cel l vari ati on i s l ess than fi fty poi nts (0.050),
the battery may be l oad tested to determi ne i ts
the proper battery l oad test procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the approxi mate state-of-charge of a battery.
Thi s test can be used i n pl ace of the hydrometer test
when a hydrometer i s not avai l abl e, or for mai nte-
nance-free batteri es wi th non-removabl e cel l caps.
AGE MAY RESULT.
CELL CAPS.
Fig. 10 Hydrometer - Typical
1 - BULB
2 - SURFACE COHESION
3 - SPECIFIC GRAVITY READING
4 - TEMPERATURE READING
5 - HYDROMETER BARREL
6 - FLOAT
BATTERY (Continued)
Before proceedi ng wi th thi s test, compl etel y charge
the battery. Refer to Standard Procedures for the
proper battery chargi ng procedures.
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the headl amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (see the i nstructi ons provi ded by the manufac-
turer of the vol tmeter), measure the open-ci rcui t vol t-
age (Fi g. 11).
See the Open-Ci rcui t Vol tage Tabl e. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty. Refer to Standard Procedures for the proper
battery l oad test procedures.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
STANDARD PROCEDURE - LOAD TEST
A battery l oad test wi l l veri fy the battery cranki ng
capaci ty. The test i s based on the Col d Cranki ng
Amperage (CCA) rati ng of the battery. To determi ne
the battery CCA rati ng, see the l abel affi xed to the
battery case or refer to Battery Speci fi cati ons for the
proper factory-i nstal l ed speci fi cati ons.
AGE MAY RESULT.
CELL CAPS.
Before proceedi ng wi th thi s test, compl etel y charge
the battery. Refer to Standard Procedures for the
proper battery chargi ng procedures.
(1) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst. The battery top and posts shoul d be
cl ean. Refer to Battery System Cl eani ng for the
proper cl eani ng procedures.
(2) Connect a sui tabl e vol t-ammeter-l oad tester
(Fi g. 12) to the battery posts (Fi g. 13). See the
i nstructi ons provi ded by the manufacturer of the
tester you are usi ng. Check the open-ci rcui t vol tage
(no l oad) of the battery. Refer to Standard Procedures
for the proper battery open-ci rcui t vol tage test proce-
dures. The battery open-ci rcui t vol tage must be 12.4
vol ts or greater.
(3) Rotate the l oad control knob (carbon pi l e rheo-
stat) to appl y a 300 ampere l oad to the battery for
fi fteen seconds, then return the control knob to the
Off posi ti on (Fi g. 14). Thi s wi l l remove the surface
charge from the battery.
(4) Al l ow the battery to stabi l i ze to open-ci rcui t
vol tage. I t may take up to fi ve mi nutes for the bat-
tery vol tage to stabi l i ze.
(5) Rotate the l oad control knob to mai ntai n a l oad
equal to 50% of the CCA rati ng of the battery (Fi g.
15). After fi fteen seconds, record the l oaded vol tage
readi ng, then return the l oad control knob to the Off
posi ti on.
Fig. 11 Testing Open-Circuit Voltage - Typical
BATTERY (Continued)
(6) The vol tage drop wi l l vary wi th the battery
temperature at the ti me of the l oad test. The battery
temperature can be esti mated by usi ng the ambi ent
temperature duri ng the past several hours. I f the
battery has been charged, boosted, or l oaded a few
mi nutes pri or to the test, the battery wi l l be some-
what warmer. See the Load Test Temperature Tabl e
for the proper l oaded vol tage readi ng.
LOAD TEST TEMPERATURE TABLE
Minimum Voltage
Temperature
F C
9.6 volts 70and above 21and above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
(7) I f the vol tmeter readi ng fal l s bel ow 9.6 vol ts, at
a mi ni mum battery temperature of 21 C (70 F), the
battery i s faul ty and must be repl aced.
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term I gni ti on-Off Draw (I OD) i denti fi es a nor-
mal condi ti on where power i s bei ng drai ned from the
battery wi th the i gni ti on swi tch i n the Off posi ti on. A
normal vehi cl e el ectri cal system wi l l draw from fi ve
to thi rty-fi ve mi l l i amperes (0.005 to 0.035 ampere)
wi th the i gni ti on swi tch i n the Off posi ti on, and al l
non-i gni ti on control l ed ci rcui ts i n proper worki ng
order. Up to thi rty-fi ve mi l l i amperes are needed to
enabl e the memory functi ons for the Powertrai n Con-
trol Modul e (PCM), di gi tal cl ock, el ectroni cal l y tuned
radi o, and other modul es whi ch may vary wi th the
vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
Fig. 12 Volt-Ammeter-Load Tester - Typical
Fig. 13 Volt-Ammeter-Load
1 - INDUCTION AMMETER CLAMP
2 - NEGATIVE CLAMP
3 - POSITIVE CLAMP
Fig. 14 Remove Surface Charge from Battery
Fig. 15 Load 50% CCA Rating - Note Voltage -
Typical
BATTERY (Continued)
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on.
Faul ty or i mproperl y adjusted swi tches.
Faul ty or shorted el ectroni c modul es and compo-
nents.
An i nternal l y shorted generator.
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th an i l l umi -
nated entry system or an el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes. See the El ectroni c Modul e I gni -
ti on-Off Draw Tabl e for more i nformati on.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Module
Time Out?
(If Yes, Interval And Wake-Up Input)
IOD
IOD After Time
Out
Radio No
1 to 3
milliamperes
N/A
Audio Power
Amplifier
No
up to 1
milliampere
N/A
Central Timer Module
(CTM)
No
4.75
milliamperes
(max.)
N/A
Powertrain Control
Module (PCM)
No 0.95 milliampere N/A
ElectroMechanical
Instrument Cluster
(EMIC)
No 0.44 milliampere N/A
Combination Flasher No 0.08 milliampere N/A
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then di sconnect the l amp wi re harness
connector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e ter-
mi nal cl amp and the battery negati ve termi nal post.
Make sure that the doors remai n cl osed so that the
i l l umi nated entry system i s not acti vated. The mul ti -
meter amperage readi ng may remai n hi gh for up to
three mi nutes, or may not gi ve any readi ng at al l
whi l e set i n the hi ghest amperage scal e, dependi ng
upon the el ectri cal equi pment i n the vehi cl e. The
mul ti -meter l eads must be securel y cl amped to the
battery negati ve cabl e termi nal cl amp and the bat-
tery negati ve termi nal post. I f conti nui ty between the
battery negati ve termi nal post and the negati ve cabl e
termi nal cl amp i s l ost duri ng any part of the I OD
test, the el ectroni c ti mer functi on wi l l be acti vated
and al l of the tests wi l l have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment i n the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove and repl ace each fuse or ci rcui t
breaker i n the Power Di stri buti on Center (PDC) and
then i n the Juncti on Bl ock (JB), one at a ti me unti l
the amperage readi ng becomes very l ow, or nonexi st-
ent. Refer to the appropri ate wi ri ng i nformati on i n
thi s servi ce manual for compl ete PDC and JB fuse,
ci rcui t breaker, and ci rcui t i denti fi cati on. Thi s wi l l
i sol ate each ci rcui t and i denti fy the ci rcui t that i s the
source of the hi gh-amperage I OD. I f the amperage
readi ng remai ns hi gh after removi ng and repl aci ng
each fuse and ci rcui t breaker, di sconnect the wi re
harness from the generator. I f the amperage readi ng
now becomes very l ow or nonexi stent, refer to Charg-
i ng System for the proper chargi ng system di agnosi s
and testi ng procedures. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker remove-and-re-
BATTERY (Continued)
pl ace process to i denti fy and correct al l sources of
excessi ve I OD. I t i s now safe to sel ect the l owest mi l -
l i ampere scal e of the mul ti -meter to check the l ow-
amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty-fi ve mi l l i am-
peres (0.035 ampere). I f the current draw exceeds
thi rty-fi ve mi l l i amperes, i sol ate each ci rcui t usi ng the
fuse and ci rcui t breaker remove-and-repl ace process
i n Step 5. The mul ti -meter readi ng wi l l drop to
wi thi n the acceptabl e l i mi t when the source of the
excessi ve current draw i s di sconnected. Repai r thi s
ci rcui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post (Fi g. 16).
(4) Loosen the battery posi ti ve cabl e termi nal
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Remove the battery hol d downs from the bat-
tery. Refer to Battery Hold Downs i n thi s secti on
for the l ocati on of the proper battery hol d down
removal procedures.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery from the battery tray.
INSTALLATION
(1) Cl ean and i nspect the battery. Refer to Bat-
tery System i n thi s secti on for the l ocati on of the
proper battery cl eani ng and i nspecti on procedures.
(2) Posi ti on the battery onto the battery tray.
Ensure that the battery posi ti ve and negati ve termi -
nal posts are correctl y posi ti oned. The battery cabl e
termi nal cl amps must reach the correct battery ter-
mi nal post wi thout stretchi ng the cabl es (Fi g. 17).
(3) Rei nstal l the battery hol d downs onto the bat-
tery. Refer to Battery Hold Downs i n thi s secti on
for the l ocati on of the proper battery hol d down
i nstal l ati on procedures.
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reverse battery polarity may damage
electrical components of the vehicle.
(4) Cl ean the battery cabl e termi nal cl amps and
the battery termi nal posts. Refer to Battery i n thi s
secti on for the l ocati on of the proper battery cl eani ng
and i nspecti on procedures.
(5) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
Fig. 16 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
Fig. 17 Battery Cables
1 - POWER DISTRIBUTION CENTER
2 - CLIP
3 - BATTERY
4 - TRAY
5 - NEGATIVE CABLE
6 - POSITIVE CABLE
7 - CLIP
8 - WHEELHOUSE INNER PANEL
BATTERY (Continued)
the termi nal cl amp pi nch-bol t hex nut to 7.9 Nm (70
i n. l bs.).
(6) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
i n. l bs.).
(7) Appl y a thi n coati ng of petrol eum jel l y or chas-
si s grease to the exposed surfaces of the battery cabl e
termi nal cl amps and the battery termi nal posts.
BATTERY HOLDDOWN
DESCRIPTION
The battery hol d down hardware (Fi g. 18) i ncl udes
two bol ts, two U-nuts and a hol d down strap/battery
thermoguard uni t. The mol ded pl asti c battery hol d
down strap i s i ntegral to the battery thermoguard
uni t, whi ch encl oses the si des of the battery case.
When i nstal l i ng a battery i nto the battery tray, be
certai n that the hol d down hardware i s properl y
i nstal l ed and that the fasteners are ti ghtened to the
proper speci fi cati ons. I mproper hol d down fastener
ti ghtness, whether too l oose or too ti ght, can resul t i n
damage to the battery, the vehi cl e or both. Refer to
Battery Hold Downs i n thi s secti on for the l ocati on
of the proper battery hol d down i nstal l ati on proce-
dures, i ncl udi ng the proper hol d down fastener ti ght-
ness speci fi cati ons.
OPERATION
The battery hol ddown secures the battery i n the
battery tray. Thi s hol ddown i s desi gned to prevent
battery movement duri ng the most extreme vehi cl e
operati on condi ti ons. Peri odi c removel and l ubri ca-
ti on of the battery hol ddown hardware i s recomended
to prevent hardware sei zure at a l ater date.
NOTE: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post.
(4) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(5) Remove the two hol d down bol ts that secure
the hol d down strap/battery thermal guard uni t to
the U-nuts i n the battery tray (Fi g. 19).
(6) Remove the hol d down strap/battery thermal
guard uni t from the top of the battery case.
INSTALLATION
(1) Cl ean and i nspect the battery hol d down hard-
ware. Refer to Battery i n the i ndex of thi s servi ce
manual for the l ocati on of the proper battery hol d
down hardware cl eani ng and i nspecti on procedures.
(2) I nstal l the hol d down strap/battery thermo-
guard uni t over the top of the battery case.
(3) I nstal l and ti ghten the two hol d down bol ts
that secure the hol d down strap/battery thermoguard
uni t to the U-nuts i n the battery tray. Ti ghten the
bol ts to 2.1 Nm (19 i n. l bs.).
(4) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
Fig. 18 Battery Hold Downs
1 - CLIPS
2 - BOLT
3 - TRAY
4 - BATTERY
5 - HOLD DOWN STRAP AND THERMAL GUARD
6 - POSITIVE CABLE
7 - NEGATIVE CABLE
BATTERY (Continued)
i n. l bs.).
(5) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
i n. l bs.).
BATTERY CABLE
DESCRIPTION
The battery cabl es (Fi g. 20) are l arge gauge,
stranded copper wi res sheathed wi thi n a heavy pl as-
ti c or syntheti c rubber i nsul ati ng jacket. The wi re
used i n the battery cabl es combi nes excel l ent fl exi bi l -
i ty and rel i abi l i ty wi th hi gh el ectri cal current carry-
i ng capaci ty. Refer to Wiring Diagrams i n the i ndex
of thi s servi ce manual for the l ocati on of the proper
battery cabl e wi re gauge i nformati on.
The battery cabl es cannot be repai red and, i f dam-
aged or faul ty they must be repl aced. Both the bat-
tery posi ti ve and negati ve cabl es are avai l abl e for
servi ce repl acement onl y as a uni t wi th the battery
posi ti ve cabl e wi re harness or the battery negati ve
cabl e wi re harness, whi ch may i ncl ude porti ons of
the wi ri ng ci rcui ts for the generator and other com-
ponents on some model s. Refer to Wiring Diagrams
i n the i ndex of thi s servi ce manual for the l ocati on of
more i nformati on on the vari ous wi ri ng ci rcui ts
i ncl uded i n the battery cabl e wi re harnesses for the
vehi cl e bei ng servi ced.
The battery cabl es feature a stamped brass cl amp-
i ng type femal e battery termi nal cri mped onto one
end of the battery cabl e wi re and then sol der-di pped.
A square headed pi nch-bol t and hex nut are i nstal l ed
at the open end of the femal e battery termi nal cl amp.
The battery posi ti ve cabl e al so i ncl udes a red mol ded
rubber protecti ve cover for the femal e battery termi -
nal cl amp. Large eyel et type termi nal s are cri mped
onto the opposi te end of the battery cabl e wi re and
then sol der-di pped. The battery posi ti ve cabl e wi res
have a red i nsul ati ng jacket to provi de vi sual i denti -
fi cati on and feature a l arger femal e battery termi nal
cl amp to al l ow connecti on to the l arger battery posi -
ti ve termi nal post. The battery negati ve cabl e wi res
have a bl ack i nsul ati ng jacket and a smal l er femal e
battery termi nal cl amp.
OPERATION
The battery cabl es connect the battery termi nal
posts to the vehi cl e el ectri cal system. These cabl es
al so provi de a return path for el ectri cal current gen-
Fig. 19 Battery Hold Downs Remove/Install
1 - CLIPS
2 - BOLT
3 - TRAY
4 - BATTERY
5 - HOLD DOWN STRAP AND THERMAL GUARD
6 - POSITIVE CABLE
7 - NEGATIVE CABLE
Fig. 20 Battery Cables
2 - CLIP
3 - BATTERY
4 - TRAY
5 - NEGATIVE CABLE
6 - POSITIVE CABLE
7 - CLIP
BATTERY HOLDDOWN (Continued)
erated by the chargi ng system for restori ng the vol t-
age potenti al of the battery. The femal e battery
termi nal cl amps on the ends of the battery cabl e
wi res provi de a strong and rel i abl e connecti on of the
battery cabl e to the battery termi nal posts. The ter-
mi nal pi nch bol ts al l ow the femal e termi nal cl amps
to be ti ghtened around the mal e termi nal posts on
the top of the battery. The eyel et termi nal s secured
to the ends of the battery cabl e wi res opposi te the
femal e battery termi nal cl amps provi de secure and
rel i abl e connecti on of the battery to the vehi cl e el ec-
tri cal system.
DIAGNOSIS & TESTING - BATTERY CABLES
DIAGNOSIS
A vol tage drop test wi l l determi ne i f there i s exces-
si ve resi stance i n the battery cabl e termi nal connec-
ti ons or the battery cabl es. I f excessi ve resi stance i s
found i n the battery cabl e connecti ons, the connec-
ti on poi nt shoul d be di sassembl ed, cl eaned of al l cor-
rosi on or forei gn materi al , then reassembl ed.
Fol l owi ng reassembl y, check the vol tage drop for the
battery cabl e connecti on and the battery cabl e agai n
to confi rm repai r.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
TESTING
VOLTAGE DROP TEST
WARNING:
I F THE BATTERY SHOWS SI GNS OF FREEZ-
I NG, LEAKI NG, LOOSE POSTS, OR LOW ELEC-
TROLYTE LEVEL, DO NOT TEST, ASSI ST-BOOST,
OR CHARGE. THE BATTERY MAY ARC I NTER-
NALLY AND EXPLODE. PERSONAL I NJURY
AND/OR VEHI CLE DAMAGE MAY RESULT.
EXPLOSI VE HYDROGEN GAS FORMS I N
USE FLAME, OR CREATE SPARKS NEAR THE
BATTERY. PERSONAL I NJURY AND/OR VEHI CLE
DAMAGE MAY RESULT.
THE BATTERY CONTAI NS SULFURI C ACI D,
WHI CH I S POI SONOUS AND CAUSTI C. AVOI D
CONTACT WI TH THE SKI N, EYES, OR CLOTH-
I NG. I N THE EVENT OF CONTACT, FLUSH WI TH
WATER AND CALL A PHYSI CI AN I MMEDI ATELY.
KEEP OUT OF THE REACH OF CHI LDREN.
I F THE BATTERY I S EQUI PPED WI TH
REMOVABLE CELL CAPS, BE CERTAI N THAT
EACH OF THE CELL CAPS I S I N PLACE AND
TI GHT BEFORE THE BATTERY I S RETURNED TO
SERVI CE. PERSONAL I NJURY AND/OR VEHI CLE
DAMAGE MAY RESULT FROM LOOSE OR MI SS-
I NG CELL CAPS.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
The battery i s ful l y-charged and l oad tested.
Refer to Battery Charging i n the i ndex of thi s ser-
vi ce manual for the l ocati on of the proper battery
chargi ng procedures. Refer to Battery i n the i ndex of
thi s servi ce manual for the l ocati on of the battery
di agnosi s and testi ng procedures, i ncl udi ng the
proper battery l oad test procedures.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 21). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
necti on between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
BATTERY CABLE (Continued)
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 22). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 23). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 24). Rotate
and hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
Fig. 21 Test Battery Negative Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 22 Test Battery Positive Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
Fig. 23 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 24 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
BATTERY CABLE (Continued)
BATTERY TRAY
DESCRIPTION
The battery i s mounted i n a mol ded pl asti c tray
(Fi g. 25) l ocated i n the l eft front corner of the engi ne
compartment. The battery tray i s secured on the
i nboard si de wi th screws to a stamped steel battery
tray support l ocated on the l eft si de of the radi ator,
on the outboard si de wi th screws to the front exten-
si on of the l eft front wheel house i nner panel and at
the front to the front cl osure panel on the l eft si de of
the radi ator yoke. The battery tray support i s
secured at the front wi th screws to the l eft si de of
the radi ator yoke, and at the rear wi th a screw to the
front extensi on of the l eft front wheel house i nner
panel .
A hol e i n the bottom of the battery tray i s fi tted
wi th a battery temperature sensor. Refer to Battery
Temperature Sensor i n the i ndex of thi s servi ce
manual for the l ocati on of more i nformati on on the
battery temperature sensor. The battery tray al so
i ncl udes two stanchi ons that are mol ded i nto the rear
of the tray, whi ch support the forward end of the
Power Di stri buti on Center (PDC). Refer to Power
Distribution Center i n the i ndex of thi s servi ce
PDC mounti ng.
OPERATION
The battery tray provi des a secure mounti ng l oca-
ti on and supports the battery. On some vehi cl es, the
battery tray al so provi des the anchor poi nt/s for the
battery hol ddown hardware. The battery tray and
the battery hol ddown hardware combi ne to secure
and stabi l i ze the battery i n the engi ne compartment,
whi ch prevents battery movement duri ng vehi cl e
operati on. Unrestrai ned battery movement duri ng
vehi cl e operati on coul d resul t i n damage to the vehi -
cl e, the battery, or both.
REMOVAL
(1) Remove the battery from the battery tray.
Refer to Battery i n the i ndex of thi s servi ce manual
for the l ocati on of the proper battery removal proce-
dures.
(2) Remove the Power Di stri buti on Center (PDC)
from the stanchi ons on the rear of the battery tray.
Refer to Power Distribution Center i n the i ndex of
thi s servi ce manual for the l ocati on of the proper
PDC removal procedures.
(3) Remove the two screws that secure the i nboard
si de of the battery tray to the battery tray support
(Fi g. 26).
(4) Remove the two screws that secure the out-
board si de of the battery tray to the front extensi on
of the l eft front wheel house i nner panel .
(5) Remove the one screw that secures the front of
the battery tray to the front cl osure panel on the l eft
si de of the radi ator yoke.
(6) Remove the battery temperature sensor from
the battery tray. Refer to Battery Temperature
Sensor i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery temperature sensor
removal procedures.
(7) Remove the battery tray from the battery tray
support and the front extensi on of the l eft front
wheel house i nner panel .
(8) Remove the one screw that secures the rear of
the battery tray support to the front extensi on of the
l eft front wheel house i nner panel .
(9) Remove the two screws that secure the front of
the battery tray support to the l eft si de of the radi a-
tor yoke.
(10) Remove the battery tray support from the l eft
front wheel house i nner panel and the l eft si de of the
radi ator yoke.
Fig. 25 Battery Tray
1 - SCREW
2 - SENSOR
3 - YOKE
4 - SCREW
5 - SUPPORT
6 - SCREW
8 - TRAY
9 - SCREW
INSTALLATION
(1) Cl ean and i nspect the battery tray. Refer to
Battery i n the i ndex of thi s servi ce manual for the
l ocati on of the proper battery tray cl eani ng and
i nspecti on procedures.
(2) Posi ti on the battery tray support onto the l eft
front wheel house i nner panel and the l eft si de of the
radi ator yoke.
the battery tray support to the l eft si de of the radi a-
tor yoke. Ti ghten the screws to 11.3 Nm (100 i n.
l bs.).
(4) I nstal l and ti ghten the one screw that secures
the rear of the battery tray support to the front
extensi on of the l eft front wheel house i nner panel .
Ti ghten the screw to 11.3 Nm (100 i n. l bs.).
(5) I nstal l the battery temperature sensor onto the
battery tray. Refer to Battery Temperature Sensor
the proper battery temperature sensor i nstal l ati on
procedures.
(6) Posi ti on the battery tray onto the battery tray
support and the front extensi on of the l eft front
wheel house i nner panel . Be certai n that the battery
temperature sensor wi ri ng i s properl y routed.
(7) I nstal l and ti ghten the two screws (rear screw
fi rst) that secure the outboard si de of the battery
tray to the front extensi on of the l eft front wheel -
house i nner panel . Ti ghten the screws to 12.4 Nm
(110 i n. l bs.).
the i nboard si de of the battery tray to the battery
tray support. Ti ghten the screws to 12.4 Nm (110 i n.
l bs.).
the front of the battery tray to the front cl osure
panel on the l eft si de of the radi ator yoke. Ti ghten
the screw to 12.4 Nm (110 i n. l bs.).
(10) I nstal l the Power Di stri buti on Center (PDC)
onto the stanchi ons on the rear of the battery tray.
Refer to Power Distribution Center i n the i ndex of
thi s servi ce manual for the l ocati on of the proper
PDC i nstal l ati on procedures.
(11) I nstal l the battery onto the battery tray. Refer
to Battery i n the i ndex of thi s servi ce manual for
the l ocati on of the proper battery i nstal l ati on proce-
dures.
Fig. 26 Battery Tray Remove/Install
1 - SCREW
2 - SENSOR
3 - YOKE
4 - SCREW
5 - SUPPORT
6 - SCREW
8 - TRAY
9 - SCREW
BATTERY TRAY (Continued)
CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 25
BATTERY TEMPERATURE SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
VOLTAGE REGULATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHARGING
DESCRIPTION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
I gni ti on swi tch (refer to 8, I gni ti on System for
i nformati on)
Battery (refer to 8, Battery for i nformati on)
Battery temperature sensor
Generator Lamp (i f equi pped)
Check Gauges Lamp (i f equi pped)
Vol tmeter (refer to 8, I nstrument Panel and
Gauges for i nformati on)
Wi ri ng harness and connecti ons (refer to 8, Wi r-
i ng for i nformati on)
OPERATION
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. The system i s on when the engi ne i s
runni ng and the ASD rel ay i s energi zed. When the
ASD rel ay i s on, vol tage i s suppl i ed to the ASD rel ay
sense ci rcui t at the PCM. Thi s vol tage i s connected
through the PCM and suppl i ed to one of the genera-
tor fi el d termi nal s (Gen. Source +) at the back of the
generator.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng EVR
(fi el d control ) ci rcui try, are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for certai n fai l ures i t detects. Refer to
Di agnosti c Troubl e Codes i n; Powertrai n Control
Modul e; El ectroni c Control Modul es for more DTC
i nformati on.
The Check Gauges Lamp (i f equi pped) moni tors:
charging system voltage, engi ne cool ant tempera-
ture and engi ne oi l pressure. I f an extreme condi ti on
i s i ndi cated, the l amp wi l l be i l l umi nated. Thi s i s
done as remi nder to check the three gauges. The si g-
nal to acti vate the l amp i s sent vi a the CCD bus ci r-
cui ts. The l amp i s l ocated on the i nstrument panel .
Refer to 8, I nstrument Panel and Gauges for addi -
ti onal i nformati on.
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
the check gauges l amp (i f equi pped) i s i l l umi -
nated wi th the engi ne runni ng
the vol tmeter (i f equi pped) does not regi ster
properl y
an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
accessori es bei ng l eft on wi th the engi ne not
runni ng
8F - 24 CHARGING AN
a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. Refer to I gni ti on-Off Draw
Test i n 8, Battery for more i nformati on.
INSPECTION
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some chargi ng system ci rcui ts are
checked conti nuousl y, and some are checked onl y
under certai n condi ti ons.
Refer to Di agnosti c Troubl e Codes i n; Powertrai n
Control Modul e; El ectroni c Control Modul es for more
DTC i nformati on. Thi s wi l l i ncl ude a compl ete l i st of
DTCs i ncl udi ng DTCs for the chargi ng system.
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to 8, Bat-
tery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n 7, Cool i ng System.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to 7, Cool i ng System for i nformati on.
(7) I nspect generator el ectri cal connecti ons at gen-
erator fi el d, battery output, and ground termi nal (i f
equi pped). Al so check generator ground wi re connec-
ti on at engi ne (i f equi pped). They shoul d al l be cl ean
and ti ght. Repai r as requi red.
SPECIFICATIONS
SPECIFICATIONS - GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56028686AA 117 2.5L 88
DENSO 56028687AA 136 2.5L 95
DENSO 56029913AA 117 3.9L/5.9L 90
DENSO 56030914AA 136 3.9L/5.9L 100
DENSO 56041693AB 136 4.7L 100
DENSO 56028692AA 117 4.7L 90
SPECIFICATIONS - TORQUE- CHARGING SYSTEM
Generator Mounting Bolt - 3.9L/5.9L Engines 41 30
Generator Pivot Bolt -3.9L/5.9L Engines 41 30
Generator Mounting Bolt 2.5L Engine 55 41
Generator Pivot Bolt - 2.5L Engine 55 41
Generator Vertical Mounting Bolt - 4.7L V-8 Engine 55 40
Generator (long) Horizontal Mounting Bolt - 4.7L V-8 Engine 55 40
Generator (short) Horizontal Mounting Bolt - 4.7L V-8 Engine 74 55
Generator B+ Output Cable Terminal Nut 12 108
AN CHARGING 8F - 25
CHARGING (Continued)
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) i s attached
to the battery tray l ocated under the battery.
OPERATION
The BTS i s used to determi ne the battery temper-
ature and control battery chargi ng rate. Thi s temper-
ature data, al ong wi th data from moni tored l i ne
vol tage, i s used by the PCM to vary the battery
chargi ng rate. System vol tage wi l l be hi gher at col der
temperatures and i s gradual l y reduced at warmer
temperatures.
The PCM sends 5 vol ts to the sensor and i s
grounded through the sensor return l i ne. As temper-
ature i ncreases, resi stance i n the sensor decreases
and the detecti on vol tage at the PCM i ncreases.
The BTS i s al so used for OBD I I di agnosti cs. Cer-
tai n faul ts and OBD I I moni tors are ei ther enabl ed
or di sabl ed, dependi ng upon BTS i nput (for exampl e,
di sabl e purge and enabl e Leak Detecti on Pump
(LDP) and O2 sensor heater tests). Most OBD I I
moni tors are di sabl ed bel ow 20 degrees F.
REMOVAL
The battery temperature sensor i s l ocated under
vehi cl e battery (Fi g. 1) and i s attached to a mounti ng
hol e on battery tray.
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Di sconnect sensor pi gtai l harness from engi ne
wi re harness. Sensor pi gtai l harness i s cl i pped to
vehi cl e near i ts el ectri cal connector.
(3) Pry sensor strai ght up from battery tray
mounti ng hol e.
INSTALLATION
The battery temperature sensor i s l ocated under
vehi cl e battery (Fi g. 1) and i s attached to a mounti ng
hol e on battery tray.
(1) Feed pi gtai l harness through hol e i n top of bat-
tery tray and press sensor i nto top of battery tray.
(2) Connect pi gtai l harness.
(3) I nstal l battery. Refer to 8, Battery for proce-
dures.
GENERATOR
DESCRIPTION
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
OPERATION
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator battery termi nal .
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
Fig. 1 Battery Temperature Sensor Location
1 - BATTERY TEMPERATURE SENSOR
2 - BATTERY TRAY
8F - 26 CHARGING AN
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(2) Remove generator dri ve bel t. Refer to Group 7,
Cool i ng System for procedures.
(3) Unsnap pl asti c cabl e protector cover from B+
mounti ng stud.
(4) 2.5L/3.9L/5.9L Engi nes: Remove generator
pi vot and mounti ng bol ts/nut (Fi g. 2) or (Fi g. 3). Posi -
ti on generator for access to wi re connectors.
(5) 4.7L Engi ne: Remove 3 generator mounti ng
bol ts (Fi g. 4). Posi ti on generator for access to wi re
connectors.
(6) Remove B+ termi nal mounti ng nut at rear of
generator (Fi g. 5) or (Fi g. 6). Di sconnect termi nal
from generator.
(7) Di sconnect fi el d wi re connector at rear of gen-
erator by pushi ng on connector tab and pul l i ng con-
nector from generator.
(8) Remove generator from vehi cl e.
INSTALLATION
(1) Posi ti on generator to engi ne and snap fi el d
wi re connector i nto rear of generator.
(2) I nstal l B+ termi nal to generator mounti ng
stud. Ti ghten mounti ng nut to 12 Nm (108 i n. l bs.)
torque.
Fig. 2 Remove/Install Generator2.5L
1 - UPPER MOUNTING BRACKET
2 - GENERATOR
3 - UPPER BOLT
4 - LOWER BOLT
5 - SPACER
Fig. 3 Remove/Install Generator3.9L/5.9L Engines
1 - MOUNTING BOLT
2 - GENERATOR
4 - MOUNTING BOLT/NUT
Fig. 4 Remove/Install Generator4.7L V-8 Engine
1 - LOWER BOLTS
2 - REAR BOLT
3 - GENERATOR
AN CHARGING 8F - 27
GENERATOR (Continued)
(3) I nstal l generator mounti ng fasteners and
ti ghten as fol l ows:
Generator mounti ng bol t 3.9L/5.9L engi nes41
Generator pi vot bol t/nut 3.9L/5.9L engi nes41
Generator mounti ng bol t 2.5L engi ne55 Nm
(41 ft. l bs.) torque.
Generator pi vot bol t 2.5L engi ne55 Nm (41 ft.
l bs.) torque.
Verti cal mounti ng bol t 4.7L engi ne55 Nm (40
ft. l bs.)
Long hori zontal mounti ng bol t 4.7L engi ne55
Nm (40 ft. l bs.)
Short hori zontal mounti ng bol t 4.7L engi ne74
Nm (55 ft. l bs.)
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.
(4) I nstal l generator dri ve bel t. Refer to 7, Cool i ng
System for procedure.
(5) Snap cabl e protector cover to B+ mounti ng stud.
(6) I nstal l negati ve battery cabl e to battery.
VOLTAGE REGULATOR
DESCRIPTION
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
OPERATION
The amount of DC current produced by the generator
i s control l ed by EVR ci rcui try contai ned wi thi n the
PCM. Thi s ci rcui try i s connected i n seri es wi th the gen-
erators second rotor fi el d termi nal and i ts ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more i nformati on). I t then determi nes a
target chargi ng vol tage. I f sensed battery vol tage i s
0.5 vol ts or l ower than the target vol tage, the PCM
grounds the fi el d wi ndi ng unti l sensed battery vol t-
age i s 0.5 vol ts above target vol tage. A ci rcui t i n the
PCM cycl es the ground si de of the generator fi el d up
to 100 ti mes per second (100Hz), but has the capabi l -
i ty to ground the fi el d control wi re 100% of the ti me
(ful l fi el d) to achi eve the target vol tage. I f the charg-
i ng rate cannot be moni tored (l i mp-i n), a duty cycl e
of 25% i s used by the PCM i n order to have some
generator output. Al so refer to Chargi ng System
Operati on for addi ti onal i nformati on.
Fig. 5 Generator ConnectorsTypical Bosch
1 - FIELD WIRE CONNECTOR
2 - FIELD WIRES
3 - B+ (OUTPUT TERMINAL)
Fig. 6 Generator ConnectorsTypical Denso
1 - FIELD WIRES
2 - B+ (OUTPUT TERMINAL)
3 - FIELD WIRE CONNECTOR
8F - 28 CHARGING AN
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STARTER MOTOR RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
STARTING
DESCRIPTION
The starti ng system consi sts of:
Starter rel ay
Starter motor (i ncl udi ng an i ntegral starter sol e-
noi d)
Other components to be consi dered as part of start-
i ng system are:
Battery
Battery cabl es
I gni ti on swi tch and key l ock cyl i nder
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Wi re harnesses and connecti ons.
The Battery, Starti ng, and Chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct operati on of
starti ng/chargi ng systems, al l components used i n
these 3 systems must perform wi thi n speci fi cati ons.
When attempti ng to di agnose any of these systems, i t
i s i mportant that you keep thei r i nterdependency i n
mi nd.
The di agnosti c procedures used i n each of these
groups i ncl ude the most basi c conventi onal di agnosti c
methods, to the more sophi sti cated On-Board Di ag-
nosti cs (OBD) bui l t i nto the Powertrai n Control Mod-
ul e (PCM). Use of an i nducti on-type mi l l i ampere
ammeter, vol t/ohmmeter, battery charger, carbon pi l e
rheostat (l oad tester), and 12-vol t test l amp may be
requi red.
Certai n starti ng system components are moni tored
by the PCM and may produce a Di agnosti c Troubl e
Code (DTC). Refer to Di agnosti c Troubl e Codes for
addi ti onal i nformati on and a l i st of codes.
OPERATION
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter motor between 150 and 350 amperes (700
amperes - di esel engi ne), and a l ow-amperage control
ci rcui t that operates on l ess than 20 amperes. The
hi gh-amperage feed ci rcui t components i ncl ude the
battery, the battery cabl es, the contact di sc porti on of
the starter sol enoi d, and the starter motor. The l ow-
amperage control ci rcui t components i ncl ude the i gni -
ti on swi tch, the cl utch pedal posi ti on swi tch (manual
transmi ssi on), the park/neutral posi ti on swi tch (auto-
mati c transmi ssi on), the starter rel ay, the el ectro-
magneti c wi ndi ngs of the starter sol enoi d, and the
connecti ng wi re harness components.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, i t has a cl utch pedal posi ti on swi tch i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed when the i gni ti on swi tch i s turned to the
momentary Start posi ti on, unl ess the cl utch pedal i s
depressed. Thi s feature prevents starter motor oper-
ati on whi l e the cl utch di sc and the fl ywheel are
engaged. The starter rel ay coi l ground termi nal i s
al ways grounded on vehi cl es wi th a manual trans-
mi ssi on.
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the momentary Start posi ti on. The park/
neutral posi ti on swi tch i s i nstal l ed i n seri es between
the starter rel ay coi l ground termi nal and ground.
Thi s normal l y open swi tch prevents the starter rel ay
from bei ng energi zed and the starter motor from
AN STARTING 8F - 29
operati ng unl ess the automati c transmi ssi on gear
sel ector i s i n the Neutral or Park posi ti ons.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter motor. Thi s engages the starter
overrunni ng cl utch and pi ni on gear wi th the starter
ri ng gear on the manual transmi ssi on fl ywheel or on
the automati c transmi ssi on torque converter or
torque converter dri ve pl ate.
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter motor from damage by al l owi ng the
starter pi ni on gear to spi n faster than the pi ni on
shaft. When the dri ver rel eases the i gni ti on swi tch to
the On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
DIAGNOSIS AND TESTING - STARTING
SYSTEM
The battery, starti ng, and chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct starti ng/
chargi ng system operati on, al l of the components
i nvol ved i n these 3 systems must perform wi thi n
speci fi cati ons.
Starting System Diagnosis
STARTER FAILS TO
OPERATE.
1. Battery discharged or
faulty.
1. Refer to Battery. Charge or replace battery, if required.
2. Starting circuit wiring
faulty.
2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits, if required.
3. Starter relay faulty. 3. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace starter relay, if required.
4. Ignition switch faulty. 4. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch, if required.
5. Clutch pedal position
switch faulty.
5. Refer to Clutch Pedal Position Switch.
6. Park/Neutral position
switch faulty or
misadjusted.
6. Refer to Park/Neutral Position Switch. Replace
park/neutral position switch, if required.
7. Starter solenoid faulty. 7. Refer to Starter Motor. Replace starter motor assembly,
if required.
8. Starter motor faulty. 8. If all other starting system components and circuits test
OK, replace starter motor.
STARTER ENGAGES,
FAILS TO TURN
ENGINE.
1. Battery discharged or
faulty.
1. Refer to Battery. Charge or replace battery, if required.
2. Starting circuit wiring
faulty.
2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits, if required.
OK, replace starter motor assembly.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of 9, Engine.
8F - 30 STARTING AN
STARTING (Continued)
Starting System Diagnosis
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.
1. Starter ring gear faulty. 1. Refer to Starter Motor in Removal and Installation.
Remove starter motor to inspect starter ring gear.
Replace starter ring gear, if required.
OK, replace the starter motor assembly.
STARTER DOES NOT
DISENGAGE.
1. Starter motor
improperly installed.
1. Refer to Starter Motor in the Removal and Installation
section of this group. Tighten the starter mounting
hardware to the correct tightness specifications.
2. Starter relay faulty. 2. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace starter relay, if required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch, if required.
OK, replace starter motor.
INSPECTION
For compl ete starter wi ri ng ci rcui t di agrams, refer
to 8, Wi ri ng Di agrams. Before removi ng any uni t
from starti ng system for repai r or di agnosi s, perform
the fol l owi ng i nspecti ons:
BAGS, REFER TO 8, PASSIVE RESTRAINT SYS-
TEMS, BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
Battery - Vi sual l y i nspect battery for i ndi ca-
ti ons of physi cal damage and l oose or corroded cabl e
connecti ons. Determi ne the state-of-charge and
cranki ng capaci ty of battery. Charge or repl ace bat-
tery, i f requi red. Refer to Battery i n 8, Battery.
Note: If equipped with diesel engine, a dual bat-
tery system is used, and both batteries must be
inspected.
Ignition Switch - Vi sual l y i nspect i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons. Refer to Igni-
tion Switch and Key Lock Cylinder.
Clutch Pedal Position Switch - I f equi pped
wi th manual transmi ssi on, vi sual l y i nspect cl utch
pedal posi ti on swi tch for i ndi cati ons of physi cal dam-
age and l oose or corroded wi re harness connecti ons.
Refer to Clutch Pedal Position Switch i n 6,
Cl utch.
Park/Neutral Position Switch - I f equi pped
wi th automati c transmi ssi on, vi sual l y i nspect park/
neutral posi ti on swi tch for i ndi cati ons of physi cal
damage and l oose or corroded wi re harness connec-
ti ons. Refer to Park/Neutral Position Switch i n
21, Transmi ssi on.
Starter Relay - Vi sual l y i nspect starter rel ay
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons.
Starter Motor - Vi sual l y i nspect starter motor
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons.
Starter Solenoid - Vi sual l y i nspect starter sol e-
noi d for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect wi re harnesses for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red. Refer to 8, Wi ri ng Di agrams.
TESTING
COLD CRANKING TEST
For compl ete starter wi ri ng ci rcui t di agrams, refer
to 8, Wi ri ng Di agrams. The battery must be ful l y-
charged and l oad-tested before proceedi ng. Refer to
Battery i n 8, Battery.
(1) Connect vol t-ampere tester to battery termi nal s
(Fi g. 1). See i nstructi ons provi ded by manufacturer of
vol t-ampere tester bei ng used. Note: If equipped
with dual battery system (diesel), tester should
be connected to driver side battery only. Also,
tester current reading must be taken from bat-
tery positive cable lead that connects to starter
motor.
(2) Ful l y engage parki ng brake.
(3) I f equi pped wi th manual transmi ssi on, pl ace
gearshi ft sel ector l ever i n Neutral posi ti on and bl ock
cl utch pedal i n ful l y depressed posi ti on. I f equi pped
wi th automati c transmi ssi on, pl ace gearshi ft sel ector
l ever i n Park posi ti on.
AN STARTING 8F - 31
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) To prevent a gasol i ne engi ne from starti ng,
remove Automati c ShutDown (ASD) rel ay. To prevent
a di esel engi ne from starti ng, remove Fuel Pump
Rel ay. These rel ays are l ocated i n Power Di stri buti on
Center (PDC). Refer to l abel on PDC cover for rel ay
l ocati on.
WARNING: IF EQUIPPED WITH DIESEL ENGINE,
ATTEMPT TO START ENGINE A FEW TIMES
BEFORE PROCEEDING WITH FOLLOWING STEP.
(6) Rotate and hol d i gni ti on swi tch i n Start posi -
ti on. Note cranki ng vol tage and current (amperage)
draw readi ngs shown on vol t-ampere tester.
(a) I f vol tage reads bel ow 9.6 vol ts, refer to
Starter Motor i n Di agnosi s and Testi ng. I f starter
motor i s OK, refer to Engine Diagnosis i n 9,
Engi ne for further testi ng of engi ne. I f starter
motor i s not OK, repl ace faul ty starter motor.
(b) I f vol tage reads above 9.6 vol ts and current
(amperage) draw reads bel ow speci fi cati ons, refer
to Feed Circuit Test i n thi s secti on.
(c) I f vol tage reads 12.5 vol ts or greater and
starter motor does not turn, refer to Control Cir-
cuit Testing i n thi s secti on.
(d) I f vol tage reads 12.5 vol ts or greater and
starter motor turns very sl owl y, refer to Feed Cir-
cuit Test i n thi s secti on.
NOTE: A cold engine will increase starter current
(amperage) draw reading, and reduce battery volt-
age reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n
hi gh-amperage feed ci rcui t. For compl ete starter wi r-
i ng ci rcui t di agrams, refer 8, Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that vol tage drop i s gi vi ng an i ndi cati on of
resi stance between two poi nts at whi ch vol tmeter
probes are attached.
Example: When testi ng resi stance of battery posi -
ti ve cabl e, touch vol tmeter l eads to battery posi ti ve
cabl e cl amp and cabl e connector at starter sol enoi d.
I f you probe battery posi ti ve termi nal post and cabl e
connector at starter sol enoi d, you are readi ng com-
bi ned vol tage drop i n battery posi ti ve cabl e cl amp-to-
termi nal post connecti on and battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng tests,
be certai n that fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged and l oad-tested. Refer to
Battery i n 8, Battery.
Ful l y engage parki ng brake.
I f equi pped wi th manual transmi ssi on, pl ace
gearshi ft sel ector l ever i n Neutral posi ti on and bl ock
cl utch pedal i n ful l y depressed posi ti on. I f equi pped
wi th automati c transmi ssi on, pl ace gearshi ft sel ector
l ever i n Park posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
To prevent a gasol i ne engi ne from starti ng,
remove Automati c ShutDown (ASD) rel ay. To prevent
a di esel engi ne from starti ng, remove Fuel Pump
Rel ay. These rel ays are l ocated i n Power Di stri buti on
Center (PDC). Refer to l abel on PDC cover for rel ay
l ocati on.
(1) Connect posi ti ve l ead of vol tmeter to battery
negati ve termi nal post. Connect negati ve l ead of vol t-
meter to battery negati ve cabl e cl amp (Fi g. 2). Rotate
and hol d i gni ti on swi tch i n Start posi ti on. Observe
vol tmeter. I f vol tage i s detected, correct poor contact
between cabl e cl amp and termi nal post. Note: If
equipped with a dual battery system (diesel),
procedure must be performed twice, once for
each battery.
(2) Connect posi ti ve l ead of vol tmeter to battery
posi ti ve termi nal post. Connect negati ve l ead of vol t-
meter to battery posi ti ve cabl e cl amp (Fi g. 3). Rotate
and hol d i gni ti on swi tch i n Start posi ti on. Observe
vol tmeter. I f vol tage i s detected, correct poor contact
between cabl e cl amp and termi nal post. Note: If
equipped with a dual battery system (diesel),
this procedure must be performed twice, once
for each battery.
Fig. 1 Volts-Amps Tester Connections - Typical
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
8F - 32 STARTING AN
(3) Connect vol tmeter to measure between battery
posi ti ve termi nal post and starter sol enoi d battery
termi nal stud (Fi g. 4). Rotate and hol d i gni ti on
swi tch i n Start posi ti on. Observe vol tmeter. I f read-
i ng i s above 0.2 vol t, cl ean and ti ghten battery cabl e
connecti on at sol enoi d. Repeat test. I f readi ng i s sti l l
above 0.2 vol t, repl ace faul ty battery posi ti ve cabl e.
Note: If equipped with a dual battery system
(diesel), this procedure must be performed on
driver side battery only.
(4) Connect vol tmeter to measure between battery
negati ve termi nal post and a good cl ean ground on
engi ne bl ock (Fi g. 5). Rotate and hol d i gni ti on swi tch
i n Start posi ti on. Observe vol tmeter. I f readi ng i s
above 0.2 vol t, cl ean and ti ghten battery negati ve
cabl e attachment on engi ne bl ock. Repeat test. I f
readi ng i s sti l l above 0.2 vol t, repl ace faul ty battery
negati ve cabl e. Note: If equipped with dual bat-
tery system (diesel), this procedure must be
performed twice, once for each battery.
Fig. 2 Test
1 - VOLTMETER
2 - BATTERY
Fig. 3 Test Battery Positive Connection Resistance -
Typical
1 - VOLTMETER
2 - BATTERY
Fig. 4 Test Battery Positive Cable
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 5 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
AN STARTING 8F - 33
(5) Connect posi ti ve l ead of vol tmeter to starter
housi ng. Connect negati ve l ead of vol tmeter to bat-
tery negati ve termi nal post (Fi g. 6). Rotate and hol d
i gni ti on swi tch i n Start posi ti on. Observe vol tmeter.
I f readi ng i s above 0.2 vol t, correct poor starter to
engi ne bl ock ground contact. Note: If equipped
with a dual battery system (diesel), this proce-
dure must be performed on driver side battery
only.
(6) I f equi pped wi th dual battery system (di esel ),
connect posi ti ve l ead of vol tmeter to dri ver si de bat-
tery posi ti ve cabl e cl amp. Connect negati ve l ead of
vol tmeter to passenger si de battery posi ti ve termi nal
post. Rotate and hol d i gni ti on swi tch i n Start posi -
ti on. Observe vol tmeter. I f readi ng i s above 0.2 vol t,
cl ean and ti ghten passenger si de battery posi ti ve
cabl e eyel et connecti on at dri ver si de battery posi ti ve
cabl e cl amp bol t. Repeat test. I f readi ng i s sti l l above
0.2 vol t, repl ace faul ty passenger si de battery posi -
ti ve cabl e.
I f resi stance tests detect no feed ci rcui t probl ems,
refer to Starter Motor i n the Di agnosi s and Testi ng.
CONTROL CIRCUIT TESTING
The starter control ci rcui t components shoul d be
tested i n the order i n whi ch they are l i sted, as fol -
l ows:
Starter Relay - Refer to Starter Relay Di ag-
nosi s and Testi ng.
Starter Solenoid - Refer to Starter Motor
Di agnosi s and Testi ng.
Ignition Switch - Refer to Ignition Switch
and Key Lock Cylinder
Clutch Pedal Position Switch - I f equi pped
wi th manual transmi ssi on, refer to Clutch Pedal
Position Switch i n 6, Cl utch.
Park/Neutral Position Switch - I f equi pped
wi th automati c transmi ssi on, refer to Park/Neutral
Position Switch i n 21, Transmi ssi on.
Wire harnesses and connections - Refer to 8,
Wi ri ng Di agrams.
SPECIFICATIONS
SPECIFICATIONS - STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer Mitsubishi Denso Denso
Part Number 56041013AC 56027702AC 56028715
Engine Application 2.5L 3.9L, 4.7L (Manual), 5.9L 4.7L (Auto)
Power Rating
1.2 Kilowatt - (1.6
Horsepower)
1.4 Kilowatt - (1.9
Horsepower
1.4 Kilowatt - (1.9
Horsepower
Voltage 12 Volts 12 Volts 12 Volts
Pinion Teeth 9 10 10
Number of Fields 4 4 4
Number of Poles 4 4 4
Number of Brushes 4 4 4
Drive Type
Planetary Gear
Reduction
Reduction Gear Train Reduction Gear Train
Free Running Test Voltage 11.2 Volts 11 Volts 11 Volts
Fig. 6 Test Starter Ground - Typical
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
8F - 34 STARTING AN
Starter Motor and Solenoid
Free Running Test Maximum
Amperage Draw
90 Amperes 73 Amperes 73 Amperes
Free Running Test Minimum
Speed
2600 rpm 3601 rpm 3601 rpm
Solenoid Closing Maximum
Voltage Required
7.8 Volts 7.5 Volts 7.5 Volts
* Cranking Amperage Draw
Test
130 Amperes 125 - 250 Amperes 125 - 250 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
SPECIFICATIONS - TORQUE - STARTING SYSTEM
Battery Cable Eyelet Nut at Solenoid Stud 14 120
Starter Mounting Bolts 2.5L Engine 54 40
Starter Mounting Nuts/Bolts V-6/V-8 Engines 68 50
STARTER MOTOR
DESCRIPTION
The 2.5L starter i s mounted wi th two bol ts to the
cl utch housi ng on the ri ght si de of the engi ne. The
4.7L automati c transmi ssi on starter motor i s
mounted wi th two bol ts to the torque converter hous-
i ng on the l eft si de of the engi ne. The starter motors
for al l of the remai ni ng engi ne and transmi ssi on
combi nati ons are mounted wi th one bol t, a stud and
a nut to the cl utch or convertor housi ng, and are
l ocated on the l eft si de of the engi ne.
The el ectri c motors of both starters have four
brushes contacti ng the motor commutator. The 2.5L
starter motor uses four permanent magnets for the
fi el d pol es, whi l e the other starter motors feature
four el ectromagneti c fi el d coi l s wound around four
pol e shoes.
The starter motors are servi ced onl y as a uni t wi th
starter sol enoi ds, and cannot be repai red. I f ei ther
component i s faul ty or damaged, the enti re starter
motor and starter sol enoi d uni t must be repl aced.
OPERATION
The starter motor i s equi pped wi th a gear reduc-
ti on (i ntermedi ate transmi ssi on) system. The gear
reducti on system consi sts of a gear that i s i ntegral to
the output end of the el ectri c motor armature shaft
that i s i n conti nual engagement wi th a l arger gear
that i s spl i ned to the i nput end of the starter pi ni on
gear shaft. Thi s feature makes i t possi bl e to reduce
the di mensi ons of the starter. At the same ti me, i t
al l ows hi gher armature rotati onal speed, and del i vers
i ncreased torque through the starter pi ni on gear to
the starter ri ng gear.
The starter motor i s acti vated by an i ntegral heavy
duty starter sol enoi d swi tch mounted to the overrun-
ni ng cl utch housi ng. Thi s el ectromechani cal swi tch
connects and di sconnects the feed of battery vol tage
to the starter motor, and actuates a shi ft fork that
engages and di sengages the starter pi ni on gear wi th
the starter ri ng gear.
The starter motor uses an overrunni ng cl utch and
starter pi ni on gear uni t to engage and dri ve the
gears on the fl ywheel (or fl ywheel ri ng gear).
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operati on can be confi rmed
by performi ng fol l owi ng free runni ng bench test. Thi s
test can onl y be performed wi th starter motor
removed from vehi cl e. Refer to Starti ng Speci fi ca-
ti ons for starter motor speci fi cati ons.
(1) Remove starter motor from vehi cl e. Refer to
Starter MotorRemoval and I nstal l ati on.
(2) Mount starter motor securel y i n a soft-jawed
bench vi se. The vi se jaws shoul d be cl amped on
mounti ng fl ange of starter motor. Never cl amp on
starter motor by fi el d frame.
(3) Connect sui tabl e vol t-ampere tester and 12-vol t
battery to starter motor i n seri es, and set ammeter to
100 ampere scal e. See i nstructi ons provi ded by man-
ufacturer of vol t-ampere tester bei ng used.
(4) I nstal l jumper wi re from sol enoi d termi nal to
sol enoi d battery termi nal . The starter motor shoul d
operate. I f starter motor fai l s to operate, repl ace
faul ty starter motor assembl y.
AN STARTING 8F - 35
(5) Adjust carbon pi l e l oad of tester to obtai n free
runni ng test vol tage. Refer to Starti ng Speci fi cati ons
for starter motor free runni ng test vol tage speci fi ca-
ti ons.
(6) Note readi ng on ammeter and compare readi ng
to free runni ng test maxi mum amperage draw. Refer
to Starti ng Speci fi cati ons secti on for starter motor
free runni ng test maxi mum amperage draw speci fi ca-
ti ons.
(7) I f ammeter readi ng exceeds maxi mum amper-
age draw speci fi cati on, repl ace faul ty starter motor
assembl y.
STARTER MOTOR SOLENOID
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e.
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor Removal and I nstal l ati on.
(2) Di sconnect wi re from sol enoi d fi el d coi l termi -
nal .
(3) Check for conti nui ty between sol enoi d termi nal
and sol enoi d fi el d coi l termi nal wi th conti nui ty tester
(Fi g. 7) or (Fi g. 8). There shoul d be conti nui ty. I f OK,
go to Step 4. I f not OK, repl ace faul ty starter motor
assembl y.
(4) Check for conti nui ty between sol enoi d termi nal
and sol enoi d case (Fi g. 9) or (Fi g. 10). There shoul d
be conti nui ty. I f not OK, repl ace faul ty starter motor
assembl y.
REMOVAL
2. 5L Engine
(1) Di sconnect and i sol ate negati ve battery cabl e.
(3) Remove bol t and washer (forward faci ng) secur-
i ng starter to cl utch housi ng (Fi g. 11).
(4) Whi l e supporti ng starter motor, remove bol t
and washer (rearward faci ng) securi ng starter motor
to transmi ssi on housi ng.
(5) Lower starter motor far enough to access and
remove battery cabl e eyel et termi nal nut at starter
sol enoi d. Al ways support starter motor duri ng thi s
process. Do not l et starter motor hang from wi re har-
ness.
(6) Remove battery cabl e from stud.
(7) Di sconnect sol enoi d termi nal wi re harness con-
nector from starter sol enoi d.
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - 2.5L Engine - Typical
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL
and Field Coil Terminal - 3.9L/4.7L/5.9L Engine -
Typical
1 - OHMMETER
3 - FIELD COIL TERMINAL
and Solenoid Case - 2.5L Engine - Typical
1 - SOLENOID
3 - OHMMETER
and Solenoid Case - 3.9L/4.7L/5.9L Engine - Typical
2 - OHMMETER
3 - SOLENOID
8F - 36 STARTING AN
STARTER MOTOR (Continued)
(8) Remove starter motor from transmi ssi on hous-
i ng.
All 3. 9L/5. 9L, or 4. 7L With Manual Transmission
(3) Remove nut securi ng starter motor to stud on
transmi ssi on housi ng (Fi g. 12).
securi ng starter motor to transmi ssi on housi ng.
(5) I f equi pped wi th automati c transmi ssi on, sl i de
transmi ssi on cool er tube bracket forward on tubes far
enough for starter motor to be removed from l ower
mounti ng stud.
(6) Lower starter motor from front transmi ssi on
housi ng far enough to access and remove nut secur-
i ng battery cabl e eyel et to starter sol enoi d stud.
Al ways support starter motor duri ng thi s process. Do
not l et starter motor hang from wi re harness.
(7) Remove sol enoi d wi re sol enoi d termi nal stud.
(8) Di sconnect battery cabl e sol enoi d wi re from
receptacl e on starter sol enoi d.
i ng.
4. 7L With Automatic Transmission
(3) Remove bol t and washer (rearward faci ng)
securi ng starter motor to the transmi ssi on housi ng
(Fi g. 13).
Fig. 11 Starter Motor Remove/Install - 2.5L Engine
2 - EYELET TERMINAL
3 - NUT
4 - BATTERY POSITIVE CABLE WIRE HARNESS
7 - STARTER MOTOR
Fig. 12 Starter Motor Remove/Install - All 3.9L/5.9L,
or 4.7L Engine with Man. Trans.
1 - EYELET TERMINAL
2 - NUT
3 - BRACKET
4 - STUD
5 - STARTER MOTOR
6 - LOCK WASHER
8 - NUT
Fig. 13 Starter Motor Remove/Install - 4.7L Engine
with Automatic Transmission
1 - EYELET TERMINAL
2 - NUT
3 - SCREW AND WASHER (2)
4 - STARTER MOTOR
AN STARTING 8F - 37
and washer (rearward faci ng) securi ng starter motor
to the transmi ssi on housi ng.
(5) Lower starter motor from front of transmi ssi on
housi ng far enough to access and remove nut secur-
i ng battery posi ti ve cabl e eyel et termi nal to the
starter sol enoi d B(+) termi nal stud. Al ways support
starter motor duri ng thi s process. Do not l et starter
motor hang from wi re harness.
(6) Remove battery cabl e eyel et termi nal from sol e-
noi d B(+) termi nal stud.
(7) Di sconnect battery cabl e sol enoi d termi nal wi re
harness connector from receptacl e on starter sol e-
noi d.
i ng.
INSTALLATION
2. 5L Engine
(1) Posi ti on starter motor to transmi ssi on housi ng.
(2) Connect battery cabl e sol enoi d termi nal wi re
harness connector to connector receptacl e on starter
sol enoi d. Al ways support starter motor duri ng thi s
process. Do not l et starter motor hang from wi re har-
ness.
(3) I nstal l battery cabl e eyel et termi nal onto sol e-
(4) I nstal l and ti ghten nut securi ng battery cabl e
eyel et termi nal to starter sol enoi d B(+) termi nal
stud. Ti ghten nut to 13.6 Nm (120 i n. l bs.).
(5) Posi ti on starter motor and i nstal l bol ts/wash-
ers. Ti ghten bol ts to 54.2 Nm (40 ft. l bs.).
All 3. 9L/5. 9L, or 4. 7L With Manual Trans.
sol enoi d. Al ways support the starter motor duri ng
thi s process. Do not l et the starter motor hang from
the wi re harness.
(5) Posi ti on starter motor over stud on transmi s-
si on housi ng.
(6) I f equi pped wi th automati c transmi ssi on, sl i de
automati c transmi ssi on cool er tube bracket rearward
on tubes and i nto posi ti on over starter motor fl ange.
(7) Loosel y i nstal l the washers, bol t, and nut to
starter. Ti ghten bol t and nut to 67.8 Nm (50 ft. l bs.).
4. 7L With Automatic Trans.
sol enoi d. Al ways support the starter motor duri ng
thi s process. Do not l et the starter motor hang from
the wi re harness.
(5) Posi ti on starter motor to transmi ssi on housi ng
and l oosel y i nstal l two bol ts/washers.
(6) Ti ghten bol ts to 67.8 Nm (50 ft. l bs.).
STARTER MOTOR RELAY
DESCRIPTION
The starter rel ay i s an el ectromechani cal devi ce
that swi tches battery current to the pul l -i n coi l of the
starter sol enoi d when i gni ti on swi tch i s turned to
Start posi ti on. The starter rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment. See PDC cover for rel ay i denti fi cati on and
l ocati on.
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) rel ay. Rel ays conformi ng to I SO
speci fi cati ons have common physi cal di mensi ons, cur-
rent capaci ti es, termi nal patterns, and termi nal func-
ti ons.
The starter rel ay cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When el ectro-
magneti c coi l i s energi zed, i t draws the movabl e con-
tact away from normal l y cl osed fi xed contact, and
hol ds i t agai nst the other (normal l y open) fi xed con-
tact.
When el ectromagneti c coi l i s de-energi zed, spri ng
pressure returns movabl e contact to normal l y cl osed
posi ti on. The resi stor or di ode i s connected i n paral l el
wi th el ectromagneti c coi l wi thi n rel ay, and hel ps to
di ssi pate vol tage spi kes produced when coi l i s de-en-
ergi zed.
8F - 38 STARTING AN
DIAGNOSIS AND TESTING - STARTER RELAY
The starter rel ay (Fi g. 14) i s l ocated i n Power Di s-
tri buti on Center (PDC). Refer to PDC cover for rel ay
i denti fi cati on and l ocati on. For compl ete starter rel ay
wi ri ng ci rcui t di agrams, refer to 8, Wi ri ng Di agrams.
(1) Remove starter rel ay from PDC.
(2) A rel ay i n de-energi zed posi ti on shoul d have
conti nui ty between termi nal s 87A and 30, and no
conti nui ty between termi nal s 87 and 30. I f OK, go to
Step 3. I f not OK, repl ace faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
4. I f not OK, repl ace faul ty rel ay.
(4) Connect 12V battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform Rel ay Ci rcui t Test that fol -
l ows. I f not OK, repl ace faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r open ci r-
cui t to fuse i n PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to common feed termi nal (30) i n the energi zed
posi ti on. Thi s termi nal suppl i es battery vol tage to
starter sol enoi d fi el d coi l s. There shoul d be conti nu-
i ty between cavi ty for rel ay termi nal 87 and starter
sol enoi d termi nal at al l ti mes. I f OK, go to Step 4. I f
not OK, repai r open ci rcui t to starter sol enoi d as
requi red.
(4) The coi l battery termi nal (86) i s connected to
el ectromagnet i n rel ay. I t i s energi zed when i gni ti on
swi tch i s hel d i n Start posi ti on. On vehi cl es wi th
manual transmi ssi on, cl utch pedal must be ful l y
depressed for thi s test. Check for battery vol tage at
cavi ty for rel ay termi nal 86 wi th i gni ti on swi tch i n
Start posi ti on, and no vol tage when i gni ti on swi tch i s
rel eased to On posi ti on. I f OK, go to Step 5. I f not
OK wi th automati c transmi ssi on, check for open or
short ci rcui t to i gni ti on swi tch and repai r, i f requi red.
I f ci rcui t to i gni ti on swi tch i s OK, refer to Ignition
Switch and Key Lock Cylinder . I f not OK wi th a
manual transmi ssi on, check ci rcui t between rel ay
and cl utch pedal posi ti on swi tch for open or a short.
I f ci rcui t i s OK, refer to Clutch Pedal Position
Switch i n 6 , Cl utch.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. On vehi cl es wi th
manual transmi ssi on, i t i s grounded at al l ti mes. On
vehi cl es wi th automati c transmi ssi on, i t i s grounded
through park/neutral posi ti on swi tch onl y when gear-
shi ft sel ector l ever i s i n Park or Neutral posi ti ons.
Check for conti nui ty to ground at cavi ty for rel ay ter-
mi nal 85. I f not OK wi th manual transmi ssi on,
repai r ci rcui t to ground as requi red. I f not OK wi th
automati c transmi ssi on, check for pen or short ci rcui t
to park/neutral posi ti on swi tch and repai r, i f
requi red. I f ci rcui t to park/neutral posi ti on swi tch i s
OK, refer to Park/Neutral Position Switch i n 21,
Transmi ssi on.
REMOVAL
(2) Remove cover from Power Di stri buti on Center
(PDC) (Fi g. 15).
(3) See fuse and rel ay l ayout l abel affi xed to
undersi de of PDC cover for starter rel ay i denti fi ca-
ti on and l ocati on.
(4) Remove starter rel ay from PDC.
Fig. 14 Starter Relay
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
AN STARTING 8F - 39
STARTER MOTOR RELAY (Continued)
INSTALLATION
(1) See fuse and rel ay l ayout l abel affi xed to
undersi de of PDC cover for proper starter rel ay l oca-
ti on.
(2) Posi ti on starter rel ay i n proper receptacl e i n
PDC.
(3) Al i gn starter rel ay termi nal s wi th termi nal
cavi ti es i n PDC receptacl e.
(4) Push down fi rml y on starter rel ay unti l termi -
nal s are ful l y seated i n termi nal cavi ti es i n PDC
receptacl e.
(5) I nstal l cover onto PDC.
(6) Reconnect negati ve battery cabl e.
Fig. 15 Power Distribution Center
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8F - 40 STARTING AN
STARTER MOTOR RELAY (Continued)
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REAR WINDOW DEFOGGER SYSTEM . . . . . . . 1
REAR WINDOW DEFOGGER GRID
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR WINDOW DEFOGGER GRID . . . . . . . . . . 3
REAR WINDOW DEFOGGER GRID REPAIR . . . 3
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEATED GLASS
DESCRIPTION - REAR WINDOW DEFOGGER
The system consi sts of a rear gl ass wi th two verti -
cal bus bars and a seri es of el ectri cal l y connected
gri d l i nes fi red on the i nsi de surface. A control swi tch
and a ti mi ng ci rcui t are combi ned i nto the HVAC
control assembl y. A push button on the HVAC control
assembl y turns the defroster ON or OFF. Ci rcui t pro-
tecti on i s provi ded by a cartri dge fuse l ocated i n the
Power Di stri buti on Center (PDC) for the heated gri d
ci rcui t, and a fuse i n the fuse bl ock for the control
ci rcui t.
OPERATION - REAR WINDOW DEFOGGER
The defogger system i s control l ed by a momentary
swi tch i n the HVAC Control assembl y, whi ch al so
i ncl udes the swi tch for the rear wi per and washer
system. An amber i ndi cator l amp i n the HVAC Con-
trol assembl y wi l l l i ght to i ndi cate when the defogger
system i s turned on. The rear wi ndow swi tch al so
contai ns the defogger system control ci rcui try i ncl ud-
i ng the ti mer l ogi c and the defogger rel ay.
The defogger system wi l l be automati cal l y turned
off after a programmed ti me i nterval of about ten
mi nutes. After the i ni ti al ti me i nterval has expi red, i f
the defogger swi tch i s turned on agai n duri ng the
same i gni ti on cycl e, the defogger system wi l l auto-
mati cal l y turn off after about fi ve mi nutes.
The defogger system wi l l automati cal l y shut off i f
the i gni ti on swi tch i s turned to the Off posi ti on, or i t
can be turned off manual l y by depressi ng the defog-
ger swi tch a second ti me. Refer to the owners man-
ual i n the vehi cl e gl ove box for more i nformati on on
the features, use and operati on of the defogger sys-
tem.
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM
For ci rcui t descri pti ons and di agrams, refer to Rear
Wi ndow Defogger i n Wi ri ng Di agrams. The operati on
of the el ectri cal l y heated rear wi ndow defogger sys-
tem can be confi rmed i n one of the fol l owi ng man-
ners:
Turn the i gni ti on swi tch to the On posi ti on.
Whi l e moni tori ng the i nstrument panel vol tmeter, set
the defogger swi tch i n the On posi ti on. When the
defogger swi tch i s turned On, a di sti nct vol tmeter
needl e defl ecti on shoul d be noted.
AN HEATED SYSTEMS 8G - 1
Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The rear wi n-
dow defogger operati on can be checked by feel i ng the
rear wi ndow or outsi de rear vi ew mi rror gl ass. A di s-
ti nct di fference i n temperature between the gri d l i nes
and the adjacent cl ear gl ass or the mi rror gl ass can
be detected wi thi n three to four mi nutes of operati on.
Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal A (ri ght si de) wi th the
negati ve l ead, and termi nal B (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm system operati on.
I l l umi nati on of the defogger swi tch i ndi cator l amp
means that there i s el ectri cal current avai l abl e at the
output of the rear wi ndow defogger l ogi c and ti mer
ci rcui try, but does not confi rm that the el ectri cal cur-
rent i s reachi ng the rear gl ass heati ng gri d l i nes.
I f the defogger system does not operate, the prob-
l em shoul d be i sol ated i n the fol l owi ng manner:
(1) Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
(2) Ensure that the rear gl ass heati ng gri d feed
and ground wi res are connected to the gl ass. Confi rm
that the ground wi re has conti nui ty to ground.
(3) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and i n the juncti on bl ock. The fuses must
be ti ght i n thei r receptacl es and al l el ectri cal connec-
ti ons must be secure.
When the above steps have been compl eted and the
rear gl ass heati ng gri d i s sti l l i noperati ve, one or
more of the fol l owi ng i s faul ty:
Rear wi ndow swi tch (HVAC Control Assembl y).
Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve).
I f setti ng the defogger swi tch to the On posi ti on
produces a severe vol tmeter defl ecti on, check for a
short ci rcui t between the rear wi ndow swi tch defog-
ger rel ay output and the rear gl ass heati ng gri d.
REAR WINDOW DEFOGGER
GRID
DESCRIPTION - REAR GLASS HEATING GRID
The heated rear wi ndow gl ass has two el ectri cal l y
conducti ve verti cal bus bars and a seri es of hori zon-
tal gri d l i nes made of a si l ver-cerami c materi al ,
whi ch i s baked on and bonded to the i nsi de surface of
the gl ass. The gri d l i nes and bus bars compri se a
paral l el el ectri cal ci rcui t. A control swi tch and a ti m-
i ng ci rcui t are combi ned i nto the heati ng-A/C control
assembl y.
A push-button on the heater-A/C control assembl y
turns the defroster ON and OFF.
Ci rcui t protecti on i s provi ded by a cartri dge fuse
l ocated i n the Power Di stri buti on Center (PDC) for
the heated gri d ci rcui t.
OPERATION - REAR GLASS HEATING GRID
When the rear wi ndow defogger swi tch i s pl aced i n
the On posi ti on, el ectri cal current i s di rected to the
rear wi ndow gri d l i nes through the bus bars. The
gri d l i nes heat the rear wi ndow to cl ear the surface
of fog or snow. Protecti on for the heati ng gri d ci rcui t
i s provi ded by a fuse i n the Power Di stri buti on Cen-
ter (PDC).
The gri d l i nes and bus bars are hi ghl y resi stant to
abrasi on. However, i t i s possi bl e for an open ci rcui t
to occur i n an i ndi vi dual gri d l i ne, resul ti ng i n no
current fl ow through the l i ne.
The gri d l i nes can be damaged or scraped off wi th
sharp i nstruments. Care shoul d be taken when cl ean-
i ng the gl ass or removi ng forei gn materi al s, decal s,
or sti ckers from the gl ass. Normal gl ass cl eani ng sol -
vents or hot water used wi th rags or towel i ng i s rec-
ommended.
A repai r ki t i s avai l abl e to repai r the gri d l i nes and
bus bars, or to rei nstal l the heated gl ass termi nal s.
Fig. 1 Grid Line Test
1 - VIEW FROM INSIDE VEHICLE
2 - REAR WINDOW DEFOGGER
3 - BUS BARS
4 - VOLTAGE FEED (A)
5 - VOLTMETER
6 - MID-POINT (C)
7 - PICK-UP LEADS
8 - GROUND (B)
8G - 2 HEATED GLASS AN
HEATED GLASS (Continued)
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER GRID
For ci rcui t descri pti ons and di agrams, refer to Rear
Wi ndow Defogger i n Wi ri ng Di agrams. To detect
breaks i n the gri d l i nes, the fol l owi ng procedure i s
requi red:
(1) Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The i ndi cator
l amp shoul d l i ght. I f OK, go to Step 2. I f not OK,
(Refer to 8 - ELECTRI CAL/HEATED GLASS/REAR
WI NDOW DEFOGGER SWI TCH - DI AGNOSI S AND
TESTI NG).
(2) Usi ng a 12-vol t DC vol tmeter, contact the ver-
ti cal bus bar on the ri ght si de of the vehi cl e wi th the
negati ve l ead. Wi th the posi ti ve l ead, contact the ver-
ti cal bus bar on the l eft si de of the vehi cl e. The vol t-
meter shoul d read battery vol tage. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t to the defogger
rel ay as requi red.
(3) Wi th the negati ve l ead of the vol tmeter, contact
a good body ground poi nt. The vol tage readi ng shoul d
not change. I f OK, go to Step 4. I f not OK, repai r the
ci rcui t to ground as requi red.
(4) Connect the negati ve l ead of the vol tmeter to
the ri ght si de bus bar and touch each gri d l i ne at
mi dpoi nt C wi th the posi ti ve l ead. A readi ng of
approxi matel y si x vol ts i ndi cates a l i ne i s good. A
readi ng of zero vol ts i ndi cates a break i n the gri d
l i ne between mi dpoi nt C and the l eft si de bus bar. A
readi ng of ten to fourteen vol ts i ndi cates a break
between mi dpoi nt C and the ri ght si de bus bar. Move
the posi ti ve l ead on the gri d l i ne towards the break
and the vol tage readi ng wi l l change as soon as the
break i s crossed.
STANDARD PROCEDURE - REAR WINDOW
DEFOGGER GRID REPAIR
Repai r of the rear gl ass heati ng gri d l i nes, bus
bars, termi nal s or pi gtai l wi res can be accompl i shed
usi ng a Mopar Rear Wi ndow Defogger Repai r Ki t
(Part Number 4267922) or equi val ent.
WARNING: MATERIALS CONTAINED IN THE REPAIR
KIT MAY CAUSE SKIN OR EYE IRRITATION. THE
KIT CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(2) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
(3) For gri d l i ne repai rs, mask the area to be
repai red wi th maski ng tape or a templ ate (Fi g. 2).
(4) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mi l l i meters (0.75 i nch).
(5) For a termi nal or pi gtai l wi re repl acement,
mask the adjacent areas so the epoxy can be
extended onto the adjacent gri d l i ne as wel l as the
bus bar. Appl y a thi n l ayer of epoxy to the area
where the termi nal or pi gtai l wi re was fastened and
onto the adjacent gri d l i ne.
(6) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal or bare wi re end of the pi gtai l and pl ace i t
i n the proper l ocati on on the bus bar. To prevent the
termi nal or pi gtai l wi re from movi ng whi l e the epoxy
i s curi ng, i t must be wedged or cl amped.
(7) Careful l y remove the maski ng tape or tem-
pl ate.
CAUTION: Do not allow the glass surface to exceed
204 C (400 F) or the glass may fracture.
(8) Al l ow the epoxy to cure 24 hours at room tem-
perature, or use a heat gun wi th a 260 to 371 C
(500 to 700 F) range for fi fteen mi nutes. Hol d the
heat gun approxi matel y 25.4 centi meters (10 i nches)
from the repai r.
(9) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal or pi g-
tai l wi re. Do not attach the wi re harness connectors
unti l the curi ng process i s compl ete.
Fig. 2 Grid Line Repair - Typical
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
AN HEATED GLASS 8G - 3
REAR WINDOW DEFOGGER GRID (Continued)
(10) Check the operati on of the rear wi ndow defog-
ger gl ass heati ng gri d.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The rear wi ndow defogger swi tch i s i ntegral to the
heaterA/C control assembl y, whi ch i ncl udes the
rear wi per and washer swi tches.
The rear wi ndow swi tch al so contai ns the rear wi n-
dow defogger l ogi c and ti mer ci rcui try, an amber
defogger i ndi cator l amp, the rear wi ndow defogger
rel ay, and two swi tch i l l umi nati on l amps. The i ndi ca-
tor and i l l umi nati on l amps i n the swi tch pod use
i ncandescent bul bs, whi ch can be servi ced.
The momentary-type rear wi ndow defogger swi tch
provi des a hard wi red ground si gnal to the rear wi n-
dow defogger l ogi c and ti mer ci rcui try, each ti me i t i s
depressed.
OPERATION
The rear wi ndow defogger ti mer and l ogi c ci rcui try
responds by energi zi ng or de-energi zi ng the rear wi n-
dow defogger rel ay and the amber defogger i ndi cator
l amp, whi ch l i ghts to i ndi cate when the defogger sys-
tem i s turned On. Energi zi ng the rear wi ndow defog-
ger rel ay provi des el ectri cal current to the rear
wi ndow defogger gri d.
The rear wi ndow swi tch cannot be repai red. I f any
functi on of the swi tch except l i ghti ng i s faul ty or
damaged, the enti re heaterA/C control assembl y
must be repl aced.
8G - 4 HEATED GLASS AN
REAR WINDOW DEFOGGER GRID (Continued)
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEATED MIRROR GRID
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEATED MIRRORS
DESCRIPTION
The opti onal heated mi rror system onl y operates i n
concert wi th the rear defogger system, and wi l l be
automati cal l y turned off after a programmed ti me
i nterval of about ten mi nutes. After the i ni ti al ti me
i nterval has expi red, i f the defogger swi tch i s turned
on agai n duri ng the same i gni ti on cycl e, the heated
mi rror system wi l l automati cal l y turn off after about
fi ve mi nutes.
The heated mi rror system wi l l automati cal l y shut
off i f the i gni ti on swi tch i s turned to the Off posi ti on,
or i t can be turned off manual l y by depressi ng the
defogger swi tch a second ti me. Refer to the owners
manual i n the vehi cl e gl ove box for more i nformati on
on the features, use and operati on of the heated mi r-
ror system.
When the rear wi ndow defogger swi tch i s i n the
On posi ti on, an el ectri c heater gri d l ocated behi nd
the gl ass of each of the outsi de rear vi ew mi rrors i s
energi zed. When energi zed, each of these heater
gri ds produce heat to hel p cl ear the outsi de rear vi ew
mi rrors of i ce, snow, or fog.
The heated mi rror system i s control l ed by a
momentary rear wi ndow defogger swi tch i n the
HVAC Control panel , whi ch al so i ncl udes the swi tch
for the rear wi per and washer system. An amber
i ndi cator l amp i n the swi tch control wi l l l i ght to i ndi -
cate when the defogger system i s turned on. The
HVAC control assembl y al so contai ns the defogger
system control ci rcui try i ncl udi ng the ti mer l ogi c and
the defogger rel ay.
OPERATION
The heated mi rror system onl y operates i n concert
wi th the rear defogger system, and wi l l be automat-
i cal l y turned off after a programmed ti me i nterval of
about ten mi nutes. After the i ni ti al ti me i nterval has
expi red, i f the defogger swi tch i s turned on agai n
duri ng the same i gni ti on cycl e, the heated mi rror
system wi l l automati cal l y turn off after about fi ve
mi nutes.
The heated mi rror system wi l l automati cal l y shut
off i f the i gni ti on swi tch i s turned to the Off posi ti on,
or i t can be turned off manual l y by depressi ng the
defogger swi tch a second ti me. Refer to the owners
on the features, use and operati on of the heated mi r-
ror system.
HEATED MIRROR GRID
DESCRIPTION
Vehi cl es equi pped wi th the opti onal heated mi rror
system have an el ectri c heati ng gri d l ocated behi nd
the mi rror gl ass of each outsi de rear vi ew mi rror.
The heated mi rrors are control l ed by the rear wi n-
dow defogger swi tch. El ectri cal current i s di rected to
the heati ng gri d i nsi de the mi rror onl y when the rear
wi ndow defogger swi tch i s i n the On posi ti on.
I f the outsi de mi rror heati ng gri ds are both i noper-
ati ve, see Rear Wi ndow Defogger System i n the Di ag-
nosi s and Testi ng secti on of thi s group. I f onl y one of
the outsi de mi rror heati ng gri ds i s i noperati ve(Refer
to 8 - ELECTRI CAL/POWER MI RRORS - DI AGNO-
SI S AND TESTI NG).
The heati ng gri d behi nd each outsi de mi rror gl ass
cannot be repai red and, i f faul ty or damaged, the
enti re power mi rror uni t must be repl aced(Refer to 8
- ELECTRI CAL/POWER MI RRORS/SI DEVI EW MI R-
ROR - REMOVAL).
AN HEATED MIRRORS 8G - 5
HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 5
HORN SYSTEM
DESCRIPTION
A dual -note el ectri c horn system i s standard facto-
ry-i nstal l ed equi pment on thi s model . The standard
equi pment horn system features one l ow-note horn
uni t and one hi gh-note horn uni t. The horn system
uses a non-swi tched source of battery current so that
the system wi l l remai n functi onal , regardl ess of the
i gni ti on swi tch posi ti on. The horn system i ncl udes
the fol l owi ng components:
Cl ockspri ng
Hi gh-l i ne Central Ti mer Modul e (CTM)
Horns
Horn rel ay
Horn swi tch
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - DESCRI PTI ON) for more i nformati on on
thi s component. (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES/BODY CONTROL/
CENTRAL TI MER MODUL - DESCRI PTI ON) for
more i nformati on on thi s component. Refer to the
nectors, spl i ces and grounds. Fol l owi ng are general
descri pti ons of the remai ni ng major components i n
the horn system.
OPERATION
The horn system i s acti vated by a horn swi tch con-
ceal ed beneath the dri ver si de ai rbag modul e tri m
cover i n the center of the steeri ng wheel . Depressi ng
the center of the dri ver si de ai rbag modul e tri m cover
cl oses the horn swi tch. Cl osi ng the horn swi tch acti -
vates the horn rel ay. The acti vated horn rel ay then
swi tches the battery current needed to energi ze the
horns.
Refer to the owners manual i n the vehi cl e gl ove
box for more i nformati on on the features, use and
operati on of the horn system.
The hi gh-l i ne Central Ti mer Modul e (CTM) can
al so operate the horn system. A hi gh-l i ne CTM i s
used on hi gh-l i ne versi ons of thi s vehi cl e. The CTM
combi nes the functi ons of a chi me/buzzer modul e, an
i ntermi ttent wi pe modul e, an i l l umi nated entry mod-
ul e, a remote keyl ess entry modul e, and a vehi cl e
theft securi ty system modul e i n a si ngl e uni t.
The hi gh-l i ne CTM al so control s and i ntegrates
many of the addi ti onal el ectroni c functi ons and fea-
tures i ncl uded on model s wi th thi s opti on. The horn
rel ay i s one of the hard wi red outputs of the CTM.
The hi gh-l i ne CTM i s programmed to energi ze or de-
energi ze the horn rel ay i n response to certai n i nputs
from the Remote Keyl ess Entry (RKE) system and/or
the Vehi cl e Theft Securi ty System (VTSS).
(Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/BODY CONTROL/CENTRAL
TI MER MODUL - DESCRI PTI ON) for more i nforma-
ti on on the hi gh-l i ne CTM. (Refer to 8 - ELECTRI -
CAL/POWER LOCKS - GENERAL I NFORMATI ON)
for more i nformati on on the RKE system. Refer to
RI TY - GENERAL I NFORMATI ON) for more i nfor-
mati on on the VTSS.
AN HORN 8H - 1
HORN
DESCRIPTION
The dual el ectromagneti c di aphragm-type horns
are standard equi pment on thi s model . Both horns
are mounted on a si ngl e bracket that i s secured to
the front of the l eft verti cal member of the radi ator
support, just behi nd the radi ator gri l l e and forward
of the radi ator. The hi gh-note horn i s connected i n
paral l el wi th the l ow-note horn. The horns are con-
nected to the vehi cl e el ectri cal system through the
headl amp and dash wi re harness. Each horn i s
grounded through i ts wi re harness connector and a
ground ci rcui t to an eyel et termi nal secured by a
ground screw l ocated on the ri ght front i nner fender
behi nd the ri ght headl amp, and recei ves battery cur-
rent through the cl osed contacts of the horn rel ay.
Both horns and the mounti ng bracket are servi ced
as a si ngl e uni t. The horns cannot be repai red or
adjusted and, i f faul ty or damaged, the enti re horn
and bracket uni t must be repl aced.
OPERATION
Wi thi n the two hal ves of the mol ded pl asti c horn
housi ng are a fl exi bl e di aphragm, a pl unger, an el ec-
tromagneti c coi l and a set of contact poi nts. The di a-
phragm i s secured i n suspensi on around i ts
peri meter by the mati ng surfaces of the horn hous-
i ng. The pl unger i s secured to the center of the di a-
phragm and extends i nto the center of the
el ectromagneti c coi l . The contact poi nts control the
current fl ow through the el ectromagnet.
When the horn i s energi zed, el ectri cal current
fl ows through the cl osed contact poi nts to the el ectro-
magnet. The resul ti ng el ectromagneti c fi el d draws
the pl unger and di aphragm toward i t unti l that
movement mechani cal l y opens the contact poi nts.
When the contact poi nts open, the el ectromagneti c
fi el d col l apses al l owi ng the pl unger and di aphragm to
return to thei r rel axed posi ti ons and cl osi ng the con-
tact poi nts agai n. Thi s cycl e conti nues repeati ng at a
very rapi d rate produci ng the vi brati on and move-
ment of ai r that creates the sound that i s di rected
through the horn outl et.
DIAGNOSIS AND TESTING - HORN
(1) Di sconnect the wi re harness connector(s) from
the horn connector receptacl e(s). Measure the resi s-
tance between the ground ci rcui t cavi ty of the horn(s)
wi re harness connector(s) and a good ground. There
shoul d be no measurabl e resi stance. I f OK, go to Step
2. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
(2) Check for battery vol tage at the horn rel ay out-
put ci rcui t cavi ty of the horn(s) wi re harness connec-
tor(s). There shoul d be zero vol ts. I f OK, go to Step 3.
I f not OK, repai r the shorted horn rel ay output ci r-
cui t or repl ace the faul ty horn rel ay as requi red.
(3) Depress the horn swi tch. There shoul d now be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the horn(s) wi re harness connector(s). I f OK,
repl ace the faul ty horn(s). I f not OK, repai r the open
horn rel ay output ci rcui t to the horn rel ay as
requi red.
REMOVAL
cabl e.
(2) Di sconnect the headl amp and dash wi re har-
ness connectors from the horn connector receptacl es
(Fi g. 1) .
(3) Remove the screw that secures the horn and
mounti ng bracket uni t to the front of the l eft verti cal
member of the radi ator support.
(4) Remove the horn and mounti ng bracket uni t
from the radi ator support.
Fig. 1 Horns Remove/Install
1 - RADIATOR SUPPORT
2 - HEADLAMP AND DASH WIRE HARNESS
3 - LOW NOTE
4 - SCREW
5 - HORN AND BRACKET
6 - HIGH NOTE
8H - 2 HORN AN
INSTALLATION
(1) Posi ti on the horn and mounti ng bracket uni t
onto the front of the l eft verti cal member of the radi -
ator support.
horn and mounti ng bracket uni t to the radi ator sup-
port. Ti ghten the screw to 10.7 Nm (95 i n. l bs.).
(3) Reconnect the headl amp and dash wi re harness
connectors to the horn connector receptacl es.
HORN RELAY
DESCRIPTION
The horn rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the horn when the horn
swi tch grounds the rel ay coi l . The horn rel ay i s
l ocated i n the Juncti on Bl ock (JB), on the l eft end of
the i nstrument panel i n the passenger compartment.
I f a probl em i s encountered wi th a conti nuousl y
soundi ng horn, i t can usual l y be qui ckl y resol ved by
removi ng the horn rel ay from the JB unti l further
di agnosi s i s compl eted. See the fuse and rel ay l ayout
l abel affi xed to the i nsi de surface of the fuse access
panel for horn rel ay i denti fi cati on and l ocati on.
The horn rel ay i s a I nternati onal Standards Orga-
ni zati on (I SO) mi cro-rel ay. Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The I SO mi cro-rel ay termi nal functi ons
are the same as a conventi onal I SO rel ay. However,
the I SO mi cro-rel ay termi nal pattern (or footpri nt) i s
di fferent, the current capaci ty i s l ower, and the phys-
i cal di mensi ons are smal l er than those of the conven-
ti onal I SO rel ay.
The horn rel ay cannot be repai red or adjusted and,
i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor or di ode i s con-
nected i n paral l el wi th the el ectromagneti c coi l i n the
rel ay, and hel ps to di ssi pate vol tage spi kes that are
produced when the coi l i s de-energi zed.
DIAGNOSIS AND TESTING - HORN RELAY
The horn rel ay (Fi g. 2) i s l ocated i n the Juncti on
Bl ock (JB) on the l eft end of the i nstrument panel i n
the passenger compartment of the vehi cl e. I f a prob-
l em i s encountered wi th a conti nuousl y soundi ng
horn, i t can usual l y be qui ckl y resol ved by removi ng
the horn rel ay from the JB unti l further di agnosi s i s
compl eted. See the fuse and rel ay l ayout l abel affi xed
to the i nsi de surface of the fuse access panel for horn
rel ay i denti fi cati on and l ocati on. For compl ete ci rcui t
(1) Remove the horn rel ay from the JB. (Refer to 8
- ELECTRI CAL/HORN/HORN RELAY - REMOVAL)
for the procedures.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
and 30. I f OK, perform the Rel ay Ci rcui t Test that
fol l ows. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the horn(s). There shoul d be conti nui ty between
the cavi ty for rel ay termi nal 87 and the horn rel ay
output ci rcui t cavi ty of each horn wi re harness con-
AN HORN 8H - 3
HORN (Continued)
nector at al l ti mes. I f OK, go to Step 4. I f not OK,
repai r the open ci rcui t to the horn(s) as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
OK, go to Step 5. I f not OK, repai r the open ci rcui t to
the fuse i n the PDC as requi red.
the el ectromagnet i n the rel ay. I t i s grounded
through the horn swi tch when the horn swi tch i s
depressed. On vehi cl es equi pped wi th the Remote
Keyl ess Entry (RKE) system, the horn rel ay coi l
ground termi nal can al so be grounded by the Central
Ti mer Modul e (CTM) i n response to certai n i nputs
rel ated to the RKE system or the Vehi cl e Theft Secu-
ri ty System. Check for conti nui ty to ground at the
cavi ty for rel ay termi nal 85. There shoul d be conti -
nui ty wi th the horn swi tch depressed, and no conti -
nui ty wi th the horn swi tch rel eased. I f not OK,
(Refer to 8 - ELECTRI CAL/HORN/HORN SWI TCH -
DI AGNOSI S AND TESTI NG).
REMOVAL
INJURY.
cabl e.
(2) Remove the fuse access panel by i nserti ng a
fi nger i n the fi nger recess mol ded i nto the panel and
then pul l i ng the panel sharpl y away from the l eft
outboard end of the i nstrument panel .
(3) See the fuse and rel ay l ayout l abel affi xed to
the i nsi de of the fuse access panel for horn rel ay
i denti fi cati on and l ocati on.
(4) Grasp the horn rel ay fi rml y and pul l i t strai ght
out from the JB.
INSTALLATION
INJURY.
the i nsi de of the fuse access panel for the proper
horn rel ay l ocati on.
(2) Posi ti on the horn rel ay i n the proper receptacl e
i n the JB.
(3) Al i gn the horn rel ay termi nal s wi th the termi -
nal cavi ti es i n the JB receptacl e.
(4) Push i n fi rml y on the horn rel ay unti l the ter-
mi nal s are ful l y seated i n the termi nal cavi ti es i n the
JB receptacl e.
(5) I nsert the tabs on the forward edge of the fuse
access panel i n the notches on the forward edge of
the i nstrument panel fuse access panel openi ng.
(6) Press the rear edge of the fuse access panel i n
toward the i nstrument panel unti l the panel snaps
back i nto pl ace.
Fig. 2 Horn Relay
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
8H - 4 HORN AN
HORN RELAY (Continued)
HORN SWITCH
DESCRIPTION
A center-bl ow, normal l y open, resi sti ve membrane-
type horn swi tch i s secured wi th heat stakes to the
back si de of the dri ver si de ai rbag modul e tri m cover
i n the center of the steeri ng wheel (Fi g. 3) . The
swi tch consi sts of two pl asti c membranes, one that i s
fl at and one that i s sl i ghtl y convex. These two mem-
branes are secured to each other around the peri me-
ter. I nsi de the swi tch, the centers of the faci ng
surfaces of these membranes each has a gri d made
wi th an el ectri cal l y conducti ve materi al appl i ed to i t.
One of the gri ds i s connected to a ci rcui t that pro-
vi des i t wi th conti nui ty to ground at al l ti mes. The
gri d of the other membrane i s connected to the horn
rel ay control ci rcui t.
The steeri ng wheel and steeri ng col umn must be
properl y grounded i n order for the horn swi tch to
functi on properl y. The horn swi tch i s onl y servi ced as
a part of the dri ver si de ai rbag modul e tri m cover. I f
the horn swi tch i s damaged or faul ty, or i f the dri ver
si de ai rbag i s depl oyed, the dri ver si de ai rbag modul e
tri m cover and horn swi tch must be repl aced as a
uni t.
OPERATION
When the center area of the dri ver si de ai rbag tri m
cover i s depressed, the el ectri cal l y conducti ve gri ds
on the faci ng surfaces of the horn swi tch membranes
contact each other, cl osi ng the swi tch ci rcui t. The
compl eted horn swi tch ci rcui t provi des a ground for
the control coi l si de of the horn rel ay, whi ch acti vates
the rel ay. When the horn swi tch i s rel eased, the
resi sti ve tensi on of the convex membrane separates
the two el ectri cal l y conducti ve gri ds and opens the
swi tch ci rcui t.
DIAGNOSIS AND TESTING - HORN SWITCH
cabl e. Remove the steeri ng col umn openi ng cover
from the i nstrument panel .
(2) Check for conti nui ty between the metal steer-
i ng col umn jacket and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 3. I f not OK, (Refer to
19 - STEERI NG/COLUMN - I NSTALLATI ON) for
proper i nstal l ati on of the steeri ng col umn.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Di sconnect the horn swi tch wi re har-
ness connectors from the dri ver si de ai rbag modul e.
(4) Remove the horn rel ay from the Juncti on Bl ock
(JB). Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and a good ground. There shoul d be no
shorted horn rel ay control ci rcui t to the horn rel ay i n
the JB as requi red.
(5) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the JB. There shoul d be conti nui ty.
I f OK, go to Step 6. I f not OK, repai r the open horn
rel ay control ci rcui t to the horn rel ay i n the JB as
requi red.
Fig. 3 Driver Side Airbag Module Trim Cover and
Horn Switch
1 - RETAINER SLOTS
2 - RETAINER SLOTS
3 - HORN SWITCH
4 - LOCKING BLOCKS
AN HORN 8H - 5
(6) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
dri ver si de ai rbag modul e. There shoul d be no conti -
nui ty. I f OK, go to Step 7. I f not OK, repl ace the
faul ty horn swi tch.
(7) Depress the center of the dri ver si de ai rbag
modul e tri m cover and check for conti nui ty between
the horn swi tch feed wi re and the horn swi tch
ground wi re on the dri ver si de ai rbag modul e. There
shoul d now be conti nui ty. I f not OK, repl ace the
faul ty horn swi tch.
8H - 6 HORN AN
HORN SWITCH (Continued)
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2
AUTO SHUT DOWN RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ASD AND FUEL PUMP RELAYS. . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAMSHAFT POSITION SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISTRIBUTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DISTRIBUTOR CAP
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . 12
DISTRIBUTOR ROTOR
DISTRIBUTOR ROTOR. . . . . . . . . . . . . . . . . . . 13
IGNITION COIL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPARK PLUG
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPARK PLUG CONDITIONS. . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPARK PLUG CABLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPARK PLUG CABLES. . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
IGNITION CONTROL
DESCRIPTION
Two di fferent i gni ti on systems are used. One type
of system i s for the 2.5L 4cyl i nder, the 3.9L V-6
engi ne and the 5.9L V-8 engi ne. The other i s for the
4.7L V-8 engi ne.
The i gni ti on systems used on 2.5L 4cyl i nder, 3.9L
V-6 and 5.9L V-8 engi nes are basi cal l y i denti cal usi ng
a conventi onal di stri butor and remotel y mounted coi l .
The 4.7L V-8 engi ne does not use a di stri butor and
has 8 separate coi l s.
OPERATION
The i gni ti on system i s control l ed by the Powertrai n
Control Modul e (PCM) on al l engi nes.
The i gni ti on system consi sts of:
Spark Pl ugs
I gni ti on Coi l (s)
Secondary I gni ti on Cabl es (2.5L/3.9L/5.9L
engi nes)
Di stri butor (contai ns rotor and camshaft posi ti on
sensor) (2.5L/3.9L/5.9L engi nes)
Powertrai n Control Modul e (PCM)
Crankshaft Posi ti on and Camshaft Posi ti on Sen-
sors
The MAP, TPS, I AC and ECT al so have an effect
on the control of the i gni ti on system.
AN IGNITION CONTROL 8I - 1
SPECIFICATIONS
IGNITION TIMING
I gni ti on ti mi ng i s not adjustabl e on any engi ne.
ENGINE FIRING ORDER 2. 5L 4-CYLINDER
ENGINE
ENGINE FIRING ORDER 3. 9L V-6 ENGINE
ENGINE FIRING ORDER 4. 7L V-8 ENGINE
ENGINE FIRING ORDER 5. 2L/5. 9L V-8
ENGINES
8I - 2 IGNITION CONTROL AN
SPECIFICATIONS - TORQUE - IGNITION
Camshaft Position Sensor Bolt4.7L V-8 Engine 12 106
Crankshaft Position Sensor2.5L Engine 12 9
Crankshaft Position Sensor3.9L/5.2L/5.9L Engines 8 70
Crankshaft Position Sensor Bolt4.7L V-8 Engine 28 21
Distributor Hold Down Bolt 23 17
Ignition Coil Mounting (except 4.7L) (if tapped bolts are used) 5 50
Ignition Coil Mounting (except 4.7L) (if nuts/bolts are used) 11 100
Ignition Coil Mounting Nut4.7L V-8 Engine 8 70
Spark PlugsExcept 4.7L 35-41 26-30
Spark Plugs4.7L V-8 Engine 27 20
SPECIFICATIONS - IGNITION COIL RESISTANCE - 4. 7L V-8 ENGINE
PRIMARY RESISTANCE 21-27C (70-80F) SECONDARY RESISTANCE 21-27C (70-80F)
0.6 - 0.9 Ohms 6,000 - 9,000 Ohms
SPECIFICATIONS - IGNITION COIL RESISTANCE EXCEPT 4. 7L
COIL MANUFACTURER
PRIMARY RESISTANCE @
21-27C (70-80F)
SECONDARY RESISTANCE @ 21-27C
(70-80F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
SPECIFICATIONS - SPARK PLUG CABLE
RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
SPECIFICATIONS - SPARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
2.5L 4-CYL. RC12ECC 0.89 mm (.035 in.)
3.9L V-6 RC12LC4 1.01 mm (.040 in.)
4.7L V-8 RC12MCC4 1.01 mm (.040 in.)
5.2L V-8 RC12LC4 1.01 mm (.040 in.)
5.9L V-8 RC12LC4 1.01 mm (.040 in.)
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT
The 5pi n, 12vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION - ASD SENSE - PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ement, i gni ti on
coi l and fuel i njectors to 12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the Powertrai n Control Modul e
(PCM) does not see 12 vol ts at thi s i nput when the
ASD shoul d be acti vated, i t wi l l set a Di agnosti c
Troubl e Code (DTC).
OPERATION - PCM OUTPUT
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12vol ts to the
oxygen sensor heati ng el ements.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
The ASD rel ay wi l l be shutdown, meani ng the
12vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f:
the i gni ti on key i s l eft i n the ON posi ti on. Thi s
i s i f the engi ne has not been runni ng for approxi -
matel y 1.8 seconds.
there i s a crankshaft posi ti on sensor si gnal to
the PCM that i s l ower than pre-determi ned val ues.
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered. Two di fferent
types of rel ays may be used, (Fi g. 1) or (Fi g. 2).
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
Fig. 1 ASD and Fuel Pump Relay TerminalsType 1
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 2 ASD and Fuel Pump Relay TerminalsType 2
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be 75 ohms +/-
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to 8, Wi ri ng Di a-
grams.
REMOVAL
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 3). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 3). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION - EXCEPT 4. 7L
The Camshaft Posi ti on (CMP) sensor i s l ocated i n
the di stri butor.
DESCRIPTION - 4. 7L
The Camshaft Posi ti on Sensor (CMP) on the 4.7L
V8 engi ne i s bol ted to the front/top of the ri ght cyl -
OPERATION - EXCEPT 4. 7L
The sensor contai ns a hal l effect devi ce cal l ed a
sync si gnal generator to generate a fuel sync si gnal .
Thi s sync si gnal generator detects a rotati ng pul se
ri ng (shutter) on the di stri butor shaft. The pul se ri ng
rotates 180 degrees through the sync si gnal genera-
tor. I ts si gnal i s used i n conjuncti on wi th the Crank-
shaft Posi ti on (CKP) sensor to di fferenti ate between
fuel i njecti on and spark events. I t i s al so used to syn-
chroni ze the fuel i njectors wi th thei r respecti ve cyl i n-
ders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
Fig. 3 Power Distribution Center (PDC) Location
AUTO SHUT DOWN RELAY (Continued)
OPERATION - 4. 7L
The CMP sensor contai ns a hal l effect devi ce cal l ed
a sync si gnal generator to generate a fuel sync si g-
nal . Thi s sync si gnal generator detects notches
l ocated on a tonewheel . The tonewheel i s l ocated at
the front of the camshaft for the ri ght cyl i nder head
(Fi g. 5). As the tonewheel rotates, the notches pass
through the sync si gnal generator. The pattern of the
notches (vi ewed counter-cl ockwi se from front of
engi ne) i s: 1 notch, 2 notches, 3 notches, 3 notches, 2
notches 1 notch, 3 notches and 1 notch. The si gnal
from the CMP sensor i s used i n conjuncti on wi th the
crankshaft posi ti on sensor to di fferenti ate between
fuel i njecti on and spark events. I t i s al so used to syn-
chroni ze the fuel i njectors wi th thei r respecti ve cyl i n-
ders.
REMOVAL - EXCEPT 4. 7L
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor on al l 2.5/3.9/5.2/5.9L engi nes (Fi g. 6).
Di stri butor removal i s not necessary to remove
camshaft posi ti on sensor.
(2) Di sconnect negati ve cabl e from battery.
(3) Remove di stri butor cap from di stri butor (two
screws).
(4) Di sconnect camshaft posi ti on sensor wi ri ng
harness from mai n engi ne wi ri ng harness.
(5) Remove di stri butor rotor from di stri butor shaft.
(6) Li ft the camshaft posi ti on sensor assembl y
from the di stri butor housi ng (Fi g. 6).
Fig. 4 CMP Location4.7L Engine
2 - CAMSHAFT POSITION SENSOR
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
Fig. 5 CMP Sensor and Tonewheel4.7L Engine
1 - NOTCHES
4 - TONEWHEEL
Fig. 6 Camshaft Position SensorTypical (3.9/5.2/
5.9L Shown)
1 - SYNC SIGNAL GENERATOR
3 - PULSE RING
4 - DISTRIBUTOR ASSEMBLY
CAMSHAFT POSITION SENSOR (Continued)
REMOVAL - 4. 7L
I t i s easi er to remove/i nstal l sensor from under
vehi cl e.
(2) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 7).
(3) Remove sensor mounti ng bol t (Fi g. 7).
(4) Careful l y pry sensor from cyl i nder head i n a
rocki ng acti on wi th two smal l screwdri vers.
(5) Check condi ti on of sensor o-ri ng.
INSTALLATION - EXCEPT 4. 7L
tri butor on al l 2.5/3.9/5.2/5.9L engi nes (Fi g. 6).
(1) I nstal l camshaft posi ti on sensor to di stri butor.
Al i gn sensor i nto notch on di stri butor housi ng.
(2) Connect wi ri ng harness.
(3) I nstal l rotor.
(4) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
(5) I nstal l ai r cl eaner assembl y.
(1) Cl ean out machi ned hol e i n cyl i nder head.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto cyl i nder head wi th a sl i ght
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder head.
If sensor is not flush, damage to sensor mounting
tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 12 Nm
(106 i n. l bs.) torque.
DISTRIBUTOR
DESCRIPTION
Al l 2.5L/3.9L/5.9L engi nes are equi pped wi th a
camshaft dri ven mechani cal di stri butor (Fi g. 8) con-
tai ni ng a shaft dri ven di stri butor rotor. Al l di stri bu-
tors are equi pped wi th an i nternal camshaft posi ti on
(fuel sync) sensor (Fi g. 8).
OPERATION
The camshaft posi ti on sensor provi des fuel i njec-
ti on synchroni zati on and cyl i nder i denti fi cati on.
Fig. 7 CMP Location4.7L Engine
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
Fig. 8 Distributor and Camshaft Position Sensor-
Typical (3.9L/5.9L Shown)
1 - SYNC SIGNAL GENERATOR
3 - PULSE RING
4 - DISTRIBUTOR ASSEMBLY
CAMSHAFT POSITION SENSOR (Continued)
The di stri butor does not have bui l t i n centri fugal
or vacuum assi sted advance. Base i gni ti on ti mi ng
and al l ti mi ng advance i s control l ed by the Power-
trai n Control Modul e (PCM). Because i gni ti on ti mi ng
i s control l ed by the PCM, base ignition timing is
not adjustable on any of these engines.
Al l 2.5L/3.9L/5.9L di stri butors contai n an i nternal
oi l seal that prevents oi l from enteri ng the di stri bu-
tor housi ng. The seal i s not servi ceabl e.
REMOVAL - 2. 5 L
The di stri butor contai ns an i nternal oi l seal that
prevents oi l from enteri ng the di stri butor housi ng.
The seal i s not servi ceabl e.
Factory repl acement di stri butors are equi pped wi th
a pl asti c al i gnment pi n al ready i nstal l ed. The pi n i s
l ocated i n an access hol e on the bottom of the di stri b-
utor housi ng (Fi g. 9). I t i s used to temporari l y l ock
the rotor to the cyl i nder number 1 posi ti on duri ng
i nstal l ati on. The pi n must be removed after i nstal l -
i ng di stri butor.
tri butor on al l engi nes (Fi g. 10). For removal /i nstal -
l ati on procedures, refer to Camshaft Posi ti on Sensor.
Di stri butor removal i s not necessary for sensor
removal .
Refer to (Fi g. 10) for an expl oded vi ew of the di s-
tri butor.
A fork wi th a sl ot i s suppl i ed on the bottom of the
di stri butor housi ng where the housi ng base seats
agai nst the engi ne bl ock (Fi g. 10). The centerl i ne of
the sl ot al i gns wi th the di stri butor hol ddown bol t
hol e i n the engi ne bl ock. Because of the fork, the di s-
tri butor cannot be rotated. Di stri butor rotati on i s not
necessary as al l i gni ti on ti mi ng requi rements are
handl ed by the powertrai n control modul e (PCM).
The posi ti on of the di stri butor determi nes fuel syn-
chroni zati on onl y. I t does not determi ne i gni ti on ti m-
i ng.
NOTE: Do not attempt to modify this fork to attain
ignition timing.
(2) Remove ai r tube between throttl e body and ai r
cl eaner housi ng.
(3) Di sconnect coi l secondary cabl e at coi l .
(4) Remove di stri butor cap from di stri butor (2
screws). Do not remove cabl es from cap. Do not
remove rotor.
Fig. 9 Plastic Alignment Pin
1 - PLASTIC ALIGNMENT PIN
Fig. 10 Distributor2.5L EngineTypical
1 - CAP
3 - HOUSING
4 - FORK WITH SLOT
5 - DRIVE GEAR
6 - ROLL PIN
7 - WASHER
8 - GASKET
9 - HOLDDOWN CLAMP
10 - HOLDDOWN BOLT
11 - SHAFT
12 - PULSE RING
13 - ROTOR
DISTRIBUTOR (Continued)
(5) Di sconnect di stri butor wi ri ng harness from
mai n engi ne harness.
(6) Remove cyl i nder number 1 spark pl ug.
(7) Hol d a fi nger over open spark pl ug hol e. Rotate
engi ne at vi brati on dampener bol t unti l compressi on
(pressure) i s fel t.
(8) Sl owl y conti nue to rotate engi ne. Do thi s unti l
ti mi ng i ndex mark on vi brati on damper pul l ey al i gns
wi th top dead center (TDC) mark (0 degree) on ti m-
i ng degree scal e (Fi g. 11). Al ways rotate engi ne i n
di recti on of normal rotati on. Do not rotate engi ne
backward to al i gn ti mi ng marks.
(9) Remove di stri butor hol ddown bol t and cl amp.
(10) Remove di stri butor from engi ne by sl owl y l i ft-
i ng strai ght up.
(11) Note that rotor wi l l rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up di stri butor.
The oi l pump gear wi l l al so rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up di stri butor.
Thi s i s due to the hel i cal cut gears on di stri butor and
camshaft.
(12) Note removed posi ti on of rotor duri ng di stri b-
utor removal . Duri ng i nstal l ati on, thi s wi l l be
referred to as the Pre-posi ti on.
(13) Observe sl ot i n oi l pump gear through hol e on
si de of engi ne. I t shoul d be sl i ghtl y before (counter-
cl ockwi se of) 10 ocl ock posi ti on (Fi g. 12).
(14) Remove and di scard the ol d di stri butor-to-en-
gi ne bl ock gasket.
REMOVAL - 3. 9L/5. 2L/5. 9L
CAUTION: Base ignition timing is not adjustable on
any engine. Distributors do not have built in centrif-
ugal or vacuum assisted advance. Base ignition
timing and timing advance are controlled by the
Powertrain Control Module (PCM). Because a con-
ventional timing light can not be used to adjust dis-
tributor position after installation, note position of
distributor before removal.
(3) Remove di stri butor cap from di stri butor (two
screws).
(4) Mark the posi ti on of di stri butor housi ng i n
rel ati onshi p to engi ne or dash panel . Thi s i s done to
ai d i n i nstal l ati on.
(5) Before di stri butor i s removed, the number one
cyl i nder must be brought to the Top Dead Center
(TDC) fi ri ng posi ti on.
(6) Attach a socket to the Crankshaft Vi brati on
Damper mounti ng bol t.
(7) Sl owl y rotate engi ne cl ockwi se, as vi ewed from
front, unti l i ndi cati ng mark on crankshaft vi brati on
damper i s al i gned to 0 degree (TDC) mark on ti mi ng
chai n cover (Fi g. 13).
(8) The di stri butor rotor shoul d now be al i gned to
the CYL. NO. 1 al i gnment mark (stamped) i nto the
camshaft posi ti on sensor (Fi g. 14). I f not, rotate the
crankshaft through another compl ete 360 degree
turn. Note the posi ti on of the number one cyl i nder
spark pl ug cabl e (on the cap) i n rel ati on to rotor.
Rotor shoul d now be al i gned to thi s posi ti on.
(9) Di sconnect camshaft posi ti on sensor wi ri ng
harness from mai n engi ne wi ri ng harness.
Fig. 11 Align Timing Marks
1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK
Fig. 12 Slot At 10 Oclock Position2.5L Engine
1 - 10 0CLOCK POSITION
2 - OIL PUMP SLOT
(10) Remove di stri butor rotor from di stri butor
shaft.
(11) Remove di stri butor hol ddown cl amp bol t and
cl amp (Fi g. 15). Remove di stri butor from vehi cl e.
CAUTION: Do not crank engine with distributor
removed. Distributor/crankshaft relationship will be
lost.
(1) I f engi ne crankshaft has been rotated after di s-
tri butor removal , cyl i nder number 1 must be
returned to i ts proper fi ri ng stroke. Refer to previ ous
REMOVAL Step 6 and Step 7. These steps must be
done before i nstal l i ng di stri butor.
(2) Check posi ti on of sl ot on oi l pump gear. I t
shoul d be just sl i ghtl y before (countercl ockwi se of) 10
ocl ock posi ti on (Fi g. 12). I f not, pl ace a fl at bl ade
screwdri ver i nto oi l pump gear and rotate i t i nto
proper posi ti on.
(3) Factory repl acement di stri butors are equi pped
wi th a pl asti c al i gnment pi n al ready i nstal l ed (Fi g.
9). Thi s pi n i s used to temporari l y hol d rotor to cyl -
i nder number 1 fi ri ng posi ti on duri ng di stri butor
i nstal l ati on. I f thi s pi n i s i n pl ace, proceed to Step 8.
I f not, proceed to next step.
(4) I f ori gi nal di stri butor i s to be rei nstal l ed, such
as duri ng engi ne overhaul , the pl asti c pi n wi l l not be
avai l abl e. A 3/16 i nch dri ft pi n punch tool may be
substi tuted for pl asti c pi n.
(5) Remove camshaft posi ti on sensor from di stri b-
utor housi ng. Li ft strai ght up.
(6) Four di fferent al i gnment hol es are provi ded on
the pl asti c ri ng (Fi g. 16). Note that 2.5L 4cylinder
and 4.0L 6cylinder engines have different
alignment holes (Fig. 16).
(7) Rotate di stri butor shaft and i nstal l pi n punch
tool through proper al i gnment hol e i n pl asti c ri ng
(Fi g. 16) and i nto mati ng access hol e i n di stri butor
housi ng. Thi s wi l l prevent di stri butor shaft and rotor
from rotati ng.
(8) Cl ean di stri butor mounti ng hol e area of engi ne
bl ock.
(9) I nstal l new di stri butor-to-engi ne bl ock gasket
(Fi g. 10).
(10) I nstal l rotor to di stri butor shaft.
Fig. 13 Damper-To-Cover Alignment MarksTypical
1 - ALIGNMENT MARK
2 - TIMING CHAIN COVER MARKS
3 - CRANKSHAFT VIBRATION DAMPER
Fig. 14 Rotor Alignment Mark3.9/5.2/5.9L Engines
1 - CAMSHAFT POSITION SENSOR ALIGNMENT MARK
2 - ROTOR
3 - DISTRIBUTOR
Fig. 15 Distributor Holddown Clamp3.9/5.2/5.9L
Engines
1 - CLAMP BOLT
2 - HOLDDOWN CLAMP
3 - DISTRIBUTOR HOUSING
(11) Pre-posi ti on di stri butor i nto engi ne whi l e
hol di ng centerl i ne of base sl ot i n 1 ocl ock posi ti on
(Fi g. 17). Conti nue to engage di stri butor i nto engi ne.
The rotor and di stri butor wi l l rotate cl ockwi se duri ng
i nstal l ati on. Thi s i s due to hel i cal cut gears on di s-
tri butor and camshaft. When di stri butor i s ful l y
seated to engi ne bl ock, the centerl i ne of base sl ot
shoul d be al i gned to cl amp bol t mounti ng hol e on
engi ne (Fi g. 18). The rotor shoul d al so be poi nted
sl i ghtl y past (cl ockwi se of) 3 ocl ock posi ti on.
I t may be necessary to rotate rotor and di stri butor
shaft (very sl i ghtl y) to engage di stri butor shaft wi th
sl ot i n oi l pump gear. The same may have to be done
to engage di stri butor gear wi th camshaft gear.
The distributor is correctly installed when:
rotor i s poi nted at the 3 ocl ock posi ti on
pl asti c al i gnment pi n (or pi n punch tool ) i s sti l l
i nstal l ed to di stri butor.
number 1 cyl i nder pi ston i s set at top dead cen-
ter (TDC) (compressi on stroke).
centerl i ne of sl ot at base of di stri butor i s al i gned
to centerl i ne of di stri butor hol ddown bol t hol e on
engi ne. I n thi s posi ti on, hol ddown bol t shoul d easi l y
pass through sl ot and i nto engi ne.
No adjustments are necessary. Proceed to next
step.
Fig. 16 Pin Alignment Holes
1 - DISTRIBUTOR HOUSING (TOP VIEW)
2 - PULSE RING
3 - 4.0L 6CYLINDER ENGINE ALIGN. HOLE
4 - 2.5L 4CYLINDER ENGINE ALIGN. HOLE
5 - MATING ACCESS HOLE IN DISTRIBUTOR HOUSING
6 - PLASTIC RING
Fig. 17 Distributor Pre-position
1 - 1 OCLOCK POSITION
2 - BASE SLOT
3 - DISTRIBUTOR BASE
Fig. 18 Distributor Engaged Position2.5L
4-Cylinder Engine
1 - DISTRIBUTOR BASE SLOT
2 - CLAMP BOLT MOUNTING HOLE (ON ENGINE)
3 - DISTRIBUTOR BASE
(12) I nstal l di stri butor hol ddown cl amp and bol t.
(13) Remove pi n punch tool from di stri butor. Or, i f
pl asti c al i gnment pi n was used, remove i t strai ght
down from bottom of di stri butor. Di scard pl asti c pi n.
(14) I f removed, i nstal l camshaft posi ti on sensor to
di stri butor. Al i gn wi ri ng harness grommet to notch i n
di stri butor housi ng.
(15) I nstal l rotor.
CAUTION: If the distributor cap is incorrectly posi-
tioned on distributor housing, the cap or rotor may
be damaged when engine is started.
(16) I nstal l di stri butor cap. Ti ghten di stri butor cap
hol ddown screws to 3 Nm (26 i n. l bs.) torque.
(17) I f removed, i nstal l spark pl ug cabl es to di s-
tri butor cap. For proper fi ri ng order, refer to Engi ne
Fi ri ng Order i n Speci fi cati ons.
(18) Connect di stri butor wi ri ng harness to mai n
engi ne harness.
(19) Connect ai r tube between throttl e body and
ai r cl eaner housi ng.
I f engi ne has been cranked whi l e di stri butor i s
removed, establ i sh the rel ati onshi p between di stri bu-
tor shaft and number one pi ston posi ti on as fol l ows:
Rotate crankshaft i n a cl ockwi se di recti on, as
vi ewed from front, unti l number one cyl i nder pi ston
i s at top of compressi on stroke (compressi on shoul d
be fel t on fi nger wi th number one spark pl ug
removed). Then conti nue to sl owl y rotate engi ne
cl ockwi se unti l i ndi cati ng mark (Fi g. 13) i s al i gned to
0 degree (TDC) mark on ti mi ng chai n cover.
(1) Cl ean top of cyl i nder bl ock for a good seal
between di stri butor base and bl ock.
(2) Li ghtl y oi l the rubber o-ri ng seal on the di stri b-
utor housi ng.
(3) I nstal l rotor to di stri butor shaft.
(4) Posi ti on di stri butor i nto engi ne to i ts ori gi nal
posi ti on. Engage tongue of di stri butor shaft wi th sl ot
i n di stri butor oi l pump dri ve gear. Posi ti on rotor to
the number one spark pl ug cabl e posi ti on.
(5) I nstal l di stri butor hol ddown cl amp and cl amp
bol t. Do not ti ghten bol t at thi s ti me.
(6) Rotate the di stri butor housi ng unti l rotor i s
al i gned to CYL. NO. 1 al i gnment mark on the cam-
shaft posi ti on sensor (Fi g. 14).
(7) Ti ghten cl amp hol ddown bol t (Fi g. 15) to 22.5
(8) Connect camshaft posi ti on sensor wi ri ng har-
ness to mai n engi ne harness.
(9) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
(10) Refer to the fol l owi ng, Checki ng Di stri butor
Posi ti on.
Checking Distributor Position
To veri fy correct di stri butor rotati onal posi ti on, the
DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
(1) Connect DRB scan tool to data l i nk connector.
The data l i nk connector i s l ocated i n passenger com-
partment, bel ow and to l eft of steeri ng col umn.
(2) Gai n access to SET SYNC screen on DRB.
(3) Fol l ow di recti ons on DRB screen and start
engi ne. Bri ng to operati ng temperature (engi ne must
be i n cl osed l oop mode).
(4) Wi th engi ne runni ng at idle speed, the words
I N RANGE shoul d appear on screen al ong wi th 0.
Thi s i ndi cates correct di stri butor posi ti on.
(5) I f a pl us (+) or a mi nus (-) i s di spl ayed next to
degree number, and/or the degree di spl ayed i s not
zero, l oosen but do not remove di stri butor hol ddown
cl amp bol t. Rotate di stri butor unti l I N RANGE
appears on screen. Conti nue to rotate di stri butor
unti l achi evi ng as cl ose to 0 as possi bl e. After
adjustment, ti ghten cl amp bol t to 22.5 Nm (200 i n.
l bs.) torque.
The degree scal e on SET SYNC screen of DRB i s
referri ng to fuel synchroni zati on onl y. It is not
referring to ignition timing. Because of thi s, do
not attempt to adjust i gni ti on ti mi ng usi ng thi s
method. Rotati ng di stri butor wi l l have no effect on
i gni ti on ti mi ng. Al l i gni ti on ti mi ng val ues are con-
trol l ed by Powertrai n Control Modul e (PCM).
After testi ng, i nstal l ai r cl eaner assembl y.
DISTRIBUTOR CAP
DIAGNOSIS AND TESTING - DISTRIBUTOR
CAP
Remove the di stri butor cap and wi pe i t cl ean wi th
a dry l i nt free cl oth. Vi sual l y i nspect the cap for
cracks, carbon paths, broken towers or damaged
rotor button (Fi g. 19) or (Fi g. 20). Al so check for
whi te deposi ts on the i nsi de (caused by condensati on
enteri ng the cap through cracks). Repl ace any cap
that di spl ays charred or eroded termi nal s. The
machi ned surface of a termi nal end (faces toward
rotor) wi l l i ndi cate some evi dence of erosi on from
normal operati on. Exami ne the termi nal ends for evi -
dence of mechani cal i nterference wi th the rotor ti p.
DISTRIBUTOR ROTOR
DIAGNOSIS AND TESTING - DISTRIBUTOR
ROTOR
Vi sual l y i nspect the rotor (Fi g. 21) for cracks, evi -
dence of corrosi on or the effects of arci ng on the
metal ti p. Al so check for evi dence of mechani cal
i nterference wi th the cap. Some charri ng i s normal
on the end of the metal ti p. The si l i cone-di el ectri c-
varni sh-compound appl i ed to the rotor ti p for radi o
i nterference noi se suppressi on, wi l l appear charred.
Thi s i s normal . Do not remove the charred com-
pound. Test the spri ng for i nsuffi ci ent tensi on.
Repl ace a rotor that di spl ays any of these adverse
condi ti ons.
IGNITION COIL
A si ngl e i gni ti on coi l i s used. The coi l i s not oi l
fi l l ed. The coi l wi ndi ngs are embedded i n an epoxy
compound. Thi s provi des heat and vi brati on resi s-
tance that al l ows the coi l to be mounted on the
engi ne.
DESCRIPTION - 4. 7L
The 4.7L V8 engi ne uses 8 dedi cated, and i ndi vi d-
ual l y fi red coi l (Fi g. 22) for each spark pl ug. Each
coi l i s mounted di rectl y to the top of each spark pl ug
(Fi g. 23).
OPERATION - EXCEPT 4. 7L
The Powertrai n Control Modul e (PCM) opens and
cl oses the i gni ti on coi l ground ci rcui t for i gni ti on coi l
operati on.
Battery vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal from the ASD rel ay. I f the PCM does
not see a si gnal from the crankshaft and camshaft
sensors (i ndi cati ng the i gni ti on key i s ON but the
engi ne i s not runni ng), i t wi l l shut down the ASD ci r-
cui t.
Fig. 19 Cap InspectionExternalTypical
1 - BROKEN TOWER
2 - DISTRIBUTOR CAP
3 - CARBON PATH
4 - CRACK
Fig. 20 Cap InspectionInternalTypical
1 - CHARRED OR ERODED TERMINALS
2 - WORN OR DAMAGED ROTOR BUTTON
3 - CARBON PATH
Fig. 21 Rotor InspectionTypical
1 - INSUFFICIENT SPRING TENSION
2 - CRACKS
3 - EVIDENCE OF PHYSICAL CONTACT WITH CAP
4 - ROTOR TIP CORRODED
DISTRIBUTOR CAP (Continued)
Base ignition timing is not adjustable on any
engine. By control l i ng the coi l ground ci rcui t, the
PCM i s abl e to set the base ti mi ng and adjust the
i gni ti on ti mi ng advance. Thi s i s done to meet chang-
i ng engi ne operati ng condi ti ons.
OPERATION - 4. 7L
Battery vol tage i s suppl i ed to the 8 i gni ti on coi l s
from the ASD rel ay. The Powertrai n Control Modul e
(PCM) opens and cl oses each i gni ti on coi l ground ci r-
cui t at a determi ned ti me for i gni ti on coi l operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used.
REMOVAL - 2. 5L
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
The i gni ti on coi l i s mounted to a bracket on the
si de of the engi ne to the rear of the di stri butor (Fi g.
24).
(1) Di sconnect the i gni ti on coi l secondary cabl e
from i gni ti on coi l (Fi g. 24).
(2) Di sconnect engi ne harness connector from i gni -
ti on coi l .
(3) Remove i gni ti on coi l mounti ng bol ts (nuts may
al so be used on back si de of bracket).
(4) Remove coi l .
Fig. 22 Ignition Coil4.7L Engine
1 - O-RING
2 - IGNITION COIL
Fig. 23 Ignition Coil Location4.7L Engine
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
1 - IGNITION COIL
4 - SECONDARY CABLE
IGNITION COIL (Continued)
REMOVAL - 3. 9L/5. 2L/5. 9L
The coi l i s mounted to a bracket that i s bol ted to
the front of the ri ght engi ne cyl i nder head (Fi g. 25).
Thi s bracket i s mounted on top of the automati c bel t
tensi oner bracket usi ng common bol ts.
(1) Di sconnect the pri mary wi ri ng from the i gni -
ti on coi l .
(2) Di sconnect the secondary spark pl ug cabl e from
the i gni ti on coi l .
WARNING: DO NOT REMOVE THE COIL MOUNTING
BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS.
THE COIL MOUNTING BRACKET IS UNDER ACCES-
SORY DRIVE BELT TENSION. IF THIS BRACKET IS
TO BE REMOVED FOR ANY REASON, ALL BELT
TENSION MUST FIRST BE RELIEVED. REFER TO
THE BELT SECTION OF 7, COOLING SYSTEM.
(3) Remove i gni ti on coi l from coi l mounti ng
bracket (two bol ts).
REMOVAL - 4. 7L
An i ndi vi dual i gni ti on coi l i s used for each spark
pl ug (Fi g. 26). The coi l fi ts i nto machi ned hol es i n the
cyl i nder head. A mounti ng stud/nut secures each coi l
to the top of the i ntake mani fol d (Fi g. 27). The bot-
tom of the coi l i s equi pped wi th a rubber boot to seal
the spark pl ug to the coi l . I nsi de each rubber boot i s
a spri ng. The spri ng i s used for a mechani cal contact
between the coi l and the top of the spark pl ug. These
rubber boots and spri ngs are a permanent part of the
coi l and are not servi ced separatel y. An o-ri ng (Fi g.
26) i s used to seal the coi l at the openi ng i nto the cyl -
i nder head.
(1) Dependi ng on whi ch coi l i s bei ng removed, the
throttl e body ai r i ntake tube or i ntake box may need
to be removed to gai n access to coi l .
(2) Di sconnect el ectri cal connector (Fi g. 27) from
coi l by pushi ng downward on rel ease l ock on top of
connector and pul l connector from coi l .
(3) Cl ean area at base of coi l wi th compressed ai r
before removal .
(4) Remove coi l mounti ng nut from mounti ng stud
(Fi g. 27).
(5) Careful l y pul l up coi l from cyl i nder head open-
i ng wi th a sl i ght twi sti ng acti on.
(6) Remove coi l from vehi cl e.
(1) I nstal l i gni ti on coi l to bracket. I f nut and bol ts
are used to secure coi l to coi l bracket, ti ghten to 11
Nm (100 i n. l bs.) torque. I f bol ts are used, ti ghten
bol ts to 5 Nm (50 i n. l bs.) torque.
(2) Connect engi ne harness connector to coi l .
(3) Connect i gni ti on coi l cabl e to i gni ti on coi l .
Fig. 25 Ignition Coil3.9L V-6 or 5.2/5.9L V-8
Engines
1 - ACCESSORY DRIVE BELT TENSIONER
2 - COIL CONNECTOR
3 - IGNITION COIL
4 - COIL MOUNTING BOLTS
Fig. 26 Ignition Coil4.7L V8 Engine
1 - O-RING
2 - IGNITION COIL
(1) I nstal l the i gni ti on coi l to coi l bracket. I f nuts
and bol ts are used to secure coi l to coi l bracket,
ti ghten to 11 Nm (100 i n. l bs.) torque. I f the coi l
mounti ng bracket has been tapped for coi l mounti ng
bol ts, ti ghten bol ts to 5 Nm (50 i n. l bs.) torque.
(2) Connect al l wi ri ng to i gni ti on coi l .
(1) Usi ng compressed ai r, bl ow out any di rt or con-
tami nants from around top of spark pl ug.
(2) Check condi ti on of coi l o-ri ng and repl ace as
necessary. To ai d i n coi l i nstal l ati on, appl y si l i cone to
coi l o-ri ng.
(3) Posi ti on i gni ti on coi l i nto cyl i nder head openi ng
and push onto spark pl ug. Do thi s whi l e gui di ng coi l
base over mounti ng stud.
(4) I nstal l mounti ng stud nut and ti ghten to 8 Nm
(5) Connect el ectri cal connector to coi l by snappi ng
i nto posi ti on.
(6) I f necessary, i nstal l throttl e body ai r tube or
box.
SPARK PLUG
DESCRIPTION
Al l engi nes use resi stor type spark pl ugs. 4.7L V-8
engi nes are equi pped wi th fi red i n suppressor seal
type spark pl ugs usi ng a copper core ground el ec-
trode.
Because of the use of an al umi num cyl i nder head
on the 4.7L engi ne, spark pl ug torque i s very cri ti cal .
To prevent possi bl e pre-i gni ti on and/or mechani cal
engi ne damage, the correct type/heat range/number
spark pl ug must be used.
OPERATION
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. A si n-
gl e pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
Lubri cati on and Mai ntenance.
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Al so refer to Spark Pl ug Condi ti ons.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 28). There wi l l not be evi dence of el ectrode
burni ng. On al l engi nes except the 4.7L V-8, gap
growth wi l l not average more than approxi matel y
0.025 mm (.001 i n) per 3200 km (2000 mi l es) of oper-
ati on. On the 4.7L V-8, gap growth wi l l not average
more than approxi matel y .0015 i n per 3200 km (2000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Fig. 27 Ignition Coil Location4.7L V8 Engine
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance may be
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 28). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 29), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 30).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
Fig. 28 Normal Operation and Cold (Carbon) Fouling
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
Fig. 29 Oil or Ash Encrusted
Fig. 30 Electrode Gap Bridging
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
SPARK PLUG (Continued)
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 31). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 32). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 33). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
34). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 2000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
REMOVAL
On 3.9L V-6 and 5.2/5.9L V-8 engi nes, spark pl ug
cabl e heat shi el ds are pressed i nto the cyl i nder head
to surround each cabl e boot and spark pl ug (Fi g. 35).
Fig. 31 Scavenger Deposits
1 - GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
Fig. 32 Chipped Electrode Insulator
1 - GROUND ELECTRODE
3 - CHIPPED INSULATOR
Fig. 33 Preignition Damage
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
I f removal of the heat shi el d(s) i s necessary,
remove the spark pl ug cabl e and compress the si des
of shi el d for removal . Each shi el d i s sl otted to al l ow
for compressi on and removal . To i nstal l the shi el ds,
al i gn shi el d to machi ned openi ng i n cyl i nder head
and tap i nto pl ace wi th a bl ock of wood.
4.7L V8 Engi ne: Each i ndi vi dual spark pl ug i s
l ocated under each i gni ti on coi l . Each i ndi vi dual i gni -
ti on coi l must be removed to gai n access to each spark
pl ug. Refer to I gni ti on Coi l Removal /I nstal l ati on.
(1) Except 4.7L Engi ne: Pri or to removi ng spark
pl ug, spray compressed ai r around spark pl ug hol e
and area around spark pl ug. Thi s wi l l hel p prevent
forei gn materi al from enteri ng combusti on chamber.
(2) 4.7L V8 Engi ne: Pri or to removi ng spark pl ug,
spray compressed ai r around base of i gni ti on coi l at
cyl i nder head. Thi s wi l l hel p prevent forei gn materi al
from enteri ng combusti on chamber.
(3) Remove spark pl ug from cyl i nder head usi ng a
qual i ty socket wi th a rubber or foam i nsert. I f
equi pped wi th a 4.7L V-8 engi ne, al so check condi ti on
of coi l o-ri ng and repl ace as necessary.
(4) Except 4.7L: Al ways remove spark pl ug or i gni -
ti on coi l cabl es by graspi ng at the cabl e boot (Fi g.
37). Turn the cabl e boot 1/2 turn and pul l strai ght
back i n a steady moti on. Never pul l di rectl y on the
cabl e. I nternal damage to cabl e wi l l resul t.
(5) I nspect spark pl ug condi ti on. Refer to Spark
Pl ug Condi ti ons.
CLEANING
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e center el ectrode fl at wi th a smal l poi nt fi l e or
jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
INSTALLATION
CAUTION: The 4.7L V8 engine is equipped with
copper core ground electrode spark plugs. They
must be replaced with the same type/number spark
plug as the original. If another spark plug is substi-
tuted, pre-ignition will result.
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
Except 4.7L Engi ne: When repl aci ng the spark pl ug
and i gni ti on coi l cabl es, route the cabl es correctl y and
secure them i n the appropri ate retai ners. Fai l ure to
route the cabl es properl y can cause the radi o to repro-
duce i gni ti on noi se. I t coul d cause cross i gni ti on of the
spark pl ugs or short ci rcui t the cabl es to ground.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Except 4.7L Engi ne: Ti ghten spark pl ugs to
35-41 Nm (26-30 ft. l bs.) torque.
(3) Except 4.7L Engi ne: I nstal l spark pl ug cabl es
over spark pl ugs.
(4) 4.7L V8 Engi ne: Ti ghten spark pl ugs to 27
(5) 4.7L V8 Engi ne: Before i nstal l i ng coi l (s), check
condi ti on of coi l o-ri ng and repl ace as necessary. To ai d
i n coi l i nstal l ati on, appl y si l i cone to coi l o-ri ng.
(6) 4.7L V8 Engi ne: I nstal l i gni ti on coi l (s). Refer
to I gni ti on Coi l Removal /I nstal l ati on.
Fig. 34 Spark Plug Overheating
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
Fig. 35 Heat Shields3.9/5.2/5.9L Engines
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
SPARK PLUG CABLE
DESCRIPTION
Spark pl ug cabl es are someti mes referred to as sec-
ondary i gni ti on wi res.
OPERATION
The spark pl ug cabl es transfer el ectri cal current
from the i gni ti on coi l (s) and/or di stri butor, to i ndi vi d-
ual spark pl ugs at each cyl i nder. The resi sti ve spark
pl ug cabl es are of nonmetal l i c constructi on. The
cabl es provi de suppressi on of radi o frequency emi s-
si ons from the i gni ti on system.
DIAGNOSIS AND TESTING - SPARK PLUG
CABLES
Check the spark pl ug cabl e connecti ons for good
contact at the coi l (s), di stri butor cap towers, and
spark pl ugs. Termi nal s shoul d be ful l y seated. The
i nsul ators shoul d be i n good condi ti on and shoul d fi t
ti ghtl y on the coi l , di stri butor and spark pl ugs. Spark
pl ug cabl es wi th i nsul ators that are cracked or torn
must be repl aced.
Cl ean hi gh vol tage i gni ti on cabl es wi th a cl oth
moi stened wi th a non-fl ammabl e sol vent. Wi pe the
cabl es dry. Check for bri ttl e or cracked i nsul ati on.
On 3.9L V-6 and 5.2/5.9L V-8 engi nes, spark pl ug
cabl e heat shi el ds are pressed i nto the cyl i nder head
to surround each spark pl ug cabl e boot and spark
pl ug (Fi g. 36). These shi el ds protect the spark pl ug
boots from damage (due to i ntense engi ne heat gen-
erated by the exhaust mani fol ds) and shoul d not be
removed. After the spark pl ug cabl e has been
i nstal l ed, the l i p of the cabl e boot shoul d have a
smal l ai r gap to the top of the heat shi el d (Fi g. 36).
TESTING
When testi ng secondary cabl es for damage wi th an
osci l l oscope, fol l ow the i nstructi ons of the equi pment
manufacturer.
I f an osci l l oscope i s not avai l abl e, spark pl ug cabl es
may be tested as fol l ows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Wi th the engi ne runni ng, remove spark pl ug cabl e
from spark pl ug (one at a ti me) and hol d next to a
good engi ne ground. I f the cabl e and spark pl ug are
i n good condi ti on, the engi ne rpm shoul d drop and
the engi ne wi l l run poorl y. I f engi ne rpm does not
drop, the cabl e and/or spark pl ug may not be operat-
i ng properl y and shoul d be repl aced. Al so check
engi ne cyl i nder compressi on.
Wi th the engi ne not runni ng, connect one end of a
test probe to a good ground. Start the engi ne and run
the other end of the test probe al ong the enti re
l ength of al l spark pl ug cabl es. I f cabl es are cracked
or punctured, there wi l l be a noti ceabl e spark jump
from the damaged area to the test probe. The cabl e
runni ng from the i gni ti on coi l to the di stri butor cap
can be checked i n the same manner. Cracked, dam-
aged or faul ty cabl es shoul d be repl aced wi th resi s-
tance type cabl e. Thi s can be i denti fi ed by the words
ELECTRONI C SUPPRESSI ON pri nted on the cabl e
jacket.
Use an ohmmeter to test for open ci rcui ts, exces-
si ve resi stance or l oose termi nal s. I f equi pped,
remove the di stri butor cap from the di stri butor. Do
not remove cables from cap. Remove cabl e from
spark pl ug. Connect ohmmeter to spark pl ug termi -
nal end of cabl e and to correspondi ng el ectrode i n
di stri butor cap. Resi stance shoul d be 250 to 1000
Ohms per i nch of cabl e. I f not, remove cabl e from di s-
tri butor cap tower and connect ohmmeter to the ter-
mi nal ends of cabl e. I f resi stance i s not wi thi n
speci fi cati ons as found i n the SPARK PLUG CABLE
RESI STANCE chart, repl ace the cabl e. Test al l spark
pl ug cabl es i n thi 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 Fig. 36 Heat Shields3.9/5.2/5.9L Engines
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
To test i gni ti on coi l -to-di stri butor cap cabl e, do not
remove the cabl e from the cap. Connect ohmmeter to
rotor button (center contact) of di stri butor cap and
termi nal at i gni ti on coi l end of cabl e. I f resi stance i s
not wi thi n speci fi cati ons as found i n the Spark Pl ug
Cabl e Resi stance chart, remove the cabl e from the
di stri butor cap. Connect the ohmmeter to the termi -
nal ends of the cabl e. I f resi stance i s not wi thi n spec-
i fi cati ons as found i n the Spark Pl ug Cabl e
Resi stance chart, repl ace the cabl e. I nspect the i gni -
ti on coi l tower for cracks, burns or corrosi on.
REMOVAL
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 37). Grasp the boot (not the cable) and pull it
off with a steady, even force.
I nstal l cabl es i nto the proper engi ne cyl i nder fi ri ng
order. Refer to Fi ri ng Order i n Speci fi cati ons.
INSTALLATION
I nstal l cabl es i nto the proper engi ne cyl i nder fi ri ng
order. Refer to Fi ri ng Order i n Speci fi cati ons.
When repl aci ng the spark pl ug and coi l cabl es,
route the cabl es correctl y and secure i n the proper
retai ners. Fai l ure to route the cabl es properl y can
cause the radi o to reproduce i gni ti on noi se. I t coul d
al so cause cross i gni ti on of the pl ugs or short ci rcui t
the cabl es to ground.
When i nstal l i ng new cabl es, make sure a posi ti ve
connecti on i s made. A snap shoul d be fel t when a
good connecti on i s made between the pl ug cabl e and
the di stri butor cap tower.
Fig. 37 Cable Removal
1 - SPARK PLUG CABLE AND BOOT
2 - SPARK PLUG BOOT PULLER
3 - TWIST AND PULL
4 - SPARK PLUG
SPARK PLUG CABLE (Continued)
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ABS INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AIRBAG INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE/PARK BRAKE INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHECK GAUGES INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COOLANT LOW INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CRUISE INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DOOR AJAR INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE TEMPERATURE GAUGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL GAUGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GEAR SELECTOR INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HIGH BEAM INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HIGH BEAM INDICATOR . . . . . . . . . . . . . . . . . 22
LOW FUEL INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ODOMETER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OIL PRESSURE GAUGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OVERDRIVE OFF INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SEATBELT INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECURITY INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE 4WD INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPEEDOMETER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TACHOMETER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TRANSMISSION TEMP INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TURN SIGNAL INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TURN SIGNAL INDICATOR. . . . . . . . . . . . . . . . 32
UPSHIFT INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VOLTAGE GAUGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
WAIT-TO-START INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
WAIT-TO-START INDICATOR . . . . . . . . . . . . . . 35
AN INSTRUMENT CLUSTER 8J - 1
WASHER FLUID INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
WASHER FLUID INDICATOR . . . . . . . . . . . . . . 36
WATER-IN-FUEL INDICATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTRUMENT CLUSTER
DESCRIPTION
The i nstrument cl uster for thi s model i s an El ec-
troMechani cal I nstrument Cl uster (EMI C) modul e
that i s l ocated i n the i nstrument panel above the
steeri ng col umn openi ng, di rectl y i n front of the
dri ver (Fi g. 1). The EMI C gauges and i ndi cators are
protected by an i ntegral cl ear pl asti c cl uster l ens,
and are vi si bl e through a dedi cated openi ng i n the
cl uster bezel on the i nstrument panel . Just behi nd
the cl uster l ens i s the cl uster hood and i ntegral cl us-
ter mask, whi ch are constructed of mol ded bl ack
pl asti c. The cl uster hood serves as a vi sor and shi el ds
the face of the cl uster from ambi ent l i ght and refl ec-
ti ons to reduce gl are, whi l e the cl uster mask serves
to separate the defi ne the i ndi vi dual gauges and the
i nformati on center area of the EMI C. Behi nd the
cl uster hood and mask i s the cl uster overl ay and
gauges. The overl ay i s a l ami nated pl asti c uni t. The
dark, vi si bl e surface of the outer l ayer of the overl ay
i s marked wi th al l of the gauge i denti fi cati on and
graduati ons, but thi s l ayer i s al so transl ucent. The
darkness of thi s outer l ayer prevents the cl uster from
appeari ng cl uttered or busy by conceal i ng the cl uster
i ndi cators that are not i l l umi nated, whi l e the trans-
l ucence of thi s l ayer al l ows those i ndi cators and i cons
that are i l l umi nated to be readi l y vi si bl e. The under-
l yi ng l ayer of the overl ay i s opaque and al l ows l i ght
from the vari ous i ndi cators and i l l umi nati on l amps
behi nd i t to be vi si bl e through the outer l ayer of the
overl ay onl y through predetermi ned cutouts. On the
l ower edge of the cl uster l ens just l eft of center, the
odometer/tri p odometer swi tch knob protrudes
through dedi cated hol es i n the cl uster mask and the
cl uster l ens. The remai nder of the EMI C, i ncl udi ng
the mounts and the el ectri cal connecti ons, are con-
ceal ed behi nd the cl uster bezel . The mol ded pl asti c
EMI C housi ng has four i ntegral mounti ng tabs, two
each on the upper and l ower edges of the housi ng.
The EMI C i s secured to the mol ded pl asti c i nstru-
ment panel cl uster carri er wi th four screws. Al l el ec-
tri cal connecti ons to the EMI C are made at the back
of the cl uster housi ng through two take outs of the
i nstrument panel wi re harness, each equi pped wi th a
sel f-docki ng connector.
A si ngl e EMI C modul e i s offered on thi s model ;
however, some vari ati ons of thi s modul e exi st due to
opti onal equi pment and regul atory requi rements.
Thi s modul e uti l i zes i ntegrated ci rcui try and i nfor-
mati on carri ed on the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus network for control of
al l gauges and many of the i ndi cators. (Refer to 8 -
ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/COMMUNI CATI ON - DESCRI PTI ON). The
EMI C al so uses several hard wi red i nputs i n order to
perform i ts many functi ons. I n addi ti on to i nstru-
mentati on and i ndi cators, the EMI C has hardware
and/or software to support the fol l owi ng functi ons:
Chime Warning Requests - The EMI C sends
chi me tone requests over the PCI data bus network
to the Central Ti mer Modul e (CTM) when i t moni tors
certai n condi ti ons or i nputs. The CTM repl aces the
chi me or buzzer modul e and performs the functi ons
necessary to provi de audi bl e al erts that are synchro-
ni zed wi th the vi sual al erts provi ded by the EMI C.
(Refer to 8 - ELECTRI CAL/CHI ME/BUZZER -
DESCRI PTI ON).
Vacuum Fluorescent Display (VFD) Dim-
ming Service - The EMI C performs the functi ons
necessary to el i mi nate the need for a separate VFD
di mmi ng modul e by provi di ng control and synchroni -
zati on of the i l l umi nati on i ntensi ty of al l vacuum fl u-
orescent di spl ays i n the vehi cl e, as wel l as a parade
mode.
The EMI C modul e i ncorporates a bl ue-green di gi tal
VFD for di spl ayi ng odometer and tri p odometer i nfor-
mati on, as wel l as the amber crui se i ndi cator di spl ay
functi on. Some vari ati ons of the EMI C are necessary
to support opti onal equi pment and regul atory
requi rements. The EMI C i ncl udes the fol l owi ng ana-
l og gauges:
Fig. 1 Instrument Cluster
1 - INSTRUMENT PANEL TOP COVER
2 - INSTRUMENT CLUSTER
3 - CLUSTER BEZEL
8J - 2 INSTRUMENT CLUSTER AN
Coolant Temperature Gauge
Fuel Gauge
Oil Pressure Gauge
Speedometer
Tachometer
Voltage Gauge
The EMI C al so i ncl udes provi si ons for the fol l ow-
i ng i ndi cators:
Airbag Indicator
Antilock Brake System (ABS) Indicator
Brake Indicator
Check Gauges Indicator
Coolant Low Indicator (Diesel Engine Only)
Cruise Indicator (Odometer VFD)
Door Ajar Indicator
High Beam Indicator
Low Fuel Indicator
Malfunction Indicator Lamp (MIL)
Overdrive-Off Indicator (Automatic Trans-
mission Only)
Seatbelt Indicator
Security Indicator
Service Four-Wheel Drive Indicator
Transmission Overtemp Indicator
Turn Signal (Right and Left) Indicators
Upshift Indicator
Wait-To-Start Indicator (Diesel Engine
Only)
Washer Fluid Indicator
Water-In-Fuel Indicator (Diesel Engine
Only)
Some of these i ndi cators are ei ther programmabl e
or automati cal l y confi gured when the EMI C i s con-
nected to the vehi cl e el ectri cal system. Thi s feature
al l ows those i ndi cators to be acti vated or deacti vated
for compati bi l i ty wi th certai n opti onal equi pment. On
model s equi pped wi th an automati c transmi ssi on, the
EMI C al so i ncorporates a bl ue-green di gi tal VFD i n
the l ower ri ght corner of the cl uster for di spl ayi ng
the transmi ssi on gear that has been sel ected wi th
the automati c transmi ssi on gear sel ector l ever, as
wel l as the amber overdri ve-off i ndi cator di spl ay
functi on.
Cl uster i l l umi nati on i s accompl i shed by adjustabl e
i ncandescent back l i ghti ng, whi ch i l l umi nates the
gauges for vi si bi l i ty when the exteri or l i ghti ng i s
turned on. The EMI C hi gh beam i ndi cator, turn si g-
nal i ndi cators, and wai t-to-start i ndi cator are al so
i l l umi nated by dedi cated i ncandescent bul bs. The
remai ni ng i ndi cators i n the EMI C are each i l l umi -
nated by a dedi cated Li ght Emi tti ng Di ode (LED)
that i s sol dered onto the el ectroni c ci rcui t board.
Each of the i ncandescent bul bs i s secured by an i nte-
gral bul b hol der to the el ectroni c ci rcui t board from
the back of the cl uster housi ng.
Hard wi red ci rcui try connects the EMI C to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
and to the EMI C through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
further detai l s on wi re harness routi ng and reten-
ti on, as wel l as pi n-out and l ocati on vi ews for the
The EMI C modul es for thi s model are servi ced onl y
as compl ete uni ts. The EMI C modul e cannot be
adjusted or repai red. I f a gauge, an LED i ndi cator,
the VFD, the el ectroni c ci rcui t board, the ci rcui t
board hardware, the cl uster overl ay, or the EMI C
housi ng are damaged or faul ty, the enti re EMI C mod-
ul e must be repl aced. The cl uster l ens and the hood
and mask uni t, the rear cl uster housi ng cover, and
the i ncandescent l amp bul bs wi th hol ders are avai l -
abl e for i ndi vi dual servi ce repl acement.
OPERATION
The El ectroMechani cal I nstrument Cl uster (EMI C)
i s desi gned to al l ow the vehi cl e operator to moni tor
the condi ti ons of many of the vehi cl e components and
operati ng systems. The gauges and i ndi cators i n the
EMI C provi de val uabl e i nformati on about the vari ous
standard and opti onal powertrai ns, fuel and emi s-
si ons systems, cool i ng systems, l i ghti ng systems,
safety systems and many other conveni ence i tems.
The EMI C i s i nstal l ed i n the i nstrument panel so
that al l of these moni tors can be easi l y vi ewed by the
vehi cl e operator when dri vi ng, whi l e sti l l al l owi ng
rel ati ve ease of access for servi ce. The mi croproces-
sor-based EMI C hardware and software uses vari ous
i nputs to control the gauges and i ndi cators vi si bl e on
the face of the cl uster. Some of these i nputs are hard
wi red, but most are i n the form of el ectroni c mes-
sages that are transmi tted by other el ectroni c mod-
ul es over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. (Refer to 8 -
ULES/COMMUNI CATI ON - OPERATI ON).
The EMI C mi croprocessor smooths the i nput data
usi ng al gori thms to provi de gauge readi ngs that are
accurate, stabl e and responsi ve to operati ng condi -
ti ons. These al gori thms are desi gned to provi de
gauge readi ngs duri ng normal operati on that are con-
si stent wi th customer expectati ons. However, when
abnormal condi ti ons exi st, such as l ow/hi gh battery
vol tage, l ow oi l pressure, or hi gh cool ant tempera-
INSTRUMENT CLUSTER (Continued)
ture, the al gori thm dri ves the gauge poi nter to an
extreme posi ti on and the mi croprocessor turns on a
Check Gauges i ndi cator to provi de a di sti nct vi sual
i ndi cati on of a probl em to the vehi cl e operator. The
i nstrument cl uster ci rcui try may al so generate an
el ectroni c chi me tone request message to the Central
Ti mer Modul e (CTM) over the PCI data bus when i t
moni tors certai n condi ti ons or i nputs, i n order to pro-
vi de the vehi cl e operator wi th an audi bl e al ert to
suppl ement a vi sual i ndi cati on. One such al ert i s a
turn si gnal warni ng chi me, whi ch the EMI C provi des
by moni tori ng the turn si gnal i ndi cators and PCI bus
messages from the PCM for vehi cl e speed and di s-
tance. I f the EMI C determi nes that a turn si gnal i s
l eft on for a di stance greater than about 1.6 ki l ome-
ters (1 mi l e) at a vehi cl e speed greater than about 24
ki l ometers per hour (15 mi l es per hour), i t wi l l send
an el ectroni c message to the CTM requesti ng a con-
ti nuous chi me to sound unti l the turn si gnal i s
turned off or the vehi cl e speed i s l ess than 24 ki l o-
meters per hour (15 mi l es per hour).
The EMI C ci rcui try operates on battery current
recei ved through a fused B(+) fuse i n the Juncti on
Bl ock (JB) on a non-swi tched fused B(+) ci rcui t, and
on battery current recei ved through a fused i gni ti on
swi tch output (run-start) fuse i n the JB on a fused
i gni ti on swi tch output (run-start) ci rcui t. Thi s
arrangement al l ows the EMI C to provi de some fea-
tures regardl ess of the i gni ti on swi tch posi ti on, whi l e
other features wi l l operate onl y wi th the i gni ti on
swi tch i n the On or Start posi ti ons. The EMI C ci r-
cui try i s grounded through two separate ground ci r-
cui ts l ocated i n one of the two i nstrument cl uster
connectors and take outs of the i nstrument panel
wi re harness. One ground ci rcui t recei ves ground
through a take out wi th an eyel et termi nal connector
of the i nstrument panel wi re harness that i s secured
by a nut to a ground stud l ocated on the l eft cowl
si de i nner panel bel ow the i nstrument panel , whi l e
the other ground ci rcui t recei ves ground through a
take out wi th an eyel et termi nal connector of the
headl amp and dash wi re harness that i s secured by a
nut to a ground stud l ocated on the l eft front fender
i nner shi el d near the battery i n the engi ne compart-
ment.
The EMI C al so has a sel f-di agnosti c actuator test
capabi l i ty, whi ch wi l l test each of the PCI bus mes-
sage-control l ed functi ons of the cl uster by l i ghti ng
the appropri ate i ndi cators and posi ti oni ng the gauge
needl es at several predetermi ned l ocati ons on the
gauge faces i n a prescri bed sequence. (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER - DI AGNO-
SI S AND TESTI NG). See the owners manual i n the
vehi cl e gl ove box for more i nformati on on the fea-
tures, use and operati on of the EMI C.
GAUGES
Al l gauges recei ve battery current through the
EMI C ci rcui try when the i gni ti on swi tch i s i n the On
or Start posi ti ons. Wi th the i gni ti on swi tch i n the Off
posi ti on battery current i s not suppl i ed to any
gauges, and the EMI C ci rcui try i s programmed to
move al l of the gauge needl es back to the l ow end of
thei r respecti ve scal es. Therefore, the gauges do not
accuratel y i ndi cate any vehi cl e condi ti on unl ess the
i gni ti on swi tch i s i n the On or Start posi ti ons. Al l of
the EMI C gauges, except the odometer, are ai r core
magneti c uni ts. Two fi xed el ectromagneti c coi l s are
l ocated wi thi n each gauge. These coi l s are wrapped
at ri ght angl es to each other around a movabl e per-
manent magnet. The movabl e magnet i s suspended
wi thi n the coi l s on one end of a pi vot shaft, whi l e the
gauge needl e i s attached to the other end of the
shaft. One of the coi l s has a fi xed current fl owi ng
through i t to mai ntai n a constant magneti c fi el d
strength. Current fl ow through the second coi l
changes, whi ch causes changes i n i ts magneti c fi el d
strength. The current fl owi ng through the second coi l
i s changed by the EMI C ci rcui try i n response to mes-
sages recei ved over the PCI data bus. The gauge nee-
dl e moves as the movabl e permanent magnet al i gns
i tsel f to the changi ng magneti c fi el ds created around
i t by the el ectromagnets.
The gauges are di agnosed usi ng the EMI C sel f-di -
agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the data bus message i nputs to the EMI C that con-
trol each gauge requi re the use of a DRBI I I scan
Speci fi c operati on detai l s for each gauge may be
found el sewhere i n thi s servi ce manual .
VACUUM-FLUORESCENT DISPLAY
The Vacuum-Fl uorescent Di spl ay (VFD) modul e i s
sol dered to the EMI C ci rcui t board. The di spl ay i s
acti ve wi th the i gni ti on swi tch i n the On or Start
posi ti ons, and i nacti ve when the i gni ti on swi tch i s i n
any other posi ti on. The VFD has several di spl ay
capabi l i ti es i ncl udi ng odometer, tri p odometer, and
an amber CRUI SE i ndi cati on whenever the
opti onal speed control system i s turned On. The
crui se i ndi cator functi on of the VFD i s automati cal l y
enabl ed or di sabl ed by the EMI C ci rcui try based
upon whether the vehi cl e i s equi pped wi th the speed
control opti on. An odometer/tri p odometer swi tch on
the EMI C ci rcui t board i s used to control several of
the di spl ay modes. Thi s swi tch i s actuated manual l y
by depressi ng the odometer/tri p odometer swi tch but-
ton that extends through the l ower edge of the cl us-
ter l ens, just l eft of center. Actuati ng thi s swi tch
momentari l y wi th the i gni ti on swi tch i n the On posi -
ti on wi l l toggl e the VFD between the odometer and
tri p odometer modes. The word TRI P wi l l al so
appear i n bl ue-green text when the VFD tri p odome-
ter mode i s acti ve. Depressi ng the swi tch button for
about two seconds whi l e the VFD i s i n the tri p odom-
eter mode wi l l reset the tri p odometer val ue to zero.
Hol di ng thi s swi tch depressed whi l e turni ng the i gni -
ti on swi tch from the Off posi ti on to the On posi ti on
wi l l acti vate the EMI C sel f-di agnosti c actuator test.
The EMI C wi l l automati cal l y fl ash the odometer or
tri p odometer i nformati on on and off i f there i s a l oss
of PCI data bus communi cati on. The VFD wi l l al so
di spl ay vari ous i nformati on used i n several di agnos-
ti c procedures. Refer to the appropri ate di agnosti c
i nformati on for addi ti onal detai l s on thi s VFD func-
ti on.
Model s equi pped wi th an automati c transmi ssi on
have a second VFD sol dered to the EMI C ci rcui t
board, whi ch serves as the el ectroni c transmi ssi on
gear sel ector i ndi cator. Li ke the odometer/tri p odom-
eter VFD, thi s di spl ay i s acti ve wi th the i gni ti on
swi tch i n the On or Start posi ti ons, and i nacti ve
when the i gni ti on swi tch i s i n any other posi ti on.
Thi s VFD al so has an amber O/D OFF i ndi cator
that i l l umi nates when the automati c transmi ssi on
el ectroni c overdri ve i s turned off by depressi ng the
overdri ve-off swi tch button l ocated i n the knob on the
end of the gear sel ector l ever on the ri ght si de of the
steeri ng col umn. Thi s VFD di spl ays the characters
P, R, N, D, 2,and 1, whi ch represent each of
the avai l abl e gear sel ector posi ti ons. A smal l rectan-
gul ar box i s i l l umi nated around the character repre-
senti ng the gear posi ti on that i s currentl y sel ected.
Both VFDs are di agnosed usi ng the EMI C sel f-di -
agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
TESTI NG). Proper testi ng of the PCI data bus and
the data bus message i nputs to the EMI C that con-
trol some of the VFD functi ons requi res the use of a
ti c i nformati on. Speci fi c operati on detai l s for the
odometer, tri p odometer, gear sel ector i ndi cator,
crui se i ndi cator, and overdri ve-off i ndi cator functi ons
of these VFDs may be found el sewhere i n thi s servi ce
manual .
INDICATORS
I ndi cators are l ocated i n vari ous posi ti ons wi thi n
the EMI C and are al l connected to the EMI C ci rcui t
board. The hi gh beam i ndi cator, washer fl ui d i ndi ca-
tor, turn si gnal i ndi cators, and the di esel engi ne
wai t-to-start i ndi cator are hard wi red. The brake
i ndi cator i s control l ed by PCI data bus messages
from the Control l er Anti -l ock Brake (CAB) and the
hard wi red park brake swi tch i nput to the EMI C.
The seatbel t i ndi cator i s control l ed by the EMI C pro-
grammi ng, PCI data bus messages from the Ai rbag
Control Modul e (ACM), and the hard wi red seat bel t
swi tch i nput to the EMI C. The securi ty i ndi cator i s
control l ed by a hard wi red Central Ti mer Modul e
(CTM) i nput to the EMI C, and by PCI data bus mes-
sages from the Sentry Key I mmobi l i zer Modul e
(SKI M) i f the vehi cl e i s equi pped wi th the opti onal
Sentry Key I mmobi l i zer System (SKI S). The Mal -
functi on I ndi cator Lamp (MI L) i s normal l y control l ed
by PCI data bus messages from the Powertrai n Con-
trol Modul e (PCM); however, i f the EMI C l oses PCI
data bus communi cati ons, the EMI C ci rcui try wi l l
automati cal l y turn the MI L on, and fl ash the odom-
eter VFD on and off repeatedl y unti l PCI data bus
communi cati on i s restored. The EMI C uses PCI data
bus messages from the CTM, the PCM, the Transfer
Case Control Modul e (TCCM), the ACM, and the
CAB to control al l of the remai ni ng i ndi cators. Di ffer-
ent i ndi cators are control l ed by di fferent strategi es;
some recei ve fused i gni ti on swi tch output from the
EMI C ci rcui try cl uster and have a swi tched ground,
whi l e others are grounded through the EMI C ci r-
cui try and have a swi tched battery feed.
I n addi ti on, certai n i ndi cators i n thi s i nstrument
cl uster are programmabl e or confi gurabl e. Thi s fea-
ture al l ows the programmabl e i ndi cators to be acti -
vated or deacti vated wi th a DRBI I I scan tool , whi l e
the confi gurabl e i ndi cators wi l l be automati cal l y
enabl ed or di sabl ed by the EMI C ci rcui try for com-
pati bi l i ty wi th certai n opti onal equi pment. The onl y
programmabl e i ndi cator for thi s model i s the upshi ft
i ndi cator. The crui se i ndi cator, servi ce 4WD i ndi cator,
gear sel ector i ndi cator, overdri ve-off i ndi cator, and
the transmi ssi on overtemp i ndi cator are automati -
cal l y confi gured, ei ther el ectroni cal l y or mechani cal l y.
I f the EMI C i s di sconnected from the fused B(+) ci r-
cui t for more than about fi ve mi nutes the EMI C wi l l
forget i ts previ ous el ectroni c confi gurati on setti ngs,
but wi l l l earn the proper i ndi cator confi gurati on set-
ti ngs agai n when i t i s rei nstal l ed i n a vehi cl e.
The hard wi red i ndi cators are di agnosed usi ng con-
venti onal di agnosti c methods. The EMI C and PCI
bus message control l ed i ndi cator l amps are di agnosed
usi ng the EMI C sel f-di agnosti c actuator test. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DI AGNOSI S AND TESTI NG). Proper testi ng of the
PCI data bus and the data bus message i nputs to the
EMI C that control each i ndi cator requi re the use of a
ti c i nformati on. Speci fi c operati on detai l s for each
i ndi cator may be found el sewhere i n thi s servi ce
manual .
CLUSTER ILLUMINATION
The EMI C has several i l l umi nati on l amps that are
i l l umi nated when the exteri or l i ghti ng i s turned on
wi th the headl amp swi tch. The i l l umi nati on bri ght-
ness of these l amps i s adjusted by the panel l amps
di mmer rheostat when the headl amp swi tch thumb-
wheel i s rotated (down to di m, up to bri ghten). The
i l l umi nati on l amps recei ve battery current through
the panel l amps di mmer rheostat and a fuse i n the
JB on a fused panel l amps di mmer swi tch si gnal ci r-
cui t. The i l l umi nati on l amps are grounded at al l
ti mes.
I n addi ti on, an anal og/di gi tal (A/D) converter i n
the EMI C converts the anal og panel l amps di mmer
rheostat i nput from the headl amp swi tch to a di gi tal
di mmi ng l evel si gnal for control l i ng the l i ghti ng l evel
of the VFD. The EMI C al so broadcasts thi s di gi tal
di mmi ng i nformati on as a message over the PCI data
bus for use by the Compass Mi ni -Tri p Computer
(CMTC) i n synchroni zi ng the l i ghti ng l evel of i ts
VFD wi th that of the EMI C. The headl amp swi tch
thumbwheel al so has a Parade posi ti on to provi de a
parade mode. The EMI C moni tors the request for
thi s mode through a hard wi red day bri ghtness sense
ci rcui t i nput from the headl amp swi tch. I n thi s mode,
the EMI C wi l l overri de the sel ected panel di mmer
swi tch si gnal and send a message over the PCI data
bus to i l l umi nate al l vacuum fl uorescent di spl ays at
ful l bri ghtness for easi er vi si bi l i ty when dri vi ng i n
dayl i ght wi th the exteri or l i ghti ng turned On. The
parade mode has no effect on the i ncandescent bul b
i l l umi nati on i ntensi ty.
The hard wi red cl uster i l l umi nati on l amps are
di agnosed usi ng conventi onal di agnosti c methods.
Proper testi ng of the VFD di mmi ng l evel and the PCI
data bus di mmi ng l evel message functi ons requi res
the use of a DRBI I I scan tool . Refer to the appro-
pri ate di agnosti c i nformati on.
CHIME WARNING REQUESTS
The EMI C i s programmed to request chi me servi ce
from the Central Ti mer Modul e (CTM) when certai n
i ndi cator l amps are i l l umi nated. When the pro-
grammed condi ti ons are met, the EMI C generates an
el ectroni c chi me request message and sends i t over
the PCI data bus to the CTM. Upon recei vi ng the
proper chi me request message, the CTM acti vates an
i ntegral chi me tone generator to provi de the audi bl e
chi me tone to the vehi cl e operator. (Refer to 8 -
ELECTRI CAL/CHI ME/BUZZER - OPERATI ON).
Proper testi ng of the EMI C, the CTM and the PCI
data bus chi me request message functi ons requi res
pri ate di agnosti c i nformati on.
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
I f al l of the i nstrument cl uster gauges and/or i ndi -
cator l amps are i noperati ve, refer to PRELI MI NARY
DI AGNOSI S. I f an i ndi vi dual gauge or Programma-
bl e Communi cati ons I nterface (PCI ) data bus mes-
sage-control l ed i ndi cator l amp i s i noperati ve, refer to
ACTUATOR TEST. I f an i ndi vi dual hard wi red i ndi -
cator l amp i s i noperati ve, refer to the di agnosi s and
testi ng i nformati on for that speci fi c i ndi cator. I f the
i nstrument cl uster i l l umi nati on l i ghti ng i s i nopera-
ti ve, refer to CLUSTER I LLUMI NATI ON DI AGNO-
SI S. I f the i nstrument cl uster Vacuum-Fl uorescent
Di spl ay (VFD) di mmer servi ce or chi me request func-
ti on i s i noperati ve, use a DRBI I I scan tool to di ag-
nose the probl em. Refer to the appropri ate di agnosti c
procedures.
NOTE: Certain indicators in this instrument cluster
are programmable or automatically configured. This
feature allows those indicators to be activated or
deactivated for compatibility with certain optional
equipment. If the problem being diagnosed involves
improper illumination of the upshift indicator, use a
DRBIII scan tool to be certain that the instrument
cluster has been programmed with the proper vehi-
cle equipment option settings. If the problem being
diagnosed involves improper illumination of the
cruise indicator, the door or gate ajar indicators, the
overdrive-off indicator, the service four-wheel drive
indicator, the transmission overtemp indicator, or
the gear selector indicator, disconnect and isolate
the battery negative cable. After about five minutes,
reconnect the battery negative cable and turn the
ignition switch to the On position. The instrument
cluster will automatically relearn the equipment in
the vehicle and properly configure the configurable
indicators accordingly.
PRELIMINARY DIAGNOSIS
INJURY.
(1) I f the i ndi cators operate, but none of the
gauges operate, go to Step 2. I f al l of the gauges and
the PCI data bus message-control l ed i ndi cator l amps
are i noperati ve, go to Step 5.
(2) Check the fused B(+) fuse (Fuse 1 - 15 ampere)
i n the Juncti on Bl ock (JB). I f OK, go to Step 3. I f not
(Fuse 1 - 15 ampere) i n the JB. I f OK, go to Step 4. I f
not OK, repai r the open fused B(+) ci rcui t between
the JB and the Power Di stri buti on Center (PDC) as
requi red.
cabl e. Remove the i nstrument cl uster. Connect the
battery negati ve cabl e. Check for battery vol tage at
the fused B(+) ci rcui t cavi ty of the i nstrument panel
wi re harness connector (Connector C1) for the i nstru-
ment cl uster. I f OK, refer to ACTUATOR TEST. I f
the i nstrument cl uster and the JB as requi red.
start) fuse (Fuse 8 - 10 ampere) i n the JB. I f OK, go
to Step 6. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
output (run-start) fuse (Fuse 8 - 10 ampere) i n the
JB. I f OK, go to Step 7. I f not OK, repai r the open
fused i gni ti on swi tch output (run-start) ci rcui t
Rei nstal l the i nstrument cl uster. Reconnect the bat-
tery negati ve cabl e. Turn the i gni ti on swi tch to the
On posi ti on. Set the park brake. The brake i ndi cator
i n the i nstrument cl uster shoul d l i ght. I f OK, go to
Step 8. I f not OK, go to Step 9.
Turn on the park l amps and adjust the panel l amps
di mmer thumbwheel on the headl amp swi tch to the
ful l bri ght posi ti on. The cl uster i l l umi nati on l amps
shoul d l i ght. I f OK, go to Step 10. I f not OK, repai r
the open ground ci rcui t (Z1) between the i nstrument
i nstrument cl uster and ground (G208) as requi red.
Remove the i nstrument cl uster. Connect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Check for battery vol tage at the fused i gni -
ti on swi tch output (run-start) ci rcui t cavi ty of the
i nstrument panel wi re harness connector (Connector
C1) for the i nstrument cl uster. I f OK, refer to
ACTUATOR TEST. I f not OK, repai r the open fused
i gni ti on swi tch output (run-start) ci rcui t between the
i nstrument cl uster and the JB as requi red.
cabl e. Remove the i nstrument cl uster. Check for con-
ti nui ty between the ground ci rcui t (Z2) cavi ty of the
C1) for the i nstrument cl uster and a good ground.
There shoul d be conti nui ty. I f OK, refer to ACTUA-
TOR TEST. I f not OK, repai r the open ground ci rcui t
to ground (G113) as requi red.
ACTUATOR TEST
INJURY.
The i nstrument cl uster actuator test wi l l put the
i nstrument cl uster i nto i ts sel f-di agnosti c mode. I n
thi s mode the i nstrument cl uster can perform a sel f-
di agnosti c test that wi l l confi rm that the i nstrument
cl uster ci rcui try, the gauges, and the PCI data bus
message-control l ed i ndi cators are capabl e of operat-
i ng as desi gned. Duri ng the actuator test the i nstru-
ment cl uster ci rcui try wi l l posi ti on each of the gauge
needl es at vari ous cal i brati on poi nts, i l l umi nate each
of the segments i n the Vacuum-Fl uorescent Di spl ays
(VFDs), and turn al l of the PCI data bus message-
control l ed i ndi cators on and off agai n.
Successful compl eti on of the actuator test wi l l con-
fi rm that the i nstrument cl uster i s operati onal . How-
ever, there may sti l l be a probl em wi th the PCI data
bus, the Powertrai n Control Modul e (PCM), the
Engi ne Control Modul e (ECM), the Central Ti mer
Modul e (CTM), the Transmi ssi on Control Modul e
(TCM), the Transfer Case Control Modul e (TCCM),
the Ai rbag Control Modul e (ACM), the Control l er
Anti -l ock Brake (CAB), or the i nputs to one of these
el ectroni c control modul es. Use a DRBI I I scan tool
to di agnose these components. Refer to the appropri -
ate di agnosti c i nformati on.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the odometer/tri p odometer swi tch but-
ton.
(3) Whi l e sti l l hol di ng the odometer/tri p odometer
swi tch button depressed, turn the i gni ti on swi tch to
the On posi ti on, but do not start the engi ne.
(4) Keep the odometer/tri p odometer swi tch button
depressed for about ten seconds, unti l CHEC
appears i n the odometer di spl ay, then rel ease the
odometer/tri p odometer swi tch button.
(5) A seri es of three-di gi t numeri c fai l ure messages
may appear i n the odometer di spl ay, dependi ng upon
the fai l ure mode. I f a fai l ure message appears, refer
to the I nstrument Cl uster Fai l ure Message chart for
the descri pti on and proper correcti on. I f no fai l ure
message appears, the actuator test wi l l proceed as
descri bed i n Step 6.
INSTRUMENT CLUSTER FAILURE MESSAGE
Message Description Correction
110 A failure has been identified in the instrument
cluster CPU, RAM, or EEPROM.
1. Replace the faulty instrument cluster.
900 The PCI data bus is not operational. 1. Check the PCI data bus connection at the
instrument cluster.
2. Check the instrument cluster fuses.
3. Check the PCI data bus functionality using a
DRBIII scan tool. Refer to the appropriate
diagnostic information.
920 The instrument cluster is not receiving a
vehicle speed message from the PCM.
1. Check the PCM software level and reflash if
required.
2. Use a DRBIII scan tool to verify that the
vehicle speed message is being sent by the
PCM.
distance pulse message from the PCM.
1. Check the PCM software level and reflash if
required.
2. Use a DRBIII scan tool to verify that the
distance pulse message is being sent by the
PCM.
940 The instrument cluster is not receiving an
airbag lamp-on message from the ACM.
1. Check the PCI data bus connection at the
ACM.
2. Check the ACM fuse.
950 The instrument cluster is not receiving an ABS
lamp-on message from the CAB.
CAB.
2. Check the CAB fuse.
PRND21 message from the TCM.
TCM.
2. Check the TCM fuse.
999 An error has been discovered. 1. Record the failure message.
2. Depress the odometer/trip odometer switch
button to continue the Actuator Test.
(6) The i nstrument cl uster wi l l begi n the Vacuum
Fl uorescent Di spl ay (VFD) wal ki ng segment test.
Thi s test wi l l requi re the operator to vi sual l y i nspect
each VFD segment as i t i s di spl ayed to determi ne a
pass or fai l condi ti on. Fi rst, al l of the segments wi l l
be i l l umi nated at once; then, each i ndi vi dual segment
of the VFD wi l l be i l l umi nated i n sequence. I f any
segment i n the di spl ay fai l s to i l l umi nate, repeat the
test to confi rm the fai l ure. I f the fai l ure i s confi rmed,
repl ace the faul ty i nstrument cl uster. Fol l owi ng com-
pl eti on of the VFD wal ki ng segment test, the actua-
tor test wi l l proceed as descri bed i n Step 7.
(7) The i nstrument cl uster wi l l perform a bul b
check of each i ndi cator that the i nstrument cl uster
ci rcui try control s. Each of the i nstrument cl uster ci r-
cui try control l ed i ndi cators except the crui se i ndi ca-
tor and the overdri ve-off i ndi cator are i l l umi nated by
a Li ght Emi tti ng Di ode (LED). I f an LED fai l s to i l l u-
mi nate duri ng thi s test, the i nstrument cl uster must
be repl aced. Fol l owi ng the bul b check test, the actua-
tor test wi l l proceed as descri bed i n Step 8.
(8) The i nstrument cl uster wi l l perform a gauge
actuator test. I n thi s test the i nstrument cl uster ci r-
cui try posi ti ons each of the gauge needl es at three
di fferent cal i brati on poi nts, then returns the gauge
needl es to thei r rel axed posi ti ons. I f an i ndi vi dual
gauge does not respond properl y, or does not respond
at al l duri ng the gauge actuator test, the i nstrument
cl uster shoul d be removed. However, check that the
gauge termi nal pi ns are properl y i nserted through
the spri ng-cl i p termi nal pi n receptacl es on the i nstru-
ment cl uster el ectroni c ci rcui t board before consi der-
i ng i nstrument cl uster repl acement. I f the gauge
termi nal connecti ons are OK, repl ace the faul ty
i nstrument cl uster.
(9) The actuator test i s now compl eted. The i nstru-
ment cl uster wi l l automati cal l y exi t the sel f-di agnos-
ti c mode and return to normal operati on at the
compl eti on of the test, i f the i gni ti on swi tch i s turned
to the Off posi ti on duri ng the test, or i f a vehi cl e
speed message i ndi cati ng that the vehi cl e i s movi ng
i s recei ved from the PCM on the PCI data bus duri ng
the test.
(10) Go back to Step 1 to repeat the test, i f
requi red.
CLUSTER ILLUMINATION DIAGNOSIS
The di agnosi s found here addresses an i noperati ve
i nstrument cl uster i l l umi nati on l amp condi ti on. I f
the probl em bei ng di agnosed i s a si ngl e i noperati ve
i l l umi nati on l amp, be certai n that the bul b and bul b
hol der uni t are properl y i nstal l ed i n the i nstrument
cl uster el ectroni c ci rcui t board. I f no i nstal l ati on
probl ems are found repl ace the faul ty bul b and bul b
hol der uni t. I f al l of the cl uster i l l umi nati on l amps
are i noperati ve and the probl em bei ng di agnosed
i ncl udes i noperati ve exteri or l i ghti ng control l ed by
the headl amp swi tch, that system needs to be
repai red fi rst. (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR - DI AGNOSI S AND TEST-
I NG). I f no exteri or l i ghti ng system probl ems are
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the cl uster i l l umi nati on l amp ci rcui t.
I f the probl em bei ng di agnosed i nvol ves a l ack of
di mmi ng control for the odometer/tri p odometer or
gear sel ector i ndi cator Vacuum Fl uorescent Di spl ays
(VFDs), but al l of the other cl uster i l l umi nati on
l amps can be di mmed, test and repai r the day bri ght-
ness ci rcui t between the i nstrument cl uster and the
headl amp swi tch as requi red. Refer to the appropri -
ate wi ri ng i nformati on. The wi ri ng i nformati on
INJURY.
(1) Check the i nstrument panel di mmer fuse (Fuse
9 - 5 ampere) i n the Juncti on Bl ock (JB). I f OK, go to
Step 2. I f not OK, repai r the shorted ci rcui t or com-
ponent as requi red and repl ace the faul ty fuse.
(2) Turn the exteri or l amps On wi th the headl amp
swi tch. Rotate the headl amp swi tch panel l amps di m-
mer thumbwheel upward to just before the i nteri or
l amps detent. Check for battery vol tage at the i nstru-
ment panel di mmer fuse (Fuse 9 - 5 ampere) i n the
JB. Rotate the panel l amps di mmer thumbwheel
downward whi l e observi ng the test vol tmeter. The
readi ng shoul d go from battery vol tage to zero vol ts.
I f OK, go to Step 3. I f not OK, repai r the open panel
l amps di mmer swi tch si gnal ci rcui t between the
headl amp swi tch and the JB as requi red.
(3) Turn the exteri or l amps Off. Di sconnect and
i sol ate the battery negati ve cabl e. Remove the i nstru-
ment cl uster. Remove the i nstrument panel di mmer
fuse (Fuse 9 - 5 ampere) from the JB. Probe the
fused panel l amps di mmer swi tch si gnal ci rcui t cav-
i ty of the i nstrument panel wi re harness connector
(Connector C2) for the i nstrument cl uster. Check for
conti nui ty to a good ground. There shoul d be no con-
ti nui ty. I f OK, go to Step 4. I f not OK, repai r the
shorted fused panel l amps di mmer swi tch si gnal ci r-
cui t between the i nstrument cl uster and the JB as
requi red.
(4) Rei nstal l the i nstrument panel di mmer fuse
(Fuse 9 - 5 ampere) i n the JB. Reconnect the battery
negati ve cabl e. Turn the exteri or l amps On wi th the
headl amp swi tch. Rotate the headl amp swi tch panel
l amps di mmer thumbwheel upward to just before the
i nteri or l amps detent. Check for battery vol tage at
the fused panel l amps di mmer swi tch si gnal ci rcui t
cavi ty of the i nstrument panel wi re harness connec-
tor (Connector C2) for the i nstrument cl uster. I f OK,
repl ace the faul ty bul b and bul b hol der uni ts. I f not
OK, repai r the open fused panel l amps di mmer
swi tch si gnal ci rcui t between the i nstrument cl uster
and the JB as requi red.
REMOVAL
INJURY.
cabl e.
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the four screws that secure the i nstru-
ment cl uster to the i nstrument panel (Fi g. 2).
(4) Pul l the i nstrument cl uster rearward far
enough to di sengage the two sel f-docki ng i nstrument
panel wi re harness connectors from the cl uster con-
nector receptacl es.
(5) Rol l the bottom of the i nstrument cl uster
upward and rearward to remove i t from the i nstru-
ment panel .
DISASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude: the i ncandescent
i nstrument cl uster i ndi cator l amp and i l l umi nati on
l amp bul bs (i ncl udi ng the i ntegral bul b hol ders), the
cl uster l ens and hood uni t, and the cl uster housi ng
rear cover. The remai ni ng components are servi ced
onl y as a part of the cl uster housi ng uni t, whi ch
i ncl udes: the cl uster housi ng, the el ectroni c ci rcui t
board uni t, the cl uster overl ay, the gauges, and the
odometer/tri p odometer reset swi tch button. Fol l ow-
i ng are the procedures for di sassembl i ng the servi ced
components from the i nstrument cl uster uni t.
INJURY.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator l amp bul b and
bul b hol der uni ts. However, the i l l umi nati on l amps
and the i ndi cator l amps use di fferent bul b and bul b
hol der uni t si zes. They must never be i nterchanged.
cabl e.
Fig. 2 Instrument Cluster Remove/Install
3 - SCREW (4)
4 - SELF-DOCKING CONNECTOR (2)
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bul b hol der countercl ockwi se about
si xty degrees on the cl uster el ectroni c ci rcui t board
(Fi g. 3).
(4) Pul l the bul b and bul b hol der uni t strai ght
back to remove i t from the bul b mounti ng hol e i n the
cl uster el ectroni c ci rcui t board.
CLUSTER LENS AND HOOD
cabl e.
(3) Remove the seven screws that secure the l ens
and hood uni t to the cl uster housi ng (Fi g. 4).
(4) Gentl y pul l the l ens and hood uni t away from
the cl uster housi ng.
CAUTION: Do not touch the face of the gauge over-
lay or the back of the cluster lens with your finger.
It will leave a permanent finger print.
CLUSTER HOUSING REAR COVER
cabl e.
(3) Remove the si x screws that secure the rear
cover to the back of the cl uster housi ng (Fi g. 5).
(4) Remove the rear cover from the back of the
cl uster housi ng.
CLUSTER HOUSING
cabl e.
(3) Remove the l ens and hood uni t from the cl uster
housi ng. Refer to CLUSTER LENS AND HOOD.
(4) Remove the rear cover from the cl uster hous-
i ng. Refer to CLUSTER HOUSI NG REAR COVER.
Fig. 3 Cluster Bulb Remove/Install
2 - BULB AND HOLDER
Fig. 4 Instrument Cluster Components
1 - COVER
2 - HOUSING
3 - OVERLAY AND GAUGES
4 - HOOD
5 - LENS
6 - CIRCUIT BOARD
7 - ODOMETER SWITCH BUTTON
Fig. 5 Cluster Housing Rear Cover Remove/Install
1 - REAR CLUSTER HOUSING COVER
ASSEMBLY
INJURY.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator l amp bul b and
bul b hol der uni ts. However, the i l l umi nati on l amps
and the i ndi cator l amps use di fferent bul b and bul b
hol der uni t si zes. They must never be i nterchanged.
CAUTION: Be certain that any bulb and bulb holder
unit removed from the cluster electronic circuit
board is reinstalled in the correct position. Always
use the correct bulb size and type for replacement.
An incorrect bulb size or type may overheat and
cause damage to the instrument cluster, the elec-
tronic circuit board and/or the gauges.
(1) I nsert the bul b and bul b hol der uni t strai ght
i nto the correct bul b mounti ng hol e i n the cl uster
el ectroni c ci rcui t board (Fi g. 3).
(2) Wi th the bul b hol der ful l y seated agai nst the
cl uster el ectroni c ci rcui t board, turn the bul b hol der
cl ockwi se about si xty degrees to l ock i t i nto pl ace.
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
CLUSTER LENS AND HOOD
CAUTION: Do not touch the face of the gauge over-
lay or the back of the cluster lens with your finger.
It will leave a permanent finger print.
(1) Al i gn the cl uster l ens and hood uni t wi th the
cl uster housi ng. Be certai n that the odometer/tri p
odometer swi tch button i s i nstal l ed through the
cl earance hol e i n the l ens (Fi g. 4).
(2) I nstal l and ti ghten the seven screws that
secure the l ens and hood uni t to the cl uster housi ng.
Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
CLUSTER HOUSING REAR COVER
(1) Posi ti on the rear cover onto the back of the
cl uster housi ng (Fi g. 5).
(2) I nstal l and ti ghten the si x screws that secure
the rear cover to the back of the cl uster housi ng.
CLUSTER HOUSING
(1) Assembl e the rear cover onto the cl uster hous-
i ng. Refer to CLUSTER HOUSI NG REAR COVER.
(2) Assembl e the l ens and hood uni t onto the cl us-
ter housi ng. Refer to CLUSTER LENS AND HOOD.
INSTALLATION
INJURY.
(1) Posi ti on the i nstrument cl uster to the i nstru-
ment panel by i nserti ng the top of the i nstrument
cl uster between the steeri ng wheel and the top of the
i nstrument panel , then rol l i ng the bottom of the cl us-
ter downward and forward.
(2) Al i gn the i nstrument cl uster wi th the cl uster
openi ng i n the i nstrument panel and push the cl uster
fi rml y and evenl y i nto pl ace. The i nstrument panel
wi re harness has two sel f-docki ng connectors that
wi l l be automati cal l y al i gned wi th, and connected to
the i nstrument cl uster connector receptacl es when
the cl uster i s properl y i nstal l ed i n the i nstrument
panel .
the i nstrument cl uster to the i nstrument panel (Fi g.
2). Ti ghten the screws to 2 Nm (17 i n. l bs.).
(4) Rei nstal l the cl uster bezel onto the i nstrument
CLUSTER BEZEL - I NSTALLATI ON).
NOTE: Some of the indicators in this instrument
cluster are either programmable (upshift indicator)
or automatically configured (cruise, door and gate
ajar, gear selector indicator, service four-wheel
drive, overdrive-off, and transmission overtemp
indicators) when the cluster is connected to the
vehicle electrical system. This feature allows those
indicators to be enabled or disabled for compatibil-
ity with certain optional equipment. If a new instru-
ment cluster is being installed, use a DRBIII scan
tool to program the instrument cluster with the
proper vehicle equipment option setting to enable
and/or disable the upshift indicator lamp. Refer to
the appropriate diagnostic information.
ABS INDICATOR
DESCRIPTION
An Anti l ock Brake System (ABS) i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters. Thi s i ndi -
cator serves both the standard equi pment Rear
Wheel Anti -Lock (RWAL) and opti onal equi pment
4-Wheel Anti -Lock (4WAL) brake systems. The ABS
i ndi cator i s l ocated i n the I nformati on Center area of
the i nstrument cl uster, to the l eft of center. The ABS
i ndi cator consi sts of a stenci l l ed cutout of the I nter-
nati onal Control and Di spl ay Symbol i con for Fai l -
ure of Anti -l ock Braki ng System i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. An amber
l ens behi nd the cutout i n the opaque l ayer of the
overl ay causes the i con to appear i n amber through
the transl ucent outer l ayer of the overl ay when i t i s
i l l umi nated from behi nd by a Li ght Emi tti ng Di ode
(LED) sol dered onto the i nstrument cl uster el ectroni c
ci rcui t board. The ABS i ndi cator i s servi ced as a uni t
wi th the i nstrument cl uster.
OPERATION
The ABS i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the ABS system i s faul ty or i nop-
erati ve. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
ter programmi ng and el ectroni c messages recei ved by
the cl uster from the Control l er Anti l ock Brake (CAB)
(PCI ) data bus. The ABS i ndi cator Li ght Emi tti ng
Di ode (LED) recei ves battery current on the i nstru-
ment cl uster el ectroni c ci rcui t board through the
fused i gni ti on swi tch output (run-start) ci rcui t when-
ever the i gni ti on swi tch i s i n the On or Start posi -
ti ons; therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the ABS i ndi cator for
the fol l owi ng reasons:
Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the ABS i ndi cator i s i l l u-
mi nated by the cl uster for about two seconds as a
bul b test.
ABS Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the CAB, the
ABS i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a
l amp-off message from the CAB, or unti l the i gni ti on
fi rst.
Communication Error - I f the cl uster recei ves
no l amp-on or l amp-off messages from the CAB for
si x consecuti ve seconds, the ABS i ndi cator i s i l l umi -
nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves a val i d message from the CAB, or
Actuator Test - Each ti me the i nstrument cl us-
ter i s put through the actuator test, the ABS i ndi ca-
tor wi l l be turned on, then off agai n duri ng the bul b
check porti on of the test to confi rm the functi onal i ty
of the LED and the cl uster control ci rcui try.
ABS Diagnostic Test - The ABS i ndi cator i s
bl i nked on and off by l amp-on and l amp-off messages
from the CAB duri ng the performance of the ABS
di agnosti c tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. The CAB then sends the proper
l amp-on or l amp-off messages to the i nstrument cl us-
ter. I f the CAB sends a l amp-on message after the
bul b test, i t i ndi cates that the CAB has detected a
system mal functi on and/or that the ABS system has
become i noperati ve. The CAB wi l l store a Di agnosti c
Troubl e Code (DTC) for any mal functi on i t detects.
Each ti me the ABS i ndi cator fai l s to l i ght due to an
open or short i n the cl uster ABS i ndi cator ci rcui t, the
cl uster sends a message noti fyi ng the CAB of the
condi ti on, and the CAB wi l l store a DTC. For proper
di agnosi s of the anti l ock brake system, the CAB, the
PCI data bus, or the message i nputs to the i nstru-
ment cl uster that control the ABS i ndi cator, a
DRBI I I scan tool i s requi red. Refer to the appropri -
AIRBAG INDICATOR
DESCRIPTION
An ai rbag i ndi cator i s standard equi pment on al l
i nstrument cl usters. However, on vehi cl es not
equi pped wi th ai rbags, thi s i ndi cator i s el ectroni cal l y
di sabl ed. The ai rbag i ndi cator i s l ocated i n the I nfor-
mati on Center area of the i nstrument cl uster, to the
ri ght of center. The ai rbag i ndi cator consi sts of a
stenci l ed cutout of the word AI RBAG i n the opaque
l ayer of the i nstrument cl uster overl ay. The dark
outer l ayer of the overl ay prevents the i ndi cator from
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. A red
l ens behi nd the cutout i n the opaque l ayer of the
overl ay causes the AI RBAG text to appear i n red
through the transl ucent outer l ayer of the overl ay
when i t i s i l l umi nated from behi nd by a Li ght Emi t-
ti ng Di ode (LED) sol dered onto the i nstrument cl us-
ter el ectroni c ci rcui t board. The ai rbag i ndi cator i s
servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The ai rbag i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the ai rbag system i s faul ty or
i noperati ve. The ai rbag i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng and el ectroni c mes-
sages recei ved by the cl uster from the Ai rbag Control
Modul e (ACM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The ai rbag i ndi cator
Li ght Emi tti ng Di ode (LED) recei ves battery current
on the i nstrument cl uster el ectroni c ci rcui t board
through the fused i gni ti on swi tch output (run-start)
ci rcui t whenever the i gni ti on swi tch i s i n the On or
Start posi ti ons; therefore, the i ndi cator wi l l al ways
be off when the i gni ti on swi tch i s i n any posi ti on
except On or Start. The LED onl y i l l umi nates when
i t i s provi ded a path to ground by the i nstrument
cl uster transi stor. The i nstrument cl uster wi l l turn
on the ai rbag i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the ai rbag i ndi cator i s i l l u-
mi nated for about seven seconds. The fi rst two sec-
onds i s the cl uster bul b test functi on, and the
remai nder i s the ACM bul b test functi on.
ACM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the ACM, the
ai rbag i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated for about twel ve seconds or unti l
the cl uster recei ves a l amp-off message from the
ACM, whi chever i s l onger.
no ai rbag messages for three consecuti ve seconds, the
ai rbag i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated for about twel ve seconds or unti l
the cl uster recei ves a si ngl e l amp-off message from
the ACM, whi chever i s l onger.
Actuator Test - Each ti me the cl uster i s put
through the actuator test, the ai rbag i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper l amp-on or l amp-off messages to the i nstru-
ment cl uster. I f the ACM sends a l amp-on message
after the bul b test, i t i ndi cates that the ACM has
detected a system mal functi on and/or that the ai r-
bags may not depl oy when requi red, or may depl oy
when not requi red. The ACM wi l l store a Di agnosti c
Troubl e Code (DTC) for any mal functi on i t detects.
Each ti me the ai rbag i ndi cator fai l s to i l l umi nate due
to an open or short i n the cl uster ai rbag i ndi cator ci r-
cui t, the cl uster sends a message noti fyi ng the ACM
of the condi ti on. The ACM wi l l store a DTC and the
cl uster wi l l begi n bl i nki ng the seat bel t i ndi cator.
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER/SEATBELT I NDI CATOR - OPERATI ON). For
proper di agnosi s of the ai rbag system, the ACM, the
PCI data bus, or the message i nputs to the i nstru-
ment cl uster that control the ai rbag i ndi cator, a
BRAKE/PARK BRAKE
INDICATOR
DESCRIPTION
A brake i ndi cator i s standard equi pment on al l
i nstrument cl usters. The brake i ndi cator i s l ocated i n
the I nformati on Center area of the i nstrument cl us-
ter, to the ri ght of center. The brake i ndi cator con-
si sts of a stenci l ed cutout of the word BRAKE and
the I nternati onal Control and Di spl ay Symbol i cons
for Brake Fai l ure and Parki ng Brake i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
A red l ens behi nd the cutout i n the opaque l ayer of
the overl ay causes the BRAKE text and the two
i cons to appear i n red through the transl ucent outer
l ayer of the overl ay when the i ndi cator i s i l l umi nated
from behi nd by a Li ght Emi tti ng Di ode (LED) sol -
dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The brake i ndi cator i s servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The brake i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the parki ng brake i s appl i ed, or
when there are certai n brake hydraul i c system mal -
functi ons. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng, and el ectroni c messages
recei ved by the cl uster from the Central Ti mer Mod-
ul e (CTM) and the Control l er Anti l ock Brake (CAB)
(PCI ) data bus. The brake i ndi cator Li ght Emi tti ng
Di ode (LED) recei ves battery current on the i nstru-
ment cl uster el ectroni c ci rcui t board through the
fused i gni ti on swi tch output (run-start) ci rcui t when-
ever the i gni ti on swi tch i s i n the On or Start posi -
ti ons; therefore, the LED wi l l al ways be off when the
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the brake i ndi cator
for the fol l owi ng reasons:
turned to the On posi ti on the brake i ndi cator i s i l l u-
mi nated by the i nstrument cl uster for about four sec-
onds as a bul b test.
Brake Lamp-On Message - Each ti me the
cl uster recei ves a l amp-on message from the CTM or
the CAB, the brake i ndi cator wi l l be i l l umi nated. I f
the park brake i s appl i ed or not ful l y rel eased, or i f
the pressures i n the two hal ves of the spl i t brake
hydraul i c system are not equal wi th the i gni ti on
swi tch i n the On posi ti on, the brake i ndi cator i s i l l u-
mi nated sol i d. The brake i ndi cator wi l l bl i nk on and
off repeatedl y when the park brake i s appl i ed or not
ful l y rel eased and the i gni ti on swi tch i s i n the On
posi ti on i f a vehi cl e wi th an automati c transmi ssi on
i s not i n Park or Neutral , or i f the engi ne i s runni ng
on vehi cl es wi th a manual transmi ssi on. The i ndi ca-
tor remai ns i l l umi nated unti l the cl uster recei ves
l amp-off messages from both the CTM and the CAB,
or unti l the i gni ti on swi tch i s turned to the Off posi -
ti on, whi chever occurs fi rst.
ter i s put through the actuator test, the brake i ndi -
cator wi l l be turned on, then off agai n duri ng the
bul b check porti on of the test to confi rm the functi on-
al i ty of the LED and the cl uster control ci rcui try.
The park brake swi tch on the park brake pedal
mechani sm provi des a hard wi red ground i nput to
the CTM ci rcui try through the park brake swi tch
sense ci rcui t whenever the park brake i s appl i ed or
not ful l y rel eased. The CTM then sends the proper
l amp-on or l amp-off messages to the i nstrument cl us-
ter. The brake pressure swi tch on the brake combi na-
ti on val ve provi des a hard wi red ground i nput to the
CAB ci rcui try through the brake pressure swi tch
sense ci rcui t whenever the pressures i n the two
hal ves of the spl i t brake hydraul i c system are
unequal . The CAB then sends the proper l amp-on or
l amp-off messages to the i nstrument cl uster. I f the
CAB sends a l amp-on message after the bul b test, i t
i ndi cates that the CAB has detected a brake hydrau-
l i c system mal functi on and/or that the ABS system
has become i noperati ve. The CAB wi l l store a Di ag-
nosti c Troubl e Code (DTC) for any mal functi on i t
detects. The park brake swi tch i nput to the CTM and
the brake pressure swi tch i nput to the CAB can be
methods. For proper di agnosi s of the anti l ock brake
system, the CTM, the CAB, the PCI data bus, or the
message i nputs to the i nstrument cl uster that control
the brake i ndi cator, a DRBI I I scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
CHECK GAUGES INDICATOR
DESCRIPTION
A check gauges i ndi cator i s standard equi pment on
al l i nstrument cl usters. The check gauges i ndi cator i s
l ocated i n the I nformati on Center area of the i nstru-
ment cl uster, to the ri ght of center. The check gauges
i ndi cator consi sts of a stenci l ed cutout of the words
CHECK GAGES i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents the i ndi cator from bei ng cl earl y vi s-
i bl e when i t i s not i l l umi nated. A red l ens behi nd the
cutout i n the opaque l ayer of the overl ay causes the
CHECK GAGES text to appear i n red through the
transl ucent outer l ayer of the overl ay when the i ndi -
cator i s i l l umi nated from behi nd by a Li ght Emi tti ng
Di ode (LED) sol dered onto the i nstrument cl uster
el ectroni c ci rcui t board. The check gauges i ndi cator i s
OPERATION
The check gauges i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when certai n i nstrument cl uster
gauge readi ngs refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. Thi s i ndi cator i s control l ed by a tran-
si stor on the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The check gauges
i ndi cator Li ght Emi tti ng Di ode (LED) recei ves bat-
tery current on the i nstrument cl uster el ectroni c ci r-
cui t board through the fused i gni ti on swi tch output
(run-start) ci rcui t whenever the i gni ti on swi tch i s i n
the On or Start posi ti ons; therefore, the LED wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The LED onl y i l l umi nates
BRAKE/PARK BRAKE INDICATOR (Continued)
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the check gauges i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the check gauges i ndi cator
i s i l l umi nated for about two seconds as a bul b test.
Engine Temperature High Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne cool ant temperature of a gaso-
l i ne engi ne i s about 122 C (253 F) or hi gher, or a
di esel engi ne i s about 112 C (233 F) or hi gher, the
check gauges i ndi cator wi l l be i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
message from the PCM i ndi cati ng that the tempera-
ture of a gasol i ne engi ne i s about 119 C (246 F) or
l ower, a di esel engi ne i s about 109 C (226 F) or
l ower, or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst.
Engine Oil Pressure Low Message - Each
i ndi cati ng the engi ne oi l pressure of a gasol i ne
engi ne i s about 3.45 kPa (0.5 psi ) or l ower, or a di esel
engi ne i s about 51.71 kPa (7.5 psi ) or l ower, the
check gauges i ndi cator wi l l be i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
message from the PCM i ndi cati ng that the engi ne oi l
pressure of a gasol i ne engi ne i s above 3.45 kPa (0.5
psi ), a di esel engi ne i s above 51.71 kPa (7.5 psi ), or
whi chever occurs fi rst. The cl uster wi l l onl y turn the
i ndi cator on i n response to an engi ne oi l pressure l ow
message i f the engi ne speed i s greater than zero.
System Voltage Low Message - Each ti me the
cl uster recei ves a message from the PCM i ndi cati ng
the el ectri cal system vol tage i s l ess than 11.5 vol ts,
the check gauges i ndi cator wi l l be i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a message from the PCM i ndi cati ng the el ec-
tri cal system vol tage i s greater than 12.0 vol ts (but
l ess than 16.6 vol ts), or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst.
System Voltage High Message - Each ti me
the cl uster recei ves a message from the PCM i ndi cat-
i ng the el ectri cal system vol tage i s greater than 16.6
vol ts, the check gauges i ndi cator wi l l be i l l umi nated.
The i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a message from the PCM i ndi cati ng the el ec-
tri cal system vol tage i s l ess than 16.1 vol ts (but
greater than 11.5 vol ts), or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
through the actuator test, the i ndi cator wi l l be
The PCM conti nual l y moni tors the engi ne temper-
ature, oi l pressure, and el ectri cal system vol tage,
then sends the proper messages to the i nstrument
cl uster. For further di agnosi s of the check gauges
i ndi cator or the i nstrument cl uster ci rcui try that con-
trol s the LED, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
For proper di agnosi s of the PCM, the PCI data bus,
or the message i nputs to the i nstrument cl uster that
control the check gauges i ndi cator, a DRBI I I scan
tool i s requi red. Refer to the appropri ate di agnosti c
i nformati on.
COOLANT LOW INDICATOR
DESCRIPTION
A cool ant l ow i ndi cator i s onl y found i n the i nstru-
ment cl usters of vehi cl es equi pped wi th an opti onal
di esel engi ne. The cool ant l ow i ndi cator i s l ocated i n
the I nformati on Center area of the i nstrument cl us-
ter, to the l eft of center. The cool ant l ow i ndi cator
consi sts of a stenci l ed cutout of the words LOW
COOLANT i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. A red l ens behi nd the cut-
out i n the opaque l ayer of the overl ay causes the
LOW COOLANT text to appear i n red through the
el ectroni c ci rcui t board. The cool ant l ow i ndi cator i s
OPERATION
The cool ant l ow i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the engi ne cool ant l evel i s l ow.
Thi s i ndi cator i s control l ed by a transi stor on the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
the cl uster from the Powertrai n Control Modul e
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The cool ant l ow i ndi cator
Start posi ti ons; therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the i nstrument cl uster
transi stor. The i nstrument cl uster wi l l turn on the
cool ant l ow i ndi cator for the fol l owi ng reasons:
CHECK GAUGES INDICATOR (Continued)
turned to the On posi ti on the cool ant l ow i ndi cator i s
i l l umi nated for about two seconds as a bul b test.
Coolant Low Lamp-On Message - Each ti me
i ng the engi ne cool ant l evel i s l ow, the cool ant l ow
i ndi cator wi l l be i l l umi nated, and a si ngl e chi me tone
i s sounded. The i ndi cator remai ns i l l umi nated unti l
i ng that the engi ne cool ant l evel i s not l ow, or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst. The chi me tone feature wi l l
onl y repeat duri ng the same i gni ti on cycl e i f the cool -
ant l ow i ndi cator i s cycl ed off and then on agai n by
the appropri ate l amp-off and l amp-on messages from
the PCM.
The PCM conti nual l y moni tors the engi ne cool ant
l evel through the l ow cool ant l evel swi tch, then sends
the proper messages to the i nstrument cl uster. For
further di agnosi s of the cool ant l ow i ndi cator or the
i nstrument cl uster ci rcui try that control s the LED,
TER - DI AGNOSI S AND TESTI NG). For proper
di agnosi s of the l ow cool ant l evel swi tch, the PCM,
the PCI data bus, or the message i nputs to the
i nstrument cl uster that control the cool ant l ow i ndi -
cator, a DRBI I I scan tool i s requi red. Refer to the
appropri ate di agnosti c i nformati on.
CRUISE INDICATOR
DESCRIPTION
A crui se i ndi cator i s standard equi pment on al l
equi pped wi th the opti onal speed control system, thi s
i ndi cator i s el ectroni cal l y di sabl ed. The crui se i ndi ca-
tor consi sts of the word CRUI SE, whi ch appears i n
the l ower porti on of the odometer/tri p odometer Vac-
uum-Fl uorescent Di spl ay (VFD). The VFD i s part of
the cl uster el ectroni c ci rcui t board, and i s vi si bl e
through a cutout l ocated i n the l ower l eft corner of
the cl uster overl ay. The dark l ens of the VFD pre-
vents the i ndi cator from bei ng cl earl y vi si bl e when i t
i s not i l l umi nated. The word CRUI SE appears i n
an amber col or and at the same l i ghti ng l evel as the
odometer/tri p odometer i nformati on when i t i s i l l umi -
nated by the i nstrument cl uster el ectroni c ci rcui t
board. The crui se i ndi cator i s servi ced as a uni t wi th
the VFD i n the i nstrument cl uster.
OPERATION
The crui se i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the speed control system i s turned
On, regardl ess of whether the speed control i s
engaged. Thi s i ndi cator i s control l ed by the i nstru-
ment cl uster ci rcui t board based upon cl uster pro-
grammi ng and el ectroni c messages recei ved by the
cl uster from the Powertrai n Control Modul e (PCM)
(PCI ) data bus. The crui se i ndi cator recei ves battery
current on the i nstrument cl uster el ectroni c ci rcui t
board through the fused i gni ti on swi tch output (run-
start) ci rcui t whenever the i gni ti on swi tch i s i n the
On or Start posi ti ons; therefore, the i ndi cator wi l l
ti on except On or Start. The i ndi cator onl y i l l umi -
nates when i t i s swi tched to ground by the
i nstrument cl uster ci rcui try. The i nstrument cl uster
wi l l turn on the crui se i ndi cator for the fol l owi ng rea-
sons:
turned to the On posi ti on the crui se i ndi cator i s i l l u-
mi nated for about two seconds as a bul b test.
Cruise Lamp-On Message - Each ti me the
cl uster recei ves a crui se l amp-on message from the
PCM i ndi cati ng the speed control system has been
turned On, the crui se i ndi cator i s i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a crui se l amp-off message from the PCM or
through the actuator test, the crui se i ndi cator wi l l be
turned on, then off agai n duri ng the VFD porti on of
the test to confi rm the functi onal i ty of the VFD, and
agai n duri ng the bul b check porti on of the test to
confi rm the functi onal i ty of the cl uster control ci r-
cui try.
The PCM conti nual l y moni tors the speed control
swi tches to determi ne the proper outputs to the
speed control servo. The PCM then sends the proper
crui se i ndi cator l amp-on and l amp-off messages to
the i nstrument cl uster. For further di agnosi s of the
crui se i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the speed control
system, the PCM, the PCI data bus, or the message
i nputs to the i nstrument cl uster that control the
crui se i ndi cator, a DRBI I I scan tool i s requi red.
COOLANT LOW INDICATOR (Continued)
DOOR AJ AR INDICATOR
DESCRIPTION
A door ajar i ndi cator i s standard equi pment on al l
equi pped wi th thi s opti onal feature, thi s i ndi cator i s
el ectroni cal l y di sabl ed. The door ajar i ndi cator i s
ment cl uster, to the l eft of center. The door ajar i ndi -
cator consi sts of a stenci l ed cutout of the words
DOOR AJAR i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. A red l ens behi nd the cut-
out i n the opaque l ayer of the overl ay causes the
DOOR AJAR text to appear i n red through the
el ectroni c ci rcui t board. The door ajar i ndi cator i s
OPERATION
The door ajar i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that one or more of the passenger
compartment doors may be open or not compl etel y
l atched. Thi s i ndi cator i s control l ed by a transi stor
cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Central Ti mer Mod-
ul e (CTM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The door ajar i ndi cator
door ajar i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the door ajar i ndi cator i s
i l l umi nated for about two seconds as a bul b test.
Door Ajar Lamp-On Message - Each ti me the
cl uster recei ves a door ajar l amp-on message from
the CTM i ndi cati ng that a door i s open or not com-
pl etel y l atched, the door ajar i ndi cator wi l l be i l l umi -
nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves an door ajar l amp-off message from
the CTM, or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst.
through the actuator test, the door ajar i ndi cator wi l l
be turned on, then off agai n duri ng the bul b check
porti on of the test to confi rm the functi onal i ty of the
cl uster control ci rcui try.
The CTM conti nual l y moni tors the door ajar
swi tches to determi ne the status of the doors. The
CTM then sends the proper door ajar l amp-on and
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the door ajar i ndi cator or the
i nstrument cl uster ci rcui try that control s the i ndi ca-
tor, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For
proper di agnosi s of the door ajar swi tches and ci r-
cui ts, (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG
- I NTERI OR/DOOR AJAR SWI TCH - DI AGNOSI S
AND TESTI NG). For proper di agnosi s of the CTM,
i nstrument cl uster that control the door ajar i ndi ca-
tor, a DRBI I I scan tool i s requi red. Refer to the
ENGINE TEMPERATURE
GAUGE
DESCRIPTION
An engi ne cool ant temperature gauge i s standard
equi pment on al l i nstrument cl usters. The engi ne
cool ant temperature gauge i s l ocated i n the l ower l eft
quadrant of the i nstrument cl uster, bel ow the vol tage
gauge. The engi ne cool ant temperature gauge con-
si sts of a movabl e gauge needl e or poi nter control l ed
by the i nstrument cl uster ci rcui try and a fi xed 90
degree scal e on the cl uster overl ay that reads l eft-to-
ri ght from C (or Col d) to H (or Hot) for al l
engi nes. An I nternati onal Control and Di spl ay Sym-
bol i con for Engi ne Cool ant Temperature i s l ocated
on the cl uster overl ay, i n the center of the gauge
di rectl y above the hub of the gauge needl e. The
engi ne cool ant temperature gauge graphi cs are whi te
agai nst a bl ack fi el d except for a si ngl e red gradua-
ti on at the hi gh end of the gauge scal e, maki ng them
cl earl y vi si bl e wi thi n the i nstrument cl uster i n day-
l i ght. When i l l umi nated from behi nd by the panel
l amps di mmer control l ed cl uster i l l umi nati on l i ghti ng
wi th the exteri or l amps turned On, the whi te graph-
i cs appear bl ue-green and the red graphi cs appear
red. The orange gauge needl e i s i nternal l y i l l umi -
nated. Gauge i l l umi nati on i s provi ded by repl aceabl e
i ncandescent bul b and bul b hol der uni ts l ocated on
the i nstrument cl uster el ectroni c ci rcui t board. The
engi ne cool ant temperature gauge i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The engi ne cool ant temperature gauge gi ves an
i ndi cati on to the vehi cl e operator of the engi ne cool -
ant temperature. Thi s gauge i s control l ed by the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
I nterface (PCI ) data bus. The engi ne cool ant temper-
ature gauge i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
Engine Temperature Message - Each ti me
i ng the engi ne cool ant temperature i s between the
l ow end of normal [about 54 C (130 F) for gasol i ne
engi nes, or 65 C (149 F) for di esel engi nes] and the
hi gh end of normal [about 129 C (264 F) for gaso-
l i ne engi nes, or 120 C (248 F) for di esel engi nes],
the gauge needl e i s moved to the actual temperature
posi ti on on the gauge scal e.
Engine Temperature Low Message - Each
i ndi cati ng the engi ne cool ant temperature i s bel ow
the l ow end of normal [about 54 C (130 F) for gas-
ol i ne engi nes, or 65 C (149 F) for di esel engi nes],
the gauge needl e i s hel d at the C i ncrement at the
far l eft end of the gauge scal e. The gauge needl e
remai ns at the far l eft end of the scal e unti l the cl us-
ter recei ves a message from the PCM i ndi cati ng that
the engi ne temperature i s above about 54 C (130 F)
for gasol i ne engi nes, or 65 C (149 F) for di esel
engi nes, or unti l the i gni ti on swi tch i s turned to the
Engine Temperature High Message - Each
i ndi cati ng the engi ne cool ant temperature i s above
about 122 C (251 F) for gasol i ne engi nes, or 108 C
(226 F) for di esel engi nes, the gauge needl e i s moved
to the appropri ate posi ti on on the gauge scal e, the
check gauges i ndi cator i s i l l umi nated, and a si ngl e
chi me tone i s sounded. The check gauges i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng that the engi ne tem-
perature i s bel ow about 119 C (246 F) for gasol i ne
engi nes, or 104 C (219 F) for di esel engi nes, or
onl y repeat duri ng the same i gni ti on cycl e i f the
check gauges i ndi cator i s cycl ed off and then on
agai n by the appropri ate engi ne temperature mes-
sages from the PCM.
Message Failure - I f the cl uster fai l s to recei ve
an engi ne temperature message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on unti l a new mes-
sage i s recei ved, or unti l the i gni ti on swi tch i s turned
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
i n a prescri bed sequence i n order to confi rm the func-
ti onal i ty of the gauge and the cl uster control ci r-
cui try.
The PCM conti nual l y moni tors the engi ne cool ant
temperature sensor to determi ne the engi ne operat-
i ng temperature. The PCM then sends the proper
engi ne cool ant temperature messages to the i nstru-
ment cl uster. For further di agnosi s of the engi ne cool -
ant temperature gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). I f the i nstrument cl uster turns on
the check gauges i ndi cator due to a hi gh engi ne tem-
perature gauge readi ng, i t may i ndi cate that the
engi ne or the engi ne cool i ng system requi res servi ce.
For proper di agnosi s of the engi ne cool ant tempera-
ture sensor, the PCM, the PCI data bus, or the mes-
sage i nputs to the i nstrument cl uster that control the
engi ne cool ant temperature gauge, a DRBI I I scan
i nformati on.
FUEL GAUGE
DESCRIPTION
A fuel gauge i s standard equi pment on al l i nstru-
ment cl usters. The fuel gauge i s l ocated i n the l ower
ri ght quadrant of the i nstrument cl uster, bel ow the
oi l pressure gauge. The fuel gauge consi sts of a mov-
abl e gauge needl e or poi nter control l ed by the i nstru-
ment cl uster ci rcui try and a fi xed 90 degree scal e on
the cl uster overl ay that reads l eft-to-ri ght from E (or
Empty) to F (or Ful l ). An I nternati onal Control and
Di spl ay Symbol i con for Fuel i s l ocated on the cl us-
ter overl ay, i n the center of the gauge di rectl y above
the hub of the gauge needl e. An arrowhead poi nted
to the l eft si de of the vehi cl e i s i mpri nted on the cl us-
ter overl ay next to the Fuel i con i n the fuel gauge
to provi de the dri ver wi th a remi nder as to the l oca-
ti on of the fuel fi l l er access. The fuel gauge graphi cs
are whi te agai nst a bl ack fi el d except for a si ngl e red
graduati on at the l ow end of the gauge scal e, maki ng
them cl earl y vi si bl e wi thi n the i nstrument cl uster i n
dayl i ght. When i l l umi nated from behi nd by the panel
ENGINE TEMPERATURE GAUGE (Continued)
fuel gauge i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The fuel gauge gi ves an i ndi cati on to the vehi cl e
operator of the l evel of fuel i n the fuel tank. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
fuel gauge i s an ai r core magneti c uni t that recei ves
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
Percent Tank Full Message - Each ti me the
the percent tank ful l , the cl uster programmi ng
appl i es an al gori thm to cal cul ate the proper gauge
needl e posi ti on, then moves the gauge needl e to the
proper posi ti on on the gauge scal e. The al gori thm i s
used to dampen gauge needl e movement agai nst the
negati ve effect that fuel sl oshi ng wi thi n the fuel tank
can have on accurate i nputs from the fuel tank send-
i ng uni t to the PCM.
Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves messages from the
PCM i ndi cati ng the percent tank ful l i s 12.5 (one-
ei ghth) or l ess for 10 consecuti ve seconds and the
vehi cl e speed i s zero, or for 60 consecuti ve seconds
and the vehi cl e speed i s greater than zero, the gauge
needl e i s moved to the proper posi ti on on the gauge
scal e, the l ow fuel i ndi cator i s i l l umi nated, and a si n-
gl e chi me tone i s sounded. The l ow fuel i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves mes-
sages from the PCM i ndi cati ng that the percent tank
ful l i s greater than 12.5 (one-ei ghth) for 10 consecu-
ti ve seconds and the vehi cl e speed i s zero, or for 60
consecuti ve seconds and the vehi cl e speed i s greater
than zero, or unti l the i gni ti on swi tch i s turned to
the Off posi ti on, whi chever occurs fi rst. The chi me
tone feature wi l l onl y repeat duri ng the same i gni -
ti on cycl e i f the l ow fuel i ndi cator i s cycl ed off and
then on agai n by the appropri ate percent tank ful l
messages from the PCM.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the gauge needl e i s moved to the far l eft (l ow)
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s a
short ci rcui t.
More Than Full Percent Tank Full Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the gauge needl e i s moved to the far l eft (l ow)
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s an
open ci rcui t.
a percent tank ful l message, i t wi l l hol d the gauge
needl e at the l ast i ndi cati on unti l a new message i s
recei ved, or unti l the i gni ti on swi tch i s turned to the
cui try.
The PCM conti nual l y moni tors the fuel tank send-
i ng uni t, then sends the proper messages to the
i nstrument cl uster. For further di agnosi s of the fuel
gauge or the i nstrument cl uster ci rcui try that con-
trol s the gauge, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
For proper di agnosi s of the fuel tank sendi ng uni t,
the PCM, the PCI data bus, or the message i nputs to
the i nstrument cl uster that control the fuel gauge, a
GEAR SELECTOR INDICATOR
DESCRIPTION
An el ectroni c automati c transmi ssi on gear sel ector
i ndi cator i s standard factory-i nstal l ed equi pment on
thi s model , when i t i s al so equi pped wi th an opti onal
automati c transmi ssi on. The gear sel ector i ndi cator
i nformati on i s di spl ayed i n a Vacuum-Fl uorescent
Di spl ay (VFD), whi ch i s vi si bl e through a smal l wi n-
dow cutout l ocated i n the l ower ri ght quadrant of the
cl uster overl ay. The gear sel ector i ndi cator di spl ays
the fol l owi ng characters from l eft to ri ght: P, R,
N, D, 2, and 1. Respecti vel y, these characters
represent the park, reverse, neutral , dri ve, second
gear, and fi rst gear posi ti ons of the transmi ssi on gear
sel ector l ever on the steeri ng col umn. The VFD i l l u-
FUEL GAUGE (Continued)
mi nates a rectangul ar box around the character that
represents the currentl y sel ected l ever posi ti on.
Duri ng dayl i ght hours (exteri or l amps Off) the gear
sel ector i ndi cator VFD i s i l l umi nated at ful l bri ght-
ness for cl ear vi si bi l i ty. At ni ght (exteri or l amps are
On) the VFD l i ghti ng l evel i s adjusted wi th the other
cl uster i l l umi nati on l amps usi ng the panel l amps
di mmer thumbwheel on the headl amp swi tch. How-
ever, a Parade mode posi ti on of the panel l amps
di mmer thumbwheel al l ows the VFD to be i l l umi -
nated at ful l bri ghtness whi l e the exteri or l amps are
turned On duri ng dayl i ght hours. The gear sel ector
i ndi cator VFD i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The el ectroni c gear sel ector i ndi cator gi ves an i ndi -
cati on to the vehi cl e operator of the transmi ssi on
gear that has been sel ected wi th the automati c trans-
mi ssi on gear sel ector l ever. Thi s gauge i s control l ed
by the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng. The cl uster ci rcui try automati -
cal l y confi gures i tsel f for the proper automati c trans-
mi ssi on model based upon the hard wi red
transmi ssi on range sensor mux ci rcui t i nput to the
cl uster. Each ti me the cl uster i s di sconnected from
battery current for more than about fi ve mi nutes, i t
must confi gure i tsel f agai n for the automati c trans-
mi ssi on model that i s i n the vehi cl e when i t i s recon-
nected to battery current. The gear sel ector i ndi cator
i nformati on i s di spl ayed by a dedi cated Vacuum Fl u-
orescent Di spl ay (VFD) on the i nstrument cl uster
el ectroni c ci rcui t board, and the VFD wi l l not di spl ay
the gear sel ector i ndi cator i nformati on after the i gni -
ti on swi tch i s turned to the Off posi ti on. The i nstru-
ment cl uster ci rcui try confi gures the gear sel ector
i ndi cator VFD based upon the fol l owi ng i nputs from
the transmi ssi on range sensor:
Open Circuit - I f the transmi ssi on range sensor
mux ci rcui t i s open, the cl uster ci rcui try control s the
gear sel ector i ndi cator di spl ay based upon el ectroni c
messages recei ved from the el ectroni c Transmi ssi on
Control Modul e (TCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. I f the i nput i s
open ci rcui t and no el ectroni c messages are recei ved
from the TCM wi thi n two seconds, the i nstrument
cl uster ci rcui try wi l l cycl e the i ndi cated gear sel ector
posi ti on from P, to R, to N, to D to 2 repeatedl y and
conti nuousl y unti l the condi ti on i s resol ved or unti l
Resolved Circuit - I f the transmi ssi on range
sensor mux ci rcui t i s resol ved, the cl uster ci rcui try
control s the gear sel ector i ndi cator di spl ay based
upon the resi stance val ue of the hard wi red i nput
from the transmi ssi on range sensor. I f the cl uster
has confi gured i tsel f for the transmi ssi on range sen-
sor i nput and detects a short to ground i n the trans-
mi ssi on range sensor mux i nput, the cl uster wi l l
i ndi cate al l posi ti ons i n the VFD; or, i f thi s i nput i s
open ci rcui t, the cl uster wi l l bl i nk al l posi ti ons i n the
VFD. The VFD di spl ay for the short-to-ground and
open ci rcui t condi ti ons wi l l conti nue unti l the condi -
ti on i s resol ved or unti l the i gni ti on swi tch i s turned
through the actuator test, the VFD wi l l di spl ay al l of
i ts characters at once, then step through each char-
acter segment i ndi vi dual l y duri ng the VFD porti on of
the test to confi rm the functi onal i ty of the VFD and
the cl uster control ci rcui try.
On model s wi th a TCM, the TCM conti nual l y mon-
i tors the transmi ssi on range sensor, then sends the
proper gear sel ector i ndi cator messages to the i nstru-
ment cl uster. On model s wi thout a TCM, the i nstru-
ment cl uster conti nual l y moni tors the hard wi red
transmi ssi on range sensor mul ti pl exed i nput. For
further di agnosi s of the gear sel ector i ndi cator or the
i nstrument cl uster ci rcui try that control s thi s func-
ti on, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). On mod-
el s wi thout a TCM, for further di agnosi s of the trans-
mi ssi on range sensor, (Refer to 21 -
TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
42RE/TRANSMI SSI ON RANGE SENSOR - DI AG-
NOSI S AND TESTI NG) or (Refer to 21 - TRANSMI S-
SI ON/TRANSAXLE/AUTOMATI C - 46RE/
TRANSMI SSI ON RANGE SENSOR - DI AGNOSI S
AND TESTI NG). On model s wi th a TCM, for proper
di agnosi s of the transmi ssi on range sensor, the TCM,
i nstrument cl uster that control the gear sel ector i ndi -
HIGH BEAM INDICATOR
DESCRIPTION
A hi gh beam i ndi cator i s standard equi pment on
al l i nstrument cl usters. The hi gh beam i ndi cator i s
l ocated near the upper edge of the i nstrument cl uster
overl ay, between the tachometer and the speedome-
ter. The hi gh beam i ndi cator consi sts of a stenci l ed
cutout of the I nternati onal Control and Di spl ay Sym-
bol i con for Hi gh Beam i n the opaque l ayer of the
i nstrument cl uster overl ay. The dark outer l ayer of
the overl ay prevents the i ndi cator from bei ng cl earl y
vi si bl e when i t i s not i l l umi nated. A bl ue l ens behi nd
the cutout i n the opaque l ayer of the overl ay causes
the i con to appear i n bl ue when i t i s i l l umi nated
from behi nd by a repl aceabl e i ncandescent bul b and
GEAR SELECTOR INDICATOR (Continued)
bul b hol der uni t l ocated on the i nstrument cl uster
el ectroni c ci rcui t board. The hi gh beam i ndi cator i s
OPERATION
The hi gh beam i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the headl amp hi gh beams are
i l l umi nated. Thi s i ndi cator i s hard wi red on the
i nstrument cl uster el ectroni c ci rcui t board, and i s
control l ed by the Central Ti mer Modul e (CTM)
through the hi gh beam i ndi cator dri ver ci rcui t i nput
to the cl uster based upon a control si gnal to the CTM
from the headl amp beam sel ect swi tch. The head-
l amp beam sel ect swi tch i s i ntegral to the mul ti -func-
ti on swi tch on the l eft si de of the steeri ng col umn.
The hi gh beam i ndi cator bul b recei ves battery cur-
rent on the i nstrument cl uster el ectroni c ci rcui t
board through a fused B(+) ci rcui t at al l ti mes; there-
fore, the i ndi cator remai ns operati onal regardl ess of
the i gni ti on swi tch posi ti on. The i ndi cator onl y i l l u-
mi nates when i t i s provi ded wi th a path to ground by
the CTM. The hi gh beam i ndi cator can be di agnosed
usi ng conventi onal di agnosti c tool s and methods. For
proper di agnosi s of the CTM and the i nputs to the
CTM that control the hi gh beam i ndi cator dri ver ci r-
cui t, a DRBI I I scan tool i s requi red. Refer to the
DIAGNOSIS AND TESTING - HIGH BEAM
INDICATOR
headl amp hi gh beam i ndi cator condi ti on. I f the prob-
l em bei ng di agnosed i s rel ated to i noperati ve head-
l amp hi gh beams, be certai n to repai r the headl amp
system before attempti ng to di agnose or repai r the
hi gh beam i ndi cator. I f no headl amp system probl ems
are found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the hi gh beam i ndi cator dri ver ci r-
cui t. Refer to the appropri ate wi ri ng i nformati on. The
INJURY.
INDICATOR DOES NOT ILLUMINATE WITH HIGH BEAMS
SELECTED
the JB and the Power Di stri buti on Center (PDC) as
requi red.
cabl e. Remove the i nstrument cl uster from the
i nstrument panel . Reconnect the battery negati ve
cabl e. Check for battery vol tage at the fused B(+) ci r-
cui t cavi ty of the i nstrument panel wi re harness con-
nector (Connector C1) for the i nstrument cl uster. I f
OK, go to Step 4. I f not OK, repai r the open fused
B(+) ci rcui t between the i nstrument cl uster and the
JB as requi red.
connector (Connector C1) for the Central Ti mer Mod-
ul e (CTM) from the CTM connector receptacl e. Check
for conti nui ty between the hi gh beam i ndi cator dri ver
ci rcui t cavi ti es of the i nstrument panel wi re harness
connector (Connector C1) for the CTM and the
C1) for the i nstrument cl uster. There shoul d be con-
ti nui ty. I f OK, go to Step 5. I f not OK, repai r the
open hi gh beam i ndi cator dri ver ci rcui t between the
i nstrument cl uster and the CTM as requi red.
i nstrument panel . Reconnect the battery negati ve
cabl e. I nstal l a jumper wi re between the hi gh beam
i ndi cator dri ver ci rcui t cavi ty of the i nstrument panel
wi re harness connector (Connector C1) for the CTM
and a good ground. The i ndi cator shoul d i l l umi nate.
I f OK, di agnose the CTM and i ts i nputs usi ng a
ti c procedures. I f not OK, repl ace the faul ty hi gh
beam i ndi cator bul b and bul b hol der uni t.
INDICATOR STAYS ILLUMINATED WITH HIGH BEAMS NOT
SELECTED
connector (Connector C1) for the Central Ti mer Mod-
ul e (CTM) from the CTM connector receptacl e. Check
for conti nui ty between the hi gh beam i ndi cator dri ver
ci rcui t cavi ty of the i nstrument panel wi re harness
connector (Connector C1) for the CTM and a good
HIGH BEAM INDICATOR (Continued)
ground. There shoul d be no conti nui ty. I f OK, di ag-
nose the CTM and i ts i nputs usi ng a DRBI I I scan
tool . Refer to the appropri ate di agnosti c procedures.
I f not OK, repai r the shorted hi gh beam i ndi cator
dri ver ci rcui t between the CTM and the i nstrument
cl uster as requi red.
LOW FUEL INDICATOR
DESCRIPTION
A l ow fuel i ndi cator i s standard equi pment on al l
i nstrument cl usters. The l ow fuel i ndi cator i s l ocated
i n the I nformati on Center area of the i nstrument
cl uster overl ay, to the l eft of center. The l ow fuel i ndi -
cator consi sts of a stenci l ed cutout of the I nterna-
ti onal Control and Di spl ay Symbol i con for Fuel i n
the opaque l ayer of the i nstrument cl uster overl ay.
The dark outer l ayer of the overl ay prevents the i ndi -
cator from bei ng cl earl y vi si bl e when i t i s not i l l umi -
nated. An amber l ens behi nd the cutout i n the
opaque l ayer of the overl ay causes the i con to appear
i n amber through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by a Li ght Emi tti ng Di ode (LED) sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The l ow fuel i ndi cator i s servi ced as a uni t wi th the
OPERATION
The l ow fuel i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the l evel of fuel i n the fuel
tank becomes l ow. Thi s i ndi cator i s control l ed by a
sages recei ved by the cl uster from the Powertrai n
Control Modul e (PCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. The l ow fuel
the On or Start posi ti ons; therefore, the LED wi l l
turn on the l ow fuel i ndi cator for the fol l owi ng rea-
sons:
turned to the On posi ti on the i ndi cator i s i l l umi nated
for about two seconds as a bul b test.
Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves messages from the
PCM i ndi cati ng the percent tank ful l i s 12.5 (one-
ei ghth) or l ess for 10 consecuti ve seconds and the
vehi cl e speed i s zero, or for 60 consecuti ve seconds
and the vehi cl e speed i s greater than zero, the l ow
fuel i ndi cator i s i l l umi nated and a si ngl e chi me tone
i s sounded. The l ow fuel i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves messages from the
PCM i ndi cati ng that the percent tank ful l i s greater
than 12.5 (one-ei ghth) for 10 consecuti ve seconds and
the vehi cl e speed i s zero, or for 60 consecuti ve sec-
onds and the vehi cl e speed i s greater than zero, or
onl y repeat duri ng the same i gni ti on cycl e i f the l ow
fuel i ndi cator i s cycl ed off and then on agai n by the
appropri ate percent tank ful l messages from the
PCM.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s a short ci rcui t.
More Than Full Percent Tank Full Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s an open ci rcui t.
The PCM conti nual l y moni tors the fuel tank send-
i ng uni t, then sends the proper messages to the
i nstrument cl uster. For further di agnosi s of the l ow
fuel i ndi cator or the i nstrument cl uster ci rcui try that
control s the LED, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the fuel tank sendi ng
uni t, the PCM, the PCI data bus, or the message
i nputs to the i nstrument cl uster that control the l ow
fuel i ndi cator, a DRBI I I scan tool i s requi red. Refer
to the appropri ate di agnosti c i nformati on.
MALFUNCTION INDICATOR
LAMP (MIL)
DESCRIPTION
A Mal functi on I ndi cator Lamp (MI L) i s standard
equi pment on al l i nstrument cl usters. The MI L i s
ment cl uster overl ay, to the l eft of center. The MI L
consi sts of a stenci l l ed cutout of the I nternati onal
Control and Di spl ay Symbol i con for Engi ne i n the
HIGH BEAM INDICATOR (Continued)
An amber l ens behi nd the cutout i n the opaque l ayer
of the overl ay causes the i con to appear i n amber
when the i ndi cator i s i l l umi nated from behi nd by a
Li ght Emi tti ng Di ode (LED) sol dered onto the i nstru-
ment cl uster el ectroni c ci rcui t board. The MI L i s ser-
vi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The Mal functi on I ndi cator Lamp (MI L) gi ves an
i ndi cati on to the vehi cl e operator when the Power-
trai n Control Modul e (PCM) has recorded a Di agnos-
ti c Troubl e Code (DTC) for an On-Board Di agnosti cs
I I (OBDI I ) emi ssi ons-rel ated ci rcui t or component
mal functi on. I n addi ti on, on model s wi th a di esel
engi ne an Engi ne Control Modul e (ECM) suppl e-
ments the PCM, and can al so record an OBDI I DTC.
The MI L i s control l ed by a transi stor on the i nstru-
ment cl uster ci rcui t board based upon cl uster pro-
grammi ng and el ectroni c messages recei ved by the
cl uster from the PCM or ECM over the Programma-
bl e Communi cati ons I nterface (PCI ) data bus. The
MI L Li ght Emi tti ng Di ode (LED) recei ves battery
current on the i nstrument cl uster el ectroni c ci rcui t
board through the fused i gni ti on swi tch output (run-
start) ci rcui t whenever the i gni ti on swi tch i s i n the
On or Start posi ti ons; therefore, the LED wi l l al ways
be off when the i gni ti on swi tch i s i n any posi ti on
except On or Start. The LED onl y i l l umi nates when
i t i s provi ded a path to ground by the i nstrument
cl uster transi stor. The i nstrument cl uster wi l l turn
on the MI L for the fol l owi ng reasons:
for about seven seconds as a bul b test.
PCM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the PCM or
ECM, the i ndi cator wi l l be i l l umi nated. The i ndi cator
can be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the PCM or ECM message. For some DTCs,
i f a probl em does not recur, the PCM or ECM wi l l
send a l amp-off message automati cal l y. Other DTCs
may requi re that a faul t be repai red and the PCM or
ECM be reset before a l amp-off message wi l l be sent.
For more i nformati on on the PCM, the ECM, and the
DTC set and reset parameters, (Refer to 25 - EMI S-
SI ONS CONTROL - OPERATI ON).
no l amp-on message from the PCM or ECM for
twenty seconds, the MI L i s i l l umi nated by the i nstru-
ment cl uster to i ndi cate a l oss of bus communi cati on.
The i ndi cator remai ns control l ed and i l l umi nated by
the cl uster unti l a val i d l amp-on message i s recei ved
from the PCM or ECM.
turned on duri ng the bul b check porti on of the test to
confi rm the functi onal i ty of the LED and the cl uster
control ci rcui try.
The PCM/ECM conti nual l y moni tors the fuel and
emi ssi ons system ci rcui ts and sensors to deci de
whether the system i s i n good operati ng condi ti on.
The PCM or ECM then sends the proper l amp-on or
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the MI L or the i nstrument cl uster
ci rcui try that control s the LED, (Refer to 8 - ELEC-
the MI L after the bul b test, i t may i ndi cate that a
mal functi on has occurred and that the fuel and emi s-
si ons systems may requi re servi ce. For proper di ag-
nosi s of the fuel and emi ssi ons systems, the PCM,
the ECM, the PCI data bus, or the message i nputs to
the i nstrument cl uster that control the MI L, a
ODOMETER
DESCRIPTION
An odometer and tri p odometer are standard
equi pment i n al l i nstrument cl usters. The odometer
and tri p odometer i nformati on are di spl ayed i n a
common el ectroni c Vacuum-Fl uorescent Di spl ay
(VFD), whi ch i s vi si bl e through a smal l wi ndow cut-
out l ocated i n the l eft l ower quadrant of the cl uster
overl ay. However, the odometer and tri p odometer
i nformati on are not di spl ayed si mul taneousl y. The
tri p odometer reset swi tch on the i nstrument cl uster
ci rcui t board toggl es the di spl ay between odometer
and tri p odometer modes by depressi ng the odometer/
tri p odometer swi tch knob that extends through the
l ower edge of the cl uster l ens, just ri ght of the odom-
eter VFD. When the tri p odometer i nformati on i s di s-
pl ayed, the word TRI P i s al so i l l umi nated i n a
green col or and at the same l i ghti ng l evel as the tri p
odometer i nformati on i n the l ower ri ght corner of the
VFD. Both the odometer and the tri p odometer i nfor-
mati on i s stored i n the i nstrument cl uster memory.
The odometer can di spl ay val ues up to 499,999
ki l ometers (499,999 mi l es). The odometer l atches at
these val ues, and wi l l not rol l over to zero. The tri p
odometer can di spl ay val ues up to 999.9 ki l ometers
(999.9 mi l es) before i t rol l s over to zero. The odome-
ter di spl ay does not have a deci mal poi nt and wi l l
not show val ues l ess than a ful l uni t (ki l ometer or
mi l e), the tri p odometer di spl ay does have a deci mal
poi nt and wi l l show tenths of a uni t (ki l ometer or
mi l e). The uni t of measure (ki l ometers or mi l es) for
MALFUNCTION INDICATOR LAMP (MIL) (Continued)
the odometer and tri p odometer di spl ay i s not shown
i n the VFD. The uni t of measure for the i nstrument
cl uster odometer/tri p odometer i s sel ected at the ti me
that i t i s manufactured, and cannot be changed. Dur-
i ng dayl i ght hours (exteri or l amps Off) the VFD i s
i l l umi nated at ful l bri ghtness for cl ear vi si bi l i ty. At
ni ght (exteri or l amps are On) the VFD l i ghti ng l evel
i s adjusted wi th the other cl uster i l l umi nati on l amps
usi ng the panel l amps di mmer thumbwheel on the
headl amp swi tch. However, a Parade mode posi ti on
of the panel l amps di mmer thumbwheel al l ows the
VFD to be i l l umi nated at ful l bri ghtness whi l e the
exteri or l amps are turned On duri ng dayl i ght hours.
The VFD, the tri p odometer swi tch, and the tri p
odometer swi tch button are servi ced as a uni t wi th
OPERATION
The odometer and tri p odometer gi ve an i ndi cati on
to the vehi cl e operator of the di stance the vehi cl e has
travel ed. Thi s gauge i s control l ed by the i nstrument
cl uster ci rcui t board based upon cl uster programmi ng
and el ectroni c messages recei ved by the cl uster from
the Powertrai n Control Modul e (PCM) over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data
bus. The odometer and tri p odometer i nformati on i s
di spl ayed by the i nstrument cl uster Vacuum Fl uores-
cent Di spl ay (VFD), and the VFD wi l l not di spl ay
odometer or tri p odometer i nformati on after the i gni -
ti on swi tch i s turned to the Off posi ti on. The i nstru-
ment cl uster ci rcui try control s the VFD and provi des
the fol l owi ng features:
Odometer/Trip Odometer Display Toggling -
Actuati ng the tri p odometer reset swi tch momen-
tari l y wi th the i gni ti on swi tch i n the On posi ti on wi l l
toggl e the VFD between the odometer and tri p odom-
eter di spl ay. Each ti me the i gni ti on swi tch i s turned
to the On posi ti on the VFD wi l l automati cal l y return
to the mode (odometer or tri p odometer) l ast di s-
pl ayed when the i gni ti on swi tch was turned to the
Off posi ti on.
Trip Odometer Reset - When the tri p odome-
ter reset swi tch i s pressed and hel d for l onger than
about two seconds, the tri p odometer wi l l be reset to
000.0 ki l ometers (mi l es). The VFD must be di spl ay-
i ng the tri p odometer i nformati on i n order for the
tri p odometer i nformati on to be reset.
a di stance message duri ng normal operati on, i t wi l l
fl ash the odometer/tri p odometer di stance i nforma-
ti on on and off repeatedl y unti l a di stance message i s
Off posi ti on, whi chever occurs fi rst. I f the cl uster
does not recei ve a di stance message wi thi n one sec-
ond after the i gni ti on swi tch i s turned to the On posi -
ti on, i t wi l l di spl ay the l ast di stance message stored
i n the cl uster memory. I f the cl uster i s unabl e to di s-
pl ay di stance i nformati on due to an error i nternal to
the cl uster, the VFD di spl ay wi l l be bl ank.
through the actuator test, the VFD wi l l di spl ay al l of
i ts characters at once, then step through each char-
acter segment i ndi vi dual l y duri ng the VFD porti on of
the test to confi rm the functi onal i ty of the VFD and
the cl uster control ci rcui try.
The PCM conti nual l y moni tors the vehi cl e speed
sensor, then sends the proper di stance messages to
the i nstrument cl uster. For further di agnosi s of the
odometer/tri p odometer or the i nstrument cl uster ci r-
cui try that control s these functi ons, (Refer to 8 -
SI S AND TESTI NG). For proper di agnosi s of the
vehi cl e speed sensor, the PCM, the PCI data bus, or
the message i nputs to the i nstrument cl uster that
control the odometer/tri p odometer, a DRBI I I scan
i nformati on.
OIL PRESSURE GAUGE
DESCRIPTION
An oi l pressure gauge i s standard equi pment on al l
i nstrument cl usters. The oi l pressure gauge i s l ocated
i n the upper ri ght quadrant of the i nstrument cl us-
ter, above the fuel gauge. The oi l pressure gauge con-
ri ght from L (or Low) to H (or Hi gh). An I nterna-
ti onal Control and Di spl ay Symbol i con for Engi ne
Oi l i s l ocated on the cl uster overl ay, i n the center of
the gauge di rectl y above the hub of the gauge needl e.
The oi l pressure gauge graphi cs are whi te agai nst a
bl ack fi el d except for a si ngl e red graduati on at the
l ow end of the gauge scal e, maki ng them cl earl y vi s-
i bl e wi thi n the i nstrument cl uster i n dayl i ght. When
i l l umi nated from behi nd by the panel l amps di mmer
control l ed cl uster i l l umi nati on l i ghti ng wi th the exte-
ri or l amps turned On, the whi te graphi cs appear
bl ue-green and the red graphi cs appear red. The
orange gauge needl e i s i nternal l y i l l umi nated. Gauge
i l l umi nati on i s provi ded by repl aceabl e i ncandescent
bul b and bul b hol der uni ts l ocated on the i nstrument
cl uster el ectroni c ci rcui t board. The oi l pressure
gauge i s servi ced as a uni t wi th the i nstrument cl us-
ter.
OPERATION
The oi l pressure gauge gi ves an i ndi cati on to the
vehi cl e operator of the engi ne oi l pressure. Thi s
ODOMETER (Continued)
oi l pressure gauge i s an ai r core magneti c uni t that
recei ves battery current on the i nstrument cl uster
el ectroni c ci rcui t board through the fused i gni ti on
swi tch output (run-start) ci rcui t whenever the i gni -
ti on swi tch i s i n the On or Start posi ti ons. The cl us-
ter i s programmed to move the gauge needl e back to
the l ow end of the scal e after the i gni ti on swi tch i s
turned to the Off posi ti on. The i nstrument cl uster
ci rcui try control s the gauge needl e posi ti on and pro-
vi des the fol l owi ng features:
Engine Oil Pressure Message - The i nstru-
ment cl uster ci rcui try restri cts the oi l pressure gauge
needl e operati on i n order to provi de readi ngs that
are consi stent wi th customer expectati ons. Each ti me
i ng the engi ne oi l pressure i s between about 6.9 kPa
(1 psi ) and 137.9 kPa (20 psi ) for gasol i ne engi nes, or
76 kPa (11 psi ) and 206 kPa (30 psi ) for di esel
engi nes, the cl uster hol ds the gauge needl e at a poi nt
about 11 degrees above the l ow end of normal i ncre-
ment on the gauge scal e. Each ti me the cl uster
recei ves a message from the PCM i ndi cati ng the
engi ne oi l pressure i s between about 517.1 kPa (75
psi ) and 755 kPa (109.5 psi ) for gasol i ne engi nes, or
689 kPa (100 psi ) and 755 kPa (109.5 psi ) for di esel
engi nes, the cl uster hol ds the gauge needl e at a poi nt
about 7.4 degrees bel ow the hi gh end of normal
i ncrement on the gauge scal e. When the cl uster
recei ves messages from the PCM i ndi cati ng the
engi ne oi l pressure i s between about 137.9 kPa (20
psi ) and 517.1 kPa (75 psi ) for gasol i ne engi nes, or
58.6 kPa (8.5 psi ) and 551.6 kPa (80 psi ) for di esel
engi nes], the gauge needl e i s moved to the actual
pressure posi ti on on the gauge scal e.
Engine Oil Pressure Low Message - Each
i ndi cati ng the engi ne oi l pressure i s bel ow about 6.9
kPa (1 psi ) for gasol i ne engi nes, or 76 kPa (11 psi ) for
di esel engi nes, the gauge needl e i s moved to the L
(Low) graduati on at the far l eft end of the gauge
scal e, the check gauges i ndi cator i s i l l umi nated, and
a si ngl e chi me tone i s generated. The gauge needl e
remai ns at the l ow end of the scal e and the check
gauges i ndi cator remai ns i l l umi nated unti l the cl us-
ter recei ves a message from the PCM i ndi cati ng that
the engi ne oi l pressure i s above about 6.9 kPa (1 psi )
for gasol i ne engi nes, or 76 kPa (11 psi ) for di esel
engi nes, or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst. The cl uster wi l l
onl y turn the check gauges i ndi cator l amp on i n
response to an engi ne oi l pressure l ow message i f the
engi ne speed message i s greater than zero.
Engine Oil Pressure High Message - Each
i ndi cati ng the engi ne oi l pressure i s above about 755
kPa (109.5 psi ) for gasol i ne or di esel engi nes, the
gauge needl e i s moved to the H (Hi gh) graduati on at
the far ri ght end of the gauge scal e. The gauge nee-
dl e remai ns at the hi gh end of the scal e unti l the
that the engi ne oi l pressure i s bel ow about 755 kPa
(109.5 psi ) for gasol i ne or di esel engi nes, or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst.
an engi ne oi l pressure message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on unti l a new mes-
sage i s recei ved, or unti l the i gni ti on swi tch i s turned
cui try.
The PCM conti nual l y moni tors the engi ne oi l pres-
sure sensor to determi ne the engi ne oi l pressure. The
PCM then sends the proper engi ne oi l pressure mes-
sages to the i nstrument cl uster. For further di agnosi s
of the oi l pressure gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
the check gauges i ndi cator due to a l ow oi l pressure
gauge readi ng, i t may i ndi cate that the engi ne or the
engi ne oi l i ng system requi res servi ce. For proper
di agnosi s of the engi ne oi l pressure sensor, the PCM,
i nstrument cl uster that control the oi l pressure
gauge, a DRBI I I scan tool i s requi red. Refer to the
OVERDRIVE OFF INDICATOR
DESCRIPTION
An overdri ve off i ndi cator i s standard equi pment
on al l i nstrument cl usters. However, on vehi cl es not
equi pped wi th the opti onal overdri ve automati c
transmi ssi on, thi s i ndi cator i s el ectroni cal l y di sabl ed.
The overdri ve off i ndi cator consi sts of the text O/D
OFF, whi ch appears i n the l ower porti on of the el ec-
troni c gear sel ector i ndi cator Vacuum Fl uorescent
Di spl ay (VFD). The VFD i s part of the cl uster el ec-
troni c ci rcui t board, and i s vi si bl e through a cutout
l ocated i n the l ower ri ght corner of the cl uster over-
l ay. The dark l ens of the VFD prevents the i ndi cator
OIL PRESSURE GAUGE (Continued)
The text O/D OFF appears i n an amber col or and
at the same l i ghti ng l evel as the gear sel ector i ndi ca-
tor i nformati on when i t i s i l l umi nated by the i nstru-
ment cl uster el ectroni c ci rcui t board. The overdri ve
off i ndi cator i s servi ced as a uni t wi th the VFD i n
OPERATION
The overdri ve off i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the Off posi ti on of the
overdri ve off swi tch has been sel ected, di sabl i ng the
el ectroni cal l y control l ed overdri ve feature of the auto-
mati c transmi ssi on. Thi s i ndi cator i s control l ed by
I nterface (PCI ) data bus. The overdri ve off i ndi cator
ti on swi tch i s i n the On or Start posi ti ons; therefore,
the i ndi cator wi l l al ways be off when the i gni ti on
swi tch i s i n any posi ti on except On or Start. The
i ndi cator onl y i l l umi nates when i t i s swi tched to
ground by the i nstrument cl uster ci rcui try. The
i nstrument cl uster wi l l turn on the overdri ve off i ndi -
cator for the fol l owi ng reasons:
turned to the On posi ti on the overdri ve off i ndi cator
Overdrive Off Lamp-On Message - Each ti me
the cl uster recei ves an overdri ve off l amp-on message
from the PCM i ndi cati ng that the Off posi ti on of the
overdri ve off swi tch has been sel ected, the overdri ve
off i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves an
overdri ve off l amp-off message from the PCM, or
through the actuator test, the overdri ve off i ndi cator
wi l l be turned on, then off agai n duri ng the VFD por-
VFD, and agai n duri ng the bul b check porti on of the
test to confi rm the functi onal i ty of the cl uster control
ci rcui try.
The PCM conti nual l y moni tors the overdri ve off
swi tch to determi ne the proper outputs to the auto-
mati c transmi ssi on. The PCM then sends the proper
overdri ve off l amp-on and l amp-off messages to the
i nstrument cl uster. For further di agnosi s of the over-
dri ve off i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the overdri ve con-
trol system, the PCM, the PCI data bus, or the mes-
overdri ve off i ndi cator, a DRBI I I scan tool i s
mati on.
SEATBELT INDICATOR
DESCRIPTION
A seatbel t i ndi cator i s standard equi pment on al l
i nstrument cl usters. The seatbel t i ndi cator i s l ocated
i n the I nformati on Center area of the i nstrument
cl uster, to the ri ght of center. The seatbel t i ndi cator
consi sts of a stenci l l ed cutout of the I nternati onal
Control and Di spl ay Symbol i con for Seat Bel t i n
the opaque l ayer of the i nstrument cl uster overl ay.
The dark outer l ayer of the overl ay prevents the i ndi -
cator from bei ng cl earl y vi si bl e when i t i s not i l l umi -
nated. A red l ens behi nd the cutout i n the opaque
l ayer of the overl ay causes the i con to appear i n red
ment cl uster el ectroni c ci rcui t board. The seatbel t
i ndi cator i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The seatbel t i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the dri ver si de front
seatbel t. Thi s i ndi cator i s control l ed by a transi stor
cl uster programmi ng and a hard wi red i nput from
the seatbel t swi tch i n the dri ver si de front seatbel t
retractor through the seat bel t i ndi cator dri ver ci r-
cui t. The seatbel t i ndi cator Li ght Emi tti ng Di ode
(LED) recei ves battery current on the i nstrument
cl uster el ectroni c ci rcui t board through the fused
i gni ti on swi tch output (run-start) ci rcui t whenever
the i gni ti on swi tch i s i n the On or Start posi ti ons;
therefore, the i ndi cator wi l l al ways be off when the
The LED onl y i l l umi nates when i t i s swi tched to
ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the seatbel t i ndi cator
for the fol l owi ng reasons:
Seatbelt Reminder Function - Each ti me the
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t, the i ndi ca-
tor wi l l be i l l umi nated as a seatbel t remi nder for
about seven seconds, or unti l the i gni ti on swi tch i s
Thi s remi nder functi on wi l l occur regardl ess of the
status of the seatbel t swi tch i nput to the cl uster.
OVERDRIVE OFF INDICATOR (Continued)
Driver Side Front Seatbelt Not Buckled -
Fol l owi ng the seatbel t remi nder functi on, each ti me
the cl uster detects an open ci rcui t on the seat bel t
i ndi cator dri ver ci rcui t (seatbel t swi tch open - seat-
bel t unbuckl ed) wi th the i gni ti on swi tch i n the Start
or On posi ti ons, the i ndi cator wi l l be i l l umi nated.
The seatbel t i ndi cator remai ns i l l umi nated unti l the
seat bel t i ndi cator dri ver i nput to the cl uster i s
cl osed to ground (seatbel t swi tch cl osed - seatbel t
buckl ed), or unti l the i gni ti on swi tch i s turned to the
The seatbel t swi tch i nput to the i nstrument cl uster
ci rcui try can be di agnosed usi ng conventi onal di ag-
nosti c tool s and methods. For further di agnosi s of the
seatbel t i ndi cator or the i nstrument cl uster ci rcui try
that control s the LED, (Refer to 8 - ELECTRI CAL/
TESTI NG).
SECURITY INDICATOR
DESCRIPTION
A securi ty i ndi cator i s standard equi pment on al l
equi pped wi th the opti onal Vehi cl e Theft Securi ty
System (VTSS), thi s i ndi cator i s mechani cal l y di s-
abl ed. The securi ty i ndi cator i s l ocated i n the I nfor-
mati on Center area of the i nstrument cl uster, to the
l eft of center. The securi ty i ndi cator consi sts of a
stenci l ed cutout of the word SECURI TY i n the
the overl ay causes the SECURI TY text to appear i n
red through the transl ucent outer l ayer of the over-
l ay when i t i s i l l umi nated from behi nd by a Li ght
Emi tti ng Di ode (LED) sol dered onto the i nstrument
cl uster el ectroni c ci rcui t board. The securi ty i ndi cator
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The securi ty i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the Vehi cl e Theft Securi ty Sys-
tem (VTSS) i s armi ng or i s armed. On model s
equi pped wi th the Sentry Key I mmobi l i zer System
(SKI S), the securi ty i ndi cator al so gi ves an i ndi cati on
to the vehi cl e operator of the status of the SKI S. Thi s
i ndi cator i s control l ed by a hard wi red i nput to the
i nstrument cl uster from the Central Ti mer Modul e
(CTM) on the VTSS i ndi cator dri ver ci rcui t and, i f
the vehi cl e i s so equi pped, by a transi stor on the
i nstrument cl uster ci rcui t board based upon el ec-
troni c messages recei ved by the cl uster from the Sen-
try Key I mmobi l i zer Modul e (SKI M) over the
bus. The securi ty i ndi cator Li ght Emi tti ng Di ode
(LED) recei ves battery current on the i nstrument
cl uster el ectroni c ci rcui t board at al l ti mes through
the fused B(+) ci rcui t at al l ti mes; therefore, the LED
wi l l remai n functi onal regardl ess of the i gni ti on
swi tch posi ti on. The LED onl y i l l umi nates when i t i s
provi ded a path to ground by the CTM or by the
i nstrument cl uster transi stor. The securi ty i ndi cator
wi l l be i l l umi nated for the fol l owi ng reasons:
Bulb Test - I f the vehi cl e i s equi pped wi th
SKI S, each ti me the i gni ti on swi tch i s turned to the
On posi ti on the securi ty i ndi cator i s i l l umi nated by
the i nstrument cl uster for about three seconds based
upon an el ectroni c l amp-on message recei ved from
the SKI M as a bul b test. There i s no bul b test per-
formed for model s that are not equi pped wi th the
opti onal SKI S.
VTSS Indication - Duri ng the seventeen sec-
ond VTSS armi ng functi on, the CTM wi l l fl ash the
securi ty i ndi cator on and off repeatedl y at a steady,
fast rate to i ndi cate that the VTSS i s i n the process
of armi ng. Fol l owi ng successful VTSS armi ng, the
CTM fl ashes the securi ty i ndi cator on and off conti n-
uousl y at a sl ower rate to i ndi cate that the VTSS i s
armed. The securi ty i ndi cator conti nues fl ashi ng at
the sl ower rate unti l the VTSS i s di sarmed or tri g-
gered. I f the VTSS al arm i s tri ggered, the CTM wi l l
fl ash the securi ty i ndi cator at a steady, fast rate for
up to ei ghteen mi nutes or unti l the tri ggeri ng condi -
ti on i s removed, before returni ng to the sl ower,
armed fl ash rate.
SKIM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the SKI M, the
securi ty i ndi cator wi l l be i l l umi nated. The i ndi cator
can be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the SKI M message. The i ndi cator remai ns
i l l umi nated sol i d or conti nues to fl ash unti l the cl us-
ter recei ves a l amp-off message from the SKI M, or
whi chever occurs fi rst. For more i nformati on on the
SKI S and the securi ty i ndi cator control parameters,
RI TY/SENTRY KEY I MMOBI LI ZER SYSTEM -
OPERATI ON).
ter i s put through the actuator test, the securi ty i ndi -
cator wi l l be turned on, then off agai n duri ng the
bul b check porti on of the test to confi rm the functi on-
al i ty of the LED and the cl uster control ci rcui try.
SEATBELT INDICATOR (Continued)
The CTM provi des a hard wi red ground i nput to
the i nstrument cl uster ci rcui try through the VTSS
i ndi cator dri ver ci rcui t whenever the i gni ti on swi tch
i s i n the Off posi ti on and the VTSS i s armi ng, armed,
or tri ggered. Whenever the i gni ti on swi tch i s i n the
On or Start posi ti ons, the SKI M performs a sel f-test
to deci de whether the system i s i n good operati ng
condi ti on. The SKI M then sends the proper l amp-on
or l amp-off messages to the i nstrument cl uster. For
further di agnosi s of the securi ty i ndi cator or the
i nstrument cl uster ci rcui try that control s the i ndi ca-
tor, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). I f the
SKI S turns on the securi ty i ndi cator after the bul b
test, ei ther sol i d or fl ashi ng, i t i ndi cates that a SKI S
mal functi on has occurred or that the SKI S i s i noper-
ati ve. The VTSS i ndi cator dri ver ci rcui t i nput to the
i nstrument cl uster can be di agnosed usi ng conven-
ti onal di agnosti c tool s and methods. For proper di ag-
nosi s of the VTSS, the CTM, the SKI S, the PCI data
bus, or the message i nputs to the i nstrument cl uster
that control the securi ty i ndi cator, a DRBI I I scan
i nformati on.
SERVICE 4WD INDICATOR
DESCRIPTION
A servi ce 4WD i ndi cator i s standard equi pment on
al l i nstrument cl usters. However, on vehi cl es not
equi pped wi th the opti onal four-wheel dri ve system
and el ectroni cal l y shi fted transfer case, thi s i ndi cator
i s el ectroni cal l y di sabl ed. The servi ce 4WD i ndi cator
i s l ocated i n the I nformati on Center area of the
i nstrument cl uster, to the ri ght of center. The servi ce
4WD i ndi cator consi sts of a stenci l l ed cutout of the
words SERVI CE 4WD i n the opaque l ayer of the
vi si bl e when i t i s not i l l umi nated. An amber l ens
behi nd the cutout i n the opaque l ayer of the overl ay
causes the SERVI CE 4WD text to appear i n amber
ment cl uster el ectroni c ci rcui t board. The servi ce
4WD i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The servi ce 4WD i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the Transfer Case Control
Modul e (TCCM) has recorded a Di agnosti c Troubl e
Code (DTC) for an el ectroni c transfer case ci rcui t or
component mal functi on. Thi s i ndi cator i s control l ed
by a transi stor on the i nstrument cl uster ci rcui t
TCCM over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The servi ce 4WD i ndi cator
servi ce 4WD i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the servi ce 4WD i ndi cator
Service 4WD Lamp-On Message - Each ti me
the cl uster recei ves a l amp-on message from the
TCCM, the i ndi cator wi l l be i l l umi nated. The i ndi ca-
tor remai ns i l l umi nated unti l the cl uster recei ves a
servi ce 4WD l amp-off message from the TCCM, or
no messages from the TCCM for si x seconds, the ser-
vi ce 4WD i ndi cator i s i l l umi nated by the i nstrument
cl uster to i ndi cate a l oss of TCCM communi cati on.
The i ndi cator remai ns control l ed and i l l umi nated by
the cl uster unti l a val i d message i s recei ved from the
TCCM.
through the actuator test, the servi ce 4WD i ndi cator
wi l l be turned on, then off agai n duri ng the bul b
check porti on of the test to confi rm the functi onal i ty
of the LED and the cl uster control ci rcui try.
The TCCM conti nual l y moni tors the el ectroni c
transfer case swi tch and ci rcui ts to determi ne the
condi ti on of the system, then sends the proper mes-
sages to the i nstrument cl uster. For further di agnosi s
of the servi ce 4WD i ndi cator or the i nstrument cl us-
ter ci rcui try that control s the LED, (Refer to 8 -
SI S AND TESTI NG). For proper di agnosi s of the
TCCM, the PCI data bus, or the message i nputs to
the i nstrument cl uster that control the servi ce 4WD
i ndi cator, a DRBI I I scan tool i s requi red. Refer to
the appropri ate di agnosti c i nformati on.
SPEEDOMETER
DESCRIPTION
A speedometer i s standard equi pment on al l i nstru-
ment cl usters. The speedometer i s l ocated next to the
SECURITY INDICATOR (Continued)
tachometer, just to the ri ght of center i n the i nstru-
ment cl uster. The speedometer consi sts of a movabl e
gauge needl e or poi nter control l ed by the i nstrument
cl uster ci rcui try and a fi xed 210 degree pri mary scal e
on the gauge di al face that reads l eft-to-ri ght ei ther
from 0 to 120 mph, or from 0 to 200 km/h, dependi ng
upon the market for whi ch the vehi cl e i s manufac-
tured. Each versi on al so has a secondary i nner scal e
on the gauge di al face that provi des the equi val ent
opposi te uni ts from the pri mary scal e. Text appeari ng
on the cl uster overl ay just above the hub of the
speedometer needl e abbrevi ates the uni t of measure
for the pri mary scal e i n al l upper case l etters (i .e.:
MPH or KM/H), fol l owed by the uni t of measure for
the secondary scal e i n al l l ower case l etters (i .e.: mph
or km/h). The speedometer graphi cs are whi te (pri -
mary scal e) and red (secondary scal e) agai nst a bl ack
fi el d, maki ng them cl earl y vi si bl e wi thi n the i nstru-
ment cl uster i n dayl i ght. When i l l umi nated from
behi nd by the panel l amps di mmer control l ed cl uster
i l l umi nati on l i ghti ng wi th the exteri or l amps turned
On, the whi te graphi cs appear bl ue-green and the
red graphi cs appear red. The orange gauge needl e i s
i nternal l y i l l umi nated. Gauge i l l umi nati on i s pro-
vi ded by repl aceabl e i ncandescent bul b and bul b
hol der uni ts l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. The speedometer i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The speedometer gi ves an i ndi cati on to the vehi cl e
operator of the vehi cl e road speed. Thi s gauge i s con-
trol l ed by the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
ti ons I nterface (PCI ) data bus. The speedometer i s an
ai r core magneti c uni t that recei ves battery current
Start posi ti ons. The cl uster i s programmed to move
the gauge needl e back to the l ow end of the scal e
after the i gni ti on swi tch i s turned to the Off posi ti on.
The i nstrument cl uster ci rcui try control s the gauge
needl e posi ti on and provi des the fol l owi ng features:
a speedometer message, i t wi l l hol d the gauge needl e
at the l ast i ndi cati on for about four seconds, or unti l
whi chever occurs fi rst. I f a new speedometer message
i s not recei ved after about four seconds, the gauge
needl e wi l l return to the far l eft (l ow) end of the
scal e.
cui try.
The PCM conti nual l y moni tors the vehi cl e speed
sensor to determi ne the vehi cl e road speed, then
sends the proper vehi cl e speed messages to the
i nstrument cl uster. For further di agnosi s of the
speedometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
I NG). For proper di agnosi s of the vehi cl e speed
sensor, the PCM, the PCI data bus, or the message
speedometer, a DRBI I I scan tool i s requi red. Refer
TACHOMETER
DESCRIPTION
A tachometer i s standard equi pment on al l i nstru-
ment cl usters. The tachometer i s l ocated to the l eft of
the speedometer, just to the l eft of center i n the
i nstrument cl uster. The tachometer consi sts of a
movabl e gauge needl e or poi nter control l ed by the
i nstrument cl uster ci rcui try and a fi xed 210 degree
scal e on the gauge di al face that reads l eft-to-ri ght
from 0 to 7 for gasol i ne engi nes, or from 0 to 5 for
di esel engi nes. The text RPM X 1000 i mpri nted on
the cl uster overl ay di rectl y above the hub of the
tachometer needl e i denti fi es that each number on the
tachometer scal e i s to be mul ti pl i ed by 1000 rpm.
The tachometer graphi cs are whi te agai nst a bl ack
fi el d, maki ng them cl earl y vi si bl e wi thi n the i nstru-
ment cl uster i n dayl i ght. When i l l umi nated from
behi nd by the panel l amps di mmer control l ed cl uster
i l l umi nati on l i ghti ng wi th the exteri or l amps turned
On, the whi te graphi cs appear bl ue-green. The
orange gauge needl e i s i nternal l y i l l umi nated. Gauge
i l l umi nati on i s provi ded by repl aceabl e i ncandescent
bul b and bul b hol der uni ts l ocated on the i nstrument
cl uster el ectroni c ci rcui t board. The tachometer i s
OPERATION
The tachometer gi ves an i ndi cati on to the vehi cl e
operator of the engi ne speed. Thi s gauge i s control l ed
by the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng and el ectroni c messages
ti ons I nterface (PCI ) data bus. The tachometer i s an
ai r core magneti c uni t that recei ves battery current
SPEEDOMETER (Continued)
Start posi ti ons. The cl uster i s programmed to move
the gauge needl e back to the l ow end of the scal e
after the i gni ti on swi tch i s turned to the Off posi ti on.
The i nstrument cl uster ci rcui try control s the gauge
needl e posi ti on and provi des the fol l owi ng features:
an engi ne speed message, i t wi l l hol d the gauge nee-
dl e at the l ast i ndi cati on for about four seconds, or
whi chever occurs fi rst. I f a new engi ne speed mes-
sage i s not recei ved after about four seconds, the
gauge needl e wi l l return to the far l eft (l ow) end of
the scal e.
cui try.
The PCM conti nual l y moni tors the crankshaft posi -
ti on sensor to determi ne the engi ne speed, then
sends the proper engi ne speed messages to the
i nstrument cl uster. For further di agnosi s of the
tachometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
I NG). For proper di agnosi s of the crankshaft posi ti on
sensor, the PCM, the PCI data bus, or the message
tachometer, a DRBI I I scan tool i s requi red. Refer to
the appropri ate di agnosti c i nformati on.
TRANSMISSION TEMP
INDICATOR
DESCRIPTION
A transmi ssi on over-temperature i ndi cator l amp i s
standard equi pment on al l i nstrument cl usters. How-
ever, on vehi cl es not equi pped wi th the opti onal auto-
mati c transmi ssi on, thi s i ndi cator i s el ectroni cal l y
di sabl ed. The transmi ssi on over-temperature i ndi ca-
tor i s l ocated i n the I nformati on Center area of the
i nstrument cl uster, to the l eft of center. The trans-
mi ssi on over-temperature i ndi cator consi sts of a sten-
ci l l ed cutout of the words TRANS TEMP i n the
the overl ay causes the TRANS TEMP text to
appear i n red through the transl ucent outer l ayer of
the overl ay when the i ndi cator i s i l l umi nated from
behi nd by a Li ght Emi tti ng Di ode (LED) sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The transmi ssi on over-temperature i ndi cator i s ser-
OPERATION
The transmi ssi on over-temperature i ndi cator gi ves
an i ndi cati on to the vehi cl e operator when the trans-
mi ssi on fl ui d temperature i s excessi ve, whi ch may
l ead to accel erated transmi ssi on component wear or
fai l ure. Thi s i ndi cator i s control l ed by a transi stor on
I nterface (PCI ) data bus. The transmi ssi on over-tem-
perature i ndi cator Li ght Emi tti ng Di ode (LED)
ti on swi tch i s i n the On or Start posi ti ons; therefore,
the LED wi l l al ways be off when the i gni ti on swi tch
i s i n any posi ti on except On or Start. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the transmi ssi on over-tempera-
ture i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the transmi ssi on over-tem-
perature i ndi cator i s i l l umi nated for about two sec-
onds as a bul b test.
Trans Over-Temp Lamp-On Message - Each
ti me the cl uster recei ves a trans over-temp l amp-on
message from the PCM i ndi cati ng that the transmi s-
si on fl ui d temperature i s 135 C (275 F) or hi gher,
the i ndi cator wi l l be i l l umi nated and a si ngl e chi me
tone i s sounded. The l amp remai ns i l l umi nated unti l
the cl uster recei ves a trans over-temp l amp-off mes-
sage from the PCM, or unti l the i gni ti on swi tch i s
The chi me tone feature wi l l onl y repeat duri ng the
same i gni ti on cycl e i f the transmi ssi on over-tempera-
ture i ndi cator i s cycl ed off and then on agai n by the
appropri ate trans over-temp messages from the PCM.
The PCM conti nual l y moni tors the transmi ssi on
temperature sensor to determi ne the transmi ssi on
operati ng condi ti on, then sends the proper messages
to the i nstrument cl uster. I f the i nstrument cl uster
turns on the transmi ssi on over-temperature i ndi cator
due to a hi gh transmi ssi on oi l temperature condi ti on,
i t may i ndi cate that the transmi ssi on and/or the
transmi ssi on cool i ng system are bei ng overl oaded or
that they requi re servi ce. For further di agnosi s of the
TACHOMETER (Continued)
transmi ssi on over-temperature i ndi cator or the
i nstrument cl uster ci rcui try that control s the LED,
di agnosi s of the transmi ssi on temperature sensor, the
PCM, the PCI data bus, or the message i nputs to the
i nstrument cl uster that control the transmi ssi on
over-temperature i ndi cator, a DRBI I I scan tool i s
mati on.
TURN SIGNAL INDICATOR
DESCRIPTION
Two turn si gnal i ndi cators, one ri ght and one l eft,
are standard equi pment on al l i nstrument cl usters.
The turn si gnal i ndi cators are l ocated near the upper
edge of the i nstrument cl uster overl ay, between the
speedometer and the tachometer. Each turn si gnal
i ndi cator consi sts of a stenci l ed cutout of the I nterna-
ti onal Control and Di spl ay Symbol i con for Turn
Warni ng i n the opaque l ayer of the i nstrument cl us-
ter overl ay. The dark outer l ayer of the overl ay pre-
vents these i cons from bei ng cl earl y vi si bl e when
thei r l amps are not i l l umi nated. The i cons appear i n
green through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by a repl aceabl e i ncandescent bul b and bul b
hol der uni t l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. The turn si gnal i ndi cators are
OPERATION
The turn si gnal i ndi cators gi ve an i ndi cati on to the
vehi cl e operator that the turn si gnal (l eft or ri ght
i ndi cator fl ashi ng) or hazard warni ng (both l eft and
ri ght i ndi cators fl ashi ng) have been sel ected. These
i ndi cators are control l ed by two i ndi vi dual hard
wi red i nputs to the i nstrument cl uster el ectroni c ci r-
cui t board. The turn si gnal i ndi cator bul bs are
grounded on the i nstrument cl uster el ectroni c ci rcui t
board at al l ti mes. The turn si gnal i ndi cator bul bs
onl y i l l umi nate when they are provi ded wi th battery
current by the turn si gnal and hazard warni ng ci r-
cui try of the combi nati on fl asher through separate
l eft and ri ght turn si gnal ci rcui t i nputs to the i nstru-
ment cl uster; therefore, these i ndi cators can be i l l u-
mi nated, regardl ess of the i gni ti on swi tch posi ti on.
The turn si gnal i ndi cators are connected i n seri es
between ground and the output of the combi nati on
fl asher ci rcui try, but i n paral l el wi th the other turn
si gnal ci rcui ts. Thi s arrangement al l ows the turn si g-
nal i ndi cators to remai n functi onal regardl ess of the
condi ti on of the other ci rcui ts i n the turn si gnal and
hazard warni ng system. For more i nformati on on the
turn si gnal and hazard warni ng system, (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR -
OPERATI ON - TURN SI GNAL & HAZARD WARN-
I NG SYSTEM). The turn si gnal i ndi cators can be
methods.
DIAGNOSIS AND TESTING - TURN SIGNAL
INDICATOR
turn si gnal i ndi cator condi ti on. I f the probl em bei ng
di agnosed i s rel ated to i noperati ve turn si gnal s or
hazard warni ng l amps, be certai n to repai r the turn
si gnal and hazard warni ng system before attempti ng
to di agnose or repai r the turn si gnal i ndi cators. I f no
turn si gnal or hazard warni ng system probl ems are
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the l eft or ri ght turn si gnal i ndi cator
ci rcui ts. Refer to the appropri ate wi ri ng i nformati on.
proper wi re and connector repai r procedures, detai l s
of wi re harness routi ng and retenti on, connector pi n-
out i nformati on and l ocati on vi ews for the vari ous
wi re harness connectors, spl i ces and grounds.
cabl e. Remove the i nstrument cl uster.
(2) Connect the battery negati ve cabl e. Acti vate
the hazard warni ng system by movi ng the hazard
warni ng swi tch button to the On posi ti on. Check for
battery vol tage at the i noperati ve (ri ght or l eft) turn
si gnal ci rcui t cavi ty of the i nstrument panel wi re
harness connector (Connector C2) for the i nstrument
cl uster. There shoul d be a swi tchi ng (on and off) bat-
tery vol tage si gnal . I f OK, repl ace the faul ty turn si g-
nal i ndi cator bul b. I f not OK, repai r the open (ri ght
or l eft) turn si gnal ci rcui t between the i nstrument
cl uster and the combi nati on fl asher as requi red.
UPSHIFT INDICATOR
DESCRIPTION
An upshi ft i ndi cator i s standard equi pment on al l
equi pped wi th a manual transmi ssi on, thi s i ndi cator
i s di sabl ed. The upshi ft i ndi cator i s l ocated near the
center of the tachometer gauge i n the i nstrument
cl uster overl ay, to the l eft of center. The upshi ft i ndi -
cator consi sts of an upward poi nted arrow i con that
i s a stenci l ed cutout i n the opaque l ayer of the
causes the i con to appear i n amber through the
TRANSMISSION TEMP INDICATOR (Continued)
el ectroni c ci rcui t board. The upshi ft i ndi cator i s ser-
OPERATION
The upshi ft i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the transmi ssi on shoul d be
shi fted to the next hi ghest gear i n order to achi eve
the best fuel economy. Thi s i ndi cator i s control l ed by
a transi stor on the i nstrument cl uster ci rcui t board
muni cati ons I nterface (PCI ) data bus. The upshi ft
the On or Start posi ti ons; therefore, the i ndi cator wi l l
ment cl uster transi stor. On model s not equi pped wi th
a manual transmi ssi on, a uni que versi on of the
i nstrument cl uster i s used that does not i ncl ude the
upshi ft i ndi cator. The i nstrument cl uster wi l l turn on
the upshi ft i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the upshi ft i ndi cator i s i l l u-
mi nated for about two seconds as a bul b test.
Upshift Lamp-On Message - Each ti me the
cl uster recei ves an upshi ft l amp-on message from the
PCM i ndi cati ng the engi ne speed and l oad condi ti ons
are ri ght for a transmi ssi on upshi ft to occur, the
upshi ft i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves an
upshi ft l amp-off message from the PCM or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst. The PCM wi l l normal l y send an
upshi ft l amp-off message three to fi ve seconds after a
l amp-on message, i f an upshi ft i s not performed. The
i ndi cator wi l l then remai n off unti l the vehi cl e stops
accel erati ng and i s brought back i nto the range of
i ndi cator operati on, or unti l the transmi ssi on i s
shi fted i nto another gear.
i ndi cator and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne speed
and l oad condi ti ons to determi ne the proper fuel and
i gni ti on requi rements. The PCM then sends the
proper messages to the i nstrument cl uster. For fur-
ther di agnosi s of the upshi ft i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the i ndi cator,
di agnosi s of the PCM, the PCI data bus, or the mes-
upshi ft i ndi cator, a DRBI I I scan tool i s requi red.
VOLTAGE GAUGE
DESCRIPTION
A vol tage gauge i s standard equi pment on al l
i nstrument cl usters. The vol tage gauge i s l ocated i n
the upper l eft quadrant of the i nstrument cl uster,
above the temperature gauge. The vol tage gauge con-
ri ght from L (or Low) to H (or Hi gh). An I nterna-
ti onal Control and Di spl ay Symbol i con for Battery
Chargi ng Condi ti on i s l ocated on the cl uster overl ay,
i n the center of the gauge di rectl y above the hub of
the gauge needl e. The vol tage gauge graphi cs are
whi te agai nst a bl ack fi el d except for a si ngl e red
graduati on at each end of the gauge scal e, maki ng
them cl earl y vi si bl e wi thi n the i nstrument cl uster i n
dayl i ght. When i l l umi nated from behi nd by the panel
vol tage gauge i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The vol tage gauge gi ves an i ndi cati on to the vehi -
cl e operator of the el ectri cal system vol tage. Thi s
vol tage gauge i s an ai r core magneti c uni t that
ti on swi tch i s i n the On or Start posi ti ons. The cl us-
ter i s programmed to move the gauge needl e back to
the l ow end of the scal e after the i gni ti on swi tch i s
turned to the Off posi ti on. The i nstrument cl uster
ci rcui try control s the gauge needl e posi ti on and pro-
vi des the fol l owi ng features:
UPSHIFT INDICATOR (Continued)
Charge Fail Message - Each ti me the cl uster
recei ves a message from the PCM i ndi cati ng a charge
fai l condi ti on (system vol tage i s 10.8 vol ts or l ower),
the gauge needl e i s moved to the L graduati on on
the gauge scal e and the check gauges i ndi cator i s
i l l umi nated. The gauge needl e remai ns on the L
graduati on and the check gauges i ndi cator remai ns
i l l umi nated unti l the cl uster recei ves a message from
the PCM i ndi cati ng there i s no charge fai l condi ti on
(system vol tage i s 10.9 vol ts or hi gher, but l ower
than 16.7 vol ts), or unti l the i gni ti on swi tch i s turned
Voltage High Message - Each ti me the cl uster
recei ves a message from the PCM i ndi cati ng a vol t-
age hi gh condi ti on (system vol tage i s 16.7 vol ts or
hi gher), the gauge needl e i s moved to the H gradu-
ati on on the gauge scal e and the check gauges i ndi -
cator i s i l l umi nated. The gauge needl e remai ns on
the H graduati on and the check gauges i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng there i s no vol tage
hi gh condi ti on (system vol tage i s 16.6 vol ts or l ower,
but hi gher than 10.9 vol ts), or unti l the i gni ti on
fi rst.
a system vol tage message, i t wi l l hol d the gauge nee-
dl e at the l ast i ndi cati on unti l a new message i s
cui try.
The PCM conti nual l y moni tors the system vol tage
to control the generator output. The PCM then sends
the proper system vol tage messages to the i nstru-
ment cl uster. For further di agnosi s of the vol tage
gauge or the i nstrument cl uster ci rcui try that con-
trol s the gauge, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG). I f
the i nstrument cl uster turns on the check gauges
i ndi cator due to a charge fai l or vol tage hi gh condi -
ti on, i t may i ndi cate that the chargi ng system
requi res servi ce. For proper di agnosi s of the chargi ng
system, the PCI data bus, or the message i nputs to
the i nstrument cl uster that control the vol tage
gauge, a DRBI I I scan tool i s requi red. Refer to the
WAIT-TO-START INDICATOR
DESCRIPTION
A wai t-to-start i ndi cator i s onl y found i n the
i nstrument cl usters of vehi cl es equi pped wi th an
opti onal di esel engi ne. The wai t-to-start i ndi cator i s
ment cl uster, to the ri ght of center. The wai t-to-start
WAI T TO START i n the opaque l ayer of the cl uster
overl ay. The dark outer l ayer of the overl ay prevents
the i ndi cator from bei ng cl earl y vi si bl e when i t i s not
i l l umi nated. A red l ens l ocated behi nd the cutout
causes the WAI T TO START text to appear i n red
repl aceabl e i ncandescent bul b and bul b hol der uni t
on the i nstrument cl uster el ectroni c ci rcui t board.
The wai t-to-start i ndi cator i s servi ced as a uni t wi th
OPERATION
The wai t-to-start i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the di esel engi ne gl ow
pl ugs are energi zed i n thei r pre-heat operati ng mode.
Thi s i ndi cator i s control l ed by a hard wi red i nput to
the i nstrument cl uster from the Engi ne Control Mod-
ul e (ECM). The wai t-to-start i ndi cator bul b recei ves
put (st-run) ci rcui t whenever the i gni ti on swi tch i s i n
the On or Start posi ti ons; therefore, the l amp wi l l
ti on except On or Start. The i ndi cator bul b onl y i l l u-
mi nates when i t i s swi tched to ground by the i nput
from the ECM. The ECM wi l l turn on the wai t-to-
start i ndi cator by pul l i ng the wai t-to-start i ndi cator
dri ver ci rcui t to ground each ti me the i gni ti on swi tch
i s turned to the On or Start posi ti ons. The i ndi cator
then remai ns i l l umi nated unti l the ECM determi nes
that the gl ow pl ugs have been energi zed for a suffi -
ci ent durati on to ensure rel i abl e and effi ci ent engi ne
starti ng, unti l the ECM detects that the engi ne i s
runni ng, or unti l the i gni ti on swi tch i s turned to the
The ECM conti nual l y moni tors the cool ant temper-
ature sensor and uses thi s i nput al ong wi th i ts i nter-
nal programmi ng to determi ne how l ong the gl ow
pl ugs must be heated i n the pre-heat operati ng mode,
then i l l umi nates the wai t-to-start i ndi cator for that
durati on. The wai t-to-start i ndi cator dri ver ci rcui t
can be di agnosed usi ng conventi onal di agnosti c tool s
and methods. For proper di agnosi s of the wai t-to-
start i ndi cator, the ECM, or the i nputs the ECM uses
to control the wai t-to-start i ndi cator operati on, a
VOLTAGE GAUGE (Continued)
DIAGNOSIS AND TESTING - WAIT-TO-START
INDICATOR
wai t-to-start i ndi cator condi ti on. I f the probl em bei ng
di agnosed i s rel ated to i ndi cator accuracy, be certai n
to confi rm that the probl em i s wi th the i ndi cator and
not wi th a faul ty engi ne cool ant temperature sensor,
or an i noperati ve Engi ne Control Modul e (ECM). I f
no engi ne cool ant temperature sensor or ECM prob-
l em i s found, the fol l owi ng procedure wi l l hel p to
l ocate a short or open i n the wai t-to-start i ndi cator
dri ver ci rcui t. Refer to the appropri ate wi ri ng i nfor-
INJURY.
INDICATOR DOES NOT ILLUMINATE WITH ENGINE COLD
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector (Connector C1) for the ECM
from the ECM connector receptacl e. Check for conti -
nui ty between the wai t-to-start i ndi cator dri ver ci r-
cui t cavi ti es of the i nstrument panel wi re harness
connector (Connector C1) for the i nstrument cl uster
and the i nstrument panel wi re harness connector
(Connector C1) for the ECM. There shoul d be conti -
nui ty. I f OK, repl ace the faul ty wai t-to-start i ndi cator
bul b and bul b hol der uni t. I f not OK, repai r the open
wai t-to-start i ndi cator dri ver ci rcui t between the
i nstrument cl uster and the ECM as requi red.
INDICATOR STAYS ILLUMINATED WITH ENGINE WARM
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector (Connector C1) for the ECM
from the ECM connector receptacl e. Check for conti -
nui ty between the wai t-to-start i ndi cator dri ver ci r-
cui t cavi ty of the i nstrument panel wi re harness
connector (Connector C1) for the i nstrument cl uster
and a good ground. There shoul d be no conti nui ty. I f
OK, use a DRBI I I scan tool to di agnose the ECM.
Refer to the appropri ate di agnosti c i nformati on. I f
not OK, repai r the shorted wai t-to-start i ndi cator
dri ver ci rcui t between the i nstrument cl uster and the
ECM as requi red.
WASHER FLUID INDICATOR
DESCRIPTION
A washer fl ui d i ndi cator i s standard equi pment on
al l i nstrument cl usters. The washer fl ui d i ndi cator i s
ment cl uster, to the ri ght of center. The washer fl ui d
i ndi cator consi sts of a stenci l ed cutout of the I nterna-
ti onal Control and Di spl ay Symbol i con for Wi nd-
shi el d Washer Fl ui d i n the opaque l ayer of the
causes the i con to appear i n amber through the
transl ucent outer l ayer of the overl ay when i t i s i l l u-
mi nated from behi nd by a Li ght Emi tti ng Di ode
(LED) sol dered onto the i nstrument cl uster el ectroni c
ci rcui t board. The washer fl ui d i ndi cator i s servi ced
as a uni t wi th the i nstrument cl uster.
OPERATION
The washer fl ui d i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the fl ui d l evel i n the
washer fl ui d reservoi r i s l ow. Thi s i ndi cator i s con-
trol l ed by a transi stor on the i nstrument cl uster el ec-
troni c ci rcui t board based upon cl uster programmi ng
and a hard wi red washer fl ui d l evel swi tch i nput to
the cl uster. The washer fl ui d i ndi cator Li ght Emi t-
ti ng Di ode (LED) recei ves battery current on the
i nstrument cl uster el ectroni c ci rcui t board through
the fused i gni ti on swi tch output (run-start) ci rcui t
whenever the i gni ti on swi tch i s i n the On or Start
posi ti ons; therefore, the i ndi cator wi l l al ways be off
washer fl ui d i ndi cator for the fol l owi ng reasons:
for about two seconds as a bul b test.
WAIT-TO-START INDICATOR (Continued)
Washer Fluid Level Switch Input - I mmedi -
atel y after the bul b test, i f the cl uster senses ground
on the washer fl ui d swi tch sense ci rcui t for more
than about thi rty seconds, i t turns on the washer
fl ui d i ndi cator. Any ti me after the bul b test, the cl us-
ter must sense ground on the washer fl ui d swi tch
sense ci rcui t for more than about si xty seconds before
i t turns on the i ndi cator. Once i l l umi nated, the i ndi -
cator wi l l remai n i l l umi nated unti l the i gni ti on
swi tch i s cycl ed and the cl uster senses an open ci r-
cui t on the l ow washer fl ui d sense i nput. Thi s strat-
egy i s i ntended to reduce the effect that fl ui d
sl oshi ng wi thi n the washer reservoi r can have on
rel i abl e i ndi cator operati on.
The washer fl ui d l evel swi tch i s connected i n seri es
between ground and the washer fl ui d swi tch sense
i nput to the i nstrument cl uster. For more i nforma-
ti on on the washer fl ui d l evel swi tch,(Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS/WASHER FLUI D
LEVEL SWI TCH - OPERATI ON). For further di ag-
nosi s of the washer fl ui d i ndi cator or the i nstrument
cl uster ci rcui try that control s the i ndi cator, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). The washer fl ui d l evel
swi tch i nput to the cl uster can be di agnosed usi ng
conventi onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - WASHER FLUID
INDICATOR
washer fl ui d i ndi cator condi ti on. I f the probl em bei ng
di agnosed i s rel ated to i ndi cator accuracy, be certai n
to confi rm that the probl em i s wi th the i ndi cator or
washer fl ui d l evel swi tch i nput and not wi th a dam-
aged or empty washer fl ui d reservoi r, or i noperati ve
i nstrument cl uster i ndi cator control ci rcui try. I nspect
the washer fl ui d reservoi r for proper fl ui d l evel and
si gns of damage or di storti on that coul d affect
washer fl ui d l evel swi tch performance and perform
the i nstrument cl uster actuator test before you pro-
ceed wi th the fol l owi ng di agnosi s. I f no washer fl ui d
reservoi r or i nstrument cl uster control ci rcui try prob-
l em i s found, the fol l owi ng procedure wi l l hel p to
l ocate a short or open i n the washer fl ui d swi tch
sense ci rcui t. Refer to the appropri ate wi ri ng i nfor-
INJURY.
INDICATOR DOES NOT ILLUMINATE WITH WASHER
RESERVOIR EMPTY
cabl e. Di sconnect the headl amp and dash wi re har-
ness connector for the washer fl ui d l evel swi tch from
the washer fl ui d l evel swi tch connector receptacl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the headl amp and dash wi re harness connector
for the washer fl ui d l evel swi tch and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 2. I f not
OK, repai r the open ground ci rcui t to ground (G112)
as requi red.
ment panel . Check for conti nui ty between the washer
fl ui d swi tch sense ci rcui t cavi ti es of the headl amp
and dash wi re harness connector for the washer fl ui d
l evel swi tch and the i nstrument panel wi re harness
connector (Connector C2) for the i nstrument cl uster.
I f OK, repl ace the faul ty washer fl ui d l evel swi tch. I f
not OK, repai r the open washer fl ui d swi tch sense
ci rcui t between the washer fl ui d l evel swi tch and the
i nstrument cl uster as requi red.
INDICATOR STAYS ILLUMINATED WITH WASHER
RESERVOIR FULL
cabl e. Di sconnect the headl amp and dash wi re har-
Check for conti nui ty between the ground ci rcui t ter-
mi nal and the washer fl ui d swi tch sense termi nal i n
There shoul d be no conti nui ty. I f OK, go to Step 2. I f
not OK, repl ace the faul ty washer fl ui d l evel swi tch.
ment panel . Check for conti nui ty between the washer
fl ui d swi tch sense ci rcui t cavi ty of the headl amp and
dash wi re harness connector for the washer fl ui d
l evel swi tch and a good ground. There shoul d be no
conti nui ty. I f not OK, repai r the shorted washer fl ui d
WASHER FLUID INDICATOR (Continued)
swi tch sense ci rcui t between the washer fl ui d l evel
swi tch and the i nstrument cl uster as requi red.
WATER-IN-FUEL INDICATOR
DESCRIPTION
A water-i n-fuel i ndi cator i s onl y found i n the
i nstrument cl usters of vehi cl es equi pped wi th an
opti onal di esel engi ne. The water-i n-fuel i ndi cator i s
ment cl uster, to the l eft of center. The water-i n-fuel
WATER I N FUEL i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents the i ndi cator from bei ng cl earl y vi s-
i bl e when i t i s not i l l umi nated. A red l ens behi nd the
cutout i n the opaque l ayer of the overl ay causes the
WATER I N FUEL text to appear i n red through the
el ectroni c ci rcui t board. The water-i n-fuel i ndi cator i s
OPERATION
The water-i n-fuel i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when there i s excessi ve water i n
the fuel system. Thi s i ndi cator i s control l ed by a
muni cati ons I nterface (PCI ) data bus. The water-i n-
fuel i ndi cator Li ght Emi tti ng Di ode (LED) recei ves
i n the On or Start posi ti ons; therefore, the LED wi l l
turn on the water-i n-fuel i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the water-i n-fuel i ndi cator
Water-In-Fuel Lamp-On Message - Each ti me
i ng there i s excessi ve water i n the fuel system, the
water-i n-fuel i ndi cator wi l l be i l l umi nated, and a si n-
gl e chi me tone i s sounded. The i ndi cator remai ns
i l l umi nated unti l the cl uster recei ves a message from
the PCM i ndi cati ng that the water i n the fuel system
i s not excessi ve, or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst. The chi me
tone feature wi l l onl y repeat duri ng the same i gni -
ti on cycl e i f the water-i n-fuel i ndi cator i s cycl ed off
and then on agai n by the appropri ate l amp-off and
l amp-on messages from the PCM.
The PCM conti nual l y moni tors the water i n the
fuel system through the water-i n-fuel sensor, then
sends the proper messages to the i nstrument cl uster.
For further di agnosi s of the water-i n-fuel i ndi cator or
the i nstrument cl uster ci rcui try that control s the
LED, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For
proper di agnosi s of the water-i n-fuel -sensor, the
PCM, the PCI data bus, or the message i nputs to the
i nstrument cl uster that control the water-i n-fuel i ndi -
WASHER FLUID INDICATOR (Continued)
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 25
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TURN SIGNAL & HAZARD WARNING
SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXTERIOR LAMPS. . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE LAMP SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CARGO LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CENTER HIGH MOUNTED STOP LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMBINATION FLASHER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FOG LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEADLAMP SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HEADLAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LICENSE PLATE LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LICENSE PLATE LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MULTI-FUNCTION SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PARK/TURN SIGNAL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TAIL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TAIL LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TURN SIGNAL CANCEL CAM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
AN LAMPS 8L - 1
DESCRIPTION - EXTERIOR LAMPS
The exteri or l i ghti ng system consi st of the fol l ow-
i ng components:
Central Timer Module (CTM) - l ocated on the
l eft cowl si de i nner panel bel ow the i nstrument
panel .
Headlamp Switch - l ocated on the l eft si de of
the i nstrument panel .
Fog Lamp Relay - l ocated i n the Power Di stri -
buti on Center (PDC) under the hood near the bat-
tery.
Park Lamp Relay - l ocated i n the Juncti on
Bl ock i n the l eft end cap of the i nstrument panel .
Vehi cl es have i ncandescent l i ghti ng on the exteri or
for i l l umi nati ng and i ndi cati ng purposes. Li ghti ng
ci rcui ts are protected by fuses. Li ghti ng ci rcui ts
requi re an overl oad protected power source, on/off
devi ce, l amps and body ground to operate properl y.
Repl ace sockets and bul bs that are corroded.
Wi re connectors can make i ntermi ttent contact or
become corroded. Before coupl i ng wi re connectors,
i nspect the termi nal s i nsi de the connector. Mal e termi -
nal s shoul d not be bent or di sengaged from the i nsu-
l ator. Femal e termi nal s shoul d not be sprung open or
di sengaged from the i nsul ator. Bent and sprung termi -
nal s can be repai red usi ng needl e nose pl i ers and pi ck
tool . Corroded termi nal s appear chal ky or green. Cor-
roded termi nal s shoul d be repl aced to avoi d recur-
rence of the probl em symptoms.
Begi n el ectri cal system fai l ure di agnosi s by testi ng
rel ated fuses i n the Juncti on Bl ock (JB) and the
Power Di stri buti on Center (PDC). Veri fy that bul bs
are i n good condi ti on and test conti nui ty of the ci r-
cui t ground. Refer to the appropri ate wi ri ng i nforma-
ti on. The wi ri ng i nformati on i ncl udes wi ri ng
grounds.
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM
A turn si gnal and hazard warni ng system i s stan-
dard factory-i nstal l ed safety equi pment on thi s
model . The turn si gnal and hazard warni ng system
i ncl udes the fol l owi ng major components, whi ch are
descri bed i n further detai l el sewhere i n thi s servi ce
i nformati on:
Combination Flasher - The el ectroni c combi -
nati on fl asher i s i nstal l ed i n a dedi cated connector of
the i nstrument panel wi re harness l ocated under the
i nstrument panel outboard of the steeri ng col umn
openi ng.
Hazard Warning Switch - The hazard warni ng
swi tch i s i ntegral to the mul ti -functi on swi tch on the
l eft si de of the steeri ng col umn. The hazard warni ng
swi tch button protrudes from a dedi cated openi ng i n
the shroud on the top of the steeri ng col umn, just
bel ow the steeri ng wheel .
Turn Signal Cancel Cam - The turn si gnal
cancel cam i s i ntegral to the cl ockspri ng, whi ch i s
l ocated beneath the steeri ng col umn shrouds at the
top of the steeri ng col umn, just bel ow the steeri ng
wheel .
Turn Signal Indicators - The two turn si gnal
i ndi cators, one ri ght and one l eft, are i ntegral to the
El ectroMechani cal I nstrument Cl uster (EMI C)
l ocated i n the i nstrument panel .
Turn Signal Lamps - The front turn si gnal
l amps are i ntegral to the l ower front outboard ends
of the headl amp modul es, l ocated just outboard of the
two si des of the radi ator gri l l e openi ng. The rear
turn si gnal l amps are i ntegral to the tai l l amp mod-
ul es that are secured to the quarter panel s at each
si de of the tai l gate openi ng.
Turn Signal Switch - The turn si gnal swi tch i s
i ntegral to the mul ti -functi on swi tch on the l eft si de
of the steeri ng col umn. The mul ti -functi on swi tch
control stal k that actuates the turn si gnal swi tch
protrudes from a dedi cated openi ng i n the steeri ng
col umn shrouds on the l eft si de of the col umn, just
bel ow the steeri ng wheel .
The turn si gnal system i n thi s vehi cl e i ncl udes a
turn si gnal warni ng chi me feature. The EMI C moni -
tors the turn si gnal i ndi cators and sends an el ec-
troni c chi me request message to the Central Ti mer
Modul e (CTM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus network i f the i ndi ca-
tor remai ns i l l umi nated wi th the vehi cl e speed above
about 25 ki l ometers per hour (15 mi l es per hour) for
a di stance of greater than about 1.6 ki l ometers (1
mi l e). (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DESCRI PTI ON).
Hard wi red ci rcui try connects the turn si gnal and
hazard warni ng system components to each other
through the el ectri cal system of the vehi cl e. These
hard wi red ci rcui ts are i ntegral to several wi re har-
nesses, whi ch are routed throughout the vehi cl e and
retai ned by many di fferent methods. These ci rcui ts
may be connected to each other, to the vehi cl e el ec-
tri cal system and to the turn si gnal and hazard
warni ng system components through the use of a
combi nati on of sol dered spl i ces, spl i ce bl ock connec-
tors and many di fferent types of wi re harness termi -
nal connectors and i nsul ators. Refer to the
8L - 2 LAMPS/LIGHTING - EXTERIOR AN
nectors, spl i ces and grounds.
OPERATION - EXTERIOR LAMPS
The headl amps operate through the headl amp
swi tch whi ch provi des a ground si gnal to the head-
l amp beam sel ector i n the mul ti -functi on swi tch. The
mul ti -functi on swi tch sends a l ow or hi gh beam si g-
nal i nput to the Central Ti mer Modul e (CTM), whi ch
provi des current to the headl amps accordi ngl y.
For park l amps operati on the headl amp swi tch
provi des a ground si gnal to the Central Ti mer Mod-
ul e (CTM), whi ch energi zes the park l amp rel ay.
Once the park l amp rel ay i s energi zed, current i s
provi ded to the park l amps through fuse 4 i n the
juncti on bl ock.
For fog l amps operati on the headl amp swi tch pro-
vi des a ground si gnal to the Central Ti mer Modul e
(CTM) whi ch energi zes the fog l amp rel ay. Once the
fog l amp rel ay i s energi zed, current i s provi ded to the
fog l amps through fuse H i n the Power Di stri buti on
Center (PDC).
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM
The turn si gnal system operates on battery current
recei ved on a fused i gni ti on swi tch output (run-acc)
ci rcui t so that the turn si gnal s wi l l onl y operate wi th
the i gni ti on swi tch i n the On or Accessory posi ti ons.
The hazard warni ng system operates on non-
swi tched battery current recei ved on a fused B(+) ci r-
cui t so that the hazard warni ng remai ns operati onal
regardl ess of the i gni ti on swi tch posi ti on. When the
turn si gnal (mul ti -functi on) swi tch control stal k i s
moved up (ri ght turn) or down (l eft turn), the turn
si gnal system i s acti vated. When the turn si gnal sys-
tem i s acti vated, the ci rcui try of the turn si gnal
swi tch and the combi nati on fl asher wi l l cause the
sel ected (ri ght or l eft) turn si gnal i ndi cator, front
park/turn si gnal l amp, and rear tai l /stop/turn si gnal
l amp to fl ash on and off. Wi th the hazard warni ng
(mul ti -functi on) swi tch i n the On posi ti on, the hazard
warni ng system i s acti vated. When the hazard warn-
i ng system i s acti vated, the ci rcui try of the hazard
warni ng swi tch and the combi nati on fl asher wi l l
cause both the ri ght si de and the l eft si de turn si gnal
i ndi cators, front park/turn si gnal l amps, and rear
tai l /stop/turn si gnal l amps to fl ash on and off.
I n order to provi de the turn si gnal on warni ng, the
El ectroMechani cal I nstrument Cl uster (EMI C) moni -
tors vehi cl e speed and di stance messages recei ved
from the Powertrai n Control Modul e (PCM) over the
bus and the hard wi red turn si gnal swi tch i nput to
the cl uster el ectroni c ci rcui t board. I f a turn si gnal
remai ns i ndi cated for a di stance of greater than
about 1.6 ki l ometers (1 mi l e) and the vehi cl e speed
remai ns greater than about 24 ki l ometers-per-hour
(15 mi l es-per-hour), the EMI C generates an el ec-
troni c chi me request message to the Central Ti mer
Modul e (CTM) over the PCI data bus. The CTM then
generates an audi bl e chi me tone through i ts i ntegral
chi me tone generator to provi de an audi bl e remi nder
that a turn si gnal has been l eft on. Once the warni ng
chi me begi ns to sound, i t wi l l conti nue unti l the turn
si gnal i s cancel l ed (ei ther manual l y or mechani cal l y),
unti l the vehi cl e speed fal l s bel ow about 24 ki l ome-
ters-per-hour (15 mi l es-per-hour), or unti l the i gni -
ti on swi tch i s turned to the Off posi ti on, whi chever
occurs fi rst.
The hard wi red ci rcui ts of the turn si gnal and haz-
ard warni ng system can be di agnosed usi ng conven-
ti onal di agnosti c tool s and methods; however, for
proper di agnosi s of the turn si gnal on warni ng fea-
ture, the EMI C, the CTM, and the PCI data bus
must be tested usi ng a DRBI I I scan tool . Refer to
the appropri ate di agnosti c i nformati on. Refer to the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use and operati on of the
turn si gnal and hazard warni ng system.
WARNING - SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION:
Do not touch the glass of halogen bulbs with fin-
gers or other possibly oily surface, reduced bulb
life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays having
greater amperage value than indicated on the fuse
panel or in the Owners Manual.
NOTE: When it is necessary to remove components
to service another, it should not be necessary to
apply excessive force or bend a component to
remove it. Before damaging a trim component, ver-
ify hidden fasteners or captured edges are not hold-
ing the component in place.
AN LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
DIAGNOSIS AND TESTING - TURN SIGNAL &
HAZARD WARNING SYSTEM
When di agnosi ng the turn si gnal and hazard warn-
i ng ci rcui ts, remember that hi gh generator output
can burn out bul bs rapi dl y and repeatedl y. I f thi s i s a
probl em on the vehi cl e bei ng di agnosed, be certai n to
di agnose and repai r the chargi ng system as requi red.
I f the probl em bei ng di agnosed i s rel ated to a fai l ure
of the turn si gnal s to automati cal l y cancel fol l owi ng
compl eti on of a turn, i nspect the mul ti -functi on
swi tch for a faul ty or damaged cancel actuator and
i nspect the turn si gnal cancel cam on the cl ockspri ng
for damaged l obes or i mproper i nstal l ati on. The hard
wi red ci rcui ts of the turn si gnal and hazard warni ng
system can be di agnosed usi ng conventi onal di agnos-
ti c tool s and methods; however, for di agnosi s of the
turn si gnal on warni ng feature, the use of a DRBI I I
scan tool i s requi red. Refer to the appropri ate di ag-
nosti c i nformati on.
Actuate the turn si gnal swi tch or the hazard warni ng
swi tch. Observe the turn si gnal i ndi cator(s) i n the
i nstrument cl uster. I f the fl ash rate i s very hi gh,
check for a turn si gnal bul b that i s not l i t or i s very
di ml y l i t. Repai r the ci rcui ts to that l amp or repl ace
the faul ty bul b, as requi red. I f the turn si gnal i ndi -
cator(s) fai l to l i ght, go to Step 2.
Check the fused i gni ti on swi tch output (run-acc) fuse
(Fuse 19 - 10 ampere) i n the Juncti on Bl ock (JB) and
the fused B(+) fuse (Fuse 1 - 30 ampere) i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
as requi red and repl ace the faul ty fuse(s).
(Fuse 1 - 30 ampere) i n the PDC. I f OK, go to Step 4.
I f not OK, repai r the open B(+) ci rcui t between the
PDC and the battery as requi red.
output (run-acc) fuse (Fuse 19 - 10 ampere) i n the
fused i gni ti on swi tch output (run-acc) ci rcui t between
the JB and the i gni ti on swi tch as requi red.
Remove the combi nati on fl asher from the i nstrument
panel wi re harness connector and repl ace i t wi th a
known good uni t. Reconnect the battery negati ve
cabl e. Test the operati on of the turn si gnal and haz-
ard warni ng systems. I f OK, di scard the faul ty com-
bi nati on fl asher. I f not OK, remove the test fl asher
and go to Step 6.
output (run-acc) ci rcui t cavi ty i n the i nstrument
panel wi re harness connector for the combi nati on
fl asher. I f OK, go to Step 7. I f not OK, repai r the
open fused i gni ti on swi tch output (run-acc) ci rcui t
between the combi nati on fl asher and the fused i gni -
ti on swi tch output (run-acc) fuse (Fuse 19 - 10
ampere) i n the JB as requi red.
cavi ty of the i nstrument panel wi re harness connec-
tor for the combi nati on fl asher. I f OK, go to Step 8. I f
the combi nati on fl asher and the fused B(+) fuse
(Fuse 1 - 30 ampere) i n the PDC as requi red.
connector for the mul ti -functi on swi tch from the
swi tch connector receptacl e. Check for conti nui ty
between the hazard fl asher si gnal ci rcui t cavi ti es i n
the i nstrument panel wi re harness connector for the
combi nati on fl asher and the i nstrument panel wi re
harness connector for the mul ti -functi on swi tch.
OK, repai r the open hazard fl asher si gnal ci rcui t
between the combi nati on fl asher and the mul ti -func-
ti on swi tch as requi red.
(9) Check for conti nui ty between the ri ght turn
swi tch sense ci rcui t cavi ti es i n the i nstrument panel
wi re harness connector for the combi nati on fl asher
and the i nstrument panel wi re harness connector for
the mul ti -functi on swi tch. Repeat thi s check between
the l eft turn swi tch sense ci rcui t cavi ti es i f these
same connectors. I f OK, go to Step 10. I f not OK,
repai r the open ri ght and/or l eft turn swi tch sense
ci rcui t(s) between the combi nati on fl asher and the
mul ti -functi on swi tch as requi red.
(10) Check for conti nui ty between the ri ght and/or
l eft turn si gnal ci rcui t cavi ti es (there are two of each)
i n the i nstrument panel wi re harness connector for
the combi nati on fl asher and the i ndi vi dual turn si g-
nal l amps. There shoul d be conti nui ty. I f OK, test the
mul ti -functi on swi tch. (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/MULTI -FUNC-
TI ON SWI TCH - DI AGNOSI S AND TESTI NG). I f
not OK, repai r the open ri ght and/or l eft turn si gnal
ci rcui t(s) between the combi nati on fl asher and the
turn si gnal l amp(s) as requi red.
DIAGNOSIS AND TESTING - EXTERIOR LAMPS
A good ground i s necessary for proper l i ghti ng
operati on. Groundi ng i s provi ded by the l amp socket
when i t comes i n contact wi th the metal body, or
through a separate ground wi re.
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. For com-
pl ete ci rcui t di agrams, refer to the appropri ate wi r-
i ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
HEADLAMPS
HEADLAMPS ARE DIM
WITH ENGINE IDLING
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system.
4. Battery has insufficient charge. 4. Test battery state-of -charge.
5. Battery is sulfated or shorted. 5. Load test battery.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations.
7. Both headlamp bulbs faulty. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN
OUT
1. Charging system output too high. 1. Test and repair charging system.
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs faulty. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY
locations.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Faulty headlamps switch circuit
breaker.
3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.
splices.
HEADLAMPS (HIGH &
LOW) DO NOT
ILLUMINATE
1. No voltage at either headlamp. 1. Voltage should always be present. Trace
short circuit and replace BOTH headlamp
fuses. Check wiring circuit from Right
headlamp fuse to headlamp. (Repeat for
Left side)
2. No ground for high and low beam
circuit.
2. Ground should always be present
according to switch position. Check ground
at headlamp switch. Check wiring circuit
from headlamp switch to Multifunction
switch. Check headlamp switch and
Multifunction switch continuity. Repair circuit
ground.
3. Headlamp bulb(s) faulty. 3. Replace bulb(s).
4. Faulty headlamp switch. 4. Replace headlamp switch.
5. Faulty headlamp dimmer
(Multifunction) switch.
5. Replace Multifunction switch.
6. Broken connector terminal or wire
splice in headlamp circuit.
6. Repair connector terminal or wire splice.
7. Faulty CTM 7. Replace CTM
HEADLAMPS (LOW
BEAM) DO NOT
ILLUMINATE.
1. No ground for low beam circuit. 1. Ground should be present according to
Multifunction switch position. Check wiring
circuit from Multifunction switch to
headlamp . Trace open circuit in wiring and
repair.
Check Multifunction Switch for continuity.
HEADLAMPS (HIGH
BEAM) DO NOT
ILLUMINATE.
1. No ground for high beam circuit. 1. Ground should be present according to
headlamp . Trace open circuit in wiring and
repair.
Check Multifunction Switch for continuity.
HEADLAMPS (LOW
BEAM) ALWAYS
ILLUMINATE AND CAN
NOT BE SHUT OFF.( IF
HEADLAMP DELAY IS
SELECTED, THE
HEADLAMPS WILL
REMAIN ON FOR 60
SECONDS)
1. Low beam circuit from bulb to
Multifunction switch is shorted to
ground.
1. Ground should be present according to
headlamp . Trace short circuit in wiring and
repair.
HEADLAMPS (HIGH
BEAM) ALWAYS
ILLUMINATE AND CAN
NOT BE SHUT OFF.
1. High beam circuit from bulb to
Multifunction switch is shorted to
ground.
1. Ground should be present according to
headlamp . Trace short circuit in wiring and
repair.
HEADLAMP SWITCH OFF
HEADLAMPS AND
HIGHBEAM INDICATOR
REMAIN ON AND ARE
DIM.
1. Headlamp switch feed circuit
shorted to ground.
1. Check wiring circuit from right headlamp
fuse to headlamp. Repeat for left side.
Trace short circuit in wiring and repair.
HEADLAMP SWITCH ON
(LOW BEAMS ON), ONE
LOW BEAM ON AND
BOTH HIGH BEAMS DIM.
1. Headlamp feed circuit shorted to
ground.
HEADLAMP SWITCH ON
(HIGH BEAMS ON), ONE
HIGH BEAM ON AND
BOTH LOW BEAMS DIM.
1. Headlamp feed circuit shorted to
ground.
HEADLAMP SWITCH ON,
ONE HEADLAMP
FILAMENT WILL BE AT
FULL INTENSITY AND ALL
OTHER FILAMENTS ARE
ON AND DIM.
1. Faulty headlamp fuse. 1. Trace short circuit and replace fuse.
2. Open circuit from headlamp fuse
to headlamp.
2. Repair open headlamp circuit.
3. Faulty CTM. 3. Replace CTM.
1. HEADLAMPS STAY ON
WITH KEY OUT - DRLM
EQUIPPED VEHICLES ( IF
HEADLAMP DELAY IS
SELECTED, THE
HEADLAMPS WILL
REMAIN ON FOR 60
SECONDS).
1. Faulty CTM 1. Replace CTM.
*Canada vehicles must have lamps ON.
FOG LAMPS
FOG LAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
4. Battery has insufficient charge. 4. Test battery state-of -charge.
5. Battery is sulfated or shorted. 5. Load test battery.
locations.
FOG LAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system.
splices in circuit.
splices.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
locations.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY
locations.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch. 3. Replace headlamp switch.
splices in circuit.
splices.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse.
2. No Z1-ground at fog lamps. 2. Repair circuit ground.
3. Faulty fog lamp switch. 3. Replace headlamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
4. Repair connector terminal or wire splice.
5. Faulty or burned out bulb. 5. Replace bulb.
FOG LAMPS ARE
INOPERATIVE AND FOG
LAMP INDICATOR LIGHT
ALWAYS STAYS ON.
1. Fog lamp/DRL* feed shorted to
ground.
1. Check wiring circuit from fog lamp/DRL*
fuse to fog lamp. Trace short circuit in wiring
and repair.
FOG LAMPS ARE
INOPERATIVE AND FOG
LAMP INDICATOR LIGHT
IS ILLUMINATED.
1. Fog lamp/DRL* fuse defective. 1. Trace short circuit and replace fuse.
2. Open circuit from fog lamp fuse to
fog lamp.
2. Check wiring circuit from fog lamp/DRL*
fuse to fog lamp. Trace open circuit in wiring
and repair.
PARK LAMPS ARE
INOPERATIVE. FOG LAMP
INDICATOR IS ON WHEN
ALL SWITCHES ARE OFF
AND FUNCTIONS
OPPOSITE TO FOG
LAMPS.
1. Park lamp feed is shorted. 1. Check wiring circuit from park lamp fuse
to headlamp switch. Trace short circuit in
wiring and repair.
PARK LAMPS ARE
INOPERATIVE. FOG LAMP
INDICATOR FUNCTIONS
OPPOSITE TO FOG
LAMPS.
1. Park lamp fuse is faulty. 1. Trace short circuit and replace fuse.
2. Open circuit from park lamp fuse to
headlamp switch.
2. Check wiring circuit from park lamp fuse
to headlamp switch. Trace open circuit in
wiring and repair.
*Canada vehicles use Daytime Running Lamps (DRL).
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or
other oily surfaces. Bulb life will be reduced.
The fol l owi ng Bul b Appl i cati on Tabl e l i sts the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght.
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3157
CARGO 921
CENTER HIGH
MOUNTED STOP
921
FRONT FOG LAMP 899
FRONT SIDE MARKER 194
HEADLAMP 9007
LICENSE PLATE 168
PARK/TURN SIGNAL 3157
TAIL/BRAKE/TURN
SIGNAL
3157
UNDERHOOD 561
SPECIAL TOOLS
SPECIAL TOOLS - HEADLAMP ALIGNMENT
BRAKE LAMP SWITCH
DESCRIPTION
The pl unger type stop l amp swi tch i s mounted on a
bracket attached to the brake pedal support.
CAUTION: The switch can only be adjusted during
initial installation. If the switch is not adjusted prop-
erly a new switch must be installed.
OPERATION
The brake l amp swi tch i s used for the brake l amp,
speed control and brake sensor ci rcui ts. The brake
l amp ci rcui t i s open unti l the pl unger i s depressed.
The speed control and brake sensor ci rcui ts i s cl osed
unti l the pl unger i s depressed.
Headlamp Aiming Kit C-4466A
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
The brake l amp swi tch can be tested wi th an ohm-
meter. The ohmmeter i s used to check conti nui ty
between the pi n termi nal s (Fi g. 1).
SWITCH CIRCUIT IDENTIFICATION
Termi nal s 1 and 2: brake l amp ci rcui t
Termi nal s 3 and 4: RWAL/ABS modul e and Pow-
ertrai n Control Modul e (PCM) ci rcui t
Termi nal s 5 and 6: speed control ci rcui t
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
Wi th swi tch pl unger extended, attach test l eads to
pi ns 1 and 2. Repl ace swi tch i f meter i ndi cates no
conti nui ty.
Wi th swi tch pl unger retracted, attach test l eads to
conti nui ty.
Wi th swi tch pl unger retracted, attach test l eads to
conti nui ty.
REMOVAL
(1) Di sconnect swi tch harness (Fi g. 2).
(2) Press and hol d brake pedal i n appl i ed posi ti on.
(3) Rotate swi tch countercl ockwi se about 30 to
al i gn swi tch l ock tab wi th notch i n bracket.
(4) Pul l swi tch rearward out of mounti ng bracket
and rel ease brake pedal .
INSTALLATION
(1) Press and hol d brake pedal down.
(2) Al i gn tab on new swi tch wi th notch i n swi tch
bracket. Then i nsert swi tch i n bracket and turn i t
cl ockwi se about 30 to l ock i t i n pl ace.
(3) Connect harness wi res to swi tch.
(4) Rel ease brake pedal .
(5) Move the rel ease l ever (Fi g. 2) on the swi tch to
engage the swi tch pl unger. The swi tch i s now
adjusted and can not be adjusted agai n.
CARGO LAMP BULB
REMOVAL
The cargo l amp bul b i s i ncorporated i n the CHMSL
assembl y, (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/CENTER HI GH
MOUNTED STOP LAMP - REMOVAL) for bul b
repl acement.
Fig. 1 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Fig. 2 Brake Lamp Switch & Bracket
1 - RELEASE LEVER
2 - BRACKET
3 - BRAKE PEDAL SUPPORT
4 - BRAKE LAMP SWITCH
BRAKE LAMP SWITCH (Continued)
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
cabl e.
(2) Remove the CHMSL from the roof panel .
(3) Rotate the sockets 1/4 turn cl ockwi se and
remove from l amp.
(4) Pul l bul b from socket.
INSTALLATION
(1) Push bul b i nto socket.
(2) Posi ti on socket i n l amp and rotate socket 1/4
turn countercl ockwi se.
(3) I nstal l the CHMSL.
COMBINATION FLASHER
DESCRIPTION
The combi nati on fl asher i s l ocated i n a dedi cated
connector on a take out of the i nstrument panel wi re
harness, l ocated under the i nstrument panel just out-
board of the i nstrument panel steeri ng col umn open-
i ng (Fi g. 3). The combi nati on fl asher i s a smart rel ay
that functi ons as both the turn si gnal system and the
hazard warni ng system fl asher. The combi nati on
fl asher has fourteen bl ade-type termi nal s that con-
nect i t to the vehi cl e el ectri cal system through four-
teen matchi ng cavi ti es i n the i nstrument panel wi re
harness connector; however, onl y ten of the combi na-
ti on fl asher termi nal s are used i n thi s appl i cati on.
The combi nati on fl asher contai ns acti ve el ectroni c
I ntegrated Ci rcui try (I C) el ements. Thi s fl asher i s
desi gned to handl e the current fl ow requi rements of
the factory-i nstal l ed l i ghti ng. I f suppl emental l i ght-
i ng i s added to the turn si gnal l amp ci rcui ts, such as
when towi ng a trai l er wi th l i ghts, the combi nati on
fl asher wi l l automati cal l y try to compensate to keep
the fl ash rate the same.
The combi nati on fl asher cannot be repai red or
adjusted and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The combi nati on fl asher has fourteen bl ade-type
termi nal s, but onl y ten are used i n thi s appl i cati on.
These ten termi nal s are i ntended for the fol l owi ng
i nputs and outputs: fused B(+), fused i gni ti on swi tch
output, ri ght turn si gnal sense, l eft turn si gnal sense,
hazard fl asher si gnal , brake l amp swi tch output, and
two outputs each for the ri ght and l eft turn si gnal
ci rcui ts. Constant battery vol tage i s suppl i ed to the
fl asher so that i t can perform the hazard warni ng
functi on, and i gni ti on swi tched battery vol tage i s
suppl i ed for the turn si gnal functi on. The I ntegrated
Ci rcui t (I C) wi thi n the combi nati on fl asher contai ns
the l ogi c that control s the fl asher operati on and the
fl ash rate. The I C recei ves separate sense ground
i nputs from the mul ti -functi on swi tch for the hazard
fl asher, ri ght turn si gnal , and l eft turn si gnal . A spe-
ci al desi gn feature of the combi nati on fl asher al l ows
i t to sense that a turn si gnal ci rcui t or bul b i s not
operati ng, and provi de the dri ver an i ndi cati on of the
condi ti on by fl ashi ng the remai ni ng bul bs i n the
affected ci rcui t at a hi gher rate (120 fl ashes-per-
mi nute or hi gher). Conventi onal fl ashers ei ther con-
ti nue fl ashi ng at thei r typi cal rate (heavy-duty type),
or di sconti nue fl ashi ng the affected ci rcui t enti rel y
(standard-duty type).
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
venti onal automoti ve el ectri cal test equi pment. I f the
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal and hazard warni ng system. Then
repl ace the combi nati on fl asher wi th a known good
uni t to confi rm system operati on. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/TURN
SI GNAL & HAZARD WARNI NG SYSTEM - DI AG-
NOSI S AND TESTI NG).
Fig. 3 Combination Flasher
1 - COMBINATION FLASHER
3 - 16-WAY DATA LINK CONNECTOR
4 - STEERING COLUMN OPENING COVER
REMOVAL
cabl e.
(2) Reach under the outboard si de of the steeri ng
col umn openi ng i n the i nstrument panel to access the
i nstrument panel wi re harness connector for the com-
bi nati on fl asher l ocated on a mounti ng tab on the
back of the i nstrument panel armature (Fi g. 4).
(3) Grasp the combi nati on fl asher and connector
fi rml y and pul l them toward the dash panel to di sen-
gage the connector from the mounti ng tab on the
i nstrument panel armature.
(4) Remove the combi nati on fl asher from the
i nstrument panel wi re harness connector.
INSTALLATION
(1) Posi ti on the combi nati on fl asher to the i nstru-
ment panel wi re harness connector (Fi g. 4).
(2) Al i gn the combi nati on fl asher termi nal s wi th
the termi nal cavi ti es i n the i nstrument panel wi re
harness connector.
(3) Usi ng hand pressure, push i n fi rml y on the
combi nati on fl asher unti l the termi nal s are ful l y
seated i n the termi nal cavi ti es i n the i nstrument
panel wi re harness connector.
(4) Al i gn the sl ot i n the combi nati on fl asher con-
nector wi th the mounti ng tab on the i nstrument
panel armature.
(5) Usi ng hand pressure, push the combi nati on
fl asher connector fi rml y onto the mounti ng tab unti l
i t i s ful l y engaged i n the sl ot.
Fig. 4 Combination Flasher
1 - COMBINATION FLASHER
3 - 16-WAY DATA LINK CONNECTOR
COMBINATION FLASHER (Continued)
FOG LAMP
REMOVAL
cabl e.
(2) Di sengage fog l amp harness connector.
(3) Rotate bul b socket a 1/4 turn countercl ockwi se
and pul l from l amp to separate (Fi g. 5).
(4) Grasp bul b and pul l from l amp.
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) Posi ti on bul b i n l amp, push to seat and rotate
a 1/4 turn cl ockwi se.
(2) Connect fog l amp harness connector.
FOG LAMP UNIT
REMOVAL
NOTE: The fog lamps are serviced from the rear-
ward side of the front bumper.
cabl e.
(2) Di sengage fog l amp harness connector.
(3) Remove the bol ts attachi ng the fog l amp to the
bumper (Fi g. 6).
(4) Separate fog l amp from bumper.
INSTALLATION
(1) Posi ti on fog l amp i n bumper.
(2) I nstal l the bol ts attachi ng the fog l amp to the
bumper.
(3) Connect fog l amp harness connector.
(4) Check for proper operati on and beam al i gn-
ment.
ADJUSTMENTS - FOG LAMP UNIT
Prepare an al i gnment screen. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/HEAD-
LAMP UNI T - ADJUSTMENTS). A properl y al i gned
fog l amp wi l l project a pattern on the al i gnment
screen 100 mm (4 i n.) bel ow the fog l amp centerl i ne
and strai ght ahead (Fi g. 7). Rotate the adjustment
screw to adjust beam hei ght (Fi g. 8).
Fig. 5 Fog Lamp Bulb
1 - FOG LAMP
2 - FOG LAMP BULB
Fig. 6 Fog Lamp
1 - FOG LAMP
2 - FRONT BUMPER
HEADLAMP SWITCH
DESCRIPTION
The headl amp swi tch i s l ocated on the i nstrument
panel . The headl amp swi tch control s the parki ng
l amps, the headl amps, the i nteri or l amps and the
i nstrument cl uster i l l umi nati on. The headl amp
swi tch al so contai ns a rheostat for control l i ng the
i l l umi nati on l evel of the i nstrument cl uster l amps.
OPERATION
The headl amp swi tch cl oses a path to ground for
the Central Ti mer Modul e (CTM) when the park or
head l amps are on and the dri ver door ajar swi tch i s
cl osed (dri ver door i s open). The headl amp swi tch
opens the ground path when the headl amp swi tch i s
turned off. The ground path i s al so opened when the
dri ver door ajar swi tch i s open (dri ver door i s cl osed).
Fig. 7 Fog Lamp Alignment
1 - VEHICLE CENTERLINE
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 - HIGH-INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS
5 - 100 mm (4 in.)
6 - 7.62 METERS (25 FEET)
7 - FRONT OF FOG LAMP
Fig. 8 Fog Lamp Adjustment
1 - FOG LAMP
2 - ADJUSTMENT SCREW
FOG LAMP UNIT (Continued)
The headl amp swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
HEADLAMP SWI TCH - REMOVAL) for the servi ce
procedures.
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
(1) Remove the headl amp swi tch. (Refer to 8 -
HEADLAMP SWI TCH - REMOVAL).
(2) Usi ng an ohmmeter, test for conti nui ty between
the termi nal s of the swi tch as shown i n the Head-
l amp Swi tch Conti nui ty tabl e (Fi g. 9).
(3) I f test resul ts are not obtai ned as shown i n the
Headl amp Swi tch Conti nui ty tabl e, repl ace the head-
l amp swi tch.
For ci rcui t descri pti ons and di agrams, refer to the
HEADLAMP SWITCH CONTINUITY TABLE
SWITCH POSITION CONTINUITY BETWEEN
OFF PIN 2 AND 4, PIN 1 AND
14
PARK PIN 3 AND 4
HEAD PIN 4 AND 6
FOG LAMP PIN 5 AND 4
INTERIOR LAMPS
DIMMER
PIN 12 AND 9, PIN 1
AND 14, PIN 1 AND 8
PARADE PIN 1 AND 14, PIN 12
AND 9
DOME PIN 1 AND 8, PIN 1 AND
14, PIN 10 AND 9
CARGO PIN 1 AND 14, PIN 1
AND 8, PIN 10 AND 9,
PIN 11 AND 9
REMOVAL
cabl e.
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
(3) Di sconnect the wi re harness connector from the
headl amp swi tch.
(4) Remove the headl amp swi tch from the cl uster
bezel .
INSTALLATION
(1) Posi ti on the headl amp swi tch to the cl uster
bezel .
Fig. 9 HEADLAMP SWITCH
HEADLAMP SWITCH (Continued)
headl amp swi tch. Ti ghten the screws to 2.2 Nm (20
i n. l bs.).
(3) Reconnect the wi re harness to the headl amp
swi tch.
(4) I nstal l the cl uster bezel onto the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
HEADLAMP
REMOVAL
cabl e.
(2) Remove headl amp assembl y. (Refer to 8 -
HEADLAMP UNI T - REMOVAL).
(3) Remove the retai ni ng ri ng hol di ng bul b to
headl amp.
(4) Pul l bul b socket from headl amp (Fi g. 10).
(5) Grasp bul b and pul l from socket.
INSTALLATION
(1) Posi ti on bul b i nto socket and push i nto pl ace.
(2) Posi ti on bul b socket i n headl amp.
(3) I nstal l retai ni ng ri ng hol di ng bul b to head-
l amp.
(4) I nstal l headl amp assembl y.
HEADLAMP UNIT
REMOVAL
cabl e.
(2) Remove the bol ts attachi ng headl amp to the
i nner fender panel (Fi g. 11).
(3) Grasp the headl amp and fi rml y pul l the head-
l amp to di sengage i t from the panel .
(4) Di sengage the connector from the headl amp
bul b.
(5) Separate bul b from headl amp.
(6) Remove the bul b sockets from the front park/
turn si gnal /si de marker l amps.
(7) Separate headl amp modul e from vehi cl e.
INSTALLATION
(1) I nstal l bul b sockets for the front park/turn si g-
nal /si de marker l amps.
(2) Engage the connector to the headl amp bul b.
(3) Posi ti on headl amp i n i nner fender panel and
fi rml y push headl amp i nward to l ock i nto pl ace.
(4) I nstal l the bol ts attachi ng headl amp to the
panel .
Fig. 10 Headlamp Bulb
1 - HEADLAMP BULB SOCKET
2 - HEADLAMP
3 - BULB
4 - SIDE MARKER LAMP BULB SOCKET
Fig. 11 Headlamp
1 - FENDER
2 - SEAL
3 - INNER FENDER
HEADLAMP SWITCH (Continued)
ADJUSTMENTS
HEADLAMP ALIGNMENT
Headl amps can be al i gned usi ng the screen method
provi ded. Al i gnment Tool C-4466A or equi val ent can
al so be used. Refer to the i nstructi ons provi ded wi th
the tool for proper procedures.
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
LAMP ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft) away from front
of headl amp l ens (Fi g. 12).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft) away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 ft)
and tape a l i ne on the wal l at the centerl i ne of the
vehi cl e. Si ght al ong the centerl i ne of the vehi cl e
(from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
Fig. 12 Headlamp Alignment ScreenTypical
1 - CENTER OF VEHICLE
2 - CENTER OF HEADLAMP
3 - 7.62 METERS (25 FT.)
4 - FRONT OF HEADLAMP
HEADLAMP UNIT (Continued)
HEADLAMP ALIGNMENT
A properl y ai med l ow beam headl amp wi l l project a
hi gh i ntensi ty l i ght pattern on the screen wi th the
hori zontal cut-off l i ne al i gned wi th the tape l i ne 130
mm. (5.12 i n.) bel ow the headl amp centerl i ne. The
i ntersecti on of the hori zontal and 15 degree cut-off
l i nes i n the projected pattern shoul d al i gn to the
i ntersecti on of the headl amp centerl i ne verti cal tape
l i ne and the tape l i ne 130 mm. (5.12 i n.) bel ow the
headl amp hori zontal centerl i ne. The hi gh beam pat-
tern shoul d be correct when the l ow beams are
al i gned properl y.
To adjust l ow beam headl amp, rotate al i gnment
screws (Fi g. 13) to achi eve the speci fi ed ai m.
LICENSE PLATE LAMP
REMOVAL
cabl e.
(2) From the undersi de of the bumper, grasp the
bul b socket and rotate counter cl ockwi se.
(3) Pul l bul b socket from l amp.
(4) Grasp bul b and pul l from socket.
INSTALLATION
(1) Posi ti on bul b i n socket and press i nto pl ace.
(2) Posi ti on bul b socket i n l amp and rotate cl ock-
wi se to l ock i nto pl ace.
LICENSE PLATE LAMP UNIT
REMOVAL
cabl e.
(2) Remove l i cense pl ate l amp bul b socket.
(3) From the undersi de of the bumper and usi ng a
smal l fl at bl ade, push i n retai ni ng tab to rel ease the
l amp from the bumper.
(4) Separate l amp from bumper.
INSTALLATION
(1) Posi ti on l amp i n bumper and press i nto pl ace.
(2) I nstal l l i cense pl ate l amp bul b socket.
MULTI-FUNCTION SWITCH
DESCRIPTION
The mul ti -functi on swi tch i s secured wi th two
screws to the mul ti -functi on swi tch mounti ng hous-
i ng on the l eft si de of the steeri ng col umn, just bel ow
the steeri ng wheel (Fi g. 14). The onl y vi si bl e parts of
the mul ti -functi on swi tch are the control stal k that
extends through a dedi cated openi ng i n the l eft si de
of the upper steeri ng col umn shrouds, and the haz-
ard warni ng swi tch push button that protrudes
through an openi ng i n the upper steeri ng col umn
shroud on the top of the steeri ng col umn. The
remai nder of the swi tch, i ts mounti ng provi si ons, and
i ts el ectri cal connecti ons are al l conceal ed beneath
Fig. 13 Headlamp Adjustment Screws
1 - HEADLAMP
2 - UP/DOWN ADJUSTMENT
3 - LEFT/RIGHT ADJUSTMENT
4 - PARK LAMP
Fig. 14 Multi-Function Switch
1 - MULTI-FUNCTION SWITCH
2 - HAZARD WARNING BUTTON
3 - TURN SIGNAL CANCEL ACTUATOR
4 - CONTROL STALK
5 - CONTROL KNOB
HEADLAMP UNIT (Continued)
the steeri ng col umn shrouds. The mul ti -functi on
swi tch control stal k has both nomencl ature and
I nternati onal Control and Di spl ay Symbol graphi cs
appl i ed to i t, whi ch i denti fy i ts many functi ons. An
I nternati onal Control and Di spl ay Symbol i con for
Hazard Warni ng i s appl i ed to the top of the hazard
warni ng swi tch push button.
The swi tch housi ng and i ts control s are constructed
of mol ded bl ack pl asti c. A si ngl e connector receptacl e
connects the swi tch to the vehi cl e el ectri cal system
through a take out and connector of the i nstrument
panel wi re harness.
The mul ti -functi on swi tch supports the fol l owi ng
functi ons and features:
Continuous Wipe Modes - The control knob of
the mul ti -functi on swi tch provi des two conti nuous
wi pe swi tch posi ti ons, l ow speed or hi gh speed.
Hazard Warning Control - The i nternal ci r-
cui try and hardware of the mul ti -functi on swi tch pro-
vi de detent swi tchi ng for acti vati on and deacti vati on
of the hazard warni ng system.
Headlamp Beam Selection - The i nternal ci r-
cui try and hardware of the mul ti -functi on swi tch pro-
vi de detent swi tchi ng for sel ecti on of the headl amp
hi gh or l ow beams.
Headlamp Optical Horn - The i nternal ci r-
cui try and hardware of the mul ti -functi on swi tch
i ncl udes momentary swi tchi ng of the headl amp hi gh
beam ci rcui ts to provi de an opti cal horn feature
(someti mes referred to as fl ash-to-pass), whi ch al l ows
the vehi cl e operator to momentari l y fl ash the head-
l amp hi gh beams as an opti cal si gnal l i ng devi ce.
Intermittent Wipe Mode - The control knob of
the mul ti -functi on swi tch provi des an i ntermi ttent
wi pe mode wi th mul ti pl e del ay i nterval posi ti ons.
Turn Signal Control - The i nternal ci rcui try
and hardware of the mul ti -functi on swi tch provi de
both momentary non-detent swi tchi ng and detent
swi tchi ng wi th automati c cancel l ati on for both the
l eft and ri ght turn si gnal s.
Washer Mode - The control knob of the mul ti -
functi on swi tch provi des washer system operati on
when the knob i s depressed towards the steeri ng col -
umn.
The mul ti -functi on swi tch cannot be adjusted or
repai red. I f any functi on of the swi tch i s faul ty, or i f
the swi tch i s damaged, the enti re swi tch uni t must
be repl aced.
OPERATION
The mul ti -functi on swi tch uses conventi onal l y
swi tched outputs and a vari abl e resi stor to control
the many functi ons and features i t provi des usi ng
hard wi red ci rcui try. The swi tch i s grounded at al l
ti mes through a si ngl e wi re take out wi th an eyel et
termi nal connector of the i nstrument panel wi re har-
ness that i s secured by a nut to a ground stud
l ocated on the l eft cowl si de i nner panel , near the l eft
i nstrument panel end bracket. When the i gni ti on
swi tch i s i n the Accessory or On posi ti ons, battery
current from a fuse i n the Juncti on Bl ock (JB) i s pro-
vi ded through a fused i gni ti on swi tch output (run-
acc) ci rcui t. Fol l owi ng are descri pti ons of how the
mul ti -functi on swi tch operates to control the many
functi ons and features i t provi des:
Continuous Wipe Modes - When the control
knob of the mul ti -functi on swi tch i s rotated to the
Hi gh or Low posi ti ons, the ci rcui try wi thi n the
swi tch provi des a battery current output di rectl y to
the hi gh or l ow speed brush of the wi per motor.
When the control knob i s i n the Off posi ti on, the ci r-
cui try wi thi n the swi tch connects the output of the
wi per motor park swi tch to the l ow speed brush of
the wi per motor.
Hazard Warning Control - The hazard warn-
i ng push button i s pushed down to unl atch the
swi tch and acti vate the hazard warni ng system, and
pushed down agai n to l atch the swi tch and turn the
system off. When the hazard warni ng swi tch i s
l atched (hazard warni ng off), the push button wi l l be
i n a l owered posi ti on on the top of the steeri ng col -
umn shroud; and, when the hazard warni ng swi tch i s
unl atched (hazard warni ng on), the push button wi l l
be i n a rai sed posi ti on. The mul ti -functi on swi tch
hazard warni ng ci rcui try provi des a si gnal to the
hazard warni ng sense of the combi nati on fl asher to
acti vate or deacti vate the fl asher output to the haz-
ard warni ng l amps.
Headlamp Beam Selection - The mul ti -func-
ti on swi tch control stal k i s pul l ed towards the steer-
i ng wheel past a detent, then rel eased to actuate the
headl amp beam sel ecti on swi tch. Each ti me the con-
trol stal k i s actuated i n thi s manner, the opposi te
headl amp mode from what i s currentl y sel ected wi l l
be acti vated. The i nternal ci rcui try of the headl amp
beam sel ecti on swi tch di rects a ground si gnal output
from the headl amp swi tch to the appropri ate l ow
beam or hi gh beam sense of the Central Ti mer Mod-
ul e (CTM). The CTM then control s a hard wi red out-
put to acti vate the sel ected headl amp beams.
Headlamp Optical Horn - The l eft mul ti -func-
ti on swi tch control stal k i s pul l ed towards the steer-
i ng wheel to just before a detent, to momentari l y
acti vate the headl amp hi gh beams. The hi gh beams
wi l l remai n i l l umi nated unti l the control stal k i s
rel eased. The i nternal ci rcui try of the headl amp
beam sel ecti on swi tch provi des a momentary ground
path to the CTM hi gh beam sense.
Intermittent Wipe Mode - When the mul ti -
functi on swi tch control knob i s rotated to the Del ay
posi ti on, the ci rcui try wi thi n the swi tch provi des a
battery current si gnal to the Central Ti mer Modul e
MULTI-FUNCTION SWITCH (Continued)
(CTM). I f the Del ay mode i s sel ected, the control
knob can then be rotated to mul ti pl e mi nor detent
posi ti ons, whi ch actuates a vari abl e resi stor wi thi n
the swi tch and provi des a hard wi red output to the
CTM that si gnal s the desi red del ay i nterval for the
i ntermi ttent wi per feature.
Turn Signal Control - The mul ti -functi on
swi tch control stal k actuates the turn si gnal swi tch.
When the control stal k i s moved i n the upward di rec-
ti on, the ri ght turn si gnal ci rcui try i s acti vated; and,
when the control stal k i s moved i n the downward
di recti on, the l eft turn si gnal ci rcui try i s acti vated.
The mul ti -functi on swi tch turn si gnal ci rcui try pro-
vi des a si gnal to the ri ght or l eft turn si gnal sense of
the combi nati on fl asher to acti vate or deacti vate the
fl asher output to the proper turn si gnal l amps. The
turn si gnal swi tch has a detent posi ti on i n each
di recti on that provi des turn si gnal s wi th automati c
cancel l ati on, and an i ntermedi ate, momentary posi -
ti on i n each di recti on that provi des turn si gnal s onl y
unti l the mul ti -functi on swi tch control stal k i s
rel eased. When the control stal k i s moved to a turn
si gnal swi tch detent posi ti on, the cancel actuator
extends toward the center of the steeri ng col umn. A
turn si gnal cancel cam that i s i ntegral to the cl ock-
spri ng mechani sm rotates wi th the steeri ng wheel
and the cam l obes contact the cancel actuator when
i t i s extended from the mul ti -functi on swi tch. When
the steeri ng wheel i s rotated duri ng a turni ng
maneuver, one of the two turn si gnal cancel cam
l obes wi l l contact the turn si gnal cancel actuator. The
cancel actuator l atches agai nst the cancel cam rota-
ti on i n the di recti on opposi te that whi ch i s si gnal ed.
I n other words, i f the l eft turn si gnal detent i s
sel ected, the l obes of the cancel cam wi l l ratchet past
the cancel actuator when the steeri ng wheel i s
rotated to the l eft, but wi l l unl atch the cancel actua-
tor as the steeri ng wheel rotates to the ri ght and
returns to center, whi ch wi l l cancel the turn si gnal
event and rel ease the control stal k from the detent so
i t returns to the neutral Off posi ti on.
Washer Mode - Pushi ng the control knob on
the end of the mul ti -functi on swi tch control stal k
towards the steeri ng col umn provi des a battery cur-
rent output through the momentary si ngl e pol e, si n-
gl e throw washer swi tch ci rcui try to provi de a
washer si gnal i nput to the CTM. The CTM then pro-
vi des a battery current output to operate the washer
pump/motor. I f the wi pers are not operati ng when
the washer swi tch i s actuated, the CTM wi l l operate
the wi per motor for as l ong as the washer swi tch i s
depressed pl us about three addi ti onal wi pe cycl es. I f
the wi pers are operati ng i n the i ntermi ttent mode
when the washer swi tch i s actuated, the CTM wi l l
operate the wi per motor at a fi xed l ow speed for as
l ong as the washer swi tch i s depressed pl us about
three addi ti onal wi pe cycl es before the wi pers return
to the sel ected i ntermi ttent wi pe i nterval .
DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
(1) Remove the mul ti -functi on swi tch from the
swi tch mounti ng housi ng on the steeri ng col umn.
(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/MULTI -FUNCTI ON SWI TCH - REMOV-
AL).
(2) Usi ng an ohmmeter, perform the conti nui ty
and resi stance tests at the termi nal s i n the mul ti -
functi on swi tch connector receptacl e as shown i n the
Mul ti -Functi on Swi tch Tests chart (Fi g. 15).
(3) I f the mul ti -functi on swi tch fai l s any of the
conti nui ty or resi stance tests, repl ace the faul ty
swi tch uni t as requi red.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
STEERING COLUMN, SEAT BELT TENSIONER, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE AIRBAG SYSTEM CAPAC-
ITOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIRBAG SYSTEM.
cabl e.
trol stal k.
the l ower shroud.
shroud.
(8) Remove the l ower shroud from the steeri ng col -
umn.
connector for the mul ti -functi on swi tch from the
swi tch connector receptacl e.
Fig. 15 Multi-Function Switch Tests
TURN & HAZARD SWITCH POSITIONS
CONTINUITY BETWEEN
TURN SIGNAL HAZARD WARNING
Left Off Pins 5 & 11
Right Off Pins 3 & 11
Neutral On Pins 1 & 11
WIPER & WASHER SWITCH POSITIONS CONTINUITY BETWEEN
Off Pins 14 & 15
*Delay Pins 4 & 18, Pins 14 & 15
Low Pins 15 & 17
High Pins 15 & 16
Wash Pins 18 & 19
*Resistance for the five intermittent wipe detent positions should also be checked between Pins 2 & 4. The
resistance values are as follows, 10%.
INTERMITTENT WIPE DETENT POSITIONS RESISTANCE
Detent 1 (Longest Delay) 18 kilohms
Detent 2 12 kilohms
Detent 3 6.2 kilohms
Detent 4 3.3 kilohms
Detent 5 (Shortest Delay) zero ohms
HEADLAMP BEAM SELECT SWITCH POSITIONS CONTINUITY BETWEEN
Low Beam Pins 6 & 9
High Beam Pins 8 & 9
Flash (Optical Horn) Pins 7 & 8
(10) Remove the two screws that secure the mul ti -
functi on swi tch to the mul ti -functi on swi tch mount-
i ng housi ng (Fi g. 16).
(11) Grasp the mul ti -functi on swi tch control stal k
and pul l i t strai ght toward the outboard si de of the
vehi cl e to di sengage the swi tch from the mul ti -func-
ti on swi tch mounti ng housi ng.
INSTALLATION
(1) Posi ti on the mul ti -functi on swi tch onto the
mul ti -functi on swi tch mounti ng housi ng (Fi g. 16).
the mul ti -functi on swi tch to the mul ti -functi on
swi tch mounti ng housi ng. Ti ghten the screws to 2
Nm (20 i n. l bs.).
connector for the mul ti -functi on swi tch to the swi tch
connector receptacl e.
umn.
i n. l bs.).
PARK/TURN SIGNAL LAMP
REMOVAL
cabl e.
(2) Remove park and turn si gnal l amp.
(3) Rotate bul b socket 1/4 turn countercl ockwi se
and pul l turn si gnal l amp socket from back of l amp
(Fi g. 17).
(4) Pul l park and turn si gnal l amp bul b from
socket.
Fig. 16 Multi-Function Switch
1 - MULTI-FUNCTION SWITCH CONTROL STALK
2 - SCREW (2)
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
4 - CLOCKSPRING
Fig. 17 Park And Turn Signal Lamp bulb
1 - SIDE MARKER LAMP BULB
2 - PARK/TURN SIGNAL LAMP BULB
INSTALLATION
(1) I nstal l park and turn si gnal l amp bul b i n
socket.
(2) I nstal l park and turn si gnal l amp socket i nto
back of l amp.
(3) I nstal l park/turn si gnal l amp.
TAIL LAMP
REMOVAL
cabl e.
(2) Remove screws from tai l l amp.
(3) Grasp l amp, fi rml y pul l l amp rearward to di s-
engage retai ni ng studs.
(4) Remove sockets from tai l l amp (Fi g. 18).
(5) Pul l bul b from socket.
(6) Separate tai l l amp from cargo box.
INSTALLATION
(1) I nstal l bul b i n socket.
(2) I nstal l socket i n tai l l amp.
(3) Posi ti on tai l l amp i n cargo box, engage retai n-
i ng studs and i nstal l screws.
TAIL LAMP UNIT
REMOVAL
cabl e.
(2) Rel ease tai l gate l atch and open tai l gate.
(3) Remove screw hol di ng tai l l amp to cargo box
(Fi g. 19).
(4) Grasp l amp, fi rml y pul l l amp rearward to di s-
engage retai ni ng studs.
(5) Remove sockets from tai l l amp.
(6) Separate tai l l amp from cargo box.
INSTALLATION
(1) I nstal l sockets i n tai l l amp.
(2) Posi ti on tai l l amp at cargo box, engage retai n-
i ng studs (Fi g. 20) and i nstal l screw.
(3) Cl ose tai l gate.
(4) Connect the negati ve battery cabl e.
Fig. 18 Tail, Brake, Turn Signal And
1 - TAIL/STOP/TURN SIGNAL LAMP BULB
2 - BACK-UP LAMP BULB
Fig. 19 Tail Lamp
1 - CARGO BOX
2 - TAIL/STOP BACK-UP LAMP
3 - ROUND CLIP
Fig. 20 Retaining Studs
1 - RETAINING STUDS
2 - TAIL LAMP
PARK/TURN SIGNAL LAMP (Continued)
TURN SIGNAL CANCEL CAM
DESCRIPTION
The turn si gnal cancel cam i s conceal ed wi thi n the
steeri ng col umn bel ow the steeri ng wheel . The turn
si gnal cancel cam consi sts of two l obes on a mol ded
pl asti c ri ng that i s snapped i nto the l ower hub of the
cl ockspri ng rotor. The cl ockspri ng mechani sm pro-
vi des turn si gnal cancel l ati on as wel l as a constant
el ectri cal connecti on between the horn swi tch, dri ver
ai rbag, speed control swi tches, and remote radi o
swi tches on the steeri ng wheel and the i nstrument
panel wi re harness on the steeri ng col umn. The
housi ng of the cl ockspri ng i s secured to the mul ti -
functi on swi tch mounti ng housi ng on the steeri ng
col umn and remai ns stati onary. The rotor of the
cl ockspri ng, i ncl udi ng the turn si gnal cancel cam
l obes rotate wi th the steeri ng wheel .
The turn si gnal cancel cam i s servi ced as a uni t
wi th the cl ockspri ng and cannot be repai red. I f faul ty
or damaged, the enti re cl ockspri ng uni t must be
repl aced. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL).
OPERATION
The turn si gnal cancel cam has two l obes and i s
secured to the l ower hub openi ng of the cl ockspri ng
rotor. When the turn si gnal s are acti vated by movi ng
the mul ti -functi on swi tch control stal k to a detent
posi ti on, a turn si gnal cancel actuator i s extended
from the i nsi de surface of the mul ti -functi on swi tch
housi ng toward the center of the steeri ng col umn and
the turn si gnal cancel cam. When the steeri ng wheel
i s rotated duri ng a turni ng maneuver, one of the two
turn si gnal cancel cam l obes wi l l contact the turn si g-
nal cancel actuator. The cancel actuator l atches
agai nst the cancel cam rotati on i n the di recti on oppo-
si te that whi ch i s si gnal ed. I n other words, i f the l eft
turn si gnal detent i s sel ected, the l obes of the cancel
cam wi l l ratchet past the cancel actuator when the
steeri ng wheel i s rotated to the l eft, but wi l l unl atch
the cancel actuator as the steeri ng wheel rotates to
the ri ght and returns to center, whi ch wi l l cancel the
turn si gnal event and rel ease the control stal k from
the detent so i t returns to the neutral Off posi ti on.
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 25
DOME LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DOOR AJAR SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DOOR AJAR SWITCH. . . . . . . . . . . . . . . . . . . . 27
GLOVE BOX LAMP SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
READING LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPECIFICATIONS
INTERIOR LAMPS
CAUTION: Do not use bulbs other than the those
listed in the Bulb Application Table. Damage to
lamp can result.
Some components have l amps that can onl y be ser-
vi ced by an Authori zed Servi ce Center (ASC) after
the component i s removed from the vehi cl e.
The fol l owi ng Bul b Appl i cati on Tabl es l i sts the
l amp ti tl e on the l eft si de of the col umn and trade
number or part number on the ri ght.
BULB APPLICATION TABLE
LAMP BULB TYPE
A/C Heater Control 6233137
Airbag LED
Anti-lock Brake PC74
Ash Receiver 161
Brake Warning LED
Check Engine PC74
Check Gauges LED
Cruise PC74
Dome 579
Engine Oil Pressure PC74
Four Wheel Drive PC194
Glove Compartment 194
Headlamp Switch 158
Heater Control 6233137
High Beam PC74
Ignition Key 53
Instrument Cluster PC194
Low Fuel PC74
Low Washer Fluid PC74
Overdrive Off PC74
Overhead Console 578
Radio ASC
RWAL PC74
Seat Belt LED
Security PC74
Stepwell 904
Turn Signal PC194
Upshift PC74
AN LAMPS/LIGHTING - INTERIOR 8L - 25
DOME LAMP
REMOVAL
cabl e.
(2) Usi ng a smal l fl at bl ade, pry the l eft si de (dri v-
ers si de) of the dome l amp l ens downward from
dome l amp.
(3) Al l ow the l ens to hang down (Fi g. 1), thi s wi l l
di sengage the ri ght si de of the l amp (passengers
si de) from the headl i ner.
(4) Pul l the ri ght si de of the l amp down and sl i de
the l amp to the ri ght (Fi g. 2).
(5) Separate the l amp from the headl i ner.
(6) Di sengage dome l amp wi re connector from body
wi re harness.
(7) Separate dome l amp from vehi cl e.
INSTALLATION
(1) Posi ti on dome l amp at headl i ner.
(2) Connect dome l amp wi re connector to body
wi re harness.
(3) Posi ti on the l eft si de of the l amp i n the head-
l i ner openi ng and sl i de l amp to the l eft.
(4) Push the ri ght si de of the l amp i n the head-
l i ner openi ng and push the l amp l ens up i nto the
l amp to secure.
DOOR AJ AR SWITCH
DESCRIPTION
The door ajar swi tches are i ntegral to the door
l atches on each door. The swi tches cl ose a path to
ground for the Central Ti mer Modul e (CTM) when a
door i s opened, and open the ground path when a
door i s cl osed.
The door ajar swi tches cannot be repai red and, i f
faul ty or damaged, the door l atch uni t must be
repl aced.
OPERATION
The door ajar swi tches cl ose a path to ground for
the Central Ti mer Modul e (CTM) when a door i s
opened, and opens the ground path when a door i s
cl osed. The passenger si de front door and both rear
door ajar swi tches are connected i n a paral l el -seri es
ci rcui t between ground and the CTM, whi l e the
dri ver si de front door ajar swi tch i s connected i n
seri es between ground and the CTM to provi de a
uni que i nput. The CTM reads the swi tch status
through an i nternal pul l -up, then sends the proper
swi tch status messages to other el ectroni c modul es
(PCI ) data bus network. The door ajar swi tches can
be di agnosed usi ng conventi onal di agnosti c tool s and
methods.
Fig. 1 Dome Lamp
1 - SLIDE LAMP
Fig. 2 Dome Lamp Lens
1 - HEAD LINER
2 - DOME LAMP
3 - LENS
8L - 26 LAMPS/LIGHTING - INTERIOR AN
DIAGNOSIS AND TESTING - DOOR AJAR
SWITCH
INJURY.
cabl e. Di sconnect the door l atch pi gtai l wi re connec-
tor from the door wi re harness connector. Check for
conti nui ty between the ground ci rcui t cavi ty i n the
door wi re harness connector and a good ground.
OK, repai r the open ground ci rcui t to ground as
requi red.
cui t cavi ty and the dri ver or passenger door ajar
swi tch sense ci rcui t cavi ty i n the door l atch pi gtai l
wi re connector. There shoul d be conti nui ty wi th the
door opened, and no conti nui ty wi th the door cl osed.
I f OK, go to Step 3. I f not OK, repl ace the faul ty door
l atch uni t.
(Connector C2) for the Central Ti mer Modul e (CTM)
from the CTM connector receptacl e. Check for conti -
nui ty between the dri ver or passenger door ajar
swi tch sense ci rcui t cavi ty of the body wi re harness
connector (Connector C2) and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 4. I f not
OK, repai r the shorted dri ver or passenger door ajar
swi tch sense ci rcui t between the door l atch and the
CTM as requi red.
(4) Check for conti nui ty between the dri ver or pas-
senger door ajar swi tch sense ci rcui t cavi ti es of the
body wi re harness connector (Connector C2) and the
door wi re harness connector for the door l atch. There
shoul d be conti nui ty. I f OK, use a DRBI I I scan tool
to di agnose the CTM. Refer to the appropri ate di ag-
nosti c procedures. I f not OK, repai r the open dri ver
or passenger door ajar swi tch sense ci rcui t between
the door l atch and the CTM as requi red.
GLOVE BOX LAMP SWITCH
REMOVAL
cabl e.
(2) Open the gl ove box.
(3) Reach through the gl ove box openi ng and
behi nd the gl ove box openi ng upper rei nforcement i n
the i nstrument panel to access and depress the
retai ni ng l atches on the top and bottom of the gl ove
box l amp and swi tch housi ng.
(4) Whi l e hol di ng the retai ni ng l atches depressed,
push the gl ove box l amp and swi tch out through the
mounti ng hol e i n the i nstrument panel gl ove box
openi ng upper rei nforcement (Fi g. 3).
Fig. 3 Glove Box Lamp and Switch
1 - GLOVE BOX LAMP AND SWITCH
2 - CONNECTOR
AN LAMPS/LIGHTING - INTERIOR 8L - 27
DOOR AJ AR SWITCH (Continued)
(5) Pul l the gl ove box l amp and swi tch out from
the mounti ng hol e far enough to access the wi re har-
ness connector.
connector from the gl ove box l amp and swi tch con-
nector receptacl e.
(7) Remove the gl ove box l amp and swi tch from
the i nstrument panel .
INSTALLATION
(1) Posi ti on the gl ove box l amp and swi tch to the
i nstrument panel .
connector to the gl ove box l amp and swi tch connector
receptacl e.
(3) Feed the i nstrument panel wi re harness back
i nto the gl ove box l amp and swi tch mounti ng hol e i n
the gl ove box openi ng upper rei nforcement.
(4) Al i gn the gl ove box l amp and swi tch housi ng
wi th the mounti ng hol e i n the i nstrument panel
gl ove box openi ng upper rei nforcement.
(5) Push the gl ove box l amp and swi tch i nto the
mounti ng hol e i n the i nstrument panel gl ove box
openi ng upper rei nforcement unti l the retai ni ng
l atches are ful l y engaged.
(6) Cl ose the gl ove box.
READING LAMP
REMOVAL
cabl e.
(2) From the center of the l ens outward, pry the
l ens from the overhead consol e.
(3) Remove bul b.
INSTALLATION
(1) I nstal l bul b.
(2) Snap l ens i nto posi ti on.
8L - 28 LAMPS/LIGHTING - INTERIOR AN
GLOVE BOX LAMP SWITCH (Continued)
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COMPASS VARIATION ADJUSTMENT . . . . . . . . 2
COMPASS CALIBRATION. . . . . . . . . . . . . . . . . . 2
COMPASS DEMAGNETIZING. . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPASS/MINI-TRIP COMPUTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPASS MINI-TRIP COMPUTER. . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AMBIENT TEMP SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AMBIENT TEMPERATURE SENSOR . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
UNIVERSAL TRANSMITTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ERASING TRANSMITTER CODES . . . . . . . . . . 11
SETTING TRANSMITTER CODES . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OVERHEAD CONSOLE
DESCRIPTION
OVERHEAD CONSOLE
The overhead consol e for thi s model i ncl udes two
front-mounted readi ng and courtesy l amps, a sun-
gl asses storage bi n, uni versal transmi tter and ei ther
a standard papercl i p or an opti onal compass mi ni -
tri p computer.
The overhead consol e i s secured wi th two snap
cl i ps at the rear and a si ngl e screw at the front to
the overhead consol e mounti ng bracket. The front of
the overhead consol e mounti ng bracket i s secured to
the roof header near the wi ndshi el d wi th two screws,
and the rear of the bracket i s secured wi th doubl e-
faced tape to the i nsi de surface of the roof panel . A
si ngl e el ectri cal connecti on joi ns the overhead consol e
wi re harness to the roof wi re harness.
Fol l owi ng are general descri pti ons of the major
components used i n the overhead consol e. See the
i nformati on on the use and operati on of the vari ous
overhead consol e features.
SUNGLASS STORAGE BIN
A sungl asses storage bi n i s i ncl uded i n the over-
head consol e. The storage bi n i s l ocated near the cen-
ter of the overhead consol e and i s hel d i n the cl osed
posi ti on by a spri ng-l oaded l atch mechani sm that i s
i ntegral to the storage bi n door. The i nteri or of the
bi n i s l i ned wi th a foam rubber paddi ng materi al to
protect the sungl asses from bei ng scratched. A
damper spri ng i s snapped onto the pi vot shaft of the
sungl asses storage bi n door. The damper spri ng
engages two fl ats on the shaft and i s anchored i n a
sl ot i n the rear fl ange of the overhead consol e read-
i ng and courtesy l amp housi ng to provi de a smooth
openi ng acti on and an open detent posi ti on for the
storage bi n uni t.
The sungl asses storage bi n and door uni t i s avai l -
abl e for servi ce repl acement. The bi n and door uni t
i ncl udes the spri ng-l oaded l atch mechani sm, the bi n
l i ner and the damper spri ng. I f any of these compo-
nents i s damaged or faul ty, the sungl asses storage
bi n and door uni t must be repl aced.
The sungl asses storage bi n i s opened by pressi ng
the l atch on the rear edge of the door towards the
front of the vehi cl e, then pul l i ng the bi n downward to
the open detent posi ti on. The spri ng-l oaded l atch
mechani sm on the sungl asses bi n door wi l l automat-
i cal l y engage when the bi n i s cl osed. See the owners
on the use and operati on of the sungl asses storage
bi n.
PAPERCLIP
A papercl i p i s standard equi pment on the base ver-
si on of the overhead consol e. The papercl i p provi des
a conveni ent pl ace for storage and easy retri eval of
notes, maps, tol l ti ckets or stubs and other paper
AN MESSAGE SYSTEMS 8M - 1
i tems that may be requi red or desi red whi l e dri vi ng.
The papercl i p i s l ocated near the front of the over-
head consol e and i s secured i n the overhead consol e
housi ng by four screws.
The papercl i p i s avai l abl e for servi ce repl acement,
but i t cannot be adjusted or repai red. I f the papercl i p
i s damaged or faul ty i t must be repl aced.
STANDARD PROCEDURE - COMPASS
VARIATION ADJUSTMENT
Compass vari ance, al so known as magneti c decl i -
nati on, i s the di fference i n angl e between magneti c
north and true geographi c north. I n some geographi c
l ocati ons, the di fference between magneti c and geo-
graphi c north i s great enough to cause the compass
to gi ve fal se readi ngs. I f thi s probl em occurs, the
compass vari ance must be set.
To set the compass vari ance:
(1) Usi ng the Vari ance Setti ngs map, fi nd your
geographi c l ocati on and note the zone number (Fi g.
1).
(2) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the Step
push button to step through the di spl ay opti ons unti l
you have reached the compass/temperature di spl ay.
(3) Depress both the U.S./Metri c, and the Step
push buttons and hol d the buttons down unti l VAR
appears i n the di spl ay. Thi s takes about fi ve seconds.
(4) Rel ease both of the push buttons. VAR al ong
wi th the current vari ance zone wi l l appear i n the di s-
pl ay.
(5) Momentari l y depress and rel ease the U.S./Met-
ri c push button to step through the zone numbers,
unti l the zone number for your geographi c l ocati on
appears i n the di spl ay.
(6) Momentari l y depress and rel ease the Step push
button to enter the di spl ayed zone number i nto the
compass uni t memory.
(7) Confi rm that the correct di recti ons are now
i ndi cated by the compass.
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The el ectroni c compass uni t features a sel f-cal i -
brati ng desi gn, whi ch si mpl i fi es the cal i brati on pro-
cedure. Thi s feature automati cal l y updates the
compass cal i brati on whi l e the vehi cl e i s bei ng dri ven.
Thi s al l ows the compass uni t to compensate for smal l
changes i n the resi dual magneti sm that the vehi cl e
may acqui re duri ng normal use. I f the compass read-
i ngs appear to be errati c or out of cal i brati on, per-
form the fol l owi ng cal i brati on procedure. Al so, new
Fig. 1 Variance Settings
8M - 2 MESSAGE SYSTEMS AN
OVERHEAD CONSOLE (Continued)
servi ce repl acement compass mi ni -tri p computer
modul es must have thei r compass cal i brated usi ng
thi s procedure. Do not attempt to cal i brate the com-
pass near l arge metal objects such as other vehi cl es,
l arge bui l di ngs, or bri dges; or, near overhead or
underground power l i nes.
NOTE: Whenever the compass is calibrated manu-
ally, the variation number must also be reset. See
Compass Variation Adjustment in the Service Pro-
cedures section of this group.
Cal i brate the compass manual l y as fol l ows:
(1) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the Step
push button to step through the di spl ay opti ons unti l
you have reached the compass/temperature di spl ay.
(2) Depress both the U.S./Metri c and the Step
push buttons. Hol d the push buttons down unti l
CAL appears i n the di spl ay. Thi s takes about ten
seconds, and appears about fi ve seconds after VAR
i s di spl ayed.
(3) Rel ease both of the push buttons.
(4) Dri ve the vehi cl e on a l evel surface, away from
l arge metal objects and power l i nes, through three or
more compl ete ci rcl es i n not l ess than 48 seconds.
The CAL message wi l l di sappear from the di spl ay
to i ndi cate that the compass i s now cal i brated.
NOTE: If the CAL message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure at least one more time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
DEMAGNETIZING
A degaussi ng tool (Speci al Tool 6029) i s used to
demagneti ze, or degauss, the overhead consol e for-
ward mounti ng screw and the roof panel above the
overhead consol e. Equi val ent uni ts must be rated as
conti nuous duty for 110/115 vol ts and 60 Hz. They
must al so have a fi el d strength of over 350 gauss at 7
mi l l i meters (0.25 i nch) beyond the ti p of the probe.
To demagneti ze the roof panel and the overhead
consol e forward mounti ng screw, proceed as fol l ows:
(1) Be certai n that the i gni ti on swi tch i s i n the Off
posi ti on, before you begi n the demagneti zi ng proce-
dure.
(2) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(3) Sl owl y approach the head of the overhead con-
sol e forward mounti ng screw wi th the degaussi ng
tool connected.
(4) Contact the head of the screw wi th the pl asti c
coated ti p of the degaussi ng tool for about two sec-
onds.
(5) Wi th the degaussi ng tool sti l l energi zed, sl owl y
back i t away from the screw. When the ti p of the tool
i s at l east 61 centi meters (2 feet) from the screw
head, di sconnect the tool .
(6) Pl ace a pi ece of paper approxi matel y 22 by 28
centi meters (8.5 by 11 i nches), ori ented on the vehi cl e
l engthwi se from front to rear, on the center l i ne of
the roof at the wi ndshi el d header (Fi g. 2). The pur-
pose of the paper i s to protect the roof panel from
scratches, and to defi ne the area to be demagneti zed.
(7) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(8) Sl owl y approach the center l i ne of the roof
panel at the wi ndshi el d header, wi th the degaussi ng
tool connected.
Fig. 2 Roof Demagnetizing Pattern
(9) Contact the roof panel wi th the pl asti c coated
ti p of the degaussi ng tool . Be sure that the templ ate
i s i n pl ace to avoi d scratchi ng the roof panel . Usi ng a
sl ow, back-and-forth sweepi ng moti on, and al l owi ng
13 mi l l i meters (0.50 i nch) between passes, move the
tool at l east 11 centi meters (4 i nches) to each si de of
the roof center l i ne, and 28 centi meters (11 i nches)
back from the wi ndshi el d header.
(10) Wi th the degaussi ng tool sti l l energi zed,
sl owl y back i t away from the roof panel . When the
ti p of the tool i s at l east 61 centi meters (2 feet) from
the roof panel , di sconnect the tool .
(11) Cal i brate the compass and adjust the compass
vari ance. Refer to Compass Variation Adjustment
and Compass Calibration i n the Servi ce Proce-
dures secti on of thi s group for the procedures.
REMOVAL - OVERHEAD CONSOLE
cabl e.
(2) Remove the screw that secures the front of the
overhead consol e to the front of the overhead consol e
bracket (Fi g. 3).
(3) I nsert the fi ngerti ps of both hands between the
headl i ner and the si des of the overhead consol e hous-
i ng i n the area between the garage door opener stor-
age bi n and the sungl asses storage bi n.
(4) Pul l downward on the si des of the overhead
consol e housi ng fi rml y and evenl y to di sengage the
two snap cl i ps that secure the rear of the uni t from
thei r receptacl es i n the overhead consol e bracket.
(5) Lower the overhead consol e from the headl i ner
far enough to access the wi re harness connector.
(6) Di sconnect the roof wi re harness connector
from the overhead consol e wi re harness connector.
(7) Remove the overhead consol e from the head-
l i ner.
REMOVAL - OVERHEAD CONSOLE BRACKET
cabl e.
(2) Remove the overhead consol e from the over-
head consol e bracket. Refer to Overhead Console i n
the Removal and I nstal l ati on secti on of thi s group for
the procedures.
(3) Remove the headl i ner from the roof panel .
Refer to Headliner i n the Removal and I nstal l ati on
secti on of Body for the procedures.
(4) Remove the two screws that secure the front of
the overhead consol e bracket to the roof front header
(Fi g. 4).
(5) Usi ng a sharp uti l i ty kni fe, cut through the
doubl e-faced tape that secures the rear fl ange of the
overhead consol e bracket to the roof panel .
(6) Remove the overhead consol e bracket from the
roof panel .
Fig. 3 Overhead Console Remove/Install
1 - HEADLINER
2 - BRACKET
3 - ROOF PANEL
4 - LOCATING PIN
5 - OVERHEAD CONSOLE
6 - SCREW
7 - ROOF WIRE HARNESS CONNECTOR
8 - FRONT HEADER
9 - SNAP CLIP (2)
Fig. 4 Overhead Console Bracket Remove/Install
1 - ROOF PANEL
2 - DOUBLE-FACED TAPE
3 - OVERHEAD CONSOLE BRACKET
4 - SCREW (2)
5 - FRONT HEADER
OVERHEAD CONSOLE DISASSEMBLY
(1) Remove the readi ng and courtesy l amp housi ng
from the overhead consol e. Refer to Overhead Con-
sole Reading and Courtesy Lamp Housing i n
Lamps for the procedure.
(2) Unl atch and remove the sungl asses storage bi n
from the overhead consol e housi ng.
PAPERCLIP
l i ner. Refer to Overhead Console i n the Removal
and I nstal l ati on secti on of thi s group for the proce-
dures.
(2) Remove the four screws that secure the paper-
cl i p to the overhead consol e housi ng.
(3) Pul l the papercl i p away from the overhead con-
sol e far enough to access the wi re harness connec-
tors.
(4) Di sengage the overhead consol e wi re harness
connector from the mount on the papercl i p by push-
i ng the connector fi rml y toward the l eft si de of the
overhead consol e housi ng.
(5) Remove the papercl i p from the overhead con-
sol e housi ng.
OVERHEAD CONSOLE ASSEMBLY
(1) Posi ti on the sungl asses storage bi n i nto the
(2) Engage the l atch of the sungl asses storage bi n
wi th the l atch stri ker on the rear of the storage bi n
openi ng i n the overhead consol e housi ng.
(3) Be certai n that the sungl asses storage bi n pi vot
shaft i s l ocated i n the two pi vot receptacl es just
behi nd the readi ng and courtesy l amp l enses i n the
(4) Be certai n that the sungl asses storage bi n
damper spri ng i s i nstal l ed on the pi vot shaft wi th the
two end tabs of the spri ng engaged wi th the fl ats on
the rear of the shaft, and the center tab engaged over
the front of the shaft.
(5) I nstal l the readi ng and courtesy l amp housi ng
onto the overhead consol e. Refer to Overhead Con-
sole Reading and Courtesy Lamp Housing i n
Lamps for the procedure.
PAPERCLIP
(1) Posi ti on the papercl i p onto the overhead con-
sol e housi ng.
(2) Engage the overhead consol e wi re harness con-
nector onto the mount on the papercl i p by al i gni ng
the channel s on the connector wi th the tab on the
mount and pushi ng the connector fi rml y toward the
ri ght si de of the overhead consol e housi ng.
the papercl i p to the overhead consol e housi ng.
(4) I nstal l the overhead consol e onto the headl i ner.
Refer to Overhead Console i n the Removal and
I nstal l ati on secti on of thi s group for the procedures.
INSTALLATION - OVERHEAD CONSOLE
(1) Posi ti on the overhead consol e near the mount-
i ng l ocati on on the headl i ner.
(2) Reconnect the roof wi re harness connector to
the overhead consol e wi re harness connector.
(3) Al i gn the l ocati ng pi n on the rear of the over-
head consol e housi ng wi th the receptacl e i n the rear
of the overhead consol e bracket.
(4) Al i gn the two snap cl i ps on the overhead con-
sol e housi ng wi th thei r receptacl es i n the overhead
consol e bracket.
(5) Push upward fi rml y and evenl y on the si des of
the overhead consol e housi ng over both of the snap
cl i p l ocati ons unti l each of the two snap cl i ps i s ful l y
engaged wi th i ts receptacl e i n the overhead consol e
bracket.
front of the overhead consol e housi ng to the overhead
consol e bracket. Ti ghten the screw to 1.9 Nm (17 i n.
l bs.).
INSTALLATION - OVERHEAD CONSOLE
BRACKET
(1) Remove any remnants of the ol d doubl e-faced
tape from the roof panel and the rear fl ange of the
overhead consol e bracket and cl ean these areas wi th
a sui tabl e sol vent to remove any traces of grease, oi l
or adhesi ve resi due. When i nstal l i ng the overhead
consol e bracket, al ways appl y a new pi ece of doubl e-
faced tape to the rear fl ange of the bracket.
(2) Al i gn the two l ocati ng pi ns on the front of the
overhead consol e bracket wi th the receptacl es i n the
roof front header.
(3) Lower the rear fl ange of the overhead consol e
bracket from the roof panel far enough to access and
remove the rel ease paper from the doubl e-faced tape.
(4) Push upward fi rml y and evenl y on the rear
fl ange of the overhead consol e bracket over the dou-
bl e-faced tape to ensure compl ete adhesi on to the
roof panel .
the front of the overhead consol e bracket to the roof
front header. Ti ghten the screws to 1.9 Nm (17 i n.
l bs.).
(6) I nstal l the headl i ner onto the roof panel . Refer
to Headliner i n the Removal and I nstal l ati on sec-
ti on of Body for the procedures.
(7) I nstal l the overhead consol e onto the overhead
consol e bracket. Refer to Overhead Console i n the
Removal and I nstal l ati on secti on of thi s group for the
procedures.
SPECIAL TOOLS
OVERHEAD CONSOLE SYSTEMS
COMPASS/MINI-TRIP
COMPUTER
DESCRIPTION
The compass mi ni -tri p computer i s l ocated i n the
overhead consol e on model s equi pped wi th thi s
opti on. The compass mi ni -tri p computer uni ts i ncl ude
the el ectroni c control modul e, a Vacuum-Fl uorescent
Di spl ay (VFD), a compass sensor uni t and two push
button functi on swi tches.
The compass mi ni -tri p computer modul e contai ns a
central processi ng uni t and i nterfaces wi th other
el ectroni c modul es i n the vehi cl e on the Programma-
bl e Communi cati on I nterface (J1850) data bus net-
work. The J1850 data bus network al l ows the
shari ng of sensor i nformati on. Thi s hel ps to reduce
wi re harness compl exi ty, reduce i nternal control l er
hardware, and reduce component sensor current
l oads. At the same ti me, thi s system provi des
i ncreased rel i abi l i ty, enhanced di agnosti cs, and
al l ows the addi ti on of many new feature capabi l i ti es.
The compass mi ni -tri p computer provi des several
el ectroni c functi ons and features. Some of the func-
ti ons and features that the compass mi ni -tri p com-
puter modul e supports and/or control s, i ncl ude the
fol l owi ng di spl ay opti ons:
Compass and temperature - provi des the out-
si de temperature and one of ei ght compass readi ngs
to i ndi cate the di recti on the vehi cl e i s faci ng.
Trip odometer (TRIP ODO) - shows the di s-
tance travel l ed si nce the l ast tri p computer reset.
Average fuel economy (AVG ECO) - shows
the average fuel economy si nce the l ast tri p computer
reset.
Instant fuel economy (ECO) - shows the
present fuel economy based upon the current vehi cl e
di stance and fuel used i nformati on.
Distance to empty (DTE) - shows the esti -
mated di stance that can be travel l ed wi th the fuel
remai ni ng i n the fuel tank. Thi s esti mated di stance
i s computed usi ng the average mi l es-per-gal l on from
the l ast 30 gal l ons of fuel used.
Elapsed time (ET) - shows the accumul ated
i gni ti on-on ti me si nce the l ast tri p computer reset.
Blank screen - the compass mi ni -tri p VFD i s
turned off.
The ambi ent temperature sensor i s hard wi red to
the HVAC control head. Data i nput for al l other com-
pass mi ni -tri p computer functi ons, i ncl udi ng VFD
di mmi ng l evel , i s recei ved through J1850 data bus
messages. The compass mi ni -tri p computer uses i ts
i nternal programmi ng and al l of these i nputs to cal -
cul ate and di spl ay the requested data. I f the data
di spl ayed i s i ncorrect, perform the sel f-di agnosti c
tests as descri bed i n thi s group. I f these tests prove
i nconcl usi ve, the use of a DRB scan tool and the
proper Di agnosti c Procedures manual are recom-
mended for further testi ng of the compass mi ni -tri p
computer modul e and the J1850 data bus.
The compass mi ni -tri p computer modul e cannot be
repai red, and i s avai l abl e for servi ce onl y as a uni t.
Thi s uni t i ncl udes the push button swi tches and the
pl asti c modul e and di spl ay l ens. I f any of these com-
ponents i s faul ty or damaged, the compl ete compass
mi ni -tri p computer modul e must be repl aced.
COMPASS
Whi l e i n the compass/temperature mode, the com-
pass wi l l di spl ay the di recti on i n whi ch the vehi cl e i s
poi nted usi ng the ei ght major compass headi ngs
(Exampl es: north i s N, northeast i s NE). The sel f-cal -
i brati ng compass uni t requi res no adjusti ng i n nor-
mal use. The onl y cal i brati on that may prove
necessary i s to dri ve the vehi cl e i n three compl ete
ci rcl es, on l evel ground, i n not l ess than forty-ei ght
seconds. Thi s wi l l reori ent the compass uni t to i ts
vehi cl e.
The compass uni t al so wi l l compensate for magne-
ti sm the body of the vehi cl e may acqui re duri ng nor-
mal use. However, avoi d pl aci ng anythi ng magneti c
di rectl y on the roof of the vehi cl e. Magneti c mounts
for an antenna, a repai r order hat, or a funeral pro-
cessi on fl ag can exceed the compensati ng abi l i ty of
the compass uni t i f pl aced on the roof panel . Mag-
neti c bi t dri vers used on the fasteners that hol d the
overhead consol e assembl y to the roof header can
al so affect compass operati on. I f the vehi cl e roof
Degaussing Tool 6029
shoul d become magneti zed, the demagneti zi ng and
cal i brati on procedures found i n thi s group may be
requi red to restore proper compass operati on.
THERMOMETER
The thermometer di spl ays the outsi de ambi ent
temperature i n whol e degrees. The temperature di s-
pl ay can be changed from Fahrenhei t to Cel si us
usi ng the U.S./Metri c push button. The di spl ayed
temperature i s not an i nstant readi ng of condi ti ons,
but an average temperature. I t may take the ther-
mometer di spl ay several mi nutes to respond to a
major temperature change, such as dri vi ng out of a
heated garage i nto wi nter temperatures.
When the i gni ti on swi tch i s turned to the Off posi -
ti on, the l ast di spl ayed temperature readi ng stays i n
the thermometer uni t memory. When the i gni ti on
swi tch i s turned to the On posi ti on agai n, the ther-
mometer wi l l di spl ay the memory temperature i f the
engi ne cool ant temperature i s above about 52 C
(125 F). I f the engi ne cool ant temperature i s bel ow
about 52 C (125 F), the thermometer wi l l di spl ay
the actual temperature sensed by the ambi ent tem-
perature sensor. The thermometer temperature di s-
pl ay update i nterval vari es wi th the vehi cl e speed.
The thermometer functi on i s supported by an
ambi ent temperature sensor. The sensor i s mounted
outsi de the passenger compartment near the front
and center of the vehi cl e, and i s hard wi red to the
HVAC control head whi ch sends temperature on
J1850 data bus ci rcui t. The ambi ent temperature
sensor i s avai l abl e as a separate servi ce i tem.
NOTE: The compass mini-trip computer will display
OC for temperatures below -40 C and SC for
temperatures above 55C.
OPERATION
The compass mi ni -tri p computer onl y operates wi th
the i gni ti on swi tch i n the On posi ti on. When the i gni -
ti on swi tch i s turned to the On posi ti on, al l of the
segments i n the compass mi ni -tri p computer VFD
wi l l be turned off for one second, then the di spl ay
wi l l return to the l ast functi on bei ng di spl ayed before
the i gni ti on was turned to the Off posi ti on. Wi th the
i gni ti on swi tch i n the On posi ti on, momentari l y
depressi ng and rel easi ng the Step push button swi tch
wi l l cause the compass-mi ni -tri p computer to change
i ts mode of operati on, and momentari l y depressi ng
and rel easi ng the U.S./Metri c push button wi l l cause
the uni t to toggl e between U.S. and Metri c measure-
ments.
Thi s compass mi ni -tri p computer features several
functi ons that can be reset. I f both the Step and U.S./
Metri c push buttons are depressed at the same ti me
for more than one second wi th the i gni ti on swi tch i n
the On posi ti on, the tri p computer i nformati on that
can be reset i s reset. However, the reset wi l l onl y
occur i f the functi on currentl y di spl ayed i s a functi on
that can be reset. The functi ons that can be reset
are: TRI P ODO, AVG ECO, and ET.
For more i nformati on on the features and control
functi ons of the compass mi ni -tri p computer, see the
owners manual i n the vehi cl e gl ove box.
DIAGNOSIS & TESTING - COMPASS MINI-TRIP
COMPUTER
I f the probl em wi th the compass mi ni -tri p com-
puter modul e i s an OC or SC i n the compass/ther-
mometer di spl ay, refer to Ambient Temperature
Sensor i n the Di agnosi s and Testi ng secti on of thi s
group. I f the probl em wi th the compass mi ni -tri p
computer modul e i s an i naccurate or scrambl ed di s-
pl ay, refer to Self-Diagnostic Test i n the Di agnosi s
and Testi ng secti on of thi s group. I f the probl em wi th
the compass mi ni -tri p computer modul e i s i ncorrect
Vacuum Fl uorescent Di spl ay (VFD) di mmi ng l evel s,
use a DRB scan tool and the proper Di agnosti c Pro-
cedures manual to test for the correct di mmi ng mes-
sage i nputs bei ng recei ved from the i nstrument
cl uster over the J1850 data bus. I f the probl em i s a
no-di spl ay condi ti on, use the fol l owi ng procedures.
For compl ete ci rcui t di agrams, refer to Overhead
Console i n the Contents of Wi ri ng Di agrams.
(1) Check the fused i gni ti on swi tch output (run/
start) fuse i n the juncti on bl ock. I f OK, go to Step 2.
I f not OK, repai r the shorted ci rcui t or component as
output (run/start) fuse i n the juncti on bl ock. I f OK,
go to Step 3. I f not OK, repai r the open fused i gni ti on
swi tch output (run/start) ci rcui t to the i gni ti on swi tch
as requi red.
Remove the overhead consol e. Check for conti nui ty
between the ground ci rcui t cavi ti es of the roof wi re
harness connector for the overhead consol e and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
vol tage at the fused i gni ti on swi tch output (run/start)
ci rcui t cavi ty of the roof wi re harness connector for
the overhead consol e. I f OK, refer to Self-Diagnos-
tic Test i n the Di agnosi s and Testi ng secti on of thi s
group for further di agnosi s of the compass mi ni -tri p
computer modul e and the J1850 data bus. I f not OK,
repai r the open fused i gni ti on swi tch output (run/
start) ci rcui t to the juncti on bl ock fuse as requi red.
COMPASS/MINI-TRIP COMPUTER (Continued)
SELF-CHECK DIAGNOSTICS
A sel f-di agnosti c test i s used to determi ne that the
compass mi ni -tri p computer modul e i s operati ng
properl y el ectri cal l y. I ni ti ate the sel f-di agnosti c test
as fol l ows:
(1) Wi th the i gni ti on swi tch i n the Off posi ti on,
si mul taneousl y depress and hol d the Step button and
the U.S./Metri c button whi l e rotati ng the i gni ti on
swi tch to the On posi ti on..
(2) Conti nue to hol d both buttons depressed unti l
the compass mi ni -tri p computer modul e enters the
di spl ay segment test. I n thi s test, al l of the Vacuum
Fl uorescent Di spl ay (VFD) segments are l i ghted
whi l e the compass mi ni -tri p computer modul e per-
forms the fol l owi ng checks:
Non-Vol ati l e Memory Test (EEPROM)
Asi c Communi cati ons Test
Vref Vol tage Test.
Compass Test
J1850 Communi cati ons Test
(3) Fol l owi ng compl eti on of these tests, the com-
pass mi ni -tri p computer wi l l return to normal opera-
ti on or di spl ay one of two messages: FAI L or BUS.
Respond to these test resul ts as fol l ows:
I f no test resul t message i s di spl ayed, but com-
pass mi ni -tri p computer operati on i s sti l l i mproper,
the use of a DRB scan tool and the proper Di agnosti c
Procedures manual are requi red for further di agno-
si s.
I f the FAI L message i s di spl ayed, the compass
mi ni -tri p computer modul e i s faul ty and must be
repl aced.
I f the BUS message i s di spl ayed, one or more
of the requi red J1850 messages are not present (see
l i st bel ow) and the use of a DRB scan tool and the
proper Di agnosti c Procedures manual are requi red
for further di agnosi s.
I f any VFD segment shoul d fai l to l i ght duri ng
the di spl ay segment test, the compass mi ni -tri p com-
puter modul e i s faul ty and must be repl aced.
(4) I f the fi rst fi ve tests pass, the Compass mi ni -
tri p computer shal l veri fy that al l the requi red J1850
messages are present on the J1850 bus. I f al l
requi red J1850 messages are present on the J1850
bus, or i f the i gni ti on swi tch i s turned to the Off posi -
ti on, the compass mi ni -tri p computer modul e wi l l
automati cal l y return to normal operati on. The
requi red J1850 messages are:
Di mmi ng message
Fuel Used message
Di stance Pul ses message
Percentage Fuel Tank Ful l message
Fuel Type message
VI N (Vehi cl e I denti fi cati on Number)
Vehi cl e Speed message
Engi ne gauge data (Cool ant temperature data)
NOTE: The Fuel Used J1850 message shall be
ignored if the engine type is Diesel or Compressed
Natural Gas.
NOTE: Pressing the STEP or US/M switches during
any portion of the testing procedure will cause the
compass mini-trip computer to exit diagnostics and
return to compass/temperature mode.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earths mag-
netic field strength, based on geographic location.
Refer to Compass Variation Adjustment in the Ser-
vice Procedures section of this group.
NOTE: If the compass reading has blanked out, and
only CAL appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. Refer to Compass
Demagnetizing in the Service Procedures section of
this group.
REMOVAL
cabl e.
l i ner. Refer to Overhead Console i n the Removal
and I nstal l ati on secti on of thi s group for the proce-
dures.
(3) Remove the four screws that secure the com-
pass mi ni -tri p computer modul e to the overhead con-
sol e housi ng (Fi g. 5).
(4) Pul l the compass mi ni -tri p computer modul e
away from the overhead consol e far enough to access
the wi re harness connectors.
(5) Di sengage the overhead consol e wi re harness
connector from the mount on the compass mi ni -tri p
computer modul e housi ng by pushi ng the connector
fi rml y toward the l eft si de of the overhead consol e
housi ng.
(6) Di sconnect the overhead consol e wi re harness
connector from the compass mi ni -tri p computer mod-
ul e connector receptacl e.
(7) Remove the compass mi ni -tri p computer mod-
ul e from the overhead consol e housi ng.
INSTALLATION
(1) Posi ti on the compass mi ni -tri p computer mod-
ul e onto the overhead consol e housi ng.
(2) Reconnect the overhead consol e wi re harness
connector to the compass mi ni -tri p computer modul e
(3) Engage the overhead consol e wi re harness con-
nector onto the mount on the compass mi ni -tri p com-
puter modul e housi ng by al i gni ng the channel s on
the connector wi th the tab on the mount and pushi ng
the connector fi rml y toward the ri ght si de of the
the compass mi ni -tri p computer modul e to the over-
head consol e housi ng. Ti ghten the screws to 2.2 Nm
(20 i n. l bs.).
(5) I nstal l the overhead consol e onto the headl i ner.
Refer to Overhead Console i n the Removal and
NOTE: If a new compass mini-trip computer has
been installed, the compass will have to be cali-
brated and the variance set. Refer to Compass Vari-
ation Adjustment and Compass Calibration in the
Service Procedures section of this group for the
procedures.
AMBIENT TEMP SENSOR
DESCRIPTION
Ambi ent ai r temperature i s moni tored by the com-
pass mi ni -tri p computer modul e through the ambi ent
temperature sensor. The ambi ent temperature sensor
i s a vari abl e resi stor mounted to a bracket that i s
secured wi th a screw to the ri ght si de of the radi ator
yoke, behi nd the radi ator gri l l e and i n front of the
For compl ete ci rcui t di agrams, refer to Wiring
Diagrams. The ambi ent temperature sensor cannot
be adjusted or repai red and, i f faul ty or damaged, i t
must be repl aced.
OPERATION
The ambi ent temperature sensor i s a vari abl e
resi stor that operates on a fi ve-vol t reference si gnal
sent to i t by the HVAC control head uni t. The resi s-
tance i n the sensor changes as temperature changes,
changi ng the temperature sensor si gnal ci rcui t vol t-
age to the HVAC control head uni t. Based upon the
resi stance i n the sensor, the HVAC control head uni t
senses a speci fi c vol tage on the temperature sensor
si gnal ci rcui t, whi ch i t i s programmed to correspond
to a speci fi c temperature.
DIAGNOSIS & TESTING - AMBIENT
TEMPERATURE SENSOR
The thermometer functi on i s supported by the
ambi ent temperature sensor, a wi ri ng ci rcui t, and a
porti on of the HVAC control head uni t.. I f any por-
ti on of the ambi ent temperature sensor ci rcui t fai l s,
the compass/thermometer di spl ay functi on wi l l sel f-
di agnose the ci rcui t. An SC (short ci rcui t) wi l l
appear i n the di spl ay i n pl ace of the temperature,
when the sensor i s exposed to temperatures above
55 C, or i f the sensor ci rcui t i s shorted. An OC
(open ci rcui t) wi l l appear i n the di spl ay i n pl ace of
the temperature, when the sensor i s exposed to tem-
peratures bel ow 40 C, or i f the sensor ci rcui t i s
open.
The ambi ent temperature sensor ci rcui t can al so be
di agnosed usi ng the fol l owi ng Sensor Test, and Sen-
sor Ci rcui t Test. I f the temperature sensor and ci r-
cui t are confi rmed to be OK, but the temperature
di spl ay i s i noperati ve or i ncorrect, refer to Compass
Mini-Trip Computer i n the Di agnosi s and Testi ng
secti on of thi s group. For compl ete ci rcui t di agrams,
refer to Overhead Console i n the Contents of Wi r-
i ng Di agrams.
SENSOR TEST
Di sconnect the ambi ent temperature sensor wi re har-
ness connector.
(2) Measure the resi stance of the ambi ent temper-
ature sensor. At 40 C (40 F), the sensor resi s-
tance i s 336 ki l ohms. At 55 C (131 F), the sensor
resi stance i s 2.488 ki l ohms. The sensor resi stance
shoul d read between these two val ues. I f OK, refer to
Sensor Circuit Test i n the Di agnosi s and Testi ng
Fig. 5 Compass Mini-Trip Computer
1 - COMPASS MINI-TRIP COMPUTER MODULE
2 - OVERHEAD CONSOLE WIRE HARNESS CONNECTOR
3 - OVERHEAD CONSOLE HOUSING
4 - SCREW (4)
5 - COMPUTER CONNECTOR
secti on of thi s group. I f not OK, repl ace the faul ty
ambi ent temperature sensor.
SENSOR CIRCUIT TEST
ness connector and the HVAC control head uni t con-
nector.
(2) Connect a jumper wi re between the two termi -
nal s i n the body hal f of the ambi ent temperature sen-
sor wi re harness connector.
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
ci rcui t cavi ti es of the HVAC control head uni t connec-
tor. There shoul d be conti nui ty. I f OK, go to Step 4. I f
not OK, repai r the open sensor return ci rcui t or
ambi ent temperature sensor si gnal ci rcui t to the
ambi ent temperature sensor as requi red.
(4) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the HVAC
control head uni t connector and a good ground. There
shoul d be no conti nui ty. I f OK, refer to Compass
Mini-Trip Computer i n the Di agnosi s and Testi ng
secti on of thi s group. I f not OK, repai r the shorted
ambi ent temperature sensor si gnal ci rcui t as
requi red.
REMOVAL
cabl e.
(2) Locate the ambi ent temperature sensor, on the
ri ght si de of the radi ator yoke behi nd the gri l l e (Fi g.
6).
ambi ent temperature sensor connector receptacl e.
(4) Remove the one screw that secures the ambi ent
temperature sensor bracket to the radi ator yoke.
(5) Remove the ambi ent temperature sensor from
the radi ator yoke.
INSTALLATION
(1) Posi ti on the ambi ent temperature sensor onto
the radi ator yoke.
the ambi ent temperature sensor bracket to the radi -
ator yoke. Ti ghten the screw to 5.6 Nm (50 i n. l bs.).
(3) Reconnect the wi re harness connector to the
UNIVERSAL TRANSMITTER
DESCRIPTION
On some model s a Uni versal Garage Door Opener
(UGDO) transcei ver i s standard factory-i nstal l ed
equi pment. The UGDO transcei ver i s i ntegral to the
overhead consol e. The onl y vi si bl e component of the
UGDO are the three transmi tter push buttons at the
rear of the overhead consol e. The three UGDO trans-
mi tter push buttons are i denti fi ed wi th one, two or
three rai sed tacti l e bumps so that they be easi l y
i denti fi ed by si ght or by feel .
Each of the three UGDO transmi tter push buttons
control s an i ndependent radi o transmi tter channel .
Each of these three channel s can be trai ned to trans-
mi t a di fferent radi o frequency si gnal for the remote
operati on of garage door openers, motori zed gate
openers, home or offi ce l i ghti ng, securi ty systems or
just about any other devi ce that can be equi pped
wi th a radi o recei ver i n the 286 to 399 MegaHertz
(MHz) frequency range for remote operati on. The
UGDO i s capabl e of operati ng systems usi ng ei ther
rol l i ng code or non-rol l i ng code technol ogy.
The UGDO cannot be repai red, and i s avai l abl e for
servi ce onl y as a uni t. Thi s uni t i ncl udes the push
button swi tches and the pl asti c modul e.
Fig. 6 Ambient Temperature Sensor Remove/Install
1 - YOKE
2 - CONNECTOR
3 - SCREW
4 - SENSOR
AMBIENT TEMP SENSOR (Continued)
OPERATION
The UGDO operates on a non-swi tched source of
battery current so the uni t wi l l remai n functi onal ,
regardl ess of the i gni ti on swi tch posi ti on. For more
i nformati on on the features, programmi ng procedures
and operati on of the UGDO, see the owners manual
i n the vehi cl e gl ove box.
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES
To erase the uni versal transmi tter codes, si mpl y
hol d down the two outsi de buttons unti l the red LED
begi ns to fl ash (Fi g. 7).
NOTE: Individual channels cannot be erased. Eras-
ing the transmitter codes will erase ALL pro-
grammed codes.
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES
(1) Turn off the engi ne.
(2) Erase the factory test codes by pressi ng the
two outsi de buttons. Rel ease the buttons when the
red l i ght begi ns to fl ash (about 20 seconds).
(3) Choose one of the three buttons to trai n. Pl ace
the hand-hel d transmi tter wi thi n one i nch of the uni -
versal transmi tter and push the buttons on both
transmi tters. The red l i ght on the uni versal trans-
mi tter wi l l begi n to fl ash sl owl y.
(4) When the red l i ght on the uni versal transmi t-
ter begi ns to fl ash rapi dl y (thi s may take as l ong as
60 seconds), rel ease both buttons. Your uni versal
transmi tter i s now trai ned. To trai n the other but-
tons, repeat Step 3 and Step 4. Be sure to keep your
hand-hel d transmi tter i n case you need to retrai n the
uni versal transmi tter.
REMOVAL
(1) Remove the overhead consol e from the vehi cl e.
Refer to the procedure i n thi s secti on.
(2) Remove the transmi tter retai ni ng screws.
(3) Di sconnect harness connector from Uni versal
Transmi tter and remove from the overhead consol e.
INSTALLATION
(1) Connect harness connector on Uni versal Trans-
mi tter and i nstal l i n the overhead consol e.
(2) I nstal l the transmi tter retai ni ng screws.
(3) I nstal l the overhead consol e i n the vehi cl e.
Refer to the procedure i n thi s secti on.
Fig. 7 Universal Transmitter
UNIVERSAL TRANSMITTER (Continued)
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 13
POWER SEAT SYSTEM. . . . . . . . . . . . . . . . . . . . . 17
POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 21
POWER LOCKS
TABLE OF CONTENTS
page page
POWER LOCKS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER LOCK & REMOTE KEYLESS
ENTRY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 4
DOOR CYLINDER LOCK SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DOOR CYLINDER LOCK SWITCH . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DRIVER DOOR MODULE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DRIVER DOOR MODULE. . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER LOCK MOTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 9
POWER LOCK SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER LOCK SWITCH. . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOTE KEYLESS ENTRY TRANSMITTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOTE KEYLESS ENTRY TRANSMITTER. . . 12
RKE TRANSMITTER PROGRAMMING . . . . . . . 12
RKE TRANSMITTER BATTERIES . . . . . . . . . . . 12
POWER LOCKS
DESCRIPTION - POWER LOCK SYSTEM
A power l ock system i s opti onal factory-i nstal l ed
equi pment on thi s model . The power l ock system i s
offered onl y on model s that are al so equi pped wi th
power wi ndows. On vehi cl es equi pped wi th power
l ocks, the power l ock motors are control l ed by a
mi croprocessor-based Central Ti mer Modul e (CTM).
The CTM i s used to provi de many el ectroni c features
and conveni ences that are not possi bl e wi th a con-
venti onal hard wi red power l ock system. The CTM
mi croprocessor i s abl e to control power l ock system
operati on based upon the CTM programmi ng and
el ectroni c message i nputs recei ved from other el ec-
troni c modul es i n the vehi cl e over the Programmabl e
Communi cati ons I nterface (PCI ) data bus network,
Radi o Frequency (RF) i nputs recei ved from the
opti onal Remote Keyl ess Entry (RKE) system trans-
mi tters, as wel l as many hard wi red i nputs.
The power l ock system i ncl udes the fol l owi ng
major components, whi ch are descri bed i n further
detai l el sewhere i n thi s servi ce manual :
Modul e (CTM) i s l ocated on the l eft cowl si de i nner
panel under the dri ver si de outboard end of the
i nstrument panel . The CTM contai ns a mi croproces-
sor and software that al l ow i t to provi de the many
AN POWER SYSTEMS 8N - 1
el ectroni c functi ons and features not avai l abl e wi th
conventi onal hard wi red power l ock systems.
Driver Door Module - A power l ock swi tch i s
i ntegral to the dri ver door modul e uni t l ocated near
the forward end of the arm rest on the dri ver si de
front door tri m panel and al l ows the power l ock sys-
tem to be operated by the dri ver.
Power Lock Motors - A reversi bl e el ectri c
motor i ntegral to the door l atch of each door l ocks or
unl ocks the l atches when provi ded wi th the appropri -
ate el ectri cal i nputs.
Power Lock Switch - An i ndi vi dual power l ock
swi tch i s secured to a swi tch bezel near the forward
end of the arm rest on the passenger si de front door
tri m panel and al l ows the power l ock system to be
operated by the front seat passenger.
On those model s equi pped wi th the opti onal Vehi -
cl e Theft Securi ty System (VTSS), the power l ock
system al so i ncl udes the fol l owi ng components, whi ch
are descri bed i n further detai l el sewhere i n thi s ser-
vi ce manual :
Door Cylinder Lock Switches - A resi stor-
mul ti pl exed swi tch l ocated on the back of each front
door l ock cyl i nder al l ows the power door l ock system
to be operated usi ng a key i nserted i n ei ther the
dri ver or passenger front door l ock cyl i nder.
Some of the addi ti onal features of the power l ock
system i n thi s model i ncl ude:
Automatic Door Lock - The CTM provi des an
opti onal automati c door l ock feature (al so known as
rol l i ng door l ocks). Thi s i s a programmabl e feature.
Central Locking - On model s al so equi pped
wi th the opti onal VTSS (i ncl udes door cyl i nder l ock
swi tches), the CTM provi des an opti onal central l ock-
i ng/unl ocki ng feature.
Door Lock Inhibit - The CTM provi des a door
l ock i nhi bi t feature.
Enhanced Accident Response - The CTM pro-
vi des an opti onal enhanced acci dent response fea-
ture. Thi s i s a programmabl e feature.
Hard wi red ci rcui try connects the power l ock sys-
tem components to the el ectri cal system of the vehi -
cl e. These hard wi red ci rcui ts are i ntegral to several
wi re harnesses, whi ch are routed throughout the
vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the power l ock sys-
tem components through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
Many of the el ectroni c features i n the vehi cl e con-
trol l ed or supported by the CTM are programmabl e
usi ng the DRBI I I scan tool . I n addi ti on, the CTM
software i s Fl ash compati bl e, whi ch means i t can be
reprogrammed usi ng Fl ash reprogrammi ng proce-
dures. However, i f any of the CTM hardware compo-
nents are damaged or faul ty, the enti re CTM uni t
must be repl aced. The power l ock system components
and the hard wi red i nputs or outputs of the CTM can
be di agnosed usi ng conventi onal di agnosti c tool s and
methods; however, for di agnosi s of the CTM or the
PCI data bus, the use of a DRBI I I scan tool i s
mati on.
DESCRIPTION - REMOTE KEYLESS ENTRY
SYSTEM
A Remote Keyl ess Entry (RKE) system i s an avai l -
abl e opti on on thi s model when i t i s equi pped wi th
the opti onal power l ock system. The RKE system i s a
Radi o Frequency (RF) system that al l ows the remote
operati on of the power l ock system and, i f the vehi cl e
i s so equi pped, the Vehi cl e Theft Securi ty System
(VTSS). (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY - DESCRI PTI ON). The RKE sys-
tem i ncl udes the fol l owi ng major components, whi ch
vi ce manual :
sor, an RF recei ver, and the software that al l ow i t to
provi de the many el ectroni c functi ons and features of
the RKE system.
Keyless Entry Transmitter - The keyl ess
entry transmi tter i s a smal l , battery-powered, RF
transmi tter that i s contai ned wi thi n a mol ded pl asti c
case that i s desi gned to al so serve as a conveni ent
key fob.
Some addi ti onal features of the RKE system
i ncl ude:
Driver Door Unlock Only - Thi s i s a program-
mabl e feature on quad cab model s onl y, whi ch al l ows
the opti on of havi ng a si ngl e press of the RKE trans-
mi tter Unl ock button unl ock onl y the dri ver door, or
al l doors. I f the dri ver door onl y opti on i s sel ected, a
second press of the Unl ock button wi l l unl ock the
remai ni ng doors.
Horn Chirp - Thi s feature provi des a short,
sharp chi rp of the vehi cl e horn to gi ve an audi bl e
confi rmati on that a val i d Lock si gnal has been
recei ved from the RKE transmi tter. Thi s feature can
be enabl ed or di sabl ed and, i f enabl ed, one of two
opti onal horn chi rp durati ons (twenty or forty mi l l i -
seconds) can al so be sel ected.
8N - 2 POWER LOCKS AN
POWER LOCKS (Continued)
Illuminated Entry - Thi s feature turns on the
courtesy l amps i n the vehi cl e for a ti med i nterval
(about thi rty seconds) each ti me a val i d Unl ock si g-
nal has been recei ved from the RKE transmi tter.
Optical Chirp - Thi s feature provi des a fl ash of
the vehi cl e park l amps to gi ve an opti cal confi rma-
ti on that a val i d Lock or Unl ock si gnal has been
recei ved from the RKE transmi tter. The l amps fl ash
once for a Lock si gnal , and twi ce for an Unl ock si g-
nal . Thi s feature can be enabl ed or di sabl ed.
Panic Mode - Thi s feature al l ows the vehi cl e
operator to cause the vehi cl e horn to pul se and head-
l i ghts to fl ash for about three mi nutes, and the cour-
tesy l amps to i l l umi nate for about thi rty seconds by
depressi ng a Pani c button on the RKE transmi tter.
Pressi ng the Pani c button a second ti me wi l l cancel
the Pani c mode. A vehi cl e speed of about 24 ki l ome-
ters-per-hour (15 mi l es-per-hour) wi l l al so cancel the
pani c mode.
OPERATION - POWER LOCK SYSTEM
The power l ock system al l ows al l doors to be l ocked
or unl ocked el ectri cal l y by operati ng the power l ock
swi tch on ei ther front door tri m panel . On vehi cl es
that are al so equi pped wi th the opti onal Remote Key-
l ess Entry (RKE) system the power l ocks can al so be
operated usi ng the RKE transmi tter, and on vehi cl es
that are equi pped wi th the opti onal Vehi cl e Theft
Securi ty System (VTSS) the power l ocks can al so be
operated usi ng a key i n ei ther front door or the l i ft-
gate l ock cyl i nder. I f certai n features of the power
l ock system have been el ectroni cal l y enabl ed, the
power l ocks may al so be operated automati cal l y by
the Central Ti mer Modul e (CTM) based upon vari ous
other i nputs. Those features and thei r i nputs are:
Automatic Door Lock - I f enabl ed, the CTM
wi l l automati cal l y l ock the doors when i t recei ves a
message from the Powertrai n Control Modul e (PCM)
i ndi cati ng that the vehi cl e speed i s about 24 ki l ome-
ters-per-hour (15 mi l es-per-hour) or greater. The
CTM al so moni tors the door ajar swi tches, and wi l l
not acti vate the automati c door l ock feature unti l al l
doors have been cl osed for at l east fi ve seconds. I f
thi s feature i s enabl ed and a door i s opened after the
vehi cl e i s movi ng at 24 ki l ometers-per-hour (15
mi l es-per-hour) or greater, the CTM wi l l l ock the
doors agai n fi ve seconds after al l doors are agai n
cl osed.
Central Locking - Vehi cl es equi pped wi th the
opti onal VTSS al so have a resi stor-mul ti pl exed door
cyl i nder l ock swi tch mounted to the back of the l ock
cyl i nder wi thi n each front door. The CTM conti nual l y
moni tors the i nput from these swi tches to provi de the
central l ocki ng/unl ocki ng feature. The CTM wi l l
automati cal l y l ock or unl ock al l doors when ei ther
front door i s l ocked or unl ocked usi ng a key.
Door Lock Inhibit - The CTM recei ves i nputs
from the key-i n i gni ti on swi tch, the headl amp swi tch,
and the door ajar swi tches. The l ogi c wi thi n the CTM
al l ows i t to moni tor these i nputs to provi de a door
l ock i nhi bi t feature. The door l ock i nhi bi t feature pre-
vents the power l ock system from bei ng energi zed
wi th a power l ock swi tch i nput i f the dri ver door i s
open wi th the headl amps on or the key sti l l i n the
i gni ti on swi tch. However, the l ocks can sti l l be oper-
ated wi th the manual door l ock button or wi th a key
i n the door l ock cyl i nder, and the power l ocks wi l l
sti l l operate usi ng the RKE transmi tter whi l e the
dri ver door i s open wi th the headl amps on or a key
i n the i gni ti on.
Enhanced Accident Response - I f enabl ed,
the CTM provi des an enhanced acci dent response
feature. Thi s feature uses el ectroni c message i nputs
recei ved by the CTM from the Ai rbag Control Modul e
(ACM) to determi ne when an ai rbag has been
depl oyed. The CTM al so moni tors the state of the
power l ock system and the vehi cl e speed messages
from the PCM i n order to provi de thi s feature. I f an
ai rbag has been depl oyed and the vehi cl e has stopped
movi ng, the CTM wi l l automati cal l y unl ock the
doors, prevent the doors from bei ng l ocked, and turn
on the courtesy l amps i nsi de the vehi cl e. Of course,
these responses are dependent upon a functi onal bat-
tery and el ectri cal ci rcui try fol l owi ng the i mpact.
The power l ock system operates on battery current
recei ved through a fused B(+) ci rcui t from a fuse i n
the Juncti on Bl ock (JB) so that the system remai ns
functi onal , regardl ess of the i gni ti on swi tch posi ti on.
Al so, each power l ock swi tch operates i ndependent of
the other and recei ves ground through a si ngl e wi re
take out of the body wi re harness wi th an eyel et ter-
mi nal connector that i s secured by a ground screw to
the l ower l eft B-pi l l ar. The power l ock swi tches di rect
a resi stor mul ti pl exed ground Lock or Unl ock request
si gnal to the CTM, and the CTM energi zes i nternal
rel ays to di rect the appropri ate battery current and
ground feeds to the i ndi vi dual power l ock motors.
OPERATION - REMOTE KEYLESS ENTRY
SYSTEM
On vehi cl es wi th the Remote Keyl ess Entry (RKE)
system, the power l ocks can be operated remotel y
usi ng the RKE transmi tter. I f the vehi cl e i s so
equi pped, the RKE transmi tter al so arms and di s-
arms the factory-i nstal l ed Vehi cl e Theft Securi ty Sys-
tem (VTSS). Three smal l , recessed buttons on the
outsi de of the transmi tter case l abel l ed Lock, Unl ock,
and Pani c al l ow the user to choose the functi on that
i s desi red. The RKE transmi tter then sends the
appropri ate Radi o Frequency (RF) si gnal . An RF
recei ver that i s i ntegral to the Central Ti mer Modul e
(CTM) recei ves the transmi tted si gnal , whi ch then
AN POWER LOCKS 8N - 3
uses i ts i nternal el ectroni c programmi ng to deter-
mi ne whether the recei ved si gnal i s val i d and what
functi on has been requested. I f the si gnal i s val i d,
the CTM then provi des the programmed features.
Besi des operati ng the power l ock system and arm-
i ng or di sarmi ng the VTSS, the RKE system al so
control s the fol l owi ng features:
Driver Door Unlock Only - On quad cab mod-
el s onl y, i f thi s feature i s enabl ed, the CTM unl ocks
onl y the dri ver si de front door upon recei pt of a fi rst
val i d Unl ock si gnal through a separate i nternal rel ay
and control outputs to the dri ver si de front door
power l ock motor. Then upon recei pt of a second val i d
Unl ock si gnal , the CTM unl ocks al l of the remai ni ng
doors through a separate i nternal rel ay and control
ci rcui ts for those power l ock motors.
Horn Chirp - I f thi s feature i s enabl ed, the
CTM provi des a horn chi rp by i nternal l y pul l i ng the
control coi l of the horn rel ay to ground through a
hard wi red ci rcui t output.
Illuminated Entry - The CTM provi des i l l umi -
nated entry by i nternal l y control l i ng the current fl ow
to the courtesy l amps i n the vehi cl e through a hard
wi red output ci rcui t.
Optical Chirp - I f thi s feature i s enabl ed, the
CTM provi des fl ashes of the park l amps by i nternal l y
pul l i ng the control coi l of the park l amp rel ay to
ground through a hard wi red ci rcui t output.
Panic Mode - The CTM provi des the horn pul se
by i nternal l y pul l i ng the control coi l of the horn rel ay
through a hard wi red ci rcui t output, then fl ashes the
headl amps and i l l umi nates the courtesy l amps
through i ts i nternal hi gh si de control of these ci r-
cui ts. The CTM al so moni tors the vehi cl e speed
through el ectroni c messages i t recei ves from the
mabl e Communi cati ons I nterface (PCI ) data bus net-
work.
The RKE system operates on battery current
recei ved through a fused B(+) ci rcui t from a fuse i n
the Juncti on Bl ock (JB) so that the system remai ns
functi onal , regardl ess of the i gni ti on swi tch posi ti on.
The RKE system can retai n the vehi cl e access codes
of up to four RKE transmi tters. The transmi tter
codes are retai ned i n RKE system memory, even i f
the battery i s di sconnected. I f a transmi tter i s faul ty
or i s l ost, new transmi tter vehi cl e access codes can be
programmed i nto the system usi ng a DRBI I I scan
Many of the el ectroni c features i n the vehi cl e con-
trol l ed or supported by the CTM are programmabl e
usi ng the DRBI I I scan tool . I n addi ti on, the CTM
software i s Fl ash compati bl e, whi ch means i t can be
reprogrammed usi ng Fl ash reprogrammi ng proce-
dures. However, i f any of the CTM hardware compo-
nents are damaged or faul ty, the enti re CTM uni t
must be repl aced. The hard wi red i nputs or outputs
of the CTM can be di agnosed usi ng conventi onal
di agnosti c tool s and methods; however, for di agnosi s
of the CTM or the PCI data bus, the use of a
DIAGNOSIS AND TESTING - POWER LOCK &
REMOTE KEYLESS ENTRY SYSTEM
These tests wi l l hel p to di agnose the hard wi red
components and ci rcui ts of the power l ock system.
However, these tests may not prove concl usi ve i n the
di agnosi s of thi s system. I n order to obtai n concl usi ve
testi ng of the power l ock and RKE systems, the Pro-
grammabl e Communi cati on I nterface (PCI ) data bus
network and al l of the el ectroni c modul es that pro-
vi de i nputs to, or recei ve outputs from the power l ock
and RKE system components must be checked.
The most rel i abl e, effi ci ent, and accurate means to
di agnose the power l ock and RKE systems requi res
the use of a DRBI I I scan tool . The DRBI I I scan
tool can provi de confi rmati on that the PCI data bus
i s functi onal , that al l of the el ectroni c modul es are
sendi ng and recei vi ng the proper messages on the
PCI data bus, that the Central Ti mer Modul e (CTM)
i s recei vi ng the proper hard wi red i nputs, and that
the power l ock motors are bei ng sent the proper hard
wi red outputs by the CTM.
PRELIMINARY TESTS
To begi n thi s test, note the system operati on whi l e
you actuate both the Lock and Unl ock functi ons wi th
the power l ock swi tches, the door cyl i nder l ock
swi tches (i f equi pped wi th the opti onal Vehi cl e Theft
Securi ty System (VTSS), and the RKE transmi tter.
Then, proceed as fol l ows:
I f the enti re power l ock system fai l s to functi on
wi th the power l ock swi tches, the door cyl i nder l ock
swi tches, or the RKE transmi tter, check the fused
B(+) fuse i n the Juncti on Bl ock (JB). I f the fuse i s
OK, proceed to the di agnosi s of the power l ock
motors. (Refer to 8 - ELECTRI CAL/POWER LOCKS/
POWER LOCK MOTOR - DI AGNOSI S AND TEST-
I NG).
I f the power l ock system functi ons wi th both
power l ock swi tches, and both the door cyl i nder l ock
swi tches, but not wi th the RKE transmi tter, proceed
to the di agnosi s of the transmi tter. (Refer to 8 -
ELECTRI CAL/POWER LOCKS/REMOTE KEYLESS
ENTRY TRANSMI TTER - DI AGNOSI S AND TEST-
I NG).
I f the enti re power l ock system functi ons wi th
the RKE transmi tter, and both door cyl i nder l ock
swi tches, but not wi th one or both of the power l ock
swi tches, proceed to di agnosi s of the Dri ver Door
Modul e (DDM) for the dri ver si de swi tch or to power
l ock swi tch for the passenger si de swi tch. (Refer to 8
- ELECTRI CAL/POWER LOCKS/DRI VER DOOR
MODULE - DI AGNOSI S AND TESTI NG) and/or
(Refer to 8 - ELECTRI CAL/POWER LOCKS/POWER
LOCK SWI TCH - DI AGNOSI S AND TESTI NG).
I f the enti re power l ock system functi ons wi th
the RKE transmi tter, and both power l ock swi tches,
but not wi th one or al l of the door cyl i nder l ock
swi tches, proceed to di agnosi s of the door cyl i nder
l ock swi tches. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/DOOR CYLI NDER LOCK SWI TCH - DI AG-
NOSI S AND TESTI NG).
I f one power l ock motor fai l s to operate wi th
both of the power l ock swi tches, al l of the door cyl i n-
der l ock swi tches, and/or the RKE transmi tter, pro-
ceed to di agnosi s of the power l ock motor. (Refer to 8
- ELECTRI CAL/POWER LOCKS/POWER LOCK
MOTOR - DI AGNOSI S AND TESTI NG).
I f the probl em bei ng di agnosed i s rel ated to one or
more of the el ectroni c features (automati c l ocks,
dri ver door unl ock onl y, door l ock i nhi bi t, enhanced
acci dent response, i l l umi nated entry, pani c mode,
RKE horn chi rp, or RKE opti cal chi rp), further di ag-
nosi s shoul d be performed usi ng a DRBI I I scan tool .
DOOR CYLINDER LOCK
SWITCH
DESCRIPTION
A door cyl i nder l ock swi tch i s snapped onto the
back of the key l ock cyl i nder i nsi de each front door.
The door cyl i nder l ock swi tch i s a resi stor mul ti -
pl exed momentary swi tch that i s hard wi red i n seri es
between a body ground and the Central Ti mer Mod-
ul e (CTM) through the front door wi re harness. The
door cyl i nder l ock swi tches are dri ven by the key l ock
cyl i nders and contai n three i nternal resi stors. One
resi stor i s used for the neutral swi tch posi ti on, one
for the Lock posi ti on, and one for the Unl ock posi -
ti on.
The door cyl i nder l ock swi tches cannot be adjusted
or repai red and, i f faul ty or damaged, they must be
repl aced.
OPERATION
The door cyl i nder l ock swi tches are actuated by the
key l ock cyl i nder when the key i s i nserted i n the l ock
cyl i nder and turned to the l ock or unl ock posi ti ons.
The door cyl i nder l ock swi tch cl oses a path to ground
through one of three i nternal resi stors for the Cen-
tral Ti mer Modul e (CTM) when the front door key
l ock cyl i nder i s i n the Lock, Unl ock, or Neutral posi -
ti ons. The CTM reads the swi tch status through an
i nternal pul l -up, then uses thi s i nformati on as an
i nput for both power l ock system and Vehi cl e Theft
Securi ty System (VTSS) operati on.
The door cyl i nder l ock swi tches and ci rcui ts can be
methods.
DIAGNOSIS AND TESTING - DOOR CYLINDER
LOCK SWITCH
(1) Di sconnect the door cyl i nder l ock swi tch pi gtai l
wi re connector from the door wi re harness connector.
(2) Usi ng an ohmmeter, perform the swi tch resi s-
tance checks between the two cavi ti es of the door cyl -
i nder l ock swi tch pi gtai l wi re connector. Actuate the
swi tch by rotati ng the key i n the door l ock cyl i nder
to test for the proper resi stance val ues i n each of the
three swi tch posi ti ons, as shown i n the Door Cyl i nder
Lock Swi tch chart.
DOOR CYLINDER LOCK SWITCH
Switch Position
Resistance
Driver Side Passenger Side
Neutral Neutral 12 Kilohms
Lock (Clockwise)
Lock (Counter
Clockwise)
644 Ohms
Unlock (Counter
Clockwise)
Unlock
(Clockwise)
1565 Ohms
(3) I f a door cyl i nder l ock swi tch fai l s any of the
resi stance tests, repl ace the faul ty swi tch as
requi red.
REMOVAL
cabl e.
(2) Remove the door outsi de l atch handl e mount-
i ng hardware and l i nkage from the i nsi de of the door.
(Refer to 23 - BODY/DOOR - FRONT/EXTERI OR
HANDLE - REMOVAL).
(3) From the outsi de of the door, pul l the door out-
si de l atch handl e out from the door far enough to
access the door cyl i nder l ock swi tch (Fi g. 1).
(4) Di sengage the door cyl i nder l ock swi tch from
the back of the l ock cyl i nder.
(5) Di sconnect the door cyl i nder l ock swi tch pi gtai l
wi re connector from the door wi re harness connector.
(6) Di sengage the retai ners that secure the door
cyl i nder l ock swi tch pi gtai l wi re harness to the i nner
door panel .
(7) Remove the door cyl i nder l ock swi tch from the
door.
INSTALLATION
(1) Posi ti on the door cyl i nder l ock swi tch i nto the
door (Fi g. 1).
(2) Engage the retai ners that secure the door cyl -
i nder l ock swi tch pi gtai l wi re harness to the i nner
door panel .
(3) Reconnect the door cyl i nder l ock swi tch pi gtai l
wi re connector to the door wi re harness connector.
(4) Rei nstal l the door cyl i nder l ock swi tch onto the
back of the l ock cyl i nder.
(5) Rei nstal l the door outsi de l atch handl e mount-
i ng hardware and l i nkage on the i nsi de of the door.
(Refer to 23 - BODY/DOOR - FRONT/EXTERI OR
HANDLE - I NSTALLATI ON).
DRIVER DOOR MODULE
DESCRIPTION
A Dri ver Door Modul e (DDM) i s used on al l model s
equi pped wi th power l ocks, power wi ndows, and
power mi rrors. The dri ver door modul e consi sts of a
mol ded pl asti c housi ng that i s secured wi th three
screws to a mol ded pl asti c swi tch bezel . The swi tch
bezel i s secured by metal snap cl i ps wi thi n an open-
i ng near the forward end of the arm rest i n the
dri ver si de front door tri m panel so that the DDM
can be servi ced wi thout removi ng the front door tri m
panel . Two i ntegral connector receptacl es on the back
of the DDM connect i t to the vehi cl e el ectri cal system
through two take outs and connectors of the l eft front
door wi re harness. The DDM houses the fol l owi ng
swi tches:
Power Lock Switch - The DDM i ncl udes a
two-way, momentary, resi stor mul ti pl exed swi tch to
control the power l ock system.
Power Mirror Selector Switch - A three-posi -
ti on rocker swi tch i n the DDM sel ects the ri ght or
l eft power mi rror for adjustment, or turns the power
mi rror system Off.
Power Mirror Adjustment Switches - Four
momentary, arrowhead shaped, di recti onal swi tches
al l ow the dri ver to adjust the sel ected power mi rror
i n the Up, Down, Ri ght, or Left di recti ons.
Power Window Lockout Switch - A two-way,
l atchi ng, push-button swi tch i n the DDM al l ows the
vehi cl e operator to l ock out the power wi ndow
swi tches on each passenger door so that the passen-
ger door power wi ndows may be operated onl y from
the master swi tches i n the DDM.
Power Window Switches - The DDM houses a
two-way, momentary power wi ndow swi tch for the
dri ver si de front door. Thi s swi tch al so has a second
detent i n the Down di recti on and i nternal ci rcui try to
provi de an Auto-Down feature for the dri ver si de
front door power wi ndow. I n addi ti on to the power
wi ndow swi tch for i ts own door, the DDM houses
i ndi vi dual master swi tches for each passenger door
power wi ndow.
The DDM al so i ncorporates several green Li ght-
Emi tti ng Di odes (LEDs) that i l l umi nate the power
Fig. 1 Door Cylinder Lock Switch - Typical
1 - DOOR OUTSIDE LATCH HANDLE
2 - DOOR
3 - DOOR CYLINDER LOCK SWITCH
4 - CONNECTOR
5 - RETAINERS
DOOR CYLINDER LOCK SWITCH (Continued)
l ock and power wi ndow swi tch paddl es, and the
power mi rror swi tch di recti onal buttons to i mprove
swi tch vi si bi l i ty i n dark ambi ent l i ghti ng condi ti ons.
The DDM cannot be adjusted or repai red and, i f
faul ty or damaged, the enti re DDM uni t must be
repl aced.
OPERATION
The Dri ver Door Modul e (DDM) combi nes a power
l ock swi tch, a dri ver power wi ndow swi tch wi th an
Auto-down feature, master swi tches for each passen-
ger door power wi ndow, a power wi ndow l ockout
swi tch, a power mi rror sel ector swi tch, and four
power mi rror adjustment swi tches i n a si ngl e uni t.
The swi tches i n the DDM can be di agnosed usi ng
conventi onal di agnosti c tool s and methods.
Power Lock Switch
The DDM power l ock swi tch ci rcui try i s connected
i n seri es between ground and the dri ver door swi tch
mux i nput of the Central Ti mer Modul e (CTM). Each
power l ock swi tch posi ti on (Lock, Unl ock, and Neu-
tral ) provi des a di fferent resi stance val ue to the CTM
i nput, whi ch al l ows the CTM to sense the swi tch
posi ti on. Based upon the power l ock swi tch i nput, the
CTM control s the battery and ground feed outputs to
the i ndi vi dual power l ock motors to l ock or unl ock
the door and l i ftgate l atches. The Li ght-Emi tti ng
Di ode (LED) i n the DDM power l ock swi tch i s con-
nected to battery current through the power wi ndow
ci rcui t breaker i n the Juncti on Bl ock (JB) on a fused
i gni ti on swi tch output (run-acc) ci rcui t so that the
swi tch wi l l be i l l umi nated whenever the i gni ti on
swi tch i s i n the On or Accessory posi ti ons.
Power Window Switches
The DDM power wi ndow swi tch ci rcui try i s con-
nected to battery current through a ci rcui t breaker i n
the Juncti on Bl ock (JB) on a fused i gni ti on swi tch
output (run-acc) ci rcui t so that the power wi ndows
wi l l operate whenever the i gni ti on swi tch i s i n the
On or Accessory posi ti ons. Each two-way, momentary
master passenger power wi ndow swi tch i n the DDM
provi des battery current and ground to the i ndi vi dual
power wi ndow swi tches on each passenger door so
that the power wi ndow swi tch control s the battery
current and ground feeds to i ts respecti ve power wi n-
dow motor. The DDM swi tch for the dri ver si de front
door power wi ndow i s l abel ed wi th the text Auto
and i ncl udes an auto-down feature. When thi s swi tch
i s depressed to a second momentary detent posi ti on
and rel eased, the dri ver door power wi ndow i s auto-
mati cal l y operated through an i nternal ci rcui t and
rel ay to i ts ful l y l owered posi ti on. The Auto-down
event i s cancel l ed i f the swi tch paddl e i s depressed a
second ti me i n ei ther the Up or Down di recti on.
When the two posi ti on wi ndow l ockout swi tch i n the
DDM i s depressed and l atched i n the l ockout posi -
ti on, the battery current feed to each of the i ndi vi d-
ual passenger power wi ndow swi tches i s i nterrupted
so that the passenger door power wi ndows can onl y
be operated from the master swi tches i n the DDM.
The wi ndow l ockout swi tch al so control s the battery
current feed for the LED i n each passenger power
wi ndow swi tch so that the swi tch wi l l not be i l l umi -
nated when i t i s l ocked out.
Power Mirror Switches
The DDM power mi rror swi tch ci rcui try i s con-
nected to battery current through a fuse i n the JB on
a fused B(+) ci rcui t so that the power mi rrors remai n
operati onal regardl ess of the i gni ti on swi tch posi ti on.
A rocker type sel ector swi tch has three posi ti ons, one
to sel ect the ri ght mi rror, one to sel ect the l eft mi r-
ror, and a neutral Off posi ti on. After the ri ght or l eft
mi rror i s sel ected, one of four di recti onal buttons i s
depressed to move the sel ected mi rror Up, Down,
Ri ght or Left. The DDM power mi rror swi tch ci r-
cui try control s the battery current and ground feeds
to each of the four (two i n each mi rror head) power
mi rror motors. The Li ght-Emi tti ng Di ode (LED) i n
the DDM power mi rror swi tch i s connected to battery
current through the power wi ndow ci rcui t breaker i n
the Juncti on Bl ock (JB) on a fused i gni ti on swi tch
output (run-acc) ci rcui t so that the swi tch di recti onal
buttons wi l l be i l l umi nated whenever the i gni ti on
swi tch i s i n the On or Accessory posi ti ons.
DIAGNOSIS AND TESTING - DRIVER DOOR
MODULE
The Li ght-Emi tti ng Di ode (LED) i l l umi nati on
l amps for al l of the Dri ver Door Modul e (DDM)
power wi ndow, power l ock, and power mi rror
swi tches recei ve battery current through the power
wi ndow ci rcui t breaker i n the Juncti on Bl ock (JB). I f
al l of the LEDs are i noperati ve i n the DDM, be cer-
tai n to di agnose the power wi ndow system before
repl aci ng the swi tch uni t. (Refer to 8 - ELECTRI -
CAL/POWER WI NDOWS - DI AGNOSI S AND TEST-
I NG). I f onl y one LED i n the DDM i s i noperati ve,
repl ace the faul ty DDM. I f the dri ver si de front door
power wi ndow operates i n a normal manner, but the
Auto-Down feature i s i noperati ve, repl ace the faul ty
DDM. Refer to the appropri ate wi ri ng i nformati on.
cabl e. Remove the DDM from the door tri m panel .
DRIVER DOOR MODULE (Continued)
Di sconnect the door wi re harness connectors for the
DDM from the DDM connector receptacl es.
(2) Test the DDM swi tch conti nui ty. See the Dri ver
Door Modul e Swi tch Tests chart to determi ne i f the
conti nui ty i s correct for the suspect swi tches i n each
swi tch posi ti on (Fi g. 2) and/or (Fi g. 3). I f not OK,
repl ace the faul ty DDM as requi red.
DRIVER DOOR MODULE SWITCH TESTS
POWER LOCK SWITCH
SWITCH POSITION
RESISTANCE BETWEEN
CONNECTOR C-1 PINS
7 & 11
NEUTRAL 10 KILOHMS 1%
LOCK 820 OHMS 1%
UNLOCK 320 OHMS 1%
POWER MIRROR SWITCH
SWITCH POSITION
CONTINUITY BETWEEN
PINS OF CONNECTOR
C-2
LEFT MIRROR SELECTED
UP PINS 1 & 3
DOWN PINS 2 & 3
RIGHT PINS 2 & 3
LEFT PINS 3 & 6
RIGHT MIRROR SELECTED
UP PINS 3 & 7
DOWN PINS 2 & 3
RIGHT PINS 2 & 3
LEFT PINS 3 & 4
POWER WINDOW SWITCH
PINS OF CONNECTOR
C-1
NEUTRAL PINS 1 & 8, PINS 2 & 8,
PINS 3 & 8, PINS 4 & 8,
PINS 5 & 8, PINS 6 & 8,
PINS 8 & 10, PINS 8 &
12
LEFT FRONT UP PINS 5 & 9
LEFT FRONT DOWN PINS 9 & 12
RIGHT FRONT UP PINS 3 & 9
RIGHT FRONT DOWN PINS 6 & 9
LEFT REAR UP PINS 4 & 9
LEFT REAR DOWN PINS 9 & 10
RIGHT REAR UP PINS 2 & 9
RIGHT REAR DOWN PINS 1 & 9
POWER WINDOW LOCKOUT SWITCH
OFF (SWITCH BUTTON
RAISED - NOT
DEPRESSED)
PIN 9 OF CONNECTOR
C-1 & PIN 8 OF
CONNECTOR C-2
Fig. 2 Driver Door Module Connector C1 Receptacle
Fig. 3 Driver Door Module Connector C2 Receptacle
REMOVAL
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de fl at
bl aded tool and starti ng at the rear of the Dri ver
Door Modul e (DDM) bezel , gentl y pry the DDM up
and out from the dri ver si de front door tri m panel
(Fi g. 4).
(3) Pul l the DDM away from the tri m panel open-
i ng far enough to access the two connector recepta-
cl es on the back of the uni t.
(4) Di sconnect the two door wi re harness connec-
tors for the DDM from the DDM connector recepta-
cl es.
(5) Remove the DDM from the door tri m panel .
INSTALLATION
(1) Posi ti on the Dri ver Door Modul e (DDM) to the
openi ng i n the dri ver si de front door tri m panel .
(2) Reconnect the two door wi re harness connec-
tors for the DDM to the DDM connector receptacl es.
(3) I nsert the front of the DDM bezel i nto the
openi ng i n the dri ver si de front door tri m panel (Fi g.
4).
(4) Usi ng hand pressure, gentl y and evenl y press
down on the rear of the DDM bezel unti l i t snaps
i nto pl ace.
POWER LOCK MOTOR
DESCRIPTION
Model s equi pped wi th the opti onal power l ock sys-
tem have a power operated l ocki ng mechani sm
l ocated wi thi n each door. The l ock mechani sms are
actuated by a reversi bl e el ectri c power l ock motor.
Thi s motor i s i ntegral to the door l atch uni t wi thi n
each door. A si ngl e short pi gtai l wi re wi th a mol ded
pl asti c connector i nsul ator connects each l ock motor
to the vehi cl e el ectri cal system through a take out
and connector of the wi re harness wi thi n each door.
The power l ock motors cannot be adjusted or
repai red and, i f faul ty or damaged, the enti re door
l atch uni t must be repl aced.
OPERATION
The dri ver si de front door power l ock motor i s con-
trol l ed by a uni que dri ver unl ock rel ay output of the
Central Ti mer Modul e (CTM), whi l e the remai ni ng
power l ock motors are al l connected i n paral l el and
share common CTM l ock and unl ock rel ay outputs.
The dri ver si de front door power l ock motor al so
shares the common l ock rel ay output from the CTM.
Thi s ci rcui t arrangement makes the Remote Keyl ess
Entry (RKE) system dri ver door unl ock onl y feature
opti on for quad cab model s possi bl e. A posi ti ve and
negati ve battery connecti on to the two power l ock
motor termi nal s wi l l cause the power l ock motor
pl unger to move i n one di recti on. Reversi ng the cur-
rent through these same two connecti ons wi l l cause
the power l ock motor pl unger to move i n the opposi te
di recti on. The power l ock motors and ci rcui ts can be
tested usi ng conventi onal di agnosti c tool s and meth-
ods.
DIAGNOSIS AND TESTING - POWER LOCK
MOTOR
Before you proceed wi th thi s di agnosi s, confi rm
proper power l ock swi tch, Central Ti mer Modul e
(CTM), and power l ock swi tch output ci rcui t opera-
ti on. Remember, the CTM ci rcui try control s the out-
put to each of the power l ock motors. Refer to the
(1) Check each power l ock motor for correct opera-
ti on whi l e movi ng the power l ock swi tch to both the
Lock and Unl ock posi ti ons. I f al l of the power l ock
motors are i noperati ve, go to Step 2. I f one power
l ock motor i s i noperati ve, go to Step 3.
(2) I f al l of the power l ock motors are i noperati ve,
the probl em may be caused by one shorted motor.
Di sconnecti ng a shorted power l ock motor from the
power l ock ci rcui t wi l l al l ow the good power l ock
motor to operate. Di sconnect the wi re harness con-
nector from each power l ock motor, one at a ti me,
and recheck both the l ock and unl ock functi ons by
operati ng the power l ock swi tch. I f al l of the power
l ock motors are sti l l i noperati ve after the above test,
check for a short or open ci rcui t between the power
Fig. 4 Driver Door Module
l ock motors and the CTM. I f di sconnecti ng one power
l ock motor causes the other motors to become func-
ti onal , go to Step 3 to test the di sconnected motor.
(3) Once i t has been determi ned whi ch power l ock
motor i s i noperati ve, that motor can be tested as fol -
l ows. Di sconnect the wi re harness connector from the
i noperati ve power l ock motor. Appl y 12 vol ts to the
l ock and unl ock dri ver ci rcui t cavi ti es of the power
l ock motor pi gtai l wi re connector to check i ts opera-
ti on i n one di recti on. Reverse the pol ari ty to check
the motor operati on i n the opposi te di recti on. I f OK,
repai r the shorted or open l ock or unl ock dri ver ci r-
cui ts between the power l ock motor and the CTM as
requi red. I f not OK, repl ace the faul ty power l ock
motor.
POWER LOCK SWITCH
DESCRIPTION
The power l ock system can be control l ed by a two-
way, momentary, resi stor mul ti pl exed, si ngl e gang
swi tch on a power l ock and wi ndow swi tch bezel
l ocated near the forward end of the armrest on the
passenger si de front door tri m panel . The power l ock
swi tch on the dri ver si de front door tri m panel i s
i ntegral to the dri ver door modul e. (Refer to 8 -
ELECTRI CAL/POWER LOCKS/DRI VER DOOR
MODULE - DESCRI PTI ON). The power l ock swi tch
i s secured by i ntegral l atch tabs i n a mol ded pl asti c
receptacl e on the back si de of the power wi ndow and
l ock swi tch bezel so that onl y the swi tch paddl e i s
vi si bl e where i t protrudes through the bezel . The
power wi ndow and l ock swi tch bezel i s secured by
smal l metal snap cl i ps wi thi n an openi ng near the
forward end of the arm rest i n the passenger si de
front door tri m panel so that the swi tches can be ser-
vi ced wi thout removi ng the front door tri m panel . An
i ntegral connector receptacl e on the back of the
swi tch connects i t to the vehi cl e el ectri cal system
through a take out and connector of the ri ght front
door wi re harness. The power l ock swi tch has a green
Li ght-Emi tti ng Di ode (LED) l ocated i n the swi tch
paddl e to i mprove swi tch vi si bi l i ty i n dark ambi ent
l i ghti ng condi ti ons. The power l ock swi tch cannot be
adjusted or repai red and, i f faul ty or damaged, the
swi tch uni t must be repl aced.
OPERATION
The two-way, momentary, power l ock swi tch on the
passenger si de front door i s connected i n seri es
between ground and the passenger door swi tch mux
i nput of the Central Ti mer Modul e (CTM). The power
l ock swi tch on the dri ver si de front door tri m panel i s
MODULE - OPERATI ON). Each power l ock swi tch
posi ti on Lock, Unl ock, and Neutral provi des a di ffer-
ent resi stance val ue to the CTM i nput whi ch al l ows
the CTM to sense the swi tch posi ti on. Based upon
the power l ock swi tch i nputs, the CTM control s the
battery and ground feed outputs to the power l ock
motors to l ock or unl ock the door and l i ftgate l atches.
The Li ght-Emi tti ng Di ode (LED) i n the paddl e of the
passenger door power l ock swi tch i s connected to bat-
tery current through a fuse i n the Juncti on Bl ock
(JB) on a fused i gni ti on swi tch output (run) ci rcui t;
therefore, the swi tch wi l l onl y be i l l umi nated when
the i gni ti on swi tch i s i n the On posi ti on. The power
l ock swi tch can be di agnosed usi ng conventi onal
di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - POWER LOCK
SWITCH
The Li ght-Emi tti ng Di ode (LED) i l l umi nati on l amp
of the power l ock swi tch recei ves battery current
through a fuse i n the Juncti on Bl ock (JB) on a fused
i gni ti on swi tch output (run) ci rcui t. The power l ock
swi tch on the dri ver si de front door tri m panel i s
MODULE - DI AGNOSI S AND TESTI NG). I f the
power l ock swi tch operates, but the LED i s i nopera-
ti ve, check for battery current at the swi tch wi th the
i gni ti on swi tch i n the On posi ti on. I f OK, repl ace the
faul ty swi tch. Refer to the appropri ate wi ri ng i nfor-
cabl e. Remove the power l ock swi tch from the door
tri m panel . Di sconnect the door wi re harness connec-
tor for the power l ock swi tch from the swi tch connec-
tor receptacl e.
(2) Test the power l ock swi tch resi stance. See the
Power Lock Swi tch Test chart to determi ne i f the
resi stance i s correct for the swi tch i n each swi tch
posi ti on (Fi g. 5). I f not OK, repl ace the faul ty power
l ock swi tch as requi red.
POWER LOCK MOTOR (Continued)
POWER LOCK SWITCH TEST
SWITCH POSITION RESISTANCE BETWEEN
PINS 1 & 5
NEUTRAL 10 KILOHMS 1%
LOCK 820 OHMS 1%
UNLOCK 330 OHMS 1%
REMOVAL
The power l ock swi tch on the dri ver si de front door
tri m panel i s i ntegral to the dri ver door modul e.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/DRI VER
DOOR MODULE - REMOVAL).
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de fl at
bl aded tool and starti ng at the rear of the passenger
door power wi ndow and l ock swi tch bezel , gentl y pry
the bezel up and out from the passenger si de front
door tri m panel .
(3) Pul l the power wi ndow and l ock swi tch bezel
away from the tri m panel openi ng far enough to
access the two swi tch connector receptacl es on the
back of the uni t.
(4) Di sconnect the door wi re harness connectors
for the power l ock and power wi ndow swi tches from
the swi tch connector receptacl es.
(5) Remove the power wi ndow and l ock swi tch
bezel from the door tri m panel .
(6) Usi ng a smal l thi n-bl aded screwdri ver, gentl y
pry the snap cl i ps at the si des of the power l ock
swi tch receptacl e on the back of the power wi ndow
and l ock swi tch bezel and pul l the swi tch out of the
receptacl e.
INSTALLATION
The power l ock swi tch on the dri ver si de front door
tri m panel i s i ntegral to the dri ver door modul e.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/DRI VER
DOOR MODULE - I NSTALLATI ON).
(1) Al i gn the power l ock swi tch wi th the receptacl e
on the back of the power wi ndow and l ock swi tch
bezel .
down on the power l ock swi tch i t snaps i nto pl ace i n
the power wi ndow and l ock swi tch bezel receptacl e.
(3) Posi ti on the power wi ndow and l ock swi tch
bezel to the openi ng i n the passenger si de front door
tri m panel .
(4) Reconnect the two door wi re harness connec-
tors for the power wi ndow and power l ock swi tches to
the swi tch connector receptacl es.
(5) I nsert the front of the power wi ndow and l ock
swi tch bezel i nto the openi ng i n the passenger si de
front door tri m panel .
down on the rear of the power wi ndow and l ock
swi tch bezel unti l i t snaps i nto pl ace.
REMOTE KEYLESS ENTRY
TRANSMITTER
DESCRIPTION
The Remote Keyl ess Entry (RKE) system Radi o
Frequency (RF) transmi tter i s equi pped wi th three
buttons, l abel ed Lock, Unl ock, and Pani c. I t i s al so
equi pped wi th a key ri ng and i s desi gned to serve as
a key fob. The operati ng range of the transmi tter
radi o si gnal i s up to 7 meters (23 feet) from the RKE
recei ver. The RKE recei ver i s i ntegral to the Central
Ti mer Modul e (CTM) i n thi s vehi cl e.
Each RKE transmi tter has a di fferent vehi cl e
access code, whi ch must be programmed i nto the
memory of the RKE recei ver i n the vehi cl e i n order
to operate the RKE system. The RKE recei ver can
retai n the access codes for up to four transmi tters i n
i ts memory. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/REMOTE KEYLESS ENTRY TRANSMI T-
TER - STANDARD PROCEDURE - RKE TRANS-
MI TTER PROGRAMMI NG).
The RKE transmi tter operates on two Duracel l
DL2016, Panasoni c CR2016 (or equi val ent) batteri es.
Typi cal battery l i fe i s from one to two years. The
Fig. 5 Power Lock Switch Connector Receptacle
POWER LOCK SWITCH (Continued)
RKE transmi tter cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
OPERATION
of the Remote Keyl ess Entry (RKE) transmi tters.
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY TRANSMITTER
(1) Repl ace the Remote Keyl ess Entry (RKE)
transmi tter batteri es. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/REMOTE KEYLESS ENTRY
TRANSMI TTER - STANDARD PROCEDURE - RKE
TRANSMI TTER BATTERI ES). Test each of the RKE
transmi tter functi ons. I f OK, di scard the faul ty bat-
teri es. I f not OK, go to Step 2.
(2) Program the suspect RKE transmi tter and
another known good transmi tter i nto the RKE
recei ver. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/REMOTE KEYLESS ENTRY TRANSMI T-
TER - STANDARD PROCEDURE - RKE TRANS-
MI TTER PROGRAMMI NG).
(3) Test the RKE system operati on wi th both
transmi tters. I f both transmi tters fai l to operate the
power l ock system, a DRBI I I scan tool i s requi red
for further di agnosi s of the RKE system. Refer to the
appropri ate di agnosti c i nformati on. I f the known
good RKE transmi tter operates the power l ocks and
the suspect transmi tter does not, repl ace the faul ty
RKE transmi tter.
NOTE: Be certain to perform the RKE Transmitter
Programming procedure again following this test.
This procedure will erase the access code of the
test transmitter from the RKE receiver.
STANDARD PROCEDURE - RKE TRANSMITTER
PROGRAMMING
To program the Remote Keyl ess Entry (RKE)
transmi tter access codes i nto the RKE recei ver i n the
Central Ti mer Modul e (CTM) requi res the use of a
ti c i nformati on.
STANDARD PROCEDURE - RKE TRANSMITTER
BATTERIES
The Remote Keyl ess Entry (RKE) transmi tter case
snaps open and shut for battery access. To repl ace
the RKE transmi tter batteri es:
(1) Usi ng a tri m sti ck or a thi n coi n, gentl y pry at
the notch i n the center seam of the RKE transmi tter
case hal ves l ocated near the key ri ng unti l the two
hal ves unsnap.
(2) Li ft the back hal f of the transmi tter case off of
the RKE transmi tter.
(3) Remove the two batteri es from the RKE trans-
mi tter.
(4) Repl ace the two batteri es wi th new Duracel l
DL2016, or thei r equi val ent. Be certai n that the bat-
teri es are i nstal l ed wi th thei r pol ari ty correctl y ori -
ented.
(5) Al i gn the two RKE transmi tter case hal ves
wi th each other, and squeeze them fi rml y and evenl y
together usi ng hand pressure unti l they snap back
i nto pl ace.
REMOTE KEYLESS ENTRY TRANSMITTER (Continued)
POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
POWER MIRRORS. . . . . . . . . . . . . . . . . . . . . . 13
AUTOMATIC DAY / NIGHT MIRROR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AUTOMATIC DAY/NIGHT MIRROR . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
POWER MIRROR SWITCH
POWER MIRROR SWITCH. . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SIDEVIEW MIRROR
SIDEVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
POWER MIRRORS
DESCRIPTION
AUTOMATIC DAY/NIGHT MIRROR
The automati c day/ni ght mi rror system i s abl e to
automati cal l y change the refl ectance of the i nsi de
rear vi ew mi rror i n order to reduce the gl are of head-
l amps approachi ng the vehi cl e from the rear. The
automati c day/ni ght rear vi ew mi rror recei ves bat-
tery current through a fuse i n the juncti on bl ock onl y
when the i gni ti on swi tch i s i n the On posi ti on.
OUTSIDE REAR VIEW MIRROR
The power operated or power operated and heated
outsi de rear vi ew mi rrors al l ow the dri ver to adjust
both outsi de mi rrors el ectri cal l y from the dri ver si de
front seat posi ti on by operati ng a swi tch on the
dri ver si de front door tri m panel . The power mi rrors
recei ve a non-swi tched battery feed through a fuse i n
the juncti on bl ock so that the system wi l l remai n
operati onal , regardl ess of the i gni ti on swi tch posi ti on.
OPERATION
AUTOMATIC DAY/NIGHT MIRROR
A swi tch l ocated on the bottom of the automati c
day/ni ght mi rror housi ng al l ows the vehi cl e operator
to sel ect whether the automati c di mmi ng feature i s
operati onal . When the automati c day/ni ght mi rror i s
turned on, the mi rror swi tch i s l i ghted by an i ntegral
Li ght-Emi tti ng Di ode (LED). The mi rror wi l l auto-
mati cal l y di sabl e i ts sel f-di mmi ng feature whenever
the vehi cl e i s bei ng dri ven i n reverse.
Fol l owi ng i s a general descri pti on of the automati c
day/ni ght mi rror. Refer to the owners manual i n the
vehi cl e gl ove box for more i nformati on on the fea-
tures, use and operati on of the automati c day/ni ght
mi rror system.
OUTSIDE REAR VIEW MIRROR
The heated mi rror opti on i s avai l abl e onl y on quad
cab model s wi th the rear wi ndow defogger opti on.
The heated mi rrors i ncl ude an el ectri c heati ng gri d
behi nd the mi rror gl ass i n each outsi de mi rror, whi ch
can cl ear the mi rror gl ass of i ce, snow, or fog. (Refer
to 8 - ELECTRI CAL/HEATED MI RRORS -
DESCRI PTI ON) for more i nformati on.
DIAGNOSIS AND TESTING - POWER MIRRORS
(1) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and the juncti on bl ock. I f OK, go to Step 2.
I f not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse(s).
(2) Check for battery vol tage at the fuse i n the
juncti on bl ock. I f OK, go to Step 3. I f not OK, repai r
the open ci rcui t to the PDC as requi red.
cabl e. Remove the dri ver si de power wi ndow swi tch
and bezel assembl y and unpl ug the wi re harness con-
nector from the power mi rror swi tch. Connect the
battery negati ve cabl e. Check for battery vol tage at
the fused B(+) ci rcui t cavi ty i n the door wi re harness
hal f of the power mi rror swi tch wi re harness connec-
tor. I f OK, go to Step 4. I f not OK, repai r the open
ci rcui t to the juncti on bl ock as requi red.
cabl e. Check for conti nui ty between the ground ci r-
AN POWER MIRRORS 8N - 13
cui t cavi ty i n the door wi re harness hal f of the power
mi rror swi tch wi re harness connector and a good
ground. There shoul d be conti nui ty. I f OK, (Refer to 8
- ELECTRI CAL/POWER MI RRORS/SI DEVI EW MI R-
ROR - DI AGNOSI S AND TESTI NG).
AUTOMATIC DAY / NIGHT
MIRROR
DESCRIPTION
The automati c day/ni ght mi rror uses a thi n l ayer
of el ectrochromi c materi al between two pi eces of con-
ducti ve gl ass to make up the face of the mi rror.
When the mi rror swi tch i s i n the On posi ti on, two
photocel l sensors are used by the mi rror ci rcui try to
moni tor external l i ght l evel s and adjust the refl ec-
tance of the mi rror.
OPERATION
The ambi ent photocel l sensor i s l ocated on the for-
ward-faci ng (wi ndshi el d si de) of the rear vi ew mi rror
housi ng, and detects the ambi ent l i ght l evel s outsi de
of the vehi cl e. The headl amp photocel l sensor i s
l ocated i nsi de the rear vi ew mi rror housi ng behi nd
the mi rror gl ass and faces rearward, to detect the
l evel of the l i ght bei ng recei ved at the rear wi ndow
si de of the mi rror. When the ci rcui try of the auto-
mati c day/ni ght mi rror detects that the di fference
between the two l i ght l evel s i s too great (the l i ght
l evel recei ved at the rear of the mi rror i s much
hi gher than that at the front of the mi rror), i t begi ns
to darken the mi rror.
The automati c day/ni ght mi rror ci rcui try al so mon-
i tors the transmi ssi on usi ng an i nput from the
backup l amp ci rcui t. The mi rror ci rcui try i s pro-
grammed to automati cal l y di sabl e i ts sel f-di mmi ng
feature whenever i t senses that the transmi ssi on
backup l amp ci rcui t i s energi zed.
The automati c day/ni ght mi rror i s a compl etel y
sel f-contai ned uni t and cannot be repai red. I f faul ty
or damaged, the enti re mi rror assembl y must be
repl aced.
DIAGNOSIS AND TESTING - AUTOMATIC
DAY/NIGHT MIRROR
(1) Check the fuse i n the juncti on bl ock. I f OK, go
Check for battery vol tage at the fuse i n the juncti on
bl ock. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the i gni ti on swi tch as requi red.
Unpl ug the wi re harness connector from the auto-
mati c day/ni ght mi rror (Fi g. 1). Connect the battery
posi ti on. Check for battery vol tage at the fused i gni -
ti on swi tch output (run/start) ci rcui t cavi ty of the
automati c day/ni ght mi rror wi re harness connector. I f
OK, go to Step 4. I f not OK, repai r the open ci rcui t to
the juncti on bl ock as requi red.
i ty of the automati c day/ni ght mi rror wi re harness
nui ty. I f OK, go to Step 5. I f not OK, repai r the ci r-
cui t to ground as requi red.
i gni ti on swi tch to the On posi ti on. Set the parki ng
brake. Pl ace the transmi ssi on gear sel ector l ever i n
the Reverse posi ti on. Check for battery vol tage at the
backup l amp swi tch output ci rcui t cavi ty of the auto-
mati c day/ni ght mi rror wi re harness connector. I f
OK, go to Step 6. I f not OK, repai r the open ci rcui t
as requi red.
Di sconnect the battery negati ve cabl e. Pl ug i n the
automati c day/ni ght mi rror wi re harness connector.
Connect the battery negati ve cabl e. Turn the i gni ti on
Fig. 1 Automatic Day/Night Mirror
1 - REAR FACING SENSOR
2 - CONNECTOR
3 - FORWARD FACING SENSOR
4 - SWITCH
8N - 14 POWER MIRRORS AN
POWER MIRRORS (Continued)
swi tch to the On posi ti on. Pl ace the transmi ssi on
gear sel ector l ever i n the Neutral posi ti on. Pl ace the
mi rror swi tch i n the On (the LED i n the mi rror
swi tch i s l i ghted) posi ti on. Cover the forward faci ng
ambi ent photocel l sensor to keep out any ambi ent
l i ght.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shi ne a l i ght i nto the rearward faci ng head-
l amp photocel l sensor. The mi rror gl ass shoul d
darken. I f OK, go to Step 8. I f not OK, repl ace the
faul ty automati c day/ni ght mi rror uni t.
(8) Wi th the mi rror gl ass darkened, pl ace the
transmi ssi on gear sel ector l ever i n the Reverse posi -
ti on. The mi rror shoul d return to i ts normal refl ec-
tance. I f not OK, repl ace the faul ty automati c day/
ni ght mi rror uni t.
REMOVAL
cabl e.
(2) Unpl ug the wi re harness connector from the
automati c day/ni ght mi rror (Fi g. 2).
(3) Remove the set screw that secures the auto-
mati c day/ni ght mi rror to the wi ndshi el d support
button.
(4) Push the automati c day/ni ght mi rror upwards
far enough for the mounti ng bracket to cl ear the sup-
port button and remove the mi rror from the wi nd-
shi el d support button.
INSTALLATION
(1) I nstal l the mi rror to the support button.
(2) I nstal l the set screw. Ti ghten the set screw to
1.7 Nm (15 i n. l bs.).
(3) Reconnect the wi re harness to the mi rror.
POWER MIRROR SWITCH
DIAGNOSIS AND TESTING - POWER MIRROR
SWITCH
The power mi rror swi tch i s i ncl uded wi th the
Dri ver Door Modul e. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/DOOR MODULE - DI AGNOSI S
AND TESTI NG) for servi ce procedures.
REMOVAL
The power mi rror swi tch i s i ncl uded wi th the
Dri ver Door Modul e. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/DOOR MODULE - REMOVAL) for
servi ce procedures.
Fig. 2 Automatic Day/Night Mirror Remove/Install
1 - ON/OFF SWITCH
AN POWER MIRRORS 8N - 15
AUTOMATIC DAY / NIGHT MIRROR (Continued)
SIDEVIEW MIRROR
DIAGNOSIS AND TESTING - SIDEVIEW
MIRROR
Unpl ug the wi re harness connector at the i nopera-
ti ve power mi rror (Fi g. 3).
Use two jumper wi res, one connected to a 12 - vol t
battery feed, and the other connected to a good body
ground. See the Power Mi rror Test chart for the cor-
rect jumper wi re connecti ons to the power mi rror
hal f of the power mi rror wi re harness connector. I f
the power mi rror(s) do not respond as i ndi cated i n
the chart, repl ace the faul ty power mi rror assembl y.
I f the power mi rror(s) do respond as i ndi cated i n the
chart, repai r the ci rcui ts between the power mi rror
and the power mi rror swi tch for a short or open as
requi red.
REMOVAL
For removal procedures, (Refer to 23 - BODY/EX-
TERI OR/SI DE VI EW MI RROR - REMOVAL).
Fig. 3 Power Mirror Test
Left or Right Mirror
12 Volts Ground MIRROR
MOVEMENT
Pin 1 Pin 3 UP
Pin 3 Pin 1 DOWN
Pin 2 Pin 3 LEFT
Pin 3 Pin 2 RIGHT
8N - 16 POWER MIRRORS AN
POWER SEAT SYSTEM
TABLE OF CONTENTS
page page
POWER SEAT SYSTEM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . . . 17
DRIVER SEAT SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DRIVER SEAT SWITCH . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
POWER SEAT TRACK
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
POWER SEAT TRACK . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
POWER SEAT SYSTEM
DESCRIPTION
The power seat system opti on al l ows the dri ver to
el ectri cal l y adjust hi s seati ng posi ti on for opti mum
control and comfort usi ng the power seat swi tches
l ocated on the outboard seat cushi on si de shi el d. The
power seat system al l ows the seati ng posi ti on to be
adjusted forward, rearward, front up, front down,
rear up, or rear down. The power seat system
recei ves battery current through a fuse i n the Power
Di stri buti on Center, regardl ess of the i gni ti on swi tch
posi ti on.
The power seat system i ncl udes the power seat
adjuster and motors uni t (seat track) and the power
seat swi tch. Fol l owi ng are general descri pti ons of the
major components i n the power seat system. Refer to
the owners manual i n the vehi cl e gl ove box for more
power seat system.
OPERATION
The power seat system recei ves battery current
through a fuse i n the Power Di stri buti on Center
(PDC), regardl ess of the i gni ti on swi tch posi ti on.
DIAGNOSIS AND TESTING - POWER SEAT
SYSTEM
Before any testi ng of the power seat system i s
attempted, the battery shoul d be ful l y-charged and
al l wi re harness connecti ons and pi ns cl eaned and
ti ghtened to ensure proper conti nui ty and grounds.
For ci rcui t descri pti ons and di agrams, refer to Wi ri ng
Di agrams.
Wi th the dome l amp on, appl y the power seat
swi tch i n the di recti on of the fai l ure. I f the dome
l amp di ms, the seat may be jammi ng. Check under
and behi nd the seat for bi ndi ng or obstructi ons. I f
the dome l amp does not di m, proceed wi th testi ng of
the i ndi vi dual components and ci rcui ts.
DRIVER SEAT SWITCH
DESCRIPTION
The power seat can be adjusted i n si x di fferent
ways usi ng the power seat swi tch. The swi tch i s
l ocated on the outboard si de of the seat cushi on si de
shi el d.
The i ndi vi dual swi tches i n the power seat swi tch
uni t cannot be repai red. I f one swi tch i s damaged or
faul ty, the enti re power seat swi tch uni t must be
repl aced.
OPERATION
When a power swi tch control knob or knobs are
actuated, a battery feed and a ground path are
appl i ed through the swi tch contacts to the power seat
track or recl i ner adjuster motor. The sel ected
adjuster motor operates to move the seat track or
recl i ner through i ts dri ve uni t i n the sel ected di rec-
ti on unti l the swi tch i s rel eased, or unti l the travel
l i mi t of the adjuster i s reached. When the swi tch i s
moved i n the opposi te di recti on, the battery feed and
ground path to the motor are reversed through the
swi tch contacts. Thi s causes the adjuster motor to
run i n the opposi te di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the adjuster has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
AN POWER SEAT SYSTEM 8N - 17
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH
For ci rcui t descri pti ons and di agrams, refer to Wi r-
i ng Di agrams.
cabl e.
(2) Remove the power seat swi tch from the power
seat.
(3) Wi th assi stance from another person, use an
ohmmeter to test the conti nui ty of the power seat
swi tches i n each posi ti on. See the Power Seat Swi tch
schemati c and Conti nui ty chart (Fi g. 1) . I f OK, see
the Power Seat Track Di agnosi s and Testi ng proce-
dure i n thi s secti on . I f not OK, repl ace the faul ty
power seat swi tch uni t.
REMOVAL
cabl e.
(2) Remove the screw that secures the recl i ner
l ever to the recl i ner mechani sm rel ease shaft on the
outboard si de of the dri ver si de front seat.
(3) Pul l the recl i ner l ever off of the recl i ner mech-
ani sm rel ease shaft.
(4) Remove the two screws that secure the dri ver
si de seat cushi on si de shi el d to the outboard seat
cushi on frame.
(5) Pul l the dri ver si de seat cushi on si de shi el d
away from the seat cushi on frame far enough to
access the power seat swi tch modul e wi re harness
connector.
power seat swi tch modul e.
(7) Remove the seat cushi on si de shi el d and power
seat swi tch modul e from the seat as a uni t.
(8) Remove the two screws that secure the power
seat swi tch to the i nsi de of the seat cushi on si de
shi el d (Fi g. 2).
(9) Remove the power seat swi tch from the seat
cushi on si de shi el d.
INSTALLATION
(1) I nstal l the two screws that secure the power
seat swi tch to the i nsi de of the seat cushi on si de
shi el d.
(2) I nstal l the wi re harness connector on the power
seat swi tch modul e.
(3) I nstal l the seat cushi on si de shi el d and power
seat swi tch modul e on the seat as a uni t. Refer to
Body for the procedure.
Fig. 1 Power Seat Switch Continuity Test
POWER SEAT SWITCH TEST TABLE
OFF B & N, B & J, B & M, B &
E, B & L, B & K
VERTICAL UP A & J, A & N, B & M, B
&E
VERTICAL DOWN A & E, A & M, B & N, B &
J
HORIZONTAL
FORWARD
A & K, B & L
HORIZONTAL AFT A & L, B & K
FRONT TILT UP A & J, B & E
FRONT TILT DOWN A & E, B & J
REAR TILT UP A & N, B & M
REAR TILT DOWN A & M, B & N
Fig. 2 Power Seat Switch Remove/Install - Typical
1 - Seat Side Shield
2 - Power Seat Switch
3 - Screws
8N - 18 POWER SEAT SYSTEM AN
DRIVER SEAT SWITCH (Continued)
(4) I nstal l the recl i ner l ever on the recl i ner mech-
ani sm rel ease shaft.
(5) I nstal l the screw that secures the recl i ner l ever
to the recl i ner mechani sm rel ease shaft on the out-
board si de of the dri ver si de front seat.
POWER SEAT TRACK
DESCRIPTION
Vehi cl es equi pped wi th the power seat opti on, uti -
l i ze a power seat track. Three reversi bl e DC motors
are i ncorporated i nto the power seat track. The
motors are connected to worm-dri ve gearboxes that
move the seat track through a combi nati on of screw-
type dri ve uni ts.
The front and rear of the seat are operated by di f-
ferent motors. They can be rai sed or l owered i nde-
pendentl y of each other. When the center power seat
swi tch i s pushed i n the Up or Down di recti on, both
the front and rear motors operate i n uni son. On stan-
dard cab model s the enti re seat i s moved up or down.
On extended cab model s the seat cushi on moves
i ndependentl y of the seat back i n the up or down
di recti ons.
Each motor contai ns a sel f-resetti ng ci rcui t breaker
to protect i t from overl oad. Consecuti ve or frequent
resetti ng of the ci rcui t breakers must not be al l owed
to conti nue, or the motors may be damaged.
The power seat track (adjuster) cannot be repai red,
and i s servi ced onl y as a compl ete assembl y. I f any
component i n thi s assembl y i s faul ty or damaged, the
enti re power seat track must be repl aced.
OPERATION
When a power seat swi tch i s actuated, a battery
feed and a ground path are appl i ed through the
power seat swi tch contacts to the appropri ate motor
or motors. The motor and dri ve uni t operate to move
the seat i n the sel ected di recti on unti l the swi tch i s
rel eased, or unti l the travel l i mi t of the power seat
track i s reached. When the swi tch i s moved i n the
opposi te di recti on, the battery feed and ground path
to the motor i s reversed through the swi tch contacts.
Thi s causes the motor to run i n the opposi te di rec-
ti on.
DIAGNOSIS AND TESTING - POWER SEAT
TRACK
For compl ete power seat ci rcui t descri pti ons and
di agrams, refer to Wi ri ng Di agrams.
Operate the power seat swi tch to move al l three
seat motors i n each di recti on. The seat shoul d move
i n each of the sel ected di recti ons. I f the power seat
track fai l s to operate i n onl y one di recti on, move the
seat track a short di stance i n the opposi te di recti on
and test agai n to be certai n that the track i s not at
i ts travel l i mi t. I f the power seat track sti l l fai l s to
operate i n onl y one di recti on, refer to Di agnosi s and
Testi ng of the Power Seat Swi tch i n thi s secti on. I f
the power seat track fai l s to operate i n more than
one di recti on, proceed as fol l ows:
(1) Check the power seat fuse i n the power di stri -
buti on center. I f OK, go to Step 2. I f not OK, repl ace
the faul ty fuse.
(2) Remove the power seat swi tch from the seat.
cavi ty of the power seat swi tch wi re harness connec-
tor. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the power di stri buti on center as requi red.
cui t cavi ty of the power seat swi tch wi re harness con-
nector and a good ground. There shoul d be
open ci rcui t to ground as requi red.
(4) Test the power seat swi tch as descri bed i n thi s
group. I f the swi tch tests OK, check the wi re harness
between the power seat swi tch and the motor for
shorts or opens. I f the ci rcui ts check OK, repl ace the
faul ty power seat track (adjuster) assembl y. I f the
ci rcui ts are not OK, repai r the wi re harness as
requi red.
REMOVAL
cabl e.
(2) Remove the dri ver si de seat assembl y from the
vehi cl e. Refer to the Body secti on of the servi ce man-
ual for the procedure.
(3) Di sconnect the power seat wi re harness connec-
tors.
(4) Di sconnect the power seat wi re harness retai n-
ers from the seat track assembl y.
(5) Remove the four bol ts that secure the power
seat track assembl y to the seat cushi on frame.
(6) I f the vehi cl e i s equi pped wi th a spl i t bench
seat, remove the fasteners that secure the center seat
cushi on secti on to the brackets on the power seat
track assembl y.
(7) Remove the power seat track assembl y from
the seat cushi on frame.
CAUTION: Before installing the seat into the vehi-
cle, be certain to adjust the seat fully rearward on
its tracks. Then install and tighten the front track
mounting screws before installing the rear screws
or the tracks may be damaged.
INSTALLATION
(1) Posi ti on the power seat track assembl y on the
seat cushi on frame and compare the ol d and repl ace-
AN POWER SEAT SYSTEM 8N - 19
DRIVER SEAT SWITCH (Continued)
ment seat tracks to be certai n the correct part i s
avai l abl e.
(2) I f the vehi cl e i s equi pped wi th a spl i t bench
seat, I nstal l the fasteners that secure the center seat
cushi on secti on to the brackets on the power seat
track assembl y.
(3) I nstal l the four bol ts that secure the power
seat track assembl y to the seat cushi on frame.
Torque the bol ts to 27 Nm (20 ft. l bs.).
(4) I nstal l the power seat wi re harness retai ners
on the seat track assembl y.
(5) Connect the power seat wi re harness connec-
tors.
(6) I nstal l the dri ver si de seat assembl y i n the
vehi cl e. Refer to the Body secti on of the servi ce man-
ual for the procedure.
8N - 20 POWER SEAT SYSTEM AN
POWER SEAT TRACK (Continued)
POWER WINDOWS
TABLE OF CONTENTS
page page
POWER WINDOWS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . 22
POWER WINDOW SWITCH
POWER WINDOW SWITCH . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
WINDOW MOTOR
WINDOW MOTOR . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
POWER WINDOWS
DESCRIPTION
Power wi ndows are avai l abl e as factory-i nstal l ed
opti onal equi pment on thi s model . The Remote Key-
l ess Entry (RKE) system and power l ock system are
i ncl uded on vehi cl es equi pped wi th the power wi n-
dow opti on. For compl ete ci rcui t di agrams, refer to
the appropri ate wi ri ng i nformati on. The wi ri ng i nfor-
mati on i ncl udes wi ri ng di agrams, proper wi re and
connector repai r procedures, detai l s of wi re harness
The power wi ndow system al l ows each of the door
wi ndows to be rai sed and l owered el ectri cal l y by
actuati ng a swi tch on the tri m panel of each respec-
ti ve door. A master swi tch on the dri ver si de front
door tri m panel al l ows the dri ver to rai se or l ower
each of the passenger door wi ndows and, on quad cab
model s, to l ock out the i ndi vi dual swi tches on the
passenger doors from operati on. The power wi ndow
system recei ves battery feed through a ci rcui t
breaker i n the juncti on bl ock, onl y when the i gni ti on
swi tch i s i n the On posi ti on.
The power wi ndow system i ncl udes the power wi n-
dow swi tches on each door tri m panel , the ci rcui t
breaker i n the juncti on bl ock, and the power wi ndow
motors i nsi de each door. Thi s group covers di agnosi s
and servi ce of onl y the el ectri cal components i n the
power wi ndow system. For servi ce of mechani cal
components, such as the regul ator, l i ft pl ate, wi ndow
tracks, or gl ass refer to Group 23 - Body.
components i n the power wi ndow system. Refer to
power wi ndow system.
OPERATION
POWER WINDOW SWITCH
On conventi onal cab and cl ub cab model s, the
power wi ndows are control l ed by two-way swi tches
i ntegral to the power wi ndow and l ock swi tch bezel
on the passenger si de and the Dri ver Door Modul e on
the dri ver si de of the tri m panel of each front door. A
second power wi ndow swi tch i n the dri ver si de swi tch
and bezel uni t al l ows the dri ver to control the pas-
senger si de wi ndow. On quad cab model s, the power
wi ndows are control l ed by four two-way swi tches and
a power wi ndow l ockout swi tch that are i ntegral to
the Dri ver Door Modul e on the dri ver si de front door
tri m panel . Addi ti onal l y, each of the passenger doors
has a si ngl e gang two-way power wi ndow swi tch
mounted i n a bezel on thei r respecti ve door tri m pan-
el s.
On al l model s, the power wi ndow swi tch for the
dri ver si de front door wi ndow has an Auto l abel on i t.
Thi s swi tch has a second detent posi ti on beyond the
normal Down posi ti on that provi des an automati c
one-touch wi ndow down feature. Thi s feature i s con-
trol l ed by an el ectroni c ci rcui t and a rel ay that are
i ntegral to the dri ver si de front door power wi ndow
and l ock swi tch uni t.
The power wi ndow swi tches control the battery
and ground feeds to the power wi ndow motors. Al l of
the passenger door power wi ndow swi tches recei ve
thei r battery and ground feeds through the ci rcui try
of the dri ver si de master swi tch uni t. On quad cab
model s, when the power wi ndow l ockout swi tch i s i n
the Lock posi ti on, the battery feed for the i ndi vi dual
passenger door power wi ndow swi tches i s i nter-
rupted.
A Li ght-Emi tti ng Di ode (LED) i n the paddl e of
each swi tch i s i l l umi nated whenever the i gni ti on
swi tch i s i n the On posi ti on. However, on quad cab
model s the LEDs for the passenger power wi ndow
swi tches are exti ngui shed whenever the dri ver
AN POWER WINDOWS 8N - 21
sel ects the Lock posi ti on wi th the power wi ndow
l ockout swi tch.
POWER WINDOW MOTOR
A permanent magnet reversi bl e motor moves the
wi ndow regul ator through an i ntegral gearbox mech-
ani sm. A posi ti ve and negati ve battery connecti on to
the two motor termi nal s wi l l cause the motor to
rotate i n one di recti on. Reversi ng the current
through these same two connecti ons wi l l cause the
motor to rotate i n the opposi te di recti on.
I n addi ti on, each power wi ndow motor i s equi pped
wi th an i ntegral sel f-resetti ng ci rcui t breaker to pro-
tect the motor from overl oads. The power wi ndow
motor and gearbox assembl y cannot be repai red and,
i f faul ty or damaged, the enti re power wi ndow regu-
l ator assembl y must be repl aced.
CIRCUIT BREAKER
An automati c resetti ng ci rcui t breaker i n the junc-
ti on bl ock i s used to protect the power wi ndow sys-
tem ci rcui t. The ci rcui t breaker can protect the
system from a short ci rcui t, or from an overl oad con-
di ti on caused by an obstructed or stuck wi ndow gl ass
or regul ator.
The ci rcui t breaker cannot be repai red and, i f
faul ty, i t must be repl aced.
DIAGNOSIS AND TESTING - POWER
WINDOWS
ALL WINDOWS INOPERATIVE
(1) Check the ci rcui t breaker i n the juncti on bl ock,
as descri bed i n thi s group. I f OK, go to Step 2. I f not
OK, repl ace the faul ty ci rcui t breaker.
cabl e. Remove the power wi ndow and l ock master
swi tch uni t from the dri ver si de front door tri m
panel . Unpl ug the wi re harness connector from the
master swi tch uni t.
cui t cavi ty of the power wi ndow and l ock master
swi tch uni t wi re harness connector and a good
ground. I f OK, go to Step 4. I f not OK, repai r the ci r-
cui t to ground as requi red.
vol tage at the fused i gni ti on swi tch output (run) ci r-
cui t cavi ty of the power wi ndow and l ock master
swi tch uni t wi re harness connector. I f OK, (Refer to 8
- ELECTRI CAL/POWER WI NDOWS/POWER WI N-
DOW SWI TCH - DI AGNOSI S AND TESTI NG). I f not
OK, repai r the ci rcui t to the juncti on bl ock as
requi red.
ONE WINDOW INOPERATIVE
The wi ndow gl ass must be free to sl i de up and
down for the power wi ndow motor to functi on prop-
erl y. I f the gl ass i s not free to move up and down, the
motor wi l l overl oad and tri p the i ntegral ci rcui t
breaker. To determi ne i f the gl ass i s free, di sconnect
the regul ator pl ate from the gl ass. Then sl i de the
wi ndow up and down by hand.
There i s an al ternate method to check i f the gl ass
i s free. Posi ti on the gl ass between the up and down
stops. Then, shake the gl ass i n the door. Check that
the gl ass can be moved sl i ghtl y from si de to si de,
front to rear, and up and down. Then check that the
gl ass i s not bound ti ght i n the tracks. I f the gl ass i s
free, proceed wi th the di agnosi s that fol l ows. I f the
gl ass i s not free, refer to Group 23 - Body for the
door wi ndow gl ass and hardware servi ce and adjust-
ment procedures.
I f the onl y i noperati ve wi ndow i s i n the dri ver si de
front door and the precedi ng checks have not i denti -
fi ed a probl em, (Refer to 8 - ELECTRI CAL/POWER
WI NDOWS/WI NDOW MOTOR - DI AGNOSI S AND
TESTI NG). I f the probl em bei ng di agnosed i nvol ves
onl y the Auto-down feature for the dri ver si de front
door wi ndow, but al l of the power wi ndows are oper-
ati onal , repl ace the faul ty Dri ver Door Modul e. I f the
probl em bei ng di agnosed i nvol ves onl y an i noperati ve
power wi ndow swi tch Li ght-Emi tti ng Di ode (LED),
but the power wi ndow that the swi tch control s oper-
ates sati sfactori l y from that swi tch, repl ace the
faul ty swi tch uni t. For any other si ngl e power wi n-
dow probl em proceed wi th di agnosi s as fol l ows:
cabl e. Unpl ug the wi re harness connector from the
power wi ndow swi tch uni t on the door wi th the i nop-
erati ve power wi ndow. Check for conti nui ty between
the ground ci rcui t cavi ty of the power wi ndow swi tch
wi re harness connector and a good ground. There
shoul d be conti nui ty. I f OK, go to Step 2. I f not OK,
repai r the open ci rcui t to the power wi ndow and door
l ock master swi tch as requi red.
vol tage at the fused i gni ti on swi tch output (run) ci r-
cui t cavi ty i n the body hal f of the power wi ndow
swi tch uni t wi re harness connector. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t to the power
wi ndow and door l ock master swi tch as requi red.
(3) Test the power wi ndow swi tch conti nui ty (Refer
to 8 - ELECTRI CAL/POWER WI NDOWS/POWER
8N - 22 POWER WINDOWS AN
POWER WINDOWS (Continued)
WI NDOW SWI TCH - DI AGNOSI S AND TESTI NG) .
I f OK, go to Step 4. I f not OK, repl ace the faul ty
power wi ndow swi tch uni t.
(4) For compl ete ci rcui t di agrams, refer to the
nectors, spl i ces and grounds. Check the conti nui ty i n
each ci rcui t between the i noperati ve power wi ndow
swi tch wi re harness connector cavi ti es and the corre-
spondi ng power wi ndow motor wi re harness connec-
tor cavi ti es. I f OK, (Refer to 8 - ELECTRI CAL/
POWER WI NDOWS/WI NDOW MOTOR -
DI AGNOSI S AND TESTI NG). I f not OK, repai r the
open ci rcui t(s) as requi red.
NOTE: All passenger door power window switches
receive their battery and ground feed for operating
the passenger door power window motors through
the driver side power window and lock master
switch and wire harness connector.
CIRCUIT BREAKER
(1) Locate the ci rcui t breaker i n the juncti on bl ock.
Pul l out the ci rcui t breaker sl i ghtl y, but be certai n
that the ci rcui t breaker termi nal s sti l l contact the
termi nal s i n the juncti on bl ock cavi ti es.
(2) Connect the negati ve l ead of a 12-vol t DC vol t-
meter to a good ground.
(3) Wi th the vol tmeter posi ti ve l ead, check both
termi nal s of the ci rcui t breaker for battery vol tage.
I f onl y one termi nal has battery vol tage, the ci rcui t
breaker i s faul ty and must be repl aced. I f nei ther ter-
mi nal has battery vol tage, repai r the open ci rcui t
from the Power Di stri buti on Center (PDC) as
requi red. I f the ci rcui t breaker checks OK, but no
power wi ndows operate, refer to ALL WI NDOWS
I NOPERATI VE.
POWER WINDOW SWITCH
DIAGNOSIS AND TESTING - POWER WINDOW
SWITCH
CONVENTIONAL CAB AND CLUB CAB
l amps for al l of the power wi ndow and l ock swi tch
and bezel uni t swi tch paddl es recei ve battery current
through the power wi ndow ci rcui t breaker i n the
juncti on bl ock. I f al l of the LEDs are i noperati ve i n
ei ther or both power wi ndow and l ock swi tch and
bezel uni ts and the power wi ndows are i noperati ve,
perform the di agnosi s for Power Wi ndow System i n
thi s group. I f the power wi ndows operate, but any or
al l of the LEDs are i noperati ve, the power wi ndow
and l ock swi tch and must be repl aced. For compl ete
ci rcui t di agrams, refer to the appropri ate wi ri ng
i nformati on. The wi ri ng i nformati on i ncl udes wi ri ng
grounds.
(1) Check the ci rcui t breaker i n the juncti on bl ock.
I f OK, go to Step 2. I f not OK, repl ace the faul ty ci r-
cui t breaker.
Check for battery vol tage at the ci rcui t breaker i n
the juncti on bl ock. I f OK, turn the i gni ti on swi tch to
the Off posi ti on and go to Step 3. I f not OK, repai r
the ci rcui t to the i gni ti on swi tch as requi red.
cabl e. Remove the power wi ndow swi tch uni t from
the door tri m panel (passenger doors onl y). For di ag-
nosi s of the dri ver si de power wi ndow swi tch (Refer
to 8 - ELECTRI CAL/POWER LOCKS/DOOR MOD-
ULE - DI AGNOSI S AND TESTI NG). Unpl ug the
wi re harness connector from the swi tch uni t.
(4) Test the power wi ndow swi tch conti nui ty. See
the Power Wi ndow Swi tch Conti nui ty chart to deter-
mi ne i f the conti nui ty i s correct i n the Neutral , Up
and Down swi tch posi ti ons (Fi g. 1). I f OK, (Refer to 8
- ELECTRI CAL/POWER WI NDOWS/WI NDOW
MOTOR - DI AGNOSI S AND TESTI NG). I f not OK,
repl ace the faul ty swi tch.
NEUTRAL PIN 4 AND 1, PIN 2 AND
5
UP PIN 6 AND 5
DOWN PIN 6 AND 1
POWER WINDOWS (Continued)
QUAD CAB
l amps for al l of the power wi ndow and l ock swi tch
and bezel uni t swi tch paddl es recei ve battery current
through the power wi ndow ci rcui t breaker i n the
juncti on bl ock. I f al l of the LEDs are i noperati ve i n
both the power wi ndow and l ock swi tch uni ts and the
power wi ndows are i noperati ve, (Refer to 8 - ELEC-
TRI CAL/POWER WI NDOWS - DI AGNOSI S AND
TESTI NG). I f the power wi ndows operate, but any or
al l of the LEDs are i noperati ve, the power wi ndow
and l ock swi tch uni ts wi th the i noperati ve LED(s) i s
faul ty and must be repl aced. For compl ete ci rcui t di a-
grams, refer to the appropri ate wi ri ng i nformati on.
(1) Check the ci rcui t breaker i n the juncti on bl ock.
I f OK, go to Step 2. I f not OK, repl ace the faul ty ci r-
cui t breaker.
Check for battery vol tage at the ci rcui t breaker i n
the juncti on bl ock. I f OK, turn the i gni ti on swi tch to
the Off posi ti on and go to Step 3. I f not OK, repai r
the ci rcui t to the i gni ti on swi tch as requi red.
cabl e. Remove the power wi ndow swi tch uni t from
the door tri m panel (passenger doors onl y). For di ag-
nosi s of the dri ver si de power wi ndow swi tch (Refer
to 8 - ELECTRI CAL/POWER LOCKS/DOOR MOD-
ULE - DI AGNOSI S AND TESTI NG). Unpl ug the
wi re harness connector from the swi tch uni t.
(4) Test the power wi ndow swi tch conti nui ty. See
the Power Wi ndow Swi tch Conti nui ty chart to deter-
mi ne i f the conti nui ty i s correct i n the Off, Up and
Down swi tch posi ti ons (Fi g. 2). I f OK, (Refer to 8 -
ELECTRI CAL/POWER WI NDOWS/WI NDOW
MOTOR - DI AGNOSI S AND TESTI NG). I f not OK,
repl ace the faul ty swi tch.
NEUTRAL PIN 2 AND 5, PIN 4 AND
1
UP (FRONT
PASSENGER)
PIN 6 AND 5
UP (REAR
PASSENGER)
PIN 6 AND 1
DOWN (FRONT
PASSENGER)
PIN 6 AND 1
DOWN (REAR
PASSENGER)
PIN 6 AND 5
REMOVAL
The dri ver si de power wi ndow swi tch i s i ncl uded
wi th the Dri ve Door Modul e. (Refer to 8 - ELECTRI -
CAL/POWER LOCKS/DOOR MODULE - REMOVAL)
for the servi ce procedures.
cabl e.
(2) Usi ng a tri m sti ck, start at the rear of the
swi tch bezel and pry up from door tri m panel .
(3) Di sconnect the wi re harness connector from
swi tch.
(4) Remove swi tch from bezel .
INSTALLATION
The dri ver si de power wi ndow swi tch i s i ncl uded
wi th the Dri ve Door Modul e. (Refer to 8 - ELECTRI -
CAL/POWER LOCKS/DOOR MODULE - I NSTALLA-
TI ON) for the servi ce procedures.
(1) I nstal l swi tch to bezel .
(2) Connect wi re harness connector to swi tch.
(3) I nsert the front of the swi tch i nto the door tri m
panel fi rst, then press i nto posi ti on.
Fig. 1 PASSENGER DOOR SWITCH
Fig. 2 PASSENGER DOOR SWITCH
8N - 24 POWER WINDOWS AN
POWER WINDOW SWITCH (Continued)
WINDOW MOTOR
DIAGNOSIS AND TESTING - WINDOW MOTOR
cabl e. Remove the tri m panel from the door wi th the
i noperati ve power wi ndow.
(2) Unpl ug the power wi ndow motor wi re harness
connector. Appl y 12 vol ts across the motor termi nal s
to check i ts operati on i n one di recti on. Reverse the
connecti ons across the motor termi nal s to check the
operati on i n the other di recti on. Remember, i f the
wi ndow i s i n the ful l up or ful l down posi ti on, the
motor wi l l not operate i n that di recti on by desi gn. I f
OK, repai r the ci rcui ts from the power wi ndow motor
to the power wi ndow swi tch as requi red. I f not OK,
repl ace the faul ty motor.
(3) I f the motor operates i n both di recti ons, check
the operati on of the wi ndow gl ass and l i ft mechani sm
through i ts compl ete up and down travel . There
shoul d be no bi ndi ng or sti cki ng of the wi ndow gl ass
or l i ft mechani sm through the enti re travel range. I f
not OK, refer to Group 23 - Body to check the wi n-
dow gl ass, tracks, and regul ator for sti cki ng, bi ndi ng,
or i mproper adjustment.
REMOVAL
The power wi ndow motor and mechani sm i s i nte-
gral to the power wi ndow regul ator uni t. I f the power
wi ndow motor or mechani sm i s faul ty or damaged,
the enti re power wi ndow regul ator uni t must be
repl aced. (Refer to 23 - BODY/DOOR - FRONT/WI N-
DOW REGULATOR - REMOVAL) or (Refer to 23 -
BODY/DOORS - REAR/WI NDOW REGULATOR -
REMOVAL) for the wi ndow regul ator servi ce
procedures.
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIRBAG SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 4
HANDLING NON-DEPLOYED PASSIVE
RESTRAINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AFTER AN AIRBAG
DEPLOYMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VERIFICATION TEST . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AIRBAG CONTROL MODULE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHILD TETHER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLOCKSPRING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLOCKSPRING CENTERING . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DRIVER AIRBAG
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FRONT SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PASSENGER AIRBAG
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PASSENGER AIRBAG ON/OFF SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REAR SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR SEAT LAP BELT/BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SEAT BELT SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . 30
SEAT BELT TENSIONER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SEAT BELT TURNING LOOP ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TURNING LOOP HEIGHT ADJUSTER KNOB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RESTRAINTS
DESCRIPTION
A dual front ai rbag system i s standard factory-i n-
stal l ed safety equi pment on thi s model . The ai rbag
system i s a passi ve, i nfl atabl e, Suppl emental
Restrai nt System (SRS) and vehi cl es wi th thi s equi p-
ment can be readi l y i denti fi ed by the SRS - AI R-
BAG l ogo mol ded i nto the dri ver ai rbag tri m cover
i n the center of the steeri ng wheel and al so i nto the
passenger ai rbag door on the i nstrument panel above
the gl ove box (Fi g. 1). Vehi cl es wi th the ai rbag sys-
tem can al so be i denti fi ed by the ai rbag i ndi cator,
whi ch wi l l i l l umi nate i n the i nstrument cl uster for
about seven seconds as a bul b test each ti me the
i gni ti on swi tch i s turned to the On posi ti on.
The dual front ai rbag system consi sts of the fol l ow-
i ng major components, whi ch are descri bed i n further
detai l el sewhere i n thi s servi ce manual :
Airbag Control Module - The Ai rbag Control
Modul e (ACM) i s l ocated on a mount on the fl oor
AN RESTRAINTS 8O - 1
panel transmi ssi on tunnel , bel ow the center of the
i nstrument panel .
Airbag Indicator - The ai rbag i ndi cator i s i nte-
gral to the El ectroMechani cal I nstrument Cl uster
(EMI C), whi ch i s l ocated on the i nstrument panel i n
front of the dri ver.
Clockspring - The cl ockspri ng i s l ocated near
the top of the steeri ng col umn, di rectl y beneath the
steeri ng wheel .
Driver Airbag - The dri ver ai rbag i s l ocated i n
the center of the steeri ng wheel , beneath the dri ver
ai rbag tri m cover.
Driver Knee Blocker - The dri ver knee bl ocker
i s a mol ded pl asti c structural uni t secured to the
back si de of and i ntegral to the i nstrument panel
steeri ng col umn openi ng cover.
Passenger Airbag - The passenger ai rbag i s
l ocated on the i nstrument panel , beneath the passen-
ger ai rbag door on the i nstrument panel above the
gl ove box on the passenger si de of the vehi cl e.
Passenger Airbag On/Off Switch - The pas-
senger ai rbag on/off swi tch i s l ocated i n a dedi cated
openi ng i n the l ower ri ght corner of the i nstrument
panel , to the ri ght of the ci gar l i ghter or power out-
l et. The passenger ai rbag on/off swi tch i s not used on
quad cab model s.
Passenger Knee Blocker - The passenger knee
bl ocker i s a structural rei nforcement that i s i ntegral
to and conceal ed wi thi n the gl ove box door.
Seat Belt Tensioners - Quad cab model s are
equi pped wi th front seat bel t tensi oners for both out-
board front seati ng posi ti ons. These tensi oners are
control l ed by the ACM and are i ntegral to the front
seat bel t and retractor assembl y.
The ACM and the EMI C each contai n a central
processi ng uni t and programmi ng that al l ow them to
communi cate wi th each other usi ng the Programma-
bl e Communi cati on I nterface (PCI ) data bus network.
Thi s method of communi cati on i s used for control of
the ai rbag i ndi cator on al l model s. (Refer to 8 -
ULES/COMMUNI CATI ON - DESCRI PTI ON).
Hard wi red ci rcui try connects the ai rbag system
components to each other through the el ectri cal sys-
tem of the vehi cl e. These hard wi red ci rcui ts are
i ntegral to several wi re harnesses, whi ch are routed
throughout the vehi cl e and retai ned by many di ffer-
ent methods. These ci rcui ts may be connected to each
other, to the vehi cl e el ectri cal system, and to the ai r-
bag system components through the use of a combi -
nati on of sol dered spl i ces, spl i ce bl ock connectors,
and many di fferent types of wi re harness termi nal
connectors and i nsul ators. Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATION
The ai rbag system i s referred to as a suppl emental
restrai nt system because i t was desi gned and i s
i ntended to enhance the protecti on for the front seat
occupants of the vehi cl e only when used i n conjunc-
ti on wi th the seat bel ts. I t i s referred to as a passi ve
system because the vehi cl e occupants are not
requi red to do anythi ng to make i t work. The pri -
mary passenger restrai nts i n thi s or any other vehi -
cl e are the standard equi pment factory-i nstal l ed seat
bel ts. Seat bel ts are referred to as an acti ve restrai nt
because the vehi cl e occupants are requi red to physi -
cal l y fasten and properl y adjust these restrai nts i n
order to benefi t from them. The vehi cl e occupants
must be weari ng thei r seat bel ts i n order to obtai n
the maxi mum safety benefi t from the factory-i n-
stal l ed ai rbag system.
The ai rbag system el ectri cal ci rcui ts are conti nu-
ousl y moni tored and control l ed by a mi croprocessor
and software contai ned wi thi n the Ai rbag Control
Modul e (ACM). An ai rbag i ndi cator i n the El ectroMe-
chani cal I nstrument Cl uster (EMI C) l i ghts for about
seven seconds as a bul b test each ti me the i gni ti on
swi tch i s turned to the On or Start posi ti ons. Fol l ow-
i ng the bul b test, the ai rbag i ndi cator i s turned on or
off by the ACM to i ndi cate the status of the ai rbag
system. I f the ai rbag i ndi cator comes on at any ti me
other than duri ng the bul b test, i t i ndi cates that
there i s a probl em i n the ai rbag system el ectri cal ci r-
cui ts. Such a probl em may cause the ai rbags not to
depl oy when requi red, or to depl oy when not
requi red.
The cl ockspri ng on the top of the steeri ng col umn
al l ows a conti nuous el ectri cal ci rcui t to be mai n-
tai ned between the stati onary steeri ng col umn and
Fig. 1 SRS Logo
8O - 2 RESTRAINTS AN
RESTRAINTS (Continued)
the dri ver ai rbag i nfl ator, whi ch rotates wi th the
steeri ng wheel . The passenger ai rbag on/off swi tch
al l ows the passenger si de ai rbag to be di sabl ed when
ci rcumstances necessi tate that a chi l d, or an adul t
wi th certai n medi cal condi ti ons be pl aced i n the front
passenger seati ng posi ti on. Quad cab model s are not
equi pped wi th a passenger ai rbag on/off swi tch, as
thi s model has a ful l -si zed rear seat. Refer to the
owners manual i n the vehi cl e gl ove box for recom-
mendati ons concerni ng the speci fi c ci rcumstances
where the passenger ai rbag on/off swi tch shoul d be
used to di sabl e the passenger ai rbag.
Depl oyment of the ai rbags depends upon the angl e
and severi ty of the i mpact. The ai rbag system i s
desi gned to depl oy upon a frontal i mpact wi thi n a
thi rty degree angl e from ei ther si de of the vehi cl e
center l i ne. Depl oyment i s not based upon vehi cl e
speed; rather, depl oyment i s based upon the rate of
decel erati on as measured by the forces of gravi ty (G
force) upon the ai rbag system i mpact sensor, whi ch i s
i ntegral to the ACM. When a frontal i mpact i s severe
enough, the mi croprocessor i n the ACM si gnal s the
i nfl ator uni ts of both ai rbag modul es to depl oy the
ai rbags. On quad cab model s, the seat bel t tensi oners
are provi ded wi th a depl oyment si gnal by the ACM i n
conjuncti on wi th the ai rbags. Duri ng a frontal vehi cl e
i mpact, the knee bl ockers work i n concert wi th prop-
erl y fastened and adjusted seat bel ts to restrai n both
the dri ver and the front seat passenger i n the proper
posi ti on for an ai rbag depl oyment. The knee bl ockers
al so absorb and di stri bute the crash energy from the
dri ver and the front seat passenger to the structure
of the i nstrument panel . The seat bel t tensi oners on
quad cab model s remove the sl ack from the outboard
front seat bel ts to provi de further assurance that the
dri ver and front seat passenger are properl y posi -
ti oned and restrai ned for an ai rbag depl oyment.
Typi cal l y, the dri ver and front seat passenger recal l
more about the events precedi ng and fol l owi ng a col -
l i si on than they have of the ai rbag depl oyment i tsel f.
Thi s i s because the ai rbag depl oyment and defl ati on
occur so rapi dl y. I n a typi cal 48 ki l ometer-per-hour
(30 mi l e-per-hour) barri er i mpact, from the moment
of i mpact unti l both ai rbags are ful l y i nfl ated takes
about 40 mi l l i seconds. Wi thi n one to two seconds
from the moment of i mpact, both ai rbags are al most
enti rel y defl ated. The ti mes ci ted for these events are
approxi mati ons, whi ch appl y onl y to a barri er i mpact
at the gi ven speed. Actual ti mes wi l l vary somewhat,
dependi ng upon the vehi cl e speed, i mpact angl e,
severi ty of the i mpact, and the type of col l i si on.
When the ACM moni tors a probl em i n any of the
ai rbag system ci rcui ts or components, i ncl udi ng the
seat bel t tensi oners on quad cab model s, i t stores a
faul t code or Di agnosti c Troubl e Code (DTC) i n i ts
memory ci rcui t and sends an el ectroni c message to
the EMI C to turn on the ai rbag i ndi cator. Proper
testi ng of the ai rbag system components, the Pro-
grammabl e Communi cati on I nterface (PCI ) data bus,
the data bus message i nputs to and outputs from the
EMI C or the ACM, as wel l as the retri eval or erasure
of a DTC from the ACM requi res the use of a
ti c i nformati on.
of al l of the factory-i nstal l ed passenger restrai nts,
i ncl udi ng the ai rbag system.
WARNING
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
INJURY.
WARNING: THE DRIVER AIRBAG INFLATOR UNIT
CONTAINS SODIUM AZIDE AND POTASSIUM
NITRATE. THESE MATERIALS ARE POISONOUS
AND EXTREMELY FLAMMABLE. CONTACT WITH
ACID, WATER, OR HEAVY METALS MAY PRODUCE
HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE OF
MOISTURE) OR COMBUSTIBLE COMPOUNDS. THE
PASSENGER AIRBAG UNIT CONTAINS ARGON GAS
PRESSURIZED TO OVER 2500 PSI. DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG UNIT OR
TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
INCINERATE, OR BRING INTO CONTACT WITH
ELECTRICITY. DO NOT STORE AT TEMPERATURES
EXCEEDING 93 C (200 F).
WARNING: WHEN HANDLING A SEAT BELT TEN-
SIONER RETRACTOR, PROPER CARE SHOULD BE
EXERCISED TO KEEP FINGERS OUT FROM UNDER
THE RETRACTOR COVER AND AWAY FROM THE
SEAT BELT WEBBING WHERE IT EXITS FROM THE
RETRACTOR COVER.
WARNING: REPLACE AIRBAG SYSTEM COMPO-
NENTS ONLY WITH PARTS SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
SUBSTITUTE PARTS MAY APPEAR INTERCHANGE-
ABLE, BUT INTERNAL DIFFERENCES MAY RESULT
IN INFERIOR OCCUPANT PROTECTION.
WARNING: THE FASTENERS, SCREWS, AND
BOLTS ORIGINALLY USED FOR THE AIRBAG SYS-
TEM COMPONENTS HAVE SPECIAL COATINGS
AND ARE SPECIFICALLY DESIGNED FOR THE AIR-
BAG SYSTEM. THEY MUST NEVER BE REPLACED
WITH ANY SUBSTITUTES. ANY TIME A NEW FAS-
TENER IS NEEDED, REPLACE IT WITH THE COR-
RECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR SPECIFIED IN THE DAIMLER-
CHRYSLER MOPAR PARTS CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN
AIRBAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
Proper di agnosi s and testi ng of the ai rbag system
components, the PCI data bus, the data bus message
i nputs to and outputs from the El ectroMechani cal
I nstrument Cl uster (EMI C) or the Ai rbag Control
Modul e (ACM), as wel l as the retri eval or erasure of
a Di agnosti c Troubl e Code (DTC) from the ACM
requi res the use of a DRBI I I scan tool . Refer to the
COLUMN, FRONT SEAT BELT TENSIONER, OR
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED PASSIVE RESTRAINTS
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of a non-de-
pl oyed ai rbag or seat bel t tensi oner. When carryi ng a
non-depl oyed ai rbag, the tri m cover or ai rbag cushi on
si de of the uni t shoul d be poi nted away from the
body to mi ni mi ze i njury i n the event of an acci dental
depl oyment. I f the ai rbag uni t i s pl aced on a bench or
any other surface, the tri m cover or ai rbag cushi on
si de of the uni t shoul d be face up to mi ni mi ze move-
ment i n the event of an acci dental depl oyment. When
handl i ng a non-depl oyed seat bel t tensi oner, take
proper care to keep fi ngers out from under the
retractor cover and away from the seat bel t webbi ng
where i t exi ts from the retractor cover. I n addi ti on,
the ai rbag system shoul d be di sarmed whenever any
steeri ng wheel , steeri ng col umn, seat bel t tensi oners,
or i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury.
Al l damaged, faul ty or non-depl oyed ai rbags or
seat bel t tensi oners whi ch are repl aced on vehi cl es
are to be returned. I f an ai rbag or seat bel t tensi oner
uni t i s faul ty or damaged and non-depl oyed, fol l ow
the i nstructi ons i n the current Mopar Hazardous
Materi al Awareness Manual or the current Dai ml er-
Chrysl er Corporati on Warranty Pol i ci es and Proce-
dures manual for the proper handl i ng and di sposal
procedures.
PASSIVE RESTRAINT STORAGE
Ai rbags and seat bel t tensi oners must be stored i n
there ori gi nal , speci al contai ner unti l they are used
for servi ce. Al so, they must be stored i n a cl ean, dry
envi ronment; away from sources of extreme heat,
sparks, and hi gh el ectri cal energy. Al ways pl ace or
store any ai rbag on a surface wi th i ts tri m cover or
ai rbag cushi on si de faci ng up, to mi ni mi ze movement
i n case of an acci dental depl oyment.
STANDARD PROCEDURE - SERVICE AFTER AN
AIRBAG DEPLOYMENT
Any vehi cl e whi ch i s to be returned to use fol l ow-
i ng an ai rbag depl oyment, must have both ai rbags,
the dri ver ai rbag tri m cover, the horn swi tch, the
cl ockspri ng, and the steeri ng col umn assembl y
repl aced. On quad cab model s, the seat bel t tensi on-
ers must al so be repl aced. These components are not
i ntended for reuse and wi l l be damaged or weakened
as a resul t of an ai rbag depl oyment, whi ch may or
may not be obvi ous duri ng a vi sual i nspecti on. Other
vehi cl e components shoul d be cl osel y i nspected, but
are to be repl aced onl y as requi red by the extent of
the vi si bl e damage i ncurred.
CLEANUP PROCEDURE
Fol l owi ng an ai rbag depl oyment, the vehi cl e i nte-
ri or wi l l contai n a powdery resi due. Thi s resi due con-
si sts pri mari l y of harml ess parti cul ate by-products of
the smal l pyrotechni c charge used to i ni ti ate the pro-
pel l ant used to depl oy the ai rbags. However, thi s res-
i due may al so contai n traces of sodi um hydroxi de
powder, a chemi cal by-product of the propel l ant
materi al that i s used to generate the ni trogen gas
that i nfl ates the ai rbag. Si nce sodi um hydroxi de pow-
der can i rri tate the ski n, eyes, nose, or throat, be
sure to wear safety gl asses, rubber gl oves, and a
l ong-sl eeved shi rt duri ng cl eanup (Fi g. 2).
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
Begi n the cl eanup by removi ng both ai rbags from
the vehi cl e. On quad cab model s, al so remove both
front seat bel t tensi oners. Refer to the appropri ate
servi ce manual removal procedures. Pl ace the
depl oyed ai rbags and seat bel t tensi oners i n your
vehi cul ar scrap pi l e.
Next, use a vacuum cl eaner to remove any resi dual
powder from the vehi cl e i nteri or. Cl ean from outsi de
the vehi cl e and work your way i nsi de, so that you
avoi d kneel i ng or si tti ng on a non-cl eaned area. Be
certai n to vacuum the heater and ai r condi ti oni ng
outl ets as wel l (Fi g. 3). Run the heater and ai r con-
di ti oner bl ower on the l owest speed setti ng and vac-
uum any powder expel l ed from the outl ets. You may
need to vacuum the i nteri or of the vehi cl e a second
ti me to recover al l of the powder.
STANDARD PROCEDURE - VERIFICATION TEST
The fol l owi ng procedure shoul d be performed usi ng
a DRBI I I scan tool to veri fy proper ai rbag system
operati on fol l owi ng the servi ce or repl acement of any
ai rbag system component.
COLUMN, SEAT bELT TENSIONER, OR INSTRU-
Fig. 2 Wear Safety Glasses and Rubber Gloves -
Typical
Fig. 3 Vacuum Heater and A/C Outlets - Typical
(1) Duri ng the fol l owi ng test, the battery negati ve
cabl e remai ns di sconnected and i sol ated, as i t was
duri ng the ai rbag component removal and i nstal l a-
ti on procedures.
(2) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn (Fi g. 4).
(3) Turn the i gni ti on swi tch to the On posi ti on and
exi t the vehi cl e wi th the DRBI I I .
(4) Check to be certai n that nobody i s i n the vehi -
cl e, then reconnect the battery negati ve cabl e.
(5) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
(6) Next, use the DRBI I I to read and record any
stored (hi stori cal ) DTC data.
(7) I f any DTC i s found i n Step 5 or Step 6, refer
(8) Use the DRBI I I to erase the stored DTC data.
I f any probl ems remai n, the stored DTC data wi l l not
erase. Refer to the appropri ate di agnosti c i nforma-
ti on to di agnose any stored DTC that wi l l not erase.
I f the stored DTC i nformati on i s successful l y erased,
go to Step 9.
(9) Turn the i gni ti on swi tch to the Off posi ti on for
about fi fteen seconds, and then back to the On posi -
ti on. Observe the ai rbag i ndi cator i n the i nstrument
cl uster. I t shoul d l i ght for si x to ei ght seconds, and
then go out. Thi s i ndi cates that the ai rbag system i s
functi oni ng normal l y and that the repai rs are com-
pl ete. I f the ai rbag i ndi cator fai l s to l i ght, or l i ghts
and stays on, there i s sti l l an acti ve ai rbag system
faul t or mal functi on. Refer to the appropri ate di ag-
nosti c i nformati on to di agnose the probl em.
SPECIAL TOOLS
SPECIAL TOOLS - AIRBAG SYSTEM
AIRBAG CONTROL MODULE
DESCRIPTION
The Ai rbag Control Modul e (ACM) i s secured wi th
screws to a mount wel ded onto the top of the fl oor
panel transmi ssi on tunnel behi nd the i nstrument
panel center support bracket i n the passenger com-
partment of the vehi cl e. The ACM contai ns an el ec-
troni c mi croprocessor, an el ectroni c i mpact sensor, an
el ectromechani cal safi ng sensor, and an energy stor-
age capaci tor. The ACM i s connected to the vehi cl e
el ectri cal system through a take out and connector of
the i nstrument panel wi re harness.
The ACM cannot be repai red or adjusted and, i f
damaged or faul ty, i t must be repl aced.
OPERATION
The mi croprocessor i n the ACM contai ns the ai rbag
system l ogi c ci rcui ts, and i t moni tors and control s al l
of the ai rbag system components. The ACM al so uses
On-Board Di agnosti cs (OBD) and can communi cate
wi th other el ectroni c modul es i n the vehi cl e as wel l
as wi th the DRBI I I scan tool usi ng the Programma-
bl e Communi cati ons I nterface (PCI ) data bus net-
work. Thi s method of communi cati on i s used for
control of the ai rbag i ndi cator i n the El ectroMechani -
cal I nstrument Cl uster (EMI C) and for ai rbag system
di agnosi s and testi ng through the 16-way data l i nk
connector l ocated on the l ower l eft edge of the i nstru-
MENT CLUSTER/AI RBAG I NDI CATOR -
OPERATI ON). The ACM mi croprocessor conti nuousl y
moni tors al l of the ai rbag system el ectri cal ci rcui ts to
determi ne the system readi ness. I f the ACM detects
Fig. 4 16-Way Data Link Connector - Typical
2 - BOTTOM OF INSTRUMENT PANEL
Puller C-3428-B
a moni tored system faul t, i t sets an acti ve Di agnosti c
Troubl e Code (DTC) and sends messages to the
EMI C over the PCI data bus to turn on the ai rbag
i ndi cator. I f the ai rbag system faul t i s sti l l present
when the i gni ti on swi tch i s turned to the Off posi -
ti on, the DTC i s stored i n memory by the ACM. How-
ever, i f a faul t does not recur for a number of i gni ti on
cycl es, the ACM wi l l automati cal l y erase the stored
DTC.
For model s equi pped wi th the passenger ai rbag
on/off swi tch (al l except quad cab), the ACM recei ves
a resi stor mul ti pl exed i nput from thi s swi tch and
provi des a control output for the Off i ndi cator i n the
swi tch through a passenger ai rbag i ndi cator dri ver
ci rcui t. I f the passenger ai rbag on/off swi tch i s set to
the Off posi ti on, the ACM turns on the passenger ai r-
bag on/off swi tch Off i ndi cator and wi l l i nternal l y di s-
abl e the passenger ai rbag from bei ng depl oyed i f an
i mpact i s detected that i s suffi ci ent for an ai rbag
depl oyment. The ACM al so turns on the on/off swi tch
Off i ndi cator for about seven seconds each ti me the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. Fol l owi ng the bul b test, the ACM control s the
status of the Off i ndi cator based upon the resi stance
of the i nput from the on/off swi tch. The ACM wi l l
al so set and/or store a DTC for faul ts i t detects i n the
passenger ai rbag on/off swi tch ci rcui ts, and wi l l turn
on the ai rbag i ndi cator i n the EMI C i f a faul t has
been detected.
The ACM recei ves battery current through two ci r-
cui ts, on a fused i gni ti on swi tch output (run) ci rcui t
through a fuse i n the Juncti on Bl ock (JB), and on a
through a second fuse i n the JB. The ACM i s
grounded through a ground ci rcui t and take out of
the i nstrument panel wi re harness. Thi s take out has
a si ngl e eyel et termi nal connector secured by a
ground screw to the l eft si de of the fl oor panel trans-
mi ssi on tunnel near the ACM i n the passenger com-
partment. Therefore, the ACM i s operati onal
whenever the i gni ti on swi tch i s i n the Start or On
posi ti ons. The ACM al so contai ns an energy-storage
capaci tor. When the i gni ti on swi tch i s i n the Start or
On posi ti ons, thi s capaci tor i s conti nual l y bei ng
charged wi th enough el ectri cal energy to depl oy the
ai rbags for up to one second fol l owi ng a battery di s-
connect or fai l ure. The purpose of the capaci tor i s to
provi de backup ai rbag system protecti on i n case
there i s a l oss of battery current suppl y to the ACM
duri ng an i mpact. The capaci tor i s onl y servi ced as a
uni t wi th the ACM.
Two sensors are contai ned wi thi n the ACM, an
el ectroni c i mpact sensor and a safi ng sensor. The
el ectroni c i mpact sensor i s an accel erometer that
senses the rate of vehi cl e decel erati on, whi ch pro-
vi des veri fi cati on of the di recti on and severi ty of an
i mpact. A pre-programmed deci si on al gori thm i n the
ACM mi croprocessor determi nes when the decel era-
ti on rate as si gnal ed by the i mpact sensor i ndi cates
an i mpact that i s severe enough to requi re ai rbag
system protecti on. When the programmed condi ti ons
are met, the ACM sends an el ectri cal si gnal to depl oy
the ai rbags and, on quad cab model s, the seat bel t
tensi oners. The safi ng sensor i s an el ectromechani cal
sensor wi thi n the ACM that i s connected i n seri es
between the ACM mi croprocessor depl oyment ci rcui t
and the ai rbags/seat bel t tensi oners. The safi ng sen-
sor i s a normal l y open swi tch that i s used to veri fy or
confi rm the need for an ai rbag depl oyment by detect-
i ng i mpact energy of a l esser magni tude than that of
the el ectroni c i mpact sensor, and must be cl osed i n
order for the ai rbags/seat bel t tensi oners to depl oy.
The i mpact sensor and safi ng sensor are cal i brated
for the speci fi c vehi cl e, and are onl y servi ced as a
uni t wi th the ACM.
REMOVAL
STEERING COLUMN, SEAT BELT TENSIONERS, OR
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER
STRIKE OR KICK THE AIRBAG CONTROL MODULE,
AS IT CAN DAMAGE THE IMPACT SENSOR OR
AFFECT ITS CALIBRATION. IF AN AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
cabl e. I f ei ther of the ai rbags has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) From the ri ght si de of the fl oor panel transmi s-
si on tunnel , remove the screw that secures the fl oor
AIRBAG CONTROL MODULE (Continued)
duct adapter to the bottom of the heater-ai r condi -
ti oner housi ng.
(3) Remove the fl oor duct adapter from the bottom
of the heater-ai r condi ti oner housi ng.
(4) Pul l the carpet on the ri ght and l eft si des of
the fl oor panel transmi ssi on tunnel rearward far
enough to access the Ai rbag Control Modul e (ACM).
(5) Remove the two screws that secure the ACM to
the ri ght si de of the mounti ng bracket that i s wel ded
onto the fl oor panel transmi ssi on tunnel (Fi g. 5).
(6) Remove the two screws that secure the ACM to
the l eft si de of the mounti ng bracket that i s wel ded
onto the fl oor panel transmi ssi on tunnel .
(7) Li ft the ACM upward from the mounti ng
bracket far enough to di sengage the l ocator pi ns on
the ACM housi ng from the l ocator hol es i n the
mounti ng bracket, then pul l the ACM out from under
the i nstrument panel far enough to access the wi re
harness connector.
connector for the ACM from the ACM connector
receptacl e. To di sconnect the i nstrument panel wi re
harness connector for the ACM:
(a) Sl i de the red Connector Posi ti on Assurance
(CPA) l ock on the top of the connector toward the
ri ght si de of the vehi cl e.
(b) Depress the l atch tab on the upper surface of
the connector, and pul l the connector strai ght away
from the ACM connector receptacl e.
(9) Remove the ACM from beneath the i nstrument
panel .
INSTALLATION
STEERING COLUMN, SEAT BELT TENSIONERS, OR
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER
STRIKE OR KICK THE AIRBAG CONTROL MODULE,
AS IT CAN DAMAGE THE IMPACT SENSOR OR
AFFECT ITS CALIBRATION. IF AN AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
RIES.
(1) Posi ti on the Ai rbag Control Modul e (ACM)
beneath the i nstrument panel .
connector for the ACM to the ACM connector recep-
tacl e (Fi g. 5). Be certai n that the connector l atch and
the red Connector Posi ti on Assurance (CPA) l ock are
ful l y engaged.
(3) Careful l y posi ti on the ACM to the mounti ng
bracket that i s wel ded onto the fl oor panel transmi s-
si on tunnel . When the ACM i s correctl y posi ti oned,
the l ocator pi ns on the ACM housi ng wi l l be engaged
i n the l ocator hol es i n the mounti ng bracket, and the
arrow on the ACM l abel wi l l be poi nted forward i n
the vehi cl e.
the ACM to the ri ght si de of the mounti ng bracket
that i s wel ded onto the fl oor panel transmi ssi on tun-
nel . Ti ghten the screws to 12 Nm (105 i n. l bs.).
the ACM to the l eft si de of the mounti ng bracket that
i s wel ded onto the fl oor panel transmi ssi on tunnel .
Ti ghten the screws to 12 Nm (105 i n. l bs.).
Fig. 5 Airbag Control Module
2 - SCREW (4)
3 - AIRBAG CONTROL MODULE
4 - WIRE HARNESS
5 - CONNECTOR POSITION ASSURANCE LOCK
6 - CONNECTOR
7 - GROUND EYELET TERMINALS (2)
8 - GROUND SCREWS (2)
(6) Restore the carpet on the ri ght and l eft si des of
the fl oor panel transmi ssi on tunnel to i ts proper posi -
ti on beneath the i nstrument panel .
(7) From the ri ght si de of the fl oor panel transmi s-
si on tunnel , posi ti on the fl oor duct adapter onto the
bottom of the heater-ai r condi ti oner housi ng.
fl oor duct adapter to the bottom of the heater-ai r con-
di ti oner housi ng. Ti ghten the screw to 2 Nm (17 i n.
l bs.).
(9) Do not reconnect the battery negati ve cabl e at
thi s ti me. The ai rbag system veri fi cati on test proce-
dure shoul d be performed fol l owi ng servi ce of any
ai rbag system component. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS - STANDARD PROCEDURE -
VERI FI CATI ON TEST).
CHILD TETHER
REMOVAL
Standard cab model s have two chi l d tether straps
secured near the top of the cab back panel . Cl ub cab
and quad cab model s have three chi l d tether straps
secured near the top of the cab back panel .
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Remove the screw that secures the chi l d tether
strap (2 used on standard cab, 3 used on cl ub/quad
cab) to the cab back panel (Fi g. 6).
(2) Remove the chi l d tether strap from the cab
back panel .
INSTALLATION
Standard cab model s have two chi l d tether straps
secured near the top of the cab back panel . Cl ub cab
and quad cab model s have three chi l d tether straps
secured near the top of the cab back panel .
(1) Posi ti on the chi l d tether strap onto the cab
back panel (Fi g. 6).
chi l d tether strap onto the cab back panel . Ti ghten
the screw to 13.5 Nm (120 i n. l bs.).
Fig. 6 Child Tether Straps
1 - CHILD TETHER STRAPS - STD. CAB (2)
2 - CAB BACK PANEL
3 - CHILD TETHER STRAPS - CLUB/QUAD CAB (3)
CLOCKSPRING
DESCRIPTION
The cl ockspri ng assembl y i s secured wi th two
screws onto the mul ti -functi on swi tch mounti ng
housi ng near the top of the steeri ng col umn behi nd
the steeri ng wheel (Fi g. 7). The cl ockspri ng consi sts
of a fl at, round mol ded pl asti c case wi th a stubby tai l
that hangs bel ow the steeri ng col umn and contai ns
two connector receptacl es that face toward the
i nstrument panel . Wi thi n the pl asti c housi ng i s a
spool -l i ke mol ded pl asti c rotor wi th a l arge exposed
hub. The upper surface of the rotor hub has a l arge
center hol e, two l arge fl ats, an engagement dowel
wi th a yel l ow rubber boot, a short pi gtai l wi re wi th
connector, and two connector receptacl es that face
toward the steeri ng wheel . The l ower surface of the
rotor hub has a mol ded pl asti c turn si gnal cancel
cam wi th two l obes that i s keyed to the rotor and i s
secured there wi th four i ntegral snap features.
Wi thi n the pl asti c case and wound around the rotor
spool i s a l ong ri bbon-l i ke tape that consi sts of sev-
eral thi n copper wi re l eads sandwi ched between two
thi n pl asti c membranes. The outer end of the tape
termi nates at the connector receptacl es that face the
i nstrument panel , whi l e the i nner end of the tape
termi nates at the pi gtai l wi re and connector recepta-
cl es on the hub of the cl ockspri ng rotor that face the
steeri ng wheel .
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a l ocki ng pi n that snaps i nto a
receptacl e on the rotor and i s engaged between two
tabs on the upper surface of the rotor case. The l ock-
i ng pi n secures the centered cl ockspri ng rotor to the
cl ockspri ng case duri ng shi pment, but the l ocki ng pi n
must be removed from the cl ockspri ng after i t i s
i nstal l ed on the steeri ng col umn. (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/CLOCKSPRI NG - STAN-
DARD PROCEDURE - CLOCKSPRI NG
CENTERI NG).
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the dri ver ai rbag has
been depl oyed, the cl ockspri ng must be repl aced.
OPERATION
The cl ockspri ng i s a mechani cal el ectri cal ci rcui t
component that i s used to provi de conti nuous el ectri -
cal conti nui ty between the fi xed i nstrument panel
wi re harness and the el ectri cal components mounted
on or i n the rotati ng steeri ng wheel . On thi s model
the rotati ng el ectri cal components i ncl ude the dri ver
ai rbag, the horn swi tch, the speed control swi tches,
and the remote radi o swi tches i f the vehi cl e i s so
equi pped. The cl ockspri ng case i s posi ti oned and
secured to the mul ti -functi on swi tch mounti ng hous-
i ng near the top of the steeri ng col umn. The connec-
tor receptacl es on the tai l of the fi xed cl ockspri ng
case connect the cl ockspri ng to the vehi cl e el ectri cal
system through two take outs wi th connectors from
the i nstrument panel wi re harness. The cl ockspri ng
rotor i s movabl e and i s keyed by an engagement
dowel that i s mol ded onto the rotor hub between two
fi ns that are cast i nto the l ower surface of the steer-
i ng wheel armature. A yel l ow rubber boot i s i nstal l ed
over the engagement dowel to el i mi nate noi se. The
two l obes on the turn si gnal cancel cam on the l ower
surface of the cl ockspri ng rotor hub contact a turn
si gnal cancel actuator of the mul ti -functi on swi tch to
provi de automati c turn si gnal cancel l ati on. The yel -
l ow sl eeved pi gtai l wi res on the upper surface of the
cl ockspri ng rotor connect the cl ockspri ng to the
dri ver ai rbag, whi l e a steeri ng wheel wi re harness
connects the two connector receptacl es on the upper
surface of the cl ockspri ng rotor to the horn swi tch
and, i f the vehi cl e i s so equi pped, to the opti onal
speed control and remote radi o swi tches on the steer-
i ng wheel .
Li ke the cl ockspri ng i n a ti mepi ece, the cl ockspri ng
tape has travel l i mi ts and can be damaged by bei ng
wound too ti ghtl y duri ng ful l stop-to-stop steeri ng
wheel rotati on. To prevent thi s from occurri ng, the
cl ockspri ng i s centered when i t i s i nstal l ed on the
Fig. 7 Clockspring and Multi-Function Switch
1 - CLOCKSPRING
2 - LOCATING PIN
3 - SCREW (2)
4 - LOCKING PIN
5 - ENGAGEMENT DOWEL AND BOOT
steeri ng col umn. Centeri ng the cl ockspri ng i ndexes
the cl ockspri ng tape to the movabl e steeri ng compo-
nents so that the tape can operate wi thi n i ts
desi gned travel l i mi ts. However, i f the cl ockspri ng i s
removed from the steeri ng col umn or i f the steeri ng
shaft i s di sconnected from the steeri ng gear, the
cl ockspri ng spool can change posi ti on rel ati ve to the
movabl e steeri ng components and must be re-cen-
tered fol l owi ng compl eti on of the servi ce or the tape
may be damaged. Servi ce repl acement cl ockspri ngs
are shi pped pre-centered and wi th a pl asti c l ocki ng
pi n i nstal l ed. Thi s l ocki ng pi n shoul d not be di sen-
gaged unti l the cl ockspri ng has been i nstal l ed on the
steeri ng col umn. I f the l ocki ng pi n i s removed or
damaged before the cl ockspri ng i s i nstal l ed on a
steeri ng col umn, the cl ockspri ng centeri ng procedure
must be performed. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - STANDARD PROCE-
DURE - CLOCKSPRI NG CENTERI NG).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
The cl ockspri ng i s desi gned to wi nd and unwi nd
when the steeri ng wheel i s rotated, but i s onl y
desi gned to rotate the same number of turns (about
fi ve compl ete rotati ons) as the steeri ng wheel can be
turned from stop to stop. Centeri ng the cl ockspri ng
i ndexes the cl ockspri ng tape to other steeri ng compo-
nents so that i t can operate wi thi n i ts desi gned
travel l i mi ts. The rotor of a centered cl ockspri ng can
be rotated two and one-hal f turns i n ei ther di recti on
from the centered posi ti on, wi thout damagi ng the
cl ockspri ng tape.
However, i f the cl ockspri ng i s removed for servi ce
or i f the steeri ng col umn i s di sconnected from the
steeri ng gear, the cl ockspri ng tape can change posi -
ti on rel ati ve to the other steeri ng components. The
cl ockspri ng must then be re-centered fol l owi ng com-
pl eti on of such servi ce or the cl ockspri ng tape may be
damaged. Servi ce repl acement cl ockspri ngs are
shi pped pre-centered and wi th a pl asti c l ocki ng pi n
i nstal l ed (Fi g. 8). Thi s l ocki ng pi n shoul d not be
removed unti l the cl ockspri ng has been i nstal l ed on
the steeri ng col umn. I f the l ocki ng pi n i s removed
before the cl ockspri ng i s i nstal l ed on a steeri ng col -
umn, the cl ockspri ng centeri ng procedure must be
performed.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the cl ockspri ng from the steeri ng col -
umn (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL).
(3) Rotate the cl ockspri ng rotor cl ockwi se to the
end of i ts travel . Do not apply excessive torque.
(4) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se.
The engagement dowel and yel l ow rubber boot
shoul d end up at the bottom, and the arrows on the
cl ockspri ng rotor and case shoul d be i n al i gnment.
The cl ockspri ng i s now centered.
(5) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. Rei nstal l the cl ockspri ng onto the
steeri ng col umn (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
1 - CLOCKSPRING
2 - LOCATING PIN
3 - SCREW (2)
4 - LOCKING PIN
CLOCKSPRING (Continued)
REMOVAL
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the dri ver ai rbag from the steeri ng
wheel (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
connectors from the upper cl ockspri ng connector
receptacl es.
(4) Remove the screw that secures the steeri ng
wheel armature to the steeri ng col umn upper shaft,
whi ch i s l ocated wi thi n the hub cavi ty of the steeri ng
wheel .
CAUTION: Be certain that the screws that secure
the steering wheel puller to the steering wheel are
fully engaged in the steering wheel armature with-
out passing through the steering wheel and damag-
ing the clockspring.
(5) Pul l the steeri ng wheel off of the steeri ng col -
umn upper shaft spl i ne usi ng a steeri ng wheel pul l er
(Speci al Tool C-3428-B).
trol stal k.
the l ower shroud.
shroud.
(12) Remove the l ower shroud from the steeri ng
col umn.
(13) Di sconnect the two i nstrument panel wi re
harness connectors for the cl ockspri ng from the l ower
cl ockspri ng connector receptacl es.
(14) Remove the two screws that secure the cl ock-
spri ng to the mul ti -functi on swi tch mounti ng housi ng
(Fi g. 9).
(15) Remove the cl ockspri ng from the mul ti -func-
ti on swi tch mounti ng housi ng. The cl ockspri ng can-
not be repai red. I t must be repl aced i f faul ty or
damaged, or i f the dri ver ai rbag has been depl oyed.
(16) I f the removed cl ockspri ng i s to be reused,
secure the cl ockspri ng rotor to the cl ockspri ng case to
mai ntai n cl ockspri ng centeri ng unti l i t i s rei nstal l ed
1 - CLOCKSPRING
2 - LOCATING PIN
3 - SCREW (2)
4 - LOCKING PIN
on the steeri ng col umn. I f cl ockspri ng centeri ng i s
not mai ntai ned, the cl ockspri ng must be centered
agai n before i t i s rei nstal l ed. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - STANDARD
PROCEDURE - CLOCKSPRI NG CENTERI NG).
INSTALLATION
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
I f the cl ockspri ng i s not properl y centered i n rel a-
ti on to the steeri ng wheel , steeri ng shaft and steer-
i ng gear, i t may be damaged. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG). Servi ce repl acement cl ockspri ngs are
shi pped pre-centered and wi th a pl asti c l ocki ng pi n
i nstal l ed. Thi s l ocki ng pi n shoul d not be removed
unti l the cl ockspri ng has been i nstal l ed on the steer-
i ng col umn. I f the l ocki ng pi n i s removed before the
cl ockspri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) Careful l y sl i de the centered cl ockspri ng down
over the steeri ng col umn upper shaft unti l the hol e
i n the l ocati ng tab at the el even ocl ock posi ti on on
the cl ockspri ng case i s engaged over the l ocati ng pi n
on the mul ti -functi on swi tch mounti ng housi ng (Fi g.
9).
the cl ockspri ng to the mul ti -functi on swi tch mount-
i ng housi ng. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
ness connectors for the cl ockspri ng to the l ower cl ock-
spri ng connector receptacl es.
umn.
i n. l bs.).
(11) Rei nstal l the steeri ng wheel onto the steeri ng
col umn upper shaft. Be certai n to i ndex the yel l ow
rubber booted engagement dowel on the upper sur-
face of the cl ockspri ng rotor between the two fi ns
cast i nto the l ower surface of the steeri ng wheel
armature hub. Pul l the upper cl ockspri ng pi gtai l wi re
through the upper hol e between the steeri ng wheel
back tri m cover and the steeri ng wheel armature.
steeri ng wheel to the steeri ng col umn upper shaft.
Ti ghten the screw to 61 Nm (45 ft. l bs.). Be certai n
not to pi nch the cl ockspri ng pi gtai l wi re or the steer-
i ng wheel wi re harness between the steeri ng wheel
and the screw.
(13) Reconnect the steeri ng wheel wi re harness
connectors to the upper cl ockspri ng connector recep-
tacl es. Be certai n that the steeri ng wi re harness i s
routed between the steeri ng wheel back tri m cover
and the steeri ng wheel armature.
(14) Rei nstal l the dri ver ai rbag onto the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON).
DRIVER AIRBAG
DESCRIPTION
The dri ver ai rbag protecti ve tri m cover i s the most
vi si bl e part of the dri ver ai rbag (Fi g. 10). The ai rbag
used i n thi s model i s a Next Generati on-type that
compl i es wi th revi sed federal ai rbag standards to
depl oy wi th l ess force than those used i n some pri or
model s. The dri ver ai rbag i s l ocated i n the center of
the steeri ng wheel , where i t i s secured wi th two
screws to the steeri ng wheel armature. Conceal ed
beneath the dri ver ai rbag tri m cover are the horn
swi tch, the fol ded ai rbag cushi on, the ai rbag retai ner
or housi ng, the ai rbag i nfl ator, and the retai ners that
secure the i nfl ator to the ai rbag housi ng. The resi s-
ti ve membrane-type horn swi tch i s secured wi thi n a
pl asti c tray that i s i nserted i n a pocket or pouch
sewn onto the ai rbag cushi on retai ner strap, between
the tri m cover and the fol ded ai rbag cushi on (Fi g.
11). The ai rbag i nfl ator i s a conventi onal non-azi de,
pyrotechni c-type uni t wi th four studs and i t i s
secured to the stamped metal ai rbag housi ng wi th
four nuts.
The tri m cover has an ai rbag receptacl e mol ded
i nto the back si de of i t. The four verti cal wal l s of thi s
receptacl e have a total of twel ve smal l wi ndows wi th
bl ocki ng tabs that are engaged by twel ve hook forma-
ti ons around the peri meter of the ai rbag housi ng.
Each hook i s i nserted through one of the wi ndows,
the i ntegral bl ocki ng tab i n each wi ndow keeps each
hook properl y engaged wi th the tri m cover, l ocki ng
the cover securel y i nto pl ace. One horn swi tch pi gtai l
wi re has an eyel et termi nal connector that i s cap-
tured beneath a nut and washer on the upper ri ght
i nfl ator mounti ng stud. The other horn swi tch pi gtai l
wi re i s routed between the upper l eft i nfl ator mount-
i ng stud and the i nfl ator, where i t i s captured by a
smal l pl asti c retai ner that i s pushed onto the stud.
The dri ver ai rbag cannot be repai red, and must be
repl aced i f depl oyed or i n any way damaged. The
dri ver ai rbag tri m cover and the horn swi tch wi th
tray are avai l abl e, and may be di sassembl ed from the
dri ver ai rbag for servi ce repl acement.
OPERATION
The dri ver ai rbag i s depl oyed by an el ectri cal si g-
nal generated by the Ai rbag Control Modul e (ACM)
through the dri ver ai rbag l i ne 1 and l i ne 2 (or squi b)
ci rcui ts. When the ACM sends the proper el ectri cal
si gnal to the ai rbag i nfl ator, the el ectri cal energy
generates enough heat to i ni ti ate a smal l pyrotechni c
charge whi ch, i n turn, i gni tes chemi cal pel l ets wi thi n
the i nfl ator. Once i gni ted, these chemi cal pel l ets burn
rapi dl y and produce a l arge quanti ty of ni trogen gas.
The i nfl ator i s seal ed to the back of the ai rbag hous-
i ng and a di ffuser i n the i nfl ator di rects al l of the
ni trogen gas i nto the ai rbag cushi on, causi ng the
cushi on to i nfl ate. As the cushi on i nfl ates, the dri ver
ai rbag tri m cover wi l l spl i t at predetermi ned break-
out l i nes, then fol d back out of the way al ong wi th
Fig. 10 Driver Airbag
1 - HOUSING HOOKS (12)
2 - HORN SWITCH GROUND PIGTAIL WIRE
3 - HORN SWITCH FEED PIGTAIL WIRE
Fig. 11 Horn Switch
1 - HORN SWITCH GROUND PIGTAIL WIRE
2 - HORN SWITCH
3 - POUCH
4 - DRIVER AIRBAG (TRIM COVER REMOVED)
5 - TRAY
6 - HORN SWITCH FEED PIGTAIL WIRE
7 - POUCH SLITS
DRIVER AIRBAG (Continued)
the horn swi tch and tray uni t. Fol l owi ng an ai rbag
depl oyment, the ai rbag cushi on qui ckl y defl ates by
venti ng the ni trogen gas towards the i nstrument
panel through the porous fabri c materi al used on the
steeri ng wheel si de of the ai rbag cushi on.
Some of the chemi cal s used to create the ni trogen
gas may be consi dered hazardous i n thei r sol i d state,
before they are burned, but they are securel y seal ed
wi thi n the ai rbag i nfl ator. However, the ni trogen gas
that i s produced when the chemi cal s are burned i s
harml ess. A smal l amount of resi due from the burned
chemi cal s may cause some temporary di scomfort i f i t
contacts the ski n, eyes, or breathi ng passages. I f ski n
or eye i rri tati on i s noti ced, ri nse the affected area
wi th pl enty of cool , cl ean water. I f breathi ng pas-
sages are i rri tated, move to another area where there
i s pl enty of cl ean, fresh ai r to breath. I f the i rri tati on
i s not al l evi ated by these acti ons, contact a physi ci an.
REMOVAL
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the dri ver ai rbag
has been depl oyed, the cl ockspri ng and the steeri ng
col umn assembl y must al so be repl aced. (Refer to 8 -
REMOVAL) (Refer to 19 - STEERI NG/COLUMN -
REMOVAL).
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG CUSHION AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver ai rbag
to the steeri ng wheel armature (Fi g. 12).
(3) Pul l the dri ver ai rbag away from the steeri ng
wheel far enough to access the two wi re harness con-
nectors at the back of the ai rbag.
connector for the horn swi tch from the horn swi tch
feed pi gtai l wi re connector, whi ch i s l ocated at the
back of the dri ver ai rbag.
CAUTION: Do not pull on the clockspring pigtail
wire to disengage the connector from the driver air-
bag inflator connector receptacle.
(5) The cl ockspri ng dri ver ai rbag pi gtai l wi re con-
nector i s a ti ght snap-fi t i nto the ai rbag i nfl ator con-
nector receptacl e, whi ch i s l ocated at the back of the
dri ver ai rbag. Fi rml y grasp and pul l or gentl y pry on
the cl ockspri ng dri ver ai rbag wi re harness connector
to di sconnect i t from the ai rbag i nfl ator connector
receptacl e.
wheel .
(7) I f the dri ver ai rbag has been depl oyed, the
cl ockspri ng and the steeri ng col umn must be
repl aced. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL). (Refer to 19 - STEER-
I NG/COLUMN - REMOVAL).
DISASSEMBLY
The fol l owi ng procedures can be used to repl ace
the dri ver ai rbag tri m cover or the horn swi tch and
tray uni t. I f the dri ver ai rbag i s faul ty or depl oyed,
the enti re dri ver ai rbag, tri m cover, and horn swi tch
must be repl aced as a uni t.
WARNING: THE HORN SWITCH IS INTEGRAL TO
THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT
SHOULD BE PERFORMED ONLY BY DAIMLER-
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
RIES.
DRI VER AI RBAG - REMOVAL).
(3) Usi ng hand pressure, press the ai rbag housi ng
down i nto the receptacl e on the back of the dri ver
ai rbag tri m cover.
(4) Careful l y pry back the wal l s of the dri ver ai r-
bag receptacl e on the back of the tri m cover to
rel ease each of the twel ve wi ndows of the tri m cover
receptacl e from the twel ve hook formati ons on the
peri meter of the ai rbag housi ng.
(5) Remove the housi ng, i nfl ator, cushi on, and
horn swi tch as a uni t from the dri ver ai rbag tri m
cover receptacl e.
(6) Gentl y pry off the pl asti c wi re retai ner that
captures the horn swi tch feed pi gtai l wi re between
the upper ri ght i nfl ator stud and the i nfl ator on the
back of the dri ver ai rbag housi ng.
horn swi tch ground pi gtai l wi re eyel et termi nal to
the upper l eft i nfl ator stud on the back of the dri ver
ai rbag housi ng.
(8) Remove the horn swi tch ground pi gtai l wi re
eyel et termi nal from the upper l eft i nfl ator stud on
the back of the dri ver ai rbag housi ng.
(9) Sl i de the horn swi tch and tray uni t al l the way
to one si de of the pouch on the dri ver ai rbag cushi on
Fig. 12 Driver Airbag Remove/Install
1 - CLOCKSPRING DRIVER AIRBAG PIGTAIL WIRE
2 - STEERING WHEEL WIRE HARNESS
3 - STEERING WHEEL
4 - CONNECTOR FOR HORN SWITCH FEED PIGTAIL WIRE
5 - DRIVER AIRBAG
6 - SCREW (2)
7 - CLOCKSPRING
retai ner strap to di sengage one of the retai ni ng tabs
on the tray from one of the sl i ts l ocated i n each si de
of the pouch.
(10) Remove the horn swi tch and tray as a uni t
from the pouch on the dri ver ai rbag cushi on retai ner
strap (Fi g. 13).
ASSEMBLY
The fol l owi ng procedures can be used to repl ace
the dri ver ai rbag tri m cover or the horn swi tch and
tray uni t. I f the dri ver ai rbag i s faul ty or depl oyed,
the enti re dri ver ai rbag, tri m cover, and horn swi tch
must be repl aced as a uni t.
WARNING: THE HORN SWITCH IS INTEGRAL TO
THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT
SHOULD BE PERFORMED ONLY BY DAIMLER-
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
RIES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT TRIM
COVERS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) I nstal l the horn swi tch and tray uni t i nto the
pouch on the dri ver ai rbag cushi on retai ner strap. Be
certai n that the tray i s faci ng the ai rbag cushi on,
that the horn swi tch membrane i s faci ng the ai rbag
tri m cover, that the horn swi tch feed pi gtai l wi re i s
on the ri ght, that the horn swi tch ground pi gtai l wi re
i s on the l eft, and that the retai ni ng tabs on the tray
are each engaged i n one of the sl i ts l ocated i n each
si de of the pouch (Fi g. 14)
Fig. 13 Horn Switch Remove/Install
Fig. 14 Horn Switch Installed
(2) Route the horn swi tch ground pi gtai l wi re
through the cl earance notch between the two upper
l eft hooks on the dri ver ai rbag housi ng. I nstal l the
eyel et termi nal over the upper l eft i nfl ator stud and
engage the termi nal under the anti -rotati on tab
di rectl y above the stud on the back of the dri ver ai r-
bag housi ng.
secure the horn swi tch ground pi gtai l wi re eyel et ter-
mi nal to the upper l eft i nfl ator stud on the back of
the dri ver ai rbag housi ng. Ti ghten the nut to 7 Nm
(65 i n. l bs.).
(4) Route the horn swi tch feed pi gtai l wi re through
the cl earance notch between the two upper ri ght
hooks and between the upper ri ght i nfl ator stud and
the i nfl ator on the back of the dri ver ai rbag housi ng.
(5) Usi ng hand pressure, press the pl asti c wi re
retai ner onto the upper ri ght i nfl ator stud to capture
the horn swi tch feed pi gtai l wi re between the stud
and the i nfl ator on the back of the dri ver ai rbag
housi ng.
(6) Careful l y posi ti on the dri ver ai rbag i nto the
receptacl e on the back of the tri m cover. Be certai n
that the horn swi tch feed and ground pi gtai l wi res
remai n properl y routed through the cl earance
notches at the top of the ai rbag housi ng and are not
pi nched between the ai rbag housi ng and the wal l s of
the tri m cover receptacl e.
(7) Work around the peri meter of the uni t engag-
i ng each of the twel ve hooks on the dri ver ai rbag
housi ng through the wi ndows i n the wal l s of the tri m
cover receptacl e.
(8) After each of the twel ve hooks on the dri ver
ai rbag housi ng has been engaged i n a wi ndow of the
tri m cover receptacl e, try pul l i ng the tri m cover and
the ai rbag housi ng away from each other. Thi s acti on
wi l l ful l y seat the edges of the wi ndows i nto the cra-
dl es of the hooks.
(9) After al l of the wi ndows i n the wal l s of the
tri m cover receptacl e have been ful l y seated i n the
cradl es of the hooks on the ai rbag housi ng, push the
bl ocki ng tabs of the two wi ndows on the ri ght and
l eft si de wal l s of the tri m cover receptacl e i nward so
that they are ori ented behi nd the ai rbag housi ng
hooks, as shown i n (Fi g. 15).
(10) I nspect the ai rbag housi ng hooks i n the wi n-
dows of the upper and l ower wal l s of the tri m cover
receptacl e to be certai n they are ful l y engaged and
that the bl ocki ng tabs for these wi ndows are ori ented
over the tops of the hooks, as shown i n (Fi g. 16).
(11) Rei nstal l the dri ver ai rbag onto the steeri ng
DRI VER AI RBAG - I NSTALLATI ON).
INSTALLATION
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the dri ver ai rbag
has been depl oyed, the cl ockspri ng and the steeri ng
col umn assembl y must al so be repl aced. (Refer to 8 -
REMOVAL) and (Refer to 19 - STEERI NG/COLUMN
- REMOVAL).
Fig. 15 Driver Airbag Trim Cover Side Blocking Tabs
1 - BLOCKING TAB
2 - DRIVER AIRBAG TRIM COVER
3 - HORN SWITCH
4 - AIRBAG HOUSING HOOK
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT TRIM
COVERS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Assembl e the dri ver ai rbag tri m cover onto the
ai rbag housi ng. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - ASSEMBLY).
(2) When i nstal l i ng the dri ver ai rbag, reconnect
the cl ockspri ng dri ver ai rbag pi gtai l wi re connector
to the ai rbag i nfl ator connector receptacl e by press-
i ng strai ght i n on the connector (Fi g. 12). You can be
certai n that the connector i s ful l y engaged by l i sten-
i ng careful l y for a di sti nct, audi bl e cl i ck as the con-
nector snaps i nto pl ace.
(3) Reconnect the steeri ng wheel wi re harness con-
nector for the horn swi tch to the horn swi tch feed
pi gtai l wi re connector, whi ch i s l ocated at the back of
the dri ver ai rbag.
(4) Careful l y posi ti on the dri ver ai rbag i n the
steeri ng wheel . Be certai n that the cl ockspri ng pi g-
tai l wi re and steeri ng wheel wi re harness i n the
steeri ng wheel hub area are not pi nched between the
dri ver ai rbag and the steeri ng wheel armature.
(5) From the undersi de of the steeri ng wheel ,
i nstal l and ti ghten the two screws that secure the
dri ver ai rbag to the steeri ng wheel armature.
FRONT SEAT BELT &
RETRACTOR
REMOVAL - QUAD CAB
Fig. 16 Driver Airbag Trim Cover Upper & Lower
Blocking Tabs
1 - BLOCKING TAB
2 - DRIVER AIRBAG TRIM COVER
3 - HORN SWITCH
4 - AIRBAG HOUSING HOOK
(1) Move the front seats to thei r most forward
posi ti on for easi est access to the l ower seat bel t
anchor pl ate, the retractor, and the B-pi l l ar.
(3) Li ft the cover on the l ower seat bel t anchor
pl ate far enough to access the screw that secures the
anchor pl ate to the front seat adjuster.
(4) Remove the screw that secures the l ower seat
bel t anchor pl ate to the seat adjuster (Fi g. 17).
(5) Unsnap and remove the front shoul der bel t
turni ng l oop cover to access the screw that secures
the turni ng l oop to the hei ght adjuster.
(6) Remove the screw that secures the shoul der
bel t turni ng l oop to the hei ght adjuster (Fi g. 18).
(7) Remove the shoul der bel t turni ng l oop from the
hei ght adjuster.
(8) Remove the tri m from the B-pi l l ar. (Refer to 23
- BODY/I NTERI OR/B-PI LLAR TRI M - REMOVAL).
(9) Remove the two screws that secure the seat
bel t web gui de to the B-pi l l ar above the retractor.
(10) Di sconnect the seat bel t tensi oner pi gtai l wi re
connector from the body wi re harness connector.
(11) On the dri ver si de onl y, di sconnect the seat
bel t swi tch pi gtai l wi re connector from the body wi re
harness connector.
(12) Remove the screw that secures the retractor
to the B-pi l l ar.
(13) Remove the front shoul der bel t and retractor
from the B-pi l l ar.
Fig. 17 Front Seat Belt Lower Anchor
1 - SCREW
2 - SEAT
Fig. 18 Front Shoulder Belt & Retractor - Quad Cab
1 - TURNING LOOP
2 - HEIGHT ADJUSTER
3 - UPPER B-PILLAR TRIM
4 - B-PILLAR
5 - SHIELD
6 - SCREW
7 - LOWER B-PILLAR TRIM
8 - RETRACTOR
FRONT SEAT BELT & RETRACTOR (Continued)
REMOVAL - STANDARD/CLUB CAB
(1) Move the front seats to thei r most forward
posi ti on for easi est access to the l ower seat bel t
anchor pl ate, the retractor, and the B-pi l l ar.
cabl e.
(3) Unsnap and remove the front shoul der bel t
the turni ng l oop to the hei ght adjuster.
bel t turni ng l oop to the hei ght adjuster (Fi g. 19).
hei ght adjuster.
(6) Remove the tri m from the quarter i nner panel .
(Refer to 23 - BODY/I NTERI OR/QUARTER TRI M
PANEL - REMOVAL).
bel t anchor pl ate to the B-pi l l ar.
(8) Remove the l ower seat bel t anchor pl ate from
the B-pi l l ar.
(9) On the dri ver si de onl y, di sconnect the seat bel t
swi tch pi gtai l wi re connector from the body wi re har-
ness connector.
(10) Remove the screw that secures the retractor
to the B-pi l l ar.
(11) Remove the front shoul der bel t and retractor
from the B-pi l l ar.
INSTALLATION - QUAD CAB
(1) Be certai n that the retractor shi el d i s properl y
i nstal l ed i n the B-pi l l ar and i n good condi ti on before
i nstal l i ng the retractor (Fi g. 18).
(2) Posi ti on the retractor i nto the B-pi l l ar.
Fig. 19 Front Shoulder Belt & Retractor - Standard/
Club Cab - Typical
1 - TURNING LOOP
2 - QUARTER TRIM
3 - RETRACTOR
4 - LOWER ANCHOR
5 - SEAT BELT SWITCH CONNECTOR (DRIVER SIDE ONLY)
6 - HEIGHT ADJUSTER
retractor to the B-pi l l ar. Ti ghten the screw to 40 Nm
(29 ft. l bs.).
(4) Reconnect the seat bel t tensi oner pi gtai l wi re
connector to the body wi re harness connector.
(5) On the dri ver si de onl y, reconnect the seat bel t
swi tch pi gtai l wi re connector to the body wi re har-
ness connector.
(6) Posi ti on the seat bel t web gui de to the B-pi l l ar
above the retractor.
the seat bel t web gui de to the B-pi l l ar. Ti ghten the
(8) Rei nstal l the tri m onto the B-pi l l ar. (Refer to
23 - BODY/I NTERI OR/B-PI LLAR TRI M - I NSTAL-
LATI ON).
(9) Posi ti on the shoul der bel t turni ng l oop onto the
hei ght adjuster.
shoul der bel t turni ng l oop to the hei ght adjuster.
Ti ghten the screw to 30 Nm (22 ft. l bs.).
(11) Snap the tri m cover over the front shoul der
bel t turni ng l oop anchor pl ate to conceal the screw
that secures the turni ng l oop to the hei ght adjuster.
(12) Posi ti on the l ower seat bel t anchor pl ate to
the seat adjuster (Fi g. 17).
l ower seat bel t anchor pl ate to the seat adjuster.
(14) Reposi ti on the cover over the l ower seat bel t
anchor pl ate to conceal the screw that secures the
anchor pl ate to the front seat adjuster.
INSTALLATION - STANDARD/CLUB CAB
(1) Posi ti on the retractor i nto the B-pi l l ar (Fi g.
18).
retractor to the B-pi l l ar. Ti ghten the screw to 40 Nm
(29 ft. l bs.).
(3) On the dri ver si de onl y, reconnect the seat bel t
swi tch pi gtai l wi re connector to the body wi re har-
ness connector.
(4) Posi ti on the l ower seat bel t anchor pl ate to the
B-pi l l ar.
l ower seat bel t anchor pl ate to the B-pi l l ar. Ti ghten
the screw to 40 Nm (29 ft. l bs.).
(6) Rei nstal l the tri m onto the quarter i nner panel .
(Refer to 23 - BODY/I NTERI OR/QUARTER TRI M
PANEL - I NSTALLATI ON).
hei ght adjuster.
shoul der bel t turni ng l oop to the hei ght adjuster.
(9) Snap the tri m cover over the front shoul der
bel t turni ng l oop anchor pl ate to conceal the screw
that secures the turni ng l oop to the hei ght adjuster.
FRONT SEAT BELT BUCKLE
REMOVAL
(1) I f the vehi cl e i s so equi pped, remove the con-
sol e from the fl oor panel transmi ssi on tunnel . (Refer
to 23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL).
(2) I f the vehi cl e i s so equi pped, remove the bench
seat from the passenger compartment. (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL - BENCH).
(3) I f the vehi cl e i s so equi pped, remove the center
seat from the passenger compartment. (Refer to 23 -
BODY/SEATS/CENTER SEAT ARMREST/CONSOLE
- REMOVAL - CENTER SEAT/CONSOLE).
(4) Remove the screw that secures the front seat
bel t buckl e uni t to the seat adjuster (Fi g. 20).
(5) Remove the front seat bel t buckl e from the seat
adjuster.
INSTALLATION
(1) Posi ti on the front seat bel t buckl e to the seat
adjuster (Fi g. 20).
front seat bel t buckl e uni t to the seat adjuster.
Ti ghten the screw to 23 Nm (17 ft. l bs.). The buckl e
shoul d be free to pi vot sl i ghtl y fore and aft after the
screw i s ti ghtened.
(3) I f the vehi cl e i s so equi pped, rei nstal l the cen-
ter seat i nto the passenger compartment. (Refer to 23
- BODY/SEATS/CENTER SEAT ARMREST/CON-
SOLE - I NSTALLATI ON - CENTER SEAT/CON-
SOLE).
(4) I f the vehi cl e i s so equi pped, rei nstal l the
bench seat i nto the passenger compartment.(Refer to
23 - BODY/SEATS/SEAT - I NSTALLATI ON -
BENCH).
(5) I f the vehi cl e i s so equi pped, rei nstal l the con-
sol e onto the fl oor panel transmi ssi on tunnel . (Refer
I NSTALLATI ON).
PASSENGER AIRBAG
DESCRIPTION
The rearward faci ng surface of the passenger ai r-
bag door above the gl ove box i s the most vi si bl e part
of the passenger ai rbag. The ai rbag used i n thi s
model i s a Next Generati on-type that compl i es wi th
revi sed federal ai rbag standards to depl oy wi th l ess
force than those used i n some pri or model s. The pas-
senger ai rbag i s l ocated i n the i nstrument panel i n
front of the front seat passenger seati ng posi ti on,
where i t i s secured to the i nstrument panel . Con-
ceal ed beneath the passenger ai rbag door are the
fol ded ai rbag cushi on, the ai rbag retai ner or housi ng,
and the ai rbag i nfl ator. The ai rbag i nfl ator i s a
hybri d-type uni t that i s secured to and seal ed wi thi n
the ai rbag housi ng al ong wi th the fol ded ai rbag cush-
i on. The ai rbag housi ng i s constructed of a l ong
U-shaped al umi num extrusi on wi th two stamped
steel end pl ates. Two tabs that extend from the bot-
tom of the extrusi on serve as the rear mounti ng
brackets, whi l e an angl ed foot on the bottom of each
end pl ate serve as the front mounti ng brackets. The
front brackets are secured wi th screws to the i nstru-
ment panel armature above the gl ove box, whi l e the
rear brackets are secured wi th screws to the upper
gl ove box openi ng rei nforcement. A yel l ow connector
on the end of a short, two-wi re pi gtai l harness con-
nects the passenger ai rbag i nfl ator to the vehi cl e
el ectri cal system.
The mol ded pl asti c passenger ai rbag door has a
predetermi ned hori zontal breakout l i ne near i ts cen-
ter whi ch i s conceal ed beneath i ts decorati ve outer
surface. Return fl anges near the top and bottom of
the ai rbag door feature wi ndows that are engaged on
hook formati ons at the top and bottom of the ai rbag
housi ng. Three tabs extend downward from the l ower
return fl ange and are secured wi th the same screws
that secure the gl ove box modul e to the upper gl ove
box openi ng rei nforcement. Fi ve mol ded snap fea-
tures al ong the top of the ai rbag door above the
upper return fl ange snap i nto receptacl es l ocated i n
the i nstrument panel base tri m just bel ow the i nstru-
ment panel top cover. Fol l owi ng a passenger ai rbag
Fig. 20 Front Seat Belt Buckle - Typical
1 - SCREW
2 - SEAT ADJUSTER
3 - SEAT CUSHION
4 - SEAT BELT BUCKLE
FRONT SEAT BELT BUCKLE (Continued)
depl oyment, the passenger ai rbag and ai rbag door
uni t must be repl aced. The passenger ai rbag cannot
be repai red, and must be repl aced i f faul ty or i n any
way damaged. The passenger ai rbag door i s servi ced
onl y as a uni t wi th the passenger ai rbag.
OPERATION
The passenger ai rbag i s depl oyed by an el ectri cal
si gnal generated by the Ai rbag Control Modul e
(ACM) through the passenger ai rbag l i ne 1 and l i ne 2
(or squi b) ci rcui ts. The hybri d-type i nfl ator assembl y
i ncl udes a smal l cani ster of hi ghl y compressed argon
gas. When the ACM sends the proper el ectri cal si gnal
to the ai rbag i nfl ator, the el ectri cal energy generates
enough heat to i gni te chemi cal pel l ets wi thi n the
i nfl ator. Once i gni ted, these chemi cal pel l ets burn
rapi dl y and produce the pressure necessary to rup-
ture a contai nment di sk i n the argon gas cani ster.
The i nfl ator and argon gas cani ster are seal ed to the
ai rbag cushi on so that al l of the rel eased argon gas i s
di rected i nto the ai rbag cushi on, causi ng the cushi on
to i nfl ate. As the cushi on i nfl ates, the passenger ai r-
bag door wi l l spl i t at the breakout l i ne and the two
hal ves of the door wi l l pi vot out of the way. Fol l owi ng
an ai rbag depl oyment, the ai rbag cushi on qui ckl y
defl ates by venti ng the argon gas through vents on
the i nstrument panel si de of the ai rbag cushi on.
Some of the chemi cal s used to create the pressure
to burst the argon gas contai nment di sk are consi d-
ered hazardous i n thei r sol i d state, before they are
burned, but they are securel y seal ed wi thi n the ai r-
bag i nfl ator. However, the gas that i s produced when
the chemi cal s are burned i s harml ess. A smal l
amount of resi due from the burned chemi cal s may
cause some temporary di scomfort i f i t contacts the
ski n, eyes, or breathi ng passages. I f ski n or eye i rri -
tati on i s noti ced, ri nse the affected area wi th pl enty
of cool , cl ean water. I f breathi ng passages are i rri -
tated, move to another area where there i s pl enty of
cl ean, fresh ai r to breath. I f the i rri tati on i s not al l e-
vi ated by these acti ons, contact a physi ci an i mmedi -
atel y.
REMOVAL
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
SKIN AND EYES.
(2) Remove the gl ove box modul e from the i nstru-
ment panel (Refer to 23 - BODY/I NSTRUMENT
PANEL/GLOVE BOX - REMOVAL).
(3) Remove the radi o from the i nstrument panel
(Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
REMOVAL).
(4) Reach through the radi o openi ng i n the i nstru-
ment panel to access and di sconnect the i nstrument
panel wi re harness connector for the passenger ai r-
bag from the passenger ai rbag pi gtai l wi re connector
on the i nstrument panel armature to the l eft of the
gl ove box openi ng (Fi g. 21).
(5) Di sengage the passenger ai rbag pi gtai l wi re
connector retai ners from the i nstrument panel arma-
ture.
(6) Worki ng through the gl ove box openi ng, remove
the two screws that secure the passenger ai rbag
front brackets to the i nstrument panel armature
(Fi g. 22).
Fig. 21 Passenger Airbag Connector
1 - GLOVE BOX
2 - PASSENGER AIRBAG PIGTAIL WIRE CONNECTOR
4 - RETAINER (2)
PASSENGER AIRBAG (Continued)
(7) Remove the two screws that secure the passen-
ger ai rbag rear brackets to the gl ove box openi ng
upper rei nforcement.
fl at-bl aded tool , gentl y pry the top of the passenger
ai rbag door away from the i nstrument panel far
enough to di sengage the fi ve snap features on the
ai rbag door from thei r receptacl es i n the i nstrument
panel .
(9) Remove the passenger ai rbag and ai rbag door
from the i nstrument panel as a uni t.
INSTALLATION
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
WARNING: THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAG DOORS ARE SERVICED IN THE ORIGINAL
COLORS. PAINT MAY CHANGE THE WAY IN WHICH
THE MATERIAL OF THE AIRBAG DOOR RESPONDS
TO AN AIRBAG DEPLOYMENT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Careful l y posi ti on the passenger ai rbag i nto the
i nstrument panel .
(2) Al i gn the fi ve snap features on the upper edge
of the passenger ai rbag door wi th the receptacl es i n
the i nstrument panel top cover.
(3) Usi ng hand pressure, press fi rml y on the pas-
senger ai rbag door over each of the snap feature l oca-
ti ons unti l each of them i s ful l y engaged i n i ts
receptacl e.
the passenger ai rbag rear brackets to the gl ove box
openi ng upper rei nforcement (Fi g. 22). Ti ghten the
(5) Worki ng through the gl ove box openi ng, i nstal l
and ti ghten the two screws that secure the passenger
ai rbag front brackets to the i nstrument panel arma-
ture. Ti ghten the screws to 9 Nm (80 i n. l bs.).
(6) Reach through the radi o openi ng i n the i nstru-
ment panel to access and reconnect the i nstrument
panel wi re harness connector for the passenger ai r-
bag to the passenger ai rbag pi gtai l wi re connector
(Fi g. 21). Be certai n that the passenger ai rbag pi gtai l
wi re connector i s ful l y engaged wi th and l atched to
the i nstrument panel wi re harness connector.
(7) Engage the passenger ai rbag pi gtai l wi re con-
nector retai ners i n the mounti ng hol es provi ded on
the i nstrument panel armature.
(8) Rei nstal l the radi o i nto the i nstrument panel
I NSTALLATI ON).
(9) Rei nstal l the gl ove box modul e onto the i nstru-
ment panel (Refer to 23 - BODY/I NSTRUMENT
PANEL/GLOVE BOX - I NSTALLATI ON).
Fig. 22 Passenger Airbag Mounting
1 - PASSENGER AIRBAG DOOR
2 - REAR SCREW (2)
3 - PASSENGER AIRBAG REAR BRACKET
4 - INSTRUMENT PANEL ARMATURE
5 - FRONT SCREW (2)
6 - GLOVE BOX OPENING UPPER REINFORCEMENT
PASSENGER AIRBAG ON/OFF
SWITCH
DESCRIPTION
The passenger ai rbag on-off swi tch i s standard
equi pment on al l versi ons of thi s model except quad
cab. Thi s swi tch i s a two-posi ti on, resi stor mul ti -
pl exed swi tch wi th a si ngl e i ntegral red Li ght-Emi t-
ti ng Di ode (LED), and a non-coded key cyl i nder-type
actuator. The swi tch i s l ocated i n the l ower ri ght cor-
ner of i nstrument panel cl uster bezel , near the center
of i nstrument panel to make the Off i ndi cator vi si bl e
to al l front seat occupants. When the swi tch i s i n i ts
i nstal l ed posi ti on, the onl y components vi si bl e
through the dedi cated openi ng of the cl uster bezel
are the swi tch face pl ate and nomencl ature, the key
cyl i nder actuator, and a smal l round l ens wi th the
text Off i mpri nted on i t. The On posi ti on of the
swi tch i s desi gnated by text i mpri nted upon the face
pl ate of the swi tch, but i s not i l l umi nated. The
remai nder of the swi tch i s conceal ed behi nd the
swi tch face pl ate and the i nstrument panel cl uster
bezel .
The passenger ai rbag on-off swi tch housi ng i s con-
structed of mol ded pl asti c and has three i ntegral
mounti ng tabs. These mounti ng tabs are used to
secure the swi tch to the back of the mol ded pl asti c
swi tch face pl ate wi th three smal l screws. The
mol ded pl asti c face pl ate al so has three i ntegral
mounti ng tabs that are used to secure the swi tch and
face pl ate uni t to the i nstrument panel cl uster bezel
wi th three addi ti onal screws. A mol ded pl asti c con-
nector receptacl e on the back of the swi tch housi ng
connects the swi tch to the vehi cl e el ectri cal system
through a dedi cated take out of the i nstrument panel
wi re harness. The harness take out i s equi pped wi th
a mol ded pl asti c connector i nsul ator that i s keyed
and l atched to ensure proper and secure swi tch el ec-
tri cal connecti ons. The passenger ai rbag on/off swi tch
cannot be adjusted or repai red and, i f faul ty or dam-
aged, the swi tch must be repl aced.
OPERATION
The passenger ai rbag on-off swi tch al l ows the cus-
tomer to turn the passenger ai rbag functi on On or
Off to accommodate certai n uses of the ri ght front
seati ng posi ti on where ai rbag protecti on may not be
desi red. See the owners manual i n the vehi cl e gl ove
box for speci fi c recommendati ons on when to enabl e
or di sabl e the passenger ai rbag. The Off i ndi cator of
the swi tch wi l l be i l l umi nated whenever the swi tch i s
turned to the Off posi ti on. The i gni ti on key i s the
onl y key or object that shoul d ever be i nserted i nto
the swi tch. The on-off swi tch requi res onl y a parti al
key i nserti on to ful l y depress a spri ng-l oaded l ocki ng
pl unger. The spri ng-l oaded l ocki ng pl unger prevents
the user from l eavi ng the key i n the swi tch. The key
wi l l be automati cal l y ejected when force i s not
appl i ed. To actuate the passenger si de ai rbag on/off
swi tch, i nsert the i gni ti on key i nto the swi tch key
actuator far enough to ful l y depress the pl unger, and
rotate the actuator to the desi red swi tch posi ti on.
When the swi tch key actuator i s rotated to i ts cl ock-
wi se stop (the key actuator sl ot wi l l be al i gned wi th
the Off i ndi cator), the Off i ndi cator i s i l l umi nated
and the passenger ai rbag i s di sabl ed. When the
swi tch i s rotated to i ts countercl ockwi se stop (the key
actuator sl ot wi l l be i n a verti cal posi ti on), the Off
i ndi cator wi l l be exti ngui shed and the passenger ai r-
bag i s enabl ed.
The passenger ai rbag on/off swi tch i s connects one
of two i nternal resi stors i n seri es between the pas-
senger ai rbag mux swi tch sense and passenger ai r-
bag mux swi tch return ci rcui ts of the Ai rbag Control
Modul e (ACM). The ACM conti nual l y moni tors the
resi stance i n these ci rcui ts to determi ne the swi tch
posi ti on that has been sel ected. When the swi tch i s
i n the Off posi ti on, the ACM provi des a ground i nput
to the swi tch through the passenger ai rbag i ndi cator
dri ver ci rcui t, whi ch energi zes the Li ght-Emi tti ng
Di ode (LED) that i l l umi nates the Off i ndi cator of the
swi tch. The ACM wi l l al so i l l umi nate the Off i ndi ca-
tor of the swi tch for about seven seconds each ti me
the i gni ti on swi tch i s turned to the On posi ti on as a
bul b test. The ACM wi l l al so store a Di agnosti c Trou-
bl e Code (DTC) for any faul t i t detects i n the passen-
ger ai rbag on/off swi tch or i ndi cator ci rcui ts, and wi l l
i l l umi nate the ai rbag i ndi cator i n the i nstrument
cl uster i f a faul t i s detected. For proper di agnosi s of
the passenger ai rbag on/off swi tch or the ACM, a
REMOVAL
(3) Remove the three screws that secure the pas-
senger ai rbag on/off swi tch and face pl ate uni t to the
back of the cl uster bezel (Fi g. 23).
(4) Remove the passenger ai rbag on/off swi tch and
face pl ate from the cl uster bezel as a uni t.
INSTALLATION
(1) Posi ti on the passenger ai rbag on/off swi tch and
face pl ate uni t to the back of the cl uster bezel (Fi g.
23).
the passenger ai rbag on/off swi tch face pl ate to the
cl uster bezel . Ti ghten the screws to 2 Nm (17 i n.
l bs.).
REAR SEAT BELT &
RETRACTOR
REMOVAL
(1) Unsnap and remove the rear shoul der bel t
the turni ng l oop to the quarter i nner panel (cl ub cab)
or the C-pi l l ar (quad cab).
bel t turni ng l oop to the quarter i nner panel (cl ub
cab) (Fi g. 24) or the C-pi l l ar (quad cab) (Fi g. 25).
Fig. 23 Passenger Airbag On/Off Switch
1 - CLUSTER BEZEL
2 - SCREW (3)
3 - PASSENGER AIRBAG ON/OFF SWITCH
PASSENGER AIRBAG ON/OFF SWITCH (Continued)
quarter i nner panel (cl ub cab) or the C-pi l l ar (quad
cab).
(4) Remove the tri m from the quarter i nner panel
(cl ub cab) (Refer to 23 - BODY/I NTERI OR/QUAR-
TER TRI M PANEL - REMOVAL) or the C-pi l l ar
(quad cab) (Refer to 23 - BODY/I NTERI OR/C-PI L-
LAR TRI M - REMOVAL).
bel t anchor pl ate to the quarter i nner panel (cl ub
cab) or the C-pi l l ar (quad cab).
(6) Remove the l ower seat bel t anchor pl ate from
the quarter i nner panel (cl ub cab) or the C-pi l l ar
(quad cab).
(7) Remove the screw that secures the retractor to
(quad cab).
(8) Remove the rear shoul der bel t and retractor
from the quarter i nner panel (cl ub cab) or the C-pi l -
l ar (quad cab).
INSTALLATION
(1) Posi ti on the retractor onto the quarter i nner
panel (cl ub cab) (Fi g. 24) or the C-pi l l ar (quad cab)
(Fi g. 25).
retractor to the quarter i nner panel (cl ub cab) or the
C-pi l l ar (quad cab). Ti ghten the screw to 40 Nm (29
ft. l bs.).
(3) Posi ti on the l ower seat bel t anchor pl ate onto
(quad cab).
l ower seat bel t anchor pl ate to the quarter i nner
Fig. 24 Rear Seat Belt & Retractor - Club Cab
1 - TURNING LOOP
2 - LAP BELT/BUCKLE ANCHOR
3 - BUCKLE/BUCKLE ANCHOR
4 - LOWER ANCHOR
5 - RETRACTOR
Fig. 25 Rear Seat Belt & Retractor - Quad Cab
1 - TURNING LOOP
2 - SCREW
3 - COVER
4 - LOWER C-PILLAR TRIM
5 - SCREW
6 - SCREW
7 - RETRACTOR
8 - UPPER C-PILLAR TRIM
REAR SEAT BELT & RETRACTOR (Continued)
panel (cl ub cab) or the C-pi l l ar (quad cab). Ti ghten
the screw to 40 Nm (29 ft. l bs.).
(5) Rei nstal l the tri m onto the quarter i nner panel
(cl ub cab) (Refer to 23 - BODY/I NTERI OR/QUAR-
TER TRI M PANEL - I NSTALLATI ON) or the C-pi l -
l ar (quad cab) (Refer to 23 - BODY/I NTERI OR/C-
PI LLAR TRI M - I NSTALLATI ON).
quarter i nner panel (cl ub cab) or the C-pi l l ar (quad
cab).
shoul der bel t turni ng l oop to the quarter i nner panel
(cl ub cab) or the C-pi l l ar (quad cab). Ti ghten the
screw to 30 Nm (22 ft. l bs.).
(8) Snap the tri m cover over the rear shoul der bel t
turni ng l oop anchor pl ate to conceal the screw that
secures the turni ng l oop to the quarter i nner panel
(cl ub cab) or the C-pi l l ar (quad cab).
REAR SEAT LAP BELT/BUCKLE
REMOVAL
Cl ub cab and quad cab model s both have a com-
bi ned rear seat buckl e/buckl e uni t on the ri ght si de
of the vehi cl e that i s secured to the rear fl oor panel
beneath the rear seat cushi on. Cl ub cab model s have
a combi ned rear seat l ap bel t/buckl e uni t on the l eft
si de of the vehi cl e that i s secured to the rear fl oor
panel beneath the rear seat cushi on. The l eft si de of
the quad cab model s has a rear l ap bel t uni t that i s
secured to a stud on the l eft center rear seat ri ser
bracket, and a rear buckl e uni t that i s secured to the
rear of the l eft seat cushi on frame.
REAR SEAT BUCKLE/BUCKLE UNIT (CLUB OR QUAD CAB) &
LAP BELT/BUCKLE UNIT (CLUB CAB ONLY)
(1) Remove the rear seat from the rear fl oor panel
(cl ub cab) (Refer to 23 - BODY/SEATS/SEAT CUSH-
I ON - REMOVAL) or fol d up the rear seat cushi on
(quad cab).
(2) Remove the screw that secures the anchor
pl ate of the rear seat buckl e/buckl e uni t (ri ght si de -
cl ub cab or quad cab) or l ap bel t/buckl e uni t (l eft si de
- cl ub cab onl y) to the rear fl oor panel (Fi g. 26).
(3) Remove the rear seat buckl e/buckl e uni t (ri ght
si de) or l ap bel t/buckl e uni t (l eft si de) from the rear
fl oor panel .
REAR SEAT LAP BELT UNIT - LEFT SIDE - QUAD CAB ONLY
(1) Fol d up the rear seat cushi ons agai nst the rear
seat back.
(2) Remove the nut that secures the rear seat l ap
bel t anchor pl ate to the stud on the i nboard si de of
the l eft center rear seat ri ser bracket.
(3) Remove the rear seat l ap bel t uni t from the
i nboard si de of the l eft center rear seat ri ser bracket.
REAR SEAT BUCKLE UNIT - LEFT SIDE - QUAD CAB ONLY
(1) Fol d up the rear seat cushi ons agai nst the rear
seat back.
(2) Remove the screw that secures the rear seat
bel t buckl e anchor pl ate to the rear of the l eft seat
cushi on frame.
(3) Remove the rear seat bel t buckl e uni t from the
INSTALLATION
Cl ub cab and quad cab model s both have a com-
bi ned rear seat buckl e/buckl e uni t on the ri ght si de
of the vehi cl e that i s secured to the rear fl oor panel
Fig. 26 Rear Seat Belts - Club Cab
1 - REAR SEAT LAP BELT/BUCKLE
REAR SEAT BELT & RETRACTOR (Continued)
beneath the rear seat cushi on. Cl ub cab model s have
a combi ned rear seat l ap bel t/buckl e uni t on the l eft
si de of the vehi cl e that i s secured to the rear fl oor
panel beneath the rear seat cushi on. The l eft si de of
the quad cab model s has a rear l ap bel t uni t that i s
secured to a stud on the l eft center rear seat ri ser
bracket, and a rear buckl e uni t that i s secured to the
REAR SEAT BUCKLE/BUCKLE UNIT (CLUB OR QUAD CAB) &
LAP BELT/BUCKLE UNIT (CLUB CAB ONLY)
(1) Posi ti on the rear seat buckl e/buckl e uni t (ri ght
si de) or l ap bel t/buckl e uni t (l eft si de) onto the rear
fl oor panel (Fi g. 26).
anchor pl ate of the rear seat buckl e/buckl e uni t
(ri ght si de - cl ub cab or quad cab) or l ap bel t/buckl e
uni t (l eft si de - cl ub cab onl y) to the rear fl oor panel .
(3) Rei nstal l the rear seat onto the rear fl oor panel
(cl ub cab) (Refer to 23 - BODY/SEATS/SEAT CUSH-
I ON - I NSTALLATI ON) or fol d down the rear seat
cushi on (quad cab).
REAR SEAT LAP BELT UNIT - LEFT SIDE - QUAD CAB ONLY
(1) Posi ti on the rear seat l ap bel t uni t onto the
stud on the i nboard si de of the l eft center rear seat
ri ser bracket.
(2) I nstal l and ti ghten the nut that secures the
rear seat l ap bel t anchor pl ate to the stud on the
i nboard si de of the l eft center rear seat ri ser bracket.
Ti ghten the nut to 40 Nm (29 ft. l bs.).
(3) Fol d down the rear seat cushi ons.
REAR SEAT BUCKLE UNIT - LEFT SIDE - QUAD CAB ONLY
(1) Posi ti on the rear seat bel t buckl e uni t onto the
rear seat bel t buckl e anchor pl ate to the rear of the
l eft seat cushi on frame. Ti ghten the screw to 40 Nm
(29 ft. l bs.).
(3) Fol d down the rear seat cushi ons.
SEAT BELT SWITCH
DESCRIPTION
The seat bel t swi tch i s a smal l , normal l y open, si n-
gl e pol e, si ngl e throw, pl unger actuated, momentary
swi tch. Onl y one seat bel t swi tch i s i nstal l ed i n the
vehi cl e, and i t i s i ntegral to the dri ver seat bel t
retractor assembl y. The seat bel t swi tch i s connected
to the vehi cl e el ectri cal system through a short pi g-
tai l wi re to a dedi cated take out and connector of the
body wi re harness.
The seat bel t swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, the enti re dri ver seat bel t
and retractor uni t must be repl aced.
OPERATION
The seat bel t swi tch i s desi gned to control a path
to ground for the seat bel t swi tch sense i nput of the
El ectro-Mechani cal I nstrument Cl uster (EMI C). The
seat bel t swi tch pl unger i s actuated by the seat bel t
webbi ng wound onto the seat bel t retractor spool .
When the seat bel t ti p-hal f webbi ng i s pul l ed out of
the retractor far enough to engage the seat bel t buck-
l e-hal f, the swi tch pl unger i s extended and cl oses the
seat bel t swi tch sense ci rcui t to ground; and, when
the seat bel t ti p-hal f webbi ng i s wound onto the
retractor the swi tch pl unger i s depressed, openi ng
the ground path. The EMI C moni tors the seat bel t
swi tch status, then control s the seatbel t i ndi cator
and sends el ectroni c chi me request messages over
the Programmabl e Communi cati ons I nterface (PCI )
data bus to the Central Ti mer Modul e (CTM) based
upon that i nput.
The seat bel t swi tch recei ves ground through i ts
pi gtai l wi re connecti on to the body wi re harness from
another take out of the body wi re harness. An eyel et
termi nal connector on that ground take out i s
secured under a ground screw to the l eft l ower B-pi l -
l ar. The seat bel t swi tch i s connected i n seri es
between ground and the seat bel t swi tch sense i nput
of the EMI C.
DIAGNOSIS AND TESTING - SEAT BELT
SWITCH
REAR SEAT LAP BELT/BUCKLE (Continued)
cabl e. Di sconnect the body wi re harness connector for
the seat bel t swi tch from the seat bel t swi tch pi gtai l
wi re connector from the dri ver si de front seat bel t
retractor. Check for conti nui ty between the ground
ci rcui t cavi ty of the body wi re harness connector for
the seat bel t swi tch and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 2. I f not OK, repai r
the open ground ci rcui t to ground (G307) as requi red.
(2) Check for conti nui ty between the two cavi ti es
i n the seat bel t swi tch pi gtai l wi re connector. There
shoul d be no conti nui ty wi th the seat bel t webbi ng
retracted, and conti nui ty wi th the seat bel t webbi ng
pul l ed out of the retractor far enough to engage the
seat bel t buckl e. I f OK, go to Step 3. I f not OK,
repl ace the faul ty dri ver si de front seat bel t and
retractor uni t.
ment panel . Check for conti nui ty between the seat
bel t swi tch sense ci rcui t cavi ty of the body wi re har-
ness connector for the seat bel t swi tch and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the shorted seat bel t swi tch
sense ci rcui t between the seat bel t swi tch and the
i nstrument cl uster as requi red.
(4) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ti es of the i nstrument panel
wi re harness connector (Connector C2) for the i nstru-
ment cl uster and the body wi re harness connector for
the seat bel t swi tch. There shoul d be conti nui ty. I f
OK, proceed to the di agnosi s for the i nstrument cl us-
ter. (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). I f not OK,
repai r the open seat bel t swi tch sense ci rcui t between
the seat bel t swi tch and the i nstrument cl uster as
requi red.
SEAT BELT TENSIONER
DESCRIPTION
Seat bel t tensi oners suppl ement the ai rbag system
for al l quad cab versi ons of thi s model . The seat bel t
tensi oners are i ntegral to the front seat bel t retrac-
tors, whi ch are secured wi thi n each B-pi l l ar i n the
vehi cl e where they are conceal ed behi nd the B-pi l l ar
tri m. The seat bel t tensi oner consi sts pri mari l y of a
sprocket/pi ni on, a steel tube, a cast metal housi ng,
numerous steel bal l s, a stamped metal bal l trap, a
torsi on bar, a smal l pyrotechni cal l y acti vated gas
generator, and a short pi gtai l wi re. Al l of these com-
ponents are l ocated on one si de of the retractor spool
on the outsi de of the retractor housi ng except for the
torsi on bar, whi ch serves as the spi ndl e upon whi ch
the retractor spool ri des. The seat bel t tensi oners are
control l ed by the Ai rbag Control Modul e (ACM) and
are connected to the vehi cl e el ectri cal system through
a dedi cated take out of the body wi re harness by a
keyed and l atchi ng mol ded pl asti c connector i nsul a-
tor to ensure a secure connecti on.
The seat bel t tensi oners cannot be repai red and, i f
faul ty or damaged, the enti re front seat bel t, retrac-
tor, and tensi oner uni t must be repl aced. The seat
bel t tensi oners are not i ntended for reuse, and both
tensi oners must be repl aced fol l owi ng any ai rbag
depl oyment. A growl i ng or gri ndi ng sound whi l e
attempti ng to operate the seat bel t retractor i s a sure
i ndi cati on that the seat bel t tensi oner has been
depl oyed and requi res repl acement. For seat bel t ten-
si oner servi ce procedures, (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/FRONT SEAT BELT &
RETRACTOR - REMOVAL).
OPERATION
The seat bel t tensi oners are depl oyed i n conjunc-
ti on wi th the ai rbags by a si gnal generated by the
Ai rbag Control Modul e (ACM) through the dri ver or
passenger seat bel t tensi oner l i ne 1 and l i ne 2 (or
squi b) ci rcui ts. When the ACM sends the proper el ec-
tri cal si gnal to the tensi oner, the el ectri cal energy
generates enough heat to i ni ti ate a smal l pyrotechni c
gas generator. The gas generator i s i nstal l ed i n one
end of a steel tube that contai ns numerous steel
bal l s. As the gas expands, i t pushes the steel bal l s
through the tube i nto a cast metal housi ng, where a
bal l gui de di rects the bal l s i nto engagement wi th the
teeth of a sprocket that i s geared to one end of the
retractor spool . As the bal l s dri ve past the sprocket,
the sprocket turns and dri ves the seat bel t retractor
spool causi ng the sl ack to be removed from the front
seat bel ts. The bal l trap captures the bal l s as they
l eave the sprocket and are expel l ed from the housi ng.
Removi ng excess sl ack from the front seat bel ts not
onl y keeps the occupants properl y posi ti oned for an
SEAT BELT SWITCH (Continued)
ai rbag depl oyment fol l owi ng a frontal i mpact of the
vehi cl e, but al so hel ps to reduce the l i kel i hood of a
harmful contact wi th i nteri or components. Al so, the
seat bel t tensi oner torsi on bar that the retractor
spool ri des upon i s desi gned to deform i n order to
control the l oadi ng bei ng appl i ed to the occupants by
the seat bel ts duri ng a frontal i mpact, further reduc-
i ng the potenti al for occupant i njuri es.
The ACM moni tors the condi ti on of the seat bel t
tensi oners through ci rcui t resi stance, and wi l l i l l umi -
nate the ai rbag i ndi cator i n the i nstrument cl uster
and store a Di agnosti c Troubl e Code (DTC) for any
faul t that i s detected. For proper di agnosi s of the
seat bel t tensi oners, a DRBI I I scan tool i s requi red.
SEAT BELT TURNING LOOP
ADJ USTER
REMOVAL
(1) Remove the knob from the l ever of the seat bel t
turni ng l oop adjuster. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/TURNI NG LOOP HEI GHT ADJUSTER
KNOB - REMOVAL).
bel t turni ng l oop to the hei ght adjuster.
(3) Remove the tri m from the upper B-pi l l ar (quad
cab) or from the quarter i nner panel (standard/cl ub
cab). (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
TRI M - REMOVAL) or (Refer to 23 - BODY/I NTERI -
OR/QUARTER TRI M PANEL - REMOVAL).
(4) Remove the screw that secures the upper end
of the hei ght adjuster to the B-pi l l ar.
(5) Pul l the upper end of the hei ght adjuster away
from the B-pi l l ar far enough to di sengage the hooks
on the l ower end of the adjuster from the sl ots i n the
pi l l ar.
(6) Remove the adjuster from the B-pi l l ar.
INSTALLATION
(1) Posi ti on the hei ght adjuster to the B-pi l l ar
wi th the hook formati ons ori ented toward the l ower
end of the adjuster.
(2) Engage the hooks on the l ower end of the
adjuster i nto the sl ots i n the B-pi l l ar.
(3) Ti l t the upper end of the hei ght adjuster up
i nto posi ti on agai nst the B-pi l l ar.
upper end of the hei ght adjuster to the B-pi l l ar.
(5) Rei nstal l the tri m onto the upper B-pi l l ar
(quad cab) or onto the quarter i nner panel (standard/
cl ub cab). (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
TRI M - I NSTALLATI ON) or (Refer to 23 - BODY/I N-
TERI OR/QUARTER TRI M PANEL - I NSTALLA-
TI ON).
(6) I nstal l and ti ghten the anchor screw that
secures the seat bel t turni ng l oop to the adjuster.
(7) Rei nstal l the knob onto the l ever of the seat
bel t turni ng l oop adjuster. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/TURNI NG LOOP HEI GHT
ADJUSTER KNOB - I NSTALLATI ON).
SEAT BELT TENSIONER (Continued)
TURNING LOOP HEIGHT
ADJ USTER KNOB
REMOVAL
(1) Unsnap the seat bel t turni ng l oop cover to
expose the anchor screw that secures the turni ng
l oop to the hei ght adjuster.
(2) Usi ng the head of the turni ng l oop anchor
screw as a ful crum, careful l y pry the knob from the
hei ght adjuster l ever wi th a sui tabl e tri m tool (Fi g.
27).
INSTALLATION
(1) Snap the seat bel t turni ng l oop cover back i nto
pl ace over the anchor screw that secures the turni ng
l oop to the adjuster.
(2) Posi ti on the hei ght adjuster knob to the seat
bel t turni ng l oop hei ght adjuster l ever.
(3) Usi ng hand pressure, push the knob fi rml y and
evenl y onto the l ever unti l i t i s ful l y engaged.
Fig. 27 Turning Loop Height Adjuster Knob
Removal - Typical
1 - KNOB
2 - ADJUSTER LEVER
3 - SEAT BELT TURNING LOOP
4 - TRIM TOOL (SNAP-ON A179A)
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ROAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2
CABLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVO
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VACUUM RESERVOIR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPEED CONTROL
DESCRIPTION
The speed control system i s el ectroni cal l y con-
trol l ed and vacuum operated. El ectroni c control of
the speed control system i s i ntegrated i nto the Pow-
ertrai n Control Modul e (PCM). The control s consi st
of two steeri ng wheel mounted swi tches. The
swi tches are l abel ed: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
The system i s desi gned to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM al l ows a set speed to be stored
i n PCM RAM for speed control . To store a set speed,
depress the SET swi tch whi l e the vehi cl e i s movi ng
at a speed between 35 and 85 mph. I n order for the
speed control to engage, the brakes cannot be
appl i ed, nor can the gear sel ector be i ndi cati ng the
transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
Depressi ng the cl utch pedal (i f equi pped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM.
For added safety, the speed control system i s pro-
grammed to di sengage for any of the fol l owi ng condi -
ti ons:
An i ndi cati on of Park or Neutral
A rapi d i ncrease rpm (i ndi cates that the cl utch
has been di sengaged)
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The speed si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the coeffi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
The speed si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
Once the speed control has been di sengaged,
depressi ng the RES/ACCEL swi tch (when speed i s
greater than 30 mph) restores the vehi cl e to the tar-
get speed that was stored i n the PCM.
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the RES/AC-
CEL swi tch. The new target speed i s stored i n the
PCM when the RES/ACCEL i s rel eased. The PCM
al so has a tap-up feature i n whi ch vehi cl e speed
i ncreases at a rate of approxi matel y 2 mph for each
momentary swi tch acti vati on of the RES/ACCEL
swi tch.
AN SPEED CONTROL 8P - 1
A tap down feature i s used to decel erate wi thout
di sengagi ng the speed control system. To decel erate
from an exi sti ng recorded target speed, momentari l y
depress the COAST swi tch. For each swi tch acti va-
ti on, speed wi l l be l owered approxi matel y 1 mph.
OVERSHOOT/UNDERSHOOT
I f the vehi cl e operator repeatedl y presses and
rel eases the SET button wi th thei r foot off of the
accel erator (referred to as a l i ft foot set), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 mph (8 km/h). I t may al so decel erate to l ess
than the desi red set speed, before fi nal l y achi evi ng
the desi red set speed.
The Speed Control System has an adapti ve strat-
egy that compensates for vehi cl e-to-vehi cl e vari ati ons
i n speed control cabl e l engths. When the speed con-
trol i s set wi th the vehi cl e operators foot off of the
accel erator pedal , the speed control thi nks there i s
excessi ve speed control cabl e sl ack and adapts
accordi ngl y. I f the l i ft foot sets are conti nual l y used,
a speed control overshoot/undershoot condi ti on wi l l
devel op.
To unl earn the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed usi ng
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turni ng the crui se control swi tch to
the OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 1015 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d be
corrected before proceedi ng. Refer to Group 8E, I nstru-
ment Panel and Gauges for speedometer di agnosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose, damaged or corroded el ectri cal connec-
ti ons at the servo. Corrosi on shoul d be removed from
el ectri cal termi nal s and a l i ght coati ng of Mopar
Mul ti Purpose Grease, or equi val ent, appl i ed.
Leaki ng vacuum reservoi r.
Loose or l eaki ng vacuum hoses or connecti ons.
Defecti ve one-way vacuum check val ve.
Secure attachment of both ends of the speed con-
trol servo cabl e.
Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS
TORQUE - SPEED CONTROL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Servo Mounting Bracket-to-Servo Nuts 8.5 75
Servo Mounting Bracket-to-Body Nuts 7-10 63-94
Switch Module Mounting Screws 1.5 14
Vacuum Reservoir Mounting Bolts 2.2 20
8P - 2 SPEED CONTROL AN
SPEED CONTROL (Continued)
CABLE
DESCRIPTION
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage.
OPERATION
Thi s cabl e causes the throttl e control l i nkage to
open or cl ose the throttl e val ve i n response to move-
ment of the vacuum servo di aphragm.
(2) Usi ng fi nger pressure onl y, remove speed con-
trol cabl e connector at throttl e body bel l crank by
pushi ng connector off the bel l crank pi n (Fi g. 1) or
(Fi g. 2). DO NOT try to pull connector off per-
pendicular to the bellcrank pin. Connector will
be broken.
(3) 2.5L Engi ne: Remove cabl e from cabl e gui de at
top of val ve cover.
(4) Squeeze 2 tabs on si des of speed control cabl e
at throttl e body mounti ng bracket (l ocki ng pl ate) and
push out of bracket.
(5) Remove servo cabl e from servo. Refer to Speed
Control Servo Removal /I nstal l ati on.
REMOVAL - 4. 7L
(2) Remove ai r box housi ng from throttl e body.
The accel erator cabl e must be parti al l y removed to
gai n access to speed control cabl e.
(3) Usi ng fi nger pressure onl y, di sconnect accel era-
tor cabl e connector at throttl e body bel l crank pi n by
pushi ng connector off bel l crank pi n towards front of
vehi cl e (Fi g. 3). DO NOT try to pull connector off
perpendicular to the bellcrank pin. Connector
will be broken.
(4) Li ft accel erator cabl e from top of cabl e cam
(Fi g. 3).
(5) Press tab (Fi g. 4) to rel ease pl asti c cabl e mount
from bracket. Press on tab only enough to
release cable from bracket. If tab is pressed too
much, it will be broken. Sl i de pl asti c mount (Fi g.
4) towards passenger si de of vehi cl e to remove cabl e
from bracket.
(6) Usi ng fi nger pressure onl y, di sconnect speed
control cabl e connector at throttl e body bel l crank pi n
by pushi ng connector off bel l crank pi n towards front
of vehi cl e (Fi g. 3). DO NOT try to pull connector
off perpendicular to the bellcrank pin. Connec-
tor will be broken.
(7) Sl i de speed control cabl e pl asti c mount towards
passenger si de of vehi cl e to remove cabl e from
bracket (Fi g. 5).
Fig. 1 Cable Connection at Throttle Body2.5L
Engine
1 - BELLCRANK
2 - CABLE CONNECTOR
3 - SPEED CONTROL CABLE
Fig. 2 Cable Connection at Throttle Body3.9L/
5.2L/5.9L Engines
1 - VEHICLE SPEED CONTROL CABLE
(8) Remove servo cabl e from servo. Refer to Speed
Control Servo Removal /I nstal l ati on.
(1) I nstal l end of cabl e to speed control servo.
Refer to Speed Control Servo Removal and I nstal l a-
ti on.
(2) I nstal l cabl e i nto throttl e body mounti ng
bracket (snaps i n).
(3) I nstal l speed control cabl e connector at throttl e
body bel l crank pi n (snaps on).
(4) 2.5L Engi ne: I nstal l cabl e to cabl e gui de at top
of val ve cover.
(5) Connect negati ve battery cabl e at battery.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
(1) I nstal l end of cabl e to speed control servo.
Refer to Speed Control Servo Removal /I nstal l ati on.
(2) Sl i de speed control cabl e pl asti c mount i nto
bracket.
(3) I nstal l speed control cabl e connector onto throt-
tl e body bel l crank pi n (snaps on).
(4) Sl i de accel erator cabl e pl asti c mount i nto
bracket. Conti nue sl i di ng unti l tab (Fi g. 4) i s al i gned
to hol e i n mounti ng bracket.
(5) Route accel erator cabl e over top of cabl e cam
(Fi g. 3).
(6) I nstal l accel erator cabl e connector onto throttl e
body bel l crank pi n (snaps on).
(7) I nstal l ai r box housi ng to throttl e body.
(8) Connect negati ve battery cabl e at battery.
SERVO
DESCRIPTION
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The sol enoi d val ve body con-
tai ns three sol enoi ds:
Vacuum
Vent
Dump
The vacuum chamber contai ns a di aphragm wi th a
cabl e attached to control the throttl e l i nkage.
Fig. 3 Cable Connectors at Bell Crank4.7L V-8
Engine
1 - THROTTLE BODY
2 - SPEED CONTROL CABLE CONNECTOR
3 - OFF
4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
6 - CABLE CAM
7 - BELLCRANK
Fig. 4 Accelerator Cable Release Tab4.7L V-8
Engine
1 - ACCELERATOR CABLE
2 - PLASTIC CABLE MOUNT
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
5 - SLIDE FOR REMOVAL
CABLE (Continued)
OPERATION
The Powertrai n Control Modul e (PCM) control s the
sol enoi d val ve body. The sol enoi d val ve body control s
the appl i cati on and rel ease of vacuum to the di a-
phragm of the vacuum servo. The servo uni t cannot
be repai red and i s servi ced onl y as a compl ete assem-
bl y.
Power i s suppl i ed to the servos by the PCM
through the brake swi tch. The PCM control s the
ground path for the vacuum and vent sol enoi ds.
The dump sol enoi d i s energi zed anyti me i t recei ves
power. I f power to the dump sol enoi d i s i nterrupted,
the sol enoi d dumps vacuum i n the servo. Thi s pro-
vi des a safety backup to the vent and vacuum sol e-
noi ds.
The vacuum and vent sol enoi ds must be grounded
at the PCM to operate. When the PCM grounds the
vacuum servo sol enoi d, the sol enoi d al l ows vacuum
to enter the servo and pul l open the throttl e pl ate
usi ng the cabl e. When the PCM breaks the ground,
the sol enoi d cl oses and no more vacuum i s al l owed to
enter the servo. The PCM al so operates the vent sol e-
noi d vi a ground. The vent sol enoi d opens and cl oses a
passage to bl eed or hol d vacuum i n the servo as
requi red.
The PCM duty cycl es the vacuum and vent sol e-
noi ds to mai ntai n the set speed, or to accel erate and
decel erate the vehi cl e. To i ncrease throttl e openi ng,
the PCM grounds the vacuum and vent sol enoi ds. To
decrease throttl e openi ng, the PCM removes the
grounds from the vacuum and vent sol enoi ds. When
the brake i s rel eased, i f vehi cl e speed exceeds 30
mph to resume, 35 mph to set, and the RES/ACCEL
swi tch has been depressed, ground for the vent and
vacuum ci rcui ts i s restored.
REMOVAL
(2) Di sconnect vacuum hose (l i ne) at servo (Fi g. 6).
(3) Di sconnect el ectri cal connector at servo.
(4) Di sconnect servo cabl e at throttl e body. Refer to
Servo Cabl e Removal /I nstal l ati on.
(5) Remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 6) or (Fi g. 7).
(6) Pul l speed control cabl e sl eeve and servo away
from servo mounti ng bracket to expose cabl e retai n-
i ng cl i p (Fi g. 7) and remove cl i p. Note: The servo
mounti ng bracket di spl ayed i n (Fi g. 7) i s a typi cal
bracket and may/may not be appl i cabl e to thi s model
vehi cl e.
(7) Remove servo from mounti ng bracket. Whi l e
removi ng, note ori entati on of servo to bracket.
Fig. 5 Speed Control Cable at Bracket4.7L V-8
Engine
3 - BRACKET
Fig. 6 Speed Control Servo Location
1 - SPEED CONTROL SERVO
2 - VACUUM HOSE
3 - SERVO BRACKET NUTS (2)
4 - SERVO CABLE
5 - CABLE SLEEVE
6 - SERVO MOUNTING NUTS (2)
SERVO (Continued)
INSTALLATION
(1) Posi ti on servo to mounti ng bracket.
(2) Al i gn hol e i n cabl e connector wi th hol e i n servo
pi n. I nstal l cabl e-to-servo retai ni ng cl i p.
(3) I nsert servo mounti ng studs through hol es i n
servo mounti ng bracket.
(4) I nstal l servo mounti ng nuts and ti ghten to 8.5
Nm (75 i n. l bs.).
(5) Connect vacuum l i ne at servo.
(6) Connect el ectri cal connector at servo.
(7) Connect servo cabl e to throttl e body. Refer to
Servo Cabl e Removal /I nstal l ati on.
SWITCH
DESCRIPTION
There are two separate swi tch pods that operate
the speed control system. The steeri ng-wheel -
mounted swi tches use mul ti pl exed ci rcui ts to provi de
i nputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
OPERATION
When speed control i s sel ected by depressi ng the
ON, OFF swi tch, the PCM al l ows a set speed to be
stored i n i ts RAM for speed control . To store a set
speed, depress the SET swi tch whi l e the vehi cl e i s
movi ng at a speed between approxi matel y 35 and 85
mph. I n order for the speed control to engage, the
brakes cannot be appl i ed, nor can the gear sel ector
be i ndi cati ng the transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
The speed control can be di sengaged al so by any of
the fol l owi ng condi ti ons:
An i ndi cati on of Park or Neutral
The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
Depressi ng the cl utch pedal .
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
I f the actual speed i s not wi thi n 20 mph of the
set speed
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch restores the vehi cl e to
the target speed that was stored i n the PCMs RAM.
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCMs RAM.
I f, whi l e the speed control i s engaged, the dri ver
wi shes to i ncrease vehi cl e speed, the PCM i s pro-
grammed for an accel erati on feature. Wi th the
ACCEL swi tch hel d cl osed, the vehi cl e accel erates
sl owl y to the desi red speed. The new target speed i s
stored i n the PCMs RAM when the ACCEL swi tch i s
rel eased. The PCM al so has a tap-up feature i n
whi ch vehi cl e speed i ncreases at a rate of approxi -
matel y 2 mph for each momentary swi tch acti vati on
of the ACCEL swi tch.
The PCM al so provi des a means to decel erate wi th-
out di sengagi ng speed control . To decel erate from an
exi sti ng recorded target speed, depress and hol d the
COAST swi tch unti l the desi red speed i s reached.
Then rel ease the swi tch. The ON, OFF swi tch oper-
ates two components: the PCMs ON, OFF i nput, and
the battery vol tage to the brake swi tch, whi ch powers
the speed control servo.
Fig. 7 Servo Cable Clip Remove/InstallTypical
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
SERVO (Continued)
Multiplexing
The PCM sends out 5 vol ts through a fi xed resi stor
and moni tors the vol tage change between the fi xed
resi stor and the swi tches. I f none of the swi tches are
depressed, the PCM wi l l measure 5 vol ts at the sen-
sor poi nt (open ci rcui t). I f a swi tch wi th no resi stor i s
cl osed, the PCM wi l l measure 0 vol ts (grounded ci r-
cui t). Now, i f a resi stor i s added to a swi tch, then the
PCM wi l l measure some vol tage proporti onal to the
si ze of the resi stor. By addi ng a di fferent resi stor to
each swi tch, the PCM wi l l see a di fferent vol tage
dependi ng on whi ch swi tch i s pushed.
Another resi stor has been added to the at rest ci r-
cui t causi ng the PCM to never see 5 vol ts. Thi s was
done for di agnosti c purposes. I f the swi tch ci rcui t
shoul d open (bad connecti on), then the PCM wi l l see
the 5 vol ts and know the ci rcui t i s bad. The PCM wi l l
then set an open ci rcui t faul t.
REMOVAL
WARNING: BEFORE BEGINNING ANY AIRBAG SYS-
TEM COMPONENT REMOVAL OR INSTALLATION,
REMOVE AND ISOLATE THE NEGATIVE (-) CABLE
FROM THE BATTERY. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. THEN
WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO
DISCHARGE BEFORE FURTHER SYSTEM SERVICE.
FAILURE TO DO THIS COULD RESULT IN ACCIDEN-
TAL AIRBAG DEPLOYMENT AND POSSIBLE
INJURY.
(2) Remove ai rbag modul e. Refer to 8, Passi ve
Restrai nt Systems for procedures.
(3) Remove swi tch-to-steeri ng wheel mounti ng
screws (Fi g. 8).
(4) Remove swi tch.
(5) Remove el ectri cal connector at swi tch.
INSTALLATION
(1) I nstal l el ectri cal connector to swi tch.
(2) I nstal l swi tch and mounti ng screws.
(3) Ti ghten screws to 1.5 Nm (14 i n. l bs.) torque.
(4) I nstal l ai rbag modul e. Refer to 8, Passi ve
Restrai nt Systems for procedures.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s a pl asti c storage tank con-
nected to an engi ne vacuum source by vacuum l i nes.
OPERATION
The vacuum reservoi r i s used to suppl y the vac-
uum needed to mai ntai n proper speed control opera-
ti on when engi ne vacuum drops, such as i n cl i mbi ng
a grade whi l e dri vi ng. A one-way check val ve i s used
i n the vacuum l i ne between the reservoi r and the
vacuum source. Thi s check val ve i s used to trap
engi ne vacuum i n the reservoi r. On certai n vehi cl e
appl i cati ons, thi s reservoi r i s shared wi th the heat-
i ng/ai r-condi ti oni ng system. The vacuum reservoi r
cannot be repai red and must be repl aced i f faul ty.
DIAGNOSIS AND TESTING - VACUUM SUPPLY
TEST
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
Fig. 8 Speed Control Switches
1 - MOUNTING SCREWS (2)
2 - SPEED CONTROL SWITCHES (2)
SWITCH (Continued)
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
REMOVAL
The vacuum reservoi r i s l ocated under the pl asti c
cowl pl enum cover at l ower base of wi ndshi el d (Fi g.
9) or (Fi g. 11).
(1) Di sconnect and i sol ate negati ve battery at
cabl e.
(2) Remove both wi ndshi el d wi per arm/bl ade
assembl i es. Refer to 8, Wi per and Washer Systems.
(3) Remove rubber weather-stri p at front edge of
cowl gri l l (Fi g. 10).
(4) Remove four pl asti c nuts securi ng cowl pl enum
cover/gri l l e panel to studs on cowl top panel near
base of wi ndshi el d (Fi g. 11).
(5) Remove two pl asti c ri vets securi ng each si de of
the cowl pl enum cover/gri l l e panel to cowl pl enum
panel and cowl top panel .
(6) Li ft cowl pl enum cover/gri l l e panel from vehi cl e
far enough to access wi ndshi el d washer and vacuum
pl umbi ng near ri ght end of cowl pl enum.
(7) Di sconnect wi ndshi el d washer suppl y hose at
i n-l i ne connector.
(8) Di sconnect vacuum suppl y hose from vacuum
suppl y connector at vacuum reservoi r (Fi g. 9).
(9) Remove cowl pl enum cover/gri l l e panel from
vehi cl e.
(10) Remove three reservoi r mounti ng screws (Fi g.
9).
(11) Remove vacuum reservoi r from vehi cl e.
INSTALLATION
The vacuum reservoi r i s l ocated under the pl asti c
cowl pl enum cover at l ower base of wi ndshi el d (Fi g.
9) or (Fi g. 11).
(1) I nstal l vacuum reservoi r and three mounti ng
screws to pl asti c cowl cover. Ti ghten three screws to
2.2 Nm (20 i n. l bs.) torque.
(2) Posi ti on cowl pl enum cover/gri l l e panel to vehi -
cl e.
(3) Connect vacuum suppl y hose to vacuum reser-
voi r.
Fig. 9 Vacuum Reservoir Mounting
1 - VACUUM SUPPLY CONNECTOR
2 - COWL PLENUM COVER/GRILLE PANEL
3 - VACUUM RESERVOIR
4 - SCREWS
Fig. 10 Cowl Grille Panel Weather-strip
1 - COWL GRILLE
2 - WEATHERSTRIP
VACUUM RESERVOIR (Continued)
(4) Connect wi ndshi el d washer suppl y hose at i n-
l i ne connector.
(5) I nstal l and ti ghten cowl cover fasteners to vehi -
cl e body.
(6) I nstal l rubber weather-stri p at front edge of
cowl gri l l .
(7) I nstal l wi ndshi el d wi per arms. Refer to 8,
Wi per and Washer Systems.
(8) Connect negati ve battery to cabl e.
Fig. 11 Cowl Plenum Cover/Grille Panel Remove/Install
1 - PLASTIC RIVET
2 - IN-LINE WASHER SUPPLY HOSE CONNECTOR
3 - STUD
4 - PLASTIC NUT
5 - COWL PLENUM COVER/GRILLE PANEL
VACUUM RESERVOIR (Continued)
VEHICLE THEFT SECURITY
TABLE OF CONTENTS
page page
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
VEHICLE THEFT SECURITY SYSTEM . . . . . . . . 3
SENTRY KEY IMMOBILIZER SYSTEM . . . . . . . . 4
SKIS INITIALIZATION. . . . . . . . . . . . . . . . . . . . . 6
SENTRY KEY TRANSPONDER
PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSPONDER KEY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION - VEHICLE THEFT SECURITY
SYSTEM
The Vehi cl e Theft Securi ty System (VTSS) i s an
avai l abl e factory-i nstal l ed opti on on thi s model . The
VTSS i s desi gned to provi de peri meter protecti on
agai nst unauthori zed use or tamperi ng by moni tori ng
the vehi cl e doors and the i gni ti on system. I f unautho-
ri zed use or tamperi ng i s detected, the system
responds by pul si ng the horn and fl ashi ng the head-
l amp hi gh beams. I f the vehi cl e i s al so equi pped wi th
the opti onal Sentry Key I mmobi l i zer System (SKI S),
whi ch provi des passi ve vehi cl e protecti on by prevent-
i ng the engi ne from operati ng unl ess a val i d el ectron-
i cal l y encoded key i s detected i n the i gni ti on l ock
cyl i nder, the VTSS wi l l al so di sabl e the engi ne from
operati ng unti l the system i s di sarmed. (Refer to 8 -
ELECTRI CAL/VEHI CLE THEFT SECURI TY - DESCRI P-
TI ON - SENTRY KEY I MMOBI LI ZER SYSTEM).
The VTSS i ncl udes the fol l owi ng major compo-
nents, whi ch are descri bed i n further detai l el se-
where i n thi s servi ce i nformati on:
sor and software that al l ow i t to provi de the proper
VTSS features and outputs based upon the moni -
tored i nputs. The CTM ci rcui try moni tors hard wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c modul es on the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network. (Refer to 8 - ELECTRI CAL/ELECTRONI C
CONTROL MODULES/BODY CONTROL/CENTRAL
TI MER MODULE - DESCRI PTI ON).
Door Ajar Switch - A door ajar swi tch i s i nte-
gral to the l atch of each door i n the vehi cl e. These
swi tches provi de an i nput to the VTSS i ndi cati ng
whether each door i s opened or cl osed. (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - I NTERI OR/
DOOR AJAR SWI TCH - DESCRI PTI ON).
Door Cylinder Lock Switch - A door cyl i nder
l ock swi tch i s l ocated on the back of each front door
l ock cyl i nder. Thi s swi tch provi des an i nput to the
VTSS i ndi cati ng whether the system shoul d remai n
armed or be di sarmed. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/DOOR CYLI NDER LOCK SWI TCH
- DESCRI PTI ON).
Horn Relay - The horn rel ay i s l ocated i n the
partment near the battery. The horn rel ay i s nor-
mal l y acti vated by the horn swi tch to control the
soundi ng of the vehi cl e horn or horns. However, i t
can al so be acti vated by an output of the CTM to pro-
vi de an audi bl e i ndi cati on that unauthori zed vehi cl e
use or tamperi ng has been detected. (Refer to 8 -
ELECTRI CAL/HORN/HORN RELAY - DESCRI PTI ON).
Security Indicator - A red Li ght Emi tti ng
Di ode (LED) l ocated i n the El ectroMechani cal I nstru-
ment Cl uster (EMI C) i s i l l umi nated by an output of
the CTM to i ndi cate the status of the VTSS or SKI S.
Thi s LED i s i ntegral to the i nstrument cl uster. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DESCRI PTI ON).
Hard wi red ci rcui try connects many of the VTSS
components to each other through the el ectri cal sys-
tem of the vehi cl e. These hard wi red ci rcui ts are
i ntegral to several wi re harnesses, whi ch are routed
throughout the vehi cl e and retai ned by many di ffer-
ent methods. These ci rcui ts may be connected to each
other, to the vehi cl e el ectri cal system and to the
VTSS components through the use of a combi nati on
of sol dered spl i ces, spl i ce bl ock connectors, and many
AN VEHICLE THEFT SECURITY 8Q - 1
DESCRIPTION - SENTRY KEY IMMOBILIZER
SYSTEM
The Sentry Key I mmobi l i zer System (SKI S) i s
avai l abl e as a factory-i nstal l ed opti on on thi s model .
Vehi cl es equi pped wi th thi s opti on can be readi l y
i denti fi ed by a gray mol ded rubber cap on the head of
the i gni ti on key. Model s not equi pped wi th SKI S
have a bl ack mol ded rubber cap on the head of the
i gni ti on key.
The SKI S i ncl udes the fol l owi ng major components,
whi ch are descri bed i n further detai l el sewhere i n
thi s servi ce i nformati on:
Powertrain Control Module - The Powertrai n
Control Modul e (PCM) i s l ocated on the ri ght front
fender i nner shi el d above the ri ght front wheel house
i n the engi ne compartment.
Sentry Key Immobilizer Module - The Sentry
Key I mmobi l i zer Modul e (SKI M) i s l ocated on the
ri ght si de of the steeri ng col umn near the i gni ti on
l ock cyl i nder housi ng and an i ntegral mol ded pl asti c
antenna ri ng ci rcl es the i gni ti on l ock cyl i nder l i ke a
hal o. The SKI M and i ts antenna are conceal ed
beneath the steeri ng col umn shrouds.
Sentry Key Transponder - The Sentry Key
transponder i s mol ded i nto the head of the i gni ti on
key, and conceal ed by a gray mol ded rubber cap.
Security Indicator - The securi ty i ndi cator i s
ment cl uster, to the l eft of center. (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER/SECURI TY
I NDI CATOR - DESCRI PTI ON).
Except for the Sentry Key transponders, whi ch rel y
upon Radi o Frequency (RF) communi cati on, hard
wi red ci rcui try connects the SKI S components to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
and to the SKI S components through the use of a
combi nati on of sol dered spl i ces, spl i ce bl ock connec-
tors, and many di fferent types of wi re harness termi -
nal connectors and i nsul ators. Refer to the
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
OPERATION - VEHICLE THEFT SECURITY
SYSTEM
A Central Ti mer Modul e (CTM) i s used on thi s
model to control and i ntegrate many of the el ectroni c
functi ons and features i ncl uded i n the Vehi cl e Theft
Securi ty System (VTSS). I n the VTSS, the CTM
recei ves i nputs i ndi cati ng the status of the door ajar
swi tches, the door cyl i nder l ock swi tch, and the i gni -
ti on swi tch. The programmi ng i n the CTM al l ows i t
to process the i nformati on from al l of these i nputs
and send control outputs to energi ze or de-energi ze
the horn rel ay, the headl amp hi gh beams, and the
securi ty i ndi cator. I f the VTSS al arm i s tri ggered, the
CTM pul ses the horn for about three mi nutes and
fl ashes the headl amp hi gh beams and securi ty i ndi -
cator for about ei ghteen mi nutes or unti l the system
i s di sarmed, whi chever occurs fi rst. The control of
these i nputs and outputs are what consti tute al l of
the features of the VTSS. Fol l owi ng i s i nformati on on
the operati on of each of the VTSS features. Refer to
VTSS.
ENABLING
The CTM must have the VTSS functi on el ectroni -
cal l y enabl ed i n order for the VTSS to perform as
desi gned. The l ogi c i n the CTM keeps i ts VTSS func-
ti on dormant unti l i t i s enabl ed usi ng a DRBI I I
scan tool . The VTSS functi on of the CTM i s enabl ed
on vehi cl es equi pped wi th the VTSS opti on at the
factory, but a servi ce repl acement CTM must be
VTSS-enabl ed by the deal er usi ng a DRBI I I scan
ARMING
Passi ve armi ng of the VTSS occurs when the vehi -
cl e i s exi ted wi th the key removed from the i gni ti on
swi tch, the headl amps are turned off, and the doors
are l ocked whi l e they are open usi ng the power l ock
swi tch, or l ocked after they are cl osed by turni ng
ei ther front door l ock cyl i nder to the l ock posi ti on
usi ng the key. The power l ock swi tch wi l l not func-
ti on i f the key i s i n the i gni ti on swi tch or the head-
l amps are turned on wi th the dri ver si de front door
open. The VTSS wi l l not arm i f the doors are l ocked
usi ng the mechani cal l ock button. Acti ve armi ng of
the VTSS occurs when the Lock button on the
Remote Keyl ess Entry (RKE) transmi tter i s
depressed to l ock the vehi cl e. For acti ve armi ng to
occur, the doors must be cl osed and the i gni ti on
swi tch must be i n the Off posi ti on when the RKE
transmi tter Lock button i s depressed. However,
once the VTSS armi ng process has been compl eted,
the i gni ti on swi tch can be turned to the Accessory
posi ti on wi thout tri ggeri ng the al arm.
Pre-armi ng of the VTSS i s i ni ti ated when a door i s
open when the vehi cl e i s l ocked usi ng a power door
l ock swi tch or a key i n the door l ock cyl i nder (pas-
si ve), or when the RKE transmi tter Lock button i s
depressed (acti ve). Pre-armi ng wi l l not occur i f the
key i s i n the i gni ti on swi tch or the headl amps are
8Q - 2 VEHICLE THEFT SECURITY AN
VEHICLE THEFT SECURITY (Continued)
turned on wi th the dri ver si de front door open. When
the VTSS i s pre-armed, the armi ng sequence i s
del ayed unti l al l of the doors have been cl osed.
Once the VTSS begi ns the passi ve or acti ve armi ng
sequence, the securi ty i ndi cator i n the i nstrument
cl uster wi l l fl ash rapi dl y for about seventeen seconds.
Thi s i ndi cates that the VTSS armi ng i s i n progress.
I f the i gni ti on swi tch i s turned to the On posi ti on, a
door i s opened, a door i s unl ocked by any means, or
the RKE Pani c button i s depressed duri ng the sev-
enteen second armi ng process, the securi ty i ndi cator
wi l l stop fl ashi ng and the armi ng process wi l l abort.
Once the seventeen second armi ng sequence i s suc-
cessful l y compl eted, the securi ty i ndi cator wi l l fl ash
at a sl ower rate, i ndi cati ng that the VTSS i s armed.
DISARMING
Passi ve di sarmi ng of the VTSS occurs when the
vehi cl e i s unl ocked usi ng the key to unl ock ei ther
front door or, i f the vehi cl e i s equi pped wi th the
opti onal Sentry Key I mmobi l i zer System (SKI S), by
turni ng the i gni ti on swi tch to the On posi ti on usi ng a
val i d SKI S key. Acti ve di sarmi ng of the VTSS occurs
when the vehi cl e i s unl ocked by depressi ng the
Unl ock button of the RKE transmi tter. Once the
al arm has been acti vated (horn pul si ng and head-
l amps fl ashi ng), ei ther di sarmi ng method wi l l al so
deacti vate the al arm. Depressi ng the Pani c button
on the RKE transmi tter wi l l not di sarm the VTSS.
POWER-UP MODE
When the armed VTSS senses that the battery has
been di sconnected and reconnected, i t enters i ts pow-
er-up mode. I n the power-up mode the al arm system
remai ns armed fol l owi ng a battery fai l ure or di scon-
nect. I f the VTSS was armed pri or to a battery di s-
connect or fai l ure, the techni ci an or vehi cl e operator
wi l l have to acti vel y or passi vel y di sarm the al arm
system after the battery i s reconnected. The pow-
er-up mode wi l l al so appl y i f the battery goes dead
whi l e the system i s armed, and battery jump-starti ng
i s attempted. The VTSS wi l l be armed unti l the tech-
ni ci an or vehi cl e operator has acti vel y or passi vel y
di sarmed the al arm system. I f the VTSS i s i n the di s-
armed mode pri or to a battery di sconnect or fai l ure,
i t wi l l remai n di sarmed after the battery i s recon-
nected or repl aced, or i f jump-starti ng i s attempted.
TAMPER ALERT
The VTSS tamper al ert feature wi l l sound the horn
three ti mes upon di sarmi ng, i f the al arm was tri g-
gered and has si nce ti med-out (about ei ghteen mi n-
utes). Thi s feature al erts the vehi cl e operator that
the VTSS al arm was acti vated whi l e the vehi cl e was
unattended.
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM
The Sentry Key I mmobi l i zer System (SKI S) i s
desi gned to provi de passi ve protecti on agai nst unau-
thori zed vehi cl e use by di sabl i ng the engi ne after
about two seconds of runni ng, whenever any method
other than a val i d Sentry Key i s used to start the
vehi cl e. The SKI S i s consi dered a passi ve protecti on
system because i t i s al ways acti ve when the i gni ti on
system i s energi zed and does not requi re any cus-
tomer i nterventi on. The SKI S uses Radi o Frequency
(RF) communi cati on to obtai n confi rmati on that the
key i n the i gni ti on swi tch i s a val i d key for operati ng
the vehi cl e. The mi croprocessor-based SKI S hard-
ware and software al so uses el ectroni c messages to
communi cate wi th other el ectroni c modul es i n the
vehi cl e over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. (Refer to 8 - ELECTRI CAL/
ELECTRONI C CONTROL MODULES/COMMUNI -
CATI ON - OPERATI ON).
Pre-programmed Sentry Key transponders are pro-
vi ded wi th the vehi cl e from the factory. Each Sentry
Key I mmobi l i zer Modul e (SKI M) wi l l recogni ze a
maxi mum of ei ght Sentry Keys. I f the customer
woul d l i ke addi ti onal keys other than those provi ded
wi th the vehi cl e, they may be purchased from any
authori zed deal er. These addi ti onal keys must be pro-
grammed to the SKI M i n the vehi cl e i n order for the
system to recogni ze them as val i d keys. Thi s can be
done by the deal er usi ng a DRBI I I scan tool or, i f
Customer Learn programmi ng i s an avai l abl e SKI S
feature i n the market where the vehi cl e was pur-
chased, the customer can program the addi ti onal
keys, as l ong as at l east two val i d Sentry Keys are
al ready avai l abl e. (Refer to 8 - ELECTRI CAL/VEHI -
CLE THEFT SECURI TY - STANDARD PROCE-
DURE - TRANSPONDER PROGRAMMI NG).
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTCs) i f a system mal functi on i s
detected. The SKI S can be di agnosed, and any stored
DTCs can be retri eved usi ng a DRBI I I scan tool .
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM
The Vehi cl e Theft Securi ty System (VTSS)-rel ated
hard wi red i nputs to and outputs from the Central
Ti mer Modul e (CTM) may be di agnosed and tested
usi ng conventi onal di agnosti c tool s and procedures.
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the CTM or the
bus network. I n order to obtai n concl usi ve testi ng of
the VTSS, the CTM and the PCI data bus network
must al so be checked. The most rel i abl e, effi ci ent,
and accurate means to di agnose the VTSS requi res
pri ate di agnosti c i nformati on. The DRBI I I scan tool
can provi de confi rmati on that the PCI data bus net-
work i s functi onal , that al l of the el ectroni c modul es
are sendi ng and recei vi ng the proper messages over
the PCI data bus, and that these modul es are recei v-
i ng the proper hard wi red i nputs and respondi ng
wi th the proper hard wi red outputs needed to per-
form thei r functi ons. See the Vehi cl e Theft Securi ty
System menu i tem on the DRBI I I scan tool .
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM
SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS
SECURITY INDICATOR
FAILS TO LIGHT DURING
BULB TEST
1. Light-Emitting Diode (LED)
faulty.
1. Perform the instrument cluster actuator test.
(Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING -
ACTUATOR TEST)..
2. Fuse faulty. 2. Check the SKIM fused B(+) fuse and the fused
ignition switch output (run-start) fuse in the JB.
Replace fuses, if required.
3. Ground path faulty. 3. Check for continuity to ground at the connector
for the SKIM. Repair wiring, if required.
4. Battery feed faulty. 4. Check for battery current at the connector for
the SKIM. Repair wiring, if required.
5. Ignition feed faulty. 5. Check for battery current at the connector for
the SKIM with the ignition switch in the On
position. Repair wiring, if required.
SECURITY INDICATOR
FLASHES FOLLOWING
BULB TEST
1. Invalid key in ignition
switch lock cylinder.
1. Replace the key with a known valid key.
2. Key-related fault. 2. Use a DRBIII scan tool and the appropriate
diagnostic information for further diagnosis.
SECURITY INDICATOR
LIGHTS SOLID FOLLOWING
BULB TEST
1. SKIS system malfunction/
fault detected.
1. Use a DRBIII scan tool and the appropriate
2. SKIS system inoperative. 2. Use a DRBIII scan tool and the appropriate
SECURITY INDICATOR FAILS TO LIGHT DURING BULB TEST
I f the securi ty i ndi cator i n the i nstrument cl uster
fai l s to i l l umi nate for about three seconds after the
i gni ti on swi tch i s turned to the On posi ti on (bul b
test), perform the i nstrument cl uster actuator test.
TER - DI AGNOSI S AND TESTI NG - ACTUATOR
TEST). I f the securi ty i ndi cator sti l l fai l s to l i ght dur-
i ng the bul b test, a wi ri ng probl em resul ti ng i n the
l oss of battery current or ground to the Sentry Key
I mmobi l i zer Modul e (SKI M) shoul d be suspected, and
the fol l owi ng procedure shoul d be used for di agnosi s.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System requires the use of
a DRBIII scan tool. Refer to the appropriate diag-
nostic information.
not OK, repai r the open B(+) ci rcui t between the JB
fuse and the Power Di stri buti on Center (PDC) as
requi red.
start) fuse (Fuse 10 - 10 ampere) i n the JB. I f OK, go
output (run-start) fuse (Fuse 10 - 10 ampere) i n the
connector for the Sentry Key I mmobi l i zer Modul e
(SKI M) from the SKI M connector receptacl e. Check
for conti nui ty between the ground ci rcui t cavi ty of
the i nstrument panel wi re harness connector for the
SKI M and a good ground. There shoul d be conti nui ty.
I f OK, go to Step 6. I f not OK, repai r the open
ground ci rcui t to ground (G208) as requi red.
(6) Reconnect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
i nstrument panel wi re harness connector for the
SKI M. I f OK, go to Step 7. I f not OK, repai r the open
fused B(+) ci rcui t between the SKI M and the JB as
requi red.
output (run-start) ci rcui t cavi ty of the i nstrument
panel wi re harness connector for the SKI M. I f OK,
refer to the appropri ate di agnosti c i nformati on and
use a DRBI I I scan tool to compl ete the di agnosi s of
the SKI S. I f not OK, repai r the open fused i gni ti on
swi tch output (run-start) ci rcui t between the SKI M
and the JB fuse as requi red.
SECURITY INDICATOR FLASHES OR LIGHTS SOLID
FOLLOWING BULB TEST
A securi ty i ndi cator that fl ashes fol l owi ng a suc-
cessful bul b test i ndi cates that an i nval i d key has
been detected, or that a key-rel ated faul t has been
set. A securi ty i ndi cator that l i ghts sol i d fol l owi ng a
successful bul b test i ndi cates that the SKI M has
detected a system mal functi on or that the SKI S i s
i noperati ve. I n ei ther case, faul t i nformati on wi l l be
stored i n the SKI M memory. For retri eval of thi s
faul t i nformati on and further di agnosi s of the SKI S,
the PCI data bus, the SKI M message outputs to the
Central Ti mer Modul e (CTM) that control the secu-
ri ty i ndi cator, or the message i nputs and outputs
between the SKI M and the Powertrai n Control Mod-
ul e (PCM) that control engi ne operati on, a DRBI I I
scan tool and the appropri ate di agnosti c i nformati on
are requi red. Fol l owi ng are prel i mi nary troubl eshoot-
i ng gui del i nes to be fol l owed duri ng di agnosi s usi ng a
DRBI I I scan tool :
(1) Usi ng the DRBI I I scan tool , read and record
the faul ts as they exi st i n the SKI M when you fi rst
begi n your di agnosi s of the vehi cl e. I t i s i mportant to
document these faul ts because the SKI M does not
di fferenti ate between hi stori cal faul ts (those that
have occurred i n the past) and acti ve faul ts (those
that are currentl y present). I f thi s probl em turns out
to be an i ntermi ttent condi ti on, thi s i nformati on may
become i nval uabl e to your di agnosi s.
(2) Usi ng the DRBI I I scan tool , erase al l of the
faul ts from the SKI M.
(3) Cycl e the i gni ti on swi tch to the Off posi ti on,
then back to the On posi ti on.
(4) Usi ng the DRBI I I scan tool , read any faul ts
that are now present i n the SKI M. These are the
acti ve faul ts.
(5) Usi ng thi s acti ve faul t i nformati on, refer to the
proper procedure i n the appropri ate di agnosti c i nfor-
mati on for the addi ti onal speci fi c di agnosti c steps.
STANDARD PROCEDURE - SKIS
INITIALIZATION
The Sentry Key I mmobi l i zer System (SKI S) must
be i ni ti al i zed fol l owi ng a Sentry Key I mmobi l i zer
Modul e (SKI M) repl acement. SKI S i ni ti al i zati on
requi res the use of a DRBI I I scan tool . I ni ti al i zati on
wi l l al so requi re that you have access to the uni que
four-di gi t PI N code that was assi gned to the ori gi nal
SKI M. The PI N code must be used to enter the
Secured Access Mode i n the SKI M. Thi s PI N number
may be obtai ned from the vehi cl e owner, from the
ori gi nal vehi cl e i nvoi ce, or from the Dai ml erChrysl er
Customer Center. (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES - STANDARD PRO-
CEDURE - PCM/SKI M PROGRAMMI NG).
NOTE: If a Powertrain Control Module (PCM) is
replaced on a vehicle equipped with the Sentry Key
Immobilizer System (SKIS), the unique Secret Key
data must be transferred from the Sentry Key
Immobilizer Module (SKIM) to the new PCM using
the PCM replacement procedure. This procedure
also requires the use of a DRBIII scan tool and the
unique four-digit PIN code to enter the Secured
Access Mode in the SKIM. Refer to the appropriate
diagnostic information for the proper PCM replace-
ment procedures.
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING
Al l Sentry Keys i ncl uded wi th the vehi cl e are pre-
programmed to work wi th the Sentry Key I mmobi -
l i zer System (SKI S) when i t i s shi pped from the
factory. The Sentry Key I mmobi l i zer Modul e (SKI M)
can be programmed to recogni ze up to a total of ei ght
Sentry Keys. When programmi ng a bl ank Sentry Key
transponder, the key must fi rst be cut to match the
i gni ti on swi tch l ock cyl i nder i n the vehi cl e for whi ch
i t wi l l be used. Once the addi ti onal or new key has
been cut, the SKI M must be programmed to recog-
ni ze i t as a val i d key. There are two possi bl e methods
to program the SKI M to recogni ze a new or addi -
ti onal val i d key, the Secured Access Method and the
Customer Learn Method. Fol l owi ng are the detai l s of
these two programmi ng methods.
SECURED ACCESS METHOD
The Secured Access method appl i es to al l vehi cl es.
Thi s method requi res the use of a DRBI I I scan tool .
Thi s method wi l l al so requi re that you have access to
the uni que four-di gi t PI N code that was assi gned to
the ori gi nal SKI M. The PI N code must be used to
enter the Secured Access Mode i n the SKI M. Thi s
PI N number may be obtai ned from the vehi cl e owner,
from the ori gi nal vehi cl e i nvoi ce, or from the Dai m-
l erChrysl er Customer Center. Refer to the appropri -
ate di agnosti c i nformati on for the proper Secured
Access method programmi ng procedures.
CUSTOMER LEARN METHOD
The Customer Learn feature i s onl y avai l abl e on
domesti c vehi cl es, or those vehi cl es whi ch have a
U.S. country code desi gnator. Thi s programmi ng
method al so requi res access to at l east two val i d Sen-
try Keys. I f two val i d Sentry Keys are not avai l abl e,
or i f the vehi cl e does not have a U.S. country code
desi gnator, the Secured Access Method must be used
to program new or addi ti onal val i d keys to the SKI M.
The Customer Learn programmi ng method proce-
dures are as fol l ows:
(1) Obtai n the bl ank Sentry Key(s) that are to be
programmed as val i d keys for the vehi cl e. Cut the
bl ank key(s) to match the i gni ti on swi tch l ock cyl i n-
der mechani cal key codes.
(2) I nsert one of the two val i d Sentry Keys i nto the
i gni ti on swi tch and turn the i gni ti on swi tch to the
On posi ti on.
(3) After the i gni ti on swi tch has been i n the On
posi ti on for l onger than three seconds, but no more
than fi fteen seconds, cycl e the i gni ti on swi tch back to
the Off posi ti on. Repl ace the fi rst val i d Sentry Key i n
the i gni ti on swi tch l ock cyl i nder wi th the second
val i d Sentry Key and turn the i gni ti on swi tch back to
the On posi ti on. The second val i d Sentry Key must
be i nserted i n the l ock cyl i nder wi thi n fi fteen seconds
of removi ng the fi rst val i d key.
(4) About ten seconds after the compl eti on of Step
3, the securi ty i ndi cator i n the i nstrument cl uster
wi l l start to fl ash to i ndi cate that the system has
entered the Customer Learn programmi ng mode.
(5) Wi thi n si xty seconds of enteri ng the Customer
Learn programmi ng mode, turn the i gni ti on swi tch to
the Off posi ti on, repl ace the val i d Sentry Key wi th a
bl ank Sentry Key transponder, and turn the i gni ti on
swi tch back to the On posi ti on.
(6) About ten seconds after the compl eti on of Step
5, the securi ty i ndi cator wi l l stop fl ashi ng, stay on
sol i d for three seconds, then turn off to i ndi cate that
the bl ank Sentry Key has been successful l y pro-
grammed. The SKI S wi l l i mmedi atel y exi t the Cus-
tomer Learn programmi ng mode and the vehi cl e may
now be started usi ng the newl y programmed val i d
Sentry Key.
Each of these steps must be repeated and com-
pl eted i n thei r enti rety for each addi ti onal Sentry
Key that i s to be programmed. I f the above steps are
not compl eted i n the gi ven sequence, or wi thi n the
al l otted ti me, the SKI S wi l l exi t the Customer Learn
programmi ng mode and the programmi ng wi l l be
unsuccessful . The SKI S wi l l al so automati cal l y exi t
the Customer Learn programmi ng mode i f i t sees a
non-bl ank Sentry Key transponder when i t shoul d
see a bl ank, i f i t has al ready programmed ei ght (8)
val i d Sentry Keys, or i f the i gni ti on swi tch i s turned
to the Off posi ti on for more than about fi fty seconds.
NOTE: If an attempt is made to start the vehicle
while in the Customer Learn mode (security indica-
tor flashing), the SKIS will respond as though the
vehicle were being started with an invalid key. In
other words, the engine will stall after about two
seconds of operation. No faults will be set.
NOTE: Once a Sentry Key has been programmed as
a valid key to a vehicle, it cannot be programmed
as a valid key for use on any other vehicle.
TRANSPONDER KEY
DESCRIPTION
Each i gni ti on key used i n the Sentry Key I mmobi -
l i zer System (SKI S) has an i ntegral transponder chi p
(Fi g. 1). I gni ti on keys wi th thi s feature can be readi l y
i denti fi ed by a gray rubber cap mol ded onto the head
of the key, whi l e conventi onal i gni ti on keys have a
bl ack mol ded rubber cap. The transponder chi p i s
conceal ed beneath the mol ded rubber cap, where i t i s
Fig. 1 Sentry Key Immobilizer Transponder
1 - MOLDED CAP
2 - TRANSPONDER CHIP
3 - MOLDED CAP REMOVED
4 - TRANSPONDER KEY
mol ded wi thi n a pl asti c mount i nto the head of the
metal key. I n addi ti on to bei ng cut to match the
mechani cal codi ng of the i gni ti on l ock cyl i nder, each
new Sentry Key has a uni que transponder i denti fi ca-
ti on code permanentl y programmed i nto i t by the
manufacturer. The Sentry Key transponder cannot be
adjusted or repai red. I f faul ty or damaged, the enti re
key must be repl aced.
OPERATION
When the i gni ti on swi tch i s turned to the On posi -
ti on, the Sentry Key I mmobi l i zer Modul e (SKI M)
communi cates through i ts antenna wi th the Sentry
Key transponder usi ng a Radi o Frequency (RF) si g-
nal . The SKI M then l i stens for a RF response from
the transponder through the same antenna. The Sen-
try Key transponder chi p i s wi thi n the range of the
SKI M transcei ver antenna ri ng when i t i s i nserted
i nto the i gni ti on l ock cyl i nder. The SKI M determi nes
whether a val i d key i s present i n the i gni ti on l ock
cyl i nder based upon the response from the transpon-
der. I f a val i d key i s detected, that fact i s communi -
cated by the SKI M to the Powertrai n Control Modul e
I nterface (PCI ) data bus, and the PCM al l ows the
engi ne to conti nue runni ng. I f the PCM recei ves an
i nval i d key message, or recei ves no message from the
SKI M over the PCI data bus, the engi ne wi l l be di s-
abl ed after about two seconds of operati on. The El ec-
troMechani cal I nstrument Cl uster (EMI C) wi l l al so
respond to the i nval i d key message on the PCI data
bus by fl ashi ng the securi ty i ndi cator on and off.
Each Sentry Key has a uni que transponder i denti -
fi cati on code permanentl y programmed i nto i t by the
manufacturer. Li kewi se, the SKI M has a uni que
Secret Key code programmed i nto i t by the manufac-
turer. When a Sentry Key i s programmed i nto the
memory of the SKI M, the SKI M stores the transpon-
der i denti fi cati on code from the Sentry Key, and the
Sentry Key l earns the Secret Key code from the
SKI M. Once the Sentry Key l earns the Secret Key
code of the SKI M, i t i s permanentl y stored i n the
memory of the transponder. Therefore, once a Sentry
Key has been programmed to a parti cul ar vehi cl e, i t
cannot be used on any other vehi cl e. (Refer to 8 -
ELECTRI CAL/VEHI CLE THEFT SECURI TY -
STANDARD PROCEDURE - TRANSPONDER PRO-
GRAMMI NG).
store key-rel ated faul t i nformati on i n the form of
Di agnosti c Troubl e Codes (DTCs) i n SKI M memory i f
a Sentry Key transponder probl em i s detected. The
Sentry Key transponder chi p can be di agnosed, and
any stored DTCs can be retri eved usi ng a DRBI I I
scan tool . Refer to the appropri ate di agnosti c
i nformati on.
TRANSPONDER KEY (Continued)
WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WIPER & WASHER SYSTEM . . . . . . . . . . . . . . . 3
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECK VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WASHER FLUID LEVEL SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WASHER HOSES/TUBES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WASHER NOZZLE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WASHER PUMP/MOTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WASHER RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WIPER ARM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WIPER BLADE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WIPER MODULE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WIPER RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WIPER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WIPERS/WASHERS
DESCRIPTION
An el ectri cal l y operated i ntermi ttent wi per and
washer system i s standard factory-i nstal l ed safety
equi pment on thi s model . The wi per and washer sys-
tem i ncl udes the fol l owi ng major components, whi ch
vi ce i nformati on:
sor and software that al l ow i t to provi de the many
el ectroni c functi ons and features not avai l abl e wi th
most conventi onal hard wi red wi per and washer sys-
tems. The CTM provi des the proper wi per and
washer system features based upon the moni tored
i nputs. The CTM ci rcui try moni tors hard wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c modul es on the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network. (Refer to 8 - ELECTRI CAL/ELECTRONI C
CONTROL MODULES/BODY CONTROL/CENTRAL
TI MER MODULE - DESCRI PTI ON).
Multi-Function Switch - The mul ti -functi on
swi tch i s secured to the l eft si de of the steeri ng col -
umn, just bel ow the steeri ng wheel . Onl y the control
stal k for the mul ti -functi on swi tch i s vi si bl e, the
remai nder of the swi tch i s conceal ed beneath the
steeri ng col umn shrouds. The mul ti -functi on swi tch
contai ns al l of the swi tches for both the wi per and
washer systems.(Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/MULTI -FUNCTI ON
SWI TCH - DESCRI PTI ON)
Washer Fluid Level Switch - The washer fl ui d
l evel swi tch i s l ocated i n a dedi cated hol e near the
AN WIPERS/WASHERS 8R - 1
front of the wi ndshi el d washer reservoi r on the ri ght
outboard end of the upper radi ator shroud.
Washer Nozzles - The dual fl ui di c washer noz-
zl es are secured wi th i ntegral snap features to dedi -
cated openi ngs i n the cowl pl enum cover/gri l l e panel
l ocated near the base of the wi ndshi el d. The washer
pl umbi ng fi tti ngs for the washer nozzl es are con-
ceal ed beneath the cowl pl enum cover/gri l l e panel .
Washer Pump/Motor - The washer pump/mo-
tor uni t i s l ocated i n a dedi cated hol e near the bot-
tom of the wi ndshi el d washer reservoi r on the ri ght
end of the upper radi ator shroud.
Washer Reservoir - The washer reservoi r i s
i ntegral to and l ocated on the ri ght end of the upper
radi ator shroud. The washer reservoi r fi l l er i s
accessed from the ri ght front corner of the engi ne
compartment.
Wiper Arms - The two wi per arms are secured
to the two wi per pi vots, whi ch extend through the
cowl pl enum cover/gri l l e panel l ocated near the base
of the wi ndshi el d.
Wiper Blades - The two wi per bl ades are
secured to the two wi per arms, and are parked on
the gl ass near the bottom of the wi ndshi el d when the
wi per system i s not i n operati on.
Wiper Module - The wi per pi vots are the onl y
vi si bl e components of the wi per modul e. The remai n-
der of the modul e i s conceal ed wi thi n the cowl pl e-
num beneath the cowl pl enum cover/gri l l e panel . The
wi per modul e i ncl udes the modul e bracket, the si ngl e
wi per motor, the wi per l i nkage, and the two wi per
pi vots.
Wiper Relay - The wi per rel ay i s l ocated i n the
partment near the battery.
Features of the wi per and washer system i ncl ude
the fol l owi ng:
Continuous Wipe Modes - The two-speed
wi per motor and the i nternal ci rcui try of the mul ti -
functi on swi tch work i n concert to provi de two con-
ti nuous wi pe cycl es, l ow speed or hi gh speed.
Intermittent Wipe Mode - The i nternal ci r-
cui try of the mul ti -functi on swi tch, the CTM, and the
wi per rel ay work i n concert to provi de an i ntermi t-
tent wi pe mode wi th mul ti pl e del ay i nterval sel ec-
ti ons. The CTM al so automati cal l y adjusts each
manual l y sel ected del ay i nterval to compensate for
vehi cl e speed.
Washer Mode - When the washer system i s
acti vated wi th the mul ti -functi on swi tch whi l e the
wi per system i s operati ng, washer fl ui d wi l l be di s-
pensed onto the wi ndshi el d gl ass through the washer
nozzl es for as l ong as the washer pump/motor i s
energi zed.
Wipe-After-Wash Mode - The i nternal ci rcui try
of the CTM provi des a wi pe-after-wash feature
whi ch, i f the wi pers are turned Off, wi l l operate the
washer pump/motor and the wi pers for as l ong as the
washer system i s acti vated, then provi de several
addi ti onal wi pe cycl es after the washer system i s
deacti vated before parki ng the wi per bl ades near the
base of the wi ndshi el d.
Hard wi red ci rcui try connects the wi per and
washer system components to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the wi per and washer
system components through the use of a combi nati on
of sol dered spl i ces, spl i ce bl ock connectors, and many
OPERATION
The wi per and washer system i s i ntended to pro-
vi de the vehi cl e operator wi th a conveni ent, safe, and
rel i abl e means of mai ntai ni ng vi si bi l i ty through the
wi ndshi el d gl ass. The vari ous components of thi s sys-
tem are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ades to wi pe the
outsi de surface of the gl ass, as wel l as i nto the
hydraul i c acti on of the washer system to appl y
washer fl ui d stored i n an on-board reservoi r to the
area of the gl ass to be wi ped. When combi ned, these
components provi de the means to effecti vel y mai n-
tai n cl ear vi si bi l i ty for the vehi cl e operator by remov-
i ng excess accumul ati ons of rai n, snow, bugs, mud, or
other mi nor debri s that mi ght be encountered whi l e
dri vi ng the vehi cl e under numerous types of i ncl em-
ent operati ng condi ti ons from the outsi de wi ndshi el d
gl ass surface. The vehi cl e operator i ni ti ates al l wi per
and washer system functi ons wi th the mul ti -functi on
swi tch control stal k that extends from the l eft si de of
the steeri ng col umn, just bel ow the steeri ng wheel .
Rotati ng the knob on the end of the mul ti -functi on
swi tch control stal k sel ects the desi red wi per system
operati ng mode. The wi per system al l ows the vehi cl e
operator to sel ect from two conti nuous wi per speeds,
Hi or Lo, or one of several i ntermi ttent wi pe Del ay
mode i nterval s. Pushi ng the knob on the end of the
control stal k towards the steeri ng col umn acti vates
the washer pump/motor, whi ch di spenses washer
fl ui d onto the wi ndshi el d gl ass through the washer
nozzl es.
8R - 2 WIPERS/WASHERS AN
WIPERS/WASHERS (Continued)
When the i gni ti on swi tch i s i n the Accessory or On
posi ti ons, battery current from a fuse i n the Juncti on
Bl ock (JB) i s provi ded through a fused i gni ti on
swi tch output (run-acc) ci rcui t to the wi per motor
park swi tch, the wi per rel ay, and the mul ti -functi on
swi tch. The i nternal ci rcui try of the mul ti -functi on
swi tch provi des a di rect hard wi red battery current
output to the l ow speed or hi gh speed brushes of the
wi per motor when the Lo or Hi swi tch setti ng i s
sel ected, whi ch causes the wi pers to cycl e at the
sel ected speed. The i ntermi ttent wi pe, and wi pe-af-
ter-wash features of the wi per and washer system
are provi ded by the el ectroni c i ntermi ttent wi pe l ogi c
ci rcui t wi thi n the Central Ti mer Modul e (CTM). I n
order to provi de the i ntermi ttent wi pe feature, the
CTM moni tors the wi per swi tch state and the wi per
motor park swi tch state. I n order to provi de the
wi pe-after-wash feature, the CTM moni tors both the
washer swi tch state and the wi per motor park swi tch
state. When a Del ay posi ti on i s sel ected wi th the
mul ti -functi on swi tch control knob, the CTM l ogi c ci r-
cui t responds by cal cul ati ng the correct del ay i nter-
val . The CTM then energi zes the wi per rel ay by
pul l i ng the rel ay control coi l to ground. The ener-
gi zed wi per rel ay di rects battery current through the
normal l y open contact of the rel ay back through the
i nternal Del ay posi ti on ci rcui try of the mul ti -functi on
swi tch to the l ow speed brush of the wi per motor.
The CTM moni tors the wi per motor operati on
through the wi per park swi tch sense ci rcui t, whi ch
al l ows the CTM to determi ne the proper ti mi ng to
begi n the next wi per bl ade sweep. The normal del ay
i nterval s are dri ver adjustabl e from about one-hal f
second to about ei ghteen seconds.
The CTM al so provi des a speed sensi ti ve i ntermi t-
tent wi pe feature. By moni tori ng vehi cl e speed mes-
sages recei ved from the Powertrai n Control Modul e
I nterface (PCI ) data bus network, the CTM i s abl e to
adjust the del ay i nterval s to compensate for vehi cl e
speed. Above about si xteen ki l ometers-per-hour (ten
mi l es-per-hour) the del ay i s dri ver adjustabl e from
about one-hal f second to about ei ghteen seconds.
Bel ow about si xteen ki l ometers-per-hour (ten mi l es-
per-hour) the del ay ti mes are doubl ed by the CTM,
from about one second to about thi rty-si x seconds.
When the Off posi ti on of the mul ti -functi on swi tch
wi per control knob i s sel ected, one of two events i s
possi bl e. The event that wi l l occur depends upon the
posi ti on of the wi per bl ades on the wi ndshi el d at the
moment that the Off posi ti on i s sel ected. I f the wi per
bl ades are i n the down posi ti on on the wi ndshi el d
when the Off posi ti on i s sel ected, the park swi tch
that i s i ntegral to the wi per motor i s cl osed to ground
and the wi per motor ceases to operate. I f the wi per
bl ades are not i n the down posi ti on on the wi ndshi el d
at the moment the Off posi ti on i s sel ected, the park
swi tch i s cl osed to battery current through a fused
i gni ti on swi tch output (run-acc) ci rcui t. The park
swi tch sense ci rcui t di rects thi s battery current to
the l ow speed brush of the wi per motor through the
normal l y cl osed contact of the wi per rel ay and the
i nternal Off posi ti on ci rcui try of the mul ti -functi on
swi tch. Thi s causes the wi per motor to conti nue run-
ni ng unti l the wi per bl ades are i n the down posi ti on
on the wi ndshi el d and the park swi tch i s agai n
cl osed to ground.
When the Wash posi ti on of the mul ti -functi on
swi tch i s sel ected, the Wash posi ti on ci rcui try wi thi n
the swi tch di rects a battery current si gnal i nput to
the CTM. The CTM moni tors the washer swi tch state
through thi s i nput to control a battery current output
to the washer pump/motor uni t. When the washer
swi tch i s cl osed wi th the wi per system turned Off,
the CTM operates the wi per motor through the wi per
rel ay i n the same manner as i t does to provi de the
Del ay mode operati on. After the state of the washer
swi tch changes to open, the CTM moni tors the wi per
motor through the wi per park swi tch sense ci rcui t,
whi ch al l ows the CTM to moni tor the number of
wi per bl ade sweeps. After the appropri ate number of
wi per sweeps, the CTM de-energi zes the wi per rel ay
and the wi pers return to thei r park posi ti on.
Proper testi ng of the CTM, the PCM, or the PCI
data bus vehi cl e speed messages requi res a DRBI I I
scan tool . Refer to the appropri ate di agnosti c i nfor-
mati on. Refer to the owners manual i n the vehi cl e
gl ove box for more i nformati on on the features and
operati on of the wi per and washer system.
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM
WIPER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve wi per system. I f the wi per motor oper-
ates, but the wi pers do not move on the wi ndshi el d,
repl ace the faul ty wi per modul e. I f the wi pers oper-
ate, but chatter, l i ft, or do not cl ear the gl ass, cl ean
and i nspect the wi per system components as
requi red. (Refer to 8 - ELECTRI CAL/WI PERS/
WASHERS - I NSPECTI ON) and (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS - CLEANI NG). Refer to
the appropri ate wi ri ng i nformati on. The wi ri ng i nfor-
mati on i ncl udes wi ri ng di agrams, proper wi re and
connector repai r procedures, detai l s of wi re harness
The fol l owi ng tests wi l l hel p to di agnose the hard
wi red components and ci rcui ts of the wi per system.
However, these tests may not prove concl usi ve i n the
di agnosi s of the Central Ti mer Modul e (CTM). I n
order to obtai n concl usi ve testi ng of the CTM, the
bus network and al l of the el ectroni c modul es that
provi de i nputs to or recei ve outputs from the wi per
system components must be checked. The most rel i -
abl e, effi ci ent, and accurate means to di agnose the
CTM requi res the use of a DRBI I I scan tool . Refer
to the appropri ate di agnosti c i nformati on. The
DRBI I I scan tool can provi de confi rmati on that the
PCI data bus i s functi onal , that al l of the el ectroni c
modul es are sendi ng and recei vi ng the proper mes-
sages on the PCI data bus, and that the wi per rel ay
i s bei ng sent the proper hard wi red outputs by the
CTM for i t to perform i ts wi per system functi ons.
acc) fuse (Fuse 5 - 20 ampere) i n the Juncti on Bl ock
(JB). I f OK, go to Step 2. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
output (run-acc) fuse (Fuse 5 - 20 ampere) i n the JB.
I f OK, go to Step 3. I f not OK, repai r the open fused
i gni ti on swi tch output (run-acc) ci rcui t between the
JB and the i gni ti on swi tch as requi red.
nector for the mul ti -functi on swi tch from the swi tch
output (run-acc) ci rcui t cavi ty of the i nstrument
panel wi re harness connector for the mul ti -functi on
swi tch. I f OK, go to Step 4. I f not OK, repai r the
open fused i gni ti on swi tch output (run-acc) ci rcui t
between the mul ti -functi on swi tch and the JB as
requi red.
(4) I f the probl em bei ng di agnosed i nvol ves onl y
the i ntermi ttent wi pe feature, go to Step 5. I f the
probl em bei ng di agnosed i nvol ves al l wi per modes, or
onl y the Low and/or Hi gh speed modes, go to Step 7.
connector receptacl e. Check for conti nui ty between
the i ntermi ttent front wi per mode sense ci rcui t cavi -
ti es of the i nstrument panel wi re harness connector
for the mul ti -functi on swi tch and the i nstrument
CTM. There shoul d be conti nui ty. I f OK, go to Step 6.
I f not OK, repai r the open i ntermi ttent front wi per
mode sense ci rcui t between the mul ti -functi on swi tch
and the CTM as requi red.
(6) Check for conti nui ty between the i ntermi ttent
front wi per swi tch si gnal ci rcui t cavi ti es of the
i nstrument panel wi re harness connector for the
mul ti -functi on swi tch and the i nstrument panel wi re
harness connector (Connector C1) for the CTM. There
shoul d be conti nui ty. I f OK, proceed to the di agnosi s
for the wi per rel ay. (Refer to 8 - ELECTRI CAL/WI P-
ERS/WASHERS/WI PER RELAY - DI AGNOSI S AND
TESTI NG). I f not OK, repai r the open i ntermi ttent
front wi per swi tch si gnal ci rcui t between the mul ti -
functi on swi tch and the CTM as requi red.
(7) Check for conti nui ty between the two front
wi per l ow speed ci rcui t cavi ti es of the i nstrument
swi tch. There shoul d be conti nui ty. I f OK, go to Step
8. I f not OK, repai r the open front wi per l ow speed
ci rcui t between the two cavi ti es of the i nstrument
swi tch as requi red.
(8) Test the mul ti -functi on swi tch conti nui ty.
(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/MULTI -FUNCTI ON SWI TCH - DI AG-
NOSI S AND TESTI NG). I f the mul ti -functi on swi tch
tests OK, reconnect the i nstrument panel wi re har-
ness connector for the mul ti -functi on swi tch to the
swi tch connector receptacl e and go to Step 9. I f not
OK, repl ace the faul ty mul ti -functi on swi tch and test
the wi per system operati on agai n. I f sti l l not OK, go
to Step 9.
Measure the resi stance between the headl amp and
dash wi re harness ground wi re for the wi per motor
and a good ground. The meter shoul d read zero
ohms. I f OK, go to Step 10. I f not OK, repai r the
open ground ci rcui t to ground (G113) as requi red.
ness connector for the wi per modul e from the wi per
motor pi gtai l wi re connector. Reconnect the battery
posi ti on. Pl ace the mul ti -functi on swi tch i n the posi -
ti ons i ndi cated i n the tests bel ow, and check for bat-
tery vol tage at the appropri ate cavi ty of the
headl amp and dash wi re harness connector for the
wi per motor.
(a) Check for battery vol tage at the fused i gni -
ti on swi tch output (run-acc) ci rcui t cavi ty of the
headl amp and dash wi re harness connector for the
wi per modul e wi th the mul ti -functi on swi tch i n
any posi ti on. I f OK, go to Step b. I f not OK, repai r
the open fused i gni ti on swi tch output (run-acc) ci r-
cui t between the wi per modul e and the JB as
requi red.
(b) Check for battery vol tage at the front wi per
l ow speed ci rcui t cavi ty of the headl amp and dash
wi re harness connector for the wi per modul e wi th
the mul ti -functi on swi tch i n the Lo posi ti on. I f OK,
go to Step c. I f not OK, repai r the open front wi per
l ow speed ci rcui t between the wi per modul e and
the mul ti -functi on swi tch as requi red.
(c) Check for battery vol tage at the front wi per
hi gh speed ci rcui t cavi ty of the headl amp and dash
wi re harness connector for the wi per modul e wi th
the mul ti -functi on swi tch i n the Hi posi ti on. I f OK,
go to Step d. I f not OK, repai r the open front wi per
hi gh speed ci rcui t between the wi per modul e and
the mul ti -functi on swi tch as requi red.
(d) Check for battery vol tage at the front wi per
park swi tch sense ci rcui t cavi ty of the headl amp
and dash wi re harness connector for the wi per
modul e wi th the mul ti -functi on swi tch i n the Lo or
Hi posi ti on, then move the swi tch to the Off posi -
ti on. The meter shoul d swi tch between battery
vol tage and zero vol ts whi l e the wi pers are cycl i ng.
The meter shoul d read battery vol tage when the
swi tch i s fi rst moved to the Off posi ti on unti l the
wi pers park, and then read a steady zero vol ts. I f
not OK, repl ace the faul ty wi per modul e.
WASHER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve washer system. However, these tests may
not prove concl usi ve i n the di agnosi s of the Central
Ti mer Modul e (CTM). I n order to obtai n concl usi ve
testi ng of the CTM, the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus network and al l of the
el ectroni c modul es that provi de i nputs to or recei ve
outputs from the washer system components must be
checked. The most rel i abl e, effi ci ent, and accurate
means to di agnose the CTM requi res the use of a
ti c i nformati on. I f the washer pump/motor operates,
but no washer fl ui d i s emi tted from the washer noz-
zl es, be certai n to check the fl ui d l evel i n the reser-
voi r. Al so i nspect the washer system components as
WASHERS - I NSPECTI ON). Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
Turn the mul ti -functi on swi tch wi per control knob to
the Lo or Hi speed posi ti on. Check whether the wi p-
ers operate. I f OK, go to Step 2. I f not OK, repai r the
wi per system as requi red before proceedi ng wi th the
fol l owi ng tests. Refer to WI PER SYSTEM .
(2) Turn the mul ti -functi on swi tch wi per control
knob to the Off posi ti on. Depress the control knob to
the Wash posi ti on. The washer pump shoul d operate
and the wi pers shoul d operate for as l ong as the con-
trol knob i s depressed. The wi pers shoul d conti nue to
operate for about three sweep cycl es after the control
knob i s rel eased before they park. I f the wi pers are
OK, but the washers are not, go to Step 3. I f the
washers are OK, but the wi pers are not, go to Step 5.
Di sconnect the headl amp and dash wi re harness con-
nector for the washer pump/motor from the motor
connector receptacl e. Measure the resi stance between
the ground ci rcui t cavi ty of the headl amp and dash
wi re harness connector for the washer pump/motor
and a good ground. The meter shoul d read zero
ohms. I f OK, go to Step 4. I f not OK, repai r the open
ground ci rcui t to ground (G112) as requi red.
(4) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Wi th the control
knob of the mul ti -functi on swi tch depressed to the
Wash posi ti on, check for battery vol tage at the front
washer pump/motor control ci rcui t cavi ty of the head-
l amp and dash wi re harness connector for the washer
pump/motor. I f OK, repl ace the faul ty washer pump/
motor. I f not OK, repai r the open front washer pump/
motor control ci rcui t between the washer pump/
motor and the CTM as requi red.
Wi th the control knob of the mul ti -functi on swi tch
depressed to the Wash posi ti on, check for battery
vol tage at the front washer pump/motor control ci r-
cui t cavi ty of the i nstrument panel wi re harness con-
nector (Connector C1) for the CTM. I f OK, proceed to
the di agnosi s for the wi per rel ay. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER RELAY -
DI AGNOSI S AND TESTI NG). I f not OK, repai r the
open front washer pump/motor control ci rcui t
between the CTM and the mul ti -functi on swi tch as
requi red.
CLEANING - WIPER & WASHER SYSTEM
WIPER SYSTEM
The squeegees of wi per bl ades exposed to the el e-
ments for a l ong ti me tend to l ose thei r wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegees i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ades, arms, and wi ndshi el d gl ass shoul d
onl y be cl eaned usi ng a sponge or soft cl oth and
wi ndshi el d washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. I f the wi per bl ades conti nue to
l eave streaks, smears, hazi ng, or beadi ng on the
gl ass after thorough cl eani ng of the squeegees and
the gl ass, the enti re wi per bl ade assembl y must be
repl aced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
front washer pump/motor from the reservoi r. Cl ean
forei gn materi al from the i nsi de of the washer reser-
voi r usi ng cl ean washer fl ui d, a mi l d detergent, or a
non-abrasi ve cl eaner. Fl ush forei gn materi al from the
washer system pl umbi ng by fi rst di sconnecti ng the
washer hoses from the washer nozzl es, then runni ng
the washer pump/motor to run cl ean washer fl ui d or
water through the system. Pl ugged or restri cted
washer nozzl es shoul d be careful l y back-fl ushed
usi ng compressed ai r. I f the washer nozzl e obstruc-
ti on cannot be cl eared, repl ace the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - WIPER & WASHER SYSTEM
WIPER SYSTEM
The wi per bl ades and wi per arms shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) I nspect the wi per arms for any i ndi cati ons of
damage, or contami nati on. I f the wi per arms are con-
tami nated wi th any forei gn materi al , cl ean them as
WASHERS - CLEANI NG). I f a wi per arm i s damaged
or corrosi on i s evi dent, repl ace the wi per arm wi th a
new uni t. Do not attempt to repai r a wi per arm that
i s damaged or corroded.
(2) Careful l y l i ft the wi per bl ade off of the gl ass.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no
si de-to-si de l ooseness evi dent. I f there i s any bi ndi ng
evi dent i n the wi per arm hi nge, or there i s evi dent
si de-to-si de pl ay i n the wi per arm hi nge, repl ace the
wi per arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
Remove the wi per bl ade from the wi per arm. Ei ther
pl ace a smal l postal scal e between the bl ade end of
the wi per arm and the gl ass, or careful l y l i ft the
bl ade end of the arm away from the gl ass usi ng a
smal l fi sh scal e. Compare the scal e readi ngs between
the ri ght and l eft wi per arms. Repl ace a wi per arm i f
i t has comparati vel y l ower spri ng tensi on, as evi -
denced by a l ower scal e readi ng.
(4) I nspect the wi per bl ades and squeegees for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 1). I f the wi per bl ades or squeegees
are contami nated wi th any forei gn materi al , cl ean
them and the gl ass as requi red. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS - CLEANI NG). After
cl eani ng the wi per bl ade and the gl ass, i f the wi per
bl ade sti l l fai l s to cl ear the gl ass wi thout smeari ng,
streaki ng, chatteri ng, hazi ng, or beadi ng, repl ace the
wi per bl ade. Al so, i f a wi per bl ade i s damaged or the
squeegee rubber i s damaged or deteri orated, repl ace
the wi per bl ade wi th a new uni t. Do not attempt to
repai r a wi per bl ade that i s damaged.
WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/WI P-
ERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
CHECK VALVE
DESCRIPTION
A washer system check val ve i s standard equi p-
ment on thi s model . The check val ve i s i ntegral to
the washer nozzl e pl umbi ng wye fi tti ng l ocated i n
the cowl pl enum beneath the cowl pl enum cover/
gri l l e panel near the base of the wi ndshi el d. The
check val ve consi sts of a mol ded pl asti c body wi th a
round center secti on. Three barbed hose ni ppl es are
formed i n a wye confi gurati on on the outsi de ci rcum-
ference of the center secti on of the val ve body. Wi thi n
the check val ve body, a smal l check val ve operated by
a smal l coi l ed spri ng restri cts fl ow through the uni t
unti l the val ve i s unseated by a predetermi ned i nl et
fl ui d pressure. The check val ve cannot be adjusted or
repai red and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The check val ve provi des more than one functi on
i n thi s appl i cati on. I t serves as a wye connector fi t-
ti ng between the cowl gri l l e panel and washer nozzl e
secti ons of the washer suppl y hose. I t al so prevents
washer fl ui d from drai ni ng out of the washer suppl y
hoses back to the washer reservoi r. Thi s drai n-back
woul d resul t i n a l engthy del ay from when the
washer swi tch i s actuated unti l washer fl ui d was di s-
pensed through the washer nozzl es, because the
washer pump woul d have to refi l l the washer pl umb-
i ng from the reservoi r to the nozzl es. Fi nal l y, the
check val ve prevents washer fl ui d from si phoni ng
through the washer nozzl es after the washer system
i s turned Off. When the washer pump pressuri zes
and pumps washer fl ui d from the reservoi r through
the washer pl umbi ng, the fl ui d pressure overri des
the spri ng pressure appl i ed to the check val ve and
unseats the val ve, al l owi ng washer fl ui d to fl ow
toward the washer nozzl es. When the washer pump
stops operati ng, spri ng pressure seats the check
val ve and fl ui d fl ow i n ei ther di recti on wi thi n the
washer pl umbi ng i s prevented.
REMOVAL
(1) Remove the wi per arms from the wi per pi vots.
(Refer to 8 - ELECTRI CAL/WI PERS/WASHERS/
WI PER ARMS - REMOVAL).
Fig. 1 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
(2) Open the hood and pul l the hood to pl enum
seal off of the forward fl anges of the cowl gri l l e cover
and the pl enum panel .
(3) Remove the cowl pl enum cover/gri l l e panel
from the top of the cowl pl enum. (Refer to 23 -
BODY/EXTERI OR/COWL GRI LLE - REMOVAL).
(4) From the undersi de of the cowl pl enum cover/
gri l l e panel , di sconnect the washer hoses from the
three barbed ni ppl es of the wye fi tti ng/check val ve
uni t.
(5) Remove the wye fi tti ng/check val ve uni t from
the undersi de of the cowl pl enum cover/gri l l e panel .
INSTALLATION
(1) Posi ti on the wye fi tti ng/check val ve uni t to the
undersi de of the cowl pl enum cover/gri l l e panel .
gri l l e panel , reconnect the three washer hoses to the
barbed ni ppl es of the wye fi tti ng/check val ve uni t.
(3) Rei nstal l the washer hoses for the washer noz-
zl es i nto thei r l ocati ng cl i ps on the undersi de of the
cowl pl enum cover/gri l l e panel .
(4) Rei nstal l the cowl pl enum cover/gri l l e panel
onto the top of the cowl pl enum panel . (Refer to 23 -
BODY/EXTERI OR/COWL GRI LLE - I NSTALLA-
TI ON).
(5) Rei nstal l the wi per arms onto the wi per pi vots.
WI PER ARMS - I NSTALLATI ON).
WASHER FLUID LEVEL
SWITCH
DESCRIPTION
The washer fl ui d l evel swi tch i s a si ngl e pol e, si n-
gl e throw reed-type swi tch mounted on the outboard
si de of the washer reservoi r forward of the washer
pump/motor, i n the ri ght front corner of the engi ne
compartment. Onl y the mol ded pl asti c swi tch mount-
i ng fl ange and connector receptacl e are vi si bl e when
the swi tch i s i nstal l ed i n the reservoi r. A short ni ppl e
formati on extends from the i nner surface of the
swi tch mounti ng fl ange, and a barb on the ni ppl e
near the swi tch mounti ng fl ange i s press-fi t i nto a
rubber grommet seal i nstal l ed i n the mounti ng hol e
of the reservoi r. A smal l pl asti c fl oat pi vots on the
end of a bracket that extends from the swi tch ni ppl e
formati on. Wi thi n the fl oat i s a smal l magnet, whi ch
actuates the reed swi tch. The washer fl ui d l evel
swi tch cannot be adjusted or repai red. I f faul ty or
damaged, the swi tch must be repl aced.
OPERATION
The washer fl ui d l evel swi tch uses a pi voti ng,
obl ong fl oat to moni tor the l evel of the washer fl ui d
i n the washer reservoi r. The fl oat contai ns a smal l
magnet. When the fl oat pi vots, the changi ng proxi m-
i ty of i ts magneti c fi el d wi l l cause the contacts of the
smal l , stati onary reed swi tch to open or cl ose. When
the fl ui d l evel i n the washer reservoi r i s at or above
the fl oat l evel , the fl oat moves to a verti cal posi ti on
and the swi tch contacts open. When the fl ui d l evel i n
the washer reservoi r fal l s bel ow the pi voti ng fl oat,
the fl oat moves to a hori zontal posi ti on and the
swi tch contacts cl ose. The swi tch contacts are con-
nected i n seri es between ground and the washer fl ui d
swi tch sense i nput of the i nstrument cl uster. The
swi tch i s connected to the vehi cl e el ectri cal system
through a dedi cated take out and connector of the
headl amp and dash wi re harness. The swi tch
recei ves ground through another take out of the
headl amp and dash wi re harness wi th a si ngl e eyel et
termi nal connector that i s secured under a nut to a
ground stud l ocated on the ri ght front fender i nner
shi el d i n the engi ne compartment. The washer fl ui d
l evel swi tch can be di agnosed usi ng conventi onal
di agnosti c tool s and methods. (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER/WASHER FLUI D
I NDI CATOR - DI AGNOSI S AND TESTI NG).
REMOVAL
The washer fl ui d l evel swi tch can be removed from
the washer reservoi r wi thout removi ng the reservoi r
from the vehi cl e.
cabl e.
(2) Di sconnect the washer hose from the barbed
outl et ni ppl e of the washer pump/motor uni t and
al l ow the washer fl ui d to drai n i nto a cl ean contai ner
for reuse.
the swi tch connector receptacl e (Fi g. 2).
NOTE: The pivoting float of the washer fluid level
switch must be in a horizontal position within the
reservoir in order to be removed. With the reservoir
empty and in an upright position, the pivoting float
will orient itself to the horizontal position when the
switch connector receptacle is pointed straight
downwards.
fl at-bl aded tool , gentl y pry the barbed ni ppl e of the
washer fl ui d l evel swi tch out of the rubber grommet
seal on the outboard si de of the reservoi r. Care must
be taken not to damage the reservoi r.
(5) Remove the washer fl ui d l evel swi tch and fl oat
from the washer reservoi r.
(6) Remove the rubber grommet seal from the
washer fl ui d l evel swi tch mounti ng hol e i n the
washer reservoi r and di scard.
CHECK VALVE (Continued)
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer fl ui d l evel swi tch mounti ng hol e i n the out-
board si de of the washer reservoi r. Al ways use a new
rubber grommet seal on the reservoi r.
(2) Posi ti on the fl oat of the washer fl ui d l evel
swi tch through the rubber grommet seal i n the
washer reservoi r (Fi g. 2). The connector receptacl e of
the washer fl ui d l evel swi tch shoul d be poi nted
downward.
(3) Press fi rml y and evenl y on the washer fl ui d
l evel swi tch usi ng hand pressure unti l the barbed
ni ppl e i s ful l y seated i n the rubber grommet seal i n
the washer reservoi r mounti ng hol e.
connector for the washer fl ui d l evel swi tch to the
(5) Reconnect the washer hose to the barbed outl et
ni ppl e of the washer pump/motor uni t.
(6) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
WASHER HOSES/TUBES
DESCRIPTION
The washer pl umbi ng consi sts of a smal l di ameter
rubber hose that i s routed from the barbed outl et
ni ppl e of the washer pump/motor on the washer res-
ervoi r through the engi ne compartment al ong the
headl amp and dash wi re harness near the ri ght
i nner fender shi el d to the dash panel . The washer
hose passes from the engi ne compartment i nto the
cowl pl enum area through a dedi cated hol e wi th a
rubber grommet near the ri ght end of the cowl pl e-
num panel . Beneath the cowl pl enum cover/gri l l e
panel , a mol ded pl asti c i n-l i ne fi tti ng wi th barbed
ni ppl es joi ns the engi ne compartment hose to a cowl
pl enum cover/gri l l e panel hose. The cowl pl enum cov-
er/gri l l e panel hose i s routed through l ocati ng cl i ps
mol ded to the undersi de of the cowl pl enum cover/
gri l l e panel to a mol ded pl asti c wye fi tti ng wi th
barbed ni ppl es and an i ntegral check val ve near the
passenger si de washer nozzl e. Two hoses are then
routed from the wye fi tti ng through addi ti onal l ocat-
i ng cl i ps on the undersi de of the cowl pl enum cover/
gri l l e panel to the two washer nozzl es.
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. The mol ded
pl asti c washer hose fi tti ngs cannot be repai red. I f
these fi tti ngs are faul ty or damaged, they must be
repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the washer pump/motor through the
washer system pl umbi ng and fi tti ngs to the two
washer nozzl es. Whenever routi ng the washer hose
or a wi re harness contai ni ng a washer hose, i t must
be routed away from hot, sharp, or movi ng parts;
and, sharp bends that mi ght pi nch the hose must be
avoi ded.
WASHER NOZZLE
DESCRIPTION
The two washer nozzl es have i ntegral snap fea-
tures that secure them i n dedi cated hol es i n the cowl
pl enum cover/gri l l e panel l ocated near the base of the
wi ndshi el d. The domed upper surface of the washer
nozzl e i s vi si bl e on the top of the pl enum cover/gri l l e
panel , and the nozzl e ori fi ce i s ori ented towards the
Fig. 2 Washer Fluid Level Switch
1 - WASHER RESERVOIR FILLER CAP
2 - UPPER RADIATOR SHROUD
3 - WASHER FLUID LEVEL SWITCH
5 - WASHER SUPPLY HOSE
6 - WASHER PUMP/MOTOR
WASHER FLUID LEVEL SWITCH (Continued)
wi ndshi el d gl ass. The washer pl umbi ng fi tti ngs for
the washer nozzl es are conceal ed beneath the cowl
pl enum cover/gri l l e panel . These fl ui di c washer noz-
zl es are constructed of mol ded pl asti c. The cowl pl e-
num cover/gri l l e panel must be removed from the
vehi cl e to access the nozzl es for servi ce. The washer
nozzl es cannot be adjusted or repai red and, i f faul ty
or damaged, they must be repl aced.
OPERATION
The two washer nozzl es are desi gned to di spense
washer fl ui d i nto the wi per pattern area on the out-
si de of the wi ndshi el d gl ass. Pressuri zed washer fl ui d
i s fed to each nozzl e from the washer reservoi r by the
washer pump/motor through rubber hoses, whi ch are
attached to a barbed ni ppl e on each washer nozzl e
bel ow the cowl pl enum cover/gri l l e panel . The washer
nozzl es i ncorporate a fl ui di c desi gn, whi ch causes the
nozzl e to emi t the pressuri zed washer fl ui d as an
osci l l ati ng stream to more effecti vel y cover a l arger
area of the gl ass area to be cl eaned.
REMOVAL
from the top of the cowl pl enum. (Refer to 23 -
BODY/EXTERI OR/COWL GRI LLE - REMOVAL).
gri l l e panel , di sconnect the washer hose from the
nozzl e fi tti ng.
gri l l e panel , compress the snap features of the
washer nozzl e and push the nozzl e out through the
top of the panel .
INSTALLATION
(1) Al i gn the washer nozzl e wi th the openi ng on
the top of cowl pl enum cover/gri l l e panel .
(2) Usi ng hand pressure, push the washer nozzl e
i nto the openi ng from the top of the cowl pl enum cov-
er/gri l l e panel unti l the snap features of the nozzl e
are ful l y engaged.
gri l l e panel , reconnect the washer hose to the nozzl e
fi tti ng.
onto the top of the cowl pl enum. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE - I NSTALLATI ON).
WASHER PUMP/MOTOR
DESCRIPTION
The washer pump/motor uni t i s l ocated on the out-
board si de of the washer reservoi r, near the bottom
i n the ri ght front corner of the engi ne compartment.
A smal l permanentl y l ubri cated and seal ed el ectri c
motor i s coupl ed to the rotor-type washer pump. A
seal fl ange wi th a l arge barbed i nl et ni ppl e on the
pump housi ng passes through a rubber grommet seal
i nstal l ed i n the dedi cated mounti ng hol e near the
bottom of the washer reservoi r. A smal l er barbed out-
l et ni ppl e on the pump housi ng connects the uni t to
the washer hose. The washer pump/motor uni t i s
retai ned on the reservoi r by the i nterference fi t
between the barbed pump i nl et ni ppl e and the grom-
met seal , whi ch i s a l i ght press fi t. An i ntegral el ec-
tri cal connector receptacl e i s l ocated on the motor
housi ng. The washer pump/motor uni t cannot be
repai red. I f faul ty or damaged, the enti re washer
pump/motor uni t must be repl aced.
OPERATION
The washer pump/motor uni t i s connected to the
vehi cl e el ectri cal system through a si ngl e take out
and two-cavi ty connector of the headl amp and dash
wi re harness. The washer pump/motor i s grounded at
al l ti mes through a take out of the headl amp and
dash wi re harness wi th a si ngl e eyel et termi nal con-
nector that i s secured by a nut to a ground stud
l ocated on the ri ght front fender i nner shi el d i n the
engi ne compartment. The washer pump/motor
recei ves battery current on a front washer pump/mo-
tor control ci rcui t through an output of the Central
Ti mer Modul e (CTM) whenever the CTM recei ves an
i nput through the cl osed contacts of the momentary
washer swi tch wi thi n the mul ti -functi on swi tch.
Washer fl ui d i s gravi ty-fed from the washer reservoi r
to the i nl et si de of the washer pump. When the pump
motor i s energi zed, the rotor-type pump pressuri zes
the washer fl ui d and forces i t through the pump out-
l et ni ppl e, the washer pl umbi ng, and the washer noz-
zl es onto the wi ndshi el d gl ass.
REMOVAL
cabl e.
ness connector for the washer pump/motor from the
motor connector receptacl e (Fi g. 3).
(3) Di sconnect the washer suppl y hose from the
barbed outl et ni ppl e of the washer pump/motor and
al l ow the washer fl ui d to drai n i nto a cl ean contai ner
for reuse.
fl at-bl aded tool , gentl y pry the barbed i nl et ni ppl e of
WASHER NOZZLE (Continued)
the washer pump out of the rubber grommet seal i n
the reservoi r. Care must be taken not to damage the
reservoi r.
(5) Remove the rubber grommet seal from the
washer pump mounti ng hol e i n the washer reservoi r
and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer pump mounti ng hol e i n the washer reservoi r.
Al ways use a new rubber grommet seal on the reser-
voi r.
(2) Posi ti on the barbed i nl et ni ppl e of the washer
pump to the rubber grommet seal i n the reservoi r.
(3) Usi ng hand pressure, press fi rml y and evenl y
on the washer pump unti l the barbed i nl et ni ppl e i s
ful l y seated i n the rubber grommet seal i n the
washer reservoi r mounti ng hol e.
ni ppl e of the washer pump.
connector for the washer pump/motor to the motor
connector receptacl e (Fi g. 3).
procedure.
WASHER RESERVOIR
DESCRIPTION
The mol ded pl asti c washer fl ui d reservoi r i s i nte-
gral to, and l ocated on the ri ght end of the upper
radi ator shroud i n the ri ght front corner of the
engi ne compartment (Fi g. 4). A bri ght yel l ow pl asti c
fi l l er cap wi th a rubber seal and an I nternati onal
Control and Di spl ay Symbol i con for Wi ndshi el d
Washer and the text Washer Fl ui d Onl y mol ded
i nto i t snaps over the open end of the fi l l er neck. The
cap hi nges on and i s secured to a mol ded-i n hook for-
mati on on the top of the reservoi r just i nboard of the
fi l l er neck when i t i s removed for i nspecti ng or
adjusti ng the fl ui d l evel i n the reservoi r. There are
separate, dedi cated hol es on the outboard si de of the
reservoi r provi ded for the mounti ng of the washer/
pump motor uni t and the washer fl ui d l evel swi tch.
The washer reservoi r i s servi ced onl y as a uni t
wi th the upper radi ator shroud. The washer reservoi r
cannot be repai red and, i f faul ty or damaged, the
upper fan shroud uni t must be repl aced. The grom-
met seal s for the washer pump/motor uni t and the
Fig. 3 Washer Pump/Motor Remove/Install
Fig. 4 Washer Reservoir
WASHER PUMP/MOTOR (Continued)
washer fl ui d l evel swi tch, and the fi l l er cap are each
avai l abl e for servi ce repl acement.
OPERATION
The washer fl ui d reservoi r provi des a secure,
on-vehi cl e storage l ocati on for a l arge reserve of
washer fl ui d for operati on of the washer system. The
washer reservoi r fi l l er neck provi des a cl earl y
marked and readi l y accessi bl e poi nt from whi ch to
add washer fl ui d to the reservoi r. The washer/pump
motor uni t i s l ocated i n a sump area near the bottom
of the reservoi r to be certai n that washer fl ui d wi l l
be avai l abl e to the pump as the fl ui d l evel i n the res-
ervoi r becomes depl eted. The washer fl ui d l evel
swi tch i s mounted just above the sump area of the
reservoi r so that there wi l l be adequate warni ng to
the vehi cl e operator that the washer fl ui d l evel i s
l ow, before the washer system wi l l no l onger operate.
REMOVAL
NOTE: The washer reservoir is integral to the right
end of the upper radiator shroud, and the engine
coolant reserve/overflow tank is integral to the left
end of the upper radiator shroud (Fig. 5).
cabl e.
the swi tch connector receptacl e (Fi g. 6).
ness connector for the washer pump/motor uni t from
the motor connector receptacl e.
(4) Di sconnect the washer hose from the barbed
outl et ni ppl e of the washer pump/motor and al l ow
the washer fl ui d to drai n i nto a cl ean contai ner for
reuse.
(5) Di sconnect the engi ne cool ant reserve/overfl ow
hose from the ni ppl e of the radi ator fi l l er spout i n
the upper radi ator hose.
(6) Remove the si x screws that secure the upper
radi ator shroud to the radi ator.
(7) Di sengage the l ocator dowel s on the bottom of
the upper radi ator shroud from the l ocator hol es i n
the upper fl anges of the l ower shroud.
(8) Remove the upper radi ator shroud from the
radi ator.
Fig. 5 Upper Fan Shroud Remove/Install
1 - RADIATOR
3 - UPPER SHROUD & WASHER RESERVOIR UNIT
4 - SCREW
5 - LOWER SHROUD
Fig. 6 Washer Pump/Motor Remove/Install
WASHER RESERVOIR (Continued)
INSTALLATION
NOTE: The washer reservoir is integral to the right
end of the upper radiator shroud, and the engine
coolant reserve/overflow tank is integral to the left
end of the upper radiator shroud (Fig. 5).
(1) Posi ti on the upper radi ator shroud onto the
radi ator.
(2) Engage the l ocator dowel s on the bottom of the
upper radi ator shroud i nto the l ocator hol es i n the
upper fl anges of the l ower shroud.
the upper radi ator shroud to the radi ator. Ti ghten
(4) Reconnect the engi ne cool ant reserve/overfl ow
hose to the ni ppl e of the radi ator fi l l er spout i n the
upper radi ator hose.
ni ppl e of the washer pump/motor (Fi g. 6).
connector for the washer pump/motor uni t to the
motor connector receptacl e.
connector for the washer fl ui d l evel swi tch to the
procedure.
WIPER ARM
DESCRIPTION
The wi per arms are the ri gi d members l ocated
between the wi per pi vots that protrude from the cowl
pl enum cover/gri l l e panel near the base of the wi nd-
shi el d and the wi per bl ades on the wi ndshi el d gl ass.
These wi per arms feature an over-center hi nge that
al l ows easy access to the wi ndshi el d gl ass for cl ean-
i ng. The wi per arm has a di e cast metal pi vot end
wi th a l arge mounti ng hol e wi th i nternal serrati ons
at one end. A mol ded bl ack pl asti c cap fi ts over the
wi per arm retai ni ng nut to conceal the nut and thi s
mounti ng hol e fol l owi ng wi per arm i nstal l ati on. The
wi de end of a tapered, stamped steel channel hi nges
on and i s secured wi th a hi nge pi n to the bl ade end
of the wi per arm pi vot end. One end of a l ong, ri gi d,
stamped steel strap, wi th a smal l hol e near i ts pi vot
end, i s ri veted and cri mped wi thi n the narrow end of
the stamped steel channel . The ti p of the wi per bl ade
end of thi s strap i s bent back under i tsel f to form a
smal l hook. Conceal ed wi thi n the stamped steel
channel , one end of a l ong spri ng i s engaged wi th a
wi re hook on the undersi de of the di e cast pi vot end,
whi l e the other end of the spri ng i s hooked through
the smal l hol e i n the steel strap. The enti re wi per
arm has a sati n bl ack fi ni sh appl i ed to al l of i ts vi s-
i bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The front wi per arms are desi gned to mechani cal l y
transmi t the moti on from the wi per pi vots to the
wi per bl ades. The wi per arm must be properl y
i ndexed to the wi per pi vot i n order to mai ntai n the
proper wi per bl ade travel on the gl ass. The mounti ng
hol e formati on wi th i nternal serrati ons i n the wi per
arm pi vot end i nterl ocks wi th the serrati ons on the
outer ci rcumference of the wi per pi vot dri ver, al l ow-
i ng posi ti ve engagement and fi ni te adjustment of thi s
connecti on. The mounti ng nut l ocks the wi per arm to
the threaded stud on the wi per pi vot. The spri ng-
l oaded wi per arm hi nge control s the down-force
appl i ed through the ti p of the wi per arm to the wi per
bl ade on the gl ass. The hook formati on on the ti p of
the wi per arm provi des a cradl e for securi ng and
l atchi ng the wi per bl ade pi vot bl ock to the wi per
arm.
REMOVAL
(1) Li ft the wi per arm to i ts over-center posi ti on to
hol d the wi per bl ade off of the gl ass and rel i eve the
spri ng tensi on on the wi per arm to wi per pi vot con-
necti on.
(2) Open the hood of the vehi cl e.
(3) Careful l y pry the pl asti c nut cap off of the
pi vot end of the wi per arm (Fi g. 7).
(4) Remove the nut that secures the wi per arm to
the wi per pi vot shaft.
(5) Use a sui tabl e battery termi nal pul l er to di sen-
gage the wi per arm from the wi per pi vot shaft
spl i nes (Fi g. 8).
(6) Remove the wi per arm pi vot end from the
wi per pi vot.
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the wiper arms.
Turn the ignition switch to the On position and
move the multi-function switch control knob to its
Off position. If the wiper pivots move, wait until
they stop moving, then turn the ignition switch
back to the Off position. The wiper motor is now in
its park position.
(1) The wi per arms must be i ndexed to the wi per
pi vots wi th the wi per motor i n the park posi ti on to
WASHER RESERVOIR (Continued)
be properl y i nstal l ed. Posi ti on the wi per arm pi vot
ends onto the wi per pi vots so that the l ower edge of
the bl ade i s al i gned wi th the wi per al i gnment l i nes
conceal ed i n the upper margi n of the l ower wi nd-
shi el d bl ackout area, 15 mm ( 0.59 i n.) (Fi g. 9).
(2) Once the wi per bl ade i s al i gned, l i ft the wi per
arm away from the wi ndshi el d sl i ghtl y to rel i eve the
spri ng tensi on on the pi vot end and push the pi vot
hol e on the end of the wi per arm down over the
wi per pi vot shaft.
wi per arm to the wi per pi vot shaft. Ti ghten the nut
to 23.7 Nm (210 i n. l bs.).
(4) Wet the wi ndshi el d gl ass, then operate the wi p-
ers. Turn the wi per swi tch to the Off posi ti on, then
check for the correct wi per arm posi ti on and readjust
as requi red.
(5) Rei nstal l the pl asti c nut cap onto the wi per
arm pi vot nut.
WIPER BLADE
DESCRIPTION
Each wi per bl ade i s secured by an i ntegral l atchi ng
pi vot bl ock to the hook formati on on the ti p of the
wi per arms, and rests on the gl ass near the base of
the wi ndshi el d when the wi pers are not i n operati on.
The wi per bl ade consi sts of the fol l owi ng components:
Superstructure - The superstructure i ncl udes
several stamped steel bri dges and l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. The
dri ver si de and passenger si de wi per bl ades are not
i nterchangeabl e. The superstructure of the dri ver
si de bl ade features an addi ti onal bri dge, whi ch pro-
vi des an addi ti onal set of cl aws to retai n the wi per
squeegees. Thei r are ei ght sets of cl aws on the dri ver
si de, and si x sets of cl aws used on the passenger
si de. Al so i ncl uded i n thi s uni t i s the l atchi ng,
mol ded pl asti c pi vot bl ock that secures the super-
structure to the wi per arm. Al l of the metal compo-
nents of the wi per bl ade have a sati n bl ack fi ni sh
appl i ed.
Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l Dakota truck model s have two 50 centi meter
(19.69 i nch) wi per bl ades wi th non-repl aceabl e rub-
ber el ements (squeegees). These wi per bl ades al so
Fig. 7 Wiper Arm Remove/Install
1 - NUT CAP
2 - WIPER ARM AND BLADE
3 - NUT
Fig. 8 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT
3 - BATTERY TERMINAL PULLER
Fig. 9 Wiper Arm Installation
1 - WIPER ALIGNMENT LINES 15 mm ( 0.59 in.)
WIPER ARM (Continued)
i ncl ude an anti -l i ft feature. The wi per bl ades cannot
be adjusted or repai red. I f faul ty, worn, or damaged
the enti re wi per bl ade uni t must be repl aced.
OPERATION
The wi per bl ade i s moved back and forth across the
gl ass by the wi per arms when the wi pers are bei ng
operated. The wi per bl ade superstructure i s the fl ex-
i bl e frame that gri ps the wi per bl ade el ement and
evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature found
across the gl ass surface. The wi per el ement fl exor
provi des the cl aws of the bl ade superstructure wi th a
ri gi d, yet fl exi bl e component on the el ement whi ch
can be gri pped. The rubber el ement i s desi gned to be
sti ff enough to mai ntai n an even cl eani ng edge as i t
i s drawn across the gl ass, but resi l i ent enough to
conform to the gl ass surface and fl i p from one cl ean-
i ng edge to the other each ti me the wi per bl ade
changes di recti ons.
REMOVAL
NOTE: The driver side and passenger side wiper
blades are not interchangeable. The driver side
wiper blade has an extra bridge and eight pairs of
claws securing the wiper element. The passenger
side wiper blade has six pairs of claws securing the
wiper element. The notched retainer end of both
wiper elements should always be oriented towards
the end of the wiper blade that is nearest to the
wiper pivot.
(1) Turn the wi per control knob on the end of the
mul ti -functi on swi tch control stal k to the On posi -
ti on. Cycl e the wi per bl ades to a conveni ent worki ng
l ocati on on the wi ndshi el d by turni ng the i gni ti on
swi tch to the On and Off posi ti ons.
(2) Li ft the wi per arm to rai se the wi per bl ade and
el ement off of the gl ass.
(3) To remove the wi per bl ade from the wi per arm,
push the pi vot bl ock l atch rel ease tab under the ti p
of the arm and sl i de the bl ade away from the ti p
towards the pi vot end of the arm far enough to di s-
engage the pi vot bl ock from the hook (Fi g. 10).
(4) Extract the hook formati on on the ti p of the
wi per arm from the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(5) Gentl y l ower the wi per arm ti p onto the gl ass.
INSTALLATION
NOTE: The driver side and passenger side wiper
blades are not interchangeable. The driver side
wiper blade has an extra bridge and eight pairs of
claws securing the wiper element. The passenger
side wiper blade has six pairs of claws securing the
wiper element. The notched retainer end of both
wiper elements should always be oriented towards
the end of the wiper blade that is nearest to the
wiper pivot.
(1) Li ft the wi per arm off of the wi ndshi el d gl ass.
(2) Posi ti on the wi per bl ade near the hook forma-
ti on on the ti p of the arm wi th the notched retai ner
for the wi per el ement ori ented towards the end of the
wi per arm that i s nearest to the wi per pi vot.
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t far enough to engage the pi vot bl ock wi th
the hook (Fi g. 10).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
(5) Gentl y l ower the wi per bl ade onto the gl ass.
WIPER MODULE
DESCRIPTION
The wi per modul e i s secured wi th screws through
four rubber grommet-type i nsul ators to the cowl pl e-
num panel and conceal ed wi thi n the cowl pl enum
area beneath the cowl pl enum cover/gri l l e panel . The
ends of the wi per pi vot shafts that protrude through
dedi cated openi ngs i n the cowl pl enum cover/gri l l e
panel to dri ve the wi per arms and bl ades are the
onl y vi si bl e components of the wi per modul e. The
Fig. 10 Wiper Blade Remove/Install - Typical
1 - RELEASE TAB
WIPER BLADE (Continued)
wi per modul e consi sts of the fol l owi ng major compo-
nents:
Bracket - The wi per modul e bracket consi sts of
a l ong tubul ar steel mai n member that has a
stamped pi vot bracket formati on near each end
where the two wi per pi vots are secured. A stamped
steel mounti ng pl ate for the wi per motor i s secured
wi th wel ds near the center of the mai n member.
Crank Arm - The wi per motor crank arm i s a
stamped steel uni t that has a sl otted hol e on the
dri ven end that i s secured to the wi per motor output
shaft wi th a nut, and has a bal l stud secured to the
dri ve end.
Linkage - The two wi per l i nkage members are
each constructed of stamped steel . A dri ver si de dri ve
l i nk wi th a pl asti c socket-type bushi ng i n the l eft
end, and a pl asti c sl eeve-type bushi ng i n the ri ght
end. Socket bushi ng i s snap-fi t over the pi vot bal l
stud on the l eft pi vot, whi l e the sl eeve bushi ng i s fi t
over the l onger wi per motor crank arm pi vot stud.
The passenger si de dri ve l i nk has a pl asti c socket-
type bushi ng on each end. One end of thi s dri ve l i nk
i s snap-fi t over the pi vot bal l stud on the ri ght pi vot,
whi l e the other end i s snap-fi t over the exposed end
of the l onger bal l stud on the wi per motor crank arm.
Motor - The wi per motor i s secured wi th three
screws to the motor mounti ng pl ate near the center
of the wi per modul e bracket. The wi per motor output
shaft passes through a hol e i n the modul e bracket,
where a nut secures the wi per motor crank arm to
the motor output shaft. The two-speed permanent
magnet wi per motor features an i ntegral transmi s-
si on, an i nternal park swi tch, and an i nternal Posi -
ti ve Temperature Coeffi ci ent (PTC) ci rcui t breaker.
Pivots - The two wi per pi vots are secured to the
ends of the wi per modul e bracket. The crank arms
that extend from the bottom of the pi vot shafts each
have a bal l stud on thei r end. The upper end of each
pi vot shaft where the wi per arms wi l l be fastened
each has an external l y serrated drum secured to i t.
The wi per modul e cannot be adjusted or repai red.
I f any component of the modul e i s faul ty or damaged,
the enti re wi per modul e uni t must be repl aced.
OPERATION
The wi per modul e operati on i s control l ed by the
vehi cl e operator through battery current i nputs
recei ved by the wi per motor from the mul ti -functi on
swi tch on the steeri ng col umn. The wi per motor
speed i s control l ed by current fl ow to ei ther the l ow
speed or the hi gh speed set of brushes. The park
swi tch i s a si ngl e pol e, si ngl e throw, momentary
swi tch wi thi n the wi per motor that i s mechani cal l y
actuated by the wi per motor transmi ssi on compo-
nents. The park swi tch al ternatel y cl oses the wi per
park swi tch sense ci rcui t to ground or to battery cur-
rent, dependi ng upon the posi ti on of the wi pers on
the gl ass. Thi s feature al l ows the motor to compl ete
i ts current wi pe cycl e after the wi per system has
been turned Off, and to park the wi per bl ades i n the
l owest porti on of the wi pe pattern. The automati c
resetti ng ci rcui t breaker protects the motor from
overl oads. The wi per motor crank arm, the two wi per
l i nkage members, and the two wi per pi vots mechan-
i cal l y convert the rotary output of the wi per motor to
the back and forth wi pi ng moti on of the wi per arms
and bl ades on the gl ass.
REMOVAL
cabl e.
from the cowl pl enum. (Refer to 23 - BODY/EXTERI -
OR/COWL GRI LLE - REMOVAL).
(4) Remove the four screws that secure the wi per
modul e bracket to the cowl pl enum panel and the
dash panel (Fi g. 11).
(5) Reach i nto the cowl pl enum to move the wi per
modul e far enough to access the wi per modul e el ec-
tri cal connecti ons.
Fig. 11 Wiper Module Remove/Install
1 - WIPER MODULE
2 - SCREW (4)
WIPER MODULE (Continued)
ness connector for the wi per motor from the wi per
motor pi gtai l wi re connector.
ness ground connector from the wi per motor ground
termi nal .
(8) Remove the wi per modul e from the cowl pl e-
num as a uni t.
INSTALLATION
(1) Posi ti on the wi per modul e i nto the cowl pl e-
num as a uni t.
ground connector to the wi per motor ground termi nal
(Fi g. 11).
connector for the wi per motor to the wi per motor pi g-
tai l wi re connector.
(4) Reach i nto the cowl pl enum to al i gn the wi per
modul e mounti ng bracket wi th the l ocati ons for the
mounti ng screws.
the wi per modul e bracket to the cowl pl enum panel
and the dash panel . Ti ghten the screws to 8 Nm (72
i n. l bs.).
over the top of the cowl pl enum. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE - I NSTALLATI ON).
WIPER RELAY
DESCRIPTION
The wi per rel ay (or i ntermi ttent wi pe rel ay) i s
l ocated i n the Power Di stri buti on Center (PDC) near
the battery i n the engi ne compartment. See the fuse
and rel ay l ayout l abel affi xed to the i nsi de surface of
the PDC cover for wi per rel ay i denti fi cati on and l oca-
ti on. The wi per rel ay i s a conventi onal I nternati onal
Standards Organi zati on (I SO) mi cro rel ay. Rel ays
conformi ng to the I SO speci fi cati ons have common
physi cal di mensi ons, current capaci ti es, termi nal pat-
terns, and termi nal functi ons. The rel ay i s contai ned
wi thi n a smal l , rectangul ar, mol ded pl asti c housi ng.
The rel ay i s connected to al l of the requi red i nputs
and outputs through i ts PDC receptacl e by fi ve mal e
spade-type termi nal s that extend from the bottom of
the rel ay base. The I SO desi gnati on for each termi -
nal i s mol ded i nto the base adjacent to the termi nal .
The I SO termi nal desi gnati ons are as fol l ows:
30 (Common Feed) - Thi s termi nal i s con-
nected to the movabl e contact poi nt of the rel ay.
85 (Coil Ground) - Thi s termi nal i s connected
to the ground feed si de of the rel ay control coi l .
86 (Coil Battery) - Thi s termi nal i s connected
to the battery feed si de of the rel ay control coi l .
87 (Normally Open) - Thi s termi nal i s con-
nected to the normal l y open fi xed contact poi nt of the
rel ay.
87A (Normally Closed) - Thi s termi nal i s con-
nected to the normal l y cl osed fi xed contact poi nt of
the rel ay.
The wi per rel ay cannot be adjusted or repai red. I f
the rel ay i s damaged or faul ty, i t must be repl aced.
OPERATION
The wi per rel ay (or i ntermi ttent wi pe rel ay) i s an
el ectromechani cal swi tch that uses a l ow current
i nput from the Central Ti mer Modul e (CTM) to con-
trol a hi gh current output to the l ow speed brush of
the wi per motor. The movabl e common feed contact
poi nt i s hel d agai nst the fi xed normal l y cl osed con-
tact poi nt by spri ng pressure. When the rel ay coi l i s
energi zed, an el ectromagneti c fi el d i s produced by the
coi l wi ndi ngs. Thi s el ectromagneti c fi el d draws the
movabl e rel ay contact poi nt away from the fi xed nor-
mal l y cl osed contact poi nt, and hol ds i t agai nst the
fi xed normal l y open contact poi nt. When the rel ay
coi l i s de-energi zed, spri ng pressure returns the mov-
abl e contact poi nt back agai nst the fi xed normal l y
cl osed contact poi nt. A resi stor or di ode i s connected
i n paral l el wi th the rel ay coi l i n the rel ay, and hel ps
to di ssi pate vol tage spi kes and el ectromagneti c i nter-
ference that can be generated as the el ectromagneti c
fi el d of the rel ay coi l col l apses.
The wi per rel ay termi nal s are connected to the
vehi cl e el ectri cal system through a connector recepta-
cl e i n the Power Di stri buti on Center (PDC). The
i nputs and outputs of the wi per rel ay i ncl ude:
The common feed termi nal (30) i s connected to
the wi per motor l ow speed brush through the wi per
control ci rcui try of the mul ti -functi on swi tch on the
steeri ng col umn. When the wi per rel ay i s de-ener-
gi zed, the common feed termi nal i s connected to the
wi per park swi tch output through the CTM on the
front wi per park swi tch sense ci rcui t. The wi per park
swi tch output may be battery current (wi pers are not
parked), or ground (wi pers are parked). When the
wi per rel ay i s energi zed, the common feed termi nal
of the rel ay i s connected to battery current from a
fuse i n the Juncti on Bl ock (JB) through a fused i gni -
ti on swi tch output (run-acc) ci rcui t.
The coi l ground termi nal (85) i s connected to the
rel ay control output of the CTM through the wi per
rel ay control ci rcui t. The CTM control s the ground
path for thi s ci rcui t i nternal l y to energi ze or de-ener-
gi ze the wi per rel ay based upon i ts programmi ng,
i nputs from the wi per and washer control ci rcui try of
WIPER MODULE (Continued)
the mul ti -functi on swi tch, and i nputs from the wi per
motor park swi tch.
The coi l battery termi nal (86) i s connected to
battery current from a fuse i n the Juncti on Bl ock
(JB) through a fused i gni ti on swi tch output (run-acc)
Accessory posi ti ons.
The normal l y open termi nal (87) i s connected to
battery current from a fuse i n the Juncti on Bl ock
(JB) through a fused i gni ti on swi tch output (run-acc)
ci rcui t whenever the wi per rel ay control coi l i s ener-
gi zed by the CTM. Thi s ci rcui t provi des fused i gni -
ti on swi tch output (run-acc) current to the wi per
motor l ow speed brush onl y when the wi per rel ay
control coi l i s energi zed.
The normal l y cl osed termi nal (87A) i s connected
to the output of the wi per motor park swi tch through
the CTM on the front wi per park swi tch sense ci r-
cui t. Thi s ci rcui t provi des battery current (wi pers are
not parked) or ground (wi pers are parked) to the
wi per motor l ow speed brush whenever the wi per
rel ay control coi l i s de-energi zed and the Off posi ti on
of the wi per control ci rcui try wi thi n the mul ti -func-
ti on swi tch i s sel ected.
The wi per rel ay can be di agnosed usi ng conven-
ti onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - WIPER RELAY
The wi per rel ay (or i ntermi ttent wi pe rel ay) (Fi g.
12) i s l ocated i n the Power Di stri buti on Center (PDC)
i n the engi ne compartment. See the fuse and rel ay
l ayout l abel affi xed to the i nsi de surface of the PDC
cover for wi per rel ay i denti fi cati on and l ocati on.
(1) Remove the wi per rel ay from the PDC. (Refer
to 8 - ELECTRI CAL/WI PERS/WASHERS/WI PER
RELAY - REMOVAL).
and 30. I f OK, test the rel ay i nput and output ci r-
cui ts. Refer to RELAY CI RCUI T TEST . I f not OK,
repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
connected to the mul ti -functi on swi tch. There shoul d
be conti nui ty between the receptacl e for termi nal 30
of the wi per rel ay i n the PDC and the i ntermi ttent
front wi per l ow speed ci rcui t cavi ty of the i nstrument
swi tch at al l ti mes. I f OK, go to Step 2. I f not OK,
repai r the open i ntermi ttent front wi per l ow speed
ci rcui t between the PDC and the mul ti -functi on
swi tch as requi red.
connected to the wi per motor park swi tch through
the CTM on the front wi per park swi tch sense ci r-
cui t. There shoul d be conti nui ty between the recepta-
cl e for termi nal 87A of the wi per rel ay i n the PDC
and the front wi per park swi tch sense ci rcui t cavi ty
of the headl amp and dash wi re harness connector for
the wi per motor at al l ti mes. I f OK, go to Step 3. I f
not OK, repai r the open front wi per park swi tch
sense ci rcui t between the PDC and the wi per motor
as requi red.
nected to a fused i gni ti on swi tch output (run-acc)
fuse i n the Juncti on Bl ock (JB) through a fused i gni -
ti on swi tch output (run-acc) ci rcui t. There shoul d be
battery vol tage at the receptacl e for termi nal 87 of
the wi per rel ay i n the PDC whenever the i gni ti on
swi tch i s i n the On or Accessory posi ti ons. I f OK, go
to Step 4. I f not OK, repai r the open fused i gni ti on
Fig. 12 Wiper Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
WIPER RELAY (Continued)
swi tch output (run-acc) ci rcui t between the PDC and
the JB as requi red.
(4) The coi l battery termi nal (86) i s connected to a
fused i gni ti on swi tch output (run-acc) fuse i n the JB
through a fused i gni ti on swi tch output (run-acc) ci r-
cui t. There shoul d be battery vol tage at the recepta-
cl e for termi nal 86 of the wi per rel ay i n the PDC
whenever the i gni ti on swi tch i s i n the On or Acces-
sory posi ti ons. I f OK, go to Step 5. I f not OK, repai r
the open fused i gni ti on swi tch output (run-acc) ci r-
cui t between the PDC and the JB as requi red.
the output of the Central Ti mer Modul e (CTM)
through the wi per rel ay control ci rcui t. There shoul d
be conti nui ty between the receptacl e for termi nal 85
of the wi per rel ay i n the PDC and the wi per rel ay
control ci rcui t cavi ty of the i nstrument panel wi re
harness connector (Connector C3) for the CTM at al l
ti mes. I f not OK, repai r the open wi per rel ay control
ci rcui t between the PDC and the CTM as requi red.
REMOVAL
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 13).
the undersi de of the PDC cover for wi per rel ay i den-
ti fi cati on and l ocati on.
(4) Remove the wi per rel ay by graspi ng i t fi rml y
and pul l i ng i t strai ght out from the receptacl e i n the
PDC.
INSTALLATION
the undersi de of the PDC cover for the proper wi per
rel ay l ocati on (Fi g. 13).
(2) Posi ti on the wi per rel ay i n the proper recepta-
cl e i n the PDC.
(3) Al i gn the wi per rel ay termi nal s wi th the termi -
nal cavi ti es i n the PDC receptacl e.
(4) Push fi rml y and evenl y on the top of the wi per
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the PDC receptacl e.
(5) Rei nstal l the cover onto the PDC.
Fig. 13 Power Distribution Center - Typical
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
WIPER RELAY (Continued)
WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . . 8W-12-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
REAR WHEEL ANTILOCK BRAKES. . . . . . . 8W-34-1
ALL WHEEL ANTILOCK BRAKES . . . . . . . . 8W-35-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
CENTRAL TIMER MODULE. . . . . . . . . . . . . 8W-45-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
CONNECTOR PINOUTS. . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR/GROUND LOCATIONS . . . . . . 8W-90-1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . 8W-95-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
AN WIRING 8W - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . 5
TESTING OF VOLTAGE POTENTIAL . . . . . . . . . 6
TESTING FOR CONTINUITY . . . . . . . . . . . . . . . 6
TESTING FOR SHORT TO GROUND . . . . . . . . . 6
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS . . . . . . . . 7
TESTING FOR VOLTAGE DROP . . . . . . . . . . . . 7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONNECTOR - AUGAT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONNECTOR - MOLEX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONNECTOR - THOMAS AND BETTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIODE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TERMINAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 11
WIRING DIAGRAM
INFORMATION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
Dai ml erChrysl er Corporati on wi ri ng di agrams are
desi gned to provi de i nformati on regardi ng the vehi -
cl es wi ri ng content. I n order to effecti vel y use the
wi ri ng di agrams to di agnose and repai r Dai ml er-
Chrysl er Corporati on vehi cl es, i t i s i mportant to
understand al l of thei r features and characteri sti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page (Fi g. 1).
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on (Fi g. 2).
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around the component i ndi -
cates that the component i s bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d (Fi g. 3).
AN 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
Fig. 1 WIRING DIAGRAM EXAMPLE 1
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION AN
WIRING DIAGRAM INFORMATION (Continued)
Fig. 2 WIRING DIAGRAM EXAMPLE 2
Fig. 3 WIRING DIAGRAM SYMBOLS
TERMINOLOGY
Thi s i s a l i st of terms and defi ni ti ons used i n the
wi ri ng di agrams.
LHD . . . . . . . . . . . . . . . . . Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . . Ri ght Hand Dri ve Vehi cl es
ATX . . Automati c Transmi ssi ons-Front Wheel Dri ve
MTX . . . . Manual Transmi ssi ons-Front Wheel Dri ve
AT . . . . Automati c Transmi ssi ons-Rear Wheel Dri ve
MT . . . . . Manual Transmi ssi ons-Rear Wheel Dri ve
SOHC . . . . . . . . . . . Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . Doubl e Over Head Cam Engi ne
Bui l t-Up-Export . . . . . . . . Vehi cl es Bui l t For Sal e I n
Markets Other Than North Ameri ca
Except-Bui l t-Up-Export . . Vehi cl es Bui l t For Sal e I n
North Ameri ca
WARNINGS - GENERAL
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING:: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND LOOSE CLOTH-
ING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicles
electrical system can cause damage to the equip-
ment and provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 4)Sel ect the proper si ze
tool from Speci al Tool Package 6807, and i nsert i t
i nto the termi nal bei ng tested. Use the other end of
the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y, check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i nto
posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt or moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on
Wi ri ng broken i nsi de of the i nsul ati on
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em area.
(6) Veri fy the proper operati on. For thi s step,
check for proper operati on of al l i tems on the
repai red ci rcui t. Refer to the wi ri ng di agrams.
STANDARD PROCEDURE - TESTING FOR
VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 5).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 6)
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
Fig. 4 PROBING TOOL
1 - SPECIAL TOOL 6801
2 - PROBING END
Fig. 5 TESTING FOR VOLTAGE POTENTIAL
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng the i tems i n the fuse ci rcui t
one at a ti me. When the fuse bl ows the ci rcui t wi th
the short to ground has been i sol ated.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
the si de of the ci rcui t cl osest to the battery (Fi g. 7).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch or component.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
Fig. 6 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
Fig. 7 TESTING FOR VOLTAGE DROP
SPECIAL TOOLS
SPECIAL TOOLS - WIRING/TERMINAL
CONNECTOR - AUGAT
REMOVAL
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) Push down on the yel l ow connector l ocki ng tab
to rel ease the termi nal s (Fi g. 8).
(4) Usi ng speci al tool 6932, push the termi nal to
remove i t from the connector (Fi g. 9).
(5) Repai r or repl ace the termi nal as necessary.
INSTALLATION
(1) Reset the termi nal l ocki ng tang.
PROBING TOOL PACKAGE 6807
TERMINAL PICK 6680
TERMINAL REMOVING TOOL 6932
TERMINAL REMOVING TOOL 6934
Fig. 8 AUGAT CONNECTOR REPAIR
1 - LOCKING TAB
2 - CONNECTOR
Fig. 9 USING
2 - CONNECTOR
(2) I nsert the removed wi re i n the same cavi ty on
the repai r connector.
(3) Repeat steps for each wi re i n the connector,
bei ng sure that al l wi res are i nserted i nto the proper
cavi ti es. For addi ti onal connector pi n-out i denti fi ca-
ti on, refer to the wi ri ng di agrams.
(4) When the connector i s re-assembl ed, the l ock-
i ng tab must be pl aced i n the l ocked posi ti on to pre-
vent termi nal push out.
(5) Connect connector to i ts mati ng hal f/compo-
nent.
(6) Connect battery and test al l affected systems.
CONNECTOR - MOLEX
REMOVAL
component.
(3) I nsert speci al tool 6742 i nto the termi nal end of
the connector (Fi g. 10).
(4) Usi ng speci al tool 6742, rel ease the l ocki ng fi n-
gers on the termi nal (Fi g. 11).
(5) Pul l on the wi re to remove i t from the connec-
tor.
INSTALLATION
bei ng sure that al l wi res are i nserted i nto the proper
cavi ti es. For addi ti onal connector pi n-out i denti fi ca-
ti on, refer to the wi ri ng di agrams.
nent.
CONNECTOR - THOMAS AND
BETTS
REMOVAL
component.
(3) Push i n the two l ock tabs on the si de of the
Fig. 10 MOLEX CONNECTOR REPAIR
1 - CONNECTOR
Fig. 11 USING SPECIAL TOOL 6742
1 - CONNECTOR
Fig. 12 THOMAS AND BETTS CONNECTOR LOCK
RELEASE TABS
1 - LOCK TABS
CONNECTOR - AUGAT (Continued)
(4) I nsert the probe end of speci al tool 6934 i nto
the back of the connector cavi ty (Fi g. 13).
(5) Grasp the wi re and tool 6934, then sl owl y
remove the wi re and termi nal from the connector.
INSTALLATION
bei ng sure that al l wi res are ful l y seated i nto the
proper cavi ti es. For addi ti onal connector pi n-out
i denti fi cati on, refer to the wi ri ng di agrams.
(4) Push i n the si ngl e l ock tab on the si de of the
nent.
DIODE
REMOVAL
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 15).
INSTALLATION
(1) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(2) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary, refer to the
appropri ate wi ri ng di agram for current fl ow (Fi g. 15).
(3) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(4) Tape the di ode to the harness usi ng el ectri cal
tape. Make sure the di ode i s compl etel y seal ed from
the el ements.
(5) Re-connect the battery and test affected sys-
tems.
Fig. 13 REMOVING WIRE TERMINAL
Fig. 14 SINGLE LOCK TAB
1 - SINGLE LOCK TAB
Fig. 15 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
CONNECTOR - THOMAS AND BETTS (Continued)
TERMINAL
REMOVAL
(2) Di sconnect the connector bei ng repai red from
i ts mati ng hal f/component.
(3) Remove the connector l ocki ng wedge, i f
requi red (Fi g. 16).
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 17) (Fi g. 18).
(5) Cut the wi re 6 i nches from the back of the con-
nector.
INSTALLATION
(1) Sel ect a wi re from the termi nal repai r assem-
bl y that best matches the col or wi re bei ng repai red.
(2) Cut the repai r wi re to the proper l ength and
remove onehal f (1/2) i nch of i nsul ati on.
(3) Spl i ce the repai r wi re to the wi re harness .
(4) I nsert the repai red wi re i nto the connector.
(5) I nstal l the connector l ocki ng wedge, i f requi red,
and reconnect the connector to i ts mati ng hal f/compo-
nent.
(6) Re-tape the wi re harness starti ng at 11/2
i nches behi nd the connector and 2 i nches past the
repai r.
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When spl i ci ng a wi re, i t i s i mportant that the cor-
rect gage be used as shown i n the wi ri ng di agrams.
(1) Remove one-hal f (1/2) i nch of i nsul ati on from
each wi re that needs to be spl i ced.
(2) Pl ace a pi ece of adhesi ve l i ned heat shri nk tub-
i ng on one si de of the wi re. Make sure the tubi ng wi l l
be l ong enough to cover and seal the enti re repai r
area.
(3) Pl ace the strands of wi re overl appi ng each
other i nsi de of the spl i ce cl i p (Fi g. 19).
(4) Usi ng cri mpi ng tool , Mi l l er p/n 8272, cri mp the
spl i ce cl i p and wi res together (Fi g. 20)
(5) Sol der the connecti on together usi ng rosi n core
type sol der onl y (Fi g. 21).
Fig. 16 CONNECTOR LOCKING WEDGE TAB
(TYPICAL)
1 - CONNECTOR
2 - CONNECTOR LOCKING WEDGE TAB
Fig. 17 TERMINAL REMOVAL
1 - CONNECTOR
2 - FROM SPECIAL TOOL KIT 6680
Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL
1 - FROM SPECIAL TOOL KIT 6680
2 - CONNECTOR
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng (Fi g. 22).
Fig. 19 SPLICE CLIP
Fig. 20 CRIMPING TOOL
Fig. 21 SOLDER
Fig. 22 HEAT SHRINK TUBING
WIRE (Continued)
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-42
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C- Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . . 8W-42
A/C Pressure Transducer . . . . . . . . . . . . . . . . 8W-42
Aftermarket CHMS Connector . . . . . . . . . . . . 8W-51
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . 8W-43
Ambi ent Temperature Sensor . . . . . . . . . . . . 8W-42
Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . 8W-44
Automati c Shut Down Rel ay . . . . . . . . . . . . . 8W-30
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51
Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Base Overhead Consol e . . . . . . . . . . . . . . . . . 8W-49
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-30
Brake Pressure Swi tch . . . . . . . . . . . . . . . 8W-34, 35
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Cargo Lamps . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Center Consol e Lamp . . . . . . . . . . . . . . . . . . . 8W-44
Center Hi gh Mounted Stop Lamp . . . . . . . . . 8W-51
Center Power Outl et . . . . . . . . . . . . . . . . . . . 8W-41
Central Ti mer Modul e . . . . . . . . . . . . . . 8W-45, 45-9
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Ci rcui t Breaker No. 28 . . . . . . . . . . . . . . . . . . 8W-12
Cl ockspri ng . . . . . . . . . . . . . . . . . . 8W-33, 41, 43, 47
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . . . 8W-40
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . . 8W-21
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . . . 8W-21
Coi l On Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . 8W-52
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-34, 35
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-18
Di agnosti c Juncti on Port . . . . . . . . . . . . . . . . 8W-18
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Door Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-39
Door Power Lock Motor/Ajar Swi tch . . . . 8W-39, 61
Door Speaker . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Door Tweeters . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Door Woofer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Dri ver Ai rbag . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . . . 8W-61
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . . 8W-39
Dri ver Door Modul e . . . . . . . . . . . . . . 8W-60, 61, 62
Dri ver Door Power Lock
Motor/Ajar Swi tch . . . . . . . . . . . . . . . . 8W-39, 61
Component Page
Dri ver Door Power Wi ndow Motor . . . . . . . . . 8W-60
Dri ver Power Mi rror . . . . . . . . . . . . . . . . 8W-48, 62
Dri ver Seat Bel t Tensi oner . . . . . . . . . . . . . . 8W-43
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . . 8W-54
Engi ne Cool ant Temperature Sensor . . . . . . . 8W-30
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . . . 8W-30
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . 8W-21
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . 8W-21
Evaporator Temperature Sensor . . . . . . . . . . 8W-42
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Front Door Woofer . . . . . . . . . . . . . . . . . . . . . 8W-47
Front Washer Pump/Motor . . . . . . . . . . . . . . 8W-53
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-53
Front Wi per Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-53
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Gl ove Box Lamp And Swi tch . . . . . . . . . . . . . 8W-44
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-44, 50
Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Heater Control . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . . . 8W-40
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
I /O Processor . . . . . . . . . . . . . . . . . . . . . 8W-40, 40-6
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-31
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . 8W-30
Joi nt Connectors . . . . . . . . . . . . . . . . . . . . . . 8W-10
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . 8W-30
Li cense Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-31
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Low Washer Fl ui d I ndi cator . . . . . . . . . . . . . 8W-40
Mani fol d Absol ute Pressure Sensor . . . . . . . . 8W-30
Mode Door Actuator . . . . . . . . . . . . . . . . . . . . 8W-42
Mul ti - Functi on Swi tch . . . . . . . . . . . . . . . . . 8W-50
Output Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31
Overdri ve Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-30
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . 8W-49
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30
AN 8W-02 COMPONENT INDEX 8W - 02 - 1
Component Page
Oxygen Sensor 1/2 Downstream . . . . . . . . . . 8W-30
Oxygen Sensor Downstream Heater Rel ay . . 8W-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-45
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-50
Park/Turn Si gnal Lamps . . . . . . . . . . . . . 8W-50, 52
Passenger Ai rbag On/Off Swi tch . . . . . . . . . . 8W-43
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . . . 8W-43
Passenger Cyl i nder Lock Swi tch . . . . . . . . . . 8W-61
Passenger Door Ajar Swi tch . . . . . . . . . . . . . . 8W-39
Passenger Door Lock Swi tch . . . . . . . . . . . . . 8W-61
Passenger Door Power Lock
Motor/Ajar Swi tch . . . . . . . . . . . . . . . . 8W-39, 61
Passenger Door Power Wi ndow Motor . . . . . . 8W-60
Passenger Door Power Wi ndow Swi tch . . . . . 8W-60
Passenger Power Mi rror . . . . . . . . . . . . . . 8W-48, 62
Passenger Seat Bel t Tensi oner . . . . . . . . . . . . 8W-43
Power Di stri buti on Center . . . . . . . . . . . . . . . 8W-10
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Seat Motors . . . . . . . . . . . . . . . . . . . . . 8W-63
Power Seat Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-63
Power Steeri ng Pressure Swi tch . . . . . . . . . . 8W-30
Power Wi ndow Motor . . . . . . . . . . . . . . . . . . . 8W-60
Power Wi ndow Swi tch . . . . . . . . . . . . . . . . . . 8W-60
Powertrai n Control Modul e . . . . . . . . . . . . . . 8W-30
Proporti onal Purge Sol enoi d . . . . . . . . . . . . . 8W-30
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . . . 8W-42
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . 8W-42
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rear Wheel Speed Sensor . . . . . . . . . . . . 8W-34, 35
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . 8W-48
Component Page
Reci rcul ati on Door Actuator . . . . . . . . . . . . 8W-42-6
Remote Radi o Swi tch . . . . . . . . . . . . . . . . 8W-45, 47
RKE Antenna . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61
Spl i ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Seatbel t Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8W-39
Shi ft Bezel Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Si de Marker Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Speed Control Servo . . . . . . . . . . . . . . . . . . . 8W-33
Speed Control Swi tch . . . . . . . . . . . . . . . . . . . 8W-33
Tai l /Stop/Turn Si gnal Lamp . . . . . . . . . . . . . . 8W-51
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-30
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . 8W-54
Transfer Case Control Modul e . . . . . . . . . . . . 8W-31
Transfer Case Mode Sensor . . . . . . . . . . . . . . 8W-31
Transfer Case Sel ector Swi tch . . . . . . . . . . . . 8W-31
Transfer Case Shi ft Motor . . . . . . . . . . . . . . . 8W-31
Transmi ssi on Control Modul e . . . . . . . . . . . . 8W-31
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . 8W-31
Transmi ssi on Range Sensor . . . . . . . . . . . . . . 8W-40
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . . 8W-31
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . 8W-31
Turn I ndi cator . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . . 8W-52
Vol tmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
VTSS I ndi cator . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-40
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-35
Wi per Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53
8W - 02 - 2 8W-02 COMPONENT INDEX AN
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . . . . 8W-10-16
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . 8W-10-13, 16, 37
A/C Pressure Transducer . . . . . . . . . . . . . . . . . . . . 8W-10-39
Aftermarket CHMSL Connector . . . . . . . . . . . . . . . . 8W-10-25
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . . . . . 8W-10-34
Automati c Shut Down Rel ay . . . . . . . . . . . . . . 8W-10-15, 23, 27
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Battery Temperature Sensor . . . . . . . . . . . . . . . . . . 8W-10-39
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . 8W-10-14, 25, 36
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
Center Hi gh Mounted Stop Lamp . . . . . . . . . . . . . . . 8W-10-25
Center Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Central Ti mer Modul e . . . . . . . . . . . . . 8W-10-14, 15, 17, 23, 32
Ci rcui t Breaker No. 28 . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-39
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . . . . . . . . 8W-10-37
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 7 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Coi l On Pl ug No. 8 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Combi nati on Fl asher . . . . . . . . . . . . . . . . 8W-10-14, 22, 25, 36
Control l er Anti l ock Brake . . . . . . . . . . . . . . . . 8W-10-14, 26, 36
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 25, 26
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-10-15, 22, 37, 38
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . 8W-10-29, 30, 31
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . . . . . 8W-10-30, 31
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-10-23, 39
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 33
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 37
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 38
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 38
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Fuse 1 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 22
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 23
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 23
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 24
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 25
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 26
Component Page
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 26
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 26
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 17
Fuse 10 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 17
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 27
Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32
Fuse 13 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 17
Fuse 14 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 22
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 17
Fuse A (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 16
Fuse B (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 16
Fuse C (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 16
Fuse D (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 16
Fuse E (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 17
Fuse F (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 20
Fuse H (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 21
Fuse T (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33
Fuse U (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29, 31
I gni ti on Swi tch . . . . . . . . . . . . . . . . . 8W-10-13, 15, 17, 18, 19
Joi nt Connector No. 1 . . . 8W-10-13, 14, 20, 21, 23, 25, 27, 28, 34, 35
Joi nt Connector No. 2 . . . . . . . . . . . . . . . . . . 8W-10-27, 36, 37
Joi nt Connector No. 3 . . . . . . . . . . . . . . 8W-10-13, 21, 33, 38, 39
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-10-13, 14, 16, 18, 19, 24,
25, 26, 33, 34, 36, 37, 38
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Left Front Park/Turn Si gnal Lamp No. 1 . . . . . . . . . 8W-10-33, 36
Left Front Park/Turn Si gnal Lamp No. 2 . . . . . . . . . 8W-10-33, 36
Left Front Si de Marker Lamp . . . . . . . . . . . . . . . . . 8W-10-33
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . . . . . . . . 8W-10-28
Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . . . . . 8W-10-28
Oxygen Sensor 2/1 Upstream . . . . . . . . . . . . . . . . . . 8W-10-28
Oxygen Sensor 2/2 Downstream . . . . . . . . . . . . . . . . 8W-10-28
Oxygen Sensor Downstream Heater Rel ay . . . . . . . . . . 8W-10-28
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 33
Passenger Power Mi rror . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Power Di stri buti on Center . . . 8W-10-13, 14, 15, 16, 17, 2, 20, 21, 22,
23, 24, 25, 26, 27, 32, 33
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Power Seat Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32
Power Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
Powertrai n Control Modul e . . . . . . 8W-10-23, 27, 29, 31, 35, 36, 39
Proporti onal Purge Sol enoi d . . . . . . . . . . . . . . . . . . 8W-10-37
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . 8W-10-14, 24, 38
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Ri ght Front Park/Turn Si gnal Lamp No. 1 . . . . . . . . 8W-10-33, 36
Ri ght Front Park/Turn Si gnal Lamp No. 2 . . . . . . . . 8W-10-33, 36
Ri ght Front Si de Marker Lamp . . . . . . . . . . . . . . . . . 8W-10-33
Trai l er Tow Connector . . . . . . . . . . . . . . . 8W-10-13, 16, 33, 34
Transfer Case Control Modul e . . . . . . . . . . . . . 8W-10-13, 16, 37
Transmi ssi on Control Modul e . . . . . . . . . . . . . 8W-10-20, 35, 38
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . 8W-10-13, 20, 35
Transmi ssi on Range Sensor . . . . . . . . . . . . . . . . . . . 8W-10-34
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . . . . . . . . 8W-10-20
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . . . . . . 8W-10-20, 34
AN 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8W-12 J UNCTION BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-12-12
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-12-14, 20
Aftermarket CHMSL Connector . . . . . . . . . . 8W-12-21
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-12-13, 14
Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Automati c Day/Ni ght Mi rror . . . . . . . . . 8W-12-12, 16
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-12-15
Base Overhead Consol e . . . . . . . . . . . . . . . . . 8W-12-7
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . 8W-12-21
Cargo Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-12-6
Cargo Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-12-6
Center Consol e Lamp . . . . . . . . . . . . . . . . . . 8W-12-6
Center Hi gh Mounted Stop Lamp . . . . . . . . . 8W-12-21
Center Power Outl et . . . . . . . . . . . . . . . . . . 8W-12-21
Central Ti mer Modul e . . . . . . . . . . 8W-12-12, 17, 8, 9
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 20
Ci rcui t Breaker No. 28 . . . . . . . . . . . . . . . . 8W-12-17
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Combi nati on Fl asher . . . . . . . . . . . . 8W-12-18, 21, 22
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8W-12-14
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-12-6
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 7
Dri ver Door Modul e . . . . . . . . . . . . . . . . . 8W-12-17, 6
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . 8W-12-19
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . 8W-12-18
Front Wi per Motor . . . . . . . . . . . . . . . . . 8W-12-11, 17
Front Wi per Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-17
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 7
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Fuse D (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Component Page
Fuse T (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Gl ove Box Lamp And Swi tch . . . . . . . . . . . . . 8W-12-6
Headl amp Swi tch . . . . . . . . . . . . . . . . 8W-12-9, 11, 20
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
I nstrument Cl uster . . . . . . 8W-12-6, 11, 13, 18, 20, 22
Joi nt Connector No. 1 . . . . . . . . . . . . 8W-12-15, 16, 21
Joi nt Connector No. 2 . . . . . . . . . . . . . . 8W-12-12, 22
Joi nt Connector No. 3 . . . . . . . . . . . . . 8W-12-9, 14, 18
Joi nt Connector No. 4 . . . . . . . . . . . . . . . . . 8W-12-11
Juncti on Bl ock . . . 8W-12-2, 3, 6, 7, 8, 9, 10, 11, 12, 13,
14, 15, 16, 17, 18, 19, 20, 21, 22,
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . 8W-12-16
Left Front Park/Turn Si gnal Lamp No. 1 . 8W-12-9, 22
Left Front Park/Turn Si gnal Lamp No. 2 . 8W-12-9, 22
Left Front Si de Marker Lamp . . . . . . . . . . . . 8W-12-9
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-13
Left Tai l /Stop/Turn Si gnal Lamp . . . . . . . . . 8W-12-13
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Overhead Consol e . . . . . . . . . . . . . . . . . 8W-12-12, 20
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . 8W-12-7
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Passenger Ai rbag On/Off Swi tch . . . . . . . . . 8W-12-13
Passenger Door Lock Swi tch . . . . . . . . . . . . 8W-12-15
Passenger Power Mi rror . . . . . . . . . . . . . . . 8W-12-19
Power Di stri buti on Center . . . . . . . . . . . 8W-12-19, 21
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-12-10
Proporti onal Purge Sol enoi d . . . . . . . . . . . . 8W-12-12
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . 8W-12-10
Radi o . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 11, 18, 20
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-12-19
Rear Wi ndow Defogger Rel ay . . . . . . . . . 8W-12-14, 19
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-12-16
Ri ght Front Park/Turn Si gnal
Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-12-9, 22
Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-12-9, 22
Ri ght Front Si de Marker Lamp . . . . . . . . 8W-12-9, 13
Ri ght Tai l /Stop/Turn Si gnal Lamp . . . . . . . . 8W-12-13
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-12-10, 6
Shi ft Bezel Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-20
Trai l er Tow Connector . . . . . . . . . . . . . . . . . 8W-12-16
Transfer Case Sel ector Swi tch . . . . . . . . 8W-12-12, 20
Transmi ssi on Control Modul e . . . . . . . . . . . 8W-12-18
Transmi ssi on Range Sensor . . . . . . . . . . . . . 8W-12-15
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . 8W-12-15
Wi per Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 17
AN 8W-12 JUNCTION BLOCK 8W - 12 - 1
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8W-15-3
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-15-3
A/C- Heater Control . . . . . . . . . . . . . . . . . . 8W-15-8
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-15-8
Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Automati c Day/Ni ght Mi rror . . . . . . . . . . . 8W-15-12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-15-8
Brake Pressure Swi tch . . . . . . . . . . . . . . . . 8W-15-7
Central Ti mer Modul e . . . . . . . . . . . . . . . 8W-15-8, 9
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . 8W-15-3, 7
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-15-9
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . 8W-15-11
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . 8W-15-11
Dri ver Door Modul e . . . . . . . . . . . . . . . . . 8W-15-11
Motor/Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-15-11
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . 8W-15-11
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
Front Washer Pump/Motor . . . . . . . . . . . . . 8W-15-4
Front Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-15-7
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-15-5
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6, 7
G115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 9
G305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-15-10
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-15-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-10
I nstrument Cl uster . . . . . . . . . . . . . . . . 8W-15-7, 10
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-15-5
Component Page
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Left Front Park/Turn Si gnal Lamp No. 1 . . 8W-15-7
Left Front Si de Marker Lamp . . . . . . . . . . . 8W-15-7
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . 8W-15-5
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Overdri ve Swi tch . . . . . . . . . . . . . . . . . . . . 8W-15-9
Overhead Consol e . . . . . . . . . . . . . . . . . . . 8W-15-12
Oxygen Sensor 1/2 Downstream . . . . . . . 8W-15-2, 3
Oxygen Sensor 2/2 Downstream . . . . . . . 8W-15-2, 3
Passenger Cyl i nder Lock Swi tch . . . . . . . . 8W-15-12
Passenger Door Ajar Swi tch . . . . . . . . . . . 8W-15-12
Passenger Door Lock Swi tch . . . . . . . . . . . 8W-15-12
Passenger Power Mi rror . . . . . . . . . . . . . . 8W-15-12
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Power Steeri ng Pressure Swi tch . . . . . . . . . 8W-15-3
Powertrai n Control Modul e . . . . . . . . . . . 8W-15-2, 7
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . 8W-15-4
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . 8W-15-5
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Ri ght Front Park/Turn Si gnal Lamp No. 1 . 8W-15-4
Ri ght Front Si de Marker Lamp . . . . . . . . . 8W-15-4
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-15-5
Ri ght Tai l /Stop/Turn Si gnal Lamp . . . . . . . 8W-15-5
Seatbel t Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-12
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-15-10
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-15-4
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8W-15-10
Transfer Case Control Modul e . . . . . . . . . . 8W-15-8
Transfer Case Sel ector Swi tch . . . . . . . . . . 8W-15-8
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-15-6
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . 8W-15-9
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . 8W-15-4
AN 8W-15 GROUND DISTRIBUTION 8W - 15 - 1
8W-18 BUS COMMUNICATIONS
Component Page
Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3
Central Ti mer Modul e . . . . . . . . . . . . . . . . . 8W-18-3
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-18-2, 3
Di agnosti c Juncti on Port . . . . . . . . . . . . . 8W-18-2, 3
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-18-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
Overhead Consol e . . . . . . . . . . . . . . . . . . . . 8W-18-3
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-18-3
Transmi ssi on Control Modul e . . . . . . . . . 8W-18-2, 3
AN 8W-18 BUS COMMUNICATIONS 8W - 18 - 1
8W-20 CHARGING SYSTEM
Component Page
Automati c Shut Down Rel ay . . . . . . . . . . . . 8W-20-4
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Battery Temperature Sensor . . . . . . . . . . . . 8W-20-4
Engi ne Starter Motor . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Component Page
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Joi nt Connector No. 1 . . . . . . . . . . . . . . . 8W-20-2, 3
Leak Detecti on Pump . . . . . . . . . . . . . . . . . 8W-20-3
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-20-3
AN 8W-20 CHARGING SYSTEM 8W - 20 - 1
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . 8W-21-3
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . 8W-21-3
Engi ne Starter Motor . . . . . . . . . . . . . . . . . 8W-21-2
Engi ne Starter Motor Rel ay . . . . . . . . . . 8W-21-2, 3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
G110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Component Page
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-21-2
Transmi ssi on Range Sensor . . . . . . . . . . . . 8W-21-3
Transmi ssi on Sol enoi d/Trs Assembl y . . . . . . 8W-21-3
AN 8W-21 STARTING SYSTEM 8W - 21 - 1
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8W-30-26
A/C Low Pressure Swi tch . . . . . . . . . . . . . 8W-30-27
A/C Pressure Transducer . . . . . . . . . . . . . 8W-30-32
Automati c Shut Down Rel ay . . . . . . 8W-30-5, 7, 12,
13, 9, 15
Battery Temperature Sensor . . . . . . . . . . . 8W-30-24
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-30-28
Camshaft Posi ti on Sensor . . . . . . . . 8W-30-8, 14, 21
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-30
Cl utch I nterl ock Swi tch Jumper . . . . . . 8W-30-9, 15
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 7 . . . . . . . . . . . . . . . . . . 8W-30-18
Coi l On Pl ug No. 8 . . . . . . . . . . . . . . . . . . 8W-30-18
Control l er Anti l ock Brake . . . . . . . . . . 8W-30-24, 28
Crankshaft Posi ti on Sensor . . . . . . . 8W-30-8, 14, 21
Di agnosti c Juncti on Port . . . . . . . . . . . . . . 8W-30-31
Engi ne Cool ant Temperature Sensor . . . . . 8W-30-25
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8W-30-24
Engi ne Starter Motor Rel ay . . . . . . . . . 8W-30-9, 15
Fuel I njector No. 1 . . . . . . . . . . . . . 8W-30-7, 12, 19
Fuel I njector No. 5 . . . . . . . . . . . . . . . 8W-30-12, 19
Fuel Pump Modul e . . . . . . . . . . . . . . . . . 8W-30-3, 4
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . 8W-30-2, 3, 26
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 26
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 3
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
Fuse U . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6, 10, 16
Fuse U (PDC) . . . . . . . . . . . . . . . . . . 8W-30-5, 9, 15
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
G105 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11, 17, 27
Component Page
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
G115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-30
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . 8W-30-25
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . 8W-30-5, 9
I ntake Ai r Temperature Sensor . . . . . . . . . 8W-30-25
Joi nt Connector No. 1 . . . . . . . . . 8W-30-5, 6, 10, 29,
9, 15, 16, 2, 22, 3, 31
Joi nt Connector No. 2 . . . . . . . . . 8W-30-5, 7, 12, 13,
9, 15, 26, 28, 3
Joi nt Connector No. 3 . . . . . . . . 8W-30-30, 24, 32, 4
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-30-2, 26, 28, 3
Leak Detecti on Pump . . . . . . . . . . . . . . . . 8W-30-22
Left Speed Control Swi tch . . . . . . . . . . . . 8W-30-30
Mani fol d Absol ute Pressure Sensor . . . . . . 8W-30-23
Output Speed Sensor . . . . . . . . . . . . . . . . 8W-30-29
Overdri ve Swi tch . . . . . . . . . . . . . . . . . . . 8W-30-30
Oxygen Sensor 1/1 Upstream . . . . . 8W-30-6, 11, 17
Oxygen Sensor 1/2 Downstream . . . 8W-30-6, 11, 17
Oxygen Sensor 2/1 Upstream . . . . . . . 8W-30-11, 17
Oxygen Sensor 2/2 Downstream . . . . . 8W-30-11, 17
Oxygen Sensor Downstream
Heater Rel ay . . . . . . . . . . . . . . . . . . 8W-30-10, 16
Power Di stri buti on Center . . 8W-30-5, 7, 12, 13, 29,
9, 15, 2, 3
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-30-27
Powertrai n Control Modul e . 8W-30-5, 6, 7, 8, 30, 10,
11, 12, 13, 14, 29, 9, 15, 16,
17, 18, 19, 20, 21, 2, 22, 23,
24, 25, 26, 27, 28, 3, 31, 32, 4
Proporti onal Purge Sol enoi d . . . . . . . . . . . . 8W-30-3
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . 8W-30-26
Ri ght Speed Control Swi tch . . . . . . . . . . . 8W-30-30
Speed Control Servo . . . . . . . . . . . . . . 8W-30-30, 28
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-30-23
Transmi ssi on Control Modul e . . . . . . . 8W-30-30, 21,
23, 24, 31
Transmi ssi on Control Rel ay . . . . . . . . 8W-30-29, 22
Transmi ssi on Sol enoi d Assembl y . . . . . 8W-30-29, 32
Transmi ssi on Sol enoi d/Trs Assembl y . . . . . 8W-30-15
AN 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . 8W-31-6
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-31-9
Data Li nk Connector . . . . . . . . . . . . . . . 8W-31-3, 12
Di agnosti c Juncti on Port . . . . . . . . . . . . 8W-31-3, 12
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-31-12
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-10
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-31-10
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8
Fuse A (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-31-11
Fuse F (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-10
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31-7
Joi nt Connector No. 1 . . . . . . . . . . . 8W-31-2, 3, 4, 8
Component Page
Joi nt Connector No. 2 . . . . . . . . . . . . . . . . 8W-31-12
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-31-8, 10
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . 8W-31-7
Output Speed Sensor . . . . . . . . . . . . . . . 8W-31-2, 7
Overdri ve Swi tch . . . . . . . . . . . . . . . . . . . . 8W-31-9
Power Di stri buti on Center . . . . . . . . . 8W-31-2, 4, 11
Powertrai n Control Modul e . . . . . . . 8W-31-2, 3, 6, 9
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . 8W-31-9
Transfer Case Control Modul e . . . . 8W-31-10, 11, 12
Transfer Case Mode Sensor . . . . . . . . . . . . 8W-31-12
Transfer Case Sel ector Swi tch . . . . . . . 8W-31-10, 11
Transfer Case Shi ft Motor . . . . . . . . . . . . . 8W-31-11
Transmi ssi on Control Modul e . . . . . . . 8W-31-3, 4, 5,
6, 7, 8, 9
Transmi ssi on Control Rel ay . . . . . . 8W-31-2, 4, 5, 6
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . 8W-31-2
Transmi ssi on Sol enoi d/TRS
Assembl y . . . . . . . . . . . . . . . . . . . 8W-31-5, 6, 7, 8
AN 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8W-33 VEHICLE SPEED CONTROL
Component Page
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
Di agnosti c Juncti on Port . . . . . . . . . . . . . . . 8W-33-2
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Component Page
Left Speed Control Swi tch . . . . . . . . . . . . . 8W-33-3
Ri ght Speed Control Swi tch . . . . . . . . . . . . 8W-33-3
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-33-2
AN 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1
8W-34 REAR WHEEL ANTILOCK BRAKES
Component Page
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-34-2, 3
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-34-2
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-34-2
Component Page
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-34-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-34-2
Rear Wheel Speed Sensor . . . . . . . . . . . . . . 8W-34-3
AN 8W-34 REAR WHEEL ANTILOCK BRAKES 8W - 34 - 1
8W-35 ALL WHEEL ANTILOCK BRAKES
Component Page
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-35-2, 3
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-3
Rear Wheel Speed Sensor . . . . . . . . . . . . . . 8W-35-2
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-35-3
AN 8W-35 ALL WHEEL ANTILOCK BRAKES 8W - 35 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Central Ti mer Modul e . . . . . . . . . . . . 8W-39-2, 3, 4,
5, 6, 7, 8, 9
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . . 8W-39-9
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-39-4
Dri ver Door Modul e . . . . . . . . . . . . . . . . 8W-39-5, 7
Motor/Ajar Swi tch . . . . . . . . . . . . . . . . 8W-39-5, 7
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3
G307 . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5, 6, 7, 8, 9
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Component Page
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-39-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-39-2, 3, 6
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Left Rear Door Ajar Swi tch . . . . . . . . . . . . . 8W-39-4
Left Rear Door Power Lock
Motor/Ajar Swi tch . . . . . . . . . . . . . . . . . . 8W-39-8
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Passenger Cyl i nder Lock Swi tch . . . . . . . . . 8W-39-9
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-39-4
Passenger Door Lock Swi tch . . . . . . . . . . . . 8W-39-6
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . 8W-39-4
Ri ght Rear Door Power Lock
AN 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8W-40 INSTRUMENT CLUSTER
Component Page
Central Ti mer Modul e . . . . . . . . . . . . . 8W-40-5, 6, 7
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . 8W-40-8
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-40-7
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . 8W-40-3, 4, 6
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-9
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 8
G208 . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 4, 7, 8
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40-8
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . 8W-40-7
I /O Processor . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 6
I nstrument Cl uster . . . . . . . . . . . . 8W-40-2, 3, 4, 5,
6, 7, 8, 9
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-40-2, 3, 4,
6, 7, 8, 9
Left Turn I ndi cator . . . . . . . . . . . . . . . . . . . 8W-40-7
Low Washer Fl ui d I ndi cator . . . . . . . . . . . . 8W-40-6
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-40-8
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . 8W-40-9
Ri ght Turn I ndi cator . . . . . . . . . . . . . . . . . . 8W-40-7
Seatbel t Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Vol tmeter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Vtss I ndi cator . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . 8W-40-6
AN 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Center Power Outl et . . . . . . . . . . . . . . . . . . 8W-41-3
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse D (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Component Page
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
AN 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8W-42-5
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-42-5
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-42-5
A/C Pressure Transducer . . . . . . . . . . . . . . 8W-42-7
A/C- Heater Control . . . . . . . . . . . . 8W-42-2, 3, 4, 6
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-42-2
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-42-6
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Bl ower Motor Resi stor Bl ock . . . . . . . . . . 8W-42-2, 3
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-42-4, 8
Evaporator Temperature Sensor . . . . . . . . . 8W-42-4
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5
Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-42-4, 8
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-42-4, 8
Fuse 13 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
Component Page
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
Fuse B (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
G207 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3, 4, 6, 8
Heater Control . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-42-3, 4, 5, 8, 9
Mode Door Actuator . . . . . . . . . . . . . . . . . . 8W-42-6
Power Di stri buti on Center . . . . . . . . . 8W-42-2, 5, 9
Powertrai n Control Modul e . . . . . . . . . 8W-42-5, 7, 9
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . 8W-42-9
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . 8W-42-9
Rear Wi ndow Defogger Rel ay . . . . . . . . . 8W-42-4, 8
Reci rcul ati on Door Actuator . . . . . . . . . . . . 8W-42-6
AN 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . 8W-43-2, 3, 4
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Dri ver Ai rbag . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Dri ver Seat Bel t Tensi oner . . . . . . . . . . . . . 8W-43-4
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Component Page
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . 8W-43-2
Passenger Ai rbag On/Off Swi tch . . . . . . . . . 8W-43-3
Passenger Seat Bel t Tensi oner . . . . . . . . . . 8W-43-4
AN 8W-43 AIRBAG SYSTEM 8W - 43 - 1
8W-44 INTERIOR LIGHTING
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . . 8W-44-14
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . 8W-44-13
Base Overhead Consol e . . . . . . . . . . . . . . 8W-44-6, 7
Cargo Lamp No. 1 . . . . . . . . . . . . . . 8W-44-5, 6, 7, 8
Cargo Lamp No. 2 . . . . . . . . . . . . . . 8W-44-5, 6, 7, 8
Center Consol e Lamp . . . . . . . . . . . 8W-44-5, 6, 7, 8
Central Ti mer Modul e . . . . . . . . 8W-44-2, 5, 6, 7, 8,
9, 10, 11, 12
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
Dome Lamp . . . . . . . . . . . . . . . . . . . 8W-44-5, 6, 7, 8
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-44-9
Fuse 1 (JB) . . . . . . . . . . . . . . . . . 8W-44-5, 6, 7, 8, 9
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3, 4
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-44-14
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-44-13
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3, 4
G208 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 4, 10
G307 . . . . . . . . . . . . . . . . . . . . 8W-44-10, 11, 12, 14
Gl ove Box Lamp And Swi tch . . . . . . . . . . . . 8W-44-9
Component Page
Joi nt Connector No. 1 . . . . . . . . . . . . . 8W-44-13, 14
Juncti on Bl ock . . . . . . . . . . . . . . 8W-44-2, 3, 4, 5, 6,
7, 8, 9, 13, 14
Left Rear Door Ajar Swi tch . . . . . . . . . . . . 8W-44-11
Overhead Consol e . . . . . . . . . . . . . . . . . . 8W-44-3, 8
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-44-2
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 9
Transmi ssi on Range Sensor . . . . . . . . . . . 8W-44-13
Transmi ssi on Sol enoi d/Trs Assembl y . . . . . 8W-44-13
AN 8W-44 INTERIOR LIGHTING 8W - 44 - 1
8W-45 CENTRAL TIMER MODULE
Component Page
Base Overhead Consol e . . . . . . . . . . . . . . . . 8W-45-7
Cargo Lamp No. 1 . . . . . . . . . . . . . . . . . . . 8W-45-19
Cargo Lamp No. 2 . . . . . . . . . . . . . . . . . . . 8W-45-19
Center Consol e Lamp . . . . . . . . . . . . . . . 8W-45-6, 7
Central Ti mer Modul e . . . . . . . . 8W-45-2, 3, 4, 5, 6,
7, 8, 9, 10, 11, 12, 13, 14,
15, 16, 17, 18, 19
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-8
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-45-6, 7
Dri ver Door Modul e . . . . . . . . . . . . . . . 8W-45-12, 14
Motor/Ajar Swi tch . . . . . . . . . . . . . . 8W-45-12, 14
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Front Wi per Motor . . . . . . . . . . . . . . . . 8W-45-9, 10
Front Wi per Rel ay . . . . . . . . . . . . . . . . . 8W-45-9, 10
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . 8W-45-2, 9, 10
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-45-19
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . 8W-45-13, 15
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
Fuse H (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 9
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 10
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
G208 . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2, 4, 5, 8
Component Page
G307 . . . . . . . . . . . . . . . . . . . . 8W-45-11, 12, 13, 14,
15, 16, 18
Gl ove Box Lamp And Swi tch . . . . . . . . . . . . 8W-45-3
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
I nstrument Cl uster . . . . . . . . . . . . . . . . 8W-45-5, 19
Juncti on Bl ock . . . . . . . 8W-45-2, 3, 9, 10, 13, 15, 19
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-45-5
Left Rear Door Ajar Swi tch . . . . . . . . . . . . 8W-45-11
Left Remote Radi o Swi tch . . . . . . . . . . . . . . 8W-45-8
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Mul ti - Functi on Swi tch . . . . . . . . . . . . . . . . 8W-45-5
Park Brake Swi tch . . . . . . . . . . . . . . . . . . 8W-45-19
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-45-3
Passenger Door Lock Swi tch . . . . . . . . 8W-45-13, 15
Motor/Ajar Swi tch . . . . . . . . . . . 8W-45-13, 15, 16
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-8
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-45-5
Ri ght Remote Radi o Swi tch . . . . . . . . . . . . 8W-45-8
Wi per Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
AN 8W-45 CENTRAL TIMER MODULE 8W - 45 - 1
8W-47 AUDIO SYSTEM
Component Page
Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 7, 8
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . 8W-47-5, 7, 8
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7, 8
G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6
Joi nt Connector No. 4 . . . . . . . . . . . 8W-47-2, 5, 7, 8
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-47-2, 5
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-47-7, 8
Component Page
Left Front Door Speaker . . . . . . . . . . . . . 8W-47-3, 4
Left Front Door Tweeter . . . . . . . . . . . . . . . 8W-47-5
Left Front Door Woofer . . . . . . . . . . . . . . . . 8W-47-5
Left Rear Speaker . . . . . . . . . . . . . . . . 8W-47-3, 4, 7
Left Rear Speaker . . . . . . . . . . . . . . . . . . . . 8W-47-8
Left Remote Radi o Swi tch . . . . . . . . . . . . . . 8W-47-6
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-47-2
Radi o . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7, 8
Ri ght Front Door Speaker . . . . . . . . . . . . 8W-47-3, 4
Ri ght Front Door Tweeter . . . . . . . . . . . . . 8W-47-5
Ri ght Front Door Woofer . . . . . . . . . . . . . . . 8W-47-5
Ri ght Rear Speaker . . . . . . . . . . . . . . . 8W-47-3, 4, 7
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . . 8W-47-8
Ri ght Remote Radi o Swi tch . . . . . . . . . . . . 8W-47-6
AN 8W-47 AUDIO SYSTEM 8W - 47 - 1
8W-48 REAR WINDOW DEFOGGER
Component Page
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3
Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-48-2
AN 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
8W-49 OVERHEAD CONSOLE
Component Page
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
Component Page
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
AN 8W-49 OVERHEAD CONSOLE 8W - 49 - 1
8W-50 FRONT LIGHTING
Component Page
Central Ti mer Modul e . . . . . . . . . . . . . 8W-50-2, 3, 4
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Fuse H (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3, 4
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3, 4
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Component Page
Left Front Si de Marker Lamp . . . . . . . . . . . 8W-50-3
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Mul ti - Functi on Swi tch . . . . . . . . . . . . . . . . 8W-50-4
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-50-3
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Ri ght Front Si de Marker Lamp . . . . . . . . . 8W-50-3
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-50-4
AN 8W-50 FRONT LIGHTING 8W - 50 - 1
8W-51 REAR LIGHTING
Component Page
Aftermarket CHMSL Connector . . . . . . . . . 8W-51-5
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . 8W-51-3
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-2
Center Hi gh Mounted Stop Lamp . . . . . . . . 8W-51-5
Combi nati on Fl asher . . . . . . . . . . . . . . . . 8W-51-5, 6
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
Fuse T (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 7
G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . 8W-51-2, 3, 4, 5
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . 8W-51-7
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-51-4
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . 8W-51-3, 7
Trai l er Tow Connector . . . . . . . . . . . . . 8W-51-3, 4, 6
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . 8W-51-2
AN 8W-51 REAR LIGHTING 8W - 51 - 1
8W-52 TURN SIGNALS
Component Page
Combi nati on Fl asher . . . . . . . . . . . . . . . . 8W-52-2, 4
Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Fuse 1 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 4
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-52-2, 4
Component Page
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . 8W-52-2
AN 8W-52 TURN SIGNALS 8W - 52 - 1
8W-53 WIPERS
Component Page
Front Wi per Motor . . . . . . . . . . . . . . . . . 8W-53-2, 3
Front Wi per Rel ay . . . . . . . . . . . . . . . . . 8W-53-2, 3
Component Page
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
Wi per Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
AN 8W-53 WIPERS 8W - 53 - 1
8W-54 TRAILER TOW
Component Page
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Fuse C (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Fuse T (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Component Page
G305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-54-2
Trai l er Tow Connector . . . . . . . . . . . . . . . 8W-54-2, 3
Transmi ssi on Sol enoi d/Trs Assembl y . . . . . . 8W-54-3
AN 8W-54 TRAILER TOW 8W - 54 - 1
8W-60 POWER WINDOWS
Component Page
Ci rcui t Breaker No. 28 . . . . . . . . . . . . . . 8W-60-2, 4
Dri ver Door Modul e . . . . . . . . . 8W-60-2, 3, 4, 5, 6, 7
Dri ver Door Power Wi ndow Motor . . . . . 8W-60-2, 4
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-60-2, 4
Left Rear Power Wi ndow Motor . . . . . . . . . 8W-60-6
Component Page
Left Rear Power Wi ndow Swi tch . . . . . . . 8W-60-4, 6
Passenger Door Power Wi ndow Motor . . 8W-60-3, 5
Passenger Door Power Wi ndow
Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 4, 5
Ri ght Rear Power Wi ndow Motor . . . . . . . . 8W-60-7
Ri ght Rear Power Wi ndow Swi tch . . . . . 8W-60-4, 7
AN 8W-60 POWER WINDOWS 8W - 60 - 1
8W-61 POWER DOOR LOCKS
Component Page
Central Ti mer Modul e . . . . . . . 8W-61-2, 3, 4, 5, 6, 7
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . . 8W-61-7
Dri ver Door Modul e . . . . . . . . . . . . . . . . 8W-61-3, 5
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-61-4, 5
G208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
G307 . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 4, 5, 7
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-61-2, 4, 5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-61-2
Passenger Cyl i nder Lock Swi tch . . . . . . . . . 8W-61-7
Passenger Door Lock Swi tch . . . . . . . . . . 8W-61-4, 5
RKE Antenna . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
AN 8W-61 POWER DOOR LOCKS 8W - 61 - 1
8W-62 POWER MIRRORS
Component Page
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-62-2
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
AN 8W-62 POWER MIRRORS 8W - 62 - 1
8W-63 POWER SEAT
Component Page
Fuse 14 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-63-2
G307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2
Component Page
Power Seat Motors . . . . . . . . . . . . . . . . . . . 8W-63-2
Power Seat Swi tch . . . . . . . . . . . . . . . . . . . 8W-63-2
AN 8W-63 POWER SEAT 8W - 63 - 1
8W-70 SPLICE INFORMATION
Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29, 31
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-32
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
S173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-23
S174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3
S175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-21
S178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7
S179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
S181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
S183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
S184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
S187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6
S240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Component Page
S240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-7
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 8
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11, 12
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 6
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 6
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 6
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 6
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-4
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7, 8
S323 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5, 6, 7, 8
S324 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 6, 7, 8
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4, 5
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4, 5
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4, 5
S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
S401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
AN 8W-70 SPLICE INFORMATION 8W - 70 - 1
8W-80 CONNECTOR PINOUTS
Component Page
A/C Compressor Cl utch (Except 2.5L) . . . . . 8W-80-4
A/C-Heater Control C1 Or Heater
Control C1 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-4
A/C-Heater Control C2 . . . . . . . . . . . . . . . . 8W-80-4
A/C Low Pressure Swi tch (2.5L/3.9L/5.9L) . 8W-80-5
A/C Low Pressure Swi tch (4.7L) . . . . . . . . . 8W-80-5
A/C Pressure Transducer . . . . . . . . . . . . . . 8W-80-5
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-80-6
Ampl i fi er C1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-6
Ampl i fi er C2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-6
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . 8W-80-7
Battery Temperature Sensor . . . . . . . . . . . . 8W-80-7
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-80-7
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . 8W-80-8
C105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
C105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
C107 (4.7L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
C107 (4.7L) (I n PDC) . . . . . . . . . . . . . . . . 8W-80-11
C108 (2.5L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C108 (2.5L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C201 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C201 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Component Page
C360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C361 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C361 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C361 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C361 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C362 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C362 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C362 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C362 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C363 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C363 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C363 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C363 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C364 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C364 (2 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C364 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C364 (4 Door) . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Camshaft Posi ti on Sensor . . . . . . . . . . . . . 8W-80-27
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Cargo Lamp No. 1 . . . . . . . . . . . . . . . . . . . 8W-80-27
Cargo Lamp No. 2 . . . . . . . . . . . . . . . . . . . 8W-80-27
Center Consol e Lamp . . . . . . . . . . . . . . . . 8W-80-28
Center Hi gh Mounted Stop Lamp . . . . . . . 8W-80-28
Center Power Outl et . . . . . . . . . . . . . . . . . 8W-80-28
Central Ti mer Modul e C1 . . . . . . . . . . . . . 8W-80-28
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Cl ockspri ng C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl ockspri ng C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl ockspri ng C3 . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl ockspri ng C4 (Premi um Radi o) . . . . . . . 8W-80-30
Cl utch I nterl ock Swi tch (M/T) . . . . . . . . . . 8W-80-30
Cl utch I nterl ock Swi tch Jumper (A/T) . . . 8W-80-31
Coi l On Pl ug No. 1 (4.7L) . . . . . . . . . . . . . 8W-80-31
Coi l On Pl ug No. 2 (4.7L) . . . . . . . . . . . . . 8W-80-31
Coi l On Pl ug No. 3 (4.7L) . . . . . . . . . . . . . 8W-80-31
Coi l On Pl ug No. 4 (4.7L) . . . . . . . . . . . . . 8W-80-31
Coi l On Pl ug No. 5 (4.7L) . . . . . . . . . . . . . 8W-80-32
Coi l On Pl ug No. 6 (4.7L) . . . . . . . . . . . . . 8W-80-32
Coi l On Pl ug No. 7 (4.7L) . . . . . . . . . . . . . 8W-80-32
Coi l On Pl ug No. 8 (4.7L) . . . . . . . . . . . . . 8W-80-32
Control l er Anti l ock Brake C1 . . . . . . . . . . 8W-80-33
Control l er Anti l ock Brake C2 . . . . . . . . . . 8W-80-33
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-80-33
AN 8W-80 CONNECTOR PINOUTS 8W - 80 - 1
Component Page
Di agnosti c Juncti on Port . . . . . . . . . . . . . . 8W-80-34
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Dri ver Ai rbag . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Dri ver Door Ajar Swi tch (Base) . . . . . . . . . 8W-80-35
Dri ver Door Power Lock/Motor Ajar Swi tch
(Premi um) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
Dri ver Door Modul e C1 . . . . . . . . . . . . . . . 8W-80-35
Dri ver Door Modul e C2 . . . . . . . . . . . . . . . 8W-80-36
Dri ver Door Power Wi ndow Motor . . . . . . 8W-80-36
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . 8W-80-36
Dri ver Seatbel t Tensi oner . . . . . . . . . . . . . 8W-80-36
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . 8W-80-36
Sensor (2.5L) . . . . . . . . . . . . . . . . . . . . . 8W-80-37
Sensor (3.9L/5.9L) . . . . . . . . . . . . . . . . . 8W-80-37
Engi ne Cool ant Temperature Sensor (4.7L) . 8W-80-37
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8W-80-37
Evaporator Temperature Sensor . . . . . . . . 8W-80-37
Front Washer Pump/Motor . . . . . . . . . . . . 8W-80-38
Front Wi per Motor . . . . . . . . . . . . . . . . . . 8W-80-38
Fuel I njector No. 1 (2.5L) . . . . . . . . . . . . . 8W-80-38
Fuel I njector No. 1 (3.9L/4.7L/5.9L) . . . . . 8W-80-38
Fuel I njector No. 7 (4.7L/5.9L) . . . . . . . . . 8W-80-40
Fuel I njector No. 8 (4.7L/5.9L) . . . . . . . . . 8W-80-40
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-80-40
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
Gl ove Box Lamp And Swi tch . . . . . . . . . . . 8W-80-41
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8W-80-41
I dl e Ai r Control Motor (2.5L/4.7L) . . . . . . . 8W-80-41
I dl e Ai r Control Motor (3.9L/5.9L) . . . . . . . 8W-80-42
I gni ti on Coi l (Except 4.7L) . . . . . . . . . . . . 8W-80-42
I nput Speed Sensor (4.7L A/T) . . . . . . . . . 8W-80-42
I nstrument Cl uster C1 . . . . . . . . . . . . . . . 8W-80-42
I nstrument Cl uster C2 . . . . . . . . . . . . . . . 8W-80-43
I ntake Ai r Temperature Sensor . . . . . . . . . 8W-80-43
Joi nt Connector No. 1 (I n PDC) . . . . . . . . 8W-80-43
Joi nt Connector No. 4 . . . . . . . . . . . . . . . . 8W-80-45
Juncti on Bl ock C1 . . . . . . . . . . . . . . . . . . . 8W-80-45
Component Page
Juncti on Bl ock C10 . . . . . . . . . . . . . . . . . . 8W-80-48
Leak Detecti on Pump . . . . . . . . . . . . . . . . 8W-80-48
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-49
Left Front Door Speaker (Base) . . . . . . . . 8W-80-49
Left Front Door Tweeter
(Mi dl evel /Premi um) . . . . . . . . . . . . . . . . 8W-80-49
Left Front Door Woofer
Left Front Park/Turn Si gnal Lamp No. 1 . 8W-80-50
Left Front Park/Turn Si gnal Lamp No. 2 . 8W-80-50
Left Front Si de Marker Lamp . . . . . . . . . . 8W-80-50
Left Front Wheel Speed Sensor . . . . . . . . . 8W-80-50
Left Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-80-50
Left Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-80-50
Left Rear Door Ajar Swi tch (Base) . . . . . . 8W-80-51
Motor/Ajar Swi tch (Premi um) . . . . . . . . 8W-80-51
Left Rear Door Power Wi ndow Motor . . . . 8W-80-51
Left Rear Door Power Wi ndow Swi tch . . . 8W-80-51
Left Rear Speaker . . . . . . . . . . . . . . . . . . . 8W-80-51
Left Remote Radi o Swi tch (Premi um) . . . . 8W-80-52
Left Speed Control Swi tch . . . . . . . . . . . . 8W-80-52
Left Tai l /Stop/Turn Si gnal Lamp . . . . . . . . 8W-80-52
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
Li ne Pressure Sensor (4.7L) . . . . . . . . . . . 8W-80-52
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-80-53
Mani fol d Absol ute Pressure Sensor
(4.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
Mani fol d Absol ute Pressure Sensor
(Except 4.7L) . . . . . . . . . . . . . . . . . . . . . 8W-80-53
Mode Door Actuator . . . . . . . . . . . . . . . . . 8W-80-53
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8W-80-53
Output Speed Sensor (4.7L) . . . . . . . . . . . 8W-80-54
Output Speed Sensor (3.9L/5.9L) . . . . . . . 8W-80-54
Overdri ve Swi tch . . . . . . . . . . . . . . . . . . . 8W-80-54
Overhead Consol e . . . . . . . . . . . . . . . . . . . 8W-80-54
Oxygen Sensor 1/1 Upstream (3.9L/5.9L) . 8W-80-55
Oxygen Sensor 1/1 Upstream
(Except 3.9L/5.9L) . . . . . . . . . . . . . . . . . 8W-80-55
Oxygen Sensor 1/2 Downstream (2.5L) . . . 8W-80-55
Oxygen Sensor 1/2 Downstream
(3.9L/5.9L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56
Oxygen Sensor 2/1 Upstream (3.9L/5.9L) . 8W-80-56
Oxygen Sensor 2/1 Upstream (4.7L) . . . . . 8W-80-56
8W - 80 - 2 8W-80 CONNECTOR PINOUTS AN
Component Page
Oxygen Sensor 2/2 Downstream
(3.9L/5.9L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . 8W-80-57
Passenger Ai rbag On/Off Swi tch . . . . . . . . 8W-80-57
Passenger Door Ajar Swi tch (Base) . . . . . . 8W-80-58
Passenger Door Power Lock Swi tch . . . . . 8W-80-58
Passenger Door Power Wi ndow Motor . . . . 8W-80-58
Passenger Door Power Wi ndow Swi tch
(2 Door) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58
Passenger Door Power Wi ndow Swi tch
(4 Door) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
Passenger Power Mi rror . . . . . . . . . . . . . . 8W-80-59
Passenger Seatbel t Tensi oner . . . . . . . . . . 8W-80-59
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
Power Seat Motors . . . . . . . . . . . . . . . . . . 8W-80-59
Power Seat Swi tch . . . . . . . . . . . . . . . . . . 8W-80-60
Power Steeri ng Pressure Swi tch
(2.5L/4.7L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-60
Powertrai n Control Modul e C1 (2.5L) . . . . 8W-80-60
Powertrai n Control Modul e C1
(3.9L/4.7L/5.9L) . . . . . . . . . . . . . . . . . . . 8W-80-61
Powertrai n Control Modul e C2 (2.5L) . . . . 8W-80-62
Powertrai n Control Modul e C2
(3.9L/4.7L/5.9L) . . . . . . . . . . . . . . . . . . . 8W-80-62
Powertrai n Control Modul e C3 . . . . . . . . . 8W-80-63
Radi ator Fan Motor . . . . . . . . . . . . . . . . . 8W-80-64
Radi o C1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Radi o C2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Radi o C3 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Rear Wheel Speed Sensor . . . . . . . . . . . . . 8W-80-65
Reci rcul ati on Door Actuator . . . . . . . . . . . 8W-80-65
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . 8W-80-65
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-65
Ri ght Front Door Speaker (Base) . . . . . . . 8W-80-65
Ri ght Front Door Tweeter
Component Page
Ri ght Front Door Woofer
Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-80-66
Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-80-66
Ri ght Front Si de Marker Lamp . . . . . . . . 8W-80-66
Ri ght Front Wheel Speed Sensor . . . . . . . 8W-80-66
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 8W-80-66
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . 8W-80-67
Ri ght Rear Door Ajar Swi tch (Base) . . . . . 8W-80-67
Ri ght Rear Power Wi ndow Motor . . . . . . . 8W-80-67
Ri ght Rear Power Wi ndow Swi tch . . . . . . 8W-80-67
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . . 8W-80-68
Ri ght Remote Radi o Swi tch (Premi um) . . . 8W-80-68
Ri ght Speed Control Swi tch . . . . . . . . . . . 8W-80-68
Ri ght Tai l /Stop/Turn Si gnal Lamp . . . . . . 8W-80-68
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . 8W-80-68
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-80-69
Shi ft Bezel Lamp . . . . . . . . . . . . . . . . . . . 8W-80-69
Speed Control Servo (Except 2.5L) . . . . . . 8W-80-69
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-80-69
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8W-80-69
Transfer Case Control Modul e C1 . . . . . . . 8W-80-70
Transfer Case Mode Sensor . . . . . . . . . . . . 8W-80-71
Transfer Case Shi ft Motor . . . . . . . . . . . . . 8W-80-71
Transmi ssi on Control Modul e (4.7L) . . . . . 8W-80-72
Transmi ssi on Range Sensor
(3.9L/5.9L A/T) . . . . . . . . . . . . . . . . . . . 8W-80-73
Transmi ssi on Sol enoi d/Trs
Assembl y (4.7L) . . . . . . . . . . . . . . . . . . 8W-80-73
Transmi ssi on Sol enoi d Assembl y
(3.9L/5.9L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-74
Washer Fl ui d Level Swi tch . . . . . . . . . . . . 8W-80-74
A/C COMPRESSOR CLUTCH (EXCEPT 2.5L) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z1 18BK GROUND
A/C-HEATER CONTROL C1 OR HEATER CONTROL C1 - BLACK 16 WAY
1 F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z1 20BK GROUND
3 C57 20DB/GY SENSOR GROUND
4 - -
5 G32 20BK/LB SENSOR GROUND
6 C21 20DB/OR A/C SWITCH SENSE
7 Z1 20BK GROUND
8 E2 20OR PANEL LAMPS FEED
9 C62 20DB/PK DUAL ZONE A/C ACTUATOR (+/-)
10 C35 20DG/YL MODE DOOR DRIVER
11 C34 20DB/WT COMMON DOOR DRIVER
12 C32 20GY/DB RECIRCULATION DOOR DRIVER
13 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
14 - -
15 C80 20DB/WT REAR WINDOW DEFOGGER RELAY CONTROL
16 D25 20VT/YL PCI BUS
A/C-HEATER CONTROL C2 - BLACK 10 WAY
1 - -
2 C4 16TN LOW SPEED BLOWER MOTOR DRIVER
3 C6 14LB M2 SPEED BLOWER MOTOR DRIVER
4 - -
5 Z1 10BK GROUND
6 - -
7 C5 14LG M1 SPEED BLOWER MOTOR DRIVER
8 - -
9 - -
10 C7 12BK/TN HIGH SPEED BLOWER MOTOR DRIVER
A/C LOW PRESSURE SWITCH (2.5L/3.9L/5.9L) - GRAY 2 WAY
1 Z1 18BK (3.9L/5.9L) GROUND
1 C20 18BR (2.5L) A/C SWITCH SENSE
2 C20 18BR (3.9L/5.9L) A/C SWITCH SENSE
2 Z1 18BK (2.5L) GROUND
A/C LOW PRESSURE SWITCH (4.7L) - GRAY 2 WAY
1 Z1 18BK GROUND
2 C20 18BR A/C SWITCH SENSE
A/C PRESSURE TRANSDUCER - BLACK 4 WAY
1 K4 18BK/LB SENSOR GROUND
2 K6 18VT/WT 5V SUPPLY
3 C18 18DB A/C PRESSURE SIGNAL
4 - -
AIRBAG CONTROL MODULE - YELLOW 23 WAY
1 - -
2 - -
3 - -
4 Z6 18BK/PK GROUND
5 R45 18DG/LB AIRBAG LINE 2
6 R43 18BK/LB AIRBAG LINE 1
7 R42 18BK/YL PASSENGER AIRBAG LINE 1
8 R44 18DG/YL PASSENGER AIRBAG LINE 2
9 R54 18LB/YL PASSENGER SEATBELT TENSIONER LINE 2
10 R56 18LB/DG PASSENGER SEATBELT TENSIONER LINE 1
11 R55 18LG/DG DRIVER SEATBELT TENSIONER (-) LINE 1
12 R166 20LG/BR PASSENGER AIRBAG INDICATOR DRIVER
12 R53 18LG/YL DRIVER SEATBELT TENSIONER (+) LINE 2
13 - -
14 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
15 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
16 - -
17 - -
18 - -
19 R66 20LG/DG PASSENGER AIRBAG MUX SWITCH RETURN
20 R65 20LG/OR PASSENGER AIRBAG MUX SWITCH SENSE
AIRBAG CONTROL MODULE - YELLOW 23 WAY
22 - -
23 - -
AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY
1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 18BK/LB SENSOR GROUND
AMPLIFIER C1 - WHITE 14 WAY
1 F75 18VT FUSED B(+)
3 - -
4 X87 18LG/VT AMPLIFIED LEFT DOOR SPEAKER (+)
5 X94 18TN/VT AMPLIFIED RIGHT REAR SPEAKER (+)
6 X93 18WT/RD AMPLIFIED LEFT REAR SPEAKER (+)
7 Z46 18BK/LB GROUND
8 Z47 18BK/LB GROUND
10 X80 18LB/BK AMPLIFIED RIGHT DOOR SPEAKER (-)
11 X82 18LB/VT AMPLIFIED RIGHT DOOR SPEAKER (+)
12 X85 18LG/DG AMPLIFIED LEFT DOOR SPEAKER (-)
13 X92 18TN/BK AMPLIFIED RIGHT REAR SPEAKER (-)
14 X91 18WT/BK AMPLIFIED LEFT REAR SPEAKER (-)
AMPLIFIER C2 - WHITE 10 WAY
1 X55 20BR/RD LEFT FRONT SPEAKER (-)
2 X56 20DB/RD RIGHT FRONT SPEAKER (-)
3 X58 20DB/OR RIGHT REAR SPEAKER (-)
4 X60 20DG/RD RADIO 12V OUTPUT
5 X53 20DG LEFT FRONT SPEAKER (+)
6 X54 20VT RIGHT FRONT SPEAKER (+)
7 X51 20BR/YL LEFT REAR SPEAKER (+)
8 X57 20BR/LB LEFT REAR SPEAKER (-)
9 X52 20DB/WT RIGHT REAR SPEAKER (+)
10 - -
AUTOMATIC DAY/NIGHT MIRROR - BLACK 7 WAY
1 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z1 20BK GROUND
3 L1 18VT/BK BACK-UP LAMP FEED
4 - -
5 - -
6 - -
7 - -
BACK-UP LAMP SWITCH - BLACK 2 WAY
A L1 18VT/BK (3.9L/5.9L) BACK-UP LAMP FEED
A L1 18VT/BK (EXCEPT 3.9L/5.9L) BACK-UP LAMP FEED
B L10 18BR/LG (3.9L/5.9L) TRS REVERSE SENSE
B L10 18BR/LG (EXCEPT 3.9L/5.9L) FUSED IGNITION SWITCH OUTPUT (RUN)
BASE OVERHEAD CONSOLE - 3 WAY
1 Y158 20YL/VT INTERIOR LAMP DRIVER
2 M1 20PK FUSED B(+)
3 M2 20YL COURTESY LAMP DRIVER
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
2 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
BLEND DOOR ACTUATOR - 2 WAY
1 C62 20DB/PK BLEND DOOR DRIVER
BLOWER MOTOR - BLACK 2 WAY
1 C1 12DG BLOWER MOTOR FEED
2 C73 12DB/YL BLOWER MOTOR COMMON DRIVER
BLOWER MOTOR RESISTOR BLOCK - BLACK 5 WAY
1 C7 12BK/TN HIGH SPEED BLOWER MOTOR DRIVER
2 C73 12DB/YL COMMON DRIVER
3 C6 14LB M2 SPEED BLOWER MOTOR DRIVER
4 C5 14LG/YL M1 SPEED BLOWER MOTOR DRIVER
5 C4 16TN LOW SPEED BLOWER MOTOR DRIVER
BRAKE LAMP SWITCH - BLACK 6 WAY
1 F32 14PK/DB FUSED B(+)
2 L50 14WT/TN BRAKE LAMP SWITCH OUTPUT
3 V30 20DB/RD BRAKE LAMP SWITCH OUTPUT
4 V32 20YL/RD SPEED CONTROL SUPPLY
5 Z2 18BK/LG GROUND
6 V40 20WT/PK BRAKE LAMP SWITCH SENSE
BRAKE PRESSURE SWITCH - BLACK 2 WAY
1 B10 20BR/WT BRAKE PRESSURE SWITCH SENSE
2 Z1 20BK GROUND
C105 - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 K30 18PK (3.9L/5.9L)
2 T16 16RD (EXCEPT 2.5L)
3 Y193 20WT/LG (4.7L)
4 Y128 20DG/GY (EXCEPT 2.5L)
5 K6 18VT/WT
6 K125 18WT/DB
7 C18 18DB
8 A142 14DG/OR
9 C20 18BR
10 F84 16YL/WT (4.7L)
C105 - BLACK (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 K30 18PK (3.9L/5.9L)
2 T16 16RD (EXCEPT 2.5L)
3 Y193 20WT/LG
4 Y128 20DG/GY
5 K6 18VT/WT
6 K125 18WT/DB
7 C18 18DB
8 A142 14DG/OR
9 C20 18BR
10 F84 16YL/WT (4.7L)
C106 - NATURAL (ENGINE SIDE)
CAV CIRCUIT
1 F142 18OR/DG (3.9L/5.9L)
1 F142 16OR/DG (EXCEPT 3.9L/5.9L)
2 Y112 18YL/BR (EXCEPT 2.5L)
3 Y124 16DG/VT (EXCEPT 2.5L)
4 Y125 16DG/WT (EXCEPT 2.5L)
5 Y115 18YL/WT (EXCEPT 2.5L)
6 Y117 18YL/DB (EXCEPT 2.5L)
7 Y119 18YL/TN (EXCEPT 2.5L)
8 Y114 18YL/VT (EXCEPT 2.5L)
9 L1 18VT/BK
10 A142 14DG/OR
11 F242 18DG/PK (3.9L/5.9L)
12 A14 16RD/WT
13 L10 18BR/LG
14 G7 20DB (3.9L/5.9L)
15 Y113 18YL/OR (EXCEPT 2.5L)
16 K200 18VT/OR
17 K100 18VT/WT
18 F18 18LG/BK
19 K125 18WT/DB
20 D25 18VT/YL (4.7L)
21 K4 18BK/LB (EXCEPT 2.5L)
22 T41 18BK/WT (EXCEPT 2.5L)
23 C3 18DB/BK
24 -
C106 - NATURAL (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 F142 16OR/DG
2 Y112 18YL/BR
3 Y124 16DG/VT
4 Y125 16DG/WT
5 Y115 18YL/WT
6 Y117 18YL/DB
7 Y119 18YL/TN
8 Y114 18YL/VT
9 L1 18VT/BK
10 A142 14DG/OR
11 A169 18RD/YL (4.7L)
11 F242 16DG/OR (3.9L/5.9L)
12 A14 16RD/WT
13 L10 18BR/LG
14 G7 18WT/OR
15 Y113 18YL/OR
16 K200 18VT/OR
17 K100 18VT/WT
18 F18 20LG/BK
19 K125 18WT/DB
20 D25 18VT/YL (4.7L)
20 C24 18DB/PK (EXCEPT 4.7L)
22 T41 18BK/WT (EXCEPT 2.5L)
23 C3 18DB/BK
24 -
C107 (4.7L) - WHITE (ENGINE SIDE)
CAV CIRCUIT
1 -
2 D22 20PK/BK
3 D21 18PK
4 F11 18RD/WT
5 T15 18LG
6 F242 18DG/OR
7 T6 18OR/WT
8 T10 18YL/DG
9 -
10 C24 18DB/PK
C107 (4.7L) (IN PDC) - WHITE (HEADLAMP
AND DASH SIDE)
CAV CIRCUIT
1 -
2 D22 20PK/BK
3 D21 18PK
4 F11 18RD/WT
5 T15 18LG
6 F242 18DG/PK
7 T6 18OR/WT
8 T10 18YL/DG
9 -
10 F242 18DG/OR
C108 (2.5L) - (ENGINE SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 K200 18VT/OR
3 K4 18BK/LB
4 K141 18TN/WT
C108 (2.5L) - (OXYGEN SENSOR J UMPER)
CAV CIRCUIT
1 F142 18OR/DG
2 K200 18VT/OR
3 K4 18BK/LB
4 K141 18TN/WT
C126 - (ELECTRIC BRAKE SIDE)
CAV CIRCUIT
1 A6 12RD/BK
2 B40 12LB
3 L50 18WT/TN
4 Z1 12BK
C126 - BLUE (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 Y202 12RD/TN
2 B40 14LB
3 L50 14WT/TN
4 Z1 14BK
CAV CIRCUIT
1 V40 20WT/OR
2 -
3 -
4 G32 18BK/LB
5 -
6 -
7 G31 18VT/LG
8 -
9 -
10 A111 10RD/LB
11 Y124 16DG/VT
12 F91 12GY/RD
13 C15 10BK/WT
14 -
15 A19 16RD/YL
16 Y125 16DG/WT
17 -
18 L39 12LB
19 -
20 D21 18PK
21 -
22 D20 18LG
23 -
24 -
25 V23 16BR/PK
26 D22 20PK/BK (4.7L)
27 Y113 18YL/OR
28 -
30 -
31 -
32 -
33 V30 20DB/RD (SPEED CONTROL)
34 L63 16DG/RD
35 -
36 -
37 L62 16BR/RD
38 T6 18OR/WT (EXCEPT 2.5L)
39 -
40 -
41 -
42 V49 18RD/BK
43 D25 18VT/YL
44 -
45 -
46 D25 18VT/YL
47 Y112 18YL/BR
48 Y119 18YL/TN
49 -
50 T41 18BK/WT
51 Y115 18YL/WT
52 Y114 18YL/VT
CAV CIRCUIT
53 V45 18VT
54 Y128 20DG/GY
55 Y117 18YL/DB
56 Z2 18BK/LG
57 D25 18VT/YL
58 Y193 20WT/LG
59 A34 16LB/RD
60 V48 18RD/GY
61 L9 14BK/WT
62 A2 12BR/WT
63 C40 12BR/WT
64 A1 12RD
65 A18 12RD/BK
66 -
67 C80 18DB/WT
68 F18 20LG/BK
69 G29 18BK/TN
70 C43 18OR/LB
71 V32 18YL/RD (EXCEPT 2.5L)
72 F32 14PK/DB
73 V37 18RD/LG (EXCEPT 2.5L)
74 V20 18BK/WT
C200 - BLACK (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 V40 20WT/PK
2 -
3 -
4 G32 20BK/LB
5 -
6 -
7 G31 20VT/LG
8 -
9 -
10 A111 10RD/LB
11 Y124 16DG/VT
12 F91 12GY/RD
13 C15 12BK/WT
14 -
15 A19 16RD/YL
16 Y125 16DG/WT
17 -
18 L39 18LB
19 -
20 D21 20PK
21 -
22 D20 20LG
23 -
24 -
25 V23 16BR/PK
26 D22 20PK/BK
CAV CIRCUIT
27 Y113 18YL/OR
28 -
30 -
31 -
32 -
33 V30 20DB/RD
34 L63 16DG/RD
35 -
36 -
37 L62 16BR/RD
38 T6 20OR/WT (EXCEPT 2.5L)
39 -
40 -
41 -
42 V49 18RD/BK
43 D25 18VT/YL
44 -
45 -
46 D25 18VT/YL
47 Y112 18YL/BR
48 Y119 18YL/TN
49 -
50 T41 18BK/WT
51 Y115 18YL/WT
52 Y114 18YL/VT
53 V45 18VT
54 Y128 20DG/GY
55 Y117 18YL/DB
56 Z2 20BK/LG
57 D25 20VT/YL
58 Y193 20ST/LG
59 A34 16LB/RD
60 V48 16RD/GY
61 L9 14BK/WT
62 A2 12PK/BK
63 -
64 A1 12RD
65 A18 12RD/BK
66 -
67 C80 20DB/WT
68 F18 20LG/BK
69 G29 18BK/TN
70 C43 20OR/LB
71 V32 20YL/RD
72 F32 14PK/DB
73 V37 20RD/LG (EXCEPT 2.5L)
74 V20 20BK/WT
C201 (4 DOOR) - YELLOW (BODY SIDE)
CAV CIRCUIT
1 Z2 20BK/LG
2 G73 20LG/OR
C201 (4 DOOR) - YELLOW (INSTRUMENT
PANEL SIDE)
CAV CIRCUIT
1 M1 20PK
1 M1 20PK
2 M3 20PK/DB
2 M3 20PK/DB
C202 - NATURAL (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 -
2 -
3 -
4 -
5 C35 20DG/YL
6 C57 20DB/GY
7 C5 14LG
8 C6 14LB
9 C62 20DB/GY
10 C4 16TN
11 C21 20DB/OR
12 C32 20GY/DB
13 C1 12DG
14 C7 12BK/TN
15 -
16 C34 20DB/WT
C202 - NATURAL (FRONT HVAC J UMPER SIDE)
CAV CIRCUIT
1 -
2 -
3 -
4 -
5 C35 20DG/YL
6 C57 20DB/GY
7 C5 14LG/YL
8 C6 14LB
9 C62 20DB/PK
C202 - NATURAL (FRONT HVAC J UMPER SIDE)
CAV CIRCUIT
10 C4 16TN
11 C21 20DB/OR
12 C32 20GYDB
13 C1 12DG
14 C7 12BK/TN
15 -
16 C34 20DB/WT
CAV CIRCUIT
1 X87 18LG/VT
2 X85 18LG/DG
3 X82 18LB/VT
4 X80 18LB/BK
5 X93 18WT/RD
6 X91 18WT/BK
7 C15 12BK/WT
8 F91 12GY/RD
9 X94 18TN/VT
10 X92 18TN/BK
11 D25 20VT/YL
12 C63 20LB
13 -
14 C70 12DG
15 G13 20BR/RD
16 -
C246 - BLACK (BODY SIDE)
CAV CIRCUIT
1 X87 18LG/VT
2 X85 18LG/DG
3 X82 18LB/VT
4 X80 18LB/BK
5 X93 18WT/RD
6 X91 18WT/BK
7 C15 12BK/WT (REAR WINDOW DEFOG-
GER)
8 F91 12GY/RD (EXCEPT STANDARD)
9 X94 18TN/VT
10 X92 18TN/BK
11 D25 20VT/YL
12 -
13 -
14 -
15 G13 20DB/RD
16 -
CAV CIRCUIT
1 Z1 14BK
2 F91 12GY/RD
C248 - BLACK (DRIVER SEAT SIDE)
CAV CIRCUIT
1 Z1 12BK
2 A4 12BK/PK
C301 - BLACK (BASE CONSOLE SIDE)
CAV CIRCUIT
1 A12 16RD/TN
2 M1 20PK
3 Z1 16BK
4 Y158 20YL/VT
CAV CIRCUIT
1 A12 16RD/TN
2 M1 20PK
3 Z1 16BK (4 DOOR)
3 Z1 18BK (2 DOOR)
4 Y158 20YL/VT
CAV CIRCUIT
1 Z1 20BK
2 L7 20BK/YL
C323 - BLACK (CHASSIS SIDE)
CAV CIRCUIT
1 Z1 18BK (STEP BUMPER)
1 Z1 20BK (SPORT BUMPER)
2 L7 18BK/YL
C325 - BLACK (TAIL LAMPS SIDE)
CAV CIRCUIT
1 L7 20BK/YL
2 Z1 20BK
3 L632 16DG/RD
4 L1 20VT/BK
CAV CIRCUIT
1 L7 20BK/YL
2 Z1 20BK
3 L63 16DG/RD
4 L1 20VT/BK
CAV CIRCUIT
1 M1 20PK
2 M3 20PK/DB
3 L50 14WT/TN
4 Z1 18BK
5 -
6 -
C329 - BLACK (CARGO LAMPS SIDE)
CAV CIRCUIT
1 M1 20PK (CARGO LAMPS)
2 M3 20PK/DB (CARGO LAMPS)
3 L50 18WT/TN
4 Z1 20BK
5 -
6 -
CAV CIRCUIT
1 -
2 L62 16BR/RD
3 L1 20VT/BK
4 Y203 16RD/WT
5 L207 18YL/BK
6 -
7 B40 14LB
8 Z1 14BK
9 Z1 14BK
10 L63 16DG/RD
C341 - BLACK (TRAILER TOW)
CAV CIRCUIT
1 -
2 L62 18BK/PK
3 L1 20VT/BK
4 Y203 16RD/WT
5 L207 18BK/OR
6 -
7 B40 14LB
8 Z1 14BK
9 Z1 14BK
10 L63 18DG/RD
CAV CIRCUIT
1 L1 18VT/BK
2 L62 16BR/RD
3 L63 16DG/RD
4 Y203 16RD/WT
5 L207 18YL/BK
6 B40 14LB
7 L50 14WT/TN
8 L7 20BK/YL
9 B113 20RD/VT
10 B114 20WT/VT
11 K4 18BK/LB
12 K226 18DB/WT
13 A61 16DG/BK
14 Z1 16BK
CAV CIRCUIT
1 L1 20VT/BK
2 L62 16BR/RD
2 L62 16BR/RD
3 L63 16DG/RD
3 L63 16DG/RD
4 Y203 16RD/WT
5 L207 18YL/BK
6 B40 14LB
7 L50 18WT/TN
8 L7 20BK/YL
9 B113 20RD/VT
10 B114 20WT/VT
11 K4 18BK/LB
12 K226 18DB/WT
13 A61 16DG/BK
14 Z1 16BK
C360 - BLACK (TAIL LAMPS SIDE)
CAV CIRCUIT
1 L7 20BK/YL
2 Z1 20BK
3 L632 16DG/BR
4 L1 20VT/BK
CAV CIRCUIT
1 L7 20BK/YL
2 Z1 20BK
3 L62 16BR/RD
3 L62 16BR/RD
4 L1 20VT/BK
C361 (2 DOOR) - WHITE (BODY SIDE)
CAV CIRCUIT
1 Q1 14YL
2 -
3 -
4 P34 16PK/BK
5 P33 16OR/BK
6 Q26 14VT/WT
CAV CIRCUIT
7 Q16 14BR/WT
8 G73 20LG/OR
9 P96 20WT/LG
10 -
C361 (2 DOOR) - NATURAL (RIGHT FRONT
DOOR SIDE)
CAV CIRCUIT
1 Q1 14YL
2 -
3 -
4 P34 18PK/BK
5 P33 18OR/BK
6 Q26 14VT/WT
7 Q16 14BR/WT
8 G73 20LG/OR (VTSS)
9 P96 20WT/LG
10 -
CAV CIRCUIT
1 -
2 -
3 -
4 P34 16PK/BK
5 P33 16OR/BK
6 Q26 14VT/WT
7 Q16 14BR/WT
9 L10 18BR/LG
10 P96 20WT/LG
DOOR SIDE)
CAV CIRCUIT
1 -
2 -
3 -
4 P34 18PK/BK
5 P33 18OR/BK
6 Q26 14VT/WT
7 Q16 14BR/WT
DOOR SIDE)
CAV CIRCUIT
9 L10 20BR/LG
10 P96 20WT/LG
C362 (2 DOOR) - GREEN (BODY SIDE)
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB
3 P72 22YL/BK
4 X82 18LB/VT
5 X80 18LB/BK
6 -
7 G74 20TN/RD
8 Z2 20BK/LG
9 -
10 Z1 20BK
11 F121 20TN/BK
12 L10 18BR/LG
DOOR SIDE)
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB
3 P72 22YL/BK
4 X82 18LB/VT
5 X80 18LB/BK
6 -
7 G74 20TN/RD
8 Z2 20BK/LG
9 -
10 Z1 20BK
11 F121 20TN/BK
12 L10 18BR/LG
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB
3 P72 22YL/BK
4 X82 18LB/VT
5 X80 18LB/BK
6 G74 20TN/RD
7 Q1 14YL (POWER WINDOWS/LOCKS)
8 F121 20TN/BK (HEATED MIRRORS)
9 Z1 20BK
CAV CIRCUIT
10 Z2 20BK/LG
DOOR SIDE)
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB
3 P72 22YL/BK
4 X82 18LB/VT
5 X80 18LB/BK
6 G74 20TN/RD (POWER WINDOWS/
LOCKS)
9 Z1 20BK
10 Z2 20BK/TN
C363 (2 DOOR) - GREEN (BODY SIDE (PREMI-
UM))
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB
3 P72 22YL/BK
4 X87 18LG/VT
5 X85 18LG/DG
6 M1 20PK
7 G75 20TN
8 Z2 20BK/LG
9 F21 12TN (POWER WINDOWS/LOCKS)
10 Z1 14BK (POWER WINDOWS/LOCKS)
11 F121 20TN/BK
12 -
C363 (2 DOOR) - BLACK (LEFT FRONT DOOR
SIDE (PREMIUM))
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB (HEATED MIRRORS)
3 P72 22YL/BK (HEATED MIRRORS)
4 X87 18LG/VT
5 X85 18LG/DG
6 M1 20PK (POWER MIRRORS)
7 G75 20TN
8 Z2 20BK/LG
9 F21 14TN (POWER WINDOWS/LOCKS)
10 Z1 14BK
11 F121 20TN/BK
SIDE (PREMIUM))
CAV CIRCUIT
12 -
C363 (4 DOOR) - GREEN (BODY SIDE (PREMI-
UM))
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB
3 P72 22YL/BK
4 X87 18LG/VT
5 X85 18LG/DG
6 G75 20TN
7 Z1 12BK (POWER WINDOWS/LOCKS)
9 M1 20PK
10 Z2 20BK/LG
SIDE (PREMIUM))
CAV CIRCUIT
1 P76 22OR/YL
2 P74 22DB (POWER MIRRORS)
3 P72 22YL/BK (POWER MIRRORS)
4 X87 18LG/VT
5 X85 18LG/DG
6 G75 20TN
7 Z1 12BK
9 M1 20PK (POWER MIRRORS)
10 Z2 20BK/LG
C364 (2 DOOR) - (BODY SIDE)
CAV CIRCUIT
1 Q1 14YL
2 -
3 -
4 P34 16PK/BK
5 P33 16OR/BK
6 Q26 14VT/WT
7 Q16 14BR/WT
8 G73 20LG/OR
9 P97 18WT/DG
10 -
C364 (2 DOOR) - NATURAL (LEFT FRONT
DOOR SIDE)
CAV CIRCUIT
1 Q1 14YL
2 -
3 -
4 P34 18PK/BK
5 P33 16OR/BK
6 Q26 14VT/WT
7 Q16 14BR/WT
8 G73 20LG/OR
9 P97 20WT/DG
10 -
C364 (4 DOOR) - BLACK (BODY SIDE)
CAV CIRCUIT
1 -
2 -
3 P97 18WT/DG
4 P59 18DB
5 P33 16OR/BK
6 Q26 14VT/WT
7 Q1 14YL
8 F21 12TN
9 Q28 14DG/WT
10 G73 20LG/OR
11 Q18 14GY/BK
12 Q16 14BR/WT
13 Q27 14RD/BK
14 Q17 14DB/WT
SIDE)
CAV CIRCUIT
1 P114 20YL/BK
2 P115 20YL/DB
3 P97 20WT/DG
4 P59 18DB
5 P33 18OR/BK
6 Q26 14VT/WT
7 Q1 14YL
8 F21 14TN
9 Q28 14DG/WT
11 Q18 14GY/BK
12 Q16 14BR/WT
13 Q27 14RD/BK
14 Q17 14DB/WT
C365 - WHITE (BODY SIDE)
CAV CIRCUIT
1 Z2 20BK/LG
2 G74 20TN/RD
3 P33 16OR/BK
4 P34 16PK/BK
6 Q17 14DB/WT (POWER WINDOWS/
LOCKS)
7 Q27 14RD/BK (POWER WINDOWS/
LOCKS)
8 X93 18WT/RD
9 X91 18WT/BK
10 -
C365 - WHITE (REAR DOOR SIDE) (LEFT)
CAV CIRCUIT
1 Z2 20BK/LG
2 G74 18TN/RD
3 P33 16OR/BK (POWER WINDOWS/
LOCKS)
4 P34 16PK/BK (POWER WINDOWS/
LOCKS)
5 Q1 14YL
6 Q17 14DB/WT
7 Q27 14RD/BK
8 X93 18WT/RD
9 X91 18WT/BK
10 -
C366 - WHITE (BODY SIDE)
CAV CIRCUIT
1 Z2 20BK/LG
2 G74 20TN/RD
3 P33 16OR/BK
4 P34 16PK/BK
6 Q18 14GY/BK (POWER WINDOWS/
LOCKS)
7 Q28 14DG/WT
8 X94 18TN/VT
9 X92 18TN/BK
10 -
C366 - WHITE (REAR DOOR) (RIGHT)
CAV CIRCUIT
1 Z2 20BK/LG
2 G74 18TN/RD
3 P33 16OR/BK (POWER WINDOWS/
LOCKS)
4 P34 16PK/BK (POWER WINDOWS/
LOCKS)
5 Q1 14YL
6 Q18 14GY/BK
7 Q28 14DG/WT
8 X94 18TN/VT
9 X92 18TN/BK
10 -
CAMSHAFT POSITION SENSOR - GRAY 3 WAY
1 K44 18TN/YL (3.9L/5.9L) CAMSHAFT POSITION SENSOR SIGNAL
1 K44 16TN/YL (2.5L) CAMSHAFT POSITION SENSOR SIGNAL
2 K4 18BK/LB (3.9L/5.9L) SENSOR GROUND
2 K4 16BK/LB (2.5L) SENSOR GROUND
3 K7 16OR (3.9L/5.9L) 5V SUPPLY
3 K7 18OR (2.5L) 5V SUPPLY
CAPACITOR - BLACK 2 WAY
1 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
2 - -
CARGO LAMP NO. 1 - BLACK 2 WAY
2 M3 20PK/DB CARGO LAMP DRIVER
CARGO LAMP NO. 2 - BLACK 2 WAY
CENTER CONSOLE LAMP - 2 WAY
CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY
2 Z1 20BK GROUND
CENTER POWER OUTLET - RED 3 WAY
1 A12 16RD/TN FUSED B(+)
2 - -
3 Z1 16BK GROUND
CENTRAL TIMER MODULE C1 - GRAY 26 WAY
1 Z2 18BK/LG GROUND
2 Z1 16BK GROUND
3 M3 20PK/DB CARGO LAMP SWITCH SENSE
4 L79 20RD/YL PARK LAMP RELAY CONTROL
5 X3 20BK/RD HORN RELAY CONTROL
6 G69 20BK/OR VTSS INDICATOR DRIVER
7 L308 20LG/RD PARK LAMP SWITCH SENSE
8 V52 18DG/RD INTERMITTENT FRONT WIPER MODE SENSE
9 M4 18GY/BK INTERIOR LAMP DEFEAT
11 L4 18VT/WT LOW BEAM SWITCH OUTPUT
12 X20 20GY/WT RADIO CONTROL MUX
13 V51 20WT INTERMITTENT FRONT WIPER SWITCH SIGNAL
14 Y158 20YL/VT GLOVE BOX LAMP DRIVER
15 V10 18BR FRONT WIPER PUMP/MOTOR CONTROL
16 Z2 18BK/LG GROUND
17 - -
18 G34 18RD/GY HIGH BEAM INDICATOR DRIVER
19 G26 18LB KEY-IN IGNITION SWITCH SENSE
20 - -
21 M11 20PK/LB COURTESY LAMP SWITCH SENSE
22 L27 18WT/TN FOG LAMP SWITCH SENSE
23 L80 18WT/DG HEADLAMP SWITCH OFF SENSE
24 L3 18RD/OR HIGH BEAM RELAY OUTPUT
26 V6 18DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 P96 20WT/LG PASSENGER DOOR SWITCH MUX
4 P33 18OR/BK DOOR LOCK RELAY OUTPUT
5 P34 18PK/BK DOOR UNLOCK RELAY OUTPUT
6 P59 18DB DRIVER DOOR UNLOCK RELAY OUTPUT
7 - -
8 G11 20WT/BK PARK BRAKE SWITCH SENSE
9 - -
10 P97 20WT/DG (4 DOOR) DRIVER DOOR SWITCH MUX
10 P97 18WT/DG (2 DOOR) DRIVER DOOR SWITCH MUX
11 - -
12 - -
13 G74 20TN/RD PASSENGER DOOR AJ AR SWITCH SENSE
14 G73 20LG/OR CYLINDER LOCK SWITCH SENSE
15 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
16 Y158 20YL/VT (STANDARD) INTERIOR LAMP DRIVER
16 Y158 18YL/VT (EXCEPT STANDARD) INTERIOR LIGHTS CONTROL
2 L34 18RD/OR RIGHT HIGH BEAM DRIVER
3 L33 18LG/BR LEFT HIGH BEAM DRIVER
4 L43 18VT/WT LEFT LOW BEAM DRIVER
5 L44 18VT/WT RIGHT LOW BEAM DRIVER
6 A301 16RD/LG FUSED B(+)
7 V18 18YL/DG FRONT WIPER RELAY CONTROL
8 L26 20WT/VT FOG LAMP RELAY CONTROL
9 - -
10 V5 18DG/YL FRONT WIPER PARK SWITCH SENSE
12 V10 18BR FRONT WASHER PUMP/MOTOR CONTROL
CIGAR LIGHTER - RED 3 WAY
1 F38 16RD/TN FUSED B(+)
2 E2 20OR PANEL LAMP FEED
3 Z1 16BK GROUND
CLOCKSPRING C1 - WHITE 6 WAY
1 X20 20GY/WT RADIO CONTROL MUX
2 Z2 20BK/LG GROUND
5 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
6 - -
CLOCKSPRING C2 - YELLOW 4 WAY
1 - -
2 - -
3 R43 18BK/LB AIRBAG LINE 1
4 R45 18DG/LB AIRBAG LINE 2
CLOCKSPRING C3 - BLACK 4 WAY
1 - -
2 V37 22RD/LG (SPEED CONTROL) SPEED CONTROL SWITCH SIGNAL
3 K4 22BK/LB (SPEED CONTROL) SENSOR GROUND
CLOCKSPRING C4 (PREMIUM RADIO) - BLACK 2 WAY
1 X20 22RD/BK RADIO CONTROL MUX
2 Z2 22BK/LG GROUND
CLUTCH INTERLOCK SWITCH (M/T) - GREEN 2 WAY
1 Z1 18BK (2.5L) GROUND
1 T41 18BK/WT (EXCEPT 2.5L) PARK/NEUTRAL POSITION SWITCH SENSE (T41)
2 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SNESE (T41)
CLUTCH INTERLOCK SWITCH J UMPER (A/T) - BLACK 2 WAY
1 T141 18YL PARK/NEUTRAL POSITION SWITCH SENSE (T41)
2 T141 18YL PARK/NEUTRAL POSITION SWITCH SENSE (T41)
COIL ON PLUG NO. 1 (4.7L) - BLACK 3 WAY
1 K19 16BK/GY COIL DRIVER NO. 1
2 A142 16DG/OR AUTMATIC SHUT DOWN RELAY OUTPUT
3 - -
1 K92 16TN/PK COIL DRIVER NO. 2
3 - -
1 K93 16TN/OR COIL DRIVER NO. 3
3 - -
1 K94 16TN/LG COIL DRIVER NO. 4
3 - -
1 K95 16TN/DG COIL DRIVER NO. 5
3 - -
1 K96 16TN/LB COIL DRIVER NO. 6
3 - -
1 K17 16DB/TN COIL DRIVER NO. 7
3 - -
1 K98 16LB/RD COIL DRIVER NO. 8
3 - -
COMBINATION FLASHER - BLACK 14 WAY
A1 L9 14BK/WT FUSED B(+)
A2 L63 16DG/RD LEFT TURN SIGNAL
A3 L61 16LG LEFT TURN SIGNAL
A4 - -
A5 Z1 18BK GROUND
A6 L5 18BK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
A7 L305 18LB/WT LEFT TURN SWITCH SENSE
A8 - -
B1 L19 16PK HAZARD FLASHER SIGNAL
B2 - -
B3 L60 16TN RIGHT TURN SIGNAL
B4 L62 16BR/RD RIGHT TURN SIGNAL
B5 L50 14WT/TN BRAKE LAMP SWITCH OUTPUT
COMBINATION FLASHER - BLACK 14 WAY
B6 - -
B7 L302 18LB/YL RIGHT TURN SWITCH SENSE
B8 - -
CONTROLLER ANTILOCK BRAKE C1 - BLACK 14 WAY
1 B113 20RD/VT REAR WHEEL SPEED SENSOR (+)
2 - -
4 A20 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
5 - -
6 Z19 12BK/PK GROUND
7 A10 12RD/DG FUSED B(+)
8 B114 20WT/VT REAR WHEEL SPEED SENSOR (-)
10 - -
11 B10 20BR/WT BRAKE PRESSURE SWITCH SENSE
12 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
13 Z19 12BK/PK GROUND
14 A10 12RD/DG FUSED B(+)
CONTROLLER ANTILOCK BRAKE C2 - BLACK 4 WAY
1 B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+)
2 B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-)
3 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
4 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+)
CRANKSHAFT POSITION SENSOR - BLACK 3 WAY
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
3 K7 18OR 5V SUPPLY
DATA LINK CONNECTOR - BLACK 16 WAY
1 - -
3 - -
4 Z12 18BK/TN GROUND
5 Z1 18BK GROUND
6 D20 20LG SCI RECEIVE
DATA LINK CONNECTOR - BLACK 16 WAY
7 D21 20PK SCI TRANSMIT
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 D22 20PK/BK SCI RECEIVE
15 - -
DIAGNOSTIC J UNCTION PORT - BLACK 16 WAY
1 D25 20VT/YL PCI BUS (MIC)
2 D25 18VT/YL PCI BUS (TCCM)
3 D25 18VT/YL PCI BUS (CTM)
4 D25 20VT/YL PCI BUS (OVERHEAD)
5 D25 20VT/YL PCI BUS (DLC)
6 D25 18VT/YL PCI BUS (PCM)
7 D25 18VT/YL PCI BUS (TCM)
8 D25 20VT/YL PCI BUS (CAB)
9 - -
10 - -
11 D25 20VT/YL PCI BUS (AMP)
12 D25 20VT/YL PCI BUS (RADIO)
13 D25 20VT/YL PCI BUS (HVAC)
14 - -
15 D25 18VT/YL PCI BUS (ACM)
16 D25 20VT/YL PCI BUS (SKIM)
DOME LAMP - BLACK 3 WAY
DRIVER AIRBAG - YELLOW 2 WAY
1 R45 DG/LB DRIVER AIRBAG LINE 2
2 R43 BK/LB DRIVER AIRBAG LINE 1
DRIVER CYLINDER LOCK SWITCH - BLACK 2 WAY
1 Z2 20BK/LG GROUND
2 G73 20LG/OR CYLINDER LOCK SWITCH MUX
DRIVER DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
2 Z2 20BK/LG GROUND
DRIVER DOOR POWER LOCK/MOTOR AJ AR SWITCH (PREMIUM) - BLACK 4 WAY
2 Z2 20BK/LG GROUND
3 P59 18DB (4 DOOR) DRIVER DOOR UNLOCK RELAY OUTPUT
3 P34 18PK/BK (2 DOOR) DOOR UNLOCK RELAY OUTPUT
4 P33 18OR/BK (2 DOOR) DOOR LOCK RELAY OUTPUT
4 P33 16OR/BK (4 DOOR) DOOR LOCK RELAY OUTPUT
DRIVER DOOR MODULE C1 - BLUE 12 WAY
1 Q28 14DG/WT MASTER WINDOW SWITCH RIGHT REAR (DOWN)
2 Q18 14GY/BK MASTER WINDOW SWITCH RIGHT REAR (UP)
3 Q16 14BR/WT MASTER WINDOW SWITCH RIGHT FRONT (UP)
4 Q17 14DB/WT LEFT REAR WINDOW DRIVER (UP)
5 Q11 14LB LEFT FRONT WINDOW DRIVER (UP)
6 Q26 14VT/WT MASTER WINDOW SWITCH RIGHT FRONT (DOWN)
7 P97 20WT/DG DRIVER DOOR SWITCH MUX
8 Z1 14BK GROUND
9 F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 Q27 14RD/BK LEFT REAR WINDOW DRIVER (DOWN)
12 Q21 14WT LEFT FRONT WINDOW DRIVER (DOWN)
DRIVER DOOR MODULE C2 - BLUE 8 WAY
1 P71 22YL DRIVER MIRROR UP MOVEMENT
2 P76 22OR/YL MIRROR COMMON DRIVER
4 P74 22DB RIGHT MIRROR LEFT MOVEMENT
5 Z1 20BK GROUND
6 P75 22DB/WT DRIVER MIRROR LEFT MOVEMENT
7 P72 22YL/BK RIGHT MIRROR UP MOVEMENT
8 Q1 14YL WINDOW SWITCH FEED
DRIVER DOOR POWER WINDOW MOTOR - BLACK 2 WAY
1 Q21 14WT LEFT FRONT WINDOW DRIVER (DOWN)
2 Q11 14LB LEFT FRONT WINDOW DRIVER (UP)
DRIVER POWER MIRROR - WHITE 8 WAY
1 P71 22YL DRIVER MIRROR UP MOVEMENT
2 P75 22DB/WT DRIVER MIRROR LEFT MOVEMENT
4 F121 20TN/BK FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
5 P114 20YL/BK (4 DOOR) AUTO DAY/NIGHT MIRROR (-)
6 P115 20YL/DG (4 DOOR) AUTO DAY/NIGHT MIRROR (+)
7 - -
8 Z1 20BK GROUND
DRIVER SEATBELT TENSIONER - YELLOW 2 WAY
A R55 18LG/DB DRIVER SEATBELT TENSIONER (-) LINE 1
B R53 18LG/YL DRIVER SEATBELT TENSIONER (+) LINE 2
DUTY CYCLE EVAP/PURGE SOLENOID - GRAY 2 WAY
1 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
ENGINE COOLANT TEMPERATURE SENSOR (2.5L) - BLACK 2 WAY
1 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR (3.9L/5.9L) - BLACK 2 WAY
ENGINE COOLANT TEMPERATURE SENSOR (4.7L) - BLACK 2 WAY
ENGINE OIL PRESSURE SENSOR - BLACK 2 WAY
2 G60 18GY/YL (2.5L/4.7L) ENGINE OIL PRESSURE SENSOR SIGNAL
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY
1 C57 20DB/GY SENSOR GROUND
2 C21 20DB/OR A/C SWITCH SENSE
FRONT WASHER PUMP/MOTOR - BLACK 2 WAY
1 V10 18BR FRONT WASHER PUMP/MOTOR CONTROL
2 Z1 18BK GROUND
FRONT WIPER MOTOR - BLACK 6 WAY
3 - -
4 Z1 18BK GROUND
5 V45 18VT FRONT WIPER LOW SPEED
6 V48 18RD/GY FRONT WIPER HIGH SPEED
FUEL INJ ECTOR NO. 1 (2.5L) - BLACK 2 WAY
1 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
FUEL INJ ECTOR NO. 1 (3.9L/4.7L/5.9L) - BLACK 2 WAY
1 K11 18ST/DB FUEL INJ ECTOR NO. 1 DRIVER
1 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
1 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
1 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
1 K38 18GY FUEL INJ ECTOR NO. 5 DRIVER
FUEL INJ ECTOR NO. 7 (4.7L/5.9L) - BLACK 2 WAY
1 K26 18VT FUEL INJ ECTOR NO. 7 DRIVER
FUEL INJ ECTOR NO. 8 (4.7L/5.9L) - BLACK 2 WAY
1 K28 18GY/LB FUEL INJ ECTOR NO. 8 DRIVER
FUEL PUMP MODULE - LT. GRAY 4 WAY
1 Z1 18BK GROUND
3 K226 18DB/WT FUEL PUMP RELAY CONTROL
4 A61 16DG/BK FUEL PUMP RELAY OUTPUT
GENERATOR - BLACK 2 WAY
1 K125 18WT/DB GENERATOR SOURCE
2 K20 18DG GENERATOR FIELD
GLOVE BOX LAMP AND SWITCH - BLACK 2 WAY
1 Y158 20YL/VT GLOVE BOX DRIVER
HEADLAMP SWITCH - BLACK 14 WAY
1 L7 20BK/YL PARK LAMP RELAY OUTPUT
2 L80 18WT/DG HEADLAMP SWITCH OFF SENSE
3 L308 20LG/RD PARK LAMP SWITCH SENSE
4 Z141 18BK/OR GROUND
5 L27 18WT/TN FOG LAMP SWITCH SENSE
6 L307 18LG/OR HEADLAMP SWITCH SENSE
7 L39 18LB FOG LAMP RELAY OUTPUT
8 L107 20WT HEADLAMP SWITCH OUTPUT
9 Z1 18BK GROUND
10 M11 20PK/LB COURTESY LAMP SWITCH SENSE
11 M3 20PK/DB CARGO LAMP SWITCH SENSE
12 M4 18GY/BK INTERIOR LAMP DEFEAT
13 - -
14 E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL
HIGH NOTE HORN - BLACK 2 WAY
1 Z1 18BK GROUND
2 X2 18DG/RD HORN RELAY OUTPUT
IDLE AIR CONTROL MOTOR (2.5L/4.7L) - GRAY 4 WAY
1 K39 18GY/RD (2.5L) IDLE AIR CONTROL NO. 1 DRIVER
2 K60 18YL/BK (2.5L) IDLE AIR CONTROL NO. 2 DRIVER
3 K40 18BR/WT (2.5L) IDLE AIR CONTROL NO. 3 DRIVER
4 K59 18VT/BK (2.5L) IDLE AIR CONTROL NO. 4 DRIVER
IDLE AIR CONTROL MOTOR (3.9L/5.9L) - BLACK 4 WAY
A K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
B K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
C K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
D K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
IGNITION COIL (EXCEPT 4.7L) - LT. GRAY 2 WAY
2 K19 16BK/GY IGNITION COIL NO. 1 DRIVER
IGNITION SWITCH - BLACK 14 WAY
1 A111 10RD/LB FUSED B(+)
2 A81 18DG/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 A21 16DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
4 A19 16RD/YL FUSED B(+)
5 G26 18LB KEY-IN IGNITION SWITCH SENSE
6 Z1 20BK GROUND
7 A22 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN)
8 C1 12DG BLOWER MOTOR FEED
9 A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 A30 12RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
11 A1 12RD FUSED B(+)
12 A18 12RD/BK FUSED B(+)
13 A41 16YL FUSED IGNITION SWITCH OUTPUT (START)
14 A2 12PK/BK FUSED B(+)
INPUT SPEED SENSOR (4.7L A/T) - 2 WAY
1 T13 18DB/BK SPEED SENSOR GROUND
2 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
INSTRUMENT CLUSTER C1 - BLACK 10 WAY
1 Y128 20DG/GY TRANS RANGE SENSOR 5V SUPPLY
2 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
3 G69 20BK/OR DOOR DISARM SWITCH SENSE
4 Z2 20BK/LG GROUND
5 Z1 20BK GROUND
INSTRUMENT CLUSTER C1 - BLACK 10 WAY
7 F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 - -
10 - -
INSTRUMENT CLUSTER C2 - GRAY 10 WAY
2 G29 18BK/TN WASHER FLUID SWITCH SENSE
3 G13 20DB/RD SEAT BELT INDICATOR DRIVER
4 Y193 20WT/LG TRANS RANGE SENSOR MUX
6 L61 16LG LEFT TURN SIGNAL
7 - -
8 L60 16TN RIGHT TURN SIGNAL
9 G34 18RD/GY HIGH BEAM INDICATOR DRIVER
10 - -
INTAKE AIR TEMPERATURE SENSOR - GRAY 2 WAY
1 K4 18BK/LB (EXCEPT 2.5L) SENSOR GROUND
2 K21 18BK/RD (EXCEPT 2.5L) INTAKE AIR TEMPERATURE SIGNAL
A K4 18BK/LB (2.5L) SENSOR GROUND
B K21 18BK/RD (2.5L) INTAKE AIR TEMPERATURE SIGNAL
J OINT CONNECTOR NO. 1 (IN PDC) - GRAY 28 WAY
4 F142 16OR/DG FUSED AUTOMATIC SHUT-DOWN RELAY OUTPUT
8 L39 18LB FUSED B(+)
12 F84 16YL/WT (4.7L) FUSED B(+)
12 K125 18WT/DB (3.9L/5.9L GENERATOR SOURCE
13 K125 18WT/DB (3.9L/5.9L) GENERATOR SOURCE
13 F84 16YL/WT (4.7L) FUSED B(+)
14 F84 16YL/WT (4.7L) FUSED B(+)
14 K125 18WT/DB (3.9L/5.9L) GENERATOR SOURCE
15 D21 18PK (4.7L) SCI TRANSMIT
J OINT CONNECTOR NO. 1 (IN PDC) - GRAY 28 WAY
21 A14 16RD/WT FUSED B(+)
25 - -
26 - -
27 - -
28 - -
J OINT CONNECTOR NO. 2 (IN PDC) - BLACK 18 WAY
4 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
13 A142 14DG/OR AUTOMATIC SHUT-DOWN RELAY OUTPUT
1 A114 18GY/RD FUSED B(+)
4 - -
5 - -
6 - -
12 A169 18RD/YL FUSED IGNITION SWITCH OUTPUT (START)
24 - -
25 F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN)
27 - -
28 - -
J OINT CONNECTOR NO. 4 - WHITE 22 WAY
1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 F75 18VT (PREMIUM RADIO) FUSED B(+)
16 - -
17 - -
19 F75 18VT (PREMIUM RADIO) FUSED B(+)
20 - -
21 - -
22 - -
J UNCTION BLOCK C1 - ORANGE 4 WAY
1 A7 12RD/BK FUSED B(+)
4 L7 18BK/YL HEADLAMP SWITCH OUTPUT
J UNCTION BLOCK C2 - BLUE 15 WAY
1 - -
2 A20 20RD/DB MODULE IDENTIFICATION
3 - -
7 - -
10 - -
12 L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
13 - -
15 - -
J UNCTION BLOCK C3 - LT. GRAY 13 WAY
1 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 - -
3 - -
9 - -
11 - -
J UNCTION BLOCK C4 - BROWN 14 WAY
1 M120PK FUSED B(+)
2 M1 20PK (HIGHLINE/BASE) FUSED B(+)
2 M1 18PK (MIDLINE/PREMIUM) FUSED B(+)
3 - -
4 - -
7 - -
8 - -
10 - -
11 - -
13 - -
J UNCTION BLOCK C5 - WHITE 12 WAY
6 - -
8 - -
9 F21 12TN FUSED IGNITION SWITCH OUTPUT (RUN)
10 - -
11 - -
12 - -
J UNCTION BLOCK C6 - GREEN 6 WAY
1 A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 - -
3 E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL
5 - -
6 A81 18DG/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
J UNCTION BLOCK C7 - BLACK 8 WAY
1 - -
2 - -
4 - -
5 - -
7 - -
8 - -
J UNCTION BLOCK C8 - BROWN 11 WAY
4 L79 20RD/YL PARK LAMP RELAY CONTROL
9 - -
1 - -
3 L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN)
4 - -
9 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
J UNCTION BLOCK C10 - LT. GRAY 12 WAY
2 - -
3 - -
6 - -
7 - -
8 - -
11 - -
12 - -
J UNCTION BLOCK C11 - WHITE 16 WAY
1 - -
2 - -
3 - -
4 - -
5 F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
6 - -
7 - -
8 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
10 - -
13 C15 14BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
14 A41 16YL FUSED IGNITION SWITCH OUTPUT (START)
J UNCTION BLOCK C12 - ORANGE 8 WAY
1 A30 12RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
3 A22 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN)
5 - -
6 F38 16RD/TN FUSED B(+)
7 A21 16DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
LEAK DETECTION PUMP - BLACK 4 WAY
1 - -
3 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
LEFT BACK-UP LAMP - GRAY 3 WAY
1 Z1 20BK GROUND
2 - -
LEFT FOG LAMP - BLACK 2 WAY
A Z1 18BK GROUND
B L39 18LB FOG LAMP RELAY OUTPUT
LEFT FRONT DOOR SPEAKER (BASE) - BLACK 3 WAY
2 - -
LEFT FRONT DOOR TWEETER (MIDLEVEL/PREMIUM) - NATURAL 2 WAY
LEFT FRONT DOOR WOOFER (MIDLEVEL/PREMIUM) - BLACK 3 WAY
2 - -
LEFT FRONT PARK/TURN SIGNAL LAMP NO. 1 - BLACK 3 WAY
3 Z1 20BK GROUND
LEFT FRONT PARK/TURN SIGNAL LAMP NO. 2 - BLACK 3 WAY
3 Z1 20BK GROUND
LEFT FRONT SIDE MARKER LAMP - 2 WAY
2 Z1 20BK GROUND
LEFT FRONT WHEEL SPEED SENSOR - LT. GRAY 2 WAY
1 B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-)
2 B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT HEADLAMP - BLUE 3 WAY
A L43 18VT/WT LEFT LOW BEAM DRIVER
B Z1 18BK GROUND
C L33 18LG/BR LEFT HIGH BEAM DRIVER
LEFT LICENSE LAMP - BLACK 2 WAY
1 Z1 18BK GROUND
LEFT REAR DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
2 Z2 20BK/LG GROUND
LEFT REAR DOOR POWER LOCK MOTOR/AJ AR SWITCH (PREMIUM) - BLACK 4 WAY
2 Z2 20BK/LG GROUND
LEFT REAR DOOR POWER WINDOW MOTOR - BLACK 2 WAY
1 Q23 14RD/WT LEFT REAR WINDOW DRIVER (DOWN)
2 Q13 14DB LEFT REAR WINDOW DRIVER (UP)
LEFT REAR DOOR POWER WINDOW SWITCH - BLUE 6 WAY
1 Q13 14DB LEFT REAR WINDOW DRIVER (UP)
2 Q27 14RD/BK LEFT REAR WINDOW DRIVER (DOWN)
3 - -
4 Q17 14DB/WT LEFT REAR WINDOW DRIVER (UP)
5 Q23 14RD/WT LEFT REAR WINDOW DRIVER (DOWN)
LEFT REAR SPEAKER - BLACK 3 WAY
1 X93 18WT/RD AMPLIFIED LEFT REAR SPEAKER (+)
2 - -
3 X91 18WT/BK AMPLIFIED LEFT REAR SPEAKER (-)
LEFT REMOTE RADIO SWITCH (PREMIUM) - 2 WAY
2 Z2 22BK/LG GROUND
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY
LEFT TAIL/STOP/TURN SIGNAL LAMP - BLACK 3 WAY
1 Z1 20BK GROUND
3 L632 16DG/BR LEFT REAR TURN SIGNAL
LICENSE LAMP - NATURAL 2 WAY
2 Z1 20BK GROUND
LINE PRESSURE SENSOR (4.7L) - BLACK 4 WAY
1 Z113 16BK GROUND
2 T38 18VT/TN 5V SUPPLY
3 T39 18GY/LB LINE PRESSURE SENSOR SIGNAL
4 - -
LOW NOTE HORN - BLACK 2 WAY
1 Z1 18BK GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.7L) - BLACK 3 WAY
1 K7 18OR 5V SUPPLY
3 K1 18DG/RD MAP SENSOR SIGNAL
MANIFOLD ABSOLUTE PRESSURE SENSOR (EXCEPT 4.7L) - BLACK 3 WAY
3 K7 18OR 5V SUPPLY
MODE DOOR ACTUATOR - GRAY 2 WAY
1 C35 20DG/YL MODE DOOR DRIVER
MULTI-FUNCTION SWITCH - GRAY 20 WAY
1 L19 16PK HAZARD FLASHER SIGNAL
2 V51 20WT FRONT WIPER SWITCH SENSE
3 L302 18LB/YL RIGHT TURN SWITCH SENSE
4 V52 18DG/RD INTERMITTENT WIPER MODE SENSE
5 L305 20LB/WT LEFT TURN SWITCH SENSE
6 L4 18VT/WT LOW BEAM SWITCH OUTPUT
7 Z1 18BK GROUND
8 L3 18RD/OR HIGH BEAM SWITCH OUTPUT
MULTI-FUNCTION SWITCH - GRAY 20 WAY
9 L307 18LG/OR HEADLAMP SWITCH SENSE
10 - -
11 Z1 18BK GROUND
12 - -
13 - -
14 V49 18RD/BK INTERMITTENT FRONT WIPER LOW SPEED
16 V48 16RD/GY FRONT WIPER HIGH SPEED
19 V10 18BR FRONT WIPER PUMP/MOTOR CONTROL
20 - -
OUTPUT SPEED SENSOR (4.7L) - BLACK 2 WAY
2 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
OUTPUT SPEED SENSOR (3.9L/5.9L) - GRAY 2 WAY
OVERDRIVE SWITCH - NATURAL 2 WAY
1 Z1 20BK GROUND
2 T6 20OR/WT OVERDRIVE OFF SWITCH SENSE
OVERHEAD CONSOLE - 12 WAY
3 - -
4 - -
OVERHEAD CONSOLE - 12 WAY
8 - -
9 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
10 - -
11 - -
OXYGEN SENSOR 1/1 UPSTREAM (3.9L/5.9L) - BLACK 4 WAY
1 K100 18VT/WT PWM 1/1 HEATER DRIVER
2 F142 16OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/1 UPSTREAM (EXCEPT 3.9L/5.9L) - BLACK 4 WAY
2 K100 18VT/WT PWM 1/1 HEATER DRIVER
OXYGEN SENSOR 1/2 DOWNSTREAM (2.5L) - BLACK 4 WAY
2 K200 18VT/OR OXYGEN SENSOR RELAY DRIVER
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM (3.9L/5.9L) - BLACK 4 WAY
1 Z11 18BK/WT GROUND
2 F242 16DG/PK OXYGEN SENSOR DOWNSTREAM HEATER RELAY
OUTPUT
1 F242 18DG/PK (4.7L A/T) OXYGEN SENSOR DOWNSTREAM HEATER RELAY
OUTPUT
1 Z11 18BK/WT (4.7L M/T) GROUND
2 F242 18DG/PK (4.7L M/T) OXYGEN SENSOR DOWNSTREAM HEATER RELAY
OUTPUT
2 Z11 18BK/WT (4.7L A/T) GROUND
3 K141 18TN/WT (4.7L M/T) OXYGEN SENSOR 1/2 SIGNAL
3 K4 18BK/LB (4.7L A/T) SENSOR GROUND
4 K141 18TN/WT (4.7L M/T) OXYGEN SENSOR 1/2 SIGNAL
4 K4 18BK/LB (4.7L A/T) SENSOR GROUND
OXYGEN SENSOR 2/1 UPSTREAM (3.9L/5.9L) - BLACK 4 WAY
1 K200 18VT/OR PWM 2/1 HEATER
3 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
OXYGEN SENSOR 2/1 UPSTREAM (4.7L) - BLACK 4 WAY
2 K200 18BR/WT PWM 2/1 HEATER
OXYGEN SENSOR 2/2 DOWNSTREAM (3.9L/5.9L) - BLACK 4 WAY
OUTPUT
OUTPUT
PASSENGER AIRBAG - YELLOW 4 WAY
1 - -
2 - -
3 R44 18DG/YL PASSENGER AIRBAG LINE 2
4 R42 18BK/YL PASSENGER AIRBAG LINE 1
PASSENGER AIRBAG ON/OFF SWITCH - 6 WAY
1 R65 20LG/OR PASSENGER AIRBAG MUX SWITCH SENSE
2 R66 20LG/DG PASSENGER AIRBAG MUX SWITCH SENSE
3 R166 20LG/BR PASSENGER AIRBAG MUX SWITCH SENSE
4 F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
5 - -
6 - -
PASSENGER CYLINDER LOCK SWITCH - LT. GRAY 2 WAY
1 Z2 20BK/TN (4 DOOR) GROUND
1 Z2 20BK/LG (2 DOOR) GROUND
2 G73 20LG/OR CYLINDER LOCK SWITCH MUX
PASSENGER DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
2 Z2 20BK/LG GROUND
PASSENGER DOOR POWER LOCK MOTOR/AJ AR SWITCH (PREMIUM) - BLACK 4 WAY
PASSENGER DOOR POWER LOCK SWITCH - NATURAL 6 WAY
1 P96 20WT/LG PASSENGER DOOR SWITCH MUX
2 L10 20BR/LG (4 DOOR) FUSED IGNITION SWITCH OUTPUT (RUN)
2 L10 18BR/LG (2 DOOR) FUSED IGNITION SWITCH OUTPUT (RUN)
3 - -
4 - -
6 - -
PASSENGER DOOR POWER WINDOW MOTOR - BLACK 2 WAY
1 Q22 14VT PASSENGER WINDOW DRIVER (DOWN)
2 Q12 14BR PASSENGER WINDOW DRIVER (UP)
PASSENGER DOOR POWER WINDOW SWITCH (2 DOOR) - BLUE 6 WAY
3 - -
PASSENGER DOOR POWER WINDOW SWITCH (4 DOOR) - BLUE 6 WAY
1 - -
PASSENGER POWER MIRROR - WHITE 8 WAY
1 P72 22YL/BK RIGHT MIRROR UP MOVEMENT
2 P74 22DB RIGHT MIRROR LEFT MOVEMENT
5 - -
6 - -
7 - -
8 Z1 20BK GROUND
PASSENGER SEATBELT TENSIONER - YELLOW 2 WAY
A R56 18LB/DG PASSENGER SEATBELT TENSIONER LINE 1
B R54 18LB/YL PASSENGER SEATBELT TENSIONER LINE 2
POWER OUTLET - BLACK 3 WAY
2 - -
3 Z1 16BK GROUND
POWER SEAT MOTORS - BLACK 6 WAY
1 P17 14RD/LB SEAT HORIZONTAL REARWARD SWITCH SENSE
2 P19 14YL/LG SEAT FRONT UP SWITCH SENSE
3 P11 14YL/WT SEAT REAR UP SWITCH SENSE
4 P15 14YL/LB SEAT HORIZONTAL FORWARD SWITCH SENSE
5 P21 14RD/LG SEAT FRONT DOWN SWITCH SENSE
6 P13 14RD/WT SEAT REAR DOWN SWITCH SENSE
POWER SEAT SWITCH - BLACK 14 WAY
A A4 12BK/PK FUSED B(+)
B Z1 12BK GROUND
C - -
D - -
E P21 14RD/LG SEAT FRONT DOWN SWITCH SENSE
F - -
G - -
H - -
I - -
J P19 14YL/LG SEAT FRONT UP SWITCH SENSE
K P15 14YL/LB SEAT HORIZONTAL FORWARD SWITCH SENSE
L P17 14RD/LB SEAT HORIZONTAL REARWARD SWITCH SENSE
M P13 14RD/WT SEAT REAR DOWN SWITCH SENSE
N P11 14YL/WT SEAT REAR UP SWITCH SENSE
POWER STEERING PRESSURE SWITCH (2.5L/4.7L) - BLACK 2 WAY
1 Z1 18BK GROUND
2 K10 18DB/OR STEERING PRESSURE SWITCH SENSE
POWERTRAIN CONTROL MODULE C1 (2.5L) - BLACK 32 WAY
1 - -
3 - -
5 - -
6 - -
7 K19 16BK/GY IGNITION COIL NO. 1 DRIVER
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/OR STEERING PRESSURE SWITCH SENSE
13 - -
14 - -
15 K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL
17 K7 18OR 5V SUPPLY
18 K44 16TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
POWERTRAIN CONTROL MODULE C1 (2.5L) - BLACK 32 WAY
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
26 - -
28 - -
29 - -
30 - -
POWERTRAIN CONTROL MODULE C1 (3.9L/4.7L/5.9L) - BLACK 32 WAY
1 K93 16TN/OR (4.7L) COIL DRIVER NO. 3
3 K94 16TN/LG (4.7L) COIL DRIVER NO. 4
5 K96 16TN/LB (4.7L) COIL DRIVER NO. 6
6 T41 18BK/WT (A/T) PARK/NEUTRAL POSITION SWITCH SENSE (T41)
7 K19 16BK/GY COIL DRIVER NO. 1
9 K98 16LB/RD (4.7L) COIL DRIVER NO. 8
10 K60 18YL/BK (3.9L/5.9L) IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT (3.9L/5.9L) IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/OR (4.7L) STEERING PRESSURE SWITCH SENSE
13 - -
14 - -
15 K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL
17 K7 18OR 5V SUPPLY
18 K44 18TN/YL (3.9L/5.9L) CAMSHAFT POSITION SENSOR SIGNAL
18 K44 16TN/YL (4.7L) CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/RD (3.9L/5.9L) IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK (3.9L/5.9L) IDLE AIR CONTROL NO. 4 DRIVER
21 K95 16TN/DG (4.7L) COIL DRIVER NO. 5
28 - -
30 - -
POWERTRAIN CONTROL MODULE C2 (2.5L) - WHITE 32 WAY
1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO .1 DRIVER
6 - -
7 - -
8 - -
9 - -
10 K20 18DG GENERATOR FIELD
11 - -
12 - -
13 - -
14 - -
17 C24 18DB/PK RADIATOR FAN RELAY CONTROL
18 - -
20 - -
21 - -
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 - -
26 - -
28 - -
29 - -
30 - -
32 - -
POWERTRAIN CONTROL MODULE C2 (3.9L/4.7L/5.9L) - WHITE 32 WAY
1 T34 18GY/BK (3.9L/5.9L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
2 K26 18VT (4.7L/5.9L) FUEL INJ ECTOR NO. 7 DRIVER
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
7 K17 16DB/TN (4.7L) COIL DRIVER NO. 7
8 K88 18VT/WT (A/T 3.9L/5.9L) VARIABLE FORCE SOLENOID CONTROL
9 K92 16TN/PK (4.7L) COIL DRIVER NO. 2
10 K20 18DB (3.9L/5.9L) GENERATOR FIELD
10 K20 18DG (4.7L) GENERATOR FIELD
11 K54 18OR/BK (A/T 3.9L/5.9L) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 K58 18BR/DB FUEL INJ ECTOR NO. 6 DRIVER
13 K28 18GY/LB (4.7L/5.9L) FUEL INJ ECTOR NO. 8 DRIVER
14 - -
17 C24 18DB/PK RADIATOR FAN RELAY CONTROL
18 - -
POWERTRAIN CONTROL MODULE C2 (3.9L/4.7L/5.9L) - WHITE 32 WAY
20 - -
21 T60 18BR (A/T 3.9L/5.9L) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 G60 18GY/YL (4.7L) ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 T13 18DB/BK (A/T 3.9L/5.9L) SPEED SENSOR GROUND
26 - -
27 G7 20DB (3.9L/5.9L) VEHICLE SPEED SENSOR SIGNAL
27 G7 18WT/OR (4.7L) VEHICLE SPEED SENSOR SIGNAL
28 T14 18LG/WT (A/T 3.9L/5.9L) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/RD (A/T 3.9L/5.9L) GOVERNOR PRESSURE SIGNAL
30 K30 18PK (3.9L/5.9L) TRANSMISSION CONTROL RELAY CONTROL
32 - -
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2 - -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 - -
8 K100 18VT/WT OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18DG/BK OXYGEN SENSOR DOWNSTREAM HEATER RELAY
CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD SPEED CONTROL SUPPLY
13 T10 18YL/DG (2.5L/4.7L) TORQUE MANAGEMENT REQUEST SENSE
13 T6 18OR/WT (3.9L/5.9L) OVERDRIVE OFF SWITCH SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K200 18VT/OR OXYGEN SENSOR RELAY DRIVER
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
21 - -
22 C20 18BR A/C SWITCH SENSE
23 - -
26 K226 18DB/WT FUEL PUMP RELAY CONTROL
28 - -
29 D20 18LG SCI RECEIVE
31 - -
RADIATOR FAN MOTOR - BLACK 2 WAY
1 C25 10LG HIGH SPEED FAN RELAY OUTPUT
2 Z1 10BK GROUND
RADIO C1 - GRAY 7 WAY
1 - -
2 X85 18LG/DG (BASE RADIO) AMPLIFIED LEFT DOOR SPEAKER (-)
2 X55 20BR/RD (PREMIUM RADIO) LEFT FRONT SPEAKER (-)
3 X80 18LB/BK (BASE RADIO) AMPLIFIED RIGHT DOOR SPEAKER (-)
3 X56 20DB/RD (PREMIUM RADIO) RIGHT FRONT SPEAKER (-)
6 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
RADIO C2 - BLACK 7 WAY
1 X60 20DG/RD RADIO 12V OUTPUT
2 X93 18WT/RD (BASE RADIO) AMPLIFIED LEFT REAR SPEAKER (+)
2 X51 20BR/YL (PREMIUM RADIO) LEFT REAR SPEAKER (+)
3 X94 18TN/VT (BASE RADIO) AMPLIFIED RIGHT REAR SPEAKER (+)
3 X52 20DB/WT (PREMIUM RADIO) RIGHT REAR SPEAKER (+)
4 X87 18LG/VT (BASE RADIO) AMPLIFIED LEFT DOOR SPEAKER (+)
4 X53 20DG (PREMIUM RADIO) LEFT FRONT SPEAKER (+)
5 X82 18LB/VT (BASE RADIO) AMPLIFIED RIGHT DOOR SPEAKER (+)
5 X54 20VT (PREMIUM RADIO) RIGHT FRONT SPEAKER (+)
6 X91 18WT/BK (BASE RADIO) AMPLIFIED LEFT REAR SPEAKER (-)
6 X57 20BR/LB (PREMIUM RADIO) LEFT REAR SPEAKER (-)
7 X92 18TN/BK (BASE RADIO) AMPLIFIED RIGHT REAR SPEAKER (-)
7 X58 20DB/OR (PREMIUM RADIO) RIGHT REAR SPEAKER (-)
RADIO C3 - NATURAL 2 WAY
2 - -
REAR WHEEL SPEED SENSOR - BLACK 2 WAY
1 B114 20WT/VT REAR WHEEL SPEED SENSOR (-)
2 B113 20RD/VT REAR WHEEL SPEED SENSOR (+)
RECIRCULATION DOOR ACTUATOR - GRAY 2 WAY
1 C32 20GY/DB RECIRCULATION DOOR DRIVER
RIGHT BACK-UP LAMP - GRAY 3 WAY
1 Z1 20BK GROUND
2 - -
RIGHT FOG LAMP - BLACK 2 WAY
A Z1 18BK GROUND
B L39 18LB FOG LAMP RELAY OUTPUT
RIGHT FRONT DOOR SPEAKER (BASE) - BLACK 3 WAY
2 - -
RIGHT FRONT DOOR TWEETER (MIDLEVEL/PREMIUM) - NATURAL 2 WAY
RIGHT FRONT DOOR WOOFER (MIDLEVEL/PREMIUM) - BLACK 3 WAY
2 - -
RIGHT FRONT PARK/TURN SIGNAL LAMP NO. 1 - BLACK 3 WAY
3 Z1 20BK GROUND
RIGHT FRONT PARK/TURN SIGNAL LAMP NO. 2 - BLACK 3 WAY
3 Z1 20BK GROUND
RIGHT FRONT SIDE MARKER LAMP - 2 WAY
2 Z1 20BK GROUND
RIGHT FRONT WHEEL SPEED SENSOR - LT. GRAY 2 WAY
1 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT HEADLAMP - BLUE 3 WAY
A L44 18VT/WT FUSED RIGHT LOW BEAM OUTPUT
B Z1 18BK GROUND
C L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
RIGHT LICENSE LAMP - BLACK 2 WAY
1 Z1 18BK GROUND
RIGHT REAR DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
2 Z2 20BK/LG GROUND
RIGHT REAR DOOR POWER LOCK MOTOR/AJ AR SWITCH (PREMIUM) - BLACK 4 WAY
2 Z2 20BK/LG GROUND
RIGHT REAR POWER WINDOW MOTOR - BLACK 2 WAY
1 Q24 14DG RIGHT REAR WINDOW DRIVER (DOWN)
2 Q14 14GY RIGHT REAR WINDOW DRIVER (UP)
RIGHT REAR POWER WINDOW SWITCH - BLUE 6 WAY
1 Q14 14GY RIGHT REAR WINDOW DRIVER (UP)
2 Q28 14DG/WT MASTER WINDOW SWITCH RIGHT REAR (DOWN)
3 - -
RIGHT REAR POWER WINDOW SWITCH - BLUE 6 WAY
4 Q18 14GY/BK MASTER WINDOW SWITCH RIGHT REAR (UP)
5 Q24 14DG RIGHT REAR WINDOW DRIVER (DOWN)
RIGHT REAR SPEAKER - BLACK 3 WAY
1 X94 18TN/VT AMPLIFIED RIGHT REAR SPEAKER (+)
2 - -
3 X92 18TN/BK AMPLIFIED RIGHT REAR SPEAKER (-)
RIGHT REMOTE RADIO SWITCH (PREMIUM) - 2 WAY
2 Z2 22BK/LG GROUND
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY
RIGHT TAIL/STOP/TURN SIGNAL LAMP - BLACK 3 WAY
1 Z1 20BK GROUND
3 L632 16DG/BR RIGHT REAR TURN SIGNAL
SEAT BELT SWITCH - GRAY 2 WAY
1 Z2 20BK/LG GROUND
2 G13 20DB/RD SEAT BELT INDICATOR DRIVER
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
1 - -
3 - -
SHIFT BEZEL LAMP - BLACK 2 WAY
1 Z1 20BK GROUND
SPEED CONTROL SERVO (EXCEPT 2.5L) - BLACK 4 WAY
1 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD BRAKE LAMP SWITCH OUTPUT
4 Z1 18BK GROUND
THROTTLE POSITION SENSOR - GRAY 3 WAY
1 K4 18BK/LB (2.5L) SENSOR GROUND
1 K7 18OR (3.9L/4.7L/5.9L) 5V SUPPLY
3 K4 18BK/LB (3.9L/4.7L/5.9L) 5V SUPPLY
3 K7 18OR (2.5L) SENSOR GROUND
TRAILER TOW CONNECTOR - BLACK 7 WAY
1 Z1 14BK GROUND
2 B40 14LB TRAILER TOW BRAKE B(+)
3 L207 18BK/OR TRAILER TOW RELAY OUTPUT
4 Y203 16RD/TN FUSED B(+)
5 L63 18DG/RD LEFT TURN SIGNAL
6 L62 18BK/PK RIGHT TURN SIGNAL
TRANSFER CASE CONTROL MODULE C1 - BLACK 16 WAY
A1 D25 18VT/YL PCI BUS
A2 - -
A3 - -
A4 Y122 20DG/BR 4WD LOW INDICATOR
A5 Y123 20DG/OR 4WD HIGH INDICATOR
A6 Y120 20YL/DG MODE SELECT
A7 Y119 18YL/TN MODE SENSOR GROUND
A8 Z1 18BK GROUND
B1 - -
B2 - -
B3 - -
B4 Y121 20YL/LG NEUTRAL INDICATOR
B5 Y187 20PK/GY DEFAULT INDICATOR
B6 Y112 18YL/BR MODE SENSOR D
B7 - -
B8 Z2 18BK/LG GROUND
TRANSFER CASE CONTROL MODULE C2 - GRAY 16 WAY
A1 Y114 18YL/VT 5 VOLT SELECTOR SWITCH SUPPLY
A2 Y113 18YL/OR MODE SENSOR A
A3 - -
A4 - -
A5 - -
A6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
A7 - -
A8 Y117 18YL/DB 5 VOLT MODE SENSOR SUPPLY
B1 - -
B2 Y115 18YL/WT MODE SENSOR C
B3 - -
B4 - -
B5 - -
B6 - -
B7 - -
B8 Y118 20YL/LB 5 VOLT SELECTOR SWITCH SUPPLY
TRANSFER CASE CONTROL MODULE C3 - BLACK 4 WAY
A Z1 16BK GROUND
B A34 16LB/RD FUSED B(+)
C Y124 16DG/VT SHIFT MOTOR CONTROL A
D Y125 16DG/WT SHIFT MOTOR CONTROL B
TRANSFER CASE MODE SENSOR - BLACK 6 WAY
A Y119 18YL/TN MODE SENSOR GROUND
B Y113 18YL/OR MODE SENSOR A
C Y115 18YL/WT MODE SENSOR C
D Y114 18YL/VT MODE SENSOR B
E Y117 18YL/DB 5 VOLT MODE SENSOR SUPPLY
F Y112 18YL/BR MODE SENSOR D
TRANSFER CASE SELECTOR SWITCH - BLACK 12 WAY
1 Y118 20YL/LB 5 VOLT SELECTOR SWITCH SUPPLY
2 Y187 20PK/GY DEFAULT INDICATOR
3 - -
4 Y121 20YL/LG NEUTRAL INDICATOR
5 Y120 20YL/DG MODE SELECT
8 Y122 20DG/BR 4WD LOW INDICATOR
9 Y123 20DG/OR 4WD HIGH INDICATOR
10 - -
11 Z1 20BK GROUND
12 - -
TRANSFER CASE SHIFT MOTOR - BLACK 2 WAY
A Y124 16DG/VT SHIFT MOTOR CONTROL A
B Y125 16DG/WT SHIFT MOTOR CONTROL B
TRANSMISSION CONTROL MODULE (4.7L) - BLACK 60 WAY
1 T1 18LG/BK TRS T1 SENSE
2 T4 18PK/OR TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
15 T15 18LG TRANSMISSION RELAY CONTROL
16 T16 18RD TRANSMISSION CONTROL RELAY OUTPUT
18 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T120 18LG LR/CC SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T39 18GY/LB LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
37 Z13 16BK/RD GROUND
38 T38 18VT/TN 5V SUPPLY
40 T140 18VT/LG MS SOLENOID CONTROL
41 T41 16YL TRS T41 SENSE
42 T42 18VT/WT TRS T42 SENSE
44 - -
45 - -
46 D22 20PK/BK SCI RECEIVE
47 T47 18YL/BK 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z113 16BK GROUND
54 T54 20VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
TRANSMISSION CONTROL MODULE (4.7L) - BLACK 60 WAY
55 T59 18PK UNDERDRIVE SOLENOID CONTROL
56 F84 16YL/WT FUSED B(+)
58 - -
59 T159 18DG/WT 4C SOLENOID CONTROL
60 T60 18BR 3-4 SHIFT SOLENOID CONTROL
TRANSMISSION RANGE SENSOR (3.9L/5.9L A/T) - BLACK 6 WAY
2 Y193 20WT/LG TRANS RANGE SENSOR MUX
3 - -
5 Y128 20DG/GY TRANS RANGE SENSOR 5V SUPPLY
TRANSMISSION SOLENOID/TRS ASSEMBLY (4.7L) - BLACK 23 WAY
2 T120 18LG LR/CC SOLENOID CONTROL
4 T41 16YL TRS T41 SENSE
5 T42 18VT/WT TRS T42 SENSE
7 T60 18BR 3-4 SHIFT SOLENOID CONTROL
8 T3 18VT TRS T3 SENSE
9 T1 18LG/BK TRS T1 SENSE
11 T48 18DB 4C PRESSURE SWITCH SENSE
12 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
13 T4 18PK/OR TRS T4 SENSE
14 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
15 T47 18YL/BK 2C PRESSURE SWITCH SENSE
16 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
17 T59 18PK UNDERDRIVE SOLENOID CONTROL
18 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
19 T159 18DG/WT 4C SOLENOID CONTROL
20 T119 18WT/DB 2C SOLENOID CONTROL
21 T140 18VT/LG MS SOLENOID CONTROL
23 T54 20VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
TRANSMISSION SOLENOID ASSEMBLY (3.9L/5.9L) - BLACK 8 WAY
4 T25 18LG/RD GOVERNOR PRESSURE SIGNAL
5 K88 18VT/WT GOVERNOR PRESSURE SOLENOID CONTROL
6 T60 18BR OVERDRIVE SOLENOID CONTROL
7 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T34 18GY/BK TRANSMISSION TEMPERATURE SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - GRAY 2 WAY
1 Z1 18BK GROUND
2 G29 18BK/TN WASHER FLUID SWITCH SENSE
8W-90 CONNECTOR/GROUND LOCATIONS
TABLE OF CONTENTS
page
CONNECTOR/GROUND LOCATIONS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND
LOCATIONS
DESCRIPTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng com-
ponent and connector l ocati ons i n the vehi cl e. A con-
nector i ndex i s provi ded. Use the wi ri ng di agrams i n
each secti on for connector i denti fi cati on. Refer to the
i ndex for the proper fi gure number. For i tems that
are not shown i n thi s secti on N/S i s pl aced i n the
Fi g. col umn.
Connector Name/Number Color Location Fig.
A/C Compressor Clutch BK Side of A/C Compressor, Rear of A/C
Compressor
10, 11, 14, 17
A/C Heater Control - C1 BK At HVAC Control 30
A/C Heater Control - C2 BK At HVAC Control 30
A/C Low Pressure Switch GN Right Rear of Engine Compartment 7, 19
A/C Pressure Transducer BK Right Fender Side Shield 1
Airbag Control Module YL Lower Center of Instrument Panel 31, 32, 33
Ambient Temperature
Sensor
BK Radiator Top Support 1
Amplifier-C1 WT Right Side of Instrument Panel 30, 32
Amplifier-C2 WT Right Side of Instrument Panel 30, 32
Automatic Day/Night Mirror BK Top of Windshield 38
Back-Up Lamp Switch BK Side of Transmission 20, 21, 22, 23
Base Overhead Console Headliner N/S
Battery Temperature Sensor BK At Battery 2
Blend Door Actuator Right Center of Instrument Panel N/S
Blower Motor BK Upper Center of Instrument Panel N/S
Blower Motor Resistor Block BK Upper Center of Instrument Panel N/S
Brake Lamp Switch BK Lower Left of Instrument Panel 31
Brake Pressure Switch BK At Anti-Lock Brake Controller 8
C105 BK Right Fender Side Shield 1, 7, 19
C106 NAT Left Fender Side Shield N/S
C107 (4.7L) Left Fender Side Shield N/S
C108 (2.5L) Side of Transmission 20
C126 BL Lower Left of Instrument Panel 5
C200 BK Lower Left of Instrument Panel 5, 6, 31, 32
C201 Right Side of Instrument Panel N/S
C202 Upper Center of Instrument Cluster 30, 32
AN 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1
C246 Lower Left of Instrument Panel 31, 38
C248 BK Under Driver Seat 40
C301 BK Between Front Seats 40
C323 BK Rear of Frame 41
C325 BK At Tail Lamp 41, 42
C329 BK Near Cargo Lamps N/S
C341 BK Trailer Tow Wiring 41
C352 BK Frame Ground Left Fender 4, 41
C360 BK Left Inner Fender 41
C361 NAT Near Right Front Door Hinge 36, 40
C362 BK Near Right Front Door Hinge 36, 40
C363 BK Near Left Front Door Hinge 36, 40
C364 (2 Door) NAT Near Left Front Door Hinge 36, 40
C364 (4 Door) BK Near Left Front Door Hinge N/S
C365 BK Near Left Rear Door Hinge 37, 40
C366 BK Near Right Rear Door Hinge 40
Camshaft Position Sensor GY At Distributor, Right Front of Engine 10, 13, 18
Capacitor BK Left Side of Engine 19
Cargo Lamp No. 1 BK At Lamp N/S
Cargo Lamp No. 2 BK At Lamp N/S
Center Console Lamp In Center of Console N/S
Center High Mounted Stop
Lamp
BK Headliner N/S
Center Power Outlet In Center of Console N/S
Central Timer Module-C1 Right Side of Instrument Panel 32
Central Timer Module-C2 Right Side of Instrument Panel 40
Central Timer Module-C3 GY Right Side of Instrument Panel N/S
Cigar Lighter NAT Upper Center of Instrument Panel 30
Clockspring-C1 Steering Column 31, 34
Clockspring-C2 Steering Column 31, 34
Clockspring-C3 BK Steering Column N/S
Clockspring-C4 Steering Column N/S
Clutch Interlock Switch
(M/T)
GN Left Side of Instrument Panel 6
Clutch Interlock Switch
Jumper (A/T)
BK Left Side of Instrument Panel 6
Coil On Plug No.1 BK Left Side of Engine 16
Coil On Plug No.2 BK Right Side of Engine 17
8W - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS AN
CONNECTOR/GROUND LOCATIONS (Continued)
Combination Flasher BK Lower Left Side of Instrument Panel 31, 32
Controller Antilock Brake-C1 BK At Antilock Brake Controller 8
Controller Antilock Brake-C2 BK At Antilock Brake Controller 8
Crankshaft Position Sensor
(2.5L)
BK Rear of Engine 9
(4.7L)
BK Rear of Engine 17
(A/T 3.9L/5.9L)
BK Rear of Engine 13
(M/T 3.9L/5.9L)
NAT Rear of Engine 13
Data Link Connector BK Lower Left of Instrument Panel 31, 32
Diagnostic Junction Port BK Lower Left of Instrument Panel 31, 32
Dome Lamp BK Headliner N/S
Driver Airbag YL Steering Column N/S
Driver Cylinder Lock Switch BK Driver Door 36
Driver Door Ajar Switch BK Driver Door Jamb N/S
Driver Door Module-C1 BL Driver Door 36
Driver Door Module-C2 BL Driver Door 36
Driver Door Power Lock
Motor/Ajar Switch (Premium)
BK Driver Door 36
Driver Door Power Window
Motor
BK Driver Door 36
Driver Power Mirror Driver Door 36
Driver Seatbelt Tensioner Pillar Between Driver Doors N/S
Duty Cycle Evap/Purge
Solenoid
GY Rear of Engine Compartment 2, 7, 19
Engine Coolant Temperature
Sensor (2.5L/3.9L/5.9L)
BK At Thermostat Housing 9, 13
Engine Coolant Temperature
Sensor (4.7L)
BK At Thermostat Housing 18
Engine Oil Pressure Sensor BK Right Front of Engine 10, 13, 16
Evaporator Temperature
Sensor
BK Upper Center of Instrument Cluster N/S
Front Washer Pump Motor BK At Washer Fluid Reservoir 1
Front Wiper Motor BK At Motor 4
Fuel Injector No. 1 BK At Injector 9, 11, 14, 16
Fuel Injector No. 5 BK At Injector 11, 14, 16
Fuel Injector No. 6 BK At Injector 12, 15, 17
Fuel Injector No. 7 BK At Injector 14, 16
Fuel Injector No. 8 BK At Injector 15, 17
Fuel Pump Module LTGY At Fuel Tank 41
G100 Right Front of Engine Compartment N/S
G102 Left Inner Fender 4
G105 Top Rear of Valve Cover, Right Front
of Engine
9, 18
G110 Left Front Inner Fender N/S
G111 Engine Ground 11, 14, 16
G112 Right Fender Side Shield 1
G113 Near Battery 2
G115 Right Fender Side Shield 7, 19
G201 Lower Center of Instrument Panel 31, 32, 33
G205 Right Side Instrument Panel 30, 32
G207 Lower Center of Instrument Panel 31, 32, 33
G208 Right Side Instrument Panel 32
G305 Frame Ground Left Fender 4, 41
G307 Near T/O to Seatbelt Switch 40
Generator BK At Generator 10, 12, 15, 16
Glove Box Lamp and Switch BK Upper Center of Instrument Panel 30, 32
Headlamp Switch BK Left Side of Instrument Panel 31
Heater Control BK At HVAC Control N/S
High Note Horn BK Left Front Inner Fender 1
Idle Air Control Motor
(3.9L/5.9L)
BK At Throttle Body 11, 14
Idle Air Control Motor
(2.5L/4.7L)
GY At Throttle Body 9, 16
Ignition Coil LT GY Near Distributor, Right Front of
Engine
10, 12, 15
Ignition Switch BK Steering Column 31, 34
Input Speed Sensor Left Side of Transmission 27, 28
Instrument Cluster-C1 GY At Instrument Cluster 31
Instrument Cluster-C2 BK At Instrument Cluster 31
Intake Air Temperature
Sensor
GY At Throttle Body, Right Top of Intake
Manifold
9, 12, 15, 16
Joint Connector No. 1 Power Distribution Center N/S
Joint Connector No. 2 Power Distribution Center N/S
Joint Connector No. 3 Left Side Instrument Panel N/S
Joint Connector No. 4 Near Steering Column 30, 32
Junction Block-C1 At Junction Block 5
Junction Block-C3 At Junction Block N/S
Junction Block-C6 GN At Junction Block 35
Junction Block-C7 BK At Junction Block 35
Junction Block-C8 BR At Junction Block 35
Junction Block-C9 BL At Junction Block 35
Junction Block-C10 LTGY At Junction Block 35
Junction Block-C12 OR At Junction Block 35
Key-in Switch GY Steering Column N/S
Leak Detection Pump BK Near Battery 2, 8
Left Back-Up Lamp BK At Lamp 42
Left Front Door Speaker Left Door N/S
Left Front Door Tweeter NAT Left Door 36
Left Front Door Woofer Left Door 36
Left Fog Lamp WT At Lamp 1
Left Front Park/Turn Signal
Lamp No.1
BK At Lamp N/S
Left Front Park/Turn Signal
Lamp No.2
BK At Lamp N/S
Left Front Side Marker
Lamp
At Lamp N/S
Left Front Wheel Speed
Sensor
LT GY Near Brake Controller 2, 8
Left Headlamp BL At Lamp N/S
Left License Lamp BK At Lamp N/S
Left Rear Door Ajar Switch
(Base)
BK Rear Door N/S
BK Rear Door 37
Left Rear Speaker Left Door 37, 39
Left Rear Door Power
Window Motor
BK Left Door 37
Left Rear Door Power
Window Switch
BL Left Door 37
Left Remote Radio Switch Steering Column N/S
Left Speed Control Switch WT Steering Column N/S
Left Tail/Stop/Turn Signal
Lamp
BK At Lamp 42
License Lamp At Lamp N/S
Line Pressure Sensor Right Side of Transmission 27, 29
Low Note Horn BK At Horn 1
Manifold Absolute Pressure
Sensor
BK On Throttle Body 9, 11, 14, 18
Mode Door Actuator Right Center of Instrument Panel N/S
Multi-Function Switch GY At Steering Column 31, 34
Output Speed Sensor BK Under Transmission, Left Side of
Transmission
25, 26, 27, 28
Overdrive Switch NAT At Steering Column 31, 34
Overhead Console Headliner 38
Oxygen Sensor 1/1
Upstream
BK At Oxygen Sensor 20, 21, 22, 23, 25, 26, 27,
28
Oxygen Sensor 1/2
Downstream
BK At Oxygen Sensor 20, 21, 22, 23, 25, 26, 27,
28
Oxygen Sensor 2/1
Upstream
BK At Oxygen Sensor 21, 22, 24, 25, 26, 27, 29
Oxygen Sensor 2/2
Downstream
BK At Oxygen Sensor 21, 22, 24, 25, 26, 27, 29
Park Brake Switch Left Side of Instrument Panel 38
Passenger Airbag YL Right Center of Instrument Panel 30
Passenger Airbag On/Off
Switch
Instrument Panel 30
Passenger Door Ajar Switch
(Base)
BK Passenger Door N/S
Passenger Lock Cylinder
Switch
LTGY Passenger Door N/S
Switch
NAT Passenger Door N/S
Passenger Door Power
Window Motor
Passenger Door Power
Window Switch
BL Passenger Door N/S
Passenger Power Mirror Passenger Door N/S
Passenger Seatbelt
Tensioner
Pillar Between Passenger Doors N/S
Power Mirror Switch Driver Door 36
Power Outlet BK Upper Center of Instrument Panel 30, 32
Power Seat Motors BK Under Seat N/S
Power Seat Switch At Switch N/S
Power Steering Pressure
Switch
BK Near Power Steering Pump 9, 16
Powertrain Control
Module-C1
BK At Powertrain Control Module 7
Powertrain Control
Module-C2
WT At Powertrain Control Module 7
Powertrain Control
Module-C3
GY At Powertrain Control Module 1, 7
Radiator Fan Motor BK Below Radiator 1
Radio-C1 GY Upper Center of Instrument Panel 30
Radio-C2 BK Upper Center of Instrument Panel 30
Radio-C3 NAT Upper Center of Instrument Panel 30
Radio Case Ground Upper Center of Instrument Panel 30
Rear Wheel Speed Sensor BK At Rear Axle 41
Rear Window Defogger
Switch
BK Upper Center of Instrument Panel N/S
Recirculation Door Actuator Right Center of Instrument Panel N/S
Right Back-Up Lamp BK At Lamp N/S
Right Front Door Speaker Right Door N/S
Right Front Door Tweeter NAT Right Door N/S
Right Front Door Woofer Right Door N/S
Right Fog Lamp WT At Lamp 1
Right Front Park/Turn Signal
Lamp No.1
BK At Lamp 3
Right Front Park/Turn Signal
Lamp No.2
BK At Lamp 3
Right Front Side Marker
Lamp
At Lamp 3
Right Front Wheel Speed
Sensor
LTGY Right Fender Side Shield 1
Right Headlamp BL At Lamp 3
Right License Lamp BK At Lamp N/S
Right Rear Door Ajar Switch
(Base)
BK Right Rear Door N/S
Right Rear Door Power
Lock Motor/Ajar Switch
(Premium)
Right Rear Speaker BK Right Door N/S
Right Rear Power Window
Motor
Right Rear Power Window
Switch
BL Right Rear Door N/S
Right Remote Radio Switch Steering Column N/S
Right Speed Control Switch WT Steering Column N/S
Right Tail Stop/Turn Signal
Lamp
BK At Lamp N/S
Seatbelt Switch NAT Near Left Rear Speaker, at Seatbelt
Switch
39, 40
Sentry Key Immobilizer
Module
BK On Steering Column 31
Shift Bezel Lamp Lower Center of Instrument Panel 30, 32
Speed Control Servo BK Right Fender Side Shield 1
Throttle Position Sensor
(3.9L/5.9L)
GY On Throttle Body 11, 14
(2.5L)
NAT On Throttle Body 9
(4.7L)
GY On Throttle Body 16
Trailer Tow Connector BK Rear of Frame N/S
Transfer Case Control
Module-C1
Right Side of Steering Column N/S
Module-C2
Module-C3
Transfer Case Mode Sensor BK Side of Transmission 23, 26, 28
Transfer Case Selector
Switch
BK Center of Instrument Panel at Switch 30
Transfer Case Shift Motor BK Side of Transmission 23, 26, 28
Transmission Control
Module
BK Right Front of Engine Compartment N/S
Transmission Range Sensor BK On Transmission 25, 26
Transmission Solenoid
Assembly
BK Left Side of Transmission 25, 26
Transmission Solenoid/TRS
Assembly
BK Left Side of Transmission 27, 28
Washer Fluid Level Switch GY At Washer Fluid Reservoir 1
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Fig. 3 RIGHT FENDER AREA
Fig. 4 LEFT FENDER AREA
Fig. 5 KICK PANEL AREAS
Fig. 6 ENGINE COMPARTMENT TO DASH
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Fig. 9 ENGINE LEFT SIDE 2.5L
Fig. 10 ENGINE RIGHT SIDE 2.5L
Fig. 13 ENGINE REAR 3.9L
Fig. 18 ENGINE CONNECTORS FRONT 4.7L
Fig. 19 RIGHT REAR ENGINE COMPARTMENT CONNECTORS
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Fig. 21 MANUAL TRANSMISSION CONNECTORS 3.9L
Fig. 22 MANUAL TRANSMISSION 4.7L (4X2)
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Fig. 27 AUTOMATIC TRANSMISSION 4.7L (4X2)
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Fig. 33 AIRBAG CONTROL MODULE
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Fig. 35 JUNCTION BLOCK CONNECTORS
Fig. 36 FRONT DOOR CONNECTORS
Fig. 37 REAR DOOR CONNECTORS
Fig. 38 LEFT FRONT BODY WIRING
Fig. 39 CAB WIRING
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Fig. 42 TAIL LAMPS
8W-95 SPLICE LOCATIONS
TABLE OF CONTENTS
page
SPLICE LOCATIONS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPLICE LOCATIONS
DESCRIPTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for proper spl i ce number. For spl i ces that are
not shown i n the fi gures N/S appears i n the Fi g. col -
umn.
Splice No. Location Fig.
S100 Near Power Distribution Center N/S
S101 (2.5L) Near T/O for Injector 3 1
S101 (3.9L, 5.9L) Rear of Engine N/S
S101 (4.7L) Near T/O for Injector 7 N/S
S103 (2.5L) Rear of Engine 1
S103 (3.9L, 4.7L, 5.9L) Rear of Engine 3, 6
S106 (2.5L) Rear of Engine 2
S106 (3.9L, 5.9L) Near Inj #4 4
S107 (2.5L) Rear of Engine N/S
S107 (3.9L, 5.2L) Rear of Engine N/S
S107 (4.7L) Right Rear of Engine N/S
S110 Near Inj #5 T/O 3, 5
S121 Near Mode Door Motor N/S
S122 Rear of Engine N/S
S123 Right Rear of Engine 2, 6
S126 In T/O for Controller Anti-Lock Brakes 12
S134 Right Rear of Engine 6
S135 Near Powertrain Control Module N/S
S141 Near Battery N/S
S177 Right Rear of Engine N/S
S178 Near Transmission Control Module N/S
S179 Right Rear of Engine 6
S181 Near Injector 3 T/O 7
S183 Near Injector 6 T/O 7
AN 8W-95 SPLICE LOCATIONS 8W - 95 - 1
Splice No. Location Fig.
S184 In Wiring Trough 7
S187 Near Power Distribution Center N/S
S207 In Steering Wheel Jumper N/S
S208 In Steering Wheel Jumper N/S
S240 Between Instrument Cluster T/Os 8
S300 Near T/O for Tweeter 13
S301 Front of Left Door N/S
S302 Near T/O for CTM 10
S306 Near Fuel Tank T/O 11
S314 Near T/O for Tail Lamps 11
S316 Left Rear Frame Rail 11
S318 Left Rear Frame Rail 11
S322 Left A Post 9
S323 Left A-Pillar 9
S324 Left A Post 9
S327 Near T/O for Speaker 13
S328 Near T/O for Speaker N/S
S401 In Tail Lamp Harness N/S
S404 In Tail Lamp Harness N/S
S405 Near RT License Lamp N/S
S406 Near RT License Lamp N/S
8W - 95 - 2 8W-95 SPLICE LOCATIONS AN
SPLICE LOCATIONS (Continued)
Fig. 1 LEFT SIDE ENGINE HARNESS SPLICES 2.5L
Fig. 2 RIGHT SIDE ENGINE HARNESS SPLICES 2.5L
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Fig. 9 A-PILLAR SPLICES
Fig. 10 CAB SPLICES
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Fig. 13 FRONT DOOR SPLICES
8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CIGAR LIGHTER OUTLET
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CIRCUIT BREAKER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CIRCUIT BREAKER/SEAT . . . . . . . . . . . . . . . . . 4
CIRCUIT BREAKER/WINDOW . . . . . . . . . . . . . . 4
GENERATOR CARTRIDGE FUSE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IOD FUSE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
JUNCTION BLOCK
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
POWER DISTRIBUTION CENTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER OUTLET
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER OUTLET . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RELAY CENTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REAR POWER OUTLET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
POWER DISTRIBUTION
DESCRIPTION
Thi s group covers the vari ous standard and
opti onal power di stri buti on components used on thi s
model . The power di stri buti on system for thi s vehi cl e
consi sts of the fol l owi ng components:
Power Di stri buti on Center (PDC)
Juncti on Bl ock (JB)
Rel ay and Fuse Bl ock.
The power di stri buti on system al so i ncorporates
vari ous types of ci rcui t control and protecti on fea-
tures, i ncl udi ng:
Automati c resetti ng ci rcui t breakers
Bl ade-type fuses
Cartri dge fuses
Ci rcui t spl i ce bl ocks
Fl ashers
Rel ays.
components i n the power di stri buti on system. See the
i nformati on on the features and use of al l of the
power di stri buti on system components. Refer to the
i ndex i n thi s servi ce manual for the l ocati on of com-
pl ete ci rcui t di agrams for the vari ous power di stri bu-
ti on system components.
OPERATION
The power di stri buti on system for thi s vehi cl e i s
desi gned to provi de safe, rel i abl e, and central i zed di s-
tri buti on poi nts for the el ectri cal current requi red to
operate al l of the many standard and opti onal facto-
ry-i nstal l ed el ectri cal and el ectroni c powertrai n,
chassi s, safety, securi ty, comfort and conveni ence sys-
tems. At the same ti me, the power di stri buti on sys-
tem was desi gned to provi de ready access to these
el ectri cal di stri buti on poi nts for the vehi cl e techni -
ci an to use when conducti ng di agnosi s and repai r of
faul ty ci rcui ts. The power di stri buti on system can
al so prove useful for the sourci ng of addi ti onal el ec-
tri cal ci rcui ts that may be requi red to provi de the
el ectri cal current needed to operate many accessori es
that the vehi cl e owner may choose to have i nstal l ed
i n the aftermarket.
CIGAR LIGHTER OUTLET
DESCRIPTION
A ci gar l i ghter i s standard equi pment on thi s
model . The ci gar l i ghter i s i nstal l ed i n the i nstru-
ment panel l ower bezel , whi ch i s l ocated near the
center of the i nstrument panel , bel ow the radi o (Fi g.
1). The ci gar l i ghter base i s secured by a snap fi t
wi thi n the i nstrument panel l ower bezel .
The ci gar l i ghter knob and heati ng el ement uni t,
and the ci gar l i ghter receptacl e uni t are avai l abl e for
servi ce. These components cannot be repai red and, i f
faul ty or damaged, they must be repl aced.
OPERATION
The ci gar l i ghter consi sts of two major components:
a knob and heati ng el ement uni t, and the ci gar
l i ghter base or receptacl e shel l . The receptacl e shel l
i s connected to ground, and an i nsul ated contact i n
the bottom of the shel l i s connected to battery cur-
rent. The ci gar l i ghter recei ves battery vol tage from a
fuse i n the juncti on bl ock onl y when the i gni ti on
swi tch i s i n the Accessory or On posi ti ons.
The knob and heati ng el ement are encased wi thi n
a spri ng-l oaded housi ng, whi ch al so features a sl i di ng
protecti ve heat shi el d. When the knob and heati ng
el ement are i nserted i n the receptacl e shel l , the heat-
i ng el ement resi stor coi l i s grounded through i ts
housi ng to the receptacl e shel l . I f the ci gar l i ghter
knob i s pushed i nward, the heat shi el d sl i des up
toward the knob exposi ng the heati ng el ement, and
the heati ng el ement extends from the housi ng toward
the i nsul ated contact i n the bottom of the receptacl e
shel l .
Two smal l spri ng-cl i p retai ners are l ocated on
ei ther si de of the i nsul ated contact i nsi de the bottom
of the receptacl e shel l . These cl i ps engage and hol d
the heati ng el ement agai nst the i nsul ated contact
l ong enough for the resi stor coi l to heat up. When the
heati ng el ement i s engaged wi th the contact, battery
current can fl ow through the resi stor coi l to ground,
causi ng the resi stor coi l to heat.
When the resi stor coi l becomes suffi ci entl y heated,
excess heat radi ates from the heati ng el ement caus-
i ng the spri ng-cl i ps to expand. Once the spri ng-cl i ps
expand far enough to rel ease the heati ng el ement,
the spri ng-l oaded housi ng forces the knob and heat-
i ng el ement to pop back outward to thei r rel axed
posi ti on. When the ci gar l i ghter knob and el ement
are pul l ed out of the receptacl e shel l , the protecti ve
heat shi el d sl i des downward on the housi ng so that
the heati ng el ement i s recessed and shi el ded around
i ts ci rcumference for safety.
CIGAR LIGHTER
For compl ete ci rcui t di agrams, refer to Cigar
Lighter i n the Component I ndex of Group 8W - Wi r-
i ng Di agrams.
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
INJURY.
(1) Check the fused i gni ti on swi tch output (run/ac-
cessory) fuse i n the juncti on bl ock. I f OK, go to Step
as requi red and repl ace the faul ty fuse.
output (run/accessory) fuse i n the juncti on bl ock. I f
OK, go to Step 3. I f not OK, repai r the open fused
i gni ti on swi tch output (run/accessory) ci rcui t to the
i gni ti on swi tch as requi red.
Remove the ci gar l i ghter knob and el ement from the
ci gar l i ghter receptacl e. Check for conti nui ty between
the i nsi de ci rcumference of the ci gar l i ghter recepta-
cl e and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 4. I f not OK, go to Step 5.
Check for battery vol tage at the i nsul ated contact
l ocated at the back of the ci gar l i ghter receptacl e. I f
OK, repl ace the faul ty ci gar l i ghter knob and el e-
ment. I f not OK, go to Step 5.
Fig. 1 Cigar Lighter and Power Outlet
1 - INSTRUMENT PANEL LOWER BEZEL
2 - CIGAR LIGHTER KNOB AND ELEMENT
3 - POWER OUTLET BASE AND MOUNT
4 - POWER OUTLET CAP
8W - 97 - 2 8W-97 POWER DISTRIBUTION AN
Remove the i nstrument panel l ower bezel . Check for
conti nui ty between the ground ci rcui t cavi ty of the
ci gar l i ghter wi re harness connector and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
6. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
vol tage at the fused i gni ti on swi tch output (run/ac-
cessory) ci rcui t cavi ty of the ci gar l i ghter wi re har-
ness connector. I f OK, repl ace the faul ty ci gar l i ghter
receptacl e. I f not OK, repai r the open fused i gni ti on
swi tch output (run/accessory) ci rcui t to the juncti on
bl ock fuse as requi red.
REMOVAL
INJURY.
cabl e.
(2) Remove the l ower bezel from the i nstrument
panel . Refer to Instrument Panel Lower Bezel i n
(3) Pul l the ci gar l i ghter knob and el ement out of
the ci gar l i ghter receptacl e base, or unsnap the pro-
tecti ve cap from the power outl et receptacl e base
(Fi g. 2).
(4) Look i nsi de the ci gar l i ghter or power outl et
receptacl e base and note the posi ti on of the rectangu-
l ar retai ni ng bosses of the mount that secures the
receptacl e base to the i nstrument panel l ower bezel
(Fi g. 3).
(5) I nsert a pai r of external snap ri ng pl i ers i nto
the ci gar l i ghter or power outl et receptacl e base and
engage the ti ps of the pl i ers wi th the retai ni ng
bosses of the mount.
(6) Squeeze the pl i ers to di sengage the mount
retai ni ng bosses from the receptacl e base and, usi ng
a gentl e rocki ng moti on, pul l the pl i ers and the
receptacl e base out of the mount.
(7) Remove the ci gar l i ghter or power outl et mount
from the i nstrument panel l ower bezel .
Fig. 3 Cigar Lighter and Power Outlet Remove/
Install - Typical
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
CIGAR LIGHTER OUTLET (Continued)
INSTALLATION
INJURY.
(1) I nstal l the ci gar l i ghter or power outl et mount
i nto the i nstrument panel l ower bezel .
(2) Al i gn the spl i nes on the outsi de of the ci gar
l i ghter or power outl et receptacl e base connector
receptacl e wi th the grooves on the i nsi de of the
mount.
(3) Press fi rml y on the ci gar l i ghter or power out-
l et receptacl e base unti l the retai ni ng bosses of the
mount are ful l y engaged i n thei r receptacl es.
(4) I nstal l the ci gar l i ghter knob and el ement i nto
the ci gar l i ghter receptacl e base, or the protecti ve cap
i nto the power outl et receptacl e base.
(5) I nstal l the l ower bezel onto the i nstrument
the procedures.
CIRCUIT BREAKER
DESCRIPTION
ti on bl ock i s used to protect the power seat system
ci rcui t. The ci rcui t breaker can protect the system
from a short ci rcui t, or from an overl oad condi ti on
caused by an obstructed or stuck seat adjuster.
faul ty or damaged, i t must be repl aced.
DESCRIPTION
ti on bl ock i s used to protect the power wi ndow sys-
tem ci rcui t. The ci rcui t breaker can protect the
system from a short ci rcui t, or from an overl oad con-
di ti on caused by an obstructed or stuck wi ndow gl ass
or regul ator.
faul ty, i t must be repl aced.
CIRCUIT BREAKER
For ci rcui t descri pti ons and di agrams, refer to
8W-63 - Power Seat i n Group 8W - Wi ri ng Di agrams.
(1) Locate the correct ci rcui t breaker i n the junc-
ti on bl ock. Pul l out the ci rcui t breaker sl i ghtl y, but
be certai n that the ci rcui t breaker termi nal s sti l l con-
tact the termi nal s i n the juncti on bl ock cavi ti es.
requi red.
CIRCUIT BREAKER
For ci rcui t descri pti ons and di agrams, refer to
8W-60 - Power Wi ndows i n Group 8W - Wi ri ng Di a-
grams.
(1) Locate the ci rcui t breaker i n the juncti on bl ock.
Pul l out the ci rcui t breaker sl i ghtl y, but be certai n
that the ci rcui t breaker termi nal s sti l l contact the
termi nal s i n the juncti on bl ock cavi ti es.
requi red. I f the ci rcui t breaker checks OK, but no
power wi ndows operate, see Power Wi ndow System
i n the Di agnosi s and Testi ng secti on of thi s group.
GENERATOR CARTRIDGE
FUSE
DESCRIPTION
A 140 ampere generator cartri dge fuse i s used on
thi s model . The generator cartri dge fuse i s si mi l ar to
other cartri dge fuses found i n the Power Di stri buti on
Center (PDC). Thi s fuse has a col or-coded pl asti c
housi ng and a cl ear pl asti c fuse conductor i nspecti on
cover l i ke other cartri dge fuses, but has a hi gher cur-
rent rati ng and i s connected and secured wi th screws
i nstead of bei ng pushed onto mal e spade-type termi -
nal s. The generator cartri dge fuse cannot be repai red
OPERATION
The generator cartri dge fuse i s secured between
the two B(+) termi nal stud connecti on bus bars
wi thi n the Power Di stri buti on Center (PDC). Thi s
fuse protects the vehi cl e el ectri cal system from dam-
age that coul d be caused by excessi ve chargi ng sys-
CIGAR LIGHTER OUTLET (Continued)
tem output and/or excessi ve el ectri cal system current
l evel s resul ti ng from a faul ty generator or faul ty
chargi ng system control ci rcui ts. I f the current rati ng
of the fuse i s exceeded, the fuse conductor mel ts to
open the generator output ci rcui t connecti on to the
PDC. I f a generator cartri dge fuse fai l s, be certai n to
compl etel y i nspect and test the vehi cl e chargi ng sys-
tem before repl aci ng the fuse and returni ng the vehi -
cl e to servi ce. Refer to Charging System i n the
i ndex of thi s servi ce manual for the chargi ng system
di agnosti c procedures. Refer to Power Distribution
compl ete PDC ci rcui t di agrams.
REMOVAL
I f a generator cartri dge fuse fai l s, be certai n to
i nspect and test the vehi cl e chargi ng system before
repl aci ng the cartri dge fuse and returni ng the vehi cl e
to servi ce. Refer to Charging Systemi n the i ndex of
thi s servi ce manual for the chargi ng system di agnos-
ti c procedures.
cabl e.
(2) Unl atch and remove the cover from the Power
Di stri buti on Center (PDC).
(3) Remove the two screws that secure the genera-
tor cartri dge fuse to the two B(+) termi nal stud bus
bars wi thi n the PDC.
(4) Remove the generator cartri dge fuse from the
PDC.
INSTALLATION
I f a generator cartri dge fuse fai l s, be certai n to
i nspect and test the vehi cl e chargi ng system before
repl aci ng the cartri dge fuse and returni ng the vehi cl e
to servi ce. Refer to Charging Systemi n the i ndex of
thi s servi ce manual for the chargi ng system di agnos-
ti c procedures.
(1) Posi ti on the generator cartri dge fuse onto the
two B(+) termi nal stud bus bars wi thi n the PDC.
the generator cartri dge fuse to the two B(+) termi nal
stud bus bars wi thi n the PDC. Ti ghten the screws to
3.4 Nm (30 i n. l bs.). Be certain that both screws
are tightened to the proper torque value.
(3) I nstal l and l atch the cover onto the PDC.
IOD FUSE
DESCRIPTION
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse (Fi g. 4) that i s di sconnected wi thi n
the Juncti on Bl ock (JB) when the vehi cl e i s shi pped
from the factory. Deal er personnel are to reconnect
the I OD fuse i n the JB as part of the preparati on
procedures performed just pri or to new vehi cl e del i v-
ery.
The l eft end of the i nstrument panel cover has a
snap-fi t fuse access panel that can be removed to pro-
vi de servi ce access to the fuses i n the JB. A fi nger
recess i s mol ded i nto the access panel for easy
removal . An adhesi ve-backed fuse l ayout map i s
secured to the i nstrument panel si de of the access
panel to ensure proper fuse i denti fi cati on. The I OD
fuse i s a 15 ampere mi ni bl ade-type fuse. The fuse i s
secured wi thi n a bl ack mol ded pl asti c fuse hol der
and pul l er uni t that serves both as a tool for di scon-
necti ng and reconnecti ng the fuse i n i ts JB cavi ty,
and as a fuse hol der that conveni entl y stores the fuse
i n the same JB cavi ty after i t has been di sconnected.
OPERATION
The term i gni ti on-off draw i denti fi es a normal con-
di ti on where power i s bei ng drai ned from the battery
wi th the i gni ti on swi tch i n the Off posi ti on. The I OD
fuse feeds the memory and sl eep mode functi ons for
some of the el ectroni c modul es i n the vehi cl e as wel l
as vari ous other accessori es that requi re battery cur-
rent when the i gni ti on swi tch i s i n the Off posi ti on,
i ncl udi ng the cl ock. The onl y reason the I OD fuse i s
di sconnected i s to reduce the normal I OD of the vehi -
cl e el ectri cal system duri ng new vehi cl e transporta-
ti on and pre-del i very storage to reduce battery
Fig. 4 Ignition-Off Draw Fuse - Typical
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
3 - LEFT INSTRUMENT PANEL END BRACKET
GENERATOR CARTRIDGE FUSE (Continued)
depl eti on, whi l e sti l l al l owi ng vehi cl e operati on so
that the vehi cl e can be l oaded, unl oaded and moved
as needed by both vehi cl e transportati on company
and deal er personnel .
The I OD fuse i s di sconnected from JB fuse cavi ty
12 when the vehi cl e i s shi pped from the assembl y
pl ant. Deal er personnel must reconnect the I OD fuse
when the vehi cl e i s bei ng prepared for del i very i n
order to restore ful l el ectri cal system operati on. Once
the vehi cl e i s prepared for del i very, the I OD functi on
of thi s fuse becomes transparent and the fuse that
has been assi gned the I OD desi gnati on becomes onl y
another Fused B(+) ci rcui t fuse. The I OD fuse serves
no useful purpose to the deal er techni ci an i n the ser-
vi ce or di agnosi s of any vehi cl e system or condi ti on,
other than the same purpose as that of any other
standard ci rcui t protecti on devi ce.
The I OD fuse can be used by the vehi cl e owner as
a conveni ent means of reduci ng battery depl eti on
when a vehi cl e i s to be stored for peri ods not to
exceed about thi rty days. However, i t must be
remembered that di sconnecti ng the I OD fuse wi l l not
el i mi nate I OD, but onl y reduce thi s normal condi ti on.
I f a vehi cl e wi l l be stored for more than about thi rty
days, the battery negati ve cabl e shoul d be di scon-
nected to el i mi nate normal I OD; and, the battery
shoul d be tested and recharged at regul ar i nterval s
duri ng the vehi cl e storage peri od to prevent the bat-
tery from becomi ng di scharged or damaged. Refer to
Battery i n the i ndex of thi s servi ce manual for the
l ocati on of addi ti onal servi ce i nformati on coveri ng
the battery.
REMOVAL
The I gni ti on-Off Draw (I OD) fuse i s di sconnected
from Juncti on Bl ock (JB) fuse cavi ty 12 (Fi g. 5) when
the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must reconnect the I OD fuse when
the vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on.
NOTE: When removing or installing the IOD fuse, it
is important that the ignition switch be in the Off
position. Failure to place the ignition switch in the
Off position can cause the radio display to become
scrambled when the IOD fuse is installed. Remov-
ing and installing the IOD fuse again with the igni-
tion switch in the Off position will usually correct
the scrambled radio display condition.
REMOVAL
(2) Remove the fuse access panel by unsnappi ng i t
from the l eft outboard end of the i nstrument panel .
(3) Grasp the upper and l ower tabs of the I OD
fuse hol der uni t i n fuse cavi ty 12 of the JB between
the thumb and forefi nger and pul l the uni t fi rml y
outward.
(4) I nstal l the fuse access panel by snappi ng i t
onto the l eft outboard end of the i nstrument panel .
INSTALLATION
The I gni ti on-Off Draw (I OD) fuse i s di sconnected
from Juncti on Bl ock (JB) fuse cavi ty 12 (Fi g. 5) when
the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must reconnect the I OD fuse when
the vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on.
from the l eft outboard end of the i nstrument panel .
(3) To i nstal l the I OD fuse, use a thumb to press
the I OD fuse hol der uni t i n fuse cavi ty 12 fi rml y i nto
the JB.
J UNCTION BLOCK
DESCRIPTION
An el ectri cal Juncti on Bl ock (JB) i s conceal ed
behi nd the l eft outboard end of the i nstrument panel
cover (Fi g. 6). The JB serves to si mpl i fy and central -
i ze numerous el ectri cal components, and to di stri bute
Fig. 5 Ignition-Off Draw Fuse - Typical
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
3 - LEFT INSTRUMENT PANEL END BRACKET
IOD FUSE (Continued)
el ectri cal current to many of the accessory systems i n
the vehi cl e. I t al so el i mi nates the need for numerous
spl i ce connecti ons and serves i n pl ace of a bul khead
connector between many of the engi ne compartment,
i nstrument panel , and body wi re harnesses. The JB
houses up to ni neteen bl ade-type fuses (two stan-
dard-type and seventeen mi ni -type), up to two bl ade-
type automati c resetti ng ci rcui t breakers, and two
I nternati onal Standards Organi zati on (I SO) rel ays
(one standard-type and one mi cro-type).
The mol ded pl asti c JB housi ng has i ntegral mount-
i ng brackets that are secured wi th two screws to the
l eft i nstrument panel end bracket. The l eft end of the
i nstrument panel cover has a snap-fi t fuse access
panel that can be removed for servi ce of the JB. A
fuse pul l er and spare fuse hol ders are l ocated on the
back of the fuse access cover, as wel l as an adhesi ve-
backed fuse l ayout map to ensure proper fuse i denti -
fi cati on.
The JB uni t cannot be repai red and i s onl y ser-
vi ced as an assembl y. I f any i nternal ci rcui t or the JB
housi ng i s faul ty or damaged, the enti re JB uni t
must be repl aced.
OPERATION
Al l of the ci rcui ts enteri ng and l eavi ng the JB do
so through up to ni ne wi re harness connectors, whi ch
are connected to the JB through i ntegral connector
receptacl es mol ded i nto the JB housi ng. I nternal con-
necti on of al l of the JB ci rcui ts i s accompl i shed by an
i ntri cate combi nati on of hard wi ri ng and bus bars.
Refer to J unction Block i n the i ndex of thi s servi ce
manual for the l ocati on of compl ete JB ci rcui t di a-
grams.
REMOVAL
INJURY.
cabl e.
from the l eft outboard end of the i nstrument panel
(Fi g. 7).
(3) Reach through the i nstrument panel fuse
access panel openi ng to access and remove the one
screw that secures the Juncti on Bl ock (JB) to the l eft
i nstrument panel end bracket.
from the i nstrument panel . Refer to Steering Col-
umn Opening Cover i n the i ndex of thi s servi ce
manual for the l ocati on of the steeri ng col umn open-
i ng cover removal procedures.
(5) Reach through the outboard si de of the i nstru-
ment panel steeri ng col umn openi ng to access and
di sconnect al l of the wi re harness connectors from
the JB connector receptacl es (Fi g. 8).
Fig. 6 Junction Block Location
1 - FUSE ACCESS PANEL
2 - JUNCTION BLOCK
Fig. 7 Fuse Access Panel Remove/Install
3 - SCREW
J UNCTION BLOCK (Continued)
remove the rel ay and fuse bl ock from the JB. Push
the rel ay and fuse bl ock towards the l eft end of the
i nstrument panel to di sengage i ts mounti ng sl ots
from the tabs on the JB.
remove the one screw that secures the JB to the l eft
i nstrument panel end bracket.
ment panel steeri ng col umn openi ng to remove the
JB from the l eft i nstrument panel end bracket.
INSTALLATION
INJURY.
NOTE: If the Junction Block (JB) is being replaced
with a new unit, be certain to transfer each of the
fuses, circuit breakers and relays from the faulty JB
to the proper cavities of the replacement JB. Refer
to Junction Block in the index of this service man-
ual for the location of complete circuit diagrams
and cavity assignments for the JB.
ment panel steeri ng col umn openi ng to posi ti on the
JB onto the l eft i nstrument panel end bracket.
ment panel steeri ng col umn openi ng to i nstal l and
ti ghten the one screw that secures the JB to the l eft
i nstrument panel end bracket. Ti ghten the screw to
2.2 Nm (20 i n. l bs.).
i nstal l the rel ay and fuse bl ock onto the JB by engag-
i ng the rel ay and fuse bl ock mounti ng sl ots wi th the
tabs on the JB.
reconnect al l of the wi re harness connectors to the
JB connector receptacl es.
(5) I nstal l the steeri ng col umn openi ng cover onto
the i nstrument panel . Refer to Steering Column
Opening Cover i n the i ndex of thi s servi ce manual
for the l ocati on of the steeri ng col umn openi ng cover
i nstal l ati on procedures.
(6) Reach through the i nstrument panel fuse
access panel openi ng to i nstal l and ti ghten the one
screw that secures the juncti on bl ock to the l eft
i nstrument panel end bracket. Ti ghten the screw to
2.2 Nm (20 i n. l bs.).
POWER DISTRIBUTION
CENTER
DESCRIPTION
Al l of the el ectri cal current di stri buted throughout
thi s vehi cl e i s di rected through the standard equi p-
ment Power Di stri buti on Center (PDC) (Fi g. 9). The
mol ded pl asti c PDC housi ng i s l ocated i n the l eft
front corner of the engi ne compartment, just behi nd
the battery. The PDC houses the generator cartri dge
fuse and up to ten maxi -type cartri dge fuses, whi ch
repl ace al l i n-l i ne fusi bl e l i nks. The PDC al so houses
up to seven bl ade-type mi ni fuses, up to thi rteen
I nternati onal Standards Organi zati on (I SO) rel ays
(one standard-type and twel ve mi cro-type), two joi nt
connectors (one si xteen-way and one twenty-si x-way)
and a si xteen-way engi ne wi re harness i n-l i ne con-
nector.
Fig. 8 Junction Block Remove/Install
1 - JUNCTION BLOCK
3 - SCREW
4 - CONNECTORS
J UNCTION BLOCK (Continued)
The PDC housi ng i s secured i n the engi ne compart-
ment at three poi nts. I ntegral mounts on the front
and i nboard si des of the PDC housi ng engage and
l atch to stanchi ons that are i ntegral to the mol ded
pl asti c battery tray. An i ntegral bracket on the rear
of the PDC housi ng i s secured wi th a screw to the
top of the l eft front i nner wheel house. The PDC
housi ng has a mol ded pl asti c cover that i ncl udes two
i ntegral l atches, one on each si de. The PDC cover i s
easi l y opened and removed for servi ce access and has
a conveni ent fuse and rel ay l ayout map i ntegral to
the i nsi de surface of the cover to ensure proper com-
ponent i denti fi cati on.
The PDC uni t cannot be repai red and i s onl y ser-
vi ced as a uni t wi th the headl amp and dash wi re
harness. I f the i nternal ci rcui ts or the PDC housi ng
are faul ty or damaged, the headl amp and dash wi re
harness uni t must be repl aced.
OPERATION
Al l of the current from the battery and the gener-
ator output enters the PDC through one cabl e wi th
eyel ets that are secured wi th a nut to the one B(+)
termi nal stud l ocated just i nsi de the i nboard si de of
the PDC housi ng. The PDC cover i s unl atched and
removed to access the battery and generator output
connecti on B(+) termi nal studs, the fuses, the rel ays,
the joi nt connectors and the engi ne wi re harness i n-
l i ne connector. I nternal connecti on of al l of the PDC
ci rcui ts i s accompl i shed by an i ntri cate combi nati on
of hard wi ri ng and bus bars. Refer to Power Distri-
bution i n the i ndex of thi s servi ce manual for the
l ocati on of compl ete PDC ci rcui t di agrams.
REMOVAL
The Power Di stri buti on Center (PDC) i s servi ced
as a uni t wi th the headl amp and dash wi re harness.
I f any i nternal ci rcui t of the PDC or the PDC hous-
i ng i s faul ty or damaged, the enti re PDC and head-
l amp and dash wi re harness uni t must be repl aced.
cabl e.
(2) Di sconnect each of the headl amp and dash wi re
harness connectors. Refer to Connector Locations
i n the Wi ri ng Secti on of thi s servi ce manual for the
l ocati on of more i nformati on on the headl amp and
dash wi re harness connector l ocati ons.
(3) Remove al l of the fasteners that secure each of
the headl amp and dash wi re harness ground eyel ets
to the vehi cl e body and chassi s components. Refer to
Connector Locations i n the i ndex of thi s servi ce
ground eyel et l ocati ons.
(4) Di sengage each of the retai ners that secure the
headl amp and dash wi re harness to the vehi cl e body
and chassi s components. Refer to Connector Loca-
tions i n the i ndex of thi s servi ce manual for the l oca-
ti on of more i nformati on on the headl amp and dash
wi re harness retai ner l ocati ons.
(5) Unl atch and remove the cover from the PDC.
(6) Di sconnect the engi ne wi re harness i n-l i ne con-
nector from the PDC connector receptacl e.
(7) Sl i de the engi ne wi re harness retai ner cl i p
upward and di sengage the harness from the trough
on the rear of the PDC housi ng.
(8) Remove the nut that secures the eyel et of the
battery negati ve cabl e generator output take out to
the rearward B(+) termi nal stud i n the PDC and
remove the eyel et from the stud.
(9) Remove the nut that secures the eyel et of the
battery posi ti ve cabl e PDC take out to the B(+) ter-
mi nal stud i n the PDC and remove the eyel et from
the stud.
(10) Remove the screw that secures the PDC hous-
i ng to the l eft front fender wheel housi ng.
(11) Di sengage the l atches for the two PDC
mounts and l i ft the uni t off of the battery tray stan-
chi ons.
(12) Remove the PDC and the headl amp and dash
wi re harness from the engi ne compartment as a uni t.
INSTALLATION
The Power Di stri buti on Center (PDC) i s servi ced
as a uni t wi th the headl amp and dash wi re harness.
I f any i nternal ci rcui t of the PDC or the PDC hous-
i ng i s faul ty or damaged, the enti re PDC and head-
l amp and dash wi re harness uni t must be repl aced.
Fig. 9 Power Distribution Center Location - Typical
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
POWER DISTRIBUTION CENTER (Continued)
NOTE: If the PDC is being replaced with a new unit,
be certain to transfer each of the blade-type fuses,
cartridge fuses and relays from the faulty PDC to
the proper cavities of the replacement PDC. Refer
to Power Distribution in the index of this service
manual for the location of complete PDC circuit dia-
grams and cavity assignments.
(1) Posi ti on the PDC and the headl amp and dash
wi re harness uni t i n the engi ne compartment.
(2) I nstal l the two PDC mounts onto the two stan-
chi ons of the battery tray.
PDC housi ng to the l eft front fender wheel housi ng.
Ti ghten the screw to 7.9 Nm (70 i n. l bs.).
(4) I nstal l the eyel et of the battery posi ti ve cabl e
PDC take out onto the forward B(+) termi nal stud i n
the PDC.
eyel et of the battery posi ti ve cabl e PDC take out to
the forward B(+) termi nal stud i n the PDC. Ti ghten
the nut to 9 Nm (80 i n. l bs.).
(6) I nstal l the eyel et of the battery negati ve cabl e
generator output take out onto the rearward B(+) ter-
mi nal stud i n the PDC.
eyel et of the battery negati ve cabl e generator output
take out to the rearward B(+) termi nal stud i n the
PDC. Ti ghten the nut to 9 Nm (80 i n. l bs.).
(8) Engage the engi ne wi re harness i n the trough
on the back of the PDC housi ng and secure i t wi th
the retai ner cl i p.
(9) Reconnect the engi ne wi re harness i n-l i ne con-
nector to the PDC i n-l i ne connector receptacl e.
(10) I nstal l and l atch the cover onto the PDC.
(11) Engage each of the retai ners that secure the
headl amp and dash wi re harness to the vehi cl e body
and chassi s components. Refer to Connector Loca-
wi re harness retai ner l ocati ons.
(12) I nstal l al l of the fasteners that secure each of
the headl amp and dash wi re harness ground eyel ets
to the vehi cl e body and chassi s components. Refer to
Connector Locations i n the i ndex of thi s servi ce
ground eyel et l ocati ons.
(13) Reconnect each of the headl amp and dash
wi re harness connectors. Refer to Connector Loca-
wi re harness connector l ocati ons.
POWER OUTLET
DESCRIPTION
An accessory power outl et i s opti onal equi pment on
thi s model . The power outl et i s i nstal l ed i n the
i nstrument panel l ower bezel , whi ch i s l ocated near
the center of the i nstrument panel , bel ow the radi o.
The power outl et base i s secured by a snap fi t wi thi n
the i nstrument panel l ower bezel . A pl asti c protecti ve
cap snaps i nto the power outl et base when the power
outl et i s not bei ng used, and hangs from the power
outl et base mount by an i ntegral bai l strap whi l e the
power outl et i s i n use.
The power outl et receptacl e uni t and the accessory
power outl et protecti ve cap are avai l abl e for servi ce.
The power outl et receptacl e cannot be repai red and,
OPERATION
The power outl et base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The power outl et recei ves battery vol tage from a fuse
i n the Power Di stri buti on Center (PDC) at al l ti mes.
Whi l e the power outl et i s very si mi l ar to a ci gar
l i ghter base uni t, i t does not i ncl ude the two smal l
spri ng-cl i p retai ners i nsi de the bottom of the recepta-
cl e shel l that are used to secure the ci gar l i ghter
heati ng el ement to the i nsul ated contact.
POWER OUTLET
For compl ete ci rcui t di agrams, refer to Power
Outlet i n the Component I ndex of Group 8W - Wi r-
i ng Di agrams.
INJURY.
(1) Check the fused B(+) fuse i n the Power Di stri -
buti on Center (PDC). I f OK, go to Step 2. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse.
i n the PDC. I f OK, go to Step 3. I f not OK, repai r the
open fused B(+) ci rcui t to the battery as requi red.
(3) Remove the pl asti c protecti ve cap from the
power outl et receptacl e. Check for conti nui ty between
the i nsi de ci rcumference of the power outl et recepta-
POWER DISTRIBUTION CENTER (Continued)
cl e and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 4. I f not OK, go to Step 5.
(4) Check for battery vol tage at the i nsul ated con-
tact l ocated at the back of the power outl et recepta-
cl e. I f not OK, go to Step 5.
cabl e. Remove the i nstrument panel l ower bezel .
i ty of the power outl et wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 6. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
(6) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
power outl et wi re harness connector. I f OK, repl ace
the faul ty power outl et receptacl e. I f not OK, repai r
the open fused B(+) ci rcui t to the PDC fuse as
requi red.
REMOVAL
INJURY.
cabl e.
(Fi g. 10).
(Fi g. 11).
Fig. 11 Cigar Lighter and Power Outlet Remove/
Install - Typical
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
POWER OUTLET (Continued)
INSTALLATION
INJURY.
mount.
the procedures.
RELAY CENTER
DESCRIPTION
The rel ay and fuse bl ock i s snap fi t onto mounti ng
tabs l ocated on the end of the Juncti on Bl ock (JB)
nearest to the dash panel , under the l eft outboard
end of the i nstrument panel (Fi g. 12). The rel ay and
fuse bl ock provi des addi ti onal capaci ty for di stri bu-
ti on and control of el ectri cal current for some of the
accessory systems that are uni que to thi s vehi cl e,
and whi ch coul d not be accommodated by the JB or
the Power Di stri buti on Center (PDC). The rel ay and
fuse bl ock has cavi ti es for up to four addi ti onal
bl ade-type mi ni fuses, the el ectroni c combi nati on
fl asher, and three addi ti onal I nternati onal Standards
Organi zati on rel ays (one standard-type and two
mi cro-type).
The rel ay and fuse bl ock components are accessed
for servi ce by removi ng the steeri ng col umn openi ng
cover from the i nstrument panel . The rel ay and fuse
bl ock i s then di sengaged from the JB mounti ng tabs
and pul l ed out from under the i nstrument panel . Ser-
vi ce repl acement of the rel ay and fuse bl ock uni t
requi res i nstrument panel assembl y removal .
The rel ay and fuse bl ock uni t cannot be repai red
and i s onl y servi ced as a uni t wi th the i nstrument
panel wi re harness assembl y. I f the rel ay and fuse
bl ock housi ng or i ts i nternal ci rcui ts are faul ty or
damaged, the enti re i nstrument panel wi re harness
uni t must be repl aced.
OPERATION
The rel ay and fuse bl ock i s i ntegral to the i nstru-
ment panel wi re harness, and al l ci rcui ts enteri ng or
l eavi ng thi s modul e do so through the i nstrument
panel wi re harness. I nternal connecti on of al l of the
rel ay and fuse bl ock ci rcui ts i s accompl i shed by hard
wi ri ng. Refer to Fuse/Fuse Block i n the i ndex of
thi s servi ce manual for the l ocati on of compl ete ci r-
cui t di agrams and cavi ty assi gnments for the rel ay
and fuse bl ock.
REMOVAL
The rel ay and fuse bl ock i s servi ced as a uni t wi th
the i nstrument panel wi re harness. I f any i nternal
ci rcui t of the rel ay and fuse bl ock or the rel ay and
fuse bl ock housi ng i s faul ty or damaged, the enti re
i nstrument panel wi re harness uni t must be
repl aced.
Fig. 12 Relay and Fuse Block Location
1 - JUNCTION BLOCK
2 - RELAY AND FUSE BLOCK
POWER OUTLET (Continued)
INJURY.
cabl e.
(2) Remove the i nstrument panel assembl y from
the dash panel . Refer to Instrument Panel Assem-
bly i n the i ndex of thi s servi ce manual for the i nstru-
ment panel assembl y removal procedures.
(3) Di sconnect each of the i nstrument panel wi re
more i nformati on on the i nstrument panel wi re har-
ness connector l ocati ons.
(4) Remove al l of the fasteners that secure each of
the i nstrument panel wi re harness ground eyel ets to
the i nstrument panel components. Refer to Connec-
tor Locations i n the i ndex of thi s servi ce manual
for the l ocati on of more i nformati on on the ground
eyel et l ocati ons.
(5) Di sengage each of the retai ners that secure the
i nstrument panel wi re harness to the i nstrument
panel components. Refer to Connector Locations i n
the i ndex of thi s servi ce manual for the l ocati on of
ness retai ner l ocati ons.
(6) Push the rel ay and fuse bl ock towards the l eft
end of the i nstrument panel to di sengage i ts mount-
i ng sl ots from the tabs on the Juncti on Bl ock (JB)
(Fi g. 13) .
(7) Remove the rel ay and fuse bl ock and the
i nstrument panel wi re harness from the i nstrument
panel as a uni t.
INSTALLATION
The rel ay and fuse bl ock i s servi ced as a uni t wi th
the i nstrument panel wi re harness. I f any i nternal
ci rcui t of the rel ay and fuse bl ock or the rel ay and
fuse bl ock housi ng i s faul ty or damaged, the enti re
i nstrument panel wi re harness uni t must be
repl aced.
INJURY.
NOTE: If the relay and fuse block is being replaced
with a new unit, be certain to transfer each of the
fuses, the flasher and the relays from the faulty
relay and fuse block to the proper cavities of the
replacement relay and fuse block. Refer to Fuse/
Fuse Block in the index of this service manual for
the location of complete relay and fuse block circuit
diagrams and cavity assignments.
(1) Posi ti on the rel ay and fuse bl ock and the
i nstrument panel wi re harness onto the i nstrument
panel .
(2) I nstal l the rel ay and fuse bl ock by engagi ng i ts
mounti ng sl ots onto the tabs on the Juncti on Bl ock
(JB).
(3) Engage each of the retai ners that secure the
i nstrument panel wi re harness to the i nstrument
panel components. Refer to Connector Locations i n
the i ndex of thi s servi ce manual for the l ocati on of
Fig. 13 Relay and Fuse Block Remove/Install
1 - JUNCTION BLOCK
2 - RELAY AND FUSE BLOCK
RELAY CENTER (Continued)
ness retai ner l ocati ons.
(4) I nstal l al l of the fasteners that secure each of
the i nstrument panel wi re harness ground eyel ets to
the i nstrument panel components. Refer to Connec-
tor Locations i n the i ndex of thi s servi ce manual
for the l ocati on of more i nformati on on the ground
eyel et l ocati ons.
(5) Reconnect each of the i nstrument panel wi re
ness connector l ocati ons.
(6) I nstal l the i nstrument panel assembl y onto the
dash panel . Refer to Instrument Panel Assembly
the i nstrument panel assembl y i nstal l ati on proce-
dures.
REAR POWER OUTLET
REMOVAL
INJURY.
cabl e.
(Fi g. 10).
(Fi g. 11).
INSTALLATION
INJURY.
mount.
the procedures.
RELAY CENTER (Continued)
ENGINE
TABLE OF CONTENTS
page page
ENGINE 2. 5L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE 3. 9L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ENGINE 4. 7L. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ENGINE 5. 9L. . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
ENGINE 2.5L
TABLE OF CONTENTS
page page
ENGINE 2.5L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE DIAGNOSIS - INTRODUCTION. . . . . . . 3
ENGINE DIAGNOSIS - PERFORMANCE . . . . . . 4
ENGINE DIAGNOSIS - MECHANICAL. . . . . . . . . 6
ENGINE DIAGNOSIS - LUBRICATION . . . . . . . . 8
CYLINDER COMPRESSION PRESSURE . . . . . . 8
CYLINDER COMBUSTION PRESSURE
LEAKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FORM-IN-PLACE GASKETS AND SEALERS. . . . 9
REPAIR DAMAGED OR WORN THREADS . . . . 10
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . . 10
CYLINDER BORE HONING. . . . . . . . . . . . . . . . 11
ENGINE CORE AND OIL GALLERY PLUGS . . . 11
ENGINE GASKET SURFACE PREPARATION . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CYLINDER HEAD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . 20
VALVE GUIDE WEAR - MEASURING . . . . . . . . 21
VALVE GUIDE SERVICE. . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CYLINDER HEAD COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ROCKER ARMS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VALVE TIMING VERIFICATION. . . . . . . . . . . . . 26
REFACING VALVES AND SEATS . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
VALVE SPRINGS
VALVE SPRING - TESTING . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGINE BLOCK
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CONNECTING ROD BEARINGS
CONNECTING ROD BEARING - FITTING. . . . . 32
CRANKSHAFT
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
AN ENGINE 9 - 1
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CRANKSHAFT MAIN BEARINGS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CRANKSHAFT MAIN BEARINGS - FITTING . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT OIL SEAL - FRONT
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HYDRAULIC LIFTERS (CAM IN BLOCK)
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PISTON & CONNECTING ROD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
PISTON RINGS
PISTON RING FITTING . . . . . . . . . . . . . . . . . . 46
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
LUBRICATION
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . . 51
ENGINE OIL LEAKS . . . . . . . . . . . . . . . . . . . . . 51
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . 53
OIL
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INTAKE MANIFOLD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
EXHAUST MANIFOLD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
VALVE TIMING
CHECKING TIMING CHAIN WEAR . . . . . . . . . . 60
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9 - 2 ENGINE 2. 5L AN
ENGINE 2.5L
DESCRIPTION
The 2.5 l i ter (150 CI D) four-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Thi s engi ne i s desi gned for unl eaded fuel . The
engi ne cyl i nder head has dual quench-type combus-
ti on chambers that create turbul ence and fast burn-
i ng of the ai r/fuel mi xture. Thi s resul ts i n good fuel
economy.
The cyl i nders are numbered 1 through 4 from front
to rear. The fi ri ng order i s 1-3-4-2 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n fi ve mai n beari ngs and the camshaft rotates
wi thi n four beari ngs.
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.3 and No.4 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (8 = 1998).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (HX = A 2.5 l i ter (150 CI D) 9.1:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
FOR EXAMPLE: Code * 801HX23 * i denti fi es a
2.5 l i ter (150 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 9.1:1 compressi on rati o and bui l t on
January 23, 1998.
DIAGNOSIS AND TESTING ENGINE
DIAGNOSIS - INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther
mechani cal (e.g., a strange noi se), or performance
(e.g., engi ne i dl es rough and stal l s).
(Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG - Preformance) or (Refer to 9 - ENGI NE - DI AG-
NOSI S AND TESTI NG - Mechani cal ). Refer to 14 -
FUEL SYSTEM for fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can-
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng:
Cyl i nder Compressi on Pressure Test (Refer to 9 -
ENGI NE - DI AGNOSI S AND TESTI NG)
Cyl i nder Combusti on Pressure Leakage Test
(Refer to 9 - ENGI NE - DI AGNOSI S AND TESTI NG)
Cyl i nder Head Gasket Fai l ure Di agnosi s (Refer
to 9 - ENGI NE/CYLI NDER HEAD - DI AGNOSI S
AND TESTI NG)
I ntake Mani fol d Leakage Di agnosi s (Refer to 9 -
ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
DI AGNOSI S AND TESTI NG)
Lash Adjuster (Tappet) Noi se Di agnosi s (Refer to
9 - ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FT-
ERS (CAM I N BLOCK) - DI AGNOSI S AND TEST-
I NG)
Engi ne Oi l Leak I nspecti on (Refer to 9 - ENGI NE/
LUBRI CATI ON - DI AGNOSI S AND TESTI NG)
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
1 - NO. 4 CYLINDER
2 - NO. 3 CYLINDER
3 - DAY
4 - MONTH
5 - YEAR
6 - MACHINED SURFACE
AN ENGINE 2. 5L 9 - 3
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTGASOLINE ENGINES
ENGINE WILL NOT
CRANK
1. Weak or dead battery 1. Charge/Replace Battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE).
Check charging system. (Refer to 8 -
ELECTRICAL/CHARGING -
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/starter
connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to 8 -
ELECTRICAL/STARTING - DIAGNOSIS
AND TESTING)
4. Seized accessory drive component 4. Remove accessory drive belt and
attempt to start engine. If engine starts,
repair/replace seized component.
5. Engine internal mechanical failure or
hydro-static lock
5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT
WILL NOT START
1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s) and
driver circuits. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL PUMP
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE -
ENGINE LOSS OF
POWER
1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark plugs 3. Clean plugs and set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer to 9
- ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
ENGINE 2.5L (Continued)
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/IGNITION COIL -
REMOVAL).
ENGINE STALLS OR
ROUGH IDLE
1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/THROTTLE BODY -
REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer
to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap spark
plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
5. Spark plug cables defective or
crossed
5. Check for correct firing order or
replace spark plug cables. (Refer to 8 -
SPARK PLUG CABLE - DIAGNOSIS
AND TESTING)
6. Faulty coil 6. Test and replace, if necessary (Refer
REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket and
vacuum hoses (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD -
ENGINE MISSES ON
ACCELERATION
plugs
1. Replace spark plugs or clean and set
gap. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
crossed
2. Replace or rewire secondary ignition
cables. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
CABLE - REMOVAL)
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary (Refer
REMOVAL)
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust oil
level by draining or adding as needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok, Perform
oil pressure test. (Refer to 9 - ENGINE/
LUBRICATION - DIAGNOSIS AND
TESTING) for engine oil pressure
test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic tappets/lash
adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms and
replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and replace
as necessary
9. Excessive runout of valve seats or
valve faces
9. Grind valves and seats
CONNECTING ROD
NOISE
1. Insufficient oil supply 1. Check engine oil level.
TESTING) engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity. (Refer
to 9 - ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE) for correct
procedure/engine oil specifications
4. Excessive connecting rod bearing
clearance
Measure bearings for correct clearance
with plasti-gage. Repair as necessary
5. Connecting rod journal out of round 5. Replace crankshaft or grind journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
TESTING)
3. Thin or diluted oil 3. Change oil to correct viscosity.
4. Excessive main bearing clearance 4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing for
excessive wear on flanges
6. Crankshaft main journal out of round
or worn
6. Grind journals or replace crankshaft
7. Loose flywheel or torque converter 7. Inspect crankshaft, flexplate/flywheel
and bolts for damage. Tighten to correct
torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean and
reinstall
8. Oil pump suction tube loose, broken,
bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or cracked 9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated gaskets 1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup plug 4. Remove and reseal threaded plug.
Replace cup style plug
EXCESSIVE OIL
CONSUMPTION OR
SPARK PLUGS OIL
FOULED
1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE EMISSIONS
- DESCRIPTION) for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end gap
and side clearance. Replace if
necessary
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.
(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary.
3. Crankshaft seal flange.
Scratched, nicked or grooved.
3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan.
5. Timing chain cover seal,
damaged or misaligned.
5. Replace seal.
6. Scratched or damaged vibration
damper hub.
6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit.
3. Low oil pressure. 3. Check pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter.
5. Worn oil pump. 5. Replace as necessary.
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Clean or replace relief valve.
9. Oil pump suction tube loose or
damaged.
9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING
1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.
DIAGNOSIS AND TESTING CYLINDER
COMPRESSION PRESSURE
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se, the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sconnect the i gni ti on coi l .
(5) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(6) Record the compressi on pressure on the thi rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
(Refer to 9 - ENGI NE - SPECI FI CATI ONS) for the
correct engi ne compressi on pressures.
COMBUSTION PRESSURE LEAKAGE
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng)
Leaks between adjacent cyl i nders or i nto water
jacket
Any causes for combusti on/compressi on pressure
l oss
WARNING: DO NOT REMOVE THE RADIATOR CAP
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
Start and operate the engi ne unti l i t attai ns nor-
mal operati ng temperature, then turn OFF the
engi ne.
Remove the spark pl ugs.
Remove the oi l fi l l er cap.
Remove the ai r cl eaner.
Cal i brate the tester accordi ng to the manufactur-
ers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
Perform the test procedure on each cyl i nder accord-
i ng to the tester manufacturers i nstructi ons. Whi l e
testi ng, l i sten for pressuri zed ai r escapi ng through
the throttl e body, tai l pi pe or oi l fi l l er cap openi ng.
Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to CYLI NDER COMBUSTI ON PRESSURE
LEAKAGE DI AGNOSI S CHART bel ow
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous pl aces where form-i n-pl ace
gaskets are used on the engi ne. Care must be taken
when appl yi ng form-i n-pl ace gaskets to assure
obtai ni ng the desi red resul ts. Do not use form-in-
place gasket material unless specified. Bead si ze,
conti nui ty, and l ocati on are of great i mportance. Too
thi n a bead can resul t i n l eakage whi l e too much can
resul t i n spi l l -over whi ch can break off and obstruct
fl ui d feed l i nes. A conti nuous bead of the proper
wi dth i s essenti al to obtai n a l eak-free gasket.
There are numerous types of form-i n-pl ace gasket
materi al s that are used i n the engi ne area. Mopar
Engi ne RTV GEN I I , Mopar ATF-RTV, and Mopar
Gasket Maker gasket materi al s, each have di fferent
properti es and can not be used i n pl ace of the other.
MOPAR ENGINE RTV GEN II
Mopar Engi ne RTV GEN I I i s used to seal com-
ponents exposed to engi ne oi l . Thi s materi al i s a spe-
ci al l y desi gned bl ack si l i cone rubber RTV that
retai ns adhesi on and seal i ng properti es when
exposed to engi ne oi l . Moi sture i n the ai r causes the
materi al to cure. Thi s materi al i s avai l abl e i n three
ounce tubes and has a shel f l i fe of one year. After one
year thi s materi al wi l l not properl y cure. Al ways
i nspect the package for the expi rati on date before
use.
MOPAR ATF RTV
Mopar ATF RTV i s a speci fi cal l y desi gned bl ack
si l i cone rubber RTV that retai ns adhesi on and seal -
i ng properti es to seal components exposed to auto-
mati c transmi ssi on fl ui d, engi ne cool ants, and
moi sture. Thi s materi al i s avai l abl e i n three ounce
tubes and has a shel f l i fe of one year. After one year
thi s materi al wi l l not properl y cure. Al ways i nspect
the package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker i s an anaerobi c type gasket
materi al . The materi al cures i n the absence of ai r
when squeezed between two metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. The anaerobi c
materi al i s for use between two machi ned surfaces.
Do not use on fl exi bl e metal fl anges.
MOPAR GASKET SEALANT
Mopar Gasket Seal ant i s a sl ow dryi ng, perma-
nentl y soft seal er. Thi s materi al i s recommended for
seal i ng threaded fi tti ngs and gaskets agai nst l eakage
of oi l and cool ant. Can be used on threaded and
machi ned parts under al l temperatures. Thi s mate-
ri al i s used on engi nes wi th mul ti -l ayer steel (MLS)
cyl i nder head gaskets. Thi s materi al al so wi l l pre-
vent corrosi on. Mopar Gasket Seal ant i s avai l abl e i n
a 13 oz. aerosol can or 4oz./16 oz. can w/appl i cator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care but i ts easi er then usi ng precut gas-
kets.
Mopar Gasket Maker materi al shoul d be appl i ed
spari ngl y 1 mm (0.040 i n.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can eas-
i l y be wi ped off. Components shoul d be torqued i n
pl ace wi thi n 15 mi nutes. The use of a l ocati ng dowel
i s recommended duri ng assembl y to prevent smear-
i ng materi al off the l ocati on.
Mopar Engi ne RTV GEN I I or ATF RTV gasket
materi al shoul d be appl i ed i n a conti nuous bead
approxi matel y 3 mm (0.120 i n.) i n di ameter. Al l
mounti ng hol es must be ci rcl ed. For corner seal i ng, a
3.17 or 6.35 mm (1/8 or 1/4 i n.) drop i s pl aced i n the
center of the gasket contact area. Uncured seal ant
may be removed wi th a shop towel . Components
shoul d be torqued i n pl ace whi l e the seal ant i s sti l l
wet to the touch (wi thi n 10 mi nutes). The usage of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng materi al off the l ocati on.
Mopar Gasket Seal ant i n an aerosol can shoul d be
appl i ed usi ng a thi n, even coat sprayed compl etel y
over both surfaces to be joi ned, and both si des of a
gasket. Then proceed wi th assembl y. Materi al i n a
can w/appl i cator can be brushed on evenl y over the
seal i ng surfaces. Materi al i n an aerosol can shoul d be
used on engi nes wi th mul ti -l ayer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
STANDARD PROCEDURE HYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY -
(2) Di sconnect the negati ve cabl e(s) from the bat-
tery.
(3) I nspect ai r cl eaner, i nducti on system, and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the spark pl ugs.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (cool ant, fuel ,
oi l , etc.).
(7) Be sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt a smal l amount of engi ne oi l i nto the
cyl i nders to l ubri cate the wal l s. Thi s wi l l prevent
damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 41 Nm (30 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l . (Refer to LUBRI CATI ON &
MAI NTENANCE - SPECI FI CATI ONS).
(15) Connect the negati ve cabl e(s) to the battery.
(16) Start the engi ne and check for any l eaks.
STANDARD PROCEDURE CYLINDER BORE
HONING
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823, equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round, as wel l as removi ng l i ght
scuffi ng, scori ng and scratches. Usual l y, a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). about 20-60
strokes, dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Usi ng honi ng
oi l C-3501-3880, or a l i ght honi ng oi l , avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 3).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 4).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
Fig. 4 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Mopar
Stud and Beari ng Mount. Make certai n the new pl ug
i s cl eaned of al l oi l or grease. Usi ng proper dri ve
pl ug, dri ve pl ug i nto hol e so that the sharp edge of
the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de the
l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed.
Never use the fol l owi ng to cl ean gasket surfaces:
Metal scraper
Abrasi ve pad or paper to cl ean cyl i nder bl ock
and head
Hi gh speed power tool wi th an abrasi ve pad or a
wi re brush (Fi g. 5)
Onl y use the fol l owi ng for cl eani ng gasket surfaces:
Sol vent or a commerci al l y avai l abl e gasket
remover
Pl asti c or wood scraper (Fi g. 5)
Dri l l motor wi th 3M Rol oc Bri stl e Di sc (whi te
or yel l ow) (Fi g. 5)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Drai n the cool ant (Refer to 7 - COOLI NG -
(4) Remove the ai r cl eaner assembl y, ai r i n-l et
hose and resonator assembl y (Fi g. 6).
(5) Recover refri gerant (i f equi pped wi th A/C).(Re-
fer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG - 24 - HEATI NG & AI R
CONDI TI ONI NG).
(6) Remove the radi ator l ower hose.
Fig. 5 PROPER TOOL USAGE FOR SURFACE
PREPARATION
1 - ABRASIVE PAD
2 - 3M ROLOC BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 6 Air Cleaner and Resonator Removal and
Installation
1 - AIR CLEANER ASSEMBLY
2 - NUT AND WASHER
3 - RESONATOR ASSEMBLY
4 - AIR INLET HOSE
(7) Remove the radi ator upper hose and cool ant
recovery hose (Fi g. 7).
(8) Remove the fan shroud (Fi g. 7).
(9) Remove the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - REMOVAL) and condenser
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG/A/C CONDENSER - REMOVAL) (i f
equi pped wi th ai r condi ti oni ng).
(10) Remove fan assembl y and i nstal l a 5/16 x 1/2-
i nch SAE capscrew through fan pul l ey i nto water
pump fl ange. Thi s wi l l mai ntai n the pul l ey and
water pump i n al i gnment when crankshaft i s rotated.
(11) Di sconnect the heater hoses.
(12) Di sconnect the throttl e cabl e, speed control
cabl e (i f equi pped) and transmi ssi on cabl e (i f
equi pped).
(13) Di sconnect the body ground at the fi rewal l .
(14) Di sconnect the wi res from the starter motor
sol enoi d.
(15) Di sconnect al l fuel i njecti on harness connec-
ti ons.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE DISCONNECTING FUEL
LINES, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(16) Perform fuel pressure rel ease procedure
(17) Di sconnect the qui ck-connect fuel l i ne at the
fuel rai l (Refer to 14 - FUEL SYSTEM/FUEL DELI V-
ERY/QUI CK CONNECT FI TTI NG - STANDARD
PROCEDURE).
(18) Di sconnect sucti on/di scharge hose from A/C
compressor and cap off ports to prevent i ntrusi on of
forei gn materi al or refri gerant oi l l oss.
(19) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(20) I f equi pped wi th power steeri ng:
(a) Di sconnect the power steeri ng hoses from the
fi tti ngs at the steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn materi al from enteri ng the
system.
(21) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(23) Remove the oi l fi l ter.
(24) Remove the starter motor(Refer to 8 - ELEC-
TRI CAL/STARTI NG/STARTER MOTOR - REMOV-
AL).
(25) Di sconnect the exhaust pi pe from the exhaust
mani fol d.
(26) Remove the fl ywheel housi ng access cover.
(27) Remove the upper fl ywheel and converter
housi ng bol ts and l oosen the bottom bol ts.
(28) Remove the engi ne support cushi on-to-engi ne
compartment bracket bol ts.
(29) Remove the engi ne shock damper bracket
from the si l l .
(31) Attach a l i fti ng devi ce to the engi ne.
(32) Rai se the engi ne sl i ghtl y off the front sup-
ports.
(33) Pl ace a support stand under the converter or
fl ywheel housi ng.
(34) Li ft the engi ne out of the engi ne compartment
and i nstal l on an engi ne stand.
(35) I nstal l the oi l fi l ter to keep forei gn materi al
out of the engi ne.
INSTALLATION
(1) Remove the oi l fi l ter.
(2) Li ft the engi ne off the stand and l ower i t i nto
the engi ne compartment. For easi er i nstal l ati on, i t
may be useful to remove the engi ne support cushi ons
from the engi ne support brackets as an ai de for
al i gnment of the engi ne-to-transmi ssi on.
(3) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne. (M/T model s)
(4) Al i gn the fl ywheel housi ng wi th the engi ne.
(5) I nstal l and ti ghten the fl ywheel housi ng l ower
bol ts.
(6) I nstal l the engi ne support cushi ons (i f
removed).
Fig. 7 Upper Radiator Hose, Coolant Recovery Hose
& Fan Shroud
1 - UPPER RADIATOR HOSE
2 - FAN SHROUD
3 - COOLANT RECOVERY HOSE
(7) Lower the engi ne and engi ne support cushi ons
onto the engi ne compartment brackets.
(8) Remove the engi ne l i fti ng devi ce.
(10) I nstal l the converter-housi ng access cover.
(11) I nstal l the exhaust pi pe support.
(12) I nstal l the starter motor (Refer to 8 - ELEC-
TRI CAL/STARTI NG/STARTER MOTOR - I NSTAL-
LATI ON).
(13) Ti ghten the engi ne support cushi on through-
bol t nuts.
(14) Connect the exhaust pi pe to the mani fol d.
(15) I nstal l the oi l fi l ter.
(17) Connect the cool ant hoses and ti ghten the
cl amps.
(18) I f equi pped wi th power steeri ng:
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(19) Remove the pul l ey-to-water pump fl ange
al i gnment capscrew and i nstal l the fan assembl y.
(20) I nstal l the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - I NSTALLATI ON),condenser
PLUMBI NG/A/C CONDENSER - I NSTALLATI ON)
(i f equi pped wi th ai r condi ti oni ng) and fan shroud.
(21) Connect the radi ator hoses.
(22) Connect the oxygen sensor wi re connector.
(23) Connect the throttl e cabl e and i nstal l the rod.
Connect the transmi ssi on and speed control cabl es (i f
equi pped)
(24) Connect the fuel suppl y l i ne to the i njector
rai l (Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
QUI CK CONNECT FI TTI NG - STANDARD PROCE-
DURE).
(25) Connect al l the vacuum hoses and wi re con-
nectors.
(26) Connect sucti on/di scharge hose to compressor
(i f equi pped).
(27) Fi l l the power steeri ng reservoi r.
(28) Recharge ai r condi ti oni ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
(29) Connect the battery cabl es.
(30) I nstal l the resonator assembl y, ai r i n-l et hose
and ai r cl eaner (Fi g. 6).
(31) I nstal l the hood.
(32) Add engi ne oi l and cool ant.
(33) Start the engi ne and i nspect for l eaks.
(34) Stop the engi ne and check the fl ui d l evel s.
Add fl ui d, as requi red.
SPECIFICATIONS
2. 5L ENGINE
ENGINE DESCRIPTION
Engine Type In-line 4 Cylinder
Bore and Stroke 98.4 x 81.0 mm
(3.88 x 3.19 in.)
Displacement 2.5L (150 cu. in.)
Compression Ratio 9.1:1
Compression Pressure
Range
827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders
206 kPa (30 psi)
Firing Order 1342
Lubrication Pressure FeedFull Flow
Filtration
Cooling System Liquid CooledForced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
Pistons Aluminum Alloy
Cylinder Combustion
Cavity
Double Quench
Connecting Rods Cast Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
Bearing Clearance 0.025 - 0.076 mm
(0.001 - 0.003 in.)
Bearing Journal Diameter
No. 1 51.54 - 51.56 mm
(2.029 - 2.030 in.)
No. 2 51.28 - 51.31 mm
(2.019 - 2.020 in.)
No. 3 51.03 - 51.05 mm
(2.009 - 2.010 in.)
No. 4 50.78 - 50.80 mm
(1.999 - 2.000 in.)
Base Circle Runout
(Max)
0.03 mm
(0.001 in.)
Camshaft Lobe Lift
Exhaust 6.579 mm (0.259 in.)
Intake 6.477 mm (0.255 in.)
Camshaft Duration
Intake 253.3
Exhaust 259
VALVES
Valve Lift
Exhaust 10.528 mm (0.4145 in.)
Intake 10.350 mm (0.4075 in.)
Intake Valve Timing
Opens 15.4(BTDC)
Closes 58(ABDC)
Duration 253.3
Exhaust Valve Timing
Opens 52.8(BBDC)
Closes 26.2(ATDC)
Duration 259
Valve Overlap 41.6
Valve Lenght (Overall)
Intake 124.435 - 125.070 mm
(4.899 - 4.924 in.)
Exhaust 125.120 - 125.755 mm
(4.927 - 4.952 in.)
Valve Stem Diameter 7.899 - 7.925 mm
(0.311 - 0.312 in.)
Stem to Guide Clearance 0.025 - 0.076 mm
(0.001 - 0.003 in.)
ValveFace Angle
Intake 46.5
Exhaust 46.5
Valve Head Diameter
Intake 48.387 - 48.641 mm
(1.905 - 1.915 in.)
Exhaust 37.973 - 38.227 mm
(1.495 - 1.505 in.)
Tip Refinishing (Max
Alowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.) 47.65 mm (1.876 in.)
Spring Load
Valve Closed 316 to 351 N @ 41.656
mm
(71 to 79 Lbs. @ 1.64
in.)
Valve Open 898.6 to 969.7 N @
30.89 mm
(202 to 218 Lbs. @ 1.216
in.)
Inside Diameter (Top) 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height 41.656 mm (1.640 in.)
CRANKSHAFT
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
Width
No. 1 27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 2 32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 3-4-5 30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Main Bearing Clearance
(Preferred) 0.051 mm
(0.002 in.)
Connecting Rod Journal
Diameter 53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Connecting Rod Journal
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out of Round - Max 0.013 mm (0.0005 in.)
Taper - Max 0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height 236.73 mm (9.320 in.)
Deck Clearance 0.000 mm (0.000 in.)
Cylinder Bore Diameter
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Cylinder Bore Diameter
Taper (Max) 0.025 mm
(0.001 in.)
Out of Round (Max) 0.025 mm
(0.001 in.)
Tappet Bore Diameter 23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max 0.20 mm for total length
(0.008 in. for total length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING RODS
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (Center to Center) 155.52 to 155.62 mm
(6.123 to 6.127 in.)
Piston Pin Bore Diameter 23.59 to 23.62 mm
(0.9288 to 0.9298 in.)
Bore (Less Bearings) 56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Bearing Clearance
(Preferred)
0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max) 0.002 mm per mm
(0.002 in. per in.)
Bend (Max) 0.006 mm per mm
(0.006 in. per inch.)
CYLINDER HEAD
Combustion Chamber 49.9 to 52.9 cc
(3.04 to 3.23 cu. in.)
Valve Guide I.D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Seat Angle
Intake 44.5
Exhaust 44.5
Valve Seat Width 1.01 to 1.52 mm
(0.040 to 0.060 in.)
Valve Seat Runout 0.064 mm
(0.0025 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness (Max) 0.20 mm for total length
(0.008 in. for total length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio 1.6:1
Push Rod Length (Blue) 241.300 to 241.808 mm
(9.500 to 9.520 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet to Bore Clearance 0.025 to 0.063 mm
(0.001 to 0.0025 in.)
PISTON
Weight (Less Pin) 417 to 429 grams
(14.7 to 15.1 oz.)
Compression Height 40.61 to 40.72 mm
(1.599 to 1.603 in.)
Piston to Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Piston Ring Groove
Height
Compression Rings 1.530 to 1.555 mm
(0.0602 to 0.0612 in.)
Oil Control Ring 4.035 to 4.060 mm
(0.1589 to 0.1598 in.)
Piston Ring Groove
Diameter
Compression Ring #1 88.39 to 88.65 mm
(3.48 to 3.49 in.)
Compression Ring #2 87.63 to 87.88 mm
(89.66 to 89.92 in.)
Oil Control Ring 89.66 to 89.92 mm
(3.53 to 3.54 in.)
Piston Pin Bore Diameter 23.650 to 23.658 mm
(0.9312 to 0.9315 in.)
Piston Pin Diameter 23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston to Pin Clearance 0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
PISTON RINGS
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
Ring Side Clearance
Compression Rings 0.042 to 0.084 mm
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
OIL PUMP AND OIL PRESSURE
Gear to Body Clearance
(Radial) 0.051 to 0.102 mm
(0.002 to 0.004 in.)
(Radial Preferred) 0.051 mm
(0.002 in.)
Gear End Clearance
Plastigage 0.051 to 0.152 mm
(0.002 to 0.006 in.)
Plastigage Preferred 0.051 mm
(0.002 in.)
Feeler Gauge 0.1016 to 0.2032 mm
(0.004 to 0.008 in.)
Feeler Gauge Preferred 0.1778 mm
(0.007 in.)
Min. Pressure (600 rpm) 89.6 kPa
(13 psi)
Min. Pressure at Idle
(800 rpm)
172 to 241 kPa
(25 to 35 psi)
Min. Pressure at 1600
rpm and Higher
255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief 517 kPa
(75 psi)
TORQUE
2.5L ENGINE
DESCRIPTION Nm Ft.
Lbs.
In. Lbs
A/C Compressor Bracket 47 35
to EngineBolts
A/C Compressor Mounting
Bolts
28 250
Block Heater Nut 1.8 16
Camshaft Sprocket Bolt 108 80
Clutch Cover to Flywheel
Bolts
31 23
Connecting Rod Cap Nuts 45 33
Cylinder Block Drain Plugs 41 30
Cylinder Head Bolts #110 149 110
& #1214
Cylinder Head Bolt #11 135 100
Cylinder Head Cover Bolts 13 115
Dipstick Tube Bracket to 19 168
Cylinder BlockBolt
Distributor Hold-Down
Clamp Bolt
23 204
Engine Front Insulator
Bracket
81 60
Bolts
Insulator BracketNuts 47 35
InsulatorThrough Bolt 81 60
Engine Rear Support
Cushion
22 192
/CrossmemberNuts
Support Cushion/Bracket
Nuts
46 34
Transmission Support
Bracket
43 32
Bolts
Bracket
75 55
/CushionBolt
Adaptor
75 55
BracketBolts
Exhaust Manifold/Pipe
Nuts
27 20
Exhaust Manifold
Bolt #1 41 30
DESCRIPTION Nm Ft.
Lbs.
In. Lbs
Bolts #2-5 31 23
Nuts 6 and 7 14 126
Flywheel/Converter
Housing Bolts
38 28
Flywheel to Crankshaft
Bolts
143 105
Front Cover to Block Bolts
1/4-20
7 60
Front Cover to Block
5/16-18
22 192
Generator Mounting
Bolts
57 42
Generator Mounting 47 35
Bracket to EngineBolts
Main Bearing Cap Bolts 108 80
Oil Filter Adaptor Bolt 102 75
Oil Filter Connector 68 50
Oil Filter 18 13
Oil Galley Plug 41 30
Oil Pan 1/4-20 Bolts 9.5 84
Oil Pan 5/16-18 Bolts 15 132
Oil Pan Drain Plug 34 25
Oil Pressure Sending Unit 15 130
Oil Pump Short Attaching
Bolts
23 204
Oil Pump Long Attaching
Bolts
23 204
Oil Pump Cover Bolts 8 70
Rocker ArmBolts 28 21
Spark Plugs 37 27
Starter Motor Mounting
Bolts
45 33
Thermostat Housing Bolts 18 156
Throttle Body Bolts 10 90
Vibration Damper Bolt 108 80
Water Pump to Block Bolts 31 23
SPECIAL TOOLS
2. 5L ENGINE
AIR CLEANER ELEMENT
REMOVAL
Housi ng removal i s not necessary for el ement (fi l -
ter) repl acement.
(1) Pry up spri ng cl i ps from housi ng cover (spri ng
cl i ps retai n cover to housi ng).
(2) Rel ease housi ng cover from l ocati ng tabs on
housi ng (Fi g. 8) and remove cover.
(3) Remove ai r cl eaner el ement (fi l ter) from hous-
i ng.
(4) Cl ean i nsi de of housi ng before repl aci ng el e-
ment.
Valve Spring Compressor Tool MD-998772A
Hydraulic Valve Tappet Removal Tool C4129A
Vibration Damper Removal Tool 7697
Timing Case Cover Alignment and Seal Tool 6139
Pressure Tester Kit 7700
BlocChekKit C-3685A
Fig. 8 Air Cleaner Housing Assembly
1 - AIR CLEANER ELEMENT COVER
2 - TABS
3 - HOUSING
INSTALLATION
(1) I nstal l el ement i nto housi ng.
(2) Posi ti on housi ng cover i nto housi ng l ocati ng
tabs.
(3) Pry up spri ng cl i ps and l ock cover to housi ng.
CYLINDER HEAD
DESCRIPTION
The cast i ron cyl i nder head (Fi g. 9) i s mounted to
the cyl i nder bl ock usi ng ten bol ts. The spark pl ugs
are l ocated i n the peak of the wedge between the
val ves.
OPERATION
The cyl i nder head cl oses the combusti on chamber
al l owi ng the pi stons to compress the ai r fuel mi xture
to the correct rati o for i gni ti on. The val ves l ocated i n
the cyl i nder head open and cl ose to ei ther al l ow cl ean
ai r i nto the combusti on chamber or to al l ow the
exhaust gases out, dependi ng on the stroke of the
engi ne.
DIAGNOSIS AND TESTING CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
Possi bl e i ndi cati ons of the cyl i nder head gasket
l eaki ng between adjacent cyl i nders are:
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
cent cyl i nders wi l l resul t i n approxi matel y a 5070%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 158 kPa (23 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
Fig. 9 Cylinder Head2.5L Engine
1 - BRIDGE
2 - PIVOT ASM.
3 - ROCKER ARM
4 - CYLINDER HEAD
5 - HEAD GASKET
6 - PUSH ROD
AIR CLEANER ELEMENT (Continued)
STANDARD PROCEDURE VALVE GUIDE
WEAR - MEASURING
Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i n.), repl ace the val ve.
Measure val ve stem gui de cl earance as fol l ows:
(1) I nstal l Val ve Gui de Sl eeve Tool C-3973 over
val ve stem and i nstal l val ve (Fi g. 10). The speci al
sl eeve pl aces the val ve at the correct hei ght for
checki ng wi th a di al i ndi cator.
(2) Attach di al i ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl es to val ve stem bei ng
measured (Fi g. 11).
(3) Move val ve to and from the i ndi cator. The total
di al i ndi cator readi ng shoul d not exceed 0.432 mm
(0.017 i n.). Ream the gui des for val ves wi th oversi ze
stems i f di al i ndi cator readi ng i s excessi ve or i f the
stems are scuffed or scored.
STANDARD PROCEDURE VALVE GUIDE
SERVICE
Servi ce val ves wi th oversi ze stems are avai l abl e.
Refer to REAMER SI ZES CHART .
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
(1) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Ream the
valve guides from standard to 0.381 mm (0.015
in.). Use a two step procedure so the valve
guides are reamed true in relation to the valve
seat:
Step 1Ream to 0.0763 mm (0.003 i nch).
REMOVAL
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant (Refer to 7 - COOLI NG -
STANDARD PROCEDURE) and di sconnect the hoses
at the engi ne thermostat housi ng. DO NOT waste
reusabl e cool ant. I f the sol uti on i s cl ean and i s bei ng
drai ned onl y to servi ce the engi ne or cool i ng system,
drai n the cool ant i nto a cl ean contai ner for reuse.
(3) Remove the ai r i n-l et hose and resonator
assembl y.
(4) Remove the engi ne cyl i nder head cover (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - REMOVAL).
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms (Fi g. 12).
(6) Remove the push rods (Fi g. 12). Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the accessory dri ve bel t at the power
steeri ng pump bracket, i f equi pped or at the i dl er
pul l ey bracket (Refer to 7 - COOLI NG/ACCESSORY
DRI VE/DRI VE BELTS - REMOVAL).
Fig. 10 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 11 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
CYLINDER HEAD (Continued)
(8) I f equi pped wi th ai r condi ti oni ng, perform the
fol l owi ng:
(a) Remove the bol ts from the A/C compressor
mounti ng bracket and set the compressor asi de.
(b) Remove the ai r condi ti oner compressor
bracket bol ts from the engi ne cyl i nder head.
(c) Loosen the through bol t at the bottom of the
bracket.
(9) I f equi pped, di sconnect the power steeri ng
pump bracket. Set the pump and bracket asi de. DO
NOT di sconnect the hoses.
(10) Perform fuel pressure rel ease procedure
(11) Remove the l atch cl i p and di sconnect the fuel
suppl y hose (Refer to 14 - FUEL SYSTEM/FUEL
DELI VERY/QUI CK CONNECT FI TTI NG - STAN-
DARD PROCEDURE).
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head (Refer to 9 -
REMOVAL).
(13) Number and di sconnect the i gni ti on wi res and
remove the spark pl ugs.
(14) Di sconnect the cool ant temperature sendi ng
uni t connector.
(15) Remove the engi ne cyl i nder head bol ts.
(16) Remove the engi ne cyl i nder head and gasket
(Fi g. 13).
(17) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(18) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If valves, springs, or seals are to be inspect-
ed/replaced at this time, refer to Valves and Valve
Springs later in this section for proper inspection
procedures.
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
exhaust mani fol d and engi ne cyl i nder head mati ng
surfaces. Remove al l gasket materi al and carbon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
Fig. 12 Rocker Arm Assembly
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
Fig. 13 Engine Cylinder Head Assembly
1 - BRIDGE
2 - PIVOT ASM.
3 - ROCKER ARM
4 - CYLINDER HEAD
5 - HEAD GASKET
6 - PUSH ROD
INSTALLATION
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Fabri cate two engi ne cyl i nder head al i gnment
dowel s from used head bol ts (Fi g. 14). Use the l ong-
est head bol t. Cut the head of the bol t off bel ow the
hex head. Then cut a sl ot i n the top of the dowel to
al l ow easi er removal wi th a screwdri ver.
(2) I nstal l one dowel i n bol t hol e No.10 and the
other dowel i n bol t hol e No.8 (Fi g. 15).
(3) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(4) Pl ace the engi ne cyl i nder head gasket (wi th the
numbers faci ng up) over the dowel s.
(5) Pl ace the engi ne cyl i nder head over the dowel s.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(6) Coat the threads of bol t No.7 onl y, wi th Locti te
PST seal ant or equi val ent.
(7) I nstal l al l head bol ts, except No.8 and No.10.
(8) Remove the dowel s.
(9) I nstal l No.8 and No.10 head bol ts.
CAUTION: During the final tightening sequence,
bolt No.7 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt No.7.
(10) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
16):
(a) Ti ghten al l bol ts i n sequence (1 through 10)
to 30 Nm (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 10)
(c) Check al l bol ts to veri fy they are set to 61
(d) Ti ghten bol ts (i n sequence):
Bol ts 1 through 6 to 149 Nm (110 ft. l bs.)
torque.
Bol t 7 to 136 Nm (100 ft. l bs.) torque.
Bol ts 8 through 10 to 149 Nm (110 ft. l bs.)
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(11) Connect the cool ant temperature sendi ng uni t
connector.
(12) I nstal l the spark pl ugs (Refer to 8 - ELEC-
I NSTALLATI ON).
(13) I nstal l the i ntake and exhaust mani fol ds.
(14) I nstal l the fuel suppl y l i ne (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY/QUI CK CON-
NECT FI TTI NG - STANDARD PROCEDURE).
(15) I f equi pped, attach the power steeri ng pump
and bracket.
(16) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed.
(17) I nstal l the engi ne cyl i nder head cover (Refer
HEAD COVER(S) - I NSTALLATI ON).
Fig. 14 Fabricate Alignment Dowels
1 - USED CYLINDER HEAD BOLT
2 - SLOT
Fig. 15 Alignment Dowel Locations
1 - ALIGNMENT DOWEL
2 - ALIGNMENT DOWEL
(18) Attach the ai r condi ti oni ng compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 Nm (30 ft. l bs.) torque.
(19) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The accessory drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(20) I nstal l the accessory dri ve bel t and correctl y
tensi on the bel t (Refer to 7 - COOLI NG/ACCESSORY
DRI VE/DRI VE BELTS - I NSTALLATI ON).
(21) I nstal l the resonator assembl y and ai r i n-l et
hose. Ti ghten cl amps to 4 Nm (35 i n. l bs.).
(22) Connect the hoses to the thermostat housi ng.
(23) I nstal l the cool ant temperature sendi ng uni t
connector.
(24) Connect negati ve cabl e to battery.
(25) Connect the upper radi ator hose and heater
hose at the thermostat housi ng.
(26) Fi l l the cool i ng system. (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE) Check for l eaks.
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(27) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
REMOVAL
A cured gasket i s part of the engi ne cyl i nder head
cover.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover (Fi g.
17).
(3) Remove the ai r i nl et hose and resonator from
the ai r cl eaner and throttl e body.
(4) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(5) Remove the engi ne cyl i nder head cover (Fi g.
17).
(6) Remove any ori gi nal seal er from the cover seal -
i ng surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
(7) Remove al l resi due from the seal i ng surface
usi ng a cl ean, dry cl oth.
CLEANING
Cl ean cyl i nder head cover gasket surface.
Cl ean head rai l , i f necessary.
INSPECTION
I nspect cover for di storti on and strai ghten, i f nec-
essary.
Fig. 16 Engine cylinder head Bolt Tightening
Sequence
Fig. 17 Engine Cylinder Head Cover
1 - AIR INLET FITTING
2 - AIR FILTER COVER
3 - FIXED ORIFICE FITTING
Check the gasket for use i n head cover i nstal l ati on.
I f damaged, use a new gasket.
INSTALLATION
A cured gasket i s part of the engi ne cyl i nder head
cover.
(1) I nspect the engi ne cyl i nder head cover for
cracks. Repl ace the cover, i f cracked.
NOTE: The original dark grey gasket material
should NOT be removed. If sections of the gasket
material are missing or are compressed, replace the
engine cylinder head cover. However, sections with
minor damage such as small cracks, cuts or chips
may be repaired with a hand held applicator. The
new material must be smoothed over to maintain
gasket height. Allow the gasket material to cure
prior to engine cylinder head cover installation.
(2) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet the oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(3) I nstal l engi ne cyl i nder head cover. Ti ghten the
mounti ng bol ts to 13 Nm (115 i n. l bs.) torque.
(4) Connect the CCV hoses (Fi g. 17).
(6) I nstal l the ai r i nl et hose and resonator.
ROCKER ARMS
REMOVAL
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 18). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 18). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
(6) Cl ean al l the components wi th cl eani ng sol -
vent.
(7) Use compressed ai r to bl ow out the oi l passages
i n the rocker arms and push rods.
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or
equi val ent, l ubri cate the area of the rocker arm that
Fig. 18 Rocker Arm Assembly
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
CYLINDER HEAD COVER(S) (Continued)
the pi vot contacts. I nstal l rocker arms, pi vots and
bri dge above each cyl i nder i n thei r ori gi nal posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover (Refer to
9 - ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON).
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the i ntake and exhaust val ves are made of
steel . The i ntake val ve i s 48.768 mm (1.92 i nches) i n
di ameter and the exhaust val ve i s 41.148 mm (1.62
i nches) i n di ameter and has a 2.032 mm (0.080 i nch)
wafer i nteri a wel ded to the ti p for durabi l i ty. These
val ves are not spl ayed.
STANDARD PROCEDURE VALVE TIMING
VERIFICATION
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assem-
bl y, and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.4 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1
cyl i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Set the di al i ndi cator poi nter at zero.
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from
the front of the engi ne) unti l the di al i ndi cator
poi nter i ndi cates 0.305 mm (0.012 i nch) travel di s-
tance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2
i nch) away from the TDC mark i n ei ther di recti on,
the val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be
a broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
STANDARD PROCEDURE REFACING VALVES
AND SEATS
VALVE REFACING
The i ntake and exhaust val ves have a 43-1/4 to
43-3/4 face angl e and a 44-1/4 to 44-3/4 seat angl e
(Fi g. 19).
VALVE FACE AND VALVE SEAT ANGLE CHART
ITEM DESCRIPTION SPECIFICATION
A SEAT WIDTH
INTAKE 1.016 - 1.524 mm
(0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm
(0.060 - 0.080 in.)
B FACE ANGLE
(INT. AND EXT.) 43- 43
C SEAT ANGLE
D CONTACT
SURFACE
I nspect the remai ni ng margi n after the val ves are
refaced (Fi g. 20). Val ves wi th l ess than 1.190 mm
(0.047 i n.) margi n shoul d be di scarded.
Fig. 19 Valve Face and
1 - CONTACT POINT
A,B,C and D Refer to VALVE FACE AND VALVE SEAT ANGLE
CHART
ROCKER ARMS (Continued)
VALVE SEAT REFACING
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 21).
(1) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng a
di al i ndi cator. Total runout shoul d not exceed 0.051
mm (0.002 i n.) total i ndi cator readi ng.
(3) I nspect the val ve seat wi th Prussi an bl ue, to
determi ne where the val ve contacts the seat. To do
thi s, coat val ve seat LI GHTLY wi th Prussi an bl ue
then set val ve i n pl ace. Rotate the val ve wi th l i ght
pressure. I f the bl ue i s transferred to the center of
val ve face, contact i s sati sfactory. I f the bl ue i s trans-
ferred to the top edge of val ve face, l ower val ve seat
wi th a 15 stone. I f the bl ue i s transferred to bottom
edge of val ve face rai se val ve seat wi th a 60 stone.
(4) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.016-1.524 mm (0.040-0.060
i n.). The wi dth of the exhaust seats shoul d be 1.524-
2.032 mm (0.060-0.080 i n.).
REMOVAL VALVES
NOTE: This procedure is done with the head
removed.
(1) Compress val ve spri ngs usi ng Val ve Spri ng
Compressor Tool MD-998772-A and adapter 6716A.
(2) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s, and val ve spri ngs.
(3) Before removi ng val ves, remove any burrs from
val ve stem l ock grooves to prevent damage to the
val ve gui des. I denti fy val ves to ensure i nstal l ati on i n
ori gi nal l ocati ons.
CLEANING
Cl ean val ves thoroughl y. Di scard burned, warped,
or cracked val ves.
Remove carbon and varni sh deposi ts from i nsi de of
val ve gui des wi th a rel i abl e gui de cl eaner.
INSTALLATION VALVES
(1) Coat val ve stems wi th l ubri cati on oi l and i nsert
them i n cyl i nder head.
(2) I f val ves or seats are reground, check val ve stem
hei ght. I f val ve i s too l ong, repl ace cyl i nder head.
(3) I nstal l new seal s on al l val ve gui des. I nstal l
val ve spri ngs and val ve retai ners.
(4) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool MD-998772A and adapter 6716A,
i nstal l l ocks and rel ease tool . I f val ves and/or seats
are ground, measure the i nstal l ed hei ght of spri ngs.
Be sure the measurement i s taken from bottom of
spri ng seat i n cyl i nder head to the bottom surface of
spri ng retai ner. I f spacers are i nstal l ed, measure
from the top of spacer. I f hei ght i s greater than 42.86
mm (1-11/16 i nches), i nstal l a 1.587 mm (1/16 i n.)
spacer i n head counterbore. Thi s shoul d bri ng spri ng
hei ght back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 i n.).
Fig. 20 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4 - FACE
Fig. 21 Refacing Valve Seats
1 - STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
INTAKE/EXHAUST VALVES & SEATS (Continued)
VALVE SPRINGS
STANDARD PROCEDURE VALVE SPRING -
TESTING
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d
be tested. As an exampl e the compressi on l ength of
the spri ng to be tested i s 1-5/16 i n.. Turn tabl e of
Uni versal Val ve Spri ng Tester Tool unti l surface i s i n
l i ne wi th the 1-5/16 i n. mark on the threaded stud.
Be sure the zero mark i s to the front (Fi g. 22). Pl ace
spri ng over stud on the tabl e and l i ft compressi ng
l ever to set tone devi ce. Pul l on torque wrench unti l
pi ng i s heard. Take readi ng on torque wrench at thi s
i nstant. Mul ti pl y thi s readi ng by 2. Thi s wi l l gi ve the
spri ng l oad at test l ength. Fracti onal measurements
are i ndi cated on the tabl e for fi ner adjustments.
(Refer to 9 - ENGI NE - SPECI FI CATI ONS) to obtai n
speci fi ed hei ght and al l owabl e tensi ons. Di scard the
spri ngs that do not meet speci fi cati ons.
REMOVAL VALVE SPRINGS
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(2) Remove cap screws, bri dge and pi vot assem-
bl i es and rocker arms for access to each val ve spri ng
to be removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) I nstal l a 14 mm (1/2 i nch) (thread si ze) ai r hose
adaptor i n the spark pl ug hol e.
(7) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(8) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 23).
(9) Remove val ve spri ng and retai ner (Fi g. 23).
(10) Remove val ve stem oi l seal s (Fi g. 23). Note
the val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(i ntake/bl ack i n col or) or EXH (exhaust/brown i n
col or). DO NOT mi x the seal s.
Fig. 22 Testing Valve Spring for Compressed
Length
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 23 Valve and Valve Components
1 - VALVE LOCKS (3BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
INSTALLATION VALVE SPRINGS
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge cap screws al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
cap screws to 28 Nm (21 ft. l bs.) torque.
ENGINE BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e, the fi l ter
bypass hol e (Fi g. 24).
The front and rear oi l gal l ey hol es (Fi g. 25) (Fi g.
26).
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Mopar Thread Seal ant wi th Tefl on to the threads of
the front and rear oi l gal l ey pl ugs. Ti ghten the pl ugs
INSPECTION
I nspect the cyl i nder bores for si gns of scorri ng, pi t-
ti ng or cracks. I f the cyl i nder bores are scorred or
pi tted the cyl i nder bores wi l l requi re borei ng or hon-
i ng to cl ean them up. Refer to Honi ng Cyl i nder Bores
i n thi s Secti on. I f the cyl i nder bore(s) are cracked the
cyl i nder bl ock must be repl aced.
I nspect the cyl i nder bl ock to cyl i nder head mati ng
surface for fl atness and/or pi tti ng.
Fig. 24 Oil Filter Adaptor Hole
1 - FILTER BYPASS HOLE
2 - OIL FILTER ADAPTOR HOLE
Fig. 25 Front Oil Galley Hole
1 - FRONT OIL GALLEY HOLE
VALVE SPRINGS (Continued)
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL CAMSHAFT
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
I NG - STANDARD PROCEDURE). DO NOT waste
reusabl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto
a cl ean contai ner for reuse.
ENGI NE/RADI ATOR - REMOVAL) or radi ator and
condenser, i f equi pped wi th A/C.
(4) Scri be a mark on the di stri butor housi ng i n
l i ne wi th the l i p of the rotor.
(5) Scri be a mark on the di stri butor housi ng near
the cl amp and conti nue the scri be mark on the cyl i n-
der bl ock i n l i ne wi th the di stri butor mark.
(6) For ease of i nstal l ati on, note the posi ti on of the
rotor and di stri butor housi ng i n rel ati on to adjacent
engi ne components.
(7) Remove the di stri butor and i gni ti on wi res.
(8) Remove the ai r i n-l et hose and resonator
assembl y.
(10) Remove the rocker arms, bri dges and pi vots.
(11) Remove the push rods.
(12) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder head.
(13) Remove the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(14) Remove the ti mi ng case cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL).
(15) Remove the ti mi ng chai n and sprockets (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
CHAI N AND SPROCKETS - REMOVAL).
(16) Remove the camshaft (Fi g. 27).
REMOVAL CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
NOTE: This procedure must be done with the
engine removed and completely disassembled.
(1) Remove the camshaft (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK)- REMOVAL)
(2) Usi ng Speci al tool 8544 or equi val ent, remove
the camshaft beari ngs.
Fig. 26 Rear Oil Galley Hole
1 - REAR OIL GALLEY HOLE
Fig. 27 Camshaft
1 - CAMSHAFT
2 - CRANKSHAFT
ENGINE BLOCK (Continued)
INSTALLATION CAMSHAFT BEARINGS
(1) I nspect the camshaft beari ng journal s for
uneven wear pattern or fi ni sh.
(2) I nspect the camshaft l obes and di stri butor gear
for wear.
(3) I nspect the camshaft thrust pl ate for wear. I f
the pl ate shows excessi ve wear i nspect the camshaft
oi l pressure rel i ef hol es i n the rear cam journal . The
rel i ef hol es must be cl ean and free of debri s.
CAUTION: Make sure outside diameter of number 1
bearing is clean. Make sure that the bearing is
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear-
ing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.
(4) Usi ng speci al tool 8544 Camshaft Bushi ng
Remover I nstal l er or equi val ent, i nstal l new cam-
shaft beari ngs.
(5) Lubri cate the camshaft wi th Mopar engi ne oi l
suppl ement, or equi val ent.
(6) I nstal l the camshaft (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK) - I NSTALLATI ON).
INSTALLATION CAMSHAFT
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne
Oi l Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 27).
(8) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 28).
(9) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 28).
(10) I nstal l the ti mi ng chai n and sprockets (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
CHAI N AND SPROCKETS - I NSTALLATI ON).
(11) Rel ease the ti mi ng chai n tensi oner by movi ng
the l ever to the unl ock posi ti on (Fi g. 28).
(12) I nstal l the ti mi ng case cover wi th a repl acement
oi l seal (Fi g. 29) (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT /CHAI N COVER(S) - I NSTALLATI ON).
(13) I nstal l the vi brati on damper (Refer to 9 -
I NSTALLATI ON).
(14) I nstal l the hydraul i c val ve tappets.
(15) I nstal l the push rods.
(16) I nstal l the rocker arms, bri dges and pi vots.
(17) I nstal l the engi ne cyl i nder head cover (Refer
HEAD COVER(S) - I NSTALLATI ON).
(18) I nstal l the di stri butor and i gni ti on wi res.
(Refer to 8 - ELECTRI CAL/I GNI TI ON CONTROL/
DI STRI BUTOR - I NSTALLATI ON).
(19) I nstal l the resonator assembl y and ai r i n-l et
hose. Ti ghten cl amps to 4 Nm (35 i n. l bs.).
Fig. 28 Loading Timing Chain Tensioner
1 - LOCK
2 - UNLOCK
3 - TENSIONER BLOCK
4 - TENSIONER LEVER
Fig. 29 Timing Case Cover
1 - TIMING CASE COVER
2 - CAMSHAFT
3 - CRANKSHAFT
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
(20) I nstal l the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(21) Fi l l the cool i ng system (Refer to 7 - COOLI NG
STANDARD PROCEDURE CONNECTING ROD
BEARING - FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 30) (Fi g. 31). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 32) . Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
33). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 34). (Refer to 9 -
ENGI NE - SPECI FI CATI ONS) for the proper cl ear-
ance. Plastigage should indicate the same clear-
Fig. 30 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN ALWAYS GREATER ON UPPER
BEARING
5 - LOWER BEARING HALF
Fig. 31 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 32 Scoring Caused by Insufficient Lubrication
ance across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance Refer to
CONNECTI NG ROD BEARI NG FI TTI NG CHART .
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING CONNECTING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 53.2257-53.2079 mm Yellow - Standard Yellow - Standard
(2.0955-2.0948 in.)
Orange 53.2079 - 53.1901 mm Yellow - Standard Blue - Undersize
(2.0948 - 2.0941 in.) 0.025 mm (0.001 in.)
0.0178 mm (0.0007 in.)
Undersize
Blue 53.1901 - 53.1724 mm Blue - Undersize Blue - Undersize
(2.0941 - 2.0934 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0356 mm (0.0014 in.)
Undersize
Red 52.9717 - 52.9539 mm Red - Undersize Red - Undersize
(2.0855 - 2.0848 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
0.254 mm (0.010 in.)
Undersize
Fig. 33 Rod and Piston Assembly Installation
Fig. 34 Measuring Bearing Clearance
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
CONNECTING ROD BEARINGS (Continued)
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 Nm (33 ft. l bs.) torque. Sl i de snug-fi tti ng
feel er gauge between the connecti ng rod and crank-
shaft journal fl ange (Fi g. 35). (Refer to 9 - ENGI NE -
SPECI FI CATI ONS) for the proper cl earance. Repl ace
the connecti ng rod i f the si de cl earance i s not wi thi n
speci fi cati on.
CRANKSHAFT
DESCRIPTION
The crankshaft (Fi g. 36) i s of a forged steel desi gn,
wi th fi ve mai n beari ng journal s and ei ght counter
bal ance wei ghts.The crankshaft i s l ocated at the bot-
tom of the engi ne bl ock and i s hel d i n pl ace wi th fi ve
mai n beari ng caps.
OPERATION
The crankshaft transfers force generated by com-
busti on wi thi n the cyl i nder bores to the fl ywheel or
fl expl ate.
REMOVAL
(1) Remove the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL).
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
REMOVAL).
(4) Remove the ti mi ng chai n cover (Refer to 9 -
(5) I denti fy beari ng caps before removal . Remove
beari ng caps and beari ngs one at a ti me.
(6) Li ft the crankshaft out of the bl ock.
(7) Remove and di scard the crankshaft rear oi l
seal s.
(8) Remove and di scard the front crankshaft oi l
seal .
INSTALLATION
(1) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l .
(2) I nstal l the new upper rear beari ng oi l seal wi th
the whi te pai nt faci ng towards the rear of the engi ne.
(3) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(4) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(5) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(6) Appl y 5 mm (0.20 i n) drop of Mopar Gasket
El i mi nator, or equi val ent, on each si de of the rear
mai n beari ng cap (Fi g. 37). DO NOT over appl y seal -
ant or al l ow the seal ant to contact the rubber seal .
Assembl e beari ng cap to cyl i nder bl ock i mmedi atel y
after seal ant appl i cati on.
Fig. 35 Checking Connecting Rod Side Clearance -
Typical
Fig. 36 Crankshaft 3.9L Engine
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
(7) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(8) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
ti ghten to 115 Nm (85 ft. l bs.) torque.
(9) I nstal l oi l pump (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PUMP - I NSTALLATI ON).
(10) I nstal l the ti mi ng chai n cover (Refer to 9 -
I NSTALLATI ON).
(12) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 38).
Appl y enough seal ant unti l a smal l amount i s
squeezed out. Wi thdraw nozzl e and wi pe excess seal -
ant off the oi l pan seal groove.
(13) I nstal l new front crankshaft oi l seal (Refer to
9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - FRONT - I NSTALLATI ON).
(14) I mmedi atel y i nstal l the oi l pan (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
CRANKSHAFT MAIN
BEARINGS
DESCRIPTION
Mai n beari ngs (Fi g. 39) are l ocated i n the cyl i nder
bl ock. One hal f of the mai n beari ng i s l ocated i n the
crankshaft mai n bore the other hal f of the matchi ng
beari ng i s l ocated i n the mai n beari ng cap. there are
fi ve mai n beari ngs. Number two mai n beari ng i s
fl anged, thi s fl ange control s crankshaft thrust.
OPERATION
The mai n beari ngs enci rcl e the crankshaft mai n
beari ng journal s, thi s al i gns the crankshaft to the
centerl i ne of the engi ne and al l ows the crankshaft to
turn wi thout wobbl i ng or shaki ng therefore el i mi nat-
i ng vi brati on. The mai n beari ngs are avai l abl e i n
standard and undersi zes.
Fig. 37 Sealant Application to Bearing Cap
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 - MOPAR GASKET MAKER (OR EQUIVALENT)
3 - CAP ALIGNMENT SLOT
4 - REAR MAIN BEARING CAP
Fig. 38 Apply Sealant to Bearing Cap to Block
1 - MOPAR GEN II SILICONE RUBBER ADHESIVE SEALANT
NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
Fig. 39 Main Bearing Orientation
CRANKSHAFT (Continued)
STANDARD PROCEDURE CRANKSHAFT MAIN
BEARINGS - FITTING
CRANKSHAFT INSTALLED
The mai n beari ng caps, numbered (front to rear)
from 1 through 5 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark on the adjacent
cheek or counterwei ght towards the rear of the
crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size.
BEARING INSERT PAIR CHART
INSERT CORRECT INCORRECT
UPPER STANDARD STANDARD
LOWER 0.025 mm U/S 0.051 mm U/S
(0.001 in.) (0.002 in.)
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, (Refer
to 9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT
MAI N BEARI NGS - I NSTALLATI ON).
CRANKSHAFT REMOVED
Remove the crankshaft from the cyl i nder bl ock.
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
Once the proper cl earances have been obtai ned,
(Refer to 9 - ENGI NE/ENGI NE BLOCK/CRANK-
SHAFT MAI N BEARI NGS - I NSTALLATI ON).
MAIN BEARING FITTING CHART
Crankshaft Journals #1 - #4
Color Diameter Upper
Insert
Lower Insert
Code Size Size
Yellow 63.5025 - Yellow - Yellow -
63.4898
mm
Standard Standard
(2.5001 -
2.4996
in.)
Orange 63.4898 - Blue - Yellow -
63.4771
mm
Undersize Standard
(2.4996 - 0.025 mm
2.4991
in.)
(0.001 in.)
0.0127
mm
(0.0005
in.)
Undersize
Blue 63.4771 - Blue - Blue -
63.4644
mm
Undersize Undersize
(2.4991 - 0.025 mm 0.025 mm
2.4986
in.)
(0.001 in.) (0.001 in.)
0.0254
mm
(0.001
in.)
Undersize
Green 63.4644 - Blue - Green -
63.4517
mm
Undersize Undersize
(2.4986 - 0.025 mm 0.051 mm
2.4981
in.)
(0.001 in.) (0.002 in.)
CRANKSHAFT MAIN BEARINGS (Continued)
0.0381
mm
(0.0015
in.)
Undersize
Red 63.2485 - Red - Red -
63.2358
mm
Undersize Undersize
(2.4901 - 0.254 mm 0.254 mm
2.4896
in.)
(0.010 in.) (0.010 in.)
0.254
mm
(0.010
in.)
Undersize
Crankshaft Journal #5 Only
Color Diameter Upper
Insert
Lower Insert
Code Size Size
Yellow 63.4873 - Yellow - Yellow -
63.4746
mm
Standard Standard
(2.4995 -
2.4990
in.)
Orange 63.4746 - Blue - Yellow -
63.4619
mm
Undersize Standard
(2.4990 - 0.025 mm
2.4985
in.)
(0.001 in.)
0.0127
mm
(0.0005
in.)
Undersize
Blue 63.4619 - Blue - Blue -
63.4492
mm
Undersize Undersize
(2.4985 - 0.025 mm 0.025 mm
2.4980
in.)
(0.001 in.) (0.001 in.)
0.0254
mm
(0.001
in.)
Undersize
Green 63.4492 - Blue - Green -
63.4365
mm
Undersize Undersize
(2.4980 - 0.025 mm 0.051 mm
2.4975
in.)
(0.001 in.) (0.002 in.)
0.0381
mm
(0.0015
in.)
Undersize
Red 63.2333 - Red - Red -
63.2206
mm
Undersize Undersize
(2.4895 - 0.254 mm 0.254 mm
2.4890
in.)
(0.010 in.) (0.010 in.)
0.254
mm
(0.010
in.)
MEASURING BEARING-TO-JOURNAL CLEARANCE
(CRANKSHAFT INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 40). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert.
I nstal l beari ngs (Refer to 9 - ENGI NE/ENGI NE
BLOCK/CRANKSHAFT MAI N BEARI NGS -
I NSTALLATI ON).
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cated wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
I f journal s 1 through 5 di ameters are l ess than
63.4517 mm (2.4981 i nches), repl ace crankshaft or
gri nd crankshaft down to accept the appropri ate
undersi ze beari ng i nserts.
Once the proper cl earances have been obtai ned,
SHAFT MAI N BEARI NGS - I NSTALLATI ON).
REMOVAL
(2) Remove the spark pl ugs.
BRI CATI ON/OI L PAN - REMOVAL) and oi l pump
(Refer to 9 - ENGI NE/LUBRI CATI ON/OI L PUMP -
REMOVAL).
(5) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 41).
Fig. 40 Measuring Bearing Clearance with
Plastigage
Fig. 41 Removing Main Bearing Caps and Lower
Inserts
1 - CONNECTING ROD JOURNAL
2 - MAIN BEARING CAPS
(6) Remove the l ower i nsert from the beari ng cap.
(7) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 42). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 42). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(8) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 43).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Cl ean the rear mai n beari ng cap (No.5) mati ng
surfaces.
(6) Appl y Mopar Gasket Maker, or equi val ent on
the rear beari ng cap (Fi g. 44). The bead shoul d be 3
mm (0.125 i n) thi ck. DO NOT appl y Mopar Gasket
Maker, or equi val ent to the l i p of the seal .
(7) I nstal l the rear mai n beari ng cap. DO NOT stri ke
the cap more than twi ce for proper engagement.
(8) Ti ghten the bol ts of caps 1, 3, 4 and 5 to 54
Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to 95
Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these bol ts to
(9) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.2 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
(10) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(11) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
Fig. 42 Removing Upper Inserts
1 - COTTER PIN
2 - FABRICATED TOOL
3 - BEARING INSERT
4 - TONGUE DEPRESSOR
Fig. 43 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 45). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(12) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock.
(13) I nstal l the oi l pump (Refer to 9 - ENGI NE/
LUBRI CATI ON/OI L PUMP - I NSTALLATI ON).
(14) I nstal l the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON).
(16) I nstal l new rear mai n seal . (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - REAR - I NSTALLATI ON).
(18) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(19) Fi l l the oi l pan wi th engi ne oi l to the safe
mark on the di psti ck l evel .
CRANKSHAFT OIL SEAL -
FRONT
DESCRIPTION
Both the crankshaft front seal and rear mai n seal
are a one pi ece vi ton seal wi th a steel housi ng. The
front seal i s l ocated i n the engi ne front cover. The
rear seal i s l ocated i n a bore at the rear of the engi ne
bl ock, the crankshaft protrudes through the rear
mai n seal .
OPERATION
The crankshaft seal s prevent oi l from l eaki ng from
around the crankshaft, ei ther from the rear of the
engi ne or from the engi ne front cover.
REMOVAL
The oi l seal can be repl aced wi thout removi ng the
ti mi ng chai n cover, provi ded that the cover i s not
mi sal i gned.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove vi brati on damper (Refer to 9 -
REMOVAL).
Fig. 44 Location of Mopar Gasket Maker
2 - 19 mm (.75 IN)
3 - 6 mm (0.025 IN)
Fig. 45 Crankshaft End Play Measurement
1 - DIAL INDICATOR
2 - CRANKSHAFT
(3) I f front seal i s suspected of l eaki ng, check front
oi l seal al i gnment to crankshaft. The seal i nstal l a-
ti on/al i gnment Tool 6635, shoul d fi t wi th mi ni mum
i nterference. I f tool does not fi t, the cover must be
removed and i nstal l ed properl y.
(4) Pl ace a sui tabl e tool behi nd the l i ps of the oi l
seal to pry the oi l seal outward. Be careful not to
damage the crankshaft seal bore of cover.
INSTALLATION
(1) Pl ace the smal l er di ameter of the oi l seal over
Front Oi l Seal I nstal l ati on Tool 6635. Seat the oi l
seal i n the groove of the tool .
(2) Posi ti on the seal and tool onto the crankshaft.
(3) Usi ng the vi brati on damper bol t, ti ghten the
bol t to draw the seal i nto posi ti on on the crankshaft
(Fi g. 46).
(4) Remove the vi brati on damper bol t and seal
i nstal l ati on tool .
(5) I nspect the seal fl ange on the vi brati on
damper.
(6) I nstal l the vi brati on damper(Refer to 9 -
I NSTALLATI ON).
(7) Connect the negati ve cabl e to the battery.
REAR
REMOVAL
(1) Remove the fl ywheel or converter dri ve pl ate.
Di scard the ol d bol ts.
(2) Pry out the seal from around the crankshaft
fl ange, maki ng sure not to scratch or ni ck the crank-
shaft. (Fi g. 47).
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Coat the outer l i p of the repl acement rear mai n
beari ng seal wi th engi ne oi l .
(3) Careful l y posi ti on the seal i nto pl ace. Use rear
mai n Seal I nstal l er Tool 6271A to i nstal l the seal
fl ush wi th the cyl i nder bl ock.
CAUTION: The felt lip must be located inside the
flywheel mounting surface. If the lip is not posi-
tioned correctly the flywheel could tear the seal.
(4) I nstal l the fl ywheel or converter dri ve pl ate.
New bol ts MUST be used when i nstal l i ng the fl y-
wheel or converter pl ate. Ti ghten the new bol ts to 68
Nm (50 ft. l bs.) torque. Turn the bol ts an addi ti onal
60.
Fig. 46 Installing Oil Seal
Fig. 47 Replacement of Rear Crankshaft Oil Seal
1 - CRANKSHAFT
2 - CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL - FRONT (Continued)
HYDRAULIC LIFTERS (CAM IN
BLOCK)
DIAGNOSIS AND TESTING HYDRAULIC
TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, check the oi l pressure. I f vehi cl e
has no oi l pressure gauge, i nstal l a rel i abl e gauge at
the pressure sendi ng-uni t. The pressure shoul d be
between 207-552 kPa (30-80 psi ) at 3,000 RPM.
Check the oi l l evel after the engi ne reaches normal
operati ng temperature. Al l ow 5 mi nutes to stabi l i ze
oi l l evel , check di psti ck. The oi l l evel i n the pan
shoul d never be above the FULL mark or bel ow the
ADD OI L mark on di psti ck. Ei ther of these two con-
di ti ons coul d be responsi bl e for noi sy tappets.
OIL LEVEL
HIGH
I f oi l l evel i s above the FULL mark, i t i s possi bl e
for the connecti ng rods to di p i nto the oi l . Wi th the
engi ne runni ng, thi s condi ti on coul d create foam i n
the oi l pan. Foam i n oi l pan woul d be fed to the
hydraul i c tappets by the oi l pump causi ng them to
l ose l ength and al l ow val ves to seat noi si l y.
LOW
Low oi l l evel may al l ow oi l pump to take i n ai r.
When ai r i s fed to the tappets, they l ose l ength,
whi ch al l ows val ves to seat noi si l y. Any l eaks on
i ntake si de of oi l pump through whi ch ai r can be
drawn wi l l create the same tappet acti on. Check the
l ubri cati on system from the i ntake strai ner to the
pump cover, i ncl udi ng the rel i ef val ve retai ner cap.
When tappet noi se i s due to aerati on, i t may be
i ntermi ttent or constant, and usual l y more than one
tappet wi l l be noi sy. When oi l l evel and l eaks have
been corrected, operate the engi ne at fast i dl e. Run
engi ne for a suffi ci ent ti me to al l ow al l of the ai r
i nsi de the tappets to be bl ed out.
TAPPET NOISE DIAGNOSIS
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by exces-
si ve l eak-down around the uni t pl unger, or by the
pl unger parti al l y sti cki ng i n the tappet body cyl i nder.
The tappet shoul d be repl aced. A heavy cl i ck i s
caused by a tappet check val ve not seati ng, or by for-
ei gn parti cl es wedged between the pl unger and the
tappet body. Thi s wi l l cause the pl unger to sti ck i n
the down posi ti on. Thi s heavy cl i ck wi l l be accompa-
ni ed by excessi ve cl earance between the val ve stem
and rocker arm as val ve cl oses. I n ei ther case, tappet
assembl y shoul d be removed for i nspecti on and cl ean-
i ng.
(4) The val ve trai n generates a noi se very much
l i ke a l i ght tappet noi se duri ng normal operati on.
Care must be taken to ensure that tappets are mak-
i ng the noi se. I f more than one tappet seems to be
noi sy, i ts probabl y not the tappets.
LEAK-DOWN TEST
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 48).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Uni versal Leak-
Down Tester .
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
REMOVAL
Retai n al l the components i n the same order as
removed.
(2) Remove the bri dge and pi vot assembl i es and
rocker arms by removi ng the capscrews at each
bri dge. Al ternatel y l oosen each capscrew, one turn at
a ti me, to avoi d damagi ng the bri dges.
(4) Remove the tappets through the push rod open-
i ngs i n the cyl i nder head wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 49).
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(4) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(5) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
DESCRIPTION
The pi stons are made of al umi num and have three
ri ng grooves, the top two grooves are for the compres-
si on ri ngs and the bottom groove i s for the oi l control
ri ng. The connecti ng rods are forged steel and are
coi ned pri or to heat treat. The pi ston pi ns are press
fi t.
Fig. 48 Leak-Down Tester
1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP
5 - HANDLE
6 - PUSH ROD
Fig. 49 Hydraulic Valve Tappet Removal/Installation
Tool
1 - HYDRAULIC VALVE TAPPET REMOVAL/INSTALLATION TOOL
HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued)
STANDARD PROCEDURE PISTON FITTING
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 51).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 50). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
REMOVAL
(2) Remove the rocker arms, bri dges and pi vots.
(4) Remove the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL).
Fig. 50 Moly Coated Piston
1 - MOLY COATED
2 - MOLY COATED
Fig. 51 Bore Gauge
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
PISTON & CONNECTING ROD (Continued)
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(7) Drai n the engi ne oi l .
BRI CATI ON/OI L PAN - REMOVAL) and gasket.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 52).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 53).
CLEANING
Cl ean the pi ston and connecti ng rod assembl y
usi ng a sui tabl e sol vent.
INSPECTION
Check the connecti ng rod journal for excessi ve
wear, taper and scori ng. Refer to Connecti ng Rod
Beari ngs i n the Servi ce Procedures porti on of thi s
Secti on.
Check the connecti ng rod for si gns of twi st or bend-
i ng.
Check the pi ston for taper and el l i pti cal shape
before i t i s fi tted i nto the cyl i nder bore. Refer to Fi t-
ti ng Pi stons i n the Servi ce Procedures porti on of thi s
Secti on.
Check the pi ston for scori ng, or scrapi ng marks i n
the pi ston ski rts. Check the ri ng l ands for cracks
and/or deteri orati on.
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed (Refer to 9 - ENGI NE/ENGI NE BLOCK/
PI STON RI NGS - STANDARD PROCEDURE).
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts do not
scratch the crankshaft journals or cylinder walls.
Short pieces of rubber hose slipped over the con-
necting rod bolts will provide protection during
installation.
Fig. 52 Stamped Connecting Rods and Caps
1 - CONNECTING ROD CAP
2 - CONNECTING ROD
Fig. 53 Removal of Connecting Rod and Piston
Assembly
1 - PISTON
2 - CONNECTING ROD
3 - CYLINDER BLOCK
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 54).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 54).
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart (Refer to 9 - ENGI NE/ENGI NE
BLOCK/CONNECTI NG ROD BEARI NGS - STAN-
DARD PROCEDURE). The col or code appears on the
edge of the beari ng i nsert. The si ze i s not stamped on
i nserts used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r refer
to Connecti ng Rod Beari ng Fi tti ng Chart (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CONNECTI NG ROD
BEARI NGS - STANDARD PROCEDURE). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
BRI CATI ON/OI L PAN - I NSTALLATI ON) and gas-
ket.
(13) I nstal l the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON),
push rods, rocker arms, bri dges, pi vots and engi ne
cyl i nder head cover (Refer to 9 - ENGI NE/CYLI N-
DER HEAD/CYLI NDER HEAD COVER(S) -
I NSTALLATI ON).
(14) Fi l l the crankcase wi th engi ne oi l .
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 55) (Fi g. 56). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
Fig. 54 Rod and Piston Assembly Installation
Fig. 55 Piston Dimensions
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 57).
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 58).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 60).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 59) (Fi g.
61).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Fig. 56 Ring Side Clearance Measurement
1 - FEELER GAUGE
Fig. 57 Gap Measurement
1 - FEELER GAUGE
Fig. 58 Top Compression ring
1 - TOP COMPRESSION RING
PISTON RINGS (Continued)
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
62).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
Fig. 59 Second Compression Ring Identification
1 - SECOND COMPRESSION RING
2 - CHAMFER
3 - ONE DOT
Fig. 60 Compression Ring Chamfer Location
3 - PISTON
4 - CHAMFER
Fig. 61 Compression Ring
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
Fig. 62 Ring Gap Orientation
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
VIBRATION DAMPER
REMOVAL
(2) Remove the serpenti ne dri ve bel t (Refer to 7 -
REMOVAL) and fan shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 63).
INSTALLATION
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i n posi ti on, al i gn the keyway on
the vi brati on damper hub wi th the crankshaft key
and tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(4) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
I NSTALLATI ON) and ti ghten to the speci fi ed tensi on
(Refer to 7 - COOLI NG/ACCESSORY DRI VE/DRI VE
BELTS - ADJUSTMENTS).
FRONT MOUNT
REMOVAL
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
(3) Support the engi ne.
(4) Remove through bol t and nut.
(5) Rai se engi ne to al l ow cl earance when removi ng
i nsul ator.
(6) Remove the retai ni ng bol ts attachi ng i nsul ator
assembl y to engi ne bl ock.
(7) Remove the i nsul ator assembl y (Fi g. 64) (Fi g.
65).
INSTALLATION
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
(1) Posi ti on i nsul ator assembl y on cyl i nder bl ock
and i nstal l the nuts and bol ts. Ti ghten the bol ts to 81
Nm (60 ft. l bs.) torque. Ti ghten the nuts to 47 Nm
(35 ft. l bs.)
(2) I nstal l the through bol t and retai ni ng nut but
DO NOT TI GHTEN.
(3) Lower engi ne unti l through bol t and nut are
resti ng i n frame bracket and wei ght of engi ne i s off
of supporti ng devi ce.
(4) Ti ghten the through bol t nut to 68 Nm (60 ft.
l bs.) torque.
(5) Remove the engi ne support.
Fig. 63 Vibration Damper Removal Tool 7697
1 - VIBRATION DAMPER REMOVAL TOOL
2 - WRENCH
Fig. 64 Right Front Engine Mount Assembly
1 - STUD
2 - GENERATOR BRACKET
3 - NUT
4 - INSULATOR
5 - THROUGH BOLT
6 - BOLT
REAR MOUNT
REMOVAL
(3) Remove the through bol t and nut.
(4) Support the transmi ssi on wi th a jack. Rai se
transmi ssi on sl i ghtl y.
(5) Remove nuts securi ng i nsul ator to crossmem-
ber (Fi g. 66).
(6) Remove i nsul ator.
INSTALLATION
(1) I f the rear engi ne support bracket was
removed, posi ti on the bracket to the transmi ssi on.
Ti ghten the stud nuts to 41 Nm (30 ft. l bs.) torque.
(2) I nstal l the i nsul ator onto the transmi ssi on
mounti ng crossmember. Ti ghten the stud nuts to 41
(3) Lower the transmi ssi on and engi ne whi l e al i gn-
i ng the rear engi ne support bracket to the i nsul ator.
(a) I nstal l through-bol t i n bracket and i nsul ator.
Ti ghten through-bol t nut to 68 Nm (50 ft. l bs.)
torque.
(4) Remove transmi ssi on jack.
LUBRICATION
DESCRIPTION
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
Fig. 65 Left Front Engine Mount Assembly
1 - STUD
2 - BOLT
3 - INSULATOR
4 - THROUGH BOLT
5 - FRAME
6 - NUT
7 - NUT
Fig. 66 Rear Engine Support
1 - TRANSMISSION
2 - CROSSMEMBER
3 - INSULATOR
4 - SUPPORT BRACKET
FRONT MOUNT (Continued)
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan (Fi g. 67).
DIAGNOSIS AND TESTING REAR SEAL AREA
LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs, oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri zed the crank-
case as outl i ned i n (Refer to 9 - ENGI NE/LUBRI CA-
TI ON - DI AGNOSI S AND TESTI NG)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed. Refer to the servi ce Di agnosi sMechani -
cal , under the Oi l Leak row, for components
i nspecti ons on possi bl e causes and correcti ons.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed, (Refer to 9 -
SEAL - REAR - REMOVAL), for proper repl acement
procedures.
DIAGNOSIS AND TESTING ENGINE OIL
LEAKS
Begi n wi th a through vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l -sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
be sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght source.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat previ ous step.
(5) I f the oi l l eak source i s not posi ti vel y i denti fi ed
at thi s ti me, proceed wi th the ai r l eak detecti on test
method as fol l ows:
(6) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(7) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(8) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
LUBRICATION (Continued)
Fig. 67 Oil Lubrication System2.5L Engine
(9) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(10) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(11) I f no l eaks are detected, turn off the ai r sup-
pl y and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose. Proceed
to next step.
(12) Cl ean the oi l off the suspect oi l l eak area
usi ng a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
PRESSURE
(1) Remove oi l pressure sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292. Start engi ne and record pressure. (Refer to 9
- ENGI NE - SPECI FI CATI ONS).
OIL
STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engi ne oi l l evel i ndi cator i s l ocated at the ri ght
front of the engi ne, l eft of the generator (Fi g. 68).
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck.
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng.
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n the Mai ntenance Schedul e. Thi s i nfor-
mati on can be found i n the owners manual .
TO CHANGE ENGINE OIL
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st vehi cl e.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug and
gasket i f damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Change oi l fi l ter (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L FI LTER - REMOVAL).
1 - CAM/CRANK MAIN GALLERY (5)
2 - TAPPET GALLERY
3 - TAPPET GALLERY
4 - CAMSHAFT BEARING
5 - NUMBER 1 CAMSHAFT BEARING JOURNAL
6 - CAMSHAFT SPROCKET
7 - TAPPET GALLERY
Fig. 68 Oil Level Indicator Location
1 - CYLINDER HEAD COVER
2 - ENGINE OIL FILL CAP
3 - DIPSTICK
4 - ENGINE OIL FILTER
5 - FILTER BOSS
(8) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type (Refer to LUBRI CATI ON & MAI NTENANCE/
FLUI D TYPES - DESCRI PTI ON) and amount of
engi ne oi l (Refer to LUBRI CATI ON & MAI NTE-
NANCE - SPECI FI CATI ONS).
(9) I nstal l oi l fi l l cap.
(10) Start engi ne and i nspect for l eaks.
(11) Stop engi ne and i nspect oi l l evel .
OIL FILTER
REMOVAL
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Dai ml erChrysl er Cor-
porati on recommends a Mopar or equi val ent oi l
fi l ter be used.
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss (Fi g. 69).
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 70) of oi l and gri me.
(6) I nstal l new fi l ter (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L FI LTER - I NSTALLATI ON).
INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 70) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l (Refer to 9 - ENGI NE/LUBRI CATI ON/
OI L - STANDARD PROCEDURE).
OIL PAN
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the engi ne
exhaust mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the engi ne starter motor.
(7) Remove the fl ywheel /torque converter housi ng
access cover.
(8) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(9) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(10) Remove the engi ne mount through bol ts.
(11) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(12) I f equi pped, di sconnect the transmi ssi on
cool er l i nes and oxygen sensor harness from oi l pan
mounti ng studs.
(13) Remove the oi l pan bol ts and studs. Careful l y
remove the oi l pan and gasket.
CLEANING
Cl ean the bl ock and pan gasket surfaces.
Tri m or remove excess seal ant fi l m i n the rear
mai n cap oi l pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
I f present, tri m excess seal ant from i nsi de the
engi ne.
Cl ean oi l pan i n sol vent and wi pe dry wi th a cl ean
cl oth.
Cl ean oi l screen and pi pe thoroughl y i n cl ean sol -
vent. I nspect condi ti on of screen.
Fig. 69 Oil Filter RemovalTypical
2 - OIL FILTER WRENCH
Fig. 70 Oil Filter Sealing SurfaceTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
OIL (Continued)
INSPECTION
I nspect oi l drai n pl ug and pl ug hol e for stri pped or
damaged threads. Repai r as necessary.
I nspect oi l pan mounti ng fl ange for bends or di stor-
ti on. Strai ghten fl ange, i f necessary.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1/4 x 1 1/2
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 71).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 72).
(4) Appl y Mopar Si l i cone Adhesi ve Seal ant onto
the cyl i nder bl ock i n four l ocati on as shown (Fi g. 73)
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket.
(7) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 74). Ti ghten these bol ts to 15
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(10) I nstal l the through bol ts and ti ghten the nuts.
(11) Lower the jack stand and remove the pi ece of
wood.
Fig. 71 Fabrication of Alignment Dowels
1 - 1/4'' 1 1/2'' BOLT
2 - DOWEL
3 - SLOT
Fig. 72 Position of Dowels in Cylinder Block
1 - 5/16'' HOLES
2 - DOWEL HOLES
3 - CYLINDER BLOCK
4 - 5/16'' HOLES
Fig. 73 Location of Mopar Silicone Adhesive
Sealant on
1 - SEALER LOCATIONS
Fig. 74 Position of 5/16 inch Oil Pan Bolts
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
OIL PAN (Continued)
(12) I nstal l the fl ywheel and torque converter
housi ng access cover.
(13) I nstal l the engi ne starter motor.
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l the oi l pan drai n pl ug (Fi g. 74).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(18) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(19) Start the engi ne and i nspect for l eaks.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 2wi re, el ectri cal /mechani cal engi ne oi l pres-
sure sensor (sendi ng uni t) i s l ocated i n an engi ne oi l
pressure gal l ery.
OPERATION
The oi l pressure sensor uses two ci rcui ts. They are:
A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
A sensor ground through the PCMs sensor
return
The oi l pressure sensor returns a vol tage si gnal
back to the PCM rel ati ng to engi ne oi l pressure. Thi s
si gnal i s then transferred (bussed) to the i nstrument
panel on a CCD bus ci rcui t to operate the oi l pres-
sure gauge and the check gauges l amp. Ground for
the sensor i s provi ded by the PCM through a l ow-
noi se sensor return.
OIL PUMP
REMOVAL
The posi ti ve-di spl acement gear-type oi l pump i s
dri ven by the di stri butor shaft, whi ch i s dri ven by a
gear on the camshaft. Oi l i s si phoned i nto the pump
through an i nl et tube and strai ner assembl y that i s
pressed i nto the pump body.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
(1) Drai n the engi ne oi l .
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
75).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
The posi ti ve-di spl acement gear-type oi l pump i s
dri ven by the di stri butor shaft, whi ch i s dri ven by a
gear on the camshaft. Oi l i s si phoned i nto the pump
through an i nl et tube and strai ner assembl y that i s
pressed i nto the pump body.
Fig. 75 Oil Pump Assembly
1 - OIL FILTER ADAPTOR
2 - BLOCK
3 - GASKET
4 - OIL INLET TUBE
5 - OIL PUMP
6 - STRAINER ASSEMBLY
7 - ATTACHING BOLTS
OIL PAN (Continued)
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(2) I nstal l the oi l pan and gasket (Refer to 9 -
TI ON).
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
INTAKE MANIFOLD
DESCRIPTION
The al umi num i ntake mani fol d i s a si ngl e pl ane
desi gn.
The i ntake mani fol d and the exhaust mani fol d
share a common one pi ece seal i ng gasket.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
REMOVAL
(3) Remove the ai r i nl et hose and resonator from
the throttl e body and ai r cl eaner (Fi g. 76).
(4) Loosen the accessory dri ve bel t tensi on and
remove the bel t from the power steeri ng pump (Refer
to 7 - COOLI NG/ACCESSORY DRI VE/DRI VE
BELTS - REMOVAL).
(5) Remove the power steeri ng pump and brackets
from the water pump and i ntake mani fol d. Secure
power steeri ng pump and bracket out of the way.
(6) Perform fuel system pressure rel ease procedure
(7) Di sconnect fuel suppl y tube from the fuel rai l
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
DURE).
(8) Di sconnect the accel erator cabl e, the crui se
control cabl e (i f equi pped), and the transmi ssi on l i ne
pressure cabl e (i f equi pped) from the throttl e body
and remove them from the cabl e bracket.
CAUTION: When disconnecting the cruise control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Di sconnect the el ectri cal connectors. Pul l the
harnesses away from the mani fol d and secure them
so they do not i nterfere wi th the mani fol d removal
and i nstal l ati on process.
The throttl e posi ti on sensor.
The i dl e ai r control motor.
The cool ant temperature sensor at the thermo-
stat.
Fig. 76 Air Cleaner, Resonator and Air Inlet Hose
Removal and Installation
1 - AIR CLEANER ASSEMBLY
2 - NUT AND WASHER
3 - RESONATOR ASSEMBLY
4 - AIR INLET HOSE
OIL PUMP (Continued)
The mani fol d ai r temperature sensor at the
i ntake mani fol d.
The fuel i njectors.
The oxygen sensor.
(10) Di sconnect the crankcase venti l ati on (CCV)
vacuum hose and mani fol d absol ute pressure (MAP)
sensor vacuum hose connector at the i ntake mani -
fol d.
(11) Di sconnect vacuum hose from vacuum port on
the i ntake mani fol d.
(12) Di sconnect CCV hose at the cyl i nder head
cover (Fi g. 77).
(13) Remove the mol ded vacuum harness.
(14) Di sconnect the vacuum brake booster hose at
the i ntake mani fol d.
(15) Remove bol ts 2 through 5 securi ng the i ntake
mani fol d to the cyl i nder head (Fi g. 78). Sl i ghtl y
l oosen bol t No.1 and nuts 6 and 7.
(16) Remove the i ntake mani fol d and gaskets.
Drai n the cool ant from the mani fol d.
CLEANING
CAUTION: DO NOT allow foreign material to enter
either the intake manifold ports, or the cylinder
head ports.
Cl ean the i ntake mani fol d to cyl i nder head mati ng
surfaces.
INSPECTION
I nspect mani fol d to cyl i nder head mati ng surfaces
for cracks and/or pi tti ng. I nspect mani fol d for warp
or twi st.
INSTALLATION
(1) Cl ean the i ntake mani fol d and cyl i nder head
mati ng surfaces. DO NOT allow foreign material
to enter either the intake manifold or the ports
in the cylinder head.
(2) I nstal l the new i ntake mani fol d gasket over the
l ocati ng dowel s.
(3) Posi ti on the mani fol d i n pl ace and fi nger
ti ghten the mounti ng bol ts.
(4) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 78).
Fastener No.1Ti ghten to 41 Nm (30 ft. l bs.)
torque.
Fasteners Nos.2 through 5Ti ghten to 31 Nm
Fasteners Nos.6 and 7Ti ghten to 23 Nm (17
ft. l bs.) torque.
(5) Connect fuel suppl y tube to the fuel rai l i nl et
DURE).
(6) Pul l out on the fuel suppl y tube to ensure that
i t i s l ocked i n pl ace.
(7) Connect the mol ded vacuum hoses to the vac-
uum port on the i ntake mani fol d and the cyl i nder
head cover.
(8) Connect the el ectri cal connectors.
The throttl e posi ti on sensor.
The i dl e ai r control motor.
The cool ant temperature sensor at the thermo-
stat housi ng.
The fuel i njectors.
The ai r mani fol d temperature sensor.
The oxygen sensor.
(9) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttl e body.
(10) I nstal l the power steeri ng pump and bracket
assembl y to the water pump and i ntake mani fol d.
Hand start the three (3) tensi oner bracket to p/s
pump to i ntake mani fol d bol ts and the two (2) ten-
si oner bracket to water pump bol ts.
(11) Ti ghten the power steeri ng pump bol ts to 28
Nm (21 ft. l bs.) Ti ghten the tensi oner bracket to
water pump bol ts to 28 Nm (21 ft. l bs.).
(12) Connect the accel erator cabl e, crui se control
cabl e (i f equi pped), and the transmi ssi on l i ne pres-
sure cabl e (i f equi pped) to the hol d-down bracket and
the throttl e l ever.
(13) I nstal l and tensi on the accessory dri ve bel t.
BELTS - I NSTALLATI ON).
Fig. 77 Crankcase Ventilation (CCV) Hose2.5L
2 - AIR FILTER COVER
INTAKE MANIFOLD (Continued)
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the
water pump to turn in the opposite direction result-
ing in engine overheating. Refer to Group 7, Cool-
ing System for the proper procedure.
(14) Connect the ai r i nl et hose and resonator to
the throttl e body and the ai r cl eaner. Ti ghten cl amps
to 4 Nm (35 i n. l bs.).
(16) Start the engi ne and check for l eaks.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol d i s constructed of cast i ron
and has a bal l fl ange desi gned exhaust pi pe mount-
i ng fl ange.
The exhaust mani fol d and the i ntake mani fol d
share a common one pi ece seal i ng gasket.
OPERATION
The exhaust mani fol d col l ects the engi ne exhaust
exi ti ng the combusti on chambers, then channel s the
exhaust gases to the exhaust pi pe attached to the
mani fol d.
REMOVAL
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d.
(6) Remove i ntake mani fol d (Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - REMOVAL).
(7) Remove fasteners 2 through 5 and remove the
i ntake mani fol d (Fi g. 78).
(8) Remove fasteners 1, 6 and 7 and remove the
engi ne exhaust mani fol d (Fi g. 78).
CLEANING
Cl ean mati ng surfaces on cyl i nder head and mani -
fol d, wash wi th sol vent and bl ow dry wi th com-
pressed ai r.
INSPECTION
I nspect mani fol d for cracks, I nspect mati ng sur-
faces of mani fol d for fl atness wi th a strai ght edge.
Seal surfaces must be fl at wi thi n 0.1 mm (0.004 i nch)
overal l .
INSTALLATION
(1) Cl ean the i ntake and engi ne exhaust mani fol ds
and cyl i nder head mati ng surfaces. DO NOT allow
foreign material to enter either the intake man-
ifold or the ports in the cylinder head.
(2) I nstal l a new i ntake mani fol d gasket over the
al i gnment dowel s on the cyl i nder head.
(3) I nstal l the engi ne exhaust mani fol d assembl y.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 78).
(4) Ti ghten bol t No.1 to 41 Nm (30 ft. l bs.) torque
(Fi g. 78).
(5) I nstal l the i ntake mani fol d on the cyl i nder
head dowel s (Fi g. 78).
(6) I nstal l bol ts 2 through 5 (Fi g. 78). Ti ghten
these bol ts to 31 Nm (23 ft. l bs.) torque.
(7) I nstal l new engi ne exhaust mani fol d spacers
over the engi ne exhaust mani fol d mounti ng studs i n
the cyl i nder head (Fi g. 78).
(8) Ti ghten nuts 6 and 7 to 23 Nm (17 ft. l bs.)
torque (Fi g. 78).
(9) I nstal l the i ntake mani fol d (Refer to 9 -
I NSTALLATI ON).
(11) Connect the exhaust pi pe to the engi ne
exhaust mani fol d. Ti ghten the bol ts to 31 Nm (23 ft.
l bs.) torque.
Fig. 78 Intake/Exhaust Manifold Removal/Installation
VALVE TIMING
STANDARD PROCEDURE - CHECKING TIMING
CHAIN WEAR
NOTE: Timing chain tensioner must be removed for
this operation.
(1) Pl ace a scal e next to the ti mi ng chai n so that
any movement of the chai n can be measured.
(2) Pl ace a torque wrench and socket over cam-
shaft sprocket attachi ng bol t. Appl y torque i n the
di recti on of crankshaft rotati on to take up sl ack; 41
Nm (30 ft. l bs.) torque wi th cyl i nder head i nstal l ed
or 20 Nm (15 ft. l bs.) torque wi th cyl i nder head
removed. Wi th torque appl i ed to the camshaft
sprocket bol t, crankshaft shoul d not be permi tted to
move. I t may be necessary to bl ock the crankshaft to
prevent rotati on.
(3) Hol d a scal e wi th di mensi onal readi ng even
wi th the edge of a chai n l i nk. Wi th cyl i nder heads
i nstal l ed, appl y 14 Nm (30 ft. l bs.) torque i n the
reverse di recti on. Wi th the cyl i nder heads removed,
appl y 20 Nm (15 ft. l bs.) torque i n the reverse di rec-
ti on. Note the amount of chai n movement (Fi g. 79) .
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
REMOVAL).
(3) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(4) Remove the fan and hub assembl y and remove
the fan shroud.
(5) Remove the A/C compressor (i f equi pped) (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
I NG/A/C COMPRESSOR - REMOVAL) and generator
bracket assembl y from the engi ne cyl i nder head and
move to one si de.
REMOVAL) (Fi g. 80).
(7) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(8) Remove the ti mi ng case cover and gasket from
the engi ne.
(9) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 80).
INSTALLATION
(1) Cl ean the ti mi ng case cover, oi l pan and cyl i n-
der bl ock gasket surfaces.
(2) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CRANKSHAFT OI L SEAL - FRONT - I NSTALLA-
TI ON). The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(3) Posi ti on the gasket on the cyl i nder bl ock.
(4) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(5) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 81).
(6) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
Fig. 79 Measuring Timing Chain Wear and Stretch
1 - TORQUE WRENCH
2 - 3.175 MM (0.125 IN.)
Fig. 80 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
(7) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover bol ts to 9.5 Nm (84 i n.
l bs.) torque.
(8) Remove the cover al i gnment tool .
(9) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
I NSTALLATI ON).
(11) I nstal l the A/C compressor (i f equi pped) (Refer
I NG/A/C COMPRESSOR - I NSTALLATI ON) and
generator bracket assembl y.
(12) I nstal l the engi ne fan and hub assembl y and
shroud.
I NSTALLATI ON) and ti ghten to obtai n the speci fi ed
tensi on.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
The chai n dri ve system i s equi pped wi th a ti mi ng
chai n tensi oner whi ch reduces noi se and prol ongs
ti mi ng chai n l i fe. I n addi ti on, i t compensates for
wear and temperature changes on the val ve trai n for
proper engi ne operati on.
(2) Remove the fan and shroud.
REMOVAL).
(4) Remove the crankshaft vi brati on damper (Refer
to 9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - REMOVAL).
(5) Remove the ti mi ng case cover (Refer to 9 -
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 82).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y (Fi g.
83).
Fig. 81 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 - TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
Fig. 82 CrankshaftCamshaft Alignment
1 - TIMING MARKS
Fig. 83 Camshaft and Crankshaft Sprockets and
Chain
2 - CRANKSHAFT SPROCKET
3 - CHAIN
TIMING BELT / CHAIN COVER(S) (Continued)
INSTALLATION
The chai n dri ve system i s equi pped wi th a ti mi ng
chai n tensi oner whi ch reduces noi se and prol ongs
ti mi ng chai n l i fe. I n addi ti on, i t compensates for
wear and temperature changes on the val ve trai n for
proper engi ne operati on.
(1) Turn the tensi oner l ever to the unl ocked (down)
(2) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 84).
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i n the crankshaft keyway, i nstal l
the crankshaft, camshaft sprockets and ti mi ng chai n.
Ensure the ti mi ng marks on the sprockets are prop-
erl y al i gned (Fi g. 82).
(4) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(5) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 85). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 20 pi ns.
(6) Turn the chai n tensi oner l ever to the unl ocked
(down) posi ti on (Fi g. 84).
(7) I nstal l the oi l sl i nger.
(8) Repl ace the oi l seal i n the ti mi ng case cover
SHAFT OI L SEAL - FRONT - I NSTALLATI ON).
(9) I nstal l the ti mi ng case cover and gasket (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT /
CHAI N COVER(S) - I NSTALLATI ON).
(10) Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 Nm (80 ft.
l bs.) torque.
(11) I nstal l the fan and shroud.
Fig. 84 Loading Timing Chain Tensioner
1 - LOCK
2 - UNLOCK
3 - TENSIONER BLOCK
4 - TENSIONER LEVER
Fig. 85 Verify SprocketChain Installation
2 - 20 PINS
4 - TIMING MARKS
TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE 3.9L
TABLE OF CONTENTS
page page
ENGINE 3.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ENGINE DIAGNOSIS - INTRODUCTION. . . . . . 65
ENGINE DIAGNOSIS - PERFORMANCE. . . . . . 65
ENGINE DIAGNOSIS - MECHANICAL. . . . . . . . 68
ENGINE DIAGNOSIS - LUBRICATION . . . . . . . 70
CYLINDER COMPRESSION PRESSURE . . . . . 70
LEAKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CYLINDER BORE HONING . . . . . . . . . . . . . . . 71
ENGINE GASKET SURFACE PREPARATION . . 72
ENGINE CORE AND OIL GALLERY PLUGS . . . 72
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . . 73
REPAIR DAMAGED OR WORN THREADS . . . . 73
FORM-IN-PLACE GASKETS AND SEALERS. . . 73
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 75
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 80
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CYLINDER HEAD
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 82
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CYLINDER HEAD GASKET FAILURE . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 84
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
VALVES, GUIDES AND SPRINGS. . . . . . . . . . . 85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE BLOCK
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 90
CONNECTING ROD BEARING FITTING. . . . . . 92
CRANKSHAFT
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 92
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 92
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
MAIN BEARING FITTING . . . . . . . . . . . . . . . . . 93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . . 95
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DISTRIBUTOR BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
HYDRAULIC LIFTERS (CAM IN BLOCK)
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . 99
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 100
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 101
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 101
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 101
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 102
PISTON RINGS
PISTON RING FITTING. . . . . . . . . . . . . . . . . . 102
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 104
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 106
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 108
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 109
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . . . . 111
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . 111
ENGINE OIL LEAKS . . . . . . . . . . . . . . . . . . . . 111
OIL
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 111
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 112
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 113
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 113
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 116
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 116
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INTAKE MANIFOLD LEAKAGE . . . . . . . . . . . . 116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 117
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 119
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 119
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 120
TIMING BELT/CHAIN TENSIONER AND PULLEY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 120
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 122
ENGINE 3.9L
DESCRIPTION
The 3.9 Li ter (238 CI D) si x-cyl i nder engi ne i s a
V-Type, l i ghtwei ght, si ngl e cam, overhead val ve
engi ne wi th hydraul i c rol l er tappets. Thi s engi ne i s
desi gned to use unl eaded fuel .
The engi ne l ubri cati on system consi sts of a rotor
type oi l pump and a ful l -fl ow oi l fi l ter.
The cyl i nders are numbered from front to rear; 1,
3, 5 on the l eft bank and 2, 4, 6 on the ri ght bank.
The fi ri ng order i s 1-6-5-4-3-2 (Fi g. 1).
The engi ne seri al number i s stamped i nto a
machi ned pad l ocated on the l eft front corner of the
cyl i nder bl ock. When component part repl acement i s
necessary, use the engi ne type and seri al number for
Fig. 1 Firing Order
AND TESTI NG)
I NG)
Engi ne Oi l Leak I nspecti on (Refer to 9 -
ENGI NE/LUBRI CATI ON - DI AGNOSI S AND TEST-
I NG)
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
4. Seized accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock
Fig. 2 Engine Identification (Serial) Number
ENGINE CRANKS BUT WILL NOT
START
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
pressure test. (Refer to 9 - ENGINE
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
8. Low compression 8. Test cylinder compression (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
system
cables
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit.
plugs
3. Replace or clean and re-gap
spark plugs (Refer to 8 -
SPARK PLUG - CLEANING)
crossed
replace spark plug cables. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG CABLE -
6. Faulty coil 6. Test and replace, if necessary
COIL - REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD - DIAGNOSIS AND
TESTING).
ENGINE MISSES ON
ACCELERATION
plugs
1. Replace spark plugs or clean and
set gap. (Refer to 8 - ELECTRICAL/
- CLEANING)
crossed
2. Replace or rewire secondary
ignition cables. (Refer to 8 -
SPARK PLUG CABLE - REMOVAL)
5. Faulty coil 5. Test and replace as necessary
COIL - REMOVAL)
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - MECHANICAL
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust oil
level by draining or adding as needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 - ENGINE/
PROCEDURE)
TESTING) for engine oil pressure
test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic tappets/lash
adjusters
6. Worn rocker arms 6. Inspect oil supply to rocker arms and
replace worn arms as needed
adjusters
8. Worn valve guides 8. Inspect all valve guides and replace
as necessary
9. Excessive runout of valve seats or
valve faces
CONNECTING ROD
NOISE
1. Insufficient oil supply 1. Check engine oil level.
TESTING) engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity. (Refer
to 9 - ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE) for correct
4. Excessive connecting rod bearing
clearance
Measure bearings for correct clearance
with plasti-gage. Repair as necessary
5. Connecting rod journal out of round 5. Replace crankshaft or grind journals
TESTING)
4. Excessive main bearing clearance 4. Measure bearings for correct
5. Excessive end play 5. Check crankshaft thrust bearing for
excessive wear on flanges
6. Crankshaft main journal out of round
or worn
6. Grind journals or replace crankshaft
7. Loose flywheel or torque converter 7. Inspect crankshaft, flexplate/flywheel
and bolts for damage. Tighten to correct
torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean and
reinstall
8. Oil pump suction tube loose, broken,
bent or clogged
9. Oil pump cover warped or cracked 9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated gaskets 1. Replace gasket
metal part
leaking
3. Replace seal
4. Leaking oil gallery plug or cup plug 4. Remove and reseal threaded plug.
Replace cup style plug
EXCESSIVE OIL
CONSUMPTION OR
SPARK PLUGS OIL
FOULED
CONTROL/EVAPORATIVE EMISSIONS
- DESCRIPTION) for correct operation
3. Worn or broken piston rings 3. Hone cylinder bores. Install new rings
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon piston
necessary
grooves
7. Remove rings and check ring end gap
and side clearance. Replace if
necessary
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - LUBRICATION
porous metal parts.
5. Replace seal.
damper hub.
clearance.
damaged.
PLUGS FOULING
rings.
ti ons.
ai r.
REMOVAL).
revol uti ons.
(6) Record the compressi on pressure on the thi rd rev-
ol uti on. Conti nue the test for the remai ni ng cyl i nders.
i ng)
jacket
l oss
OCCUR.
engi ne.
mended.
AIR ESCAPES THROUGH
THROTTLE BODY
seated properly
AIR ESCAPES THROUGH
TAILPIPE
seated properly
AIR ESCAPES THROUGH
RADIATOR
adjacent cylinders
necessary
cylinder wall
HONING
area.
taper and out-of-round, as wel l as removi ng l i ght scuff-
i ng, scori ng and scratches. Usual l y, a few strokes wi l l
cl ean up a bore and mai ntai n the requi red l i mi ts.
hatch angl e.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
preparati on must be performed.
Never use the fol l owi ng to cl ean gasket surfaces:
Metal scraper
Abrasi ve pad or paper to cl ean cyl i nder bl ock
and head
Hi gh speed power tool wi th an abrasi ve pad or a
wi re brush (Fi g. 4)
Onl y use the fol l owi ng for cl eani ng gasket surfaces:
Sol vent or a commerci al l y avai l abl e gasket
remover
Pl asti c or wood scraper (Fi g. 4)
Dri l l motor wi th 3M Rol oc Bri stl e Di sc (whi te
or yel l ow) (Fi g. 4)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Mopar
Stud and Beari ng Mount. Make certai n the new pl ug
i s cl eaned of al l oi l or grease. Usi ng proper dri ve
pl ug, dri ve pl ug i nto hol e so that the sharp edge of
the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de the
l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
2 - INTERSECT ANGLE
Fig. 4 PROPER TOOL USAGE FOR SURFACE
PREPARATION
1 - ABRASIVE PAD
2 - 3M ROLOC BRISTLE DISC
LOCK
steps bel ow.
tery.
oi l , etc.).
cyl i nders.
damage on restart.
fi l ter.
OR WORN THREADS
equi val ent.
GASKETS AND SEALERS
use.
Fig. 5 Core Hole Plug Removal
1 - CYLINDER BLOCK
4 - DRIFT PUNCH
5 - CUP PLUG
MOPAR ATF RTV
MOPAR GASKET MAKER
APPLICATION
kets.
REMOVAL
(1) Scri be hood hi nge outl i nes on hood. Remove the
hood.
(2) Remove the battery.
(4) Remove the ai r cl eaner, ai r i n-l et hose and res-
onator assembl y.
(5) Di sconnect the radi ator and heater hoses.
Remove radi ator. (Refer to 7 - COOLI NG/ENGI NE/
RADI ATOR - REMOVAL).
(6) Di sconnect the vacuum l i nes from the i ntake
mani fol d.
(7) Remove the di stri butor cap and wi ri ng.
(8) Di sconnect the accel erator l i nkage (Refer to 14
- FUEL SYSTEM/FUEL I NJECTI ON/THROTTLE
CONTROL CABLE - REMOVAL).
(9) Remove throttl e body (Refer to 14 - FUEL SYS-
TEM/FUEL I NJECTI ON/THROTTLE BODY -
REMOVAL).
(10) Perform the Fuel System Pressure Rel ease
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELI VERY - STANDARD PROCEDURE).
(11) Di sconnect the starter wi res.
(12) Di sconnect the oi l pressure wi re.
(13) Di scharge the ai r condi ti oni ng system, i f
equi pped. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/REFRI GERANT - STAN-
DARD PROCEDURE).
(14) Di sconnect the ai r condi ti oni ng hoses.
(15) Di sconnect the power steeri ng hoses, i f
equi pped.
(16) Remove starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL).
(17) Remove the generator (Refer to 8 - ELECTRI -
CAL/CHARGI NG/GENERATOR - REMOVAL).
(18) Rai se and support the vehi cl e on a hoi st.
(19) Di sconnect exhaust pi pe at mani fol ds.
(20) RemoveTransmi ssi on. Refer to 21 - TRANS-
MI SSI ON AND TRANSFER CASE.
CAUTION: DO NOT lift the engine by the intake
manifold.
(21) I nstal l an engi ne l i fti ng fi xture.
(22) 2WD VEHICLESRemove engi ne front
mount bol ts.
(23) 4WD VEHICLESThe engi ne and front
dri vi ng axl e (engi ne/axl e/transmi ssi on) are connected
through i nsul ators and support brackets. Separate
the engi ne as fol l ows:
LEFT SIDERemove 2 bol ts attachi ng (engi ne/
pi ni on nose/transmi ssi on) bracket to transmi ssi on
bel l housi ng. Remove 2 bracket to pi ni on nose adap-
tor bol ts. Separate engi ne from i nsul ator by removi ng
upper nut washer assembl y and bol t from engi ne
support bracket.
RIGHT SIDERemove 2 bracket to axl e (di s-
connect housi ng) bol ts and 1 bracket to bel l housi ng
bol t. Separate engi ne from i nsul ator by removi ng
support bracket.
(25) On automati c transmi ssi on vehi cl es, di scon-
nect the engi ne from the torque converter dri ve pl ate.
On manual transmi ssi on vehi cl es, move engi ne for-
ward unti l dri ve pi ni on shaft cl ears the cl utch di sc.
Remove engi ne from engi ne compartment.
(26) I nstal l engi ne assembl y on engi ne repai r
stand.
INSTALLATION
(1) Remove engi ne from the repai r stand and posi -
ti on i n the engi ne compartment.
(2) I nstal l an engi ne support fi xture.
(4) I nstal l transmi ssi on.
(5) I nstal l the front engi ne mounts (Refer to 9 -
ENGI NE/ENGI NE MOUNTI NG/FRONT MOUNT -
I NSTALLATI ON).
(6) I nstal l exhaust pi pe to mani fol d.
(8) Remove engi ne l i fti ng fi xture.
(9) I nstal l the generator (Refer to 8 - ELECTRI -
CAL/CHARGI NG/GENERATOR - I NSTALLATI ON).
(10) I nstal l starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - I NSTALLA-
TI ON).
(11) Connect power steeri ng hoses, i f equi pped.
(12) Connect ai r condi ti oni ng hoses.
(13) Evacuate and charge the ai r condi ti oni ng sys-
tem, i f equi pped (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG/REFRI GERANT -
(14) Usi ng a new gasket, i nstal l throttl e body
(Refer to 14 - FUEL SYSTEM/FUEL I NJECTI ON/
THROTTLE BODY - I NSTALLATI ON).
(15) Connect the accel erator l i nkage (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON/THROTTLE
CONTROL CABLE - I NSTALLATI ON).
(16) Connect the starter wi res.
(17) Connect the oi l pressure sensor wi re.
(18) I nstal l the di stri butor cap and wi ri ng.
(19) Connect the vacuum l i nes.
(20) Connect the fuel suppl y l i ne (Refer to 14 -
ENGI NE/RADI ATOR - I NSTALLATI ON). Connect
the radi ator hoses and heater hoses.
(22) I nstal l fan shroud i n posi ti on.
(24) I nstal l the ai r cl eaner, resonator assembl y and
ai r i n-l et hose. Ti ghten cl amps to 4 Nm (35 i n. l bs.).
(25) I nstal l the battery.
(26) Warm engi ne and adjust.
(27) I nstal l hood and l i ne up wi th the scri be
marks.
(28) Road test vehi cl e.
SPECIFICATIONS
TORQUE
TORQUE CHART 3.9L ENGINE
DESCRIPTION Nm In. Ft.
Lbs. Lbs.
Camshaft SprocketBolt 68 50
Camshaft Thrust
PlateBolts
24 210
Timing Chain Case
Cover
41 30
Bolts
Connecting Rod
CapBolts
61 45
Main Bearing CapBolts 115 85
Crankshaft PulleyBolts 24 210
Cylinder HeadBolts
Step 1 68 50
Step 2 143 105
Cylinder Head Cover
Bolts
11 95
Engine Support Bracket 41 30
to Block (4wd)Bolts
Exhaust Manifold to
Cylinder
34 25
Headbolts/nuts
FlywheelBolts 75 55
Front Insulatorthrough
Bolts
95 70
Front Insulator to
Support
Bracket (4wd)
Stud Nut 41 30
Through Bolt/Nut 102 75
Front Insulator to Block 95 70
Bolts (2wd)
GeneratorMounting
Bolt
41 30
Intake ManifoldBolts Refer to Procedure
Oil PanBolts 24 215
Oil PanDrain Plug 34 25
Oil PumpMounting
Bolts
41 30
Oil Pump CoverBolts 11 95
Rear Insulator to
Bracket
68 50
Through-Bolt (2WD)
Rear Insulator to
Crossmember
41 30
Support BracketNut
(2WD)
Rear Insulator to 68 50
CrossmemberNuts
(4WD)
Rear Insulator to
Transmission
68 50
Bolts (4WD)
Rear Insulator Bracket
Bolts
68 50
(4WD Automatic)
Rear Support Bracket to 41 30
Crossmember Flange
Nuts
Rear Support Plate to
Transfer
41 30
CaseBolts
Spark Plugs 41 30
Starter MotorMounting
Bolts
68 50
Thermostat Housing
Bolts
25 225
Throttle BodyBolts 23 200
Torque Converter Drive
Plate
31 270
Bolts
Transfer Case to
Insulator
204 150
Mounting PlateNuts
Bracket
68 50
Bolts (2WD)
Vibration DamperBolt 183 135
Water Pump to Timing
Chain
41 30
Case Cover Bolts
3. 9L ENGINE
GENERAL DESCRIPTION
Engine Type 90V-6 OHV
(3.91 x 3.31 in.)
Displacement 3.9L (238 c.i.)
Firing Order 165432
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
CAMSHAFT
Bearing Diameter (Inside)
No. 1 50.800 - 50.825 mm
(2.000 - 2.001 in.)
No. 2 50.394 - 50.825 mm
(1.984 - 1.985 in.)
No. 3 49.606 - 49.632 mm
(1.953 - 1.954 in.)
No. 4 39.688 - 39.713 mm
(1.5265 - 1.5653 in.)
Journal Diameter
No. 1 50.749 - 50.775 mm
(1.998 - 1.999 in.)
No. 2 50.343 - 50.368 mm
(1.982 - 1.983 in.)
No. 3 49.555 - 49.581 mm
(1.951 - 1.952 in.)
No. 4 39.637 - 39.662 mm
(1.5605 - 1.5615 in.)
Bearing to Journal
Clearance
Standard 0.0254 - 0.0762 mm
(0.001 - 0.003 in.)
Max Allowable 0.127 mm
(0.005 in.)
End Play 0.051 - 0.254 mm
(0.002 - 0.010 in.)
CONNECTING RODS
Piston Pin Bore Diameter 24.940 - 24.978 mm
(0.9819 - 0.9834 in.)
Side Clearance
(Two Rods) 0.152 - 0.356 mm
(0.006 - 0.014 in.)
Total Weight 762 grams
(25.61 oz.)
CRANKSHAFT
Rod Journal Diameter 53.950 - 53.975 mm
(2.124 - 2.125 in.)
Rod Journal Out of
Round
(Max) 0.0254 mm
(0.001 in.)
Rod Journal Taper
(Max) 0.0254 mm
(0.001 in.)
Rod Journal Bearing
Clearance
0.013 - 0.056 mm
(0.0005 - 0.0022 in.)
Rod Journal Service Limit 0.08 mm
(0.003 in.)
Main Journal Diameter 63.487 - 63.513 mm
(2.4995 - 2.5005 in.)
Main Journal Out of
Round
(Max) 0.0254 mm
(0.001 in.)
Main Journal Taper
(Max) 0.0254 mm
(0.001 in.)
Main Journal Beraing
Clearance
No. 1 0.013 - 0.038 mm
(0.0005 - 0.0015 in.)
No. 2 - 4 0.013 - 0.051 mm
(0.0005 - 0.0020 in.)
Service Limit 0.064 mm
(0.0025 in.)
End Play 0.051 - 0.178 mm
(0.002 - 0.007 in.)
End Play Service Limit 0.254 mm
(0.010 in.)
CYLINDER BLOCK
Cylinder Bore Diameter 99.308 - 99.371 mm
(3.9098 - 3.9122 in.)
Cylinder Bore Out of
Round and
taper
(Max) 0.025 mm
(0.001 in.)
Lifter Bore Diameter 22.99 - 23.01 mm
(0.9501 - 0.9059 in.)
Distributor Drive Bushing
to
Bore Interference (Press
Fit)
0.0127 - 0.3556 mm
(0.0005 - 0.0140 in.)
Distributor Shaft to
Bushing
Clearance 0.0178 - 0.0686 mm
(0.0007 - 0.0027 in.)
CYLINDER HEAD and VALVES
Valve Seat Angle 44.25- 44.75
Valve Seat Runout
(Max) 0.0762 mm
(0.003 in.)
Valve Seat Width (Finish)
Intake 1.016 - 1.542 mm
(0.040 - 0.060 in.)
Exhaust 1.524 - 2.032 mm
(0.040 - 0.060 in.)
Valve Face Angle 43.25- 43.75
Valve Head Diameter
Intake 48.666 mm
(1.916 in.)
Exhaust 41.250 mm
(1.624 in.)
Valve Length (Overall)
Intake 124.28 - 125.92 mm
(4.893 - 4.918 in.)
Exhaust 124.64 - 125.27 mm
(4.907 - 4.932 in.)
Valve Lift (@ Zero Lash) 10.973 mm
(0.432 in.)
Valve Stem Diameter 7.899 - 7.925 mm
(0.311 - 0.312 in.)
Valve Guide Bore
Diameter
7.950 - 7.976 mm
(0.313 - 0.314 in.)
Valve Stem to Guide
Clearance
0.0254 - 0.0762 mm
(0.001 - 0.003 in.)
Valve Stem to Guide
Clearance
Service Limit (Rocking
Method)
0.4318 mm
(0.017 in.)
VALVE SPRINGS
Free Length 49.962 mm
(1.967 in.)
Spring Tension
Valve Closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve Open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm
(1.64 in.)
Wire Diameter 4.50 mm
(0.177 in.)
HYDRAULIC TAPPETS
Body Diameter 22.949 - 22.962 mm
(0.9035 - 0.9040 in.)
Clearance in Block 0.0279 - 0.0610 mm
(0.0011 - 0.210 in.)
Dry Lash 1.524 - 5.334 mm
(0.060 - 0.210 in.)
Push Rod Length 175.64 - 176.15 mm
(6.915 - 6.935 in.)
OIL PRESSURE
@ Curb Idle (Min.)* 41.4 kPa
(6 psi)
@ 3000 rpm 207 - 552 kPa
(30 - 80 psi)
Bypass Valve Setting 62 - 103 kPa
(9 - 15 psi)
Switch Actuating
Pressure
34.5 - 48.3 kPa
(5 - 7 psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance Over Rotors
(Max) 0.1016 mm
(0.004 in.)
Cover Out of Flat
(Max) 0.0381 mm
(0.0015 in.)
Inner Rotor Thickness
(Min) 20.955 mm
(0.825 in.)
Outer Rotor Clearance
(Max) 0.3556 mm
(0.014 in.)
Outer Rotor Diameter
(Min) 62.7126 mm
(2.469 in.)
Outer Rotor Thickness
(Min) 20.955 mm
(0.825 in.)
Tip Clearance Between
Rotors
(Max) 0.2032 mm
(0.008 in.)
PISTONS
Clearance at Top of Skirt 0.0127 - 0.0381 mm
(0.0005 - 0.0015 in.)
Land Clearance
(Diameter)
0.635 - 1.016 mm
(0.025 - 0.040 in.)
Piston Length 86.360 mm
(3.40 in.)
Ring Groove Depth
#1 & 2 4.572 - 4.826 mm
(0.180 - 0.190 in.)
#3 3.810 - 4.064 mm
(0.150 - 0.160 in.)
Weight 592.6 - 596.6 grams
(20.90 - 21.04 oz.)
PISTON PINS
Clearance in Piston 0.0064 - 0.0191 mm
(0.00025 - 0.00075 in.)
Clearance in Rod
(Interference)
0.0178 - 0.0356 mm
(0.0007 - 0.0014 in.)
Diameter 24.996 - 25.001 mm
(0.9841 - 0.9843 in.)
End Play None
Length 75.946 - 76.454 mm
(2.990 - 3.010 in.)
PISTON RINGS
Ring Gap
Compression Rings 0.254 - 0.508 mm
(0.010 - 0.020 in.)
Oil Control (Steel Rails) 0.254 - 1.270 mm
(0.010 - 0.050 in.)
Ring Side Clearance
(0.0015 - 0.0030 in.)
(0.002 - 0.008 in.)
Ring Width
(0.0776 - 0.0783 in.)
(0.1515 - 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes 16(ATDC)
Opens 52(BBDC)
Duration 248
Intake Valve
Closes 50(ABDC)
Opens 10(BTDC)
Duration 240
Valve Overlap 26
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US Item Identification Location of
Identification
U/S Crankshaft R or M M-2-3
ect.
Milled flat on
.0254
MM
(indicating No.
2 &
No. eight
(.001
IN.)
3 main
bearing
crankshaft
journal) and/or counterweight.
R-1-4 ect.
(indicating No.
1 &
4 connecting
rod
journal)
O/S Tappets 3/8
.2032
mm
diamound
(.008 in.) -shaped
stamp Top
pad
Front of
engine and
flat
ground on
outside
surface
of each O/S
tappet bore.
O/S Valve
Stems
X Milled pad
.127 mm adjacent to
two
(0.005
in.)
3/8 tapped
holes on
each
end of
cylinder
head.
SPECIAL TOOLS
ENGINE 3. 9L
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487A
Valve Spring Compressor MD-998772A
Adapter 6633
Adapter 6716A
Valve Guide Sleeve C-3973
Puller C-3688
Front Oil Seal Installer 6635
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/Burnisher C-3053
Piston Ring Compressor C-385
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
AIR CLEANER ELEMENT
REMOVAL
ter) repl acement.
i ng.
ment.
INSTALLATION
tabs.
CYLINDER HEAD
DESCRIPTION
The cast i ron cyl i nder heads (Fi g. 7) are mounted
to the cyl i nder bl ock usi ng ei ght bol ts. The spark
pl ugs are l ocated i n the peak of the wedge between
the val ves.
OPERATION
engi ne.
GASKET FAILURE
BlocChekKit C-3685A
2 - TABS
3 - HOUSING
Fig. 7 Cylinder Head Assembly3.9L Engine
1 - SPARK PLUGS
2 - SPARK PLUG
3 - INTAKE VALVE
4 - EXHAUST VALVES
5 - INTAKE VALVES
6 - EXHAUST VALVE
Poor fuel economy
jacket are:
Loss of cool ant
exhaust
Cool ant foami ng
dures i n Cyl i nder Compressi on Pressure Test i n thi s
secti on. An engi ne cyl i nder head gasket l eaki ng
between adjacent cyl i nders wi l l resul t i n approxi -
matel y a 5070% reducti on i n compressi on pressure.
SURE CAP REMOVED.
VISUAL TEST METHOD
thermostat opens.
l eak i s evi dent.
REMOVAL
The al l oy cast i ron cyl i nder heads (Fi g. 8) are hel d
i n pl ace by ei ght bol ts. The spark pl ugs are l ocated
at the peak of the wedge between the val ves.
(1) Di sconnect the battery negati ve cabl e from the
battery.
(3) Remove the i ntake mani fol d-to-generator
bracket support rod. Remove the generator.
(4) Remove cl osed crankcase venti l ati on system.
(5) Di sconnect the evaporati on control system.
onator.
(7) Perform fuel system pressure rel ease procedure
(8) Di sconnect the fuel suppl y l i ne from the fuel
rai l (Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
DURE).
(9) Di sconnect accel erator l i nkage and i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(10) Remove di stri butor cap and wi res.
(11) Di sconnect the coi l wi res.
(12) Di sconnect cool ant temperature sendi ng uni t
wi re.
(13) Di sconnect heater hoses and bypass hose.
(14) Di sconnect the vacuum suppl y hoses from the
i ntake mani fol d.
(15) Di sconnect the fuel i njector harness and
secure out of the way.
(16) Remove cyl i nder head covers and gaskets
(Refer to 9 - ENGI NE/CYLI NDER HEAD/CYLI N-
DER HEAD COVER(S) - REMOVAL).
(17) Remove i ntake mani fol d and throttl e body as
an assembl y. Di scard the fl ange si de gaskets and the
front and rear cross-over gaskets.
(18) Remove exhaust mani fol ds (Refer to 9 -
ENGI NE/MANI FOLDS/EXHAUST MANI FOLD -
REMOVAL).
(19) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(20) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
(21) Remove spark pl ugs.
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
Cl ean cyl i nder bl ock front and rear gasket surfaces
INSPECTION
I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out-of-fl atness
exceeds 0.00075mm/mm (0.0001i n./i n.) ti mes the
span l ength i n any di recti on, ei ther repl ace head or
l i ghtl y machi ne the head surface.
FOR EXAMPLE:A 305 mm (12 i n.) span i s
0.102 mm (0.004 i n.) out-of-fl at. The al l owabl e out-of-
fl at i s 305 x 0.00075 (12 x 0.00075) equal s 0.23 mm
(0.009 i n.). Thi s amount of out-of-fl at i s acceptabl e.
The cyl i nder head surface fi ni sh shoul d be
1.78-3.00 mi crons (70-125 mi croi nches).
I nspect push rods. Repl ace worn or bent rods.
INSTALLATION
The al l oy cast i ron cyl i nder heads (Fi g. 8) are hel d
i n pl ace by ei ght bol ts. The spark pl ugs are l ocated
at the peak of the wedge between the val ves.
(1) Posi ti on the new cyl i nder head gaskets onto
the cyl i nder bl ock.
(2) Posi ti on the cyl i nder heads onto head gaskets
and cyl i nder bl ock.
(3) Starti ng at top center, ti ghten al l cyl i nder head
bol ts, i n sequence, to 68 Nm (50 ft. l bs.) torque (Fi g.
8). Repeat procedure, ti ghten al l cyl i nder head bol ts
to 143 Nm (105 ft. l bs.) torque. Repeat procedure to
confi rm that al l bol ts are at 143 Nm (105 ft. l bs.)
torque.
CAUTION: When tightening the rocker arm bolts, be
sure the piston in that cylinder is NOT at TDC. Con-
tact between the valves and piston could occur.
(4) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti ons. Ti ghten the bol ts to 28 Nm
I NSTALLATI ON) and throttl e body assembl y.
(6) I nstal l exhaust mani fol ds (Refer to 9 -
I NSTALLATI ON).
(7) Adjust spark pl ugs to speci fi cati ons. I nstal l the
pl ugs and ti ghten to 41 Nm (30 ft. l bs.) torque.
(8) I nstal l coi l wi res.
(9) Connect cool ant temperature sendi ng uni t wi re.
(10) Connect the fuel i njector harness.
(11) Connect the vacuum suppl y hoses to the
i ntake mani fol d.
(12) Connect the heater hoses and bypass hose.
(13) I nstal l di stri butor cap and wi res.
(14) Connect the accel erator l i nkage and, i f so
down cabl es.
(15) I nstal l the fuel suppl y l i ne.
(16) I nstal l the generator and accessory dri ve bel t
BELTS - I NSTALLATI ON). Ti ghten generator
mounti ng bol t to 41 Nm (30 ft. l bs.) torque.
(17) I nstal l the i ntake mani fol d-to-generator
bracket support rod. Ti ghten the bol ts.
(18) I nstal l cyl i nder head covers. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
(19) I nstal l cl osed crankcase venti l ati on system.
(20) Connect the evaporati on control system.
(21) I nstal l the resonator assembl y, ai r i n-l et hose
and ai r cl eaner.
(22) I nstal l the heat shi el ds. Ti ghten the bol ts to
DESCRIPTION CYLINDER HEAD COVER
GASKET
The cyl i nder head cover gasket (Fi g. 9) i s a steel -
backed si l i cone gasket, desi gned for l ong l i fe usage.
REMOVAL
A steel -backed si l i cone gasket i s used wi th the cyl -
i nder head cover (Fi g. 10). Thi s gasket can be used
agai n.
(2) Di sconnect cl osed venti l ati on system and evap-
orati on control system from cyl i nder head cover.
(3) Remove cyl i nder head cover bol ts, cover and
gasket. The gasket may be used agai n.
CLEANING
Fig. 8 Cylinder Head Bolt -Tightening Sequence
INSPECTION
essary.
INSTALLATION
A steel -backed si l i cone gasket i s used wi th the cyl -
i nder head cover (Fi g. 10) . Thi s gasket can be used
agai n.
(1) Posi ti on the cyl i nder head cover gasket onto
the head rai l .
(2) Posi ti on the cyl i nder head cover onto the gas-
ket and i nstal l the bol ts. Ti ghten the bol ts to 11 Nm
(3) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
(5) Start engi ne and check for l eaks.
SEATS
DESCRIPTION
STANDARD PROCEDURE VALVES, GUIDES
AND SPRINGS
VALVE CLEANING
or cracked val ves.
VALVE GUIDES
Fig. 9 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
1 - VALVE
2 - SPACER TOOL
VALVE GUIDES
Refer to REAMER SI ZES CHART
REAMER SIZES CHART
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
seat:
REFACING VALVES AND VALVE SEATS
(Fi g. 13).
A SEAT WIDTH
INTAKE 1.016 - 1.524 mm
(0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm
(0.060 - 0.080 in.)
B FACE ANGLE
C SEAT ANGLE
D CONTACT
SURFACE
1 - VALVE
Fig. 13 Valve Face and Seat Angles
1 - CONTACT POINT
CHART
VALVES
VALVE SEATS
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
2.032 mm (0.060-0.080 i n.).
VALVE SPRINGS
Refer to speci fi cati ons to obtai n speci fi ed hei ght and
al l owabl e tensi ons. Di scard the spri ngs that do not
meet speci fi cati ons.
REMOVAL
(1) Remove the cyl i nder head (Refer to 9 -
Compressor Tool MD- 998772A and adapter 6716A.
retai ners, val ve stem seal s and val ve spri ngs.
ori gi nal l ocati on.
CLEANING
or cracked val ves.
1 - MARGIN
3 - STEM
4 - FACE
1 - STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
INSPECTION
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
Make sure the measurement i s taken from bottom of
mm (1-11/16 i nches), i nstal l a 1.587 mm (1/16 i nch)
1-11/16 i nch).
(8) I nstal l cyl i nder head (Refer to 9 - ENGI NE/
CYLI NDER HEAD - I NSTALLATI ON).
Length
1 - TORQUE WRENCH
1 - VALVE
2 - SPACER TOOL
1 - VALVE
ENGINE BLOCK
CLEANING
Cl ean cyl i nder bl ock thoroughl y and check al l core
hol e pl ugs for evi dence of l eakage.
INSPECTION
Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out-of-
round and taper. Refer to Honi ng Cyl i nder Bores i n
the Servi ce Procedures porti on of thi s Secti on.
I nspect the oi l l i ne pl ug, the oi l l i ne pl ug i s l ocated
i n the verti cal passage at the rear of the bl ock
between the oi l -to-fi l ter and oi l -from-fi l ter passages
(Fi g. 19) . I mproper i nstal l ati on or mi ssi ng pl ug coul d
cause errati c, l ow, or no oi l pressure.
The oi l pl ug must come out the bottom. Use fl at
dowel , down the oi l pressure sendi ng uni t hol e from
the top, to remove oi l pl ug.
(1) Remove oi l pressure sendi ng uni t from back of
bl ock.
(2) I nsert a 3.175 mm (1/8 i n.) fi ni sh wi re, or
equi val ent, i nto passage.
(3) Pl ug shoul d be 190.0 to 195.2 mm (7-1/2 to
7-11/16 i n.) from machi ned surface of bl ock (Fi g. 19) .
I f pl ug i s too hi gh, use a sui tabl e fl at dowel to posi -
ti on properl y.
(4) I f pl ug i s too l ow, remove oi l pan and No. 4
mai n beari ng cap. Use sui tabl e fl at dowel to posi ti on
properl y . Coat outsi de di ameter of pl ug wi th Mopar
Stud and Beari ng Mount Adhesi ve. Pl ug shoul d be
54.0 to 57.7 mm (2-1/8 to 2-5/16 i n.) from bottom of
the bl ock.
BLOCK)
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 20).
REMOVAL CAMSHAFT
(2) Remove radi ator. (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - REMOVAL).
(3) Remove i ntake mani fol d. (Refer to 9 -
REMOVAL).
(4) Remove di stri butor assembl y (Refer to 8 -
ELECTRI CAL/I GNI TI ON CONTROL/DI STRI BUTOR
- REMOVAL).
(5) Remove cyl i nder head covers (Refer to 9 -
Fig. 19 Oil Line Plug
1 - RIGHT OIL GALLERY
2 - CYLINDER BLOCK
3 - OIL FROM FILTER TO SYSTEM
4 - OIL TO FILTER
5 - FROM OIL PUMP
6 - CRANKSHAFT
7 - PLUG
Fig. 20 Camshaft Bearings Removal and Installation
with Tool C-3132-A
1 - SPECIAL TOOL C-3132A
(6) Remove rocker arms (Refer to 9 - ENGI NE/
CYLI NDER HEAD/ROCKER ARM / ADJUSTER
ASSY - REMOVAL).
(7) Remove push rods and tappets (Refer to 9 -
ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FTERS
(CAM I N BLOCK) - REMOVAL). I denti fy each part
so i t can be i nstal l ed i n the ori gi nal l ocati ons.
(8) Remove ti mi ng chai n cover. (Refer to 9 -
(9) Al i gn ti mi ng marks (Fi g. 21) and remove ti m-
i ng chai n and sprockets.
(10) Remove the three tensi oner to bl ock mounti ng
bol ts and remove tensi oner.
(11) I nstal l a l ong bol t i nto front of camshaft to ai d
i n removal of the camshaft. Remove camshaft, bei ng
careful not to damage cam beari ngs wi th the cam
l obes.
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool C-3132-A by sl i di ng
the new camshaft beari ng shel l over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and, by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 51 mm (2
i nches) of i ts fi nal posi ti on i n cyl i nder bl ock.
(2) I nstal l Camshaft Hol di ng Tool C-3509 wi th
tongue back of di stri butor dri ve gear (Fi g. 22) .
Fig. 21 Alignment of Timing Marks
1 - TIMING MARKS
Fig. 22 Camshaft Holding Tool C-3509 (Installed
Position)
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
Fig. 23 Compressing Tensioner Shoe For Timing
Chain Installation
1 - SCREWDRIVER
2 - INSERT PIN HERE
(3) Hol d tool i n posi ti on wi th a di stri butor l ock-
pl ate bol t. Thi s tool wi l l restri ct camshaft from bei ng
pushed i n too far and prevent knocki ng out the wel ch
pl ug i n rear of cyl i nder bl ock. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) I nstal l ti mi ng chai n tensi oner. Torque bol ts to
24 Nm (210 i n. l bs.) torque.
(5) Compress tensi oner shoe (Fi g. 23) and i nstal l a
sui tabl e si zed pi n to retai n shoe for chai n i nstal l a-
ti on.
(6) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on an exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(7) Pl ace ti mi ng chai n around both sprockets.
(8) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(9) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(10) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 24) .
(11) I nstal l the camshaft bol t/cup washer. Ti ghten
bol t to 68 Nm (50 ft. l bs.) torque.
(12) Measure camshaft end pl ay (Fi g. 25). (Refer to
9 - ENGI NE - SPECI FI CATI ONS) for proper cl ear-
ance. I f not wi thi n l i mi ts, i nstal l a new ti mi ng chai n
tensi oner.
(13) Each tappet reused must be i nstal l ed i n the
same posi ti on at whi ch i t was removed. When cam-
shaft is replaced, all of the tappets must be
replaced.I nstal l hydraul i c tappets (Refer to 9 -
ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FTERS
(CAM I N BLOCK) - I NSTALLATI ON).
(14) I nstal l ti mi ng chai n cover (Refer to 9 -
(15) I nstal l i ntake mani fol d (Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - I NSTALLA-
TI ON).
(16) I nstal l di stri butor (Refer to 8 - ELECTRI CAL/
I GNI TI ON CONTROL/DI STRI BUTOR - I NSTALLA-
TI ON).
(17) I nstal l cyl i nder head covers (Refer to 9 -
(18) I nstal l radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - I NSTALLATI ON).
1 - TIMING MARKS
Fig. 25 Checking Camshaft End Play
1 - SCREWDRIVER
2 - DIAL INDICATOR
3 - CAM SPROCKET
BEARING FITTING
Fi t al l rods on a bank unti l compl eted. DO NOT
al ternate from one bank to another, because connect-
i ng rods and pi stons are not i nterchangeabl e from
one bank to another.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to ensure correct
assembl y.
Each beari ng cap has a smal l V-groove across the
parti ng face. When i nstal l i ng the l ower beari ng shel l ,
be certai n that the V-groove i n the shel l i s i n l i ne
wi th the V-groove i n the cap. Thi s provi des l ubri ca-
ti on of the cyl i nder wal l i n the opposi te bank.
The beari ng shel l s must be i nstal l ed so that the
tangs are i n the machi ned grooves i n the rods and
caps.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i n.).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i n.), 0.051
mm (0.002 i n.), 0.076 mm (0.003 i n.), 0.254 mm
(0.010 i n.) and 0.305 mm (0.012 i n.) undersi ze.
Install the bearings in pairs. DO NOT use a new
bearing half with an old bearing half. DO NOT
file the rods or bearing caps.
CRANKSHAFT
DESCRIPTION
The crankshaft (Fi g. 26) i s of a forged steel spl ayed
type desi gn, wi th four mai n beari ng journal s.The
crankshaft i s l ocated at the bottom of the engi ne
bl ock and i s hel d i n pl ace wi th four mai n beari ng
caps.
OPERATION
fl expl ate.
REMOVAL
(2) Remove the oi l pump (Refer to 9 - ENGI NE/
LUBRI CATI ON/OI L PUMP - REMOVAL).
beari ng caps and beari ngs one at a ti me.
(4) Li ft the crankshaft out of the bl ock.
seal s.
seal .
INSTALLATION
oi l .
oi l .
(6) Appl y 5 mm (0.20 i n.) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 27). DO NOT over-appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
ment dowel , and cap bol ts. DO NOT remove excess
more than two ti mes for proper engagement.
ant, or equi val ent, at beari ng cap-to-bl ock joi nt to
provi de cap-to-bl ock and oi l pan seal i ng (Fi g. 28).
Appl y enough seal ant so that a smal l amount i s
TI ON).
Fig. 26 Crankshaft3.9L Engine
(13) I nstal l new rear oi l seal (Refer to 9 -
SEAL - REAR - I NSTALLATI ON).
CRANKSHAFT MAIN
BEARINGS
DESCRIPTION
four mai n beari ngs. Number two mai n beari ng i s
OPERATION
BEARING FITTING
Beari ng caps are NOT i nterchangeabl e and shoul d
be marked at removal to ensure correct assembl y.
Upper and l ower beari ng hal ves are NOT i nter-
changeabl e. Lower mai n beari ng hal ves of No. 1 and
3 are i nterchangeabl e.
Upper and l ower No. 2 beari ng hal ves are fl anged
to carry the crankshaft thrust l oads. They are NOT
i nterchangeabl e wi th any other beari ng hal ves i n the
engi ne (Fi g. 30). Beari ng shel l s are avai l abl e i n stan-
dard and the fol l owi ng undersi zes: 0.25 mm (0.001
i n.), 0.051 mm (0.002 i n.), 0.076 mm (0.003 i n.), 0.254
mm (0.010 i n.) and 0.305 mm (0.012 i n.). Never
i nstal l an undersi ze beari ng that wi l l reduce cl ear-
ance bel ow speci fi cati ons.
2 - LOCTITE 515 (OR EQUIVALENT)
Fig. 28 Apply Sealant to Bearing Cap-to-Block Joint
NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
Fig. 30 Main Bearing Identification
CRANKSHAFT IDENTIFICATION LOCATION
CHART
ITEM MEASUREMENT IDENTIFICATION
ROD U/S 0.025 mm R1-R2-R3 ect.
(0.001 in.) indicates rod
journal
No. 1, 2 and 3.
MAIN U/S 0.025 mm M1-M2-M3 or M4
(0.001 in.) indicates main
journal
No. 1, 2, 3, and 4.
REMOVAL
beari ng caps one at a ti me.
(4) Remove upper hal f of beari ng by i nserti ng
Crankshaft Mai n Beari ng Remover/I nstal l er Tool
C-3059 i nto the oi l hol e of crankshaft (Fi g. 31).
(5) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Onl y one mai n beari ng shoul d be sel ecti vel y fi tted
whi l e al l other mai n beari ng caps are properl y ti ght-
ened. Al l beari ng capbol ts removed duri ng servi ce
procedures are to be cl eaned and oi l ed before i nstal -
l ati on. DO NOT use a new beari ng hal f wi th an ol d
beari ng hal f.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Crankshaft
Mai n Beari ng Remover/I nstal l er Tool C-3059 i nto oi l
hol e of crankshaft (Fi g. 31).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Tool C-3059.
(3) I nstal l the beari ng caps. Cl ean and oi l the
bol ts. Ti ghten the capbol ts to 115 Nm (85 ft. l bs.)
torque.
(4) I nstal l the oi l pump (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PUMP - I NSTALLATI ON).
FRONT
DESCRIPTION
The crankshaft front seal i s a one pi ece vi ton seal
wi th a steel housi ng. The front seal i s l ocated i n the
engi ne front cover.
OPERATION
REMOVAL
mi sal i gned.
REMOVAL).
INSTALLATION
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 32) . Seat
the oi l seal i n the groove of the tool .
(2) Posi ti on the seal and tool onto the crankshaft
(Fi g. 33).
Fig. 31 Upper Main Bearing Removal and
Installation with Tool C-3059
2 - BEARING
4 - BEARING
(Fi g. 34).
damper.
I NSTALLATI ON).
REAR
DESCRIPTION
The crankshaft rear seal i s a two pi ece vi ton seal .
One part of the two pi ece rear seal i s l ocated i n a sl ot
i n the number four (4) crankshaft mai n bore, the sec-
ond part of the two pi ece seal i s l ocated i n the num-
ber four (4) mai n beari ng cap.
OPERATION
LEAKS
area:
Fig. 32 Placing Oil Seal on Installation Tool 6635
1 - CRANKSHAFT FRONT OIL SEAL
2 - INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 33 Position Tool and Seal onto Crankshaft
2 - OIL SEAL
seal.
procedures.
REMOVAL
The servi ce seal i s a two pi ece, Vi ton seal . The
upper seal hal f can be i nstal l ed wi th crankshaft
removed from engi ne or wi th crankshaft i nstal l ed.
When a new upper seal i s i nstal l ed, i nstal l a new
l ower seal . The l ower seal hal f can be i nstal l ed onl y
wi th the rear mai n beari ng cap removed.
UPPER SEAL CRANKSHAFT REMOVED
(1) Remove the crankshaft (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CRANKSHAFT - REMOVAL). Di s-
card the ol d upper seal .
UPPER SEAL CRANKSHAFT INSTALLED
(3) Remove the rear mai n beari ng cap. Remove
and di scard the ol d l ower oi l seal .
(4) Careful l y remove and di scard the ol d upper oi l
seal .
LOWER SEAL
(3) Remove the rear mai n beari ng cap and di scard
the ol d l ower seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock rear cap mati ng sur-
face. Be sure the seal groove i s free of debri s. Check
for burrs at the oi l hol e on the cyl i nder bl ock mati ng
surface to rear cap.
oi l .
the whi te pai nt faci ng toward the rear of the engi ne.
oi l .
(7) Appl y 5 mm (0.20 i n.) drop of Mopar Gasket
Maker, or equi val ent, on each si de of the rear mai n
beari ng cap (Fi g. 35). DO NOT over-appl y seal ant or
al l ow the seal ant to contact the rubber seal . Assem-
bl e beari ng cap to cyl i nder bl ock i mmedi atel y after
seal ant appl i cati on.
(10) I nstal l oi l pump (Refer to 9 - ENGI NE/LU-
(11) Appl y Mopar GEN I I Si l i cone Rubber Adhe-
si ve Seal ant, or equi val ent, at beari ng cap-to-bl ock
joi nt to provi de cap to bl ock and oi l pan seal i ng (Fi g.
36) . Appl y enough seal ant so that a smal l amount i s
CRANKSHAFT OIL SEAL - REAR (Continued)
TI ON).
(1) Cl ean the cyl i nder bl ock mati ng surfaces before
oi l seal i nstal l ati on. Check for burrs at the oi l hol e on
the cyl i nder bl ock mati ng surface to rear cap.
oi l . To al l ow ease of i nstal l ati on of the seal , l oosen at
l east the two mai n beari ng caps forward of the rear
beari ng cap.
(3) Rotate the new upper seal i nto the cyl i nder
bl ock, bei ng careful not to shave or cut the outer sur-
face of the seal . To ensure proper i nstal l ati on, use the
i nstal l ati on tool provi ded wi th the ki t. I nstal l the
new seal wi th the whi te pai nt faci ng toward the rear
of the engi ne.
the beari ng cap wi th the whi te pai nt faci ng toward
seal ant appl i cati on. Be sure the whi te pai nt faces
toward the rear of the engi ne.
(7) I nstal l the rear mai n beari ng cap wi th cl eaned
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
joi nt to provi de cap-to-bl ock and oi l pan seal i ng (Fi g.
36). Appl y enough seal ant unti l a smal l amount i s
TI ON).
LOWER SEAL
(1) Cl ean the rear mai n cap mati ng surfaces
i ncl udi ng the oi l pan gasket groove.
(2) Careful l y i nstal l a new upper seal . Refer to
UPPER SEALCRANKSHAFT I NSTALLED .
oi l .
(4) I nstal l a new l ower seal i n beari ng cap wi th
the whi te pai nt faci ng the rear of engi ne.
NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
joi nt to provi de cap to bl ock and oi l pan seal i ng.
TI ON).
DISTRIBUTOR BUSHING
REMOVAL
(1) Remove di stri butor (Refer to 8 - ELECTRI CAL/
I GNI TI ON CONTROL/DI STRI BUTOR - REMOVAL).
(2) Remove the i ntake mani fol d (Refer to 9 -
REMOVAL).
(3) I nsert Di stri butor Dri ve Shaft Bushi ng Pul l er
Tool C-3052 i nto ol d bushi ng and thread down unti l a
ti ght fi t i s obtai ned (Fi g. 37) .
(4) Hol d pul l er screw and ti ghten pul l er nut unti l
bushi ng i s removed.
INSTALLATION
(1) Sl i de new bushi ng over burni shi ng end of Di s-
tri butor Dri ve Shaft Bushi ng Dri ver/Burni sher Tool
C-3053. I nsert the tool and bushi ng i nto the bore.
(2) Dri ve bushi ng and tool i nto posi ti on, usi ng a
hammer (Fi g. 38) .
(3) As the burni sher i s pul l ed through the bushi ng,
the bushi ng i s expanded ti ght i n the bl ock and bur-
ni shed to correct si ze (Fi g. 39). DO NOT ream this
bushing.
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) I nstal l the i ntake mani fol d. (Refer to 9 -
I NSTALLATI ON).
(5) I nstal l the di stri butor.
Fig. 37 Distributor Driveshaft Bushing Removal
2 - BUSHING
Fig. 38 Distributor Driveshaft Bushing Installation
2 - BUSHING
Fig. 39 Burnishing Distributor Bushing
2 - BUSHING
HYDRAULIC LIFTERS (CAM IN
BLOCK)
TAPPETS
OIL LEVEL
HIGH
LOW
operati on.
i ng.
LEAK-DOWN TEST
Down Tester .
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
pet.
posi ti on.
rod.
seconds.
REMOVAL
(1) Remove the ai r cl eaner assembl y and ai r i n-l et
hose.
(2) Remove cyl i nder head cover (Refer to 9 -
(3) Remove rocker assembl y and push rods (Refer
to 9 - ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). I denti fy push rods
to ensure i nstal l ati on i n ori gi nal l ocati ons.
(5) Remove yoke retai ner and al i gni ng yokes.
(6) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
(7) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
(8) I f the tappet or bore i n cyl i nder bl ock i s scored,
scuffed, or shows si gns of sti cki ng, ream the bore to
next oversi ze. Repl ace wi th oversi ze tappet.
CLEANING
Cl ean tappet wi th a sui tabl e sol vent. Ri nse i n hot
water and bl ow dry wi th a cl ean shop rag or com-
pressed ai r.
INSTALLATION
(1) Lubri cate tappets wi th Mopar Engi ne Oi l
Suppl ement or equi val ent.
(2) I nstal l tappets and push rods i n thei r ori gi nal
posi ti ons . Ensure that the oi l feed hol e i n the si de of
the tappet body faces up (away from the crankshaft).
(3) I nstal l al i gni ng yokes wi th ARROW toward
camshaft.
(4) I nstal l yoke retai ner. Ti ghten the bol ts to 23
Nm (200 i n. l bs.) torque. I nstal l i ntake mani fol d
(Refer to 9 - ENGI NE/MANI FOLDS/I NTAKE MANI -
FOLD - I NSTALLATI ON).
(5) I nstal l rocker arms (Refer to 9 - ENGI NE/CYL-
I NDER HEAD/ROCKER ARM / ADJUSTER ASSY -
I NSTALLATI ON).
(6) I nstal l cyl i nder head cover (Refer to 9 -
(7) I nstal l ai r cl eaner assembl y and ai r i n-l et hose.
(8) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP
5 - HANDLE
6 - PUSH ROD
9 - 100 ENGINE 3. 9L AN
HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued)
DESCRIPTION
fi t.
Check the cyl i nder bl ock bore for out-of-round,
taper, scori ng, or scuffi ng.
Check the pi stons for taper and el l i pti cal shape
before they are fi tted i nto the cyl i nder bore (Fi g. 41).
Pi ston and cyl i nder wal l must be cl ean and dry.
Speci fi ed cl earance between the pi ston and the cyl i n-
der wal l i s 0.013-0.038 mm (0.0005-0.0015 i n.) at
21C (70F).
Pi ston di ameter shoul d be measured at the top of
ski rt, 90 to pi ston pi n axi s. Cyl i nder bores shoul d be
measured hal fway down the cyl i nder bore and trans-
verse to the engi ne crankshaft center l i ne.
Pi stons and cyl i nder bores shoul d be measured at
normal room temperature, 21C (70F).
PISTON MEASUREMENTS CHART
PISTON A DIA = PISTON BORE
SIZE DIAMETER DIAMETER
MIN. MAX. MIN. MAX.
mm
(in.)
mm
(in.)
mm
(in.)
mm (in.)
A 99.280 99.294 99.308 99.320
(3.9087) (3.9092) (3.9098) (3.9103)
B 99.294 99.306 99.320 99.333
(3.9092) (3.9097) (3.9103) (3.9108)
C 99.306 99.319 99.333 99.345
(3.9097) (3.9102) (3.9108) (3.9113)
D 99.319 99.332 99.346 99.358
(3.9102) (3.9107) (3.9113) (3.9118)
E 99.332 99.344 99.358 99.371
(3.9107) (3.9112) (3.9118) (3.9123)
PISTON PIN BORE 25.007 - 25.014 mm
(.9845 - .9848 in.)
RING GROOVE
HEIGHT
4.0309 - 4.0538 mm
(OIL RAIL) (.1587 - .1596 in.)
RING GROOVE
HEIGHT
2.0294 - 2.0548 mm
(COMPRESSION
RAIL)
(.0799 - .0809 in.)
TOTAL FINISHED 594.6 2 grams
WEIGHT (20.974 .0706 ounces)
REMOVAL
(1) Remove the engi ne from the vehi cl e (Refer to 9
- ENGI NE - REMOVAL).
(4) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pi stons covered
duri ng thi s operati on.
(5) Be sure each connecti ng rod and connecti ng rod
cap i s i denti fi ed wi th the cyl i nder number. Remove
connecti ng rod cap. I nstal l connecti ng rod bol t gui de
set on connecti ng rod bol ts.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. When removi ng the
assembl i es from the engi ne, rotate crankshaft so that
Fig. 41 Piston Measurements
1 - 62.230 mm
(2.45 IN.)
AN ENGINE 3. 9L 9 - 101
the connecti ng rod i s centered i n cyl i nder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
CLEANING
INSPECTION
wear, taper and scori ng (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CONNECTI NG ROD BEARI NGS -
i ng.
before i t i s fi tted i nto the cyl i nder bore (Refer to 9 -
ENGI NE/ENGI NE BLOCK/PI STON & CONNECT-
I NG ROD - STANDARD PROCEDURE).
INSTALLATION
(1) Be sure that compressi on ri ng gaps are stag-
gered so that nei ther i s i n l i ne wi th oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, be sure
the oi l ri ng expander ends are butted and the rai l
gaps l ocated properl y (Fi g. 42) .
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Sl i de Pi ston Ri ng Compressor Tool C-385
over the pi ston and ti ghten wi th the speci al wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts. The l ong protector shoul d be i nstal l ed on the
numbered si de of the connecti ng rod.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. Be sure
connecti ng rod and cyl i nder bore number are the
same. I nsert rod and pi ston i nto cyl i nder bore and
gui de rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on crankshaft journal .
(7) The notch, or groove, on top of pi ston must be
poi nti ng toward front of engi ne. The l arger chamfer
of the connecti ng rod bore must be i nstal l ed toward
crankshaft journal fi l l et.
(8) I nstal l rod caps. Be sure connecti ng rod, con-
necti ng rod cap, and cyl i nder bore number are the
same. I nstal l nuts on cl eaned and oi l ed rod bol ts and
ti ghten nuts to 61 Nm (45 ft. l bs.) torque.
(10) I nstal l the cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
(11) I nstal l the engi ne i nto the vehi cl e (Refer to 9 -
ENGI NE - I NSTALLATI ON).
PISTON RINGS
FITTING
(1) Measurement of end gaps:
(a) Measure pi ston ri ng gap 2 i n. from bottom of
cyl i nder bore. An i nverted pi ston can be used to
push the ri ngs down to ensure posi ti oni ng ri ngs
squarel y i n the cyl i nder bore before measuri ng.
(b) I nsert feel er gauge i n the gap. The top com-
pressi on ri ng gap shoul d be between 0.254-0.508
mm (0.010-0.020 i n.). The second compressi on ri ng
gap shoul d be between 0.508-0.762 mm
(0.020-0.030 i n.). The oi l ri ng gap shoul d be 0.254-
1.270 mm (0.010-0.050 i n.).
(c) Ri ngs wi th i nsuffi ci ent end gap may be prop-
erl y fi l ed to the correct di mensi on. Ri ngs wi th
excess gaps shoul d not be used.
(2) I nstal l ri ngs, and confi rm ri ng si de cl earance:
(a) I nstal l oi l ri ngs bei ng careful not to ni ck or
scratch the pi ston. I nstal l the oi l control ri ngs
accordi ng to i nstructi ons i n the package. I t i s not
necessary to use a tool to i nstal l the upper and
l ower rai l s. I nsert oi l rai l spacer fi rst, then si de
rai l s.
(b) I nstal l the second compressi on ri ngs usi ng
I nstal l ati on Tool C-4184. The compressi on ri ngs
Fig. 42 Proper Ring Installation
1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP
9 - 102 ENGINE 3. 9L AN
must be i nstal l ed wi th the i denti fi cati on mark face
up (toward top of pi ston) and chamfer faci ng down.
An i denti fi cati on mark on the ri ng i s a dri l l poi nt,
a stamped l etter O, an oval depressi on, or the
word TOP (Fi g. 43) (Fi g. 45).
(c) Usi ng a ri ng i nstal l er, i nstal l the top com-
pressi on ri ng wi th the chamfer faci ng up (Fi g. 44)
(Fi g. 45). An i denti fi cati on mark on the ri ng i s a
dri l l poi nt, a stamped l etter O, an oval depressi on
or the word TOP faci ng up.
(d) Measure si de cl earance between pi ston ri ng
and ri ng l and. Cl earance shoul d be 0.074-0.097 mm
(0.0029-0.0038 i n.) for the compressi on ri ngs. The
steel rai l oi l ri ng shoul d be free i n groove, but
shoul d not exceed 0.246 mm (0.0097 i n.) si de cl ear-
ance.
(e) Pi stons wi th i nsuffi ci ent, or excessi ve, si de
cl earance shoul d be repl aced.
(3) Ori ent the ri ngs:
(a) Arrange top compressi on ri ng 90 counter-
cl ockwi se from the oi l ri ng rai l gap (Fi g. 46) .
(b) Arrange second compressi on ri ng 90 cl ock-
wi se from the oi l ri ng rai l gap (Fi g. 46) .
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS
Fig. 44 Top Compression Ring Identification
(Typical)
1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT
(Typical)
1 - CHAMFER
4 - PISTON
5 - CHAMFER
(TOP)
AN ENGINE 3. 9L 9 - 103
VIBRATION DAMPER
REMOVAL
(2) Remove fan, and fan dri ve (Refer to 7 - COOL-
I NG/ENGI NE/FAN DRI VE VI SCOUS CLUTCH -
REMOVAL).
REMOVAL).
(4) Remove the vi brati on damper pul l ey.
(5) Remove vi brati on damper bol t and washer from
end of crankshaft.
(6) I nstal l bar and screw from Pul l er Tool Set
C-3688. I nstal l two bol ts wi th washers through the
pul l er tool and i nto the vi brati on damper (Fi g. 47).
(7) Pul l vi brati on damper off of the crankshaft.
INSTALLATION
(1) Posi ti on the vi brati on damper onto the crank-
shaft.
(2) Pl ace i nstal l i ng tool , part of Pul l er Tool Set
C-3688, i n posi ti on and press the vi brati on damper
onto the crankshaft (Fi g. 48).
(3) I nstal l the crankshaft bol t and washer. Ti ghten
the bol t to 244 Nm (180 ft. l bs.) torque.
(4) I nstal l the crankshaft pul l ey. Ti ghten the pul -
l ey bol ts to 23 Nm (200 i n. l bs.) torque.
(5) I nstal l the serpenti ne bel t (Refer to 7 - COOL-
LATI ON).
(6) I nstal l vi scous fan dri ve and fan (Refer to 7 -
COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - I NSTALLATI ON).
(7) I nstal l the fan shroud.
FRONT MOUNT
REMOVAL
2WD
(2) Rai se hood and posi ti on fan to assure cl earance
for radi ator top tank and hose.
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(5) Remove the i nsul ator through bol t (Fi g. 49)
(Fi g. 50) (Fi g. 51).
(6) Rai se engi ne wi th l i fti ng fi xture SLI GHTLY.
Remove i nsul ator retai ni ng bol ts and remove the
i nsul ator assembl y.
(7) Remove i nsul ator heat shi el d and transfer to
new i nsul ator.
4WD
On 4-WD vehi cl es the engi ne front support brack-
ets attach di rectl y to engi ne bl ock and the axl e hous-
i ng. The brackets provi de a sol i d i nterconnecti on for
these uni ts (Fi g. 52) (Fi g. 53). Engi ne and front axl e
must be supported duri ng any servi ce procedures
i nvol vi ng the front support assembl i es.
(3) I nstal l engi ne l i fti ng (support) fi xture.
(4) Remove front axl e.(Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/FRONT AXLE - C205F -
REMOVAL).
Fig. 47 Vibration Damper Assembly
Fig. 48 Installing Vibration Damper
9 - 104 ENGINE 3. 9L AN
(5) Left mount insulator only. Remove starter
wi res and starter motor assembl y.
(6) Remove i nsul ator to frame throught bol t (Fi g.
54).
(7) Rai se engi ne sl i ghtl y.
(8) Remove upper i nsul ator to support bracket
stud nut and i nsul ator to support through bol t.
(9) Remove engi ne mount i nsul ator. (Fi g. 52) (Fi g.
53).
(10) I f engi ne support bracket i s to be removed/re-
pl aced, remove support bracket to transmi ssi on bel l
housi ng bol t(s) and three (3) support bracket to
engi ne bl ock bol ts. Remove support bracket (Fi g. 52)
(Fi g. 53).
Fig. 49 Engine Right Front Insulator Mount2WD
Vehicles
1 - HEAT SHIELD
2 - INSULATOR
Fig. 50 Engine Left Front Insulator Mount2WD
Vehicles
1 - HEAT SHIELD
2 - INSULATOR
Fig. 51 Engine Mount Insulator at Frame
1 - NUT
2 - INSULATOR
3 - FRAME
4 - THROUGH BOLT
AN ENGINE 3. 9L 9 - 105
INSTALLATION
2WD
(1) Wi th the engi ne rai sed SLI GHTLY, posi ti on
i nsul ator assembl y onto the engi ne bl ock and i nstal l
bol ts (Fi g. 46) (Fi g. 47). Ti ghten the bol ts to 41 Nm
(2) Lower engi ne wi th l i fti ng fi xture whi l e gui di ng
i nsul ator assembl y i nto the engi ne i nsul ator bracket
(Fi g. 48).
(3) I nstal l i nsul ator to bracket thru-bol t. Ti ghten
the thru-bol t nut to 68 Nm (50 ft. l bs.) torque.
(4) Remove l i fti ng fi xture.
4WD
(1) I f engi ne support brackets were removed, i ntal l
them and thei r fasteners (Fi g. 52) (Fi g. 53). Ti ghten
support bracket to bl ock bol ts to 41 Nm (30 ft. l bs.).
Ti ghten support bracket to transmi ssi on bel l housi ng
bol t(s) to 88 Nm (65 ft. l bs.)
(2) I nstal l Engi ne mount i nsul ator and ti ghten
i nsul ator to support bracket nut to 41 Nm (30 ft.
l bs.). Ti ghten i nsul ator to support bracket through
bol t nut to 102 Nm (75 ft. l bs.)
(3) Lower engi ne and i nstal l i nsul ator to frame
through bol t and nut (Fi g. 54). Ti ghten nut to 95 Nm
(70 ft. l bs.)
(4) I nstal l starter motor and mounti ng bol ts.
Ti ghten bol ts to 68 Nm (50 ft. l bs.)
(5) Connect starter wi res.
(6) Remove engi ne l i fti ng (support) fi xture.
(7) I nstal l front axl e assembl y (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/FRONT AXLE - C205F
- I NSTALLATI ON).
Fig. 52 Right Engine Mount Insulator and Support
Bracket4WD Vehicles
1 - ENGINE SUPPORT BRACKET
2 - INSULATOR
3 - FRONT AXLE
Fig. 53 Left Engine Mount Insulator and Support
Bracket4WD Vehicles
2 - INSULATOR
3 - FRONT AXLE
9 - 106 ENGINE 3. 9L AN
REAR MOUNT
REMOVAL
2WD
(2) Rai se the vehi cl e on a hoi st.
(3) Support the transmi ssi on wi th a jack.
NOTE: AUTOMATIC TRANSMISSION
Remove engi ne support bracketi nsul ator thru-
bol t (Fi g. 55).
Rai se the transmi ssi on and engi ne sl i ghtl y.
Remove stud nuts attachi ng i nsul ator to cross-
member (Fi g. 55). Remove i nsul ator.
NOTE: MANUAL TRANSMISSION
Remove the stud nuts attachi ng the i nsul ator to
the transmi ssi on extensi on (Fi g. 56).
Rai se the transmi ssi on and engi ne sl i ghtl y.
Remove stud nuts attachi ng i nsul ator to cross-
4WD
(3) Support the transmi ssi on wi th a transmi ssi on
jack.
Remove stud nuts hol di ng the i nsul ator to the
crossmember (Fi g. 57).
Rai se rear of transmi ssi on SLI GHTLY.
Remove bol ts hol di ng the i nsul ator to the i nsu-
l ator bracket (Fi g. 57). Remove the i nsul ator.
Remove stud nuts hol di ng the i nsul ator to the
Rai se rear of transmi ssi on SLI GHTLY.
Remove bol ts hol di ng the i nsul ator to the trans-
mi ssi on (Fi g. 58). Remove the i nsul ator.
Fig. 54 Engine Mount
1 - NUT
3 - INSULATOR
4 - NUT
5 - THROUGH BOLT
6 - FRAME
7 - FRONT AXLE
Fig. 55 Rear Insulator Automatic Transmission
2WD
2 - THROUGH BOLT
3 - CROSSMEMBER
4 - INSULATOR
5 - TRANSMISSION EXTENSION
AN ENGINE 3. 9L 9 - 107
REAR MOUNT (Continued)
INSTALLATION
2WD
(1) I f the engi ne support bracket (Automati c
Transmi ssi ons) was removed, posi ti on the bracket to
the transmi ssi on extensi on (Fi g. 55). Ti ghten the
bol ts to 68 Nm (50 ft. l bs.) torque.
I nstal l the i nsul ator onto crossmember. Ti ghten
the stud nuts to 41 Nm (30 ft. l bs) torque.
Lower the transmi ssi on and engi ne whi l e al i gn-
i ng the engi ne support bracket to the i nsul ator.
I nstal l thru-bol t i n bracket and i nsul ator.
Ti ghten thru-bol t nut to 68 Nm (50 ft. l bs.) torque.
I nstal l the i nsul ator onto crossmember. Ti ghten
the stud nuts to 41 Nm (30 ft. l bs) torque.
Lower the transmi ssi on and engi ne whi l e al i gn-
i ng the i nsul ator studs i nto the transmi ssi on exten-
si on.
I nstal l the stud nuts. Ti ghten the stud nuts to
41 Nm (30 ft. l bs) torque.
4WD
I f the i nsul ator bracket was removed, i nstal l the
bracket to the transmi ssi on (Fi g. 57). Ti ghten the
I nstal l the bol ts hol di ng i nsul ator to i nsul ator
torque.
Lower rear of transmi ssi on whi l e al i gni ng the
i nsul ator studs i nto the mounti ng support bracket.
I nstal l stud nuts and ti ghten to 68 Nm (50 ft. l bs.)
torque.
I nstal l the bol ts hol di ng i nsul ator to i nsul ator
torque.
Fig. 56 Rear Insulator Manual Transmission2WD
2 - INSULATOR
3 - CROSSMEMBER
Fig. 57 Rear Insulator Automatic Transmission
4WD
2 - INSULATOR BRACKET
3 - INSULATOR
4 - CROSSMEMBER
9 - 108 ENGINE 3. 9L AN
Lower rear of transmi ssi on whi l e al i gni ng the
I nstal l stud nuts and ti ghten to 68 Nm (50 ft. l bs.)
torque.
(1) Remove the transmi ssi on jack.
LUBRICATION
DESCRIPTION
A gear-type posi ti ve di spl acement pump (Fi g. 59) i s
mounted at the undersi de of the rear mai n beari ng
cap. The pump uses a pi ck-up tube and screen
assembl y to gather engi ne oi l from the oi l pan.
OPERATION
channel s the oi l up to the mai n gal l ery, whi ch
extends the enti re l ength on the ri ght si de of the
bl ock. The oi l then goes down to the No. 1 mai n bear-
i ng, back up to the l eft si de of the bl ock, and i nto the
oi l gal l ery on the l eft si de of the engi ne.
mai n beari ng journal s to the connecti ng rod journal s.
Each connecti ng rod beari ng has hal f a hol e i n i t, oi l
passes through the hol e when the rods rotate and the
hol e l i nes up, oi l i s then thrown off as the rod
rotates. Thi s oi l throwoff l ubri cates the camshaft
l obes, di stri butor dri ve gear, cyl i nder wal l s, and pi s-
ton pi ns.
from the mai n oi l gal l ery. The camshaft beari ngs
recei ve oi l from the mai n beari ng gal l eri es. The front
camshaft beari ng journal passes oi l through the cam-
shaft sprocket to the ti mi ng chai n. Oi l drai ns back to
the oi l pan under the No. 1 mai n beari ng cap.
tappets, whi ch pass oi l through hol l ow push rods to a
rocker arm l ubri cates the val ve trai n components.
The oi l then passes down through the push rod gui de
hol es and the oi l drai n-back passages i n the cyl i nder
head, past the val ve tappet area, and then returns to
the oi l pan (Fi g. 60).
Fig. 58 Rear Insulator Manual Transmission4WD
1 - MANUAL TRANSMISSION
2 - INSULATOR
3 - CROSSMEMBER
Fig. 59 Positive Displacement Oil PumpTypical
1 - INNER ROTOR AND SHAFT
2 - BODY
3 - DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
8 - LARGE CHAMFERED EDGE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
AN ENGINE 3. 9L 9 - 109
Fig. 60 Oil Lubrication System
1 - OIL DEFLECTOR TAB
2 - BOLT
3 - ROCKER ARM PIVOT
4 - ROCKER ARM
5 - DRIP OILING FOR VALVE TIP
6 - CYLINDER HEAD BOSS
7 - TO MAIN BEARINGS
8 - TO CAMSHAFT BEARINGS
9 - ROCKER ARM
10 - HOLLOW PUSH ROD
11 - TAPPET
12 - TO CONNECTING ROD BEARINGS
13 - OIL INTAKE
14 - OIL PUMP
15 - OIL FILTER
16 - CRANKSHAFT
17 - FROM OIL PUMP
18 - OIL TO FILTER
20 - PASSAGE TO CAMSHAFT REAR BEARING
22 - PLUG
23 - OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
24 - OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
25 - OIL SUPPLY FROM HOLLOW PUSH ROD
9 - 110 ENGINE 3. 9L AN
PRESSURE
LEAKS
ni ppl e.
procedures.
Leak.
to next step.
OIL
tube.
di psti ck.
3 - DIPSTICK
5 - FILTER BOSS
AN ENGINE 3. 9L 9 - 111
ENGINE OIL CHANGE
perature.
engi ne off.
drai n.
gasket i f damaged.
OIL FILTER
REMOVAL
fi l ter be used.
ter from vehi cl e.
INSTALLATION
OIL PAN
REMOVAL
(2) Remove engi ne oi l di psti ck.
(4) Drai n engi ne oi l .
(5) Remove exhaust pi pe.
(6) Remove l eft engi ne to transmi ssi on strut.
(7) Loosen the ri ght si de engi ne support bracket
cushi on through-bol t nut and rai se the engi ne
sl i ghtl y. Remove oi l pan by sl i di ng backward and out.
(8) Remove the one-pi ece gasket.
CLEANING
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 112 ENGINE 3. 9L AN
OIL (Continued)
engi ne.
cl oth.
INSPECTION
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate four al i gnment dowel s from 5/16 X 1
1/2 i nch bol ts. Cut the head off the bol ts and cut a
sl ot i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 64)
.
(3) I nstal l the dowel s i n the cyl i nder bl ock (Fi g.
65) .
(4) Appl y smal l amount of Mopar Si l i cone Rubber
Adhesi ve Seal ant, or equi val ent, i n the corner of the
cap and the cyl i nder bl ock.
onto the bl ock.
the gasket.
(7) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
(8) Remove the dowel s. I nstal l the remai ni ng oi l
pan bol ts. Ti ghten these bol ts to 24 Nm (215 i n. l bs.)
torque.
(9) Lower the engi ne i nto the support cushi on
brackets and ti ghten the through-bol t nut to the
proper torque.
(10) I nstal l the drai n pl ug. Ti ghten drai n pl ug to
(11) I nstal l the engi ne to transmi ssi on strut.
(12) I nstal l exhaust pi pe.
(14) I nstal l di psti ck.
(16) Fi l l crankcase wi th oi l to proper l evel .
OIL PUMP
REMOVAL
(2) Remove the oi l pump from rear mai n beari ng
cap.
DISASSEMBLY
(1) Remove the rel i ef val ve as fol l ows:
(a) Remove cotter pi n. Dri l l a 3.175 mm (1/8 i n.)
hol e i nto the rel i ef val ve retai ner cap and i nsert a
sel f-threadi ng sheet metal screw i nto cap.
(b) Cl amp screw i nto a vi se and whi l e support-
i ng oi l pump, remove cap by tappi ng pump body
usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 66) .
(2) Remove oi l pump cover (Fi g. 67) .
(3) Remove pump outer rotor and i nner rotor wi th
shaft (Fi g. 67) .
(4) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
1 - 5/16 X 1 BOLT
2 - DOWEL
3 - SLOT
1 - DOWEL
2 - DOWEL
3 - DOWEL
4 - DOWEL
AN ENGINE 3. 9L 9 - 113
OIL PAN (Continued)
CLEANING
Use onl y mi l d sol vents to cl ean the oi l pump. Do
not use any abrasi ve materi al to cl ean the oi l pump
housi ng or rotors.
INSPECTION
Mati ng surface of the oi l pump cover shoul d be
smooth. Repl ace pump assembl y i f cover i s scratched
or grooved.
Lay a strai ghtedge across the pump cover surface
(Fi g. 68) . I f a 0.038 mm (0.0015 i n.) feel er gauge can
be i nserted between cover and strai ghtedge, pump
assembl y shoul d be repl aced.
Measure thi ckness and di ameter of outer rotor. I f
outer rotor thi ckness measures 20.9 mm (0.825 i n.)
or l ess, or i f the di ameter i s 62.7 mm (2.469 i n.) or
l ess, repl ace outer rotor (Fi g. 69) .
Fig. 66 Oil Pressure Relief Valve
1 - OIL PUMP ASSEMBLY
2 - COTTER PIN
3 - RELIEF VALVE
4 - RETAINER CAP
5 - SPRING
Fig. 67 Oil Pump
2 - BODY
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
Fig. 68 Checking Oil Pump Cover Flatness
1 - COVER
2 - STRAIGHT EDGE
3 - FEELER GAUGE
Fig. 69 Measuring Outer Rotor Thickness
9 - 114 ENGINE 3. 9L AN
I f i nner rotor measures 20.9 mm (0.825 i n.) or l ess,
repl ace i nner rotor and shaft assembl y (Fi g. 70) .
Sl i de outer rotor i nto pump body. Press rotor to the
si de wi th your fi ngers and measure cl earance
between rotor and pump body (Fi g. 71) . I f cl earance
i s 0.356 mm (0.014 i n.) or more, repl ace oi l pump
assembl y.
I nstal l i nner rotor and shaft i nto pump body. I f
cl earance between i nner and outer rotors i s 0.203
mm (0.008 i n.) or more, repl ace shaft and both rotors
(Fi g. 72) .
Pl ace a strai ghtedge across the face of the pump,
between bol t hol es. I f a feel er gauge of 0.102 mm
(0.004 i n.) or more can be i nserted between rotors
and the strai ghtedge, repl ace pump assembl y (Fi g.
73) .
I nspect oi l pressure rel i ef val ve pl unger for scori ng
and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
The rel i ef val ve spri ng has a free l ength of approx-
i matel y 49.5 mm (1.95 i n.). The spri ng shoul d test
between 19.5 and 20.5 pounds when compressed to
34 mm (1-11/32 i n.). Repl ace spri ng that fai l s to meet
these speci fi cati ons (Fi g. 74) .
I f oi l pressure was l ow and pump i s wi thi n speci fi -
cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
ASSEMBLY
(1) I nstal l pump rotors and shaft, usi ng new parts
as requi red.
(2) Posi ti on the oi l pump cover onto the pump
body. Ti ghten cover bol ts to 11 Nm (95 i n. l bs.)
torque.
Fig. 70 Measuring Inner Rotor Thickness
Fig. 71 Measuring Outer Rotor Clearance in
Housing
1 - PUMP BODY
2 - OUTER ROTOR
3 - FEELER GAUGE
Fig. 72 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 73 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
AN ENGINE 3. 9L 9 - 115
(3) I nstal l the rel i ef val ve and spri ng. I nsert the
cotter pi n.
(4) Tap on a new retai ner cap.
(5) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
INSTALLATION
(1) I nstal l oi l pump. Duri ng i nstal l ati on, sl owl y
rotate pump body to ensure dri veshaft-to-pump rotor
shaft engagement.
(2) Hol d the oi l pump base fl ush agai nst mati ng
surface on No. 4 mai n beari ng cap. Fi nger-ti ghten
pump attachi ng bol ts. Ti ghten attachi ng bol ts to 41
INTAKE MANIFOLD
DESCRIPTION
The al umi num i ntake mani fol d (Fi g. 75) i s a si ngl e
pl ane desi gn wi th equal l ength runners. Thi s mani -
fol d uses a separate pl enum pan and gasket, there-
fore the pl enum gasket i s servi cabl e. I t al so uses
separate fl ange gaskets and front and rear cross-over
gaskets. Extreme care must be used when seal i ng
the gaskets to ensure that excess seal ant does not
enter the i ntake runners causi ng a restri cti on.
OPERATION
The i ntake mani fol d, meters and del i vers ai r to the
combusti on chambers al l owi ng the fuel del i vered by
the fuel i njectors to i gni te, thus produci ng power.
DIAGNOSIS AND TESTING INTAKE
MANIFOLD LEAKAGE
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
l eak area.
(3) I f a change i n RPMs occurs, the area of the
REMOVAL
(3) Remove the A/C compressor (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
COMPRESSOR - REMOVAL).
(5) Remove the accessory dri ve bracket.
(6) Remove the ai r cl eaner.
(7) Perform the Fuel System Pressure rel ease pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELI V-
Fig. 74 Proper Installation of Retainer Cap
1 - RETAINER CAP
2 - CHAMFER
3 - COTTER KEY
Fig. 75 Intake Manifold with Tightening Sequence
3.9L Engine
9 - 116 ENGINE 3. 9L AN
ERY - STANDARD PROCEDURE). Di sconnect the
fuel l i nes (Refer to 14 - FUEL SYSTEM/FUEL
DARD PROCEDURE).
CONTROL CABLE - REMOVAL) and i f so equi pped,
the speed control and transmi ssi on ki ckdown cabl es.
(9) Remove the return spri ng.
(10) Remove the di stri butor cap and wi res.
(12) Di sconnect the heat i ndi cator sendi ng uni t
wi re.
(13) Di sconnect the heater hoses and bypass hose.
(14) Remove the cl osed crankcase venti l ati on and
evaporati on control systems.
(15) Remove i ntake mani fol d bol ts.
(16) Li ft the i ntake mani fol d and throttl e body out
of the engi ne compartment as an assembl y.
(17) Remove and di scard the fl ange si de gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttl e body (Refer to 14 - FUEL
SYSTEM/FUEL I NJECTI ON/THROTTLE BODY -
REMOVAL).
(19) I f requi red, remove the pl enum pan and gas-
ket. Di scard gasket.
CLEANING
Cl ean mani fol d i n sol vent and bl ow dry wi th com-
pressed ai r.
The pl enum pan rai l must be cl ean and dry (free of
al l forei gn materi al ).
INSPECTION
I nspect mani fol d for cracks.
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ghtedge.
INSTALLATION
(1) I f the pl enum pan was removed, posi ti on a new
gasket and i nstal l the pl enum pan (Fi g. 76). Ti ghten
bol ts i n the fol l owi ng sequence:
Step 1. Ti ghten bol ts to 5.4 Nm (48 i n. l bs.)
Step 3. Check bol ts to 9.5 Nm (84 i n. l bs.)
(2) I nstal l the fl ange gaskets. Ensure that the ver-
ti cal port al i gnment tab i s resti ng on the deck face of
the bl ock. Al so the hori zontal al i gnment tabs must be
i n posi ti on wi th the mati ng cyl i nder head gasket tabs
(Fi g. 78). The words MANI FOLD SI DE shoul d be vi s-
i bl e on the center of each fl ange gasket.
si ve Seal ant, or equi val ent, to the four corner joi nts.
An excessi ve amount of seal ant i s not requi red to
ensure a l eak proof seal . However, an excessi ve
amount of seal ant may reduce the effecti veness of
the fl ange gasket. The seal ant shoul d be approxi -
matel y 5 mm (0.2 i n) i n di ameter.
(4) I nstal l the front and rear cross-over gaskets
(Fi g. 77).
Fig. 76 Plenum Pan Bolt Tightening Sequence
Fig. 77 Cross-Over Gaskets
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
AN ENGINE 3. 9L 9 - 117
(5) Usi ng a new gasket, i nstal l the throttl e body
onto the i ntake mani fol d (Refer to 14 - FUEL SYS-
I NSTALLATI ON).
(6) Careful l y l ower i ntake mani fol d i nto posi ti on
on the cyl i nder bl ock and cyl i nder heads. After i ntake
mani fol d i s i n pl ace, i nspect to make sure seal s are
i n pl ace.
(7) I nstal l the i ntake mani fol d bol ts and ti ghten as
fol l ows (Fi g. 79):
Step 1. Ti ghten bol ts 1 and 2 to 8 Nm (72 i n.
l bs.) Ti ghten i n al ternati ng steps 1.4 Nm (12 i n. l bs.)
at a ti me
Step 2. Ti ghten bol ts 3 through 12 to 8 Nm (72
i n. l bs.)
Step 3. Check al l bol ts are torqued to 8 Nm (72
i n. l bs.)
Step 4. Ti ghten al l bol ts i n sequence to 16 Nm
(12 ft. l bs.)
Step 5. Check al l bol ts are torqued to 16 Nm
(12 ft. l bs.)
(8) I nstal l cl osed crankcase venti l ati on and evapo-
rati on control systems.
(9) Connect the coi l wi res.
(10) Connect the heat i ndi cator sendi ng uni t wi re.
(13) Hook up the return spri ng.
CONTROL CABLE - I NSTALLATI ON) and i f so
down cabl es.
(15) I nstal l the fuel l i nes (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/QUI CK CONNECT FI T-
TI NG - STANDARD PROCEDURE).
(16) I nstal l the accessory dri ve bracket and A/C
Compressor (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/A/C COMPRESSOR -
I NSTALLATI ON).
CAL/CHARGI NG/GENERATOR - I NSTALLATI ON)
and dri ve bel t (Refer to 7 - COOLI NG/ACCESSORY
DRI VE/DRI VE BELTS - I NSTALLATI ON).
(18) I nstal l the ai r cl eaner.
Fig. 78 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 79 Intake Manifold Bolt Tightening Sequence
9 - 118 ENGINE 3. 9L AN
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds (Fi g. 80) are constructed of
cast i ron and are LOG type wi th bal anced fl ow. One
exhaust mani fol d i s attached to each cyl i nder head.
OPERATION
The exhaust mani fol ds col l ect the engi ne exhaust
exhaust gases to the exhaust pi pes attached to the
mani fol ds.
REMOVAL
(3) Di sconnect the exhaust pi pe from the exhaust
mani fol d (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PI PE - REMOVAL).
(5) Remove the exhaust heat shi el ds.
(6) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(7) Remove mani fol d from the cyl i nder head.
CLEANING
fol d. Wash wi th sol vent and bl ow dry wi th com-
pressed ai r.
INSPECTION
wi th a strai ght edge. Gasket surfaces must be fl at
wi thi n 0.2 mm per 300 mm (0.008 i nch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Posi ti on the engi ne exhaust mani fol ds on the
two studs l ocated on the cyl i nder head. I nstal l coni -
cal washers and nuts on these studs (Fi g. 81) .
(2) I nstal l two bol ts and coni cal washers at the
i nner ends of the engi ne exhaust mani fol d outboard
arms. I nstal l two bol ts WI THOUT washers on the
center arm of engi ne exhaust mani fol d (Fi g. 81) .
Starti ng at the center arm and worki ng outward,
ti ghten the bol ts and nuts to 34 Nm (25 ft. l bs.)
torque.
(3) I nstal l the exhaust heat shi el ds.
(5) Assembl e exhaust pi pe to mani fol d and secure
wi th bol ts, nuts and retai ners. Ti ghten the bol ts and
nuts to 34 Nm (25 ft. l bs.) torque.
Fig. 80 Exhaust Manifolds3.9L Engine
1 - EXHAUST MANIFOLD (RIGHT)
2 - EXHAUST MANIFOLD (LEFT)
3 - BOLTS & WASHERS
4 - NUTS & WASHERS
Fig. 81 Engine Exhaust Manifold Installation3.9L
Engine
3 - BOLTS & WASHERS
4 - NUTS & WASHERS
AN ENGINE 3. 9L 9 - 119
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(3) Remove the serpenti ne bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - REMOV-
AL).
(4) Remove water pump (Refer to 7 - COOLI NG/
ENGI NE/WATER PUMP - REMOVAL).
(5) Remove power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - REMOVAL).
REMOVAL).
(7) Loosen oi l pan bol ts and remove the front bol t
at each si de.
(8) Remove the cover bol ts.
(9) Remove chai n case cover and gasket usi ng
extreme cauti on to avoi d damagi ng oi l pan gasket.
(10) From the i nsi de of the cover tap the front
crankshaft oi l seal outward. Be careful not to damage
the ti mi ng cover seal i ng surface.
INSTALLATION
(1) Be sure mati ng surfaces of chai n case cover
and cyl i nder bl ock are cl ean and free from burrs.
(2) Usi ng a new cover gasket, careful l y i nstal l
chai n case cover to avoi d damagi ng oi l pan gasket.
Use a smal l amount of Mopar GEN I I Si l i cone Rub-
ber Adhesi ve Seal ant, or equi val ent, at the joi nt
between ti mi ng chai n cover gasket and the oi l pan
gasket. Fi nger ti ghten the ti mi ng chai n cover bol ts at
thi s ti me.
CAUTION: If chain cover is replaced for any reason,
be sure the oil hole (passenger side of cover) is
plugged.
NOTE: Special Tool 6635 must be used to align
cover and seal with crankshaft.
(3) Posi ti on the speci al tool 6635 onto the crank-
shaft (Fi g. 82).
(4) Ti ghten chai n case cover bol ts to 41 Nm (30 ft.
l bs.) torque. Ti ghten oi l pan bol ts to 24 Nm (215 i n.
l bs.) torque.
(5) Remove speci al tool 6635.
damper.
(7) I nstal l vi brati on damper (Refer to 9 - ENGI NE/
ENGI NE BLOCK/VI BRATI ON DAMPER - I NSTAL-
LATI ON).
(8) I nstal l water pump (Refer to 7 - COOLI NG/EN-
GI NE/WATER PUMP - I NSTALLATI ON).
(9) I nstal l power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
LATI ON).
(11) I nstal l the cool i ng system fan (Refer to 7 -
(12) Posi ti on the fan shroud and i nstal l the bol ts.
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
TIMING BELT/CHAIN
TENSIONER AND PULLEY
DESCRIPTION
The ti mi ng chai n tensi oner i s a stamped steel con-
stant tensi on mechani cal desi gn. I t i s mounted to the
front of the engi ne, behi nd the ti mi ng chai n dri ve.
OPERATION
The ti mi ng chai n tensi on i s mai ntai ned by routi ng
the ti mi ng chai n through the tensi oner assembl y. A
nyl on covered spri ng steel arm presses on the ti mi ng
chai n mai ntai ni ng the correct chai n tensi on.
Fig. 82 Position Special Tool 6635 onto Crankshaft
2 - OIL SEAL
9 - 120 ENGINE 3. 9L AN
SPROCKETS
REMOVAL
(3) Remove ti mi ng chai n cover (Refer to 9 -
(4) Rotate crankshaft to al i gn ti mi ng marks (Fi g.
84) to #1 TDC.
(5) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
(6) Sl i p crankshaft sprocket onto crankshaft and
compress tensi oner shoe by pl aci ng a l arge screw-
dri ver between crankshaft sprocket and tensi oner
shoe (Fi g. 83). Compress shoe unti l hol e i n shoe l i nes
up wi th hol e i n bracket. Sl i de a sui tabl e pi n i nto the
hol es (Fi g. 83) and remove screwdri ver.
(7) I f tensi oner assembl y i s to be repl aced, remove
the three tensi oner to bl ock bol ts and remove ten-
si oner assembl y.
INSPECTION MEASURING TIMING CHAIN
STRETCH
NOTE: Timing chain tensioner must be removed for
this operation.
(1) Pl ace a scal e next to the ti mi ng chai n so that
any movement of the chai n can be measured.
(2) Pl ace a torque wrench and socket over cam-
shaft sprocket attachi ng bol t. Appl y torque i n the
di recti on of crankshaft rotati on to take up sl ack; 41
Nm (30 ft. l bs.) torque wi th cyl i nder head i nstal l ed
or 20 Nm (15 ft. l bs.) torque wi th cyl i nder head
removed. Wi th torque appl i ed to the camshaft
sprocket bol t, crankshaft shoul d not be permi tted to
move. I t may be necessary to bl ock the crankshaft to
prevent rotati on.
(3) Hol d a scal e wi th di mensi onal readi ng even
wi th the edge of a chai n l i nk. Wi th cyl i nder heads
i nstal l ed, appl y 14 Nm (30 ft. l bs.) torque i n the
reverse di recti on. Wi th the cyl i nder heads removed,
appl y 20 Nm (15 ft. l bs.) torque i n the reverse di rec-
ti on. Note the amount of chai n movement (Fi g. 85) .
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
Fig. 83 Compressing Tensioner For Chain
Installation
1 - SCREWDRIVER
2 - INSERT PIN HERE
1 - TIMING MARKS
AN ENGINE 3. 9L 9 - 121
INSTALLATION
(1) I f tensi oner assembl y i s bei ng repl aced, i nstal l
tensi oner and mounti ng bol ts. Torque bol ts to 24 Nm
(210 i n. l bs.).
sprocket on the bench wi th ti mi ng marks on an exact
crankshaft bores.
ti ve shafts and veri fy al i gnment of ti mi ng marks
(Fi g. 86) wi th a strai ght-edge i f necessary.
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
(7) Remove tensioner pin. Agai n, veri fy al i gn-
ment of ti mi ng marks.
(8) I nstal l ti mi ng cover (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- I NSTALLATI ON).
(11) Start engi ne and check for oi l and cool ant
l eaks.
Fig. 85 Measuring Timing Chain Wear and Stretch
1 - TORQUE WRENCH
2 - 3.175 MM (0.125 IN.)
1 - TIMING MARKS
9 - 122 ENGINE 3. 9L AN
ENGINE 4.7L
TABLE OF CONTENTS
page page
ENGINE 4.7L
ENGINE DIAGNOSIS - INTRODUCTION. . . . . 124
ENGINE DIAGNOSIS - PERFORMANCE. . . . . 125
ENGINE DIAGNOSIS - MECHANICAL. . . . . . . 127
ENGINE DIAGNOSIS - LUBRICATION . . . . . . 128
CYLINDER COMPRESSION PRESSURE . . . . 129
LEAKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
REPAIR DAMAGED OR WORN THREADS . . . 130
FORM-IN-PLACE GASKETS AND SEALERS. . 130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 135
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 136
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 139
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 142
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 143
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 147
CAMSHAFT(S) - LEFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 150
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 150
CAMSHAFT(S) - RIGHT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 154
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 156
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 158
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 158
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 159
REFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 160
HYDRAULIC LASH ADJUSTER. . . . . . . . . . . . 160
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 160
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 161
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 162
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 162
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 162
CYLINDER BORE HONING. . . . . . . . . . . . . . . 162
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
CONNECTING ROD BEARING FITTING . . . . . 164
CORE PLUGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 166
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 166
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 167
CRANKSHAFT MAIN BEARING - FITTING . . . 169
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 171
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . 172
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 172
FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 173
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 173
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 173
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 175
PISTON RINGS
AN ENGINE 4. 7L 9 - 123
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 179
STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 179
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 180
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 181
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 182
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 183
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ENGINE OIL LEAK . . . . . . . . . . . . . . . . . . . . . 184
OIL
ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . 186
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 187
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 189
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 190
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 190
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 190
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 192
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 193
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 194
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 194
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 197
VALVE TIMING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
MEASURING TIMING CHAIN WEAR. . . . . . . . 200
ENGINE TIMING - VERIFICATION . . . . . . . . . 200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 204
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 207
ENGINE 4.7L
DIAGNOSIS AND TESTING - ENGINE
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
I NG)PERFORMANCE and (Refer to 9 - ENGI NE -
DI AGNOSI S AND TESTI NG)MECHANI CAL for
possi bl e causes and correcti ons of mal functi ons.
DI AGNOSI S AND TESTI NG) and (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON - DI AGNOSI S
AND TESTI NG) for the fuel system di agnosi s.
necessary for speci fi c engi ne mal functi ons that can
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
ENGI NE - DI AGNOSI S AND TESTI NG).
I NG).
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s
(Refer to 9 - ENGI NE/CYLI NDER HEAD - DI AGNO-
SI S AND TESTI NG).
9 - 124 ENGINE 4. 7L AN
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
- CLEANING).
6. Dirt or water in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture to lean or to rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
COIL - REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.
- CLEANING).
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), repair
as necessary.
6. Burned, warped or pitted valves. 6. Replace as necessary.
AN ENGINE 4. 7L 9 - 125
system.
7. Inspect and replace as
necessary.
COIL - REMOVAL).
1. ENGINE MISSES ON
ACCELERATION
1. Spark plugs dirty or incorrectly
gapped.
- CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
COIL - REMOVAL).
1. ENGINE MISSES AT HIGH
SPEED
1. Spark plugs dirty or incorrectly
gapped.
- CLEANING).
COIL - REMOVAL).
filter.
9 - 126 ENGINE 4. 7L AN
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.
1. (Refer to LUBRICATION &
SPECIFICATIONS).
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
8. Excessive runout of valve seats
on valve faces.
8. Service valves and valve seats.
(Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
SPECIFICATIONS).
wear.
5. Connecting rod journal
out-of-round.
5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
SPECIFICATIONS).
wear.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.
7. Tighten to correct torque
AN ENGINE 4. 7L 9 - 127
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
porous metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
- REMOVAL).
damper hub.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pump suction tube loose,
damaged or clogged.
9 - 128 ENGINE 4. 7L AN
PLUGS FOULING
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
DIAGNOSIS AND TESTING - CYLINDER
ti ons.
Otherwi se the i ndi cated compressi on pressures may
ai r.
(4) Di sabl e the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - DESCRI PTI ON).
(5) Remove the ASD rel ay (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
revol uti ons.
(7) Record the compressi on pressure on the 3rd
ders.
(8) (Refer to 9 - ENGI NE - SPECI FI CATI ONS) for
the correct engi ne compressi on pressures.
DIAGNOSIS AND TESTING - CYLINDER
i ng).
jacket.
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(4) Remove the oi l fi l l er cap.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Set pi ston of cyl i nder to be tested at TDC compres-
si on,Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
LEAKAGE DI AGNOSI S CHART .
AN ENGINE 4. 7L 9 - 129
AIR ESCAPES THROUGH
THROTTLE BODY
seated properly
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPE
seated properly
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATOR
adjacent cylinders
necessary
cylinder wall
OR WORN THREADS
equi val ent.
GASKETS AND SEALERS
use.
MOPAR ATF RTV
MOPAR GASKET MAKER
9 - 130 ENGINE 4. 7L AN
APPLICATION
kets.
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Di sconnect the battery negati ve and posi ti ve
cabl es.
(2) Remove the battery and the battery tray.
(4) Remove exhaust crossover pi pe from exhaust
mani fol ds.
(5) 4X4 vehiclesDi sconnect axl e vent tube from
l eft si de engi ne mount.
(6) Remove the through bol t retai ni ng nut and bol t
from both the l eft and ri ght si de engi ne mounts (Fi g.
1) (Fi g. 2).
(7) 4X4 vehiclesRemove l ocknut from l eft and
ri ght si de engi ne mount brackets (Fi g. 2).
Fig. 1 Engine Mount Through Bolt and Nut Removal
/ Installation4X2
1 - LOCKNUT AND WASHER
2 - ENGINE MOUNT/INSULATOR
3 - THROUGH BOLT
4 - FRAME
Fig. 2 Engine Mount Through Bolt and Nut Removal
/ Installation4X4
1 - ENGINE MOUNT BRACKET (2)
2 - THROUGH BOLT (2)
3 - LOCKNUT AND WASHER (2)
4 - ENGINE ISOLATOR TO ENGINE MOUNT BRACKET STUD (2)
5 - LOCKNUT (2)
AN ENGINE 4. 7L 9 - 131
(8) Di sconnect two ground straps from the l ower
l eft hand si de and one ground strap from the l ower
ri ght hand si de of the engi ne.
(9) Di sconnect crankshaft posi ti on sensor. (Fi g. 4)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10) 4X4 vehiclesRemove the axl e i sol ator bracket
from the engi ne, transmi ssi on and the axl e (Fi g. 3).
(11) Remove structural cover (Refer to 9 -
ENGI NE/ENGI NE BLOCK/STRUCTURAL COVER -
REMOVAL).
(12) Remove starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - REMOVAL).
(14) Remove torque converter bol ts (Automati c
Transmi ssi on Onl y).
(15) Remove transmi ssi on to engi ne mounti ng
bol ts.
(16) Di sconnect the engi ne bl ock heater power
cabl e from the bl ock heater, i f equi pped.
(18) Remove throttl e body resonator assembl y and
ai r i nl et hose.
(19) Di sconnect throttl e and speed control cabl es.
(20) Di sconnect tube from both the l eft and ri ght
si de crankcase breathers (Fi g. 5). Remove breathers
(21) Di scharge A/C system (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/REFRI G-
ERANT - STANDARD PROCEDURE).
(22) Remove A/C compressor (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C COM-
PRESSOR - REMOVAL).
Fig. 3 Axle Isolator Bracket Removal / Installation
4X4 Vehicles With
1 - TRANSMISSION
2 - AXLE ISOLATOR BRACKET
3 - FRONT AXLE 4X4 VEHICLES
4 - BOLTS
5 - ENGINE
Fig. 4 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
Fig. 5 Crankcase Breather Connection Points
1 - CRANKCASE BREATHERS
9 - 132 ENGINE 4. 7L AN
(23) Remove shroud, fan assembl y (Refer to 7 -
CLUTCH - REMOVAL) and accessory dri ve bel t
BELTS - REMOVAL).
(24) Di sconnect transmi ssi on oi l cool er l i nes at the
radi ator.
(25) Di sconnect radi ator upper and l ower hoses.
(26) Remove radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - REMOVAL), A/C condenser
PLUMBI NG/A/C CONDENSER - REMOVAL) and
transmi ssi on oi l cool er.
(27) Remove generator (Refer to 8 - ELECTRI CAL/
CHARGI NG/GENERATOR - REMOVAL).
(28) Di sconnect the two heater hoses from the ti m-
i ng chai n cover and heater core.
(29) Uncl i p and remove heater hoses and tubes
from the i ntake mani fol d (Fi g. 6).
(30) Di sconnect engi ne harness at the fol l owi ng
poi nts :
I ntake ai r temperature (I AT) sensor (Fi g. 7)
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
I dl e Ai r Control (I AC) Motor
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d absol ute pressure (MAP) Sensor
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(31) Di sconnect the vacuum l i nes at the throttl e
body and i ntake mani fol d.
(32) Rel ease fuel rai l pressure (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - STANDARD PROCE-
DURE) then di sconnect the fuel suppl y qui ck connect
fi tti ng at the fuel rai l (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/QUI CK CONNECT FI TTI NG -
(33) Remove power steeri ng pump and posi ti on out
of the way.
(34) I nstal l Speci al Tool s 8400 Li fti ng Studs, i nto
the cyl i nder heads.
(35) I nstal l Engi ne Li fti ng Fi xture Speci al Tool
8347 (Fi g. 8) fol l owi ng these steps.
Hol di ng the l i fti ng fi xture at a sl i ght angl e, sl i de
the l arge bore i n the front pl ate over the hex porti on
of the l i fti ng stud.
Posi ti on the two remai ni ng fi xture arms onto
the two Speci al Tool s 8400 Li fti ng Studs, i n the cyl -
i nder heads.
Fig. 6 Heater Hoses and Tubes Removal /
Installation
1 - HEATER HOSES AND TUBES
2 - ROUTING/RETAINING CLIPS
Fig. 7 Throttle Body Connection Points
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR
5 - MOUNTING SCREWS
AN ENGINE 4. 7L 9 - 133
Pul l foward and upward on the l i fti ng fi xture so
that the l i fti ng stud rest i n the sl otted area bel ow the
l arge bore.
Secure the l i fti ng fi xture to the three studs
usi ng three 7/16 14 N/C l ocknuts.
Make sure the l i fti ng l oop i n the l i fti ng fi xture i s
i n the l ast hol e (cl osest to the throttl e body) to mi n-
i mi ze the angl e of engi ne duri ng removal .
(36) Di sconnect body ground strap at the ri ght si de
cowl (Fi g. 9).
(37) Di sconnect body ground strap at the l eft si de
cowl (Fi g. 10).
NOTE: It will be necessary to support the transmis-
sion in order to remove the engine.
(38) Posi ti on a sui tabl e jack under the transmi s-
si on.
(39) Remove engi ne from the vehi cl e.
Fig. 8 Engine Lifting Fixture Attachment Locations
1 - ATTACHING LOCATION
2 - ADJUSTABLE HOOK
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 - ATTACHING LOCATIONS
Fig. 9 Body Ground StrapRight Side Removal /
Installation
1 - NUT
2 - A/C ACCUMULATOR
3 - GROUND STRAP
Fig. 10 Body Ground StrapLeft Side Removal /
Installation
1 - NUT
2 - GROUND STRAP
3 - BRAKE BOOSTER
9 - 134 ENGINE 4. 7L AN
INSTALLATION
(1) Posi ti on engi ne i n the vehi cl e.
Posi ti on both the l eft and ri ght si de engi ne mount
brackets and i nstal l the through bol ts and nuts.
Ti ghten nuts to 4X2 vehicles 95 Nm (70 ft. l bs.).
4X4 vehicles 102 Nm (75 ft. l bs.).
(2) 4X4 vehicles I nstal l l ocknuts onto the engi ne
mount brackets. Ti ghten l ocknuts to 41 Nm (30 ft.
l bs.).
(3) Remove jack from under the transmi ssi on.
(4) Remove Engi ne Li fti ng Fi xture Speci al Tool
8347 (Fi g. 8).
(5) Remove Speci al Tool s 8400 Li fti ng Studs.
(6) Posi ti on generator wi ri ng behi nd the oi l di p-
sti ck tube, then i nstal l the oi l di psti ck tube upper
mounti ng bol t.
(7) Connect both l eft and ri ght si de body ground
straps.
(8) I nstal l power steeri ng pump.
(9) Connect fuel suppl y l i ne qui ck connect fi tti ng
DURE).
(10) Connect the vacuum l i nes at the throttl e body
and i ntake mani fol d.
(11) Connect engi ne harness at the fol l owi ng
poi nts (Fi g. 7):
I ntake Ai r Temperature (I AT) Sensor
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d Absol ute Pressure (MAP) Sensor
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(12) Posi ti on and i nstal l heater hoses and tubes
onto i ntake mani fol d.
(13) I nstal l the heater hoses onto the heater core
and the engi ne front cover.
(14) I nstal l generator (Refer to 8 - ELECTRI CAL/
CHARGI NG/GENERATOR - I NSTALLATI ON).
(15) I nstal l A/C condenser (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG/A/C CON-
DENSER - I NSTALLATI ON), radi ator (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR - I NSTALLATI ON)
and transmi ssi on oi l cool er.
(16) Connect radi ator upper and l ower hoses.
(17) Connect the transmi ssi on oi l cool er l i nes to
the radi ator.
(18) I nstal l accessory dri ve bel t (Refer to 7 -
I NSTALLATI ON), fan assembl y and shroud (Refer to
7 - COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
(19) I nstal l A/C compressor (Refer to 24 - HEAT-
PRESSOR - I NSTALLATI ON).
(20) I nstal l both breathers. Connect tube to both
crankcase breathers (Fi g. 5).
(21) Connect throttl e and speed control cabl es.
(22) I nstal l throttl e body resonator assembl y and
ai r i nl et hose. Ti ghten cl amps 4 Nm (35 i n. l bs.).
(24) I nstal l transmi ssi on to engi ne mounti ng bol ts.
Ti ghten the bol ts to 41 Nm (30 ft. l bs.).
(25) I nstal l torque converter bol ts (Automati c
Transmi ssi on Onl y).
(26) Connect crankshaft posi ti on sensor (Fi g. 4).
(27) 4X4 vehicles Posi ti on and i nstal l the axl e
i sol ator bracket onto the axl e, transmi ssi on and
engi ne bl ock. Ti ghten bol ts to speci fi cati on (Refer to 9
(28) I nstal l starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - I NSTALLATI ON).
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(29) I nstal l structural cover (Refer to 9 - ENGI NE/
ENGI NE BLOCK/STRUCTURAL COVER - I NSTAL-
LATI ON).
(30) I nstal l exhaust crossover pi pe.
(31) I nstal l engi ne bl ock heater power cabl e, I f
equi pped.
(32) 4X4 vehicles Connect axl e vent tube to l eft
si de engi ne mount.
(34) Check and fi l l engi ne oi l .
(35) Recharge the A/C system (Refer to 24 - HEAT-
(36) Refi l l the engi ne cool i ng system (Refer to 7 -
(37) I nstal l the battery tray and battery.
(38) Connect the battery posi ti ve and negati ve
cabl es.
AN ENGINE 4. 7L 9 - 135
SPECIFICATIONS
4. 7L ENGINE
GENERAL SPECIFICATIONS
Engine Type 90SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701cc
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Horsepower 235 BHP @ 4800 RPM
Torque 295 LB-FT @ 3200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Bore Diameter 93.010 .0075 mm
(3.6619 0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
PISTONS
Material Aluminum Alloy
Diameter 92.975 mm (3.6605 in.)
Weight 367.5 grams (12.96 oz)
Ring Groove Diameter
No. 1 83.73 - 83.97 mm
(3.296 - 3.269 in.)
No. 2 82.833 - 83.033 mm
(3.261 - 3.310 in.)
No. 3 83.88 - 84.08 mm
(3.302 - 3.310 in.)
PISTON PINS
Type Pressed Fit
Clearance In Piston 0.010 - 0.019 mm
(0.0004 - 0.0008 in.)
Diameter 24.013 - 24.016 mm
(0.9454 - 0.9456 in.)
PISTON RINGS
Ring Gap
(0.0146 - 0.0249 in.)
Second Compression
Ring
0.37 - 0.63 mm
(0.0146 - 0.0249 in.)
(0.0099 - 0.30 in.)
Side Clearance
Top Compression Ring .051 - .094 mm
(0.0020 - 0.0037 in.)
Second Compression
Ring
0.040 - 0.080 mm
(0.0016 - 0.0031 in.)
Oil Ring (Steel Ring) .019 - .229 mm
(.0007 - .0091 in.)
Ring Width
(0.057 - 0.058 in.)
Second Compression
Ring
1.472 - 1.490 mm
(0.057 - 0.058 in.)
Oil Ring (Steel Rails) 0.445 - 0.470 mm
(0.017 - 0.018 in.)
CONNECTING RODS
(0.0004 - 0.0019 in.)
Side Clearance 0.10 - 0.35 mm
(0.004 - 0.0138 in.)
Piston Pin Bore Diameter .022 - .045 mm
(Interference Fit) (0.0009 - 0.0018 in.)
Bearing Bore Out of
Round
0.004 mm
(MAX) (0.0002 in.)
Total Weight (Less
Bearing)
555 grams (19.5771
ounces)
CRANKSHAFT
Main BearingJournal
Diameter 63.488 - 63.512 mm
(2.4996 - 2.5005 in.)
(0.0008 - 0.0021 in.)
9 - 136 ENGINE 4. 7L AN
Taper (MAX) 0.008 mm (0.0004 in.)
End Play 0.052 - 0.282 mm
(0.0021 - 0.0112 in.)
End Play (MAX) 0.282 mm (0.0112 in)
Connecting Rod
Journal
Diameter 50.992 - 51.008 mm
(2.0076 - 2.0082 in.)
(0.0006 -0.0022 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
CAMSHAFT
Bore Diameter 26.02 - 26.04 mm
(1.0245 - 1.0252 in.)
Bearing Journal Diameter 25.975 - 25.995 mm
(1.0227 - 1.0235 in.)
(0.001 - 0.0026 in.)
Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
End Play .075 - .200 mm
(0.003 - 0.0079 in.)
End Play (MAX) .200 mm (0.0079 in.)
VALVE TIMING
Intake
Opens (ATDC) 3.6
Closes (ATDC) 247.1
Duration 243.5
Exhaust
Opens (BTDC) 232.5
Closes (ATDC) 21.2
Duration 253.70
Valve Overlap 17.6
VALVES
Face Angle 45- 45.5
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake .018 - .069 mm
(0.0008 - 0.0028 in.)
Exhaust .047 - .098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem -
to -
Guide Clearance
(Rocking
Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake 11.25 mm (0.443 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Length (Approx)
Intake and Exhaust 48.6 mm (1.9134 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 315.5 - 352.5 N @ 40.89
mm
(70.92722 - 79.24515 lbs.
@ 1.6099 in.)
Spring Force (Valve
Open)
Intake and Exhaust 786.0 - 860.0 N @ 29.64
mm
176.6998 - 193.3357 lbs.
@ 1.167 in.)
AN ENGINE 4. 7L 9 - 137
Number of Coils
Intake and Exhaust 6.69
Wire Diameter
Intake and Exhaust 4.2799 - 4.3561 mm
(0.1685 - 0.1715 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
Nominal
Intake 40.97 mm (1.613 in.)
Exhaust 40.81 mm (1.606 in.)
CYLINDER HEAD
Gasket Thickness
(Compressed) .7 mm (0.0276 in.)
Valve Seat Angle 44.5- 45.0
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)
6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness) 0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over Rotors /
End Face (MAX)
.035 - .095 mm
(0.0014 - 0.0038 in.)
Cover Out - of -Flat
(MAX)
.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
Outer Rotor Clearance
(MAX)
.235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)
85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) .150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*
25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run
engine at 3000 rpm.
TORQUE
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90
Bearing Cap Bolts 11 100
Timing Chain CoverBolts 54 40
Connecting Rod CapBolts 27 20
PLUS 90TURN
Bed PlateBolts Refer to Procedure
Crankshaft DamperBolt 175 130
Cylinder HeadBolts
M11 Bolts 81 60
M8 Bolts 26 19
Cylinder Head CoverBolts 12 105
Exhaust ManifoldBolts 25 18
Exhaust Manifold Heat
ShieldNuts
8 72
Then loosen 45
FlexplateBolts 60 45
Engine Mount Bracket to
BlockBolts
61 45
Rear Mount to
TransmissionBolts
46 34
Generator MountingBolts
M10 Bolts 54 40
M8 Bolts 28 250
Intake ManifoldBolts 12 105
Refer to Procedure
for
Tightening Sequence
Oil PanBolts 15 130
9 - 138 ENGINE 4. 7L AN
Lbs. Lbs.
Oil PumpBolts 28 250
Oil Pickup TubeBolt and
Nut
28 250
Oil Dipstick Tube to Engine
BlockBolt 15 130
Oil Fill TubeBolts 12 105
Timing Chain GuideBolts 28 250
Timing Chain Tensioner
ArmSpecial
Pin Bolt 17 150
Hydraulic TensionerBolts 28 250
Timing Chain Primary
TensionerBolts
28 250
Timing Drive Idler Sprocket
Bolt
34 25
Thermostat HousingBolts 13 115
Water PumpBolts 54 40
SPECIAL TOOLS
4. 7L ENGINE
Spanner Wrench 6958
Adapter Pins 8346
Engine Lifting Studs 8400
Engine Lift Fixture 8347
Front Crankshaft Seal Remover 8511
Front Crankshaft Seal Installer 8348
AN ENGINE 4. 7L 9 - 139
Handle C-4171
Rear Crankshaft Seal Installer 8349
Rear Crankshaft Seal Remover 8506
Connecting Rod Guides 8507
Crankshaft Damper Installer 8512
Puller 1026
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8350
9 - 140 ENGINE 4. 7L AN
Chain Tensioner Pins 8514
Secondary Chain Holder 8515
Remover, Rocker Arm 8516
Valve Spring Compressor 8387
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
Valve Spring Tester C-647
AN ENGINE 4. 7L 9 - 141
AIR CLEANER ELEMENT
REMOVAL
ter) repl acement.
i ng.
ment.
INSTALLATION
tabs.
Valve Spring Compressor C-3422-B
Bore Size Indicator C-119
BlocChekKit C-3685A
2 - TABS
3 - HOUSING
9 - 142 ENGINE 4. 7L AN
CYLINDER HEAD
DESCRIPTION - CYLINDER HEAD
The cyl i nder heads are made of an al umi num al l oy.
The cyl i nder head features two val ves per cyl i nder
wi th pressed i n powdered metal val ve gui des. The
cyl i nder heads al so provi de encl osures for the ti mi ng
chai n drai n, necessi tati ng uni que l eft and ri ght cyl i n-
der heads.
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
REMOVAL - LEFT CYLINDER HEAD
(3) Di sconnect the exhaust pi pe at the l eft si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant. Refer to COOLI NG
SYSTEM.
REMOVAL).
(7) Remove the cyl i nder head cover (Refer to 9 -
(8) Remove the fan shroud and fan bl ade assembl y
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - REMOVAL).
REMOVAL).
(10) Remove the power steeri ng pump and set
asi de.
(11) Rotate the crankshaft unti l the damper ti mi ng
mark i s al i gned wi th TDC i ndi cator mark (Fi g. 12).
(12) Veri fy the V8 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on (Fi g. 14). Rotate the
crankshaft one turn i f necessary.
(13) Remove the crankshaft damper (Refer to 9 -
REMOVAL).
(15) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8515 (Fi g. 13).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V8 mark on the camshaft dri ve gear
(Fi g. 14).
Fig. 12 Engine Top Dead Center (TDC) Indicator
Mark
2 - CRANKSHAFT TIMING MARKS
Fig. 13 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
AN ENGINE 4. 7L 9 - 143
(17) Remove the l eft si de secondary chai n ten-
si oner (Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
I NG BELT/CHAI N AND SPROCKETS - REMOVAL).
(18) Remove the cyl i nder head access pl ug (Fi g.
15).
(19) Remove the l eft si de secondary chai n gui de
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT/CHAI N AND SPROCKETS - REMOVAL).
(20) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. Severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(21) Remove the cyl i nder head retai ni ng bol ts.
(22) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
REMOVAL - RIGHT CYLINDER HEAD
(1) Di sconnect battery negi ti ve cabl e.
Fig. 14 Camshaft Sprocket V8 Marks
1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD
Fig. 15 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
9 - 144 ENGINE 4. 7L AN
(3) Di sconnect the exhaust pi pe at the ri ght si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant (Refer to 7 - COOL-
REMOVAL).
(8) Remove the fan shroud (Refer to 7 - COOLI NG/
ENGI NE/FAN DRI VE VI SCOUS CLUTCH -
REMOVAL).
(9) Remove oi l fi l l housi ng from cyl i nder head.
REMOVAL).
(11) Rotate the crankshaft unti l the damper ti mi ng
mark i s al i gned wi th TDC i ndi cator mark (Fi g. 16).
(12) Veri fy the V8 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on (Fi g. 17). Rotate the
crankshaft one turn i f necessary.
(13) Remove the crankshaft damper (Refer to 9 -
REMOVAL).
(15) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8515 (Fi g. 18).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V8 mark on the camshaft dri ve gear
(Fi g. 17).
(17) Remove the ri ght si de secondary chai n ten-
si oner (Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
I NG BELT/CHAI N AND SPROCKETS - REMOVAL).
(18) Remove the cyl i nder head access pl ug (Fi g.
19).
(19) Remove the ri ght si de secondary chai n gui de
(20) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(21) Remove the cyl i nder head retai ni ng bol ts.
(22) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components. (Refer to 9 -
ENGI NE - STANDARD PROCEDURE)
Mark
AN ENGINE 4. 7L 9 - 145
INSPECTION
(1) I nspect the cyl i nder head for out-of-fl atness,
usi ng a strai ghtedge and a feel er gauge. I f tol erances
exceed 0.0508 mm (0.002 i n.) repl ace the cyl i nder
head.
(2) I nspect the val ve seats for damage. Servi ce the
val ve seats as necessary.
Fig. 18 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
4 - IDLER SPROCKET
9 - 146 ENGINE 4. 7L AN
(3) I nspect the val ve gui des for wear, cracks or
l ooseness. I f ei ther condi ti on exi st, repl ace the cyl i n-
der head.
INSTALLATION - LEFT CYLINDER HEAD
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced (Fi g. 20).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces (Fi g. 21).
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ten M11 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesive then i nstal l the
bol ts.
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Ti ghten the bol ts i n sequence (Fi g. 22) usi ng
the fol l owi ng steps and torque val ues:
Step 1: Ti ghten bol ts 110, 20 Nm (15 ft. l bs.).
Ti ghten bol ts 1114, 25 Nm (18 ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees. Ti ghten
bol ts 1114, 30 Nm (22 ft. l bs.).
(7) Posi ti on the secondary chai n onto the camshaft
dri ve gear, maki ng sure one marked chai n l i nk i s on
Fig. 20 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 21 Proper Tool Usage for
Fig. 22 Cylinder Head Tightening Sequence
AN ENGINE 4. 7L 9 - 147
ei ther si de of the V8 mark on the gear and posi ti on
the gear onto the camshaft.
(8) I nstal l the camshaft dri ve gear retai ni ng bol t.
(9) I nstal l the l eft si de secondary chai n gui de
BELT/CHAI N AND SPROCKETS - I NSTALLA-
TI ON).
(10) I nstal l the cyl i nder head access pl ug (Fi g. 23).
(11) Re-set and I nstal l the l eft si de secondary
chai n tensi oner (Refer to 9 - ENGI NE/VALVE TI M-
I NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(12) Remove Speci al Tool 8515.
(14) I nstal l the crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(15) I nstal l the power steeri ng pump.
(16) I nstal l the fan bl ade assembl y and fan shroud
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - I NSTALLATI ON).
(17) I nstal l the cyl i nder head cover (Refer to 9 -
I NSTALLATI ON).
(19) Refi l l the cool i ng system (Refer to 7 - COOL-
(21) I nstal l the exhaust pi pe onto the l eft exhaust
mani fol d.
INSTALLATION - RIGHT CYLINDER HEAD
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced (Fi g. 24).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces (Fi g. 25).
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ten M10 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesive then i nstal l the
bol ts.
Fig. 24 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
9 - 148 ENGINE 4. 7L AN
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Ti ghten the bol ts i n sequence (Fi g. 26) usi ng
the fol l owi ng steps and torque val ues:
Ti ghten bol ts 1114, 25 Nm (18 ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees. Ti ghten
bol ts 1114, 30 Nm (22 ft. l bs.).
(7) Posi ti on the secondary chai n onto the camshaft
dri ve gear, maki ng sure one marked chai n l i nk i s on
ei ther si de of the V8 mark on the gear and posi ti on
the gear onto the camshaft.
(8) I nstal l the camshaft dri ve gear retai ni ng bol t.
(9) I nstal l the ri ght si de secondary chai n gui de
BELT / CHAI N COVER(S) - I NSTALLATI ON).
(10) I nstal l the ri ght si de cyl i nder head access
pl ug (Fi g. 27).
(11) Re-set and i nstal l the ri ght si de secondary
chai n tensi oner.
(12) Remove Speci al Tool 8515.
(14) I nstal l the crankshaft damper (Refer to 9 -
I NSTALLATI ON).
I NSTALLATI ON).
(16) I nstal l the fan shroud.
I NSTALLATI ON).
(19) I nstal l oi l fi l l housi ng onto cyl i nder head.
(22) I nstal l the exhaust pi pe onto the ri ght
exhaust mani fol d.
(24) Reconnect battery negi ti ve cabl e.
Fig. 25 Proper Tool Usage for
Fig. 26 Cylinder Head Tightening Sequence
AN ENGINE 4. 7L 9 - 149
CAMSHAFT(S) - LEFT
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. A steel
post or nose pi ece i s fri cti on-wel ded to the steel cam-
shaft tube. Fi ve beari ng journal s are machi ned i nto
the camshaft, four on the steel tube and one on the
steel nose pi ece. Camshaft end pl ay i s control l ed by
two thrust wal l s that border the nose pi ece journal .
Engi ne oi l enters the hol l ow camshafts at the thi rd
journal and l ubri cates every i ntake l obe rocker
through a dri l l ed passage i n the i ntake l obe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use Special Tool
8350 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
COVER(S) - REMOVAL) .
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V8 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V8 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave the bol t snug agai nst
the sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Posi ti on Speci al Tool 8350 ti mi ng chai n wedge
between the ti mi ng chai n strands, tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de (Fi g. 28).
NOTE: When gripping the camshaft, place the pliers
on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
(6) Hol d the camshaft wi th adjustabl e pl i ers whi l e
removi ng the camshaft sprocket bol t and sprocket
(Fi g. 29).
(7) Usi ng the pl i ers, gentl y al l ow the camshaft to
rotate 15 cl ockwi se unti l the camshaft i s i n the neu-
tral posi ti on (no val ve l oad).
(8) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Remove the camshaft beari ng caps and the
camshaft.
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 oclock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
9 - 150 ENGINE 4. 7L AN
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
the retai ni ng bol ts.
(4) Worki ng i n turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 30).
(5) Torque the camshaft beari ng cap retai ni ng
bol ts to 11 Nm (100 i n. l bs.).
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V8 mark between the two
marked chai n l i nks (Two l i nks marked duri ng
removal ) (Fi g. 31).
Fig. 28 Securing Timing Chain Tensioners Using Timing Chain Wedge
3 - SPECIAL TOOL 8350 WEDGE
Fig. 29 Camshaft Sprocket and Chain
1 - CAMSHAFT SPROCKET AND CHAIN
2 - ADJUSTABLE PLIERS
3 - CAMSHAFT
AN ENGINE 4. 7L 9 - 151
CAMSHAFT(S) - LEFT (Continued)
(7) Usi ng the adjustabl e pl i ers, rotate the cam-
shaft unti l the camshaft sprocket dowel i s al i gned
wi th the sl ot i n the camshaft sprocket. I nstal l the
sprocket onto the camshaft (Fi g. 32).
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from bol t, then i nstal l the
camshaft sprocket retai ni ng bol t and hand ti ghten.
(9) Remove Speci al Tool 8350 ti mi ng chai n wedge
(Fi g. 33).
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346 (Fi g. 34), torque the camshaft
sprocket retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the cyl i nder head cover.
Fig. 30 Camshaft Bearing Caps Tightening
Sequence
Fig. 31 Timing Chain to Sprocket Alignment
9 - 152 ENGINE 4. 7L AN
Fig. 32 Camshaft Sprocket Installation
2 - CAMSHAFT DOWEL
Fig. 33 SPECIAL TOOL 8350
AN ENGINE 4. 7L 9 - 153
CAMSHAFT(S) - RIGHT
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. A steel
post or nose pi ece i s fri cti on-wel ded to the steel cam-
shaft tube. Fi ve beari ng journal s are machi ned i nto
the camshaft, four on the steel tube and one on the
steel nose pi ece. Camshaft end pl ay i s control l ed by
two thrust wal l s that border the nose pi ece journal .
Engi ne oi l enters the hol l ow camshafts at the thi rd
journal and l ubri cates every i ntake l obe rocker
through a dri l l ed passage i n the i ntake l obe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use special tool 8350
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Remove the cyl i nder head covers (Refer to 9 -
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V8 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V8 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave bol t snug agai nst
sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Posi ti on Speci al Tool 8350 ti mi ng chai n wedge
between the ti mi ng chai n strands. Tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de (Fi g. 35).
(6) Remove the camshaft posi ti on sensor (Fi g. 36).
(7) Hol d the camshaft wi th adjustabl e pl i ers whi l e
removi ng the camshaft sprocket bol t and sprocket
(Fi g. 37).
(8) Usi ng the pl i ers, gentl y al l ow the camshaft to
rotate 45 counter-cl ockwi se unti l the camshaft i s i n
the neutral posi ti on (no val ve l oad).
(9) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
Fig. 34 Tightening Left Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
9 - 154 ENGINE 4. 7L AN
Fig. 36 Camshaft Position Sensor
Fig. 37 Camshaft Sprocket and Chain
2 - SPROCKET BOLT
4 - CAMSHAFT
AN ENGINE 4. 7L 9 - 155
CAMSHAFT(S) - RIGHT (Continued)
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(10) Remove the camshaft beari ng caps and the
camshaft.
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 oclock
position, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
the retai ni ng bol ts.
(4) Worki ng i n 1/2 turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 38).
(5) Torque the camshaft beari ng cap retai ni ng
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V8 mark between the two
marked chai n l i nks (Two l i nks marked duri ng
removal ) (Fi g. 39).
(7) Usi ng the adjustabl e pl i ers, rotate the cam-
shaft unti l the camshaft sprocket dowel i s al i gned
wi th the sl ot i n the camshaft sprocket . I nstal l the
sprocket onto the camshaft (Fi g. 40).
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from camshaft sprocket bol t,
then i nstal l the camshaft sprocket retai ni ng bol t and
hand ti ghten.
(9) Remove ti mi ng chai n wedge speci al tool 8350
(Fi g. 35).
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346 (Fi g. 41), torque the camshaft
sprocket retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the camshaft posi ti on sensor (Fi g. 36).
Fig. 38 Camshaft Bearing Caps Tightening
Sequence
9 - 156 ENGINE 4. 7L AN
Fig. 39 Timing Chain to Sprocket Alignment
Fig. 40 Camshaft Sprocket Installation
2 - CAMSHAFT DOWEL
Fig. 41 Tightening Right Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
AN ENGINE 4. 7L 9 - 157
DESCRIPTION
The cyl i nder head covers are made of di e cast mag-
nesi um, and are not i nterchangeabl e from si de-to-
si de. I t i s i mperati ve that nothi ng rest on the
cyl i nder head covers. Prol onged contact wi th other
i tems may wear a hol e i n the cyl i nder head cover.
REMOVAL - RIGHT SIDE
(2) Remove ai r cl eaner assembl y, resonator assem-
bl y and ai r i nl et hose.
REMOVAL).
(5) Remove ai r condi ti oni ng compressor retai ni ng
bol ts and move compressor to the l eft.
(6) Remove heater hoses.
(7) Di sconnect i njector and i gni ti on coi l connectors.
(8) Di sconnect and remove posi ti ve crankcase ven-
ti l ati on (PCV) hose.
(9) Remove oi l fi l l tube.
(10) Un-cl i p i njector and i gni ti on coi l harness and
move away from cyl i nder head cover.
(11) Remove ri ght rear breather tube and fi l ter
assembl y.
(12) Remove cyl i nder head cover retai ni ng bol ts.
(13) Remove cyl i nder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
REMOVAL - LEFT SIDE
(2) Remove the resonator assembl e and ai r i nl et
hose.
(3) Di sconnect i njector connectors and un-cl i p the
i njector harness.
(4) Route i njector harness i n front of cyl i nder head
cover.
(5) Di sconnect the l eft si de breather tube and
remove the breather tube.
(6) Remove the cyl i nder head cover mounti ng
bol ts.
(7) Remove cyl i nder head cover and gasket.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
INSTALLATION - RIGHT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) I nstal l cyl i nder head cover and hand start al l
fasteners. Veri fy that al l doubl e ended studs are i n
the correct l ocati on shown i n (Fi g. 42).
(3) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs).
(4) I nstal l ri ght rear breather tube and fi l ter
assembl y.
(5) Connect i njector, i gni ti on coi l el ectri cal connec-
tors and harness retai ni ng cl i ps.
(6) I nstal l the oi l fi l l tube.
(7) I nstal l PCV hose.
(8) I nstal l heater hoses.
(9) I nstal l ai r condi ti oni ng compressor retai ni ng
bol ts.
I NSTALLATI ON).
(11) Fi l l Cool i ng system (Refer to 7 - COOLI NG -
Fig. 42 Cylinder Head CoverRight
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 Nm (105 in. lbs.)
9 - 158 ENGINE 4. 7L AN
(12) I nstal l ai r cl eaner assembl y, resonator assem-
INSTALLATION LEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) I nstal l cyl i nder head cover and hand start al l
fasteners. Veri fy that al l studs are i n the correct l oca-
ti on shown i n (Fi g. 43).
(3) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs.).
(4) I nstal l l eft si de breather and connect breather
tube.
(5) Connect i njector el ectri cal connectors and i njec-
tor harness retai ni ng cl i ps.
(6) I nstal l the resonator and ai r i nl et hose.
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
STANDARD PROCEDURE REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.75 2.36 mm (0.0689
0.0928 i n.) and the exhaust seat must be 1.71 2.32
mm (0.0673 0.0911 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 41.44 mm (1.6315 i n.) .
(5) The val ve seat and val ve face must mai ntai n a
face angl e of 44.5 45 degrees angl e (Fi g. 44).
Fig. 43 Cylinder Head CoverLeft
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 Nm (105 in. lbs.)
AN ENGINE 4. 7L 9 - 159
ROCKER ARM / ADJ USTER
ASSEMBLY
DESCRIPTION
The rocker arms are steel stampi ngs wi th an i nte-
gral rol l er beari ng. The rocker arms i ncorporate a 2.8
mm (0.11 i nch) oi l hol e i n the l ash adjuster socket for
rol l er and camshaft l ubri cati on.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
Remove suspected l ash adjusters, and repl ace.
Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(2) For rocker arm removal on cyl i nders 3 and 5
Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
compressi on stroke.
(6) Usi ng speci al tool 8516 Rocker Arm Remover,
press downward on the val ve spri ng, remove rocker
arm (Fi g. 45).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
Fig. 44 Valve Assembly Configuration
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 160 ENGINE 4. 7L AN
(1) For rocker arm i nstal l ati on on cyl i nders 3 and
5 Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
(5) Usi ng speci al tool 8516 press downward on the
val ve spri ng, i nstal l rocker arm (Fi g. 45).
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs are made from hi gh strength
chrome si l i con steel . The spri ngs are common for
i ntake and exhaust appl i cati ons. The val ve spri ng
seat i s i ntegral wi th the val ve stem seal , whi ch i s a
posi ti ve type seal to control l ubri cati on.
REMOVAL
(2) Usi ng Speci al Tool 8516 Rocker Arm Remover,
remove the rocker arms and the hydraul i c l ash
adjusters (Fi g. 46).
(3) Remove the spark pl ug for the cyl i nder the
val ve spri ng and seal are to be removed from.
(4) Appl y shop ai r to the cyl i nder to hol d the
val ves i n pl ace when the spri ng i s removed
(5) Remove the camshaft (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: All eight valve springs and seals are
removed in the same manner; this procedure only
covers one valve seal and valve spring.
(6) Usi ng Speci al Tool 8387 Val ve Spri ng Compres-
sor, compress the val ve spri ng.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(7) Remove the two spri ng retai ner l ock hal ves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
Fig. 45 Rocker ArmRemoval
1 - CAMSHAFT
Fig. 46 Rocker ArmRemoval
1 - CAMSHAFT
AN ENGINE 4. 7L 9 - 161
ROCKER ARM / ADJ USTER ASSEMBLY (Continued)
(8) Remove the val ve spri ng compressor.
(9) Remove the spri ng retai ner, and the spri ng.
(10) Remove the val ve stem seal .
NOTE: The valve stem seals are common between
intake and exhaust.
INSTALLATION
(1) coat the val ve stem wi th cl ean engi ne oi l and
i nstal l the val ve stem seal . Make sure the seal i s
ful l y seated and that the garter spri ng at the top of
the seal i s i ntact.
(2) I nstal l the spri ng and the spri ng retai ner (Fi g.
47).
(3) Usi ng Speci al Tool 8387 Val ve Spri ng Compres-
sor, compress the spri ng and i nstal l the two val ve
spri ng retai ner hal ves.
(4) Rel ease the val ve spri ng compressor and make
sure the two spri ng retai ner hal ves and the spri ng
retai ner are ful l y seated.
(5) I nstal l the camshaft (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CAMSHAFT(S) - I NSTALLA-
TI ON).
(6) Posi ti on the hydraul i c l ash adjusters and
rocker arms (Fi g. 46).
VALVE STEM SEALS
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate an i ntegral steel val ve spri ng seat. The i nte-
gral garter spri ng mai ntai ns consi stent l ubri cati on
control to the val ve stems.
ENGINE BLOCK
DESCRIPTION
The cyl i nder bl ock i s made of cast i ron. The bl ock
i s a cl osed deck desi gn wi th the l eft bank forward. To
provi de hi gh ri gi di ty and i mproved NVH an
enhanced compacted graphi te bedpl ate i s bol ted to
the bl ock. The bl ock desi gn al l ows cool ant fl ow
between the cyl i nders bores, and an i nternal cool ant
bypass to a si ngl e poppet i nl et thermostat i s i ncl uded
i n the cast al umi num front cover.
HONING
area.
i ts.
Fig. 47 Valve Assembly Configuration
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 162 ENGINE 4. 7L AN
VALVE SPRINGS (Continued)
hatch angl e.
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter. To correctl y
sel ect the proper si ze pi ston, a cyl i nder bore gauge,
capabl e of readi ng i n 0.003 mm (.0001 i n.) I NCRE-
MENTS i s requi red. I f a bore gauge i s not avai l abl e,
do not use an i nsi de mi crometer (Fi g. 49).
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
bl ock must be repl aced. A sl i ght amount of taper
al ways exi sts i n the cyl i nder bore after the engi ne
has been i n use for a peri od of ti me.
2 - INTERSECT ANGLE
Fig. 49 Bore GaugeTypical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
AN ENGINE 4. 7L 9 - 163
ENGINE BLOCK (Continued)
BEARING FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 50) (Fi g. 51). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 52). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(3) Use pi ston ri ng compressor and Gui de Pi ns
Speci al Tool 8507 (Fi g. 53) to i nstal l the rod and pi s-
ton assembl i es. The oi l sl i nger sl ots i n the rods must
face front of the engi ne. The Fs near the pi ston
wri st pi n bore shoul d poi nt to the front of the engi ne.
(4) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(5) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us a
90 turn. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(6) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 54). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
Fig. 50 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN ALWAYS GREATER ON UPPER
BEARING
5 - LOWER BEARING HALF
Fig. 51 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 52 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
9 - 164 ENGINE 4. 7L AN
(8) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, determi n whi ch servi ces beari ng set to
use the beari ng si zes are as fol l ows:
Bearing
Mark
SIZE USED WITH
JOURNAL SIZE
.025 US .025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std. STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US .250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
(9) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(10) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 27 Nm (20 ft. l bs.) pl us a 90 turn.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 55).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
Fig. 53 Piston and Connecting RodInstallation
1 - F TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
Fig. 54 Measuring Bearing Clearance with
Plastigage
Fig. 55 Checking Connecting Rod Side Clearance
Typical
AN ENGINE 4. 7L 9 - 165
CORE PLUGS
REMOVAL
(2) Usi ng a bl unt tool such as a dri ft or a screw
dri ver and a hammer, stri ke the bottom edge of the
cup pl ug (Fi g. 56)
(3) Usi ng a sui tabl e pai r of pl i ers, grasp the core
pl ug and remove.
INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all
of the old sealer.
(1) Coat the edges of the engi ne core pl ug and the
core pl ug bore wi th Mopar Gasket Maker, or equi va-
l ent.
NOTE: It is not necessary to wait for the sealant to
cure on the core plugs. The cooling system can be
filled and the vehicle returned to service immedi-
ately.
(2) Usi ng proper pl ug dri ver, dri ve core pl ug i nto
the core pl ug bore. The sharp edge of the core pl ug
shoul d be at l east 0.50 mm (0.020 i n.) i nsi de the l ead
i n chamfer.
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a crosshaped four throw desi gn
wi th ei ght counterwei ghts for bal anci ng purposes.
The crankshaft i s supported by fi ve sel ect fi t mai n
beari ngs wi th the number three servi ng as the thrust
washer l ocati on. The mai n journal s of the crankshaft
are cross dri l l ed to i mprove rod beari ng l ubri cati on.
The number ei ght counterwei ght has provi si ons for
crankshaft posi ti on sensor target wheel mounti ng.
The sel ect fi t mai n beari ng marki ngs are l ocated on
the rear si de of the target wheel . The crankshaft oi l
seal s are one pi ece desi gn. The front oi l seal i s
retai ned i n the ti mi ng chai n cover, and the rear seal
i s pressed i n to a bore formed by the cyl i nder bl ock
and the bedpl ate assembl y.
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engi ne. (Refer to 9 - ENGI NE -
REMOVAL).
(2) Remove the engi ne oi l pump.(Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - REMOVAL).
(4) Remove the oi l pump pi ckup tube and oi l pan
gasket /wi ndage tray.
(5) Remove the bedpl ate mounti ng bol ts. Note the
l ocati on of the three stud bol ts for i nstal l ati on.
(6) Remove the connecti ng rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
Fig. 56 Engine Core Plug Removal
1 - CYLINDER BLOCK
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 166 ENGINE 4. 7L AN
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are on both the
left and right sides, only the left side is shown.
(7) Careful l y pry on the pry poi nts (Fi g. 57) to
l oosen the bedpl ate then remove the bedpl ate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft.
(9) Remove the crankshaft target wheel .
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
I f connecti ng rod beari ng bores show damage, the
cyl i nder heads must be removed to servi ce the pi ston
and rod assembl i es. I f the bedpl ate or the cyl i nder
bl ock mai n beari ng bores show damage the engi ne
must be repl aced.
(1) I f requi red, remove the mai n beari ng hal ves
from the cyl i nder bl ock and bedpl ate.
(2) Thoroughl y cl ean the bedpl ate to cyl i nder bl ock
seal i ng surfaces and mai n beari ng bores. Remove al l
oi l and seal ant resi due.
(3) I nspect the bedpl ate mai n beari ng bores for
cracks, scori ng or severe bl uei ng. I f ei ther condi ti on
exi sts the engi ne must be repl aced.
(4) I nspect the crankshaft thrust washer for scor-
i ng, scratches or bl uei ng. I f ei ther condi ti on exi st
repl ace the thrust washer.
(5) I nspect the oi l pan gasket/wi ndage tray for
spl i ts, tears or cracks i n the gasket seal i ng surfaces.
Repl ace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
(1) Lubri cate upper mai n beari ng hal ves wi th
cl ean engi ne oi l .
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the target wheel retaining
screws prior to installation.
(2) I nstal l the crankshaft target wheel . Torque the
mounti ng screws to 22 Nm (21 ft. l bs.).
(3) Posi ti on crankshaft i n cyl i nder bl ock.
(4) I nstal l the thrust washers (Fi g. 58).
Fig. 57 Bedplate Pry Point Location
1 - CYLINDER BLOCK
2 - BEDPLATE
3 - PRY POINT
Fig. 58 Crankshaft Thrust Washer Installation
1 - CRANKSHAFT THRUST WASHER
AN ENGINE 4. 7L 9 - 167
CAUTION: The bedplate to cylinder block mateing
surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks.
NOTE: The installation time to install the bedplate
after the sealant has been applied is critical.
NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
(5) Appl y a 2.5mm (0.100 i nch) (Fi g. 59) bead of
Mopar Gen I I Si l i cone Rubber Adhesi ve seal ant to
the cyl i nder bl ock-to-bedpl ate mati ng surface as
shown (Fi g. 60).
(6) Coat the crankshaft mai n beari ng journal s
wi th cl ean engi ne oi l and posi ti on the bedpl ate onto
the cyl i nder bl ock.
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) I nstal l the bedpl ate retai ni ng bol ts, maki ng
sure to pl ace the stud bol ts i n the correct l ocati on,
Torque the bol ts i n the sequence shown (Fi g. 61).
Ti ghten bol ts A L to 54 Nm (40 ft. l bs.)
Ti ghten bol ts 110 to 2.8 Nm (25 i n. l bs.)
Turn bol ts 110 an addi ti onal 90.
Ti ghten bol ts A1 A6 to 27 Nm (20 ft. l bs.)
(8) Measure crankshaft end pl ay. (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(9) I nstal l the connecti ng rods and measure si de
cl earance. (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CONNECTI NG ROD BEARI NGS - STANDARD
PROCEDURE).
(10) Posi ti on the oi l pan gasket/wi ndage tray,
usi ng a new o-ri ng, i nstal l the oi l pi ckup tube.
Torque the bol t to 28Nn (20 ft. l bs.) torque the nuts
to 28Nm (20 ft. l bs.).
(11) I nstal l the oi l pan. Torque the retai ni ng bol ts
to 15 Nm (11 ft. l bs.) i n the sequence shown (Fi g.
62).
(12) I nstal l the engi ne (Refer to 9 - ENGI NE -
I NSTALLATI ON).
Fig. 59 Cutting Aplicator to Achieve 2.5mm (0.100
in.) Bead
1 - CUT HERE
Fig. 60 Cylinder Block-to-Bedplate Sealent Bead
Location
1 - CYLINDER BLOCK
2 - SEALANT BEAD LOCATION
9 - 168 ENGINE 4. 7L AN
CRANKSHAFT MAIN
BEARINGS
BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Crankshaft removed from the cyl i nder bl ock.
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper i s 0.008mm (0.0004
i nch.) and maxi mum out of round i s 0.005mm (0.002
i nch). Compare the measured di ameter wi th the jour-
nal di ameter speci fi cati on (Mai n Beari ng Fi tti ng
Chart). Sel ect i nserts requi red to obtai n the speci fi ed
beari ng-to-journal cl earance.
CRANKSHAFT MAIN BEARING SELECTION
The mai n beari ngs are sel ect fi t to achi eve proper
oi l cl earances. For mai n beari ng sel ecti on, the crank-
shaft posi ti on sensor target wheel has grade i denti fi -
cati on marks stamped i nto i t (Fi g. 63). These marks
are read from l eft to ri ght, correspondi ng wi th jour-
nal number 1, 2, 3, 4 and 5. The crankshaft posi ti on
sensor target wheel i s mounted to the number 8
counter wei ght on the crankshaft.
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
Fig. 61 Bedplate Tightening Sequence
1 - BEDPLATE 2 - CYLINDER BLOCK
Fig. 62 Oil Pan Tightening Sequence
AN ENGINE 4. 7L 9 - 169
MAIN BEARING SELECTION CHART4.7L
GRADE SIZE mm
(in.)
FOR USE WITH
MARKING JOURNAL SIZE
A 0.008 mm
U/S
63.48863.496 mm
(0.0004 in.)
U/S
(2.49962.4999 in.)
B NOMINAL 63.49663.504 mm
(2.49992.5002 in.)
C 0.008 mm
O/S
63.50463.512 mm
(0.0004 in.)
O/S
(2.50022.5005 in.)
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 64).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FRONT
REMOVAL
REMOVAL).
(3) Remove A/C compressor mouni ng fasteners and
set asi de.
(5) Remove upper radi ator hose.
(6) Di sconnect el ectri cal connector for fan mounted
i nsi de radi ator shroud.
(7) Remove radi ator shroud attachi ng fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(8) Remove radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bol t.
(10) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 65).
(11) Usi ng Speci al Tool 8511, remove crankshaft
front seal (Fi g. 66).
Fig. 63 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 64 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
9 - 170 ENGINE 4. 7L AN
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Usi ng Speci al Tool 8348 and 8512, i nstal l
crankshaft front seal (Fi g. 67).
(2) I nstal l vi brati on damper (Refer to 9 - ENGI NE/
ENGI NE BLOCK/VI BRATI ON DAMPER - I NSTAL-
LATI ON).
(3) I nstal l radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(4) I nstal l upper radi ator hose.
(5) I nstal l A/C compressor and ti ghten fasteners to
54 Nm (40 ft. l bs.).
(6) I nstal l accessory dri ve bel t refer (Refer to 7 -
I NSTALLATI ON).
Fig. 65 Crankshaft DamperRemoval
1 - SPECIAL TOOL 8513 INSERT
Fig. 66 Crankshaft Front SealRemoval
Fig. 67 Crankshaft Front SealInstallation
AN ENGINE 4. 7L 9 - 171
REAR
LEAKS
area:
bl ock mati ng surfaces. See Engi ne, for proper
repai r procedures of these i tems.
case as outl i ned i n the secti on, I nspecti on (Engi ne oi l
Leaks i n general )
seal.
assembl ed. (Refer to 9 - ENGI NE - DI AGNOSI S AND
TESTI NG), under the Oi l Leak row, for components
SEAL - REAR - REMOVAL).
REMOVAL
NOTE: This procedure can be preformed in vehicle.
(1) I f bei ng preformed i n vehi cl e, remove the
transmi ssi on.
(2) Remove the fl expl ate (Refer to 9 - ENGI NE/
ENGI NE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Usi ng Speci al Tool 8506 (Fi g. 68), remove the
crankshaft rear oi l seal .
INSTALLATION
(1) Posi ti on the magneti c seal gui de Speci al Tool
83492 (Fi g. 69) onto the crankshaft rear face. Then
posi ti on the crankshaft rear oi l seal onto the gui de.
(2) Usi ng Speci al Tool s 8349 Crankshaft Rear Oi l
Seal I nstal l er and C-4171 Dri ver Handl e (Fi g. 70),
wi th a hammer, tap the seal i nto pl ace. Conti nue to
tap on the dri ver handl e unti l the seal i nstal l er seats
agai nst the cyl i nder bl ock crankshaft bore.
(3) I nstal l the fl expl ate.
(4) I f removed, i nstal l the transmi ssi on.
Fig. 68 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
9 - 172 ENGINE 4. 7L AN
FLEX PLATE
REMOVAL
(1) Remove the transmi ssi on.
(2) Remove the bol ts and fl expl ate.
INSTALLATION
(1) Posi ti on the fl expl ate onto the crankshaft and
i nstal l the bol ts hand ti ght.
(2) Ti ghten the fl expl ate retai ni ng bol ts to 60 Nm
(45 ft. l bs.) i n the sequence shown (Fi g. 71).
(3) I nstal l the transmi ssi on.
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pi stons are made of a hi gh strength al umi num
al l oy. The anodi zed top ri ng groove and crown has
been repl aced wi th a coated top ri ng that i s bl ue i n
col or. Pi ston ski rts are coated wi th a sol i d l ubri cant
(Mol ykote) to reduce fri cti on and provi de scuff resi s-
tance. The connecti ng rods are made of forged pow-
dered metal , wi th a fractured cap desi gn. A pressed
fi t pi ston pi n i s used to attach the pi ston and con-
necti ng rod.
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
Fig. 69 Crankshaft Rear Oil Seal Guide Special Tool
83492 and Oil
2 - SPECIAL TOOL 83492 GUIDE
Fig. 70 Crankshaft Rear Oil Seal Installation
2 - SPECIAL TOOL 83491 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
Fig. 71 Flexplate Tightening Sequence
1 - FLEXPLATE
AN ENGINE 4. 7L 9 - 173
bore at a poi nt 38.0 mm (1.5 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 73).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 72). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
REMOVAL
(2) Remove the fol l owi ng components:
Oi l pan and gasket/wi ndage tray (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - REMOVAL).
Ti mi ng chai n cover (Refer to 9 - ENGI NE/
- REMOVAL).
Cyl i nder head(s) (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - REMOVAL) and (Refer to 9 - ENGI NE/
CYLI NDER HEAD - REMOVAL).
(3) I f necessary, remove top ri dge of cyl i nder bores
wi th a rel i abl e ri dge reamer before removi ng pi stons
from cyl i nder bl ock. Be sure to keep tops of pis-
tons covered during this operation. Pi stons and
connecti ng rods must be removed from top of cyl i nder
bl ock. When removi ng pi ston and connecti ng rod
assembl i es from the engi ne, rotate crankshaft so the
each connecti ng rod i s centered i n cyl i nder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecti ng rod and beari ng cap posi ti ons
usi ng a permanent i nk marker or scri be tool (Fi g.
74).
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
Fig. 72 Moly Coated PistonTypical
1 - MOLY COATED
2 - MOLY COATED
Fig. 73 Bore GaugeTypical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
9 - 174 ENGINE 4. 7L AN
(5) Remove connecti ng rod cap. I nstal l Speci al Tool
8507 Connecti ng Rod Gui des i nto the connecti ng rod
bei ng removed. Remove pi ston from cyl i nder bore.
Repeat thi s procedure for each pi ston bei ng removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) I mmedi atel y after pi ston and connecti ng rod
removal , i nstal l beari ng cap on the mati ng connect-
i ng rod to prevent damage to the fractured cap and
rod surfaces.
(7) Careful l y remove pi ston ri ngs from pi ston(s),
starti ng from the top ri ng down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Usi ng a sui tabl e cl eani ng sol vent cl ean the pi s-
tons i n warm water and towel dry.
(2) Use a wood or pl asti c scraper to cl ean the ri ng
l and grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
i ng.
INSTALLATION
(1) Before i nstal l i ng pi ston and connecti ng rod
assembl i es i nto the bore, i nstal l the pi ston ri ngs.
engi ne oi l . Posi ti on a ri ng compressor over the pi ston
and ri ngs. Ti ghten ri ng compressor. Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Posi ti on beari ng onto connecti ng rod. Ensure
that hol e i n beari ng shel l al i gns wi th hol e i n connect-
i ng rod. Lubri cate beari ng surface wi th cl ean engi ne
oi l .
(4) I nstal l Speci al Tool 8507 Connecti ng Rod
Gui des i nto connecti ng rod bol t threads (Fi g. 75).
(5) The pi stons are marked on the pi ston pi n bore
surface wi th an rai sed F i ndi cati ng i nstal l ati on
posi ti on. Thi s mark must be poi nti ng toward the
front of engi ne on both cyl i nder banks. The connect-
Fig. 74 Identify Connecting Rod to Cylinder
PositionTypical
Fig. 75 Piston and Connecting RodInstallation
1 - F TOWARD FRONT OF ENGINE
3 - RING COMPRESSOR
AN ENGINE 4. 7L 9 - 175
i ng rod oi l sl i nger sl ot faces the front of the engi ne
(Fi g. 76).
(6) Wi pe cyl i nder bore cl ean and l ubri cate wi th
engi ne oi l .
(7) Rotate crankshaft unti l connecti ng rod journal
i s on the center of cyl i nder bore. I nsert rod and pi s-
ton i nto cyl i nder bore and careful l y posi ti on connect-
i ng rod gui des over crankshaft journal .
(8) Tap pi ston down i n cyl i nder bore usi ng a ham-
mer handl e. Whi l e at the same ti me, gui de connect-
i ng rod i nto posi ti on on rod journal .
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Lubri cate rod bol ts and beari ng surfaces wi th
engi ne oi l . I nstal l connecti ng rod cap and beari ng.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us 90.
(10) I nstal l the fol l owi ng components:
Cyl i nder head(s). (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - I NSTALLATI ON).
Ti mi ng chai n and cover. (Refer to 9 - ENGI NE/
- I NSTALLATI ON).
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
I NSTALLATI ON).
Oi l pan and gasket/wi ndage tray. (Refer to 9 -
TI ON).
(11) Fi l l crankcase wi th proper engi ne oi l to cor-
rect l evel .
PISTON RINGS
FITTING
Before rei nstal l i ng used ri ngs or i nstal l i ng new
ri ngs, the ri ng cl earances must be checked.
(1) Wi pe the cyl i nder bore cl ean.
(2) I nsert the ri ng i n the cyl i nder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Usi ng a pi ston, to ensure that the ri ng i s
squared i n the cyl i nder bore, sl i de the ri ng downward
i nto the cyl i nder.
(4) Usi ng a feel er gauge check the ri ng end gap
(Fi g. 77). Repl ace any ri ngs not wi thi n speci fi cati on.
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
(5) Measure the ri ng si de cl earance as shown (Fi g.
78)make sure the feel er gauge fi ts snugl y between
the ri ng l and and the ri ng. Repl ace any ri ng not
wi thi n speci fi cati on.
Fig. 76 Piston and Connecting Rod Orientation
1 - MAJOR THRUST SIDE OF PISTON
Fig. 77 Ring End Gap Measurement - Typical
1 - FEELER GAUGE
9 - 176 ENGINE 4. 7L AN
(6) Rotate the ri ng around the pi ston, the ri ng
must rotate i n the groove wi th out bi ndi ng.
PISTON RING SPECIFICATION CHART
Ring Position Groove Maximum
Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020- .0037 in.) (0.004 in.)
Intermediate
Ring
0.04-0.08mm 0.10mm
(0.0016-0.0031 in.) (0.004 in.)
Oil Control
Ring
.019-.229mm .25mm
(Steel Rails) (.0007-.0090 in.) (0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.23-0.39mm 0.43mm
(0.009-0.015 in.) (0.0017 in.)
Intermediate
Ring
0.40-0.66mm 0.74mm
(0.015-0.026 in.) (0.029 in.)
Oil Control
Ring
0.028-0.79mm 1.55mm
(Steel Rail) (0.011- 0.031 in.) (0.061 in.)
(7) The No. 1 and No. 2 pi ston ri ngs have a di ffer-
ent cross secti on. Ensure No. 2 ri ng i s i nstal l ed wi th
manufacturers I .D. mark (Dot) faci ng up, towards top
of the pi ston.
NOTE: Piston rings are installed in the following
order:
Oi l ri ng expander.
Upper oi l ri ng si de rai l .
Lower oi l ri ng si de rai l .
No. 2 I ntermedi ate pi ston ri ng.
No. 1 Upper pi ston ri ng.
(8) I nstal l the oi l ri ng expander.
(9) I nstal l upper si de rai l (Fi g. 79) by pl aci ng one
end between the pi ston ri ng groove and the expander
ri ng. Hol d end fi rml y and press down the porti on to
be i nstal l ed unti l si de rai l i s i n posi ti on. Repeat thi s
step for the l ower si de rai l .
(10) I nstal l No. 2 i ntermedi ate pi ston ri ng usi ng a
pi ston ri ng i nstal l er (Fi g. 80).
(11) I nstal l No. 1 upper pi ston ri ng usi ng a pi ston
ri ng i nstal l er (Fi g. 80).
(12) Posi ti on pi ston ri ng end gaps as shown i n
(Fi g. 81). I t i s i mportant that expander ri ng gap i s at
l east 45 from the si de rai l gaps, but not on the pi s-
ton pi n center or on the thrust di recti on.
VIBRATION DAMPER
REMOVAL
REMOVAL).
Fig. 78 Measuring Piston Ring Side Clearance
1 - FEELER GAUGE
Fig. 79 Side RailInstallation
1 - SIDE RAIL END
AN ENGINE 4. 7L 9 - 177
(4) Remove radi ator upper hose.
(5) Remove upper fan shroud.
(6) Usi ng Speci al Tool s 6958 Spanner wi th Adapter
Pi ns 8346, l oosen fan and vi scous assembl y from
water pump (Fi g. 82).
(7) Remove fan and vi scous assembl y.
(8) Di sconnect el ectri cal connector for fan mounted
i nsi de radi ator shroud.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(9) Remove crankshaft damper bol t.
(10) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 83).
Fig. 80 Upper and Intermediate RingsInstallation
Fig. 81 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 82 Fan AssemblyRemoval/Installation
PINS 8346
2 - FAN
Fig. 83 Crankshaft DamperRemoval
9 - 178 ENGINE 4. 7L AN
VIBRATION DAMPER (Continued)
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512A, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Al i gn crankshaft damper sl ot wi th key i n
crankshaft. Sl i de damper onto crankshaft sl i ghtl y.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assembl e Speci al Tool 8512A as fol l ows, The
nut i s threaded onto the shaft fi rst. Then the rol l er
beari ng i s pl aced onto the threaded rod (The hard-
ened beari ng surface of the beari ng MUSTface the
nut). Then the hardened washer sl i des onto the
threaded rod (Fi g. 84). Once assembl ed coat the
threaded rods threads wi th Mopar Ni ckel Anti -
Sei ze or (Locti te No. 771).
(3) Usi ng Speci al Tool 8512A, press damper onto
crankshaft (Fi g. 85).
(4) I nstal l then ti ghten crankshaft damper bol t to
175 Nm (130 ft. l bs.).
(5) I nstal l fan bl ade assembl y (Refer to 7 - COOL-
I NG/ENGI NE/FAN DRI VE VI SCOUS CLUTCH -
I NSTALLATI ON).
(6) I nstal l radi ator upper shroud and ti ghten fas-
teners to 11 Nm (95 i n. l bs.).
(7) Connect el ectri cal connector for shroud fan.
(8) I nstal l radi ator upper hose.
LATI ON).
STRUCTURAL COVER
DESCRIPTION
The structural dust cover i s made of di e cast al u-
mi num and joi ns the l ower hal f of the transmi ssi on
bel l housi ng to the engi ne bedpl ate.
OPERATION
The structural cover provi des addi ti onal power-
trai n sti ffness and reduces noi se and vi brati on.
REMOVAL
(2) Remove the l eft hand exhaust pi pe from
exhaust mani fol d.
(3) Loosen the ri ght hand exhaust mani fol d-to-ex-
haust pi pe retai ni ng bol ts.
(4) Remove the ei ght bol ts retai ni ng structural
cover (Fi g. 86) i n the sequence shown.
(5) Pi vot the exhaust pi pe downward and remove
the structural cover.
Fig. 84 Proper Assembly Method for Special Tool
8512A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 85 Crankshaft Damper Installation
AN ENGINE 4. 7L 9 - 179
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Posi ti on the structural cover i n the vehi cl e.
(2) I nstal l al l four bol ts retai ni ng the cover-to-en-
gi ne. DO NOT ti ghten the bol ts at thi s ti me.
(3) I nstal l the four cover-to-transmi ssi on bol ts. Do
NOT ti ghten at thi s ti me.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starti ng wi th the two rear cover-to-engi ne
bol ts, ti ghten bol ts (1) (Fi g. 87) to 54 Nm (40 ft. l bs.),
then ti ghten bol ts (2) (Fi g. 87) and (3) to 54 Nm ( 40
ft. l bs.) i n the sequence shown.
(5) I nstal l the exhaust pi pe on l eft hand exhaust
mani fol d.
(6) Ti ghten exhaust mani fol d-to-exhaust pi pe
retai ni ng bol ts to 2026 Nm (1520 ft. l bs.).
FRONT MOUNT
REMOVAL
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the fan bl ade, fan cl utch and fan
shroud (Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE
VI SCOUS CLUTCH - REMOVAL).
(3) Remove the engi ne oi l fi l ter.
(4) Support the engi ne wi th a sui tabl e jack and a
bl ock of wood across the ful l wi dth of the engi ne oi l
pan.
(5) Remove the four (4) cyl i nder bl ock-to-i nsul ator
mount bol ts and the nut from the engi ne i nsul ator
mount through bol t (4x2 Vehi cl es onl y) (Fi g. 88) (Fi g.
89).
(6) Remove the three (3) cyl i nder bl ock-to-i nsul ator
mount bol ts and l oosen the nut from the engi ne i nsu-
l ator mount through bol t (4x4 Vehi cl es onl y) (Fi g. 90)
(Fi g. 91).
Fig. 86 Structural Cover
Fig. 87 Structural Cover
Fig. 88 Engine Insulator Mount 4x2 VehicleLeft
Side
1 - ENGINE INSULATOR MOUNT-LEFT SIDE
2 - MOUNTING BOLT
9 - 180 ENGINE 4. 7L AN
STRUCTURAL COVER (Continued)
(7) Usi ng the jack, rai se the engi ne hi gh enough to
remove the engi ne i nsul ator mount through bol t and
the i nsul ator mount.
INSTALLATION
(1) Posi ti on the i nsul ator mount and i nstal l the
i nsul ator mount through bol t.
(2) Lower the engi ne unti l the four cyl i nder bl ock-
to-i nsul ator mount bol ts can be i nstal l ed.
(3) Remove the jack and bl ock of wood.
(4) Torque the cyl i nder bl ock-to-i nsul ator mount
bol ts to 61Nm ( 45 ft. l bs.).
(5) I nstal l and torque the through bol t retai ni ng
nut to 61Nm (45 ft. l bs.).
(6) I nstal l the fan bl ade, fan cl utch and fan
shroud.
REAR MOUNT
REMOVAL
(2) Usi ng a sui tabl e jack, support transmi ssi on.
(3) Remove the nut from the i nsul ator mount
through bol t (Manual transmi ssi on and 4x2 auto-
mati c transmi ssi on onl y) (Fi g. 92) (Fi g. 93).
(4) Remove the four bol ts and washers retai ni ng
the mount to the transmi ssi on (4x4 automati c trans-
mi ssi on onl y) (Fi g. 94).
(5) Rai se the transmi ssi on enough to remove the
through bol t (Manual transmi ssi on and 4x2 auto-
mati c transmi ssi on onl y) (Fi g. 92) (Fi g. 93).
(6) Rai se the transmi ssi on and remove the bol ts
retai ni ng the mount to the crossmember (4x4 auto-
mati c transmi ssi on onl y) (Fi g. 94).
Fig. 89 Engine Insulator Mount 4x2 VehicleRight
Side
1 - ENGINE INSULATOR MOUNT-RIGHT SIDE
2 - MOUNTING BOLT
Fig. 90 Engine Insulator Mount 4x4 VehicleLeft
Side
1 - ENGINE INSULATOR MOUNT-LEFT SIDE
2 - MOUNTING BOLT
Fig. 91 Engine Insulator Mount 4x4 VehicleRight
Side
1 - ENGINE INSULATOR MOUNT-RIGHT SIDE
2 - MOUNTING BOLT
AN ENGINE 4. 7L 9 - 181
(7) Remove the two nuts retai ni ng the i sol ator to
the crossmember (Manual transmi ssi on and 4x2
automati c transmi ssi on onl y) (Fi g. 92) (Fi g. 93).
(8) Remove the bol ts (two bol ts manual transmi s-
si on)(three bol ts 4x2 automati c transmi ssi on) retai n-
i ng the i nsul ator bracket to the transmi ssi on.
INSTALLATION
(1) Fol l ow the removal procedure i n the reverse
order.
(2) Ti ghten the through bol t retai ni ng nut to 101
Nm (75 ft. l bs.).
(3) Ti ghten the i sol ator bracket to transmi ssi on
retai ni ng bol ts (Manual transmi ssi on and 4x2 auto-
mati c transmi ssi on onl y) to 68 Nm (50 ft. l bs.).
(4) Ti ghten the mount bracket to transmi ssi on
retai ni ng bol ts (4x4 automati c transmi ssi on onl y) to
68 Nm (50 ft. l bs.).
(5) Ti ghten the i sol ator mount to crossmember
retai ni ng nuts (Manual transmi ssi on and 4x2 auto-
mati c transmi ssi on onl y) to 41 Nm (30 ft. l bs.).
(6) Ti ghten the mount bracket to crossmember
retai ni ng bol ts (4x4 automati c transmi ssi on onl y) to
28 Nm (250 i n. l bs.).
Fig. 92 Engine Rear Mount4X2 Automatic
Transmission
1 - ENGINE REAR MOUNT
2 - BOLT
3 - NUT
4 - THROUGH BOLT NUT
5 - TRANSMISSION
Fig. 93 Engine Rear Mount4X2 and 4X4 Manual
Transmission
1 - THROUGH BOLT
2 - BOLT
3 - INSULATOR SUPPORT
4 - NUT
5 - NUT AND WASHER
6 - INSULATOR BRACKET TO TRANSMISSION
Fig. 94 Engine Rear Mount4X4 Automatic
Transmission
1 - TRANSMISSION
2 - ENGINE REAR MOUNT
3 - BOLT
9 - 182 ENGINE 4. 7L AN
LUBRICATION
DESCRIPTION
The l ubri cati on system (Fi g. 95) i s a ful l fl ow fi l -
trati on pressure feed type.
OPERATION
Oi l from the oi l pan i s pumped by a gerotor type oi l
pump di rectl y mounted to the crankshaft nose. Oi l
pressure i s control l ed by a rel i ef val ve mounted
i nsi de the oi l pump housi ng. For l ubri cati on fl ow
refer to (Fi g. 95).
Fig. 95 Engine Oil Lubrication System
1 - LEFT CYLINDER HEAD OIL GALLERY
2 - OIL PRESSURE SENSOR LOCATION
3 - TO LEFT CYLINDER HEAD
4 - OIL FEED TO IDLER SHAFT
5 - OIL PUMP OUTLET TO BLOCK
6 - OIL PUMP
7 - TO CRANKSHAFT MAIN JOURNALS
8 - RIGHT CYLINDER HEAD OIL GALLERY
9 - TO RIGHT CYLINDER HEAD
10 - CYLINDER BLOCK MAIN GALLERY
11 - OIL FEED TO BOTH SECONDARY TENSIONERS
AN ENGINE 4. 7L 9 - 183
The camshaft exhaust val ve l obes and rocker arms
are l ubri cated through a smal l hol e i n the rocker
arm; oi l fl ows through the l ash adjuster then through
the rocker arm and onto the camshaft l obe. Due to
the orentati on of the rocker arm, the camshaft i ntake
l obes are not l ubed i n the same manner as the
exhaust l obes. The i ntake l obes are l ubed through
i nternal passages i n the camshaft. Oi l fl ows through
a bore i n the number 3 camshaft beari ng bore, and
as the camshaft turns, a hol e i n the camshaft al i gns
wi th the hol e i n the camshaft bore al l owi ng engi ne
oi l to enter the camshaft tube. The oi l then exi ts
through 1.6mm (0.063 i n.) hol es dri l l ed i nto the
i ntake l obes, l ubri cati ng the l obes and the rocker
arms.
ENGINE LUBRICATION FLOW CHARTBLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2.Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads.
ENGINE LUBRICATION FLOW CHARTCYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
PRESSURE
(1) Remove oi l pressure sendi ng uni t (Fi g. 96)and
i nstal l gauge assembl y C-3292.
(2) Run engi ne unti l thermostat opens.
(3) Oi l Pressure:
Curb I dl e25 Kpa (4 psi ) mi ni mum
3000 rpm170 - 550 KPa (25 - 80 psi )
(4) I f oi l pressure i s 0 at i dl e, shut off engi ne.
Check for a cl ogged oi l pi ck-up screen or a pressure
rel i ef val ve stuck open.
DIAGNOSIS AND TESTING ENGINE OIL LEAK
Begi n wi th a thorough vi sual i nspecti on of the
(2) Add an oi l sol ubl e dye (use as recommended by
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
9 - 184 ENGINE 4. 7L AN
repeat i nspecti on.If the oil leak source is not pos-
itively identified at this time, proceed wi th the ai r
l eak detecti on test method.
Air Leak Detection Test Method
ni ppl e.
procedures.
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
INSPECTION FOR REAR SEAL AREA LEAKS
area:
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
seal.
assembl ed.
Fig. 96 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
AN ENGINE 4. 7L 9 - 185
OIL
STANDARD PROCEDURE ENGINE OIL
SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conform to
thi s servi ce grade.
SAE VISCOSITY
cosi ty of engi ne oi l . Use onl y engi ne oi l s wi th mul ti -
pl e vi scosi ti es such as 5W-30 or 10W-30 i n the 4.7L
engi nes. These are speci fi ed wi th a dual SAE vi scos-
i ty grade whi ch i ndi cates the col d-to-hot temperature
vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 97).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 98).
rear of the engi ne on the 4.7L engi nes. (Fi g. 99).
Fig. 97 Temperature/Engine Oil Viscosity4.7L
Engine
Fig. 98 Engine Oil Container Standard Notations
Fig. 99 Engine Oil Dipstick 4.7L Engine
1 - TRANSMISSION DIPSTICK
2 - ENGINE OIL DIPSTICK
9 - 186 ENGINE 4. 7L AN
pressure loss or oil foaming can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Unl ess the engi ne has exhi b-
i ted l oss of oi l pressure, run the engi ne for about fi ve
mi nutes before checki ng oi l l evel . Checki ng engi ne oi l
l evel on a col d engi ne i s not accurate.
tube.
di psti ck.
ENGINE OIL CHANGE
descri bed i n Mai ntenance Schedul es.
perature.
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
drai n.
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
OIL FILTER
REMOVAL
fi l ter be used.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g.
100)to remove i t from the cyl i nder bl ock oi l fi l ter
boss.
(4) When fi l ter separates from cyl i nder bl ock oi l
fi l ter boss, ti p gasket end upward to mi ni mi ze oi l
spi l l . Remove fi l ter from vehi cl e.
NOTE: Make sure filter gasket was removed with fil-
ter.
surface of oi l and gri me.
INSTALLATION
oi l .
makes contact wi th seal i ng surface, (Fi g. 101)hand
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
Fig. 100 Oil Filter - 4.7L Engine
AN ENGINE 4. 7L 9 - 187
OIL (Continued)
OIL PAN
REMOVAL 4X2
(2) Remove the upper fan shroud.
(3) Remove the throttl e body resonator and ai r
i nl et hose.
REMOVAL).
(6) Di sconnect exhaust pi pe at exhaust mani fol ds.
(7) Remove the structural dust cover (Refer to 9 -
REMOVAL) (Fi g. 102) usi ng sequence shown.
(8) Drai n engi ne oi l and remove oi l fi l ter.
(9) Posi ti on sui tabl e jack under engi ne.
(10) Remove both l eft and ri ght si de engi ne mount
through bol ts (Fi g. 103).
(11) Rai se engi ne to provi de cl earance to remove
oi l pan.
(12) Pl ace bl ocks of wood between engi ne brackets
and l ower mounts to provi de stabi l i ty to engi ne.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is mounted to engine and does not come out
with oil pan.
(13) Remove the oi l pan mounti ng bol ts and oi l
pan (Fi g. 104).
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
Fig. 102 Structural Dust Cover Removal /
Installation
Fig. 103 Engine Mount Through Bolt and Nut
Removal / Installation
1 - LOCKNUT AND WASHER
2 - ENGINE MOUNT/INSULATOR
3 - THROUGH BOLT
4 - FRAME
Fig. 104 Oil Pan Mounting Bolts and Oil Pan
9 - 188 ENGINE 4. 7L AN
OIL FILTER (Continued)
(14) Unbol t oi l pump pi ckup tube and remove tube
and oi l pan gasket from engi ne.
REMOVAL 4X4
NOTE: 4X4 vehicles equipped with a 4.7L engine
must have the front axle removed before the oil pan
can be removed.
(1) Remove the front axl e from vehi cl e. Refer to
DI FFERENTI AL AND DRI VELI NE.
(2) Remove the structural dust cover (Refer to 9 -
REMOVAL) (Fi g. 105) usi ng sequence shown.
(3) Drai n the engi ne oi l and remove oi l fi l ter.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is mounted to engine and does not come out
with oil pan.
(4) Remove the oi l pan mounti ng bol ts and oi l pan
(Fi g. 106).
(5) Unbol t oi l pump pi ckup tube and remove tube
and oi l pan gasket from engi ne.
INSTALLATION 4X2
(1) Cl ean the oi l pan gasket mati ng surface of the
bedpl ate and oi l pan.
(2) Posi ti on the oi l pan gasket and pi ckup tube
wi th new o-ri ng. I nstal l the mounti ng bol t and nuts.
Ti ghten bol t and nuts to 28 Nm (20 ft. l bs.).
(3) Posi ti on the oi l pan and i nstal l the mounti ng
bol ts. Ti ghten the mounti ng bol ts to 15 Nm (11 ft.
l bs.) i n the sequence shown (Fi g. 104).
(4) Rai se the engi ne and remove the bl ocks of
wood.
(5) Lower engi ne and i nstal l both the l eft and
ri ght si de engi ne mount through bol ts (Fi g. 103).
Ti ghten the nuts to 68 Nm (50 ft. l bs.).
(6) Remove jack and i nstal l oi l fi l ter.
(7) I nstal l structural dust cover (Refer to 9 -
I NSTALLATI ON).
(8) I nstal l exhaust pi pe onto exhaust mani fol ds.
TI ON).
(11) I nstal l throttl e body resonator and ai r i nl et
hose.
(12) I nstal l upper fan shroud.
(14) Fi l l engi ne oi l .
INSTALLATION 4X4
(1) Cl ean the oi l pan gasket mati ng surface of the
bedpl ate and oi l pan.
(2) Posi ti on the oi l pan gasket and pi ckup tube
wi th new o-ri ng. I nstal l the mounti ng bol t and nuts.
Ti ghten bol t and nuts to 28 Nm (20 ft. l bs.).
(3) Posi ti on the oi l pan and i nstal l the mounti ng
bol ts. Ti ghten the mounti ng bol ts to 15 Nm (11 ft.
l bs.) i n the sequence shown (Fi g. 106).
(4) I nstal l structural dust cover (Refer to 9 -
I NSTALLATI ON).
(5) I nstal l oi l fi l ter.
(6) I nstal l front axl e. Refer to DI FFERENTI AL
AND DRI VELI NE.
(8) Fi l l engi ne oi l .
(9) Start engi ne check for l eaks.
Fig. 105 Structural Dust Cover Removal
Fig. 106 Oil Pan Mounting Bolts and Oil Pan
AN ENGINE 4. 7L 9 - 189
OIL PAN (Continued)
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 2wi re, el ectri cal /mechani cal engi ne oi l pres-
sure sensor (sendi ng uni t) i s l ocated i n an engi ne oi l
pressure gal l ery.
OPERATION
The oi l pressure sensor uses two ci rcui ts. They are:
A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
A sensor ground through the PCMs sensor
return
The oi l pressure sensor returns a vol tage si gnal
back to the PCM rel ati ng to engi ne oi l pressure. Thi s
si gnal i s then transferred (bussed) to the i nstrument
panel on a CCD bus ci rcui t to operate the oi l pres-
sure gauge and the check gauges l amp. Ground for
the sensor i s provi ded by the PCM through a l ow-
noi se sensor return.
REMOVAL
(3) Remove front spl ash shi el d.
(4) Di sconnect oi l pressure sender wi re (Fi g. 107).
(5) Remove the pressure sender (Fi g. 107).
INSTALLATION
(1) I nstal l oi l pressure sender.
(2) Connect oi l pressure sender wi re.
(3) I nstal l front spl ash shi el d.
(5) Connect the negati ve battery cabl e.
OIL PUMP
REMOVAL
(1) Remove the oi l pan and pi ck-up tube (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(3) Remove the ti mi ng chai ns and tensi oners
(4) Remove the four bol ts, pri mary ti mi ng chai n
tensi oner and the oi l pump.
DISASSEMBLY
(1) Remove oi l pump cover screws and l i ft off cover
pl ate.
(2) Remove pump i nner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) I f i t i s necessary to remove the pressure rel i ef
val ve, dri ve the rol l pi n from pump housi ng and
remove cup pl ug, spri ng and val ve.
CLEANING
(1) Wash al l parts i n a sui tabl e sol vent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
the these components are disassembled andr
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Cl ean al l parts thoroughl y. Mati ng surface of
the oi l pump housi ng shoul d be smooth. I f the pump
cover i s scratched or grooved the oi l pump assembl y
shoul d be repl aced.
(2) Lay a strai ght edge across the pump cover sur-
face (Fi g. 108). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between the cover and the strai ght
edge the oi l pump assembl y shoul d be repl aced.
(3) Measure the thi ckness of the outer rotor (Fi g.
109). I f the outer rotor thi ckness measures at 12.005
Fig. 107 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
9 - 190 ENGINE 4. 7L AN
mm (0.4727 i n.) or l ess the oi l pump assembl y must
be repl aced.
(4) Measure the di ameter of the outer rotor. I f the
outer rotor di ameter measures at 85.925 mm (3.3829
i n.) or l ess the oi l pump assembl y must be repl aced.
(5) Measure the thi ckness of the i nner rotor (Fi g.
110). I f the i nner rotor thi ckness measures at 12.005
mm (0.4727 i n.) or l ess then the oi l pump assembl y
must be repl aced.
(6) Sl i de outer rotor i nto the body of the oi l pump.
Press the outer rotor to one si de of the oi l pump body
and measure cl earance between the outer rotor and
the body (Fi g. 111). I f the measurement i s 0.235mm
(0.009 i n.) or more the oi l pump assembl y must be
repl aced.
(7) I nstal l the i nner rotor i n the i nto the oi l pump
body. Measure the cl earance between the i nner and
outer rotors (Fi g. 112). I f the cl earance between the
rotors i s .150 mm (0.006 i n.) or more the oi l pump
assembl y must be repl aced.
(8) Pl ace a strai ght edge across the body of the oi l
pump (between the bol t hol es), i f a feel er gauge of
.095 mm (0.0038 i n.) or greater can be i nserted
between the strai ghtedge and the rotors, the pump
must be repl aced (Fi g. 113).
NOTE: 4.7 Oil pump is released as an assembly.
There are no DaimlerChrysler part numbers for Sub-
Assembly components. In the event the oil pump is
not functioning or out of specification it must be
replaced as an assembly.
ASSEMBLY
(2) I nstal l i nner and outer rotors
(3) I nstal l oi l pump cover pl ate and i nstal l cover
bol ts and ti ghten them to 12 Nm (105 i n. l bs.).
(5) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs or other
causes for oi l pressure l oss.
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
AN ENGINE 4. 7L 9 - 191
INSTALLATION
(1) Posi ti on the oi l pump onto the crankshaft and
i nstal l two oi l pump retai ni ng bol ts.
(2) Posi ti on the pri mary ti mi ng chai n tensi oner
and i nstal l the two retai ni ng bol ts.
(3) Ti ghten the oi l pump and pri mary ti mi ng chai n
tensi oner retai ni ng bol ts to 28 Nm (250 i n. l bs.) i n
the sequence shown (Fi g. 114).
(4) I nstal l the secondary ti mi ng chai n tensi oners
and ti mi ng chai ns (Refer to 9 - ENGI NE/VALVE
TI MI NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(6) I nstal l the pi ck-up tube and oi l pan (Refer to 9
- ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
1 - FEELER GAUGE
2 - OUTER ROTOR
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 114 Oil Pump and Primary Timing Chain
Tightening Sequence
9 - 192 ENGINE 4. 7L AN
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of a composi te mate-
ri al and features l ong runners whi ch maxi mi zes l ow
end torque. The i ntake mani fol d uses si ngl e pl ane
seal i ng whi ch consi st of ei ght i ndi vi dual press i n
pl ace port gaskets to prevent l eaks. Ei ght studs and
two bol ts are used to fasten the i ntake to the head.
MANIFOLD LEAKAGE
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
l eak area.
(3) I f a change i n RPM i s observed the area of the
REMOVAL
(2) Remove resonator assembl y and ai r i nl et hose.
(3) Di sconnect throttl e and speed control cabl es.
(4) Di sconnect el ectri cal connectors for the fol l ow-
i ng components:
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
(5) Di sconnect brake booster hose and posi ti ve
crankcase venti l ati on (PCV) hose.
(6) Di sconnect generator el ectri cal connecti ons.
(7) Di sconnect ai r condi ti oni ng compressor el ectri -
cal connecti ons.
(8) Di sconnect l eft and ri ght radi o suppressor
straps.
(9) Di sconnect and remove i gni ti on coi l towers
(Refer to 8 - ELECTRI CAL/I GNI TI ON CONTROL/
I GNI TI ON COI L - REMOVAL).
(10) Remove top oi l di psti ck tube retai ni ng bol t
and ground strap.
(11) Bl eed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY - STANDARD PROCE-
DURE).
(12) Remove fuel rai l (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/FUEL RAI L - REMOVAL).
(13) Remove throttl e body assembl y and mounti ng
bracket.
(14) Drai n cool i ng system bel ow cool ant tempera-
ture l evel (Refer to 7 - COOLI NG - STANDARD
PROCEDURE).
(15) Remove the heater hoses from the engi ne
front cover and the heater core.
(16) Uncl i p and remove heater hoses and tubes
from i ntake mani fol d (Fi g. 115).
(17) Remove cool ant temperature sensor (Refer to
7 - COOLI NG/ENGI NE/ENGI NE COOLANT TEM-
PERATURE SENSO - REMOVAL).
(18) Remove i ntake mani fol d retai ni ng fasteners i n
reverse order of ti ghteni ng sequence (Fi g. 116).
(19) Remove i ntake mani fol d.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before i nstal l i ng the i ntake mani fol d thoroughl y
cl ean the mati ng surfaces. Use a sui tabl e cl eani ng
sol vent, then ai r dry.
Fig. 115 Heater Hoses and Tubes Removal /
Installation
1 - HEATER HOSES AND TUBES
2 - ROUTING/RETAINING CLIPS
AN ENGINE 4. 7L 9 - 193
INSPECTION
(1) I nspect the i ntake seal i ng surface for cracks,
ni cks and di storti on.
(2) I nspect the i ntake mani fol d vacuum hose fi t-
ti ngs for l ooseness or bl ockage.
(3) I nspect the mani fol d to throttl e body mati ng
surface for cracks, ni cks and di storti on.
INSTALLATION
(1) I nstal l i ntake mani fol d gaskets.
(2) Posi ti on i ntake mani fol d.
(3) I nstal l i ntake mani fol d retai ni ng bol ts and
ti ghten i n sequence shown i n (Fi g. 117) to 12 Nm
(105 i n. l bs.).
(4) I nstal l l eft and ri ght radi o suppressor straps.
(5) I nstal l throttl e body assembl y.
(6) I nstal l throttl e cabl e bracket.
(7) Connect throttl e cabl e and speed control cabl e
to throttl e body.
(8) I nstal l fuel rai l (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/FUEL RAI L - I NSTALLATI ON).
(9) I nstal l i gni ti on coi l towers (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/I GNI TI ON COI L -
I NSTALLATI ON).
(10) Posi ti on and i nstal l heater hoses and tubes
onto i ntake mani fol d.
(11) I nstal l the heater hoses to the heater core and
(12) Connect el ectri cal connectors for the fol l owi ng
components:
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
I gni ti on coi l towers
Fuel i njectors
(13) I nstal l top oi l di psti ck tube retai ni ng bol t and
ground strap.
(14) Connect generator el ectri cal connecti ons.
(15) Connect Brake booster hose and Posi ti ve
crankcase venti l ati on (PCV) hose.
(17) I nstal l resonator assembl y and ai r i nl et hose.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds are l og styl e wi th a pat-
ented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh
si l i con mol ybdenum cast i ron. A perforated core
graphi te exhaust mani fol d gasket i s used to i mprove
seal i ng to the cyl i nder head. The exhaust mani fol ds
are covered by a three l ayer l ami nated heat shi el d
for thermal protecti on and noi se reducti on. The heat
shi el ds are fastened wi th a torque prevai l i ng nut
that i s backed off sl i ghtl y to al l ow for the thermal
expansi on of the exhaust mani fol d.
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Di sconnect negati ve cabl e for battery.
(2) Remove ai r cl eaner assembl y, resonator assem-
Fig. 116 Intake Manifold Tightening Sequence
Fig. 117 Intake Manifold Tightening Sequence
9 - 194 ENGINE 4. 7L AN
REMOVAL).
PRESSOR - REMOVAL).
(5) Remove A/C accumul ator support bracket fas-
tener.
(6) Drai n cool ant bel ow heater hose l evel (Refer to
7 - COOLI NG - STANDARD PROCEDURE).
(7) Remove heater hoses at engi ne.
(8) Remove fasteners attachi ng exhaust mani fol d
heat shi el d.
(9) Remove heat shi el d.
(10) Remove upper exhaust mani fol d attachi ng fas-
teners.
(12) Di sconnect exhaust pi pe from mani fol d.
(13) Remove fasteners attachi ng starter. Move
starter asi de.
(14) Remove l ower exhaust mani fol d attachi ng fas-
teners.
(15) Remove exhaust mani fol d and gasket (Fi g.
118). Mani fol d i s removed from bel ow the engi ne
compartment.
LEFT EXHAUST MANIFOLD
(1) Di sconnect negati ve cabl e for battery.
(3) Di sconnect exhaust pi pe at mani fol d.
Fig. 118 Exhaust ManifoldRight
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
2 Bolt (Qty 4) 5 Nut (Qty 2)
3 Stud (Qty 2)
AN ENGINE 4. 7L 9 - 195
EXHAUST MANIFOLD (Continued)
(5) Remove the front two exhaust heat shi el d
retai ni ng fasteners. Rai se vehi cl e and remove the
fasteners at rear of heat shi el d.
(6) Remove heat shi el d (Fi g. 119).
(7) Lower vehi cl e and remove the upper exhaust
mani fol d retai ni ng bol ts (Fi g. 119).
(8) Rai se vehi cl e and remove the l ower exhaust
mani fol d retai ni ng bol ts (Fi g. 119).
(9) Remove exhaust mani fol d and gasket (Fi g.
119). Mani fol d i s removed from bel ow the engi ne
compartment.
CLEANING
(1) Cl ean the exhaust mani fol d usi ng a sui tabl e
cl eani ng sol vent, then al l ow to ai r dry.
(2) Cl ean al l gasket resi due from the mani fol d
mati ng surface.
INSPECTION
(1) I nspect the exhaust mani fol d for cracks i n the
mati ng surface and at every mounti ng bol t hol e.
(2) Usi ng a strai ght edge and a feel er gauge, check
the mati ng surface for warp and twi st.
Fig. 119 Exhaust ManifoldLeft
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
3 Stud (Qty 2)
9 - 196 ENGINE 4. 7L AN
(3) I nspect the mani fol d to exhaust pi pe mati ng
surface for cracks, gouges, or other damage that
woul d prevent seal i ng.
INSTALLATION
RIGHT EXHAUST MANIFOLD
(1) I nstal l exhaust mani fol d and gasket (Fi g. 120)
from bel ow engi ne compartment.
(2) I nstal l l ower exhaust mani fol d fasteners. DO
NOT ti ghten unti l al l fasteners are i n pl ace.
(3) Lower vehi cl e and i nstal l upper exhaust mani -
fol d fasteners. Ti ghten al l mani fol d bol ts starti ng at
center and worki ng outward to 25 Nm (18 ft. l bs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) I nstal l exhaust mani fol d heat shi el d. Ti ghten
fasteners to 8 Nm (72 i n. l bs.), then l oosen 45
degrees.
(5) I nstal l starter and fasteners.
(6) Connect exhaust pi pe to mani fol d.
(7) Connect heater hoses at engi ne.
(8) I nstal l fastener attachi ng A/C accumul ator.
(9) I nstal l A/C compressor and fasteners.
I NSTALLATI ON).
(11) I nstal l ai r cl eaner assembl y, resonator assem-
Fig. 120 Exhaust ManifoldRight
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
3 Stud (Qty 2)
AN ENGINE 4. 7L 9 - 197
(12) I nstal l battery and connect cabl es.
LEFT EXHAUST MANIFOLD
(1) I nstal l exhaust mani fol d and gasket from bel ow
(2) I nstal l l ower exhaust mani fol d fasteners (Fi g.
121). DO NOT ti ghten unti l al l fasteners are i n
pl ace.
(3) Lower vehi cl e and i nstal l upper exhaust mani -
fol d fasteners (Fi g. 121). Ti ghten al l mani fol d bol ts
starti ng at center and worki ng outward to 25 Nm
(18 ft. l bs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) I nstal l exhaust mani fol d heat shi el d (Fi g. 121).
Ti ghten fasteners to 8 Nm (72 i n. l bs.), then l oosen
45 degrees.
(5) Connect exhaust pi pe to mani fol d.
Fig. 121 Exhaust ManifoldLeft
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
3 Stud (Qty 2)
9 - 198 ENGINE 4. 7L AN
VALVE TIMING
DESCRIPTION TIMING DRIVE SYSTEM
The ti mi ng dri ve system (Fi g. 122) has been
desi gned to provi de qui et performance and rel i abi l i ty
to support a non-free wheeling engi ne. Speci fi cal l y
the i ntake val ves are non-free wheel i ng and can be
easi l y damaged wi th forceful engi ne rotati on i f cam-
shaft-to-crankshaft ti mi ng i s i ncorrect. The ti mi ng
dri ve system consi sts of a pri mary chai n and two sec-
ondary ti mi ng chai n dri ves.
OPERATION TIMING DRIVE SYSTEM
The pri mary ti mi ng chai n i s a si ngl e i nverted tooth
type. The pri mary chai n dri ves the l arge fi fty tooth
i dl er sprocket di rectl y from a 25 tooth crankshaft
sprocket. Pri mary chai n moti on i s control l ed by a
pi voti ng l eaf spri ng tensi oner arm and a fi xed gui de.
The arm and the gui de both use nyl on pl asti c wear
faces for l ow fri cti on and l ong wear. The pri mary
chai n recei ves oi l spl ash l ubri cati on from the second-
ary chai n dri ve and oi l pump l eakage. The i dl er
sprocket assembl y connects the pri mary and second-
ary chai n dri ves. The i dl er sprocket assembl y con-
si sts of two i ntegral thi rty tooth sprockets and a fi fty
tooth sprocket that i s spl i ned to the assembl y. The
spl i ne joi nt i s a non servi ceabl e press fi t anti rattl e
type. A spi ral ri ng i s i nstal l ed on the outboard si de of
the fi fty tooth sprocket to prevent spl i ne di sengage-
ment. The i dl er sprocket assembl y spi ns on a stati on-
ary i dl er shaft. The i dl er shaft i s press-fi t i nto the
cyl i nder bl ock. A l arge washer on the i dl er shaft bol t
and the rear fl ange of the i dl er shaft are used to con-
trol sprocket thrust movement. Pressuri zed oi l i s
routed through the center of the i dl er shaft to pro-
vi de l ubri cati on for the two bushi ngs used i n the
i dl er sprocket assembl y.
Fig. 122 Timing Drive System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
3 - SECONDARY TENSIONER ARM
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
10 - PRIMARY CHAIN TENSIONER
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
AN ENGINE 4. 7L 9 - 199
There are two secondary dri ve chai ns, both are
i nverted tooth type, one to dri ve the camshaft i n each
SOHC cyl i nder head. There are no shaft speed
changes i n the secondary chai n dri ve system. Each
secondary chai n dri ves a thi rty tooth cam sprocket
di rectl y from the thi rty tooth sprocket on the i dl er
sprocket assembl y. A fi xed chai n gui de and a hydrau-
l i c oi l damped tensi oner are used to mai ntai n tensi on
i n each secondary chai n system. The hydraul i c ten-
si oners for the secondary chai n systems are fed pres-
suri zed oi l from oi l reservoi r pockets i n the bl ock.
Each tensi oner al so has a mechani cal ratchet system
that l i mi ts chai n sl ack i f the tensi oner pi ston bl eeds
down after engi ne shut down. The tensi oner arms
and gui des al so uti l i ze nyl on wear faces for l ow fri c-
ti on and l ong wear. The secondary ti mi ng chai ns
recei ve l ubri cati on from a smal l ori fi ce i n the ten-
si oners. Thi s ori fi ce i s protected from cl oggi ng by a
fi ne mesh screen whi ch i s l ocated on the back of the
hydraul i c tensi oners (Fi g. 122).
STANDARD PROCEDURE MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the ti mi ng chai n cover. (Refer to 9 -
(2) To determi ne i f the secondary ti mi ng chai ns
are worn, rotate the engi ne cl ockwi se unti l maxi mum
tensi oner pi ston extensi on i s obtai ned. Measure the
di stance between the secondary ti mi ng chai n ten-
si oner housi ng and the step l edge on the pi ston (Fi g.
123). The measurement at poi nt (A) must be l ess
than 15mm (0.5906 i nches).
(3) I f the measurement exceeds the speci fi cati on
the secondary ti mi ng chai ns are worn and requi re
repl acement. (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT/CHAI N AND SPROCKETS -
REMOVAL).
NOTE: If the secondary chains are to be replaced
the primary chain must also be replaced.
STANDARD PROCEDURE - ENGINE TIMING -
VERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engi ne base ti mi ng can be veri fi ed by the fol l owi ng
procedure:
(1) Remove the cyl i nder head covers (Refer to 9 -
(2) Usi ng a mi rror, l ocate the TDC arrow on the
front cover (Fi g. 124). Rotate the crankshaft unti l the
mark on the crankshaft damper i s al i gned wi th the
TDC arrow on the front cover. The engi ne i s now at
TDC.
(3) Note the l ocati on of the V8 mark stamped i nto
the camshaft dri ve gears (Fi g. 125). I f the V8 mark
on each camshaft dri ve gear i s at the twel ve ocl ock
posi ti on, the engi ne i s at TDC (cyl i nder #1) on the
exhaust stroke. I f the V8 mark on each gear i s at the
si x ocl ock posi ti on, the engi ne i s at TDC (cyl i nder
#1) on the compressi on stroke.
Fig. 123 Measuring Secondary Timing Chains For
Wear
2 - SECONDARY CHAIN TENSIONER PISTON
9 - 200 ENGINE 4. 7L AN
VALVE TIMING (Continued)
(4) I f both of the camshaft dri ve gears are off i n
the same or opposi te di recti ons, the pri mary chai n or
both secondary chai ns are at faul t. Refer to Ti mi ng
Chai n and Sprockets procedure i n thi s secti on.
(5) I f onl y one of the camshaft dri ve gears i s off
and the other i s correct, the probl em i s confi ned to
one secondary chai n. Refer to Si ngl e camshaft ti m-
i ng, i n thi s procedure.
(6) I f both camshaft dri ve gear V8 marks are at
the twel ve ocl ock or the si x o cl ock posi ti on the
engi ne base ti mi ng i s correct. Rei nstal l the cyl i nder
head covers.
SINGLE CAMSHAFT TIMING
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.
(1) Usi ng Chai n Tensi oner Wedge, speci al tool
8350, stabi l i ze the secondary chai n dri ve (Fi g. 126).
For reference purposes, mark the chai n-to-sprocket
(2) Remove the camshaft dri ve gear retai ni ng bol t.
(3) Careful l y remove the camshaft dri ve gear from
the camshaft.
(4) Re-i ndex the camshaft dri ve gear i n the chai n
unti l the V8 mark i s at the same posi ti on as the V8
mark on the opposi te camshaft dri ve gear.
Mark
AN ENGINE 4. 7L 9 - 201
(5) Usi ng a sui tabl e pai r of adjustabl e pl i ers,
rotate the camshaft unti l the al i gnment dowel on the
camshaft i s al i gned wi th the sl ot i n the camshaft
dri ve gear (Fi g. 127).
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(6) Posi ti on the camshaft dri ve gear onto the cam-
shaft, remove oi l from bol t then i nstal l the retai ni ng
bol t. Usi ng Speci al Tool s, Spanner Wrench 6958 wi th
Adapter Pi ns 8346 and a sui tabl e torque wrench,
Ti ghten retai ni ng bol t to 122Nm (90 ft. Lbs.) (Fi g.
128) (Fi g. 129).
(7) Remove speci al tool 8350.
(8) Rotate the crankshaft two ful l revol uti ons, then
reveri fy that the camshaft dri ve gear V8 marks are
i n fact al i gned.
(9) I nstal l the cyl i nder head covers (Refer to 9 -
Fig. 127 Camshaft Dowel To
2 - CAMSHAFT DOWEL
9 - 202 ENGINE 4. 7L AN
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(3) Remove fan and fan dri ve assembl y (Refer to 7
- COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - REMOVAL).
(4) Di sconnect both heater hoses at ti mi ng cover.
(5) Di sconnect l ower radi ator hose at engi ne.
(6) Remove crankshaft damper (Refer to 9 -
REMOVAL).
(7) Remove accessory dri ve bel t tensi oner assembl y
(Fi g. 130).
PRESSOR - REMOVAL).
(10) Remove cover and gasket (Fi g. 131).
Fig. 128 Camshaft Sprocket Left Cylinder Head
1 - TORQUE WRENCH
Fig. 129 Camshaft Sprocket InstallationRight
Cylinder Head
1 - TORQUE WRENCH
Fig. 130 Accessory Drive Belt Tensioner
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
AN ENGINE 4. 7L 9 - 203
INSTALLATION
(1) Cl ean ti mi ng chai n cover and bl ock surface.
I nspect cover gasket and repl ace as necessary.
(2) I nstal l cover and gasket. Ti ghten fasteners i n
sequence as shown i n (Fi g. 132) to 54 Nm (40 ft.
l bs.) .
(3) I nstal l the A/C compressor (Refer to 24 - HEAT-
PRESSOR - I NSTALLATI ON).
(5) I nstal l crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(6) I nstal l accessory dri ve bel t tensi oner assembl y
(Refer to 7 - COOLI NG/ACCESSORY DRI VE/BELT
TENSI ONERS - I NSTALLATI ON).
(7) I nstal l radi ator l ower hose.
(8) I nstal l both heater hoses.
(9) I nstal l radi ator shroud and vi scous fan dri ve
assembl y (Refer to 7 - COOLI NG/ENGI NE/FAN
DRI VE VI SCOUS CLUTCH - I NSTALLATI ON).
SPROCKETS
REMOVAL
(3) Remove ri ght and l eft cyl i nder head covers
(4) Remove radi ator fan shroud.
(5) Rotate engi ne unti l ti mi ng mark on crankshaft
damper al i gns wi th TDC mark on ti mi ng chai n cover
(Fi g. 133) (#1 cyl i nder exhaust stroke) and the cam-
shaft sprocket V8 marks are at the 12 ocl ock posi -
ti on (Fi g. 134).
(6) Remove power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - REMOVAL).
(7) Remove access pl ugs (2) from l eft and ri ght cyl -
i nder heads for access to chai n gui de fasteners (Fi g.
135).
(8) Remove the oi l fi l l housi ng to gai n access to the
ri ght si de tensi oner arm fastener.
(9) Remove crankshaft damper (Refer to 9 -
REMOVAL) and ti mi ng chai n cover (Refer to 9 -
(10) Col l apse and pi n pri mary chai n tensi oner
(Fi g. 136).
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chai n tensi oners.
(12) Remove camshaft posi ti on sensor from ri ght
cyl i nder head (Fi g. 137).
Fig. 131 Timing Chain Cover Fasteners
Fig. 132 Timing Chain Cover Fasteners
9 - 204 ENGINE 4. 7L AN
CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
Mark
Fig. 135 Cylinder Head Access Plug Location
AN ENGINE 4. 7L 9 - 205
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Remove l eft and ri ght camshaft sprocket bol ts.
(14) Whi l e hol di ng the l eft camshaft steel tube
wi th adjustabl e pl i ers, (Fi g. 138) remove the l eft
camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 15 degrees cl ockwi se to a neutral posi -
ti on.
Fig. 136 Collapsing And Pinning Primary Chain
Tensioner
Fig. 137 Camshaft Position SensorRemoval
Fig. 138 Camshaft RotationLeft Side
3 - CAMSHAFT
9 - 206 ENGINE 4. 7L AN
(15) Whi l e hol di ng the ri ght camshaft steel tube
wi th adjustabl e pl i ers, (Fi g. 139) remove the ri ght
camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 45 degrees countercl ockwi se to a neu-
tral posi ti on.
(16) Remove i dl er sprocket assembl y bol t.
(17) Sl i de the i dl er sprocket assembl y and crank
sprocket forward si mul taneousl y to remove the pri -
mary and secondary chai ns.
(18) Remove both pi voti ng tensi oner arms and
chai n gui des.
(19) Remove chai n tensi oner.
INSPECTION
I nspect the fol l owi ng components:
Sprockets for excessi ve tooth wear. Some tooth
marki ngs are normal and not a cause for sprocket
repl acement.
I dl er sprocket assembl y bushi ng and shaft for
excessi ve wear.
I dl er sprocket assembl y spl i ne joi nt. The joi nt
shoul d be ti ght wi th no backl ash or axi al movement.
Chai n gui des and tensi oner arms. Repl ace these
parts i f groovi ng i n pl asti c face i s more than 1 mm
(0.039 i n.) deep. I f pl asti c face i s severel y grooved or
mel ted, the tensi oner l ube jet may be cl ogged. The
tensi oner shoul d be repl aced.
secondary chai n tensi oner pi ston and ratcheti ng
devi ce. I nspect for evi dence of heavy contact between
tensi oner pi ston and tensi oner arm. I f thi s condi ti on
exi st the tensi oner and tensi oner arm shoul d be
repl aced.
Pri mary chai n tensi oner pl asti c faces. Repl ace as
requi red (Fi g. 140).
INSTALLATION
(1) Usi ng a vi se, l i ghtl y compress the secondary
chai n tensi oner pi ston unti l the pi ston step i s fl ush
wi th the tensi oner body. Usi ng a pi n or sui tabl e tool ,
rel ease ratchet pawl by pul l i ng pawl back agai nst
spri ng force through access hol e on si de of tensi oner.
Whi l e conti nui ng to hol d pawl back, Push ratchet
devi ce to approxi matel y 2 mm from the tensi oner
body. I nstal l Speci al Tool 8514 l ock pi n i nto hol e on
front of tensi oner. Sl owl y open vi se to transfer pi ston
spri ng force to l ock pi n (Fi g. 141).
(2) Posi ti on pri mary chai n tensi oner over oi l pump
and i nsert bol ts i nto l ower two hol es on tensi oner
bracket. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx bolt to specified torque only.
Fig. 139 Camshaft RotationRight Side
2 - CAMSHAFT DOWEL
AN ENGINE 4. 7L 9 - 207
(3) I nstal l ri ght si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 17
Nm (150 i n. l bs.).
NOTE: The silver bolts retain the guides to the cyl-
inder heads and the black bolts retain the guides to
the engine block.
(4) I nstal l the l eft si de chai n gui de. Ti ghten the
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx bolt to specified torque only.
(5) I nstal l l eft si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 17
Nm (150 i n. l bs.).
(6) I nstal l the ri ght si de chai n gui de. Ti ghten the
(7) I nstal l both secondary chai ns onto the i dl er
sprocket. Al i gn two pl ated l i nks on the secondary
chai ns to be vi si bl e through the two l ower openi ngs
on the i dl er sprocket (4 ocl ock and 8 ocl ock). Once
the secondary ti mi ng chai ns are i nstal l ed, posi ti on
speci al tool 8515 to hol d chai ns i n pl ace for i nstal l a-
ti on (Fi g. 142).
(8) Al i gn pri mary chai n doubl e pl ated l i nks wi th
the ti mi ng mark at 12 ocl ock on the i dl er sprocket.
Al i gn the pri mary chai n si ngl e pl ated l i nk wi th the
ti mi ng mark at 6 ocl ock on the crankshaft sprocket
(Fi g. 140).
Fig. 140 Timing Chain System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
9 - 208 ENGINE 4. 7L AN
(9) Lubri cate i dl er shaft and bushi ngs wi th cl ean
engi ne oi l .
(10) I nstal l al l chai ns, crankshaft sprocket, and
i dl er sprocket as an assembl y (Fi g. 143). After gui d-
i ng both secondary chai ns through the bl ock and cyl -
i nder head openi ngs, affi x chai ns wi th a el asti c strap
or the equi val ent, Thi s wi l l mai ntai n tensi on on
chai ns to ai d i n i nstal l ati on.
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Al i gn l eft camshaft sprocket L dot to pl ated
l i nk on chai n.
(12) Al i gn ri ght camshaft sprocket R dot to
pl ated l i nk on chai n.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
(13) Remove Speci al Tool 8515, then attach both
sprockets to camshafts. Remove excess oi l from bol ts,
then I nstal l sprocket bol ts, but do not ti ghten at thi s
ti me.
(14) Veri fy that al l pl ated l i nks are al i gned wi th
the marks on al l sprockets and the V8 marks on
camshaft sprockets are at the 12 ocl ock posi ti on (Fi g.
140).
Fig. 141 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 142 Installing Secondary Timing Chains on
Idler Sprocket
1 - LOCK ARM
4 - IDLER SPROCKET
Fig. 143 Installing Idler Gear, Primary and
Secondary Timing Chains
2 - PRIMARY CHAIN IDLER SPROCKET
AN ENGINE 4. 7L 9 - 209
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) I nstal l both secondary chai n tensi oners.
Ti ghten bol ts to 28 Nm (250 i n. l bs.).
NOTE: Left and right secondary chain tensioners
are not common.
(16) Before i nstal l i ng i dl er sprocket bol t, l ubri cate
washer wi th oi l , and ti ghten i dl er sprocket assembl y
retai ni ng bol t to 34 Nm (25 ft. l bs.).
(17) Remove al l l ocki ng pi ns (3) from tensi oners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(18) Usi ng Speci al Tool 6958, Spanner wi th Adaptor
Pi ns 8346, ti ghten l eft (Fi g. 144) and ri ght (Fi g. 145)
camshaft sprocket bol ts to 122 Nm (90 ft. l bs.).
(19) Rotate engi ne two ful l revol uti ons. Veri fy ti m-
i ng marks are at the fol l ow l ocati ons:
pri mary chai n i dl er sprocket dot i s at 12 ocl ock
(Fi g. 140)
pri mary chai n crankshaft sprocket dot i s at 6
ocl ock (Fi g. 140)
secondary chai n camshaft sprockets V8 marks
are at 12 ocl ock (Fi g. 140)
(20) Lubri cate al l three chai ns wi th engi ne oi l .
Fig. 144 Tightening Left Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
Fig. 145 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
9 - 210 ENGINE 4. 7L AN
(21) After i nstal l i ng al l chai ns, i t i s recommended
that the i dl er gear end pl ay be checked (Fi g. 146).
The end pl ay must be wi thi n 0.100.25 mm (0.004
0.010 i n.). I f not wi thi n speci fi cati on, the i dl er gear
must be repl aced.
(22) I nstal l ti mi ng chai n cover (Refer to 9 -
COVER(S) - I NSTALLATI ON) and crankshaft
damper (Refer to 9 - ENGI NE/ENGI NE BLOCK/VI -
BRATI ON DAMPER - I NSTALLATI ON).
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(24) Coat the l arge threaded access pl ug wi th
Mopar Thread Sealant with Teflon, then i nstal l
i nto the ri ght cyl i nder head and ti ghten to 81 Nm
(60 ft. l bs.) (Fi g. 135).
(25) I nstal l the oi l fi l l housi ng.
(26) I nstal l access pl ug i n l eft cyl i nder head (Fi g.
135).
(27) I nstal l power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
(28) I nstal l radi ator fan shroud.
Fig. 146 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
AN ENGINE 4. 7L 9 - 211
ENGINE 5.9L
TABLE OF CONTENTS
page page
ENGINE 5.9L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 213
ENGINE DIAGNOSIS - INTRODUCTION. . . . . 213
ENGINE DIAGNOSIS - PERFORMANCE. . . . . 214
ENGINE DIAGNOSIS - MECHANICAL. . . . . . . 216
ENGINE DIAGNOSIS - LUBRICATION . . . . . . 219
CYLINDER COMPRESSION PRESSURE . . . . 219
LEAKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
FORM-IN-PLACE GASKETS AND SEALERS. . 221
REPAIR DAMAGED OR WORN THREADS . . . 221
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . 221
CYLINDER BORE HONING. . . . . . . . . . . . . . . 222
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 223
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 224
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 228
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 230
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 230
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
CYLINDER HEAD GASKET FAILURE . . . . . . . 231
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 232
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 233
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 233
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 233
VALVES, GUIDES AND SPRINGS. . . . . . . . . . 233
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 236
ROCKER ARM / ADJUSTER ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 237
ENGINE BLOCK
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 238
CONNECTING ROD BEARING FITTING . . . . . 239
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 240
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 240
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 241
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
CRANKSHAFT MAIN BEARING FITTING . . . . 241
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 242
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 242
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 243
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 243
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . 244
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 244
DISTRIBUTOR BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 246
HYDRAULIC LIFTERS
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . 247
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 248
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 248
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 249
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 250
9 - 212 ENGINE 5. 9L AN
PISTON RINGS
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 252
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 253
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 254
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 255
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
ENGINE OIL LEAKS . . . . . . . . . . . . . . . . . . . . 256
OIL
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 258
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 259
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 260
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 261
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 263
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 263
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 264
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 265
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 266
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 268
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 270
ENGINE 5.9L
DESCRIPTION
The 5.9 Li ter (360 CI D) ei ght-cyl i nder engi ne i s a
V-Type l i ghtwei ght, si ngl e cam, overhead val ve
engi ne wi th hydraul i c rol l er tappets. Thi s engi ne i s
desi gned for unl eaded fuel .
The engi ne l ubri cati on system consi sts of a rotor
type oi l pump and a ful l fl ow oi l fi l ter.
The cyl i nders are numbered from front to rear; 1,
3, 5, 7 on the l eft bank and 2, 4, 6, 8 on the ri ght
bank. The fi ri ng order i s 1-8-4-3-6-5-7-2 (Fi g. 1).
The engi ne seri al number i s stamped i nto a
machi ned pad l ocated on the l eft, front corner of the
cyl i nder bl ock. When component part repl acement i s
necessary, use the engi ne type and seri al number for
Fig. 1 Firing Order
AN ENGINE 5. 9L 9 - 213
AND TESTI NG)
I NG)
Engi ne Oi l Leak I nspecti on (Refer to 9 -
ENGI NE/LUBRI CATI ON - DI AGNOSI S AND TEST-
I NG)
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
4. Seized accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock
Fig. 2 Engine Identification Number
9 - 214 ENGINE 5. 9L AN
ENGINE CRANKS BUT WILL NOT
START
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
pressure test. (Refer to 9 - ENGINE
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
8. Low compression 8. Test cylinder compression (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
system
cables
COIL - REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit.
AN ENGINE 5. 9L 9 - 215
plugs
3. Replace or clean and re-gap
spark plugs (Refer to 8 -
SPARK PLUG - CLEANING)
crossed
replace spark plug cables. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG CABLE -
6. Faulty coil 6. Test and replace, if necessary
COIL - REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD - DIAGNOSIS AND
TESTING).
ENGINE MISSES ON
ACCELERATION
plugs
1. Replace spark plugs or clean and
set gap. (Refer to 8 - ELECTRICAL/
- CLEANING)
crossed
2. Replace or rewire secondary
ignition cables. (Refer to 8 -
SPARK PLUG CABLE - REMOVAL)
5. Faulty coil 5. Test and replace as necessary
COIL - REMOVAL)
DIAGNOSIS - MECHANICAL
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
9 - 216 ENGINE 5. 9L AN
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
engine oil pressure test/
specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
(Refer to 9 - ENGINE/
PROCEDURE) for correct
4. Excessive connecting rod
bearing clearance
Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
4. Excessive main bearing
clearance
4. Measure bearings for correct
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
AN ENGINE 5. 9L 9 - 217
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
metal part
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
necessary
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
9 - 218 ENGINE 5. 9L AN
DIAGNOSIS - LUBRICATION
porous metal parts.
5. Replace seal.
damper hub.
clearance.
damaged.
PLUGS FOULING
rings.
ti ons.
ai r.
REMOVAL).
revol uti ons.
AN ENGINE 5. 9L 9 - 219
(6) Record the compressi on pressure on the thi rd
ders.
i ng)
jacket
l oss
OCCUR.
engi ne.
mended.
AIR ESCAPES THROUGH
THROTTLE BODY
seated properly
AIR ESCAPES THROUGH
TAILPIPE
seated properly
AIR ESCAPES THROUGH
RADIATOR
adjacent cylinders
necessary
cylinder wall
9 - 220 ENGINE 5. 9L AN
GASKETS AND SEALERS
use.
MOPAR ATF RTV
MOPAR GASKET MAKER
APPLICATION
kets.
OR WORN THREADS
equi val ent.
LOCK
steps bel ow.
AN ENGINE 5. 9L 9 - 221
tery.
oi l , etc.).
cyl i nders.
damage on restart.
fi l ter.
HONING
area.
i ts.
hatch angl e.
REMOVAL
(1) Scri be hood hi nge outl i nes on hood. Remove the
hood.
(2) Remove the battery.
onator assembl y.
(5) Di sconnect the radi ator and heater hoses.
Remove radi ator. (Refer to 7 - COOLI NG/ENGI NE/
RADI ATOR - REMOVAL).
2 - INTERSECT ANGLE
9 - 222 ENGINE 5. 9L AN
(6) Di sconnect the vacuum l i nes from the i ntake
mani fol d.
(7) Remove the di stri butor cap and wi ri ng.
CONTROL CABLE - REMOVAL).
(9) Remove throttl e body (Refer to 14 - FUEL SYS-
REMOVAL).
(10) Perform the Fuel System Pressure Rel ease
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELI VERY - STANDARD PROCEDURE).
(11) Di sconnect the starter wi res.
(12) Di sconnect the oi l pressure wi re.
(13) Di scharge the ai r condi ti oni ng system, i f
equi pped. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/REFRI GERANT - STAN-
DARD PROCEDURE).
(14) Di sconnect the ai r condi ti oni ng hoses.
(15) Di sconnect the power steeri ng hoses, i f
equi pped.
(16) Remove starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL).
(19) Di sconnect exhaust pi pe at mani fol ds.
(20) RemoveTransmi ssi on. Refer to 21 - TRANS-
MI SSI ON AND TRANSFER CASE.
manifold.
(21) I nstal l an engi ne l i fti ng fi xture.
(22) 2WD VEHICLESRemove engi ne front
mount bol ts.
(23) 4WD VEHICLESThe engi ne and front
dri vi ng axl e (engi ne/axl e/transmi ssi on) are connected
through i nsul ators and support brackets. Separate
the engi ne as fol l ows:
LEFT SIDERemove 2 bol ts attachi ng (engi ne/
pi ni on nose/transmi ssi on) bracket to transmi ssi on
bel l housi ng. Remove 2 bracket to pi ni on nose adap-
tor bol ts. Separate engi ne from i nsul ator by removi ng
support bracket.
RIGHT SIDERemove 2 bracket to axl e (di s-
connect housi ng) bol ts and 1 bracket to bel l housi ng
bol t. Separate engi ne from i nsul ator by removi ng
support bracket.
(25) On automati c transmi ssi on vehi cl es, di scon-
nect the engi ne from the torque converter dri ve pl ate.
On manual transmi ssi on vehi cl es, move engi ne for-
ward unti l dri ve pi ni on shaft cl ears the cl utch di sc.
Remove engi ne from engi ne compartment.
(26) I nstal l engi ne assembl y on engi ne repai r
stand.
INSTALLATION
(1) Remove engi ne from the repai r stand and posi -
ti on i n the engi ne compartment.
(2) I nstal l an engi ne support fi xture.
(4) I nstal l transmi ssi on.
(5) I nstal l the front engi ne mounts (Refer to 9 -
ENGI NE/ENGI NE MOUNTI NG/FRONT MOUNT -
I NSTALLATI ON).
(6) I nstal l exhaust pi pe to mani fol d.
(8) Remove engi ne l i fti ng fi xture.
TI ON).
(11) Connect power steeri ng hoses, i f equi pped.
(12) Connect ai r condi ti oni ng hoses.
(13) Evacuate and charge the ai r condi ti oni ng sys-
tem, i f equi pped (Refer to 24 - HEATI NG & AI R
(14) Usi ng a new gasket, i nstal l throttl e body
(Refer to 14 - FUEL SYSTEM/FUEL I NJECTI ON/
THROTTLE BODY - I NSTALLATI ON).
CONTROL CABLE - I NSTALLATI ON).
(16) Connect the starter wi res.
(17) Connect the oi l pressure sensor wi re.
(18) I nstal l the di stri butor cap and wi ri ng.
(19) Connect the vacuum l i nes.
(20) Connect the fuel suppl y l i ne (Refer to 14 -
ENGI NE/RADI ATOR - I NSTALLATI ON). Connect
the radi ator hoses and heater hoses.
(22) I nstal l fan shroud i n posi ti on.
(24) I nstal l the ai r cl eaner, resonator assembl y and
ai r i n-l et hose. Ti ghten cl amps to 4 Nm (35 i n. l bs.).
(25) I nstal l the battery.
(26) Warm engi ne and adjust.
(27) I nstal l hood and l i ne up wi th the scri be
marks.
(28) Road test vehi cl e.
AN ENGINE 5. 9L 9 - 223
SPECIFICATIONS
5. 9L ENGINE
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Engine Type 90V-8 OHV
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Firing Order 18436572
Lubrication Pressure Feed Full
Flow
Filtration
Cooling System Liquid Cooled Forced
Circulation
Cylinder Head Cast Iron
Crankshaft Nodular Iron
Camshaft Nodular Cast Iron
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Compression Pressure 689.5 kPa (100 psi)
(Min.)
CAMSHAFT
Bearing Diameter
No. 1 50.800 50.825 mm
(2.000 2.001 in.)
No. 2 50.394 50.419 mm
(1.984 1.985 in.)
No. 3 50.013 50.038 mm
(1.969 1.970 in.)
No. 4 49.606 49.632 mm
(1.953 1.954 in.)
No. 5 39.688 39.713 mm
(1.5625 1.5635 in.)
Bearing Journal Diameter
No. 1 50.723 50.775 mm
(1.997 1.999 in.)
No. 2 50.317 50.368 mm
(1.981 1.983 in.)
No. 3 49.936 49.987 mm
(1.966 1.968 in.)
No. 4 49.53 49.581 mm
(1.950 1.952 in.)
No. 5 39.611 39.662 mm
(1.5595 1.5615 in.)
Bearing to Journal
Clearance
Standard 0.0254 0.0762 mm
(0.001 0.003 in.)
Service Limit 0.127 mm (0.005 in.)
Camshaft End Play 0.051 0.254 mm
(0.002 0.010 in.)
CONNECTING RODS
Piston Pin bore Diameter 24.966 24.978 mm
(0.9829 0.9834 in.)
Side Clearance 0.152 0.356 mm
(0.006 0.014 in.)
CRANKSHAFT
Rod Journal
Diameter 53.950 53.975 mm
(2.124 2.125 in.)
Out of Round (Max.) 0.0254 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Bearing Clearance 0.013 0.056 mm
(0.0005 0.0022 in.)
(2.8095 2.8105 in.)
Out of Round (Max.) 0.127 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Bearing Clearance
9 - 224 ENGINE 5. 9L AN
Journal #1 0.013 0.038 mm
(0.0005 0.0015 in.)
Journals # 2 - 5 0.013 0.051 mm
(0.0005 0.002 in.)
Service Limit
Journal #1 0.0381 mm (0.0015 in.)
Journals #2-5 0.064 mm (0.0025 in.)
Crankshaft End Play 0.051 0.178 mm
(0.002 0.007 in.)
Service Limit 0.254 mm (0.010 in.)
CYLINDER BLOCK
Cylinder Bore
(4.000 4.002 in.)
Out of Round (Max.) .0254 mm (0.001 in.)
Taper (Max.) .0254 mm (0.001 in.)
Lifter Bore
(0.9051 0.9059 in.)
Distributor Drive Bushing
Press Fit
Bushing to Bore
Interference
0.0127 0.3556 mm
(0.0005 0.0140 in.)
Shaft to Bushing
Clearance
0.0178 0.0686 mm
(0.0007 0.0027 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle 44.25 44.75
Runout (Max.) 0.0762 mm (0.003 in.)
Width (Finish)
Intake 1.016 1.524 mm
(0.040 0.060 in.)
Exhaust 1.524 2.032 mm
(0.060 0.080 in.)
Valves
Face Angle 43.25 43.75
Head Diameter
Intake 47.752 mm (1.88 in.)
Exhaust 41.072 (1.617 in.)
Length (Overall)
Intake 126.21 126.85 mm
(4.969 4.994 in.)
Exhaust 126.44 127.30 mm
(4.978 5.012 in.)
Lift (@ zero lash)
Intake 10.414 mm (0.410 in.)
Exhaust 10.592 mm (0.417 in.)
Stem Diameter
Intake 9.449 9.474 mm
(0.372 0.373 in.)
Exhaust 9.423 9.449 mm
(0.371 0.372 in.)
Guide Bore 9.500 9.525 mm
(0.374 0.375 on.)
Stem to Guide Clearance
Intake 0.0254 0.0762 mm
(0.001 0..003 in.)
Exhaust 0.0508 0.1016 mm
(0.002 0.004 in.)
Service Limit 0.4318 (0.017 in.)
Valve Springs
Free Length 49.962 mm (1.967 in.)
Spring Tension
Valve closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)
Wire Diameter 4.50 mm (0.177 in.)
AN ENGINE 5. 9L 9 - 225
HYDRAULIC TAPPETS
Body Diameter 22.949 22.962 mm
(0.9035 0.9040 in.)
Clearance (to bore) 0.0279 0.0610 mm
(0.0011 0.0024 in.)
Dry Lash 1.524 5.334 mm
(0.060 0.210 in.)
Push Rod Length 175.64 176.15 mm
(6.915 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*) 41.4 kPa (6 psi)
@ 3000 rpm 207 552 kPa (30 80
psi)
Oil Pressure Bypass
Valve Setting 62 103 kPa (9 15 psi)
Switch Actuating
Pressure
34.5 48.3 kPa (5 7
psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.)
0.1016 mm (0.004 in.)
Cover Out of Flat (Max.) 0.0381 mm (0.0015 in.)
Inner Rotor Thickness
(Min.)
20.955 mm (0.825 in.)
Outer Rotor
Clearance (Max.) 0.3556 mm (0.014 in.)
Diameter (Min.) 62.7126 mm (2.469 in.)
Thickness (Min.) 20.955 mm (0.825 in.)
Tip Clearance between
Rotors (Max.) 0.2032 mm (0.008 in.)
PISTONS
Clearance at Top of Skirt 0.013 0.038 mm
(0.0005 0.0015 in.)
Land Clearance (Diam.) 0.508 0.660 mm
(0.020 0.026 in.)
Piston Length 81.03 mm (3.19 in.)
Piston Ring Groove
Depth
Groove #1&2 4.761 4.912 mm
(0.187 0.193 in.)
Groove #3 3.996 4.177 mm
(0.157 0.164 in.)
Weight 582 586 grams
(20.53 20.67 oz.)
PISTON PINS
Clearance in Piston 0.006 0.019 mm
(0.00023 0.00074 in.)
(0.9845 0.9848 in.)
End Play NONE
Length 67.8 68.3 mm
(2.67 2.69 in.)
PISTON RINGS
Ring Gap
Compression Ring (Top) 0.30 0.55 mm
(0.012 0.022 in.)
Compression Ring (2nd) 0.55 0.80 mm
(0.022 0.031 in.)
Oil Control (Steel Rails) 0.381 1.397 mm
(0.015 0.055 in.)
Ring Side Clearance
Compression Rings 0.040 0.085 mm
(0.0016 0.0033 in.)
Oil Ring (Steel Rails) 0.05 0.21 mm
(0.002 0.008 in.)
Ring Width
Compression rings 1.530 1.555 mm
(0.060 0.061 in.)
Oil Ring (Steel Rails)
Max.
0.447 0.473 mm
(0.018 0.019 in.)
9 - 226 ENGINE 5. 9L AN
VALVE TIMING
Exhaust Valve
Closes (ATDC) 33
Opens (BBDC) 56
Duration 269
Intake Valve
Closes (ATDC) 62
Opens (BBDC) 7
Duration 249
Valve Overlap 41
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
Identification
U/S Crankshaft R or M M-2-3
ect.
Milled flat on
.025 MM (indicating No.
2 &
No. three
(.001 in.) 3 main
bearing
crankshaft
journal) and/or counterweight.
R-1-4 ect.
(indicating
No. 1 &
4 connecting
rod
journal)
O/S Cylinder A Following
.508 mm Bores engine serial
(.020 in.) number.
O/S Tappets 3/8
.203 mm diamound
(.008 in.) -shaped
stamp Top
pad
Front of
engine and
flat
ground on
outside
surface
Identification
of each O/S
tappet bore.
O/S Valve
Stems
X Milled pad
.127 mm adjacent to
two
(.005 in.) 3/8 tapped
holes on
each
end of
cylinder
head.
TORQUE
TORQUE CHART 5.9L ENGINE
Lbs. Lbs.
Camshaft SprocketBolt 68 50
Camshaft Thrust PlateBolts 24 210
Timing Chain Case Cover
Bolts
41 30
Connecting Rod CapBolts 61 45
Main Bearing CapBolts 115 85
Crankshaft PulleyBolts 24 210
Cylinder HeadBolts
Step 1 68 50
Step 2 143 105
Cylinder Head CoverBolts 11 95
Engine Support Bracket to
Block
41 30
Bolts (4WD)
Exhaust Manifold to Cylinder
Head
34 25
Bolts/Nuts
FlywheelBolts 75 55
Front InsulatorThrough
bolt/nut
95 70
Front Insulator to Support
Bracket
Stud Nut (4WD) 41 30
Through Bolt/Nut (4WD) 102 75
AN ENGINE 5. 9L 9 - 227
Front Insulator to Block
Bolts (2WD)
95 70
GeneratorMounting Bolt 41 30
Intake ManifoldBolts Refer to Procedure
Oil PanBolts 24 215
Oil PumpAttaching Bolts 41 30
Rear Insulator to Bracket 68 50
Through-Bolt (2WD)
Rear Insulator to
Crossmember
41 30
Support BracketNut (2WD)
Rear Insulator to
Crossmember
68 50
Nuts (4WD)
Rear Insulator to
Transmission
68 50
Bolts (4WD)
Rear Insulator BracketBolts 68 50
(4WD Automatic)
Rear Support Bracket to 41 30
Crossmember FlangeNuts
Rear Support Plate to
Transfer
41 30
CaseBolts
Spark Plugs 41 30
Starter MotorMounting Bolts 68 50
Thermostat HousingBolts 25 225
Throttle BodyBolts 23 200
Torque Converter Drive
PlateBolts
31 270
Transfer Case to Insulator 204 105
Mounting PlateNuts
Bracket
68 50
Bolts (2WD)
Vibration DamperBolt 244 180
Water Pump to Timing Chain 41 30
Case CoverBolts
SPECIAL TOOLS
5. 9L ENGINE
Engine Support Fixture C-3487A
Valve Spring Compressor MD-998772A
Adaptor 6633
Adaptor 6716A
9 - 228 ENGINE 5. 9L AN
Valve Guide Sleeve C-3973
Puller C-3688
Puller 1026
Crankshaft Damper Removal Insert 8513
Front Oil Seal Installer 6635
Cam Bearing Remover/Installer C3132A
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/Burnisher C-3053
AN ENGINE 5. 9L 9 - 229
AIR CLEANER ELEMENT
REMOVAL
ter) repl acement.
i ng.
ment.
INSTALLATION
tabs.
CYLINDER HEAD
DESCRIPTION
The cast i ron cyl i nder heads (Fi g. 5) are mounted
to the cyl i nder bl ock usi ng ten bol ts. The spark pl ugs
are l ocated i n the peak of the wedge between the
val ves.
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
BlocCheckKit C-3685A
2 - TABS
3 - HOUSING
9 - 230 ENGINE 5. 9L AN
OPERATION
engi ne.
GASKET FAILURE
Poor fuel economy
jacket are:
Loss of cool ant
exhaust
Cool ant foami ng
dures i n Cyl i nder Compressi on Pressure Test i n thi s
secti on. An engi ne cyl i nder head gasket l eaki ng
between adjacent cyl i nders wi l l resul t i n approxi -
matel y a 5070% reducti on i n compressi on pressure.
SURE CAP REMOVED.
VISUAL TEST METHOD
thermostat opens.
l eak i s evi dent.
REMOVAL
(3) Remove the ai r cl eaner resonator and duct
work.
(4) Remove the i ntake mani fol d-to-generator
bracket support rod. Remove the generator.
(5) Remove cl osed crankcase venti l ati on system.
(6) Di sconnect the evaporati on control system.
(7) Perform the Fuel System Pressure Rel ease pro-
fuel suppl y l i ne (Refer to 14 - FUEL SYSTEM/FUEL
DARD PROCEDURE).
Fig. 5 Cylinder Head AssemblyV-8 Gas Engines
1 - EXHAUST VALVE
2 - SPARK PLUGS
3 - EXHAUST VALVES
4 - SPARK PLUGS
5 - EXHAUST VALVE
6 - INTAKE VALVES
7 - INTAKE VALVES
AN ENGINE 5. 9L 9 - 231
(8) Di sconnect accel erator l i nkage and i f so
down cabl es.
(9) Remove di stri butor cap and wi res.
(11) Di sconnect heat i ndi cator sendi ng uni t wi re.
(12) Di sconnect heater hoses and bypass hose.
(13) Remove cyl i nder head covers and gaskets
(14) Remove i ntake mani fol d (Refer to 9 -
REMOVAL) and throttl e body as an assembl y. Di s-
card the fl ange si de gaskets and the front and rear
cross-over gaskets.
(15) Remove exhaust mani fol ds (Refer to 9 -
REMOVAL).
(16) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(17) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
(18) Remove spark pl ugs.
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
INSPECTION
I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out-of-fl atness
exceeds 0.00075mm/mm (0.0001i n./i n.) ti mes the
span l ength i n any di recti on, ei ther repl ace head or
l i ghtl y machi ne the head surface.
FOR EXAMPLE:A 305 mm (12 i n.) span i s
0.102 mm (0.004 i n.) out-of-fl at. The al l owabl e out-of-
fl at i s 305 x 0.00075 (12 x 0.00075) equal s 0.23 mm
(0.009 i n.). Thi s amount of out-of-fl at i s acceptabl e.
The cyl i nder head surface fi ni sh shoul d be
1.78-3.00 mi crons (70-125 mi croi nches).
I nspect push rods. Repl ace worn or bent rods.
INSTALLATION
(1) Cl ean al l surfaces of cyl i nder bl ock and cyl i n-
der heads.
(2) Cl ean cyl i nder bl ock front and rear gasket sur-
faces usi ng a sui tabl e sol vent.
(3) Posi ti on new cyl i nder head gaskets onto the
cyl i nder bl ock.
(4) Posi ti on cyl i nder heads onto head gaskets and
cyl i nder bl ock.
(5) Starti ng at top center, ti ghten al l cyl i nder head
bol ts, i n sequence (Fi g. 6).
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(6) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti on. Ti ghten the bol ts to 28 Nm
I NSTALLATI ON) and throttl e body assembl y.
(8) I nstal l exhaust mani fol ds (Refer to 9 -
I NSTALLATI ON).
(9) I f requi red, adjust spark pl ugs to speci fi cati ons.
I nstal l the pl ugs and ti ghten to 41 Nm (30 ft. l bs.)
torque.
(10) I nstal l coi l wi re.
(11) Connect heat i ndi cator sendi ng uni t wi re.
(14) Connect the accel erator l i nkage and i f so
down cabl es.
(15) I nstal l the fuel suppl y l i ne (Refer to 14 -
(16) I nstal l the generator and dri ve bel t (Refer to 7
- COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON). Ti ghten generator mounti ng bol t
to 41 Nm (30 ft. l bs.) torque. Ti ghten the adjusti ng
strap bol t to 23 Nm (200 i n. l bs.) torque.
(17) I nstal l the i ntake mani fol d-to-generator
bracket support rod. Ti ghten the bol ts.
(18) Pl ace the cyl i nder head cover gaskets i n posi -
ti on and i nstal l cyl i nder head covers (Refer to 9 -
(19) I nstal l cl osed crankcase venti l ati on system.
Fig. 6 Cylinder Head Bolt Tightening Sequence
9 - 232 ENGINE 5. 9L AN
(20) Connect the evaporati on control system.
DESCRIPTION - CYLINDER HEAD COVER
GASKET
The cyl i nder head cover gasket (Fi g. 7) i s a steel -
backed si l i cone gasket, desi gned for l ong l i fe usage.
OPERATION - CYLINDER HEAD COVER
GASKET
The steel -backed si l i cone gasket i s desi gned to seal
the cyl i nder head cover for l ong peri ods of ti me
through extensi ve heat and col d, wi thout fai l ure. The
gasket i s desi gned to be reusabl e.
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 8). This gasket can be
used again.
(2) Di sconnect the spark pl ug wi res form the spark
pl ugs and set asi de.
(3) Di sconnect cl osed venti l ati on system and evap-
orati on control system from cyl i nder head cover.
(4) Remove cyl i nder head cover and gasket.
CLEANING
INSPECTION
essary.
INSTALLATION
(1) The cyl i nder head cover gasket can be used
agai n. I nstal l the gasket onto the head rai l .
(2) Posi ti on the cyl i nder head cover onto the gas-
ket. Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
(3) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
(4) Connect the spark pl ug wi res to the spark
pl ugs.
SEATS
DESCRIPTION
STANDARD PROCEDURE VALVES, GUIDES
AND SPRINGS
VALVE CLEANING
or cracked val ves.
VALVE GUIDES
Fig. 7 Cylinder Head Cover Gasket V-8 Gas Engines
AN ENGINE 5. 9L 9 - 233
VALVE GUIDES
Refer to REAMER SI ZES CHART
REAMER SIZES CHART
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
seat:
REFACING VALVES AND VALVE SEATS
(Fi g. 11).
1 - VALVE
2 - SPACER TOOL
1 - VALVE
Fig. 11 Valve Face and Seat Angles
1 - CONTACT POINT
CHART
9 - 234 ENGINE 5. 9L AN
A SEAT WIDTH
INTAKE 1.016 - 1.524 mm
(0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm
(0.060 - 0.080 in.)
B FACE ANGLE
C SEAT ANGLE
D CONTACT
SURFACE
VALVES
VALVE SEATS
the correct si ze val ve gui de pi l ot be used for reseati ng
stones. A true and compl ete surface must be obtai ned.
2.032 mm (0.060-0.080 i n.).
VALVE SPRINGS
Refer to speci fi cati ons to obtai n speci fi ed hei ght and
al l owabl e tensi ons. Di scard the spri ngs that do not
meet speci fi cati ons.
1 - MARGIN
3 - STEM
4 - FACE
1 - STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
AN ENGINE 5. 9L 9 - 235
REMOVAL
Compressor Tool MD- 998772A and adapter 6716A.
retai ners, val ve stem seal s and val ve spri ngs.
ori gi nal l ocati on.
CLEANING
or cracked val ves.
INSPECTION
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
Make sure the measurement i s taken from bottom of
Length
1 - TORQUE WRENCH
1 - VALVE
2 - SPACER TOOL
1 - VALVE
9 - 236 ENGINE 5. 9L AN
mm (1-11/16 i nches), i nstal l a 1.587 mm (1/16 i nch)
1-11/16 i nch).
(8) I nstal l cyl i nder head (Refer to 9 - ENGI NE/
CYLI NDER HEAD - I NSTALLATI ON).
ROCKER ARM / ADJ USTER
ASSEMBLY
REMOVAL
(1) Remove cyl i nder head cover and gasket (Refer
(2) Remove the rocker arm bol ts and pi vots (Fi g.
17). Pl ace them on a bench i n the same order as
removed.
(3) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Rotate the crankshaft unti l the V8 mark l i nes
up wi th the TDC mark on the ti mi ng chai n case
cover. Thi s mark i s l ocated 147 ATDC from the No.1
fi ri ng posi ti on.
(2) I nstal l the push rods i n the same order as
removed.
(3) I nstal l rocker arm and pi vot assembl i es i n the
same order as removed. Ti ghten the rocker arm bol ts
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
ENGINE BLOCK
CLEANING
Cl ean cyl i nder bl ock thoroughl y and check al l core
hol e pl ugs for evi dence of l eakage.
INSPECTION
Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out-of-
round and taper. Refer to Honi ng Cyl i nder Bores i n
the Servi ce Procedures porti on of thi s Secti on.
I nspect the oi l l i ne pl ug, the oi l l i ne pl ug i s l ocated
i n the verti cal passage at the rear of the bl ock
between the oi l -to-fi l ter and oi l -from-fi l ter passages
(Fi g. 18) . I mproper i nstal l ati on or mi ssi ng pl ug coul d
cause errati c, l ow, or no oi l pressure.
The oi l pl ug must come out the bottom. Use fl at
dowel , down the oi l pressure sendi ng uni t hol e from
the top, to remove oi l pl ug.
(1) Remove oi l pressure sendi ng uni t from back of
bl ock.
(2) I nsert a 3.175 mm (1/8 i n.) fi ni sh wi re, or
equi val ent, i nto passage.
(3) Pl ug shoul d be 190.0 to 195.2 mm (7-1/2 to
7-11/16 i n.) from machi ned surface of bl ock (Fi g. 18) .
I f pl ug i s too hi gh, use a sui tabl e fl at dowel to posi -
ti on properl y.
(4) I f pl ug i s too l ow, remove oi l pan and No. 4
mai n beari ng cap. Use sui tabl e fl at dowel to posi ti on
properl y . Coat outsi de di ameter of pl ug wi th Mopar
Stud and Beari ng Mount Adhesi ve. Pl ug shoul d be
54.0 to 57.7 mm (2-1/8 to 2-5/16 i n.) from bottom of
the bl ock.
BLOCK)
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 19).
Fig. 17 Rocker Arms
1 - ROCKER ARMS
2 - CYLINDER HEAD
AN ENGINE 5. 9L 9 - 237
REMOVAL CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 20) .
ENGI NE/RADI ATOR - REMOVAL).
(2) Remove the A/C Condenser (i f equi pped)
(3) Remove the engi ne cover.
(5) Remove cyl i nder head covers (Refer to 9 -
(6) Remove ti mi ng case cover (Refer to 9 -
COVER(S) - REMOVAL) and ti mi ng chai n (Refer to 9
- ENGI NE/VALVE TI MI NG/TI MI NG BELT/CHAI N
AND SPROCKETS - REMOVAL).
(7) Remove rocker arms.
(8) Remove push rods and tappets. I denti fy each
part so i t can be i nstal l ed i n i ts ori gi nal l ocati on.
(9) Remove di stri butor and l i ft out the oi l pump
and di stri butor dri ve shaft.
(10) Remove camshaft thrust pl ate, note l ocati on of
oi l tab (Fi g. 21).
(11) I nstal l a l ong bol t i nto front of camshaft to ai d
i n removal of the camshaft. Remove camshaft, bei ng
careful not to damage cam beari ngs wi th the cam
l obes.
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool C-3132-A by sl i di ng
the new camshaft beari ng shel l over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
Fig. 18 Oil Line Plug
2 - CYLINDER BLOCK
4 - OIL TO FILTER
5 - FROM OIL PUMP
6 - CRANKSHAFT
7 - PLUG
Fig. 19 Camshaft Bearings
1 - SPECIAL TOOL C-3132A
2 - MAIN BEARING OIL HOLE
Fig. 20 Camshaft and Sprocket Assembly
1 - THRUST PLATE
2 - OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL
WITH CAMSHAFT
9 - 238 ENGINE 5. 9L AN
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 51 mm (2
i nches) of i ts fi nal posi ti on i n cyl i nder bl ock.
(2) I nstal l Camshaft Hol der Tool C-3509 wi th
tongue back of di stri butor dri ve gear (Fi g. 22).
(3) Hol d tool i n posi ti on wi th a di stri butor l ock-
pl ate bol t. Thi s tool wi l l restri ct camshaft from bei ng
pushed i n too far and prevent knocki ng out the wel ch
pl ug i n rear of cyl i nder bl ock. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) I nstal l camshaft thrust pl ate and chai n oi l tab.
Make sure tang enters lower right hole in
thrust plate. Ti ghten bol ts to 24 Nm (210 i n. l bs.)
torque. Top edge of tab shoul d be fl at agai nst thrust
pl ate i n order to catch oi l for chai n l ubri cati on.
(5) I nstal l ti mi ng chai n and gears (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT/CHAI N
AND SPROCKETS - I NSTALLATI ON).
(6) Measure camshaft end pl ay (Refer to 9 -
ENGI NE - SPECI FI CATI ONS). I f not wi thi n l i mi ts
i nstal l a new thrust pl ate.
(7) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
(8) I nstal l di stri butor and di stri butor dri ve shaft.
(9) I nstal l push rods and tappets.
(10) I nstal l rocker arms.
(11) I nstal l ti mi ng case cover (Refer to 9 -
TI ON).
(14) I nstal l the engi ne cover.
(15) I nstal l the A/C Condenser (i f equi pped)
ENGI NE/RADI ATOR - I NSTALLATI ON).
BEARING FITTING
Fi t al l rods on a bank unti l compl eted. DO NOT
al ternate from one bank to another, because connect-
i ng rods and pi stons are not i nterchangeabl e from
one bank to another.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to ensure correct
assembl y.
Each beari ng cap has a smal l V-groove across the
parti ng face. When i nstal l i ng the l ower beari ng shel l ,
be certai n that the V-groove i n the shel l i s i n l i ne
wi th the V-groove i n the cap. Thi s provi des l ubri ca-
ti on of the cyl i nder wal l i n the opposi te bank.
The beari ng shel l s must be i nstal l ed so that the
tangs are i n the machi ned grooves i n the rods and
caps.
Fig. 21 Timing Chain Oil
1 - THRUST PLATE FRONT SIDE
2 - CHAIN OIL TAB
3 - THRUST PLATE REAR SIDE
Fig. 22 Camshaft Holding Tool C-3509 (Installed
Position)
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
AN ENGINE 5. 9L 9 - 239
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i n.).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i n.), 0.051
mm (0.002 i n.), 0.076 mm (0.003 i n.), 0.254 mm
(0.010 i n.) and 0.305 mm (0.012 i n.) undersi ze.
Install the bearings in pairs. DO NOT use a new
bearing half with an old bearing half. DO NOT
file the rods or bearing caps.
CRANKSHAFT
DESCRIPTION
The crankshaft (Fi g. 23) i s of a cast nodul ar steel
spl ayed type desi gn, wi th fi ve mai n beari ng journal -
s.The crankshaft i s l ocated at the bottom of the
engi ne bl ock and i s hel d i n pl ace wi th fi ve mai n bear-
i ng caps. The number 3 counterwei ght i s the l ocati on
for journal si ze i denti fi cati on.
OPERATION
fl expl ate.
REMOVAL
NOTE: This procedure can be done in vehicle. How-
ever the transmission must be removed first.
(1) I f crankshaft i s to be removed whi l e engi ne i s
i n vehi cl e remove the transmi ssi on. Refer to 21 -
TRANSMI SSI ON/TRANSAXLE.
i ng cap (Refer to 9 - ENGI NE/LUBRI CATI ON/OI L
PUMP - REMOVAL).
REMOVAL).
(6) I denti fy rod beari ng caps before removal .
Remove rod beari ng caps wi th beari ngs.
CAUTION: Support crankshaft before removing
main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.
(7) Usi ng a sui tabl e jack, support the crankshaft.
(8) I denti fy mai n beari ng caps before removal .
Remove mai n beari ng caps and beari ngs one at a
ti me.
(9) Lower the crankshaft out of the bl ock.
seal s.
seal .
INSTALLATION
(1) Cl ean Gasket Maker resi due and seal ant from
the cyl i nder bl ock and rear cap mati ng surface. Do
thi s before appl yi ng the Mopar Gasket Maker and
the i nstal l ati on of rear cap.
oi l .
oi l .
(7) Appl y 5 mm (0.20 i n) drop of Mopar Gasket
beari ng cap (Fi g. 24). DO NOT over appl y seal ant or
ment dowel and cap bol ts. DO NOT remove excess
more than 2 ti mes for proper engagement.
Fig. 23 Crankshaft with Journal Size Identification
9 - 240 ENGINE 5. 9L AN
I NSTALLATI ON).
(13) Posi ti on the connecti ng rods onto the crank-
shaft and i nstal l the rod beari ng caps. Ti ghten the
nuts to 61 Nm (45 ft. l bs.).
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 25).
Appl y enough seal ant unti l a smal l amount i s
TI ON).
(17) I f the transmi ssi on was removed, i nstal l the
transmi ssi on. Refer to 21 - TRANSMI SSI ON/TRAN-
SAXLE.
CRANKSHAFT MAIN
BEARINGS
DESCRIPTION
fi ve mai n beari ngs. Number three mai n beari ng i s
OPERATION
BEARING FITTING
Beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to ensure correct assembl y.
Upper and l ower beari ng hal ves are NOT i nter-
changeabl e. Lower mai n beari ng hal ves of No.2 and 4
are i nterchangeabl e.
Upper and l ower No.3 beari ng hal ves are fl anged
to carry the crankshaft thrust l oads. They are NOT
i nterchangeabl e wi th any other beari ng hal ves i n the
engi ne (Fi g. 27). Beari ng shel l s are avai l abl e i n stan-
dard and the fol l owi ng undersi zes: Never i nstal l an
1 - .25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR MAIN
CAP
Fig. 25 Apply Sealant to Bearing Cap to Block Joint
NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
AN ENGINE 5. 9L 9 - 241
undersi ze beari ng that wi l l reduce cl earance bel ow
speci fi cati ons.
Main Bearing Undersize Availability List
0.25 mm (0.001 i nch)
0.051 mm (0.002 i nch)
0.076 mm (0.003 i nch)
0.254 mm (0.010 i nch)
0.305 mm (0.012 i nch)
REMOVAL
i ng cap (Refer to 9 - ENGI NE/LUBRI CATI ON/OI L
PUMP - REMOVAL).
beari ng caps one at a ti me.
(4) Remove upper hal f of beari ng by i nserti ng
Crankshaft Mai n Beari ng Remover/I nstal l er Tool
C-3059 i nto the oi l hol e of crankshaft (Fi g. 28).
(5) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Onl y one mai n beari ng shoul d be sel ecti vel y fi tted
whi l e al l other mai n beari ng caps are properl y ti ght-
ened. Al l beari ng capbol ts removed duri ng servi ce
procedures are to be cl eaned and oi l ed before i nstal -
l ati on.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Crankshaft
Mai n Beari ng Remover/I nstal l er Tool C-3059 i nto oi l
hol e of crankshaft (Fi g. 28).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Tool C-3059.
(3) I nstal l the beari ng caps. Cl ean and oi l the
bol ts. Ti ghten the capbol ts to 115 Nm (85 ft. l bs.)
torque.
(4) I nstal l the oi l pump (Refer to 9 - ENGI NE/LU-
FRONT
DESCRIPTION
The crankshaft front seal i s a one pi ece vi ton seal
wi th a steel housi ng. The front seal i s l ocated i n the
OPERATION
REMOVAL
mi sal i gned.
REMOVAL).
Fig. 27 Main Bearing
Fig. 28 Upper Main Bearing Removal and
Installation with Tool C-3059
2 - BEARING
4 - BEARING
9 - 242 ENGINE 5. 9L AN
INSTALLATION
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 29) . Seat
(Fi g. 30).
(Fi g. 31).
damper.
I NSTALLATI ON).
REAR
DESCRIPTION
The crankshaft rear seal i s a two pi ece vi ton seal .
One part of the two pi ece rear seal i s l ocated i n a sl ot
i n the cyl i nder bl ock oppsi te the crankshaft mai n
beari ng cap, the second part of the two pi ece seal i s
l ocated i n the mai n beari ng cap i tsel f.
2 - OIL SEAL
AN ENGINE 5. 9L 9 - 243
OPERATION
LEAKS
area:
seal.
procedures.
REMOVAL
(1) Remove the crankshaft (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CRANKSHAFT - REMOVAL). Di s-
card the ol d upper seal .
(3) Remove the rear mai n beari ng cap. Remove
and di scard the ol d l ower oi l seal .
(4) Careful l y remove and di scard the ol d upper oi l
seal .
LOWER SEAL
(3) Remove the rear mai n beari ng cap and di scard
the ol d l ower seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock rear cap mati ng sur-
face. Be sure the seal groove i s free of debri s. Check
for burrs at the oi l hol e on the cyl i nder bl ock mati ng
surface to rear cap.
oi l .
the whi te pai nt faci ng toward the rear of the engi ne.
oi l .
9 - 244 ENGINE 5. 9L AN
joi nt to provi de cap to bl ock and oi l pan seal i ng (Fi g.
33) . Appl y enough seal ant so that a smal l amount i s
TI ON).
(1) Cl ean the cyl i nder bl ock mati ng surfaces before
oi l seal i nstal l ati on. Check for burrs at the oi l hol e on
the cyl i nder bl ock mati ng surface to rear cap.
oi l . To al l ow ease of i nstal l ati on of the seal , l oosen at
l east the two mai n beari ng caps forward of the rear
beari ng cap.
(3) Rotate the new upper seal i nto the cyl i nder
bl ock, bei ng careful not to shave or cut the outer sur-
face of the seal . To ensure proper i nstal l ati on, use the
i nstal l ati on tool provi ded wi th the ki t. I nstal l the
new seal wi th the whi te pai nt faci ng toward the rear
of the engi ne.
the beari ng cap wi th the whi te pai nt faci ng toward
seal ant appl i cati on. Be sure the whi te pai nt faces
toward the rear of the engi ne.
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
joi nt to provi de cap-to-bl ock and oi l pan seal i ng (Fi g.
33). Appl y enough seal ant unti l a smal l amount i s
NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
AN ENGINE 5. 9L 9 - 245
TI ON).
LOWER SEAL
(1) Cl ean the rear mai n cap mati ng surfaces
i ncl udi ng the oi l pan gasket groove.
(2) Careful l y i nstal l a new upper seal . Refer to
UPPER SEALCRANKSHAFT I NSTALLED .
oi l .
(4) I nstal l a new l ower seal i n beari ng cap wi th
the whi te pai nt faci ng the rear of engi ne.
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
joi nt to provi de cap to bl ock and oi l pan seal i ng.
TI ON).
DISTRIBUTOR BUSHING
REMOVAL
(1) Remove di stri butor (Refer to 8 - ELECTRI CAL/
I GNI TI ON CONTROL/DI STRI BUTOR - REMOVAL).
REMOVAL).
(3) I nsert Di stri butor Dri ve Shaft Bushi ng Pul l er
Tool C-3052 i nto ol d bushi ng and thread down unti l a
ti ght fi t i s obtai ned (Fi g. 34).
(4) Hol d pul l er screw and ti ghten pul l er nut unti l
bushi ng i s removed.
INSTALLATION
(1) Sl i de new bushi ng over burni shi ng end of Di s-
tri butor Dri ve Shaft Bushi ng Dri ver/Burni sher Tool
C-3053. I nsert the tool and bushi ng i nto the bore.
(2) Dri ve bushi ng and tool i nto posi ti on, usi ng a
hammer (Fi g. 35).
(3) As the burni sher i s pul l ed through the bushi ng,
the bushi ng i s expanded ti ght i n the bl ock and bur-
ni shed to correct si ze (Fi g. 36). DO NOT ream this
bushing.
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
I NSTALLATI ON).
(5) I nstal l the di stri butor (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/DI STRI BUTOR -
I NSTALLATI ON).
Fig. 34 Distributor Driveshaft Bushing Removal
2 - BUSHING
Fig. 35 Distributor Driveshaft Bushing Installation
2 - BUSHING
9 - 246 ENGINE 5. 9L AN
HYDRAULIC LIFTERS
TAPPETS
OIL LEVEL
HIGH
LOW
operati on.
i ng.
LEAK-DOWN TEST
Down Tester .
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
pet.
Fig. 36 Burnishing Distributor Driveshaft Bushing
2 - BUSHING
AN ENGINE 5. 9L 9 - 247
DISTRIBUTOR BUSHING (Continued)
posi ti on.
rod.
seconds.
REMOVAL
(1) Remove the ai r cl eaner assembl y and ai r i n-l et
hose.
(3) Remove rocker assembl y and push rods (Refer
to 9 - ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). I denti fy push rods
to ensure i nstal l ati on i n ori gi nal l ocati ons.
(5) Remove yoke retai ner and al i gni ng yokes.
(6) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
(7) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
(8) I f the tappet or bore i n cyl i nder bl ock i s scored,
scuffed, or shows si gns of sti cki ng, ream the bore to
next oversi ze. Repl ace wi th oversi ze tappet.
CLEANING
Cl ean tappet wi th a sui tabl e sol vent. Ri nse i n hot
water and bl ow dry wi th a cl ean shop rag or com-
pressed ai r.
INSTALLATION
(1) Lubri cate tappets wi th Mopar Engi ne Oi l
Suppl ement or equi val ent.
(2) I nstal l tappets and push rods i n thei r ori gi nal
posi ti ons . Ensure that the oi l feed hol e i n the si de of
the tappet body faces up (away from the crankshaft).
(3) I nstal l al i gni ng yokes wi th ARROW toward
camshaft.
(4) I nstal l yoke retai ner. Ti ghten the bol ts to 23
Nm (200 i n. l bs.) torque. I nstal l i ntake mani fol d
(Refer to 9 - ENGI NE/MANI FOLDS/I NTAKE MANI -
FOLD - I NSTALLATI ON).
(5) I nstal l rocker arms (Refer to 9 - ENGI NE/CYL-
I NDER HEAD/ROCKER ARM / ADJUSTER ASSY -
I NSTALLATI ON).
(7) I nstal l ai r cl eaner assembl y and ai r i n-l et hose.
(8) Start and operate engi ne. Warm up to normal
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
DESCRIPTION
fi t.
1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP
5 - HANDLE
6 - PUSH ROD
9 - 248 ENGINE 5. 9L AN
HYDRAULIC LIFTERS (Continued)
STANDARD PROCEDURE - PISTON FITTING
Pi ston and cyl i nder wal l must be cl ean and dry.
Speci fi ed cl earance between the pi ston and the cyl i n-
der wal l i s 0.013-0.038 mm (0.0005-0.0015 i nch) at
21C (70F).
Pi ston di ameter shoul d be measured at the top of
ski rt, 90 to pi ston pi n axi s. Cyl i nder bores shoul d be
measured hal fway down the cyl i nder bore and trans-
verse to the engi ne crankshaft center l i ne.
Pi stons and cyl i nder bores shoul d be measured at
normal room temperature, 21C (70F).
Check the pi stons for taper and el l i pti cal shape
before they are fi tted i nto the cyl i nder bore (Fi g. 38).
PISTON MEASUREMENT CHART
MIN. MAX. MIN. MAX.
mm
(in.)
mm
(in.)
mm
(in.)
mm (in.)
A
B 101.580 101.592 101.605 101.618
(3.9992) (3.9997) (4.0002) (4.0007)
C 101.592 101.605 101.618 101.630
(3.9997) (4.0002) (4.0007) (4.0012)
MIN. MAX. MIN. MAX.
mm
(in.)
mm
(in.)
mm
(in.)
mm (in.)
D 101.605 101.618 101.630 101.643
(4.0002) (4.0007) (4.0012) (4.0017)
E
PISTON PIN BORE 25.007 - 25.015 mm
(.9845 - .9848 in.)
RING GROOVE
HEIGHT
OIL RAIL 4.033 - 4.058 mm
(.1588 - .1598 in.)
COMPRESSION
RAIL
1.529 - 1.554 mm
(.0602 - .0612 in.)
TOTAL FINISHED 470.8 2 grams
WEIGHT (16.607 .0706 ounces)
REMOVAL
(1) Remove the engi ne from the vehi cl e (Refer to 9
- ENGI NE - REMOVAL).
(4) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pi stons covered
duri ng thi s operati on.
(5) Be sure each connecti ng rod and connecti ng rod
cap i s i denti fi ed wi th the cyl i nder number. Remove
connecti ng rod cap. I nstal l connecti ng rod bol t gui de
set on connecti ng rod bol ts.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. When removi ng the
assembl i es from the engi ne, rotate crankshaft so that
the connecti ng rod i s centered i n cyl i nder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
CLEANING
Fig. 38 Piston Measurements
1 - 49.53 mm
(1.95 IN.)
AN ENGINE 5. 9L 9 - 249
INSPECTION
i ng.
INSTALLATION
(1) Be sure that compressi on ri ng gaps are stag-
gered so that nei ther i s i n l i ne wi th oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, be sure
the oi l ri ng expander ends are butted and the rai l
gaps l ocated properl y (Fi g. 39) .
engi ne oi l . Sl i de Pi ston Ri ng Compressor Tool C-385
over the pi ston and ti ghten wi th the speci al wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts. The l ong protector shoul d be i nstal l ed on the
numbered si de of the connecti ng rod.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. Be sure
connecti ng rod and cyl i nder bore number are the
same. I nsert rod and pi ston i nto cyl i nder bore and
gui de rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on crankshaft journal .
(7) The notch, or groove, on top of pi ston must be
poi nti ng toward front of engi ne. The l arger chamfer
of the connecti ng rod bore must be i nstal l ed toward
crankshaft journal fi l l et.
(8) I nstal l rod caps. Be sure connecti ng rod, con-
necti ng rod cap, and cyl i nder bore number are the
same. I nstal l nuts on cl eaned and oi l ed rod bol ts and
ti ghten nuts to 61 Nm (45 ft. l bs.) torque.
(10) I nstal l the cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
(11) I nstal l the engi ne i nto the vehi cl e (Refer to 9 -
ENGI NE - I NSTALLATI ON).
PISTON RINGS
FITTING
(1) Measurement of end gaps:
(a) Measure pi ston ri ng gap 2 i n. from bottom of
cyl i nder bore. An i nverted pi ston can be used to
push the ri ngs down to ensure posi ti oni ng ri ngs
squarel y i n the cyl i nder bore before measuri ng.
(b) I nsert feel er gauge i n the gap. The top com-
pressi on ri ng gap shoul d be between 0.254-0.508
mm (0.010-0.020 i n.). The second compressi on ri ng
gap shoul d be between 0.508-0.762 mm
(0.020-0.030 i n.). The oi l ri ng gap shoul d be 0.254-
1.270 mm (0.010-0.050 i n.).
(c) Ri ngs wi th i nsuffi ci ent end gap may be prop-
erl y fi l ed to the correct di mensi on. Ri ngs wi th
excess gaps shoul d not be used.
(2) I nstal l ri ngs, and confi rm ri ng si de cl earance:
(a) I nstal l oi l ri ngs bei ng careful not to ni ck or
scratch the pi ston. I nstal l the oi l control ri ngs
accordi ng to i nstructi ons i n the package. I t i s not
necessary to use a tool to i nstal l the upper and
l ower rai l s. I nsert oi l rai l spacer fi rst, then si de
rai l s.
(b) I nstal l the second compressi on ri ngs usi ng
I nstal l ati on Tool C-4184. The compressi on ri ngs
must be i nstal l ed wi th the i denti fi cati on mark face
up (toward top of pi ston) and chamfer faci ng down.
An i denti fi cati on mark on the ri ng i s a dri l l poi nt,
a stamped l etter O, an oval depressi on, or the
word TOP (Fi g. 40) (Fi g. 42).
(c) Usi ng a ri ng i nstal l er, i nstal l the top com-
pressi on ri ng wi th the chamfer faci ng up (Fi g. 41)
(Fi g. 42). An i denti fi cati on mark on the ri ng i s a
dri l l poi nt, a stamped l etter O, an oval depressi on
or the word TOP faci ng up.
(TOP)
9 - 250 ENGINE 5. 9L AN
(d) Measure si de cl earance between pi ston ri ng
and ri ng l and. Cl earance shoul d be 0.074-0.097 mm
(0.0029-0.0038 i n.) for the compressi on ri ngs. The
steel rai l oi l ri ng shoul d be free i n groove, but
shoul d not exceed 0.246 mm (0.0097 i n.) si de cl ear-
ance.
(e) Pi stons wi th i nsuffi ci ent, or excessi ve, si de
cl earance shoul d be repl aced.
(3) Ori ent the ri ngs:
(a) Arrange top compressi on ri ng 90 counter-
cl ockwi se from the oi l ri ng rai l gap (Fi g. 43).
(b) Arrange second compressi on ri ng 90 cl ock-
wi se from the oi l ri ng rai l gap (Fi g. 43).
VIBRATION DAMPER
REMOVAL
(2) Remove the cool i ng system fan (Refer to 7 -
CLUTCH - REMOVAL).
REMOVAL).
(4) Remove vi brati on damper bol t and washer from
end of crankshaft.
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS
Fig. 41 Top Compression Ring Identification
(Typical)
1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT
(Typical)
1 - CHAMFER
4 - PISTON
5 - CHAMFER
(TOP)
AN ENGINE 5. 9L 9 - 251
(5) Posi ti on Speci al Tool 8513 I nsert i nto the
crankshaft nose.
(6) I nstal l Speci al Tool 1026 Three Jaw Pul l er onto
the vi brati on damper (Fi g. 44).
(7) Pul l vi brati on damper off of the crankshaft.
INSTALLATION
CAUTION: Thoroughly remove any contaminants
from the crankshaft nose and the vibration damper
bore. Failure to do so can cause sever damage to
the crankshaft.
(1) Posi ti on the vi brati on damper onto the crank-
shaft.
(2) Pl ace i nstal l i ng tool , part of Pul l er Tool Set
C-3688 i n posi ti on and press the vi brati on damper
onto the crankshaft (Fi g. 45).
(3) I nstal l the crankshaft bol t and washer. Ti ghten
the bol t to 244 Nm (180 ft. l bs.) torque.
I NSTALLATI ON).
Ti ghten the retai ner bol ts to 11 Nm (95 i n. l bs.) torque.
(6) I nstal l the cool i ng fan (Refer to 7 - COOLI NG/
ENGI NE/FAN DRI VE VI SCOUS CLUTCH -
I NSTALLATI ON).
FRONT MOUNT
REMOVAL
2WD
(2) Rai se hood and posi ti on fan to assure cl earance
for radi ator top tank and hose.
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(5) Remove the i nsul ator through bol t (Fi g. 46)
(Fi g. 47).
(6) Rai se engi ne wi th l i fti ng fi xture SLI GHTLY.
Remove i nsul ator retai ni ng bol ts and remove the
i nsul ator assembl y.
(7) Remove i nsul ator heat shi el d and transfer to
new i nsul ator.
Fig. 44 Vibration Damper Removal
Fig. 45 Vibration Damper Installation
Fig. 46 Engine Right Front Insulator Mount2WD
Vehicles
1 - HEAT SHIELD
2 - INSULATOR
9 - 252 ENGINE 5. 9L AN
4WD
On 4WD vehi cl es the engi ne front support brackets
attach di rectl y to engi ne bl ock and the axl e housi ng.
The brackets provi de a sol i d i nterconnecti on for these
uni ts (Fi g. 49) (Fi g. 50). Engi ne must be supported
duri ng any servi ce procedures i nvol vi ng the front
support assembl i es.
(3) I nstal l engi ne l i fti ng (support) fi xture.
(4) Remove front axl e (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/FRONT AXLE - C205F -
REMOVAL).
(5) Left mount insulator only. Remove starter
wi res and starter motor assembl y (Refer to 8 - ELEC-
TRI CAL/STARTI NG/STARTER MOTOR - REMOV-
AL).
(6) Remove i nsul ator to frame through bol t (Fi g.
51).
(8) Remove upper i nsul ator to support bracket
stud nut and i nsul ator to support through bol t.
(9) Remove engi ne mount i nsul ator (Fi g. 49) (Fi g.
50).
(10) I f engi ne support bracket i s to be removed/re-
pl aced, remove support bracket to transmi ssi on bel l
housi ng bol t(s) and three (3) support bracket to
engi ne bl ock bol ts. Remove support bracket (Fi g. 49)
(Fi g. 50).
INSTALLATION
2WD
(1) Wi th the engi ne rai sed SLI GHTLY, posi ti on
i nsul ator assembl y onto the engi ne bl ock and i nstal l
bol ts (Fi g. 46) (Fi g. 47). Ti ghten the bol ts to 41 Nm
(2) Lower engi ne wi th l i fti ng fi xture whi l e gui di ng
i nsul ator assembl y i nto the engi ne i nsul ator bracket
(Fi g. 48).
(3) I nstal l i nsul ator to bracket thru-bol t. Ti ghten
the thru-bol t nut to 68 Nm (50 ft. l bs.) torque.
(4) Remove l i fti ng fi xture.
4WD
(1) I f engi ne support brackets were removed,
i nstal l them and thei r fasteners (Fi g. 49) (Fi g. 50) .
Ti ghten support bracket to bl ock bol ts to 41 Nm (30
ft. l bs.). Ti ghten support bracket to transmi ssi on bel l -
housi ng bol t(s) to 88 Nm (65 ft. l bs.).
(2) I nstal l Engi ne mount i nsul ator and ti ghten
i nsul ator to support bracket nut to 41 Nm (30 ft.
l bs.). Ti ghten i nsul ator to support bracket through
bol t nut to 102 Nm (75 ft. l bs.).
Fig. 47 Engine Left Front Insulator
1 - HEAT SHIELD
2 - INSULATOR
Fig. 48 Engine Mount Insulator at Frame
1 - NUT
2 - INSULATOR
3 - FRAME
4 - THROUGH BOLT
AN ENGINE 5. 9L 9 - 253
(3) Lower engi ne and i nstal l i nsul ator to frame
through bol t and nut (Fi g. 51). Ti ghten nut to 95 Nm
(70 ft. l bs.).
TI ON).
(5) Connect starter wi res.
(6) Remove engi ne l i fti ng (support) fi xture.
(7) I nstal l front axl e assembl y (Refer to 3 - DI F-
- I NSTALLATI ON).
REAR MOUNT
REMOVAL
2WD
(3) Support the transmi ssi on wi th a jack.
(4) Remove engi ne support bracket and i nsul ator
thru-bol t (Fi g. 52).
(5) Rai se the transmi ssi on and engi ne sl i ghtl y.
(6) Remove stud nuts attachi ng i nsul ator to cross-
4WD
(3) Support the transmi ssi on wi th a transmi ssi on
jack.
(4) Remove stud nuts hol di ng the i nsul ator to the
(5) Rai se rear of transmi ssi on SLI GHTLY.
(6) Remove bol ts hol di ng the i nsul ator to the i nsu-
l ator bracket (Fi g. 53). Remove the i nsul ator.
INSTALLATION
2WD
(1) I f the engi ne support bracket was removed,
posi ti on the bracket to the transmi ssi on extensi on
(Fi g. 52). Ti ghten the bol ts to 68 Nm (50 ft. l bs.)
torque.
(2) I nstal l the i nsul ator onto crossmember. Ti ghten
the stud nuts to 41 Nm (30 ft. l bs.) torque.
Fig. 49 Right Engine Mount Insulator and Support
Bracket4WD Vehicles
2 - INSULATOR
3 - FRONT AXLE
Fig. 50 Left Engine Mount Insulator and Support
Bracket4WD Vehicles
2 - INSULATOR
3 - FRONT AXLE
9 - 254 ENGINE 5. 9L AN
(3) Lower the transmi ssi on and engi ne whi l e al i gn-
i ng the engi ne support bracket to the i nsul ator.
(4) I nstal l thru-bol t i n bracket and i nsul ator.
Ti ghten thru-bol t nut to 68 Nm (50 ft. l bs.) torque.
4WD
(1) I f the i nsul ator bracket was removed, i nstal l
the bracket to the transmi ssi on (Fi g. 53). Ti ghten the
bol ts to 28 Nm (250 i n. l bs.) torque.
(2) I nstal l the bol ts hol di ng i nsul ator to i nsul ator
bracket. Ti ghten the bol ts to 28 Nm (250 i n. l bs.)
torque.
(3) Lower rear of transmi ssi on whi l e al i gni ng the
I nstal l stud nuts and ti ghten to 28 Nm (250 i n. l bs.)
torque.
(4) Remove the transmi ssi on jack.
LUBRICATION
DESCRIPTION
A gear-type posi ti ve di spl acement pump (Fi g. 54) i s
mounted at the undersi de of the rear mai n beari ng
cap. The pump uses a pi ck-up tube and screen
assembl y to gather engi ne oi l from the oi l pan.
OPERATION
channel s the oi l up to the mai n gal l ery, whi ch
extends the enti re l ength on the ri ght si de of the
bl ock. The oi l then goes down to the No. 1 mai n bear-
i ng, back up to the l eft si de of the bl ock, and i nto the
oi l gal l ery on the l eft si de of the engi ne.
Fig. 51 Engine Mount Insulator at Frame4WD
Vehicles
1 - NUT
3 - INSULATOR
4 - NUT
5 - THROUGH BOLT
6 - FRAME
7 - FRONT AXLE
Fig. 52 Rear Insulator2WD Vehicles
2 - THROUGH BOLT
3 - CROSSMEMBER
4 - INSULATOR
AN ENGINE 5. 9L 9 - 255
mai n beari ng journal s to the connecti ng rod journal s.
Each connecti ng rod beari ng has hal f a hol e i n i t, oi l
passes through the hol e when the rods rotate and the
hol e l i nes up, oi l i s then thrown off as the rod
rotates. Thi s oi l throwoff l ubri cates the camshaft
l obes, di stri butor dri ve gear, cyl i nder wal l s, and pi s-
ton pi ns.
from the mai n oi l gal l ery. The camshaft beari ngs
recei ve oi l from the mai n beari ng gal l eri es. The front
camshaft beari ng journal passes oi l through the cam-
shaft sprocket to the ti mi ng chai n. Oi l drai ns back to
the oi l pan under the No. 1 mai n beari ng cap.
tappets, whi ch pass oi l through hol l ow push rods to a
rocker arm l ubri cates the val ve trai n components.
The oi l then passes down through the push rod gui de
hol es and the oi l drai n-back passages i n the cyl i nder
head, past the val ve tappet area, and then returns to
the oi l pan (Fi g. 55).
LEAKS
ni ppl e.
Fig. 53 Rear Insulator4WD Vehicles
2 - INSULATOR BRACKET
3 - INSULATOR
4 - CROSSMEMBER
Fig. 54 Positive Displacement Oil PumpTypical
2 - BODY
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
9 - 256 ENGINE 5. 9L AN
Fig. 55 Oil Lubrication System
1 - OIL DEFLECTOR TAB
2 - BOLT
3 - ROCKER ARM PIVOT
4 - ROCKER ARM
5 - DRIP OILING FOR VALVE TIP
6 - CYLINDER HEAD BOSS
7 - TO MAIN BEARINGS
8 - TO CAMSHAFT BEARINGS
9 - ROCKER ARM
10 - HOLLOW PUSH ROD
11 - TAPPET
12 - TO CONNECTING ROD BEARINGS
13 - OIL INTAKE
14 - OIL PUMP
15 - OIL FILTER
16 - CRANKSHAFT
17 - FROM OIL PUMP
18 - OIL TO FILTER
20 - PASSAGE TO CAMSHAFT REAR BEARING
22 - PLUG
23 - OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT
24 - OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM
OIL GALLERY METERED THROUGH HYDRAULIC TAPPET
25 - OIL SUPPLY FROM HOLLOW PUSH ROD
AN ENGINE 5. 9L 9 - 257
procedures.
Leak.
to next step.
PRESSURE
OIL
tube.
di psti ck.
ENGINE OIL CHANGE
perature.
engi ne off.
drai n.
gasket i f damaged.
3 - DIPSTICK
5 - FILTER BOSS
9 - 258 ENGINE 5. 9L AN
OIL FILTER
REMOVAL
fi l ter be used.
ter from vehi cl e.
INSTALLATION
OIL PAN
REMOVAL
2WD
(3) Di sconnect di stri butor cap and posi ti on away
from cowl .
(6) Remove engi ne mount i nsul ator through bol ts.
(7) Rai se engi ne by way of oi l pan usi ng a bl ock of
wood between the jack and oi l pan.
(8) When engi ne i s hi gh enough, pl ace mount
through bol ts i n the engi ne mount attachi ng poi nts
on the frame brackets.
(9) Lower engi ne so bottom of engi ne mounts rest
on the repl acement bol ts pl aced i n the engi ne mount
frame brackets.
(10) Remove oi l pan and one-pi ece gasket.
4WD
(5) Remove front dri vi ng axl e (Refer to 3 - DI F-
- REMOVAL).
(6) Remove both engi ne mount support brackets
(Refer to 9 - ENGI NE/ENGI NE MOUNTI NG/FRONT
MOUNT - REMOVAL).
(7) Remove transmi ssi on i nspecti on cover.
(8) Remove oi l pan and one-pi ece gasket.
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
AN ENGINE 5. 9L 9 - 259
OIL (Continued)
CLEANING
engi ne.
cl oth.
INSPECTION
INSTALLATION
2WD
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
60).
Adhesi ve Seal ant, or equi val ent i n the corner of the
onto the bl ock.
the gasket.
torque.
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
(9) Rai se engi ne by way of oi l pan wi th a wood
bl ock pl aced between jack and oi l pan.
(10) Remove temporary bol ts from frame brackets
and l ower engi ne. I nstal l mount i nsul ator through
bol ts and ti ghten to 95 Nm (70 ft. l bs.).
(12) Connect the di stri butor cap.
4WD
(1) Fabri cate 4 al i gnment dowel s from 1 1/2 x 5/16
60).
Adhesi ve Seal ant, or equi val ent i n the corner of the
onto the bl ock.
the gasket.
1 - 1 1/2 x 5/16 BOLT
2 - DOWEL
3 - SLOT
1 - DOWEL
2 - DOWEL
3 - DOWEL
4 - DOWEL
9 - 260 ENGINE 5. 9L AN
OIL PAN (Continued)
torque.
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
(9) I nstal l transmi ssi on i nspecti on cover.
(10) I nstal l engi ne mount support brackets and
i nsul ators (Refer to 9 - ENGI NE/ENGI NE MOUNT-
I NG/FRONT MOUNT - I NSTALLATI ON).
(11) I nstal l front dri vi ng axl e (Refer to 3 - DI F-
- I NSTALLATI ON).
(12) Lower vehi cl e
(13) Connect the di stri butor cap.
OIL PUMP
REMOVAL
(2) Remove the oi l pump from rear mai n beari ng
cap.
DISASSEMBLY
(1) Remove the rel i ef val ve as fol l ows:
(a) Remove cotter pi n. Dri l l a 3.175 mm (1/8
i nch) hol e i nto the rel i ef val ve retai ner cap and
i nsert a sel f-threadi ng sheet metal screw.
(b) Cl amp screw i nto a vi se and whi l e support-
i ng oi l pump, remove cap by tappi ng pump body
usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 61).
(2) Remove oi l pump cover (Fi g. 62).
(3) Remove pump outer rotor and i nner rotor wi th
shaft (Fi g. 62).
INSPECTION
Mati ng surface of the oi l pump cover shoul d be
smooth. Repl ace pump assembl y i f cover i s scratched
or grooved.
Lay a strai ghtedge across the pump cover surface
(Fi g. 63). I f a 0.038 mm (0.0015 i nch) feel er gauge
can be i nserted between cover and strai ghtedge,
pump assembl y shoul d be repl aced.
Measure thi ckness and di ameter of OUTER rotor.
I f outer rotor thi ckness measures 20.9 mm (0.825
i nch) or l ess or i f the di ameter i s 62.7 mm (2.469
i nches) or l ess, repl ace outer rotor (Fi g. 64).
I f i nner rotor measures 20.9 mm (0.825 i nch) or
l ess, repl ace i nner rotor and shaft assembl y (Fi g. 65).
Sl i de outer rotor i nto pump body. Press rotor to the
si de wi th your fi ngers and measure cl earance
between rotor and pump body (Fi g. 66). I f cl earance
i s 0.356 mm (0.014 i nch) or more, repl ace oi l pump
assembl y.
Fig. 61 Oil Pressure Relief Valve
1 - OIL PUMP ASSEMBLY
2 - COTTER PIN
3 - RELIEF VALVE
4 - RETAINER CAP
5 - SPRING
Fig. 62 Oil Pump
2 - BODY
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
AN ENGINE 5. 9L 9 - 261
OIL PAN (Continued)
I nstal l i nner rotor and shaft i nto pump body. I f
cl earance between i nner and outer rotors i s 0.203
mm (0.008 i nch) or more, repl ace shaft and both
rotors (Fi g. 67).
1 - COVER
2 - STRAIGHT EDGE
3 - FEELER GAUGE
Housing
1 - PUMP BODY
2 - OUTER ROTOR
3 - FEELER GAUGE
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
9 - 262 ENGINE 5. 9L AN
Pl ace a strai ghtedge across the face of the pump,
between bol t hol es. I f a feel er gauge of 0.102 mm
(0.004 i nch) or more can be i nserted between rotors
and the strai ghtedge, repl ace pump assembl y (Fi g.
68).
I nspect oi l pressure rel i ef val ve pl unger for scori ng
and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
The rel i ef val ve spri ng has a free l ength of approx-
i matel y 49.5 mm (1.95 i nches). The spri ng shoul d
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 i nches). Repl ace spri ng that fai l s
to meet these speci fi cati ons (Fi g. 69).
I f oi l pressure was l ow and pump i s wi thi n speci fi -
cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
ASSEMBLY
(1) I nstal l pump rotors and shaft, usi ng new parts
as requi red.
(2) Posi ti on the oi l pump cover onto the pump
body. Ti ghten cover bol ts to 11 Nm (95 i n. l bs.)
torque.
(3) I nstal l the rel i ef val ve and spri ng. I nsert the
cotter pi n.
(4) Tap on a new retai ner cap.
INSTALLATION
(1) I nstal l oi l pump. Duri ng i nstal l ati on sl owl y
rotate pump body to ensure dri veshaft-to-pump rotor
shaft engagement.
(2) Hol d the oi l pump base fl ush agai nst mati ng
surface on No.5 mai n beari ng cap. Fi nger ti ghten
pump attachi ng bol ts. Ti ghten attachi ng bol ts to 41
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds (Fi g. 70) are constructed of
cast i ron and are LOG type wi th bal anced fl ow. One
exhaust mani fol d i s attached to each cyl i nder head.
OPERATION
The exhaust mani fol ds col l ect the engi ne exhaust
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 69 Proper Installation of Retainer Cap
1 - RETAINER CAP
2 - CHAMFER
3 - COTTER KEY
Fig. 70 Exhaust ManifoldsV-8 Gas Engines Typical
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
5 - BOLTS & WASHERS
AN ENGINE 5. 9L 9 - 263
exhaust gases to the exhaust pi pes attached to the
mani fol ds.
REMOVAL
(3) Remove the exhaust pi pe to mani fol d nuts.
(5) Remove three nuts, heat shi el d and washers
from the ri ght si de exhaust mani fol d, i f necessary
(Fi g. 71).
(6) Remove two nuts, heat shi el d and washers
from the l eft si de exhaust mani fol d, i f necessary (Fi g.
72).
(7) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(8) Remove mani fol d from the cyl i nder head.
CLEANING
fol d. Wash wi th sol vent and bl ow dry wi th com-
pressed ai r.
INSPECTION
wi th a strai ght edge. Gasket surfaces must be fl at
wi thi n 0.2 mm per 300 mm (0.008 i nch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the exhaust manifold, install new studs.
(1) Posi ti on the exhaust mani fol ds on the two
studs l ocated on the cyl i nder head. I nstal l coni cal
washers and nuts on these studs (Fi g. 73).
(2) I nstal l new bol t and washer assembl i es i n the
remai ni ng hol es (Fi g. 73). Start at the center arm
and work outward. Ti ghten the bol ts and nuts to 24
(3) Posi ti on three washers, heat shi el d and nuts on
the ri ght si de exhaust mani fol d. Ti ghten nuts to 24
Nm (18 ft. l bs.).
(4) Posi ti on two washers, heat shi el d and nuts on
the l eft si de exhaust mani fol d. Ti ghten nuts to 24
Nm (18 ft. l bs.).
Fig. 71 Exhaust Manifold Heat ShieldRight Side
1 - WASHER
2 - NUT AND WASHER
3 - EXHAUST MANIFOLD HEAT SHIELD
Fig. 72 Exhaust Manifold Heat ShieldLeft Side
1 - WASHER
2 - NUT AND WASHER
3 - EXHAUST MANIFOLD HEAT SHIELD
Fig. 73 Exhaust Manifold Installation5.9L Engine
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
5 - BOLTS & WASHERS
9 - 264 ENGINE 5. 9L AN
(6) Assembl e the exhaust pi pe to the exhaust man-
i fol d and secure wi th bol ts, nuts and washers.
Ti ghten these nuts to 27 Nm (20 ft. l bs.) torque.
INTAKE MANIFOLD
DESCRIPTION
The al umi num i ntake mani fol d (Fi g. 74) i s a si ngl e
pl ane desi gn wi th equal l ength runners and uses a
separate pl enum, therefore the mani fol d does have a
pl enum gasket. I t al so uses separate fl ange gaskets
and front and rear cross-over gaskets. Extreme care
must be used when seal i ng the gaskets to ensure
that excess seal ant does not enter the i ntake runners
causi ng a restri cti on. Whenever the i ntake mani fol d
i s removed i nspect the pl enum pan for evi dence of
excess oi l bui l dup, thi s condi ti on i ndi cates that the
pl enum pan gasket i s l eaki ng.
OPERATION
The i ntake mani fol d, meters and del i vers ai r to the
combusti on chambers al l owi ng the fuel del i vered by
the fuel i njectors to i gni te, thus produci ng power.
MANIFOLD LEAKAGE
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
l eak area.
(3) I f a change i n RPMs occurs, the area of the
REMOVAL
(3) Remove the A/C compressor (Refer to 24 -
COMPRESSOR - REMOVAL).
(5) Remove the accessory dri ve bracket.
(7) Perform the Fuel System Pressure rel ease pro-
fuel l i nes (Refer to 14 - FUEL SYSTEM/FUEL
DARD PROCEDURE).
CONTROL CABLE - REMOVAL) and i f so equi pped,
the speed control and transmi ssi on ki ckdown cabl es.
(9) Remove the return spri ng.
(10) Remove the di stri butor cap and wi res.
(12) Di sconnect the heat i ndi cator sendi ng uni t
wi re.
(13) Di sconnect the heater hoses and bypass hose.
(14) Remove the cl osed crankcase venti l ati on and
evaporati on control systems.
(15) Remove i ntake mani fol d bol ts.
(16) Li ft the i ntake mani fol d and throttl e body out
of the engi ne compartment as an assembl y.
(17) Remove and di scard the fl ange si de gaskets
and the front and rear end seal s.
(18) Remove the throttl e body bol ts and l i ft the
throttl e body off the i ntake mani fol d (Fi g. 75). Di s-
card the gasket.
Fig. 74 Intake Manifold and Throttle BodyV-8 Gas
Engines Typical
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
AN ENGINE 5. 9L 9 - 265
(19) I f requi red, remove the pl enum pan and gas-
ket. Di scard gasket.
CLEANING
Cl ean mani fol d i n sol vent and bl ow dry wi th com-
pressed ai r.
The pl enum pan rai l must be cl ean and dry (free of
al l forei gn materi al ).
INSPECTION
wi th a strai ghtedge.
INSTALLATION
(1) I f removed, posi ti on new pl enum gasket and
i nstal l pl enum pan (Fi g. 76).
(2) Ti ghten pl enum pan mounti ng bol ts as fol l ows:
Step 3. Check al l bol ts are at 9.5 Nm (84 i n.
l bs.)
(3) I nstal l the fl ange gaskets. Ensure that the ver-
ti cal port al i gnment tab i s resti ng on the deck face of
the bl ock. Al so the hori zontal al i gnment tabs must be
i n posi ti on wi th the mati ng cyl i nder head gasket tabs
(Fi g. 78). The words MANI FOLD SI DE shoul d be vi s-
i bl e on the center of each fl ange gasket.
(4) Appl y Mopar GEN I I Si l i cone Rubber Adhesi ve
Seal ant, or equi val ent, to the four corner joi nts. An
excessi ve amount of seal ant i s not requi red to ensure
a l eak proof seal . However, an excessi ve amount of
seal ant may reduce the effecti veness of the fl ange gas-
ket. The seal ant shoul d be approxi matel y 5 mm (0.2
i n) i n di ameter and 15mm (0.6i n) l ong.
(5) I nstal l the front and rear end seal s (Fi g. 77).
Make sure the mol ded dowel pi ns on the end seal s
ful l y enter the correspondi ng hol es i n the cyl i nder
bl ock.
(6) Careful l y l ower i ntake mani fol d i nto posi ti on
on the cyl i nder bl ock and cyl i nder heads. After i ntake
mani fol d i s i n pl ace, i nspect to make sure seal s are
i n pl ace.
(7) Usi ng a new gasket, i nstal l the throttl e body
onto the i ntake mani fol d. Ti ghten the bol ts to 23 Nm
(8) I nstal l the i ntake mani fol d bol ts and ti ghten as
fol l ows (Fi g. 79):
i n. l bs.) Ti ghten i n al ternati ng steps 1.4 Nm (12 i n.
l bs.) at a ti me
i n. l bs.)
Step 3. Check al l bol ts are torqued to 8 Nm (72
i n. l bs.)
Step 4. Ti ghten al l bol ts i n sequence to 16 Nm
(12 ft. l bs.)
Step 5. Check al l bol ts are torqued to 16 Nm
(12 ft. l bs.)
(9) I nstal l cl osed crankcase venti l ati on and evapo-
rati on control systems.
Fig. 75 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
Fig. 76 Plenum Pan Bolt Tightening Sequence
9 - 266 ENGINE 5. 9L AN
(10) Connect the coi l wi res.
(11) Connect the heat i ndi cator sendi ng uni t wi re.
(14) Hook up the return spri ng.
CONTROL CABLE - I NSTALLATI ON) and i f so
down cabl es.
(16) I nstal l the fuel l i nes (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/QUI CK CONNECT FI T-
TI NG - STANDARD PROCEDURE).
(17) I nstal l the accessory dri ve bracket and A/C
compressor (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/A/C COMPRESSOR -
I NSTALLATI ON).
(18) I nstal l the generator and dri ve bel t (Refer to 7
- COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON). Ti ghten generator mounti ng bol t
Fig. 77 Front and End Rear Seals
1 - FRONT END SEAL
2 - REAR END SEAL
Fig. 78 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 79 Intake Manifold Bolt Tightening Sequence
AN ENGINE 5. 9L 9 - 267
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(3) Remove the serpenti ne bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - REMOV-
AL).
(4) Remove water pump (Refer to 7 - COOLI NG/
ENGI NE/WATER PUMP - REMOVAL).
(5) Remove power steeri ng pump (refer to Steer-
i ng).
REMOVAL).
(7) Remove fuel l i nes (refer to Fuel System).
(8) Loosen oi l pan bol ts and remove the front bol t
at each si de.
(9) Remove the cover bol ts.
(10) Remove chai n case cover and gasket usi ng
extreme cauti on to avoi d damagi ng oi l pan gasket.
damage the crankshaft seal surface of cover (Fi g. 80).
INSTALLATION
(1) Be sure mati ng surfaces of chai n case cover
and cyl i nder bl ock are cl ean and free from burrs.
(2) The water pump mounti ng surface must be
cl eaned.
(3) Usi ng a new cover gasket, careful l y i nstal l
chai n case cover to avoi d damagi ng oi l pan gasket.
Use a smal l amount of Mopar GEN I I Si l i cone Rub-
ber Adhesi ve Seal ant, or equi val ent, at the joi nt
between ti mi ng chai n cover gasket and the oi l pan
gasket. Fi nger ti ghten the ti mi ng chai n cover bol ts at
thi s ti me.
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 81). Seat
(Fi g. 82).
(6) Ti ghten the 4 l ower chai n case cover bol ts to
13Nm (10 ft.l bs.) to prevent the cover from ti ppi ng
duri ng seal i nstal l ati on.
(Fi g. 83).
Fig. 80 Removal of Front Crankshaft Oil Seal
2 - OIL SEAL
9 - 268 ENGINE 5. 9L AN
(8) Loosen the 4 bol ts ti ghtened i n step 4 to al l ow
real i gnment of front cover assembl y.
(9) Ti ghten chai n case cover bol ts to 41 Nm (30 ft.
l bs.) torque. Ti ghten oi l pan bol ts to 24 Nm (215 i n.
l bs.) torque.
(11) I nstal l vi brati on damper (Refer to 9 -
I NSTALLATI ON).
(12) I nstal l water pump (Refer to 7 - COOLI NG/
ENGI NE/WATER PUMP - I NSTALLATI ON).
(13) I nstal l power steeri ng pump (refer to Steer-
i ng).
LATI ON).
(15) I nstal l the cool i ng system fan (Refer to 7 -
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
SPROCKETS
REMOVAL
(2) Remove Ti mi ng Chai n Cover (Refer to 9 -
(3) Re-i nstal l the vi brati on damper bol t fi nger
ti ght. Usi ng a sui tabl e socket and breaker bar, rotate
the crankshaft to al i gn ti mi ng marks as shown i n
(Fi g. 84).
(4) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
1 - TIMING MARKS
AN ENGINE 5. 9L 9 - 269
INSTALLATION
sprocket on the bench wi th ti mi ng marks on exact
crankshaft bores.
(3) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 85).
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
(7) Check camshaft end pl ay. The end pl ay shoul d
be 0.051-0.152 mm (0.002-0.006 i nch) wi th a new
thrust pl ate and up to 0.254 mm (0.010 i nch) wi th a
used thrust pl ate. I f not wi thi n these l i mi ts i nstal l a
new thrust pl ate.
1 - TIMING MARKS
9 - 270 ENGINE 5. 9L AN
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4
CATALYTIC CONVERTER - 2.5L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CATALYTIC CONVERTER - 3.9L/5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST PIPE - 2.5L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST PIPE - 3.9L AND 5.9L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EXHAUST PIPE - 4.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HEAT SHIELDS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INTERMEDIATE PIPE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MUFFLER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TAILPIPE - 2.5L/3.9L/4.7L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TAILPIPE - 5.9L
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EXHAUST SYSTEM
DESCRIPTION EXHAUST SYSTEM 2. 5L
ENGINE
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The gasol i ne engi ne exhaust system consi sts of
engi ne exhaust mani fol ds, exhaust pi pes, catal yti c
converter(s), extensi on pi pe (i f needed), exhaust heat
shi el ds, muffl er and exhaust tai l pi pe.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. Mi ni mum
cl earance between any exhaust component and the
body or frame i s 25.4 mm (1.0 i n.). I f the system con-
tacts any body panel , i t may ampl i fy objecti onabl e
noi ses from the engi ne or body (Fi g. 1).
DESCRIPTION EXHAUST SYSTEM 3. 9L/4. 7L
AND 5. 9L ENGINES
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
AN EXHAUST SYSTEM 11 - 1
The gasol i ne engi ne exhaust system consi sts of
engi ne exhaust mani fol ds, exhaust pi pes, catal yti c
converter(s), extensi on pi pe (i f needed), exhaust heat
shi el ds, muffl er and exhaust tai l pi pe.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. Mi ni mum
cl earance between any exhaust component and the
body or frame i s 25.4 mm (1.0 i n.). I f the system con-
tacts any body panel , i t may ampl i fy objecti onabl e
noi ses from the engi ne or body (Fi g 2).
Fig. 1 Exhaust System 2.5L EnginesTypical
1 - TAILPIPE
2 - MUFFLER
3 - MUFFLER HANGER BRACKET AND ISOLATOR
4 - CLAMP
5 - EXHAUST PIPE
6 - CATALYTIC CONVERTER
7 - EXTENSION PIPE
8 - MUFFLER HEAT SHIELD
Fig. 2 Exhaust System 3.9L, 4.7L and 5.9L EnginesTypical
1 - TAILPIPE
2 - MUFFLER HANGER BRACKET AND ISOLATOR
3 - CLAMP
4 - EXHAUST PIPE
6 - EXTENSION PIPE
11 - 2 EXHAUST SYSTEM AN
EXHAUST SYSTEM (Continued)
DIAGNOSIS AND TESTING EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps to specified
torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).
2. Burned or blown out muffler. 2. Replace muffler assembly (Refer
to 11 - EXHAUST SYSTEM/
MUFFLER - REMOVAL). Check
exhaust system.
3. Burned or rusted-out exhaust
pipe.
3. Replace exhaust pipe (Refer to
11 - EXHAUST SYSTEM/EXHAUST
PIPE - REMOVAL).
4. Exhaust pipe leaking at manifold
flange.
4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).
7. Restriction in muffler or tailpipe. 7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Exhaust system contacting body
or chassis.
8. Re-align exhaust system to clear
surrounding components.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking
joints (Refer to 11 - EXHAUST
SYSTEM - SPECIFICATIONS).
SPECIFICATIONS
TORQUE
Lbs. Lbs.
EGR TubeBolts 23 17
Exhaust ClampsNuts 41 30
Exhaust Pipe to Manifold
Nuts
26 19
Heat ShieldNuts
Floor Pan/Dash Panel 6 55
Floor Pan (All Except 4 Door
Cab)
7 60
Floor Pan (4 Door Cab) 5 45
Electrical Connector (45RFE
Trans.)
20 175
Heat ShieldScrews
Floor Pan 22 16
Muffler 22 16
Tail Pipe 22 16
Center Bearing 22 16
Muffler HangerScrews 22 16
Tail Pipe HangerScrews 22 16
DESCRIPTION
Cal i forni a emi ssi ons vehi cl es i ncorporate mi ni cat-
al yti c converters i nto the exhaust system. These cat-
al yti c converters are made of stai nl ess steel desi gned
to operate at extremel y hi gh temperatures.
OPERATION
The catal yti c converter captures and burns any
unburned fuel mi xture exi ti ng the combusti on cham-
bers duri ng the exhaust stroke of the engi ne. Thi s
process ai ds i n reduci ng emi ssi ons output.
REMOVAL
CAUTION: When servicing or replacing exhaust
system components, disconnect the oxygen sensor
connector(s). Allowing the exhaust to hang by the
oxygen sensor wires will damage the harness
and/or sensor.
(2) Saturate the bol ts and nuts wi th Mopar Rust
Penetrant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the cl amp hol di ng the catal yti c con-
verter fl ange to the exhaust pi pe(s) (Fi g. 3).
verter fl ange to the muffl er or extensi on pi pe .
(5) Remove the rear engi ne mount.(Refer to 9 -
ENGI NE/ENGI NE MOUNTI NG/REAR MOUNT -
REMOVAL)
(6) Remove the crossmember.
(7) Remove the catal yti c converter. You may have
to l oosen up other secti ons of the exhaust system.
INSPECTION
Look at the stai nl ess steel body of the converter,
i nspect for bul gi ng or other di storti on that coul d be a
resul t of overheati ng. I f the converter has a heat
shi el d attached make sure i t i s not bent or l oose.
I f you suspect i nternal damage to the catal yst, tap-
pi ng the bottom of the catal yst wi th a rubber mal l et
may i ndi cate a damaged core.
Fig. 3 Catalytic Converter2.5L Engine
1 - EXHAUST PIPE
2 - CATALYTIC CONVERTER AND PIPE
3 - CLAMP
INSTALLATION
and/or sensor.
(1) Al i gn and connect the catal yti c converter fl ange
to the exhaust pi pe (Fi g. 9).
(2) I nstal l the catal yti c converter fl ange i nto the
muffl er or extensi on pi pe (Fi g. 4).
(3) I f other secti ons of the exhaust system where
l oosened i n removal , refer to that i nformati on for the
ti ghteni ng procedures.
(4) At the catal yti c converter fl ange connecti ons,
i nstal l the cl amp and nuts. Ti ghten the cl amp nuts to
(5) I nstal l the crossmember.
(6) I nstal l the rear engi ne mount (Refer to 9 -
I NSTALLATI ON).
(8) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
CATALYTIC CONVERTER -
3.9L/5.9L
DESCRIPTION
OPERATION
REMOVAL
and/or sensor.
verter fl ange to the exhaust pi pe(s) (Fi g. 3) (Fi g. 5).
(5) Remove the engi ne rear mount (Refer to 9 -
REMOVAL).
Fig. 4 Extension Pipe/Muffler to Catalytic Converter
Flange
1 - CATALYTIC CONVERTER FLANGE
2 - EXTENSION PIPE
Fig. 5 Catalytic Converter3.9L/5.9L Engine
1 - EXHAUST PIPE
3 - CLAMP
4 - EXTENSION PIPE TO MUFFLER
CATALYTIC CONVERTER - 2.5L (Continued)
INSPECTION
INSTALLATION
and/or sensor.
I NSTALLATI ON).
DESCRIPTION
OPERATION
REMOVAL
The mi ni catal yti c converters used on the 4.7L
engi ne i s an i ntegeral part of the exhaust pi pe. To
repl ace the mi ni catal yti c converters, the enti re
exhaust pi pe assembl y must be repl aced. (Refer to 11
- EXHAUST SYSTEM/EXHAUST PI PE - REMOV-
AL).
and/or sensor.
verter fl ange to the exhaust pi pe(s).
(5) Remove the engi ne rear mount (Refer to 9 -
REMOVAL).
INSPECTION
Flange
2 - EXTENSION PIPE
CATALYTIC CONVERTER - 3.9L/5.9L (Continued)
INSTALLATION
and/or sensor.
I NSTALLATI ON).
EXHAUST PIPE - 2.5L
REMOVAL
and/or sensor.
(3) Di sconnect the oxygen sensor(s).
(4) Remove the exhaust mani fol d-to-exhaust pi pe
nuts (Fi g. 8).
(5) Remove exhaust pi pe to converter exhaust
cl amp.
(6) Di sconnect the exhaust pi pe from the catal yti c
converter front fl ange.
(7) Remove the exhaust pi pe.
Flange
2 - EXTENSION PIPE
Fig. 8 Exhaust Pipe to Manifold Connection(2.5L)
2 - EXHAUST PIPE
3 - SUPPORT BRACKET
4 - NUT
CATALYTIC CONVERTER - 4.7L (Continued)
INSPECTION
Di scard rusted cl amps, broken or worn supports
and attachi ng parts. Repl ace a component wi th ori g-
i nal equi pment parts, or equi val ent. Thi s wi l l assure
proper al i gnment wi th other parts i n the system and
provi de acceptabl e exhaust noi se l evel s.
INSTALLATION
(1) Connect the exhaust pi pe(s) to the exhaust
mani fol d. Ti ghten the nuts to 26 Nm (19 ft. l bs.)
torque.
(2) Al i gn and connect the exhaust pi pe to the cat-
al yti c converter fl ange (Fi g. 9). I nstal l exhaust cl amp
and ti ghten cl amp nuts to 41 Nm (33 ft. l bs.) torque.
(3) Connect oxygen sensor connector(s).
EXHAUST PIPE - 3.9L AND
5.9L
REMOVAL
and/or sensor.
nuts (Fi g. 10).
cl amp.
Fig. 9 Exhaust Pipe-to-Catalytic Converter Flange
AlignmentTypical
1 - 7.87417.526 mm (0.310.69 in.)
3 - 20 mm (0.79) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
Fig. 10 Exhaust Pipe to Manifold Connection(3.9L/
5.9L)
1 - BOLT
2 - RETAINER
4 - NUT
5 - EXHAUST PIPE
EXHAUST PIPE - 2.5L (Continued)
INSPECTION
INSTALLATION
torque.
al yti c converter fl ange (Fi g. 11). I nstal l exhaust
cl amp and ti ghten cl amp nuts to 41 Nm (33 ft. l bs.)
torque.
EXHAUST PIPE - 4.7L
REMOVAL
and/or sensor.
nuts (Fi g. 12).
cl amp.
AlignmentTypical
1 - 7.87417.526 mm (0.310.69 in.)
3 - 20 mm (0.79) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
Fig. 12 Exhaust Pipe(s) to Manifold Connection - (50
State Models)
1 - BOLT
2 - RETAINER
4 - NUT
5 - EXHAUST PIPE
EXHAUST PIPE - 3.9L AND 5.9L (Continued)
INSPECTION
INSTALLATION
torque.
al yti c converter fl ange (Fi g. 13). I nstal l exhaust
cl amp and ti ghten cl amp nuts to 41 Nm (33 ft. l bs.)
torque.
HEAT SHIELDS
DESCRIPTION
There are two types of heat shi el ds used. One i s
stamped steel the other i s mol ded foi l sheets. The
shi el ds attach to the vehi cl e around the exhaust sys-
tem to prevent heat from the exhaust system from
enteri ng the passenger area and other areas where
the heat can cause damage to other components (Fi g.
14, 15, 16, 17, 18, 19, 20, 21, 22).
REMOVAL
(2) Remove the screws and/or nuts hol di ng the
heat shi el ds to the frame and/or fl oor pan.
(3) When removi ng muffl er heat shi el d, the muf-
fl er front support bracket must be removed fi rst.
(4) Sl i de the shi el ds out around the exhaust sys-
tem.
Fig. 14 Floor Pan Heat ShieldsStandard Cab
1 - FLOOR PAN HEAT SHIELD
2 - SCREW AND WASHER SELF TAPPING
3 - NUT AND WASHER
Fig. 15 Floor Pan Heat ShieldsExtended Cab
1 - FLOOR PAN AND CATALYTIC CONVERTER HEAT SHIELD
3 - NUT AND WASHER
AlignmentTypical
1 - 7.87417.526 mm (0.310.69 in.)
3 - 20 mm (0.79) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
EXHAUST PIPE - 4.7L (Continued)
Fig. 16 Floor Pan Heat Shields, Front and Middle
Shields4 Door Cab
1 - FLOOR PAN (FRONT) HEAT SHIELD
2 - NUT AND WASHER
3 - SELF TAPPING SCREW
4 - FLOOR PAN (MIDDLE) HEAT SHIELD
Fig. 17 Floor Pan Heat Shields Front Floor Pan
Shield4 Door Cab
1 - FLOOR PAN (MIDDLE) HEAT SHIELD
2 - NUT AND WASHER
3 - FLOOR PAN (FRONT) HEAT SHIELD
Fig. 18 Center Bearing Heat ShieldStandard Cab
and Extended Cab
2 - CENTER BEARING HEAT SHIELD
Fig. 19 Dash/Floor Pan Heat Shields
1 - SCREWS
2 - NUT AND WASHER
3 - FRONT FLOOR/DASH HEAT SHIELD
Fig. 20 Tail Pipe Heat Shield
1 - TAILPIPE HEAT SHIELD
2 - FUEL TANK CROSSMEMBER
HEAT SHIELDS (Continued)
INSTALLATION
(1) Posi ti on the heat shi el ds to the fl oor pan or
the frame and i nstal l the screws and/or nuts.
(2) Ti ghten the nuts and/or screws to speci fi cati on.
Refer to Speci fi cati ons i n thi s secti on for correct
torque val ues.
INTERMEDIATE PIPE
REMOVAL
(2) Saturate the cl amp nuts wi th Mopar Rust
(3) Remove the front and rear cl amp nuts.
(4) I t may be necessary to l oosen other secti ons of
the exhaust system to remove the extensi on pi pe.
INSTALLATION
(1) Posi ti on the extensi on pi pe i n the muffl er and
the catal yti c converter fl ange.
l oosened i n removal , refer to the secti on for ti ghten-
i ng procedures.
(3) I nstal l the cl amps and nuts (Fi g. 4). Ti ghten
the nuts to 47 Nm (35 ft. l bs.) torque.
(5) Start the engi ne, i nspect for exhaust l eaks and
exhaust system contact wi th the body panel s. Adjust
the al i gnment, i f needed.
MUFFLER
DESCRIPTION
Al l engi nes use a stai nl ess steel muffl er to control
exhaust noi se l evel s and exhaust back pressure.
REMOVAL
and/or sensor.
(3) Remove the muffl er cl amp nuts from the front
hanger and the rear muffl er to tai l pi pe connecti on
(Fi g. 23).
(4) Di sconnect the muffl er from the tai l pi pe. The
tai l pi pe shoul d be supported when the muffl er i s di s-
connected.
(5) Remove the muffl er from the extensi on pi pe or
catal yti c converter fl ange.
Fig. 21 Electrical Connector Heat Shield45RFE
Transmission
1 - BOLT RETAINER
2 - LOCKNUT
3 - STUDS
4 - HEAT SHIELD
Fig. 22 Muffler Heat Shield4 Door Cab
1 - SCREW SELF TAPPING
3 - SCREW SELF TAPPING
4 - ISOLATOR
5 - HANGER BRACKET
HEAT SHIELDS (Continued)
INSTALLATION
and/or sensor.
(1) I f the upper front muffl er support was removed
(Fi g. 23), i nstal l the bol ts i nto the frame. Ti ghten the
bol ts to 23 Nm (200 i n. l bs.) torque. The i nsul ators
sl i p over the ends of the upper and l ower muffl er
hangers.
(2) I nstal l the muffl er i nto the extensi on pi pe or
catal yti c converter fl ange. I nstal l the cl amp and
ti ghten the nuts fi nger ti ght.
(3) I nstal l the tai l pi pe i nto the rear of the muffl er.
(4) Ti ghten the cl amp nuts on the front and rear
muffl er hangers to 41 Nm (30 ft. l bs.) torque.
TAILPIPE - 2.5L/3.9L/4.7L
DESCRIPTION
The tai l pi pe i s made of stai nl ess steel and attaches
to the muffl er.
REMOVAL
and/or sensor.
(3) Remove muffl er to tai l pi pe exhaust cl amp.
(4) Remove the tai l pi pe from the front and rear
i nsul ators (Fi g. 24).
(5) Remove the tai l pi pe.
Fig. 23 Muffler and Tailpipe Assembly
1 - TAILPIPE HANGER
2 - MUFFLER AND TAILPIPE
3 - FRONT MUFFLER HANGER
4 - REAR MUFFLER HANGER
Fig. 24 Tailpipe and Hangers2.5L/3.9L/4.7L
1 - INSULATORS
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
MUFFLER (Continued)
INSTALLATION
and/or sensor.
(1) Posi ti on the tai l pi pe i nto the muffl er. I nstal l
the nuts onto the cl amp bol t fi nger ti ght.
(2) I nstal l the tai l pi pe i nto the i nsul ators.
(3) Posi ti on tai l pi pe and ti ghten the muffl er rear
cl amp nuts to 47 Nm (35 ft. l bs.) torque.
TAILPIPE - 5.9L
DESCRIPTION
The tai l pi pe i s made of stai nl ess steel and attaches
to the muffl er.
REMOVAL
and/or sensor.
(3) Remove muffl er to tai l pi pe exhaust cl amp.
(4) Remove the tai l pi pe from the front and rear
i nsul ators (Fi g. 25).
(5) Remove the tai l pi pe.
INSTALLATION
and/or sensor.
(1) Posi ti on the tai l pi pe i nto the muffl er. I nstal l
the nuts onto the cl amp bol t fi nger ti ght.
(2) I nstal l the tai l pi pe i nto the i nsul ators.
(3) Posi ti on tai l pi pe and ti ghten the muffl er rear
cl amp nuts to 47 Nm (35 ft. l bs.) torque.
Fig. 25 Tailpipe and Hangers5.9L R/T
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
TAILPIPE - 2.5L/3.9L/4.7L (Continued)
FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT FASCIA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRAME
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRAME SERVICE. . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL TANK SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRAILER HITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VALANCE PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUMPERS
DESCRIPTION
Bumpers are used at the front and rear of the
vehi cl e. Bumpers are i ncorporated i nto the desi gn of
the front and rear fasci as. They are mounted to the
frame wi th brackets and may contai n some l amp el e-
ments.
OPERATION
Bumpers are desi gned to protect the exteri or sheet-
metal i n l ow i mpact si tuati ons. The bumpers are
attached to the frame and provi de mounti ng poi nts
for some opti onal accessori es such as fog l i ghts and
tow hooks.
FRONT BUMPER
REMOVAL
(1) Open hood.
(2) Support front bumper on a sui tabl e l i fti ng
devi ce.
(3) Di sengage wi re connectors from fog l amps, i f
equi pped.
(4) Di sengage push-i n fasteners attachi ng ai r
defl ector to bottom of bumper fasci a.
(5) Pul l the front wheel house l i ner back at the
bumper and remove bol ts attachi ng outer bumper
brackets to frame rai l (Fi g. 1).
(6) Remove the bol ts attachi ng the bumper to the
i nner bumper bracket.
(7) Separate front bumper wi th outer bracket
attached from vehi cl e.
AN FRAME & BUMPERS 13 - 1
INSTALLATION
When the front bumper i s i nstal l ed, there shoul d
be a 19 mm gap between the bumper and front
fender.
(1) Pl ace the bumper on a sui tabl e l i fti ng devi ce
and posi ti on the bumper at the vehi cl e.
(2) I nstal l the bol ts attachi ng front bumper to
i nner bumper bracket. Ti ghten to 94 Nm (70 ft. l bs.)
torque.
(3) I nstal l the bol ts attachi ng outer bumper brack-
ets to the frame rai l . Ti ghten to 94 Nm (70 ft. l bs.)
torque. Ensure front wheel house l i ners are posi ti oned
correctl y behi nd bumper.
(4) Engage wi re connectors to fog l amps, i f
equi pped.
(5) I nstal l push-i n fasteners attachi ng ai r defl ector
to front bumper fasci a.
(6) Remove l i fti ng devi ce.
(7) Cl ose hood.
FRONT FASCIA
REMOVAL
(1) Remove the front bumper.
(2) Remove the bol ts attachi ng the fasci a to the
bumper.
(3) Separate fasci a from bumper.
INSTALLATION
(1) Posi ti on fasci a on bumper.
(2) I nstal l the bol ts attachi ng the fasci a to the
bumper.
(3) I nstal l the front bumper.
REAR BUMPER
REMOVAL
(1) Support rear bumper on a sui tabl e l i fti ng
devi ce.
(2) Remove bol ts attachi ng i nner bumper brackets
to frame rai l s (Fi g. 2).
Fig. 1 Front Bumper
1 - FOG LAMP
2 - FRONT BUMPER
3 - OUTER BUMPER BRACKET
4 - U-NUT
5 - FRAME
6 - INNER BUMPER BRACKET
7 - FASCIA BRACKET
13 - 2 FRAME & BUMPERS AN
FRONT BUMPER (Continued)
(3) Di sengage l i cense pl ate l amp wi re connector
from body wi re harness, i f equi pped.
(4) Separate rear bumper from vehi cl e.
INSTALLATION
(1) Pl ace bumper on a sui tabl e l i fti ng devi ce and
rai se i nto posi ti on.
(2) Engage l i cense pl ate l amp wi re connector from
body wi re harness, i f equi pped.
(3) I nstal l bol ts attachi ng i nner bumper brackets
to frame rai l s. Ti ghten to 94 Nm (70 ft. l bs.) torque.
(4) Remove l i fti ng devi ce.
FRAME
DESCRIPTION
Dakota trucks have a l adder-type frame wi th Box-
secti on front rai l s, dropped center secti on and open-
channel si de rai l s i n the rear (Fi g. 3) and (Fi g. 4).
Cross members attached to the frame si de rai l s
wi th ri vets, wel ds or bol ts form a l adder-type con-
structi on. Addi ti onal l y, the Dakota Quad Cab uses a
mass dampener l ocated between the frame rai l s,
i mmedi atel y forward of the rear bumper. Thi s
damper i s used to address NVH i ssues. The cab i s
i sol ated from the frame wi th rubber l oad cushi ons
(Fi g. 5) and (Fi g. 6) wi th through-bol ts. The cargo
box or bed i s attached to the frame wi th bol ts (Fi g. 7)
(Refer to 23 - BODY/EXTERI OR/CARGO BOX -
REMOVAL).
OPERATION
The frame i s desi gned to absorb and di ssi pate fl ex-
i ng and twi sti ng due to accel erati on, braki ng, corner-
i ng and road surface vari ances wi thout bendi ng when
subjected to normal dri vi ng condi ti ons. The frame i s
the mounti ng pl atform for the fol l owi ng systems and
components:
Front and rear suspensi on systems.
Engi ne, transmi ssi on, and transfer case.
Steeri ng gear and l i nkage.
Exhaust system and heat shi el ds.
Fuel cel l and fuel l i ne tubi ng.
Front end sheet metal and radi ator cl osure
panel .
Ski d pl ate.
Passenger cab.
Cargo box or bed.
Spare ti re wi nch.
Front and rear bumper systems.
Fig. 2 Rear Bumper
1 - REAR BUMPER
2 - OUTER BRACKET
3 - INNER BRACKET
4 - FRAME
REAR BUMPER (Continued)
STANDARD PROCEDURE - FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566C (1050F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventi onal frame that i s bent
or twi sted can be strai ghtened by appl i cati on of heat.
The temperature must not exceed 566C (1050F).
The metal wi l l have a dul l red gl ow at the desi red
temperature. Excessi ve heat wi l l decrease the
strength of the metal and resul t i n a weakened
frame.
Wel di ng the joi nts around ri veted cross members
and frame si de rai l s i s not recommended.
Fig. 3 4X2 Frame
1 - CENTER BEARING CROSSMEMBER
3 - TRAILER HITCH
4 - FRAME
FRAME (Continued)
A strai ghteni ng repai r process shoul d be l i mi ted to
frame members that are not severel y damaged. The
repl acement bol ts, nuts and ri vets that are used to
joi n the frame members shoul d conform to the same
speci fi cati ons as the ori gi nal bol ts, nuts and ri vets.
FRAME REPAIRS
DRILLING HOLES
Do not dri l l hol es i n frame si de rai l top and bottom
fl anges, metal fati gue can resul t causi ng frame fai l -
ure. Hol es dri l l ed i n the si de of the frame rai l must
be at l east 38 mm (1.5 i n.) from the top and bottom
fl anges.
Addi ti onal dri l l hol es shoul d be l ocated away from
exi sti ng hol es.
WELDING
Use MI G, TI G or arc wel di ng equi pment to repai r
wel ded frame components.
Frame components that have been damaged shoul d
be i nspected for cracks before returni ng the vehi cl e
to use. I f cracks are found i n accessi bl e frame com-
ponents perform the fol l owi ng procedures.
(1) Dri l l a hol e at each end of the crack wi th a 3
mm (O.125 i n.) di ameter dri l l bi t.
(2) Usi ng a sui tabl e di e gri nder wi th 3 i nch cut off
wheel , V-groove the crack to al l ow 100% wel d pene-
trati on.
(3) Wel d the crack.
(4) I f necessary when a si de rai l i s repai red, gri nd
the wel d smooth and i nstal l a rei nforcement channel
(Fi g. 8) over the repai red area.
Fig. 4 4X4 Frame
2 - TRAILER HITCH
3 - FRAME
FRAME (Continued)
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 8).
FRAME FASTENERS
Bol ts, nuts and ri vets can be used to repai r frames
or to i nstal l a rei nforcement secti on on the frame.
Bol ts can be used i n pl ace of ri vets. When repl aci ng
ri vets wi th bol ts, i nstal l the next l arger si ze di ameter
bol t to assure proper fi t. I f necessary, ream the hol e
out just enough to suffi ci entl y recei ve the bol t.
Coni cal -type washers are preferred over the spl i t-
ri ng type l ock washers. Normal l y, grade-5 bol ts are
adequate for frame repai r. Grade-3 bolts or softer
should not be used. Ti ghteni ng bol ts/nuts wi th the
correct torque, refer to the I ntroducti on Group at the
front of thi s manual for ti ghteni ng i nformati on.
Fig. 5 Cab Mounts
1 - FLOOR PAN
2 - REAR CAB ISOLATOR
3 - UNDER CAB ISOLATOR
4 - UNDER CAB ISOLATOR
5 - FRAME
6 - FRONT CAB ISOLATOR
Fig. 6 Radiator Closure Panel
1 - RADIATOR CLOSURE PANEL
2 - FRAME
3 - ISOLATOR
4 - ISOLATOR
FRAME (Continued)
Fig. 7 Cargo Box
1 - CARGO BOX
2 - FRAME RAIL
Fig. 8 Frame Reinforcement
1 - .250 IN FROM EDGE
2 - TOP FLANGE
3 - BOTTOM FLANGE
4 - FRAME RAIL
5 - FRAME REPAIR REINFORCEMENT
FRAME (Continued)
SPECIFICATIONS
FRAME DIMENSIONS
Al l di mensi ons are l i sted i n mi l l i meters.
4X4 FRAME TOP VIEW
WHEELBASE 4X2
4X4
DIMN A DIMN B DIMN C DIMN D DIMN E DIMN F DIMN G
112 4X4 1674.8 1901.0 2159.3 3539.4 3738.5 2591.0 2081.7
124 4X4 1674.8 1901.0 2464.0 3844.2 4208.5 2591.0 2506.1
131 4X4 2156.7 2383.0 2641.9 4022.0 4220.5 3034.9 2081.7
FRAME (Continued)
4X4 FRAME SIDE VIEW
FRAME (Continued)
4X2 FRAME TOP VIEW
WHEELBASE 4X2
4X4
DIMN A DIMN B DIMN C DIMN D DIMN E DIMN F DIMN G
112 4X2 1674.8 1901.0 2176.9 3539.5 3738.5 2591.0 2081.7
124 4X2 1674.8 1901.0 2481.6 3844.2 4208.5 2591.0 2506.1
131 4X2 2156.7 2383.0 2659.5 4022.1 4220 3034.9 2081.7
4X2 FRAME SIDE VIEW
FRAME (Continued)
Cab bolts 81 Nm (60 ft. lbs.)
Front axle skid plate-to-
front x-member bolt
23 Nm (17 ft. lbs.)
Front axle skid plate-to-
trans x-member bolt
23 Nm (17 ft. lbs.)
Front bumper brkt-to-
frame nut
94 Nm (70 ft. lbs.)
Front bumper outer brace
bolt
94 Nm (70 ft. lbs.)
Fuel tank skid plate to
x-member nut
41 Nm (30 ft. lbs.)
Fuel tank skid plate to
side rail screws
23 Nm (200 in. lbs.)
Rear bumper-to-brace
nut
94 Nm (70 ft. lbs.)
Rear bumper brace-to-
brkt nut
94 Nm (70 ft. lbs.)
Rear bumper brkt-to-
frame nut
94 Nm (70 ft. lbs.)
Transfer case skid
plate-to-x-member bolt
23 Nm (17 ft. lbs.)
Trailer hitch nut 108 Nm (80 ft. lbs.)
FRONT SKID PLATE
REMOVAL
(1) Posi ti on a support under the ski d pl ate.
(2) Remove the bol ts that attach the ski d pl ate to
the front crossmember (Fi g. 9).
(3) Remove the bol ts that attach the ski d pl ate to
the ski d pl ate crossmember (Fi g. 10).
(4) Separate the crossmember from the vehi cl e.
INSTALLATION
(1) Posi ti on and support the ski d pl ate at the front
crossmember.
(2) I nstal l the bol ts that attach the ski d pl ate to
the transmi ssi on crossmember. Ti ghten to 23 Nm (17
ft. l bs.) torque.
(3) I nstal l the bol ts that attach the ski d pl ate to
the front crossmember. Ti ghten to 23 Nm (17 ft. l bs.)
torque.
(4) Remove the support from under the ski d pl ate.
Fig. 9 Front Axle Skid Plate
1 - U-NUT
2 - FRAME
3 - SKID PLATE
Fig. 10 Front Axle Skid Plate
1 - U-NUT
2 - BRACKET
3 - SKID PLATE CROSSMEMBER
4 - SKID PLATE
FRAME (Continued)
FUEL TANK SKID PLATE
REMOVAL
(1) Posi ti on a support under the ski d pl ate.
(2) Remove the nuts that attach the ski d pl ate to
the fuel tank crossmember and the frame crossmem-
ber (Fi g. 11).
(3) Remove the screws that attach the ski d pl ate
to the support bracket and the frame si de rai l .
(4) Remove the support and the ski d pl ate from
the vehi cl e.
INSTALLATION
(1) Posi ti on and support the ski d pl ate under the
fuel tank.
(2) I nstal l the nuts to attach the ski d pl ate to the
fuel tank crossmember and the frame crossmember.
Ti ghten the nuts wi th 41 Nm (30 ft. l bs.) torque.
(3) I nstal l the screws to attach the ski d pl ate to
the frame si de rai l and the support bracket. Ti ghten
the screws wi th 23 Nm (200 i n. l bs.) torque.
(4) Remove the support from under the ski d pl ate.
TRAILER HITCH
REMOVAL
(1) Support trai l er hi tch on a sui tabl e l i fti ng
devi ce.
(2) Remove fasteners attachi ng trai l er wi ri ng con-
nector to trai l er hi tch, i f equi pped.
(3) Remove bol ts attachi ng trai l er hi tch to frame
rai l s (Fi g. 12).
(4) Separate trai l er hi tch from vehi cl e.
INSTALLATION
(1) Posi ti on trai l er hi tch on vehi cl e.
(2) I nstal l the bol ts attachi ng trai l er hi tch to
frame rai l s and remove l i fti ng devi ce. Ti ghten to 108
(3) I nstal l fasteners attachi ng trai l er wi ri ng con-
nector to trai l er hi tch, i f equi pped.
Fig. 11 Fuel Tank Skid Plate4WD
1 - SKID PLATE SUPPORT BRACKET
2 - SCREW
3 - FUEL TANK
5 - FRAME CROSSMEMBER
6 - LOCK NUT
7 - SCREW
8 - SKID PLATE
9 - U-NUT
10 - FRAME RAIL
Fig. 12 Trailer Hitch
1 - FRAME
2 - TRAILER HITCH
VALANCE PANEL
REMOVAL
(1) Remove nuts attachi ng val ance panel to
bracket (Fi g. 13).
(2) Di sengage l i cense pl ate l amp harness connec-
tor.
(3) Separate val ance panel from cargo box.
INSTALLATION
(1) Posi ti on val ance panel on cargo box.
(2) Engage l i cense pl ate l amp harness connector.
(3) I nstal l nuts attachi ng val ance panel to bracket
.
TRANSFER CASE SKID PLATE
REMOVAL
(2) Remove bol ts attachi ng ski d pl ate to crossmem-
bers (Fi g. 14).
(3) Separate ski d pl ate from vehi cl e.
INSTALLATION
(1) Posi ti on ski d pl ate on vehi cl e.
(2) I nstal l bol ts attachi ng ski d pl ate to crossmem-
bers. (Fi g. 14) Ti ghten to 23 Nm (17 ft. l bs.) torque.
(3) Remove safety stands and l ower vehi cl e.
Fig. 13 Valance Panel
1 - BRACKET
2 - VALANCE PANEL
3 - FRAME
4 - BRACKET
Fig. 14 Transfer Case Skid Plate
1 - TRANSMISSION CROSSMEMBER
2 - TORSION BAR CROSSMEMBER
3 - FRAME
4 - U-NUT
5 - TRANSFER CASE SKID PLATE
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 26
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL PRESSURE LEAK DOWN TEST . . . . . . . . 2
FUEL SYSTEM PRESSURE RELEASE. . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL LINES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL PUMP
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . 8
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . 8
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . 9
FUEL PUMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL RAIL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL TANK
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INLET FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
QUICK CONNECT FITTING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . 22
ROLLOVER VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL DELIVERY
DESCRIPTION
The fuel del i very system consi sts of:
the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
fuel tubes/l i nes/hoses
qui ck-connect fi tti ngs
fuel i njector rai l
fuel i njectors
fuel tank
fuel tank fi l l er/vent tube assembl y
AN FUEL SYSTEM 14 - 1
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
OPERATION
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and rol l over val ve (refer to rol l over val ve
for i nformati on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum, 1/4 turn fuel fi l l er cap i s used. The fuel
fi l l er tube contai ns a fl ap door l ocated bel ow the fuel
fi l l cap.
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Emi ssi on Control
Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
DIAGNOSIS AND TESTING - FUEL PRESSURE
LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Fuel Tubes/Li nes/Hoses and Cl amps for proce-
dures. On some engi nes, ai r cl eaner housi ng removal
may be necessary before fuel l i ne di sconnecti on.
(2) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(3) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose between di sconnected fuel l i ne
and fuel rai l (Fi g. 1).
(4) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The DRB III Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engi ne and bri ng to normal operati ng
temperature.
(6) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa +/34 kPa (49.2 psi +/5 psi ).
(7) Shut engi ne off.
(8) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
Fig. 1 Connecting Adapter ToolTypical
1 - VEHICLE FUEL LINE
2 - TEST PORT T
3 - SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 - FUEL PRESSURE TEST GAUGE
5 - FUEL LINE CONNECTION AT RAIL
6 - FUEL RAIL
14 - 2 FUEL DELIVERY AN
FUEL DELIVERY (Continued)
(9) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(10) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(11) Shut engi ne off.
(12) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(13) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump or fi l ter/
regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the fi l ter/regul ator. A sl ow
l oss of pressure usual l y i ndi cates a defecti ve check
val ve i n the el ectri c fuel pump.
The el ectri c fuel pump i s not servi ced separatel y.
Repl ace the fuel pump modul e assembl y. The fi l ter/reg-
ul ator may be repl aced separatel y on certai n appl i ca-
ti ons. Refer to Fuel Fi l ter/Fuel Pressure Regul ator
Removal /I nstal l ati on for addi ti onal i nformati on.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi ).
TORQUE - FUEL DELIVERY
Accelerator Pedal Bracket Mounting Nuts 7 _ 65
Fuel Pump Module Locknut 54 _ 40
Fuel Rail Mounting Bolts - 3.9L/5.2L/5.9L 23 _ 200
Fuel Rail Mounting Bolts - 4.7L 27 20 _
Fuel Rail Mounting Bolts - 2.5L 11 _ 100
Fuel Tank Mounting Nuts 27-54 20-40 _
Fuel Hose Clamps 3 _ 25
AN FUEL DELIVERY 14 - 3
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench6856
Adapters, Fuel Pressure Test6539 and/or 6631
Fitting, Air Metering6714
O2S (Oxygen Sensor) Remover/InstallerC-4907
Test Kit, Fuel
Test Kit, Fuel PressureC-4799-B
Fuel Line Removal Tool6782
FUEL FILTER/PRESSURE
REGULATOR
DESCRIPTION
A combi nati on fuel fi l ter and fuel pressure regul a-
tor (Fi g. 2) i s used on al l engi nes. I t i s l ocated on the
top of the fuel pump modul e. A separate frame
mounted fuel fi l ter i s not used wi th any engi ne.
OPERATION
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the powertrai n control
modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa 34
kPa (49.2 psi 5 psi ) at the fuel i njectors. I t contai ns
a di aphragm, cal i brated spri ngs and a fuel return
val ve. The i nternal fuel fi l ter (Fi g. 2) i s al so part of
the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 2).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel PumpDescription and
Operation for more information. Also refer to
the Fuel Pressure Leak Down Test and the Fuel
Pump Pressure Tests.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49.2 psi , an i nternal di aphragm opens
and excess fuel pressure i s routed back i nto the tank
through the bottom of pressure regul ator.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant i nput
vol tage source of about 12 vol ts (battery vol tage) i s
suppl i ed to the resi stor track on the fuel gauge send-
i ng uni t. Thi s i s fed di rectl y from the Powertrai n
Control Modul e (PCM). NOTE: For diagnostic pur-
poses, this 12V power source can only be veri-
fied with the circuit opened (fuel pump module
electrical connector unplugged). With the con-
nectors plugged, output voltages will vary from
about 0.6 volts at FULL, to about 8.6 volts at
EMPTY (about 8.6 volts at EMPTY for J eep
models, and about 7.0 volts at EMPTY for
Dodge Truck models). The resi stor track i s used to
vary the vol tage (resi stance) dependi ng on fuel tank
fl oat l evel . As fuel l evel i ncreases, the fl oat and arm
move up, whi ch decreases vol tage. As fuel l evel
decreases, the fl oat and arm move down, whi ch
i ncreases vol tage. The vari ed vol tage si gnal i s
returned back to the PCM through the sensor return
ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
Fig. 2 Side ViewFilter/Regulator
1 - INTERNAL FUEL FILTER
2 - FUEL FLOW TO FUEL INJECTORS
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - EXCESS FUEL BACK TO TANK
5 - FUEL INLET
6 - RUBBER GROMMET
7 - TOP OF PUMP MODULE
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
DIAGNOSIS AND TESTING - FUEL GAUGE
SENDING UNIT
The fuel gauge sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to 8, I nstrument
Panel and Gauges for Fuel Gauge testi ng. To test the
gauge sendi ng uni t onl y, i t must be removed from
vehi cl e. The uni t i s part of the fuel pump modul e.
Refer to Fuel Pump Modul e Removal /I nstal l ati on for
procedures. Measure the resi stance across the send-
i ng uni t termi nal s. Wi th fl oat i n up posi ti on, resi s-
tance shoul d be 20 ohms 6 ohms. Wi th fl oat i n down
posi ti on, resi stance shoul d be 220 ohms 6 ohms.
REMOVAL
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 3) or (Fi g. 4). The fuel pump modul e i s
l ocated i nsi de of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) 2 Door Models:
(a) Unpl ug 4way el ectri cal connector (Fi g. 3).
(b) Di sconnect 2 sendi ng uni t wi res at 4way
connector. The l ocki ng col l ar of connector must be
removed before wi res can be rel eased from connec-
tor. Note l ocati on of wi res wi thi n 4way connector.
(c) The sendi ng uni t i s retai ned to pump modul e
wi th a smal l l ock tab and notch (Fi g. 5). Careful l y
push l ock tab to the si de and away from notch
whi l e sl i di ng sendi ng uni t downward on tracks for
removal . Note wi re routi ng whi l e removi ng uni t
from modul e.
(4) 4 Door Models:
(a) Remove el ectri cal connector at sendi ng uni t
termi nal s.
(b) Press on rel ease tab (Fi g. 6) to remove send-
i ng uni t from pump modul e.
Fig. 3 Fuel Gauge Sending Unit - 2 Door Models
1 - FUEL FILTER/PRESSURE REGULATOR
3 - ELECTRIC FUEL PUMP
4 - FUEL GAUGE FLOAT
5 - FUEL PUMP INLET FILTER
6 - FUEL GAUGE SENDING UNIT
7 - MODULE LOCK TABS (3)
Fig. 4 Fuel Gauge Sending Unit Location 4 Door
Models
1 - FUEL GAUGE FLOAT
2 - PICK-UP FILTER
5 - ELECTRIC FUEL PUMP
6 - PIGTAIL WIRING HARNESS
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
INSTALLATION
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 3) or (Fi g. 4). The fuel pump modul e i s
l ocated i nsi de of fuel tank.
(1) 2 Door Models:
(a) Posi ti on sendi ng uni t i nto tracks. Note wi re
routi ng.
(b) Push uni t on tracks unti l l ock tab snaps i nto
notch.
(c) Connect 2 sendi ng uni t wi res i nto 4way con-
nector and i nstal l l ocki ng col l ar.
(d) Connect 4way el ectri cal connector to mod-
ul e.
(2) 4 Door Models:
(a) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(b) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
(4) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL LINES
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
FUEL PUMP
DESCRIPTION
The fuel pump i s l ocated i nsi de of the fuel pump
modul e. A 12 vol t, permanent magnet, el ectri c motor
powers the fuel pump.
Fig. 5 Fuel Gauge Sending Unit Lock Tab/Tracks - 2
Door Models
2 - LOCK TAB
3 - NOTCH
4 - TRACKS
Fig. 6 Fuel Gauge Sending Unit Release Tab - 4
Door Models
3 - RELEASE TAB
4 - FUEL PUMP MODULE
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test for more i nformati on.
DIAGNOSIS AND TESTING - FUEL PUMP
PRESSURE TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found el sewhere i n thi s
group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protecti ve cap at fuel rai l test port.
Connect the 0414 kPa (0-60 psi ) fuel pressure gauge
(from gauge set 5069) to test port pressure fi tti ng on
fuel rai l (Fi g. 7). The DRB III Scan Tool along
with the PEP module, the 500 psi pressure
transducer, and the transducer-to-test port
adapter may also be used in place of the fuel
pressure gauge.
(2) Start and warm engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, but speci fi cati ons for ei ther the Fuel Pump
Capaci ty, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, repl ace fuel pump
modul e assembl y. Refer to Fuel Pump Modul e
Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for more i nformati on.
(5) I nstal l protecti ve cap to fuel rai l test port.
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Rel ease fuel system pressure. Refer to Fuel
Pressure Rel ease Procedure.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs. Some engi nes may requi re
ai r cl eaner housi ng removal before l i ne di sconnecti on.
Fig. 7 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL
FUEL PUMP (Continued)
(3) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(4) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose i nto di sconnected fuel suppl y l i ne.
I nsert other end of Adaptor Tool Hose i nto a gradu-
ated contai ner.
(5) Remove fuel fi l l cap.
(6) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50 F (10
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 8) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Be sure fuel tank contai ns fuel before starti ng
test. I f tank i s empty or near empty, amperage read-
i ngs wi l l be i ncorrect.
(2) Obtai n LCS adapter.
(3) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(4) Pl ug DRB i nto vehi cl e 16way connector (data
l i nk connector).
(5) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
(6) Gai n access to MAI N MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(9) Press ENTER three ti mes.
(10) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(11) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Di stri buti on Center
(PDC).
(13) Remove fuel pump rel ay from PDC. Refer to
l abel on PDC cover for rel ay l ocati on.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type3.
Fig. 8 Low Current Shunt
1 - LOW CURRENT SHUNT ADAPTER
2 - PLUG TO DRB
3 - TEST LEAD RECEPTACLES
(14) I f equi pped wi th type1 relay (Fi g. 9), attach
test l eads from LCS adapter i nto PDC rel ay cavi ti es
number 30 and 87. For l ocati on of these cavi ti es,
refer to numbers stamped to bottom of rel ay (Fi g. 9).
(15) I f equi pped wi th type2 relay (Fi g. 10),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 10).
(16) I f equi pped wi th type3 relay (Fi g. 11),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 11).
(17) When LCS adapter test l eads are attached
i nto rel ay cavi ti es, fuel pump will be activated.
Determi ne fuel pump amperage on DRB screen.
Amperage shoul d be bel ow 10.0 amps. I f amperage i s
bel ow 10.0 amps, and speci fi cati ons for the Fuel
Pump Pressure, Fuel Pump Capaci ty and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ul e i s OK.
(18) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
(19) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
Fig. 9 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
TERMINAL LEGEND
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e on al l model s/al l engi nes i s
i nstal l ed i n the top of the fuel tank (Fi g. 12) or (Fi g.
13). The fuel pump modul e contai ns the fol l owi ng
components :
A combi nati on fuel fi l ter/fuel pressure regul ator
El ectri c fuel pump
Fuel pump reservoi r
A separate i n-tank fuel fi l ter (at bottom of mod-
ul e)
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y l i ne connecti on at fi l ter/regul ator
A threaded l ocknut to retai n pump modul e to
fuel tank
A rubber gasket between tank fl ange and pump
modul e
The fuel gauge sendi ng uni t (fuel l evel sensor), and
pi ck-up fi l ter (at bottom of modul e) may be servi ced
separatel y. I f the el ectri cal fuel pump requi res ser-
vi ce, the enti re fuel pump modul e must be repl aced.
OPERATION
Refer to Fuel Pump, Fuel Fi l ter/Fuel Pressure Reg-
ul ator and Fuel Gauge Sendi ng Uni t.
REMOVAL
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING FUEL PUMP MODULE, FUEL
SYSTEM PRESSURE MUST BE RELEASED.
(1) Drai n fuel tank and remove tank. Refer to Fuel
Tank Removal .
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) The fuel pump modul e l ocknut i s threaded onto
fuel tank (Fi g. 14) or (Fi g. 15). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 16).
(4) Remove modul e from fuel tank.
Fig. 12 Fuel Tank/Fuel Pump Module2 Door
Models
1 - FILL HOSE
2 - VENT HOSE
3 - ROLLOVER VALVE
4 - LOCKNUT
6 - FUEL TANK
Fig. 13 Fuel Tank/Fuel Pump Module4 Door
Models
2 - ROLLOVER VALVE
3 - FUEL TANK SHIELD
4 - LOCKNUT
6 - ROLLOVER VALVE
7 - FUEL TANK
8 - FILL HOSE
9 - VENT HOSE
10 - PIGTAIL HARNESS
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
the module gasket must be replaced.
(1) Usi ng a new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank. Be sure rubber gasket
remai ns i n pl ace. 2 Door Models: Rotate modul e
assembl y unti l modul e al i gnment arrow i s at 7
ocl ock posi ti on (Fi g. 14). The front of fuel tank i s to
the ri ght i n (Fi g. 14). Arrow shoul d be poi nted to fuel
tank marki ngs (Fi g. 14). 4 Door Models: Rotate
modul e assembl y unti l modul e al i gnment arrow i s at
4 ocl ock posi ti on (Fi g. 15). The front of fuel tank i s to
the ri ght i n (Fi g. 15). Arrow shoul d be poi nted to fuel
tank marki ngs (Fi g. 15). Thi s step must be fol l owed
to prevent fl oat/fl oat rod from contacti ng si des of fuel
tank.
(2) Posi ti on l ocknut over top of fuel pump modul e.
Ti ghten fi nger ti ght.
(3) Careful l y rotate fuel fi l ter/fuel pressure regul a-
tor unti l fuel fi tti ng i s poi nted towards dri vers si de of
vehi cl e (Fi g. 14) or (Fi g. 15). The front of fuel tank i s
to the ri ght i n (Fi g. 14) or (Fi g. 15).
(4) I nstal l Speci al Tool 6856 to l ocknut.
(5) Ti ghten l ocknut to 54 Nm (40 ft. l bs.) torque.
Whi l e ti ghteni ng l ocknut, be sure modul e has not
rotated.
(6) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on.
Fig. 14 Top View of Fuel Pump Module2 Door
Models
1 - LOCKNUT
2 - TANK FITTINGS
3 - EVAP FITTING
4 - ROLLOVER VALVE
5 - MODULE ALIGNMENT ARROW (7 OCLOCK)
6 - TANK MARKINGS
7 - FUEL TANK
Fig. 15 Top View of Fuel Pump Module4 Door
Models
1 - MODULE ALIGNMENT ARROW (4 OCLOCK)
2 - TANK MARKINGS
3 - LOCKNUT
4 - FUEL TANK
Fig. 16 Locknut Removal/InstallationTypical
2 - LOCKNUT
FUEL PUMP MODULE (Continued)
FUEL RAIL
DESCRIPTION - 3. 9L/5. 2L/5. 9L
The fuel i njector rai l i s used to attach the fuel
i njectors to the engi ne. I t i s mounted to the engi ne
(Fi g. 17).
DESCRIPTION - 4. 7L
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne. I t i s mounted to the i ntake
mani fol d (Fi g. 18).
DESCRIPTION - 2. 5L
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne (Fi g. 19). On the 2.5L 4cyl i n-
der engi ne, a fuel damper i s l ocated at the front of
the fuel rai l (Fi g. 19).
OPERATION - 3. 9L/5. 2L/5. 9L
Hi gh pressure from the fuel pump i s routed to the
fuel rai l . The fuel rai l then suppl i es the necessary
fuel to each i ndi vi dual fuel i njector.
A fuel pressure test port i s l ocated on the fuel rai l .
A qui ck-connect fi tti ng wi th a safety l atch cl i p i s
used to attach the fuel l i ne to the fuel rai l .
The fuel rai l i s not repai rabl e.
CAUTION: The left and right sections of the fuel rail
are connected with a flexible connecting hose. Do
not attempt to separate the rail halves at this con-
necting hose. Due to the design of this connecting
hose, it does not use any clamps. Never attempt to
install a clamping device of any kind to the hose.
When removing the fuel rail assembly for any rea-
son, be careful not to bend or kink the connecting
hose.
OPERATION - 4. 7L
Hi gh pressure fuel from the fuel pump i s routed to
the fuel rai l . The fuel rai l then suppl i es the neces-
sary fuel to each i ndi vi dual fuel i njector.
A fuel pressure test port i s l ocated on the fuel rai l
(Fi g. 18). A qui ck-connect fi tti ng wi th a safety l atch
i s used to attach the fuel l i ne to the fuel rai l .
Fig. 17 Fuel Rail3.9/5.2/5.9L EngineTypical
1 - FUEL RAIL CONNECTING HOSE
2 - FUEL RAIL
Fig. 18 Fuel Injector Rail4.7L V-8 Engine
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
OPERATION - 2. 5L
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
REMOVAL - 2. 5L
The fuel damper i s not servi ced separatel y.
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure as descri bed i n thi s Group.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Remove i njector harness el ectri cal connectors
at each i njector. Each i njector connector shoul d have
a numeri cal tag attached i denti fyi ng i ts correspond-
i ng cyl i nder (Fi g. 20). I f not, i denti fy each connector
before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs i n
thi s group for procedures.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on i n thi s group
for procedures.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System for procedures.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket (Fi g. 20) at
i ntake mani fol d.
(11) Remove nut securi ng crankshaft posi ti on sen-
sor pi gtai l harness to fuel rai l mounti ng stud.
Remove cl amp and harness from fuel rai l mounti ng
stud.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
20).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
Fig. 19 Fuel Injector Rail/Fuel Damper2.5L Engine
1 - FUEL DAMPER
2 - FUEL INJECTOR
3 - NUMBERED TAG
4 - FUEL RAIL
5 - FUEL RAIL MOUNTING BOLTS/NUTS
6 - TEST PORT
7 - CABLE BRACKET
Fig. 20 Fuel Rail Mounting2.5L Engine
1 - FUEL DAMPER
2 - FUEL INJECTOR
3 - NUMBERED TAG
4 - FUEL RAIL
5 - FUEL RAIL MOUNTING BOLTS/NUTS
6 - TEST PORT
7 - CABLE BRACKET
FUEL RAIL (Continued)
REMOVAL - 3. 9L/5. 2L/5. 9L
STANT PRESSURE (EVEN WITH ENGINE TURNED
OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
To rel ease fuel pressure, refer to Fuel System Pres-
sure Rel ease Procedure i n thi s group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connecting hose (Fig. 21). Due to the
design of this connecting hose, it does not use any
clamps. Never attempt to install a clamping device
of any kind to hose. When removing fuel rail
assembly for any reason, be careful not to bend or
kink connecting hose.
(1) Remove negati ve battery cabl e at battery.
(2) Remove ai r cl eaner.
(3) Perform fuel pressure rel ease procedure.
(4) Remove throttl e body from i ntake mani fol d.
Refer to Throttl e Body removal i n thi s group.
(5) I f equi pped wi th ai r condi ti oni ng, remove
A-shaped A/C compressor-to-i ntake mani fol d support
bracket (three bol ts) (Fi g. 22).
(6) Di sconnect el ectri cal connectors at al l 8 fuel
i njectors. To remove connector refer to (Fi g. 23). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(7) 3.9L (V-6) engi ne onl y: Di sconnect el ectri cal
connector at i ntake mani fol d ai r temperature sensor.
Do not remove sensor.
(8) Di sconnect fuel tube (l i ne) at si de of fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures,
(9) Remove remai ni ng fuel rai l mounti ng bol ts.
(10) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
Fig. 21 Fuel Rail Assembly3.9/5.2/5.9L Engine
Typical
1 - FUEL RAIL CONNECTING HOSE
2 - FUEL RAIL
Fig. 22 A/C Compressor Support
1 - AIR CONDITIONING COMPRESSOR SUPPORT BRACKET
2 - MOUNTING BOLTS
Fig. 23 Remove/Install Injector Connector
(11) Gentl y rock and pul l left fuel rai l unti l fuel
i njectors just start to cl ear i ntake mani fol d. Gentl y
rock and pul l right fuel rai l unti l fuel i njectors just
start to cl ear i ntake mani fol d. Repeat thi s procedure
(l eft/ri ght) unti l al l fuel i njectors have cl eared i ntake
mani fol d.
(12) Remove fuel rai l (wi th i njectors attached)
from engi ne.
(13) Remove cl i p(s) retai ni ng i njector(s) to fuel rai l
(Fi g. 24) or (Fi g. 25).
REMOVAL - 4. 7L
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
halves at connector tube (Fig. 26). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Remove negati ve battery cabl e at battery.
(4) Remove ai r duct at throttl e body ai r box.
(5) Remove ai r box at throttl e body.
(6) Remove wi ri ng at rear of generator.
(7) Di sconnect fuel l i ne l atch cl i p and fuel l i ne at
fuel rai l . A speci al tool wi l l be necessary for fuel l i ne
di sconnecti on. Refer to Qui ck-Connect Fi tti ngs.
(8) Remove vacuum l i nes at throttl e body.
(9) Di sconnect el ectri cal connectors at al l 8 fuel
i njectors. To remove connector refer to (Fi g. 27). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(10) Di sconnect el ectri cal connectors at throttl e
body.
(11) Di sconnect el ectri cal connectors at MAP and
I AT sensors.
(12) Remove fi rst three i gni ti on coi l s on each bank
(cyl i nders #1, 3, 5, 2, 4 and 6). Refer to I gni ti on Coi l
(13) Remove 4 fuel rai l mounti ng bol ts (Fi g. 26).
(14) Gentl y rock and pul l left si de of fuel rai l unti l
fuel i njectors just start to cl ear machi ned hol es i n
cyl i nder head. Gentl y rock and pul l right si de of rai l
unti l i njectors just start to cl ear cyl i nder head hol es.
Repeat thi s procedure (l eft/ri ght) unti l al l i njectors
have cl eared cyl i nder head hol es.
(15) Remove fuel rai l (wi th i njectors attached)
from engi ne.
(16) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
Fig. 24 Fuel Injector
1 - CLIP
2 - INJECTOR
3 - FUEL RAIL
Fig. 25 Injector Retaining
1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR
4 - FUEL RAIL
(1) Cl ean each i njector bore at i ntake mani fol d.
(2) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(5) Posi ti on crankshaft posi ti on sensor pi gtai l wi re
harness cl amp and wi re harness to fuel rai l mount-
i ng stud. I nstal l nut securi ng harness to fuel rai l
mounti ng stud.
(6) Connect tagged i njector harness connectors to
appropri ate i njector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs i n thi s group for
procedures.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(16) Start engi ne and check for fuel l eaks.
STANT PRESSURE (EVEN WITH ENGINE TURNED
OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY,
sure Rel ease Procedure i n thi s group.
Fig. 26 Fuel Rail Mounting4.7L V-8 Engine
2 - INJ.#7
3 - INJ.#5
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
Fig. 27 Remove/Install Injector Connector4.7L V-8
Engine
halves at connecting hose (Fig. 21). Due to the
design of this connecting hose, it does not use any
clamps. Never attempt to install a clamping device
of any kind to hose. When removing fuel rail
assembly for any reason, be careful not to bend or
kink connecting hose.
each fuel i njector o-ri ng. Thi s wi l l hel p i n fuel rai l
i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel rai l .
(3) Posi ti on fuel rai l /fuel i njector assembl y to i njec-
tor openi ngs on i ntake mani fol d.
(4) Gui de each i njector i nto i ntake mani fol d. Be
careful not to tear i njector o-ri ng.
(5) Push right fuel rai l down unti l fuel i njectors
have bottomed on i njector shoul der. Push left fuel
rai l down unti l fuel i njectors have bottomed on i njec-
tor shoul der.
(6) I nstal l fuel rai l mounti ng bol ts.
(7) Connect el ectri cal connector to i ntake mani fol d
ai r temperature sensor.
(8) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 23). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(9) I nstal l A/C support bracket (i f equi pped).
(10) I nstal l throttl e body to i ntake mani fol d. Refer
to Throttl e Body i nstal l ati on i n thi s group.
(11) I nstal l fuel tube (l i ne) at si de of fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures.
(12) I nstal l ai r cl eaner.
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(3) Posi ti on fuel rai l /fuel i njector assembl y to
machi ned i njector openi ngs i n cyl i nder head.
(4) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
(5) Push right si de of fuel rai l down unti l fuel
i njectors have bottomed on cyl i nder head shoul der.
Push left fuel rai l down unti l i njectors have bot-
tomed on cyl i nder head shoul der.
(6) I nstal l 4 fuel rai l mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(7) I nstal l i gni ti on coi l s. Refer to I gni ti on Coi l
(8) Connect el ectri cal connectors to throttl e body.
(9) Connect el ectri cal connectors to MAP and I AT
sensors.
(10) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 27). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(11) Connect vacuum l i nes to throttl e body.
(12) Connect fuel l i ne l atch cl i p and fuel l i ne to
fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(13) Connect wi ri ng to rear of generator.
(14) I nstal l ai r box to throttl e body.
(15) I nstal l ai r duct to ai r box.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e.
OPERATION
Al l model s pass a ful l 360 degree rol l over test wi thout
fuel l eakage. To accompl i sh thi s, fuel and vapor fl ow
control s are requi red for al l fuel tank connecti ons.
A rol l over val ve(s) i s mounted i nto the top of the
fuel tank (or pump modul e). Refer to Rol l over Val ve
i nformati on.
An evaporati on control system i s connected to the
rol l over val ve(s) to reduce emi ssi ons of fuel vapors
i nto the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP). Refer to Emi ssi on Control
System for addi ti onal i nformati on.
REMOVAL
BEFORE DRAINING FUEL TANK, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
The fuel tank cannot be drai ned through the fi l l
or vent fi tti ngs at the top of the fuel tank. Two di f-
ferent procedures may be used to drai n fuel tank
(usi ng an approved gasol i ne drai ni ng stati on, or
usi ng the DRB scan tool al ong wi th an approved gas-
ol i ne drai ni ng stati on). Drai ni ng i s done from the di s-
connected fuel l i ne, at the fuel rai l , wi th ei ther
procedure.
(2) Perform Fuel System Pressure Rel ease proce-
dure.
(4) Di sconnect qui ck-connect fuel l i ne at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures.
(5) The hose from the gasol i ne drai ni ng stati on
must be adapted i nto the 5/16 qui ck-connect fi tti ng
on di sconnected fuel l i ne. One way to accompl i sh thi s
i s to obtai n a 5/16 test fi tti ng such as from Snap-On
Fuel I njecti on Adapter Set #FI DA44. Snap the fi t-
ti ng i nto the di sconnected fuel l i ne and attach hose
from gasol i ne drai ni ng stati on.
(6) Operate the gasol i ne drai ni ng stati on to drai n
fuel tank. As an al ternati ve procedure, the el ectri c
fuel pump may be acti vated. Refer to DRB scan tool
for fuel pump acti vati on procedures. Acti vate el ectri c
fuel pump, or gasol i ne drai ni ng stati on, and drai n
tank unti l empty. I f el ectri c fuel pump i s not operat-
i ng, the gasol i ne drai ni ng stati on must be used.
(7) Rai se vehi cl e and remove spl ash shi el d i n front
of l eft/rear wheel house.
(8) Remove hose cl amps and di sconnect rubber fi l l
and vent hoses (Fi g. 29) at fi l l and vent tubes (Fi g.
28). Do not di sconnect hoses at fuel tank.
Fig. 28 Fuel Fill and Vent Tubes
1 - FUEL FILL TUBE
2 - L.R. BRAKE DRUM
3 - FUEL VENT TUBE
Fig. 29 Fuel Tank and Hoses
1 - FUEL TANK (4DOOR)
2 - TANK FITTINGS
3 - FILL HOSE
4 - VENT HOSE
5 - FUEL TUBE ASSEMBLY
6 - VENT HOSE
7 - TANK FITTINGS
9 - FILL HOSE
10 - CLAMPS
FUEL TANK (Continued)
(9) I f equi pped wi th a 2pi ece dri veshaft, the
crossmember l ocated bel ow the fuel tank must be
removed.
(a) Remove bol ts/nuts securi ng dri veshaft center
beari ng carri er bracket to crossmember.
(b) Rai se and support dri veshaft and carri er
bracket assembl y usi ng a l ength of rope.
(c) Center punch al l ri vets.
(d) Dri l l out ri vets wi th a 3/8 dri l l bi t. Do not
use a l arger bi t, as hol es i n crossmember and vehi -
cl e frame may become too l arge.
(e) Remove crossmember from vehi cl e.
(f) Remove remai ni ng ri vet materi al from cross-
member and vehi cl e frame.
(10) I f equi pped, remove fuel tank ski d pl ate.
Refer to 23, Body
(11) Pl ace and secure a transmi ssi on jack under
center of fuel tank and appl y sl i ght pressure.
(12) Remove two tank mounti ng nuts from mount-
i ng straps (Fi g. 30). Posi ti on tank mounti ng straps to
si de of vehi cl e and l ower tank just enough to al l ow
access to connecti ons at top of tank.
(13) Cl ean qui ck-connect fi tti ngs of any di rt/con-
tami nants before removal .
(14) Di sconnect fuel suppl y l i ne from fuel fi l ter/
fuel pressure regul ator fi tti ng at top of tank. Refer to
Qui ck-Connect Fi tti ngs for procedures.
(15) Di sconnect fuel vapor l i ne(s) from rol l over
val ve(s) at top of tank.
(16) Di sconnect el ectri cal connector at pump mod-
ul e at top of tank.
(17) Lower tank from vehi cl e. On certai n model s,
the tank must fi rst be moved rearward, and then
down, for removal .
(18) Remove tank from hydraul i c jack.
(19) I f fuel pump modul e requi res servi ce, refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(20) I f fi l l and vent hoses are to be removed from
tank, note thei r posi ti on on fuel tank fi tti ngs before
removal .
Fig. 30 Fuel Tank Mounting
2 - STRAPS (2)
3 - NUTS (2)
5 - NUTS (2)
6 - STRAPS (2)
INSTALLATION
(1) I f fuel pump modul e i s bei ng i nstal l ed, refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(2) I nstal l fi l l and vent hoses to tank fi tti ngs.
(3) Pl ace and secure fuel tank to transmi ssi on
jack.
(4) Rai se tank up enough to connect fuel l i ne, el ec-
tri cal connector and vapor hoses to top of fuel tank.
Refer to Qui ck-Connect Fi tti ngs for fuel l i ne proce-
dures.
(5) Conti nue rai si ng tank i nto posi ti on and i nstal l
mounti ng straps and nuts. Ti ghten nuts to 2754
Nm (2040 ft. l bs.) torque. Do not over tighten
mounting strap nuts.
(7) I f equi pped, i nstal l fuel tank ski d pl ate. Refer
to 23, Body.
(8) I f equi pped wi th a 2pi ece dri veshaft:
(a) Obtai n new bol ts and nuts to secure cross-
member to frame. Use the same OEM bol ts/nuts
that are used to secure the upper fuel tank cross-
member to the vehi cl e frame.
(b) Posi ti on crossmember to vehi cl e frame.
I nstal l bol ts and ti ghten to 54 Nm (40 ft. l bs.)
torque.
(c) Posi ti on dri veshaft and carri er bracket
assembl y to crossmember.
(d) I nstal l bol ts and ti ghten to 54 Nm (40 ft.
l bs.) torque.
(9) I nstal l fi l l and vent hoses to fi l l and vent tubes.
(10) I nstal l spl ash shi el d i n front of l eft/rear
wheel house.
(12) Refi l l fuel tank and i nstal l fi l l cap.
(13) I nspect al l hoses and l i nes for l eaks.
INLET FILTER
REMOVAL
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of the fuel pump modul e (Fi g. 31) or (Fi g.
32). The fuel pump modul e i s l ocated i nsi de of fuel
tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
(3) 2 Door Model s: Remove fi l ter by careful l y pry-
i ng 2 l ock tabs at bottom of modul e wi th 2 screwdri v-
ers. Fi l ter i s snapped to modul e.
(4) 4 Door Model s: Remove fi l ter by careful l y pry-
i ng i t from bottom of pump modul e wi th 2 screwdri v-
ers. Fi l ter i s snapped to modul e.
(5) Cl ean bottom of pump modul e.
INSTALLATION
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of the fuel pump modul e (Fi g. 31) or (Fi g.
32). The fuel pump modul e i s l ocated i nsi de of fuel
tank.
Fig. 31 Fuel Pump Inlet Filter2 Door Models
2 - LOCK TABS (2)
3 - FUEL PUMP MODULE (BOTTOM)
Fig. 32 Fuel Pump Inlet Filter4 Door Models
(1) Snap new fi l ter to bottom of modul e. Be sure
o-ri ng i s i n correct posi ti on.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
(3) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
QUICK CONNECT FITTING
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Some are equi pped wi th
safety l atch cl i ps. Some may requi re the use of a spe-
ci al tool for di sconnecti on and removal . Refer to
Qui ck-Connect Fi tti ngs Removal /I nstal l ati on for more
i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 33). The tab
i s removabl e. After tab i s removed, qui ck-connect fi t-
ti ng can be separated from fuel system component.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 34). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 34).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 35).
(5) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 36). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 36) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
Fig. 33 Single-Tab Type Fitting
1 - PULL TAB
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
INLET FILTER (Continued)
(6) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 37) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 37). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
Fig. 34 Disconnecting Single-Tab Type Fitting
1 - PULL TAB
2 - SCREWDRIVER
Fig. 35 Removing Pull Tab
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
4 - FUEL TUBE STOP
Fig. 36 Typical Two-Tab Type Quick-Connect Fitting
1 - TAB(S)
Fig. 37 Plastic Retainer Ring Type Fitting
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
QUICK CONNECT FITTING (Continued)
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(7) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 38) or (Fi g. 39). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 38).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 39) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 40). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(8) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
Fig. 38 Latch ClipType 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
Fig. 39 Latch ClipType 2
1 - LATCH CLIP
Fig. 40 Fuel Line Disconnection Using Special Tool
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
ROLLOVER VALVE
DESCRIPTION
The fuel tank on 2-door model s i s equi pped wi th 1
rol l over val ve. Thi s val ve i s l ocated on the top of the
fuel tank (Fi g. 41). The fuel tank on 4-door model s i s
equi pped wi th 2 rol l over val ves. These val ves are
al so l ocated on the top of the fuel tank (Fi g. 42).
OPERATION
The rol l over val ve(s) wi l l prevent fuel fl ow through
the fuel tank vent (EVAP) hoses i n the event of an
acci dental vehi cl e rol l over. The EVAP cani ster draws
fuel vapors from the fuel tank through thi s val ve(s).
The val ve(s) cannot be servi ced separatel y. I f
repl acement i s necessary, the fuel tank must be
repl aced. Refer to Fuel Tank Removal /I nstal l ati on.
REMOVAL
The rol l over val ves(s) are/i s mol ded i nto the fuel
tank and are not servi ced separatel y. I f repl acement
i s necessary, the fuel tank must be repl aced. Refer to
Fuel Tank Removal /I nstal l ati on.
INSTALLATION
The rol l over val ves(s) are/i s mol ded i nto the fuel
tank and are not servi ced separatel y. I f repl acement
i s necessary, the fuel tank must be repl aced. Refer to
Fuel Tank Removal /I nstal l ati on.
Fig. 41 Rollover Valve Location (2Door Models)
1 - FILL HOSE
2 - VENT HOSE
3 - ROLLOVER VALVE
4 - LOCKNUT
6 - FUEL TANK
Fig. 42 Rollover Valve Locations (4Door Models)
2 - ROLLOVER VALVE
3 - FUEL TANK SHIELD
4 - LOCKNUT
6 - ROLLOVER VALVE
7 - FUEL TANK
8 - FILL HOSE
9 - VENT HOSE
10 - PIGTAIL HARNESS
FUEL INJ ECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
VISUAL INSPECTION - 3.9/5.2/5.9L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
VISUAL INSPECTION - 2.5L ENGINE . . . . . . . . 31
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 34
ACCELERATOR PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CRANKSHAFT POSITION SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL INJECTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FUEL INJECTOR TEST. . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FUEL PUMP RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
IDLE AIR CONTROL MOTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MAP SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
O2 HEATER RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
O2 SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
THROTTLE BODY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
THROTTLE CONTROL CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
THROTTLE POSITION SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 57
14 - 26 FUEL INJECTION AN
FUEL INJ ECTION
DIAGNOSIS AND TESTING - VISUAL
INSPECTION 3. 9L/5. 2L/5. 9L ENGINES
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy three 32way el ectri cal connectors are
ful l y i nserted i nto connector of powertrai n control
modul e (PCM) (Fi g. 1).
(2) I nspect battery cabl e connecti ons. Be sure they
are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect ASD
rel ay connecti ons. I nspect starter motor rel ay connec-
ti ons. I nspect rel ays for si gns of physi cal damage and
corrosi on. The rel ays are l ocated i n Power Di stri bu-
ti on Center (PDC) (Fi g. 2). Refer to l abel on PDC
cover for rel ay l ocati on.
(4) I nspect i gni ti on coi l connecti ons. Veri fy coi l sec-
ondary cabl e i s fi rml y connected to coi l (Fi g. 3).
(5) Veri fy di stri butor cap i s correctl y attached to
di stri butor. Be sure spark pl ug cabl es are fi rml y con-
nected to the di stri butor cap and the spark pl ugs are
i n thei r correct fi ri ng order. Be sure coi l cabl e i s
fi rml y connected to di stri butor cap and coi l . Be sure
camshaft posi ti on sensor wi re connector (at the di s-
tri butor) i s fi rml y connected to harness connector.
I nspect spark pl ug condi ti on. Refer to 8, I gni ti on.
Connect vehi cl e to an osci l l oscope and i nspect spark
events for foul ed or damaged spark pl ugs or cabl es.
(6) Veri fy generator output wi re, generator connec-
tor and ground wi re are fi rml y connected to genera-
tor.
(7) I nspect system body grounds for l oose or di rty
connecti ons. Refer to 8, Wi ri ng for ground l ocati ons.
Fig. 1 Powertrain Control Module (PCM)
4 - COVER
Fig. 3 Ignition Coil3.9/5.2/5.9L EnginesTypical
1 - ACCESSORY DRIVE BELT TENSIONER
2 - COIL CONNECTOR
3 - IGNITION COIL
4 - COIL MOUNTING BOLTS
AN FUEL INJECTION 14 - 27
(8) Veri fy posi ti ve crankcase venti l ati on (PCV)
val ve operati on. Refer to 25, Emi ssi on Control Sys-
tem for addi ti onal i nformati on. Veri fy PCV val ve
hose i s fi rml y connected to PCV val ve and mani fol d
(Fi g. 4).
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy hose connecti ons to al l ports of vacuum
fi tti ngs on i ntake mani fol d are ti ght and not l eaki ng.
(11) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
necti ons (i f equi pped). Check thei r connecti ons to
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
vacuum booster hose i s fi rml y connected to fi tti ng on
i ntake mani fol d. Al so check connecti on to brake vac-
uum booster.
(13) I nspect ai r cl eaner i nl et and ai r cl eaner el e-
ment for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy i ntake mani fol d ai r temperature sensor
wi re connector i s fi rml y connected to harness connec-
tor (Fi g. 5).
(16) Veri fy MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 6). Al so veri fy
rubber L-shaped fi tti ng from MAP sensor to throttl e
body i s fi rml y connected (Fi g. 7).
Fig. 4 PCV Valve Hose Connections3.9/5.2/5.9L
EnginesTypical
1 - PCV VALVE
2 - PCV VALVE HOSE CONNECTIONS
Fig. 5 Intake Manifold Air Temperature Sensor
Typical
1 - INTAKE MANIFOLD AIR TEMPERATURE SENSOR
Fig. 6 Sensor and IAC Motor LocationTypical (V-8
Shown)
1 - MAP SENSOR
2 - IDLE AIR CONTROL MOTOR
3 - THROTTLE POSITION SENSOR
FUEL INJ ECTION (Continued)
(17) Veri fy fuel i njector wi re harness connectors
are fi rml y connected to i njectors i n correct order.
Each harness connector i s numeri cal l y tagged wi th
i njector number (I NJ 1, I NJ 2 etc.) of i ts correspond-
i ng fuel i njector and cyl i nder number.
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor, throttl e posi -
ti on sensor (TPS) and mani fol d absol ute pressure
(MAP) sensor (Fi g. 6).
(19) Veri fy wi re harness connector i s fi rml y con-
nected to engi ne cool ant temperature sensor (Fi g. 8).
(21) All 3.9L V-6 and 5.2L V-8. All 5.9L V-8
With Four Wheel Drive (4WD) : Veri fy both
upstream and downstream oxygen sensor wi re con-
nectors are fi rml y connected to sensors. I nspect sen-
sors and connectors for damage (Fi g. 9) or (Fi g. 10).
Fig. 7 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body
1 - MAP SENSOR
2 - RUBBER FITTING
3 - IDLE AIR PASSAGE
Fig. 8 Engine Coolant Temperature Sensor3.9/5.2L
1 - GENERATOR
2 - A/C COMPRESSOR
4 - ELEC. CONN.
Fig. 9 Upstream Oxygen SensorAll 3.9/5.2L
Engines or 5.9L
1 - EXHAUST PIPE
2 - UPSTREAM OXYGEN SENSOR
(22) 5.9L V-8 Engine With Two Wheel Drive
(2WD):
(a) Thi s engi ne/transmi ssi on i s equi pped wi th 4
oxygen sensors. Veri fy both pre-catal yst and post-
catal yst oxygen sensor wi re connectors (before and
after catal yti c convertor) are fi rml y connected to
sensors (Fi g. 11). I nspect sensors and connectors
for damage.
(b) Veri fy l eft and ri ght oxygen sensor wi re con-
nectors (at exhaust downpi pes) are fi rml y con-
nected to sensors (Fi g. 12). I nspect sensors and
connectors for damage.
(23) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(24) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(25) I f equi pped wi th automati c transmi ssi on, ver-
i fy el ectri cal harness i s fi rml y connected to park/neu-
tral swi tch. Refer to Automati c Transmi ssi on.
(26) Veri fy el ectri cal harness i s fi rml y connected to
rear wheel speed sensor. Veri fy rear wheel speed sen-
sor i s fi rml y attached to rear axl e wi th proper ai r
gap. Refer to 5, Brakes for i nformati on.
(27) I f equi pped wi th 4wheel anti l ock brake sys-
tem, veri fy el ectri cal harness i s fi rml y connected to
each front wheel speed sensor. Veri fy both front
wheel speed sensors are fi rml y attached. Refer to 5,
Brakes for i nformati on.
(28) Veri fy fuel pump/gauge sender uni t wi re con-
nector i s fi rml y connected to harness connector.
(29) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
(30) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(31) Veri fy battery cabl e and sol enoi d feed wi re
connecti ons to starter sol enoi d are ti ght and cl ean.
I nspect for chaffed wi res or wi res rubbi ng agai nst
other components.
Fig. 10 Downstream Oxygen Sensor3.9/5.2L
Engines or 5.9L Engine With 4WD
1 - DOWNSTREAM OXYGEN SENSOR
2 - FRAME RAIL
Fig. 11 Pre-Catalyst/Post-Catalyst Oxygen
Sensors5.9L Engine With 2WD
1 - PRE-CATALYST OXYGEN SENSOR
2 - POST-CATALYST OXYGEN SENSOR
Fig. 12 Left/Right Oxygen Sensors5.9L Engine
With 2WD
1 - LEFT OXYGEN SENSOR
2 - RIGHT OXYGEN SENSOR
DIAGNOSIS AND TESTING - VISUAL
INSPECTION 2. 5L ENGINE
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy three 32way el ectri cal connectors are
ful l y i nserted i nto connector of powertrai n control
modul e (PCM) (Fi g. 13).
(2) I nspect battery cabl e connecti ons. Be sure they
are cl ean and ti ght.
(3) I nspect fuel pump rel ay connecti ons. I nspect
ASD rel ay connecti ons. I nspect starter motor rel ay
connecti ons. I nspect rel ays for si gns of physi cal dam-
age and corrosi on. The rel ays are l ocated i n Power
Di stri buti on Center (PDC) (Fi g. 14). Refer to l abel on
PDC cover for rel ay l ocati on.
(4) I nspect i gni ti on coi l connecti ons. Veri fy coi l sec-
ondary cabl e i s fi rml y connected to coi l (Fi g. 15).
(5) Veri fy di stri butor cap i s correctl y attached to
di stri butor. Be sure spark pl ug cabl es are fi rml y con-
nected to di stri butor cap and the spark pl ugs are i n
thei r correct fi ri ng order. Be sure coi l cabl e i s fi rml y
connected to di stri butor cap and coi l . Be sure cam-
shaft posi ti on sensor wi re connector (at the di stri bu-
tor) i s fi rml y connected to harness connector. I nspect
spark pl ug condi ti on. Refer to 8, I gni ti on. Connect
vehi cl e to an osci l l oscope and i nspect spark events
for foul ed or damaged spark pl ugs or cabl es.
(6) Veri fy generator output wi re, generator connec-
tor and ground wi re are fi rml y connected to the gen-
erator.
(7) I nspect system body grounds for l oose or di rty
connecti ons. Refer to 8, Wi ri ng for ground l ocati ons.
Fig. 13 Powertrain Control Module (PCM)
4 - COVER
1 - IGNITION COIL
4 - SECONDARY CABLE
(8) Veri fy Crankcase Venti l ati on (CCV) system
operati on. Veri fy CCV system hoses and fi xed ori fi ce
fi tti ng are fi rml y connected (Fi g. 16). Refer to 25,
Emi ssi on Control System for addi ti onal i nformati on.
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy hose connecti ons to al l ports of vacuum
fi tti ngs on i ntake mani fol d are ti ght and not l eaki ng.
(11) I nspect accel erator cabl e and throttl e cabl e.
Check thei r connecti ons to throttl e arm of throttl e
body for any bi ndi ng or restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
vacuum booster hose i s fi rml y connected to fi tti ng on
i ntake mani fol d. Al so check connecti on to brake vac-
uum booster.
(13) I nspect ai r cl eaner i nl et and ai r cl eaner el e-
ment for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy i ntake mani fol d ai r temperature sensor
wi re connector i s fi rml y connected to harness connec-
tor (Fi g. 17).
(16) Veri fy MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 18). Al so veri fy
rubber L-shaped fi tti ng from MAP sensor to throttl e
body i s fi rml y connected.
(17) Veri fy fuel i njector wi re harness connectors
are fi rml y connected to i njectors i n the correct order.
Each harness connector i s numeri cal l y tagged wi th
i njector number (I NJ 1, I NJ 2 etc.) of i ts correspond-
i ng fuel i njector and cyl i nder number.
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor, throttl e posi -
Fig. 16 CCV System2.5L Engine
3 - CCV TUBE
4 - CCV TUBE
2.5L Engine
1 - FUEL PRESSURE TEST PORT
4 - FUEL INJECTOR
Fig. 18 Sensor Location2.5L Engine
2 - IAT SENSOR
3 - THROTTLE BODY
5 - MAP SENSOR
6 - IDLE AIR CONTROL PASSAGE INLET
7 - THROTTLE BODY MOUNTING BOLTS (4)
ti on sensor (TPS) and mani fol d absol ute pressure
(MAP) sensor (Fi g. 18).
(19) Veri fy wi re harness connector i s fi rml y con-
nected to engi ne cool ant temperature sensor (Fi g.
19).
(21) Veri fy both upstream and downstream oxygen
sensor wi re connectors are fi rml y connected to sen-
sors. I nspect sensors and connectors for damage (Fi g.
20) or (Fi g. 21).
(22) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(23) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(24) Veri fy el ectri cal harness i s fi rml y connected to
rear wheel speed sensor. Veri fy rear wheel speed sen-
sor i s fi rml y attached to rear axl e wi th proper ai r
gap. Refer to 5, Brakes for i nformati on.
(25) I f equi pped wi th 4wheel anti l ock brake sys-
tem, veri fy el ectri cal harness i s fi rml y connected to
each front wheel speed sensor. Veri fy both front
wheel speed sensors are fi rml y attached. Refer to 5,
Brakes for i nformati on.
(26) Veri fy fuel pump/gauge sender uni t wi re con-
nector i s fi rml y connected to harness connector.
(27) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
(28) I nspect cl utch housi ng for damage to ti mi ng
ri ng on dri ve pl ate/fl ywheel .
(29) Veri fy battery cabl e and sol enoi d feed wi re
connecti ons to the starter sol enoi d are ti ght and
cl ean. I nspect for chaffed wi res or wi res rubbi ng
agai nst other components.
Engine
Fig. 20 Upstream Oxygen Sensor2.5L Engine
2 - EXHAUST PIPE
Fig. 21 Downstream Oxygen
2 - FRAME RAIL
SPECIFICATIONS
SPECIFICATIONS - TORQUE
Engine Coolant Temperature SensorAll Engines 11 96
IAC Motor-To-Throttle Body Bolts 7 60
Intake Manifold Air Temp. SensorAll Engines 28 20
MAP Sensor Mounting ScrewsAll Engines 3 25
Oxygen SensorAll Engines 30 22
Power Steering Pressure Switch 14-22 124-195
Powertrain Control Module Mounting Screws 3-5 30-40
Throttle Body Mounting Bolts2.5L Engine 11 100
Throttle Body Mounting Bolts3.9L/5.2L Engines 23 200
Throttle Position Sensor Mounting ScrewsAll
Engines
7 60
ACCELERATOR PEDAL
REMOVAL
Al l engi nes are equi pped wi th torsi on return
spri ngs l ocated on the throttl e body shaft. 3.9L V-6
and 5.2/5.9L V-8 engi nes equi pped wi th a manual
transmi ssi on have an addi ti onal pedal return spri ng
on the throttl e body l i nkage.
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or cables.
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner and throttl e
cabl e core wi re from upper end of pedal arm (Fi g.
22). Pl asti c cabl e retai ner snaps i nto pedal arm.
(2) Remove two accel erator pedal /bracket nuts
(Fi g. 22)and remove pedal /bracket assembl y from
vehi cl e.
INSTALLATION
Al l engi nes are equi pped wi th torsi on return
spri ngs l ocated on the throttl e body shaft. 3.9L V-6
and 5.2/5.9L V-8 engi nes equi pped wi th a manual
transmi ssi on have an addi ti onal pedal return spri ng
on the throttl e body l i nkage.
(1) Posi ti on pedal /bracket assembl y over the two
dash panel mounti ng studs and i nstal l retai ni ng
nuts.
(2) Ti ghten nuts to 7 Nm (65 i n. l bs.) torque.
(3) From i nsi de the vehi cl e, hol d up the accel erator
pedal . I nstal l the throttl e cabl e core wi re and pl asti c
cabl e retai ner i nto the upper end of the pedal arm.
The pl asti c retai ner i s snapped i nto the pedal arm.
Fig. 22 Accelerator PedalRemoval or Installation
1 - PINCH SIDES
2 - CABLE
3 - CABLE RETAINER
4 - NUTS (2)
5 - ACCELERATOR PEDAL
When i nstal l i ng the pl asti c retai ner to the accel era-
tor pedal arm, note the i ndex tab on the pedal arm
(Fi g. 23). Al i gn the i ndex sl ot (Fi g. 23) on the pl asti c
cabl e retai ner to thi s i ndex tab.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION - 2. 5L
The Crankshaft Posi ti on (CKP) sensor i s l ocated
near the outer edge of the fl ywheel (or starter
ri ngear).
DESCRIPTION - 3. 9L
near the outer edge of the fl ywheel (starter ri ngear).
DESCRIPTION - 5. 2L/5. 9L
near the outer edge of the fl ywheel (starter ri ngear).
DESCRIPTION - 4. 7L
The Crankshaft Posi ti on Sensor (CKP) i s mounted
i nto the ri ght-rear si de of the engi ne bl ock (Fi g. 24).
OPERATION - 2. 5L
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP sensor. The sensor generates pul ses
that are the i nput sent to the Powertrai n Control
Modul e (PCM). The PCM i nterprets the sensor i nput
to determi ne the crankshaft posi ti on. The PCM then
uses thi s posi ti on, al ong wi th other i nputs, to deter-
mi ne i njector sequence and i gni ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
The fl ywheel /dri ve pl ate has groups of four notches
at i ts outer edge. On 2.5L 4-cyl i nder engi nes there
are two sets of notches (Fi g. 25).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are two
groups of four pul ses generated on 2.5L 4-cyl i nder
engi nes.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
The engi ne wi l l not operate i f the PCM does not
recei ve a CKP sensor i nput.
OPERATION - 3. 9L
The fl ywheel /dri ve pl ate has groups of notches at
i ts outer edge. On 3.9L V-6 engi nes, there are three
Fig. 23 Index Tab and Slot
1 - INDEX TAB
2 - INDEX SLOT
3 - CABLE RETAINER
4 - PEDAL ARM
Fig. 24 CKP Sensor Location4.7L V8 Engine
2 - MOUNTING BOLT
ACCELERATOR PEDAL (Continued)
sets of doubl e notches and three sets of si ngl e
notches (Fi g. 26).
to the PCM.
OPERATION - 5. 2L/5. 9L
On 5.2/5.9L V-8 engi nes, the fl ywheel /dri ve pl ate
has 8 si ngl e notches, spaced every 45 degrees, at i ts
outer edge (Fi g. 27).
to the PCM. For each engi ne revol uti on, there are 8
pul ses generated on V-8 engi nes.
Fig. 25 CKP Sensor Operation2.5L 4-Cyl. Engine
2 - NOTCHES
3 - FLYWHEEL
Fig. 26 CKP Sensor Operation3.9L Engine
1 - FLYWHEEL
2 - NOTCHES
Fig. 27 CKP Sensor Operation5.2L/5.9L Engine
2 - NOTCHES
3 - FLYWHEEL
CRANKSHAFT POSITION SENSOR (Continued)
OPERATION - 4. 7L
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
On the 4.7L V8 engi ne, a tonewheel i s bol ted to
the engi ne crankshaft (Fi g. 28). Thi s tonewheel has
sets of notches at i ts outer edge (Fi g. 28).
to the PCM.
REMOVAL - 2. 5L
The crankshaft posi ti on sensor i s mounted i n the
transmi ssi on bel l housi ng at l eft/rear si de of engi ne
bl ock (Fi g. 29).
(1) Remove ai r tube between throttl e body and ai r
cl eaner housi ng.
(2) Near rear of i ntake mani fol d, di sconnect pi gtai l
harness (on the sensor) from mai n el ectri cal harness.
(3) Remove 2 sensor mounti ng bol ts.
(4) Remove sensor.
(5) Remove cl i p from sensor wi re harness.
REMOVAL - 3. 9/5. 2/5. 9L
The sensor i s bol ted to the top of the cyl i nder bl ock
near the rear of ri ght cyl i nder head (Fi g. 30). The
sensor i s accessed by removi ng the ri ght front fender
l i ner.
(1) Remove ri ght front ti re and ri ght front wheel -
house l i ner. Refer to Front Wheel house Li ner i n
Group 23, Body.
(2) Di sconnect crankshaft posi ti on sensor pi gtai l
harness from mai n wi ri ng harness.
(3) Remove two sensor (recessed hex head) mount-
i ng bol ts (Fi g. 30).
(4) Remove sensor from engi ne.
Fig. 28 CKP Sensor Operation and Tonewheel4.7L
V8 Engine
1 - TONEWHEEL
2 - NOTCHES
4 - CRANKSHAFT
Fig. 29 Crankshaft Position Sensor2.5L 4-Cylinder
Engine
2 - TRANSMISSION BELLHOUSING
5 - RUBBER GROMMET
6 - PIGTAIL HARNESS
REMOVAL - 4. 7L
The Crankshaft Posi ti on (CKP) sensor i s l ocated at
the ri ght-rear si de of the engi ne cyl i nder bl ock (Fi g.
31). I t i s posi ti oned and bol ted i nto a machi ned hol e
i n the engi ne bl ock.
(1) Di sconnect CKP el ectri cal connector at sensor.
(2) Remove CKP mounti ng bol t (Fi g. 31).
(3) Careful l y pry sensor from cyl i nder bl ock i n a
rocki ng acti on wi th two smal l screwdri vers.
(4) Remove sensor from vehi cl e.
(5) Check condi ti on of sensor o-ri ng.
The crankshaft posi ti on sensor i s mounted i n the
transmi ssi on bel l housi ng at l eft/rear si de of engi ne
bl ock (Fi g. 29).
(1) I nstal l sensor fl ush agai nst openi ng i n trans-
mi ssi on housi ng.
(2) I nstal l and ti ghten two sensor mounti ng bol ts
CAUTION: Two bolts are used to secure the sensor
to transmission. These bolts are specially machined
to correctly space the unit to flywheel. Do not
attempt to install any other bolts.
(4) I nstal l cl i p on sensor wi re harness.
(5) I nstal l ai r tube between throttl e body and ai r
cl eaner housi ng.
INSTALLATION - 3. 9/5. 2/5. 9L
(1) Posi ti on crankshaft posi ti on sensor to engi ne.
(2) I nstal l mounti ng bol ts and ti ghten to 8 Nm (70
i n. l bs.) torque.
(3) Connect mai n harness el ectri cal connector to
sensor.
(4) I nstal l ri ght front ti re and ri ght front wheel -
house l i ner. Refer to Front Wheel house Li ner i n
Group 23, Body.
(1) Cl ean out machi ned hol e i n engi ne bl ock.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto engi ne bl ock wi th a sl i ght
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 28 Nm
Fig. 30 Crankshaft Position Sensor3.9/5.2/5.9L
Engines
1 - GROMMET
4 - RIGHT EXHAUST MANIFOLD
5 - TRANSMISSION BELL HOUSING
Fig. 31 CKP Sensor Location/Removal/Installation
4.7L V8 Engine
2 - MOUNTING BOLT
FUEL INJ ECTOR
DESCRIPTION
An i ndi vi dual fuel i njector (Fi g. 32) i s used for each
i ndi vi dual cyl i nder.
OPERATION
The top (fuel entry) end of the i njector (Fi g. 32) i s
attached i nto an openi ng on the fuel rai l .
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
OPERATION - PCM OUTPUT
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a sequen-
ti al order by the Powertrai n Control Modul e (PCM). The
PCM wi l l adjust i njector pul se wi dth by swi tchi ng the
ground path to each i ndi vi dual i njector on and off. I njec-
tor pul se wi dth i s the peri od of ti me that the i njector i s
energi zed. The PCM wi l l adjust i njector pul se wi dth
based on vari ous i nputs i t recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
DIAGNOSIS AND TESTING - FUEL INJECTOR
TEST
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, use the DRB scan tool and refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. The i njector i s equi pped wi th 2
el ectri cal termi nal s (pi ns). Pl ace an ohmmeter across
the termi nal s. Resi stance readi ng shoul d be approxi -
matel y 12 ohms 1.2 ohms at 20C (68F).
REMOVAL
STANT PRESSURE EVEN WITH ENGINE TURNED
OFF. BEFORE SERVICING FUEL INJECTOR(S),
sure Rel ease Procedure.
To remove one or more fuel i njectors, fuel rai l
assembl y must be removed from engi ne.
(2) Remove fuel i njector rai l assembl y. Refer to
Fuel I njector Rai l Removal /I nstal l ati on i n thi s group.
(3) Remove cl i p(s) retai ni ng the i njector(s) to fuel
rai l (Fi g. 24) or (Fi g. 25).
(4) Remove i njector(s) from fuel rai l .
Fig. 32 Fuel InjectorTypical
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
INSTALLATION
STANT PRESSURE EVEN WITH ENGINE TURNED
OFF. BEFORE SERVICING FUEL INJECTOR(S),
sure Rel ease Procedure.
To remove one or more fuel i njectors, fuel rai l
assembl y must be removed from engi ne.
each fuel i njector o-ri ng. Thi s wi l l hel p i n fuel rai l
i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel
rai l .
(3) I nstal l fuel rai l assembl y. Refer to Fuel I njector
Rai l Removal /I nstal l ati on.
(4) I nstal l ai r cl eaner.
FUEL PUMP RELAY
DESCRIPTION
The 5pi n, 12vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 13 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
REMOVAL
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 33) . Refer to l abel on PDC
INSTALLATION
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 33) . Refer to l abel on PDC
IDLE AIR CONTROL MOTOR
DESCRIPTION
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes.
A pi ntl e on the I AC stepper motor protrudes i nto a
passage i n the throttl e body, control l i ng ai r fl ow
through the passage. The I AC i s control l ed by the
Powertrai n Control Modul e (PCM) to mai ntai n the
target engi ne i dl e speed.
OPERATION
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
FUEL INJ ECTOR (Continued)
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
Decel erati on ai r fl ow control
A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a No-Load engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
REMOVAL - 3. 9L/5. 2L/5. 9L
The I AC motor i s l ocated on the back of the throt-
tl e body (Fi g. 34).
(1) Remove ai r duct at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 34).
(4) Remove I AC motor from throttl e body.
REMOVAL - 4. 7L
The I AC motor i s l ocated on the throttl e body.
(1) Remove ai r duct and ai r resonator box at throt-
tl e body.
(2) Di sconnect el ectri cal connector from I AC motor
(Fi g. 54).
REMOVAL - 2. 5L
The I AC motor i s l ocated on the si de of the throttl e
body (Fi g. 35).
(2) Di sconnect el ectri cal connector from I AC motor.
Fig. 34 Mounting Bolts (Screws)IAC Motor3.9/
5.2/5.9L Engines
1 - MOUNTING SCREWS
2 - IDLE SPEED MOTOR
IDLE AIR CONTROL MOTOR (Continued)
The I AC motor i s l ocated on the back of the throt-
tl e body (Fi g. 34).
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r duct at throttl e body.
(4) I nstal l ai r duct/ai r box to throttl e body.
The I AC motor i s l ocated on the si de of the throttl e
body (Fi g. 35).
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The 2wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
REMOVAL - 3. 9L/5. 2L/5. 9L
The i ntake mani fol d ai r temperature sensor i s
l ocated i n the front/si de of the i ntake mani fol d (Fi g.
36).
(2) Di sconnect el ectri cal connector at sensor (Fi g.
36).
Fig. 35 Mounting Bolts (Screws)
IAC Motor2.5L Engine
2 - MOUNTING SCREWS
3.9/5.2/5.9L EnginesTypical
IDLE AIR CONTROL MOTOR (Continued)
REMOVAL - 4. 7L
The I ntake Mani fol d Ai r Temperature (I AT) sensor
i s i nstal l ed i nto the i ntake mani fol d pl enum near the
l eft si de of the throttl e body (Fi g. 37).
(1) Di sconnect el ectri cal connector from sensor.
REMOVAL - 2. 5L
l ocated i n the i ntake mani fol d (Fi g. 38).
(2) Di sconnect el ectri cal connector at sensor (Fi g.
38).
l ocated i n the front/si de of the i ntake mani fol d (Fi g.
36).
(1) I nstal l sensor to i ntake mani fol d. Ti ghten to 28
(1) I nstal l sensor i nto i ntake mani fol d. Ti ghten
sensor to 28 Nm (20 ft. l bs.) torque.
l ocated i n the i ntake mani fol d (Fi g. 38).
(1) I nstal l sensor to i ntake mani fol d. Ti ghten to 28
MAP SENSOR
The Mani fol d Absol ute Pressure (MAP) sensor i s
attached to the si de of the engi ne throttl e body wi th
2 screws. The sensor i s connected to the throttl e body
wi th a rubber L-shaped fi tti ng.
Fig. 37 Intake Manifold Air Sensor Location4.7L
V-8 Engine
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR
5 - MOUNTING SCREWS
2.5L Engine
1 - FUEL PRESSURE TEST PORT
4 - FUEL INJECTOR
INTAKE AIR TEMPERATURE SENSOR (Continued)
DESCRIPTION - 4. 7L
The MAP sensor i s l ocated on the front of the
i ntake mani fol d. An o-ri ng seal s the sensor to the
i ntake mani fol d.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 015
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
Mani fol d pressure
Barometri c pressure
Engi ne l oad
Spark-advance programs
Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
I dl e speed
Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
The range of vol tage output from the sensor i s usu-
al l y between 4.6 vol ts at sea l evel to as l ow as 0.3
vol ts at 26 i n. of Hg. Barometri c pressure i s the pres-
sure exerted by the atmosphere upon an object. At
sea l evel on a standard day, no storm, barometri c
pressure i s approxi matel y 29.92 i n Hg. For every 100
feet of al ti tude, barometri c pressure drops .10 i n. Hg.
I f a storm goes through i t can change barometri c
pressure from what shoul d be present for that al ti -
tude. You shoul d know what the average pressure
and correspondi ng barometri c pressure i s for your
area.
MAP SENSOR (Continued)
REMOVAL - 3. 9L/5. 2L/5. 9L
throttl e body (Fi g. 39). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
40).
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 39).
(3) Whi l e removi ng MAP sensor, sl i de the vacuum
rubber L-shaped fi tti ng (Fi g. 40) from the throttl e
body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
REMOVAL - 4. 7L
i ntake mani fol d (Fi g. 41). An o-ri ng seal s the sensor
to the i ntake mani fol d.
(1) Di sconnect el ectri cal connector at sensor.
(2) Cl ean area around MAP sensor.
(3) Remove 2 sensor mounti ng bol ts (Fi g. 41).
(4) Remove MAP sensor from i ntake mani fol d.
Fig. 39 MAP Sensor Location3.9/5.2/5.9L Engines
1 - MAP SENSOR
Fig. 40 MAP Sensor L-Shaped Rubber Fitting3.9/
5.2/5.9L Engines
1 - MAP SENSOR
2 - RUBBER FITTING
3 - IDLE AIR PASSAGE
Fig. 41 MAP and ECT Sensor Locations4.7L V8
Engine
1 - ECT SENSOR
3 - MAP SENSOR
4 - INTAKE MANIFOLD
REMOVAL - 2. 5L
The MAP sensor i s mounted to the si de of the
43).
(2) Remove el ectri cal connector at sensor.
(3) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 43).
(4) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 43) from the throttl e body.
(5) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
40).
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
i ntake mani fol d (Fi g. 41). An o-ri ng seal s the sensor
to the i ntake mani fol d.
(1) Cl ean MAP sensor mounti ng hol e at i ntake
mani fol d.
(2) Check MAP sensor o-ri ng seal for cuts or tears.
(3) Posi ti on sensor i nto mani fol d.
(5) Connect el ectri cal connector.
The MAP sensor i s mounted to the si de of the
43).
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(4) I nstal l el ectri cal connector at sensor.
Fig. 42 MAP Sensor Location2.5L Engine
2 - IAT SENSOR
3 - THROTTLE BODY
5 - MAP SENSOR
Fig. 43 MAP Sensor Mounting and Rubber
Fitting2.5L Engine
1 - THROTTLE BODY
2 - MAP SENSOR
3 - RUBBER FITTING
O2 HEATER RELAY
DESCRIPTION
The oxygen (O2) sensor heater rel ay i s l ocated i n
the Powertrai n Di stri buti on Center (PDC).
OPERATION
Refer to Oxygen Sensor for oxygen sensor rel ay
i nformati on.
REMOVAL
The oxygen sensor heater rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 33). Refer to
INSTALLATION
The oxygen sensor heater rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 33). Refer to
O2 SENSOR
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the emi ssi on package, the vehi cl e may use a total
of ei ther 2 or 4 sensors.
NAA Emissions Package: Two sensors are used:
upstream (referred to as 1/1) and downstream
(referred to as 1/2). Wi th thi s emi ssi on package, the
upstream sensor (1/1) i s l ocated just before the mai n
catal yti c convertor. The downstream sensor (1/2) i s
l ocated just after the mai n catal yti c convertor.
NAS or NAE Emissions Package: On thi s emi s-
si ons package, 4 sensors are used: 2 upstream
(referred to as 1/1 and 2/1) and 2 downstream
(referred to as 1/2 and 2/2). Wi th thi s emi ssi on pack-
age, the ri ght upstream sensor (2/1) i s l ocated i n the
ri ght exhaust downpi pe just before the mi ni -catal yti c
convertor. The l eft upstream sensor (1/1) i s l ocated i n
the l eft exhaust downpi pe just before the mi ni -cata-
l yti c convertor. The ri ght downstream sensor (2/2) i s
l ocated i n the ri ght exhaust downpi pe just after the
mi ni -catal yti c convertor, and before the mai n cata-
l yti c convertor. The l eft downstream sensor (1/2) i s
l ocated i n the l eft exhaust downpi pe just after the
mi ni -catal yti c convertor, and before the mai n cata-
l yti c convertor.
OPERATION
An O2 sensor i s a gal vani c battery that provi des
the PCM wi th a vol tage si gnal (0-1 vol t) i nversel y
proporti onal to the amount of oxygen i n the exhaust.
I n other words, i f the oxygen content i s l ow, the vol t-
age output i s hi gh; i f the oxygen content i s hi gh the
output vol tage i s l ow. The PCM uses thi s i nformati on
to adjust i njector pul se-wi dth to achi eve the
14.7to1 ai r/fuel rati o necessary for proper engi ne
operati on and to control emi ssi ons.
The O2 sensor must have a source of oxygen from
outsi de of the exhaust stream for compari son. Cur-
rent O2 sensors recei ve thei r fresh oxygen (outsi de
ai r) suppl y through the wi re harness. Thi s i s why i t
i s i mportant to never sol der an O2 sensor connector,
or pack the connector wi th grease.
Four wi res (ci rcui ts) are used on each O2 sensor: a
12vol t feed ci rcui t for the sensor heati ng el ement; a
ground ci rcui t for the heater el ement; a l ow-noi se
sensor return ci rcui t to the PCM, and an i nput ci r-
cui t from the sensor back to the PCM to detect sen-
sor operati on.
Oxygen Sensor Heater Relay: I f the vehi cl e i s
equi pped wi th 4 oxygen sensors, a separate oxygen
sensor rel ay i s used to suppl y vol tage to the sensor
heati ng el ements. Thi s parti cul ar rel ay i s used onl y
for the 1/2 and 2/2 downstream sensors. Vol tage for
the other 2 sensor heati ng el ements i s suppl i ed
di rectl y from the ASD rel ay. Refer to 8, Wi ri ng Di a-
grams to determi ne whi ch rel ay i s used.
To avoi d the l arge si mul taneous current surge
needed to operate al l 4 sensors, power i s del ayed to
the 2 downstream heater el ements by the PCM for
approxi matel y 2 seconds.
Oxygen Sensor Heater Elements:
The O2 sensor uses a Posi ti ve Thermal Co-effi ci ent
(PTC) heater el ement. As temperature i ncreases,
resi stance i ncreases. At ambi ent temperatures
around 70F, the resi stance of the heati ng el ement i s
approxi matel y 4.5 ohms on 2.5/3.9/5.2 and 5.9L
engi nes. I t i s approxi matel y 13.5 ohms on the 4.7L
engi ne. As the sensors temperature i ncreases, resi s-
tance i n the heater el ement i ncreases. Thi s al l ows
the heater to mai ntai n the opti mum operati ng tem-
perature of approxi matel y 930-1100F (500-600 C).
Al though the sensors operate the same, there are
physi cal di fferences, due to the envi ronment that
they operate i n, that keep them from bei ng i nter-
changeabl e.
Mai ntai ni ng correct sensor temperature at al l
ti mes al l ows the system to enter i nto cl osed l oop
operati on sooner. Al so, i t al l ows the system to remai n
i n cl osed l oop operati on duri ng peri ods of extended
i dl e.
I n Cl osed Loop operati on, the PCM moni tors cer-
tai n O2 sensor i nput(s) al ong wi th other i nputs, and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
Upstream Sensor - Engine Equipped With 2
Sensors: The upstream sensor (1/1) provi des an
i nput vol tage to the PCM. The i nput tel l s the PCM
the oxygen content of the exhaust gas. The PCM uses
thi s i nformati on to fi ne tune fuel del i very to mai n-
tai n the correct oxygen content at the downstream
oxygen sensor. The PCM wi l l change the ai r/fuel
rati o unti l the upstream sensor i nputs a vol tage that
the PCM has determi ned wi l l make the downstream
sensor output (oxygen content) correct.
The upstream oxygen sensor al so provi des an i nput
to determi ne catal yti c convertor effi ci ency.
Downstream Sensor - Engine Equipped With
2 Sensors: The downstream oxygen sensor (1/2) i s
al so used to determi ne the correct ai r-fuel rati o. As
the oxygen content changes at the downstream sen-
sor, the PCM cal cul ates how much ai r-fuel rati o
change i s requi red. The PCM then l ooks at the
upstream oxygen sensor vol tage and changes fuel
del i very unti l the upstream sensor vol tage changes
enough to correct the downstream sensor vol tage
(oxygen content).
The downstream oxygen sensor al so provi des an
i nput to determi ne catal yti c convertor effi ci ency.
Upstream Sensors - Engine Equipped With 4
Sensors: Two upstream sensors are used (1/1 and
2/1). The 1/1 sensor i s the fi rst sensor to recei ve
exhaust gases from the #1 cyl i nder. They provi de an
i nput vol tage to the PCM. The i nput tel l s the PCM
the oxygen content of the exhaust gas. The PCM uses
thi s i nformati on to fi ne tune fuel del i very to mai n-
tai n the correct oxygen content at the downstream
oxygen sensors. The PCM wi l l change the ai r/fuel
rati o unti l the upstream sensors i nput a vol tage that
the PCM has determi ned wi l l make the downstream
sensors output (oxygen content) correct.
The upstream oxygen sensors al so provi de an i nput
to determi ne mi ni -catal yst effi ci ency. Mai n catal yti c
convertor effi ci ency i s not cal cul ated wi th thi s pack-
age.
Downstream Sensors - Engine Equipped With
4 Sensors: Two downstream sensors are used (1/2
and 2/2). The downstream sensors are used to deter-
mi ne the correct ai r-fuel rati o. As the oxygen content
changes at the downstream sensor, the PCM cal cu-
l ates how much ai r-fuel rati o change i s requi red. The
PCM then l ooks at the upstream oxygen sensor vol t-
age, and changes fuel del i very unti l the upstream
sensor vol tage changes enough to correct the down-
stream sensor vol tage (oxygen content).
The downstream oxygen sensors al so provi de an
i nput to determi ne mi ni -catal yst effi ci ency. Mai n cat-
al yti c convertor effi ci ency i s not cal cul ated wi th thi s
package.
Engi nes equi pped wi th ei ther a downstream sen-
sor(s), or a post-catal yti c sensor, wi l l moni tor cata-
l yti c convertor effi ci ency. I f effi ci ency i s bel ow
emi ssi on standards, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated and a Di agnosti c Troubl e
Code (DTC) wi l l be set. Refer to Moni tored Systems
i n Emi ssi on Control Systems for addi ti onal i nforma-
ti on.
O2 SENSOR (Continued)
Never apply any type of grease to the oxygen
sensor electrical connector, or attempt any sol-
dering of the sensor wiring harness. For sensor
operation, it must have a comparison source of
oxygen from outside the exhaust system. This
fresh air is supplied to the sensor through its
pigtail wiring harness.
For sensor l ocati ons, refer to (Fi g. 44), (Fi g. 45),
(Fi g. 46) (Fi g. 47) or (Fi g. 48).
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
Fig. 44 Upstream Oxygen Sensor Locations
Except 4.7L V-8 Engine
1 - EXHAUST PIPE
Fig. 45 Downstream Oxygen Sensor Location
2 - FRAME RAIL
Fig. 46 Pre-Catalyst/Post-Catalyst Oxygen Sensor
LocationsExcept 4.7L V-8 Engine
1 - PRE-CATALYST OXYGEN SENSOR
2 - POST-CATALYST OXYGEN SENSOR
Fig. 47 Left/Right Oxygen Sensor Locations
1 - LEFT OXYGEN SENSOR
2 - RIGHT OXYGEN SENSOR
(2) Di sconnect the wi re connector from the O2S
sensor.
CAUTION: When disconnecting the sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove the O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
Fig. 48 Oxygen Sensor Locations4.7L V-8 Engine
REMOVAL - 2. 5L
Never apply any type of grease to the oxygen
sensor electrical connector, or attempt any sol-
dering of the sensor wiring harness. For sensor
operation, it must have a comparison source of
oxygen from outside the exhaust system. This
fresh air is supplied to the sensor through its
pigtail wiring harness.
The upstream O2S sensor i s l ocated i n the exhaust
downpi pe. The downstream sensor i s l ocated near
outl et end of catal yti c converter. Refer to (Fi g. 49) or
(Fi g. 50).
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Di sconnect the wi re connector from the O2S
sensor.
CAUTION: When disconnecting the sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove the O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) I nstal l the O2S sensor. Ti ghten to 30 Nm (22
ft. l bs.) torque.
(2) Connect the O2S sensor wi re connector.
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) I nstal l the O2S sensor. Ti ghten to 30 Nm (22
ft. l bs.) torque.
(2) Connect the O2S sensor wi re connector.
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
Fig. 49 Upstream Oxygen Sensor Location2.5L
Engine
2 - EXHAUST PIPE
Fig. 50 Downtream Oxygen Sensor Location2.5L
Engine
2 - FRAME RAIL
control l ed by the PCM.
REMOVAL - 3. 9L/5. 2L/5. 9L
control l ed by the powertrai n control modul e (PCM).
(1) Remove the ai r duct at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 51).
(3) Remove vacuum l i ne at throttl e body.
(4) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throttl e
Cabl e secti on of thi s group for addi ti onal i nformati on.
(5) Remove four throttl e body mounti ng bol ts (Fi g.
52).
(7) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
REMOVAL - 2. 5L
at MAP sensor, I AC motor and TPS (Fi g. 53).
Fig. 51 Sensor Electrical Connectors3.9/5.2/5.9L
EnginesTypical
1 - MAP SENSOR
Fig. 52 Throttle
2 - THROTTLE BODY
Fig. 53 Throttle Body2.5L Engine
2 - IAT SENSOR
3 - THROTTLE BODY
5 - MAP SENSOR
THROTTLE BODY (Continued)
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(5) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
REMOVAL - 4. 7L
(1) Remove the ai r duct and ai r resonator box at
throttl e body.
at I AC motor and TPS (Fi g. 54).
(3) Remove vacuum l i ne at throttl e body.
(l ever) arm. Refer to Accel erator Pedal and Throttl e
Cabl e.
(5) Remove three throttl e body mounti ng bol ts
(Fi g. 54).
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 23
(5) I nstal l control cabl es.
(6) I nstal l vacuum l i ne to throttl e body.
(7) I nstal l el ectri cal connectors.
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
(1) Cl ean throttl e body-to-i ntake mani fol d o-ri ng.
(2) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(3) I nstal l throttl e body to i ntake mani fol d by posi -
ti oni ng throttl e body to mani fol d al i gnment pi ns.
(4) I nstal l three mounti ng bol ts. Ti ghten bol ts to
12 Nm (105 i n. l bs.) torque.
(6) I nstal l vacuum l i ne to throttl e body.
(8) I nstal l ai r duct/ai r box at throttl e body.
Fig. 54 Throttle Body, Sensors and Electrical
Connectors4.7L V-8 Engine
2 - THROTTLE BODY
3 - IAT SENSOR CONNECTOR
4 - IAC MOTOR CONNECTOR
5 - TPS CONNECTOR
THROTTLE BODY (Continued)
THROTTLE CONTROL CABLE
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal or cables.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner and throttl e cabl e core
wi re from upper end of pedal arm (Fi g. 22). Pl asti c
cabl e retai ner snaps i nto pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, pi nch both si des of cabl e
housi ng retai ner at dash panel (Fi g. 22). Remove
cabl e housi ng from dash panel and pul l i nto engi ne
compartment.
(4) Remove ai r tube at top of throttl e body.
(5) 3.9/5.2/5.9L Engines:
(a) Operate throttl e body l ever (by hand) to ful l
open throttl e posi ti on. Sl i p cabl e end rearward
from pi n on throttl e l ever (Fi g. 55).
(b) Remove cabl e housi ng at throttl e body
mounti ng bracket by pressi ng forward on rel ease
tab wi th a smal l screwdri ver (Fi g. 56). To prevent
cable housing breakage, press on tab only
enough to release cable from bracket. Li ft
cabl e housi ng strai ght up from bracket whi l e press-
i ng on rel ease tab. Remove cabl e housi ng.
(6) 2.5L Engine:
(a) Remove cabl e bal l socket at throttl e body
l i nkage (snaps off toward rear of vehi cl e).
(b) Pi nch si des of cabl e housi ng cl i ps at cabl e
mounti ng bracket (Fi g. 57) to rel ease housi ng from
bracket.
(c) Unsnap cabl e housi ng at val ve cover retai ner.
(d) Remove cabl e from vehi cl e.
Fig. 55 Throttle Cable at Throttle
1 - THROTTLE LEVER PIN
2 - CAM (V-8 ENGINE ONLY)
3 - THROTTLE CABLE END
Fig. 56 Cable Release TabTypical V-6/V8 Engine
1 - TAB
Fig. 57 Throttle Cable2.5L Engine
1 - VALVE COVER RETAINER
2 - CABLE AND HOUSING
3 - BALL SOCKET
4 - THROTTLE LINKAGE BAIL
6 - CABLE HOUSING CLIPS
(7) Remove cabl e from vehi cl e.
REMOVAL - 4. 7L
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm (Fi g. 22).
Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, remove cl i p hol di ng cabl e
to dashpanel (Fi g. 22).
(4) Remove ai r box at throttl e body.
(5) Unsnap cabl e from dashpanel routi ng cl i p.
(6) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
(7) Usi ng fi nger pressure onl y, di sconnect accel era-
tor cabl e connector at throttl e body bel l crank pi n by
pushi ng connector off bel l crank pi n towards front of
vehi cl e (Fi g. 58). DO NOT try to pull connector
off perpendicular to the bellcrank pin. Connec-
tor will be broken.
(8) Li ft accel erator cabl e from top of cabl e cam
(Fi g. 58).
(9) Press tab (Fi g. 59) to rel ease pl asti c cabl e
mount from bracket. Press on tab only enough to
release cable from bracket. If tab is pressed too
much, it will be broken. Sl i de pl asti c mount (Fi g.
59) towards passenger si de of vehi cl e to remove cabl e
from bracket.
(10) Remove throttl e cabl e from vehi cl e.
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal or cables.
(1) 3.9/5.2/5.9L Engines:
(a) Snap cabl e end onto l ever pi n (Fi g. 55). On
model s wi th V-8 engi nes, be sure cabl e i s routed
under pl asti c cam (Fi g. 55).
(b) Connect cabl e to throttl e body mounti ng
bracket (push down and l ock).
(2) 2.5L Engine:
(a) Sl i p cabl e housi ng through hol e i n mounti ng
bracket and snap cabl e i nto bracket.
(b) Attach bal l socket at throttl e body l i nkage
(snaps on).
(c) Attach cabl e housi ng at val ve cover retai ner
(snaps on).
(3) I nstal l remai ni ng cabl e housi ng end i nto dash
panel openi ng (snaps i nto posi ti on).
(4) I nstal l bal l end of cabl e wi re through hol e i n
pedal arm. I nstal l pl asti c cabl e retai ner. The pl asti c
retai ner i s snapped i nto pedal arm. When i nstal l i ng
retai ner to accel erator pedal arm, note i ndex tab on
pedal arm (Fi g. 23). Al i gn i ndex sl ot (Fi g. 57) on pl as-
ti c retai ner to thi s i ndex tab.
(5) Operate and test throttl e before starti ng
engi ne.
(6) I nstal l ai r tube to throttl e body.
(1) Sl i de accel erator cabl e pl asti c mount i nto
bracket. Conti nue sl i di ng unti l tab (Fi g. 59) i s
al i gned to hol e i n mounti ng bracket.
(2) Route accel erator cabl e over top of cabl e cam.
(3) Connect cabl e end to throttl e body bel l crank
pi n (snaps on rearward).
(4) Sl i de rubber grommet away from pl asti c cabl e
housi ng.
(5) I nstal l rubber grommet i nto dash panel unti l
seated.
(6) Push cabl e housi ng i nto rubber grommet and
through openi ng i n dash panel .
Fig. 58 Accelerator Cable at Bell Crank4.7L V-8
Engine
1 - THROTTLE BODY
2 - SPEED CONTROL CABLE CONNECTOR
3 - OFF
4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
6 - CABLE CAM
7 - BELLCRANK
THROTTLE CONTROL CABLE (Continued)
(7) From i nsi de vehi cl e, i nstal l cl i p hol di ng cabl e
to dashpanel (Fi g. 22).
(8) From i nsi de vehi cl e, sl i de throttl e cabl e core
wi re i nto openi ng i n top of pedal arm.
(9) Push cabl e retai ner (cl i p) i nto pedal arm open-
i ng unti l i t snaps i n pl ace.
(10) Snap cabl e i nto dashpanel routi ng cl i p.
(11) I nstal l ai r box to throttl e body.
THROTTLE POSITION SENSOR
DESCRIPTION
The 3wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade.
OPERATION
The TPS i s a 3wi re vari abl e resi stor that provi des
the Powertrai n Control Modul e (PCM) wi th an i nput
si gnal (vol tage) that represents the throttl e bl ade
posi ti on of the throttl e body. The sensor i s connected
to the throttl e bl ade shaft. As the posi ti on of the
throttl e bl ade changes, the resi stance (output vol t-
age) of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
I gni ti on ti mi ng advance
Fuel i njecti on pul se-wi dth
I dl e (l earned val ue or mi ni mum TPS)
Off-i dl e (0.06 vol t)
Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
Decel erati on fuel l ean out
Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
REMOVAL - 3. 9L/5. 2L/5. 9L
The TPS i s l ocated on si de of throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove two TPS mounti ng bol ts (Fi g. 60).
(4) Remove TPS from throttl e body.
REMOVAL - 4. 7
The TPS i s l ocated on the throttl e body.
Fig. 59 Accelerator Cable Release Tab4.7L V-8
Engine
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
Fig. 60 TPS Mounting Bolts3.9/5.2/5.9L Engines
2 - MOUNTING SCREWS
THROTTLE CONTROL CABLE (Continued)
(1) Remove ai r duct and ai r resonator box at throt-
tl e body.
(2) Di sconnect TPS el ectri cal connector (Fi g. 54).
(3) Remove two TPS mounti ng bol ts (screws) (Fi g.
61).
(4) Remove TPS from throttl e body.
REMOVAL - 2. 5L
The TPS i s mounted to the throttl e body (Fi g. 53).
(2) Di sconnect TPS el ectri cal connector.
(3) Remove TPS mounti ng screws (Fi g. 62).
(4) Remove TPS.
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 63). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs.
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l the TPS and two retai ni ng bol ts.
(2) Ti ghten bol ts to 7 Nm (60 i n. l bs.) torque.
(3) Manual l y operate the throttl e control l ever by
hand to check for any bi ndi ng of the TPS.
(4) Connect TPS el ectri cal connector to TPS.
Fig. 61 TPS Mounting Bolts4.7L V8
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR
5 - MOUNTING SCREWS
Fig. 62 TPS Mounting Screws2.5L Engine
1 - MOUNTING SCREWS
2 - TPS
Fig. 63 Installation3.9/5.2/5.9L EnginesTypical
1 - THROTTLE BODY
3 - THROTTLE SHAFT
4 - SOCKET LOCATING TANGS
THROTTLE POSITION SENSOR (Continued)
The throttl e shaft end of throttl e body sl i des i nto a
socket i n TPS (Fi g. 64). The TPS must be i nstal l ed so
that i t can be rotated a few degrees. I f sensor wi l l
not rotate, i nstal l sensor wi th throttl e shaft on other
si de of socket tangs. The TPS wi l l be under sl i ght
tensi on when rotated.
(1) I nstal l TPS and two retai ni ng bol ts.
(2) Ti ghten bol ts to 7 Nm (60 i n. l bs.) torque.
(3) Manual l y operate throttl e control l ever by hand
to check for any bi ndi ng of TPS.
(5) I nstal l ai r duct/ai r box to throttl e body.
The TPS i s mounted to the throttl e body (Fi g. 53).
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 65). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l the TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(4) Manual l y operate the throttl e (by hand) to
check for any TPS bi ndi ng before starti ng the engi ne.
Fig. 64 TPS Installation4.7L
1 - THROTTLE BODY
2 - LOCATING TANGS
4 - SOCKET
5 - THROTTLE SHAFT
Fig. 65 Throttle Position Sensor Installation2.5L
Engine
1 - TANGS
2 - THROTTLE SHAFT
3 - THROTTLE BODY
4 - TPS
THROTTLE POSITION SENSOR (Continued)
STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING SYSTEM. . . . . . . . . . . . . . . 2
POWER STEERING FLOW AND PRESSURE . . . 4
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STEERING
DESCRIPTION
Power steeri ng systems consi st of:
Steeri ng col umn
Rack and pi ni on steeri ng gear
Bel t dri ven hydraul i c steeri ng pump
Pump pressure and return hoses
Oi l Cool er
OPERATION
The steeri ng col umn shaft i s attached to the gear
pi ni on. The rotati on of the pi ni on moves the gear
rack from si de-to-si de. Thi s l ateral acti on of the rack
pushes and pul l s the ti e rods to change the di recti on
of the front wheel s.
Power assi st i s provi ded by an engi ne mounted
hydraul i c pump, (Fi g. 1) and (Fi g. 2) the pump sup-
pl i es hydraul i c fl ui d pressure to the steeri ng gear.
Some vehi cl es are equi pped wi th an oi l cool er.
Fig. 1 Steering Pump, Gear And Oil Cooler - 5.2L & 5.9L
1 - HYDRAULIC PUMP
2 - RACK AND PINION GEAR
3 - OIL COOLER
Fig. 2 Steering Pump, Gear And Oil Cooler - 4.7L
1 - HYDRAULIC PUMP
3 - OIL COOLER
AN STEERING 19 - 1
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
OBJECTIONAL HISS OR WHISTLE 1. Steering intermediate shaft to
dash panel seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering
gear.
2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.
2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with
other components.
4. Reposition hose.
5. Loose or damaged intermediate
shaft or column.
5. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with
other components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on
hose fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and
reservoir.
4. Repair as necessary.
5. Reservoir cap not installed
correctly.
5. Install reservoir cap correctly.
SCRUBBING OR KNOCKING 1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
19 - 2 STEERING AN
STEERING (Continued)
BINDING AND STICKING
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
3. Steering components (ball joints/tie
rod ends).
3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
HARD TURNING OR
MOMENTARY INCREASE IN
TURNING EFFORT
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO
CENTER POSITION
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
EXCESSIVE PLAY IN
STEERING WHEEL
1. Worn or loose suspension or
steering components.
1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS
TO ONE SIDE.
1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
AN STEERING 19 - 3
DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool ki t 6815 (Fi g. 3) and (Fi g. 4)
Adapter Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6844.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect the tube to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to the adapter.
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge and to get ai r out of the fl ui d. Then shut off
engi ne.
(9) Check fl ui d l evel , add fl ui d as necessary. Start
engi ne agai n and l et i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. I f the fl ow rate (GPM) i s bel ow
speci fi cati on, (refer to pump speci fi cati on chart for
GPM) the pump shoul d be repl aced.
Fig. 3 Analyzer With Tube and Adapter For 5.2L &
5.9L
1 - GAUGE HOSE
2 - TUBE
3 - ADAPTER FITTINGS
4 - ANALYZER
Fig. 4 Analyzer With Tube and Adapter For 4.7L
1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE
19 - 4 STEERING AN
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
(12) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons three
ti mes agai nst the stops. Record the hi ghest pressure
readi ng at each posi ti on. Compare readi ngs to the
pump speci fi cati ons chart. I f pressures readi ngs are
not wi thi n 50 psi of each other, the gear i s l eaki ng
i nternal l y and must be repl aced.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.
PUMP SPECIFICATION
ENGINE
RELIEF PRESSURE
50
FLOW RATE
(GPM) AT 1500
RPM
5.2L 10342 kPa (1500 psi) 2.4 - 2.8
4.7L 10342 kPa (1450 psi) 2.4 - 2.8
5.9L 10342 kPa (1500 psi) 2.4 - 2.8
AN STEERING 19 - 5
COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9
IGNITION SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IGNITION SWITCH. . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
KEY-IN IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION SWITCH AND KEY LOCK
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LOCK CYLINDER HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GEAR SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COLUMN
DESCRIPTION
The ti l t and standard col umn (Fi g. 1) has been
desi gned to be servi ced as an assembl y; l ess wi ri ng,
swi tches, shrouds, steeri ng wheel , etc. Most steeri ng
col umn components can be servi ced wi thout remov-
i ng the steeri ng col umn from the vehi cl e.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Restrai nts and fol l ow al l WARNI NGS and
CAUTI ONS.
NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column shaft
or shift tube. This may cause damage to the shaft,
shift tube or bearing.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
DIAGNOSIS AND TESTING - STEERING
COLUMN
I f the vehi cl e i s i nvol ved i n a front end col l i si on/the
ai r bag has depl oyed the col umn must be i nspected.
Thi s i nspecti on wi l l determi ne i f the Col umn has col -
l apsed. I nspect the col umn mounti ng capsul es vi su-
al l y and manual l y push and pul l them to check
separati on or movement. (Fi g. 1)
19 - 6 COLUMN AN
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
(1) Posi ti on front wheel s strai ght ahead.
(2) Remove the negati ve (ground) cabl e from the
battery.
(3) Remove the ai rbag,(Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(5) Remove the steeri ng col umn openi ng cover and
knee bl ocker. (Refer to 23 - BODY/I NSTRUMENT
PANEL - REMOVAL). (Fi g. 2).
(6) Remove ti l t l ever handl e (i f equi pped) from col -
umn.
(7) Remove the l ower and upper shrouds.
(8) Di sconnect the shi ft cabl e by unsnappi ng the
shi ft cabl e cl i p from the shi ft l ever and remove from
the cabl e bracket. (Fi g. 3)
(9) Remove the turn si gnal mul ti -functi on swi tch
connector.
(10) Remove remai ni ng el ectri cal connecti ons from
the col umn swi tches.
(11) Remove upper steeri ng shaft coupl er bol t and
sl i de the shaft down (Fi g. 4).
(12) Remove steeri ng col umn mounti ng nuts (Fi g.
5).
(13) Remove col umn from vehi cl e.
(14) Remove cl ockspri ng, swi tches and key cyl i n-
der, (Fi g. 6)(Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - REMOVAL) & (Refer
to 19 - STEERI NG/COLUMN/LOCK CYLI NDER
HOUSI NG - REMOVAL).
Fig. 1 STEERING COLUMN
1 - Shift Lever
2 - Steering Column
3 - Mounting Crash Capsules
4 - Igntion Switch
5 - Tilt Lever/Cable Assembly
6 - Key Cylinder Housing
Fig. 2 LOWER COLUMN COVER/KNEE BLOCKER
2 - KNEE BLOCKER
3 - LOWER COLUMN COVER
Fig. 3 SHIFT CABLE CONNECTOR
1 - Shift lever
2 - Cable Connection
3 - Overdrive Electrical Wiring
4 - Mounting Screws
AN COLUMN 19 - 7
COLUMN (Continued)
CAUTION: Failure to follow Restraints procedure for
clockspring removal, may damage the clockspring
plastic latches.
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) I nstal l swi tches, cl ockspri ng and key cyl i nder-
,(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - I NSTALLATI ON) & (Refer to 19 -
STEERI NG/COLUMN/LOCK CYLI NDER HOUSI NG
- I NSTALLATI ON).
(2) Posi ti on the col umn to the panel bracket and
attachi ng studs. I nstal l , but loose assemble the
mounti ng nuts.
(3) Fi rml y sl i de steeri ng col umn upward agai nst
the studs i n dash panel and hand ti ghten the nuts.
(4) I nstal l steeri ng shaft coupl er on the steeri ng
shaft and i nstal l a new bol t.
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
(5) Ti ghten col umn mounti ng nuts to 28 Nm (250
i n. l bs.).
CAUTION: Ensure that the shift lever is in the PARK
position and snap the shift cable adjustment clip in
place.
(6) I nstal l shi ft cabl e.
(7) Connect the mul ti -functi on swi tch wi ri ng and
ti ghten to 12 Nm (105 i n. l bs.).
(8) I nstal l the wi ri ng connecti ons to the col umn
swi tches.
(9) I nstal l the l ower and upper shrouds.
Fig. 4 Steering Coupler
1 - COUPLER BOLT
2 - COLUMN
3 - COUPLER
Fig. 5 (TYPICAL) MOUNTING NUTS
1 - COLUMN MOUNTING NUTS
Fig. 6 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
19 - 8 COLUMN AN
COLUMN (Continued)
(10) I nstal l the ti l t l ever handl e (i f equi pped).
(11) I nstal l the knee bl ocker and steeri ng col umn
openi ng cover,(Refer to 23 - BODY/I NSTRUMENT
PANEL - I NSTALLATI ON).
(12) I nstal l steeri ng wheel by al i gni ng the D fl at
on the wheel to the D fl at on the col umn al so use a
new bol t and ti ghten the bol t to 61 Nm (45 ft. l bs.).
(13) I nstal l ai rbag,(Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - I NSTALLATI ON).
(14) Connect the battery ground (negati ve) cabl e.
(15) Check operati on of the automati c transmi s-
si on shi ft l i nkage and adjust as necessary,(Refer to
21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
46RE/GEAR SHI FT CABLE - ADJUSTMENTS).
(16) Test the operati on of the horn, l i ghts and any
other functi ons that are steeri ng col umn operated.
SPECIFICATIONS
TORQUE CHART
Steering Column
Steering Wheel Bolt
61 45 540
Steering Column
Mounting Nuts
28 21 250
Steering Column
Shaft Coupler Bolt/Nut
49 36 434
Steering Column
Multi-function Switch
Screws
12 9 105
Steering Column
Shifter lever Screws
12 9 105
IGNITION SWITCH
DESCRIPTION
The el ectri cal i gni ti on swi tch i s l ocated on the
steeri ng col umn. I t i s used as the mai n on/off swi tch-
i ng devi ce for most el ectri cal components. The
mechani cal key l ock cyl i nder i s used to engage/di sen-
gage the el ectri cal i gni ti on swi tch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an i nterl ock devi ce i s l ocated wi thi n the steeri ng col -
umn. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s i n the LOCKED or ACCESSORY
posi ti on. I f i t i s di ffi cul t to rotate the key to or from
the LOCK or ACCESSORY posi ti on, the i nterl ock
devi ce wi thi n the steeri ng col umn may be defecti ve.
Thi s devi ce i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced.
(Refer to 19 - STEERI NG/COLUMN - REMOVAL).
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a l ever i s l ocated on the steeri ng col umn behi nd
the i gni ti on key l ock cyl i nder. The l ever must be
manual l y operated to al l ow rotati on of the i gni ti on
key l ock cyl i nder to the LOCK or ACCESSORY posi -
ti on. I f i t i s di ffi cul t to rotate the key to the LOCK or
ACCESSORY posi ti on, the l ever mechani sm may be
defecti ve. Thi s mechani sm i s not servi ceabl e. I f
repai r i s necessary, the steeri ng col umn assembl y
must be repl aced. (Refer to 19 - STEERI NG/COL-
UMN - REMOVAL).
On other model s, the i gni ti on key cyl i nder must be
depressed to al l ow i t to be rotated i nto the LOCK or
ACCESSORY posi ti on. I f i t i s di ffi cul t to rotate the
key to the LOCK or ACCESSORY posi ti on, the l ock
mechani sm wi thi n the steeri ng col umn may be defec-
ti ve. Thi s mechani sm i s not servi ceabl e. I f repai r i s
necessary, the steeri ng col umn assembl y must be
repl aced. (Refer to 19 - STEERI NG/COLUMN -
REMOVAL).
AN COLUMN 19 - 9
COLUMN (Continued)
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
I f the key removal effort i s excessi ve on a vehi cl e
wi th a automati c transmi ssi on fi rst adjust the shi ft
l i nkage, (Refer to 21 - TRANSMI SSI ON/TRAN-
SAXLE/AUTOMATI C - 46RE/GEAR SHI FT CABLE -
ADJUSTMENTS).
I f the i gni ti on swi tch effort i s excessi ve remove the
i gni ti on key cyl i nder from the steeri ng col umn. (Refer
to 19 - STEERI NG/COLUMN/LOCK CYLI NDER
HOUSI NG - REMOVAL). Check the turni ng effort of
the key cyl i nder. I f the i gni ti on key cyl i nder effort i s
excessi ve repl ace the key cyl i nder. I f the i gni ti on key
cyl i nder operates properl y l ook for the fol l owi ng con-
di ti ons.
REMOVAL
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) Remove the negati ve (ground) cabl e from the
battery.
(2) Di sabl e the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
(3) Remove the l ower and upper shrouds.
(4) Remove key cyl i nder. (Refer to 19 - STEER-
I NG/COLUMN/LOCK CYLI NDER HOUSI NG -
REMOVAL).
(5) Di sconnect the l ower cl ockspri ng connectors.
(6) Remove the wi re retai ner from the ti l t l ever
bracket.
(7) Remove the ti l t l ever mounti ng screws to gai n
access to the i gni ti on swi tch mounti ng screws.
(8) For col umns wi thout ti l t remove the bracket to
gai n access to the i gni ti on swi tch mounti ng screws.
(Fi g. 7)
(9) Di sconnect the el ectri cal connector at rear of
i gni ti on swi tch (Fi g. 8).
(10) Remove i gni ti on swi tch mounti ng screw.
(11) Usi ng a smal l screwdri ver, push on l ocki ng
tab and remove swi tch from steeri ng col umn.
INSTALLATION
cyl i nder I nstal l ati on. The key cyl i nder must be
i nstal l ed after i nstal l i ng the i gni ti on swi tch.
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on.
(2) Connect the el ectri cal connector to rear of the
i gni ti on swi tch. Make sure that l ocki ng tabs are ful l y
seated i nto wi ri ng connector.
(3) Posi ti on swi tch to col umn and i nstal l tamper
proof screw. Ti ghten screw to 12 Nm (105 i n. l bs.).
(4) I nstal l the ti l t l ever bracket mounti ng screws.
Ti ghten screw to 4.5 Nm (40 i n. l bs.).
(5) I f the col umn i s equi pped wi th a non-ti l t i nstal l
the bracket. Ti ghten screw to 4.5 Nm (40 i n. l bs.)
(Fi g. 7)
(6) I nsert the wi re retai ner to the ti l t l ever
bracket.
(7) Reconnect the l ower cl ockspri ng connectors.
(8) I nstal l the key cyl i nder.
(9) I nstal l the Upper and l ower shrouds.
(10) I nstal l steeri ng col umn l ower cover.
(11) Enabl e the ai rbag system. (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/DRI VER AI RBAG - I NSTAL-
LATI ON).
Fig. 7 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 8 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
19 - 10 COLUMN AN
IGNITION SWITCH (Continued)
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the l eft si de of the
steeri ng col umn. I t cl oses a path to ground for the
Central Ti mer Modul e (CTM) when the i gni ti on key
i s i nserted i n the i gni ti on l ock cyl i nder and the
dri ver door ajar swi tch i s cl osed (dri ver door i s open).
The key-i n i gni ti on swi tch opens the ground path
when the key i s removed from the i gni ti on l ock cyl -
i nder. The ground path i s al so opened when the
dri ver door ajar swi tch i s open (dri ver door i s cl osed).
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced,(Refer to 19 - STEERI NG/COLUMN/I G-
NI TI ON SWI TCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For i gni ti on swi tch el ectri cal schemati cs, refer to
the appropri ate secti on i n Wi ri ng Di agrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an i nterl ock devi ce i s l ocated wi thi n the steeri ng col -
umn. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s i n the LOCKED or ACCESSORY
posi ti on. I f i t i s di ffi cul t to rotate the key to or from
the LOCK or ACCESSORY posi ti on, the i nterl ock
devi ce wi thi n the steeri ng col umn may be defecti ve.
Thi s devi ce i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced.
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a l ever i s l ocated on the steeri ng col umn behi nd
the i gni ti on key l ock cyl i nder. The l ever must be
manual l y operated to al l ow rotati on of the i gni ti on
key l ock cyl i nder to the LOCK or ACCESSORY posi -
ti on. I f i t i s di ffi cul t to rotate the key to the LOCK or
ACCESSORY posi ti on, the l ever mechani sm may be
defecti ve. Thi s mechani sm i s not servi ceabl e. I f
repai r i s necessary, the steeri ng col umn assembl y
must be repl aced. (Refer to 19 - STEERI NG/COL-
UMN - REMOVAL).
On other model s, the i gni ti on key cyl i nder must be
depressed to al l ow i t to be rotated i nto the LOCK or
ACCESSORY posi ti on. I f i t i s di ffi cul t to rotate the
key to the LOCK or ACCESSORY posi ti on, the l ock
mechani sm wi thi n the steeri ng col umn may be defec-
ti ve. Thi s mechani sm i s not servi ceabl e. I f repai r i s
necessary, the steeri ng col umn assembl y must be
repl aced. (Refer to 19 - STEERI NG/COLUMN -
REMOVAL).
LOCK CYLINDER HOUSING
REMOVAL
cyl i nder removal .
(2) Remove upper and l ower covers (shrouds) from
steeri ng col umn.
(3) Pl ace shi fter i n PARK posi ti on.
(4) A retai ni ng pi n (Fi g. 9) i s l ocated at si de of key
cyl i nder assembl y.
(a) Rotate key to RUN posi ti on.
(b) Press i n on retai ni ng pi n whi l e pul l i ng key
cyl i nder from i gni ti on swi tch.
INSTALLATION
cyl i nder i nstal l ati on.
(1) I nstal l the key cyl i nder i nto the housi ng usi ng
care to al i gn the end of the key cyl i nder wi th the
i gni ti on swi tch.
(2) Push the key cyl i nder i n unti l i t cl i cks.
(3) Repl ace the upper and l ower shrouds.
(4) Reconnect the battery.
Fig. 9 KEY CYLINDER
1 - Key Lock Cylinder
2 - Key
3 - Reataining Pin Hole
AN COLUMN 19 - 11
GEAR SHIFT LEVER
REMOVAL
(1) Remove the kneebl ocker. (Refer to 23 - BODY/
I NSTRUMENT PANEL/STEERI NG COLUMN
OPENI NG COVER - REMOVAL).
(2) Loosen the steeri ng col umn bol ts enough to
l ower the col umn wi thout removi ng.
(3) Remove the upper and l ower shrouds.
(4) Di sconnect over dri ve swi tch wi ri ng.
(5) Di sconnect the shi ft cabl e from the pi n and
unsnap the cabl e adjusti ng cl i p.
(6) Remove the screws retai ni ng the gear shi ft
l ever. (Fi g. 10)
(7) Remove the gear shi ft l ever from the steeri ng
col umn assembl y.
INSTALLATION
(1) I nstal l the gear shi ft l ever onto the steeri ng
col umn assembl y (Fi g. 10).
(2) I nstal l the shi ft l ever screws. Ti ghten the
screws to 12 N.m (105 I n. Lbs).
(3) Connect the shi ft cabl e to the pi n ensuri ng the
shi ft l ever i s i n PARK and snap the shi ft cabl e
adjustment cl i p i n pl ace.
(4) Connect over dri ve swi tch wi ri ng.
(5) I nstal l the upper and l ower shrouds.
(6) Ti ghten the steeri ng col umn mounti ng nuts to
28 N.m (250 I n. Lbs).
(7) I nstal l the kneebl ocker. (Refer to 23 - BODY/
I NSTRUMENT PANEL/STEERI NG COLUMN
OPENI NG COVER - I NSTALLATI ON).
Fig. 10 Gear Shift Lever Removal
1 - SCREWS
2 - GEARSHIFT LEVER
19 - 12 COLUMN AN
GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 16
GEAR
DESCRIPTION
A rack and pi ni on steeri ng gears (Fi g. 1) i s made
up of two mai n components, the pi non shaft and the
rack. The gear cannot be adjusted or i nternal l y ser-
vi ced. I f a mal functi on or a fl ui d l eak occurs, the gear
must be repl aced as an assembl y. I f a boot seal
becomes damaged, the steeri ng gear must be
removed to repl ace the boot seal .
OPERATION
The steeri ng col umn shaft i s attached to the gear
pi ni on. The rotati on of the pi ni on moves the gear
rack from si de-to-si de. Thi s l ateral acti on of the rack
pushes and pul l s the ti e rods to change the di recti on
of the front wheel s.
REMOVAL - 2WD
(2) Remove the nuts from the ti e rod ends.
(3) Separate ti e rod ends from the knuckl es wi th
Pul l er C-3894-A (Refer to 19 - STEERI NG/LI NKAGE/
TI E ROD END - REMOVAL) (Fi g. 2).
Fig. 1 Rack & Pinion Steering Gear
1 - TIE ROD
2 - TIE ROD
3 - TIE ROD END
4 - BOOTS
5 - TIE ROD END
Fig. 2 Tie Rod End Puller
1 - TOOL C-3894-A
2 - BALL STUD
3 - SEAL
4 - TIE-ROD END
5 - LOCKNUT
AN GEAR 19 - 13
(4) Remove the power steeri ng l i nes from the gear.
(Refer to 19 - STEERI NG/PUMP/HOSES - REMOV-
AL),(Refer to 19 - STEERI NG/PUMP/HOSES -
REMOVAL).
(5) Remove the l ower coupl er bol t and sl i de the
coupl er off the gear (Fi g. 3).
(6) Remove the mounti ng bol ts from the gear to
the front crossmember and remove the gear (Fi g. 4).
REMOVAL - 4WD
(2) Remove the spl ash shi el d from under the front
end to gai n access to the gear.
(3) Remove the nuts from the ti e rod ends.
(4) Separate ti e rod ends from the knuckl es wi th
Pul l er C-3894-A (Refer to 19 - STEERI NG/LI NKAGE/
TI E ROD END - REMOVAL) (Fi g. 5).
(5) Remove the power steeri ng l i nes from the gear.
(Refer to 19 - STEERI NG/PUMP/HOSES - REMOV-
AL),(Refer to 19 - STEERI NG/PUMP/HOSES -
REMOVAL).
Fig. 3 Gear Coupler
1 - COUPLER
2 - LOWER SHAFT
3 - TOE PLATE
4 - STEERING COLUMN
5 - UPPER SHAFT
6 - RACK AND PINION STEERING GEAR
Fig. 4 Rack & Pinion Steering Gear - 4x2
2 - BUSHING
Fig. 5 Tie
1 - TOOL C-3894A
2 - BALL STUD
3 - SEAL
4 - TIE-ROD END
5 - LOCK NUT
19 - 14 GEAR AN
GEAR (Continued)
(6) Remove the l ower coupl er bol t and sl i de the
coupl er off the gear (Fi g. 6).
(7) Remove the mounti ng bol ts (Fi g. 7) from the
gear to the front crossmember. Sl i de the gear to the
ri ght si de of the vehi cl e. Then ti l t the l eft end of the
gear down and remove the gear.
INSTALLATION - 2WD
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
(1) I nstal l gear on front crossmember and ti ghten
mounti ng bol ts to 258 Nm (190 ft. l bs.).
(2) Sl i de shaft coupl er onto gear. I nstal l new bol t
and ti ghten to 49 Nm (36 ft. l bs.).
(3) Cl ean ti e rod end studs and knuckl e tapers.
(4) I nstal l ti e rod ends i nto the steeri ng knuckl es
and ti ghten the nuts to 108 Nm (80 ft. l bs.). (Refer
I NSTALLATI ON).
(5) I nstal l power steeri ng l i nes to steeri ng gear.
(Refer to 19 - STEERI NG/PUMP/HOSES - I NSTAL-
LATI ON),(Refer to 19 - STEERI NG/PUMP/HOSES -
I NSTALLATI ON).
(7) Fi l l system wi th fl ui d, (Refer to 19 - STEER-
I NG/PUMP - STANDARD PROCEDURE).
(8) Adjust the toe posi ti on. (Refer to 2 - SUSPEN-
DURE).
INSTALLATION - 4WD
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
(1) I nstal l gear on front crossmember and ti ghten
mounti ng bol ts to 230 Nm (170 ft. l bs.).
(2) Sl i de shaft coupl er onto gear. I nstal l new bol t
and ti ghten to 49 Nm (36 ft. l bs.).
(3) Cl ean ti e rod end studs and knuckl e tapers.
(4) I nstal l ti e rod ends i nto the steeri ng knuckl es
and ti ghten the nuts to 88 Nm (65 ft. l bs.). (Refer to
19 - STEERI NG/LI NKAGE/TI E ROD END -
I NSTALLATI ON).
(5) I nstal l power steeri ng l i nes to steeri ng gear.
(Refer to 19 - STEERI NG/PUMP/HOSES - I NSTAL-
LATI ON),(Refer to 19 - STEERI NG/PUMP/HOSES -
I NSTALLATI ON).
(6) I nstal l the spl ash shi el d.
(8) Fi l l system wi th fl ui d, (Refer to 19 - STEER-
I NG/PUMP - STANDARD PROCEDURE).
(9) Adjust the toe posi ti on. (Refer to 2 - SUSPEN-
DURE).
Fig. 6 Gear Coupler
1 - COUPLER
2 - LOWER SHAFT
3 - TOE PLATE
4 - STEERING COLUMN
5 - UPPER SHAFT
Fig. 7 Rack & Pinion Steering Gear - 4x4
1 - MOUNTING BOLT
AN GEAR 19 - 15
GEAR (Continued)
SPECIFICATIONS
TORQUE CHART
Rack and Pinion Steering
Gear
Gear to Frame Bolts
258 190
Rack and Pinion Steering
Gear
Intermediate Shaft Bolt
49 36
Tie Rod End
Knuckle Nut
108 80
Tie Rod End
Jam Nut
75 55
Power Steering Line
Pressure Line
35 25
Power Steering Line
Return Line
35 25
SPECIAL TOOLS
RACK & PINION STEERING GEAR
Puller C-3894-A
19 - 16 GEAR AN
LINKAGE
TABLE OF CONTENTS
page page
TIE ROD END
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BOOT SEAL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TIE ROD END
REMOVAL - INNER TIE ROD END
(2) Remove the ti re and wheel assembl y.
(3) Remove the outer ti e rod end,(Refer to 19 -
STEERI NG/LI NKAGE/TI E ROD END - REMOVAL).
(4) Remove the i nner ti e rod end from the rack
and pi ni on (Fi g. 1).
REMOVAL - OUTER TIE ROD END
NOTE: Do not twist the boot at anytime during
removal or installation.
(1) Loosen the jam nut.
(2) Remove the outer ti e rod end nut at the steer-
i ng knuckl e.
(3) Separate the ti e rod bal l stud from the knuckl e
wi th Remover MB-991113 (Fi g. 2).
(4) Unthread the outer ti e rod end from the i nner
ti e rod.
INSTALLATION - INNER TIE ROD END
installation.
(1) Thread the i nner ti e rod end i nto the rack and
pi ni on (Fi g. 3).
(2) Ti ghten the i nner ti e to 68 Nm (50 ft. l bs.).
(3) I nstal l the out ti e rod end,(Refer to 19 -
STEERI NG/LI NKAGE/TI E ROD END - I NSTALLA-
TI ON).
(4) I nstal l the ti re and wheel assembl y. (Refer to
CEDURE).
Fig. 1 Inner Tie Rod
1 - WRENCH
2 - INNER TIE ROD
Fig. 2 Tie Rod End
2 - REMOVER
3 - TIE ROD END
AN LINKAGE 19 - 17
(6) Set wheel toe pattern,(Refer to 2 - SUSPENSI ON/
WHEEL ALI GNMENT - STANDARD PROCEDURE).
INSTALLATION - OUTER TIE ROD END
removal or installation.
(1) Thread the outer ti e rod end onto the i nner ti e
rod, to i ts ori gi nal posi ti on.
(2) I nstal l the outer ti e rod end i nto the steeri ng
knuckl e.
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 88 Nm (65 ft. l bs.).
(4) Ti ghten jam nut to 75 Nm (55 ft. l bs.).
(5) Set wheel toe pattern,(Refer to 2 - SUSPENSI ON/
WHEEL ALI GNMENT - STANDARD PROCEDURE).
BOOT SEAL
DESCRIPTION
The boot seal i s a bel l ows type seal the protects
di rt and contami nates from enteri ng the open gears
of the rack and pi ni on uni t.
OPERATION
The boot seal operates wi th the i nward and out-
ward moti ons of the rack and pi ni on, I f the seal i s
worn or ri pped i n any way i t must be repl aced.
REMOVAL
(1) Loosen the jam nut to remove the outer ti e rod
end,(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD
END - REMOVAL).
(2) Remove the jam nut.
(3) Remove the outer cl amp from the rubber boot
(Fi g. 4).
(4) Remove the boot i nner cl amp.
(5) On 4x2 vehi cl es mark the breather tube l oca-
ti on on steeri ng gear before removi ng the rubber boot
(Fi g. 4).
INSTALLATION
(1) Lubri cate the boot outer groove (ti e rod) wi th
si l i cone type l ubri cant. Ensure that the boot i s not
twi sted.
(2) On 4x2 vehi cl es al i gn the breather tube wi th
the reference mark on the steeri ng gear.
(3) Posi ti on and al i gn the new boot over the hous-
i ng.
(4) I nstal l i nner cl amp on the rubber boot.
(5) I nstal l the snorkel cl amp on 4x2 vehi cl es.
(6) I nstal l outer cl amp on the i nner ti e rod.
(7) I nstal l the jam nut and the outer ti e rod
end,(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD
END - I NSTALLATI ON).
(8) Perform a wheel al i gnment,(Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
Fig. 3 Inner Tie Rod
1 - INNER TIE ROD
2 - CENTER LINK
Fig. 4 Boot Seal - 4x2
1 - CIRCLE A
2 - MARK BREATHER TUBE LOCATION
3 - BOOT
4 - SNORKEL CLAMP
5 - BOOT CLAMP (OUTER)
6 - JAM NUT
7 - USE LUBE HERE
8 - BOOT CLAMP (INNER)
9 - BOOT SEAL
10 - BREATHER TUBE
11 - BREATHER TUBE
19 - 18 LINKAGE AN
TIE ROD END (Continued)
PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PUMP LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . 19
POWER STEERING PUMP - INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 22
FLUID COOLER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HOSES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
POWER STEERING PRESSURE SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PUMP
DESCRIPTION
The pump i s connected to the steeri ng gear vi a the
pressure hose and the return hose. The pump shaft
has a pressed-on pul l ey that i s bel t dri ven by the
crankshaft pul l ey.
Trai l er tow opti on vehi cl es are equi pped wi th a
power steeri ng pump oi l cool er. On the 5.2L and 5.9L
the oi l cool er i s mounted to the engi ne bl ock. On the
4.7L the oi l cool er i s mounted to the power steeri ng
pump.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraul i c pressure i s provi ded for the power steer-
i ng gear by the bel t dri ven power steeri ng pump (Fi g.
1) and (Fi g. 2). The power steeri ng pumps are con-
stant fl ow rate and di spl acement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump i s servi ced as an assembl y and shoul d
not be di sassembl ed. Pl asti c pump reservoi rs can be
repl ace and the reservoi r O-ri ng.
Check for l eaks i n the fol l owi ng areas:
Pump shaft seal behi nd the pul l ey
Pump to reservoi r O-ri ng
Reservoi r cap
Pressure and return l i nes
Fl ow control val ve fi tti ng
Fig. 1 Power Steering Pump - 5.2L & 5.9L
1 - RESERVOIR CAP AND DIPSTICK
2 - RESERVOIR
AN PUMP 19 - 19
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal temperature.
(1) Turn steeri ng wheel al l the way to the l eft
(2) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two (2) mi nutes.
(3) Rai se the front wheel s off the ground.
(4) Sl owl y turn the steeri ng wheel l ock-to-l ock 20
ti mes wi th the engi ne off whi l e checki ng the fl ui d
l evel .
NOTE: Vehicles with long return lines or oil coolers
turn wheel 40 times.
(5) Start the engi ne. Wi th the engi ne i dl i ng mai n-
tai n the fl ui d l evel .
(6) Lower the front wheel s and l et the engi ne i dl e
for two mi nutes.
(7) Turn the steeri ng wheel i n both di recti on and
veri fy power assi st and qui et operati on of the pump.
I f the fl ui d i s extremel y foamy or mi l ky l ooki ng,
al l ow the vehi cl e to stand a few mi nutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL - POWER STEERING PUMP - 4. 7L
(1) Remove the serpenti ne dri ve bel t, (Refer to 7 -
REMOVAL).
(2) Remove return hose from the pump reservoi r
and drai n the pump.
(3) Remove power steeri ng pressure swi tch connec-
tor and remove pressure l i ne from the bottom of the
pump.
(4) Remove the oi l cool er mounti ng bol t from the
pump bracket i f equi pped.
(5) Remove 3 pump mounti ng bol ts (Fi g. 3)
through pul l ey access hol es.
(6) Remove the pump from the l eft cyl i nder head.
Fig. 2 Power Steering Pump - 4.7L
1 - PUMP
2 - RESERVOIR
3 - PULLEY
Fig. 3 Power Steering Pump - 4.7L
1 - PUMP
2 - MOUNTING BOLTS
19 - 20 PUMP AN
PUMP (Continued)
REMOVAL - POWER STEERING PUMP - 5. 2L &
5. 9L
(1) Remove the serpenti ne dri ve bel t, (Refer to 7 -
REMOVAL).
(2) Cl amp the fl ui d return hose and di sconnect the
hoses from the power steeri ng pump. Cap the fi t-
ti ngs.
(3) Remove battery ground cabl e and bracket bol ts.
(4) Remove the pump assembl y (Fi g. 4).
(5) Remove the pump pul l ey, (Refer to 19 -
STEERI NG/PUMP/PULLEY - REMOVAL). Thi s wi l l
al l ow access to the pump attachi ng screws.
(6) Remove the pump bracket bol ts (Fi g. 5) and
remove the bracket.
INSTALLATION - POWER STEERING PUMP -
4. 7L
(1) Al i gn the pump wi th the mounti ng hol es i n the
l eft cyl i nder head.
(2) I nstal l 3 pump mounti ng bol ts through the pul -
l ey access hol es. Ti ghten the bol ts to 28 Nm (21 ft.
l bs.).
(3) I nstal l the oi l cool er to the pump bracket i f
equi pped. I nstal l the oi l cool er mounti ng bol t.
(4) I nstal l the pressure l i ne and return hose to the
pump. Ti ghten the pressure l i ne to 35 Nm (25 ft.
l bs.).
(5) I nstal l power steeri ng pressure swi tch connec-
tor.
(6) I nstal l the serpenti ne dri ve bel t, (Refer to 7 -
I NSTALLATI ON).
(7) Fi l l the power steeri ng pump, (Refer to 19 -
STEERI NG/PUMP - STANDARD PROCEDURE).
INSTALLATION - POWER STEERING PUMP -
5. 2L & 5. 9L
(1) I nstal l the bracket on the pump and ti ghten
bol ts to 41 Nm (30 ft. l bs.).
(2) I nstal l the pump pul l ey, (Refer to 19 - STEER-
I NG/PUMP/PULLEY - I NSTALLATI ON).
(3) I nstal l pump assembl y on the engi ne bl ock and
ti ghten the bol ts to 41 Nm (30 ft. l bs.).
(4) I nstal l the battery ground wi re and ti ghten nut
to 41 Nm (30 ft. l bs.).
(5) Connect the fl ui d hoses to the pump.
(6) I nstal l the serpenti ne dri ve bel t, (Refer to 7 -
I NSTALLATI ON).
(7) Fi l l the reservoi r wi th power steeri ng fl ui d,
(Refer to 19 - STEERI NG/PUMP - STANDARD PRO-
CEDURE).
Fig. 4 Pump Assembly
1 - PUMP ASSEMBLY
2 - BOLTS
Fig. 5 Pump Mounting Bracket
1 - PULLEY
2 - PUMP BRACKET
3 - STEERING PUMP
4 - BOLT
AN PUMP 19 - 21
PUMP (Continued)
SPECIFICATIONS
TORQUE CHART
5.2L/5.9L Power Steering Pump
Pump Bracket Bolts
41 30
Pump Mounting Bolts
41 30
Flow Control Valve
75 55
Pressure Line
35 25
4.7L Power Steering Pump
Pump Mounting Bolts
28 21
Flow Control Valve
81 60
Pressure Line
35 25
SPECIAL TOOLS
POWER STEERING PUMP
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
19 - 22 PUMP AN
FLUID COOLER
REMOVAL
(1) Si phon the power steeri ng system.
(2) Di sconnect the return hose at the pump.
(4) Di sconnect the return hose at the cool er.
(5) Remove the cool er mounti ng nut and bol t.
(6) Remove the cool er.
INSTALLATION
(1) I nstal l the cool er.
(2) I nstal l the cool er mounti ng nut and bol t.
(3) Reconnect the return hose at the cool er.
(5) Reconnect the return hose at the pump.
(6) Refi l l the power steeri ng system,(Refer to 19 -
HOSES
REMOVAL - RETURN HOSE
(3) Di sconnect the return hose at the cool er.
(4) Di sconnect the return hose at the gear.
(5) Remove the pressure hose from the vehi cl e.
REMOVAL - PRESSURE HOSE
(3) Di sconnect the pressure hose at the pump.
(4) Di sconnect the pressure hose at the gear.
(5) Remove the pressure hose from the vehi cl e.
INSTALLATION - RETURN HOSE
(1) I nstal l the return hose to the vehi cl e.
(2) Reconnect the return hose at the cool er.
Ti ghten the hose to 34 Nm (25 ft. l bs.).
(3) Reconnect the return hose at the gear. Ti ghten
the hose to 34 Nm (25 ft. l bs.).
INSTALLATION - PRESSURE HOSE
(1) I nstal l the pressure hose to the vehi cl e.
(2) Reconnect the pressure hose at the gear.
(3) Reconnect the pressure hose at the pump.
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensi ng swi tch (Fi g. 6) i s i ncl uded i n
the power steeri ng system (mounted on the hi gh-
pressure l i ne). Thi s swi tch wi l l be used onl y on vehi -
cl es equi pped wi th a 4.7L V8 engi ne and power
steeri ng.
OPERATION
The power steeri ng pressure swi tch provi des an
i nput to the Powertrai n Control Modul e (PCM). Thi s
i nput i s provi ded duri ng peri ods of hi gh pump l oad
and l ow engi ne rpm; such as duri ng parki ng maneu-
vers. The PCM wi l l then i ncrease the i dl e speed
through the I dl e Ai r Control (I AC) motor. Thi s i s
done to prevent the engi ne from stal l i ng under the
i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa
690 kPa (475 psi 100 psi ), the normal l y cl osed
swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
Fig. 6 Power Steering Pump Pressure Switch4.7L
V-8 Engine
1 - HYDRAULIC PUMP
2 - POWER STEERING PRESSURE SWITCH
4 - OIL COOLER
AN PUMP 19 - 23
REMOVAL
Thi s swi tch i s used onl y wi th 4.7L V-8 engi ne.
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 6).
(1) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(2) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(3) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION
Thi s swi tch i s used onl y wi th 4.7L V-8 engi ne.
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne.
(2) Ti ghten to 1422 Nm (124195 i n. l bs.) torque.
(3) Connect el ectri cal connector to swi tch.
(4) Check power steeri ng fl ui d and add as neces-
sary.
(5) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
PULLEY
REMOVAL
CAUTION: On vehicles equipped with the 4.7L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Remove pump assembl y, (Refer to 19 - STEER-
I NG/PUMP 4.7L - REMOVAL) OR (Refer to 19 -
STEERI NG/PUMP 5.2 L & 5.9L - REMOVAL).
(2) Remove pul l ey from pump wi th Pul l er C-4333
(Fi g. 7).
INSTALLATION
CAUTION: On vehicles equipped with the 4.7L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
(Fi g. 8) fl ush wi th the end of the shaft. Ensure the
tool and pul l ey remai n al i gned wi th the pump shaft.
(3) I nstal l pump assembl y, (Refer to 19 - STEER-
I NG/PUMP 4.7L - I NSTALLATI ON) OR (Refer to 19
- STEERI NG/PUMP 5.2L & 5.9L - I NSTALLATI ON).
(4) Wi th Serpenti ne Bel ts; Run engi ne unti l warm
(5 mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
Fig. 7 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
Fig. 8 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063B
19 - 24 PUMP AN
POWER STEERING PRESSURE SWITCH (Continued)
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV1500 . . . . . . . . . . . . . . . . . . . . . . . . 1
MANUAL - NV3500 . . . . . . . . . . . . . . . . . . . . . . . 33
AUTOMATIC TRANSMISSION - 42RE . . . . . . . . . 78
AUTOMATIC TRANSMISSION - 46RE . . . . . . . . 256
AUTOMATIC TRANSMISSION - 45RFE . . . . . . . 439
TRANSFER CASE - NV233 . . . . . . . . . . . . . . . . 537
TRANSFER CASE - NV244 . . . . . . . . . . . . . . . . 567
MANUAL - NV1500
TABLE OF CONTENTS
page page
MANUAL - NV1500
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NV1500 MANUAL TRANSMISSION. . . . . . . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 31
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 31
MANUAL - NV1500
DESCRIPTION
The NV1500 i s a medi um-duty, 5-speed, constant
mesh, ful l y synchroni zed manual transmi ssi on. Fi fth
gear i s an overdri ve range wi th a rati o of 0.80:1. The
Transmi ssi on i s avai l abl e i n 4-cyl . equi pped 2WD
model s.
The transmi ssi on gear case consi sts of two al umi -
num gear housi ngs and a detachabl e cl utch housi ng.
The mai nshaft i s supported by two seal ed bal l
beari ngs, and the countershaft i s supported by two
tapered rol l er beari ngs. The transmi ssi on gears al l
rotate on caged type needl e beari ngs. A rol l er beari ng
i s used between the i nput and output shaft.
The Transmi ssi on has a si ngl e shaft shi ft mecha-
ni sm wi th three shi ft forks al l mounted on the shaft.
The shaft i s supported i n the front and rear housi ngs
by bushi ngs. I nternal shi ft components consi st of the
forks, shaft, shi ft l ever socket, and detent compo-
nents.
NV1500 GEAR RATIOS
RANGE RATIO
FIRST 3.85 :1
SECOND 2.25 :1
THIRD 1.48 :1
FOURTH 1.00 :1
FIFTH 0.80 :1
REVERSE 3.52 :1
I denti fi cati on bar code tags (Fi g. 1) are l ocated on
each si de of the transmi ssi on, bel ow the shi ft tower.
The tag l ocated on the ri ght si de has the part num-
ber and the tag l ocated on the l eft si de has the bui l d
sequence and date i nformati on.
AN TRANSMISSION AND TRANSFER CASE 21 - 1
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
shaft gear. At thi s poi nt, al l the transmi ssi on gears
are spi nni ng.
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft, or the countershaft i n some cases, and
movi ng the bl ocker ri ng i nto contact wi th the gears
fri cti on cone. As the bl ocker ri ng and fri cti on cone
come together, the gear speed i s brought up or down
to the speed of the synchroni zer. As the two speeds
match, the spl i nes on the i nsi de of the synchroni zer
sl eeve become al i gned wi th the teeth on the bl ocker
ri ng and the fri cti on cone and eventual l y wi l l sl i de
over the teeth, l ocki ng the gear to the mai nshaft, or
countershaft, through the synchroni zer.
DIAGNOSIS AND TESTING - NV1500 MANUAL
TRANSMISSION
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adaptor or extensi on
Fig. 1 NV1500 IDENTIFICATION
21 - 2 MANUAL - NV1500 AN
MANUAL - NV1500 (Continued)
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a nonrecommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng nonrecommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Component damage, i ncorrect cl utch adjustment,
or a damaged cl utch pressure pl ate or di sc are addi -
ti onal probabl e causes of i ncreased shi ft effort. I ncor-
rect adjustment or a worn/damaged pressure pl ate or
di sc can cause i ncorrect rel ease. I f the cl utch probl em
i s advanced, gear cl ash duri ng shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear cl ash
when shi fti ng i nto any forward gear. I n some new or
rebui l t transmi ssi ons, new synchro ri ngs may tend to
sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n most
cases, thi s condi ti on wi l l decl i ne as the ri ngs wear
i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear breakage.
REMOVAL
(2) Shi ft transmi ssi on i nto Neutral .
(3) Remove fl oor consol e. Refer to 23 Body for pro-
cedures.
(4) Remove screws attachi ng shi ft boot to fl oorpan.
Then sl i de boot upward on l ever extensi on.
(5) Remove shi ft l ever extensi on from the shi ft
tower and l ever assembl y.
(7) Mark propel l er shaft and axl e compani on
fl ange for al i gnment reference. Use pai nt, scri ber, or
chal k to mark fl ange.
(9) Di sconnect and remove exhaust system Y-pi pe.
(10) Di sconnect wi res at backup l i ght swi tch.
(11) Support engi ne wi th adjustabl e safety stand
and wood bl ock.
(12) I f transmi ssi on i s to be di sassembl ed for
repai r, remove drai n pl ug and drai n l ubri cant from
transmi ssi on.
(13) Remove bol ts/nuts attachi ng transmi ssi on to
rear mount.
(14) Support transmi ssi on wi th a transmi ssi on
jack. Secure transmi ssi on to jack wi th safety chai ns.
(15) Remove rear crossmember.
(16) Remove bol ts attachi ng cl utch sl ave cyl i nder
to cl utch housi ng. Then move cyl i nder asi de for work-
i ng cl earance.
(17) Remove starter.
(18) Remove transmi ssi on dust shi el d.
(19) Remove transmi ssi on harness wi res from cl i ps
on transmi ssi on shi ft cover.
(20) Lower transmi ssi on sl i ghtl y.
(21) Remove the bol ts attachi ng the shi ft tower
and l ever assembl y to the transmi ssi on housi ng.
Then remove the shi ft tower and l ever assembl y.
(22) Remove bol ts attachi ng transmi ssi on to
engi ne.
(23) Sl i de transmi ssi on and jack rearward unti l
i nput shaft cl ears cl utch di sc.
(24) Lower transmi ssi on jack and remove trans-
mi ssi on from under vehi cl e.
DISASSEMBLY
FRONT HOUSING
(2) Remove drai n pl ug and drai n l ubri cant i nto a
contai ner.
(3) I nspect drai n pl ug magnet for debri s.
(4) Remove backup l i ght swi tch (Fi g. 2).
(5) Remove shi ft tower bol ts and remove tower and
l ever assembl y (Fi g. 3).
AN MANUAL - NV1500 21 - 3
(6) Remove shi ft shaft l ock bol t (Fi g. 4). Bol t
secures the shi ft shaft bushi ng and l ever.
(7) Remove shi ft shaft detent pl ug wi th Remover
8117A.
(8) Remove shi ft shaft detent pl unger and spri ng
wi th a penci l magnet (Fi g. 5).
Fig. 2 BACKUP LIGHT SWITCH
1 - BACKUP LAMP SWITCH
Fig. 3 SHIFT TOWER
1 - SHIFT TOWER AND LEVER ASSEMBLY
2 - SHIFT SOCKET
3 - SEAL
Fig. 4 SHIFT SHAFT BUSHING LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 5 SHIFT SHAFT DETENT PLUNGER
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
(9) Remove i nput shaft beari ng retai ner bol ts (Fi g.
6).
(10) Remove beari ng retai ner from i nput shaft
wi th a pry tool (Fi g. 7).
(11) Remove snap ri ng securi ng i nput shaft i n
front beari ng (Fi g. 8).
(12) Remove front housi ng bol ts (Fi g. 9). Leave one
bol t i n pl ace unti l geartrai n i s ready to be removed
from case. Three bol ts at the rear of housi ng are for
the output shaft beari ng retai ner.
Fig. 6 INPUT SHAFT BEARING RETAINER BOLTS
1 - BOLTS (5)
2 - BEARING RETAINER
Fig. 7 INPUT SHAFT BEARING RETAINER
2 - OIL FEED
Fig. 8 INPUT SHAFT SNAP RING
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
Fig. 9 HOUSING AND BEARING RETAINER BOL
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
(13) Tap front housi ng off al i gnment dowel s wi th a
pl asti c mal l et and separate the housi ng (Fi g. 10).
(14) Remove i nput shaft beari ng (Fi g. 11).
(15) Note posi ti on of i nput shaft, shi ft shaft, forks,
and geartrai n components i n housi ng (Fi g. 12).
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER
(1) Dri ve out rol l pi n that secures shi ft bushi ng
and l ever to shi ft shaft wi th a hammer and punch
(Fi g. 13).
(2) Posi ti on shi ft socket off to the si de so rol l pi n
removal does not i nterfere wi th gears.
Fig. 10 FRONT HOUSING
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
Fig. 11 INPUT SHAFT AND COUNTERSHAFT
BEARING
1 - COUNTERSHAFT FRONT BEARING RACE
2 - INPUT SHAFT BEARING
3 - FRONT HOUSING
Fig. 12 GEARTRAIN AND SHIFT COMPONENT
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
Fig. 13 SHIFT SHAFT LEVER & BUSHING ROLL PIN
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
(3) Dri ve out shi ft socket rol l pi n wi th a hammer
and punch.
NOTE: Use proper size punch to prevent damage to
the shift shaft.
(4) Pul l shi ft shaft strai ght out of rear housi ng,
shi ft socket, fi fth-reverse fork and 1-2 fork (Fi g. 14).
(5) Remove shi ft socket from rear housi ng (Fi g.
15).
(6) Remove l ever and bushi ng (Fi g. 16).
(7) Rotate 3-4 fork around synchro sl eeve unti l
fork cl ears shi ft arms on 1-2 and fi fth-reverse forks,
then remove 3-4 fork (Fi g. 17). Fig. 14 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 15 SHIFT SOCKET AND ROLL PIN
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 16 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 17 3-4 SHIFT FORK
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
(8) Remove front reverse i dl er shaft support bol t
and l oosen rear bol t (Fi g. 18).
(9) Remove reverse i dl er shaft support by sl i di ng i t
strai ght out of housi ng.
(10) Remove rear reverse i dl er shaft bol t.
(11) Remove reverse i dl er shaft, i dl er gear, beari ng
and thrust washer (Fi g. 19).
GEARTRAIN
(1) Remove output shaft beari ng retai ner bol ts
(Fi g. 20). Bol ts are rear of shi ft tower openi ng.
(2) Grab hol d of mai nshaft and countershaft and
remove geartrai n from rear housi ng (Fi g. 21).
Fig. 18 REVERSE IDLER SHAFT/SUPPORT BOLT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 19 REVERSE IDLER ASSEMBLY
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
Fig. 20 OUTPUT SHAFT BEARING RETAINER
BOLTS
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
AT OPPOSITE SIDE OF CASE)
Fig. 21 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
GEARTRAIN
(1) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(2) Separate countershaft from mai nshaft.
(3) Separate i nput shaft from output shaft.
COUNTERSHAFT
(1) Remove countershaft front and rear beari ng
wi th Pul l er 8356.
(2) Remove rear beari ng race (i n rear housi ng)
wi th Beari ng Race Remover L-4454. I nstal l new race
wi th Dri ver C-4656 and Dri ver Handl e C-4171.
(3) Remove beari ng shi m cap from front housi ng
(bel ow i nput shaft beari ng retai ner). Remove shi m.
Dri ve race through and out of housi ng wi th Dri ver
C-4656 and Dri ver Handl e C-4171. I nstal l new race
i nto housi ng from outsi de. Do not drive all the
way into position. Tightening the shim cap will
install the race to the proper position. I nstal l
shi m and shi m cap and torque cap bol ts to 28.5 Nm
(21 ft. l bs.).
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different.
Remove synchronizer unit as an assembly to avoid
intermixing parts. Mark each synchro hub and
sleeve for assembly reference.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembl y, thi rd gear syn-
chro ri ng and thi rd gear wi th a shop press and Spl i t-
ter 1130. Posi ti on spl i tter between second and thi rd
gears.
(3) Remove thi rd gear needl e beari ng (Fi g. 22).
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft.
(5) Remove two-pi ece thrust washer (Fi g. 23). Note
posi ti on of washer l ocati ng l ugs i n shaft notches for
(6) Remove second gear and needl e beari ng (Fi g.
24).
(7) Remove 2nd-3rd gear thrust washer l ocati ng
pi n.
(8) Remove second gear synchro ri ng and synchro
cone.
(9) Remove 1-2 synchro hub snap ri ng.
Fig. 22 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 23 TWO-PIECE THRUST WASH
1 - WASHER (2 HALVES)
2 - PIN RELIEF
3 - PIN
Fig. 24 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
(10) Remove 1-2 synchro hub and sl eeve and fi rst
gear from output shaft wi th shop press and Spl i tter
1130 (Fi g. 25). Posi ti on spl i tter between fi rst and
reverse gears.
(11) Remove fi rst gear needl e beari ng (Fi g. 26).
(12) Remove output shaft beari ng snap ri ng (Fi g.
27).
(13) Remove output shaft beari ng from shaft wi th
shop press and Spl i tter 1130. Posi ti on spl i tter
between beari ng and fi fth gear.
(14) Remove fi fth gear (Fi g. 28).
(15) Remove fi fth gear needl e beari ng. Spread
beari ng apart just enough to cl ear shoul der on output
shaft (Fi g. 29).
(16) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 30).
Fig. 25 1-2 SYNCHRO HUB AND SLEEVE
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - SPECIAL TOOL
1130
Fig. 26 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 27 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
Fig. 28 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 29 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
21 - 10 MANUAL - NV1500 AN
(17) Remove fi fth-reverse synchro hub and sl eeve
wi th shop press (Fi g. 31).
(18) Remove reverse gear and needl e beari ng (Fi g.
32).
CLEANING
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopardegreasi ng sol vent, Gunk, or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry, or wi pe them dry
wi th cl ean shop towel s.
INSPECTION
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l or i nternal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 33). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks or scores. The pl unger spri ng shoul d be
strai ght and not col l apsed or di storted. Mi nor
scratches or ni cks on the pl unger can be smoothed
wi th 320/400 gri t emery soaked i n oi l . Repl ace the
pl unger and spri ng i f i n doubt about condi ti on. Check
condi ti on of detent pl unger bushi ngs. Repl ace i f dam-
aged.
I nspect the shi ft shaft, shi ft shaft bushi ng and
beari ng. The shaft l ever and the l ever bushi ng that
fi ts over the l ever. Repl ace the shaft i f bent, cracked,
or severel y scored. Mi nor burrs, ni cks or scratches
Fig. 30 FIFTH REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
Fig. 31 FIFTH-REVERSE SYNCHRO HUB AND
SLEEVE
1 - PRESS
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 32 REVERSE GEAR AND NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
AN MANUAL - NV1500 21 - 11
can be smoothed off wi th 320/400 gri t emery cl oth
fol l owed by pol i shi ng wi th crocus cl oth. Repl ace the
shi ft shaft bushi ng or beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed, or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
ai r.
as Mopardegreasi ng sol vent, Gunk or si mi l ar sol -
Al l ow the beari ngs to ei ther ai r dry or wi pe them dry
I nspect the housi ngs careful l y. Look for cracks,
stri pped threads, scored mati ng surfaces, damaged
beari ng bores or worn dowel pi n hol es. Mi nor ni cks
on mati ng surfaces can be dressed off wi th a fi ne fi l e
or emery cl oth. Damaged threads can be renewed by
ei ther re-tappi ng or i nstal l i ng Hel i coi l i nserts.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. If a countershaft
bearing failure results, the bearing races must be
replaced also.
I nspect i nput shaft beari ng retai ner. Be sure the
rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Mi nor ni cks on the surface can be
smoothed off wi th 320/420 gri t emery cl oth and fi nal
pol i shed wi th oi l coated crocus cl oth. Repl ace the
retai ner seal i f necessary.
I nspect output shaft beari ng retai ner. Be sure the
U-shaped retai ner i s fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged or i f
the retai ner i s bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs are standard tapered
rol l er beari ngs wi th matchi ng races. The races are
pressed i nto the front and rear housi ngs. I nspect
countershaft beari ngs and races for abnormal wear
or damage.
REVERSE IDLER COMPONENTS
I nspect i dl er gear, beari ng, shaft, thrust washer
and support for excessi ve wear or fai l ure (Fi g. 34).
Repl ace beari ng i f any of the needl e beari ng rol l ers
Fig. 33 SHIFT FORKS AND SHAFT
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING
4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
21 - 12 MANUAL - NV1500 AN
are worn, chi pped, cracked, fl at-spotted or bri nnel l ed.
Al so repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace thrust washer, i f cracked, chi pped or worn.
Repl ace i dl er gear i f the teeth are chi pped, cracked or
worn thi n. Repl ace shaft i f worn, scored or the bol t
threads are damaged beyond repai r. Repl ace support
segment i f cracked or chi pped and repl ace the i dl er
attachi ng bol ts i f the threads are damaged.
Shift Socket
I nspect shi ft socket for wear or damage. Repl ace
socket i f the rol l pi n or shi ft shaft bores are dam-
aged. Mi nor ni cks i n the shi ft l ever bal l seat i n the
socket can be smoothed down wi th 400 gri t emery or
wet/dry paper. Repl ace socket i f the bal l seat i s worn,
or cracked. Do not reuse the ori gi nal shi ft socket rol l
pi n. The socket rol l pi n i s approxi matel y i s approxi -
matel y 33 mm (1-1/4 i n.) l ong.
Output Shaft And Geartrain
I nspect al l gears for worn, cracked, chi pped or bro-
ken teeth. Check condi ti on of the beari ng bore i n each
gear. The bores shoul d be smooth and free of surface
damage. Di scol orati on of the gear bores i s a normal
occurrence and i s not a reason for repl acement.
Repl ace gears onl y when tooth damage has occurred or
i f the bores are bri nnel l ed or severel y scored.
I nspect shaft spl i nes and beari ngs surfaces. Mi nor
ni cks on the beari ng surfaces can be smoothed wi th
320/420 gri t emery and fi nal pol i shed wi th crocus
cl oth. Repl ace the shaft i f the spl i nes are damaged or
beari ng surfaces are deepl y scored, worn or bri nnel l ed.
ASSEMBLY
SYNCHRONIZER
NOTE: The easiest method of assembling each syn-
chro is to install the springs, struts and detent balls
one at a time.
(1) Sl i de the sl eeve part way onto the hub. Leave
enough room to i nstal l the spri ng i n the hub and the
strut i n the hub groove.
(2) I nstal l fi rst spri ng i n the hub and then i nstal l
a strut over the spri ng. Veri fy spri ng i s seated i n the
spri ng bore i n the strut.
(3) Sl i de the sl eeve onto the hub just far enough to
hol d the fi rst strut and spri ng i n pl ace.
(4) Pl ace detent bal l i n the top of the strut. Then
work the sl eeve over the bal l to hol d i t i n pl ace. Use
a smal l fl at bl ade screwdri ver to press the bal l i nto
pl ace whi l e movi ng the sl eeve over i t.
(5) Repeat procedure for the remai ni ng spri ngs,
struts and bal l s. Tape or rubber band each strut and
bal l temporari l y as they are i nstal l ed.
(6) Veri fy the three spri ngs, struts and detent bal l s
are al l i n pl ace (Fi g. 35).
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
Fig. 35 ASSEMBLED SYNCHRO COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
AN MANUAL - NV1500 21 - 13
OUTPUT SHAFT
NOTE: Lubricate shaft, gears and bearings with rec-
ommended lubricant and immerse each synchro
ring in lubricant before installation. Petroleum jelly
can be used to hold parts in place.
(1) I nstal l reverse gear needl e beari ng on shaft
(Fi g. 36). Sl i de beari ng up agai nst shoul der on output
shaft.
(2) I nstal l reverse gear over needl e beari ng (Fi g.
37).
(3) I nstal l sol i d brass synchro ri ng on reverse gear
(Fi g. 38).
NOTE: This synchro ring is different than all the
rest. The angle on the friction face is 9 versus the
6.5 of all the other synchro rings.
(4) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th shop press and Remover 6310-1 (Fi g. 39).
CAUTION: Fifth-reverse synchro hub and sleeve
can be installed backwards. One side of the sleeve
has double grooves and offset teeth. This side must
be installed away from reverse gear (towards 5th).
NOTE: The synchro hub is a press fit design. There
may be instances where the press is not necessary.
As long as there is a snug fit between the hub and
the shaft, the hub does not need to be replaced.
Fig. 36 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
Fig. 37 REVERSE GEAR
1 - REVERSE GEAR
Fig. 38 REVERSE GEAR SYNCHRO RING
1 - REVERSE GEAR
2 - SYNCHRO RING (SOLID BRASS)
Fig. 39 FIFTH-REVERSE SYNCHRO ASSEMBLY
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - SPECIAL TOOL 6310-1
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
21 - 14 MANUAL - NV1500 AN
(5) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
40) and veri fy snap ri ng i s seated i n the shaft groove.
NOTE: Install thickest snap ring that will fit in shaft
groove.
(6) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 41).
(7) I nstal l fi fth gear beari ng, spreadi ng beari ng
onl y enough to cl ear shoul der on output shaft (Fi g.
42). Veri fy beari ng i s seated.
(8) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 43).
(9) I nstal l output shaft beari ng.
(10) I nstal l output shaft beari ng snap ri ng, spread
snap ri ng onl y enough to i nstal l i t (Fi g. 44). Veri fy
snap ri ng i s seated i n shaft groove.
Fig. 40 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
Fig. 41 FIFTH GEAR SYNCHRO RING
1 - FIFTH-SPEED SYNCHRO RING
Fig. 42 FIFTH GEAR BEARING
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 43 FIFTH GEAR
1 - FIFTH GEAR
2 - BEARING
AN MANUAL - NV1500 21 - 15
(11) I nvert output shaft and set the shaft i n
Remover 6310-1 so that fi fth gear i s seated on the
tool (Fi g. 45).
(12) I nstal l fi rst gear beari ng on output shaft (Fi g.
45). Veri fy beari ng i s seated on shaft shoul der and i s
properl y joi ned.
(13) I nstal l synchro cone onto fi rst gear. Veri fy
synchro cone l ocati ng tabs are properl y l ocated to the
recesses i n fi rst gear.
(14) I nstal l fi rst gear on shaft and over beari ng
wi th beari ng synchro cone faci ng up (Fi g. 46).
(15) I nstal l fi rst gear synchro ri ng (Fi g. 47).
(16) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 48). Be sure synchro sl eeve i s properl y posi -
ti oned.
CAUTION: The 1-2 synchro hub and sleeve can be
installed backwards. One side of the sleeve has a
groove and offset teeth. This side must be installed
towards 1st gear (away from 2nd gear).
Fig. 44 OUTPUT SHAFT BEARING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 45 FIRST GEAR BEARING
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
4 - PRESS BLOCKS
Fig. 46 FIRST GEAR
1 - FIRST GEAR
3 - BEARING
Fig. 47 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
3 - FIRST GEAR
21 - 16 MANUAL - NV1500 AN
(17) Press 1-2 synchro onto output shaft wi th sui t-
abl e si ze pi pe and shop press (Fi g. 49).
CAUTION: Align synchro ring and sleeve as hub is
being pressed onto the shaft. The synchro ring can
be cracked if it becomes misaligned.
(18) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
50) wi th the thi ckest snap ri ng that wi l l fi t i n shaft
groove. Veri fy snap ri ng i s seated i n shaft groove.
(19) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 51). Veri fy synchro ri ng i s
seated i n sl eeve.
(20) I nstal l synchro cone i nto synchro ri ng.
(21) I nstal l second gear needl e beari ng on shaft
(Fi g. 52).
(22) I nstal l second gear onto shaft and beari ng
(Fi g. 53). Veri fy second gear i s seated on synchro
components.
(23) I nstal l thrust washer pi n to shaft and i nstal l
two-pi ece thrust washer (Fi g. 54). Veri fy washer
hal ves are seated i n shaft groove and pi n rel i efs are
posi ti oned at washer l ocati ng pi n.
(24) Seat retai ni ng ri ng around two-pi ece thrust
washer.
Fig. 48 START 1-2 SYNCHRO ON SHAFT
1 - 1-2 SYNCHRO ASSEMBLY
2 - FIRST GEAR
4 - BE SURE THIS IS SINGLE GROOVE SIDE OF SYNCHRO
SLEEVE
Fig. 49 PRESS 1-2 SYNCHRO ASSEMBLY
1 - SUITABLE SIZE PIPE TOOL
2 - SYNCHRO RING
5 - PRESS RAM
Fig. 50 1-2 SYNCHRO HUB SNAP RING
1 - 1-2 SYNCHRO
3 - SYNCHRO SNAP RING
AN MANUAL - NV1500 21 - 17
Fig. 51 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - SPECIAL TOOL
6310-1
Fig. 52 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - SPECIAL TOOL
6310-1
Fig. 53 SECOND GEAR
1 - SPECIAL TOOL
6310-1
3 - BEARING
4 - SECOND GEAR
1 - WASHER (2 HALVES)
2 - PIN RELIEF
3 - PIN
21 - 18 MANUAL - NV1500 AN
(25) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
55).
(26) I nstal l thi rd gear on shaft and beari ng (Fi g.
56).
(27) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 57).
(28) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 58).
installed backwards. One side of the sleeve has two
grooves and offset teeth. This side must be
installed towards 3rd gear (away from 4th gear).
Fig. 55 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 56 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 57 THIRD SPEED SYNCHRO RING
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
AN MANUAL - NV1500 21 - 19
(29) Press 3-4 synchro assembl y onto output shaft
wi th shop press and sui tabl e si ze pi pe tool (Fi g. 59).
Press tool must be as cl ose to the hub center as pos-
si bl e but not contacti ng the shaft spl i nes.
(30) I nstal l 3-4 synchro hub new snap ri ng (Fi g.
60) wi th thi ckest snap ri ng that wi l l fi t i n shaft
groove. Veri fy snap ri ng i s seated i n groove.
(31) Veri fy posi ti on of synchro sl eeves before pro-
ceedi ng (Fi g. 61).
Fig. 58 START 3-4 SYNCHRO HUB ON OUTPUT
SHAFT
1 - GROOVED SIDE OF SLEEVE (TO FRONT)
Fig. 59 PRESS 3-4 SYNCHRO ASSEMBLY ON
SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
1 - 3-4 SYNCHRO HUB SNAP RING
21 - 20 MANUAL - NV1500 AN
GEARTRAIN
(1) I nstal l i nput shaft i nto Support Stand 8355
(Fi g. 62).
(2) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 62).
(3) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 63).
(4) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 64). Rotate output shaft unti l the
3-4 synchro ri ng seats i n synchro hub and sl eeve.
(5) Sl i de countershaft i nto fi xture sl ot. Veri fy coun-
tershaft and output shaft gears are ful l y meshed
wi th the mai nshaft gears (Fi g. 65).
(6) Thread one Pi l ot Stud 8120 i n center or pas-
senger si de hol e of output shaft beari ng retai ner.
Then posi ti on retai ner on fi fth gear.
(7) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
66). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
Fig. 61 SYNCHRO SLEEVE POSITION
1 - 2 GROOVES
2 - 1 GROOVE
3 - 2 GROOVES
4 - FOURTH GEAR
5 - THIRD GEAR
6 - SECOND GEAR
7 - FIRST GEAR
8 - REVERSE GEAR
9 - FIFTH GEAR
Fig. 62 INPUT SHAFT AND PILOT BEARING
1 - PILOT BEARING
2 - INPUT SHAFT
3 - STAND 8355
AN MANUAL - NV1500 21 - 21
(8) I nstal l assembl ed shi ft forks i n synchro sl eeves
(Fi g. 67). Veri fy forks are seated i n sl eeves.
Fig. 63 FOURTH GEAR SYNCHRO RING ON INPUT
SHAFT
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
3 - STAND 8355
Fig. 64 MAINSHAFT ON SUPPORT STAND
1 - MAIN SHAFT
2 - SUPPORT STAND 8355
Fig. 65 COUNTERSHAFT ON SUPPORT STAND
1 - COUNTER SHAFT
2 - MAIN SHAFT
3 - SUPPORT STAND 8355
Fig. 66 1-2 AND FIFTH-REVERSE SHIFT FORKS
1 - INSERT ARM THROUGH 1-2 FORK
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
21 - 22 MANUAL - NV1500 AN
REAR HOUSING
(1) Lubri cate countershaft rear beari ng race.
(2) I nstal l rear housi ng onto geartrai n (Fi g. 68).
Veri fy beari ng retai ner pi l ot stud i s i n correct bol t
hol e and countershaft and output shaft beari ngs are
al i gned i n housi ng and on countershaft.
(3) Seat rear housi ng on output shaft rear beari ng
and countershaft. Tap housi ng i nto pl ace wi th pl asti c
or rawhi de hammer.
(4) Appl y MoparGasket Maker or equi val ent to
bol t threads, bol t shanks and under bol t heads (Fi g.
69).
(5) Start fi rst two bol ts i n retai ner (Fi g. 70). I t
may be necessary to move retai ner rearward (wi th
pi l ot stud) i n order to start bol ts.
(6) Remove Pi l ot Stud 8120 and i nstal l l ast
retai ner bol t (Fi g. 70).
(7) Ti ghten al l three retai ner bol ts to 22 Nm (16
ft. l bs.).
NOTE: All bolts except the reverse idler shaft bolts
have o-rings to seal the bolts to the transmission
case. Inspect the o-rings to ensure that they are in
good condition.
REVERSE IDLER
(1) Remove geartrai n and housi ng assembl y from
support stand wi th ai d of hel per.
(2) Assembl e shaft, gear and washer (wi thout
beari ng or support) and i nstal l i nto housi ng (Fi g. 71).
Fig. 67 SHIFT FORKS AND SYNCHROS
1 - FIFTH REVERSE SHIFT FORK
2 - 1-2 SHIFT FORK
1 - REAR HOUSING
Fig. 69 RETAINER AND HOUSING BOLTS
1 - MOPAR GASKET MAKER
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
AN MANUAL - NV1500 21 - 23
NOTE: The small shoulder on the reverse idler gear
goes toward the front of the transmission.
(3) Appl y Mopar Gasket Maker or equi val ent
seal er to undersi de of i dl er shaft and support bol t
heads, bol t shanks and bol t threads (Fi g. 69).
(4) Al i gn hol e i n housi ng wi th threaded hol e i n
shaft and start shaft rear bol t a few threads.
(5) I nstal l beari ng i nto posi ti on.
(6) I nstal l segment (Fi g. 71), al i gn housi ng hol e
wi th segment threaded hol e, and start support bol t a
few threads.
(7) Ti ghten l arge i dl er shaft bol t to 43 Nm (31.7
ft. l bs.). Ti ghten smal l i dl er shaft bol t to 22 Nm
(16.2 ft. l bs.).
CAUTION: Verify idler shaft and support segment
are properly seated and firmly in place while tight-
ening the shaft bolts. The segment, housing or
shaft threads can be damaged if the idler shaft is
allowed to shift out of position.
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT
SOCKET
(1) Veri fy al l synchro sl eeves are i n Neutral posi -
ti on (centered on hub).
CAUTION: Synchros must all be in Neutral position
to prevent damage to the housings, shift forks and
gears during installation of the two housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g. 72).
Veri fy groove i n fork arm i s al i gned wi th grooves i n
1-2 and fi fth-reverse fork arms.
(3) Sl i de shi ft shaft through 3-4 shi ft fork (Fi g.
73). Veri fy shaft detent notches are to front.
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 74). Sl ot i n bushi ng must face up and rol l pi n
hol e for l ever to al i gn wi th hol e i n shaft.
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 75).
Fig. 70 PILOT STUD AND RETAINER BOLTS
1 - BEARING RETAINER BOLT
2 - SPECIAL TOOL
8120
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
21 - 24 MANUAL - NV1500 AN
(6) Sl i de shi ft shaft through 1-2 and fi fth-reverse
fork and i nto shi ft l ever openi ng i n rear housi ng (Fi g.
76).
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
CAUTION: Positioning of the shift shaft detent
notch is important. Both of the shaft roll pins can
be installed even when the shaft is 180 off. If this
occurs, transmission will have to be disassembled
to correct shaft alignment.
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 78). Shaft l ever rol l pi n i s approxi matel y 22 mm
(7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi matel y
33 mm (1-1/4 i n.) l ong.
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng, then start rol l pi n i nto shaft l ever by hand
(Fi g. 79).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
80).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
Fig. 73 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
1 - SHIFT SHAFT
3 - 34 FORK
Fig. 76 LEVER OPENING IN HOUSING
1 - SHIFT SHAFT
AN MANUAL - NV1500 21 - 25
(12) Veri fy l ock pi n sl ot i n l ever bushi ng i s posi -
ti oned as shown (Fi g. 80).
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 81).
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be i nstal ed fl ush wi th socket (Fi g. 82).
(15) Veri fy notches i n shi ft fork arms are al i gned.
Fig. 77 SHIFT SOCKET AND SHAFT
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 78 SHAFT LEVER AND SOCKET ROLL PINS
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 79 STARTING ROLL PIN IN SHIFT SHAFT
LEVER
2 - LEVER AND BUSHING
Fig. 80 SEATING SHIFT SHAFT LEVER ROLL PIN
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 81 STARTING ROLL PIN IN SHIFT SOCKET
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
21 - 26 MANUAL - NV1500 AN
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
(1) I f previ ousl y removed, i nstal l i nput shaft bear-
i ng i n front housi ng bore (Fi g. 83). I nstal l snap ri ng
and use pl asti c mal l et to seat beari ng. Beari ng goes
i n from front si de of housi ng onl y.
(2) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng (Fi g. 84).
(3) Appl y 1/8 i n. wi de bead of Mopar Gasket
Maker or equi val ent to mati ng surfaces of front and
rear housi ngs (Fi g. 84).
(4) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(5) Work front housi ng downward onto geartrai n
unti l seated on rear housi ng.
CAUTION: If the front housing will not seat on the
rear housing, the shift components are not in Neu-
tral, or one or more components are misaligned. Do
not force the front housing into place.
(6) Pl ace transmi ssi on i n hori zontal posi ti on.
(7) Appl y MoparGasket Maker or equi val ent to
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 85).
(8) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 85). Then ti ghten bol ts to 34 Nm (25 ft.
l bs.).
(9) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 86).
Appl y MoparGasket Maker or equi val ent to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
Fig. 82 SEATING SHIFT SOCKET ROLL PIN
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
BEARING
1 - SHIFT SHAFT BUSHING
3 - COUNTERSHAFT FRONT BEARING RACE
Fig. 84 SEALER TO FRONT/REAR HOUSING
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
AN MANUAL - NV1500 21 - 27
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(10) Remove countershaft beari ng shi m cap and
shi m. Attach a di al i ndi cator and move countershaft
front and back to measure shaft end pl ay. The
requi red countershaft pre-l oad 0.001-0.003 i nches.
Add thi s amount to the measured amount of counter-
shaft end-pl ay. Thi s gi ves the amount of shi ms nec-
essary to correctl y pre-l oad the front and rear
countershaft beari ngs.
(11) I nstal l the sel ected shi ms and the shi m cap.
Ti ghten shi m cap bol ts to 29 Nm (21.4 ft. l bs.). Ver-
i fy the shi m sel ecti on by rotati ng the i nput shaft by
hand wi th the transmi ssi on i n neutral . The proper
torque requi red to rotate the i nput shaft and the
countershaft i s approxi matel y 5-7 i n.l bs.. The i nput
shaft shoul d therefore be easi l y rotated by hand. I f
the i nput shaft cannot be rotated by hand or i s not
smooth through several rotati ons, re-check the coun-
tershaft pre-l oad.
(12) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore (Fi g. 87). Lubri cate pl unger
wi th petrol eum jel l y or gear l ubri cant. Be sure
plunger is fully seated in detent notch in shift
shaft.
(13) I nstal l detent spri ng i nsi de pl unger (Fi g. 87).
(14) I nstal l detent pl ug i n end of I nstal l er 8123.
Posi ti on pl ug on detent spri ng and compress spri ng
unti l detent pl ug pi l ots i n detent pl unger bore. Dri ve
detent pl ug i nto transmi ssi on case unti l pl ug seats.
(15) I nstal l backup l i ght swi tch (Fi g. 88).
(16) I nstal l i nput shaft snap ri ng (Fi g. 89).
(17) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er 6448 (Fi g. 90).
(18) Appl y bead of Mopar Si l i cone Seal er or
equi val ent to fl ange surface of front beari ng retai ner.
Fig. 85 HOUSING ATTACHING BOLTS
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
2 - SHAFT SOCKET
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
21 - 28 MANUAL - NV1500 AN
(19) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
91). Al though retai ner i s one-way fi t on housi ng, be
sure bol t hol es are al i gned before seati ng retai ner.
NOTE: Be sure that no sealer gets into the oil feed
hole in the transmission case or bearing retainer.
(20) I nstal l and ti ghten beari ng retai ner bol ts to
29 Nm (21.4 ft. l bs.) (Fi g. 92).
1 - BACKUP LAMP SWITCH
Fig. 90 BEARING RETAINER OIL SEAL
1 - SPECIAL TOOL
6448
2 - FRONT BEARING RETAINER
2 - OIL FEED
Fig. 92 INPUT SHAFT BEARING RETAINER BOLTS
1 - BOLTS (5)
AN MANUAL - NV1500 21 - 29
SHIFT TOWER AND LEVER
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 93). Veri fy shi ft bal l i s seated i n socket and
offset i n the tower i s toward the passenger si de of
the vehi cl e before i nstal l i ng tower bol ts.
(4) I nstal l shi ft tower bol ts (Fi g. 94) and ti ghten
bol ts to 8.5 Nm (75.2 i n. l bs.).
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th MoparTransmi ssi on.
(6) I nstal l and ti ghten fi l l pl ug to 34 Nm (25 ft.
l bs.).
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
INSTALLATION
NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.
(1) Appl y l i ght coat of Moparhi gh temperature
beari ng grease to contact surfaces of fol l owi ng com-
ponents:
i nput shaft spl i nes.
rel ease beari ng sl i de surface of front retai ner.
rel ease beari ng bore.
rel ease fork.
rel ease fork bal l stud.
propel l er shaft sl i p yoke.
(2) Appl y seal er to threads of drai n pl ug and
i nstal l pl ug i n case.
(3) Mount transmi ssi on on jack and posi ti on trans-
mi ssi on under vehi cl e.
(4) Rai se transmi ssi on unti l i nput shaft i s centered
i n cl utch di sc hub.
(5) Move transmi ssi on forward and start i nput
shaft i n cl utch di sc and pi l ot bushi ng.
(6) Work transmi ssi on forward unti l seated agai nst
engi ne. Do not al l ow transmi ssi on to remai n unsup-
ported after i nput shaft has entered cl utch di sc.
(7) I nstal l and ti ghten transmi ssi on-to-engi ne bol ts
to 108 Nm (80 ft. l bs.).
(8) I nstal l cl utch sl ave cyl i nder.
(9) I nstal l transmi ssi on dust shi el d.
(10) I nstal l starter.
(11) Connect backup l i ght swi tch wi res.
(12) Fi l l transmi ssi on wi th recommended l ubri -
cant. Correct fi l l l evel i s bottom edge of fi l l pl ug hol e.
(13) I nstal l shi ft tower and l ever assembl y. Ti ghten
shi ft tower bol ts to 7-10 Nm (5-7 ft. l bs.).
(14) Posi ti on transmi ssi on harness wi res i n cl i ps
on shi ft cover.
(15) I nstal l transmi ssi on mount on transmi ssi on or
rear crossmember.
(16) I nstal l rear crossmember.
(17) Remove transmi ssi on jack and engi ne support
fi xture.
(18) Al i gn and i nstal l propel l er shaft.
(20) I nstal l the shi ft l ever extensi on onto the shi ft
(21) I nstal l shi ft boot.
(22) I nstal l fl oor consol e. Refer to 23 Body for pro-
cedures.
Fig. 93 SHIFT TOWER
2 - SHIFT SOCKET
3 - SEAL
Fig. 94 SHIFT TOWER BOLT
21 - 30 MANUAL - NV1500 AN
SPECIFICATIONS
SPECIFICATIONS - NV1500
Back up Lamp Switch 41 30 -
Coutershaft Bearing Shim
Cap
41 30 -
Bearing Retainer - Front 41 30 -
Bearing Retainer - Rear 34 25 -
Drain/Fill Plug 34 25 -
Shift Shaft Lock Bolt 27 20 -
Idler Shaft Bolts - M8 27 20 -
Idler Shaft Bolts - M10 52 40 -
Shift Tower Bolts 14 10 120
SPECIAL TOOLS
MANUAL - NV1500
Installer, Seal C-3995-A
Remover, Bushing 6957
Installer, Bushing 8160
Driver, Bearing Race C-4656
Installer, Seal 6448
Handle C-4171
AN MANUAL - NV1500 21 - 31
Remover 8117
Support Stand 8355
Remover, Bearing 8356
Remover, Bearing Race L-4454
Splitter, Bearing 1130
Tube 6310-1
Remover/Installer 8119
Stud, Alignment 8120
21 - 32 MANUAL - NV1500 AN
MANUAL - NV3500
TABLE OF CONTENTS
page page
MANUAL - NV3500
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 73
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 74
EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FLUID
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
MANUAL - NV3500
DESCRIPTION
The NV3500 i s a medi um-duty, 5-speed, constant
mesh, ful l y synchroni zed manual transmi ssi on. Fi fth
gear i s an overdri ve range wi th a rati o of 0.73:1. The
NV3500 i s avai l abl e i n two and fourwheel dri ve con-
fi gurati ons.
The transmi ssi on gear case consi sts of two al umi -
num housi ngs (Fi g. 1). The cl utch housi ng i s not a
removabl e component. I t i s an i ntegral part of the
transmi ssi on front housi ng.
A combi nati on of rol l er and bal l beari ngs are used
to support the transmi ssi on shafts i n the two hous-
i ngs. The transmi ssi on gears al l rotate on caged type
needl e beari ngs. A rol l er beari ng i s used between the
i nput and output shaft.
AN MANUAL - NV3500 21 - 33
Fig. 1 NV3500 Manual Transmission
21 - 34 MANUAL - NV3500 AN
The NV3500 has a si ngl e shaft shi ft mechani sm
wi th three shi ft forks al l mounted on the shaft. The
shaft i s supported i n the front and rear housi ngs by
bushi ngs and one l i near bal l beari ng. I nternal shi ft
components consi st of the forks, shaft, shi ft l ever
socket, and detent components (Fi g. 2).
Two versi ons of the NV3500 are avai l abl e a wi de
rati o and a cl ose rati o versi on.
WIDE RATIO VERSION
GEAR RATIO
FIRST 4.01:1
SECOND 2.32:1
THIRD 1.40:1
FOURTH 1:1
FIFTH 0.73:1
REVERSE 3.55:1
CLOSE RATIO VERSION
GEAR RATIO
FIRST 3.48:1
SECOND 2.16:1
THIRD 1.40:1
FOURTH 1:1
FIFTH 0.73:1
REVERSE 3.55:1
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
shaft gear. At thi s poi nt, al l the transmi ssi on gears
are spi nni ng.
Fig. 2 NV3500 Shift Mechanism
1 - 34 FORK
2 - SHIFT SHAFT LEVER AND BUSHING
3 - 12 FORK
5 - ROLL PIN
6 - SHIFT SHAFT
7 - REAR HOUSING
8 - SHIFT LEVER SOCKET
9 - DETENT PLUNGER
10 - DETENT SPRING
11 - DETENT PLUG
12 - FRONT HOUSING
13 - SHIFT SHAFT
AN MANUAL - NV3500 21 - 35
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft, or the countershaft i n some cases, and
movi ng the bl ocker ri ng i nto contact wi th the gears
fri cti on cone. As the bl ocker ri ng and fri cti on cone
come together, the gear speed i s brought up or down
to the speed of the synchroni zer. As the two speeds
match, the spl i nes on the i nsi de of the synchroni zer
sl eeve become al i gned wi th the teeth on the bl ocker
ri ng and the fri cti on cone and eventual l y wi l l sl i de
over the teeth, l ocki ng the gear to the mai nshaft, or
countershaft, through the synchroni zer.
DIAGNOSIS AND TESTING - MANUAL
TRANSMISSION
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adaptor or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a nonrecommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng nonrecommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Component damage, i ncorrect cl utch adjustment, or
a damaged cl utch pressure pl ate or di sc are addi ti onal
probabl e causes of i ncreased shi ft effort. I ncorrect
adjustment or a worn/damaged pressure pl ate or di sc
can cause i ncorrect rel ease. I f the cl utch probl em i s
advanced, gear cl ash duri ng shi fts can resul t. Worn or
damaged synchro ri ngs can cause gear cl ash when
shi fti ng i nto any forward gear. I n some new or rebui l t
transmi ssi ons, new synchro ri ngs may tend to sti ck
sl i ghtl y causi ng hard or noi sy shi fts. I n most cases,
thi s condi ti on wi l l decl i ne as the ri ngs weari n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear breakage.
REMOVAL
(3) Remove fl oor consol e. Refer to Group 23 Body
for proper procedures.
(4) Remove shi ft l ever boot.
(5) Remove the shi ft l ever extensi on from the shi ft
(7) Remove ski d pl ate, i f equi pped (4WD).
(8) I f transmi ssi on wi l l be di sassembl ed for repai r,
remove drai n pl ug and drai n l ubri cant from trans-
mi ssi on.
(9) Mark propel l er shafts and compani on fl ange for
assembl y reference.
(10) Di sconnect and remove propel l er shafts.
(11) Di sconnect and remove exhaust system Y-pi pe.
Then di sconnect and l ower remai ni ng exhaust pi pes
for cl earance as necessary.
(12) Di sconnect backup l i ght swi tch wi res.
2WD
rear mount.
(2) Support transmi ssi on wi th a transmi ssi on jack.
Secure transmi ssi on to jack wi th safety chai ns.
21 - 36 MANUAL - NV3500 AN
(3) Remove rear crossmember.
(4) Remove bol ts attachi ng cl utch sl ave cyl i nder to
cl utch housi ng. Then move cyl i nder asi de for worki ng
cl earance.
(5) Remove starter.
(6) Remove transmi ssi on dust shi el d.
(7) Remove transmi ssi on harness wi res from cl i ps
on transmi ssi on shi ft cover.
(9) Remove the bol ts attachi ng the shi ft tower and
l ever assembl y to the transmi ssi on housi ng. Then
remove the shi ft tower and l ever assembl y.
engi ne.
(11) Sl i de transmi ssi on and jack rearward unti l
i nput shaft cl ears cl utch di sc.
(12) Lower transmi ssi on jack and remove trans-
mi ssi on from under vehi cl e.
4WD
(1) Support engi ne wi th adjustabl e safety stand.
(2) Di sconnect transfer case shi ft l i nkage at trans-
fer case range l ever.
(3) Remove transfer case shi ft l ever from transmi s-
si on.
rear support.
(5) Remove crossmember bol ts/nuts and remove
crossmember.
(6) Support transfer case wi th transmi ssi on jack.
Secure transfer case to jack wi th safety chai ns.
(7) Remove transfer case attachi ng nuts.
(8) Move transfer case rearward unti l i nput gear
cl ears transmi ssi on output shaft.
(9) Lower transfer case assembl y and move i t from
under vehi cl e.
(10) Support transmi ssi on wi th transmi ssi on jack.
Secure transmi ssi on to jack wi th safety chai ns.
(11) Remove transmi ssi on harness from retai ni ng
cl i ps on transmi ssi on shi ft cover.
(12) Remove cl utch sl ave cyl i nder spl ash shi el d, i f
equi pped.
(13) Remove cl utch sl ave cyl i nder attachi ng nuts.
Move cyl i nder asi de for worki ng cl earance.
(14) Remove starter.
(15) Remove transmi ssi on spl ash shi el d.
(17) Remove bol ts attachi ng shi ft tower and l ever
assembl y to rear case. Then remove shi ft tower and
l ever as an assembl y.
engi ne.
(19) Move transmi ssi on rearward unti l i nput shaft
cl ears cl utch di sc.
(20) Lower transmi ssi on and remove i t from under
vehi cl e.
DISASSEMBLY
FRONT HOUSING
(2) Remove drai n pl ug and drai n l ubri cant.
(3) I nspect drai n pl ug magnet for debri s.
(4) Remove backup l i ght swi tch. Swi tch i s l ocated
on passenger si de of rear housi ng (Fi g. 3).
(5) Remove shi ft tower bol ts and remove tower and
l ever assembl y (Fi g. 4).
(6) Remove shi ft shaft l ock bol t (Fi g. 5) l ocated on
top of the housi ng just forward of shi ft tower.
(7) Remove shi ft shaft detent pl ug wi th Remover
8117A. Attach the fi ngers of the remover to the
detent pl ug (Fi g. 6). Then push the cup down ti l l i t
contacts the trans. Ti ghten the nut (Fi g. 7) ti l l i t
pul l s the pl ug from the trans case.
1 - BACKUP LIGHT SWITCH
Fig. 4 SHIFT TOWER
2 - SHIFT SOCKET
3 - SEAL
AN MANUAL - NV3500 21 - 37
(8) Remove shi ft shaft detent pl unger and spri ng
(Fi g. 8). Remove spri ng and pl unger wi th a penci l
magnet.
(9) Remove bol ts attachi ng i nput shaft beari ng
retai ner to front housi ng and remove retai ner.
NOTE: Use pry tool to carefully lift retainer and
break sealer bead (Fig. 9).
(10) Remove beari ng retai ner from i nput shaft
(Fi g. 10).
(11) Remove snap ri ng that secures i nput shaft i n
front beari ng (Fi g. 11).
(12) Remove bol ts that attach front housi ng to rear
housi ng (Fi g. 12). Three bol ts at extreme rear of
housi ng are actual l y for the output shaft beari ng
retai ner. I t i s not necessary to remove al l three bol ts
at thi s ti me. Leave at l east one bol t i n pl ace unti l
geartrai n i s ready to be removed from case.
Fig. 5 SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 6 DETENT PULLER
1 - REMOVER 8117A
2 - DETENT PLUG
Fig. 7 PULL DETENT PLUG
1 - NUT
2 - REMOVER
Fig. 8 DETENT PLUNGER
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
Fig. 9 BEARING RETAINER SEAL
1 - PRY TOOL
2 - INPUT SHAFT BEARING RETAINER
21 - 38 MANUAL - NV3500 AN
(13) Separate front housi ng from rear housi ng
(Fi g. 13). Wi th a pl asti c mal l et tap the front housi ng
off the al i gnment dowel s.
(14) Remove and i nspect i nput shaft beari ng and
countershaft front beari ng race (Fi g. 14).
(15) Remove screw from reverse bl ocker and
remove bl ocker (Fi g. 15) from case.
(16) Note posi ti on of i nput shaft, shi ft shaft and
forks, and geartrai n components i n housi ng (Fi g. 16).
1 - SHAFT BEARING
3 - INPUT SHAFT
2 - OIL FEED
Fig. 12 HOUSING AND BEARING RETAINER BOLTS
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
Fig. 13 FRONT HOUSING
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
AN MANUAL - NV3500 21 - 39
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Unseat the rol l pi n that secures the shi ft
socket to the shi ft shaft wi th Remover 6858 as fol -
l ows:
(a) Posi ti on remover on the shi ft shaft. Center
the tool over the rol l pi n and veri fy that the tool
l egs are fi rml y seated on the shi ft socket (Fi g. 17).
(b) Ti l t the socket toward the si de of the case.
Thi s posi ti ons the rol l pi n at a sl i ght angl e to avoi d
trappi ng the pi n between the gear teeth.
(c) Ti ghten the tool to press the rol l pi n down-
ward and out of the shi ft socket (Fi g. 17).
NOTE: Press the roll pin just enough to clear the
shift shaft. Be careful not to push the pin into the
geartrain.
BEARING RACE
2 - FRONT HOUSING
3 - COUNTERSHAFT FRONT BEARING
Fig. 15 REVERSE BLOCKER
1 - REVERSE BLOCKER
2 - SHIFTER SHAFT BUSHING
3 - VENT
Fig. 16 GEARTRAIN AND SHIFT COMPONENT
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
Fig. 17 SHIFT SOCKET ROLL PIN
2 - SHIFT SOCKET
21 - 40 MANUAL - NV3500 AN
(2) Wi th a hammer and punch dri ve out rol l pi n
that secures shi ft bushi ng and l ever to shi ft shaft
(Fi g. 18).
NOTE: Use proper size punch to avoid bending the
shift shaft.
(3) Pul l shi ft shaft strai ght (Fi g. 19) out of rear
housi ng.
(4) Remove shi ft socket from rear housi ng (Fi g. 20).
(5) Remove l ever and bushi ng (Fi g. 21).
(6) Rotate 3-4 fork around synchro sl eeve unti l
fork cl ears shi ft arms on 1-2 and fi fth-reverse forks,
then remove 3-4 fork (Fi g. 22).
(7) Remove the reverse i dl er shaft support bol t
(front bol t) (Fi g. 23).
Fig. 18 SHIFT SHAFT LEVER AND BUSHING ROLL
PIN
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 19 SHIFT SHAFT
1 - SHIFTER SHAFT
2 - SHIFTER SHAFT DETENT
3 - 3-4 SHIFT FORK
Fig. 20 SHIFT SOCKET AND ROLL PIN
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
2 - 3-4 FORK
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
AN MANUAL - NV3500 21 - 41
(8) Loosen rear reverse i dl er shaft bol t (rear bol t)
(Fi g. 23).
(9) Remove reverse i dl er shaft support (Fi g. 24)
segment by sl i di ng i t strai ght out of housi ng.
(10) Support geartrai n and rear housi ng on Fi x-
ture 6747 as fol l ows:
(a) Adjust hei ght of reverse i dl er pedestal rod
unti l the reverse i dl e shaft bottoms i n Cup 8115.
(b) Posi ti on Adapters 6747-1A and 6747-2B on
Fi xture 6747.
(c) Sl i de fi xture tool onto i nput shaft, counter-
shaft and i dl er gear (Fi g. 25).
(d) Stand geartrai n and rear housi ng upri ght on
fi xture (Fi g. 26). Have hel per hol d fi xture tool i n
pl ace whi l e housi ng and geartrai n i s bei ng rotated
i nto upri ght posi ti on.
(11) Remove rear bol t hol di ng reverse i dl er shaft
i n housi ng.
Fig. 23 REVERSE IDLER SHAFT/SUPPORT BOLT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 24 IDLER SHAFT SUPPORT
1 - IDLER SHAFT
2 - IDLER SHAFT SUPPORT
Fig. 25 FIXTURE ASSEMBLY
2 - SPECIAL TOOL 6747-1A
4 - REVERSE IDLER PEDESTAL
5 - SPECIAL TOOL 6747-2B
Fig. 26 GEARTRAIN AND HOUSING ON FIXTURE
1 - INPUT SHAFT
2 - COUNTERSHAFT
21 - 42 MANUAL - NV3500 AN
REAR HOUSING - 2WD
(1) On 2-wheel dri ve transmi ssi on, remove three
bol ts that attach output shaft beari ng retai ner to
rear case (Fi g. 27). Bol ts are rear of shi ft tower open-
i ng.
(2) Unseat output shaft beari ng from beari ng bore
i n rear housi ng. Use pl asti c/rawhi de mal l et to tap
rear housi ng upward and off output shaft beari ng as
shown (Fi g. 28).
(3) Li ft rear housi ng up and off geartrai n (Fi g. 29).
(4) Remove countershaft rear beari ng from coun-
tershaft (Fi g. 30).
(5) Exami ne condi ti on of beari ng bore and i dl er
shaft notch i n rear housi ng . Repl ace housi ng i f any
of these components are damaged.
Fig. 27 OUTPUT SHAFT
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
Fig. 28 REAR HOUSING - 2WD
1 - REAR HOUSING
2 - PLASTIC OR RAWHIDE MALLET
3 - FIXTURE TOOL
AN MANUAL - NV3500 21 - 43
REAR ADAPTER HOUSING - 4WD
(1) Locate rear seal di mpl es (Fi g. 31). Wi th sl i de
hammer mounted screw, remove rear seal by i nsert-
i ng screw i nto one of the seal di mpl es (Fi g. 32).
(2) Remove rear beari ng snap ri ng from output
shaft wi th snap ri ng pl i ers (Fi g. 33).
(3) Li ft rear adapter housi ng upward and off
geartrai n (Fi g. 34).
(4) Remove beari ng retai ner bol ts and remove rear
beari ng retai ner and rear beari ng (Fi g. 35). I f needed
push or tap beari ng out of the housi ng wi th a ham-
mer.
(5) Exami ne condi ti on of beari ng bore, counter-
shaft rear beari ng race and i dl er shaft notch i n rear
housi ng. Repl ace housi ng i f race, bore or notch are
worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove reverse i dl er gear assembl y from
assembl y fi xture cup.
(2) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(3) Sl i de countershaft out of fi xture tool .
1 - REAR HOUSING
Fig. 30 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - OUTPUT SHAFT
3 - COUNTER SHAFT
Fig. 31 DIMPLES IN SEAL FACE - 4WD
1 - LOCATION OF DIMPLES
2 - SEAL FACE
Fig. 32 REAR SEAL - 4WD
1 - SLIDE HAMMER
2 - REMOVER TOOL
3 - REAR SEAL
21 - 44 MANUAL - NV3500 AN
(4) Remove output shaft beari ng retai ner from
rear surface of fi fth gear (retai ner wi l l drop onto gear
after bol ts are removed).
(5) Li ft and remove output shaft and gears off
i nput shaft.
(6) Li ft and remove i nput shaft, pi l ot beari ng and
fourth gear synchro ri ng from assembl y fi xture tool .
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. Remove each
synchronizer unit as an assembly to avoid intermix-
ing parts. Reference mark or tag each synchro hub
and sleeve for correct assembly.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembl y, thi rd gear syn-
chro ri ng and thi rd gear wi th shop press and Beari ng
Spl i tter 1130. Posi ti on spl i tter between second and
thi rd gears.
(3) Remove thi rd gear needl e beari ng (Fi g. 36).
Fig. 33 REAR BEARING SNAP RING - 4WD
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 34 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
Fig. 35 REAR ADAPTER HOUSING COMPONENTS
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 36 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
AN MANUAL - NV3500 21 - 45
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft (Fi g. 37). Use a smal l pry tool
to remove retai ni ng ri ng.
(5) Remove two-pi ece thrust washer (Fi g. 38). Note
posi ti on of washer l ocati ng l ugs i n shaft notches for
(6) Remove second gear and needl e beari ng (Fi g.
39).
(7) Remove second gear synchro ri ng, synchro fri c-
ti on cone and synchro cone (Fi g. 40).
(8) Remove i nterm ri ng.
(9) Remove 1-2 synchro hub snap ri ng.
Fig. 37 THRUST WASHER
1 - PRY TOOL
2 - THRUST WASHER RETAINING RING
Fig. 38 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2PIECE)
3 - WASHER LOCATING LUG
Fig. 39 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 40 SECOND GEAR SYNCHRO RING AND
CONES
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
21 - 46 MANUAL - NV3500 AN
(10) Remove 1-2 synchro hub and sl eeve and fi rst
gear from output shaft wi th press and Beari ng Spl i t-
ter 1130 (Fi g. 41). Posi ti on spl i tter between fi rst and
reverse gears.
(11) Remove fi rst gear needl e beari ng (Fi g. 42).
(12) Remove output shaft beari ng snap ri ng (Fi g.
43).
(13) On 2-wheel dri ve model s, remove output shaft
beari ng.
(14) Remove fi fth gear (Fi g. 44).
(15) Remove fi fth gear needl e beari ng. Spread
beari ng apart just enough to cl ear shoul der on output
shaft (Fi g. 45).
Fig. 41 HUB SLEEVE AND 1-2 SYNCHRO
2 - SPECIAL TOOL
1130
Fig. 42 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 43 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
Fig. 44 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 45 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO
CLEAR SHOULDER ON SHAFT)
AN MANUAL - NV3500 21 - 47
(16) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 46).
(17) Remove fi fth-reverse synchro hub and sl eeve
wi th a press (Fi g. 47).
(18) Remove reverse gear and needl e beari ng (Fi g.
48).
REVERSE IDLER
(1) Remove i dl er gear snap ri ngs (Fi g. 49).
(2) Remove thrust washer, wave washer, thrust
pl ate and i dl er gear from shaft.
(3) Remove i dl er gear needl e beari ng from shaft.
CLEANING
ai r.
as Mopardegreasi ng sol vent, Gunk, or si mi l ar sol -
Al l ow the beari ngs to ei ther ai r dry, or wi pe them dry
Fig. 46 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
2 - SYNCHRO HUB SNAP RING
Fig. 47 FIFTH-REVERSE SYNCHRO HUB AND
SLEEVE
1 - PRESS
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 48 REVERSE GEAR AND NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
21 - 48 MANUAL - NV3500 AN
INSPECTION
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l , or i nternal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 50). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks, or scores. The pl unger spri ng shoul d be
strai ght and not col l apsed, or di storted. Mi nor
scratches, or ni cks on the pl unger can be smoothed
wi th 320/400 gri t emery soaked i n oi l . Repl ace the
pl unger and spri ng i f i n doubt about condi ti on. Check
condi ti on of detent pl unger bushi ngs. Repl ace i f dam-
aged.
I nspect the shi ft shaft, shi ft shaft bushi ng and
beari ng, the shaft l ever, and the l ever bushi ng that
fi ts over the l ever. Repl ace the shaft i f bent, cracked,
or severel y scored. Mi nor burrs, ni cks, or scratches
can be smoothed off wi th 320/400 gri t emery cl oth
fol l owed by pol i shi ng wi th crocus cl oth. Repl ace the
shi ft shaft bushi ng or beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed, or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
I nspect the housi ngs careful l y. Look for cracks,
stri pped threads, scored mati ng surfaces, damaged
beari ng bores, or worn dowel pi n hol es. Mi nor ni cks
on mati ng surfaces can be dressed off wi th a fi ne fi l e,
or emery cl oth. Damaged threads can be renewed by
ei ther re-tappi ng or i nstal l i ng Hel i coi l i nserts.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
front housing will have to be replaced if the coun-
tershaft bearing race is loose, worn, or damaged.
The rear housing will have to be replaced if the
countershaft rear bearing race is loose, worn, or
damaged.
I nspect the i nput shaft beari ng retai ner. Be sure
the rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Mi nor ni cks on the surface can be
smoothed off wi th 320/420 gri t emery cl oth and fi nal
pol i shed wi th oi l coated crocus cl oth. Repl ace the
retai ner seal i f necessary.
I nspect the output shaft beari ng retai ner. Be sure
the U-shaped retai ner i s fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged, or i f
the retai ner i s bent, or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs and races are machi ne
l apped duri ng manufacture to form matched sets.
The beari ngs and races shoul d not be i nterchanged.
Fig. 49 REVERSE IDLER COMPONENTS
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR
6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
AN MANUAL - NV3500 21 - 49
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, it will be necessary to
replace the front or rear housing as necessary. A
new countershaft bearing will be supplied with each
new housing for service use.
The countershaft beari ngs can be i nstal l ed back-
wards i f care i s not exerci sed. The beari ng rol l er cage
i s a di fferent di ameter on each si de. Be sure the
beari ng i s i nstal l ed so the l arge di ameter si de of the
cage i s faci ng the countershaft gear (Fi g. 51). The
smal l di ameter si de goes i n the beari ng race.
REVERSE IDLER COMPONENTS
I nspect the i dl er gear, beari ng, shaft, thrust
washer, wave washer and thrust pl ate. Repl ace the
beari ng i f any of the needl e beari ng rol l ers are worn,
chi pped, cracked, fl at-spotted, or bri nnel l ed. Al so
repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace the thrust washer, wave washer, or thrust
pl ate i f cracked, chi pped, or worn. Repl ace the i dl er
gear i f the teeth are chi pped, cracked or worn thi n.
Repl ace the shaft i f worn, scored, or the bol t threads
are damaged beyond repai r. Repl ace the support seg-
ment i f cracked, or chi pped and repl ace the i dl er
attachi ng bol ts i f the threads are damaged.
Fig. 50 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING
4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
Fig. 51 Countershaft Bearings
1 - COUNTERSHAFT
2 - BEARING CAGE
21 - 50 MANUAL - NV3500 AN
Shift Socket
I nspect the shi ft socket for wear or damage.
repl ace the socket i f the rol l pi n, or shi ft shaft bores
are damaged. Mi nor ni cks i n the shi ft l ever bal l seat
i n the socket can be smoothed down wi th 400 gri t
emery or wet/dry paper. Repl ace the socket i f the bal l
seat i s worn, or cracked. Do not reuse the ori gi nal
shi ft socket rol l pi n. I nstal l a new pi n duri ng reas-
sembl y. The socket rol l pi n i s approxi matel y i s
approxi matel y 33 mm (1-1/4 i n.) l ong.
Output Shaft And Geartrain
I nspect al l of the gears for worn, cracked, chi pped,
or broken teeth. Al so check condi ti on of the beari ng
bore i n each gear. The bores shoul d be smooth and
free of surface damage. Di scol orati on of the gear
bores i s a normal occurrence and i s not a reason for
repl acement. Repl ace gears onl y when tooth damage
has occurred, or i f the bores are bri nnel l ed or
severel y scored.
I nspect the shaft spl i nes and beari ngs surfaces.
Mi nor ni cks on the beari ng surfaces can be smoothed
wi th 320/420 gri t emery and fi nal pol i shed wi th cro-
cus cl oth. Repl ace the shaft i f the spl i nes are dam-
aged or beari ng surfaces are deepl y scored, worn, or
bri nnel l ed.
ASSEMBLY
Seal ers are used at al l case joi nts. Usa Mopar Gas-
ket Maker for al l case joi nts and Mopar si l i cone
seal er or equi val ent, for the i nput shaft beari ng
retai ner. Appl y these products as i ndi cated i n the
assembl y procedures.
CAUTION: The transmission shift components must
be in the Neutral position during assembly. This
prevents damage to the synchro and shift compo-
nents when the housings are installed.
SYNCHRONIZER
To assembl e each synchro i nstal l the spri ngs,
struts and detent bal l s one at a ti me as fol l ows:
(1) Sl i de the sl eeve part way onto the hub. Leave
enough room to i nstal l the spri ng i n the hub and the
strut i n the hub groove.
(2) I nstal l the fi rst spri ng i n the hub. Then i nstal l
a strut over the spri ng. Be sure the spri ng i s seated
i n the spri ng bore i n the strut.
(3) Sl i de the sl eeve onto the hub just far enough to
hol d the fi rst strut and spri ng i n pl ace.
(4) Pl ace the detent bal l i n the top of the strut.
Then careful l y work the sl eeve over the bal l to hol d
i t i n pl ace. Use a smal l fl at bl ade screwdri ver to
press the bal l i nto pl ace whi l e movi ng the sl eeve over
i t.
(5) Repeat the procedure for the remai ni ng
spri ngs, struts and bal l s. Tape or rubber band each
strut and bal l to temporari l y secure as they are
i nstal l ed.
(6) Veri fy synchro spri ngs, struts and detent bal l s
are al l i n pl ace (Fi g. 52).
OUTPUT SHAFT
Lubri cate shaft, gears and beari ngs wi th recom-
mended l ubri cant duri ng assembl y. Petrol eum jel l y
can be used to hol d parts i n pl ace. Check beari ng
surfaces of output shaft for ni cks or scratches.
Smooth surfaces wi th 320/400 gri t emery cl oth i f nec-
essary. Appl y oi l to emery cl oth and shaft surface
before pol i shi ng.
I nspect and repl ace any synchro ri ng i f worn or
damage. I mmerse each synchro ri ng i n l ubri cant
before i nstal l ati on.
(1) Lubri cate and i nstal l reverse gear needl e bear-
i ng on shaft (Fi g. 53). Sl i de beari ng up agai nst shoul -
der on output shaft.
(2) I nstal l reverse gear over needl e beari ng (Fi g.
54).
(3) I nstal l brass synchro ri ng on reverse gear (Fi g.
55).
(4) Assembl e fi fth-reverse synchro hub, sl eeve,
struts, spri ngs and detent bal l s, i f not previ ousl y
done.
Fig. 52 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
AN MANUAL - NV3500 21 - 51
CAUTION: One side of the hub has shoulders
around the hub bore, this side of the hub faces the
front of the shaft. One side of the sleeve is tapered
the tapered side faces the front of the shaft.
(5) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th a press and Cup 6310-1 (Fi g. 56).
(6) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
57) and veri fy the snap ri ng i s seated.
NOTE: Snap rings are available in thicknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 in.). Install
thickest snap ring that will fit in shaft groove.
Fig. 53 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
Fig. 54 REVERSE GEAR
1 - REVERSE GEAR
Fig. 55 REVERSE SYNCHRO
1 - REVERSE GEAR
2 - SYNCHRO RING
Fig. 56 FIFTH-REVERSE SYNCHRO ASSEMBLY
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
5 - CUP
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
Fig. 57 FIFTH/REVERSE SYNCHRO HUB SNAP RING
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
21 - 52 MANUAL - NV3500 AN
(7) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 58).
(8) I nstal l fi fth gear beari ng, spreadi ng beari ng
onl y enough to cl ear shoul der on output shaft (Fi g.
59). Veri fy beari ng i s properl y seated.
(9) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 60).
(10) I nvert output shaft and set the shaft i n Cup
6310-1 so that fi fth gear i s seated on the tool (Fi g.
61).
(11) I nstal l fi rst gear beari ng on output shaft (Fi g.
61). Veri fy beari ng i s seated on shaft shoul der and i s
properl y joi ned.
(12) I nstal l fi rst gear on shaft and over beari ng
wi th beari ng synchro cone faci ng up (Fi g. 62).
(13) I nstal l fi rst gear synchro ri ng (Fi g. 63).
(14) Assembl e 1-2 synchro hub sl eeve, spri ngs,
struts and detent bal l s.
Fig. 58 FIFTH GEAR SYNCHRO RING
1 - FIFTH-SPEED SYNCHRO RING
Fig. 59 FIFTH GEAR BEARING
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 60 FIFTH GEAR
1 - FIFTH GEAR
2 - BEARING
Fig. 61 FIRST GEAR BEARING
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - SPECIAL TOOL
4 - PRESS BLOCKS
AN MANUAL - NV3500 21 - 53
installed backwards. One side of the synchro sleeve
is marked First Gear Side. Verify this side of the
sleeve is facing first gear.
(15) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 64). Veri fy synchro sl eeve i s properl y posi ti oned.
(16) Press 1-2 synchro onto output shaft usi ng
sui tabl e si ze pi pe tool and shop press (Fi g. 65).
CAUTION: Align the synchro ring and sleeve as hub
the is being pressed onto the shaft. The synchro
ring can crack if not aligned.
Fig. 62 FIRST GEAR
1 - FIRST GEAR
2 - SPECIAL TOOL
3 - BEARING
Fig. 63 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
2 - SPECIAL TOOL
3 - FIRST GEAR
Fig. 64 STARTING 1-2 SYNCHRO ON SHAFT
2 - CUP
3 - FIRST GEAR SIDE OF SYNCHRO SLEEVE
Fig. 65 PRESS 1-2 SYNCHRO
1 - SUITABLE SIZE PIPE
2 - SYNCHRO RING
3 - SPECIAL TOOL
5 - PRESS RAM
21 - 54 MANUAL - NV3500 AN
(17) I nstal l i nterm ri ng.
(18) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
66) and verfi y the snap ri ng i s seated.
(19) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 67). Veri fy synchro ri ng i s
properl y seated.
(20) I nstal l synchro fri cti on cone and synchro cone
i n synchro ri ng.
(21) I nstal l second gear needl e beari ng on shaft
(Fi g. 68).
(22) I nstal l second gear onto shaft and beari ng
(Fi g. 69). Veri fy second gear i s ful l y seated on syn-
chro components.
(23) I nstal l two-pi ece thrust washer (Fi g. 70).
Ensure washer hal ves are seated i n shaft groove and
that washer l ugs are seated i n shaft l ug bores. Veri fy
i .d. grooves and marki ngs noted duri ng removal are
faci ng the correct di recti on.
1 - 1-2 SYNCHRO
2 - CUP
3 - SYNCHRO SNAP RING
Fig. 67 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - SPECIAL TOOL
Fig. 68 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - SPECIAL TOOL
Fig. 69 SECOND GEAR
1 - SPECIAL TOOL
3 - BEARING
4 - SECOND GEAR
AN MANUAL - NV3500 21 - 55
(24) Start retai ni ng ri ng around two-pi ece thrust
washer (Fi g. 71). Ensure l ocati ng di mpl e i s between
the thrust washer hal ves.
(25) Seat thrust washer retai ni ng ri ng wi th pl asti c
mal l et (Fi g. 72).
(26) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
73).
1 - WASHER GROOVE IN SHAFT
2 - LUG BORE
3 - THRUST WASHER LUGS
4 - LUG BORE
5 - LUG
6 - WASHER HALF
Fig. 71 RETAINING RING
2 - THRUST WASHER HALVES
3 - SECOND GEAR
4 - LOCATING DIMPLE
Fig. 72 THRUST WASHER
1 - PLASTIC MALLET
21 - 56 MANUAL - NV3500 AN
(27) I nstal l thi rd gear on shaft and beari ng (Fi g.
74).
(28) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 75).
(29) Assembl e 3-4 synchro hub, sl eeve, spri ngs,
struts and detent bal l s.
(30) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 76).
installed backwards. One side of the sleeve has
grooves in it. This side of sleeve faces the front of
the shaft.
Fig. 73 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 74 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 75 THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 76 3-4 SYNCHRO HUB ON OUTPUT SHAFT
1 - GROOVED SIDE OF SLEEVE (TO FRONT)
AN MANUAL - NV3500 21 - 57
(31) Press 3-4 synchro assembl y onto output shaft
wi th shop press and sui tabl e si ze pi pe tool (Fi g. 77).
NOTE: Place the pipe on hub as close to output
shaft as possible without contacting the shaft
splines.
(32) I nstal l 3-4 synchro hub snap ri ng (Fi g. 78)and
veri fy snap ri ng i s seated.
(33) I nstal l output shaft beari ng.
(34) I nstal l output shaft beari ng snap ri ng, spread-
i ng i t just enough to i nstal l i t (Fi g. 79). Veri fy snap
ri ng i s seated i n shaft groove.
(35) Veri fy posi ti on of synchro sl eeves before pro-
ceedi ng wi th assembl y operati ons (Fi g. 80). Grooved
si de of 3-4 sl eeve shoul d be faci ng forward. Fi rst gear
si de of 1-2 sl eeve shoul d be faci ng fi rst gear. Tapered
si de of fi fth-reverse sl eeve shoul d be faci ng forward.
REVERSE IDLER ASSEMBLY
(1) Lubri cate i dl er components wi th gear l ube.
(2) Sl i de i dl er gear beari ng on shaft (Fi g. 81).
Beari ng fi ts ei ther way on shaft.
(3) Sl i de gear onto shaft. Si de of gear wi th recess
goes to rear (Fi g. 81).
(4) Pl ace fi rst l ock bal l i n di mpl e at rear end of
i dl er shaft (Fi g. 81). Hol d bal l i n pl ace wi th petro-
l eum jel l y.
(5) Sl i de thrust rear thrust washer onto shaft and
over l ock bal l (Fi g. 82).
(6) I nstal l snap ri ng i n groove at rear of shaft (Fi g.
82).
Fig. 77 PRESS 3-4 SYNCHRO ON OUTPUT SHAF
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
1 - 3-4 SYNCHRO HUB SNAP RING
Fig. 79 OUTPUT SHAFT BEARING
21 - 58 MANUAL - NV3500 AN
Fig. 80 SYNCHRO SLEEVE LOCATIONS
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD
5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
Fig. 81 IDLER GEAR AND BEARING
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFT
Fig. 82 IDLER GEAR REAR THRUST WASHER
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
AN MANUAL - NV3500 21 - 59
(7) I nstal l l ock bal l i n di mpl e at front of shaft.
Hol d bal l i n pl ace wi th petrol eum jel l y.
(8) I nstal l front thrust washer on shaft and sl i de
washer up agai nst gear and over l ock bal l (Fi g. 83).
(9) I nstal l wave washer, fl at washer and remai n-
i ng snap ri ng on i dl er shaft (Fi g. 83). Veri fy snap
ri ng i s seated.
SHIFT SHAFT AND BUSHINGS/BEARINGS
I nspect shi ft shaft bushi ng and beari ng for damage
and repl ace i f necessary.
(1) Locate a bol t that wi l l thread i nto the bushi ng
wi thout great effort.
(2) Thread the bol t i nto the bushi ng, al l owi ng the
bol t to make i ts own threads i n the bushi ng.
(3) Attach a sl i de hammer or sui tabl e pul l er to the
bol t and remove bushi ng.
(4) Use the short end of I nstal l er 8119 to i nstal l
the new bushi ng.
(5) The bushi ng i s correctl y i nstal l ed i f the bush-
i ng i s fl ush wi th the transmi ssi on case.
(6) To repl ace the beari ng l ocate a bol t that wi l l
thread i nto the beari ng wi thout great effort.
(7) Thread the bol t i nto the beari ng as much as
possi bl e.
(8) Attach a sl i de hammer or sui tabl e pul l er to the
bol t and remove the beari ng.
(9) Use the short end of I nstal l er 8119 to i nstal l
the new beari ng.
(10) The beari ng i s correctl y i nstal l ed i f the bear-
i ng i s fl ush wi th the transmi ssi on case.
DETENT PLUNGER BUSHING
I nspect detent pl unger bushi ngs for damage and
repl ace i f necessary.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(1) Usi ng the l ong end of I nstal l er 8119, dri ve the
detent bushi ngs through the outer case and i nto the
shi ft shaft bore.
(2) Remove the bushi ngs from the shi ft shaft bore.
(3) I nstal l a new detent pl unger bushi ng on the
l ong end of I nstal l er 8118.
(4) Start the bushi ng i n the detent pl unger bore i n
the case.
(5) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
(6) I nstal l a new detent pl unger bushi ng on the
short end of I nstal l er 8118.
(7) Start the bushi ng i n the detent pl unger bore i n
the case.
(8) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
GEARTRAIN ASSEMBLY
(1) I nstal l Adapter 6747-1A on i nput shaft hub of
Fi xture 6747 (Fi g. 84).
(2) I nstal l i nput shaft i n fi xture tool . Make sure
Adapter 6747-1A i s posi ti oned under shaft as shown
(Fi g. 85).
(3) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 85).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
Fig. 83 IDLER GEAR AND SHAFT ASSEMBLY
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
21 - 60 MANUAL - NV3500 AN
(4) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 86).
(5) Adjust hei ght of i dl er gear pedestal on assem-
bl y fi xture (Fi g. 87). Start wi th a basi c hei ght of 18.4
cm (7-1/4 i n.). Fi nal adjustment can be made after
gear i s posi ti oned on pedestal .
(6) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 88). Careful l y rotate output shaft
unti l the 3-4 synchro ri ng seats i n synchro hub and
sl eeve.
Fig. 84 ASSEMBLY FIXTURE FOR GEARTRAIN
1 - SPECIAL TOOL 6747-2A
2 - SPECIAL TOOL
8115
3 - SPECIAL TOOL
6747-1A
4 - SPECIAL TOOL
6747
Fig. 85 PILOT BEARING AND INPUT SHAFT
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 86 FOURTH GEAR SYNCHRO
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 87 IDLER PEDESTAL BASIC HEIGHT
1 - REVERSE IDLER PEDESTAL
AN MANUAL - NV3500 21 - 61
(7) I nstal l Adapter 6747-2B on front beari ng hub
of countershaft. The adapter has a shoul der on one
si de that goes towards the countershaft.
(8) Sl i de countershaft (and adapter) i nto fi xture
sl ot. Veri fy countershaft and output shaft gears are
ful l y meshed wi th the mai nshaft gears (Fi g. 89).
(9) Check al i gnment of countershaft and output
shaft gear teeth. Note that gears may not al i gn per-
fectl y. A di fference i n hei ght of 1.57 to 3.18 mm (1/16
to 1/8 i n.) wi l l probabl y exi st. Thi s di fference wi l l not
i nterfere wi th assembl y.
(10) Posi ti on reverse i dl er i n support cup of assem-
bl y fi xture (Fi g. 90). Ensure i dl er gear i s properl y
meshed and al i gned wi th shaft gear teeth and that
bol t hol es are faci ng out and not toward geartrai n.
Adjust pedestal up or down i f necessary. Al so be sure
that short end of i dl er shaft i s faci ng up as shown.
(11) On 2-wheel dri ve transmi ssi on, thread one
Al i gnment Pi n 8120 i n center or passenger si de hol e
of output shaft beari ng retai ner. Then posi ti on
retai ner on fi fth gear as shown (Fi g. 91).
(12) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
92). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
(13) I nstal l assembl ed shi ft forks i n synchro
sl eeves (Fi g. 93). Veri fy forks are properl y seated i n
sl eeves.
Fig. 88 OUTPUT SHAFT AND GEARTRAIN
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE
Fig. 89 COUNTERSHAFT ON FIXTURE
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
21 - 62 MANUAL - NV3500 AN
REAR HOUSING - 2WD
(1) Dri ve adapter housi ng al i gnment dowel s back
i nto housi ng unti l dowel s are fl ush wi th mounti ng
surface (Fi g. 94).
(2) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft rear beari ng and beari ng race.
(3) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 95).
CAUTION: Be sure the large diameter side of the
roller retainer faces the countershaft and the small
diameter side faces the race and housing (Fig. 96).
(4) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(5) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n rear housi ng (Fi g. 96).
(6) Reach i nto countershaft rear beari ng wi th fi n-
ger and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace. Thi s avoi ds havi ng rol l ers becomi ng di s-
pl aced duri ng housi ng i nstal l ati on.
Fig. 90 REVERSE IDLER ASSEMBLY POSITION
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - PEDESTAL
Fig. 91 POSITIONING OUTPUT SHAFT BEARING
1 - ALIGNMENT TOOL
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 92 1-2 AND FIFTH-REVERSE
1 - INSERT ARM THROUGH 1-2 FORK
2 - 1-2 FORK
Fig. 93 SHIFT FORKS IN SYNCHRO
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
AN MANUAL - NV3500 21 - 63
(7) I nstal l rear housi ng onto geartrai n (Fi g. 97).
Veri fy beari ng retai ner pi l ot stud i s i n correct bol t
hol e i n housi ng. Al so be sure countershaft and output
shaft beari ngs are al i gned i n housi ng and on counter-
shaft. I t may be necessary to l i ft upward on counter-
shaft sl i ghtl y to ensure that the countershaft rear
beari ng engages to the countershaft before the rear
output shaft beari ng engages the housi ng.
Fig. 94 REAR HOUSING DOWELS
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
Fig. 95 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY
Fig. 96 COUNTERSHAFT REAR BEARING SEATED
1 - SHIFT SHAFT BUSHING/BEARING
2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE)
Fig. 97 REAR HOUSING - 2WD
1 - REAR HOUSING
21 - 64 MANUAL - NV3500 AN
(8) Seat rear housi ng on output shaft rear beari ng
and countershaft. Use pl asti c or rawhi de mal l et to
tap housi ng i nto pl ace.
(9) Appl y Mopar Gasket Maker or equi val ent, to
housi ng bol t threads, bol t shanks and under bol t
heads (Fi g. 98).
(10) Start fi rst two bol ts i n retai ner (Fi g. 99). I t
may be necessary to move retai ner rearward (wi th
pi l ot stud) i n order to start bol ts i n retai ner.
(11) Remove Al i gnment Pi n 8120 and i nstal l l ast
retai ner bol t (Fi g. 99).
(12) Ti ghten al l three retai ner bol ts to 30-35 Nm
(22-26 ft. l bs.).
ADAPTER HOUSING - 4WD
(1) I nstal l rear beari ng i n adapter housi ng. Use
wood hammer handl e or wood dowel to tap beari ng
i nto pl ace.
(2) Posi ti on rear beari ng retai ner i n adapter hous-
i ng (Fi g. 100).
(3) Appl y Mopar Gasket Maker or equi val ent, to
threads, bol t shanks and under hex heads of beari ng
retai ner bol ts (Fi g. 98).
countershaft rear beari ng and beari ng race.
(5) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 96).
CAUTION: Be sure the large diameter side of the
roller retainer faces the countershaft and the small
diameter side faces the race and housing (Fig. 96).
(6) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(7) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n adapter housi ng (Fi g. 96).
(8) I nstal l adapter housi ng on geartrai n.
(9) I nstal l rear beari ng snap ri ng on output shaft
(Fi g. 101).
(10) Lubri cate l i p of new rear seal (Fi g. 102) wi th
Mopar Door Ease or transmi ssi on fl ui d.
Fig. 98 SEAL RETAING BOLTS
1 - MOPAR GASKET MAKER (OR LOCTITE 518)
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 99 PILOT STUD AND RETAINER BOLTS - 2WD
1 - BEARING RETAINER BOLT
2 - ALIGNMENT PIN
Fig. 100 ADAPTER HOUSING - 4WD
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
AN MANUAL - NV3500 21 - 65
(11) I nstal l new rear seal i n adapter housi ng bore
wi th I nstal l er C-3860-A. Veri fy seal i s seated i n hous-
i ng bore (Fi g. 102).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Veri fy that al l synchro sl eeves are i n Neutral
posi ti on (centered on hub).
CAUTION: The transmission synchros must all be
in Neutral position for assembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g.
103). Veri fy that groove i n fork arm i s al i gned wi th
grooves i n 1-2 and fi fth-reverse fork arms as shown.
(3) Sl i de the end of shi ft shaft wi th shaft detent
notches through 3-4 shi ft fork.
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 104). Be sure sl ot i n bushi ng i s faci ng up and
rol l pi n hol e for l ever i s al i gned wi th hol e i n shaft.
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 105).
(6) Sl i de shi ft shaft through 1-2 and fi fth-reverse
fork and i nto shi ft l ever openi ng i n rear housi ng (Fi g.
106).
Fig. 101 REAR BEARING SNAP RING - 4WD
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 102 REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 104 LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
21 - 66 MANUAL - NV3500 AN
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
CAUTION: Positioning of the shift shaft detent
notch is important. Both of the shaft roll pins can
be installed even when the shaft is 180 off. If this
occurs, the transmission will have to be disassem-
bled again to correct shaft alignment.
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 108). Shaft l ever rol l pi n i s approxi matel y 22
mm (7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi -
matel y 33 mm (1-1/4 i n.) l ong.
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng. Then start rol l pi n i nto shaft l ever by hand
(Fi g. 109).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
110).
CAUTION: The shaft lever roll pin must be flush
with the surface of the lever. The lever bushing will
bind on the roll pin if the pin is not seated flush.
(12) Veri fy that l ock pi n sl ot i n l ever bushi ng i s
posi ti oned as shown (Fi g. 110).
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 111).
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be fl ush wi th socket (Fi g. 112).
(15) Veri fy that notches i n shi ft fork arms are
al i gned. Real i gn arms i f necessary.
Fig. 105 LEVER AND BUSHING ASSENBLY
1 - SHIFT SHAFT
3 - 3-4 FORK
Fig. 106 SHAFT IN LEVER OPENING
1 - SHIFT SHAFT
Fig. 107 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 108 ROLL PIN IDENTIFICATION
2 - SHIFT SOCKET ROLL PIN
AN MANUAL - NV3500 21 - 67
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) I nstal l reverse bl ocker, retai nter and retai ner
bol t i n front housi ng.
(2) I f previ ousl y removed, i nput shaft beari ng i n
front housi ng (Fi g. 113). I nstal l snap ri ng and use
pl asti c mal l et to seat beari ng. Beari ng goes i n from
front si de of housi ng onl y.
countershaft front beari ng. Then i nsert beari ng i n
front housi ng race (Fi g. 113). Large di ameter si de of
beari ng cage goes toward countershaft (Fi g. 114).
Smal l di ameter si de goes toward beari ng race i n
housi ng.
(4) Reach i nto countershaft front beari ng wi th fi n-
ger, and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace. Thi s avoi ds havi ng rol l ers becomi ng di s-
pl aced duri ng housi ng i nstal l ati on.
Fig. 109 ROLL PIN IN SHIFT SHAFT
1 - SHAFT LEVER ROLL PIN ( LONG)
2 - LEVER AND BUSHING
Fig. 110 SHIFT SHAFT LEVER ROLL
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 111 ROLL PIN IN SHIFT SOCKET
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 112 SEATING SHIFT SOCKET ROLL PIN
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
21 - 68 MANUAL - NV3500 AN
(5) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng.
(6) Appl y 1/8 i n. wi de bead of Mopar Gasket
Maker or equi val ent, to mati ng surfaces of front and
rear housi ngs (Fi g. 115).
(7) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(8) Work front housi ng downward onto geartrai n
unti l seated on rear housi ng.
CAUTION: If the front housing will not seat on the
rear housing, either the shift components are not in
Neutral, or one or more components are mis-
aligned. Do not force the front housing into place.
This will only result in damaged components.
(9) Tap rear housi ng al i gnment dowel s back i nto
pl ace wi th hammer and pi n punch. Both dowel s
shoul d be fl ush fi t i n each housi ng. Have hel per hol d
transmi ssi on upri ght whi l e dowel s are tapped back
i nto pl ace.
(11) Appl y Mopar Gasket Maker or equi val ent to
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 116).
(12) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 116). Then ti ghten bol ts to 34 Nm (25 ft.
l bs.).
(13) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 117).
Appl y Mopar Gasket Maker or equi val ent, to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral or the shaft bushing (or
lever) is misaligned.
FRONT BEARING
3 - SHIFT SHAFT BUSHING
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
Fig. 115 SEAL FRONT/REAR HOUSINGS
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER
AN MANUAL - NV3500 21 - 69
(14) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore (Fi g. 118). Lubri cate pl unger
wi th petrol eum jel l y or gear l ubri cant. Verify
plunger is fully seated in detent notch in shift
shaft.
(15) I nstal l detent spri ng i nsi de pl unger (Fi g. 118).
(16) I nstal l pl ug on detent spri ng and compress
spri ng. Then dri ve detent pl ug i nto transmi ssi on case
unti l pl ug seats.
(17) I nstal l backup l i ght swi tch (Fi g. 119).
(18) I nstal l i nput shaft snap ri ng (Fi g. 120).
Fig. 116 HOUSING BOLTS
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
2 - SHAFT SOCKET
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
1 - BACKUP LIGHT SWITCH
Fig. 120 SHAFT SNAP RING - TYPICAL
21 - 70 MANUAL - NV3500 AN
(19) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er 6448 (Fi g. 121).
(20) Appl y bead of Mopar si l i cone seal er or equi v-
al ent to fl ange surface of front beari ng retai ner (Fi g.
122).
(21) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
123). Al though retai ner i s one-way fi t on housi ng, be
sure bol t hol es are al i gned before seati ng retai ner.
NOTE: Ensure no sealer gets into the oil feed hole
in the transmission case or bearing retainer.
(22) I nstal l and ti ghten beari ng retai ner bol ts to
7-10 Nm (5-7 ft. l bs.) (Fi g. 124).
SHIFT TOWER AND LEVER
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 125). Be sure shi ft bal l i s seated i n socket
and the offset i n the tower i s toward the passenger
si de of the vehi cl e before i nstal l i ng tower bol ts.
(4) I nstal l shi ft tower bol ts (Fi g. 126). Ti ghten
bol ts to 8.5 Nm (75.2 i n. l bs.).
Fig. 121 OIL SEAL IN FRONT BEARING RETAINER
1 - INSTALLER
Fig. 122 SEAL BEARING RETAINER AND HOUSING
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
Fig. 124 BEARING RETAINER BOLTS
1 - RETAINER BOLTS
AN MANUAL - NV3500 21 - 71
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th Mopar Transmi ssi on Lubri cant.
(6) I nstal l and ti ghten fi l l pl ug to 34 Nm (25 ft.
l bs.).
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
INSTALLATION
NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.
(1) Appl y l i ght coat of Moparhi gh temperature
beari ng grease to contact surfaces of fol l owi ng com-
ponents:
i nput shaft spl i nes.
rel ease beari ng sl i de surface of front retai ner.
rel ease beari ng bore.
rel ease fork.
rel ease fork bal l stud.
propel l er shaft sl i p yoke.
(2) Appl y seal er to threads of drai n pl ug, then
i nstal l pl ug i n case.
(3) Mount transmi ssi on on jack and posi ti on trans-
mi ssi on under vehi cl e. Secure transmi ssi on to jack
wi th safety chai ns.
(4) Rai se transmi ssi on unti l i nput shaft i s centered
i n cl utch di sc hub.
(5) Move transmi ssi on forward and start i nput
shaft i n cl utch di sc.
(6) Work transmi ssi on forward unti l seated agai nst
engi ne. Do not al l ow transmi ssi on to remai n unsup-
ported after i nput shaft has entered cl utch di sc.
(7) I nstal l and ti ghten transmi ssi on to engi ne bol ts
to 108 Nm (80 ft. l bs.).
(8) Posi ti on transmi ssi on harness wi res i n cl i ps on
shi ft cover.
(9) I nstal l sl ave cyl i nder and shi el d, i f equi pped.
(10) I nstal l transmi ssi on mount on transmi ssi on or
rear crossmember.
2WD
NOTE: Ensure wiring harness is clear before install-
ing crossmember.
fi xture.
(3) Al i gn and i nstal l propel l er shaft.
(6) I nstal l shi ft boot.
cedures.
4WD
(1) I nstal l transfer case shi ft l ever on transmi s-
si on.
NOTE: Ensure wiring harness is clear before install-
ing crossmember.
Fig. 125 SHIFT TOWER
1 - SHIFT TOWER
Fig. 126 SHIFT TOWER BOLTS
21 - 72 MANUAL - NV3500 AN
fi xture.
(4) I nstal l transfer case on transmi ssi on jack.
Secure transfer case to jack wi th safety chai ns.
(5) Rai se jack and al i gn transfer case i nput gear
wi th transmi ssi on output shaft.
(6) Move transfer case forward and seat i t on
transmi ssi on.
(7) I nstal l and ti ghten transfer case attachi ng
nuts. Ti ghten nuts to 41-47 Nm (30-35 ft. l bs.) i f
case has 3/8 studs, or 30-41 Nm (22-30 ft. l bs.) i f
case has 5/16 studs.
(8) Connect backup l i ght swi tch wi res.
(9) I nstal l transmi ssi on dust cover.
(10) I nstal l starter.
(11) I nstal l transfer case shi ft l ever to si de of
transfer case.
(12) Connect transfer case shi ft l ever to range
l ever on transfer case.
(13) Al i gn and connect propel l er shafts.
(14) Fi l l transmi ssi on wi th requi red l ubri cant.
Check l ubri cant l evel i n transfer case and add l ubri -
cant i f necessary.
(15) I nstal l transfer case ski d pl ate, i f equi pped,
and crossmember. Ti ghten attachi ng bol ts/nuts to 41
Nm (30 ft. l bs.).
(16) I nstal l exhaust system components.
(19) I nstal l shi ft l ever boot.
cedures.
SPECIFICATIONS
SPECIFICATIONS - NV3500
Clutch Housing Bolts 54-61 40-45 -
Crossmember Bolts 61-75 45-55 -
Crossmember Insulator
Nuts
54-61 40-45 -
Drain/Fill Plug 9-27 14-20 -
Front to Rear Housing
Bolts
30-35 22-26 -
Front Bearing Bolts 7-10 5-7 62-88
Idler Shaft Bolts 19-25 14-18 -
Rear Bearing Bolts 30-35 22-26 -
Shift Tower Bolts 7-10 5-7 -
Slave Cylinder Nuts 23 17 203
Transfer Case Nuts 47 35 -
AN MANUAL - NV3500 21 - 73
SPECIAL TOOLS
MANUAL - NV3550
Remover Seal C-3985-B
Installer Seal C-3972-A
Remover Bushing 6957
Installer Bushing 6951
Handle C-4171
Remover Plug 8117
Fixture 6747
21 - 74 MANUAL - NV3500 AN
Adapter 6747-1A
Adapter 6747-2B
Cup Adapter 8115
Splitter Bearing 1130
Tube 6310-1
Installer Bushing 8118
Pin Alignment 8120
Installer Seal C-3860-A
Installer 8123
Installer Cone 6448
AN MANUAL - NV3500 21 - 75
REMOVAL - YOKE SEAL 2WD
(1) Rai se rai se and support vehi cl e.
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th Remover C-3985-B (Fi g.
127) from transmi ssi on housi ng.
REMOVAL - YOKE BUSHING
(2) Mark reference l i nes on the propel l er shaft and
remove shaft.
(3) Remove housi ng yoke seal .
(4) I nsert Remover 6957 i nto rear housi ng and
ti ghten tool to bushi ng and remove bushi ng (Fi g.
128).
INSTALLATION - YOKE SEAL 2WD
(1) Pl ace seal i n posi ti on on transmi ssi on housi ng.
(2) Dri ve new seal i nto transmi ssi on housi ng wi th
I nstal l er C-3972-A and Handl e C-4171 (Fi g. 129).
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes.
al i gned.
(6) Check transmi ssi on fl ui d l evel .
INSTALLATION - YOKE BUSHING
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n rear
housi ng.
(2) Tap bushi ng i nto pl ace wi th I nstal l er 6951 and
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng I nstal l er
C-3972-A (Fi g. 130).
al i gned.
(6) Check transmi ssi on fl ui d l evel .
Fig. 127 TRANSMISSION YOKE SEAL
1 - REMOVER
2 - SEAL
Fig. 128 Bushing Removal - Typical
1 - REMOVER
2 - EXTENSION HOUSING BUSHING
Fig. 129 Transmission Housing Yoke Seal
1 - HANDLE
2 - INSTALLER
Fig. 130 Rear Housing Seal
1 - HANDLE
2 - INSTALLER
21 - 76 MANUAL - NV3500 AN
FLUID
DESCRIPTION
The l ubri cant for the NV3550 i s MoparManual
Transmi ssi on Lubri cant, P/N 4761526. Thi s i s the
only l ubri cant to be used, no other l ubri cants are
acceptabl e, or recommended.
The correct transmi ssi on l ubri cant l evel i s to the
bottom edge of the fi l l pl ug hol e (Fi g. 131).
The transmi ssi on must be l evel to obtai n an accu-
rate l ubri cant l evel check. A dri veon type of hoi st i s
recommended for thi s purpose.
The l ubri cant capaci ty i s approxi matel y 2.28 l i ters
(4.8 pi nts). Thi s i s the approxi mate quanti ty needed
to refi l l the transmi ssi on after a l ubri cant change or
overhaul .
The fi l l pl ug i s l ocated i n the front housi ng and the
drai n pl ug i s on the bottom of the housi ng (Fi g. 131).
Fig. 131 Drain and Fill Plug Locations
1 - DRAIN PLUG
2 - FILL PLUG
AN MANUAL - NV3500 21 - 77
AUTOMATIC TRANSMISSION - 42RE
TABLE OF CONTENTS
page page
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 79
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
AUTOMATIC TRANSMISSION. . . . . . . . . . . . . . 87
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . . . . 87
ROAD TESTING. . . . . . . . . . . . . . . . . . . . . . . . 87
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . 88
AIR CHECKING TRANSMISSION CLUTCH
AND BAND OPERATION. . . . . . . . . . . . . . . . . . 91
CONVERTER HOUSING FLUID LEAK . . . . . . . 91
DIAGNOSIS CHARTS. . . . . . . . . . . . . . . . . . . . 92
ALUMINUM THREAD REPAIR. . . . . . . . . . . . . 103
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 104
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 117
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . 119
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 131
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 133
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 136
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
BANDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 137
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 138
ELECTRONIC GOVERNOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 139
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 141
EXTENSION HOUSING BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 143
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 144
FLUID AND FILTER
EFFECTS OF INCORRECT FLUID LEVEL . . . 144
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . 144
FLUID CONTAMINATION . . . . . . . . . . . . . . . . 144
FLUID LEVEL CHECK. . . . . . . . . . . . . . . . . . . 144
FLUID AND FILTER REPLACEMENT . . . . . . . 145
TRANSMISSION FILL . . . . . . . . . . . . . . . . . . . 147
FRONT CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 147
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 148
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
FRONT SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 151
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 152
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
GEARSHIFT CABLE
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . 153
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 154
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 155
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 156
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
OIL PUMP VOLUME CHECK. . . . . . . . . . . . . . 156
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 157
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
OUTPUT SHAFT FRONT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 161
OUTPUT SHAFT REAR BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 161
OVERDRIVE CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 161
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OVERDRIVE ELECTRICAL CONTROLS . . . . . 162
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 163
OVERDRIVE UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 164
21 - 78 AUTOMATIC TRANSMISSION - 42RE AN
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 181
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 182
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 182
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 185
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 186
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 187
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
REAR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 193
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 194
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
REAR SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 197
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 197
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 198
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
THROTTLE VALVE CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 200
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 200
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 202
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 207
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 208
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
TORQUE CONVERTER DRAINBACK VALVE . 208
TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 208
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
TRANSMISSION RANGE SENSOR (TRS) . . . . 210
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 212
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 213
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 213
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 233
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 253
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 254
AUTOMATIC TRANSMISSION -
42RE
DESCRIPTION
The 42RE i s a four speed ful l y automati c transmi s-
si on (Fi g. 1) wi th an el ectroni c governor. The 42RE i s
equi pped wi th a l ock-up cl utch i n the torque con-
verter. Fi rst through thi rd gear ranges are provi ded
by the cl utches, bands, overrunni ng cl utch, and pl an-
etary gear sets i n the transmi ssi on. Fourth gear
range i s provi ded by the overdri ve uni t that contai ns
an overdri ve cl utch, di rect cl utch, pl anetary gear set,
and overrunni ng cl utch.
The transmi ssi on contai ns a front, rear, and di rect
cl utch whi ch functi on as the i nput dri vi ng compo-
nents. I t al so contai ns the ki ckdown (front) and the
l ow/reverse (rear) bands whi ch, al ong wi th the over-
runni ng cl utch and overdri ve cl utch, serve as the
hol di ng components. The dri vi ng and hol di ng compo-
nents combi ne to sel ect the necessary pl anetary gear
components, i n the front, rear, or overdri ve pl anetary
gear set, transfer the engi ne power from the i nput
shaft through to the output shaft.
The val ve body i s mounted to the l ower si de of the
transmi ssi on and contai ns the val ves to control pres-
sure regul ati on, fl ui d fl ow control , and cl utch/band
appl i cati on. The oi l pump i s mounted at the front of
the transmi ssi on and i s dri ven by the torque con-
verter hub. The pump suppl i es the oi l pressure nec-
essary for cl utch/band actuati on and transmi ssi on
l ubri cati on.
AN AUTOMATIC TRANSMISSION - 42RE 21 - 79
F
i
g
.
1
4
2
R
E
T
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a
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s
m
i
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s
i
o
n
AUTOMATIC TRANSMISSION - 42RE (Continued)
IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
GEAR RATIOS The 42RE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.74:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69:1
Rev. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21:1
OPERATION
The appl i cati on of each dri vi ng or hol di ng compo-
nent i s control l ed by the val ve body based upon the
manual l ever posi ti on, throttl e pressure, and gover-
nor pressure. The governor pressure i s a vari abl e
pressure i nput to the val ve body and i s one of the
si gnal s that a shi ft i s necessary. Fi rst through fourth
gear are obtai ned by sel ecti vel y appl yi ng and rel eas-
i ng the di fferent cl utches and bands. Engi ne power i s
thereby routed to the vari ous pl anetary gear assem-
bl i es whi ch combi ne wi th the overrunni ng cl utch
assembl i es to generate the di fferent gear rati os. The
torque converter cl utch i s hydraul i cal l y appl i ed and
i s rel eased when fl ui d i s vented from the hydraul i c
ci rcui t by the torque converter control (TCC) sol enoi d
on the val ve body. The torque converter cl utch i s con-
trol l ed by the Powertrai n Control Modul e (PCM). The
torque converter cl utch engages i n fourth gear, and
i n thi rd gear under vari ous condi ti ons, such as when
the O/D swi tch i s OFF, when the vehi cl e i s crui si ng
on a l evel surface after the vehi cl e has warmed up.
The torque converter cl utch wi l l di sengage momen-
tari l y when an i ncrease i n engi ne l oad i s sensed by
the PCM, such as when the vehi cl e begi ns to go
uphi l l or the throttl e pressure i s i ncreased. The
torque converter cl utch feature i ncreases fuel econ-
omy and reduces the transmi ssi on fl ui d temperature.
Si nce the overdri ve cl utch i s appl i ed i n fourth gear
onl y and the di rect cl utch i s appl i ed i n al l ranges
except fourth gear, the transmi ssi on operati on for
park, neutral , and fi rst through thi rd gear wi l l be
descri bed fi rst. Once these powerfl ows are descri bed,
the thi rd to fourth shi ft sequence wi l l be descri bed.
1 - CONVERTER CLUTCH 15 - HOUSING
2 - TORQUE CONVERTER 16 - REAR BEARING
3 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 17 - OUTPUT SHAFT
4 - FRONT BAND 18 - SEAL
5 - FRONT CLUTCH 19 - OVERDRIVE OVERRUNNING CLUTCH
6 - DRIVING SHELL 20 - OVERDRIVE PLANETARY GEAR
7 - REAR BAND 21 - DIRECT CLUTCH SPRING
8 - TRANSMISSION OVERRUNNING CLUTCH 22 - OVERDRIVE CLUTCH PISTON
9 - OVERDRIVE UNIT 23 - VALVE BODY ASSEMBLY
10 - PISTON RETAINER 24 - FILTER
11 - OVERDRIVE CLUTCH 25 - FRONT PLANETARY GEAR
12 - DIRECT CLUTCH 26 - REAR CLUTCH
13 - INTERMEDIATE SHAFT 27 - TRANSMISSION
14 - FRONT BEARING 28 - REAR PLANETARY GEAR
Fig. 2 Transmission Part And Serial Number
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
PARK POWERFLOW
As the engi ne i s runni ng and the crankshaft i s
rotati ng, the fl expl ate and torque converter, whi ch
are al so bol ted to i t, are al l rotati ng i n a cl ockwi se
di recti on as vi ewed from the front of the engi ne. The
notched hub of the torque converter i s connected to
the oi l pumps i nternal gear, suppl yi ng the transmi s-
si on wi th oi l pressure. As the converter turns, i t
turns the i nput shaft i n a cl ockwi se di recti on. As the
i nput shaft i s rotati ng, the front cl utch hub-rear
cl utch retai ner and al l thei r associ ated parts are al so
rotati ng, al l bei ng di rectl y connected to the i nput
shaft. The power fl ow from the engi ne through the
front cl utch hub and rear cl utch retai ner stops at the
rear cl utch retai ner. Therefore, no power fl ow to the
output shaft occurs because no cl utches are appl i ed.
The onl y mechani sm i n use at thi s ti me i s the park-
i ng sprag (Fi g. 3), whi ch l ocks the parki ng gear on
the output shaft to the transmi ssi on case.
NEUTRAL POWERFLOW
Wi th the gear sel ector i n the NEUTRAL posi ti on
(Fi g. 4), the power fl ow of the transmi ssi on i s essen-
ti al l y the same as i n the park posi ti on. The onl y
operati onal di fference i s that the parki ng sprag has
been di sengaged, unl ocki ng the output shaft from the
transmi ssi on case and al l owi ng i t to move freel y.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5 - PAWL
REVERSE POWERFLOW
When the gear sel ector i s moved i nto the
REVERSE posi ti on (Fi g. 5), the front cl utch and the
rear band are appl i ed. Wi th the appl i cati on of the
front cl utch, engi ne torque i s appl i ed to the sun gear,
turni ng i t i n a cl ockwi se di recti on. The cl ockwi se
rotati on of the sun gear causes the rear pl anet pi n-
i ons to rotate agai nst engi ne rotati on i n a counter-
cl ockwi se di recti on. The rear band i s hol di ng the l ow
reverse drum, whi ch i s spl i ned to the rear carri er.
Si nce the rear carri er i s bei ng hel d, the torque from
the pl anet pi ni ons i s transferred to the rear annul us
gear, whi ch i s spl i ned to the output shaft. The output
shaft i n turn rotates wi th the annul us gear i n a
countercl ockwi se di recti on gi vi ng a reverse gear out-
put. The enti re transmi ssi on of torque i s appl i ed to
the rear pl anetary gearset onl y. Al though there i s
torque i nput to the front gearset through the sun
gear, no other member of the gearset i s bei ng hel d.
Duri ng the enti re reverse stage of operati on, the
front pl anetary gears are i n an i dl i ng condi ti on.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
FIRST GEAR POWERFLOW
When the gearshi ft l ever i s moved i nto the DRI VE
posi ti on the transmi ssi on goes i nto fi rst gear (Fi g. 6).
As soon as the transmi ssi on i s shi fted from PARK or
NEUTRAL to DRI VE, the rear cl utch appl i es, appl y-
i ng the rear cl utch pack to the front annul us gear.
Engi ne torque i s now appl i ed to the front annul us
gear turni ng i t i n a cl ockwi se di recti on. Wi th the
front annul us gear turni ng i n a cl ockwi se di recti on, i t
causes the front pl anets to turn i n a cl ockwi se di rec-
ti on. The rotati on of the front pl anets cause the sun
to revol ve i n a countercl ockwi se di recti on. The sun
gear now transfers i ts countercl ockwi se rotati on to
the rear pl anets whi ch rotate back i n a cl ockwi se
di recti on. Wi th the rear annul us gear stati onary, the
rear pl anet rotati on on the annul us gear causes the
rear pl anet carri er to revol ve i n a countercl ockwi se
di recti on. The rear pl anet carri er i s spl i ned i nto the
l ow-reverse drum, and the l ow reverse drum i s
spl i ned to the i nner race of the over-runni ng cl utch.
Wi th the over-runni ng cl utch l ocked, the pl anet car-
ri er i s hel d, and the resul ti ng torque provi ded by the
pl anet pi ni ons i s transferred to the rear annul us
gear. The rear annul us gear i s spl i ned to the output
shaft and rotated al ong wi th i t (cl ockwi se) i n an
underdri ve gear reducti on mode.
Fig. 6 First Gear Powerflow
1 - OUTPUT SHAFT 5 - OVER-RUNNING CLUTCH HOLDING
2 - OVER-RUNNING CLUTCH HOLDING 6 - INPUT SHAFT
3 - REAR CLUTCH APPLIED 7 - REAR CLUTCH APPLIED
SECOND GEAR POWERFLOW
I n DRI VE-SECOND (Fi g. 7), the same el ements
are appl i ed as i n MANUAL-SECOND. Therefore, the
power fl ow wi l l be the same, and both gears wi l l be
di scussed as one i n the same. I n DRI VE-SECOND,
the transmi ssi on has proceeded from fi rst gear to i ts
shi ft poi nt, and i s shi fti ng from fi rst gear to second.
The second gear shi ft i s obtai ned by keepi ng the rear
cl utch appl i ed and appl yi ng the front (ki ckdown)
band. The front band hol ds the front cl utch retai ner
that i s l ocked to the sun gear dri vi ng shel l . Wi th the
rear cl utch sti l l appl i ed, the i nput i s sti l l on the front
annul us gear turni ng i t cl ockwi se at engi ne speed.
Now that the front band i s hol di ng the sun gear sta-
ti onary, the annul us rotati on causes the front pl anets
to rotate i n a cl ockwi se di recti on. The front carri er i s
then al so made to rotate i n a cl ockwi se di recti on but
at a reduced speed. Thi s wi l l transmi t the torque to
the output shaft, whi ch i s di rectl y connected to the
front pl anet carri er. The rear pl anetary annul us gear
wi l l al so be turni ng because i t i s di rectl y spl i ned to
the output shaft. Al l power fl ow has occurred i n the
front pl anetary gear set duri ng the dri ve-second
stage of operati on, and now the over-runni ng cl utch,
i n the rear of the transmi ssi on, i s di sengaged and
freewheel i ng on i ts hub.
Fig. 7 Second Gear Powerflow
1 - KICKDOWN BAND APPLIED 6 - INPUT SHAFT
2 - OUTPUT SHAFT 7 - REAR CLUTCH APPLIED
3 - REAR CLUTCH ENGAGED 8 - KICKDOWN BAND APPLIED
5 - OVER-RUNNING CLUTCH FREE-WHEELING
DIRECT DRIVE POWERFLOW
The vehi cl e has accel erated and reached the shi ft
poi nt for the 2-3 upshi ft i nto di rect dri ve (Fi g. 8).
When the shi ft takes pl ace, the front band i s
rel eased, and the front cl utch i s appl i ed. The rear
cl utch stays appl i ed as i t has been i n al l the forward
gears. Wi th the front cl utch now appl i ed, engi ne
torque i s now on the front cl utch retai ner, whi ch i s
l ocked to the sun gear dri vi ng shel l . Thi s means that
the sun gear i s now turni ng i n engi ne rotati on (cl ock-
wi se) and at engi ne speed. The rear cl utch i s sti l l
appl i ed so engi ne torque i s al so sti l l on the front
annul us gear. I f two members of the same pl anetary
set are dri ven, di rect dri ve resul ts. Therefore, when
two members are rotati ng at the same speed and i n
the same di recti on, i t i s the same as bei ng l ocked up.
The rear pl anetary set i s al so l ocked up, gi ven the
sun gear i s sti l l the i nput, and the rear annul us gear
must turn wi th the output shaft. Both gears are
turni ng i n the same di recti on and at the same speed.
The front and rear pl anet pi ni ons do not turn at al l
i n di rect dri ve. The onl y rotati on i s the i nput from
the engi ne to the connected parts, whi ch are acti ng
as one common uni t, to the output shaft.
Fig. 8 Direct Drive Powerflow
1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
FOURTH GEAR POWERFLOW
Fourth gear overdri ve range i s el ectroni cal l y con-
trol l ed and hydraul i cal l y acti vated. Vari ous sensor
i nputs are suppl i ed to the powertrai n control modul e
to operate the overdri ve sol enoi d on the val ve body.
The sol enoi d contai ns a check bal l that opens and
cl oses a vent port i n the 3-4 shi ft val ve feed passage.
The overdri ve sol enoi d (and check bal l ) are not ener-
gi zed i n fi rst, second, thi rd, or reverse gear. The vent
port remai ns open, di verti ng l i ne pressure from the
2-3 shi ft val ve away from the 3-4 shi ft val ve. The
overdri ve control swi tch must be i n the ON posi ti on
to transmi t overdri ve status to the PCM. A 3-4
upshi ft occurs onl y when the overdri ve sol enoi d i s
energi zed by the PCM. The PCM energi zes the over-
dri ve sol enoi d duri ng the 3-4 upshi ft. Thi s causes the
sol enoi d check bal l to cl ose the vent port al l owi ng
l i ne pressure from the 2-3 shi ft val ve to act di rectl y
on the 3-4 upshi ft val ve. Li ne pressure on the 3-4
shi ft val ve overcomes val ve spri ng pressure movi ng
the val ve to the upshi ft posi ti on. Thi s acti on exposes
the feed passages to the 3-4 ti mi ng val ve, 3-4 qui ck
fi l l val ve, 3-4 accumul ator, and ul ti matel y to the
overdri ve pi ston. Li ne pressure through the ti mi ng
val ve moves the overdri ve pi ston i nto contact wi th
the overdri ve cl utch. The di rect cl utch i s di sengaged
before the overdri ve cl utch i s engaged. The boost
val ve provi des i ncreased fl ui d appl y pressure to the
overdri ve cl utch duri ng 3-4 upshi fts, and when accel -
erati ng i n fourth gear. The 3-4 accumul ator cushi ons
overdri ve cl utch engagement to smooth 3-4 upshi fts.
The accumul ator i s charged at the same ti me as
appl y pressure acts agai nst the overdri ve pi ston.
TRANSMISSION
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(6) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned by
compari ng whi ch i nternal uni ts are appl i ed i n the var-
i ous gear ranges. The Cl utch and Band Appl i cati on
chart provi des a basi s for anal yzi ng road test resul ts.
CLUTCH AND BAND APPLICATION CHART
SHIFT
LEVER
POSITION
TRANSMISSION CLUTCHES AND BANDS OVERDRIVE CLUTCHES
FRONT
CLUTCH
FRONT
BAND
REAR
CLUTCH
REAR
BAND
OVER-
RUNNING
CLUTCH
OVER-
DRIVE
CLUTCH
DIRECT
CLUTCH
OVER-
RUNNING
CLUTCH
Reverse X X X
Drive -
First
X X X X
Drive -
Second
X X X X
Drive -
Third
X X X X
Drive -
Fourth
X X X
Manual
Second
X X X X X
Manual
First
X X X X X
Note that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Note that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear.
For exampl e: I f sl i ppage occurs i n fi rst gear i n D
and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, note that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd and fourth gear. I f the
transmi ssi on sl i ps i n thi rd gear, ei ther the front
cl utch or the rear cl utch i s sl i ppi ng.
I f the transmi ssi on sl i ps i n fourth gear but not i n
thi rd gear, the overdri ve cl utch i s sl i ppi ng. By sel ect-
i ng another gear whi ch does not use these cl utches,
the sl i ppi ng uni t can be determi ned. For exampl e, i f
the transmi ssi on al so sl i ps i n Reverse, the front
cl utch i s sl i ppi ng. I f the transmi ssi on does not sl i p i n
Reverse, the rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the 3-4 shi ft or onl y i n
fourth gear, the overdri ve cl utch i s sl i ppi ng. Si mi -
l arl y, i f the di rect cl utch were to fai l , the transmi s-
si on woul d l ose both reverse gear and overrun
braki ng i n 2 posi ti on (manual second gear).
I f the transmi ssi on wi l l not shi ft to fourth gear, the
control swi tch, overdri ve sol enoi d or rel ated wi ri ng
may al so be the probl em cause.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and pressure test gauges
are requi red. Test Gauge C-3292 has a 100 psi range
and i s used at the accumul ator, governor, and front
servo ports. Test Gauge C-3293-SP has a 300 psi
range and i s used at the rear servo and overdri ve
ports where pressures exceed 100 psi .
Pressure Test Port Locations
Test ports are l ocated at both si des of the transmi s-
si on case (Fi g. 9).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
The rear servo and governor pressure ports are at
the ri ght rear of the transmi ssi on case. The overdri ve
cl utch pressure port i s at the l eft rear of the case.
Test One - Transmission In Manual Low
NOTE: This test checks pump output, pressure reg-
ulation, and condition of the rear clutch and servo
circuit. Both test gauges are required for this test.
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be observed from dri ver seat i f hel per
wi l l be operati ng engi ne. Rai se vehi cl e on hoi st that
wi l l al l ow rear wheel s to rotate freel y.
(2) Connect 100 psi Gauge C-3292 to accumul ator
port. Then connect 300 psi Gauge C-3293-SP to rear
servo port.
(3) Di sconnect throttl e and gearshi ft cabl es from
l evers on transmi ssi on val ve body manual shaft.
(4) Have hel per start and run engi ne at 1000 rpm.
(5) Move transmi ssi on shi ft l ever ful l y forward
i nto 1 range.
(6) Gradual l y move transmi ssi on throttl e l ever
from ful l forward to ful l rearward posi ti on and note
pressures on both gauges:
Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
throttl e l ever i s moved rearward.
Rear servo pressure shoul d be same as l i ne pres-
sure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
NOTE: This test checks pump output, line pressure
and pressure regulation. Use 100 psi Test Gauge
C-3292 for this test.
(1) Leave vehi cl e i n pl ace on hoi st and l eave Test
Gauge C-3292 connected to accumul ator port.
(3) Move transmi ssi on shi ft l ever one detent rear-
ward from ful l forward posi ti on. Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure on
gauge.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range Third Gear
NOTE: This test checks pressure regulation and
condition of the clutch circuits. Both test gauges
are required for this test.
(1) Turn OD swi tch off.
(2) Leave vehi cl e on hoi st and l eave Gauge C-3292
i n pl ace at accumul ator port.
(3) Move Gauge C-3293-SP over to front servo port
for thi s test.
(4) Have hel per start and run engi ne at 1600 rpm
for thi s test.
(5) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(6) Read pressures on both gauges as transmi ssi on
throttl e l ever i s gradual l y moved from ful l forward to
ful l rearward posi ti on:
Li ne pressure at accumul ator i n D range thi rd
gear, shoul d be 54-60 psi (372-414 kPa) wi th throttl e
l ever forward and i ncrease as l ever i s moved rear-
ward.
Front servo pressure i n D range thi rd gear,
shoul d be wi thi n 3 psi (21 kPa) of l i ne pressure up to
ki ckdown poi nt.
Fig. 9 Pressure Test Port Locations
1 - OVERDRIVE CLUTCH TEST PORT
2 - GOVERNOR TEST PORT
3 - ACCUMULATOR TEST PORT
4 - FRONT SERVO TEST PORT
5 - REAR SERVO TEST PORT
Test Four - Transmission In Reverse
ulation and the front clutch and rear servo circuits.
Use 300 psi Test Gauge C-3293-SP for this test.
(1) Leave vehi cl e on hoi st and l eave gauge C-3292
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
for test.
(4) Move transmi ssi on shi ft l ever four detents
rearward from ful l forward posi ti on. Thi s i s Reverse
range.
(5) Move transmi ssi on throttl e l ever ful l y forward
then ful l y rearward and note readi ng at Gauge
C-3293-SP.
(6) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th throttl e l ever forward and i ncrease to 230 -
280 psi (1586-1931 kPa) as l ever i s gradual l y moved
rearward.
Test Five - Governor Pressure
NOTE: This test checks governor operation by mea-
suring governor pressure response to changes in
vehicle speed. It is usually not necessary to check
governor operation unless shift speeds are incor-
rect or if the transmission will not downshift. The
test should be performed on the road or on a hoist
that will allow the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(3) Have hel per start and run engi ne at curb i dl e
speed. Then fi rml y appl y servi ce brakes so wheel s
wi l l not rotate.
(4) Note governor pressure:
Governor pressure shoul d be no more than 20.6
kPa (3 psi ) at curb i dl e speed and wheel s not rotat-
i ng.
I f pressure exceeds 20.6 kPa (3 psi ), a faul t
exi sts i n governor pressure control system.
(5) Rel ease brakes, sl owl y i ncrease engi ne speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
Or approxi matel y 6.89 kPa (1 psi ) for every 1 mph.
(6) Governor pressure ri se shoul d be smooth and
drop back to no more than 20.6 kPa (3 psi ), after
engi ne returns to curb i dl e and brakes are appl i ed to
prevent wheel s from rotati ng.
(7) Compare resul ts of pressure test wi th anal ysi s
chart.
Test Six - Transmission In Overdrive Fourth Gear
NOTE: This test checks line pressure at the over-
drive clutch in fourth gear range. Use 300 psi Test
Gauge C-3293-SP for this test. The test should be
performed on the road or on a chassis dyno.
(1) Remove tachometer; i t i s not needed for thi s
test.
(2) Move 300 psi Gauge to overdri ve cl utch pres-
sure test port. Then remove other gauge and rei nstal l
test port pl ug.
(4) Turn OD swi tch on.
(5) Secure test gauge so i t can be vi ewed from
dri vers seat.
(6) Start engi ne and shi ft i nto D range.
(7) I ncrease vehi cl e speed gradual l y unti l 3-4 shi ft
occurs and note gauge pressure.
(8) Pressure shoul d be 469-496 kPa (68-72 psi )
wi th cl osed throttl e and i ncrease to 620-827 kPa (90-
120 psi ) at 1/2 to 3/4 throttl e. Note that pressure can
i ncrease to around 896 kPa (130 psi ) at ful l throttl e.
(9) Return to shop or move vehi cl e off chassi s
dyno.
PRESSURE TEST ANALYSIS CHART
TEST CONDITION INDICATION
Line pressure OK during
any one test
Pump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear Range
Overdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area
Pressure OK in 2 but low
in R and 1
Leakage in rear servo
Front servo pressure in 2 Leakage in servo; broken
servo ring or cracked
servo piston
Pressure low in all
positions
Clogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speed
Governor pressure
solenoid valve system
fault. Refer to diagnostic
book.
Governor pressure low at
all mph figures
Faulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Lubrication pressure low
at all throttle positions
Clogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Line pressure high Output shaft plugged,
sticky regulator valve
Line pressure low Sticky regulator valve,
clogged filter, worn pump
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH AND BAND
OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 10).
Front Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Apply Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
body l eaks fol l ow the same path as a seal l eak (Fi g.
11). Pump vent or pump attachi ng bol t l eaks are gen-
eral l y deposi ted on the i nsi de of the converter hous-
i ng and not on the converter i tsel f (Fi g. 11). Pump
o-ri ng or gasket l eaks usual l y travel down the i nsi de
of the converter housi ng. Front band l ever pi n pl ug
Fig. 10 Air Pressure Test Passages
1 - REAR SERVO APPLY
2 - FRONT SERVO APPLY
3 - PUMP SUCTION
4 - FRONT CLUTCH APPLY
5 - FRONT SERVO RELEASE
6 - LINE PRESSURE TO ACCUMULATOR
7 - PUMP PRESSURE
8 - TO CONVERTER
9 - REAR CLUTCH APPLY
10 - FROM CONVERTER
11 - TO COOLER
l eaks are general l y deposi ted on the housi ng and not
on the converter.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 12).
(2) Leaks at the converter hub wel d (Fi g. 12).
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or PermatexNo. 2 to
pl ug threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
PARK, NEUTRAL, FI RST, SECOND, THI RD,
FOURTH, MANUAL FI RST, MANUAL SECOND,
and REVERSE gear ranges. Normal worki ng pres-
sures are al so suppl i ed for each of the gear ranges.
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 12 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
DIAGNOSIS CHARTS
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Add Fluid
2. Throttle Linkage Mis-adjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Mis-adjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty. 11. Replace converter and flush cooler and
line before installing new converter.
DELAYED ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Mis-adjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Torque Converter Drain Back (Oil
drains from torque converter into
transmission sump).
4. If vehicle moves normally after 5
seconds after shifting into gear, no repair is
necessary. If longer, inspect pump bushing
for wear. Replace pump house.
5. Rear Band Mis-adjusted. 5. Adjust band.
6. Valve Body Filter Plugged. 6. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
7. Oil Pump Gears Worn/Damaged. 7. Remove transmission and replace oil
pump.
8. Governor Circuit and Solenoid
Valve Electrical Fault.
8. Test with DRB scan tool and repair as
required.
9. Hydraulic Pressure Incorrect. 9. Perform pressure test, remove
transmission and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.
10. Remove transmission, remove oil pump
and replace seal rings.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
11. Remove and disassemble transmission
12. Regulator Valve Stuck. 12. Clean.
13. Cooler Plugged. 13. Transfer case failure can plug cooler.
NO DRIVE RANGE
(REVERSE OK)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
restored.
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body. Replace
valve body (as assembly) if any valve or
bore is damaged. Clean and reassemble
correctly if all parts are in good condition.
7. Transmission Internal Component
Damaged.
needed.
8. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.
8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return
to closed throttle at transmission.
Mis-adjusted.
5. Adjust linkage/cable as described in
service section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
7. Governor Circuit Electrical Fault. 7. Test using DRB scan tool and repair as
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)
Mis-adjusted/Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor
plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
1. Governor Circuit Electrical Fault. 1. Test with DRB scan tool and repair as
required.
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in
Bore.
3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR
NORMAL DOWNSHIFT
1. Throttle Linkage Mis-adjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Verify floor mat is not under pedal, repair
worn accelerator cable or bent brackets.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
required.
5. Valve Body Malfunction. 5. Perform hydraulic pressure tests to
required.
6. TPS Malfunction. 6. Replace sensor, check with DRB scan
tool.
7. PCM Malfunction. 7. Check with DRB scan tool and replace
if required.
8. Valve Body Malfunction. 8. Repair sticking 1-2, 2-3 shift valves,
governor plugs, 3-4 solenoid, 3-4 shift
valve, 3-4 timing valve.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
1. Throttle Linkage Mis-adjusted/
Stuck.
1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
or damaged.
3. Governor Component Electrical
Fault.
3. Check operating pressures and test with
DRB scan tool, repair faulty component.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Mis-adjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped. 2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Mis-assembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Mis-assembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Mis-adjusted. 2. Adjust linkage.
4. Rear Band Worn. 4. Replace as required.
5. Overdrive Direct Clutch Worn. 5. Disassemble overdrive. Repair as
needed.
6. Hydraulic Pressure Too Low. 6. Perform hydraulic pressure tests to
determine cause.
7. Rear Servo Leaking. 7. Air pressure check clutch-servo operation
and repair as required.
8. Band Linkage Binding. 8. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged Filter
or Cooler Lines.
6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo operation
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR D
ONLY, BUT NOT IN
MANUAL 1 POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands Mis-
adjusted.
8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Mis-adjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.
1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRB scan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRB scan tool at
PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid
if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
NO 4-3 DOWNSHIFT
WHEN CONTROL SWITCH
IS TURNED OFF
1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.
2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction. 3. Test with DRB scan tool. Replace PCM
if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup timing
valve.
CLUNK NOISE FROM
DRIVELINE ON CLOSED
THROTTLE 4-3
DOWNSHIFT
1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.
3. Replace overdrive piston thrust plate
spacer.
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT
1. Overdrive Solenoid Connector or
Wiring Shorted.
1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRB scan tool.
3. PCM Malfunction. 3. Test PCM with DRB scan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect
valve body components. Make sure all
valves and plugs slide freely in bores.
Polish valves with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.
3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.
4. Check with DRB scan tool and repair
or replace as necessary.
5. TPS Malfunction. 5. Check with DRB scan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.
6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRB scan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.
9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
SLIPS IN OVERDRIVE
FOURTH GEAR
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch
pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.
3. Disassemble transmission, remove
retainer and replace orifice.
4. Overdrive Piston or Seal
Malfunction.
4. Remove overdrive unit. Replace seals if
worn. Replace piston if damaged. If piston
retainer is damaged, remove and
disassemble the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.
5. Remove and overhaul valve body.
Replace accumulator seals. Make sure all
valves operate freely in bores and do not
bind or stick. Make sure valve body screws
are correctly tightened and separator plates
are properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.
6. Disassemble overdrive unit and replace
thrust bearing (NO. 1 thrust bearing is
between overdrive piston and clutch hub;
NO. 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; NO. 3 thrust bearing is between
overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.
7. Check for function/secure orifice insert in
O/D piston retainer.
DELAYED 3-4 UPSHIFT
(SLOW TO ENGAGE)
2. Throttle Valve Cable Mis-adjusted. 2. Adjust throttle valve cable.
3. Overdrive Clutch Pack Worn/
Burnt.
3. Remove unit and rebuild clutch pack.
4. TPS Faulty. 4. Test with DRB scan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice
Plugged.
5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.
6. Test solenoid and check wiring for
loose/corroded connections or shorts/
grounds. Replace solenoid if faulty and
repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and
select proper spacer.
8. O/D Check Valve Missing or
Stuck.
8. Check for presence of check valve.
Repair or replace as required.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2, 2-3, 3-4 OR
3-2 SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL
Mis-adjusted.
1. Adjust linkage/cable.
2. Neutral Sense Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Park/Neutral Switch, or
Transmission Range Sensor Faulty.
3. Refer to service section for test and
replacement procedure.
Transmission Range Sensor
Connection Faulty.
4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
3. Front Clutch Malfunctioned/
Burned.
3. Air-pressure test clutch operation.
Remove and rebuild if necessary.
4. Overdrive Thrust Bearing Failure. 4. Disassemble geartrain and replace
bearings.
5. Direct Clutch Spring Collapsed/
Broken.
5. Remove and disassemble unit. Check
clutch position and replace spring.
OIL LEAKS. 1. Fluid Lines and Fittings Loose/
Leaks/Damaged.
1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Fill Tube (where tube enters case)
Leaks/Damaged.
2. Replace tube seal. Inspect tube for
cracks in fill tube.
3. Pressure Port Plug Loose
Loose/Damaged.
3. Tighten to correct torque. Replace plug
or reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
5. Replace shaft seal.
6. Rear Bearing Access Plate Leaks. 6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.
7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.
8. Replace gasket.
Leaks/Damaged.
9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.
11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.
12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION IN
FOURTH GEAR ONLY
1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.
2. Remove and disassemble unit. Replace
either thrust bearing if damaged.
3. Output Shaft Bearings Scored/
Damaged.
either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.
5. Remove and overhaul overdrive unit.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s , or equi val ent. Thi s repai r con-
si sts of dri l l i ng out the worn-out damaged threads.
Then tap the hol e wi th a speci al Hel i -Coi l tap, or
equi val ent, and i nstal l i ng a Hel i -Coi l i nsert, or
equi val ent, i nto the hol e. Thi s bri ngs the hol e back to
i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL
The overdri ve uni t can be removed and servi ced
separatel y. I t i s not necessary to remove the enti re
transmi ssi on assembl y to perform overdri ve uni t
repai rs.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.
(2) Hoi st and support vehi cl e.
(4) Remove ski d pl ate support crossmember, i f
equi pped.
(5) Di sconnect and l ower or remove necessary
exhaust components.
fl anges for assembl y al i gnment. Then di sconnect and
remove propel l er shaft. (Refer to 3 - DI FFERENTI AL
& DRI VELI NE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
(7) Remove starter motor. (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL)
(8) Support engi ne wi th sui tabl e support stand
and wood bl ock.
(9) Remove bol ts attachi ng engi ne-to-transmi ssi on
brackets to transmi ssi on.
(10) Remove bol t and nut attachi ng each engi ne-
to-transmi ssi on bracket to the motor mounts.
(11) Remove bol ts hol di ng the engi ne-to-transmi s-
si on brackets to the front axl e, i f equi pped.
(12) Loosen bol ts attachi ng engi ne-to-transmi ssi on
brackets to each si de of the engi ne bl ock.
(14) Remove torque converter access cover.
(15) Ti ghten bol ts attachi ng engi ne-to-transmi s-
si on brackets to each si de of the engi ne bl ock.
(16) Lower engi ne.
(17) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(18) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(19) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . On 4x4
model s, i t wi l l al so be necessary to remove bol t
attachi ng transfer case vent tube to converter hous-
i ng (Fi g. 13).
(20) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(21) Di sconnect wi res from the transmi ssi on range
sensor and transmi ssi on sol enoi ds connector.
(22) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(23) On 4x4 model s, di sconnect shi ft rod from
transfer case shi ft l ever. Or remove shi ft l ever from
transfer case and ti e rod and l ever to chassi s compo-
nent wi th wi re.
(24) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(25) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember. Rai se trans-
mi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket (Fi g. 14) and remove rear support.
(26) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(27) On 4x4 model s, di sconnect vent hose from
transfer case. Then remove transfer case.
(28) Remove al l converter housi ng bol ts.
(29) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(30) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
DISASSEMBLY
(1) Cl ean transmi ssi on exteri or wi th steam gun or
wi th sol vent. Wear eye protecti on duri ng cl eani ng
operati ons.
(2) Pl ace transmi ssi on i n a verti cal posi ti on.
(3) Measure i nput shaft end pl ay as fol l ows (Fi g.
15).
(a) Attach Adapter 8266-6 to Handl e 8266-8.
(b) Attach di al i ndi cator C-3339 to Handl e
8266-8.
Fig. 13 Fill Tube Attachment
1 - TRANSFER CASE VENT TUBE
2 - FILL TUBE (V8)
3 - TUBE SEAL
4 - FILL TUBE (V6)
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 8266-6 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move the i nput shaft i n and out. Record the
maxi mum travel for assembl y reference.
(4) Remove shi ft and throttl e l evers from val ve
body manual l ever shaft.
(6) Remove transmi ssi on oi l pan and gasket.
(7) Remove fi l ter from val ve body (Fi g. 16). Keep
fi l ter screws separate from other val ve body screws.
Fi l ter screws are l onger and shoul d be kept wi th fi l -
ter.
(8) Remove the transmi ssi on range sensor.
(9) Remove hex head bol ts attachi ng val ve body to
transmi ssi on case (Fi g. 17). A total of 10 bol ts are
used. Note di fferent bol t l engths for assembl y refer-
ence.
(10) Remove val ve body assembl y. Push val ve body
harness connector out of case. Then work park rod
and val ve body out of case (Fi g. 18).
(11) Remove accumul ator pi ston and i nner and
outer spri ngs (Fi g. 19).
(12) Remove pump oi l seal wi th sui tabl e pry tool
or sl i de-hammer mounted screw.
(13) Loosen front band adjusti ng screw l ocknut 4-5
turns. Then ti ghten band adjusti ng screw unti l band
front/rear cl utches from comi ng out wi th pump and
possi bl y damagi ng cl utch or pump components.
(14) Remove oi l pump bol ts.
(15) Thread bol ts of Sl i de Hammer Tool s C-3752
i nto threaded hol es i n pump body fl ange (Fi g. 20).
(16) Bump sl i de hammer wei ghts outward to
remove pump and reacti on shaft support assembl y
from case (Fi g. 20).
Fig. 14 Rear Support and Cushion
1 - EXHAUST PIPE ARM AND BRACKET
2 - CROSSMEMBER
3 - REAR SUPPORT AND CUSHION
Fig. 15 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
Fig. 16 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
(17) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose.
(18) Squeeze front band together and remove band
strut (Fi g. 21).
(19) Remove front band l ever (Fi g. 22).
(20) Remove front band l ever shaft pl ug, i f neces-
sary, from converter housi ng.
(21) Remove front band l ever shaft.
Fig. 17 Valve Body Bolt Locations
1 - VALVE BODY BOLTS
Fig. 18 Valve Body Removal
1 - GOVERNOR PRESSURE SENSOR
2 - VALVE BODY
3 - PARK ROD
4 - ACCUMULATOR PISTON
5 - GOVERNOR PRESSURE SOLENOID
Fig. 19 Accumulator Piston And Springs
2 - OUTER SPRING
3 - INNER SPRING
Fig. 20 Removing Oil Pump And Reaction Shaft
Support Assembly
1 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 - SLIDE HAMMER TOOLS C-3752
(22) Remove front and rear cl utch uni ts as assem-
bl y. Grasp i nput shaft, hol d cl utch uni ts together and
remove them from case (Fi g. 23).
(23) Li ft front cl utch off rear cl utch (Fi g. 24). Set
cl utch uni ts asi de for overhaul .
(24) Remove i ntermedi ate shaft thrust washer
from front end of shaft or from rear cl utch hub (Fi g.
25).
(25) Remove output shaft thrust pl ate from i nter-
medi ate shaft hub (Fi g. 26).
Fig. 21 Removing Front Band Strut
1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND
Fig. 22 Removing Front Band Lever
1 - FRONT BAND LEVER
Fig. 23 Removing Front/Rear Clutch Assemblies
1 - INPUT SHAFT
2 - FRONT CLUTCH
3 - REAR CLUTCH
Fig. 24 Separating Front/Rear Clutch Assemblies
1 - FRONT CLUTCH
2 - REAR CLUTCH
(26) Sl i de front band off dri vi ng shel l (Fi g. 27) and
remove band from case.
(27) Remove pl anetary geartrai n as assembl y (Fi g.
28). Support geartrai n wi th both hands duri ng
removal . Do not al l ow machi ned surfaces on i nterme-
di ate shaft or overdri ve pi ston retai ner to become
ni cked or scratched.
(28) I f overdri ve uni t i s not to be servi ced, i nstal l
Al i gnment Shaft 6227-2 i nto the overdri ve uni t to
prevent mi sal i gnment of the overdri ve cl utches dur-
i ng servi ce of mai n transmi ssi on components.
(29) Loosen rear band adjusti ng screw 4-5 turns.
(30) Remove l ow-reverse drum snap-ri ng (Fi g. 29).
Fig. 25 Removing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
Fig. 26 Removing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 27 Front Band Removal
1 - DRIVING SHELL
2 - FRONT BAND
Fig. 28 Removing Planetary Geartrain And
Intermediate Shaft Assembly
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
(31) Remove l ow-reverse drum and reverse band.
(32) Remove overrunni ng cl utch rol l er and spri ng
assembl y as a uni t (Fi g. 30).
(33) Compress front servo rod gui de about 1/8 i nch
wi th Val ve Spri ng Compressor C-3422-B (Fi g. 31).
(34) Remove front servo rod gui de snap-ri ng. Exer-
ci se cauti on when removi ng snap-ri ng. Servo bore
can be scratched or ni cked i f care i s not exerci sed.
(35) Remove compressor tool s and remove front
servo rod gui de, spri ng and servo pi ston.
(36) Compress rear servo spri ng retai ner about
1/16 i nch wi th Val ve Spri ng Compressor C-3422-B
(Fi g. 32).
(37) Remove rear servo spri ng retai ner snap-ri ng.
Then remove compressor tool s and remove rear servo
spri ng and pi ston.
(38) I nspect transmi ssi on components.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
CLEANING
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
Lubri cate transmi ssi on parts wi th MoparATF +4,
type 9602, transmi ssi on fl ui d duri ng overhaul and
assembl y. Use petrol eum jel l y, MoparDoor Ease, or
Ru-Gl yde to prel ubri cate seal s, O-ri ngs, and thrust
Fig. 29 Removing Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 30 Overrunning Clutch Assembly Removal
1 - OVERRUNNING CLUTCH CAM
2 - REAR BAND REACTION PIN
3 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 31 Compressing Front Servo Rod Guide
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
washers. Petrol eum jel l y can al so be used to hol d
parts i n pl ace duri ng reassembl y.
INSPECTION
I nspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repai red wi th Hel i coi l thread i nserts. However, the
case wi l l have to be repl aced i f i t exhi bi ts any type of
damage or wear.
Lubri cate the front band adjusti ng screw threads
wi th petrol eum jel l y and thread the screw part-way
i nto the case. Be sure the screw turns freel y.
I nspect the transmi ssi on bushi ngs duri ng overhaul .
Bushi ng condi ti on i s i mportant as worn, scored bush-
i ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. However, do
not repl ace bushi ngs as a matter of course. Repl ace
bushi ngs onl y when they are actual l y worn, or
scored.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l , and
seat bushi ngs correctl y. The bushi ng repl acement
tool s are i ncl uded i n Bushi ng Tool Set C-3887-B.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
shafts, or val ves, use extreme care to avoi d roundi ng
off sharp edges. Sharp edges are vi tal as they pre-
vent forei gn matter from getti ng between the val ve
and val ve bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
ASSEMBLY
Do not al l ow di rt, grease, or forei gn materi al to
enter the case or transmi ssi on components duri ng
assembl y. Keep the transmi ssi on case and compo-
nents cl ean. Al so make sure the tool s and workbench
area used for assembl y operati ons are equal l y cl ean.
Shop towel s used for wi pi ng off tool s and hands
must be made from lint free materi al . Li nt wi l l sti ck
to transmi ssi on parts and coul d i nterfere wi th val ve
operati on, or even restri ct fl ui d passages.
Lubri cate the transmi ssi on components wi th
Mopar transmi ssi on fl ui d duri ng reassembl y. Use
Mopar Door Ease, or Ru-Gl yde on seal s and
O-ri ngs to ease i nstal l ati on.
Petrol eum jel l y can al so be used to hol d thrust
washers, thrust pl ates and gaskets i n posi ti on duri ng
assembl y. However, do not use chassi s grease, bear-
i ng grease, whi te grease, or si mi l ar l ubri cants on any
transmi ssi on part. These types of l ubri cants can
eventual l y bl ock or restri ct fl ui d passages and i nter-
fere wi th val ve operati on. Use petrol eum jel l y onl y.
Do not force parts i nto pl ace. The transmi ssi on
components and subassembl i es are easi l y i nstal l ed by
hand when properl y al i gned.
I f a part seems extremel y di ffi cul t to i nstal l , i t i s
ei ther mi sal i gned or i ncorrectl y assembl ed. Al so ver-
i fy that thrust washers, thrust pl ates and seal ri ngs
are correctl y posi ti oned before assembl y. These parts
can i nterfere wi th proper assembl y i f mi s-posi ti oned.
The pl anetary geartrai n, front/rear cl utch assem-
bl i es and oi l pump are al l much easi er to i nstal l
when the transmi ssi on case i s upri ght.
(1) I nstal l rear servo pi ston, spri ng and retai ner
(Fi g. 33). I nstal l spri ng on top of servo pi ston and
i nstal l retai ner on top of spri ng.
(2) I nstal l front servo pi ston assembl y, servo
spri ng and rod gui de (Fi g. 34).
(3) Compress front/rear servo spri ngs wi th Val ve
Spri ng Compressor C-3422-B and i nstal l each servo
snap-ri ng (Fi g. 35).
Fig. 32 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
(4) Lubri cate cl utch cam rol l ers wi th transmi ssi on
fl ui d.
(5) I nstal l rear band i n case (Fi g. 36). Be sure twi n
l ugs on band are seated agai nst reacti on pi n.
(6) I nstal l l ow-reverse drum and check overrun-
ni ng cl utch operati on as fol l ows:
(a) Lubri cate overrunni ng cl utch race (on drum
hub) wi th transmi ssi on fl ui d.
(b) Gui de drum through rear band.
(c) Ti l t drum sl i ghtl y and start race (on drum
hub) i nto overrunni ng cl utch rol l ers.
(d) Press drum rearward and turn i t i n cl ock-
wi se di recti on unti l drum seats i n overrunni ng
cl utch (Fi g. 37).
Fig. 33 Rear Servo Components
1 - SERVO PISTON
2 - PISTON SPRING
3 - SNAP-RING
4 - RETAINER
5 - PISTON SEAL
Fig. 34 Front Servo Components
1 - PISTON SEAL RINGS
2 - SERVO PISTON
3 - SNAP-RING
4 - ROD GUIDE
5 - SPRING
6 - ROD
Fig. 35 Compressing Front/Rear Servo Springs
1 - SPRING COMPRESSOR TOOL C-3422-B
Fig. 36 Rear Band Installation
1 - REAR BAND
(e) Turn drum back and forth. Drum shoul d rotate
freel y i n cl ockwi se di recti on and l ock i n counter-
cl ockwi se di recti on (as vi ewed from front of case).
(7) I nstal l snap-ri ng that secures l ow-reverse drum
to hub of overdri ve pi ston retai ner (Fi g. 38).
(8) I nstal l rear band l ever and pi vot pi n (Fi g. 39).
Al i gn l ever wi th pi n bores i n case and push pi vot pi n
i nto pl ace.
(9) I nstal l pl anetary geartrai n assembl y (Fi g. 40).
(10) I nstal l thrust pl ate on i ntermedi ate shaft hub
(Fi g. 41). Use petrol eum jel l y to hol d thrust pl ate i n
pl ace.
(11) Check seal ri ng on rear cl utch retai ner hub
and seal ri ngs on i nput shaft (Fi g. 42). Al so veri fy
that shaft seal ri ngs are i nstal l ed i n sequence shown.
(12) I nstal l rear cl utch thrust washer (Fi g. 43).
Use addi ti onal petrol eum jel l y to hol d washer i n
pl ace i f necessary.
Fig. 37 Installing Low-Reverse Drum
1 - REAR BAND
Fig. 38 Installing Low-Reverse Drum Retaining
Snap-Ring
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 39 Rear Band Lever And Pivot Pin Installation
1 - REAR BAND LEVER
2 - LEVER PIVOT PIN
Fig. 40 Installing Planetary Geartrain
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
(13) Al i gn cl utch di scs i n front cl utch and i nstal l
front cl utch on rear cl utch (Fi g. 44). Rotate front
cl utch retai ner back and forth unti l compl etel y
seated on rear cl utch retai ner.
(14) Coat i ntermedi ate shaft thrust washer wi th
petrol eum jel l y. Then i nstal l washer i n rear cl utch
hub (Fi g. 45). Use enough petrol eum jel l y to hol d
washer i n pl ace. Be sure grooved si de of washer faces
rearward (toward output shaft) as shown. Al so note
that washer onl y fi ts one way i n cl utch hub. Note
thi ckness of thi s washer. I t i s a sel ect fi t part and i s
used to control transmi ssi on end pl ay.
(15) Al i gn dri ve teeth on rear cl utch di scs wi th
smal l screwdri ver (Fi g. 46). Thi s makes i nstal l ati on
on front pl anetary easi er.
(16) Rai se front end of transmi ssi on upward as far
as possi bl e and support case wi th wood bl ocks. Front/
rear cl utch and oi l pump assembl i es are easi er to
i nstal l i f transmi ssi on i s as cl ose to upri ght posi ti on
as possi bl e.
(17) Sl i de front band i nto case.
(18) I nstal l front and rear cl utch uni ts as assembl y
(Fi g. 47). Al i gn rear cl utch wi th front annul us gear
and i nstal l assembl y i n dri vi ng shel l . Be sure output
shaft thrust washer and thrust pl ate are not di s-
pl aced duri ng i nstal l ati on.
Fig. 41 Installing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 42 Input Shaft Seal Ring Location
1 - INPUT SHAFT
2 - TEFLON SEAL RING
3 - PLASTIC SEAL RING
4 - REAR CLUTCH RETAINER
Fig. 43 Installing Rear Clutch Thrust Washer
2 - REAR CLUTCH THRUST WASHER (FIBER)
Fig. 44 Assembling Front And Rear Clutch Units
1 - TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 - REAR CLUTCH ASSEMBLY
(19) Careful l y work assembl ed cl utches back and
forth to engage and seat rear cl utch di scs on front
annul us gear. Al so be sure front cl utch dri ve l ugs are
ful l y engaged i n sl ots of dri vi ng shel l after i nstal l ati on.
(20) Assembl e front band strut.
(21) I nstal l front band adjuster, strut and adjust-
i ng screw (Fi g. 48).
(22) Ti ghten band adjusti ng screw unti l band just
gri ps cl utch retai ner. Veri fy that front/rear cl utches
are sti l l seated before conti nui ng.
Fig. 45 Installing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
Fig. 46 Aligning Rear Clutch Disc Lugs
1 - REAR CLUTCH DISCS
2 - USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
Fig. 47 Installing Front/Rear Clutch Assemblies
1 - INPUT SHAFT
2 - FRONT CLUTCH
3 - REAR CLUTCH
Fig. 48 Front Band Linkage Installation
1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND
(23) Check seal ri ngs on reacti on shaft support
hub. Veri fy that seal ri ngs are hooked together and
that front cl utch thrust washer i s properl y posi ti oned
(Fi g. 49). Use petrol eum jel l y to hol d thrust washer
i n pl ace i f necessary.
(24) Lubri cate oi l pump body seal wi th petrol eum
jel l y. Lubri cate pump shaft seal l i p wi th petrol eum
jel l y.
(25) Thread two Pi l ot Stud Tool s C-3288-B i nto
bol t hol es i n oi l pump bore fl ange (Fi g. 50).
(26) Al i gn and i nstal l oi l pump gasket (Fi g. 50).
(27) I nstal l oi l pump (Fi g. 51). Al i gn and posi ti on
pump on pi l ot studs. Sl i de pump down studs and
work i t i nto front cl utch hub and case by hand. Then
i nstal l 2 or 3 pump bol ts to hol d pump i n pl ace.
(28) Remove pi l ot stud tool s and i nstal l remai ni ng
oi l pump bol ts. Ti ghten bol ts al ternatel y i n di agonal
pattern to 20 Nm (15 ft. l bs.).
(29) Measure i nput shaft end pl ay (Fi g. 52).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or the intermediate shaft
thrust washer is incorrect. The intermediate shaft
thrust washer is selective.
8266-8.
shaft.
tor.
(e) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.56-2.31 mm (0.022-0.091
i n.). Adjust as necessary.
(30) I nstal l accumul ator pi ston and i nner and
outer spri ngs (Fi g. 53).
(31) Veri fy that val ve body sol enoi d harness i s
secured i n 3-4 accumul ator housi ng cover pl ate.
Fig. 49 Reaction Shaft Support Seal Rings And
Front Clutch Thrust Washer
1 - REACTION SHAFT SUPPORT HUB
2 - FRONT CLUTCH THRUST WASHER
3 - SEAL RINGS
Fig. 50 Installing Pilot Studs And Oil Pump Gasket
1 - OIL PUMP GASKET
2 - PILOT STUD TOOLS C-3288-B
Fig. 51 Installing Oil Pump
1 - OIL PUMP
2 - PILOT STUD TOOL
3 - PILOT STUD TOOL
(32) I nstal l val ve body as fol l ows:
(a) Al i gn and careful l y i nsert park rod i nto pawl .
Rod wi l l make cl i ck noi se as i t enters pawl . Move
rod sl i ghtl y to check engagement.
(b) Al i gn and seat val ve body on case. Be sure
manual l ever shaft and overdri ve connector are
ful l y seated i n case. Al so be sure val ve body wi ri ng
i s not pi nched or ki nked.
(c) I nstal l and start al l val ve body attachi ng
bol ts by hand. Then ti ghten bol ts evenl y, i n a di ag-
onal pattern to 12 Nm (105 i n. l bs.) torque. Do not
overti ghten val ve body bol ts. Thi s coul d resul t i n
di storti on and cross l eakage after i nstal l ati on.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) I nstal l new fi l ter on val ve body. Ti ghten fi l ter
(34) Adjust front and rear bands.
(35) I nstal l new val ve body manual shaft seal i n
case (Fi g. 54). Lubri cate seal l i p and manual shaft
wi th petrol eum jel l y. Start seal over shaft and i nto
case. Seat seal wi th 15/16 i nch, deep wel l socket.
(36) Thread the transmi ssi on range sensor mount-
i ng bracket i nto the transmi ssi on case, i f necessary.
Use Adapter 8581 and an appropri ate torque wrench
to torque the mounti ng bracket to 34 Nm (300
i n.l bs.) (Fi g. 55).
(37) I nstal l the transmi ssi on range sensor (Fi g. 56)
i nto the mounti ng bracket wi th the el ectri cal connec-
tor faci ng the front of the transmi ssi on. I nstal l the
screws to hol d the sensor to the mounti ng bracket
and ti ghten to 3.4 Nm (30 i n.l bs.).
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
2 - VALVE BODY
3 - PARK ROD
Fig. 54 Installing Manual Lever Shaft Seal
1 - 15/16'' SOCKET
2 - SEAL
(38) I nstal l magnet i n oi l pan. Magnet goes on
smal l protrusi on at corner of pan.
(39) Posi ti on new oi l pan gasket on case and
i nstal l oi l pan. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.).
(40) I nstal l throttl e val ve and shi ft sel ector l evers
on val ve body manual l ever shaft.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
(2) Lubri cate oi l pump seal l i p wi th transmi ssi on
fl ui d.
(3) Lubri cate converter pi l ot hub pocket i n the rear
of the crankshaft wi th a l i ght coati ng of Mopar
Hi gh Temp Grease.
(4) Al i gn and i nstal l converter i n oi l pump.
(5) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(6) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 57). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) Temporari l y secure converter wi th wedge tool
or C-cl amp.
Fig. 55 Tighten the TRS Mounting Bracket
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
3 - ADAPTER 8581
Fig. 56 Install the Transmission Range Sensor
3 - TRANSMISSION RANGE SENSOR
Fig. 57 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
(8) Posi ti on transmi ssi on on jack and secure i t
wi th chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Al so be sure transmi ssi on dowel pi ns are seated i n
engi ne bl ock and protrude far enough to hel d trans-
mi ssi on i n al i gnment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
(13) I nstal l bol ts attachi ng converter housi ng to
engi ne.
(14) I nstal l transfer case, i f necessary.
(15) I nstal l rear support. Then l ower transmi ssi on
onto crossmember and i nstal l bol ts attachi ng trans-
mi ssi on mount to crossmember.
(16) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused.
(17) Connect gearshi ft and throttl e cabl e to trans-
mi ssi on.
(18) Connect wi res to the transmi ssi on range sen-
sor, transmi ssi on sol enoi d case connector, and oxygen
sensor. Be sure that al l transmi ssi on harnesses are
properl y routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(19) I nstal l torque converter-to-dri vepl ate bol ts.
(22) I nstal l converter housi ng access cover.
(23) I nstal l bol ts attachi ng engi ne-to-transmi ssi on
(25) Lower engi ne.
(26) I nstal l bol t and nut attachi ng each engi ne-to-
transmi ssi on bracket to the motor mounts.
(27) Remove engi ne support.
(28) I nstal l bol ts to hol d engi ne-to-transmi ssi on
brackets to the front axl e, i f equi pped.
TI ON) and cool er l i ne bracket.
(30) Connect cool er l i nes to transmi ssi on.
(31) I nstal l transmi ssi on fi l l tube. I nstal l new seal
on tube before i nstal l ati on.
(32) I nstal l exhaust components.
(33) Al i gn and connect propel l er shaft(s). (Refer to
3 - DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - I NSTALLATI ON)
(34) I nstal l rear ski d pl ate, i f equi pped.
(35) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(36) I nstal l front ski d pl ate, i f equi pped.
(38) Fi l l transmi ssi on wi th MoparATF +4, Type
9602 fl ui d.
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
H
Y
D
R
A
U
L
I
C
F
L
O
W
I
N
P
A
R
K
H
Y
D
R
A
U
L
I
C
F
L
O
W
I
N
N
E
U
T
R
A
L
H
Y
D
R
A
U
L
I
C
F
L
O
W
I
N
R
E
V
E
R
S
E
H
Y
D
R
A
U
L
I
C
F
L
O
W
I
N
D
R
I
V
E
F
I
R
S
T
G
E
A
R
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SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.127-1.22 mm 0.005-0.048 in.
Input shaft end play 0.56-2.31 mm 0.022-0.091 in.
Clutch pack
clearance/Front.
1.70-3.40mm 0.067-0.134 in.
Clutch pack
clearance/Rear.
0.559-0.914
mm
0.022-0.036 in.
Front clutch 4 discs
Rear clutch 4 discs
Overdrive clutch 3 discs
Direct clutch 6 discs
Band adjustment
from 72 in. lbs.
Front band Back off 3 turns
Rear band Back off 4 turns
Recommended fluid Mopar ATF +4, type 9602
GEAR RATIOS
1ST GEAR 2.74:1
2ND GEAR 1.54:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.21:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Front clutch thrust washer (reaction shaft
support hub)
1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) Select fit to set end play
Output shaft thrust washer (rear clutch hub) 1.5-1.6 mm 0.060-0.063 in.
Rear clutch pack snap-ring 1.5 mm 0.060 in.
1.95 mm 0.076 in.
2.45 mm 0.098 in.
Planetary geartrain snap-ring (at front of output shaft) Select fit (three thicknesses avalible)
Overdrive piston thrust plate Thrust plate and spacer
are select fit. Refer to size
charts and selection
procedures in Overdrive
Unit D&A procedures
Intermiediate shaft spacer
PRESSURE TEST
Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa
(90-130 psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line
pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line
pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa
(270 psi) at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in
mph and return to 0-7 kPa (0-1.5 psi) when
stopped with transmission in D, 1, 2. Pressure
above 7 kPa (1.5 psi) at stand still will prevent
transmission from downshifting.
Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 31 - 270
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Bolt, fluid pan 17 13 -
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
Bracket, transmission range sensor mounting 34 - 300
Screw, transmission range sensor to mounting bracket 3.4 - 30
SPECIAL TOOLS
RE TRANSMISSIONS
Shaft, Spring Compressor and Alignment - 6227
Bar, Gauge - 6311
Pilot, Extension Housing - C-3288-B
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Compressor, Spring - C-3422-C
Puller, Slide Hammer - C-3752
Gauge, Throttle Setting - C-3763
Installer, Seal - C-3860-A
Remover, Seal - C-3985-B
Handle, Universal - C-4171
Dial Caliper - C-4962
Kit, Bushing Remover/Installer - C-3887-J
Nut, Bushing Remover - SP-1191, From kit C-3887-J
Cup, Bushing Remover - SP-3633, From kit C-3887-J
Remover, Bushing - SP-3551
Installer, Bushing - SP-5117
Remover, Bushing - SP-5324
Installer, Bushing - SP-5325
Compressor, Spring - C-3575-A
Gauge - 6312
Adapter, Band Adjuster - C-3705
Flusher, Oil Cooler - 6906-B
Installer, Piston - 8114
Remover, Bushing - 6957
Installer, Bushing - 6951
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 58) i s a hydraul i c devi ce
that has the sol e purpose of cushi oni ng the appl i ca-
ti on of a band or cl utch. The accumul ator consi sts of
a dual -l and pi ston and a spri ng l ocated i n a bore i n
the transmi ssi on case. The 3-4 accumul ator i s l ocated
i n a housi ng attached to the si de of the val ve body
(Fi g. 59).
OPERATION
Both the accumul ator and the 3-4 accumul ator
functi on the same. Li ne pressure i s di rected to the
smal l end of the pi ston when the transmi ssi on i s
pl aced i nto a DRI VE posi ti on (Fi g. 60), bottomi ng i t
agai nst the accumul ator pl ate. When the 1-2 upshi ft
occurs (Fi g. 61), l i ne pressure i s di rected to the l arge
end of the pi ston and then to the ki ckdown servo. As
the l i ne pressure reaches the accumul ator, the com-
bi nati on of spri ng pressure and l i ne pressure forces
the pi ston away from the accumul ator pl ate. Thi s
causes a bal anced pressure si tuati on, whi ch resul ts
i n a cushi oned band appl i cati on. After the ki ckdown
servo has become i mmovabl e, l i ne pressure wi l l fi n-
i sh pushi ng the accumul ator up i nto i ts bore. When
the l arge end of the accumul ator pi ston i s seated i n
i ts bore, the band or cl utch i s ful l y appl i ed.
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
Retainer, Detent Ball and Spring - 6583
Socket, TRS Mounting Bracket - 8581
Fig. 58 Accumulator
2 - PISTON SPRING
Fig. 59 3-4 Accumulator and Housing
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
INSPECTION
I nspect the accumul ator pi ston and seal ri ngs (Fi g.
62). Repl ace the seal ri ngs i f worn or cut. Repl ace the
pi ston i f chi pped or cracked.
Check condi ti on of the accumul ator i nner and
outer spri ngs (Fi g. 62). Repl ace the spri ngs i f the
coi l s are cracked, di storted or col l apsed.
BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
The ki ckdown, or front, band (Fi g. 63) hol ds the
common sun gear of the pl anetary gear sets. The
front (ki ckdown) band i s made of steel , and faced on
i ts i nner ci rcumference wi th a fri cti on-type l i ni ng.
One end of the band i s anchored to the transmi ssi on
case, and the other i s acted on wi th a pushi ng force
by a servo pi ston. The front band i s a si ngl e-wrap
desi gn (the band does not compl etel y encompass/
wrap the drum that i t hol ds).
LOW/REVERSE (REAR) BAND
The l ow/reverse band, or rear, band (Fi g. 64) i s
si mi l ar i n appearance and operati on to the front
band. The rear band i s sl i ghtl y di fferent i n that i t
does not use a l i nk bar, but i s acted di rectl y on by
the appl y l ever. Thi s i s referred to as a doubl e-wrap
band desi gn (the drum i s compl etel y encompassed/
wrapped by the band). The doubl e-wrap band pro-
vi des a greater hol di ng power i n compari son to the
si ngl e-wrap desi gn.
Fig. 60 Accumulator in DRIVE - FIRST GEAR
POSITION
1 - LINE PRESSURE
Fig. 61 Accumulator in SECOND Gear Position
1 - BOTTOM OF BORE
2 - LINE PRESSURE
3 - SHUTTLE VALVE
Fig. 62 Accumulator Components
1 - INNER SPRING
3 - OUTER SPRING
4 - SEAL RINGS
ACCUMULATOR (Continued)
OPERATION
The ki ckdown band hol ds the common sun gear of
the pl anetary gear sets by appl yi ng and hol di ng the
front cl utch retai ner, whi ch i s spl i ned to the sun gear
dri vi ng shel l , and i n turn spl i ned di rectl y to the sun
gear. The appl i cati on of the band by the servo i s typ-
i cal l y done by an appl y l ever and l i nk bar.
The rear band hol ds the rear pl anet carri er sta-
ti onary by bei ng mounted around and appl i ed to the
l ow/reverse drum.
ADJUSTMENT - BANDS
FRONT BAND
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 65).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench
C-3380-A, a 3-i n. extensi on and appropri ate Torx
socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw, tighten the screw to only 5 Nm
(47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 3 turns.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 Nm (30 ft. l bs.) torque.
REAR BAND
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
Fig. 63 Front Band
1 - FRONT BAND
2 - TRANSMISSION HOUSING
Fig. 64 Rear Band
1 - ADJUSTING SCREW
2 - LOCKNUT
3 - LEVER
4 - REAR BAND
5 - REACTION PIN
6 - O-RINGS
7 - PIVOT PIN
Fig. 65 Front Band Adjustment Screw Location
1 - LOCK-NUT
2 - FRONT BAND ADJUSTER
BANDS (Continued)
(3) Loosen band adjusti ng screw l ocknut 5-6 turns
(Fi g. 66). Be sure adjusti ng screw turns freel y i n
l ever.
(4) Ti ghten adjusti ng screw to 8 Nm (72 i n. l bs.)
torque.
(5) Back off adjusti ng screw 4 turns.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
(8) Lower vehi cl e and refi l l transmi ssi on wi th
MoparATF +4, type 9602, fl ui d.
ELECTRONIC GOVERNOR
DESCRIPTION
Governor pressure i s control l ed el ectroni cal l y. Com-
ponents used for governor pressure control i ncl ude:
Governor body
Val ve body transfer pl ate
Governor pressure sol enoi d val ve
Governor pressure sensor
Fl ui d temperature thermi stor
Transmi ssi on speed sensor
Powertrai n control modul e (PCM)
GOVERNOR PRESSURE SOLENOID VALVE
The sol enoi d val ve i s a duty-cycl e sol enoi d whi ch
regul ates the governor pressure needed for upshi fts
and downshi fts. I t i s an el ectro-hydraul i c devi ce
l ocated i n the governor body on the val ve body trans-
fer pl ate (Fi g. 67).
GOVERNOR PRESSURE SENSOR
The governor pressure sensor measures output pres-
sure of the governor pressure sol enoi d val ve (Fi g. 68).
GOVERNOR BODY AND TRANSFER PLATE
The transfer pl ate i s desi gned to suppl y transmi s-
si on l i ne pressure to the governor pressure sol enoi d
val ve and to return governor pressure.
The governor pressure sol enoi d val ve i s mounted i n
the governor body. The body i s bol ted to the l ower
si de of the transfer pl ate (Fi g. 68).
GOVERNOR PRESSURE CURVES
There are four governor pressure curves pro-
grammed i nto the transmi ssi on control modul e. The
di fferent curves al l ow the control modul e to adjust gov-
ernor pressure for varyi ng condi ti ons. One curve i s
used for operati on when fl ui d temperature i s at, or
bel ow, 1C (30F). A second curve i s used when fl ui d
temperature i s at, or above, 10C (50F) duri ng normal
ci ty or hi ghway dri vi ng. A thi rd curve i s used duri ng
wi de-open throttl e operati on. The fourth curve i s used
when dri vi ng wi th the transfer case i n l ow range.
Fig. 66 Rear Band Adjusting Screw Location
1 - ADJUSTING SCREW
2 - REAR BAND LEVER
3 - LOCKNUT
Fig. 67 Governor Pressure Solenoid Valve
1 - SOLENOID FILTER
Fig. 68 Governor Pressure Sensor
1 - GOVERNOR BODY
2 - GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
BANDS (Continued)
OPERATION
Compensati on i s requi red for performance vari a-
ti ons of two of the i nput devi ces. Though the sl ope of
the transfer functi ons i s ti ghtl y control l ed, offset may
vary due to vari ous envi ronmental factors or manu-
facturi ng tol erances.
The pressure transducer i s affected by barometri c
pressure as wel l as temperature. Cal i brati on of the
zero pressure offset i s requi red to compensate for
shi fti ng output due to these factors.
Normal cal i brati on wi l l be performed when sump
temperature i s above 50 degrees F, or i n the absence
of sump temperature data, after the fi rst 10 mi nutes
of vehi cl e operati on. Cal i brati on of the pressure
transducer offset occurs each ti me the output shaft
speed fal l s bel ow 200 RPM. Cal i brati on shal l be
repeated each 3 seconds the output shaft speed i s
bel ow 200 RPM. A 0.5 second pul se of 95% duty cycl e
i s appl i ed to the governor pressure sol enoi d val ve
and the transducer output i s read duri ng thi s pul se.
Averagi ng of the transducer si gnal i s necessary to
reject el ectri cal noi se.
Under col d condi ti ons (bel ow 50 degrees F sump),
the governor pressure sol enoi d val ve response may
be too sl ow to guarantee 0 psi duri ng the 0.5 second
cal i brati on pul se. Cal i brati on pul ses are conti nued
duri ng thi s peri od, however the transducer output
val ves are di scarded. Transducer offset must be read
at key-on, under condi ti ons whi ch promote a stabl e
readi ng. Thi s val ue i s retai ned and becomes the off-
set duri ng the col d peri od of operati on.
The i nl et si de of the sol enoi d val ve i s exposed to
normal transmi ssi on l i ne pressure. The outl et si de of
the val ve l eads to the val ve body governor ci rcui t.
The sol enoi d val ve regul ates l i ne pressure to pro-
duce governor pressure. The average current sup-
pl i ed to the sol enoi d control s governor pressure. One
amp current produces zero kPa/psi governor pres-
sure. Zero amps sets the maxi mum governor pres-
sure.
The powertrai n control modul e (PCM) turns on the
trans control rel ay whi ch suppl i es el ectri cal power to
the sol enoi d val ve. Operati ng vol tage i s 12 vol ts
(DC). The PCM control s the ground si de of the sol e-
noi d usi ng the governor pressure sol enoi d control ci r-
cui t.
The sensor output si gnal provi des the necessary
feedback to the PCM. Thi s feedback i s needed to ade-
quatel y control governor pressure.
The transfer pl ate channel s l i ne pressure to the
sol enoi d val ve through the governor body. I t al so
channel s governor pressure from the sol enoi d val ve
to the governor ci rcui t. I t i s the sol enoi d val ve that
devel ops the necessary governor pressure.
LOW TRANSMISSION FLUID TEMPERATURE
When the transmi ssi on fl ui d i s col d the conven-
ti onal governor can del ay shi fts, resul ti ng i n hi gher
than normal shi ft speeds and harsh shi fts. The el ec-
troni cal l y control l ed l ow temperature governor pres-
sure curve i s hi gher than normal to make the
transmi ssi on shi ft at normal speeds and sooner. The
PCM uses a temperature sensor i n the transmi ssi on
oi l sump to determi ne when l ow temperature gover-
nor pressure i s needed.
NORMAL OPERATION
Normal operati on i s refi ned through the i ncreased
computi ng power of the PCM and through access to
data on engi ne operati ng condi ti ons provi ded by the
PCM that were not avai l abl e wi th the previ ous
stand-al one el ectroni c modul e. Thi s faci l i tated the
devel opment of a l oad adapti ve shi ft strategy - the
abi l i ty to al ter the shi ft schedul e i n response to vehi -
cl e l oad condi ti on. One mani festati on of thi s capabi l -
i ty i s grade hunti ng preventi on - the abi l i ty of the
transmi ssi on l ogi c to del ay an upshi ft on a grade i f
the engi ne does not have suffi ci ent power to mai n-
tai n speed i n the hi gher gear. The 3-2 downshi ft and
the potenti al for hunti ng between gears occurs wi th a
heavi l y l oaded vehi cl e or on steep grades. When
hunti ng occurs, i t i s very objecti onabl e because shi fts
are frequent and accompani ed by l arge changes i n
noi se and accel erati on.
WIDE OPEN THROTTLE OPERATION
I n wi de-open throttl e (WOT) mode, adapti ve mem-
ory i n the PCM assures that up-shi fts occur at the
preprogrammed opti mum speed. WOT operati on i s
determi ned from the throttl e posi ti on sensor, whi ch
i s al so a part of the emi ssi on control system. The i ni -
ti al setti ng for the WOT upshi ft i s bel ow the opti -
mum engi ne speed. As WOT shi fts are repeated, the
PCM l earns the ti me requi red to compl ete the shi fts
by compari ng the engi ne speed when the shi fts occur
to the opti mum speed. After each shi ft, the PCM
adjusts the shi ft poi nt unti l the opti mum speed i s
reached. The PCM al so consi ders vehi cl e l oadi ng,
grade and engi ne performance changes due to hi gh
al ti tude i n determi ni ng when to make WOT shi fts. I t
does thi s by measuri ng vehi cl e and engi ne accel era-
ti on and then factori ng i n the shi ft ti me.
ELECTRONIC GOVERNOR (Continued)
TRANSFER CASE LOW RANGE OPERATION
On four-wheel dri ve vehi cl es operati ng i n l ow
range, the engi ne can accel erate to i ts peak more
rapi dl y than i n Normal range, resul ti ng i n del ayed
shi fts and undesi rabl e engi ne fl are. The l ow range
governor pressure curve i s al so hi gher than normal
to i ni ti ate upshi fts sooner. The PCM compares el ec-
troni c vehi cl e speed si gnal used by the speedometer
to the transmi ssi on output shaft speed si gnal to
determi ne when the transfer case i s i n l ow range.
REMOVAL
(2) Remove transmi ssi on fl ui d pan and fi l ter.
(3) Di sengage wi re connectors from pressure sen-
sor and sol enoi d (Fi g. 69).
(4) Remove screws hol di ng pressure sol enoi d
retai ner to governor body.
(5) Separate sol enoi d retai ner from governor (Fi g.
70).
(6) Pul l sol enoi d from governor body (Fi g. 71).
(7) Pul l pressure sensor from governor body.
(8) Remove bol ts hol di ng governor body to val ve
body.
(9) Separate governor body from val ve body (Fi g.
72).
(10) Remove governor body gasket.
INSTALLATION
Before i nstal l i ng the pressure sensor and sol enoi d
i n the governor body, repl ace o-ri ng seal s, cl ean the
gasket surfaces and repl ace gasket.
(1) Pl ace gasket i n posi ti on on back of governor
body (Fi g. 73).
(2) Pl ace governor body i n posi ti on on val ve body.
Fig. 69 Governor Solenoid And Pressure Sensor
1 - PRESSURE SENSOR
2 - PRESSURE SOLENOID
3 - GOVERNOR
Fig. 70 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
Fig. 71 Pressure Solenoid and O-ring
2 - O-RING
3 - GOVERNOR
(3) I nstal l bol ts to hol d governor body to val ve
body.
(4) Lubri cate o-ri ng on pressure sensor wi th trans-
mi ssi on fl ui d.
(5) Al i gn pressure sensor to bore i n governor body.
(6) Push pressure sensor i nto governor body.
(7) Lubri cate o-ri ng, on pressure sol enoi d, wi th
transmi ssi on fl ui d.
(8) Al i gn pressure sol enoi d to bore i n governor
body (Fi g. 74).
(9) Push sol enoi d i nto governor body.
(10) Pl ace sol enoi d retai ner i n posi ti on on governor
(Fi g. 75).
(11) I nstal l screws to hol d pressure sol enoi d
(12) Engage wi re connectors i nto pressure sensor
and sol enoi d (Fi g. 76).
(13) I nstal l transmi ssi on fl ui d pan and (new) fi l ter.
Fig. 72 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
1 - GOVERNOR BODY
2 - GASKET
2 - O-RING
3 - GOVERNOR
2 - GOVERNOR
EXTENSION HOUSING
BUSHING
REMOVAL
(1) Remove extensi on housi ng yoke seal .
(2) I nsert Remover 6957 i nto the extensi on hous-
i ng. Ti ghten tool to bushi ng and remove bushi ng
(Fi g. 77).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n extensi on
housi ng.
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng Seal
I nstal l er C-3995-A (Fi g. 78).
REMOVAL
(2) Mark propel l er shaft and axl e yoke, or compan-
i on fl ange, for al i gnment reference.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 79) from overdri ve extensi on housi ng.
1 - PRESSURE SENSOR
3 - GOVERNOR
1 - REMOVER
Fig. 78 Extension Housing Seal Installation
1 - SPECIAL TOOL C-3995-A OR C-3972-A
Fig. 79 Removing Transmission Housing Yoke Seal
1 - SPECIAL TOOL C-3985-B
2 - SEAL
INSTALLATION
(1) Pl ace seal i n posi ti on on overdri ve housi ng.
(2) Dri ve seal i nto overdri ve housi ng wi th Seal
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
FLUID AND FILTER
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve and cl utch operati on. Foami ng al so causes fl ui d
expansi on whi ch can resul t i n fl ui d overfl ow from the
transmi ssi on vent or fi l l tube. Fl ui d overfl ow can eas-
i l y be mi staken for a l eak i f i nspecti on i s not careful .
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
fai l ure to repl ace contami nated converter after
repai r
The use of non-recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on, an overhaul i s necessary.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
Fig. 80 Installing Overdrive Housing Seal
EXTENSION HOUSING SEAL (Continued)
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transmssi on has too much fl ui d, the
geartrai n churns up foam and cause the same condi -
ti ons whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, ai r bubbl es can cause overheati ng
and/or fl ui d oxi dati on, and varni shi ng. Thi s can
i nterfere wi th normal val ve, cl utch, and accumul ator
operati on. Foami ng can al so resul t i n fl ui d escapi ng
from the transmi ssi on vent where i t may be mi s-
taken for a l eak.
Al ong wi th fl ui d l evel , i t i s i mportant to check the
condi ti on of the fl ui d. When the fl ui d smel l s burned,
and i s contami nated wi th metal or fri cti on materi al
parti cl es, a compl ete transmi ssi on recondi ti on i s
needed. Be sure to exami ne the fl ui d on the di psti ck
cl osel y. I f there i s any doubt about i ts condi ti on,
drai n out a sampl e for a doubl e check.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
The transmi ssi on has a di psti ck to check oi l l evel .
I t i s l ocated on the ri ght si de of the engi ne. Be sure
to wi pe al l di rt from di psti ck handl e before removi ng.
Fl ui d l evel i s checked wi th the engi ne runni ng at
curb i dl e speed, the transmi ssi on i n NEUTRAL and
the transmi ssi on fl ui d at normal operati ng tempera-
ture. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmi ssi on fl ui d l evel can be checked two
ways.
PROCEDURE ONE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(3) Start and run engi ne at curb i dl e speed.
(4) Appl y parki ng brakes.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to NEUTRAL.
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 81) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough MoparATF
+4, type 9602, to restore correct l evel . Do not over-
fi l l .
PROCEDURE TWO
(1) Start engi ne and appl y parki ng brake.
(2) Shi ft the transmi ssi on i nto DRI VE for approxi -
matel y 2 seconds.
(3) Shi ft the transmi ssi on i nto REVERSE for
(4) Shi ft the transmi ssi on i nto PARK.
(5) Hook up DRBscan tool and sel ect engi ne.
(6) Sel ect sensors.
(7) Read the transmi ssi on temperature val ue.
(8) Compare the fl ui d temperature val ue wi th the
fi gure. (Fi g. 82)
(9) Adjust transmi ssi on fl ui d l evel shown on the
di psti ck accordi ng to the fi gure.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmi ssi on for l eaks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper servi ce i nterval s (Refer to LUBRI CA-
TI ON & MAI NTENANCE/MAI NTENANCE SCHED-
ULES - DESCRI PTI ON). The servi ce fl ui d fi l l after a
fi l ter change i s approxi matel y 3.8 l i ters (4.0 quarts).
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 83).
(4) Loosen bol ts hol di ng rear of pan to transmi ssi on.
(5) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(6) Hol d up pan and remove remai ni ng bol t hol d-
i ng pan to transmi ssi on.
(7) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
Fig. 81 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
FLUID AND FILTER (Continued)
(9) Remove screws hol di ng fi l ter to val ve body
(Fi g. 84).
(10) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(11) Di spose of used trans fl ui d and fi l ter properl y.
Fig. 82 42/44RE Fluid Fill Graph
Fig. 83 Transmission Pan
1 - TRANSMISSION
2 - GASKET
3 - PAN
Fig. 84 Transmission Filter
1 - TRANSMISSION
2 - FILTER
STANDARD PROCEDURE - TRANSMISSION
FILL
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of MoparATF
+4, type 9602, to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF +4 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
+4 to transmi ssi on.
(4) Start and run engi ne at normal curb i dl e
speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
FRONT CLUTCH
DESCRIPTION
The front cl utch assembl y (Fi g. 85) i s composed of
the front cl utch retai ner, pressure pl ate, cl utch
pl ates, dri vi ng di scs, pi ston, pi ston return spri ng,
return spri ng retai ner, and snap-ri ngs. The front
cl utch i s the forward-most component i n the trans-
mi ssi on geartrai n and i s di rectl y behi nd the oi l pump
and i s consi dered a dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap-ri ng i s
used to cushi on the appl i cati on of the cl utch pack.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one-way bal l -check-val ve l ocated i n the
cl utch retai ner. The check-val ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
DISASSEMBLY
(1) Remove waved snap-ri ng and remove pressure
pl ate, cl utch pl ates and cl utch di scs (Fi g. 86).
(2) Compress cl utch pi ston spri ng wi th Compressor
Tool C-3575-A (Fi g. 87). Be sure l egs of tool are
seated squarel y on spri ng retai ner before compress-
i ng spri ng.
(3) Remove retai ner snap-ri ng and remove com-
pressor tool .
(4) Remove spri ng retai ner and cl utch spri ng. Note
posi ti on of retai ner on spri ng for assembl y reference.
Fig. 85 Front Clutch Components
1 - SNAP-RING (WAVE) 7 - SEAL
2 - REACTION PLATE 8 - PISTON
3 - CLUTCH DISC 9 - SPRING
4 - CLUTCH PLATE 10 - SNAP-RING
5 - SEAL 11 - SPRING RETAINER
6 - CLUTCH RETAINER
FRONT CLUTCH (Continued)
(5) Remove cl utch pi ston from cl utch retai ner.
Remove pi ston by rotati ng i t up and out of retai ner.
(6) Remove seal s from cl utch retai ner pi ston bore
and cl utch retai ner hub. Di scard both seal s as they
are not reusabl e.
Fig. 86 42RE Front Clutch Components
1 - SNAP-RING (WAVE) 7 - SEAL
2 - REACTION PLATE 8 - PISTON
3 - CLUTCH DISC 9 - SPRING
4 - CLUTCH PLATE 10 - SNAP-RING
5 - SEAL 11 - SPRING RETAINER
6 - CLUTCH RETAINER
INSPECTION
I nspect the front cl utch components. Repl ace the
cl utch di scs i f warped, worn, scored, burned or
charred, or i f the faci ng i s fl aki ng off. Repl ace the
steel pl ates i f heavi l y scored, warped, or broken. Be
sure the dri vi ng l ugs on the pl ates are i n good con-
di ti on. The l ugs must not be bent, cracked or dam-
aged i n any way.
Repl ace the cl utch spri ng and spri ng retai ner i f
ei ther i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged.
Check acti on of the check bal l i n the retai ner (Fi g.
88). The bal l must move freel y and not sti ck.
NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 89). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
ASSEMBLY
NOTE: The 42RE transmission uses four plates and
discs for the front clutch.
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal s i n the cl utch retai ner l ower
groove and on outer di ameter of the retai ner hub. Be
sure l i p of each seal faces i nteri or of cl utch retai ner.
(3) Lubri cate l i ps of the retai ner seal s wi th l i beral
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub, bore and pi ston wi th l i ght coat of trans-
mi ssi on fl ui d.
(4) I nstal l cl utch pi ston i n retai ner (Fi g. 90). Use
twi sti ng moti on to seat pi ston i n bottom of retai ner.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip.
(5) Posi ti on spri ng i n cl utch pi ston (Fi g. 91).
Fig. 87 Compressing Front Clutch Piston Spring
1 - FRONT CLUTCH SPRING
2 - COMPRESSOR TOOL C-3575-A
3 - RETAINER SNAP-RING
4 - SPRING RETAINER
Fig. 88 Front Clutch Piston Retainer Check Ball
Location
1 - RETAINER CHECK BALL
Fig. 89 Retainer Bushing Location/Inspection
1 - FRONT CLUTCH RETAINER BUSHINGS (NON-
SERVICEABLE)
(6) Posi ti on spri ng retai ner on top of pi ston spri ng.
Make sure retai ner i s properl y i nstal l ed (Fi g. 86).
(7) Compress pi ston spri ng and retai ner wi th Com-
pressor Tool C-3575-A (Fi g. 87). Then i nstal l new
snap-ri ng to secure spri ng retai ner and spri ng.
(8) I nstal l cl utch pl ates and di scs (Fi g. 86). I nstal l
steel pl ate then di sc unti l al l pl ates and di scs are
i nstal l ed. The front cl utch uses 4 cl utch di scs and
pl ates i n a 42RE transmi ssi on.
(9) I nstal l pressure pl ate and waved snap-ri ng
(Fi g. 86).
Cl earance shoul d be 1.70 to 3.40 mm (0.067 to
0.134 i n.). I f cl earance i s i ncorrect, cl utch di scs,
pl ates, pressure pl ates and snap-ri ng may have to be
changed.
FRONT SERVO
DESCRIPTION
The ki ckdown servo (Fi g. 92) consi sts of a two-l and
pi ston wi th an i nner pi ston, a pi ston rod and gui de,
and a return spri ng. The dual -l and pi ston uses seal
ri ngs on i ts outer di ameters and an O-ri ng for the
i nner pi ston.
OPERATION
The appl i cati on of the pi ston i s accompl i shed by
appl yi ng pressure between the two l ands of the pi s-
ton. The pressure acts agai nst the l arger l ower l and
to push the pi ston downward, al l owi ng the pi ston rod
to extend though i ts gui de agai nst the appl y l ever.
Rel ease of the servo at the 2-3 upshi ft i s accom-
pl i shed by a combi nati on of spri ng and l i ne pressure,
acti ng on the bottom of the l arger l and of the pi ston.
The smal l pi ston i s used to cushi on the appl i cati on of
the band by bl eedi ng oi l through a smal l ori fi ce i n
the l arger pi ston. The rel ease ti mi ng of the ki ckdown
servo i s very i mportant to obtai n a smooth but fi rm
shi ft. The rel ease has to be very qui ck, just as the
front cl utch appl i cati on i s taki ng pl ace. Otherwi se,
engi ne runaway or a shi ft hesi tati on wi l l occur. To
accompl i sh thi s, the band retai ns i ts hol di ng capaci ty
unti l the front cl utch i s appl i ed, gi vi ng a smal l
amount of overl ap between them.
Fig. 90 Front Clutch Piston Installation
1 - CLUTCH PISTON
2 - FRONT CLUTCH RETAINER
Fig. 91 Clutch Piston Spring Installation
1 - RETAINER
2 - CLUTCH SPRING
3 - PISTON
Fig. 92 Front Servo
1 - VENT
2 -PISTON ROD
3 - PISTON
4 - SPRING
5 - RELEASE PRESSURE
6 - APPLY PRESSURE
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 93).
(2) Remove smal l snap-ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component o-ri ng
and seal ri ngs.
CLEANING
Cl ean the servo pi ston components (Fi g. 94) wi th
sol vent and dry them wi th compressed ai r.
INSPECTION
I nspect the servo components (Fi g. 95). Repl ace the
spri ngs i f col l apsed, di storted or broken. Repl ace the
gui de, rod and pi ston i f cracked, bent, or worn. Di s-
card the servo snap-ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
Fig. 93 Front Servo
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
5 - PISTON ROD GUIDE
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
Fig. 94 Front Servo Piston
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
FRONT SERVO (Continued)
ASSEMBLY
Cl ean and i nspect front servo components.
(1) Lubri cate new o-ri ng and seal ri ngs wi th petro-
l eum jel l y and i nstal l them on pi ston, gui de and rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap-ri ng (Fi g.
96).
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE
(1) The shi fter l ever and gate posi ti ons shoul d be
i n al i gnment wi th al l transmi ssi on PARK, NEU-
TRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th shi ft l ever
i n PARK or NEUTRAL gate posi ti ons onl y. Engi ne
starts must not be possi bl e i n any other gear posi -
ti on.
(3) Wi th shi ft l ever handl e i n:
(a) PARK posi ti on - Appl y forward force on cen-
ter of l ever and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti on - Appl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti on - Normal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti on - Engi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft l ever. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
REMOVAL
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove the dash panel i nsul ati on pad as nec-
essary to access the gearshi ft cabl e bracket mounti ng
nuts.
(3) Remove nuts retai ni ng the gearshi ft cabl e
mounti ng bracket to the dash panel (Fi g. 97) or (Fi g.
98).
(4) Di sconnect cabl e at l ower col umn l ever and
feed cabl e through dash panel openi ng to undersi de
of vehi cl e (Fi g. 99).
(6) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng bracket
(Fi g. 100) or (Fi g. 101). Remove ol d cabl e from vehi -
cl e.
Fig. 96 Front Servo
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
Fig. 97 Cable Mounting at Dash Panel - 4X2
1 - DASH PANEL
2 - GEARSHIFT CABLE MOUNTING BRACKET
3 - GEARSHIFT CABLE
INSTALLATION
(1) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and snap the cabl e
eyel et onto the manual control l ever bal l stud.
(3) Route cabl e through hol e i n dash panel (Fi g.
102) or (Fi g. 103).
1 - DASH PANEL
3 - GEARSHIFT CABLE
Fig. 99 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
Fig. 100 Gearshift Cable at Transmission - RFE
1 - GEARSHIFT CABLE
2 - RFE TRANSMISSION
3 - MANUAL LEVER
Fig. 101 Gearshift Cable at Transmission - RE
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
GEARSHIFT CABLE (Continued)
(4) Seat the cabl e mounti ng bracket to dash panel
and i nstal l retai ni ng nuts to hol d the cabl e housi ng
bracket to the dash panel .
(5) Ti ghten the nuts to 34 Nm (25 ft.l bs.).
(6) Pl ace the transmi ssi on manual shi ft l ever i n
the PARK detent (rearmost) posi ti on and rotate
prop shaft to ensure transmi ssi on i s i n PARK.
(7) Connect shi ft cabl e to the steeri ng col umn shi ft
l ever (Fi g. 104) by snappi ng the cabl e retai ni ng ears
i nto shi fter bracket and snappi ng the cabl e eyel et on
the steeri ng col umn bal l stud.
(8) Lock the shi ft cabl e adjustment by pressi ng the
cabl e adjuster l ock upward unti l i t snaps i nto pl ace.
(9) Check for proper operati on of the transmi ssi on
range sensor.
(10) Adjust the gearshi ft cabl e as necessary.
ADJUSTMENTS - GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n PARK
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the transmi ssi on range sensor may be
faul ty.
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
Gearshift Adjustment Procedure
(2) Rel ease cabl e adjuster l ock tab (underneath the
steeri ng col umn) (Fi g. 105) to unl ock cabl e.
(4) Di sengage the cabl e eyel et from the transmi s-
si on manual shi ft l ever.
(5) Veri fy transmi ssi on shi ft l ever i s i n PARK
detent by movi ng l ever ful l y rearward. Last rearward
detent i s PARK posi ti on.
(6) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(7) Snap the cabl e eyel et onto the transmi ssi on
manual shi ft l ever.
(9) Lock shi ft cabl e by pressi ng cabl e adjuster l ock
tab upward unti l i t snaps i nto pl ace.
(10) Check engi ne starti ng. Engi ne shoul d start
onl y i n PARK and NEUTRAL
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 106) i s l ocated i n the pump
housi ng i nsi de the bel l housi ng of the transmi ssi on
case. The oi l pump consi sts of an i nner and outer
gear (Fi g. 107), a housi ng, and a cover that al so
serves as the reacti on shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
Fig. 106 Oil Pump and Reaction Shaft Support
1 - REACTION SHAFT SUPPORT
2 - PUMP
Fig. 107 Pump Gear Removal
2 - INNER GEAR
3 - OUTER GEAR
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th MoparATF +4, type 9602, Auto-
mati c Transmi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 20 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 20 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
(5) Refi l l the transmi ssi on to proper l evel .
DISASSEMBLY
(1) Remove seal ri ng from housi ng and reacti on
shaft support (Fi g. 108).
(2) Mark pump housi ng and support assembl y for
al i gnment reference.
(3) Remove bol ts attachi ng pump body to support
(Fi g. 109).
(4) Separate support from pump housi ng (Fi g.
110).
(5) Remove i nner and outer gears from reacti on
shaft support (Fi g. 111).
(6) I f pump seal was not removed duri ng transmi s-
si on di sassembl y, remove seal wi th punch and ham-
mer.
(7) Remove front cl utch thrust washer from sup-
port hub (Fi g. 112).
Fig. 108 Removing Pump Seal Ring
1 - PUMP HOUSING SEAL RING
Fig. 109 Pump Support Bolts
2 - PUMP
Fig. 110 Separating Pump Housing From Reaction
Shaft Support
2 - PUMP HOUSING
Fig. 111 Pump Gear Removal
2 - INNER GEAR
3 - OUTER GEAR
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng Remover SP-3551 from Tool Set
C-3887-J (Fi g. 113).
(2) I nstal l new pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng I nstal l er SP-5117 (Fi g. 113).
Bushi ng shoul d be fl ush wi th pump housi ng bore.
(3) Stake new pump bushi ng i n two pl aces wi th
bl unt punch (Fi g. 114). Remove burrs from stake
poi nts wi th kni fe bl ade afterward.
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Bushi ng Remover Tool s SP-1191,
3633 and 5324 (Fi g. 115). Do not cl amp any part of
reacti on shaft or support i n vi se.
(2) Hol d Cup Tool SP-3633 fi rml y agai nst reacti on
shaft and thread remover SP-5324 i nto bushi ng as
far as possi bl e by hand. Then thread remover tool 3-4
addi ti onal turns i nto bushi ng wi th a wrench.
(3) Turn remover tool hex nut down agai nst
remover cup to pul l bushi ng from shaft. Cl ean al l
chi ps from shaft after bushi ng removal .
(4) Li ghtl y gri p ol d bushi ng i n vi se or wi th pl i ers
and back remover tool out of bushi ng.
(5) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5325 (Fi g. 115).
(6) Sl i de new bushi ng onto I nstal l er Tool SP-5325.
(7) Posi ti on reacti on shaft support upri ght on a
cl ean smooth surface.
(8) Al i gn bushi ng i n bore. Then tap bushi ng i nto
pl ace unti l Bushi ng I nstal l er SP-5325 bottoms.
(9) Cl ean reacti on shaft support thoroughl y after
i nstal l i ng bushi ng.
Fig. 112 Support Hub Thrust Washer
1 - BUSHING
3 - THRUST WASHER
4 - HUB
Fig. 113 Removing Oil Pump Bushing
2 - SPECIAL TOOL SP-3551
3 - BUSHING
5 - BUSHING
7 - PUMP HOUSING
Fig. 114 Staking Oil Pump Bushing
1 - NARROW BLADE
2 - BLUNT PUNCH
3 - TWO STAKES
CLEANING
Cl ean pump and support components wi th sol vent
and dry them wi th compressed ai r.
INSPECTION
Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
I nspect the pump and support components. Repl ace
the pump or support i f the seal ri ng grooves or
machi ned surfaces are worn, scored, pi tted, or dam-
aged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
I nspect the pump bushi ng. Then check the reacti on
shaft support bushi ng. Repl ace ei ther bushi ng onl y i f
heavi l y worn, scored or damaged. I t i s not necessary
to repl ace the bushi ngs unl ess they are actual l y dam-
aged.
Cl earance between outer gear and reacti on shaft
housi ng shoul d be 0.010 to 0.063 mm (0.0004 to
0.0025 i n.). Cl earance between i nner gear and reac-
ti on shaft housi ng shoul d be 0.010 to 0.063 mm
(0.0004 to 0.0025 i n.). Both cl earances can be mea-
sured at the same ti me by i nstal l i ng the gears i n the
pump body and measure pump component cl earances
as fol l ows:
(1) Posi ti on an appropri ate pi ece of Pl asti gage
across both gears.
(2) Al i gn the pl asti gage to a fl at area on the reac-
ti on shaft housi ng.
(3) I nstal l the reacti on shaft to the pump housi ng.
(4) Separate the reacti on shaft housi ng from the
pump housi ng and measure the Pl asti gage fol l ow-
i ng the i nstructi ons suppl i ed wi th i t.
Cl earance between i nner gear tooth and outer gear
shoul d be 0.08 to 0.19 mm (0.0035 to 0.0075 i n.).
Measure cl earance wi th an appropri ate feel er gauge.
Cl earance between outer gear and pump housi ng
shoul d be 0.10 to 0.19 mm (0.004 to 0.0075 i n.). Mea-
sure cl earance wi th an appropri ate feel er gauge.
ASSEMBLY
(1) Lubri cate gear bore i n pump housi ng wi th
(2) Lubri cate pump gears wi th transmi ssi on fl ui d.
(3) Support pump housi ng on wood bl ocks (Fi g.
116).
(4) I nstal l outer gear i n pump housi ng (Fi g. 116).
Gear can be i nstal l ed ei ther way (i t i s not a one-way
fi t).
(5) I nstal l pump i nner gear (Fi g. 117).
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
faces forward (to front of pump).
(6) I nstal l new thrust washer on hub of reacti on
shaft support. Lubri cate washer wi th transmi ssi on
fl ui d or petrol eum jel l y.
(7) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub (Fi g. 118).
Lubri cate seal ri ngs wi th transmi ssi on fl ui d or petro-
l eum jel l y after i nstal l ati on. Squeeze each ri ng unti l
ri ng ends are securel y hooked together.
Fig. 115 Replacing Reaction Shaft Support Bushing
5 - REACTION SHAFT
7 - BUSHING
Fig. 116 Supporting Pump And Installing Outer Gear
1 - OUTER GEAR
2 - PUMP HOUSING
3 - WOOD BLOCKS
CAUTION: The reaction shaft support seal rings will
break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
(8) I nstal l reacti on shaft support on pump housi ng
(Fi g. 119).
(9) Al i gn reacti on support on pump housi ng. Use
al i gnment marks made at di sassembl y. Or, rotate
support unti l bol t hol es i n support and pump housi ng
are al l al i gned (hol es are offset for one-way fi t).
(10) I nstal l al l bol ts that attach support to pump
housi ng. Then ti ghten bol ts fi nger ti ght.
(11) Ti ghten support-to-pump bol ts to requi red
torque as fol l ows:
(a) Reverse pump assembl y and i nstal l i t i n
transmi ssi on case. Posi ti on pump so bol ts are fac-
i ng out and are accessi bl e.
(b) Secure pump assembl y i n case wi th 2 or 3
bol ts, or wi th pi l ot studs.
(c) Ti ghten support-to-pump bol ts to 20 Nm (15
ft. l bs.).
(d) Remove pump assembl y from transmi ssi on
case.
(12) I nstal l new oi l seal i n pump wi th Speci al Tool
C-4193 and Tool Handl e C-4171 (Fi g. 120). Be sure
seal l i p faces i nward.
(13) I nstal l new seal ri ng around pump housi ng.
Be sure seal i s properl y seated i n groove.
(14) Lubri cate l i p of pump oi l seal and O-ri ng seal
wi th transmi ssi on fl ui d.
OUTPUT SHAFT FRONT
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e.
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap-ri ng hol di ng output shaft front
beari ng to overdri ve geartrai n. (Fi g. 121).
(4) Pul l beari ng from output shaft.
Fig. 117 Pump Inner Gear Installation
1 - OUTER GEAR
2 - INNER GEAR
Fig. 118 Hub Seal Ring Position
1 - SEAL RINGS
2 - SUPPORT HUB
Fig. 119 Assembling Reaction Shaft Support And
Pump Housing
1 - PUMP HOUSING
Fig. 120 Pump Oil Seal Installation
1 - PUMP BODY
2 - PUMP SEAL
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on on
geartrai n wi th l ocati ng retai ner groove toward the
rear.
(2) Push beari ng onto shaft unti l the snap-ri ng
groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng onto output
shaft.
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
OUTPUT SHAFT REAR
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e. (Refer
to 21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C/
OVERDRI VE - REMOVAL)
(3) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto overdri ve housi ng (Fi g. 122).
(4) Usi ng a sui tabl e dri ver i nserted through the
rear end of housi ng, dri ve beari ng from housi ng.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on i n hous-
i ng.
(2) Usi ng a sui tabl e dri ver, dri ve beari ng i nto
housi ng unti l the snap-ri ng groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng i nto housi ng
(Fi g. 122).
OVERDRIVE CLUTCH
DESCRIPTION
The overdri ve cl utch (Fi g. 123) i s composed of the
pressure pl ate, cl utch pl ates, hol di ng di scs, overdri ve
pi ston retai ner, pi ston, pi ston spacer, and snap-ri ngs.
The overdri ve cl utch i s the forwardmost component
i n the transmi ssi on overdri ve uni t and i s consi dered
a hol di ng component. The overdri ve pi ston retai ner,
pi ston, and pi ston spacer are l ocated on the rear of
the mai n transmi ssi on case.
OPERATION
the pi ston retai ner and pi ston. The fl ui d pressure i s
cl utch through passages at the l ower rear porti on of
the val ve body area. Wi th pressure appl i ed between
the pi ston retai ner and pi ston, the pi ston moves
away from the pi ston retai ner and compresses the
cl utch pack. Thi s acti on appl i es the cl utch pack,
al l owi ng torque to fl ow through the i ntermedi ate
shaft i nto the overdri ve pl anetary gear set. The over-
dri ve cl utch di scs are attached to the overdri ve cl utch
hub whi l e the overdri ve cl utch pl ates, reacti on pl ate,
and pressure pl ate are l ugged to the overdri ve hous-
i ng. Thi s al l ows the i ntermedi ate shaft to transfer
the engi ne torque to the pl anetary gear and overrun-
Fig. 121 Output Shaft Front Bearing
1 - OUTPUT SHAFT FRONT BEARING
2 - SNAP-RING
3 - OUTPUT SHAFT
4 - GROOVE TO REAR
5 - OVERDRIVE GEARTRAIN
Fig. 122 Output Shaft Rear Bearing
1 - OUTPUT SHAFT REAR BEARING
2 - OVERDRIVE HOUSING
3 - SNAP-RING
OUTPUT SHAFT FRONT BEARING (Continued)
ni ng cl utch. Thi s dri ves the pl anetary gear i nsi de the
annul us, whi ch i s attached to the overdri ve cl utch
drum and output shaft, creati ng the desi red gear
rati o. The waved snap-ri ng i s used to cushi on the
appl i cati on of the cl utch pack.
OVERDRIVE SWITCH
DESCRIPTION
The overdri ve OFF (control ) swi tch i s l ocated i n
the shi ft l ever arm (Fi g. 124). The swi tch i s a
momentary contact devi ce that si gnal s the PCM to
toggl e current status of the overdri ve functi on.
OPERATION
At key-on, overdri ve operati on i s al l owed. Pressi ng
the swi tch once causes the overdri ve OFF mode to be
entered and the overdri ve OFF swi tch l amp to be
i l l umi nated. Pressi ng the swi tch a second ti me
causes normal overdri ve operati on to be restored and
the overdri ve l amp to be turned off. The overdri ve
OFF mode defaul ts to ON after the i gni ti on swi tch i s
cycl ed OFF and ON. The normal posi ti on for the con-
trol swi tch i s the ON posi ti on. The swi tch must be i n
thi s posi ti on to energi ze the sol enoi d and al l ow a 3-4
upshi ft. The control swi tch i ndi cator l i ght i l l umi nates
onl y when the overdri ve swi tch i s turned to the OFF
posi ti on, or when i l l umi nated by the transmi ssi on
control modul e.
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS
The overdri ve off swi tch, val ve body sol enoi d, case
connectors and rel ated wi ri ng can al l be tested wi th
a 12 vol t test l amp or a vol t/ohmmeter. Check conti -
nui ty of each component when di agnosi s i ndi cates
thi s i s necessary.
Swi tch and sol enoi d conti nui ty shoul d be checked
whenever the transmi ssi on fai l s to shi ft i nto fourth
gear range.
Fig. 123 Overdrive Clutch
1 - REACTION PLATE 2 - PRESSURE PLATE
Fig. 124 Overdrive Off Switch
OVERDRIVE CLUTCH (Continued)
REMOVAL
(1) Usi ng a pl asti c tri m tool , remove the overdri ve
off swi tch retai ner from the shi ft l ever (Fi g. 125).
(2) Pul l the swi tch outwards to rel ease i t from the
connector i n the l ever (Fi g. 126)
INSTALLATION
NOTE: There is enough slack in the wire to pull out
the connector from the lever.
(1) Pul l the connector out of the l ever just enough
to grasp i t.
CAUTION: Be careful not to bend the pins on the
overdrive off switch. Use care when installing the
switch, as it is not indexed, and can be accidentally
installed incorrectly.
(2) I nstal l the overdri ve off swi tch i nto the connec-
tor (Fi g. 127)
(3) Push the overdri ve off swi tch and wi ri ng i nto
the shi ft l ever.
(4) I nstal l the overdri ve off swi tch retai ner onto
the shi ft l ever.
OVERDRIVE UNIT
REMOVAL
(3) Remove transfer case, i f equi pped.
(4) Mark propel l er shaft uni versal joi nt(s) and axl e
pi ni on yoke, or the compani on fl ange and fl ange
yoke, for al i gnment reference at i nstal l ati on, i f necc-
esary.
(5) Di sconnect and remove the rear propel l er shaft,
i f necessary. (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmi ssi on oi l pan, remove gasket,
drai n oi l and rei nstal l pan.
(7) I f overdri ve uni t had mal functi oned, or i f fl ui d
i s contami nated, remove enti re transmi ssi on. I f di ag-
nosi s i ndi cated overdri ve probl ems onl y, remove just
the overdri ve uni t.
Fig. 125 Overdrive Off Switch Retainer
1 - GEAR SHIFT LEVER
2 - OVERDRIVE OFF SWITCH RETAINER
3 - PLASTIC TRIM TOOL
Fig. 126 Remove the Overdrive Off Switch
2 - OVERDRIVE OFF SWITCH
Fig. 127 Install the Overdrive Off Switch
2 - OVERDRIVE OFF SWITCH WIRING CONNECTOR
OVERDRIVE SWITCH (Continued)
(9) Remove bol ts attachi ng overdri ve uni t to trans-
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Careful l y work overdri ve uni t off i ntermedi ate
shaft. Do not ti l t uni t duri ng removal . Keep i t as
l evel as possi bl e.
(11) I f overdri ve uni t does not requi re servi ce,
i mmedi atel y i nsert Al i gnment Tool 6227-2 i n spl i nes
of pl anetary gear and overrunni ng cl utch to prevent
spl i nes from rotati ng out of al i gnment. I f mi sal i gn-
ment occurs, overdri ve uni t wi l l have to be di sassem-
bl ed i n order to real i gn spl i nes.
(12) Remove and retai n overdri ve pi ston thrust
beari ng. Beari ng may remai n on pi ston or i n cl utch
hub duri ng removal .
(13) Posi ti on drai n pan on workbench.
(14) Pl ace overdri ve uni t over drai n pan. Ti l t uni t
to drai n resi dual fl ui d from case.
(15) Exami ne fl ui d for cl utch materi al or metal
fragments. I f fl ui d contai ns these i tems, overhaul wi l l
be necessary.
(16) I f overdri ve uni t does not requi re any servi ce,
l eave al i gnment tool i n posi ti on. Tool wi l l prevent
acci dental mi sal i gnment of pl anetary gear and over-
runni ng cl utch spl i nes.
DISASSEMBLY
(1) Remove transmi ssi on speed sensor and O-ri ng
seal from overdri ve case (Fi g. 129).
(2) Remove overdri ve pi ston thrust beari ng (Fi g.
130).
OVERDRIVE PISTON
(1) Remove overdri ve pi ston thrust pl ate (Fi g.
131). Retai n thrust pl ate. I t i s a sel ect fi t part and
may possi bl y be reused.
(2) Remove i ntermedi ate shaft spacer (Fi g. 132).
Retai n spacer. I t i s a sel ect fi t part and may possi bl y
be reused.
Fig. 128 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
Fig. 129 Transmission Speed Sensor Removal
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
Fig. 130 Overdrive Piston Thrust Bearing Removal
1 - THRUST BEARING
2 - OVERDRIVE PISTON
3 - THRUST PLATE
OVERDRIVE UNIT (Continued)
(3) Remove overdri ve pi ston from retai ner (Fi g.
133).
OVERDRIVE CLUTCH PACK
(1) Remove overdri ve cl utch pack wi re retai ni ng
ri ng (Fi g. 134).
(2) Remove overdri ve cl utch pack (Fi g. 135).
NOTE: The 42RE transmission has three clutch
discs and two clutch plates.
(3) Note posi ti on of cl utch pack components for
assembl y reference (Fi g. 136).
Fig. 131 Overdrive Piston Thrust Plate Removal
2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 132 Intermediate Shaft Spacer Location
1 - INTERMEDIATE SHAFT
2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
Fig. 133 Overdrive Piston Removal
1 - PISTON RETAINER
Fig. 134 Removing Overdrive Clutch Pack Retaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 135 Overdrive Clutch Pack Removal
1 - OVERDRIVE CLUTCH PACK
OVERDRIVE GEARTRAIN
(1) Remove overdri ve cl utch wave spri ng (Fi g.
137).
(2) Remove overdri ve cl utch reacti on snap-ri ng
(Fi g. 138). Note that snap-ri ng i s l ocated i n same
groove as wave spri ng.
(3) Remove Torx head screws that attach access
cover and gasket to overdri ve case (Fi g. 139).
(4) Remove access cover and gasket (Fi g. 140).
Fig. 136 42RE Overdrive Clutch Component
Position
1 - PRESSURE PLATE (TO FRONT)
3 - CLUTCH DISC (3)
4 - CLUTCH PLATE (2)
5 - REACTION PLATE (TO REAR)
Fig. 137 Overdrive Clutch Wave
1 - WAVE SPRING
Fig. 138 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
Fig. 139 Access Cover Screw Removal
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 140 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
(5) Expand output shaft beari ng snap-ri ng wi th
expandi ng-type snap-ri ng pl i ers. Then push output
shaft forward to rel ease shaft beari ng from l ocati ng
ri ng (Fi g. 141).
(6) Li ft gear case up and off geartrai n assembl y
(Fi g. 142).
(7) Remove snap-ri ng that retai ns rear beari ng on
output shaft.
(8) Remove rear beari ng from output shaft (Fi g.
143).
DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrai n assembl y i n shop press (Fi g.
144).
(2) Posi ti on Compressor Tool 6227-1 on cl utch hub
(Fi g. 144). Support output shaft fl ange wi th steel
press pl ates as shown and center assembl y under
press ram.
(3) Appl y press pressure sl owl y. Compress hub and
spri ng far enough to expose cl utch hub retai ni ng ri ng
and rel i eve spri ng pressure on cl utch pack snap-ri ng
(Fi g. 144).
Fig. 141 Releasing Bearing From Locating Ring
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 142 Removing Gear Case From Geartrain
Assembly
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 143 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
(4) Remove di rect cl utch pack snap-ri ng (Fi g. 145).
(5) Remove di rect cl utch hub retai ni ng ri ng (Fi g.
146).
(6) Rel ease press l oad sl owl y and compl etel y (Fi g.
147).
(7) Remove Speci al Tool 6227-1. Then remove
cl utch pack from hub (Fi g. 147).
Fig. 144 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
Fig. 145 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
3 - DIRECT CLUTCH PACK SNAP-RING
4 - PRESS PLATES
5 - CLUTCH DRUM
Fig. 146 Direct Clutch Hub Retaining Ring Removal
2 - CLUTCH HUB RETAINING RING
3 - PRESS BED
4 - PRESS PLATES
GEARTRAIN
(1) Remove di rect cl utch hub and spri ng (Fi g. 148).
(2) Remove sun gear and spri ng pl ate. Then
remove pl anetary thrust beari ng and pl anetary gear
(Fi g. 149).
(3) Remove overrunni ng cl utch assembl y wi th
expandi ng type snap-ri ng pl i ers (Fi g. 150). I nsert pl i -
ers i nto cl utch hub. Expand pl i ers to gri p hub spl i nes
and remove cl utch wi th countercl ockwi se, twi sti ng
moti on.
(4) Remove thrust beari ng from overrunni ng
cl utch hub.
(5) Remove overrunni ng cl utch from hub.
(6) Mark posi ti on of annul us gear and di rect cl utch
drum for assembl y al i gnment reference (Fi g. 151).
Use smal l center punch or scri ber to make al i gnment
marks.
Fig. 147 Direct Clutch Pack Removal
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 148 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
Fig. 149 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
Fig. 150 Overrunning Clutch
1 - OVERRUNNING CLUTCH
2 - NEEDLE BEARING
(7) Remove di rect cl utch drum rear retai ni ng ri ng
(Fi g. 152).
(8) Remove di rect cl utch drum outer retai ni ng ri ng
(Fi g. 153).
(9) Mark annul us gear and output shaft for assem-
bl y al i gnment reference (Fi g. 154). Use punch or
scri ber to mark gear and shaft.
(10) Remove snap-ri ng that secures annul us gear
on output shaft (Fi g. 155). Use two screwdri vers to
unseat and work snap-ri ng out of groove as shown.
(11) Remove annul us gear from output shaft (Fi g.
156). Use rawhi de or pl asti c mal l et to tap gear off
shaft.
GEAR CASE AND PARK LOCK
(1) Remove l ocati ng ri ng from gear case.
(2) Remove park pawl shaft retai ni ng bol t and
remove shaft, pawl and spri ng.
(3) Remove reacti on pl ug snap-ri ng and remove
reacti on pl ug.
(4) Remove output shaft seal .
Fig. 151 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
Fig. 152 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
3 - ANNULUS GEAR
Fig. 153 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 154 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
CLEANING
Cl ean the geartrai n and case components wi th sol -
vent. Dry al l parts except the beari ngs wi th com-
pressed ai r. Al l ow beari ngs to ai r dry.
Do not use shop towel s for wi pi ng parts dry unl ess
the towel s are made from a l i nt-free materi al . A suf-
fi ci ent quanti ty of l i nt (from shop towel s, cl oths, rags,
etc.) coul d pl ug the transmi ssi on fi l ter and fl ui d pas-
sages.
Di scard the ol d case gasket and seal s. Do not
attempt to sal vage these parts. They are not reus-
abl e. Repl ace any of the overdri ve uni t snap-ri ngs i f
di storted or damaged.
Mi nor ni cks or scratches on components can be
smoothed wi th crocus cl oth. However, do not attempt
to reduce severe scori ng on any components wi th
abrasi ve materi al s. Repl ace severel y scored compo-
nents; do not try to sal vage them.
INSPECTION
Check condi ti on of the park l ock components and
the overdri ve case.
Check the bushi ngs i n the overdri ve case. Repl ace
the bushi ngs i f severel y scored or worn. Al so repl ace
the case seal i f l oose, di storted, or damaged.
Exami ne the overdri ve and di rect cl utch di scs and
pl ates. Repl ace the di scs i f the faci ng i s worn,
severel y scored, or burned and fl aki ng off. Repl ace
the cl utch pl ates i f worn, heavi l y scored, or cracked.
Check the l ugs on the cl utch pl ates for wear. The
pl ates shoul d sl i de freel y i n the drum. Repl ace the
pl ates or drum i f bi ndi ng occurs.
Check condi ti on of the annul us gear, di rect cl utch
hub, cl utch drum and cl utch spri ng. Repl ace the gear,
hub and drum i f worn or damaged. Repl ace the
spri ng i f col l apsed, di storted, or cracked.
Be sure the spl i nes and l ugs on the gear, drum and
hub are i n good condi ti on. The cl utch pl ates and
di scs shoul d sl i de freel y i n these components.
I nspect the thrust beari ngs and spri ng pl ate.
Repl ace the pl ate i f worn or scored. Repl ace the bear-
i ngs i f rough, noi sy, bri nnel l ed, or worn.
I nspect the pl anetary gear assembl y and the sun
gear and bushi ngs. I f ei ther the sun gear or the
bushi ngs are damaged, repl ace the gear and bush-
i ngs as an assembl y. The gear and bushi ngs are not
servi ced separatel y.
The pl anetary carri er and pi ni ons must be i n good
condi ti on. Al so be sure the pi ni on pi ns are secure and
i n good condi ti on. Repl ace the carri er i f worn or dam-
aged.
I nspect the overrunni ng cl utch and race. The race
surface shoul d be smooth and free of scores. Repl ace
the overrunni ng cl utch assembl y or the race i f ei ther
assembl y i s worn or damaged i n any way.
Repl ace the shaft pi l ot bushi ng and i nner bushi ng
i f damaged. Repl ace ei ther shaft beari ng i f rough or
noi sy. Repl ace the beari ng snap-ri ngs i f di storted or
cracked.
Check the machi ned surfaces on the output shaft.
These surfaces shoul d cl ean and smooth. Very mi nor
ni cks or scratches can be smoothed wi th crocus cl oth.
Repl ace the shaft i f worn, scored or damaged i n any
way.
I nspect the output shaft bushi ngs. The smal l bush-
i ng i s the i ntermedi ate shaft pi l ot bushi ng. The l arge
bushi ng i s the overrunni ng cl utch hub bushi ng.
Repl ace ei ther bushi ng i f scored, pi tted, cracked, or
worn.
Fig. 155 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 156 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak di rect cl utch and overdri ve cl utch di scs i n
MoparATF +4, type 9602, transmi ssi on fl ui d. Al l ow
di scs to soak for 10-20 mi nutes.
(2) I nstal l new pi l ot bushi ng and cl utch hub bush-
i ng i n output shaft i f necessary (Fi g. 157). Lubri cate
bushi ngs wi th petrol eum jel l y, or transmi ssi on fl ui d.
(3) I nstal l annul us gear on output shaft, i f
removed. Then i nstal l annul us gear retai ni ng snap-
ri ng (Fi g. 158).
(4) Al i gn and i nstal l cl utch drum on annul us gear
(Fi g. 159). Be sure drum i s engaged i n annul us gear
l ugs.
(5) I nstal l cl utch drum outer retai ni ng ri ng (Fi g.
159).
(6) Sl i de cl utch drum forward and i nstal l i nner
retai ni ng ri ng (Fi g. 160).
(7) I nstal l rear beari ng and snap-ri ng on output
shaft (Fi g. 161). Be sure l ocati ng ri ng groove i n bear-
i ng i s toward rear.
Fig. 157 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
Fig. 158 Annulus Gear Installation
1 - SNAP-RING
3 - ANNULUS GEAR
Fig. 159 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
(8) I nstal l overrunni ng cl utch on hub (Fi g. 162).
Note that cl utch onl y fi ts one-way. Shoul der on cl utch
shoul d seat i n smal l recess at edge of hub.
(9) I nstal l thrust beari ng on overrunni ng cl utch
hub. Use generous amount of petrol eum jel l y to hol d
beari ng i n pl ace for i nstal l ati on. Beari ng fi ts one-way
onl y. Be sure beari ng i s seated squarel y agai nst hub.
Rei nstal l beari ng i f i t does not seat squarel y.
(10) I nstal l overrunni ng cl utch i n output shaft
(Fi g. 163). I nsert snap-ri ng pl i ers i n hub spl i nes.
Expand pl i ers to gri p hub. Then i nstal l assembl y
wi th countercl ockwi se, twi sti ng moti on.
(11) I nstal l pl anetary gear i n annul us gear (Fi g.
164). Be sure pl anetary pi ni ons are ful l y seated i n
annul us gear before proceedi ng.
(12) Coat pl anetary thrust beari ng and beari ng
contact surface of spri ng pl ate wi th generous amount
of petrol eum jel l y. Thi s wi l l hel p hol d beari ng i n
pl ace duri ng i nstal l ati on.
Fig. 160 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 161 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
Fig. 162 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
Fig. 163 Overrunning Clutch Installation
1 - CLUTCH DRUM
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
(13) I nstal l pl anetary thrust beari ng on sun gear
(Fi g. 165). Sl i de beari ng onto gear and seat i t agai nst
spri ng pl ate as shown. Beari ng fi ts one-way onl y. I f i t
does not seat squarel y agai nst spri ng pl ate, remove
and reposi ti on beari ng.
(14) I nstal l assembl ed sun gear, spri ng pl ate and
thrust beari ng (Fi g. 166). Be sure sun gear and
thrust beari ng are ful l y seated before proceedi ng.
(15) Mount assembl ed output shaft, annul us gear,
and cl utch drum i n shop press. Di rect cl utch spri ng,
hub and cl utch pack are easi er to i nstal l wi th assem-
bl y mounted i n press.
(16) Al i gn spl i nes i n hubs of pl anetary gear and
overrunni ng cl utch wi th Al i gnment tool 6227-2 (Fi g.
167). I nsert tool through sun gear and i nto spl i nes of
both hubs. Be sure al i gnment tool i s ful l y seated
before proceedi ng.
(17) I nstal l di rect cl utch spri ng (Fi g. 168). Be sure
spri ng i s properl y seated on spri ng pl ate.
NOTE: The 42RE transmission has 6 direct clutch
discs and 5 clutch plates.
Fig. 164 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 165 Planetary Thrust Bearing Installation
1 - SPRING PLATE
3 - SUN GEAR
Fig. 166 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
Fig. 167 Alignment Tool Installation
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
(18) Assembl e and i nstal l di rect cl utch pack on
hub as fol l ows:
(a) Assembl e cl utch pack components (Fi g. 169).
(b) I nstal l di rect cl utch reacti on pl ate on cl utch
hub fi rst. Note that one si de of reacti on pl ate i s
counterbored. Be sure thi s si de faces rearward.
Spl i nes at rear of hub are rai sed sl i ghtl y. Counter-
bore i n pl ate fi ts over rai sed spl i nes. Pl ate shoul d
be fl ush wi th thi s end of hub (Fi g. 170).
(c) I nstal l fi rst cl utch di sc fol l owed by a steel
pl ate unti l al l di scs and pl ates have been i nstal l ed.
(d) I nstal l pressure pl ate. Thi s i s l ast cl utch
pack i tem to be i nstal l ed. Be sure pl ate i s i nstal l ed
wi th shoul der si de faci ng upward (Fi g. 171).
(19) I nstal l cl utch hub and cl utch pack on di rect
cl utch spri ng (Fi g. 172). Be sure hub i s started on
sun gear spl i nes before proceedi ng.
WARNING: THE NEXT STEP IN GEARTRAIN ASSEM-
BLY INVOLVES COMPRESSING THE DIRECT CLUTCH
HUB AND SPRING. IT IS EXTREMELY IMPORTANT
THAT PROPER EQUIPMENT BE USED TO COM-
PRESS THE SPRING AS SPRING FORCE IS APPROX-
IMATELY 830 POUNDS. USE COMPRESSOR TOOL
C-6227-1 AND A HYDRAULIC-TYPE SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 6 INCHES. THE
PRESS MUST ALSO HAVE A BED THAT CAN BE
ADJUSTED UP OR DOWN AS REQUIRED. RELEASE
CLUTCH SPRING TENSION SLOWLY AND COM-
PLETELY TO AVOID PERSONAL INJURY.
Fig. 169 42RE Direct Clutch Pack Components
Fig. 168 Direct Clutch Spring Installation
3 - CLUTCH HUB
4 - PRESS PLATES
(20) Posi ti on Compressor Tool 6227-1 on cl utch
hub.
(21) Compress cl utch hub and spri ng just enough
to pl ace tensi on on hub and hol d i t i n pl ace.
(22) Sl owl y compress cl utch hub and spri ng. Com-
press spri ng and hub onl y enough to expose ri ng
grooves for cl utch pack snap ri ng and cl utch hub
retai ni ng ri ng.
(23) Real i gn cl utch pack on hub and seat cl utch
di scs and pl ates i n cl utch drum.
(24) I nstal l di rect cl utch pack snap-ri ng (Fi g. 173).
Be very sure snap-ri ng i s ful l y seated i n cl utch drum
ri ng groove.
(25) I nstal l cl utch hub retai ni ng ri ng (Fi g. 174). Be
very sure retai ni ng ri ng i s ful l y seated i n sun gear
ri ng groove.
(26) Sl owl y rel ease press ram, remove compressor
tool s and remove geartrai n assembl y.
Fig. 170 Correct Position Of Direct Clutch Reaction
Plate
1 - REACTION PLATE COUNTERBORE
2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF
HUB)
3 - CLUTCH HUB
Fig. 171 Correct Position Of Direct Clutch Pressure
Plate
1 - DIRECT CLUTCH PRESSURE PLATE
2 - CLUTCH PACK
3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
Fig. 172 Direct Clutch
1 - CLUTCH HUB
3 - CLUTCH DRUM
GEAR CASE
(1) Posi ti on park pawl and spri ng i n case and
i nstal l park pawl shaft. Veri fy that end of spri ng
wi th 90 bend i s hooked to pawl and strai ght end of
spri ng i s seated agai nst case.
(2) I nstal l pawl shaft retai ni ng bol t. Ti ghten bol t
(3) I nstal l park l ock reacti on pl ug. Note that pl ug
has l ocati ng pi n at rear (Fi g. 175). Be sure pi n i s
seated i n hol e i n case before i nstal l i ng snap-ri ng.
(4) I nstal l reacti on pl ug snap-ri ng (Fi g. 176). Com-
press snap ri ng onl y enough for i nstal l ati on; do not
di stort i t.
(5) I nstal l new seal i n gear case. On 4x4 gear case,
use Tool Handl e C-4171 and I nstal l er C-3860-A to
seat seal i n case. On 4 x 2 gear case, use same Han-
dl e C-4171 and I nstal l er C-3995-A to seat seal i n
case.
(6) Veri fy that tab ends of rear beari ng l ocati ng
ri ng extend i nto access hol e i n gear case (Fi g. 177).
(7) Support geartrai n on Tool 6227-1 (Fi g. 178). Be
sure tool i s securel y seated i n cl utch hub.
(8) I nstal l overdri ve gear case on geartrai n (Fi g.
178).
(9) Expand front beari ng l ocati ng ri ng wi th snap-
ri ng pl i ers (Fi g. 179). Then sl i de case downward unti l
l ocati ng ri ng l ocks i n beari ng groove and rel ease
snap-ri ng.
(10) I nstal l l ocati ng ri ng access cover and gasket
i n overdri ve uni t case (Fi g. 180).
Fig. 173 Direct Clutch Pack Snap-Ring Installation
Fig. 174 Clutch Hub Retaining Ring Installation
Fig. 175 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
Fig. 176 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
2 - SNAP-RING PLIERS
OVERDRIVE CLUTCH
(1) I nstal l overdri ve cl utch reacti on ri ng fi rst.
Reacti on ri ng i s fl at wi th notched ends (Fi g. 181).
(2) I nstal l wave spri ng on top of reacti on ri ng (Fi g.
182). Reacti on ri ng and wave ri ng both fi t i n same
ri ng groove. Use screwdri ver to seat each ri ng
securel y i n groove. Al so ensure that the ends of the
two ri ngs are offset from each other.
NOTE: The 42RE transmission has 3 overdrive
clutch discs and 2 plates.
(3) Assembl e overdri ve cl utch pack (Fi g. 183).
(4) I nstal l overdri ve cl utch reacti on pl ate fi rst.
NOTE: The reaction plate is thinner than the pres-
sure plate in a 42RE transmission.
Fig. 177 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 178 Overdrive Gear Case Installation
2 - GEAR CASE
Fig. 179 Seating Locating Ring In Rear Bearing
PLIERS
2 - ACCESS HOLE
Fig. 180 Locating Ring Access Cover And Gasket
Installation
Fig. 181 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
(5) I nstal l fi rst cl utch di sc fol l owed by fi rst cl utch
pl ate. Then i nstal l remai ni ng cl utch di scs and pl ates
i n same order.
(6) I nstal l cl utch pack pressure pl ate.
(7) I nstal l cl utch pack wi re-type retai ni ng ri ng
(Fi g. 184).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness i ntermedi ate shaft
spacer as fol l ows:
(a) I nsert Speci al Tool 6312 through sun gear,
pl anetary gear and i nto pi l ot bushi ng i n output
shaft. Be sure tool bottoms agai nst pl anetary
shoul der.
(b) Posi ti on Gauge Tool 6311 across face of over-
dri ve case (Fi g. 185). Then posi ti on Di al Cal i per
C-4962 over gauge tool .
Fig. 183 42RE Overdrive Clutch Components
Fig. 182 Overdrive Clutch Wave Spring Installation
1 - WAVE SPRING
Fig. 184 Overdrive Clutch Pack Retaining Ring
Installation
(c) Extend sl i di ng scal e of di al cal i per downward
through gauge tool sl ot unti l scal e contacts end of
Gauge Al i gnment Tool 6312. Lock scal e i n pl ace.
Remove di al cal i per tool and note di stance mea-
sured (Fi g. 185).
(d) Sel ect proper thi ckness end pl ay spacer from
spacer chart based on di stance measured (Fi g.
186).
(e) Remove Gauge Al i gnment Tool 6312.
OD THRUST PLATE SELECTION
(2) Determi ne correct thi ckness overdri ve pi ston
thrust pl ate as fol l ows:
(a) Posi ti on Gauge Tool 6311 across face of over-
dri ve case. Then posi ti on Di al Cal i per C-4962 over
gauge tool (Fi g. 187).
(b) Measure di stance to cl utch hub thrust bear-
i ng seat at four poi nts 90 apart. Then average
measurements by addi ng them and di vi di ng by 4.
(c) Sel ect and i nstal l requi red thrust pl ate from
i nformati on i n thrust pl ate chart (Fi g. 188).
(3) Leave Al i gnment Tool 6227-2 i n pl ace. Tool wi l l
keep pl anetary and cl utch hub spl i nes i n al i gnment
unti l overdri ve uni t i s ready for i nstal l ati on on trans-
mi ssi on.
(4) Transmi ssi on speed sensor can be i nstal l ed at
thi s ti me i f desi red. However, i t i s recommended that
sensor not be i nstal l ed unti l after overdri ve uni t i s
secured to transmi ssi on.
Fig. 185 Shaft End Play Measurement
Fig. 186 Intermediate Shaft End Play Spacer
Selection
Fig. 187 Overdrive Piston Thrust Plate Measurement
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
Fig. 188 Overdrive Piston Thrust Plate Selection
OVERDRIVE PISTON
(1) I nstal l new seal s on over dri ve pi ston.
(2) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(3) Posi ti on Gui de Ri ng 8114-1 on outer edge of
overdri ve pi ston retai ner.
(4) Posi ti on Seal Gui de 8114-2 on i nner edge of
(5) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by: al i gni ng l ocati ng l ugs on overdri ve pi ston
to the two mati ng hol es i n retai ner.
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th
MoparDoor Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 8114-2 and
i nsi de Gui de Ri ng 8114-1.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
(6) I nstal l i ntermedi ate shaft spacer on i ntermedi -
ate shaft.
(7) I nstal l overdri ve pi ston thrust pl ate on over-
dri ve pi ston.
(8) I nstal l overdri ve pi ston thrust beari ng on over-
dri ve pi ston.
(9) I nstal l transmi ssi on speed sensor and O-ri ng
seal i n overdri ve case (Fi g. 129).
INSTALLATION
(1) Be sure overdri ve uni t Al i gnment Tool 6227-2
i s ful l y seated before movi ng uni t. I f tool i s not
seated and gear spl i nes rotate out of al i gnment, over-
dri ve uni t wi l l have to be di sassembl ed i n order to
real i gn spl i nes.
(2) I f overdri ve pi ston retai ner was not removed
duri ng servi ce and ori gi nal case gasket i s no l onger
reusabl e, prepare new gasket by tri mmi ng i t.
(3) Cut out ol d case gasket around pi ston retai ner
wi th razor kni fe (Fi g. 189).
(4) Use ol d gasket as templ ate and tri m new gas-
ket to fi t.
(5) Posi ti on new gasket over pi ston retai ner and
on transmi ssi on case. Use petrol eum jel l y to hol d
gasket i n pl ace i f necessary. Do not use any type of
seal er to secure gasket. Use petrol eum jel l y onl y.
(6) I nstal l sel ecti ve spacer on i ntermedi ate shaft, i f
removed. Spacer goes i n groove just rearward of
shaft rear spl i nes (Fi g. 190).
(7) I nstal l thrust beari ng i n overdri ve uni t sl i di ng
hub. Use petrol eum jel l y to hol d beari ng i n posi ti on.
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Veri fy that spl i nes i n overdri ve pl anetary gear
and overrunni ng cl utch hub are al i gned wi th Al i gn-
ment Tool 6227-2. Overdri ve uni t cannot be i nstal l ed
i f spl i nes are not al i gned. I f spl i nes have rotated out
of al i gnment, uni t wi l l have to be di sassembl ed to
(9) Careful l y sl i de Al i gnment Tool 6227-2 out of
overdri ve pl anetary gear and overrunni ng cl utch
spl i nes.
(10) Rai se overdri ve uni t and careful l y sl i de i t
strai ght onto i ntermedi ate shaft. I nsert park rod i nto
park l ock reacti on pl ug at same ti me. Avoi d ti l ti ng
overdri ve duri ng i nstal l ati on as thi s coul d cause
pl anetary gear and overrunni ng cl utch spl i nes to
rotate out of al i gnment. I f thi s occurs, i t wi l l be nec-
essary to remove and di sassembl e overdri ve uni t to
Fig. 189 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 190 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
(11) Work overdri ve uni t forward on i ntermedi ate
shaft unti l seated agai nst transmi ssi on case.
(12) I nstal l bol ts attachi ng overdri ve uni t to trans-
mi ssi on uni t. Ti ghten bol ts i n di agonal pattern to 34
Nm (25 ft-l bs).
(13) Connect the transmi ssi on speed sensor and
overdri ve wi ri ng connectors.
(14) I nstal l the transfer case, i f equi pped.
(15) Al i gn and i nstal l rear propel l er shaft, i f nec-
essary. (Refer to 3 - DI FFERENTI AL & DRI VELI NE/
PROPELLER SHAFT/PROPELLER SHAFT -
I NSTALLATI ON)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunni ng cl utch (Fi g. 191) consi sts of an
i nner race, an outer race (or cam), rol l ers and
spri ngs, and the spri ng retai ner. The number of rol l -
ers and spri ngs depends on what transmi ssi on and
whi ch overrunni ng cl utch i s bei ng deal t wi th.
OPERATION
As the i nner race i s rotated i n a cl ockwi se di recti on
(as vi ewed from the front of the transmi ssi on), the
race causes the rol l ers to rol l toward the spri ngs,
causi ng them to compress agai nst thei r retai ner. The
compressi on of the spri ngs i ncreases the cl earance
between the rol l ers and cam. Thi s i ncreased cl ear-
ance between the rol l ers and cam resul ts i n a free-
wheel i ng condi ti on. When the i nner race attempts to
rotate countercl ockwi se, the acti on causes the rol l ers
to rol l i n the same di recti on as the race, ai ded by the
pushi ng of the spri ngs. As the rol l ers try to move i n
the same di recti on as the i nner race, they are
wedged between the i nner and outer races due to the
desi gn of the cam. I n thi s condi ti on, the cl utch i s
l ocked and acts as one uni t.
DISASSEMBLY
NOTE: To service the overrunning clutch cam and
the overdrive piston retainer, the transmission
geartrain and the overdrive unit must be removed
from the transmission.
(1) Remove the overdri ve pi ston (Fi g. 192).
(2) Remove the overdri ve pi ston retai ner bol ts.
(3) Remove overdri ve pi ston retai ner.
(4) Remove case gasket.
(5) Mark the posi ti on of the overrunni ng cl utch
cam i n the case (Fi g. 193).
(6) Remove the overrunni ng cl utch cam bol ts.
(7) Remove the overrunni ng cl utch cam.
CLEANING
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
INSPECTION
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
1 - OVERDRIVE CLUTCH PISTON
4 - PISTON RETAINER
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
ASSEMBLY
(1) Exami ne bol t hol es i n overrunni ng cl utch cam.
Note that one hol e i s not threaded (Fi g. 194). Thi s
hol e must al i gn wi th bl ank area i n cl utch cam bol t
ci rcl e (Fi g. 195). Mark hol e l ocati on on cl utch cam
and bl ank area i n case wi th grease penci l , pai nt
stri pe, or scri be mark for assembl y reference.
(2) Mark l ocati on of non-threaded hol e i n cl utch
cam and bl ank area i n bol t ci rcl e wi th grease penci l .
(3) Al i gn and i nstal l overrunni ng cl utch and cam
i n case (Fi g. 196). Be sure cam i s correctl y i nstal l ed.
Bol t hol es i n cam are sl i ghtl y countersunk on one
si de. Be sure thi s si de of cam faces rearward (toward
pi ston retai ner).
(4) Veri fy that non-threaded hol e i n cl utch cam i s
properl y al i gned. Check al i gnment by threadi ng a
bol t i nto each bol t hol e. Adjust cl utch cam posi ti on i f
necessary.
(5) I nstal l and ti ghten overrunni ng cl utch cam
bol ts to 17 Nm (13 ft. l bs.) torque. Note that cl utch
cam bol ts are shorter than pi ston retai ner bol ts.
(6) I nstal l new gasket at rear of transmi ssi on case.
Use petrol eum jel l y to hol d gasket i n pl ace. Be sure
to al i gn governor feed hol es i n gasket wi th feed pas-
sages i n case (Fi g. 197). Al so i nstal l gasket before
overdri ve pi ston retai ner. Center hol e i n gasket i s
smal l er than retai ner and cannot be i nstal l ed over
retai ner.
Fig. 193 Overrunning Clutch Cam Removal
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
Fig. 194 Location Of Non-Threaded Hole In Clutch
Cam
1 - NON-THREADED HOLE
2 - OVERRUNNING CLUTCH CAM
Fig. 195 Location Of Blank Area In Clutch Cam Bolt
Circle
1 - OVERRUNNING CLUTCH CAM SEAT IN CASE
2 - NON-THREADED HOLE IN CLUTCH CAM ALIGNS HERE
(BLANK AREA) OF SEAT
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)
(7) Posi ti on overdri ve pi ston retai ner on transmi s-
si on case and al i gn bol t hol es i n retai ner, gasket and
case (Fi g. 198). Then i nstal l and ti ghten retai ner
(8) I nstal l new seal s on over dri ve pi ston.
i ng.
(b) Lubri cate overdri ve pi ston seal s wi th
MoparDoor Ease, or equi val ent.
retai ner.
NOTE: Install the remaining transmission compo-
nents and the overdrive unit.
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
Fig. 197 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
Fig. 198 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches, whi l e others are used to appl y bands.
They al l have i n common the fact that they are
round or ci rcul ar i n shape, l ocated wi thi n a smooth
wal l ed cyl i nder, whi ch i s cl osed at one end and con-
verts fl ui d pressure i nto mechani cal movement. The
fl ui d pressure exerted on the pi ston i s contai ned
wi thi n the system through the use of pi ston ri ngs or
seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e
i s known as Pascal s Law. Pascal s Law can be stated
as: Pressure on a confi ned fl ui d i s transmi tted
equal l y i n al l di recti ons and acts wi th equal force on
equal areas.
PRESSURE
Pressure (Fi g. 199) i s nothi ng more than force
(l bs.) di vi ded by area (i n or ft.), or force per uni t
area. Gi ven a 100 l b. bl ock and an area of 100 sq. i n.
on the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 200)
by appl yi ng a force to some gi ven area i n contact
wi th the fl ui d. A good exampl e of thi s i s a cyl i nder
fi l l ed wi th fl ui d and equi pped wi th a pi ston that i s
cl osel y fi tted to the cyl i nder wal l . I f a force i s appl i ed
to the pi ston, pressure wi l l be devel oped i n the fl ui d.
Of course, no pressure wi l l be created i f the fl ui d i s
not confi ned. I t wi l l si mpl y l eak past the pi ston.
There must be a resi stance to fl ow i n order to create
pressure. Pi ston seal i ng i s extremel y i mportant i n
hydraul i c operati on. Several ki nds of seal s are used
to accompl i sh thi s wi thi n a transmi ssi on. These
i ncl ude but are not l i mi ted to O-ri ngs, D-ri ngs, l i p
seal s, seal i ng ri ngs, or extremel y cl ose tol erances
between the pi ston and the cyl i nder wal l . The force
exerted i s downward (gravi ty), however, the pri nci pl e
remai ns the same no matter whi ch di recti on i s taken.
The pressure created i n the fl ui d i s equal to the force
appl i ed, di vi ded by the pi ston area. I f the force i s 100
l bs., and the pi ston area i s 10 sq. i n., then the pres-
sure created equal s 10 PSI . Another i nterpretati on of
Pascal s Law i s that regardl ess of contai ner shape or
si ze, the pressure wi l l be mai ntai ned throughout, as
l ong as the fl ui d i s confi ned. I n other words, the
pressure i n the fl ui d i s the same everywhere wi thi n
the contai ner.
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 201), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 201), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
Fig. 199 Force and Pressure Relationship
Fig. 200 Pressure on a Confined Fluid
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i ts a wei ght-to-di stance output rather than a
pressure-to-area output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 202) has to move ten ti mes the di stance
requi red to move the l arger pi ston one i nch. There-
fore, for every i nch the l arger pi ston moves, the
smal l er pi ston moves ten i nches. Thi s pri nci pl e i s
true i n other i nstances al so. A common garage fl oor
jack i s a good exampl e. To rai se a car wei ghi ng 2000
l bs., an effort of onl y 100 l bs. may be requi red. For
every i nch the car moves upward, the i nput pi ston at
the jack handl e must move 20 i nches downward.
PLANETARY GEARTRAIN/
OUTPUT SHAFT
DESCRIPTION
The pl anetary gearsets (Fi g. 203) are desi gnated as
the front, rear, and overdri ve pl anetary gear assem-
bl i es and l ocated i n such order. A si mpl e pl anetary
gearset consi sts of three mai n members:
The sun gear whi ch i s at the center of the sys-
tem.
Fig. 201 Force Multiplication
Fig. 202 Piston Travel
Fig. 203 Planetary Gearset
1 - ANNULUS GEAR
2 - SUN GEAR
3 - PLANET CARRIER
4 - PLANET PINIONS (4)
PISTONS (Continued)
The pl anet carri er wi th pl anet pi ni on gears
whi ch are free to rotate on thei r own shafts and are
i n mesh wi th the sun gear.
The annul us gear, whi ch rotates around and i s
i n mesh wi th the pl anet pi ni on gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
Wi th any gi ven pl anetary gearset, several condi -
ti ons must be met for power to be abl e to fl ow:
One member must be hel d.
Another member must be dri ven or used as an
i nput.
The thi rd member may be used as an output for
power fl ow.
For di rect dri ve to occur, two gear members i n
the front pl anetary gearset must be dri ven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
DISASSEMBLY
(1) Remove pl anetary snap-ri ng (Fi g. 204).
(2) Remove front annul us and pl anetary assembl y
from dri vi ng shel l (Fi g. 204).
(3) Remove snap-ri ng that retai ns front pl anetary
gear i n annul us gear (Fi g. 205).
(4) Remove tabbed thrust washer and tabbed
thrust pl ate from hub of front annul us (Fi g. 206).
(5) Separate front annul us and pl anetary gears
(Fi g. 206).
(6) Remove front pl anetary gear front thrust
washer from annul us gear hub.
(7) Separate and remove dri vi ng shel l , rear pl ane-
tary and rear annul us from output shaft (Fi g. 207).
(8) Remove front pl anetary rear thrust washer
from dri vi ng shel l .
(9) Remove tabbed thrust washers from rear pl an-
etary gear.
(10) Remove l ock ri ng that retai ns sun gear i n
dri vi ng shel l . Then remove sun gear, spacer and
thrust pl ates.
INSPECTION
Check sun gear and dri vi ng shel l condi ti on.
Repl ace the gear i f damaged or i f the bushi ngs are
scored or worn. The bushi ngs are not servi ceabl e.
Repl ace the dri vi ng shel l i f worn, cracked or dam-
aged.
Repl ace pl anetary gear sets i f gears, pi ni on pi ns, or
carri er are damaged i n any way. Repl ace the annul us
gears and supports i f ei ther component i s worn or
damaged.
Fig. 204 Front Annulus And Planetary Assembly
Removal
1 - DRIVING SHELL
2 - FRONT ANNULUS AND PLANETARY ASSEMBLY
3 - PLANETARY SNAP-RING
Fig. 205 Front Planetary Snap-Ring Removal
1 - FRONT ANNULUS GEAR
Fig. 206 Front Planetary And Annulus Gear
Disassembly
1 - FRONT ANNULUS
2 - THRUST WASHER
3 - THRUST PLATE
4 - FRONT THRUST WASHER
5 - FRONT PLANETARY
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)
I nspect the geartrai n spacers, thrust pl ates, snap-
ri ngs, and thrust washers. Repl ace any of these parts
that are worn, di storted or damaged. Do not attempt
to reuse these parts.
The pl anetary gear thrust washers are di fferent
si zes. The l arge di ameter washers go on the front
pl anetary and the smal l er washers go on the rear
pl anetary. Al l the washers have four l ocati ng tabs on
them. These tabs fi t i n the hol es or sl ots provi ded i n
each pl anetary gear.
I nspect the output shaft careful l y. Pay parti cul ar
attenti on to the machi ned bushi ng/beari ng surfaces
on the shaft and the governor val ve shaft bore at the
shaft rear.
Repl ace the output shaft i f the machi ned surfaces
are scored, pi tted, or damaged i n any way. Al so
repl ace the shaft i f the spl i nes are damaged, or
exhi bi ts cracks at any l ocati on (especi al l y at the gov-
ernor val ve shaft bore).
The annul us gears can be removed from thei r sup-
ports i f necessary. Just remove the snap-ri ngs and
separate the two parts when repl acement i s neces-
sary. I n addi ti on, the annul us gear bushi ngs can be
repl aced i f severel y worn, or scored. However i t i s not
necessary to repl ace the bushi ngs i f they onl y exhi bi t
normal wear. Check bushi ng fi t on the output shaft
to be sure.
ASSEMBLY
(1) Lubri cate output shaft and pl anetary compo-
nents wi th transmi ssi on fl ui d. Use petrol eum jel l y to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on.
(2) Assembl e rear annul us gear and support i f di s-
assembl ed. Be sure support snap-ri ng i s seated and
that shoul der-si de of support faces rearward (Fi g.
208).
(3) I nstal l rear thrust washer on rear pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace. Al so be sure al l four washer tabs are properl y
engaged i n gear sl ots.
(4) I nstal l rear annul us over and onto rear pl ane-
tary gear (Fi g. 208).
(5) I nstal l assembl ed rear pl anetary and annul us
gear on output shaft (Fi g. 209). Veri fy that assembl y
i s ful l y seated on shaft.
(6) I nstal l front thrust washer on rear pl anetary
gear (Fi g. 210). Use enough petrol eum jel l y to hol d
washer on gear. Be sure al l four washer tabs are
seated i n sl ots.
(7) I nstal l spacer on sun gear (Fi g. 211).
(8) I nstal l thrust pl ate on sun gear (Fi g. 212). Note
that dri vi ng shel l thrust pl ates are i nterchangeabl e.
Use ei ther pl ate on sun gear and at front/rear of
shel l .
Fig. 207 Removing Driving Shell, Rear Planetary
And Rear Annulus
1 - REAR ANNULUS
2 - REAR PLANETARY
3 - DRIVING SHELL
4 - OUTPUT SHAFT
Fig. 208 Assembling Rear Annulus And Planetary
Gear
1 - REAR ANNULUS GEAR
2 - TABBED THRUST WASHER
3 - REAR PLANETARY
Fig. 209 Installing Rear Annulus And Planetary On
Output Shaft
1 - REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 - OUTPUT SHAFT
Fig. 210 Installing Rear Planetary Front Thrust
Washer
1 - FRONT TABBED THRUST WASHER
2 - REAR PLANETARY GEAR
Fig. 211 Installing Spacer On Sun Gear
1 - SUN GEAR
2 - SUN GEAR SPACER
Fig. 212 Installing Driving Shell Front Thrust Plate
On Sun Gear
1 - SPACER
2 - SUN GEAR
3 - THRUST PLATE
(9) Hol d sun gear i n pl ace and i nstal l thrust pl ate
over sun gear at rear of dri vi ng shel l (Fi g. 213).
(10) Posi ti on wood bl ock on bench and support sun
gear on bl ock (Fi g. 214). Thi s makes i t easi er to al i gn
and i nstal l sun gear l ock ri ng. Keep wood bl ock
handy as i t wi l l al so be used for geartrai n end pl ay
check.
(11) Al i gn rear thrust pl ate on dri vi ng shel l and
i nstal l sun gear l ock ri ng. Be sure ri ng i s ful l y seated
i n sun gear ri ng groove (Fi g. 215).
(12) I nstal l assembl ed dri vi ng shel l and sun gear
on output shaft (Fi g. 216).
(13) I nstal l rear thrust washer on front pl anetary
gear (Fi g. 217). Use enough petrol eum jel l y to hol d
washer i n pl ace and be sure al l four washer tabs are
seated.
(14) I nstal l front pl anetary gear on output shaft
and i n dri vi ng shel l (Fi g. 218).
(15) I nstal l front thrust washer on front pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace and be sure al l four washer tabs are seated.
Fig. 213 Installing Driving Shell Rear Thrust Plate
1 - DRIVING SHELL
2 - SUN GEAR
3 - REAR THRUST PLATE
Fig. 214 Supporting Sun Gear On Wood Block
1 - SUN GEAR
2 - DRIVING SHELL
3 - WOOD BLOCK
Fig. 215 Installing Sun Gear Lock Ring
1 - LOCK RING GROOVE
2 - SUN GEAR LOCK RING
3 - DRIVING SHELL
4 - REAR THRUST PLATE
(16) Assembl e front annul us gear and support, i f
necessary. Be sure support snap-ri ng i s seated.
(17) I nstal l front annul us on front pl anetary (Fi g.
218).
(18) Posi ti on thrust pl ate on front annul us gear
support (Fi g. 219). Note that pl ate has two tabs on i t.
These tabs fi t i n notches of annul us hub.
(19) I nstal l thrust washer i n front annul us (Fi g.
220). Al i gn fl at on washer wi th fl at on pl anetary hub.
Al so be sure washer tab i s faci ng up.
(20) I nstal l front annul us snap-ri ng (Fi g. 221). Use
snap-ri ng pl i ers to avoi d di storti ng ri ng duri ng
i nstal l ati on. Al so be sure ri ng i s ful l y seated.
(21) I nstal l pl anetary sel ecti ve snap-ri ng wi th
snap-ri ng pl i ers (Fi g. 222). Be sure ri ng i s ful l y
seated.
(22) Turn pl anetary geartrai n assembl y over so
dri vi ng shel l i s faci ng workbench. Then support
geartrai n on wood bl ock posi ti oned under forward
end of output shaft. Thi s al l ows geartrai n compo-
nents to move forward for accurate end pl ay check.
(23) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 223). Gauge goes between shoul der
on output shaft and end of rear annul us support.
(24) Geartrai n end pl ay shoul d be 0.12 to 1.22 mm
(0.005 to 0.048 i n.). I f end pl ay i s i ncorrect, snap-ri ng
(or thrust washers) may have to be repl aced. Snap-
ri ngs are avai l abl e i n three di fferent thi cknesses for
adjustment purposes.
Fig. 216 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
1 - SUN GEAR/DRIVING SHELL ASSEMBLY
2 - OUTPUT SHAFT
Fig. 217 Installing Rear Thrust Washer On Front
Planetary Gear
1 - FRONT PLANETARY GEAR
2 - REAR TABBED THRUST WASHER
Fig. 218 Installing Front Planetary And Annulus
Gears
2 - FRONT THRUST WASHER
Fig. 219 Positioning Thrust Plate On Front Annulus
Support
1 - FRONT ANNULUS
2 - THRUST PLATE
Fig. 220 Installing Front Annulus Thrust Washer
1 - WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB
2 - FRONT ANNULUS THRUST WASHER
3 - TAB FACES FRONT
Fig. 221 Installing Front Annulus Snap-Ring
2 - FRONT ANNULUS SNAP-RING
Fig. 222 Installing Planetary Selective Snap-Ring
1 - SELECTIVE SNAP-RING
Fig. 223 Checking Planetary Geartrain End Play
1 - OUTPUT SHAFT
3 - FEELER GAUGE
REAR CLUTCH
DESCRIPTION
The rear cl utch assembl y (Fi g. 224) i s composed of
the rear cl utch retai ner, pressure pl ate, cl utch pl ates,
dri vi ng di scs, pi ston, Bel l evi l l e spri ng, and snap-
ri ngs. The Bel l evi l l e spri ng acts as a l ever to mul ti -
pl y the force appl i ed on to i t by the appl y pi ston. The
i ncreased appl y force on the rear cl utch pack, i n com-
pari son to the front cl utch pack, i s needed to hol d
agai nst the greater torque l oad i mposed onto the rear
pack. The rear cl utch i s di rectl y behi nd the front
cl utch and i s consi dered a dri vi ng component.
OPERATION
l ugged to the cl utch retai ner. The waved spri ng i s
The snap-ri ng i s sel ecti ve and used to adjust cl utch
pack cl earance.
Fig. 224 Rear Clutch
1 - PISTON SPRING 10 - TOP PRESSURE PLATE
2 - REAR CLUTCH PISTON 11 - CLUTCH DISCS (4)
3 - CLUTCH PISTON SEALS 12 - BOTTOM PRESSURE PLATE
4 - OUTPUT SHAFT THRUST WASHER (METAL) 13 - WAVE SPRING
5 - INPUT SHAFT SNAP-RING 14 - CLUTCH PLATES (3)
6 - REAR CLUTCH RETAINER 15 - RETAINER SEAL RING
7 - INPUT SHAFT 16 - SHAFT REAR SEAL RING (PLASTIC)
8 - REAR CLUTCH THRUST WASHER (FIBER) 17 - SHAFT FRONT SEAL RING (TEFLON)
9 - CLUTCH PACK SNAP-RING (SELECTIVE)
vent and one-way bal l -check-val ve l ocated i n the pi s-
ton. The check-val ve i s needed to el i mi nate the pos-
si bi l i ty of pl ate drag caused by centri fugal force
acti ng on the resi dual fl ui d trapped i n the cl utch pi s-
ton retai ner.
DISASSEMBLY
(1) Remove fi ber thrust washer from forward si de
of cl utch retai ner.
(2) Remove i nput shaft front/rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap-ri ng (Fi g.
225).
(4) Remove top pressure pl ate, cl utch di scs, steel
pl ates, bottom pressure pl ate and wave snap-ri ng
and wave spri ng (Fi g. 225).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft snap-ri ng (Fi g. 226). I t
may be necessary to press the i nput shaft i n sl i ghtl y
to rel i eve tensi on on the snap-ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
CLEANING
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r. Do not use rags or shop
towel s to dry any of the cl utch parts. Li nt from such
materi al s wi l l adhere to component surfaces and
coul d restri ct or bl ock fl ui d passages after assembl y.
Fig. 225 Rear Clutch Components
1 - PISTON SPRING 10 - TOP PRESSURE PLATE
2 - REAR CLUTCH PISTON 11 - CLUTCH DISCS (4)
3 - CLUTCH PISTON SEALS 12 - BOTTOM PRESSURE PLATE
4 - OUTPUT SHAFT THRUST WASHER (METAL) 13 - WAVE SPRING
5 - INPUT SHAFT SNAP-RING 14 - CLUTCH PLATES (3)
6 - REAR CLUTCH RETAINER 15 - RETAINER SEAL RING
7 - INPUT SHAFT 16 - SHAFT REAR SEAL RING (PLASTIC)
8 - REAR CLUTCH THRUST WASHER (FIBER) 17 - SHAFT FRONT SEAL RING (TEFLON)
9 - CLUTCH PACK SNAP-RING (SELECTIVE)
REAR CLUTCH (Continued)
INSPECTION
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off. Repl ace the top and bottom pres-
sure pl ates i f scored, warped, or cracked. Be sure the
dri vi ng l ugs on the pressure and cl utch pl ates are
al so i n good condi ti on. The l ugs must not be bent,
cracked or damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
cl utch and pressure pl ates shoul d sl i de freel y i n the
sl ots. Repl ace the retai ner i f the grooves are worn or
damaged. Al so check acti on of the check bal l s i n the
retai ner and pi ston. Each check bal l must move
freel y and not sti ck.
Repl ace the retai ner bushi ng i f worn, scored, or
doubt exi sts about bushi ng condi ti on.
Check condi ti on of the fi ber thrust washer and
metal output shaft thrust washer. Repl ace ei ther
washer i f worn or damaged.
Check condi ti on of the seal ri ngs on the i nput shaft
and cl utch retai ner hub. Repl ace the seal ri ngs onl y
i f worn, di storted, or damaged. The i nput shaft front
seal ri ng i s tefl on wi th chamfered ends. The rear ri ng
i s metal wi th i nterl ocki ng ends.
Check the i nput shaft for wear, or damage. Repl ace
the shaft i f worn, scored or damaged i n any way.
ASSEMBLY
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft, i f necessary, (Fi g. 227) and (Fi g.
228).
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then press i nput
shaft i nto retai ner (Fi g. 229). Use a sui tabl y si zed
press tool to support retai ner as cl ose to i nput shaft
as possi bl e.
(4) I nstal l i nput shaft snap-ri ng (Fi g. 226).
(5) I nvert retai ner and press i nput shaft i n oppo-
si te di recti on unti l snap-ri ng i s seated.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston (Fi g. 230). Concave si de of spri ng faces down-
ward (toward pi ston).
(10) I nstal l wave spri ng i n retai ner (Fi g. 230). Be
sure spri ng i s compl etel y seated i n retai ner groove.
(11) I nstal l bottom pressure pl ate (Fi g. 225).
Ri dged si de of pl ate faces downward (toward pi ston)
and fl at si de toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
bottom pressure pl ate. Then i nstal l a cl utch pl ate fol -
l owed by a cl utch di sc unti l enti re cl utch pack i s
i nstal l ed (4 di scs and 3 pl ates are requi red) (Fi g.
225).
(13) I nstal l top pressure pl ate.
(14) I nstal l sel ecti ve snap-ri ng. Be sure snap-ri ng
i s ful l y seated i n retai ner groove.
Fig. 226 Removing Input Shaft Snap-Ring
2 - INPUT SHAFT SNAP-RING
Fig. 227 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 - REAR CLUTCH RETAINER HUB SEAL RING
2 - INPUT SHAFT SEAL RINGS
Fig. 228 Input Shaft Seal Ring Identification
1 - PLASTIC REAR SEAL RING
2 - TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
Fig. 229 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
3 - PRESS RAM
Fig. 230 Piston Spring/Wave Spring Position
2 - PISTON SPRING
3 - WAVE SPRING
4 - CLUTCH PISTON
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 231).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 231).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.559 - 0.914 mm (0.022 -
0.036 i n.). I f cl earance i s i ncorrect, steel pl ates, di scs,
sel ecti ve snap ri ng and pressure pl ates may have to
be changed.
The sel ecti ve snap-ri ng thi cknesses are:
0.107-0.109 i n.
0.098-0.100 i n.
0.095-0.097 i n.
0.083-0.085 i n.
0.076-0.078 i n.
0.071-0.073 i n.
0.060-0.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 232). Use enough petrol eum
jel l y to hol d washer i n pl ace.
REAR SERVO
DESCRIPTION
The rear (l ow/reverse) servo consi sts of a si ngl e
stage or di ameter pi ston and a spri ng l oaded pl ug.
The spri ng i s used to cushi on the appl i cati on of the
rear (l ow/reverse) band.
OPERATION
Whi l e i n the de-energi zed state (no pressure
appl i ed), the pi ston i s hel d up i n i ts bore by the pi s-
ton spri ng. The pl ug i s hel d down i n i ts bore, i n the
pi ston, by the pl ug spri ng. When pressure i s appl i ed
to the top of the pi ston, the pl ug i s forced down i n i ts
bore, taki ng up any cl earance. As the pi ston moves, i t
causes the pl ug spri ng to compress, and the pi ston
moves down over the pl ug. The pi ston conti nues to
move down unti l i t hi ts the shoul der of the pl ug and
ful l y appl i es the band. The peri od of ti me from the
i ni ti al appl i cati on, unti l the pi ston i s agai nst the
shoul der of the pl ug, represents a reduced shocki ng
of the band that cushi ons the shi ft.
DISASSEMBLY
(1) Remove smal l snap-ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 233).
(2) Remove and di scard servo pi ston seal ri ng.
Fig. 231 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4 - STAND
5 - REAR CLUTCH
6 - GAUGE BAR
2 - REAR CLUTCH THRUST WASHER
CLEANING
Remove and di scard the servo pi ston seal ri ng (Fi g.
234). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap-ri ngs and use new ones at assembl y.
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s (Fi g. 235)
wi th petrol eum jel l y. Lubri cate other servo parts wi th
MoparATF +4, type 9602, transmi ssi on fl ui d.
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap-
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
SHIFT MECHANISM
DESCRIPTION
The gear shi ft mechani sm provi des si x shi ft posi -
ti ons whi ch are:
PARK (P)
REVERSE (R)
NEUTRAL (N)
DRI VE (D)
Manual SECOND (2)
Manual LOW (1)
OPERATION
Manual LOW (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range. Man-
ual SECOND (2) range provi des fi rst and second gear
onl y.
DRI VE range provi des fi rst, second thi rd and over-
dri ve fourth gear ranges. The shi ft i nto overdri ve
fourth gear range occurs onl y after the transmi ssi on
has compl eted the shi ft i nto D thi rd gear range. No
further movement of the shi ft mechani sm i s requi red
to compl ete the 3-4 shi ft.
The fourth gear upshi ft occurs automati cal l y when
the overdri ve sel ector swi tch i s i n the ON posi ti on.
No upshi ft to fourth gear wi l l occur i f any of the fol -
l owi ng are true:
The transmi ssi on fl ui d temperature i s bel ow 10
C (50 F) or above 121 C (250 F).
The shi ft to thi rd i s not yet compl ete.
Vehi cl e speed i s too l ow for the 3-4 shi ft to occur.
Battery temperature i s bel ow -5 C (23 F).
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
REAR SERVO (Continued)
SOLENOID
DESCRIPTION
The typi cal el ectri cal sol enoi d used i n automoti ve
appl i cati ons i s a l i near actuator. I t i s a devi ce that
produces moti on i n a strai ght l i ne. Thi s strai ght l i ne
moti on can be ei ther forward or backward i n di rec-
ti on, and short or l ong di stance.
A sol enoi d i s an el ectromechani cal devi ce that uses
a magneti c force to perform work. I t consi sts of a coi l
of wi re, wrapped around a magneti c core made from
steel or i ron, and a spri ng l oaded, movabl e pl unger,
whi ch performs the work, or strai ght l i ne moti on.
The sol enoi ds used i n transmi ssi on appl i cati ons
are attached to val ves whi ch can be cl assi fi ed as nor-
mally open or normally closed. The normally
open sol enoi d val ve i s defi ned as a val ve whi ch
al l ows hydraul i c fl ow when no current or vol tage i s
appl i ed to the sol enoi d. The normally closed sol e-
noi d val ve i s defi ned as a val ve whi ch does not al l ow
hydraul i c fl ow when no current or vol tage i s appl i ed
to the sol enoi d. These val ves perform hydraul i c con-
trol functi ons for the transmi ssi on and must there-
fore be durabl e and tol erant of di rt parti cl es. For
these reasons, the val ves have hardened steel pop-
pets and bal l val ves. The sol enoi ds operate the val ves
di rectl y, whi ch means that the sol enoi ds must have
very hi gh outputs to cl ose the val ves agai nst the si z-
abl e fl ow areas and l i ne pressures found i n current
transmi ssi ons. Fast response ti me i s al so necessary
to ensure accurate control of the transmi ssi on.
The strength of the magneti c fi el d i s the pri mary
force that determi nes the speed of operati on i n a par-
ti cul ar sol enoi d desi gn. A stronger magneti c fi el d wi l l
cause the pl unger to move at a greater speed than a
weaker one. There are basi cal l y two ways to i ncrease
the force of the magneti c fi el d:
I ncrease the amount of current appl i ed to the
coi l or
I ncrease the number of turns of wi re i n the coi l .
The most common practi ce i s to i ncrease the num-
ber of turns by usi ng thi n wi re that can compl etel y
fi l l the avai l abl e space wi thi n the sol enoi d housi ng.
The strength of the spri ng and the l ength of the
pl unger al so contri bute to the response speed possi -
bl e by a parti cul ar sol enoi d desi gn.
A sol enoi d can al so be descri bed by the method by
whi ch i t i s control l ed. Some of the possi bi l i ti es
i ncl ude vari abl e force, pul se-wi dth modul ated, con-
stant ON, or duty cycl e. The vari abl e force and pul se-
wi dth modul ated versi ons uti l i ze si mi l ar methods to
control the current fl ow through the sol enoi d to posi -
ti on the sol enoi d pl unger at a desi red posi ti on some-
where between ful l ON and ful l OFF. The constant
ON and duty cycl ed versi ons control the vol tage
across the sol enoi d to al l ow ei ther ful l fl ow or no fl ow
through the sol enoi ds val ve.
OPERATION
When an el ectri cal current i s appl i ed to the sol e-
noi d coi l , a magneti c fi el d i s created whi ch produces
an attracti on to the pl unger, causi ng the pl unger to
move and work agai nst the spri ng pressure and the
l oad appl i ed by the fl ui d the val ve i s control l i ng. The
pl unger i s normal l y di rectl y attached to the val ve
whi ch i t i s to operate. When the current i s removed
from the coi l , the attracti on i s removed and the
pl unger wi l l return to i ts ori gi nal posi ti on due to
spri ng pressure.
The pl unger i s made of a conducti ve materi al and
accompl i shes thi s movement by provi di ng a path for
the magneti c fi el d to fl ow. By keepi ng the ai r gap
between the pl unger and the coi l to the mi ni mum
necessary to al l ow free movement of the pl unger, the
magneti c fi el d i s maxi mi zed.
SPEED SENSOR
DESCRIPTION
The speed sensor (Fi g. 236) i s l ocated i n the over-
dri ve gear case. The sensor i s posi ti oned over the
park gear and moni tors transmi ssi on output shaft
rotati ng speed.
OPERATION
Speed sensor si gnal s are tri ggered by the park
gear l ugs as they rotate past the sensor pi ckup face.
I nput si gnal s from the sensor are sent to the trans-
mi ssi on control modul e for processi ng. Si gnal s from
thi s sensor are shared wi th the powertrai n control
modul e.
Fig. 236 Transmission Output Speed Sensor
1 - TRANSMISSION OUTPUT SHAFT SPEED SENSOR
2 - SEAL
DESCRIPTION
Transmi ssi on throttl e val ve cabl e (Fi g. 237) adjust-
ment i s extremel y i mportant to proper operati on.
Thi s adjustment posi ti ons the throttl e val ve, whi ch
control s shi ft speed, qual i ty, and part-throttl e down-
shi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve.
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 238). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
ADJUSTMENT VERIFICATION
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on (Fi g. 239). Then veri fy that the transmi ssi on
throttl e l ever (Fi g. 240) i s al so at i dl e (ful l y forward)
posi ti on.
Fig. 237 Throttle Valve Cable Attachment - At
Engine
1 - THROTTLE VALVE CABLE
2 - CABLE BRACKET
3 - THROTTLE BODY LEVER
Fig. 238 Throttle Valve Cable at Throttle Linkage
1 - THROTTLE LINKAGE
2 - THROTTLE VALVE CABLE LOCKING CLIP
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on (Fi g. 241).
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
ADJUSTMENT PROCEDURE
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) Pry the T.V. cabl e l ock (A) i nto the UP posi ti on
(Fi g. 241). Thi s wi l l unl ock the cabl e and al l ow for
readjustment.
(6) Appl y just enough tensi on on the T.V. cabl e (B)
to remove any sl ack i n the cabl e.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment. Sl i de the
sheath of the T.V. cabl e (D) back and forth unti l the
centerl i nes of the T.V. cabl e end (B) and the throttl e
bel l crank l ever (C) are al i gned wi thi n one mi l l i meter
(1mm) (Fi g. 241).
Engine
2 - CABLE BRACKET
Fig. 240 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OR 2)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
THROTTLE VALVE CABLE (Continued)
(7) Whi l e hol di ng the T.V. cabl e i n the set posi ti on
push the T.V. cabl e l ock (A) i nto the down posi ti on
(Fi g. 241). Thi s wi l l l ock the present T.V. cabl e
adjustment.
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(8) Reconnect the T.V. cabl e (B) to the throttl e
bel l crank l ever (C).
(9) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 242) i s a hydraul i c devi ce
that coupl es the engi ne crankshaft to the transmi s-
si on. The torque converter consi sts of an outer shel l
wi th an i nternal turbi ne, a stator, an overrunni ng
cl utch, an i mpel l er and an el ectroni cal l y appl i ed con-
verter cl utch. The converter cl utch provi des reduced
engi ne speed and greater fuel economy when engaged.
Cl utch engagement al so provi des reduced transmi s-
si on fl ui d temperatures. The torque converter hub
dri ves the transmi ssi on oi l (fl ui d) pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the all transmission fluid
cooler(s) and lines.
Fig. 242 Torque Converter Assembly
1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - FRONT COVER
6 - CONVERTER CLUTCH DISC
7 - DRIVE PLATE
IMPELLER
The i mpel l er (Fi g. 243) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng members of the system.
Fig. 243 Impeller
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
5 - ENGINE ROTATION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TORQUE CONVERTER (Continued)
TURBINE
The turbi ne (Fi g. 244) i s the output, or dri ven,
member of the converter. The turbi ne i s mounted
wi thi n the housi ng opposi te the i mpel l er, but i s not
attached to the housi ng. The i nput shaft i s i nserted
through the center of the i mpel l er and spl i ned i nto
the turbi ne. The desi gn of the turbi ne i s si mi l ar to
the i mpel l er, except the bl ades of the turbi ne are
curved i n the opposi te di recti on.
Fig. 244 Turbine
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembl y (Fi g. 245) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 246).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fi g. 247) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock-free power transfer, i t i s
natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel l er
and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
OPERATION
The converter i mpel l er (Fi g. 248) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
Fig. 245 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 246 Stator Location
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 247 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes bl ades i t con-
ti nues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stators over-runni ng cl utch to i ts shaft (Fi g. 249).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the overrun-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a hel pi ng
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ock-up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
The torque converter cl utch i s hydraul i cal l y
appl i ed and i s rel eased when fl ui d i s vented from the
hydraul i c ci rcui t by the torque converter control
(TCC) sol enoi d on the val ve body. The torque con-
verter cl utch i s control l ed by the Powertrai n Control
Modul e (PCM). The torque converter cl utch engages
i n fourth gear, and i n thi rd gear under vari ous con-
di ti ons, such as when the O/D swi tch i s OFF, when
the vehi cl e i s crui si ng on a l evel surface after the
vehi cl e has warmed up. The torque converter cl utch
wi l l di sengage momentari l y when an i ncrease i n
engi ne l oad i s sensed by the PCM, such as when the
vehi cl e begi ns to go uphi l l or the throttl e pressure i s
i ncreased.
Fig. 248 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
Fig. 249 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
Fig. 250 Checking Torque Converter Seating -
Typical
1 - SCALE
2 - STRAIGHTEDGE
TORQUE CONVERTER
DRAINBACK VALVE
DESCRIPTION
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne.
OPERATION
The val ve prevents fl ui d from drai ni ng from the
converter i nto the cool er and l i nes when the vehi cl e
i s shut down for l engthy peri ods. Producti on val ves
have a hose ni ppl e at one end, whi l e the opposi te end
i s threaded for a fl are fi tti ng. Al l val ves have an
arrow (or si mi l ar mark) to i ndi cate di recti on of fl ow
through the val ve.
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates si gni fi cant amounts of sl udge and/or cl utch par-
ti cl es and metal shavi ngs, the val ve must be
repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) (Fi g. 251)
has 3 pri mary functi ons:
Provi de a PARK/NEUTRAL start si gnal to the
engi ne control l er and the starter rel ay.
Turn the Back-up l amps on when the transmi s-
si on i s i n REVERSE and the engi ne (i gni ti on) i s on.
Provi de a transmi ssi on range si gnal to the
Fig. 251 Transmission Range Sensor
The sensor i s mounted i n the transmi ssi on housi ng
near the val ve body, just above the pan rai l . I ts i n
the same posi ti on as the Park/Neutral swi tch on
other transmi ssi ons. The TRS contacts a cammed
surface on the manual val ve l ever. The cammed sur-
face transl ates the rotati onal moti on of the manual
l ever i nto the l i near moti on of the sensor. The
cammed surface on the manual l ever i s compri sed of
two parts control l i ng the TRS si gnal : The i nsul ator
porti on contacts the swi tch poppet when the manual
l ever i s not i n PARK or NEUTRAL. The manual
l ever i tsel f contacts the poppet when the l ever i s i n
PARK or NEUTRAL; provi di ng a ground for the si g-
nal from the starter rel ay and the JTEC engi ne con-
trol l er.
OPERATION
As the swi tch moves through i ts l i near moti on (Fi g.
252) contacts sl i de across a ci rcui t board whi ch
changes the resi stance between the range sensi ng
pi ns of the swi tch. A power suppl y on the i nstrument
cl uster provi des a regul ated vol tage si gnal to the
swi tch. The return si gnal i s decoded by the cl uster,
whi ch then control s the PRNDL di spl ay to corre-
spond wi th the correct transmi ssi on range. A bus
message of transmi ssi on range i s al so sent by the
cl uster. I n REVERSE range a second contact set
cl oses the ci rcui t provi di ng power to the reverse
l amps. Fig. 252 Transmission Range Sensor Linear
Movement
TRANSMISSION RANGE SENSOR (Continued)
Mechanical State Electronic Display
(Ignition Unlocked)
Electronic Display
(Ignition On)
Indicated Gear Position Transmission
Status
Column Shifter
Position
P P P Vehicle is in PARK
with the pawl
engaged.
In the PARK gate.
R The PARK pawl is
disengaged and the
vehicle is free to
roll, but REVERSE
is not engaged.
Between the PARK
and REVERSE
gates.
R R R The transmission is
hydraulically in
REVERSE.
In the REVERSE
gate.
N The transmission is
transitioning
between REVERSE
and NEUTRAL.
Between the
REVERSE and
NEUTRAL gates.
N N N The vehicle is in
NEUTRAL.
In the NEUTRAL
gate.
transitioning
between NEUTRAL
and DRIVE, but is
not in DRIVE.
Between the
NEUTRAL and
DRIVE gates.
D D D The transmission is
hydraulically in
DRIVE.
In the DRIVE gate,
2 2 2 The transmission is
hydraulically in
Manual SECOND.
In the SECOND
gate.
hydraulically in
Manual FIRST.
In the FIRST gate.
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)
NOTE: For all circuit identification in the following
steps, Refer to the appropriate Wiring Information.
(1) Rai se vehi cl e on sui tabl e hoi st.
(2) Di sconnect the vehi cl es shi ft cabl e from the
manual l ever.
(3) Wi th the manual l ever i n the PARK posi ti on
(the PARK posi ti on i s wi th the manual l ever moved
to the ful l rearward posi ti on), measure the resi stance
between the Park/Neutral Posi ti on Sense pi n of the
TRS and the transmi ssi on case. The resi stance
shoul d be l ess than 5 ohms.
(4) Wi th the manual l ever i n the NEUTRAL posi ti on
(the NEUTRAL posi ti on i s wi th the manual l ever
moved two detents forward of the ful l rearward posi -
ti on), measure the resi stance between the Park/Neutral
Posi ti on Sense pi n of the TRS and the transmi ssi on
case. The resi stance shoul d be l ess than 5 ohms.
(5) I f the resi stance i s greater than 5 ohms i n
ei ther of the previ ous steps, check for a di rty contact
between the ti p of the TRS rod and the val ve body
manual l ever. I f the contact i s OK, repl ace the TRS.
(6) Wi th the manual l ever i n the REVERSE posi ti on
(the REVERSE posi ti on i s wi th the manual l ever
moved one detent forward of the ful l rearward posi -
ti on), measure the resi stance between the Fused I gni -
ti on Swi tch Output and the Back-up Lamp feed pi ns of
the TRS. The resi stance shoul d be l ess than 5 ohms. I f
the resi stance i s greater than 5 ohms, repl ace the TRS.
between the Cl uster Resi stance Si gnal and the Cl us-
ter Si gnal Return pi ns of the TRS. The resi stance
shoul d be 522.2 ohms. I f the resi stance i s not correct,
repl ace the TRS.
(8) Wi th the manual l ever i n the REVERSE posi -
ti on (the REVERSE posi ti on i s wi th the manual l ever
ti on), measure the resi stance between the Cl uster
Resi stance Si gnal and the Cl uster Si gnal Return pi ns
of the TRS. The resi stance shoul d be 206.2 ohms. I f
the resi stance i s not correct, repl ace the TRS.
(9) Wi th the manual l ever i n the NEUTRAL posi -
ti on (the NEUTRAL posi ti on i s wi th the manual
l ever moved two detents forward of the ful l rearward
posi ti on), measure the resi stance between the Cl uster
(10) Wi th the manual l ever i n the DRI VE posi ti on
(the DRI VE posi ti on i s wi th the manual l ever moved
three detents forward of the ful l rearward posi ti on),
measure the resi stance between the Cl uster Resi s-
tance Si gnal and the Cl uster Si gnal Return pi ns of
the TRS. The resi stance shoul d be 59.9 ohms. I f the
resi stance i s not correct, repl ace the TRS.
(11) Wi th the manual l ever i n the SECOND posi -
ti on (the SECOND posi ti on i s wi th the manual l ever
moved one detent rearward of the ful l forward posi -
ti on), measure the resi stance between the Fused
I gni ti on Swi tch Output and the Back-up Lamp feed
pi ns of the TRS. The resi stance shoul d be 31.9 ohms.
I f the resi stance i s not correct, repl ace the TRS.
(12) Wi th the manual l ever i n the LOW posi ti on
(the LOW posi ti on i s wi th the manual l ever moved to
the ful l forward posi ti on), measure the resi stance
between the Fused I gni ti on Swi tch Output and the
Back-up Lamp feed pi ns of the TRS. The resi stance
repl ace the TRS.
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under the
transmi ssi on range sensor (TRS).
(2) Move the transmi ssi on manual l ever to the
manual LOW posi ti on. The manual LOW posi ti on i s
wi th the manual l ever i n the forward-most detent.
(3) Di sengage the wi ri ng connector from the TRS.
(4) Remove the two screws hol di ng the TRS to the
TRS mounti ng bracket.
(5) Remove the TRS (Fi g. 253) from the TRS
mounti ng bracket by pul l i ng i t strai ght out of the
bracket.
(6) Loosen the TRS mounti ng bracket i n the trans-
mi ssi on case usi ng Adapter 8581 (Fi g. 254).
Fig. 253 Remove Transmission Range Sensor
Fig. 254 Loosen the TRS Mounting Bracket
3 - ADAPTER 8581
(7) Remove the TRS mounti ng bracket (Fi g. 255)
from the transmi ssi on case.
INSTALLATION
(1) Move the transmi ssi on manual shaft l ever to
the manual LOW posi ti on.
(2) I nstal l the TRS mounti ng bracket i nto the
transmi ssi on case. Usi ng Adapter 8581 (Fi g. 256),
ti ghten the mounti ng bracket to 34 Nm (300 i n.l bs.).
(3) I nstal l the TRS (Fi g. 257) i nto the mounti ng
bracket wi th the wi ri ng connector faci ng the front of
the transmi ssi on.
(4) I nstal l the two screws to hol d the TRS to the
mounti ng bracket. Ti ghten the screws to 3.4 Nm (30
i n.l bs.).
(5) Veri fy proper sensor operati on (Fi g. 258).
the PARK posi ti on.
(7) Connect TRS wi ri ng connector to the TRS and
l ower vehi cl e.
(8) Refi l l the transmi ssi on fl ui d to the correct
l evel .
Fig. 255 Remove TRS Mounting Bracket
3 - ADAPTER 8581
Fig. 258 Transmission Range Sensor Operation
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SENSOR PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
Transmi ssi on fl ui d temperature readi ngs are sup-
pl i ed to the transmi ssi on control modul e by the ther-
mi stor (Fi g. 259). The temperature readi ngs are used
to control engagement of the fourth gear overdri ve
cl utch, the converter cl utch, and governor pressure.
Normal resi stance val ue for the thermi stor at room
temperature i s approxi matel y 1000 ohms.
The thermi stor i s part of the governor pressure
sensor assembl y and i s i mmersed i n transmi ssi on
fl ui d at al l ti mes.
OPERATION
The PCM prevents engagement of the converter
cl utch and overdri ve cl utch, when fl ui d temperature
i s bel ow approxi matel y 10C (50F).
I f fl ui d temperature exceeds 126C (260F), the
PCM causes a 4-3 downshi ft and engage the con-
verter cl utch. Engagement i s accordi ng to the thi rd
gear converter cl utch engagement schedul e.
The overdri ve OFF l amp i n the i nstrument panel
i l l umi nates when the shi ft back to thi rd occurs. The
transmi ssi on wi l l not al l ow fourth gear operati on
unti l fl ui d temperature decreases to approxi matel y
110C (230F).
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and transfer pl ate. The val ve
body contai ns val ves and check bal l s that control
fl ui d del i very to the torque converter cl utch, bands,
and fri cti onal cl utches. The val ve body contai ns the
fol l owi ng components (Fi g. 260), (Fi g. 261), (Fi g.
262), and (Fi g. 263):
Regul ator val ve
Regul ator val ve throttl e pressure pl ug
Li ne pressure pl ug and sl eeve
Ki ckdown val ve
Ki ckdown l i mi t val ve
1-2 shi ft val ve
1-2 control val ve
2-3 shi ft val ve
2-3 governor pl ug
3-4 shi ft val ve
3-4 ti mi ng val ve
3-4 qui ck fi l l val ve
3-4 accumul ator
Throttl e val ve
Throttl e pressure pl ug
Swi tch val ve
Manual val ve
Converter cl utch l ock-up val ve
Converter cl utch l ock-up ti mi ng Val ve
Shuttl e val ve
Shuttl e val ve throttl e pl ug
Boost Val ve
10 check bal l s
By adjusti ng the spri ng pressure acti ng on the reg-
ul ator val ve, transmi ssi on l i ne pressure can be
adjusted.
1 - GOVERNOR BODY
Fig. 260 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
VALVE BODY (Continued)
Fig. 261 Shuttle and Boost Valve Locations
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
Fig. 262 Upper Housing Shift Valve and Pressure Plug Locations
1 - UPPER HOUSING 8 - RETAINER
2 - 1-2 SHIFT VALVE AND SPRING 9 - 1-2 SHIFT CONTROL VALVE AND SPRING
3 - 2-3 SHIFT VALVE AND SPRING 10 - PRESSURE PLUG COVER
4 - 2-3 THROTTLE PLUG 11 - LINE PRESSURE PLUG
5 - LIMIT VALVE HOUSING 12 - PLUG SLEEVE
6 - LIMIT VALVE COVER 13 - THROTTLE PRESSURE SPRING AND PLUG
7 - LIMIT VALVE AND SPRING
Fig. 263 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
CHECK BALLS
CHECK BALL NUMBER DESCRIPTION
1 Allows either the manual valve to put line pressure on the 1-2 governor plug or
the KD Valve to put WOT line pressure on the 1-2 governor plug.
3 Allows either the Reverse circuit or the 3rd gear circuit to pressurize the front
clutch.
4 Allows either the Manual Low circuit from the Manual Valve or the Reverse
from the Manual Valve circuit to pressurize the rear servo.
5 Directs line pressure to the spring end of the 2-3 shift valve in either Manual
Low or Manual 2nd, forcing the downshift to 2nd gear regardless of governor
pressure.
6 Provides a by-pass around the front servo orifice so that the servo can release
quickly.
7 Provides a by-pass around the rear clutch orifice so that the clutch can release
quickly.
8 Directs reverse line pressure through an orifice to the throttle valve eliminating
the extra leakage and insuring that Reverse line pressure pressure will be
sufficient.
9 Provides a by-pass around the rear servo orifice so that the servo can release
quickly.
ECE (10) Allows the lockup clutch to used at WOT in 3rd gear by putting line pressure
from the 3-4 Timing Valve on the interlock area of the 2-3 shift valve, thereby
preventing a 3rd gear Lock-up to 2nd gear kickdown.
REGULATOR VALVE
The pressure regul ator val ve i s needed to control
the hydraul i c pressure wi thi n the system and reduce
the amount of heat produced i n the fl ui d. The pres-
sure regul ator val ve i s l ocated i n the val ve body near
the manual val ve. The pressure regul ator val ve trai n
control s the maxi mum pressure i n the l i nes by
meteri ng the dumpi ng of fl ui d back i nto the sump.
Regul ated pressure i s referred to as l i ne pressure.
The regul ator val ve (Fi g. 264) has a spri ng on one
end that pushes the val ve to the l eft. Thi s cl oses a
dump (vent) that i s used to l ower pressure. The cl os-
i ng of the dump wi l l cause the oi l pressure to
i ncrease. Oi l pressure on the opposi te end of the
val ve pushes the val ve to the ri ght, openi ng the
dump and l oweri ng oi l pressure. The resul t i s spri ng
pressure worki ng agai nst oi l pressure to mai ntai n
the oi l at speci fi c pressures. Wi th the engi ne run-
ni ng, fl ui d fl ows from the pump to the pressure reg-
ul ator val ve, manual val ve, and the i nterconnected
ci rcui ts. As fl ui d i s sent through passages to the reg-
ul ator val ve, the pressure pushes the val ve to the
ri ght agai nst the l arge spri ng. I t i s al so sent to the
reacti on areas on the l eft si de of the throttl e pressure
pl ug and the l i ne pressure pl ug. Wi th the gear sel ec-
tor i n the PARK posi ti on, fl ui d reci rcul ates through
the regul ator and manual val ves back to the sump.
Fig. 264 Regulator Valve in PARK Position
Meanwhi l e, the torque converter i s fi l l ed sl owl y. I n
al l other gear posi ti ons (Fi g. 265), fl ui d fl ows
between two ri ght si de l ands to the swi tch val ve and
torque converter. At l ow pump speeds, the fl ow i s
control l ed by the pressure val ve groove to reduce
pressure to the torque converter. After the torque
converter and swi tch val ve fi l l wi th fl ui d, the swi tch
val ve becomes the control l i ng meteri ng devi ce for
torque converter pressure. The regul ator val ve then
begi ns to control the l i ne pressure for the other
transmi ssi on ci rcui ts. The bal ance of the fl ui d pres-
sure pushi ng the val ve to the ri ght and the spri ng
pressure pushi ng to the l eft determi nes the si ze of
the meteri ng passage at l and #2 (l and #1 bei ng at
the far ri ght of the val ve i n the di agram). As fl ui d
l eaks past the l and, i t moves i nto a groove connected
to the fi l ter or sump. As the l and meters the fl ui d to
the sump, i t causes the pressure to reduce and the
spri ng decreases the si ze of the meteri ng passage.
When the si ze of the meteri ng passage i s reduced,
the pressure ri ses agai n and the si ze of the l and i s
i ncreased agai n. Pressure i s regul ated by thi s con-
stant bal ance of hydraul i c and spri ng pressure.
The meteri ng at l and #2 establ i shes the l i ne pres-
sure throughout the transmi ssi on. I t i s vari ed accord-
i ng to changes i n throttl e posi ti on and the
transmi ssi ons i nternal condi ti on wi thi n a range of
57-94 psi (except i n REVERSE) (Fi g. 266). The regu-
l ated l i ne pressure i n REVERSE (Fi g. 267) i s hel d at
much hi gher pressures than i n the other gear posi -
ti ons: 145-280 psi . The hi gher pressure for
REVERSE i s achi eved by the manual val ve bl ocki ng
the suppl y of l i ne pressure to the reacti on area l eft of
l and #4. Wi th thi s pressure bl ocked, there i s l ess
area for pressure to act on to bal ance the force of the
spri ng on the ri ght. Thi s al l ows l i ne pressure to push
the val ve trai n to the ri ght, reduci ng the amount of
fl ui d returned to the pumps i nl et, i ncreasi ng l i ne
pressure.
Fig. 265 Regulator Valve in NEUTRAL Position
Fig. 266 Regulator Valve in DRIVE Position
Fig. 267 Regulator Valve in REVERSE Position
KICKDOWN VALVE
When the throttl e val ve i s as far over to the l eft as
i t can go, the maxi mum l i ne pressure possi bl e wi l l
enter the throttl e pressure ci rcui t. I n thi s case, throt-
tl e pressure wi l l equal l i ne pressure. Wi th the ki ck-
down val ve (Fi g. 268) pushed i nto the bore as far as
i t wi l l go, fl ui d i ni ti al l y fl ows through the annul ar
groove of the 2-3 shi ft val ve (whi ch wi l l be i n the
di rect dri ve posi ti on to the ri ght).
After passi ng the annul ar groove, the fl ui d i s
routed to the spri ng end of the 2-3 shi ft val ve. Fl ui d
pressure reacti ng on the area of l and #1 overcomes
governor pressure, downshi fti ng the 2-3 shi ft val ve
i nto the ki ckdown, or second gear stage of operati on.
The val ve i s hel d i n the ki ckdown posi ti on by throttl e
pressure routed from a seated check bal l (#2). Agai n,
i f vehi cl e speed i s l ow enough, throttl e pressure wi l l
al so push the 1-2 shi ft val ve l eft to seat i ts governor
pl ug, and downshi ft to dri ve breakaway.
Fig. 268 Kickdown Valve-Wide Open Throttle
KICKDOWN LIMIT VALVE
The purpose of the l i mi t val ve i s to prevent a 3-2
downshi ft at hi gher speeds when a part-throttl e
downshi ft i s not desi rabl e. At these hi gher speeds
onl y a ful l throttl e 3-2 downshi ft wi l l occur. At l ow
road speeds (Fi g. 269) the l i mi t val ve does not come
i nto pl ay and does not affect the downshi fts. As the
vehi cl es speed i ncreases (Fi g. 270), the governor
pressure al so i ncreases. The i ncreased governor pres-
sure acts on the reacti on area of the bottom l and of
the l i mi t val ve overcomi ng the spri ng force tryi ng to
push the val ve toward the bottom of i ts bore. Thi s
pushes the val ve upward agai nst the spri ng and bot-
toms the val ve agai nst the top of the housi ng. Wi th
the val ve bottomed agai nst the housi ng, the throttl e
pressure suppl i ed to the val ve wi l l be cl osed off by
the bottom l and of the l i mi t val ve. When the suppl y
of throttl e pressure has been shut off, the 3-2 part
throttl e downshi ft pl ug becomes i noperati ve, because
no pressure i s acti ng on i ts reacti on area.
Fig. 269 Kickdown Limit Valve-Low Speeds
Fig. 270 Kickdown Limit Valve-High Speeds
1-2 SHIFT VALVE
The 1-2 shi ft val ve assembl y (Fi g. 271), or mecha-
ni sm, consi sts of: the 1-2 shi ft val ve, governor pl ug,
and a spri ng on the end of the val ve. After the man-
ual val ve has been pl aced i nto a forward gear range,
l i ne pressure i s di rected to the 1-2 shi ft val ve. As the
throttl e i s depressed, throttl e pressure i s appl i ed to
the ri ght si de of the 1-2 shi ft val ve assembl y. Wi th
throttl e pressure appl i ed to the ri ght si de of the
val ve, there i s now both spri ng pressure and throttl e
pressure acti ng on the val ve, hol di ng i t agai nst the
governor pl ug. As the vehi cl e begi ns to move and
bui l d speed, governor pressure i s created and i s
appl i ed to the l eft of the val ve at the governor pl ug.
When governor pressure bui l ds to a poi nt where i t
can overcome the combi ned force of the spri ng and
throttl e pressure on the other si de of the val ve, the
val ve wi l l begi n to move over to the ri ght. As the
val ve moves to the ri ght, the mi ddl e l and of the val ve
wi l l cl ose off the ci rcui t suppl yi ng the throttl e pres-
sure to the ri ght si de of the val ve. When the throttl e
pressure i s cl osed off, the val ve wi l l move even far-
ther to the ri ght, al l owi ng l i ne pressure to enter
another ci rcui t and energi ze the front servo, appl yi ng
the front band (Fi g. 272).
Fig. 272 1-2 Shift Valve-After Shift
Fig. 271 1-2 Shift Valve-Before Shift
The governor pl ug serves a dual purpose:
I t al l ows the shi ft val ves to move ei ther l eft or
ri ght, al l owi ng both upshi fts and downshi fts.
When i n a manual sel ecti on posi ti on, i t wi l l be
hydraul i cal l y bl ocked i nto posi ti on so no upshi ft can
occur.
The physi cal bl ocki ng of the upshi ft whi l e i n the
manual 1 posi ti on i s accompl i shed by the di recti ng
of l i ne pressure between both l ands of the governor
pl ug. The l i ne pressure reacts agai nst the l arger l and
of the pl ug, pushi ng the pl ug back agai nst the end
pl ate overcomi ng governor pressure. Wi th the combi -
nati on of the l i ne pressure and spri ng pressure, the
val ve cannot move, preventi ng any upshi ft.
1-2 SHIFT CONTROL VALVE
I t contai ns a val ve wi th four l ands and a spri ng. I t
i s used as both a rel ay and bal anced val ve.
The val ve has two speci fi c operati ons (Fi g. 273):
Ai d i n qual i ty of the 1-2 upshi ft.
Ai d i n the qual i ty and ti mi ng of the 3-2 ki ck-
down ranges.
When the manual val ve i s set to the DRI VE posi -
ti on and the transmi ssi on i s i n the fi rst or second
gear range, 1-2 shi ft control or modul ated throttl e
pressure i s suppl i ed to the mi ddl e of the accumul a-
tor pi ston by the 1-2 shi ft control val ve. Duri ng the
1-2 upshi ft, thi s pressure i s used to control the ki ck-
down servo appl y pressure that i s needed to appl y
the ki ckdown and accumul ator pi stons. Thus, the 1-2
shi ft poi nt i s cushi oned and the qual i ty i s
i mproved. Duri ng a WOT ki ckdown, ki ckdown pres-
sure i s appl i ed between the ki ckdown val ve and the
1-2 shi ft control val ve. Thi s addi ti onal pressure i s
di rected to the 1-2 shi ft control s spri ng cavi ty, add-
i ng to the spri ng l oad on the val ve. The resul t of thi s
i ncreased modul ated throttl e pressure i s a fi rmer
WOT upshi ft.
2-3 SHIFT VALVE
The 2-3 shi ft val ve mechani sm (Fi g. 274) consi sts
of the 2-3 shi ft val ve, governor pl ug and spri ng, and
a throttl e pl ug. After the 1-2 shi ft val ve has com-
pl eted i ts operati on and appl i ed the front band, l i ne
pressure i s di rected to the 2-3 shi ft val ve through the
connecti ng passages from the 1-2 shi ft val ve. The l i ne
pressure wi l l then deadend at l and #2 unti l the 2-3
val ve i s ready to make i ts shi ft. Now that the vehi cl e
i s i n moti on and under accel erati on, there i s throttl e
pressure bei ng appl i ed to the spri ng si de of the val ve
and between l ands #3 and #4.
As vehi cl e speed i ncreases, governor pressure
i ncreases proporti onatel y, unti l i t becomes great
enough to overcome the combi ned throttl e and spri ng
pressure on the ri ght si de of the val ve. Si nce the
throttl e pressure end of the 2-3 shi ft val ve i s l arger
i n di ameter than the 1-2 shi ft val ve, the 2-3 shi ft wi l l
al ways happen at a greater speed than the 1-2 shi ft.
When thi s happens, the governor pl ug i s forced
agai nst the shi ft val ve movi ng i t to the ri ght. The
Fig. 273 1-2 Shift Control Valve
shi ft val ve causes l and #4 to cl ose the passage sup-
pl yi ng throttl e pressure to the 2-3 shi ft val ve. Wi th-
out throttl e pressure present i n the ci rcui t now, the
governor pl ug wi l l push the val ve over far enough to
bottom the val ve i n i ts bore. Thi s al l ows l and #2 to
di rect l i ne pressure to the front cl utch.
After the shi ft (Fi g. 275), l i ne pressure i s di rected
to the l and between the shi ft val ve and the governor
pl ug, and to the rel ease si de of the ki ckdown servo.
Thi s rel eases the front band and appl i es the front
cl utch, shi fti ng i nto thi rd gear or di rect dri ve. The
rear cl utch remai ns appl i ed, as i t has been i n the
other gears. Duri ng a manual 1 or manual 2 gear
sel ecti on, l i ne pressure i s sent between the two l ands
of the 2-3 governor pl ug. Thi s l i ne pressure at the
governor pl ug l ocks the shi ft val ve i nto the second
gear posi ti on, preventi ng an upshi ft i nto di rect dri ve.
The theory for the bl ocki ng of the val ve i s the same
as that of the 1-2 shi ft val ve.
3-4 SHIFT VALVE
The PCM energi zes the overdri ve sol enoi d duri ng
the 3-4 upshi ft (Fi g. 276). Thi s causes the sol enoi d
check bal l to cl ose the vent port al l owi ng l i ne pres-
sure from the 2-3 shi ft val ve to act di rectl y on the 3-4
upshi ft val ve. Li ne pressure on the 3-4 shi ft val ve
overcomes val ve spri ng pressure movi ng the val ve to
the upshi ft posi ti on (Fi g. 277). Thi s acti on exposes
overdri ve pi ston.
3-4 TIMING VALVE
The 3-4 ti mi ng val ve i s moved by l i ne pressure
comi ng through the 3-4 shi ft val ve (Fi g. 277). After
the shi ft, the ti mi ng val ve hol ds the 2-3 shi ft val ve i n
an upshi ft posi ti on. The purpose i s to prevent the 2-3
val ve from downshi fti ng before the 3-4 val ve (Fi g.
276).
3-4 QUICK FILL VALVE
The 3-4 qui ck fi l l val ve provi des faster engagement
of the overdri ve cl utch duri ng 3-4 upshi fts. The val ve
temporari l y bypasses the cl utch pi ston feed ori fi ce at
the start of a 3-4 upshi ft (Fi g. 276). Thi s exposes a
l arger passage i nto the pi ston retai ner resul ti ng i n a
much faster cl utch fi l l and appl y sequence. The qui ck
fi l l val ve does not bypass the regul ar cl utch feed ori -
fi ce throughout the 3-4 upshi ft. I nstead, once a pre-
determi ned pressure devel ops wi thi n the cl utch, the
val ve cl oses the bypass (Fi g. 277). Cl utch fi l l i s then
compl eted through the regul ar feed ori fi ce.
Fig. 276 3-4 Shift Valve Before Shift Fig. 277 3-4 Shift Valve After Shift
THROTTLE VALVE
I n al l gear posi ti ons the throttl e val ve (Fi g. 278) i s
bei ng suppl i ed wi th l i ne pressure. The throttl e val ve
meters and reduces the l i ne pressure that now
becomes throttl e pressure. The throttl e val ve i s
moved by a spri ng and the ki ckdown val ve, whi ch i s
mechani cal l y connected to the throttl e. The l arger
the throttl e openi ng, the hi gher the throttl e pressure
(to a maxi mum of l i ne pressure). The smal l er the
throttl e openi ng, the l ower the throttl e pressure (to a
mi ni mum of zero at i dl e). As engi ne speed i ncreases,
the i ncrease i n pump speed i ncreases pump output.
The i ncrease i n pressure and vol ume must be regu-
l ated to mai ntai n the bal ance wi thi n the transmi s-
si on. To do thi s, throttl e pressure i s routed to the
reacti on area on the ri ght si de of the throttl e pres-
sure pl ug (i n the regul ator val ve).
The hi gher engi ne speed and l i ne pressure woul d
open the vent too far and reduce l i ne pressure too
much. Throttl e pressure, whi ch i ncreases wi th engi ne
speed (throttl e openi ng), i s used to oppose the move-
ment of the pressure val ve to hel p control the meter-
i ng passage at the vent. The throttl e pressure i s
combi ned wi th spri ng pressure to reduce the force of
the throttl e pressure pl ug on the pressure val ve. The
l arger spri ng at the ri ght cl oses the regul ator val ve
passage and mai ntai ns or i ncreases l i ne pressure.
The i ncreased l i ne pressure works agai nst the reac-
ti on area of the l i ne pressure pl ug and the reacti on
area l eft of l and #3 si mul taneousl y moves the regu-
l ator val ve trai n to the ri ght and control s the meter-
i ng passage.
The ki ckdown val ve, al ong wi th the throttl e val ve,
serve to del ay upshi fts unti l the correct vehi cl e speed
has been reached. I t al so control s downshi fts upon
dri ver demand, or i ncreased engi ne l oad. I f these
val ves were not i n pl ace, the shi ft poi nts woul d be at
the same speed for al l throttl e posi ti ons. The ki ck-
down val ve i s actuated by a cam connected to the
throttl e. Thi s i s accompl i shed through ei ther a l i nk-
age or a cabl e. The cam forces the ki ckdown val ve
toward the throttl e val ve compressi ng the spri ng
between them and movi ng the throttl e val ve. As the
throttl e val ve l and starts to uncover i ts port, l i ne
pressure i s metered out i nto the ci rcui ts and vi ewed
as throttl e pressure. Thi s i ncreased throttl e pressure
i s metered out i nto the ci rcui ts i t i s appl i ed to: the
1-2 and 2-3 shi ft val ves. When the throttl e pressure
i s hi gh enough, a 3-2 downshi ft wi l l occur. I f the
vehi cl e speed i s l ow enough, a 2-1 downshi ft wi l l
occur.
Fig. 278 Throttle Valve
SWITCH VALVE
When the transmi ssi on i s i n Dri ve Second before
the TCC appl i cati on occurs (Fi g. 279), the pressure
regul ator val ve i s suppl yi ng torque converter pres-
sure to the swi tch val ve. The swi tch val ve di rects
thi s pressure through the transmi ssi on i nput shaft,
i nto the converter, through the converter, back out
between the i nput shaft and the reacti on shaft, and
back up to the swi tch val ve. From the swi tch val ve,
the fl ui d pressure i s di rected to the transmi ssi on
cool er, and l ubri cati on pressure returns from the
cool er to l ubri cate di fferent porti ons of the transmi s-
si on.
Once the TCC control val ve has moved to the ri ght
(Fi g. 280), l i ne pressure i s di rected to the ti p of the
swi tch val ve, forci ng the val ve to the ri ght. The
swi tch val ve now vents oi l from the front of the pi s-
ton i n the torque converter, and suppl i es l i ne pres-
sure to the (rear) appl y si de of the torque converter
pi ston. Thi s pressure di fferenti al causes the pi ston to
appl y agai nst the fri cti on materi al , cutti ng off any
further fl ow of l i ne pressure oi l . After the swi tch
val ve i s shuttl ed ri ght al l owi ng l i ne pressure to
engage the TCC, torque converter pressure i s
di rected past the swi tch val ve i nto the transmi ssi on
cool er and l ubri cati on ci rcui ts.
Fig. 279 Switch Valve-Torque Converter Unlocked
MANUAL VALVE
The manual val ve (Fi g. 281) i s a rel ay val ve. The
purpose of the manual val ve i s to di rect fl ui d to the
correct ci rcui t needed for a speci fi c gear or dri vi ng
range. The manual val ve, as the name i mpl i es, i s
manual l y operated by the dri ver wi th a l ever l ocated
on the si de of the val ve body. The val ve i s connected
mechani cal l y by ei ther a cabl e or l i nkage to the gear-
shi ft mechani sm. The val ve i s hel d i n each of i ts
posi ti ons by a spri ng-l oaded rol l er or bal l that
engages the roostercomb of the manual val ve l ever.
CONVERTER CLUTCH LOCK-UP VALVE
The torque converter cl utch (TCC) l ock-up val ve
control s the back (ON) si de of the torque converter
cl utch. When the PCM energi zes the TCC sol enoi d to
engage the converter cl utch pi ston, pressure i s
appl i ed to the TCC l ock-up val ve whi ch moves to the
ri ght and appl i es pressure to the torque converter
cl utch.
Fig. 280 Switch Valve-Torque Converter Locked
CONVERTER CLUTCH LOCK-UP TIMING VALVE
The torque converter cl utch (TCC) l ock-up ti mi ng
val ve i s there to bl ock any 4-3 downshi ft unti l the
TCC i s compl etel y unl ocked and the cl utch i s di sen-
gaged.
SHUTTLE VALVE
The assembl y i s contai ned i n a bore i n the val ve
body above the shi ft val ves. When the manual val ve
i s posi ti oned i n the Dri ve range, throttl e pressure
acts on the throttl e pl ug of the shuttl e val ve (Fi g.
273) to move i t agai nst a spri ng, i ncreasi ng the
spri ng force on the shuttl e val ve. Duri ng a part or
ful l throttl e 1-2 upshi ft, the throttl e pl ug i s bottomed
by throttl e pressure, hol di ng the shuttl e val ve to the
ri ght agai nst governor pressure, and openi ng a
bypass ci rcui t. The shuttl e val ve control s the qual -
i ty of the ki ckdown shi ft by restri cti ng the rate of
fl ui d di scharge from the front cl utch and servo
rel ease ci rcui ts. Duri ng a 3-2 ki ckdown, fl ui d di s-
charges through the shuttl e by-pass ci rcui t. When
the shuttl e val ve cl oses the by-pass ci rcui t, fl ui d di s-
charge i s restri cted and control l ed for the appl i cati on
of the front band. Duri ng a 2-3 l i ft foot upshi ft, the
shuttl e val ve by-passes the restri cti on to al l ow ful l
fl ui d fl ow through the by-pass groove for a faster
rel ease of the band.
BOOST VALVE
The boost val ve (Fi g. 282) provi des i ncreased fl ui d
appl y pressure to the overdri ve cl utch duri ng 3-4
upshi fts (Fi g. 283), and when accel erati ng i n fourth
gear. The boost val ve al so serves to i ncrease l i ne
pressure duri ng torque converter l ock-up.
Fig. 281 Manual Valve
Fig. 282 Boost Valve Before Lock-up
REMOVAL
The val ve body can be removed for servi ce wi thout
havi ng to remove the transmi ssi on assembl y.
The val ve body can be di sassembl ed for cl eani ng
and i nspecti on of the i ndi vi dual components.
The onl y repl aceabl e val ve body components are:
Manual l ever.
Manual l ever washer, seal , E-cl i p, and shaft
seal .
Manual l ever detent bal l .
Throttl e l ever.
Fl ui d fi l ter.
Pressure adjusti ng screw bracket.
Governor pressure sol enoi d.
Governor pressure sensor (i ncl udes transmi ssi on
temperature thermi stor).
Converter cl utch/overdri ve sol enoi d assembl y
and harness .
Governor housi ng gasket.
Sol enoi d case connector O-ri ngs.
(1) Shi ft transmi ssi on i nto NEUTRAL.
(3) Remove gearshi ft and throttl e l evers from shaft
of val ve body manual l ever.
(4) Di sconnect wi res at sol enoi d case connector
(Fi g. 284).
(6) Posi ti on drai n pan under transmi ssi on oi l pan.
(8) Remove fl ui d fi l ter from val ve body.
(9) Remove bol ts attachi ng val ve body to transmi s-
si on case.
(10) Lower val ve body enough to remove accumu-
l ator pi ston and spri ngs.
(11) Work manual l ever shaft and el ectri cal con-
nector out of transmi ssi on case.
(12) Lower val ve body, rotate val ve body away
from case, pul l park rod out of sprag, and remove
val ve body (Fi g. 285).
Fig. 283 Boost Valve After Lock-up
Fig. 284 Transmission Case Connector
Fig. 285 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Di sconnect wi res from governor pressure sen-
sor and sol enoi d.
(2) Remove screws attachi ng governor body and
retai ner pl ate to transfer pl ate.
(3) Remove retai ner pl ate, governor body and gas-
ket from transfer pl ate.
(4) Remove governor pressure sensor from gover-
nor body.
(5) Remove governor pressure sol enoi d by pul l i ng
i t strai ght out of bore i n governor body. Remove and
di scard sol enoi d O-ri ngs i f worn, cut, or torn.
(6) Remove smal l shoul der bol t that secures sol e-
noi d harness case connector to 3-4 accumul ator hous-
i ng (Fi g. 286). Retai n shoul der bol t. Ei ther tape i t to
harness or thread i t back i nto accumul ator housi ng
after connector removal .
(7) Unhook overdri ve/converter sol enoi d harness
from 3-4 accumul ator cover pl ate (Fi g. 287).
(8) Turn val ve body over and remove screws that
attach overdri ve/converter sol enoi d assembl y to val ve
body (Fi g. 288).
(9) Remove sol enoi d and harness assembl y from
(10) Remove boost val ve cover (Fi g. 290).
(11) Remove boost val ve retai ner, val ve spri ng and
boost val ve (Fi g. 291).
Fig. 286 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
Fig. 287 Unhooking Solenoid Harness From
Accumulator Cover Plate
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
(12) Secure detent bal l and spri ng wi th Retai ner
Tool 6583 (Fi g. 292).
(13) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 293).
(14) Remove E-cl i p and washer that retai ns throt-
tl e l ever shaft i n manual l ever (Fi g. 294).
(15) Remove manual l ever and throttl e l ever (Fi g.
295). Rotate and l i ft manual l ever off val ve body and
throttl e l ever shaft. Then sl i de throttl e l ever out of
val ve body.
Fig. 288 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 289 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 290 Boost Valve
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 291 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
(16) Posi ti on penci l magnet next to detent housi ng
to catch detent bal l and spri ng. Then careful l y
remove Retai ner Tool 6583 and remove detent bal l
and spri ng (Fi g. 296).
(17) Remove screws attachi ng pressure adjusti ng
screw bracket to val ve body and transfer pl ate (Fi g.
297). Hol d bracket fi rml y agai nst spri ng tensi on
whi l e removi ng l ast screw.
Fig. 292 Detent Ball And Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 293 Park Rod
1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD
Fig. 294 Throttle Lever E-Clip And Washer
1 - THROTTLE LEVER SHAFT
2 - E-CLIP AND WASHER
3 - MANUAL SHAFT
Fig. 295 Manual And Throttle Lever
1 - PARK ROD
2 - MANUAL LEVER ASSEMBLY
3 - THROTTLE LEVER
(18) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw, pressure regul ator val ve spri ng and
swi tch val ve spri ng (Fi g. 298). Do not remove throttl e
pressure adjusti ng screw from bracket and do not
di sturb setti ng of ei ther adjusti ng screw duri ng
removal .
(19) Turn upper housi ng over and remove swi tch
val ve, regul ator val ve and spri ng, and manual val ve
(Fi g. 299).
(20) Remove ki ckdown detent, ki ckdown val ve, and
throttl e val ve and spri ng (Fi g. 299).
(21) Loosen l eft-si de 3-4 accumul ator housi ng
attachi ng screw about 2-3 threads. Then remove cen-
ter and ri ght-si de housi ng attachi ng screws (Fi g.
300).
(22) Careful l y rotate 3-4 accumul ator housi ng
upward and remove 3-4 shi ft val ve spri ng and con-
verter cl utch val ve pl ug and spri ng (Fi g. 301).
(23) Remove l eft-si de screw and remove 3-4 accu-
mul ator housi ng from val ve body (Fi g. 302).
(24) Bend back tabs on boost val ve tube brace (Fi g.
303).
1 - DETENT HOUSING
2 - DETENT SPRING
3 - DETENT BALL
4 - PENCIL MAGNET
Fig. 297 Adjusting Screw Bracket Fastener
1 - T25 TORX BIT
2 - REMOVE THESE SCREWS FIRST
3 - BRACKET
4 - BRACKET
5 - REMOVE THIS SCREW LAST
Fig. 298 Adjusting Screw Bracket And Spring
1 - SWITCH VALVE SPRING
2 - LINE PRESSURE SCREW
3 - THROTTLE PRESSURE ADJUSTING SCREW
4 - ADJUSTING SCREW BRACKET
5 - PRESSURE REGULATOR VALVE SPRING
(25) Remove boost val ve connecti ng tube (Fi g.
304). Di sengage tube from upper housi ng port fi rst.
Then rock opposi te end of tube back and forth to
work i t out of l ower housi ng.
Fig. 300 Accumulator Housing Screw Locations
1 - LOOSEN THIS SCREW
2 - REMOVE THESE SCREWS
Fig. 301 3-4 Shift And Converter Clutch Valve
Springs And Plug
1 - ACCUMULATOR HOUSING
2 - CONVERTER CLUTCH VALVE SPRING
3 - CLUTCH VALVE PLUG
4 - 3-4 SHIFT VALVE SPRING
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(26) Turn val ve body over so l ower housi ng i s fac-
i ng upward (Fi g. 305). I n thi s posi ti on, the two check
bal l s i n upper housi ng wi l l remai n i n pl ace and not
fal l out when l ower housi ng and separator pl ate are
removed.
(27) Remove screws attachi ng val ve body l ower
housi ng to upper housi ng and transfer pl ate (Fi g.
305). Note posi ti on of boost val ve tube brace for
(28) Remove l ower housi ng and overdri ve separa-
tor pl ate from transfer pl ate (Fi g. 305).
(29) Remove the ECE check bal l from the transfer
pl ate (Fi g. 306). The ECE check bal l i s approxi matel y
4.8 mm (3/16 i n.) i n di ameter.
(30) Remove transfer pl ate from upper housi ng
(Fi g. 307).
(31) Turn transfer pl ate over so upper housi ng sep-
arator pl ate i s faci ng upward.
(32) Remove upper housi ng separator pl ate from
transfer pl ate (Fi g. 308). Note posi ti on of fi l ter i n
separator pl ate for assembl y reference.
(33) Remove rear cl utch and rear servo check bal l s
from transfer pl ate. Note check bal l l ocati on for
Fig. 302 Accumulator Housing, Valve Springs And
Plug
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
Fig. 303 Boost Valve Tube Brace
2 - TUBE BRACE (DOUBLE TAB)
Fig. 304 Boost Valve Tube
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 305 Lower Housing
1 - LOWER HOUSING
2 - OVERDRIVE SEPARATOR PLATE
3 - TRANSFER PLATE AND UPPER HOUSING
Fig. 306 ECE Check Ball
1 - ECE CHECK BALL (3/16)
Fig. 307 Transfer Plate
1 - UPPER HOUSING
2 - TRANSFER PLATE
Fig. 308 Upper Housing Separator Plate
1 - TRANSFER PLATE
2 - UPPER HOUSING SEPARATOR PLATE
3 - FILTER SCREEN
4 - BRACE
Fig. 309 Rear Clutch And Rear Servo Check Ball
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
VALVE BODY UPPER HOUSING
(1) Note l ocati on of check bal l s i n val ve body upper
housi ng (Fi g. 310). Then remove the one l arge di am-
eter and the si x smal l er di ameter check bal l s.
(2) Remove governor pl ug and shuttl e val ve covers
(Fi g. 312).
(3) Remove E-cl i p that secures shuttl e val ve sec-
ondary spri ng on val ve stem (Fi g. 311).
(4) Remove throttl e pl ug, pri mary spri ng, shuttl e
val ve, secondary spri ng, and spri ng gui des (Fi g. 312).
(5) Remove boost val ve retai ner, spri ng and val ve
i f not previ ousl y removed.
(6) Remove throttl e pl ug and 1-2 and 2-3 governor
pl ugs (Fi g. 299).
(7) Turn upper housi ng around and remove l i mi t
val ve and shi ft val ve covers (Fi g. 313).
(8) Remove l i mi t val ve housi ng. Then remove
retai ner, spri ng, l i mi t val ve, and 2-3 throttl e pl ug
from l i mi t val ve housi ng (Fi g. 313).
(9) Remove 1-2 shi ft control val ve and spri ng (Fi g.
313).
(10) Remove 1-2 shi ft val ve and spri ng (Fi g. 313).
(11) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 313).
(12) Remove pressure pl ug cover (Fi g. 313).
(13) Remove l i ne pressure pl ug, sl eeve, throttl e
pressure pl ug and spri ng (Fi g. 313).
Fig. 310 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (6)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 311 Shuttle Valve E-Clip And Secondary Spring
Location
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
Fig. 312 Shuttle And Boost Valve Components
Fig. 313 Upper Housing Shift Valve And Pressure Plug Locations
VALVE BODY LOWER HOUSING
(1) Remove ti mi ng val ve cover.
(2) Remove 3-4 ti mi ng val ve and spri ng.
(3) Remove 3-4 qui ck fi l l val ve, spri ng and pl ug.
(4) Remove 3-4 shi ft val ve and spri ng.
(5) Remove converter cl utch val ve, spri ng and pl ug
(Fi g. 314).
(6) Remove converter cl utch ti mi ng val ve, retai ner
and val ve spri ng.
3-4 ACCUMULATOR HOUSING
(1) Remove end pl ate from housi ng.
(2) Remove pi ston spri ng.
(3) Remove pi ston. Remove and di scard pi ston
seal s (Fi g. 315).
CLEANING
Cl ean the val ve housi ngs, val ves, pl ugs, spri ngs,
and separator pl ates wi th a standard parts cl eani ng
sol uti on onl y. Do not use gasol i ne, kerosene, or any
type of causti c sol uti on.
Do not i mmerse any of the el ectri cal components i n
cl eani ng sol uti on. Cl ean the governor sol enoi d and
sensor and the dual sol enoi d and harness assembl y
by wi pi ng them off wi th dry shop towel s onl y.
Dry al l except the el ectri cal parts wi th compressed
ai r. Make sure al l passages are cl ean and free from
obstructi ons. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wi pe the governor pressure sensor and sol enoi d
val ve wi th dry, l i nt free shop towel s onl y. The O-ri ngs
on the sensor and sol enoi d val ve are the onl y servi ce-
abl e components. Be sure the vent ports i n the sol e-
noi d val ve are open and not bl ocked by di rt or debri s.
Repl ace the val ve and/or sensor onl y when DRB scan
tool di agnosi s i ndi cates thi s i s necessary. Or, i f ei ther
part has sustai ned physi cal damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface may
be corrected by smoothi ng the surface wi th a sheet of
crocus cl oth. Posi ti on the crocus cl oth on a surface
pl ate, sheet of pl ate gl ass or equal l y fl at surface. I f di s-
torti on i s severe or any surfaces are heavi l y scored, the
val ve body wi l l have to be repl aced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth but
do not round off the edges of the valve or plug
lands.Mai ntai ni ng sharpness of these edges i s vi tal l y
i mportant. The edges prevent forei gn matter from
l odgi ng between the val ves and pl ugs and the bore.
Fig. 315 Accumulator Housing Components
3 - TEFLON SEALS
4 - PISTON SPRING
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
spri ngs must be free of di storti on, warpage or broken
coi l s.
Check the two separator pl ates for di storti on or
damage of any ki nd. I nspect the upper housi ng,
l ower housi ng, 3-4 accumul ator housi ng, and transfer
pl ate careful l y. Be sure al l fl ui d passages are cl ean
and cl ear. Check condi ti on of the upper housi ng and
transfer pl ate check bal l s as wel l . The check bal l s
and bal l seats must not be worn or damaged.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores.
Val ve body bores do not change di mensi onal l y wi th
use. I f the val ve body functi oned correctl y when new,
i t wi l l conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
The onl y servi ceabl e val ve body components are
l i sted bel ow. The remai ni ng val ve body components
are servi ced onl y as part of a compl ete val ve body
assembl y. Servi ceabl e parts are:
dual sol enoi d and harness assembl y
sol enoi d gasket
sol enoi d case connector O-ri ngs and shoul der
bol t
swi tch val ve and spri ng
pressure adjusti ng screw and bracket assembl y
throttl e l ever
manual l ever and shaft seal
throttl e l ever shaft seal , washer, and E-cl i p
fl ui d fi l ter and screws
detent bal l and spri ng
val ve body screws
governor pressure sol enoi d
governor pressure sensor and retai ni ng cl i p
park l ock rod and E-cl i p
ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
(1) Lubri cate val ves, spri ngs, and the housi ng
val ve and pl ug bores wi th cl ean transmi ssi on fl ui d
(Fi g. 314).
(2) I nstal l 3-4 ti mi ng val ve spri ng and val ve i n
l ower housi ng.
(3) I nstal l 3-4 qui ck fi l l val ve i n l ower housi ng.
(4) I nstal l 3-4 qui ck fi l l val ve spri ng and pl ug i n
housi ng.
(5) I nstal l ti mi ng val ve end pl ate. Ti ghten end
pl ate screws to 4 Nm (35 i n. l bs.) torque.
3-4 ACCUMULATOR
(1) Lubri cate accumul ator pi ston, seal s and housi ng
pi ston bore wi th cl ean transmi ssi on fl ui d (Fi g. 315).
(2) I nstal l new seal ri ngs on accumul ator pi ston.
(3) I nstal l pi ston and spri ng i n housi ng.
(4) I nstal l end pl ate on housi ng.
TRANSFER PLATE
(1) I nstal l rear cl utch and rear servo check bal l s i n
transfer pl ate (Fi g. 316).
(2) I nstal l fi l ter screen i n upper housi ng separator
pl ate (Fi g. 317).
(3) Al i gn and posi ti on upper housi ng separator
pl ate on transfer pl ate (Fi g. 318).
(4) I nstal l brace pl ate (Fi g. 318). Ti ghten brace
attachi ng screws to 4 Nm (35 i n. l bs.) torque.
(5) I nstal l remai ni ng separator pl ate attachi ng
screws. Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
Locations
3 - TRANSFER PLATE
UPPER AND LOWER HOUSING
(1) Posi ti on upper housi ng so i nternal passages
and check bal l seats are faci ng upward. Then i nstal l
check bal l s i n housi ng (Fi g. 319). Ei ght check bal l s
are used. The si ngl e l arge check bal l i s approxi -
matel y 8.7 mm (11/32 i n.) di ameter. The si ngl e smal l
check bal l i s approxi matel y 4.8 mm (3/16 i n.) i n
di ameter. The remai ni ng 6 check bal l s are approxi -
matel y 6.3 mm (1/4 i n.) i n di ameter.
(2) Posi ti on assembl ed transfer pl ate and upper
housi ng separator pl ate on upper housi ng (Fi g. 320).
Be sure fi l ter screen i s seated i n proper housi ng recess.
(3) I nstal l the ECE check bal l i nto the transfer
(4) Posi ti on l ower housi ng separator pl ate on
(5) I nstal l l ower housi ng on assembl ed transfer
pl ate and upper housi ng (Fi g. 322).
(6) I nstal l and start al l val ve body screws by hand
except for the screws to hol d the boost val ve tube
brace. Save those screws for l ater i nstal l ati on. Then
ti ghten screws evenl y to 4 Nm (35 i n. l bs.) torque.
Start at center and work out to si des when ti ghten-
i ng screws (Fi g. 322).
Fig. 317 Separator Plate Filter Screen Installation
2 - FILTER SCREEN
Fig. 318 Brace Plate
1 - BRACE
2 - TRANSFER PLATE
3 - SEPARATOR PLATE
Fig. 320 Installing Transfer Plate On Upper Housing
1 - FILTER SCREEN
2 - TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY
3 - UPPER HOUSING
UPPER HOUSING VALVE AND PLUG
Refer to (Fi g. 323), (Fi g. 324) and (Fi g. 325) to per-
form the fol l owi ng steps.
(1) Lubri cate val ves, pl ugs, spri ngs wi th cl ean
(2) Assembl e regul ator val ve l i ne pressure pl ug,
sl eeve, throttl e pl ug and spri ng. I nsert assembl y i n
upper housi ng and i nstal l cover pl ate. Ti ghten cover
(3) I nstal l 1-2 and 2-3 shi ft val ves and spri ngs.
(4) I nstal l 1-2 shi ft control val ve and spri ng.
(5) I nstal l retai ner, spri ng, l i mi t val ve, and 2-3
throttl e pl ug from l i mi t val ve housi ng.
(6) I nstal l l i mi t val ve housi ng and cover pl ate.
Ti ghten screws to 4 Nm (35 i n. l bs.).
(7) I nstal l shuttl e val ve as fol l ows:
(a) I nsert pl asti c gui des i n shuttl e val ve second-
ary spri ng and i nstal l spri ng on end of val ve.
(b) I nstal l shuttl e val ve i nto housi ng.
(c) Hol d shuttl e val ve i n pl ace.
(d) Compress secondary spri ng and i nstal l E-cl i p
i n groove at end of shuttl e val ve.
(e) Veri fy that spri ng and E-cl i p are properl y
seated before proceedi ng.
(8) I nstal l shuttl e val ve cover pl ate. Ti ghten cover
(9) I nstal l 1-2 and 2-3 val ve governor pl ugs i n
val ve body.
(10) I nstal l shuttl e val ve pri mary spri ng and
throttl e pl ug.
(11) Al i gn and i nstal l governor pl ug cover. Ti ghten
cover screws to 4 Nm (35 i n. l bs.) torque.
Fig. 321 Lower Housing Separator Plate
1 - BE SURE TO ALIGN BORES
2 - TRANSFER PLATE
3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
Fig. 322 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
Fig. 323 Shuttle And Boost Valve Components
BOOST VALVE TUBE AND BRACE
(1) Posi ti on val ve body assembl y so l ower housi ng
i s faci ng upward (Fi g. 326).
(2) Lubri cate tube ends and housi ng ports wi th
transmi ssi on fl ui d or petrol eum jel l y.
(3) Start tube i n l ower housi ng port fi rst. Then
swi ng tube downward and work opposi te end of tube
i nto upper housi ng port (Fi g. 326).
(4) I nsert and seat each end of tube i n housi ngs.
(5) Sl i de tube brace under tube and i nto al i gnment
wi th val ve body screw hol es (Fi g. 327).
(6) I nstal l and fi nger ti ghten three screws that
secure tube brace to val ve body housi ngs (Fi g. 327).
(7) Bend tube brace tabs up and agai nst tube to
hol d i t i n posi ti on (Fi g. 328).
(8) Ti ghten al l val ve body housi ng screws to 4 Nm
(35 i n. l bs.) torque after tube and brace are i nstal l ed.
Ti ghten screws i n di agonal pattern starti ng at center
and worki ng outward.
Fig. 325 Upper Housing Shift Valve And Pressure Plug Locations
3-4 ACCUMULATOR
(1) Posi ti on converter cl utch val ve and 3-4 shi ft
val ve spri ngs i n housi ng (Fi g. 329).
(2) Loosel y attach accumul ator housi ng wi th ri ght-
si de screw (Fi g. 329). I nstal l onl y one screw at thi s
ti me as accumul ator must be free to pi vot upward for
ease of i nstal l ati on.
(3) I nstal l 3-4 shi ft val ve and spri ng.
(4) I nstal l converter cl utch ti mi ng val ve and
spri ng.
(5) Posi ti on pl ug on end of converter cl utch val ve
spri ng. Then compress and hol d spri ngs and pl ug i n
pl ace wi th fi ngers of one hand.
(6) Swi ng accumul ator housi ng upward over val ve
spri ngs and pl ug.
(7) Hol d accumul ator housi ng fi rml y i n pl ace and
i nstal l remai ni ng two attachi ng screws. Be sure
spri ngs and cl utch val ve pl ug are properl y seated
(Fi g. 330). Ti ghten screws to 4 Nm (35 i n. l bs.).
2 - LOWER HOUSING
4 - UPPER HOUSING
Fig. 327 Boost Valve Tube And Brace
2 - TUBE BRACE
Fig. 328 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
Fig. 329 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
VALVE BODY FINAL
(1) I nstal l boost val ve, val ve spri ng, retai ner and
cover pl ate. Ti ghten cover pl ate screws to 4 Nm (35
i n. l bs.) torque.
(2) I nsert manual l ever detent spri ng i n upper
housi ng.
(3) Posi ti on detent bal l on end of spri ng. Then hol d
detent bal l and spri ng i n detent housi ng wi th
Retai ner Tool 6583 (Fi g. 331).
(4) I nstal l throttl e l ever i n upper housi ng. Then
i nstal l manual l ever over throttl e l ever and start
manual l ever i nto housi ng.
(5) Al i gn manual l ever wi th detent bal l and man-
ual val ve. Hol d throttl e l ever upward. Then press
down on manual l ever unti l ful l y seated. Remove
detent bal l retai ner tool after l ever i s seated.
(6) Then i nstal l manual l ever seal , washer and
E-cl i p.
(7) Veri fy that throttl e l ever i s al i gned wi th end of
ki ckdown val ve stem and that manual l ever arm i s
engaged i n manual val ve (Fi g. 332).
(8) Posi ti on l i ne pressure adjusti ng screw i n
adjusti ng screw bracket.
(9) I nstal l spri ng on end of l i ne pressure regul ator
val ve.
(10) I nstal l swi tch val ve spri ng on tang at end of
(11) I nstal l manual val ve.
(12) I nstal l throttl e val ve and spri ng.
(13) I nstal l ki ckdown val ve and detent.
(14) I nstal l pressure regul ator val ve.
(15) I nstal l swi tch val ve.
(16) Posi ti on adjusti ng screw bracket on val ve
body. Al i gn val ve spri ngs and press bracket i nto
pl ace. I nstal l short, upper bracket screws fi rst and
l ong bottom screw l ast. Veri fy that val ve spri ngs and
bracket are properl y al i gned. Then ti ghten al l three
bracket screws to 4 Nm (35 i n. l bs.) torque.
(17) Perform Li ne Pressure and Throttl e Pressure
adjustments. (Refer to 21 - TRANSMI SSI ON/TRAN-
SAXLE/AUTOMATI C/VALVE BODY - ADJUST-
MENTS)
(18) Lubri cate sol enoi d case connector O-ri ngs and
shaft of manual l ever wi th l i ght coat of petrol eum
jel l y.
(19) Attach sol enoi d case connector to 3-4 accumu-
l ator wi th shoul der-type screw. Connector has smal l
l ocati ng tang that fi ts i n di mpl e at top of accumul a-
tor housi ng (Fi g. 333). Seat tang i n di mpl e before
ti ghteni ng connector screw.
(20) I nstal l sol enoi d assembl y and gasket. Ti ghten
sol enoi d attachi ng screws to 8 Nm (72 i n. l bs.)
torque.
(21) Veri fy that sol enoi d wi re harness i s properl y
routed (Fi g. 334). Sol enoi d harness must be cl ear of
manual l ever and park rod and not be pi nched
between accumul ator housi ng and cover.
GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn val ve body assembl y over so accumul ator
si de of transfer pl ate i s faci ng down.
(2) I nstal l new O-ri ngs on governor pressure sol e-
noi d and sensor.
(3) Lubri cate sol enoi d and sensor O-ri ngs wi th
cl ean transmi ssi on fl ui d.
(4) I nstal l governor pressure sensor i n governor
body.
(5) I nstal l governor pressure sol enoi d i n governor
body. Push sol enoi d i n unti l i t snaps i nto pl ace i n
body.
(6) Posi ti on governor body gasket on transfer
pl ate.
Fig. 330 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
Fig. 331 Detent Ball Spring
(7) I nstal l retai ner pl ate on governor body and
around sol enoi d. Be sure sol enoi d connector i s posi -
ti oned i n retai ner cutout.
(8) Al i gn screw hol es i n governor body and trans-
fer pl ate. Then i nstal l and ti ghten governor body
screws to 4 Nm (35 i n. l bs.) torque.
(9) Connect harness wi res to governor pressure
sol enoi d and governor pressure sensor.
(10) I nstal l fl ui d fi l ter and pan.
(12) Fi l l transmi ssi on wi th recommended fl ui d and
road test vehi cl e to veri fy repai r.
INSTALLATION
(1) Check condi ti on of O-ri ng seal s on val ve body
harness connector (Fi g. 335). Repl ace seal s on con-
nector body i f cut or worn.
(2) Check condi ti on of manual l ever shaft seal i n
transmi ssi on case. Repl ace seal i f l i p i s cut or worn.
I nstal l new seal wi th 15/16 deep wel l socket (Fi g.
336).
(3) Check condi ti on of seal s on accumul ator pi ston
(Fi g. 337). I nstal l new pi ston seal s, i f necessary.
(4) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) so bal l on park l ock rod wi l l be easi er to i nstal l
i n sprag.
(5) Lubri cate shaft of manual l ever wi th petrol eum
jel l y. Thi s wi l l ease i nserti ng shaft through seal i n
case.
(6) Lubri cate seal ri ngs on val ve body harness con-
nector wi th petrol eum jel l y.
(7) Posi ti on val ve body i n case and work end of
park l ock rod i nto and through pawl sprag. Turn pro-
pel l er shaft to al i gn sprag and park l ock teeth i f nec-
essary. The rod wi l l cl i ck as i t enters pawl . Move rod
to check engagement.
in the pawl and has not displaced into this cavity.
(8) I nstal l accumul ator spri ngs and pi ston i nto
case. Then swi ng val ve body over pi ston and outer
spri ng to hol d i t i n pl ace.
(9) Al i gn accumul ator pi ston and outer spri ng,
manual l ever shaft and el ectri cal connector i n case.
(10) Then seat val ve body i n case and i nstal l one
or two bol ts to hol d val ve body i n pl ace.
Fig. 332 Manual And Throttle Lever Alignment
1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE
Shoulder Bolt
Fig. 334 Solenoid Harness Routing
(11) Ti ghten val ve body bol ts al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
(12) I nstal l new fl ui d fi l ter on val ve body. Ti ghten
fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(13) I nstal l throttl e and gearshi ft l evers on val ve
(14) Check and adjust front and rear bands i f nec-
essary.
(15) Connect sol enoi d case connector wi res.
(16) I nstal l the transmi ssi on range sensor.
(17) I nstal l oi l pan and new gasket. Ti ghten pan
(18) Lower vehi cl e and fi l l transmi ssi on wi th
(19) Check and adjust gearshi ft and throttl e val ve
cabl es, i f necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 338).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
Fig. 335 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
Fig. 336 Manual Lever Shaft Seal
1 - 15/16'' SOCKET
2 - SEAL
Fig. 337 Accumulator Piston Components
1 - INNER SPRING
3 - OUTER SPRING
4 - SEAL RINGS
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 339).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 338 Line Pressure Adjustment
1 - WRENCH
2 - 15/16 INCH
Fig. 339 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 257
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
AUTOMATIC TRANSMISSION. . . . . . . . . . . . . 265
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . . . 265
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . 265
HYDRAULIC PRESSURE TEST . . . . . . . . . . . 266
AIR TESTING TRANSMISSION CLUTCH
AND BAND OPERATION. . . . . . . . . . . . . . . . . 269
CONVERTER HOUSING FLUID LEAK . . . . . . 269
DIAGNOSIS CHARTS. . . . . . . . . . . . . . . . . . . 270
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 283
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 298
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 312
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 314
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 317
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
BANDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 318
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 319
ELECTRONIC GOVERNOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 320
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 323
EXTENSION HOUSING BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 324
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 325
FLUID AND FILTER
FRONT CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 328
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 329
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
FRONT SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 332
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 333
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
GEARSHIFT CABLE
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . 334
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 336
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 337
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 337
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 339
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
OUTPUT SHAFT FRONT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 343
OUTPUT SHAFT REAR BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 344
OVERDRIVE CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 344
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 345
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
OVERDRIVE ELECTRICAL CONTROLS . . . . . 345
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 346
OVERDRIVE UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 347
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 364
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 365
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 366
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 369
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 370
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 371
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
REAR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 376
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 377
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
REAR SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 380
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 380
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 381
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 381
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 382
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 383
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 383
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 385
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 390
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 391
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
TORQUE CONVERTER DRAINBACK VALVE . 391
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 391
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
TRANSMISSION RANGE SENSOR (TRS) . . . . 393
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 394
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 395
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 396
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 416
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 437
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 438
46RE
DESCRIPTION
The 46RE (Fi g. 1) i s a four speed ful l y automati c
transmi ssi ons wi th an el ectroni c governor. The 46RE
i s equi pped wi th a l ock-up cl utch i n the torque con-
verter. Fi rst through thi rd gear ranges are provi ded
by the cl utches, bands, overrunni ng cl utch, and pl an-
etary gear sets i n the transmi ssi on. Fourth gear
range i s provi ded by the overdri ve uni t that contai ns
an overdri ve cl utch, di rect cl utch, pl anetary gear set,
and overrunni ng cl utch.
The transmi ssi on contai ns a front, rear, and di rect
cl utch whi ch functi on as the i nput dri vi ng compo-
nents. I t al so contai ns the ki ckdown (front) and the
l ow/reverse (rear) bands whi ch, al ong wi th the over-
runni ng cl utch and overdri ve cl utch, serve as the
hol di ng components. The dri vi ng and hol di ng compo-
nents combi ne to sel ect the necessary pl anetary gear
components, i n the front, rear, or overdri ve pl anetary
gear set, transfer the engi ne power from the i nput
shaft through to the output shaft.
The val ve body i s mounted to the l ower si de of the
transmi ssi on and contai ns the val ves to control pres-
sure regul ati on, fl ui d fl ow control , and cl utch/band
appl i cati on. The oi l pump i s mounted at the front of
the transmi ssi on and i s dri ven by the torque con-
verter hub. The pump suppl i es the oi l pressure nec-
essary for cl utch/band actuati on and transmi ssi on
l ubri cati on.
F
i
g
.
1
4
6
R
E
T
r
a
n
s
m
i
s
s
i
o
n
IDENTIFICATION
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
GEAR RATIOS The 46RE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69:1
Rev. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
OPERATION
The appl i cati on of each dri vi ng or hol di ng compo-
nent i s control l ed by the val ve body based upon the
manual l ever posi ti on, throttl e pressure, and gover-
nor pressure. The governor pressure i s a vari abl e
pressure i nput to the val ve body and i s one of the
si gnal s that a shi ft i s necessary. Fi rst through fourth
gear are obtai ned by sel ecti vel y appl yi ng and rel eas-
i ng the di fferent cl utches and bands. Engi ne power i s
thereby routed to the vari ous pl anetary gear assem-
bl i es whi ch combi ne wi th the overrunni ng cl utch
assembl i es to generate the di fferent gear rati os. The
torque converter cl utch i s hydraul i cal l y appl i ed and
i s rel eased when fl ui d i s vented from the hydraul i c
ci rcui t by the torque converter control (TCC) sol enoi d
on the val ve body. The torque converter cl utch i s con-
trol l ed by the Powertrai n Control Modul e (PCM). The
torque converter cl utch engages i n fourth gear, and
i n thi rd gear under vari ous condi ti ons, such as when
the O/D swi tch i s OFF, when the vehi cl e i s crui si ng
on a l evel surface after the vehi cl e has warmed up.
The torque converter cl utch wi l l di sengage momen-
tari l y when an i ncrease i n engi ne l oad i s sensed by
the PCM, such as when the vehi cl e begi ns to go
uphi l l or the throttl e pressure i s i ncreased. The
torque converter cl utch feature i ncreases fuel econ-
omy and reduces the transmi ssi on fl ui d temperature.
Si nce the overdri ve cl utch i s appl i ed i n fourth gear
onl y and the di rect cl utch i s appl i ed i n al l ranges
except fourth gear, the transmi ssi on operati on for
park, neutral , and fi rst through thi rd gear wi l l be
descri bed fi rst. Once these powerfl ows are descri bed,
the thi rd to fourth shi ft sequence wi l l be descri bed.
1 - TORQUE CONVERTER 11 - DIRECT CLUTCH
2 - INPUT SHAFT 12 - PLANETARY GEAR
3 - OIL PUMP 13 - OUTPUT SHAFT
4 - FRONT BAND 14 - SEAL
5 - FRONT CLUTCH 15 - INTERMEDIATE SHAFT
6 - REAR CLUTCH 16 - OVERDRIVE OVERRUNNING CLUTCH
7 - PLANETARIES 17 - DIRECT CLUTCH SPRING
8 - REAR BAND 18 - OVERDRIVE PISTON RETAINER
9 - OVERRUNNING CLUTCH 19 - FILTER
10 - OVERDRIVE CLUTCH 20 - VALVE BODY
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
PARK POWERFLOW
As the engi ne i s runni ng and the crankshaft i s
rotati ng, the fl expl ate and torque converter, whi ch
are al so bol ted to i t, are al l rotati ng i n a cl ockwi se
di recti on as vi ewed from the front of the engi ne. The
notched hub of the torque converter i s connected to
the oi l pumps i nternal gear, suppl yi ng the transmi s-
si on wi th oi l pressure. As the converter turns, i t
turns the i nput shaft i n a cl ockwi se di recti on. As the
i nput shaft i s rotati ng, the front cl utch hub-rear
cl utch retai ner and al l thei r associ ated parts are al so
rotati ng, al l bei ng di rectl y connected to the i nput
shaft. The power fl ow from the engi ne through the
front cl utch hub and rear cl utch retai ner stops at the
rear cl utch retai ner. Therefore, no power fl ow to the
output shaft occurs because no cl utches are appl i ed.
The onl y mechani sm i n use at thi s ti me i s the park-
i ng sprag (Fi g. 3), whi ch l ocks the parki ng gear on
the output shaft to the transmi ssi on case.
NEUTRAL POWERFLOW
Wi th the gear sel ector i n the NEUTRAL posi ti on
(Fi g. 4), the power fl ow of the transmi ssi on i s essen-
ti al l y the same as i n the park posi ti on. The onl y
operati onal di fference i s that the parki ng sprag has
been di sengaged, unl ocki ng the output shaft from the
transmi ssi on case and al l owi ng i t to move freel y.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5 - PAWL
REVERSE POWERFLOW
When the gear sel ector i s moved i nto the
REVERSE posi ti on (Fi g. 5), the front cl utch and the
rear band are appl i ed. Wi th the appl i cati on of the
front cl utch, engi ne torque i s appl i ed to the sun gear,
turni ng i t i n a cl ockwi se di recti on. The cl ockwi se
rotati on of the sun gear causes the rear pl anet pi n-
i ons to rotate agai nst engi ne rotati on i n a counter-
cl ockwi se di recti on. The rear band i s hol di ng the l ow
reverse drum, whi ch i s spl i ned to the rear carri er.
Si nce the rear carri er i s bei ng hel d, the torque from
the pl anet pi ni ons i s transferred to the rear annul us
gear, whi ch i s spl i ned to the output shaft. The output
shaft i n turn rotates wi th the annul us gear i n a
countercl ockwi se di recti on gi vi ng a reverse gear out-
put. The enti re transmi ssi on of torque i s appl i ed to
the rear pl anetary gearset onl y. Al though there i s
torque i nput to the front gearset through the sun
gear, no other member of the gearset i s bei ng hel d.
Duri ng the enti re reverse stage of operati on, the
front pl anetary gears are i n an i dl i ng condi ti on.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
FIRST GEAR POWERFLOW
When the gearshi ft l ever i s moved i nto the DRI VE
posi ti on the transmi ssi on goes i nto fi rst gear (Fi g. 6).
As soon as the transmi ssi on i s shi fted from PARK or
NEUTRAL to DRI VE, the rear cl utch appl i es, appl y-
i ng the rear cl utch pack to the front annul us gear.
Engi ne torque i s now appl i ed to the front annul us
gear turni ng i t i n a cl ockwi se di recti on. Wi th the
front annul us gear turni ng i n a cl ockwi se di recti on, i t
causes the front pl anets to turn i n a cl ockwi se di rec-
ti on. The rotati on of the front pl anets cause the sun
to revol ve i n a countercl ockwi se di recti on. The sun
gear now transfers i ts countercl ockwi se rotati on to
the rear pl anets whi ch rotate back i n a cl ockwi se
di recti on. Wi th the rear annul us gear stati onary, the
rear pl anet rotati on on the annul us gear causes the
rear pl anet carri er to revol ve i n a countercl ockwi se
di recti on. The rear pl anet carri er i s spl i ned i nto the
l ow-reverse drum, and the l ow reverse drum i s
spl i ned to the i nner race of the over-runni ng cl utch.
Wi th the over-runni ng cl utch l ocked, the pl anet car-
ri er i s hel d, and the resul ti ng torque provi ded by the
pl anet pi ni ons i s transferred to the rear annul us
gear. The rear annul us gear i s spl i ned to the output
shaft and rotated al ong wi th i t (cl ockwi se) i n an
underdri ve gear reducti on mode.
Fig. 6 First Gear Powerflow
1 - OUTPUT SHAFT 5 - OVER-RUNNING CLUTCH HOLDING
2 - OVER-RUNNING CLUTCH HOLDING 6 - INPUT SHAFT
3 - REAR CLUTCH APPLIED 7 - REAR CLUTCH APPLIED
SECOND GEAR POWERFLOW
I n DRI VE-SECOND (Fi g. 7), the same el ements
are appl i ed as i n MANUAL-SECOND. Therefore, the
power fl ow wi l l be the same, and both gears wi l l be
di scussed as one i n the same. I n DRI VE-SECOND,
the transmi ssi on has proceeded from fi rst gear to i ts
shi ft poi nt, and i s shi fti ng from fi rst gear to second.
The second gear shi ft i s obtai ned by keepi ng the rear
cl utch appl i ed and appl yi ng the front (ki ckdown)
band. The front band hol ds the front cl utch retai ner
that i s l ocked to the sun gear dri vi ng shel l . Wi th the
rear cl utch sti l l appl i ed, the i nput i s sti l l on the front
annul us gear turni ng i t cl ockwi se at engi ne speed.
Now that the front band i s hol di ng the sun gear sta-
ti onary, the annul us rotati on causes the front pl anets
to rotate i n a cl ockwi se di recti on. The front carri er i s
then al so made to rotate i n a cl ockwi se di recti on but
at a reduced speed. Thi s wi l l transmi t the torque to
the output shaft, whi ch i s di rectl y connected to the
front pl anet carri er. The rear pl anetary annul us gear
wi l l al so be turni ng because i t i s di rectl y spl i ned to
the output shaft. Al l power fl ow has occurred i n the
front pl anetary gear set duri ng the dri ve-second
stage of operati on, and now the over-runni ng cl utch,
i n the rear of the transmi ssi on, i s di sengaged and
freewheel i ng on i ts hub.
Fig. 7 Second Gear Powerflow
1 - KICKDOWN BAND APPLIED 6 - INPUT SHAFT
3 - REAR CLUTCH ENGAGED 8 - KICKDOWN BAND APPLIED
5 - OVER-RUNNING CLUTCH FREE-WHEELING
DIRECT DRIVE POWERFLOW
The vehi cl e has accel erated and reached the shi ft
poi nt for the 2-3 upshi ft i nto di rect dri ve (Fi g. 8).
When the shi ft takes pl ace, the front band i s
rel eased, and the front cl utch i s appl i ed. The rear
cl utch stays appl i ed as i t has been i n al l the forward
gears. Wi th the front cl utch now appl i ed, engi ne
torque i s now on the front cl utch retai ner, whi ch i s
l ocked to the sun gear dri vi ng shel l . Thi s means that
the sun gear i s now turni ng i n engi ne rotati on (cl ock-
wi se) and at engi ne speed. The rear cl utch i s sti l l
appl i ed so engi ne torque i s al so sti l l on the front
annul us gear. I f two members of the same pl anetary
set are dri ven, di rect dri ve resul ts. Therefore, when
two members are rotati ng at the same speed and i n
the same di recti on, i t i s the same as bei ng l ocked up.
The rear pl anetary set i s al so l ocked up, gi ven the
sun gear i s sti l l the i nput, and the rear annul us gear
must turn wi th the output shaft. Both gears are
turni ng i n the same di recti on and at the same speed.
The front and rear pl anet pi ni ons do not turn at al l
i n di rect dri ve. The onl y rotati on i s the i nput from
the engi ne to the connected parts, whi ch are acti ng
as one common uni t, to the output shaft.
Fig. 8 Direct Drive Powerflow
1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
FOURTH GEAR POWERFLOW
Fourth gear overdri ve range i s el ectroni cal l y con-
trol l ed and hydraul i cal l y acti vated. Vari ous sensor
i nputs are suppl i ed to the powertrai n control modul e
to operate the overdri ve sol enoi d on the val ve body.
The sol enoi d contai ns a check bal l that opens and
cl oses a vent port i n the 3-4 shi ft val ve feed passage.
The overdri ve sol enoi d (and check bal l ) are not ener-
gi zed i n fi rst, second, thi rd, or reverse gear. The vent
port remai ns open, di verti ng l i ne pressure from the
2-3 shi ft val ve away from the 3-4 shi ft val ve. The
overdri ve control swi tch must be i n the ON posi ti on
to transmi t overdri ve status to the PCM. A 3-4
upshi ft occurs onl y when the overdri ve sol enoi d i s
energi zed by the PCM. The PCM energi zes the over-
dri ve sol enoi d duri ng the 3-4 upshi ft. Thi s causes the
sol enoi d check bal l to cl ose the vent port al l owi ng
l i ne pressure from the 2-3 shi ft val ve to act di rectl y
on the 3-4 upshi ft val ve. Li ne pressure on the 3-4
shi ft val ve overcomes val ve spri ng pressure movi ng
the val ve to the upshi ft posi ti on. Thi s acti on exposes
overdri ve pi ston. Li ne pressure through the ti mi ng
val ve moves the overdri ve pi ston i nto contact wi th
the overdri ve cl utch. The di rect cl utch i s di sengaged
before the overdri ve cl utch i s engaged. The boost
val ve provi des i ncreased fl ui d appl y pressure to the
overdri ve cl utch duri ng 3-4 upshi fts, and when accel -
erati ng i n fourth gear. The 3-4 accumul ator cushi ons
overdri ve cl utch engagement to smooth 3-4 upshi fts.
The accumul ator i s charged at the same ti me as
appl y pressure acts agai nst the overdri ve pi ston.
TRANSMISSION
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
forward).
VEHICLE IS DRIVEABLE
scan tool .
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(6) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
fol l owi ng:
si on and check for damaged dri ve pl ate, converter,
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned by
compari ng whi ch i nternal uni ts are appl i ed i n the var-
i ous gear ranges. The Cl utch and Band Appl i cati on
chart provi des a basi s for anal yzi ng road test resul ts.
CLUTCH AND BAND APPLICATION CHART
SHIFT
LEVER
POSITION
TRANSMISSION CLUTCHES AND BANDS OVERDRIVE CLUTCHES
FRONT
CLUTCH
FRONT
BAND
REAR
CLUTCH
REAR
BAND
OVERRUNNING
CLUTCH
OVERDRIVE
CLUTCH
DIRECT
CLUTCH
OVERRUNNING
CLUTCH
Reverse X X X
Drive -
First
X X X X
Drive -
Second
X X X X
Drive -
Third
X X X X
Drive -
Fourth
X X X
Manual
Second
X X X X X
Manual
First
X X X X X
Note that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Note that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear.
For exampl e: I f sl i ppage occurs i n fi rst gear i n D
and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, note that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd and fourth gear. I f the
transmi ssi on sl i ps i n thi rd gear, ei ther the front
cl utch or the rear cl utch i s sl i ppi ng.
I f the transmi ssi on sl i ps i n fourth gear but not i n
thi rd gear, the overdri ve cl utch i s sl i ppi ng. By sel ect-
i ng another gear whi ch does not use these cl utches,
the sl i ppi ng uni t can be determi ned. For exampl e, i f
the transmi ssi on al so sl i ps i n Reverse, the front
cl utch i s sl i ppi ng. I f the transmi ssi on does not sl i p i n
Reverse, the rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the 3-4 shi ft or onl y i n
fourth gear, the overdri ve cl utch i s sl i ppi ng. Si mi -
l arl y, i f the di rect cl utch were to fai l , the transmi s-
si on woul d l ose both reverse gear and overrun
braki ng i n 2 posi ti on (manual second gear).
I f the transmi ssi on wi l l not shi ft to fourth gear, the
control swi tch, overdri ve sol enoi d or rel ated wi ri ng
may al so be the probl em cause.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
are requi red. Test Gauge C-3292 has a 100 psi range
and i s used at the accumul ator, governor, and front
servo ports. Test Gauge C-3293-SP has a 300 psi
range and i s used at the rear servo and overdri ve
ports where pressures exceed 100 psi .
Test ports are l ocated at both si des of the transmi s-
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
The rear servo and governor pressure ports are at
the ri ght rear of the transmi ssi on case. The overdri ve
cl utch pressure port i s at the l eft rear of the case.
Test One - Transmission In Manual Low
ulation, and condition of the rear clutch and servo
circuit. Both test gauges are required for this test.
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be observed from dri ver seat i f hel per
wi l l be operati ng engi ne. Rai se vehi cl e on hoi st that
wi l l al l ow rear wheel s to rotate freel y.
(2) Connect 100 psi Gauge C-3292 to accumul ator
port. Then connect 300 psi Gauge C-3293-SP to rear
servo port.
(3) Di sconnect throttl e and gearshi ft cabl es from
l evers on transmi ssi on val ve body manual shaft.
(5) Move transmi ssi on shi ft l ever ful l y forward
i nto 1 range.
(6) Gradual l y move transmi ssi on throttl e l ever
from ful l forward to ful l rearward posi ti on and note
pressures on both gauges:
Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
throttl e l ever i s moved rearward.
Rear servo pressure shoul d be same as l i ne pres-
sure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
NOTE: This test checks pump output, line pressure
and pressure regulation. Use 100 psi Test Gauge
C-3292 for this test.
(1) Leave vehi cl e i n pl ace on hoi st and l eave Test
Gauge C-3292 connected to accumul ator port.
(3) Move transmi ssi on shi ft l ever one detent rear-
ward from ful l forward posi ti on. Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure on
gauge.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range Third Gear
NOTE: This test checks pressure regulation and
condition of the clutch circuits. Both test gauges
are required for this test.
(1) Turn OD swi tch off.
(2) Leave vehi cl e on hoi st and l eave Gauge C-3292
(3) Move Gauge C-3293-SP over to front servo port
for thi s test.
for thi s test.
(6) Read pressures on both gauges as transmi ssi on
throttl e l ever i s gradual l y moved from ful l forward to
ful l rearward posi ti on:
Li ne pressure at accumul ator i n D range thi rd
gear, shoul d be 54-60 psi (372-414 kPa) wi th throttl e
l ever forward and i ncrease as l ever i s moved rear-
ward.
Front servo pressure i n D range thi rd gear,
shoul d be wi thi n 3 psi (21 kPa) of l i ne pressure up to
ki ckdown poi nt.
Fig. 9 Pressure Test Port Locations
1 - REAR SERVO TEST PORT
2 - GOVERNOR TEST PORT
3 - ACCUMULATOR TEST PORT
4 - FRONT SERVO TEST PORT
5 - OVERDRIVE CLUTCH TEST PORT
Test Four - Transmission In Reverse
ulation and the front clutch and rear servo circuits.
Use 300 psi Test Gauge C-3293-SP for this test.
(1) Leave vehi cl e on hoi st and l eave gauge C-3292
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
for test.
(4) Move transmi ssi on shi ft l ever four detents
rearward from ful l forward posi ti on. Thi s i s Reverse
range.
(5) Move transmi ssi on throttl e l ever ful l y forward
then ful l y rearward and note readi ng at Gauge
C-3293-SP.
(6) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th throttl e l ever forward and i ncrease to 230 -
280 psi (1586-1931 kPa) as l ever i s gradual l y moved
rearward.
Test Five - Governor Pressure
NOTE: This test checks governor operation by mea-
suring governor pressure response to changes in
vehicle speed. It is usually not necessary to check
governor operation unless shift speeds are incor-
rect or if the transmission will not downshift. The
test should be performed on the road or on a hoist
that will allow the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(3) Have hel per start and run engi ne at curb i dl e
speed. Then fi rml y appl y servi ce brakes so wheel s
wi l l not rotate.
(4) Note governor pressure:
Governor pressure shoul d be no more than 20.6
kPa (3 psi ) at curb i dl e speed and wheel s not rotat-
i ng.
I f pressure exceeds 20.6 kPa (3 psi ), a faul t
exi sts i n governor pressure control system.
(5) Rel ease brakes, sl owl y i ncrease engi ne speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
Or approxi matel y 6.89 kPa (1 psi ) for every 1 mph.
(6) Governor pressure ri se shoul d be smooth and
drop back to no more than 20.6 kPa (3 psi ), after
engi ne returns to curb i dl e and brakes are appl i ed to
prevent wheel s from rotati ng.
(7) Compare resul ts of pressure test wi th anal ysi s
chart.
Test Six - Transmission In Overdrive Fourth Gear
NOTE: This test checks line pressure at the over-
drive clutch in fourth gear range. Use 300 psi Test
Gauge C-3293-SP for this test. The test should be
performed on the road or on a chassis dyno.
(1) Remove tachometer; i t i s not needed for thi s
test.
(2) Move 300 psi Gauge to overdri ve cl utch pres-
sure test port. Then remove other gauge and rei nstal l
test port pl ug.
(4) Turn OD swi tch on.
(5) Secure test gauge so i t can be vi ewed from
dri vers seat.
(6) Start engi ne and shi ft i nto D range.
(7) I ncrease vehi cl e speed gradual l y unti l 3-4 shi ft
occurs and note gauge pressure.
(8) Pressure shoul d be 469-496 kPa (68-72 psi )
wi th cl osed throttl e and i ncrease to 620-827 kPa (90-
120 psi ) at 1/2 to 3/4 throttl e. Note that pressure can
i ncrease to around 896 kPa (130 psi ) at ful l throttl e.
(9) Return to shop or move vehi cl e off chassi s
dyno.
PRESSURE TEST ANALYSIS CHART
Line pressure OK during
any one test
Pump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear Range
Overdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area
Pressure OK in 2 but low
in R and 1
Leakage in rear servo
Front servo pressure in 2 Leakage in servo; broken
servo ring or cracked
servo piston
Pressure low in all
positions
Clogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speed
Governor pressure
solenoid valve system
fault. Refer to diagnostic
book.
Governor pressure low at
all mph figures
Faulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Lubrication pressure low
at all throttle positions
Clogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Line pressure high Output shaft plugged,
sticky regulator valve
Line pressure low Sticky regulator valve,
clogged filter, worn pump
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
servo and cl utch appl y passages are shown (Fi g. 10).
Front Clutch Air Test
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
HOUSING FLUID LEAK
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
body l eaks fol l ow the same path as a seal l eak (Fi g.
11). Pump vent or pump attachi ng bol t l eaks are gen-
eral l y deposi ted on the i nsi de of the converter hous-
i ng and not on the converter i tsel f (Fi g. 11). Pump
o-ri ng or gasket l eaks usual l y travel down the i nsi de
of the converter housi ng. Front band l ever pi n pl ug
l eaks are general l y deposi ted on the housi ng and not
on the converter.
1 - LINE PRESSURE TO ACCUMULATOR
2 - REAR SERVO APPLY
3 - FRONT SERVO APPLY
4 - FRONT SERVO RELEASE
5 - PUMP SUCTION
6 - PUMP PRESSURE
7 - FRONT CLUTCH APPLY
8 - REAR CLUTCH APPLY
9 - TO TORQUE CONVERTOR
10 - TO COOLER
11 - FROM TORQUE CONVERTER
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or PermatexNo. 2 to
pl ug threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
PARK, NEUTRAL, FI RST, SECOND, THI RD,
FOURTH, MANUAL FI RST, MANUAL SECOND,
and REVERSE gear ranges. Normal worki ng pres-
sures are al so suppl i ed for each of the gear ranges.
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 12 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
DIAGNOSIS CHARTS
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Add Fluid
2. Throttle Linkage Mis-adjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Mis-adjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty. 11. Replace converter and flush cooler and
line before installing new converter.
DELAYED ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
or damaged.
4. Torque Converter Drain Back (Oil
drains from torque converter into
transmission sump).
4. If vehicle moves normally after 5
seconds after shifting into gear, no repair is
necessary. If longer, inspect pump bushing
for wear. Replace pump house.
6. Valve Body Filter Plugged. 6. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
7. Oil Pump Gears Worn/Damaged. 7. Remove transmission and replace oil
pump.
8. Governor Circuit and Solenoid
Valve Electrical Fault.
8. Test with DRB scan tool and repair as
required.
9. Hydraulic Pressure Incorrect. 9. Perform pressure test, remove
transmission and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.
10. Remove transmission, remove oil pump
and replace seal rings.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
11. Remove and disassemble transmission
12. Regulator Valve Stuck. 12. Clean.
13. Cooler Plugged. 13. Transfer case failure can plug cooler.
NO DRIVE RANGE
(REVERSE OK)
restored.
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
restored.
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body. Replace
valve body (as assembly) if any valve or
bore is damaged. Clean and reassemble
correctly if all parts are in good condition.
7. Transmission Internal Component
Damaged.
needed.
8. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.
8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return
to closed throttle at transmission.
Mis-adjusted.
5. Adjust linkage/cable as described in
service section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)
Mis-adjusted/Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor
plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
stuck 1-2 valve or governor plug.
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
required.
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in
Bore.
3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR
NORMAL DOWNSHIFT
2. Accelerator Pedal Travel
Restricted.
2. Verify floor mat is not under pedal, repair
worn accelerator cable or bent brackets.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.
3. Perform hydraulic pressure tests to
required.
required.
5. Valve Body Malfunction. 5. Perform hydraulic pressure tests to
required.
6. TPS Malfunction. 6. Replace sensor, check with DRB scan
tool.
if required.
8. Valve Body Malfunction. 8. Repair sticking 1-2, 2-3 shift valves,
governor plugs, 3-4 solenoid, 3-4 shift
valve, 3-4 timing valve.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
1. Throttle Linkage Mis-adjusted/
Stuck.
1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
or damaged.
3. Governor Component Electrical
Fault.
3. Check operating pressures and test with
DRB scan tool, repair faulty component.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Mis-adjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped. 2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Mis-assembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Mis-assembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
4. Rear Band Worn. 4. Replace as required.
5. Overdrive Direct Clutch Worn. 5. Disassemble overdrive. Repair as
needed.
6. Hydraulic Pressure Too Low. 6. Perform hydraulic pressure tests to
determine cause.
7. Rear Servo Leaking. 7. Air pressure check clutch-servo operation
8. Band Linkage Binding. 8. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged Filter
or Cooler Lines.
6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo operation
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR D
ONLY, BUT NOT IN
MANUAL 1 POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.
6. Output Shaft Bearing or Bushing
Damaged.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands Mis-
adjusted.
8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Mis-adjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.
1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRB scan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRB scan tool at
PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid
if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
NO 4-3 DOWNSHIFT
WHEN CONTROL SWITCH
IS TURNED OFF
1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.
2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction. 3. Test with DRB scan tool. Replace PCM
if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup timing
valve.
CLUNK NOISE FROM
DRIVELINE ON CLOSED
THROTTLE 4-3
DOWNSHIFT
1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.
3. Replace overdrive piston thrust plate
spacer.
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT
1. Overdrive Solenoid Connector or
Wiring Shorted.
1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRB scan tool.
3. PCM Malfunction. 3. Test PCM with DRB scan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect
valve body components. Make sure all
valves and plugs slide freely in bores.
Polish valves with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.
3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.
4. Check with DRB scan tool and repair
or replace as necessary.
5. TPS Malfunction. 5. Check with DRB scan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.
6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRB scan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.
9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
SLIPS IN OVERDRIVE
FOURTH GEAR
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch
pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.
3. Disassemble transmission, remove
retainer and replace orifice.
4. Overdrive Piston or Seal
Malfunction.
4. Remove overdrive unit. Replace seals if
worn. Replace piston if damaged. If piston
retainer is damaged, remove and
disassemble the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.
5. Remove and overhaul valve body.
Replace accumulator seals. Make sure all
valves operate freely in bores and do not
bind or stick. Make sure valve body screws
are correctly tightened and separator plates
are properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.
6. Disassemble overdrive unit and replace
thrust bearing (NO. 1 thrust bearing is
between overdrive piston and clutch hub;
NO. 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; NO. 3 thrust bearing is between
overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.
7. Check for function/secure orifice insert in
O/D piston retainer.
DELAYED 3-4 UPSHIFT
(SLOW TO ENGAGE)
2. Throttle Valve Cable Mis-adjusted. 2. Adjust throttle valve cable.
3. Overdrive Clutch Pack Worn/
Burnt.
4. TPS Faulty. 4. Test with DRB scan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice
Plugged.
5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.
6. Test solenoid and check wiring for
loose/corroded connections or shorts/
grounds. Replace solenoid if faulty and
repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and
select proper spacer.
8. O/D Check Valve Missing or
Stuck.
8. Check for presence of check valve.
Repair or replace as required.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2, 2-3, 3-4 OR
3-2 SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL
Mis-adjusted.
1. Adjust linkage/cable.
2. Neutral Sense Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
Transmission Range Sensor Faulty.
3. Refer to service section for test and
replacement procedure.
Connection Faulty.
4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
3. Front Clutch Malfunctioned/
Burned.
3. Air-pressure test clutch operation.
Remove and rebuild if necessary.
4. Overdrive Thrust Bearing Failure. 4. Disassemble geartrain and replace
bearings.
5. Direct Clutch Spring Collapsed/
Broken.
5. Remove and disassemble unit. Check
clutch position and replace spring.
OIL LEAKS. 1. Fluid Lines and Fittings Loose/
Leaks/Damaged.
1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Fill Tube (where tube enters case)
Leaks/Damaged.
2. Replace tube seal. Inspect tube for
cracks in fill tube.
3. Pressure Port Plug Loose
Loose/Damaged.
3. Tighten to correct torque. Replace plug
or reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
5. Replace shaft seal.
6. Rear Bearing Access Plate Leaks. 6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.
7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.
8. Replace gasket.
Leaks/Damaged.
9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.
11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.
12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION IN
FOURTH GEAR ONLY
1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.
either thrust bearing if damaged.
3. Output Shaft Bearings Scored/
Damaged.
either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.
5. Remove and overhaul overdrive unit.
THREAD REPAIR
ers.
REMOVAL
The overdri ve uni t can be removed and servi ced
separatel y. I t i s not necessary to remove the enti re
transmi ssi on assembl y to perform overdri ve uni t
repai rs.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.
(2) Hoi st and support vehi cl e.
(4) Remove ski d pl ate support crossmember, i f
equi pped.
(5) Di sconnect and l ower or remove necessary
exhaust components.
fl anges for assembl y al i gnment. Then di sconnect and
remove propel l er shaft. (Refer to 3 - DI FFERENTI AL
& DRI VELI NE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
(7) Remove starter motor. (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL)
(8) Support engi ne wi th sui tabl e support stand
and wood bl ock.
(9) Remove bol ts attachi ng engi ne-to-transmi ssi on
(10) Remove bol t and nut attachi ng each engi ne-
to-transmi ssi on bracket to the motor mounts.
(11) Remove bol ts hol di ng the engi ne-to-transmi s-
si on brackets to the front axl e, i f equi pped.
(14) Remove torque converter access cover.
(16) Lower engi ne.
(17) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(18) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(19) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . On 4x4
model s, i t wi l l al so be necessary to remove bol t
attachi ng transfer case vent tube to converter hous-
i ng (Fi g. 13).
dampener bol t.
(21) Di sconnect wi res from the transmi ssi on range
sensor and transmi ssi on sol enoi ds connector.
(22) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(23) On 4x4 model s, di sconnect shi ft rod from
transfer case shi ft l ever. Or remove shi ft l ever from
transfer case and ti e rod and l ever to chassi s compo-
nent wi th wi re.
i on to transmi ssi on and crossmember. Rai se trans-
mi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket (Fi g. 14) and remove rear support.
(27) On 4x4 model s, di sconnect vent hose from
transfer case. Then remove transfer case.
(28) Remove al l converter housi ng bol ts.
Fig. 13 Fill Tube Attachment
1 - TRANSFER CASE VENT TUBE
2 - FILL TUBE (V8)
3 - TUBE SEAL
4 - FILL TUBE (V6)
DISASSEMBLY
(1) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(2) Pl ace transmi ssi on i n verti cal posi ti on.
(3) Measure the i nput shaft end pl ay as fol l ows
(Fi g. 15).
8266-8.
shaft.
tor.
i ng. Record the maxi mum travel for assembl y ref-
erence
(4) Remove throttl e and shi ft l evers from val ve
body manual shaft and throttl e l ever shaft.
(6) Remove fi l ter from val ve body (Fi g. 16). Keep
fi l ter screws separate from other val ve body screws.
Fi l ter screws are l onger and shoul d be kept wi th fi l ter.
Fig. 14 Rear Support and Cushion
1 - EXHAUST PIPE ARM AND BRACKET
2 - CROSSMEMBER
3 - REAR SUPPORT AND CUSHION
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
Fig. 16 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
(8) Remove hex head bol ts attachi ng val ve body to
transmi ssi on case (Fi g. 17). A total of 10 bol ts are
used. Note di fferent bol t l engths for assembl y refer-
ence.
(9) Remove val ve body assembl y. Push val ve body
harness connector out of case. Then work park rod
and val ve body out of case (Fi g. 18).
(10) Remove accumul ator outer spri ng, pi ston and
i nner spri ng (Fi g. 19). Note posi ti on of pi ston and
spri ngs for assembl y reference. Remove and di scard
pi ston seal s i f worn or cut.
(11) Remove pump oi l seal wi th sui tabl e pry tool or
sl i de-hammer mounted screw.
(12) Remove front band l ever pi n access pl ug (Fi g.
20). Use square end of 1/4 i n. dri ve extensi on to
remove pl ug as shown.
Fig. 17 Valve Body Bolt Locations
Fig. 18 Valve Body Removal
2 - VALVE BODY
3 - PARK ROD
Fig. 19 Accumulator Component Removal
2 - OUTER SPRING
3 - INNER SPRING
(13) Remove oi l pump and reacti on shaft support
assembl y as fol l ows:
(a) Ti ghten front band adjusti ng screw unti l
band i s ti ght around front cl utch retai ner (Fi g. 21).
Thi s wi l l prevent retai ner from comi ng out wi th
pump and possi bl y damagi ng cl utch or pump com-
ponents.
(b) Remove oi l pump bol ts.
(c) Thread Sl i de Hammer Tool s C-3752 i nto
threaded hol es i n fl ange of oi l pump housi ng (Fi g.
22).
(d) Remove oi l pump and reacti on shaft support
by bumpi ng sl i de hammers outward al ternatel y to
pul l pump from case (Fi g. 23).
(14) Remove oi l pump gasket (Fi g. 24). Note gas-
ket posi ti on i n case for assembl y reference.
(15) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose.
(16) Remove front band strut and anchor (Fi g. 25).
(17) Squeeze front band together sl i ghtl y and sl i de
band over front cl utch retai ner and out of case (Fi g.
26).
Fig. 20 Front Band Lever Pin Access Plug
1 - FRONT BAND REACTION PIN ACCESS PLUG
2 - 1/4 DRIVE EXTENSION AND RATCHET
Fig. 21 Tightening Front Band To Hold Front Clutch
In Place
1 - LOCK-NUT
Fig. 22 Oil Pump Removal Tools
1 - PUMP HOUSING
2 - SLIDE HAMMER TOOLS (THREAD INTO PUMP HOUSING)
(18) Remove front and rear cl utch assembl i es as a
uni t (Fi g. 27).
(19) Remove front band reacti on pi n and l ever.
Start pi n through l ever and out of case bore wi th
dri ft or punch. Then use penci l magnet to wi thdraw
pi n compl etel y (Fi g. 28).
(20) Remove i ntermedi ate shaft thrust washer. Tri -
angul ar shaped washer wi l l ei ther be on shaft pi l ot
hub or i n rear cl utch retai ner (Fi g. 29).
Fig. 23 Oil Pump Removal
1 - OIL PUMP AND REACTION SHAFT SUPPORT
Fig. 24 Oil Pump Gasket
1 - OIL PUMP GASKET
Fig. 25 Front Band Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
Fig. 26 Front Band Removal
1 - FRONT BAND
(21) Remove thrust pl ate from i ntermedi ate shaft
hub (Fi g. 30).
(22) Remove i ntermedi ate shaft-pl anetary geartrai n
assembl y (Fi g. 31).
(23) I f overdri ve uni t i s not to be servi ced, i nstal l
Al i gnment Shaft 6227-2 i nto the overdri ve uni t to
prevent mi sal i gnment of the overdri ve cl utches dur-
i ng servi ce of mai n transmi ssi on components.
(24) Loosen rear band l ocknut and l oosen adjust-
i ng screw 3-4 turns.
(25) Remove snap-ri ng that retai ns l ow-reverse
drum on overdri ve pi ston retai ner hub (Fi g. 32).
(26) Sl i de l ow-reverse drum and thrust washer off
pi ston retai ner hub and out of rear band (Fi g. 33).
(27) Note that overrunni ng cl utch race wi l l remai n
on spl i nes of l ow-reverse drum after removal (Fi g.
34). The race is a permanent press fit on the
hub splines. Do not attempt to remove the race.
Fig. 27 Removing Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 28 Front Band Lever And Pin
1 - BAND LEVER
2 - USE PENCIL MAGNET TO REMOVE REACTION PIN
Fig. 29 Intermediate Shaft Thrust Washer
1 - THRUST WASHER
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 30 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
(28) Remove overrunni ng cl utch assembl y (Fi g.
35). Assembl y can be removed wi thout di spl aci ng
rol l ers and spri ngs i f care i s exerci sed. Note posi ti on
of rol l ers and spri ngs for assembl y reference.
(29) Remove rear band adjusti ng l ever, reacti on
l ever and pi n (Fi g. 36).
(30) Remove strut from rear band. Keep strut wi th
l evers and pi n for cl eani ng, i nspecti on and assembl y
reference.
(31) Remove rear band and l i nk (Fi g. 37).
(32) Compress front servo rod gui de wi th l arge
C-cl amp and Tool C-4470, or Compressor Tool
C-3422-B (Fi g. 38). Compress gui de onl y enough to
permi t snap-ri ng removal (about 1/8 i n.).
Fig. 31 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEARTRAIN
ASSEMBLY
Fig. 32 Low-Reverse Drum Snap-Ring
2 - TABBED WASHER
3 - SNAP-RING
Fig. 33 Low-Reverse Drum And Thrust Washer
2 - SPOTFACE FOR WASHER
3 - THRUST WASHER
Fig. 34 Overrunning Clutch Race Position On
Low-Reverse Drum
1 - OVERRUNNING CLUTCH RACE
(33) Remove servo pi ston snap-ri ng (Fi g. 38).
Unseat one end of ri ng. Then careful l y work removal
tool around back of ri ng unti l free of ri ng groove.
Exercise caution when removing snap-ring.
Servo bore can be scratched or nicked if care is
not exercised.
(34) Remove tool s and remove servo pi ston and
spri ng.
(35) Compress rear servo pi ston wi th C-cl amp and
Tool C-4470, or Val ve Spri ng Compressor C-3422-B
(Fi g. 39). Compress servo spri ng retai ner onl y
enough to permi t snap-ri ng removal .
(36) Remove servo pi ston snap-ri ng (Fi g. 39). Start
one end of ri ng out of bore. Then careful l y work
removal tool around back of snap-ri ng unti l free of
ri ng groove. Exercise caution when removing
snap-ring. Servo bore can be scratched or
nicked if care is not exercised.
(37) Remove tool s and remove rear servo retai ner,
spri ng and pi ston assembl y.
Fig. 35 Overrunning Clutch Removal
1 - CLUTCH CAM
Fig. 36 Rear Band Levers And Pins
1 - REAR BAND ADJUSTING LEVER
2 - REACTION LEVER
3 - BAND LINK
4 - REAR BAND REACTION PIN
Fig. 37 Rear Band And Link
1 - BAND LINK
2 - REAR BAND
Fig. 38 Front Servo Retaining Snap-Ring
1 - C-CLAMP
2 - FRONT SERVO ROD GUIDE
3 - SNAP-RING
4 - TOOL C-4470
CLEANING
type 9602, transmi ssi on fl ui d duri ng overhaul and
INSPECTION
damage or wear.
Lubri cate the front band adjusti ng screw threads
wi th petrol eum jel l y and thread the screw part-way
i nto the case. Be sure the screw turns freel y.
I nspect the transmi ssi on bushi ngs duri ng overhaul .
Bushi ng condi ti on i s i mportant as worn, scored bush-
i ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. However, do
not repl ace bushi ngs as a matter of course. Repl ace
bushi ngs onl y when they are actual l y worn, or
scored.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l , and
seat bushi ngs correctl y. The bushi ng repl acement
tool s are i ncl uded i n Bushi ng Tool Set C-3887-B.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced.
and val ve bore.
as wel l .
ASSEMBLY
Do not al l ow di rt, grease, or forei gn materi al to
enter the case or transmi ssi on components duri ng
assembl y. Keep the transmi ssi on case and compo-
nents cl ean. Al so make sure the tool s and workbench
area used for reassembl y operati ons are equal l y
cl ean.
Shop towel s used for wi pi ng off tool s and your
hands must be made from lint free materi al s. Li nt
wi l l sti ck to transmi ssi on parts and coul d i nterfere
wi th val ve operati on or even restri ct fl ui d passages.
Lubri cate transmi ssi on cl utch and gear compo-
nents wi th MoparATF +4, type 9602, duri ng reas-
sembl y. Soak cl utch di scs i n transmi ssi on fl ui d before
i nstal l ati on.
Use MoparDoor Ease, or Ru-Gl yde on pi ston
seal s and O-ri ngs to ease i nstal l ati on. Petrol eum jel l y
can al so be used to l ubri cate and hol d thrust washers
and pl ates i n posi ti on duri ng assembl y.
Do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of l ubri cants can eventual l y bl ock or
restri ct fl ui d passages and val ve operati on. Use
petrol eum jel l y onl y.
Do not force parts i nto pl ace. The transmi ssi on
components and sub-assembl i es are easi l y i nstal l ed
by hand when properl y al i gned. I f a part seems di f-
fi cul t to i nstal l , i t i s ei ther mi sal i gned or i ncorrectl y
assembl ed. Veri fy that thrust washers, thrust pl ates
and seal ri ngs are correctl y posi ti oned.
The pl anetary geartrai n, front/rear cl utch assem-
bl i es and oi l pump are al l much easi er to i nstal l
Fig. 39 Rear Servo Retaining Snap-Ring
1 - TOOL C-4470
2 - C-CLAMP
3 - REAR SERVO SPRING RETAINER
when the transmi ssi on case i s upri ght. Ei ther ti l t the
case upward wi th wood bl ocks, or cut a hol e i n the
bench l arge enough for the i ntermedi ate shaft and
rear support. Then l ower the shaft and support i nto
the hol e and support the rear of the case di rectl y on
the bench.
FRONT/REAR SERVO
(1) Lubri cate rear servo pi ston seal wi th Mopar
Door Ease or ATF +4. Lubri cate servo bore i n case
wi th ATF +4.
(2) I nstal l rear servo pi ston i n case. Posi ti on pi ston
at sl i ght angl e to bore and i nsert pi ston wi th twi sti ng
moti on (Fi g. 40).
(3) I nstal l rear servo spri ng and retai ner i n case
bore (Fi g. 41). Be sure spri ng i s seated on pi ston.
(4) Compress rear servo pi ston wi th C-cl amp or
Val ve Spri ng Compressor C-3422-B and i nstal l servo
pi ston snap-ri ng (Fi g. 42).
(5) Lubri cate front servo pi ston components and
servo bore i n case wi th transmi ssi on fl ui d.
(6) I nstal l front servo pi ston i n bore. Careful l y
run smal l , sui tabl e tool around pi ston ri ng to press
i t back i nto groove and ease i nstal l ati on (Fi g. 43).
Rotate pi ston i nto bore at same ti me. Rock pi ston
sl i ghtl y to ease pi ston ri ng past snap-ri ng groove and
i nto bore.
Fig. 40 Rear Servo Piston
1 - REAR SERVO PISTON
Fig. 41 Rear Servo Piston Spring And Retainer
1 - PISTON SPRING
2 - REAR SERVO PISTON
3 - SPRING RETAINER
Fig. 42 Rear Servo Snap-Ring
1 - TOOL C-4470
2 - C-CLAMP
3 - REAR SERVO SPRING RETAINER
(7) Bottom front servo pi ston i n bore and i nstal l
servo spri ng.
(8) I nstal l front servo pi ston rod gui de as fol l ows:
(a) Pl ace Tool SP-5560 (or si mi l ar si ze tool ) on
gui de and posi ti on C-cl amp on tool and case (Fi g.
44).
(b) Sl owl y compress rod gui de whi l e si mul ta-
neousl y easi ng seal ri ng i nto bore wi th sui tabl e
tool .
(9) I nstal l rod gui de snap-ri ng (Fi g. 44).
OVERRUNNING CLUTCH, REAR BAND, AND
LOW-REVERSE DRUM
(1) I nstal l overrunni ng cl utch components.
(2) Posi ti on rear band and l i nk i n case (Fi g. 45).
(3) I nstal l l ow-reverse drum (Fi g. 46). Sl i de drum
through rear band, onto pi ston retai ner hub and i nto
engagement wi th overrunni ng cl utch and race.
(4) I nstal l thrust washer i n l ow-reverse drum spot-
face (Fi g. 47). Use petrol eum jel l y to hol d washer i n
pl ace.
(5) I nstal l snap-ri ng that secures l ow-reverse drum
to pi ston retai ner hub (Fi g. 47).
1 - USE SUITABLE TOOL TO HELP SEAT PISTON RING
2 - FRONT SERVO PISTON
Fig. 44 Front Servo Rod Guide And Snap-Ring
1 - C-CLAMP
2 - ROD GUIDE
3 - SMALL SCREWDRIVER
5 - TOOL SP-5560
1 - REAR BAND
2 - BAND LINK
(6) I nsert band reacti on pi n part way i nto case and
band l i nk (Fi g. 48).
(7) I nstal l rear band adjusti ng l ever, reacti on l ever,
and strut (Fi g. 49). Be sure l evers and strut are
al i gned and engaged before seati ng band reacti on pi n
i n case.
Fig. 46 Low-Reverse Drum
2 - REAR BAND LINK
Fig. 47 Low-Reverse Drum Snap-Ring
2 - TABBED WASHER
3 - SNAP-RING
Fig. 48 Rear Band Reaction Pin
1 - REACTION PIN
2 - BAND LINK
3 - REAR BAND
4 - O-RINGS
Fig. 49 Rear Band Levers And Strut
1 - ADJUSTING SCREW AND NUT
2 - ADJUSTING LEVER
3 - REACTION LEVER
4 - STRUT
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH,
AND FRONT BAND
(1) Remove Al i gnment Shaft 6227-2, i f i nstal l ed
previ ousl y.
(2) I nstal l assembl ed i ntermedi ate shaft and pl an-
etary geartrai n (Fi g. 50). Support shaft careful l y dur-
i ng i nstal l ati on. Do not al l ow shaft beari ng/bushi ng
surfaces to become ni cked or scratched.
(3) Lubri cate i ntermedi ate shaft thrust pl ate wi th
petrol eum jel l y and i nstal l pl ate on shaft pi l ot hub
(Fi g. 51).
(4) Check i nput shaft front seal ri ngs, fi ber thrust
washer and rear seal ri ng (Fi g. 52). Be ends of rear
seal ri ng are hooked together and the square cut
ends of front seal ri ngs are fi rml y seated agai nst
each other. Lubri cate seal ri ngs wi th petrol eum jel l y
after checki ng them.
(5) Assembl e front and rear cl utches (Fi g. 53).
Al i gn l ugs on front cl utch di scs. Mount front cl utch
on rear cl utch. Turn front cl utch retai ner back and
forth unti l front cl utch di scs are ful l y seated on rear
cl utch spl i ned hub.
Fig. 50 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEARTRAIN
ASSEMBLY
Fig. 51 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
Fig. 52 Input Shaft Seal Rings And Thrust Washer
1 - TORLON FRONT SEAL RINGS
2 - INPUT SHAFT
3 - REAR SEAL RING
4 - THRUST WASHER
(6) I nstal l i ntermedi ate shaft thrust washer i n hub
of rear cl utch retai ner (Fi g. 54). Use petrol eum jel l y
to hol d washer i n pl ace. Posi ti on washer so grooves
are faci ng outward. Washer onl y fi ts one way i n
cl utch retai ner hub.
(7) Pl ace transmi ssi on case i n upri ght posi ti on, or
pl ace bl ocks under front end of transmi ssi on repai r
stand to ti l t case rearward. Thi s makes i t easi er to
i nstal l front/rear cl utch assembl y.
(8) Al i gn di scs i n rear cl utch. Then i nstal l and
engage assembl y i n front pl anetary and dri vi ng shel l
(Fi g. 55). Turn cl utch retai ners back and forth unti l
both cl utches are seated.
(9) Posi ti on front band l ever i n case and over servo
rod gui de. Then i nstal l front band l ever pi n i n case
and sl i de i t through l ever.
(10) Coat threads of front band pi n access pl ug
wi th seal er and i nstal l i t i n case. Ti ghten pl ug to 17
(11) Sl i de front band over front cl utch retai ner and
i nstal l front band strut and anchor (Fi g. 56).
i s ti ght on cl utch retai ner. Thi s wi l l hol d cl utches i n
pl ace whi l e oi l pump i s bei ng i nstal l ed. Veri fy that
front/rear cl utch assembl y i s sti l l properl y seated
before ti ghteni ng band.
Fig. 53 Assembling Front And Rear Clutches
1 - FRONT CLUTCH ASSEMBLY
2 - REAR CLUTCH ASSEMBLY
3 - REAR CLUTCH SPLINED HUB
Fig. 54 Intermediate Shaft Thrust Washer
1 - BE SURE WASHER GROOVES FACE OUT AS SHOWN
3 - OUTPUT SHAFT THRUST WASHER
Fig. 55 Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
OIL PUMP
(1) I nstal l oi l pump Pi l ot Studs C-3288-B i n case
(Fi g. 57).
(2) I nstal l new oi l pump gasket on pi l ot studs and
seat i t i n case. Be sure gasket i s properl y al i gned
wi th fl ui d passages i n case (Fi g. 57).
(3) Coat front cl utch fi ber thrust washer wi th
petrol eum jel l y to hol d i t i n pl ace. Then i nstal l
washer over reacti on shaft hub and seat i t on pump
(Fi g. 58).
CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
(4) Check seal ri ngs on reacti on shaft support. Be
sure ri ngs are hooked together correctl y. Al so be sure
fi ber thrust washer i s i n posi ti on (Fi g. 59). Use extra
petrol eum jel l y to hol d washer i n pl ace i f necessary.
(5) Lubri cate oi l pump seal s wi th petrol eum
MoparATF +4, type 9602.
(6) Mount oi l pump on pi l ot studs and sl i de pump
i nto case openi ng (Fi g. 60). Work pump i nto case by
hand. Do not use a mal l et or si mi l ar tool s to seat
pump.
(7) Remove pi l ot studs and i nstal l oi l pump bol ts.
Ti ghten pump bol ts al ternatel y and evenl y to ful l y
seat pump i n case. Then fi nal -ti ghten pump bol ts to
(8) Veri fy correct i nstal l ati on. Rotate i nput and
i ntermedi ate shafts and check for bi nd. I f bi nd exi sts,
components are ei ther mi s-assembl ed, or not seated.
Di sassembl e and correct as necessary before proceed-
i ng.
Fig. 56 Front Band And Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
Fig. 57 Oil Pump Gasket And Pilot Studs
1 - OIL PUMP GASKET
2 - PILOT STUDS C-3288-B
Fig. 58 Front Clutch Thrust Washer
1 - THRUST WASHER
2 - CHAMFERED SIDE OF WASHER BORE GOES TOWARD
PUMP
INPUT SHAFT END PLAY CHECK
NOTE: Overdrive unit must be installed in order to
correctly measure the input shaft end-play.
(1) Measure i nput shaft end pl ay (Fi g. 61).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or reaction shaft thrust
washer is incorrect. The reaction shaft thrust
washer is selective.
8266-8.
shaft.
tor.
i ng. End pl ay shoul d be 0.86 - 2.13 mm (0.034 -
0.084 i n.). Adjust as necessary.
Fig. 59 Reaction Shaft Seal Ring And Thrust Washer
1 - SEAL RINGS
3 - THRUST WASHER (FIBER)
Fig. 60 Oil Pump
1 - SEAT OIL PUMP IN CASE BY HAND
2 - REMOVE PILOT STUDS WHEN PUMP IS SEATED
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
ACCUMULATOR, VALVE BODY, OIL PAN, AND
TORQUE CONVERTER
(1) I nstal l accumul ator i nner spri ng, pi ston and
outer spri ng (Fi g. 62).
(2) I nstal l new val ve body manual shaft seal i n
case (Fi g. 63). Lubri cate seal l i p and manual shaft
wi th petrol eum jel l y. Start seal over shaft and i nto
case. Seat seal wi th 15/16 i nch, deep wel l socket.
(3) I nstal l val ve body as fol l ows:
(a) Start park rod i nto park pawl . I f rod wi l l not
sl i de past park pawl , pawl i s engaged i n park gear.
Rotate overdri ve output shaft wi th sui tabl e si ze 12
poi nt socket; thi s wi l l free pawl and al l ow rod to
engage.
(b) Al i gn and seat val ve body on case. Be sure
manual l ever shaft and overdri ve connector are
ful l y seated i n case.
(c) I nstal l and start al l val ve body attachi ng
bol ts by hand. Then ti ghten bol ts evenl y, i n a di ag-
onal pattern to 12 Nm (105 i n. l bs.) torque. Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation..
(4) I nstal l new fi l ter on val ve body. Ti ghten fi l ter
CAUTION: If the condition of the transmission
before the overhaul procedure caused excessive
metallic or fiber contamination in the fluid, replace
the torque converter and reverse flush the cooler(s)
and cooler lines. Fluid contamination and transmis-
sion failure can result if not done.
(6) I nstal l torque converter. Use C-cl amp or metal
strap to hol d converter i n pl ace for i nstal l ati on.
BAND ADJUSTMENT AND FINAL
(1) Adjust front and rear bands as fol l ows:
(a) Loosen l ocknut on each band adjusti ng screw
4-5 turns.
(b) Ti ghten both adjusti ng screws to 8 Nm (72
i n. l bs.).
(c) Back off front band adjusti ng screw 2-7/8
turns.
(d) Back off rear band adjusti ng screw 2 turns.
(e) Hol d each adjusti ng screw i n posi ti on and
ti ghten l ocknut to 34 Nm (25 ft. l bs.) torque.
(2) I nstal l magnet i n oi l pan. Magnet seats on
smal l protrusi on at corner of pan.
(3) Posi ti on new oi l pan gasket on case and i nstal l
oi l pan. Ti ghten pan bol ts to 17 Nm (13 ft. l bs.).
(4) I nstal l throttl e val ve and shi ft sel ector l evers
on val ve body manual l ever shaft.
(5) Appl y smal l quanti ty of di el ectri c grease to ter-
mi nal pi ns of sol enoi d case connector and transmi s-
si on range sensor.
(6) Fi l l transmi ssi on wi th recommended fl ui d.
Refer to Servi ce Procedures secti on of thi s group.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
fl ui d.
(3) Lubri cate converter pi l ot hub pocket i n the rear
of the crankshaft wi th a l i ght coati ng of Mopar
Hi gh Temp Grease.
(4) Al i gn and i nstal l converter i n oi l pump.
2 - OUTER SPRING
3 - INNER SPRING
1 - 15/16'' SOCKET
2 - SEAL
pump gears.
(7) Temporari l y secure converter wi th wedge tool
or C-cl amp.
wi th chai ns.
Al so be sure transmi ssi on dowel pi ns are seated i n
engi ne bl ock and protrude far enough to hel d trans-
mi ssi on i n al i gnment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
crankshaft.
(13) I nstal l bol ts attachi ng converter housi ng to
engi ne.
(14) I nstal l transfer case, i f necessary.
(15) I nstal l rear support. Then l ower transmi ssi on
onto crossmember and i nstal l bol ts attachi ng trans-
mi ssi on mount to crossmember.
(16) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused.
(17) Connect gearshi ft and throttl e cabl e to trans-
mi ssi on.
(18) Connect wi res to the transmi ssi on range sen-
sor, transmi ssi on sol enoi d case connector, and oxygen
sensor. Be sure that al l transmi ssi on harnesses are
properl y routed.
(22) I nstal l converter housi ng access cover.
(23) I nstal l bol ts attachi ng engi ne-to-transmi ssi on
(25) Lower engi ne.
(26) I nstal l bol t and nut attachi ng each engi ne-to-
transmi ssi on bracket to the motor mounts.
(27) Remove engi ne support.
(28) I nstal l bol ts to hol d engi ne-to-transmi ssi on
brackets to the front axl e, i f equi pped.
TI ON) and cool er l i ne bracket.
(31) I nstal l transmi ssi on fi l l tube. I nstal l new seal
on tube before i nstal l ati on.
(33) Al i gn and connect propel l er shaft(s). (Refer to
3 - DI FFERENTI AL & DRI VELI NE/PROPELLER
(34) I nstal l rear ski d pl ate, i f equi pped.
(35) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(36) I nstal l front ski d pl ate, i f equi pped.
(38) Fi l l transmi ssi on wi th MoparATF +4, Type
9602 fl ui d.
Fig. 64 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
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SPECIFICATIONS
TRANSMISSION
GENERAL
Planetary end play 0.150-1.22 mm 0.006-0.048 in.
Input shaft end play 0.86-2.13 mm 0.034-0.084 in.
Clutch pack
clearance/Front.
1.78-3.28 mm 0.070-0.129 in.
Clutch pack
clearance/Rear.
0.635-0.914
mm
0.025-0.036 in.
Front clutch 3 discs
Rear clutch 4 discs
Overdrive clutch 4 discs
Direct clutch 8 discs
Band adjustment
from 72 in. lbs.
Front band Back off 2 7/8 turns
Rear band Back off 2 turns
Recommended fluid Mopar ATF +4, type 9602
GEAR RATIOS
1ST GEAR 2.45:1
2ND GEAR 1.45:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.21:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
2.15 mm 0.084 in.
2.59 mm 0.102 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.75-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.085 in.
Rear clutch pack snap-ring 1.5-1.6 mm 0.060-0.062 in.
1.9-1.95 mm 0.074-0.076 in.
Planetary geartrain snap-ring (at front of output shaft) 1.4-1.5 mm 0.055-0.059 in.
1.6-1.7 mm 0.062-0.066 in.
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures
Intermediate shaft spacer
PRESSURE TEST
Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 31 - 270
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Bolt, fluid pan 17 13 -
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
Bracket, transmission range sensor mounting 34 - 300
Screw, transmission range sensor to mounting
bracket
3.4 - 30
SPECIAL TOOLS
RE TRANSMISSION
Flusher, Oil Cooler - 6906
Retainer, Detent Ball and Spring - 6583
Gauge, Block - 6312
Fixture, Engine Support - C-3487-A
Stand, Transmission Repair - C-3750-B
Compressor, Spring - C-3863-A
Spring Compressor and Alignment Shaft - 6227
Bar, Gauge - 6311
Studs, Oil Pump Pilot - C-3288-B
Gauge, Pressure - C-3292
Gauge, Pressure - C-3293SP
Set, Dial Indicator - C-3339
Compressor, Spring - C-3422-B
Puller, Slide Hammer - C-3752
Gauge, Throttle Setting - C-3763
Remover, Seal - C-3985-B
Installer, Overdrive Piston Seal - 8114
Remover/Installer, Bushing - C-4470
Dial Caliper - C-4962
Set, Bushing Remover/Installer - C-3887-J
Nut, Bushing Remover - SP-1191, From kit C-3887-J
Remover, Front Clutch Bushing - SP-3629, From kit
C-3887-J
Cup, Bushing Remover - SP-3633, From kit C-3887-J
Installer, Oil Pump Bushing - SP-5118, From kit
C-3887-J
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 65) i s a hydraul i c devi ce
that has the sol e purpose of cushi oni ng the appl i ca-
ti on of a band or cl utch. The accumul ator consi sts of
a dual -l and pi ston and a spri ng l ocated i n a bore i n
the transmi ssi on case. The 3-4 accumul ator i s l ocated
i n a housi ng attached to the si de of the val ve body
(Fi g. 66).
Remover, Reaction Shaft Bushing - SP-5301, From
Kit C-3887-J
Installer, Reaction Shaft Bushing - SP-5302, From
kit C-3887-J
Installer, Front Clutch Bushing - SP-5511, From kit
C-3887-J
Remover, Bushing - SP-3550, From kit C-3887-J
Adapter, Band Adjuster - C-3705
Fig. 65 Accumulator
2 - PISTON SPRING
3 - TEFLON SEALS
4 - PISTON SPRING
OPERATION
Both the accumul ator and the 3-4 accumul ator
functi on the same. Li ne pressure i s di rected to the
smal l end of the pi ston when the transmi ssi on i s
pl aced i nto a DRI VE posi ti on (Fi g. 67), bottomi ng i t
agai nst the accumul ator pl ate. When the 1-2 upshi ft
occurs (Fi g. 68), l i ne pressure i s di rected to the l arge
end of the pi ston and then to the ki ckdown servo. As
the l i ne pressure reaches the accumul ator, the com-
bi nati on of spri ng pressure and l i ne pressure forces
the pi ston away from the accumul ator pl ate. Thi s
causes a bal anced pressure si tuati on, whi ch resul ts
i n a cushi oned band appl i cati on. After the ki ckdown
servo has become i mmovabl e, l i ne pressure wi l l fi n-
i sh pushi ng the accumul ator up i nto i ts bore. When
the l arge end of the accumul ator pi ston i s seated i n
i ts bore, the band or cl utch i s ful l y appl i ed.
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
INSPECTION
I nspect the accumul ator pi ston and seal ri ngs (Fi g.
69). Repl ace the seal ri ngs i f worn or cut. Repl ace the
pi ston i f chi pped or cracked.
Check condi ti on of the accumul ator i nner and
outer spri ngs (Fi g. 69). Repl ace the spri ngs i f the
coi l s are cracked, di storted or col l apsed.
BANDS
DESCRIPTION
The ki ckdown, or front, band (Fi g. 70) hol ds the
common sun gear of the pl anetary gear sets. The
front (ki ckdown) band i s made of steel , and faced on
i ts i nner ci rcumference wi th a fri cti on-type l i ni ng.
One end of the band i s anchored to the transmi ssi on
Fig. 67 Accumulator in DRIVE - FIRST GEAR
POSITION
1 - LINE PRESSURE
Fig. 68 Accumulator in SECOND Gear Position
1 - BOTTOM OF BORE
2 - LINE PRESSURE
3 - SHUTTLE VALVE
Fig. 69 Accumulator Components
1 - INNER SPRING
3 - OUTER SPRING
4 - SEAL RINGS
case, and the other i s acted on wi th a pushi ng force
by a servo pi ston. The front band i s a si ngl e-wrap
desi gn (the band does not compl etel y encompass/
wrap the drum that i t hol ds).
The l ow/reverse band, or rear, band (Fi g. 71) i s
si mi l ar i n appearance and operati on to the front
band. The rear band i s al so a si ngl e-wrap desi gn (
the band does not compl etel y encompass/wrap the
drum that i t hol ds).
OPERATION
The ki ckdown band hol ds the common sun gear of
the pl anetary gear sets by appl yi ng and hol di ng the
front cl utch retai ner, whi ch i s spl i ned to the sun gear
dri vi ng shel l , and i n turn spl i ned di rectl y to the sun
gear. The appl i cati on of the band by the servo i s typ-
i cal l y done by an appl y l ever and l i nk bar.
The rear band hol ds the rear pl anet carri er sta-
ti onary by bei ng mounted around and appl i ed to the
l ow/reverse drum.
ADJUSTMENT - BANDS
FRONT BAND
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 72).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench
C-3380-A, a 3-i n. extensi on and an appropri ate
Torx socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw, tighten the screw to only 5 Nm
(47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 2-7/8
turns.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 Nm (30 ft. l bs.) torque.
REAR BAND
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns.
Be sure adjusti ng screw turns freel y i n l ever.
(4) Ti ghten adjusti ng screw to 8 Nm (72 i n. l bs.)
torque (Fi g. 73).
(5) Back off adjusti ng screw 2 turns.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
Fig. 70 Front Band
1 - FRONT BAND
2 - TRANSMISSION HOUSING
1 - BAND LINK
2 - REAR BAND
BANDS (Continued)
(8) Lower vehi cl e and refi l l transmi ssi on wi th
MoparATF +4, Type 9602 fl ui d.
ELECTRONIC GOVERNOR
DESCRIPTION
Governor pressure i s control l ed el ectroni cal l y. Com-
ponents used for governor pressure control i ncl ude:
Governor body
Val ve body transfer pl ate
Governor pressure sol enoi d val ve
Governor pressure sensor
Fl ui d temperature thermi stor
Transmi ssi on speed sensor
Powertrai n control modul e (PCM)
The sol enoi d val ve i s a duty-cycl e sol enoi d whi ch
regul ates the governor pressure needed for upshi fts
and downshi fts. I t i s an el ectro-hydraul i c devi ce
l ocated i n the governor body on the val ve body trans-
fer pl ate (Fi g. 74).
The governor pressure sensor measures output
pressure of the governor pressure sol enoi d val ve (Fi g.
75).
The transfer pl ate i s desi gned to suppl y transmi s-
si on l i ne pressure to the governor pressure sol enoi d
val ve and to return governor pressure.
The governor pressure sol enoi d val ve i s mounted i n
the governor body. The body i s bol ted to the l ower
si de of the transfer pl ate (Fi g. 75).
Fig. 72 Front Band Adjustment Screw Location
1 - LOCK-NUT
Fig. 73 Rear Band Adjustment Screw Location
1 - LOW-REVERSE BAND ADJUSTMENT
Fig. 74 Governor Pressure Solenoid Valve
1 - SOLENOID FILTER
1 - GOVERNOR BODY
BANDS (Continued)
There are four governor pressure curves pro-
grammed i nto the transmi ssi on control modul e. The
di fferent curves al l ow the control modul e to adjust
governor pressure for varyi ng condi ti ons. One curve
i s used for operati on when fl ui d temperature i s at, or
bel ow, 1C (30F). A second curve i s used when fl ui d
temperature i s at, or above, 10C (50F) duri ng nor-
mal ci ty or hi ghway dri vi ng. A thi rd curve i s used
duri ng wi de-open throttl e operati on. The fourth curve
i s used when dri vi ng wi th the transfer case i n l ow
range.
OPERATION
Compensati on i s requi red for performance vari a-
ti ons of two of the i nput devi ces. Though the sl ope of
the transfer functi ons i s ti ghtl y control l ed, offset may
vary due to vari ous envi ronmental factors or manu-
facturi ng tol erances.
The pressure transducer i s affected by barometri c
pressure as wel l as temperature. Cal i brati on of the
zero pressure offset i s requi red to compensate for
shi fti ng output due to these factors.
Normal cal i brati on wi l l be performed when sump
temperature i s above 50 degrees F, or i n the absence
of sump temperature data, after the fi rst 10 mi nutes
of vehi cl e operati on. Cal i brati on of the pressure
transducer offset occurs each ti me the output shaft
speed fal l s bel ow 200 RPM. Cal i brati on shal l be
repeated each 3 seconds the output shaft speed i s
bel ow 200 RPM. A 0.5 second pul se of 95% duty cycl e
i s appl i ed to the governor pressure sol enoi d val ve
and the transducer output i s read duri ng thi s pul se.
Averagi ng of the transducer si gnal i s necessary to
reject el ectri cal noi se.
Under col d condi ti ons (bel ow 50 degrees F sump),
the governor pressure sol enoi d val ve response may
be too sl ow to guarantee 0 psi duri ng the 0.5 second
cal i brati on pul se. Cal i brati on pul ses are conti nued
duri ng thi s peri od, however the transducer output
val ves are di scarded. Transducer offset must be read
at key-on, under condi ti ons whi ch promote a stabl e
readi ng. Thi s val ue i s retai ned and becomes the off-
set duri ng the col d peri od of operati on.
The i nl et si de of the sol enoi d val ve i s exposed to
normal transmi ssi on l i ne pressure. The outl et si de of
the val ve l eads to the val ve body governor ci rcui t.
The sol enoi d val ve regul ates l i ne pressure to pro-
duce governor pressure. The average current sup-
pl i ed to the sol enoi d control s governor pressure. One
amp current produces zero kPa/psi governor pres-
sure. Zero amps sets the maxi mum governor pres-
sure.
The powertrai n control modul e (PCM) turns on the
trans control rel ay whi ch suppl i es el ectri cal power to
the sol enoi d val ve. Operati ng vol tage i s 12 vol ts
(DC). The PCM control s the ground si de of the sol e-
noi d usi ng the governor pressure sol enoi d control ci r-
cui t.
The sensor output si gnal provi des the necessary
feedback to the PCM. Thi s feedback i s needed to ade-
quatel y control governor pressure.
The transfer pl ate channel s l i ne pressure to the
sol enoi d val ve through the governor body. I t al so
channel s governor pressure from the sol enoi d val ve
to the governor ci rcui t. I t i s the sol enoi d val ve that
devel ops the necessary governor pressure.
LOW TRANSMISSION FLUID TEMPERATURE
When the transmi ssi on fl ui d i s col d the conven-
ti onal governor can del ay shi fts, resul ti ng i n hi gher
than normal shi ft speeds and harsh shi fts. The el ec-
troni cal l y control l ed l ow temperature governor pres-
sure curve i s hi gher than normal to make the
transmi ssi on shi ft at normal speeds and sooner. The
PCM uses a temperature sensor i n the transmi ssi on
oi l sump to determi ne when l ow temperature gover-
nor pressure i s needed.
NORMAL OPERATION
Normal operati on i s refi ned through the i ncreased
computi ng power of the PCM and through access to
data on engi ne operati ng condi ti ons provi ded by the
PCM that were not avai l abl e wi th the previ ous
stand-al one el ectroni c modul e. Thi s faci l i tated the
devel opment of a l oad adapti ve shi ft strategy - the
abi l i ty to al ter the shi ft schedul e i n response to vehi -
cl e l oad condi ti on. One mani festati on of thi s capabi l -
i ty i s grade hunti ng preventi on - the abi l i ty of the
transmi ssi on l ogi c to del ay an upshi ft on a grade i f
the engi ne does not have suffi ci ent power to mai n-
tai n speed i n the hi gher gear. The 3-2 downshi ft and
the potenti al for hunti ng between gears occurs wi th a
heavi l y l oaded vehi cl e or on steep grades. When
hunti ng occurs, i t i s very objecti onabl e because shi fts
are frequent and accompani ed by l arge changes i n
noi se and accel erati on.
WIDE OPEN THROTTLE OPERATION
I n wi de-open throttl e (WOT) mode, adapti ve mem-
ory i n the PCM assures that up-shi fts occur at the
preprogrammed opti mum speed. WOT operati on i s
determi ned from the throttl e posi ti on sensor, whi ch
i s al so a part of the emi ssi on control system. The i ni -
ti al setti ng for the WOT upshi ft i s bel ow the opti -
mum engi ne speed. As WOT shi fts are repeated, the
PCM l earns the ti me requi red to compl ete the shi fts
by compari ng the engi ne speed when the shi fts occur
to the opti mum speed. After each shi ft, the PCM
adjusts the shi ft poi nt unti l the opti mum speed i s
reached. The PCM al so consi ders vehi cl e l oadi ng,
grade and engi ne performance changes due to hi gh
al ti tude i n determi ni ng when to make WOT shi fts. I t
does thi s by measuri ng vehi cl e and engi ne accel era-
ti on and then factori ng i n the shi ft ti me.
TRANSFER CASE LOW RANGE OPERATION
On four-wheel dri ve vehi cl es operati ng i n l ow
range, the engi ne can accel erate to i ts peak more
rapi dl y than i n Normal range, resul ti ng i n del ayed
shi fts and undesi rabl e engi ne fl are. The l ow range
governor pressure curve i s al so hi gher than normal
to i ni ti ate upshi fts sooner. The PCM compares el ec-
troni c vehi cl e speed si gnal used by the speedometer
to the transmi ssi on output shaft speed si gnal to
determi ne when the transfer case i s i n l ow range.
REMOVAL
(2) Remove transmi ssi on fl ui d pan and fi l ter.
(3) Di sengage wi re connectors from pressure sen-
sor and sol enoi d (Fi g. 76).
(4) Remove screws hol di ng pressure sol enoi d
(5) Separate sol enoi d retai ner from governor (Fi g.
77).
(6) Pul l sol enoi d from governor body (Fi g. 78).
(7) Pul l pressure sensor from governor body.
(8) Remove bol ts hol di ng governor body to val ve
body.
(9) Separate governor body from val ve body (Fi g.
79).
(10) Remove governor body gasket.
1 - PRESSURE SENSOR
3 - GOVERNOR
2 - GOVERNOR
2 - O-RING
3 - GOVERNOR
INSTALLATION
Before i nstal l i ng the pressure sensor and sol enoi d
i n the governor body, repl ace o-ri ng seal s, cl ean the
gasket surfaces and repl ace gasket.
(1) Pl ace gasket i n posi ti on on back of governor
body (Fi g. 80).
(2) Pl ace governor body i n posi ti on on val ve body.
(3) I nstal l bol ts to hol d governor body to val ve
body.
(4) Lubri cate o-ri ng on pressure sensor wi th trans-
mi ssi on fl ui d.
(5) Al i gn pressure sensor to bore i n governor body.
(6) Push pressure sensor i nto governor body.
(7) Lubri cate o-ri ng, on pressure sol enoi d, wi th
(8) Al i gn pressure sol enoi d to bore i n governor
body (Fi g. 81).
(9) Push sol enoi d i nto governor body.
(10) Pl ace sol enoi d retai ner i n posi ti on on governor
(Fi g. 82).
(11) I nstal l screws to hol d pressure sol enoi d
1 - GOVERNOR BODY
2 - GASKET
1 - GOVERNOR BODY
2 - GASKET
2 - O-RING
3 - GOVERNOR
2 - GOVERNOR
(12) Engage wi re connectors i nto pressure sensor
and sol enoi d (Fi g. 83).
(13) I nstal l transmi ssi on fl ui d pan and (new) fi l ter.
EXTENSION HOUSING
BUSHING
REMOVAL
(1) Remove extensi on housi ng yoke seal .
(2) I nsert Remover 6957 i nto the extensi on hous-
i ng. Ti ghten tool to bushi ng and remove bushi ng
(Fi g. 84).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n extensi on
housi ng.
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng Seal
REMOVAL
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 86) from overdri ve housi ng.
1 - PRESSURE SENSOR
3 - GOVERNOR
1 - REMOVER
Fig. 85 Extension Housing Seal Installation
Fig. 86 Removing Transmission Housing Yoke Seal
1 - REMOVER
2 - SEAL
INSTALLATION
(1) Pl ace seal i n posi ti on on overdri ve housi ng.
(2) Dri ve seal i nto overdri ve housi ng wi th Seal
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
FLUID AND FILTER
BURNT FLUID
whi ch has two pri mary causes.
or ki nked l i nes.
CONTAMINATION
resul t of:
checki ng l evel
down)
repai r
repai r
nants.
Fig. 87 Installing Overdrive Housing Seal
EXTENSION HOUSING SEAL (Continued)
CHECK
taken for a l eak.
Fl ui d l evel i s checked wi th the engi ne runni ng at
curb i dl e speed, the transmi ssi on i n NEUTRAL and
the transmi ssi on fl ui d at normal operati ng tempera-
ture. The engine should be running at idle
on level ground.
The transmi ssi on fl ui d l evel can be checked two
ways.
PROCEDURE ONE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(3) Start and run engi ne at curb i dl e speed.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to NEUTRAL.
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 88) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar ATF
+4, type 9602, to restore correct l evel . Do not over-
fi l l .
PROCEDURE TWO
matel y 2 seconds.
(5) Hook up DRB scan tool and sel ect engi ne.
fi gure (Fi g. 89).
di psti ck accordi ng to the fi gure.
Fig. 88 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
REPLACEMENT
ULES - DESCRI PTI ON). The servi ce fl ui d fi l l after a
fi l ter change i s approxi matel y 3.8 l i ters (4.0 quarts).
transmi ssi on (Fi g. 90).
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(6) Hol d up pan and remove remai ni ng bol t hol d-
transmi ssi on.
(9) Remove screws hol di ng fi l ter to val ve body
(Fi g. 91).
(10) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(11) Di spose of used trans fl ui d and fi l ter properl y.
Fig. 89 46RE Fluid Fill Graph
Fig. 90 Transmission Pan
1 - TRANSMISSION
2 - GASKET
3 - PAN
FILL
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
+4, type 9602, to transmi ssi on:
pints (1-1/2 quarts) of ATF +4 to transmi ssi on.
cool er was fl ushed, add 12 pints (6 quarts) of ATF
+4 to transmi ssi on.
(4) Start and run engi ne at normal curb i dl e
speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
FRONT CLUTCH
DESCRIPTION
The front cl utch assembl y (Fi g. 92) i s composed of
the front cl utch retai ner, pressure pl ate, cl utch
pl ates, dri vi ng di scs, pi ston, pi ston return spri ng,
return spri ng retai ner, and snap-ri ngs. The front
cl utch i s the forward-most component i n the trans-
mi ssi on geartrai n and i s di rectl y behi nd the oi l pump
and i s consi dered a dri vi ng component.
OPERATION
l ugged to the cl utch retai ner. The waved snap-ri ng i s
vent and one-way bal l -check-val ve l ocated i n the
cl utch retai ner. The check-val ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
Fig. 91 Transmission Filter
1 - TRANSMISSION
2 - FILTER
DISASSEMBLY
(1) Remove the waved snap-ri ng, reacti on pl ate,
cl utch pl ates, and cl utch di scs.
(2) Compress cl utch pi ston retai ner and pi ston
spri ngs wi th Compressor Tool C-3863-A (Fi g. 93).
(3) Remove retai ner snap-ri ng and remove com-
pressor tool .
(4) Remove cl utch pi ston spri ngs (Fi g. 94). Note
posi ti on of pi ston spri ngs for assembl y reference.
(5) Remove cl utch pi ston from retai ner wi th a
twi sti ng moti on.
(6) Remove and di scard cl utch pi ston i nner and
outer seal s.
(7) Assembl e Tool Handl e C-4171 and Bushi ng
Remover SP-3629 (Fi g. 95).
(8) I nsert remover tool i n bushi ng and dri ve bush-
i ng strai ght out of cl utch retai ner.
1 - INNER PISTON SEAL 7 - CLUTCH DISCS
2 - CLUTCH PISTON 8 - RETAINER SNAP-RING
3 - CLUTCH PISTON SPRING RETAINER 9 - CLUTCH PISTON SPRINGS (9)
4 - CLUTCH PLATES 10 - OUTER PISTON SEAL
5 - CLUTCH PACK SNAP-RING (WAVED) 11 - FRONT CLUTCH RETAINER
6 - REACTION PLATE
Fig. 93 Removing Front Clutch Spring Retainer
Snap-Ring
1 - SPECIAL TOOL C-3863-A
2 - SNAP-RING
INSPECTION
I nspect the front cl utch components. Repl ace the
cl utch di scs i f warped, worn, scored, burned or
charred, the l ugs are damaged, or i f the faci ng i s
fl aki ng off. Repl ace the steel pl ates and reacti on
pl ate i f heavi l y scored, warped, or broken. Be sure
the dri vi ng l ugs on the di scs and pl ate are al so i n
good condi ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the pi ston spri ngs and spri ng retai ner i f
ei ther are di storted, warped or broken.
Check the l ug grooves i n the cl utch pi ston retai ner.
The steel pl ates shoul d sl i de freel y i n the sl ots.
Repl ace the pi ston retai ner i f the grooves are worn or
damaged. Al so check acti on of the check bal l i n the
pi ston retai ner. The bal l must move freel y and not
sti ck.
there i s any doubt about bushi ng condi ti on.
Check the cl utch pi ston check bal l . The bal l shoul d
be securel y i n pl ace. Repl ace the pi ston i f the bal l i s
mi ssi ng, or sei zed i n pl ace.
1 - INNER PISTON SEAL 7 - CLUTCH DISCS
2 - CLUTCH PISTON 8 - RETAINER SNAP-RING
3 - CLUTCH PISTON SPRING RETAINER 9 - CLUTCH PISTON SPRINGS (9)
4 - CLUTCH PLATES 10 - OUTER PISTON SEAL
5 - CLUTCH PACK SNAP-RING (WAVED) 11 - FRONT CLUTCH RETAINER
6 - REACTION PLATE
ASSEMBLY
NOTE: The 46RE transmission uses three plates
and discs for the front clutch.
(1) Mount Bushi ng I nstal l er SP-5511 on tool han-
dl e (Fi g. 96).
(2) Sl i de new bushi ng onto i nstal l er tool and start
bushi ng i nto retai ner.
(3) Tap new bushi ng i nto pl ace unti l i nstal l er tool
bottoms agai nst cl utch retai ner.
(4) Remove i nstal l er tool s and cl ean retai ner thor-
oughl y.
(5) Soak cl utch di scs i n transmi ssi on fl ui d.
(6) I nstal l new i nner pi ston seal onto the outer
di ameter of the cl utch retai ner i nner hub.
(7) I nstal l new outer seal onto the cl utch pi ston.
Be sure seal l i ps of both seal s face the i nteri or of the
retai ner.
(8) Lubri cate new i nner and outer pi ston seal s
wi th Ru-Gl yde , or Mopar Door Ease.
stri p of pl asti c (about 0.015 - 0.020 i n. thi ck), can be
used to gui de seal s i nto pl ace i f necessary.
(10) I nstal l and posi ti on ni ne cl utch pi ston spri ngs
(Fi g. 97).
(11) I nstal l spri ng retai ner on top of pi ston
spri ngs.
Fig. 95 Front Clutch Retainer
Bushing Replacement Tools
Fig. 96 Front Clutch Retainer
Bushing Replacement Tools
Fig. 97 Front Clutch Spring Position
1 - 9 SPRING CLUTCH
(12) Compress spri ng retai ner and pi ston spri ngs
wi th Tool C-3863-A.
(13) I nstal l spri ng retai ner snap-ri ng and remove
compressor tool .
(14) I nstal l cl utch pl ates and di scs (Fi g. 94). Three
cl utch di scs, three steel pl ates and one reacti on pl ate
are requi red.
(15) I nstal l reacti on pl ate fol l owed by waved snap-
ri ng.
(16) Check cl utch pack cl earance wi th feel er gauge
(Fi g. 98). Cl earance between waved spri ng and pres-
sure pl ate shoul d 1.78 - 3.28 mm (0.070 - 0.129 i n.).
I f cl earance i s i ncorrect, cl utch pl ates, cl utch di scs,
snap-ri ng, or pressure pl ate may have to be changed.
FRONT SERVO
DESCRIPTION
The ki ckdown servo (Fi g. 99) consi sts of a two-l and
pi ston wi th an i nner pi ston, a pi ston rod and gui de,
and a return spri ng. The dual -l and pi ston uses seal
ri ngs on i ts outer di ameters and an O-ri ng for the
i nner pi ston.
OPERATION
The appl i cati on of the pi ston i s accompl i shed by
appl yi ng pressure between the two l ands of the pi s-
ton. The pressure acts agai nst the l arger l ower l and
to push the pi ston downward, al l owi ng the pi ston rod
to extend though i ts gui de agai nst the appl y l ever.
Rel ease of the servo at the 2-3 upshi ft i s accom-
pl i shed by a combi nati on of spri ng and l i ne pressure,
acti ng on the bottom of the l arger l and of the pi ston.
The smal l pi ston i s used to cushi on the appl i cati on of
the band by bl eedi ng oi l through a smal l ori fi ce i n
the l arger pi ston. The rel ease ti mi ng of the ki ckdown
servo i s very i mportant to obtai n a smooth but fi rm
shi ft. The rel ease has to be very qui ck, just as the
front cl utch appl i cati on i s taki ng pl ace. Otherwi se,
engi ne runaway or a shi ft hesi tati on wi l l occur. To
accompl i sh thi s, the band retai ns i ts hol di ng capaci ty
unti l the front cl utch i s appl i ed, gi vi ng a smal l
amount of overl ap between them.
Fig. 98 Typical Method Of Measuring Front Clutch
Pack Clearance
1 - FEELER GAUGE
2 - WAVED SNAP-RING
3 - FEELER GAUGE
Fig. 99 Front Servo
1 - VENT
2 - INNER PISTON
3 - PISTON
4 - SPRING
6 - APPLY PRESSURE
7 - PISTON ROD
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 100).
(2) Remove smal l snap-ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component O-ri ng
and seal ri ngs.
CLEANING
Cl ean the servo pi ston components (Fi g. 101) wi th
sol vent and dry them wi th compressed ai r.
INSPECTION
I nspect the servo components (Fi g. 102). Repl ace
the spri ngs i f col l apsed, di storted or broken. Repl ace
the gui de, rod and pi ston i f cracked, bent, or worn.
Di scard the servo snap-ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
Fig. 100 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
1 - VENT
2 - INNER PISTON
3 - PISTON
4 - SPRING
6 - APPLY PRESSURE
7 - PISTON ROD
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
ASSEMBLY
Cl ean and i nspect front servo components.
(1) Lubri cate new o-ri ng and seal ri ngs wi th petro-
l eum jel l y and i nstal l them on pi ston, gui de and rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap-ri ng (Fi g.
103).
GEARSHIFT CABLE
CABLE
ti on.
must be possi bl e.
must be possi bl e.
REMOVAL
nuts.
mounti ng bracket to the dash panel (Fi g. 104) or
(Fi g. 105).
(Fi g. 107) or (Fi g. 108). Remove ol d cabl e from vehi -
cl e.
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
1 - GEARSHIFT CABLE
3 - MANUAL LEVER
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
INSTALLATION
109) or (Fi g. 110).
range sensor.
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
and NEUTRAL. Adjustment i s CORRECT i f the engi ne
starts onl y i n these posi ti ons. Adjustment i s I NCOR-
RECT i f the engi ne starts i n one but not both posi -
ti ons. I f the engi ne starts i n any posi ti on other than
PARK or NEUTRAL, or i f the engi ne wi l l not start at
al l , the transmi ssi on range sensor may be faul ty.
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 113) i s l ocated i n the pump
housi ng i nsi de the bel l housi ng of the transmi ssi on
case. The oi l pump consi sts of an i nner and outer
gear, a housi ng, and a reacti on shaft support.
OPERATION
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
CHECK
proper l evel wi th Mopar ATF +4, type 9602, Auto-
connected l i ne.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - O RING
6 - SEAL RINGS
DISASSEMBLY
(1) Mark posi ti on of support i n oi l pump body for
assembl y al i gnment reference. Use scri ber or pai nt to
make al i gnment marks.
(2) Pl ace pump body on two wood bl ocks.
(3) Remove reacti on shaft support bol ts and sepa-
rate support from pump body (Fi g. 114).
(4) Remove pump i nner and outer gears (Fi g. 115).
(5) Remove o-ri ng seal from pump body (Fi g. 116).
Di scard seal after removal .
(6) Remove oi l pump seal wi th Remover Tool
C-3981. Di scard seal after removal .
OIL PUMP BUSHING REMOVAL
(1) Posi ti on pump housi ng on cl ean, smooth sur-
face wi th gear cavi ty faci ng down.
(2) Remove bushi ng wi th Tool Handl e C-4171 and
Bushi ng Remover SP-3550 (Fi g. 117).
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Cup Tool SP-3633, Nut SP-1191 and
Bushi ng Remover SP-5301 (Fi g. 118).
(2) Hol d cup tool fi rml y agai nst reacti on shaft.
Thread remover tool i nto bushi ng as far as possi bl e
by hand.
(3) Usi ng wrench, thread remover tool an addi -
ti onal 3-4 turns i nto bushi ng to fi rml y engage tool .
(4) Ti ghten tool hex nut agai nst cup tool to pul l
bushi ng from shaft. Cl ean al l chi ps from shaft and
support after bushi ng removal .
Fig. 114 Reaction Shaft Support
1 - OIL PUMP
Fig. 115 Pump Gears
1 - GEAR BORE
2 - PUMP BODY
3 - INNER GEAR
4 - OUTER GEAR
CLEANING
INSPECTION
severel y worn.
heavi l y worn, scored or damaged. I t i s not necessary
to repl ace the bushi ngs unl ess they are actual l y dam-
aged.
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - O RING
6 - SEAL RINGS
Cl earance between outer gear and reacti on shaft
housi ng shoul d be 0.010 to 0.063 mm (0.0004 to
0.0025 i n.). Cl earance between i nner gear and reac-
ti on shaft housi ng shoul d be 0.010 to 0.063 mm
(0.0004 to 0.0025 i n.). Both cl earances can be mea-
sured at the same ti me by i nstal l i ng the gears i n the
pump body and measure pump component cl earances
as fol l ows:
(1) Posi ti on an appropri ate pi ece of Pl asti gage
across both gears.
(2) Al i gn the pl asti gage to a fl at area on the reac-
ti on shaft housi ng.
(3) I nstal l the reacti on shaft to the pump housi ng.
(4) Separate the reacti on shaft housi ng from the
pump housi ng and measure the Pl asti gage fol l ow-
i ng the i nstructi ons suppl i ed wi th i t.
Cl earance between i nner gear tooth and outer gear
shoul d be 0.08 to 0.19 mm (0.0035 to 0.0075 i n.).
Measure cl earance wi th an appropri ate feel er gauge
(Fi g. 119).
Cl earance between outer gear and pump housi ng
shoul d be 0.10 to 0.19 mm (0.004 to 0.0075 i n.). Mea-
sure cl earance wi th an appropri ate feel er gauge.
Fig. 117 Oil Pump Bushing
3 - BUSHING
6 - PUMP HOUSING
Fig. 118 Reaction Shaft Bushing
6 - BUSHING
7 - REACTION SHAFT
8 - BUSHING
Fig. 119 Checking Pump Gear Tip Clearance
1 - FEELER GAUGE
2 - INNER GEAR
3 - OUTER GEAR
ASSEMBLY
OIL PUMP BUSHING
(1) Assembl e Tool Handl e C-4171 and Bushi ng
I nstal l er SP-5118 (Fi g. 120).
(2) Pl ace bushi ng on i nstal l er tool and start bush-
i ng i nto shaft.
(3) Tap bushi ng i nto pl ace unti l I nstal l er Tool
SP-5118 bottoms i n pump cavi ty. Keep tool and bush-
i ng square wi th bore. Do not al l ow bushi ng to become
cocked duri ng i nstal l ati on.
(4) Stake pump bushi ng i n two pl aces wi th bl unt
punch. Remove burrs from stake poi nts wi th kni fe
bl ade (Fi g. 121).
REACTION SHAFT SUPPORT BUSHING
(1) Pl ace reacti on shaft support upri ght on a cl ean,
smooth surface.
(2) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5302. Then sl i de new bushi ng onto i nstal l er tool
(Fi g. 122).
(3) Start bushi ng i n shaft. Tap bushi ng i nto shaft
unti l i nstal l er tool bottoms agai nst support fl ange.
(4) Cl ean reacti on shaft support thoroughl y after
bushi ng repl acement (to remove any chi ps).
Fig. 120 Oil Pump Bushing
3 - BUSHING
6 - PUMP HOUSING
Fig. 121 Staking-Deburring Oil Pump Bushing
1 - TWO STAKES
2 - NARROW BLADE
3 - BLUNT PUNCH
Fig. 122 Reaction Shaft Bushing
6 - BUSHING
7 - REACTION SHAFT
8 - BUSHING
OIL PUMP BODY
(1) Lubri cate pump gears wi th transmi ssi on fl ui d
and i nstal l them i n pump body.
(2) I nstal l thrust washer on reacti on shaft support
hub. Lubri cate washer wi th petrol eum jel l y or trans-
mi ssi on fl ui d before i nstal l ati on.
(3) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub. Lubri cate seal
ri ngs wi th transmi ssi on fl ui d or petrol eum jel l y after
i nstal l ati on. Squeeze each ri ng unti l ri ng ends are
securel y hooked together.
CAUTION: The reaction shaft support seal rings will
break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
(4) Al i gn and i nstal l reacti on shaft support on
pump body.
(5) I nstal l bol ts attachi ng reacti on shaft support to
pump. Ti ghten bol ts to 20 Nm (175 i n. l bs.) torque.
(6) I nstal l new pump seal wi th I nstal l er Tool
C-3860-A (Fi g. 123). Use hammer or mal l et to tap
seal i nto pl ace.
(7) I nstal l new o-ri ng on pump body. Lubri cate oi l
seal and o-ri ng wi th petrol eum jel l y.
(8) Cover pump assembl y to prevent dust entry
and set asi de for assembl y i nstal l ati on.
OUTPUT SHAFT FRONT
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e.
(3) Remove snap-ri ng hol di ng output shaft front
beari ng to overdri ve geartrai n. (Fi g. 124).
(4) Pul l beari ng from output shaft.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on on
geartrai n wi th l ocati ng retai ner groove toward the
rear.
(2) Push beari ng onto shaft unti l the snap-ri ng
groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng onto output
shaft.
Fig. 123 Oil Pump Seal
1 - SPECIAL TOOL C-3860-A
2 - PUMP BODY
3 - PUMP SEAL
Fig. 124 Output Shaft Front Bearing
2 - SNAP-RING
3 - OUTPUT SHAFT
4 - GROOVE TO REAR
5 - OVERDRIVE GEARTRAIN
OUTPUT SHAFT REAR
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e. (Refer
to 21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C/
OVERDRI VE - REMOVAL)
(3) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto overdri ve housi ng (Fi g. 125).
(4) Usi ng a sui tabl e dri ver i nserted through the
rear end of housi ng, dri ve beari ng from housi ng.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on i n hous-
i ng.
(2) Usi ng a sui tabl e dri ver, dri ve beari ng i nto
housi ng unti l the snap-ri ng groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng i nto housi ng
(Fi g. 122).
OVERDRIVE CLUTCH
DESCRIPTION
The overdri ve cl utch (Fi g. 126) i s composed of the
pressure pl ate, cl utch pl ates, hol di ng di scs, overdri ve
pi ston retai ner, pi ston, pi ston spacer, and snap-ri ngs.
The overdri ve cl utch i s the forwardmost component
i n the transmi ssi on overdri ve uni t and i s consi dered
a hol di ng component. The overdri ve pi ston retai ner,
pi ston, and pi ston spacer are l ocated on the rear of
the mai n transmi ssi on case.
OPERATION
the pi ston retai ner and pi ston. The fl ui d pressure i s
cl utch through passages at the l ower rear porti on of
the val ve body area. Wi th pressure appl i ed between
the pi ston retai ner and pi ston, the pi ston moves
away from the pi ston retai ner and compresses the
cl utch pack. Thi s acti on appl i es the cl utch pack,
al l owi ng torque to fl ow through the i ntermedi ate
shaft i nto the overdri ve pl anetary gear set. The over-
dri ve cl utch di scs are attached to the overdri ve cl utch
hub whi l e the overdri ve cl utch pl ates, reacti on pl ate,
and pressure pl ate are l ugged to the overdri ve hous-
i ng. Thi s al l ows the i ntermedi ate shaft to transfer
the engi ne torque to the pl anetary gear and overrun-
ni ng cl utch. Thi s dri ves the pl anetary gear i nsi de the
annul us, whi ch i s attached to the overdri ve cl utch
drum and output shaft, creati ng the desi red gear
rati o. The waved snap-ri ng i s used to cushi on the
appl i cati on of the cl utch pack.
Fig. 125 Output Shaft Rear Bearing
1 - OUTPUT SHAFT REAR BEARING
2 - OVERDRIVE HOUSING
3 - SNAP-RING
OVERDRIVE SWITCH
DESCRIPTION
the shi ft l ever arm (Fi g. 127). The swi tch i s a
momentary contact devi ce that si gnal s the PCM to
toggl e current status of the overdri ve functi on.
OPERATION
control modul e.
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS
The overdri ve off swi tch, val ve body sol enoi d, case
connectors and rel ated wi ri ng can al l be tested wi th
a 12 vol t test l amp or a vol t/ohmmeter. Check conti -
nui ty of each component when di agnosi s i ndi cates
thi s i s necessary.
Swi tch and sol enoi d conti nui ty shoul d be checked
whenever the transmi ssi on fai l s to shi ft i nto fourth
gear range.
Fig. 126 Overdrive Clutch
OVERDRIVE CLUTCH (Continued)
REMOVAL
INSTALLATION
to grasp i t.
tor (Fi g. 130)
the shi ft l ever.
the shi ft l ever.
OVERDRIVE UNIT
REMOVAL
(3) Remove transfer case, i f equi pped.
(4) Mark propel l er shaft uni versal joi nt(s) and axl e
pi ni on yoke, or the compani on fl ange and fl ange
yoke, for al i gnment reference at i nstal l ati on, i f necc-
esary.
(5) Di sconnect and remove the rear propel l er shaft,
i f necessary. (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmi ssi on oi l pan, remove gasket,
drai n oi l and rei nstal l pan.
(7) I f overdri ve uni t had mal functi oned, or i f fl ui d
i s contami nated, remove enti re transmi ssi on. I f di ag-
nosi s i ndi cated overdri ve probl ems onl y, remove just
the overdri ve uni t.
(9) Remove bol ts attachi ng overdri ve uni t to trans-
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Careful l y work overdri ve uni t off i ntermedi ate
shaft. Do not ti l t uni t duri ng removal . Keep i t as
l evel as possi bl e.
(11) I f overdri ve uni t does not requi re servi ce,
i mmedi atel y i nsert Al i gnment Tool 6227-2 i n spl i nes
of pl anetary gear and overrunni ng cl utch to prevent
spl i nes from rotati ng out of al i gnment. I f mi sal i gn-
ment occurs, overdri ve uni t wi l l have to be di sassem-
bl ed i n order to real i gn spl i nes.
(12) Remove and retai n overdri ve pi ston thrust
beari ng. Beari ng may remai n on pi ston or i n cl utch
hub duri ng removal .
(13) Posi ti on drai n pan on workbench.
(14) Pl ace overdri ve uni t over drai n pan. Ti l t uni t
to drai n resi dual fl ui d from case.
(15) Exami ne fl ui d for cl utch materi al or metal
fragments. I f fl ui d contai ns these i tems, overhaul wi l l
be necessary.
(16) I f overdri ve uni t does not requi re any servi ce,
l eave al i gnment tool i n posi ti on. Tool wi l l prevent
acci dental mi sal i gnment of pl anetary gear and over-
runni ng cl utch spl i nes.
DISASSEMBLY
(1) Remove transmi ssi on speed sensor and o-ri ng
seal from overdri ve case (Fi g. 132).
(2) Remove overdri ve pi ston thrust beari ng (Fi g.
133).
OVERDRIVE PISTON
(1) Remove overdri ve pi ston thrust pl ate (Fi g.
134). Retai n thrust pl ate. I t i s a sel ect fi t part and
may possi bl y be reused.
Fig. 131 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
Fig. 132 Transmission Speed Sensor
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
Fig. 133 Overdrive Piston Thrust Bearing Removal/
Installation
1 - THRUST BEARING
3 - THRUST PLATE
(2) Remove i ntermedi ate shaft spacer (Fi g. 135).
Retai n spacer. I t i s a sel ect fi t part and may possi bl y
be reused.
(3) Remove overdri ve pi ston from retai ner (Fi g.
136).
OVERDRIVE CLUTCH PACK
(1) Remove overdri ve cl utch pack wi re retai ni ng
ri ng (Fi g. 137).
(2) Remove overdri ve cl utch pack (Fi g. 138).
(3) Note posi ti on of cl utch pack components for
Fig. 134 Overdrive Piston Thrust Plate Removal/
Installation
2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 135 Intermediate Shaft Spacer Location
2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
1 - PISTON RETAINER
Fig. 137 Removing Overdrive Clutch Pack Retaining
Ring
Fig. 138 Overdrive Clutch Pack Removal
OVERDRIVE GEARTRAIN
(1) Remove overdri ve cl utch wave spri ng (Fi g.
140).
(2) Remove overdri ve cl utch reacti on snap-ri ng
(Fi g. 141). Note that snap-ri ng i s l ocated i n same
groove as wave spri ng.
(3) Remove Torx head screws that attach access
cover and gasket to overdri ve case (Fi g. 142).
(4) Remove access cover and gasket (Fi g. 143).
Fig. 139 Overdrive Clutch Component Position -
Typical
1 - REACTION PLATE
2 - CLUTCH PLATES (3)
3 - PRESSURE PLATE
4 - CLUTCH DISCS (4)
Fig. 140 Overdrive Clutch Wave Spring Removal
1 - WAVE SPRING
Fig. 141 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
Fig. 142 Access Cover Screw Removal
Fig. 143 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
(5) Expand output shaft beari ng snap-ri ng wi th
expandi ng-type snap-ri ng pl i ers. Then push output
shaft forward to rel ease shaft beari ng from l ocati ng
ri ng (Fi g. 144).
(6) Li ft gear case up and off geartrai n assembl y
(Fi g. 145).
(7) Remove snap-ri ng that retai ns rear beari ng on
output shaft.
(8) Remove rear beari ng from output shaft (Fi g.
146).
DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
Fig. 144 Releasing Bearing From Locating Ring
PLIERS
2 - ACCESS HOLE
Fig. 145 Removing Geartrain
2 - GEAR CASE
Fig. 146 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
(1) Mount geartrai n assembl y i n shop press (Fi g.
147).
(2) Posi ti on Compressor Tool 6227-1 on cl utch hub
(Fi g. 147). Support output shaft fl ange wi th steel
press pl ates as shown and center assembl y under
press ram.
(3) Appl y press pressure sl owl y. Compress hub and
spri ng far enough to expose cl utch hub retai ni ng ri ng
and rel i eve spri ng pressure on cl utch pack snap-ri ng
(Fi g. 147).
(4) Remove di rect cl utch pack snap-ri ng (Fi g. 148).
(5) Remove di rect cl utch hub retai ni ng ri ng (Fi g.
149).
(6) Rel ease press l oad sl owl y and compl etel y (Fi g.
150).
(7) Remove Speci al Tool 6227-1. Then remove
cl utch pack from hub (Fi g. 150).
Fig. 147 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
Fig. 148 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
4 - PRESS PLATES
5 - CLUTCH DRUM
Fig. 149 Direct Clutch Hub Retaining Ring Removal
3 - PRESS BED
4 - PRESS PLATES
GEARTRAIN
(1) Remove di rect cl utch hub and spri ng (Fi g. 151).
(2) Remove sun gear and spri ng pl ate. Then
remove pl anetary thrust beari ng and pl anetary gear
(Fi g. 152).
(3) Remove overrunni ng cl utch assembl y wi th
expandi ng type snap-ri ng pl i ers (Fi g. 153). I nsert pl i -
ers i nto cl utch hub. Expand pl i ers to gri p hub spl i nes
and remove cl utch wi th countercl ockwi se, twi sti ng
moti on.
(4) Remove thrust beari ng from overrunni ng
cl utch hub.
(5) Remove overrunni ng cl utch from hub.
(6) Mark posi ti on of annul us gear and di rect cl utch
drum for assembl y al i gnment reference (Fi g. 154).
Use smal l center punch or scri ber to make al i gnment
marks.
Fig. 150 Direct Clutch Pack Removal
Fig. 151 Direct Clutch Hub And Spring Removal
Fig. 152 Removing Sun Gear,
Thrust Bearing And Planetary Gear
1 - PLANETARY GEAR
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
Fig. 153 Overrunning Clutch Assembly Removal/
Installation
2 - NEEDLE BEARING
(7) Remove di rect cl utch drum rear retai ni ng ri ng
(Fi g. 155).
(8) Remove di rect cl utch drum outer retai ni ng ri ng
(Fi g. 156).
(9) Mark annul us gear and output shaft for assem-
bl y al i gnment reference (Fi g. 157). Use punch or
scri ber to mark gear and shaft.
Fig. 154 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
2 - HAMMER
3 - PUNCH
Fig. 155 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
3 - ANNULUS GEAR
Fig. 156 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 157 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
(10) Remove snap-ri ng that secures annul us gear
on output shaft (Fi g. 158). Use two screwdri vers to
unseat and work snap-ri ng out of groove as shown.
(11) Remove annul us gear from output shaft (Fi g.
159). Use rawhi de or pl asti c mal l et to tap gear off
shaft.
GEAR CASE AND PARK LOCK
(1) Remove l ocati ng ri ng from gear case.
(2) Remove park pawl shaft retai ni ng bol t and
remove shaft, pawl and spri ng.
(3) Remove reacti on pl ug snap-ri ng and remove
reacti on pl ug.
(4) Remove output shaft seal .
CLEANING
Cl ean the geartrai n and case components wi th sol -
vent. Dry al l parts except the beari ngs wi th com-
pressed ai r. Al l ow beari ngs to ai r dry.
Do not use shop towel s for wi pi ng parts dry unl ess
the towel s are made from a l i nt-free materi al . A suf-
fi ci ent quanti ty of l i nt (from shop towel s, cl oths, rags,
etc.) coul d pl ug the transmi ssi on fi l ter and fl ui d pas-
sages.
Di scard the ol d case gasket and seal s. Do not
attempt to sal vage these parts. They are not reus-
abl e. Repl ace any of the overdri ve uni t snap-ri ngs i f
di storted or damaged.
Mi nor ni cks or scratches on components can be
smoothed wi th crocus cl oth. However, do not attempt
to reduce severe scori ng on any components wi th
abrasi ve materi al s. Repl ace severel y scored compo-
nents; do not try to sal vage them.
INSPECTION
Check condi ti on of the park l ock components and
the overdri ve case.
Check the bushi ngs i n the overdri ve case. Repl ace
the bushi ngs i f severel y scored or worn. Al so repl ace
the case seal i f l oose, di storted, or damaged.
Exami ne the overdri ve and di rect cl utch di scs and
pl ates. Repl ace the di scs i f the faci ng i s worn,
severel y scored, or burned and fl aki ng off. Repl ace
the cl utch pl ates i f worn, heavi l y scored, or cracked.
Check the l ugs on the cl utch pl ates for wear. The
pl ates shoul d sl i de freel y i n the drum. Repl ace the
pl ates or drum i f bi ndi ng occurs.
Check condi ti on of the annul us gear, di rect cl utch
hub, cl utch drum and cl utch spri ng. Repl ace the gear,
hub and drum i f worn or damaged. Repl ace the
spri ng i f col l apsed, di storted, or cracked.
Be sure the spl i nes and l ugs on the gear, drum and
hub are i n good condi ti on. The cl utch pl ates and
di scs shoul d sl i de freel y i n these components.
I nspect the thrust beari ngs and spri ng pl ate.
Repl ace the pl ate i f worn or scored. Repl ace the bear-
i ngs i f rough, noi sy, bri nnel l ed, or worn.
I nspect the pl anetary gear assembl y and the sun
gear and bushi ngs. I f ei ther the sun gear or the
bushi ngs are damaged, repl ace the gear and bush-
i ngs as an assembl y. The gear and bushi ngs are not
Fig. 158 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 159 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
The pl anetary carri er and pi ni ons must be i n good
condi ti on. Al so be sure the pi ni on pi ns are secure and
i n good condi ti on. Repl ace the carri er i f worn or dam-
aged.
I nspect the overrunni ng cl utch and race. The race
surface shoul d be smooth and free of scores. Repl ace
the overrunni ng cl utch assembl y or the race i f ei ther
assembl y i s worn or damaged i n any way.
Repl ace the shaft pi l ot bushi ng and i nner bushi ng
i f damaged. Repl ace ei ther shaft beari ng i f rough or
noi sy. Repl ace the beari ng snap-ri ngs i f di storted or
cracked.
Check the machi ned surfaces on the output shaft.
These surfaces shoul d cl ean and smooth. Very mi nor
ni cks or scratches can be smoothed wi th crocus cl oth.
Repl ace the shaft i f worn, scored or damaged i n any
way.
I nspect the output shaft bushi ngs. The smal l bush-
i ng i s the i ntermedi ate shaft pi l ot bushi ng. The l arge
bushi ng i s the overrunni ng cl utch hub bushi ng.
Repl ace ei ther bushi ng i f scored, pi tted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak di rect cl utch and overdri ve cl utch di scs i n
Mopar ATF +4, type 9602, transmi ssi on fl ui d. Al l ow
di scs to soak for 10-20 mi nutes.
(2) I nstal l new pi l ot bushi ng and cl utch hub bush-
i ng i n output shaft i f necessary (Fi g. 160). Lubri cate
bushi ngs wi th petrol eum jel l y, or transmi ssi on fl ui d.
(3) I nstal l annul us gear on output shaft, i f
removed. Then i nstal l annul us gear retai ni ng snap-
ri ng (Fi g. 161).
(4) Al i gn and i nstal l cl utch drum on annul us gear
(Fi g. 162). Be sure drum i s engaged i n annul us gear
l ugs.
(5) I nstal l cl utch drum outer retai ni ng ri ng (Fi g.
162).
Fig. 160 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
Fig. 161 Annulus Gear Installation
1 - SNAP-RING
3 - ANNULUS GEAR
Fig. 162 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
(6) Sl i de cl utch drum forward and i nstal l i nner
retai ni ng ri ng (Fi g. 163).
(7) I nstal l rear beari ng and snap ri ng on output
shaft (Fi g. 164). Be sure l ocati ng ri ng groove i n bear-
i ng i s toward rear.
(8) I nstal l overrunni ng cl utch on hub (Fi g. 165).
Note that cl utch onl y fi ts one way. Shoul der on cl utch
shoul d seat i n smal l recess at edge of hub.
(9) I nstal l thrust beari ng on overrunni ng cl utch
hub. Use generous amount of petrol eum jel l y to hol d
beari ng i n pl ace for i nstal l ati on. Beari ng fi ts one way
onl y. Be sure beari ng i s seated squarel y agai nst hub.
Rei nstal l beari ng i f i t does not seat squarel y.
(10) I nstal l overrunni ng cl utch i n output shaft
(Fi g. 166). I nsert snap ri ng pl i ers i n hub spl i nes.
Expand pl i ers to gri p hub. Then i nstal l assembl y
wi th countercl ockwi se, twi sti ng moti on.
(11) I nstal l pl anetary gear i n annul us gear (Fi g.
167). Be sure pl anetary pi ni ons are ful l y seated i n
annul us gear before proceedi ng.
(12) Coat pl anetary thrust beari ng and beari ng
contact surface of spri ng pl ate wi th generous amount
of petrol eum jel l y. Thi s wi l l hel p hol d beari ng i n
pl ace duri ng i nstal l ati on.
(13) I nstal l pl anetary thrust beari ng on sun gear
(Fi g. 168). Sl i de beari ng onto gear and seat i t agai nst
spri ng pl ate as shown. Beari ng fi ts one way onl y. I f i t
does not seat squarel y agai nst spri ng pl ate, remove
and reposi ti on beari ng.
(14) I nstal l assembl ed sun gear, spri ng pl ate and
thrust beari ng (Fi g. 169). Be sure sun gear and
thrust beari ng are ful l y seated before proceedi ng.
(15) Mount assembl ed output shaft, annul us gear,
and cl utch drum i n shop press. Di rect cl utch spri ng,
hub and cl utch pack are easi er to i nstal l wi th assem-
bl y mounted i n press.
Fig. 163 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 164 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
Fig. 165 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
(16) Al i gn spl i nes i n hubs of pl anetary gear and
overrunni ng cl utch wi th Al i gnment tool 6227-2 (Fi g.
170). I nsert tool through sun gear and i nto spl i nes of
both hubs. Be sure al i gnment tool i s ful l y seated
before proceedi ng.
1 - CLUTCH DRUM
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 167 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 168 Planetary Thrust Bearing Installation
1 - SPRING PLATE
3 - SUN GEAR
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
(17) I nstal l di rect cl utch spri ng (Fi g. 171). Be sure
spri ng i s properl y seated on spri ng pl ate.
NOTE: The direct clutch in a 46RE transmission
uses 8 clutch discs.
(18) Assembl e and i nstal l di rect cl utch pack on
hub as fol l ows:
(a) Assembl e cl utch pack components (Fi g. 172).
(b) I nstal l di rect cl utch reacti on pl ate on cl utch
hub fi rst. Note that one si de of reacti on pl ate i s
counterbored. Be sure thi s si de faces rearward.
Spl i nes at rear of hub are rai sed sl i ghtl y. Counter-
bore i n pl ate fi ts over rai sed spl i nes. Pl ate shoul d
be fl ush wi th thi s end of hub (Fi g. 173).
(c) I nstal l fi rst cl utch di sc fol l owed by a steel
pl ate unti l al l di scs and pl ates have been i nstal l ed.
(d) I nstal l pressure pl ate. Thi s i s l ast cl utch
pack i tem to be i nstal l ed. Be sure pl ate i s i nstal l ed
wi th shoul der si de faci ng upward (Fi g. 174).
(19) I nstal l cl utch hub and cl utch pack on di rect
cl utch spri ng (Fi g. 175). Be sure hub i s started on
sun gear spl i nes before proceedi ng.
WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6
INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS
REQUIRED. RELEASE CLUTCH SPRING TENSION
SLOWLY AND COMPLETELY TO AVOID PERSONAL
INJURY.
Fig. 170 Alignment Tool Installation
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 171 Direct Clutch Spring Installation
3 - CLUTCH HUB
4 - PRESS PLATES
(20) Posi ti on Compressor Tool 6227-1 on cl utch
hub.
(21) Compress cl utch hub and spri ng just enough
to pl ace tensi on on hub and hol d i t i n pl ace.
(22) Sl owl y compress cl utch hub and spri ng. Com-
press spri ng and hub onl y enough to expose ri ng
grooves for cl utch pack snap ri ng and cl utch hub
retai ni ng ri ng.
Fig. 172 46RE Direct Clutch Pack Components
1 - CLUTCH DISCS (8) 3 - CLUTCH PLATES (7)
2 - PRESSURE PLATE 4 - REACTION PLATE
Fig. 173 Correct Position Of Direct Clutch Reaction
Plate
1 - REACTION PLATE COUNTERBORE
2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF
HUB)
3 - CLUTCH HUB
Fig. 174 Correct Position Of Direct Clutch
1 - DIRECT CLUTCH PRESSURE PLATE
2 - CLUTCH PACK
3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
(23) Real i gn cl utch pack on hub and seat cl utch
di scs and pl ates i n cl utch drum.
(24) I nstal l di rect cl utch pack snap ri ng (Fi g. 176).
Be very sure snap ri ng i s ful l y seated i n cl utch drum
ri ng groove.
(25) I nstal l cl utch hub retai ni ng ri ng (Fi g. 177). Be
very sure retai ni ng ri ng i s ful l y seated i n sun gear
ri ng groove.
(26) Sl owl y rel ease press ram, remove compressor
tool s and remove geartrai n assembl y.
GEAR CASE
(1) Posi ti on park pawl and spri ng i n case and
i nstal l park pawl shaft. Veri fy that end of spri ng
wi th 90 bend i s hooked to pawl and strai ght end of
spri ng i s seated agai nst case.
(2) I nstal l pawl shaft retai ni ng bol t. Ti ghten bol t
(3) I nstal l park l ock reacti on pl ug. Note that pl ug
has l ocati ng pi n at rear (Fi g. 178). Be sure pi n i s
seated i n hol e i n case before i nstal l i ng snap ri ng.
(4) I nstal l reacti on pl ug snap-ri ng (Fi g. 179). Com-
press snap ri ng onl y enough for i nstal l ati on; do not
di stort i t.
Fig. 175 Direct Clutch Pack And Clutch Hub
Installation
1 - CLUTCH HUB
3 - CLUTCH DRUM
Fig. 176 Direct Clutch Pack Snap-Ring Installation
Fig. 177 Clutch Hub Retaining Ring Installation
Fig. 178 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
(5) I nstal l new seal i n gear case. Use Handl e
C-4171 and I nstal l er C-3995-A to seat seal i n case.
(6) Veri fy that tab ends of rear beari ng l ocati ng
ri ng extend i nto access hol e i n gear case (Fi g. 180).
(7) Support geartrai n on Tool 6227-1 (Fi g. 181). Be
sure tool i s securel y seated i n cl utch hub.
(8) I nstal l overdri ve gear case on geartrai n (Fi g.
181).
(9) Expand front beari ng l ocati ng ri ng wi th snap
ri ng pl i ers (Fi g. 182). Then sl i de case downward unti l
l ocati ng ri ng l ocks i n beari ng groove and rel ease
snap ri ng.
(10) I nstal l l ocati ng ri ng access cover and gasket
i n overdri ve uni t case (Fi g. 183).
Fig. 179 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
Fig. 180 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 181 Overdrive Gear Case Installation
2 - GEAR CASE
Fig. 182 Seating Locating Ring In Rear Bearing
PLIERS
2 - ACCESS HOLE
OVERDRIVE CLUTCH
NOTE: The overdrive clutch in a 46RE transmission
uses 4 clutch discs.
(1) I nstal l overdri ve cl utch reacti on ri ng fi rst.
Reacti on ri ng i s fl at wi th notched ends (Fi g. 184).
(2) I nstal l wave spri ng on top of reacti on ri ng (Fi g.
185). Reacti on ri ng and wave ri ng both fi t i n same
ri ng groove. Use screwdri ver to seat each ri ng
securel y i n groove. Al so ensure that the ends of the
two ri ngs are offset from each other.
(3) Assembl e overdri ve cl utch pack (Fi g. 186).
(4) I nstal l overdri ve cl utch reacti on pl ate fi rst.
NOTE: The reaction plate is the same thickness as
the pressure plate in a 46RE transmission.
(5) I nstal l fi rst cl utch di sc fol l owed by fi rst cl utch
pl ate. Then i nstal l remai ni ng cl utch di scs and pl ates
i n same order.
(6) I nstal l cl utch pack pressure pl ate.
(7) I nstal l cl utch pack wi re-type retai ni ng ri ng
(Fi g. 187).
INTERMEDIATE SHAFT SPACER SELECTION
(2) Determi ne correct thi ckness i ntermedi ate shaft
spacer as fol l ows:
(a) I nsert Speci al Tool 6312 through sun gear,
pl anetary gear and i nto pi l ot bushi ng i n output
shaft. Be sure tool bottoms agai nst pl anetary
shoul der.
(b) Posi ti on Gauge Tool 6311 across face of over-
dri ve case (Fi g. 188). Then posi ti on Di al Cal i per
C-4962 over gauge tool .
(c) Extend sl i di ng scal e of di al cal i per downward
through gauge tool sl ot unti l scal e contacts end of
Gauge Al i gnment Tool 6312. Lock scal e i n pl ace.
Remove di al cal i per tool and note di stance mea-
sured (Fi g. 188).
(d) Sel ect proper thi ckness end pl ay spacer from
spacer chart based on di stance measured (Fi g.
189).
(e) Remove Gauge Al i gnment Tool 6312.
Fig. 183 Locating Ring Access Cover And Gasket
Installation
Fig. 184 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 185 Overdrive Clutch Wave Spring Installation
1 - WAVE SPRING
Fig. 186 46RE Overdrive Clutch Components
2 - CLUTCH PLATES (3) 4 - CLUTCH DISCS (4)
Fig. 187 Overdrive Clutch Pack Retaining Ring
Installation
Fig. 188 Shaft End Play Measurement
Fig. 189 Intermediate Shaft End Play Spacer
Selection
OD THRUST PLATE SELECTION
(2) Determi ne correct thi ckness overdri ve pi ston
thrust pl ate as fol l ows:
(a) Posi ti on Gauge Tool 6311 across face of over-
dri ve case. Then posi ti on Di al Cal i per C-4962 over
gauge tool (Fi g. 190).
(b) Measure di stance to cl utch hub thrust bear-
i ng seat at four poi nts 90 apart. Then average
measurements by addi ng them and di vi di ng by 4.
(c) Sel ect and i nstal l requi red thrust pl ate from
i nformati on i n thrust pl ate chart (Fi g. 191).
(3) Leave Al i gnment Tool 6227-2 i n pl ace. Tool wi l l
keep pl anetary and cl utch hub spl i nes i n al i gnment
unti l overdri ve uni t i s ready for i nstal l ati on on trans-
mi ssi on.
(4) Transmi ssi on speed sensor can be i nstal l ed at
thi s ti me i f desi red. However, i t i s recommended that
sensor not be i nstal l ed unti l after overdri ve uni t i s
secured to transmi ssi on.
OVERDRIVE PISTON
(1) I nstal l new seal s on overdri ve pi ston.
i ng.
retai ner by:
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 81143 and
i nsi de Gui de Ri ng 81141.
retai ner.
(6) I nstal l i ntermedi ate shaft spacer on i ntermedi -
ate shaft.
(7) I nstal l overdri ve pi ston thrust pl ate on over-
dri ve pi ston.
(8) I nstal l overdri ve pi ston thrust beari ng on over-
dri ve pi ston.
(9) I nstal l transmi ssi on speed sensor and O-ri ng
seal i n overdri ve case.
INSTALLATION
(1) Be sure overdri ve uni t Al i gnment Tool 6227-2
i s ful l y seated before movi ng uni t. I f tool i s not
seated and gear spl i nes rotate out of al i gnment, over-
dri ve uni t wi l l have to be di sassembl ed i n order to
(2) I f overdri ve pi ston retai ner was not removed
duri ng servi ce and ori gi nal case gasket i s no l onger
reusabl e, prepare new gasket by tri mmi ng i t.
(3) Cut out ol d case gasket around pi ston retai ner
wi th razor kni fe (Fi g. 192).
(4) Use ol d gasket as templ ate and tri m new gas-
ket to fi t.
(5) Posi ti on new gasket over pi ston retai ner and
on transmi ssi on case. Use petrol eum jel l y to hol d
gasket i n pl ace i f necessary. Do not use any type of
seal er to secure gasket. Use petrol eum jel l y onl y.
Fig. 190 Overdrive Piston Thrust Plate Measurement
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
Fig. 191 Overdrive Piston Thrust Plate Selection
(6) I nstal l sel ecti ve spacer on i ntermedi ate shaft, i f
removed. Spacer goes i n groove just rearward of
shaft rear spl i nes (Fi g. 193).
(7) I nstal l thrust beari ng i n overdri ve uni t sl i di ng
hub. Use petrol eum jel l y to hol d beari ng i n posi ti on.
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Veri fy that spl i nes i n overdri ve pl anetary gear
and overrunni ng cl utch hub are al i gned wi th Al i gn-
ment Tool 6227-2. Overdri ve uni t cannot be i nstal l ed
i f spl i nes are not al i gned. I f spl i nes have rotated out
of al i gnment, uni t wi l l have to be di sassembl ed to
(9) Careful l y sl i de Al i gnment Tool 6227-2 out of
overdri ve pl anetary gear and overrunni ng cl utch
spl i nes.
(10) Rai se overdri ve uni t and careful l y sl i de i t
strai ght onto i ntermedi ate shaft. I nsert park rod i nto
park l ock reacti on pl ug at same ti me. Avoi d ti l ti ng
overdri ve duri ng i nstal l ati on as thi s coul d cause
pl anetary gear and overrunni ng cl utch spl i nes to
rotate out of al i gnment. I f thi s occurs, i t wi l l be nec-
essary to remove and di sassembl e overdri ve uni t to
(11) Work overdri ve uni t forward on i ntermedi ate
shaft unti l seated agai nst transmi ssi on case.
(12) I nstal l bol ts attachi ng overdri ve uni t to trans-
mi ssi on uni t. Ti ghten bol ts i n di agonal pattern to 34
Nm (25 ft-l bs).
(13) Connect the transmi ssi on speed sensor and
overdri ve wi ri ng connectors.
(14) I nstal l the transfer case, i f equi pped.
(15) Al i gn and i nstal l rear propel l er shaft, i f nec-
essary. (Refer to 3 - DI FFERENTI AL & DRI VELI NE/
PROPELLER SHAFT/PROPELLER SHAFT -
I NSTALLATI ON)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunni ng cl utch (Fi g. 194) consi sts of an
i nner race, an outer race (or cam), rol l ers and
spri ngs, and the spri ng retai ner. The number of rol l -
ers and spri ngs depends on what transmi ssi on and
whi ch overrunni ng cl utch i s bei ng deal t wi th.
Fig. 192 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 193 Intermediate Shaft Selective Spacer
Location
2 - SPACER GROOVE
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
OPERATION
As the i nner race i s rotated i n a cl ockwi se di recti on
(as vi ewed from the front of the transmi ssi on), the
race causes the rol l ers to rol l toward the spri ngs,
causi ng them to compress agai nst thei r retai ner. The
compressi on of the spri ngs i ncreases the cl earance
between the rol l ers and cam. Thi s i ncreased cl ear-
ance between the rol l ers and cam resul ts i n a free-
wheel i ng condi ti on. When the i nner race attempts to
rotate countercl ockwi se, the acti on causes the rol l ers
to rol l i n the same di recti on as the race, ai ded by the
pushi ng of the spri ngs. As the rol l ers try to move i n
the same di recti on as the i nner race, they are
wedged between the i nner and outer races due to the
desi gn of the cam. I n thi s condi ti on, the cl utch i s
l ocked and acts as one uni t.
DISASSEMBLY
(1) Remove the overdri ve pi ston (Fi g. 195).
(2) Remove the overdri ve pi ston retai ner bol ts.
(3) Remove overdri ve pi ston retai ner.
(4) Remove case gasket.
(5) Tap ol d cam out of case wi th pi n punch. I nsert
punch through bol t hol es at rear of case (Fi g. 196).
Al ternate posi ti on of punch to avoi d cocki ng cam dur-
i ng removal .
(6) Cl ean cl utch cam bore and case. Be sure to
remove al l chi ps/shavi ngs generated duri ng cam
removal .
CLEANING
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
INSPECTION
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
ASSEMBLY
(1) Temporari l y i nstal l overdri ve pi ston retai ner i n
case. Use 3-4 bol ts to secure retai ner.
(2) Al i gn and start new cl utch cam i n the trans-
mi ssi on case. Be sure serrati ons on cam and i n case
are al i gned (Fi g. 197). Then tap cam i nto case just
enough to hol d i t i n pl ace.
(3) Veri fy that cam i s correctl y posi ti oned before
proceedi ng any further. Narrow ends of cam ramps
shoul d be to l eft when cam i s vi ewed from front end
of case (Fi g. 197).
1 - OVERDRIVE CLUTCH PISTON
4 - PISTON RETAINER
Fig. 196 Overrunning Clutch Cam
1 - PIN PUNCH
2 - REAR SUPPORT BOLT HOLES
(4) I nsert Adapter Tool SP-5124 i nto pi ston
retai ner (Fi g. 198).
(5) Assembl e Pul l er Bol t SP-3701 and Press Pl ate
SP-3583-A (Fi g. 199).
(6) I nstal l assembl ed pul l er pl ate and bol t (Fi g.
200). I nsert bol t through cam, case and adapter tool .
Be sure pl ate i s seated squarel y on cam.
(7) Hol d pul l er pl ate and bol t i n pl ace and i nstal l
pul l er nut SP-3701 on pul l er bol t (Fi g. 201).
(8) Ti ghten pul l er nut to press cl utch cam i nto
case (Fi g. 201). Be sure cam i s pressed i nto case
evenl y and does not become cocked.
(9) Remove cl utch cam i nstal l er tool s.
(10) Stake case i n 14 pl aces around cl utch cam to
hel p secure cam i n case. Use bl unt punch or chi sel to
stake case.
(11) Remove pi ston retai ner from case. Cover
retai ner wi th pl asti c sheeti ng, or paper to keep i t
dust free.
(12) Cl ean case and cam thoroughl y. Be sure any
chi ps/shavi ngs generated duri ng cam i nstal l ati on are
removed from case.
Fig. 197 Positioning Replacement Clutch Cam In
Case
1 - ALIGN SERRATIONS ON CAM AND IN CASE
2 - CLUTCH CAM
Fig. 198 Positioning Adapter Tool In Overdrive
Piston Retainer
1 - PISTON RETAINER
Fig. 199 Assembling Clutch Cam Puller Bolt And
Press Plate
1 - PULLER BOLT SP-3701
2 - PRESS PLATE SP-3583-A
Fig. 200 Positioning Puller Plate On Clutch Cam
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAM
(13) I nstal l new gasket at rear of transmi ssi on
case. Use petrol eum jel l y to hol d gasket i n pl ace. Be
sure to al i gn governor feed hol es i n gasket wi th feed
passages i n case (Fi g. 202). Al so i nstal l gasket before
overdri ve pi ston retai ner. Center hol e i n gasket i s
smal l er than retai ner and cannot be i nstal l ed over
retai ner.
(14) Posi ti on overdri ve pi ston retai ner on trans-
mi ssi on case and al i gn bol t hol es i n retai ner, gasket
and case (Fi g. 203). Then i nstal l and ti ghten retai ner
(15) I nstal l new seal s on overdri ve pi ston.
(16) Stand transmi ssi on case upri ght on bel l housi ng.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
retai ner.
Fig. 201 Pressing Overrunning Clutch Cam Into
Case
1 - SPECIAL TOOL SP-3583-A
2 - TIGHTEN NUT TO DRAW CAM INTO CASE (NUT IS PART OF
BOLT SP-3701)
Fig. 202 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
Fig. 203 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
PISTONS
DESCRIPTION
seal s.
OPERATION
equal areas.
PRESSURE
Pressure (Fi g. 204) i s nothi ng more than force
(l bs.) di vi ded by area (i n or ft.), or force per uni t
area. Gi ven a 100 l b. bl ock and an area of 100 sq. i n.
on the fl oor, the pressure exerted by the bl ock i s: 100
the contai ner.
PISTON TRAVEL
PLANETARY GEARTRAIN/
OUTPUT SHAFT
DESCRIPTION
The pl anetary gearsets (Fi g. 208) are desi gnated as
the front, rear, and overdri ve pl anetary gear assem-
bl i es and l ocated i n such order. A si mpl e pl anetary
gearset consi sts of three mai n members:
Fig. 208 Planetary Gearset
1 - ANNULUS GEAR
2 - SUN GEAR
3 - PLANET CARRIER
4 - PLANET PINIONS (4)
PISTONS (Continued)
The sun gear whi ch i s at the center of the sys-
tem.
The pl anet carri er wi th pl anet pi ni on gears
whi ch are free to rotate on thei r own shafts and are
i n mesh wi th the sun gear.
The annul us gear, whi ch rotates around and i s
i n mesh wi th the pl anet pi ni on gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
Wi th any gi ven pl anetary gearset, several condi -
ti ons must be met for power to be abl e to fl ow:
One member must be hel d.
Another member must be dri ven or used as an
i nput.
The thi rd member may be used as an output for
power fl ow.
For di rect dri ve to occur, two gear members i n
the front pl anetary gearset must be dri ven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
DISASSEMBLY
(1) Remove pl anetary snap-ri ng from i ntermedi ate
shaft (Fi g. 209). Di scard snap-ri ng as i t i s not reus-
abl e.
(2) Remove front pl anetary gear and front annul us
gear as assembl y (Fi g. 210).
(3) Remove front pl anetary gear and thrust
washer from front annul us gear (Fi g. 211). Note
thrust washer posi ti on for assembl y reference.
(4) Remove tabbed thrust washer from dri vi ng
shel l (Fi g. 212). Note washer posi ti on for assembl y
reference.
(5) Remove sun gear and dri vi ng shel l as assembl y
(Fi g. 213).
(6) Remove tabbed thrust washer from rear pl ane-
tary gear (Fi g. 214). Note washer posi ti on on gear for
(7) Remove rear pl anetary gear and rear annul us
gear from i ntermedi ate shaft (Fi g. 215).
(8) Remove thrust pl ate from rear annul us gear
(Fi g. 216).
Fig. 209 Removing Planetary Snap-Ring
Fig. 210 Removing Front Planetary And Annulus
Gears
1 - DRIVING SHELL
Fig. 211 Disassembling Front Planetary And
Annulus Gears
Fig. 212 Driving Shell Thrust Washer Removal
1 - DRIVING SHELL
3 - SUN GEAR
Fig. 213 Sun Gear And Driving Shell Removal
2 - DRIVING SHELL
3 - SUN GEAR
Fig. 214 Rear Planetary Thrust Washer Removal
1 - SUN GEAR
2 - REAR PLANETARY THRUST WASHER
3 - DRIVING SHELL
Fig. 215 Rear Planetary And Annulus Gear Removal
INSPECTION
I nspect the pl anetary gear sets and annul us gears.
The pl anetary pi ni ons, shafts, washers, and retai ni ng
pi ns are servi ceabl e. However, i f a pi ni on carri er i s
damaged, the enti re pl anetary gear set must be
repl aced as an assembl y.
Repl ace the annul us gears i f the teeth are chi pped,
broken, or worn, or the gear i s cracked. Repl ace the
pl anetary thrust pl ates and the tabbed thrust wash-
ers i f cracked, scored or worn.
I nspect the machi ned surfaces of the i ntermedi ate
shaft. Be sure the oi l passages are open and cl ear.
Repl ace the shaft i f scored, pi tted, or damaged.
I nspect the sun gear and dri vi ng shel l . I f ei ther
component i s worn or damaged, remove the sun gear
rear retai ni ng ri ng and separate the sun gear and
thrust pl ate from the dri vi ng shel l . Then repl ace the
necessary component.
Repl ace the sun gear as an assembl y i f the gear
teeth are chi pped or worn. Al so repl ace the gear as
an assembl y i f the bushi ngs are scored or worn. The
sun gear bushi ngs are not servi ceabl e. Repl ace the
thrust pl ate i f worn, or severel y scored. Repl ace the
dri vi ng shel l i f di storted, cracked, or damaged i n any
way.
Repl ace al l snap-ri ngs duri ng geartrai n assembl y.
Reusi ng snap-ri ngs i s not recommended.
ASSEMBLY
(1) Lubri cate sun gear and pl anetary gears wi th
transmi ssi on fl ui d duri ng assembl y. Use petrol eum
jel l y to l ubri cate i ntermedi ate shaft bushi ng surfaces,
thrust washers and thrust pl ates and to hol d these
parts i n pl ace duri ng assembl y.
(2) I nstal l front snap-ri ng on sun gear and i nstal l
gear i n dri vi ng shel l . Then i nstal l thrust pl ate over
sun gear and agai nst rear si de of dri vi ng shel l (Fi g.
217). I nstal l rear snap-ri ng to secure sun gear and
thrust pl ate i n dri vi ng shel l .
(3) I nstal l rear annul us gear on i ntermedi ate shaft
(Fi g. 218).
(4) I nstal l thrust pl ate i n annul us gear (Fi g. 219).
Be sure pl ate i s seated on shaft spl i nes and agai nst
gear.
Fig. 216 Rear Annulus Thrust Plate Removal
2 - THRUST PLATE
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
Fig. 218 Installing Rear Annulus Gear On
Intermediate Shaft
2 - OUTPUT SHAFT
(5) I nstal l rear pl anetary gear i n rear annul us
gear (Fi g. 220). Be sure pl anetary carri er i s seated
agai nst annul us gear.
(6) I nstal l tabbed thrust washer on front face of
rear pl anetary gear (Fi g. 221). Seat washer tabs i n
matchi ng sl ots i n face of gear carri er. Use extra
petrol eum jel l y to hol d washer i n pl ace i f desi red.
(7) Lubri cate sun gear bushi ngs wi th petrol eum
jel l y or transmi ssi on fl ui d.
(8) I nstal l sun gear and dri vi ng shel l on i nterme-
di ate shaft (Fi g. 222). Seat shel l agai nst rear pl ane-
tary gear. Veri fy that thrust washer on pl anetary
gear was not di spl aced duri ng i nstal l ati on.
(9) I nstal l tabbed thrust washer i n dri vi ng shel l
(Fi g. 223), be sure washer tabs are seated i n tab sl ots
of dri vi ng shel l . Use extra petrol eum jel l y to hol d
washer i n pl ace i f desi red.
(10) I nstal l tabbed thrust washer on front pl ane-
tary gear (Fi g. 224). Seat washer tabs i n matchi ng
sl ots i n face of gear carri er. Use extra petrol eum jel l y
to hol d washer i n pl ace i f desi red.
(11) I nstal l front annul us gear over and onto front
pl anetary gear (Fi g. 225). Be sure gears are ful l y
meshed and seated.
(12) I nstal l front pl anetary and annul us gear
assembl y (Fi g. 226). Hol d gears together and sl i de
them onto shaft. Be sure pl anetary pi ni ons are
seated on sun gear and that pl anetary carri er i s
seated on i ntermedi ate shaft.
(13) Pl ace geartrai n i n upri ght posi ti on. Rotate
gears to be sure al l components are seated and prop-
erl y assembl ed. Snap-ri ng groove at forward end of
i ntermedi ate shaft wi l l be compl etel y exposed when
components are assembl ed correctl y.
(14) I nstal l new pl anetary snap-ri ng i n groove at
end of i ntermedi ate shaft (Fi g. 227).
(15) Turn pl anetary geartrai n over. Posi ti on wood
bl ock under front end of i ntermedi ate shaft and sup-
port geartrai n on shaft. Be sure al l geartrai n parts
have moved forward agai nst pl anetary snap-ri ng.
Thi s i s i mportant for accurate end pl ay check.
(16) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 228). I nsert gauge between rear
annul us gear and shoul der on i ntermedi ate shaft as
shown. End pl ay shoul d be 0.15 to 1.22 mm (0.006 to
0.048 i n.).
(17) I f end pl ay i s i ncorrect, i nstal l thi nner/thi cker
pl anetary snap-ri ng as needed.
Fig. 219 Installing Rear Annulus Thrust Plate
2 - THRUST PLATE
Fig. 220 Installing Rear Planetary Gear
Fig. 221 Installing Rear Planetary Thrust Washer
Fig. 222 Installing Sun Gear And Driving Shell
1 - OUTPUT SHAFT
2 - DRIVING SHELL
4 - OUTPUT SHAFT
5 - SUN GEAR
Fig. 223 Installing Driving Shell Thrust Washer
1 - TAB SLOTS (3)
2 - DRIVING SHELL
Fig. 224 Installing Thrust Washer On Front
Planetary Gear
Fig. 225 Assembling Front Planetary And Annulus
Gears
REAR CLUTCH
DESCRIPTION
The rear cl utch assembl y (Fi g. 229) i s composed of
the rear cl utch retai ner, pressure pl ate, cl utch pl ates,
dri vi ng di scs, pi ston, Bel l evi l l e spri ng, and snap-
ri ngs. The Bel l evi l l e spri ng acts as a l ever to mul ti -
pl y the force appl i ed on to i t by the appl y pi ston. The
i ncreased appl y force on the rear cl utch pack, i n com-
pari son to the front cl utch pack, i s needed to hol d
agai nst the greater torque l oad i mposed onto the rear
pack. The rear cl utch i s di rectl y behi nd the front
cl utch and i s consi dered a dri vi ng component.
OPERATION
l ugged to the cl utch retai ner. The waved spri ng i s
The snap-ri ng i s sel ecti ve and used to adjust cl utch
pack cl earance.
Fig. 226 Installing Front Planetary And Annulus
Gear Assembly
1 - DRIVING SHELL
2 - ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS
Fig. 227 Installing Planetary Snap-Ring
Fig. 228 Checking Planetary Geartrain End Play
1 - OUTPUT SHAFT
3 - FEELER GAUGE
vent and one-way bal l -check-val ve l ocated i n the pi s-
ton. The check-val ve i s needed to el i mi nate the pos-
si bi l i ty of pl ate drag caused by centri fugal force
acti ng on the resi dual fl ui d trapped i n the cl utch pi s-
ton retai ner.
DISASSEMBLY
(1) Remove fi ber thrust washer from forward si de
of cl utch retai ner.
(2) Remove i nput shaft front and rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap-ri ng (Fi g.
230).
(4) Remove the reacti on pl ate, cl utch di scs, steel
pl ates, pressure pl ate, wave spri ng, spacer ri ng, and
pi ston spri ng (Fi g. 230).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft retai ni ng ri ng. I t may be
necessary to press the i nput shaft i n sl i ghtl y to
rel i eve tensi on on the retai ni ng ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
CLEANING
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r. Do not use rags or shop
towel s to dry any of the cl utch parts. Li nt from such
materi al s wi l l adhere to component surfaces and
coul d restri ct or bl ock fl ui d passages after assembl y.
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLON SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)
INSPECTION
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off. Repl ace the top and bottom pres-
sure pl ates i f scored, warped, or cracked. Be sure the
dri vi ng l ugs on the pressure and cl utch pl ates are
al so i n good condi ti on. The l ugs must not be bent,
cracked or damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
cl utch and pressure pl ates shoul d sl i de freel y i n the
sl ots. Repl ace the retai ner i f the grooves are worn or
damaged. Al so check acti on of the check bal l s i n the
retai ner and pi ston. Each check bal l must move
freel y and not sti ck.
doubt exi sts about bushi ng condi ti on.
Check condi ti on of the fi ber thrust washer and
metal output shaft thrust washer. Repl ace ei ther
washer i f worn or damaged.
Check condi ti on of the seal ri ngs on the i nput shaft
and cl utch retai ner hub. Repl ace the seal ri ngs onl y
i f worn, di storted, or damaged. The i nput shaft front
seal ri ng i s tefl on wi th chamfered ends. The rear ri ng
i s metal wi th i nterl ocki ng ends.
Check the i nput shaft for wear, or damage. Repl ace
the shaft i f worn, scored or damaged i n any way.
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLON SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)
ASSEMBLY
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft i f necessary.
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then parti al l y press
i nput shaft i nto retai ner (Fi g. 231). Use a sui tabl y
si zed press tool to support retai ner as cl ose to i nput
shaft as possi bl e.
(4) I nstal l i nput shaft retai ni ng ri ng.
(5) Press the i nput shaft the remai nder of the way
i nto the cl utch retai ner.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston. Concave si de of spri ng faces downward
(toward pi ston).
(10) I nstal l the spacer ri ng and wave spri ng i nto
the retai ner. Be sure spri ng i s compl etel y seated i n
retai ner groove.
(11) I nstal l pressure pl ate (Fi g. 230). Ri dged si de
of pl ate faces downward (toward pi ston) and fl at si de
toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
pressure pl ate. Then i nstal l a cl utch pl ate fol l owed
by a cl utch di sc unti l enti re cl utch pack i s i nstal l ed
(4 di scs and 3 pl ates are requi red) (Fi g. 230).
(13) I nstal l the reacti on pl ate.
(14) I nstal l sel ecti ve snap-ri ng. Be sure snap-ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 232).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 232).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.635 - 0.914 mm (0.025 -
0.036 i n.). I f cl earance i s i ncorrect, steel pl ates, di scs,
sel ecti ve snap ri ng and pressure pl ates may have to
be changed.
Fig. 231 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
3 - PRESS RAM
The sel ecti ve snap ri ng thi cknesses are:
0.107 - 0.109 i n.
0.098 - 0.100 i n.
0.095 - 0.097 i n.
0.083 - 0.085 i n.
0.076 - 0.078 i n.
0.071 - 0.073 i n.
0.060 - 0.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 233). Use enough petrol eum
jel l y to hol d washer i n pl ace.
(17) Set rear cl utch asi de for i nstal l ati on duri ng
fi nal assembl y.
REAR SERVO
DESCRIPTION
The rear (l ow/reverse) servo consi sts of a si ngl e
stage or di ameter pi ston and a spri ng l oaded pl ug.
The spri ng i s used to cushi on the appl i cati on of the
rear (l ow/reverse) band.
OPERATION
Whi l e i n the de-energi zed state (no pressure
appl i ed), the pi ston i s hel d up i n i ts bore by the pi s-
ton spri ng. The pl ug i s hel d down i n i ts bore, i n the
pi ston, by the pl ug spri ng. When pressure i s appl i ed
to the top of the pi ston, the pl ug i s forced down i n i ts
bore, taki ng up any cl earance. As the pi ston moves, i t
causes the pl ug spri ng to compress, and the pi ston
moves down over the pl ug. The pi ston conti nues to
move down unti l i t hi ts the shoul der of the pl ug and
ful l y appl i es the band. The peri od of ti me from the
i ni ti al appl i cati on, unti l the pi ston i s agai nst the
shoul der of the pl ug, represents a reduced shocki ng
of the band that cushi ons the shi ft.
DISASSEMBLY
(1) Remove smal l snap-ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 234).
(2) Remove and di scard servo pi ston seal ri ng.
CLEANING
Remove and di scard the servo pi ston seal ri ng (Fi g.
235). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap-ri ngs and use new ones at assembl y.
Fig. 232 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4 - STAND
5 - REAR CLUTCH
6 - GAUGE BAR
2 - REAR CLUTCH THRUST WASHER
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s (Fi g. 236)
wi th petrol eum jel l y. Lubri cate other servo parts wi th
Mopar ATF +4, type 9602, transmi ssi on fl ui d.
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap-
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
SHIFT MECHANISM
DESCRIPTION
ti ons whi ch are:
PARK (P)
REVERSE (R)
NEUTRAL (N)
DRI VE (D)
Manual SECOND (2)
Manual LOW (1)
OPERATION
Manual LOW (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range. Man-
ual SECOND (2) range provi des fi rst and second gear
onl y.
DRI VE range provi des fi rst, second thi rd and over-
dri ve fourth gear ranges. The shi ft i nto overdri ve
fourth gear range occurs onl y after the transmi ssi on
has compl eted the shi ft i nto D thi rd gear range. No
further movement of the shi ft mechani sm i s requi red
to compl ete the 3-4 shi ft.
The fourth gear upshi ft occurs automati cal l y when
the overdri ve sel ector swi tch i s i n the ON posi ti on.
No upshi ft to fourth gear wi l l occur i f any of the fol -
l owi ng are true:
C (50 F) or above 121 C (250 F).
The shi ft to thi rd i s not yet compl ete.
SOLENOID
DESCRIPTION
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
REAR SERVO (Continued)
coi l or
OPERATION
spri ng pressure.
SPEED SENSOR
DESCRIPTION
The speed sensor (Fi g. 237) i s l ocated i n the over-
dri ve gear case. The sensor i s posi ti oned over the
park gear and moni tors transmi ssi on output shaft
rotati ng speed.
OPERATION
Speed sensor si gnal s are tri ggered by the park
gear l ugs as they rotate past the sensor pi ckup face.
I nput si gnal s from the sensor are sent to the trans-
mi ssi on control modul e for processi ng. Si gnal s from
thi s sensor are shared wi th the powertrai n control
modul e.
Fig. 237 Transmission Output Speed Sensor
1 - TRANSMISSION OUTPUT SHAFT SPEED SENSOR
2 - SEAL
SOLENOID (Continued)
DESCRIPTION
Transmi ssi on throttl e val ve cabl e (Fi g. 238) adjust-
ment i s extremel y i mportant to proper operati on.
Thi s adjustment posi ti ons the throttl e val ve, whi ch
control s shi ft speed, qual i ty, and part-throttl e down-
shi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve.
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 239). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
ADJUSTMENT VERIFICATION
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on (Fi g. 240). Then veri fy that the transmi ssi on
throttl e l ever (Fi g. 241) i s al so at i dl e (ful l y forward)
posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
Engine
2 - CABLE BRACKET
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on (Fi g. 242).
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
ADJUSTMENT PROCEDURE
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) Pry the T.V. cabl e l ock (A) i nto the UP posi ti on
(Fi g. 242). Thi s wi l l unl ock the cabl e and al l ow for
readjustment.
(6) Appl y just enough tensi on on the T.V. cabl e (B)
to remove any sl ack i n the cabl e.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment. Sl i de the
sheath of the T.V. cabl e (D) back and forth unti l the
centerl i nes of the T.V. cabl e end (B) and the throttl e
bel l crank l ever (C) are al i gned wi thi n one mi l l i meter
(1mm) (Fi g. 242).
(7) Whi l e hol di ng the T.V. cabl e i n the set posi ti on
push the T.V. cabl e l ock (A) i nto the down posi ti on
(Fi g. 242). Thi s wi l l l ock the present T.V. cabl e
adjustment.
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
Engine
2 - CABLE BRACKET
Fig. 241 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OR 2)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
(8) Reconnect the T.V. cabl e (B) to the throttl e
bel l crank l ever (C).
(9) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 243) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The torque
converter hub dri ves the transmi ssi on oi l (fl ui d)
pump.
is contaminated, flush the all transmission fluid
cooler(s) and lines.
IMPELLER
1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - FRONT COVER
6 - CONVERTER CLUTCH DISC
7 - DRIVE PLATE
TURBINE
Fig. 244 Impeller
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
5 - ENGINE ROTATION
Fig. 245 Turbine
STATOR
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
OPERATION
2 - ROLLER
3 - SPRING
4 - INNER RACE
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
TURBINE
STATOR
cl ockwi se di recti on. When thi s happens the overrun-
The torque converter cl utch i s hydraul i cal l y
appl i ed and i s rel eased when fl ui d i s vented from the
hydraul i c ci rcui t by the torque converter control
(TCC) sol enoi d on the val ve body. The torque con-
verter cl utch i s control l ed by the Powertrai n Control
Modul e (PCM). The torque converter cl utch engages
i n fourth gear, and i n thi rd gear under vari ous con-
di ti ons, such as when the O/D swi tch i s OFF, when
the vehi cl e i s crui si ng on a l evel surface after the
vehi cl e has warmed up. The torque converter cl utch
wi l l di sengage momentari l y when an i ncrease i n
engi ne l oad i s sensed by the PCM, such as when the
vehi cl e begi ns to go uphi l l or the throttl e pressure i s
i ncreased.
Fig. 249 Torque Converter Fluid Operation
REMOVAL
from vehi cl e.
transmission.
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
fl ui d.
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
i ng.
pump gears.
fl ui d.
2 - FRONT OF ENGINE
Fig. 251 Checking Torque Converter Seating -
Typical
1 - SCALE
2 - STRAIGHTEDGE
TORQUE CONVERTER
DRAINBACK VALVE
DESCRIPTION
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne.
OPERATION
The val ve prevents fl ui d from drai ni ng from the
converter i nto the cool er and l i nes when the vehi cl e
i s shut down for l engthy peri ods. Producti on val ves
have a hose ni ppl e at one end, whi l e the opposi te end
i s threaded for a fl are fi tti ng. Al l val ves have an
arrow (or si mi l ar mark) to i ndi cate di recti on of fl ow
through the val ve.
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates si gni fi cant amounts of sl udge and/or cl utch par-
ti cl es and metal shavi ngs, the val ve must be
repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) (Fi g. 252)
has 3 pri mary functi ons:
Provi de a PARK/NEUTRAL start si gnal to the
engi ne control l er and the starter rel ay.
Turn the Back-up l amps on when the transmi s-
si on i s i n REVERSE and the engi ne (i gni ti on) i s on.
Provi de a transmi ssi on range si gnal to the
The sensor i s mounted i n the transmi ssi on housi ng
near the val ve body, just above the pan rai l . I ts i n
the same posi ti on as the Park/Neutral swi tch on
other transmi ssi ons. The TRS contacts a cammed
surface on the manual val ve l ever. The cammed sur-
face transl ates the rotati onal moti on of the manual
l ever i nto the l i near moti on of the sensor. The
cammed surface on the manual l ever i s compri sed of
two parts control l i ng the TRS si gnal : The i nsul ator
porti on contacts the swi tch poppet when the manual
l ever i s not i n PARK or NEUTRAL. The manual
l ever i tsel f contacts the poppet when the l ever i s i n
PARK or NEUTRAL; provi di ng a ground for the si g-
nal from the starter rel ay and the JTEC engi ne con-
trol l er.
OPERATION
As the swi tch moves through i ts l i near moti on (Fi g.
253) contacts sl i de across a ci rcui t board whi ch
changes the resi stance between the range sensi ng
pi ns of the swi tch. A power suppl y on the i nstrument
cl uster provi des a regul ated vol tage si gnal to the
swi tch. The return si gnal i s decoded by the cl uster,
whi ch then control s the PRNDL di spl ay to corre-
spond wi th the correct transmi ssi on range. A bus
message of transmi ssi on range i s al so sent by the
cl uster. I n REVERSE range a second contact set
cl oses the ci rcui t provi di ng power to the reverse
l amps.
Fig. 252 Transmission Range Sensor
Mechanical
State
Electronic Display
(Ignition
Unlocked)
Electronic Display
(Ignition On)
Indicated Gear Position Transmission Status Column Shifter
Position
P P P Vehicle is in PARK with the
pawl engaged.
In the PARK gate.
R The PARK pawl is disengaged
and the vehicle is free to roll,
but REVERSE is not engaged.
Between the PARK
and REVERSE
gates.
R R R The transmission is
hydraulically in REVERSE.
In the REVERSE
gate.
transitioning between
REVERSE and NEUTRAL.
Between the
REVERSE and
NEUTRAL gates.
N N N The vehicle is in NEUTRAL. In the NEUTRAL
gate.
transitioning between
NEUTRAL and DRIVE, but is
not in DRIVE.
Between the
NEUTRAL and
DRIVE gates.
D D D The transmission is
hydraulically in DRIVE.
In the DRIVE gate,
Fig. 253 Transmission Range Sensor Linear Movement
Mechanical
State
Electronic Display
(Ignition
Unlocked)
Electronic Display
(Ignition On)
Indicated Gear Position Transmission Status Column Shifter
Position
hydraulically in Manual
SECOND.
In the SECOND
gate.
hydraulically in Manual FIRST.
In the FIRST gate.
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)
NOTE: For all circuit identification in the following
steps, Refer to the appropriate Wiring Information.
(1) Rai se vehi cl e on sui tabl e hoi st.
(2) Di sconnect the vehi cl es shi ft cabl e from the
manual l ever.
between the Park/Neutral Posi ti on Sense pi n of the
TRS and the transmi ssi on case. The resi stance
shoul d be l ess than 5 ohms.
posi ti on), measure the resi stance between the Park/
Neutral Posi ti on Sense pi n of the TRS and the trans-
mi ssi on case. The resi stance shoul d be l ess than 5
ohms.
(5) I f the resi stance i s greater than 5 ohms i n
ei ther of the previ ous steps, check for a di rty contact
between the ti p of the TRS rod and the val ve body
manual l ever. I f the contact i s OK, repl ace the TRS.
pi ns of the TRS. The resi stance shoul d be l ess than 5
ohms. I f the resi stance i s greater than 5 ohms,
repl ace the TRS.
between the Cl uster Resi stance Si gnal and the Cl us-
ter Si gnal Return pi ns of the TRS. The resi stance
repl ace the TRS.
ti on), measure the resi stance between the Cl uster
posi ti on), measure the resi stance between the Cl uster
(10) Wi th the manual l ever i n the DRI VE posi ti on
(the DRI VE posi ti on i s wi th the manual l ever moved
three detents forward of the ful l rearward posi ti on),
measure the resi stance between the Cl uster Resi s-
tance Si gnal and the Cl uster Si gnal Return pi ns of
the TRS. The resi stance shoul d be 59.9 ohms. I f the
resi stance i s not correct, repl ace the TRS.
(11) Wi th the manual l ever i n the SECOND posi -
ti on (the SECOND posi ti on i s wi th the manual l ever
moved one detent rearward of the ful l forward posi -
pi ns of the TRS. The resi stance shoul d be 31.9 ohms.
I f the resi stance i s not correct, repl ace the TRS.
(12) Wi th the manual l ever i n the LOW posi ti on
(the LOW posi ti on i s wi th the manual l ever moved to
the ful l forward posi ti on), measure the resi stance
between the Fused I gni ti on Swi tch Output and the
Back-up Lamp feed pi ns of the TRS. The resi stance
repl ace the TRS.
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under the
transmi ssi on range sensor (TRS).
(2) Move the transmi ssi on manual l ever to the
manual LOW posi ti on. The manual LOW posi ti on i s
wi th the manual l ever i n the forward-most detent.
(3) Di sengage the wi ri ng connector from the TRS.
(4) Remove the two screws hol di ng the TRS to the
TRS mounti ng bracket.
(5) Remove the TRS (Fi g. 254) from the TRS
mounti ng bracket by pul l i ng i t strai ght out of the
bracket.
(6) Loosen the TRS mounti ng bracket i n the trans-
mi ssi on case usi ng Adapter 8581 (Fi g. 255).
(7) Remove the TRS mounti ng bracket (Fi g. 256)
from the transmi ssi on case.
INSTALLATION
the manual LOW posi ti on.
(2) I nstal l the TRS mounti ng bracket i nto the
transmi ssi on case. Usi ng Adapter 8581 (Fi g. 257),
ti ghten the mounti ng bracket to 34 Nm (300 i n.l bs.).
(3) I nstal l the TRS (Fi g. 258) i nto the mounti ng
bracket wi th the wi ri ng connector faci ng the front of
the transmi ssi on.
Fig. 255 Loosen the TRS Mounting Bracket
3 - ADAPTER 8581
Fig. 256 Remove TRS Mounting Bracket
3 - ADAPTER 8581
(4) I nstal l the two screws to hol d the TRS to the
mounti ng bracket. Ti ghten the screws to 3.4 Nm (30
i n.l bs.).
(5) Veri fy proper sensor operati on (Fi g. 259).
the PARK posi ti on.
(7) Connect TRS wi ri ng connector to the TRS and
l ower vehi cl e.
(8) Refi l l the transmi ssi on fl ui d to the correct
l evel .
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
Transmi ssi on fl ui d temperature readi ngs are sup-
pl i ed to the transmi ssi on control modul e by the ther-
mi stor (Fi g. 260). The temperature readi ngs are used
to control engagement of the fourth gear overdri ve
cl utch, the converter cl utch, and governor pressure.
Normal resi stance val ue for the thermi stor at room
temperature i s approxi matel y 1000 ohms.
The thermi stor i s part of the governor pressure
sensor assembl y and i s i mmersed i n transmi ssi on
fl ui d at al l ti mes.
OPERATION
The PCM prevents engagement of the converter
cl utch and overdri ve cl utch, when fl ui d temperature
i s bel ow approxi matel y 10C (50F).
I f fl ui d temperature exceeds 126C (260F), the
PCM causes a 4-3 downshi ft and engage the con-
verter cl utch. Engagement i s accordi ng to the thi rd
gear converter cl utch engagement schedul e.
The overdri ve OFF l amp i n the i nstrument panel
i l l umi nates when the shi ft back to thi rd occurs. The
transmi ssi on wi l l not al l ow fourth gear operati on
unti l fl ui d temperature decreases to approxi matel y
110C (230F).
Fig. 259 Transmission Range Sensor Operation
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SENSOR PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
1 - GOVERNOR BODY
VALVE BODY
DESCRIPTION
body, a separator pl ate, and transfer pl ate. The val ve
body contai ns val ves and check bal l s that control
fl ui d del i very to the torque converter cl utch, bands,
and fri cti onal cl utches. The val ve body contai ns the
fol l owi ng components (Fi g. 261), (Fi g. 262), (Fi g.
263), and (Fi g. 264):
Regul ator val ve
Regul ator val ve throttl e pressure pl ug
Li ne pressure pl ug and sl eeve
Ki ckdown val ve
Ki ckdown l i mi t val ve
1-2 shi ft val ve
1-2 control val ve
2-3 shi ft val ve
2-3 governor pl ug
3-4 shi ft val ve
3-4 ti mi ng val ve
3-4 qui ck fi l l val ve
3-4 accumul ator
Throttl e val ve
Throttl e pressure pl ug
Swi tch val ve
Manual val ve
Converter cl utch l ock-up val ve
Converter cl utch l ock-up ti mi ng Val ve
Shuttl e val ve
Shuttl e val ve throttl e pl ug
Boost Val ve
10 check bal l s
By adjusti ng the spri ng pressure acti ng on the reg-
ul ator val ve, transmi ssi on l i ne pressure can be
adjusted.
OPERATION
and design.
CHECK BALLS
CHECK BALL NUMBER DESCRIPTION
3 Allows either the Reverse circuit or the 3rd gear circuit to pressurize the front
clutch.
4 Allows either the Manual Low circuit from the Manual Valve or the Reverse
from the Manual Valve circuit to pressurize the rear servo.
5 Directs line pressure to the spring end of the 2-3 shift valve in either Manual
Low or Manual 2nd, forcing the downshift to 2nd gear regardless of governor
pressure.
6 Provides a by-pass around the front servo orifice so that the servo can release
quickly.
7 Provides a by-pass around the rear clutch orifice so that the clutch can release
quickly.
8 Directs reverse line pressure through an orifice to the throttle valve eliminating
the extra leakage and insuring that Reverse line pressure pressure will be
sufficient.
9 Provides a by-pass around the rear servo orifice so that the servo can release
quickly.
ECE (10) Allows the lockup clutch to used at WOT in 3rd gear by putting line pressure
from the 3-4 Timing Valve on the interlock area of the 2-3 shift valve, thereby
preventing a 3rd gear Lock-up to 2nd gear kickdown.
REGULATOR VALVE
The pressure regul ator val ve i s needed to control
the hydraul i c pressure wi thi n the system and reduce
the amount of heat produced i n the fl ui d. The pres-
sure regul ator val ve i s l ocated i n the val ve body near
the manual val ve. The pressure regul ator val ve trai n
control s the maxi mum pressure i n the l i nes by
meteri ng the dumpi ng of fl ui d back i nto the sump.
Regul ated pressure i s referred to as l i ne pressure.
The regul ator val ve (Fi g. 265) has a spri ng on one
end that pushes the val ve to the l eft. Thi s cl oses a
dump (vent) that i s used to l ower pressure. The cl os-
i ng of the dump wi l l cause the oi l pressure to
i ncrease. Oi l pressure on the opposi te end of the
val ve pushes the val ve to the ri ght, openi ng the
dump and l oweri ng oi l pressure. The resul t i s spri ng
pressure worki ng agai nst oi l pressure to mai ntai n
the oi l at speci fi c pressures. Wi th the engi ne run-
ni ng, fl ui d fl ows from the pump to the pressure reg-
ul ator val ve, manual val ve, and the i nterconnected
ci rcui ts. As fl ui d i s sent through passages to the reg-
ul ator val ve, the pressure pushes the val ve to the
ri ght agai nst the l arge spri ng. I t i s al so sent to the
reacti on areas on the l eft si de of the throttl e pressure
pl ug and the l i ne pressure pl ug. Wi th the gear sel ec-
tor i n the PARK posi ti on, fl ui d reci rcul ates through
the regul ator and manual val ves back to the sump.
Meanwhi l e, the torque converter i s fi l l ed sl owl y. I n
al l other gear posi ti ons (Fi g. 266), fl ui d fl ows
between two ri ght si de l ands to the swi tch val ve and
torque converter. At l ow pump speeds, the fl ow i s
control l ed by the pressure val ve groove to reduce
pressure to the torque converter. After the torque
converter and swi tch val ve fi l l wi th fl ui d, the swi tch
val ve becomes the control l i ng meteri ng devi ce for
torque converter pressure. The regul ator val ve then
begi ns to control the l i ne pressure for the other
transmi ssi on ci rcui ts. The bal ance of the fl ui d pres-
sure pushi ng the val ve to the ri ght and the spri ng
pressure pushi ng to the l eft determi nes the si ze of
the meteri ng passage at l and #2 (l and #1 bei ng at
the far ri ght of the val ve i n the di agram). As fl ui d
l eaks past the l and, i t moves i nto a groove connected
to the fi l ter or sump. As the l and meters the fl ui d to
the sump, i t causes the pressure to reduce and the
spri ng decreases the si ze of the meteri ng passage.
When the si ze of the meteri ng passage i s reduced,
the pressure ri ses agai n and the si ze of the l and i s
i ncreased agai n. Pressure i s regul ated by thi s con-
stant bal ance of hydraul i c and spri ng pressure.
The meteri ng at l and #2 establ i shes the l i ne pres-
sure throughout the transmi ssi on. I t i s vari ed accord-
i ng to changes i n throttl e posi ti on and the
transmi ssi ons i nternal condi ti on wi thi n a range of
57-94 psi (except i n REVERSE) (Fi g. 267). The regu-
l ated l i ne pressure i n REVERSE (Fi g. 268) i s hel d at
much hi gher pressures than i n the other gear posi -
ti ons: 145-280 psi . The hi gher pressure for
REVERSE i s achi eved by the manual val ve bl ocki ng
the suppl y of l i ne pressure to the reacti on area l eft of
l and #4. Wi th thi s pressure bl ocked, there i s l ess
area for pressure to act on to bal ance the force of the
spri ng on the ri ght. Thi s al l ows l i ne pressure to push
the val ve trai n to the ri ght, reduci ng the amount of
fl ui d returned to the pumps i nl et, i ncreasi ng l i ne
pressure.
Fig. 265 Regulator Valve in PARK Position
Fig. 266 Regulator Valve in NEUTRAL Position
Fig. 267 Regulator Valve in DRIVE Position
KICKDOWN VALVE
When the throttl e val ve i s as far over to the l eft as
i t can go, the maxi mum l i ne pressure possi bl e wi l l
enter the throttl e pressure ci rcui t. I n thi s case, throt-
tl e pressure wi l l equal l i ne pressure. Wi th the ki ck-
down val ve (Fi g. 269) pushed i nto the bore as far as
i t wi l l go, fl ui d i ni ti al l y fl ows through the annul ar
groove of the 2-3 shi ft val ve (whi ch wi l l be i n the
di rect dri ve posi ti on to the ri ght).
After passi ng the annul ar groove, the fl ui d i s
routed to the spri ng end of the 2-3 shi ft val ve. Fl ui d
pressure reacti ng on the area of l and #1 overcomes
governor pressure, downshi fti ng the 2-3 shi ft val ve
i nto the ki ckdown, or second gear stage of operati on.
The val ve i s hel d i n the ki ckdown posi ti on by throttl e
pressure routed from a seated check bal l (#2). Agai n,
i f vehi cl e speed i s l ow enough, throttl e pressure wi l l
al so push the 1-2 shi ft val ve l eft to seat i ts governor
pl ug, and downshi ft to dri ve breakaway.
KICKDOWN LIMIT VALVE
The purpose of the l i mi t val ve i s to prevent a 3-2
downshi ft at hi gher speeds when a part-throttl e
downshi ft i s not desi rabl e. At these hi gher speeds
onl y a ful l throttl e 3-2 downshi ft wi l l occur. At l ow
road speeds (Fi g. 270) the l i mi t val ve does not come
i nto pl ay and does not affect the downshi fts. As the
vehi cl es speed i ncreases (Fi g. 271), the governor
pressure al so i ncreases. The i ncreased governor pres-
sure acts on the reacti on area of the bottom l and of
the l i mi t val ve overcomi ng the spri ng force tryi ng to
push the val ve toward the bottom of i ts bore. Thi s
pushes the val ve upward agai nst the spri ng and bot-
toms the val ve agai nst the top of the housi ng. Wi th
the val ve bottomed agai nst the housi ng, the throttl e
pressure suppl i ed to the val ve wi l l be cl osed off by
the bottom l and of the l i mi t val ve. When the suppl y
of throttl e pressure has been shut off, the 3-2 part
throttl e downshi ft pl ug becomes i noperati ve, because
no pressure i s acti ng on i ts reacti on area.
Fig. 268 Regulator Valve in REVERSE Position
Fig. 269 Kickdown Valve-Wide Open Throttle
Fig. 270 Kickdown Limit Valve-Low Speeds
1-2 SHIFT VALVE
The 1-2 shi ft val ve assembl y (Fi g. 272), or mecha-
ni sm, consi sts of: the 1-2 shi ft val ve, governor pl ug,
and a spri ng on the end of the val ve. After the man-
ual val ve has been pl aced i nto a forward gear range,
l i ne pressure i s di rected to the 1-2 shi ft val ve. As the
throttl e i s depressed, throttl e pressure i s appl i ed to
the ri ght si de of the 1-2 shi ft val ve assembl y. Wi th
throttl e pressure appl i ed to the ri ght si de of the
val ve, there i s now both spri ng pressure and throttl e
pressure acti ng on the val ve, hol di ng i t agai nst the
governor pl ug. As the vehi cl e begi ns to move and
bui l d speed, governor pressure i s created and i s
appl i ed to the l eft of the val ve at the governor pl ug.
When governor pressure bui l ds to a poi nt where i t
can overcome the combi ned force of the spri ng and
throttl e pressure on the other si de of the val ve, the
val ve wi l l begi n to move over to the ri ght. As the
val ve moves to the ri ght, the mi ddl e l and of the val ve
wi l l cl ose off the ci rcui t suppl yi ng the throttl e pres-
sure to the ri ght si de of the val ve. When the throttl e
pressure i s cl osed off, the val ve wi l l move even far-
ther to the ri ght, al l owi ng l i ne pressure to enter
another ci rcui t and energi ze the front servo, appl yi ng
the front band (Fi g. 273).
Fig. 271 Kickdown Limit Valve-High Speeds
The governor pl ug serves a dual purpose:
I t al l ows the shi ft val ves to move ei ther l eft or
ri ght, al l owi ng both upshi fts and downshi fts.
When i n a manual sel ecti on posi ti on, i t wi l l be
hydraul i cal l y bl ocked i nto posi ti on so no upshi ft can
occur.
The physi cal bl ocki ng of the upshi ft whi l e i n the
manual 1 posi ti on i s accompl i shed by the di recti ng
of l i ne pressure between both l ands of the governor
pl ug. The l i ne pressure reacts agai nst the l arger l and
of the pl ug, pushi ng the pl ug back agai nst the end
pl ate overcomi ng governor pressure. Wi th the combi -
nati on of the l i ne pressure and spri ng pressure, the
val ve cannot move, preventi ng any upshi ft.
1-2 SHIFT CONTROL VALVE
I t contai ns a val ve wi th four l ands and a spri ng. I t
i s used as both a rel ay and bal anced val ve.
The val ve has two speci fi c operati ons (Fi g. 274):
Ai d i n qual i ty of the 1-2 upshi ft.
Ai d i n the qual i ty and ti mi ng of the 3-2 ki ck-
down ranges.
When the manual val ve i s set to the DRI VE posi ti on
and the transmi ssi on i s i n the fi rst or second gear range,
1-2 shi ft control or modul ated throttl e pressure i s sup-
pl i ed to the mi ddl e of the accumul ator pi ston by the 1-2
shi ft control val ve. Duri ng the 1-2 upshi ft, thi s pressure
i s used to control the ki ckdown servo appl y pressure that
i s needed to appl y the ki ckdown and accumul ator pi s-
tons. Thus, the 1-2 shi ft poi nt i s cushi oned and the
qual i ty i s i mproved. Duri ng a WOT ki ckdown, ki ckdown
pressure i s appl i ed between the ki ckdown val ve and the
1-2 shi ft control val ve. Thi s addi ti onal pressure i s
di rected to the 1-2 shi ft control s spri ng cavi ty, addi ng to
the spri ng l oad on the val ve. The resul t of thi s i ncreased
modul ated throttl e pressure i s a fi rmer WOT upshi ft.
2-3 SHIFT VALVE
The 2-3 shi ft val ve mechani sm (Fi g. 275) consi sts
of the 2-3 shi ft val ve, governor pl ug and spri ng, and
a throttl e pl ug. After the 1-2 shi ft val ve has com-
pl eted i ts operati on and appl i ed the front band, l i ne
pressure i s di rected to the 2-3 shi ft val ve through the
connecti ng passages from the 1-2 shi ft val ve. The l i ne
pressure wi l l then deadend at l and #2 unti l the 2-3
val ve i s ready to make i ts shi ft. Now that the vehi cl e
i s i n moti on and under accel erati on, there i s throttl e
pressure bei ng appl i ed to the spri ng si de of the val ve
and between l ands #3 and #4.
As vehi cl e speed i ncreases, governor pressure
i ncreases proporti onatel y, unti l i t becomes great
enough to overcome the combi ned throttl e and spri ng
pressure on the ri ght si de of the val ve. Si nce the
throttl e pressure end of the 2-3 shi ft val ve i s l arger
i n di ameter than the 1-2 shi ft val ve, the 2-3 shi ft wi l l
al ways happen at a greater speed than the 1-2 shi ft.
When thi s happens, the governor pl ug i s forced
agai nst the shi ft val ve movi ng i t to the ri ght. The
shi ft val ve causes l and #4 to cl ose the passage sup-
pl yi ng throttl e pressure to the 2-3 shi ft val ve. Wi th-
out throttl e pressure present i n the ci rcui t now, the
governor pl ug wi l l push the val ve over far enough to
bottom the val ve i n i ts bore. Thi s al l ows l and #2 to
di rect l i ne pressure to the front cl utch.
After the shi ft (Fi g. 276), l i ne pressure i s di rected
to the l and between the shi ft val ve and the governor
pl ug, and to the rel ease si de of the ki ckdown servo.
Thi s rel eases the front band and appl i es the front
cl utch, shi fti ng i nto thi rd gear or di rect dri ve. The
rear cl utch remai ns appl i ed, as i t has been i n the
other gears. Duri ng a manual 1 or manual 2 gear
sel ecti on, l i ne pressure i s sent between the two l ands
of the 2-3 governor pl ug. Thi s l i ne pressure at the
governor pl ug l ocks the shi ft val ve i nto the second
gear posi ti on, preventi ng an upshi ft i nto di rect dri ve.
The theory for the bl ocki ng of the val ve i s the same
as that of the 1-2 shi ft val ve.
Fig. 274 1-2 Shift Control Valve
3-4 SHIFT VALVE
The PCM energi zes the overdri ve sol enoi d duri ng
the 3-4 upshi ft (Fi g. 277). Thi s causes the sol enoi d
check bal l to cl ose the vent port al l owi ng l i ne pres-
sure from the 2-3 shi ft val ve to act di rectl y on the 3-4
upshi ft val ve. Li ne pressure on the 3-4 shi ft val ve
overcomes val ve spri ng pressure movi ng the val ve to
the upshi ft posi ti on (Fi g. 278). Thi s acti on exposes
overdri ve pi ston.
Fig. 277 3-4 Shift Valve Before Shift
3-4 TIMING VALVE
The 3-4 ti mi ng val ve i s moved by l i ne pressure
comi ng through the 3-4 shi ft val ve (Fi g. 278). After
the shi ft, the ti mi ng val ve hol ds the 2-3 shi ft val ve i n
an upshi ft posi ti on. The purpose i s to prevent the 2-3
val ve from downshi fti ng before the 3-4 val ve (Fi g.
277).
3-4 QUICK FILL VALVE
The 3-4 qui ck fi l l val ve provi des faster engagement
of the overdri ve cl utch duri ng 3-4 upshi fts. The val ve
temporari l y bypasses the cl utch pi ston feed ori fi ce at
the start of a 3-4 upshi ft (Fi g. 277). Thi s exposes a
l arger passage i nto the pi ston retai ner resul ti ng i n a
much faster cl utch fi l l and appl y sequence. The qui ck
fi l l val ve does not bypass the regul ar cl utch feed ori -
fi ce throughout the 3-4 upshi ft. I nstead, once a pre-
determi ned pressure devel ops wi thi n the cl utch, the
val ve cl oses the bypass (Fi g. 278). Cl utch fi l l i s then
compl eted through the regul ar feed ori fi ce.
THROTTLE VALVE
I n al l gear posi ti ons the throttl e val ve (Fi g. 279) i s
bei ng suppl i ed wi th l i ne pressure. The throttl e val ve
meters and reduces the l i ne pressure that now
becomes throttl e pressure. The throttl e val ve i s
moved by a spri ng and the ki ckdown val ve, whi ch i s
mechani cal l y connected to the throttl e. The l arger
the throttl e openi ng, the hi gher the throttl e pressure
(to a maxi mum of l i ne pressure). The smal l er the
throttl e openi ng, the l ower the throttl e pressure (to a
mi ni mum of zero at i dl e). As engi ne speed i ncreases,
the i ncrease i n pump speed i ncreases pump output.
The i ncrease i n pressure and vol ume must be regu-
l ated to mai ntai n the bal ance wi thi n the transmi s-
si on. To do thi s, throttl e pressure i s routed to the
reacti on area on the ri ght si de of the throttl e pres-
sure pl ug (i n the regul ator val ve).
The hi gher engi ne speed and l i ne pressure woul d
open the vent too far and reduce l i ne pressure too
much. Throttl e pressure, whi ch i ncreases wi th engi ne
speed (throttl e openi ng), i s used to oppose the move-
ment of the pressure val ve to hel p control the meter-
i ng passage at the vent. The throttl e pressure i s
combi ned wi th spri ng pressure to reduce the force of
the throttl e pressure pl ug on the pressure val ve. The
l arger spri ng at the ri ght cl oses the regul ator val ve
passage and mai ntai ns or i ncreases l i ne pressure.
The i ncreased l i ne pressure works agai nst the reac-
ti on area of the l i ne pressure pl ug and the reacti on
area l eft of l and #3 si mul taneousl y moves the regu-
l ator val ve trai n to the ri ght and control s the meter-
i ng passage.
The ki ckdown val ve, al ong wi th the throttl e val ve,
serve to del ay upshi fts unti l the correct vehi cl e speed
has been reached. I t al so control s downshi fts upon
dri ver demand, or i ncreased engi ne l oad. I f these
val ves were not i n pl ace, the shi ft poi nts woul d be at
the same speed for al l throttl e posi ti ons. The ki ck-
down val ve i s actuated by a cam connected to the
throttl e. Thi s i s accompl i shed through ei ther a l i nk-
age or a cabl e. The cam forces the ki ckdown val ve
toward the throttl e val ve compressi ng the spri ng
between them and movi ng the throttl e val ve. As the
throttl e val ve l and starts to uncover i ts port, l i ne
pressure i s metered out i nto the ci rcui ts and vi ewed
as throttl e pressure. Thi s i ncreased throttl e pressure
i s metered out i nto the ci rcui ts i t i s appl i ed to: the
1-2 and 2-3 shi ft val ves. When the throttl e pressure
i s hi gh enough, a 3-2 downshi ft wi l l occur. I f the
vehi cl e speed i s l ow enough, a 2-1 downshi ft wi l l
occur.
Fig. 278 3-4 Shift Valve After Shift
SWITCH VALVE
When the transmi ssi on i s i n Dri ve Second before
the TCC appl i cati on occurs (Fi g. 280), the pressure
regul ator val ve i s suppl yi ng torque converter pres-
sure to the swi tch val ve. The swi tch val ve di rects
thi s pressure through the transmi ssi on i nput shaft,
i nto the converter, through the converter, back out
between the i nput shaft and the reacti on shaft, and
back up to the swi tch val ve. From the swi tch val ve,
the fl ui d pressure i s di rected to the transmi ssi on
cool er, and l ubri cati on pressure returns from the
cool er to l ubri cate di fferent porti ons of the transmi s-
si on.
Once the TCC control val ve has moved to the ri ght
(Fi g. 281), l i ne pressure i s di rected to the ti p of the
swi tch val ve, forci ng the val ve to the ri ght. The
swi tch val ve now vents oi l from the front of the pi s-
ton i n the torque converter, and suppl i es l i ne pres-
sure to the (rear) appl y si de of the torque converter
pi ston. Thi s pressure di fferenti al causes the pi ston to
appl y agai nst the fri cti on materi al , cutti ng off any
further fl ow of l i ne pressure oi l . After the swi tch
val ve i s shuttl ed ri ght al l owi ng l i ne pressure to
engage the TCC, torque converter pressure i s
di rected past the swi tch val ve i nto the transmi ssi on
cool er and l ubri cati on ci rcui ts.
Fig. 279 Throttle Valve
Fig. 280 Switch Valve-Torque Converter Unlocked
MANUAL VALVE
The manual val ve (Fi g. 282) i s a rel ay val ve. The
purpose of the manual val ve i s to di rect fl ui d to the
correct ci rcui t needed for a speci fi c gear or dri vi ng
range. The manual val ve, as the name i mpl i es, i s
manual l y operated by the dri ver wi th a l ever l ocated
on the si de of the val ve body. The val ve i s connected
mechani cal l y by ei ther a cabl e or l i nkage to the gear-
shi ft mechani sm. The val ve i s hel d i n each of i ts
posi ti ons by a spri ng-l oaded rol l er or bal l that
engages the roostercomb of the manual val ve l ever.
CONVERTER CLUTCH LOCK-UP VALVE
The torque converter cl utch (TCC) l ock-up val ve
control s the back (ON) si de of the torque converter
cl utch. When the PCM energi zes the TCC sol enoi d to
engage the converter cl utch pi ston, pressure i s
appl i ed to the TCC l ock-up val ve whi ch moves to the
ri ght and appl i es pressure to the torque converter
cl utch.
Fig. 281 Switch Valve-Torque Converter Locked
CONVERTER CLUTCH LOCK-UP TIMING VALVE
The torque converter cl utch (TCC) l ock-up ti mi ng
val ve i s there to bl ock any 4-3 downshi ft unti l the
TCC i s compl etel y unl ocked and the cl utch i s di sen-
gaged.
SHUTTLE VALVE
The assembl y i s contai ned i n a bore i n the val ve
body above the shi ft val ves. When the manual val ve
i s posi ti oned i n the Dri ve range, throttl e pressure
acts on the throttl e pl ug of the shuttl e val ve (Fi g.
274) to move i t agai nst a spri ng, i ncreasi ng the
spri ng force on the shuttl e val ve. Duri ng a part or
ful l throttl e 1-2 upshi ft, the throttl e pl ug i s bottomed
by throttl e pressure, hol di ng the shuttl e val ve to the
ri ght agai nst governor pressure, and openi ng a
bypass ci rcui t. The shuttl e val ve control s the qual -
i ty of the ki ckdown shi ft by restri cti ng the rate of
fl ui d di scharge from the front cl utch and servo
rel ease ci rcui ts. Duri ng a 3-2 ki ckdown, fl ui d di s-
charges through the shuttl e by-pass ci rcui t. When
the shuttl e val ve cl oses the by-pass ci rcui t, fl ui d di s-
charge i s restri cted and control l ed for the appl i cati on
of the front band. Duri ng a 2-3 l i ft foot upshi ft, the
shuttl e val ve by-passes the restri cti on to al l ow ful l
fl ui d fl ow through the by-pass groove for a faster
rel ease of the band.
BOOST VALVE
The boost val ve (Fi g. 283) provi des i ncreased fl ui d
appl y pressure to the overdri ve cl utch duri ng 3-4
upshi fts (Fi g. 284), and when accel erati ng i n fourth
gear. The boost val ve al so serves to i ncrease l i ne
pressure duri ng torque converter l ock-up.
Fig. 282 Manual Valve
Fig. 283 Boost Valve Before Lock-up
REMOVAL
and i nspecti on of the i ndi vi dual components.
The onl y repl aceabl e val ve body components are:
Manual l ever.
Manual l ever washer, seal , E-cl i p, and shaft
seal .
Manual l ever detent bal l .
Throttl e l ever.
Fl ui d fi l ter.
Pressure adjusti ng screw bracket.
Governor pressure sol enoi d.
Governor pressure sensor (i ncl udes transmi ssi on
temperature thermi stor).
Converter cl utch/overdri ve sol enoi d assembl y
and harness .
Governor housi ng gasket.
Sol enoi d case connector O-ri ngs.
(1) Shi ft transmi ssi on i nto NEUTRAL.
(3) Remove gearshi ft and throttl e l evers from shaft
of val ve body manual l ever.
(4) Di sconnect wi res at sol enoi d case connector
(Fi g. 285).
(8) Remove fl ui d fi l ter from val ve body.
si on case.
(10) Lower val ve body enough to remove accumu-
l ator pi ston and spri ngs.
(11) Work manual l ever shaft and el ectri cal con-
nector out of transmi ssi on case.
(12) Lower val ve body, rotate val ve body away
from case, pul l park rod out of sprag, and remove
Fig. 284 Boost Valve After Lock-up
Fig. 285 Transmission Case Connector
Fig. 286 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Di sconnect wi res from governor pressure sen-
sor and sol enoi d.
(2) Remove screws attachi ng governor body and
retai ner pl ate to transfer pl ate.
(3) Remove retai ner pl ate, governor body and gas-
ket from transfer pl ate.
(4) Remove governor pressure sensor from gover-
nor body.
(5) Remove governor pressure sol enoi d by pul l i ng
i t strai ght out of bore i n governor body. Remove and
di scard sol enoi d O-ri ngs i f worn, cut, or torn.
(6) Remove smal l shoul der bol t that secures sol e-
noi d harness case connector to 3-4 accumul ator hous-
i ng (Fi g. 287). Retai n shoul der bol t. Ei ther tape i t to
harness or thread i t back i nto accumul ator housi ng
after connector removal .
(7) Unhook overdri ve/converter sol enoi d harness
from 3-4 accumul ator cover pl ate (Fi g. 288).
(8) Turn val ve body over and remove screws that
attach overdri ve/converter sol enoi d assembl y to val ve
body (Fi g. 289).
(9) Remove sol enoi d and harness assembl y from
(10) Remove boost val ve cover (Fi g. 291).
(11) Remove boost val ve retai ner, val ve spri ng and
boost val ve (Fi g. 292).
Shoulder Bolt
(12) Secure detent bal l and spri ng wi th Retai ner
Tool 6583 (Fi g. 293).
(13) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 294).
(14) Remove E-cl i p and washer that retai ns throt-
tl e l ever shaft i n manual l ever (Fi g. 295).
(15) Remove manual l ever and throttl e l ever (Fi g.
296). Rotate and l i ft manual l ever off val ve body and
throttl e l ever shaft. Then sl i de throttl e l ever out of
val ve body.
(16) Posi ti on penci l magnet next to detent housi ng
to catch detent bal l and spri ng. Then careful l y
remove Retai ner Tool 6583 and remove detent bal l
Fig. 289 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 290 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 291 Boost Valve Cover Location
1 - BOOST VALVE HOUSING AND COVER
Fig. 292 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
(17) Remove screws attachi ng pressure adjusti ng
screw bracket to val ve body and transfer pl ate (Fi g.
298). Hol d bracket fi rml y agai nst spri ng tensi on
whi l e removi ng l ast screw.
Fig. 294 Park Rod
1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD
Fig. 295 Throttle Lever E-Clip And Washer
1 - THROTTLE LEVER SHAFT
2 - E-CLIP AND WASHER
3 - MANUAL SHAFT
Fig. 296 Manual And Throttle Lever
1 - PARK ROD
2 - MANUAL LEVER ASSEMBLY
3 - THROTTLE LEVER
(18) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw, pressure regul ator val ve spri ng and
swi tch val ve spri ng (Fi g. 299). Do not remove throttl e
pressure adjusti ng screw from bracket and do not
di sturb setti ng of ei ther adjusti ng screw duri ng
removal .
(19) Turn upper housi ng over and remove swi tch
val ve, regul ator val ve and spri ng, and manual val ve
(Fi g. 300).
(20) Remove ki ckdown detent, ki ckdown val ve, and
throttl e val ve and spri ng (Fi g. 300).
(21) Loosen l eft-si de 3-4 accumul ator housi ng
attachi ng screw about 2-3 threads. Then remove cen-
ter and ri ght-si de housi ng attachi ng screws (Fi g.
301).
(22) Careful l y rotate 3-4 accumul ator housi ng
upward and remove 3-4 shi ft val ve spri ng and con-
verter cl utch val ve pl ug and spri ng (Fi g. 302).
(23) Remove l eft-si de screw and remove 3-4 accu-
mul ator housi ng from val ve body (Fi g. 303).
(24) Bend back tabs on boost val ve tube brace (Fi g.
304).
1 - DETENT HOUSING
2 - DETENT SPRING
3 - DETENT BALL
4 - PENCIL MAGNET
Fig. 298 Adjusting Screw Bracket Fastener
1 - T25 TORX BIT
2 - REMOVE THESE SCREWS FIRST
3 - BRACKET
4 - BRACKET
5 - REMOVE THIS SCREW LAST
Fig. 299 Adjusting Screw Bracket
1 - SWITCH VALVE SPRING
2 - LINE PRESSURE SCREW
3 - THROTTLE PRESSURE ADJUSTING SCREW
4 - ADJUSTING SCREW BRACKET
5 - PRESSURE REGULATOR VALVE SPRING
Fig. 301 Accumulator Housing Screw Locations
1 - LOOSEN THIS SCREW
2 - REMOVE THESE SCREWS
Fig. 302 3-4 Shift And Converter Clutch Valve
Springs and Plug
1 - ACCUMULATOR HOUSING
3 - CLUTCH VALVE PLUG
(25) Remove boost val ve connecti ng tube (Fi g.
305). Di sengage tube from upper housi ng port fi rst.
Then rock opposi te end of tube back and forth to
work i t out of l ower housi ng.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(26) Turn val ve body over so l ower housi ng i s fac-
i ng upward (Fi g. 306). I n thi s posi ti on, the two check
bal l s i n upper housi ng wi l l remai n i n pl ace and not
fal l out when l ower housi ng and separator pl ate are
removed.
(27) Remove screws attachi ng val ve body l ower
housi ng to upper housi ng and transfer pl ate (Fi g.
306). Note posi ti on of boost val ve tube brace for
(28) Remove l ower housi ng and overdri ve separa-
tor pl ate from transfer pl ate (Fi g. 306).
(29) Remove the ECE check bal l from the transfer
(30) Remove transfer pl ate from upper housi ng
(Fi g. 308).
(31) Turn transfer pl ate over so upper housi ng sep-
arator pl ate i s faci ng upward.
(32) Remove upper housi ng separator pl ate from
transfer pl ate (Fi g. 309). Note posi ti on of fi l ter i n
separator pl ate for assembl y reference.
(33) Remove rear cl utch and rear servo check bal l s
from transfer pl ate. Note check bal l l ocati on for
Fig. 303 Accumulator Housing, Valve Springs, and
Plug
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
Fig. 304 Boost Valve Tube Brace
2 - TUBE BRACE (DOUBLE TAB)
2 - LOWER HOUSING
4 - UPPER HOUSING
Fig. 306 Lower Housing
1 - LOWER HOUSING
2 - OVERDRIVE SEPARATOR PLATE
3 - TRANSFER PLATE AND UPPER HOUSING
Fig. 307 ECE Check Ball
1 - ECE CHECK BALL (3/16)
Fig. 308 Transfer Plate
1 - UPPER HOUSING
2 - TRANSFER PLATE
Fig. 309 Upper Housing Separator Plate
1 - TRANSFER PLATE
3 - FILTER SCREEN
4 - BRACE
VALVE BODY UPPER HOUSING
(1) Note l ocati on of check bal l s i n val ve body upper
housi ng (Fi g. 311). Then remove the one l arge di am-
eter and the si x smal l er di ameter check bal l s.
(2) Remove governor pl ug and shuttl e val ve covers
(Fi g. 313).
(3) Remove E-cl i p that secures shuttl e val ve sec-
ondary spri ng on val ve stem (Fi g. 312).
(4) Remove throttl e pl ug, pri mary spri ng, shuttl e
val ve, secondary spri ng, and spri ng gui des (Fi g. 313).
(5) Remove boost val ve retai ner, spri ng and val ve
i f not previ ousl y removed.
(6) Remove throttl e pl ug and 1-2 and 2-3 governor
pl ugs (Fi g. 300).
(7) Turn upper housi ng around and remove l i mi t
val ve and shi ft val ve covers (Fi g. 314).
(8) Remove l i mi t val ve housi ng. Then remove
retai ner, spri ng, l i mi t val ve, and 2-3 throttl e pl ug
from l i mi t val ve housi ng (Fi g. 314).
(9) Remove 1-2 shi ft control val ve and spri ng (Fi g.
314).
(10) Remove 1-2 shi ft val ve and spri ng (Fi g. 314).
(11) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 314).
(12) Remove pressure pl ug cover (Fi g. 314).
(13) Remove l i ne pressure pl ug, sl eeve, throttl e
pressure pl ug and spri ng (Fi g. 314).
Fig. 310 Rear Clutch and Rear Servo Check Ball
Locations
3 - TRANSFER PLATE
Fig. 312 Shuttle Valve E-Clip And Secondary Spring
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
Fig. 313 Shuttle and Boost Valve Location
VALVE BODY LOWER HOUSING
(1) Remove ti mi ng val ve cover.
(2) Remove 3-4 ti mi ng val ve and spri ng.
(3) Remove 3-4 qui ck fi l l val ve, spri ng and pl ug.
(4) Remove 3-4 shi ft val ve and spri ng.
(5) Remove converter cl utch val ve, spri ng and pl ug
(Fi g. 315).
(6) Remove converter cl utch ti mi ng val ve, retai ner
and val ve spri ng.
3-4 ACCUMULATOR HOUSING
(1) Remove end pl ate from housi ng.
(2) Remove pi ston spri ng.
(3) Remove pi ston. Remove and di scard pi ston
seal s (Fi g. 316).
CLEANING
type of causti c sol uti on.
cl eani ng sol uti on. Cl ean the governor sol enoi d and
sensor and the dual sol enoi d and harness assembl y
by wi pi ng them off wi th dry shop towel s onl y.
Wi pe the governor pressure sensor and sol enoi d
val ve wi th dry, l i nt free shop towel s onl y. The O-ri ngs
on the sensor and sol enoi d val ve are the onl y servi ce-
abl e components. Be sure the vent ports i n the sol e-
noi d val ve are open and not bl ocked by di rt or debri s.
Repl ace the val ve and/or sensor onl y when DRB scan
tool di agnosi s i ndi cates thi s i s necessary. Or, i f ei ther
part has sustai ned physi cal damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth
but do not round off the edges of the valve or
plug lands.Mai ntai ni ng sharpness of these edges i s
vi tal l y i mportant. The edges prevent forei gn matter
from l odgi ng between the val ves and pl ugs and the
bore.
coi l s.
3 - TEFLON SEALS
4 - PISTON SPRING
Check the two separator pl ates for di storti on or
damage of any ki nd. I nspect the upper housi ng,
l ower housi ng, 3-4 accumul ator housi ng, and transfer
pl ate careful l y. Be sure al l fl ui d passages are cl ean
and cl ear. Check condi ti on of the upper housi ng and
transfer pl ate check bal l s as wel l . The check bal l s
and bal l seats must not be worn or damaged.
dl i ng.
The onl y servi ceabl e val ve body components are
l i sted bel ow. The remai ni ng val ve body components
are servi ced onl y as part of a compl ete val ve body
assembl y. Servi ceabl e parts are:
dual sol enoi d and harness assembl y
sol enoi d gasket
sol enoi d case connector O-ri ngs and shoul der
bol t
swi tch val ve and spri ng
pressure adjusti ng screw and bracket assembl y
throttl e l ever
manual l ever and shaft seal
throttl e l ever shaft seal , washer, and E-cl i p
fl ui d fi l ter and screws
detent bal l and spri ng
val ve body screws
governor pressure sol enoi d
governor pressure sensor and retai ni ng cl i p
park l ock rod and E-cl i p
ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
val ve and pl ug bores wi th cl ean transmi ssi on fl ui d
(Fi g. 314).
(2) I nstal l 3-4 ti mi ng val ve spri ng and val ve i n
l ower housi ng.
(3) I nstal l 3-4 qui ck fi l l val ve i n l ower housi ng.
(4) I nstal l 3-4 qui ck fi l l val ve spri ng and pl ug i n
housi ng.
(5) I nstal l ti mi ng val ve end pl ate. Ti ghten end
3-4 ACCUMULATOR
(1) Lubri cate accumul ator pi ston, seal s and hous-
i ng pi ston bore wi th cl ean transmi ssi on fl ui d (Fi g.
315).
(2) I nstal l new seal ri ngs on accumul ator pi ston.
(3) I nstal l pi ston and spri ng i n housi ng.
(4) I nstal l end pl ate on housi ng.
TRANSFER PLATE
(1) I nstal l rear cl utch and rear servo check bal l s i n
(2) I nstal l fi l ter screen i n upper housi ng separator
pl ate (Fi g. 318).
(3) Al i gn and posi ti on upper housi ng separator
pl ate on transfer pl ate (Fi g. 319).
(4) I nstal l brace pl ate (Fi g. 319). Ti ghten brace
attachi ng screws to 4 Nm (35 i n. l bs.) torque.
(5) I nstal l remai ni ng separator pl ate attachi ng
screws. Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
Locations
3 - TRANSFER PLATE
UPPER AND LOWER HOUSING
(1) Posi ti on upper housi ng so i nternal passages
and check bal l seats are faci ng upward. Then i nstal l
check bal l s i n housi ng (Fi g. 320). Ei ght check bal l s
are used. The si ngl e l arge check bal l i s approxi -
matel y 8.7 mm (11/32 i n.) di ameter. The si ngl e smal l
check bal l i s approxi matel y 4.8 mm (3/16 i n.) i n
di ameter. The remai ni ng 6 check bal l s are approxi -
matel y 6.3 mm (1/4 i n.) i n di ameter.
(2) Posi ti on assembl ed transfer pl ate and upper
housi ng separator pl ate on upper housi ng (Fi g. 321).
Be sure fi l ter screen i s seated i n proper housi ng
recess.
(3) I nstal l the ECE check bal l i nto the transfer
(4) Posi ti on l ower housi ng separator pl ate on
(5) I nstal l l ower housi ng on assembl ed transfer
pl ate and upper housi ng (Fi g. 323).
(6) I nstal l and start al l val ve body screws by hand
except for the screws to hol d the boost val ve tube
brace. Save those screws for l ater i nstal l ati on. Then
ti ghten screws evenl y to 4 Nm (35 i n. l bs.) torque.
Start at center and work out to si des when ti ghten-
i ng screws (Fi g. 323).
Fig. 318 Separator Plate Filter Screen Installation
2 - FILTER SCREEN
Fig. 319 Brace Plate
1 - BRACE
2 - TRANSFER PLATE
3 - SEPARATOR PLATE
Fig. 321 Installing Transfer Plate On Upper Housing
1 - FILTER SCREEN
2 - TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY
3 - UPPER HOUSING
UPPER HOUSING VALVE AND PLUG
Refer to (Fi g. 324), (Fi g. 325) and (Fi g. 326) to per-
form the fol l owi ng steps.
(1) Lubri cate val ves, pl ugs, spri ngs wi th cl ean
(2) Assembl e regul ator val ve l i ne pressure pl ug,
sl eeve, throttl e pl ug and spri ng. I nsert assembl y i n
upper housi ng and i nstal l cover pl ate. Ti ghten cover
(3) I nstal l 1-2 and 2-3 shi ft val ves and spri ngs.
(4) I nstal l 1-2 shi ft control val ve and spri ng.
(5) I nstal l retai ner, spri ng, l i mi t val ve, and 2-3
throttl e pl ug from l i mi t val ve housi ng.
(6) I nstal l l i mi t val ve housi ng and cover pl ate.
Ti ghten screws to 4 Nm (35 i n. l bs.).
(7) I nstal l shuttl e val ve as fol l ows:
(a) I nsert pl asti c gui des i n shuttl e val ve second-
ary spri ng and i nstal l spri ng on end of val ve.
(b) I nstal l shuttl e val ve i nto housi ng.
(c) Hol d shuttl e val ve i n pl ace.
(d) Compress secondary spri ng and i nstal l E-cl i p
i n groove at end of shuttl e val ve.
(e) Veri fy that spri ng and E-cl i p are properl y
seated before proceedi ng.
(8) I nstal l shuttl e val ve cover pl ate. Ti ghten cover
(9) I nstal l 1-2 and 2-3 val ve governor pl ugs i n
val ve body.
(10) I nstal l shuttl e val ve pri mary spri ng and
throttl e pl ug.
(11) Al i gn and i nstal l governor pl ug cover. Ti ghten
cover screws to 4 Nm (35 i n. l bs.) torque.
Fig. 322 Lower Housing Separator Plate
1 - BE SURE TO ALIGN BORES
2 - TRANSFER PLATE
3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
Fig. 323 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
BOOST VALVE TUBE AND BRACE
(1) Posi ti on val ve body assembl y so l ower housi ng
i s faci ng upward (Fi g. 327).
(2) Lubri cate tube ends and housi ng ports wi th
transmi ssi on fl ui d or petrol eum jel l y.
(3) Start tube i n l ower housi ng port fi rst. Then
swi ng tube downward and work opposi te end of tube
i nto upper housi ng port (Fi g. 327).
(4) I nsert and seat each end of tube i n housi ngs.
(5) Sl i de tube brace under tube and i nto al i gnment
wi th val ve body screw hol es (Fi g. 328).
(6) I nstal l and fi nger ti ghten three screws that
secure tube brace to val ve body housi ngs (Fi g. 328).
(7) Bend tube brace tabs up and agai nst tube to
hol d i t i n posi ti on (Fi g. 329).
(8) Ti ghten al l val ve body housi ng screws to 4 Nm
(35 i n. l bs.) torque after tube and brace are i nstal l ed.
Ti ghten screws i n di agonal pattern starti ng at center
and worki ng outward.
3-4 ACCUMULATOR
(1) Posi ti on converter cl utch val ve and 3-4 shi ft
val ve spri ngs i n housi ng (Fi g. 330).
(2) Loosel y attach accumul ator housi ng wi th ri ght-
si de screw (Fi g. 330). I nstal l onl y one screw at thi s
ti me as accumul ator must be free to pi vot upward for
ease of i nstal l ati on.
(3) I nstal l 3-4 shi ft val ve and spri ng.
(4) I nstal l converter cl utch ti mi ng val ve and
spri ng.
(5) Posi ti on pl ug on end of converter cl utch val ve
spri ng. Then compress and hol d spri ngs and pl ug i n
pl ace wi th fi ngers of one hand.
(6) Swi ng accumul ator housi ng upward over val ve
spri ngs and pl ug.
(7) Hol d accumul ator housi ng fi rml y i n pl ace and
i nstal l remai ni ng two attachi ng screws. Be sure
spri ngs and cl utch val ve pl ug are properl y seated
(Fi g. 331). Ti ghten screws to 4 Nm (35 i n. l bs.).
2 - LOWER HOUSING
4 - UPPER HOUSING
Fig. 328 Boost Valve Tube And Brace
2 - TUBE BRACE
Fig. 329 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
VALVE BODY FINAL
(1) I nstal l boost val ve, val ve spri ng, retai ner and
cover pl ate. Ti ghten cover pl ate screws to 4 Nm (35
i n. l bs.) torque.
(2) I nsert manual l ever detent spri ng i n upper
housi ng.
(3) Posi ti on detent bal l on end of spri ng. Then hol d
detent bal l and spri ng i n detent housi ng wi th
Retai ner Tool 6583 (Fi g. 332).
(4) I nstal l throttl e l ever i n upper housi ng. Then
i nstal l manual l ever over throttl e l ever and start
manual l ever i nto housi ng.
(5) Al i gn manual l ever wi th detent bal l and man-
ual val ve. Hol d throttl e l ever upward. Then press
down on manual l ever unti l ful l y seated. Remove
detent bal l retai ner tool after l ever i s seated.
(6) Then i nstal l manual l ever seal , washer and
E-cl i p.
(7) Veri fy that throttl e l ever i s al i gned wi th end of
ki ckdown val ve stem and that manual l ever arm i s
engaged i n manual val ve (Fi g. 333).
(8) Posi ti on l i ne pressure adjusti ng screw i n
(9) I nstal l spri ng on end of l i ne pressure regul ator
val ve.
(10) I nstal l swi tch val ve spri ng on tang at end of
(11) I nstal l manual val ve.
(12) I nstal l throttl e val ve and spri ng.
(13) I nstal l ki ckdown val ve and detent.
(14) I nstal l pressure regul ator val ve.
(15) I nstal l swi tch val ve.
(16) Posi ti on adjusti ng screw bracket on val ve
body. Al i gn val ve spri ngs and press bracket i nto
pl ace. I nstal l short, upper bracket screws fi rst and
l ong bottom screw l ast. Veri fy that val ve spri ngs and
bracket are properl y al i gned. Then ti ghten al l three
bracket screws to 4 Nm (35 i n. l bs.) torque.
(17) Perform Li ne Pressure and Throttl e Pressure
adjustments. (Refer to 21 - TRANSMI SSI ON/TRAN-
SAXLE/AUTOMATI C/VALVE BODY - ADJUST-
MENTS)
(18) Lubri cate sol enoi d case connector O-ri ngs and
shaft of manual l ever wi th l i ght coat of petrol eum
jel l y.
(19) Attach sol enoi d case connector to 3-4 accumu-
l ator wi th shoul der-type screw. Connector has smal l
l ocati ng tang that fi ts i n di mpl e at top of accumul a-
tor housi ng (Fi g. 334). Seat tang i n di mpl e before
ti ghteni ng connector screw.
(20) I nstal l sol enoi d assembl y and gasket. Ti ghten
sol enoi d attachi ng screws to 8 Nm (72 i n. l bs.)
torque.
(21) Veri fy that sol enoi d wi re harness i s properl y
routed (Fi g. 335). Sol enoi d harness must be cl ear of
manual l ever and park rod and not be pi nched
between accumul ator housi ng and cover.
Fig. 330 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
Fig. 331 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn val ve body assembl y over so accumul ator
si de of transfer pl ate i s faci ng down.
(2) I nstal l new O-ri ngs on governor pressure sol e-
noi d and sensor.
(3) Lubri cate sol enoi d and sensor O-ri ngs wi th
cl ean transmi ssi on fl ui d.
(4) I nstal l governor pressure sensor i n governor
body.
(5) I nstal l governor pressure sol enoi d i n governor
body. Push sol enoi d i n unti l i t snaps i nto pl ace i n
body.
(6) Posi ti on governor body gasket on transfer
pl ate.
(7) I nstal l retai ner pl ate on governor body and
around sol enoi d. Be sure sol enoi d connector i s posi -
ti oned i n retai ner cutout.
(8) Al i gn screw hol es i n governor body and trans-
fer pl ate. Then i nstal l and ti ghten governor body
(9) Connect harness wi res to governor pressure
sol enoi d and governor pressure sensor.
(10) I nstal l fl ui d fi l ter and pan.
(12) Fi l l transmi ssi on wi th recommended fl ui d and
road test vehi cl e to veri fy repai r.
Fig. 333 Manual And Throttle Lever Alignment
1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE
Shoulder Bolt
INSTALLATION
(1) Check condi ti on of O-ri ng seal s on val ve body
harness connector (Fi g. 336). Repl ace seal s on con-
nector body i f cut or worn.
(2) Check condi ti on of manual l ever shaft seal i n
transmi ssi on case. Repl ace seal i f l i p i s cut or worn.
I nstal l new seal wi th 15/16 deep wel l socket (Fi g.
337).
(3) Check condi ti on of seal s on accumul ator pi ston
(Fi g. 338). I nstal l new pi ston seal s, i f necessary.
(4) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) so bal l on park l ock rod wi l l be easi er to i nstal l
i n sprag.
(5) Lubri cate shaft of manual l ever wi th petrol eum
jel l y. Thi s wi l l ease i nserti ng shaft through seal i n
case.
(6) Lubri cate seal ri ngs on val ve body harness con-
nector wi th petrol eum jel l y.
(7) Posi ti on val ve body i n case and work end of
park l ock rod i nto and through pawl sprag. Turn pro-
pel l er shaft to al i gn sprag and park l ock teeth i f nec-
essary. The rod wi l l cl i ck as i t enters pawl . Move rod
to check engagement.
(8) I nstal l accumul ator spri ngs and pi ston i nto
case. Then swi ng val ve body over pi ston and outer
spri ng to hol d i t i n pl ace.
(9) Al i gn accumul ator pi ston and outer spri ng,
manual l ever shaft and el ectri cal connector i n case.
(10) Then seat val ve body i n case and i nstal l one
or two bol ts to hol d val ve body i n pl ace.
(11) Ti ghten val ve body bol ts al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(13) I nstal l throttl e and gearshi ft l evers on val ve
(14) Check and adjust front and rear bands i f nec-
essary.
(15) Connect sol enoi d case connector wi res.
(17) I nstal l oi l pan and new gasket. Ti ghten pan
Mopar ATF +4, type 9602, fl ui d.
(19) Check and adjust gearshi ft and throttl e val ve
cabl es, i f necessary.
Fig. 336 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
1 - 15/16'' SOCKET
2 - SEAL
Fig. 338 Accumulator Piston Components
1 - INNER SPRING
3 - OUTER SPRING
4 - SEAL RINGS
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 339).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 340).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 339 Line Pressure Adjustment
1 - WRENCH
2 - 15/16 INCH
Fig. 340 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
AUTOMATIC TRANSMISSION - 45RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 45RFE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 440
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
AUTOMATIC TRANSMISSION. . . . . . . . . . . . . 441
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . 441
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . 442
HYDRAULIC PRESSURE TEST . . . . . . . . . . . 442
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 444
CONVERTER HOUSING FLUID LEAK . . . . . . 444
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 446
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 459
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 480
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 481
4C RETAINER/BULKHEAD
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 484
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 485
FLUID AND FILTER
GEARSHIFT CABLE
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . 489
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 490
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 491
HOLDING CLUTCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 492
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
INPUT CLUTCH ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 495
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 496
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
INPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 504
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 504
LINE PRESSURE (LP) SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 505
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 505
LOW/REVERSE CLUTCH
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 506
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 508
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 510
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
OIL PUMP FRONT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 513
OUTPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 513
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 513
OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 514
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 515
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 515
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
PLANETARY GEARTRAIN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 517
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 518
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
AN AUTOMATIC TRANSMISSION - 45RFE 21 - 439
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 519
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
SOLENOID SWITCH VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 520
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
SOLENOIDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 520
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 521
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 526
TRANSMISSION CONTROL RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 527
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 527
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 528
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 529
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 529
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 530
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 532
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 536
45RFE
DESCRIPTION
The 45RFE automati c transmi ssi on i s a sophi sti -
cated, mul ti -range, el ectroni cal l y control l ed transmi s-
si on whi ch combi nes opti mi zed gear rati os for
responsi ve performance, state of the art effi ci ency fea-
tures and l ow NVH. Other features i ncl ude dri ver
adapti ve shi fti ng and three pl anetary gear sets to pro-
vi de wi de rati o capabi l i ty wi th preci se rati o steps for
opti mum dri veabi l i ty. The three pl anetary gear sets
al so make avai l abl e a uni que al ternate second gear
rati o. The pri mary 2nd gear rati o fi ts between 1st and
3rd gears for normal through-gear accel erati ons. The
al ternate second gear rati o (2pri me) al l ows smoother
4-2 ki ckdowns at hi gh speeds to provi de 2nd gear pass-
i ng performance over a wi der hi ghway crui si ng range.
The hydraul i c porti on of the transmi ssi on consi sts
of the transmi ssi on fl ui d, fl ui d passages, hydraul i c
val ves, and vari ous l i ne pressure control components.
The pri mary mechani cal components of the trans-
mi ssi on consi st of the fol l owi ng:
Three mul ti pl e di sc i nput cl utches
Three mul ti pl e di sc hol di ng cl utches
Fi ve hydraul i c accumul ators
Three pl anetary gear sets
Dual Stage Hydraul i c oi l pump
Val ve body
Sol enoi d pack
The TCM i s the heart or brai n of the el ectroni c
control system and rel i es on i nformati on from vari -
ous di rect and i ndi rect i nputs (sensors, swi tches, etc.)
to determi ne dri ver demand and vehi cl e operati ng
condi ti ons. Wi th thi s i nformati on, the TCM can cal -
cul ate and perform ti mel y and qual i ty shi fts through
vari ous output or control devi ces (sol enoi d pack,
transmi ssi on control rel ay, etc.).
TRANSMISSION IDENTIFICATION
on the l eft si de of the case just above the oi l pan
seal i ng surface (Fi g. 1). Refer to thi s i nformati on
when orderi ng repl acement parts. A l abel i s attached
to the transmi ssi on case above the stamped numbers.
The l abel gi ves addi ti onal i nformati on whi ch may
al so be necessary for i denti fi cati on purposes.
Location
1 - IDENTIFICATION NUMBERS (STAMPED)
21 - 440 AUTOMATIC TRANSMISSION - 45RFE AN
GEAR RATIOS The 45RFE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Pri me . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
OPERATION
The 45RFE offers ful l el ectroni c control of al l auto-
mati c up and downshi fts, and features real -ti me
adapti ve cl osed-l oop shi ft and pressure control . El ec-
troni c shi ft and torque converter cl utch control s hel p
protect the transmi ssi on from damage due to hi gh
temperatures, whi ch can occur under severe operat-
i ng condi ti ons. By al teri ng shi ft schedul es, l i ne pres-
sure, and converter cl utch control , these control s
reduce heat generati on and i ncrease transmi ssi on
cool i ng.
To hel p reduce effi ci ency-robbi ng parasi ti c l osses,
the transmi ssi on i ncl udes a dual -stage transmi ssi on
fl ui d pump wi th el ectroni c output pressure control .
Under most dri vi ng condi ti ons, pump output pres-
sure greatl y exceeds that whi ch i s needed to keep the
cl utches appl i ed. The 45RFE pump-pressure control
system moni tors i nput torque and adjusts the pump
pressure accordi ngl y. The pri mary stage of the pump
works conti nuousl y; the second stage i s bypassed
when demand i s l ow. The control system al so moni -
tors i nput and output speed and, i f i nci pi ent cl utch
sl i p i s observed, the pressure control sol enoi d duty
cycl e i s vari ed, i ncreasi ng pressure i n proporti on to
demand.
A hi gh-travel torque converter damper assembl y
al l ows earl i er torque converter cl utch engagement to
reduce sl i ppage. Needl e-type thrust beari ngs reduce
i nternal fri cti on. The 45RFE i s packaged i n a one-
pi ece di e-cast al umi num case. To reduce NVH, the
case has hi gh l ateral , verti cal and torsi onal sti ffness.
I t i s al so desi gned to maxi mi ze the benefi t of the
structural dust cover that connects the bottom of the
bel l housi ng to the engi ne bedpl ate, enhanci ng over-
al l power trai n sti ffness. Dual fi l ters protect the
pump and other components. A pump return fi l ter i s
added to the customary mai n sump fi l ter. I ndepen-
dent l ubri cati on and cool er ci rcui ts assure ampl e
pressure for normal transmi ssi on operati on even i f
the cool er i s obstructed or the fl ui d cannot fl ow due
to extremel y l ow temperatures.
The hydraul i c control system desi gn (wi thout el ec-
troni c assi st) provi des the transmi ssi on wi th PARK,
REVERSE, NEUTRAL, SECOND, and THI RD gears,
based sol el y on dri ver shi ft l ever sel ecti on. Thi s
desi gn al l ows the vehi cl e to be dri ven (i n l i mp-i n
mode) i n the event of a el ectroni c control system fai l -
ure, or a si tuati on that the Transmi ssi on Control
Modul e (TCM) recogni zes as potenti al l y damagi ng to
the transmi ssi on.
The TCM al so performs certai n sel f-di agnosti c
functi ons and provi des comprehensi ve i nformati on
(sensor data, DTCs, etc.) whi ch i s hel pful i n proper
di agnosi s and repai r. Thi s i nformati on can be vi ewed
wi th the DRB scan tool .
TRANSMISSION
CAUTION: Before attempting any repair on a 45RFE
automatic transmission, check for Diagnostic Trou-
ble Codes with the DRB scan tool.
Transmi ssi on mal functi ons may be caused by these
general condi ti ons:
Poor engi ne performance
I mproper adjustments
Hydraul i c mal functi ons
Mechani cal mal functi ons
El ectroni c mal functi ons
Di agnosi s of these probl ems shoul d al ways begi n
by checki ng the easi l y accessi bl e vari abl es: fl ui d l evel
and condi ti on, gearshi ft cabl e adjustment. Then per-
form a road test to determi ne i f the probl em has been
corrected or i f more di agnosi s i s necessary. I f the
probl em persi sts after the prel i mi nary tests and cor-
recti ons are compl eted, hydraul i c pressure checks
shoul d be performed.
DIAGNOSIS
forward).
VEHICLE IS DRIVABLE
scan tool .
(3) Adjust gearshi ft cabl e i f compl ai nt was based
on del ayed, errati c, or harsh shi fts.
(5) Perform stal l test i f compl ai nt i s based on sl ug-
gi sh accel erati on. Or, i f abnormal throttl e openi ng i s
needed to mai ntai n normal speeds wi th a properl y
tuned engi ne.
(7) Perform ai r-pressure test to check cl utch oper-
ati on.
AUTOMATIC TRANSMISSION - 45RFE (Continued)
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft
cabl e.
fol l owi ng:
si on and check for damaged dri vepl ate, converter,
adjusted i f necessary. Veri fy that al l di agnosti c trou-
bl e codes have been resol ved.
cl utch, overrunni ng cl utch, or l i ne pressure probl ems.
A sl i ppi ng cl utch can often be determi ned by com-
pari ng whi ch i nternal uni ts are appl i ed i n the vari -
ous gear ranges. The Cl utch Appl i cati on chart
provi des a basi s for anal yzi ng road test resul ts.
CLUTCH APPLICATION CHART
SLP UD OD R 2C 4C L/R OVERRUNNING
PPARK ON
RREVERSE ON ON
N-NEUTRAL ON
DOVERDRIVE
FIRST
ON ON* ON
SECOND ON ON
SECOND PRIME ON ON
THIRD ON ON
FOURTH ON ON
LIMP-IN ON ON
2FIRST ON ON* ON
SECOND ON ON
LIMP-IN ON ON
1LOW ON ON ON
*L/R clutch is on only with the output shaft speed below 150 rpm.
PRESSURE TEST
are requi red. Test Gauge C-3293-SP has a 300 psi
range and i s used at al l l ocati ons where pressures
exceed 100 psi .
Onl y two pressure ports are suppl i ed on the trans-
mi ssi on case. The torque converter cl utch appl y and
rel ease ports are l ocated on the ri ght si de of the
transmi ssi on case (Fi g. 2).
To determi ne the l i ne pressure, there are two avai l -
abl e methods. The DRBscan tool can be used to
read l i ne pressure from the l i ne pressure sensor. The
second method i s to i nstal l Li ne Pressure Adapter
8259 (Fi g. 4) i nto the transmi ssi on case and then
i nstal l the pressure gauge and the ori gi nal sensor
i nto the adapter. Thi s wi l l al l ow a compari son of the
DRB readi ngs and the gauge readi ng to determe
the accuracy of the l i ne pressure sensor. The DRB
l i ne pressure readi ng shoul d match the gauge read-
i ng wi thi n 10 psi .
I n order to access any other pressure tap l ocati ons,
the transmi ssi on oi l pan must be removed, the pres-
sure port pl ugs removed and Val ve Body Pressure
Tap Adapter 8258-A (Fi g. 5) i nstal l ed. The extensi ons
suppl i ed wi th Adapter 8258-A wi l l al l ow the i nstal l a-
ti on of pressure gauges to the val ve body. Refer to
(Fi g. 3) for correct pressure tap l ocati on i denti fi ca-
ti on.
TEST PROCEDURE
Al l pressure readi ngs shoul d be taken wi th the
transmi ssi on fl ui d l evel ful l , transmi ssi on oi l at the
normal operati ng temperature, and the engi ne at
1500 rpm. Check the transmi ssi on for proper opera-
ti on i n each gear posi ti on that i s i n questi on or i f a
speci fi c el ement i s i n questi on, check the pressure
readi ngs i n at l east two gear posi ti ons that empl oy
that el ement. Refer to the Hydraul i c Schemati cs at
the rear of thi s secti on to determi ne the correct pres-
sures for each el ement i n a gi ven gear posi ti on.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
3 - TOOL 8259
4 - PRESSURE TAP
Fig. 5 Valve Body Pressure Tap Adapter 8258-A
1 - 45RFE TRANSMISSION
2 - TOOL 8258-A
NOTE: The 45RFE utilizes closed loop control of
pump line pressure. The pressure readings may
therefore vary greatly but should always follow line
pressure.
Some common pressures that can be measured to
eval uate pump and cl utch performance are the
upshi ft/downshi ft pressures and the garage shi ft
pressures. The upshi ft/downshi ft pressure for al l
shi fts i s 120 psi . The garage shi ft pressure when per-
formi ng a N-R shi ft i s 220 psi . The garage shi ft pres-
sure for the R-N and N-1 shi fts i s 120 psi .
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION
si on cl utch operati on. The test can be conducted wi th
the transmi ssi on ei ther i n the vehi cl e or on the work
bench, as a fi nal check.
cl utch appl y passages are shown (Fi g. 6).
NOTE: The air supply which is used must be free of
moisture and dirt. Use a pressure of 30 psi to test
clutch operation.
Appl y ai r pressure at each port. I f the cl utch i s
functi oni ng, a soft thump wi l l be heard as the cl utch
i s appl i ed. The cl utch appl i cati on can al so be fel t by
touchi ng the appropri ate el ement whi l e appl yi ng ai r
pressure. As the ai r pressure i s rel eased, the cl utch
shoul d al so rel ease.
HOUSING FLUID LEAK
for repai r. Torque converter seal l eaks tend to move
al ong the dri ve hub and onto the rear of the con-
verter. Pump cover seal tend to run down the cover
and the i nsi de surface of the bel l housi ng.
Some l eaks, or suspected l eaks, may be parti cu-
l arl y di ffi cul t to l ocate. I f necessary, a Mopar
approved dye may be used to l ocate a l eak.
1 - LOW REVERSE CLUTCH
2 - 4TH CLUTCH
3 - 2ND CLUTCH
4 - OVERDRIVE CLUTCH
5 - UNDERDRIVE CLUTCH
6 - REVERSE CLUTCH
1 - TURBINE ASSEMBLY
2 - STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
THREAD REPAIR
ers.
REMOVAL
(1) Di sconnect the negati ve battery cabl e.
(2) Rai se and support the vehi cl e
(3) Remove any necessary ski d pl ates. (Refer to 13
- FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - REMOVAL)
fl anges for assembl y al i gnment.
(5) Remove the rear propel l er shaft
(6) Remove the front propel l er shaft, i f necessary.
(7) Remove the engi ne to transmi ssi on col l ar (Fi g.
8).
(8) Remove the exhaust support bracket from the
rear of the transmi ssi on.
(9) Di sconnect and l ower or remove any necessary
exhaust components.
(10) Remove the starter motor.
dampener bol t.
(12) Di sconnect wi res from sol enoi d and pressure
swi tch assembl y, i nput and output speed sensors, and
l i ne pressure sensor.
(13) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever (Fi g. 9).
(14) Di sconnect transmi ssi on fl ui d cool er l i nes at
transmi ssi on fi tti ngs and cl i ps.
(15) Di sconnect the transmi ssi on vent hose from
the transmi ssi on.
(16) Support rear of engi ne wi th safety stand or
jack.
i on to transmi ssi on and crossmember (Fi g. 10).
(20) Remove transfer case.
(21) Remove al l remai ni ng converter housi ng bol ts.
(23) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(25) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
Fig. 8 Transmission Collar
1 - ENGINE
2 - ENGINE TO TRANSMISSION COLLAR
3 - TRANSMISSION
Fig. 9 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
DISASSEMBLY
(1) Drai n fl ui d from transmi ssi on.
(2) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(3) Remove the torque converter from the trans-
mi ssi on.
(4) Remove the manual shi ft l ever from the trans-
mi ssi on.
(5) Remove the i nput, output, and l i ne pressure
sensors from the transmi ssi on case (Fi g. 11).
(6) I nspect the ends of the sensors for debri s,
whi ch may i ndi cate the nature of the transmi ssi on
fai l ure.
(7) I nstal l Support Stand 8257 onto the transmi s-
(8) Usi ng Adapter 8266-1 from End-Pl ay Tool Set
8266 and Di al I ndi cator C-3339, measure and record
the i nput shaft end-pl ay (Fi g. 13).
NOTE: When measuring the input shaft end-play,
two stops will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first stop felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
Fig. 10 Rear Transmission Crossmember
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 11 Remove Input, Output, and Line Pressure
Sensors
Fig. 12 Install Support Stand - Tool 8257
1 - TOOL 8257
(9) Remove the bol ts hol di ng the transmi ssi on
extensi on/adapter housi ng to the transmi ssi on case.
(10) Remove the extensi on/adapter housi ng from
the transmi ssi on case.
(11) Usi ng Al i gnment Pl ate 8261, Adapter 8266-17
from End-Pl ay Tool Set 8266 and Di al I ndi cator
C-3339, measure and record the output shaft end-
pl ay (Fi g. 14).
(12) Remove the bol ts hol di ng the transmi ssi on oi l
pan to the transmi ssi on case.
(13) Remove the transmi ssi on oi l pan from the
transmi ssi on case.
(14) Remove the pri mary oi l fi l ter and the oi l
cool er return fi l ter (Fi g. 15).
(15) Remove the cool er return fi l ter bypass val ve.
(16) Remove the bol ts hol di ng the val ve body to
the transmi ssi on case (Fi g. 16).
(17) Remove the val ve body from the transmi ssi on
case.
Fig. 13 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 14 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 15 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 16 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
(18) Remove the outer snap-ri ng securi ng the
transmi ssi on front cover i nto the transmi ssi on case
(Fi g. 17).
(19) Remove the i nner snap-ri ng securi ng the
transmi ssi on front cover to the oi l pump (Fi g. 17).
(20) Reachi ng through a case openi ng i n the val ve
body area wi th a l ong bl unted tool , remove the trans-
mi ssi on front cover from the transmi ssi on case.
(21) Remove the bol ts hol di ng the oi l pump i nto
(22) Remove the oi l pump. Hol d i nward on the
i nput shaft to prevent pul l i ng the i nput cl utch
assembl y wi th the oi l pump (Fi g. 18).
(23) Remove the number 1 beari ng from the i nput
cl utch assembl y (Fi g. 19).
(24) Remove the i nput cl utch assembl y from the
(25) Remove the number 5 beari ng and sel ecti ve
thrust pl ate from the i nput cl utch assembl y (Fi g. 19),
or the 4C cl utch retai ner/bul khead.
(26) Remove the 4C cl utch retai ner/bul khead
tapered snap-ri ng from the transmi ssi on case (Fi g.
20).
(27) Remove the 4C cl utch retai ner/bul khead from
Fig. 17 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 18 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 19 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
(28) Remove the front 2C cl utch pack snap-ri ng
from the transmi ssi on case (Fi g. 21).
(29) Remove the 2C cl utch pack from the transmi s-
(30) Remove the rear sel ecti ve pl ate and number 6
beari ng from the reacti on annul us (Fi g. 22).
(31) Remove the reacti on annul us from the reac-
ti on pl anetary carri er (Fi g. 22).
(32) Remove the number 7 beari ng (Fi g. 22).
(33) Remove the reacti on sun gear (Fi g. 22).
(34) Remove the number 8 beari ng from the reac-
ti on pl anetary carri er (Fi g. 22).
(35) Remove the reacti on pl anetary carri er (Fi g.
22). Note that thi s pl anetary gear set has three pi n-
i on gears.
(36) Remove the number 9 beari ng from the
reverse pl anetary gear set (Fi g. 22).
(37) Remove the snap-ri ng hol di ng the park sprag
gear onto the output shaft (Fi g. 23).
(38) Remove the park sprag gear from the output
shaft (Fi g. 24).
(39) Remove the i nput/reverse pl anetary assembl y
(Fi g. 25).
(40) Remove the number 12 beari ng from the
i nput/reverse pl anetary assembl y (Fi g. 25).
(41) Remove the snap-ri ng hol di ng the l ow/reverse
cl utch retai ner i nto the transmi ssi on case (Fi g. 26).
(42) Remove the l ow/reverse cl utch retai ner from
(43) Remove the park pawl rod and e-cl i p (Fi g. 27).
(44) Remove the park pawl rod gui de snap-ri ng
(Fi g. 27).
(45) Remove the park pawl rod gui de (Fi g. 27).
(46) Remove the park pawl pi vot shaft, park pawl ,
(47) Remove the manual sel ector shaft (Fi g. 27).
(48) Remove the manual sel ector shaft seal .
(49) Remove the di psti ck tube seal .
Fig. 20 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 21 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 22 Remove Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
Fig. 23 Remove Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 24 Remove Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 25 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
Fig. 26 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
CLEANING
and val ve bore.
as wel l .
Type 9602, transmi ssi on fl ui d duri ng overhaul and
INSPECTION
damage or wear.
ASSEMBLY
(1) Cl ean and i nspect al l components. Repl ace any
components whi ch show evi dence of excessi ve wear
or scori ng.
(2) I nstal l the cool er fi l ter bypass val ve.
(3) Torque the bypass val ve to speci fi cati on. The
val ve uses a tapered pi pe thread and excessi ve
torque can damage the transmi ssi on case. Ti ghten
the cool er fi l ter bypass val ve to 4.5 Nm (40 i n.l bs.).
(4) I nstal l a new sel ector shaft seal usi ng Seal
I nstal l er 8253 (Fi g. 28).
Fig. 27 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 28 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
(5) I nstal l the manual sel ector shaft and retai ni ng
screw. Ti ghten the manual sel ector shaft retai ni ng
screw to 28 Nm (250 i n.l bs.).
(6) I nstal l the park pawl , spri ng, and shaft (Fi g.
29).
(7) I nstal l the park rod and e-cl i p (Fi g. 29).
(8) I nstal l the park rod gui de and snap-ri ng (Fi g.
29).
(9) I nstal l a new di psti ck tube seal usi ng Seal
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) I nstal l the 2C reacti on pl ate i nto the trans-
mi ssi on case (Fi g. 31). The reacti on pl ate i s di rec-
ti onal . The pl ate must be i nstal l ed wi th the fl at si de
toward the front of the transmi ssi on.
(11) I nstal l the 2C cl utch pack i nto the transmi s-
(12) I nstal l the fl at 2C cl utch snap-ri ng i nto the
Fig. 29 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 30 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 31 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
(13) I nstal l the 4C retai ner/bul khead i nto the
transmi ssi on case. Make sure that the oi l feed hol es
are poi nti ng toward the val ve body area.
(14) I nstal l the 4C retai ner/bul khead tapered
snap-ri ng i nto the transmi ssi on case. Make sure that
the open ends of the snap-ri ng are l ocated i n the case
openi ng toward the val ve body area.
(15) Usi ng a feel er gauge through the openi ng i n
the rear of the transmi ssi on case, measure the 2C
cl utch pack cl earance between the 2C reacti on pl ate
and the transmi ssi on case at four di fferent poi nts.
The average of these measurements i s the 2C cl utch
pack cl earance. The correct cl utch cl earance i s 0.533-
1.27 mm (0.021-0.050 i n.). The reacti on pl ate i s not
sel ecti ve. I f the cl utch pack cl earance i s not wi thi n
speci fi cati on, the reacti on pl ate, al l the fri cti on di scs,
and steel s must be repl aced.
(16) Remove the 4C retai ner/bul khead and al l of
the 2C cl utch components from the transmi ssi on
case.
(17) I nstal l the l ow/reverse cl utch assembl y (Fi g.
32). Make sure that the oi l feed hol e poi nts toward
the val ve body area and that the bl eed ori fi ce i s
al i gned wi th the notch i n the rear of the transmi s-
si on case.
(18) I nstal l the snap-ri ng to hol d the l ow/reverse
cl utch retai ner i nto the transmi ssi on case (Fi g. 32).
The snap-ri ng i s tapered and must be i nstal l ed wi th
the tapered si de forward. Once i nstal l ed, veri fy that
the snap-ri ng i s ful l y seated i n the snap-ri ng groove.
(19) Ai r check the l ow/reverse cl utch and veri fy
correct overrunni ng cl utch operati on.
(20) I nstal l the number 12 beari ng over the output
shaft of the rear pl anetary gear set and onto the l ow/
reverse cl utch assembl y. The fl at si de of the beari ng
goes toward the cl utch assembl y.
(21) I nstal l the reverse/i nput pl anetary assembl y
through the l ow/reverse cl utch assembl y (Fi g. 33).
(22) I nstal l the park sprag onto the output shaft
(Fi g. 34).
(23) I nstal l the snap-ri ng to hol d the park sprag
onto the output shaft (Fi g. 35).
Fig. 32 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 33 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
(24) I nstal l the 2C reacti on pl ate i nto the trans-
mi ssi on case (Fi g. 36). The reacti on pl ate i s di rec-
ti onal . The pl ate must be i nstal l ed wi th the fl at si de
toward the front of the transmi ssi on.
(25) I nstal l the 2C cl utch pack i nto the transmi s-
(26) I nstal l the number 8 beari ng i nsi de the reac-
ti on carri er wi th the round si de agai nst the pl ane-
tary carri er.
(27) I nstal l the reacti on pl anetary gear set and the
number 9 beari ng, wi th the fl at si de toward the reac-
ti on pl anetary, i nto the transmi ssi on case (Fi g. 37).
(28) I nstal l the fl at 2C cl utch snap-ri ng i nto the
(29) I nstal l the reacti on sun gear i nto the reacti on
pl anetary gear set. Make sure the smal l shoul der i s
faci ng the front of the transmi ssi on (Fi g. 37).
(30) I nstal l the number 7 beari ng onto the reacti on
sun gear wi th the fl at si de agai nst the sun gear (Fi g.
37).
Fig. 34 Install Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 35 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 36 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
(31) I nstal l the output shaft sel ecti ve thrust pl ate
onto the reacti on annul us wi th the oi l grooves faci ng
the annul us gear and the tabs and notches al i gned as
shown i n (Fi g. 38).
(32) I nstal l the number 6 beari ng agai nst the out-
put shaft sel ecti ve thrust pl ate wi th the fl at si de
agai nst the thrust pl ate (Fi g. 37).
(33) I nstal l the reacti on annul us i nto the reacti on
pl anetary gear set (Fi g. 37).
(34) I nstal l the 4C retai ner/bul khead i nto the
transmi ssi on case. Make sure that the oi l feed hol es
are poi nti ng toward the val ve body area. Rotate the
reacti on annul us duri ng the i nstal l ati on of the 4C
retai ner/bul khead to ease i nstal l ati on.
(35) I nstal l the 4C retai ner/bul khead tapered
snap-ri ng i nto the transmi ssi on case (Fi g. 39). Make
sure that the open ends of the snap-ri ng are l ocated
i n the case openi ng toward the val ve body area.
(36) Ai r check the 2C and 4C cl utch operati on.
(37) Usi ng Al i gnment Pl ate 8261, Adapter 8266-17
from End-Pl ay Tool Set 8266 and Di al I ndi cator
C-3339, measure and record the output shaft end-
pl ay (Fi g. 40). The correct output shaft end-pl ay i s
0.22-0.55 mm (0.009-0.021 i n.). Adjust as necessary.
I nstal l the chosen output shaft sel ecti ve thrust pl ate
and re-measure end-pl ay to veri fy sel ecti on.
(38) Appl y a bead of RTV si l i cone and i nstal l the
extensi on/adapter housi ng onto the transmi ssi on
case.
(39) I nstal l and torque the bol ts to hol d the exten-
si on/adapter housi ng onto the transmi ssi on case. The
correct torque i s 54 Nm (40 ft.l bs.).
(40) I nstal l the number 5 beari ng and sel ecti ve
thrust pl ate onto the 4C retai ner/bul khead (Fi g. 41).
(41) I nstal l the i nput cl utch assembl y i nto the
transmi ssi on case (Fi g. 41). Make sure that the i nput
cl utch assembl y i s ful l y i nstal l ed by performi ng a
vi sual i nspecti on through the i nput speed sensor
Fig. 37 Install Reaction Annulus and Carrier
hol e. I f the tone wheel teeth on the i nput cl utch
assembl y are vi si bl e, the assembl y i s ful l y i nstal l ed.
(42) I nstal l the number 1 beari ng wi th the fl at
si de up i n the pocket of the i nput cl utch assembl y
(Fi g. 41).
(43) I nstal l the oi l pump i nto the transmi ssi on
case (Fi g. 42).
(44) I nstal l the bol ts to hol d the oi l pump i nto the
transmi ssi on case. Ti ghten the oi l pump bol ts to 28
Nm (250 i n.l bs.).
(45) Usi ng Adapter 8266-1 from End-Pl ay Tool Set
8266 and Di al I ndi cator C-3339, measure and record
the i nput shaft end-pl ay (Fi g. 43). The correct end-
pl ay i s 0.46-0.89 mm (0.018-0.035 i n.). Adjust as nec-
essary. I nstal l the chosen thrust pl ater on the
number 5 beari ng and re-measure end-pl ay to veri fy
sel ecti on.
Fig. 38 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 39 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 40 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 41 Install Input Clutch Assembly
2 - THRUST PLATE (SELECT)
NOTE: When measuring the input shaft end-play,
two stops will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first stop felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(46) I nstal l the transmi ssi on front cover i nto the
(47) I nstal l the outer snap-ri ng to hol d the trans-
mi ssi on front cover i nto the transmi ssi on case (Fi g.
44).
(48) Parti al l y i nstal l the i nner transmi ssi on front
cover snap-ri ng onto the oi l pump (Fi g. 44).
(49) Usi ng I nstal l er 8255, i nstal l the i nner trans-
mi ssi on front cover snap-ri ng the remai nder of the
way onto the oi l pump (Fi g. 45).
Fig. 42 Install Oil Pump
2 - OIL PUMP
Fig. 43 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 44 Install the Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 45 Seat Snap-Ring Using Tool 8255
1 - TOOL 8255
2 - SNAP-RING
(50) I nstal l the val ve body (Fi g. 46). Veri fy that
the pi n on the manual l ever has properl y engaged
the TRS sel ector pl ate. Ti ghten the val ve body to
transmi ssi on case bol ts to 12 Nm (105 i n.l bs.).
(51) Veri fy that the pri mary oi l fi l ter seal i s prop-
erl y i nstal l ed i n the oi l pump i nl et bore.
(52) I nstal l the pri mary oi l fi l ter and the oi l cool er
return fi l ter (Fi g. 47). Ti ghten the screw to hol d the
pri mary oi l fi l ter to the val ve body to 4.5 Nm (40
i n.l bs.). Usi ng Oi l Fi l ter Wrench 8321, ti ghten the
cool er return oi l fi l ter to the transmi ssi on case to 14
Nm (125 i n.l bs.).
(53) Appl y RTV si l i cone to the oi l pan and i nstal l
the transmi ssi on oi l pan. Ti ghten the bol ts to 12 Nm
(105 i n.l bs.).
(54) I nstal l the i nput, output, and l i ne pressure
sensors (Fi g. 48). Ti ghten the bol ts to 12 Nm (105
i n.l bs.).
(55) I nstal l the manual shi ft l ever from the trans-
mi ssi on. Torque the retai ni ng cross-bol t to 16 Nm
(140 i n.l bs.).
INSTALLATION
(1) Check torque converter hub and hub dri ve fl ats
for sharp edges burrs, scratches, or ni cks. Pol i sh the
hub and fl ats wi th 320/400 gri t paper and crocus
cl oth i f necessary. Veri fy that the converter hub
o-ri ng i s properl y i nstal l ed and i s free of any debri s.
The hub must be smooth to avoi d damagi ng pump
seal at i nstal l ati on.
(2) I f a repl acement transmi ssi on i s bei ng
i nstal l ed, transfer any components necessary, such as
the manual shi ft l ever and shi ft cabl e bracket, from
the ori gi nal transmi ssi on onto the repl acement trans-
mi ssi on.
fl ui d.
Fig. 46 Install Valve Body Assembly
Fig. 47 Install Primary Oil and Cooler Filters
4 - VALVE BODY
Fig. 48 Install Input, Output, and Line Pressure
Sensors
(4) Al i gn converter and oi l pump.
pump gears.
shoul d be at l east 13mm (1/2 i n.) to rear of strai ght-
edge when converter i s ful l y seated.
(7) Temporari l y secure converter wi th C-cl amp.
wi th chai ns.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Appl y a l i ght coati ng of MoparHi gh Temp
Grease to the torque converter hub pocket i n the rear
pocket of the engi nes crankshaft.
(11) Rai se transmi ssi on and al i gn the torque con-
verter wi th the dri ve pl ate and transmi ssi on con-
verter housi ng wi th the engi ne bl ock.
or ti l t transmi ssi on to al i gn the converter housi ng
wi th engi ne bl ock dowel s.
crankshaft. Veri fy that no wi res, or the transmi ssi on
vent hose, have become trapped between the engi ne
bl ock and the transmi ssi on.
(14) I nstal l two bol ts to attach the transmi ssi on to
the engi ne.
(15) I nstal l remai ni ng torque converter housi ng to
engi ne bol ts. Ti ghten to 68 Nm (50 ft.l bs.).
(16) I nstal l transfer case, i f equi pped. Ti ghten
transfer case nuts to 35 Nm (26 ft.l bs.).
(17) I nstal l rear transmi ssi on crossmember.
Ti ghten crossmember to frame bol ts to 68 Nm (50
ft.l bs.).
(18) I nstal l rear support to transmi ssi on. Ti ghten
bol ts to 47 Nm (35 ft.l bs.).
(19) Lower transmi ssi on onto crossmember and
i nstal l bol ts attachi ng transmi ssi on mount to cross-
member. Ti ghten cl evi s bracket to crossmember bol ts
to 47 Nm (35 ft.l bs.). Ti ghten the cl evi s bracket to
rear support bol t to 68 Nm (50 ft.l bs.).
(20) Remove engi ne support fi xture.
(21) Connect gearshi ft cabl e to transmi ssi on.
(22) Connect wi res to sol enoi d and pressure swi tch
assembl y connector, i nput and output speed sensors,
and l i ne pressure sensor. Be sure transmi ssi on har-
nesses are properl y routed.
(24) I nstal l starter motor and cool er l i ne bracket.
(26) I nstal l transmi ssi on fi l l tube.
(28) I nstal l the engi ne col l ar onto the transmi ssi on
and the engi ne. Ti ghten the bol ts to 54 Nm (40
ft.l bs.).
(29) Al i gn and connect propel l er shaft(s).
(30) Adjust gearshi ft cabl e i f necessary.
(31) I nstal l any ski d pl ates removed previ ousl y.
(Refer to 13 - FRAMES & BUMPERS/FRAME/
TRANSFER CASE SKI D PLATE - I NSTALLATI ON)
(33) Fi l l transmi ssi on wi th MoparATF +4, type
9602, Automati c Transmi ssi on Fl ui d.
Fig. 49 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
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SPECIFICATIONS
TRANSMISSION
GENERAL
Output Shaft End Play 0.22-0.55
mm
0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm
0.018-0.035
in.
2C Clutch Pack
Clearance
0.53-1.27
mm
0.021-0.050
in.
4C Clutch Pack
Clearance
0.81-1.35
mm
0.032-0.053
in.
L/R Clutch Pack
Clearance
1.14-1.91
mm
0.045-0.075
in.
OD Clutch Pack
Clearance
1.016-1.65
mm
0.040-0.065
in.
UD Clutch Pack
Clearance
0.76-1.160
mm
0.030-0.063
in.
Reverse Clutch Pack
Clearance
0.81-1.24
mm
0.032-0.049
in.
Recommended fluid Mopar ATF Plus 4, type
9602
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
REVERSE 3.00:1
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to
crankshaft
75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to
cover
4.5 - 40
Screw, plate to oil pump
body
4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft
support
11.8 - 105
Screw, valve body to
transfer plate
5.6 - 50
Screw, solenoid module to
transfer plate
5.7 - 50
Screw, accumulator cover 4.5 - 40
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter
bypass
4.5 - 40
Screw, manual valve cam
retaining
4.5 - 40
Bolt, manual lever 28.2 - 250
SPECIAL TOOLS
RFE TRANSMISSION
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Flusher, Oil Cooler - 6906-C
Compressor, Spring - 8249
Installer, Seal - 8253
Installer, Snap-ring - 8255
Stand, Support - 8257
Adapter, Pressure Tap - 8258-A
Adapter, Line Pressure - 8259
Fixture, Input Clutch Pressure - 8260
Plate, Alignment - 8261
End Play Set - 8266
Installer, Bearing - 8320
Wrench, Filter - 8321
4C RETAINER/BULKHEAD
DISASSEMBLY
(1) Remove the 2C pi ston bel l evi l l e spri ng snap-
ri ng from the 4C retai ner /bul khead (Fi g. 50).
(2) Remove the 2C pi ston Bel l evi l l e spri ng from
the retai ner/bul khead (Fi g. 50).
(3) Remove the 2C pi ston from the retai ner/bul k-
head. Use 20 psi of ai r pressure to remove the pi ston
i f necessary.
(4) Remove the 4C cl utch snap-ri ng from the
retai ner/bul khead (Fi g. 50).
(5) Remove the 4C cl utch pack from the retai ner/
bul khead (Fi g. 50).
(6) Usi ng Spri ng Compressor 8250 and a sui tabl e
shop press, compress the 4C pi ston return spri ng and
remove the snap-ri ng (Fi g. 50).
(7) Remove the 4C pi ston return spri ng and pi ston
from the retai ner/bul khead (Fi g. 50). Use 20 psi of
ai r pressure to remove the pi ston i f necessary.
Fig. 50 4C Retainer/Bulkhead Components
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
ASSEMBLY
or scori ng.
(2) I nstal l new seal s on the 2C and 4C pi stons
(Fi g. 50).
(3) Lubri cate al l seal s wi th MoparATF +4, type
9602 pri or to i nstal l ati on.
(4) I nstal l the 4C pi ston i nto the 4C retai ner/bul k-
head (Fi g. 50).
(5) Posi ti on the 4C pi ston return spri ng onto the
4C pi ston.
shop press, compress the 4C pi ston return spri ng and
i nstal l the snap-ri ng (Fi g. 51).
(7) Assembl e and i nstal l the 4C cl utch pack i nto
the retai ner/bul khead (Fi g. 50) wi th the steel separa-
tor pl ate agai nst the pi ston.
(8) I nstal l the 4C reacti on pl ate and snap-ri ng i nto
the retai ner/bul khead (Fi g. 50). The 4C reacti on pl ate
i s non-di recti onal .
(9) Measure the 4C cl utch cl earance. The correct
cl utch cl earance i s 0.81-1.35 mm (0.032-0.053 i n.).
The snap-ri ng i s sel ectabl e. I nstal l the chosen snap-
ri ng and re-measure to veri fy the sel ecti on.
(10) I nstal l the 2C pi ston i nto the retai ner/bul k-
head (Fi g. 50).
(11) Posi ti on the 2C Bel l evi l l e spri ng onto the 2C
pi ston.
(12) Posi ti on the 2C Bel l evi l l e spri ng snap-ri ng
onto the 2C Bel l evi l l e spri ng (Fi g. 50).
shop press (Fi g. 52), compress the bel l evi l l e spri ng
unti l the snap-ri ng i s engaged wi th the snap-ri ng
groove i n the retai ner/bul khead.
ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the transfer case from the transmi s-
si on.
(2) Usi ng a screw mounted on a sl i de hammer,
remove the adapter housi ng seal .
INSTALLATION
(1) Cl ean the adapter seal bore i n the adapter
housi ng of any resi due or parti cl es remai ni ng from
the ori gi nal seal .
(2) I nstal l new oi l seal i n the adapter housi ng
usi ng Seal I nstal l er C-3860-A (Fi g. 53). A properl y
i nstal l ed seal i s fl ush to the face of the seal bore.
(3) I nstal l the transfer case onto the transmi ssi on.
Fig. 51 Compress 4C Piston Return Spring Using
Tool 8250
1 - PRESS
2 - TOOL 8250
Fig. 52 Compress 2C Belleville Spring Using Tool
8249
1 - PRESS
2 - TOOL 8249
4C RETAINER/BULKHEAD (Continued)
FLUID AND FILTER
BURNT FLUID
whi ch has three pri mary causes.
(1) I nternal cl utch sl i ppage, usual l y caused by l ow
l i ne pressure, i nadequate cl utch appl y pressure, or
cl utch seal fai l ure.
or ki nked l i nes.
CONTAMINATION
resul t of:
checki ng l evel
down)
repai r
repai r
nants.
CHECK
Fig. 53 Adapter Housing Seal Installation
1 - TOOL C-3860-A
ADAPTER HOUSING SEAL (Continued)
taken for a l eak.
The torque converter fi l l s i n both the P (PARK)
and N (NEUTRAL) posi ti ons. Pl ace the sel ector l ever
i n P (PARK) to be sure that the fl ui d l evel check i s
accurate. The engine should be running at idle
on level ground. At normal operati ng temperature
(approxi matel y 82 C. or 180 F.), the fl ui d l evel i s cor-
rect i f i t i s i n the HOT regi on (cross-hatched area) on
the oi l l evel i ndi cator. The fl ui d l evel wi l l be approx-
i matel y at the upper COLD hol e of the di psti ck at
70 F fl ui d temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
matel y 2 seconds.
(5) Hook up DRBscan tool and sel ect transmi s-
si on.
chart.
di psti ck accordi ng to the chart.
REPLACEMENT
ULES - DESCRI PTI ON).
REMOVAL
transmi ssi on.
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(6) Hol d up pan and remove remai ni ng bol ts hol d-
transmi ssi on.
(9) Remove screw hol di ng fi l ter to val ve body (Fi g.
54).
(10) Separate fi l ter from val ve body and oi l pump
and pour fl ui d i n fi l ter i nto drai n pan.
(11) Remove and di scard the oi l fi l ter seal from the
bottom of the oi l pump.
(12) I f repl acei ng the cool er return fi l ter, use Oi l
Fi l ter Wrench 8321 to remove the fi l ter from the
transmi ssi on.
(13) Di spose of used trans fl ui d and fi l ter(s) prop-
erl y.
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal . A l i ght coati ng of cl utch materi al
on the bottom of the pan does not i ndi cate a probl em
unl ess accompani ed by a sl i ppi ng condi ti on or shi ft
l ag. I f fl ui d and pan are contami nated wi th excessi ve
amounts of debri s, refer to the di agnosi s secti on of
thi s group.
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and mag-
net.
(2) Usi ng a sui tabl e gasket scraper, cl ean ori gi nal
seal i ng materi al from surface of transmi ssi on case
and the transmi ssi on pan.
INSTALLATION
(1) I nstal l a new oi l fi l ter seal i nto the bottom of
the oi l pump.
NOTE: Do not attempt to install the seal onto the oil
filter first and then into the oil pump. An unsatisfac-
tory seal between the oil pump and filter will result,
allowing air to be drawn into the pump.
(2) Pl ace repl acement fi l ter i n posi ti on on val ve
body and i nto the oi l pump.
(3) I nstal l screw to hol d fi l ter to val ve body (Fi g.
54). Ti ghten screw to 4.5 Nm (40 i n. l bs.) torque.
(4) I nstal l new cool er return fi l ter onto the trans-
mi ssi on, i f necessary. Torque the fi l ter to 14.12 Nm
(125 i n.l bs.).
(5) Pl ace bead of Mopar RTV seal ant onto the
transmi ssi on case seal i ng surface.
(6) Pl ace pan i n posi ti on on transmi ssi on.
(7) I nstal l bol ts to hol d pan to transmi ssi on.
Ti ghten bol ts to 11.8 Nm (105 i n. l bs.) torque.
MoparATF +4, type 9602 fl ui d.
FILL
Transmission Fluid Temperature Chart
Fig. 54 Transmission Filters - 4X4 Shown
4 - VALVE BODY
(2) Add fol l owi ng i ni ti al quanti ty of MoparATF
+4 to transmi ssi on:
pints (5 quarts) of ATF +4 to transmi ssi on.
cool er was fl ushed, add 24 pints (12 quarts) of
ATF +4 to transmi ssi on.
(3) Check the transmi ssi on fl ui d (Refer to 21 -
TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
45RFE/FLUI D - STANDARD PROCEDURE) and
adjust as requi red.
GEARSHIFT CABLE
CABLE
ti on.
must be possi bl e.
must be possi bl e.
REMOVAL
nuts.
mounti ng bracket to the dash panel (Fi g. 55) or (Fi g.
56).
(Fi g. 58) or (Fi g. 59). Remove ol d cabl e from vehi cl e.
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - DASH PANEL
3 - GEARSHIFT CABLE
INSTALLATION
60) or (Fi g. 61).
range sensor.
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
1 - GEARSHIFT CABLE
3 - MANUAL LEVER
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the transmi ssi on range sensor may be
faul ty.
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - DASH PANEL
3 - GEARSHIFT CABLE
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
HOLDING CLUTCHES
DESCRIPTION
Three hydraul i cal l y appl i ed mul ti -di sc cl utches are
used to hol d some pl anetary geartrai n components
stati onary whi l e the i nput cl utches dri ve others. The
2C, 4C, and Low/Reverse cl utches are consi dered
hol di ng cl utches. The 2C and 4C cl utches are l ocated
i n the 4C retai ner/bul khead (Fi g. 64), whi l e the Low/
Reverse cl utch i s l ocated at the rear of the transmi s-
OPERATION
2C CLUTCH
The 2C cl utch i s hydraul i cal l y appl i ed i n second
gear by pressuri zed fl ui d agai nst the 2C pi ston.
When the 2C cl utch i s appl i ed, the reverse sun gear
assembl y i s hel d or grounded to the transmi ssi on
case by hol di ng the reacti on pl anetary carri er.
4C CLUTCH
The 4C cl utch i s hydraul i cal l y appl i ed i n second
pri me and fourth gear by pressuri zed fl ui d agai nst
the 4C cl utch pi ston. When the 4C cl utch i s appl i ed,
the reacti on annul us gear i s hel d or grounded to the
LOW/REVERSE CLUTCH
The Low/Reverse cl utch i s hydraul i cal l y appl i ed i n
park, reverse, neutral , and fi rst gear, onl y at l ow
speeds, by pressuri zed fl ui d agai nst the Low/Reverse
cl utch pi ston. When the Low/Reverse cl utch i s
appl i ed, the i nput annul us assembl y i s hel d or
grounded to the transmi ssi on case.
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
Fig. 64 2C and 4C Clutches
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
HOLDING CLUTCHES (Continued)
Fig. 65 Low/Reverse Clutch
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
HOLDING CLUTCHES (Continued)
INPUT CLUTCH ASSEMBLY
DESCRIPTION
Three hydraul i cal l y appl i ed i nput cl utches are used
to dri ve pl anetary components. The underdri ve, over-
dri ve, and reverse cl utches are consi dered i nput
cl utches and are contai ned wi thi n the i nput cl utch
assembl y (Fi g. 66) and (Fi g. 67). The i nput cl utch
assembl y al so contai ns:
I nput shaft
I nput hub
Cl utch retai ner
Underdri ve pi ston
Overdri ve/reverse pi ston
Overdri ve hub
Underdri ve hub
OPERATION
The three i nput cl utches are responsi bl e for dri vi ng
di fferent components of the pl anetary geartrai n.
UNDERDRIVE CLUTCH
The underdri ve cl utch i s hydraul i cal l y appl i ed i n
fi rst, second, second pri me, and thi rd (di rect) gears
by pressuri zed fl ui d agai nst the underdri ve pi ston.
When the underdri ve cl utch i s appl i ed, the under-
dri ve hub dri ves the i nput sun gear.
Fig. 66 Input Clutch Assembly - Part 1
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
OVERDRIVE CLUTCH
The overdri ve cl utch i s hydraul i cal l y appl i ed i n
thi rd (di rect) and fourth gears by pressuri zed fl ui d
agai nst the overdri ve/reverse pi ston. When the over-
dri ve cl utch i s appl i ed, the overdri ve hub dri ves the
reverse carri er/i nput annul us assembl y.
REVERSE CLUTCH
The reverse cl utch i s hydraul i cal l y appl i ed i n
reverse gear by pressuri zed fl ui d agai nst the over-
dri ve/reverse pi ston. When the reverse cl utch i s
appl i ed, the reacti on annul us gear i s dri ven.
DISASSEMBLY
(1) Remove the reverse reacti on pl ate sel ecti ve
snap-ri ng from the i nput cl utch retai ner (Fi g. 68).
(2) Remove the reverse reacti on pl ate from the
i nput cl utch retai ner.
(3) Remove the reverse hub and reverse cl utch
pack from the i nput cl utch retai ner.
(4) Remove the number 4 beari ng from the over-
dri ve hub.
(5) Remove the overdri ve hub from the i nput
cl utch retai ner (Fi g. 68).
1 - BEARING NUMBER 3 10 - SNAP-RING (SELECT)
2 - OD HUB/SHAFT 11 - PLATE
3 - SNAP-RING (WAVE) 12 - DISC
4 - REV/OD REACTION PLATE 13 - OD CLUTCH
5 - BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
9 - REVERSE REACTION PLATE 18 - BEARING NUMBER 2
INPUT CLUTCH ASSEMBLY (Continued)
(6) Remove the number 3 beari ng from the under-
dri ve hub.
(7) Remove the OD/reverse reacti on pl ate snap-
ri ng from the i nput cl utch retai ner.
(8) Remove the underdri ve hub, overdri ve cl utch,
and overdri ve reacti on pl ate from the i nput cl utch
NOTE: The overdrive friction discs and steel discs
are thicker than the matching components in the
underdrive and reverse clutches.
cl utch hub.
(10) Remove the overdri ve cl utch wave snap-ri ng
from the i nput cl utch retai ner.
(11) Remove the UD/OD reacti on pl ate tapered
snap-ri ng from the i nput cl utch retai ner.2
(12) Remove the UD/OD reacti on pl ate from the
(13) Remove the UD/OD reacti on pl ate fl at snap-
ri ng from the i nput cl utch retai ner (Fi g. 68).
(14) Remove the underdri ve cl utch pack from the
i nput cl utch retai ner (Fi g. 70).
(15) Usi ng Spri ng Compressor 8251, compress the
UD/OD bal ance pi ston and remove the snap-ri ng
from the i nput cl utch hub (Fi g. 69).
(16) Remove the UD/OD bal ance pi ston and pi ston
return spri ng from the i nput cl utch retai ner (Fi g. 70).
(17) Remove the underdri ve pi ston from the i nput
NOTE: Both the UD/OD balance piston and the
underdrive piston have seals molded onto them. If
the seal is damaged, do not attempt to install a new
seal onto the piston. The piston/seal must be
replaced as an assembly.
(18) Remove the i nput cl utch retai ner tapered
snap-ri ng.
(19) Separate i nput cl utch retai ner from i nput
cl utch hub.
(20) Separate OD/reverse pi ston from i nput cl utch
hub retai ner (Fi g. 70).
(21) Remove al l seal s and o-ri ngs from the i nput
shaft and i nput hub. The o-ri ngs on the i nput hub
are col or coded. Be sure to make note of whi ch o-ri ng
bel ongs i n whi ch l ocati on.
ASSEMBLY
(1) I nstal l al l new seal s and o-ri ngs onto the i nput
shaft and i nput hub. The o-ri ngs on the i nput hub
are col or coded. Be sure to i nstal l the correct o-ri ng
i n the correct l ocati on.
(2) Check the transmi ssi on l ubri cati on check val ve
l ocated i n the i nput shaft usi ng shop ai r. The val ve
shoul d onl y al l ow ai r fl ow i n one di recti on. I f the
val ve al l ows no ai r fl ow, or ai r fl ow i n both di rec-
ti ons, the val ve wi l l need to be repl aced.
(3) Lubri cate al l seal s wi th MoparATF +4, type
9602, pri or to i nstal l ati on.
(4) Assembl e the OD/reverse pi ston onto the i nput
cl utch hub (Fi g. 71).
(5) Assembl e the i nput cl utch retai ner onto the
i nput cl utch hub.
(6) I nstal l the i nput cl utch retai ner tapered snap-
ri ng wi th tapered si de up onto the i nput cl utch hub.
Fig. 69 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
Fig. 71 Input Clutch Assembly - Part II
(7) I nstal l Pi ston Gui des 8504 i nto the i nput cl utch
retai ner (Fi g. 72) and onto the i nput cl utch hub to
gui de the i nner and outer underdri ve pi ston seal s
i nto posi ti on.
(8) I nstal l the underdri ve pi ston i nto the i nput
cl utch retai ner and over the i nput cl utch hub (Fi g.
71).
(9) I nstal l the UD/OD bal ance pi ston return spri ng
pack i nto the i nput cl utch retai ner.
(10) I nstal l Pi ston Gui de 8252 i nto the i nput
cl utch retai ner (Fi g. 73) to gui de the UD/OD bal ance
pi ston seal i nto posi ti on i nsi de the underdri ve pi ston.
(11) I nstal l the UD/OD bal ance pi ston i nto the
i nput cl utch retai ner and the underdri ve pi ston.
(12) Usi ng Spri ng Compressor 8251, compress the
UD/OD return spri ng pack and secure the pi ston i n
pl ace wi th the snap-ri ng (Fi g. 74).
(13) I nstal l the underdri ve cl utch pack i nto the
i nput cl utch retai ner (Fi g. 71).
(14) I nstal l the UD/OD reacti on pl ate l ower fl at
snap-ri ng (Fi g. 75). The correct snap-ri ng can be
i denti fi ed by the two tabbed ears.
(15) I nstal l the UD/OD reacti on pl ate i nto the
i nput cl utch retai ner. The reacti on pl ate i s to be
i nstal l ed wi th the bi g step down.
(16) I nstal l the UD/OD reacti on pl ate upper
tapered snap-ri ng wi th tapered si de up.
Fig. 72 Install Underdrive Piston Using Tool 8504
1 - TOOL 8504
Fig. 73 Install Balance Piston Using Tool 8252
1 - TOOL 8252
Fig. 74 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
Fig. 75 Input Clutch Assembly - Part I
(17) I nstal l the i nput cl utch assembl y i nto I nput
Cl utch Pressure Fi xture 8260 (Fi g. 76). Mount a di al
i ndi cator to the assembl y, push down on the cl utch
di scs and zero the i ndi cator agai nst the underdri ve
cl utch di scs (Fi g. 77). Appl y 20 psi of ai r pressure to
the underdri ve cl utch and record the di al i ndi cator
readi ng. Measure and record UD cl utch pack mea-
surement i n four (4) pl aces, 90 apart. Take average
of four measurements and compare wi th UD cl utch
pack cl earance speci fi cati on. The correct cl utch cl ear-
ance i s 0.76-1.16 mm (0.030-0.063 i n.). The reacti on
pl ate i s not sel ecti ve. I f the cl utch cl earance i s not
wi thi n speci fi cati on, repl ace the reacti on pl ate al ong
wi th al l the fri cti on and steel di scs.
(18) I nstal l the overdri ve cl utch pack i nto the
i nput cl utch retai ner (Fi g. 75). The overdri ve steel
separator pl ates can be i denti fi ed by the l ack of the
hal f-moon cuts i n the l ocati ng tabs.
(19) I nstal l the overdri ve cl utch wavy snap-ri ng
wi th the two tabbed ears i nto the i nput cl utch
retai ner.
(20) I nstal l the OD/reverse reacti on pl ate i nto the
i nput cl utch retai ner. The reacti on pl ate i s non-di rec-
ti onal (Fi g. 75).
(21) I nstal l the OD/reverse reacti on pl ate fl at
snap-ri ng i nto the i nput cl utch retai ner.
(22) Mount a di al i ndi cator to the assembl y and
zero the i ndi cator agai nst the OD/reverse reacti on
pl ate (Fi g. 78). Appl y 20 psi of ai r pressure to the
overdri ve cl utch and record the di al i ndi cator read-
i ng. Measure and record OD cl utch pack measure-
ment i n four (4) pl aces, 90 apart. Take average of
four measurements and compare wi th OD cl utch
pack cl earance speci fi cati on.Veri fy that the cl utch
cl earance i s 1.016-1.65 mm (0.040-0.065 i n.). The
reacti on pl ate i s not sel ecti ve. I f the cl utch cl earance
i s not wi thi n speci fi cati on, repl ace the reacti on pl ate
al ong wi th al l the fri cti on and steel di scs.
Fig. 76 Input Clutch Assembly Mounted on Tool
8260
2 - TOOL 8260
Fig. 77 Measuring UD Clutch Clearance
1 - TOOL C-3339
2 - UNDERDRIVE CLUTCH PACK
Fig. 78 Measuring OD Clutch Clearance
1 - TOOL C-3339
2 - OD/REV REACTION PLATE
(23) I nstal l the reverse cl utch pack i nto the i nput
(24) I nstal l the reverse reacti on pl ate i nto the
(25) I nstal l the reverse reacti on pl ate sel ecti ve
snap-ri ng i nto the i nput cl utch retai ner.
(26) Mount a di al i ndi cator to the assembl y, push
down on the cl utch di scs, pul l up on the reacti on
pl ate to ensure the pl ate i s properl y seated and zero
the i ndi cator agai nst the reverse cl utch di scs (Fi g.
79). Appl y 20 psi of ai r pressure to the reverse cl utch
and record the di al i ndi cator readi ng. Measure and
record Reverse cl utch pack measurement i n four (4)
pl aces, 90 apart. Take average of four measurements
and compare wi th Reverse cl utch pack cl earance
speci fi cati on. The correct cl utch cl earance i s 0.81-1.24
mm (0.032-0.049 i n.). Adjust as necessary. I nstal l the
chosen snap-ri ng and re-measure to veri fy sel ecti on.
(27) Remove the reverse cl utch pack from the
(28) I nstal l the number 2 beari ng onto the under-
dri ve hub wi th fl at si de up/forward wi th petrol eum
jel l y.
(29) I nstal l the underdri ve hub i nto the i nput
cl utch retai ner.
(30) I nstal l the number 3 beari ng i nto the over-
dri ve hub wi th the fl at si de up/forward wi th petro-
l eum jel l y.
(31) I nstal l the overdri ve hub i nto the i nput cl utch
retai ner.
(32) I nstal l the number 4 beari ng i nto the reverse
hub wi th fl at si de up/forward wi th petrol eum jel l y.
(33) I nstal l the reverse hub i nto the i nput cl utch
retai ner.
(34) I nstal l the compl ete reverse cl utch pack.
(35) I nstal l the reverse reacti on pl ate and snap-
ri ng.
(36) Push up on reacti on pl ate to al l ow reverse
cl utch to move freel y.
INPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors are two-wi re
magneti c pi ckup devi ces that generate AC si gnal s as
rotati on occurs. They are mounted i n the l eft si de of
the transmi ssi on case and are consi dered pri mary
i nputs to the Transmi ssi on Control Modul e (TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
Transmi ssi on gear rati o
Speed rati o error detecti on
CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
Torque converter cl utch sl i ppage
Torque converter el ement speed rati o
REMOVAL
(2) Pl ace a sui tabl e fl ui d catch pan under the
transmi ssi on.
(3) Remove the wi ri ng connector from the i nput
speed sensor (Fi g. 80).
(4) Remove the bol t hol di ng the i nput speed sensor
to the transmi ssi on case.
(5) Remove the i nput speed sensor from the trans-
mi ssi on case.
INSTALLATION
(1) I nstal l the i nput speed sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the i nput speed sensor
i nto the transmi ssi on case. Ti ghten the bol t to 11.9
Nm (105 i n.l bs.).
Fig. 79 Measuring Reverse Clutch Clearance
1 - TOOL C-3339
2 - REVERSE CLUTCH PACK
(3) I nstal l the wi ri ng connector onto the i nput
speed sensor
(4) Veri fy the transmi ssi on fl ui d l evel . Add fl ui d as
necessary.
LINE PRESSURE (LP) SENSOR
DESCRIPTION
The TCM uti l i zes a cl osed-l oop system to control
transmi ssi on l i ne pressure. The system contai ns a
vari abl e force styl e sol enoi d, the Pressure Control
Sol enoi d, mounted on the si de of the sol enoi d and
pressure swi tch assembl y. The sol enoi d i s duty cycl e
control l ed by the TCM to vent the unnecessary l i ne
pressure suppl i ed by the oi l pump back to the sump.
The system al so contai ns a vari abl e pressure styl e
sensor, the Li ne Pressure Sensor, whi ch i s a di rect
i nput to the TCM. The l i ne pressure sol enoi d moni -
tors the transmi ssi on l i ne pressure and compl etes the
feedback l oop to the TCM. The TCM uses thi s i nfor-
mati on to adjust i ts control of the pressure control
sol enoi d to achi eve the desi red l i ne pressure.
OPERATION
The TCM cal cul ates the desi red l i ne pressure
based upon i nputs from the transmi ssi on and engi ne.
The TCM cal cul ates the torque i nput to the trans-
mi ssi on and uses that i nformati on as the pri mary
i nput to the cal cul ati on. The l i ne pressure i s set to a
predetermi ned val ue duri ng shi fts and when the
transmi ssi on i s i n the PARK and NEUTRAL posi -
ti ons. Thi s i s done to ensure consi stent shi ft qual i ty.
Duri ng al l other operati on, the actual l i ne pressure i s
compared to the desi red l i ne pressure and adjust-
ments are made to the pressure control sol enoi d duty
cycl e.
REMOVAL
transmi ssi on.
(3) Remove the wi ri ng connector from the l i ne
pressure sensor (Fi g. 81).
(4) Remove the bol t hol di ng the l i ne pressure sen-
sor to the transmi ssi on case.
(5) Remove the l i ne pressure sensor from the
INSTALLATION
(1) I nstal l the l i ne pressure sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the l i ne pressure sensor
Nm (105 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the l i ne pres-
sure sensor
necessary.
Fig. 80 Input Speed Sensor
Fig. 81 Line Pressure Sensor
INPUT SPEED SENSOR (Continued)
LOW/REVERSE CLUTCH
DISASSEMBLY
(1) Remove the i nner overrunni ng cl utch snap-ri ng
from the l ow/reverse cl utch retai ner (Fi g. 82).
(2) Remove the outer l ow/reverse reacti on pl ate
fl at snap-ri ng (Fi g. 82).
(3) Remove the l ow/reverse cl utch and the over-
runni ng cl utch from the l ow/reverse cl utch retai ner
as an assembl y (Fi g. 82).
(4) Separate the l ow/reverse cl utch from the over-
runni ng cl utch.
Fig. 82 Low/Reverse Clutch Assembly
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
(5) Remove the overrunni ng cl utch snap-ri ng (Fi g.
83).
(6) Remove the spacer from the overrunni ng cl utch
(Fi g. 83).
(7) Separate the i nner and outer races of the over-
runni ng cl utch (Fi g. 83).
(8) Remove the overrunni ng cl utch l ower snap-ri ng
(Fi g. 83).
shop press (Fi g. 84), compress the l ow/reverse pi ston
Bel l evi l l e spri ng and remove the spl i t retai ni ng ri ng
hol di ng the Bel l evi l l e spri ng i nto the l ow/reverse
cl utch retai ner.
(10) Remove the l ow/reverse cl utch Bel l evi l l e
spri ng and pi ston from the l ow/reverse cl utch
retai ner. Use 20 psi of ai r pressure to remove the pi s-
ton i f necessary.
CLEANING
and l ow-reverse cl utch retai ner. Dry them wi th com-
pressed ai r after cl eani ng.
INSPECTION
Repl ace the l ow-reverse cl utch retai ner i f the
cl utch race, rol l er surface or i nsi de di ameter i s
scored, worn or damaged.
ASSEMBLY
(1) Check the bl eed ori fi ce to ensure that i t i s not
pl ugged or restri cted.
(2) I nstal l a new seal on the l ow/reverse pi ston.
Lubri cate the seal wi th MoparATF +4, type 9602,
pri or to i nstal l ati on.
(3) I nstal l the l ow/reverse pi ston i nto the l ow/re-
verse cl utch retai ner.
(4) Posi ti on the l ow/reverse pi ston Bel l evi l l e spri ng
on the l ow/reverse pi ston.
shop press (Fi g. 84), compress the l ow/reverse pi ston
Bel l evi l l e spri ng and i nstal l the spl i t retai ni ng ri ng
to hol d the Bel l evi l l e spri ng i nto the l ow/reverse
cl utch retai ner.
(6) I nstal l the l ower overrunni ng cl utch snap-ri ng
(Fi g. 83).
(7) Assembl e the i nner and outer races of the over-
runni ng cl utch (Fi g. 83).
(8) Posi ti on the overrunni ng cl utch spacer on the
overrunni ng cl utch.
(9) I nstal l the upper overrunni ng cl utch snap-ri ng
(Fi g. 83).
(10) Assembl e and i nstal l the l ow/reverse cl utch
pack i nto the l ow/reverse cl utch retai ner (Fi g. 82).
(11) I nstal l the l ow/reverse reacti on pl ate i nto the
l ow/reverse cl utch retai ner (Fi g. 82). The reacti on
1 - SNAP-RING
2 - OUTER RACE
4 - SPACER
Fig. 84 Compress Low/Reverse Belleville Spring
Using Tool 8285
1 - PRESS
2 - TOOL 8285
3 - BELLEVILLE SPRING
LOW/REVERSE CLUTCH (Continued)
pl ate i s di recti onal and must be i nstal l ed wi th the
fl at si de down.
(12) I nstal l the l ow/reverse cl utch pack snap-ri ng
(Fi g. 82). The snap-ri ng i s sel ectabl e and shoul d be
chosen to gi ve the correct cl utch pack cl earance.
(13) Measure the l ow/reverse cl utch pack cl earance
and adjust as necessary. The correct cl utch cl earance
i s 1.14-1.91 mm (0.045-0.075 i n.).
(14) I nstal l the overrunni ng cl utch i nto the l ow/re-
verse cl utch retai ner maki ng sure that the i ndex
spl i nes are al i gned wi th the retai ner.
(15) I nstal l the overrunni ng cl utch i nner snap-
ri ng.
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 85) i s l ocated at the front of the
transmi ssi on i nsi de the bel l housi ng and behi nd the
transmi ssi on front cover. The oi l pump consi sts of
two i ndependent pumps (Fi g. 86), a number of val ves
(Fi g. 87), a front seal (Fi g. 88), and a bol t on reacti on
shaft. The converter cl utch swi tch and regul ator
val ves, pressure regul ator val ve, and converter pres-
sure l i mi t val ve are al l l ocated i n the oi l pump hous-
i ng.
OPERATION
rotates the oi l pump dri ve gear. As the dri ve gear
rotates both dri ven gears, the cl earance between the
gear teeth i ncreases i n the crescent area, and creates
a sucti on at the i nl et si de of the pump. Thi s sucti on
draws fl ui d through the pump i nl et from the oi l pan.
As the cl earance between the gear teeth i n the cres-
cent area decreases, i t forces pressuri zed fl ui d i nto
the pump outl et and to the oi l pump val ves.
At l ow speeds, both pumps suppl y fl ui d to the
transmi ssi on. As the speed of the torque converter
i ncreases, the pressure output of both pumps
i ncreases unti l the pri mary pump pressure reaches
the poi nt where i t can cl ose off the check val ve
l ocated between the two pumps. When the check
val ve i s cl osed, the secondary pump i s shut down and
the pri mary pump suppl i es al l the fl ui d to the trans-
mi ssi on.
Fig. 85 Oil Pump
2 - OIL PUMP
Fig. 86 Oil Pump Gears
1 - PUMP BODY
2 - DRIVE GEAR
3 - DRIVEN GEARS
Fig. 87 Oil Pump Valves
1 - TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE
2 - TORQUE CONVERTER CLUTCH CONTROL VALVE
3 - TORQUE CONVERTER CLUTCH SWITCH VALVE
4 - PUMP COVER
5 - PRESSURE REGULATOR VALVE
6 - TORQUE CONVERTER CLUTCH LIMIT VALVE
LOW/REVERSE CLUTCH (Continued)
CONVERTER CLUTCH SWITCH VALVE
The converter cl utch swi tch val ve i s used to control
the hydraul i c pressure suppl i ed to the front (OFF)
si de of the torque converter cl utch.
CONVERTER CLUTCH REGULATOR VALVE
The converter cl utch regul ator val ve i s used to con-
trol the hydraul i c pressure suppl i ed to the back (ON)
si de of the torque converter cl utch.
TORQUE CONVERTER LIMIT VALVE
The torque converter l i mi t val ve serves to l i mi t the
avai l abl e l i ne pressure to the torque converter cl utch
to approxi matel y 120 psi .
CHECK
proper l evel wi th MoparATF +4, type 9602, Auto-
connected l i ne.
Fig. 88 Oil Pump Reaction Shaft
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - VALVE BODY
(2) Run the engi ne at 1800 rpm, wi th the shi ft
sel ector i n neutral . Veri fy that the transmi ssi on fl ui d
temperature i s bel ow 104.5 C (220 F) for thi s test.
DISASSEMBLY
(1) Remove the bol ts hol di ng the reacti on shaft
support to the oi l pump (Fi g. 89).
(2) Remove the reacti on shaft support from the oi l
pump (Fi g. 89).
(3) Remove al l bol ts hol di ng the oi l pump hal ves
together (Fi g. 89).
(4) Usi ng sui tabl e pryi ng tool s, separate the oi l
pump secti ons by i nserti ng the tool s i n the suppl i ed
areas and pryi ng the hal ves apart.
NOTE: The oil pump halves are aligned to each
other through the use of two dowels. Be sure to pry
upward evenly to prevent damage to the oil pump
components.
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - VALVE BODY
(5) Remove the screws hol di ng the separator pl ate
onto the oi l pump body (Fi g. 90).
(6) Remove the separator pl ate from the oi l pump
body (Fi g. 90).
(7) Mark al l gears for l ocati on. The gears are
sel ect fi t and i f the oi l pump i s to be reused, the
gears must be returned to thei r ori gi nal l ocati ons.
(8) Remove the oi l pump gears from the oi l pump
case (Fi g. 90).
(9) Remove the oi l pump val ve retai ners and asso-
ci ated val ve and spri ng one at a ti me (Fi g. 91) (Fi g.
92). Mark the combi nati on of components as a group
and tag them as to the l ocati on from whi ch they were
removed.
CLEANING
INSPECTION
severel y worn.
Fig. 90 Oil Pump Housing and Gears
1 - SEPARATOR PLATE 5 - DOWEL (2)
2 - DRIVEN GEAR (2) 6 - DRIVE GEAR
3 - CHECK VALVE 7 - SCREW
4 - PUMP HOUSING
heavi l y worn, scored or damaged. I t i s not necessary to
repl ace the bushi ngs unl ess they are actual l y damaged.
ni cks, or scores. Mi nor surface scratches on steel val ves
and pl ugs can be removed wi th crocus cl oth but do not
round off the edges of the valve or plug lands.
Mai ntai ni ng sharpness of these edges i s vi tal l y
i mportant. The edges prevent forei gn matter from
l odgi ng between the val ves and pl ugs and the bore.
I nspect al l the val ve and pl ug bores i n the oi l pump
cover. Use a penl i ght to vi ew the bore i nteri ors. Repl ace
the oi l pump i f any bores are di storted or scored.
I nspect al l of the val ve spri ngs. The spri ngs must be
free of di storti on, warpage or broken coi l s.
ASSEMBLY
(1) Cl ean and i nspect al l components. Make sure
that al l passages are thoroughl y cl eaned and are free
from di rt or debri s. Make sure that al l val ves move
freel y i n thei r proper bore. Make sure that al l gear
pockets and bushi ngs are free from excessi ve wear
and scori ng. Repl ace the oi l pump i f any excessi ve
wear or scori ng i s found.
(2) Coat the gears wi th Mopar ATF +4, type
9602, and i nstal l i nto thei r ori gi nal l ocati ons.
(3) Lubri cate the oi l pump val ves wi th Mopar
ATF +4, type 9602, and i nstal l the val ve, spri ng and
retai ner i nto the appropri ate oi l pump val ve body
bore (Fi g. 91) (Fi g. 92).
(4) Pl ace the separator pl ate onto the oi l pump
body (Fi g. 90).
(5) I nstal l the screws to hol d the separator pl ate
onto the oi l pump body (Fi g. 90). Ti ghten the screws
to 4.5 Nm (40 i n.l bs.).
(6) Posi ti on the oi l pump cover onto the l ocati ng
dowel s (Fi g. 89).
(7) Seat the two oi l pump hal ves together and
i nstal l al l bol ts fi nger ti ght.
(8) Torque al l bol ts down sl owl y starti ng i n the
center and worki ng outward. The correct torque i s
4.5 Nm (40 i n.l bs.).
(9) Veri fy that the oi l pump gears rotate freel y and
smoothl y.
(10) Posi ti on the reacti on shaft support i nto the oi l
pump (Fi g. 89).
Fig. 91 Oil Pump Valve Body
1 - T/C REGULATOR VALVE
2 - T/C LIMIT VALVE
3 - REGULATOR VALVE
4 - OIL PUMP VALVE BODY
Fig. 92 T/C Switch Valve
1 - RETAINER
2 - T/C SWITCH VALVE
3 - OIL PUMP VALVE BODY
(11) I nstal l and torque the bol ts to hol d the reac-
ti on shaft support to the oi l pump (Fi g. 89). The cor-
rect torque i s 12 Nm (105 i n.l bs.).
OIL PUMP FRONT SEAL
REMOVAL
(1) Remove transmi ssi on from the vehi cl e.
(2) Remove the torque converter from the trans-
mi ssi on.
(3) Usi ng a screw mounted i n a sl i de hammer,
remove the oi l pump front seal .
INSTALLATION
(1) Cl ean seal bore of the oi l pump of any resi due
or parti cl es from the ori gi nal seal .
(2) I nstal l new oi l seal i n the oi l pump housi ng
usi ng Seal I nstal l er C-3860-A (Fi g. 93).
OUTPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors are two-wi re
magneti c pi ckup devi ces that generate AC si gnal s as
rotati on occurs. They are mounted i n the l eft si de of
the transmi ssi on case and are consi dered pri mary
i nputs to the Transmi ssi on Control Modul e (TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
Transmi ssi on gear rati o
Speed rati o error detecti on
CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
Torque converter cl utch sl i ppage
Torque converter el ement speed rati o
REMOVAL
transmi ssi on.
(3) Remove the wi ri ng connector from the output
speed sensor (Fi g. 94).
(4) Remove the bol t hol di ng the output speed sen-
sor to the transmi ssi on case.
(5) Remove the output speed sensor from the
INSTALLATION
(1) I nstal l the output speed sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the output speed sensor
Nm (105 i n.l bs.).
Fig. 93 Install Oil Pump Front Seal
1 - TOOL C-3860-A
Fig. 94 Output Speed Sensor
(3) I nstal l the wi ri ng connector onto the output
speed sensor
necessary.
OVERDRIVE SWITCH
DESCRIPTION
the shi ft l ever arm (Fi g. 95). The swi tch i s a momen-
tary contact devi ce that si gnal s the PCM to toggl e
current status of the overdri ve functi on.
OPERATION
control modul e.
REMOVAL
OUTPUT SPEED SENSOR (Continued)
INSTALLATION
to grasp i t.
tor (Fi g. 98)
the shi ft l ever.
the shi ft l ever.
PISTONS
DESCRIPTION
seal s.
OPERATION
equal areas.
PRESSURE
Pressure (Fi g. 99) i s nothi ng more than force (l bs.)
di vi ded by area (i n or ft.), or force per uni t area.
Gi ven a 100 l b. bl ock and an area of 100 sq. i n. on
the fl oor, the pressure exerted by the bl ock i s: 100
the contai ner.
PISTON TRAVEL
PISTONS (Continued)
PLANETARY GEARTRAIN
DESCRIPTION
The pl anetary geartrai n i s l ocated behi nd the 4C
retai ner/bul khead, toward the rear of the transmi s-
si on. The pl anetary geartrai n consi sts of three pri -
mary assembl i es:
Reacti on (Fi g. 103).
Reverse (Fi g. 104).
I nput (Fi g. 104).
OPERATION
REACTION PLANETARY GEARTRAIN
The reacti on pl anetary carri er and reverse sun
gear of the reacti on pl anetary geartrai n are a si ngl e
component whi ch i s hel d by the 2C cl utch when
requi red. The reacti on annul us gear i s a stand al one
component that can be dri ven by the reverse cl utch
or hel d by the 4C cl utch. The reacti on sun gear i s
dri ven by the overdri ve cl utch.
REVERSE PLANETARY GEARTRAIN
The reverse pl anetary geartrai n i s the mi ddl e of
the three pl anetary sets. The reverse pl anetary car-
ri er can be dri ven by the overdri ve cl utch as
requi red. The reverse pl anetary carri er i s al so
spl i ned to the i nput annul us gear, whi ch can be hel d
by the l ow/reverse cl utch. The reverse pl anetary
annul us, i nput pl anetary carri er, and output shaft
are al l one pi ece.
INPUT PLANETARY GEARTRAIN
The i nput sun gear of the i nput pl anetary
geartrai n i s dri ven by the underdri ve cl utch.
Fig. 103 Reaction Planetary Geartrain
DISASSEMBLY
(1) Remove the snap-ri ng hol di ng the i nput annu-
l us i nto the i nput carri er (Fi g. 105).
(2) Remove the i nput annul us from the i nput car-
ri er (Fi g. 105).
(3) Remove the number 9 beari ng from the reverse
pl anetary carri er. Note that thi s pl anetary carri er
has four pi ni on gears.
(4) Remove the reverse pl anetary gear carri er (Fi g.
105).
sun gear (Fi g. 105).
(6) Remove the i nput sun gear from the i nput car-
ri er (Fi g. 105).
carri er (Fi g. 105).
CLEANING
Cl ean the pl anetary components i n sol vent and dry
them wi th compressed ai r.
INSPECTION
Check sun gear and dri vi ng shel l condi ti on.
Repl ace the gear i f damaged or i f the bushi ngs are
scored or worn. The bushi ngs are not servi ceabl e.
Repl ace the dri vi ng shel l i f worn, cracked or dam-
aged.
Repl ace pl anetary gear sets i f gears, pi ni on pi ns, or
carri er are damaged i n any way. Repl ace the annul us
gears and supports i f ei ther component i s worn or
damaged.
Repl ace the output shaft i f the machi ned surfaces
are scored, pi tted, or damaged i n any way. Al so
repl ace the shaft i f the spl i nes are damaged, or
exhi bi ts cracks at any l ocati on.
ASSEMBLY
or scori ng.
(2) I nstal l the number 11 beari ng i nto the i nput
pl anetary carri er wi th the fl at si de up and faci ng for-
ward (Fi g. 105).
Fig. 104 Reverse/Input Planetary Geartrain
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
PLANETARY GEARTRAIN (Continued)
(3) I nstal l the i nput sun gear i nto the i nput carri er
(Fi g. 105).
(4) I nstal l the number 10 beari ng onto the rear of
the reverse pl anetary carri er wi th the fl at si de
toward the carri er (Fi g. 105).
(5) I nstal l the number 9 beari ng onto the front of
the reverse pl anetary carri er wi th the rounded si de
toward the carri er and the fl at si de faci ng upward
(Fi g. 105).
(6) I nstal l the reverse pl anetary gear carri er i nto
the i nput carri er (Fi g. 105).
(7) I nstal l the i nput annul us gear i nto the i nput
carri er (Fi g. 105).
(8) I nstal l the snap-ri ng to hol d the i nput annul us
gear i nto the i nput carri er (Fi g. 105).
SHIFT MECHANISM
DESCRIPTION
ti ons whi ch are:
Park (P)
Reverse (R)
Neutral (N)
Dri ve (D)
Manual second (2)
Manual l ow (1)
OPERATION
MANUAL LOW (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range.
MANUAL SECOND (2) range provi des fi rst and sec-
ond gear onl y.
DRI VE range provi des FI RST, SECOND THI RD
and OVERDRI VE FOURTH gear ranges. The shi ft
i nto OVERDRI VE FOURTH gear range occurs onl y
after the transmi ssi on has compl eted the shi ft i nto D
THI RD gear range. No further movement of the shi ft
mechani sm i s requi red to compl ete the 3-4 shi ft.
The FOURTH gear upshi ft occurs automati cal l y
when the overdri ve sel ector swi tch i s i n the ON posi -
ti on. No upshi ft to FOURTH gear wi l l occur i f any of
the fol l owi ng are true:
Fig. 105 Reverse/Input Planetary Carrier Assembly
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
PLANETARY GEARTRAIN (Continued)
C (50 F) or above 121 C (250 F).
The shi ft to THI RD i s not yet compl ete.
DESCRIPTION
The Sol enoi d Swi tch Val ve (SSV) i s l ocated i n the
val ve body and control s the di recti on of the transmi s-
si on fl ui d when the L/R-TCC sol enoi d i s energi zed.
OPERATION
The Sol enoi d Swi tch Val ve control s l i ne pressure
from the LR-TCC sol enoi d. I n 1st gear, the SSV wi l l
be i n the downshi fted posi ti on, thus di recti ng fl ui d to
the L/R cl utch ci rcui t. I n 2nd, 3rd, and 4th, the sol e-
noi d swi tch val ve wi l l be i n the upshi fted posi ti on
and di rects the fl ui d i nto the torque converter cl utch
(TCC) ci rcui t.
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement i nto
the downshi fted posi ti on. The L/R pressure swi tch i s
moni tored to confi rm SSV movement. I f the move-
ment i s not confi rmed (the L/R pressure swi tch does
not cl ose), 2nd gear i s substi tuted for 1st. A DTC wi l l
be set after three unsuccessful attempts are made to
get i nto 1st gear i n one gi ven key start.
SOLENOIDS
DESCRIPTION
coi l or
OPERATION
spri ng pressure.
SHIFT MECHANISM (Continued)
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 106) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The con-
verter cl utch engages i n thi rd gear. The torque con-
verter hub dri ves the transmi ssi on oi l (fl ui d) pump
and contai ns an o-ri ng seal to better control oi l fl ow.
is contaminated, flush the fluid cooler and lines.
1 - TURBINE ASSEMBLY
2 - STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
IMPELLER
Fig. 107 Impeller
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 - ENGINE ROTATION
TURBINE
Fig. 108 Turbine
STATOR
pi ston wi th fri cti on materi al was added to the tur-
bi ne assembl y to provi de thi s mechani cal l ock-up.
I n order to reduce heat bui l d-up i n the transmi s-
si on and buffer the powertrai n agai nst torsi onal
vi brati ons, the TCM can duty cycl e the L/R-CC Sol e-
noi d to achi eve a smooth appl i cati on of the torque
converter cl utch. Thi s functi on, referred to as El ec-
troni cal l y Modul ated Converter Cl utch (EMCC) can
occur at vari ous ti mes dependi ng on the fol l owi ng
vari abl es:
Shi ft l ever posi ti on
Current gear range
Transmi ssi on fl ui d temperature
Engi ne cool ant temperature
I nput speed
Throttl e angl e
Engi ne speed
2 - ROLLER
3 - SPRING
4 - INNER RACE
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
OPERATION
TURBINE
STATOR
cl ockwi se di recti on. When thi s happens the over-run-
I n a standard torque converter, the i mpel l er and
turbi ne are rotati ng at about the same speed and the
stator i s freewheel i ng, provi di ng no torque mul ti pl i -
cati on. By appl yi ng the turbi nes pi ston and fri cti on
materi al to the front cover, a total converter engage-
ment can be obtai ned. The resul t of thi s engagement
i s a di rect 1:1 mechani cal l i nk between the engi ne
and the transmi ssi on.
The cl utch can be engaged i n second, thi rd, and
fourth gear ranges dependi ng on overdri ve control
swi tch posi ti on. I f the overdri ve control swi tch i s i n
the normal ON posi ti on, the cl utch wi l l engage after
Fig. 112 Torque Converter Fluid Operation - Typical
the shi ft to fourth gear, and above approxi matel y 72
km/h (45 mph). I f the control swi tch i s i n the OFF
posi ti on, the cl utch wi l l engage after the shi ft to
thi rd gear, at approxi matel y 56 km/h (35 mph) at
l i ght throttl e.
The TCM control s the torque converter by way of
i nternal l ogi c software. The programmi ng of the soft-
ware provi des the TCM wi th control over the L/R-CC
Sol enoi d. There are four output l ogi c states that can
be appl i ed as fol l ows:
No EMCC
Parti al EMCC
Ful l EMCC
Gradual -to-no EMCC
NO EMCC
Under No EMCC condi ti ons, the L/R Sol enoi d i s
OFF. There are several condi ti ons that can resul t i n
NO EMCC operati ons. No EMCC can be i ni ti ated
due to a faul t i n the transmi ssi on or because the
TCM does not see the need for EMCC under current
dri vi ng condi ti ons.
PARTIAL EMCC
Parti al EMCC operati on modul ates the L/R Sol e-
noi d (duty cycl e) to obtai n parti al torque converter
cl utch appl i cati on. Parti al EMCC operati on i s mai n-
tai ned unti l Ful l EMCC i s cal l ed for and actuated.
Duri ng Parti al EMCC some sl i p does occur. Parti al
EMCC wi l l usual l y occur at l ow speeds, l ow l oad and
l i ght throttl e si tuati ons.
FULL EMCC
Duri ng Ful l EMCC operati on, the TCM i ncreases
the L/R Sol enoi d duty cycl e to ful l ON after Parti al
EMCC control bri ngs the engi ne speed wi thi n the
desi red sl i p range of transmi ssi on i nput speed rel a-
ti ve to engi ne rpm.
GRADUAL-TO-NO EMCC
Thi s operati on i s to soften the change from Ful l or
Parti al EMCC to No EMCC. Thi s i s done at mi d-
throttl e by decreasi ng the L/R Sol enoi d duty cycl e.
REMOVAL
from vehi cl e.
transmission.
mi ssi on.
INSTALLATION
Check converter hub and dri ve fl ats for sharp
fl ats wi th 320/400 gri t paper or crocus cl oth i f neces-
sary. Veri fy that the converter hub o-ri ng i s properl y
i nstal l ed and i s free from debri s. The hub must be
smooth to avoi d damagi ng the pump seal at i nstal l a-
ti on.
fl ui d.
si on.
CAUTION: Do not damage oil pump seal or con-
verter hub o-ring while inserting torque converter
into the front of the transmission.
i ng.
pump gears.
2 - FRONT OF ENGINE
shoul d be at l east 13 mm (1/2 i n.) to rear of strai ght-
edge when converter i s ful l y seated.
fl ui d.
TRANSMISSION CONTROL
RELAY
DESCRIPTION
The rel ay i s suppl i ed fused B+ vol tage, energi zed
by the TCM, and i s used to suppl y power to the sol e-
noi d pack when the transmi ssi on i s i n normal oper-
ati ng mode.
OPERATION
When the rel ay i s off, no power i s suppl i ed to the
sol enoi d pack and the transmi ssi on i s i n l i mp-i n
mode. After a control l er reset, the TCM energi zes the
rel ay. Pri or to thi s, the TCM veri fi es that the con-
tacts are open by checki ng for no vol tage at the
swi tched battery termi nal s. After thi s i s veri fi ed, the
vol tage at the sol enoi d pack pressure swi tches i s
checked. After the rel ay i s energi zed, the TCM mon-
i tors the termi nal s to veri fy that the vol tage i s
greater than 3 vol ts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) i s mounted
to the top of the val ve body i nsi de the transmi ssi on.
The Transmi ssi on Range Sensor (TRS) has si x
swi tch contacts that:
Determi ne shi ft l ever posi ti on
Suppl y ground to the Starter Rel ay i n Park and
Neutral onl y.
Suppl y ground to the TCM for backup l amp con-
trol i n Reverse onl y.
The TRS al so has an i ntegrated temperature sen-
sor (thermi stor) that communi cates transmi ssi on
temperature to the TCM and PCM.
OPERATION
The Transmi ssi on Range Sensor (TRS) communi -
cates shi ft l ever posi ti on to the TCM as a combi na-
ti on of open and cl osed swi tches. Each shi ft l ever
posi ti on has an assi gned combi nati on of swi tch states
(open/cl osed) that the TCM recei ves from four sense
ci rcui ts. The TCM i nterprets thi s i nformati on and
determi nes the appropri ate transmi ssi on gear posi -
ti on and shi ft schedul e.
There are many possi bl e combi nati ons of open and
cl osed swi tches (codes). Seven of these possi bl e codes
are rel ated to gear posi ti on and fi ve are recogni zed
as between gear codes. Thi s resul ts i n many codes
whi ch shoul d never occur. These are cal l ed
i nval i d codes. An i nval i d code wi l l resul t i n a DTC,
and the TCM wi l l then determi ne the shi ft l ever
posi ti on based on pressure swi tch data. Thi s al l ows
reasonabl y normal transmi ssi on operati on wi th a
TRS fai l ure.
GEAR C5 C4 C3 C2 C1
Park CL OP OP CL CL
Temp 1 CL OP OP CL OP
Reverse OP OP OP CL OP
Temp 2 OP OP CL CL OP
Neutral 1 OP OP CL CL CL
Neutral 2 OP CL CL CL CL
Temp 3 OP CL CL CL OP
Drive OP CL CL OP OP
Temp 4 OP CL OP OP OP
Manual 2 CL CL OP OP OP
Temp 5 CL OP OP OP OP
Manual 1 CL OP CL OP OP
Fig. 114 Checking Torque Converter Seating-Typical
1 - SCALE
2 - STRAIGHTEDGE
TRANSMISSION SOLENOID/
TRS ASSEMBLY
DESCRIPTION
The transmi ssi on sol enoi d/TRS assembl y i s i nter-
nal to the transmi ssi on and mounted on the val ve
body assembl y (Fi g. 115). The assembl y consi sts of
si x sol enoi ds that control hydraul i c pressure to the
si x fri cti on el ements (transmi ssi on cl utches), and the
torque converter cl utch. The pressure control sol e-
noi d i s l ocated on the si de of the sol enoi d/TRS assem-
bl y. The sol enoi d/TRS assembl y al so contai ns fi ve
pressure swi tches that feed i nformati on to the TCM.
OPERATION
SOLENOIDS
Sol enoi ds are used to control the L/R, 2C, 4C, OD,
and UD fri cti on el ements. The reverse cl utch i s con-
trol l ed by l i ne pressure and the posi ti on of the man-
ual val ve i n the val ve body. Al l the sol enoi ds are
contai ned wi thi n the Sol enoi d and Pressure Swi tch
Assembl y. The sol enoi d and pressure swi tch assembl y
contai ns one addi ti onal sol enoi d, Mul ti -Sel ect (MS),
whi ch serves pri mari l y to provi de 2nd and 3rd gear
l i mp-i n operati on.
The sol enoi ds recei ve el ectri cal power from the
Transmi ssi on Control Rel ay through a si ngl e wi re.
The TCM energi zes or operates the sol enoi ds i ndi vi d-
ual l y by groundi ng the return wi re of the sol enoi d as
necessary. When a sol enoi d i s energi zed, the sol enoi d
val ve shi fts, and a fl ui d passage i s opened or cl osed
(vented or appl i ed), dependi ng on i ts defaul t operat-
i ng state. The resul t i s an appl y or rel ease of a fri c-
ti onal el ement.
The MS and UD sol enoi ds are normal l y appl i ed to
al l ow transmi ssi on l i mp-i n i n the event of an el ectri -
cal fai l ure.
The conti nui ty of the sol enoi ds and ci rcui ts are
peri odi cal l y tested. Each sol enoi d i s turned on or off
dependi ng on i ts current state. An i nducti ve spi ke
shoul d be detected by the TCM duri ng thi s test. I f no
spi ke i s detected, the ci rcui t i s tested agai n to veri fy
the fai l ure. I n addi ti on to the peri odi c testi ng, the
sol enoi d ci rcui ts are tested i f a speed rati o or pres-
sure swi tch error occurs.
PRESSURE SWITCHES
The TCM rel i es on fi ve pressure swi tches to moni -
tor fl ui d pressure i n the L/R, 2C, 4C, UD, and OD
hydraul i c ci rcui ts. The pri mary purpose of these
swi tches i s to hel p the TCM detect when cl utch ci r-
cui t hydraul i c fai l ures occur. The swi tches cl ose at 23
psi and open at 11 psi , and si mpl y i ndi cate whether
or not pressure exi sts. The swi tches are conti nuousl y
moni tored by the TCM for the correct states (open or
cl osed) i n each gear as shown i n the fol l owi ng chart:
GEAR L/R 2C 4C UD OD
R OP OP OP OP OP
P/N CL OP OP OP OP
1ST CL* OP OP CL OP
2ND OP CL OP CL OP
2ND
PRIME
OP OP CL CL OP
D OP OP OP CL CL
FOURTH OP OP CL OP CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
A Di agnosti c Troubl e Code (DTC) wi l l set i f the
TCM senses any swi tch open or cl osed at the wrong
ti me i n a gi ven gear.
Fig. 115 Transmission Solenoid/TRS Assembly
1 - PRESSURE CONTROL SOLENOID
3 - 23-WAY CONNECTOR
4 - SOLENOID PACK
REMOVAL
(1) Remove the val ve body from the transmi ssi on
(Fi g. 116).
(2) Remove the screws hol di ng the transmi ssi on
sol enoi d/TRS assembl y onto the val ve body (Fi g. 117).
(3) Separate the transmi ssi on sol enoi d/TRS assem-
bl y from the val ve body.
INSTALLATION
(1) Pl ace TRS sel ector pl ate i n the PARK posi ti on.
(2) Posi ti on the transmi ssi on sol enoi d/TRS assem-
bl y onto the val ve body. Be sure that both al i gnment
dowel s are ful l y seated i n the val ve body and that
the TRS swi tch contacts are properl y posi ti oned i n
the sel ector pl ate
(3) I nstal l the screws to hol d the transmi ssi on
sol enoi d/TRS assembl y onto the val ve body.
(4) Ti ghten the sol enoi d assembl y screws adjacent
to the arrows cast i nto the bottom of the val ve body
fi rst. Ti ghten the screws to 5.7 Nm (50 i n.l bs.).
(5) Ti ghten the remai nder of the sol enoi d assembl y
screws to 5.7 Nm (50 i n.l bs.).
(6) I nstal l the val ve body i nto the transmi ssi on.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
The transmi ssi on temperature sensor i s a ther-
mi stor that i s i ntegral to the Transmi ssi on Range
Sensor (TRS).
OPERATION
The transmi ssi on temperature sensor i s used by
the TCM to sense the temperature of the fl ui d i n the
sump. Si nce fl ui d temperature can affect transmi s-
si on shi ft qual i ty and convertor l ock up, the TCM
requi res thi s i nformati on to determi ne whi ch shi ft
schedul e to operate i n.
Calculated Temperature
A fai l ure i n the temperature sensor or ci rcui t wi l l
resul t i n cal cul ated temperature bei ng substi tuted for
actual temperature. Cal cul ated temperature i s a pre-
di cted fl ui d temperature whi ch i s cal cul ated from a
combi nati on of i nputs:
Battery (ambi ent) temperature
Engi ne cool ant temperature
I n-gear run ti me si nce start-up
Fig. 116 Valve Body Bolts
Fig. 117 Ttransmission Solenoid/TRS Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)
VALVE BODY
DESCRIPTION
body, a separator pl ate, and a transfer pl ate. The
val ve body contai ns val ves and check bal l s that con-
trol fl ui d del i very to the torque converter cl utch,
bands, and fri cti onal cl utches. The val ve body con-
tai ns the fol l owi ng components (Fi g. 118) and (Fi g.
119):
Sol enoi d swi tch val ve
Manual val ve
Low/reverse swi tch val ve
5 Accumul ators
7 check bal l s
Fig. 118 Valve Body Components
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
5 - SOLENOID SWITCH VALVE
Fig. 119 Check Ball Locations
OPERATION
and design.
The Sol enoi d Swi tch Val ve (SSV) control s the di rec-
ti on of the transmi ssi on fl ui d when the L/R-TCC sol e-
noi d i s energi zed.
The Sol enoi d Swi tch Val ve control s l i ne pressure
from the LR-TCC sol enoi d. I n 1st gear, the SSV wi l l
be i n the downshi fted posi ti on, thus di recti ng fl ui d to
the L/R cl utch ci rcui t. I n 2nd, 3rd, and 4th gears, the
sol enoi d swi tch val ve wi l l be i n the upshi fted posi ti on
and di rects the fl ui d i nto the torque converter cl utch
(TCC) ci rcui t.
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement i nto
the downshi fted posi ti on. The L/R pressure swi tch i s
moni tored to confi rm SSV movement. I f the move-
ment i s not confi rmed (the L/R pressure swi tch does
not cl ose), 2nd gear i s substi tuted for 1st. A DTC wi l l
be set after three unsuccessful attempts are made to
get i nto 1st gear i n one gi ven key start.
MANUAL VALVE
The manual val ve i s a rel ay val ve. The purpose of
the manual val ve i s to di rect fl ui d to the correct ci r-
cui t needed for a speci fi c gear or dri vi ng range. The
manual val ve, as the name i mpl i es, i s manual l y oper-
ated by the dri ver wi th a l ever l ocated on the top of
the val ve body. The val ve i s connected mechani cal l y
by a cabl e to the gearshi ft mechani sm. The val ve i s
hel d i n each of i ts posi ti ons by a rol l er detent spri ng
(Fi g. 120) that engages the roostercomb of the TRS
sel ector pl ate.
LOW/REVERSE SWITCH VALVE
The l ow/reverse swi tch val ve al l ows the l ow/reverse
cl utch to be operated by ei ther the LR/CC sol enoi d or
the MS sol enoi d.
REMOVAL
and i nspecti on of the i ndi vi dual components. (Refer
to 21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C
- 45RFE/VALVE BODY - DI SASSEMBLY)
(3) Di sconnect wi res at the sol enoi d and pressure
swi tch assembl y connector.
(5) Remove transmi ssi on oi l pan.
(6) Remove the pri mary oi l fi l ter from val ve body.
(Fi g. 121)
Fig. 120 TRS Selector Plate and Detent Spring
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
Fig. 121 Remove Primary Oil Filter
4 - VALVE BODY
(8) Lower the val ve body and work the el ectri cal
connector out of transmi ssi on case.
(9) Separate the val ve body from the transmi ssi on.
DISASSEMBLY
(1) Remove the screws hol di ng the sol enoi d and
pressure swi tch assembl y to the val ve body (Fi g.
123). Do not remove the screws on the top of the sol e-
noi d and pressure swi tch assembl y.
(2) Separate the sol enoi d and pressure swi tch
assembl y from the val ve body.
(3) Remove the screw hol di ng the detent spri ng
(Fi g. 124) onto the val ve body.
(4) Remove the detent spri ng from the val ve body.
(5) Remove the TRS sel ector pl ate from the val ve
body and the manual val ve.
(6) Remove the cl utch passage seal s from the val ve
body, i f necessary.
Fig. 122 Valve Body Bolts
Fig. 123 Solenoid and Pressure Switch Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
Fig. 124 Valve Body External Components
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
(7) Remove the screws hol di ng the accumul ator
cover onto the val ve body (Fi g. 125).
(8) Remove the accumul ator spri ngs and pi stons
from the val ve body. Note whi ch accumul ator pi ston
and spri ng bel ong i n each l ocati on.
(9) Pl ace the val ve body on the bench wi th the
transfer pl ate upward.
NOTE: The valve body contains seven check balls.
The transfer plate must be placed upward to pre-
vent losing the check balls when the transfer plate
is removed from the valve body.
(10) Remove the screws hol di ng the val ve body to
the val ve body transfer pl ate.
(11) Remove the transfer pl ate from the val ve
body. Note the l ocati on of al l check bal l s (Fi g. 126).
(12) Remove the check bal l s from the val ve body.
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
Fig. 126 Check Ball Locations
(13) Remove the retai ners securi ng the sol enoi d
swi tch val ve, manual val ve, and the l ow/reverse
swi tch val ve i nto the val ve body and remove the
associ ated val ve and spri ng. Tag each val ve and
spri ng combi nati on wi th l ocati on i nformati on to ai d
i n assembl y. (Fi g. 127)
CLEANING
type of causti c sol uti on. (Fi g. 128)
cl eani ng sol uti on. Cl ean the el ectri cal components by
wi pi ng them off wi th dry shop towel s onl y.
INSPECTION
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
2 - MANUAL VALVE
3 - LOW REVERSE SWITCH VALVE
4 - LOW REVERSE ACCUMULATOR
5 - 2ND CLUTCH ACCUMULATOR
6 - UNDERDRIVE ACCUMULATOR
7 - OVERDRIVE ACCUMULATOR
8 - 4TH CLUTCH ACCUMULATOR
9 - CHECK BALLS (7)
2 - MANUAL VALVE
9 - CHECK BALLS (7)
I nspect the val ves and pl ugs (Fi g. 129) for
scratches, burrs, ni cks, or scores. Mi nor surface
scratches on steel val ves and pl ugs can be removed
wi th crocus cl oth but do not round off the edges
of the valve or plug lands. Mai ntai ni ng sharpness
of these edges i s vi tal l y i mportant. The edges prevent
forei gn matter from l odgi ng between the val ves and
pl ugs and the bore.
coi l s.
dl i ng.
I nspect al l the accumul ator bores i n the val ve body.
Use a penl i ght to vi ew the bore i nteri ors. Repl ace the
val ve body i f any bores are di storted or scored.
I nspect al l of the accumul ator spri ngs. The spri ngs
must be free of di storti on, warpage or broken coi l s.
I nspect al l the fl ui d seal s on the val ve body (Fi g.
130). Repl ace any seal s that are cracked, di storted, or
damaged i n any way. These seal s pass fl ui d pressure
di rectl y to the cl utches. Any pressure l eak at these
poi nts, may cause transmi ssi on performance prob-
l ems.
ASSEMBLY
val ve bores wi th cl ean transmi ssi on fl ui d.
(2) I nstal l sol enoi d swi tch val ve, manual val ve,
and the l ow/reverse swi tch val ve i nto the val ve body.
(3) I nstal l the retai ners to hol d each val ve i nto the
val ve body.
(4) I nstal l the val ve body check bal l s i nto thei r
proper l ocati ons.
(5) Posi ti on the transfer pl ate onto the val ve body.
2 - MANUAL VALVE
9 - CHECK BALLS (7)
Fig. 130 Valve Body Seals
1 - UNDERDRIVE ACCUMULATOR (2 SPRINGS)
2 - 4TH CLUTCH ACCUMULATOR (2 SPRINGS)
3 - 2ND CLUTCH ACCUMULATOR (2 SPRINGS)
4 - LOW REVERSE ACCUMULATOR (2 SPRINGS)
5 - LOW/REVERSE PASSAGE SEAL
6 - 2ND CLUTCH PASSAGE SEAL
7 - 4TH CLUTCH PASSAGE SEAL
8 - OVERDRIVE ACCUMULATOR (1 SPRING)
(6) I nstal l the screws to hol d the transfer pl ate to
the val ve body. Ti ghten the screws to 5.6 Nm (50 i n.
l bs.).
(7) I nstal l the accumul ator pi stons and spri ngs
i nto the val ve body i n the l ocati on from whi ch they
were removed. Note that al l accumul ators except the
overdri ve have two spri ngs. The overdri ve accumul a-
tor pi ston has onl y one spri ng.
(8) Posi ti on the accumul ator cover onto the val ve
body.
(9) I nstal l the screws to hol d the accumul ator
cover onto the val ve body. Ti ghten the screws to 4.5
Nm (40 i n. l bs.).
(10) I nstal l the TRS sel ector pl ate onto the val ve
body and the manual val ve.
(11) I nstal l the sol enoi d and pressure swi tch
assembl y onto the val ve body.
(12) I nstal l the screws to hol d the sol enoi d and
pressure swi tch assembl y onto the val ve body.
Ti ghten the screws to 5.7 Nm (50 i n. l bs.). Ti ghten
the screws adjacent to the arrows cast i nto the bot-
tom of the transfer pl ate fi rst.
(13) Posi ti on the detent spri ng onto the val ve body.
(14) I nstal l the screw to hol d the detent spri ng
onto the val ve body. Ti ghten the screw to 4.5 Nm (40
i n. l bs.).
(15) I nstal l new cl utch passage seal s onto the
val ve body, i f necessary
INSTALLATION
(1) Check condi ti on of seal s on val ve body and the
sol enoi d and pressure swi tch assembl y. Repl ace seal s
i f cut or worn.
(2) Pl ace TRS sel ector pl ate i n the PARK posi ti on.
(3) Pl ace the transmi ssi on i n the PARK posi ti on.
(4) Lubri cate seal on the sol enoi d and pressure
swi tch assembl y connector wi th petrol eum jel l y.
(5) Posi ti on val ve body i n transmi ssi on and al i gn
the manual l ever on the val ve body to the pi n on the
transmi ssi on manual shi ft l ever.
(6) Seat val ve body i n case and i nstal l one or two
bol ts to hol d val ve body i n pl ace.
(7) Ti ghten val ve body bol ts al ternatel y and evenl y
fi l ter screws to 4.5 Nm (40 i n. l bs.) torque.
(9) Connect the sol enoi d and pressure swi tch
assembl y connector.
(10) I nstal l oi l pan. Ti ghten pan bol ts to 12 Nm
(12) Check and adjust gearshi ft cabl e, i f necessary.
TRANSFER CASE - NV233
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 537
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
TRANSFER CASE - NV233. . . . . . . . . . . . . . . 538
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 540
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 558
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 559
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 559
FLUID
FLUID DRAIN AND REFILL. . . . . . . . . . . . . . . 561
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 561
MODE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 562
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
REAR RETAINER BUSHING AND SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 563
SELECTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 564
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
SHIFT MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 565
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 566
DESCRIPTION
The NV233 i s an el ectroni cal l y control l ed part-ti me
transfer case wi th a l ow range gear reducti on system.
The NV233 has three operati ng ranges pl us a NEU-
TRAL posi ti on. The l ow range system provi des a gear
reducti on rati o for i ncreased l ow speed torque capa-
bi l i ty.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
2WD (2-wheel dri ve)
4HI (4-wheel dri ve)
4LO (4-wheel dri ve l ow range)
NEUTRAL
The 2WD range i s for use on any road surface at
any ti me.
The 4HI and 4LO ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4LO range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a dash
mounted shi ft sel ector swi tch. The shi ft sel ector
swi tch provi des a i nput to the Transfer Case Control
Modul e (TCCM) to i ndi cate the dri vers desi re to
change operati ng ranges. The TCCM uses thi s i nput,
al ong wi th i nput from the transfer case mounted
mode sensor and i nformati on from the vehi cl es bus,
to determi ne i f a shi ft i s permi tted. I f the TCCM
deci des the shi ft i s permi tted, the TCCM control s the
shi ft motor, mounted to the exteri or of the transfer
case, to perform the shi ft.
AN TRANSFER CASE - NV233 21 - 537
IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range sl eeve.
The front output shaft i s operated by a dri ve chai n
that connects the shaft to a dri ve sprocket on the
mai nshaft. The dri ve sprocket i s engaged/di sengaged
by the mode fork, whi ch operates the mode sl eeve
and hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV233
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Transfer case electronically
controlled shift system malfunction.
1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.
2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with
the correct quantity of Mopar ATF
+4, type 9602, Automatic
Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.
4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
Transmission Fluid.
damaged.
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
21 - 538 TRANSFER CASE - NV233 AN
TRANSFER CASE - NV233 (Continued)
Condition Possible Cause Correction
Transfer case noisy while in, or
jumps out of, 4LO mode.
1) Transfer case not completely
engaged in 4LO position.
1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
necessary.
3) Low range gear worn or
damaged.
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4HI mode
on dry surfaces,
1) Operate vehicle in 2WD mode on
dry surfaces.
REMOVAL
(1) Shi ft transfer case i nto 2WD.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shafts for al i gn-
ment reference.
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember and ski d pl ate, i f
equi pped.
(7) Di sconnect front and rear propel l er shafts at
transfer case.
(8) Di sconnect transfer case shi ft motor and mode
sensor wi re connectors.
(9) Di sconnect transfer case vent hose.
(11) Secure transfer case to jack wi th chai ns.
(12) Remove nuts attachi ng transfer case to trans-
(13) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(14) Remove transfer case from under vehi cl e.
Fig. 2 Transfer Case Mounting - Typical
1 - MOUNTING STUDS
2 - TRANSFER CASE
3 - TRANSMISSION
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
REAR RETAINER AND OIL PUMP
(1) Remove extensi on housi ng bol ts.
(2) Tap extensi on housi ng wi th pl asti c or rawhi de
mal l et to l oosen seal er (Fi g. 3).
(3) Separate extensi on housi ng from rear retai ner.
(4) Remove rear beari ng snap-ri ng (Fi g. 4).
(5) Remove bol ts hol di ng rear retai ner to rear case
hal f.
(6) Loosen rear retai ner wi th pry tool to break
seal er bead. Pry onl y agai nst retai ner boss as shown
(Fi g. 5).
(7) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y (Fi g. 6).
(8) Remove pi ck-up tube o-ri ng from oi l pump (Fi g.
7), i f necessary. Do not di sassembl e the oi l pump, i t
i s not servi ceabl e.
Fig. 3 Remove Extension Housing
1 - EXTENSION HOUSING
2 - PLASTIC HAMMER
3 - REAR RETAINER
Fig. 4 Remove Rear Bearing Snap-Ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Fig. 5 Loosening Rear Retainer
1 - REAR RETAINER
2 - TAB (2)
3 - SCREWDRIVER
4 - TAB
1 - OIL PUMP
COMPANION FLANGE AND SHIFT MOTOR
ASSEMBLY
(1) Remove front compani on fl ange nut wi th a
socket and i mpact wrench
(2) Remove the front compani on fl ange. I f the
fl ange i s di ffi cul t to remove by hand, remove i t wi th
beari ng spl i tter, or wi th standard two jaw pul l er. Be
sure pul l er tool i s posi ti oned on the fl ange and not on
the sl i nger, as sl i nger wi l l be damaged.
(3) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(4) Remove the bol ts (Fi g. 8) whi ch hol d the shi ft
motor and mode sensor assembl y to the transfer
case.
(5) Remove the shi ft motor and mode sensor
assembl y from the transfer case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case.
The case al i gnment bol ts requi re fl at washers (Fi g.
9).
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert pry tool bl ade onl y i nto
notches provi ded at each end of case (Fi g. 10).
(4) Remove rear case from front case.
Fig. 7 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
Fig. 8 Remove the Shift Motor and Mode Sensor
Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
Fig. 9 Rear Case Alignment Bolt Locations
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 10 Loosening Rear Case
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
(5) Remove oi l pi ckup tube from rear case (Fi g.
11).
(6) Remove mode fork spri ng (Fi g. 12).
(7) Pul l front output shaft upward and out of front
output shaft beari ng (Fi g. 13).
(8) Remove front output shaft and chai n.
SHIFT FORKS AND MAINSHAFT
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 14).
(2) Remove mai nshaft from mode sl eeve and i nput
gear pi l ot beari ng.
Fig. 11 Oil Pickup Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
Fig. 12 Mode Fork Spring Removal
1 - MODE SPRING
Fig. 13 Remove Front Output Shaft And Drive Chain
1 - DRIVE CHAIN
2 - FRONT OUTPUT SHAFT
3 - SHAFT FRONT BEARING
Fig. 14 Detent Plug, Spring, And Plunger Removal
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
(3) Remove mode fork and sl eeve as an assembl y
(Fi g. 15). Note posi ti on of sl eeve for assembl y refer-
ence. The short si de of the sl eeve faces upward.
(4) Remove range fork and hub as an assembl y
(Fi g. 16). Note fork posi ti on for i nstal l ati on reference.
(5) Remove shi ft sector from front case (Fi g. 17).
(6) Remove shi ft sector o-ri ng (Fi g. 18).
Fig. 15 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 16 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 17 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 18 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
MAINSHAFT
(1) Remove mode hub retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 19).
(2) Sl i de mode hub off mai nshaft (Fi g. 20).
(3) Sl i de dri ve sprocket off mai nshaft (Fi g. 21).
INPUT GEAR AND LOW RANGE GEAR
(1) Remove front beari ng retai ner attachi ng bol ts
(Fi g. 22).
Fig. 22 Front Bearing Retainer Bolts
1 - FRONT CASE
3 - RETAINER BOLTS
Fig. 19 Mode Hub Retaining Ring Removal
1 - MODE HUB
2 - SNAP-RING PLIERS (HEAVY DUTY)
3 - MODE HUB RETAINING RING
Fig. 20 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 21 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
(2) Remove front beari ng retai ner. Pry retai ner
l oose wi th pry tool posi ti oned i n sl ots at each end of
(3) Remove front beari ng retai ner seal . Tap seal
out wi th dri ft and hammer.
(4) Remove i nput gear retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 24)
(5) Pl ace front case i n hori zontal posi ti on. Then
remove i nput gear and l ow range gear as an assem-
bl y (Fi g. 25). Tap gear out of beari ng wi th pl asti c
mal l et i f necessary.
INPUT AND LOW RANGE GEAR
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 26).
Fig. 26 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 23 Front Bearing Retainer Removal
2 - RETAINER SLOT
Fig. 24 Removing Input Gear Retaining Ring
1 - INPUT GEAR BEARING RETAINING RING
2 - INPUT GEAR BEARING
Fig. 25 Input Gear And Planetary Carrier Removal
1 - INPUT AND LOW RANGE GEAR ASSEMBLY
(2) Remove retai ner (Fi g. 27).
(3) Remove front tabbed thrust washer (Fi g. 28).
(4) Remove i nput gear (Fi g. 29).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 30).
CLEANING
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and
3M al l purpose cl eaner. Use compressed ai r to
remove sol vent resi due from oi l feed passages i n the
case hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket (Fi g. 31). Mi nor ni cks and
scratches can be smoothed wi th an oi l stone. However,
repl ace any part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320-400 gri t emery cl oth but do not
try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 32). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
Fig. 27 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 28 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 29 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 30 Rear Tabbed Thrust Washer
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
beari ng surface on the gear can be smoothed wi th
300-400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for wear
or cracks. Repl ace them i f necessary. Al so repl ace the
l ock retai ni ng ri ng i f bent, di storted, or broken.
Fig. 31 Mainshaft, Mode Hub, And Drive Sprocket
1 - MODE HUB 3 - MAINSHAFT
2 - DRIVE SPROCKET 4 - MODE HUB RETAINING RING
Fig. 32 Input Gear and Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 33). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320-400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 34). The
mode and range fork pads are servi ceabl e and can be
repl aced i f necessary.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER AND EXTENSION HOUSING
I nspect the retai ner components. Repl ace the bear-
i ng i f rough or noi sy. Check the retai ner for cracks or
wear i n the beari ng bore. Cl ean the retai ner seal i ng
surfaces wi th a scraper and 3M al l purpose
cl eaner. Thi s wi l l ensure proper adhesi on of the
seal er duri ng reassembl y.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended.
I nspect the extensi on housi ng seal and bushi ng.
Repl ace both components i f ei ther show any si gn of
wear or damage.
FRONT OUTPUT SHAFT/FLANGE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces on the
compani on fl ange sl i nger. Thi s surface must be cl ean
and smooth to ensure proper seal l i fe. Repl ace the
fl ange nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320-400 gri t emery to
smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 35)
FRONT/REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Repl ace the i nput retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai n-
l ess steel i nserts i f requi red.
Fig. 33 Shift Forks
1 - RANGE FORK
3 - MODE SPRING
Fig. 34 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ASSEMBLY
Lubri cate transfer case components wi th Mopar
ATF +4, type 9602, Automati c Transmi ssi on Fl ui d or
petrol eum jel l y (where i ndi cated) duri ng assembl y.
BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
wi th pry tool (Fi g. 36).
(2) Remove beari ng retai ni ng ri ng wi th screw-
dri ver (Fi g. 37).
Fig. 37 Front Output Shaft Bearing Retaining Ring
Removal
1 - SCREWDRIVERS
2 - SNAP-RING
3 - FRONT OUTPUT SHAFT BEARING
4 - FRONT CASE
Fig. 36 Front Output Seal Removal - Typical
1 - OUTPUT SHAFT SEAL
2 - PRY TOOL
Fig. 35 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
(3) Remove beari ng wi th Tool Handl e C-4171 and
Tool 5065 (Fi g. 38).
(4) I nstal l front output shaft front beari ng i n case
wi th Tool Handl e C-4171 and I nstal l er 5064 (Fi g. 39).
(5) I nstal l output shaft front beari ng retai ni ng
ri ng (Fi g. 40). Start ri ng i nto pl ace by hand. Then
use smal l screwdri ver to work ri ng i nto case groove.
Be sure ri ng i s ful l y seated before proceedi ng.
(6) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143-A as fol l ows:
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 41). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
Fig. 38 Front Output Shaft Bearing Removal
1 - FRONT CASE
Fig. 39 Front Output Shaft Bearing Installation
Fig. 40 Installing Front Output Shaft Bearing
Retaining Ring
1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL
SCREWDRIVER
Fig. 41 Front Output Seal Installation - Typical
1 - INSTALLER 8143-A
2 - TRANSFER CASE
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 42).
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 43). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 44).
Fig. 42 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
Fig. 43 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 44 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case (Fi g. 45).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 46).
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 47).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 5065
and Handl e C-4171 (Fi g. 48).
Fig. 45 Input Shaft Bearing Removal
Fig. 46 Seating Input Shaft Bearing
1 - SNAP-RING
Fig. 47 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 48 Install Input Gear Pilot Bearing
3 - INPUT GEAR
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
(16) I nstal l new front beari ng retai ner wi th
(17) Remove seal from oi l pump housi ng wi th a
sui tabl e pry tool
(18) I nstal l new seal i n oi l pump housi ng wi th
(19) Remove rear retai ner beari ng wi th I nstal l er
(20) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 51).
INPUT AND LOW RANGE GEAR
(1) Lubri cate gears and thrust washers (Fi g. 52)
wi th recommended transmi ssi on fl ui d.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 52). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
Fig. 49 Install Front Bearing Retainer Seal
Fig. 50 Oil Pump Seal Installation
1 - HOUSING SEAL
3 - OIL PUMP FEED HOUSING
Fig. 51 Installing Rear Bearing In Retainer
3 - REAR RETAINER
INPUT GEAR AND LOW RANGE GEAR
(1) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 53). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
(2) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 54).
(3) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(4) Appl y a 3 mm (1/8 i n.) bead of MoparGasket
Maker, or equi val ent si l i cone adhesi ve, to seal i ng
surface of retai ner.
(5) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Mopar Gas-
ket Maker, or equivalent silicone adhesive sealer.
Seal failure and fluid leak can result.
(6) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 55). Ti ghten to 16-25 Nm (12-18 ft. l bs.) of
torque.
Fig. 52 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 53 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
Fig. 54 Install Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 55 Install Front Bearing Retainer
MAINSHAFT
(1) Lubri cate mai nshaft spl i nes wi th recommended
(2) Sl i de dri ve sprocket onto mai nshaft.
(3) Sl i de mode hub onto mai nshaft.
(4) I nstal l mode hub retai ni ng ri ng. Veri fy that the
retai ni ng ri ng i s ful l y seated i n mai nshaft groove.
(1) I nstal l new sector shaft O-ri ng.
(2) I nstal l shi ft sector i n case (Fi g. 56). Lubri cate
sector shaft wi th transmi ssi on fl ui d before i nstal l a-
ti on.
(3) Assembl e and i nstal l range fork and hub (Fi g.
57). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
(4) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
(5) I nstal l assembl ed mai nshaft (Fi g. 58). Be sure
shaft i s seated i n pi l ot beari ng and i nput gear.
(6) I nstal l new pads on mode fork i f necessary.
(7) I nsert mode sl eeve i n mode fork mode fork. Be
sure l ong si de of sl eeve i s toward l ong end of shi ft
rai l (Fi g. 59).
Fig. 56 Shift Sector Installation
1 - SHIFT SECTOR
Fig. 57 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 58 Mainshaft Assembly Installation
1 - DRIVE SPROCKET
2 - MODE HUB
3 - MAINSHAFT
Fig. 59 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
(8) I nstal l assembl ed mode fork and sl eeve (Fi g.
60). Be sure fork rai l goes through range fork and
i nto case bore. Al so be sure sl eeve i s al i gned and
seated on mai nshaft hub.
(9) Rotate sector to NEUTRAL posi ti on.
(10) I nstal l new O-ri ng on detent pl ug (Fi g. 61).
(11) Lubri cate detent pl unger wi th transmi ssi on
fl ui d or l i ght coat of petrol eum jel l y.
(12) I nstal l detent pl unger, spri ng and pl ug (Fi g.
61).
(13) Veri fy that pl unger i s properl y engaged i n sec-
tor.
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n and dri ve sprocket wi th transmi ssi on fl ui d.
(2) Assembl e dri ve chai n and front output shaft
(Fi g. 62).
(3) Start chai n on mai nshaft dri ve sprocket.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 62).
(5) I nstal l mode spri ng on upper end of mode fork
shi ft rai l (Fi g. 63).
Fig. 60 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
Fig. 61 Shift Detent Components
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
Fig. 62 Installing Drive Chain And Front Output Shaft
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE SPROCKET
Fig. 63 Install Mode Fork Spring
1 - MODE SPRING
OIL PUMP AND REAR CASE
(1) I nstal l magnet i n front case pocket (Fi g. 64).
(2) Assembl e oi l pi ckup screen, connecti ng hose,
and tube.
(3) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 65).
(4) I nsert oi l pi ckup tube i n oi l pump i nl et.
(5) Posi ti on assembl ed oi l pump and pi ckup tube
i n rear case. Be sure pi ckup screen i s securel y seated
i n case sl ot. Al so be sure oi l pump l ocati ng tabs are
outsi de rear case (Fi g. 66).
(6) Appl y 3 mm (1/8 i n.) wi de bead of MoparGas-
ket Maker, or equi val ent si l i cone adhesi ve seal er, to
mounti ng fl ange of front case. Work seal er bead
around bol t hol es.
(7) Li ft rear case and oi l pump and careful l y posi -
ti on assembl y on front case. Be sure case dowel s are
al i gned and that mode fork rai l extends through rear
case before seati ng rear case on front case.
(8) I nstal l case attachi ng bol ts. Al i gnment bol ts at
each end of case are onl y ones requi ri ng washers
(Fi g. 67).
(9) Ti ghten case bol ts to 27-34 Nm (20-25 ft. l bs.)
torque.
COMPANION FLANGE AND SHIFT MOTOR AND
MODE SENSOR ASSEMBLY
(1) Posi ti on the shi ft motor and mode sensor
assembl y onto the transfer case.
(2) I nstal l the bol ts to hol d the shi ft motor and
mode sensor assembl y to the transfer case. Ti ghten
the bol ts to 16-25 Nm (12-18 ft. l bs.) torque.
Fig. 64 Installing Case Magnet
1 - MAGNET
Fig. 65 Pickup Tube O-Ring Position
1 - OIL PUMP
2 - O-RING
Fig. 66 Oil Pump And Pickup Tube Installation
1 - OIL PUMP
2 - PICKUP TUBE
3 - PICKUP SCREEN AND CONNECTOR
Fig. 67 Alignment Bolt Location
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
Mopar Lock & Seal or Loctite 242 to replenish
the lock patch material originally found on the bolts
(3) I nstal l new seal washer onto the front output
shaft (Fi g. 68).
(4) Lubri cate the compani on fl ange hub wi th
transmi ssi on fl ui d and i nstal l the fl ange onto the
front output shaft.
(5) I nstal l a new compani on fl ange nut onto the
front output shaft.
(6) Ti ghten the fl ange nut to 122-176 Nm (90-130
ft. l bs.) torque. Use Tool 6958, or si mi l ar tool to hol d
fl ange whi l e ti ghteni ng nut.
REAR RETAINER
mounti ng surface of rear retai ner. Al l ow seal er to
set-up sl i ghtl y before proceedi ng.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 27-34 Nm (20-25 ft. l bs.).
(3) I nstal l new output shaft beari ng snap-ri ng
(Fi g. 69). Li ft mai nshaft sl i ghtl y to seat snap-ri ng i n
shaft groove, i f necessary.
mounti ng surface of extensi on housi ng. Al l ow seal er
to set-up sl i ghtl y before proceedi ng.
(5) I nstal l extensi on housi ng on rear retai ner.
(6) I nstal l extensi on housi ng bol ts and ti ghten to
27-34 Nm (20-25 ft. l bs.).
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case onto the transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 27-34 Nm (20-25 ft. l bs.) torque.
(6) Connect the vent hose.
(7) Connect the shi ft motor and mode sensor wi r-
i ng connectors. Secure wi re harness to cl i ps on trans-
fer case.
(8) Al i gn and connect the propel l er shafts.
(9) Fi l l transfer case wi th correct fl ui d. (Refer to
21 - TRANSMI SSI ON/TRANSAXLE/TRANSFER
CASE/FLUI D - STANDARD PROCEDURE)
(10) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts to 41 Nm (30
ft. l bs.) torque.
(11) Remove transmi ssi on jack and support stand.
(12) Lower vehi cl e and veri fy transfer case shi ft
operati on.
Fig. 68 Yoke Seal Washer Installation
1 - YOKE SEAL WASHER
Fig. 69 Install Output Bearing Snap-Ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
SPECIFICATIONS
SPECIFICATIONS - TRANSFER CASE - NV233
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 16-25 12-18 -
Bolt, Case Half 27-34 20-25 -
Nut, Companion Flange 122-176 90-130 -
Bolt, Shift motor and
Mode Sensor Assembly
16-25 12-18 -
Bolt, Rear Retainer 27-34 20-25 -
Bolt, Extension Housing 27-34 20-25 -
Nut, Mounting 27-34 20-25 -
SPECIAL TOOLS
Installer, Seal - 8143-A
Installer, Seal - D-163
Installer, Seal - C-4210
Installer, Bushing5066
Remover - L-4454
Cup - 8148
Installer, Pump Housing Seal - 7888
Wrench, Spanner - 6958
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 70).
(2) Posi ti on drai n pan under transfer case.
(3) Remove drai n and fi l l pl ugs and drai n l ubri -
cant compl etel y.
(4) I nstal l drai n pl ug. Ti ghten pl ug to 41-54 Nm
(30-40 ft. l bs.).
(5) Remove drai n pan.
(6) Fi l l transfer case to bottom edge of fi l l pl ug
openi ng wi th Mopar ATF +4, type 9602, Automati c
Transmi ssi on fl ui d.
(7) I nstal l and ti ghten fi l l pl ug to 41-54 Nm
(30-40 ft. l bs.).
REMOVAL
(2) Remove front propel l er shaft. (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove front output shaft compani on fl ange.
(4) Remove seal from front case wi th sui tabl e pry
tool (Fi g. 71).
INSTALLATION
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
pi ng seal i nto bore unti l i nstal l er tool seats agai nst
case.
(2) I nstal l the front output shaft compani on fl ange.
Ti ghten the fl ange nut to 122-176 Nm (90-130
ft.l bs.).
(3) I nstal l the front propel l er shaft. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/PROPELLER
Fig. 70 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 71 Remove Front Output Shaft Seal - Typical
2 - PRY TOOL
Fig. 72 Front Output Shaft Seal Installation - Typical
2 - TRANSFER CASE
MODE SENSOR
DESCRIPTION
The transfer case mode sensor (Fi g. 73) i s an el ec-
troni c devi ce whose output can be i nterpreted to i ndi -
cate the shi ft motor shafts rotary posi ti on. The
sensor consi sts of a magneti c ri ng and four Hal l
Effect Transi stors to create a 4 channel di gi tal devi ce
(non-contacti ng) whose output converts the motor
shaft posi ti on i nto a coded si gnal . The TCCM must
suppl y 5VDC (+/- 0.5v) to the sensor and moni tor the
shi ft motor posi ti on. The four channel s are denoted
A, B, C, and D. The sensor i s mechani cal l y l i nked to
the shaft of the cam whi ch causes the transfer case
shi fti ng. The mode sensor draws l ess than 53 mA.
OPERATION
Duri ng normal vehi cl e operati on, the Transfer Case
Control Modul e (TCCM) moni tors the mode sensor
outputs at l east every 250 (+/-50) mi l l i seconds when
the shi ft motor i s stati onary and 400 mi croseconds
when the shi ft motor i s acti ve. A mode sensor si gnal
between 3.8 Vol ts and 0.8 Vol ts i s consi dered to be
undefi ned.
Refer to for the rel ati ve angl es of the transfer case
shi ft sector versus the i nterpreted transfer case gear
operati ng mode. Refer to for the sensor codes
returned to the TCCM for each transfer case mode
sensor posi ti on. The vari ous between gears posi ti ons
can al so be referred as the transfer cases coarse
posi ti on. These coarse posi ti ons come i nto pl ay dur-
i ng shi ft attempts.
SECTOR ANGLES VS. TRANSFER CASE POSITION
Shaft Angle (Degrees) Transfer Case Position
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
MODE SENSOR CODES
Transfer Case
Angle (degrees)
Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
Between Gears H H L H
+40 (4LO) H H L L
Between Gears H L L H
+20 (NEUTRAL) H L L L
Between Gears H L H H
0 (2WD/AWD) H L H L
Between Gears L L H H
-20 (4HI) L L H L
Between Gears L H H H
Fig. 73 Mode Sensor
1 - TRANSFER CASE MODE SENSOR
REAR RETAINER BUSHING
AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. (Refer to 3 - DI F-
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 8158, remove the bushi ng from
rear retai ner (Fi g. 74).
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
(3) Usi ng I nstal l er 8157, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 75).
(4) Usi ng I nstal l er D-163, i nstal l seal i n rear
(5) I nstal l the rear propel l er shaft. (Refer to 3 -
(6) Veri fy proper fl ui d l evel .
Fig. 74 Rear Retainer Bushing Removal
1 - REMOVER 8158
2 - REAR RETAINER BUSHING
Fig. 75 Rear Retainer Bushing Installation
2 - INSTALLER 8157
Fig. 76 Install Rear Retainer Seal
2 - SPECIAL TOOL D-163
SELECTOR SWITCH
DESCRIPTION
The sel ector swi tch assembl y (Fi g. 77) i s mounted
i n the vehi cl e I nstrument Panel (I P) and consi sts of a
rotary knob connected to a resi sti ve network for the
mode and range shi ft sel ecti ons. Al so l ocated i n thi s
assembl y i s a recessed, normal l y open momentary
swi tch for maki ng shi fts i nto and out of transfer case
NEUTRAL. A pen, or si mi l ar i nstrument, i s used to
make a NEUTRAL shi ft sel ecti on, thus reduci ng the
l i kel i hood of an i nadvertent shi ft request.
The sel ector swi tch al so contai ns four l i ght emi t-
ti ng di odes (LEDs) to i ndi cate the transfer case posi -
ti on and whether a shi ft i s i n progress.
OPERATION
As the posi ti on of the sel ector swi tch vari es, the
resi stance between the Mode Sensor suppl y vol tage
pi n and the Mode Sensor output wi l l vary. Hardware,
software, and cal i brati ons wi thi n the Transfer Case
Control Modul e (TCCM) are provi ded that i nterpret
the sel ector swi tch resi stance as gi ven i n the tabl e
bel ow:
SELECTOR SWITCH INTERPRETATION
Step Resistance
Range (ohms)
Required
Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4H
E 3050-5950 2WD/AWD
(Default)
F 9.5-12.5K In between
positions
G >15.5K Open
For resi stances between the ranges B-E shown for
each val i d posi ti on (T-Case NEUTRAL, 4LO, 4HI ,
2WD/AWD), the TCCM may i nterpret the resi stance
as:
ei ther of the nei ghbori ng val i d posi ti ons.
as an i nval i d faul t posi ti on.
For resi stances between the ranges E and F shown
for AWD/2WD and i n-between posi ti ons, the TCCM
may i nterpret the resi stance as:
the AWD/2WD posi ti on.
an i nval i d faul t posi ti on.
a val i d i n-between posi ti on.
For resi stances between the ranges F and G shown
for i n-between posi ti ons and faul t condi ti on (open),
the TCCM may i nterpret the resi stance as:
For resi stances between the ranges A and B shown
for the faul t condi ti on (short) and , T-Case NEU-
TRAL, the TCCM may i nterpret the resi stance as:
the T-Case NEUTRAL posi ti on.
The LEDs i n the sel ector assembl y are i l l umi nat-
ed/fl ashed i n the fol l owi ng manner to i ndi cate a par-
ti cul ar condi ti on or state.
A sol i dl y i l l umi nated LED i ndi cates a success-
ful l y compl eted shi ft and the current operati ng mode
of the transfer case. Whi l e a shi ft has been requested
but not yet compl eted, the LED for the source trans-
fer case posi ti on remai ns sol i dl y i l l umi nated.
A fl ashi ng operati ng mode LED for the desi red
gear i ndi cates that a shi ft to that posi ti on has been
requested, but al l of the dri ver control l abl e condi ti ons
have not been met. Thi s i s i n an attempt to noti fy
the dri ver that the transmi ssi on needs to be put i nto
NEUTRAL, the vehi cl e speed i s too great, or some
other condi ti on outl i ned (other than a di agnosti c fai l -
ure that woul d prevent thi s shi ft) above i s not met.
Note that thi s fl ashi ng wi l l conti nue i ndefi ni tel y
unti l the condi ti ons are eventual l y met, or the sel ec-
Fig. 77 Selector Switch
1 - TRANSFER CASE MODE SELECTOR SWITCH
tor swi tch posi ti on i s changed, or i f di agnosti c rou-
ti nes no l onger al l ow the requested shi ft.
I f the dri ver attempts to make a shi ft i nto trans-
fer case NEUTRAL, and any of the dri ver control l a-
bl e condi ti ons are not met, the request wi l l be
i gnored unti l al l of the condi ti ons are met or unti l
the NEUTRAL sel ect button i s rel eased. Addi ti onal l y
the neutral l amp wi l l fl ash, or begi n to fl ash whi l e
the button i s depressed and operator control l abl e
condi ti ons are not bei ng met. Al l of the LEDs except
the Neutral wi l l fl ash i f any of the operator control -
l abl e condi ti ons for shi fti ng are not met whi l e the
Neutral button i s depressed. Thi s toggl e type of fea-
ture i s necessary because the TCCM woul d i nterpret
another request i mmedi atel y after the shi ft i nto
transfer case NEUTRAL has compl eted.
No LEDs i l l umi nated i ndi cate a faul t i n the
transfer case control system.
SHIFT MOTOR
DESCRIPTION
The shi ft motor (Fi g. 78) consi sts of a permanent
magnet D.C. motor wi th gear reducti on to convert a
hi gh speed-l ow torque devi ce i nto a l ow speed-hi gh
torque devi ce. The output of the devi ce i s coupl ed to
a shaft whi ch i nternal l y moves the mode and range
forks that change the transfer case operati ng ranges.
The motor i s rated at 25 amps maxi mum at 72 F
wi th 10 vol ts at the motor l eads.
OPERATION
The transfer case shi ft motor responds to the
Transfer Case Control Modul e (TCCM) commands to
move the transfer case shi ft sector bi -di recti onal l y, as
requi red, to obtai n the transfer case operati ng mode
i ndi cated by the i nstrument panel mounted sel ector
swi tch.
REMOVAL
(1) Rai se the vehi cl e on a sui tabl e hoi st.
(2) Remove the front propel l er shaft. (Refer to 3 -
SHAFT/PROPELLER SHAFT - REMOVAL)
(3) Di sengage the wi ri ng connectors from the shi ft
motor and mode sensor.
(4) Remove the front output shaft compani on
fl ange from the transfer case.
(5) Remove the bol ts (Fi g. 79) hol di ng the shi ft
motor and mode sensor assembl y onto the transfer
case.
(6) Separate the shi ft motor and mode sensor
Fig. 78 Shift Motor - Shown Inverted
1 - TRANSFER CASE SHIFT MOTOR
Assembly Bolts
1 - TRANSFER CASE
3 - BOLT
SELECTOR SWITCH (Continued)
INSTALLATION
(1) Veri fy that the shi ft sector o-ri ng i s cl ean and
properl y posi ti oned over the shi ft sector and agai nst
the transfer case.
(3) I nstal l the bol ts (Fi g. 80) to hol d the assembl y
onto the transfer case. Ti ghten the bol ts to 16-24
Nm (12-18 ft.l bs.).
(4) Engage the wi ri ng connectors to the shi ft motor
and mode sensor.
(5) I nstal l the transfer case front output shaft
compani on fl ange onto the transfer case. Ti ghten the
fl ange nut to 122-176 Nm (90-130 ft.l bs.).
(7) Refi l l the transfer case as necessary.
(8) Lower vehi cl e and veri fy transfer case opera-
ti on.
Fig. 80 Install the Shift Motor and Mode Sensor
Assembly Bolts
1 - TRANSFER CASE
3 - BOLT
SHIFT MOTOR (Continued)
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 567
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
TRANSFER CASE - NV244. . . . . . . . . . . . . . . 568
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 570
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 593
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 593
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 594
FLUID
FLUID DRAIN AND REFILL. . . . . . . . . . . . . . . 595
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 596
MODE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 596
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
REAR RETAINER BUSHING AND SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 598
SELECTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 599
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
SHIFT MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 600
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 601
DESCRIPTION
The NV244 i s an el ectroni cal l y control l ed ful l and
part-ti me transfer case wi th no two wheel dri ve oper-
ati on.
A di fferenti al i n the transfer case i s used to control
torque transfer to the front and rear axl es. A l ow
range gear reducti on system provi des i ncreased l ow
speed torque capabi l i ty for off road operati on. The
l ow range provi des a 2.72:1 reducti on rati o.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
NV244 operati ng ranges are:
AWD(Al l -Wheel Dri ve)
4HI (Part-ti me)
4LO
NEUTRAL
The AWD mode can be used at any ti me and on
any road surface.
The 4HI (Part-ti me) and 4LO ranges are for off
road use onl y. The onl y ti me these ranges can be
used i s when the road surface i s covered wi th snow,
i ce, or other l oose sl i ppery materi al .
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a dash
mounted shi ft sel ector swi tch. The shi ft sel ector
swi tch provi des a i nput to the Transfer Case Control
Modul e (TCCM) to i ndi cate the dri vers desi re to
change operati ng ranges. The TCCM uses thi s i nput,
al ong wi th the i nput from the transfer case mounted
mode sensor and i nformati on from the vehi cl es bus,
to determi ne i f a shi ft i s permi tted. I f the TCCM
deci des the shi ft i s permi tted, the TCCM control s the
shi ft motor, mounted to the exteri or of the transfer
case, to perform the shi ft.
IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range sl eeve.
The front output shaft i s operated by a dri ve chai n
that connects the shaft to a dri ve sprocket on the
mai nshaft. The dri ve sprocket i s engaged/di sengaged
by the mode fork, whi ch operates the mode sl eeve
and hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV244
DIAGNOSIS CHART
Transfer case difficult to shift or will
not shift into desired range.
1) Transfer case electronically
controlled shift system malfunction.
1) Verify proper operation per the
appropriate diagnostic manual.
Transmission Fluid.
damaged.
necessary.
Transfer case noisy in all drive
modes.
Transmission Fluid.
damaged.
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Transfer case noisy while in, or
jumps out of, 4LO.
1) Transfer case not completely
engaged in 4LO position.
1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or the
clutch depressed on vehicles
equipped with a manual
transmission, shift the transfer case
to the AWD or 4HI position, and
then back into the 4LO position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
necessary.
3) Low range gear worn or
damaged.
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
3) Replace suspect seal.
Transfer case will not shift through
4HI (Part-time) range.
1) Incomplete shift due to drivetrain
torque load.
1) Drive in a straight line and
momentarily release the accelerator
pedal to complete the shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
REMOVAL
(1) Shi ft transfer case i nto AWD.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shafts for al i gn-
ment reference.
(5) Di sconnect front and rear propel l er shafts at
transfer case.
(6) Support transmi ssi on wi th jack stand.
(7) Remove rear crossmember and ski d pl ate, i f
equi pped.
(8) Di sconnect transfer case shi ft motor and mode
sensor wi re connectors.
(9) Di sconnect transfer case vent hose.
(12) Remove nuts attachi ng transfer case to trans-
(13) Pul l transfer case and jack rearward to di sen-
gage transfer case from the transmi ssi on adapter
housi ng and output shaft.
(14) Remove transfer case from under vehi cl e.
Fig. 2 Transfer Case Mounting - Typical
1 - MOUNTING STUDS
2 - TRANSFER CASE
3 - TRANSMISSION
DISASSEMBLY
COMPANION FLANGE AND SHIFT MOTOR
ASSEMBLY
(1) Remove front compani on fl ange nut wi th a
socket and i mpact wrench
(2) Remove the front compani on fl ange. I f the
fl ange i s di ffi cul t to remove by hand, remove i t wi th
beari ng spl i tter, or wi th standard two jaw pul l er. Be
sure pul l er tool i s posi ti oned on the fl ange and not on
the sl i nger, as sl i nger wi l l be damaged.
(3) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(4) Remove the bol ts (Fi g. 3) whi ch hol d the shi ft
case.
(5) Remove the shi ft motor and mode sensor
REAR RETAINER
(1) Remove extensi on housi ng bol ts.
(2) Tap extensi on housi ng wi th pl asti c or rawhi de
mal l et to l oosen seal er (Fi g. 4).
(3) Separate extensi on housi ng from rear retai ner.
(4) Remove rear beari ng snap-ri ng (Fi g. 5).
(5) Remove bol ts hol di ng rear retai ner to rear case
hal f.
Assembly Bolts
1 - TRANSFER CASE
3 - BOLT
Fig. 4 Remove Extension Housing
1 - EXTENSION HOUSING
2 - PLASTIC HAMMER
3 - REAR RETAINER
Fig. 5 Remove the Output Bearing Snap-Ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
(6) Loosen rear retai ner wi th pry tool to break
seal er bead. Pry onl y agai nst retai ner boss as shown
(Fi g. 6).
(7) Remove rear beari ng O.D. retai ni ng ri ng wi th
snap-ri ng pl i ers. Then ti l t pump and sl i de i t off out-
put shaft (Fi g. 7)
(8) Remove pi ckup tube o-ri ng from pump (Fi g. 8)
but do not di sassembl e pump; i t i s not a repai rabl e
part.
(9) Remove seal from oi l pump wi th pry tool .
(10) Remove bol ts attachi ng rear case to front case
(Fi g. 9). Note posi ti on of the two bl ack fi ni sh bol ts at
each end of the case. These bol ts go through the case
dowel s and requi re a washer under the bol t head.
Fig. 6 Loosening Rear Retainer
1 - REAR RETAINER
2 - TAB (2)
3 - SCREWDRIVER
4 - TAB
1 - OIL PUMP
Fig. 8 Pickup Tube O-Ring Location
1 - OIL PUMP
2 - O-RING
Fig. 9 Spline And Dowel Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLT (5)
3 - SPLINE HEAD BOLT (1)
(11) Remove rear case from front case (Fi g. 10).
I nsert screwdri vers i nto sl ots cast i nto each end of
case. Then pry upward to break seal er bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of
either case half as the surfaces will become dam-
aged.
(12) Remove oi l pi ckup tube and screen from rear
case (Fi g. 11).
(1) Remove dri ve sprocket snap-ri ng (Fi g. 12).
(2) Remove dri ve sprocket and chai n (Fi g. 13).
(3) Remove front output shaft (Fi g. 14).
Fig. 10 Loosening/Removing Rear Case
1 - MAINSHAFT
2 - SCREWDRIVER
3 - FRONT CASE
4 - SCREWDRIVER
5 - REAR CASE
Fig. 11 Oil Pickup Screen, Hose And Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
Fig. 12 Drive Sprocket Snap-Ring Removal
1 - DRIVE SPROCKET
2 - DRIVE SPROCKET SNAP-RING
Fig. 13 Drive Sprocket And Chain Removal
2 - DRIVE CHAIN
3 - DRIVE SPROCKET
(1) Remove shi ft detent pl ug, spri ng and pi n (Fi g.
15).
(2) Remove shi ft rai l by pul l i ng i t strai ght up and
out of fork (Fi g. 16).
(3) Remove mode fork and mai nshaft as assembl y
(Fi g. 17).
Fig. 14 Removing Front Output Shaft
Fig. 15 Detent Pin, Spring, And Plug Removal
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
Fig. 16 Shift Rail Removal
1 - SHIFT RAIL
2 - MODE FORK
Fig. 17 Mainshaft And Mode Fork Removal
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
(4) Remove mode shi ft sl eeve and mode fork
assembl y from mai nshaft (Fi g. 18). Note posi ti on of
mode sl eeve i n fork and remove sl eeve.
(5) Remove i ntermedi ate cl utch shaft snap-ri ng
(Fi g. 19).
(6) Remove cl utch shaft thrust ri ng (Fi g. 20).
Fig. 19 Remove the Intermediate Clutch Shaft
Snap-Ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Thrust Ring
1 - CLUTCH SHAFT THRUST RING
Fig. 18 Separate Mode Fork And Sleeve
1 - MAINSHAFT
2 - SLEEVE
3 - MODE FORK ASSEMBLY
(7) Remove i ntermedi ate cl utch shaft (Fi g. 21).
(8) Remove di fferenti al snap-ri ng (Fi g. 22).
(9) Remove di fferenti al (Fi g. 23).
(10) Remove di fferenti al needl e beari ngs and both
needl e beari ng thrust washers from mai nshaft.
(11) Sl i de l ow range fork pi n out of shi ft sector sl ot
(Fi g. 24).
Fig. 22 Remove the Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 23 Remove the Differential
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 24 Disengaging the Low Range Fork
1 - SHIFT SECTOR
2 - LOW RANGE FORK
3 - PIN
4 - SLOT
(12) Remove l ow range fork and hub (Fi g. 25).
(13) Remove shi ft sector.
(14) Remove shi ft sector o-ri ng (Fi g. 26).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Remove front beari ng retai ner bol ts.
(2) Remove front beari ng retai ner. Careful l y pry
retai ner l oose wi th screwdri ver (Fi g. 27). Posi ti on
screwdri ver i n sl ots cast i nto retai ner.
(3) Remove i nput gear snap-ri ng (Fi g. 28).
Fig. 25 Low Range Fork And Hub Removal
1 - LOW RANGE FORK
2 - FORK HUB
Fig. 26 Remove the Shift Sector O-Ring
Fig. 27 Front Bearing Retainer Removal
2 - RETAINER SLOT
Fig. 28 Remove the Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
(4) Remove i nput/l ow range gear assembl y from
beari ng wi th Tool Handl e C-4171 and Tool 7829-A
(Fi g. 29).
(5) Remove l ow range gear snap-ri ng (Fi g. 30).
(6) Remove i nput gear retai ner, thrust washers,
and i nput gear from l ow range gear (Fi g. 31).
(7) I nspect l ow range annul us gear (Fi g. 32). Gear
is not a serviceable component. If damaged,
replace gear and front case as an assembly.
Fig. 29 Input And Low Range Gear Assembly
Removal
1 - INPUT-LOW RANGE GEARS
2 - SPECIAL TOOL 7829-A
Fig. 30 Remove the Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
Fig. 31 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 32 Inspecting Low Range Annulus Gear
(8) Remove oi l seal s from the fol l owi ng compo-
nents:
front beari ng retai ner.
rear retai ner.
oi l pump.
case hal ves.
DIFFERENTIAL
(1) Mark di fferenti al case hal ves for reference.
(2) Remove di fferenti al case bol ts.
(3) I nvert di fferenti al on workbench.
(4) Separate top case from bottom case. Use sl ots
i n case hal ves to pry them apart (Fi g. 33).
(5) Remove thrust washers and pl anet gears from
case pi ns (Fi g. 34).
(6) Remove mai nshaft and sprocket gears from
bottom case (Fi g. 35). Note gear posi ti on for reference
before separati ng them.
Fig. 33 Separating Differential Case Halves
1 - TOP CASE
2 - CASE BOLTS
3 - CASE BOLTS
4 - CASE SLOTS
5 - CASE BOLTS
Fig. 34 Planet Gears And Thrust Washer Removal
1 - BOTTOM CASE
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
Fig. 35 Mainshaft And Sprocket Gear Removal
1 - MAINSHAFT GEAR
2 - SPROCKET GEAR
3 - BOTTOM CASE
CLEANING
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and
3M al l purpose cl eaner. Use compressed ai r to
remove sol vent resi due from oi l feed passages i n the
case hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone. However, repl ace any
part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320-400 gri t emery cl oth but do not
try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 36). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300-400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
Fig. 36 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 37). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320-400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 38). The
mode and range fork pads are servi ceabl e and can be
repl aced i f necessary.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER AND EXTENSION HOUSING
I nspect the retai ner components. Repl ace the bear-
i ng i f rough or noi sy. Check the retai ner for cracks or
wear i n the beari ng bore. Cl ean the retai ner seal i ng
surfaces wi th a scraper and 3M al l purpose
cl eaner. Thi s wi l l ensure proper adhesi on of the
seal er duri ng reassembl y.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended.
I nspect the extensi on housi ng seal and bushi ng.
Repl ace both components i f ei ther show any si gn of
wear or damage.
FRONT OUTPUT SHAFT/FLANGE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces on the
compani on fl ange sl i nger. Thi s surface must be cl ean
and smooth to ensure proper seal l i fe. Repl ace the
fl ange nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320-400 gri t emery to
smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 39)
Fig. 37 Shift Forks
1 - RANGE FORK
3 - MODE SPRING
Fig. 38 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
Fig. 39 Low Range Annulus Gear
1 - FRONT CASE
FRONT/REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Repl ace the i nput retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai n-
l ess steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ASSEMBLY
Lubri cate transfer case components wi th automati c
transmi ssi on fl ui d or petrol eum jel l y (where i ndi -
cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
BEARINGS AND SEALS
(1) Remove snap-ri ng that retai ns front output
shaft front beari ng i n case (Fi g. 40). Then remove
beari ng. Use hammer handl e, or hammer and brass
punch to tap beari ng out of case.
(2) I nstal l new front output shaft front beari ng
wi th Tool Handl e C-4171 and I nstal l er 8033-A wi th
the tapered cone upward (Fi g. 41).
(3) I nstal l front beari ng snap-ri ng (Fi g. 40).
Fig. 40 Front Output Shaft Front Bearing Snap-Ring
Removal
1 - FRONT BEARING SNAP-RING
Fig. 41 Install the Front Output Shaft Front Bearing
2 - SPECIAL TOOL 8033-A
(4) I nstal l new front output shaft oi l seal wi th
I nstal l er 6952-A (Fi g. 42).
(5) Remove i nput shaft beari ng wi th Tool Handl e
C-4171 and Remover C-4210 (Fi g. 43).
(6) I nstal l snap-ri ng on new i nput shaft beari ng.
(7) I nstal l new i nput shaft beari ng wi th Tool Han-
dl e C-4171 and Remover C-4210. I nstal l beari ng far
enough to seat snap-ri ng agai nst case (Fi g. 44).
(8) Remove the i nput gear pi l ot beari ng by i nsert-
i ng a sui tabl y si zed dri ft i nto the spl i ned end of the
i nput gear and dri vi ng the beari ng out wi th the dri ft
and a hammer (Fi g. 45).
Fig. 45 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 42 Install Front Output Shaft Seal - Typical
2 - TRANSFER CASE
Fig. 43 Input Shaft Bearing Removal
Fig. 44 Seating Input Shaft Bearing
1 - SNAP-RING
(9) I nstal l new pi l ot beari ng wi th I nstal l er 8128
and Handl e C-4171 (Fi g. 46).
(10) I nstal l new seal i n front beari ng retai ner wi th
(11) Remove front output shaft rear beari ng wi th
the screw and jaws from Remover L-4454 and Cup
8148 (Fi g. 48).
(12) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 49). Lubri cate beari ng after
i nstal l ati on.
Fig. 46 Install Input Gear Pilot Bearing
1 - HANDLE C-4171
2 - INSTALLER 8128
3 - INPUT GEAR
Fig. 47 Front Bearing Retainer Seal Installation
Fig. 48 Remove Front Output Shaft Rear Bearing
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
Fig. 49 Install Front Output Shaft Rear Bearing
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
(13) I nstal l new seal i n oi l pump feed housi ng wi th
Speci al Tool 7888 (Fi g. 50).
(14) I nstal l new pi ckup tube o-ri ng i n oi l pump
(Fi g. 51).
(15) Remove rear retai ner beari ng wi th Remover
(16) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 52).
DIFFERENTIAL
(1) Lubri cate di fferenti al components wi th auto-
mati c transmi ssi on fl ui d.
(2) I nstal l sprocket gear i n di fferenti al bottom case
(Fi g. 53).
Fig. 50 Oil Pump Seal Installation
1 - HOUSING SEAL
3 - OIL PUMP FEED HOUSING
Fig. 51 Pickup Tube O-Ring Installation
1 - PICKUP TUBE O-RING
Fig. 52 Installing Rear Output Shaft Bearing In
Retainer
3 - REAR RETAINER
Fig. 53 Installing Differential Sprocket Gear
1 - SPROCKET GEAR
2 - BOTTOM CASE
(3) I nstal l di fferenti al pl anet gears and new thrust
washers (Fi g. 54). Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) I nstal l di fferenti al mai nshaft gear (Fi g. 54).
(5) Al i gn and posi ti on di fferenti al top case on bot-
tom case (Fi g. 55). Al i gn usi ng scri be marks made at
di sassembl y.
(6) Whi l e hol di ng di fferenti al case hal ves together,
i nvert the di fferenti al and start the di fferenti al case
bol ts.
(7) Ti ghten di fferenti al case bol ts to speci fi ed
torque.
INPUT GEAR/LOW RANGE
(1) Assembl e l ow range gear, i nput gear thrust
washers, i nput gear and i nput gear retai ner (Fi g. 56).
Fig. 56 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 54 Installing Mainshaft And Planet Gears
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
Fig. 55 Differential Case Assembly
1 - TOP CASE
2 - BOTTOM CASE
3 - CASE ALIGNMENT MARKS
(2) I nstal l l ow range gear snap-ri ng (Fi g. 57).
(3) Lubri cate i nput gear and l ow range gears wi th
automati c transmi ssi on fl ui d.
(4) Start i nput gear shaft i nto front case beari ng.
(5) Press i nput gear shaft i nto front beari ng.
(6) I nstal l new i nput gear snap-ri ng (Fi g. 58).
seal surface of front beari ng retai ner.
(8) I nstal l front beari ng retai ner (Fi g. 59). Ti ghten
retai ner bol ts to 16-25 Nm (12-18 ft. l bs.) torque.
(1) I nstal l new sector shaft o-ri ng (Fi g. 60).
Fig. 57 Install the Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
Fig. 58 Install the Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 59 Installing Front Bearing Retainer
Fig. 60 Install the Shift Sector O-ring
(2) I nstal l shi ft sector.
(3) I nstal l new pads on l ow range fork, i f neces-
sary, (Fi g. 61).
(4) Assembl e l ow range fork and hub (Fi g. 61).
(5) Posi ti on l ow range fork and hub i n case. Be
sure l ow range fork pi n i s engaged i n shi ft sector sl ot
(Fi g. 62).
(6) I nstal l fi rst mai nshaft beari ng spacer on mai n-
shaft (Fi g. 63).
(7) I nstal l beari ng rol l ers on mai nshaft (Fi g. 63).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(8) I nstal l remai ni ng beari ng spacer on mai nshaft
(Fi g. 63). Do not di spl ace any beari ngs whi l e i nstal l -
i ng spacer.
Fig. 61 Assembling Low Range Fork And Hub
1 - LOW RANGE FORK
2 - PADS
3 - HUB
Fig. 62 Positioning Low Range Fork
1 - SHIFT SECTOR
2 - LOW RANGE FORK
3 - PIN
4 - SLOT
Fig. 63 Installing Mainshaft Bearing Rollers and
Spacers
1 - MAINSHAFT BEARING ROLLERS
2 - BEARING SPACERS
(9) I nstal l di fferenti al (Fi g. 64). Do not displace
mainshaft bearings when installing differential.
(10) I nstal l di fferenti al snap-ri ng (Fi g. 65).
(11) I nstal l i ntermedi ate cl utch shaft (Fi g. 66).
(12) I nstal l cl utch shaft thrust ri ng (Fi g. 67).
Fig. 64 Differential Installation
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 65 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 66 Installing Intermediate Clutch Shaft
Fig. 67 Installing Clutch Shaft Thrust Ring
1 - CLUTCH SHAFT THRUST RING
(13) I nstal l cl utch shaft snap-ri ng (Fi g. 68).
(14) I nspect mode fork assembl y (Fi g. 69). Repl ace
pads and bushi ng i f necessary. Repl ace fork tube i f
bushi ngs i nsi de tube are worn or damaged. Al so
check spri ngs and sl i der bracket (Fi g. 69). Repl ace
worn or damaged components.
(15) I nstal l mode sl eeve i n mode fork (Fi g. 70).
Then i nstal l assembl ed sl eeve and fork on mai nshaft.
Be sure mode sl eeve spl i nes are engaged i n di fferen-
ti al spl i nes.
(16) I nstal l mode fork and mai nshaft assembl y i n
case (Fi g. 71). Rotate mai nshaft sl i ghtl y to engage
shaft wi th l ow range gears.
Fig. 68 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
Fig. 69 Mode Fork Assembly Inspection
1 - SLIDER
2 - MODE FORK
3 - BUSHING/SPRING
4 - TUBE
5 - PADS
Fig. 70 Installing Mode Fork And Sleeve
1 - MAINSHAFT
2 - SLEEVE
3 - MODE FORK ASSEMBLY
(17) Rotate mode fork pi n i nto shi ft sector sl ot.
(18) I nstal l shi ft rai l (Fi g. 72). Be sure rail is
seated in both shift forks.
(19) I nstal l detent pl unger, detent spri ng, and
detent pl ug i n case (Fi g. 73).
(1) I nstal l front output shaft (Fi g. 74).
(2) I nstal l dri ve chai n (Fi g. 74). Engage chai n wi th
front output shaft sprocket teeth.
(3) I nstal l dri ve sprocket (Fi g. 74). Engage dri ve
sprocket teeth wi th chai n. Then engage sprocket
spl i nes wi th mai nshaft spl i nes.
Fig. 72 Shift Rail Installation
1 - SHIFT RAIL
2 - MODE FORK
Fig. 71 Assembled Mainshaft And Mode Fork
Installation
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 73 Detent Pin, Spring And Plug Installation
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
Fig. 74 Drive Chain And Sprocket Installation
2 - DRIVE CHAIN
3 - DRIVE SPROCKET
(4) I nstal l dri ve sprocket snap-ri ng (Fi g. 75).
OIL PUMP AND REAR CASE
(1) I nsert oi l pi ckup tube i n oi l pump and attach
oi l screen and connector hose to pi ckup tube. Then
i nstal l assembl ed pump, tube and screen i n rear case
(Fi g. 76). Be sure screen i s seated i n case sl ot as
shown.
(2) Cl ean the transfer case magnet.
(3) I nstal l magnet i n front case pocket (Fi g. 77).
seal surface of front case.
(5) Al i gn and i nstal l rear case on front case. Be
sure case l ocati ng dowel s are i n pl ace and that mai n-
shaft spl i nes are engaged i n oi l pump i nner gear.
(6) I nstal l and ti ghten front case to rear case bol ts
to 27-34 Nm (20-25 ft. l bs.) torque. Be sure to
install a washer under each bolt used at case
dowel locations.
Fig. 75 Drive Sprocket Snap-Ring Installation
1 - DRIVE SPROCKET
2 - DRIVE SPROCKET SNAP-RING
Fig. 76 Oil Screen And Pickup Tube Installation
1 - OIL PUMP
2 - OIL SCREEN
3 - CONNECTOR
4 - PICKUP TUBE
Fig. 77 Installing Case Magnet
1 - MAGNET
REAR RETAINER
(1) I nstal l rear beari ng O.D. retai ni ng ri ng wi th
snap-ri ng pl i ers (Fi g. 78). Be sure retai ni ng ri ng i s
ful l y seated i n retai ner groove.
(2) Appl y bead of Mopar Seal er, or Locti te
Ul tra Gray, to mati ng surface of rear retai ner. Seal er
bead shoul d be a maxi mum of 3/16 i n.
(3) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 27-34 Nm (20-25 ft. l bs.) torque.
(4) I nstal l new output shaft beari ng snap-ri ng
(Fi g. 79). Li ft mai nshaft sl i ghtl y to seat snap-ri ng i n
shaft groove, i f necessary.
mounti ng surface of extensi on housi ng. Al l ow seal er
to set-up sl i ghtl y before proceedi ng.
(6) I nstal l extensi on housi ng on rear retai ner.
(7) I nstal l extensi on housi ng bol ts and ti ghten to
27-34 Nm (20-25 ft. l bs.).
COMPANION FLANGE AND SHIFT MOTOR AND
MODE SENSOR ASSEMBLY
(2) I nstal l the bol ts (Fi g. 80) to hol d the shi ft
case. Ti ghten the bol ts to 16-24 Nm (12-18 ft. l bs.)
torque.
Fig. 78 Rear Bearing Retaining Ring Installation
1 - REAR BEARING O.D. RETAINING RING
Fig. 79 Install Output Bearing Snap-Ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Assembly Bolts
1 - TRANSFER CASE
3 - BOLT
(3) I nstal l new seal washer onto the front output
shaft (Fi g. 81).
(4) Lubri cate the compani on fl ange hub wi th
transmi ssi on fl ui d and i nstal l the fl ange onto the
front output shaft.
(5) I nstal l a new compani on fl ange nut onto the
front output shaft.
(6) Ti ghten the fl ange nut to 122-176 Nm (90-130
ft. l bs.) torque. Use Tool 6958, or si mi l ar tool to hol d
fl ange whi l e ti ghteni ng nut.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case onto the transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 27-34 Nm (20-25 ft. l bs.) torque.
(6) Connect the vent hose.
(7) Connect the shi ft motor and mode sensor wi r-
i ng connectors. Secure wi re harness to cl i ps on trans-
fer case.
(8) Al i gn and connect the propel l er shafts.
(9) Fi l l transfer case wi th correct fl ui d. (Refer to
21 - TRANSMI SSI ON/TRANSAXLE/TRANSFER
CASE/FLUI D - STANDARD PROCEDURE)
(10) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts to 41 Nm (30
ft. l bs.) torque.
(11) Remove transmi ssi on jack and support stand.
(12) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SPECIFICATIONS
SPECIFICATIONS - TRANSFER CASE - NV244
Plug, Detent 16-24 12-18 -
Bolt, Differential Case 17-27 15-24 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 16-25 12-18 -
Bolt, Case Half 27-34 20-25 -
Nut, Companion Flange 122-176 90-130 -
Bolt, Shift Motor and
Mode Sensor Assembly
16-25 12-18 -
Bolt, Rear Retainer 27-34 20-25 -
Bolt, Extension Housing 27-34 20-25 -
Nut, Mounting 27-34 20-25 -
Fig. 81 Yoke Seal Washer Installation
1 - YOKE SEAL WASHER
SPECIAL TOOLS
Remover, Bearing - C-4210
Installer, Seal - 6952-A
Remover, Bearing - L-4454
Cup - 8148
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 82).
(2) Posi ti on drai n pan under transfer case.
(3) Remove drai n and fi l l pl ugs and drai n l ubri -
cant compl etel y.
(4) I nstal l drai n pl ug. Ti ghten pl ug to 41-54 Nm
(30-40 ft. l bs.).
(5) Remove drai n pan.
(6) Fi l l transfer case to bottom edge of fi l l pl ug
openi ng wi th MoparATF +4, type 9602, Automati c
Transmi ssi on fl ui d.
(7) I nstal l and ti ghten fi l l pl ug to 41-54 Nm
(30-40 ft. l bs.).
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8033-A
Fig. 82 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
FLUID (Continued)
REMOVAL
(2) Remove front propel l er shaft. (Refer to 3 - DI F-
(3) Remove front output shaft compani on fl ange.
(4) Remove seal from front case wi th sui tabl e pry
tool (Fi g. 83).
INSTALLATION
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
pi ng seal i nto bore unti l i nstal l er tool seats agai nst
case.
(2) I nstal l the front output shaft compani on fl ange.
Ti ghten the fl ange nut to 122-176 Nm (90-130
ft.l bs.).
MODE SENSOR
DESCRIPTION
The transfer case mode sensor (Fi g. 85) i s an el ec-
troni c devi ce whose output can be i nterpreted to i ndi -
cate the shi ft motor shafts rotary posi ti on. The
sensor consi sts of a magneti c ri ng and four Hal l
Effect Transi stors to create a 4 channel di gi tal devi ce
(non-contacti ng) whose output converts the motor
shaft posi ti on i nto a coded si gnal . The TCCM must
suppl y 5VDC (+/- 0.5v) to the sensor and moni tor the
shi ft motor posi ti on. The four channel s are denoted
A, B, C, and D. The sensor i s mechani cal l y l i nked to
the shaft of the cam whi ch causes the transfer case
shi fti ng. The mode sensor draws l ess than 53 mA.
Fig. 83 Remove Front Output Shaft Seal - Typical
2 - PRY TOOL
Fig. 84 Front Output Shaft Seal Installation - Typical
2 - TRANSFER CASE
Fig. 85 Mode Sensor
1 - TRANSFER CASE MODE SENSOR
OPERATION
Duri ng normal vehi cl e operati on, the Transfer Case
Control Modul e (TCCM) moni tors the mode sensor
outputs at l east every 250 (+/-50) mi l l i seconds when
the shi ft motor i s stati onary and 400 mi croseconds
when the shi ft motor i s acti ve. A mode sensor si gnal
between 3.8 Vol ts and 0.8 Vol ts i s consi dered to be
undefi ned.
Refer to for the rel ati ve angl es of the transfer case
shi ft sector versus the i nterpreted transfer case gear
operati ng mode. Refer to for the sensor codes
returned to the TCCM for each transfer case mode
sensor posi ti on. The vari ous between gears posi ti ons
can al so be referred as the transfer cases coarse
posi ti on. These coarse posi ti ons come i nto pl ay dur-
i ng shi ft attempts.
SECTOR ANGLES VS. TRANSFER CASE POSITION
Shaft Angle (Degrees) Transfer Case Position
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
MODE SENSOR CODES
Transfer Case
Angle (degrees)
Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
+40 (4LO) H H L L
+20 (NEUTRAL) H L L L
0 (2WD/AWD) H L H L
-20 (4HI) L L H L
Between Gears L H H H
MODE SENSOR (Continued)
REAR RETAINER BUSHING
AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. (Refer to 3 - DI F-
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 8158, remove the bushi ng from
rear retai ner (Fi g. 86).
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
(3) Usi ng I nstal l er 8157, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 87).
(4) Usi ng I nstal l er D-163, i nstal l seal i n rear
(5) I nstal l the rear propel l er shaft. (Refer to 3 -
(6) Veri fy proper fl ui d l evel .
Fig. 86 Rear Retainer Bushing Removal
1 - REMOVER 8158
Fig. 87 Rear Retainer Bushing Installation
2 - INSTALLER 8157
Fig. 88 Install Rear Retainer Seal
2 - SPECIAL TOOL D-163
SELECTOR SWITCH
DESCRIPTION
The sel ector swi tch assembl y (Fi g. 89) i s mounted
i n the vehi cl e I nstrument Panel (I P) and consi sts of a
rotary knob connected to a resi sti ve network for the
mode and range shi ft sel ecti ons. Al so l ocated i n thi s
assembl y i s a recessed, normal l y open momentary
swi tch for maki ng shi fts i nto and out of transfer case
NEUTRAL. A pen, or si mi l ar i nstrument, i s used to
make a NEUTRAL shi ft sel ecti on, thus reduci ng the
l i kel i hood of an i nadvertent shi ft request.
The sel ector swi tch al so contai ns four l i ght emi t-
ti ng di odes (LEDs) to i ndi cate the transfer case posi -
ti on and whether a shi ft i s i n progress.
OPERATION
As the posi ti on of the sel ector swi tch vari es, the resi s-
tance between the Mode Sensor suppl y vol tage pi n and
the Mode Sensor output wi l l vary. Hardware, software,
and cal i brati ons wi thi n the Transfer Case Control Mod-
ul e (TCCM) are provi ded that i nterpret the sel ector
swi tch resi stance as gi ven i n the tabl e bel ow:
SELECTOR SWITCH INTERPRETATION
Step Resistance
Range (ohms)
Required
Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4H
E 3050-5950 2WD/AWD
(Default)
F 9.5-12.5K In between
positions
G >15.5K Open
For resi stances between the ranges B-E shown for
each val i d posi ti on (T-Case NEUTRAL, 4LO, 4HI ,
2WD/AWD), the TCCM may i nterpret the resi stance
as:
ei ther of the nei ghbori ng val i d posi ti ons.
as an i nval i d faul t posi ti on.
For resi stances between the ranges E and F shown
for AWD/2WD and i n-between posi ti ons, the TCCM
may i nterpret the resi stance as:
the AWD/2WD posi ti on.
For resi stances between the ranges F and G shown
for i n-between posi ti ons and faul t condi ti on (open),
the TCCM may i nterpret the resi stance as:
For resi stances between the ranges A and B shown
for the faul t condi ti on (short) and , T-Case NEU-
TRAL, the TCCM may i nterpret the resi stance as:
the T-Case NEUTRAL posi ti on.
The LEDs i n the sel ector assembl y are i l l umi nat-
ed/fl ashed i n the fol l owi ng manner to i ndi cate a par-
ti cul ar condi ti on or state.
A sol i dl y i l l umi nated LED i ndi cates a success-
ful l y compl eted shi ft and the current operati ng mode
of the transfer case. Whi l e a shi ft has been requested
but not yet compl eted, the LED for the source trans-
fer case posi ti on remai ns sol i dl y i l l umi nated.
A fl ashi ng operati ng mode LED for the desi red
gear i ndi cates that a shi ft to that posi ti on has been
requested, but al l of the dri ver control l abl e condi ti ons
have not been met. Thi s i s i n an attempt to noti fy
the dri ver that the transmi ssi on needs to be put i nto
NEUTRAL, the vehi cl e speed i s too great, or some
other condi ti on outl i ned (other than a di agnosti c fai l -
ure that woul d prevent thi s shi ft) above i s not met.
Note that thi s fl ashi ng wi l l conti nue i ndefi ni tel y
unti l the condi ti ons are eventual l y met, or the sel ec-
Fig. 89 Selector Switch
1 - TRANSFER CASE MODE SELECTOR SWITCH
tor swi tch posi ti on i s changed, or i f di agnosti c rou-
ti nes no l onger al l ow the requested shi ft.
I f the dri ver attempts to make a shi ft i nto trans-
fer case NEUTRAL, and any of the dri ver control l a-
bl e condi ti ons are not met, the request wi l l be
i gnored unti l al l of the condi ti ons are met or unti l
the NEUTRAL sel ect button i s rel eased. Addi ti onal l y
the neutral l amp wi l l fl ash, or begi n to fl ash whi l e
the button i s depressed and operator control l abl e
condi ti ons are not bei ng met. Al l of the LEDs except
the Neutral wi l l fl ash i f any of the operator control -
l abl e condi ti ons for shi fti ng are not met whi l e the
Neutral button i s depressed. Thi s toggl e type of fea-
ture i s necessary because the TCCM woul d i nterpret
another request i mmedi atel y after the shi ft i nto
transfer case NEUTRAL has compl eted.
No LEDs i l l umi nated i ndi cate a faul t i n the
transfer case control system.
SHIFT MOTOR
DESCRIPTION
The shi ft motor (Fi g. 90) consi sts of a permanent
magnet D.C. motor wi th gear reducti on to convert a
hi gh speed-l ow torque devi ce i nto a l ow speed-hi gh
torque devi ce. The output of the devi ce i s coupl ed to
a shaft whi ch i nternal l y moves the mode and range
forks that change the transfer case operati ng ranges.
The motor i s rated at 25 amps maxi mum at 72 F
wi th 10 vol ts at the motor l eads.
OPERATION
The transfer case shi ft motor responds to the
Transfer Case Control Modul e (TCCM) commands to
move the transfer case shi ft sector bi -di recti onal l y, as
requi red, to obtai n the transfer case operati ng mode
i ndi cated by the i nstrument panel mounted sel ector
swi tch.
REMOVAL
(1) Rai se the vehi cl e on a sui tabl e hoi st.
(2) Remove the front propel l er shaft. (Refer to 3 -
SHAFT/PROPELLER SHAFT - REMOVAL)
(3) Di sengage the wi ri ng connectors from the shi ft
motor and mode sensor.
(4) Remove the front output shaft compani on
fl ange from the transfer case.
(5) Remove the bol ts (Fi g. 91) hol di ng the shi ft
motor and mode sensor assembl y onto the transfer
case.
(6) Separate the shi ft motor and mode sensor
Fig. 90 Shift Motor - Shown Inverted
1 - TRANSFER CASE SHIFT MOTOR
Assembly Bolts
1 - TRANSFER CASE
3 - BOLT
SELECTOR SWITCH (Continued)
INSTALLATION
(1) Veri fy that the shi ft sector o-ri ng i s cl ean and
properl y posi ti oned over the shi ft sector and agai nst
the transfer case.
(3) I nstal l the bol ts (Fi g. 92) to hol d the assembl y
onto the transfer case. Ti ghten the bol ts to 16-24
Nm (12-18 ft.l bs.).
(4) Engage the wi ri ng connectors to the shi ft motor
and mode sensor.
(5) I nstal l the transfer case front output shaft
compani on fl ange onto the transfer case. Ti ghten the
fl ange nut to 122-176 Nm (90-130 ft.l bs.).
(7) Refi l l the transfer case as necessary.
(8) Lower vehi cl e and veri fy transfer case
operati on.
Assembly Bolts
1 - TRANSFER CASE
3 - BOLT
SHIFT MOTOR (Continued)
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . 1
ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MATCH MOUNTING. . . . . . . . . . . . . . . . . . . . . . 2
TIRE AND WHEEL BALANCE. . . . . . . . . . . . . . . 4
TIRES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . 7
TREAD WEAR INDICATORS . . . . . . . . . . . . . . . 7
TIRE WEAR PATTERNS. . . . . . . . . . . . . . . . . . . 7
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . . 8
REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPARE TIRE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WHEELS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WHEEL INSPECTION. . . . . . . . . . . . . . . . . . . . . 9
WHEEL REPLACEMENT . . . . . . . . . . . . . . . . . . 9
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 11
STUDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 1).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
AN TIRES/WHEELS 22 - 1
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 2) and l ateral
runout (Fi g. 3).
STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n. (maxi mum)
ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n. (maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, Refer to match mounti ng procedure.
STANDARD PROCEDURE - ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
I ncrease tread l i fe
Mai ntai n tracti on l evel s
A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 4).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
STANDARD PROCEDURE - MATCH MOUNTING
Wheel s and ti res are match mounted at the factory.
Thi s means that the hi gh spot of the ti re i s matched
to the l ow spot on the wheel ri m. Each are marked
wi th a bri ght col ored temporary l abel on the out-
board surface for al i gnment. The wheel i s al so
marked permanentl y on the i nsi de of the ri m i n the
ti re wel l . Thi s permanent mark may be a pai nt dot
or l i ne, a permanent l abel or a stamped i mpressi on
such as an X. An opti onal l ocati on mark i s a smal l
spheri cal i ndentati on on the verti cal face of the out-
board fl ange on some non styl ed base steel wheel s.
The ti re must be removed to l ocate the permanent
mark on the i nsi de of the wheel .
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 4 Tire Rotation Pattern
22 - 2 TIRES/WHEELS AN
TIRES/WHEELS (Continued)
(1) Remove the ti re and wheel assembl y from the
vehi cl e and mount on a servi ce dynami c bal ance
machi ne.
(2) Measure the total runout on the center of the
ti re tread ri b wi th a di al i ndi cator. Record the i ndi -
cator readi ng. Mark the ti re to i ndi cate the hi gh spot.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 5).
(3) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 6).
(4) Measure the total i ndi cator runout agai n. Mark
the ti re to i ndi cate the hi gh spot.
(5) I f runout i s sti l l excessi ve, the fol l owi ng proce-
dures must be done.
I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.) of
the fi rst spot and i s sti l l excessi ve, repl ace the ti re.
I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.) of
the fi rst spot on the wheel , the wheel may be out of
speci fi cati ons. (Refer to 22 - TI RES/WHEELS -
I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 7). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount, i f not repl ace the
ri m.
Fig. 5 First Measurement On Tire
1 - REFERENCE MARK
2 - 1ST MEASUREMENT
HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
Fig. 6 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
Fig. 7 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two plane
balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd the l ocati on of the heavy
spot causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 8).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 9).
Fig. 8 Static Unbalance & Balance
1 - HEAVY SPOT
2 - CENTER LINE OF SPINDLE
3 - ADD BALANCE WEIGHTS HERE
4 - CORRECTIVE WEIGHT LOCATION
5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
TIRES
DESCRIPTION - TIRES
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe brake appl i cati ons
Hi gh speed dri vi ng
Excessi ve speeds on turns
Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val , (Refer to 22 - TI RES/WHEELS - STANDARD
PROCEDURE). Thi s wi l l hel p to achi eve a greater
tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 10).
Performance ti res have a speed rati ng l etter after
the aspect rati o number. The speed rati ng i s not
al ways pri nted on the ti re si dewal l . These rati ngs
are:
Q up to 100 mph
S up to 112 mph
T up to 118 mph
U up to 124 mph
H up to 130 mph
V up to 149 mph
Z more than 149 mph (consul t the ti re manu-
facturer for the speci fi c speed rati ng)
An Al l Season type ti re wi l l have ei ther M +S, M
& S or MS (i ndi cati ng mud and snow tracti on)
i mpri nted on the si de wal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owners Manual for more i nformati on.
DESCRIPTION - RADIAL PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Fig. 9 Dynamic Unbalance & Balance
1 - CENTER LINE OF SPINDLE
2 - ADD BALANCE WEIGHTS HERE
3 - CORRECTIVE WEIGHT LOCATION
4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
DESCRIPTION - TIRE INFLATION PRESSURES
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 11).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks (Fi g. 12).
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl es Owners Manual . A Certi fi cati on Label on the
dri vers si de door pi l l ar provi des the mi ni mum ti re
and ri m si ze for the vehi cl e. The l abel al so l i st the
col d i nfl ati on pressure for these ti res at ful l l oad
operati on
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. Ti re
pressure decreases as the ambi ent temperature
drops. Check ti re pressure frequentl y when ambi ent
temperature vari es wi del y.
Ti re i nfl ati on pressures are col d i nfl ati on pressure.
The vehi cl e must si t for at l east 3 hours to obtai n the
correct col d i nfl ati on pressure readi ng. Or be dri ven
Fig. 10 Tire Identification
Fig. 11 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 12 Over Inflation Wear
1 - THIN TIRE THREAD AREA
TIRES (Continued)
l ess than one mi l e after si tti ng for 3 hours. Ti re
i nfl ati on pressures may i ncrease from 2 to 6 pounds
per square i nch (psi ) duri ng operati on. Do not reduce
thi s normal pressure bui l d-up.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DESCRIPTION - TIRE PRESSURE FOR HIGH
SPEED
Where speed l i mi ts al l ow the vehi cl e to be dri ven
at hi gh speeds, correct ti re i nfl ati on pressure i s very
i mportant. For speeds up to and i ncl udi ng 120 km/h
(75 mph), ti res must be i nfl ated to the pressures
shown on the ti re pl acard. For conti nuous speeds i n
excess of 120 km/h (75 mph), ti res must be i nfl ated
to the maxi mum pressure speci fi ed on the ti re si de-
wal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
DESCRIPTION - REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 13).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 14).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 14).
Fig. 13 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
TIRES (Continued)
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on and
decel erati on. The engi ne, di fferenti al and exhaust
noi ses wi l l change as speed vari es, whi l e the ti re
noi se wi l l usual l y remai n constant.
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 15). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on.
CLEANING - TIRES
Remove the protecti ve coati ng on the ti res before
del i very of a vehi cl e. Thi s coati ng may cause deteri -
orati on of the ti res.
To remove the protecti ve coati ng, appl y warm
water and l et i t soak for a few mi nutes. Afterwards,
scrub the coati ng away wi th a soft bri stl e brush.
Steam cl eani ng may al so be used to remove the coat-
i ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
Fig. 14 Tire Wear Patterns
Fig. 15 Tire Repair Area
1 - REPAIRABLE AREA
TIRES (Continued)
SPECIFICATIONS
TIRE SPECIFICATION
SPECIFICATIONS
TIRE P215/75R15
TIRE P235/75R15 XL
TIRE P255/65R16
TIRE P255/55R17
TIRE P265/70R16
SPARE TIRE
DESCRIPTION
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M.P.H. when usi ng the
temporary spare ti re. Refer to Owners Manual for
compl ete detai l s.
WHEELS
DESCRIPTION
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 16) .
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
I nspect wheel s for:
Excessi ve run out
Dents or cracks
Damaged wheel l ug nut hol es
Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
WHEEL INSTALLATION
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Fig. 16 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 17).
Never use oil or grease on studs or nuts.
STANDARD PROCEDURE - WHEEL
REPLACEMENT
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 17).
Never use oil or grease on studs or nuts.
Wheel s must be repl aced i f they have:
Excessi ve runout
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
Fig. 17 Lug Nut Tightening Pattern
WHEELS (Continued)
SPECIFICATIONS
TORQUE CHART
CAUTION: DO NOT USE CHROME PLATED LUG
NUTS WITH CHROME PLATED WHEELS.
Wheel
Lug Nut
115 to 157 85 to 115
STUDS
REMOVAL
CAUTION: Do not use a hammer to remove wheel
studs.
(3) Remove the brake cal i per, cal i per adapter and
rotor, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - REMOVAL).
(4) Remove the stud from the hub wi th Remover
C-4150A (Fi g. 18).
INSTALLATION
CAUTION: Do not use a hammer to remove wheel
studs.
(1) I nstal l the new stud i nto the hub fl ange.
(2) I nstal l three washers onto the stud, then
i nstal l l ug nut wi th the fl at si de of the nut agai nst
the washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and cal -
i per, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - I NSTALLATI ON) refer to Brakes
for procedure.
(6) I nstal l the wheel and ti re assembl y, (Refer to
CEDURE) use a new l ug nut on the stud or studs
that were repl aced.
(7) Remove the support and l ower vehi cl e.
Fig. 18 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
BODY
TABLE OF CONTENTS
page page
BODY
WATER LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . 1
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . . 2
HEAT STAKING . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 58
DECKLID/HATCH/LIFTGATE/TAILGATE . . . . . . . . 59
DOOR - CARGO . . . . . . . . . . . . . . . . . . . . . . . . . 61
DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DOORS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . 71
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTRUMENT PANEL SYSTEM . . . . . . . . . . . . . . 90
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 132
WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . 137
BODY
DIAGNOSIS AND TESTING - WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
AN BODY 23 - 1
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
DIAGNOSIS AND TESTING - WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross wi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
STANDARD PROCEDURE - BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng).
23 - 2 BODY AN
BODY (Continued)
Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove tri m panel .
(2) Bend or move the tri m panel components at
the heat staked joi nts. Observe the heat staked l oca-
ti ons and/or component seams for l ooseness.
(3) Heat stake the components.
(a) I f the heat staked or component seam l oca-
ti on i s l oose, hol d the two components ti ghtl y
together and usi ng a sol deri ng gun wi th a fl at ti p,
mel t the materi al securi ng the components
together. Do not over heat the affected area, dam-
age to the exteri or of the tri m panel may occur.
(b) I f the heat staked materi al i s broken or mi ss-
i ng, use a hot gl ue gun to appl y new materi al to
the area to be repai red. The panel s that are bei ng
heat staked must be hel d together whi l e the appl y-
i ng the gl ue. Once the new materi al i s i n pl ace, i t
may be necessary to use a sol deri ng gun to mel t
the newl y appl i ed materi al . Do not over heat the
affected area, damage to the exteri or of the tri m
panel may occur.
(4) Al l ow the repai red area to cool and veri fy the
repai r.
(5) I nstal l tri m panel .
AN BODY 23 - 3
BODY (Continued)
SPECIFICATIONS
WELD LOCATIONS
FRONT FENDER AND INNER WHEELHOUSE
23 - 4 BODY AN
BODY (Continued)
ROOF PANEL REGULAR CAB
AN BODY 23 - 5
BODY (Continued)
ROOF PANEL CLUB CAB
23 - 6 BODY AN
BODY (Continued)
BODY SIDE APERTURE REGULAR CAB
AN BODY 23 - 7
BODY (Continued)
23 - 8 BODY AN
BODY (Continued)
AN BODY 23 - 9
BODY (Continued)
23 - 10 BODY AN
BODY (Continued)
BODY SIDE APERTURE CLUB CAB
AN BODY 23 - 11
BODY (Continued)
23 - 12 BODY AN
BODY (Continued)
AN BODY 23 - 13
BODY (Continued)
23 - 14 BODY AN
BODY (Continued)
CAB BACK PANEL REGULAR CAB
AN BODY 23 - 15
BODY (Continued)
CAB BACK PANEL CLUB CAB
23 - 16 BODY AN
BODY (Continued)
FLOOR PAN REGULAR CAB
AN BODY 23 - 17
BODY (Continued)
FLOOR PAN REGULAR CAB
23 - 18 BODY AN
BODY (Continued)
FLOOR PAN CLUB CAB
AN BODY 23 - 19
BODY (Continued)
FLOOR PAN CLUB CAB
23 - 20 BODY AN
BODY (Continued)
FLOOR PAN CLUB CAB
AN BODY 23 - 21
BODY (Continued)
COWL AND DASH PANEL
23 - 22 BODY AN
BODY (Continued)
COWL AND DASH PANEL
AN BODY 23 - 23
BODY (Continued)
COWL AND DASH
23 - 24 BODY AN
BODY (Continued)
CARGO BOX INNER SIDE PANEL
AN BODY 23 - 25
BODY (Continued)
23 - 26 BODY AN
BODY (Continued)
AN BODY 23 - 27
BODY (Continued)
CARGO BOX FRONT PANELS
23 - 28 BODY AN
BODY (Continued)
CARGO BOX FLOOR
AN BODY 23 - 29
BODY (Continued)
CARGO BOX FLOOR
23 - 30 BODY AN
BODY (Continued)
STRUCTURAL ADHESIVE LOCATIONS
ROOF EXTENDED CAB
1 - OUTER ROOF PANEL
2 - STRUCTURAL ADHESIVE
3 - ADHESIVE RIBBON
4 - EXTENDED CAB FRAMING
AN BODY 23 - 31
BODY (Continued)
ROOF REGULAR CAB
1 - OUTER ROOF PANEL
3 - REGULAR CAB FRAMING
23 - 32 BODY AN
BODY (Continued)
REAR QUARTER PANEL REGULAR CAB
1 - REAR QUARTER PANEL/INNER UPPER
(REGULAR CAB)
3 - CAB BACK REINFORCEMENT
(REGULAR CAB)
AN BODY 23 - 33
BODY (Continued)
REAR QUARTER PANEL EXTENDED CAB
23 - 34 BODY AN
BODY (Continued)
CARGO BOX INNER AND OUTER PANEL
AN BODY 23 - 35
BODY (Continued)
SEALER LOCATIONS
APPLICATION METHODS
23 - 36 BODY AN
BODY (Continued)
SEALER LOCATION
AN BODY 23 - 37
BODY (Continued)
APPLICATION CUT-AWAY
23 - 38 BODY AN
BODY (Continued)
COWL AND DASH PANEL
AN BODY 23 - 39
BODY (Continued)
COWL AND DASH PANEL
23 - 40 BODY AN
BODY (Continued)
FLOOR PAN
AN BODY 23 - 41
BODY (Continued)
CAB REAR PANEL
23 - 42 BODY AN
BODY (Continued)
CAB REAR PANEL
AN BODY 23 - 43
BODY (Continued)
ROOF PANEL
23 - 44 BODY AN
BODY (Continued)
CARGO BOX
AN BODY 23 - 45
BODY (Continued)
CARGO BOX
23 - 46 BODY AN
BODY (Continued)
DOORS
AN BODY 23 - 47
BODY (Continued)
BODY GAP AND FLUSH MEASUREMENTS
23 - 48 BODY AN
BODY (Continued)
BODY GAP AND FLUSH
AN BODY 23 - 49
BODY (Continued)
BODY GAP AND FLUSH EXTENDED CAB
DESCRIPTION GAP FLUSH
A Door to Window Molding 5.1 +/- 1.5 N/A
B Door to Roof 6.0 +/- 1.5 2.0 +/- 1.0
C Quarter Glass to Quarter (Top) 5.0 +/- 1.5 3.6 +/- 1.5
D Quarter Glass to Quarter (Rear) 5.0 +/- 1.5 3.6 +/- 1.5
E Cab to Standard Box 18.7 +/- 3.0 0.0 +/- 1.5
F Cab to Extended Box 18.7 +/- 3.0 0.0 +/- 1.5
G Quarter Glass to Quarter (Bottom) 5.0 +/- 1.5 N/A
H Door to Quarter 0.0 +/- 2.5 N/A
I Quarter Glass to Door 5.0 +/- 1.5 3.6 +/- 1.5
J Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 0.5
K Grille to Headlamp 8.3 +/- 3.0 N/A
L Grille to Fender 6.0 +/- 1.5 N/A
M Door to Aperture 5.0 +/- 1.0 0.0 +/- 0.5
N Door to Sill 7.0 +/- 2.0 0.0 +/- 1.5
O Hood to Fender 6.0 +/- 1.0 1.5 +/- 1.0
23 - 50 BODY AN
BODY (Continued)
BODY GAP AND FLUSH QUAD CAB
AN BODY 23 - 51
BODY (Continued)
BODY GAP AND FLUSH QUAD CAB
23 - 52 BODY AN
BODY (Continued)
BODY GAP AND FLUSH CARGO BOX
DESCRIPTION GAP FLUSH
A Fuel Filler Door to Box 3.0 +/- 1.5 0.0 +/- 1.5
B Cargo to Standard Box 18.7 +/- 3.0 0.0 +/- 1.5
C Cargo to Extended Box 18.7 +/- 3.0 0.0 +/- 1.5
E Box to Tailgate U/D N/A 0.0 +/- 1.5
F Tailgate to Bumper 9.7 +/- 3.0 N/A
G Box to Tailgate 6.0 +/- 1.0 0.0 +/- 0.5
AN BODY 23 - 53
BODY (Continued)
BODY GAP AND FLUSH CARGO BOX
23 - 54 BODY AN
BODY (Continued)
BODY OPENING DIMENSIONS
WINDSHIELD OPENING
DOOR OPENING
AN BODY 23 - 55
BODY (Continued)
QUARTER WINDOW OPENING
ENGINE COMPARTMENT OPENING
23 - 56 BODY AN
BODY (Continued)
BACKLITE OPENING
AN BODY 23 - 57
BODY (Continued)
Bench seat track to seat
frame bolt
24 Nm (17 ft. lbs.)
Bench seat outer track to
seat frame bolt
24 Nm (17 ft. lbs.)
Bench seat to floor pan
front bolt
40 Nm (30 ft. lbs.)
Bench seat to floor pan
rear bolt
28 Nm (20 ft. lbs.)
Bucket seat track to seat
frame bolt
24 Nm (17 ft. lbs.)
Bucket seat track to floor
pan front bolt
28 Nm (20 ft. lbs.)
pan rear inboard bolt
40 Nm (30 ft. lbs.)
pan rear outboard bolt
28 Nm (20 ft. lbs.)
Cab mounting bolt 81 Nm (60 ft. lbs.)
Cargo box bolt 27 Nm (20 ft. lbs.)
Center seat to bucket
seat inboard track bolts
24 Nm (17 ft. lbs.)
Console lid/seat back
pivot bolt
24 Nm (17 ft. lbs.)
Console lid/seat back to
left hinge bracket torx
screws
24 Nm (17 ft. lbs.)
Front bucket seat belt
buckle anchor bolt
40 Nm (29 ft. lbs.)
Front door hinge to hinge
pillar bolts
28 Nm (21 ft. lbs.)
Front door hinge to door
nuts and bolts
28 Nm (21 ft. lbs.)
Front seat belt retractor
bolt
44 Nm (32 ft. lbs.)
Front turning loop anchor
bolt
44 Nm (32 ft. lbs.)
Front lower belt anchor
bolt
44 Nm (32 ft. lbs.)
Front seat rear inboard
seat track to floor pan
bolts
40 Nm (30 ft. lbs.)
torque.
Front seat rear outboard
seat track to floor pan
bolts
16 Nm (11 ft. lbs.)
Front seat front seat
track to floor pan bolts
16 Nm (11 ft. lbs.)
Rear seat belt retractor
bolt
44 Nm (32 ft. lbs.)
Rear turning loop anchor
bolt
44 Nm (32 ft. lbs.)
Rear lower belt anchor
bolt
44 Nm (32 ft. lbs.)
Rearview mirror set
screw
1 Nm (9 in. lbs.)
Side view mirror nut 7 Nm (65 in. lbs.)
Rear seat belt/buckle
anchor bolt
44 Nm (32 ft. lbs.)
SPECIAL TOOLS
BODY
Trim Stick C-4755
Torx Bit Set C-4794-B
Molding Remover C-4829
23 - 58 BODY AN
BODY (Continued)
DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
TAILGATE CHECK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
TAILGATE LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
TAILGATE LATCH RELEASE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TAILGATE LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TAILGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TAILGATE CHECK CABLE
REMOVAL
(2) Pry l ock tab outward to cl ear stud head on
cargo box (Fi g. 1).
(3) Push cabl e end forward unti l stud head i s i n
cl earance hol e porti on of cabl e end.
(4) Separate cabl e end from stud.
(5) Remove screw hol di ng cabl e to tai l gate.
(6) Separate check cabl e from tai l gate.
INSTALLATION
Reverse the precedi ng operati on.
TAILGATE LATCH
REMOVAL
(1) Remove bol ts attachi ng tai l gate l atch to tai l -
gate (Fi g. 2).
(2) Remove bezel for tai l gate l atch rel ease handl e.
(3) Remove bol ts attachi ng tai l gate l atch rel ease
handl e to tai l gate.
(4) Di sengage l atch rods at tai l gate l atch rel ease
handl e.
(5) Separate l atch from tai l gate and di sengage
l atch rod from l atch.
INSTALLATION
(1) Engage l atch rods to tai l gate l atch rel ease han-
dl e.
(2) I nstal l tai l gate l atch rel ease handl e.
(3) Attach l atch rel ease rod to l atch.
(4) Posi ti on l atch i n tai l gate.
(5) I nstal l bol ts attachi ng tai l gate l atch to tai l gate.
(6) I nstal l bezel for tai l gate l atch rel ease handl e.
TAILGATE LATCH RELEASE
HANDLE
REMOVAL
(1) Usi ng a tri m sti ck and starti ng at the bottom
of the l atch rel ease handl e, di sengage the bottom
cl i ps attachi ng the bezel to the tai l gate.
(2) Sl i de the bezel downward to remove i t from the
tai l gate.
(3) Remove screws attachi ng l atch rel ease handl e
to tai l gate (Fi g. 2).
(4) Di sengage l atch rel ease rods (Fi g. 3).
(5) Separate l atch rel ease from tai l gate.
Fig. 1 Tailgate Check
1 - SCREW DRIVER
2 - TAILGATE CHECK CABLE
3 - LOCK TAB
AN DECKLID/HATCH/LIFTGATE/TAILGATE 23 - 59
INSTALLATION
(1) Posi ti on l atch rel ease i n tai l gate.
(2) Engage l atch rel ease rods.
(3) I nstal l screws attachi ng l atch rel ease handl e to
tai l gate.
(4) Posi ti on the top of the bezel i n tai l gate and
sl i de the bezel upward and snap i nto pl ace.
TAILGATE LATCH STRIKER
REMOVAL
(2) Remove tai l gate check cabl e.
(3) Usi ng a grease penci l , mark the l ocati on of the
stri ker.
(4) Remove stri ker from cargo box (Fi g. 4).
INSTALLATION
(1) Al i gn the stri ker usi ng the reference marks.
(2) I nstal l stri ker.
(3) I nstal l tai l gate check cabl e.
TAILGATE
REMOVAL
(2) Di sconnect tai l gate check cabl e.
(3) Cl ose tai l gate unti l the notch i n the ri ght hand
col l ar al i gns wi th the pi vot pi n.
(4) Sl i p tai l gate hi nge col l ar from hi nge pi ns.
(5) Sl i de tai l gate to the ri ght and separate l eft
hand col l ar from the pi vot pi n.
(6) Separate tai l gate from vehi cl e.
INSTALLATION
Reverse the precedi ng operati on.
Fig. 2 Tailgate
1 - SILENCER DISC
2 - LATCH
3 - CABLE
4 - LATCH RELEASE ROD
5 - TAILGATE
6 - BEZEL
7 - LATCH RELEASE
Fig. 3 Latch Release Rods
1 - TAILGATE LATCH RELEASE
2 - TAILGATE LATCH RELEASE RODS
Fig. 4 Tailgate Latch Striker
1 - STRIKER
2 - BODY
3 - CABLE
23 - 60 DECKLID/HATCH/LIFTGATE/TAILGATE AN
TAILGATE LATCH RELEASE HANDLE (Continued)
DOOR - CARGO
TABLE OF CONTENTS
page page
AIR EXHAUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AIR EXHAUSTER
REMOVAL
(1) Rel ease door l atch and open door.
(2) Usi ng a smal l fl at bl ade, depress the cl i ps
under the top of the exhauster frame.
(3) Separate ai r exhauster from vehi cl e.
INSTALLATION
(1) Posi ti on ai r exhauster on door shut face (Fi g.
1).
(2) Engage cl i ps and press i nto pl ace.
Fig. 1 Air Exhauster
1 - DOOR SHUT FACE
2 - AIR EXHAUSTER
AN DOOR - CARGO 23 - 61
DOOR - FRONT
TABLE OF CONTENTS
page page
FRONT DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FRONT DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FRONT DOOR OUTSIDE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FDR LOWER GLASS RUN CHANNELS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FRONT DOOR HINGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FRONT DOOR INSIDE HANDLE ACTUATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FRONT DOOR LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FRONT DOOR LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FRONT DOOR LOCK CYLINDER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FRONT DOOR WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 69
FRONT DOOR WINDOW REGULATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FRONT DOOR
REMOVAL
(2) Usi ng a sui tabl e marker, mark the outl i ne of
the door hi nges on the door end to ai d i nstal l ati on.
(3) Remove protecti ve boot from door wi re harness
connector.
(4) Di sengage door wi re harness connector.
(5) Support door on a sui tabl e l i fti ng devi ce.
(6) Whi l e hol di ng the door steady on l i ft, remove
bol ts and nuts attachi ng upper and l ower door hi nge
to door end (Fi g. 1).
(7) Separate door from vehi cl e.
INSTALLATION
(2) Posi ti on door on vehi cl e and al i gn wi th marks.
(3) I nstal l bol ts and nuts attachi ng upper and
l ower door hi nge to door end. Ti ghten fasteners to 28
(4) Engage door wi re harness connector.
(5) I nstal l protecti ve boot on door wi re harness
connector.
Fig. 1 Door Hinge
1 - UPPER HINGE
2 - LOWER HINGE
3 - DOOR
4 - STUD
23 - 62 DOOR - FRONT AN
ADJUSTMENTS - UP/DOWN
Up/down door adjustment i s done by l ooseni ng the
hi nge to cowl fasteners at both hi nges. Then move
the door to the correct posi ti on.
(1) Support the door wi th a padded fl oor jack.
(2) Loosen hi nge to cowl fasteners at both hi nges.
Move the door to the correct up/down posi ti on.
(3) Ti ghten the hi nge to cowl fasteners.
(4) Remove the fl oor jack from the door.
ADJUSTMENTS - IN/OUT
I n/out door adjustment i s done by l ooseni ng the
hi nge to door fasteners. Then move the door to the
correct posi ti on.
(1) Support the door wi th a padded fl oor jack.
(2) Loosen the appl i cabl e hi nge to door fasteners.
Move the door to the correct i n/out posi ti on.
(3) I f necessary, l oosen the other hi nge to door fas-
teners and move the door to the correct i n/out posi -
ti on.
(4) Ti ghten the hi nge to door fasteners.
(5) Remove the fl oor jack from the door.
FRONT DOOR GLASS
REMOVAL
(1) Remove door tri m panel .
(2) Remove water dam as necessary to gai n access
to gl ass regul ator arm.
(3) Remove i nner door bel t weatherstri p.
(4) Remove outer door bel t weatherstri p.
(5) Lower gl ass to ful l down posi ti on and al i gn
gl ass regul ator arm wi th access hol es i n i nner door
panel .
(6) Remove front gl ass run channel .
(7) Remove nuts attachi ng gl ass channel to regul a-
tor arm (Fi g. 2).
(8) Separate gl ass from regul ator arm.
(9) Li ft gl ass upward and out of openi ng at top of
door.
INSTALLATION
(1) Sl owl y l ower gl ass i nto door.
(2) Posi ti on gl ass i n regul ator arm.
(3) I nstal l front gl ass run channel .
(4) I nstal l nuts attachi ng gl ass channel to regul a-
tor arm.
(5) Ensure gl ass i s al i gned i n run channel s and
ti ghten run channel bol ts.
(6) I nstal l outer door bel t weatherstri p.
(7) I nstal l i nner door bel t weatherstri p.
(8) I nstal l water dam.
(9) I nstal l door tri m panel .
FRONT DOOR OUTSIDE
HANDLE
REMOVAL
(2) Remove water dam as necessary to gai n access
to door handl e.
(3) Rol l gl ass up.
(4) Remove fastener access pl ug from door end
panel (Fi g. 3).
(5) Di sengage l ock cyl i nder to l atch rod from the
l atch (Fi g. 4).
(6) Di sengage outsi de handl e to l atch rod from the
l atch.
(7) Remove nuts attachi ng outsi de door handl e to
door.
(8) Separate outsi de handl e from the door.
Fig. 2 Door Glass
1 - GLASS
2 - GLASS CHANNEL
3 - NUT
4 - REGULATOR ARM
AN DOOR - FRONT 23 - 63
FRONT DOOR (Continued)
INSTALLATION
(1) Posi ti on outsi de handl e i n the door.
(2) I nstal l nuts attachi ng outsi de door handl e to
door. Ti ghten the nuts to 5.0 Nm (45 i n. l bs) torque.
(3) Engage outsi de handl e to l atch rod to the l atch.
(4) Engage l ock cyl i nder to l atch rod to the l atch.
(5) I nstal l fastener access pl ug i n the door end
panel .
FDR LOWER GLASS RUN
CHANNELS
REMOVAL
(2) Remove water dam as necessary to access
l ower run channel s.
(3) Remove bol ts attachi ng l ower gl ass run chan-
nel s to door panel (Fi g. 5).
(4) Remove gl ass.
(5) Sl i de l ower run channel s downward to di sen-
gage from upper run channel s.
(6) Remove l ower run channel s from door.
INSTALLATION
(1) Posi ti on l ower run channel s i n door.
(2) Sl i de l ower run channel s upward to engage
i nto upper run channel s.
(3) I nstal l gl ass.
(4) I nstal l bol ts attachi ng l ower gl ass run channel s
to door panel .
Fig. 4 Outside Door Handle
1 - OUTSIDE HANDLE
2 - LOCK CYLINDER TO LATCH ROD
3 - LOCK BUTTON TO LATCH ROD
4 - LATCH
5 - INSIDE HANDLE TO LATCH ROD
6 - OUTSIDE HANDLE TO LATCH ROD
Fig. 3 Access Plug
1 - ACCESS PLUG
2 - DOOR
FRONT DOOR OUTSIDE HANDLE (Continued)
FRONT DOOR HINGE
DESCRIPTION
The hi nge pi n i s not servi ceabl e. Repl ace the hi nge
i f the hi nge pi n i s damaged.
REMOVAL
(3) Usi ng a sui tabl e marker, mark the outl i ne of
the door hi nge on the hi nge pi l l ar and door end
frame to ai d i nstal l ati on.
(4) Remove bol ts attachi ng hi nge to door (Fi g. 6).
(5) Remove bol ts attachi ng door hi nge to hi nge pi l -
l ar.
(6) Separate door hi nge from vehi cl e.
INSTALLATION
(1) I f necessary, pai nt repl acement door hi nge
before i nstal l ati on.
(2) Posi ti on door hi nge on hi nge pi l l ar usi ng al i gn-
ment marks.
(3) I nstal l bol ts attachi ng door hi nge to hi nge pi l -
l ar. Ti ghten bol ts to 28 Nm (21 ft. l bs.) torque.
(4) I nstal l bol ts attachi ng hi nge to door. Ti ghten
FRONT DOOR INSIDE HANDLE
ACTUATOR
DESCRIPTION
The front door i nsi de handl e actuator i s heat
staked to the tri m panel . I f the handl e needs servi c-
i ng, refer to the heat staki ng procedure l ocated i n
thi s secti on.
FRONT DOOR LATCH
REMOVAL
(2) Peel back water dam as necessary.
(3) For access to l atch, rol l up gl ass and remove
bol ts attachi ng rearward gl ass run channel to door.
Move and secure gl ass run channel .
Fig. 5 Lower Glass Run
1 - UPPER GLASS RUN CHANNEL
2 - UPPER CHANNEL
3 - LOWER GLASS RUN CHANNEL
4 - LOWER CHANNEL
5 - REGULATOR
6 - DOOR GLASS
Fig. 6 Door Hinge
1 - BOLT
2 - HINGE
3 - HINGE PILLAR
FDR LOWER GLASS RUN CHANNELS (Continued)
(4) Remove screws attachi ng l atch to door shut
face (Fi g. 7).
(5) Di sengage wi re harness connector for power
door l ocks, i f equi pped.
(6) Di sengage l ock button to l atch rod from the
l atch.
l atch (Fi g. 4).
(8) Di sengage i nsi de handl e to l atch rod from the
l atch.
(9) Di sengage outsi de handl e to l atch rod from the
l atch.
(10) Separate l atch from door.
INSTALLATION
(1) Engage l atch rod to outsi de handl e.
(2) Engage i nsi de handl e to l atch rod to the l atch.
(3) Engage l ock cyl i nder to l atch rod to the l atch.
(4) Engage l ock button to l atch rod to the l atch.
(5) Posi ti on l atch i n door.
(6) I nstal l screws attachi ng l atch to door shut face.
Ti ghten the screws to 9.6 Nm (85 i n. l bs.) torque.
(7) Engage outsi de handl e to l atch rod to the l atch.
(8) Engage wi re harness connector for power door
l ocks, i f equi pped.
(9) I nstal l rearward gl ass run channel .
(12) Usi ng the access hol e i n the door shut face,
l oosen the l atch adjustment screw and ensure the
outsi de door handl e i s fl ush wi th door outer panel .
Ti ghten the adjustment screw.
ADJUSTMENTS
(1) I nsert a torx dri ver through the round hol e i n
the door end frame near the l atch stri ker openi ng
(Fi g. 8).
(2) Loosen torx head screw on the si de of the l atch
l i nkage.
(3) Li ft upward on outsi de door handl e and rel ease
i t.
(4) Ti ghten torx head screw on l atch.
(5) Veri fy l atch operati on.
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Use a wax crayon or equi val ent and mark the
posi ti on of the stri ker on the B-pi l l ar.
(2) Remove the screws attachi ng the stri ker and
spacer to the B-pi l l ar (Fi g. 9).
(3) Separate the stri ker from the B-pi l l ar.
INSTALLATION
(1) Usi ng the al i gnment marks, posi ti on the spacer
and stri ker on the B-Pi l l ar.
(2) I nstal l the screws. Ti ghten the screw to 28.2
Fig. 7 Latch
1 - LATCH
2 - DOOR
Fig. 8 Door Latch Adjustment
1 - OUTSIDE DOOR HANDLE
2 - DOOR LATCH ADJUSTMENT ACCESS
FRONT DOOR LATCH (Continued)
FRONT DOOR LOCK
CYLINDER
LOCK CYLINDERS
I gni ti on, door, deck l i d, and rear hatch l ock cyl i n-
ders are al l codabl e to the key. Lock barrel s, tum-
bl ers, and tumbl er spri ngs are avai l abl e to al l ow the
techni ci an to change repl acement l ocks cyl i nders to
match the customers ori gi nal key set. See the appro-
pri ate secti on i n thi s manual for l ock cyl i nder
removal . See the Mopar catal ogue for part numbers
and l ock codi ng procedures.
REMOVAL
(2) Remove outsi de handl e.
l ock cyl i nder.
(4) Usi ng a smal l fl at bl ade, pry l ock cyl i nder
retai ni ng cl i p from l ock cyl i nder housi ng/outsi de han-
dl e (Fi g. 10).
(5) Push l ock cyl i nder out of l ock cyl i nder housi ng/
outsi de handl e.
INSTALLATION
(1) Push l ock cyl i nder i nto l ock cyl i nder housi ng/
outsi de handl e. Ensure the l ock cyl i nder i s ful l y
seated i n the handl e.
(2) I nstal l l ock cyl i nder retai ni ng cl i p. Ensure the
cl i p i s ful l y seated.
(3) Engage l ock cyl i nder to l atch rod to the l ock
cyl i nder.
(4) I nstal l outsi de handl e.
TRIM PANEL
REMOVAL
(2) Rol l wi ndow down.
(3) Remove wi ndow crank (Fi g. 11), i f equi pped.
(4) Remove screws attachi ng tri m panel to door
(Fi g. 12) and (Fi g. 13).
CAUTION: Do not forcibly pull trim panel from door,
damage to trim panel may occur.
Fig. 9 Front Door Latch Striker
1 - TAPPING PLATE
2 - SPACER
3 - STRIKER
Fig. 10 Lock Cylinder
1 - LOCK CYLINDER TO LATCH ROD
2 - STUD
3 - OUTSIDE HANDLE
4 - RETAINING CLIP
5 - STUD
6 - LOCK CYLINDER
7 - LOCK BUTTON ROD
FRONT DOOR LATCH STRIKER (Continued)
(5) Si mul taneousl y l i ft upward and outward to
rel ease retai ner steps from i nner door panel (Fi g. 14).
(6) Di sengage i nsi de handl e l i nkage rod from
i nsi de handl e.
(7) Di sconnect speaker harness wi re connector
(Fi g. 15).
(8) Di sengage cl i ps attachi ng power wi ndow/l ock
swi tch panel to door tri m panel . Di sengage wi re con-
nector from swi tch panel , i f equi pped (Fi g. 16).
(9) Separate door tri m panel from vehi cl e.
INSTALLATION
(1) Posi ti on tri m panel at door.
(2) Engage wi re connector for wi ndow/l ock swi tch
panel , i f equi pped. Engage cl i ps attachi ng power wi n-
dow/l ock swi tch panel to door tri m panel .
(3) Engage power mi rror wi re connector, i f
equi pped.
(4) Connect speaker harness wi re connector.
(5) Engage i nsi de handl e l i nkage rod to i nsi de
handl e.
(6) Al i gn tri m panel retai ner steps wi th i nner door
panel and sl i de tri m panel i nto pl ace.
Fig. 11 Window CrankTypical
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 12 Door Trim Panel
1 - TRIM PANEL
Fig. 13 Trim Panel Screw
1 - TRIM PANEL
2 - INSIDE DOOR HANDLE
3 - INSIDE DOOR HANDLE BRACKET
Fig. 14 Trim Panel Retainer
1 - TRIM PANEL
2 - RETAINER STEP
3 - INNER DOOR PANEL
TRIM PANEL (Continued)
(7) I nstal l screws attachi ng tri m panel to door.
(8) I nstal l wi ndow crank, i f equi pped.
FRONT DOOR WATERDAM
REMOVAL
(1) Remove the tri m panel from the door.
(2) Careful l y separate the waterdam from the door
i nner panel at the areas wi th adhesi ve (Fi g. 17).
Remove the waterdam from the door i nner panel .
INSTALLATION
(1) Appl y an appropri ate adhesi ve/seal ant to the
waterdam edges before i nstal l i ng i t.
(2) Posi ti on the waterdam on the door i nner panel
and press i t i nward at the areas wi th the adhesi ve to
attach i t to the i nner panel .
(3) Ensure that the retai ner step pockets are posi -
ti on correctl y i n the door i nner panel .
(4) I nstal l the door tri m panel .
Fig. 15 Speaker And Power Mirror Connector
1 - SPEAKER CONNECTOR
Fig. 16 Power Door Lock/Window Connector
1 - TRIM PANEL SWITCH BEZEL OPENING
3 - SWITCH AND BEZEL UNIT
Fig. 17 Water Dam
1 - STUFFERS
2 - RETAINER STEP POCKETS
3 - WATER DAM
TRIM PANEL (Continued)
FRONT DOOR WINDOW
REGULATOR
REMOVAL
(2) Remove water dam as necessary to access wi n-
dow regul ator.
(3) Remove gl ass from door.
(4) Di sengage power wi ndow motor wi re connector
from door harness, i f equi pped (Fi g. 18).
(5) Loosen bol ts i n sl otted hol es attachi ng regul a-
tor to door i nner panel (Fi g. 19).
(6) Remove bol ts attachi ng wi ndow regul ator to
i nner door panel .
(7) Extract wi ndow regul ator through access hol e
i n i nner door panel .
(8) Separate wi ndow regul ator from door panel .
INSTALLATION
(1) Posi ti on regul ator i n door and al i gn bol ts wi th
sl otted hol es i n door i nner panel .
(2) I nstal l bol ts attachi ng wi ndow regul ator to
i nner door panel .
(3) Engage power wi ndow motor wi re connector to
door harness, i f equi pped.
(4) I nstal l gl ass i n door.
(5) I nstal l outer bel t weatherstri p.
(6) I nstal l i nner bel t weatherstri p.
(9) Veri fy operati on.
Fig. 18 Power Regulator
1 - SCREW
2 - SCREW
3 - POWER WINDOW REGULATOR
Fig. 19 Power Regulator Bolts
1 - REMOVE BOLTS
2 - LOOSEN BOLTS
3 - DOOR INNER PANEL
DOORS - REAR
TABLE OF CONTENTS
page page
DOORS - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REAR DOOR OUTSIDE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REAR DOOR GLASS RUN CHANNELS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REAR DOOR HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR DOOR INSIDE HANDLE ACTUATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR DOOR LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR DOOR LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR DOOR TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
REAR DOOR WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
REAR DOOR WINDOW REGULATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DOORS - REAR
REMOVAL
(1) Remove B-pi l l ar tri m.
(2) Di sconnect door wi re harness connector.
(3) Support door on sui tabl e stand.
(4) Usi ng a wax crayon or equi val ent, mark hi nge
posi ti on on B-pi l l ar.
(5) Remove bol ts attachi ng hi nge to B-pi l l ar
(Fi g. 1).
INSTALLATION
(1) Al i gn and posi ti on door on vehi cl e.
(2) I nstal l bol ts attachi ng hi nge to B-pi l l ar (Fi g. 1).
Ti ghten bol ts to 28 Nm (20 ft. l bs.) torque.
(3) Connect door wi re harness connector.
(4) I nstal l B-pi l l ar tri m.
ADJUSTMENTS
Mi nor adjustment for al i gnment of the door i s
made by movi ng the l atch stri ker
IN AND OUT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker i nward i f the door charac-
ter l i ne i s outboard of the body character l i ne or tap
the l atch stri ker outward i f the door character l i ne i s
i nboard of the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker to
UP AND DOWN
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker downward i f the door
character l i ne i s hi gher than the body character l i ne
Fig. 1 Rear Door Hinge
1 - B-PILLAR
2 - LOWER HINGE
3 - UPPER HINGE
AN DOORS - REAR 23 - 71
or tap the l atch stri ker upward i f the door character
l i ne i s l ower than the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker to
DOOR GLASS
REMOVAL - REAR DOOR GLASS
(1) Remove the door outer tri m panel .
(2) Remove i nner and outer bel tl i ne weatherstri p.
(3) Remove the door waterdam. Remove the radi o
speaker, i f equi pped.
(4) Lower the wi ndow gl ass enough to access the
regul ator bol t (Fi g. 2).
(5) Remove the wi ndow gl ass to regul ator bol ts.
(6) Rai se the wi ndow gl ass manual l y.
(7) Remove the front l ower gl ass run channel .
(8) Lower the gl ass.
(9) Usi ng a tri m sti ck or other sui tabl e devi ce, pry
up the i nsi de edge of the quarter gl ass tri m (Fi g. 3).
(10) Parti al l y remove front upper wi ndow weather-
stri p.
(11) Rai se the gl ass and remove.
REMOVAL - REAR DOOR QUARTER GLASS
CAUTION: The quarter glass trim panel will be diffi-
cult to remove without damage. Check availability
of replacement before removal.
(1) Remove the rear door tri m panel .
(2) Remove the door waterdam.
(3) Remover i nner and outer bel tl i ne weatherstri p.
(4) Remove the door gl ass from the door. Refer to
door gl ass procedure i n thi s secti on.
(5) Remove the bol ts attachi ng bottom of rearward
run channel to door i nner panel .
(6) Remove nuts attachi ng stati onary gl ass to door
frame.
(7) Separate the reward run channel /stati onary
gl ass from door.
INSTALLATION - REAR DOOR GLASS
(1) Lower the gl ass i nto the door.
(2) I nstal l the front gl ass weatherstri p and the
quarter gl ass tri m.
(3) Rai se the gl ass manual l y and secure i n the
door frame.
(4) I nstal l the front l ower gl ass channel .
(5) Lower the gl ass and i nstal l the regul ator bol ts.
(6) Cycl e the gl ass to ensure proper operati on.
(7) I nstal l the waterdam and radi o speaker, i f
equi pped.
INSTALLATION - REAR DOOR QUARTER
GLASS
(1) Posi ti on the rearward run channel /stati onary
gl ass i n the door.
(2) I nstal l the nuts attachi ng stati onary gl ass to
door frame.
(3) I nstal l the bol ts attachi ng rearward run chan-
nel to door i nner panel .
(4) I nstal l the rear door gl ass. Refer to door gl ass
procedure i n thi s secti on.
(5) I nstal l i nner and outer bel t weatherstri p.
(6) I nstal l the door waterdam.
(7) I nstal l the rear door tri m panel .
Fig. 2 Window Regulator Bolt Access
1 - GLASS TO REGULATOR BOLT ACCESS
2 - GLASS TO REGULATOR BOLT
Fig. 3 Quarter Window Trim
1 - QUARTER GLASS TRIM
2 - TRIM STICK
23 - 72 DOORS - REAR AN
DOORS - REAR (Continued)
REAR DOOR OUTSIDE
HANDLE
REMOVAL
(2) Peel back waterdam to access outsi de handl e.
(3) Remove gl ass run channel .
(4) Di sconnect l atch rod (Fi g. 4).
(5) Remove nuts attachi ng handl e to outer door
panel (Fi g. 5).
(6) Separate outsi de handl e from rear door.
INSTALLATION
(1) Posi ti on outsi de handl e i n rear door.
(2) I nstal l nuts attachi ng handl e to outer door
panel (Fi g. 5).
(3) Connect l atch rod (Fi g. 4).
(4) I nstal l gl ass run channel .
(5) I nstal l waterdam.
REAR DOOR GLASS RUN
CHANNELS
REMOVAL
(2) Remove waterdam.
(3) Ensure gl ass i s i n ful l up posi ti on and sup-
ported. Remove bol ts attachi ng the run channel s to
door i nner panel (Fi g. 6).
(4) Remove speaker, i f necessary.
(5) Separate run channel s from door.
INSTALLATION
(1) Posi ti on run channel s i n door.
(2) I nstal l bol ts attachi ng the run channel s to door
i nner panel (Fi g. 6).
(3) I nstal l speaker, i f necessary.
Fig. 4 Latch Rod
1 - OUTSIDE HANDLE
2 - LATCH
3 - LATCH ROD
Fig. 5 Rear Door Outside Handle
1 - REAR DOOR
2 - HANDLE
Fig. 6 Rear Door Glass Run Channels
1 - RUN CHANNEL WITH STATIONARY GLASS
2 - REAR DOOR
3 - REGULATOR
4 - RUN CHANNEL
5 - DOOR GLASS
REAR DOOR HINGE
REMOVAL
(1) Remove B-pi l l ar tri m.
(2) Di sconnect door wi re harness connector.
(3) Support door on sui tabl e stand.
posi ti on on B-pi l l ar.
(5) Remove bol ts attachi ng hi nge to B-pi l l ar (Fi g.
1).
(6) Separate door from vehi cl e.
posi ti on on door.
(8) Remove bol ts attachi ng hi nge to door.
INSTALLATION
(1) Al i gn and posi ti on hi nge on door.
(2) I nstal l bol ts attachi ng hi nge to door. Ti ghten
(3) Al i gn and posi ti on door on vehi cl e.
(4) I nstal l bol ts attachi ng hi nge to B-pi l l ar (Fi g. 1).
(5) Connect door wi re harness connector.
REAR DOOR INSIDE HANDLE
ACTUATOR
DESCRIPTION
The rear door i nsi de handl e actuator i s heat staked
to the tri m panel . I f the handl e needs servi ci ng, refer
to the heat staki ng procedure l ocated i n thi s secti on.
REAR DOOR LATCH
REMOVAL
(2) Peel waterdam back to access l atch.
(3) Di sconnect l atch rods from l atch (Fi g. 7).
(4) Di sconnect the l atch harness connector.
(5) Remove screws attachi ng l atch to rear door
(Fi g. 8).
INSTALLATION
(1) Connect the l atch harness connector.
(2) I nstal l screws attachi ng l atch to rear door.
(3) Connect l atch rods to l atch.
REAR DOOR LATCH STRIKER
REMOVAL
(1) Use a wax crayon or equi val ent and mark posi -
ti on of stri ker on C-pi l l ar.
(2) Remove bol ts attachi ng stri ker and shi m to
C-pi l l ar.
(3) Separate stri ker from C-pi l l ar.
INSTALLATION
(1) Usi ng al i gnment marks, posi ti on shi m and
stri ker on C-Pi l l ar.
(2) I nstal l bol ts. Ti ghten bol ts to 28 Nm (20 ft.
l bs.) torque.
Fig. 7 Rear Door Latch Rods
1 - LATCH
2 - LATCH ROD
3 - LATCH ROD
4 - CONNECTOR
Fig. 8 Rear Door Latch
1 - REAR DOOR
2 - LATCH
REAR DOOR TRIM PANEL
REMOVAL
(2) Rol l wi ndow down.
(3) Remove wi ndow crank (Fi g. 9), i f equi pped.
(4) Remove screws attachi ng tri m panel to door.
CAUTION: Do not forcibly pull trim panel from door,
damage to trim panel may occur.
(5) Si mul taneousl y l i ft upward and outward to
rel ease retai ner steps from i nner door panel (Fi g. 10).
(6) Di sengage i nsi de handl e l i nkage rod from
i nsi de handl e.
(7) Di sconnect power wi dow/l ock harness connec-
tor, i f equi pped (Fi g. 11).
(8) Separate door tri m panel from vehi cl e.
(9) I f necessary, pul l upper tri m extensi on outward
to di sengage from rear door.
INSTALLATION
(1) I f removed, i nstal l upper tri m extensi on on
rear door.
(2) Posi ti on tri m panel at door.
(3) Engage harness connector for power wi ndow/
l ock, i f equi pped.
(4) Engage i nsi de handl e l i nkage rod to i nsi de
handl e.
(5) Al i gn tri m panel retai ner steps wi th i nner door
panel and sl i de tri m panel i nto pl ace.
(6) I nstal l screws attachi ng tri m panel to door.
(7) I nstal l wi ndow crank, i f equi pped.
REAR DOOR WATERDAM
REMOVAL
(2) Peel the waterdam from the door.
(3) Route the l atch rods and wi re harnesses
through the waterdam.
(4) Separate the waterdam from the door i nner
panel (Fi g. 12).
Fig. 9 Window CrankTypical
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 10 Trim Panel Retainer
1 - TRIM PANEL
2 - RETAINER STEP
3 - INNER DOOR PANEL
Fig. 11 Power Window/Lock Connector
1 - TRIM PANEL
2 - INSIDE HANDLE LATCH ROD
3 - POWER WINDOW/LOCK CONNECTOR
INSTALLATION
(1) Route the l atch rods and wi re harnesses
through the waterdam.
(2) Posi ti on the waterdam on the door, appl y adhe-
si ve as necessary and press i nto pl ace.
REAR DOOR WINDOW
REGULATOR
REMOVAL
(1) Remove the door i nner tri m panel .
(2) Remove the door waterdam and speaker, i f
equi pped.
(3) Remove the i nner and outer bel tl i ne weather-
stri p.
(4) Lower the door gl ass.
(5) Remove the bol ts attachi ng the regul ator to the
gl ass.
(6) Rai se the gl ass manual l y and secure i n the
door frame.
(7) Loosen the regul ator attachment nuts and
remove the regul ator attachment bol ts.
(8) Di sengage regul ator wi re harness.
(9) Remove the regul ator (Fi g. 13).
INSTALLATION
(1) Posi ti on the wi ndow regul ator i n the door.
(2) I nstal l the fasteners attachi ng the regul ator to
the i nner door panel .
(3) Engage the regul ator wi re harness.
(4) Lower the gl ass manual l y and i nstal l the bol ts
attachi ng the regul ator to the gl ass.
(5) Cycl e the gl ass to ensure correct operati on.
(6) I nstal l the i nner and outer bel tl i ne weather-
stri p.
(7) I nstal l the door waterdam and radi o speaker, i f
equi pped.
Fig. 12 Rear Door Waterdam
1 - WATER DAM
2 - REAR DOOR
Fig. 13 Rear Door Window Regulator
1 - HARNESS CONNECTOR
2 - POWER WINDOW REGULATOR
REAR DOOR WATERDAM (Continued)
EXTERIOR
TABLE OF CONTENTS
page page
EXTERIOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
BODY SIDE MOLDINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CARGO BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 78
COWL GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 79
EXTERIOR NAME PLATES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 80
FRONT END SPLASH SHIELDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 80
FUEL FILL DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 82
LEFT FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 83
RIGHT FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ROOF JOINT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
WHEEL OPENING MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
EXTERIOR
DESCRIPTION
Exteri or sheet metal components make up the
exteri or of the vehi cl e. Some exteri or metal systems
are wel ded assembl i es, such as doors and hoods.
Some exteri or tri m i tems are made of composi te.
OPERATION
The exteri or i s fi ni shed i n vari ous metal stampi ngs
and composi te mol di ngs. These assembl i es gi ve the
vehi cl e a fi ni shed appearance and protect the occu-
pants from the el ements. Some components are part
of the energy absorbi ng system used to protect the
occupants i n col l i si ons. The exteri or sheet metal i s
repai rabl e and adjustabl e for fi t and fi ni sh. Wel ded
and bonded component systems are adjustabl e as a
system. Tri m components made of composi te are
stamped wi th the type of materi al used. Dai ml er-
Chrysl er uses vari ous fasteners to retai n tri m i tems.
At ti mes, i t i s not possi bl e to remove tri m i tems
wi thout damagi ng the fastener. I f i t i s not possi bl e to
remove an i tem wi thout damagi ng a component, cut
or break the fasteners and use new ones when
i nstal l i ng the component.
BODY SIDE MOLDINGS
REMOVAL
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the mol di ng to use as a
gui de, i f necessary.
(2) Warm the effected sti ck-on mol di ng and body
metal to approxi matel y 38C (100F) usi ng a sui tabl e
heat l amp or heat gun.
(3) Pul l sti ck-on mol di ng from pai nted surface
(Fi g. 1).
INSTALLATION
(1) Cl ean body surface wi th MOPAR Super Kl een
sol vent or equi val ent. Wi pe surface dry wi th l i nt free
cl oth.
(2) Remove protecti ve cover from tape on back of
mol di ng. Appl y mol di ng to body bel ow the maski ng
tape gui de.
(3) Remove maski ng tape gui de and heat body and
mol di ng. Fi rml y press mol di ng to body surface to
assure adhesi on (Fi g. 1).
AN EXTERIOR 23 - 77
CARGO BOX
REMOVAL
CAUTION: The bolts attaching the cargo box to the
frame are specially coated to provide a locking
action. These bolts are not reusable and must be
replaced each time the cargo box is removed or
replaced.
(1) Open fuel fi l l door.
(2) Remove screws attachi ng fuel fi l l neck adaptor
to cargo box si de wal l .
(3) Separate fuel fi l l neck from cargo box.
(4) Di sengage tai l l amp wi re connector from mai n
body harness.
(5) Remove bol ts attachi ng cargo box to frame rai l s
(Fi g. 2).
(6) Usi ng a sui tabl e l i fti ng devi ce, separate cargo
box from vehi cl e.
INSTALLATION
(1) Posi ti on cargo box on frame rai l s.
(2) I nstal l bol ts attachi ng cargo box to frame rai l s.
(3) Engage tai l l amp wi re connector for mai n body
harness.
(4) I nstal l screws attachi ng fuel fi l l neck adaptor
to cargo box si de wal l .
Fig. 1 Body Side MoldingsWheel Opening Moldings
1 - FRONT WHEEL OPENING MOLDING
2 - DOOR MOLDING
3 - CAB MOLDING
4 - REAR WHEEL OPENING MOLDING
23 - 78 EXTERIOR AN
BODY SIDE MOLDINGS (Continued)
COWL GRILLE
REMOVAL
(1) Open hood.
(2) Mark wi per arm l ocati ons on wi ndshi el d wi th
grease penci l .
(3) Li ft cover for wi per arms and remove nuts
attachi ng wi per arms to cowl .
(4) Remove upper pl asti c nuts attachi ng cowl gri l l e
to cowl (Fi g. 3).
(5) I nsert a smal l fl at bl ade i nto the sl ots of the
pl asti c ri vet anchors i n each cowl gri l l e corner. Li ft
up on the fl at bl ade to rel ease the ri vet anchors.
(6) Remove cowl weatherstri p.
(7) Di sconnect and pl ug wi ndshi el d washer feed
l i ne from cowl .
(8) Di sconnect vacuum l i ne from cowl .
(9) Separate cowl gri l l e from cowl .
INSTALLATION
(1) Posi ti on cowl gri l l e on cowl .
(2) Connect vacuum l i ne to cowl .
(3) Remove the pl ug and connect wi ndshi el d
washer feed l i ne to cowl .
(4) I nstal l cowl weatherstri p.
(5) Posi ti on ri vet anchors i n pl ace and press down
to engage.
(6) I nstal l upper pl asti c nuts attachi ng cowl gri l l e
to cowl .
(7) Al i gn wi per arms and i nstal l the nuts.
Fig. 2 Cargo Box
1 - CARGO BOX 2 - FRAME RAIL
Fig. 3 Cowl Grille
1 - STUD
2 - PLASTIC NUT
3 - PLASTIC RIVET
4 - COWL GRILLE
AN EXTERIOR 23 - 79
CARGO BOX (Continued)
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the namepl ate to use as a
gui de, i f necessary.
(2) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng embl em.
(3) I nsert a pl asti c tri m sti ck or a hard wood
wedge behi nd the embl em to separate the adhesi ve
backi ng from the body.
(4) Cl ean adhesi ve resi due from body wi th MOPAR
Super Cl ean sol vent or equi val ent.
INSTALLATION
(1) Remove carri er from back of embl em.
(2) Posi ti on embl em properl y on body (Fi g. 4).
(3) Press embl em fi rml y to body wi th pal m of
hand.
(4) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun to assure adhesi on.
Do not exceed 52C (120F) when heati ng embl em.
FRONT END SPLASH SHIELDS
REMOVAL
(1) Rai se and support the front wheel .
(2) Remove the front wheel .
(3) Remove wheel openi ng mol di ng.
(4) Remove pl asti c ri vets attachi ng wheel house
l i ner to wheel house (Fi g. 5).
(5) Separate l i ner from vehi cl e.
INSTALLATION
(1) Posi ti on l i ner i n wheel house.
(2) I nstal l pl asti c ri vets attachi ng wheel house l i ner
to wheel house.
(3) I nstal l wheel openi ng mol di ng.
(4) I nstal l the front wheel .
Fig. 4 Exterior Nameplates
1 - HOOD NAME PLATE
2 - MAGNUM POWER NAME PLATE
3 - ENGINE NAME PLATE
23 - 80 EXTERIOR AN
FUEL FILL DOOR
REMOVAL
(1) Open the fuel fi l l er door.
(2) Remove the screws attachi ng the door to the
cargo box outer panel (Fi g. 6).
(3) Remove the door from the panel .
INSTALLATION
(1) Posi ti on the fuel fi l l er door on the cargo box
outer panel wi th the screw hol es al i gned.
(2) I nstal l the screws attachi ng the fuel fi l l er door
to the cargo box outer panel .
GRILLE
REMOVAL
(1) Rel ease pri mary hood l atch.
(2) Rel ease hood safety catch and open hood.
(3) Remove screws attachi ng bottom of gri l l e to
gri l l e mounti ng bracket.
(4) Remove nuts attachi ng gri l l e to hood (Fi g. 7).
(5) Separate gri l l e from vehi cl e.
Fig. 5 Front Wheelhouse Liner
1 - FENDER SPLASH SHIELD
2 - INNER FENDER
3 - INNER FENDER
4 - WHEELHOUSE LINER
5 - FENDER SPLASH SHIELD
6 - PLASTIC RIVET
7 - PLASTIC RIVET
9 - INNER FENDER
11 - PLASTIC RIVET
Fig. 6 Fuel Filler Door
1 - FUEL DOOR
2 - BUMPER
AN EXTERIOR 23 - 81
FRONT END SPLASH SHIELDS (Continued)
INSTALLATION
(1) Posi ti on gri l l e on hood.
(2) I nstal l nuts attachi ng gri l l e to hood.
(3) I nstal l screws attachi ng bottom of gri l l e to
gri l l e mounti ng bracket.
(4) Cl ose hood.
LEFT FRONT FENDER
REMOVAL
(1) Remove battery.
(3) Remove l eft front wheel .
(5) Remove wheel house l i ner.
(6) Remove l eft headl amp modul e.
(7) Remove PDC (power di stri buti on center).
(8) Remove battery tray and battery support
bracket (Fi g. 8).
(9) Remove HCU (hydraul i c control uni t) i f
equi pped. (Refer to 5 - BRAKES/HYDRAULI C/ME-
CHANI CAL/HCU (HYDRAULI C CONTROL UNI T) -
REMOVAL)
(10) Di sengage cl i ps attachi ng hood rel ease cabl e
to i nner fender.
(11) Di sengage cl i ps attachi ng wi re harness to
i nner fender and wheel house.
(12) Remove bol t attachi ng fender to l ower rocker
panel .
(13) Remove bol ts attachi ng fender to l ower radi a-
tor cl osure panel (Fi g. 8).
(14) Remove bol ts attachi ng fender to hood hi nge
support bracket.
(15) Remove bol ts attachi ng fender to upper cowl
(Fi g. 9).
(16) Remove bol ts attachi ng fender to upper radi a-
tor cl osure panel .
(17) Separate fender and wheel house from vehi cl e.
INSTALLATION
(1) Posi ti on fender and wheel house from vehi cl e.
(2) I nstal l bol ts attachi ng fender to upper radi ator
cl osure panel .
(3) I nstal l bol ts attachi ng fender to upper cowl .
(4) I nstal l bol ts attachi ng fender to hood hi nge
support bracket.
(5) I nstal l bol ts attachi ng fender to l ower radi ator
cl osure panel .
(6) I nstal l bol t attachi ng fender to l ower rocker
panel .
(7) Posi ti on the hood rel ease cabl e to i nner fender
and engage cl i ps.
(8) Posi ti on the wi re harnesses on the i nner fender
and wheel house and engage cl i ps.
Fig. 7 Grille
1 - GRILLE
2 - GRILLE MOUNTING BRACKET
Fig. 8 Battery Tray and Support Bracket
1 - FRONT FENDER
2 - BATTERY TRAY SUPPORT BRACKET
3 - BATTERY TRAY
23 - 82 EXTERIOR AN
GRILLE (Continued)
(9) I nstal l HCU i f equi pped. (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/HCU (HYDRAULI C
CONTROL UNI T) - I NSTALLATI ON)
(10) I nstal l battery support bracket and battery
tray.
(11) I nstal l PDC (power di stri buti on center).
(12) I nstal l l eft headl amp modul e.
(13) I nstal l battery.
(14) I nstal l wheel house l i ner.
(16) I nstal l l eft front wheel .
REAR WHEELHOUSE SPLASH
SHIELD
REMOVAL
(1) Remove bottom screw attachi ng wheel openi ng
mol di ng to cargo box.
(2) Remove screws attachi ng spl ash shi el d to i nner
wheel house (Fi g. 10).
(3) Separate spl ash shi el d from vehi cl e.
INSTALLATION
(1) Posi ti on spl ash shi el d i n wheel house.
(2) I nstal l screws attachi ng spl ash shi el d to i nner
wheel house.
(3) I nstal l bottom screw attachi ng wheel openi ng
mol di ng to cargo box.
RIGHT FRONT FENDER
REMOVAL
(3) Remove ri ght front wheel .
(5) Remove wheel house l i ner.
(6) Remove ri ght headl amp modul e.
(7) Remove ai r cl eaner el ement housi ng.
(8) Remove powertrai n control modul e.
(9) Di sengage cl i ps attachi ng wi re harnesses to
i nner fender and wheel house.
(10) Remove bol t attachi ng fender to l ower rocker
panel .
(11) Remove bol ts attachi ng fender to l ower radi a-
tor cl osure panel (Fi g. 11).
(12) Remove bol ts attachi ng fender to hood hi nge
support bracket.
(13) Remove bol ts attachi ng fender to upper cowl .
(14) Remove bol ts attachi ng fender to upper radi a-
tor cl osure panel .
(15) Separate fender and wheel house from vehi cl e.
INSTALLATION
(1) Posi ti on fender and wheel house from vehi cl e.
(2) I nstal l bol ts attachi ng fender to upper radi ator
cl osure panel .
(3) I nstal l bol ts attachi ng fender to upper cowl .
Fig. 9 Front Fender
1 - FRONT FENDER
2 - BRACKET
3 - U-NUT
4 - DASH PANEL
5 - U-NUT
Fig. 10 Rear Splash Shield
1 - U-NUT
2 - REAR SPLASH SHIELD
3 - FRONT SPLASH SHIELD
4 - U-NUT
5 - CARGO BOX
6 - U-NUT
7 - U-NUT
AN EXTERIOR 23 - 83
LEFT FRONT FENDER (Continued)
(4) I nstal l bol ts attachi ng fender to hood hi nge
support bracket.
(5) I nstal l bol ts attachi ng fender to l ower radi ator
cl osure panel .
(6) I nstal l bol t attachi ng fender to l ower rocker
panel .
(7) Posi ti on the wi re harnesses on the i nner fender
and wheel house and engage cl i ps.
(8) I nstal l powertrai n control modul e.
(9) I nstal l ai r cl eaner el ement housi ng.
(10) I nstal l ri ght headl amp modul e.
(11) I nstal l wheel house l i ner.
(13) I nstal l ri ght front wheel .
ROOF J OINT MOLDING
REMOVAL
(1) Warm the roof joi nt mol di ng and roof panel to
approxi matel y 38C (100F) usi ng a sui tabl e heat
l amp or heat gun.
(2) Pul l mol di ng from roof joi nt.
INSTALLATION
(1) Remove adhesi ve tape resi due from roof joi nt.
(2) I f mol di ng i s to be reused, remove tape resi due
from back of mol di ng. Cl ean mol di ng wi th MOPAR,
Super Kl een sol vent or equi val ent. Wi pe mol di ng dry
wi th l i nt free cl oth. Appl y new body si de mol di ng
(two si ded adhesi ve) tape to back of mol di ng.
(3) Cl ean roof joi nt wi th MOPAR, Super Kl een sol -
vent or equi val ent. Wi pe dry wi th l i nt free cl oth.
(4) Remove protecti ve cover from tape on back of
mol di ng and appl y mol di ng to roof joi nt.
(5) Heat roof and mol di ng, see step one. Fi rml y
press mol di ng i nto roof joi nt to assure adhesi on.
SIDE VIEW MIRROR
REMOVAL
(2) Remove mi rror fl ag seal (Fi g. 12).
(3) Di sengage power mi rror wi re connector from
door harness, i f equi pped (Fi g. 13).
(4) Remove nuts attachi ng si de vi ew mi rror to door
frame.
(5) Separate harness grommet form door frame, i f
equi pped.
Fig. 11 Front Fender
1 - U-NUT
2 - U-NUT
3 - FRONT FENDER
23 - 84 EXTERIOR AN
RIGHT FRONT FENDER (Continued)
(6) Separate si de vi ew mi rror from vehi cl e.
INSTALLATION
(1) Posi ti on si de vi ew mi rror on vehi cl e.
(2) I nstal l harness grommet i n door frame, i f
equi pped.
(3) I nstal l nuts attachi ng si de vi ew mi rror to door
frame. Ti ghten nuts to 7 Nm (65 i n. l bs.) torque.
(4) Engage power mi rror wi re connector from door
harness, i f equi pped.
(5) I nstal l mi rror fl ag seal .
WHEEL OPENING MOLDING
REMOVAL
(1) Remove the screws attachi ng the wheel open-
i ng mol di ng to the fender (Fi g. 1).
(2) Separate the mol di ng from the wheel openi ng.
INSTALLATION
(1) Cl ean body surface wi th MOPAR Super Kl een
sol vent or equi val ent. Wi pe surface dry wi th l i nt free
cl oth.
(2) Posi ti on the mol di ng i n the wheel openi ng.
(3) Remove the backi ng and press to secure mol d-
i ng.
(4) I nstal l the screws attachi ng the wheel openi ng
mol di ng to the fender.
Fig. 12 Mirror Flag Door Seal
1 - STUFFERS
2 - MIRROR FLAG SEAL
Fig. 13 Side View Mirror Connectors
1 - ELECTRIC FOLD AWAY SIDEVIEW MIRROR
2 - DOOR
3 - ELECTRIC SIDEVIEW MIRROR
AN EXTERIOR 23 - 85
SIDE VIEW MIRROR (Continued)
HOOD
TABLE OF CONTENTS
page page
HOOD HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 86
HOOD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 87
HOOD SILENCER PAD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 87
HOOD LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 88
HOOD RELEASE CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 88
LATCH STRIKER
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 89
HOOD SAFETY LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 89
HOOD HINGE
REMOVAL
(1) Open hood and support the si de that requi res
hi nge repl acement.
(2) Remove cowl gri l l e.
(3) Mark al l bol t and hi nge attachment l ocati ons
wi th a grease penci l or other sui tabl e devi ce to pro-
vi de reference marks for i nstal l ati on.
(4) Remove the nuts attachi ng the hi nge to the
hood (Fi g. 1).
(5) Remove the bol ts attachi ng the hi nge to the
i nner fender (Fi g. 1).
(6) Separate hi nge from vehi cl e.
INSTALLATION
(1) I f necessary, pai nt new hi nge before i nstal l a-
ti on.
(2) Posi ti on the hi nge on the vehi cl e and al i gn al l
marks.
(3) I nstal l the bol ts attachi ng the hi nge to the
i nner fender. Ti ghten the bol ts to 28.2 Nm (250 i n.
l bs.) torque.
(4) I nstal l the nuts attachi ng the hi nge to the
hood. Ti ghten the nuts to 22.6 Nm (200 i n. l bs )
torque.
(5) I nstal l cowl gri l l e.
(6) Remove support and veri fy hood operati on. The
hood shoul d be al i gned to 5 mm (0.2 i n.) gap to the
front fenders.
HOOD
REMOVAL
(3) Di sconnect the under hood l amp wi re connec-
tor.
(4) Mark al l nut and hi nge attachment l ocati ons
wi th a grease penci l or other sui tabl e devi ce to pro-
vi de reference marks for i nstal l ati on.
(5) Remove the top nuts attachi ng hood to hi nge
and l oosen the bottom nuts unti l they can be
removed by hand (Fi g. 2).
(6) Wi th assi stance of a hel per, support the hood at
the opposi te si de of the vehi cl e.
(7) Remove the bottom nuts and separate the hood
from the vehi cl e.
Fig. 1 Hood Hinge
1 - HOOD
2 - HOOD HINGE
23 - 86 HOOD AN
INSTALLATION
(1) Wi th assi stance of a hel per, posi ti on the hood
on hi nges.
(2) Al i gn al l marks and i nstal l the nuts. The hood
shoul d be al i gned to 5 mm (0.2 i n.) gap to the front
fenders and fl ush across the top surfaces al ong fend-
ers.
(3) Connect the under hood l amp wi re connector.
(4) Cl ose hood and adjust as necessary.
ADJUSTMENTS
(1) Loosen the hi nge arm-to-hood panel bol ts at
each si de of the vehi cl e.
(2) Loosen the hood l atch screws.
(3) Cl ose the hood. Adjust the fore/aft posi ti on.
(4) Rai se the hood. Ti ghten the hi nge arm-to-hood
panel bol ts.
(5) Ti ghten the l atch screws.
(6) Lower the hood. I nspect cl earance between the
hood and the cowl cover.
HOOD SILENCER PAD
REMOVAL
(1) Rai se the hood.
(2) Remove the retai ners attachi ng the si l encer
pad to the hood (Fi g. 3).
(3) Remove the si l encer pad from the hood.
INSTALLATION
(1) Posi ti on the si l encer pad on the hood.
(2) I nstal l the retai ners attachi ng the si l encer pad
to the hood.
(3) Cl ose the hood.
HOOD LATCH
REMOVAL
(3) Usi ng a grease penci l , mark l atch posi ti on for
i nstal l ati on al i gnment.
(4) Remove bol ts attachi ng hood l atch to radi ator
cl osure panel crossmember (Fi g. 4).
(5) Separate hood l atch from crossmember.
(6) Di sconnect rel ease cabl e from hood l atch (Fi g.
5).
Fig. 2 Hood
1 - HOOD
2 - HOOD HINGE
Fig. 3 Hood Silencer Pad
1 - HOOD
2 - RETAINER
3 - HOOD SILENCER PAD
Fig. 4 Hood Latch
2 - HOOD RELEASE CABLE
3 - HOOD LATCH
4 - LATCH BRACKET
AN HOOD 23 - 87
HOOD (Continued)
INSTALLATION
(1) Connect rel ease cabl e to hood l atch.
(2) Posi ti on hood l atch on crossmember. Ensure
the bottom fl ange of hood l atch (Fi g. 5) i s secured
around the l atch bracket (Fi g. 4).
(3) I nstal l the bol ts attachi ng hood l atch to radi a-
tor cl osure panel crossmember. Ti ghten the bol ts to
10.7 Nm (80 i n. l bs.) torque.
(4) Cl ose hood.
(5) Adjust l atch as necessary.
ADJUSTMENTS
(1) Open the hood.
(2) Loosen the hood l atch screws.
(3) Move the l atch to the correct l ocati on and
l i ghtl y ti ghten the screws.
(4) Cl ose the hood sl owl y and observe the l atchi ng
operati on.
(5) As necessary, adjust the l atch posi ti on and
ti ghten the screws.
HOOD RELEASE CABLE
REMOVAL
(3) Remove hood l atch.
(4) Di sconnect rel ease cabl e from hood l atch (Fi g.
5).
(5) Detach the rel ease cabl e and the retai ner cl i ps
i n the engi ne compartment.
(6) Separate the rel ease cabl e grommet from the
dash panel hol e.
(7) From the i nsi de of the vehi cl e, remove the
screws attachi ng the hood rel ease handl e to the bot-
tom of the i nstrument panel (Fi g. 6).
(8) Pul l /route the hood rel ease cabl e through the
dash panel hol e and remove i t vi a the i nsi de of the
vehi cl e.
INSTALLATION
NOTE: If replacement hood latch is also being
installed, ensure that it is thoroughly lubricated.
(1) From i nsi de the vehi cl e, pul l /route the hood
rel ease cabl e through the dash panel hol e and i nto
(2) I nstal l the hood rel ease handl e.
(3) I nstal l the cabl e grommet i n the dash panel
hol e.
(4) Attach the retai ner cl i ps to the rel ease cabl e
and i nstal l them i nto the hol es i n the engi ne com-
partment.
(5) Attach rel ease cabl e to hood l atch.
(6) I nstal l hood l atch.
(7) Test the hood l atch rel ease cabl e for proper
operati on.
Fig. 5 Hood Release Cable
2 - HOOD LATCH
3 - BOTTOM FLANGE
Fig. 6 Hood Release Cable
1 - DASH PANEL
3 - HOOD RELEASE HANDLE
23 - 88 HOOD AN
HOOD LATCH (Continued)
LATCH STRIKER
ADJUSTMENTS
(1) Open the hood.
(2) Loosen the l atch stri ker screws.
(3) Sl owl y cl ose the hood and observe the l atchi ng
operati on.As necessary, adjust the stri ker posi ti on.
Ti ghten the screws.
HOOD SAFETY LATCH
REMOVAL
(3) Remove bol ts attachi ng hood safety l atch to
hood (Fi g. 7).
(4) Separate safety l atch from hood.
INSTALLATION
(1) Posi ti on safety l atch on hood.
(2) I nstal l bol ts attachi ng safety l atch to hood.
Ti ghten the bol ts to 9.6 Nm (85 i n. l bs.) torque.
(3) Cl ose hood and veri fy operati on. Adjust as nec-
essary.
Fig. 7 Hood Safety Latch
1 - HOOD
2 - SAFETY LATCH
3 - HINGE
AN HOOD 23 - 89
INSTRUMENT PANEL SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ASH RECEIVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 97
BASE TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CLUSTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 99
DEFROSTER GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 100
END CAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 100
GLOVE BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 101
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 102
GLOVE BOX LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSIDE HOOD RELEASE BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 105
LOWER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 106
STEERING COLUMN OPENING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 107
STORAGE BIN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 108
TOP COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 109
DESCRIPTION
The i nstrument panel i s l ocated at the front of the
passenger compartment (Fi g. 1). Thi s i nstrument
panel i s mol ded from a bl end of vari ous pl asti cs that
are mechani cal l y attached to the vehi cl e. Col ors are
mol ded i nto the pl asti c components to mi ni mi ze
appearance degradati on from scratches or abrasi ons.
The panel components are i nternal l y ri bbed and ri v-
eted to steel rei nforcements for addi ti onal structural
i ntegri ty and di mensi onal stabi l i ty. The i nstrument
panel surface components are desi gned to deform
upon i mpact wi thout breaki ng. Thi s type of construc-
ti on provi des i mproved energy absorpti on whi ch, i n
conjuncti on wi th the dual ai rbags and seat bel ts,
hel ps to i mprove occupant protecti on.
The i nstrument panel for thi s vehi cl e i ncl udes the
fol l owi ng major features:
Cluster Bezel - Thi s mol ded pl asti c bezel i s
secured wi th two screws and snap cl i ps to the i nstru-
ment panel supporti ng structure. I t tri ms out the
edges of the headl amp swi tch, i nstrument cl uster,
radi o, heater-ai r condi ti oner control s, the passenger
ai rbag on-off swi tch or rear wi ndow defogger swi tch
on vehi cl es so equi pped, and the 4WD transfer case
swi tch on vehi cl es so equi pped. On vehi cl es wi thout
the passenger ai rbag on-off swi tch or rear wi ndow
defogger swi tch, a smal l storage cubby bi n i s pro-
vi ded i n the cl uster bezel . Li kewi se, on vehi cl es wi th-
out the opti onal four-wheel dri ve system, a smal l
storage cubby bi n i s provi ded i n the cl uster bezel .
Thi s bezel al so i ncorporates fi ve compl etel y adjust-
abl e panel outl ets for the cl i mate control system, and
fi l l s the openi ng between the i nstrument cl uster and
the top of the steeri ng col umn where i t passes
through the i nstrument panel .
End Caps - A mol ded pl asti c end cap i s secured
wi th snap cl i ps to each outboard end of the i nstru-
ment panel . The end cap on the ri ght end of the
i nstrument panel i s pri mari l y cosmeti c. The end cap
on the l eft end of the i nstrument panel doubl es as a
fuse access panel for the Juncti on Bl ock (JB) and fea-
tures an i ntegral pul l cup on i ts outer surface to ease
removal , whi l e a fuse l ayout map, a fuse pul l er and
spare fuses are conveni entl y conceal ed on i ts i nner
surface.
23 - 90 INSTRUMENT PANEL SYSTEM AN
Glove Box - The modul ar gl ove box i n the pas-
senger si de of the i nstrument panel features a
recessed paddl e-operated l atch handl e, a storage bi n-
type gl ove box, and a fi xed owners manual shel f at
the top of the gl ove box openi ng. A metal hi nge on
the l ower edge of the gl ove box door i s ri veted to the
modul e and secured wi th screws to the l ower edge of
the i nstrument panel support structure. The gl ove
box door al so serves as the passenger si de knee
bl ocker. A honeycomb structure between the i nner
and outer gl ove box door panel s hel ps to absorb the
i mpact l oad and di stri bute i t to the i nstrument panel
structure.
Lower Bezel - The i nstrument panel l ower
bezel i s l ocated on the l ower edge of the i nstrument
panel , near the center. Thi s bezel features an ash
recei ver wi th a hi nged door that i s secured wi th a
push/push-type l atch and an i ntegral ci gar l i ghter, an
accessory power outl et, and a center stack l i ght that
i l l umi nates the storage tray at the front of the center
fl oor consol e on the fl oor panel transmi ssi on tunnel
bel ow.
Steering Column Opening Cover - The steer-
i ng col umn openi ng cover serves as the dri ver si de
knee bl ocker. Thi s mol ded pl asti c cover has an i nte-
gral ri bbed pl asti c l i ner conceal ed behi nd i t, for
i ncreased strength and i ntegri ty. The steeri ng col umn
openi ng cover transfers i mpact l oads to the i nstru-
ment panel structural support. A paddl e-type parki ng
brake rel ease handl e i s al so i ncorporated i n the l ower
l eft corner of the steeri ng col umn openi ng cover.
Top Cover - The i nstrument panel top cover i s
the mol ded, grai ned, and col or i mpregnated pl asti c
panel that forms the top of the i nstrument panel .
Thi s panel features an i ntegral hood formati on over
the i nstrument cl uster on the l eft si de and two i nte-
gral storage tray formati ons over the ri ght si de. A
removabl e si de wi ndow demi ster outl et i s i ncorpo-
rated near each outboard end of the top cover.
Hard wi red ci rcui try connects the el ectri cal compo-
nents on the i nstrument panel to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
and to the i nstrument panel components through the
use of a combi nati on of sol dered spl i ces, spl i ce bl ock
connectors and many di fferent types of wi re harness
termi nal connectors and i nsul ators. Refer to the
ti on i ncl udes compl ete ci rcui t di agrams, proper wi re
and connector repai r procedures, further detai l s on
wi re harness routi ng and retenti on, as wel l as pi n-
out and l ocati on vi ews for the vari ous wi re harness
connectors, spl i ces, and grounds.
OPERATION
The i nstrument panel serves as the command cen-
ter of the vehi cl e, whi ch necessari l y makes i t a very
compl ex uni t. The i nstrument panel i s desi gned to
house the control s and moni tors for standard and
opti onal powertrai ns, cl i mate control systems, audi o
systems, safety systems, and many other comfort or
conveni ence i tems. When the components of the
i nstrument panel structural support are properl y
assembl ed and secured i n the vehi cl e they provi de
superi or i nstrument panel sti ffness and i ntegri ty to
hel p reduce buzzes, squeaks, and rattl es. Thi s type of
constructi on al so provi des i mproved energy absorp-
ti on whi ch, i n conjuncti on wi th the dual ai rbags and
seat bel ts, hel ps to i mprove occupant protecti on.
The i nstrument panel i s al so desi gned so that al l of
the vari ous control s can be safel y reached and the
moni tors can be easi l y vi ewed by the vehi cl e operator
when dri vi ng, whi l e sti l l al l owi ng rel ati ve ease of
access to each of these i tems for servi ce. Modul ar
i nstrument panel constructi on al l ows al l of the
gauges and control s to be servi ced from the front of
the panel . I n addi ti on, most of the i nstrument panel
el ectri cal components can be accessed wi thout com-
pl ete i nstrument panel removal . However, i f neces-
sary, the i nstrument panel can be removed from the
vehi cl e as an assembl y.
Fig. 1 Instrument Panel
1 - DEFROSTER GRILLE
2 - CLUSTER BEZEL
3 - TOP COVER
4 - LOWER BEZEL
5 - END CAP
AN INSTRUMENT PANEL SYSTEM 23 - 91
INSTRUMENT PANEL SYSTEM (Continued)
The steeri ng col umn openi ng cover wi th i ts i nte-
gral knee bl ocker l ocated on the dri ver si de of the
i nstrument panel works i n conjuncti on wi th the ai r-
bag system i n a frontal vehi cl e i mpact to keep the
dri ver properl y posi ti oned for an ai rbag depl oyment.
I n addi ti on, removal of thi s component provi des
access to the steeri ng col umn mounts, the steeri ng
col umn wi ri ng, the Juncti on Bl ock (JB) (removal of a
snap-fi t end cap on the l eft outboard end of the
i nstrument panel al l ows access to the fuses and ci r-
cui t breakers), and much of the i nstrument panel
wi ri ng.
I n a frontal col l i si on, the gl ove box door on the pas-
senger si de of the i nstrument panel provi des the
same functi on for the front seat passenger as the
knee bl ocker does for the dri ver. The gl ove box door
al so i ncorporates a recessed l atch handl e. Removal of
the gl ove box provi des access to the passenger ai rbag,
the gl ove box l amp and swi tch, the radi o antenna
coaxi al cabl e, and addi ti onal i nstrument panel wi r-
i ng.
Removal of the i nstrument panel cl uster bezel
al l ows access to the headl amp swi tch, the i nstrument
cl uster, the radi o, the passenger ai rbag on-off swi tch
(i f equi pped), the rear wi ndow defogger swi tch (i f
equi pped), the four-wheel dri ve transfer case swi tch
(i f equi pped), and the heati ng and ai r condi ti oni ng
control . Removal of the i nstrument cl uster al l ows
access to the cl uster i l l umi nati on and i ndi cator bul bs,
and more of the i nstrument panel wi ri ng. Compl ete
i nstrument panel removal i s requi red for servi ce of
most components i nternal to the heati ng and ai r con-
di ti oni ng system housi ng, i ncl udi ng the heater core
and the evaporator.
of al l of the components and systems mounted on or
i n the i nstrument panel .
REMOVAL
cabl e.
(2) Remove the defroster gri l l e from the i nstru-
ment panel (Fi g. 2). (Refer to 23 - BODY/I NSTRU-
MENT PANEL/DEFROSTER GRI LLE - REMOVAL).
(3) Remove the end caps from the l eft and ri ght
outboard ends of the i nstrument panel . (Refer to 23 -
BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL END CAP - REMOVAL).
(4) Remove the tri m from the l eft and ri ght cowl
si de i nner panel s. (Refer to 23 - BODY/I NTERI OR/
COWL TRI M COVER - REMOVAL).
panel . (Refer to 23 - BODY/I NSTRUMENT PAN-
EL/I P LOWER RI GHT CENTER BEZEL - REMOV-
AL).
Fig. 2 Instrument Panel
2 - CLUSTER BEZEL
3 - TOP COVER
4 - LOWER BEZEL
5 - END CAP
(8) I f the vehi cl e i s so equi pped, remove the con-
sol e from the fl oor panel transmi ssi on tunnel . (Refer
REMOVAL).
(9) From under the passenger si de end of the
i nstrument panel , perform the fol l owi ng:
(a) Di sconnect the two hal ves of the radi o
antenna coaxi al cabl e connector.
(b) I f the vehi cl e i s equi pped wi th the I nfi ni ty
sound system opti on, di sconnect the two i nstru-
ment panel wi re harness connectors for the ampl i -
fi er from the connector receptacl es on the bottom of
the ampl i fi er on the ri ght cowl si de i nner panel .
(c) Remove the nut that secures the i nstrument
panel wi re harness ground take out eyel et termi nal
connector to the ground stud on the ri ght cowl si de
i nner panel , and remove the eyel et termi nal from
the stud.
(10) From under the dri ver si de end of the i nstru-
ment panel , perform the fol l owi ng:
(a) Remove the two screws that secure the i nsi de
hood rel ease bracket to the i nstrument panel .
(b) Di sengage the 16-way data l i nk connector
from the i nsi de hood rel ease bracket and l ower the
rel ease handl e and bracket to the fl oor.
(c) Di sconnect the i nstrument panel wi re har-
ness connector for the Ai rbag Control Modul e
(ACM) on the fl oor panel transmi ssi on tunnel from
the ACM connector receptacl e.
(d) Remove the two screws that secure the
i nstrument panel wi re harness ground take out
eyel et termi nal connectors to the l eft si de of the
ACM mounti ng bracket on the fl oor panel trans-
mi ssi on tunnel .
(e) Di sconnect the two i nstrument panel wi re
harness connectors for the Central Ti mer Modul e
(CTM) on the l eft cowl si de i nner panel from the
two outboard connector receptacl es on the CTM.
(f) Remove the nut that secures the i nstrument
panel wi re harness ground take out eyel et termi nal
connector to the ground stud on the l eft cowl si de
i nner panel , and remove the eyel et termi nal from
the stud.
(g) Di sconnect the i nstrument panel wi re har-
ness connector for the park brake swi tch from the
swi tch termi nal on the park brake mechani sm.
(h) Di sconnect the i nstrument panel wi re har-
ness connector for the brake l amp swi tch from the
(i ) Remove the screw that secures the center of
the i nstrument panel wi re harness bul khead con-
nector to the headl amp and dash wi re harness
bul khead connector and di sconnect the connector.
(j) Di sconnect the two body wi re harness connec-
tors from the two i nstrument panel wi re harness
connectors that are pi ggybacked on the bul khead
connector.
(k) Di sconnect the body wi re harness connector
from the connector receptacl e on the back of the
Juncti on Bl ock (JB).
(l ) Di sconnect the two headl amp and dash wi re
harness connectors from the connector receptacl es
on the back of the JB.
(11) Remove the steeri ng col umn from the vehi cl e.
(12) Loosen the ri ght and l eft i nstrument panel
cowl si de rol l -down bracket screws about 13 mm
(0.50 i nch).
(13) Remove the two screws that secure the i nstru-
ment panel end brackets to each A-pi l l ar.
(14) Remove the two screws that secure the i nstru-
ment panel center bracket to the ACM mounti ng
bracket on the fl oor panel transmi ssi on tunnel .
(15) Remove the fi ve screws that secure the top of
the i nstrument panel to the top of the dash panel ,
removi ng the center screw l ast.
(16) Rol l down the i nstrument panel and i nstal l a
temporary hook i n the center hol e on top of the
i nstrument panel . Secure the other end of the hook
to the center hol e i n the top of the dash panel . The
hook shoul d support the i nstrument panel i n i ts
rol l ed down posi ti on about 46 cm (18 i nches) from
the dash panel .
(17) Wi th the i nstrument panel supported i n the
rol l -down posi ti on, di sconnect the i nstrument panel
wi re harness connector from the heater-A/C housi ng
(18) Wi th the ai d of an assi stant, remove the tem-
porary hook and l i ft the i nstrument panel assembl y
off of the rol l -down bracket screws and remove i t
from the vehi cl e.
INSTALLATION
(1) Wi th the ai d of an assi stant, l oad the i nstru-
ment panel assembl y onto the rol l -down bracket
screws on the cowl si de i nner panel s i n the vehi cl e.
I nstal l a temporary hook i n the center hol e on top of
the i nstrument panel . Secure the other end of the
hook to the center hol e i n the top of the dash panel .
The hook shoul d support the i nstrument panel i n i ts
rol l ed down posi ti on about 46 cm (18 i nches) from
the dash panel .
(2) Wi th the i nstrument panel supported i n the
rol l -down posi ti on, reconnect the i nstrument panel
wi re harness connector to the heater-A/C housi ng
(3) Remove the temporary hook from the i nstru-
ment panel and rol l the i nstrument panel up to i ts
i nstal l ed posi ti on agai nst the dash panel .
(4) I nstal l and ti ghten the fi ve screws that secure
the top of the i nstrument panel to the top of the dash
panel (Fi g. 2). Ti ghten the screws to 2 Nm (17 i n.
l bs.).
the i nstrument panel center bracket to the Ai rbag
Control Modul e (ACM) mounti ng bracket on the fl oor
panel transmi ssi on tunnel . Ti ghten the screws to 11
Nm (95 i n. l bs.).
the i nstrument panel end brackets to each A-pi l l ar.
(7) Ti ghten the ri ght and l eft i nstrument panel
cowl si de rol l -down bracket screws. Ti ghten the
screws to 28 Nm (21 ft. l bs.).
(8) Rei nstal l the steeri ng col umn i nto the vehi cl e.
(Refer to 19 - STEERI NG/COLUMN - I NSTALLA-
TI ON).
(9) From under the dri ver si de end of the i nstru-
ment panel , perform the fol l owi ng:
(a) Reconnect the two headl amp and dash wi re
harness connectors to the connector receptacl es on
the back of the Juncti on Bl ock (JB).
(b) Reconnect the body wi re harness connector to
the connector receptacl e on the back of the JB.
(c) Reconnect the two body wi re harness connec-
tors to the two i nstrument panel wi re harness con-
nectors that are pi ggybacked on the bul khead
connector.
(d) Reconnect the i nstrument panel wi re harness
bul khead connector to the headl amp and dash wi re
harness bul khead connector and ti ghten the screw
that secures the center of the connector. Ti ghten
(e) Reconnect the i nstrument panel wi re harness
connector for the brake l amp swi tch to the swi tch
(f) Reconnect the i nstrument panel wi re harness
connector for the park brake swi tch to the swi tch
termi nal on the park brake mechani sm.
(g) Rei nstal l the i nstrument panel wi re harness
ground take out eyel et termi nal connector to the
ground stud on the l eft cowl si de i nner panel , and
i nstal l and ti ghten the nut that secures the eyel et
termi nal to the stud. Ti ghten the nut to 12 Nm
(105 i n. l bs.).
(h) Reconnect the two i nstrument panel wi re
harness connectors for the Central Ti mer Modul e
(CTM) on the l eft cowl si de i nner panel to the two
outboard connector receptacl es on the CTM.
(i ) I nstal l and ti ghten the two screws that secure
the i nstrument panel wi re harness ground take out
eyel et termi nal connectors to the l eft si de of the
ACM mounti ng bracket on the fl oor panel trans-
mi ssi on tunnel . Ti ghten the screws to 12 Nm (105
i n. l bs.).
(j) Reconnect the i nstrument panel wi re harness
connector for the ACM on the fl oor panel transmi s-
si on tunnel to the ACM connector receptacl e.
(k) Engage the 16-way data l i nk connector i nto
the i nsi de hood rel ease bracket and posi ti on the
rel ease handl e and bracket to the i nstrument
panel .
(l ) I nstal l and ti ghten the two screws that secure
the i nsi de hood rel ease bracket to the i nstrument
panel . Ti ghten the screws to 2 Nm (17 i n. l bs.).
(10) From under the passenger si de end of the
i nstrument panel , perform the fol l owi ng:
(a) Reconnect the two hal ves of the radi o
antenna coaxi al cabl e connector.
(b) I f the vehi cl e i s equi pped wi th the I nfi ni ty
sound system opti on, reconnect the two i nstrument
panel wi re harness connectors for the ampl i fi er to
the connector receptacl es on the bottom of the
ampl i fi er on the ri ght cowl si de i nner panel .
(c) Rei nstal l the i nstrument panel wi re harness
ground take out eyel et termi nal connector to the
ground stud on the ri ght cowl si de i nner panel , and
i nstal l and ti ghten the nut. Ti ghten the nut to 12
Nm (105 i n. l bs.).
(11) I f the vehi cl e i s so equi pped, rei nstal l the con-
sol e onto the fl oor panel transmi ssi on tunnel . (Refer
I NSTALLATI ON).
(12) Rei nstal l the l ower bezel onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PAN-
EL/I P LOWER BEZEL - I NSTALLATI ON).
(14) Rei nstal l the cl uster bezel onto the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL/CLUSTER BEZEL - I NSTALLATI ON).
(15) Rei nstal l the tri m onto the l eft and ri ght cowl
si de i nner panel s. (Refer to 23 - BODY/I NTERI OR/
COWL TRI M COVER - I NSTALLATI ON).
(16) Rei nstal l the end caps onto the l eft and ri ght
outboard ends of the i nstrument panel . (Refer to 23 -
PANEL END CAP - I NSTALLATI ON).
(17) Rei nstal l the defroster gri l l e onto the i nstru-
PANEL/DEFROSTER GRI LLE - I NSTALLATI ON)
ASH RECEIVER
REMOVAL
INJURY.
cabl e.
(3) Open the i nstrument panel ash recei ver on the
i nstrument panel l ower bezel (Fi g. 3).
fl at-bl aded tool , gentl y pry between the upper edge of
the ash recei ver housi ng and the i nstrument panel
l ower bezel to di sengage the two i ntegral snap fea-
tures of the housi ng from the thei r receptacl es i n the
bezel .
(5) Pul l the ash recei ver and housi ng uni t rear-
ward far enough to access and the i nstrument panel
wi re harness connector for the ci gar l i ghter.
connector for the ci gar l i ghter from the receptacl e on
the back of the l i ghter.
(7) Remove the ash recei ver and housi ng uni t from
the i nstrument panel l ower bezel .
DISASSEMBLY
The push/push l atch l ever of the ash recei ver and
housi ng uni t used i n thi s vehi cl e i s servi ced i ndi vi d-
ual l y. Fol l owi ng are the procedures for di sassembl i ng
thi s component from the ash recei ver and housi ng
uni t.
(1) Remove the ash recei ver and housi ng uni t from
the i nstrument panel l ower bezel . (Refer to 23 -
BODY/I NSTRUMENT PANEL/ASH RECEI VER -
REMOVAL).
Fig. 3 Ash Receiver
1 - ASH RECEIVER HOUSING
2 - CLUSTER BEZEL
3 - CIGAR LIGHTER
(2) Usi ng hand pressure, spread the ash recei ver
housi ng far enough to di sengage the gui de/stop pi ns
on the ash recei ver door from the sl ot on each si de of
the housi ng (Fi g. 4).
(3) Unsnap the two hi nges on the bottom of the
ash recei ver door from the hi nge pi ns on the bottom
of the ash recei ver housi ng (Fi g. 5).
(4) From the top of the ash recei ver housi ng, use a
bl unt tool to push downward on the pi vot of the
push/push l atch l ever to di sengage i t from the hous-
i ng (Fi g. 6).
(5) From the i nsi de of the ash recei ver housi ng,
di sengage the push/push l atch l ever gui de tang from
the keyed end of the gui de sl ot i n the top of the hous-
i ng.
ASSEMBLY
The push/push l atch l ever of the ash recei ver and
housi ng uni t used i n thi s vehi cl e i s servi ced i ndi vi d-
ual l y. Fol l owi ng are the procedures for assembl i ng
thi s component to the ash recei ver and housi ng uni t.
engage the push/push l atch l ever gui de tang i nto the
keyed end of the gui de sl ot i n the top of the housi ng.
al i gn the push/push l atch l ever pi vot pi n wi th the
pi vot hol e i n the top of the ash recei ver housi ng.
(3) Usi ng hand pressure, push fi rml y over the
pi vot pi n unti l i t snaps i nto the pi vot hol e i n the top
of the ash recei ver housi ng.
(4) Al i gn the hi nges on the bottom of the ash
recei ver door wi th the hi nge pi ns on the bottom of
the housi ng (Fi g. 7).
Fig. 4 Ash Receiver Guide/Stop Pins
2 - GUIDE/STOP PINS
Fig. 5 Ash Receiver Disassembly/Assembly
1 - ASH RECEIVER DOOR
3 - HINGE (2)
Fig. 6 Push/Push Latch Lever
1 - BLUNT TOOL
2 - PUSH/PUSH LATCH LEVER
ASH RECEIVER (Continued)
(5) Usi ng hand pressure, snap the hi nges of the
ash recei ver door onto the hi nge pi ns of the housi ng.
CAUTION: Be certain that the free end of the push/
push latch spring on the ash receiver door is
inserted into the slotted hole in the ash receiver
housing to the left of the push/push latch lever
before completing the following step or the spring
may be damaged.
(6) Usi ng hand pressure, spread the ash recei ver
housi ng far enough to engage the gui de/stop pi ns on
the ash recei ver door i nto the sl ot on each si de of the
housi ng (Fi g. 4).
(7) Check the operati on of the push/push l atch of
the ash recei ver.
(8) Rei nstal l the ash recei ver i nto the i nstrument
panel l ower bezel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/ASH RECEI VER - I NSTALLATI ON).
INSTALLATION
(1) Posi ti on the ash recei ver and housi ng uni t to
the i nstrument panel (Fi g. 3).
connector for the ci gar l i ghter to the receptacl e on
the back of the l i ghter.
(3) I nsert the two tabs on the bottom of the ash
recei ver housi ng i nto thei r receptacl es i n the i nstru-
ment panel l ower bezel .
(4) Al i gn the snap features on the top of the ash
recei ver housi ng wi th thei r receptacl es i n the i nstru-
ment panel l ower bezel .
(5) Usi ng hand pressure, push fi rml y upward on
the ash recei ver housi ng over each of the two snap
feature l ocati ons unti l they are ful l y engaged i n thei r
receptacl es.
BASE TRIM
REMOVAL
cabl e.
(2) Remove the i nstrument panel from the vehi cl e.
(Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL).
(3) Pl ace the i nstrument panel on a sui tabl e work
surface. Be certai n to take the proper precauti ons to
protect the i nstrument panel from any possi bl e cos-
meti c damage.
(5) Remove the radi o from the i nstrument panel .
REMOVAL).
Fig. 7 Ash Receiver Hinge
1 - HOUSING
2 - HINGE (2)
ASH RECEIVER (Continued)
(6) Remove the top cover from the i nstrument
TOP COVER - REMOVAL).
NOTE: Four of the screws secure the lower instru-
ment panel duct to the base trim.
(7) Remove the screws around the peri meter of the
i nstrument panel that secure the base tri m to the
i nstrument panel structural support.
(8) Remove the base tri m from the i nstrument
panel structural support.
INSTALLATION
(1) Posi ti on the base tri m onto the i nstrument
panel structural support.
(2) I nstal l and ti ghten the screws around the
peri meter of the i nstrument panel that secure the
base tri m to the i nstrument panel structural support.
(3) Rei nstal l the top cover onto the i nstrument
TOP COVER - I NSTALLATI ON).
(4) Rei nstal l the radi o i nto the i nstrument panel .
I NSTALLATI ON).
(5) I nstal l the i nstrument cl uster i nto the i nstru-
MENT CLUSTER - I NSTALLATI ON).
(6) Rei nstal l the i nstrument panel i nto the vehi cl e.
(Refer to 23 - BODY/I NSTRUMENT PANEL -
I NSTALLATI ON).
CLUSTER BEZEL
REMOVAL
cabl e.
(2) I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, turn the i gni ti on swi tch to the Unl ock
posi ti on, set the park brake, and pl ace the automati c
transmi ssi on gear sel ector l ever i n the Low posi ti on.
(3) I f the vehi cl e i s equi pped wi th a ti l t col umn,
set the ti l t steeri ng col umn i n i ts l owest posi ti on.
(5) Remove the two screws i n the hooded area
above the i nstrument cl uster that secure the cl uster
bezel to the i nstrument panel base tri m (Fi g. 8).
fl at-bl aded tool , gentl y pry around the peri meter of
the cl uster bezel to di sengage each of the snap cl i ps
from thei r receptacl es i n the i nstrument panel base
tri m.
(7) Pul l the ri ght si de of the cl uster bezel away
from the i nstrument panel far enough to access and
di sconnect the i nstrument panel wi re harness con-
Fig. 8 Cluster Bezel
1 - SCREW (2)
2 - CLUSTER BEZEL
BASE TRIM (Continued)
nector for the headl amp swi tch from the swi tch con-
nector receptacl e.
(8) Pul l the l eft si de of the cl uster bezel away from
the i nstrument panel far enough to access and di s-
connect the i nstrument panel wi re harness connec-
tors from the receptacl es for the passenger ai rbag
on/off swi tch (i f equi pped), the rear wi ndow defogger
swi tch (i f equi pped), the heater-ai r condi ti oner con-
trol , and the transfer case swi tch (i f equi pped).
panel .
INSTALLATION
(1) Posi ti on the cl uster bezel to the i nstrument
panel .
(2) Pul l the l eft si de of the cl uster bezel away from
the i nstrument panel far enough to access and recon-
nect the i nstrument panel wi re harness connectors to
the receptacl es for the passenger ai rbag on/off swi tch
(i f equi pped), the rear wi ndow defogger swi tch (i f
equi pped), the heater-ai r condi ti oner control , and the
transfer case swi tch (i f equi pped).
(3) Pul l the ri ght si de of the cl uster bezel away
from the i nstrument panel far enough to access and
reconnect the i nstrument panel wi re harness connec-
tor for the headl amp swi tch to the swi tch connector
receptacl e.
(4) Al i gn the snap cl i ps on the cl uster bezel wi th
the receptacl es i n the i nstrument panel base tri m.
(5) Usi ng hand pressure, press fi rml y on the cl us-
ter bezel over each of the snap cl i p l ocati ons unti l
each of the snap cl i ps i s ful l y engaged i n i ts recepta-
cl e i n the i nstrument panel base tri m.
(6) I nstal l and ti ghten the two screws i n the
hooded area above the i nstrument cl uster that secure
the cl uster bezel to the i nstrument panel base tri m
(Fi g. 8). Ti ghten the screws to 2 Nm (20 i n. l bs.).
DEFROSTER GRILLE
REMOVAL
cabl e.
(2) Remove the tri m from both A-pi l l ars. (Refer to
23 - BODY/I NTERI OR/A-PI LLAR TRI M - REMOV-
AL).
the defroster gri l l e to di sengage each of the snap
cl i ps from thei r receptacl es i n the i nstrument panel
base tri m (Fi g. 9).
(4) Remove the defroster gri l l e from the top of the
Fig. 9 Defroster Grille
2 - TOP COVER
CLUSTER BEZEL (Continued)
INSTALLATION
NOTE: Be certain that the rubber defroster grille-to-
windshield seal is in place on the forward edge of
the defroster grille before it is installed to the
instrument panel.
(1) Posi ti on the defroster gri l l e onto the top of the
i nstrument panel (Fi g. 9).
(2) Al i gn the snap cl i ps on the defroster gri l l e wi th
the receptacl es i n the i nstrument panel base tri m.
(3) Usi ng hand pressure, press fi rml y on the
defroster gri l l e over each of the snap cl i p l ocati ons
unti l each of the snap cl i ps i s ful l y engaged i n i ts
receptacl e.
(4) Rei nstal l the tri m onto both A-pi l l ars. (Refer to
23 - BODY/I NTERI OR/A-PI LLAR TRI M - I NSTAL-
LATI ON).
END CAP
REMOVAL - DRIVER SIDE
(1) I nsert a fi nger i nto the pul l cup formati on
mol ded i nto the end cap and pul l fi rml y and sharpl y
outward to di sengage each of the snap cl i ps that
secure the end cap from thei r receptacl es i n the
i nstrument panel base tri m (Fi g. 10)
(2) Remove the end cap from the end of the i nstru-
ment panel .
REMOVAL - PASSENGER SIDE
the passenger si de end cap to di sengage each of the
snap cl i ps from thei r receptacl es i n the i nstrument
panel base tri m (Fi g. 11).
(2) Remove the end cap from the end of the i nstru-
ment panel .
INSTALLATION
(1) Posi ti on the end cap to the outboard end of the
i nstrument panel .
(2) Al i gn the snap cl i ps on the end cap wi th the
receptacl es i n the i nstrument panel base tri m (Fi g.
10).
(3) Usi ng hand pressure, press fi rml y on the end
cap over each of the snap cl i p l ocati ons unti l each of
the snap cl i ps i s ful l y engaged i n i ts receptacl e i n the
i nstrument panel base tri m.
Fig. 10 End Cap Remove/Install
1 - RECEPTACLES
2 - SNAP CLIPS
3 - END CAP
Fig. 11 End Cap Remove/Install - Typical
1 - RECEPTACLES
2 - SNAP CLIPS
3 - END CAP
DEFROSTER GRILLE (Continued)
GLOVE BOX
REMOVAL
cabl e.
LOWER BEZEL - REMOVAL).
(4) Remove the screw that secures the i nboard si de
of the gl ove box modul e to the i nstrument panel
behi nd the l ower bezel .
(5) Remove the passenger si de end cap from the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/END CAP - REMOVAL - PASSEN-
GER SI DE).
(6) Remove the screw that secures the outboard
end of the gl ove box modul e to the ri ght end of the
i nstrument panel behi nd the passenger si de end cap.
(7) Remove the four screws that secure the bottom
of the gl ove box modul e to the i nstrument panel (Fi g.
12).
(8) Unl atch and open the gl ove box.
(9) Remove the l atch stri ker from the upper gl ove
box openi ng rei nforcement. (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX LATCH STRI KER
- REMOVAL).
(10) Remove the two remai ni ng screws that secure
the top of the gl ove box modul e to the upper gl ove
box openi ng rei nforcement.
(11) I f the vehi cl e i s equi pped wi th a gl ove box
l amp, pul l the gl ove box modul e away from the
i nstrument panel far enough to access and di sconnect
the i nstrument panel wi re harness connector from
the gl ove box l amp and swi tch connector receptacl e
(Fi g. 13).
ment panel .
DISASSEMBLY
The gl ove box l atch and handl e uni t of the gl ove
box used i n thi s vehi cl e i s servi ced i ndi vi dual l y. Fol -
l owi ng are the procedures for di sassembl i ng thi s
component from the gl ove box modul e.
Fig. 12 Glove Box Remove Install
1 - SCREW (4)
2 - SCREW (4)
Fig. 13 Glove Box Lamp & Switch Connector
1 - GLOVE BOX MODULE
PANEL/GLOVE BOX - REMOVAL).
(2) Remove the ni ne screws that secure the fl anges
around the peri meter of the gl ove box bi n to the
i nsi de of the gl ove box door.
(3) Remove the gl ove box bi n from the i nsi de of the
gl ove box door (Fi g. 14).
(4) Remove the two screws that secure the gl ove
box l atch and handl e to the i nsi de of the gl ove box
door.
(5) Remove the gl ove box l atch and handl e from
the i nsi de of the gl ove box door.
ASSEMBLY
The gl ove box l atch and handl e uni t of the gl ove
box used i n thi s vehi cl e i s servi ced i ndi vi dual l y. Fol -
l owi ng are the procedures for assembl i ng thi s compo-
nent to the gl ove box modul e.
(1) Posi ti on the gl ove box l atch and handl e to the
i nsi de of the gl ove box door.
the gl ove box l atch and handl e to the i nsi de of the
gl ove box door. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
(3) Posi ti on the gl ove box bi n to the i nsi de of the
gl ove box door (Fi g. 14).
(4) I nstal l and ti ghten the ni ne screws that secure
the fl anges around the peri meter of the gl ove box bi n
to the i nsi de of the gl ove box door. Ti ghten the
(5) Rei nstal l the gl ove box modul e onto the i nstru-
PANEL/GLOVE BOX - I NSTALLATI ON).
INSTALLATION
(1) Posi ti on the gl ove box modul e to the i nstru-
ment panel .
(2) I f the vehi cl e i s equi pped wi th a gl ov box l amp,
reconnect the i nstrument panel wi re harness connec-
tor to the gl ove box l amp and swi tch connector recep-
tacl e (Fi g. 13).
(3) Posi ti on the top of the gl ove box modul e to the
upper gl ove box openi ng rei nforcement.
Fig. 14 Glove Box Latch & Handle
1 - TOP COVER
2 - GLOVE BOX LATCH & HANDLE
3 - GLOVE BOX DOOR
GLOVE BOX (Continued)
(4) I nstal l and ti ghten the two outboard screws
that secure the top of the gl ove box modul e to the
upper gl ove box openi ng rei nforcement (Fi g. 12).
(5) Rei nstal l the gl ove box l atch stri ker to the
upper gl ove box openi ng rei nforcement. (Refer to 23 -
BODY/I NSTRUMENT PANEL/GLOVE BOX LATCH
STRI KER - I NSTALLATI ON).
(6) Cl ose and l atch the gl ove box.
the bottom of the gl ove box modul e to the i nstrument
panel (Fi g. 12). Ti ghten the screws to 2 Nm (20 i n.
l bs.).
outboard end of the gl ove box modul e to the ri ght
end of the i nstrument panel behi nd the passenger
si de end cap. Ti ghten the screw to 2 Nm (20 i n. l bs.).
(9) Rei nstal l the passenger si de end cap onto the
MENT PANEL/I NSTRUMENT PANEL END CAP -
I NSTALLATI ON).
i nboard si de of the gl ove box modul e to the i nstru-
ment panel behi nd the l ower bezel . Ti ghten the screw
to 2 Nm (20 i n. l bs.).
(11) Open and cl ose the gl ove box to check for
proper hi nge operati on and al i gnment (Fi g. 15).
(12) Rei nstal l the l ower bezel onto the i nstrument
LOWER BEZEL - I NSTALLATI ON).
(13) Rei nstal l the cl uster bezel onto the i nstru-
PANEL/CLUSTER BEZEL - I NSTALLATI ON).
GLOVE BOX LATCH STRIKER
REMOVAL
cabl e.
(2) Unl atch and open the gl ove box.
(3) Remove the two screws that secure the l atch
stri ker to the upper gl ove box openi ng rei nforcement
(Fi g. 16).
(4) Remove the l atch stri ker from the upper gl ove
box openi ng rei nforcement.
Fig. 15 Glove Box Alignment
1 - CLUSTER BEZEL
2 - PASSENGER AIR BAG DOOR
3 - GLOVE BOX DOOR
Fig. 16 Glove Box Latch Striker Remove/Install
1 - SCREW (2)
2 - LATCH STRIKER
GLOVE BOX (Continued)
INSTALLATION
(1) Posi ti on the l atch stri ker onto the upper gl ove
box openi ng rei nforcement (Fi g. 16).
the l atch stri ker to the upper gl ove box openi ng rei n-
forcement. Ti ghten the screws to 2 Nm (20 i n. l bs.).
INSIDE HOOD RELEASE
BRACKET
REMOVAL
cabl e.
(3) Remove the two screws that secure the i nsi de
hood rel ease handl e to the i nsi de hood rel ease
bracket and l ower the rel ease handl e to the fl oor
(Fi g. 17).
(4) Depress the l atch tabs that secure the 16-way
data l i nk connector to the i nsi de hood rel ease
bracket, and push the connector out of i ts mounti ng
hol e.
(5) Remove the two screws that secure the i nsi de
hood rel ease bracket to the i nstrument panel struc-
tural support (Fi g. 18).
Fig. 17 Steering Column Opening Cover
2 - INSIDE HOOD RELEASE
3 - SCREW (3)
Fig. 18 Inside Hood Release Bracket
1 - TOP COVER
3 - INSIDE HOOD RELEASE BRACKET
GLOVE BOX LATCH STRIKER (Continued)
(6) Remove the i nsi de hood rel ease bracket from
the i nstrument panel structural support.
INSTALLATION
(1) Posi ti on the i nsi de hood rel ease bracket onto
the i nstrument panel structural support (Fi g. 18).
the i nsi de hood rel ease bracket to the i nstrument
panel structural support. Ti ghten the screws to 2
Nm (17 i n. l bs.).
(3) I nstal l the 16-way data l i nk connector i nto the
mounti ng hol e on the i nsi de hood rel ease bracket.
(4) Posi ti on the i nsi de hood rel ease handl e to the
i nstrument panel l ower rei nforcement.
the i nsi de hood rel ease handl e to the i nsi de hood
rel ease bracket. Ti ghten the screws to 3 Nm (25 i n.
l bs.).
LOWER BEZEL
REMOVAL
cabl e.
(4) Remove the two screws that secure the bottom
of the l ower bezel to the i nstrument panel structural
support (Fi g. 19).
(5) Remove the three screws that secure the top of
the l ower bezel to the i nstrument panel structural
support.
(6) I f the vehi cl e i s so equi pped, pul l the l ower
bezel away from the i nstrument panel far enough to
access and di sconnect the i nstrument panel wi re har-
ness connectors from the receptacl es for the accessory
power outl et, the l ower bezel consol e l amp, and the
ci gar l i ghter.
panel .
Fig. 19 Lower Bezel Remove/Install
1 - LOWER BEZEL
2 - SCREW (5)
INSIDE HOOD RELEASE BRACKET (Continued)
INSTALLATION
(1) Posi ti on the l ower bezel to the i nstrument
panel .
(2) I f the vehi cl e i s so equi pped, reconnect the
i nstrument panel wi re harness connectors to the
receptacl es for the accessory power outl et, the l ower
bezel consol e l amp, and the ci gar l i ghter.
(3) Posi ti on the l ower bezel onto the i nstrument
panel (Fi g. 19).
the top of the l ower bezel to the i nstrument panel
structural support. Ti ghten the screws to 2 Nm (20
i n. l bs.).
the bottom of the l ower bezel to the i nstrument panel
structural support. Ti ghten the screws to 2 Nm (20
i n. l bs.).
STEERING COLUMN OPENING
COVER
REMOVAL
cabl e.
(2) Reach under the l eft end of the i nstrument
panel to access and unsnap the rod end cl i p on the
park brake rel ease l i nk and di sengage the l i nk from
the back of the handl e (Fi g. 20).
Fig. 20 Steering Column Opening Cover
2 - INSIDE HOOD RELEASE
3 - SCREW (3)
LOWER BEZEL (Continued)
(3) Remove the three screws that secure the l ower
edge of the steeri ng col umn openi ng cover to the
fl at-bl aded tool , gentl y pry the upper edge of the
steeri ng col umn openi ng cover just bel ow the cl uster
bezel on each si de of the steeri ng col umn away from
the i nstrument panel far enough to di sengage each of
the snap cl i p retai ners from thei r receptacl es i n the
i nstrument panel base tri m (Fi g. 21).
from the i nstrument panel .
INSTALLATION
(1) Posi ti on the steeri ng col umn openi ng cover to
the i nstrument panel (Fi g. 21).
(2) Al i gn the snap cl i p retai ners on the steeri ng
col umn openi ng cover wi th the receptacl es i n the
i nstrument panel base tri m.
(3) Usi ng hand pressure, press fi rml y on the steer-
i ng col umn openi ng cover over the snap cl i p l ocati ons
unti l each of the snap cl i ps i s ful l y engaged i n i ts
receptacl e.
the l ower edge of the steeri ng col umn openi ng cover
to the i nstrument structural support (Fi g. 20).
(5) Reach under the l eft end of the i nstrument
panel to access and engage the park brake rel ease
l i nk to the back of the handl e. Then snap the rod end
cl i p over the park brake rel ease l i nk to secure the
connecti on.
STORAGE BIN
REMOVAL
A cl uster bezel may have one, two, or no storage
bi ns i nstal l ed on i t, dependi ng upon the vehi cl e
equi pment. A storage bi n i s used i n pl ace of the
opti onal four-wheel dri ve transfer case swi tch, the
opti onal passenger ai rbag on/off swi tch, and/or the
opti onal rear wi ndow defogger swi tch. I f the vehi cl e
i s equi pped wi th both of these swi tches, i t wi l l not
have a storage bi n i nstal l ed i n the cl uster bezel .
cabl e.
Fig. 21 Steering Column Opening Cover Remove/
Install
1 - INSTRUMENT PANEL TOP COVER
3 - SCREW (3)
4 - HOOD RELEASE BRACKET
STEERING COLUMN OPENING COVER (Continued)
(3) Remove the three screws that secure the stor-
age bi n to the back of the cl uster bezel (Fi g. 22).
(4) Remove the storage bi n from the back of the
cl uster bezel .
INSTALLATION
A cl uster bezel may have one, two, or no storage
bi ns i nstal l ed on i t, dependi ng upon the vehi cl e
equi pment. A storage bi n i s used i n pl ace of the
opti onal four-wheel dri ve transfer case swi tch and
the opti onal passenger ai rbag on/off swi tch. I f the
vehi cl e i s equi pped wi th both of these swi tches, i t
wi l l not have a storage bi n i nstal l ed i n the cl uster
bezel .
(1) Posi ti on the storage bi n onto the back of the
cl uster bezel (Fi g. 22).
the storage bi n to the back of the cl uster bezel .
TOP COVER
REMOVAL
cabl e.
(2) Remove the end caps from each end of the
MENT PANEL/END CAP - REMOVAL - DRI VER
SI DE) and (Refer to 23 - BODY/I NSTRUMENT PAN-
EL/END CAP - REMOVAL - PASSENGER SI DE).
(4) Remove the passenger ai rbag from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG - REMOVAL).
(5) Remove the defroster gri l l e from the i nstru-
PANEL/DEFROSTER GRI LLE - REMOVAL).
(6) Remove the si x screws that secure the forward
edge (nearest the wi ndshi el d) of the top cover to the
i nstrument panel structural support (Fi g. 23).
(7) Remove the screw that secures each outboard
end of the top cover to the i nstrument panel struc-
tural support beneath the end caps.
(8) Remove the si x screws that secure the rear-
ward edge (nearest the passenger compartment) of
the top cover to the i nstrument panel structural sup-
port.
(9) Remove the top cover from the top of the
Fig. 22 Storage Bin Remove/Install
1 - CLUSTER BEZEL
2 - STORAGE BIN (2)
STORAGE BIN (Continued)
INSTALLATION
(1) Posi ti on the top cover onto the top of the
i nstrument panel structural support (Fi g. 23).
the rearward edge (nearest the passenger compart-
ment) of the top cover to the i nstrument panel struc-
tural support. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
(3) I nstal l and ti ghten the screw that secures each
outboard end of the top cover to the i nstrument panel
structural support beneath the end caps. Ti ghten the
the forward edge (nearest the wi ndshi el d) of the top
cover to the i nstrument panel structural support.
(5) Rei nstal l the defroster gri l l e onto the i nstru-
PANEL/DEFROSTER GRI LLE - I NSTALLATI ON).
(6) Rei nstal l the passenger ai rbag i nto the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG -
I NSTALLATI ON).
(8) Rei nstal l the end caps onto each end of the
MENT PANEL/END CAP - I NSTALLATI ON).
Fig. 23 Top Cover Remove/Install
1 - SCREW (6)
2 - SCREW (2)
3 - TOP COVER
4 - SCREW (6)
TOP COVER (Continued)
INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FLOOR SHIFT BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 111
A-PILLAR TRIM
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 111
ASSIST HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 112
B-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 113
C-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 113
CARPETS AND FLOOR MATS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 113
COAT HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 114
COWL TRIM COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 114
DOOR SILL TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 114
FLOOR CONSOLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 115
HEADLINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 115
QUARTER TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 116
REAR CAB BACK PANEL TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 117
REAR STORAGE BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 117
REAR VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 118
SHIFT BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 118
SUN VISORS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 119
REAR VIEW MIRROR SUPPORT BRACKET
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 119
AIR EXHAUSTER - CAB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 120
INTERIOR
DESCRIPTION
CAUTION: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels.
To avoi d damagi ng the panel s, ensure that al l the
screws and cl i ps are removed before attempti ng to
remove an i nteri or tri m panel /mol di ng. Trim panels
are somewhat flexible but can be damaged if
handled improperly.
FLOOR SHIFT BOOT
REMOVAL
(1) Usi ng a smal l fl at bl ade, pry out i nsert from
shi ft knob (Fi g. 1).
(2) Remove nut attachi ng shi ft knob to gear shi ft.
(3) Pul l knob off gear shi ft.
(4) Usi ng a smal l fl at bl aded screwdri ver pry up
one corner of the bezel /boot assembl y. Do not sepa-
rate the boot from the bezel .
23 - 110 INTERIOR AN
(5) Li ft the boot/bezel assembl y off of the fl oor
panel and over the gear shi ft (Fi g. 2) and (Fi g. 3).
I NSTALLATI ON - FLOOR SHI FT BOOT
(1) Posi ti on shi ft boot/bezel assembl y on gear shi ft.
(2) Press shi ft boot/bezel onto the fl oor panel .
(3) Push knob onto gear shi ft.
(4) I nstal l nut attachi ng shi ft knob to gear shi ft.
(5) Press i nsert i nto shi ft knob.
A-PILLAR TRIM
REMOVAL
(1) Remove A-pi l l ar grab handl e, i f equi pped.
(2) Remove screws from cowl tri m cover.
(3) Remove cowl tri m cover.
(4) Grasp A-pi l l ar tri m and pul l outward to di sen-
gage cl i ps attachi ng A-pi l l ar tri m to A-pi l l ar (Fi g. 4).
(5) Separate A-pi l l ar tri m from vehi cl e.
INSTALLATION
(1) Posi ti on A-pi l l ar tri m at A-pi l l ar, al i gn cl i ps
and press i nto pl ace.
(2) I nstal l cowl tri m cover.
(3) I nstal l A-pi l l ar grab handl e, i f equi pped.
Fig. 1 Shift Knob Insert
1 - KNOB
2 - KNOB INSERT
3 - SHIFT BOOT
4 - FLOOR PAN
5 - TRANSFER CASE LEVER
6 - CARPET
7 - PLATE
8 - GEAR SHIFT
Fig. 2 Shift BootManual Transmission
1 - KNOB
2 - KNOB INSERT
3 - SHIFT BOOT
4 - FLOOR PAN
5 - CARPET
6 - PLATE
7 - GEAR SHIFT
Fig. 3 Shift BootTransfer Case
1 - KNOB INSERT
2 - KNOB
3 - TRANSFER CASE SHIFT LEVER
4 - FLOOR PAN
5 - PLATE
6 - BEZEL
7 - TRANSFER CASE SHIFT BOOT
AN INTERIOR 23 - 111
FLOOR SHIFT BOOT (Continued)
ASSIST HANDLE
REMOVAL
(1) Usi ng a tri m sti ck, remove the tri m coveri ng
the assi st handl e attachment screws (Fi g. 5).
(2) Remove the screw attachi ng the assi st handl e
to the roof structure.
(3) Remove the assi st handl e.
INSTALLATION
(1) Posi ti on the assi st handl e on the roof structure
and headl i ner.
(2) I nstal l the screws attachi ng the assi st handl e
to the headl i ner and roof structure.
(3) Snap i n the tri m covers.
B-PILLAR TRIM
REMOVAL
The B-pi l l ar tri m panel i s attached to the B-pi l l ar
wi th push-i n fasteners.
(1) Remove door si l l cover as necessary to cl ear
B-pi l l ar tri m.
(2) Remove shoul der bel t turni ng l oop.
(3) Grasp B-pi l l ar tri m panel and fi rml y pul l out-
ward.
(4) Di sconnect speaker harness connector, i f
equi pped.
(5) Route shoul der bel t through access sl ots i n
B-pi l l ar tri m panel .
(6) Separate B-pi l l ar tri m panel from B-pi l l ar (Fi g.
6).
Fig. 4 A-Pillar Trim
1 - A-PILLAR TRIM
2 - ASSIST HANDLE
3 - ASSIST HANDLE BOLTS
4 - PUSH IN COVER
5 - COWL TRIM CLIP
6 - COWL TRIM PANEL BOLT
7 - COWL TRIM PANEL
Fig. 5 Assist Handle
1 - HEADLINER
2 - GRAB HANDLE
3 - PUSH IN COVER
4 - SCREW
Fig. 6 B-Pillar Trim
1 - B-PILLAR TRIM
2 - TURNING LOOP
A-PILLAR TRIM (Continued)
INSTALLATION
(1) Posi ti on tri m panel i n vehi cl e.
(2) Route shoul der bel t through access sl ots i n
B-pi l l ar tri m panel .
(3) Connect speaker harness connector, i f
equi pped.
(4) Posi ti on B-pi l l ar tri m panel on B-pi l l ar and
press to seat push-i n fasteners.
(5) I nstal l shoul der bel t turni ng l oop.
(6) I nstal l door si l l cover as necessary.
C-PILLAR TRIM
REMOVAL
(1) Remove the seat bel t turni ng l oop. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT &
RETRACTOR - REMOVAL)
(2) Usi ng a tri m sti ck C-4755 or equi val ent,
remove the upper c-pi l l ar tri m panel (Fi g. 7).
(3) Remove the screws and remove posi ti on the
l ower c-pi l l ar asi de.
(4) Remove the seat bel t anchor and route seat
bel t though the l ower c-pi l l ar tri m panel .
(5) Remove the l ower c-pi l l ar tri m.
INSTALLATION
(1) Pl ace the l ower c-pi l l ar tri m i nto the vehi cl e
and route the seat bel t through the tri m.
(2) I nstal l the seat bel t anchor. (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/SEAT BELT & RETRACTOR
- I NSTALLATI ON)
(3) I nstal l the l ower c-pi l l ar tri m and i nstal l the
screws.
(4) I nstal l the upper c-pi l l ar tri m.
(5) I nstal l the seat bel t turni ng l oop.
CARPETS AND FLOOR MATS
REMOVAL
(1) Remove seat.
(2) Remove door si l l and cowl tri m covers.
(3) Remove seat bel t anchors.
(4) Remove fl oor shi ft boot/fl oor consol e, i f
equi pped.
(5) Remove rear stowage tray/storage box.
(6) Pul l carpet out from under quarter panel tri m
and cab back panel tri m.
(7) Fol d carpet or mat toward center of cab.
(8) Remove carpet or mat through door openi ng
(Fi g. 8).
INSTALLATION
(1) Posi ti on the carpet i n the cab and al i gn al l
hol es.
(2) Sl i de carpet under quarter panel tri m and cab
back panel tri m.
(3) I nstal l rear stowage tray/storage box.
(4) I nstal l fl oor shi ft boot/fl oor consol e, i f equi pped.
(5) I nstal l seat bel t anchors.
(6) I nstal l door si l l and cowl tri m covers.
(7) I nstal l seat.
Fig. 7 Upper C Pillar Trim
1 - UPPER C PILLAR TRAY
2 - LOWER C PILLAR TRIM SCREWS
Fig. 8 Floor Carpet or Mat
1 - CARPET
2 - CAB
B-PILLAR TRIM (Continued)
COAT HOOK
REMOVAL
(1) Grasp both si des of the coat hook base and
fi rml y pul l outward to di sengage the coat hook cover
from the base (Fi g. 9) and (Fi g. 10).
(2) Li ft/rock the coat hook upward to di sengage i t
from the roof panel .
INSTALLATION
(1) Posi ti on coat hook i n roof panel .
(2) Push the coat hook cover i nward and secure
the coat hook to the roof panel .
COWL TRIM COVER
REMOVAL
(1) Usi ng a tri m sti ck, pry cowl tri m cover from
cowl to di sengage cl i ps.
(2) Separate cowl tri m cover from vehi cl e.
INSTALLATION
(1) Posi ti on cowl tri m cover on cowl .
(2) Press cowl tri m cover i nto pl ace to engage cl i ps.
DOOR SILL TRIM
REMOVAL
(1) Usi ng a tri m sti ck, pry up si l l tri m cover from
door si l l .
(2) Separate si l l tri m cover from vehi cl e (Fi g. 11).
INSTALLATION
(1) Posi ti on front edge of si l l cover over cowl tri m
cover and al i gn tab.
(2) Al i gn si l l cover and press i nto pl ace.
Fig. 9 Coat Hook Removal
1 - HEADLINER
2 - COAT HOOK
Fig. 10 Coat Hook
1 - CAB
2 - COAT HOOK
Fig. 11 Sill Trim Cover
1 - CLIP
2 - SILL TRIM COVER
FLOOR CONSOLE
REMOVAL
(1) Open consol e l i d and remove bol ts attachi ng
consol e to fl oor pan (Fi g. 12).
(2) Li ft the cup hol der bi n mat and remove bol t
attachi ng the consol e to the fl oor pan.
(3) Li ft the cup hol der mat and remove the bol ts
attachi ng the consol e to the fl oor pan.
(4) Li ft the rear of the consol e and pul l the consol e
rearward to separate from the shi ft bezel .
(5) Remove the consol e from the vehi cl e.
INSTALLATION
(1) Posi ti on the consol e i n the vehi cl e.
(2) Whi l e hol di ng the consol e wi th the front of the
consol e poi nti ng downward, posi ti on the front of the
consol e on top of the shi ft bezel .
(3) Al i gn rear of consol e wi th the mounti ng
bracket.
(4) I nstal l bol ts attachi ng consol e to fl oor pan.
HEADLINER
REMOVAL
(1) Remove sun vi sors and vi sor hooks.
(2) Remove coat hooks.
(3) Remove overhead consol e, i f equi pped. Refer to
Group 8V, Overhead Consol e for removal procedure.
(4) Remove A-pi l l ar tri m.
(5) Remove quarter tri m/B-pi l l ar tri m panel s.
(6) Remove dome l amp. (Refer to 8 - ELECTRI -
CAL/LAMPS/LI GHTI NG - I NTERI OR/DOME LAMP
- REMOVAL).
(7) Separate headl i ner from roof panel (Fi g. 13)
and (Fi g. 14).
(8) Extract headl i ner through door openi ng.
INSTALLATION
(1) Posi ti on headl i ner i n vehi cl e.
(2) I nstal l quarter/B-pi l l ar tri m panel s.
(3) I nstal l A-pi l l ar tri m.
(4) I nstal l overhead consol e, i f equi pped.
(5) I nstal l dome l amp. (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - I NTERI OR/DOME LAMP -
I NSTALLATI ON).
(6) I nstal l coat hooks.
(7) I nstal l sun vi sors and vi sor hooks.
Fig. 12 Floor Console
1 - SHIFT BEZEL
2 - CUP HOLDER MAT
3 - ACCESSORY BIN MAT
4 - FLOOR CONSOLE
5 - BRACKET
Fig. 13 Quad Cab Headliner
1 - HEADLINER
2 - PUSH IN FASTENER
QUARTER TRIM PANEL
REMOVAL
(1) Remove door si l l cover as necessary to cl ear
quarter tri m.
(2) Remove cab back panel tri m.
(3) Remove front and rear shoul der bel t turni ng
l oops.
(4) Remove the screws attachi ng the quarter tri m
panel to the cab back panel .
(5) Grasp quarter tri m panel and fi rml y pul l out-
ward to di sengage the push-i n fasteners.
(6) Route front and rear shoul der bel ts through
access sl ots i n quarter tri m panel .
(7) Separate cl ub cab quarter tri m panel from
quarter panel (Fi g. 15).
INSTALLATION
(1) Posi ti on tri m panel i n vehi cl e.
(2) Route bel t webbi ng through access sl ots i n
quarter tri m panel .
(3) Posi ti on quarter tri m panel on quarter panel
and engage hooks at base of quarter tri m panel .
(4) Press quarter tri m panel i nward to seat
push-i n fasteners.
(5) I nstal l screws attachi ng quarter tri m panel to
cab back panel .
(6) I nstal l cab back panel tri m.
(7) I nstal l door si l l cover as necessary.
Fig. 14 Headliner
1 - STANDARD CAB
2 - EXTENDED CAB
3 - HEADLINER
4 - HEADLINER
Fig. 15 Quarter Trim Panel
1 - QUARTER TRIM PANEL
HEADLINER (Continued)
REAR CAB BACK PANEL TRIM
REMOVAL
The rear cab back panel tri m i s attached to the cab
wi th push-i n fasteners.
(1) Grasp rear cab back panel tri m and fi rml y pul l
to rel ease from cab (Fi g. 16) and (Fi g. 17).
INSTALLATION
(1) Posi ti on rear cab back panel tri m on cab, al i gn
hol es and press i nto pl ace.
REAR STORAGE BOX
REMOVAL
(1) Li ft rear seat.
(2) Remove bol ts attachi ng storage box to fl oor pan
(Fi g. 18).
(3) Remove rear seat bel t/buckl e anchor bol ts.
(4) Route rear seat bel t/buckl e through sl ots i n
rear of storage box.
(5) Separate storage box from vehi cl e.
INSTALLATION
(1) Posi ti on storage box i n vehi cl e.
(2) Route rear seat bel t/buckl e through sl ots i n
rear of storage box.
(3) I nstal l rear seat bel t/buckl e anchor bol ts.
(4) I nstal l bol ts attachi ng storage box to fl oor pan.
(5) Lower seat.
Fig. 16 Rear Cab Back Panel Trim
1 - REAR SEAT BACK
2 - REAR CAB PANEL TRIM
Fig. 17 Rear Cab Back Panel Trim With Carpet
1 - CAB BACK PANEL CARPET
Fig. 18 Storage Box
1 - JACK STORAGE POUCH
2 - STORAGE BOX
REAR VIEW MIRROR
REMOVAL
(1) Loosen the mi rror base setscrew (Fi g. 19).
(2) Sl i de the mi rror base upward and off the
bracket.
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket.
(2) Ti ghten setscrew to1 Nm (9 i n. l bs.) torque.
SHIFT BEZEL
REMOVAL
(1) Remove shi ft boot/s.
(2) Li ft bi n cup hol der and remove bol ts attachi ng
shi ft bezel to fl oor pan (Fi g. 20).
(3) Remove screw under shi ft boot attachi ng patch
pl ate to fl oor pan.
(4) Di sengage 4WD shi ft i ndi cator l amp connector,
i f equi pped (Fi g. 21) and (Fi g. 22).
(5) Separate shi ft bezel from vehi cl e.
INSTALLATION
(1) Posi ti on shi ft bezel i n vehi cl e.
(2) Engage 4WD shi ft i ndi cator l amp connector, i f
equi pped.
(3) I nstal l screw under shi ft boot attachi ng patch
pl ate to fl oor pan.
(4) I nstal l bol ts i n cup hol der attachi ng shi ft bezel
to fl oor pan.
(5) I nstal l shi ft boot/s.
Fig. 19 Rearview Mirror
1 - MIRROR
2 - SUPPORT BUTTON
Fig. 20 Shift Bezel 4x2
1 - SHIFT BEZEL CUP HOLDER
2 - SHIFT BEZEL 4 x 2
3 - PATCH PLATE
Fig. 21 Shift Bezel 4X4 Manual Trans
3 - PATCH PLATE
SUN VISORS
REMOVAL
NOTE: All vehicles with driver and passenger side
airbags must have a colored-coded, 5-bullet point
airbag warning label applied to the sunvisor face
surface (in the stored position). When replacing the
sunvisor, verify label availability and ensure the
label is installed.
(1) Remove the screws that attach the sunvi sor
arm support bracket to the headl i ner and the roof
panel (Fi g. 23).
(2) Detach the sunvi sor from the vi sor supports.
(3) Remove the sunvi sor from the headl i ner and
roof panel .
(4) I f necessary, remove the screw attachi ng the
vi sor supports to the headl i ner and roof panel .
INSTALLATION
NOTE: All vehicles with driver and passenger side
airbags must have a colored-coded, 5-bullet point
airbag warning label applied to the sunvisor face
surface (in the stored position). When replacing the
sunvisor, verify label availability and ensure the
label is installed.
(1) I f removed, i nstal l the vi sor supports.
(2) Posi ti on the sunvi sor i n the vi sor supports and
al i gn the arm support bracket hol es wi th the head-
l i ner hol es.
(3) I nstal l the screws that attach the sunvi sor arm
support bracket to the headl i ner and the roof panel .
REAR VIEW MIRROR SUPPORT
BRACKET
INSTALLATION
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
Crush the vi al to saturate the fel t appl i cator.
Remove the paper sl eeve.
Appl y accel erator to the contact surface on the
bracket.
Fig. 22 Shift Bezel 4X4 Automatic Trans
Fig. 23 Sunvisors
1 - VISOR SUPPORT
2 - SUNVISOR
SHIFT BEZEL (Continued)
Al l ow the accel erator to dry for fi ve mi nutes.
Do not touch the bracket contact surface after
the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
Appl y an even coat of adhesi ve to the contact
surface on the bracket.
Al i gn the bracket wi th the marked posi ti on on
the wi ndshi el d gl ass.
Press and hol d the bracket i n pl ace for at l east
one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
AIR EXHAUSTER - CAB
REMOVAL
(1) Remove cab back panel carpet/tri m.
(2) Posi ti on a l ong fl at bl ade between cab and
cargo box and depress ai r exhauster upper retai ni ng
tabs and di sengage from cab back panel .
(3) From i nsi de the vehi cl e separate ai r exhauster
from cab back panel (Fi g. 24).
INSTALLATION
(1) From i nsi de the vehi cl e posi ti on ai r exhauster
i n cab back panel .
(2) Press ai r exhauster i nward to engage retai ni ng
tabs.
Fig. 24 In Cab Air Exhausters
1 - AIR EXHAUSTERS
2 - CAB BACK PANEL
REAR VIEW MIRROR SUPPORT BRACKET (Continued)
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 121
BASE COAT/CLEAR COAT FINISH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 121
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
PAINT CODE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 121
PAINT TOUCH-UP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 121
PAINT TOUCH-UP . . . . . . . . . . . . . . . . . . . . . 122
WET SANDING/BUFFING & POLISHING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 122
PAINT
SPECIFICATIONS
2001 AN PAINT COLOR CODES
EXTERIOR COLORS
DC
CODE
EXTERIOR
COLOR
DC
CODE
EXTERIOR
COLOR
XRV
Dark Garnet
Red
PR4
Flame Red
Pearl Coat
XV3
Amber Fire
Pearl Coat
WSB
Bright Silver
Metalic
SG8
Forest Green
Pearl Coat
XTL
Medium
Bronze Pearl
Coat
WBT
Patriot Blue
Pearl Coat
VB3
Intense Blue
Pearl Coat
DX8
BLack Clear
Coat
GW7
Bright White
Clear Coat
INTERIOR COLORS
DC
CODE
INTERIOR
COLOR
DC
CODE
INTERIOR
COLOR
S
Dark Slate
Gray
T Taupe
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
The ori gi nal equi pment fi ni sh i s a mul ti -step pro-
cess that i nvol ves cl eani ng, el ectrodeposi ti on (e-coat),
base coat, and cl ear coat steps. Addi ti onal l y, sel ected
areas of the vehi cl e may be coated wi th an anti -chi p
fi ni sh.
OPERATION
On most vehi cl es a two-part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result. Do not use harsh alkaline based cleaning
solvents on painted surfaces. Damage to finish or
color can result.
PAINT CODE
DESCRIPTION
Exteri or vehi cl e body col ors are i denti fi ed on the
Body Code pl ate. The pl ate i s l ocated on the cab back
panel . Refer to the I ntroducti on secti on for body code
pl ate decodi ng. The pai nt code i s al so i denti fi ed on
the Vehi cl e Safety Certi fi cati on Label . The l abel i s
l ocated on the dri vers door shut face.
The col or names provi ded i n the Aftermarket
Repai r Product charts are the col or names used on
most repai r product contai ners.
PAINT TOUCH-UP
DESCRIPTION
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
AN PAINT 23 - 121
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
STANDARD PROCEDURE - PAINT TOUCH-UP
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN
RESULT.AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
WET SANDING/BUFFING &
POLISHING
DESCRIPTION
Mi nor aci d etchi ng, orange peel , or surface
scratches i n cl ear coat or si ngl e-stage fi ni shes can be
reduced wi th l i ght fi nesse sandi ng, buffi ng, and pol -
i shi ng. If the finish has been finesse sanded in
the past, it cannot be repeated. Finesse sanding
operation should be performed by a trained
automotive paint technician.
CAUTION: Do not remove clear coat finish more
than .5 mils, if equipped (Use a paint thickness
gauge to verify paint thickness). Base coat paint
must retain clear coat for durability.
23 - 122 PAINT AN
PAINT TOUCH-UP (Continued)
SEATS
TABLE OF CONTENTS
page page
SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 123
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CENTER CONSOLE LID
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 123
CENTER SEAT ARMREST / CONSOLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 125
CENTER SEAT CUSHION COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 125
SEAT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 127
SEAT BACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 128
SEAT BACK CUSHION / COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 129
SEAT CUSHION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 129
SEAT CUSHION COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 130
SEAT TRACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 131
SEATS
DESCRIPTION
Seat modul es are made up of a seat frame, seat
cushi on, seat back cushi on, a coveri ng materi al , and
the el ectri cal components used for power operati on, i f
equi pped. Some seat systems al so contai n seat bel t
components and suppl emental restrai nt systems.
OPERATION
Seat assembl i es transport the occupants i n comfort
and safety. Seat assembl i es al so hel p posi ti on occu-
pants correctl y i n the event of ai rbag depl oyment.
Seat cushi ons, coveri ngs, and el ectri cal components
are servi ceabl e. Refer to the appropri ate group i n
thi s manual .
CENTER CONSOLE LID
REMOVAL
(1) Remove the hi nge pi vot bol t.
(2) Remove the l eft upper hi nge bracket cover.
(3) Remove the torx screws attachi ng the l eft
hi nge bracket to the consol e l i d/seat back (Fi g. 1).
(4) Peel back the ri ght pi vot bracket cover and
careful l y pry the pi vot from the pi vot bracket (Fi g. 2).
(5) Separate the consol e l i d/seat back from the seat
cushi on.
INSTALLATION
(1) Posi ti on the consol e l i d/seat back on the seat
cushi on.
(2) Al i gn the pi vot i n the pi vot bracket.
(3) I nstal l the torx screws attachi ng the l eft hi nge
bracket to the consol e l i d/seat back. Ti ghten the torx
screws to 24 Nm (17 ft. l bs.) torque.
Fig. 1 Hinge Bracket
1 - SEAT CUSHION
2 - SEAT BACK/CONSOLE LID
3 - HINGE COVER
AN SEATS 23 - 123
(4) Al i gn the l eft upper hi nge bracket cover and
i nstal l the bol t.
(5) I nstal l the hi nge pi vot bol t. Ti ghten the bol t to
CENTER SEAT ARMREST /
CONSOLE
REMOVAL - CENTER SEAT/CONSOLE
(1) Remove bucket seats
(2) Remove the bol ts attachi ng the center seat to
the bucket seat i nboard seat tracks (Fi g. 3).
(3) Route the seat bel t buckl es through the el asti c
retai ni ng straps.
(4) Separate the center seat/consol e from the
bucket seats.
REMOVAL - CENTER ARMREST/CONSOLE
LATCH
(1) Pl ace the armrest/consol e i n the down posi ti on.
(2) Open the armrest/consol e l i d and remove the
two screws attachi ng the l atch bezel cover and
remove the l atch cover bezel and the l atch button
(Fi g. 4).
(3) Usi ng a dri l l stop, and protecti ng the surround-
i ng tri m and uphol stery, dri l l the heads off the two
ri vets hol di ng the l atch to the armrest/consol e. Do
not penetrate the l atch bracket.
(4) Remove the l atch assembl y.
(5) Usi ng the correct si ze dri l l bi t, remove the
remai ni ng porti on of the ri vet.
Fig. 2 Pivot Bracket
1 - SEAT BACK
2 - CUSHION
3 - TRIM STICK
4 - COVER
5 - PIVOT BRACKET
Fig. 3 Center Seat/Console
1 - PASSENGER SEAT
2 - CENTER SEAT/CONSOLE
3 - DRIVERS SEAT
4 - BOLTS
Fig. 4 Center Armrest/Console
1 - LATCH ASSEMBLY
2 - SCREW
3 - LATCH COVER BEZEL
4 - RIVET
5 - BUTTON
23 - 124 SEATS AN
CENTER CONSOLE LID (Continued)
REMOVAL - CENTER ARMREST UPPER
INERTIA LATCH COVER
(1) Move the dri vers seat posi ti on to ful l forward
wi th seat back ful l forward.
(2) Pl ace center arm rest i n the down posi ti on.
(3) Remove the screw securi ng the cover to the
i nerti a l atch (Fi g. 5).
(4) Remove the upper and l ower i nerti a l atch cov-
ers.
INSTALLATION - CENTER SEAT/CONSOLE
(1) Posi ti on the center seat/consol e onto the bucket
seat i nboard seat tracks.
(2) Route the seat bel t buckl es through the el asti c
retai ni ng straps.
(3) I nstal l the bol ts attachi ng the center seat to
the bucket seat i nboard tracks. Ti ghten the bol ts to
(4) I nstal l bucket seats
INSTALLATION - CENTER ARMREST/COSOLE
LATCH
(1) Before i nstal l i ng the l atch assembl y, cl ean the
area of any debri s.
(2) Al i gn the l atch wi th the hol e openi ngs i n the
bi n.
(3) Secure the l atch assembl y wi th new ri vets.
(4) Pl ace the button i n posi ti on and retai n wi th
the l atch cover bezel .
(5) Attach the l atch cover bezel wi th the screws.
(6) I nspect the l atch assembl y by cycl i ng through a
ful l range of l i d moti ons.
INSTALLATION - CENTER ARMREST UPPER
INERTIA LATCH COVER
(1) I nstal l the upper l atch cover onto the upper
l atch i nerti a arm. Ensure the check strap l oops
under the stud on the si de of the l ower stanchi on/
post.
(2) I nstal l the l ower l atch cover onto the i nerti a
l atch upper arm worki ng i t around the l atch bracket.
(3) Al i gn the l ower l atch cover, the upper l atch
cover, and the l atch bracket to the screw hol e on the
arm.
(4) Secure the cover wi th the screw and ti ghten to
4.15 Nm (37 i n. l bs.).
(5) Cycl e the armrest through a ful l range of travel
and check for freedom of movement. Adjust the l atch
covers as necessary.
CENTER SEAT CUSHION
COVER
REMOVAL
(1) Remove the bucket seats.
(2) Separate the center seat from the bucket seats.
(3) Remove the seat back/consol e l i d.
(4) Di sengage the J-straps from the cushi on frame
(Fi g. 6).
(5) Separate the cushi on/cover from the frame.
INSTALLATION
(1) Posi ti on the cushi on/cover on the frame.
(2) Engage the J-straps from the cushi on frame.
(3) I nstal l the seat back/consol e l i d.
(4) Attach the center seat to the bucket seats.
(5) I nstal l the bucket seats.
Fig. 5 Armrest/Console Inertia Latch Hinge Cover
1 - SEAT CUSHION
2 - SEAT BACK/CONSOLE LID
3 - HINGE COVER
Fig. 6 Center Seat Cushion/Cover
1 - J-STRAPS
2 - CENTER SEAT CUSHION COVER
AN SEATS 23 - 125
CENTER SEAT ARMREST / CONSOLE (Continued)
SEAT
REMOVAL - BENCH SEAT
(1) Move seat to ful l forward posi ti on.
(2) Remove bol ts attachi ng seat track to fl oor pan.
(3) Move seat to ful l rearward posi ti on.
(4) Remove bol ts attachi ng seat track to fl oor pan
(Fi g. 7).
(5) Ti l t setback forward and l i ft seat out through
door.
NOTE: Do not activate seat track adjusters once
bolts are removed.
REMOVAL - BUCKET SEAT
(1) I f equi pped, remove si de shi el d and di sengage
power seat swi tch connector.
I f the vehi cl e i s equi pped wi th a 40/20/40 seat,
remove bucket seats and consol e as one assembl y
(Fi g. 8).
(3) Remove rear screws attachi ng tri m cover to
seat track (Fi g. 9).
(4) Remove rear bol ts attachi ng rear seat track to
fl oor pan.
(5) Move seat to ful l rearward posi ti on.
(6) Remove front screws attachi ng tri m cover to
seat track (Fi g. 9).
(7) Remove front bol ts attachi ng front seat track to
fl oor pan.
NOTE: Do not actuate recliner or track adjuster
once bolts are removed.
(8) Ti l t setback forward and l i ft seat out through
door.
REMOVAL - REAR SEAT QUAD CAB
The quad cab rear seat i s a 60/40 seat. Each seat i s
servi ceabl e separatel y.
(1) Fol d the seati ng cushi on up.
(2) Remove the fasteners retai ni ng the seat to the
cab fl oor.
Fig. 7 Bench Seat
1 - U-NUT
2 - BENCH SEAT
3 - CUP HOLDER
Fig. 8 40/20/40/ Front Seat
1 - 40/20/40 FRONT SEAT
2 - UNUT
3 - TRIM COVER
Fig. 9 Bucket Seat & Seat Track Trim Cover
1 - TRIM COVER
2 - BUCKET SEAT
3 - U-NUT
23 - 126 SEATS AN
(3) Li ft the seat assembl y off the retai ni ng studs
and the cab back hooks (Fi g. 10).
(4) Feed the seat bel t between the seat cushi on
and seat back.
(5) Remove the seat through the rear door.
INSTALLATION - BENCH SEAT
(1) Posi ti on seat i n vehi cl e.
NOTE: Ensure each seat track is equally positioned
in the full rearward position.
(2) I nstal l the front bol ts attachi ng seat track to
fl oor pan. Ti ghten bol ts to 28 Nm (20 ft. l bs.) torque.
(4) I nstal l rear bol ts attachi ng seat track to fl oor
pan. Ti ghten bol ts to 40 Nm (30 ft. l bs.) torque.
INSTALLATION - BUCKET SEAT
(1) Posi ti on seat i n vehi cl e.
NOTE: Ensure each seat track is equally positioned
in the full rearward position.
(2) I nstal l bol ts attachi ng front seat track to fl oor
pan. Ti ghten to 28 Nm (20 ft. l bs.) torque.
(3) I nstal l front screws attachi ng tri m cover to seat
track.
(5) I nstal l bol ts attachi ng rear i nboard seat track
to fl oor pan. Ti ghten to 40 Nm (30 ft. l bs.) torque.
(6) I nstal l bol ts attachi ng rear outboard seat track
to fl oor pan. Ti ghten to 28 Nm (20 ft. l bs.) torque.
(7) I nstal l rear screws attachi ng tri m cover to seat
track.
(8) I f equi pped, engage power seat swi tch connec-
tor and i nstal l si de shi el d.
INSTALLATION - REAR SEAT QUAD CAB
(1) Posi ti on the seat on the cab back hooks and the
fl oor studs.
(2) Feed the seat bel t between the seat cushi on
and the seat back.
(3) Ensure the seat back i s fi rml y hooked to the
cab back retai ners.
(4) Ti ghten the cab fl oor fasteners.
Fig. 10 Rear Seat Quad Cab
1 - HOOK
2 - RETAINER
3 - CAB BACK
4 - SEAT BRACKET
5 - CAB FLOOR STUD
AN SEATS 23 - 127
SEAT (Continued)
SEAT BACK
REMOVAL - REAR SEAT BACKCLUB CAB
(1) Unsnap upper bol ster assembl y by pul l i ng for-
ward, and remove rear panel (Fi g. 11).
(2) Push seat back fi rml y downward to di sengage
retai ni ng tabs on seat back l ower edge.
(3) Di sengage seat bel t/buckl e retai ni ng l oops (Fi g.
12).
(4) Remove cab back bol ster assembl y.
REMOVAL - BENCH SEAT BACK
(2) Di sengage outer, l ower J-strap at base of seat
back.
(3) Di sengage hook and l oop fastener on rear of
seat back cover (Fi g. 13).
(4) Peel back l ower corners of seat back cover to
expose hi nge bol ts (Fi g. 14).
(5) Remove the bol ts attachi ng the hi nge bracket
to the seat back frame.
(6) Remove seat back from vehi cl e.
INSTALLATION - REAR SEAT BACKCLUB CAB
(1) Posi ti on rear seat back i n vehi cl e.
(2) Posi ti on rear seat bel t/buckl e i n the retai ni ng
l oops.
(3) Posi ti on seat back at cab back panel , al i gn
retai ni ng tabs and l i ft seat back upward to secure
seat back.
Fig. 11 Rear Seat
1 - SEAT BACK
2 - SCREW
3 - SEAT PIVOT BRACKET
Fig. 12 Rear Seat Belt Buckles
1 - REAR SEAT LAP BELT/BUCKLE
Fig. 13 Seat Back Hook and Loop Fastener
1 - SEAT BACK COVER
2 - HOOK AND LOOP FASTENER
3 - SEAT CUSHION
4 - JSTRAP
23 - 128 SEATS AN
(4) Secure cab back bol ster assembl y by al i gni ng
upper bol ster assembl y push pi ns wi th hol es i n cab
back sheetmetal and pushi ng rearward.
INSTALLATION - BENCH SEAT BACK
(1) Posi ti on seat back i n the vehi cl e.
(2) I nstal l the bol ts attachi ng the seat back frame
to the hi nge bracket.
(3) Rol l the l ower corners of seat back cover over
the hi nge bol ts.
(4) Engage hook and l oop fastener on rear of seat
back cover.
(5) Engage outer, l ower J-strap at base of seat
back.
(6) Return seat to normal posi ti on.
SEAT BACK CUSHION / COVER
REMOVAL - BENCH SEAT BACK PAD/COVER
(2) Di sengage outer, l ower J-strap at base of seat
back.
(3) Pul l seat back pad/cover upward and separate
from seat back frame.
REMOVAL - BUCKET SEAT BACK PAD/COVER
(1) Posi ti on seat i n ful l forward posi ti on.
(2) I f equi pped, remove seat rel ease handl e on rear
of seat back.
(3) Di sengage J-strap at base of seat back.
(4) Di sengage hook and l oop fastener on rear of
seat back (Fi g. 15).
(5) Usi ng a tri m sti ck, careful l y pry off l umbar
handl e.
(6) Separate pad/cover from seat back frame.
INSTALLATION - BENCH SEAT BACK
PAD/COVER
(1) Posi ti on seat back pad/cover on the seat back
frame.
(2) Engage outer, l ower J-strap at base of seat
back.
INSTALLATION - BUCKET SEAT BACK
PAD/COVER
(1) Posi ti on pad/cover on seat back frame.
(2) Posi ti on l umbar handl e on l umbar adjuster and
press i nto pl ace.
(3) Engage hook and l oop fastener on rear of seat
back.
(4) Engage J-straps at base of seat back.
(5) I f removed, i nstal l seat rel ease handl e on rear
of seat back.
SEAT CUSHION
REMOVAL
(1) Remove rear seat back
(2) Remove nuts attachi ng rear seat cushi on hi nge
to cab back panel .
(3) Separate rear seat cushi on from vehi cl e.
INSTALLATION
(1) Posi ti on rear seat cushi on i n vehi cl e.
Fig. 14 Hinge Bolts
1 - SEAT BACK FRAME
2 - SEAT BACK CUSHION
3 - SEAT BACK COVER
Fig. 15 Seat Back Cover
1 - SEAT BACK COVER
2 - HOOK AND LOOP FASTENER
3 - SEAT CUSHION
4 - JSTRAP
AN SEATS 23 - 129
SEAT BACK (Continued)
(2) I nstal l nuts attachi ng rear seat cushi on hi nge
to cab back panel .
(3) I nstal l rear seat back.
SEAT CUSHION COVER
REMOVAL - BENCH SEAT CUSHION/COVER
(1) Remove seat from vehi cl e.
(2) Remove the bol ts attachi ng the outer seat
tracks to the cushi on frame (Fi g. 17).
(3) Remove push nuts from seat adjuster l ever.
(4) Di sengage the J-straps around the peri meter of
the cushi on.
(5) Route the seat bel t/buckl es through the access
hol e i n the cushi on cover.
(6) Remove the cushi on/cover from the frame.
REMOVAL - BUCKET SEAT CUSHION/COVER
(1) Remove seat.
(2) Remove the anchor bol t attachi ng the buckl e to
the seat track (Fi g. 16).
(3) Remove the screw attachi ng the recl i ner handl e
to the recl i ner mechani sm.
(4) Di sengage the rearward corner J-straps.
(5) Di sengage the si de J-straps.
(6) Di sengage the front J-strap.
(7) Di sengage the rear J-strap.
(8) Separate the cushi on/cover from the frame.
REMOVAL - QUAD CAB REAR SEAT CUSHION
COVER
(1) Remove rear seat.
(2) Di sengage J strap from seat cushi on.
(3) Remove cup hol der, i f equi pped.
(4) Di sengage hook and l oop fasteners.
(5) Rol l seat cushi on cover off seat cushi on.
INSTALLATION - BENCH SEAT CUSHION/
COVER
(2) Route the seat bel t/buckl es through the access
hol e i n the cushi on cover.
(3) Engage the J-straps around the peri meter of
the cushi on.
(4) I nstal l the push nuts on the seat adjuster l ever.
(5) I nstal l the bol ts attachi ng the outer seat tracks
to the cushi on frame. Ti ghten the bol ts to 24 Nm (17
ft. l bs.).
(6) I nstal l the seat.
INSTALLATION - BUCKET SEAT CUSHION/
COVER
(2) Engage the rear J-strap.
(3) Engage the front J-strap.
(4) Engage the si de J-straps.
(5) Engage the rearward corner J-straps.
(6) I nstal l the recl i ner handl e.
(7) I nstal l seat. Ti ghten the front seat track bol ts
to 2234 Nm (1625 ft. l bs.). Ti ghten the rear seat
track bol ts to 89140 Nm (66103 ft. l bs.).
(8) I nstal l the anchor bol t attachi ng the buckl e to
the seat track. Ti ghten the bol t to 40 Nm (29 ft.
l bs.).
INSTALLATION - QUAD CAB REAR SEAT
CUSHION COVER
(1) Posi ti on cover on seat cushi on.
(2) Rol l cover onto cushi on.
(3) Engage the hook and l oop fasteners.
(4) I nstal l the cup hol der, i f equi pped.
(5) Engage the J strap.
(6) I nstal l rear seat.
Fig. 16 Buckle Anchor Bolt
1 - ANCHOR BOLT
2 - SEAT TRACK
3 - SEAT CUSHION
4 - BUCKLE
23 - 130 SEATS AN
SEAT CUSHION (Continued)
SEAT TRACK
REMOVAL - BENCH SEAT TRACK
(1) Remove seat from vehi cl e.
(2) Adjust the tracks as necessary to remove the
bol ts attachi ng the seat tracks to the cushi on frame
(Fi g. 17).
(3) Remove the push nut from the seat adjuster
l ever.
(4) Separate the seat track from the frame.
REMOVAL - BUCKET SEAT TRACK
(1) Remove seat.
(2) Adjust the seat track to gai n access to the torx
bol ts attachi ng the seat track to the cushi on frame.
(3) Remove the torx bol ts (Fi g. 18).
(4) Remove the push nuts from the seat l ever
adjuster.
(5) Separate the seat track from the frame.
INSTALLATION - BENCH SEAT TRACK
(1) Posi ti on the seat track on the frame.
(2) I nstal l the push nut on the seat adjuster l ever.
(3) I nstal l the bol ts attachi ng the seat tracks to
the cushi on frame. Ti ghten bol ts to 24 Nm (17 ft.
l bs.) torque.
(4) I nstal l the seat.
INSTALLATION - BUCKET SEAT TRACK
(1) Posi ti on the seat track on the frame.
(2) I nstal l the push nuts on the seat l ever adjuster.
(3) I nstal l the torx bol ts attachi ng the seat track
to the cushi on frame. Ti ghten the bol ts to 24 Nm (17
ft. l bs.) torque.
(4) I nstal l seat.
Fig. 17 Seat Track
1 - SEAT CUSHION FRAME
2 - SEAT TRACK
Fig. 18 Bucket Seat Track
AN SEATS 23 - 131
STATIONARY GLASS
TABLE OF CONTENTS
page page
STATIONARY GLASS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 132
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
BACKLITE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 133
BACKLITE VENT GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 133
QUARTER WINDOW
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 134
WINDSHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 135
STATIONARY GLASS
DESCRIPTION
Wi ndshi el ds are made of two pi eces of gl ass wi th a
pl asti c i nner l ayer. Wi ndshi el ds and sel ected stati on-
ary gl ass are structural members of the vehi cl e. The
wi ndshi el d gl ass i s bonded to the wi ndshi el d frame
wi th urethane adhesi ve.
OPERATION
Wi ndshi el ds and other stati onary gl ass protect the
occupants from the effects of the el ements. Wi nd-
shi el ds are al so used to retai n some ai rbags i n posi -
ti on duri ng depl oyment. Urethane bonded gl ass i s
di ffi cul t to sal vage duri ng removal . The urethane
bondi ng i s di ffi cul t to cut or cl ean from any surface.
Before removi ng the gl ass, check the avai l abi l i ty of
repl acement components.
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MAN-
UFACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
BACKLITE
REMOVAL
Revi ew Safety Precauti ons and Warni ngs para-
graph at the front of thi s secti on before removi ng
gl ass.
(1) Remove B-pi l l ar/quarter tri m panel s.
(2) Remove cab back panel tri m.
(3) Bend backl i te retai ni ng tabs (Fi g. 1) i nward
agai nst gl ass.
(4) Usi ng a l ong kni fe from i nsi de the vehi cl e, cut
urethane hol di ng backl i te frame to openi ng fence.
(5) Separate gl ass from vehi cl e.
23 - 132 STATIONARY GLASS AN
INSTALLATION SLIDING BACKLITE
Revi ew Safety Precauti ons and Warni ngs para-
graph at the front of thi s secti on before removi ng
gl ass.
(1) Tri m urethane adhesi ve from around rear gl ass
openi ng fence l eavi ng 12 mm of urethane on fence.
(2) Appl y RI M pri mer 25 mm (1 i n.) wi de to the
mati ng surface of the backl i te encapsul ati on.
(3) Appl y Guri t-Essex Betawi pe 4000 25 mm (1
i n.) wi de to the mati ng surface of the backl i te encap-
sul ati on.
(4) Appl y bl ackout pri mer 25 mm (1 i n.) wi de to
the mati ng surface of the backl i te encapsul ati on.
(5) Appl y pi nchwel d pri mer 25 mm (1 i n.) wi de to
the backl i te openi ng fence.
(6) Appl y a 10 mm (0.4 i n.) bead of urethane
around peri meter of backl i te al ong the i nsi de of the
encapsul ati on.
(7) Posi ti on backl i te i nto backl i te openi ng usi ng
al i gnment pi ns i n l ower corners.
(8) Fi rml y push gl ass agai nst rear wi ndow gl ass
openi ng fence.
(9) Bend tabs around edges of backl i te openi ng
fence to retai n gl ass.
(10) Cl ean excess urethane from exteri or wi th
Mopar, Super Cl ean or equi val ent.
(11) I nstal l i nteri or tri m.
BACKLITE VENT GLASS
REMOVAL
(1) Open vent gl ass to ful l open posi ti on.
(2) Sl i de the upper run channel out of the wi ndow
frame.
(3) Sl i de the vent gl ass upward to remove from the
wi ndow frame.
INSTALLATION
(1) Sl i de the vent gl ass downward i nto wi ndow
frame.
(2) Posi ti on the upper run channel i nto the wi n-
dow frame and sl i de i t i nto pl ace.
(3) Veri fy vent gl ass operati on.
QUARTER WINDOW
REMOVAL
(1) Remove quarter tri m panel .
(2) Remove the bol ts attachi ng the l atch to the cab
si de panel (Fi g. 2).
(3) Remove the nuts attachi ng the frame/hi nge to
the B-pi l l ar (Fi g. 3).
(4) Remove the gl ass from the cab.
(5) I f necessary, remove the l atch from the gl ass.
Fig. 1 Backlite
1 - URETHANE
2 - TAB
3 - BACKLITE
Fig. 2 Quarter
1 - CAB
2 - QUARTER GLASS
AN STATIONARY GLASS 23 - 133
BACKLITE (Continued)
INSTALLATION
(1) I f removed, i nstal l the l atch to the gl ass.
(2) Center the wi ndow gl ass at the openi ng, i nsert
the hi nge studs i n the B-pi l l ar hol es, and i nstal l the
nuts.
(3) Attach the l atch to the rear si de panel wi th the
bol ts. Ti ghten the bol ts wi th the l atch i n the l ock
posi ti on and pushi ng rearward on the l atch.
(4) Test the vent wi ndow for water l eaks.
(5) I nstal l quarter tri m panel .
WINDSHIELD
REMOVAL
(1) Remove rear vi ew mi rror.
(2) Remove wi pers and cowl gri l l e.
(3) Wi th doors open, remove the weatherstri p from
the si de wi ndshi el d mol di ngs.
(4) Remove the screws attachi ng the si de wi nd-
shi el d mol di ng to the A-pi l l ars (Fi g. 4).
(5) Cut urethane bondi ng from around wi ndshi el d
usi ng a sui tabl e sharp col d kni fe (Fi g. 5).
(6) Usi ng a l ong kni fe, cut urethane bondi ng from
i nsi de the cab at the base of the wi ndshi el d.
Fig. 3 Quarter Glass
1 - QUARTER GLASS
2 - QUARTER PANEL
Fig. 4 Windshield Moldings
1 - WINDSHIELD
2 - WINDSHIELD MOLDING
3 - ROOF JOINT MOLDING
4 - WINDSHIELD MOLDING
Fig. 5 Cut Urethane Around Windshield
1 - WINDSHIELD
2 - COLD KNIFE
QUARTER WINDOW (Continued)
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The wi ndshi el d fence shoul d be cl eaned of most of
i ts ol d urethane bondi ng materi al . A smal l amount of
ol d urethane, approxi matel y 1-2 mm i n hei ght,
shoul d remai n on the fence. Do not gri nd off or com-
pl etel y remove al l ol d urethane from the fence, the
pai nt fi ni sh and bondi ng strength wi l l be adversel y
affected. Support spacers l ocated on the cowl at the
bottom of the wi ndshi el d openi ng (Fi g. 6) shoul d be
repl aced wi th new parts. Repl ace any mi ssi ng or
damaged spacers around the peri meter of the wi nd-
shi el d openi ng.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng and posi ti on gl ass i n the center of the open-
i ng agai nst the support spacers. Mark the gl ass at
the support spacers wi th a grease penci l or pi eces of
maski ng tape and i nk pen to use as a reference for
i nstal l ati on. Remove repl acement wi ndshi el d from
wi ndshi el d openi ng (Fi g. 7).
(2) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 8).
(3) Cl ean i nsi de of wi ndshi el d wi th MOPAR Gl ass
Cl eaner and l i nt-free cl oth.
(4) Appl y cl ear gl ass pri mer 25 mm (1 i n.) wi de
around peri meter of wi ndshi el d and wi pe wi th a new
cl ean and dry l i nt- free cl oth.
(5) Appl y the header mol di ng to the wi ndshi el d.
(6) Appl y pi nchwel d pri mer 15 mm (.75 i n.) wi de
around the wi ndshi el d fence. Al l ow at l east three
mi nutes dryi ng ti me.
(7) Appl y a 13mm (1/2 i n.) hi gh and 10mm (3/8 i n.)
wi de bead of urethane around the peri meter of wi nd-
shi el d. At the bottom, appl y the bead 7 mm (1/4 i n.)
i nboard from the gl ass edge. On the three si des
where the mol di ng i s on the gl ass, fol l ow the edge of
mol di ng. The urethane bead shoul d be shaped i n a
tri angul ar cross-secti on, thi s can be achi eved by
notchi ng the ti p of the appl i cator (Fi g. 9).
(8) Wi th the ai d of a hel per, posi ti on the wi nd-
shi el d over the wi ndshi el d openi ng. Al i gn the refer-
ence marks at the bottom of the wi ndshi el d to the
support spacers.
(9) Sl owl y l ower wi ndshi el d gl ass to the fence
openi ng gui di ng the l ower corners i nto proper posi -
ti on. Begi nni ng at the bottom and conti nui ng to the
top, push gl ass onto fence al ong the A-Pi l l ars. Push
wi ndshi el d i nward to the fence at the bottom corners.
(10) Cl ean excess urethane from exteri or wi th
MOPAR Super Cl ean or equi val ent.
(11) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
mol di ng i n pl ace unti l urethane cures.
(12) I nstal l new screws attachi ng the si de wi nd-
shi el d mol di ngs to the A-pi l l ars.
(13) I nstal l the weatherstri p onto si de wi ndshi el d
mol di ngs.
AN STATIONARY GLASS 23 - 135
WINDSHIELD (Continued)
(14) I nstal l cowl gri l l e and wi pers.
(15) I nstal l rear vi ew mi rror.
(16) After urethane has cured, remove tape stri ps
and water test wi ndshi el d to veri fy repai r.
Fig. 6 Support Spacers
1 - WINDSHIELD
2 - SPACERS
3 - SUPPORTS
Fig. 7 Center Windshield and Mark at Support
Spacers
1 - WINDSHIELD
2 - INDEX MARKS
3 - SUPPORT SPACERS
Fig. 8 Work Surface Set up and Molding Installation
1 - WINDSHIELD AND MOULDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM
EDGE
3 - BLOCKS
Fig. 9 Applicator Tip
1 - APPLICATOR TIP
WINDSHIELD (Continued)
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
WEATHERSTRIP/SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 137
CARGO BOX SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 138
COWL WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 138
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 138
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 139
FRONT DOOR OUTER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 139
FRONT DOOR 2ND WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FRONT DOOR WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 139
QUARTER VENT GLASS WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 140
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 140
REAR DOOR INNER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 140
REAR DOOR OUTER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 141
REAR DOOR SECONDARY WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 141
REAR DOOR WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 141
ROOF RAIL WEATHERSTRIP/RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 142
WEATHERSTRIP/SEALS
REMOVAL
(1) Remove push-i n fasteners attachi ng hood seal
to i nner hood panel (Fi g. 1).
(2) Separate hood seal from vehi cl e.
INSTALLATION
(1) Posi ti on hood seal on i nner hood panel .
(2) I nstal l push-i n fasteners attachi ng hood seal to
i nner hood panel .
Fig. 1 Hood Seal
1 - INNER HOOD PANEL
2 - HOOD PANEL
AN WEATHERSTRIP/SEALS 23 - 137
CARGO BOX SEAL
REMOVAL
(1) From under the vehi cl e, use a tri m panel
removal tool and remove the push-i n fasteners
attachi ng the cargo box seal to the cargo box (Fi g. 2).
(2) Separate the seal from the cargo box.
INSTALLATION
(1) Posi ti on the seal on the cargo box
(2) I nstal l the push-i n fasteners attachi ng the
cargo box seal to the cargo box (Fi g. 2).
COWL WEATHERSTRIP
REMOVAL
(1) Grasp cowl seal and pul l seal from fl ange (Fi g.
3).
(2) Separate cowl seal from vehi cl e.
INSTALLATION
(1) Posi ti on cowl seal on fl ange and press i nto
pl ace.
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(2) Remove water dam as necessary to access
l ower gl ass run channel s.
(3) Remove the bol ts attachi ng the gl ass run chan-
nel s.
(4) Remove gl ass.
(5) Pul l the gl ass run weatherstri p and run chan-
nel s from the wi ndow openi ng (Fi g. 4).
(6) Pul l the gl ass run weatherstri p from the run
channel s.
INSTALLATION
(1) I nstal l the gl ass run weatherstri p i n the run
channel s.
(2) I nstal l the gl ass run weatherstri p i n the wi n-
dow openi ng.
(3) Posi ti on the run channel s i n the door.
(4) I nstal l gl ass.
(5) I nstal l the gl ass run channel s.
(6) I nstal l i nner bel t weatherstri p.
(7) I nstal l outer bel t weatherstri p.
Fig. 2 Cargo Box Seal
1 - CARGO BOX
2 - BOX SEAL
3 - PUSH-IN FASTENER
4 - CARGO BOX SEAL
Fig. 3 Cowl Seal
1 - COWL TO HOOD SEAL
2 - COWL
23 - 138 WEATHERSTRIP/SEALS AN
FRONT DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove screws attachi ng tri m panel to door.
(2) Li ft tri m panel up and over i nner bel t seal .
(3) Peel seal from door (Fi g. 4).
INSTALLATION
(1) Sl i de seal i nto posi ti on on door.
(2) Posi ti on tri m panel over i nner bel t seal and
i nstal l screws.
FRONT DOOR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Lower gl ass.
(2) Li ft rearward corner of weatherstri p and sl i de
weatherstri p rearward (Fi g. 4).
INSTALLATION
(1) Li ghtl y l ubri cate weatherstri p wi th si l i cone and
sl i de weatherstri p behi nd mi rror.
(2) Push weatherstri p down to seat onto door.
FRONT DOOR 2ND
WEATHERSTRIP
REMOVAL
The secondary seal i s attached wi th two si ded
adhesi ve tape.
(1) Separate the secondary seal and the tape from
the i nner door panel (Fi g. 4).
FRONT DOOR WEATHERSTRIP
REMOVAL
(1) Remove A-pi l l ar tri m.
(2) Remove cowl panel and si l l cover.
(3) Remove upper turni ng l oop anchor bol t.
(4) Pul l B-pi l l ar tri m/quarter panel tri m outward
to access weatherstri p.
(5) Pul l weatherstri p from pi nch fl ange around
door openi ng (Fi g. 5).
INSTALLATION
(1) Posi ti on the weatherstri p on the pi nch fl ange
around door openi ng and press i nto pl ace.
(2) Press i nto pl ace B-pi l l ar tri m/quarter panel
tri m.
(3) I nstal l upper turni ng l oop anchor bol t.
(4) I nstal l cowl panel and si l l cover. Ensure the
cl i ps attachi ng the si l l cover to the door si l l are ful l y
seated.
Fig. 4 Front Door Weatherstrip/Seals
1 - B-PILLAR SECONDARY SEAL
2 - GLASS RUN WEATHERSTRIP
3 - INNER BELT WEATHERSTRIP
4 - SECONDARY SEAL
5 - OUTER BELT WEATHERSTRIP
Fig. 5 Door Seal
1 - DOOR SEAL
QUARTER VENT GLASS
WEATHERSTRIP
REMOVAL
(1) Remove the quarter wi ndow. I f necessary, refer
to the removal procedure.
(2) Pul l the seal away from the fl ange around the
peri meter of the wi ndow openi ng (Fi g. 6).
(3) Cl ean the fl ange as necessary.
INSTALLATION
(1) Center and butt the seal ends together at the
bottom, centerl i ne of the openi ng.
(2) Mate the seal wi th the bottom fl ange.
(3) Mate the seal wi th the front, verti cal fl ange.
(4) Move upward and mate the seal wi th the top
fl ange.
(5) Mate the seal wi th the rear, verti cal fl ange.
(6) I nstal l the quarter wi ndow.
REAR DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(2) Remove i nner bel tl i ne weatherstri p.
(3) Remove outer bel tl i ne weatherstri p.
(4) Pul l weatherstri p from door frame and di vi der
bar channel (Fi g. 7).
INSTALLATION
(1) Posi ti on weatherstri p i n door frame and di vi der
bar channel .
(2) I nstal l outer bel tl i ne weatherstri p.
(3) I nstal l i nner bel tl i ne weatherstri p.
REAR DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(2) Pul l weatherstri p from i nner door panel (Fi g.
8).
INSTALLATION
(1) Posi ti on weatherstri p on i nner door panel (Fi g.
8).
(2) Press i nto pl ace.
Fig. 6 Quarter Vent Weatherstrip
1 - QUARTER GLASS SEAL
Fig. 7 Glass Run Weatherstrip
1 - REAR DOOR
2 - GLASS RUN WEATHERSTRIP
Fig. 8 Inner/Outer Belt Weatherstrip
1 - OUTER BELT WEATHERSTRIP
2 - INNER BELT WEATHERSTRIP
REAR DOOR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Lower gl ass.
(2) Li ft corner of weatherstri p upward and remove
weatherstri p from outer door panel .
INSTALLATION
(1) Posi ti on weatherstri p on outer door panel .
(2) Press i nto pl ace.
(3) Rai se gl ass.
REAR DOOR SECONDARY
WEATHERSTRIP
REMOVAL
(1) Separate the secondary seal from the i nner
door panel (Fi g. 9).
INSTALLATION
(1) Thoroughl y cl ean the area of ol d adhesi ve. Use
Mopar Super Kl een or equi val ent.
(2) Posi ti on the secondary seal on the i nner door
panel .
REAR DOOR WEATHERSTRIP
REMOVAL
(1) Remove door si l l tri m.
(2) Loosen upper and l ower B-pi l l ar tri m to access
weatherstri p.
(3) Remove C-pi l l ar tri m.
(4) Pul l quarter panel tri m outward to access
weatherstri p.
(5) Pul l weatherstri p from pi nch fl ange around
door openi ng.
INSTALLATION
(1) Cl ean pi nch fl ange
(2) Posi ti on the weatherstri p on the pi nch fl ange
around door openi ng and press i nto pl ace.
(3) I nstal l quarter panel tri m.
(4) I nstal l C-pi l l ar tri m.
(6) I nstal l door si l l tri m. Ensure the cl i ps attach-
i ng the si l l tri m to the door si l l are ful l y seated.
ROOF RAIL WEATHERSTRIP/
RETAINER
REMOVAL
(2) The rearward corner of the weathersti p i s
adhesi vel y attached to the body. Peel back the corner
of the weatherstri p to rel ease i t from the body.
(3) Pul l weatherstri p from retai ner.
(4) Remove screws attachi ng retai ner to roof rai l
(Fi g. 10).
(5) Separate retai ner from vehi cl e.
Fig. 9 Rear Door Secondary Seal
1 - REAR DOOR SILL SECONDARY SEAL
Fig. 10 Roof Rail Weatherstrip/Retainer
1 - ROOF RAIL WEATHERSTRIP
2 - RETAINER
INSTALLATION
NOTE: The screws attaching the retainer to the roof
are coated with wax to prevent water leakage. If the
retainer has been removed from the roof, replace
the screws.
(1) Ensure the area where tape secures the weath-
erstri p i s cl ean. Use Mopar Super Cl ean or equi va-
l ent.
(2) Posi ti on retai ner on vehi cl e.
(3) I nstal l screws attachi ng retai ner to roof rai l .
(4) Starti ng at the forward end of retai ner, push
weatherstri p on unti l seated.
(5) Peel the backi ng from the rearward end of the
weatherstri p and press to secure.
ROOF RAIL WEATHERSTRIP/RETAINER (Continued)
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . 5
REFRIGERANT SYSTEM SERVICE
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HEATING & AIR
CONDITIONING
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To mai ntai n the performance l evel of the HVAC
system, the engi ne cool i ng system must be properl y
mai ntai ned. The use of a bug screen i s not recom-
mended. Any obstructi ons i n front of the radi ator or
condenser wi l l reduce the performance of the ai r con-
di ti oni ng and engi ne cool i ng systems.
The engi ne cool i ng system i ncl udes the heater core
and the heater hoses. Refer to Cool i ng for more i nfor-
mati on before the openi ng of, or attempti ng any ser-
vi ce to the engi ne cool i ng system.
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORTS
The two refri gerant system servi ce ports are used
to charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
coupl er si zes are used on the R-134a system, to
ensure that the refri gerant system i s not acci dental l y
contami nated by the use of the wrong refri gerant
(R-12), or refri gerant system servi ce equi pment.
OPERATION - REFRIGERANT SYSTEM SERVICE
PORTS
The hi gh pressure servi ce port i s l ocated on the l i q-
ui d l i ne between the condenser and the evaporator,
near the front of the engi ne compartment. The l ow
pressure servi ce port i s l ocated on the compressor
mani fol d, di rectl y over the sucti on port of the com-
pressor, for 5.9L Engi ne. I t i s on the sucti on l i ne
between the compressor and the evaporator for the
4.7L engi ne.
Each of the servi ce ports has a threaded pl asti c
protecti ve cap i nstal l ed over i t from the factory. After
servi ci ng the refri gerant system, al ways rei nstal l
both of the servi ce port caps.
DIAGNOSIS AND TESTING - A/C
PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow humi di ty ai r. The evaporator, l ocated i n the
HVAC housi ng on the dash panel bel ow the i nstru-
ment panel , i s cool ed to temperatures near the freez-
i ng poi nt. As warm damp ai r passes through the
cool ed evaporator, the ai r transfers i ts heat to the
refri gerant i n the evaporator tubes and the moi sture
i n the ai r condenses on the evaporator fi ns. Duri ng
peri ods of hi gh heat and humi di ty, an ai r condi ti on-
i ng system wi l l be more effecti ve i n the reci rcul ati on
mode (Max-A/C). Wi th the system i n the reci rcul ati on
mode, onl y ai r from the passenger compartment
passes through the evaporator. As the passenger com-
partment ai r dehumi di fi es, the ai r condi ti oni ng sys-
tem performance l evel s i mprove.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
AN HEATING & AIR CONDITIONING 24 - 1
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
Before proceedi ng, (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - WARNI NG) and
PLUMBI NG - CAUTI ON). The ai r temperature i n
the test room and i n the vehi cl e must be a mi ni mum
of 21 C (70 F) for thi s test. Al so the fi n probe (l ocat-
ed i n the evaporator of the HVAC uni t) must be a
mi ni mum of 65 for thi s test as wel l .
(1) Connect a tachometer and a mani fol d gauge
set.
(2) Set the a/c heater control to the reci rcul ati on
mode (Max-A/C) posi ti on, the temperature control
knob i n the ful l cool posi ti on, and the bl ower motor
swi tch knob i n the hi ghest speed posi ti on.
(3) Start the engi ne and hol d the i dl e at 1,000 rpm
wi th the compressor cl utch engaged. I f the compres-
sor does not engage, see the A/C Di agnosi s chart i n
the Di agnosi s and Testi ng secti on of thi s group.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be cl osed.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the a/c system unti l i t
stabsl i zes.
(6) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature, the condenser out pres-
sure (hi gh si de), and the compressor i nl et pressure
(l ow si de). The compressor cl utch may cycl e, depend-
i ng upon the ambi ent temperature and humi di ty. I f
the cl utch cycl es, use the readi ngs obtai ned before
the cl utch di sengaged.
(7) Compare the di scharge ai r temperature read-
i ng to the Performance Temperature and Pressure
chart. I f the temperature readi ng i s hi gh, cl amp off
both heater hoses (i nl et and outl et), wai t fi ve mi n-
utes and record the temperature agai n. Compare the
second readi ng to the Performance Temperature and
Pressure chart. I f the temperature readi ng i s now
OK, see A/C Di agnosi s chart for normal pressures. Or
see A/C Performance Test i f ai r temperatures are too
hi gh,
(8) Compare the di scharge (hi gh si de) and sucti on
(l ow si de) pressure readi ngs to the Performance Tem-
perature and Pressure chart. I f the pressures are
abnormal , see (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/PLUMBI NG - DI AGNOSI S AND TEST-
I NG - REFRI GERANT SYSTEM LEAKS) and (Refer
I NG - STANDARD PROCEDURE - REFRI GERANT
SYSTEM CHARGE).
Performance Temperature and Pressure
Ambient Air Temperature
21C
(70F)
27C
(80F)
32C
(90F)
38C
(100F)
43C
(110F)
Maximum Allowable Air
Temperature at Center Panel
Outlet
7C
(45F)
7C
(45F)
13C
(55F)
13C
(55F)
18C
(64F)
Compressor Inlet Pressure at
Service Port (Low Side)
138 to 207
kPa
(20 to 30 psi)
172 to 241
kPa
(25 to 35 psi)
207 to 276
kPa
(30 to 40 psi)
241 to 310
kPa
(35 to 45 psi)
276 to 345
kPa
(40 to 50 psi)
Condensor Out Pressure at
Service Port (High Side)
1034 to 1724
kPa
(150 to 250
psi)
1379 to 2068
kPa
(200 to 300
psi)
1724 to 2413
kPa
(250 to 350
psi)
1999 to 2689
kPa
(290 to 390
psi)
2413 to 2965
kPa
(350 to 430
psi)
(9) Compare the compressor di scharge and sucti on
(evaporator i nl et) pressure readi ngs to the Perfor-
mance Temperature and Pressure chart. I f the com-
pressor di scharge pressure or sucti on pressure i s not
normal , see the Pressure Di agnosi s chart.
24 - 2 HEATING & AIR CONDITIONING AN
HEATING & AIR CONDITIONING (Continued)
A/C Diagnosis
Rapid compressor clutch
cycling (ten or more cycles
per minute).
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in the Diagnosis
and Testing section of this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
2. Faulty Evaporator. 2. See Evaporator Temperature Sensor in the
Diagnosis and Testing section of this group. Test
the Evaporator Temperature Sensor.
3. Faulty Powertrain Control
Module (PCM)
3. Refer to the proper Diagnosis Procedurers
manual for testing of the PCM. Test the PCM and
replace, if required.
4. Faulty Pressure
Transducer
4. See Pressure Transducer Diagnosis and
Testing in this section.
5. Faulty Loss of Charge
Pressure Switch
5. See Loss of Charge Pressure Switch
Diagnosis and Testing in this section
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
1. (Refer to Plumbing/Diagnosis and Testing -
Refrigerant System Leaks) in this group. Test the
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty a/c compressor
clutch coil.
3. (Refer to Controls/A/C Compressor Clutch
Coil/Diagnosis and Testing) in this group. Test the
compressor clutch coil and replace, if required.
4. Faulty a/c compressor
clutch relay.
4. (Refer to Controls/A/C Compressor Clutch
Relay/Diagnosis and Testing) in this group. Test
the compressor clutch relay and relay circuits.
Repair the circuits or replace the relay, if
required.
5. Faulty evaporator
temperature sensor.
5. (Refer to Controls/A/C Low Pressure
Switch/Diagnosis and Testing) in this group. Test
the a/c low pressure switch and tighten or
6. Faulty loss of charge
pressure switch.
6. (Refer to Controls/A/C Pressure Transducer/
Diagnosis and Testing) in this group. Test the a/c
pressure transducer and replace, if required.
7. Faulty Power Train Control
Module.
7. (Refer to Appropriate Diagnostic Information)
for testing of the PCM. Test the PCM and
8. Faulty pressure
transducer.
8. Refer to Diagnosis and Testing Faulty Pressure
Transducer in the section.
9. Faulty heater-A/C control. 9. Refer to Faulty heater-A/C Control in this
section.
A/C Diagnosis
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
1. (Refer to Plumbing/Refrigerant Oil/Standard
Procedure/Refrigerant Oil Level) in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level, if
required.
2. Blend door actuator
inoperative or faulty.
2. Check the Blend Door Actuator operation.
Replace as required.
3. Blend door inoperative or
sealing improperly.
3. (Refer to Distribution/Blend Door/Removal/
Installation) in this group. Inspect the blend door
for proper operation and sealing and correct, if
required.
4. Faulty evaporator. 4. Refer to evaporator section.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.
1. Low refrigerant system
charge.
2. Refrigerant flow through
the accumulator is restricted.
2. (Refer to Plumbing/Accumulator/Removal/
Installation in this group. Replace the restricted
accumulator, if required.
3. Refrigerant flow through
the a/c evaporator is
restricted.
3. (Refer to Plumbing/A/C Evaporator/Removal/
Installation in this group. Replace the restricted
a/c orator, if required.
4. Faulty a/c compressor. 4. (Refer to Plumbing/A/C Compressor/Removal/
Installation in this group. Replace the a/c
compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. A/C condenser air flow
restricted.
1. Check the a/c condenser for damaged fins,
foreign objects obstructing air flow through the
condenser fins, and missing or improperly
installed air seals. Refer to Cooling for more
information on air seals. Clean, repair, or replace
components as required.
2. Inoperative cooling fan. 2. Refer to Cooling for more information. Test the
cooling fan and replace, if required.
3. Refrigerant system
overcharged.
3. (Refer to Plumbing/Standard Procedure -
igerant System Charge) in this group. Recover
the refrigerant from the refrigerant system.
Charge the refrigerant system to the proper level,
if required.
4. Air in the refrigerant
system.
5. Engine overheating. 5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
6. Faulty orifice tube. 6. Refer to orifice tube section.
A/C Diagnosis
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. A/C orifice tube not
installed.
2. (Refer to Plumbing/A/C Orifice Tube) in this
group. Install the missing fixed orifice tube, if
required.
3. Faulty a/c compressor. 3. (Refer to Plumbing/A/C Compressor/Removal/
Installation in this group. Replace the compressor,
if required.
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
1. (Refer to Plumbing/Caution - Refrigerant
Hoses/Lines/Tubes Precaution) in this group.
Inspect the refrigerant lines for kinks, tight bends
or improper routing. Correct the routing or replace
the refrigerant line, if required.
through the a/c orifice tube.
2. (Refer to Plumbing/A/C Orifice Tube) in this
group. Replace the restricted fixed orifice tube, if
required.
through the a/c condenser.
3. (Refer to Plumbing/A/C Condenser) in this
group. Replace the restricted a/c condenser, if
required.
4. Restricted Filter Drier. 4. See Filter-Drier in the Removal and Installation
section of the group. Replace the restricted
Filter-Drier, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performi ng the fol l owi ng tests, refer to
Group 7 Cool i ng System for the procedures to
check the engi ne cool ant l evel and fl ow, engi ne cool -
ant reserve/recovery system operati on, accessory
dri ve bel t condi ti on and tensi on, radi ator ai r fl ow
and the fan dri ve operati on.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
swi tch knob i n the fl oor posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged at the HVAC housi ng fl oor
outl ets. Compare the test thermometer readi ng to the
Temperature Reference Chart.
Temperature Reference
Ambient Air Temperature
15.5C
(60F)
21.1C
(70F)
26.6C
(80F)
32.2C
(90F)
Minimum Air Temperature at
Floor Outlet
52.2C
(126F)
56.1C
(133F)
59.4C
(139F)
62.2C
(144F)
I f the fl oor outl et ai r temperature i s too l ow, refer
to Cool i ng to check the engi ne cool ant temperature
speci fi cati ons. Both of the heater hoses shoul d be hot
to the touch. The cool ant return heater hose shoul d
be sl i ghtl y cool er than the cool ant suppl y heater
hose. I f the return hose i s much cool er than the sup-
pl y hose, l ocate and repai r the engi ne cool ant fl ow
obstructi on i n the cool i ng system. Refer to Cool i ng
for the procedures.
OBSTRUCTED COOLANT FLOW
Possi bl e l ocati ons or causes of obstructed cool ant
fl ow:
Faul ty water pump.
Faul ty thermostat.
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
A pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s sti l l
l ow, a mechani cal probl em may exi st.
MECHANICAL PROBLEMS
Possi bl e l ocati ons or causes of i nsuffi ci ent heat:
A faul ty bl ower system.
A faul ty heater-A/C control .
An obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
A faul ty, obstructed or i mproperl y i nstal l ed
bl end-ai r door or actuator.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob on the
a/c heater control panel , the fol l owi ng coul d requi re
servi ce:
The a/c heater control .
A faul ty bl end door actuator.
The bl end door.
I mproper engi ne cool ant temperature.
Obstructed cowl ai r i ntake.
Heater Diagnosis
INSUFFICIENT HEATER
OUTPUT.
1. Incorrect engine
coolant level.
1. Check the engine coolant level. Refer to Group 7 -
Cooling System for the procedures.
2. Air trapped in engine
cooling system.
2. Check the operation of the coolant reserve/recovery
system. Refer to Group 7 - Cooling System for the
procedures.
3. Incorrect engine
coolant temperature.
3. Check the performance and operation of the engine
cooling system including: thermostat, water pump, fan
drive, accessory drive belt, coolant flow (plugged radiator
or heater core, plugged or kinked coolant hoses), air flow
(missing or improperly installed radiator air seals or fan
shroud). Refer to Group 7 - Cooling System for the
procedures.
4. Blend air door
actuator not operating
properly.
4. See Blend Door Actuator in the Removal and
Installation and in the Adjustments sections of this group.
5. Blend-air door not
operating properly.
5. Check for a damaged, obstructed or improperly
installed blend-air door or seals. See Heater-A/C Housing
Door in the Removal and Installation section of this
group.
6. Insufficient air flow
through heater housing.
6. Remove foreign material or obstructions from cowl air
intake.
7. Improper blower motor
operation.
7. See Blower Motor in the Diagnosis and Testing section
of this group.
8. Improper electric
coolant pump operation.
8. See electric coolant pump section of this group.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED,
BEFORE CONNECTING TO OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
When servi ci ng the ai r condi ti oni ng system, a
R-134a refri gerant recovery/recycl i ng/chargi ng sta-
ti on that meets SAE Standard J2210 must be used.
Contact PSE or an automoti ve servi ce equi pment
suppl i er for refri gerant recovery/recycl i ng/chargi ng
equi pment. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for the proper
care and use of thi s equi pment.
A mani fol d gauge set may be needed wi th some
recovery/recycl i ng/chargi ng equi pment (Fi g. 1). The
servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE
The l ow pressure hose (Bl ue wi th Bl ack stri pe)
attaches to the sucti on servi ce port. Thi s port i s
l ocated on the compressor mani fol d, di rectl y over the
sucti on port of the compressor.
HIGH PRESSURE GAUGE HOSE
The hi gh pressure hose (Red wi th Bl ack stri pe)
attaches to the di scharge servi ce port. Thi s port i s
l ocated on the l i qui d l i ne between the condenser and
the evaporator, near the front of the engi ne compart-
ment.
RECOVERY/RECYCLING/EVACUATION/CHARGING
HOSE
The center mani fol d hose (Yel l ow, or Whi te, wi th
Bl ack stri pe) i s used to recover, evacuate, and charge
the refri gerant system. When the l ow or hi gh pres-
sure val ves on the mani fol d gauge set are opened,
the refri gerant i n the system wi l l escape through thi s
hose.
Fig. 1 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
VEHICLE AN Dakota
SYSTEM R134a w/ fixed
orifice tube
0.057orifice
tube
COMPRESSOR Sanden
SD7H15
SP-20 PAG oil
Freezeup
Control
2-wire
evaporator
temperature
sensor
Loss of
refrigerent
charge
a/c low
pressure switch
opens < 7-13
psi - resets >
15-25 psi
accumulator
mounted
Pressure
transducer
450 psi
(cut-out) 290
psi (cut-in)
Liquid line
mounted
CONTROL
HEAD
manual type
and electric
Mode Door electric
Blend Door electric
Recirculation
Door
electric
Item Description Notes
Blower Motor hardwired to
control head
credit card
resistor block
COOLING FAN V-6 & V-8
electrical/
mechanical
cooling fan
module, I-4
(2.5) electric
fan
Relay
CLUTCH Electro-
magnetic
Control relay PCM
Draw 2.0 - 3.9 amps
@ 12 V
0.5V @ 70F
Gap 0.016 - 0.031
DRB III
Reads TPS, RPM, A/C
stransducer
pressure
Actuators clutch relay (fan
relay 2.5 only),
actuator doors
SPECIFICATIONS
Compressor Mounting
Bolts
41 30 363
Intermediate Shaft
Coupler Pinch Bolt
13.5 10 120
H-block Retaining Bolts 18 13 159
Refrigerant Lines at
Compressor
23 17 200 30
Condenser Mounting Bolts 10.7 8 95
Low Pressure Cycling
Switch: Hand Tighten Only
n/a n/a n/a
CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR HIGH PRESSURE RELIEF
VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A/C COMPRESSOR CLUTCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A/C COMPRESSOR CLUTCH COIL . . . . . . . . . 10
A/C COMPRESSOR CLUTCH BREAK-IN . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C COMPRESSOR CLUTCH RELAY. . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C HEATER CONTROL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEATER-A/C CONTROL. . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A/C LOSS OF CHARGE SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LOSS OF CHARGE SWITCH . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C PRESSURE TRANSDUCER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C PRESSURE TRANSDUCER. . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AMBIENT TEMP SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AMBIENT TEMPERATURE SENSOR . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BLEND DOOR ACTUATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BLOWER MOTOR RESISTOR BLOCK . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BLOWER MOTOR SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . 21
MODE DOOR ACTUATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
RECIRCULATION DOOR ACTUATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
A/C COMPRESSOR HIGH
PRESSURE RELIEF VALVE
DESCRIPTION
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor cyl i nder head, whi ch i s at the rear of the
compressor. Thi s mechani cal val ve i s desi gned to
vent refri gerant from the system to protect agai nst
damage to the compressor and other system compo-
nents, caused by condenser ai r fl ow restri cti on or an
overcharge of refri gerant.
AN CONTROLS 24 - 9
OPERATION
The hi gh pressure rel i ef val ve vents the system when
a di scharge pressure of 3445 to 4135 kPa (500 to 600
psi ) or above i s reached. The val ve cl oses wi th a mi ni -
mum di scharge pressure of 2756 kPa (400 psi ) i s
reached.
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
served i n the system. I f the val ve vents refri gerant, i t
does not mean the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s a factory-cal i -
brated uni t. The val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The val ve i s onl y servi ced as a part of the
compressor assembl y.
DESCRIPTION
The compressor cl utch assembl y consi sts of a stati on-
ary el ectromagneti c coi l , a hub beari ng and pul l ey
assembl y, and a cl utch pl ate (Fi g. 1). The el ectromag-
neti c coi l uni t and the hub beari ng and pul l ey assembl y
are each retai ned on the nose of the compressor front
housi ng wi th snap ri ngs. The cl utch pl ate i s mounted to
the compressor shaft and secured wi th a nut.
OPERATION
The compressor cl utch assembl y provi des the
means to engage and di sengage the compressor from
the engi ne serpenti ne accessory dri ve bel t. When the
cl utch coi l i s energi zed, i t magneti cal l y draws the
cl utch i nto contact wi th the pul l ey and dri ves the
compressor shaft. When the coi l i s not energi zed, the
pul l ey freewheel s on the cl utch hub beari ng, whi ch i s
part of the pul l ey. The compressor cl utch and coi l are
the onl y servi ced parts on the compressor.
The compressor cl utch engagement i s control l ed by
several components: the a/c heater mode control
swi tch, the a/c l oss of charge swi tch, the a/c pressure
transducer, the compressor cl utch rel ay, the evapora-
tor temperature sensor and the Powertrai n Control
Modul e (PCM). The PCM may del ay compressor
cl utch engagement for up to thi rty seconds (Refer to
8 - ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/POWERTRAI N CONTROL MODULE -
DESCRI PTI ON).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For ci rcui t descri pti ons and di agrams, (Refer to
Appropri ate Wi ri ng I nformati on). The battery must
be ful l y-charged before performi ng the fol l owi ng tests
(Refer to 8 - ELECTRI CAL/CHARGI NG - DI AGNO-
SI S AND TESTI NG).
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the a/c sel ect button depressed, and the
bl ower motor swi tch i n the l owest speed posi ti on,
start the engi ne and run i t at normal i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n 0.2 vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n 0.2 vol ts of the battery vol tage, test the cl utch
coi l feed ci rcui t for excessi ve vol tage drop and repai r
as requi red. I f there i s no vol tage readi ng at the
cl utch coi l , use a DRB I I I scan tool and (Refer to
Appropri ate Di agnosti c I nformati on) for testi ng of the
compressor cl utch ci rcui t. The fol l owi ng components
must be checked and repai red as requi red before you
can compl ete testi ng of the cl utch coi l :
Fuses i n the juncti on bl ock and the Power Di s-
tri buti on Center (PDC)
A/C Heater Control
Compressor Cl utch Rel ay
A/C Pressure Transducer
A/C Loss of Charge Pressure Swi tch
Evaporator Temperature Sensor
Powertrai n Control Modul e (PCM)
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th the el ectri cal system vol tage at 11.5 to
12.5 vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21 C (70 F). I f system vol tage
Fig. 1 COMPRESSOR CLUTCH - TYPICAL
1 - CLUTCH PLATE
2 - SHAFT KEY
3 - PULLEY
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLS AN
A/C COMPRESSOR HIGH PRESSURE RELIEF VALVE (Continued)
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s four
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the a/c heater control to the reci r-
cul ati on mode (Max-A/C), the bl ower motor swi tch to
the hi ghest speed posi ti on, and the engi ne speed at
1500 to 2000 rpm. Thi s procedure (burni shi ng) wi l l
seat the opposi ng fri cti on surfaces and provi de a
hi gher compressor cl utch torque capabi l i ty.
REMOVAL
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, pul l ey, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Remove the serpenti ne dri ve bel t. Refer to
Cool i ng for the procedures.
(3) Unpl ug the compressor cl utch coi l wi re harness
connector.
(4) I nsert the two pi ns of the spanner wrench
(Speci al Tool 6462 i n Ki t 6460) i nto the hol es of the
cl utch pl ate. Hol d the cl utch pl ate stati onary and
remove the hex nut (Fi g. 2).
(5) Remove the cl utch pl ate and the cl utch shi ms.
(6) Remove the external front housi ng snap ri ng
wi th snap ri ng pl i ers (Fi g. 3).
(7) I nstal l the l i p of the rotor pul l er (Speci al Tool
C-6141-1 i n Ki t 6460) i nto the snap ri ng groove
exposed i n Step 6, and i nstal l the shaft protector
(Speci al Tool C-6141-2 i n Ki t 6460) (Fi g. 4).
Fig. 2 CLUTCH NUT REMOVE
1 - FRONT PLATE SPANNER
Fig. 3 EXTERNAL SNAP RING REMOVE
1 - EXTERNAL SNAP RING
Fig. 4 SHAFT PROTECTOR AND PULLER
1 - PULLER SHAFT PROTECTOR
2 - JAWS
AN CONTROLS 24 - 11
A/C COMPRESSOR CLUTCH (Continued)
(8) I nstal l the pul l er through-bol ts (Speci al Tool
C-6461) through the pul l er fl ange and i nto the jaws
of the rotor pul l er and ti ghten (Fi g. 5). Turn the
pul l er center bol t cl ockwi se unti l the rotor pul l ey i s
free.
(9) Remove the screw and retai ner from the cl utch
coi l l ead wi re harness on the compressor front hous-
i ng (Fi g. 6).
(10) Remove the snap ri ng from the compressor
hub and remove the cl utch fi el d coi l (Fi g. 7). Sl i de
the cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the front pl ate for wear. The pul l ey and front
pl ate shoul d be repl aced i f there i s excessi ve wear or
scori ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for oi l . Remove the
fel t from the front cover. I f the fel t i s saturated wi th
oi l , the shaft seal i s l eaki ng and the compressor must
be repl aced.
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) I nstal l the cl utch fi el d coi l and snap ri ng.
(2) I nstal l the cl utch coi l l ead wi re harness retai n-
i ng cl i p on the compressor front housi ng and ti ghten
the retai ni ng screw.
Fig. 5 INSTALL PULLER PLATE
1 - BOLT
2 - PULLER PLATE AND BOLT
3 - BOLT
4 - JAWS
Fig. 6 CLUTCH COIL LEAD WIRE HARNESS
1 - CLIP
Fig. 7 CLUTCH FIELD COIL SNAP RING REMOVE
1 - FIELD COIL
2 - SNAP RING
24 - 12 CONTROLS AN
(3) Al i gn the rotor assembl y squarel y on the front
compressor housi ng hub.
(4) Thread the handl e (Speci al Tool 6464 i n Ki t
6460) i nto the dri ver (Speci al Tool 6143 i n Ki t 6460)
(Fi g. 8).
(5) Pl ace the dri ver tool assembl y i nto the beari ng
cavi ty on the rotor. Make certai n the outer edge of
the tool rests fi rml y on the rotor beari ng i nner race
(Fi g. 9).
(6) Tap the end of the dri ver whi l e gui di ng the
rotor to prevent bi ndi ng. Tap unti l the rotor bottoms
agai nst the compressor front housi ng hub. Li sten for
a di sti nct change of sound duri ng the tappi ng pro-
cess, to i ndi cate the bottomi ng of the rotor.
(7) I nstal l the external front rotor snap ri ng wi th
snap ri ng pl i ers. The bevel si de of the snap ri ng must
be faci ng outward. Press the snap ri ng to make sure
i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(8) I nstal l the ori gi nal cl utch shi ms on the com-
pressor shaft.
(9) I nstal l the cl utch pl ate. Use the shaft protector
(Speci al Tool 6141-2 i n Ki t 6460) to i nstal l the cl utch
pl ate on the compressor shaft (Fi g. 10). Tap the
cl utch pl ate over the compressor shaft unti l i t has
bottomed agai nst the cl utch shi ms. Li sten for a di s-
ti nct change of sound duri ng the tappi ng process, to
i ndi cate the bottomi ng of the cl utch pl ate.
(10) Repl ace the compressor shaft hex nut. Ti ghten
the nut to 14.4 Nm (10.5 ft. l bs.).
(11) Check the cl utch ai r gap wi th a feel er gauge
(Fi g. 11). I f the ai r gap does not meet the speci fi ca-
ti on, add or subtract shi ms as requi red. The ai r gap
speci fi cati on i s 0.41 to 0.79 mi l l i meter (0.016 to 0.031
i nch). I f the ai r gap i s not consi stent around the ci r-
cumference of the cl utch, l i ghtl y pry up at the mi ni -
mum vari ati ons. Li ghtl y tap down at the poi nts of
maxi mum vari ati on.
Fig. 8 ROTOR INSTALLER SET
Fig. 9 ROTOR INSTALL
Fig. 10 CLUTCH PLATE INSTALL
AN CONTROLS 24 - 13
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 milli-
meter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.
(12) To compl ete the procedure, (Refer to 24 -
COMPRESSOR - I NSTALLATI ON).
RELAY
DESCRIPTION
The a/c compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the rel ay case di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
OPERATION
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the a/c heater control , the a/c
l oss of charge swi tch, the a/c pressure transducer and
the evaporator fi n probe.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
The compressor cl utch rel ay cannot be repai red
CLUTCH RELAY
RELAY TEST
The compressor cl utch rel ay (Fi g. 12) i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
PDC l abel for rel ay i denti fi cati on and l ocati on.
Remove the rel ay from the PDC to perform the fol -
l owi ng tests:
and 30. I f OK, see the Rel ay Ci rcui t Test bel ow. I f not
OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
Appropri ate Wi ri ng I nformati on).
connected to fused battery feed. There shoul d be bat-
Fig. 11 CHECK CLUTCH AIR GAP
1 - FEELER GAUGE
Fig. 12 COMPRESSOR CLUTCH RELAY
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
24 - 14 CONTROLS AN
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the fuse i n the juncti on bl ock as
requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector C
(gray) at al l ti mes. I f not OK, repai r the open ci rcui t
as requi red.
REMOVAL
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 13).
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the
PDC.
INSTALLATION
(1) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(2) I nstal l the PDC cover.
(4) Test the rel ay operati on.
A/C HEATER CONTROL
DESCRIPTION
The a/c heater control i s a compl etel y el ectroni c
control head (Fi g. 14). The a/c heater system uses al l
el ectri cal control s. These control s provi de the vehi cl e
operator wi th a number of setti ng opti ons to hel p
control the cl i mate and comfort wi thi n the vehi cl e.
Refer to the owners manual i n the vehi cl e gl ove box
for more i nformati on on the features, use, and sug-
gested operati on of these control s.
OPERATION
The a/c heater control i s l ocated to the ri ght of the
i nstrument cl uster on the i nstrument panel . The a/c
heater control contai ns a rotary-type temperature
control knob, a rotary-type mode control knob, a rota-
ry-type bl ower motor speed knob, and push buttons
for a/c compressor and rear wi ndow defogger/heated
mi rror operati on (Fi g. 14).
The a/c heater control i s ful l y el ectroni c, contai ns
the l ogi c and control ci rcui ts for the HVAC system,
and i s on the J1850 data bus.
The a/c heater control cannot be repai red. I f faul ty
or damaged, the enti re uni t must be repl aced. The
Fig. 13 POWER DISTRIBUTION CENTER LOCATION
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
Fig. 14 A/C HEATER CONTROL
1 - BLOWER SPEED CONTROL KNOB
2 - TEMPERATURE CONTROL KNOB
3 - MODE CONTROL KNOB
4 - A/C SELECT BUTTON
5 - REAR WINDOW DEFOGGER/HEATED MIRROR SELECT
BUTTON (optional)
AN CONTROLS 24 - 15
A/C COMPRESSOR CLUTCH RELAY (Continued)
i l l umi nati on l amps are avai l abl e for servi ce repl ace-
ment.
DIAGNOSIS AND TESTING- HEATER-A/C
CONTROL
Sati sfactory heater and ai r condi ti oner perfor-
mance depends upon proper operati on and adjust-
ment of al l operati ng control s and refri gerati on
system components. For ci rcui t descri pti ons and di a-
grams, refer to Ai r Condi ti oni ng/Heater i n Group 8W
- Wi ri ng Di agrams. Use of the DRBI I I i s requi red
for di agnosi s and testi ng, fol l ow i nstructi ons on
DRBI I I .
REMOVAL
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
cabl e.
panel (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - REMOVAL).
(3) Remove the screws that secure the a/c heater
control to the cl uster bezel (Fi g. 15).
(4) Remove the a/c heater control from the cl uster
bezel .
(5) Unpl ug the wi re harness connectors from the
back of the heater-A/C control .
INSTALLATION
(1) Pl ug the wi re harness connector i nto the back
of the heater-A/C control .
(2) Posi ti on the a/c heater control i n the i nstru-
ment panel cl uster bezel .
(3) I nstal l the fastener screws and ti ghten to 2.2
Nm (17 3 i n. l bs.).
(4) I nstal l the cl uster bezel i n the i nstrument
panel (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - REMOVAL AND I NSTALLATI ON).
(6) Perform A/C cool down test wi th DRB I I I .
A/C LOSS OF CHARGE SWITCH
DESCRIPTION
The a/c l oss of charge swi tch i s l ocated on the top
of the accumul ator. The swi tch i s used to measure i f
refri gerant system pressure goes too l ow. I t i s not
responsi bl e for cycl i ng the a/c compressor cl utch. The
swi tch i s screwed onto an accumul ator fi tti ng that
contai ns a Schrader-type val ve, whi ch al l ows the
swi tch to be servi ced wi thout di schargi ng the refri g-
erant system. The accumul ator fi tti ng i s equi pped
wi th an O-ri ng to seal the swi tch connecti on.
OPERATION
The l oss of charge swi tch i s connected i n seri es
el ectri cal l y wi th the Heater-A/C control s between
ground and the Powertrai n Control Modul e (PCM).
The swi tch contacts open and cl ose causi ng the PCM
to turn the compressor cl utch on and off. Thi s pre-
vents compressor operati on when the system charge
i s l ow and prevents damage to the compressor. The
swi tch opens wi th a pressure of 7 to 13 psi and cl oses
when the pressure ri ses to 15 to 25 psi .
DIAGNOSIS AND TESTING - LOSS OF CHARGE
SWITCH
Before performi ng di agnosi s of the l oss of charge
swi tch, be certai n that the swi tch i s properl y
i nstal l ed on the accumul ator fi tti ng. I f the swi tch i s
too l oose i t may not open the Schrader-type val ve i n
the accumul ator fi tti ng, whi ch wi l l prevent the
swi tch from correctl y moni tori ng the refri gerant sys-
tem pressure. Remember that l ower ambi ent temper-
atures duri ng col d weather wi l l open the swi tch
contacts and prevent compressor operati on due to the
pressure/temperature rel ati onshi p of the refri gerant.
Fig. 15 A/C HEATER CONTROL REMOVE/INSTAL
1 - HEATER A/C CONTROL ELECTRICAL CONNECTOR
2 - HEATER A/C CONTROL
3 - HEATER A/C CONTROL MOUNTING SCREW
24 - 16 CONTROLS AN
A/C HEATER CONTROL (Continued)
Al so veri fy that the refri gerant system has the cor-
rect refri gerant charge (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - STANDARD
PROCEDURE).
For ci rcui t descri pti ons and di agrams, refer to Ai r
Condi ti oni ng/Heater i n Wi ri ng Di agrams.
cabl e.
(2) Unpl ug the l oss of charge swi tch wi re harness
connector from the swi tch on the accumul ator fi tti ng.
(3) I nstal l a jumper wi re between the two cavi ti es
of the l oss of charge swi tch wi re harness connector.
(4) Connect a mani fol d gauge set to the refri gerant
system servi ce ports (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - DESCRI PTI ON).
(6) Pl ace the heater-A/C mode control swi tch knob
i n any A/C posi ti on and start the engi ne.
(7) Check for conti nui ty between the two termi nal s
of the l ow pressure cycl i ng cl utch swi tch. There
shoul d be conti nui ty wi th a sucti on pressure readi ng
of 4889 kPa (713 psi ) or above, and no conti nui ty
wi th a sucti on pressure readi ng of 4889 kPa (713
psi ) or bel ow. I f OK, test and repai r the A/C swi tch
sense ci rcui t as requi red. I f not OK, repl ace the
faul ty swi tch.
REMOVAL
cabl e.
l oss of charge swi tch on the top of the accumul ator.
(3) Unscrew the l oss of charge swi tch from the fi t-
ti ng on the top of the accumul ator.
(4) Remove the O-ri ng seal from the accumul ator
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the accumul ator fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) I nstal l and ti ghten the l oss of charge swi tch on
the accumul ator fi tti ng. The swi tch shoul d be hand-
ti ghtened onto the accumul ator fi tti ng.
(3) Pl ug the wi re harness connector i nto the l oss of
charge swi tch.
A/C PRESSURE TRANSDUCER
DESCRIPTION
Thi s vehi cl e i s equi pped wi th an a/c pressure
transducer. Thi s transducer i s screwed onto a fi tti ng
on the l i qui d l i ne between the condenser and the
hi gh si de refri gerant system servi ce port (Fi g. 16).
OPERATION
The mai n functi on of the a/c pressure transducer i s
to di sengage the compressor cl utch when the refri g-
erant system hi gh pressures are too hi gh. The PCM
senses a vol tage from the transducer and converts i t
to a pressure. Based on thi s pressure, the PCM wi l l
di sengage the cl utch at 460 psi and re-engage the
cl utch at 290 psi . The a/c heater control al so uses the
pressure val ue to operate the auto-reci rcul ati on func-
ti on for i mproved a/c performance under extreme
condi ti ons.
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER
Before performi ng di agnosi s of the a/c pressure
transducer swi tch, veri fy that the refri gerant system
has the correct refri gerant charge. (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG - DI AGNOSI S
AND TESTI NG)
Appropri ate Wi ri ng I nformati on i n Group 8W).
(1) Turn on engi ne and have a/c sel ected.
(2) Usi ng the DRBI I I moni tor and record the
pressure val ue as i t i s sent out from the PCM.
Fig. 16 A/C PRESSURE TRANSDUCER
1 - HIGH SIDE REFRIGERANT SYSTEM SERVICE PORT
2 - LIQUID LINE
3 - A/C PRESSURE TRANSDUCER
AN CONTROLS 24 - 17
A/C LOSS OF CHARGE SWITCH (Continued)
(3) Connect the hi gh si de mani fol d gauge set to
the fi tti ng on the l i qui d l i ne hi gh si de refri gerant
system servi ce port.
(4) Compare the DRBI I I pressure val ue to the
mani fol d gauge set readi ng. The pressure readi ng
from the DRBI I I shoul d be si mi l ar to the readi ng of
the mani fol d gauge set val ue.
(5) I f not, repl ace the a/c pressure transducer.
REMOVAL
cabl e.
A/C pressure transducer, whi ch i s mounted to a fi t-
ti ng on the l i qui d l i ne between the condenser and the
hi gh si de servi ce port.
(3) Unscrew the A/C pressure transducer from the
di scharge l i ne fi tti ng.
(4) Remove the A/C pressure transducer from the
vehi cl e.
(5) Remove the O-ri ng seal from the di scharge l i ne
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the di scharge l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) I nstal l and ti ghten the A/C pressure transducer
on the di scharge l i ne fi tti ng.
(3) Pl ug the wi re harness connector i nto the A/C
pressure transducer.
AMBIENT TEMP SENSOR
DESCRIPTION
Ambi ent ai r temperature i s moni tored by the com-
pass mi ni -tri p computer modul e through the ambi ent
temperature sensor. The ambi ent temperature sensor
i s a vari abl e resi stor mounted to a bracket that i s
secured wi th a screw to the ri ght si de of the radi ator
yoke, behi nd the radi ator gri l l e and i n front of the
For compl ete ci rcui t di agrams (Refer to 8 - ELEC-
TRI CAL/WI RI NG DI AGRAM I NFORMATI ON -
DI AGNOSI S AND TESTI NG). The ambi ent tempera-
ture sensor cannot be adjusted or repai red and, i f
OPERATION
The ambi ent temperature sensor i s a vari abl e
resi stor that operates on a fi ve-vol t reference si gnal
sent to i t by the HVAC control head uni t. The resi s-
tance i n the sensor changes as temperature changes,
changi ng the temperature sensor si gnal ci rcui t vol t-
age to the HVAC control head uni t. Based upon the
resi stance i n the sensor, the HVAC control head uni t
senses a speci fi c vol tage on the temperature sensor
si gnal ci rcui t, whi ch i t i s programmed to correspond
to a speci fi c temperature.
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR
The thermometer functi on i s supported by the
ambi ent temperature sensor, a wi ri ng ci rcui t, and a
porti on of the HVAC control . I f any porti on of the
ambi ent temperature sensor ci rcui t fai l s or i f PCI
Bus i nformati on i s mi ssi ng, a ( ) wi l l appear i n the
di spl ay i n pl ace of the temperature, when the sensor
i s exposed to temperatures above 55 C (140 F), or i f
the sensor ci rcui t i s shorted. A ( ) wi l l appear i n
the di spl ay i n pl ace of the temperature, when the
sensor i s exposed to temperatures bel ow - 40 C (-
40 F), or i f the sensor ci rcui t i s open.
The ambi ent temperature sensor ci rcui t can al so be
di agnosed usi ng the fol l owi ng Sensor Test, and Sen-
sor Ci rcui t Test. I f the temperature sensor and ci r-
cui t are confi rmed to be OK, but the temperature
di spl ay i s i noperati ve or i ncorrect, refer to Di agnosi s
and Testi ng the Compass Mini-Trip Computer i n
thi s secti on. For compl ete ci rcui t di agrams, refer to
Wiring Diagrams.
SENSOR TEST
Di sconnect the ambi ent temperature sensor harness
connector.
(2) Measure the resi stance of the ambi ent temper-
ature sensor. At - 40 C (- 40 F), the sensor resi s-
tance i s 336 ki l ohms. At 55 C (140 F), the sensor
resi stance i s 2.488 ki l ohms. The sensor resi stance
shoul d read between these two val ues. I f OK, refer to
Sensor Circuit Test i n the Di agnosi s and Testi ng
secti on of thi s group. I f not OK, repl ace the faul ty
ambi ent temperature sensor.
SENSOR CIRCUIT TEST
ness connector and the HVAC control harness con-
nector.
(2) Connect a jumper wi re between the two termi -
nal s i n the body hal f of the ambi ent temperature sen-
sor harness connector.
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
24 - 18 CONTROLS AN
A/C PRESSURE TRANSDUCER (Continued)
ci rcui t cavi ti es of the HVAC control harness connec-
tor. There shoul d be conti nui ty. I f OK, go to Step 4. I f
not OK, repai r the open sensor return ci rcui t or
ambi ent temperature sensor si gnal ci rcui t to the
ambi ent temperature sensor as requi red.
(4) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the HVAC
control harness connector and a good ground. There
shoul d be no conti nui ty. I f OK, refer to Di agnosi s and
Testi ng of the Compass Mini-Trip Computer i n
thi s secti on. I f not OK, repai r the shorted ambi ent
temperature sensor si gnal ci rcui t as requi red.
REMOVAL
cabl e.
(2) Locate the ambi ent temperature sensor, on the
ri ght si de of the radi ator yoke behi nd the gri l l e (Fi g.
17).
(4) Remove the one screw that secures the ambi ent
temperature sensor bracket to the radi ator yoke.
(5) Remove the ambi ent temperature sensor from
the radi ator yoke.
INSTALLATION
(1) Posi ti on the ambi ent temperature sensor onto
the radi ator yoke.
the ambi ent temperature sensor bracket to the radi -
ator yoke. Ti ghten the screw to 5.6 Nm (50 i n. l bs.).
(3) Reconnect the wi re harness connector to the
BLEND DOOR ACTUATOR
DESCRIPTION
The bl end door actuators are reversi bl e, 12-vol t
Di rect Current (DC), servo motors. Model s wi th the
si ngl e zone heater and ai r condi ti oner system have a
si ngl e bl end ai r door, whi ch i s control l ed by a si ngl e
bl end door actuator. Model s wi th the opti onal dual
zone front heater and ai r condi ti oner system have
dual bl end ai r doors, whi ch are control l ed by two
bl end door actuators. The si ngl e zone bl end door
actuator i s l ocated on the dri ver si de end of the heat-
er-A/C housi ng uni t, cl ose to the dash panel . I n the
dual zone system, the same bl end door actuator used
for the si ngl e zone system becomes the passenger
bl end door actuator, and i s mechani cal l y connected to
onl y the passenger si de bl end ai r door. I n the dual
zone system, a second separate bl end door actuator i s
al so l ocated on the dri ver si de end of the heater-A/C
housi ng uni t cl ose to the i nstrument panel , and i s
mechani cal l y connected to onl y the dri ver si de bl end
ai r door.
The bl end door actuators are i nterchangeabl e wi th
each other, as wel l as wi th the actuators for the
mode door and the reci rcul ati on ai r door. Each actua-
tor i s contai ned wi thi n an i denti cal bl ack mol ded
pl asti c housi ng wi th an i ntegral wi re connector
receptacl e. Two i ntegral mounti ng tabs al l ow the
actuator to be secured wi th two screws to the heater-
A/C uni t housi ng. Each actuator al so has an i denti cal
output shaft wi th spl i nes that connects i t to the l i nk-
age that dri ves the proper bl end ai r door. The bl end
door actuators do not requi re mechani cal i ndexi ng to
the bl end door l i nkage, as they are el ectroni cal l y cal -
i brated by the heater-A/C control modul e. The bl end
door actuators cannot be adjusted or repai red and, i f
damaged or faul ty, they must be repl aced.
OPERATION
Each bl end door actuator i s connected to the heat-
er-A/C control modul e through the vehi cl e el ectri cal
system by a dedi cated two-wi re take out and connec-
tor of the HVAC wi re harness. The bl end door actua-
tor can move the bl end ai r door i n two di recti ons.
When the heater-A/C control modul e pul l s the vol t-
age on one si de of the motor connecti on hi gh and the
other connecti on l ow, the bl end ai r door wi l l move i n
one di recti on. When the modul e reverses the pol ari ty
Fig. 17 Ambient Temperature Sensor Remove/Install
1 - YOKE
2 - CONNECTOR
3 - SCREW
4 - SENSOR
AN CONTROLS 24 - 19
AMBIENT TEMP SENSOR (Continued)
of the vol tage to the motor, the bl end ai r door moves
i n the opposi te di recti on. When the modul e makes
the vol tage to both connecti ons hi gh or both connec-
ti ons l ow, the bl end ai r door stops and wi l l not move.
These same motor connecti ons al so provi de a feed-
back si gnal to the heater-A/C control modul e. Thi s
feedback si gnal al l ows the modul e to moni tor the
operati on and rel ati ve posi ti ons of the bl end door
actuator and the bl end ai r door. The heater-A/C con-
trol modul e l earns the bl end ai r door stop posi ti ons
duri ng the cal i brati on procedure and wi l l store a
Di agnosti c Troubl e Code (DTC) for any probl ems i t
detects i n the bl end door actuator ci rcui ts. The bl end
door actuator can be di agnosed usi ng a DRBI I I scan
REMOVAL
The si ngl e zone heati ng and ai r condi ti oni ng sys-
tem i s equi pped wi th a si ngl e bl end door actuator.
The dual zone system has two bl end door actuators,
one for the dri ver si de bl end ai r door and one for the
passenger si de bl end ai r door. The same servi ce pro-
cedures can be used for each of these actuators.
INJURY.
cabl e.
(2) Remove the si l encer from beneath the dri ver
si de end of the i nstrument panel . (Refer to 23 -
PANEL SI LENCER - REMOVAL).
(3) Remove the three screws that secure the heater
core shi el d to the l eft end of the HVAC di stri buti on
housi ng.
(4) Pul l the heater core shi el d rearward far enough
to di sengage the two l ocati on tabs that posi ti on the
front of the shi el d to the receptacl es i n the two l ower
fi nger formati ons of the heater/ai r condi ti oner hous-
i ng near the dash panel .
(5) Remove the heater core shi el d from the di stri -
buti on housi ng.
(6) Di sconnect the HVAC wi re harness connector
for the bl end door actuator from the actuator connec-
tor receptacl e.
(7) Remove the two screws that secure the bl end
door actuator to the di stri buti on housi ng.
(8) Remove the bl end door actuator from the di s-
tri buti on housi ng.
INSTALLATION
(1) Posi ti on the bl end door actuator onto the heat-
er/ai r condi ti oner housi ng. I f necessary, rotate the
actuator sl i ghtl y to al i gn the spl i nes on the actuator
output shaft wi th those i n the bl end ai r door l i nkage.
the bl end door actuator to the di stri buti on housi ng.
(3) Reconnect the HVAC wi re harness connector
for the bl end door actuator to the actuator connector
receptacl e.
(4) Posi ti on the heater core shi el d onto the di stri -
buti on housi ng. Be certai n that the two l ocati on tabs
on the front of the shi el d are engaged i n the recepta-
cl es i n the two l ower fi nger formati ons of the evapo-
rator housi ng near the dash panel .
the heater core shi el d to the l eft end of the heater/ai r
condi ti oner housi ng. Ti ghten the screws to 2 Nm (17
i n. l bs.).
(6) Rei nstal l the si l encer under the dri ver si de end
of the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/I NSTRUMENT PANEL
SI LENCER - I NSTALLATI ON).
(8) Perform the heater-A/C control cal i brati on pro-
cedure. (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALI BRATI ON).
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
Duri ng vehi cl e assembl y, the bl ower motor resi stor
i s mounted to the HVAC uni t i nsi de the passenger
compartment. I t can be accessed from the passenger
foot wel l area. See Bl ower Motor Resi stor i n the
Removal and I nstal l ati on secti on of thi s group for
more i nformati on.
OPERATION
The resi stor has mul ti pl e resi stor ci rcui ts each of
whi ch wi l l change the resi stance i n the bl ower motor
ground path to change the bl ower motor speed. The
bl ower motor swi tch di rects the ground path through
24 - 20 CONTROLS AN
BLEND DOOR ACTUATOR (Continued)
the correct resi stor ci rcui t to obtai n the sel ected
bl ower motor speed.
Wi th the bl ower motor swi tch i n the l owest speed
posi ti on, the ground path for the motor i s appl i ed
through al l of the resi stor ci rcui ts. Each hi gher speed
sel ected wi th the bl ower motor swi tch appl i es the
bl ower motor ground path through fewer of the resi s-
tor ci rcui ts, i ncreasi ng the bl ower motor speed.
The bl ower motor resi stor cannot be repai red and,
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR BLOCK
INJURY.
cabl e.
bl ower motor resi stor.
(3) Check for conti nui ty between each of the
bl ower motor swi tch i nput termi nal s of the resi stor
and the resi stor output termi nal . I n each case there
shoul d be conti nui ty. I f OK, repai r the wi re harness
ci rcui ts between the bl ower motor swi tch and the
bl ower motor resi stor or bl ower motor as requi red. I f
not OK, repl ace the faul ty bl ower motor resi stor.
REMOVAL - BLOWER MOTOR RESISTOR
BLOWER MOTOR RESISTOR
cabl e.
(2) From the passenger foot wel l area, remove the
two hex screws used to secure the bl ower motor
resi stor.
(3) Unpl ug the front bl ower motor resi stor from
the wi re harness connector.
(4) Pul l the front bl ower motor resi stor and i ts
wi re harness out of the pl enum panel and through
the cowl pl enum access hol e far enough to access the
(5) Remove the front bl ower motor resi stor from
the cowl pl enum.
INSTALLATION
(1) Pl ug the bl ower motor resi stor i nto the wi re
harness connector.
(2) I nstal l the bl ower motor resi stor to the cowl
pl enum panel by feedi ng the resi stor and wi re har-
ness back through the cowl pl enum access hol e.
the resi stor to the HVAC uni t. Ti ghten the screws to
2.2 Nm (20 i n. l bs.).
BLOWER MOTOR SWITCH
DESCRIPTION
The heater-A/C bl ower motor i s control l ed by a four
posi ti on rotary-type bl ower motor swi tch, mounted i n
the heater-A/C control panel . The swi tch al l ows the
sel ecti on of one of four bl ower motor speeds, but can
onl y be turned off by sel ecti ng the Off posi ti on wi th
the heater-A/C mode control swi tch knob.
OPERATION
The bl ower motor swi tch di rects the bl ower motor
ground path through the mode control swi tch to the
bl ower motor resi stor, or di rectl y to ground, as
requi red to achi eve the sel ected bl ower motor speed.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, the enti re heater-A/C control uni t
must be repl aced. The bl ower motor swi tch knob i s
SWITCH
INJURY.
AN CONTROLS 24 - 21
BLOWER MOTOR RESISTOR BLOCK (Continued)
(1) Check for battery vol tage at the fuse i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
as requi red and repl ace the faul ty fuse.
Remove the a/c heater control from the i nstrument
panel . (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/CONTROLS/A/C HEATER CONTROL -
REMOVAL) Check for conti nui ty between the ground
ci rcui t cavi ty of the a/c heater control wi re harness
ci rcui t to ground as requi red.
(3) Wi th the a/c heater control wi re harness con-
nector unpl ugged, pl ace the a/c heater mode control
swi tch knob i n any posi ti on except the Off posi ti on.
Check for conti nui ty between the ground ci rcui t ter-
mi nal and each of the bl ower motor dri ver ci rcui t ter-
mi nal s of the a/c heater control as you move the
bl ower motor swi tch knob to each of the four speed
posi ti ons. There shoul d be conti nui ty at each dri ver
ci rcui t termi nal i n onl y one bl ower motor swi tch
speed posi ti on. I f OK, test and repai r the bl ower
dri ver ci rcui ts between the a/c heater control connec-
tor and the bl ower motor resi stor as requi red. I f not
OK, repl ace the faul ty a/c heater control uni t.
MODE DOOR ACTUATOR
DESCRIPTION
The mode door actuator i s a reversi bl e, 12-vol t
Di rect Current (DC), servo motor. The si ngl e mode
door actuator i s l ocated on the dri ver si de end of the
heater-A/C housi ng uni t, cl ose to the top of the di s-
tri buti on housi ng. The mode door actuator i s
mechani cal l y connected to the mode door. The mode
door actuator i s i nterchangeabl e wi th the actuators
for the bl end ai r door(s) and the reci rcul ati on ai r
door. Each actuator i s contai ned wi thi n an i denti cal
bl ack mol ded pl asti c housi ng wi th an i ntegral wi re
connector receptacl e. Two i ntegral mounti ng tabs
al l ow the actuator to be secured wi th two screws to
the heater-A/C uni t housi ng. Each actuator al so has
an i denti cal output shaft wi th spl i nes that connects
i t to the l i nkage that dri ves the mode door. The mode
door actuator does not requi re mechani cal i ndexi ng
to the mode door l i nkage, as i t i s el ectroni cal l y cal i -
brated by the heater-A/C control modul e. The mode
door actuator cannot be adjusted or repai red and, i f
damaged or faul ty, i t must be repl aced.
OPERATION
The mode door actuator i s connected to the heater-
A/C control modul e through the vehi cl e el ectri cal sys-
tem by a dedi cated two-wi re take out and connector
of the HVAC wi re harness. The mode door actuator
can move the mode door i n two di recti ons. When the
heater-A/C control modul e pul l s the vol tage on one
si de of the motor connecti on hi gh and the other con-
necti on l ow, the mode door wi l l move i n one di recti on.
When the modul e reverses the pol ari ty of the vol tage
to the motor, the mode door moves i n the opposi te
di recti on. When the modul e makes the vol tage to
both connecti ons hi gh or both connecti ons l ow, the
mode door stops and wi l l not move. These same
motor connecti ons al so provi de a feedback si gnal to
the heater-A/C control modul e. Thi s feedback si gnal
al l ows the modul e to moni tor the operati on and rel a-
ti ve posi ti on of the mode door actuator and the mode
door. The heater-A/C control modul e l earns the mode
door stop posi ti ons duri ng the cal i brati on procedure
and wi l l store a Di agnosti c Troubl e Code (DTC) for
any probl ems i t detects i n the mode door actuator
ci rcui ts. The mode door actuator can be di agnosed
usi ng a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on.
REMOVAL
INJURY.
cabl e.
(2) Remove the si l encer from beneath the dri ver
si de end of the i nstrument panel . (Refer to 23 -
PANEL SI LENCER - REMOVAL).
for the mode door actuator from the actuator connec-
tor receptacl e.
(4) Remove the two screws that secure the mode
door actuator to the di stri buti on housi ng.
(5) Remove the mode door actuator from the di stri -
buti on housi ng.
24 - 22 CONTROLS AN
BLOWER MOTOR SWITCH (Continued)
INSTALLATION
INJURY.
(1) Posi ti on the mode door actuator onto the heat-
er/AC housi ng. I f necessary, rotate the actuator
sl i ghtl y to al i gn the spl i nes on the actuator output
shaft wi th those i n the mode door l i nkage.
the mode door actuator to the di stri buti on housi ng.
for the mode door actuator to the actuator connector
receptacl e.
(4) Rei nstal l the si l encer under the dri ver si de end
of the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/I NSTRUMENT PANEL
SI LENCER - I NSTALLATI ON).
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The reci rcul ati on door actuator i s a reversi bl e,
12-vol t Di rect Current (DC), servo motor. The si ngl e
reci rcul ati on door actuator i s l ocated on the passen-
ger si de end of the heater-A/C housi ng uni t, on the
bottom of the l ower i ntake ai r housi ng. The reci rcu-
l ati on door actuator i s mechani cal l y connected to the
reci rcul ati on ai r door. The reci rcul ati on door actuator
i s i nterchangeabl e wi th the actuators for the bl end
ai r door(s) and the mode door. Each actuator i s con-
tai ned wi thi n an i denti cal bl ack mol ded pl asti c hous-
i ng wi th an i ntegral wi re connector receptacl e. Two
i ntegral mounti ng tabs al l ow the actuator to be
secured wi th two screws to the l ower i ntake ai r hous-
i ng. Each actuator al so has an i denti cal output shaft
wi th spl i nes that connects i t to the l i nkage that
dri ves the reci rcul ati on ai r door. The reci rcul ati on
door actuator does not requi re mechani cal i ndexi ng
to the reci rcul ati on ai r door, as i t i s el ectroni cal l y cal -
i brated by the heater-A/C control modul e. The reci r-
cul ati on door actuator cannot be adjusted or repai red
and, i f damaged or faul ty, i t must be repl aced.
OPERATION
The reci rcul ati on door actuator i s connected to the
heater-A/C control modul e through the vehi cl e el ec-
tri cal system by a dedi cated two-wi re take out and
connector of the HVAC wi re harness. The reci rcul a-
ti on door actuator can move the reci rcul ati on door i n
two di recti ons. When the heater-A/C control modul e
pul l s the vol tage on one si de of the motor connecti on
hi gh and the other connecti on l ow, the reci rcul ati on
ai r door wi l l move i n one di recti on. When the modul e
reverses the pol ari ty of the vol tage to the motor, the
reci rcul ati on ai r door moves i n the opposi te di recti on.
When the modul e makes the vol tage to both connec-
ti ons hi gh or both connecti ons l ow, the reci rcul ati on
ai r door stops and wi l l not move. These same motor
connecti ons al so provi de a feedback si gnal to the
heater-A/C control modul e. Thi s feedback si gnal
al l ows the modul e to moni tor the operati on and rel a-
ti ve posi ti on of the reci rcul ati on door actuator and
the reci rcul ati on ai r door. The heater-A/C control
modul e l earns the reci rcul ati on ai r door stop posi -
ti ons duri ng the cal i brati on procedure and wi l l store
a Di agnosti c Troubl e Code (DTC) for any probl ems i t
detects i n the reci rcul ati on door actuator ci rcui ts.
The reci rcul ati on door actuator can be di agnosed
usi ng a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on.
REMOVAL
INJURY.
cabl e.
AN CONTROLS 24 - 23
MODE DOOR ACTUATOR (Continued)
(2) Pul l the carpet on the passenger si de front
fl oor away from the dash panel far enough to access
the reci rcul ati on door actuator.
for the reci rcul ati on door actuator from the actuator
(4) Remove the two screws that secure the reci rcu-
l ati on door actuator to the l ower i ntake ai r housi ng.
(5) Remove the reci rcul ati on door actuator from
the l ower i ntake ai r housi ng.
INSTALLATION
INJURY.
(1) Posi ti on the reci rcul ati on door actuator onto
the l ower i ntake ai r housi ng. I f necessary, rotate the
actuator sl i ghtl y to al i gn the spl i nes on the actuator
output shaft wi th those i n the reci rcul ati on ai r door.
the reci rcul ati on door actuator to the l ower i ntake ai r
housi ng. Ti ghten the screws to 2 Nm (17 i n. l bs.).
for the reci rcul ati on door actuator to the actuator
(4) Reposi ti on the carpet on the passenger si de
front fl oor back up to the dash panel .
24 - 24 CONTROLS AN
RECIRCULATION DOOR ACTUATOR (Continued)
DISTRIBUTION
TABLE OF CONTENTS
page page
BLOWER MOTOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DEFROSTER DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FLOOR DISTRIBUTION DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HVAC HOUSING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTRUMENT PANEL DEMISTER DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTRUMENT PANEL DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BLOWER MOTOR
DESCRIPTION
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the heater-A/C housi ng,
bel ow the gl ove box. The bl ower motor control s the
vel oci ty of ai r fl owi ng through the heater-A/C hous-
i ng by spi nni ng a squi rrel cage-type bl ower wheel
wi thi n the housi ng at the sel ected speed. The bl ower
motor and bl ower wheel can onl y be servi ced wi th
the heater-A/C housi ng removed from the passenger
compartment.
OPERATION
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the heater-A/C
mode control swi tch knob i s i n any posi ti on, except
Off. The bl ower motor recei ves a fused battery feed
through the bl ower motor rel ay whenever the i gni -
ti on swi tch i s i n the On posi ti on.
The bl ower motor battery feed ci rcui t i s protected
by a fuse i n the Power Di stri buti on Center (PDC).
The bl ower motor rel ay control ci rcui t i s protected by
a fuse i n the juncti on bl ock. Bl ower motor speed i s
control l ed by regul ati ng the ground path through the
heater-A/C mode control swi tch, the bl ower motor
swi tch, the bl ower motor resi stor, and the vol tage
reducti on rel ay.
The bl ower motor and bl ower motor wheel cannot
be repai red and, i f faul ty or damaged, they must be
repl aced. The bl ower motor and bl ower wheel are
each servi ced separatel y.
FORMING FURTHER DIAGNOSIS OR SERVICE.
For ci rcui t descri pti ons and di agrams, refer to Ai r
Condi ti oni ng/Heater i n Wi ri ng Di agrams. Possi bl e
causes of an i noperati ve bl ower motor i ncl ude:
Faul ty fuse
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors
Faul ty bl ower motor resi stor
Faul ty bl ower motor rel ay
Faul ty vol tage reducti on rel ay
Faul ty bl ower motor swi tch
Faul ty heater-A/C mode control swi tch
Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
Faul ty fuse
Faul ty bl ower motor swi tch
Faul ty bl ower motor resi stor
Faul ty bl ower motor rel ay
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors.
AN DISTRIBUTION 24 - 25
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower wheel out of bal ance or deformed
Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the heater-A/C system. I f the noi se goes
away, possi bl e causes i ncl ude:
Forei gn materi al i n the heater-A/C housi ng
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower motor faul ty.
REMOVAL
(1) Remove and di sassembl e the heater-A/C hous-
i ng (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/DI STRI BUTI ON/HVAC HOUSI NG - REMOVAL)
and (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/DI STRI BUTI ON/HVAC HOUSI NG - DI SAS-
SEMBLY).
(2) Remove the three screws that secure the
bl ower motor and bl ower wheel assembl y to the heat-
er-A/C housi ng.
(3) Pul l the bl ower motor and wheel assembl y out
of the passenger compartment si de of the heater-A/C
housi ng whi l e feedi ng the bl ower motor wi re harness,
grommet and connector through the hol e on the dash
panel si de of the housi ng.
(4) Remove the bl ower wheel retai ner cl i p and
remove the wheel from the bl ower motor shaft.
INSTALLATION
(1) Pl ace the bl ower motor, ai r spoi l er, and wheel
assembl y i nsi de the heater-A/C housi ng and feed the
bl ower motor wi re harness connector through the
grommet hol e i n the dash panel si de of the housi ng.
(2) Pul l the bl ower motor wi ri ng through the hol e
from the dash panel si de of the heater-A/C housi ng
unti l the grommet i s seated, whi l e posi ti oni ng the
bl ower motor and bl ower wheel assembl y i nsi de the
housi ng.
(3) I nstal l the three screws that secure the bl ower
motor, ai r spoi l er, and wheel assembl y to the heater-
A/C housi ng. Ti ghten the screws to 2.2 Nm (20 i n.
l bs.).
(4) Pl ug bl ower motor connecti ons together.
(5) Careful l y i nstal l passenger si de carpet.
(6) I nstal l l ower ri ght ki ck panel (Refer to 23 -
BODY/I NTERI OR/COWL TRI M COVER - I NSTAL-
LATI ON)
DEFROSTER DUCTS
REMOVAL
INJURY.
cabl e.
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Pl ace the i nstrument panel face down on a
sui tabl e work surface. Be certai n to take the proper
precauti ons to protect the face of the i nstrument
panel from cosmeti c damage.
(4) Remove the fasteners that secure the defroster
duct to the i nstrument panel armature.
(5) Remove the defroster duct from the i nstrument
panel .
24 - 26 DISTRIBUTION AN
BLOWER MOTOR (Continued)
INSTALLATION
INJURY.
(1) Posi ti on the defroster duct to the i nstrument
panel .
(2) I nstal l the fasteners that secure the defroster
duct to the i nstrument panel armature.
(3) Rei nstal l the i nstrument panel i n the vehi cl e.
STRUMENT PANEL ASSEMBLY - I NSTALLA-
TI ON).
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Rol l back the carpet on the front fl oor from
under the i nstrument panel toward the rear of the
vehi cl e. (Refer to 23 - BODY/I NTERI OR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Li ft the center fl oor di stri buti on duct upward
far enough to di sengage i ts l ocator hol e from the
wel d stud on the front fl oor panel .
(3) Pul l the fl oor di stri buti on duct assembl y rear-
ward far enough to di sengage the center fl oor di stri -
buti on duct from the outl et on the bottom of the
heater-A/C housi ng uni t.
INSTALLATION
(1) Assembl e the ri ght and/or l eft fl oor di stri buti on
ducts onto the center fl oor di stri buti on duct as
requi red.
(2) Sl i de the fl oor di stri buti on duct assembl y
under the i nstrument panel center stack far enough
to engage the center fl oor di stri buti on duct wi th the
outl et on the bottom of the heater-A/C housi ng uni t.
(3) Al i gn the l ocator hol e on the center fl oor di stri -
buti on duct wi th the wel d stud on the front fl oor
panel .
(4) Usi ng hand pressure, push the l ocator hol e of
the center fl oor di stri buti on duct down over the wel d
stud on the front fl oor panel .
(5) Rei nstal l the carpet onto the front fl oor panel
and under the i nstrument panel . (Refer to 23 -
BODY/I NTERI OR/CARPETS AND FLOOR MATS -
I NSTALLATI ON).
HVAC HOUSING
DESCRIPTION
Al l vehi cl es are equi pped wi th a common heater-
A/C housi ng assembl y. The system combi nes ai r con-
di ti oni ng, heati ng, and venti l ati ng capabi l i ti es i n a
si ngl e uni t housi ng mounted under the i nstrument
panel . On heater-onl y systems, the evaporator coi l
and reci rcul ati on ai r door are omi tted from the hous-
i ng.
OPERATION
Outsi de fresh ai r enters the vehi cl e through the
cowl top openi ng at the base of the wi ndshi el d, and
passes through a pl enum chamber to the heater-A/C
system bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the heater-A/C control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the heater-A/C system to recei ve a
suffi ci ent vol ume of outsi de ai r.
I t i s al so i mportant to keep the ai r i ntake openi ngs
cl ear of debri s because l eaf parti cl es and other debri s
that are smal l enough to pass through the cowl pl e-
num screen can accumul ate wi thi n the heater-A/C
housi ng. The cl osed, warm, damp and dark envi ron-
ment created wi thi n the heater-A/C housi ng i s i deal
for the growth of certai n mol ds, mi l dews and other
fungi . Any accumul ati on of decayi ng pl ant matter
provi des an addi ti onal food source for fungal spores,
whi ch enter the housi ng wi th the fresh ai r. Excess
debri s, as wel l as objecti onabl e odors created by
decayi ng pl ant matter and growi ng fungi can be di s-
charged i nto the passenger compartment duri ng
heater-A/C system operati on.
The heater and opti onal ai r condi ti oner are bl end-
ai r type systems. I n a bl end-ai r system, a bl end-ai r
door control s the amount of uncondi ti oned ai r (or
cool ed ai r from the evaporator on model s wi th ai r
condi ti oni ng) that i s al l owed to fl ow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determi nes the di s-
charge ai r temperature. By movi ng a el ectri c actua-
tor whi ch operates the bl end-ai r door. Thi s al l ows an
al most i mmedi ate manual control of the output ai r
temperature of the system.
DEFROSTER DUCTS (Continued)
The mode control knob on the heater-onl y or heat-
er-A/C control panel i s used to di rect the condi ti oned
ai r to the sel ected system outl ets. The mode control
swi tches use an el ectri c actuator to control the mode
doors.
The opti onal ai r condi ti oner for al l model s i s
desi gned for the use of non-CFC, R-134a refri gerant.
The ai r condi ti oni ng system has an evaporator to cool
and dehumi di fy the i ncomi ng ai r pri or to bl endi ng i t
wi th the heated ai r. Thi s ai r condi ti oni ng system
uses a fi xed ori fi ce tube i n the l i qui d l i ne between
the condenser and the evaporator coi l to meter refri g-
erant fl ow to the evaporator coi l .
REMOVAL- HVAC HOUSING PLENUM ADAPTER
(1) Remove the heater-A/C housi ng from the vehi -
cl e. See Heater-A/C Housi ng i n the Removal and
(2) Sl i de the heater-A/C housi ng pl enum adapter
al l the way to one si de of the pl enum openi ng.
(3) Pul l downwards sharpl y and fi rml y on the
opposi te si de of the pl enum adapter to di sengage the
snap feature from the pl enum openi ng.
(4) Remove the pl enum adapter from the pl enum
panel .
(5) When rei nstal l i ng the heater-A/C housi ng pl e-
num adapter to the pl enum panel openi ng, be certai n
that the snap features on each si de of the adapter
are ful l y engaged wi th the si des of the pl enum panel
openi ng. Thi s must be a water ti ght connecti on to
prevent l eaks.
REMOVAL- HVAC HOUSING
The heater-A/C housi ng assembl y must be removed
from the vehi cl e and di sassembl ed for servi ce access
of the bl ower motor, bl ower motor wheel , heater core,
evaporator coi l , bl end-ai r door, and each of the vari -
ous mode control doors.
cabl e.
(3) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 6. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, recover the refri gerant from the
refri gerant system (Refer to 24 - HEATI NG & AI R
(4) Di sconnect the l i qui d l i ne refri gerant l i ne fi t-
ti ng from the evaporator i nl et tube (Refer to 24 -
REMOVAL). I nstal l pl ugs i n, or tape over al l of the
opened refri gerant l i ne fi tti ngs.
(5) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube (Refer
I NG - REMOVAL). I nstal l pl ugs i n, or tape over al l of
the opened refri gerant l i ne fi tti ngs.
(6) Drai n the engi ne cool i ng system (Refer to 7 -
(7) Di sconnect the heater hoses from the heater
core tubes. Refer to Group 7 - Cool i ng System for the
procedures. I nstal l pl ugs i n, or tape over the opened
heater core tubes.
(8) Remove the two screws that retai n the hanger
strap and ai r i nl et to the pl enum.
(9) Remove the nut that secures the heater-A/C
housi ng mounti ng brace to the stud on the passenger
compartment si de of the dash panel .
(10) Pul l the heater-A/C housi ng rearward far
enough for the mounti ng studs and the evaporator
condensate drai n tube to cl ear the dash panel hol es.
cl e.
INSTALLATION- HVAC HOUSING PLENUM
ADAPTER
(1) I nstal l the heater-A/C housi ng pl enum adapter
to the pl enum panel openi ng, be certai n that the
snap features on each si de of the adapter are ful l y
engaged wi th the si des of the pl enum panel openi ng.
Thi s must be a water ti ght connecti on to prevent
l eaks.
HVAC HOUSING (Continued)
(2) I nstal l the pl enum adapter to the pl enum
panel .
(3) Push upwards sharpl y and fi rml y on the oppo-
si te si de of the pl enum adapter to di sengage the snap
feature to the pl enum openi ng.
(4) Sl i de the heater-A/C housi ng pl enum adapter
onto the pl enum openi ng.
(5) I nstal l the heater-A/C housi ng to the vehi cl e.
See Heater-A/C housi ng i n the Removal and I nstal l a-
ti on secti on of thi s group for the procedures.
INSTALLATION- HVAC HOUSING
(1) Posi ti on the heater-A/C housi ng to the dash
panel . Be certai n that the evaporator condensate
drai n tube and the housi ng mounti ng studs are
i nserted i nto thei r correct mounti ng hol es.
(2) I nstal l the screw that secures the ai r i nl et to
the pl enum.
(3) I nstal l and ti ghten the four nuts onto the heat-
er-A/C housi ng mounti ng studs on the engi ne com-
partment si de of the dash panel . Ti ghten the nuts to
7 Nm (60 i n. l bs.).
(4) I nstal l the screw that secures the hanger strap
to the pl enum.
(5) Unpl ug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
core tubes and fi l l the engi ne cool i ng system (Refer to
7 - COOLI NG - STANDARD PROCEDURE).
(6) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 10. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, unpl ug or remove the tape from the
accumul ator i nl et tube and the evaporator outl et
tube fi tti ngs. Connect the accumul ator i nl et tube cou-
pl er to the evaporator outl et tube (Refer to 24 -
I NSTALLATI ON).
(7) Unpl ug or remove the tape from the l i qui d l i ne
and the evaporator i nl et tube fi tti ngs. Connect the
l i qui d l i ne coupl er to the evaporator i nl et tube (Refer
I NG - I NSTALLATI ON).
(8) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/RE-
FRI GERANT - STANDARD PROCEDURE).
(9) Charge the refri gerant system (Refer to 24 -
(10) Rei nstal l the i nstrument panel i n the vehi cl e
TI ON).
(12) Start the engi ne and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
INJURY.
cabl e.
(4) Remove the fasteners that secure the demi ster
ducts to the i nstrument panel armature.
(5) Di sengage the demi ster ducts from the demi s-
ter outl ets.
(6) Remove the demi ster ducts from the i nstru-
ment panel .
INSTALLATION
INJURY.
(1) Posi ti on the demi ster ducts to the i nstrument
panel .
HVAC HOUSING (Continued)
(2) Engage the demi ster ducts to the demi ster out-
l ets.
(3) I nstal l the fasteners that secure the demi ster
TI ON).
INSTRUMENT PANEL DUCTS
REMOVAL
INJURY.
cabl e.
(4) Remove the fasteners that secure the panel
(5) Di sengage the panel ducts from the panel out-
l ets.
(6) Remove the panel ducts from the i nstrument
panel .
INSTALLATION
(1) Posi ti on the panel ducts to the i nstrument
panel .
(2) Engage the panel ducts to the panel outl ets.
(3) I nstal l the fasteners that secure the panel
TI ON).
INSTRUMENT PANEL DEMISTER DUCTS (Continued)
PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . 34
REFRIGERANT SYSTEM CHARGE . . . . . . . . . 34
A/C COMPRESSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A/C CONDENSER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A/C DISCHARGE LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A/C EVAPORATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
A/C ORIFICE TUBE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ACCUMULATOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HEATER CORE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
LIQUID LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REFRIGERANT
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . 44
REFRIGERANT SYSTEM EVACUATE. . . . . . . . 45
REFRIGERANT RECOVERY. . . . . . . . . . . . . . . 45
REFRIGERANT SYSTEM CHARGE . . . . . . . . . 45
REFRIGERANT OIL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REFRIGERANT OIL LEVEL. . . . . . . . . . . . . . . . 46
SUCTION LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REFRIGERANT LINE COUPLER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PLUMBING
DESCRIPTION- REFRIGERANT LINES
The refri gerant l i nes and hoses are used to carry
the refri gerant between the vari ous ai r condi ti oni ng
system components. A barri er hose desi gn wi th a
nyl on tube, whi ch i s sandwi ched between rubber l ay-
ers, i s used for the R-134a ai r condi ti oni ng system on
thi s vehi cl e. Thi s nyl on tube hel ps to further contai n
the R-134a refri gerant, whi ch has a smal l er mol ecu-
l ar structure than R-12 refri gerant. The ends of the
refri gerant hoses are made from l i ghtwei ght al umi -
num or steel , and commonl y use braze-l ess fi tti ngs.
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from the exhaust mani fol d.
AN PLUMBING 24 - 31
OPERATION- REFRIGERANT LINES
Hi gh pressures are produced i n the refri gerant sys-
tem when the ai r condi ti oni ng compressor i s operati ng.
Extreme care must be exerci sed to make sure that each
of the refri gerant system connecti ons i s pressure-ti ght
and l eak free. I t i s a good practi ce to i nspect al l fl exi bl e
hose refri gerant l i nes at l east once a year to make sure
they are i n good condi ti on and properl y routed.
The refri gerant l i nes and hoses are coupl ed wi th
other components of the HVAC system wi th peanut-
bl ock styl e fi tti ngs. A stat-O seal type fl at steel gas-
ket wi th a captured compressi bl e O-ri ng, i s used to
mate pl umbi ng l i nes wi th A/C components to ensure
the i ntegri ty of the refri gerant system.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
SERVICE WARNINGS
WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
24 - 32 PLUMBING AN
PLUMBING (Continued)
SERVICE CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a
system. Damage to the system will result.
Do not overcharge the refrigerant system. This will
cause excessive compressor head pressure and
can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not remove the secondary retention clip from
any spring-lock coupler connection while the refrig-
erant system is under pressure. Recover the refrig-
erant before removing the secondary retention clip.
Open the fittings with caution, even after the sys-
tem has been discharged. Never open or loosen a
connection before recovering the refrigerant.
The refrigerant system must always be evacuated
before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
Before disconnecting a component, clean the out-
side of the fittings thoroughly to prevent contami-
nation from entering the refrigerant system.
Immediately after disconnecting a component from
the refrigerant system, seal the open fittings with a
cap or plug.
Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
Do not remove the sealing caps from a replacement
component until it is to be installed.
When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
vent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system through care-
less work habits must be avoided.
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng
wi l l reduce the capaci ty of the enti re system. Hi gh
pressures are produced i n the system when i t i s oper-
ati ng. Extreme care must be exerci sed to make sure
that al l refri gerant system connecti ons are pressure
ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mi l l i meters (3 i nches)
from the exhaust mani fol d. I t i s a good practi ce to
i nspect al l fl exi bl e refri gerant system hose l i nes at
l east once a year to make sure they are i n good con-
di ti on and properl y routed.
There are two types of refri gerant fi tti ngs:
Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs
that are the correct si ze and approved for use wi th
R-134a refri gerant. Fai l ure to do so may resul t i n a
l eak.
Uni fi ed pl umbi ng connecti ons wi th gaskets can-
not be servi ced wi th O-ri ngs. The gaskets are not
reusabl e and new gaskets do not requi re l ubri cati on
before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
AN PLUMBING 24 - 33
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.
I f the ai r condi ti oni ng system i s not cool i ng prop-
erl y, determi ne i f the refri gerant system i s ful l y-
charged. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - DI AGNOSI S AND TESTI NG -
A/C PERFORMANCE) I f the refri gerant system i s
l ow or empty; a l eak at a refri gerant l i ne, connector
fi tti ng, component, or component seal i s l i kel y.
An el ectroni c l eak detector desi gned for R-134a
refri gerant, or a fl uorescent R-134a l eak detecti on
dye and a bl ack l i ght are recommended for l ocati ng
and confi rmi ng refri gerant system l eaks. Refer to the
operati ng i nstructi ons suppl i ed by the equi pment
manufacturer for proper care and use of thi s equi p-
ment.
An oi l y resi due on or near refri gerant system l i nes,
connector fi tti ngs, components, or component seal s
can i ndi cate the general l ocati on of a possi bl e refri g-
erant l eak. However, the exact l eak l ocati on shoul d
be confi rmed wi th an el ectroni c l eak detector pri or to
component repai r or repl acement.
To detect a l eak i n the refri gerant system wi th an
el ectroni c l eak detector, perform one of the fol l owi ng
procedures:
SYSTEM EMPTY
(1) Evacuate the refri gerant system. (Refer to 24 -
STANDARD PROCEDURE - REFRI GERANT SYS-
TEM EVACUATE)
(2) Connect and di spense 0.283 ki l ograms (0.625
pounds or 10 ounces) of R-134a refri gerant i nto the
evacuated refri gerant system. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE - REFRI GERANT SYSTEM
CHARGE)
(3) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(4) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(5) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, and the mode control
swi tch i n the reci rcul ati on mode.
SYSTEM LOW
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system
turned on for fi ve mi nutes.
components.
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, and the mode control
swi tch i n the reci rcul ati on mode.
SYSTEM CHARGE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
After the refri gerant system has been tested for
l eaks and evacuated, a refri gerant charge can be
i njected i nto the system. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - SPECI FI CA-
TI ONS - CHARGE CAPACI TY)
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
24 - 34 PLUMBING AN
used to charge the refri gerant system wi th R-134a
refri gerant. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for proper care
and use of thi s equi pment.
A/C COMPRESSOR
DESCRIPTION - A/C COMPRESSOR
The ai r condi ti oni ng system uses a Sanden
SD7H15 seven cyl i nder, reci procati ng wobbl e pl ate-
type compressor on al l model s. Thi s compressor has a
fi xed di spl acement of 150 cubi c centi meters (9.375
cubi c i nches), and has both the sucti on and di scharge
ports l ocated on the cyl i nder head. A l abel i denti fyi ng
the use of R-134a refri gerant i s l ocated on the com-
pressor.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor cyl i nder head, whi ch i s at the rear of the
compressor. Thi s mechani cal val ve i s desi gned to
vent refri gerant from the system to protect agai nst
damage to the compressor and other system compo-
nents, caused by condenser ai r fl ow restri cti on or an
overcharge of refri gerant.
OPERATION - A/C COMPRESSOR
The compressor i s dri ven by the engi ne through an
el ectri c cl utch, dri ve pul l ey and bel t arrangement.
The compressor i s l ubri cated by refri gerant oi l that i s
ci rcul ated throughout the refri gerant system wi th the
refri gerant.
The compressor draws i n l ow-pressure refri gerant
vapor from the evaporator through i ts sucti on port. I t
then compresses the refri gerant i nto a hi gh-pressure,
hi gh-temperature refri gerant vapor, whi ch i s then
pumped to the condenser through the compressor di s-
charge port.
The compressor cannot be repai red. I f faul ty or
damaged, the enti re compressor assembl y must be
repl aced. The compressor cl utch, pul l ey and cl utch
coi l are avai l abl e for servi ce.
OPERATION - HIGH PRESSURE RELIEF VALVE
The hi gh pressure rel i ef val ve vents the system
when a di scharge pressure of 3445 to 4135 kPa (500
to 600 psi ) or above i s reached. The val ve cl oses wi th
a mi ni mum di scharge pressure of 2756 kPa (400 psi )
i s reached.
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
served i n the system. I f the val ve vents refri gerant, i t
does not mean the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s a factory-cal i -
brated uni t. The val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The val ve i s onl y servi ced as a part of the
compressor assembl y.
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne speed, engi ne operati ng temperature,
and any other speci al condi ti ons. Noi ses that devel op
duri ng ai r condi ti oni ng operati on can often be mi s-
l eadi ng. For exampl e: What sounds l i ke a fai l ed front
beari ng or connecti ng rod, may be caused by l oose
bol ts, nuts, mounti ng brackets, or a l oose compressor
cl utch assembl y.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se. I mproper bel t tensi on can cause a mi sl eadi ng
noi se when the compressor cl utch i s engaged, whi ch
may not occur when the compressor cl utch i s di sen-
gaged. Check the serpenti ne dri ve bel t condi ti on and
tensi on before begi nni ng thi s procedure (Refer to 7 -
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
whi l e the cl utch i s engaged and di sengaged. Probe
the compressor wi th an engi ne stethoscope or a l ong
screwdri ver wi th the handl e hel d to your ear to bet-
ter l ocal i ze the source of the noi se.
(2) Loosen al l of the compressor mounti ng hard-
ware and reti ghten. Ti ghten the compressor cl utch
mounti ng nut. Be certai n that the cl utch coi l i s
mounted securel y to the compressor, and that the
cl utch pl ate and pul l ey are properl y al i gned and have
the correct ai r gap. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/A/C COMPRESSOR
CLUTCH - I NSTALLATI ON)
(3) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to be certai n that the di scharge pressure does not
exceed 2760 kPa (400 psi ).
(4) Check the refri gerant system pl umbi ng for
i ncorrect routi ng, rubbi ng or i nterference, whi ch can
cause unusual noi ses. Al so check the refri gerant l i nes
for ki nks or sharp bends that wi l l restri ct refri gerant
fl ow, whi ch can cause noi ses. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - CAU-
TI ON)
AN PLUMBING 24 - 35
(5) I f the noi se i s from openi ng and cl osi ng of the
hi gh pressure rel i ef val ve, recover, evacuate, and
recharge the refri gerant system. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE - REFRI GERANT RECOVERY)
PLUMBI NG - STANDARD PROCEDURE - REFRI G-
ERANT SYSTEM EVACUATE) (Refer to 24 -
STANDARD PROCEDURE - REFRI GERANT SYS-
TEM CHARGE) I f the hi gh pressure rel i ef val ve sti l l
does not seat properl y, repl ace the compressor.
(6) I f the noi se i s from l i qui d sl uggi ng on the suc-
ti on l i ne, repl ace the accumul ator. (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/AC-
CUMULATOR - REMOVAL) Check the refri gerant oi l
l evel and the refri gerant system charge. (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
REFRI GERANT OI L - STANDARD PROCEDURE -
REFRI GERANT OI L LEVEL) (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - SPECI -
FI CATI ONS - CHARGE CAPACI TY) I f the l i qui d
sl uggi ng condi ti on conti nues fol l owi ng accumul ator
repl acement, repl ace the compressor.
(7) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
REMOVAL
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
TIONING/PLUMBING - WARNING) and (Refer to 24 -
OPERATION.
(1) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG/REFRI GERANT - STANDARD
PROCEDURE).
cabl e.
REMOVAL).
(4) Unpl ug the compressor cl utch coi l wi re harness
connector.
(5) Remove the sucti on and di scharge refri gerant
l i ne mani fol d from the compressor (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
SUCTI ON LI NE - REMOVAL) and (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
LI QUI D LI NE - REMOVAL). I nstal l pl ugs i n, or tape
over al l of the opened refri gerant fi tti ngs.
(6) Remove the four screws that secure the com-
pressor to the mounti ng bracket (Fi g. 1) or (Fi g. 2).
(7) Remove the compressor from the mounti ng
bracket.
INSTALLATION
TIONING/PLUMBING - WARNING) and (Refer to 24 -
OPERATION.
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in the Service Pro-
cedures section of this group. Use only refrigerant
oil of the type recommended for the compressor in
the vehicle.
(1) I nstal l the compressor to the mounti ng bracket.
Ti ghten the four mounti ng screws to 27 Nm (20 ft.
l bs.).
(2) Remove the tape or pl ugs from al l of the
opened refri gerant l i ne fi tti ngs. I nstal l the sucti on
and di scharge l i ne mani fol d to the compressor (Refer
Fig. 1 Compressor Remove/Install - 2.5L Engine
2 - COMPRESSOR
3 - BRACKET
24 - 36 PLUMBING AN
A/C COMPRESSOR (Continued)
I NG/LI QUI D LI NE - I NSTALLATI ON) and (Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
SUCTI ON LI NE - I NSTALLATI ON).
(3) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
I NSTALLATI ON).
(4) Pl ug i n the compressor cl utch coi l wi re harness
connector.
A/C CONDENSER
DESCRIPTION
The condenser i s l ocated i n the ai r fl ow i n front of
the engi ne cool i ng radi ator. The condenser i s a heat
exchanger that al l ows the hi gh-pressure refri gerant
gas bei ng di scharged by the compressor to gi ve up i ts
heat to the ai r passi ng over the condenser fi ns, thus
causi ng the refri gerant to change to a l i qui d state.
OPERATION
When the refri gerant gas gi ves up i ts heat, i t con-
denses. When the refri gerant l eaves the condenser, i t
has become a hi gh-pressure l i qui d refri gerant. The
vol ume of ai r fl owi ng over the condenser fi ns i s cri t-
i cal to the proper cool i ng performance of the ai r con-
di ti oni ng system. Therefore, i t i s i mportant that
there are no objects pl aced i n front of the radi ator
gri l l e openi ngs i n the front of the vehi cl e or forei gn
materi al on the condenser fi ns that mi ght obstruct
Fig. 2 Compressor Remove/Install - 3.9L and 5.2L
1 - BRACKET
2 - COMPRESSOR
3 - SCREW & WASHER
4 - BRACE
5 - BOLT
AN PLUMBING 24 - 37
A/C COMPRESSOR (Continued)
proper ai r fl ow. Al so, any factory-i nstal l ed ai r seal s or
shrouds must be properl y rei nstal l ed fol l owi ng radi a-
tor or condenser servi ce.
The condenser cannot be repai red and, i f faul ty or
REMOVAL
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
OPERATION.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
cabl e.
PROCEDURE).
(3) Di sconnect the refri gerant l i ne fi tti ng that
secures the di scharge l i ne to the condenser i nl et (Fi g.
3). I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(4) Di sconnect the refri gerant l i ne fi tti ng that
secures the l i qui d l i ne to the condenser outl et. I nstal l
pl ugs i n, or tape over al l of the opened refri gerant
l i ne fi tti ngs.
(5) Remove the two screws that secure the radi ator
and fan shroud modul e to the i nsi de of the upper
radi ator crossmember.
(6) Remove the condenser cool i ng modul e from the
vehi cl e.
INSTALLATION
OPERATION.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
(1) Remove the pl ugs or tape from the refri gerant
l i ne fi tti ngs on the l i qui d l i ne and the condenser out-
l et. Connect the l i qui d l i ne to the condenser outl et.
Ti ghten the fi tti ng to 22.59 3.39 Nm (200 30 i n.
l bs.).
(2) Remove the pl ugs or tape from the refri gerant
l i ne fi tti ngs on the di scharge l i ne and the condenser
i nl et. Connect the di scharge l i ne to the condenser
i nl et. Ti ghten the fi tti ng to 22.59 3.39 Nm (200 30
i n. l bs.).
(3) Check that al l of the condenser and radi ator
ai r seal s are i n thei r proper l ocati ons.
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
Fig. 3 Condenser Line Fittings
1 - DISCHARGE LINE
2 - CONDENSOR
3 - LIQUID LINE
24 - 38 PLUMBING AN
A/C CONDENSER (Continued)
A/C DISCHARGE LINE
REMOVAL
tem when the ai r condi ti oni ng compressor i s operat-
i ng. Extreme care must be exerci sed to make sure
that each of the refri gerant system connecti ons i s
pressure-ti ght and l eak free. I t i s a good practi ce to
i nspect al l fl exi bl e hose refri gerant l i nes at l east once
a year to make sure they are i n good condi ti on and
properl y routed.
OPERATION.
cabl e.
PROCEDURE).
(3) Unpl ug the wi re harness connector from the a/c
pressure transducer swi tch.
(4) Remove the fasteners and di sconnect the refri g-
erant l i ne coupl ers at the condenser and the accumu-
l ator (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - REMOVAL). I nstal l
l i ne fi tti ngs.
(5) Remove the fastener that secures the refri ger-
ant l i ne support bracket near the compressor.
(6) Remove the screw that secures the refri gerant
l i ne mani fol d to the compressor. I nstal l pl ugs i n, or
tape over al l of the opened refri gerant l i ne fi tti ngs.
(7) Remove the sucti on and di scharge l i ne assem-
bl y from the vehi cl e.
INSTALLATION
properl y routed.
OPERATION.
(1) Remove the tape or pl ugs from al l of the refri g-
erant l i ne fi tti ngs. I nstal l the refri gerant l i ne cou-
pl ers to the condenser and the accumul ator (Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG
- I NSTALLATI ON). Ti ghten the fasteners to 22 3.38
Nm (200 30 i n. l bs.).
(2) I nstal l the refri gerant l i ne mani fol d to the com-
pressor. Ti ghten the mounti ng screw to 22 Nm (200
i n. l bs.).
(3) I nstal l the fastener that secures the refri gerant
l i ne support bracket near the compressor. Ti ghten
the mounti ng screw to 6.77 1.7 Nm (60 15 i n.
l bs.).
(4) Pl ug i n the wi re harness connector to the pres-
sure transducer swi tch.
A/C EVAPORATOR
DESCRIPTION
The evaporator coi l i s l ocated i n the heater-A/C
housi ng, under the i nstrument panel . The evaporator
coi l i s posi ti oned i n the heater-A/C housi ng so that
al l ai r that enters the housi ng must pass over the
fi ns of the evaporator before i t i s di stri buted through
the system ducts and outl ets. However, ai r passi ng
over the evaporator coi l fi ns wi l l onl y be condi ti oned
when the compressor i s engaged and ci rcul ati ng
refri gerant through the evaporator coi l tubes.
AN PLUMBING 24 - 39
OPERATION
Refri gerant enters the evaporator from the fi xed
ori fi ce tube as a l ow-temperature, l ow-pressure l i q-
ui d. As ai r fl ows over the fi ns of the evaporator, the
humi di ty i n the ai r condenses on the fi ns, and the
heat from the ai r i s absorbed by the refri gerant. Heat
absorpti on causes the refri gerant to boi l and vapor-
i ze. The refri gerant becomes a hi gh-pressure gas
when i t l eaves the evaporator.
The evaporator coi l cannot be repai red and, i f
REMOVAL
cl e (Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
DI STRI BUTI ON/HVAC HOUSI NG - REMOVAL).
(2) Remove the upper housi ng cover (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - DI SASSEMBLY).
(3) Li ft the evaporator coi l out of the heater-A/C
housi ng.
INSTALLATION
NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system.
(1) I nsert the evaporator coi l i nto the bottom of the
heater-A/C housi ng.
(2) Reassembl e the heater-A/C housi ng (Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/DI STRI BU-
TI ON/HVAC HOUSI NG - ASSEMBLY).
(3) I nstal l the heater-A/C housi ng i nto the vehi cl e
DI STRI BUTI ON/HVAC HOUSI NG - I NSTALLA-
TI ON).
A/C ORIFICE TUBE
DESCRIPTION
The fi xed ori fi ce tube i s i nstal l ed i n the l i qui d l i ne
between the outl et of the condenser and the i nl et of
the evaporator. The fi xed ori fi ce tube i s l ocated near
the front end of the rear hal f of the two-pi ece l i qui d
l i ne. I t i s accessed for servi ce by separati ng the tube
fi tti ng that joi ns the two hal ves of the l i qui d l i ne.
OPERATION
The i nl et end of the fi xed ori fi ce tube has a nyl on
mesh fi l ter screen, whi ch fi l ters the refri gerant and
hel ps to reduce the potenti al for bl ockage of the
meteri ng ori fi ce by refri gerant system contami nants
(Fi g. 4). The outl et end of the tube has a nyl on mesh
di ffuser screen. The O-ri ngs on the pl asti c body of
the fi xed ori fi ce tube seal the tube to the i nsi de of
the l i qui d l i ne and prevent the refri gerant from
bypassi ng the fi xed meteri ng ori fi ce.
The fi xed ori fi ce tube i s used to meter the fl ow of
l i qui d refri gerant i nto the evaporator coi l . The hi gh-
pressure l i qui d refri gerant from the condenser
expands i nto a l ow-pressure l i qui d as i t passes
through the meteri ng ori fi ce and di ffuser screen of
the fi xed ori fi ce tube.
The fi xed ori fi ce tube cannot be repai red and, i f
faul ty or pl ugged, i t must be repl aced.
Fig. 4 Fixed Orifice Tube - Typical
1 - DIFFUSER SCREEN
2 - O RINGS
3 - INLET FILTER SCREEN
4 - ORIFICE
24 - 40 PLUMBING AN
A/C EVAPORATOR (Continued)
REMOVAL
OPERATION.
cabl e.
PROCEDURE).
(3) Di sconnect the l i qui d l i ne refri gerant l i ne fas-
tener at the condenser outl et tube (Refer to 24 -
REMOVAL). I nstal l pl ugs i n, or tape over al l of the
opened refri gerant l i ne fi tti ngs.
CAUTION: Always use two wrenches when loosen-
ing or tightening tube fittings. Use one wrench to
hold one side of the connection stationary, while
loosening or tightening the other side of the con-
nection with a second wrench.
(4) Remove the front hal f of the l i qui d l i ne from
the rear hal f by di sconnecti ng i t at the tube fi tti ng.
I nstal l pl ugs i n, or tape over al l of the opened refri g-
erant l i ne tube fi tti ngs.
(5) Remove the fi xed ori fi ce tube from the rear hal f
of the l i qui d l i ne usi ng a pai r of needl e nose pl i ers.
Note the ori entati on of the fi xed ori fi ce tube for cor-
rect rei nstal l ati on.
INSTALLATION
OPERATION.
(1) I nsert the fi xed ori fi ce tube i nto the rear hal f of
the l i qui d l i ne. Be certai n that i t i s properl y ori ented
(Fi g. 5).
erant l i ne tube fi tti ngs. I nstal l a new O-ri ng on the
l i qui d l i ne tube fi tti ng. Connect and ti ghten the tube
fi tti ng on the front hal f of the l i qui d l i ne to the tube
fi tti ng on the rear hal f of the l i qui d l i ne (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
I NSTALLATI ON).
erant l i ne fi tti ngs. I nstal l the front hal f of the l i qui d
l i ne to the condenser outl et tube. Ti ghten the fas-
tener to 22.6 3.39 Nm (200 30 i n. l bs.).
ACCUMULATOR
DESCRIPTION
The accumul ator i s mounted i n the engi ne com-
partment between the a/c evaporator outl et tube and
the compressor i nl et.
OPERATION
Refri gerant enters the accumul ator cani ster as a
l ow pressure vapor through the i nl et tube. Any l i q-
ui d, oi l -l aden refri gerant fal l s to the bottom of the
cani ster, whi ch acts as a separator. A desi ccant bag i s
mounted i nsi de the accumul ator cani ster to absorb
any moi sture whi ch may have entered and become
trapped wi thi n the refri gerant system (Fi g. 6).
REMOVAL
OPERATION.
cabl e.
PROCEDURE).
l oss of pressure swi tch.
Fig. 5 Fixed Orifice Tube - Typical
1 - DIFFUSER SCREEN
2 - O RINGS
3 - INLET FILTER SCREEN
4 - ORIFICE
AN PLUMBING 24 - 41
A/C ORIFICE TUBE (Continued)
(4) I f the vehi cl e i s so equi pped, remove the nuts
that secure the vehi cl e speed control servo mounti ng
bracket to the studs on the cowl pl enum panel and
move the servo far enough to access the accumul ator
refri gerant l i ne coupl ers (Refer to 8 - ELECTRI CAL/
SPEED CONTROL/SERVO - REMOVAL).
(5) Loosen the screw that secures the accumul ator
retai ni ng band to the support bracket on the dash
panel .
(6) Di sconnect the sucti on l i ne refri gerant l i ne fas-
tener from the accumul ator. I nstal l pl ugs i n, or tape
over al l of the opened refri gerant l i ne fi tti ngs.
(7) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne secondary cl i p from the accumul ator. I nstal l
l i ne fi tti ngs.
(8) Pul l the accumul ator and retai ni ng band uni t
forward unti l the screw i n the band i s cl ear of the
sl otted hol e i n the support bracket on the dash panel .
(9) Remove the accumul ator from the vehi cl e.
INSTALLATION
OPERATION.
(1) I nstal l the accumul ator and retai ni ng band as
a uni t by sl i di ng the screw i n the band i nto the sl ot-
ted hol e i n the support bracket on the dash panel .
(2) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the accumul ator i nl et tube and the
evaporator outl et tube. Connect both refri gerant l i nes
to the accumul ator. Ti ghten the fasteners to 25.99
3.39 Nm (230 30 i n. l bs.).
(3) Ti ghten the accumul ator retai ni ng band screw
to 4.5 Nm (40 i n. l bs.).
(4) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
(6) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n the Servi ce Procedures sec-
ti on of thi s group.
(7) Charge the refri gerant system. See Refri gerant
System Charge i n the Servi ce Procedures secti on of
thi s group.
NOTE: If the accumulator is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
HEATER CORE
DESCRIPTION
The heater core i s l ocated i n the HVAC housi ng,
under the i nstrument panel . I t i s a heat exchanger
made of rows of tubes and fi ns.
The heater core i s not repai rabl e and i f damaged i t
must be repl aced.
OPERATION
Engi ne cool ant i s ci rcul ated through heater hoses
to the heater core at al l ti mes. As the cool ant fl ows
through the heater core, heat removed from the
engi ne i s transferred to the heater core fi ns and
tubes. Ai r di rected through the heater core pi cks up
the heat from the heater core fi ns. The bl end door
Fig. 6 ACCUMULATOR - TYPICAL
1 - A/C LOSS OF CHARGE SWITCH
2 - LOSS OF CHARGE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR
24 - 42 PLUMBING AN
al l ows control of the heater output ai r temperature
by control l i ng how much of the ai r fl owi ng through
the HVAC housi ng i s di rected through the heater
core. The bl ower motor speed control s the vol ume of
ai r fl owi ng through the HVAC housi ng.
The heater core cannot be repai red and, i f faul ty or
REMOVAL
(1) Remove the passenger si de rear tri m panel
(Refer to 23 - BODY/I NTERI OR/QUARTER PANEL
TRI M - REMOVAL).
(2) Drai n to cool i ng systems (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE) or (Refer to 7 -
(3) Remove the three bl end door actuator screws.
(4) Remove the bl end door actuator and pl ace
asi de.
(5) Remove the two screws from the heater/evapo-
rator tubes pl asti c retai ner.
(6) Usi ng spri ng cl amp type pl i ers remove the
cl amps from the heater hoses,
(7) Usi ng a twi sti ng moti on remove the heater
hoses from the heater core.
(8) Li ft the heater core out of the heater-A/C hous-
i ng.
INSTALLATION
(1) I nsert the heater core i nto the bottom of the
heater-A/C housi ng.
(2) Usi ng a twi sti ng moti on i nstal l the heater
hoses to the heater core.
(3) Usi ng spri ng cl amp type pl i ers i nstal l the
cl amps to the heater hoses.
(4) I nstal l the two screws to the heater/evaporator
tubes pl asti c retai ner.
(5) I nstal l bl end door actuator.
(6) I nstal l the three bl end door actuator screws.
I NG - STANDARD PROCEDURE) or (Refer to 7 -
(8) I nstal l the passenger si de rear tri m panel
(Refer to 23 - BODY/I NTERI OR/QUARTER PANEL
TRI M - I NSTALLATI ON).
LIQUID LINE
REMOVAL
fl ow of refri gerant i n the system. Hi gh pressures are
produced i n the refri gerant system when the ai r con-
di ti oni ng compressor i s operati ng. Extreme care must
be exerci sed to make sure that each of the refri ger-
ant system connecti ons i s pressure-ti ght and l eak
free.
OPERATION.
cabl e.
PROCEDURE).
(3) Remove the engi ne ai r fi l ter housi ng (Refer to 9
- ENGI NE/AI R I NTAKE SYSTEM/AI R CLEANER
ELEMENT - REMOVAL).
(4) I f the vehi cl e i s so equi pped, remove the nuts
that secure the vehi cl e speed control servo mounti ng
bracket to the studs on the cowl pl enum panel and
move the servo far enough to access the l i qui d l i ne to
evaporator coupl er (Refer to 8 - ELECTRI CAL/
SPEED CONTROL/SERVO - REMOVAL).
(5) Di sconnect the l i qui d l i ne fastener at the con-
denser, and refri gerant l i ne coupl er at the evaporator
PLUMBI NG - REMOVAL).
(6) Di sengage the two cl i ps that secure the l i qui d
l i ne to the i nner fender shi el d.
(7) Remove the l i qui d l i ne from the vehi cl e.
INSTALLATION
pressure-ti ght and l eak free.
AN PLUMBING 24 - 43
HEATER CORE (Continued)
OPERATION.
(1) I nstal l the l i qui d l i ne i n the two cl i ps on the
i nner fender shi el d.
(2) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the l i qui d l i ne, the condenser outl et,
and the evaporator i nl et. Connect the l i qui d l i ne to
the condenser and the evaporator and i nstal l the sec-
ondary cl i p (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG - I NSTALLATI ON). Ti ghten
the fastener at the condenser to 22.6 3.38 Nm (200
30 i n. l bs.).
(3) I f the vehi cl e i s so equi pped, rei nstal l the vehi -
cl e speed control servo mounti ng bracket to the studs
on the cowl pl enum panel (Refer to 8 - ELECTRI -
CAL/SPEED CONTROL/SERVO - I NSTALLATI ON).
(4) Rei nstal l the engi ne ai r fi l ter housi ng (Refer to
9 - ENGI NE/AI R I NTAKE SYSTEM/AI R CLEANER
ELEMENT - I NSTALLATI ON).
REFRIGERANT
DESCRIPTION
The refri gerant used i n thi s ai r condi ti oni ng sys-
tem i s a HydroFl uoroCarbon (HFC), type R-134a.
Unl i ke R-12, whi ch i s a Chl oroFl uoroCarbon (CFC),
R-134a refri gerant does not contai n ozone-depl eti ng
chl ori ne. R-134a refri gerant i s a non-toxi c, non-fl am-
mabl e, cl ear, and col orl ess l i quefi ed gas.
Even though R-134a does not contai n chl ori ne, i t
must be recl ai med and recycl ed just l i ke CFC-type
refri gerants. Thi s i s because R-134a i s a greenhouse
gas and can contri bute to gl obal warmi ng.
OPERATION
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 added to an R-134a refri gerant
system wi l l cause compressor fai l ure, refri gerant oi l
sl udge or poor ai r condi ti oni ng system performance.
I n addi ti on, the Pol yAl kyl ene Gl ycol (PAG) syntheti c
refri gerant oi l s used i n an R-134a refri gerant system
are not compati bl e wi th the mi neral -based refri ger-
ant oi l s used i n an R-12 refri gerant system.
R-134a refri gerant system servi ce ports, servi ce
tool coupl ers and refri gerant di spensi ng bottl es have
al l been desi gned wi th uni que fi tti ngs to ensure that
an R-134a system i s not acci dental l y contami nated
wi th the wrong refri gerant (R-12). There are al so
l abel s posted i n the engi ne compartment of the vehi -
cl e and on the compressor i denti fyi ng to servi ce tech-
ni ci ans that the ai r condi ti oni ng system i s equi pped
wi th R-134a.
DIAGNOSIS AND TESTING- REFRIGERANT
SYSTEM LEAKS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE LEAK
TESTING THE SYSTEM.
I f the ai r condi ti oni ng system does not cool prop-
erl y, the A/C system performance shoul d be tested.
See A/C Performance i n the Di agnosi s and Testi ng
secti on of thi s group for the procedures. I f the A/C
system refri gerant fi l l i s found to be l ow or i f the sys-
tem i s empty; a l eak at a refri gerant l i ne, connector
fi tti ng, component, or component seal i s l i kel y.
An el ectroni c l eak detector desi gned for R-134a
refri gerant, or a fl uorescent R-134a l eak detecti on
dye and a bl ack l i ght are recommended for l ocati ng
and confi rmi ng refri gerant system l eaks. Refer to the
operati ng i nstructi ons suppl i ed by the equi pment
manufacturer for the proper care and use of thi s
equi pment.
An oi l y resi due on or near refri gerant system l i nes,
connector fi tti ngs, components, or component seal s
can i ndi cate the general l ocati on of a possi bl e refri g-
erant l eak. However, the exact l eak l ocati on shoul d
be confi rmed wi th an el ectroni c l eak detector pri or to
component repai r or repl acement.
To detect a l eak i n the refri gerant system wi th an
el ectroni c l eak detector, perform one of the fol l owi ng
procedures:
SYSTEM EMPTY
(2) Connect and di spense 0.283 ki l ograms (0.625
pounds or 10 ounces) of R-134a refri gerant i nto the
evacuated refri gerant system (Refer to 24 - HEAT-
24 - 44 PLUMBING AN
LIQUID LINE (Continued)
components.
i nstrument panel outl et and the fl oor duct outl et. Set
the bl ower motor swi tch to the l owest speed posi ti on,
and the mode control swi tch i n the reci rcul ati on
mode (Max-A/C).
SYSTEM LOW
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system
turned on for fi ve mi nutes.
components.
i nstrument panel outl et and the fl oor duct outl et. Set
the bl ower motor swi tch to the l owest speed posi ti on,
and the mode control swi tch i n the reci rcul ati on
mode (Max-A/C).
SYSTEM EVACUATE
OPERATION.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. I f moi sture and ai r enters the system
and becomes mi xed wi th the refri gerant, the com-
pressor head pressure wi l l ri se above acceptabl e
operati ng l evel s. Thi s wi l l reduce the performance of
the ai r condi ti oner and damage the compressor.
Evacuati ng the refri gerant system wi l l remove the
ai r and boi l the moi sture out of the system at near
room temperature. To evacuate the refri gerant sys-
tem, use the fol l owi ng procedure:
(1) Connect a R-134a refri gerant recovery/recy-
cl i ng/chargi ng stati on that meets SAE Standard
J2210 and a mani fol d gauge set to the refri gerant
system of the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the chargi ng stati on vacuum pump. When the suc-
ti on gauge reads 88 kPa (26 i n. Hg.) vacuum or
greater, cl ose al l of the val ves and turn off the vac-
uum pump.
(a) I f the refri gerant system fai l s to reach the
speci fi ed vacuum, the system has a l eak that must
be corrected. See Refri gerant System Leaks i n the
Di agnosi s and Testi ng secti on of thi s group for the
procedures.
(b) I f the refri gerant system mai ntai ns the spec-
i fi ed vacuum for fi ve mi nutes, restart the vacuum
pump, open the sucti on and di scharge val ves and
evacuate the system for an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves, and turn off the charg-
i ng stati on vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th R-134a refri gerant. See Refri gerant
System Charge i n the Servi ce Procedures secti on of
thi s group.
STANDARD PROCEDURE- REFRIGERANT
RECOVERY
OPERATION.
used to recover the refri gerant from an R-134a refri g-
erant system. Refer to the operati ng i nstructi ons sup-
STANDARD PROCEDURE- REFRIGERANT
SYSTEM CHARGE
OPERATION.
After the refri gerant system has been tested for
l eaks and evacuated, a refri gerant charge can be
i njected i nto the system. See Refri gerant Charge
Capaci ty i n the Servi ce Procedures secti on of thi s
group for the proper amount of the refri gerant
charge.
used to charge the refri gerant system wi th R-134a
refri gerant. Refer to the operati ng i nstructi ons sup-
AN PLUMBING 24 - 45
REFRIGERANT (Continued)
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e i s: 0.907 ki l ograms (32 ounces).
REFRIGERANT OIL
DESCRIPTION
The refri gerant oi l used i n R-134a refri gerant sys-
tems i s a syntheti c-based, Pol yAl kyl ene Gl ycol (PAG),
wax-free l ubri cant. Mi neral -based R-12 refri gerant
oi l s are not compati bl e wi th PAG oi l s, and shoul d
never be i ntroduced to an R-134a refri gerant system.
There are di fferent PAG oi l s avai l abl e, and each
contai ns a di fferent addi ti ve package. The SD7H15
compressor used i n thi s vehi cl e i s desi gned to use an
SP-20 PAG refri gerant oi l . Use onl y refri gerant oi l of
thi s same type to servi ce the refri gerant system.
OPERATION
After performi ng any refri gerant recovery or recy-
cl i ng operati on, al ways repl eni sh the refri gerant sys-
tem wi th the same amount of the recommended
refri gerant oi l as was removed. Too l i ttl e refri gerant
oi l can cause compressor damage, and too much can
reduce ai r condi ti oni ng system performance.
PAG refri gerant oi l i s much more hygroscopi c than
mi neral oi l , and wi l l absorb any moi sture i t comes
i nto contact wi th, even moi sture i n the ai r. The PAG
oi l contai ner shoul d al ways be kept ti ghtl y capped
unti l i t i s ready to be used. After use, recap the oi l
contai ner i mmedi atel y to prevent moi sture contami -
nati on.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components except the compressor are
refri gerant oi l free. After the refri gerant system has
been charged and operated, the refri gerant oi l i n the
compressor i s di spersed throughout the refri gerant
system. The accumul ator, evaporator, condenser, and
compressor wi l l each retai n a si gni fi cant amount of
the needed refri gerant oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s ensures proper l ubri ca-
ti on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the ai r condi ti oni ng system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. An oi l l oss may occur due to a rupture or l eak
from a refri gerant l i ne, a connector fi tti ng, a compo-
nent, or a component seal . I f a l eak occurs, add 30
mi l l i l i ters (1 fl ui d ounce) of refri gerant oi l to the
refri gerant system after the repai r has been made.
Refri gerant oi l l oss wi l l be evi dent at the l eak poi nt
by the presence of a wet, shi ny surface around the
l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator coi l , or condenser are repl aced. See the
Refri gerant Oi l Capaci ti es chart. When a compressor
i s repl aced, the refri gerant oi l must be drai ned from
the ol d compressor and measured. Drai n al l of the
refri gerant oi l from the new compressor, then fi l l the
new compressor wi th the same amount of refri gerant
oi l that was drai ned out of the ol d compressor.
Refrigerant Oil Capacities
Component ml fl oz
A/C System 210 7.1
Accumulator 90 3
Condenser 30 1
Evaporator 60 2
Compressor
drain and measure
the oil from the old
compressor as noted
SUCTION LINE
REMOVAL
properl y routed.
OPERATION.
cabl e.
PROCEDURE).
24 - 46 PLUMBING AN
REFRIGERANT (Continued)
(3) Unpl ug the wi re harness connector from the a/c
pressure transducer swi tch.
(4) Remove the fasteners and di sconnect the refri g-
erant l i ne coupl ers at the condenser and the accumu-
l ator (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - REMOVAL). I nstal l
l i ne fi tti ngs.
(5) Remove the fastener that secures the refri ger-
ant l i ne support bracket near the compressor.
(6) Remove the screw that secures the refri gerant
l i ne mani fol d to the compressor. I nstal l pl ugs i n, or
tape over al l of the opened refri gerant l i ne fi tti ngs.
(7) Remove the sucti on and di scharge l i ne assem-
bl y from the vehi cl e.
INSTALLATION
properl y routed.
OPERATION.
erant l i ne fi tti ngs. I nstal l the refri gerant l i ne cou-
pl ers to the condenser and the accumul ator (Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG
- I NSTALLATI ON). Ti ghten the fasteners to 22 3.38
Nm (200 30 i n. l bs.).
(2) I nstal l the refri gerant l i ne mani fol d to the com-
pressor. Ti ghten the mounti ng screw to 22 Nm (200
i n. l bs.).
(3) I nstal l the fastener that secures the refri gerant
l i ne support bracket near the compressor. Ti ghten
the mounti ng screw to 6.77 1.7 Nm (60 15 i n.
l bs.).
(4) Pl ug i n the wi re harness connector to the pres-
sure transducer swi tch.
REFRIGERANT LINE COUPLER
DESCRIPTION- REFRIGERANT LINE COUPLERS
Spri ng-l ock type refri gerant l i ne coupl ers are used
to connect many of the refri gerant l i nes and other
components to the refri gerant system. These coupl ers
requi re a speci al tool for di sengagi ng the two coupl er
hal ves.
OPERATION- REFRIGERANT LINE COUPLERS
The spri ng-l ock coupl er i s hel d together by a garter
spri ng i nsi de a ci rcul ar cage on the mal e hal f of the
fi tti ng (Fi g. 7). When the two coupl er hal ves are con-
nected, the fl ared end of the femal e fi tti ng sl i ps
behi nd the garter spri ng i nsi de the cage on the mal e
fi tti ng. The garter spri ng and cage prevent the fl ared
end of the femal e fi tti ng from pul l i ng out of the cage.
Two O-ri ngs on the mal e hal f of the fi tti ng are
used to seal the connecti on. These O-ri ngs are com-
pati bl e wi th R-134a refri gerant and must be repl aced
wi th O-ri ngs made of the same materi al .
Fig. 7 Spring-Lock Coupler - Typical
1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8 - O RINGS
AN PLUMBING 24 - 47
SUCTION LINE (Continued)
Secondary cl i ps are i nstal l ed over the two con-
nected coupl er hal ves at the factory for added bl owoff
protecti on.
REMOVAL
TIONING/PLUMBING - WARNING) (Refer to 24 -
OPERATION.
PROCEDURE).
(2) Remove the secondary cl i p from the spri ng-l ock
coupl er.
(3) Fi t the proper si ze A/C l i ne di sconnect tool
(Speci al Tool Ki t 7193) over the spri ng-l ock coupl er
cage (Fi g. 8).
(4) Cl ose the two hal ves of the A/C l i ne di sconnect
tool around the spri ng-l ock coupl er.
(5) Push the A/C l i ne di sconnect tool i nto the open
si de of the coupl er cage to expand the garter spri ng.
Once the garter spri ng i s expanded and whi l e sti l l
pushi ng the di sconnect tool i nto the open si de of the
coupl er cage, pul l on the refri gerant l i ne attached to
the femal e hal f of the coupl er fi tti ng unti l the fl ange
on the femal e fi tti ng i s separated from the garter
spri ng and cage on the mal e fi tti ng wi thi n the di s-
connect tool .
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(6) Open and remove the A/C l i ne di sconnect tool
from the di sconnected spri ng-l ock coupl er.
(7) Compl ete the separati on of the two hal ves of
the coupl er fi tti ng.
INSTALLATION
OPERATION.
(1) Check to ensure that the garter spri ng i s
l ocated wi thi n the cage of the mal e coupl er fi tti ng,
and that the garter spri ng i s not damaged.
(a) I f the garter spri ng i s mi ssi ng, i nstal l a new
spri ng by pushi ng i t i nto the coupl er cage openi ng.
(b) I f the garter spri ng i s damaged, remove i t
from the coupl er cage wi th a smal l wi re hook (DO
NOT use a screwdri ver) and i nstal l a new garter
spri ng.
(2) Cl ean any di rt or forei gn materi al from both
hal ves of the coupl er fi tti ng.
(3) I nstal l new O-ri ngs on the mal e hal f of the cou-
pl er fi tti ng.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubri cate the mal e fi tti ng and O-ri ngs, and the
i nsi de of the femal e fi tti ng wi th cl ean R-134a refri g-
erant oi l . Use onl y refri gerant oi l of the type recom-
mended for the compressor i n the vehi cl e.
(5) Fi t the femal e hal f of the coupl er fi tti ng over
the mal e hal f of the fi tti ng.
(6) Push together fi rml y on the two hal ves of the
coupl er fi tti ng unti l the garter spri ng i n the cage on
the mal e hal f of the fi tti ng snaps over the fl anged
end on the femal e hal f of the fi tti ng.
(7) Ensure that the spri ng-l ock coupl er i s ful l y
engaged by tryi ng to separate the two coupl er hal ves.
Thi s i s done by pul l i ng the refri gerant l i nes on ei ther
si de of the coupl er away from each other.
(8) Rei nstal l the secondary cl i p over the spri ng-
l ock coupl er cage.
Fig. 8 Refrigerant Line Spring-Lock Coupler
Disconnect
24 - 48 PLUMBING AN
REFRIGERANT LINE COUPLER (Continued)
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EVAPORATIVE EMISSIONS . . . . . . . . . . . . . . . . . 23
EMISSIONS CONTROL
DESCRIPTION
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCMs memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator
(check engi ne) Lamp. Refer to Mal functi on I ndi cator
Lamp i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example, assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensors
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTCs. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Techni ci ans must retri eve stored DTCs by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16way data l i nk connector (Fi g. 1).
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16way data link connector to erase all
DTCs and extinguish the MIL (check engine lamp).
DESCRIPTION - STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
Fig. 1 Data Link (Diagnostic) Connector Location
AN EMISSIONS CONTROL 25 - 1
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
Remember that DTCs are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTCs, refer to the charts in this
section.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTCS USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
(2) Turn the i gni ti on swi tch on and access the
Read Faul t screen.
(3) Record al l the DTCs and freeze frame i nfor-
mati on shown on the DRB scan tool .
(4) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool . Do not erase any
DTCs until problems have been investigated
and repairs have been performed.
(M) Mal functi on I ndi cator Lamp (MI L) i l l umi nated duri ng engi ne operati on i f thi s DTC was recorded
(dependi ng i f requi red by CARB and/or EPA). MI L i s di spl ayed as an engi ne i con on i nstrument panel .
(G) Generator l amp i l l umi nated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0030 (M) 1/1 O2 Sensor Heater Relay Circuit Problem detected in oxygen sensor heater relay circuit.
P0036 (M) 1/2 O2 Sensor Heater Relay Circuit Problem detected in oxygen sensor heater relay circuit.
P0106 Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.
P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage.
P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage.
P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the
minimum acceptable voltage.
P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the
maximum acceptable voltage.
P0116 A rationatilty error has been detected in the coolant temp
sensor.
P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the
P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the
P0121 (M) TPS Voltage Does Not Agree With
MAP
TPS signal does not correlate to MAP sensor signal.
P0121 (M) Accelerator Position Sensor (APPS)
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0122 (M) Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable
voltage range.
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
25 - 2 EMISSIONS CONTROL AN
EMISSIONS CONTROL (Continued)
Generic Scan
Tool P-Code
P0123 (M) Throttle Position Sensor Voltage
High
Throttle position sensor input above the maximum
acceptable voltage.
Signal Voltage Too High
APPS voltage input above the maximum acceptable
voltage.
P0125 (M) Closed Loop Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is
excessive.
P0125 (M) Engine is Cold Too Long Engine does not reach operating temperature.
P0130 (M) 1/1 O2 Sensor Heater Circuit
Malfunction
Oxygen sensor heater element malfunction.
P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor input.
P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0136 (M) 1/2 O2 Sensor Heater Circuit
Malfunction
Oxygen sensor heater element malfunction.
operating range.
operating range.
P0139 (M) 1/2 O2 Sensor Slow Response Oxygen sensor response not as expected.
sensor.
operating range.
operating range.
sensor.
operating range.
P0152 (M) 2/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage sustained above normal
operating range.
Generic Scan
Tool P-Code
sensor.
operating range.
operating range.
P0159 2/2 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
sensor.
P0168 Decreased Engine Performance Due
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
Engine power will be derated.
P0171 (M) 1/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
P0172 (M) 1/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0174 (M) 2/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
P0175 (M) 2/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0176 Loss of Flex Fuel Calibration Signal No calibration voltage present from flex fuel sensor.
P0177 Water In Fuel Excess water found in fuel by water-in-fuel sensor.
P0178 Flex Fuel Sensor Volts Too Low Flex fuel sensor input below minimum acceptable voltage.
P0178 Water In Fuel Sensor Voltage Too
Low
Loss of water-in-fuel circuit or sensor.
P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable
voltage.
P0181 Fuel Injection Pump Failure Low power, engine derated, or engine stops.
P0182 (M) CNG Temp Sensor Voltage Too Low Compressed natural gas temperature sensor voltage
below acceptable voltage.
P0183 (M) CNG Temp Sensor Voltage Too High Compressed natural gas temperature sensor voltage
above acceptable voltage.
P0201 (M) Injector #1 Control Circuit An open or shorted condition detected in control circuit for
injector #1 or the INJ 1 injector bank.
P0204 (M) Injector #4 Control Circuit Injector #4 or INJ 4 injector bank output driver stage does
not respond properly to the control signal.
Generic Scan
Tool P-Code
P0205 (M) Injector #5 Control Circuit Injector #5 output driver stage does not respond properly
to the control signal.
P0215 Fuel Injection Pump Control Circuit Failure in fuel pump relay control circuit.
P0216 (M) Fuel Injection Pump Timing Failure High fuel supply restriction, low fuel pressure or possible
wrong or incorrectly installed pump keyway.
To Engine Overheat Condition
Engine overheating. ECM will derate engine performance.
P0219 Crankshaft Position Sensor
Overspeed Signal
Engine has exceeded rpm limits.
P0222 (M) Idle Validation Signals Both Low Problem detected with idle validation circuits within APPS.
P0223 (M) Idle Validation Signals Both High
(Above 5 Volts)
Problem detected with idle validation circuits within APPS.
P0230 Transfer Pump (Lift Pump) Circuit
Out of Range
Problem detected in fuel transfer pump circuits.
P0232 Fuel Shutoff Signal Voltage Too High Fuel shut-off signal voltage too high from ECM to fuel
injection pump.
P0234 (M) Turbo Boost Limit Exceeded Problem detected in turbocharger wastegate.
P0236 (M) Map Sensor Too High Too Long Problem detected in turbocharger wastegate.
P0237 (M) Map Sensor Voltage Too Low MAP sensor voltage input below the minimum acceptable
voltage.
P0238 (M) Map Sensor Voltage Too High MAP sensor voltage input above the maximum
acceptable voltage.
P0251 (M) Fuel Inj. Pump Mech. Failure Fuel
Valve Feedback Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0253 (M) Fuel Injection Pump Fuel Valve
Open Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0254 Fuel Injection Pump Fuel Valve
Current Too High
Problem caused by internal fuel injection pump failure.
P0300 (M) Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
P0301 (M) CYLINDER #1 MISFIRE Misfire detected in cylinder #1.
Generic Scan
Tool P-Code
P0307 (M) CYLINDER #7 MISFIRE Misfire detected in cylinder #7
P0320 (M) No Crank Referance Signal at PCM No reference signal (crankshaft position sensor) detected
during engine cranking.
P0320 (M) No RPM Signal to PCM (Crankshaft
Position Sensor Signal to JTEC)
A CKP signal has not been detected at the PCM.
P0325 Knock Sensor #1 Circuit Knock sensor (#1) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0336 (M) Crankshaft Position (CKP) Sensor
Signal
Problem with voltage signal from CKP.
P0340 (M) No Cam Signal At PCM No fuel sync
P0341 (M) Camshaft Position (CMP) Sensor
Signal
Problem with voltage signal from CMP.
P0350 Ignition Coil Draws Too Much
Current
A coil (1-5) is drawing too much current.
P0351 (M) Ignition Coil # 1 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
dwell time.
dwell time.
dwell time (High Impedance).
dwell time (High Impedance).
dwell time (high impedance).
P0370 Fuel Injection Pump Speed/Position
Sensor Sig Lost
Problem caused by internal fuel injection pump failure.
P0380 (M) Intake Air Heater Relay #1 Control
Circuit
Problem detected in #1 air heater solenoid/relay circuit
(not heater element)
Generic Scan
Tool P-Code
P0381 (M) Wait To Start Lamp Inoperative Problem detected in wait-to-start bulb circuit.
P0382 (M) Intake Air Heater Relay #2 Control
Circuit
Problem detected in #2 air heater solenoid/relay circuit
(not heater element)
P0387 Crankshaft Position Sensor Supply
Voltage Too Low
CKP sensor voltage input below the minimum acceptable
voltage.
P0388 Crankshaft Position Sensor Supply
Voltage Too High
CKP sensor voltage input above the maximum acceptable
voltage.
P0401 EGR System Failure Required change in air/fuel ration not detected during
diagnostic test.
P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR
solenoid control circuit.
P0404 EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR
duty cycle.
P0405 EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage
range.
P0406 EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage
range.
P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary
air (air switching/aspirator) solenoid control circuit.
P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level.
P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level.
P0441 (M) Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during
evaporative emission system operation.
P0442 (M) Evap Leak Monitor Medium Leak
Detected
A small leak has been detected in the evaporative
system.
P0443 (M) Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge
solenoid control circuit.
P0455 (M) Evap Leak Monitor Large Leak
Detected
A large leak has been detected in the evaporative system.
P0456 (M) Evap Leak Monitor Small Leak
Detected
Leak has been detected in the evaporative system.
P0460 Fuel Level Unit No Change Over
Miles
During low fuel
P0460 Fuel Level Unit No Change Over
Miles
Fuel level sending unit voltage does not change for more
than 40 miles.
P0462 Fuel Level Sending Unit Volts Too
Low
Fuel level sensor input below acceptable voltage.
P0462 (M) Fuel Level Sending Unit Volts Too
Low
Open circuit between PCM and fuel gauge sending unit.
P0463 Fuel Level Sending Unit Volts Too
High
Fuel level sensor input above acceptable voltage.
P0463 (M) Fuel Level Sending Unit Volts Too
High
Circuit shorted to voltage between PCM and fuel gauge
sending unit.
Generic Scan
Tool P-Code
P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load
conditions.
P0500 (M) No Vehicle Speed Sensor Signal A vehicle speed signal was not detected.
P0505 (M) Idle Air Control Motor Circuits SBEC II
P0522 Oil Pressure Voltage Too Low Oil pressure sending unit (sensor) voltage input below the
P0523 Oil Pressure Voltage Too High Oil pressure sending unit (sensor) voltage input above the
P0524 Oil Pressure Too Low Engine oil pressure is low. Engine power derated.
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
Properly
An open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
Released
Incorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0711 (M) Trans Temp Sensor, No Temp Rise
After Start
Relationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
Generic Scan
Tool P-Code
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
P0712 (M) Trans Temp Sensor Voltage Too Low Voltage less than 1.55 volts (4-speed auto. trans. only).
P0713 Trans Temp Sensor Voltage Too
High
Transmission fluid temperature sensor input above
acceptable voltage. Was MIL code 37.
P0713 (M) Trans Temp Sensor Voltage Too
High
Voltage greater than 3.76 volts (4-speed auto. trans.
only).
P0720 (M) Low Output SPD Sensor RPM,
Above 15 MPH
The relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.
P0720 (M) Low Output Spd Sensor RPM Above
15 mph
Output shaft speed is less than 60 rpm with vehicle speed
above 15 mph (4-speed auto. trans. only).
P0740 (M) Torq Con Clu, No RPM Drop at
Lockup
Relationship between engine and vehicle speeds
indicated failure of torque convertor clutch lock-up system
(TCC/PTU solenoid)
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter clutch (part throttle unlock) solenoid control
circuit. Shift solenoid C electrical fault - Aisin transmission
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit (3 or
4-speed auto. trans. only).
P0748 (M) Governor Pressur Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the Governor
Pressure Solenoid circuit or Trans Relay Circuit in JTEC
RE transmissions.
P0748 (M) Governor Pressure Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the governor
pressure solenoid or relay circuits (4-speed auto. trans.
only).
P0751 (M) O/D Switch Pressed (Lo) More Than
5 Minutes
Overdrive override switch input is in a prolonged
depressed state.
P0751 (M) O/D Switch Pressed (LO) More Than
5 Min
Overdrive Off switch input too low for more than 5
minutes (4-speed auto. trans. only).
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the overdrive
solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions. Was MIL code 45.
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the transmission
2-4 shift solenoid circuit (4-speed auto. trans. only).
P0756 AW4 Shift Sol B (2-3) Functional
Failure
Shift solenoid B (2-3) functional fault - Aisin transmission
P0783 (M) 3-4 Shift Sol, No RPM Drop at
Lockup
The overdrive solenoid is unable to engage the gear
change from 3rd gear to the overdrive gear.
P0801 Reverse Gear Lockout Circuit Open
or Short
An open or shorted condition detected in the transmission
reverse gear lock-out solenoid control circuit.
P0830 Clutch Depressed Switch Circuit Problem detected in clutch switch circuit.
P0833 Clutch Released Switch Circuit Problem detected in clutch switch circuit.
Generic Scan
Tool P-Code
P1110 Decrease Engine Performance Due
To High Intake Air Temperature
Intake manifold air temperature is above the engine
protection limit. Engine power will be derated.
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
P1195 (M) 1/1 O2 Sensor Slow During Catalyst
Monitor
A slow switching oxygen sensor has been detected in
bank 1/1 during catalyst monitor test. (Also see SCI DTC
$66) (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst
Monitor
$7A) (was P0153)
P1197 1/2 O2 Sensor Slow During Catalyst
Monitor
$68) (was P0139)
P1198 Radiator Temperature Sensor Volts
Too High
Radiator coolant temperature sensor input above the
P1199 Radiator Temperature Sensor Volts
Too Low
Radiator coolant temperature sensor input below the
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal
operating temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump
relay control circuit.
P1283 Idle Select Signal Invalid ECM or fuel injection pump module internal fault condition
detected.
P1284 (M) Fuel Injection Pump Battery Voltage
Out-Of-Range
Fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1285 (M) Fuel Injection Pump Controller
Always On
Fuel injection pump module relay circuit failure detected.
P1286 Accelerator Position Sensor (APPS)
Supply Voltage Too High
High voltage detected at APPS.
P1287 Fuel Injection Pump Controller
Supply Voltage Low
ECM or fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1288 Intake Manifold Short Runner
Solenoid Circuit
An open or shorted condition detected in the short runner
tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold
tuning valve solenoid control circuit.
P1290 CNG Fuel System Pressure Too
High
Compressed natural gas system pressure above normal
operating range.
P1291 No Temp Rise Seen From Intake
Heaters
Energizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.
P1291 (M) No Temperature Rise Seen From
Intake Air Heaters
Problem detected in intake manifold air heating system.
P1292 CNG Pressure Sensor Voltage Too
High
Compressed natural gas pressure sensor reading above
acceptable voltage.
Generic Scan
Tool P-Code
P1293 CNG Pressure Sensor Voltage Too
Low
Compressed natural gas pressure sensor reading below
acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
P1295 (M) No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.
Supply Voltage Too Low
APPS supply voltage input below the minimum
acceptable voltage.
P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been
detected.
P1297 (M) No Change in MAP From Start To
Run
No difference is recognized between the MAP reading at
engine idle and the stored barometric pressure reading.
P1298 Lean Operation at Wide Open
Throttle
A prolonged lean condition is detected during Wide Open
Throttle
P1299 Vacuum Leak Found (IAC Fully
Seated)
MAP Sensor signal does not correlate to Throttle Position
Sensor signal. Possible vacuum leak.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto
shutdown relay circuit.
P1389 No ASD Relay Output Voltage At
PCM
No Z1 or Z2 voltage sensed when the auto shutdown
relay is energized.
P1389 (M) No ASD Relay Output Voltage at
PCM
An open condition detected In the ASD relay output
circuit.
P1390 Timing Belt Skipped 1 Tooth or More Relationship between Cam and Crank signals not correct
P1391 (M) Intermittent Loss of CMP or CKP Loss of the Cam Position Sensor or Crank Position
sensor has occurred. For PL 2.0L
P1398 (M) Mis-Fire Adaptive Numerator at Limit PCM is unable to learn the Crank Sensors signal in
preparation for Misfire Diagnostics. Probable defective
Crank Sensor
P1399 Wait To Start Lamp Cicuit An open or shorted condition detected in the Wait to Start
Lamp circuit.
P1403 No 5V to EGR Sens Loss of 5v feed to the EGR position sensor.
P01475 Aux 5 Volt Supply Voltage High Sensor supply voltage for ECM sensors is too high.
P1476 Too Little Secondary Air Insufficient flow of secondary air injection detected during
aspirator test (was P0411)
P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during
aspirator test (was P0411).
P1478 Battery Temp Sensor Volts Out of
Limit
Internal temperature sensor input voltage out of an
acceptable range.
P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission
fan relay circuit.
Generic Scan
Tool P-Code
P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV
solenoid circuit.
P1481 EATX RPM Pulse Perf EATX RPM pulse generator signal for misfire detection
does not correlate with expected value.
P1482 Catalyst Temperature Sensor Circuit
Shorted Low
Catalyst temperature sensor circuit shorted low.
P1483 Catalyst Temperature Sensor Circuit
Shorted High.
Catalyst temperature sensor circuit shorted high.
P1484 Catalytic Converter Overheat
Detected
A catalyst overheat condition has been detected by the
catalyst temperature sensor.
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 Evap Leak Monitor Pinched Hose
Found
LDP has detected a pinched hose in the evaporative hose
system.
P1487 Hi Speed Rad Fan CTRL Relay
Circuit
An open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too
Low
Auxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.
P1488 5 Volt Supply Voltage Low Sensor supply voltage for ECM sensors is too low.
P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.
P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 Ambient/Batt Temp Sen Volts Too
High
External temperature sensor input above acceptable
voltage.
P1492 (M) Ambient/Batt Temp Sensor Volts Too
High
Battery temperature sensor input voltage above an
acceptable range.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
External temperature sensor input below acceptable
voltage.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
Battery temperature sensor input voltage below an
acceptable range.
P1494 (M) Leak Detection Pump Sw or
Mechanical Fault
Incorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.
P1495 Leak Detection Pump Solenoid
Circuit
An open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.
P1496 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )
P1498 High Speed Rad Fan Ground CTRL
Rly Circuit
An open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.
P1499 Hydraulic cooling fan solenoid circuit An open or shorted condition detected in the cooling fan
control solenoid circuit.
Generic Scan
Tool P-Code
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the
speed control vacuum or vent solenoid control circuits.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in the speed
control vacuum or vent solenoid circuits.
P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below the minimum acceptable
voltage.
P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable
voltage.
P1598 A/C Sensor Input Hi Problem detected in air conditioning electrical circuit.
P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable
voltage.
P1599 A/C Sensor Input Lo Problem detected in air conditioning electrical circuit.
P1680 Clutch Released Switch Circuit Problem detected in clutch switch electrical circuit.
P1681 No I/P Cluster CCD/J1850
Messages Received
No CCD/J1850 messages received from the cluster
control module.
P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage
during engine operation and no significant change in
voltage detected during active test of generator output
circuit.
P1682 Charging System Voltage Too Low Charging system output voltage low.
P1683 SPD CTRL PWR Relay; or S/C 12v
Driver CKT
An open or shorted condition detected in the speed
control servo power control circuit.
P1683 Spd ctrl pwr rly, or s/c 12v driver
circuit
An open or shorted condition detected in the speed
control servo power control circuit.
P1684 Batt Loss in 50 Star The battery has been disconnected within the last 50
starts
P1685 SKIM Invalid Key The engine controler has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
P1687 No MIC BUS Message No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1688 (M) Internal Fuel Injection Pump
Controller Failure
Internal problem within the fuel injection pump. Low
power, engine derated, or engine stops.
Generic Scan
Tool P-Code
P1689 (M) No Communication Between ECM
and Injection Pump Module
Data link circuit failure between ECM and fuel injection
pump. Low power, engine derated, or engine stops.
P1690 (M) Fuel Injection Pump CKP Sensor
Does Not Agree With ECM CKP
Sensor
Problem in fuel sync signal. Possible injection pump
timing problem. Low power, engine derated, or engine
stops.
P1691 Fuel Injection Pump Controller
Calibration Error
Internal fuel injection pump failure. Low power, engine
derated, or engine stops.
P1692 DTC Set In ECM A Companion DTC was set in both the ECM and PCM.
P1693 (M) DTC Detected in Companion Module A fault has been generated in the companion engine
control module.
P1693 (M) DTC Detected in PCM/ECM or DTC
Detected in ECM
A Companion DTC was set in both the ECM and PCM.
P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain
control module-Aisin transmission
P1694 (M) No CCD Messages received from
ECM
Bus communication failure to PCM.
P1695 No CCD/J1850 Message From Body
Control Module
No CCD/J1850 messages received from the body control
module.
P1696 PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by
the control module.
P1697 PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder
Indicator (SRI or EMR) mileage in the control module
EEPROM.
P1698 No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin
transmission controller.
P1698 No CCD Messages received from
PCM
Bus communication failure to PCM. A Companion DTC
was set in both the ECM and PCM.
P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.
P1740 TCC or OD Sol Perf A rationality error has been detected in either the TCC
solenoid or overdrive solenoid systems.
P1740 (M) TCC OR O/D Solenoid Performance Problem detected in transmission convertor clutch and/or
overdrive circuits (diesel engine with 4-speed auto. trans.
only).
P1756 (M) GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear. (Mid Pressure
Malfunction)
P1756 (M) Governor Pressure Not Equal to
Target @ 15-20 PSI
Governor sensor input not between 10 and 25 psi when
requested (4-speed auto. trans. only).
Generic Scan
Tool P-Code
P1757 GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear (Zero Pressure
Malfunction)
P1757 (M) Governor Pressure Above 3 PSI In
Gear With 0 MPH
Governor pressure greater than 3 psi when requested to
be 0 psi (4-speed auto. trans. only).
P1762 (M) Gov Press Sen Offset Volts Too Lo
or High
The Governor Pressure Sensor input is greater than a
calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.
P1762 (M) Governor Press Sen Offset Volts Too
Low or High
Sensor input greater or less than calibration for 3
consecutive Neutral/Park occurrences (4-speed auto.
trans. only).
P1763 Governor Pressure Sensor Volts Too
Hi
The Governor Pressure Sensor input is above an
acceptable voltage level.
P1763 (M) Governor Pressure Sensor Volts Too
HI
Voltage greater than 4.89 volts (4-speed auto. trans.
only).
Low
The Governor Pressure Sensor input is below an
acceptable voltage level.
Low
Voltage less than .10 volts (4-speed auto. trans. only).
P1765 (M) Trans 12 Volt Supply Relay CTRL
Circuit
An open or shorted condition is detected in the
Transmission Relay control circuit. This relay supplies
power to the TCC
P1765 (M) Trans 12 Volt Supply Relay Ctrl
Circuit
Current state of solenoid output port is different than
expected (4-speed auto. trans. only).
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch.
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch
(3 or 4-speed auto. trans. only).
DESCRIPTION - TASK MANAGER
The PCM i s responsi bl e for effi ci entl y coordi nati ng
the operati on of al l the emi ssi ons-rel ated compo-
nents. The PCM i s al so responsi bl e for determi ni ng i f
the di agnosti c systems are operati ng properl y. The
software desi gned to carry out these responsi bi l i ti es
i s cal l the Task Manager.
DESCRIPTION - MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated. These moni tors generate
Di agnosti c Troubl e Codes that can be di spl ayed wi th
the MI L or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
Mi sfi re Moni tor
Fuel System Moni tor
Oxygen Sensor Moni tor
Oxygen Sensor Heater Moni tor
Catal yst Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
The fol l owi ng i s an operati on and descri pti on of
each system moni tor :
OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
sl ow response rate
reduced output vol tage
dynami c shi ft
shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
LEAK DETECTION PUMP MONITOR (IF EQUIPPED)
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 H20.
The cycl e rate of pump strokes i s qui te rapi d as the
system begi ns to pump up to thi s pressure. As the
pressure i ncreases, the cycl e rate starts to drop off. I f
there i s no l eak i n the system, the pump woul d even-
tual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at .040 ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDPs sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. A mel tdown of the cerami c core can
cause a reducti on of the exhaust passage. Thi s can
i ncrease vehi cl e emi ssi ons and deteri orate engi ne
performance, dri veabi l i ty and fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2Ss) to moni tor the effi ci ency of the converter. The
dual O2Ss sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2Ss.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2Ss i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L wi l l be i l l u-
mi nated.
DESCRIPTION - TRIP DEFINITION
The term Tri p has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
Tri p i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
Si mi l ar Condi ti on Wi ndow for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor fai l s twi ce i n a
row and turns ON the MI L, re-runni ng that moni tor
whi ch previ ousl y fai l ed, on the next start-up and
passi ng the moni tor, i s consi dered to be a Good Tri p.
These wi l l i ncl ude the fol l owi ng:
Oxygen Sensor
Catal yst Moni tor
Purge Fl ow Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
EGR Moni tor (i f equi pped)
Oxygen Sensor Heater Moni tor
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160F and
has ri sen by at l east 40F si nce the engi ne has been
started.
DESCRIPTION - COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (MI L) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
DESCRIPTION - NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code.
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIRFLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
DESCRIPTION - HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
DESCRIPTION - LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
OPERATION - TASK MANAGER
The Task Manager determi nes whi ch tests happen
when and whi ch functi ons occur when. Many of the
di agnosti c steps requi red by OBD I I must be per-
formed under speci fi c operati ng condi ti ons. The Task
Manager software organi zes and pri ori ti zes the di ag-
nosti c procedures. The job of the Task Manager i s to
determi ne i f condi ti ons are appropri ate for tests to be
run, moni tor the parameters for a tri p for each test,
and record the resul ts of the test. Fol l owi ng are the
responsi bi l i ti es of the Task Manager software:
Test Sequence
MI L I l l umi nati on
Di agnosti c Troubl e Codes (DTCs)
Tri p I ndi cator
Freeze Frame Data Storage
Si mi l ar Condi ti ons Wi ndow
Test Sequence
I n many i nstances, emi ssi ons systems must fai l
di agnosti c tests more than once before the PCM i l l u-
mi nates the MI L. These tests are know as two tri p
moni tors. Other tests that turn the MI L l amp on
after a si ngl e fai l ure are known as one tri p moni -
tors. A tri p i s defi ned as start the vehi cl e and oper-
ate i t to meet the cri teri a necessary to run the gi ven
moni tor.
Many of the di agnosti c tests must be performed
under certai n operati ng condi ti ons. However, there
are ti mes when tests cannot be run because another
test i s i n progress (confl i ct), another test has fai l ed
(pendi ng) or the Task Manager has set a faul t that
may cause a fai l ure of the test (suspend).
Pendi ng
Under some si tuati ons the Task Manager wi l l not
run a moni tor i f the MI L i s i l l umi nated and a faul t i s
stored from another moni tor. I n these si tuati ons, the
Task Manager postpones moni tors pending resol u-
ti on of the ori gi nal faul t. The Task Manager does not
run the test unti l the probl em i s remedi ed.
For exampl e, when the MI L i s i l l umi nated for an
Oxygen Sensor faul t, the Task Manager does not run
the Catal yst Moni tor unti l the Oxygen Sensor faul t i s
remedi ed. Si nce the Catal yst Moni tor i s based on si g-
nal s from the Oxygen Sensor, runni ng the test woul d
produce i naccurate resul ts.
Confl i ct
There are si tuati ons when the Task Manager does
not run a test i f another moni tor i s i n progress. I n
these si tuati ons, the effects of another moni tor run-
ni ng coul d resul t i n an erroneous fai l ure. I f thi s con-
flict i s present, the moni tor i s not run unti l the
confl i cti ng condi ti on passes. Most l i kel y the moni tor
wi l l run l ater after the confl i cti ng moni tor has
passed.
For exampl e, i f the Fuel System Moni tor i s i n
progress, the Task Manager does not run the EGR
Moni tor. Si nce both tests moni tor changes i n ai r/fuel
rati o and adapti ve fuel compensati on, the moni tors
wi l l confl i ct wi th each other.
Suspend
Occasi onal l y the Task Manager may not al l ow a two
tri p faul t to mature. The Task Manager wi l l sus-
pend the maturi ng of a faul t i f a condi ti on exi sts
that may i nduce an erroneous fai l ure. Thi s prevents
i l l umi nati ng the MI L for the wrong faul t and al l ows
more preci s di agnosi s.
For exampl e, i f the PCM i s stori ng a one tri p faul t
for the Oxygen Sensor and the EGR moni tor, the
Task Manager may sti l l run the EGR Moni tor but
wi l l suspend the resul ts unti l the Oxygen Sensor
Moni tor ei ther passes or fai l s. At that poi nt the Task
Manager can determi ne i f the EGR system i s actu-
al l y fai l i ng or i f an Oxygen Sensor i s fai l i ng.
MIL Illumination
The PCM Task Manager carri es out the i l l umi na-
ti on of the MI L. The Task Manager tri ggers MI L i l l u-
mi nati on upon test fai l ure, dependi ng on moni tor
fai l ure cri teri a.
The Task Manager Screen shows both a Requested
MI L state and an Actual MI L state. When the MI L i s
i l l umi nated upon compl eti on of a test for a thi rd tri p,
the Requested MI L state changes to OFF. However,
the MI L remai ns i l l umi nated unti l the next key
cycl e. (On some vehi cl es, the MI L wi l l actual l y turn
OFF duri ng the thi rd key cycl e) Duri ng the key cycl e
for the thi rd good tri p, the Requested MI L state i s
OFF, whi l e the Actual MI LL state i s ON. After the
next key cycl e, the MI L i s not i l l umi nated and both
MI L states read OFF.
Diagnostic Trouble Codes (DTCs)
Wi th OBD I I , di fferent DTC faul ts have di fferent
pri ori ti es accordi ng to regul ati ons. As a resul t, the
pri ori ti es determi ne MI L i l l umi nati on and DTC era-
sure. DTCs are entered accordi ng to i ndi vi dual pri or-
i ty. DTCs wi th a hi gher pri ori ty overwri te l ower
pri ori ty DTCs.
Priorities
Pri ori ty 0 Non-emi ssi ons rel ated troubl e codes
Pri ori ty 1 One tri p fai l ure of a two tri p faul t
for non-fuel system and non-mi sfi re.
Pri ori ty 2 One tri p fai l ure of a two tri p faul t
for fuel system (ri ch/l ean) or mi sfi re.
Pri ori ty 3 Two tri p fai l ure for a non-fuel sys-
tem and non-mi sfi re or matured one tri p comprehen-
si ve component faul t.
Pri ori ty 4 Two tri p fai l ure or matured faul t
for fuel system (ri ch/l ean) and mi sfi re or one tri p cat-
al yst damagi ng mi sfi re.
Non-emi ssi ons rel ated fai l ures have no pri ori ty.
One tri p fai l ures of two tri p faul ts have l ow pri ori ty.
Two tri p fai l ures or matured faul ts have hi gher pri -
ori ty. One and two tri p fai l ures of fuel system and
mi sfi re moni tor take precedence over non-fuel system
and non-mi sfi re fai l ures.
DTC Self Erasure
Wi th one tri p components or systems, the MI L i s
i l l umi nated upon test fai l ure and DTCs are stored.
Two tri p moni tors are components requi ri ng fai l ure
i n two consecuti ve tri ps for MI L i l l umi nati on. Upon
fai l ure of the fi rst test, the Task Manager enters a
maturi ng code. I f the component fai l s the test for a
second ti me the code matures and a DTC i s set.
After three good tri ps the MI L i s exti ngui shed and
the Task Manager automati cal l y swi tches the tri p
counter to a warm-up cycl e counter. DTCs are auto-
mati cal l y erased fol l owi ng 40 warm-up cycl es i f the
component does not fai l agai n.
For mi sfi re and fuel system moni tors, the compo-
nent must pass the test under a Si mi l ar Condi ti ons
Wi ndow i n order to record a good tri p. A Si mi l ar Con-
di ti ons Wi ndow i s when engi ne RPM i s wi thi n 375
RPM and l oad i s wi thi n 10% of when the faul t
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anyti me wi th a DRB I I I . Eras-
i ng the DTC wi th the DRB I I I erases al l OBD I I
i nformati on. The DRB I I I automati cal l y di spl ays a
warni ng that erasi ng the DTC wi l l al so erase al l
OBD I I moni tor data. Thi s i ncl udes al l counter i nfor-
mati on for warm-up cycl es, tri ps and Freeze Frame.
Trip Indicator
The Trip i s essenti al for runni ng moni tors and
exti ngui shi ng the MI L. I n OBD I I terms, a tri p i s a
set of vehi cl e operati ng condi ti ons that must be met
for a speci fi c moni tor to run. Al l tri ps begi n wi th a
key cycl e.
Good Trip
The Good Tri p counters are as fol l ows:
Speci fi c Good Tri p
Fuel System Good Tri p
Mi sfi re Good Tri p
Al ternate Good Tri p (appears as a Gl obal Good
Tri p on DRB I I I )
Comprehensi ve Components
Major Moni tor
Warm-Up Cycl es
Specific Good Trip
The term Good Tri p has di fferent meani ngs
dependi ng on the ci rcumstances:
I f the MI L i s OFF, a tri p i s defi ned as when the
Oxygen Sensor Moni tor and the Catal yst Moni tor
have been compl eted i n the same dri ve cycl e.
I f the MI L i s ON and a DTC was set by the Fuel
Moni tor or Mi sfi re Moni tor (both conti nuous moni -
tors), the vehi cl e must be operated i n the Si mi l ar
Condi ti on Wi ndow for a speci fi ed amount of ti me.
I f the MI L i s ON and a DTC was set by a Task
Manager commanded once-per-tri p moni tor (such as
the Oxygen Sensor Moni tor, Catal yst Moni tor, Purge
Fl ow Moni tor, Leak Detecti on Pump Moni tor, EGR
Moni tor or Oxygen Sensor Heater Moni tor), a good
tri p i s when the moni tor i s passed on the next start-
up.
I f the MI L i s ON and any other emi ssi ons DTC
was set (not an OBD I I moni tor), a good tri p occurs
when the Oxygen Sensor Moni tor and Catal yst Mon-
i tor have been compl eted, or two mi nutes of engi ne
run ti me i f the Oxygen Sensor Moni tor and Catal yst
Moni tor have been stopped from runni ng.
Fuel System Good Trip
To count a good tri p (three requi red) and turn off
the MI L, the fol l owi ng condi ti ons must occur:
Engi ne i n cl osed l oop
Operati ng i n Si mi l ar Condi ti ons Wi ndow
Short Term mul ti pl i ed by Long Term l ess than
threshol d
Less than threshol d for a predetermi ned ti me
I f al l of the previ ous cri teri a are met, the PCM wi l l
count a good tri p (three requi red) and turn off the
MI L.
Misfire Good Trip
I f the fol l owi ng condi ti ons are met the PCM wi l l
count one good tri p (three requi red) i n order to turn
off the MI L:
Operati ng i n Si mi l ar Condi ti on Wi ndow
1000 engi ne revol uti ons wi th no mi sfi re
Warm-Up Cycles
Once the MI L has been exti ngui shed by the Good
Tri p Counter, the PCM automati cal l y swi tches to a
Warm-Up Cycl e Counter that can be vi ewed on the
DRB I I I . Warm-Up Cycl es are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycl es must
occur i n order for the PCM to sel f-erase a DTC and
Freeze Frame. A Warm-Up Cycl e i s defi ned as fol -
l ows:
Engi ne cool ant temperature must start bel ow
and ri se above 160 F
Engi ne cool ant temperature must ri se by 40 F
No further faul ts occur
Freeze Frame Data Storage
Once a fai l ure occurs, the Task Manager records
several engi ne operati ng condi ti ons and stores i t i n a
Freeze Frame. The Freeze Frame i s consi dered one
frame of i nformati on taken by an on-board data
recorder. When a faul t occurs, the PCM stores the
i nput data from vari ous sensors so that techni ci ans
can determi ne under what vehi cl e operati ng condi -
ti ons the fai l ure occurred.
The data stored i n Freeze Frame i s usual l y
recorded when a system fai l s the fi rst ti me for two
tri p faul ts. Freeze Frame data wi l l onl y be overwri t-
ten by a di fferent faul t wi th a hi gher pri ori ty.
CAUTION: Erasing DTCs, either with the DRB III or
by disconnecting the battery, also clears all Freeze
Frame data.
Similar Conditions Window
The Si mi l ar Condi ti ons Wi ndow di spl ays i nforma-
ti on about engi ne operati on duri ng a moni tor. Abso-
l ute MAP (engi ne l oad) and Engi ne RPM are stored
i n thi s wi ndow when a fai l ure occurs. There are two
di fferent Si mi l ar condi ti ons Wi ndows: Fuel System
and Mi sfi re.
FUEL SYSTEM
Fuel System Similar Conditions Window
An i ndi cator that Absol ute MAP When Fuel Sys Fai l
and RPM When Fuel Sys Fai l ed are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from NO to YES.
Absolute MAP When Fuel Sys Fail The
stored MAP readi ng at the ti me of fai l ure. I nforms
the user at what engi ne l oad the fai l ure occurred.
Absolute MAP A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
RPM When Fuel Sys Fail The stored RPM
readi ng at the ti me of fai l ure. I nforms the user at
what engi ne RPM the fai l ure occurred.
Engine RPM A l i ve readi ng of engi ne RPM
Wi ndow.
Adaptive Memory Factor The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
Upstream O2S Volts A l i ve readi ng of the
Oxygen Sensor to i ndi cate i ts performance. For
exampl e, stuck l ean, stuck ri ch, etc.
SCW Time in Window (Similar Conditions
Window Time in Window) A ti mer used by the
PCM that i ndi cates that, after al l Si mi l ar Condi ti ons
have been met, i f there has been enough good engi ne
runni ng ti me i n the SCW wi thout fai l ure detected.
Thi s ti mer i s used to i ncrement a Good Tri p.
Fuel System Good Trip Counter A Tri p
Counter used to turn OFF the MI L for Fuel System
DTCs. To i ncrement a Fuel System Good Tri p, the
engi ne must be i n the Si mi l ar Condi ti ons Wi ndow,
Adapti ve Memory Factor must be l ess than cal i -
brated threshol d and the Adapti ve Memory Factor
must stay bel ow that threshol d for a cal i brated
amount of ti me.
Test Done This Trip I ndi cates that the
moni tor has al ready been run and compl eted duri ng
the current tri p.
MISFIRE
Same Misfire Warm-Up State I ndi cates i f
the mi sfi re occurred when the engi ne was warmed up
(above 160 F).
In Similar Misfire Window An i ndi cator
that Absol ute MAP When Mi sfi re Occurred and
RPM When Mi sfi re Occurred are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from NO to YES.
Absolute MAP When Misfire Occurred
The stored MAP readi ng at the ti me of fai l ure.
I nforms the user at what engi ne l oad the fai l ure
occurred.
Absolute MAP A l i ve readi ng of engi ne l oad
Wi ndow.
RPM When Misfire Occurred The stored
RPM readi ng at the ti me of fai l ure. I nforms the user
at what engi ne RPM the fai l ure occurred.
Engine RPM A l i ve readi ng of engi ne RPM
Wi ndow.
Adaptive Memory Factor The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
200 Rev Counter Counts 0100 720 degree
cycl es.
SCWCat 200 Rev Counter Counts when i n
si mi l ar condi ti ons.
SCW FTP 1000 Rev Counter Counts 04
when i n si mi l ar condi ti ons.
Misfire Good Trip Counter Counts up to
three to turn OFF the MI L.
Misfire Data Data col l ected duri ng test.
Test Done This Trip I ndi cates YES when the
test i s done.
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 24
CCV HOSE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EVAP/PURGE SOLENOID
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL FILLER CAP
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LEAK DETECTION PUMP
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PCV VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PCV VALVE TEST - 3.9/5.2/5.9L ENGINE . . . . . 30
PCV VALVE/PCV SYSTEM TEST - 4.7L V-8
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VACUUM LINES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VAPOR CANISTER
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION - EVAPORATION CONTROL
SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal fi l l ed evap-
orati ve cani ster. The cani ster temporari l y hol ds the
vapors. The Powertrai n Control Modul e (PCM) al l ows
i ntake mani fol d vacuum to draw vapors i nto the com-
busti on chambers duri ng certai n operati ng condi -
ti ons.
Al l engi nes use a duty cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty cycl e
EVAP purge sol enoi d. Refer to Duty Cycl e EVAP
Cani ster Purge Sol enoi d.
When equi pped wi th certai n emi ssi ons packages, a
Leak Detecti on Pump (LDP) wi l l be used as part of
the evaporati ve system for OBD I I requi rements.
Al so refer to Leak Detecti on Pump.
NOTE: The evaporative system uses specially man-
ufactured lines/hoses. If replacement becomes nec-
essary, only use fuel resistant hose.
AN EVAPORATIVE EMISSIONS 25 - 23
SPECIFICATIONS
SPECIFICATIONS - TORQUE - EVAP SYSTEM
EVAP Canister Mounting Nut 17-24 150-210
EVAP Canister Purge Solenoid Mounting Bolt Except 2.5L
Engine
11 95
EVAP Canister Purge Solenoid Mounting Nuts 2.5L Engine 8 75
Leak Detection Pump (LDP) Mounting Screws 1 11
CCV HOSE
DESCRIPTION - 2. 5L
2.5L 4cyl i nder engi nes are equi pped wi th a
Crankcase Venti l ati on (CCV) system. The CCV sys-
tem performs the same functi on as a conventi onal
PCV system, but does not use a vacuum control l ed
val ve.
A mol ded vacuum tube connects a fi tti ng on the
i ntake mani fol d to a fi xed ori fi ce fi tti ng of a cal i -
brated si ze. Thi s fi tti ng meters the amount of crank-
case vapors drawn out of the engi ne. The fi xed ori fi ce
fi tti ng i s l ocated on the si de of cyl i nder head (val ve)
cover (Fi g. 1).
A fresh ai r suppl y hose from the ai r cl eaner hous-
i ng i s connected to a fi tti ng at the top/rear of cyl i nder
head cover (Fi g. 1).
When the engi ne i s operati ng, fresh ai r enters the
engi ne and mi xes wi th crankcase vapors. Engi ne vac-
uum draws the vapor/ai r mi xture through the fi xed
ori fi ce and i nto the i ntake mani fol d. The vapors are
then consumed duri ng engi ne combusti on.
EVAP/PURGE SOLENOID
DESCRIPTION
The duty cycl e EVAP cani ster purge sol enoi d (DCP)
regul ates the rate of vapor fl ow from the EVAP can-
i ster to the i ntake mani fol d. The Powertrai n Control
Modul e (PCM) operates the sol enoi d.
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
REMOVAL
3.9/5.2/5.9L Engines: The duty cycl e EVAP cani ster
purge sol enoi d i s l ocated at l eft-rear si de of engi ne com-
partment near power brake vacuum uni t (Fi g. 2).
2.5L Engine: The sol enoi d i s l ocated at ri ght-rear
si de of engi ne compartment (Fi g. 3).
(1) Di sconnect el ectri cal wi ri ng connector at sol enoi d
(2) Di sconnect vacuum harness at sol enoi d.
(3) Remove 2 support bracket mounti ng nuts.
(4) Remove sol enoi d and i ts support bracket from
vehi cl e.
Fig. 1 CCV System2.5L Engine
3 - CCV TUBE
4 - CCV TUBE
25 - 24 EVAPORATIVE EMISSIONS AN
EVAPORATIVE EMISSIONS (Continued)
INSTALLATION
3.9/5.2/5.9L Engines: The duty cycl e EVAP cani ster
purge sol enoi d i s l ocated at l eft-rear si de of engi ne com-
partment near power brake vacuum uni t (Fi g. 2).
2.5L Engine: The sol enoi d i s l ocated at ri ght-rear
si de of engi ne compartment (Fi g. 3).
(1) Posi ti on EVAP cani ster purge sol enoi d and i ts
mounti ng bracket.
(2) I nstal l mounti ng nuts and ti ghten to 8 Nm (75
i n. l bs.) torque.
(3) Connect vacuum harness and wi ri ng connector.
FUEL FILLER CAP
DESCRIPTION
The pl asti c fuel tank fi l l er tube cap i s threaded
onto the end of the fuel fi l l tube. Certai n model s are
equi pped wi th a 1/4 turn cap.
OPERATION
The l oss of any fuel or vapor out of fuel fi l l er tube
i s prevented by the use of a pressure-vacuum fuel fi l l
cap. Rel i ef val ves i nsi de the cap wi l l rel ease fuel tank
pressure at predetermi ned pressures. Fuel tank vac-
uum wi l l al so be rel eased at predetermi ned val ues.
Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with a California emissions package and a
Leak Detection Pump (LDP), the cap must be tight-
ened securely. If cap is left loose, a Diagnostic
Trouble Code (DTC) may be set.
REMOVAL/INSTALLATION
I f repl acement of the 1/4 turn fuel tank fi l l er tube
cap i s necessary, i t must be repl aced wi th an i denti -
cal cap to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
LEAK DETECTION PUMP
DESCRIPTION
The Leak Detecti on Pump (LDP) i s used onl y wi th
certai n emi ssi on packages.
The LDP i s a devi ce used to detect a l eak i n the
evaporati ve system.
The pump contai ns a 3 port sol enoi d, a pump that
contai ns a swi tch, a spri ng l oaded cani ster vent val ve
seal , 2 check val ves and a spri ng/di aphragm.
Fig. 2 Duty Cycle EVAP Canister Purge Solenoid
1 - BRACKET NUTS (2)
2 - EVAP CANISTER PURGE SOLENOID
3 - EVAP SYSTEM TEST PORT (IF EQUIPPED)
4 - VACUUM LINES
Fig. 3 Duty Cycle EVAP Canister Purge Solenoid
2.5L Engine
1 - DUTY CYCLE SOLENOID
3 - VACUUM HOSES
4 - BRACKET NUTS (2)
EVAP/PURGE SOLENOID (Continued)
I mmedi atel y after a col d start, engi ne temperature
between 40F and 86F, the 3 port sol enoi d i s bri efl y
energi zed. Thi s i ni ti al i zes the pump by drawi ng ai r i nto
the pump cavi ty and al so cl oses the vent seal . Duri ng
non-test test condi ti ons, the vent seal i s hel d open by
the pump di aphragm assembl y whi ch pushes i t open at
the ful l travel posi ti on. The vent seal wi l l remai n cl osed
whi l e the pump i s cycl i ng. Thi s i s due to the operati on
of the 3 port sol enoi d whi ch prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef i ni -
ti al i zati on peri od, the sol enoi d i s de-energi zed, al l owi ng
atmospheri c pressure to enter the pump cavi ty. Thi s
permi ts the spri ng to dri ve the di aphragm whi ch forces
ai r out of the pump cavi ty and i nto the vent system.
When the sol enoi d i s energi zed and de-energi zed, the
cycl e i s repeated creati ng fl ow i n typi cal di aphragm
pump fashi on. The pump i s control l ed i n 2 modes:
PUMP MODE: The pump i s cycl ed at a fi xed rate
to achi eve a rapi d pressure bui l d i n order to shorten
the overal l test ti me.
TEST MODE: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when the
di aphragm reaches the swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system wi l l
achi eve an equal i zed pressure of about 7.5 i nches of
water.
When the pump starts, the cycl e rate i s qui te hi gh.
As the system becomes pressuri zed pump rate drops.
I f there i s no l eak the pump wi l l qui t. I f there i s a
l eak, the test i s termi nated at the end of the test
mode.
I f there i s no l eak, the purge moni tor i s run. I f the
cycl e rate i ncreases due to the fl ow through the
purge system, the test i s passed and the di agnosti c i s
compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
A typi cal system schemati c i s shown i n (Fi g. 4).
Fig. 4 Evaporative System Monitor SchematicTypical
1 - DUTY CYCLE PURGE SOLENOID (DCPS) DRIVER
3 - 3-PORT SOLENOID DRIVER
4 - REMOTE FILTER
5 - COMBINED CANISTER VENT VALVE & LEAK DETECTION
PUMP
6 - CANISTER
7 - TANK ROLLOVER VALVE & VAPOR FLOW CONTROL ORIFICE
8 - INTAKE MANIFOLD
9 - THROTTLE BODY
10 - DCPS
11 - SWITCH SIGNAL INPUT TO THE PCM
12 - ENGINE VACUUM LINE
LEAK DETECTION PUMP (Continued)
REMOVAL
The LDP i s l ocated i n the engi ne compartment
under the battery tray and Power Di stri buti on Cen-
ter (PDC) (Fi g. 5). The LDP fi l ter i s attached to the
outsi de of battery tray (Fi g. 6). The LDP and LDP fi l -
ter are repl aced (servi ced) as one uni t.
(2) Remove battery. Refer to 8, Battery for proce-
dures.
(3) Careful l y di sconnect rubber hose from bottom
of LDP fi l ter (Fi g. 6).
(4) Remove cl i p retai ni ng LDP fi l ter to battery
tray (Fi g. 6)and remove fi l ter from tray.
(5) Di sconnect battery temperature sensor pi gtai l
wi ri ng harness at bottom of battery tray.
(6) To gai n access to LDP, the PDC must be par-
ti al l y removed. Remove PDC-to-fender mounti ng
screw at rear of PDC. Unsnap PDC from battery
tray. To prevent damage to PDC wi ri ng, careful l y
posi ti on PDC to gai n access to LDP.
(7) Remove battery tray. Refer to 8, Battery for
procedures.
(8) Careful l y remove vapor/vacuum l i nes at LDP.
(9) Di sconnect el ectri cal connector at LDP.
(10) Remove 3 LDP mounti ng screws (Fi g. 7) and
remove LDP from vehi cl e.
INSTALLATION
The LDP i s l ocated i n the engi ne compartment
under the battery tray and Power Di stri buti on Cen-
ter (PDC) (Fi g. 5). The LDP fi l ter i s attached to the
outsi de of battery tray (Fi g. 6). The LDP and LDP fi l -
ter are repl aced (servi ced) as one uni t.
(1) I nstal l LDP to bottom of battery tray. Ti ghten
(2) Careful l y i nstal l vapor/vacuum l i nes to LDP.
The vapor/vacuum lines and hoses must be
firmly connected. Check the vapor/vacuum
lines at the LDP, LDP filter and EVAP canister
Fig. 5 Leak Detection Pump (LDP) Location
1 - BATTERY
2 - LEAK DETECTION PUMP (LDP)
Fig. 6 LDP Filter Location
1 - LDP FILTER
2 - LDP FILTER-TO-LDP HOSE
3 - BATTERY TRAY
4 - LDP MOUNTING CLIP
Fig. 7 Leak Detection Pump (LDP) Mounting Screws
1 - BATTERY TRAY
2 - LDP
3 - LDP MOUNTING SCREWS (3)
purge solenoid for damage or leaks. If a leak is
present, a Diagnostic Trouble Code (DTC) may
be set.
(3) Connect el ectri cal connector to LDP.
(4) I nstal l battery tray. Refer to 8, Battery for pro-
cedures.
(5) I nstal l PDC to fender and battery tray (snaps
on to battery tray).
(6) I nstal l LDP fi l ter to battery tray (one cl i p).
(7) I nstal l connecti ng hose to bottom of LDP fi l ter.
(8) Connect battery temperature sensor pi gtai l
wi ri ng harness.
(9) I nstal l battery. Refer to 8, Battery for proce-
dures.
PCV VALVE
DESCRIPTION - 3. 9L/5. 2L/5. 9L
Al l 3.9L V-6 and 5.2/5.9L V-8 are equi pped wi th a
cl osed crankcase venti l ati on system and a posi ti ve
crankcase venti l ati on (PCV) val ve. The 2.5L 4cyl i n-
der engi ne i s not equi pped wi th a PCV val ve. Refer
to Crankcase Venti l ati on System2.5L Engi ne for
i nformati on.
Thi s system consi sts of a PCV val ve mounted on
the cyl i nder head (val ve) cover wi th a hose extendi ng
from the val ve to the i ntake mani fol d (Fi g. 8).
Another hose connects the opposi te cyl i nder head
(val ve) cover to the ai r cl eaner housi ng to provi de a
source of cl ean ai r for the system. A separate crank-
case breather/fi l ter i s not used.
DESCRIPTION - 4. 7L
The 4.7L V-8 engi ne i s equi pped wi th a cl osed
crankcase venti l ati on system and a Posi ti ve Crank-
case Venti l ati on (PCV) val ve.
Thi s system consi sts of:
a PCV val ve mounted to the oi l fi l l er housi ng
(Fi g. 9). The PCV val ve i s seal ed to the oi l fi l l er
housi ng wi th an o-ri ng.
the ai r cl eaner housi ng
two i nterconnected breathers threaded i nto the
rear of each cyl i nder head (Fi g. 10).
tubes and hose to connect the system compo-
nents.
Fig. 8 PCV Valve/HoseTypical
1 - PCV VALVE
2 - PCV VALVE HOSE CONNECTIONS
Fig. 9 PCV Valve/Oil Filler Tube (Housing)4.7L
Engine
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
OPERATION - 3. 9L/5. 2L/5. 9L
The PCV system operates by engi ne i ntake mani -
fol d vacuum (Fi g. 11). Fi l tered ai r i s routed i nto the
crankcase through the ai r cl eaner hose. The metered
ai r, al ong wi th crankcase vapors, are drawn through
the PCV val ve and i nto a passage i n the i ntake man-
i fol d. The PCV system manages crankcase pressure
and meters bl ow by gases to the i ntake system,
reduci ng engi ne sl udge formati on.
The PCV val ve contai ns a spri ng l oaded pl unger.
Thi s pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
When the engi ne i s not operati ng or duri ng an
engi ne pop-back, the spri ng forces the pl unger back
agai nst the seat (Fi g. 12). Thi s wi l l prevent vapors
from fl owi ng through the val ve.
Duri ng peri ods of hi gh mani fol d vacuum, such as
i dl e or crui si ng speeds, vacuum i s suffi ci ent to com-
pl etel y compress spri ng. I t wi l l then pul l the pl unger
to the top of the val ve (Fi g. 13). I n thi s posi ti on there
i s mi ni mal vapor fl ow through the val ve.
Fig. 10 PCV System Hoses/Tubes4.7L Engine
1 - FRESH AIR FITTING
2 - CONNECTING TUBES/HOSES
3 - CRANKCASE BREATHERS (2)
4 - RUBBER HOSE
5 - AIR CLEANER RESONATOR
Fig. 11 Typical Closed Crankcase Ventilation
System
1 - THROTTLE BODY
2 - AIR CLEANER
3 - AIR INTAKE
4 - PCV VALVE
5 - COMBUSTION CHAMBER
6 - BLOW-BY GASES
7 - CRANKCASE BREATHER/FILTER
Fig. 12 Engine Off/Engine Pop BackNo Vapor
Flow
Fig. 13 High Intake Manifold VacuumMinimal
Vapor Flow
PCV VALVE (Continued)
Duri ng peri ods of moderate mani fol d vacuum, the
pl unger i s onl y pul l ed part way back from i nl et. Thi s
resul ts i n maxi mum vapor fl ow through the val ve
(Fi g. 14).
OPERATION - 4. 7L
The PCV system operates by engi ne i ntake mani -
fol d vacuum. Fi l tered ai r i s routed i nto the crankcase
through the ai r cl eaner hose and crankcase breath-
ers. The metered ai r, al ong wi th crankcase vapors,
are drawn through the PCV val ve and i nto a passage
i n the i ntake mani fol d. The PCV system manages
crankcase pressure and meters bl ow-by gases to the
i ntake system, reduci ng engi ne sl udge formati on.
The PCV val ve contai ns a spri ng l oaded pl unger.
Thi s pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
TYPICAL PCV val ves are shown i n (Fi g. 15), (Fi g.
16) and (Fi g. 17).
When the engi ne i s not operati ng, or duri ng an
engi ne pop-back, the spri ng forces the pl unger back
agai nst the seat (Fi g. 15). Thi s wi l l prevent vapors
from fl owi ng through the val ve.
Duri ng peri ods of hi gh mani fol d vacuum, such as
i dl e or crui si ng speeds, vacuum i s suffi ci ent to com-
pl etel y compress spri ng. I t wi l l then pul l the pl unger
to the top of the val ve (Fi g. 16). I n thi s posi ti on there
i s mi ni mal vapor fl ow through the val ve.
Duri ng peri ods of moderate mani fol d vacuum, the
pl unger i s onl y pul l ed part way back from i nl et. Thi s
resul ts i n maxi mum vapor fl ow through the val ve
(Fi g. 17).
DIAGNOSIS AND TESTING - PCV VALVE
TEST 3. 9/5. 2/5. 9L ENGINE
(1) Wi th engi ne i dl i ng, remove the PCV val ve from
cyl i nder head (val ve) cover. I f the val ve i s not
pl ugged, a hi ssi ng noi se wi l l be heard as ai r passes
through the val ve. Al so, a strong vacuum shoul d be
fel t at the val ve i nl et (Fi g. 18).
Fig. 14 Moderate Intake Manifold Vacuum
Maximum Vapor Flow
Fig. 15 Engine Off or Engine Pop-BackNo Vapor
Flow
Fig. 16 High Intake Manifold VacuumMinimal
Vapor Flow
Fig. 17 Moderate Intake Manifold Vacuum
Maximum Vapor Flow
Fig. 18 Vacuum Check at PCV
1 - PCV VALVE GROMMET
2 - PCV HOSE
3 - PCV VALVE
4 - VACUUM MUST BE FELT AGAINST FINGER
5 - ENGINE VALVE COVER
(2) Return the PCV val ve i nto the val ve cover.
Remove the fi tti ng and ai r hose at the opposi te val ve
cover. Loosel y hol d a pi ece of sti ff paper, such as a
parts tag, over the openi ng (rubber grommet) at the
val ve cover (Fi g. 19).
(3) The paper shoul d be drawn agai nst the openi ng
i n the val ve cover wi th noti ceabl e force. Thi s wi l l be
after al l owi ng approxi matel y one mi nute for crank-
case pressure to reduce.
(4) Turn engi ne off and remove PCV val ve from
val ve cover. The val ve shoul d rattl e when shaken
(Fi g. 20).
(5) Repl ace the PCV val ve and retest the system i f
i t does not operate as descri bed i n the precedi ng
tests. Do not attempt to clean the old PCV valve.
(6) I f the paper i s not hel d agai nst the openi ng i n
val ve cover after new val ve i s i nstal l ed, the PCV
val ve hose may be restri cted and must be repl aced.
The passage i n the i ntake mani fol d must al so be
checked and cl eaned.
(7) To cl ean the i ntake mani fol d fi tti ng, turn a 1/4
i nch dri l l (by hand) through the fi tti ng to di sl odge
any sol i d parti cl es. Bl ow out the fi tti ng wi th shop ai r.
I f necessary, use a smal l er dri l l to avoi d removi ng
any metal from the fi tti ng.
DIAGNOSIS AND TESTING - PCV VALVE/PCV
SYSTEM TEST 4. 7L V-8 ENGINE
(1) Di sconnect PCV l i ne/hose (Fi g. 21) by di scon-
necti ng rubber connecti ng hose at PCV val ve fi tti ng.
(2) Remove PCV val ve at oi l fi l l er tube by rotati ng
PCV val ve downward unti l l ocati ng tabs have been
freed at cam l ock (Fi g. 21). After tabs have cl eared,
pul l val ve strai ght out from fi l l er tube. To prevent
damage to PCV valve locating tabs, valve must
be pointed downward for removal. Do not force
valve from oil filler tube.
(3) After val ve i s removed, check condi ti on of val ve
o-ri ng (Fi g. 21). Al so, PCV val ve shoul d rattl e when
shaken.
(4) Reconnect PCV val ve to i ts connecti ng l i ne/
hose.
(5) Start engi ne and bri ng to i dl e speed.
(6) I f val ve i s not pl ugged, a hi ssi ng noi se wi l l be
heard as ai r passes through val ve. Al so, a strong vac-
uum shoul d be fel t wi th a fi nger pl aced at val ve
i nl et.
(7) I f vacuum i s not fel t at val ve i nl et, check l i ne/
hose for ki nks or for obstructi on. I f necessary, cl ean
out i ntake mani fol d fi tti ng at rear of mani fol d. Do
thi s by turni ng a 1/4 i nch dri l l (by hand) through the
fi tti ng to di sl odge any sol i d parti cl es. Bl ow out the
fi tti ng wi th shop ai r. I f necessary, use a smal l er dri l l
to avoi d removi ng any metal from the fi tti ng.
(8) Do not attempt to clean the old PCV valve.
(9) Return PCV val ve back to oi l fi l l er tube by
pl aci ng val ve l ocati ng tabs (Fi g. 21) i nto cam l ock.
Press PCV val ve i n and rotate val ve upward. A sl i ght
cl i ck wi l l be fel t when tabs have engaged cam l ock.
Val ve shoul d be poi nted towards rear of vehi cl e.
(10) Connect PCV l i ne/hose and connecti ng rubber
hose to PCV val ve.
(11) Di sconnect rubber hose from fresh ai r fi tti ng
at l eft si de of ai r cl eaner resonator box (Fi g. 22).
Start engi ne and bri ng to i dl e speed. Hol d a pi ece of
Fig. 19 Vacuum Check at Valve Cover Opening
1 - STIFF PAPER PLACED OVER RUBBER GROMMET
2 - RUBBER GROMMET
3 - VALVE COVER
4 - FITTING REMOVED FROM VALVE COVER
5 - AIR TUBE
Fig. 20 Shake
1 - PCV VALVE GROMMET
2 - PCV VALVE
3 - PCV VALVE MUST RATTLE WHEN SHAKEN
sti ff paper (such as a parts tag) l oosel y over the
openi ng of the di sconnected rubber hose.
(12) The paper shoul d be drawn agai nst the hose
openi ng wi th noti ceabl e force. Thi s wi l l be after
al l owi ng approxi matel y one mi nute for crankcase
pressure to reduce.
(13) I f vacuum i s not present, di sconnect each PCV
system hose at top of each breather (Fi g. 22). Check
for obstructi ons or restri cti ons.
(14) I f vacuum i s sti l l not present, remove each
PCV system breather (Fi g. 22) from each cyl i nder
head. Check for obstructi ons or restri cti ons. I f
pl ugged, repl ace breather. Ti ghten breather to 12
Nm (106 i n. l bs.) torque. Do not attempt to cl ean
breather
(15) I f vacuum i s sti l l not present, di sconnect each
PCV system hose at each fi tti ng and check for
obstructi ons or restri cti ons.
REMOVAL - 4. 7L
The PCV val ve i s l ocated on the oi l fi l l er tube (Fi g.
23). Two l ocati ng tabs are l ocated on the si de of the
val ve (Fi g. 23). These 2 tabs fi t i nto a cam l ock i n the
oi l fi l l er tube. An o-ri ng seal s the val ve to the fi l l er
tube.
(1) Di sconnect PCV l i ne/hose (Fi g. 23) by di scon-
necti ng rubber hose at PCV val ve fi tti ng.
(2) Remove PCV val ve at oi l fi l l er tube by rotati ng
PCV val ve downward (counter-cl ockwi se) unti l l ocat-
i ng tabs have been freed at cam l ock (Fi g. 23). After
tabs have cl eared, pul l val ve strai ght out from fi l l er
tube. To prevent damage to PCV valve locating
tabs, valve must be pointed downward for
removal. Do not force valve from oil filler tube.
(3) After val ve i s removed, check condi ti on of val ve
o-ri ng (Fi g. 23).
Fig. 21 PCV Valve/Oil Filler Tube4.7L V-8 Engine
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
Fig. 22 PCV Breathers/Tubes/Hoses4.7L V-8
Engine
1 - FRESH AIR FITTING
2 - CONNECTING TUBES/HOSES
3 - CRANKCASE BREATHERS (2)
4 - RUBBER HOSE
5 - AIR CLEANER RESONATOR
The PCV val ve i s l ocated on the oi l fi l l er tube (Fi g.
23). Two l ocati ng tabs are l ocated on the si de of the
val ve (Fi g. 23). These 2 tabs fi t i nto a cam l ock i n the
oi l fi l l er tube. An o-ri ng seal s the val ve to the fi l l er
tube.
(1) Return PCV val ve back to oi l fi l l er tube by
pl aci ng val ve l ocati ng tabs (Fi g. 23) i nto cam l ock.
Press PCV val ve i n and rotate val ve upward. A sl i ght
cl i ck wi l l be fel t when tabs have engaged cam l ock.
Val ve shoul d be poi nted towards rear of vehi cl e.
(2) Connect PCV l i ne/hose and rubber hose to PCV
val ve.
VACUUM LINES
DESCRIPTION
A vacuum l i ne schemati c for emi ssi on rel ated i tems
can be found on the Vehi cl e Emi ssi on Control I nfor-
mati on (VECI ) l abel . For l abel l ocati on, refer to Vehi -
cl e Emi ssi on Control I nformati on (VECI ) Label .
VAPOR CANISTER
DESCRIPTION
A mai ntenance free, EVAP cani ster i s used on al l
vehi cl es. The EVAP cani ster i s l ocated under the
vehi cl e, i nsi de the l eft frame rai l , i n front of the fuel
tank (Fi g. 24).
OPERATION
The EVAP cani ster i s fi l l ed wi th granul es of an
acti vated carbon mi xture. Fuel vapors enteri ng the
EVAP cani ster are absorbed by the charcoal granul es.
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
Fig. 23 PCV Valve/Oil Filler Tube Location
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
Fig. 24 EVAP Canister Location
1 - LEFT FRAME RAIL
2 - RUBBER GROMMETS (2)
3 - LOCATING PINS (2)
4 - EVAP CANISTER
5 - MOUNTING NUT
REMOVAL
The EVAP cani ster i s l ocated bel ow the vehi cl e,
i nsi de the l eft frame rai l , i n front of the fuel tank
(Fi g. 25).
(2) Di sconnect vacuum l i nes at EVAP cani ster.
Note l ocati on of l i nes before removal .
(3) Remove cani ster mounti ng nut.
(4) Remove cani ster from mounti ng bracket.
INSTALLATION
The EVAP cani ster i s l ocated bel ow the vehi cl e,
i nsi de the l eft frame rai l , i n front of the fuel tank
(Fi g. 25).
(1) Posi ti on cani ster l ocati ng pi ns i nto mounti ng
bracket grommets (Fi g. 25) and i nstal l mounti ng nut.
(2) Ti ghten mounti ng nut to 1724 Nm (150210
i n. l bs.) torque.
(3) Connect vacuum l i nes at cani ster.
Fig. 25 EVAP Canister Location
1 - LEFT FRAME RAIL
2 - RUBBER GROMMETS (2)
3 - LOCATING PINS (2)
4 - EVAP CANISTER
5 - MOUNTING NUT
VAPOR CANISTER (Continued)
NEW VEHICLE PREPARATION
TABLE OF CONTENTS
page page
INTRODUCTION
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RECEIVING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
UNDER HOOD
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNDER VEHICLE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXTERIOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BODY INTERIOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ROAD TEST
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRE-DELIVERY STORAGE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PRE-DELIVERY STORAGE. . . . . . . . . . . . . . . . 20
PROGRAMMABLE ELECTRONIC FEATURES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
APPEARANCE TIPS
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FINAL STEPS
NEW VEHICLE PREPARATION FORM . . . . . . . 22
OWNER CHECK OUT. . . . . . . . . . . . . . . . . . . . 22
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INTRODUCTION
DESCRIPTION - THE IMPORTANCE OF
CAREFUL NEW VEHICLE PREPARATION
Today, the automobi l e i ndustry i s more competi ti ve
than i t has been for decades. Automakers around the
worl d, i ncl udi ng Dai ml erChrysl er, have made tre-
mendous i mprovements i n the qual i ty of thei r vehi -
cl es.
As a resul t, customer expectati ons have al so ri sen.
Todays customers are more parti cul ar about thei r
vehi cl es than ever before. The resul t i s that probl ems
once regarded as i nsi gni fi cant (such as a squeak or
rattl e) can now make the di fference between a repeat
customer and one who never purchases another vehi -
cl e from you deal ershi p or another Dai ml erChrysl er
Corporati on product.
As a techni ci an prepari ng a new car or truck for
del i very, you are the fi nal step i n the enti re qual i ty
process. Your i nspecti on i s the fi nal opportuni ty to
detect any fl aws that woul d di sappoi nt the customer.
Your efforts wi l l refl ect upon the thousands of men
and women who desi gn, engi neer and bui l d Dai ml er-
Chrysl er products as wel l as upon your deal ershi p
and on yoursel f as a competent, consci enti ous techni -
ci an.
As manufacturi ng qual i ty has i mproved, prep pro-
cedures have come to serve as addi ti onal qual i ty
checks. However, there are several compel l i ng rea-
sons for careful new vehi cl e preparati on.
Safety-You assure the customer that hi s or her
new vehi cl e meets al l federal safety standards.
Emi ssi ons Control s-When your customers are
assured that thei r new cars meet emi ssi ons stan-
dards, they wi l l know that they are contri buti ng to
cl eaner ai r and hel pi ng control pol l uti on.
Customer Sati sfacti on-Fi rst i mpressi ons are very
i mportant on a new vehi cl e. Careful new vehi cl e
preparati on wi l l i mpress your customer.
Competi ti on-I t i s common knowl edge i n the
i ndustry that the avai l abi l i ty of effi ci ent servi ce i s
one of the deci si ve factors i n determi ni ng whi ch cars
wi l l sel l . A vehi cl e del i vered to your customers i n
fi rst cl ass condi ti on, i nsi de and out, wi l l bri ng them
back to the deal ershi p for the ki nd of servi ce you
have l ed them to expect and for thei r next new car.
Thi s i nformati on outl i nes servi ce procedures whi ch
wi l l ensure that Dai ml erChrysl er Corporati on vehi -
cl es are ready for del i very to the customer when they
are compl ete. These procedures fol l ow a l ogi cal order,
from a careful underhood i nspecti on, to the moment
when you compl ete the warranty certi fi cate and turn
the keys over to your customer.
When you have compl eted the procedures descri bed
i n thi s i nformati on, both you and your customer wi l l
be assured that hi s or her new vehi cl e wi l l perform
as expected.
USING THE MANUAL
Thi s gui de to new vehi cl e preparati on covers al l
i tems on the New Vehi cl e Preparati on Form (Fi g. 1).
AN NEW VEHICLE PREPARATION 30 - 1
Fig. 1 NEW VEHICLE PREPARATION FORM
30 - 2 NEW VEHICLE PREPARATION AN
INTRODUCTION (Continued)
I tems found requi ri ng adjustment and/or repai r
shoul d be corrected before del i very of the vehi cl e.
NOTE: It is the dealers responsibility to protect
new vehicles from damage and deterioration prior
to retail delivery both before and after new vehicle
preparation.
The i nformati on i ncl udes the fol l owi ng features:
I nspecti on poi nts are cross-referenced to the New
Vehi cl e Preparati on Form as fol l ows:
Ti tl es i ndi cate the general area bei ng i nspected
or the types of checks bei ng made (i .e., underhood,
body-exteri or, road test, etc.).
Sub-Ti tl es i denti fy the types of i tems to be
i nspected i n that area (i .e., l i nes/hoses, wi ri ng, etc.).
Procedures fol l ow a l ogi cal order to prevent dupl i -
cati on and wasted effort.
Ti ps to hel p you do a better job are found as
NOTES.
RECEIVING
INSPECTION
The fol l owi ng procedures are recommended for
your own protecti on upon recei pt of new vehi cl es.
When a new car i s del i vered by the carri er, i t shoul d
be i nspected to ensure that i t i s i n good condi ti on
and to determi ne i f there i s any shortage or transpor-
tati on damage.
EXTERIOR
Upon recei pt of a new vehi cl e, check i mmedi atel y
for:
Under carri age damage
Chi pped or cracked wi ndshi el d, broken wi ndows,
and l oose or mi ssi ng mol di ngs and name-pl ates
Dents, scrapes, scratches, chi ps, di rt i n pai nts or
other damage to the body exteri or
Damaged or mi ssi ng si de vi ew mi rror(s)
Mi ssi ng wheel nuts
Broken or mi ssi ng l enses
Chafi ng, brui ses, cuts, or scrapes on ti re si de-
wal l s or tread
Mi ssi ng underhood i tems
Mi ssi ng fuel fi l l er cap
Shi pped l oose i tems-l i cense pl ate bracket, spare
ti re, jack and ti re wrench, radi o antenna, fl oor mats,
wheel covers, cargo nets, fuses and other i tems
Ensure that I OD fuse i s removed
Check battery test i ndi cator when easi l y vi si bl e,
or use vol tmeter (battery must be at 12.4 vol ts or
greater). Charge to ensure green dot-vi si bi l i ty, per-
manent damage may occur i f battery remai ns i n a
di scharged state for any l ength of ti me.
INTERIOR
Check i nteri or i tems such as:
Rearvi ew mi rror
Accessory control knobs
Smokers package i tems
Keys
Radi o
Speci al equi pment i tems l i sted on shi pper
Owners Manual and Consumer i nformati on Bro-
chures (normal l y stored i n the gl ove box).
Cuts, abrasi ons or stai ns on i nteri or tri m.
NOTE: Remember a careful look at new vehicles
when they are received may prevent problems when
preparing vehicles for delivery to your customers.
MAJOR INSPECTION POINTS
(1) Check operati on of hood l atch and safety catch-
adjust as requi red.
(2) Check al l fl ui ds for proper l evel and top off
wi th the proper fl ui d as requi red-engi ne oi l , auto-
mati c transmi ssi on fl ui d, brake master cyl i nder,
cl utch master cyl i nder, power steeri ng, wi ndshi el d
washer, and cool i ng system. (Vehi cl e must be at nor-
mal operati ng temperature for some of these checks.)
(3) Check brake, cl utch, fuel , and power steeri ng
l i nes and hoses for l eaks and cl earance from movi ng
and hot objects-reroute to the proper l ocati on and
ti ghten as requi red.
(4) Check battery state of charge-recharge i f neces-
sary, to ensure green dot i s vi si bl e or i nstrument
panel vol tmeter i ndi cates 12.4 vol ts or greater.
(5) Check routi ng and connecti ons of underhood
wi ri ng, vacuum hoses, refri gerant l i nes and cool ant
hoses for l eaks, l oose connecti ons and cl earance from
movi ng objects reroute and ti ghten connecti ons as
requi red. I nstal l I OD fuse on appl i cabl e vehi cl es.
NOTE: Reset radio, clock, compass, etc., after
installing, if vehicle is being delivered.
INTRODUCTION (Continued)
UNDER HOOD
INSPECTION - HOOD LATCH/SAFETY CATCH
(1) Check operati on of hood l atch and safety catch-
adjust as requi red (Fi g. 2).
NOTE: The safety catch prevents the hood from
going to full open position until it is manually
released. To test the safety catch, unlock the hood
with the interior release, then try to raise the hood
without operating the safety catch.
INSPECTION FLUID LEVELS
ENGINE OIL
CAUTION: Use only oil that meets the specified
requirements.
NOTE: If oil level is low, inspect for oil leaks.
(1) Check engi ne oi l l evel . The oi l shoul d be i n the
safe range or between the mi ni mum and maxi mum
marks.
I f the oi l l evel i s at the mi ni mum mark, add oi l
that meets speci fi cati ons, Refer to the servi ce i nfor-
mati on.
The best ti me to check the oi l i s about 5 mi nutes
after a ful l y warmed-up engi ne i s turned off, or
before starti ng the engi ne after i t has been off over-
ni ght.
For the most accurate readi ngs, the vehi cl e
shoul d be on l evel ground.
Wi pe up any excess oi l that may have spi l l ed, or
the customer coul d mi stakenl y percei ve thi s as the
resul t of a l eak.
AUTOMATIC TRANSMISSION/TRANSAXLE
CAUTION: Only use fluid that meets the vehicles
specific requirement. Consult the service manual
for information.
NOTE: Mopar ATF+4 contains special additives not
found in Mercon and Dexron II fLuids. Use of fluid
other than Mopar ATF+4 (when specified) could
result in an upshift shudder in some applications.
Transmi ssi on and transaxl e fl ui d check procedures
are speci fi c to each vehi cl e l i ne. (Refer to LUBRI CA-
TI ON & MAI NTENANCE/FLUI D CAPACI TI ES -
SPECI FI CATI ONS).
Fig. 2 HOOD LATCH, STRIKER AND SAFETY CATCH
1 - SAFETY CATCH
2 - HOOD LATCH STRIKER
3 - HOOD
4 - RADIATOR UPPER SUPPORT
5 - HOOD LATCH
CLUTCH MASTER CYLINDER
CAUTION: only use brake fluid that meets specified
requirements (DOT 3 and MVSS 116).
Check the cl utch master cyl i nder fl ui d l evel (Fi g.
3). Add fl ui d to the proper l evel i f necessary.
BRAKE MASTER CYLINDER
CAUTION: Only use fluid that meets specified
requirements (DOT 3).
NOTE: Wipe the master cylinder cover to remove
any dirt.
NOTE: On vehicles equipped with remote antilock
brakes, the fluid level check is the same as for a
normal system.
Check the brake master cyl i nder fl ui d l evel (Fi g.
4). Add fl ui d to bri ng the l evel to the ful l l i ne on the
si de of the reservoi r (or above the bottom of the spl i t
ri ng i n the pri mary fi l l er hol e). Be sure both pri mary
and secondary cavi ti es are ful l to the maxi mum l evel
as i ndi cated.
POWER STEERING RESERVOIR
CAUTION: Only use fluid that meets specified
requirements. Petroleum fluids, such as Mopar
Power Steering Fluid, are specially formulated for
use with power steering hoses and seals.
Check the fl ui d l evel ; i t shoul d be mai ntai ned at
the proper l evel i ndi cated on the di psti ck, or as
vi ewed through the transl ucent reservoi r. I f fl ui d i s
requi red, fi l l to the proper l evel . Wi th the engi ne run-
ni ng at normal operati ng temperature, turn the
steeri ng wheel from stop to stop to expel ai r from
wi thi n the system Stop the engi ne, remove the cap,
and recheck the fl ui d l evel , maki ng sure that foam-
i ng i s not present (Fi g. 5).
Fig. 3 CLUTCH MASTER CYLINDER RESERVOIR
Fig. 4 BRAKE MASTER CYLINDER FLUID
RESERVOIR
Fig. 5 POWER STEERING FLUID RESERVOIR 4.7L
ENGINE
UNDER HOOD (Continued)
WINDSHIELD WASHER RESERVOIR
CAUTION: Do not add engine coolant (antifreeze) to
this reservoir.
CAUTION: Avoid spilling washer solvent on the
vehicles paint; it could harm the finish.
Check wi ndshi el d washer sol vent reservoi r (Fi g. 6)
and fi l l as necessary.
NOTE: When using concentrated solvent such as
Mopar All-Weather Windshield Washer Solution,
dilute per container directions.
COOLING SYSTEM RESERVOIR
WARNING: Do not remove radiator cap while cool-
ing system is under pressure.
NOTE: Add coolant only to plastic reserve tank if it
is required. Engine must be at normal operating
temperature before adding coolant to reserve tank.
In cold climates, coolant in reserve tank may
appear low; do not add coolant until normal temper-
ature is reached.
Check cool ant l evel wi th engi ne i dl i ng at normal
operati ng temperature. Cool ant l evel i n pl asti c
reserve tank must be between the mi ni mum and
maxi mun marks (Fi g. 7).
I f cool ant i s added, use a 50/50 (-30F protecti on) con-
centrati on of the recommended (Refer to the Servi ce
I nformati on for speci fi cate Mopar anti freeze recom-
mendati on ) anti freeze and di sti l l ed water. Use a hi gher
concentrati on (up to 65%) i f a l ower freeze poi nt i s
requi red. Do not use recycl ed cool ant i n new vehi cl es.
INSPECTION - LINES/HOSES
I nspect the fol l owi ng for l i ne and hose l eaks. Al so
i nspect routi ng and connecti ons and reroute and
ti ghten as requi red.
Brake Li nes
Fuel Li nes
Power Steeri ng Hoses
Vacuum Hoses
Heati ng/Cool ant Hoses
Cl utch Li nes
Refri gerant Li nes
INSPECTION - BATTERY
When battery i s easi l y accessi bl e, check the test
i ndi cator (green dot), termi nal ti ghtness and fel t
(grease) washer on battery posts. Recharge battery as
requi red to assure that the green dot i s vi si bl e.
When battery i s not easi l y accessi bl e check battery
condi ti on wi th a vol tmeter at the jump start l oca-
ti ons, or check the vol tmeter on the i nstrument panel
(Fi g. 8). The readi ng shoul d be at l east 12.4 vol ts.
Recharge battery as requi red.
NOTE: Refer to service information for proper bat-
tery charging rates and times.
Fig. 6 WINDSHIELD WASHER FLUID RESERVOIR
Fig. 7 ENGINE COOLANT RESERVOIR
Fig. 8 BATTERY VOLTAGE GAUGE
INSPECTION - WIRING
The assembl y pl ant has shi pped al l vehi cl es wi th
the i nteri or l i ghts and most el ectroni c memori es non-
functi onal by way of an I gni ti on Off Draw (I OD) fuse
removed. The purpose i s to reduce the possi bi l i ty of
battery run-down duri ng shi ppi ng and storage.
Vehi cl es stored after prep shoul d have the I OD
fuse that acti vates the accessori es pul l ed to prevent
battery drai n.
NOTE: Ensure that the IOD fuse is removed to pre-
vent battery drain and possible damage. Vehicles
stored for extended periods after prep should be
washed frequently, to prevent environmental dam-
age, and reinspected for storage-related problems
before delivery.
(1) I nstal l the I OD fuse as equi pped. (ON vehi cl es
bei ng del i vered, remember to reset radi o, cl ock, com-
pass, etc., as requi red.)
(2) Check routi ng and connecti ons of al l underhood
wi ri ng-reroute and connect as requi red.
(3) Make sure the starter, generator and ai r condi -
ti oni ng cl utch wi ri ng are correctl y i nstal l ed, routed,
and i n the cl i ps where provi ded.
(4) For predel i very storage, al ways pul l the I OD
fuse that acti vates accessori es.
UNDER VEHICLE
INSPECTION - TIRE PRESSURES
(1) Usi ng the ti re pl acard or the Safety Certi fi ca-
ti on Label , check that the correct ti res are mounted
on the vehi cl e (Fi g. 9).
(2) I nstal l val ve stem extensi ons as requi red.
(3) Usi ng the ti re pl acard or the Safety Certi fi ca-
ti on Label , check ti re pressure (i ncl udi ng spare) and
adjust as requi red to recommended pressure.
NOTE: Tire pressure may have been set above normal
during manufacturing in order to properly seat the tire
bead. Be sure to adjust to proper specification.
INSPECTION - VISUAL
CAUTION: Before raising the vehicle on a hoist,
(Refer to LUBRICATION & MAINTENANCE/HOISTING
(1) Vi sual l y i nspect the fol l owi ng for l oose attach-
ment, l eakage, cl earance and routi ng, and ti ghten
connecti ons and cl amps as requi red:
Engi ne
Oi l Cool er
Cool i ng System
Transaxl e
Dri veshaft Boots
Transmi ssi on Cool er
Brake System
Fuel System
Exhaust System
Steeri ng and Suspensi on Components
INSTALLATION - WHEEL COVERS
(1) I nstal l cover on wheel by hand onl y (Fi g. 10).
(2) I nstal l and torque wheel nuts to 135 Nm (100
l b. ft.).
(3) I nstal l nut caps, i f equi pped usi ng l ug wrench,
do not over ti ghten.
(4) Remove rel ease l i ner from removal i nstructi ons
l abel and i nstal l l abel next to jacki ng i nstructi ons
l abel . Surface must be cl ean and fl at for proper adhe-
si on of l abel .
Fig. 9 WHEEL AND TIRE ASSEMBLY
EXTERIOR
INSPECTION BODY SEALING
Vi sual l y i nspect the fol l owi ng seal s duri ng the nor-
mal recommended wash. Look for areas where water
may have entered the vehi cl e.
Door and wi ndow seal s (Fi g. 12)
Wi ndshi el d
Cargo Li ght (Fi g. 11)
INSPECTION - FIT AND FINISH
(1) Remove al l protecti ve coati ngs/covers.
(2) Make sure body i s free from pai nt chi ps,
scratches, sags, run, di rt or corrosi on. Touch up any
mi nor pai nt chi ps and scratches as requi red.
(3) Ensure that mol di ngs and stri pes are al i gned
properl y.
NOTE: Painted-on accent strips require a unique
paint for touch-ups.
(4) Check that the door panel s have even gaps and
fi t wel l wi th adjacent body panel s (Fi g. 13).
(5) Check that the tai l gate has even gaps and fi ts
wel l wi th adjacent panel s (Fi g. 14).
(6) Check that the hood panel has even gaps and
fi ts wel l wi th adjacent panel s (Fi g. 15).
(7) Ensure that the body i s free from dents and
di ngs.
INSPECTION - KEYLESS ENTRY
Check operati on of keyl ess entry system and pro-
gram the transmi tter/ recei ver i f necessary (Fi g. 16).
Fig. 10 WHEEL COVER INSTALLATION
Fig. 11 CARGO LIGHT
Fig. 12 DOOR AND WINDOW SEALS
UNDER VEHICLE (Continued)
Fig. 13 Door Panel and Fender Fit
Fig. 14 Tailgate Fit and Alignment
Fig. 15 Hood Fit and Alignment
Fig. 16 Keyless Entry Transmitter
EXTERIOR (Continued)
INSPECTION - DOORS AND DOOR LOCKS
(1) Check operati on of doors and l ocks, keyl ess
entry, securi ty al arm and tai l gate (Fi g. 20). Adjust
stri kers (Fi g. 18) and l atches (Fi g. 17) as requi red.
(2) Check operati on of chi l dproof door l ocks, i f so
equi pped (Fi g. 19).
(3) Remove any protecti ve covers from the door
si l l s.
NOTE: Windows should be in the full up position
during these tests (except for the lock tests).
Open each door (i nsi de and out) to check the
rel ease mechani sm and ease of operati on.
Parti al l y cl ose the door to check the open-door
detent.
Cl ose the door to check the l atches and stri ker.
Open the door, l ower the wi ndow depress the
l ock pl unger and cl ose the door to check the l ock.
Fig. 17 DOOR LATCH
Fig. 18 DOOR STRIKER
Fig. 19 CHILDPROOF DOOR LOCK SWITCH
Fig. 20 Tailgate Operation
Unl ock each door (usi ng both keys) to check l ock
and key operati on.
NOTE: Child proof door locks should be disabled
when delivered to the customer.
BODY INTERIOR
INSPECTION - COMPASS
NOTE: Set variance after calibration.
(1) Cal i brate and set compass vari ance, i f so
equi pped (use appropri ate procedures i n servi ce
i nformati on) (Fi g. 21).
(2) Remove protecti ve fi l m from overhead consol e,
i f equi pped.
INSPECTION - FIT AND FINISH
(1) Remove any i nteri or covers.
(2) I nspect the i nstrument panel , gl ove box door
(Fi g. 22) and i nteri or mol di ngs for even gaps and
al i gnments.
(3) Check that the door panel materi al i s cl ean,
free from wri nkl es and i nstal l ed correctl y.
(4) Check that the seat materi al i s cl ean, secure
and free of wri nkl es.
(5) Check that the carpet i s cl ean, secure and free
of wri nkl es.
(6) Check that the headl i ner i s cl ean, free of l i nt
and di rt smudges.
INSPECTION - LIGHTS AND SWITCHES
(1) Remove protecti ve fi l m from al l swi tch bezel s.
(2) Operate and vi sual l y i nspect al l i nteri or l i ghts
and swi tches, i ncl udi ng:
Dome/map l amps
Vani ty mi rror l amps
Gl ove box l i ght
Ashtray l i ght
Ci gar l i ghter l i ght
Al l gauge l i ghts
Radi o di spl ay
Door-mounted l i ghts, i f equi pped
I l l umi nated entry system, i f equi pped
(3) Vi sual l y i nspect and operate al l exteri or l i ghts
and thei r swi tches, i ncl udi ng:
NOTE: Headlamp aim is preset during vehicle
assembly.
Headl i ghts, i ncl udi ng hi gh beam, opti cal horn
(fl ash to pass) and dayl i ght runni ng l amps (DRLs)
(Fi g. 23)
Tai l /stop l amps (i ncl udi ng center hi gh-mounted
stop l amp)
Parki ng l i ghts Turn si gnal s Brake l i ghts (i ncl ud-
i ng center hi gh mounted stop l amp)
Emergency fl ashers
Fog/dri vi ng l i ghts, i f equi pped
Off-road or other l i ghts, i f equi pped
Cargo bed l i ghts, i f equi pped (Fi g. 24)
(4) Check i gni ti on swi tch for proper operati on i n
al l posi ti ons (accessory, l ock, on, start and off) (Fi g.
25).
Fig. 21 COMPASS OPERATION
Fig. 22 GLOVE BOX DOOR FIT AND ALIGNMENT
INSPECTION - SEAT BELTS, SHOULDER
BELTS, RETRACTORS AND HEAD RESTRAINTS
(1) I nspect al l seat bel ts and harnesses to ensure
that they connect and hol d properl y.
(2) I nspect the condi ti on of the bel ts and anchors.
(3) I nspect for proper seat bel t retracti on.
(4) Check that safety l abel s regardi ng the use of
seat bel ts and ai r bags are i n pl ace (such as on the
sun vi sors) (Fi g. 26).
(5) Ensure head restrai nts are properl y i nstal l ed.
I nspect the hei ght adjustment for ease of operati on.
Fig. 23 HEADLAMP SWITCH
Fig. 24 CARGO LIGHT
Fig. 25 IGNITION SWITCH OPERATION
Fig. 26 SEAT BELT / AIR BAG WARNING LABEL
BODY INTERIOR (Continued)
INSPECTION - SEATS
(1) Remove protecti ve seat, carpet and door covers
(i f bei ng del i vered) where appl i cabl e.
(2) Check that manual /power seat adjustments
work properl y for al l seats.
I nspect the operati on of front seat mechani cal
sl i des and power adjusters
Check the seatback recl i ner for ease of rel ease
and operati on
Check the rear seatback l atches for ease of rel ease
On fol d-down rear seats, l atch the rear seats
and pul l forward on the seats to check that the
l atches hol d
(3) Check the seat heaters on vehi cl es equi pped
wi th heated seats.
(4) Check al l seat headrests.
(5) Check that al l seats are securel y l ocated i n
thei r adjustabl e tracks.
INSPECTION - WINDOWS, DOORS AND LOCKS
(1) Check al l power wi ndow swi tches for proper
(2) Run al l power or manual l y operated door, quar-
ter and vent wi ndows to the ful l y cl osed posi ti on to
check operati on and seal i ng.
(3) Check al l power/manual door l ocks for correct
(4) Ensure that al l doors open/cl ose easi l y.
(5) Test the remote fuel door, i f so equi pped.
(6) Check that the gl ove box door opens/cl oses eas-
i l y (Fi g. 28).
(7) Check that the consol e door opens/cl oses easi l y
(Fi g. 29).
Fig. 27 POWER WINDOW AND LOCK SWITCHES
Fig. 28 GLOVE BOX DOOR OPERATION
Fig. 29 CONSOLE DOOR OPERATION
INSTALLATION - SHIPPED LOOSE ITEMS
(1) I nstal l the antenna mast (Fi g. 30).
(2) I nstal l rear l i cense pl ate hol der and front
l i cense pl ate hol der (i f requi red).
(3) I nstal l wheel covers (i f requi red).
ROAD TEST
DESCRIPTION - ROAD TEST INSPECTION
The fol l owi ng i tems must be i nspected duri ng the
road test porti on of the new vehi cl e i nspecti on.
Check neutral safety swi tch operati on
Check operati on of shi ft/cl utch i nterl ock system
Check operati on of gauges and warni ng l i ghts
Check horn operati on
Check operati on of turn si gnal s and emergency
fl ashers
Check al l mi rror adjustments, i ncl udi ng day/
ni ght functi on
Check wi ndshi el d wi pers for proper wi pe pattern
and i ntermi ttent mode (i f equi pped)
Check washer spray pattern
Check heater, defroster and ai r condi ti oni ng for
proper operati on
Check that the fan operates qui etl y
Check the rear wi ndow defroster (i f equi pped)
Leave ai r sel ecti on l ever i n the fresh ai r posi ti on
Check the rear heater and ai r condi ti oni ng for
proper operati on
Check the rear ai r regi ster l ocati ons
Check that the i ndi cator l amps operate properl y
Check the operati on of the radi o, cassette and/or
compact di sc pl ayer, and that sound qual i ty i s good
Ensure that the cl ock di spl ays the correct ti me
Check that the tri p computer/mai ntenance
remi nder operates i n al l modes
Check al l speed control functi ons
Check the servi ce brakes to ensure that they
stop the vehi cl e i n a strai ght l i ne, wi thout noi se,
shudder or vi brati on
Check the brake warni ng l i ght
Check the parki ng brake operati on
Check the engi nes performance
Check the transmi ssi ons performance for
smooth, qui et operati on. I f the vehi cl e i s a 4x4, check
that the transfer case shi fts easi l y among al l ranges
Check Autosti ck functi on (i f equi pped)
Check the vehi cl es steeri ng and handl i ng
The steeri ng wheel shoul d be centered when
travel i ng i n a strai ght l i ne
The vehi cl e shoul d not pul l or vi brate
Check for squeaks, rattl es and wi nd noi se
Check any other vehi cl e aspects you bel i eve are
i mportant, but that may not be i ncl uded on the New
Vehi cl e Preparati on Form
Fi l l fuel tank wi th speci fi ed grade of fuel
INSPECTION - FUEL
Fi l l fuel tank wi th speci fi ed grade of gasol i ne (reg-
ul ar, mi dgrade or premi um).
INSPECTION - OTHER
As part of Dai ml erChrysl ers Customer One phi l os-
ophy, the Other bl ank i s provi ded on the New Vehi -
cl e Preparati on Form. Thi s i s desi gned to encourage
you to check any aspects of vehi cl e operati on that
you bel i eve are i mportant to your customers, but that
do not appear el sewhere on the form.
INSPECTION - SQUEAKS, RATTLES AND WIND
NOISE
(1) Make sure that the i nstrument panel , gl ove
box, seats, steeri ng wheel and col umn are free from
squeaks and rattl es. Ti ghten any obvi ous l oose fas-
teners.
(2) Check that the wi ndows and doors are free
from squeaks, rattl es and wi nd noi se.
(3) Check that the vehi cl e exteri or i s free from
squeaks, rattl es and noi se, front and rear.
(4) Make sure that al l i nteri or panel s are free from
squeaks and rattl es.
INSPECTION - STEERING AND HANDLING
(1) Check that the power assi st works properl y (i f
equi pped). Steeri ng shoul d not requi re excessi ve
effort.
Fig. 30 ANTENNA MAST
(2) Make sure the steeri ng wheel does not vi brate
at i dl e or road speed.
(3) Ensure that the steeri ng wheel i s centered
when travel i ng strai ght ahead.
(4) Check that the vehi cl e does not dri ft to one
si de.
(5) Make sure that the vehi cl e does not vi brate/
shake.
INSPECTION - TRANSMISSION/TRANSFER
CASE
AUTOMATIC TRANSMISSION
(1) Make sure that the park l ock hol ds the vehi cl e
Wi th the vehi cl e on a grade, put automati c trans-
mi ssi on i n PARK and sl owl y rel ease the servi ce
brake to see i f park l ock hol ds. I f i t does not hol d, the
transmi ssi on requi res further servi ce.
(2) Make sure shi ft l ever operates easi l y/smoothl y
(Fi g. 31).
Check for smooth shi fti ng. Check for proper
upshi fti ng and downshi fti ng.
MANUAL TRANSMISSION
(1) Check that the shi fter operates easi l y (Fi g. 32).
(2) Make sure that the cl utch operates smoothl y.
(3) Look for proper synchroni zati on.
The gears shoul d not gri nd.
4X4 TRANSFER CASE
(1) Shi ft the transfer case (Fi g. 33) through al l
ranges to make sure shi fti ng i s smooth and al l gear
posi ti ons respond accordi ngl y.
Fig. 31 AUTOMATIC TRANSMISSION RANGE
SLECTOR
Fig. 32 MANUAL TRANSMISSION RANGE SLECTOR
Fig. 33 TRANSFER CASE SLECTOR
ROAD TEST (Continued)
INSPECTION - ENGINE PERFORMANCE
Check the engi ne for proper performance. I t
shoul d:
Start promptl y
Be free from stal l i ng
I dl e smoothl y and at proper speed
Be free from stumbl i ng or hesi tati on
Produce suffi ci ent power
Be free from unusual noi ses
Operate wi thi n the proper temperature range
Stop when the i gni ti on key i s shut off
INSPECTION - PARKING BRAKE
(1) Ensure that the parki ng brake i s easy to oper-
ate (Fi g. 34).
(2) Make sure the parki ng brake does not drag.
(3) Wi th the vehi cl e stopped on a grade, fi rml y
appl y the servi ce brakes, pl ace the transmi ssi on i n
NEUTRAL and set the parki ng brake. Sl owl y rel ease
the servi ce brakes to see i f the parki ng brake wi l l
hol d.
(4) Check that the parki ng brake warni ng l i ght
comes on when the parki ng brake i s appl i ed, and i s
off when the brake i s rel eased.
INSPECTION - SERVICE BRAKES
(1) Check brake warni ng l i ght operati on at vehi cl e
startup.
(2) Check ABS warni ng l i ght operati on at vehi cl e
startup.
(3) I nspect servi ce brake pedal travel and feel (Fi g.
35).
(4) Put the vehi cl e i n gear and appl y the brakes
whi l e the car i s i n moti on. Be sure brake operati on i s
smooth and posi ti ve.
(5) Make sure that the vehi cl e stops i n a strai ght
l i ne, wi thout pul l i ng to one si de.
(6) Check that the brakes operate qui etl y, wi thout
noi se.
(7) Ensure there i s no shudder or vi brati on when
braki ng.
INSPECTION - SPEED CONTROL
Check the fol l owi ng speed control functi ons (Fi g.
36):
Check on/off swi tch
Check set operati on
Check resume functi on
Check accel erate and decel erate functi ons
Check brake rel ease functi on
Check cancel functi on
Fig. 34 PARKING BRAKE
Fig. 35 SERVICE BRAKE
INSPECTION - TRIP COMPUTER/
MAINTENANCE REMINDER
NOTE: Reset the average fuel economy when the
road test is complete.
Check that al l modes operate correctl y (Fi g. 37).
INSPECTION - RADIO
(1) Check for good AM/FM recepti on (Fi g. 38).
(2) Check for good AM/FM recepti on.
(3) Ensure that the cassette and/or compact di sc
(CD) pl ayer works properl y.
(4) Check for good sound qual i ty from al l speakers.
(5) Ensure that the radi o di spl ays the correct ti me.
(6) Check the steeri ng wheel control s (i f equi pped).
INSPECTION - HEATER/AIR CONDITIONER
(1) Check that heater/defroster works properl y
(Fi g. 39).
(2) Turn on the heater when the engi ne reaches
(3) Operate the bl ower motor i n al l speeds (Fi g. 39).
(4) Operate system i n al l modes (heat, defrost, etc.).
(5) Operate the rear heater (i f equi pped).
(6) Check for hot ai r output at al l outl ets.
(7) Operate temperature swi tch (Fi g. 39).
(8) Ensure that rear defroster works.
(9) Turn on rear defroster duri ng dri ve, then feel
wi ndow for warmth after dri ve.
(10) Check that the ai r condi ti oner cool s properl y.
(11) Turn on ai r condi ti oni ng system.
(12) Acti vate the A/C i n al l modes. (Make sure al l
modes work properl y i ncl udi ng rear uni t i f equi pped.).
(13) Operate bl ower motor swi tch at al l speeds
(Fi g. 39).
(14) Check for col d output at outl ets.
(15) Check that fan operati on i s qui et.
Fig. 36 SPEED CONTROL SWITCHES
1 - ON/OFF SWITCH
2 - ACCELERATE/RESUME SWITCH
3 - CANCEL SWITCH
4 - COAST SWITCH
5 - SET SWITCH
Fig. 37 TRIP COMPUTER OPERATION
Fig. 38 RADIO OPERATION
INSPECTION WINDSHIELD WIPERS/WASHERS
(1) Check washer spray pattern for proper opera-
ti on and ai m.
(2) Check i ntermi ttent wi pe feature for proper
operati on.
(3) I nspect wi per bl ades, check for proper wi pi ng
pattern-no streaki ng or mi ssed areas (Fi g. 40).
INSPECTION - MIRROR
(1) Check operati on of rearvi ew mi rrors day/ni ght
functi on (i f equi pped).
(2) Check ease of adjustment for al l mi rrors (power
or manual ) (Fi g. 41) and (Fi g. 42).
Fig. 39 HEATER AND A/C CONTROLS
1 - FAN SPEED CONTROL SWITCH
2 - MODE CONTROL SWITCH
3 - TEMPERATURE CONTROL SWITCH
Fig. 40 WINDSHIELD WIPER AND ARM
Fig. 41 DOOR MOUNTED REAR VIEW MIRROR
Fig. 42 INTERIOR REAR VIEW MIRROR
INSPECTION - TURN AND EMERGENCY
SIGNALS
(1) Ensure that the turn si gnal s work properl y
(i ncl udi ng cancel i ng after compl eti ng a turn) (Fi g. 43).
(2) Ensure that the emergency fl ashers work prop-
erl y (Fi g. 44).
INSPECTION - HORN
Ensure that the horn works properl y.
INSPECTION - GAUGES/WARNING LIGHTS
(1) Ensure that al l gauges, i nstrument i ndi cator
l i ghts, warni ng l i ghts and i nstrument panel l i ghts
are functi oni ng properl y (Fi g. 45).
(2) I nspect operati on of message center (i f equi pped).
Fig. 45 INSTRUMENT CLUSTER GAUGES AND WARNING LAMPS/INDICATORS
1 - GAUGES
2 - WARNING / INDICATOR LAMPS
Fig. 43 TURN SIGNAL SWITCH
Fig. 44 EMERGENCY LAMP SWITCH
INSPECTION - SHIFT/CLUTCH INTERLOCK
SYSTEM
(1) On vehi cl es wi th a manual transmi ssi on or
transaxl e, be sure engi ne starts onl y when cl utch i s
depressed.
(2) Some vehi cl es equi pped wi th an automati c
transaxl e al so have a brake i nterl ock system. On
these vehi cl es, be sure that you cannot shi ft out of
PARK wi thout pressi ng the brake pedal .
INSPECTION - NEUTRAL SAFETY SWITCH
(1) On vehi cl es wi th an automati c transmi ssi on or
transaxl e, check shi ft i ndi cator al i gnment i n al l
ranges.
(2) Be sure the engi ne starts i n both PARK and
NEUTRAL.
(3) Veri fy that the engi ne does not start i n any
REVERSE/DRI VE posi ti ons.
PRE-DELIVERY STORAGE
DESCRIPTION
Pre Del i very Storage i nformati on i s provi ded to
recommend practi ces to use when stori ng new vehi -
cl es pri or to del i very to the customer.
I f you have prepared a vehi cl e that wi l l not be
i mmedi atel y del i vered to the customer, store the
vehi cl e accordi ng to gui del i nes outl i ned i n (Refer to
30 - NEW VEHI CLE PREP/PREDELI VERY STOR-
AGE - STANDARD PROCEDURE) to prevent unnec-
essary wear and tear on the vehi cl es el ectri cal
systems, pai nt and fi ni sh and damage due to pi l fer-
age and vandal i sm.
STANDARD PROCEDURE - PRE-DELIVERY
STORAGE
(1) I f possi bl e, store vehi cl es i ndoors, i n cl ean, dry
pl aces. I f vehi cl es must be stored outdoors:
Try to avoi d storage l ocati ons that are near any
obvi ous sources of i ndustri al or envi ronmental con-
tami nati on (e.g., trees, factori es, steam or vapor
vents, rai l road tracks, etc.)
Mai ntai n ti ght securi ty to hel p prevent pi l ferage
and vandal i sm, and i nspect each vehi cl e regul arl y to
check for such damage
I f the vehi cl e must be parked on an i ncl i ne, park
i t wi th the front end hi gher than the rear; thi s wi l l
prevent hydrostati c l ock caused by fuel drai ni ng
i nto the engi ne
Ri nse the vehi cl e at l east once a week. Snow
shoul d be washed away more often, si nce i t can trap
harmful contami nants. Dry al l hori zontal surfaces
(2) The I OD fuse shoul d be removed i n order to
prevent battery drai n and possi bl e damage.
(3) Check the vehi cl es cool ant and anti -freeze pro-
tecti on.
(4) Check the vehi cl es battery at l east once a
month for a proper charge (at l east 12.4 vol ts).
Charge the battery i f necessary. Thi s wi l l hel p pre-
vent freezi ng and deteri orati on.
(5) Check the vehi cl es ti res and i nfl ate them to
thei r maxi mum recommended l evel s. Move the vehi -
cl es peri odi cal l y to avoi d fl atspotti ng the ti res.
(6) Do not engage the parki ng brake; keep i t i n the
OFF posi ti on.
(7) Keep al l wi ndows cl osed, al l doors l ocked, and
al l tri m covers i ntact and i n pl ace.
(8) Do not use chal ks, crayons or any marker con-
tai ni ng abrasi ves on pai nted, pl ated or gl ass sur-
faces.
(9) Al ways use seat covers when movi ng a vehi cl e.
PROGRAMMABLE
ELECTRONIC FEATURES
DESCRIPTION
The programmi ng of el ectroni c features appl i es to
speci fi c Dai ml erChrysl er Corporati on vehi cl es. Not
al l vehi cl es are equi pped wi th these el ectroni c fea-
tures, and not al l vehi cl es equi pped wi th el ectroni c
features have al l the avai l abl e features. Programma-
bl e el ectroni c features are subject to change and may
be added or del eted from speci fi c vehi cl e model s.
(1) The programmabl e el ectroni c features that may
be provi ded on the vehi cl e are:
Rol l i ng Power Door Locks
Horn Chi rp (When Doors Locked Wi th Remote
Keyl ess Entry)
Headl amp Fl ash (When Doors Locked or
Unl ocked Wi th Remote Keyl ess Entry)
Low Fuel Chi me
Remote Keyl ess Entry Door Unl ock Sequence
Headl i ghts On Automati cal l y Wi th Wi pers
Turn Si gnal Chi me
12V Power Outl et
Remote Unl ock
Remote Li nked To Memory
Headl amp Del ay
Servi ce I nterval
Easy Exi t Seat
(2) Programmi ng any of the above features i s to be
performed pri or to vehi cl e del i very to the customer,
dependi ng on customer preference.
NOTE: For all vehicles except Caravan/Town and
Country, the programming must be performed using
the DRB III scan tool. On Caravan/Town and Coun-
try vehicles the features can be programmed using
the DRB III scan tool or by button pushing
sequences. The customer can perform program-
ming, if desired, by following the instructions out-
lined in the owner manual.
OPERATION
NOTE: The programmable features provided on
vehicles need to be explained to the customer at
the time of sale. The customers preferences con-
cerning the features should be noted and pro-
grammed accordingly during predelivery.
NOTE: When using the DRB III scan tool to enable/
disable any programmable electronic features, go to
the main menu item #9 on the DRB III scan tool.
This is Customer Preferences. You must choose
Customer Preferences on the main menu to pro-
gram the desired features.
ROLLING POWER DOOR LOCKS
Wi th thi s feature enabl ed, the vehi cl es door l ock-
i ng mechani sms automati cal l y l ock when the vehi cl e
reaches approxi matel y 24 Km/h (15 mph).
HORN CHIRP
NOTE: This feature can be enabled with or without
the headlamp flash feature.
The horn chi rp functi on i s a feature that can be
enabl ed or di sabl ed on vehi cl es equi pped wi th
Remote Keyl ess Entry (RKE). The horn chi rps when
the vehi cl e i s l ocked wi th the RKE transmi tter.
HEADLAMP FLASH
NOTE: This feature can be enabled with or without
the horn chirp feature.
The headl amp fl ash functi on i s a feature that can
be enabl ed or di sabl ed on vehi cl es equi pped wi th
Remote Keyl ess Entry (RKE). The headl amps fl ash
once when the vehi cl e i s l ocked wi th the RKE trans-
mi tter, and fl ash twi ce when the vehi cl e i s unl ocked
wi th the RKE transmi tter.
LOW FUEL CHIME
Al l vehi cl es equi pped wi th the audi bl e l ow fuel
chi me are shi pped wi th thi s feature enabl ed.
REMOTE KEYLESS ENTRY (RKE) DOOR UNLOCK
SEQUENCE
Two door unl ock sequences are provi ded on vehi -
cl es equi pped wi th thi s feature. When usi ng the RKE
transmi tter to unl ock the doors, pressi ng the unl ock
button once when the feature i s enabl ed unl ocks onl y
the dri vers door. Pushi ng the RKE transmi tter
unl ock button a second ti me unl ocks the remai ni ng
doors. When the RKE door unl ock feature i s di sabl ed,
al l doors unl ock wi th one press of the RKE transmi t-
ter unl ock button.
HEADLIGHTS ON AUTOMATICALLY WITH WIPERS
Thi s feature appears on vehi cl es that have, as an
opti on, automati c headl i ghts. When the wi ndshi el d
wi pers are turned on, the headl i ghts automati cal l y
turn on.
12V POWER OUTLET
Thi s feature currentl y appears on Caravan/Voyag-
er/Town and Country vehi cl es. The vehi cl es are
shi pped wi th the 12V power outl ets turned off wi th
the i gni ti on key. The rel ay can be changed to make
the outl ets powered at al l ti mes. Thi s feature may be
of i nterest to customers wi th cel l phones.
TURN SIGNAL CHIME
Thi s feature i s an audi bl e turn si gnal warni ng
chi me. The chi me sounds i f the turn si gnal i s on, the
vehi cl e has travel ed one mi l e and vehi cl e speed has
exceeded 40 Km/h (25 mph).
REMOTE UNLOCK
The remote unl ock functi on i s a feature that can be
enabl ed or di sabl ed on vehi cl es equi pped wi th
Remote Keyl ess Entry (RKE). Wi th the fi rst press of
the RKE transmi tter to unl ock the doors, the dri vers
door onl y unl ocks. Wi th the second press of the RKE
transmi tter, the remai ni ng doors and the l i ftgate
unl ock. Wi th the remote unl ock feature enabl ed, the
fi rst press of the RKE transmi tter unl ocks al l doors.
REMOTE LINKED TO MEMORY
The remote l i nked to memory functi on i s currentl y
onl y avai l abl e onl y on Jeep Grand Cherokee Li mi ted
vehi cl es. When enabl ed, thi s feature recal l s a mem-
ory of seats, mi rror and radi o presets and posi ti ons
when unl ocki ng the vehi cl e wi th the RKE transmi t-
ter.
HEADLAMP DELAY
Currentl y avai l abl e onl y on Jeep Grand Cherokee
vehi cl es, the headl amp del ay ti meout can be set to
30, 60 or 90 seconds. Thi s ti meout onl y occurs when
the i gni ti on i s turned off pri or to turni ng the head-
PROGRAMMABLE ELECTRONIC FEATURES (Continued)
l amps off, or when l eavi ng the headl amps i n AUTO
mode.
SERVICE INTERVAL
vehi cl es, the i nterval for the servi ce remi nder mes-
sage can be set from 3,219 ki l ometers to 12,070 ki l o-
meters (2,000 mi l es to 7,500 mi l es).
EASY EXIT SEAT
Li mi ted vehi cl es, the dri vers seat wi l l reposi ti on
55mm (2.1 i nches) rearward, or the end of travel i f
l ess than 55mm (2.1 i nches) and ful l downward when
the key i s removed from the i gni ti on. Thi s feature
al l ows ease of exi ti ng the vehi cl e. The seat wi l l repo-
si ti on i tsel f to the memory l ocati on when the vehi cl e
i s unl ocked usi ng the RKE transmi tter or by pressi ng
the memory buttons on the door panel .
APPEARANCE TIPS
CLEANING
(1) Before del i veri ng the new vehi cl e to the cus-
tomer, the fol l owi ng checks on appearance detai l s are
recommended:
Wash the vehi cl e to remove al l traces of road
gri me and other di rt on the car from new vehi cl e
preparati on operati ons
Cl ean the ti re si dewal l s
Cl ean exteri or and i nteri or gl ass surfaces
Remove al l protecti ve covers
Remove undercoat overspray, excess wi ndow
seal er, and excess weatherstri p adhesi ve
I nspect i nteri or tri m, seats, carpeti ng, and mol d-
i ngs. Cl ean as necessary
Remove shi ppi ng and i nspecti on sti ckers
After the vehi cl e i s cl ean, i nspect the pai nt
agai n
(2) Mopar offers a wi de vari ety of car care prod-
ucts, devel oped to meet your deal ershi ps requi re-
ments. Al l are speci fi cal l y formul ated for
Dai ml erChrysl er vehi cl es
FINAL STEPS
STANDARD PROCEDURE - NEW VEHICLE
PREPARATION FORM
Compl ete the Emi ssi on Certi fi cati on Of Conformi ty
Statement on the bottom of the New Vehi cl e Prepa-
rati on Form (Fi g. 1) i n the gl ove box or storage box
after i t has been compl eted and si gned by the desi g-
nated i ndi vi dual .
STANDARD PROCEDURE - OWNER CHECK
OUT
The l ast step i n the new vehi cl e preparati on proce-
dure i s to hel p the customer become fami l i ar wi th
the features on thei r new vehi cl e. Show the new
owner where the control s and gauges are and expl ai n
how they operate.
INSPECTION - INFORMATION LABELS
Veri fy that the fol l owi ng l abel s are i nstal l ed and
l egi bl e.
Emi ssi on control l abel s
Monroney l abel
Ti re pressure l abel
Vehi cl e certi fi cati on l abel
PROGRAMMABLE ELECTRONIC FEATURES (Continued)
ABS - DESCRIPTION, BRAKES . . . . . . . 5-33,5-34
ABS - OPERATION, BRAKES . . . . . . . . . 5-34,5-35
ABS BRAKE SYSTEM - STANDARD
PROCEDURES, BLEEDING. . . . . . . . . . . . . . . 5-36
ABS INDICATOR - DESCRIPTION . . . . . . . . . 8J -13
ABS INDICATOR - OPERATION . . . . . . . . . . 8J -13
A/C APPLICATION TABLE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 24-8
A/C COMPRESSOR - DESCRIPTION . . . . . . 24-35
A/C COMPRESSOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-35
A/C COMPRESSOR - INSTALLATION . . . . . . 24-36
A/C COMPRESSOR - OPERATION . . . . . . . . 24-35
A/C COMPRESSOR - REMOVAL . . . . . . . . . 24-36
A/C COMPRESSOR CLUTCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 24-12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-10
A/C COMPRESSOR CLUTCH - REMOVAL . . 24-11
A/C COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE. . . . . . . . . . . . . . . 24-11
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-10
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-14
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . . 24-14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-15
A/C COMPRESSOR HIGH PRESSURE
RELIEF VALVE - DESCRIPTION . . . . . . . . . . . 24-9
A/C COMPRESSOR HIGH PRESSURE
RELIEF VALVE - OPERATION . . . . . . . . . . . . 24-10
A/C CONDENSER - DESCRIPTION . . . . . . . . 24-37
A/C CONDENSER - INSTALLATION . . . . . . . 24-38
A/C CONDENSER - OPERATION . . . . . . . . . . 24-37
A/C CONDENSER - REMOVAL . . . . . . . . . . . 24-38
A/C DISCHARGE LINE - INSTALLATION . . . 24-39
A/C DISCHARGE LINE - REMOVAL . . . . . . . 24-39
A/C EVAPORATOR - DESCRIPTION . . . . . . . 24-39
A/C EVAPORATOR - INSTALLATION . . . . . . 24-40
A/C EVAPORATOR - OPERATION . . . . . . . . . 24-40
A/C EVAPORATOR - REMOVAL . . . . . . . . . . 24-40
A/C HEATER CONTROL - DESCRIPTION . . . 24-15
A/C HEATER CONTROL - INSTALLATION . . . 24-16
A/C HEATER CONTROL - OPERATION . . . . . 24-15
A/C HEATER CONTROL - REMOVAL . . . . . . 24-16
A/C LOSS OF CHARGE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
A/C ORIFICE TUBE - DESCRIPTION . . . . . . . 24-40
A/C ORIFICE TUBE - INSTALLATION . . . . . . 24-41
A/C ORIFICE TUBE - OPERATION . . . . . . . . 24-40
A/C ORIFICE TUBE - REMOVAL . . . . . . . . . . 24-41
A/C PERFORMANCE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
A/C PRESSURE TRANSDUCER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
ACCELERATOR PEDAL - INSTALLATION . . . 14-34
ACCELERATOR PEDAL - REMOVAL . . . . . . . 14-34
ACCESSORY DRIVE BELT - ADJ USTMENT . . 7-24
ACCESSORY DRIVE BELT - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . 7-21,7-25,7-28
ACCUMULATOR - DESCRIPTION . . . . . . . . . 24-41
ACCUMULATOR - DESCRIPTION . . 21-136,21-317
ACCUMULATOR - INSPECTION . . . 21-137,21-318
ACCUMULATOR - INSTALLATION . . . . . . . . 24-42
ACCUMULATOR - OPERATION . . . . . . . . . . 24-41
ACCUMULATOR - OPERATION . . . . 21-136,21-318
ACCUMULATOR - REMOVAL . . . . . . . . . . . . 24-41
ACTUATION TEST MODE - DESCRIPTION,
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
ACTUATOR - DESCRIPTION, BLEND
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
ACTUATOR - DESCRIPTION, FRONT
DOOR INSIDE HANDLE . . . . . . . . . . . . . . . . 23-65
ACTUATOR - DESCRIPTION, MODE
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
ACTUATOR - DESCRIPTION, REAR DOOR
INSIDE HANDLE . . . . . . . . . . . . . . . . . . . . . 23-74
ACTUATOR - DESCRIPTION,
RECIRCULATION DOOR . . . . . . . . . . . . . . . . 24-23
ACTUATOR - INSTALLATION, BLEND
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
ACTUATOR - INSTALLATION, MODE
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
ACTUATOR - INSTALLATION,
ACTUATOR - OPERATION, BLEND DOOR . . 24-19
ACTUATOR - OPERATION, MODE DOOR . . . 24-22
ACTUATOR - OPERATION,
ACTUATOR - REMOVAL, BLEND DOOR . . . . 24-20
ACTUATOR - REMOVAL, MODE DOOR . . . . 24-22
ACTUATOR - REMOVAL, RECIRCULATION
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
ADAPTER - INSTALLATION, HVAC
HOUSING PLENUM . . . . . . . . . . . . . . . . . . . 24-28
ADAPTER - REMOVAL, HVAC HOUSING
PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-28
ADAPTER HOUSING SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-485
ADAPTER HOUSING SEAL - REMOVAL . . . 21-485
ADDING ADDITIONAL COOLANT -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . 7-16
ADDITIONAL COOLANT - STANDARD
PROCEDURE, ADDING. . . . . . . . . . . . . . . . . . 7-16
ADHESIVE LOCATIONS, SPECIFICATIONS
- STRUCTURAL . . . . . . . . . . . . . . . . . . . . . . 23-31
ADJ USTER - DIAGNOSIS AND TESTING,
HYDRAULIC LASH. . . . . . . . . . . . . . . . . . . . 9-160
ADJ USTER - INSTALLATION, SEAT BELT
TURNING LOOP . . . . . . . . . . . . . . . . . . . . . 8O-32
ADJ USTER - REMOVAL, SEAT BELT
TURNING LOOP . . . . . . . . . . . . . . . . . . . . . 8O-32
ADJ USTER ASSEMBLY - DESCRIPTION,
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . 9-160
ADJ USTER ASSEMBLY - INSTALLATION,
ROCKER ARM . . . . . . . . . . . . . . . . . . 9-160,9-237
ADJ USTER ASSEMBLY - REMOVAL,
ROCKER ARM . . . . . . . . . . . . . . . . . . 9-160,9-237
ADJ USTER KNOB - INSTALLATION,
TURNING LOOP HEIGHT . . . . . . . . . . . . . . . 8O-33
ADJ USTER KNOB - REMOVAL, TURNING
LOOP HEIGHT . . . . . . . . . . . . . . . . . . . . . . . 8O-33
ADJ USTMENT - STANDARD
PROCEDURE, CAMBER AND CASTER . . . . . . . 2-4
PROCEDURE, COMPASS VARIATION . . . . . . 8M-2
PROCEDURE, TOE . . . . . . . . . . . . . . . . . . . . . . 2-4
ADJ USTMENT 4WD - STANDARD
PROCEDURE, HEIGHT . . . . . . . . . . . . . . . . . . . 2-3
ADJ USTMENT, ACCESSORY DRIVE BELT . . . 7-24
ADJ USTMENT, BANDS . . . . . . . . . . 21-138,21-319
ADJ USTMENT, CENTER BEARING -
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . 3-10
ADJ USTMENTS, DOORS - REAR . . . . . . . . . 23-71
ADJ USTMENTS, FOG LAMP UNIT . . . . . . . . 8L-13
ADJ USTMENTS, FRONT AXLE - C205F . . . . . 3-27
ADJ USTMENTS, FRONT DOOR LATCH . . . . 23-66
ADJ USTMENTS, GEARSHIFT CABLE . . . . . 21-155,
21-337,21-491
ADJ USTMENTS, HEADLAMP UNIT . . . . . . . 8L-17
ADJ USTMENTS, HOOD . . . . . . . . . . . . . . . . 23-87
ADJ USTMENTS, HOOD LATCH . . . . . . . . . . 23-88
ADJ USTMENTS, IN/OUT . . . . . . . . . . . . . . . 23-63
ADJ USTMENTS, LATCH STRIKER . . . . . . . . 23-89
ADJ USTMENTS, REAR AXLE - 8 1/4 . . . . . . . 3-52
ADJ USTMENTS, REAR AXLE - 9 1/4 . . . . . . . 3-84
ADJ USTMENTS, REAR DRUM BRAKE . . . . . . 5-20
ADJ USTMENTS, TRANSMISSION
THROTTLE VALVE CABLE . . . . . . . 21-200,21-383
ADJ USTMENTS, UP/DOWN . . . . . . . . . . . . . 23-63
ADJ USTMENTS, VALVE BODY . . . . 21-254,21-438
AND BAND OPERATION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 21-91
OPERATION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-444
AIR CLEANER ELEMENT - INSTALLATION . 9-142,
9-20,9-230,9-82
AIR CLEANER ELEMENT - REMOVAL . 9-142,9-19,
9-230,9-82
AIR CONTROL MOTOR - DESCRIPTION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-40
AIR CONTROL MOTOR - OPERATION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-40
AIR EXHAUSTER - CAB - INSTALLATION . 23-120
AIR EXHAUSTER - CAB - REMOVAL . . . . . 23-120
AIR EXHAUSTER - INSTALLATION . . . . . . . 23-61
AIR EXHAUSTER - REMOVAL . . . . . . . . . . . 23-61
AIR TEMPERATURE SENSOR -
DESCRIPTION, INTAKE . . . . . . . . . . . . . . . . 14-42
AIR TEMPERATURE SENSOR -
OPERATION, INTAKE . . . . . . . . . . . . . . . . . . 14-42
AIR TESTING TRANSMISSION CLUTCH
AND BAND OPERATION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-269
AIRBAG - ASSEMBLY, DRIVER . . . . . . . . . . 8O-17
AIRBAG - DESCRIPTION, DRIVER . . . . . . . . 8O-13
AIRBAG - DESCRIPTION, PASSENGER . . . . 8O-23
AIRBAG - DISASSEMBLY, DRIVER . . . . . . . 8O-15
AIRBAG - INSTALLATION, DRIVER . . . . . . . 8O-18
AIRBAG - INSTALLATION, PASSENGER . . . 8O-25
AIRBAG - OPERATION, DRIVER . . . . . . . . . 8O-14
AIRBAG - OPERATION, PASSENGER . . . . . . 8O-24
AIRBAG - REMOVAL, DRIVER . . . . . . . . . . . 8O-15
AIRBAG - REMOVAL, PASSENGER . . . . . . . 8O-24
AIRBAG CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8O-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8O-8
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8O-6
AIRBAG CONTROL MODULE - REMOVAL . . . 8O-7
AIRBAG DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER AN . . . . . . . . 8O-4
AIRBAG INDICATOR - DESCRIPTION . . . . . . 8J -14
AIRBAG INDICATOR - OPERATION . . . . . . . 8J -14
AIRBAG ON/OFF SWITCH -
DESCRIPTION, PASSENGER . . . . . . . . . . . . 8O-26
AIRBAG ON/OFF SWITCH -
INSTALLATION, PASSENGER . . . . . . . . . . . 8O-27
AIRBAG ON/OFF SWITCH - OPERATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
AIRBAG ON/OFF SWITCH - REMOVAL,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-27
AIRBAG SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-4
AIRBAG SYSTEM - SPECIAL TOOLS . . . . . . . 8O-6
AJ AR INDICATOR - DESCRIPTION, DOOR . . 8J -18
AJ AR INDICATOR - OPERATION, DOOR . . . 8J -18
AJ AR SWITCH - DESCRIPTION, DOOR . . . . 8L-26
AJ AR SWITCH - DIAGNOSIS AND
TESTING, DOOR . . . . . . . . . . . . . . . . . . . . . 8L-27
AJ AR SWITCH - OPERATION, DOOR . . . . . . 8L-26
ALIGNMENT - DESCRIPTION, WHEEL . . . . . . . 2-1
ALIGNMENT - OPERATION, WHEEL . . . . . . . . 2-1
ALIGNMENT - SPECIAL TOOLS,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-9
ALIGNMENT, SPECIFICATIONS . . . . . . . . . . . . 2-5
ALUMINUM THREAD REPAIR -
STANDARD PROCEDURE. . 21-103,21-282,21-445
AMBIENT TEMP SENSOR - DESCRIPTION . 24-18
AMBIENT TEMP SENSOR - DESCRIPTION . . 8M-9
AMBIENT TEMP SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-19
AMBIENT TEMP SENSOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8M-10
AMBIENT TEMP SENSOR - OPERATION . . . 24-18
AMBIENT TEMP SENSOR - OPERATION . . . 8M-9
AMBIENT TEMP SENSOR - REMOVAL . . . . 24-19
AMBIENT TEMP SENSOR - REMOVAL . . . . 8M-10
AMBIENT TEMPERATURE SENSOR -
DIAGNOSIS & TESTING . . . . . . . . . . . . . . . . 8M-9
AMBIENT TEMPERATURE SENSOR -
AMPERAGE TEST - DIAGNOSIS AND
TESTING, FUEL PUMP . . . . . . . . . . . . . . . . . . 14-9
AMPLIFIER - DESCRIPTION . . . . . . . . . . . . . 8A-4
AMPLIFIER - DIAGNOSIS AND TESTING . . . . 8A-4
AN INDEX 1
Description Group-Page Description Group-Page Description Group-Page
AMPLIFIER - INSTALLATION . . . . . . . . . . . . . 8A-4
AMPLIFIER - OPERATION . . . . . . . . . . . . . . . 8A-4
AMPLIFIER - REMOVAL . . . . . . . . . . . . . . . . 8A-4
AN AIRBAG DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER . . . . . . . . . . . 8O-4
AN PAINT COLOR CODES,
SPECIFICATIONS - 2001 . . . . . . . . . . . . . . 23-121
ANTENNA BODY & CABLE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8A-5
ANTENNA BODY & CABLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-7
ANTENNA BODY & CABLE - REMOVAL . . . . . 8A-6
ANTENNA BODY AND CABLE -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8A-5
ANTILOCK - DIAGNOSIS AND TESTING,
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 5-35
ANTILOCK BRAKE - DESCRIPTION,
CONTROLLER REAR WHEEL . . . . . . . . . . . . . 8E-8
ANTILOCK BRAKE - INSTALLATION,
CONTROLLER REAR WHEEL . . . . . . . . . . . . 8E-10
ANTILOCK BRAKE - OPERATION,
ANTILOCK BRAKE - REMOVAL,
ANTILOCK BRAKES - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
A-PILLAR TRIM - INSTALLATION . . . . . . . 23-111
A-PILLAR TRIM - REMOVAL . . . . . . . . . . . 23-111
APPEARANCE TIPS - CLEANING . . . . . . . . . 30-22
APPLICATION TABLE, SPECIFICATIONS -
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-8
AREA LEAKS - DIAGNOSIS AND
TESTING, REAR SEAL . . . . 9-172,9-244,9-51,9-95
ARM / ADJ USTER ASSEMBLY -
DESCRIPTION, ROCKER . . . . . . . . . . . . . . . 9-160
INSTALLATION, ROCKER . . . . . . . . . . 9-160,9-237
REMOVAL, ROCKER . . . . . . . . . . . . . 9-160,9-237
ARM - DESCRIPTION, WIPER . . . . . . . . . . . 8R-13
ARM - INSTALLATION, BUSHINGS -
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 2-24,2-8
ARM - INSTALLATION, LOWER CONTROL . . 2-10,
2-17
ARM - INSTALLATION, UPPER CONTROL . . 2-14,
2-22
ARM - INSTALLATION, WIPER . . . . . . . . . . 8R-13
ARM - OPERATION, WIPER . . . . . . . . . . . . 8R-13
ARM - REMOVAL, BUSHINGS -
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 2-24,2-8
ARM - REMOVAL, LOWER CONTROL . . 2-10,2-17
ARM - REMOVAL, UPPER CONTROL . . 2-13,2-21
ARM - REMOVAL, WIPER . . . . . . . . . . . . . . 8R-13
ARMREST UPPER INERTIA LATCH
COVER - INSTALLATION, CENTER . . . . . . . 23-125
ARMREST UPPER INERTIA LATCH
COVER - REMOVAL, CENTER . . . . . . . . . . 23-125
ARMREST/CONSOLE LATCH - REMOVAL,
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-124
ARMREST/COSOLE LATCH -
INSTALLATION, CENTER . . . . . . . . . . . . . . 23-125
ARMS - CLEANING, ROCKER . . . . . . . . . . . . 9-25
ARMS - DESCRIPTION, SUSPENSION . . 2-16,2-7
ARMS - INSPECTION, ROCKER . . . . . . . . . . . 9-25
ARMS - INSTALLATION, ROCKER . . . . . . . . . 9-25
ARMS - REMOVAL, ROCKER . . . . . . . . . . . . . 9-25
ASD AND FUEL PUMP RELAYS -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8I-4
ASD SENSE - PCM INPUT - OPERATION . . . . 8I-4
ASH RECEIVER - ASSEMBLY . . . . . . . . . . . . 23-96
ASH RECEIVER - DISASSEMBLY . . . . . . . . . 23-95
ASH RECEIVER - INSTALLATION . . . . . . . . . 23-97
ASH RECEIVER - REMOVAL . . . . . . . . . . . . 23-95
ASSEMBLY - ASSEMBLY, INPUT CLUTCH . 21-498
ASSEMBLY - DESCRIPTION, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-495
ASSEMBLY - DESCRIPTION, ROCKER
ARM / ADJ USTER . . . . . . . . . . . . . . . . . . . . 9-160
ASSEMBLY - DESCRIPTION,
TRANSMISSION SOLENOID/TRS . . . . . . . . 21-528
ASSEMBLY - DISASSEMBLY, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-496
ASSEMBLY - INSTALLATION, ROCKER
ARM / ADJ USTER . . . . . . . . . . . . . . . 9-160,9-237
ASSEMBLY - INSTALLATION,
ASSEMBLY - OPERATION, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-495
ASSEMBLY - OPERATION,
ASSEMBLY - REMOVAL, ROCKER ARM /
ADJ USTER. . . . . . . . . . . . . . . . . . . . . 9-160,9-237
ASSEMBLY - REMOVAL, TRANSMISSION
SOLENOID/TRS . . . . . . . . . . . . . . . . . . . . . 21-529
ASSEMBLY, 4C RETAINER/BULKHEAD . . . . 21-485
ASSEMBLY, ASH RECEIVER . . . . . . . . . . . . . 23-96
ASSEMBLY, AUTOMATIC
TRANSMISSION - 42RE. . . . . . . . . . . . . . . 21-110
ASSEMBLY, AUTOMATIC
TRANSMISSION - 45RFE. . . . . . . . . . . . . . 21-452
ASSEMBLY, AUTOMATIC
TRANSMISSION - 46RE. . . . . . . . . . . . . . . 21-290
ASSEMBLY, DIFFERENTIAL . . . . . . 3-40,3-66,3-98
ASSEMBLY, DIFFERENTIAL - TRAC-LOK . . . 3-102,
3-70
ASSEMBLY, DRIVER AIRBAG . . . . . . . . . . . 8O-17
ASSEMBLY, FRONT CLUTCH . . . . . 21-150,21-331
ASSEMBLY, FRONT SERVO . . . . . . 21-153,21-334
ASSEMBLY, GLOVE BOX . . . . . . . . . . . . . . 23-102
ASSEMBLY, INPUT CLUTCH ASSEMBLY . . 21-498
ASSEMBLY, INSTRUMENT CLUSTER . . . . . . 8J -12
ASSEMBLY, LOW/REVERSE CLUTCH . . . . . 21-507
ASSEMBLY, MANUAL - NV1500 . . . . . . . . . 21-13
ASSEMBLY, MANUAL - NV3500 . . . . . . . . . 21-51
ASSEMBLY, OIL PUMP . . . . . . 9-115,9-191,9-263
ASSEMBLY, OIL PUMP . . . 21-159,21-342,21-512
ASSEMBLY, OVERDRIVE UNIT . . . . . 21-172,21-355
ASSEMBLY, OVERHEAD CONSOLE -
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . 8M-5
ASSEMBLY, OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON RETAINER . . . . 21-183,
21-366
ASSEMBLY, PLANETARY GEARTRAIN . . . . 21-518
ASSEMBLY, PLANETARY GEARTRAIN/
OUTPUT SHAFT . . . . . . . . . . . . . . . 21-188,21-373
ASSEMBLY, REAR CLUTCH . . . . . . 21-195,21-379
ASSEMBLY, REAR SERVO . . . . . . . 21-198,21-381
ASSEMBLY, SINGLE CARDAN
UNIVERSAL J OINTS . . . . . . . . . . . . . . . . . . . 3-11
ASSEMBLY, TRANSFER CASE - NV233 . . . 21-549
ASSEMBLY, TRANSFER CASE - NV244 . . . 21-581
ASSEMBLY, VALVE BODY . 21-245,21-428,21-535
ASSEMBLY, WHEEL CYLINDERS . . . . . . . . . . 5-28
ASSIST HANDLE - INSTALLATION . . . . . . . 23-112
ASSIST HANDLE - REMOVAL . . . . . . . . . . 23-112
AUDIO - DESCRIPTION . . . . . . . . . . . . . . . . . 8A-1
AUDIO - OPERATION . . . . . . . . . . . . . . . . . . . 8A-2
AUDIO SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2
AUDIO SYSTEMS, SPECIAL TOOLS . . . . . . . 8A-4
AUGAT - INSTALLATION, CONNECTOR . . 8W-01-8
AUGAT - REMOVAL, CONNECTOR . . . . . 8W-01-8
AUTO SHUT DOWN RELAY -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 8I-5
AUTO SHUT DOWN RELAY - REMOVAL . . . . . 8I-5
AUTOMATIC DAY / NIGHT MIRROR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8N-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-15
AUTOMATIC DAY/NIGHT MIRROR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-14
AUTOMATIC TRANSMISSION - 42RE -
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 21-110
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 21-109
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 21-79
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-104
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-110
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-117
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 21-81
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 21-104
AUTOMATIC TRANSMISSION - 45RFE -
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 21-452
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 21-452
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-440
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-446
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-452
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-459
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-441
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 21-445
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 21-290
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 21-290
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-257
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-283
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-290
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-298
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-259
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 21-282
DIAGNOSIS AND TESTING . 21-265,21-441,21-87
AUTOMATIC TRANSMISSION FLUID -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
AUTOMATIC TRANSMISSION FLUID -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
AXLE - 8 1/4 - ADJ USTMENTS, REAR . . . . . 3-52
AXLE - 8 1/4 - DESCRIPTION, REAR . . . . . . 3-47
AXLE - 8 1/4 - INSTALLATION, REAR . . . . . . 3-52
AXLE - 8 1/4 - OPERATION, REAR . . . . . . . . 3-47
AXLE - 8 1/4 - REMOVAL, REAR . . . . . . . . . . 3-52
AXLE - 9 1/4 - ADJ USTMENTS, REAR . . . . . 3-84
AXLE - 9 1/4 - DESCRIPTION, REAR . . . . . . 3-78
AXLE - 9 1/4 - INSTALLATION, REAR . . . . . . 3-83
AXLE - 9 1/4 - OPERATION, REAR . . . . . . . . 3-78
AXLE - 9 1/4 - REMOVAL, REAR . . . . . . . . . . 3-83
AXLE - C205F - ADJ USTMENTS, FRONT . . . . 3-27
AXLE - C205F - DESCRIPTION, FRONT . . . . . 3-22
AXLE - C205F - INSTALLATION, FRONT . . . . 3-26
AXLE - C205F - OPERATION, FRONT . . . . . . 3-22
AXLE - C205F - REMOVAL, FRONT . . . . . . . . 3-26
AXLE - DESCRIPTION . . . . . . . . . . . . . . . . . . . 0-6
AXLE - DIAGNOSIS AND TESTING . . . . 3-23,3-48,
3-80
AXLE, 8 1/4 - REAR . . . . . . . . . . . . . . . . . . . 3-58
AXLE, 9 1/4 - REAR . . . . . . . . . . . . . . . . . . . 3-90
AXLE BEARINGS - INSTALLATION . . . . 3-38,3-63,
3-94
AXLE BEARINGS - REMOVAL . . . . 3-38,3-63,3-94
AXLE, C205F - FRONT . . . . . . . . . . . . . . . . . . 3-34
AXLE SHAFT - INSTALLATION . . . . . . . . . . . . 3-15
AXLE SHAFT - REMOVAL . . . . . . . . . . . . . . . 3-14
AXLE SHAFT SEALS - INSTALLATION . 3-37,3-62,
3-95
AXLE SHAFT SEALS - REMOVAL . 3-37,3-62,3-95
AXLE SHAFTS - INSTALLATION . . 3-37,3-62,3-93
AXLE SHAFTS - REMOVAL . . . . . . 3-37,3-62,3-93
AXLE, SPECIAL TOOLS - 8 1/4 . . . . . . . . . . . 3-59
BACK - INSTALLATION, BENCH SEAT . . . . 23-129
BACK - REMOVAL, BENCH SEAT . . . . . . . . 23-128
BACK PAD/COVER - INSTALLATION,
BENCH SEAT . . . . . . . . . . . . . . . . . . . . . . . 23-129
BACK PAD/COVER - INSTALLATION,
BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . 23-129
BACK PAD/COVER - REMOVAL, BENCH
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-129
BACK PAD/COVER - REMOVAL, BUCKET
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-129
BACK PANEL TRIM - INSTALLATION,
REAR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 23-117
BACK PANEL TRIM - REMOVAL, REAR
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-117
BACK-CLUB CAB - INSTALLATION, REAR
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-128
BACK-CLUB CAB - REMOVAL, REAR
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-128
BACKLITE - INSTALLATION, SLIDING . . . . 23-133
BACKLITE - REMOVAL . . . . . . . . . . . . . . . . 23-132
BACKLITE VENT GLASS - INSTALLATION . 23-133
BACKLITE VENT GLASS - REMOVAL . . . . . 23-133
2 INDEX AN
BALANCE - STANDARD PROCEDURE,
TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . . 22-4
BALL J OINT - DIAGNOSIS AND TESTING,
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . 2-10,2-20
BALL J OINT - DIAGNOSIS AND TESTING,
UPPER. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13,2-21
BAND OPERATION - DIAGNOSIS AND
TESTING, AIR CHECKING
TRANSMISSION CLUTCH . . . . . . . . . . . . . . 21-91
BAND OPERATION - DIAGNOSIS AND
TESTING, AIR TESTING
TRANSMISSION CLUTCH . . . . . . . . . . . . . 21-269
BANDS - ADJ USTMENT . . . . . . . . . 21-138,21-319
BANDS - DESCRIPTION . . . . . . . . . 21-137,21-318
BANDS - OPERATION . . . . . . . . . . 21-138,21-319
BAR - DESCRIPTION, STABILIZER . . . . 2-13,2-19,
2-28
BAR - DESCRIPTION, TORSION . . . . . . . . . . 2-23
BAR - INSTALLATION, STABILIZER . . . 2-13,2-19,
2-28
BAR - INSTALLATION, TORSION . . . . . . . . . . 2-24
BAR - OPERATION, STABILIZER . . 2-13,2-19,2-28
BAR - OPERATION, TORSION . . . . . . . . . . . . 2-23
BAR - REMOVAL, STABILIZER . . . 2-13,2-19,2-28
BAR - REMOVAL, TORSION . . . . . . . . . . . . . 2-23
BASE - DESCRIPTION, BRAKES . . . . . . . . . . . 5-2
BASE BRAKE SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
BASE BRAKES, SPECIAL TOOLS . . . . . . . . . . . 5-9
BASE BRAKES, SPECIFICATIONS . . . . . . . . . . 5-8
BASE COAT/CLEAR COAT FINISH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 23-121
BASE COAT/CLEAR COAT FINISH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 23-121
BASE TRIM - INSTALLATION . . . . . . . . . . . . 23-98
BASE TRIM - REMOVAL . . . . . . . . . . . . . . . 23-97
BATTERIES - STANDARD PROCEDURE,
RKE TRANSMITTER . . . . . . . . . . . . . . . . . . 8N-12
BATTERY - DESCRIPTION . . . . . . . . . . . . . . . 8F-6
BATTERY - DIAGNOSIS AND TESTING . . . . . 8F-8
BATTERY - INSPECTION . . . . . . . . . . . . . . . . 30-6
BATTERY - INSTALLATION . . . . . . . . . . . . . . 8F-17
BATTERY - OPERATION . . . . . . . . . . . . . . . . . 8F-7
BATTERY - REMOVAL . . . . . . . . . . . . . . . . . 8F-17
BATTERY CABLE - DESCRIPTION . . . . . . . . 8F-19
BATTERY CABLE - OPERATION . . . . . . . . . . 8F-19
BATTERY CABLES - DIAGNOSIS &
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-20
BATTERY CHARGING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8F-9
BATTERY ELECTROLYTE LEVEL -
STANDARD PROCEDURE, CHECKING . . . . . . 8F-8
BATTERY HOLDDOWN - DESCRIPTION . . . . 8F-18
BATTERY HOLDDOWN - INSTALLATION . . . 8F-18
BATTERY HOLDDOWN - OPERATION . . . . . 8F-18
BATTERY HOLDDOWN - REMOVAL . . . . . . . 8F-18
BATTERY, SPECIFICATIONS . . . . . . . . . . . . . . 8F-6
BATTERY SYSTEM - CLEANING . . . . . . . . . . . 8F-5
BATTERY SYSTEM - DESCRIPTION . . . . . . . . 8F-1
BATTERY SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2
BATTERY SYSTEM - INSPECTION . . . . . . . . . 8F-6
BATTERY SYSTEM - OPERATION . . . . . . . . . 8F-2
BATTERY TEMPERATURE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8F-26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
BATTERY TRAY - DESCRIPTION . . . . . . . . . 8F-22
BATTERY TRAY - INSTALLATION . . . . . . . . . 8F-23
BATTERY TRAY - OPERATION . . . . . . . . . . . 8F-22
BATTERY TRAY - REMOVAL . . . . . . . . . . . . 8F-22
BEAM INDICATOR - DESCRIPTION, HIGH . . 8J -21
BEAM INDICATOR - DIAGNOSIS AND
TESTING, HIGH . . . . . . . . . . . . . . . . . . . . . . 8J -22
BEAM INDICATOR - OPERATION, HIGH . . . . 8J -22
BEARING - CENTER BEARING
ADJ USTMENT, CENTER . . . . . . . . . . . . . . . . . 3-10
BEARING - DESCRIPTION, CENTER . . . . . . . . 3-9
BEARING - DESCRIPTION, CLUTCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
BEARING - DESCRIPTION, PILOT . . . . . . . . . 6-12
BEARING - FITTING - STANDARD
PROCEDURE, CRANKSHAFT MAIN . . . . . . . 9-169
BEARING - INSTALLATION, CENTER . . . . . . . . 3-9
BEARING - INSTALLATION, CLUTCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
BEARING - INSTALLATION, HUB . . . . . . . 2-20,2-9
BEARING - INSTALLATION, OUTPUT
SHAFT FRONT . . . . . . . . . . . . . . . . 21-161,21-343
BEARING - INSTALLATION, OUTPUT
SHAFT REAR . . . . . . . . . . . . . . . . . 21-161,21-344
BEARING - INSTALLATION, PILOT . . . . . . . . 6-13
BEARING - OPERATION, CENTER . . . . . . . . . . 3-9
BEARING - OPERATION, CLUTCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
BEARING - OPERATION, PILOT . . . . . . . . . . . 6-12
BEARING - REMOVAL, CENTER . . . . . . . . . . . 3-9
BEARING - REMOVAL, CLUTCH RELEASE . . . 6-10
BEARING - REMOVAL, HUB . . . . . . . . . . 2-20,2-9
BEARING - REMOVAL, OUTPUT SHAFT
FRONT . . . . . . . . . . . . . . . . . . . . . . 21-160,21-343
BEARING - REMOVAL, OUTPUT SHAFT
REAR . . . . . . . . . . . . . . . . . . . . . . . 21-161,21-344
BEARING - REMOVAL, PILOT . . . . . . . . . . . . 6-12
BEARING ADJ USTMENT, CENTER
BEARING - CENTER. . . . . . . . . . . . . . . . . . . . 3-10
BEARING FITTING - STANDARD
PROCEDURE, CONNECTING ROD . . . 9-164,9-239
BEARING, FITTING - STANDARD
PROCEDURE CONNECTING ROD. . . . . . . . . . 9-32
PROCEDURE, CONNECTING ROD . . . . . . . . . 9-92
PROCEDURE, CRANKSHAFT MAIN . . . 9-241,9-93
BEARINGS - DESCRIPTION,
CRANKSHAFT MAIN . . . . . . . . . . 9-241,9-35,9-93
BEARINGS - FITTING - STANDARD
PROCEDURE, CRANKSHAFT MAIN . . . . . . . . 9-36
BEARINGS - INSPECTION, CRANKSHAFT
MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 9-170,9-39
BEARINGS - INSTALLATION, AXLE . . . . 3-38,3-63,
3-94
BEARINGS - INSTALLATION, CAMSHAFT . . 9-238,
9-31,9-90
BEARINGS - INSTALLATION,
CRANKSHAFT MAIN . . . . . . . . . . 9-242,9-39,9-94
BEARINGS - INSTALLATION,
DIFFERENTIAL CASE . . . . . . . . . . 3-103,3-41,3-72
BEARINGS - OPERATION, CRANKSHAFT
MAIN . . . . . . . . . . . . . . . . . . . . . . 9-241,9-35,9-93
BEARINGS - REMOVAL, AXLE . . . . 3-38,3-63,3-94
BEARINGS - REMOVAL, CAMSHAFT . 9-237,9-30,
9-89
BEARINGS - REMOVAL, CRANKSHAFT
MAIN . . . . . . . . . . . . . . . . . . . . . . 9-242,9-38,9-94
BEARINGS - REMOVAL, DIFFERENTIAL
CASE . . . . . . . . . . . . . . . . . . . . . . 3-103,3-41,3-72
BELT - ADJ USTMENT, ACCESSORY
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
BELT / CHAIN COVER(S) -
INSTALLATION, TIMING . 9-120,9-204,9-268,9-60
BELT / CHAIN COVER(S) - REMOVAL,
TIMING . . . . . . . . . . . . . . 9-120,9-203,9-268,9-60
BELT - DIAGNOSIS AND TESTING,
ACCESSORY DRIVE. . . . . . . . . . . . 7-21,7-25,7-28
BELT & RETRACTOR - INSTALLATION,
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-28
BELT & RETRACTOR - REMOVAL, REAR
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-27
BELT BUCKLE - INSTALLATION, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
BELT BUCKLE - REMOVAL, FRONT SEAT . . 8O-22
BELT SWITCH - DESCRIPTION, SEAT . . . . . 8O-30
BELT SWITCH - DIAGNOSIS AND
TESTING, SEAT . . . . . . . . . . . . . . . . . . . . . . 8O-30
BELT SWITCH - OPERATION, SEAT . . . . . . . 8O-30
BELT TENSIONER - DESCRIPTION, SEAT . . 8O-31
BELT TENSIONER - OPERATION, SEAT . . . . 8O-31
BELT TENSIONERS - 2.5L -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-18
BELT TENSIONERS - 2.5L - REMOVAL . . . . . 7-18
BELT TENSIONERS - 3.9L/5.9L -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-20
BELT TENSIONERS - 4.7L - OPERATION . . . . 7-20
BELT TENSIONERS - 4.7L - REMOVAL . . . . . 7-20
BELT TURNING LOOP ADJ USTER -
INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 8O-32
BELT TURNING LOOP ADJ USTER -
REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 8O-32
BELT WEATHERSTRIP - INSTALLATION,
FRONT DOOR INNER . . . . . . . . . . . . . . . . . 23-139
FRONT DOOR OUTER . . . . . . . . . . . . . . . . 23-139
REAR DOOR INNER . . . . . . . . . . . . . . . . . . 23-140
REAR DOOR OUTER . . . . . . . . . . . . . . . . . 23-141
BELT WEATHERSTRIP - REMOVAL,
FRONT DOOR INNER . . . . . . . . . . . . . . . . . 23-139
BELT WEATHERSTRIP - REMOVAL,
FRONT DOOR OUTER . . . . . . . . . . . . . . . . 23-139
BELT WEATHERSTRIP - REMOVAL, REAR
DOOR INNER . . . . . . . . . . . . . . . . . . . . . . . 23-140
BELT WEATHERSTRIP - REMOVAL, REAR
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-141
BELT/BUCKLE - INSTALLATION, REAR
SEAT LAP . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-29
BELT/BUCKLE - REMOVAL, REAR SEAT
LAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-29
BELT/CHAIN AND SPROCKETS -
INSPECTION, TIMING . . . . . . . . . . . . . . . . . 9-207
INSTALLATION, TIMING . 9-122,9-207,9-270,9-62
REMOVAL, TIMING . . . . . 9-121,9-204,9-269,9-61
BELT/CHAIN TENSIONER AND PULLEY -
DESCRIPTION, TIMING . . . . . . . . . . . . . . . . 9-120
BELT/CHAIN TENSIONER AND PULLEY -
OPERATION, TIMING. . . . . . . . . . . . . . . . . . 9-120
BELTS - 2.5L - INSTALLATION, DRIVE . . . . . 7-24
BELTS - 2.5L - REMOVAL, DRIVE . . . . . . . . . 7-23
BELTS - 3.9L/5.9L - INSTALLATION,
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
BELTS - 3.9L/5.9L - REMOVAL, DRIVE . . . . . 7-27
BELTS - 4.7L - INSTALLATION, DRIVE . . . . . 7-31
BELTS - 4.7L - REMOVAL, DRIVE . . . . . . . . . 7-31
BELTS, RETRACTORS AND HEAD
RESTRAINTS - INSPECTION, SEAT
BELTS, SHOULDER . . . . . . . . . . . . . . . . . . . 30-12
BELTS, SHOULDER BELTS, RETRACTORS
AND HEAD RESTRAINTS -
INSPECTION, SEAT . . . . . . . . . . . . . . . . . . . 30-12
BENCH SEAT - INSTALLATION . . . . . . . . . . 23-127
BENCH SEAT - REMOVAL . . . . . . . . . . . . . 23-126
BENCH SEAT BACK - INSTALLATION . . . . . 23-129
BENCH SEAT BACK - REMOVAL . . . . . . . . 23-128
BENCH SEAT BACK PAD/COVER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-129
BENCH SEAT BACK PAD/COVER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-129
BENCH SEAT CUSHION/COVER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-130
BENCH SEAT CUSHION/COVER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-130
BENCH SEAT TRACK - INSTALLATION . . . 23-131
BENCH SEAT TRACK - REMOVAL . . . . . . . 23-131
BETTS - INSTALLATION, CONNECTOR -
THOMAS . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-10
BETTS - REMOVAL, CONNECTOR -
THOMAS . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
BEZEL - INSTALLATION, CLUSTER . . . . . . . 23-99
BEZEL - INSTALLATION, LOWER . . . . . . . . 23-106
BEZEL - INSTALLATION, SHIFT . . . . . . . . . 23-118
BEZEL - REMOVAL, CLUSTER . . . . . . . . . . . 23-98
BEZEL - REMOVAL, LOWER . . . . . . . . . . . 23-105
BEZEL - REMOVAL, SHIFT . . . . . . . . . . . . . 23-118
BIN - INSTALLATION, STORAGE . . . . . . . . 23-108
BIN - REMOVAL, STORAGE . . . . . . . . . . . . 23-107
BLADE - DESCRIPTION, WIPER . . . . . . . . . 8R-14
BLADE - INSTALLATION, WIPER . . . . . . . . . 8R-15
BLADE - OPERATION, WIPER . . . . . . . . . . . 8R-15
BLADE - REMOVAL, WIPER . . . . . . . . . . . . 8R-15
BLEEDING - STANDARD PROCEDURE,
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-23
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
AN INDEX 3
BLEEDING ABS BRAKE SYSTEM -
STANDARD PROCEDURES. . . . . . . . . . . . . . . 5-36
BLEND DOOR ACTUATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-19
BLEND DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-20
BLEND DOOR ACTUATOR - OPERATION . . . 24-19
BLEND DOOR ACTUATOR - REMOVAL . . . . 24-20
BLOCK - CLEANING, ENGINE . . 9-163,9-237,9-29,
9-89
BLOCK - DESCRIPTION, BLOWER
MOTOR RESISTOR . . . . . . . . . . . . . . . . . . . 24-20
BLOCK - DESCRIPTION, ENGINE . . . . . . . . . 9-162
BLOCK - DESCRIPTION, J UNCTION . . . . . . . . 8-6
BLOCK - DIAGNOSIS AND TESTING,
BLOWER MOTOR RESISTOR. . . . . . . . . . . . 24-21
BLOCK - INSPECTION, ENGINE . . . . 9-163,9-237,
9-29,9-89
BLOCK - INSTALLATION, BLOWER
MOTOR RESISTOR . . . . . . . . . . . . . . . . . . . 24-21
BLOCK - INSTALLATION, J UNCTION . . . . . . . . 8-8
BLOCK - OPERATION, BLOWER MOTOR
RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
BLOCK - OPERATION, J UNCTION . . . . . . . . . . 8-7
BLOCK - REMOVAL, J UNCTION . . . . . . . . . . . 8-7
BLOCK HEATER - 3.9L/5.9L -
DESCRIPTION, ENGINE . . . . . . . . . . . . . . . . . 7-33
INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-34
OPERATION, ENGINE. . . . . . . . . . . . . . . . . . . 7-34
BLOCK HEATER - 3.9L/5.9L - REMOVAL,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
BLOCK HEATER - 4.7L - DESCRIPTION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
BLOCK HEATER - 4.7L - INSTALLATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
BLOCK HEATER - 4.7L - OPERATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
BLOCK HEATER - 4.7L - REMOVAL,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
BLOCK HEATER - DIAGNOSIS AND
TESTING, ENGINE . . . . . . . . . . . . . . . . . . . . . 7-35
BLOWER MOTOR - DESCRIPTION . . . . . . . 24-25
BLOWER MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
BLOWER MOTOR - INSTALLATION . . . . . . . 24-26
BLOWER MOTOR - OPERATION . . . . . . . . . 24-25
BLOWER MOTOR - REMOVAL . . . . . . . . . . . 24-26
BLOWER MOTOR RESISTOR - REMOVAL . . 24-21
BLOWER MOTOR RESISTOR BLOCK -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
BLOWER MOTOR SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-21
BLOWER MOTOR SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-21
BLOWER MOTOR SWITCH - OPERATION . . 24-21
BODY - ADJ USTMENTS, VALVE . . 21-254,21-438
BODY - ASSEMBLY, VALVE . . . . . . 21-245,21-428,
21-535
BODY & CABLE - DESCRIPTION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-5
BODY & CABLE - INSTALLATION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
BODY & CABLE - REMOVAL, ANTENNA . . . . 8A-6
BODY - CLEANING, VALVE . . . . . . 21-244,21-427,
21-534
BODY - DESCRIPTION, THROTTLE . . . . . . . 14-51
BODY - DESCRIPTION, VALVE . . . 21-213,21-396,
21-530
BODY - DISASSEMBLY, VALVE . . . 21-233,21-416,
21-532
BODY - INSPECTION, VALVE . . . . 21-244,21-427,
21-534
BODY - INSTALLATION, VALVE . . . 21-253,21-437,
21-536
BODY - OPERATION, THROTTLE . . . . . . . . . 14-51
BODY - OPERATION, VALVE . . . . . 21-218,21-400,
21-531
BODY - REMOVAL, VALVE . 21-232,21-415,21-531
BODY AND CABLE - DIAGNOSIS AND
TESTING, ANTENNA . . . . . . . . . . . . . . . . . . . 8A-5
BODY CODE PLATE - DESCRIPTION . . . . . Intro.-3
BODY GAP AND FLUSH
MEASUREMENTS, SPECIFICATIONS . . . . . . 23-48
BODY LUBRICATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
BODY OPENING DIMENSIONS,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 23-55
BODY SEALING - INSPECTION . . . . . . . . . . . 30-8
BODY SIDE MOLDINGS - INSTALLATION . . 23-77
BODY SIDE MOLDINGS - REMOVAL . . . . . . 23-77
BODY, SPECIAL TOOLS . . . . . . . . . . . . . . . . 23-58
BOOSTER - DESCRIPTION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
BOOSTER - DIAGNOSIS AND TESTING,
MASTER CYLINDER/POWER . . . . . . . . . . . . . 5-23
BOOSTER - INSTALLATION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
BOOSTER - OPERATION, POWER BRAKE . . . 5-25
BOOSTER - REMOVAL, POWER BRAKE . . . . 5-25
BOOT - INSTALLATION, CV . . . . . . . . . . . . . . 3-16
BOOT - INSTALLATION, FLOOR SHIFT . . . 23-111
BOOT - REMOVAL, CV . . . . . . . . . . . . . . . . . . 3-16
BOOT - REMOVAL, FLOOR SHIFT . . . . . . . 23-110
BOOT SEAL - DESCRIPTION . . . . . . . . . . . . 19-18
BOOT SEAL - INSTALLATION . . . . . . . . . . . 19-18
BOOT SEAL - OPERATION . . . . . . . . . . . . . . 19-18
BOOT SEAL - REMOVAL . . . . . . . . . . . . . . . 19-18
BORE HONING - STANDARD
PROCEDURE, CYLINDER. . . 9-11,9-162,9-222,9-71
BOX - ASSEMBLY, GLOVE . . . . . . . . . . . . . 23-102
BOX - DISASSEMBLY, GLOVE . . . . . . . . . . 23-101
BOX - INSTALLATION, CARGO . . . . . . . . . . 23-78
BOX - INSTALLATION, GLOVE . . . . . . . . . . 23-102
BOX - INSTALLATION, REAR STORAGE . . 23-117
BOX - REMOVAL, CARGO . . . . . . . . . . . . . . 23-78
BOX - REMOVAL, GLOVE . . . . . . . . . . . . . 23-101
BOX - REMOVAL, REAR STORAGE . . . . . . 23-117
BOX LAMP SWITCH - INSTALLATION,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
BOX LAMP SWITCH - REMOVAL, GLOVE . . 8L-27
BOX LATCH STRIKER - INSTALLATION,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-104
BOX LATCH STRIKER - REMOVAL,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-103
BOX SEAL - INSTALLATION, CARGO . . . . . 23-138
BOX SEAL - REMOVAL, CARGO . . . . . . . . 23-138
B-PILLAR TRIM - INSTALLATION . . . . . . . 23-113
B-PILLAR TRIM - REMOVAL . . . . . . . . . . . 23-112
BRACKET - INSTALLATION, INSIDE
HOOD RELEASE. . . . . . . . . . . . . . . . . . . . . 23-105
BRACKET - INSTALLATION, OVERHEAD
CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-5
BRACKET - INSTALLATION, REAR VIEW
MIRROR SUPPORT . . . . . . . . . . . . . . . . . . 23-119
BRACKET - REMOVAL, INSIDE HOOD
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . 23-104
BRACKET - REMOVAL, OVERHEAD
CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-4
BRAKE - ADJ USTMENTS, REAR DRUM . . . . 5-20
BRAKE - DESCRIPTION, CONTROLLER
REAR WHEEL ANTILOCK. . . . . . . . . . . . . . . . 8E-8
BRAKE - INSPECTION, PARKING . . . . . . . . . 30-16
BRAKE - INSTALLATION, CONTROLLER
REAR WHEEL ANTILOCK. . . . . . . . . . . . . . . 8E-10
BRAKE - OPERATION, CONTROLLER
REAR WHEEL ANTILOCK. . . . . . . . . . . . . . . . 8E-9
BRAKE - REMOVAL, CONTROLLER REAR
WHEEL ANTILOCK . . . . . . . . . . . . . . . . . . . . . 8E-9
BRAKE BOOSTER - DESCRIPTION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
BRAKE BOOSTER - INSTALLATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
BRAKE BOOSTER - OPERATION, POWER . . . 5-25
BRAKE BOOSTER - REMOVAL, POWER . . . . 5-25
BRAKE CABLE - INSTALLATION, FRONT
PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
BRAKE CABLE - REMOVAL, FRONT PARK . . 5-29
BRAKE CABLE TENSIONER, CABLES -
PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
BRAKE CABLES - INSTALLATION, REAR
PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
BRAKE CABLES - REMOVAL, REAR PARK . . 5-29
BRAKE CALIPERS - CLEANING, DISC . . . . . . 5-15
BRAKE CALIPERS - DESCRIPTION, DISC . . . 5-13
BRAKE CALIPERS - DISASSEMBLY, DISC . . . 5-14
BRAKE CALIPERS - INSPECTION, DISC . . . . 5-15
BRAKE CALIPERS - INSTALLATION, DISC . . . 5-15
BRAKE CALIPERS - OPERATION, DISC . . . . . 5-13
BRAKE CALIPERS - REMOVAL, DISC . . . . . . 5-14
BRAKE DRUM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
BRAKE DRUM MACHINING - STANDARD
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 5-17
BRAKE FLUID CONTAMINATION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-21
BRAKE FLUID LEVEL - STANDARD
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
BRAKE FLUID, SPECIFICATIONS . . . . . . . . . . 5-21
BRAKE INDICATOR - DESCRIPTION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J -14
BRAKE INDICATOR - OPERATION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J -15
BRAKE LAMP SWITCH - DESCRIPTION . . . . 8L-9
BRAKE LAMP SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-10
BRAKE LAMP SWITCH - INSTALLATION . . . 8L-10
BRAKE LAMP SWITCH - OPERATION . . . . . . 8L-9
BRAKE LAMP SWITCH - REMOVAL . . . . . . 8L-10
BRAKE LINE AND HOSES - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 5-10
BRAKE LINES - DESCRIPTION . . . . . . . . . . . 5-10
BRAKE LINES - OPERATION . . . . . . . . . . . . . 5-10
BRAKE PADS/SHOES - INSTALLATION . . . . . 5-11
BRAKE PADS/SHOES - REMOVAL . . . . . . . . . 5-10
BRAKE ROTOR - DIAGNOSIS AND
TESTING, DISC . . . . . . . . . . . . . . . . . . . . . . . 5-26
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-2
BRAKE SYSTEM - STANDARD
PROCEDURES, BLEEDING ABS . . . . . . . . . . . 5-36
BRAKE WARNING INDICATOR SWITCH -
DESCRIPTION, RED. . . . . . . . . . . . . . . . . . . . . 5-9
BRAKE WARNING INDICATOR SWITCH -
OPERATION, RED . . . . . . . . . . . . . . . . . . . . . . 5-9
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -14
BRAKE/PARK BRAKE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -15
BRAKES - ABS - DESCRIPTION . . . . . . 5-33,5-34
BRAKES - ABS - OPERATION . . . . . . . . 5-34,5-35
BRAKES - BASE - DESCRIPTION . . . . . . . . . . . 5-2
BRAKES - DIAGNOSIS AND TESTING,
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
BRAKES - INSPECTION, SERVICE . . . . . . . . 30-16
BRAKES, SPECIAL TOOLS - BASE . . . . . . . . . 5-9
BRAKES, SPECIFICATIONS - BASE . . . . . . . . . 5-8
BREAKER - CIRCUIT BREAKER, CIRCUIT . . . . 8-4
BREAKER - DESCRIPTION, CIRCUIT . . . . . . . . 8-4
BREAKER, CIRCUIT BREAKER - CIRCUIT . . . . 8-4
BREAK-IN - STANDARD PROCEDURE,
A/C COMPRESSOR CLUTCH . . . . . . . . . . . . 24-11
BUCKET SEAT - INSTALLATION . . . . . . . . . 23-127
BUCKET SEAT - REMOVAL . . . . . . . . . . . . 23-126
BUCKET SEAT BACK PAD/COVER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-129
BUCKET SEAT BACK PAD/COVER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-129
BUCKET SEAT CUSHION/COVER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-130
BUCKET SEAT CUSHION/COVER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-130
BUCKET SEAT TRACK - INSTALLATION . . . 23-131
BUCKET SEAT TRACK - REMOVAL . . . . . . 23-131
BUCKLE - INSTALLATION, FRONT SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
BUCKLE - REMOVAL, FRONT SEAT BELT . . 8O-22
BUILT-IN INDICATOR TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-11
BULB - REMOVAL, CARGO LAMP . . . . . . . . 8L-10
BUMPER - INSTALLATION, FRONT . . . . . . . . 13-2
BUMPER - INSTALLATION, REAR . . . . . . . . . 13-3
BUMPER - REMOVAL, FRONT . . . . . . . . . . . . 13-1
BUMPER - REMOVAL, REAR . . . . . . . . . . . . . 13-2
BUMPERS - DESCRIPTION . . . . . . . . . . . . . . 13-1
BUMPERS - OPERATION . . . . . . . . . . . . . . . . 13-1
BURNT FLUID - DIAGNOSIS AND
TESTING, CAUSES OF . . . . 21-144,21-325,21-486
BUSHING - INSTALLATION,
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . 9-246,9-98
BUSHING - INSTALLATION, EXTENSION
HOUSING. . . . . . . . . . . . . . . . . . . . 21-143,21-324
BUSHING - INSTALLATION, YOKE . . . . . . . . 21-76
BUSHING - REMOVAL, DISTRIBUTOR . . . . 9-246,
9-98
BUSHING - REMOVAL, EXTENSION
HOUSING. . . . . . . . . . . . . . . . . . . . 21-143,21-324
4 INDEX AN
BUSHING - REMOVAL, YOKE . . . . . . . . . . . 21-76
BUSHING AND SEAL - INSTALLATION,
REAR RETAINER . . . . . . . . . . . . . . 21-563,21-598
BUSHING AND SEAL - REMOVAL, REAR
RETAINER . . . . . . . . . . . . . . . . . . . 21-563,21-598
BUSHINGS - CONTROL ARM -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . 2-24,2-8
BUSHINGS - CONTROL ARM - REMOVAL . . 2-24,
2-8
BYPASS - DESCRIPTION, WATER PUMP . . . 7-57
BYPASS - OPERATION, WATER PUMP . . . . . 7-58
C205F - ADJ USTMENTS, FRONT AXLE . . . . . 3-27
C205F - DESCRIPTION, FRONT AXLE . . . . . . 3-22
C205F - FRONT AXLE . . . . . . . . . . . . . . . . . . 3-34
C205F - INSTALLATION, FRONT AXLE . . . . . 3-26
C205F - OPERATION, FRONT AXLE . . . . . . . . 3-22
C205F - REMOVAL, FRONT AXLE . . . . . . . . . 3-26
CAB - INSTALLATION, AIR EXHAUSTER . . 23-120
CAB - INSTALLATION, QUAD . . . . . . . . . . . 8O-21
CAB - INSTALLATION, REAR SEAT
BACK-CLUB . . . . . . . . . . . . . . . . . . . . . . . . 23-128
CAB - INSTALLATION, REAR SEAT QUAD . 23-127
CAB - INSTALLATION, SPEAKER - REAR
CAB SIDE - CLUB . . . . . . . . . . . . . . . . . . . . 8A-20
CAB - INSTALLATION, SPEAKER - REAR
CAB SIDE - REGULAR . . . . . . . . . . . . . . . . . 8A-21
CAB - INSTALLATION, STANDARD/CLUB . . 8O-22
CAB - REMOVAL, AIR EXHAUSTER . . . . . . 23-120
CAB - REMOVAL, QUAD. . . . . . . . . . . . . . . . . 8O-19
CAB - REMOVAL, REAR SEAT BACK-
CLUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-128
CAB - REMOVAL, REAR SEAT QUAD . . . . . 23-126
CAB - REMOVAL, SPEAKER - REAR CAB
SIDE - CLUB . . . . . . . . . . . . . . . . . . . . . . . . 8A-20
CAB - REMOVAL, SPEAKER - REAR CAB
SIDE - REGULAR. . . . . . . . . . . . . . . . . . . . . 8A-20
CAB - REMOVAL, STANDARD/CLUB . . . . . . 8O-21
CAB BACK PANEL TRIM -
INSTALLATION, REAR . . . . . . . . . . . . . . . . 23-117
CAB BACK PANEL TRIM - REMOVAL,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-117
CAB REAR SEAT CUSHION COVER -
INSTALLATION, QUAD . . . . . . . . . . . . . . . . 23-130
CAB REAR SEAT CUSHION COVER -
REMOVAL, QUAD. . . . . . . . . . . . . . . . . . . . 23-130
CAB SIDE - CLUB CAB - INSTALLATION,
SPEAKER - REAR . . . . . . . . . . . . . . . . . . . . 8A-20
CAB SIDE - CLUB CAB - REMOVAL,
SPEAKER - REAR . . . . . . . . . . . . . . . . . . . . 8A-20
CAB SIDE - REGULAR CAB -
INSTALLATION, SPEAKER - REAR. . . . . . . . 8A-21
CAB SIDE - REGULAR CAB - REMOVAL,
SPEAKER - REAR . . . . . . . . . . . . . . . . . . . . 8A-20
CABLE - ADJ USTMENTS, GEARSHIFT . . . 21-155,
21-337,21-491
CABLE - ADJ USTMENTS,
TRANSMISSION THROTTLE VALVE . . . . . 21-200,
21-383
CABLE - DESCRIPTION . . . . . . . . . . . . . . . . . 8P-3
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-5
CABLE - DESCRIPTION, BATTERY . . . . . . . . 8F-19
CABLE - DESCRIPTION, SPARK PLUG . . . . . 8I-20
CABLE - DESCRIPTION, THROTTLE
VALVE . . . . . . . . . . . . . . . . . . . . . . 21-200,21-383
CABLE - DIAGNOSIS AND TESTING,
ANTENNA BODY . . . . . . . . . . . . . . . . . . . . . . 8A-5
CABLE - DIAGNOSIS AND TESTING,
GEARSHIFT . . . . . . . . . . . . 21-153,21-334,21-489
CABLE - INSTALLATION, ANTENNA BODY . . 8A-7
CABLE - INSTALLATION, FRONT PARK
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CABLE - INSTALLATION, GEARSHIFT . . . . 21-154,
21-336,21-490
CABLE - INSTALLATION, HOOD RELEASE . . 23-88
CABLE - INSTALLATION, SPARK PLUG . . . . 8I-21
CABLE - INSTALLATION, TAILGATE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-59
CABLE - OPERATION . . . . . . . . . . . . . . . . . . . 8P-3
CABLE - OPERATION, BATTERY . . . . . . . . . . 8F-19
CABLE - OPERATION, SPARK PLUG . . . . . . . 8I-20
CABLE - REMOVAL, ANTENNA BODY . . . . . . 8A-6
CABLE - REMOVAL, FRONT PARK BRAKE . . 5-29
CABLE - REMOVAL, GEARSHIFT . 21-153,21-334,
21-489
CABLE - REMOVAL, HOOD RELEASE . . . . . 23-88
CABLE - REMOVAL, SPARK PLUG . . . . . . . . 8I-21
CABLE - REMOVAL, TAILGATE CHECK . . . . 23-59
CABLE RESISTANCE - SPECIFICATIONS,
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . 8I-3
CABLE TENSIONER, CABLES - PARK
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CABLES - DIAGNOSIS & TESTING,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-20
CABLES - DIAGNOSIS AND TESTING,
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . 8I-20
CABLES - INSTALLATION, REAR PARK
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CABLES - PARK BRAKE CABLE
TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CABLES - REMOVAL, REAR PARK BRAKE . . 5-29
CALIBRATION - STANDARD PROCEDURE,
COMPASS. . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-2
CALIPERS - CLEANING, DISC BRAKE . . . . . . 5-15
CALIPERS - DESCRIPTION, DISC BRAKE . . . 5-13
CALIPERS - DISASSEMBLY, DISC BRAKE . . . 5-14
CALIPERS - INSPECTION, DISC BRAKE . . . . 5-15
CALIPERS - INSTALLATION, DISC BRAKE . . . 5-15
CALIPERS - OPERATION, DISC BRAKE . . . . . 5-13
CALIPERS - REMOVAL, DISC BRAKE . . . . . . 5-14
CAM - DESCRIPTION, TURN SIGNAL
CANCEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
CAM - OPERATION, TURN SIGNAL
CANCEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
CAMBER - STANDARD PROCEDURE . . . . . . . . 2-4
CAMBER AND CASTER ADJ USTMENT -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . . 2-4
CAM/OVERDRIVE PISTON RETAINER -
ASSEMBLY, OVERRUNNING CLUTCH. . . . . 21-183,
21-366
CLEANING, OVERRUNNING CLUTCH . . . . 21-182,
21-366
DESCRIPTION, OVERRUNNING CLUTCH . 21-182,
21-365
DISASSEMBLY, OVERRUNNING
CLUTCH. . . . . . . . . . . . . . . . . . . . . 21-182,21-366
INSPECTION, OVERRUNNING CLUTCH . . 21-182,
21-366
OPERATION, OVERRUNNING CLUTCH . . . 21-182,
21-366
CAMSHAFT - INSTALLATION . . . . 9-239,9-31,9-90
CAMSHAFT - REMOVAL . . . . . . . 9-238,9-30,9-89
CAMSHAFT BEARINGS - INSTALLATION . . 9-238,
9-31,9-90
CAMSHAFT BEARINGS - REMOVAL . . 9-237,9-30,
9-89
CAMSHAFT(S) - LEFT - DESCRIPTION . . . . 9-150
CAMSHAFT(S) - LEFT - INSTALLATION . . . . 9-150
CAMSHAFT(S) - LEFT - REMOVAL . . . . . . . 9-150
CAMSHAFT(S) - RIGHT - DESCRIPTION . . . 9-154
CAMSHAFT(S) - RIGHT - INSTALLATION . . 9-156
CAMSHAFT(S) - RIGHT - REMOVAL . . . . . . 9-154
CANCEL CAM - DESCRIPTION, TURN
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
CANCEL CAM - OPERATION, TURN
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
CANISTER - DESCRIPTION, VAPOR . . . . . . 25-33
CANISTER - INSTALLATION, VAPOR . . . . . . 25-34
CANISTER - OPERATION, VAPOR . . . . . . . . 25-33
CANISTER - REMOVAL, VAPOR . . . . . . . . . . 25-34
CAP - CLEANING, RADIATOR PRESSURE . . . 7-51
CAP - DESCRIPTION, FUEL FILLER . . . . . . . 25-25
CAP - DESCRIPTION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
CAP - DIAGNOSIS AND TESTING,
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . 8I-12
CAP - INSPECTION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
CAP - INSTALLATION, END . . . . . . . . . . . . 23-100
CAP - OPERATION, FUEL FILLER . . . . . . . . 25-25
CAP - OPERATION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
CAP - PRESSURE TESTING - DIAGNOSIS
AND TESTING, RADIATOR . . . . . . . . . . . . . . . 7-50
CAP - REMOVAL/INSTALLATION, FUEL
FILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-25
CAPACITIES - SPECIFICATIONS, FLUID . . . . . . 0-1
CAPACITY TEST - DIAGNOSIS AND
TESTING, FUEL PUMP . . . . . . . . . . . . . . . . . . 14-8
CAP-TO-FILLER NECK SEAL -
DIAGNOSIS AND TESTING, RADIATOR . . . . . 7-50
CARDAN UNIVERSAL J OINTS -
ASSEMBLY, SINGLE. . . . . . . . . . . . . . . . . . . . 3-11
CARDAN UNIVERSAL J OINTS -
DISASSEMBLY, SINGLE . . . . . . . . . . . . . . . . . 3-10
CARGO BOX - INSTALLATION . . . . . . . . . . . 23-78
CARGO BOX - REMOVAL . . . . . . . . . . . . . . . 23-78
CARGO BOX SEAL - INSTALLATION . . . . . 23-138
CARGO BOX SEAL - REMOVAL . . . . . . . . . 23-138
CARGO LAMP BULB - REMOVAL . . . . . . . . 8L-10
CARPETS AND FLOOR MATS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-113
CARPETS AND FLOOR MATS - REMOVAL . 23-113
CARTRIDGE FUSE - DESCRIPTION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CARTRIDGE FUSE - INSTALLATION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CARTRIDGE FUSE - OPERATION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CARTRIDGE FUSE - REMOVAL,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
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