94 Dodge Ram Truck PDF

1 9 9 4
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
^ C H R Y S L E R
^ C O R P O R A T I O N
CHRYSLER
CORPORATION
SERVICE MANUAL
1994
RAM TRUCK
1500 - 3500
To order the special service tools used and

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

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

make additions to or Improvements In Its products without imposing any ob
ligations upon itself to install them on its products previously manufactured.
Litho In U.S.A. Copyright © 1993 Chrysler Corporation 20M0793

F O R E W O R D
The information contained i n this service manual has been prepared for the professional automotive tech
nician involved i n daily repair operations. This manual does not cover theory of operation, which is addressed
i n service training material. Information describing the operation and use of standard and optional equipment
is included i n the Owner's Manual provided with the vehicle.
Information i n this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components. To as
sist i n locating a group title page, use the Group Tab Locator on the following page. The solid bar after the
group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents
section that lists major topics within the group. I f you are not sure which Group contains the information you
need, look up the Component/System i n the alphabetical index located i n the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use i n service assembly and installation procedures using the correct OEM fasteners. When re
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components i n
this manual may have changed from prior publications. These new terms are i n compliance with S.A.E.
recommended practice J1930.
GROUP TAB LOCATOR
«—« Introduction
f) L u b r i c a t i o n a n d Maintenance
2 Front S u s p e n s i o n a n d Axle
R e a r
3 S u s p e n s i o n a n d Axles
5 Brakes
6 Clutch
7 C o o l i n g System
8 Electrical
9 Engines
"f 1 Exhaust System a n d Intake Manifold
%3 Frame a n d B u m p e r s
'f 4 Fuel S y s t e m
*f 0 Propeller Shafts
°f 0 Steering
2i T r a n s m i s s i o n s a n d Transfer Cases
2 2 w h
® 6 l s a n d Tires
2 3 Body Components
2 4 Heating a n d Air C o n d i t i o n i n g
2 5 E m i s s i o n Control Systems
Index
Service Manual C o m m e n t Forms (Rear of Manual)

• INTRODUCTION 1
I N T R O D U C T I O N
CONTENTS
page page
FASTENER TORQUE INFORMATION AND GENERAL INFORMATION 1
METRIC CONVERSION .17
GENERAL INFORMATION
INDEX
page page
Body Code Plate 1 International Vehicel Control and Display Symbols . . 3
Equipment Identification Label 2 Trailer Towing—Chassis Cab 16
GrossVehicle Weight Rating—2WD Pickup 6 Trailer Towing—Pickup 13
Gross Vehicle Weight Rating—4WD Pickup 7 Vehicle Exterior Dimensions—Chassis Cab 5
Gross Vehicle Weight Rating—Pickup 8.0L or Diesel... 8 Vehicle Exterior Dimensions—Pickup 4
Gross Vehicle Weight Rating—2WD Chassis Cab 5.9L . . 9 Vehicle Identification Number (VIN) 1
Gross Vehicle Weight Rating-4WD Chassis Cab 5.9L . 10 Vehicle Interior Dimensions . . . 3
Gross Vehicle Weight Rating—2WD Chassis Cab Vehicle Safety Certification Label 1
8.0L or Diesel . . 11
Gross Vehicle Weight Rating—4WD Chassis Cab
8.0L or Diesel 12
VEHICLE IDENTIFICATION NUMBER (VIN) • Equipment Identification Plate

The Vehicle Identification Number (VIN) plate (Fig. • Vehicle Safety Certification Label
1) is located on the lower windshield fence near the • Frame rail.
left A-pillar. The V I N contains 17 characters that To protect the consumer from theft and possible
provide data concerning the vehicle. Refer to the V I N fraud the manufacturer is required to include a
decoding chart to determine the identification of a ve Check Digit at the ninth position of the Vehicle Iden
hicle. tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta
tion. The formula to use the check digit is not re
leased to the general public.
BODY CODE PLATE

The Body Code Plate is located on the floor pan
rearward of the passenger side seat. There are seven
lines of information on the body code plate. Lines 4,
5, 6, and 7 are not used to define service information.
Information reads from left to right, starting with
line 3 in the center of the plate to line 1 at the bot
tom of the plate.
VEHICLE SAFETY CERTIFICATION LABEL

A Vehicle Safety Certification Label (Fig. 2) is at
tached to the drivers door lock pillar. The label certi
Fig. 1 Vehicle Identification Number (VIN) Location fies that the vehicle conforms to Federal Motor
The V I N is included on the: Vehicle Safety Standards (FMVSS). The certification
• Body Code Plate label lists the following:
2 INTRODUCTION •
V I N DECODING CHART • Vehicle Identification Number (VIN)
• Type of vehicle
POSITlON-INTERPiETATIOIf . . . CODE=DESCRIPTION
• Type of rear wheels (single or dual)
1 -Country of o r i g i n . . . 1 = United States • Bar code
2 = Canada
3 = Mexico
• Month, Day and Hour (MDH) of final assembly
2 - Make . . . . . . . . . . . B = Dodge
MFD BY CHRYSLER DATE OF MFR GVWR
3 - Vehicle Type 4 = Multipurpose Passenger Vehicle
CORPORATION
5 = Bus
6 = Incomplete Vehicles
7 = Truck
4-Gross Vehicle . D = 0-1360kg (1-3,000 lbs.) GAWR FRONT WITH TIRES RIMS AT PSI COLD
Weight Rating E = 1361-1814kg (3,001-4,000 lbs.
F = 1815-2267kg (4,001-5,000 lbs
G = 2268-2721kg (5,001-6,000 lbs/ GAWR REAR WITH TIRES RIMS AT PSI COLD
H « 2722-3175kg 6,001-7,000 lbs.
J « 3176-3628kg 7,001-8,000 lbs.
K = 3 6 2 9 - 4 0 8 2 k g (8,001-9,000 lbs.,
L«4083-4535kg 9,001-10,000Ibs.J THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
M = 4 5 3 6 - 6 3 5 0 k g (10,001-14,000 lbs.) STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
W = Busses/Incomplete Vehicles with
Hydraulic Brakes
5 - Car Line C = 2WD-Dodge/Ram Pickup, Chassis Cab SINGLE DUAL
VIN: TYPE:
F = 4WD-Dodae/Ram Pickup, Chassis Cab
6 - Series 1 = 1500 Job Rating
2 = 2 5 0 0 Job Rating BAR CODE
3 = 3 5 0 0 Job Rating
7 - Body Style 6 = Conventional Cap/Chassis Cab
8 - Engine C = 5.9L 6 cyl. TURBO Diesel VEHICLE MADE IN 4648503 J91IN-25
W = 8.0L 10 cyl. Gasoline MFI
X = 3 . 9 L 6 c y ( . Gasoline MFI
Y = 5.2L 8 cyl. Gasoline MFI Fig. 2 Vehicle Safety Certification Label
Z = 5 . 9 L 8 cyl. Gasloline MFI-LDC
5 = 5.9L 8 cyl. Gasoline MFI-HDC EQUIPMENT IDENTIFICATION LABEL
9 - Check Digit See V I N p a r a g r a p h
1 0 - M o d e l Year R=1994 The Equipment Identification Plate is located at
11 -Assembly Plant . . . . M = Logo, Mexico
S = Dodge City the right, front corner of the inner hood panel. The
J94IN-24 plate lists information concerning the vehicle as fol
12THRU17-Vehicle Build Sequence
lows:
• The model
BODY CODE PLATE • The wheelbase
• The V I N (Vehicle Identification Number)
PRIAAARY SECONDARY VINYL ROOF • The T.O.N, (order number)
PAINT PAINT
• The optional and special equipment installed on
the vehicle
Refer to the information listed on the plate when
ordering service parts.
VEHICLE
ORDER
NUMBER
PAINT - ENGINE
PROCEDURE (2) XXX XXXX XXXX XXXX XXX r
£ a R M B EQUIPMENT IDENTIFICATION 421MM
• TRIM
(1) XXX X xxxxxxxxxxxxxxxxx
ION
TRANSMISSION I| VIN
CODE NO.
MODELS V.I.N.
DESCRIPTION C O D E N O .
T.O.N.
DESCRIPTION
MARKET
93IN-8
• Month and year of vehicle manufacture

• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum r i m size and maximum cold tire
inflation pressure Fig. 3 Equipment Identification Plate
INTRODUCTION 3
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
ID A
HEADLIGHTS,
PARKING LIGHTS, WINDSHIELD
HIGH BEAM FOG LIGHTS PANEL UGHTS TURN SIGNAL HAZARD WARNING WASHER
WINDSHIELD
WIPE!
WINDSHIELD WIPER
AND WASHER
<9
WINDSCREEN
DEMISTING
A N D DEFROSTING
*
VENTILATING FAN
9 99
REAR W I N D O W
DEFOGGER
REAR WINDOW
WIPER
m Lt3 M-
•
REAR W I N D O W ENGINE COOLANT BATTERY CHARGING

WASHER FUEL TEMPERATURE CONDITION ENGINE OIL SEAT BELT
CD (®) n , i
REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT HOOD (TRUNK) HORN LIGHTER
93IN-9
VEHICLE INTERIOR DIMENSIONS
A Head Room 40.2

B Hip Room 65.8
C Shoulder Room 66.3
D Seat Width 60.2
E Seat Height 13.2
F Seat Depth 19.0
G Seat Adjustment (Fore and aft) 7.5
H Leg Clearance (Seat to steering wheel) 5.9
1 Steering Wheel To Seatback (Max) 15.9
J Leg Room 41.0
K Back O f Seat To Back Of C a b
—Top 3.8
—Bottom 13.2
Seatback Angle (Degrees) 21.0
Door Opening Height 47.1
Door Opening Width 41.8
Note: All dimensions are in inches unless noted.
J94IN-26
4 INTRODUCTION •
VEHICLE EXTERIOR DIMENSIONS—PICKUP
1500/ 2500/ 3500/

1500 4 x 4 2500 4 x 4 3500 4 x 4
A Wheelbase 119" 135" 135" 135"
B Box Length (feet) 6.5 8.0 8.0 8.0
C Ground Clearance (Empty)
—Front 9.7/8.1 10.0/8.1 10.1/8.1 13.1/10.2
—Rear 10.1/9.8 10.1/9.8 10.1/9.8 10.1/9.8
D Overall Length
—Without rear bumper 199.9 220.1 220.1 220.1
—With rear bumper 204.1 224.3 224.3 224.3
E Overall Height (Empty) 7 2 . 1 / 7 5 . 9 72.1/75.9 73.7/78.0 73.6/75.9
F Overall Width
—At Front Wheel Lip 79.4 79.4 79.4 79.5'
G Track
—Front 68.5 68.5 68.6 68.6
—Rear 68.0 68.0 68.0 73.0
H Tailgate Load Height 31.2/35.6 31.5/35.6 31.5/35.6 31.4/35.6
1 Overhang—Front 37.9 37.9 37.9 37.9
J Overhang—Rear
—Without Rear Bumper 47.6 47.6 47.6 47.6
—With Rear Bumper 51.7 51.7 51.7 51.7
K Back Of C a b To
Rear Bumper 87.2 107.4 107.4 107.4
L Front Bumper To
Back O f C a b 116.9 116.9 116.9 116.9
M Approach Angle (Degrees) 25.3/29.7 25.3/29.7 25.3/29.7 25.3/29.7
N Breakover Angle (Degrees) 17.8/21.0 17.8/21.0 17.8/21.0 17.8/21.0
O Departure Angle (Degrees) 30.6/36.2 30.6/36.2 30.6/36.2 30.6/36.2
' 9 3 . 5 at cargo box.
J94IN-25
EXTERIOR
4 x 2 Models 4 x 4 Models
2500 3500 3500 2500 3500 3500
Model HD DRW DRW HD DRW DRW
A Wheelbase 135 139 163 135 139 163
B C a b To Axle 55.7 59.7 83.7 55.7 59.7 83.7
C Overall Length 216.7 220.7 244.7 216.7 220.7 244.7
D Overall Height (Empty) 72.4 77.3 77.1 75.9 77.2 77.1
E Overall Width 79.4 94.6 94.6 79.4 94.6 94.6
f Track
—Front 68.6 69.8 69.8 68.9 69.8 69.8
—Rear 68.0 73.0 73.0 68.0 73.0 73.0
G Rear Track, Inside 58.0 51.4 51.4 58.0 51.4 51.4
H Rear Track, Outside 78.0 94.6 94.6 78.0 94.6 94.6
1 Overhang—Front 37.9 37.9 37.9 37.9 37.9 37.9
J Axle To End Of Frame 44.1 44.1 44.1 44.1 44.1 44.1
K Center Of Front Wheel
To Back Of C a b 79.0 79.0 79.0 79.0 79.0 79.0
L Frame To Top Of C a b 52.9 52.9 52.9 52.9 52.9 52.9
Ni
N
Top Of Frame To Ground
Inside Width Between
29.6 34.3 34.1 34.0 34.3 34.2
QJD
Frame Rails 31.7 31.7 31.7 31.7 31.7 31.7
O Outside Width Between
Frame Rails 37.6 37.6 37.6 37.6 37.6 37.6
P Front Bumper To Back
Of Cab 1169 116.9 1169 116.9 116.9 116.9
Q Front Of Dash To
Back Of C a b NA NA NA NA NA NA
R Ground Clearance
—Front 10.1 15.2 15.2 8.1 8.6 8.6
—Rear 8.5 90 9.0 8.4 9.0 9.0
N O T E : All dimensions are in inches unless noted,
DRW = Dual-rear wheel.
N A = Not available at time of printing.
6 INTRODUCTION •
G R O S S VEHICLE WEIGHT RATING—2WD PICKUP
4x2 MODELS
1500 WS 1500 MODELS 2500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD STD STD
6,010 6,400 7,500 8,800 10,500 DRW
GVWR (Z1A) (ZIB) (Z2A) (Z2B) (Z38)
AXLES
—Front 3,300 3,300 3,300 4,000 4,000
—Rear 3,900 3,900 6,200 6,200 7,500
SPRINGS
—Front 3,300 3,300 3,300 4,000 4,000
—Rear 3,800 3,800 4,670 6,085 7,500
TIRES P225/75R16 P225/75R16XL LT225/75R16 LT245/75R16 LT215/85R16
all-season all-season all-season all-season all-season
(TRW) (TRY) (TWP) (TYD) (TVV)
GAWR
—Front 3,300 3,300 3,300 4,000 4,000
—Rear 3,800 3,800 4,670 6.085 7,460
S H O R T B O X (119" W B )
PAYLOAD'
— M A G N U M 3.9L V 6 2,000 2,365
- M A G N U M 5.2L V 8 — 2,230 — — —
— M A G N U M 5.9L V 8 — 2,140 — — —
CURB WEIGHT
—Front 2,340 2,340 . ....
r n
—Rear 1,670 1,695 — —
—Total 4,010 4,035 — — —
L O N G B O X (135" WB)
PAYLOAD'
- M A G N U M 3.9L V 6 1,835 2,200 ......
- M A G N U M 5.2L V 8 _ 2,065 2,845 — —
— M A G N U M 5.9L V 8 —• 1,980 2,810 4,100 5,290

CURB WEIGHT
—Front 2,460 2,460 2,800 2,840 2,880
—Rear 1,715 1,740 1,855 1,860 2,330
—Total 4,175 4,200 4,655 4,700 5,210
DRW — Dual-rear wheel.
1
Pay load allowance must be reduced by weight of passengers and optional equipment.
J94IN-28
• INTRODUCTION 7
G R O S S V E H I C L E WEIGHT RATING—4WD PICKUP
4 x 4 MODELS
1500 MODELS 2500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD STD
6,400 7,500 8,800 10,500 DRW
GVWR (Z6A) (Z7A) (Z7B) (Z8A)
AXLES
—Front 3,500 3,500 4,500 4,500
—Rear 3,900 6,200 6,200 7,500
SPRINGS
—Front 3,500 4,000 4,500 4,500
—Rear 3,600 4,670 6,085 7,500
TIRES LT225/75R16 LT225/75R16 LT245/75R16 LT215/85R16
all-season all-season all-season all-season
(TWA) (TWP) (TYD) (TVV)
GAWR
—Front 3,500 3,500 4,500 4,500
—Rear 3,600 4,670 6,085 7,060
S H O R T B O X (119" WB) 1
1
PAYLOAD
- M A G N U M 5.2L V 8 1,885 _
- M A G N U M 5.9L V 8 1,785 — — —
CURB WEIGHT
—Front 2,730 —
—Rear 1,785 — — —
—Total 4,515 — — —
L O N G B O X (135" W B ) j
1
PAYLOAD
- M A G N U M 5.2L V 8 1,720 2,550
- M A G N U M 5.9L V 8 1,625 2,510 3,450 4,885
CURB WEIGHT
—Front 2,865 3,040 3,250 3,250
—Rear 1,815 1,910 2,000 2,365
—Total 4,680 4,950 5,250 5,615
1
J94IN-29
8 INTRODUCTION •
G R O S S VEHICLE WEIGHT RATING—PICKUP 8.0L O R DIESEL
8 . 0 L V I O A N D DIESEL E N G I N E MODELS
4x2 4x4
2500 HD MODELS 3500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD STD
8,800 10,500 DRW 8,800 10,500 DRW
GVWR (Z2B) (Z3A) (Z7B) (Z8A)
AXLES
—Front 4,000 4,000 4,500 4,500
—Rear 6,500 7,500 6,500 7,500
SPRINGS
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 7,500 6,085 7,500
TIRES LT215/75R16 LT215/85R16 LT245/75R16 LT215/85R16
all-season all-season all-season all-season
(TYD) (TVV) (TYD) (TVV)
GAWR
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 7,500 6,085 7,500
LONG B O X (135" WB)
PAYLOAD'
- M A G N U M 8.0L VIO 3,570 4,900 3,315 4,470
—Cummins 5.9L I-6 3,265 4,595 2,840 4,175
CURB WEIGHT — 8.0L ENGINE
—Front 3,165 3,180 3,555 3,555
—Rear 2,065 2,420 2,110 2,475
—Total 5,230 5,600 5,665 6,030
C U R B W E I G H T — DIESEL E N G I N E
—Front 3,460 3,475 3,845 3,845
—Rear 2,075 2,430 2,115 2,480
—Total 5,535 5,905 5,960 6,325
1
J94IN-39
• INTRODUCTION 9
G R O S S VEHICLE WEIGHT RATING—2WD CHASSIS CAB S.9L
5.9L M A G N U M V8 — 4x2
2 5 0 0 HD M O D E L S 3 5 0 0 MODELS
STD STD STD
8,800 11,000 D R W 11,000 D R W
GVWR (Z2B) (Z3B) (Z3B)
AXLES
—Front 4 , 0 0 0 IFS 4,500' 4,500'
—Rear 6,200 8,000 7,500
SPRINGS
—Front 4,000 IFS 4,670 3,830
—Rear 6,085 8,600 7,600
TIRES LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TVV) (TVV)
GAWR
—Front 4,000 4,500 3,570
—Rear 6,085 8,000 7,060
135" W B (56" CA)
2
PAYLOAD 4,360 — —
CURB WEIGHT
—Front 2,870 _ _
—Rear 1,570 —
—Total 4,440
139" W B (60" CA)
PAYLOAD 2
— 6,400 —
CURB WEIGHT
—Front 3,065
—Rear — 2,045 —
—Total — 5,110 —
1 6 3 " W B (84" CA)

PAYLOAD 9
— — 5,830
CURB WEIGHT
—Front 3,120
—Rear — 2,050
—Total — 5,170
DRW = Dual-rear wheel. IFS = Independent Front Suspension. C A = C a b to axle.
^ S O O 4 x 2 models receive the link-coil front suspension with a tubular front axle.
2
Payload allowances must be reduced by weight of passengers and optional equipment.
J94IN-31
10 INTRODUCTION •
G R O S S VEHICLE WEIGHT RATING—4WD CHASSIS CAB S.9L
5.9L M A G N U M V 8 — 4x4
2 5 0 0 HD M O D E L S 3 5 0 0 MODELS
STD STD STD
8,800 SRW 11,000 D R W 11,000 D R W
GVWR (Z6B) (Z7B) (Z7B)
AXLES
—Front 4,500 4,500 4,500
—Rear 6,200 8,000 8,000
SPRINGS
—Front 4,500 4,500 4,500
—Rear 6,085 8,000 8,000
TIRES LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TVV) (TVV)
GAWR
—Front 4,500 4,500 4,500
—Rear 6,085 8,000 8,000
135" W B (56" CA)
1
PAYLOAD 3,800 — —
CURB WEIGHT
—Front 3,285 _
—Rear 1,715 — —
—Total 5,000 — —
1 3 9 " W B (60" CA)

PAYLOAD 1
— 5,650 —
CURB WEIGHT
—Front _ 5,350
—Rear — 3,275 —
—Total — 2,075 —
163" W B (84" CA)

PAYLOAD 1
— — 5,590
CURB WEIGHT
—Front 3,335
—Rear — — 2,075
—Total — — 5,410
DRW—Dual-rear wheel. C A — C a b to axle.
^ a y l o a d allowance must be reduced by weight of passengers and optional equipment.
J94IN-32
• INTRODUCTION 11
G R O S S V E H I C L E WEIGHT RATING—2WD CHASSIS CAB 8.0L OR DIESEL
8.0L V10 A N D 5 . 9 L DIESEL — 4 x 2

2 5 0 0 HD 2 5 0 0 HD 3500 3500
VIO DIESEL VIO DIESEL
8,800 8,800 11,000 D R W 11,000 D R W
GVWR (Z2B) (Z2B) (Z3B) (Z3B)
AXLES
—Front 4,000 4,000 4,500 4,500
—Rear 6,500 6,500 8,000 8,000
SPRINGS
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 6,085 8,000 8,000
TIRES LT245/75R16E LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TYD) (TVV) (TVV)
GAWR
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 6,085 8,000 8,000
135" W B (56" C A )
PAYLOAD 1
3,825 4,115 — —
CURB WEIGHT
—Front 3,200 3,490
—Rear 1,775 1,790 — —
—Total 4,975 5,280 — —
139" W B (60" C A )
PAYLOAD 1
— — 5,500 5,195
CURB WEIGHT
—Front 3,360 3,655
—Rear — — 2,140 2,150
—Total — — 5,500 5,805
163" W B (84" C A )
PAYLOAD' — — 5,440 5,135
CURB WEIGHT
—Front «... 3,415 3,710
—Rear — — 2,145 2,155
—Total — — 5,560 5,865
DRW—Dual-rear wheel. C A — C a b to axle.
1
J94IN-33
12 INTRODUCTION •
GROSS VEHICLE WEIGHT RATINQ-4WD CHASSIS CAB 8.0L OR DIESEL
8.0L V10 A N D 5 . 9 L DIESEL — 4 x 4

2 5 0 0 HD 2 5 0 0 HD 3500 3500
VIO DIESEL V10 DIESEL
8,800 8,800 11,000 D R W 11,000 D R W
GVWR (Z7B) (Z7B) (Z8B) (Z8B)
AXLES
—Front 4,500 4,500 4,500 4,500
—Rear 6,500 6,500 8,000 8,000
SPRINGS
—Front 4,500 4,500 4,500 4,500
—Rear 6,085 6,085 8,000 8,000
TIRES LT245/75R16E LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TYD) (TVV) (TVV)
GAWR
—Front 4,500 4,500 4,500 4,500
—Rear 6,085 6,085 8,000 8,000
135" W B (56" C A )
PAYLOAD' 3,385 3,090 — —
CURB WEIGHT
—Front 3,590 3,880 _
—Rear 1,825 1,830 — —
—Total 5,415 5,710 — —
139" W B (60" C A )
PAYLOAD 1
— — 5,230 4,940
CURB WEIGHT
—Front _ _ 3,580 3,870
—Rear — 2,190 2,190
—Total — — 5,770 6,060
163" W B (84" C A )
PAYLOAD 1
— — 5,170 4,880
CURB WEIGHT
—Front _ _ 3,640 3,930
—Rear — — 2,190 2,190
—Total — — 5,830 6,120
DRW—-Dual-rear wheel. C A — C a b to axle.
1
J94IN-34
• INTRODUCTION 13
TRAILER TOWING—PICKUP
MAXIMUM
TRUCK MODEL TRAILER
AND MAXIMUM REAR GVWR WEIGHT MAXIMUM
1
TONGUE WEIGHT AXLE PACKAGE RATING GCWR
(Pounds) ENGINE & TRANSMISSION RATIO (Pounds) (Pounds) (Pounds)
1500 4 x 2 3.9L MAGNUM V6
REGULAR CAB Manual 5-speed O . D . 3.21 6,010/6,400 3,600 7,800
2
6.5' BOX 3.55/3.90 6,010/6,400 3,800 8,000
Automatic 4-$peed O . D . 3.55/3.90* 6,010/6,400 3,400 7,600
5.2L M A G N U M V 8
Manual 5-speed O . D . 3.21 6,400 3,500 7,800
3.55 6,400 5,200 9,500
3.90 6,400 5,700 10,000
Automatic 4-speed O . D . H.D. 3.21 6,400 7,700 12,000
3.55/3.90 6,400 7,700 12,000
Tongue Wt. 700 Automatic 4-speed O . D . H.D. 3.21/3.55 6,400 7,700 12,000
3.90 6,400 7,700 12,000
1500 4 x 2 3.9L M A G N U M V 6
REGULAR C A B Manual 5-speed O . D . 3.21 6,010/6,400 3,500 7,800
8.0' BOX 3.55/3.90* 6,010/6,400 3,700 8,000
Automatic 4-speed O . D . 3.55/3.90 2
6,010/6,400 3,300 7,600
Manual 5-speed O . D . 3.21 6,400 3,300 7,800
3.55 6,400 5,000 9,500
3.90 6,400 5,500 10,000
Automatic 4-speed O . D . H.D. 3.21/3.55 6,400 8,000 12,000
3.90 6,400 8,000 12,000
Tongue Wt. 700 Automatic 4-speed O . D . H.D. 3.21/3.55 6,400 7,700 12,000
3.90 6,400 7,700 12,000
2500 4 x 2 5.2L M A G N U M ¥ 8
REGULAR CAB Manual 5-speed H.D. 3.54/4.09 7,500 5,200 10,000
8.0' BOX Automatic 4-speed O . D . H.D. 3.55/3.90 7,500 7,700 12,500
Manual 5-speed H.D. 3.54/4.09 7,500 9,200 14,000
Tongue Wt. 9 0 0 Automatic 4-speed O . D . H.D. 3.55/3.90 7,500 9,200 14,000
3.54/4.09 7,500 9,200 14,000
Maximum Trailer Weight Ratings include cargo and fluids in the trailer and must be decreased by the weight of optional equipment,
trailer hitch, cargo in the truck, and passengers other than the driver.
2
The 3.90 gear ratio is recommendea when towing with the 3.9L V 6 engine.
J94IN-35
14 INTRODUCTION •
MAXIMUM
TRUCK MODEL TRAILER
TONGUE WEIGHT AXLE PACKAGE RATING' GCWR
2 5 0 0 HD 4 x 2 5.9L M A G N U M V 8
REGULAR C A B Manual 5-speed H.D. 3.54/4.09 8,800 9,200 14,000
5.9L 1-6 Cummins D i e s e l
Manual 5-speed O . D . H.D. 3.54 8,800 8,800 14,500
4.10 8,800 12,300 18,000
4.10 8,800 12,300 18,000
8.0L M A G N U M V 1 0
Tongue Wt. 9 0 0 Manual 5-speed O . D . H.D. 3.54/4.10 8,800 13,600 19,000
3500 4 x 2 5.9L M A G N U M V 8
Dual-Rear Wheels 5*91 1-6 Cummins Diesel
4.10 10,500 12,000 18,000
4.10 10,500 12,500 18,000
8.0L MAGNUM V10
Tongue Wt. 1,200 Manual 5-speed O . D . H.D. 3.54/4.10 10,500 13,400 19,000
1500 4 x 4 5.2L M A G N U M V 8
REGULAR CAB Manual 5-speed H.D. 3.55 6,400 4,800 9,500
6.5' BOX 3.90 6,400 4,800 10,000
Tongue Wt. 700 5.9L M A G N U M V 8
1500 4 x 4 5.2L M A G N U M V 8
REGULAR C A B Manual 5-speed O . D . 3.55 6,400 4,700 9,500
8.0' BOX 3.90 6,400 4,700 10,000
Tongue Wt. 700 5.9L M A G N U M V 8
Maximum Trailer Weight Ratings include cargo and fluids in the trailer and must be decreased by the weight of optional equipment,
J94IN-36
• INTRODUCTION 15
MAXIMUM
TRUCK M O D E L TRAILER
2500 4 x 4 5.2L M A G N U M V 8
Manual 5-speed H.D. 3.54/4.09 7,500 8,900 14,000
Tongue Wt. 9 0 0 Automatic 4-speed O . D . H.D. 3.55/3.90 7,500 8,900 14,000
4.09 7,500 8,900 14,000
2 5 0 0 HD 4 x 4 5.9L M A G N U M V 8
8.0' BOX 3.54/4.09 8,800 8,600 14,000
5.9 1-6 Cummins Diesel
4.10 8,800 11,700 18,000
4.10 8,800 11,700 18,000
8.0L M A G N U M V 1 0
Tongue Wt. 9 0 0 Manual 5-speed O . D . H.D. 3.54/4.10 8,800 13,200 19,000
3500 4 x 4 5.9L M A G N U M V 8
REGULAR C A B Manual 5-speed O . D . H.D. 3.54/4.09 10,500 9,400 15,000
Dual-Rear Wheels 5.9L 1-6 Cummins Diesel
4.10 10,500 11,500 18,000
4.10 10,500 11,500 18,000
8.0L M A G N U M V 1 0
Tongue Wt. 1,200 Manual 5-speed O . D . H.D. 3.54/4.10 10,500 13,000 19,000
Automatic 4-speed O.D. H.D. 3.54/4.10 10,500 13,000 19,000
Maximum Trailer Weight Ratings include cargo and fluids in the trailer and must be decreased by the w e i g h t of optional equipment,
t r a i l e r hitch, c a r g o i n t h e t r u c k , a n d p a s s e n g e r s o t h e r t h a n t h e d r i v e r .
J94IN-37
16 INTRODUCTION •
TRAILER TOWING—CHASSIS CAB
MAXIMUM
TRUCK M O D E L TRAILER
2 5 0 0 HD 5.9L M A G N U M V 8 LDC
4x2 Manual 5-speed O.D. M.D. 3.54 8,800 14,000
4.09 8,800 2 14,000
Automatic 4-speed O . D . H.D. 3.54 8,800 14,000
4.09 8,800 14,000
5.9L 1-6 C U M M I N S Diesel
Manual 5-speed O.D. M.D. 3.54 8,800 14,500
4.10 8,800 2 18,000
Automatic 4-speed O.D. H.D. 3.54 8,800 14,500
4.10 8,800 18,000
8.0L M A G N U M V 1 0
Manual 5-speed O . D . H.D. 3.54 8,800 19,000
4.10 8,800 2 19,000
Tongue Wt 9 0 0 Automatic 4-speed O . D . H.D. 3.54 8,800 19,000
4.10 8,800 19,000
3500 5.9L M A G N U M V 8 HDC
4.10 11,000 2 15,000
4.10 11,000 15,000
Manual 5-speed O.D. H.D. 3.54 11,000 14,500
4.10 11,000 2 18,000
4.10 11,000 18,000
8.0L M A G N U M V 1 0
Manual 5-speed O.D. H.D. 3.54 11,000 19,000
4.10 11,000 2 19,000
Tongue Wt 1,200 Automatic 4-speed O . D . H.D. 3.54 11,000 19,000
4.10 11,000 19,000
2 5 0 0 HD 5.9L M A G N U M V 8 HDC
4.09 8,800 2 15,000
4.09 8,800 15,000
4.10 8,800 2 18,000
Automatic 4-speed O.D. H.D. 3.54 8,800 14,500
4.10 8,800 18,000
8.0L M A G N U M V 1 0
4.10 8,800 2 19,000
Tongue Wt 9 0 0 Automatic 4-speed O.D. H.D. 3.54 8,800 19,000
4.10 8,800 19,000
3500 5.9L M A G N U M V 8 HDC
4.10 11,000 2 15,000
4.10 11,000 15,000
5.9L 1-6 C U M M I N S D i e s e l
4.10 11,000 2 18,000
4.10 11,000 18,000
8.0L M A G N U M V 1 0
4.10 11,000 2 19,000
Tongue Wt 1,200 Automatic 4-speed O . D . H.D. 3.54 11,000 19,000
4.10 11,000 19,000
Maximum Trailer Weight Ratings include cargo andfluidsin the trailer and must be decreased by the weight of optional equipment,
2
Due to large variations in the weight of body equipment installed on Chassis C a b models, no maximum trailer weights are shown.
To determine allowable trailer weight, subtract actual truck weight, passenger and cargo weight from the Gross Combination
We«ght Rating. J94IN-38
• INTRODUCTION 17
F A S T E N E R T O R Q U E INFORMATION AND METRIC C O N V E R S I O N

SPECIFICATION NOTATIONS threads. Reduce the torque value by 10 percent when
the bolt threads are lubricated and by 20 percent i f
WARNING: T H E U S E O F I N C O R R E C T ATTACHING new.
HARDWARE CAN R E S U L T IN COMPONENT DAM
A G E AND/OR P E R S O N A L INJURY. B O L T T H R E A D AND GRADE/CLASS
IDENTIFICATION
I t is important to retain the original attaching
hardware for assembly of the components. I f the at THREAD IDENTIFICATION
taching hardware is not reusable, hardware with SAE and metric bolt/nut threads are not the same.
equivalent specifications must be used. The difference is described i n the Thread Notation
chart.
METRIC AND ENGLISH/SAE CONVERSION
The following chart will assist in converting metric GRADE/CLASS IDENTIFICATION
units to equivalent English and SAE units, or vise The SAE bolt strength grades range from grade 2
versa. to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
TORQUE SPECIFICATIONS
line marks on the top of each bolt head (Fig. 1). The
TORQUE CHARTS actual bolt strength grade corresponds to the number
A torque chart for fasteners is provided at the end of line marks plus 2.
of each group (of service information). Refer to the • A grade 2 bolt has no line marks on top of the bolt
Standard Torque Specifications chart to determine head
torque values not listed in the group (Figs. 1 and 2). • A grade 5 bolt has 3 line marks on top of the bolt
It is important to be aware that the torque values head
listed i n the chart are based on clean and dry bolt
CONWERSION FORMULAS AND EQUIWALENT WALUES
Multiply By To G e t Multiply By To G o t
in-lbs x 0.11298 = Newton-Meters (Nhm) Nfn x 8.851 = In-lbs
ft-lbs x 1.3558 = Newton-Meters (N*m) N*m x 0.7376 - ft-lbs
Inches H g (60°F) x 3.377 « Kilopascals (kPaj kPa x 0.2961 = Inches H g

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 - psi
Inches x 25.4 Millimeters (mm) mm x 0.03937 = Inches

Feet x 0.3048 = Meters (M) M x 3.281 - Feet
Yards x 0.9144 » Meters (M) M x 1.0936 - Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 - Miles
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

Feet/Sec. x 0.3048 « Meters/Sec. (M/S) M/S x 3.281 - Feet/Sec.
Kilometers/Hr. x 0.27778 = Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 « Meters/Sec. (M/S) M/S x 2.237 « rnph
C O M M O N METRIC E Q U I V A L E N T S
1 Inch « 25 Millimeters 1 Cubic Inch « 16 Cubic Centimeters

1 Foot = 0.3 M e t e r 1 Cubic Foot - 0.03 Cubic Meter
1 Yard « 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1 . 6 Kilometers
J91IN-1
18 INTRODUCTION
STANDARD TORQUE SPECIFICATIONS

SAE CLASSIFICATION
BOLT TORQUE
GRADE 5 GRADE 8
6IADES
BOLT
SIZE Nitt ff-ibs N*n ft-lbs
(in-lbs) (in-lbs)
MARKINGS F O U N D
1/4-20 11 (95) 14 (125) O N TOP O F BOLT
HEAD INDICATE
1/4-28 11 (95) 17 (150)
GRADE
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25 120° 60°
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 88 65
7/16-20 75 55 95 70
1/2-13 102 75 136 100
1/2-20 115 85 149 110
9/16-12 142 105 183 135
9/16-18 156 115 203 150 GRADE 2 GRADE 5 GRADE 8
5/8-11 203 150 264 195 (SAE) BOLTS—IDENTIFICATION MARKS CORRESPOND
5/8-18 217 160 285 210 T O BOLT STRENGTH—INCREASING NUMBERS
3/4-16 237 175 305 225 REPRESENT INCREASING STRENGTH.
J89IN-11
J89IN-9
Fig. 1 SAE Bolt Grade Identification
THREAD NOTATION—SAE AND METRIC
greater the bolt strength. Some metric nuts are im
INCH METRIC printed with a single-digit strength class on the nut
face.
5/16-18 M 8 X 1.25
THREAD NUMBER THREAD DISTANCE

MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETER I N THREADS I N
IN INCHES PER INCH MILLIMETERS MILLIMETERS
METRIC BOLTS—IDENTIFICATION CLASS NUMBERS

PR606B CORRESPOND T O BOLT STRENGTH— INCREASING NUMBERS
REPRESENT INCREASING STRENGTH. J89IN-10
• A grade 7 bolt has 5 line marks on top of the bolt
head Fig. 2 Metric Bolt Class Identification
• A grade 8 bolt has 6 line marks on top of the bolt
METRIC CONVERSION
head
The most commonly used metric bolt strength Refer to the Metric Conversion chart to convert
classes are 9.8 and 12.9. The metric strength class torque values listed in metric Newton-meters (N-m).
identification number is imprinted on the head of the Also, use the chart to convert between millimeters
bolt (Fig. 2). The higher the class number, the (mm) and inches (in.)
INTRODUCTION 19
M E T R I C CONVERSION
in-lbs to N«m N»m to in-lbs

m- lb N®m in-lb N®m in-lb N®m in-lb N@m in-lb N®m N®m in-lb N®m in-lb N*m in-lb N®m in-lb
2 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2
.2260 42 4.7453 82 9.2646 122 13.7839
.4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4
4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292
.6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552
.8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8
8 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811
1 8.8511 5 44.2556 9 79.6601 13 115.0646 17
10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071
1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2
12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331
1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4
14 1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 84.9708 120.3753
1.6 14.1618 5.6 49.5663 9.6 13.6 17.6
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 86.7410 122.1455
1.8 15.9320 5.8 51.3365 9.8 13.8 17.8
18 2.0337 58 6,550) 98 11.0723 138 15.5917 178 20.1110 53.1067 88.5112 123.9157
2 17.7022 6 10 14 18
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369 54.8770 90.2815 125.6860
2.2 19.4725 6.2 10.2 14.2 18.5
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629 56.6472 92.0517 127.4562
2.4 21.2427 6.4 10.4 14.4 19
24 2.7116 64 7.2m 104 11.7502 144 16.2696 184 20.7889
2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148 60.1876 95.5921 130.9966
2.8 24.7831 6.8 10.8 14.8 20
28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2406 61.9579 97.3624 132.7669
3 26.5534 7 11 15 20.5
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 63.7281 99.1326 134.5371
3.2 3.3236 7.2 11.2 15.2 21
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 65.4983 100.9023 136.3073
3.4 30.0933 7.4 11.4 15.4 22
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 67.2685 102.6730 138.0775
3.6 31.8640 7.6 11.6 15.6 23
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447 69,0388 104.4433 139.8478
3.8 33.6342 7.8 11.8 15.8 24
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 35.4045 70.8090 106.2135 141.6180
4 8 12 16 25
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966
ft-lbs to N«m N«m to ft-lbs

ff-lb N®m ft-lb N®m ft-lb N*m ft lb N@m ft-lb N®m N«m ft-lb N»m ff-lb ft-lb N®m ft-lb N®m ft-lb
1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9688 41 30.2400 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.4801
3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9m 24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4303
7 9.4907 27 36.6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 66.3806
11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6189 92 124.7352 12 8,8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308
15 20.3373 35 47.4m 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.0*31 36 48.8094 56 75.9258 76 103.0422 96 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 56.7923 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 58 42.7786 78 57.5298 98 72.2811
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.7649 59 43.5162 79 58.2674 99 73.0187
20 27.1164 40 54.2327 60 81.3491 80 106.4654 100 135.5820 20 14.7512 40 29.5025 60 44,2537 80 59.0050 100 73.7562
in. to mm mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .00866 .42 .01654 .62 .02441 .82 .mm
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 .02480 .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .03307
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .mm
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .mm .86 .03386
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 mm .87 .03425
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465
.09 2.286 .29 7.m .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .00433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .05953 .95 .03740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .58 .02283 .78 .03071 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.066 ,99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901N-10
LUBRICATION AND MAINTENANCE 0 - 1
LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY 28 JUMP STARTING, TOWING AND HOISTING . . . 12

DIESEL ENGINE 21 MAINTENANCE SCHEDULES DIESEL ENGINE
DRIVETRAIN 25 VEHICLE 9
GASOLINE ENGINE 16 MAINTENANCE SCHEDULES—HEAVY DUTY . . . 6
GENERAL INFORMATION 1 MAINTENANCE SCHEDULES—LIGHT DUTY . . . . 3
G E N E R A L INFORMATION
INDEX
page page
Classification of Lubricants . . . 11 Fuel Usage 1
Components Requiring No Lubrication . . . 22 Parts and Lubricant Recommendations 1
Fluid Capacities 2
PARTS AND LUBRICANT RECOMMENDATIONS ity engine oil. Engine oils also have multiple
When service is required, Chrysler Corporation rec viscosities. These are specified with a dual SAE vis
ommends that only Mopar® brand parts, lubricants cosity grade which indicates the cold-to-hot tempera
and chemicals be used. Mopar provides the best en ture viscosity range (Fig. 1).
gineered products for servicing Chrysler Corporation
vehicles. API SERVICE GRADE
The A P I Service Grade specifies the type of perfor
FUEL USAGE mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con
GASOLINE ENGINES serving engine oils (Fig. 1).
Chrysler Corporation gasoline engines require un Conformance to API Service Grade specifications is
leaded fuel to reduce exhaust emissions. Refer to determined by tests that measure the ability of an oil
Group 14, Fuel Systems for fuel recommendations. to control:
• Engine wear
DIESEL ENGINES
Cummins Turbo Diesel engines require number 2 • Bearing corrosion
diesel fuel for operation in most climates. Refer to • Sludge
Group 14, Fuel Systems for fuel recommendations. • Varnish
• Oil thickening
CLASSIFICATION OF LUBRICANTS • Rust
Lubricating fluids and chassis lubricants are clas • Piston deposits
sified according to standards recommended by the: For maximum engine protection, use API Service
• Society of Automotive Engineers (SAE) Grade SG, SG/CD or SG/CE engine oil.
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI) GEAR LUBRICANTS
A dual grade is also used to specify the viscosity of
ENGINE OIL multi-purpose gear lubricants.
The API grade designation identifies gear lubri
SAE WiSCOSITY GRADE cants i n terms of recommended usage.
An SAE viscosity grade is used to specify the vis
cosity of engine oil. SAE 30 specifies a single viscos
0 - 2 LUBRICATION AND MAINTENANCE •
FLUID CAPACITIES
F u e l Tank
118 inch wheel base ..98 L (26 gal.)
A l l Others..... ...............132 L (35 gal.)
Engine Oil
3.9 L ..3.8 L (4.0 qts.)
5.2 L 3.8 L (4.0 qts.**)
5.9 L Gas.............. ........3.8 L (4.0 qts.**)
5.9 L Diesel 10.4 L (11.0 qts.**)
9400-9 8.0 L 6.6 L (6.6 qts.)
* Add 0.45 L (1/2 qt.) when oil filter is changed.
Fig. 1 SAE Oil Viscosity Grade & API Service Grade ** Add 0.9 L (1 qt.) when oil filter is changed.
CHASSIS AND WHEEL BEARING LUBRICANTS Cooling System
The chassis and wheel bearing lubricants that are 3.9 L 19 L (20.0 qts.)
recommended are identified by the NLGI Certifica 5.2 L 19 L (20.0 qts.)
tion Symbol. The symbol contains a coded designa 5.9 L Gas . 19 L (20.0 qts.)
tion. This identifies the usage and quality of the 5.9 L Diesel 24.5 L (26.0 qts.)
lubricant. 8.0 L . 22.7 L (24.0 qts.)
The letter G within the symbol designates wheel Automatic Transmission
bearing lubricant. The letter L designates chassis lu Estimated service fill
32RH 4.4 L (5.2 qts.)
bricant. When the letters are combined, the lubricant
36RH ..4.4 L (5.3 qts.)
can be used for dual applications. Use only lubricants
42RH 4.4 L (5.2 qts.)
that display the NLGI Certification Symbol (Fig. 2).
46RH... 4.9 L (5.7 qts.)
NATIONAL LUBRICATING
G R E A S E INSTITUTE
NATIONAL LUBRICATING
r NATIONAL LUBRICATING
A 47RH Not available at time of printing.
Overhaul fill capacity with torque converter empty
NLGI NLGI NLGI 32RH.. 8.1 L (8.5 qts.)
AUTOMOTIVE AUTOMOTIVE AUTOMOTIVE
W H E E L BEARING & CHASSIS
LUBRICANT
WHEEL BEARING & CHASSIS
LUBRICANT
W H E E L BEARING & CHASSIS
LUBRICANT
36RH........ 7.9 L (8.3 qts.)
42RH 9.6 L (10.1 qts.)
GC LB GC LB
46RH 10.1 L (10.7 qts.)
WHEEL CHASSIS CHASSIS A N D
46RH 5.9 L or 5.2 L W/plow... .10.3 L (10.9 qts.)
BEARINGS LUBRICATION WHEEL BEARINGS 47RH............................ ..............14.6 L (15.4 qts.)
9200-7 Manual Transmission
Fig. 2 NLGI Symbol NV4500 3.8 L (4.0 qts.)
NV3500 2.0 L (2.1 qts.)
COMPONENTS REQUIRING NO LUBRICATION AX15 .............3.1 L (3.3 qts.)
There are many components that should not be lu Getrag 3.3 L (3.5 qts.)
bricated. The components that should not be lubri Fill to bottom of fill hole.
cated are: Transfer Case
• Air pumps NP231HD .................................1.2 L (2.5 pts.)
• Generator bearings NP241 ...2.2 L (4.7 pts.)
• Brake booster cylinder NP241HD 3.1 L (6.5 pts.)
• Clutch release bearings Fill to bottom of fill hole.
• Distributors Front Axle
• Drive belts 7-1/4 in... ....1.4 L (3.0 pts.)
• Drive belt idler pulleys Spicer 44 2.7 L (5.6 pts.)
• Drive shaft center bearings Spicer 60 3.0 L (6.3 pts.)
• Idler arms R e a r Axle
• Rubber bushings 7- 1/4 i n ....................1.4 L (2.9 pts.)
• Starter motor bearings 8- 1/4 i n 2.1 L (4.4 pts.)
9- 1/4 i n ..2.3 L (4.8 pts.)
• Suspension strut bearings
Dana 60 3.0 L (6.3 pts.)
• Rear spring shackle bolts
Dana 70 3.2 L (6.7 pts.)
• Throttle control cables
Dana 80... ..3.3 L (6.8 pts.)
• Throttle linkage ball joints Power Take Off Adapter
• Water pump bearings NV-021.. ......2.1 L (4.6 pts.)
Power Steering
All.......... ...1.3 L (2.7 pts.)
• LUBRICATION AND MAINTENANCE 0 - 3
M A I N T E N A N C E S C H E D U L E S — L I G H T D U T Y
INTRODUCTION • Lubricate parking brake ratio lever pivot.

Chrysler Corporation has compiled recommended • Inspect brake linings.
lubrication and maintenance schedules and proce • Inspect brake hoses.
dures to help reduce premature wear or failure over • Rotate tires.
a broad range of operating conditions.
30,000 MILES (48 OOO KM) OR AT 24 MONTHS
SERVICE INTERVALS FOR 1500 and 2500 LIGHT • Replace air cleaner filter.
• Replace spark plugs.
DUTY VEHICLES
• Check engine coolant level, hoses and clamps.
AT EACH STOP FOR FUEL • Change engine oil.
• Check engine oil level, add as required. • Replace engine oil filter.
• Check windshield washer solvent and add i f re • Check exhaust system.
quired. • Lubricate steering linkage.
• Inspect front wheel bearings (4x4).
OHCE A MONTH • Lubricate propeller shaft universal joints and slip
• Check tire pressure and look for unusual wear or splines.
damage. • Inspect brake hoses.
• Inspect battery and clean and tighten terminals as • Rotate tires.
required.
• Check fluid levels of coolant reservoir, power steer 37 SOO
9 MILES (60 OOO KM) OR AT 30 MONTHS
ing and transmission and add as needed. • Check engine coolant level, hoses and clamps.
• Check all lights and all other electrical items for • Change engine oil.
correct operation. • Check exhaust system.
• Lubricate steering linkage.
7,500 MILES (12 OOO KM) OR AT 6 MONTHS • Lubricate propeller shaft universal joints and slip
• Check engine coolant level, hoses and clamps. splines.
• Change engine oil. • Drain and refill manual transmission.
• Check exhaust system. • Drain and refill automatic transmission, change
• Lubricate steering linkage. filters and adjust bands.
• Lubricate propeller shaft universal joints and slip • Drain and refill transfer case.
splines. • Inspect brake hoses.
• Inspect brake hoses. • Rotate tires.
• Rotate tires.
45,000 MILES (72 500 KM) OR AT 36 MONTHS
15,000 MILES (24 OOO KM) OR AT 12 MONTHS F l u s h and replace engine coolant at 52,500
• Check engine coolant level, hoses and clamps. miles or 36 months and every 30,000 miles or 24
• Change engine oil. months thereafter.
• Replace engine oil filter. • Check engine coolant level, hoses and clamps.
• Check exhaust system. • Change engine oil.
• Lubricate steering linkage. • Replace engine oil filter.
• Inspect front wheel bearings (4x4). • Check exhaust system.
• Lubricate propeller shaft universal joints and slip • Lubricate steering linkage.
splines. • Lubricate propeller shaft universal joints and slip
• Inspect brake hoses. splines.
• Rotate tires. • Lubricate front suspension ball joints (See Note 1).
• Lubricate manual transmission gearshift control.
22,500 MILES (36 OOO KM) OR AT 18 MONTHS • Lubricate parking brake ratio lever pivot.
• Check engine coolant level, hoses and clamps. • Inspect front wheel bearings.
• Change engine oil. • Inspect brake linings.
• Check exhaust system. • Inspect brake hoses.
• Lubricate steering linkage. • Rotate tires.
• Lubricate propeller shaft universal joints and slip
splines. 52,500 MILES (84 500 KM) OR AT 42 MONTHS
• Lubricate front suspension ball joints (See Note 1). • Flush and replace engine coolant, (if not done at
• Lubricate manual transmission gearshift control. 36 months).
• Inspect front wheel bearings (4x2). • Check engine coolant system hoses and clamps.
• Change engine oil. 82,500 MILES (133 000 KM) OR A T 6 6
• Check exhaust system. MONTHS
• Lubricate steering linkage. • Flush and replace engine coolant, (if not done at
• Lubricate propeller shaft universal joints and slip 60 months).
splines. ' • Check engine coolant system hoses and clamps.
• Inspect brake hoses. • Change engine oil.
• Rotate tires. • Check exhaust system.
60,000 MILES (96 500 KM) OR AT 48 MONTHS • Lubricate propeller shaft universal joints and slip
• Replace air cleaner filter. splines.
• Check PCV valve and replace as necessary (See • Inspect brake hoses.
Note 2). • Rotate tires.
• Replace ignition cables.
• Replace spark plugs. 90,000 MILES (145 OOO KM) OR A T 72
• Check engine coolant level, hoses and clamps. MONTHS
• Change engine oil. • Replace air cleaner filter.
• Replace engine oil filter. • Replace spark plugs.
• Check exhaust system. • Check engine coolant level, hoses and clamps.
• Lubricate steering linkage. • Change engine oil.
• Inspect front wheel bearings (4x4). • Replace engine oil filter.
• Lubricate propeller shaft universal joints and slip • Check exhaust system.
splines. • Lubricate steering linkage.
• Inspect brake hoses. • Lubricate propeller shaft universal joints and slip
• Rotate tires. splines.
67,500 MILES (108 500 KM) OR AT 54 • Lubricate front suspension ball joints (See Note 1)
MONTHS • Lubricate manual transmission gearshift control.
• Check engine coolant level, hoses and clamps. • Lubricate parking brake ratio lever pivot.
• Change engine oil. • Inspect front wheel bearings.
• Check exhaust system. • Inspect brake linings.
• Lubricate steering linkage. • Inspect brake hoses.
• Lubricate propeller shaft universal joints and slip • Rotate tires.
splines.
• Lubricate front suspension ball joints (See Note 1). 97,500 MILES (157 OOO KM) OR A T 78
• Lubricate manual transmission gearshift control. MONTHS
• Inspect front wheel bearings (4x2). • Check engine coolant level, hoses and clamps.
• Lubricate parking brake ratio lever pivot. • Change engine oil.
• Inspect brake linings. • Check exhaust system.
• Inspect brake hoses. • Lubricate steering linkage.
• Rotate tires. • Lubricate propeller shaft universal joints and slip
splines.
75,000 MILES (120 500 KM) OR A T 60 • Inspect brake hoses.
MONTHS • Rotate tires.
Flush and replace engine coolant at 30,000
mile intervals or 24 months after initial change. 105,000 MILES (169 OOO KM) OR A T 84
• Change engine oil. Flush and replace engine coolant at 30,000
• Replace engine oil filter. mile intervals or 24 months after initial change.
• Lubricate propeller shaft universal joints and slip • Replace engine oil filter.
splines. • Check exhaust system.
• Drain and refill manual transmission. • Lubricate steering linkage.
• Drain and refill automatic transmission, change • Inspect front wheel bearings (4x4).
filters and adjust bands. • Lubricate propeller shaft universal joints and slip
• Drain and refill transfer case. splines.
• Inspect brake hoses. • Inspect brake hoses.
• Rotate tires. • Rotate tires.
112,500 MILES (181 OOO KM) OR A T 90 • Replace spark plugs.

MONTHS • Check engine coolant level, hoses and clamps.
• Flush and replace engine coolant, (if not done at • Change engine oil.
84 months). • Replace engine oil filter.
• Check engine coolant system hoses and clamps. • Check exhaust system.
• Change engine oil. • Replace fuel filter.
• Check exhaust system. • Lubricate steering linkage.
• Lubricate steering linkage. • Inspect front wheel bearings (4x4).
• Lubricate propeller shaft universal joints and slip • Lubricate propeller shaft universal joints and slip
splines. splines.
• Lubricate front suspension ball joints (See Note 1). • Inspect brake hoses.
• Lubricate manual transmission gearshift control.
• Rotate tires.
• Inspect front wheel bearings (4x2).
Inspection and service should also be per
• Lubricate parking brake ratio lever pivot.
formed anytime a malfunction is observed or
• Inspect brake linings.
• Inspect brake hoses. suspected.
• Rotate tires. NOTE 1: Original equipment ball joints are
permanently lubricated. I f they become dam
120,000 MILES (193 OOO KM) OR A T 96 aged and require replacement, the replacement
MONTHS seals should be serviced at these intervals.
• Replace air cleaner filter. N O T E 2: This maintenance is recommended
• PCV Valve, check and replace as necessary (See by Chrysler to the owner but is not required to
Note 2). maintain the warranty on the P C V valve.
• Replace ignition cables.
0 - e LUBRICATION AND MAINTENANCE •
MAINTENANCE S C H E D U L E S — H E A V Y D U T Y
SERVICE INTERVALS FOR 2500 AND 3500 HEAVY • Lubricate front suspension ball joints (See Note 1).
DUTY VEHICLES • Lubricate front axle drive joint and pivot bearings.
• Inspect brake hoses.
AT EACH STOP FOR FUEL • Rotate tires.
• Check engine oil level, add as required.
• Check windshield washer solvent and add i f re 24,000 MILES (38 OOO K M ) OR A T 24 MONTHS
quired. • Replace air cleaner filter and air pump filter.
• Clean crankcase inlet air filter.
ONCE A MONTH • Check engine coolant level, hoses and clamps.
• Check tire pressure and look for unusual wear or • Change engine oil.
damage. • Replace engine oil filter.
• Inspect battery and clean and tighten terminals as • Check exhaust system.
required. • Lubricate steering linkage.
• Check fluid levels of coolant reservoir, power steer • Lubricate propeller shaft universal joints and slip
ing and transmission and add as needed. splines.
• Check all lights and all other electrical items for Lubricate front suspension ball joints (See Note 1).
correct operation. Lubricate front axle drive joint and pivot bearings.
• Check rubber seals on each side of the radiator for Inspect brake hoses.
proper fit. Inspect front wheel bearings.
Inspect brake linings.
6 000
9 MILES (9 600 K M ) OR A T 6 MONTHS Inspect cooling system.
• Check engine coolant level, hoses and clamps. Drain and refill automatic transmission, change
• Change engine oil. filter and adjust bands.
• Replace engine oil filter (8.0L Only). Rotate tires.
• Check exhaust system.
• Lubricate steering linkage. 30,000 MILES (48 OOO K M ) OR A T 30 MONTHS
• Lubricate propeller shaft universal joints and slip Replace spark plugs.
splines. Check engine coolant level, hoses and clamps.
• Lubricate front suspension ball joints (See Note 1). Change engine oil.
• Lubricate front axle drive joint and pivot bearings.
Replace engine oil filter (8.0L Only).
Check exhaust system.
• Rotate tires.
Lubricate steering linkage.
12,000 MILES (19 OOO K M ) OR A T 12 MONTHS Lubricate propeller shaft universal joints and slip
9
Check engine coolant level, hoses and clamps. plines.
• Change engine oil. Lubricate front suspension ball joints (See Note 1).
• Replace engine oil filter. Lubricate front axle drive joint and pivot bearings.
® Check exhaust system. Inspect brake hoses.
• Lubricate steering linkage. Rotate tires.
® Lubricate propeller shaft universal joints and slip
splines. 36,000 MILES (58 OOO K M ) OR A T 36 MONTHS
• Lubricate front suspension ball joints (See Note 1). Check engine coolant level, hoses and clamps.
• Lubricate front axle drive joint and pivot bearings. Replace engine oil filter.
• Inspect brake hoses. Change engine oil.
• Inspect front wheel bearings (4 x 4). Check exhaust system.
• Inspect cooling system. Lubricate steering linkage.
• Rotate tires. Lubricate propeller shaft universal joints and slip
splines.
18,000 MILES (29 OOO K M ) OR A T 18 MONTHS Lubricate front suspension ball joints (See Note 1).
• Check engine coolant level, hoses and clamps. Lubricate front axle drive joint and pivot bearings.
® Change engine oil. Inspect brake hoses.
• Replace engine oil filter (8.0L Only). Inspect front wheel bearings (4 x 4).
• Check exhaust system. Inspect cooling system.
• Lubricate steering linkage. Drain and refill manual transmission.
• Lubricate propeller shaft universal joints and slip Drain and refill transfer case.
splines. Rotate tires.
• LUBRICATION AND MAINTENANCE 0-7
42,000 MILES (67 OOO KM) OR A T 42 MONTHS • Lubricate steering linkage.

• Check engine coolant system hoses and clamps. • Lubricate propeller shaft universal joints and slip
• Change engine oil. splines.
• Replace engine oil filter (8.0L Only). • Lubricate front suspension ball joints (See Note 1).
• Check exhaust system. • Lubricate front axle drive joint and pivot bearings.
• Lubricate steering linkage. • Inspect brake hoses.
• Lubricate propeller shaft universal joints and slip • Inspect front wheel bearings (4 x 4).
splines. • Inspect cooling system.
• Lubricate front suspension ball joints (See Note 1). • Rotate tires.
• Inspect brake hoses. 66 0OO MILES
f (106 000 KM) OR AT 66
• Rotate tires. MONTHS
• Check engine coolant system hoses and clamps.
46,000 MILES (77 OOO KM) OR A T 48 MONTHS • Change engine oil.
• Replace air cleaner filter and air pump filter. • Replace engine oil filter (8.0L Only).
• Clean crankcase inlet air filter. • Check exhaust system.
• Check engine coolant level, hoses and clamps. • Lubricate steering linkage.
• Change engine oil. • Lubricate propeller shaft universal joints and slip
• Replace engine oil filter. splines.
• Check exhaust system. • Lubricate front suspension ball joints (See Note 1).
• Lubricate steering linkage. • Lubricate front axle drive joint and pivot bearings.
splines.
• Rotate tires.
• Lubricate front suspension ball joints (See Note 1).
• Lubricate front axle drive joint and pivot bearings. 72,000 MILES (116 000 KM) OR A T 72
• Inspect brake hoses. MONTHS
• Inspect front wheel bearings.
• Replace air cleaner filter and air pump filter.
• Inspect brake linings.
• Clean crankcase inlet air filter.
• Inspect cooling system.
• Drain and refill automatic transmission change fil
ter and adjust bands. • Change engine oil.
• Rotate tires. • Replace engine oil filter.
84,000 MILES (85 OOO KM) OR A T 54 MONTHS • Lubricate steering linkage.
• Flush and replace engine coolant. • Lubricate propeller shaft universal joints and slip
• Check engine coolant level, hoses and clamps. splines.
• Change engine oil. • Lubricate front suspension ball joints (See Note 1).
• Replace engine oil filter (8.0L Only). • Lubricate front axle drive joint and pivot bearings.
• Check exhaust system. • Inspect brake hoses.
• Lubricate steering linkage. • Inspect front wheel bearings (4 x 4).
• Lubricate propeller shaft universal joints and slip • Inspect cooling system.
splines. • Rotate tires.
• Lubricate front axle drive joint and pivot bearings. 78,000 MILES (125 000 KM) OR A T 78
• Inspect brake hoses. MONTHS
• Rotate tires. • Check engine coolant level, hoses and clamps.
• Change engine oil.
60,000 MILES (96 500 KM) OR A T 60 MONTHS • Replace engine oil filter (8.0L Only).
• Replace ignition cables. • Check exhaust system.
• Replace PCV valve. • Lubricate steering linkage.
• Replace spark plugs. • Lubricate propeller shaft universal joints and slip
• Clean EGR passages. splines.
• Replace EGR valve. • Lubricate front suspension ball joints (See Note 1).
• Check engine coolant level, hoses and clamps. • Lubricate front axle drive joint and pivot bearings.
• Change engine oil. • Inspect brake hoses.
• Replace engine oil filter. • Rotate tires.
• Check exhaust system. At 82,500 miles (133 000 km) the Oxygen Sen
• Replace battery. sor on the 5.9L engine must be replaced.
0 - 8 LUBRICATION AND MAINTENANCE #
84,000 MILES (135 OOO KM) OR AT 84 • Lubricate front axle drive joint and pivot bearings.
MONTHS • Inspect brake hoses.
• Check engine coolant level, hoses and clamps. • Inspect front wheel bearings (4 x 4).
• Change engine oil. • Inspect cooling system.
• Replace engine oil filter. • Rotate tires.
• Lubricate steering linkage. 102,000 MILES (164 OOO KM) OR AT 102
• Lubricate propeller shaft universal joints and slip MONTHS
splines. • Check engine coolant level, hoses and clamps.
• Lubricate front suspension ball joints (See Note 1). • Change engine oil.
• Lubricate front axle drive joint and pivot bearings. • Replace engine oil filter (8.0L Only).
• Inspect brake hoses. • Check exhaust system.
• Inspect front wheel bearings (4 x 4). • Lubricate steering linkage.
• Inspect cooling system. • Lubricate propeller shaft universal joints and slip
90,000 MILES (145 OOO KM) OR AT 90
MONTHS
• Replace air cleaner filter and air pump filter. • Inspect brake hoses.
• Replace spark plugs. • Rotate tires.
• Check engine coolant system hoses and clamps.
108,000 MILES (174 OOO KM) OR AT 108
• Change engine oil.
MONTHS
• Replace engine oil filter (8.0L Only).
• Lubricate propeller shaft universal joints and slip • Replace engine oil filter.
splines. • Check exhaust system.
• Lubricate front suspension ball joints (See Note 1). • Lubricate steering linkage.
• Lubricate front axle drive joint and pivot bearings. • Lubricate propeller shaft universal joints and slip
• Inspect brake hoses. splines.
• Rotate tires. • Lubricate front suspension ball joints (See Note 1).
96,000 MILES (154 OOO KM) OR AT 96 • Inspect brake hoses.
MONTHS • Inspect front wheel bearings (4 x 4).
• Clean crankcase inlet air filter. • Inspect cooling system.
• Check engine coolant level, hoses and clamps. • Rotate tires.
• Change engine oil. Inspection and service should also be per
• Replace engine oil filter. formed anytime a malfunction is observed or
• Check exhaust system. suspected.
• Lubricate steering linkage. N O T E 1: Original equipment ball joints are
• Lubricate propeller shaft universal joints and slip permanently lubricated. I f they become dam
splines. aged and require replacement, the replacement
• Lubricate front suspension ball joints (See Note 1). seals should be serviced at these intervals.
• LUBRICATION AND MAINTENANCE 0 -9
MAINTENANCE SCHEDULES DIESEL ENGINE VEHICLE
SEVERE SERVICE ' 24,000 MILES (38 OOO KM) OR AT 24 MONTHS

I f your vehicle is subjected to the conditions listed • Change engine oil and replace filter.
below, maintenance should be performed twice as fre • Replace engine coolant.
quently. Engine oil and oil filter should be changed • Replace fuel filter.
every 5,000 miles (8 000 km) or 200 hours of opera • Replace automatic transmission fluid and filter,
tion, whichever comes first. adjust bands.
• Vehicle is used for extensive trailer towing. • Adjust valve lash clearance.
• Operating under heavy load. • Inspect drive belts.
• Inspect fan hub.
A T EACH STOP FOR FUEL • Inspect damper.
• Check engine oil level, add as required. • Inspect front wheel bearings.
• Check windshield washer solvent and add i f re • Inspect and clean water pump weep hole.
quired. • Lubricate steering linkage.
ONCE A MONTH splines.
• Check tire pressure and look for unusual wear or • Lubricate front suspension ball joints.
damage. • Lubricate manual transmission gearshift control.
• Inspect battery and clean and tighten terminals as • Inspect brake linings.
required. • Inspect brake hoses.
• Check fluid levels of coolant reservoir, power steer • Rotate tires.
ing and transmission and add as needed.
• Check all lights and all other electrical items for 30,000 MILES (48 OOO KM) OR A T 30 MONTHS
correct operation. • Change engine oil and replace filter.
6,000 MILES (9 600 KM) OR AT 6 MONTHS
• Inspect front wheel bearings.
Change engine oil and replace filter.
Check engine coolant level, hoses and clamps.
Lubricate steering linkage. • Lubricate propeller shaft universal joints and slip
Lubricate propeller shaft universal joints and slip splines.
plines. • Inspect brake hoses.
Inspect brake hoses. • Rotate tires.
Rotate tires.
36,000 MILES (58 OOO KM) OR A T 36 MONTHS
12,000 MILES (19 OOO KM) OR AT 12 MONTHS • Change engine oil and replace filter.
Change engine oil and replace filter. • Check engine coolant level, hoses and clamps.
Check engine coolant level, hoses and clamps. • Replace fuel filter.
Replace fuel filter. • Replace automatic transmission fluid and filter,
Replace automatic transmission fluid and filter, adjust bands.
adjust bands. • Drain and refill manual transmission.
Inspect drive belts. • Drain and refill transfer case.
Inspect front wheel bearings. • Inspect drive belts.
Lubricate steering linkage. • Inspect and clean water pump weep hole.
Lubricate propeller shaft universal joints and slip • Lubricate steering linkage.
splines. • Lubricate propeller shaft universal joints and slip
Inspect brake hoses. splines.
Inspect and clean water pump weep hole. • Inspect brake hoses.
Rotate tires. • Rotate tires. .
18,000 MILES (29 OOO KM) OR AT 18 MONTHS 42,000 MILES (67 OOO KM) OR A T 42 MONTHS
Change engine oil and replace filter. • Change engine oil and replace filter.
Check engine coolant level, hoses and clamps. • Check engine coolant level, hoses and clamps.
Lubricate steering linkage. • Lubricate steering linkage.
Lubricate propeller shaft universal joints and slip • Lubricate propeller shaft universal joints and slip
splines. splines.
Inspect brake hoses. • Inspect brake hoses.
Rotate tires. • Rotate tires.
0 - 10 LUBRICATION AND MAINTENANCE
48,000 MILES (77 OOO KM) OR AT 48 MONTHS • Replace fuel filter.

• Change engine oil and replace filter. • Replace automatic transmission fluid and filter,
• Replace engine coolant. adjust bands.
• Replace fuel filter. • Drain and refill manual transmission.
• Replace automatic transmission fluid and filter, • Drain and refill transfer case.
adjust bands. • Adjust valve lash clearance.
• Adjust valve lash clearance. • Inspect drive belts.
• Inspect drive belts. • Inspect fan hub.
• Inspect fan hub. • Inspect damper.
• Inspect damper. • Inspect front wheel bearings.
• Inspect front wheel bearings. • Inspect and clean water pump weep hole.
• Inspect and clean water pump weep hole. • Lubricate steering linkage.
• Lubricate steering linkage. • Lubricate propeller shaft universal joints and slip
• Lubricate propeller shaft universal joints and slip splines.
splines. • Lubricate manual transmission gearshift control.
• Lubricate front suspension ball joints. • Inspect brake linings.
• Lubricate manual transmission gearshift control. • Inspect brake hoses.
• Inspect brake linings. • Rotate tires.
• Rotate tires. 78,000 MILES (125 OOO KM) OR AT 78
MONTHS
54,000 MILES (87 OOO KM) OR AT 54 MONTHS • Change engine oil and replace filter.
• Change engine oil and replace filter. • Check engine coolant level, hoses and clamps.
• Check engine coolant level, hoses and clamps. • Lubricate steering linkage.
• Lubricate steering linkage. • Lubricate propeller shaft universal joints and slip
splines.
splines.
• Rotate tires.
• Rotate tires.
84,000 MILES (135 OOO KM) OR AT 84
60,000 MILES (96 OOO KM) OR AT 60 MONTHS
MONTHS
• Change engine oil and replace filter.
• Check engine coolant level, hoses and clamps. • Change engine oil and replace filter.
• Replace fuel filter. • Check engine coolant level, hoses and clamps.
• Replace automatic transmission fluid and filter, • Replace fuel filter.
adjust bands. • Replace automatic transmission fluid and filter,
• Inspect drive belts. adjust bands.
• Inspect front wheel bearings. • Inspect drive belts.
• inspect and clean water pump weep hole. • Inspect front wheel bearings.
• Lubricate propeller shaft universal joints and slip • Inspect and clean water pump weep hole.
splines. • Lubricate steering linkage.
• Inspect brake hoses. • Lubricate propeller shaft universal joints and slip
66,000 MILES (106 OOO KM) OR AT 66 • Rotate tires.
MONTHS
• Change engine oil and replace filter. 90,000 MILES (145 OOO KM) OR AT 90
• Lubricate steering linkage. • Change engine oil and replace filter.
• Lubricate propeller shaft universal joints and slip • Check engine coolant level, hoses and clamps.
splines. • Inspect front wheel bearings.
• Inspect brake hoses. • Lubricate steering linkage.
• Rotate tires. • Lubricate propeller shaft universal joints and slip
72,000 MILES (116 OOO KM) OR AT 72 splines.
MONTHS • Inspect brake hoses.
• Change engine oil and replace filter. • Rotate tires.
• Replace engine coolant.
96 O0O MILES
f (154 OOO KM) OR AT 96 • Inspect front wheel bearings.
MONTHS • Inspect and clean water pump weep hole.
• Change engine oil and replace filter. • Lubricate steering linkage.
• Replace engine coolant. • Lubricate propeller shaft universal joints and slip
• Replace fuel filter. splines.
• Replace automatic transmission fluid and filter, • Lubricate front suspension ball joints.
adjust bands. • Lubricate manual transmission gearshift control.
• Adjust valve lash clearance. • Inspect brake linings.
• Inspect drive belts. • Inspect brake hoses.
• Inspect fan hub. • Rotate tires.
• Inspect damper.
J U M P STARTING, TOWING A N D HOISTING
INDEX
page page
Four-Wheel-Drive Vehicle Towing 14 Towing Recommendations 13
Ground Clearance and Ramp Angle 14 Towing When Keys Are Not Available 14
Hoisting Recommendations 13 Two-Wheel-Drive Vehicle Towing 14
Jump Starting 12
JUMP STARTING (2) When using another vehicle as a booster

source, turn off all accessories, place gear selector i n
WARNING: R E V I E W A L L S A F E T Y P R E C A U T I O N S park or neutral, set park brake and operate engine at
AND WARNINGS IN G R O U P 8A, BATTERY/START 1200 rpm.
ING/CHARGING S Y S T E M S DIAGNOSTICS. (3) On disabled vehicle, place gear selector in park
DO NOT JUMP S T A R T A F R O Z E N BATTERY, P E R or neutral and set park brake. Turn off all accesso
SONAL INJURY CAN RESULT. ries.
DO NOT JUMP START WHEN MAINTENANCE (4) Connect jumper cables to booster battery. RED
F R E E B A T T E R Y INDICATOR DOT IS Y E L L O W OR clamp to positive terminal (+). BLACK clamp to neg
BRIGHT C O L O R . ative terminal (-). DO NOT allow clamps at opposite
DO NOT JUMP START A V E H I C L E WHEN T H E end of cables to touch, electrical arc will result (Fig.
BATTERY FLUID IS B E L O W T H E TOP O F L E A D 3). Review all warnings i n this procedure.
PLATES. (5) On disabled vehicle, connect RED jumper cable
DO NOT A L L O W J U M P E R C A B L E C L A M P S TO clamp to positive (+) terminal. Connect BLACK
TOUCH E A C H O T H E R WHEN C O N N E C T E D TO A jumper cable clamp to engine ground as close to the
BOOSTER SOURCE. ground cable attaching point as possible (Fig. 3).
DO NOT U S E O P E N F L A M E NEAR BATTERY.
R E M O V E METALLIC J E W E L R Y WORN ON HANDS
OR W R I S T S T O AVOID INJURY B Y A C C I D E N T A L
ARCING O F B A T T E R Y CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING D E
V I C E , DO NOT A L L O W B A T T E R Y V O L T A G E TO E X
C E E D 16 V O L T S . R E F E R TO INSTRUCTIONS
PROVIDED WITH D E V I C E BEING U S E D .
CAUTION: When using another vehicle a s a

booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO J U M P S T A R T A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually in
spect engine compartment for:
Fig. 3 Jumper Cable Clamp Connections
• Battery cable clamp condition, clean i f necessary.
• Frozen battery. CAUTION: Do not crank starter motor on disabled
• Yellow or bright color test indicator, i f equipped. vehicle for more than 15 s e c o n d s , starter will over
• Low battery fluid level. heat ancf could fail.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct i f necessary. (6) Allow battery i n disabled vehicle to charge to at
least 12.4 volts (75% charge) before attempting to
CAUTION: If the c a u s e of starting problem on dis start engine. I f engine does not start within 15 sec
abled vehicle is severe, damage to booster vehicle onds, stop cranking engine and allow starter to cool
charging system can result. (15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS: • A n axle tube

• Disconnect BLACK cable clamp from engine • A body side sill
ground on disabled vehicle. • A steering linkage component
• When using a Booster vehicle, disconnect BLACK • A drive shaft
cable clamp from battery negative terminal. Discon • The engine or transmission oil pan
nect RED cable clamp from battery positive terminal. • The fuel tank
• Disconnect RED cable clamp from battery positive • A front suspension arm
terminal on. Use the correct frame rail lifting locations
only (Fig. 4).
PORTABLE STARTING UNIT
There are many types of portable starting units HOIST
available for starting engines. Follow the manufac A vehicle can be lifted with:
turer's instructions and observe the listed precau • A single-post, frame-contact hoist
tions when involved i n any engine starting • A twin-post, chassis hoist
procedure. • A ramp-type, drive-on hoist
When a frame-contact type hoist is used, ver
HOISTING RECOMMENDATIONS ify that the lifting pads are positioned properly
Refer to the Owner's Manual for emergency vehicle (Fig, 4).
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
FLOOR J A C K POINTS PROVIDED ARE FOR A COMPLETE VEHI
When properly positioned, a floor jack can be used CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO
to lift a vehicle (Fig. 4). Support the vehicle i n the NENT IS REMOVED FROM A VEHICLE, THE
raised position with jack stands at the front and rear CENTER OF GRAVITY IS ALTERED MAKING SOME
ends of the frame rails. HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING DE
VICE WHEN THESE CONDITIONS EXIST.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all vehicles.
When towing a 4WD vehicle using a wheel-lift towing
device, use a tow dolly under the opposite end of the
vehicle. A vehicle with flat-bed device can also be
used to transport a disabled vehicle.
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow
ing method.
SAFETY PRECAUTIONS
The following safety precautions must be ob
served when towing a vehicle.
• Secure loose and protruding parts.
• Always use a safety chain system that is indepen
dent of the lifting and towing equipment.
• Do not allow towing equipment to contact the dis
abled vehicle's fuel tank.
• Do not allow anyone under the disabled vehicle
while i t is lifted by the towing device.
• Do not allow passengers to ride i n a vehicle being
CORRECT VEHICLE LIFTING LOCATIONS J9400-17 towed.
• Always observe state and local laws regarding tow
Fig. 4 Vehicle Lifting Locations ing regulations.
CAUTION: Do not lift vehicle with a floor jack posi • Do not tow a vehicle in a manner that could jeop
tioned under: ardize the safety of the operator, pedestrians or other
motorists.
\
0-14 LUBRICATION AND MAINTENANCE •
• Do not attach tow chains, T-hooks, J-hooks, or a TOWING'REAR END LIFTED
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole. CAUTION: Do not u s e steering column lock to s e
• Do -not tow a heavily loaded vehicle. Damage to cure steering wheel during towing operation.
the cab, cargo box or frame may result. Use a flatbed
device to transport a loaded vehicle. • Unlock steering column and secure steering wheel
in straight ahead position with a clamp device de
GROUND CLEARANCE AND RAMP ANGLE signed for towing.
• Verify that steering components are i n good condi
GROUND CLEARANCE tion.
CAUTION: If vehicle is towed with wheels removed, TOWING-FRONT END LIFTED
install lug nuts to retain brake drums or rotors. I f a two-wheel-drive vehicle cannot be towed with
the rear wheels lifted, i t can be towed with the front
A towed vehicle should be raised until lifted wheels wheels lifted with the transmission in the neutral po
are a minimum 100 mm (4 in) from the ground. Be
sition.
sure there is adequate ground clearance at the oppo
site end of the vehicle, especially when towing over
FOUR-WHEEL-DRIVE VEHICLE TOWING
rough terrain or steep rises in the road. I f necessary,
remove the wheels from the lifted end of the vehicle Chrysler Corporation recommends that a vehicle be
and lower the vehicle closer to the ground, to in transported on a flat-bed device. A Wheel-lift or
crease the ground clearance at the opposite end of Sling-type device can be used provided all the wheels
the vehicle. Install lug nuts on wheel attaching studs are lifted off the ground using tow dollies.
to retain brake drums or rotors.
TOWING WHEN KEYS ARE NOT AVAILABLE
FLAT-BED TOWING RAMP ANGLE When the vehicle is locked and keys are not avail
I f a vehicle with flat-bed towing equipment is used, able, use a flat bed hauler. A Wheel-lift or Sling-type
the approach ramp angle should not exceed 15 de device can be used provided all the wheels are lifted
grees. off the ground using tow dollies (Fig. 5).
TWO-WHEEL-DRIVE VEHICLE TOWING

Chrysler Corporation recommends that a vehicle be
towed with the rear end lifted, whenever possible
(Fig. 5).
— C O N D I T I O N TRANSMISSION
PARKING
SHIFT LEVER
BRAKE
T O W I N G METHOD POSITION
© FLAT BED
APPLIED NEUTRAL POSITION
@ SLING TYPE/WHEEL LIFT

T O W TRUCK W I T H DOLLIES
APPLIED NEUTRAL POSITION
© SLING TYPE/TOW TRUCK
NEUTRAL POSITION
RELEASED (STEERING WHEEL
SECURED)
® SLING TYPE/WHEEL LIFT

RELEASED NEUTRAL POSITION
TOW T R U C K *
* D O N O T T O W THE VEHICLE AT A SPEED FASTER T H A N

45 K M / H (30 MPH) OR A DISTANCE GREATER T H A N 24 K M
(15 MILES).
CONDITION TRANSMISSION TRANSFER CASE

4WD PARKING SHIFT LEVER
SHIFT LEVER
BRAKE
T O W I N G METHOD ^ POSITION POSITION
© FLAT BED
APPLIED NEUTRAL POSITION NA
© SLING TYPE/WHEEL LIFT

TOW TRUCK W I T H DOLLIES
PARK (AUTO TRANS)
APPLIED 3RD OR 4TH GEAR H I G H POSITION
( M A N U A L TRANS)
J9400-18
Fig. 5 Towing
GASOLINE ENGINE
INDEX
page page
Engine Oil Filter 17 Engine Cooling System 18
Battery . 20 Engine Oil 16
Break-In Period 16 Fuel Filter 19
Crankcase Ventilation System 19 Ignition Cables, Distributor Cap, and Rotor 19
Drive Belts 19 Rubber and Plastic Component Inspection . . . . . . . 20
Emission Control System 20 Spark Plugs 19
Engine Air Cleaner 18
ENGINE OIL and fuel economy ratings of the lubricant i t contains.

Use 10w-30 ENERGY CONSERVING I I motor oil
WARNING: NEW OR USED ENGINE OIL CAN BE IR with API SERVICE SG or SG/CD classification.
RITATING TO T H E SKIN. AVOID P R O L O N G E D OR
RECOMMENDED WISCOSITW GRADES
R E P E A T E D SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN U S E D ENGINE OIL, C A U S E D BY
INTERNAL COMBUSTION, CAN B E HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH E X P O S E D
SKIN WITH SOAP AND WATER.
10W-30
>
DO NOT WASH SKIN WITH G A S O L I N E , D I E S E L <I I
5W-30
I I I
F U E L , THINNER, OR S O L V E N T S , HEALTH P R O B
F -20 0 10 20 32 60 80 100
L E M S CAN RESULT.
DO NOT P O L L U T E , D I S P O S E O F U S E D ENGINE C -29 -18 -12 -7 0 16 27 38
OIL P R O P E R L Y . CONTACT YOUR D E A L E R OR GOV ANTICIPATED TEMPERATURE RANGE

J 9 4 0 0 1 9
BEFORE NEXT OIL CHANGE "
ERNMENT A G E N C Y FOR LOCATION O F C O L L E C
TION C E N T E R IN Y O U R A R E A . .
BREAK-IN PERIOD
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
Chrysler Corporation vehicle does not require an

extended break-in period. Driving speeds of not over
80-90 km/h (50-55 mph) for the first 100 km (60 9400-9
miles) is recommended. Hard acceleration and high
engine rpm i n lower gears should be avoided. Fig. 1 API Symbol
SELECTING ENGINE OIL ENGINE OIL ADDITIVES

Chrysler Corporation recommends that Mopar En
CAUTION: Do not use non-detergent or straight gine Oil Supplement or equivalent be used when fric
mineral oil when adding or changing crankcase lu tion and corrosion reducing materials added to the
bricant. Engine failure can result. crankcase lubricant is desired.
The factory fill engine oil is a high quality, energy CRANKCASE OIL LEVEL INSPECTION
conserving, crankcase lubricant. The Recommended
SAE Viscosity Grades chart defines the viscosity CAUTION: Do not overfill crankcase with engine oil,
grades that must be used based on temperature i n oil foaming and oil pressure loss can result.
the region where vehicle is operated.
Chrysler Corporation recommends that Mopar mo Inspect engine oil level approximately every 800 k i
tor oil, or equivalent, be used when adding or chang lometers (500 miles). Position vehicle on level sur-
ing crankcase lubricant. The API symbol (Fig. 1) on
the container indicates the viscosity grade, quality
• LUBRICATION AND MAINTENANCE i - 17
face. With engine OFF, allow enough time for oil to OIL FILTER REMOVAL
settle to bottom of crankcase, remove engine oil level (1) Position a drain pan under the oil filter.
indicator (dipstick) and wipe clean. Install dipstick (2) Using a suitable oil filter wrench (Fig. 3) loosen
and verify it is seated i n the tube. Remove dipstick, filter.
with handle held above tip, take oil level reading (3) When filter separates from adapter nipple, tip
(Fig. 2). Add oil only i f level is below M I N or ADD gasket end upward to minimize oil spill. Remove fil
mark on dipstick. ter from vehicle.
(4) With a wiping cloth, clean the gasket sealing
surface (Fig. 4) of oil and grime.
OIL FILTER INSTALLATION

(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, tighten filter one
full turn. If necessary use a filter wrench, do not over
Fig. 2 Oil Level Indicator Dipstick—Typical tighten.
ENGINE OIL CHANGE (3) Add oil, verify crankcase oil level and start en
Change engine oil at mileage and time intervals gine. Inspect for oil leaks.
described in Maintenance Schedules.
TO CHANiE ENOINE OIL

(1) Position the vehicle on a level surface.
(2) Hoist and support vehicle on safety stands. Re
fer to Hoisting and Jacking Recommendations i n this
group.
(3) Place a suitable drain pan under crankcase
drain.
(4) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket i f damaged. Fig. 3 Remove Oil Filter
(5) Install drain plug i n crankcase.
(6) Lower vehicle and fill crankcase with specified
type and amount of engine oil described i n this sec
tion.
(7) Start engine and inspect for leaks.
(8) Stop engine and inspect oil level.
ENGINE OIL FILTER

SELECTING OIL FILTER
Chrysler Corporation recommends a Mopar or
equivalent oil filter be used when replacement is re
quired. A replacement filter must be designed to
Fig. 4 install Oil Filter
withstand 1756 kPa (256 psi) of internal pressure.
ENGINE COOLING SYSTEM taminated, rusty or freeze protection is inadequate.

To properly test cooling system, see Group 7, Cooling
WARNINGS AND PRECAUTIONS System.
The cooling system factory fill is a mixture of 50%
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL Glycol based antifreeze and 50% water. Using a suit
BASE COOLANT A N D IS HARMFUL IF SWAL able hydrometer, measure antifreeze concentration i n
LOWED OR INHALED., IF SWALLOWED, DRINK the radiator when the engine is cool. I f the cooling
TWO GLASSES OF WATER AND INDUCE VOMIT system has recently been serviced, allow coolant to
ING. IF INHALED, MOVE TO FRESH AIR AREA. circulate for at least 20 minutes before taking hy
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT drometer reading. Properly mixed coolant will protect
STORE IN OPEN OR UNMARKED CONTAINERS. the cooling system to -37°C (-35°F). I f the freeze pro
WASH SKIN AND CLOTHING THOROUGHLY AFTER tection is above -28°C (-20°F), drain enough coolant
COMING IN CONTACT WITH ETHYLENE GLYCOL. from the cooling system to allow room to add anti
KEEP OUT OF REACH OF CHILDREN. freeze to achieve adequate protection. A mix table on
DISPOSE OF GLYCOL BASE COOLANT PROP the coolant container indicates the amount of anti
ERLY, CONTACT YOUR DEALER OR GOVERNMENT freeze required to winterize the cooling system based
AGENCY FOR LOCATION OF COLLECTION CENTER on the capacity, see Capacity Chart i n General Infor
IN YOUR AREA. mation section of this group.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PER SELECTING ANTIFREEZE
SONAL INJURY CAN RESULT. Chrysler Corporation recommends Mopar Anti
AVOID RADIATOR COOLING FAN WHEN ENGINE freeze/Summer Coolant, or equivalent be used to win
COMPARTMENT RELATED SERVICE IS PER terize and protect cooling system.
FORMED, PERSONAL INJURY CAN RESULT.
RADIATOR C A P
The radiator cap must be secure to provide proper
CAUTION: Do n o t use s t r a i g h t antifreeze as e n g i n e pressure, release and coolant recovery. Inspect and
coolant, inadequate e n g i n e r u n n i n g temperatures test radiator cap when cooling system service is per
can result. formed or when problem is suspected.
Do not operate v e h i c l e w i t h o u t proper c o n c e n t r a
t i o n of r e c o m m e n d e d ethylene g l y c o l coolant, h i g h COOLING SYSTEM SERVICE
r u n n i n g temperatures a n d c o o l i n g s y s t e m corrosion The cooling system should be drained, flushed and
can result. filled with the proper coolant mixture at the inter
vals described i n the Lubrication and Maintenance
The engine cooling system will develop internal Schedules. Refer to General Information section of
pressure of 97 to 123 kPa (14 to 18 psi) at normal op this group. For proper service instructions see Group
erating temperature. Allow the vehicle approximately 7, Cooling System.
one half hour to cool off before opening the cooling
system. As an indicator of pressure, squeeze the up ENGINE AIR CLEANER
per radiator hose between index finger and thumb. I f The engine air cleaner should be serviced at the in
it collapses with little effort the system would have tervals described i n the Lubrication and Maintenance
low internal pressure and should be safe to open to Schedules sections of this group. Additional informa
the first safety notch of the radiator cap. Refer to tion can be found in Group 14, Fuel System and
Group 7, Cooling System. Group 25, Emission System. Inspect all air cleaner
hoses or tubes for damage or leaks when other en
COOLING SYSTEM INSPECTION
gine compartment service is performed. Replace
Coolant level should be inspected when other en faulty components.
gine compartment service is performed or when cool
ant leak is suspected. Coolant recovery tank level A I R CLEANER SERVICE
should read between the M I N and MAX marks, lo
cated on the side of recovery tank, when the engine CAUTION: The air cleaner cover m u s t be installed
is at normal operating temperature. Normal coolant properly for the e m i s s i o n s s y s t e m a n d engine c o n
level maintenance does not require the removal of ra troller t o f u n c t i o n correctly.
diator cap. Cooling system freeze protection should Do n o t i m m e r s e paper air filter element or temper
be tested at the onset of the winter season or every ature sensor in cleaning solvents, damage can re
12 months. Service is required i f coolant is low, con sult.
TO SERWiCE AIR CLEANER ASSE11LY HOUSING

(1) Raise hood of vehicle and inspect all air cleaner
components for damage or improper attachment.
(2) Remove air cleaner cover (Fig. 5 or 6).
(3) Remove paper air filter element from air
cleaner body. Hold a shop light on throttle body side
of element. Inspect air intake side of element. I f light
is visible through element, blow dust from element
and reuse. I f element is saturated with oil or light is
not visible, replace filter. I f element is saturated with
oil, perform crankcase ventilation system tests.
(4) Remove fiber crankcase filter (Fig. 5 or 6) and
clean with solvent, squeeze filter dry and apply small
amount of engine oil. I f a metallic mesh is used to re
tain fiber filter, clean mesh with solvent and reuse.
(5) Clean inside of air cleaner cover and body with
vacuum or compressed air. I f oily, wash with solvent.
To Install, reverse the preceding operation.
AIR INLET
Fig. 6 Air Cleaner—8.0 L Engine

sumption. Blockage of crankcase ventilation system
can occur at the vacuum source coupling, ventilation
valve, crankcase filter or a collapsed hose. Refer to
Group 25, Emission Control Systems for proper ser
vice information.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag
nostic and service procedures refer to Group 14, Fuel
System,
IGNITION CABLES, DISTRIBUTOR CAP, AND

ROTOR
Inspect and test ignition cables, distributor cap and
rotor when the spark plugs are replaced. Oil and
grime should be cleaned from the ignition cables and
distributor cap to avoid possible spark plug fouling.
Mopar Foamy Engine Degreaser or equivalent is rec
ommended for cleaning the engine compartment. For
proper service and diagnostic procedures refer to
Group 8D, Ignition System.
SPARK PLUGS
Fig. 5 Air Cleaner—3.9 L, 5.2 L or 5.9 L Engines
Ignition spark plugs should be replaced at the
CRANKCASE VENTILATION SYSTEM mileage interval described i n the Lubrication and
Engine crankcase pressure and emissions are Maintenance Schedules. Refer to the General Infor
vented into combustion chambers through the posi mation section of this group. For proper service pro
tive crankcase ventilation (PCV) system. The crank cedures refer to Group 8D, Ignition Systems.
case ventilation system should have enough volume
to overcome crankcase pressure created by piston DRIVE BELTS
backwash. I f a crankcase ventilation system becomes Inspect and adjust drive belts at the interval de
plugged, the crankcase pressure will increase and scribed i n the Lubrication and Maintenance Sched
force engine oil past the piston rings creating oil con- ules. Refer to General Information section of this
group. For proper inspection and adjustment proce Do not allow rubber engine mounts or other com
dures, see Group 7, Cooling System. ponents to become oil contaminated, repair cause
of oil contamination and clean area.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses All rubber and plastic components should be in
when other under hood service is performed. Refer to spected when engine compartment or under vehicle
emission system Vacuum Hose Label located on the service is performed. When evidence of deterioration
inside of the hood i n the engine compartment and exists, replacement is required. To reduce deteriora
Group 25, Emission Control Systems for proper ser tion of rubber components, Chrysler Corporation rec
vice procedures. ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
BATTERY oil and road grime.
Inspect battery tray, hold down and terminal con
nections when other under hood service is performed. EXHAUST SYSTEM ISOLATOR AND HANGER
For proper diagnostic procedures refer to Group 8A, The exhaust system should be inspected when un
Battery/Starting/Charging System Diagnostics. For der vehicle service is performed. The exhaust system
service and cleaning procedures refer to Group 8B, should not make contact with under body, brake ca
Battery/Starter Service. bles, brake/fuel lines, fuel tank or suspension compo
nents. Slight cracking i n rubber isolator or hanger is
RUBBER AND PLASTIC COMPONENT INSPECTION acceptable. Severely cracked or broken rubber compo
nents must be replaced. For proper service proce
CAUTION: Plastic h o s e s or wire harness covers will
melt or deform when exposed to heat from exhaust
dures see Group 11, Exhaust System and Intake
system or engine manifolds.
Manifold.
Position plastic or rubber components away from
moving parts in engine compartment or under vehi
cle, or damage will result.
DIESEL ENGINE
INDEX
page page
Engine Oil Filter 22 Engine Air Cleaner .. 23
Battery 23 Engine Cooling System . 23
Break-In Period 21 Engine Oil . 21
Emission Control System 23 Rubber and Plastic Component Inspection 24
ENGINE OIL the container indicates the viscosity grade, quality

and fuel economy ratings of the lubricant i t contains.
WARNING: NEW OR U S E D ENGINE OIL CAN B E IR Use 10w-30 ENERGY CONSERVING I I motor oil
RITATING TO T H E SKIN. AVOID P R O L O N G E D OR with API SERVICE SG or SG/CD classification.
R E P E A T E D SKIN CONTACT WITH ENGINE OIL.
RECOMMENDED VISCOSITY GRADES
CONTAMINANTS IN U S E D ENGINE OIL, C A U S E D B Y
INTERNAL COMBUSTION, CAN B E HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH E X P O S E D
SKIN WITH S O A P AND WATER.
DO NOT WASH SKIN WITH G A S O L I N E , D I E S E L
10W-30
>
F U E L , THINNER, OR S O L V E N T S , HEALTH P R O B <I I
5W-30
I I I
L E M S CAN RESULT.
F -20 0 10 20 32 60 80 100
DO NOT P O L L U T E , D I S P O S E O F U S E D ENGINE
C -29 -18 -12 -7 0 16 27 38
OIL P R O P E R L Y . CONTACT Y O U R D E A L E R OR GOV
ANTICIPATED TEMPERATURE RANGE
ERNMENT A G E N C Y FOR LOCATION O F C O L L E C
BEFORE NEXT OIL CHANGE J9400-19
TION C E N T E R IN YOUR A R E A . .
BREAK-IN PERIOD
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
Chrysler Corporation vehicle does not require an

extended break-in period. Driving speeds of not over
80-90 km/h (50-55 mph) for the first 100 km (60 9400-9
miles) is recommended. Hard acceleration and high
engine rpm i n lower gears should be avoided. Fig. 1 API Symbol
S E L E C T I N G ENGINE OIL ENGINE OIL ADDITIVES

Chrysler Corporation recommends that Mopar En
CAUTION: Do not use non-detergent or straight gine Oil Supplement or equivalent be used when fric
mineral oil when adding or changing crankcase lu tion and corrosion reducing materials added to the
bricant. Engine failure can result. crankcase lubricant is desired.
The factory fill engine oil is a high quality, energy CMANKCASE OIL LEVEL INSPECTION '
conserving, crankcase lubricant. The Recommended
SAE Viscosity Grades chart defines. the viscosity CAUTION: Do not overfill crankcase with engine oil,
grades that must be used based on temperature i n oil foaming and oil pressure loss can result.
the region where vehicle is operated.
Chrysler Corporation recommends that Mopar mo Inspect engine oil level approximately every 800 k i
tor oil, or equivalent, be used when adding or chang lometers (500 miles). Position vehicle on level sur
ing crankcase lubricant. The API symbol (Fig. 1) on face. With engine OFF, allow enough time for oil to
settle to bottom of crankcase, remove engine oil level OIL FILTER REMOVAL
indicator (dipstick) and wipe clean. Install dipstick (1) Position a drain pan under the oil filter.
and verify i t is seated i n the tube. Remove dipstick, (2) Using a suitable oil filter wrench (Fig. 3) loosen
with handle above tip, take oil level reading (Fig. 2). filter.
Add oil only i f level is below M I N or ADD mark on (3) When filter separates from adapter nipple, tip
dipstick. gasket end upward to minimize oil spill. Remove fil
ter from vehicle.
(4) With a wiping cloth, clean the gasket sealing
surface (Fig. 4) of oil and grime.
OIL FILTER INSTALLATION

(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, tighten filter one
Fig. 2 Oil Level Indicator Dipstick—Typical full turn. I f necessary use a filter wrench, do not over
ENGINE OIL CHANGE tighten.
Change engine oil at mileage and time intervals (3) Add oil, verify crankcase oil level and start en
described in Maintenance Schedules. gine. Inspect for oil leaks.
TO CHANGE ENGINE OIL

(1) Position the vehicle on a level surface.
(2) Hoist and support vehicle on safety stands. Re
fer to Hoisting and Jacking Recommendations i n this
group.
(3) Place a suitable drain pan under crankcase
drain.
(4) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket i f damaged.
(5) Install drain plug i n crankcase.
(6) Lower vehicle and fill crankcase with specified
type and amount of engine oil described i n this sec
tion.
(7) Start engine and inspect for leaks.
(8) Stop engine and inspect oil level.
ENGINE OIL FILTER

SELECTING OIL FILTER
Chrysler Corporation recommends a Mopar oil fil
ter or equivalent be used when replacement is re
quired. A replacement filter must be designed to
withstand 1756 kPa (256 psi) of internal pressure.
Fig. 4 Install Oil Filter
ENGINE COOLING SYSTEM taminated, rusty or freeze protection is inadequate.

To properly test cooling system, see Group 7, Cooling
WARNINGS AND PRECAUTIONS System.
The cooling system factory fill is a mixture of 50%
WARNING: A N T I F R E E Z E IS AN E T H Y L E N E G L Y C O L Glycol based antifreeze and 50% water. Using a suit
B A S E C O O L A N T AND IS HARMFUL IF SWAL able hydrometer, measure antifreeze concentration in
LOWED OR INHALED. IF S W A L L O W E D , DRINK the radiator when the engine is cool. I f the cooling
TWO G L A S S E S O F WATER AND INDUCE VOMIT system has recently been serviced, allow coolant to
ING. IF INHALED, MOVE TO F R E S H AIR A R E A . circulate for at least 20 minutes before taking hy
S E E K MEDICAL ATTENTION IMMEDIATELY. DO NOT drometer reading. Properly mixed coolant will protect
S T O R E IN O P E N OR UNMARKED CONTAINERS. the cooling system to -37°C (-35°F). I f the freeze pro
WASH SKIN AND CLOTHING THOROUGHLY A F T E R tection is above -28°C (-20°F), drain enough coolant
COMING IN CONTACT WITH E T H Y L E N E G L Y C O L . from the cooling system to allow room to add anti
K E E P OUT O F R E A C H O F C H I L D R E N . freeze to achieve adequate protection. A mix table on
DISPOSE OF GLYCOL BASE COOLANT PROP the coolant container indicates the amount of anti
ERLY, CONTACT YOUR D E A L E R OR G O V E R N M E N T freeze required to winterize the cooling system based
A G E N C Y FOR LOCATION O F C O L L E C T I O N C E N T E R on the capacity, see Capacity Chart i n General Infor
IN YOUR A R E A . mation section of this group.
DO NOT O P E N A COOLING S Y S T E M WHEN T H E
ENGINE IS AT RUNNING T E M P E R A T U R E , P E R SELECTING ANTIFREEZE
SONAL INJURY CAN RESULT. Chrysler Corporation recommends Mopar Anti
AVOID RADIATOR COOLING FAN WHEN ENGINE freeze/Summer Coolant, or equivalent be used to win
COMPARTMENT R E L A T E D S E R V I C E IS PER terize and protect cooling system.
FORMED, P E R S O N A L INJURY CAN RESULT.
RADIATOR CAP
The radiator cap must be secure to provide proper
CAUTION: Do not use straight antifreeze a s engine pressure release and coolant recovery. Inspect and
coolant, inadequate engine running temperatures test radiator cap when cooling system service is per
can result. formed or when problem is suspected.
Do not operate vehicle without proper concentra
tion of recommended ethylene glycol coolant, high COOLING SYSTEM SERVICE
running temperatures and cooling system corrosion The cooling system should be drained, flushed and
can result. filled with the proper coolant mixture at the inter
vals described i n the Lubrication and Maintenance
The engine cooling system will develop internal Schedules. Refer to General Information section of
pressure of 97 to 123 kPa (14 to 18 psi) at normal op this group. For proper service instructions see Group
erating temperature. Allow the vehicle approximately 7, Cooling System.
one half hour to cool off before opening the cooling
system. As an indicator of pressure, squeeze the up ENGINE AIR CLEANER
per radiator hose between index finger and thumb. I f The engine air filter should be serviced only when
it collapses with little effort the system would have the Filter Minder™ on the air cleaner lid indicates
low internal pressure and should be safe to open to restricted air flow (Fig. 5). Refer to Group 25, Emis
the first safety notch of the radiator cap. Refer to sion Control Systems for proper service procedures.
Group 7, Cooling System.
EMISSION CONTROL SYSTEM
COOLING SYSTEM INSPECTION Inspect all emission control components and hoses
Coolant level should be inspected when other en when other under hood service is performed. Refer to
gine compartment service is performed or when cool emission system Vacuum Hose Label located on the
ant leak is suspected. Coolant recovery tank level inside of the hood i n the engine compartment and
should read between the M I N and MAX marks, lo Group 25, Emission Control Systems fof proper ser
cated on the side of recovery tank, when the engine vice procedures.
is at normal operating temperature. Normal coolant
level maintenance does not require the removal of ra BATTERY
diator cap. Cooling system freeze protection should Inspect battery tray, hold down and terminal con
be tested at the onset of the winter season or every nections when other under hood service is performed.
12 months. Service is required i f coolant is low, con For proper diagnostic procedures refer to Group 8A,
0 - 24 LUBRICATION ANi MAINTENANCE
PRESS BUTTON
Position plastic or rubber components away from
T O RESET moving parts in engine compartment or under vehi
cle, or damage will result.
Do not allow rubber engine mounts or other c o m - .
ponents to become oil contaminated, repair c a u s e
of oil contamination and clean area.
Ml rubber and plastic components should be in

spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora
tion of rubber components, Chrysler Corporation rec
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EXHAUST SYSTEM ISOLATOR AND HANGER

The exhaust system should be inspected when un
T O AIR
FILTER H O U S I N G der vehicle service is performed. The exhaust system
should not make contact with under body brake ca
J9425-4
bles, brake/fuel lines, fuel tank or suspension compo
Fig. 5 Filter Minder™
nents. Slight cracking in rubber isolator or hanger is
acceptable. Severely cracked or broken rubber compo
Battery/Starting/Charging System Diagnostics. For nents must be replaced. For proper service proce
service and cleaning procedures refer to Group 8B, dures see Group 11, Exhaust System and Intake
Battery/Starter Service. Manifold.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic h o s e s or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
DR1¥ETRA1N
INDEX
page page
Automatic Transmission 26 Front Axle U-Joint and Pivot Bearings 27
Clutch and Brake Pedal Bushings 25 Manual Transmissions 25
Clutch Master Cylinder 25 Rear Axle . 26
Drive Shafts 27 Transfer Case (4WD Vehicles) 26
Front Axle 26
CLUTCH AND BRAKE PEDAL BUSHINGS level, position the vehicle on a level surface. Remove
I f the clutch and brake pedal mechanism squeaks, fill plug from the transmission. The oil level should
the pivot bushings should be lubricated. Use Mopar not be below 4 mm (3/16 in) from the bottom of the
oil fill opening. Refer to Group21, Transmission
Multi-Purpose Lubricant, or an equivalent. Refer to
proper service procedures.
Group 5, Brakes for location of bushings.
NV-3100 or NV-4500 MANUAL TRANSMISSION
CLUTCH MASTER CYLINDER NV-3500 and NV-4500 manual transmissions does
not require periodic maintenance. The oil should be
FLUID SELECTION
changed only when water contamination is sus
pected. I f oil has a foamy or milky appearance i t
WARNING: DO NOT A L L O W P E T R O L E U M OR WA
probably is contaminated. For proper diagnostic and
T E R B A S E LIQUIDS TO CONTAMINATE C L U T C H
service procedures, refer to Group 21, Manual Tran
FLUID, S E A L DAMAGE AND C L U T C H F A I L U R E CAN
saxle.
RESULT
AX-15 GETRAG MANUAL TRANSMISSION
The clutch reservoir level (Fig. 6) should be in
AX-15 Getrag manual transmission requires oil
spected when other under hood service is performed.
changes at the following intervals.
When fluid must be added, use Mopar, Brake Fluid
Light Duty Service-Every 60 000 k m (37,000
or equivalent. Use only brake fluid conforming to
miles).
DOT 3, Federal, Department of Transportation spec
Heavy Duty Service-Every 58 000 km (36,000
ification. To avoid fluid contamination, use fluid from
miles).
a properly sealed container.
Severe Service-Every 29 000 k m (18,000 miles).
SELECTING MANUAL TRANSAXLE OIL
NV-3600 MANUAL TRANSMISSION

Chrysler Corporation recommends Mopar Manual
Transmission Fluid (MS9224) or equivalent, be used
to fill an NV-3500 manual transmission.
NV-4100 MANUAL TRANSMISSION

Chrysler Corporation recommends API/GL-4 SAE
75w-90, Mopar Synthetic Manual Transmission Fluid
(P/N 4637579) or Castrol Syntog® be used to fill an
NV-4500 manual transmission.
Mopar and Castrol synthetic manual trans
RING mission oils are the ONLY lubricants recom
J9106-11
mended for use i n the NV-4500 transmission.
Fig. 6 Clutch Master Cylinder
AX-15 GETRAG MANUAL TRANSMISSION
MANUAL TRANSMISSIONS Chrysler Corporation recommends API/GL-5 SAE
The manual transmission should be inspected for 75w-90, Mopar Manual Transmission Fluid (P/N
oil leaks and proper oil level when other under vehi 4549624) or equivalent be used to fill an AX-15 man
cle service is performed. To inspect the transaxle oil ual transmission.
AUTOMATIC TRANSMISSION The transfer case requires periodic maintenance at

The automatic transmission fluid should be the intervals described i n the Maintenance Schedules
changed and bands adjusted at the intervals de sections of this Group. For proper diagnostic and ser
scribed i n the Maintenance Schedules section of this vice procedures, refer to Group 21, Transmission and
Group. The automatic transmission should be in Transfer Case.
spected for fluid leaks and proper fluid level when
other under hood service is performed. Refer to SELECTING LUBRICANT
Group 21, Transmission for proper service proce Chrysler Corporation recommends Mopar ATF Plus
dures. (automatic transmission fluid type 7176) be used to
fill the transfer case. I f ATF Plus is not available use
CAUTION: To minimize fluid contamination, verify Mopar Dexron I I Automatic Transmission Fluid or
that dipstick is seated in the fill tube after fluid level equivalent.
reading is taken.
FRONT AXLE
The front axle does not require periodic mainte
TO INSPECT THE TRANSMISSION FLUID LEVEL nance. Inspect the axle for oil leaks or damage and
(1) Position the vehicle on a level surface. proper oil level when other under vehicle service is
(2) Start engine and allow to idle i n PARK for at performed. Oil leaks should be repaired before re
least 60 seconds. The warmer the transmission fluid, turning vehicle to use. I f the oil appears milky or
the more- accurate the reading. foamy i t is probably water contaminated. I f contami
(3) While sitting i n driver seat, apply brakes and nation is evident, change the axle lubricant. Refer to
place gear selector i n each position. Return gear se Group 2, Front Suspension and Axle for proper ser
lector to park. vice procedures.
(4) Raise hood and remove transmission fluid level
indicator (dipstick) and wipe clean with a suitable LUBRICANT LEVEL
cloth. 7-1/4 Inch Axle—approximately 17 mm (0.75 in.)
(5) Install dipstick and verify i t is seated i n fill below the bottom of the fill hole i n the differential
hole or tube. cover.
Dana 44—approximately 6 mm (0.25 in.) below the
CAUTION: Do not overfill automatic transmission, bottom of the fill hole i n the differential cover.
leakage or damage can result. Dana 60 or 61—approximately 12 mm (0.5 in.) be
low the bottom of the fill hole i n the differential
(6) Remove dipstick, with handle above tip, take cover.
fluid level reading. I f the vehicle has been driven for The vehicle must be positioned on a level surface
at least 15 minutes before inspecting fluid level, before inspecting oil level.
transmission can be • considered hot and reading
should be above the WARM mark. I f vehicle has run SELECTING LUBRICANT
for less than 15 minutes and more than 60 seconds Use API/GL-5 SAE 80w-90, Mopar Multipurpose
transmission can be considered warm and reading Gear Lubricant or equivalent to fill the front axle.
should be above ADD mark. Add fluid only i f level is
below ADD mark on dipstick when transmission is REAR AXLE
warm. The rear axle does not require periodic mainte
nance. Inspect the axle for oil leaks or damage and
SELECTING AUTOMATIC TRANSMISSION proper oil level when other under vehicle service is
FLUID performed. Oil leaks should be repaired before re
Chrysler Corporation recommends Mopar ATF Plus turning vehicle to use. I f the oil appears milky or
(automatic transmission fluid type 7176) be used to foamy i t is probably water contaminated. I f contami
add to or replace automatic transmission fluid. I f nation is evident, change the axle lubricant. Refer to
ATF Plus is not available use Mopar Dexron I I Auto Group 3, Rear Suspension and Axle for proper service
matic Transmission Fluid or equivalent. procedures.
TRANSFER CASE (4WD VEHICLES) LUBRICANT LEVEL

The transfer case should be inspected for oil leaks 7- 1/4 Inch Axle—approximately 12 mm (0.5 in.)
and proper oil level when other under vehicle service below the bottom of the fill hole i n the differential
is performed. To inspect the transfer case oil level, cover.
position the vehicle on a level surface and remove fill 8- 1/4 Inch Axle—approximately 6 mm (0.25 in.)
plug from the case housing. The oil level should be at below the bottom of the fill hole i n the differential
the bottom edge of oil fill opening. cover.
9-1/4 Inch Axle—approximately 15 mm (0.625 in.) Do not use high pressure to lubricate the
below the bottom of the fill hole in the differential front axle universal joints.
cover.
Dana 60, 70 o r 80—approximately 17 mm (0.75 B R 1500 AND 2500 FRONT AXLE
in.) below the bottom of the fill hole in the differen The front axle universal joint and pivot bearings
tial cover. are permanently lubricated and do not require ser
The vehicle must be positioned on a level surface vice.
before inspecting oil level.
DRIVE SHAFTS
SELECTING LUBRICANT
Use API/GL-5 SAE 80w-90, Mopar Multipurpose SLIP-YOKE LUBRICATION
Gear Lubricant or equivalent to fill the rear axle. When equipped with lube fittings, i t is recom
mended that the slip-yoke splines be lubricated at
FRONT AXLE U-JOINT AND PIVOT BEARINGS the intervals described i n the Maintenance Schedules
section of this Group. Refer to Group 16, Propeller
BR 3500 WITH DANA 60 FRONT AXLE
Shafts for proper service procedures.
Lubricate Universal Joints at the intervals de
scribed i n the Maintenance Schedules section of this SELECTING LUBRICATION
Group. Refer to Group 2, Front Suspension and Axles Use Mopar, Multi-purpose Grease to lubricate the
and Group 16, Propeller Shafts for proper service universal joint pivot bearings.
procedures.
SELECTING LUBRICATION
Use Mopar, Multi-purpose Grease to lubricate the
universal joint pivot bearings.
CHASSIS A N D BODY
INDEX
page page
Body Component Mechanisms 30 Power Steering System 28
Brakes 29 Rear Wheel Bearings 29
Front Wheel Bearings 28 Steering Linkage 28
Manual Steering Gear 28 Tires 30
Parking Brake 30
STEERING LINKAGE (4) Remove reservoir cap or dipstick and wipe off
The steering linkage should be lubricated and in fluid.
spected at the intervals described i n the Maintenance (5) Install cap or dipstick.
Schedules section of this Group. Refer to Group 2, (6) Remove cap or dipstick. Holding handle or cap
Front Suspension and Axles for proper service proce above tip of dipstick, read fluid level (Fig. 1). Add
dures. fluid i f reading is below cold level mark on dipstick.
SELECTING LUBRICATION
Use Mopar, Multi-purpose Grease to lubricate the
universal joint pivot bearings.
MANUAL STEERING GEAR

The manual steering gear is permanently lubri
cated. Periodic lubrication is not necessary.
POWER STEERING SYSTEM

The power steering fluid level should be inspected
when other under hood service is performed. I f the
fluid level is low and system is not leaking, use Mo
par, Power Steering Fluid or equivalent. The power Fig. 1 Power Steering Reservoir & Cap
steering system should be inspected for leaks when
other under vehicle service is performed. For proper FRONT WHEEL BEARINGS
service procedures, refer to Group 19, Steering. I t is recommended that front wheel bearings be in
The power steering pump drive belt should be in spected for proper lubrication whenever the brake ro
spected at the time and distance interval described i n tors are removed or at least at the intervals
the Lubrication and Maintenance Schedules. Refer to described i n the Maintenance Schedules section of
the General Information section of this group. this Group.
POWER STEERING FLUID INSPECTION INSPECTION

I f the lubricant:
WARNING: ENGINE MUST NOT BE RUNNING WHEN • Is not sufficient
INSPECTING POWER STEERING FLUID L E V E L , • Contaminated with foreign particles
PERSONAL INJURY CAN RESULT. • Appears dry or has been contaminated with water
to produce a milky appearance.
CAUTION: Do not over fill power steering reservoir CAUTION: Do not add lubricant to the wheel bear
when adding fluid, seal damage and leakage c a n re ings. Re-pack completely. Mixing of different types
sult. of lubricants in wheel bearings s h o u l d be avoided.
This could possibly result in excessive thinning and
leakage of the lubricant.
TO INSPECT FLUii LEVEL:
(1) Position vehicle on a level surface with engine
at normal running temperature. LUBRICATION
(2) Turn OFF engine and remove ignition key. (1) Discard the original seal.
(3) Using a wiping cloth, clean oil and dirt residue (2) Clean the original lubricant from the bearings
from around power steering reservoir cap. and from the hub cavity (Fig. 2 and 3).
(3) Tighten wheel bearing nut to 27-34 N-m (240-

300 in. lbs.) torque while rotating hub/rotor. This will
seat the bearings.
(4) Loosen the nut 1/4 of-a-turn (90°), then tighten
it finger tight.
(5) Position nut lock on the nut with one pair of
slots aligned with the cotter pin hole. Install the cot
ter pin.
(6) Install the dust cap and wheel/tire. Tighten the
wheel lug nuts to 115 N-m (85 ft. lbs.) torque. Install
the wheel cover.
SELECTING LUBRICANT
Use a multi-purpose NLGI GC-LB lubricant, or an
equivalent lubricant).
REAR WHEEL BEARINGS

The rear wheel bearings for vehicles equipped with
a Dana 60, 70 or 80 axle should be cleaned and re
packed whenever the rear brakes are serviced. Refer
to Group 3, Rear Axles for the service procedure.
Fig. 2 Front Wheel Bearing—2WD Vehicles
BRAKES
The brake fluid level should be inspected when
other underhood service is done. I f necessary, add
fluid to raise the level to the bottom of the split
rings. With disc-brakes, the fluid level can be ex
pected to fall as the brake pads wear. However, a low
fluid level can also be caused by a leak, and repair
will then be necessary, refer to Group 5, Brakes for
proper service procedures.
SELECTING FLUID
Power brake systems require Mopar Heavy-Duty
Brake Fluid, or an equivalent product identified with
FMVSS No. 116, DOT-3 and SAE J-1703 Standard
designations.
Use brake fluid properly sealed container when
adding fluid to the reservoir. Never use reclaimed
fluid or fluid that does not conform to the DOT/SAE
Fig. 3 Front Wheel & Spindle Bearings—4WD Standards.
Vehicles
CAUTION: U s e of a brake fluid that h a s a lower ini
(3) Inspect the bearing rollers for indications of tial boiling point then specified by FMVSS No. 116
pitting. Light bearing roller discoloration is consid or DOT 3 could result in sudden brake failure dur
ered normal. A wheel bearing must be replaced i f any ing hard, prolonged braking.
serious damage exists. Do not allow petroleum base fluids to contami
(4) Re-pack the bearings with a multi-purpose nate the brake fluid. Seal damage will result.
NLGI GC-LB lubricant. The use of a bearing packer
is recommended. A small amount of fresh lubricant
also should be added to the hub cavity. BRAKE SYSTEM INSPECTION
(1) Inspect the brake pads and linings for excessive
BEARING INSTALLATION/ADJUSTMENT wear, cracks and broken rivets.
(1) Install the hub/rotor (with inner bearing and (2) Inspect brake pads and linings for contamina
seal) on steering knuckle spindle. tion with brake fluid, axle lubricant and/or other flu
(2) Install the outer bearing, the thrust washer ids.
and the nut.
0 - 30 LUBRICATION AND MAINTENANCE 0
(3) Replace the front brake pads and the rear (4) With the parking brake released, the rear
brake linings i f they are worn to within 0.78 mm wheels should rotate without restriction. Adjust the
(0.031 in) of a rivet head. parking brake cable tension, i f necessary.
(4) Operate the rear brake self-adjuster lever and (5) Repair any parking brake malfunctions.
pivot. Test the operation of the self-adjuster screw for
ease of movement.
(5) Inspect the self-adjuster components for frayed
cables, loose or overheated springs, and a binding
condition.
(6) Inspect the caliper dust boots for damage/tears
and indications of brake fluid leakage. Inspect the
bushings and pins for corrosion, tears and a binding
condition.
(7) Inspect the rear wheel cylinder dust boots for
fluid leaks. Inspect the pistons and cylinder bores for
proper appearance.
(8) Inspect the brake differential warning valve
and housing for indications of leakage, kinked hoses
and loose fittings.
BRAKE HOSE INSPECTION Fig. 4 Parking Brake Ratio Lever Lubrication
WARNING: IF FRONT W H E E L OR R E A R A X L E TIRES'

B R A K E H O S E O U T E R C O V E R IS C R A C K E D , The condition of the tires should be inspected. The
C H A F E D , OR B U L G E D , R E P L A C E H O S E IMMEDI inflation pressures tested/corrected at the same time
ATELY. B R A K E F A I L U R E CAN RESULT. as the engine oil is changed and the oil filter is re
placed.
The front wheel and rear axle brake hoses should The tires/wheels should be rotated at the intervals
be inspected at time and distance intervals described described i n the Maintenance Schedules section of
in the Lubrication and Maintenance Schedules. Refer this Group.
to the General Information section of this group. A
hose must be replaced i f i t has signs of cracking, INSPECTION
chafing, fatigue or bulging. For proper service proce Inspect the tires for excessive wear, damage. Test
dures, refer to Group 5, Brakes. the tires for the recommended inflation pressure and
adjust the pressure accordingly. Refer to the tire in
B R A K E LINE INSPECTION flation pressure decal located on the left door face.
The metal brake lines should be inspected when Also to Group 22, Tires And Wheels for tire pressure
other under vehicle service is preformed. I f a line is charts, tire replacement, and tread wear indicators.
pinched, kinked, or corroded, i t should be repaired.
For proper service procedures, refer to Group 5, ROTATION
Brakes. Tires/wheels should be rotated according to the rec
ommended interval. The first tire/wheel rotation is
PARKING BRAKE the most important for establishing the prevention of
The pivot and sliding contact areas of the parking uneven tread wear. After rotation, adjust the tire in
brake ratio lever should be lubricated (Fig. 4). flation pressure to the air pressure recommended on
(1) Apply Mopar Spray White Lube or equivalent the decal located on the left door face.
to the sliding contact areas. Refer to Group 22, Tires And Wheels for the recom
(2) Lubricate the control lever pivot areas with en mended method of tire/wheel rotation.
gine oil.
BODY COMPONENT MECHANISMS
PARKING BRAKE FUNCTIONAL TEST AND
INSPECTION LUBRICATION REQUIREMENTS
(1) Engage the parking brake pedal and then re A l l operating mechanisms and linkages should be
lease it. lubricated when necessary. This will maintain ease of
(2) Test i t for smooth operation and vehicle-holding operation and provide protection against rust and ex
capability. cessive wear. The door weatherstrip seals should be
(3) Inspect the parking brake cables for kinks, lubricated to prolong their life as well as to improve
fraying and a binding condition. door sealing.
LUBRICANT SPECIFICATIONS Mopar Multi-Mileage Lubricant or an equivalent,

All applicable exterior and interior vehicle operat should be used to lubricate the mechanisms. The
ing mechanisms should be: door weatherstrip seals should be lubricated with sil
• Inspected icone lubricant spray (Fig. 5).
• Cleaned
• A l l the pivoting/sliding contact areas on the mech
anisms should then be lubricated.
COMPONENT SIKVICI INTEiVM LUBRICANT

Door Hinges As Required Engine Oil
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch Release Mechanism & Safety Latch As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
(When Performing
Other Underhood
Services)
Hood Hinges As Required Engine Oil
Seat Regulator & Track Release Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2 IP (2)
Tailgate Hinge As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Tailgate Support Arms As Required Engine Oil
Tailgate Latches As Required White Spray Lubricant (3)
Tailgate Release Handle (Pivot & Slide Contact Surfaces) As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Window System Components (Regulators, Tracks, Rods As Required White Spray Lubricant (3)
& Channel Areas — Except Glass Run Weatherstrips
and Felt Lubricator, if Equipped)
Lock Cylinders Twice/Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB (1)
1. Mopar Wheel Bearing Grease (High Temperature)
2. Mopar Multi-Mileage Lubricant
3. Mopar Spray White Lube
4. Mopar Lock Cylinder Lubricant
J9200-58
Fig. 5 Body Lubrication Specifications

• FRONT SUSPENSION AND AXLE 2 - 1
FRONT SUSPENSION AND AXLE
CONTENTS
page page
ALIGNMENT SPECIFICATIONS ...49 INDEPENDENT FRONT SUSPENSION (IFS) . . . 14

AXLE NOISE/VIBRATION DIAGNOSIS ..19 LINK/COIL SUSPENSION 11
AXLE SPECIFICATIONS MODEL 44 AND 60 . . . 4 7 MODEL 44/60 AXLE AND TUBE AXLE (2WD) . 23
FRONT WHEEL ALIGNMENT ....4 TORQUE SPECIFICATIONS 48
GENERAL INFORMATION .... 1
GENERAL INFORMATION
FRONT SUSPENSION serviceable and is replaced as a unit only. Steering
The Ram Truck uses two suspension designs, link/ knuckles pivot on replaceable ball studs attached to
coil and independent front suspension (IFS). Both de the axle tube yokes.
signs use coil springs. IFS uses upper and lower Drive axle (4WD) is a Model 44 or 60. I t has a cast
suspension arms attached to the frame and steering iron differential case with axle shaft tubes extending
knuckles. Link/coil design uses upper and lower sus from either side.
pension arms attached to the frame and drive axle They are equipped with a vacuum disconnect to ac
(4WD), tube axle (2WD). tivate the 4WD.
Tube axle (2WD) is a one-piece tube. This axle
LINK/COIL SUSPENSION (FIG..1) mounts to the same bracketry as the four-wheel drive
axle. The steering knuckles are the same as' the
Model 60 drive axle.
The upper and lower suspension arms use bushings
to isolate road noise. The suspension arms are bolted
to the frame and axle through the rubber bushings.
The lower suspension arm uses cam bolts at the axle
to allow for caster and pinion angle adjustment. The
suspension arm travel (jounce or rebound) is limited
through the use of urethane bumpers.
Suspension components which use rubber bushings
should be tightened at vehicle ride height. This will
prevent premature failure of the bushing and main
tain ride comfort. Bushings must never be lubricated.
The coil springs control ride quality and maintain
proper ride height. The springs use a rubber isolators
between the frame bracket and spring. The isolators
Fig. 1 Link/Coil Suspension help prevent road noise. The bottom of the spring sits
on a seat mounted to the axle.
• Drive axle (4WD),tube axle (2WD) Shock absorbers dampen the jounce and rebound of
• Upper and lower suspension arms the vehicle over various road conditions. Shocks are
• Coil springs mounted inside the springs and attached at the top
• Shock absorbers to brackets with grommets. These brackets are bolted
• Track bar on the frame with three studs on a ring. The shock is
• Stabilizer bar mounted at the bottom of the axle below the spring
Link/coil suspension allows each wheel to adapt to seat.
different road surfaces. Wheels are mounted to The track bar is used to minimize front axle side-
knuckles with a hub/bearing. The hub/bearing is not to-side movement. The bar is attached to a frame rail
bracket with a ball stud and is isolated with a bush
ing at the axle bracket.
2 - 2 FRONT SUSPENSION AND AXLE •
The stabilizer bar is used to minimize vehicle front adjusted for caster and camber. The suspension arm
sway during turns. The spring steel bar helps to con travel (jounce or rebound) is limited through the use
trol the vehicle body i n relationship to the suspen of rubber bumpers.
sion. The bar extends across the front underside of The coil springs control ride quality and maintain
the chassis and connects to the frame rails. Links are proper ride height. The springs mount between the
connected from the bar to the axle brackets. Stabi lower suspension arm and the front cross member
lizer bar mounts are isolated by teflon lined rubber spring seat. A rubber isolator seats on top off the
bushings. spring to help prevent noise.
The shock absorbers dampen jounce and rebound of
INDEPENDENT FRONT SUSPENSION (IFS) the vehicle over various road conditions. Shocks are
(FIG 2,3) mounted on the bottom to the lower suspension
arms. The top of the shock mounts on frame brackets
using grommets.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con
trol the vehicle body i n relationship to the suspen
sion. The bar extends across the front underside of
the chassis and mounts on the frame rails. Links
connected the bar to the lower suspension arms. Sta
bilizer bar mounts are isolated by rubber bushings.
Links are isolated with rubber grommet.
FRONT DRIVE AXLE

The integral type housing, has the centerline of the
pinion set below the centerline of the ring gear.
The axles are equipped with optional A.B.S. brake
system. The A.B.S. tone rings are pressed onto the
Fig* 2 independent Front Suspension axle shaft near the hub and knuckle. For additional
information on the A.B.S. system refer to Group 5,
Brakes.
The Dana 44 and 60 axle has the assembly part
number and gear ratio listed on a tag. The tag is at
tached to the housing cover (Fig. 4, 5). Build date
identification codes are stamped on the axle shaft
tube cover side.
STANDARD DIFFERENTIAL OPERATION

The differential gear system divides the torque be
tween the axle shafts. I t allows the axle shafts to ro
tate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted i n a bore i n the differential case
Fig. 3 independent Front Suspension and is positioned at a right angle to the axle shafts.
I n operation, power flow occurs as follows:
• Upper and lower suspension arms • Pinion gear rotates the ring gear
• Coil springs • Ring gear (bolted to the differential case) rotates
• Shock absorbers the case
• Stabilizer bar • Differential pinion gears (mounted on the pinion
The suspension arms have replaceable ball• studs mate shaft i n the case) rotate the side gears
which are pressed into the arms. Bushings located • Side gears (splined to the axle shafts) rotate the
inboard are not replaceable. The upper arm has a shafts
pivot bar which mounts on a frame bracket. The During straight-ahead driving, the differential pin
bracket has slotted holes this allows the arm to be ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
FRONT SUSPENSION AND AXLE 2 -3
When turning corners, the outside wheel must

DIFFERENTIAL
COVER I N STRAIGHT A H E A D D R I V I N G
FILL PLUG EACH WHEEL ROTATES AT 100%
OF CASE SPEED
P I N I O N GEARS ROTATE
W I T H CASE J93C3-13
Fig. 6 Differential Operation—Straight-Ahead Driving

travel a greater distance than the inside wheel i n or
IDENTIFICATION
TAG J9202-23
der to complete a turn. This difference must be com
pensated for i n order to prevent the wheels from
Fig. 4 Model 44 Differential Cower
scuffing and skidding through the turn. To accom
plish this the differential allows the axle shafts to
DIFFERENTIAL FILL PLUG turn at unequal speeds (Fig.7). I n this instance, the
COVER
input torque applied to the pinion gears is not di
vided equally. The pinion gears now rotate around
the pinion mate shaft i n opposite directions. This al
lows the side gear and axle shaft attached to the out
side wheel to rotate at a faster speed.
AXLE <fc
OUTER WHEEL 100% DIFFERENTIAL I N N E R WHEEL

/
110% CASE SPEED CASE SPEED 9 0 % CASE SPEED
MODEL
NUMBER
RATIO
TAG
J9202-97
Fig. 5 Model 60 Differential Cover P I N I O N GEARS ROTATE

O N P I N I O N SHAFT J9303-14
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around i t (Fig. 6). Fig. 7 Differential Operation—On Turns
FRONT W H E E L ALIGNMENT
GENERAL INFORMATION POSITIVE NEGATIVE POSITIVE NEGATIVE
Front wheel alignment involves the correct posi CASTER CASTER C A M B E R ^ j CAMBER,
tioning of the wheels in relation to the vehicle. The FRONT OF VEHICLE
positioning is accomplished through suspension and
steering linkage adjustments. An alignment is con
sidered essential for. efficient steering, good direc
tional stability and to maximize tire wear. The most
important measurements of front en^ alignment are
caster, camber and toe position.
Routine inspection of the front suspension
and steering components is a good preventative
maintenance practice. Inspection also helps to
ensure safe operation of the vehicle.
PIVOT POINT*4J^;j
• CASTER is the forward or rearward tilt of the
Steering knuckle from vertical. Tilting the top of the J9402-56
knuckle rearward provides positive caster. Tilting the

top of the knuckle forward provides negative caster. Fig. 1 Alignment Angles IFS
Caster is a directional stability angle which enables • WHEEL TOE POSITION is the difference between
the front wheels to return to a straight ahead posi the leading inside edges and trailing inside edges of
tion after turns (Fig. 1,2). the front tires (Fig. 1,2). Incorrect wheel toe position
• CAMBER is the inward or outward tilt of the is the most common cause of unstable steering and
wheel relative to the center of the vehicle. Tilting the uneven tire wear. The wheel toe position is the final
top of the wheel inward provides negative camber. front wheel alignment adjustment.
Tilting the top of the wheel outward provides positive • STEERING AXIS INCLINATION ANGLE is mea
camber. Incorrect camber will cause wear on the in
sured i n degrees. I t is the angle that the steering
side or outside edge of the tire (Fig. 1,2).
CAMBER
WHEEL
TRUE ,| I - — CfcNTERLINE
VERTICAL _ jj , NEGATIVE
CAMBER
|/ ANGLE
«
_ PIVOT
1
\ LL /
u
—
CENTERLINE
SCRUB
RADIUS FRONT OF VEHICLE tS
POSITIVE CAMBER (NOT S H O W N ) — 1 -
TOP OF WHEEL OUTBOARD NEGATIVE TOE (TOE OUT) B > A
POSITIVE TOE (TOE IN) B < A
CASTER
THRUST ANGLE
POSITIVE CASTER-
K I N G PIN
4*
ANGLE OF REAR AXLE
RELATIVE TO VEHICLE CENTERLINE
VERTICAL
OF VEHICLE ( + ) AXLE POINTS LEFT ( - ) AXLE POINTS RIGHT
J9402-57
Fig. 2 Alignment Angles Link/Coil

• FRONT SUSPENSION AND AXLE 2- i
knuckles are tilted (Fig. 1). The inclination angle has (1) Tires with the same recommended air pressure,
a fixed relationship with the camber angle. I t will not size, and tread wear. Refer to Group 22, Wheels and
change except when a spindle or ball stud is dam Tires for diagnosis information.
aged or bent. The angle is not adjustable and the (2) Front wheel bearings for wear.
damaged component(s) must be replaced to correct (3) Ball studs, steering linkage pivot points and
mis-alignment. steering gear for looseness, roughness, binding or
wear. Refer to Group 19, Steering for additional in
CAUTION:Do not attempt to modify any suspension
formation.
or steering component by heating and bending.
(4) Front wheels for excessive radial or lateral
runout and unbalance. Refer to Group 22, Wheels
PRE-ALIGNMENT INSPECTION LINK/COIL and Tires for diagnosis information.
SUSPENSION (5) Suspension components for wear and noise.
Before starting a front wheel alignment, the follow Check components for correct torque. Refer to Groups
ing inspection and necessary corrections must be 2 and 3, Suspension and Axle for additional informa
completed. tion.
2 - e FRONT SUSPENSION AND AXLE
•
LINK/COIL SUSPENSION AND STEERING SYSTEM DIAGNOSIS
FRONT END
NOISE
I Ox^Si^^^^
I I IN STEERING 1 1
I FRONT WHEEL
SHIMMY | |
II VEHICLE
INSTABILITY
II
| |
DIFFICULT
STEERING
II
| |
p u u S T O I
O N E SIDE |
LOOSE OR W O R N
FRONT WHEEL
LOOSE OR W O R N
FRONT WHEEL
LOOSE C>R W O R N
WHEEL B EARINGS
1
LOW OR UNEVEN
TIRE AIR PRESSURE
LOW OR UNEVEN
TIRE AIR 1PRESSURE
LOW OR UNEVEN
TIRE PR ESSURE
BEARINGS BEARINGS
LOOSE OR W O R N
SHOCK ABSORBER LOOSE OR W O R N LOOSE, W O R N OR WHILE B R A K I N G -
TIRE/WHEEL LOOSE GLAZED P/S REFER TO
M O U N T I N G HARD STEERING COLUMN
OUT OF BALANCE WHEEL BEARINGS PUMP BELT BRAKES SERVICE
WARE OR SHAFT COUPLING
SHOCK ABSORBER
UNEVEN TIRE TREAD

LOOSE STEERING LOOSE STEERING LOW
WEAR, OR EX BROKEN OR WEAK BROKEN OR WEAK
GEAR-TO-FRAME GEAR-TO-FRAME POWER STEERING
CESSIVELY W O R N REAR SPRING REAR SPRING
RAIL BOLTS RAIL BOLTS FLUID LEVEL
TIRE TREAD
WORN W O R N TIE- W O R N TIE- SHOCK ABSORBER LACK OF ASSIST LOOSE OR W O R N

UPPER SUSPENSION ROD END ROD END NOT FUNCTIONING FROM POWER SUSPENSION
A R M BUSHINGS BALL STUDS BALL STUDS CORRECTLY STEERING PUMP BUSHINGS
INCORRECT FRONT
W O R N LOWER INCORRECT LOOSE OR W O R N INCORRECT BALL STUDS WHEEL ALIGNMENT
SUSPENSION A R M STEERING GEAR SUSPENSION ARM STEERING GEAR REQUIRE (EITHER CASTER
PIVOT BUSHINGS ADJUSTMENT BUSHINGS ADJUSTMENT LUBRICATION OR CAMBER)
LOOSE LOWER LOOSE OR W O R N LOOSE OR W O R N STEERING GEAR

SUSPENSION A R M UPPER SUSPENSION SUSPENSION ARM LUBRICANT LEVEL
ARM BALL STUDS BUSHINGS LOW
W O R N ISOLATOR INCORRECT FRONT-

INCORRECT
PAD BETWEEN COIL WHEEL ALIGNMENT INCORRECT FRONT
WHEEL ALIGNMENT STEERING GEAR
SPRING A N D (PARTICULARLY
ADJUSTMENT
FRAME BRACKET CASTER)
STEERING
GEAR
MALFUNCTION
INCORRECT FRONT
WHEEL ALIGNMENT!
(PARTICULARLY
CASTER)
J9002-97
• FRONT SUSPENSION AND AXLE 2 -7
ALiGNlENT AND ADJUST1ENTS LINK/COIL wheel is at the 0.12 degrees (0.12°) TOE-IN position.
SUSPENSION Position clamp bolts to their original position and
Before each alignment reading the vehicle should tighten to 49 N-m (36 ft. lbs.) torque. Make sure the
be jounced (rear first, then front). Grasp each toe setting does not change during clamp tight
bumper at the center and jounce the vehicle up and ening.
down several times. Always release the bumper i n
the down position. Set the front end alignment to
specifications while the vehicle is i n its NOR
MALLY LOADED C O N D I T I O N .
GAMBem
The wheel camber angle is preset at NEGATIVE
0.25 DEGREES (-0.25°). The angle is not adjustable
and cannot be altered.
CASTER
Check the caster of the front axle for correct angle.
Be sure the axle is not bent or twisted. Road test the
vehicle and make left and right turn. Observe the
steering wheel return-to-center position. Low caster
will cause poor steering wheel returnability.
Caster can be adjusted by rotating the cams on the
lower suspension arm (Fig. 3). Refer to the Align Fig. 4 Drag Link Adjustment
ment Specification Chart for the correct setting. (4) Adjust left wheel toe position with tie rod at
left knuckle. Turn the sleeve until the left wheel is at
the 0.12 degrees (0.12°) TOE-IN position. Position
clamp bolts to their original position and tighten to
27 N-m (20 ft. lbs.) torque. Make sure the toe set
ting does not change during clamp tightening.
(5) Verify the right toe setting.
CAB-CHASSIS ALIGNMENT
Cab-Chassis vehicles use Link/Coil Suspension. To
determine the correct caster alignment angle for Cab-
Chassis vehicles the following procedure must be per
formed.
(1) Take a height measurement to the center of the
front gauge hole i n the frame. Take another at the
center of the rear spring hanger bolt (Fig. 5).
(2) Subtract the front measurement from the rear
measurement. Use this number with the Caster Cor
rection Chart to get the correction value (Fig. 6).
(3) Measure the radius of the front and rear tires.
Take this measurement on both sides. Subtract the
J9302-59 front measurement from the rear measurement for
both sides. Use the average of both numbers with the
Fig. 3 Cam Adjuster
Caster Correction Chart to get the correction value
TOE POSITION (Fig. 6).
The wheel toe position adjustment should be the fi (4) Add the two caster correction values together.
nal adjustment. Then subtract this from 4.5 for 4x2 or 4.0 for 4x4 ve
(1) Start the engine and turn wheels both ways be hicles. This will be the preferred caster measure
fore straightening the wheels. Secure the steering ment.
wheel with front wheels i n a straight-ahead position
and turn off engine. PRE-ALIGNMENT INSPECTION IFS SUSPENSION
(2) Loosen the adjustment sleeve clamp bolts. Before starting a front wheel alignment, the follow
(3) Adjust the right wheel toe position with the ing inspection and necessary corrections must be
drag link (Fig. 4). Turn the sleeve until the right completed.
4 X 2
J9402-76
Fig. 5 Cab-Chassis Measurement

138.7" WHEELBASE 162 7" WHEELBASE
Hanger Bolt- Caster Rear Tire- Caster Hanger Bolt- Caster Rear Tire- Caster
Gauge Hole Correction Front Tire Correction Gauge Hole Correction Front Tire Correction
(inches) (degrees) (inches) (degrees) (inches) (degrees) (inches) (degrees)
-5.00 -0.23 -0.250 -0.10 -5.00 -0.19 -0.250 -0.09
-4.75 -0.11 -0.125 -0.05 -4.75 -0.09 -0.125 -0.04
-4.50 0.01 0.000 0.00 -4.50 0.01 0.000 0.00
-4.25 0.13 0.125 0.05 -4.25 0.11 0.125 0.04
-4.00 0.25 0.250 0.10 -4.00 0.21 0.250 0.09
-3.75 0.37 0.375 0.15 -3.75 . 0.31 0.375 0.13
-3.50 0.49 0.500 0.21 -3.50 0.41 0.500 0.18
-3.25 0.61 0.625 0.26 -3.25 0.51 0.625 0.22
-3.00 0.73 0.750 0.31 -3.00 0.61 0.750 0.26
-2.75 0.85 0.875 0.36 -2.75 0.71 0.875 0.31
-2.50 0.97 1.000 0.41 -2.50 0.81 1.000 0.35
-2.25 1.10 -2.25 0.91
-2.00 1.22 -2.00 1.01
-1.75 1.34 -1.75 1.11
-1.50 1.46 -1.50 1.21
-1.25 1.58 -1.25 1.31
-1.00 1.70 -1.00 1.41
-0.75 1.82 -0.75 1.51
-0.50 1.94 -0.50 1.61
-0.25 2.06 -0.25 1.71
0.00 2.18 0.00 1.81
J9402-77
Fig. 6 Caster Correction Chart

+ , FiONI SUSPENSION AND AXLE 2 -S
(1) Tires with the same recommended air pressure,

size, and thread wear. Refer to Group 22, Tires And
Wheels for diagnosis information.
(2) Front wheel bearings for wear or adjustment.
(3) Ball studs, linkage pivot points and steering
gear for looseness, roughness or binding. Refer to
Group 19, Steering for additional information.
(4) Front wheels for excessive radial or lateral
runout and unbalance. Refer to Group 22, Tires And
Wheels for diagnosis information.
(5) Suspension components for wear and noise.
Check components for correct torque. Refer to Groups
2 and 3, Suspension and Axle for additional informa
tion.
ALIGNMENT AND ADJUSTMENTS IFS

SUSPENSION Fig. 7 Caster Camber Adjustment Location
Before each alignment reading the vehicle should CAMBER: Move only the forward position of the
be jounced (rear first, then front). Grasp each pivot bar i n or out. This will change the camber an
bumper at the center and jounce the vehicle up and gle significantly and caster angle only slightly. The
down several times. Always release the bumper i n camber angle should be adjusted as close as possible
the down position. Set the front end alignment to
to the service reset specification.
specifications while the vehicle is in its NOR
• After adjustment is made tighten the pivot bar
MALLY L O A D E D CONDITION.
nuts to 210 N-m (155 ft. lbs.) torque.
CAMBER AND CASTER ADJUSTMENT
TOE POSITION
Camber and caster angle adjustments involve
changing the position of the upper suspension arm The wheel toe position adjustment should be the fi
pivot bar (Fig. 7). Refer to the Alignment Specifica nal adjustment.
tion Chart for the correct setting. (1) Start the engine and turn wheels both ways be
CASTER: Move only the rear position of the pivot fore straightening the wheels. Secure the steering
bar i n or out. This will change the caster angle sig wheel with the front wheels i n the straight-ahead po
nificantly and camber angle only slightly. To retain sition and turn off engine.
the camber while adjusting caster, move the rear (2) Loosen the tie rod adjustment sleeve clamp
pivot bar in or out. Move the forward pivot very bolts/nuts.
slightly i n the opposite direction. E a c h front wheel should be adjusted for one-
For example, to increase a positive caster an half of the total toe position specification. This
gle, move the rear position of the pivot bar in will ensure the steering wheel will be centered
ward (toward the engine). Move the front of when the wheels are positioned straight-ahead.
pivot bar outward (away from the engine) (3) Adjust the wheel toe position by turning the tie
slightly until the original camber angle is ob rod adjustment sleeves as necessary.
tained.
I F S SUSPENSION AND STEERING SYSTEM DIAGNOSIS
FRONT WHEEL I I
SHIMMY • I
VEHICLE
INSTABILITY
I
I
I
I
DIFFICULT
STEERING
VEHICLE
P U L L S TO
ONESIPE i
LOOSE OR W O R N LOOSE OR W O R N LOW OR UNEVEN LOW OR UNEVEN LOW OR UNEVEN
LOOSE OR W O R N
FRONT WHEEL FRONT W H E E L WHEEL BEARINGS TIRE AIR PRESSURE TIRE AIR fPRESSURE TIRE PR ESSURE
BEARINGS BEARINGS
LOOSE OR W O R N
SHOCK ABSORBER LOOSE OR W O R N LOOSE, W O R N OR WHILE B R A K I N G -
TIRE/WHEEL LOOSE GLAZED P/S REFER TO
M O U N T I N G HARD- STEERING COLUMN
OUT OF BALANCE WHEEL BEARINGS PUMP BELT BRAKES SERVICE
WARE OR SHAFT COUPLING
SHOCK ABSORBER
UNEVEN TIRE TREAD

LOOSE STEERING LOOSE STEERING LOW
WEAR, OR EX BROKEN OR WEAK BROKEN OR WEAK
GEAR-TO-FRAME GEAR-TO-FRAME POWER STEERING
CESSIVELY W O R N REAR SPRING REAR SPRING
RAIL BOLTS RAIL BOLTS FLUID LEVEL
TIRE TREAD
WORN W O R N TIE- W O R N TIE- SHOCK ABSORBER LACK OF ASSIST LOOSE OR W O R N

UPPER SUSPENSION ROD END ROD END NOT FUNCTIONING FROM POWER SUSPENSION
A R M BUSHINGS BALL STUDS BALL STUDS CORRECTLY STEERING PUMP BUSHINGS
INCORRECT FRONT
W O R N LOWER INCORRECT LOOSE OR W O R N INCORRECT BALL STUDS WHEEL ALIGNMENT
SUSPENSION A R M STEERING GEAR SUSPENSION A R M STEERING GEAR REQUIRE (EITHER CASTER
PIVOT BUSHINGS ADJUSTMENT BUSHINGS ADJUSTMENT LUBRICATION OR CAMBER)
LOOSE OR W O R N LOOSE OR W O R N STEERING GEAR

LOOSE LOWER
SUSPENSION A R M UPPER SUSPENSION SUSPENSION A R M LUBRICANT LEVEL
ARM BALL STUDS BUSHINGS • LOW
W O R N ISOLATOR INCORRECT FRONT-

INCORRECT FRONT INCORRECT
PAD BETWEEN COIL WHEEL ALIGNMENT
WHEEL ALIGNMENT STEERING GEAR
SPRING A N D (PARTICULARLY
ADJUSTMENT
FRAME BRACKET CASTER)
STEERING
GEAR
MALFUNCTION
INCORRECT FRONT
WHEEL ALIGNMENT
(PARTICULARLY
CASTER)
J9002-97
• FRONT SUSPENSION AND AXLE 2-11
LINK/COIL SUSPENSION
INDEX
page page
Coil Spring 12 Shock Diagnosis 12
Lower Suspension Arm 13 Stabilizer Bar 11
Service Information . 11 Track Bar 11
Shock Absorber 12 Upper Suspension Arm 13
SERWICE INFORMATION (2) I t may be necessary to pry the axle assembly

Periodic lubrication of the steering system compo over to install the track bar at the frame rail. Install
nents is required. Refer to Group 0, Lubrication And track bar at the frame rail bracket (Fig. 1).
Maintenance for the service interval. (3) Install the retaining nut on the stud. Tighten
the ball stud nut to 84 N-m (62 ft. lbs.) torque. Install
CAUTION: All suspension components that u s e rub a new cotter pin.
ber bushings should be tightened with the vehicle (4) Remove the supports and lower the vehicle.
at the ride height. It is important to have the (5) Tighten the bolt at the axle shaft tube bracket
springs supporting the weight of the vehicle when to 176 N-m (130 ft. lbs.) torque.
the fasteners are torqued. If springs are not at nor
mal ride height vehicle ride comfort and handling STABILIZER BAR
could be affected. This can also c a u s e premature
bushing wear. Rubber bushings must never be lu REMOVAL
bricated. (1) Raise and support the vehicle.
(2) Disconnect the stabilizer bar links from the
axle brackets.
TRACK BAR
(3) Disconnect the stabilizer bar from the links.
REMOVAL (4) Disconnect the stabilizer bar clamps from the
(1) Raise and support the vehicle. frame rails and remove the stabilizer bar (Fig. 2).
(2) Remove the cotter pin and nut from the ball
stud end at the frame rail bracket (Fig. 1).
A puller tool may be necessary to separate the
ball stud from the frame rail bracket.
(3) Remove the bolt and flag nut from the axle
bracket and remove the track bar (Fig. 1).
Fig. 2 Stabilizer Bar

INSTALLATION
(1) Position the stabilizer bar on the frame rail and
install the clamps and bolts. Ensure the bar is cen
tered with equal spacing on both sides. Tighten the
bolts to 47 N-m (35 ft. lbs.).
Fig. 1 Track Bar
(2) Install the links, grommets retainers and nuts
INSTALLATION onto the axle brackets (Fig. 2). Tighten the nuts to 37
(1) Install the track bar at axle tube bracket. N-m (27 ft. lbs.) torque.
Loosely install the retaining bolt and flag nut.
2-12 FRONT SUSPENSION AND AXLE •
(3) Install link on stabilizer bar and tighten nut to
95 N-m (70 ft. lbs.) torque.
(4) Remove the supports and lower the vehicle.
SHOCK DIAGNOSIS
A squeak noise from the shock absorber can be pro
duced i f movement between the rubber bushings and
the metal occurs. This noise can usually be stopped
by tightening the attaching nuts. I f the squeak noise
persists, inspect for damaged and worn bushings,
and attaching components. Repair as necessary.
The shock absorbers are not refillable or adjust
able. I f a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold i t i n
an upright position and force the piston into and out
of the cylinder four or five times. The action through
out each stroke should be smooth and even.
SHOCK IOLT
SHOCK ABSORBER
J9402-47
REMOVAL
(1) Remove the nut, retainer and grommet from Fig. 4 Shock Absorber Axle Mount
the upper stud i n the engine compartment.
(2) Remove three nuts from the upper shock (2) Install the lower bolt and tighten bolt to 135
bracket (Fig. 3). N-m (100 ft. lbs.) torque.
(3) Install the upper shock bracket and three nuts.
Tighten nuts to 75 N-m (55 ft. lbs.) torque.
(4) Install upper grommet and retainer. Install up
per shock nut and tighten to 41 N-m (30 ft. lbs.)
torque.
COIL SPRING
REMOVAL
(1) Raise and support the vehicle. Position a hy
draulic jack under the axle to support i t .
(2) Paint or scribe alignment marks on lower sus
pension arm cam adjusters and axle bracket for in
stallation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
J9402-46 (6) Disconnect the drag link from pitman arm.
(7) Disconnect the stabilizer bar link and shock ab
Fig. 3 Shock Absorber and Bracket sorber from the axle.
(3) Remove the lower bolt from the axle bracket (8) Lower the axle until the spring is free from the
(Fig. 4). Remove the shock absorber from engine com upper mount. Remove the coil spring.
partment.
INSTALLATION
INSTALLATION (1) Position the coil spring on the axle pad.
(1) Position the lower retainer and grommet on the (2) Raise the axle into position until the spring
upper stud. Insert the shock absorber through the seats i n the upper mount.
spring from engine compartment.
(3) Connect the stabilizer bar links and shock ab

sorbers to the axle bracket. Connect the track bar to
the frame rail bracket.
(4) Install the upper suspension arm.
(5) Install the front propeller shaft to the axle 4x4
model.
(6) Install drag link to pitman arm and tighten nut
to 88 N-m (65 ft. lbs.) torque. Install new cotter pin.
(8) Tighten the following suspension components to
proper torque:
• Link to stabilizer bar tighten nut to 95 N-m (70 ft.
lbs.) torque.
• Lower shock tighten bolt to 121 N-m (89 ft. lbs.)
torque.
• Tighten track bar bolt at the axle shaft tube
bracket to 176 N-m (130 ft. lbs.) torque.
• Upper suspension arm tighten nut at the axle
bracket to 121 N-m (89 ft. lbs.) torque. Tighten nut at
frame bracket to 84 N-m (62 ft. lbs.) torque.
• Align lower suspension arm reference marks and J9302-59
tighten cam nut to 230 N-m (170 ft. lbs.) torque.
Tighten rear nut to 119 N-m (88 ft. lbs.) torque. Fig. 5 Cam Adjuster
at the axle bracket (Fig. 6).
LOWER SUSPENSION ARM (3) Remove the nut and bolt (Fig. 6) at the frame
REMOVAL rail and remove the upper suspension arm.
(1) Raise and support the vehicle.
(2) Paint or scribe alignment marks on the cam ad
justers and suspension arm for installation reference
(Fig. 5).
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig.
6).
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut.
(3) Install the cam bolt, cam and nut i n the axle.
Re-align the reference marks.
(4) Remove support and lower the vehicle. Fig. 6 Upper and Lower Suspension Arms
(5) Tighten cam nut to 230 N-m (170 ft. lbs.)
INSTALLATION
torque. Tighten rear nut to 119 N-m (88 ft. lbs.)
torque. (1) Position the upper suspension arm at the axle
and frame rail (Fig. 6).
UPPER SUSPENSION ARM (2) Install the bolts and finger tighten the nuts.
REMOVAL (4) Tighten nut at the axle bracket to 121 N-m (89
(1) Raise and support the vehicle. ft. lbs.) torque. Tighten nut at frame bracket to 84
(2) Remove the upper suspension arm nut and bolt N-m (62 ft. lbs.) torque.
2 - 14 FRONT SUSPENSION AND AXLE
INDEPENDENT FRONT SUSPENSION (IFS}
INDEX
page page
Coil Springs 15 Stabilizer Bar 14
Lower Ball Stud 16 Steering Knuckle 18
Lower Suspension Arm 16 Upper Ball Stud 17
Service Information 14 Upper Suspension Arm 17
Shock Absorber . 14 Wheel Hub and Bearings 17
Shock Diagnosis 14
SERVICE INFORMATION
Periodic lubrication of the steering system compo
nents is required. Refer to Group 0, Lubrication And
Maintenance for the service interval.
CAUTION: All suspension components that use rub

ber bushings should be tightened with the vehicle
at the ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If the springs are not at
their normal ride height, vehicle ride comfort and
handling could be affected. This can also c a u s e
premature bushing wear. Rubber bushings must
never be lubricated.
STABILIZER BAR
REMOVAL
(2) Disconnect the link from lower suspension arm
and stabilizer bar (Fig. 1).
(3) Disconnect the stabilizer bar clamps from the Fig. 1 Stabilizer Bar
frame rails. Remove the stabilizer bar.
must be replaced. To test a shock absorber, hold it i n
INSTALLATION an upright position and force the piston into and out
(1) Position the stabilizer bar on the frame rail and of the cylinder four or five times. The action through
install the clamps and bolts. Ensure the bar is cen out each stroke should be smooth and even.
tered with equal spacing on both sides. Tighten the
bolts to 47 N-m (35 ft. lbs.) torque. SHOCK ABSORBER
(2) Install links on stabilizer bar and lower suspen
sion arm. Install grommets, retainers and nuts. REMOVAL
Tighten nuts to 34 N-m (25 ft. lbs.) torque (Fig. 1)
WARNING: DO NOT R E M O V E S H O C K UNTIL
L O W E R S U S P E N S I O N ARM IS S U P P O R T E D . T H E
SHOCK DIAGNOSIS S H O C K H O L D S T H E L O W E R S U S P E N S I O N ARM
A squeak noise from the shock absorber can be pro AND SPRING IN POSITION.
duced i f movement between the rubber bushings and
the metal occurs. This noise can usually be stopped (1) Raise and support vehicle.
by tightening the attaching nuts. I f the squeak noise (2) Remove shock upper nut and remove retainer
persists, inspect for damaged and worn bushings, and grommet.
and attaching components. Repair as necessary. (3) Remove lower mounting bolt from suspension
The shock absorbers are not refillable or adjust arm and remove shock (Fig. 2).
able. I f a malfunction occurs, the shock absorber
Fig. 2 Shock Absorber Fig. 3 Coil Spring

INSTALLATION INSTALLATION
(1) Extend shock fully, install retainer and grom (1) Install rubber isolator on top of spring. Position
met on top of shock absorber. Check grommets and spring into upper spring seat and lower suspension
retainer for wear. arm.
(2) Guide shock up through upper suspension arm (2) Raise suspension arm with jack and position
bracket. Install top grommet, retainer and nut. shock into suspension arm mount. Install shock bolt
Tighten nut to 41 N-m (30 ft. lbs.) torque. and tighten to 135 N-m (100 ft. lbs.) torque (Fig.4).
(3) Align bottom end of shock into lower suspen
sion arm and install mounting bolt. Tighten bolt to
(4) Remove support and lower vehicle.
COIL SPRINGS
REMOVAL
WARNING: DO NOT REMOVE SHOCK UNTIL

LOWER SUSPENSION ARM IS SUPPORTED. THE
SHOCK HOLDS THE LOWER SUSPENSION A R M
AND SPRING IN POSITION.
(1) Raise and support vehicle.

(2) Remove tire and wheel assembly.
(3) Remove brake caliper assembly and rotor refer Fig. 4 Shock Absorber
to Group 5, Brakes.
(4) Disconnect tie rod from steering knuckle. (3) Install steering knuckle on lower ball stud. In
(5) Disconnect stabilizer bar link from lower sus stall lower ball stud nut and tighten to 75 N-m (55 ft.
pension arm. lbs.) torque. Replace cotter pin and remove jack.
(6) Support lower suspension arm outboard end (4) Install stabilizer bar link on lower suspension
with jack. Place jack under arm i n front of shock arm. Install grommet, retainer and nut, and tighten
mount. to 34 N-m ( 35 ft. lbs.) torque (Fig.5).
(7) Remove cotter pin and nut from lower ball (5) Install tie rod on steering knuckle and tighten
stud. Separate ball stud with remover C-4150A. nut to 88 N-m (65 ft. lbs.) torque.
(8) Remove lower shock bolt from suspension arm. (6) Install brake caliper assembly and rotor refer
(9) Lower jack and suspension arm until spring to Group 5, Brakes.
tension is relieved. Remove spring and rubber isola (7) Install tire and wheel assembly.
tor (Fig. 3). (8) Remove support and lower vehicle.
REMOVAL
(1) Follow procedure under Lower Suspension Arm
Removal.
(2) Position special tool on lower suspension arm
and press out ball stud (Fig. 6).
Fig. 5 Independent Front Suspension
LOWER SUSPENSION ARM

REMOVAL SPECIAL TOOL
(1) Raise and support vehicle. C-4212F
(2) Follow procedure under Coil Spring Removal.
WARNING: DO NOT REMOWE SHOCK UNTIL

LOWER SUSPENSION ARM IS SUPPORTED. THE
SHOCK HOLDS THE LOWER SUSPENSION ARM
AND SPRING IN POSITION.
Fig. 6 Lower Ball Stud Removal
(3) Remove bolts mounting suspension arm to INSTALLATION
crossmember and remove arm. (1) Press replacement ball stud into the lower sus
pension arm bore with special tools (Fig. 7).
INSTALLATION
(1) Position suspension arm on crossmember and
install bolts snug.
(2) Follow procedure under Coil Spring Installa
tion.
(4) Tighten suspension arm crossmember bolts to SPECIAL TOOL
176 N-m (130 ft. lbs.) torque. C4212F
LOWER BALL STUD

INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far
outboard as possible. The upper suspension arms
must not contact the rebound bumpers.
(2) Install a dial indicator and clamp assembly to
the lower suspension arm.
(3) Position indicator plunger against knuckle arm
and zero indicator.
(4) Raise and lower the wheel with a pry bar un
6761 J9402-34
der the center of the tire. Measure the axial move
ment of the knuckle with respect to the suspension
Fig. 7 Lower Ball Stud Installation
arm.
(5) I f the travel of the suspension arm is 0.020 (2) Install lower suspension arm using procedure
inch (0.51 mm) or more, replace the ball joint. under Lower Suspension Arm Installation.
UPPER SUSPENSION ARM
REMOVAL
(1) Raise and support vehicle
(2) Remove tire and wheel assembly
(3) Support lower suspension arm at outboard end
with jack stand.
(4) Remove upper ball stud cotter pin and nut.
(5) Separate ball stud from knuckle with remover
MD-990635 or MD-991113.
(6) Remove pivot bar bolts from upper suspension
arm bracket and remove arm from vehicle.
INSTALLATION
(1) Position upper suspension arm on bracket and
install pivot bar bolts. Tighten to 203 N-m (150 ft.
lbs.) torque.
(2) Install ball stud in knuckle. Install nut and
tighten to 75 N-m (55 ft. lbs.) torque. Install replace
ment cotter pin.
(3) Remove jack from lower suspension arm.
(4) Install tire and wheel assembly
(5) Remove support and lower vehicle Fig. 8 Upper Ball Stud Removal
(6) Align front suspension.
UPPER BALL STUD

INSPECTION SPECIAL TOOL
(1) Position a floor jack under the lower suspension G4212F
arm. Raise the wheel and allow the tire to lightly

contact the floor (vehicle weight relieved from the
tire).
(2) Grasp the top of the tire and apply force i n and
out. Look for any movement at the ball joints be
tween the upper suspension arm and steering
knuckle.
(3) I f any lateral movement is evident, replace the
ball joint.
REMOVAL
(1) Follow procedure under Upper Suspension Arm
Removal.
(2) Position special tools on upper suspension arm
and press ball stud out of arm (Fig. 8).
J9402-35
INSTALLATION
(1) Press ball stud into upper suspension arm with Fig. 9 Upper Ball Stud Installation
special tools (Fig. 9).
(4) Remove the dust cap, cotter pin, and hub nut
(2) Follow procedure under Upper Suspension Arm
from spindle.
Installation.
CAUTION: Use care to prevent inner wheel bearing
WHEEL HUB AND BEARINGS and seal from contacting spindle threads during re
moval.
REMOVAL
(5) Carefully slide the hub/rotor from spindle.
(2) Remove the wheel and tire assembly.
(6) Remove the seal and inner wheel bearing from
(3) Remove disc brake caliper from steering
knuckle. Refer to Group 5, Brakes. the hub/rotor.
2-18 FRONT SUSPENSION AND AXLE •
(7) Remove inner bearing races from hub/rotor (7) The adjustment (above) should have 0.001 to
with a pin punch i f bearings are going to be replaced. 0.003 inch (0.254 to 0.0762 mm) end play.
(8) Clean the dust cap and apply a coating lubri
CLEANING AND INSPECTION cant to the internal surface. Do not fill the dust
(1) Thoroughly clean bearings and interior of hub/ cap with lubricant. Install the cap.
rotor. (9) Install disc brake caliper. Refer to Group 5,
(2) Clean the bearings with solvent and towel dry. Brakes.
(3) Rotate each bearing slowly and examine the (10) Install the wheel and tire assembly.
rollers for pitting and roughness. Replace bearing i f
worn or damaged.Cup and bearing must be re
STEERING KNUCKLE
placed as a matched set i f wore or damaged.
(4) Pack each bearing with multi-purpose NLGI, REMOVAL
grade 2, EP-type lubricant (or an equivalent lubri- (1) Raise and support vehicle.
cant).Ensure that lubricant is forced into all the (2) Remove wheel and tire assembly. Remove the
cavities between the b e a r i n g cage and rollers.
brake caliper, refer to Group 5, Brakes.
INSTALLATION (3) Remove the wheel hub and bearing assembly
(1) Install the new bearing cup(s) with an appro from the spindle. Refer to Wheel Hub and Bearings
priate installation tool. service removal.
(2) Apply a coating of MOPAR® Wheel Bearing (4) Remove the cotter pin and nut from the tie-rod
Grease or equivalent lubricant to inner surface area end and disconnect tie rod.
of hub/rotor. Install inner wheel bearing and seal i n (5) Remove the cotter pins and nuts from the up
the hub/rotor. per and lower ball studs. Separate upper ball stud
(3) Inspect bearing and seal contact surfaces on from knuckle with remover MD-990635 or
spindle for burrs and/or roughness. MD-991113. Separate lower ball stud with remover
(4) Remove all rough contact surfaces from spindle. C-4150A and remove knuckle.
Apply a coating of lubricant.
INSTALLATION
CAUTION: U s e care to prevent inner wheel bearing (1) Position knuckle on ball stud and install ball
and seal from contacting spindle threads during In stud nuts. Tighten nuts to 75 N«m (55 ft. lbs.) torque.
stallation. Install cotter pins.
(2) Install the brake rotor hub and bearing assem
(5) Carefully slide the hub/rotor onto spindle. In
bly on spindle. Refer to Wheel Hub and Bearings ser
stall outer wheel bearing, washer and retaining nut.
vice installation.
(6) Tighten the nut to 41-54 N-m (30-40 ft. lbs.)
torque to preload bearing while rotating the hub/ro (3) Install the brake caliper, refer to Group 5,
tor. Stop hub/rotor and loosen nut to completely re Brakes.
lease bearing preload torque. Tighten the nut finger- (4) Install wheel and tire assembly.
tight and install the nut lock. Install a new cotter (5) Remove support and lower vehicle.
pin.
A X L E NOISE/VIBRATION DIAGNOSIS
INDEX
page page
Orivellne Snap . . 20
20 Low Speed Knock 20
Gear and Bearing Noise . . 19 Vibration 20
General Information 19
GENERAL INFORMATION Excessive bearing preload may not be noisy. This

Axle bearing problem conditions are usually caused condition will cause high temperature which can re
by: sult i n bearing failure.
• Insufficient or incorrect lubricant
• Foreign matter/water contamination GEAR AND BEARING NOISE
• Incorrect bearing preload torque adjustment
G E A R NOISE
• Incorrect backlash ( to tight)
Axle gear noise can be caused by insufficient lubri
When serviced, the bearings must be cleaned thor
cant. Incorrect backlash, tooth contact, or worn/dam
oughly. They should be dried with lint-free shop tow
aged gears can cause noise.
els. Never dry bearings with compressed air.
Gear noise usually happens at a specific speed
This will overheat them and brinell the bearing
range. The range is 30 to 40 mph, or above 50 mph.
surfaces. This will result i n noisy operation af
The noise can also occur during a specific type of
ter repair.
driving condition. These conditions are acceleration,
Axle gear problem conditions are usually the result
deceleration, coast, or constant load.
of:
• Insufficient lubrication When road testing, accelerate the vehicle to the
• Incorrect or contaminated lubricant speed range where the noise is the greatest. Shift
• Overloading (excessive engine torque) out-of-gear and coast through the peak-noise range.
I f the noise stops or changes greatly, check for insuf
• Exceeding vehicle weight capacity
ficient lubricant. Incorrect ring gear backlash, or
• Incorrect clearance or backlash adjustment
Insufficient lubrication is usually the result of a gear damage can cause noise changes.
housing cover leak. I t can also be from worn axle Differential side and pinion gears can be checked
shaft or pinion gear seals. Check for cracks or porous by turning the vehicle. They usually do not cause
areas i n the housing or tubes. noise i n straight-ahead driving. These gears are
loaded during vehicle turns. I f noise does occur dur
Using the wrong lubricant will cause overheating
and gear failure. Gear tooth cracking and bearing ing vehicle turns, the side or pinion gears could be
spalling are indicators of this. worn or damaged. A worn pinion gear mate shaft can
also cause a snapping or a knocking noise.
Axle component breakage is most often the result
of: - BEARING NOISE
© Severe overloading
The axle shaft, differential and pinion gear bear
• Insufficient lubricant
ings can all produce noise when worn or damaged.
• Incorrect lubricant
Bearing noise can be either a whining, or a growling
• Improperly tightened components
sound.
Common causes of overloading is from full-throttle
Pinion gear bearings have a constant-pitch noise.
acceleration. Overloading happens when towing
heavier-than-recommended loads. Compdnent break This noise changes only with vehicle speed. Pinion
age can occur when the wheels are spun excessively. bearing noise will be higher because i t rotates at a
Insufficient or incorrect lubricants contribute to faster rate. Drive the vehicle and load the differen
breakage through overheating. Loose differential tial. I f bearing noise occurs the pinion rear bearing is
components can also cause breakage. the source of the noise. I f the bearing noise is heard
Incorrect bearing preload or gear backlash will not during a coast, front bearing is the source.
result i n component breakage. This will cause accel Worn, damaged differential bearings usually pro
erated wear and contribute to early failure. Mis-ad duce a low pitch noise. Differential bearing noise is
justment will produce noise. I f a mis-adjustment similar to pinion bearing. The pitch of differential
condition is not corrected, component failure can re bearing noise is also constant and varies only with
sult. vehicle speed.
Axle shaft bearings produce noise and vibration • Bent axle shaft
when worn or damaged. The noise generally changes Check for loose or damaged front-end components
when the bearings are loaded. Road test the vehicle. or engine/transmission mounts. These components
Turn the vehicle sharply to the left and to the right. can contribute to what appears to be a rear-end v i
This will load the bearings and change the noise bration. Do not overlook engine accessories, brackets
level. Where axle bearing damage is slight, the noise and drive belts.
is usually not noticeable at speeds above 30 mph. A l l driveline components should be examined be
fore starting any repair.
LOW SPEED KNOCK Refer to Group 22, Wheels And Tires for additional
Low speed knock is generally caused by a worn U - information.
joint or by worn side-gear thrust washers. A worn
pinion gear shaft bore will also cause low speed DRIVELINE SNAP
knock. A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
VIBRATION • High engine idle speed
Vibration at the rear of the vehicle is usually • Loose engine/transmission/transfer case mounts
caused by a: • Worn U-joints
• Damaged drive shaft • Loose spring mounts
• Missing drive shaft balance weight • Loose pinion gear nut and yoke
• Worn, out-of-balance wheels • Excessive ring gear backlash
• Loose wheel lug nuts • Excessive differential side gear-to-case clearance
• Worn U-joint The source of a snap or a clunk noise can be deter
• Loose spring U-bolts mined with the assistance of a helper. Raise the ve
• Loose/broken springs hicle on a hoist with the wheels free to rotate.
• Damaged axle shaft bearings Instruct the helper to shift the transmission into
• Loose pinion gear nut gear. Listen for the noise, a mechanics stethoscope is
• Excessive pinion yoke run out helpful i n isolating the source of a noise.
FRONT SUSPENSION AND AXLE 2 - 21
semvme DIAGNOSIS
Condition Possible Cause Correction

WHEEL NOISE (a) Wheel loose. (a) Tighten loose nuts.
(b) Faulty, brinelled wheel bearing. (b) Faulty or brinelled bearings must be
replaced.
AXLE SHAFT NOISE (a) Misaligned axle shaft tube. (a) Inspect axle shaft tube alignment.
Correct as necessary.
(b) Bent or sprung axle shaft. (b) Replace bent or sprung axle shaft.
(c) End play in drive pinion bearings. (c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Excessive gear backlash between ring (d) Check adjustment of ring gear
gear and pinion gear. backlash and pinion gear. Correct as
necessary.
(e) Improper adjustment of drive pinion (e) Adjust drive pinion shaft bearings.
gear shaft bearings. (f) Tighten drive pinion gearshaft yoke nut
(f) Loose drive pinion gearshaft yoke nut. with specified torque.
(g) Improper wheel bearing adjustment. (g) Readjust as necessary.
(h) Scuffed gear tooth contact surfaces. (h) If necessary, replace scuffed gears.
AXLE SHAFT BROKE (a) Misaligned axle shaft tube. (a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Vehicle overloaded. (b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Erratic clutch operation (c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Grabbing clutch. (d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
DIFFERENTIAL CASE (a) Improper adjustment of differential (a) Replace cracked case; examine gears
CRACKED bearings. and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Excessive ring gear backlash. (b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Vehicle overloaded. (c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Erratic clutch operation. (d) Replace cracked case. After inspecting
for other possible causes, examine
gears and bearings for possible
damage. Avoid erratic use of clutch.
DIFFERENTIAL GEARS (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
SCORED on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Excessive spinning of one wheel/tire. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
2 22 FRONT SUSPENSION AND AXLE
S E R V I C E DIAGNOSIS (CONT'D)

(b) Worn axle shaft seals. (b) Replace worn seals.
(c) Repair or replace housing as
(c) Cracked differential housing. - necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal.
(e) Scored and worn yoke. (f) Remove cover and clean flange and
(f) Axle cover not properly sealed. reseal.
AXLE OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash, (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (a) Overloading. (a) Replace gears. Examine other gears
(RING GEAR AND and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
AXLE NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Loose differential bearings. (f) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
i O D E L 4 4 / 6 0 A X L E A N D T U B E A X L E (2WD)
INDEX
page page
Axle Shaft Oil Sea! 35 Final Assembly . 45
Axle Shaft— Cardan U-Joint 26 General Information 23
Backlash and Contact Pattern Analysis 45 Hub Bearing and Axle Shaft 25
Cleaning/Inspection 37 Lubricant Change 23
Differential and Pinion Measurement . 40 Lubricant Specifications 23
Differential Assembly 38 Pinion Gear Assembly/Installation 41
Differential Disassembly 35 Pinion Gear Depth Information 38
Differential Installation 44 Pinion Removal/Disassembly 36
Differential Removal 34 Pinion Seal Replacement 24
Differential Shim Pack Measurement and Steering Knuckle and Ball Studs 31
Adjustment 43
Vacuum Disconnect 44/60 Axle 27
Drive Axle Assembly Replacement 34
GENERAL INF0R1ATI0N • Ring and pinion gears are replace

The housing for Model 44/60 front axles consists of an
iron center casting with tubes on each side. The tubes LUBRICANT SPECIFICATIONS
are pressed into and welded to the differential housing. Thermal Stable Multi-Purpose Gear Lubricant is
The integral type housing, hypoid gear design has used for Model 44/60 axles. The lubricant should
the centerline of the pinion set below the centerline have API GL 5 quality specifications. MOPAR® Ther
of the ring gear. mal Stable Multi-Purpose Gear Lubricant conforms
The axle has a vent used to relieve internal pres to these specifications.
sure caused by lubricant vaporization and internal • The factory fill for the Model 44/60 axle is SAE
expansion. 80W-90 gear lubricant
Refer to Group 0, Lubrication and Maintenance for
The axles are equipped with semi-floating axle
additional information.
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the CAUTION: If axle is submerged in water, the lubri
hub bearings. The hub bearings are bolted to the cant must be replaced Immediately to avoid con
steering knuckle at the outboard end of the axle tube tamination.
yoke. The hub bearings are serviced as an assembly.
The axles are equipped with ABS brake sensors.
The sensors are attached to the knuckle assemblies LUBRICANT CHANGE
and tone rings are pressed on the axle shaft. Use The gear lubricant will drain quicker i f the vehicle
care when removing axle shafts as NOT to dam has been recently driven.
age the tone wheel or the sensor. (1) Raise and support the vehicle.
The stamped steel cover provides a means for in (2) Remove the lubricant fill hole plug from the dif
spection and servicing the differential. ferential housing cover.
The Model 44/60 axle has the assembly part num (3) Remove the differential housing cover and
ber and gear ratio listed on a tag. The tag is attached drain the lubricant from the housing.
to the housing cover. Build date identification codes (4) Clean the housing cavity with a flushing oil,
are stamped on the axle shaft tube cover side. light engine oil or lint free cloth. Do not use water,
The differential case is a one-piece design. The dif steam, kerosene or gasoline for cleaning.
ferential pinion mate shaft is retained with a roll (5) Remove the sealant from the housing and cover
pin. Differential bearing preload and ring gear back surfaces. Use solvent to clean the mating surfaces.
lash is adjusted by the use of shims. The shims are (6) Apply a bead of MOPAR® Silicone Rubber Seal
located between the differential bearing cones and ant to the housing cover (Fig. 1). Allow the sealant
case. Pinion bearing preload is set and maintained by to cure for a few minutes.
the use of a collapsible spacer. Install the housing cover within 5 minutes af
PINION GEAR DEPTH MEASUREMENT WITH ter applying the sealant. I f not installed the
GAUGE SET 6730 and Dial Indicator C-3339 is used sealant must be removed and another bead ap
when; plied,
• Axle/differential housing is being replaced (7) Install the cover and any identification tag.
• Original pinion depth shim pack is unknown Tighten the cover bolts i n a criss-cross pattern to;
SEALING CONTOUR OF BEAD
C-452 J9102-31
Fig. 2 Pinion Yoke Remowal
SPECIAL TOOL
7797k
Fig. 1 Typical Housing Cower With Sealant

• Model 44: 41 N-m (30 ft. lbs.) torque.
• Model 60: 47 N-m (35 ft. lbs.) torque.
(8) Refill the differential with MOPAR® Hypoid
Gear Lubricant within 13 mm (1/2 in.) below the fill
plug hole.
CAUTION: Do not over fill differential. Overfilling PINION SEAL

can result in lubricant foaming and overheating.
J9402-59
(9) Install the fill hole plug and lower the vehicle.
Fig. 3 Seal Remowal
PINION SEAL REPLACEMENT
INSTALLATION
REMOVAL (1) Apply a light coating of gear lubricant on the
(1) Raise and support the vehicle. lip of pinion seal. Install seal Installer C-163.
(2) Remove wheel and tire assemblies (2) Align the installation reference marks and in
(3) Mark the propeller shaft yoke and pinion yoke stall yoke on pinion shaft with Installer W-162D for
for installation alignment reference. model 44 axle. Use Installer C-3718 for model 60
(4) Remove the propeller shaft from the yoke. axle. (Fig. 4).
(5) Rotate the pinion gear three or four times. (3) Install a new nut on the pinion gear. Tighten
Make sure brakes are not dragging during this the nut only enough to remove the shaft end
procedure. play.
(6) Measure the amount of torque necessary to ro
tate the pinion gear with a torque wrench. Note the CAUTION: Exercise care during the bearing preload
torque for installation reference. It must be known torque adjustment. Do not over-tighten, or loosen
to properly adjust the pinion gear bearing pre and then re-tighten the nut. Do not exceed the bear
load torque after seal installation. ing preload torque. The collapsible preload spacer
(7) Remove the pinion yoke nut and washer. Use on the pinion shaft will have to be replaced. The
Remover C-452 and Holder C-3281 to remove the bearing preload torque will be re-adjusted after
pinion yoke (Fig. 2). ward.
(8) Mark the positions of the yoke and pinion gear
(4) Install a socket and inch-pound torque wrench
for installation alignment reference.
(9) Use Remover 7797A and slide hammer to re on the pinion nut.
move the pinion gear seal (Fig. 3).
•
(7) Continue tightening the shaft nut i n small in
YOKE
crements until the correct bearing preload torque is
attained. Tighten the pinion shaft nut:
• M o d e l 44s No less t h a n 217 N-m (160 ft. lbs.)
torque. No greater than 271 N-m (200 ft. lbs.)
torque
• M o d e l 60s No less t h a n 298 N-m (220 ft. lbs.)
torque. No greater than 379 N-m (280 ft. lbs.)
torque
(8) Align the installation reference marks and at
tach the propeller shaft to the yoke.
(9) Add API grade GL 5 hypoid gear lubricant to
the differential housing, i f necessary.
(10) Install wheel and tire assemblies
(11) Remove support and lower the vehicle.
HUB BEARING AND AXLE SHAFT
REMOVAL
J9402-61 (2) Remove the wheel and tire assembly.
(3) Remove the brake components from the axle,
Fig. 4 Yoke installer refer to Group 5 Brakes.
(4) Remove the cotter pin and axle hub nut.
(5) Rotate the shaft with the torque wrench and
(5) Remove the hub to knuckle bolts (Fig. 6). Re
note the torque. move the hub bearing from the steering knuckle and
The required preload is equal to amount re axle shaft.
corded during removal plus 0.56 N-m (5 in. lbs.).
The used bearing preload torque must never
exceed 2.25 N-m (20 in. lbs.)
(6) Use Flange Holder 6719 to retain the yoke and
shaft (Fig. 5). Tighten the shaft nut i n very small in
crements.
DIFFERENTIAL
Fig. 6 Hub and Knuckle

(6) Remove the brake dust shield.
(7) On 4WD vehicles, remove the axle shaft
from the housing. Avoid damaging the axle
shaft oil seal.
INSTALLATION
(1) On 4x4 vehicles clean the axle shaft and apply
a thin film of Mopar Wheel Bearing Grease to the
shaft splines, seal contact surface, hub bore. Install
the axle shaft into the housing and differential side
gears. Avoid damaging the axle shaft oil seals in the
Fig. 5 Tightening Pinion Shaft Nut differential.
(2) Install dust shield and hub bearing on knuckle.
(3) Install the hub bearing to knuckle bolts and LARGE-
tighten to 170 N-m (125 ft. lbs.) torque. DIAMETER
SOCKET
(4) Install the axle washer and nut, tighten nut to WRENCH
237 N-m (175 ft. lbs.) torque. Align nut to next cotter
pin hole and install new cotter pin.
(5) Install the brake components, refer to Group 5,
Brakes.
(6) Install the wheel and tire assembly.
AXLE SHAFT— CARDAN U-JOINT
DISASSEMBLY
Single cardan U-joints are not serviceable. I f defec
tive, they must be replaced as a unit. I f the bearings,
seals, spider or bearing caps are damaged or worn,
replace the complete U-joint.
CAUTION: Clamp only the forged portion of the

yoke in the vise. Also, to avoid distorting the yoke, J8902-16
do not over tighten the vise jaws.
Fig. 8 Yoke Bearing Cap Removal
(1) Remove the bearing cap retaining snap rings (4) Release the vise jaws. Remove the sockets and
(Fig. 7). bearing cap that was partially forced out of the yoke.
BEARING (5) Repeat the above procedure for the remaining
bearing cap.
(6) Remove the remaining bearing cap, bearings,
seals and spider from the propeller shaft yoke.
CLEANING AND INSPECTION

(1) Clean all the U-joint yoke bores with cleaning
solvent and a wire brush. Ensure that all the rust
and foreign matter are removed from the bores.
(2) Inspect the yokes for distortion, cracks and
worn bearing cap bores.
(3) Replace the complete U-joint i f any of the com
ponents are defective.
ASSEMBLY
(1) Pack the bearing caps 1/3 full of wheel bearing
SNAP CAP lubricant. Apply extreme pressure (EP), lithium-base
RINGS lubricant to aid i n installation.
J8902-15 (2) Position the spider i n the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
Fig. 7 Axle Shaft Outer U-Joint bores far enough to hold the spider i n position.
It can be helpful to saturate the bearing caps (3) Place the socket (driver) against one bearing
with penetrating oil prior to removal. cap. Position the yoke with the socket wrench i n a
(2) Locate a socket that is larger i n diameter than vise.
the bearing cap. Place the socket (receiver) against (4) Compress the vise to force the bearing caps into
the yoke and around the perimeter of the bearing cap the yoke. Force the caps enough to install the retain
to be removed. Locate a socket that is smaller i n di ing clips.
ameter than the bearing cap. Place the socket (driv (5) Install the bearing cap retaining clips.
er) against the opposite bearing cap. Position the (6) Install the axle shaft, refer to Hub Bearing and
yoke with the sockets i n a vise (Fig. 8). Axle Shaft installation.
(3) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
WACUUi DISCONNECT 44/SO AXLE CHECK

VALVE
VACUUM CONTROL SYSTEM
The disconnect axle control system consists of;
• Shift motor
• Indicator switch
• Vacuum switch
• Vacuum harness (Fig. 9)
Refer to Group 21 —Transmissions for addi
tional information.
SHIFT
MOTOR J9202-55
Fig, 9 Vacuum Control System

DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
TWO-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE
INDICATOR LIGHT WILL
NOT GO OUT WHEN
TRANSFER CASE SELECTOR
IS MOVED FROM 4H TO
2H POSITION.
YES i
START ENGINE DEPRESS BRAKE TEST COMPLETE

INSPECT INDICATOR PEDAL. PLACE TRANSFER
RAISE VEHICLE SO ALL SWITCH AND WIRING ON CASE SELECTOR IN 2H POSITION
FOUR WHEELS ARE SHIFT MOTOR HOUSING AND TRANSMISSION IN
FREE TO ROTATE. FOR DAMAGE AND DRIVE (AUTOMATIC) OR FIRST
SHORT-CIRCUIT. GEAR (MANUAL). EASE OFF FROM
REPAIR AS NECESSARY. BRAKE AND LET WHEELS ROTATE
SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT ROTATES.
NOT ROTATE.
INSPECT TRANSFER
FOUR-WHEEL DRIVE CASE LINKAGE
INDICATOR LIGHT
REMAINS ON.
CHECK TRANSFER
CASE. REPAIR
PLACE TRANSMISSION AS NECESSARY.
IN NEUTRAL TEST FOR VACUUM
IN VACUUM HOSE
THAT CONNECTS TO
• INBOARD SHIFT
DICONNECTTHE MOTOR PORT.
SHIFT MOTOR VACUUM (VACUUM SHOULD BE
HOSES. BETWEEN 10-20 IN. HG.)
VACUUM OK
NO VACUUM
OR LOW VACUUM.
=3=^
STOP ENGINE
INSPECT INTAKE MANIFOLD
VACUUM SUPPLY HOSE CONNECTION,
TRANSFER CASE VACUUM SWITCH CONNECT A VACUUM
CONNECTION, VACUUM RESERVOIR, PUMP TO THE INBOARD
AND SHIFT SYSTEM VACUUM HOSES SHIFT MOTOR PORT.
FOR PROPER CONNECTION, RESTRICTION, APPLY 15 IN. HG
AIR LEAKS, AND DAMAGE. REPAIR OR REPLACE VACUUM AND ROTATE
AS NECESSARY. RIGHT WHEEL.
FRONT AXLE FRONT AXL*

DISCONNECTS. DOES NOT
DISCONNECT.
INSPECT VACUUM
HOSES FOR AIR LEAKS, KINKS, ETC.
REPAIR AS NECESSARY. REMOVE SHIFT MOTOR
HOUSING COVER. CONNECT
VACUUM PUMP TO
SHIFT MOTOR PORT. FRONT AXLE
REPLACE SHIFT MOTOR WILL NOT DISCONNECT.
IF ARMATURE DOES
NOT MOVE IN AND OUT
FREELY.
REMOVE SHIFT MOTOR HOUSING
COVER. INSPECT SHIFT FORK,
COLLAR, AND AXLE SHAFTS.
REPAIR OR REPLACE AS
J9002-95 NECESSARY.
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D!
FOUR-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE INDICATOR

LIGHT DOES NOT LIGHT WHEN
TRANSFER CASE SELECTOR IN
4H OR 4L POSITION.
RAISE VEHICLE SO ALL FOUR

WHEELS ARE FREE TO ROTATE.
START ENGINE, DEPRESS BRAKE PEDAL.

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

SHAFT DOES SHAFT TURNS.
NOT ROTATE.
INSPECT TRANSFER FRONT AXLE RECOMMENDATION:

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

SWITCH, WIRING, AND START ENGINE. TEST FOR VACUUM
LAMP FOR DAMAGE. AT HOSE REMOVED FROM OUT
REPAIR AS NECESSARY. BOARD PORT ON SHIFT MOTOR,
SHOULD BE BETWEEN 10-20 IN HG.
NO VACUUM STOP ENGINE VACUUM OK

OR LOW VACUUM.
CONNECT A VACUUM PUMP

INSPECT INTAKE MANIFOLD TO THE OUTBOARD
VACUUM SUPPLY HOSE CONNECTION, SHIFT MOTOR PORT.
TRANSFER CASE VACUUM SWITCH APPLY 15 INCHES HG. VACUUM
CONNECTION, VACUUM RESERVOIR, AND SHIFT AND ROTATE LEFT WHEEL.
SYSTEM VACUUM HOSES FOR PROPER CONNECTION,
RESTRICTION, LEAKS, AND DAMAGE.
REPAIR OR REPLACE AS NECESSARY.
FRONT AXLE FRONT AXLE

NO VACUUM CONNECTED. DOES NOT
CONNECT.
CHECK TRANSFER CASE

VACUUM SWITCH. REPLACE INSPECT VACUUM HOSES
OR REPAIR IF SWITCH FOR LEAKS, KINKS, ETC. REMOVE SHIFT MOTOR
PLUNGER IS DIFFICULT TO REPAIR AS NECESSARY. HOUSING COVER. CONNECT
MOVE OR BINDS. VACUUM PUMP TO
SHIFT MOTOR PORT.
REPLACE SHIFT MOTOR
IF ARMATURE DOES
NOT MOVE IN AND OUT
FREELY.
REMOVE SHIFT MOTOR HOUSING

COVER. INSPECT SHIFT FORK,
COLLAR, AND AXLE SHAFTS. FRONT AXLE
REPAIR OR REPLACE AS WILL NOT CONNECT.
NECESSARY.
J9002-96
SHIFT MOTOR — REMOVAL/DISASSEMBLY (4) Install the shift motor housing gasket and
(1) Disconnect the vacuum and wiring connector cover. Ensure the shift f o r k is correctly guided
from the shift housing. i n t o the shift collar groove.
(2) Remove indicator switch. (5) Install the shift motor housing shield and attach
(3) Remove the shift motor housing cover, gasket ing bolts. Tighten the bolts to 11 N-m (96 in. lbs.)
and shield from the housing (Fig. 10). torque.
(6) Add 148 ml (5 ounces) of API grade GL 5 hy-
DISCONNECT VACUUM poid gear lubricant to the shift motor housing. Add
INDICATOR LAMP SHIFT
SWITCH
HOUSING
MOTOR
lubricant through indicator switch mounting hole.
(7) Install indicator switch, electrical connector
and vacuum harness.
INTERMEDIATE
AXLE SHAFT
INTERMEDIATE AXLE SHAFT—REMOVAL/
DISASSEMBLY
Service to the Disconnect axle seals and bearing re
quire the use of Tool Set 6288 (J34659) and Seal In
staller 6228.
(1) Remove the vacuum motor housing. Refer to
BEARING Shift Motor Removal i n this section.
SHIFT FORK SHIFT SEAL
(3) Remove the outer axle shaft. Refer to Hub
COLLAR
J9402-63 Bearing and Axle Shaft in this section.
(4) Remove shift collar and intermediate axle shaft.
Fig. 10 Shift Motor Housing (5) Remove the inner axle shaft seal from the shift
motor housing with a long drift or punch. Be careful
(4) Remove the E-clips from the shift motor hous
not to damage housing.
ing and shaft. Remove shift motor and shift fork from
(6) Remove the intermediate axle shaft bearing
the housing (Fig. 11).
(Fig. 12).
INDICATOR
SWITCH SHIFT MOTOR AXLE LOCATION
HOUSING OPENING TUIE FOR OPEN-END
WRENCH
DISCONNECT HOUSING
A N D GASKET
VACUUM SPECIAL TOOL
5041-2
PORTS
SPECIAL TOOL
NUT
J9202-54
J9402-18
Fig. 11 Shift Motor Components

Fig. 12 Bearing Removal Tool Installed
(5) Remove the O-ring seal from the shift motor shaft.
(6) Clean and inspect all components. I f any com ASSEMBLY/INSTALLATION
ponent is excessively worn or damaged, i t should be (1) Position the bearing on installation tool. Seat
replaced. the bearing i n the housing bore (Fig. 13).
(2) Clean the inside perimeter of the axle shaft
ASSEMBLY/INSTALLATION tube with fine crocus cloth.
(1) Install a new O-ring seal on the shift motor shaft. (3) Apply a light film of oil to the inside lip of the
(2) Insert the shift motor shaft through the hole i n new axle shaft seal.
the housing and shift fork. The shift fork offset (4) Install the inner axle seal (Fig. 14) 44 axle (Fig.
should be toward the differential. 15) 60 axle.
The inner axle seal position is different on a 44
(3) Install the E-clips on the shift motor shaft and
then a 60 axle. Be sure to use the correct installer,
housing.
i f wrong installer is use axle w i l l not seal.
CAUTION:Apply all-purpose lubricant to the axle

SHIFT MOTOR
SPECIAL TOOL shaft s p l i n e s to prevent damage to the s e a l during
HOUSING OPENING
5041-3 axle shaft installation.
(8) Insert the axle shaft into the tube. Engage the
splined-end of the shaft with the shift collar. Refer to
Hub Bearing and Axle Shaft i n this section.
(9) Install the vacuum motor housing. Refer to
Shift Motor Installation in this section.
STEERING KNUCKLE AND BALL STUDS

Ball Stud service procedures below require removal of
the hub bearing and axle shaft. Removal and installa
tion of upper and lower ball studs requires Special
BEARING Tools.
J9402-19
Fig. 13 intermediate Shaft Bearing installation KNUCKLE REMOWAL

(1) Remove hub bearing and axle shaft. Refer to
SHIFT MOTOR LOCATION the Removal procedures i n this Group.
HOUSING OPENING FOR OPEN-END
WRENCH (2) Remove tie-rod or drag link end from the steer
ing knuckle arm. Remove the ABS sensor wire and
bracket from knuckle.
(3) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(4) Strike the steering knuckle with a brass ham
mer to loosen. Remove knuckle from axle tube yokes.
UPPER BALL STUD REPLACEMENT 44 AXLE

NUT
(1) Position tools as shown to remove ball stud
S K O A L TOOL SPECIAL TOOL
SPECIAL TOOL 50414
(Fig. 16).
504144
50414
J9402-22
Fig. 14 Inner axle seal installation 44 axle SPECIAL TOOL

C-4212F
SHIFT MOTOR LOCATION

HOUSING O P I N I N G FOR OPEN-END
WRENCH
SPECIAL TOOL
6289-1
SPECIAL TOOL
6289-3
SPECIAL TOOL
SPECIAL TOOL 50414
504140P SPECIAL TOOL
5041-3
J9402-23
Fig. 15 Inner axle seal installation 60 axle
(5) Insert the intermediate axle shaft into the dif

ferential side gear.
(6) Install the shift collar on the splined end of the
intermediate axle shaft.
( 7 ) Lubricate the splined end of the intermediate
axle shaft with multi-purpose lubricant. J9402-49
Fig. 16 Upper Ball Stud Remove
(2) Position tools as shown to install ball stud (Fig.

17).
SffQALIOOl
C-4212F
SPECIAL TOOL
6758
i SPECIAL TOOL
SPECIAL T Q O l
6289-1
6289-12
SPECIAL TOOL
C-4212F
J9402-51
J9402-48 Fig. 18 Lower Ball Stud Remove
Fig. 17 Upper Ball Stud Install

LOWER BALL STUD REPLACEMENT 44 AXLE
(Fig. 18).
19).
UPPER BALL STUD REPLACEMENT 60 AXLE

(Fig. 20).
21).
SPECIAL TOOL
6758
L O W E R BALL STUD REPLACEMENT 60 AXLE
(Fig. 22).
23).
KNUCKLE INSTALLATION MODEL 44

(1) Position the steering knuckle on the ball studs. SPECIAL TOOL
(2) Install and tighten lower ball stud nut to 108 C-4212F
N-m (80 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(3) Install and tighten upper ball stud nut to 101 J9402-50
N-m (75 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin. Fig. 19 Lower Bail Stud Install
KNUCKLE
SPECIAL TOOL
C4212F
5kJ
SPECIAL TOOL
6756
SPECIAL TOOL
6756
SPECIAL T O O L
6757 SPECIAL TOOL
6757
KNUCKLE
SPECIAL TOOL
C-4212F J9402-40
J9402-38
Fig. 22 Lower Ball Stud Remove
Fig. 20 Upper Ball Stud Remove
KNUCKLE
SPECIAL l O O L
C4212F
SPECIAL TOOL
6758
SPECIAL TOOL
6759
SPECIAL TOOL
6760
KNUCKLE
SPECIAL TOOL III

C4212F J9402-41
J9402-39
Fig. 23 Lower Bail Stud Install
Fig. 21 Upper Ball Stud Install
(2) Install and tighten lower ball stud nut to 47
(4) Install the Hub Bearing and Axle Shaft. Refer N-m (35 ft. lbs.) torque. Do not install cotter pin
to the installation procedure. at this time.
(5) Install tie-rod or drag link end onto the steer (3) Install and tighten upper ball stud nut to 94
ing knuckle arm. Install the ABS sensor wire and N-m (70 ft. lbs.) torque. Advance nut to next slot to
bracket to the knuckle, refer to Group 5, Brakes for line up hole and install new cotter pin.
proper set-up. (4) Retorque lower ball stud nut to 190 - 217 N-m
(140 - 160 ft. lbs.) torque. Advance nut to next slot to
KNUCKLE INSTALLATION MODEL 60
line up hole and install new cotter pin.
(1) Position the steering knuckle on the ball studs. (5) Install the Hub Bearing and Axle Shaft. Refer
to the installation procedure.
(6) Install tie-rod or drag link end onto the steer (5) Connect the track bar to the axle bracket and
ing knuckle arm. Install the ABS sensor wire and install the bolt. Do not tighten at this time.
bracket to the knuckle, refer to Group 5, Brakes for It is important that the springs support the
proper set-up. weight of the vehicle when the track bar is con
nected. I f the springs are not at normal ride
DRIVE AXLE ASSEMBLY REPLACEMENT height,. the vehicle ride comfort could be af
fected.
REMOVAL (6) Install the shock absorber and tighten bolts to
(1) Raise vehicle and position support stands un 121 N-m (89 ft. lbs.) torque.
der the frame rails behind the lower suspension arm (7) Install the stabilizer bar link to the axle
brackets. bracket. Tighten the nut to 37 N-m (27 ft. lbs.)
(2) Remove the front wheels assemblies. torque.
(3) Remove the brake components and ABS brake (8) Install the drag link and tie rod to the steering
sensor (if equipped). Refer to Group 5—Brakes. knuckles and tighten the nuts to 88 N-m (65 ft. lbs.)
(4) On 4WD vehicles, - disconnect the axle vent torque.
hose. Disconnect vacuum hose and electrical connec (9) Install the brake components and ABS brake
tor at disconnect housing. sensor (if equipped). Refer to Group 5—Brakes.
(5) On 4WD vehicles, mark the drive shaft yoke, (10) On 4WD vehicles, connect the vent hose to the
axle pinion yoke and transfer case flange for align tube fitting. Connect vacuum hose and electrical con
ment reference. Disconnect the drive shaft from the nector to disconnect housing.
axle and transfer case. (11) On 4WD vehicles, align the reference marks
(6) Disconnect the stabilizer bar link at the axle and connect the drive shaft to the axle yoke and
bracket. transfer case flange. Tighten the U-joint clamp bolts
(7) Disconnect the shock absorbers from axle to 19 N-m (14 ft. lbs.) torque. Tighten flange bolts to
bracket. 88 N-m (65 ft. lbs.) torque.
(8) Disconnect the track bar from the axle bracket. (12) Check differential lubricant and add i f neces
(9) Disconnect the tie rod and drag link from the sary.
steering knuckle. (13) Install the wheel and tire assemblies.
(10) Support the axle with a hydraulic jack under (14) Remove the supports and lower the vehicle.
the differential. (15) Tighten the upper suspension • arm nuts at
(11) Disconnect the upper and lower suspension axle to 121 N-m (89 ft. lbs.) torque. Tighten the upper
arms from the axle bracket. Mark cams for instal suspension arm nuts at frame to 84 N-m (62 ft. lbs.)
lation reference. torque.
(12) Lower the jack enough to remove the axle. (16) Tighten the lower suspension arm nuts at axle
The coil springs will drop with the axle. to 84 N-m (62 ft. lbs.) torque. Tighten the lower sus
(13) Remove the coil springs from the axle bracket. pension arm nuts at frame to 119 N-m (88 ft. lbs.)
torque.
INSTALLATION (17) Tighten the track bar bolt at the axle bracket
to 176 N-m (130 ft. lbs.) torque.
CAUTION: All suspension components that u s e rub (18) Check the front wheel alignment.
ber bushings should be tightened with the vehicle
at the ride height. It is important to have the DIFFERENTIAL REMOVAL
springs supporting the weight of the vehicle when To service the differential the axle assembly and
the fasteners are torqued. If the springs are not at axle shafts must be removed. Refer to the removal
their normal ride height, vehicle ride comfort could procedures i n this Group.
be affected. This can also c a u s e premature rubber (1) Note the installation reference letters
bushing wear. Rubber bushings must never be lu stamped on the bearing caps and housing ma
bricated. chined sealing surface (Fig. 24).
(2) Remove the differential bearing caps.
(1) Install the springs, retainer clip and bolts. (3) Position Spreader W-129-B with the tool dowel
(2) Support the axle on a hydraulic jack under the pins seated i n the locating holes (Fig. 25). Install the
differential. Position the axle under the vehicle. holddown clamps and tighten the tool turnbuckle fin
(3) Raise the axle with a floor jack and align i t ger-tight.
with the spring pads. (4) Install a pilot stud at the left side of the differ
(4) Position the upper and lower suspension arm at ential housing. Attach Dial Indicator to housing pilot
the axle bracket. Install bolts, nuts and align cams to stud. Load the indicator plunger against the opposite
reference marks. Do not tighten at this time. side of the housing (Fig. 25) and zero the indicator.
INSTALLATION
DIFFERENTIAL PRY BAR
EFERENCE LETTERS
J9003-92
Fig. 24 Bearing Cap identification
SPECIAL TOOL DIAL

W-129-B INDICATOR
J9302-18
Fig. 26 Differential Removal

(4) Install the inner axle seal (Fig. 27) 44 axle (Fig.
28) 60 axle.
DIFFERENTIAL POSITION
HOUSING FOR OPEN-END
WRENCH
J9402-2
\
r
"l|l|l|l|l|l|l|l|l|l|l|l|l|l|^^:^
Fig. 25 Spread Differential Housing
CAUTION: Do not spread over 0.38 m m (0.015 in.). If SPECIAL TOOL
t h e h o u s i n g is spread t o o m u c h , it c o u l d be d i s 5041-2
t o r t e d or d a m a g e d .
NUT
SEAL SPECIAL TOOL
(5) Separate the housing a maximum of 0.38 mm SPECIAL TOOL 5041-3
(0.015 in.). Measure the distance with the dial indi 5041-7 J9402-21
cator (Fig. 25).
(6) Remove the dial indicator. Fig. 27 Axle seal installation 44 axle
(7) Pry the differential case loose from the housing. DIFFERENTIAL DISASSEMBLY
To prevent damage, pivot on housing with the end of
the pry bar against spreader (Fig. 26). (1) Remove the bearings from the differential case
(8) Remove the case from housing. Mark or tag with Bearing Splitter 1130, Bearing Splitter Bridge
bearing cups indicating which side they were re 938 and button. On 44 axle use Button C-293-3 on 60
moved. Remove spreader from housing. axle use Button 919-4 (Fig. 29).
(2) Remove bearing shims from case hubs and
AXLE SHAFT OIL SEAL mark them (with hub identity) for assembly refer
(1) Remove the axle shaft seal from the differential ence. Record the thickness of the shims.
housing with a long drift or punch. Be careful n o t (3) Clamp the differential case in a vise equipped
to damage housing. with soft jaws. Remove a n d discard the ring gear
(2) Clean the inside perimeter of the differential bolts. Tap the ring gear with a rawhide or plastic
housing with fine crocus cloth. mallet and remove (Fig. 30).
(3) Apply a light film of oil to the inside lip of the (4) Remove the pinion gear mate shaft roll pin and
new axle shaft seal. shaft.
2 - 36 FRONT SUSPENSION AND AXLE — •
DIFFERENTIAL H O U S I N G POSITION
SPECIAL TOOL
5041-7
J9402-20
Fig. 28 Axle seal installation 60 axle Fig. 30 Ring Gear Removal

THRUST
WASHER
MATE GEAR SIDE GEAR J9203-61
Fig. 31 Pinion Mate Gear Removal

Fig. 29 Differential Bearing Removal
(5) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 31).
(6) Remove the differential side gears and thrust
washers.
(7) Remove the case from the vise.
PINION REMOVAL/DISASSEMBLY
(1) Remove the pinion yoke nut and washer. Use
yoke Holder C3281 and yoke Remover C-452 to re
move pinion yoke (Fig. 32).
(2) Drive out pinion gear from housing with raw
hide or plastic hammer (Fig. 33). Catch the pinion
with your hand to prevent i t from falling and being
damaged.
(3) Remove the pinion gear seal with a slide ham G452 J9102-31
mer or pry out with bar.

Fig. 32 Pinion Yoke Removal
RAWHIDE
J9302-23
Fig. 35 Rear Bearing Cup Removal

Fig. 33 Remove Pinion Gear
(4) Remove oil slinger, front bearing.
(5) Remove the front pinion bearing cup with Han
dle C-4171 and Remover D-147 for 44 axle. Use Han
dle C-4171 and Remover D-158 for 60 axle (Fig. 34).
Fig. 36 Collapsible Spacer

(9) Remove the oil slinger (select thickness-produc
tion) from the pinion gear shaft. Record the thick
ness of slinger.
Fig. 34 Front Bearing Cup Removal
CLEANING/INSPECTION
(6) Remove the rear bearing cup with Handle Wash differential components with cleaning solvent
C-4171 and Remover D-148 for 44 axle. Use Handle
and dry with compressed air. Do not steam clean
C-4171 and Remover D-162 for 60 axle (Fig. 35).
the differential components.
(7) Remove the collapsible preload spacer (Fig. 36).
Wash bearings with solvent and towel dry, do not
(8) Remove the inner bearing from the pinion with
Bearing Splitter 1130 and Bearing Splitter Bridge dry with compressed air. Cup and bearing must be
938 (Fig. 37). replaced as matched sets only.
2 - 38 FRONT SUSPENSION AND AXLE . •
(2) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(3) Install new ring gear bolts and alternately
tighten to 95-122 N-m (70-90 ft. lbs.) torque (Fig. 38).
TORQUE
Fig. 37 inner Bearing Removal

Clean the axle shaft tubes with a stiff wire brush
or clean cloth.
Inspect the components for;
• Smooth appearance with no broken/dented sur Fig. 38 Ring Gear Bolt Installation
faces on the bearing rollers or the roller contact sur
faces (4) Lubricate all differential components with a
• Bearing cups must not be distorted or cracked light coat of grease or hypoid gear lubricant.
• Machined surfaces should be smooth and without
any raised edges PINION GEAR DEPTH INFORMATION
• Raised metal on shoulders of cup bores should be Ring and pinion gears are supplied as matched sets
removed with a hand stone only. The identifying numbers for the ring and pinion
• Wear and damage to pinion gear mate shaft, pin gear are etched into the face of each gear (Fig. 39). A
ion gears, side gears and thrust washers. Replace as plus (+) number, minus (-) number or zero (0) is etched
a matched set only. into the face of the pinion gear. This number is the
• Ring and pinion gear for worn and chipped teeth amount (in thousandths of an inch) the depth varies
• Ring gear for damaged bolt threads. Replaced as a from the standard depth setting of a pinion etched with
matched set only. a (0). The standard setting from the centerline of the
• Pinion yoke for cracks, worn splines, pitted areas, ring gear to the back face of the pinion is;
and a rough/corroded seal contact surface. Repair or • Model 44 axle: 109.5 mm (4.312 inches) Fig. 40.
replace as necessary. • Model 60 axle: 127 mm (5.000 inches) Fig. 40.
• Preload shims for damage and distortion. Install The standard depth provides the best teeth contact
new shims i f necessary. pattern.
THE BUTTON END ON THE PINION GEAR
DIFFERENTIAL ASSEMBLY HEAD IS NO LONGER A MACHINED-TO-SPECIFI-
(1) Install the following components i n the differ CATIONS SURFACE. DO NOT USE THIS SUR
ential case. FACE FOR PINION DEPTH SET-UP OR
• Differential side gears and thrust washers CHECKING (Fig. 40).
• Pinion gears and thrust washers Compensation for depth variance is achieved by a
• Pinion gear mate shaft (align holes in shaft and case) selected thickness oil slinger (production) or shims
• Pinion gear mate shaft roll pin (service). The slinger is placed between the inner pin
If replacement gears and thrust washers were ion bearing cone and gear head (Fig. 41). The shim
installed, it is not necessary to measure the pack is placed under the inner (rear) bearing cup. To
gear backlash. Correct fit is due to close ma change the pinion adjustment, shims are available i n
chining tolerances during manufacture. thicknesses of 0.003, 0.005, and 0.010 inch. I f
DRIVE P I N I O N HOUSING SHIM PACK

PRODUCTION GEAR DEPTH (SELECT THICKNESS)
NUMBERS VARIANCE SERVICE
COLLAPSIBLE
SPACER
REAR (INNER)
BEARING
CUP REAR (INNER)
BEARING
CONE
GEAR MATCHING NUMBER

(SAME AS RING GEAR NUMBER) J9003-100
Fig. 39 Pinion Gear ID Numbers OIL SUNGER

(SELECT THICKNESS)
INNER PINION PRODUCTION
BEARING PINION
GEAR
HEAD J9302-32
Fig. 41 Shim and Slinger Location

equipped, the oil slinger or baffle must be mea
sured and the thickness included with the total
BUTTON END
shim pack.
STANDARD
DEPTH I f a new gear set is being installed, note the
CENTERLINE OF number etched into both pinion gears. Add or
RING GEAR subtract the thickness of original depth shims
to compensate for the difference in depth vari
ances. Refer to the Depth Variance charts.
J9403-56
Fig. 40 Pinion Gear Standard Depth/Distance
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance

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 -0001
+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 -0.0)2 -0.003 -0.004 -0.005 -0.006 -0.0)7
-4 0 -0.001 -0.002 -0.0)3 -0.004 -0.005 -0.006 -0.007 -0.008
J8902-46
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or mi
nus amount needed.
For example, i f old pinion is plus (+) 1 and the new
pinion is minus (-) 3, intersecting figure is (+)0.004
inch (0.10mm). Add this amount to the original shim.
Or i f the old pinion is (-) 3 and the new pinion is (-)
2, intersecting figure is (-)0.001 inch (0.025mm). Sub
tract this amount from original shim. Refer to the
Pinion Gear Depth Variance Chart.
DIFFERENTIAL AND PINION MEASUREMENT
DIFFERENTIAL ZERO END PLAY

MEASUREMENT
(1) Place Master Differential Bearing D-345 for 44
axle or D-343 for 60 axle on the case hubs (Fig. 42).
Fig. 43 Differential Case End Play Measurement

PINION GEAR DEPTH MEASUREMENT
Pinion gear depth measurement is necessary
when axle housing is replaced or pinion select
shim pack is unknown. It is also recommended
when ring and pinion gears are replaced.
Measurements are done with pinion cups and pin
ion bearings installed i n housing. Take measure
ments with Pinion Gauge Set 6730. Use Pinion Block
from gauge set 6734 for 44 axle or 6736 for 60 axle
(Fig. 44).
DIAL INDICATOR
J9402-64
Fig. 42 Master Bearing Tools On Hubs

(2) Install a pilot stud at the right side of housing.
Attach Dial Indicator to the pilot stud. Load indica
tor plunger against the back of the ring gear (Fig.
43).
(3) Insert a small pry bar between the bearing cap
and left side of differential case. Pry the case as far
as possible to right side (Fig. 43). Zero the dial indi
cator pointer.
(4) Pry the case to left side and record the travel
distance.
The measurement above is the shim thickness ARBOR DISC
necessary for case zero end-play. The total

thickness will be determined during the ring J9403-45
gear backlash adjustment.
Fig. 44 Pinion Gear Depth Gauge Tools
(5) Remove indicator and pilot stud.
(1) Assemble Pinion Gauge Set, Pinion Block and

SCOOTER BLOCK
pinion bearings. Install assembly into differential
pinion gear bore and hand tighten cone (Fig. 45).
PINION BLOCK
\ t
P I N I O N HEIGHT Fig. 47 Pinion Gear Depth Measurement
BLOCK
required shim pack thickness. Include oil slinger
or baffle thickness with the total shim pack
Fig. 45 Pinion Height Block thickness.
(6) Remove the measurement tools from the differ
(2) Place Arbor Disc 6732 on Arbor D-115-3 and po
ential housing.
sition in the bearing cradles (Fig. 46). Install differ
ential bearing caps on Arbor Discs and tighten caps
PINION GEAR ASSEMBLY/INSTALLATION
snug only.
(1) Place the needed shim pack thickness in the
Arbor Discs have different steps to fit other
axle sizes. Pick correct size step for axle being pinion gear rear bearing bore (service only). Install
serviced. bearing cup with Driver Handle C-4171 and Installer
D-145 for 44 axle or Installer D - l l l for 60 axle (Fig.
ARBOR DISC P I N I O N BLOCK
48). Ensure cup is correctly seated.
INSTALLER
PINION
HEIGHT BLOCK
Fig. 46 Gauge Tools In Housing

(3) Firmly place Scooter Block and Dial Indicator
on pinion height block tool and zero the dial indicator
pointer.
(4) Slide the Scooter Block across the arbor while
observing indicator (Fig. 47). Record the longest HANDLE J9402-66
travel distance, whether inward (-) or outward (+),
indicated by the pointer. Fig. 48 Pinion Rear Bearing Cup Installation
Take the plunger travel indicated, plus or mi
nus the variance etched in the gear. This will (2) Install pinion front bearing cup with Handle
be the required thickness for the depth shims. C-4171 and Installer D-144 for 44 axle or Installer
(5) Measure the thickness of each depth shim with C-4203 for 60 axle (Fig. 49). Ensure cup is correctly
a micrometer. Combine the shims necessary for total seated.
INSTALLER HANDLE
COLPfStlLE
SPACil
SHOULDER
REAR
BEARING
J9402-65
PINION
Fig. 49 Pinion Front Bearing Cup Installation OIL CEAR
SUNGER
(3) I f used, place the oil slinger on the pinion gear.
Install rear (inner) bearing on pinion gear with I n
staller W-262 for 44 axle or Installer C-3095A for 60
axle (Fig. 50). Use press and installer for this opera J9302-66
tion.
Fig. 51 Collapsible Preload Spacer
PRESS YOKE
INSTALLER
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING ^
OIL
YOKE
SUNGER
HOLDER
DRIVE
PINION GEAR J9302-68
J9402-61
Fig. 50 Rear Bearing Installation
(4) Install a new collapsible preload spacer on pin Fig. 52 Pinion Yoke Installation
ion shaft. (Fig. 51). (8) Install the yoke washer AND A NEW NUT on
(5) Install pinion front bearing and oil slinger. Ap the pinion gear. Tighten the nut to;
ply a light coating of gear lubricant on the lip of pin • Model 44: 216 N-m (160 ft. lbs.)
ion seal. Install seal with Handle C-4171 and ® Model 60: 291 N-m (215 ft. lbs.)
Installer D-163 for 44/60 axle.
(6) Install pinion gear into differential housing.
(7) Install yoke with Holder 6719 and Installer
W-162D for 44 axle. Installer C-3716A for 60 axle
(Fig. 52).
CAUTION: Never loosen pinion gear nut to decrease

pinion gear bearing preload torque a n d never ex
ceed specified preload torque. If preload torque is
exceeded a new c o l l a p s i b l e spacer m u s t be i n
stalled. The torque sequence will have to be re
peated.
The specified preload torque should not exceed;

• Model 44: 271 N-m (200 ft. lbs.)
• Model 60: 426 N-m (315 ft. lbs.)
(9) Use Holder 6719 to retain the yoke (Fig. 53).
Slowly tighten the nut i n small increments until the
rotating torque is achieved. Measure the preload
torque frequently to avoid over-tightening the
nut.
DIFFERENTIAL
Fig. 53 Tightening Pinion Nut

(10) Check bearing preload torque with an inch
pound torque wrench (Fig. 54). The torque necessary
to rotate the pinion gear should be;
• Original Bearings: 1 to 3 N-m (10 to 20 in. lbs.).
• New Bearings: 2.26 to 4.52 N-m (20 to 40 in. lbs.).
DIFFERENTIAL SHIM PACK MEASUREMENT AND Fig. 55 Shim Pack Measurement

ADJUSTMENT
(4) Insert a small pry bar between the bearing cap
(1) Place Master Differential Bearing D-345 for 44
and left side of differential case. Pry the case as far
axle or D-346 for 60 axle on the case hubs.
as possible to right side. Zero the dial indicator
(2) Place Differential assembly i n the housing. As pointer.
semble Differential bearing caps.
(5) Repeat the measurement several times to check
(3) Install a pilot stud at the left side of housing.
consistency. Record the travel distance.
Attach Dial Indicator to housing. Load the indicator
The measurement above shows shim thick
plunger against the back of the ring gear (Fig. 55).
ness necessary to eliminate ring gear backlash.
Ensure ring and pinion gear teeth are tightly
Subtract this thickness from case zero end-play
meshed. Zero the indicator.
shim thickness (Fig. 56). The shims must he SPECIAL TOOL
placed at the ring gear side between the case W-129-B
DIAL
and bearing. INDICATOR
For Example:
Indicator Reading LESS PINION 0.085 in. total
Indicator Reading WITH PINION 0.055 in. total—
BALANCE O F SHIM PACK 0.030 in. total-
Place BALANCE of shims at opposite

side of ring gear
ADD an additional 0.015 in. shim to opposite side

of ring gear for bearing preload Fig. 57 Spread Differential Housing
CAUTION: Do not spread over 0.38 mm (0.015 in). If
Ring Gear Side (Flange Side) 0.055 i n . ^
the housing is over-separated, it could be distorted
Opposite Side 0.030 in. or damaged.
Opposite Side Preload 0.015 in. (3) Separate the housing enough to install the case
in the housing. Measure the distance with the dial
Total Opposite Side 0.045 in. J9302-65 indicator (Fig. 57).
(4) Remove the dial indicator.
Fig. 56 Shim Pack Calculations (5) Install case i n the housing. Tap the differential
case to ensure the bearings are fully seated (Fig. 58).
Remove the spreader.
(7) Remove the differential case from housing.
(8) Remove the master bearing tools from the dif RAWHIDE
ferential case hubs. HAMMER
(9) Position the backlash shims (with determined
thickness) on case hub (ring gear side). Install bear
ing on the hub with Driver Handle C-4171 and Bear
ing Installer C-3716A for 44 axle. Use Bearing
Installer C-4190 for 60 axle.
(10) Position the remaining zero end-play shims on
hub at opposite side of case. Include an additional
0.015 in. (0.38 mm) thick shim on this hub. This will
provide the required differential bearing preload.
(11) Install bearing on the hub with Driver Handle
C-4171 and Bearing Installer C-3716A for 44 axle.
Use Bearing Installer C-4190 for 60 axle.
(12) Match each bearing cup with bearing (origi
nal). Install the cups on the bearings.
DIFFERENTIAL INSTALLATION
(1) Position Spreader W-129-B with the tool dowel
pins seated i n the locating holes (Fig. 57). Install the J9302-19
holddown clamps and tighten the tool turnbuckle fin
ger-tight. Fig. 58 Differential Installation
(2) Install a pilot stud at the left side of the differ (6) Install the bearing caps at their original loca
ential housing. Attach Dial Indicator to housing pilot tions (Fig. 59). Tighten the bearing cap bolts to 108
stud. Load the indicator plunger against the opposite N-m (80 ft. lbs.) torque.
side of the housing (Fig. 57) and zero the indicator.
FOR MORE BACKLASH
DECREASE SHIM INCREASE SHIM
Fig. 59 Differential Bearing Cap Reference Letters

BACKLASH AND CONTACT PATTERN ANALYSIS
(1) Rotate assembly several revolutions to seat
bearings. Measure backlash at three equally spaced • FOR LESS BACKLASH •
J9302-28
locations around the ring gear with a dial indicator
(Fig. 60). Fig. 61 Backlash Shim Adjustment
tained within the specified limits until the correct
tooth contact patterns are obtained.
(2) Apply a thin coat of hydrated ferric oxide to
the drive and coast side of the ring gear.
(3) Rotate the ring gear several revolutions i n both
directions while a load is being applied. Insert a pry
bar between the differential housing and the case
flange. This action will produce distinct contact pat
terns on both the drive side and coast side of the ring
gear teeth.
(4) Note patterns i n compound. Refer to (Fig. 62)
for interpretation of contact patterns and adjust ac
cordingly.
FINAL ASSEMBLY
(1) Install the axle shafts. Refer to Axle Shaft I n
Fig. 60 Ring Gear Backlash Measurement
stallation i n this Group.
The ring gear backlash must be within 0.005 - (2) Scrape the residual sealant from the housing
0.008 inch (0.12 - 0.20 mm). It cannot vary more and cover mating surfaces. Clean the mating surfaces
than 0.002 inch (0.05 mm) between the points with mineral spirits. Apply a bead of MOPAR® Sili
checked. cone Rubber Sealant on the housing cover (Fig. 63).
I f backlash must be adjusted, transfer shims from Allow the sealant to cure for a few minutes.
one side of carrier to the other side. Adjust the back Install the housing cover within 5 minutes af
lash accordingly (Fig. 61). DO NOT INCREASE ter applying the sealant. I f not installed the
THE TOTAL S H I M PACK THICKNESS, EXCES sealant must be removed and another bead ap
SIVE BEARING PRELOAD A N D DAMAGE MAY plied.
OCCUR. (3) Install the cover on the differential with the at
I f the mesh and backlash steps have been followed taching bolts. Install the identification tag. Tighten
in the procedures above, good gear teeth contact pat the cover bolts to;
terns should exist. • Model 44: 41 N-m (30 ft. lbs.) torque.
The ring gear teeth contact patterns will show i f • Model 60: 47 N-m (35 ft. lbs.) torque.
the pinion gear depth shim(s) have the correct thick
ness. I t will also show i f the ring gear backlash has CAUTION: Overfilling the differential can result in
been adjusted correctly. The backlash must be main- the lubricant foaming and overheating.
2 - 4S FRONT SUSPENSION AND AXLE
DRIVE SIDE COAST SIDE

O F RING O F RING
GEAR TEETH GEAR TEETH
DESIRABLE CONTACT PATTERN.

PATTERN S H O U L D BE CENTERED
O N THE DRIVE SIDE O F T O O T H .
HEEL TOE TOE HEEL
PATTERN S H O U L D BE CENTERED O N
THE COAST SIDE O F T O O T H ,
BUT M A Y BE SLIGHTLY T O W A R D
THE TOE. THERE S H O U L D ALWAYS
BE SOME CLEARANCE BETWEEN
C O N T A C T PATTERN A N D TOP O F
THE T O O T H .
RING GEAR BACKLASH CORRECT

THINNER P I N I O N GEAR DEPTH
SHIM REQUIRED.
RING GEAR BACKLASH CORRECT.

THICKER P I N I O N GEAR DEPTH
SHIM REQUIRED.
Fig. 62 Gear Tooth Contact Patterns

SEALING CONTOUR OF BEAD (5) Install the fill hole plug and tighten to 34 N-m
(25 ft. lbs.) torque.
Fig. 63 Typical Housing Cover With Sealant

(4) Refill the differential housing with the specified
quantity of MOPAR® Hypoid Gear Lubricant.
AXLE SPECIFICATIONS MODEL 4 4 A N D 6 0
MODEL 44 FRONT AXLE MODEL 60 FRONT AXLE
Axle Type . ..,......... ^........ . ....... . .......... .Hypoid
e 9 0 9 9 e8 S9 #9 Axle l ^ p e Hypoid
Lubricant SAE 80W-90 Lubricant SAE 80W-90
Lube Capacity............... ............3.43 L (116 oz.) L u b e Capacity. 3.43 L (116 oz.)
Axle Ratio 3.54, 3.92, 4.09, 4.55 Axle Ratio 3.54, 4.10, 4.56
R i n g Gear Diameter.. 215.9 mm (8.50 in.) R i n g Gear Diameter .......247.6 mm (9.75 in.)
P i n i o n S t a n d a r d Setting 109.5 mm (4.312 in.) P i n i o n Standard Setting 127 mm (5.000 in.)
P i n i o n B e a r i n g Preload P i n i o n B e a r i n g Preload
Original Bearing .1 to 2N-m (10-20 in. lbs.) Original Bearing 1 to 2N-m (10-20 i n . lbs.)
New Bearing 2.3 to 4.5N-m (20-40 in. lbs.) New Bearing ...2.3 to 4.5N-m (20-40 in. lbs.)
FRONT SUSPENSION COMPONENTS MODEL 44 AXLE

LINK/COIL
1 Description | forgtio|
I Description | Torciif 1
Fill Hole Plug 34 N*m (25 ft. lbs.)
Jounce Bumper to Bracket 41 N®m (30 ft. lbs.)
Differential Cover Bolts 4 2 N*m (31 ft. lbs.)
Track Bar Ball Stud Nut . . 84 N*m (62 ft. lbs.)
Bearing C a p Bolts 9 5 to 122 N*m
Track Bar Bolt 176 N®m (130 ft. lbs.) (70 to 90 ft. lbs.)
Stabilizer Bar Retainer Bolts 4 7 N«m (35 ft. lbs.) Pinion Yoke Nut 216to 271 N*m
Stabilizer Link to Axle Bracket Nut 3 7 N«m ( 2 7 ft. lbs.) (180 to 200 ft. lbs.)
Stabilizer Link to Stabilizer Bar Nut 95 N»m (70 ft. lbs.) Ring G e a r Bolts . 95 to 122 N*m
Shock Absorber Bracket 75 N»m (55 ft. lbs.) (70 to 90 ft. lbs.)
Shock Absorber Upper Nut . . . . . . . . . . 41 N*m ( 3 0 ft. lbs.) Shift Motor Housing Bolts . . . . . . . . . 11 N«m (8 ft. lbs.)
Shock Absorber Lower Bolt . 135 N»m (100 ft. lbs.) Axle Shaft Nut. 218 to 272 N«m
(160 to 200 ft. lbs.)
Lower Suspension Arm Cam N u t . . . . . 2 3 0 N®m (170 ft. lbs.) Bearing to Knuckle Bolts 156 to 176 N*m
Lower Suspension Arm to Frame N u t . . . 119 N«m (88 ft. lbs.) (115 to 130 ft. lbs.)
Upper Suspension Arm to Axle Lower Ball Stud N u t . . . . . 108 N*m (80 ft. lbs.)
Bracket Nut 121 N*m (89 ft. lbs.)
Upper Ball Stud Nut 101 N*m (75 ft. lbs.)
Upper Suspension Arm to
Frame Nut 84 N«m (62 ft. lbs.) RWAL/ABS Sensor Bolt 11 N*m (96 in. lbs.)
J9402-69 J9402-72
FRONT SUSPENSION COMPONENTS IFS MODEL 60 AXLE
1 Description | Torque | Description

Jounce Bumper Nut 41 N«m (30 ft. lbs.)
Lower Suspension Arm Bolts 203 N»m (150 ft. lbs.) Fill Hole Plug 34 N*m (25 ft. lbs.)
Lower Ball Stud Nut 75 N»m (55 ft. lbs.) Differential Cover Bolts 4 7 N»m (35 ft. lbs.)
Upper Suspension Arm Bolts 244 N»m (180 ft. lbs.)
Bearing C a p Bolts . . . . . . 95 to 122 N«m
(70 to 90 ft. lbs.)
Shock Absorber Upper Nut . . . . . . . . . . . . 41 N * m (30 ft. lbs.)
Pinion Yoke Nut. 292 to 427 N*m
Shock Absorber Lower Bolt 135 N»m (100 ft. lbs.)
(215 to 315 ft. lbs.)
Stabilizer Bar Retainer Bolts 47 N*m (35 ft. lbs.)
Stabilizer Bar Link Nut 34 N « m (25 ft. lbs.) Ring Gear Bolts 183 to 193 N«m
J9402-70 (120 to 140 ft. lbs.)
Shift Motor Housing Bolts 11 N»m (8 ft. lbs.)
Axle Shaft Nut 218 to 272 N » m
(160 to 200 ft. lbs.)
Bearing to Knuckle Bolts 156 to 176 N»m
(115 to 130 ft. lbs.)
Lower Ball Stud Nut 4 7 N«m (35 ft. lbs.)
Lower Ball Stud Nut Retorque 203 N»m (150 ft. lbs.)
RWAL/ABS Sensor Bolt 11 N ^ m (96 in. lbs.)
J9402-73
ALIGNMENT SPECIFICATIONS
ALIGNMENT S P E C I F I C A T I O N S 4 X 2 AND 4X4
WHEEL PREFERRED PREFERRED

4x2/4x4 GVW BASE CASTER CAMBER
(lbs) (inches) (degrees) (degrees)
(+/-1.00) (+/-0.50)
4x2 6010 118.7 3.65 0.50
4x2 6400 118.7 3.65 0.50
4x2 6010 134.7 3.80 0.50
4x2 6400 134.7 3.80 0.50
4x2 7500 134.7 3.55 0.50
4x2 8800 134.7 3.45 0.50
4x2 10500 134.7 3.25 0.50
4x4 6400 118.7 3.35 not set
4x4 6400 134.7 3.45 not set
4x4 7500 134.7 3.00 not set
4x4 8800 134.7 3.10 not set
4x4 10500 134.7 2.90 not set
Preferred Total Toe- in 0.25° (+/-0.25)
J9402-75
• REAR SUSPENSION AND AXLE 3 - 1
REAR SUSPENSION AND AXLE
CONTENTS
page page
9 1/4 AXLE 9 REAR SUSPENSION—2WD and 4WD

AXLE NOISE/VIBRATION DIAGNOSIS 5 VEHICLES 3
AXLE SPECIFICATIONS MODEL 60, SPECIFICATIONS 91/4 INCH AXLE 24
70 AND 80 52 TORQUE SPECIFICATIONS 52
GENERAL INFORMATION 1 TRAC-LOK/POWER-LOI DIFFERENTIAL 44
MODEL 60, 70 and 80 AXLES 25
GENERAL INFORMATION
SUSPENSION The removable steel cover provides a means for in
Rear suspensions are comprised of (Fig. 1); spection and service without removing the axle from
• Drive axle the vehicle.
• Leaf springs The axle are equipped with a remote vent fitting.
• Dual-action shock absorbers A stamped metal axle gear ratio identification tag
• Jounce bumpers (used to limit the travel of the is attached to the housing cover.
suspension) The rear wheel anti-lock (RWAL) or four wheel an
ti-lock (ABS) brake speed sensor is mounted on top of
the differential housing. A seal is located between the
sensor and the wire harness connector. The seal
must be in-place when the wire connector is
connected to the sensor. The RWAL/ABS brake ex
citer ring is press-fitted onto the differential case
against the flange.
A limited-slip differential is available for all rear
axles. The Model 60 and 9 1/4 use a Trac-Lok differ
ential. The Model 70 and 80 use the Power-Lok dif
ferential. The Trac-Lok differential uses a one-piece
case while the Power-Lok differential uses a two-
piece case.
SWING
CLAMP PLATE Jf403-55 IDENTIFICATION
The axle differential covers can be used for identi
Fig. 1 Rear Suspension (Typical) fication (Fig. 2, 3 and 4).
Model 60 70 and 80 axles have the gear ratio listed
The Ram Truck is equipped with leaf-type rear
on a tag. The tag is attached to the left side of the
springs. The springs have a rubber bushing pressed
housing cover (Fig. 3, 4). Build date identification
into their main leaf front and rear eye. Model 1500,
codes on axles are stamped on the axle shaft tube
2500 and 3500 vehicle have two stage leaf spring.
The 3500 cab-chassis vehicles have a single stage cover side.
spring with a auxiliary spring. The spring assemblies STANDARD DIFFERENTIAL OPERATION
are serviced as a complete unit.
The differential gear system divides the torque be
tween the axle shafts. I t allows the axle shafts to ro
AXLES
The 9 1/4-Inch and Model 60, 70 and 80 axle hous tate at different speeds when turning corners.
ings consist of a cast iron center section. They also Each differential side gear is splined to an axle
have two steel axle shaft tubes that are pressed into shaft. The pinion gears are mounted on a pinion
and welded to the differential housing. mate shaft and are free to rotate on the shaft. The
3 - 2 REAR SUSPENSION AND AXLE
IDENTIFICATION DIFFERENTIAL
TAG COVER FILL PLUG
DIFFERENTIAL
COVER
PUSH-IN
FILL PLUG
IDENTIFICATION
J9203-32 TAG J94Q3-54
Fig, 2 Differential Cower—9 1/4 Inch Axle Fig. 4 Model 70 and 80 Differential Cover
DIFFERENTIAL
During straight-ahead driving, the differential pin
COVER ion gears do not rotate on the pinion mate shaft. This
FILL PLUG occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around i t (Fig. 5).
When turning corners, the outside wheel must
I N STRAIGHT A H E A D D R I V I N G
EACH WHEEL ROTATES AT 100%
OF CASE SPEED
IDENTIFICATION
TAG J9202-23
P I N I O N GEARS ROTATE
Fig. 3 Model 60 Differential Cover W I T H CASE J9303-13
pinion gear is fitted i n a bore i n the differential case Fig. 5 Differential Operation—Straight-Ahead Driving
and is positioned at a right angle to the axle shafts.
I n operation, power flow occurs as follows: travel a greater distance than the inside wheel i n or
• Pinion gear rotates the ring gear der to complete a turn. This difference must be com
• Ring gear (bolted to the differential case) rotates pensated for i n order to prevent the wheels from
the case scuffing and skidding through the turn. To accom
• Differential pinion gears (mounted on the pinion plish this, the differential allows the axle shafts to
mate shaft i n the case) rotate the side gears turn at unequal speeds (Fig. 6). I n this instance, the
• Side gears (splined to the axle shafts) rotate the input torque applied to the pinion gears is not di
shafts vided equally. The pinion gears now rotate around
the pinion mate shaft i n opposite directions. This al-
• REAR SUSPENSION AND AXLE 3-3
lows the side gear and axle shaft attached to the out
J AXLE «fc J
side wheel to rotate at a faster speed.
OUTER W H E E L 100% DIFFERENTIAL INNER WHEEL
i
110% CASE SPEED CASE SPEED 9 0 % CASE SPEED
LUBRICANTS
Multi-purpose, hypoid gear lubricant should be
used for rear.axles with standard differential. The lu
bricant should have a API GL 5 quality specifica
tions.
The lubricant recommended for Track-Lok and
Power-Lok differential is API grade GL 5. A container
of friction modifier should be added after service.
If the rear axle is submerged in water, the lu P I N I O N GEARS ROTATE
O N P I N I O N SHAFT
bricant must be replaced immediately. Avoid J9303-14
axle failure resulting from water contamination
of the lubricant. Fig. 6 Differential Operation—On Turns
REAR SUSPENSION—2WD and 4WD V E H I C L E S

SPRING AND SHOCK DIAGNOSIS SHOCK ABSORBER
A squeak noise from shock absorber or spring bush The rear shock absorbers are mounted in two
ings can be caused i f movement between rubber configurations. Type 1 has both shocks
bushings and metal occurs. This noise can usually be mounted rearward of the axle. Type 2 has right
stopped by tightening the attaching nuts. I f the noise shock mounted forward of the axle and left
persists, inspect for damaged or worn bushings and shock mounted rearward. Service procedures
attaching components. are the same for both configurations.
The shock absorber bushings do not require any
type of lubrication. Do not lubricate the bushings to REMOVAL
reduce bushing noise. Grease or mineral oil-base lu (1) Raise vehicle and support axle.
bricants will deteriorate the bushing rubber. (2) Remove the bolt and flag nut from the frame
The shock absorbers are not refillable or adjust crossmember bracket (Fig. 1).
able. I f a malfunction occurs, the shock absorber (3) Remove the bolt and nut from the axle bracket
must be replaced. To test a shock absorber, hold i t i n (Fig. 1).
an upright position and force the piston into and out (4) Remove the rear shock absorber from the vehi
of the cylinder four or five times. The action through cle.
out each stroke should be smooth and even.
The spring eye and shock absorber bushings do not CROSSMEMBER
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio
rate the bushing rubber.
I f the vehicle is used for severe off-road operation,
the springs should be examined periodically. Check
for broken or shifted leafs, loose missing clips and
broken center spring bolts.
VEHICLE LOADING AND WEIGHT DISTRIBUTION
A vehicle should always be loaded so the vehicle
weight center-line is located immediately forward of
the rear axle. Correct vehicle loading provides proper
J9403-49
front tire-to-road contact. This results i n maximum
vehicle handling stability and safety. Refer to Spring Fig. 1 Rear Shock Absorber Type 1
and Shock Absorber Diagnosis chart for further infor
mation. INSTALLATION
Incorrect weight distribution should be con (1) Position shock absorber i n brackets.
sidered as a possible cause for erratic steering,
spring failure or tire wear.
3 - 4 REAR SUSPENSION AND AXLE •
(2) Install bolts through the brackets and shock. SPRING CLAMP
Install flag nut on top bolt and nut on lower bolt BOLT SPRING SEAT
(Fig. 1).
(3) Tighten upper bolt to 95 N-m (70 ft. lbs.)
torque. Tighten lower bolt to 136 N-m (100 ft. lbs.)
torque.
(4) Remove the support and lower vehicle.
SPRING
SPRINGS
SPACER
REMOVAL
(1) Raise vehicle and support axle to remove all
weight from springs. SPRING PLATE
(2) Remove the nuts and spring clamp bolts that
attach the spring to the axle (Fig. 2, 3, 4).
(3) Remove the nuts and bolts from the spring
i SHACKLE' J9403-61
front and rear shackle eyes. Note:To remove front

eye bolt on left side spring, fuel tank must be Fig. 3 Rear Spring—4X4
removed. Refer to Group 14 for fuel tank proce SPRING CLAMP
dure. SPRING SEAT
(4) Remove spring from vehicle.
(5) Remove shackle from spring.
AUXILIARY SPRING
SPRING CLAMP
BOLTS SPRING SEAT
SPRING
SPACER
SPRING
SPRING PLATE
SPRING PLATE
SHACKLE' J9403-62
Fig. 4 Rear Spring—Cab-Chassis 11000 GVW

(6) Install spring clamp bolts and the retaining
SHACKLE' J9403-60 nuts (Figs. 2, 3, 4).
(7) Align the auxiliary spring with the primary
Fig. 2 Rear Spring—4X2 spring i f equipped. Tighten the nuts until they force
INSTALLATION
the plate flush against the axle tube.
(1) Install shackle on rear spring eye and install (8) Remove the supports and lower the vehicle so
bolt and nut. that the weight is being supported by the tires.
(2) Position spring on axle shaft tube so spring (9) On 6,010 to 10,500 GVW vehicles, tighten the
center bolt is inserted into the locating hole i n the spring clamp retaining nuts to 149 N-m (110 ft. lbs.)
axle tube spring pad or spacer. torque. On 1100 GVW cab-chassis vehicles tighten
(3) Align spring front eye with bolt hole i n the nuts to 163 N-m (120 ft. lbs.) torque.
front bracket. Install the eye pivot bolt and nut. (10) On 6,010 to 7,500 GVW vehicles, tighten
(4) Align shackle eye with bolt hole i n rear spring front and rear eye pivot bolt nuts and shackle
bracket. Install bolt and nut. eye to 136 N-m (100 ft. lbs.) torque. On 8,800 to
(5) Tighten the spring front and rear eye pivot bolt 11,000 GVW vehicles, tighten nuts to 190 N-m (140
snug do not torque. ft. lbs.) torque.
• REAR SUSPENSION AND AXLE 3 -5
A X L E NOISE/VIBRATION D I A G N O S I S
INDEX
page page
Driveline Snap 6 Low Speed Knock 6
Gear and Bearing Noise 5 Rear Axle Alignment 6
General Information 5 Vibration 6
Limited Slip Differential 6
GENERAL INFORMATION GEAR AND BEARING NOISE

Axle bearing problem conditions are usually caused
by: GEAR NOISE
• Insufficient or incorrect lubricant Axle gear noise can be caused by insufficient lubri
• Foreign matter/water contamination cant. Incorrect backlash, tooth contact, or worn/dam
• Incorrect bearing preload torque adjustment aged gears can cause noise.
When serviced, the bearings must be cleaned thor Gear noise usually happens at a specific speed
oughly. They should be dried with lint-free shop tow range. The range is 30 to 40 mph, or above 50 mph.
els. Never dry bearings with compressed air. The noise can also occur during a specific type of
This will overheat them and brinell the bearing driving condition. These conditions are acceleration,
surfaces. This will result i n noisy operation af deceleration, coast, or constant load.
ter repair. When road testing, accelerate the vehicle to the
Axle gear problem conditions are usually the result speed range where the noise is the greatest. Shift
of: out-of-gear and coast through the peak-noise range.
• Insufficient lubrication I f the noise stops or changes greatly, check for insuf
• Incorrect or contaminated lubricant ficient lubricant. Incorrect ring gear backlash, or
• Overloading (excessive engine torque) gear damage can cause noise changes.
• Incorrect clearance or backlash adjustment Differential side and pinion gears can be checked
Insufficient lubrication is usually the result of a by turning the vehicle. They usually do not cause
housing cover leak. I t can also be from worn axle noise i n straight-ahead driving. These gears are
shaft or pinion gear seals. Check for cracks or porous loaded during vehicle turns. I f noise does occur dur
areas in the housing or tubes. ing vehicle turns, the side or pinion gears could be
Using the wrong lubricant or over filling will cause worn or damaged. A worn pinion gear mate shaft can
overheating and gear failure. Gear tooth cracking also cause a snapping or a knocking noise.
and bearing spalling are indicators of this. BEARING NOISE
Axle component breakage is most often the result The axle shaft, differential and pinion gear bear
of: ings can all produce noise when worn or damaged.
• Severe overloading Bearing noise can be either a whining, or a growling
• Insufficient lubricant sound.
• Incorrect lubricant Pinion gear bearings have a constant-pitch noise.
• Improperly tightened components This noise changes only with vehicle speed. Pinion
Common causes of overloading is from full-throttle bearing noise will be higher because i t rotates at a
acceleration. Overloading happens when towing faster rate. Drive the vehicle and load the differen
heavier-than-recommended loads. Component break tial. I f bearing noise occurs the pinion rear bearing is
age can occur when the wheels are spun excessively. the source of the noise. I f the bearing noise is heard
Insufficient or incorrect lubricants contribute to during a coast, front bearing is the source.
breakage through overheating. Loose differential Worn, damaged differential bearings usually pro
components can also cause breakage. duce a low pitch noise. Differential bearing noise is
Incorrect bearing preload or gear backlash will not similar to pinion bearing. The pitch of differential
result in component breakage. Mis-adjustment will bearing noise is also constant and varies only with
produce enough noise to cause service repair before a vehicle speed.
failure occurs. I f a mis-adjustment condition is not Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
corrected, component failure can result.
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise (2) Attach a one-inch long piece of masking tape at
level. Where axle bearing damage is slight, the noise the center of each tire tread for use as reference marks.
is usually not noticeable at speeds above 30 mph. (3) Rotate the rear wheels until both reference
marks face the front of the vehicle. Measure the dis
LOW SPEED KNOCK tance between the outside edges of the two pieces of
Low speed knock is generally caused by a worn tape. Record this measurement as the front of tire
U-joint or by worn side-gear thrust washers. A worn (FTR) measurement.
pinion gear shaft bore will also cause low speed knock. (4) Rotate the rear wheels until both reference
marks face the rear of the vehicle. Measure the dis
WiBRATtON tance between the outside edges of the two pieces of
Vibration at the rear of the vehicle is usually tape. Record this measurement as the rear of tire
caused by a: (RTR) measurement.
• Damaged drive shaft
(5) Subtract the (RTR) measurement from the
• Missing drive shaft balance weight
(FTR) measurement to obtain the amount of wheel
• Worn, out-of-balance wheels
toe. The acceptable rear wheel toe-in position is 1/16
• Loose wheel lug nuts
• Worn U-joint inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out.
• Loose spring clamp bolts (6) Rotate the rear wheels until the reference marks
• Loose/broken springs are facing downward. Measure the distance between the
• Damaged axle shaft bearings outside edges of the two pieces of tape. Record this mea
• Loose pinion gear nut surement as the bottom of tire (BTR) measurement.
• Excessive pinion yoke run out (7) Average the (FTR) and the (RTR) distance mea
• Bent axle shaft surements. Subtract the (BTR) measurement from
Check for loose or damaged front-end components this average distance to obtain the camber. The ac
or engine/transmission mounts. These components ceptable amount of camber is 1/16 inch to 3/32 inch
can contribute to what appears to be a rear-end v i (1.6 to 2.4 mm).
bration. Do not overlook engine accessories, brackets (FTE + E T E ) D I V I D E D B Y 2 (TWO) M I N U S
and drive belts. B T E EQUALS C A M B E E
A l l driveline components should be examined be If the ( B T E ) distance measurement is less
fore starting any repair. than the average F T E and E T E distance mea
Refer to Group 22, Wheels and Tires for additional surement the camber will be positive ( + ). I f
information. the ( B T E ) distance measurement is greater
than the average F T E and E T E distance, the
DRIVELINE SNAP camber will be negative ( - ).
A snap or clunk noise when the vehicle is shifted I f the toe position or camber is not acceptable, a
into gear (or the clutch engaged), can be caused by: bent or deformed rear axle shaft is most likely the
• High engine idle speed cause.
• Loose engine/transmission/transfer case mounts
• Worn U-joints LIMITED SLIP DIFFERENTIAL
• Loose spring mounts
Under normal traction conditions, engine torque is
• Loose pinion gear nut and yoke
• Excessive ring gear backlash divided evenly. With low-traction surfaces, engine
• Excessive differential side gear-to-case clearance torque is transferred to the wheel with the most tire
The source of a snap or a clunk noise can be deter traction. When diagnosing a limited-slip differential
mined with the assistance of a helper. Raise the ve problem condition, the wheel with the least traction
hicle on a hoist with the wheels free to rotate. can continue spinning.
Instruct the helper to shift the transmission into The most common problem is a chatter noise when
gear. Listen for the noise, a mechanics stethoscope is turning corners. Check for incorrect or contaminated
helpful i n isolating the source of a noise. lubricant. Replace the gear lubricant i f necessary.
• With Trac-Lok or Power-Lok differentials add a
REAR AXLE ALIGNMENT container of MOPAR® Trac-Lok Lubricant.
This will correct the condition in most instances. I f
MEASUREMENT the chatter persists, clutch damage could have occurred.
The following procedure can be used to determine After changing the lubricant, drive the vehicle and
i f abnormal rear tire tread wear is the result of a make 10 to 12 slow, figure-eight turns. This maneu
bent or deformed rear axle shaft. ver will pump lubricant through the clutches.
(1) Raise both rear wheels off the surface with a
frame contact hoist.
REAR SUSPENSION AND AXLE -3 - 7
SERVICE DIAGNOSIS

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

(b) Worn axle shaft seals. (b) Replace worn seals.
(c) Repair or replace housing as
(c) Cracked differential housing. necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal,
(e) Scored and worn yoke. (t) Remove cover and clean flange and
(f) Axle cover not properly sealed. reseal.
AXLE OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash, (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (a) Overloading. (a) Replace gears. Examine other gears
(RING GEAR AND and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
AXLE NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Loose differential bearings. (f) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
• REAR SUSPENSION AND AXLE '3 - 9
9 1/4 A X L E
INDEX
page page
9 1/4 Axle Removal/Installation 14 Lubrication Change . . 11
Axle Shaft, Seal and Bearing Service 11 Pinion Depth Measurement and Adjustment 17
Differential Service 15 Pinion Seal Replacement 13
Information 9
INFORMATION The removable steel cover provides a means for in

The 9 1/4 axle (Fig. 1) housing consist of a cast iron spection and service without removing the axle from
center section. They also have two steel axle shaft the vehicle.
tubes that are pressed into and welded to the differ
ential housing.
•
HUB AXLE DIFFERENTIAL
/ SHAFT HOUSING
Fig. 1 9 1/4 Axle

LUBRICATION CHANGE AXLE SHAFT, SEAL AND BEARING SERVICE

(2) Remove the lubricant fill hole plug from the dif CAUTION: When rear axle service is necessary,
ferential housing cover. both rear wheels must be raised off the surface s o
(3) Remove the differential housing cover. Allow that they are free to rotate. Be cautious when the
the original lubricant to completely drain from the tires are being rotated by the engine or by other
housing and axle shaft tubes. means.
(4) With standard differential, clean differential
and housing with flushing oil or light engine oil. This AXLE SHAFT REMOVAL
will remove the residual lubricant and foreign mat (1) Raise and support the vehicle.
ter. Do not use water, steam, kerosene or gaso (2) Remove tire wheel assembly.
line for flushing. (3) Remove the brake drum.
(5) Scrape the residual sealant from the housing (4) Clean all the foreign material from housing
and cover mating surfaces. Clean the mating surfaces cover area.
with mineral spirits. Apply a bead of MOPAR® Sili (5) Remove differential cover and drain the lubri
cone Rubber Sealant on the housing cover (Fig. 2). cant from the housing.
Allow the sealant to cure for a few minutes. (6) Remove the lock screw and the pinion mate
SEALING CONTOUR OF BEAD gear shaft from the case (Fig. 3).
PINION
Fig. 2 Typical Housing Cover

Install the housing cover within 5 minutes af Fig. 3 Pinion Mate Shaft Lock Screw
ter applying the sealant. I f not installed, the (7) Push the axle shaft i n and remove axle shaft C-
sealant must be removed and another bead ap clip lock from axle shaft (Fig. 4).
plied. (8) Remove the axle shaft. Use care to prevent
(6) Install the cover on the differential. Install the damage to the axle shaft bearing.
identification tag. Tighten the cover bolts to 47 N-m (9) Inspect the axle shaft bearing contact surface
(35 ft. lbs.) torque. area for indications of wear.
CAUTION: Overfilling the differential can result in
If wear exists the axle shaft and bearing
the lubricant foaming and overheating.
should be replaced. Normal bearing contact on
the shaft w i l l be a dull gray and could appear
(7) Refill the differential with the specified quan to be lightly dented. I f any of these conditions
tity of MOPAR® Hypoid Gear Lubricant. exist, the axle shaft and bearing must be re
(8) Install the fill hole plug. placed.
3 - 12 REAR SUSPENSION AND AXLE — — * — ^ •
Fig. 6 Bearing Removal

CAUTION: DO NOT use t h e new axle shaft seal t o
p o s i t i o n or seat t h e bearing in t h e axle shaft bore.
(3) Install the new axle shaft seal with Installer

C-4826 and Handle C-4171 (Fig. 7).
Fig. 4 Axle Shaft G-Clip Lock
AXLE SHAFT SEAL AND BEARING REMOVAL
(1) Remove the axle shaft seal with a small pry
bar (Fig. 5).
Fig. 7 Axle Shaft Seal Installation

(4) When the tool contacts the end of the tube
(face), the seal is at the correct position and depth.
Fig. 5 Axle Seal Removal AXLE SHAFT INSTALLATION
(2) Remove the axle shaft bearing with Remover (1) Lubricate the bearing bore and seal lip. Insert
C-4828 (Fig. 6). the axle shaft and engage the splines with the side
(3) Inspect the axle shaft tube bore for roughness gear. Use care to prevent the shaft splines from
and burrs. Remove as necessary. damaging the axle shaft seal lip.
(2) Insert the C-clip lock i n the recessed groove
BEARING AND SEAL INSTALLATION (Fig. 4). Push the axle shaft outward to seat the C-
Always install a new seal when servicing the clip lock.
axle or bearing. (3) Align and install pinion gear mate shaft i n the
(1) Wipe the bore i n the axle shaft tube clean. case. Align hole i n shaft with lock screw hole. Install
(2) Install a new bearing with Installer C-4826 and the lock screw with Loctite® on the threads. Tighten
Handle C-4735. Ensure that the bearing is not the screw to 11 N-m (8 ft. lbs.) torque.
(4) Clean the cover and apply a bead of sealant.
cocked and is seated firmly against the tube shoul
Refer to the Drain and Refill i n this section.
der.
(5) Install the brake drum.
(6) Install the wheel and tire assembly.

(7) Fill the differential with lubricant. Refer to the
Specifications chart for the type and quantity. Install
the fill hole plug.
(8) Remove support and lower vehicle. Test the
brakes and axle for correct operation.
PINION SEAL REPLACEMENT

CAUTION: The following procedures must be used
s o the correct pinion bearing preload torque is re
tained. If not completely followed, the result can be
failure of the rear axle.
REMOVAL
C-748
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
J9403-20
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft i n an upright position to
Fig. 9 Pinion Seal Removal
prevent damage to the rear U-joint.
(4) Remove wheel and tire assemblies, and brake INSTALLATION
drums. (1) Inspect splines on pinion shaft for burrs or
Brake drag can cause a false bearing preload wear, remove any burrs and clean the shaft.
torque measurement. (2) Inspect the pinion yoke for cracks, worn splines
(5) Use a Newton-meter or an inch-pound torque and worn seal contact surface. Repair or replace the
wrench to measure the pinion bearing preload. Ro yoke as necessary.
tate the pinion shaft several times with the torque The outer perimeter of the seal is pre-coated
wrench. Note the indicated torque as the wrench is with a special sealant additional sealant is not
moved through several revolutions. required.
This measurement important because, bear (3) Install pinion shaft seal with Installer
ing preload torque must be carefully re-ad C-4109-A and Handle C-4735. Seal is correctly in
justed after the new seal is installed. stalled when seal flange contacts face of differential
(6) Hold yoke with Holder 6719 and remove the housing flange.
pinion shaft nut and Belleville washer. (4) Install yoke on pinion shaft with the reference
(7) Remove the yoke with Remover C-452 (Fig. 8). marks aligned.
(5) Seat the yoke on pinion shaft with Installer
W-162D and Holder 6719 (Fig. 10).
(6) Remove tools and install the Belleville washer.
The convex side of the washer must face outward.
(7) Hold yoke with Holder 6719 and tighten the
shaft nut to 285 N-m (210 ft. lbs.) torque (Fig. 11).
Rotate pinion shaft several complete revolutions to
ensure the bearing rollers are seated.
CAUTION: Never loosen the pinion gear nut to de

crease the pinion gear bearing preload torque. If the
specified preload torque is exceeded, a new col
lapsible spacer must be installed. The torque s e
quence will have to be repeated.
(8) Continue tightening and measuring bearing

Fig. 8 Yoke Removal preload torque until the torque is the same as origi
(8) Remove the pinion shaft seal with Puller C-748 nal measurement. The bearing preload torque
and clean seal contact surface i n housing bore (Fig. should never exceed 1 N-m (10 in. lbs.) more
9). than original value.
3 - 14 REAR SUSPENSION AND AXLE — #
(11) Install the brake drums, and wheel and tire

YOKE
assemblies.
(12) Check the differential lubricant level and add
i f necessary.
9 1/4 AXLE REMOVAL/INSTALLATION

I t is not necessary to remove the complete axle
from the vehicle for routine or differential service. I f
the differential housing or axle shaft tubes are dam
aged, the complete axle can be removed and in
stalled.
REMOVAL
(2) Block the brake pedal i n the up (non-depressed)
position with a wooden block.
(3) Remove the rear wheels and brake drums.
(4) Disconnect the brake fluid tube fittings from
the wheel cylinders. Cap the fittings to prevent loss
J9402-61
of brake fluid.
(5) Remove the vent hose from the brake tee nip
Fig. 10 Yoke Installation
ple.
DIFFERENTIAL (6) Remove the brake tee bolt. Carefully detach the
brake fluid tubes from the clips.
(7) Disconnect the parking brake cables and unbolt
backing plates.
Mark the U-joint, pinion yoke, and pinion
shaft for reference.
(8) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft i n an upright position to
prevent damage to the rear U-joint.
(9) Remove the shock absorber lower attaching
nuts and bolts.
(10) Support axle and remove rear spring U-bolts
and the spring brackets.
WARNING: WHEN SPRING CLAMP B O L T S A R E R E

MOVE AXLE MAY R O T A T E ON SUPPORT.
(11) Remove the axle assembly from the vehicle.

(12) Wash and clean the outer surface of the hous
ing and tubes. Use an appropriate cleaning solution
and dry the surface with compressed air.
Fig. 11 Tightening Pinion Shaft Nut INSTALLATION
The bearing preload torque should be con (1) Position the rear axle spring pads over the
stant during a complete revolution of the pin spring center bolts.
ion gear. If preload torque varies, this indicates (2) Install the spring clamp bolts and nuts, and
a binding condition and must be corrected. shock absorber lower bolts. Tighten the nuts to the
(9) The seal replacement is unacceptable i f the fi specified torque.
nal nut torque is less than 285 N-m (210 ft. lbs.) (3) Connect the parking brake cables.
torque. (4) Connect the brake fluid tube fittings to the
(10) Install drive shaft with the installation refer wheel cylinders. Bleed and adjust brakes refer to
ence marks aligned. Tighten the U-joint yoke clamp Group 5 Brakes for procedure.
screws to 19 N-m (14 ft. lbs./170 in. lbs.) torque.
(5) Align the installation reference marks and con

nect the drive shaft yoke to the pinion yoke. Tighten
the U-joint clamp bolts to 19-23 N-m (170-200 in.
lbs.) torque.
(6) Install wheel and tire assemblies.
DIFFERENTIAL SERVICE
SERVICE INFORMATION
I t is not necessary to remove the complete axle to
service the differential.
DIFFERENTIAL CASE REMOVAL

(1) Remove the axle shafts, refer to Axle Shaft Re
moval.
Side play resulting from bearing races being Fig. 13 Mark For Installation Reference
loose on case hubs requires replacement of the (7) Loosen the threaded adjusters with Wrench
differential case. Otherwise, use threaded ad
C-4164 (Fig. 14).
juster to remove the side play before measuring
the ring gear runout.
(2) Attach Dial Indicator to Pilot stud C-3288B.
Place the indicator plunger at a right angle (90°) to
the ring gear (Fig. 12).
Fig. 14 Threaded Adjuster Tool

(8) Hold the differential case while removing bear
ing caps and adjusters.
(9) Remove the differential case.
Fig. 12 Ring Gear Runout Measurement E a c h differential bearing cup and threaded
(3) Measure runout by turning the ring gear sev adjuster must be kept with their respective
eral complete revolutions. Observe dial indicator and bearing.
mark the ring gear and differential case at maximum
PINION GEAR SHAFT REMOVAL
runout areas. The ring gear runout should not exceed
0.005 inch (0.13 mm). I f runout exceeds 0.005 inch (1) Remove pinion gear nut and washer. Use Puller
(0.13 mm), a damaged differential case could be the C-452 and Wrench C-3281 to remove the pinion yoke.
cause. (2) Drive pinion gear out of housing with plastic or
The marking on the differential case will be rawhide hammer. This will damage the front
very useful later during the differential case bearing rollers and bearing cup. The front
runout. bearing and cup must be replaced.
(4) Remove RWAL/ABS sensor from housing. (3) Remove the collapsible preload spacer
(5) Mark the differential housing and the differen (4) Remove the pinion seal with Puller C-748.
tial bearing caps for installation reference (Fig. 13). (5) Remove the front and rear bearing cups with
(6) Remove bearing threaded adjuster lock from Remover Set C-4306 and Handle C-4171.
each bearing cap. Loosen the bolts, but do not re (6) Remove rear bearing from pinion shaft (Fig.
move the bearing caps. 15). Remove and record the pinion gear depth shims.
Fig. 16 Case Flange Runout Measurement

DIFFERENTIAL CASE DISASSEMBLY
(1) Rotate the side gears until the pinion gears are
located at differential case opening and remove them.
(2) Remove the side gears and the thrust washers.
(3) Remove the differential bearings from the case
Fig. 15 inner Bearing Removal
hubs with Bearing Splitter Bridge 938 and Bearing
RING GEAR Splitter 1130 (Fig. 17).
Do not remove ring gear f r o m case ' unless
runout must be measured.
(1) Clamp the-case (with the ring gear bolts facing
upward). Use a vise equipped with soft jaws (brass).
(2) Remove and discard the ring gear bolts. The
bolts have left-hand threads. Use a hammer and a
brass drift to force the ring gear loose from the case
pilots. Remove the ring gear.
CASE FLANGE RUNOUT MEASUREMENT

(1) I f the ring gear runout exceeded 0.005 inch
(0.13 mm), case flange runout should be measured.
Install the case with the bearing cups and the
threaded adjusters close to their original position.
(2) Install the bearing caps and bolts. Tighten the
bolts lightly. Use Wrench C-4164 to thread both ad
justers inward. Remove all side play.
(3) Attach Dial Indicator to measure the flange
runout. The plunger should contact the ring squarely
between the outer edge and the gear attaching bolt
holes (Fig. 16).
(4) Rotate the differential case several times and
observe the dial indicator. Mark the area of maxi
mum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). I f the CLEANING AND INSPECTION
runout exceeds this amount replace the differential (1) Clean all of the differential components i n
case. cleaning solvent. Allow the bearings to either air dry
To reduce ring gear runout positioning the or dry them with a lint-free cloth. Dry the other com
ring gear runout mark 180 degrees opposite the ponents with compressed air.
flange runout mark. (2) Examine each component for wear or damage.
(5) Remove the differential bearing cap bolts. Re (3) Replace shims, bearings and cups as a set only.
move the differential case from the differential hous Replace bearings and cups i f either is galled, worn,
ing. cracked, or damaged.
( 4 ) Inspect the differential side and pinion gears. PILOT

Replace any gear that is worn, cracked or chipped.
(5) Inspect the differential case. Replace the case i f
cracked or damaged.
Polish each axle shaft with No. 600 crocus
cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft
seal contact surface. When polishing, the crocus
cloth should be moved around the circumfer
ence of the shaft (not in-line with the shaft).
(6) Inspect the axle shaft C-clip locks for cracks
and excessive wear. Replace them i f necessary.
(7) Test each threaded adjuster to determine i f i t
rotates freely. I f an adjuster binds, repair the dam
aged threads or replace the adjuster.
EXCITER RING REPLACEMENT Fig. 16 Case-To-Ring Gear Alignment
The ring gear must be removed before the RWAL/ CAUTION: W h e n installing a differential bearing,
ABS brake exciter ring can be replaced. never apply force to the bearing cage because bear
(1) Remove exciter ring with a hammer and drift. ing damage will result.
(2) Heat the replacement exciter ring with a heat
lamp or by immersing i n a hot fluid. The tempera (8) Install a differential bearing on each hub with
ture should not exceed 149°C (300°F). Do not use a Installer C-4213 and Handle C-4171.
torch to heat the ring.
(3) After heating, quickly position the exciter ring PINION DEPTH MEASUREMENT AND ADJUSTMENT
on the differential case adjacent to the flange. Pinion measurement are taken with C-758-D6 Tool
Set (Fig. 19) with pinion bearing cups installed.
DIFFERENTIAL CASE ASSEMBLY
When replacing a pinion or differential bear SPECIAL TOOL
ings always replace bearing and cup as a
matched set.
(1) Lubricate all the differential case components
with gear lubricant.
(2) Place thrust washers on differential side gears.
Position the gears i n the differential case counter-
bores.
If replacement side gears or thrust washers
are used, refer to Differential Side Gear Clear
ance Measurement And Adjustment.
(3) Position thrust washers on differential pinion
gears. Mesh the pinion gears with the side gears.
Ensure that the pinion gears are exactly 180 de
grees opposite each other.
(4) Rotate the side gears to align the pinion gears
and thrust washers. Align components with the mate Fig. 19 9 1/4 Axle Pinion Adjustment Tools
shaft bores i n the case.
(1) Install front (outer) bearing cup with Tool Set
(5) I f the ring gear was removed, clean all contact
C-4306 and Handle C-4171.
surfaces. Use a fine file to remove any sharp areas
from chamfered inside diameter.Heat ring gear with (2) Install rear (inner) bearing cup with Tool Set
a heat lamp or immerse in a hot fluid. The tempera C-4306 and Handle C-4171.
ture should not exceed 149°C (300°F). Do not use a • Position Spacer (SP-6017) over Shaft (SP-526)
torch to heat the ring. • Position pinion rear bearing on shaft
(6) Position heated gear on case. Use two equally • Position tools (with bearing) in the housing
spaced Pilot Studs C-3288-B to align the gear with ® Install Sleeve (SP-1730)
the flange holes (Fig. 18). • Install pinion front bearing
(7) Install replacement ring gear bolts (with left • Install Spacer (SP-6022)
hand threads). Alternately and evenly tighten each • Install Sleeve (SP-535-A), Washer (SP-534) and
bolt to 102 N-m (75 ft. lbs.) torque. Nut (SP-533)
3-18 REAR SUSPENSION AND AXLE •
• Install Cap Screw (SP-536) and tighten with
Wrench SP-531 (Fig. 20).
(5) Position Crossbore Arbor SP-6018 i n the differ
ential housing.
(6) Center the tool and place a piece of 0.002 inch
shim stock at each end of the arbor. Position the
bearing caps on the arbor tool. Install the attaching
bolts. Tighten the cap bolts to 14 N-m (10 ft. lbs.)
torque.
(7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 21). The d e p t h shim(s)
fit must be snug b u t n o t t i g h t (drag f r i c t i o n o f a
feeler gauge blade).
Fig. 20 Gauge Block

(3) Tighten the nut to seat the pinion bearings i n
the housing. Allow the sleeve to turn several times
during the tightening to prevent brinelling the bear
ing cups or the bearings.
D e p t h shim(s) are positioned between the p i n
i o n g e a r rear b e a r i n g a n d p i n i o n gear to pro
vide the s e p a r a t i o n distance. The r e q u i r e d
thickness o f the depth s h i m ( s ) i s d e t e r m i n e d ac
c o r d i n g to t h e f o l l o w i n g i n f o r m a t i o n .
(4) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri
cant. Re-tighten the compression nut tool to 1-3 N-m
(15-25 in. lbs.) torque. Rotate the pinion gear several Fig. 21 Depth Shim(s) Selection
complete revolutions to align the bearing rollers. D e p t h shims are available i n 0.001-inch incre
• Install Gauge Block SP-6020 at the end of SP-526 ments f r o m 0.020 i n c h to 0.038 i n c h .
PINION GEAR DEPTH VARIANCE

Gear Depth
Variance -4 -3 -2 -1 0 + | +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 -0.0)2
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 " -0.0)4
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0,005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
(8) Note the etched number on the face of the drive

YOKE
pinion gear (e.g., -0, - 1 , -2, +1, +2, etc.). The numbers
represent thousands-of-an-inch deviation from the
standard. I f the number is - (negative) add that value
to the required thickness of the depth shim(s). I f the
number is + (positive) subtract that value from the
thickness of the depth shim(s). I f the number is 0 no
change is necessary.
(9) Remove the tools from the differential housing.
(10) Position depth shim(s) on pinion gear shaft
and install rear bearing with Installer C-3095A (Fig.
22).
J9402-61
Fig. 23 Pinion Yoke Installation

(16) Install the Belleville washer. The convex side
of the washer must face outward. Install the pinion
nut.
(17) Retain pinion yoke with Holder 6719. Initially
tighten the drive pinion gear shaft nut enough to re
move the bearing end play. While tightening, rotate
the pinion shaft to ensure the bearing rollers are cor
rectly seated.
(18) Tighten the pinion nut to (Fig. 24) 285 N-m
1-50 (210 ft. lbs.) torque (minimum).
DIFFERENTIAL
Fig. 22 Shaft Rear Bearing Installation
(11) Install front pinion bearing and install pinion
shaft seal with Installer C-4109A and Handle
C-4735.
The outer perimeter of the seal is pre-coated
with a special sealant. A n additional applica
tion of sealant is not required.
(12) Lubricate the pinion gear front and rear bear
ings with gear lubricant.
(13) Install new collapsible spacer on pinion gear
shaft. Install pinion gear i n housing.
(14) Install the pinion yoke with Installer W-162D
and Holder 6719 (Fig. 23).
It is necessary to use tools above to correctly
seat the front bearing on drive pinion gear
shaft (Fig. 2 3 ) .
CAUTION: Use care to prevent collapsing preload

collapsible spacer during installation of the yoke
and seating the front bearing.
Fig. 24 Tightening Pinion Gear Nut
(15) Remove yoke and tools from the pinion gear.
(19) Remove the tools from the shaft. Rotate the justers i n position. Carefully position the assembled
pinion several complete revolutions (both directions) differential case i n the housing.
to additionally seat the bearing rollers. (2) Observe the reference marks and install the
differential bearing caps at their original locations
CAUTION: Never loosen the pinion gear nuttode (Fig. 26).
crease the pinion gear bearing preload torque. If the
specified preload torque is exceeded, a replacement
collapsible spacer must be installed. The torque se
(20) Measure the pinion bearing preload torque by

rotating pinion shaft with a Newton-meter or an
inch-pound torque wrench. The correct bearing pre
load torque is 2-4 N-m (20-30 i n . lbs.). This torque
value is with replacement bearings and pinion nut
tightened to a minimum of 285 N-m (210 ft. lbs.)
torque (Fig. 25)
When using original pinion rear bearing and
a replacement front bearing. The correct pre
load torque is 1 N-m (10 in. lbs.) torque plus the
torque measured and recorded during disas
sembly. Fig. 26 Bearing Caps & Bolts
(3) Install the bearing cap bolts (Fig. 26). Tighten
the upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten
the lower bolts finger-tight until the bolt head is
lightly seated.
DIFFERENTIAL BEARING PRELOAD AND RING

GEAR BACKLASH ADJUSTMENT
The following must be considered when adjusting
bearing preload and gear backlash:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm)
• Mark the gears so the same teeth are meshed dur
ing all backlash measurements
• Maintain the torque while adjusting the bearing
preload and ring gear backlash
• Excessive adjuster torque will introduce a high
Fig. 25 Bearing Preload Torque Measurement bearing load and cause premature bearing failure.
The bearing preload torque should be con Insufficient torque can cause excessive differential
stant during a complete revolution of the drive case free-play and ring gear noise
pinion gear shaft. If preload torque varies • Insufficient adjuster torque will not support the
while rotating the shaft, there is an internal ring gear correctly. This can cause excessive differen
binding that must be corrected before assem tial case free-play and ring gear noise.
bly. The differential bearing cups will not always
(21) I f specified torque is not obtained, tighten the immediately follow the threaded adjusters as
nut i n small increments until preload torque is ob they are moved during adjustment. Ensure ac
tained. curate bearing cup responses to the adjust
The differential will be unacceptable for use ments. Maintain the gear teeth engaged
i f the final nut torque is less than 285 N-m (210 (meshed) as marked. The bearings must be
ft. lbs.) torque. If preload torque is not within seated by rapidly rotating the pinion gear a
the specified range this is also unacceptable. half turn back and forth. Do this five to ten
times each time the threaded adjusters are ad
DIFFERENTIAL CASE INSTALLATION justed.
(1) Apply a coating of hypoid gear lubricant to the (1) Use Wrench C-4164 to adjust each threaded ad
differential bearings, bearing cups and threaded ad juster inward (Fig. 27). Adjust until the differential
justers. A dab of grease can be used to keep the ad bearing free-play is eliminated. Allow some ring gear
• REAi SUSPENSION AND AXLE 3 « 21
backlash (approximately 0.01 inch/0.25 mm) between Continue to tighten the right-side adjuster and seat
the ring and pinion gear. Seat the bearing cups with bearing cups until the torque remains constant at
the procedure described above. 102 N-m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Continue increasing the torque at the right-side
threaded adjuster until the specified backlash is ob
tained.
The left-side threaded adjuster torque should
have approximately 102 N-m (75 ft. lbs.) torque.
If the torque is considerably less, the complete
adjustment procedure must be repeated.
(8) Tighten the left-side threaded adjuster until
102 N-m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(9) Install the threaded adjuster locks . Ensure the
lock finger is engaged with the adjuster hole. Tighten
the lock screws to 10 N-m (90 in. lbs.) torque.
Fig. 27 Threaded Adjuster Tool
(2) Install Dial Indicator (Fig. 28). Position the SIDE GEAR CLEARANCE MEASUREMENT AND
plunger against the drive side of a ring gear tooth. ADJUSTMENT
Measure the backlash at 4 positions (90 degrees When measuring side gear clearance, check each
apart) around the ring gear. Locate and mark the gear independently. I f i t necessary to replace a side
area of minimum backlash. gear, replace both gears as a matched set.
(3) Rotate the ring gear to the position of the least (1) Install the axle shafts and C-clip locks and pin
backlash. Mark the gear so that all future backlash ion mate shaft. I f necessary, refer to the installation
measurements will be taken with the same gear located within this group.
teeth meshed. (2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub
(Fig. 29).

(4) Loosen the right-side, tighten the left-side
threaded adjuster. Obtain backlash of 0.003 to 0.004
Fig. 29 Side Gear Clearance Measurement
inch (0.076 to 0.102 mm) with each adjuster tight
ened to 14 N-m (10 ft. lbs.) torque. Seat the bearing (3) I f side gear clearances is no more than 0.005
cups with the procedure described above. inch. Determine i f the shaft is contacting the pinion
(5) Tighten the differential bearing cap bolts to 136 gear mate shaft. Do not remove the feeler
N-m (100 ft. lbs.) torque. gauges, inspect the axle shaft with the feeler
(6) Use Wrench C-4164 to tighten the right-side gauge inserted behind the side gear. I f the end of
threaded adjuster to 102 N-m (75 ft. lbs.) torque. Seat
the bearing cups with the procedure described above.
3 • 22 REAR SUSPENSION AND AXLE •
the axle shaft is not contacting the pinion gear mate (7) I f clearance is 0.012 inch (0.305 mm) or greater,
shaft, the side gear clearance is acceptable. both side gears must be replaced (matched set) and
(4) I f clearance is more than 0.005 inch (axle shaft the clearance measurements repeated.
not contacting mate shaft), record the side gear clear (8) I f clearance (above) continues to be 0.012 inch
ance. Remove the thrust washer and measure its (0.305 mm) or greater, the case must be replaced.
thickness with a micrometer. Add the washer thick
ness to the recorded side gear clearance. The sum of RING G E A R T E E T H CONTACT PATTERN
gear clearance and washer thickness will determine ANALYSIS
required thickness of replacement thrust washer The ring gear teeth contact patterns will show i f
(Fig. 30). the pinion gear depth shim(s) have the correct thick
ness. I t will also show i f the ring gear backlash has
SIDE GEAR CLEARANCE 0.007 been adjusted correctly. The backlash must be main
THRUST WASHER THICKNESS +0.033
TOTAL 0.040 tained within the specified limits until the correct
teeth contact patterns are obtained.
I • 0.040
REPLACEMENT WASHER THICKNESS -0.037 • Excessive backlash is corrected by moving the ring
NEW SIDE GEAR CLEARANCE 0.003 gear teeth closer to the pinion gear teeth
J9203-31
• Insufficient backlash is corrected by moving the
ring gear away from the pinion gear
Fig. 30 Side Gear Calculations
(1) Apply yellow ferrous (iron) oxide compound to
In some cases, the end of the axle shaft will move both drive and coast sides of ring gear teeth.
and contact the mate shaft when the feeler gauge is (2) Rotate the ring gear one complete revolution i n
inserted. The C-clip lock is preventing the side gear both directions.
from sliding on the axle shaft. (3) Note patterns i n compound. Refer to (Fig. 31)
(5) I f there is no side gear clearance, remove the for interpretation of contact patterns and adjust ac
C-clip lock from the axle shaft. Use a micrometer to cordingly.
measure the thrust washer thickness. Record the (4) Install the axle shafts. Refer to Axle Shaft I n
thickness and re-install the thrust washer. Assemble stallation within this group.
the differential case without the C-clip lock installed (5) Install the housing cover. Refill the differential
and re-measure the side gear clearance. with lubricant. Refer to Axle Shaft Installation.
(6) Compare both clearance measurements. I f the (6) Install the RWAL/ABS brake speed sensor and
difference is less than 0.012 inch (0.305 mm), add cover onto the axle housing. Tighten the sensor to 13
clearance recorded when the C-clip lock was installed N-m (10 ft. lbs.) torque.
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
REAR SUSPENSION AND AXLE 3 - 23

O F RING O F RING
DESIRABLE C O N T A C T PATTERN.
PATTERN S H O U L D BE CENTERED
HEEL TOE TOE HEEL
BUT MAY BE SLIGHTLY T O W A R D
CONTACT PATTERN A N D TOP O F
THE T O O T H .

THINNER P I N I O N GEAR DEPTH
SHIM REQUIRED.

THICKER P I N I O N GEAR DEPTH
SHIM REQUIRED.
P I N I O N GEAR DEPTH SHIM

CORRECT. DECREASE RING
GEAR BACKLASH.

CORRECT. INCREASE RING
GEAR BACKLASH.
J9003-24
Fig. 31 Gear Teeth Contact Patterns

S P E C I F I C A T I O N S 9 1/4 INCH A X L E
SPECIFICATION Ring Gear Backlash.0.005-0.008 in. (0.12-0.20 mm)
Axle Type Semi-floating, hypoid Pinion Bearing Preload 10-20 in.lbs. (1-2 N-m)
Ring Gear Diam 9.25 in. (23.50 cm) Case Flange Runout 0.003 in. (0.076 mm)
Lubricant ................SAE 80W-90 Ring Gear Runout.. 0.005 in. (0.127 mm)
Lube Capacity 76 oz. (2.26 L) Axle Ratio Options 3.21 3.55 3.9
Diff. Case Clearance 0.005 in. (0.12 mm)
MODEL 60, 70 and 80 AXLES
INDEX
page page
Axle Shaft Removal/Installation 29 Pinion Measurement and Assembly 37
Complete Axle Removal/Installation 30 Pinion Removal/Disassembly 32
Differential Assembly 34 Pinion Seal Replacement—Model 60 28
Differential Disassembly . 31 Pinion Seal Replacement—Model 70 and 80 27
Drain and Refill 27 Ring Gear Backlash and Contact Pattern 40
General Information 25 Wheel Bearing Service 30
Lubricant 27
GENERAL INFORMATION The removable steel cover provides a means for in
The housing (Fig. 1) consists of an iron center cast spection and service without removing the axle from
ing with axle shaft tubes extending from either side. the vehicle.
The tubes are pressed i n to form a one-piece axle A stamped metal axle gear ratio identification tag
housing. is attached to the housing cover with one cover bolts.
The integral type housing, hypoid gear design has This tag also identifies the number of ring and pinion
the centerline of the pinion set below the centerline teeth. An addition tag will be attached i f equipped
of the ring gear. with a limited-slip differential.
The axles are equipped with full-floating axle The differential case is a one-piece design. The dif
shafts, meaning that loads are supported by the axle ferential pinion mate shaft is retained with a roll
housing tubes. The full-float axle shafts are retained pin. Model 70 and 80 axles with the optional Power-
by bolts attached to the hub. The hub rides on two Lok use a two piece differential case. Differential
bearings at the outboard end of the axle tube. The bearing preload and ring gear backlash are adjusted
axle shafts can be removed without disturbing or re with shims located between the differential bearing
moving the wheel bearings. The wheel bearings are cones and case.
opposed tapered roller bearings that are part of the
hub assembly.
Fig. 1 Model 70 and 80 Rear Axle
LUBRICANT (7) Install the cover on the differential. Install the

Dana axles use MOPAR Thermal Stable Multi-Pur identification tag. Tighten the cover bolts to 47 N-m
pose Gear Lubricant 80W-90 or equivalent GL-5 (35 ft. lbs.) torque.
grade lubricant. Vehicles with Trac-Lok/Power-Lok
also use 6 oz. of limited slip friction modifier added CAUTION: Overfilling the differential c a n result in
to the lubricant. Dana 80 4x4 vehicles use 10 oz. of the lubricant foaming and overheating.
limited slip friction modifier added to the lubricant.
(8) Refill the differential housing with the specified
CAUTION: If a rear axle is submerged in water, the
quantity of MOPAR® Hypoid Gear Lubricant. With
axle lubricant must be replaced immediately. Trac-Lok and Power-Lok differentials, add a con
tainer of Trac-Lok Lubricant additive.
(9) Install the fill hole plug. Tighten to 34 N-m (25
DRAIN AND REFILL ft. lbs.) torque.
(1) Drive the vehicle until the gear lubricant (10) Road test vehicles with Trac-Lok/Power-Lok
reaches normal operating temperature. and make 10 to 12 slow, figure-eight turns. This ma
(2) Raise and support the vehicle. neuver will pump lubricant through clutch discs.
(3) Remove the lubricant fill hole plug from the dif
ferential housing cover. PINION SEAL REPLACEMENT—MODEL 70 AND 80
(4) Remove the differential housing cover. Allow
the lubricant to completely drain from the housing REMOVAL
and axle shaft tubes. (1) Raise and support the vehicle.
(5) Flush the differential and housing cavity with (2) Mark the U-joint, pinion yoke, and pinion shaft
flushing oil to remove residual lubricant and foreign for reference.
matter. Do not use water, steam, kerosene o r (3) Disconnect the drive shaft from the pinion
gasoline for flushing. yoke. Secure the drive shaft i n an upright position to
(6) Scrape the residual gasket from the housing prevent damage to the rear U-joint.
and cover mating surfaces. Clean the mating surfaces (4) Mark the positions of the yoke and pinion gear
with mineral spirits. Apply a bead of MOPAR® Sili for installation alignment reference.
cone Rubber Sealant on the housing cover (Fig. 2). (5) Remove the pinion yoke nut and washer. Use
Allow the sealant to cure for a few minutes. Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 3).
SEAUNG CONTOUR OF BEAD
C-452 J9102-31
Fig. 3 Pinion Yoke Removal

(6) Use Remover 7794A and slide hammer to re
move pinion seal (Fig. 4).
INSTALLATION
Fig. 2 Typical Housing Cover (1) Apply a light coating of gear lubricant on the
Install the housing cover within 5 minutes af lip of pinion seal. Install the new seal with Installer
ter applying the sealant. I f not installed? the D-187B.
sealant must be removed and another bead ap (2) Align the installation reference marks and po
plied. sition the yoke on the pinion gear.
SPECIAL TOOL DIFFERENTIAL

7794A HOUSING
SUDE HAMMER
PINION SEAL
J9402-59X
Fig. 4 Pinion Seal Remowal

(3) Install yoke with Installer D-191 (Fig. 5).
YOKE
INSTALLER
TORQUE WRENCH J9402-62
Fig. 6 Tightening Pinion Shaft Nut

(3) Mark the propeller shaft yoke and pinion yoke
for installation alignment reference.
(4) Remove the propeller shaft from the yoke.
(5) Rotate the pinion gear three or four times.
Make sure brakes are not dragging during this
procedure.
(6) Measure the amount of torque (in Newton-
meters or inch-pounds) necessary to rotate the pinion
gear with a torque wrench. Note the torque for in
YOKE stallation reference. It must be known to properly
HOLDER
adjust the pinion gear bearing preload torque
after seal installation.
(7) Remove the pinion yoke nut and washer. Use
Remover C-452 and Holder C-3281 to remove the
J9402-61 pinion yoke (Fig. 7).
Fig. 5 Yoke Installation
SPECIAL TOOL
(4) Install washer with concave surface against C-3281
yoke on Model 70 axle. Install nut on shaft and
tighten nut to (Fig. 6);
• Model 70: 298-379 N-m (220-280 ft. lbs.) torque
tach the drive shaft to the yoke.
(6) Add gear lubricant to the differential housing i f
necessary.
PINION SEAL REPLACEMENT—MODEL 60

SPECIAL TOOL
REMOVAL C-452 J9102-31
(2) Remove wheel and tire assemblies Fig. 7 Pinion Yoke Remowal
(8) Mark the positions of the yoke and pinion gear CAUTION: Exercise care d u r i n g t h e bearing preload
for installation alignment reference. t o r q u e adjustment. Do not over-tighten, or loosen
(9) Use Remover 7794A and slide hammer to re a n d then re-tighten the n u t Do not exceed the bear
move the pinion gear seal (Fig. 8). i n g preload t o r q u e . The collapsible preload spacer
o n the pinion shaft will have t o be replaced. The
SPECIAL TOOL bearing preload t o r q u e will be re-adjusted after
7794A
ward.
(4) Install a socket and inch-pound torque wrench

on the pinion nut.
(5) Rotate the shaft with the torque wrench and
note the torque.
The required preload is equal to amount re
corded during removal plus 0.56 N-m (5 in. lbs.).
The used bearing preload torque must never
exceed 2.25 N-m (20 in. lbs.)
PINION SEAL
(6) Use Flange Holder 6719 to retain the yoke and
shaft (Fig. 10). Tighten the shaft nut i n very small
increments.
J9402-59X
DIFFERENTIAL
Fig. 8 Seal Removal
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal Installer C-163.
(2) Align the installation reference marks and in
stall yoke on pinion shaft with Installer C-3718 (Fig.
9).
YOKE
Fig. 10 Tightening Pinion Shaft Nut

(7) Continue tightening the shaft nut i n small in
crements until the correct bearing preload torque is
attained. Tighten the pinion shaft nut to 292 to 497
N-m (215 to 315 ft. lbs.) torque.
tach the propeller shaft to the yoke.
J9402-61 (9) Add gear lubricant to the differential housing i f
necessary.
Fig. 9 Yoke Installer (10) Install wheel and tire assemblies
(3) Install washer with concave surface against the (11) Remove support and lower the vehicle.
yoke. Install new nut on the pinion gear. Tighten
the nut only enough to remove the shaft end AXLE SHAFT REMOVAL/INSTALLATION
play.
CAUTION: R A I S E BOTH R E A R W H E E L S off the sur
face whenever a rear axle is being serviced.
REMOVAL (3) Apply lubricant to surface area of the hub bore.
(1) Remove the axle shaft flange bolts. Install the inner wheel bearing i n the hub. Install a
(2) Slide the axle shaft out from the axle tube (Fig. replacement bearing seal with an appropriate seal in
1). stallation tool.
(4) Inspect the bearing and seal contact surfaces
INSTALLATION on the axle for burrs and/or roughness.
(1) Clean the gasket contact surface area on the (5) Remove all the rough contact surfaces from the
flange with an appropriate solvent. Install a new axle. Apply a coating of multi-purpose NLGI, grade 2,
flange gasket and slide the axle shaft into the tube. EP-type lubricant to the axle.
(2) Install the bolts and tighten to 122 N-m (90 ft.
lbs.) torque. CAUTION: Use care t o prevent the inner wheel bear
i n g a n d bearing seal f r o m c o n t a c t i n g the axle
WHEEL BEARING SERVICE t h r e a d s d u r i n g installation.
REMOVAL (6) Carefully slide the hub onto the axle and in
(1) Remove the axle shaft, refer to the removal stall outer Ayheel bearing.
procedure. (7) Install adjustment nut and tighten to 163-190
(2) Remove the nut lock and adjustment nut. N-m (120-140 ft. lbs.) torque while rotating the
(3) Remove drum and hub. The outer wheel bear wheel.
ing will slide of with the hub. (8) Back off adjustment nut 1/8 to 1/3 of a turn to
(4) Place hub on bench and remove inner grease provide 0.001-inch to 0.010-inch wheel bearing end
seal and discard seal. Remove inner and outer bear play.
ings. (9) Tap locking wedge into the spindle keyway and
adjustment nut.
CLEANING AND INSPECTION (10) Install the axle shaft, refer to the installation
(1) Thoroughly clean both wheel bearings and inte procedure.
rior of the hub. Remove all of the residual lubricant.
(2) To clean the bearings: COMPLETE AXLE REMOVAL/INSTALLATION
• Soak them i n an appropriate cleaning solvent
• Strike the flat of each bearing against a hardwood REMOVAL
block several times It is not necessary to remove the complete axle
from the vehicle for routine differential inspection
• Flush bearing between strikes
and service. I f the differential housing, case or axle
• Repeat the procedure above until each bearing is
shaft tubes are damaged the complete axle must be
clean
removed.
• Dry the bearings with compressed air but do not (1) Raise the rear of the vehicle until the rear
spin them wheels are not contacting the surface. Support the
(3) After cleaning, apply engine oil to each bearing. vehicle body at the front of the rear springs.
(4) Rotate each bearing slowly while applying (2) Use a wooden block to retain the brake pedal i n
downward force. Examine the rollers for pitting and the up position.
roughness. Replace worn or otherwise defective bear (3) Remove wheels, axle shafts, brake drums and
ings. I f a bearing has pitted or has rough surfaced hubs. Refer to axle shaft removal procedure.
rollers replace bearing.Always replace bearing (4) Disconnect the brake line and cap the fittings
cone and cup as a set. to prevent loss of brake fluid.
(5) I f reusable, remove the engine oil from each (5) Disconnect the parking brake cables.
bearing. Pack each bearing with multi-purpose Scribe installation alignment reference marks
NLGI, grade 2, EP-type lubricant. on drive shaft U-joint and on pinion yoke.
Ensure that lubricant i s forced into a l l the (6) Disconnect the drive shaft U-joint from the pin
cavities between the bearing cage and rollers. ion yoke. Secure i t in an upright position to prevent
damage to the U-joint.
INSTALLATION
(1) I f a bearing and cup must be replaced, remove WARNING:AXLE MAY ROTATE ON SUPPORT
the cup from the hub bore. Use a brass drift or an WHEN SPRING CLAMP BOLTS ARE REMOVED EN
appropriate removal tool to tap out the cup. SURE AXLE IS SECURED ON SUPPORT.
(2) Install the replacement bearing cup(s) with an
(7) Support axle, remove lower shock absorber
appropriate installation tool.
bolts and spring clamp bolts from the axle.
(8) Remove the rear axle from the vehicle.
INSTALLATION (2) Position Spreader W-129B with the tool dowel

(1) Position the axle under the rear springs, pins seated i n the locating holes (Fig. 12). Install the
(2) Install the spring clamp bolts and tighten the holddown clamps and tighten the tool turnbuckle fin
nuts to specified torque. ger-tight.
(3) Install shock absorbers bolts at axle brackets
and tighten to specified,
(4) Connect the parking brake cables and brake line.
(5) Install the hubs, axles and brake drums. Refer
axle installation procedure,
(6) Remove the block from the brake pedal. Bleed
and adjust the brakes. Refer to Group 5 brakes for
procedure.
(7) Connect drive shaft to pinion yoke with the ref
erence marks aligned. Tighten U-joint clamp bolts to
21 N-m (16 ft. lbs,/186 in. lbs.) torque.
(8) Install wheels and tire assemblies
(9) Fill the differential housing to the correct level.
Add MOPAR Hypoid Gear Lubricant Additive
for Trac-Lok and Power-Lok equipped axles.
(10) Remove the supports and lower vehicle.
(11) Road test the vehicle to evaluate the results of Fig. 12 Differential Housing Spreader
the repair. (3) Install a pilot stud at the left side of the differ
ential housing. Attach Dial Indicator to housing pilot
DIFFERENTIAL DISASSEMBLY stud. Load the indicator plunger against the opposite
side of the housing (Fig. 12) and zero the indicator.
REMOVAL/DISASSEMBLY .
Remove RWAL/ABS brake sensor hold-down CAUTION: Do not spread over the specified dis
bolt and pull the sensor from the differential tance, if the housing is over-separated if could be
housing. The sensor must be removed to pre distorted or damaged.
vent damage when disassembling or assembling
the differential components. (4) Separate the housing enough to remove the
(1) Note reference letters located on bearing caps case from the housing. S e p a r a t e h o u s i n g a m a x i
and housing machined sealing surface (Fig. 11). Re m u m d i s t a n c e of 0.38 m m (0*015 i n ) w i t h the
move the differential bearing caps. s p r e a d e r tool. Measure the distance with the dial
indicator (Fig. 12).
(5) Remove the dial indicator.
(6) Pry the differential case loose from the housing.
To prevent damage, pivot on housing with the end of
the pry bar against case.
(7) Remove the case from housing. I f they are re
usable, retain the differential bearing cups and bear
ings together as matched sets.
(8) Clamp the differential case i n a vise equipped
with soft jaws. Remove and discard the ring gear
bolts. Tap the ring gear off with a rawhide or plastic
mallet (Fig. 13).
(9) The exciter ring can be removed with a soft-
faced hammer (Fig. 14), Discard after removal.
(10) Remove bearings and shims from case hubs
and mark them (with hub identity) for assembly ref
Fig. 11 Bering Cap identification erence (Fig. 15). Record the thickness of the shims.
(11) Clamp the differential case i n a vise equipped
with soft jaws. Use a pin punch to remove the pinion
gear mate shaft lock pin (Fig. 16).
(12) Remove the mate shaft with a drift and ham
mer (Fig. 17).
3 - 32 REAR SUSPENSION AND AILE
CASE RING GEAR
SPECIAL TOOL
1130
SPECIAL TOOL
938
J9202-76
BUTTON DIFFERENTIAL
BEARING
J9403-48
DRIFT
EXCIIOR
RING
8903-33
Fig. 14 Exciter Ring Removal

(13) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 18 ).
(14) Remove the differential side gears and thrust
washers.
PINION REMOVAL/DISASSEMBLY
J9302-33
REMOVAL/DISASSEMBLY
(1) Remove the pinion yoke nut and washer. Use Fig. 16 Mate Shaft Lock Pin Removal
Remover C-452 and Wrench C-3281 to remove pinion (5) Remove rear bearing cup with;
yoke (Fig. 19). • Model 60 and 70: Remover D-162 and Handle
(2) Remove pinion, and remove pinion seal with C-4171
Remover 7794A and slide hammer (Fig. 20). • Model 80: Remover D-159 and Handle C-4171
(3) Remove oil slinger or collapsible spacer, front (6) Remove depth shims from the housing bore i f
bearing and shims. Record the thickness of the shims used. Record the thickness of the depth shims.
(Fig. 21). (7) Remove the pinion rear bearing and selective
(4) Remove front pinion bearing cup with; pinion position shim (Fig. 22).
• Model 60 and 70: Remover D-158 and Handle
C-4171
• Model 80: Remover C-4307 and Handle C-4171
C-452 J9102-31
Fig. 17 Mate Shaft Remowal Fig. 19 Pinion Yoke Remowal
THRUST SPECIAL TOOL

WASHER 7794A
PINION SEAL
J9402-59X
Fig. 20 Pinion Seal Remowal

Cup and bearing must be replaced as a
matched sets only.
• All machined surfaces i n the housing and on bear
MATE GEAR SIDE GEAR J9203-61
ing caps should be smooth and without any raised
Fig. 18 Pinion Mate Gear Remowal
edges
• Pinion gear front and rear bearing cup bores
CLEANING/INSPECTION should be smooth
(1) Wash and clean all components with cleaning • Raised metal on shoulders of cup bores should be
solvent and dry with compressed air. removed with a hand stone
Do not steam clean the differential compo (4) Examine the differential pinion gear mate
nents. shaft, pinion gears, side gears and thrust washers for
(2) Clean the axle shaft tubes. Insert a stiff wire wear and damage. Replace all defective components.
into each tube, attach a clean cloth .to the wire at the If either of the differential pinion gears is not
housing opening. Draw the wire (and cloth) from the reusable, both gears must be replaced as a
housing outward through the tube. matched set only. Do not replace only one gear.
(3) Inspect the differential and pinion gear bear (5) Examine the ring gear and the pinion gear for
ings. Inspect the differential case and housing. worn and chipped teeth. Examine the ring gear for
• Bearings and cups should have a smooth appear damaged attaching bolt threads.
ance. With no broken/dented surfaces on the bearing If replacement of either gear is necessary,
rollers or roller contact surfaces both must be replaced as a matched set only.
• Bearing races must not be distorted or cracked
PINION WASHER
YOKE
PINION
NUT
PINION
PRELOAD
SHIMS PINION
OIL SEAL
P I N I O N PRELOAD
SPACER
FRONT
BEARING
CONE
SHOULDER FOR
J9203-63
' PINION PRELOAD SPACER
Fig. 21 Pinion Front ing and Preload Shims

(7) Inspect the pinion bearing preload shims for
cracks, damage and distortion. Install replacement
shims (if necessary) for the preload torque adjust
ment.
(8) Inspect the RWAL/ABS brake exciter ring for
damage and missing teeth. I f not removed, ensure
the ring is firmly pressed onto the differential case.
Replace the ring i f loose or damaged.
DIFFERENTIAL ASSEMBLY
ASSEMBLY
(1) Lubricate all differential components with hy
poid gear lubricant.
w(2) Install the following components i n the differ
ential case.
• Differential side gears and thrust washers
• Pinion gears and thrust washers
• Pinion gear mate shaft (align holes i n shaft and
case)
(3) Install and seat the lock pin i n differential case
and mate shaft with a punch and hammer (Fig. 23).
Fig. 22 Pinion Rear Bearing Removal Peen metal part of case over pin in two places 180
(6) Inspect the pinion yoke for cracks, worn degrees apart.
splines, pitted areas, and a rough/corroded seal con If replacement gears and thrust washers were
tact surface. Repair or replace the yoke as necessary. installed, it is not necessary to measure the
gear backlash. Correct fit is due to close ma
chining tolerances during manufacture.
PUNCH
Fig. 23 Mate Shaft Pin Installation

(4) I f exciter ring was removed, align exciter ring
tab with slot i n differential case (Fig. 24).
J9402-64
Fig. 26 Master Bearing Tools On Hubs

Fig. 24 Exciter Ring Alignment (9) Install a pilot stud at the right side of housing.
(5) Invert the differential case and start two ring Attach Dial Indicator C-3339 to the pilot stud. Load
gear bolts. This will provide case-to-ring gear bolt indicator plunger against the back of the ring gear
hole alignment. (Fig. 27).
(6) Press the exciter ring onto the differential case (10) Insert a small pry bar between the bearing
using the ring gear as a pilot (Fig. 25). cap and left side of differential case. Pry the case as
(7) Install new ring gear bolts and alternately far as possible to right side (Fig. 27). Zero the dial
tighten to; indicator pointer.
• Model 60 and 70: 163-190 N-m (120-140 ft. lbs.) (11) Pry the case to left side and record the travel
torque distance.
• Model 80: 272-325 N-m (200-240 ft. lbs.) torque The measurement above is the shim thickness
necessary for case zero end-play. The total
TOOL G 3 3 3 9 • Model 60 axle, the standard depth/distance is

127.00 mm (5.000 inches)
• Model 70 axle, the standard depth/distance is
136.525 mm (5.375 inches).
• Model 80 axle, the standard depth/distance is
147.625 mm (5.812 inches).
INNER PINION
BEARING
BUTTON END
CENTERLINE OF
RING GEAR
8903-29
J9403-56
Fig. 27 Differential Case End Play Measurement

Fig. 29 Pinion Gear Standard Depth/Distance
thickness will be determined during the ring
Compensation for depth variance is achieved by
gear backlash adjustment.
two methods. One method is shims placed between
the pinion gear rear bearing cup and housing (Fig.
PINION G E A R DEPTH INFORMATION
30). The second method is selective shim between the
pinion gear head and bearing cone.
Gears are supplied as matched sets only. The iden
tifying numbers for the ring and pinion gear are PINION
etched into the face of each gear (Fig. 28). A plus (+) BEARING
PRELOAD
number, minus (-) number or zero (0) is etched into SPACER/SHIM
the face of the pinion gear. This number is the
amount (in thousandths of an inch) the depth varies
from the standard depth setting. The standard depth
provides the best teeth contact pattern.
P I N I O N GEAR
DRIVE P I N I O N DEPTH S H I M
PRODUCTION GEAR DEPTH OR
NUMBERS VARIANCE SELECTIVE
SHIM
DIFFERENTIAL
BEARING
SHIM J9403-64
GEAR MATCHING NUMBER
(SAME A S RING GEAR NUMBER) J9003-100 Fig. 30 Shim Locations
Fig. 28 Pinion Gear ID Numbers

I f new gear set is being installed, note the depth
variance etched into original and new pinion gear.
The standard depth is the distance (Fig. 29) from Add or subtract the thickness of the original depth
the centerline of the axle shaft/ring gear to the shoul shims to compensate for the difference i n the depth
der of the rear pinion bearing. variances. Refer to the Depth Variance charts.
PINION G E A R D E P T H VARIANCE

Gear Depth
Variance -4 -3 -1 -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
4-2 + 0.006 +0.005 + 0.004 +0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 +0.003 +0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
J8902-46
For example, i f old pinion is plus (+) 1 and the new DIAL INDICATOR
pinion is minus (-) 3, intersecting figure is (+)0.004
inch (0.10mm). Add this amount to the original shim.
Or i f the old pinion is (-) 3 and the new pinion is (-)
2, intersecting figure is (-)O.OOl inch (0.025mm). Sub
tract this amount from original shim. Refer to the
Pinion Gear Depth Variance Chart.
If equipped, the oil slinger must be measured
and the thickness included with the total shim
pack thickness.
Depth shim thickness for the new pinion gear must
be determined before installing differential case i n
housing.
PINION MEASUREMENT AND ASSEMBLY
PINION G E A R DEPTH MEASUREMENT

Pinion gear depth measurement is necessary
when axle housing is replaced or pinion select ARBOR DISC
shim pack is unknown. It is also recommended
when ring and pinion gears are replaced. J9403-45
Compensation for pinion depth variance is achieved
with select shims. I n production the shims are placed Fig. 31 Pinion Gear Depth Gauge Tools
between the pinion gear and the inner pinion bearing
cone. For service the shims are placed under the in
ner pinion bearing cup.
Measurements are taken with pinion cups and pin
ion bearings installed i n housing. Take measure
ments with Pinion Gauge Set 6730 and Dial
Indicator C-3339 (Fig. 31).
(1) Install front pinion bearing cup with (Fig. 32); PINION BLOCK
• Model 60 and 70: Installer C-4203 and Handle
C-4171
• Model 80: Installer C-4308 and Handle C-4171
INSTALLER HANDLE
PINION HEIGHT
BLOCK
J9403-39
Fig. 34 Pinion Height Block

Arbor Discs have different steps to fit other
J9402-65 axle sizes. P i c k correct size step for axle being
serviced.
Fig. 32 Pinion Front Bearing Cup Installation
ARBOR DISC PINION BLOCK
(2) Install rear pinion bearing cup with (Fig. 33);
• Model 60 and 70: Installer D - l l l and Handle
C-4171
INSTALLER
PINION
HEIGHT BLOCK
Fig. 35 Gauge Tools In Housing
(5) Firmly place Scooter Block and Dial Indicator

on pinion height block tool and zero the dial indicator
pointer.
(6) Slide the Scooter Block across the arbor while
observing indicator (Fig. 36). Record the longest
travel distance, whether inward (-) or outward (+),
indicated by the pointer.
The plunger travel indicated, plus or minus
HANDLE J9402-66 the variance etched i n the gear is the required
thickness for the depth shims.
Fig. 33 Pinion Rear Bearing Cup Installation
(7) Measure thickness of each depth shim with a
(3) Assemble Pinion Gauge Set, Pinion Block and micrometer and combine shims necessary for total re
pinion bearings. Install assembly into differential quired shim pack thickness. Include oil slinger or
pinion gear bore and hand tighten cone (Fig. 34). baffle thickness with the total shim pack thick
(4) Place Arbor Disc 6732 on Arbor D-115-3 and po ness.
sition i n the bearing cradles (Fig. 35). Install differ (8) Remove measurement tools from differential
ential bearing caps on Arbor Discs and tighten caps housing. Remove rear pinion bearing cup with;
snug only. • Model 60 and 70: Remover D-162 and Handle
C-4171
PRESS
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING'
Fig. 36 Pinion Gear Depth Measurement OIL

SUNGER
• Model 80: Remover D-159 and Handle C-4171
(9) Place depth shims i n pinion gear rear bearing
bore (Fig. 37). Install bearing cup with; DRIVE
PINION GEAR J9302-68
• Model 60 and 70: Installer D - l l l and Handle
C-4171
Fig. 38 Pinion Rear Bearing Installation
• Model 60: Installer C-163
INSTALLER • Model 70 and 80: Installer D-187B
(14) Install yoke, washer and nut (Fig. 39).Model
60 and 70 install washer with concave surface
against the yoke. Install the yoke with;
• Model 60: Installer C-3716 and Holder 6719
• Model 70 and 80: Installer D-191 and Holder 6719
YOKE
INSTALLER
HANDLE J9402-66
Fig. 37 Pinion Rear Bearing Cup Installation

YOKE
(10) Install rear bearing (and slinger i f used) on HOLDER
pinion gear (Fig. 38);
• Model 60: Installer C-3095A
• Model 70 and 80: Installer D-389
(11) Assemble preload shims or collapsible spacer
J9402-61
if used onto pinion and install pinion gear i n hous
ing.
Fig. 39 Pinion Yoke Installation
(12) Install pinion front bearing and oil slinger.
(13) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal with;
(15) Tighten the yoke nut (Fig. 40) to;
CAUTION: When collapsible spacer is used never

loosen pinion gear nut to decrease pinion gear
bearing preload torque. Never exceed specified pre
load torque. If preload torque is exceeded a new
collapsible spacer must be installed. The torque s e
When collapsible spacer is used tighten nut i n

small increments until rotating torque is achieved.
Measure the preload torque frequently to avoid
over-tightening the nut.
DIFFERENTIAL _
Fig. 41 Rotating Torque
Fig. 40 Torque Yoke

(16) Check bearing preload torque with an inch
pound torque wrench (Fig. 41). The torque necessary
to rotate the pinion gear should be;
• Original Bearings — 1-3 N-m (10-20 in. lbs.)
• New Bearings - 2-5 N-m (20-40 in. lbs.)
Axles equipped with shims, i f preload torque is not
within specified tolerance, correct the shim thickness
accordingly (Fig. 42);
• Increase the preload torque, decrease the shim Fig. 42 Shim Locations
thickness
• Decrease the preload torque, increase the shim • Model 70 and 80: Master Bearings D-463
thickness (2) Install a pilot stud at the right side of housing.
Attach Dial Indicator C-3339 to the pilot stud. Load
RING GEAR BACKLASH AND CONTACT PATTERN indicator plunger against the back of the ring gear
(Fig. 43). Ensure ring and pinion gear teeth are
RING G E A R BACKLASH MEASUREMENT tightly meshed. Zero the indicator.
(1) Place Master Differential Bearing case hubs;
• Model 60: Master Bearings D-343
holddown clamps and tighten the tool turnbuckle fin

ger-tight.
SPECIAL TOOL
Fig. 44 Differential Housing Separation

(13) Install a pilot stud at the left side of the dif
ferential housing. Attach Dial Indicator to housing
pilot stud. Load the indicator plunger against the op
posite side of the housing (Fig. 44) and zero the indi
(3) Insert a small pry bar between the bearing cap cator.
and right side of differential case. Pry the case as far
as possible to left side (Fig. 43). Zero the dial indica CAUTION: Do not spread over the specified dis
tor pointer. tance. If the housing is over-separated, it could be
(4) Repeat the measurement several times to check distorted or damaged.
consistency. Record the travel distance.
The measurement above shows shim thick (14) Separate the housing enough to install the
ness necessary to eliminate ring gear backlash. case i n the housing. Separate housing a maxi
The shims must be placed at the ring gear mum distance of 0.38 mm (0.015 in) with the
flange side between the case and bearing. Sub spreader tool. Measure the distance with the dial
tract this thickness from case zero end-play indicator.
shim thickness. This amount plus 0.38mm (0.015 (15) Remove the dial indicator.
in.) will be required for differential bearing (16) Install case i n the housing. Ensure the differ
preload and backlash. These shim must be ential bearings are fully seated. Remove the
placed on the opposite side. spreader.
(5) Remove indicator and pilot stud. (17) Observe the assembly reference marks and po
(6) Remove the differential case from housing. sition the bearing caps at their original locations
(7) Remove the master bearing tools from the dif (Fig. 45). Tighten the bearing cap bolts to 95-122 N-m
ferential case hubs.
(70-90 ft. lbs.) torque.
(8) Position the backlash shims (with determined
(18) Rotate the assembly several revolutions to
thickness) on case hub (ring gear side). Install bear
ing on the hub with Installer C-4190 and Handle seat bearings. Measure backlash at three equally
C-4171. spaced locations with a dial indicator (Fig. 46).
(9) Position the remaining zero end-play shims on The ring gear backlash must be within 0.004 -
hub at opposite side of case. Include an additional 0.009 inch (0.10 - 0.23 mm). It cannot vary more
0.015-in (0.38-mm) thick shim on this hub. This will than 0.002 inch (0.05 mm) between the points
provide the required differential bearing preload checked.
torque. (19) Excessive backlash is corrected by moving the
(10) Install bearing on the hub with Installer ring gear teeth closer to the pinion gear teeth. Insuf
C-4190 and Handle C-4171. ficient backlash is corrected by moving the ring gear
(11) Match each bearing cup with bearing (origi away from the pinion gear. Backlash correction is ac
nal). Install the cups on the bearings. complished by transferring shims from one side to
(12) Position Spreader W-129B with the tool dowel the other.
pins seated i n the locating holes (Fig. 44). Install the
RING G E A R T E E T H CONTACT PATTERN
ANALYSIS
The ring gear teeth contact patterns will show i f
the pinion gear depth shim(s) have the correct thick
ness. I t will also show i f the ring gear backlash has
been adjusted correctly. The backlash must be main
tained within the specified limits until the correct
teeth contact patterns are obtained.
(1) Apply a thin coat of hydrated ferric oxide, to
the drive and coast side of ring gear teeth.
(2) Rotate the ring gear one complete revolution i n
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This action will produce distinct contact pat
terns on both the drive side and coast side of the ring
gear teeth.
Fig. 45 Differential Bearing Cap Reference Letters
(3) Note patterns i n compound. Refer to (Fig. 47)
for interpretation of contact patterns and adjust ac
cordingly.
(4) Install the axle shafts. Refer to Axle Shaft I n
stallation within this group.
(5) Install the housing cover. Refill the differential
with lubricant. Refer to Axle Shaft Installation.
(6) Install the RWAL/ABS brake speed sensor and
cover onto the axle housing. Tighten the sensor to 24
N-m (18 ft. lbs.) torque.

I f the mesh and backlash steps have been followed
in the procedures above, good gear teeth contact pat
terns should exist.

OF RING O F RING
DESIRABLE CONTACT PATTERN.

PATTERN SHOULD BE CENTERED
HEEL TOE TOE HEEL
BUT M A Y BE SLIGHTLY T O W A R D
C O N T A C T PATTERN A N D TOP O F
THE T O O T H .

THINNER P I N I O N
GEAR DEPTH
S H I M REQUIRED.

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

CORRECT. DECREASE RING
GEAR BACKLASH.

CORRECT. INCREASE RING
GEAR BACKLASH.
J9003-24
Fig. 47 Gear Teeth Contact Patterns

TRAC-LOK/POWER-LOK DIFFERENTIAL
SERVICE INFORMATION
Trac-Lok differential is available on 9 1/4 and
RING DRIVE
Model 60 axles. Power-Lok differential is available on GEAR PINION
Model 70 and 80 axles.
In a conventional differential, torque applied to the
ring gear is transmitted to the axle shafts through PINION GEAR
differential gears. During normal operation, the
torque transmitted to each wheel is equal at all
times. However, i f one wheel spins, the opposite
wheel will generate only as much torque as the spin
ning wheel.
In the Trac-Lok/Power/Lok differential, part of the
ring gear torque is transmitted through clutch packs.
The clutch packs contain multiple disc clutches
which have radial grooves on the plates and concen
tric grooves on the discs.
In operation, the Trac-Lok/Power-Lok clutches are
engaged by two concurrent forces. The first being
preload force exerted through dished spring washers
contained i n the clutch packs. The second from sepa
rating forces generated by the side gears as torque is
J9303-15
applied through the ring gear (Fig. 1).
The Trac-lok design provides differential action
Fig. 1 Limited Slip Differential Operation—Both
needed for turning corners and for driving straight
Wheels Driving
ahead. However, when one wheel looses traction, the
clutch packs transfer additional torque to the wheel GINE TO TURN T H E A X L E AND W H E E L S . BOTH
having the most traction. Trac-lok differentials resist R E A R W H E E L S MUST BE RAISED AND T H E VEHI
wheel spin on bumpy roads and provide more pulling C L E S U P P O R T E D . A LIMITED S L I P A X L E CAN E X
power when one wheel looses traction. Pulling power E R T ENOUGH F O R C E (IF ONE W H E E L IS IN
is provided continuously until both wheels loose trac CONTACT WITH T H E S U R F A C E ) TO C A U S E T H E
tion. I f both wheels slip due to unequal traction, V E H I C L E TO MOVE.
Trac-lok operation is normal. I n extreme cases of dif
ferences of traction, the wheel with the least traction The differential can be tested without removing the
may spin. differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure
NOISE DIAGNOSIS ment.
I f a noise occurs when turning corners, the most (1) Engine off, transmission in neutral, and park
probable cause is incorrect or contaminated lubri ing brake off.
cant. Before removing the Trac-lok unit for repair, (2) Place blocks i n front and rear of both front
drain, flush and refill the axle with the specified lu wheels.
bricant. Refer to Lubricant change i n this Group. (3) Jack up one rear wheel until i t is completely off
A container of Trac-Lok Lubricant (friction modi the ground.
fier) should be added after repair service or a lubri (4) Remove wheel and bolt Special Tool 6790 for
cant change. Trac-Lok or Special Tool for Power-Lok to studs.
Vehicles with a limited slip differential should be (5) Use torque wrench on special tool to rotate
road tested by making 10 to 12 slow figure-eight wheel and read rotating torque (Fig. 2,3).
turns. This maneuver will pump the lubricant (6) I f rotating torque is less than 22 N-m (30 ft.
through the clutch discs to eliminate a possible chat lbs.) or more than 271 N-m (200 ft. lbs.) on either
ter or pop noise complaint. wheel the unit should be service.
additional information. LUBRICANTS
The lubricant recommended for Trac-Lok/Power-
TRAC-LOK/POWER-LOK DIFFERENTIAL TEST Lok differential is API grade GL 5. A container of
Trac-Lok Lubricant (friction modifier) should be
WARNING: WHEN SERVICING V E H I C L E S WITH A added after service.
LIMITED S L I P D I F F E R E N T I A L DO NOT U S E T H E E N -

TRAC-LOK OVERHAUL
The Trac-Lok (limited-slip) differential components
are illustrated i n (Fig. 4). Refer to this illustration
during repair service for component detail and their
location.
DISASSEMBLY
Service to the Trac-Lok differential requires the
use of Tool Set C-4487 (J-23781). Refer to differential
SPECIAL
overhaul i n the Model 60 section for differential case
TOOL removal and installation.
6790 (1) Clamp one axle shaft i n a vise (with protective
J9403-52
jaws) with the splined end upward (Fig. 5).
(2) Place shop towels on vise to avoid gear damage
Fig. 2 Trac-Loc Test
during removal of the ring gear. Position the differ
ential case on the axle shaft (Fig. 6).
(3) Remove and discard the ring gear bolts. They
are not reusable.
(4) Remove the case from the fixture. Remove the
ring gear from the case by tapping i t with brass drift
and a hammer.
(5) Position the case on the fixture.
(6) Remove the pinion gear mate shaft retaining
roll pin (Fig. 7).
(7) Remove the pinion gear mate shaft. Use a ham
mer and a brass drift and tap the shaft out.
(8) Install and lubricate Step Plate C-4487-1 (Fig.
8).
TORQUE (9) Assemble Threaded Adapter C-4487-3 into top
WRENCH ^J9403-53 side gear. Thread forcing Screw C-4487-2 into
adapter until i t becomes centered i n adapter plate.
Fig. 3 Power-Lok Test
DIFFERNTIAL -THRUST WASHER

CASE
. PINION
SIDE
RETAINER GEAR
CLUTCH PACK
PINION
MATE
SHAFT J9203-13
Fig. 4 Trac-Lok Differential

usi DIFFERENTIAL
CASE
AXLE
SHAFT
AS HOLDING
FIXTURE PINION
(EXTEND NO GEAR MATE
MORE T H A N SHAFT
2 3/4 IN.)
PUNCH
LOCKPIN
J9003-95
Fig. 7 Pinion Gear Mate Shaft Lock Pin Removal
SPECIAL
TOOL
C-4487-1
J8903-42
Fig. 5 Axle Shaft As Holding Fixture
RING GEAR
BOLTS UPWARD
DIFFERENTIAL
O N AXLE
SHAFT
LOWER
DIFFERENTIAL SIDE
CASE GEAR J9203-4
Fig. 8 Step Plate Tool Installation

(15) Remove case from fixture. Remove remaining
J8903-43
clutch pack (Fig. 12).
(16) Remove clutch pack retaining clips. Mark each
Fig, 6 Differential Case On Shaft clutch pack for installation reference.
(10) Use a small screw driver, position i t i n slot of CLEANING AND INSPECTION
Threaded Adapter C 4487-3 (Fig. 9). This will pre (1) Clean all components in cleaning solvent. Dry
vent adapter from turning. components with compressed air.
(11) Tighten forcing screw tool enough to relieve (2) Inspect clutch pack plates for wear, scoring or
clutch pack tension, Remove both pinion thrust damage. Replace both clutch packs i f any one compo
washers (Fig. 10). nent i n either pack is damaged.
(12) Loosen the forcing screw tool until the clutch (3) Inspect side and pinion gears. Replace any gear
pack tension is relieved. that is worn, cracked, chipped or damaged.
(13) Insert Turning Bar 0-4487-4 i n case. Rotate (4) Inspect differential case and pinion shaft. Re
case with tool until pinion gears can be removed (Fig. place i f worn or damaged,
11). Remove tools from the case.
(14) Remove top side gear and clutch pack. Keep ASSEMBLY
plates in correct order during removal. (1) The clutch discs are replaceable as complete
SOCKET
THREADED
THREADED ROD
ADAPTER C4487-2
DISC SPECIAL
G4487-3 TOOL
C4487^4
THREADED
ROD
G4487-2
J9203-2
DISC
J9203-1
C4487-]
Fig. 11 Pinion Gear Removal
Fig. 9 Threaded Adapter Installation
SIDE GEAR DIFFERENTIAL
SPECIAL A N D CLUTCH DISC CASE
TOOL
PACK
C4487-2
FEELER
PINION GEAR
GAUGE
THRUST
WASHER
SPECIAL TOOL
Fig. 10 Remove Pinion Thrust Washer RETAINER C-4487-i J9203-5
sets only. I f one clutch disc pack is damaged,

Fig. 12 Side Gear & Clutch Disc Removal
both packs must be replaced. Lubricate each com
ponent with gear lube before assembly and installa (7) Install lubricated Step Plate C-4487-1 on first
tion. clutch pack (Fig. 15).
(2) Assemble the clutch discs into packs (Fig. 13). (8) Install the upper side gear and clutch disc pack
(3) Secure disc packs with retaining clips (Fig. 13). (Fig. 15).
(4) Position assembled clutch disc packs on the (9) Hold assembly i n position. Insert Threaded
side gear hubs. Adapter C-4487-3 into top side gear, insert forcing
(5) Position case on fixture. Screw C-4487-2.
(6) Install clutch pack and side gear i n lower bore (10) Tighten forcing screw tool to compress clutch
(Fig. 14). Be sure clutch pack retaining clips re discs.
main i n position and are seated i n the case
pockets.
3 - 48 REAi SUSPENSION AND AXLE
CLUTCH PACK UPPER SIDE

GEAR A N D CLUTCH
RETAINER DISC PACK
DIFFERENTIAL
CASE
SIDE GEAR
RETAINER
J8903-50 SPECIAL TOOL
C-4487-1 J9203-6
Fig. 13 Clutch Disc Pack

Fig. 15 Upper Side Gear & Clutch Disc Pack
LOWER Installation
DIFFERENTIAL SIDE GEAR
CASE DIFFERENTIAL PINION MATE
AND
CASE SHAFT
CLUTCH DISC
PACK
J9003-4
Fig. 14 Clutch Discs & Lower Side Gear Installation

(11) Install pinion gears. Rotate case with Turning Fig. 16 Pinion Gear Mate Shaft Installation
Bar C-4487-4. Make sure holes of pinion mate gears
(2) Remove the case attaching bolts and remove
are aligned with case.
the button cover half (Fig. 19).
(12) Tighten forcing screw to compress the conned
(3) Remove the pinion mate gear, side gear (clutch)
plates. Lubricate and install pinion gear thrust wash
ring and clutch pack shaft (Fig. 20). Keep these parts
ers with a small screw driver or shim driver.
with the button cover half for correct installation i n
(13) Insert and tap the pinion shaft into the differ their original positions.
ential case (Fig. 16).
(4) Remove the same parts listed above from the
(14) Secure pinion shaft with new roll pin. Stake
ring gear flange half of the case. Keep these parts
roll pin to differential case.
with the flange cover half for correct installation i n
their original positions.
POWER-LOK OVERHAUL
DISASSEMBLY
(1) Mark the ring gear half and cover half for in (1) Clean all components i n cleaning solvent. Dry
stallation reference (Fig. 18). components with compressed air.
FLANGE BUTTON BOLTS
BUTTON
HALF
CLUTCH
PLATES
FLANGE
HALF
PINION Fig. 19 Cover Half Removal

MATE SHAFT J9203-71
ASSEMBLY
Fig. 17 Power-Lok Differential (1) The clutch discs are replaceable as complete
sets only. I f one clutch disc pack is damaged,
both packs must be replaced. Lubricate each com
ponent with gear lube before assembly and installa
tion.
(2) Saturate the clutch plates with Hypoid Gear
Lubricant or Additive. Assemble clutch packs into the
side gear plate i n exactly the same position as re
moved (Fig. 21).
(3) Line up the plate ears and install the assem
bled pack into the flange half (Fig. 22). Make sure
the clutch plate lugs enter the slots i n the case.
Also make sure the clutch pack bottoms out on
the case.
(4) Install pinion mate shafts and pinion mate
gears (Fig. 23).Make sure shafts are correctly in
stalled according to the alignment marks.
(5) Lubricate and install the other side gear and
clutch pack as done above i n Step 3.
(6) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(7) Tighten body screws alternately and evenly.
Fig. 18 Case Marked Tighten screws to 89-94 N-m (65 to 70 ft. lbs.) torque
(Fig. 24).
(2) Inspect clutch pack plates for wear, scoring or I f bolt heads have 7 radial lines stamped on the
damage. Replace both clutch packs i f any one compo head, tighten these to 122-136 N-m (90 to 100 ft. lbs.)
nent i n either pack is damaged.
torque.
(3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re
place i f worn or damaged.
•
FLANGE HALF CLUTCH PINION MATE
RING GEAR
PLATE DISHED PLATE DISHED PINION MATE |

DISC DISC CROSS SHAFT BUTTON HALF
J9203-74
Fig. 20 Power-Lok Components
Fig. 21 Clutch Pack Assembly Fig m 2 2 Clutch Pack Installation

AXLE SPECIFICATIONS MODEL 60 70 AND 80 9
MODEL 51 FRONT AXLE Axle Ratio.... ...3.54, 4.10, 4.56

A x l e Type Hypoid Ring Gear Diameter 247.6 mm (9.75 in.)
Lubricant ..............SAE 80W-90 Pinion Standard Setting. 136.525 mm (5.375 in.)
Lube Capacity Pinion Bearing Preload
4x2................... ..2.957 L (100 oz.) Original Bearing.. 1 to 3N-m (10-20 in. lbs.)
4x4 .......3.430 L (116 oz.) New Bearing 2 to 5N-m (20-40 in. lbs.)
Axle Ratio 3.54, 3.92, 4.09, 4.55
Ring Gear Diameter ....215.9 mm (8.50 in.) MODEL 80 FRONT AXLE
.Pinion Standard Setting 127.0 mm (5.000 in.) Axle Type Hypoid
Pinion Bearing Preload .Lubricant ..SAE 80W-90
Original Bearing........ 1 to 3N-m (10-20 in. lbs.) Lube Capacity
New Bearing 2 to 5N-m (20-40 in. lbs.) 4x2 3.223 L (109 oz.)
4x4................................. ...4.790 L (162 oz.)
MODEL 70 FRONT AXLE Axle Ratio 3.54, 4.10, 4.56
Axle Type ...Hypoid Ring Gear Diameter 247.6 mm (9.75 in.)
Lubricant , SAE 80W-90 Pinion Standard Setting. 124.625 mm (5.812 in.)
Lube Capacity Pinion Bearing Preload
4x2.. 3.311 L (112 oz.) Original Bearing 1 to 3N-m (10-20 in. lbs.)
4x4 .....3.666 L (124 oz.) New Bearing . 2 to 5N-m (20-40 in. lbs.)
R E A R SUSPENSION COMPONENTS REAR A X U HiOPEL 6 0 , 70 AMP 80

DESCRIPTION TORQUE
Description Torque
Jounce Bumper to Frame 45 N-m (33 ft. lbs.) Axle Flange to Hub Bolts . .123 N-m (90 ft. lbs.)
Shock Lower Nut 136 N-m (100 ft. lbs.) Bearing Cap Bolts 95 to 122 N*m
Shock Upper Nut 95 N-m (70 ft. lbs.)
Spring Clamp Nut (70 to 90 ft. lbs.)
6010 to 10500 GVW 149 N-m (110 ft. lbs.) Case Half Bolts (Powr-Lok). 89 to 94 N»m
Spring Clamp Nut
1100 GVW Cab-Chassis 163 N-m (120 ft. lbs.) (65 to 70 ft. lbs.)
Spring Front and Rear Eye Case Half Bolts Heavy Duty
Bolt/Nut 6010 to 7500 GVW 136 N-m (100 ft. lbs.) 122 to 136 N * m
Spring Front and Rear Eye (Powr-Lok)
Bolt/Nut 8300 to 1100 GVW 190 N-m (140 ft. lbs.) (90 to 100 ft. lbs.)
J9403-59 Differential Cover Bolts , ,.47N*m (35 ft. lbs.)
Fill Hole Plug .34 N*m (25 ft. lbs.)
9 1/4 INCH AXLE
Ring Gear Bolts (Model 60 and 70). 163 to 1 9 0 N * m
Description Torque (120 to 140 ft. lbs.)
Ring Gear Bolts (Model 80) 272 to 325 N ^ m
Bearing Cap Bolt 1 3 6 N * m ( 1 0 0 f t . lbs.) (200 to 240 ft. lbs.)
Brake Backing Plate . . 6 4 N « m ( 4 8 f t . lbs.) RWAL/ABS Brake Sensor Bolt ..24NTn(18ft. lbs.)
Differential Housing Cover Bolt . . . . 4 7 N « m ( 3 5 f t . lbs.) J9403-58
Pinion Yoke Nut (Minimum Torque) 285 N ^ m (210ft. lbs.)

Ring G e a r Bolt . 102 N « m (75 ft. lbs.)
RWAL/ABS Sensor Bolt . . 24 N^m (18 ft. lbs.)
J9403-63
• BRAKES 5 - 1
BRAKES
CONTENTS
page page
ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) . 35 POWER BRAKE VACUUM PUMP (DIESEL
DISC BRAKES 45 MODELS) 20
DRUM BRAKES 60 REAR WHEEL ANTILOCK BRAKE (RWAL)
GENERAL INFORMATION 1 SYSTEM 25
MASTER CYLINDER 8 SERVICE BRAKE DIAGNOSIS 3
PARKING BRAKES 70 SPECIFICATIONS 73
POWER BRAKE BOOSTER—BRAKE PEDAL—
BRAKELIGHT SWITCH 15
INDEX
page page
Antilock Brake Systems 2 Brake Warning Lights 2
Brake Adjustments and Bleeding Procedures 2 Model Identification 2
Brake Fluid/Lubricants/Cleaning Solvents 2 Service Brake Components 1
Brake Safety Precautions 2
SERVICE BRAKE COMPONENTS Rear Drum Brakes

The standard service brake system on 1994 BR Rear drum brakes are dual shoe units with an au
truck models consists of power assisted, front disc tomatic adjustment mechanism. Three different drum
and rear drum brakes. brake assemblies are used:
Rear wheel antilock (RWAL) brakes are standard • 11 x 2 in. rear drum brakes are used on 1/2 ton
equipment with an all-wheel antilock (ABS) brake models
system available as an option. • 13 x 2.5 in. rear drum brakes are used on 3/4 ton
models
Front Disc Brakes • 13 x 3.5 in. rear drum brakes are used on one-ton
Front disc brakes consist of single piston, floating style models
calipers. Brakeshoe lining material is semi metallic. Vented
disc brake rotors are used for all applications. Brakelining Material
Three different calipers are used. They are identi The brakelining material used for the front disc and
fied by caliper piston size and model application rear drum brakes is asbestos free. Service replace
which are: ment brakelining provided through the Mopar parts
• calipers on 1500 models have a 75 mm (2.95 in.) pis system will also be asbestos free.
ton
• calipers on 2500 models have an 80 mm (3.1 in.) pis Master Cylinder/Power Brake Booster
ton A two section master cylinder and tandem (dual) di
• calipers on 3500 models and 2500 4 x 4 models aphragm, vacuum power brake booster is used for all
with Dana 60 front axle have an 86 mm (3.385 in.) applications. Models with the Cummins diesel engine
piston option are also equipped with a vacuum pump assem
bly to operate the power brake booster.
§ - 2 BRAKES
Combination Waive MODEL IDENTIFICATION

A combination valve is used on all models. The Different model number/capacity designations are
valve consists of a front brake metering (hold-off) used for 1994 trucks. The new designations are:
valve and a front/rear pressure differential switch. • 1500 identifies 1/2 ton models
• 2500 identifies 3/4 ton models
A1TIL0CI BRAKE SYSTEMS • 2500 identifies one ton models
Two new antilock brake systems are used on BR The model number and capacity ratings are used
models. A rear wheel antilock (RWAL) brake system throughout this group to identify, differentiate from,
is standard on all models. An all-wheel antilock or indicate application of a specific brake component.
brake system (ABS) is available as an option. Both
antilock systems are manufactured and supplied by BRAKE ADJUSTMENTS AND BLEEDING
the Kelsey-Hayes Corporation. PROCEDURES
The RWAL and ABS antilock systems are designed Drum brake adjustment and brake bleeding proce
to retard wheel lockup during periods of high wheel dures are no longer located i n a separate section. Re
slip when braking. Retarding wheel lockup is accom fer to the Drum Brake service section for adjustment.
plished by modulating fluid pressure to the wheel Refer to the RWAL or ABS Brake section for the ap
brake units. Refer to the antilock brake sections for plicable bleeding techniques.
operation and service information. Different brake bleeding procedures are required
for the RWAL and ABS antilock systems. Refer to the
The RWAL antilock system uses one valve. The
appropriate procedure when brake bleeding is neces
ABS antilock system uses two valves. Refer to the sary.
appropriate antilock brake section for valve opera Parking brake and drum brake adjustment proce
tion, diagnosis and service procedures. dures are located i n the pertinent section. Refer to
the Parking Brake section for the cable adjustment
BRAKE WARNING LIGHTS procedure. Refer to the Drum Brake Section for shoe
A red warning light is used to alert the driver i f a adjustment procedures with a brake gauge.
pressure differential exists between the front and
rear hydraulic systems. The light also alerts the BRAKE SAFETY PRECAUTIONS
driver when the parking brakes are applied. The
light is located at the left side of the instrument clus WARNING: ALTHOUGH A S B E S T O S F R E E B R A K E -
ter. LINING IS FACTORY INSTALLED ON A L L B R MOD
An amber warning light is used for the antilock E L S , E X E R C I S E C A R E WHEN REPAIRING A
system. This light is located i n the same side of the V E H I C L E WITH PRIOR B R A K E S E R V I C E . SOME A F
instrument cluster as the red indicator light. The an T E R MARKET BRAKELINING MAY CONTAIN A S
tilock light alerts the driver i f a system fault occurs. B E S T O S . A S A RESULT, DUST AND DIRT ON
B R A K E PARTS MAY CONTAIN A S B E S T O S F I B E R S .
BRAKE FLUiD/LUBRICAlTS/CLEANllG S0LVE1TS BREATHING E X C E S S I V E CONCENTRATIONS O F
Recommended fluid for all BR models is Mopar A S B E S T O S F I B E R S CAN C A U S E S E R I O U S BODILY
HARM. E X E R C I S E C A R E WHEN SERVICING B R A K E
brake fluid or equivalent meeting SAE standard
COMPONENTS. DO NOT C L E A N B R A K E COMPO
J1703 and Federal standard DOT 3.
NENTS WITH C O M P R E S S E D AIR OR B Y DRY
Use Mopar multi mileage grease to lubricate cali
BRUSHING. U S E A VACUUM C L E A N E R S P E C I F I
per slide surfaces, drum brake pivot pins and shoe C A L L Y DESIGNED FOR REMOVING B R A K E DUST.
contact points on the backing plates. Use GE 661 or IF A S U I T A B L E VACUUM C L E A N E R IS NOT AVAIL
Dow 111 silicone grease (or equivalent) on caliper A B L E , CLEANING SHOULD B E DONE USING A WA
bushings and mounting bolts. T E R DAMPENED C L O T H . DO NOT C R E A T E DUST
Use Mopar brake cleaner, or denatured alcohol to B Y SANDING, GRINDING, OR SHAVING B R A K E LIN
clean or flush brake system components. These are INGS U N L E S S P R O P E R L Y VENTED EQUIPMENT IS
the only cleaning materials recommended. U S E D . D I S P O S E O F A L L DUST AND DIRT THAT
MAY CONTAIN A S B E S T O S F I B E R S IN S E A L E D
CAUTION: Never use gasoline, kerosene, methyl al B A G S OR CONTAINERS. THIS WILL MINIMIZE E X
cohol, motor oil, transmission fluid, or any fluid P O S U R E TO Y O U R S E L F AND O T H E R S . F O L L O W
containing mineral oil to clean the system compo A L L RECOMMENDED P R A C T I C E S P R E S C R I B E D B Y
nents. T h e s e fluids damage rubber c u p s and seals. T H E OCCUPATIONAL S A F E T Y AND HEALTH ADMIN
If system contamination is suspected, check the ISTRATION AND T H E ENVIRONMENTAL P R O T E C
fluid for dirt, discoloration, or separation into dis TION A G E N C Y FOR T H E HANDLING, P R O C E S S I N G ,
tinct layers. Drain and flush the system with new AND DISPOSITION O F DUST OR DIRT WHICH MAY
brake fluid if contamination is suspected. CONTAIN A S B E S T O S F I B E R S .
• SERVICE BRAKE DIAGNOSIS 5-3
S E R W i C E B R A K E DIAGNOSIS
INDEX
page page
Brake Warning Lights 3 Power Booster Check Valve Test 6
Brake Warning Lights 4 Power Booster Vacuum Test 6
Component Inspection .. 4 Preliminary Brake Check 3
Diagnosing Service Brake Problems . . . 4 Road Testing 4
General Information 3 Service Brake Diagnosis Procedures 3
Low Vacuum Switch—Diesel Models 3 Testing Diesel Engine Vacuum Pump Output 7
Master Cylinder/Power Booster Test 6
GENERAL INFORMATION The amber antilock light is connected to the an

The diagnosis information i n this section covers tilock system. The light illuminates only when a fault
service brake components only. occurs within the antilock system.
Antilock system diagnosis is provided in the
appropriate antilock brake section. Refer to the LOW VACUUM SWITCH—DIESEL MODELS
Rear Wheel Antilock Brake System (RWAL) and On diesel models, the red brake warning light is
All-Wheel Antilock Brake System (ABS) sections also used to alert the driver of a low brake booster
as necessary. vacuum condition. The warning light is iri circuit
with a vacuum warning switch mounted on the
Service brake components consist of the brake-
driver side fender panel. The vacuum side of the
shoes, calipers, wheel cylinders, brake drums and ro switch is connected to the power brake booster. The
tors, brakelines, master cylinder and booster and electrical side of the switch is connected to the brake
parking brake components. warning light.
The low vacuum switch monitors booster vacuum
SERVICE BRAKE DIAGNOSIS PROCEDURES level whenever the engine is running. I f booster vac
Brake diagnosis involves determining i f the prob uum falls below 8.5 inches vacuum for a minimum of
lem is related to a mechanical, hydraulic or vacuum 10 seconds, the switch completes the circuit to the
operated component. A preliminary check, road test warning light causing i t to illuminate. The warning
ing and component inspection can all be used to de light is designed to differentiate between a low vac
termine a problem cause. uum condition and a hydraulic circuit fault.
Road testing will either verify proper brake opera
tion or confirm the existence of a problem. Compo PRELIMINARY BRAKE CHECK
nent inspection will, i n most cases, identify the (1) Check condition of tires and wheels. Damaged
actual part causing a problem. wheels and worn, damaged, or underinflated tires
The first diagnosis step is the preliminary check. can cause pull, shudder, tramp, and a condition sim
This involves inspecting fluid level, parking brake ac ilar to grab.
tion, wheel and tire condition, checking for obvious (2) I f complaint was based on noise when braking,
leaks or component damage and testing brake pedal check suspension components. Jounce front and rear
response. of vehicle and listen for noise that might be caused
A road test will confirm the existence of a problem. by loose, worn or damaged suspension or steering
Final diagnosis procedure involves road test analysis components.
and a visual inspection of brake components. (3) Inspect brake fluid level and condition. Note
that the front disc brake reservoir fluid level will
BRAKE WARNING LIGHTS drop in proportion to normal lining wear. Also note
that brake fluid tends to darken over time. This
The red brake warning light is i n circuit with the
is normal and should not be mistaken for con
parking brake switch and pressure differential switch
t a m i n a t i o n . I f the fluid is still clear and free of
in the combination valve. foreign material, it is acceptable.
The red light illuminates when the parking brakes (a) I f fluid level is abnormally low, look for evi
are applied or when a fluid pressure drop occurs i n dence of leaks at calipers, wheel cylinders, brake-
either the front or rear brake circuit. The light will lines and master cylinder.
also illuminate for approximately 2-4 seconds at ev (b) I f fluid appears contaminated, drain out a
ery engine start up. This is a self test feature de sample. I f fluid is separated into layers, or obvi
signed to check bulb and circuit operation. ously contains oil or a substance other than brake
5 - 4 SERVICE BRAKE DIAGNOSIS •
fluid, the system seals and cups will have to be re DIAGNOSING SERVICE BRAKE PROBLEMS
placed and the hydraulic system flushed.
(4) Check parking brake operation. Verify free PEDAL FALLS AWAY
movement and full release of cables and pedal. Also A brake pedal that falls away under steady foot
note i f vehicle was being operated with parking pressure is the result of a system leak. The leak
brake partially applied. point could be at a brakeline, fitting, hose, or caliper.
(5) Check brake pedal operation. Verify that pedal Internal leakage i n the master cylinder caused by
does not bind and has adequate free play. I f pedal worn or damaged piston cups, may also be the prob
lacks free play, check pedal and power booster for be lem cause.
ing loose or for bind condition.^ Do not road test until I f leakage is severe, fluid will be evident at or
condition is corrected. around the leaking component. However, internal
(6) I f components checked appear OK, road test ve leakage i n the master cylinder may not be physically
hicle. evident. Refer to the cylinder test procedure i n this
section.
ROAD TESTING
(1) I f complaint involved low brake pedal, pump LOW PEDAL
pedal and note i f pedal returns to normal height. I f a low pedal is experienced, pump the pedal sev
(2) Check brake pedal response with transmission eral times. I f the pedal comes back up, worn lining
in Neutral and engine running. Pedal should remain and worn rotors or drums are the likely causes.
firm under steady foot pressure. A decrease i n fluid level i n the master cylinder res
(3) During road test, make normal and firm brake ervoirs may only be the result of normal lining wear.
Fluid level can be expected to decrease i n proportion
stops i n 25-40 mph (40-64 Km/h) range. Note faulty
to wear. I t is a result of the outward movement of
brake operation such as pull, grab, drag, noise, low
caliper and wheel cylinder pistons to compensate for
pedal, etc. normal wear. Top off the reservoir fluid level and
(4) Inspect suspect brake components and refer to check brake operation to verify proper brake action.
problem diagnosis information for causes of various
brake conditions. SPONGY PEDAL
A spongy pedal is most often caused by air i n the
COMPONENT INSPECTION system. Thin brake drums or substandard brake
Fluid leak points and dragging brake units can lines and hoses can also cause a spongy pedal. The
usually be located without removing any components. proper course of action is to bleed the system and re
The area around a leak point will be wet with fluid. place thin drums and suspect quality brake lines and
The components at a dragging brake unit (wheel, hoses.
tire, rotor) will be quite warm or hot to the touch.
Other brake problem conditions will require compo HARD PEDAL OR HIGH PEDAL EFFORT
nent removal for proper inspection. Raise the vehicle A hard pedal or high pedal effort may be due to lin
and remove the necessary wheels for better visual ac ing that is water soaked, contaminated, glazed, or
cess. badly worn. The power booster or check valve could
also be faulty.
BRAKE WARNING LIGHTS On diesel engine models, high pedal effort may be
the result of a low vacuum condition. I f the booster
The red brake warning light is i n circuit with the
and check valve are OK, the problem may be related
parking brake switch and pressure differential warn
to a vacuum pump hose, hose connection, hose fit
ing switch i n the combination valve. ting, pump diaphragm, or drive gear. Vacuum pump
The red light illuminates for approximately 2-4 sec output can be checked with a standard vacuum
onds at every engine start up. This is a self test fea gauge. Vacuum output should range from 8.5 to 25
ture designed to check bulb operation. inches vacuum. I f vacuum pump output is within
The red warning light illuminates when the park limits, check the power booster and check valve as
ing brake is not released. The light will also illumi described i n this section.
nate i f a fluid pressure drop occurs i n either the front
or rear brake hydraulic circuit. B R A K E DRAG
The amber antilock light is connected to the an Brake drag occurs when the lining is i n constant
tilock electronic control module and front or rear an contact with the rotor or drum. Drag can occur at one
tilock valve. The light only illuminates when a fault wheel, all wheels, fronts only, or rears only. I t is a
occurs within the antilock system. Refer to the appro product of incomplete brakeshoe release. Drag can be
priate antilock system service section within this ser minor or severe enough to overheat the linings, ro
vice manual group. tors and drums.
• SERVICE BRAKE DIAGNOSIS i -S
Brake drag can also effect fuel economy. I f undetec A common and frequently misdiagnosed pull condi
ted, minor brake drag can be misdiagnosed as an en tion is where direction of pull changes after a few
gine or transmission/torque converter problem. stops. The cause is a combination of brake drag fol
Minor drag will usually cause slight surface char lowed by fade at one of the brake units.
ring of the lining. I t can also generate hard spots i n As the dragging brake overheats, efficiency is so re
rotors and drums from the overheat-cool down pro duced that fade occurs. Since the opposite brake unit
cess. I n most cases, the rotors, drums, wheels and is still functioning normally, its braking effect is
tires are quite warm to the touch after' the vehicle is magnified. This causes pull to switch direction i n fa
stopped. vor of the normally functioning brake unit.
Severe drag can char the brake lining all the way When diagnosing a change i n pull condition, re
through. I t can also distort and score rotors and member that pull will return to the original direction
drums to the point of replacement. The wheels, tires if the dragging brake unit is allowed to cool down
and brake components will be extremely hot. I n se (and is not seriously damaged).
vere cases, the lining may generate smoke as i t chars
from overheating. R E A R B R A K E G R A B OR PULL
Some common causes of brake drag are: Rear grab or pull is usually caused by an improp
• seized or improperly adjusted parking brake cables erly adjusted or seized parking brake cable, contam
• loose/worn wheel bearing inated lining, bent or binding shoes and support
• seized caliper or wheel cylinder piston plates, or improperly assembled components. This is
• caliper binding on corroded bushings or rusted particularly true when only one rear wheel is in
slide surfaces volved. However, when both rear wheels are affected,
• loose caliper mounting bracket the master cylinder or proportioning valve could be
• drum brakeshoes binding on worn or damaged at fault.
support plates
BRAKES DO NOT HOLD AFTER DRIVING
• misassembled components
THROUGH DEEP WATER PUDDLES
• adjuster screws reversed
I f brake drag occurs at all wheels, the problem may This condition is generally caused by water soaked
be related to a blocked master cylinder return port, lining. I f the lining is only wet, i t can be dried by
or faulty power booster that binds and does not re driving with the brakes very lightly applied for a few
lease. minutes. However, i f the lining is thoroughly wet and
dirty, disassembly and cleaning will be necessary.
BRAKE FADE
BRAKE NOISE
Brake fade is a product of overheating caused by
brake drag. However, brake overheating and subse Squeak/Squeal
quent fade can also be caused by riding the brake
pedal, making repeated high deceleration stops i n a Brake squeak or squeal may be due to linings that
short time span, or constant braking on steep moun are wet or contaminated with brake fluid, grease, or
tain roads. Refer to the Brake Drag information i n oil. Glazed linings and rotors with hard spots can
this section for additional causes. also contribute to squeak. Dirt and foreign material
embedded i n the brake lining can also cause squeak/
PEDAL PULSATION squeal.
Pedal pulsation is caused by components that are A very loud squeak or squeal is frequently a sign of
loose, out of round, or worn beyond tolerance limits. severely worn brake lining. I f the lining has worn
Disc brake rotors with excessive lateral runout or through to the brakeshoes i n spots, metal-to-metal
thickness variation, or out of round brake drums are contact occurs. I f the condition is allowed to continue,
the primary causes of pulsation. Other causes are rotors can become so heavily scored that replacement
loose wheel bearings or calipers and worn, damaged is necessary.
tires.
Thump/Clunk
PULL Thumping or clunk noises during braking are fre
A front pull condition could be the result of contam quently n o t caused by brake components. I n many
inated lining i n one caliper, seized caliper piston, cases, such noises are caused by loose or damaged
binding caliper, loose caliper, loose or corroded slide steering, suspension, or engine components. However,
pins, improper brakeshoes, or a damaged rotor. calipers that bind on the slide pins, or slide surfaces,
A worn, damaged wheel bearing or suspension com can generate a thump or clunk noise. Worn out, im
ponent are further causes of pull. A damaged front properly adjusted, or improperly assembled rear
tire (bruised, ply separation) can also cause pull. brakeshoes can also produce a thump noise.
6 - 6 SERVICE BRAKE DIAGNOSIS •
Chatter uum assisted pedal applications. I f vacuum assist is
Brake chatter is usually caused by loose or worn not provided, perform booster and check valve vac
components, or glazed/burnt lining. Rotors with hard uum tests. Also check vacuum output on diesel mod
spots can also contribute to chatter. Additional causes els.
of chatter are out of tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings POWER BOOSTER CHECK VALVE TEST
and contaminated brake lining. (1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
Brakelining Contamination booster (Fig. 1). '
Brakelining contamination is usually a product of (3) Hand operated vacuum pump can be used for
leaking calipers or wheel cylinders, driving through test (Fig. 2).
deep water puddles, or lining that has become cov (4) Apply 15-20 inches (50-67 kPa) vacuum at
ered with grease and grit during repair. large end of check valve (Fig. 1).
(5) Vacuum should hold steady. I f gauge on pump
Wheel and Tire Problems indicates any vacuum loss, valve is faulty and must
Some conditions attributed to brake components be replaced.
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and BOOSTER
CHECK
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can
produce a grab-like condition as the tire loses and re
covers traction.
Flat-spotted tires can cause vibration and wheel
tramp and generate shudder during brake operation.
A tire with internal damage such as a severe bruise
or ply separation can cause pull and vibration.
MASTER CYLINDER/POWER BOOSTER TEST

(1) Start engine and check booster vacuum hose
connections. Hissing noise indicates a vacuum leak.
Correct any leaks before proceeding.
(2) Stop engine and shift transmission into Neu
tral. Fig. 1 Vacuum Check Valve And Seal
(3) Pump brake pedal until all vacuum reserve i n
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure.
(a) I f pedal holds firm, proceed to step (5).
(b) I f pedal does not hold firm and falls away,
master cylinder is faulty (internal leakage).
(5) Start engine and note pedal action.
(a) I f pedjal falls away slightly under light foot J9005-80
pressure then holds firm, proceed to step (6).
(b) I f pedal is effort is high, or no pedal action is Fig. 2 Typical Hand Operated Vacuum Pump
discernible, power booster or vacuum check valve is
faulty. Install known good check valve and repeat POWER BOOSTER VACUUM TEST
steps (2) through (5). (1) Connect a vacuum gauge to the booster check
(c) On diesel models, vacuum pump hose or valve with a short length of hose and a T-fitting (Fig.
pump component may have malfunctioned. Check 3).
pump output with vacuum gauge and repair as (2) Start and run engine at idle speed for one
necessary. Refer to service procedures i n Power minute.
Booster/Vacuum Pump section. (3) Clamp hose shut between vacuum source and
(6) Rebuild booster vacuum reserve as follows: Re check valve (Fig. 3).
lease brake pedal. Increase engine speed to 1500 (4) Stop engine and observe vacuum gauge.
rpm, close throttle and immediately turn off ignition. (5) I f vacuum drops more than one inch vacuum
(7) Wait a minimum of 90 seconds and try brake (33 millibars) within 15 seconds, either booster dia
action again. Booster should provide two or more vac phragm or check valve are faulty.
• SERVICE BRAKE DIAGNOSIS §-7
SHORT The following test checks output and condition of

CONNECTING CHECK the vacuum pump and interconnecting hoses. How
ever, a more comprehensive testing procedure is pro
vided i n the Power Brake Booster-Brake Pedal-
Vacuum Pump section. Refer to the procedure for
"Diagnosing A Low Vacuum Condition" i n that sec
tion.
(1) Check pump vacuum and booster hoses and
connections. Make sure hoses are i n good condition
and securely attached. Run engine and check for vac
uum leaks. Replace leaking hoses before proceeding.
(2) Disconnect vacuum hose at booster and connect
vacuum gauge to hose end.
(3) Run engine at curb idle speed and note vacuum
reading. Then run engine at 1/2 to 3/4 throttle and
note vacuum reading again.
(4) Vacuum should range from 8.5 to 25 inches vac
VACUUM uum at various throttle openings. Vacuum should
GAUGE hold steady and not drop below 8.5 inches.
J9005-81 (5) I f vacuum output is OK, check booster and
check valve as described i n this section. However, i f
Fig. 3 Booster Vacuum Test Connections vacuum is low, or does not hold steady, vacuum hoses
TESTING DIESEL ENGINE VACUUM PUMP OUTPUT or pump components are faulty.
On models with a Cummins turbo diesel engine, a
low vacuum condition i n the brake booster will cause
the brake warning light to illuminate.
5 - 8 MASTER CYLINDER
MASTER CYLINDER
INDEX
page page
Brake Fluid Contamination 9 Master Cylinder Identification Codes 8
Brake Fluid Level 9 Master Cylinder Installation 13
Description 8 Master Cylinder Reassembly 12
Master Cylinder Application 8 Master Cylinder Removal 9
Master Cylinder Bleeding (On Btench) . . . . . . . . . . 13 Master Cylinder Serviceability . . . . . . . . . . . . . . . . . 8
Master Cylinder Cleaning and Inspection 12 Recommended Brake Fluid . . . . . . . . . . . . . . . . . . . 9
Master Cylinder Disassembly and Overhaul . . . . . . 11
DESCRIPTION RESERVOIR
BR models are equipped with a Delco, two-section COVER
master cylinder assembly. Major components are the

aluminum cylinder body and a removable plastic res DIAPHRAGM
SEAL
ervoir (Fig. 1).
The primary and secondary pistons are located i n
the cylinder body. Grommets are used to secure and
seal the reservoir i n the cylinder body. The reservoir RESERVOIR
cover is equipped with diaphragm seal and is a snap
fit on the reservoir.
The cylinder body is equipped with a quick take-up
valve located i n the primary piston inlet port (Fig. 1).
The valve provides an extra volume of low pressure TAKE-UP VALVE
fluid during initial brake apply. Extra fluid volume (INSIDE BODY)
provides faster take-up of normal clearances i n the
calipers and wheel cylinders.
MASTER CYLINDER SERVICEABILITY

The cylinder body, piston assemblies, reservoir, CYLINDER
grommets, seal and cover are all serviceable parts. BODY
The take-up valve is the only non-serviceable compo
nent. The valve is available only as part of a com
plete cylinder body assembly.
PISTON
MASTER CYLINDER APPLICATION SPRING
Three master cylinders are used i n BR models. The
differences between them concern cylinder bore size
SEAL SNAP
and fluid reservoir capacity. RETAINER RING
• The master cylinder i n 1/2 ton (1500) models has a
28.6 mm (1.125 in.) bore. SECONDARY
• The master cylinder i n 3/4 and 1 ton (2500/3500) PISTON
models has a 31.8 mm (1.252 in.) bore. PRIMARY

PISTON
Although the master cylinders used i n 3/4 ton and ASSEMBLY J9405-13
1 ton models have the same bore size, they have dif
ferent piston stroke lengths and fluid reservoir ca Fig. 1 Delco Two-Section Master Cylinder
pacities. Refer to Brake Fluid Level and Master
Cylinder Identification i n this section for details. MASTER CYLINDER IDENTIFICATION CODES
Master cylinders and reservoirs must never The master cylinder and reservoir are coded for
be interchanged. This practice will cause unsat identification. Code letters are provided on the cylin
isfactory operation and improper brake bal der body and reservoir for proper component match
ance. ing.
The cylinder body code letters are etched into the Always clean the master cylinder reservoir and cover
front end of the cylinder (Fig. 2). The reservoir code before adding fluid. I f this is not done, dirt from the
letters are on an adhesive backed tag attached to the cover or reservoir could enter the fluid. Also check the
front face of the reservoir (Fig. 2). I.D. cover diaphragm seal and replace it i f torn or distorted.
Code letters are as follows: Add fluid to correct the level i f necessary. Note that
• code for 1/2 ton cylinder and reservoir is N K on disc brake equipped vehicles, fluid level i n the
• code for 3/4 ton cylinder and reservoir is N L front brake reservoir will decrease slightly i n propor
• code for 1 ton cylinder and reservoir is NP tion to normal lining wear.
I f fluid is needed, use Mopar brake fluid or an
equivalent meeting SAE standard J1703 and Federal
standard DOT 3.
INDICATOR
WINDOW
J9405-21
Fig. 2 Identification Code Locations For Cylinder

Body And Reservoir J9405-22
RECOMMENDED BRAKE FLUID Fig. 3 Reservoir And Fluid Level Indicator (1/2 Ton
Recommended brake fluid for all BR models is Mo Models)
par brake fluid, or an equivalent meeting SAE stan
dard J1703 and Federal standard DOT 3. Do not use BRAKE FLUID CONTAMINATION
any other type of fluid. Oil i n the fluid will cause brake system rubber
seals to soften and swell. The seals may also become
CAUTION: U s e the recommended brake fluid only porous and begin to deteriorate.
when adding fluid or refilling the system. U s e clean, I f fluid contamination is suspected, drain off a sam
fresh brake fluid only. Never u s e reclaimed fluid, ple from the master cylinder. A suction gun or similar
fluid not meeting the S A E / D O T standards, fluid device can be used for this purpose.
marked 70R1, or fluid from a container that h a s Empty the drained fluid into a glass container.
been left open for any length of time. Using non- Contaminants i n the fluid will cause the fluid to sep
recommended or unspecified fluid c a n result in arate into distinct layers. I f contamination has oc
brake failure after hard prolonged braking. curred, the system rubber seals, hoses and cups must
be replaced. The system must also be thoroughly
flushed with clean brake fluid.
BRAKE FLUID LEVEL
The correct fluid level is to the top of the oval in MASTER CYLINDER REMOVAL
dicator window on the side of the reservoir (Figs. 3, 4 Exercise care when removing/installing the
and 5). A n acceptable level is between the top of the
master cylinder, combination valve and an
indicator window and the M I N mark.
tilock valve connecting lines. The threads i n
The hydraulic system should be checked for
the cylinder and valve fluid ports can be dam
leaks, or the brakeshoes for excessive wear, if
fluid level is very near the M I N level. aged if care is not exercised. Use a flare nut
S - 10 MASTER CYLINDER
INDICATOR
WINDOW
CORRECT
FLUID
LEVEL
(TO TOP
OF WINDOW)
J9405-23
J9405-1
Fig. 4 Reservoir And Fluid Level Indicator Fig. 6 Combination Valve-To-Master Cylinder
(3/4 Ton Models) Brakelines
(3) Disconnect line that connects RWAL valve to
combination valve.
CORRECT
FLUID - (4) Disconnect harness wires from RWAL valve and
Mi LEVEL combination valve switch (Fig. 7).
J — (TO TOP OF I (5) Disconnect antilock harness ground wire from
- INDICATOR
WINDOWS) combination valve bracket (Fig. 7).
MIN«4J?»
MIN^Jr*
J94Q5-24
Fig. 5 Reservoir And Fluid Level Indicators
(1 Ton Models)
wrench to loosen or tighten the fittings and
start all brakeline fittings by hand to avoid LINES FROM
COMBINATION
cross threading. VALVE TO
(1) Apply Mopar rust penetrant to master cylinder, ; FRONT/REAR BRAKES J9405-2
combination valve and antilock valve brakeline fit
tings. Work penetrant between fittings and brake- Fig. 7 RWAL Valve Harness And Ground Wire
lines to ease removal. Connections
(2) Remove brakelines connecting master cylinder
to combination valve (Fig. 6). Use flare nut wrench to
loosen and disconnect fittings.
• MASTER CYLINDER S - 11
(6) Remove bolt attaching RWAL valve to combina

tion valve bracket (Fig. 8).
Fig. 8 RWAL Valve Attaching Bolt Location

(7) Remove nuts attaching combination valve
bracket and master cylinder to brake booster mount Fig. 10 Reservoir Removal
ing studs (Fig. 7).
(8) Slide combination valve bracket off booster (5) Remove grommets from cylinder body (Fig. 11).
mounting studs. Discard grommets as they are not reusable.
(9) Remove master cylinder from vehicle.
MASTER CYLINDER DISASSEMBLY AND

OVERHAUL
(1) Remove reservoir cover and seal (Fig. 9).
COVER
DIAPHRAGM
SEAL
i-9
Fig. 11 Reservoir Grommet Removal

(6) Remove master cylinder piston retaining snap
ring with small pointed tool and flat blade screw
J9405-7 driver.
(7) Remove primary piston and spring assembly
Fig. 9 Reservoir Seal And Cover Removal (Fig. 12). Discard assembly after removal. Do not
(2) Drain reservoir fluid into drain container. disassemble piston components as primary pis
(3) Clamp cylinder body i n vise. Clamp vise jaws t o n is serviced as complete assembly only.
on one of the cylinder mounting ears as shown (Fig. (8) Remove secondary piston (Fig. 12). Apply air
10). pressure through rear outlet port to ease piston out
(4) Remove reservoir with a rocking motion. Use a of bore.
pry tool to help ease reservoir out of cylinder body (9) Remove secondary piston spring (Fig. 12). Tilt
and grommets (Fig. 10). I f reservoir is to be re cylinder body downward so spring will slide out of
placed, note and record reservoir code letters bore.
(Fig- 2 ) .
5 - 12 MASTER CYLINDER •
CYLINDER Inspect the cylinder bore. A light discoloration of

BODY the bore surface is normal and acceptable. However,
replace the cylinder body i f the bore is scored, pitted,
SECONDARY or corroded.
PISTON
SPRING Inspect the cylinder cover and diaphragm seal. Re
place the seal i f torn, or distorted. Replace the cover
SECONDARY if warped, cracked, or the snap fasteners are dam
PISTON AND
SEALS aged.
Inspect the reservoir. A slight discoloration of the
PRIMARY PISTON, reservoir surface is normal. Replace the reservoir i f
SPRING AND distorted, cracked, or damaged i n any way.
SEAL ASSEMBLY
Inspect the take up valve i n the cylinder body. The
valve should move freely and not be stuck or seized.
The valve is not serviceable. I t will be necessary to
replace the cylinder body i f the valve is faulty.
Inspect condition of the secondary piston. Replace
the piston i f i t is scored, corroded, or doubt exists
SNAP about its condition.
RING
J9405-10
MASTER CYLINDER REASSEMBLY
(1) Coat cylinder body bore, piston components and
Fig. 12 Master Cylinder Piston Removal reservoir grommets with fresh, clean brake fluid.
(10) Disassemble secondary piston (unlike primary (2) Mount cylinder body i n vise. Clamp one cylin
piston, secondary piston components are serviceable). der mounting ear i n vise jaws.
Remove seal retainer from secondary piston. Then re (3) Assemble secondary piston components (Fig.
move front and rear seals seal from piston (Fig. 13). 13) . Be careful when installing seals. Avoid distorting
Discard seals, spring and retainer after removal. them during installation.
These parts are not reusable.
CAUTION: Do not use any kind of metal tool to e a s e
SPRING piston seal installation in the cylinder bore. Metal
tools will cut the seals and scratch the bore. If a
tool is needed, u s e a small flexible item made from
REAR S E A L
nylon, rubber or plastic only.
FRONT (4) Install secondary piston assembly (spring end

SEAL first), i n cylinder bore. Do not force piston into
bore. Work it into place with a twisting/turning
motion.
(5) Install primary piston i n cylinder bore (spring
end first). Do not force piston into bore. Work it
into place with a twisting/turning motion.
RETAINER (6) Insert piston retaining snap ring i n cylinder
body. Then push pistons inward with wood dowel and
PISTON J9405-11 seat snap ring.
Fig. 13 Secondary Piston Components CAUTION: B e very sure the piston retaining snap
ring is fully seated. Recheck snap ring installation
MASTER CYLINDER CLEANING AND INSPECTION
before proceeding.
Clean the cylinder body and reservoir with Mopar
brake cleaner only. Do not use any other type of (7) Install new grommets on cylinder body (Fig.
cleaning solvent especially on the plastic reservoir. 14) .
Dry the cylinder parts with compressed air. The res (8) Remove cylinder body from vise.
ervoir can be air dried or wiped dry with lint-free (9) Position reservoir on clean Work surface with
shop towels. fluid inlet necks facing upward (Fig. 14). Padding
work surface with clean shop towels will keep reser
voir i n place during installation. I t will also keep dirt
out as well.
4 MASTER CYLINDER 5 - 13
(10) Install cylinder body on reservoir (Fig. 14).

WOOD
Use a rocking motion to slide the reservoir necks into
the grommets.
FLUID) J9405-71
Fig. 15 Master Cylinder Bleeding

(6) Remove bleed tubes and install plastic plugs i n
cylinder outlet ports. Plugs will prevent fluid loss
and keep dirt out until cylinder assembly is ready for
installation.
RESERVOIR (7) Top off reservoir fluid level and install cover
and seal.
J9405-12
MASTER CYLINDER INSTALLATION
Fig. 14 Assembling Reservoir And Cylinder Body (1) Position master cylinder on booster mounting
(11) Verify that reservoir is properly seated and studs. Be sure booster push rod is aligned and seated
that grommets have not slipped out of place. in primary piston.
(12) Bleed master cylinder on bench before install (2) Install combination valve bracket on mounting
ing i t i n vehicle. Refer to procedure i n this section. studs. Bracket goes on top of cylinder mounting ears
as shown (Fig. 16).
MASTER CYLINDER BLEEDING (ON BENCH)
An overhauled, or new master cylinder should al
ways be bled before installation i n the vehicle. This
practice saves time during brake bleeding because air
in the cylinder will not be pumped into the lines.
The only tools needed for bench bleeding are a vise
and a pair of bleed tubes. Bleed tubes can either be
purchased or fabricated from spare brakelines and
fittings.
The bench bleeding procedure is as follows:
(1) Mount master cylinder i n vise. Clamp vise jaws
on one of the cylinder mounting ears.
(2) Install bleed tubes i n cylinder outlet ports and
direct tube ends into appropriate reservoir chambers
(Fig. 15).
(3) Fill reservoir chambers about 3/4 full with
fresh, clean brake fluid.
(4) Bleed cylinder by stroking cylinder pistons in
ward then allowing them to return under spring
pressure. Use a wood dowel, or similar tool to stroke
pistons (Fig. 15).
(5) Continue stroking pistons until bubbles no Fig. 16 Master Cylinder And Combination Valve
longer appear i n fluid entering reservoir. Bracket Mounting
5 - 14 MASTER CYLINDER •
(3) Start all brakeline fittings i n cylinder and
MASTER
valves by hand (Fig. 17). Tighten fittings about 3-4
threads to secure each line i n place.
(4) Install rear brake antilock valve i n combination
valve bracket (Fig. 17). Be sure bracket tab is seated
in valve before installing valve attaching bolt. Then
install and tighten valve bolt to 17 N-m (13 ft. lbs.)
torque.
(5) Tighten valve and cylinder brakeline fittings to
16-23 N-m (140-200 i n . lbs.) torque.
(6) Install master cylinder attaching nuts on
booster studs. Tighten nuts to 23-34 N-m (200-300 in.
lbs.) torque.
(7) Fill and bleed brake system. Refer to bleeding
procedure i n appropriate antilock brake section.
ABS VALVE SECONDARY UNE J9405-72
Fig. 17 Master Cylinder And Valve Brakeline

Connections
• POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH i - 15
POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH
INDEX
page page
Brake Pedal Installation 19 Power Brake Booster Identification 15
Brake Pedal Removal 18 Power Brake Booster Installation 17
Brakelight Switch Adjustment and Installation . . . . . 18 Power Brake Booster Operation 16
Brakelight Switch Removal 17 Power Brake Booster Removal 16
Brakelight Switch Test and Diagnosis 17 Power Brake Booster Serviceability 16
Component Description 15
COMPONENT DESCRIPTION panel. The pedal shaft is supported by bushings i n

the pedal and mounting bracket.
Power Brake Booster
All BR models are equipped with a Delco 260T, Brakelight Switch
tandem (dual) diaphragm power brake booster (Fig. A plunger style, self adjusting brakelight switch is
1). used for all applications. The switch is positioned i n
Two versions of the 260T booster are used. A stan a separate bracket attached to the pedal mounting
dard duty version is used i n all 1/2 ton models. A bracket (Fig. 3).
higher output version is used i n 3/4 and 1 ton mod
els. POWER BRAKE BOOSTER IDENTIFICATION
The standard and high output boosters are identi
Brake Pedal fied by code letters on the forward face of the booster
The brake booster is operated by a suspended type (Fig. 1).
brake pedal (Fig. 2). The pedal pivots on a shaft lo Booster I.D. code letters are as follows:
cated i n a mounting bracket attached to the dash
• 1/2 ton booster code is ZK
• 3/4 and 1 ton booster code is ZL
IDENTIFICATION BOOSTER INTEGRAL BOOSTER

CODE PUSH ROD MOUNTING PUSH ROD
LOCATION {TO MASTER BRACKET (TO BRAKE
CYLINDER) PEDAL)
CHECK
VALVE
BOOSTER
MOUNTING
MASTER
STUDS
CYLINDER
MOUNTING
STUDS
FRONT VIEW SIDE VIEW REAR V I E W
J9405-20
Fig. 1 Delco 260T Power Brake Booster

5-16 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH •
PEDAL SHAFT booster housing. The diaphragms are i n turn, con
nected to the booster push rod.
Two push rods are used to operate the booster. One
push rod connects the booster to the brake pedal. The
second push rod (at the forward end of the housing),
strokes the master cylinder pistons. The rear push
rod is connected to the two diaphragms in the
booster housing.
The atmospheric inlet valve is opened and closed
by the push rod connected to the brake pedal. The
booster vacuum supply is through a hose attached to
a fitting on the intake manifold. The hose is con
nected to a vacuum check valve i n the booster hous
ing. The check valve is a one-way device that
prevents vacuum leak back.
How Brake Boost Is Generated

Power assist is generated by utilizing the pressure
differential between normal atmospheric pressure
and a vacuum. The vacuum needed for booster oper
ation is taken directly from the engine intake mani
fold. The entry point for atmospheric pressure is
through an inlet valve at the rear of the housing.
The forward portion of the booster housing (area i n
front of the two diaphragms), is exposed to manifold
vacuum. The rear portion (area behind the dia
phragms), is exposed to normal atmospheric pressure
of 101.3 kilopascals (14.7 pounds/square in.).
Pressing the brake pedal causes the rear push rod
to open the inlet valve. This exposes the area behind
the diaphragms to atmospheric pressure. The result
ing force applied to the diaphragms is what provides
the extra boost i n apply pressure for power assist.
POWER BRAKE BOOSTER REMOVAL

BRAKELIGHT
(1) Disconnect harness wires from differential
SWITCH J9405-87 switch on combination valve and from RWAL valve.
(2) Disconnect brakeline from combination valve to
Fig. 3 Brakelight Switch Location And Mounting front brakes, or ABS valve. Then disconnect brake-
line from RWAL valve to rear brakes.
(3) Remove nuts attaching master cylinder and
POWER BRAKE BOOSTER SERWICEABILITY valves to power brake booster studs. Then remove
master cylinder and valves as assembly (Fig. 4).
The only serviceable power brake booster compo
(4) Disconnect vacuum hose at booster check valve.
nents are the vacuum hose and check valve. The
(5) Remove knee bolster for access to brake pedal
booster itself is not a repairable component. The
(Fig. 5).
booster must be replaced as an assembly whenever
(6) Remove clip and washer securing booster push
diagnosis indicates a fault has occurred.
rod to brake pedal (Fig. 6). Then slide booster push
POWER BRAKE BOOSTER OPERATION rod off pedal.
(7) Remove nuts attaching booster mounting studs
Booster Components to dash panel and pedal mounting bracket (Fig. 7).
The booster assembly consists of a housing divided (8) Remove booster from engine compartment.
into separate chambers by two internal diaphragms. (9) I f booster will be replaced, note and record code
The outer edge of each diaphragm is attached to the letters on front face of booster.
• POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 17
Fig. 4 Removing/Installing Master Cylinder And Fig. 7 Power Brake Booster Mounting
Valves As Assembly (2) Position booster on engine compartment dash
panel. Have helper hold booster i n position i f neces
sary.
(3) Install and tighten booster mounting stud nuts
to 23-34 N-m (200-300 in. lbs.) torque.
(4) Connect booster push rod to brake pedal (Fig.
4).
(5) Install knee bolster.
(6) Connect vacuum hose to booster check valve.
(7) Install master cylinder and valves on booster as
assembly (Fig. 2). Tighten mounting nuts to 23-34
N-m (200-300 in. lbs.) torque.
(8) Connect front/rear brakelines to combination
valve and RWAL valve. Tighten brakeline fittings to
16-23 N-m (140-200 in. lbs.) torque.
(9) Connect harness wires to RWAL valve and
pressure differential switch on combination valve.
Fig. 5 Knee Bolster Removal
(10) Fill and bleed brake system. Refer to proce
dures in appropriate antilock brake section.
BRAKELIGHT SWITCH REMOVAL

(1) Remove knee bolster (Fig. 5) for access to
brakelight switch and pedal (Fig. 8).
(2) Press and hold brake pedal i n applied position.
(3) Rotate brakelight counterclockwise about 30° to
align switch lock tab with notch i n bracket.
(4) Pull switch rearward out of mounting bracket
and release brake pedal.
(5) I f switch is to be tested or replaced, disconnect
wire harness and remove switch from vehicle.
BRAKELIGHT SWITCH TEST AND DIAGNOSIS

Brakelight switch operation can be tested with an
Fig. 6 Booster Push Rod Attachment At Brake Pedal ohmmeter. The ohmmeter is used to check continuity
between the pin terminals at different plunger posi
POWER BRAKE BOOSTER INSTALLATION tions (Fig. 9).
(1) I f new booster is being installed, check code let The switch wire harness, must be discon
ters to verify that correct booster is being installed. nected before testing switch continuity.
5 - 18 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH •
PEDAL SWITCH (b) Attach test leads to pins 1 and 2 and note
ohmmeter reading.
(c) I f continuity exists, switch is OK. Replace
switch i f meter indicates lack of continuity (shorted
or open).
BRAKELIGHT SWITCH ADJUSTMENT AND

INSTALLATION
(1) Pull switch plunger all the way out to fully ex
tended position.
(2) Connect harness wires to switch.
(3) Press and hold brake pedal down.
(4) Install switch as follows: Align tab on switch
BRAKELIGHT
SWITCH J9405-87
with notch i n switch bracket (Fig. 10). Then insert
switch i n bracket and turn i t clockwise about 30° to
Fig. 8 Brakelight Switch Location lock i t i n place.
(5) Release brake pedal. Then pull pedal fully rear
Switch Circuit Identification
ward. Pedal will adjust switch plunger to correct po
• Switch terminals 1 and 2 are for the brake sensor sition as pedal is moved back. Switch will make
circuit racheting sound as i t self adjusts.
• Switch terminals 5 and 6 are for the brakelight
circuit
• Switch terminals 3 and 4 are for the speed control
circuit
TERMINAL
PINS
Fig. 10 Brakelight Switch Installation
BRAKE PEDAL REMOWAL

(1) Remove knee bolster for access to brakelight
Fig. 9 Brakelight Switch Terminal Identification And switch and pedal (Fig. 5).
Plunger Test Position (2) Remove brakelight switch (Fig. 8).
(3) Remove brakelight switch bracket (Fig. 11).
Switch Continuity Test Procedure
Bracket is attached to pedal mounting bracket with
(1) Check continuity between terminal pins 5 and two screws and clip nuts.
6 as follows:
(4) Remove clip and washer attaching booster push
(a) Pull plunger all the way out to fully extended
rod to brake pedal (Fig. 6). Then slide push rod off
position.
pedal.
(b) Attach test leads to pins 5 and 6 and note
(5) Remove E-clip from passenger side of pedal
ohmmeter reading.
(c) I f continuity exists, proceed to next test. Re shaft (Fig. 12). Use flat blade screwdriver to pry clip
place switch i f meter indicates lack of continuity out of shaft groove.
(shorted or open). (6) Push shaft toward driver side of bracket just
(2) Check continuity between terminal pins 1 and enough to expose opposite E-clip. Then remove E-Clip
2 and pins 3 and 4 as follows: with flat blade screwdriver.
(a) Push switch plunger inward to fully retracted (7) Push pedal shaft back and out of passenger
position. side of bracket (Fig. 12).
• POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 19
PEDAL SHAFT
Fig. 11 Brakelight Switch Bracket Removal/

Installation
(8) Remove brake pedal and pedal shaft from vehi
cle.
BRAKE PEDAL INSTALLATION

(1) Replace bracket and pedal bushings i f neces Fig. 12 Brake Pedal Mounting (With Automatic
sary. Lubricate shaft bores i n bracket and pedal be Transmission)
fore installing bushings. Use Mopar Multi-mileage, or (6) Push pedal shaft back toward passenger side of
DOW/GE silicone grease. bracket and install remaining E-clip on pedal shaft.
(2) Apply liberal quantity of Mopar multi-mileage (7) Install booster push rod on brake pedal. Secure
grease, or DOW/GE silicone grease, to pedal shaft push rod to pedal with washer and retaining clip
and to pedal and bracket bushings. (Fig. 6).
(3) Position brake pedal i n mounting bracket. (8) Install brakelight switch bracket.
(4) Slide pedal shaft into bracket and through (9) Install brakelight switch.
pedal from passenger side. (10) Install knee bolster.
(5) Push pedal shaft out driver side of mounting
bracket just enough to allow installation of retaining
E-clip (Fig. 12).
5 - 20 POWER BRAKE VACUUM PUMP (DIESEL MODELS)
POWER B R A K E VACUUM PUMP (DIESEL MODELS)
INDEX
page page
General Information 20 Vacuum Pump Replacement 22
Low Vacuum Warning Switch 20 Vacuum Pump Serviceability 20
Pump Adapter Replacement 23 Vacuum—Steering Pump Assembly Installation . . . 23
Vacuum Pump Diagnosis 21 Vacuum—Steering Pump Assembly Removal 21
Vacuum Pump Operation 20
GENERAL INFORMATION VACUUM

The power brake vacuum pump and the power
steering pump are combined into a single assembly
on diesel engine models (Fig. 1). Both pumps are op
erated by a drive gear attached to the vacuum pump
shaft. The shaft gear is driven by the camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four vanes
mounted i n the pump rotor. The rotor is located i n
the pump housing and is pressed onto the pump
shaft.
The vacuum and steering pumps are operated by a
single drive gear pressed onto the vacuum pump
shaft. The drive gear is operated by the engine cam
shaft gear.
The vacuum and power steering pump shafts are
connected by a coupling. Each pump shaft has an
adapter with drive lugs that engage i n the coupling.
GEAR ADAPTER
The vacuum pump rotating components are lubri J9105-94
cated by engine oil. Lubricating oil is supplied to the
pump through an oil line at the underside of the Fig. 1 Diesel Vacuum And Power Steering Pump
pump housing. Assembly
The complete assembly must be removed in
A vacuum hose connects the switch to the power
order to service either pump. However, the
power steering pump can removed and serviced brake booster. A wire harness connects the switch to
separately when necessary. the brake warning light.
The switch is mounted on the driver side inner
VACUUM PUMP SERVICEABILITY fender panel just below the hood hinge (Fig. 2).
The vacuum pump is not a serviceable component.
I f diagnosis indicates a pump malfunction, the pump VACUUM PUMP OPERATION.
must be replaced as an assembly. Do not disassemble Vacuum pump output is transmitted to the power
or attempt to repair the pump. brake booster through a supply hose. The hose is con
The combined vacuum and steering pump assembly nected to an outlet port on the pump housing and to
must be removed for access to either pump. However, the check valve i n the power brake booster.
the vacuum pump can be removed without having to Pump output ranges from a minimum of 8.5 to 25
disassemble the power steering pump. inches vacuum.
I f the power steering pump requires service, simply The pump rotor and vanes are rotated by the pump
remove the assembly and separate the two pumps. drive gear. The drive gear is operated by the cam
Refer to the pump removal and installation proce shaft gear.
dures i n this section. Booster vacuum level is monitored by a warning
switch (Fig. 2). The switch consists of a vacuum
LOW VACUUM WARNING SWITCH chamber that measures vacuum level and a sensor i n
A vacuum switch is used to monitor output of the circuit with the red brake warning light.
vacuum pump. The switch is i n circuit with the The vacuum chamber is connected to the booster
brake warning light. check valve by a vacuum supply hose. A wire harness
• POWER BRAKE VACUUM PUMP (DIESEL MODELS) i - 21
booster i f necessary. However, i f booster operation is

correct but warning light is still on, continue testing.
(4) Disconnect vacuum hose at warning switch.
Plug hose and connect hand vacuum pump to switch.
(5) Start and run engine.
(6) Apply 8.5 to 9 inches of vacuum to warning
switch and observe warning light. I f light goes out,
switch vacuum hose is either loose or leaking. I f light
remains on, leave engine running and continue test
ing.
(7) Apply 20-25 inches vacuum to switch and ob
serve warning light operation. I f light now goes out,
switch is at fault and should be replaced. I f light re
mains on, continue testing.
(8) Reconnect vacuum hoses and replace original
warning switch with known good switch. Run engine
Fig. 2 Diesel Vacuum Switch Location (Without
and observe warning light operation. I f light is now
ABS)
off, old switch is faulty. I f light remains on, problem
connects the switch sensor to the brake warning is i n wiring between switch and warning light.
light. I f booster vacuum falls below 8.5 inches for
8-10 seconds or more, the switch sensor completes VACUUM—STEERING PUMP ASSEMBLY REMOVAL
the circuit to the warning light causing i t to illumi (1) Disconnect battery negative cable.
nate. (2) Position drain pan under power steering pump.
(3) Disconnect vacuum and steering pump hoses
VACUUM PUMP DIAGNOSIS from respective pumps (Pig. 3).
Vacuum pump diagnosis involves checking pump
output with a vacuum gauge. The low vacuum warn
ing switch can also be checked with a vacuum gauge.
Refer to the diagnosis procedure i n this section.
A standard vacuum gauge can be used to check
pump output when necessary. Simply disconnect the
pump supply hose and connect a vacuum gauge to
the outlet port for testing purposes. Vacuum should
hold steady i n a range of approximately 8.5 to 25
inches at various engine speeds.
DIAGNOSING LOW VACUUM OUTPUT

CONDITION
A low booster vacuum condition or a faulty low vac
uum warning switch will cause the brake warning
light to illuminate. I f the light does go on and indi
cates the existence of a low vacuum condition, check
the vacuum pump, booster and warning switch as fol
lows:
(1) Check vacuum pump oil feed line. Verify that
line connections are secure and not leaking. I f leak
age is noted and pump is noisy, replace pump.
(2) Disconnect supply hose to booster. Connect vac Fig. 3 Vacuum And Steering Pump Hose
Connections
uum gauge to this hose and run engine at various
throttle openings. Output should range from 8.5 to (4) Disconnect oil pressure sender wires at sender
25 inches vacuum. I f vacuum is consistently below (Fig. 4).
8.5 inches, problem is with vacuum hoses or pump (5) Remove oil pressure sender (Fig. 4).
component. I f output is within specified limits, con (6) Disconnect lubricating oil feed line from fitting
tinue testing. at underside of vacuum pump (Fig. 5).
(3) Check booster operation as described i n diagno (7) Remove lower bolt that attaches pump assem
sis section. Replace check valve, vacuum hoses, or bly to engine block (Fig. 6).
I - 22 POWER BRAKE VACUUM PUMP (DIESEL MODELS)
PUMP ASSEMBLY
LOWER MOUNTING
STEERING
. PUMP ENGINE BLOCK J9119-74 BOTTOM-INBOARD
ADAPTER BRACKET NUT J9105-97
Fig. 4 Oil Pressure Sender Location
Fig. 6 Adapter And Pump Mounting Fastener
(8) Remove bottom, inboard nut that attaches
Location
adapter to steering pump (Fig. 6). This nut secures a
small bracket to engine block. Nut and bracket must
be removed before pump assembly can be removed
from block.
ENGINE
BLOCK VACUUM
PUMP
J9119-76
VACUUM
PUMP Fig. 7 Removing Pump Assembly Upper Mounting
OIL FEED
UNE J9105-96 Bolt
(2) Remove vacuum pump from adapter (Fig. 9).
Fig. 5 OH Feed Line Connection At Pump Turn pump gear back and forth to disengage pump
(9) Remove upper bolt that attaches pump assem shaft from coupling i f necessary.
bly to engine block (Fig. 7). (3) Inspect adapter O-ring (Fig. 9). Replace O-ring
(10) Remove pump assembly from vehicle (Fig. 8). i f cut or torn.
(4) Lubricate adapter O-ring with engine oil.
VACUUM PUMP REPLACEMENT (5) Note position of drive slots in coupling. Then
(1) Remove nuts attaching vacuum pump to rotate drive gear to align tangs on vacuum pump
adapter (Fig. 8). shaft with coupling (Fig. 10).
• POWER BRAKE VACUUM PUMP (DIESEL MODELS) 5 - 23
ROTATE DRIVE
GEAR TO ALIGN
J9105-98
Fig. 8 Pump Assembly Removal
COUPLING
TANGS J9105-102
Fig. 10 Aligning Pump Shaft Drive Tangs
O-RING PUMP
ADAPTER
J9105-99
Fig. 9 Vacuum Pump Removed From Adapter

(6) Verify that pump is seated i n adapter and cou
pling.
(7) Install and tighten pump attaching nuts and
washers.
PUMP ADAPTER REPLACEMENT

(1) Remove coupling from adapter (Fig. 11).
(2) Remove remaining adapter attaching nuts and
remove adapter from steering pump (Fig. 12).
(3) I f steering pump will be serviced, remove
spacer from each inboard mounting stud on pump
Fig. 11 Removing/Installing Pump Drive Coupling
(Fig. 12).
(4) Clean and lubricate pump shaft with engine oil. (10) Install vacuum pump on adapter. Rotate drive
(5) Install spacers on steering pump studs (Fig. gear until tangs on pump shaft engage in coupling.
12). Verify that pump is seated before installing attaching
(6) Install O-ring on adapter (Fig. 11). nuts.
(7) Position adapter on pump studs. (11) Install and tighten vacuum pump attaching
(8) Install attaching nuts on outboard stud and on nuts.
the two upper pump studs. Do not install nut on
lower, inboard stud at this time. Tighten nuts to 24 VACUUM—STEERING PUMP ASSEMBLY
N-m (18 ft. lbs.) torque. INSTALLATION
(9) Install coupling on pump shaft. Be sure cou (1) Position new gasket on vacuum pump mount
pling is securely engaged i n shaft drive tangs. ing flange (Fig. 13). Use Mopar perfect seal, or sili-
5 - 24 POWER BRAKE VACUUM PUMP (DIESEL MODELS) •
(3) Position pump assembly on engine and install
upper bolt (Fig. 14). Tighten upper bolt only enough
to hold assembly i n place at this time.
Fig. 12 Steering Pump Mounting Stud Spacer

Locations
cone adhesive/sealer to hold gasket in place.
Fig. 14 Installing Pump Assembly On Engine

(4) Working from under vehicle, install pump as
sembly lower attaching bolt. Then tighten upper and
lower bolt to 77 N-m (57 ft. lbs.) torque.
(5) Position bracket on steering pump inboard
stud. Then install remaining adapter attaching nut
on stud. Tighten nut to 24 N-m (18 ft. lbs.) torque.
(6) Connect oil feed line to vacuum pump connec
tor. Tighten line fitting securely.
(7) Install oil pressure sender and connect sender
wires.
(8) Connect steering pump pressure and return
lines to pump. Tighten pressure line fitting to 30 N-m
(9) Connect vacuum hose to vacuum pump.
Fig. 13 Positioning Gasket On Pump Mounting (10) Connect battery cables, i f removed.
Flange (11) Fill power steering pump reservoir.
(12) Purge air from steering pump lines. Start en
(2) Insert pump assembly upper attaching bolt i n gine and slowly turn steering wheel left and right to
mounting flange and gasket. Use sealer or grease to circulate fluid and purge air from system.
hold bolt i n place i f necessary. (13) Stop engine and top off power steering reser
voir fluid level.
(14) Start engine and check brake and steering op
eration. Verify that power brake booster is providing
vacuum assist and firm brake pedal is obtained.
Then verify that steering action is correct. Do this
before moving vehicle.
• REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM 5 - 25
R E A R W H E E L ANTILOCK B R A K E (RWAL) SYSTEM
INDEX
page page
Antilock Component Serviceability 29 Rear Speed Sensor Rear Harness Removal/
Clearing A Fault Code 28 Installation 32
Combination Valve Operation 27 Rear Speed Sensor Removal/Installation 31
Control Module Removal/Installation 30 Rear Wheel Antilock System Diagnosis 28
Diagnostic Fault Flash Codes 28 Rear Wheel Antilock System Operation 27
Fault Code Capacity 28 RWAL System Brake Bleeding 32
Fault Code Identification 28 RWAL System Components 25
Fault Condition Causes 29 RWAL Valve/Combination Installation 29
General Information 25 RWAL Valve/Combination Valve Removal . 29
GENERAL INFORMATION control module for processing. The control module de
A rear wheel antilock (RWAL) brake system is termines rate of deceleration and wheel slip from
standard equipment on all BR models (Fig. 1). The these signals.
system is controlled by a separate electronic control
RWAL SYSTEM COMPONENTS
module.
RWAL system components include:
• electronic control module
• rear brake antilock (RWAL) valve
• speed sensor and exiter ring
• antilock warning lamp
A standard master cylinder and vacuum power
brake booster are used for all applications. A l l of the
RWAL system hydraulic components are located on
the driver side of the engine compartment (Fig. 2).
SPEED
SENSOR ANTILOCK MASTER
VALVE CYUNDER
ASSEMBLY
EXCITER
RING
J93GS45
Fig. 1 Rear Wheel Antilock (RWAL) Brake System

The RWAL system retards rear wheel lockup dur
ing periods of high wheel slip and deceleration. Re
tarding lockup is accomplished by modulating fluid
pressure to the rear brake units.
Rear brake fluid apply pressure is modulated ac
RWAL
cording to wheel speed, degree of wheel slip and rate VALVE J9405-76
of deceleration. A sensor i n the rear axle housing con
verts differential rotating speed into electronic sig Fig. 2 RWAL System Hydraulic Component Location
nals. The signals are transmitted to the electronic Electronic Control Module
The electronic module controls operation of the so
lenoids i n the rear brake antilock valve. The module
is separate from other electrical circuits in the vehi
cle and operates independently.
5 - 2b REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM •
The module is located under the central portion of
the instrument panel (Fig. 3). The module is accessi
ble through the opening created by removal of the
knee bolster.
The RWAL valve, speed sensor and indicator lamps
are all i n circuit with the module. The module con
tains a microprocessor that operates the system and
performs system diagnostic checks.
Speed sensor inputs are continuously monitored
and interpreted by the module. The module deter
mines wheel speed and. rate of deceleration from
these inputs and activates the appropriate solenoid
in the hydraulic valve when necessary.
The module microprocessor also contains a self test
program. The program is activated- when the ignition
switch is turned to the On position. I n this mode, the
Fig. 4 Combination Valve And RWAL Valve
module checks indicator light operation, the system
electrical circuits and the pressure limiting valve so Combination Valve
lenoids. A combination valve is used with the RWAL sys
The brake warning and antilock indicator lamps tem. The valve is attached to an integral bracket
are illuminated for approximately two seconds during that is mounted to the studs on the power brake
the system self test cycle. booster. The valve bracket is also used to mount the
RWAL valve (Fig. 4). The mounting bracket and com
bination valve are serviced as an assembly.
The combination valve contains a front brake me
tering valve and a pressure differential switch and
valve. The differential switch is i n circuit with the
red brake warning light.
The metering valve balances brake action between
the front disc and rear drum brakes. The valve
meters (holds-off) full apply pressure to the front disc
brakes until the rear brakeshoes are i n full contact
with the drums.
S P E E D S E N S O R AND E X I T E R RING
A speed sensor is used to transmit speed and rate
of deceleration inputs to the electronic control mod
ule (Fig. 5). The sensor is actuated by an exiter ring
Fig. 3 RWAL Electronic Module And Bracket on the differential case.
Location The sensor is mounted at the top of the rear axle
housing directly over the gear-type exiter ring (Fig.
RWAL VALVE
5). The exiter ring is pressed onto the differential
The RWAL (rear brake antilock) valve controls rear
case adjacent to the ring gear.
brake fluid apply pressure during antilock mode
The exiter ring is the sensor trigger mechanism.
braking. The valve is operated by the electronic con
Exiter ring rotation causes the teeth on the ring to
trol module. The valve is mounted on the combina
interrupt the magnetic field around the sensor pole.
tion valve bracket (Fig. 3).
The rate of interruption is converted into speed sig
The valve contains two solenoid valves that are in
nals which are transmitted to the control module.
active during periods of normal braking. The solenoid
The sensor is not adjustable and must be replaced
valves are activated only when braking effort and
whenever diagnosis indicates a fault has occurred.
rate of wheel slip and deceleration are high (antilock
The exiter ring is serviceable and can be replaced
mode).
when necessary.
During normal braking, the valves allows free flow
of brake fluid to the rear brake units. I n antilock
mode, the valve will decrease, hold or increase fluid
apply pressure as needed.
• i E A i WHEEL ANTiLOCI BRAIE (RWAL) SfSTEi i - 27
Start Of Antilock Mode Braking

When high pedal effort braking occurs, the de
crease i n exiter wheel rotating speed is noted and
converted into an electronic signal by the sensor. The
signal is transmitted to and processed by the control
module. The module determines that acceptable lim
its of wheel slip/deceleration are about to be ex
ceeded. The module activates the antilock solenoid
valves at this point.
The module transmits a signal that activates the
solenoid valves. The valves then decrease, or isolate
fluid apply pressure to the rear wheel cylinders as
needed.
Closing the valves prevents further fluid flow to
the rear wheel cylinders. This action isolates the rear
brakes from the master cylinder. The net effect is to
decrease rear brake apply pressure to the point
where the wheels will continue to rotate but not lock.
When rear brake pressure requirements return to
normal levels, the solenoid valves are inactivated.
This action allows the resumption of normal fluid
flow to the wheel cylinders.
Solenoid Valve Cycle Times

Activation (opening/closing) of the solenoid valves
is not static during antilock mode braking. Valve op
eration is continuous as they are rapidly cycled in re
Fig. 5 Rear Wheel Speed Sensor Location sponse to sensor inputs and control module
ANTILOCK WARNING LAMP commands. Cycle times are measured i n millisec
The amber warning lamp is located i n the instru onds.
ment cluster adjacent to the standard brake warning As the demand for antilock mode brake operation
lamp. The antilock lamp alerts the driver i f a system is decreased, the module deactivates the hydraulic
fault occurs. valve components to restore normal brake operation.
The antilock lamp is also used for troubleshooting
COMBINATION WALWE OPERATION
purposes. The lamp is i n circuit with the control
module which has a self test program. I f a system Pressure Differential Switch
fault occurs, the test program will flash the lamp The pressure differential switch is connected to the
when the diagnostic connector is grounded. The flash brake warning light. The switch is triggered by
codes are used to identify a problem component. movement of the switch valve. The purpose of the
switch is to monitor fluid pressure i n the separate
REAR WHEEL ANTILOCK SYSTEM OPERATION front/rear brake hydraulic circuits.
During light brake application, rear wheel deceler A decrease or loss of fluid pressure i n either hy
ation and/or slip is not sufficient to activate the an draulic circuit will cause the switch valve to shuttle
tilock system components. Brake fluid apply pressure forward or rearward i n response to the pressure dif
to the rear wheels remains normal and is not modu ferential. Movement of the switch valve will push the
lated. However, when braking effort, degree of wheel switch plunger upward. This closes the switch inter
slip, and rate of deceleration approach programmed nal contacts completing the electrical circuit to the
limits, sensor inputs will cause the module to acti warning light. The switch valve will remain i n an ac
vate the system. tuated position until repair restores system pressures
to normal levels.
Normal Braking Mode
In normal braking mode, the antilock solenoid Metering Valve
valves are inactive. The valves are open allowing nor The metering valve is used to balance brake action
mal fluid flow to the rear wheel cylinders. between the front disc and rear drum brakes. The
valve meters (holds-off) full apply pressure to the
front disc brakes until the rear brakeshoes are i n full
5 - 28 REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM •
contact with the drums. The valve is designed to The initial flash will be a long flash followed by a
maintain front brake fluid pressure at 2 1 - 2 0 7 kPa number of short flashes. The long flash indicates the
(3-30 psi) until the hold-off limit of approximately beginning of the fault number sequence and the
807 kPa (117 psi) is reached. A t this point, the me short flashes are a continuation of that sequence.
tering valve opens completely permitting full fluid You must count the long flash along with the
apply pressure to the front disc brake calipers. short flashes for an accurate fault code count.
REAR WHEEL ANTILOCK SYSTEM DIAGNOSIS CLEARING A FAULT CODE

An antilock system malfunction will be indicated To clear a fault code, disconnect the control module
by illumination of the amber warning lamp. connector or disconnect the battery for a minimum of
I f a problem occurs, system diagnosis should begin five seconds. During system retest, wait 30 seconds
with a fluid level check followed by a visual exami to be sure the fault code does not reappear.
nation of the system electrical and hydraulic connec
tions. I f obvious defects (low fluid, leaks, loose FAULT
connections, etc.) are not evident, road test the vehi CODE
cle. A road test should help determine i f a malfunc NUMBER TYPICAL FAILURE DETECTED
tion is actually related to an antilock component.
During the road test, note i f other conditions are 1 Not used.
evident such as a low pedal, pull, grab, or similar
condition. Remember that brake malfunctions such 2 Open isolation valve wiring or bad control
as low fluid, system leaks, or parking brakes par module.
tially applied will affect antilock system operation.
3 Open dump valve wiring or bad control
The idea is to determine i f a malfunction is actually
module.
related to an antilock component.
If a visual inspection and road test do not indicate the 4 Closed RWAL valve switch.
problem cause, check the system fault codes. Refer to
the system fault code information in this section. 5 Over 16 dump pulses generated in 2WD
vehicles (disabled for 4WD).
DIAGNOSTIC FAULT FLASH CODES
The microprocessor i n the electronic control module 6 Erratic speed sensor reading while rolling.
has a self test feature. This feature is activated
whenever the ignition switch is i n the On and Run 7 Electronic control module fuse pellet open,
positions. isolation output missing, or valve wiring
I f a system fault is detected, the control module i l shorted to ground.
luminates the antilock light and stores the fault code
8 Dump output missing or valve wiring shorted to
in the microprocessor memory. I f a fault code is gen
ground.
erated, the module will retain the code after turning
the ignition switch to Off position. 9 Speed sensor wiring/resistance (usually high
System faults are identified by a series of flash reading).
codes that operate through the antilock warning
light. Temporarily grounding the antilock diagnostic 10 Sensor wiring/resistance (usually low reading).
connector will produce the flash code sequence. Refer
to Fault Code Identification i n this section. 11 Brake switch always on. RWAL light comes on
when speed exceeds 40 mph.
FAULT CODE CAPACITY
The microprocessor memory will store and display 12 Not used.
only one fault code at a time. The stored code can be
13 Electronic control module phase lock loop
displayed by grounding the antilock diagnostic connec
failure.
tor.
14 Electronic control module program check
FAULT CODE IDENTIFICATION failure.
When a fault code is generated, the red brake
warning lamp will also illuminate. To determine 15 Electronic control module RAM failure.
what the fault code is, momentarily ground the diag
nostic connector and count the number of times the J9005-101
antilock indicator lamp flashes. Fault codes and typ
ical malfunctions are outlined i n Figure 6. Fig. 6 RWAL Antilock System Flash Codes
FAULT CONDITION CAUSES

RWA1 system faults can be generated by component
malfunction, or by the driver.
Component malfunctions will most frequently be
related to problems i n the RWAL valve wire harness.
Look for loose connections, corroded terminals, dam
aged wires, or loss of continuity due to connectors
filled with water or dirt. Blown circuit fuses and poor
ground connections are also common causes for sys
tem faults. A misadjusted, or faulty stop lamp switch
will also cause a system fault.
Speed sensor and control module failures, although
infrequent, will be indicated by flash codes The sen
sor or module should not be replaced until diagnosis
indicates this is necessary.
The driver can induce system faults by riding the Fig. 7 Valve Harness Connector And Ground Wire
brake pedal or leaving the parking brakes partially Locations
applied. Either condition will cause the antilock
warning light to illuminate, despite the fact that an
actual fault has not occurred.
Another driver induced fault involves holding the
brake pedal i n an applied position while starting the
engine. This practice causes the stoplamp switch to
be i n a closed position when the engine is started.
With the switch closed, the RWAL system self check
feature will not be completed. The result is illumina
tion of both warning lights and trouble code 11 to be
registered i n system memory.
ANTILOCK COMPONENT SERVICEABILITY

The RWAL valve, combination valve, electronic
module, rear wheel speed sensor, exiter ring and in
terconnecting brakelines are not repairable. These
components are serviced by replacement only.
The combination valve mounting bracket is not ser
viced separately. The bracket and valve are serviced
as an assembly.
BRAKES J9405-82
RWAL VALVE/COMBINATION VALVE REMOVAL

(1) Disconnect ground wire and harness wires from Fig. 8 Master Cylinder Brakeline Removal
combination valve switch and RWAL valve (Fig. 7). RWAL VALVE/COMBINATION INSTALLATION
(2) Disconnect lines to front and rear brakes from (1) Install RWAL valve on combination valve
RWAL and combination valves (Fig. 8). bracket (Fig. 10). Do not tighten RWAL valve bolt
(3) Remove brakelines connecting master cylinder completely at this time.
to combination valve (Fig. 9). (2) Install short brakeline that connects RWAL
(4) Remove nuts attaching master cylinder and valve to combination valve (Fig. 10). Tighten line fit
combination valve bracket to booster studs (Fig. 9). tings to 16-23 N-m (140-200 in. lbs.) torque.
(5) Remove master cylinder. (3) Tighten RWAL valve attaching bolt to 23-34
(6) Remove combination valve, valve bracket and N-m (200-300 in. lbs.) torque.
RWAL valve as assembly. (4) Install master cylinder on booster mounting
(7) Remove brakeline connecting combination valve studs.
to RWAL valve (Fig. 10). (5) Attach antilock harness ground wire to combi
(8) Remove bolt attaching RWAL valve to combina nation valve bracket.
tion valve bracket (Fig. 10). Then separate RWAL (6) Install combination valve bracket on booster
valve from bracket. mounting studs and against master cylinder.
J9405-83
Fig. 9 Master Cylinder Brakeline Fig. 11 Master Cylinder Brakeline Connections

Removal/Installation.
Fig. 12 Master Cylinder And Combination Valve

Fig. 10 RWAL Valve/Combination Valve Disassembly Mounting
(7) Loosely install nuts that retain master cylinder CONTROL MODULE REMOVAL/INSTALLATION
and combination valve on booster studs. The RWAL electronic control module is located un
(8) Install and connect all remaining brakelines der the central portion of the instrument panel. I t is
(Figs. 11 and 12). Tighten line fittings to 16-23 N-m mounted on a bracket attached to the back side of
(140-200 in. lbs.) torque. the panel. The module is accessible through the
(9) Connect harness wires to RWAL valve and to panel opening created by removal of the knee bolster.
combination valve switch (Fig. 7). (1) Remove knee bolster (Fig. 13). Bolster is at
(10) Fill and bleed brake system. tached to panel flanges with screws.
• REAR WHEEL ANTILOCK IRAKE (RWAL) SYSTEM 5 - 31
(4) Remove module and bracket from underside of

instrument panel.
( 5 ) Disconnect harness wires from module.
(6) I f module is to be replaced, remove module
from bracket. However, i f module is only being re
moved for access to another component, leave module
in place on bracket.
(7) Install module on mounting bracket, i f re
moved.
(8) Connect harness wires to module.
(9) Position module and bracket on instrument
panel and install attaching screws (Figs. 14 and 15).
REAR SPEED SENSOR REMOVAL/INSTALLATION

(1) Raise vehicle on hoist.
(2) Clean sensor, cover and sensor mounting area
(2) Remove module lower attaching screws (Fig. of axle housing (Figs. 16 and 17). This is necessary to
14). Screws are partially hidden by air duct but can prevent dirt entry when sensor is removed from
be removed with long shank, number 2 Phillips housing. Mopar brake cleaner or carb cleaner are
screwdriver as shown. equally acceptable for cleaning purposes.
(3) Disconnect harness wires from sensor (Fig. 16).
(4) Remove screw that secures brake cable, brake-
line, sensor cover and sensor i n axle housing (Figs.
16 and 17).
(5) Remove sensor and cover.
(6) Cover sensor opening i n axle housing to pre
vent dirt entry.
CHAINING
SCREW
m 0
CABLE-—' ^'
CLAMP
BRAKE
J948F-7 UNE
»
COVER- '
Fig. 14 RWAL Module Lower Attaching Screw Location
5 38
SENSOR- ^ "
(3) Remove module upper attaching screw (Fig. 15).
A X L E — _ - —
HOUSING
J948F-8
Fig. 15 RWAL Module Upper Attaching Screw Location Fig. 16 Rear Speed Sensor Mounting
5 - 32 REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM — ^— — — •
REAR REAR
BRAKE SENSOR
HOSE HARNESS
CONNECTOR
REAR
SENSOR
REAR
AXLE
HOUSING J9405-81
Fig. 17 Rear Speed Sensor Harness Routing And Attachment

(7) Insert sensor i n axle housing opening.
(8) Position cover over sensor and install cover and HARNESS
CUP
sensor attaching screw.
(9) Connect harness wires to sensor. SENSOR
HARNESS
(10) Lower vehicle. CONNECTOR
REAR SPEED SENSOR REAR HARNESS

REMOVAL/INSTALLATION
(2) Disconnect sensor harness at sensor. Then dis
engage small harness clip from sensor cover (Fig. 18).
(3) Disconnect sensor harness at axle connector.
(4) Unclip sensor harness from plastic retainer
that secures harness and rear brake hose (Fig. 19).
J9405-92
(5) Remove rear harness from vehicle.
(6) Install new harness and secure i n retainers. FigD 18 Disengaging Harness Connector At Rear
Then connect harness to sensor and axle connector Sensor
and lower vehicle.
MANUAL BRAKE BLEEDING PROCEDURE
RWAL SYSTEM BRAKE BLEEDING (1) I f master cylinder has been overhauled or a
Use Mopar DOT 3 brake fluid, or an equivalent new cylinder will be installed, bleed cylinder on
meeting SAE J1703-F and DOT 3 standards, to fill bench before installation. This shortens time needed
and bleed the system. to bleed system and ensures proper cylinder opera
tion.
Bleeding can be performed either manually or with
pressure equipment. However, i f pressure equipment (2) Wipe master cylinder reservoir and filler caps
is used, i t will be necessary to hold the front brake clean with shop towels. Use Mopar brake cleaner i f
metering valve open i n order to bleed the front exterior of reservoir and filler caps are extremely
dirty.
brakes. The valve can be held open with a tension
clip tool or by hand. I t will also be necessary that a (3) Remove reservoir filler caps and fill reservoir
with Mopar, or equivalent DOT 3 brake fluid.
suitable size pressure tank hose adapter be available
(4) Open all caliper and wheel cylinder bleed
for use on the master cylinder reservoir caps.
screws.
inder will allow additional air to be drawn into the

system. Check the cylinder fluid level frequently
and add fluid a s needed.
Fig. 19 Sensor Rear Harness Attachment J8905-18

(5) Close bleed screws when fluid starts flowing
Fig. 20 Typical Fluid Container And Bleed Hose
from each bleed screw.
(6) Top off master cylinder reservoir again. (10) Bleed combination valve next and rear brake
(7) Bleed brakes i n following sequence: antilock valve afterward. Bleed valves at brakeline
• master cylinder fittings one at a time. Surround line fittings with
• combination valve shop towels to catch fluid bled from valve.
• rear antilock valve (11) Bleed first wheel brake unit as follows. Start
• right rear wheel at left rear wheel:
• left rear wheel (a) Open caliper or wheel cylinder bleed fitting
• right front wheel 1/2 to 3/4 turn.
• left front wheel (b) Have helper press and hold brake pedal to
(8) Observe following precautions during bleeding floor.
procedure: (c) Tighten bleed fitting and have helper release
• Do not pump brake pedal at any time while bleed brake pedal.
ing. Air in system will be compressed into small bub (d) Continue bleeding operation until fluid enter
bles that are distributed throughout hydraulic ing bleed container is clear and free of bubbles.
system. This will make a second and third bleeding (12) Repeat bleeding operation at remaining wheel
operation necessary. brake units. Discard fluid bled into glass container. I t
• Bleed only one valve, or wheel brake unit at a should not be reused.
time and use a bleed hose on each wheel cylinder (13) Check and top off master cylinder reservoir
and caliper bleed screw. fluid level.
• Attach one end of bleed hose to bleed screw and (14) Verify proper brake operation before moving
insert opposite end i n glass container partially filled vehicle.
with brake fluid (Fig. 20). Glass container makes i t
easier to see air bubbles as they exit the bleed hose. PRESSURE BLEEDING
• Be sure end of bleed hose is immersed i n fluid. Im The front brake metering valve (in the combi
mersing hose end i n fluid prevents air from being nation valve), must be held open when using
drawn back into cylinder and brakeline. pressure bleeding equipment. This is necessary
(9) Bleed master cylinder first. Have helper oper because the 20 psi exerted by pressure equip
ment exceeds the valve hold off point causing it
ate brake pedal while bleeding each master cylinder
to close. The metering valve is in the forward
fluid outlet line.
end of the combination valve. The valve stem is
CAUTION: Do not allow the master cylinder to run accessible after removing the rubber protector
out of fluid during bleed operations. An empty cyl cap that covers the stem. The stem must be ei-
ther pressed inward, or held outward slightly (11) Repeat bleeding procedure i f system warning
in order to Meed the front brakes. Use a clip lights come on, remain on, or i f pedal is still spongy.
style tool such as Special Tool C-4121 to hold
the stem in or out. Do not use pliers or similar
tools a the stem and valve will be damaged.
(1) Fill bleeder tank i f necessary.
(2) Purge air from bleeder tank and lines before
proceeding.
(3) Clean master cylinder reservoir and cover thor
oughly.
(4) Remove master cylinder cover anddnstall suit
able adapter (Fig. 21). Various types of adapters are
usually available from the pressure tank manufac
turer.
(5) Connect bleeder tank pressure hose to adapter
(Fig. 21).
(6) Bleed master cylinder and valves. Bleed master
cylinder first, combination valve second and RWAL-
/ABS valves third.
(7) Bleed rear wheel brake units as described i n
manual bleeding procedure.
(8) Bleed front wheel brake units. Use a clip style
tool to hold metering valve i n or out. Or have a
helper hold valve i n or out by hand. Amount of valve
stem movement needed to hold valve open is quite
modest. Do not use excessive force.
Fig. 21 Typical Pressure Bleeder Tank And Adapter
(9) Remove pressure bleeding equipment and top (For Delco Master Cylinder)
off master cylinder reservoir.
(10) Verify firm brake pedal before moving vehicle.
• ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) § - 35
ALL-WHEEL A N T I L O C K BRAKE SYSTEM (ABS}
INDEX
page page
ABS Components 35 Combination Valve Testing 40
ABS Control Module Diagnosis 40 Front Speed Sensor Installation 42
ABS Diagnostic Connector Location 39 Front Speed Sensor Removal 42
ABS Normal and Fault Conditions 39 Front Tone Wheel Service 43
ABS System Diagnosis 39 Rear Speed Sensor Harness Installation 44
ABS Valve and Control Module Installation 41 Rear Speed Sensor Harness Removal 44
ABS Valve and Control Module Removal 40 Rear Speed Sensor Installation 43
ABS Valve Service and Diagnosis 40 Rear Speed Sensor Removal 43
ABS Warning Light Display 39 RWAL Valve/Combination Installation . . . . . . . . . . . 42
All Wheel Antilock System (ABS) Operation ...... 37 RWAL Valve/Combination Valve Removal . . . . . . . 41
Combination Valve Operation 38
ABS COMPONENTS The pump and motor unit is controlled by the ABS
The optionally available, all-wheel antilock brake electronic module. The pump supplies the additional
system (ABS), is a unique combined system. I t con fluid volume needed during antilock braking.
sists of the standard rear wheel antilock (RWAL) sys
tem components, plus the additional parts needed to
create an all wheel antilock brake system.
ABS components include:
• rear brake (RWAL) antilock valve
• rear wheel speed sensor and exiter ring
• front wheel speed sensors and tone rings
• front brake antilock valve
• ABS electronic control module
• electrical harnesses
• combination valve
• diagnostic connector
Front Brake ABS Valve

The front brake ABS valve consists of a solenoid
valve body and pump/motor unit combined into a sin
gle assembly (Fig. 1).
The valve is mounted on the driver side inner
fender panel (Fig. 1). The valve and motor assembly
are attached to a one piece mounting bracket and a
stud plate. A molded, flexible shield is used to protect
the top of the valve assembly.
Fig. 1 ABS Component Location
The valve body contains the solenoid valves that
modulate brake fluid apply pressure during antilock Rear Brake RWAL Valve
braking. The valves are operated by the antilock sys The RWAL valve for the rear brakes is mounted on
tem electronic control module. the combination valve bracket (Fig. 2). The bracket is
The antilock valve provides two channel pressure secured to the master cylinder mounting studs on the
control of the front brakes. One channel controls the power brake booster.
left front brake unit. The second channel controls the The RWAL valve modulates rear brake apply pres
right front brake unit. Each front brake unit is con sure during antilock braking. The valve is controlled
trolled independently. and operated by the electronic control module. Two
The solenoid valves are cycled open and closed as solenoid valves i n the valve body isolate, decrease, or
needed during antilock braking. The valves are not increase rear brake fluid apply pressure as needed
static. They are cycled rapidly and continuously to during antilock braking.
modulate pressure and control wheel slip and decel The valve solenoid valves are inactive during peri
eration. ods of normal braking. The solenoids allow free flow
5 - 36 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS)
of brake fluid to the rear brake units during normal

COMBINATION
braking. The solenoid valves are activated only when VALVE
braking effort and rate of wheel slip and deceleration AND MOUNTING
BRACKET
exceed normal braking limits. ASSEMBLY
MASTER
CYLINDER
ASSEMBLY
J9405-96
Fig. 3 Combination Valve And Integral Mounting

Bracket
1). The module is attached to the forward side of the
front antilock valve mounting bracket.
The module controls antilock valve solenoid opera
tion during all phases of antilock braking. Module
electrical inputs are provided by wheel speed signals
from the front and rear sensors.
Diagnostic Connector
The ABS diagnostic connector is at the underside of
the knee bolster. The connector is a six-way style and is
RWAL either black, or blue in color for identification purposes.
VALVE J9405-76
The connector is the ABS access point for the DRB I I
Fig. 2 RWAL Valve And Combination Valve Location scan tool. The system components can be checked once
the scan tool is attached to the connector.
Combination Valve
The combination valve used with the ABS system Wheel Speed Sensors And Tone Wheels
contains a front disc brake metering valve and a Three wheel speed sensors are used i n the all
front/rear pressure differential valve and switch. wheel ABS system. A sensor is used at each front
The metering valve controls fluid apply pressure to wheel. A single sensor is used for both rear wheels
the front disc brake calipers. Caliper apply pressure (Fig. 4).
is temporarily limited until the rear drum brake- ABS SENSOR
shoes contact the drum surface. This feature provides FRONT WIRE
balanced front/rear braking. SENSOR
STEERING
The pressure differential valve is connected to the KNUCKLE
front and rear brake hydraulic systems. A leak i n ei
ther part of the system will actuate the valve causing
it to shuttle toward the leaking side of the system.
Movement of the valve trips the plunger type warn
ing switch. The switch then closes the electrical cir
cuit to the red warning light i n the instrument panel.
The combination valve is permanently attached to
its mounting bracket. The valve bracket is also used
to mount the rear brake antilock valve (Fig. 3).
Combination valve operation and testing is fully SENSOR
BOLTS
described i n the antilock system diagnosis section. (21-25 N - m /
Refer to this information when diagnosing system 1 9 - 2 5 0 in. lbs
faults.
ABS Electronic Control Module SPLASH
SHIELD
A separate electronic control module is used to
monitor and operate the ABS system. J9405-177
The ABS module is located at the drivers inner
fender panel under the battery and battery tray (Fig. Fig. 4 Front Wheel Sensor Location
• ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) 5 - 37
The sensors convert wheel speed into an electrical

signal. The signal is transmitted to the electronic
control module for processing.
The trigger mechanism for each front wheel sensor
is a gear type, tone wheel. The tone wheels are
mounted on the inboard side of the disc brake rotor
hub (Fig. 5).
Fig. 5 Front Tone Wheel Location (In Rotor)

A single sensor is used to monitor rear wheel speed
and rate of deceleration. The sensor is mounted at
the top of the rear axle housing (Fig. 6). The trigger
mechanism for the sensor is an exiter ring pressed Fig. 6 Rear Wheel Sensor Location
onto the differential case. The ring is pressed onto The front and rear antilock valves contain electri
the case next to the ring gear. cally operated solenoid valves. The solenoid valves
The teeth on the tone wheels and exiter ring inter modulate brake fluid apply pressure during antilock
rupt the sensor magnetic field as they rotate. The braking. The valves are operated by the antilock elec
rate of interruption is converted into speed signals
tronic module.
which are transmitted to the electronic control mod
The ABS valve provides two channel pressure con
ule.
trol of the front brakes. Each front wheel brake unit
The front and rear sensors are fixed and not ad
justable. A front or rear sensor must be replaced is controlled separately. Two solenoid valves are used
when diagnosis indicates a fault has occurred. in each control channel.
The RWAL valve controls the rear wheel brakes i n
Master Cylinder And Power Brake Booster tandem. The rear brake valve contains two solenoid
A standard master cylinder and vacuum power valves.
brake booster are used with the ABS system. The During antilock braking, the solenoid valves are
same master cylinder and dual or single diaphragm opened and closed as needed. The valves are not
boosters are used with each antilock system. static. They are cycled rapidly and continuously to
modulate pressure and control wheel slip and decel
ALL WHEEL ANTILOCK SYSTEM (ABS) OPERATION eration.
The all wheel ABS system is a three channel de The pump/motor assembly on the front antilock
sign. The front wheel brakes are controlled individu valve provides the fluid volume needed during an
ally and the rear wheel brakes i n tandem (Fig. 7). tilock braking. The pump is operated by an integral
The ABS system is designed to retard wheel lockup electric motor. The DC type motor is controlled by
during periods of high wheel slip when braking. Re the ABS control module.
tarding wheel lockup is accomplished by modulating
fluid pressure to the wheel brake units. MBS OPERATION IN NORMAL BRAKING MODE
The antilock electrical system is separate from The ABS electronic control module monitors wheel
other electrical circuits i n the vehicle. A specially pro speed sensor inputs continuously while the vehicle is
grammed electronic control module is used to operate
the system components.
5 - 38 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) •
POWER
BRAKE
BOOSTER
FRONT
ANTILOCK
VALVE
RF RR
WHEEL WHEEL
LR
WHEEL
J9305-113
Fig. TABS Hydraulic System Connections

in motion. However, the module will not activate any COMBINATION VALWE OPERATION
ABS components as long as sensor inputs indicate
normal braking. Pressure Differential Switch
During normal braking, the master cylinder, power The pressure differential switch is connected to the
booster and wheel brake units all function as they brake warning light. The switch is triggered by
would i n a vehicle without ABS. The solenoid valves movement of the switch valve. The purpose of the
are not activated. switch is to monitor fluid pressure i n the separate
front/rear brake hydraulic circuits.
ABS OPERATION I N ANTILOCK BRAKING A decrease or loss of fluid pressure i n either hy
MODE draulic circuit will cause the switch valve to shuttle
The ABS module activates the system whenever forward or rearward i n response to the pressure dif
sensor signals indicate the onset of high wheel slip. ferential. Movement of the switch valve will push the
High wheel slip can be described as the point switch plunger upward. This closes the switch inter
where wheel rotation begins approaching zero (or nal contacts completing the electrical circuit to the
lockup) during braking. The antilock system retards warning light. The switch valve will remain i n an ac
lockup during high slip conditions by modulating tuated position until repair restores system pressures
fluid apply pressure to the wheel brake units. to normal levels.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera Metering Valve
tion. A sensor at each wheel converts wheel speed The metering valve is used to balance brake action
into electrical signals. These signals are transmitted between the front disc and rear drum brakes. The
to the module for processing and determination of valve meters (holds-off) full apply pressure to the
wheel slip and deceleration rate. front disc brakes until the rear brakeshoes are i n full
The ABS system has three fluid pressure control contact with the drums. The valve is designed to
channels. The front brakes are controlled separately maintain front brake fluid pressure at 21-207 kPa
and the rear brakes i n tandem. A speed sensor input (3-30 psi) until the hold-off limit of 807 kPa (117 psi)
signal indicating high slip conditions activates the is reached. At this point, the metering valve opens
control module antilock program. completely permitting full fluid apply pressure to the
The solenoid valves are not static during antilock front disc brakes.
braking. They are cycled continuously to modulate
pressure. Solenoid cycle time i n antilock mode can be
measured i n milliseconds.
ABS SYSTEM DIAGNOSIS they cycle on and off. This is a n o r m a l condition and
ABS system diagnosis involves checking only those should not be mistaken for faulty operation. Under
components that form the antilock system. Antilock most conditions, pump and solenoid valve operating
system diagnosis involves three basic steps which sounds should not be audible.
are:
Vehicle Response In Antilock Mode
• observation of the warning light display
• visual examination for low fluid, leaks, or damaged During antilock braking, the front/rear solenoid
wires valves cycle rapidly i n response to antilock electronic
• identification of the problem component control unit inputs.
The driver may experience a slight pulsing sensa
Visual examination includes a check of reservoir
tion i n the brake pedal and vehicle as the solenoid
fluid level and condition of the system components.
valves modulate fluid pressure as needed. This is a
This includes inspection of the sensor wires and elec
normal condition.
trical connections. Things to look for are leaks, loose
connections, or obvious component damage. Steering Response
Identification of the problem component involves A modest amount of steering input is required dur
using the DRB scan tool to identify a faulty compo ing extremely high deceleration braking, or when
nent. braking on differing traction surfaces. An example of
differing traction surfaces would be when the left
ABS DIAGNOSTIC CONNECTOR LOCATION side wheels are on ice and the right side wheels are
The ABS diagnostic connector is clipped to the un on relatively dry pavement.
der side of the knee bolster (Fig. 9). The connector is
positioned just below the steering column. Brake Pedal Pulsing
The diagnostic connector is a six-way type and is A light pulsing sensation may be felt through the
either light blue or black i n color. brake pedal during antilock mode braking. This is a
The connector is the ABS access point for the DRB normal occurrence and should not be mistaken for a
scan tool. System components can be tested after the system fault.
scan tool is attached to the connector.
Loss Of Sensor Input
Wheel speed sensor malfunctions will most likely
be due to loose connections, damaged sensor wires, or
incorrect sensor air gap. An additional fault would be
a result of sensor and tone wheel misalignment or
physical damage. A faulty sensor (open, shorted) can
be located with the DRB scan tool.
Driver Induced Faults

The driver can induce system faults by riding the
brake pedal or leaving the parking brakes partially
applied. Either condition will cause the antilock
warning light to illuminate, despite the fact that an
actual malfunction has not occurred.
Another driver induced fault involves holding the
J9405-164
brake pedal i n an applied position while starting the
engine. This practice causes the stoplamp switch to
Fig. 8 ABS Diagnostic Connector Location
be i n a closed position when the engine is started.
ABS NORMAL AND FAULT CONDITIONS With the switch closed, the ABS system self check
feature will not be completed. The result is illumina
Wheel/Tire Size And Input Signals tion of both warning lights and a trouble code to be
Antilock system operation depends on accurate sig registered i n system memory.
nals from the wheel speed sensors. Ideally, the vehi
cle wheels and tires should all be the same size and ABS WARNING LIGHT DISPLAY
type to ensure accurate signals and satisfactory oper
ation. Light Illuminates At Startup
The amber antilock light illuminates at startup as
Operating Sound Levels part of the system self check feature. The light illu
On the all wheel ABS system, the pump/motor and minates for 2-3 seconds then goes off as part of the
antilock valve solenoids may produce some sound as normal self check routine.
S - 40 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) •
Light Remains On After Startup (3) Connect bleed hose to a rear wheel cylinder
An ABS system fault is indicated when the light re and immerse hose end i n container partially filled
mains on after startup. Diagnosis with the DRB scan with brake fluid.
tool will be necessary to determine the faulty compo (4) Have helper press and hold brake pedal to floor
nent. and observe warning light.
(a) I f warning light illuminates, switch is operat
Light Illuminates During Brake Stop ing correctly.
A system fault such as loss of speed sensor signal (b) I f light fails to illuminate, check circuit fuse,
or solenoid failure, will cause the amber warning bulb and wiring. Repair as necessary and repeat
light to illuminate. The most effective procedure here test steps (3) and (4).
is to check for obvious damage first. Then check the (5) I f warning light still fails to illuminate, check
electronic components with the DRB scan tool, or brakelight and parking brake switches and wiring
flash codes. with test lamp. Repair or replace parts as necessary
and test differential pressure switch operation again.
ABS CONTROL MODULE DIAGNOSIS (6) I f warning light still does not illuminate, switch
The electronic module controls all phases of an is faulty. Replace combination valve assembly, bleed
tilock system operation. The module also differenti brake system and verify proper switch and valve op
ates between normal and antilock mode braking. eration.
The module monitors and processes signals gener
ated by the system sensors at all times. ABS VALVE AND CONTROL MODULE REMOVAL
The module operating program includes a self (1) I f desired, battery can be removed for improved
check routine that tests each of the system compo access to ABS valve and connecting lines.
nents. A failure of the self check program will cause (2) Disconnect ABS harness at valve (Fig. 9).
illumination of the amber warning light. The light (3) Unlatch and disconnect harness at ABS mod
will also illuminate i f a solenoid or other system com ule.
ponent fails during the dynamic phase of initializa
tion.
I f a system malfunction should occur, do not imme
diately replace the control module. A blown system
fuse, bad ground, or loss of feed voltage will cause
system faults similar to a module failure. Never re
place the module unless scan t o o l diagnosis i n
dicates replacement is actually necessary.
ABS VALVE SERVICE AND DIAGNOSIS

The front and rear antilock valves are serviced only
as assemblies. Neither valve should be replaced un
less a fault has actually been confirmed with the
DRB scan tool.
COMBINATION VALVE TESTING

Fig. 9 ABS Valve Harness Connections
T E S T I N G METERING VALVE
(4) Disconnect lines to front brakes at ABS valve
Metering valve operation can be checked visually (Fig. 10).
and with the aid of a helper. Observe the metering (5) Remove stud nuts and bolt that attach ABS
valve stem while a helper applies and releases the valve to inner fender panel (Fig. 11). Then remove
brakes. I f the valve is operating correctly, the stem valve from engine compartment.
will extend slightly when the brakes are applied and (6) I f valve is only being removed for access to an
retract when the brakes are released. I f the valve is other component, cover brakeline fluid ports with
faulty, replace the entire combination valve as an as tape or plugs to prevent dirt entry.
sembly.
(7) Remove bolts attaching module to valve and re
TESTING P R E S S U R E D I F F E R E N T I A L S W I T C H move module.
(1) Have helper sit i n drivers seat to apply brake
pedal and observe red brake warning light.
Fig. 10 ABS Valve Hydraulic Connections Fig. 12 Valve Harness Connector And Ground Wire
Locations
Fig. 11 ABS Valve Mounting

ABS VALVE AND CONTROL MODULE
INSTALLATION
(1) Install replacement module on valve i f neces
sary. BRAKES J9405-82
(2) Position ABS valve on mounting studs.
(3) Install and tighten mounting bolt and stud Fig. 13 Master Cylinder Brakeline Removal
nuts. Tighten bolts and nuts to 10-13 N-m (92-112 in.
(3) Remove brakelines connecting master cylinder
lbs.) torque.
to combination valve (Fig. 14).
(4) Connect ABS harnesses to valve and electronic
(4) Remove nuts attaching master cylinder and
module. Be sure module harness is securely latched
combination valve bracket to booster studs.
in place.
(5) Remove master cylinder.
(5) Connect brakelines to ABS valve. Tighten line
(6) Remove combination valve, valve bracket and
fittings to 19-23 N-m (170-200 in. lbs.) torque.
RWAL valve as assembly.
(6) Install battery, i f removed.
(7) Remove brakeline connecting combination valve
(7) Fill and bleed brake system. Refer to procedure
to RWAL valve.
in this section.
(8) Remove bolt attaching RWAL valve to combina
RWAL VALVE/COMBINATION ¥ALVE REMOVAL tion valve bracket (Fig. 15). Then separate RWAL
valve from bracket.
(1) Disconnect ground wire and harness wires from
combination valve switch and RWAL valve (Fig. 12).
(2) Disconnect lines to front and rear brakes from
RWAL and combination valves (Fig. 13).
5 - 42 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) •
(4) Install master cylinder on booster mounting
studs.
(5) Attach antilock harness ground wire to combi
nation valve bracket.
(6) Install combination valve bracket on booster
mounting studs and against master cylinder.
(7) Loosely install nuts that retain master cylinder
and combination valve on booster studs.
(8) Install and connect all remaining brakelines
(Figs. 16 and 10). Tighten line fittings to 16-23 N-m
(140-200 in. lbs.) torque.
J9405-83
Fig. 14 Master Cylinder Brakeline Removal/

Installation
VALVE
INTEGRAL
MOUNTING
BRACKET
COMBINATION
J9405-1
VALVE
Fig. 16 Master Cylinder Brakeline Connections

(9) Connect harness wires to RWAL valve and to
combination valve switch.
(10) Fill and bleed brake system. Refer to proce
dure i n this section.
FRONT SPEED SENSOR REM0¥AL

RWAL
VALVE
(1) Raise vehicle and support vehicle front end.
ATTACHING (2) Remove wheel and tire assembly.
BOLT (3) Press caliper piston back into bore with pry
tool.
J9405-84 (4) Remove brake caliper bolts and lift caliper from
knuckle and rotor. Secure caliper to frame or chassis
Fig. 15 RWAL Valve/Combination Valve Disassembly component with wire. Do not allow brake hose to
RWAL VALVE/COMBINATION INSTALLATION support caliper weight.
(5) Remove rotor.
(1) Install RWAL valve on combination valve
(6) Remove bolts attaching sensor to steering
bracket (Fig. 15). Do not tighten RWAL valve bolt
knuckle (Fig. 18). Retain bolts. They are special and
completely at this time. must be reused i f i n good condition.
(2) Install short brakeline that connects RWAL (7) Disconnect sensor wire and remove sensor from
valve to combination valve (Fig. 15). Tighten line fit vehicle.
tings to 16-23 N-m (140-200 in. lbs.) torque.
(3) Tighten RWAL valve attaching bolt to 23-34 FRONT SPEED SENSOR INSTALLATION
N-m (200-300 in. lbs.) torque. (1) Position sensor i n knuckle.
FRONT TONE WHEEL SERVICE

The tone wheel for the front speed sensor is located
in the rotor hub on 2-wheel drive models. On 4-wheel
MOUNTING
NUTS (2
drive models, the tone wheel is located on the front
driveshaft.
The tone wheel is not a serviceable component. On
2-wheel drive models, the complete rotor and hub as
sembly will have to be replaced i f the tone wheel be
comes damaged. On 4-wheel drive models, the
driveshaft is necessary i f the tone wheel becomes
damaged.
REAR SPEED SENSOR REMOVAL

(2) Clean sensor, cover and sensor mounting area
of axle housing (Figs. 19 and 20). This is necessary to
prevent dirt entry when sensor is removed from
housing. Mopar brake cleaner or carb cleaner are
LINES FROM equally acceptable for cleaning purposes.
COMBINATION (3) Disconnect harness wires from sensor.
A VALVE TO
^ F R O N T / R E A R BRAKES J9405-2 (4) Remove screw that secures brake cable, brake-
line, sensor cover and sensor i n axle housing (Figs.
Fig. 17 Master Cylinder And Combination Valve 21 and 22).
Mounting (5) Remove sensor and cover.
(6) Cover sensor opening i n axle housing to pre
FRONT vent dirt entry.
SENSOR SPLASH
SHIELD
STEERING
KNUCKLE RETAINING
SCREW
SENSOR
BOLTS (2)
J9405-165
Fig. 18 Front Speed Sensor Mounting (2-Wheel

Drive Shown)
(2) Install and tighten sensor bolts to 21-25 N-m
(190-250 in. lbs.) torque. Use original or replace
ment sensor bolts only. The bolts are special
and must not be substituted.
(3) Connect sensor wire to harness wire from ABS
controller.
(4) Install rotor and sic brake caliper.
(5) Install wheel and tire assembly.
(6) Lower vehicle.
(7) Verify sensor operation with scan tool.
JIIS-SO!
Fig. 19 Rear Speed Sensor Mounting
MM SPEED SEISOi INSTALLATION

(1) Insert sensor i n axle housing opening.
S - 44 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) •
REAR REAR
BRAKE SENSOR
HOSE HARNESS
CONNECTOR
REAR
SENSOR
REAR
AXLE
HOUSING J9405-81
Fig. 20 Rear Speed Sensor Harness Routing And Attachment

(2) Position cover over sensor and install cover and (3) Disconnect sensor harness at axle connector.
sensor attaching screw. (4) Unclip sensor harness from plastic retainer
(3) Connect harness wires to sensor. that secures harness and rear brake hose (Fig. 22).
(4) Lower vehicle. (5) Remove rear harness from vehicle.
REAR SPEED SENSOR HARNESS REMOVAL REAR SPEED SENSOR HARNESS INSTALLATION
(1) Raise vehicle on hoist. (5) I f sensor rear harness must also be removed, is
(2) Disconnect sensor harness at sensor. Then dis also
engage small harness clip from sensor cover (Fig. 21).
SENSOR HOSE
HARNESS U-CUP
HARNESS
CUP
SENSOR
HARNESS
CONNECTOR
J9405-92
J9405-93
Fig. 21 Disengaging Harness Connector At Rear
Sensor Fig. 22 Sensor Rear Harness Attachment
DISC B R A K E S
INDEX
page page
Caliper Operation and Wear Compensation 45 Disc Brake Rotor Removal (2-Wheel Drive) 55
Disc Brake Caliper Cleaning and Inspection 51 Disc Brake Rotor Removal (4-Wheel Drive) 57
Disc Brake Caliper Disassembly 50 Disc Brakeshoe and Caliper Inspection 48
Disc Brake Caliper Installation 53 Disc Brakeshoe Installation 48
Disc Brake Caliper Overhaul and Reassembly .... 52 Disc Brakeshoe Removal 47
Disc Brake Caliper Removal 50 General Service Information 45
Disc Brake Rotor Inspection and Service 54 Wheel Bearing Adjustment (2-Wheel
Disc Brake Rotor Installation (2-Wheel Drive Drive Models) 57
Models) 56 Wheel Bearing Replacement 59
Disc Brake Rotor Installation (4-Wheel Drive) 58 Wheel Nut Tightening 59
GENERAL SERVICE INFORMATION • calipers on 1/2 ton models have a 75 mm (2.95 in.)
bore
Caliper Types • calipers on 3/4 ton models have an 80 mm (3.14
BR models are equipped with Delco sliding type, in.) bore
• calipers on 1 ton models and 3/4 ton, 4 x 4 models
front disc brake calipers. The calipers slide on
with Dana 60 front axle, have an 86 mm (3.38 in.)
mounting bolts that attach the calipers to the steer bore
ing knuckles. The three different size calipers are not inter
changeable. Use the specified caliper or compo
Caliper Sizes And Application
nents when replacement is necessary. Do not
Two different caliper styles and three different cal intermix calipers, or components.
iper bore sizes are used on BR models (Figs. 1, 2 and
3). The caliper styles are similar i n appearance. The Brakeshoe Types And Wear Tabs
main difference between them being physical size The outboard brakeshoes on all BR models have
and caliper mounting bolt bushing type. wear tabs. The metal tabs are attached to the trail
ing end of each outboard brakeshoe (Figs. 1, 2 and 3).
The tabs contact the rotor surface when lining mate
rial has worn to a thickness of approximately 5 to 6
mm (3/16 to 1/4 in.). The resulting noise alerts the
driver that brakeshoe replacement is necessary.
The brakeshoes on 1/2 ton models are different
from those on 3/4 and 1 ton models. Do not intermix
the shoes for any reason.
Caliper Mounting
The calipers are attached directly to the steering
knuckles. Separate mounting brackets are not re
quired. Caliper mounting arms are built right into
the knuckle (Fig. 4).
The caliper mounting bolts are encased within steel
collars. The collars are permanently attached to the
bolts and cannot be serviced separately.
CALIPER OPERATION AND WEAR COMPENSATION
Caliper Operation
The significant feature of single piston caliper op
eration is that the calipers are free to slide laterally
Fig. 1 75mm Disc Brake Caliper (1/2 Ton) on the mounting bolts. I t is the freedom of lateral
Caliper piston bore sizes are: movement that allows continuous compensation for
lining wear.
Fig. 2 80mm Disc Brake Caliper (3/4 Ton) Fig. 4 Caliper Mounting (In Steering Knuckle)
the same as pressure on the piston. I n other words,
pressure against piston and caliper bore will be
equal.
Fluid pressure applied to the piston is transmitted
directly to the inboard brakeshoe. This forces the
shoe lining against the inner surface of the disc
brake rotor (Fig. 5).
At the same time, fluid pressure within the piston
bore, forces the caliper to slide inward on the mount
ing bolts. This action brings the outboard brakeshoe
lining into contact with the outer surface of the disc
brake rotor (Fig. 5).
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp
ing action. When sufficient force is applied, friction
will stop the rotors from turning and bring the vehi
cle to a stop.
Brakeshoe Wear Compensation

Application and release of the brake pedal gener
ates only a very slight movement of the caliper and
Fig. 3 86mm Disc Brake Caliper (1 Ton) piston. Upon release of the pedal, the caliper and pis
ton return to a rest position. The brakeshoes do not
A simplified cross section of a single piston caliper retract an appreciable distance from the rotor. I n
is shown i n Figure 1. The illustration graphically fact, clearance is usually at, or close to zero. The rea
portrays the forces at work when the brakes are ap sons for this are to keep road debris from getting be
plied. tween the rotor and lining and i n wiping the rotor
Upon brake application, fluid pressure exerted surface clear each revolution.
against the caliper piston increases greatly. Of equal The caliper piston seal controls the amount of pis
importance, is the fact that this fluid pressure is ex ton extension needed to compensate for normal lining
erted equally and i n all directions. What this means, wear.
is that pressure i n the caliper bore, will be exactly During brake application, the seal is deflected out
ward by fluid pressure and piston movement (Fig. 6).
• DISC BRAKES 5 - 47
INBOARD
CALIPER BRAKESHOE
PISTON
CALIPER
PISTON
PRY
TOOL
PISTON
BORE
J9405-47
Fig. 7 Pressing Caliper Piston Back Into Bore
OUTBOARD INBOARD SEAL

SHOE SHOE
J9405-102
Fig. 5 Disc Brake Caliper Operation

When the brakes and fluid pressure are released, the
seal relaxes and retracts the piston.
The amount of piston retraction is determined by
brakelining wear. Generally, the amount is just
enough to maintain contact between the piston and
inboard brakeshoe. I n addition, running clearance at
the rotor will be held between zero and a maximum
of 0.12 mm (0.005 in.). J9405-27
PISTON, CALIPER
CYLINDER BORE Fig. 8 Caliper Mounting Bolt Removal/Installation
HOUSING
PISTON SEAL
(1/2 Ton)
BRAKE
PRESSURE
ON
> DUST BOOT PR747B
Fig. 6 Lining Wear Compensation By Piston Seal
DISC BRAKESHOE REMOVAL

(1) Raise vehicle.
(2) Remove wheel and tire assemblies.
(3) Press caliper piston back into bore with large
flat blade screwdriver (Fig. 7). Use large C-clamp to J9405-48
bottom piston in bore i f additional force is required.
(4) Remove caliper mounting bolts with 3/8 hex Fig. 9 Caliper Mounting Bolt Removal/Installation
wrench or socket (Figs. 8 and 9). (3/4 and 1 Ton)
(5) Rotate caliper rearward off rotor and out of in caliper piston. Tilt this shoe out at top to unseat
steering knuckle support ledges (Fig. 10).
(6) Remove inboard and outboard brakeshoes (Figs.
11 and 12). Inboard shoe has spring clip that holds i t
Fig. 12 Outboard Brakeshoe Removal
J9405-28
Fig. 10 Caliper Removal/Installation

clip. Outboard shoe has retaining spring that secures
i t i n caliper. Unseat one spring end and rotate shoe
out of caliper.
INBOARD
Fig. 13 Supporting 2-Wheel Drive Caliper

DISC BRAKESHOE AND CALIPER INSPECTION
Inspect the brakeshoe lining for wear. Replace riv
eted lining i f worn to within 1.5 mm (1/16 in.) of
rivet heads. Replace bonded lining i f thickness is 3
mm (3/16 in.) or less.
I f the brakeshoes will be reused, do not intermix
J9405-49 them. Keep the brakeshoes with the caliper they
were removed from.
Fig. 11 Inboard Brakeshoe Removal Examine the caliper piston area for evidence of
(7) Secure caliper to convenient chassis or suspen leaks. Also check condition of the piston boot. Over
sion component with wire (Figs. 13 and 14). haul the caliper i f leakage is evident or the boot is
cut or torn.
CAUTION: Do not allow the brake hose to support Inspect condition of the caliper and steering
the caliper. Suspending the caliper by the brake knuckle arm slide surfaces (Fig. 15). Remove rust
hose can damage the hose and fitting joints. Use and corrosion from the these surfaces with a wire
wire to support and secure the caliper to a chassis brush. Then lubricate the surfaces with Mopar multi-
or suspension component. mileage grease, or equivalent.
DISC BRAKESHOE INSTALLATION

(1) Clean caliper and steering knuckle slide sur
faces with wire brush (Fig. 15). Then apply coat of
Mopar multi-mileage grease to slide surfaces.
• DISC BRAKES § - 4S
APPLY SILICONE
GREASE WHERE
INDICATED
BUSHINGS
J9405-32
Fig. 14 Supporting 4-Wheel Drive Caliper Fig. 16 Mounting Bolt Lubrication (75mm Caliper)
APPLY SILICONE GREASE MOUNTING

WHERE INDICATED BOLT
Fig. 15 Caliper And Steering Knuckle Slide Surfaces

(2) Lubricate caliper mounting bolts, collars, bush CALIPER
ings and bores with Dow 111, or GE 661 silicone
grease as follows: J9405-33
(a) On 1/2 ton models with 75 mm caliper, apply
silicone grease to mounting pins and collars. Then Fig. 17 Mounting Bolt Lubrication (80 or 86mm
fill space between bushings i n caliper as shown Caliper)
(Fig. 16). (5) Install caliper over rotor and into steering
(b) On 3/4 and 1 ton models with 80 or 86 mm knuckle mounting arms. Be sure caliper is seated
calipers, coat mounting pin and interior of bushing flush o n m o u n t i n g a r m surfaces as shown (Fig.
with silicone grease as shown (Fig. 17). 20).
(3) Install inboard brakeshoe i n caliper. Be sure (6) Start caliper mounting bolts by hand to avoid
spring clip on shoe is properly aligned and seated i n cross threading. Then tighten mounting bolts to 51
caliper piston (Fig. 18 and 19). N-m (38 ft.lbs.) torque.
(4) Install outboard brakeshoe i n caliper. Be sure (7) Install wheel and tire assemblies.
spring ends are seated i n dimples i n caliper (Fig. 19). (8) Lower vehicle and tighten wheel lug nuts to fol
lowing torque:
i - §0 DISC BRAKES •
Fig. 20 Caliper Installation

(5) Remove caliper mounting bolts with 3/8 hex
wrench or socket (Figs. 8 and 9).
(6) Rotate caliper rearward off rotor and out of
steering knuckle support ledges (Fig. 10).
(7) Remove front brake hose fitting bolt completely
and remove caliper and brakeshoes as assembly.
(8) Cover open end of front brake hose fitting to
prevent dirt entry.
DISC BRAKE CALIPER DISASSEMBLY

(1) Drain brake fluid from caliper.
(2) Remove brakeshoes from caliper.
(3) Pad interior of caliper with minimum, one-inch
thickness of shop towels (Fig. 21). Towels will cush
ion and protect caliper piston during removal.
(4) Remove caliper piston with several short
bursts of low pressure compressed air. Direct air
through fluid inlet port to ease piston out of bore
(Fig. 21).
CAUTION: Do not blow the piston out of the bore

Fig. 19 Correct Brakeshoe Position in Caliper with sustained high pressure. This practice will re
sult in a chipped, or cracked piston. In addition,
• 108-150 N-m (80-110 ft. lbs.) on 5 stud wheel N E V E R attempt to catch the piston a s it exits the
• 163-203 N-m (120-150 ft. lbs.) on 8 stud single wheel bore. This will result in personal injury.
(9) Pump brake pedal to reseat caliper pistons and
brakeshoes. Do not move vehicle u n t i l shoes (5) Remove piston dust boot with a suitable pry
have been p r o p e r l y seated. tool (Fig. 22). Discard dust boot as i t is not reusable.
(10) Check brake fluid level and add fluid i f neces Do not scratch piston bore while removing
sary. boot.
(6) Remove seal from caliper piston (Figs. 23 and
DISC BRAKE CALIPER REMOWAL 24). Discard seal as i t is not reusable.
(1) Raise and support vehicle. (7) Remove mounting bolts from calipers and in
(2) Remove wheel and tire assemblies. spect seals, boots, and bushings (Figs. 23 and 24).
(3) Press caliper piston back into bore with large Remove these components only i f cut, worn, or dam
flat blade screwdriver (Fig. 7). Use large C-clamp i f aged.
more force is required to bottom piston i n bore. (8) Remove caliper bleed screw (Figs. 23 and 24).
(4) Loosen bolt that secures front brake hose fit
ting bolt i n caliper.
SHOP TOWELS
(1-INCH THICKNESS)
DUST
FLUID WOT
INLET
J9405-38 J94Q5-39
Fig. 21 Caliper Piston Remowal Fig. 22 Dust Boot Remowal

DISC BRAKE CALIPER CLEANING AND polished by hand but only with crocus cloth. Do NOT
INSPECTION use any other type of abrasive material for polishing.
Clean the caliper and piston with Mopar brake Check condition of the caliper piston carefully. The
cleaner, clean brake fluid, or denatured alcohol. Do piston must be free of corrosion, rust, pitting, or scor
not use any other cleaning agents. ing, replace the piston i f i t exhibits any of these con
Inspect condition of the caliper piston bore. A fiber ditions. Do NOT use any kind of abrasive material to
brush can be used to clean the bore i f necessary. The restore surface finish of the piston. Abrasives will
bore should be free of corrosion, pitting, or scoring. damage, or destroy the coating applied to the piston
Discoloration of the bore is a normal condition and during manufacture.
not cause for replacement. The bore can be lightly
• BOOTS
BUSHINGS
SEALS
INBOARD
BRAKESHOE
MOUNTING
BOLTS
OUTBOARD
BRAKESHOE
BLEED
SCREW
CALIPER
PISTON
DUST
BOOT
J9405-36
Fig. 23 Caliper Components (75mm Caliper)

J9405-37
Fig. 24 Caliper Compc (80/86mm Caliper)

CAUTION: Never hone the caliper piston bore, or
use any kind of abrasive material on the piston sur
face. Honing will result in an oversize bore and
abrasives will damage the piston coating. Either of
these practices will result in piston bind and even
tual seizure.
. Inspect condition of the threads i n the inlet and

bleed screw ports. Replace the caliper i f thread dam
age is evident. Do not attempt to salvage the threads.
Check the bushings i n the caliper mounting bolt
bores. Replace the bushings i f worn, cut, or torn.
Bushing condition is important as they keep road
dirt and water from the mounting bolts.
DISC BRAKE CALIPER OVERHAUL AND

REASSEMBLY
(1) Be sure caliper assembly area of workbench is
clean and dry. This is important as dust, dirt, foreign
material, oil, or solvents can damage seals, harm pis
ton surfaces and contaminate fluid.
(2) Lubricate caliper piston, piston seal and piston
bore with liberal quantity of clean, fresh brake fluid.
(3) Install new dust boot on piston as follows:
(a) Lightly lubricate lip of new boot with Dow or
GE silicone grease. Then work boot lip into boot
groove at top of piston (Fig. 25).
(b) Stretch boot rearward as shown to straighten Fig. 25 Installing Dust Boot On Caliper Piston
boot folds. Then move boot forward until folds snap (5) Install caliper piston. Apply more brake fluid to
into place (Fig. 25). piston, seal and bore. Then work caliper piston into
(4) Install new seal on piston. Slide seal onto pis
ton and seat in groove. Be sure square cut seal is
fully seated and is not twisted.
bore. Once piston seal is properly started, press pis
ton 3/4 of way to bottom of bore by hand or with INBOARD
hammer handle. SPRING BRAKESHOE
CUP
(6) Seat dust boot in caliper with appropriate in (IN PISTON)
staller tool (Fig. 26).
• use Installer Tool 6753 on 75mm (1/2 ton) caliper
• use Installer Tool 6754 on 80 mm (3/4 ton) caliper
• use Installer Tool 6755 on 86mm (1 ton) caliper
J9405-42
Fig. 27 Inboard Brakeshoe Installation
OUTBOARD
SHOE BRAKESHOE
RETAINING
SPRING
J94Q5-41
Fig. 26 Seating Dust Boot In Caliper

(7) Finish pressing caliper piston to bottom of bore J9405-43
after dust boot is seated.

Fig. 28 Outboard Brakeshoe Installation
(8) Lubricate caliper mounting bolts, collars, bush
ings and bores with Dow 111, or GE 661 silicone (3) Start caliper mounting bolts by hand to avoid
grease (Figs. 16 and 17). cross threading. Then tighten mounting bolts to 51
(9) Install bushings, seals, boots and mounting N-m (38 ft.lbs.) torque.
bolts i n caliper (Figs. 23 and 24). (4) Connect brake hose to caliper (Figs. 29 and 30).
(10) Install but do not fully tighten caliper bleed Be sure brake hose fitting is correctly seated
screw. against locating shoulder on caliper before
(11) Install inboard brakeshoe i n caliper. Be sure tightening fitting bolt.
brakeshoe spring clip is centered and seated i n cali
per piston (Fig. 27). CAUTION: B e very sure the front brake hose is not
(12) Install outboard brakeshoe i n caliper (Fig. 28). twisted, or kinked. Also be sure the hose is cor
Align shoe and retaining spring in caliper. Then push rectly routed and clear of adjacent c h a s s i s and s u s
shoe downward into place. Be sure spring ends are pension components. This is important a s hose
correctly seated i n caliper dimples. damage will result if it is twisted or incorrectly
routed.
DISC BRAKE CALIPER INSTALLATION
(5) Fill and bleed brake system. Refer to procedure
(1) Clean caliper and steering knuckle slide sur
in appropriate antilock brake section.
faces with wire brush (Fig. 16). Then apply coat of
(6) Install wheel and tire assemblies and lower ve
Mopar multi-mileage grease, or Dow/GE silicone
hicle.
grease to slide surfaces.
(2) Install caliper over rotor and seat i t on steering
knuckle mounting arms.
5 - 54 DISC BRAKES •
• machining would cause rotor thickness to fall be
low minimum thickness requirements
CHECKING ROTOR MINIMUM THICKNESS

Measure rotor thickness at the center of the brake-
shoe contact surface. Replace the rotor i f i t is worn
below minimum thickness, or i f refinishing would re
duce thickness below the allowable minimum. Rotor
minimum thickness is usually specified on the rotor
hub, or on the outer edge of the rotor ventilated sur
face.
ROTOR THICKNESS VARIATION

Variations i n rotor thickness will cause pedal pul
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
Fig. 29 Front Brake Hose Attachment the rotor face (Fig. 31). Position the micrometer ap
proximately 25.4 mm (1 in.) from the rotor outer cir
CONTROL
cumference for each measurement.
Thickness should not vary by more than 0.025 mm
(0.001 in.) from point-to-point on the rotor. Refinish
or replace the rotor i f necessary.
FRONT HOSE
A N D TUBE
ASSEMBLY J9405-51
Fig. 30 Front Brake Hose Routing (4-Wheel Drive)

DISC BRAKE ROTOR INSPECTION AND SERVICE
Rotor Condition
Rotor condition and tolerances can be checked with
the rotor mounted i n a brake lathe, or on the axle. I f
the rotor is checked on the axle, be sure wheel bear
ing end play is reduced to zero before measuring lat
eral runout.
The rotor braking surfaces should not be machined
unless actually necessary. Light surface rust and
scale can be removed i n a lathe equipped with dual
sanding discs.
Fig. 31 Measuring Rotor Thickness Variation
Worn, or scored rotor surfaces can be restored by
machining i n a disc brake lathe but only i f surface Checking Rotor Lateral Runout
scoring and wear are light. Check rotor lateral runout i f pedal pulsation or an
The rotor should be replaced if: occasional low pedal condition was experienced. Ex
• severely scored cessive lateral runout will cause pedal pulsation and
• tapered rapid, uneven wear of the brakeshoes. Measure
• has hard spots runout with a dial indicator (Fig. 32).
• cracked Check runout with Dial Indicator C-3339 (Fig. 32).
• warped Position the indicator plunger at least 25.4 mm (1
• too thin in.) inward from the outer edge of the rotor. On
2-wheel d r i v e models, be sure wheel bearing
end play is reduced to zero before checking
runout.
Maximum allowable lateral runout is 0.127 mm
(0.005 in.).
INDICATOR I „M Z Q
J8905-68
Fig. 32 Measuring Rotor Lateral Runout

ROTOR REFINISHING
Rotor braking surfaces can be refinished by sand
ing and/or machining i n a disc brake lathe (Fig. 33).
The lathe must be capable of machining both rotor
surfaces simultaneously with dual cutter heads.
Equipment capable of machining only one side at a
time will produce a tapered rotor.
The lathe should also be equipped with a grinder
attachment or dual sanding discs for final cleanup or
light refinishing.
I f the rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive discs to clean up
the rotor surfaces. However, when a rotor is scored or
worn, machining with cutting tools will be required.
CAUTION: Do not refinish a rotor if machining

would c a u s e the rotor to fall below minimum allow
able thickness. J8905-70
The recommended final finish on a rotor braking Fig. 33 Rotor Refinishing Equipment
surface is shown i n Figure 34. The final finish should
be a non-directional, cross hatch pattern. Sanding (5) Remove caliper from rotor. Position caliper on
steering knuckle and secure i t with wire (Figs. 13
discs are required to produce this type of finish.
and 14).
DISC BRAKE ROTOR REMOVAL (2-WHEEL CAUTION: Do not allow the brake hose to support
DRIVE) the caliper. Suspending the caliper by the brake
(1) Raise vehicle. hose can damage the hose and fitting joints. U s e
(2) Remove wheel and tire assembly. wire to support and secure the caliper to a s u s p e n
(3) Bottom caliper piston in bore. Use screwdriver sion component a s shown (Figs. 13 and 1 4 ) .
or large C-clamp to press piston back to bottom of
caliper bore (Fig. 7).
(4) Remove caliper mounting bolts (Figs. 8 and 9).
FINAL FINISH SHOULD BE
NON-DIRECTIONAL SPLASH
CROSSHATCH PATTERN SHIELD
GREASE
SEAL
INNER
BEARING
A N D RACE
ROTOR
OUTER
BEARING
A N D RACE
COTTER
PIN
A N D NUT
WASHER
CAP
J8905-71
J9405-178
Fig. 34 Recommended Rotor Surface Finish
Fig. 35 Rotor And Hub Assembly (2-Wheel Drive)
(6) Remove grease cap from hub. On 1 ton models,
ABS SENSOR
use long pry tool with angled end to remove grease FRONT WIRE
cap. Pry against flats at each side of cap to loosen SENSOR
STEERING
and remove it. KNUCKLE
(7) Remove cotter pin from spindle and wheel bear
ing adjusting nut (Fig. 35).
(8) Remove locknut from wheel bearing adjusting
nut. Then remove tabbed thrust washer and outer
wheel bearing (Fig. 35).
(9) Remove rotor and hub assembly from spindle.
(10) Inspect wheel bearings and interior of hub. I f
bearings need repacking, remove grease seal and in
ner wheel bearing from rotor hub.
(11) On 2-wheel drive models with ABS brakes, SENSOR
BOLTS
also check condition of front sensor tone wheel lo (21-25 N - m /
cated i n rotor hub (Fig. 36). Entire rotor and hub 1 9 - 2 5 0 in. lbs.)
assembly will have to be replaced if tone wheel
is damaged. The tone wheel is not available as SPLASH
a separate part. SHIELD
DISC BRAKE ROTOR INSTALLATION (2-WHEEL J9405-177
DRIVE 10DELS)
Fig. 36 Front Sensor Tone Wheel Location (2-Wheel
(1) Repack wheel bearings, i f necessary, with Mo Drive Models With ABS Brakes)
par high temperature bearing grease. Apply grease to
bearing races as well. Then install inner bearing i n (5) Install disc brake caliper and tighten caliper
hub and install new grease seal. mounting bolts to 51 N-m (38 ft. lbs.) torque. Do not
(2) Apply liberal coat of bearing grease to spindle, seat caliper pistons at this time. Pistons must
interior of rotor hub, grease seal lip and seal surface not be seated until after wheel bearing adjust
of spindle. ment has been completed.
(3) Install rotor and hub assembly on spindle. (6) Install wheel and tire assembly. Tighten wheel
(4) Install outer wheel bearing, tabbed thrust nuts snug but not to final torque at this time.
washer and bearing adjusting nut. Tighten nut only (7) Adjust wheel bearings. Refer to procedure i n
enough to remove end play at this time. this section.
(8) Lower vehicle and tighten wheel lug nuts to fol
lowing torque:
• 108-150 N-m (80-110 ft. lbs.) on 5 stud wheel
(9) Install grease cap and wheel cover/hub cap.
WHEEL BEARING ADJUSTMENT (2-WHEEL DRIVE

MODELS)
(1) Raise vehicle front end.
(2) Remove front wheel covers/hub caps.
(3) Remove grease caps.
(4) Remove cotter pin and nut lock.
(5) Rotate wheel and fully tighten bearing adjust
ing nut to seat bearings.
(6) Loosen and tighten bearing adjusting nut once
again while rotating wheel.
(7) Continue rotating wheel and back off adjusting Fig. 37 Adaptor Hub Removal/Installation (1 Ton
nut until wheel end play is 0.0254 to 0.0508 mm Models)
(0.001 to 0.002 in.).
(8) Install nut lock on adjusting nut and install
new cotter pin. Adjusting nut can be tightened
slightly to align cotter pin holes i f necessary. Verify
that wheel bearing adjustment is still OK. Readjust
i f needed.
(9) Lower vehicle and tighten wheel lug nuts to fol
lowing torque:
(10) Install wheel covers/hub caps.
DISC BRAKE ROTOR REMOVAL (4-WHEEL DRIVE) Fig. 38 Hub Nut Cotter Pin Removal
(1) Raise vehicle.
(2) Remove wheel and tire assembly.
(3) Bottom caliper piston i n bore. Use screwdriver
or large C-clamp to press piston back to bottom of
caliper bore (Fig. 7).
(4) Remove caliper mounting bolts (Figs. 8 and 9).
(5) Remove caliper from rotor. Position caliper on
steering knuckle and secure i t i n place with wire. Or
suspend caliper from adjacent chassis or suspension
component with wire (Figs. 13 and 14).
CAUTION: Do not allow the brake hose to support

the caliper. Suspending the caliper by the hose c a n
damage the hose and fitting joints. U s e wire to s u p
port and secure the caliper to a suspension compo
nent a s shown (Figs. 13 and 14).
Fig. 39 Hub Nut Removal/Installation
(6) On 1 ton models, remove adapter hub from ro
tor hub (Fig. 37). (10) Remove rotor and hub assembly. Turn assem
(7) Remove cotter pin from rotor hub nut (Fig. 38). bly over and check unit bearing and seal (Fig. 41).
(8) Remove rotor hub nut (Fig. 39). An appropriate Replace seal i f necessary. Replace bearing assembly i f
size, 3/4 in. drive socket and ratchet wrench will be damaged.
required for removal (a six point, 1-3/4 in. socket will (11) Remove hub spacer from steering knuckle
remove the nut). (Fig. 42). Note spacer position for installation refer
(9) Remove bolts that secure rotor and hub to ence.
steering knuckle. Bolts are accessible from inboard
(back) side of steering knuckle (Fig. 40).
DISC BRAKE ROTOR INSTALLATION (4-WHEEL
DRIVE)
(1) Apply liberal quantity of Mopar, or Permatex
anti-seize compound to splines of front drive shaft
(Fig. 43).
(2) Replace grease seal i n wheel bearing assembly
if old one is damaged (Fig. 43). Install new wheel
bearing assembly i f necessary, before proceeding. Re
fer to procedure i n this section.
(3) Insert two rearmost, top and bottom rotor hub
bolts i n steering knuckle. Insert bolts through back
side of knuckle so they extend out front face as
shown (Fig. 43).
(4) Position hub spacer on bolts just installed i n
knuckle. Be sure flat on spacer is positioned toward
Fig. 40 Rotor And Hub Attaching Bolt Location rear (Fig. 43). Use chassis grease to hold spacer i n
place on knuckle.
Fig. 41 Rotor Hub And Unit Wheel Bearing

Assembly Fig. 43 Hub Spacer Positioning And Installation
(5) Apply 1-2 drops of Mopar Lock W Seal, or Loc-
tite 242 to threads of rotor and hub retaining bolts.
(6) Align rotor hub with drive shaft. Then start
shaft into rotor hub splines.
(7) Align bolt holes i n unit bearing flange with
bolts previously installed i n knuckle. Then thread
bolts into bearing flange far enough to hold assembly
in place.
(8) Install remaining rotor retaining bolts. Tighten
all bolts securely
(9) Install washer and hub nut. Tighten nut se
curely.
(10) Install new cotter pin i n hub nut. Tighten nut
as needed to align cotter pin hole i n shaft with open
ing i n nut.
Fig. 42 Hub Spacer Remowal (11) Install disc brake caliper. Tighten caliper
mounting bolts to 51 N-m (38 ft. lbs.) torque.
(12) Install wheel and tire assemblies and lower
vehicle.
(13) Tighten wheel lug nuts to following torque:
• 163-203 N-m (120-150 ft. lbs.) on 8 stud single The correct tightening sequence is important i n
wheel avoiding rotor and drum distortion. The correct se
(14) Apply brakes several times to reseat brake- quence is i n a diagonal crossing pattern as shown
shoes and caliper piston. Do not move vehicle until (Figs 45 and 46).
firm brake pedal is obtained. Seat the wheel and install the wheel nuts finger
tight. Tighten the nuts in recommended sequence to
WHEEL BEARING REPLACEMENT 1/2 required torque. Then repeat the tightening se
quence to final specified torque.
On models with tapered roller style front wheel
Wheel lug nut torques are:
bearings, the bearings and races can be serviced sep • 108-150 N-m (80-110 ft. lbs.) on 5 stud wheel
arately when necessary. • 163-203 N-m (120-150 ft. lbs.) on 8 stud single
The bearing races do not require special tools for wheel
removal. Either race can be removed with a long ta • 176-217 N-m (130-160 ft. lbs.) on 8 stud dual
pered brass drift punch. wheels
On models with unit style wheel bearings (Fig. 41),
the rotor, hub and bearing assembly are all pressed
together. However, i t is only necessary to drive out
the wheel studs with a copper mallet, i n order to sep
arate the rotor, bearing and hub for replacement pur
poses (Fig. 44).
Fig. 45 Wheel Nut Tightening Sequence (5 Stud

Wheel)
Fig. 44 Front Wheel Stud Removal (With Unit Style

Bearing)
WHEEL NUT TIGHTENING

The wheel attaching nuts should be properly tight
ened to ensure efficient brake operation. Overtighten
ing the nuts or tightening them i n the wrong
sequence could cause distortion of the brake rotors
and drums.
Impact wrenches are not the best tools for tighten
ing wheel nuts. A torque wrench should be used for
this purpose at all times.
Fig. 46 Wheel Nut Tightening Sequence (8 Stud
Wheel)
S - 60 DRUM BRAKES •
DRUM B R A K E S
INDEX
page page
Brake Drum Service 69 Drum Brake Adjustment . 67
Brake Support Plate Installation 69 Drum Brake Operation 60
Brake Support Plate Removal 68 General Service Information 60
Brakelining Wear Compensation 60 Wheel Cylinder Installation (All) 67
Brakeshoe Installation (11-Inch Brake) 61 Wheel Cylinder Overhaul (All) 65
Brakeshoe Installation (13-Inch Brake) . . . . . . . . . . 63 Wheel Cylinder Removal (All) 65
Brakeshoe Removal (13-Inch Brake) 62 Wheel Nut Tightening 69
Brakeshoe Removal (11-Inch Brake) 60
GENERAL SERVICE INFORMATION ates the wedging (or w r a p ) effect w h i c h produces

A l l B R models are equipped w i t h Delco rear d r u m increased force on the d r u m b r a k i n g surface.
brake assemblies. They are two-shoe, duo-servo u n i t s
w i t h a n automatic adjuster mechanism. BRAKELINING WEAR COMPENSATION
Three d r u m brake assemblies are used, w h i c h are: A l l d r u m brake assemblies used on B R models are
• 1/2 t o n models are equipped w i t h 11 x 2 i n . d r u m equipped w i t h a self adjusting mechanism. The com
brakes ponents f o r m i n g the mechanism consist of the: ad
• 3/4 t o n models are equipped w i t h 13 x 2.5 i n . d r u m j u s t e r screw, adjuster lever, actuating lever (11 i n c h
brakes brake), lever r e t u r n spring and the adjuster lever
• 1 t o n models are equipped w i t h 13 x 3.5 i n . d r u m spring. The adjuster lever on the 13 i n c h brake, is
brakes also equipped w i t h a lever and tension spring.
Two different wheel cylinders are used. The differ The adjuster mechanism performs t w o i m p o r t a n t
ence being cylinder bore size. The cylinders used on functions. F i r s t , is i n m a i n t a i n i n g proper brakeshoe
1/2 and 3/4 t o n models have a bore diameter of 23.8 operating clearance. A n d second, is to m a i n t a i n brake
m m (0.937 or 15/16 in.). The cylinders used on 1 t o n pedal height. The mechanism does so, by adjusting
models have a bore diameter of 27 m m (1.06 or t h e shoes i n s m a l l increments to compensate for l i n
1-1/16 in.). i n g wear. The adjustment process is continuous
t h r o u g h o u t t h e useful life of the b r a k e l i n i n g .
DRUM BRAKE OPERATION The adjuster components are a l l connected to the
D r u m brakes on B R models are a semi-floating, secondary brakeshoes. A c t u a l adjustment only occurs
self-energizing, servo action design. The brakeshoes d u r i n g reverse brake stops. Secondary brakeshoe
are not fixed on the support plate. This type of brake movement ( d u r i n g reverse stops), is w h a t activates
allows the shoes to pivot and move vertically to a cer the adjuster components.
t a i n extent. I n operation, secondary shoe movement causes the
I n operation, fluid apply pressure causes the wheel adjuster lever spring to exert p u l l on the lever. This
cylinder pistons to move o u t w a r d . T h i s movement is pivots the lever away from the adjuster screw teeth.
transferred directly to the brakeshoes by the cylinder W h e n the stop is completed and the brakes released,
connecting l i n k s . The r e s u l t i n g brakeshoe expansion t h e adjuster lever pivots back to a n o r m a l position. I t
brings t h e l i n i n g m a t e r i a l i n t o contact w i t h t h e rotat is d u r i n g t h i s r e t u r n movement of the lever w h e n ad
i n g brake d r u m . j u s t m e n t occurs. A t t h i s point, t h e lever comes back
U p o n contacting the d r u m , t w o forces now effect i n t o contact w i t h the adjuster screw teeth as i t moves
the brakeshoes. The f i r s t force being h y d r a u l i c pres u p w a r d . The lever w i l l t h e n rotate the adjuster screw
sure exerted t h r o u g h the wheel cylinder pistons. A n d one or two teeth as needed for adjustment.
t h e second force is the f r i c t i o n generated, t u r n i n g The adjustment process requires a complete
torque of the r o t a t i n g d r u m . stop to actually occur. Rolling stops will NOT
The d r u m forces b o t h brakeshoes to move i n t h e activate the adjuster components. In addition,
same direction of r o t a t i o n . Servo action begins w i t h the adjuster screws are left and right hand
the p r i m a r y brakeshoe w h i c h begins to wedge (or parts and must NOT be interchanged.
w r a p ) itself against the r o t a t i n g d r u m surface. T h i s
force is t r a n s m i t t e d equally to the secondary brake- BRAKESHOE REMOVAL (11-INCH BRAKE)
shoe t h r o u g h the adjuster screw a n d anchor p i n . The (1) Raise vehicle.
net result is t h a t each shoe helps t h e other exert ex (2) Remove rear wheels.
t r a force against the d r u m . I t is servo action t h a t cre- (3) Remove brake drums.
(4) Remove p r i m a r y (front) brakeshoe return
spring (Fig. 1). Use brake spring pliers to unseat and BRAKESHOE INSTALLATION (11-INCH BRAKE)
remove spring from anchor pin. (1) Clean support plate with Mopar brake cleaner.
Then smooth shoe contact pads with wire brush or
emery cloth.
(2) Apply coat of Mopar multi-mileage, or high
temp bearing grease to each shoe contact pad on sup
port plate (Fig. 3).
Lubricate adjuster levers and anchor pin and
shoe contact surfaces on support plate with Mopar
multi-mileage grease, or high temp bearing grease.
(3) Clean and check operation of adjuster screw as
semblies. Make sure each screw assembly rotates
freely. Lubricate screw threads with Mopar spray
lube. Replace either assembly i f threads are heavily
rusted, corroded, or damaged.
(4) Attach park brake lever to secondary brakeshoe
(Fig. 2). use new U-clip to secure lever to shoe. I f U-
clip is used to secure shoe, pinch clip together with
channel lock pliers to secure it. I f E-clip is used, be
sure clip is fully seated i n notch.
(5) Attach park brake cable to lever.
(6) Position adjuster lever on secondary brakeshoe
ASSEMBLY J9405-16 (Fig. 4). Then install spring retainer with shoulder
on i n lever and into shoe.
Fig. 1 Brakeshoe Mounting And Spring Attachment (7) Position secondary brakeshoe on support plate.
(11-Inch Brake) Use new holddown spring, pin and retainer to secure
shoe and adjuster lever.
(5) Remove primary shoe holddown spring, pin and (8) Attach shoe spring to secondary brakeshoe.
retainers. Use brake spring tool to rotate retainers Connect long end of spring i n secondary shoe.
and disengage pins. (9) Engage parking brake strut in secondary
(6) Tilt primary brakeshoe outward. Then disen brakeshoe and install oval shaped spring on opposite
gage shoe spring and remove primary brakeshoe. end of strut (spring end of strut goes i n primary
(7) Remove adjuster screw, shoe spring and park shoe).
brake strut and spring. (10) Install primary brakeshoe on support plate.
Use new holddown spring, pin and retainers to se
CAUTION: The adjuster screw assemblies have dif cure shoe. Be sure parking brake strut is seated i n
ferent threads and must be kept separate. The both brakeshoes.
driver side adjuster screw h a s a right hand thread. (11) Install actuator lever and spring. Hook actua
And the passenger side adjuster screw h a s a left tor lever under adjuster lever as shown (Fig. 4).
hand thread. Do not interchange them a s the brake Large diameter end of spring goes on shoe and small
s h o e s will not adjust properly. end on lever.
(12) Install adjuster screw assembly. Be sure star
(8) Remove secondary brakeshoe holddown spring, wheel is positioned adjacent to adjuster lever and
pin and retainers (Fig. 1). that notches i n buttons are properly seated on brake-
(9) Pull adjuster lever and retainer out of second shoes.
ary brakeshoe. Then rotate brakeshoe out and up
and remove adjuster spring and secondary shoe re CAUTION: B e sure the adjuster s c r e w s were not in
turn spring. termixed and are installed on the correct side. The
(10) Disconnect park brake cable from lever on sec driver side adjuster screw h a s right hand threads
ondary brakeshoe. Then remove brakeshoe. and the passenger side h a s left hand threads. Also
(11) I f brakeshoes are to be replaced, remove E-clip be sure the short end of the screw is toward the
secondary brakeshoe.
(or U-clip) that attaches park brake lever to second
ary brakeshoe and remove lever. (13) Attach shoe spring to primary brakeshoe.
(12) Inspect wheel cylinder (Fig. 2). I f leakage is (14) Install guide plate on anchor pin.
evident, remove and overhaul cylinder. Refer to over (15) Attach adjuster spring to adjuster lever.
haul procedure i n this section. (16) Install secondary brakeshoe return spring i n
shoe.
CYLINDER SUPPORT PARK
SCREWS PLATE BRAKE
LEVER
HOLDDOWN
PINS
LINK
SECONDARY SHOE
RETURN
PRIMARY SPRING
(FRONT)
BRAKESHOE
PRIMARY S H O E
ADJUSTER HOLDDOWN , RETURN S P R I N G
SCREW SPRING A N D '
FRONT ASSEMBLY RETAINERS J9405-4
Fig. 2 Drum Brake Components (11-Inch Brake)
SUPPORT BRAKESHOE (18) Install primary brakeshoe return spring (Fig.

PLATE CONTACT PAD 4).
LOCATIONS \ (19) Verify that adjuster and return springs are
properly installed (Fig. 5).
(20) Adjust brakeshoes to drum with brake gauge.
(21) Install brake drum and wheel and tire assem
blies.
(22) Lower vehicle.
(23) Tighten wheel lug nuts to 108-150 N-m
(24) Install wheel cover, or hub cap.
BRAKESHOE REMOVAL (13-INCH BRAKE)

(1) Raise vehicle.
(2) Remove rear wheel and tire assemblies.
(3) Remove brake drums.
(4) Remove primary (front) brakeshoe return
spring from anchor pin with brake spring pliers (Fig.
6).
J9405-63
(5) Remove primary brakeshoe holddown spring,
pin and retainers with holddown spring tool (Fig. 7).
Fig. 3 Typical Contact Pad Locations On Support
(6) Disconnect shoe spring and remove primary
Plate
brakeshoe and parking brake lever strut.
(7) Remove adjuster screw assembly (Fig. 8).
(17) Attach secondary shoe return spring to ad (8) Remove secondary brakeshoe holddown spring,
juster spring. Then install adjuster spring on anchor pin and retainers. Then remove adjuster lever, spring
pin (Fig. 4). and spring retainer assembly (Fig. 8). I t is not nec-
• DRUM BRAKES 5 - 63
PRIMARY ADJUSTER LEVER

SHOE SPRING
RETURN (INSTALL FIRST)
Fig. 5 Checking Return/Adjuster Spring Installation
ASSEMBLY LEVER J9405-3
Fig. 6 Return Spring Removal/Installation

Fig. 4 Self Adjuster Component Installation (11 Inch
Brake)
essary to disassemble adjuster lever components un
less they are worn, or damaged.
(9) Disconnect parking brake cable from lever at
tached to secondary brakeshoe (Fig. 8). Then remove
brakeshoe.
(10) I f brakeshoes are to be replaced, remove E-clip
attaching parking brake lever to secondary brake-
shoe and remove lever (Fig. 8).
(11) Inspect wheel cylinder. I f leakage is evident,
remove and overhaul cylinder. Refer to overhaul pro
cedure i n this section.
PRIMARY
BRAKESHOE INSTALLATION (13-INCH BRAKE) SHOE J9405-18
(1) Clean support plate with Mopar brake cleaner. Fig. 7 Holddown Spring, Pin And Retainer Removal/
Then smooth shoe contact pads with wire brush or Installation
emery cloth.
5 - 64 DRUM BRAKES •
PRIMARY SHOE PISTON UNK E-CUP PARKING
PISTON
RETURN SPRING BRAKE
LEVER
ADJUSTER
SPRING
HOLDDOWN
SPRING, PIN,
EXPANDER RETAINER
SPRING
PRIMARY
BRAKESHOE
LEVER
SPRING
ADJUSTER
HOLDDOWN
SPRING, PIN, ADJUSTER SCREW LEVER
RETAINERS ASSEMBLY ASSEMBLY J9405-65
Fig. 8 Drum Brake Coi ents (13-Inch Brake)

(2) Lubricate adjuster levers and anchor pin and (a) Clamp adjuster lever i n vise (Fig. 9). Clamp
shoe contact surfaces on support plate with Mopar center portion of lever i n vise only. Do not
multi-mileage grease, or high temp bearing grease. clamp bottom end of lever in vise. Lever
(3) Clean and check operation of both adjuster flange that rotates adjuster screw star wheel
screw assemblies. Replace either assembly i f threads teeth is at bottom of lever and will be dam
are heavily rusted, corroded, or damaged. Make sure aged.
each screw assembly rotates freely. Then lubricate (b) Position small, hooked spring retainer i n up
adjuster screw threads with Mopar spray lube. per end of lever (Fig. 9). Be sure tang on retainer is
(4) Attach parking brake lever to secondary brake- securely engaged i n hole in lever. Locking pliers
shoe. Use new E-clip to secure lever to shoe. I f lever can be used to hold retainer i n place after position
is secured with U-clip, pinch new clip together with ing.
channel lock pliers to secure i t . (c) Secure retainer i n lever with retainer spring.
(5) Attach parking brake cable to parking brake le Hook spring over end of retainer as shown (Fig.
ver. 10). Needlenose pliers and number 2 Phillips
(6) I f adjuster lever was disassembled, reassemble screwdriver can be used to attach spring to lever
it as follows: and retainer.
ADJUSTER
ADJUSTER
SPRING
LEVER
RETAINER
J9405-68
Fig. 9 Positioning Retainer On Adjuster Lever

(7) Install secondary brakeshoe and adjuster lever
as follows:
(a) Insert secondary shoe holddown pin through
support plate. Fig. 10 Assembling Adjuster Lever, Spring And
(b) Position secondary brakeshoe on support Retainer
plate and insert pin through shoe. (16) Install secondary brakeshoe return spring. At
(c) Position adjuster lever on brakeshoe and in tach short end of spring to brakeshoe. Then hook op
sert holddown spring inner retainer into lever and posite end on adjuster spring (Fig. 8). Use brake
shoe. Inner retainer has shoulder on i t which seats spring pliers, or a long shank screwdriver to engage
in lever and shoe. return spring in adjuster spring.
(d) Install holddown spring over pin and seat i t (17) Install primary brakeshoe return spring.
in inner retainer. Then install and seat holddown (18) Check component installation. Be sure ad
spring outer retainer on pin with holddown spring juster screw, wheel cylinder links and park brake
tool (Fig. 7). strut are all seated i n brakeshoes (Fig. 11).
(8) Install adjuster lever spring between brakeshoe (19) Adjust brakeshoes to drum with brake gauge.
and lever. Be sure spring is seated on lever tang. (20) Install brake drums.
(9) Attach shoe spring to secondary brakeshoe. (21) Install wheel and tire assemblies and lower
Long end of spring goes i n secondary shoe. vehicle.
(10) Install oval shaped spring on park brake strut (22) Tighten wheel lug nuts to following torque:
and engage spring end of strut i n secondary brake- • 163-203 N-m (120-150 ft. lbs.) on 8 stud single
shoe. wheel
(11) Install primary brakeshoe on support plate. • 176-217 N-m (130-160 ft. lbs.) on 8 stud dual wheel
Use new holddown spring, pin and retainers to se (23) Install wheel cover or hub cap.
cure shoe. Be sure parking brake strut is seated i n
both brakeshoes. WHEEL CYLINDER REMOVAL (ALL)
(12) Install adjuster screw assembly. Be sure star (1) Lift adjuster lever away from adjuster screw.
wheel is positioned adjacent to adjuster lever and Then turn screw star wheel until screw is fully re
that notches i n adjuster screw are properly seated on tracted.
brakeshoes. (2) Remove brakeshoe return springs, adjuster
spring and adjuster screw. Move upper ends of brake-
CAUTION: Be sure the adjuster s c r e w s were not in shoes apart to provide removal clearance for wheel
termixed and are installed on the correct side. The cylinder links.
driver side adjuster screw has right hand threads (3) I f brakeline and fitting are rusty, or corroded,
and the passenger side has left hand threads. Also apply liberal quantity of Mopar rust penetrant to line
be sure the short end of the screw is toward the and fitting. This will break corrosion and avoid dam
secondary brakeshoe. aging brakeline during removal.
(4) Disconnect brakeline from wheel cylinder.
(13) Attach shoe spring to primary brakeshoe. Use (5) Remove wheel cylinder attaching screws and
brake spring pliers and long screwdriver to seat remove cylinder from support plate
spring i n shoe.
(14) Install shoe guide plate on anchor pin. WHEEL CYLINDER OVERHAUL (ALL)
(15) Attach adjuster spring to spring retainer at
top of adjuster lever. Then seat spring on anchor pin Wheel Cylinder Disassembly
with brake spring pliers. (1) Pull links out of cylinder boots.
SECONDARY WHEEL
SCREW SHOE
ASSEMBLY SPRING J9405-19
Fig. 11 Brakeshoe Gompon Installation (13 Inch Brake)

(2) Remove piston boots. Use plastic or wood tool threads are damaged i n any way. replace the bleed
to either pry boots out or pull them out with needle- screw if the screw threads are damaged, or the screw
nose pliers. is corroded, or distorted.
(3) Push pistons, cups and expander spring out one Inspect the wheel cylinder pistons. Replace the pis
end of cylinder bore (Fig. 12). tons i f worn, scored, corroded, or pitted. Do not sand
(4) Discard boots, piston cups and expander spring. the pistons i n an attempt to restore the surface and
They are not reusable parts. reuse them. I n most cases, i f the pistons are dam
(5) Remove bleed screw from cylinder. aged, the cylinder bore will also be damaged requir
ing complete replacement.
Wheel Cylinder Cleaning And Inspection The wheel cylinder connecting links can be cleaned
Clean the cylinder, pistons and links with Mopar up with a wire brush i f rusty, or corroded. However,
brake cleaner. Clean the wheel cylinder and support be sure the link notches are i n good condition and
plate mounting surfaces with a wire brush to ensure will seat properly i n the brakeshoes.
proper seating at installation.
Inspect the cylinder bore. The bore should be Wheel Cylinder Assembly
smooth and free of scoring, corrosion, or pitting. (1) Install bleed screw i n cylinder. Finger tighten
Light discoloration of the bore is a normal condition cylinder only at this time.
and does indicate replacement is necessary. Very (2) Coat cylinder bore, pistons and piston cups
slight scratches, or nicks can be polished out by hand with liberal quantity of fresh, clean brake fluid.
with crocus cloth. (3) Cylinder components can be installed two ways.
The cylinder bore can be cleaned out with a fiber Either as an assembly (Fig. 13), or individually. Pro
bristle brush i f necessary. However, D O NOT hone cedures are as follows:
the cylinder bore. Replace the wheel cylinder (a) To install as assembly, assemble pistons, new
as an assembly if the bore surface is corroded, cups and expander spring as shown (Fig. 13). Start
pitted or scored. one piston and cup into bore. Then slide expander
Check condition of the cylinder brakeline and bleed and remaining cup and piston into bore in one mo
screw threads. Replace the wheel cylinder i f the tion.
BLEED
SCREW
Fig. 14 Seating Wheel Cylinder Dust Boots

COMPRESSION
SPRING A N D (2) Apply thin coat of Mopar silicone sealer to
EXPANDERS J9405-6 wheel cylinder mounting surface of support plate
(Fig. 15). Sealer prevents road splash from entering
Fig. 12 Wheel Cylinder Components (Mil) brake drum past cylinder.
(b) To install parts individually, install first pis*
ton cup i n bore. Be sure open end of cup faces bore
interior and flat side of cup faces piston. Install
first piston in bore and seat i t against piston cup.
Then insert expander spring and remaining, re
maining piston cup and piston.
CUPS
Fig. 15 Wheel Cylinder Mounting Surface (On

Support Plate)
(3) Start brakeline in cylinder inlet by hand. Do
not tighten fitting at this time.
PISTONS J9405-69 (4) Mount wheel cylinder on support plate and in
stall cylinder attaching screws. Tighten screws to 20
Fig. 13 Assembling Wheel Cylinder Pistons, Cups N-m (15 ft. lbs.) torque.
And Expander (5) Tighten brakeline fitting to 13 N-m (115 in.
(4) Start piston dust boots i n each end of cylinder lbs.) torque.
bore by hand. Then seat boots i n cylinder with a (6) Install brakeshoe components.
bench vise (Fig. 14). Press boots into place until flush (7) Adjust brakeshoes to drum using brake gauge.
with ends of cylinder. (8) Install brake drum.
(5) Apply light coat of silicone grease, or dielectric (9) Fill and bleed brake system.
(anti-corrosion) grease to wheel cylinder links. Then (10) Install wheel and tire assemblies and lower
insert links into dust boots and seat them against vehicle.
pistons.
DRUM BRAKE ADJUSTMENT
WHEEL CYLINDER INSTALLATION (ALL) The rear drum brakes are equipped with a self-ad
(1) Clean support plate and lubricate shoe contact justing mechanism. Under normal circumstances, the
pads with multi-mileage or silicone grease (Fig. 3). only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
Adjustment can be made with a standard brake BRAKE SHOES
gauge. Adjustment is performed with the complete
brake assembly i n place on the support plate. Proce
dure is as follows:
ADJUSTMENT P R O C E D U R E (WITH B R A K E
GAUGE)
(1) Be sure parking brakes are fully released.
(2) Raise rear of vehicle and remove wheels and
brake drums.
(3) Verify that left and right automatic adjuster le
vers and cables are properly connected.
(4) Insert brake gauge i n drum. Expand gauge un
t i l gauge inner legs contact drum braking surface.
Then lock gauge i n position (Fig. 16).
Fig. 17 Adjusting Brakeshoes To Gauge
BRAKE SUPPORT PLATE REMOVAL
(1) Remove wheel and tire assemblies.
(2) Remove brake drums
(3) Remove axle shaft and retainer. Refer to Group
3 for procedures.
(4) Remove primary brakeshoe for access to park
ing brake cable.
(5) Compress parking brake cable retainer tabs
with a hose clamp (Fig. 18). Then push retainer and
cable through and out of support plate.
Fig. 16 Setting Gauge To Brake Drum Diameter

(5) Reverse gauge and install i t on brakeshoes
(Fig. 17). Position gauge legs at shoe centers as
shown. I f gauge does not fit (too loose/too tight), ad
just shoes.
(6) Pull shoe adjuster screw star wheel away from
adjuster lever.
(7) Turn adjuster screw star wheel (by hand) to ex
pand or retract brakeshoes. Continue adjustment un
t i l gauge outside legs are light drag-fit on shoes (Fig.
(8) Repeat adjustment at opposite brakeshoe as

sembly.
(9) Install brake drums and wheels and lower ve Fig. 18 Compressing Parking Brake Cable Retainer
hicle. Tabs
(10) Make final adjustment as follows: (6) Disconnect brake line at wheel cylinder.
(a) Drive vehicle and make one forward stop fol (7) Remove wheel cylinder and secondary brake-
lowed by one reverse stop. shoe from support plate.
(b) Repeat procedure 8-10 times to operate auto (8) On models with full float rear axle, remove axle
matic adjusters and equalize adjustment. shaft. Then remove hub and bearing assembly.
(c) Bring vehicle to complete standstill at (9) Remove bolts attaching support plate to axle
each stop. Incomplete, rolling stops will not and remove support plate.
activate automatic adjusters.
BRAKE SUPPORT PLATE INSTALLATION
(1) Apply thin bead of Mopar silicone sealer
around wheel cylinder mounting surface. Then trans
fer wheel cylinder to new support plate.
(2) Apply thin bead of Mopar silicone sealer
around axle mounting surface of support plate.
(3) Install support plate on axle flange. Tighten at
taching bolts to 47-68 N-m (35-50 ft. lbs.).
(4) Install parking brake cable i n support plate.
(5) Install axle shaft and retainer.
(6) On models with full float axle, install bearing
hub and axle shaft.
(7) Start brakeline i n wheel cylinder and install
cylinder on support plate. Tighten brakeline fitting
after cylinder installation.
(8) Connect parking brake cable to lever on second
ary shoe and install brakeshoes on support plate.
(9) Adjust brakeshoes to drum with brake gauge.
(10) Install brake drums.
(11) Fill and bleed brake system.
(12) Install wheel and tire assemblies and lower
vehicle.
BRAKE DRUM SERVICE Fig. 19 Typical Location Of Drum Maximum

Diameter
BRAKE DRUM REFINISHING
The brake drums can be resurfaced on a drum Variations i n drum diameter should not exceed
lathe when necessary. Initial machining cuts should 0.076 mm (0.003 in). Drum runout should not exceed
be no more than 0.12 mm (0.005 in.) as heavier feed 0.20 mm (0.008 in.) out of round. Refinish the drum
rates can produce taper and surface variation. Final if runout or variation exceed these values. Replace
finish cuts of 0.025 mm (0.001 in.) are recommended the drum i f refinishing would cause the drum to ex
and will generally provide the best surface finish. ceed maximum allowable diameter.
Be sure the drum is securely mounted i n the lathe
before machining operations. A damper strap should WHEEL NUT TI0HTENING
always be used around the drum to reduce vibration The wheel attaching nuts should be properly tight
and avoid chatter marks. ened to ensure efficient brake operation. Overtighten
ing the nuts or tightening them i n the wrong
BRAKE DRUM REFINISH L I M I T S
sequence could cause distortion of the brake rotors
The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum and drums.
outer edge (Fig. 19). Generally, a drum can be ma Impact wrenches are not the best tools for tighten
chined to a maximum of 1.5 mm (0.060 in.) oversize. ing wheel nuts. A torque wrench should be used for
Always replace the drum i f machining would cause this purpose at all times.
drum diameter to exceed indicated size limit. The correct tightening sequence is important i n
avoiding rotor and drum distortion. The correct se
BRAKE DRUM RUNOUT quence is i n a diagonal crossing pattern.
Measure drum diameter and runout with an accu Seat the wheel and install the wheel nuts finger
rate gauge. The most accurate method of measure tight. Tighten the nuts i n the sequence to 1/2 re
ment involves mounting the drum i n a brake lathe quired torque. Then repeat the tightening sequence
and checking variation and runout with a dial indi to final specified torque.
cator.
5 - 70 PARKING BRAKES •
PARKING B R A K E S
INDEX
page page
Front Cable Replacement 70 Parking Brake Pedal Assembly Replacement 72
Parking Brake Cable Tensioner Adjustment 71 Rear Cable Replacement 70
FRONT CABLE REPLACEMENT

(1) Remove knee bolster.
(2) Release parking brake pedal completely.
(3) Raise vehicle.
(4) Loosen tensioner nut to create slack i n front ca
ble and extension cable (Fig. 1).
EXTENSION
CABLE
FRONT
CABLE
TENSIONER GROMMET/SEAL \ J9405-171
Fig. 2 Front Cable Grommet (In Floorpan)
PEDAL
ASSEMBLY
CABLE
CONNECTORS J9405-169
Fig. 1 Extension-To-Front Cable Attachment

(5) Disengage front cable from connector from ex
tension cable (Fig. 1). Note that extension cable can
also be removed at this time i f necessary.
(6) Lower vehicle.
(7) Roll back carpet and loosen cable grommet (Fig.
2). Then pull cable through floorpan grommet and re
move cable.
(8) Disengage front cable from arm on foot pedal
assembly (Fig. 3).
(9) Insert new cable through floorpan grommet
FRONT
(Fig. 3). Then feed cable up to arm on pedal assembly CABLE
(Fig. 2).
(10) Hook cable T-connector i n arm on pedal as
J9405-170
sembly (Fig. 2).
(11) Secure floorpan grommet/seal.
Fig. 3 Front Cable Attachment (At Foot Pedal)
(12) Realign floor carpet.
(13) Install knee bolster (if removed). REAR CABLE REPLACEMENT
(14) Engage front cable and extension cable i n ca (1) Raise vehicle and remove necessary wheel and
ble connectors (Fig. 1). brake drum.
(15) Adjust cable tensioner. Refer to procedure i n (2) Remove secondary brakeshoe. Then disconnect
this section. cable from parking lever attached to secondary shoe.
(3) Compress rear cable retainer with hose clamp
or pliers and pull cable out of support plate (Fig. 4).
(6) Remove cable from frame bracket (Fig. 6). Com
press cable retainer with hose clamp or pliers and
slide cable out of bracket (Fig. 6).
(7) Remove cable.
(8) Route new cable to rear brake support plate.
(9) Insert cable through support plate, seat cable
retainers and attach cable to parking brake lever on
secondary brakeshoe.
(10) Install brakeshoes but do not install brake
drum at this time.
(11) Seat cable i n body clips, reaction bracket, and
frame bracket.
(12) Connect cable to tensioner.
(13) Adjust cable tensioner, Refer to procedure i n
this section.
Fig. 4 Rear Cable Routing
(14) Install wheel and tire assemblies.
(4) Remove one (or both) cables as needed from re (15) Lower vehicle.
action bracket on right rear fame rail (Fig. 5). (16) Verify parking brake operation.
PARKING BRAKE CABLE TENSIONER ADJUSTMENT

Tensioner adjustment is only necessary w h e n
t h e tensioner, o r a cable has been replaced o r
disconnected for service. When adjustment is
necessary, p e r f o r m adjustment o n l y as de
scribed i n the f o l l o w i n g procedure. This is nec
essary t o avoid faulty p a r k i n g b r a k e operation.
(1) Raise vehicle.
(2) Back off cable tensioner adjusting nut to create
slack i n cables.
(3) Remove rear wheel/tire assemblies. Then re
l u - i o iN-m
(90-140 in. lbs.) move brake drums.
(4) Check rear brakeshoe adjustment with stan
J9405-174 dard brake gauge. Also check condition of brake parts
Fig. 5 Rear Cable Reaction Bracket Location as follows:
(5) Disengage rear cable from tensioner (Fig. 6). (a) Replace worn parts i f necessary. Excessive
shoe-to-drum clearance, or w o r n components
w i l l result i n faulty p a r k i n g b r a k e adjustment
a n d operation.
(b) Verify that parking brake cables operate
freely and are not binding, or seized. Replace faulty
cables, before proceeding.
(c) Adjust rear brakeshoes to drums.
(d) Install drums and verify that drums rotate
freely without drag.
(5) Reinstall wheel/tire assemblies after brakeshoe
adjustment is complete.
(6) Lower vehicle enough for access to parking
brake foot pedal. T h e n fully apply p a r k i n g
brakes. Leave brakes applied u n t i l adjustment
is complete.
(7) Raise vehicle again.
(8) Mark tensioner rod 6.5 mm (1/4 in.) from edge
CABLE
TENSIONER of tensioner bracket (Fig. 7).
(9) T i g h t e n adjusting n u t at equalizer u n t i l
J9405-173 m a r k o n tensioner r o d moves i n t o a l i g n m e n t
Fig. 6 Cable And Tensioner Attachment w i t h tensioner bracket (Fig. 7).
5 - 72 PARKING BRAKES •
CAUTION: Do not loosen, or tighten the tensioner (7) Disconnect brakelight wire from switch on
adjusting nut for any reason after completing ad pedal assembly.
justment. (8) Roll carpet back and loosen front cable grom-
met/seal from floorpan (Fig. 2).
(10) Lower vehicle until rear wheels are 15-20 cm (9) Disengage cable end connector from arm on
(6-8 in.) off shop floor. pedal assembly (Fig. 3).
(11) Release parking brake foot pedal and verify (10) Remove bolts/nuts attaching pedal assembly
that rear wheels rotate freely without drag. Then to cowl, dash panels, and instrument panels (Fig. 8).
lower vehicle. (11) Remove old pedal assembly.
PEDAL COWL DASH
CABLE ASSEMBLY
CONNECTOR
THREADED
ROD
(TO EQUALIZER)
TENSIONER
ROD
PLACE
MARK
HERE
ITEM TORQUE
TENSIONER BRACKET A 21-34 N-m (200-300 in. lbs.)
J9405-175
J9405-176
Fig. 8 Parking Brake Pedal Mounting

Fig. 7 Placing Adjustment Mark On Cable Tensioner
Rod (12) Position replacement pedal assembly on dash
and cowl.
PARKING BRAKE PEDAL ASSEMBLY (13) Install and tighten pedal assembly bolts/nuts
REPLACEMENT to 21-34 N-m (200-300 in. lbs.) torque.
(1) Release parking brakes. (14) Connect front cable to arm on pedal assembly.
(2) Raise vehicle. (15) Connect wires to brakelight switch on pedal
(3) Loosen cable tensioner nut at equalizer to cre assembly.
ate slack i n front cable. (16) Install knee bolster and any trim removed for
(4) Lower vehicle. pedal access.
(5) Remove knee bolster. (17) Raise vehicle.
(6) remove necessary dash trim, or ducting for bet (18) Adjust parking brake cable tensioner. Refer to
ter access to pedal assembly as needed. procedure i n this section.
ik
SPECIFICATIONS
Disc Brake Caliper Type (All) Single Piston, Slider
Disc Brake Caliper Piston Diameter:

1/2 Ton Models 75 mm (2.95 in.)
3/4 Ton Models 80 mm (3.14 in.)
1 Ton Models 86 mm (3.38 in.)
Disc Brake Rotor Diameter x Thickness:

1/2 Ton Models . 2 . 9 4 x 3 2 mm (11.57x1.26 in.)
3/4 Ton Models 3 1 7 . 5 x 3 8 mm (12.5x1.5 in.)
1 Ton Models . 3 1 7 . 5 x 3 8 mm (12.5x1.5 in.)
Drum Brake Size:

1/2 Ton Models . . 1 1 x 2 in. (279x51 mm)
3/4 Ton Models 1 3 x 2 . 5 in. ( 3 3 0 x 6 3 . 5 mm)
1 Ton Models 1 3 x 3 . 5 in. ( 3 3 0 x 8 9 mm)
Drum Brake Type (All) Dual Shoe With Self-Adjusting Mechanism
Master Cylinder Bore Size:

1/2 Ton Models , 28.6 mm (1.125 in.)
3/4 Ton Models 31.8 mm (1.25 in.)
1 Ton Models 31.8 mm (1.25 in.)
Wheel Cylinder Bore Size:

1/2 Ton Models 23.8 mm (0.937 in.)
3/4 Ton Models ..: . . . . . . . . 2 3 . 8 mm (0.937 in.)
1 Ton Models 27 mm (1.06 in.)
Recommended Brake Fluid MOPAR Brake Fluid or Equivalent Meeting

SAE Standard J1703 and
Federal Standard DOT 3
J9405-14
t
I
I
• CLUTCH 6-1
CLUTCH
CONTENTS
page page
CLUTCH COMPONENTS I• B 1 CLUTCH SERVICE . 12
CLUTCH COMPONENTS CLUTCH DISC APPLICATION

The clutch mechanism i n BR models with a gas or A 281 mm (11 in.) clutch disc and cover are used i n
diesel engine consists of a single, dry-type clutch disc models with a 3.9L, 5.2L, or 5.9L gas engine (Figs. 1
and a diaphragm style clutch cover. A hydraulic link and 2).
age is used to engage/disengage the clutch disc and A 312.5 mm (12.3 in.) clutch disc and cover are
cover. used in models with a 5.9L diesel or VIO gas engine
The transmission input shaft is supported i n the (Figs. 3 and 4).
crankshaft by a bearing. A sleeve type release bear The four clutch discs are all equipped with damper
ing is used to engage and disengage the clutch cover springs i n the hub. The 281 mm discs have four
pressure plate. springs while the 312.5 mm disc has five springs.
The release bearing is operated by a release fork i n The damper springs provide smoother torque transfer
the clutch housing. The fork pivots on a ball stud and disc engagement.
mounted inside the housing. The release fork is actu
ated by a hydraulic slave cylinder mounted i n the FACING
MATERIAL
housing. The slave cylinder is operated by a clutch
master cylinder mounted on the dash panel. The cyl
inder push rod is connected to the clutch pedal.
The clutch disc has damper springs i n the disc hub.
The clutch disc facing is riveted to the hub. The fac
ing is made from a non-asbestos material. The clutch
cover pressure plate is a diaphragm type with a one-
piece spring and multiple release fingers. The pres
sure plate release fingers are preset during 281 mm
manufacture and are not adjustable. (11 In.)
FACING
MATERIAL
J9406-8
Fig. 2 V8 Engine Clutch Disc

CLUTCH COVER APPLICATION
Two clutch covers are used for all applications. The
281 mm cover (Fig. 5), is used for 3.9L, 5.2L and 5.9L
gas engine applications.
The 312.5 mm cover (Fig. 6), is used for 5.9L diesel
and VIO gas engine applications.
CLUTCH PEDAL POSITION SWITCH

[Vol J9406-7 All BR models are equipped with a clutch pedal po
sition switch (Fig. 7). The switch is i n circuit with
Fig. 1 ¥6 Engine Clutch Disc the starter relay and is mounted on the clutch mas-
6 - 2 CLUTCH •
COVER
DAMPER
SPRINGS (5)
312.5 mm
(12.3 in.)
1DIESEL/V101 J9406-11
J9406-9
Fig. 3 V10 Engine Clutch Disc Fig. 5 V6/V8 Gas Engine Clutch Covet
FACING COVER
MATERIAL
PRESSURE
PLATE
281 mm
I DIESEL I J9406-10 (11 in.) rV67V8l J9406-12
Fig. 4 Diesel Engine Clutch Disc Fig. 6 VWDiesel Engine Clutch Cover
ter cylinder push rod. The switch is actuated by CLUTCH HYDRAULIC LINKAGE
clutch pedal movement. The clutch pedal must be The hydraulic linkage consists of a remote reser
fully depressed i n order to start the engine. voir, clutch master cylinder, clutch slave cylinder and
The position switch is an integral part of the clutch interconnecting fluid lines (Fig. 8).
master cylinder push rod and is not serviced sepa The clutch master cylinder is connected to the
rately. clutch pedal and the slave cylinder is connected to
Position switch circuitry is provided at the end of the clutch release fork. The master cylinder is
this section (refer to Figure 10). mounted on the drivers' side of the dash panel adja
cent to the brake master cylinder.
• CLUTCH e-3
to satisfactory operation. The correct lubricant and

not overlubricating are equally important. Apply rec
ommended lubricant sparingly to avoid disc and pres
sure plate contamination.
V6/V8
Clutch and transmission components requiring l u
brication are:
CLUTCH • pilot bearing
MASTER
CYLINDER • release lever pivot ball stud
CLUTCH PEDAL • release lever contact surfaces
POSITION SWITCH
• clutch disc hub splines
• clutch pedal pivot shaft bore
• clutch pedal bushings
V10/DIESEL • input shaft splines
• input shaft pilot hub
J9406-14 • transmission front bearing retainer slide surface
Do not apply grease to any part of the clutch
Fig. 7 Clutch Pedal Position (Interlock) Switch cover, disc, or release bearing.
DASH
OPENING RECOMMENDED LUBRICANTS
Use Mopar multi-purpose grease for the clutch
RESERVOIR
pedal bushings and pivot shaft. Use Mopar high tem
DASH perature grease (or equivalent) for all other lubrica
PANEL
tion requirements. Apply recommended amounts and
do not overlubricate.
GENERAL DIAGNOSIS INFORMATION

Unless the cause of a clutch problem is obvious, a
FLUID CYLINDER road test and component inspection will be required
LINES DASH SEAL for accurate diagnosis.
A road test will help determine the type of fault
CLUTCH while component inspection will identify the problem
MASTER component.
CYLINDER
During a road test, drive the vehicle at normal
speeds. Shift the transmission through all gear
ranges and observe clutch action.
I f chatter, grab, slip, or improper release is experi
enced, remove and inspect the clutch components.
SLAVE BODY
CYLINDER CLIP J9406-15
However, i f the problem is noise or hard shifting, fur
ther diagnosis is needed. The transmission or an
Fig. 8 Clutch Hydraulic Linkage
other driveline component may actually be at fault.
Careful observation during a road test will help
CLUTCH LINKAGE FLUID narrow the problem area.
The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are prefilled with fluid at the CLUTCH PROBLEM CAUSES
factory during assembly operations.
The hydraulic system should not require additional CONTAMINATION
fluid under normal circumstances. I n fact, the reser Fluid contamination is one of the more common
voir fluid level will actually increase as normal causes of clutch malfunctions. Oil, water, or clutch
clutch wear occurs. F o r this reason, it is impor fluid on the clutch contact surfaces will result i n
tant to avoid overfilling, or removing fluid from faulty operation. The usual result is chatter, slip, or
the reservoir. grab.
I f inspection or diagnosis indicates additional fluid During inspection, note i f any components are con
may be needed, use Mopar brake fluid, or an equiv taminated with oil, hydraulic fluid, or water/road
alent meeting SAE and DOT standards J1703 and splash.
DOT 3. Do not use any other type of fluid. Oil contamination indicates a leak at either the
rear main seal or transmission input shaft.
CLUTCH COMPONENT LUBRICATION Oil leakage produces a residue of oil on the housing
Proper clutch component lubrication is important interior and on the clutch cover and flywheel.
6 - 4 CLUTCH •
Heat buildup caused by slippage between the cover, Clutch Cover And Disc Runout
disc and flywheel, can sometimes bake the oil residue Check the clutch disc before installation. Axial
onto the components. The glaze-like residue ranges (face) runout of a new disc should not exceed 0.5 mm
in color from amber to black. (0.020 in.). Measure runout about 6 mm (1/4 in.) from
Road splash contamination means dirt and water the outer edge of the disc facing. Obtain another disc
are entering the clutch housing due to loose bolts, i f runout is excessive.
housing cracks, vent openings, or through the slave Check condition of the clutch before installation. A
cylinder opening. Driving through deep water pud warped cover or diaphragm spring will cause grab
dles can force water/road splash into the housing and incomplete release or engagement.
through such openings. Be careful when handling the cover and disc. Im
An additional problem caused by water contamina pact can distort the cover, diaphragm spring, release
tion and especially by steam cleaning, involves clutch fingers and the hub of the clutch disc.
disc sticking and poor release. Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalign
Water and steam vapors can be absorbed by the
ment which could result i n cover distortion and disc
clutch facing material. I f the vehicle sits idle for long
damage.
periods after water contamination, the force exerted
A frequent cause of clutch cover distortion (and
by the pressure plate may cause the disc to bond i t
consequent misalignment) is improper bolt tighten
self to the flywheel or pressure plate. ing. To avoid warping the cover, tighten the bolts al
Frequently, the only remedy for the above condition ternately (in a diagonal pattern) and evenly (2-3
is component replacement. To avoid this problem, a threads at a time) to specified torque.
vehicle should be driven as soon as possible to heat
and dry the clutch components. Clutch Housing Misalignment And Runout
Clutch fluid leaks are from a loose or damaged Clutch housing alignment is important to proper
slave cylinder line or connection. However, clutch operation. The housing bore maintains alignment be
fluid leaks will usually be noted and corrected before tween the crankshaft and transmission input shaft.
severe contamination occurs. Misalignment can cause noise, incomplete clutch
release and chatter. I t can also result i n premature
CLUTCH MISALIGNMENT wear of the pilot bearing, cover release fingers and
Clutch components must be i n proper alignment clutch disc. I n severe cases, misalignment can also
with the crankshaft and transmission input shaft. cause premature wear of the transmission input
Misalignment caused by excessive runout or warpage shaft and bearing.
of any clutch component will cause grab, chatter and Housing face misalignment is generally caused by
improper clutch release. incorrect seating on the engine or transmission, loose
housing bolts, missing alignment dowels or housing
Flywheel Runout damage. Infrequently, misalignment may also be
Common causes of runout are heat warping, im caused by housing mounting surfaces that are not
proper machining, mounting the flywheel on a dirty parallel.
crankshaft flange, incorrect bolt tightening, or im I f housing misalignment is suspected, the housing
proper seating on the crankshaft flange shoulder. is probably not fully seated on either the engine,
Very light scratches or surface roughness on the alignment dowels, or transmission front face. Since
flywheel face can be cleaned up by scuff sanding with the NV3500 clutch housing is an integral part of the
180 grit emery cloth. However, i f the surface is transmission front case, i t will be necessary to re
warped or severely scored, replace the flywheel. move the transmission and housing as an assembly
to check seating. Housing bore and face runout can
Do not machine the flywheel. The flywheel
only be checked i n the vehicle on models with a
face is manufactured with a unique surface NV4500 transmission. The runout check procedure is
contour. Machining would negate this feature described in detail i n the Clutch Service section.
and could result in unsatisfactory operation.
Clean the crankshaft flange before mounting the INSTALLATION METHODS AND PARTS
flywheel. Dirt and grease on the flange surface may USAGE
cock the flywheel causing runout. Distortion of clutch components during installation
Use new bolts when remounting a flywheel and se and the use of non-standard components are addi
cure the bolts with Mopar Lock And Seal, or Loctite tional causes of clutch malfunction.
242. Tighten flywheel bolts to specified torque only. Improper clutch cover bolt tightening can distort
Overtightening could distort the flywheel hub caus the cover. The usual result is clutch grab, chatter
ing runout. and rapid wear. Tighten the cover bolts as described
in the Clutch Service section.
• CLUTCH e-§
Improperly seated flywheels and clutch housings Use the chart as a check list to help avoid overlook
are other causes of clutch failure. Improper seating ing potential problem sources during service opera
will produce misalignment and subsequent clutch tions.
problems. The diagnosis charts describe common clutch prob
Tighten the clutch housing bolts to proper torque lems, causes and correction. Fault conditions are
before installing any struts. Also be sure the align listed at the top of each chart. Conditions, causes and
ment dowels are i n place and seated i n the block and corrective action are outlined i n the indicated col
housing beforehand. umns.
The use of non-standard or low quality parts can
The charts are provided as a convenient reference
also lead to problems and wear. Use the recom
when diagnosing faulty clutch operation.
mended factory quality parts to avoid comebacks.
INSPECTION AND DIAGNOSIS CHARTS

The clutch inspection chart (Fig. 9) outlines items
to be checked before and during clutch installation.
6 - 6 CLUTCH •
9 Inspect release bearing slide surface of trans, front

bearing retainer. Surface should be smooth, free of
nicks, scores. Replace retainer if necessary.
Lubricate slide surface before installing release
bearing.
10 Do not replace release bearing unless actually

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

fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with
factory spring setting as clutch problems will result.
12 Check condition of clutch cover. Replace clutch

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

Replace housing if damaged.
14 Verify that housing alignment dowels are in position

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

housing. Dirt, grime can produce misalignment.
1 Check clutch housing bolts. Tighten if loose. Be sure 16 Make sure side of clutch disc marked "flywheel
housing is fully seated on engine block. side" is toward flywheel.
2 Check flywheel. Scuff sand face to remove glaze. 17 Check rear main seal if clutch disc and cover were
Clean surface with wax and grease remover. oil covered. Replace seal if necessary.
Replace flywheel if severely scored, worn or
c r a c k e d . Secure flywheel with new bolts (if 18 Check crankshaft flange (if flywheel is removed). Be
removed). Do not reuse old bolts. Use Mopar Lock sure flange is clean and flywheel bolt threads are in
N'Seal on bolts. good condition.
3 Tighten clutch cover bolts 2-3 threads at a time, 19 Check pilot bearing. Replace bearing if damaged.
alternately and evenly (in a diagonal pattern) to Lube with Mopar high temp, bearing grease before
specified torque. Failure to do so coula warp the installation.
cover.
20 Check transmission input shaft. Disc must slide freely
4 Check release fork. Replace fork if bent or worn. on shaft splines. Lightly grease splines before
Make sure pivot and bearing contact surfaces are installation. Replace shaft if splines or pilot bearing
lubricated. hub are damaged.
5 Check release fork pivot (in housing). Be sure pivot 21 Check flywheel bolt torque. If bolts are loose,
is secure and ball end is lubricated. replace them. Use Mopar Lock N'Seal to secure new
bolts.
6 Transmission input shaft bearing will cause noise,
chatter, or improper release if damaged. Check 22 Check clutch disc facing. Replace disc if facing is
condition before installing transmission. charred, scored, flaking off, or worn. Also check
runout of new disc. Runout should not exceed 0.5
7 Check slave cylinder. Replace it if leaking. Be sure mm (0.02 in.).
cylinder is properly secured in housing and cylinder k
piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc were

oil covered. Replace seal if worn, or cut.
J9406-6
Fig. 9 Clutch Inspection Points

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

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

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

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

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

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

splines or disc and input shaft. to splines and replace disc (do
not clean and reuse the disc).
2. Clutch disc and/or cover Incorrect or substandard parts. Replace disc and/or cover with
w a r p e d , or disc facings exhibit correct parts.
unusual wear or appear to be
wrong type.
3. Clutch master or slave cylinder a) Master or slave cylinder a) Replace both cylinders as
plunger dragging-binding. components worn or corroded. assembly (and reservoir).
4. No fault found with clutch a) Problem actually related to a) Further diagnosis required.
components. suspension or driveline Check engine/transmission
component. mounts, propeller shafts and
U-joints, tires, suspension
attaching parts and other
driveline components as
needed.
b) Engine related problem. b) Check EFI and igniton systems.

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

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

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

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

clutch components. Check front
bearing retainer sleeve surface.
Replace if damaged.
6. Release bearing is noisy. Release bearing defect. Replace bearing.
7. Clutch pedal squeak. a) Pivot pin loose. Tighten pivot pin. Replace bushings
if worn or damaged. Lubricate pin
b) Pedal bushings worn out or and bushings with silicone base
cracked. lubricator chassis grease.
J9206-10
CLUTCH 6 - 11
TO FUEL
SHUT DOWN
RELAY
F E E D
POWER f
DISTRIBUTION >
CENTER
A2
12PK GREEN GREEN
BK* A41 A41
18YL 18YL
JFEED BYPASS CLUTCH
JUMPER PEDAL P O S I T I O N
TO IGNITION
(SWITCH) MANUAL
SWITCH -A41 20YL- (ON CLUTCH TRANSMISSION
CYLINDER
AUTOMATIC
P U S H ROD]
TRANSMISSION
J9406-24
Fig. 10 Clutch Pedal Position Switch Circuitry

e - 12 CLUTCH •
CLUTCH SER¥1CE
INDEX
page page
Checking NV4500 Clutch Housing Runout 19 Clutch Pedal Installation 18
Clutch Cover and Disc Installation 12 Clutch Pedal Removal 17
Clutch Cover and Disc Removal 12 Flywheel Service 18
Clutch Housing Installation 15 Pilot Bearing Replacement 15
Clutch Housing Removal (NV4500) 14 Release Bearing Replacement 15
Clutch Linkage Service 16
CLUTCH COVER AND DISC REMOVAL (4) Support engine with wood block and adjustable
(1) Raise vehicle. jack stand (Fig. 3). Supporting engine is necessary to
(2) Remove transmission and transfer case i f avoid undue strain on engine mounts.
equipped. Refer to Group 21 for procedures.
(3) On models with NV4500 transmission, remove
clutch slave cylinder from clutch housing (Fig. 1).
Then remove transmission and clutch housing from
engine (Fig. 2).
MOUNTING
STUDS
19-26 N-m
( 1 7 0 - 2 3 0 in. lbs.)
FLUID
LINE
J9106-22
CLUTCH Fig. 3 Supporting Engine With Jack Stand And

HOUSING
Wood Block (Diesel Model Shown)
SLAVE
(5) I f clutch cover will be reused, mark position of
CYLINDER J9406-13 cover on flywheel with paint or scriber (Fig. 4).
(6) Insert clutch alignment tool i n clutch disc and
Fig. 1 Slave Cylinder Mounting into pilot bushing. Tool will hold disc i n place when
CLUTCH
cover bolts are removed.
HOUSING (7) I f clutch cover will be reused, loosen cover bolts
evenly, only few threads at a time, and i n a diagonal
pattern (Fig. 5). This relieves cover spring tension
evenly to avoid warping.
NV4500 (8) Remove cover bolts completely and remove
TRANSMISSION
cover, disc and alignment tool.
CLUTCH COVER AND DISC INSTALLATION

(1) Check runout and free operation of new clutch
disc:
(a) Install disc on transmission input shaft
splines and check fit. Disc should slide freely on
splines.
J9406-16 (b) Leave disc on shaft and check disc runout
with dial indicator.
Fig. 2 Transmission/Clutch Housing (With NV4500)
(c) Position indicator plunger about 1/4 inch from
outer edge of disc facing.
CLUTCH 8 • 13
ALIGNMENT CLUTCH
MARKS DISC
FLYWHEEL (SCRIBE O R PAINT)
"FLYWHEEL SIDE"
STAMPED O N
THIS SURFACE
J9006-33
Fig. 6 Clutch Disc Position (Typical)

(5) Insert alignment tool i n pilot bearing and posi
tion disc on flywheel surface (Fig. 7).
(6) Position clutch cover over disc and onto fly
wheel (Fig. 7).
CLUTCH COVER
A N D DISC
CLUTCH
COVER J9406-17
Fig. 4 Marking Clutch Cower Position

CLUTCH DISC
A L I G N M E N T TOOL
J9106-18
FLYWHEEL. _
Fig. 7 Clutch Disc And Cower Alignment/Installation

(7) Align and hold clutch cover i n position and in
stall cover bolts finger tight.
(8) Tighten cover bolts evenly and a few threads at
a time. Cover bolts must be tightened evenly
and to specified torque to avoid distorting
cover.
• Tighten 5/16 in. diameter bolts to 23 N-m (17 ft.
lbs.)
• Tighten 3/8 in. diameter bolts to 41 N-m (30 ft.
J9106-17
lbs.).
Fig. 5 Clutch Cower Bolt Loosening/Tightening (9) Remove release lever and release bearing from
Pattern clutch housing. Apply Mopar high temperature bear
ing grease to bore of release bearing, release lever
(d) Runout should not exceed 0.5 mm (0.020 in.). contact surfaces and release lever pivot stud (Fig. 8).
Obtain another clutch disc i f runout exceeds this
(10) Apply light coat of Mopar high temperature
limit. bearing grease to splines of transmission input shaft
(2) Lubricate crankshaft pilot bearing with Mopar (or drive gear) and to release bearing slide surface of
high temperature bearing grease. the transmission front bearing retainer (Fig. 9). Do
(3) Insert clutch alignment tool i n clutch disc hub. not overlubricate shaft splines. This can result
(4) Verify that disc hub is positioned correctly. Side in grease contamination of disc.
of hub marked "Flywheel Side" should face flywheel
(Fig. 6).
6 - 14 CLUTCH •
FORK
J9406-18
Fig. 10 Release Fork And Bearing Spring Clip

Position
(13) Install transmission.
(14) Check fluid level in clutch master cylinder.
ENGINE BLOCK CLUTCH DISC A N D COVER
Fig. 8 Clutch Release Component Lubrication

Points
APPLY LIGHT COAT OF

HI-TEMP GREASE T O THESE
SURFACES BEFORE INSTALLATION J9106-15 J9006-32
Fig. 9 Input Shaft Lubrication Points (Typical) Fig. 11 Clutch Housing Installation (NV4500)
(11) Install release lever and bearing i n clutch CLUTCH HOUSiNi REMOVAL (NV4500)
housing. Be sure spring clips that retain fork on
(1) Raise vehicle and remove transmission and
pivot ball and release bearing on fork are properly
transfer case i f equipped.
installed and (Fig. 10).
(2) Remove clutch housing bolts and remove hous
(12) Install clutch housing (Figs. 11 and 12). Be ing from engine (Figs. 2 and 11).
sure housing is properly seated on alignment dowels (3) Clean housing mounting surface of engine block
before tightening housing bolts. with wax and grease remover.
• CLUTCH e - 15
ball stud and release lever pivot surface with Mopar

high temperature bearing grease.
(7) Install release fork and release bearing (Fig.
14). Be sure fork and bearing are properly secured by
spring clips.
(8) Install clutch housing, i f removed.
(9) Install transmission. Also install transfer case
on 4-wheel drive models.
Fig. 12 Clutch Housing/Transmlsslon Installation

(Diesel Engine) AND SLEEVE FORK RN1232
(4) Verify that clutch housing alignment dowels are
Fig. 13 Clutch Release Components
in good condition and properly seated.
(5) Transfer slave cylinder, release fork and boot, fork
pivot stud and wire/hose brackets to new housing.
CLUTCH HOUSING INSTALLATION

(1) Lubricate release fork and pivot contact sur
faces with Mopar High Temperature wheel bearing
grease before installation.
(2) Align and install clutch housing on transmission.
Tighten housing bolts closest to alignment dowels first
and to torque values indicated (Figs. 2 and 11).
(3) Install transmission-to-engine strut after in
stalling clutch housing. Tighten bolt attaching strut
to clutch housing first and engine bolt last.
(4) Install transmission and transfer case i f
equipped. Refer to procedure i n Group 21.
RELEASE BEARING REPLACEMENT Fig. 14 Clutch Release Fork And Bearing Installation
(1) Remove transmission.
PILOT BEARING REPLACEMENT
(2) On models with gas engine and new style re
lease fork, remove clutch housing for access to re (1) Remove transmission and clutch housing.
lease fork and release bearing retainer springs. (2) Remove clutch cover and disc.
(3) Disconnect release bearing from release fork (3) Remove pilot bearing. Use blind hole puller
and remove bearing (Fig. 13). tools such as those included i n Snap-On set CG40CB
(4) Inspect bearing slide surface on transmission to remove bearing.
front bearing retainer. Replace retainer i f slide sur (4) Clean bearing bore with solvent and wipe dry
face is scored, worn or cracked. with shop towel.
(5) Inspect release lever and pivot stud. Be sure (5) Install new bearing with clutch alignment tool
stud is secure and i n good condition. Be sure fork is (Fig. 15). Keep bearing straight during installation.
not distorted or worn. Replace fork spring clips i f Do not allow bearing to become cocked. Tap bearing
bent or damaged. into place until flush with edge of bearing bore. Do
(6) Lubricate crankshaft pilot bearing, input shaft not recess bearing.
splines, bearing retainer slide surface, lever pivot
I - 16 CLUTCH •
SLAVE CLUTCH
KEEP BEARING STRAIGHT CYLINDER HOUSING
DURING INSTALLATION FLANGE
TO AVOID DAMAGE
PILOT
BEARING
ALIGNMENT
TOOL
BEARING SEAL
MUST FACE J9106-21
TRANSMISSION
Fig. 16 Slave Cylindet Removal/installation
and connecting lines are sealed units. They are
prefilled with fluid during manufacture and
must not be disassembled nor disconnected.
J9206-8
Fig. 15 Typical Method Of Installing Pilot Beating L I N K A G E REMOVAL
(1) Raise vehicle.
(6) Lubricate bearing with Mopar high tempera
(2) On diesel models, remove slave cylinder shield
ture grease, or an equivalent quality grease.
from clutch housing i f equipped.
(7) Install clutch cover and disc.
(3) Remove nuts attaching slave cylinder to studs
(8) Install clutch housing, transmission and trans
on clutch housing.
fer case on 4-wheel drive models.
(4) Remove slave cylinder from clutch housing (Fig. 16).
(5) Disengage slave cylinder fluid line from body
CLUTCH LINKAGE SERVICE
retainer clips.
The clutch master cylinder, remote reservoir, (6) Lower vehicle.
slave cylinder and connecting lines are all ser (7) Disconnect clutch pedal interlock switch wires.
viced as an assembly. These components cannot (8) Remove locating clip from clutch master cylin
be serviced separately. The linkage cylinders der mounting bracket (Fig. 17).
CYLINDER CLUTCH
RESERVOIR DASH PEDAL
SEAL
LOCATING,
PINS
CLUTCH CLUTCH
MASTER PUSH
CYLINDER ROD
SLAVE
J9406-20 CYLINDER
Fig. 17 Clutch Hydtaulic Linkage

• CLUTCH 6 - 17
(9) Remove retaining clip, flat washer and wave (5) I f cylinder seal is hard to seat, unlock cylinder
washer that attach clutch master cylinder push rod and reseat seal i f necessary. Then relock cylinder af
to clutch pedal (Fig. 18). terward.
(10) Slide clutch master cylinder push rod off pedal (6) Position clutch fluid reservoir on dash panel
pin. and install reservoir screws. Tighten screws to 5 N-m
(11) Inspect condition of bushing on clutch pedal (40 in. lbs.) torque.
pin (Fig. 18). Remove and replace bushing i f worn or (7) Install reservoir mounting bracket on dash
damaged. panel, i f removed.
(12) Verify that cap on clutch master cylinder res (8) Install replacement bushing on clutch pedal pin
ervoir is tight. This will avoid spillage during re if necessary.
moval. (9) Install clutch master cylinder push rod on
(13) Remove screws that attach clutch fluid reser clutch pedal pin. Secure rod with wave washer, flat
voir to dash panel. washer and retainer ring.
(14) Remove reservoir mounting bracket screws (10) Connect clutch pedal position (interlock)
switch wires.
and remove reservoir from dash panel.
(11) Install locating clip i n clutch master cylinder
(15) Rotate clutch master cylinder 45° counter
mounting bracket.
clockwise to unlock it. Then remove cylinder from (12) Raise vehicle.
dash panel. (13) Install slave cylinder. Be sure cap at end of
(16) Remove clutch master cylinder rubber seal cylinder rod is seated i n release lever. Check this be
from dash panel (Fig. 17). fore installing cylinder attaching nuts.
(17) Remove clutch cylinders, reservoir and con (14) Install and tighten slave cylinder attaching
necting lines from vehicle. nuts to 23 N-m (200 in. lbs.) torque.
PIN (15) Lower vehicle.
(16) I f new linkage has been installed, remove
plastic shipping stop from master cylinder push rod.
Do this after installing slave cylinder and before op
erating linkage.
(17) Operate linkage several times to verify proper
operation.
CLUTCH PEDAL REMOVAL

(1) Remove retaining ring, flat washer and wave
washer that secure brake and clutch pedals to push
rods (Fig. 18).
(2) Remove knee bolster (Fig. 19) for access to
pedal pivot shaft.
PEDAL
J9406-21
Fig. 18 Clutch Cylinder Push Rod Attachment

LINKAGE INSTALLATION
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser
voir i n vehicle engine compartment.
(3) Lubricate cylinder seal with liquid dish soap to
ease installation. Then seat seal i n dash and around
cylinder.
(4) Insert clutch master cylinder i n dash panel. Ro (3) Remove brakelight switch. Turn switch clock
tate cylinder 45° clockwise to lock i t i n place. wise about 30° to release i t then remove switch from
bracket.
6 - 18 CLUTCH •
(4) Remove retainer from passenger side of pedal (3) Position clutch pedal in support. Align pedal
pivot shaft (Fig. 20). with pivot shaft and slide shaft through pedal bush
ings. Then repeat process for brake pedal.
PEDAL PEDAL
SUPPORT PIVOT (4) Slide pedal shaft through support and install
shaft retainer.
(5) Secure push rods to clutch and brake pedals.
(6) Install brakelight switch in bracket. Rotate
switch into place to lock it in bracket.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc,
cover and housing are removed for service. Check
condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts.
Minor scratches, burrs, or glazing on the flywheel
face can be scuff sanded with 180 grit emery cloth.
However, the flywheel should be replaced if the disc
contact surface is severely scored, heat checked,
cracked, or obviously worn.
Cleanup of minor flywheel scoring should be per
formed with surface grinding equipment. Remove
only enough material to reduce scoring (approximate
19406-22 ly 0.001 - 0.003 in.). Heavy stock removal is not rec
Fig. 20 Clutch/Brake Pedal Mounting
ommended. Replace theflywheelif scoring is severe
(5) Push pedal pivot shaft toward driver side of and deeper than 0.076 mm (0.003 in.). Excessive
support only enough to remove clutch pedal. It is not stock removal can result in flywheel cracking or
necessary to remove shaft from pedal support en warpage after installation; it can also weaken the fly
tirely. wheel and interfere with proper clutch release.
(6) Remove clutch pedal. Check flywheel runout if misalignment is sus
pected. Runout should not exceed 0.08 mm (0.003
CLUTCH PEDAL INSTALLATION in.). Measure runout at the outer edge of the fly
(1) Inspect bushings in clutch and brake pedals wheel face with a dial indicator. Mount the dial indi
(Fig. 21). Replace bushings if worn, cracked, or dis cator on a stud installed in place of one of the
torted. flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced and use Mopar Lock N' Seal, or Loctite
242 on replacement bolt threads.
Recommended flywheel bolt torques are:
• 75 N-m (55 ft. lbs.) for gas engine flywheels
• 137 N-m (101 ft. lbs.) for diesel flywheels
Inspect the teeth on the starter ring gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom
mended and preferred method of repair.
Fig. 21 Clutch/Brake Pedal Bushings
In cases where a newflywheelis not readily avail
(2) Lubricate pedal shaft, pedal shaft bore (Figs. able, a replacement ring gear can be installed. How
20 and 21) and all bushings with Mopar Multi Mile ever, the following precautions must be observed to
age, or high temperature bearing grease. avoid damaging the flywheel and replacement gear.
• CLUTCH 6 - 19
(a) Mark position of the old gear for alignment MEASURING CLUTCH HOUSING BORE
reference on the flywheel. Use a scriber for this RUNOUT (NV4S00 ONLY)
purpose. (1) Remove the clutch housing and strut.
(b) Wear protective goggles or approved safety (2) Remove the clutch cover and disc.
glasses. Also wear heat resistent gloves when han (3) Replace one of the flywheel bolts with an ap
dling a heated ring gear. propriate size threaded rod that is 10 in. (25.4 cm)
(c) Remove the old gear by cutting most of the long (Fig. 22). The rod will be used to mount the dial
way through i t (at one point) with an abrasive cut indicator.
off wheel. Then complete removal with a cold chisel (4) Remove the release fork from the clutch hous
or punch. ing.
(d) The ring gear is a shrink fit on the flywheel. (5) Reinstall the clutch housing. Tighten the hous
This means the gear must be expanded by heating ing bolts nearest the alignment dowels first.
in order to install it. The method of heating and (6) Mount the dial indicator on the threaded rod
expanding the gear is extremely important. and position the indicator plunger on the surface of
Every surface of the gear must be heated at the the clutch housing bore (Fig. 23).
same time to produce uniform expansion. An oven (7) Rotate the crankshaft until the indicator
or similar enclosed heating device must be used. plunger is at the top center of the housing bore. Zero
Temperature required for uniform expansion is the indicator at this point.
325-350° F. (8) Rotate the crankshaft and record the indicator
readings at eight points (45° apart) around the bore
CAUTION: Never u s e an oxy/acetylene torch to re (Figs. 22-23). Repeat the measurement at least twice
move the old gear, or to heat and expand a new for accuracy.
gear. The high temperature of the torch flame will (9) Subtract each reading from the one 180° oppo
cause localized heating and damage the flywheel. In site to determine magnitude and direction of runout.
addition, using the torch to heat a replacement gear Refer to Figure 24 and following example.
will c a u s e uneven heating and expansion. The torch Bore runout example:
flame will also anneal the gear teeth resulting in 0.000 - (-0.007) = 0.007 in.
rapid wear and damage after installation. +0.002 - (-0.010) = 0.012 in.
+0.004 - (-0.005) = 0.009 in.
(e) The heated gear must be installed evenly to -0.001 - (+0.001) = -0.002 in. (= 0.002 inch)
avoid misalignment or distortion. A shop press and I n the above example, the largest difference is
suitable press plates should be used to install the 0.012 in. and is called the total indicator reading
gear i f at all possible. (TIR). This means that the housing bore is offset
(f) Be sure to wear eye and hand protection. from the crankshaft centerline by 0.006 in. (which is
Heat resistent gloves and safety goggles are needed 1/2 of 0.012 in.).
for personal safety. Also use metal tongs, vise grips, On gas engines, the acceptable maximum TIR for
or similar tools to position the gear as necessary housing bore runout is 0.010 inch. I f measured TIR is
for installation. more than 0.010 in. (as i n the example), bore runout
(g) Allow the flywheel and ring gear to cool down will have to be corrected with offset dowels. Offset
before installation. Set the assembly on a work dowels are available i n 0.007, 0.014 and 0.021 in.
bench and let i t cool i n normal shop air. sizes for this purpose (Fig. 24). Refer to Correcting
Housing Bore Runout for dowel installation.
CAUTION: Do not u s e water, or compressed air to On diesel engines, the acceptable maximum
cool the flywheel. The rapid cooling produced by T I R for housing bore runout is 0.015 inch. How
water or compressed air can distort, or crack the ever, unlike gas engines, offset dowels are not
gear and flywheel. available to correct runout on diesel engines. I f
bore runout exceeds the stated maximum on a
diesel engine, it may.be necessary to replace ei
CHECKING NV4600 CLUTCH HOUSING RUNOUT ther the clutch housing, or transmission
Only the NV4500 clutch housing can be adapter plate.
checked using the following bore and face
runout procedures. The NV3500 clutch housing C O R R E C T I N G C L U T C H HOUSING BORE
RUNOUT tN¥4S00 GAS ENGINE ONLY)
is an integral part of the transmission front
case and can only be checked off the vehicle. On gas engine vehicles, clutch housing bore runout
is corrected with offset dowels. However, i f bore
runout exceeds 0.015 in. TIR on a diesel equipped
model, the clutch housing, or transmission adapter
6 - 20 CLUTCH •
plate may have to be replaced. Offset dowels are not
available for diesel models.
The dial indicator reads positive when the plunger
moves inward (toward indicator) and negative when
i t moves outward (away from indicator). As a result,
the lowest or most negative reading determines the + .004
direction of housing bore offset (runout).
In the sample readings shown i n Figure 24 and i n
step (7) above, the bore is offset toward the 0.010
inch reading. To correct this, remove the housing and
original dowels. Then install the new offset dowels i n
the direction needed to center the bore with the CLUTCH
HOUSING
crankshaft centerline. BORE
(SAMPLE READINGS) J9Q06-27
In the example, TIR was 0.012 inch. The dowels CIRCLE
needed for correction would have an offset of 0.007
in. (Fig. 25). Fig. 24 Housing Bore Measurement Points And
Install the dowels with the slotted side facing out Sample Readings
so they can be turned with a screwdriver. Then i n OFFSET
SLOT SHOWS DIRECTION
stall the housing, remount the dial indicator and OF OFFSET
check bore runout again. Rotate the dowels until the
TIR is less than 0.010 in. i f necessary.
I f a TIR of 0.053 in. or greater is encountered, i t
may be necessary to replace the clutch housing.
7/16 - 20 THREAD NUT DOWEL S ELECTION
STUD O R THREADED ROD TIR OFFSET DOWEL
/
VALUE REQUIRED
0.011 - 0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch

•10 INCHES L O N G -
J9206-7
J9O06-25 Fig. 25 Housing Bore Alignment Dowel Selection

M E A S U R I N G CLUTCH HOUSING FACE
Fig. 22 Dial Indicator Mounting Stud Or Rod RUNOUT (NW4S00I
MOUNTING STUD DIAL INDICATOR (1) Reposition the dial indicator plunger on the
housing face (Fig. 26). Place the indicator plunger at
the r i m of the housing bore as shown.
(2) Rotate the crankshaft until the indicator
INDICATOR
PLUNGER
plunger is at the 10 O'clock position on the bore.
Then zero the dial indicator.
(3) Measure and record face runout at four points
90° apart around the housing face (Fig. 27). Perform
the measurement at least twice for accuracy.
(4) Subtract the lowest reading from the highest to
determine total runout. As an example, refer to the
sample readings shown i n Figure 27. I f the low read
CLUTCH
ing was m i n u s 0.004 i n . and the highest reading was
HOUSING plus 0.009 in., total runout is actually 0.013 inch.
BORE J9006-26 (5) Total allowable face runout is 0.010 inch. I f
runout exceeds this figure, runout will have to be
Fig. 23 Checking Clutch Housing Bore Runout
corrected. Refer to Correcting Clutch Housing Face
Runout.
• CLUTCH 6 - 21
C O R R E C T I N G CLUTCH HOUSING FACE

RUNOUT (NV4500)
Housing face runout, on gas or diesel engines, can
be corrected by installing shims between the clutch
housing and transmission (Fig. 28). The shims can be
made from shim stock or similar materials of the re
quired thickness.
As an example, assume that face runout is the
same as shown i n Figure 27 and i n step (4) above. I n
this case, three shims will be needed. Shim thick
nesses should be 0.009 in. (at the 0.000 corner), 0.012
in. (at the -0.003 corner) and 0.013 in. (at the -0.004
corner). (AT R I M
After installing the clutch assembly and housing, OF BORE) J9006-30
tighten the housing bolts nearest the alignment dow
els first. Fig. 27 Housing Face Measurement Points And
Clutch housing preferred bolt torques are: Sample Readings
• 41 N-m (30 ft. lbs.) for 3/8 in. diameter bolts
• 68 N-m (50 ft. lbs.) for 7/16 in. diameter bolts CUT/DRILL
• 47 N-m (35 ft. lbs.) for V10 and diesel clutch hous BOLT ; w
ing bolts HOLE 7

T O SIZE /
During final transmission installation, install the
SHIM
shims between the clutch housing and transmission
X / X STOCK
at the appropriate bolt locations.
INDICATOR DIAL I N D I C A T O R
PLUNGER CLUTCH
HOUSING
FACE
MAKE SHIM
1-INCH
DIAMETER J9006-31
Fig. 28 Housing Face Alignment Shims
INDICATOR M O U N T I N G ^
STUD O R R O D J9006-29
Fig. 26 Measuring Clutch Housing Face Runout

COOLING SYSTEM 7-1
COOLING SYSTEM
CONTENTS
page page
AUTOMATIC TRANSMISSION OIL COOLERS .. 47 ENGINE BLOCK HEATERS 58

DIAGNOSIS 4 SERVICE PROCEDURES 16
ENGINE ACCESSORY DRIVE BELTS §1 SPECIFICATIONS 5i
GENERAL INFORMATION (Heavy Duty Cycle) engine. The 8.0L V-10 engine will
Throughout this group, references are made to par be referred to as: HDC (Heavy Duty Cycle) engine.
ticular vehicle models by alphabetical designation or Either of the HDC gas powered engines can be eas
by the particular vehicle nameplate. A chart showing ily identified by the use of an engine mounted air in
a breakdown of alphabetical designations is included jection pump. The 3.9L V-6, 5.2/5.9L V-8 LDC gas
in the Introduction section at the beginning of this engines or the diesel engine will not use an air injec
manual. tion pump.
A l l vehicles are equipped with either a 3.9L V-6 en
gine, a 5.2L V-8 engine, two different 5.9L V-8 en COOLING SYSTEM
gines, an 8.0L V-10 engine or a 5.9L Cummins in-line The cooling system regulates engine operating tem
6 cylinder diesel engine. perature. I t allows the engine to reach normal oper
The 3.9L V-6 and 5.2L V-8 engines will be referred ating temperature as quickly as possible. I t also
maintains normal operating temperature and pre
to i n this Cooling group as: LDC (Light Duty Cycle)
vents overheating.
engines. The 5.9L V-8 gas powered engine will be re
The cooling system also provides a means of heat
ferred to as either: LDC (Light Duty Cycle) or HDC
ing the passenger compartment and cooling the auto-
Fig. 1 Typical Cooling System Flow—Gas Powered Engines

7 - 2 COOLING SYSTEM •
Fig. 2 Typical Cooling System Flow—Diesel Powered Engine

matic transmission fluid (if equipped). The cooling COOLING SYSTEM COMPONENTS—DIESEL
system is pressurized and uses a centrifugal water ENGINE
pump on all engines to circulate coolant throughout Coolant flow circuits for the 5.9L diesel engine are
the system. shown i n figure 2.
An optional factory installed maximum duty cool The diesel cooling system consists of: a cross-flow
ing package is available for some engines on most radiator, engine driven cooling fan, thermal viscous
models. This package will provide additional cooling fan drive, fan shroud, radiator pressure cap, thermo
capacity for vehicles used under extreme conditions stat, a vertically mounted one-way check valve (jiggle
such as trailer towing i n high ambient temperatures. pin) at cylinder head, a bypass hose at thermostat,
coolant reserve/overflow system, transmission oil
COOLING SYSTEM COMPONENTS—ALL EXCEPT cooler (if equipped with an automatic transmission),
coolant, water pump, hoses and hose clamps.
DIESEL ENGINE Coolant is drawn from radiator into the water
The cooling system consists of: pump. Water pump output is directed to the engine
• A cross-flow radiator oil cooler cavity of the cylinder block (Fig. 3).
• Thermal viscous fan drive From the oil cooler cavity, the coolant circulates
• Fan shroud around each cylinder. I t then crosses to the lift pump
• Radiator pressure cap side of engine where i t flows up into cylinder head
• Thermostat through openings i n top of cylinder block (Fig. 3).
• Coolant reserve/overflow system Coolant flows past the valve bridges (Fig. 4), to ex
• Transmission oil cooler (automatic transmission) haust manifold side of engine and to thermostat. As
• Coolant coolant flows toward the thermostat, i t provides cool
• Water pump (to circulate coolant) ing for the injector nozzle.
• Hoses and hose clamps Also refer to Thermostat Operation—5.9L Diesel
Typical coolant flow circuits for gas powered en Engine. This can be found i n the Thermostat section
gines are shown i n figure 1. of this group.
COOLING SYSTEM 7-
1. Coolant Flow from Cylinder Block
Fig. 3 Cylinder Block Coolant Routing—Diesel

Engine
DIAGNOSIS
INDEX
page page
DRB Scan Tool .. 4 Preliminary Checks 4
On-Board Diagnostics (OBD) 4
ON-BOARD DIAGNOSTICS (OBD)
F O R COOLING SYSTEM COMPONENTS

The powertrain control module (PCM) has been
programmed to monitor certain cooling system com
ponents:
• I f the engine has remained cool for too long a pe
riod, such as with a stuck open thermostat, a Diag
nostic Trouble Code (DTC) number 17 can be
observed at the Check Engine Lamp.
I f the problem is sensed i n a monitored circuit of
ten enough to indicate an actual problem, a DTC is
stored. The DTC will be stored i n the PCM memory
for eventual display to the service technician. I f the POWERTRAIN CONTROL
problem is repaired or ceases to exist, the PCM can MODULE (PCM) J9414-11
cels the DTC after 51 engine starts.
Certain criteria must be met for a DTC to be en Fig. 5 PCM and Data Link Connector—Typical
tered into PCM memory. The criteria may be a spe • I f the lamp flashes 3 times, pauses and flashes 5
cific range of engine rpm, engine temperature and/or more times, a flashing Diagnostic Trouble Code
input voltage to the PCM. (DTC) number 35 is indicated.
A DTC indicates that the PCM has recognized an After any stored DTC information has been ob
abnormal signal i n a circuit or the system. A DTC served, the display will end with a flashing DTC
may indicate the result of a failure, but never iden number 55. This will indicate the end of all stored in
tify the failed component directly. formation.
I t is possible that a DTC for a monitored circuit
may not be entered into memory even though a mal E R A S I N G TROUBLE CODES
function has occurred. Refer to On-Board Diagnostics After the problem has been repaired, use the DRB
(OBD) i n Group 14, Fuel Systems for additional in scan tool to erase a DTC. Refer to the appropriate
formation. Powertrain Diagnostic Procedures service manual for
ACCESSING DIAGNOSTIC TROUBLE CODES
operation of the DRB scan tool.
A stored Diagnostic Trouble Code (DTC) can be dis
played by cycling the ignition key On-Off-On-OfF-On DRB SCAN TOOL
within three seconds and observing the Malfunction For operation of the DRB scan tool, refer to the ap
Indicator Lamp. This lamp was formerly referred to propriate Powertrain Diagnostic Procedures service
as the Check Engine Lamp. The lamp is located on manual.
the instrument panel.
They can also be displayed through the use of the PRELIMINARY CHECKS
Diagnostic Readout Box (DRB) scan tool. The DRB
connects to the data link connector i n the engine ENGINE COOLING SYSTEM OVERHEATING
compartment (Fig. 5). For operation of the DRB, refer Establish what driving conditions caused the com
to the appropriate Powertrain Diagnostic Procedures plaint. Abnormal loads on the cooling system such as
service manual. the following may be the cause:
1. P R O L O N G E D I D L E , V E R Y H I G H A M B I E N T
EXAMPLES: T E M P E R A T U R E , S L I G H T T A I L WIND AT I D L E ,
• I f the lamp flashes 1 time, pauses and flashes 7 SLOW T R A F F I C , T R A F F I C JAMS, H I G H S P E E D
more times, a flashing Diagnostic Trouble Code OR S T E E P GRADES.
(DTC) number 17 is indicated. Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at 4. R E C E N T SERVICE OR A C C I D E N T REPAIR:
end of normal range. Determine i f any recent service has been performed
• Increasing engine speed for more air flow is recom on vehicle that may effect cooling system. This may
mended. be:
2, T R M L E E TOWINGs • Engine adjustments (incorrect ignition timing)
• Slipping engine accessory drive belt(s)
Consult Trailer Towing section of owners manual.
• Brakes (possibly dragging)
Do not exceed limits.
• Changed parts. Incorrect water pump or pump ro
3. A I R C O N D I T I O N I N G ; ADD-ON OR A F T E R tating i n wrong direction due to belt not correctly
MARKETS routed
A maximum cooling package should have been or • Reconditioned radiator or cooling system refilling
dered with vehicle i f add-on or after market A/C is (possibly under filled or air trapped i n system).
installed. I f not, maximum cooling system compo I f investigation reveals none of the above as a
nents should be installed for model involved per cause for an engine overheating complaint, refer to
manufacturer's specifications. the following Symptom and Action chart:
SYMPTOM AND ACTION (SEE PRELIMINARY CHECKS FIRST)
SYMPTOM ACTION
Slinking E n g i n e T e m p e r a t u r e Normal during temporary operation with heavy load, towing a trailer, high
W a r n i n g Light o r H i g h G a u g e outdoor temperatures, and/or on a steep loss grade.
Indication—-
Without C o o l a n t Loss
C o o l a n t Loss Improper refilling procedures can result in trapped air in the system, Subsequent
operation of the pressure cap and coolantreservesystem will deaereate the
cooling system. A low coolant lmm\ will thenresultin the coolant reserve/overflow
tank. Ada coolant. If condition persists, refer to System Diagnosis.
Hot Vehicle (Not Englno) Check heat shielding, exhaust system, engine emission controls, ignition timing,
Hoot D a m a g e , engine misfiring.
Hot C a r p o t , S o a t f
Hot C a t a l y t i c C o n v e r t e r ,
S m o k e , Burnt O d o r
Hot Englno A moderate amount of sound from heating metal can be expected with any
Crackling Noiso vehicle. However, a crackling sound from the thermostat housing, a hot smell
Hot S m e l l and/or severe local hot spots on an engine can indicate blockedcoolant passages,
S e v e r e Local Hot Spots bad casting, core sand deposits and subsequent blockage, cracked cylinder block
or head, or blown cylinder head gasket. Usually accompanied with coolant loss.
C o o l a n t Color Coolant color is not necessarily an indication of adequate temperature or
corrosion protection.
C o o l a n t R e s e r v e l O v e r f low Level changes are to be expected as coolant volume fluctuates with enaine
Tank Lovol C h a n g o s temperature. If the level in the tank is between the FULL and ADD marks at normal
engine operating temperature, the level should return to within that range after
operation at elevated temperatures.
Coolant Not Returning Coolant will not return to the radiator if the radiator cap vent valve does not
To R a d i a t o r function, if an air leak destroys vacuum, or if the overflow passage is blocked or
restricted. Inspect all portions of the overflow passage, pressure cap, filler neck
nipple, hose, and passages within the tank for vacuum leak only. Coolant return
failure will be evident by a low level in the radiator. Reserve/overflow tank level
should increase during neat-up.
J9407-2
COOLING SYSTEM DIAGNOSIS (ALL EXCEPT DIESEL)
STANDARD GAUGE OPTIONAL GAUGE

(TYPICAL) (TYPICAL)
HIGH
TEMP.
LOW HIGH
TEMP. TEMP.
C O N D I T I O N A N D CNECKS DIAGNOSIS
GAUGE R E A D I N G L O W :
N o r m a l G o u g e Travel
(1) Verify gauge reading. Is a low temperature indicated? (1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) Is code 17 recorded in On-Board Diagnostics memory? (2) If code 17 is recorded, replace the thermostat. If not, the
thermostat is not the cause of the low gauge reading.
(3) Is the gauge reading in the cold range? (3) Inspect for disconnected sending unit electrical connector
or incorrect sending unit. Ensure that gauge sending unit
is installed and not an indicator light switch.
(4) Low coolant level during cold ambient temperatures (4) WARNINGS DO NOT REMOWE THE RADIATOR
(accompanied with poor heater performance). CAP OP A HOT PRESSURIZED E N G I N E .
#
SERIOUS INJURY C A N RESULT FROM

SCALDING COOLANT®
Inspect coolant level in the coolant reserve tank and
radiator. Inspect system for leaks.
(5) Coolant level is correct. (5) Inspect heater door controls. Refer to Group 24, Heating
and Air Conditioning.
GAUGE READING HIGH. (NO PRESSURE BLOW OFF

FROM RADIATOR P R E S S U R E CAP OR STEAM FROM
COOLANT RESERVE/OVERFLOW TANK):
High G a u g e Reading—Hot W e a t h e r — H e a v y Load
(1) Verify gauge reading. Is a high temperature reading (1) Compare gauge reading to High Gauge Reading
indicated? illustration above.
(2) Gauge reading high without signs of boiling. (2) Inspect for grounded gauge, sending unit or circuit.
Refer to Group 8, Electrical.
(3) Low coolant level in radiator and coolant reserve tank. (3) a - F i l l to full.
b —Inspect for leaks in system and repair as necessary,
c — Ensure radiator pressure cap was shut tight. Verify
proper operation of the radiator cap upper and
lower seals.
(4) Coolant level in radiator is low, but not low in coolant (4) o —Fill to full.
reserve tank. b — Inspect for leaks in the system and repair as necessary,
c — Inspect for leaks in the coolant reserve tank to
radiator hose,
d — Verify proper operation of the radiator cap upper
and lower seals.
J9407-3
COOLING SYSTEM DIAGNOSIS (ALL EXCEPT DIESEL)—CONTINUED
CONDITION AND CHECKS DIAGNOSIS
(5) Test coolant freeze point. (5) a —Adjust coolant solution to 50/50 mixture of anti
freeze a n d water. Refer to C o o l a n t in this group,
b — If a r e a d i n g is not recorded o r b e l o w - 5 0 ,
the mixture is too rich. C l e a n system a n d fill
with a 50/50 mixture of anti-freeze a n d water.
Refer to C o o l a n t in this group.
(6) Ensure proper coolant flow. (6) a — W i t h the thermostat o p e n a n d a slight amount of
• coolant removed, inspect for coolant flow through
the radiator at the filler neck o p e n i n g ,
b — Determine reason for lack of coolant flow a n d r e p a i r
a s necessary.
(7) Other possible causes. (7) a — If symptom occurs during high s p e e d operation
inspect for p l u g g e d a i r inlet side of the radiator
or condenser, p l u g g e d r a d i a t o r c o r e tubes, a d d - o n
A / C p a c k a g e without proper radiator, engine not
operating within specifications, dragging brakes,
trailer towing or hill climbing, or an insect screen.
b —If symptom occurs during high or low speed
operation inspect for: thermostat being stuck
partially open if ambient temperature is below 7 0 ° F
and the vehicle has high mileage, plugged air inlet
side of the radiator or condenser, add on A / C with
incorrect radiator.
c — If symptom occurs during low speed operation only,
inspect the thermal viscous fan drive. Repair as
necessary.
TEMPERATURE GAUGE READS HOT. PRESSURE

CAP VENTS RESULTING IN STEAM AND COOLANT
TRANSFER TO COOLANT RESERVE TANK:
(1) Coolant level low in radiator and coolant reserve tank. (1) a — Fill cooling system and vent trapped air.
b —Inspect for leaks. Repair as necessary.
c — Ensure that pressure cap is completely shut and seals.
d — If level is low in radiator but normal in the coolant
reserve tank, check the filler cap-to-coolant reserve
bottle connection and pressure cap seal.
(2) Test coolant freeze point. (2) Adjust coolant to 50/50 mix of anti-freeze and water.
Refer to Coolant section in this group.
(3) Ensure coolant is flowing through system. (3) a — With the coolant level low and the thermostat open,
check for coolant flow through the radiator at the
filler neck.
b — If a metal cracking sound is heard, inspect for core
sand restricting coolant flow through the water
jacket and/or a faulty cylinder head casting.
(4) Thermostat stuck in the closed position {prevalent in (4) Replace thermostat if found to be stuck in closed
cold ambient temperatures). position. Refer to the Thermostat Testing section in
this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket with a
commercially available Block Leak Tester.
J9407-4
CONDITION A N D CHECKS DIAGNOSIS
TEMPERATURE GAUGE IS INCONSISTENT*

CYCLES AND/OR IS ERRATIC:
(1) Is cycl® normal? (1) a—The gauge pointer may move up and down within
the normal range. This is the raction to the cycles of
the thermostat,
b—The gauge pointer may move to the high end of the
normal range. This is due to heavy use or after an
engine shutdown and restart.
(2) Is coolant in radiator low (air will build up in the cooling (2) Fill system, vent trapped air and check for leaks.
system and cause the thermostat to open late)?
(3) Is a cylinder head gasket leak allowing exhaust gas to (3) a—Test for leaking cylinder head gasket leak with a
enter cooling system (exhaust gas building up in the commercially available Block Leak Tester,
cooling system will cause the thermostat to open late)? b—Check for coolant in engine oil
c — Inspect for white steam from exhaust system.
(4) Water pump impeller loose on shaft. Loose accessory (4) Repair or replace as necessary.
drive belt.
(5) Air leak on the suction side of the water pump (allows (5) Find leak and repair.
air to build up in cooling system causing thermostat to
open late).
C O N D I T I O N A N D CHECKS DIAGNOSIS
P R E S S U R E CAP VENTS TO ATMOSPHERE A N D

C O O L A N T R E S E R V E T A N K . TEMPERATURE G A U G E
R E A D I N G A B O V E N O R M A L BUT N O T H I G H :
(1) Test r a d i a t o r pressure c a p relief pressure. Refer t o Radiator (1) Replace c a p if relief pressure is lower than 14 psi.
Pressure c a p section in this g r o u p .
C O O L A N T LOSS V I S I B L E O N G R O U N D B E L O W
V E H I C L E , BUT N O P R E S S U R E C A P B L O W O F F :
(1) Inspect system for leaks. (1) Repair as necessary
C O O L A N T L O S S PAST P R E S S U R E C A P TOP S E A L ,
V I S I B L E O N R A D I A T O R FILLER N E C K :
(1) W i t h n o r m a l g a u g e r e a d i n g . (1) a — Pressure c a p not installed tightly,
b —Pressure c a p t o p seal leaks.
c — Pressure c a p d i a p h r a g m b o w e d .
d — D a m a g e d r a d i a t o r filler neck.
e — Pressure c a p t o p seal out o f p o s i t i o n .
(2) W i t h high o r l o w g a u g e r e a d i n g o n new vehicle. (2) a — Kinked coolant reserve/overflow system hose.
b — C o o l a n t reserve system tank plastic tube p l u g g e d ,
c — Pressure c a p seal out o f p o s i t i o n .
DETONATION O R P R E I G N I T I O N . NOT CAUSED BY

IGNITION OR ENGINE CONDITIONS:
(1) Check engine coolant freeze point. If the tester does not (1) a — A d j u s t c o o l a n t solution t o 5 0 / 5 0 w a t e r ethylene-glycol
register a r e a d i n g o r if the r e a d i n g is b e l o w 5 0 ° F, inspect mixture.
ethylene-glycol/water ratio. A 1 0 0 percent solution o f b — I f 100 percent ethylene-glycol solution is f o u n d in
ethylene-glycol in the system causes the engine t o run hotter system, clean a n a flush system before r e p l a c i n g w i t h
a n a possibly overheat. 5 0 / 5 0 mixture o f ethylene-glycol a n d water.
C O O L I N G SYSTEM HOSES COLLAPSE

ON COOLDOWN:
(1) Inspect pressure c a p vent valve. (1) a — Gasket swell can prevent valve from o p e n i n g ,
b — Replace pressure cap.
(2) Coolant reserve tank hose p l u g g e d o r k i n k e d . (2) Repair as necessary.
(3) Inside o f pressure c a p p l u g g e d . (3) Clean c a p o r replace i f necessary.
C O O L I N G S Y S T E M SUSPECTED AS CAUSE O F
INADEQUATE AIR C O N D I T I O N I N G SYSTEM
PERFORMANCE:
(1) Inspect for p l u g g e d r a d i a t o r and/or condenser. (1) Clean with l o w pressure w a t e r from fan side.
(2) Inspect for missing a i r seals in the recirculating a i r p a t h . (2) Repair as necessary.
EXCESSIVE FAN N O I S E :
(1) Inspect for loose o r bent fan blades. (1) Replace fan.
(2) Inspect clearance between fan a n d adjacent p a r t . (2) Repair o r replace as necessary.
(3) Inspect r a d i a t o r a n d condenser for incoming a i r (3) Clean a i r p a t h w i t h l o w pressure w a t e r from f a n side.
obstructions.
(4) Inspect thermal viscous fan drive. (4) Replace if viscous drive does not o p e r a t e p r o p e r l y .
HEAT O D O R :
(1) Was temperature g a u g e r e a d i n g high? (1) If YES, refer t o G A U G E R E A D I N G H I G H . If N O , refer to
steps 2 , 3 , a n d 4 .
(2) A r e a l l heat shields in place? (2) If YES, refer t o steps 3 a n d 4 . If N O , r e p a i r as r e q u i r e d .
(3) Is the a i r side o f the heat exchanger plugged? (3) Clean as necessary.
(4) Engine running rich causing catalytic converter to overheat. (4) Repair as necessary.
1
P O O R D R I V E A B I L I T Y , S U S P E C T THERMOSTAT FAILED
IN O P E N POSITION:
(1) Check O n - B o a r d Diagnostics. Is code 17 set in memory? (1) If YES, replace thermostat. If N O , refer to the a p p r o p r i a t e
Powertrain Diagnostic Procedures m a n u a l .
J9407-6
7 - 11 COOLING SYSTEM
POOR HEATER PERFORMANCE. SUSPECT

THERMOSTAT FAILED I N OPEN POSITIONS
(1) Does gauge read low? (1) If YES, replace thermostat. If NO, inspect the heater
hoses for kinks or binds. Also inspect condition of heat
doors in heater. Refer to Group 24, Heat and Air
Conditioning.
Conditioning.
(2) Is coolant level low? (2) Fill cooling system and inspect for leaks. Repair as
necessary.
(3) Check On-Board Diagnostics. Is code 17 set in memory? (3) If YES, replace thermostat. If NO, inspect the heater
hoses for kinks or binds. Also inspect condition of heat
doors in heater. Refer to Group 24, Heat and Air
Conditioning.
J9407-7
COOLING SYSTEM 7 - 11
COOLING SYSTEM DIAGNOSIS—DIESEL
STANDARD G A U G E OPTIONAL GAUGE

(TYPICAL) (TYPICAL)
LOW
TEMP.
GAUGE READING LOWs

N o r m a l G a u g o Travel
(1) Verify gauge reading. Is a low temperature indicated? (1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) Thermostat stuck in open position? (2) Confirm by placing radiator thermometer in radiator.
Replace thermostat if necessary.
(3) Is the gauge reading in the cold range? (3) Inspect for disconnected sending unit electrical connector
or incorrect sending unit.
(4) Low coolant level during cold ambient temperatures (4) WARNINGS D O NOT REMOVE THE RADIATOR
(accompanied with poor heater performance). CAP OF A HOT* PRESSURIZED ENGINE.
SERIOUS INJURY C A N RESULT FROM
SCALDING COOLANT*
Inspect coolant level in the coolant reserve tank and
radiator. Inspect system for leaks.
(5) Coolant level is correct. (5) Inspect heater door controls. Refer to Group 24, Heating
and Air Conditioning.
GAUGE READING H I G H . ( N O PRESSURE BLOW OFF

FROM RADIATOR PRESSURE CAP OR STEAM FROM
COOLANT RESERVE/OVERFLOW TANKJs
H i g h G a u g o Roading—Hot W o a t h o r — H o a v y Load
(1) Verify gauge reading. Is a high temperature reading (1) Compare gauge reading to High Gauge Reading
indicated? illustration above.
(2) Gauge reading high without signs of boiling. (2) Inspect for grounded gauge, sending unit or circuit.
Refer to Group 8 , Electrical.
(3) Low coolant level in radiator and coolant reserve tank. (3) a —Fill to full.
b —- Inspect for leaks in system and repair as necessary,
c — Ensure radiator pressure cap was shut tight. Verify
proper operation of the radiator cap upper and
lower seals.
(4) Coolant level in radiator is low, but not low in coolant (4) a - F i l l to full.
reserve tank. b — Inspect for leaks in the system and repair as necessary,
c — Inspect for leaks in the coolant reserve tank to
radiator hose,
d — Verify proper operation of the radiator cap .upper
and lower seals.
J9407-8
COOLING SYSTEM DIAGNOSIS—DIESEL—CONTINUED
CONDITION A N D CHECKS DIAGNOSIS
(5) Test coolant freeze point. (5) a—Adjust coolant solution to 5 0 / 5 0 mixture of anti
f r e e z e a n d water. Refer to Coolant in this group,
b—If a reading is not recorded or below - 5 0 ,
the mixture is too rich. Clean system a n d fill
with a 5 0 / 5 0 mixture of anti-freeze a n d water.
Refer to Coolant in this group.
(6) Ensure proper coolant flow. (6) a — W i t h the thermostat open and a slight amount of
coolant removed, inspect for coolant flow through
the radiator at the filler neck opening,
b—Determine reason for lack of coolant flow a n d repair
a s necessary.
(7) Other possible causes. (7) a —If symptom occurs during high speed operation
inspect for plugged air inlet side of the radiator
or condenser, plugged radiator core tubes, a d d - o n
A / C p a c k a g e without proper radiator, engine not
operating within specifications, d r a g g i n g b r a k e s ,
trailer towing or hill climbing, or an insect screen.
b — If symptom occurs during high or low s p e e d
operation inspect for: thermostat being stuck
partially open if ambient temperature is below 7 0 ° F
a n d the vehicle has high mileage, p l u g g e d a i r inlet
side of the radiator or condenser, add on A / C with
incorrect radiator. .
c — If symptom occurs during low speed operation only,
inspect the thermal viscous fan drive. Repair a s '
necessary.
TEMPERATURE GAUGE READS HOT. PRESSURE

CAP VENTS RESULTING IN STEAM A N D COOLANT
TRANSFER TO COOLANT RESERVE TANK:
(1) Coolant level low in radiator and coolant reserve tank. (1) a — F i l l cooling system and vent trapped air.
b —Inspect for leaks. Repair as necessary.
c — Ensure that pressure cap is completely shut a n d s e a l s .
d —If level is low in radiator but normal in th© coolant
reserve tank, check the filler cap-to-coolant reserve
bottle connection and pressure cap seal.
(2) Test coolant freeze point. (2) Adjust coolant to 5 0 / 5 0 mix of anti-freeze a n d water.
Refer to Coolant section in this group.
(3) Ensure coolant is flowing through system. (3) a — With the coolant level low and the thermostat open,
check for coolant flow through the radiator at the
filler neck.
b — If a metal cracking sound is heard, inspect for core
sand restricting coolant flow through the water
jacket and/or a faulty cylinder head casting.
(4) Thermostat stuck in the closed position (prevalent in (4) Replace thermostat if found to be stuck in closed
cold ambient temperatures). position. Refer to the Thermostat Testing section in
this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket with a
commercially available Block Leak Tester.
J9407-4
1
COOLING SYSTEM DIAGNOSIS—DIESEL-CONTINUED
C O N D I T I O N AND CHECKS DIAGNOSIS
TEMPERATURE G A U G E IS INCONSISTENT,
CYCLES A N DIOR IS ERRATICs
(1) Is cycle normal? (1) a —The gauge pointer may move up and down within
the normal range. This is the raction to the cycles of
the thermostat.
b —The gauge pointer may move to the high end of the
normal range. This is due to heavy use or after an
engine shutdown and restart.
(2) Is coolant in radiator low (air will build up in the cooling (2) Fill system, vent trapped air and check for leaks.
system and cause the thermostat to open late)?
(3) Is a cylinder head gasket leak allowing exhaust gas to (3) a —Test for leaking cylinder head gasket leak with a
enter cooling system (exhaust gas building up in the commercially available Block Leak Tester,
cooling system will cause the thermostat to open late)? b —Check for coolant in engine oil
c — Inspect for white steam from exhaust system.
(4) Water pump impeller loose on shaft. Loose accessory (4) Repair or replace as necessary.
drive belt.
(5) Air leak on the suction side of the water pump (allows (5) Find leak and repair.
air to build up in cooling system causing thermostat to
open late).
J9407-5
PRESSURE C A P WENTS TO ATMOSPHERE A N D

C O O L A N T RESERVE T A N K . TEMPERATURE G A U G E
READING A B O V E N O R M A L B U T NOT H I G H s
(1) Test r a d i a t o r pressure c a p relief pressure. Refer t o (1) R e p l a c e c a p i f relief pressure is l o w e r t h a n 14 p s i .
R a d i a t o r Pressure c a p section in this g r o u p .
C O O L A N T LOSS VISIBLE O N G R O U N D BELOW

V E H I C L E , B U T N O PRESSURE CAP BLOW OP ft
(1) Inspect system f o r leaks. (1) R e p a i r as necessary.
C O O L A N T L O S S PAST PRESSURE C A P T O P S E A L ,
VISIBLE O N R A D I A T O R FILLER N E C K s
(1) With normal gauge reading. (1) a — Pressure c a p n o t i n s t a l l e d t i g h t l y ,
b — Pressure c a p t o p seal leaks.
c — Pressure c a p d i a p h r a g m b o w e d .
d — D a m a g e d r a d i a t o r filler n e c k .
e — Pressure c a p t o p s e a l o u t o f p o s i t i o n .
(2) W i t h h i g h o r l o w g a u g e r e a d i n g o n n e w vehicle. (2) a — K i n k e d c o o l a n t reserve/overflow system hose.
b — C o o l a n t reserve system t a n k plastic t u b e p l u g g e d ,
c — Pressure c a p seal o u t o f p o s i t i o n .
C O O L I N G SYSTEM HOSES COLLAPSE

ON COOLDOWNt
(1) Inspect pressure c a p vent v a l v e . (1) a — G a s k e t s w e l l c a n prevent v a l v e f r o m o p e n i n g ,
b — R e p l a c e pressure c a p .
(2) C o o l a n t reserve t a n k hose p l u g g e d o r k i n k e d . (2) R e p a i r as necessary.
(3) Inside o f pressure c a p p l u g g e d . (3) C l e a n c a p o r r e p l a c e i f necessary.
C O O L I N G SYSTEM SUSPECTED A S CAUSE O F

I N A D E Q U A T E AIR C O N D I T I O N I N G S Y S T E M
PERFORMANCE!
(1) Inspect for p l u g g e d r a d i a t o r a n d / o r condenser. (1) C l e a n w i t h l o w pressure w a t e r f r o m f a n side.
(2) Inspect f o r missing a i r seals in the r e c i r c u l a t i n g a i r p a t h . (2) R e p a i r as necessary.
E X C E S S I V E F A N NOISEs
(1) Inspect f o r l o o s e o r b e n t f a n b l a d e s . (1) Replace f a n .
(2) Inspect c l e a r a n c e b e t w e e n f a n a n d a d j a c e n t p a r t . (2) R e p a i r o r r e p l a c e as necessary.
(3) Inspect r a d i a t o r a n d c o n d e n s e r f o r i n c o m i n g a i r (3) C l e a n a i r p a t h w i t h l o w pressure w a t e r f r o m f a n side.
obstructions.
(4) Inspect t h e r m a l viscous fan d r i v e . (4) R e p l a c e i f viscous d r i v e d o e s n o t o p e r a t e p r o p e r l y .
HEATODORi
(1) W a s t e m p e r a t u r e g a u g e r e a d i n g high? (1) If Y E S , refer t o G A U G E R E A D I N G H I G H . If N O , check
c o n d i t i o n o f a l l h e a t shields.
(2) A r e a l l h e a t shields i n p l a c e ? (2) If N O , r e p a i r as r e q u i r e d .
J9407-9
P O O R HEATER P E R F O R M A N C E . SUSPECT
THERMOSTAT FAILED I N O P E N P O S I T I O N :
(1) D o e s g a u g e r e a d l o w ? (1) If YES, r e p l a c e t h e r m o s t a t . If N O , inspect the h e a t e r
hoses f o r kinks o r b i n d s . A l s o i n s p e c t c o n d i t i o n o f h e a t
d o o r s in heater. Refer t o G r o u p 2 4 , H e a t a n d A i r
Conditioning.
(2) Is c o o l a n t level l o w ? (2) Fill c o o l i n g system a n d inspect f o r l e a k s . R e p a i r as
necessary.
(3) T h e r m o s t a t stuck i n o p e n p o s i t i o n ? (3) C o n f i r m b y p l a c i n g r a d i a t o r t h e r m o m e t e r in r a d i a t o r . .
R e p l a c e t h e r m o s t a t if necessary.
J9407-10
SERWiCE P R O C E D U R E S
INDEX
page page
Coolant 34 Refilling Cooling System 36
Coolant Reserve/Overflow System 39 Testing Cooling System for Leaks 37
Cooling System Cleaning/Reverse Flushing 36 Thermostat 28
Cooling System Fan—Diesel Engine 45 Viscous Fan Drive 45
Cooling System Fan—Gas Engines 43 Water Pump Bypass Hose 24
Cooling System Hoses 43 Water Pump—5.9L Diesel 23
Draining Cooling System 36 Water Pump—8.0L V-10 Engine 19
Radiator Pressure Cap 40 Water Pumps—Except Diesel and
Radiators 41 8.0L V-10 Engine 16
WATER PUMPS—EXCEPT DIESEL AND 8.0L ¥-10 (3) Remove windshield washer reservoir tank from
ENGINE radiator fan shroud. Refer to Group 8K, Windshield
Wiper and Washer Systems.
A centrifugal water pump circulates coolant
(4) Except 8.0L V-10: Disconnect the coolant re
through the water jackets, passages, intake manifold,
serve/overflow tank-to-radiator hose at the tank.
radiator core, cooling system hoses and heater core.
(5) Remove the four fan shroud mounting bolts at
The pump is driven from the engine crankshaft by a
the radiator (Fig. 1). Do not attempt to remove
drive belt. shroud from vehicle at this time.
The water pump impeller is pressed onto the rear
of a shaft that rotates i n a bearing pressed into the RADIATOR
water pump body. The body has a small hole for ven
tilation. The water pump seals are lubricated by an
tifreeze i n the coolant mixture. Additional lubrication
is not necessary.
A quick test to determine i f pump is working is to
check i f heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
REMOVAL
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover.
On all gas powered engines except the 8.0L V-10, a
gasket is used as a seal between the water pump and
timing chain case/cover.
I f water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling FAN SHROUD M O U N T I N G BOLTS J9407-37
fan assembly should also be inspected. Inspect for fa

tigue cracks, loose blades or loose rivets that could Fig. 1 Typical Fan Shroud Mounting
have resulted from excessive vibration. Replace fan i f WARNING: CONSTANT TENSION HOSE CLAMPS
any of these conditions are found. Also check condi ARE USED ON MOST COOLING SYSTEM HOSES.
tion of the thermal viscous fan drive. Refer to Viscous WHEN REMOVING OR INSTALLING, USE ONLY
Fan Drive i n this group. TOOLS DESIGNED FOR SERVICING THIS TYPE OF
(1) Disconnect negative battery cable from battery. CLAMP, SUCH A S SPECIAL CLAMP TOOL (NUMBER
(2) Drain cooling system. Refer to Draining Cooling 60§4) (FIG. 2). SNAP-ON CLAMP TOOL (NUMBER
System i n this group. HPC-20) MAY BE USED FOR LARGER CLAMPS. A L
Do not waste reusable coolant. I f solution is clean, WAYS WEAR SAFETY GLASSES WHEN SERVICING
drain coolant into a clean container for reuse. CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into t h e I f water pump is being replaced, do not unbolt fan
tongue of constant tension clamps (Fig. 3). If re blade assembly (Fig. 4) from the thermal control fan
placement is necessary, u s e only an original equip drive.
ment clamp with a matching number or letter. (8) Remove fan blade/fan drive and fan shroud as
an assembly from vehicle.
(6) Remove upper radiator hose at radiator. After removing fan blade/fan drive assembly, do
HOSE CLAMP HOSE not place the thermal viscous fan drive i n the hori
TOOL 6094 CLAMP zontal position. I f stored horizontally, the silicone
fluid i n the viscous drive could drain into its bearing
assembly and contaminate the bearing lubricant.
Do not remove the water pump pulley bolts at this
time.
F A N BLADE WATER WATER PUMP
ASSEMBLY PUMP
PULLEY
THREADED
NUT
J9207-36
Fig. 2 Hose damp Tool—Typical

TYPICAL
CONSTANT
T E N S I O N HOSE
CLAMP
THREADED SHAFT CRANKSHAFT

(WATER PUMP HUB) PULLEY
VISCOUS FAN DRIVE

J9307-32
Fig. 4 Fan Blade and Viscous Fan Drive—Typical .

(9) Remove accessory drive belt as follows: The
drive belt is equipped with a spring loaded automatic
tensioner (Figs. 5 or 6).
3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: Relax
the tension from the belt by rotating the tensioner
TYPICAL
HOSE
clockwise (as viewed from front) (Fig. 5). When all
CLAMP
belt tension has been relaxed, remove accessory drive
NUMBER/LETTER belt.
LOCATION J9407-39 5.9L HDC-Gas Engine: Relax the tension from the
belt by rotating the tensioner counterclockwise (as
Fig. 3 Clamp Number/Letter Location viewed from front) (Fig. 6). When all belt tension has
(7) The thermal viscous fan drive is attached been relaxed, remove accessory drive belt.
(threaded) to the water pump hub shaft (Fig. 4). Re (10) Remove the four water pump pulley-to-water
move the fan/fan drive assembly from water pump by pump hub bolts (Fig. 4) and remove pulley from ve
turning the mounting nut counterclockwise (as hicle.
viewed from front). Threads on the fan drive are (11) Remove the lower radiator hose and heater
R I G H T H A N D . A Snap-On 36 M M Fan Wrench hose from water pump.
(number SP346 from Snap-On Cummins Diesel Tool (12) Loosen heater hose coolant return tube
Set number 2017DSP) can be used. Place a bar or mounting bolt (Figs. 7 or 8) and remove tube from
screwdriver between the water pump pulley bolts water pump. Discard the old tube O-ring.
(Fig. 4) to prevent the pulley from rotating. (13) Remove the seven water pump mounting bolts
(Fig. 9).
7-18 COOLING SYSTI1 •
Fig. 5 Belt Tensioner—3.9L V-6 or 5.2/5.9L V-8 Fig. 7 Coolant Return Tube—3.9L V-6 or 5.2/5.9L V-8
LDC-Gas Engines LDC-Gas Engines
Fig. 6 Belt Tensioner—5.9L HDC-Gas Engine Fig. 8 Coolant Return Tube—5.9L HDC-Gas Engine
(14) Loosen the clamp at the water pump end of INSPECTION
bypass hose (Fig. 4). Slip the bypass hose from the Replace water pump assembly i f i t has any of the
water pump while removing pump from vehicle. Do following conditions:
not remove the clamp from the bypass hose. • The body is cracked or damaged
(15) Discard old gasket. • Water leaks from the shaft seal. This is evident by
traces of coolant below the vent hole
CAUTION: Do not pry the water pump at timing • Loose or rough turning bearing. Also inspect ther
chain case/cover. The machined surfaces may be mal fan drive
damaged resulting in leaks. • Impeller rubs either the pump body or timing
chain case/cover
Fig. 9 Water Pump Bolts—3.9L ¥-6 or 5.2/5.9L ¥-8
Gas Engines—Typical
INSTALLATION
(1) Clean gasket mating surfaces. *IF VEHICLE IS N O T EQUIPPED WITH POWER
(2) Using a new gasket, install water pump to en STEERING, THIS WILL BE A N IDLER PULLEY. J9307-26
gine as follows: Guide water pump nipple into bypass

Fig. 10 Belt Routing—3.9L ¥-6 or 5.2/5.9L W~8
hose as pump is being installed. Install water pump
LDC-Gas Engines
bolts (Fig. 9). Tighten water pump mounting bolts to
40 N-m (30 ft. lbs.) torque. AUTOMATIC
(3) Position bypass hose clamp to bypass hose. TENSIONER
(4) Spin water pump to be sure that pump impeller

does not rub against timing chain case/cover.
(5) Install a new O-ring to the heater hose coolant
return tube (Figs. 7 or 8). Coat the new O-ring with
antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Figs. 7 or 8). Be sure the slot i n tube PWR.
STRG.
bracket is bottomed to mounting bolt. This will prop PUMP
erly position return tube.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to coolant
return tube.
(9) Install water pump pulley. Tighten bolts to 27
N*m (20 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 4) to prevent
pulley from rotating.
(10) Relax tension from automatic belt tensioner
(Figs. 5 or 6). Install drive belt. J9307-53
CAUTION: When installing the serpentine accessory Fig. 11 Belt Routing—5.9L HDC-Gas Engine—With
drive belt, belt must be routed correctly. If not, en A/C
gine may overheat due to water pump rotating in (14) Fill cooling system. Refer to Refilling Cooling
wrong direction. Refer to (Figs. 10,11 or 12) for cor System i n this group.
rect belt routing. The correct belt with correct
(15) Connect negative battery cable.
length must be used.
(16) Start and warm the engine. Check for leaks.
(11) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit. WATER PUMP—8.0L V-10 ENGINE
(12) Install fan shroud. A centrifugal water pump circulates coolant
(13) Install fan blade/viscous fan drive assembly to through the water jackets, passages, intake manifold,
water pump shaft.
AUTOMATIC
(2) Drain cooling system. Refer to Draining Cooling
TENSIONER System in this group.
Do not waste reusable coolant. I f solution is clean,
drain coolant into a clean container for reuse.
(3) Remove windshield washer reservoir tank from
radiator fan shroud. Refer to Group 8K, Windshield
Wiper and Washer Systems.
(4) Remove the four fan shroud mounting bolts at
the radiator (Fig. 13). Do not attempt to remove
shroud from vehicle at this time.
RADIATOR
J9307-56
Fig. 12 Beit Routing—5.9L HDC-Gas Engine—

Without A/C
radiator core, cooling system hoses and heater core.
The pump is driven from the engine crankshaft by a
drive belt.
The water pump impeller is pressed onto the rear
of a shaft that rotates i n a bearing pressed into the
water pump body. The body has a small hole for ven
tilation. The water pump seals are lubricated by an
FAN SHROUD M O U N T I N G BOLTS J9407-37
tifreeze i n the coolant mixture. Additional lubrication
is not necessary. Fig. 13 Typical Fan Shroud Mounting
A quick test to determine i f pump is working is to
WARNING: CONSTANT TENSION HOSE CLAMPS
check i f heater warms properly. A defective water
A R E USED ON MOST COOLING SYSTEM HOSES.
pump will not be able to circulate heated coolant
WHEN REMOVING OR INSTALLING, USE ONLY
through the long heater hose to the heater core.
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
REMOVAL CLAMP, SUCH A S SPECIAL CLAMP TOOL (NUMBER
The water pump on all models can be removed 6094) (FIG. 14). SNAP-ON CLAMP TOOL (NUMBER
without discharging the air conditioning system (if HPC-20) MAY BE USED FOR LARGER CLAMPS. A L
equipped). WAYS WEAR SAFETY GLASSES WHEN SERVICING
The water pump. on all gas powered engines is CONSTANT TENSION CLAMPS.
bolted directly to the engine timing chain case/cover.
On the 8.0L V-10 engine, a rubber O-ring (instead CAUTION: A number or letter is stamped into the
of a gasket) is used as a seal between the water tongue of constant tension clamps (Fig. 15). If re
pump and timing chain case/cover. placement is necessary, u s e only an original equip
I f water pump is replaced because of bearing/shaft ment clamp with a matching number or letter.
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for fa (5) Remove upper radiator hose at radiator.
tigue cracks, loose blades or loose rivets that could (6) The thermal viscous fan drive is attached
have resulted from excessive vibration. Replace fan i f (threaded) to the water pump hub shaft (Fig. 16). Re
any of these conditions are found. Also check condi move the fan/fan drive assembly from water pump by
tion of the thermal viscous fan drive. Refer to Viscous turning the mounting nut counterclockwise (as
Fan Drive i n this group. viewed from front). Threads on the fan drive are
(1) Disconnect negative battery cable from battery. R I G H T H A N D . A Snap-On 36 M M Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
• COOLING SYSTEM 7 - 21
HOSE CLAMP HOSE F A N BLADE WATER WATER PUMP
J9207-36
Fig. 14 Hose Clamp Tool—Typical

TYPICAL
CONSTANT
T E N S I O N HOSE
CLAMP VISCOUS FAN DRIVE
J9307-32
Fig. 16 Fan Blade and Viscous Fan Drive—Typical

(8) Remove accessory drive belt as follows: The
drive belt is equipped with a spring loaded automatic
tensioner (Fig. 17).
Relax the tension from the belt by rotating the ten
sioner counterclockwise (as viewed from front) (Fig.
17). When all belt tension has been relaxed, remove
accessory drive belt.
TYPICAL
HOSE
CLAMP
NUMBER/LETTER
LOCATION J9407-39
Fig. 15 Clamp Number/Letter Location

Set number 2017DSP) can be used. Place a bar or
screwdriver between the water pump pulley bolts
(Fig. 16) to prevent the pulley from rotating.
I f water pump is being replaced, do not unbolt fan
blade assembly (Fig. 16) from the thermal control fan
drive.
(7) Remove fan blade/fan drive and fan shroud as
an assembly from vehicle.
After removing fan blade/fan drive assembly, do
n o t place the thermal viscous fan drive i n the hori
zontal position. I f stored horizontally, the silicone
fluid in the viscous drive could drain into its bearing
assembly and contaminate the bearing lubricant. Fig. 17 Belt Tensioner—8.0L VW Engine
Do n o t remove the water pump pulley bolts at this (9) Remove the four water pump pulley-to-water
time. pump hub bolts (Fig. 16) and remove pulley from ve
hicle.
(10) Remove the lower radiator hose at water CAUTION: Do not pry the water pump at timing
pump. chain case/cover. The machined surfaces may be
(11) Remove heater hose at water pump fitting. damaged resulting in leaks.
(12) Remove the seven water pump mounting bolts
(Fig. 18).
INSPECTION
Replace water pump assembly i f i t has any of the
following conditions:
• The body is cracked or damaged
• Water leaks from the shaft seal. This is evident by
traces of coolant below the vent hole
• Loose or rough turning bearing. Also inspect ther
mal fan drive
• Impeller rubs either the pump body or timing
chain case/cover
INSTALLATION
(1) I f water pump is being replaced, install the
heater hose fitting to the pump. Tighten fitting to 16
N-m (144 in. lbs.) torque. After fitting has been
torqued, position fitting as shown i n figure 20. When
positioning fitting, do not back off (rotate counter
clockwise). Use a sealant on the fitting such as Mo
par™ Thread Sealant With Teflon. Refer to the
directions on the package.
J9407-19
CAUTION: This heater hose fitting must be installed
Fig. 18 Water Pump Bolts—8.0L ¥-10—Typical to pump before pump is installed to engine.
(13) Loosen the- clamp at the water pump end of

bypass hose. Slip the bypass hose from the water
pump while removing pump from vehicle. Do not re
move the clamp from the bypass hose. HEATER
HOSE
(14) Discard the water pump-to-timing chain/case FITTING
cover O-ring seal (Fig. 19).
WATER PUMP
WATER
PUMP
FRONT
O-RING
SEAL
J9407-17
J9407-18
Fig. 20 Heater Hose Fitting Position—8.0L ¥-10
Fig. 19 Water Pump O-Ring Seal—8.0L ¥-10
(2) Clean the O-ring mating surfaces at rear of wa
(15) Remove the heater hose fitting from water ter pump and front of timing chain/case cover.
pump i f pump replacement is necessary. Note posi (3) Apply a small amount of petroleum jelly to O-
tion (direction) of fitting before removal. Fitting must ring (Fig. 19). This will help retain O-ring to water
be re-installed to same position. pump.
(4) Install water pump to engine as follows: Guide AUTOMATIC

water pump fitting into bypass hose as pump is being TENSIONER
installed. Install water pump bolts (Fig. 18). Tighten
water pump mounting bolts to 40 N-m (30 ft. lbs.)
torque.
(5) Position bypass hose clamp to bypass hose.
(6) Spin water pump to be sure that pump impeller
does not rub against timing chain case/cover.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to heater
hose fitting.
(9) Install water pump pulley. Tighten bolts to 22
N-m (16 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 16) to prevent
pulley from rotating.
(10) Relax tension from automatic belt tensioner
(Fig. 17). Install drive belt.
CAUTION: When installing the serpentine a c c e s s o r y

drive belt, belt must be routed correctly. If not, en
J9307-56
gine may overheat due to water pump rotating in
wrong direction. Refer to (Figs. 21 or 22) for correct Fig. 22 Belt Routing—8.0L V-10 Engine—Without
belt routing. The correct belt with correct length A/C '
must be used.
WATER PUMP—5 J L DIESEL
AUTOMATIC The diesel engine water pump draws coolant from
TENSIONER
radiator outlet and circulates i t through engine,
heater core and back to radiator inlet. The crank
shaft pulley drives the water pump via a serpentine
drive belt (Fig. 23). A n automatic belt tensioner (Fig.
23) is used to prevent the belt from slipping.
J9307-55
Fig. 21 Belt Routing—8.0L V-10 Engine—With A/C

Fig. 23 Water Pump—5.9L Diesel—Typical (non-A/C
drive assembly to vehicle as a complete unit.
shown)
(12) Install fan shroud to radiator. Tighten bolts to
6 N-m (50 in. lbs.) torque. REMOVAL
(13) Install fan blade/viscous fan drive assembly to (1) Disconnect the negative battery cables from
water pump shaft. both batteries.
(14) Fill cooling system. Refer to Refilling Cooling (2) Drain cooling system. Refer to Draining Cooling
System i n this group. System i n this section.
(3) Remove the bolt retaining the wiring harness WATER PUMP BYPASS HOSE
near the top of water pump. Position wire harness to A water pump bypass hose (Fig. 26) is used be
the side. tween the intake manifold and water pump on all
(4) Remove the accessory drive belt. Refer to the gas powered engines. To test for leaks, refer to Test
Engine Accessory Drive Belt section of this group. ing Cooling System for Leaks i n this group.
(5) Remove water pump mounting bolts (Fig. 24).
F A N BLADE WATER WATER PUMP
ASSEMBLY PUMP
PULLEY
THREADED
NUT
u %
^J9107-5
Fig. 24 Pump Removal/Installation—5.9L Diesel

THREADED SHAFT CRANKSHAFT
(6) Clean water pump sealing surface on cylinder (WATER PUMP HUB) PULLEY
block.
VISCOUS FAN DRIVE J9307-32
INSTALLATION
(1) Install new O-ring seal i n groove on water Fig. 26 Water Pump Bypass Hose—Typical
pump (Fig. 25).
REMOVAL—3.9L V - 6 O R 5.2/5.9L V-8 ENGINES
WITHOUT AIR CONDITIONING
(1) Partially drain cooling system. Refer to Drain
O-RING ing Cooling System i n this group.
SEAL
Do not waste reusable coolant. I f the solution is
clean, drain the coolant into a clean container for re
use.
GROOVE
WARNING: CONSTANT TENSION H O S E C L A M P S
A R E U S E D ON MOST COOLING S Y S T E M H O S E S .
WHEN REMOVING O R INSTALLING, U S E ONLY
T O O L S D E S I G N E D F O R SERVICING THIS T Y P E O F
CLAMP, S U C H A S S P E C I A L CLAMP T O O L (NUMBER
WATER 6094) (FIG. 27). SNAP-ON C L A M P T O O L (NUMBER
PUMP HPC-20) MAY B E U S E D F O R L A R G E R C L A M P S . A L
J9107-6
WAYS W E A R S A F E T Y G L A S S E S WHEN SERVICING
Fig. 25 Pump O-ring Seal—5.9L Diesel CONSTANT TENSION C L A M P S .
(2) Install water pump. Tighten mounting bolts to

24 N-m (18 ft. lbs.) torque. CAUTION: A number or letter is stamped into the
(3) Install accessory drive belt. Refer to the Engine tongue of constant tension clamps (Fig. 28). If re
Accessory Drive Belt section of this group. placement is necessary, u s e only an original equip
(4) Install the bolt retaining the wiring harness ment clamp with a matching number or letter.
near top of water pump.
(5) Fill cooling system. Refer to Refilling Cooling (2) Loosen both bypass hose clamps and position to
System i n this section. the center of hose.
(6) Connect both battery cables. (3) Remove hose from vehicle.
HOSE CLAMP HOSE system is not necessary. Do n o t remove any refriger

ant lines from A/C compressor.
SUPPORT BRACKET (ROD)
J9207-36
GENERATOR/COMPRESSOR
M O U N T I N G BRACKET
J9307-66
Fig. 29 Generator—A/C Compressor Mounting

Bracket—Typical
WARNING: THE A / C SYSTEM (S UNDER PRESSURE
E V E N WITH T H E ENGINE OFF. REFER TO REFRIG
ERANT WARNINGS IN GROUP 24, HEATING A N D
AIR CONDITIONING.
(1) Disconnect negative battery cable from battery.

(2) Partially drain cooling system. Refer to Drain
ing Cooling System i n this group.
TYPICAL
HOSE Do not waste reusable coolant. I f the solution is
CLAMP clean, drain the coolant into a clean container for re
NUMBER/LETTER use.
LOCATION J9407-39
(3) Remove upper radiator hose clamp at radiator.
Fig. 28 Clamp Number/Letter Location A special clamp tool (Fig. 27) must be used to remove
the constant tension clamps. Remove hose at radia
INSTALLATION
tor.
(1) Position bypass hose clamps to the center of (4) Disconnect throttle cable from clip at radiator
hose. fan shroud.
(2) Install bypass hose to engine. (5) Unplug wiring harness from A/C compressor.
(3) Secure both hose clamps. ( 6 ) Remove the air cleaner assembly.
(4) Fill cooling system. Refer to Refilling Cooling (7) Remove accessory drive belt. Refer to Belt Re
System i n this group. moval/Installation i n the Engine Accessory Drive Belt
(5) Start and warm the engine. Check for leaks. section of this group.
REMOVAL—3*9L V-6 O R B»2/5»9L V-8 ENGINE—
(8) 3.9L V-6 o r 5.2/5.9L V-8 LDC-Gas; The drive
WITH AIR CONDITIONING
belt idler pulley must be removed to gain access to
I f equipped with A/C, the generator and A/C com one of the A/C compressor/generator bracket mount
pressor along with their common mounting bracket ing bolts. Remove the idler pulley bolt and remove
(Fig. 29) must be partially removed. Removing the idler pulley (Fig. 30).
generator or A/C compressor from their mounting 5.9L HDC-Gas: The automatic belt tensioner/pul-
bracket is not necessary. Also, discharging the A/C ley assembly must be removed to gain access to one
7 - 2S COOLING SYSTEM
GENERATOR/COMPRESSOR (11) Remove heater hose coolant return tube

A N D BRACKET mounting bolt (Figs. 32 or 33) and remove tube from
engine. Discard the old tube O-ring.
SUPPORT BRACKET
IGNITION
COIL BRACKET
Fig. 30 idler Pulley—3.9L ¥-6 or 5.2/5.9L ¥-8

LDC-Gas Engines
of the A/C compressor/generator bracket mounting
bolts. Remove the tensioner mounting bolt (Fig. 31) Fig. 32 Coolant Return Tube—3.9L ¥-6 or 5.2/5.9L
and remove tensioner. ¥-8 LDC-Gas Engines
Fig. 31 Belt Tensioner—5.9L HDC-Gas Engine Fig. 33 Coolant Return Tube—5.9L HDC-Gas Engine
(9) Remove the engine oil dipstick tube mounting (12) Remove bracket-to-intake manifold bolts
bolt at the side of the A/C-generator mounting (number 1 and 2 Fig. 29).
bracket. (13) Remove remaining bracket-to-engine bolts
(10) Disconnect throttle body control cables. Refer (Figs. 33 or 34).
to Accelerator Pedal and Throttle Cable i n Group 14, (14) Lift and position generator and A/C compres
Fuel System. sor (along with their common mounting bracket) to
INSTALLATION
(1) Position bypass hose clamps to the center of
hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Install generator-A/C mounting bracket assem
bly to engine. Tighten bolt number 1 (Fig. 29) to 41
N-m (30 ft. lbs.) torque. Tighten bolt number 2 (Fig.
29) to 28 N-m (20 ft. lbs.) torque. Tighten bracket
mounting bolts (Figs. 34 or 35) to 40 N-m (30 ft. lbs.)
torque.
(5) Install a new O-ring to the heater hose coolant
return tube (Figs. 32 or 33). Coat the new O-ring
with antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Figs. 32 or 33).
(7) Connect throttle body control cables.
(8) Install oil dipstick mounting bolt.
(9) 3.9L V-6 or &J2/5.9L V-8 LDC-Gas Engines:
Install idler pulley. Tighten bolt to 41 N-m (30 ft.
lbs.) torque.
5.9L HDC-Gas: Install automatic belt tensioner
Fig. 34 Bracket Bolts—3.9L V-6 or 5.2/5.9L V-8 assembly to mounting bracket. A dowel pin is located
LDC-Gas Engines on back of tensioner (Fig. 36). Align this to dowel
hole (Fig. 37) i n tensioner mounting bracket. Tighten
bolt to 41 N-m (30 ft. lbs.) torque.
BELT TENSIONER
DOWEL PIN J9307-63
Fig. 36 Tensioner Dowel Pin—5.9L HDC-Gas Engine

(10) Install drive belt. Refer to Belt Removal/In
stallation i n the Engine Accessory Drive Belt section
of this group.
Fig. 35 Bracket Bolts—5.9L HDC-Gas Engine
gain access to bypass hose. A block of wood may be drive belt, the belt must be routed correctly. If not,
used to hold assembly i n position. the engine may overheat due to the water pump ro
(15) Loosen and position both hose clamps to the tating in the wrong direction. Refer to Belt Schemat
center of bypass hose. A special clamp tool (Fig. 27) ics in the Engine A c c e s s o r y Drive Belt section of
must be used to remove the constant tension clamps. this group for correct belt routing. The correct belt
Remove hose from vehicle. with the correct length must be used.
(11) Install air cleaner assembly.

(12) Install upper radiator hose to radiator.
7 - 28 COOLING SYSTE1
TEMP. COOLANT
Fig. 37 Tensioner Mounting Bracket Dowel

Hole—5.9L HDC-Gas Engine
(13) Connect throttle cable to clip at radiator fan
shroud.
(14) Connect wiring harness to A/C compressor.
(15) Fill cooling system. Refer to Refilling Cooling
System i n this group.
THERMOSTAT RUBBER LIP SEAL J9407-16
GENERAL INFORMATION Fig. 39 Thermostat—8.0L V-10 Engine

The thermostat on all gas powered engines is lo
cated beneath the thermostat housing at the front of The thermostat of the 5.9L diesel engine is located
the intake manifold (Figs. 38 or 39). i n the thermostat housing (Fig. 40). The housing is
located behind the generator mounting bracket, at
front of cylinder head.
THERMOSTAT
BOLTS THERMOSTAT SEAL J9407-U
MACHINED GROOVE Fig. 40 Thermostat—5.9L Diesel—Typical

Gas powered engines: The thermostat is a wax pel
J9207-14 let driven, reverse poppet choke type (3.9L/5.2L/
5.9L), or moveable sleeve type (8.0L V-10). The wax
Fig. 38 Thermostat—3.9L ¥-6 or 5.2/5.9L V-8 Gas pellet is located i n a sealed container at the spring
Powered Engines end of the thermostat. When heated, the pellet ex
pands, overcoming closing spring tension and water
pump pressure to force the valve to open. Coolant

leakage into the pellet container will cause the ther
mostat to fail i n the open position. Thermostats very
rarely stick. Do not attempt to free a thermostat with
a prying device.
The same thermostat is used for winter and sum
mer seasons. A n engine should not be operated with
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance, in
creased exhaust emissions and crankcase condensa
tion that can result i n sludge formation.
CAUTION: Do not operate an engine without a ther

mostat, except for servicing or testing.
THERMOSTAT OPERATION—EXCEPT DIESEL

Depending upon length of time that vehicle is oper
The thermostat controls the operating temperature ated, pressure cap may vent. This will expel steam
of the engine by controlling the amount of coolant
and coolant to coolant reserve/overflow tank and to
flow to the radiator. The thermostat is closed below
surface below vehicle. Refer to the Diagnosis section
88°C (192°F). When the coolant reaches this temper
of this group. Also refer to the DRB scan tool and the
ature, the thermostat begins to open, allowing cool
appropriate Powertrain Diagnostic Procedures man
ant flow to the radiator. This provides quick engine
ual.
warm-up and overall temperature control. The ther
Vehicles equipped with a 5.9L diesel engine do not
mostat is designed to provide a minimum engine op
have the DTC number 17 malfunction indicator lamp
erating temperature of 88 to 93°C (192 to 199°F). I t
(check engine lamp) feature. On-Board Diagnostics
should be fully open for maximum coolant flow dur
for the 5.9L diesel engine can be obtained through
ing operation i n hot ambient temperatures of approx
the DRB scan tool and appropriate Powertrain Diag
imately 104°C (220°F). Above 104°C (220°F), coolant
nostic Procedures manual.
temperature is controlled by the radiator, fan and
ambient temperature. To access the cooling system DTC, refer to Access
ing Diagnostic Trouble Codes i n the Diagnosis section
CAUTION: Never operate the diesel engine without of this group. Also refer to On-Board Diagnostics
a thermostat. Without a thermostat, coolant will not (OBD) i n Group 14, Fuel Systems for more informa
flow to radiator causing engine overheating. tion on other Diagnostic Trouble Codes.
T H E R M O S T A T R E M O V A L — 3 . 9 L V-6 O R
ON-BOARD DIAGNOSTICS 5.2/5.9L V-8 G A S POWERED ENGINES
FOR COOLING SYSTEM COMPONENTS WARNING: DO NOT LOOSEN THE RADIATOR

The powertrain control module (PCM) (Fig. 41) con DRAINCOCK WITH THE SYSTEM HOT AND PRES
tains certain On-Board Diagnostics (OBD) for cooling SURIZED. SERIOUS BURNS FROM THE COOLANT
system components. OBD will be used to help detect CAN OCCUR.
a thermostat open-too-soon failure condition.
The Malfunction Indicator Lamp (formerly called Do not waste reusable coolant. I f the solution is
the Check Engine Lamp) will not be l i t by an open- clean, drain the coolant into a clean container for re
too-soon condition. But, i f the thermostat has failed use.
open, a Diagnostic Trouble Code (DTC) number 17 I f the thermostat is being replaced, be sure that
will be set and stored i n the PCM. Do not change a the replacement is the specified thermostat for the
thermostat for lack of heat as indicated by the in vehicle model and engine type.
strument panel gauge or heater performance unless a
Factory installed thermostat housings on 3.9L V-6
DTC number 17 is present. Refer to the Diagnosis
or 5.2/5.9L V-8 engines are installed on a gasket with
section of this group for other probable causes.
an anti-stick coating. This will aid i n gasket removal
The more common type of thermostat failure, usu
and clean-up.
ally found on high milage vehicles, is a thermostat
(1) Disconnect negative battery cable at battery.
failed i n the shut position. The temperature gauge (if
equipped) will give an indication of this condition.
(2) Drain cooling system until coolant level is be HOSE CLAMP HOSE
low thermostat. Refer to Draining Cooling System i n
this group. I f not equipped with air conditioning, pro
ceed to step number 4.
(3) I f equipped with air conditioning:
(a) Remove the support bracket" (rod) located
near the rear of generator (Fig. 42).
J9207-36
Fig, 42 Support Bracket—Generator Mounting

BrackeMo-lntake Manifold—Typical
(b) The drive belt must be removed. Refer to Belt
Removal/Installation i n the Engine Accessory Drive
Belt section of this group.
(c) The generator must be partially removed. Re
move the two generator mounting bolts. Do not re
move any wiring at. generator. I f equipped with
4WD, unplug the 4WD indicator lamp wiring har
ness (located near rear of generator).
(d) Remove generator. Position generator to gain TYPICAL
HOSE J
access for thermostat gasket removal. CLAMP
NUMBER/LETTER
WARNING: CONSTANT TENSION H O S E C L A M P S LOCATION J9407-39
A R E U S E D ON MOST C O O L I N G S Y S T E M H O S E S .
WHEN REMOVING OR INSTALLING, U S E ONLY Fig. 44 Clamp Number/Letter Location
T O O L S D E S I G N E D F O R S E R V I C I N G THIS T Y P E O F (6) Remove thermostat housing mounting bolts,
CLAMP, S U C H A S S P E C I A L C L A M P TOOL (NUMBER thermostat housing, gasket and thermostat (Fig. 45).
6094) (FIG. 43). SNAP-ON C L A M P TOOL (NUMBER Discard old gasket.
HPC-20) MAY B E U S E D F O R L A R G E R C L A M P S . A L
WAYS W E A R S A F E T Y G L A S S E S WHEN SERVICING INSTALLATION
CONSTANT TENSION C L A M P S . (1) Clean mating areas of intake manifold and
thermostat housing.
CAUTION: A number or letter is stamped into the
(2) Install thermostat (spring side down) into re
tongue of constant tension clamps (Fig. 44). If re
cessed machined groove on intake manifold (Fig. 45).
placement is necessary, u s e only an original equip (3) Install gasket on intake manifold and over
ment clamp with a matching number or letter. thermostat (Fig. 45).
(4) Position the thermostat housing to the intake
(4) Remove upper radiator hose clamp. Remove up manifold. Note the word FRONT stamped on the
per radiator hose at thermostat housing. housing (Fig. 46). For adequate clearance, this must
(5) Position the wiring harness (behind the ther be placed towards the front of vehicle. The housing
mostat housing) to gain access to thermostat hous should be slightly angled forward after installation to
ing. intake manifold.
(6) Install upper radiator hose to thermostat hous
ing.
(7) Air conditioned vehicles:
(a) Install generator. Tighten bolts to 41 N-m (30
ft. lbs.) torque.
(b) Install support bracket (generator mounting
bracket-to-intake manifold) (Fig. 42). Tighten bolts

drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump ro
tating in the wrong direction. Refer to Belt Schemat
ics in the Engine A c c e s s o r y Drive Belt section of
this group for correct engine belt routing. The cor
THERMOSTAT
rect belt with the correct length must be used.
(8) Fill cooling system. Refer to Refilling Cooling

MACHINED GROOVE System i n this group.
(9) Connect negative battery cable to battery.
J9207-14 (10) Start and warm engine. Check for leaks.
Fig. 45 Thermostat—3.9L V-6 or 5.2/5.91 V-8 Gas THERMOSTAT REMOVAL—8*01 V-10 ENGINE
Engines
WARNING: DO NOT L O O S E N T H E RADIATOR
DRAINCOCK WITH T H E S Y S T E M HOT AND P R E S
S U R I Z E D . S E R I O U S B U R N S FROM T H E C O O L A N T
CAN O C C U R .
Do not waste reusable coolant. I f the solution is

clean, drain the coolant into a clean container for re
use.
I f the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
A rubber lip-type seal with a metal shoulder is
pressed into the intake manifold beneath the thermo
stat (Fig. 47).
Fig. 46 Thermostat Position—3.9L V-6 or 5.2/5.9L

V-8 Gas Engines
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 N-m (200 in. lbs.) torque.
CAUTION: Housing must be tightened evenly and

thermostat must be centered into recessed groove
in intake manifold. If not, it may result in a cracked
housing, damaged intake manifold threads or cool Fig. 47 Thermostat Seal—8.0L V-10 Engine
ant leak. (1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is be TEMP. COOLANT
low thermostat. Refer to Draining Cooling System i n
this group.
(3) - Remove the two support rod mounting bolts
and remove support rod (intake manifold-to-genera
tor mount) (Fig. 48).
Fig. 48 Support RodS.OL V-10 Engine

WARNING: CONSTANT TENSION H O S E CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, U S E ONLY RUBBER LIP SEAL J9407-16
CLAMP, SUCH A S S P E C I A L CLAMP T O O L (NUMBER Fig. 49 Thermostat—8.0L V-10 Engine
6094) (FIG. 43). SNAP-ON CLAMP T O O L (NUMBER Maker. Install the seal into the manifold using Spe
HPC-20) MAY B E U S E D F O R L A R G E R C L A M P S . A L cial Seal Tool number C-3995-A with handle tool
WAYS W E A R S A F E T Y G L A S S E S WHEN S E R V I C I N G number C-4171.
CONSTANT TENSION C L A M P S . (3) Install thermostat into recessed machined
groove on intake manifold (Fig. 49).
CAUTION: A number or letter is stamped into the (4) Install gasket on intake manifold and over
tongue of constant tension clamps (Fig. 44). If re thermostat (Fig. 49).
placement is necessary, u s e only an original equip (5) Install housing-to-intake manifold bolts.
ment clamp with a matching number or letter. Tighten bolts to 25 N-m (220 in. lbs.) torque.
CAUTION: Housing bolts should be tightened
(4) Remove upper radiator hose clamp. Remove up
per radiator hose at thermostat housing. evenly to prevent damage to housing and to pre
(5) Disconnect the wiring connectors at both of the vent leaks.
sensors located on thermostat housing.
(6) Connect the wiring to both sensors.
(6) Remove six thermostat housing mounting bolts,
(7) Install the upper radiator hose and hose clamp
thermostat housing, gasket and thermostat (Fig. 49).
to thermostat housing.
Discard old gasket.
(8) Install support rod.
INSTALLATION (9) Fill cooling system. Refer to Refilling Cooling
(1) Clean mating areas of intake manifold and System i n this group.
thermostat housing. (10) Connect negative battery cable to battery.
(2) Check the condition (for tears or cracks) of the (11) Start and warm engine. Check for leaks.
rubber thermostat seal located i n the intake manifold
THERMOSTAT OPERATION—5.9L DIESEL
(Figs. 47 or 49). The thermostat should fit snugly
ENGINE
into the rubber seal.
The thermostat controls the operating temperature
I f seal replacement is necessary, coat the outer
of the engine by controlling the amount of coolant
(metal) portion of the seal with Mopar® Gasket
flow to the radiator. When coolant temperature is be

low 83°C (181°F), the thermostat is closed (Fig. 50).
Fig. 50 Thermostat Operation—5.9L Diesel—Typical

When coolant temperature reaches 83°C (181°F),
the thermostat begins to open allowing coolant flow
to the radiator. This provides quick engine warm-up
Fig. 51 One-Way Check Valve (Jiggle Pin) Location
and overall temperature control. The thermostat is
designed to provide a minimum engine operating Do not waste reusable coolant. I f the solution is
temperature of 83°C (181°F) and to be fully open for clean, drain the coolant into a clean container for re
maximum coolant flow at approximately 95°C use.
(203°F). Above 95°C (203°F), coolant temperature is (1) Disconnect both negative battery cables from
controlled by the radiator, fan and ambient tempera both batteries.
ture. (2) Remove accessory drive belt. Refer to Belt Re
The air bleeds (jiggle pins) that were used on the moval/Installation i n the Engine Accessory Drive Belt
thermostats of diesel engines i n previous years are section i n this group.
no longer used. They have been replaced by a verti (3) Drain cooling system until coolant level is be
cally mounted one-way check valve (jiggle pin) and a low thermostat. Refer to Draining Cooling System i n
rubber bypass hose. The check valve is used as a ser this section.
vicing feature and will vent air when the system is
WARNING: CONSTANT TENSION H O S E C L A M P S
being filled. I t is also used to block the flow of cool
A R E U S E D ON MOST COOLING S Y S T E M H O S E S .
ant during engine operation (all coolant will pass
WHEN REMOVING OR INSTALLING, U S E ONLY
through the thermostat).
Water pressure (or flow) will hold the pin closed.
CLAMP, S U C H A S S P E C I A L CLAMP T O O L (NUMBER
When the engine is off, the check valve will be i n
8094) (FIG. 43). SNAP-ON CLAMP T O O L (NUMBER
the open position. When the engine is operating, the
check valve will be in the closed position.
WAYS W E A R S A F E T Y G L A S S E S WHEN SERVICING
The check valve is located inside of a brass fitting.
CONSTANT TENSION C L A M P S .
This fitting is threaded into the front of the cylinder
head (Fig. 51). I t is connected to the thermostat
housing with a rubber hose and screw-type clamps CAUTION: A number or letter is stamped into the
(Fig. 51). tongue of constant tension clamps (Fig. 44). If re
placement is necessary, u s e only an original equip
THERMOSTAT REMOVAL—DIESEL E N G I N E ment clamp with a matching number or letter.
WARNING: DO NOT L O O S E N T H E RADIATOR (4) Remove radiator hose clamp and hose from
DRAINCOCK WITH T H E S Y S T E M HOT AND P R E S thermostat housing. A special clamp tool (Fig. 43)
SURIZED. S E R I O U S BURNS FROM T H E C O O L A N T must be used to remove the constant tension clamps.
CAN O C C U R . (5) Remove the hose clamp and check valve hose at
thermostat housing (Fig. 52).
(2) Position the thermostat seal with the shoulder
towards the housing (Fig. 54).
BOLTS THERMOSTAT SEAL J9407-U
Fig. 52 Thermostat Remowal—5.91 Diesel

SHOULDER J9407-12
(6) Remove the two upper generator bracket
mounting bolts (Fig. 53). Fig. 54 Thermostat Seal—5.9L Diesel—Typical
(3) Install thermostat, lifting bracket, seal and
housing. Tighten mounting bolts to 24 N-m (18 ft.
lbs.) torque.
(4) Position generator i n place. Tighten mounting
bolts to 24 N-m torque. Tighten pivot bolt to 43 N-m
(5) Install the check valve hose and hose clamp at
thermostat housing (Fig. 52).
(6) Install accessory drive belt. Refer to Belt Re
moval/Installation i n the Engine Accessory Drive Belt
section of this group.
(7) Connect negative battery cables to both batter
ies.
(8) Fill cooling system and check for leaks. Refer to
Refilling Cooling System i n this group.
COOLANT
GENERAL INFORMATION
The cooling system is designed around the coolant.
GENERATOR J9407-13 Coolant flows through the engine water jacket ab
sorbing heat produced during engine operation. The
Fig, 53 Generator Mounting Bracket Bolts—Diesel coolant carries the heat to radiator and heater core.
Here i t is transferred to the ambient air passing
(7) Remove the upper generator mounting bracket
through the radiator and heater core fins. The cool
(Fig. 53).
ant also removes heat from the automatic transmis
(8) Loosen but do not remove the generator lower sion fluid i n vehicles equipped with an automatic
pivot bolt, transmission.
(9) Position the generator to gain access to thermo
stat housing and housing bolts. COOLANT PERFORMANCE
(10) Remove thermostat housing mounting bolts. The required ethylene-glycol (antifreeze) and water
(11) Remove the thermostat housing, thermostat, mixture depends upon climate and vehicle operating
thermostat seals and lifting bracket (Fig. 52). conditions. The coolant performance of various mix
(12) Clean the mating surfaces of the thermostat tures follows:
housing and the cylinder head. P u r e Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur
INSTALLATION pose of heat transfer only. Water also freezes at a
(1) Install the thermostat i n the housing. higher temperature and allows corrosion.
100% Ethylene-Glycol-The corrosion inhibiting The coolant reserve/overflow system provides a

additives i n ethylene-glycol need the presence of wa quick visual method for determining the coolant level
ter to dissolve. Without water, additives form depos without removing the radiator pressure cap. With en
its in system. These act as insulation causing gine idling and at normal operating temperature, ob
temperature to rise to as high as 149°C (300°F). This serve coolant level i n coolant reserve/overflow tank.
temperature is hot enough to melt plastic and soften The coolant level should be between the ADD and
solder. The increased temperature can result i n en FULL marks.
gine detonation. I n addition, 100 percent ethylene-
glycol freezes at -22°C (-8°F). ADDING ADDITIONAL COOLANT—ROUTINE
50/50 Ethylene-Glycol and Water-Is the recom Do not remove the radiator cap to add cool
mended mixture, i t provides protection against freez ant to the system. When adding coolant to main
ing to -37°C (-35°F). The antifreeze concentration tain the correct level, do so at the coolant reserve/
must always be a minimum of 44 percent, year- overflow tank with a 50/50 mixture of ethylene-glycol
round in all climates. I f percentage is lower, engine antifreeze (containing Alugard 340-2 ™) and water.
parts may be eroded by cavitation. Maximum protec Remove the radiator cap only for testing or when re
tion against freezing is provided with a 68 percent filling the system after service. Removing cap unnec
antifreeze concentration, which prevents freezing essarily can cause loss of coolant and allow air to
down to -67.7°C (-90°F). A higher percentage will enter system. This produces corrosion.
freeze at a warmer temperature. Also, a higher per
centage of antifreeze can cause the engine to over COOLANT LEVEL CHECK—SERVICE
heat because specific heat of antifreeze is lower than The cooling system is closed and designed to main
that of water. tain coolant level to the top of the radiator.
CAUTION: Richer antifreeze mixtures cannot be WARNING: DO NOT OPEN RADIATOR DRAINCOCK
measured with normal field equipment and can WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
c a u s e problems associated with 100 percent ethyl AND COOLING SYSTEM IS UNDER PRESSURE.
ene-glycol.
When vehicle servicing requires a coolant level
check i n the radiator, drain several ounces of coolant
COOLANT SELECTIONÂDDITIVES
from the radiator drain cock. Do this while observing
The presence of aluminum components i n the cool
the coolant reserve/overflow system tank. The coolant
ing system requires strict corrosion protection. Main
level i n the reserve/overflow tank should drop
tain coolant at specified level with a mixture of
slightly. I f not, inspect for a leak between radiator
ethylene-glycol based antifreeze and water. Only use
and coolant reserve/overflow system connection. Re
an antifreeze containing ALUGARD 340-2 ™ such as
move radiator cap. The coolant level should be to the
Mopar Antifreeze. I f coolant becomes contaminated
top of the radiator. I f not and i f coolant level i n re
or looses color, drain and flush cooling system and fill
serve/overflow tank is at the ADD mark, check for:
with correctly mixed solution.
• A n air leak i n the coolant reserve/overflow tank
CAUTION: Do not u s e coolant additives that are • A n air leak i n the radiator filler neck
claimed to improve engine cooling. • Leak i n the pressure cap seal to the radiator filler
neck
COOLANT SERVICE—EXCEPT DIESEL LOW COOLANT LEVEL-AERATION

It is recommended that the cooling system be I f the coolant level i n the radiator drops below the
drained and flushed at 84,000 kilometers (52,500 top of the radiator core tubes, air will enter the sys
miles) or 3 years, whichever occurs first. Then every tem.
two years or 48,000 kilometers (30,000 miles), which Low coolant level can cause the thermostat pellet
ever occurs first. to be suspended i n air instead of coolant. This will
cause the thermostat to open later, which in turn
COOLANT SERVICE—DIESEL ENGINE causes higher coolant temperature. A i r trapped i n
I t is recommended that the cooling system be cooling system also reduces the amount of coolant
drained and flushed every 24 months or 38,600 kilo circulating i n the heater core. This may result i n low
meters (24,000 miles), whichever occurs first. heat output.
COOLANT LEVEL CHECK—ROUTINE DEAERATION

D o not remove radiator cap for routine cool As the engine operates, air trapped i n the cooling
ant level inspections. The coolant level can be system gathers under the radiator cap. The next time
checked at the coolant reserve/overflow tank. engine is operated, thermal expansion of coolant will
push trapped air past radiator cap into coolant re (3) Fill the cooling system with a 50/50 mixture of
serve/overflow tank. Here i t escapes to atmosphere i n water and antifreeze. 5.9L Diesel Engine Only: The
the tank. When engine cools down the coolant, i t will diesel engine is equipped with a one-way check valve
be drawn from reserve/overflow tank into radiator to (jiggle pin). The check valve is used as a servicing
replace removed air. feature and will vent air when the system is being
filled. Water pressure (or flow) will hold the valve
DRAINING COOLING SYSTEM closed. Due to the use of t h i s valve, the engine
must not be operating when refilling the cool
WARNING: DO NOT R E M O V E T H E C Y L I N D E R ing system. Refer to Thermostat Operation—5.9L
B L O C K DRAIN P L U G S OR L O O S E N T H E RADIATOR Diesel Engine i n the Thermostat section of this group
DRAIN P L U G WITH S Y S T E M HOT AND UNDER for more information.
P R E S S U R E . S E R I O U S B U R N S FROM C O O L A N T (4) Fill coolant reserve/overflow tank to the FULL
CAN O C C U R . mark.
(5) Start and operate engine until thermostat
DO NOT WASTE reusable coolant. I f the solution
opens. Upper radiator hose should be warm to touch.
is clean, drain the coolant into a clean container for
(6) I f necessary, add 50/50 water and antifreeze
reuse.
(1) Start the engine and place the heater control mixture to the coolant reserve/overflow tank to main
temperature selector i n the Full-On position. Engine tain coolant level. This level should be between the
vacuum is needed to actuate the heater controls. ADD and FULL marks. The level i n the reserve/over
(2) Turn the ignition off. flow tank may drop below the ADD mark after three
(3) Do not remove radiator cap when draining cool or four warm-up and cool-down cycles.
ant from reserve/overflow tank. Open radiator drain
plug and when tank is empty, remove radiator cap. I f COOLING SYSTEM CLEANING/REVERSE FLUSHING
the coolant reserve/overflow tank does not drain, re
fer to the Testing Cooling System for Leaks section i n CLEANING
this group. The coolant need not be removed from Drain cooling system and refill with water. Run en
tank unless the system is being refilled with fresh gine with radiator cap installed until upper radiator
mixture. hose is hot. Stop engine and drain water from sys
(4) On vehicles equipped with gas powered en tem. I f water is dirty, fill system with water, run en
gines, remove the cylinder block drain plugs. These gine and drain system. Repeat until water drains
are located on the sides of the block just above the oil clean.
pan (Fig. 55).
REVERSE FLUSHING
Reverse flushing of cooling system is the forcing of
water through the cooling system. This is done using
air pressure i n the opposite direction of normal cool
ant flow. I t is usually only necessary with very dirty
systems with evidence of partial plugging.
R E V E R S E FLUSHING RADIATOR
Disconnect radiator hoses from radiator inlet and
outlet. Attach a section of radiator hose to radiator
bottom outlet fitting and insert flushing gun. Con
nect a water supply hose and air supply hose to
flushing gun.
CAUTION: Internal radiator pressure must not ex

ceed 138 k P a (20 psi) a s damage to radiator may re
Fig. 55 Drain Plugs—Gas Powered Engines—Typical sult.
(5) Remove radiator pressure cap. Allow radiator to fill with water. When radiator is
filled, apply air i n short blasts. Allow radiator to re
REFILLING COOLING SYSTEM fill between blasts. Continue this reverse flushing
Clean cooling system prior to refilling. Refer to until clean water flows out through rear of radiator
Cooling System Cleaning section of this group. cooling tube passages. Have radiator cleaned more
(1) Install the cylinder block drain plugs (Fig. 55). extensively by a radiator repair shop.
(2) Close radiator drain plug.
R E V E R S E FLUSHING ENGINE—EMCEPT (5) Attach water supply hose to heater tube.

DIESEL (6) Back-flush the engine until clean water exits
Drain cooling system. Remove thermostat housing the water pump inlet.
and thermostat. Install thermostat housing. Discon
nect radiator upper hose from radiator and attach CHEMICAL CLEANING
flushing gun to hose. Disconnect radiator lower hose In some instances, use a radiator cleaner (Mopar
from water pump and attach a lead-away hose to wa Radiator Kleen or equivalent) before flushing. This
ter pump inlet fitting. will soften scale and other deposits and aid flushing
operation.
CAUTION: O n v e h i c l e s e q u i p p e d w i t h a heater water
c o n t r o l v a l v e , he s u r e heater c o n t r o l valve is c l o s e d CAUTION: Follow manufacturers i n s t r u c t i o n s w h e n
(heat off). T h i s w i l l prevent c o o l a n t f l o w w i t h scale using these products.
a n d other d e p o s i t s f r o m entering heater c o r e .
Connect water supply hose and air supply hose to TESTING COOLING SYSTEM FOR LEAKS
flushing gun. Allow engine to fill with water. When
ULTRAVIOLET LIGHT METHOD
engine is filled, apply air i n short blasts, allowing
system to fill between air blasts. Continue until clean A leak detection additive is available through the
water flows through the lead away hose. parts department that can be added to cooling sys
tem. The additive is highly visible under ultraviolet
Remove lead away hose, flushing gun, water supply
light (black light). Pour one ounce of additive into
hose and air supply hose. Remove thermostat hous
cooling system. Place heater control unit i n HEAT
ing and install thermostat. Install thermostat hous
position. Start and operate engine until radiator up
ing with a replacement gasket. Refer to Thermostat
per hose is warm to touch. A i m black light (tool
Replacement. Connect radiator hoses. Refill cooling
C-4555 or an equivalent) at components to be
system with correct antifreeze/water mixture. Refer
checked. I f leaks are present, black light will cause
to Refilling the Cooling System.
additive to glow a bright green color.
R E V E R S E FLUSHING ENGINE—DIESEL The black light can be used i n conjunction with a
(1) Drain the cooling system. pressure tester to determine i f any external leaks ex
(2) Disconnect the upper hose from the radiator. ist (Fig. 57).
(3) Disconnect the radiator lower hose from the
water pump.
CAUTION: Be s u r e t h e heater c o n t r o l valve is

c l o s e d (heat off). T h i s w i l l prevent c o o l a n t f l o w w i t h
scale a n d other d e p o s i t s f r o m entering the heater
core.
(4) Remove the heater core inlet hose from tube

(Fig. 56).
Fig. 57 Leak Detection Using Black Light—Typical
Fig. 56 Typical Reverse-flushing—5.9L Diesel

PRESSURE TESTER METHOD with a Sealer Lubricant (or equivalent). Repair leak
The engine should be at normal operating temper holes and inspect system again with pressure ap
ature. Recheck the system cold i f cause of coolant plied.
loss is not located during the warm engine examina Drops Quickly: Indicates that serious leakage is
tion. occurring. Examine system for external leakage. I f
leaks are not visible, inspect for internal leakage.
WARNING: HOT, P R E S S U R I Z E D COOLANT CAN Large radiator leak holes should be repaired by a
C A U S E INJURY B Y S C A L D I N G . reputable radiator repair shop.
Carefully remove radiator pressure cap from filler INTERNAL LEAKAGE INSPECTION
neck and check coolant level. Push down on cap to Remove engine oil pan drain plug and drain a
disengage i t from stop tabs. Wipe inside of filler neck small amount of engine oil. I f coolant is present i n
and examine lower inside sealing seat for nicks, the pan, i t will drain first because i t is heavier than
cracks, paint, dirt and solder residue. Inspect radia oil. A n alternative method is to operate engine for a
tor-to-reserve/overflow tank hose for internal obstruc short period to churn the oil. After this is done, re
tions. Insert a wire through the hose to be sure i t is move engine dipstick and inspect for water globules.
not obstructed. Also inspect transmission dipstick for water globules
Inspect cams on outside of filler neck. I f cams are and transmission fluid cooler for leakage.
bent, seating of pressure cap valve and tester seal
will be affected. Bent cams can be reformed i f done WARNING: WITH P R E S S U R E T E S T E R TOOL 7700
carefully. Attach pressure tester (7700 or an equiva INSTALLED ON RADIATOR, DO NOT ALLOW P R E S
lent) to radiator filler neck (Fig. 58). S U R E T O E X C E E D 110 KPA (20 PSI). P R E S S U R E
WILL BUILD UP QUICKLY IF A COMBUSTION L E A K
C O O L I N G SYSTEM IS P R E S E N T . TO R E L E A S E P R E S S U R E , R O C K
T E S T E R FROM SIDE TO S I D E . WHEN REMOVING
T E S T E R , DO NOT TURN T E S T E R MORE THAN 1/2
TURN IF S Y S T E M IS UNDER P R E S S U R E .
Operate engine without pressure cap on radiator

until thermostat opens. Attach a Pressure Tester to
filler neck. I f pressure builds up quickly i t indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack i n engine. Repair
as necessary.
I f there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Fig. 58 Pressure Testing Cooling System—Typical Because the vehicle is equipped with a catalytic
Operate tester pump to apply 103.4 kPa (15 psi) converter, do not remove spark plug cables or short
pressure to system. I f hoses enlarge excessively or out cylinders (non-diesel engines) to isolate compres
bulges while testing, replace as necessary. Observe sion leak.
gauge pointer and determine condition of cooling sys I f the needle on dial of pressure tester does not
tem according to following criteria: fluctuate, race engine a few times to check for an ab
normal amount of coolant or steam. This would be
Holds Steady: I f pointer remains steady for two
emitting from exhaust pipe. Coolant or steam from
minutes, serious coolant leaks are not present i n sys
exhaust pipe may indicate a faulty cylinder head gas
tem. However, there could be an internal leak that
ket, cracked engine cylinder block or cylinder head.
does not appear with normal system test pressure. I f
A convenient check for exhaust gas leakage into
i t is certain that coolant is being lost and leaks can cooling system is provided by a commercially avail
not be detected, inspect for interior leakage or per able Block Leak Check tool. Follow manufacturers i n
form Internal Leakage Test. structions when using this product.
Drops Slowly: Indicates a small leak or seepage is
occurring. Examine all connections for seepage or COMBUSTION LEAKAGE TEST—WITHOUT
slight leakage with a flashlight. Inspect radiator, PRESSURE TESTER
hoses, gasket edges and heater. Seal small leak holes DO NOT WASTE reusable coolant. I f solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK

DRAIN P L U G S OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM H O T * ' . I D U M r S R PRESSURE,
K
SERIOUS B U R N S ¥îml M ' V - * v CC2UR.
Drain sufficient coolant to allow thermostat re

moval. Refer to Thermostat Replacement. Disconnect
water pump drive belt.
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: A v o i d overheating. Do n o t operate e n

g i n e for an e x c e s s i v e period of t i m e , © p e n d r a i n -
c o c k immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to

approximately 3000 rpm while observing coolant. I f
internal engine combustion gases are leaking into
cooling system, bubbles will appear i n coolant. I f bub
bles do not appear, internal combustion gas leakage
is not present.
COOLANT RESERVE/OVERFLOW SYSTEM Fig. 59 Coolant Reserve/Overflow Tank—All Except

The coolant reserve/overflow system works i n con 8.0L V-10 Engine
junction with the radiator pressure cap. I t utilizes COOLANT
thermal expansion and contraction of coolant to keep RESERVE/OVERFLOW
coolant free of trapped air. I t provides a volume for
expansion and contraction of coolant. I t also provides
a convenient and safe method for checking coolant
level and adjusting level at atmospheric pressure.
This is done without removing radiator pressure cap.
I t also provides some reserve coolant to cover minor
leaks and evaporation or boiling losses.
The coolant reserve/overflow tank is mounted to
the fan shroud on all engines except the 8.0L V-10
(Fig. 59). On the 8.0L V-10 engine the tank is
mounted to right inner fender (Fig. 60).
Refer to Coolant Level Check—Service, Deaeration
and Radiator Pressure Cap sections i n this group for BOLTS (2) J948D-21
coolant reserve/overflow system operation and ser
vice. Fig. 60 Coolant Reserve/Overflow Tank—8.0L V-10
Should the reserve/overflow tank become coated Engine
with corrosion, i t can be cleaned with detergent and
(2) Connect overflow hose to radiator.
water. Rinse tank thoroughly before refilling cooling
system as described in the Coolant section of this TANK REMOVAL—8.0L V-10 ENGINE
group. (1) Remove overflow hose from radiator.
T A N K REMOVAL—ALL &XGEPT i ^ L V-fO
(2) Remove three tank mounting bolts (Fig. 60)
ENGINE
and remove tank.
(1) Remove overflow hose from radiator.
INSTALLATION
(2) Unsnap the coolant reserve/overflow tank from
(1) Position tank to inner fender.
fan shroud. Lift straight up. The fan shroud is
equipped with T-shaped slots (Fig. 59) to attach the (2) Install bolts and tighten to 6 N-m (50 in. lbs.)
tank. A n alignment pin is located on the side of tank. torque.
(3) Connect overflow hose to radiator.
INSTALLATION
(1) Snap the tank into the two T-siots and the
alignment pin on fan shroud.
RADIATOR PRESSURE CAP BUILDS UP IN COOLING SYSTEM. TO P R E V E N T
Radiators are equipped with a pressure cap, which SCALDING OR INJURY, RADIATOR C A P S H O U L D
releases pressure at some point within a range of 97- NOT B E R E M O V E D WHILE S Y S T E M IS HOT AND/OR
124 kPa (14-18 psi). The pressure relief point (in UNDER P R E S S U R E .
pounds) is engraved on top of cap.
The cooling system will operate at pressures Do not remove radiator cap at any time except for
slightly above atmospheric pressure. This results i n a the following purposes:
higher coolant boiling point allowing increased radi • Check and adjust antifreeze freeze point
ator cooling capacity. The cap (Fig. 61) contains a • Refill system with new antifreeze
spring-loaded pressure relief valve that opens when • Conducting service procedures
system pressure reaches release range of 97-124 kPa • Checking for vacuum leaks
(14-18 psi).
WARNING: IF V E H I C L E HAS B E E N RUN R E C E N T L Y ,
WAIT AT L E A S T 15 MINUTES B E F O R E REMOVING
RADIATOR CAP. WITH A R A G , S Q U E E Z E RADIATOR
U P P E R H O S E T O C H E C K IF S Y S T E M IS UNDER
P R E S S U R E . P L A C E A RAG OVER C A P AND WITH
OUT PUSHING CAP DOWN, ROTATE IT COUNTER
C L O C K W I S E TO FIRST STOP. ALLOW FLUID TO
E S C A P E THROUGH T H E COOLANT R E S E R V E /
O V E R F L O W H O S E INTO RESERVE/OVERFLOW
TANK. S Q U E E Z E RADIATOR UPPER HOSE TO DE
TERMINE WHEN PRESSURE HAS BEEN RE
L E A S E D . WHEN COOLANT AND STEAM STOP
BEING P U S H E D INTO TANK AND SYSTEM P R E S
S U R E DROPS, REMOVE RADIATOR CAP COM
Fig. 61 Radiator Pressure Cap and Filler Neck- PLETELY
Typical
A vent valve i n the center of cap allows a small
coolant flow through cap when coolant is below boil P R E S S U R E T E S T I N G RADIATOR CAPS
ing temperature. The valve is completely closed when Remove cap from radiator. Be sure that sealing
boiling point is reached. As the coolant cools, i t con surfaces are clean. Moisten rubber gasket with water
tracts and creates a vacuum i n the cooling system. and install cap on pressure tester 7700 or an equiv
This causes the vacuum valve to open and coolant i n alent (Fig. 62).
the reserve/overflow tank to be drawn through its
connecting hose into radiator. I f the vacuum valve is
stuck shut, the radiator hoses will collapse on cool-
down. Clean the vent valve (Fig. 61).
A rubber gasket seals radiator filler neck to pre
vent leakage. This is done to keep system under
pressure. I t also maintains vacuum during coolant
cool-down allowing coolant to return from reserve/
overflow tank.
RADIATOR C A P - T O - F I L L E R NECK SEAL-

PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure re
lief can be tested by removing overflow hose from ra
diator filler neck nipple. Attach hose of pressure
tester tool 7700 or equivalent to nipple. I t will be
necessary to disconnect hose from its adapter for
filler neck. Pump air into radiator. The pressure cap
upper gasket should relieve at 69-124 kPa (10-18 psi)
and hold pressure at a minimum of 55 kPa (8 psi).
WARNING: T H E WARNING W O R D S — D O NOT

O P E N HOT— ON RADIATOR P R E S S U R E CAP, A R E Fig. 62 Pressure Testing Radiator Cap—Typical
A S A F E T Y P R E C A U T I O N . WHEN HOT, P R E S S U R E Tester
Operate tester pump to bring pressure to 104 kPa WARNING: HOT, P R E S S U R I Z E D C O O L A N T CAN
(15 psi) on gauge. I f pressure cap fails to hold pres C A U S E INJURY B Y S C A L D I N G . USING A R A G TO
sure of at least 97 kPa (14 psi) replace cap. Refer to C O V E R T H E RADIATOR P R E S S U R E CAP, O P E N RA
C A U T I O N below. DIATOR C A P S L O W L Y TO T H E F I R S T STOP. THIS
The pressure cap may test properly while posi WILL A L L O W ANY BUILT-UP P R E S S U R E TO VENT
tioned on tool 7700 (or equivalent). I t may not hold TO T H E R E S E R V E / O V E R F L O W TANK. A F T E R P R E S
pressure or vacuum when installed on radiator. I f so, S U R E BUILD-UP H A S B E E N R E L E A S E D , R E M O V E
inspect radiator filler neck and cap's top gasket for C A P FROM F I L L E R N E C K .
damage. Also inspect for dirt or distortion that may
prevent cap from sealing properly. (2) Drain a small amount of coolant from the radi
ator until the ends of the radiator tubes are visible
CAUTION: Tool 7700 is very sensitive to small air through the filler neck. Idle the engine at normal op
leaks, which will not c a u s e cooling system prob erating temperature. I f coolant is flowing past the ex
lems. A pressure cap that does not have a history posed tubes, the coolant is circulating.
of coolant loss should not be replaced just because
it leaks slowly when tested with this tool. Add water R A D I A T O R REMOVAL—ALL ENGINES
to tool. Turn tool upside down and recheck pres (1) All Engines Except Diesel: Disconnect nega
sure cap to confirm that c a p needs replacement. tive battery cable from battery.
Diesel engine: Disconnect both negative battery
cables at both batteries. Remove the nuts retaining
INSPECTION the positive cable to the top of radiator. Position pos
Hold cap at eye level, right side up. The vent valve itive battery cable to rear of vehicle.
(Fig. 62) at bottom of cap should open. I f rubber gas
ket has swollen and prevents vent valve from open WARNING: DO NOT R E M O V E T H E C Y L I N D E R
ing, replace cap. B L O C K DRAIN P L U G S OR L O O S E N T H E RADIATOR
Hold cap at eye level, upside down. I f any light can DRAINCOCK WITH T H E S Y S T E M HOT AND UNDER
be seen between vent valve and rubber gasket, re P R E S S U R E . S E R I O U S B U R N S FROM C O O L A N T
place cap. Do not use a replacement cap that has CAN O C C U R .
a spring to hold vent shut. A replacement cap
must be the type designed for a coolant reserve/over (2) Drain the cooling system. Refer to Draining
flow system with a completely sealed diaphragm Cooling System i n this group.
spring and a rubber gasket. This gasket is used to (3) Disconnect throttle cable from clip at top of ra
seal to radiator filler neck top surface. Use of proper diator fan shroud.
cap will allow coolant return to radiator. HOSE CLAMP HOSE
HAOIATOiS
GENERAL INFORMATION
The radiator used on all engines (both gas powered
and diesel) are of a cross-flow design with horizontal
tubes through the radiator core and vertical side
tanks.
Aluminum cores with plastic side tanks are used
on all 3.9L V-6 and 5.2/5.9L V-8 engines. Copper-
brass cores are used with the 8.0L V-10 and diesel
engines.
The radiator supplies sufficient heat transfer to
cool the engine and automatic transmission (if J9207-36
equipped).
RADIATOR COOLANT FLOW CHECK
Use the following procedure to determine i f coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. I f the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow
ing to the radiator.
7 - 42 COOLING SYSTE1
(10) Remove the four fan shroud mounting bolts

(Fig. 65). Position shroud rearward over the fan
blades towards engine.
RADIATOR
TYPICAL
HOSE
CLAMP
NUMBER/LETTER
LOCATION J9407-39
Fig. 84 Clamp Number/Letter Location

WARNING: CONSTANT TENSION HOSE CLAMPS FAN SHROUD M O U N T I N G BOLTS J9407-37
A R E U S E D ON MOST C O O L I N G S Y S T E M H O S E S .
WHEN REMOVING OR INSTALLING, U S E ONLY Fig. 65 Typical Fan Shroud Mounting
CLAMP, S U C H A S S P E C I A L C L A M P T O O L (NUMBER
(11) A l l Engines Except 8.0L V-10 and Diesel: Re
6094) (FIG. 63). SNAP-ON CLAMP T O O L (NUMBER
move the plastic clips retaining the rubber shields to
HPC-20) MAY B E U S E D F O R L A R G E R C L A M P S . A L the sides of radiator. Position rubber shields to the
WAYS W E A R S A F E T Y G L A S S E S WHEN S E R V I C I N G side.
CONSTANT TENSION C L A M P S . (12) Remove the two radiator upper mounting
bolts (Fig. 66).
MOUNTING
CAUTION: A number or letter is stamped into the BOLTS
ment clamp with a matching number or letter.
(4) Remove hose clamps and hoses from radiator.

(5) A l l engines: Remove coolant reserve/overflow
tank hose from radiator filler neck nipple.
(6) A l l engines except 8.0L V-10: Remove the cool
ant reserve/overflow tank from the fan shroud (pull
straight up). The tank slips into T-slots on the fan
shroud.
(7) Disconnect electrical connectors at windshield
washer reservoir tank and remove tank. Refer to
Group 8K,' Windshield Wiper and Washer Systems
for procedures.
(8) I f equipped with an automatic transmission (all
engines except diesel), disconnect oil cooler lines
(hoses) at radiator tank. A special tool must be used
to disconnect the lines. Refer to Group 21, Transmis ALIGNMENT
DOWELS (2) J9407-38
sions for procedures.
(9) Diesel Engine Only: Remove the two metal
Fig. 66 Typical Radiator Mounting
clips retaining the upper part of fan shroud to the
top of radiator.
(13) Lift radiator straight up and out of engine Inspect the hoses at regular intervals. Replace
compartment. The bottom of the radiator is equipped hoses that are cracked, feel brittle when squeezed or
with two alignment dowels that fit into holes in the swell excessively when system is pressurized. The
lower radiator support panel (Fig. 66). Rubber bis use of molded replacement hoses is recommended.
cuits (insulators) are installed to these dowels. Take When performing a hose inspection, inspect radiator
care not to damage cooling fins or tubes on the radi lower hose for proper position and condition of
ator and air conditioning condenser when removing. spring.
RADIATOR INSTALLATION WARNING: CONSTANT TENSION H O S E C L A M P S
(1) Position fan shroud over the fan blades rear A R E U S E D ON MOST COOLING S Y S T E M H O S E S .
ward towards engine. WHEN REMOVING OR INSTALLING, U S E ONLY
(2) Install rubber insulators to alignment dowels at T O O L S D E S I G N E D F O R SERVICING THIS T Y P E O F
lower part of radiator. CLAMP, S U C H A S S P E C I A L CLAMP T O O L (NUMBER
(3) Lower the radiator into position while guiding 6094) (FIG. 67). SNAP-ON CLAMP T O O L (NUMBER
the two alignment dowels into lower radiator sup
port. Different alignment holes are provided in the
WAYS W E A R S A F E T Y G L A S S E S WHEN S E R V I C I N G
lower radiator support for each engine application.
CONSTANT TENSION C L A M P S .
(4) Install two upper radiator mounting bolts.
Tighten bolts to 11 N-m (95 i n . lbs.) torque.
(5) 3.9L V-6 or 5.2L/5.9L V-8 Engines: Position the CAUTION: A number or letter is stamped into the
rubber shields to the sides of radiator. Install the tongue of constant tension clamps (Fig. 68). If re
plastic clips retaining the rubber shields to the sides placement is necessary, u s e only an original equip
of radiator. ment clamp with a matching number or letter.
(6) Connect both radiator hoses. Refer to previous
CAUTION and install hose clamps. Ordinary worm gear type hose clamps (when
(7) I f equipped, connect transmission oil cooler equipped) can be removed with a straight screw
lines to radiator tank. Refer to Group 21, Transmis driver or a hex socket. To prevent damage to
sions for procedures. hoses or clamps, the hose clamps should be
(8) Install windshield washer reservoir tank. Refer tightened to 4 N-m (34 in. lbs.) torque. Do not
to Group 8K. over tighten hose clamps.
(9) Position fan shroud to flanges on sides of radi For all vehicles: I n areas where specific routing
ator. Install fan shroud mounting bolts (Fig. 65). clamps are not provided, be sure that hoses are posi
Tighten bolts to 6 N-m (50 i n . lbs.) torque. tioned with sufficient clearance. Check clearance
(10) Diesel Engines: Install metal clips to top of from exhaust manifolds and pipe, fan blades, drive
fan shroud. belts and sway bars. Improperly positioned hoses can
(11) A l l engines: Install coolant reserve/overflow be damaged, resulting i n coolant loss and engine
tank hose to radiator filler neck nipple. overheating.
(12) A l l engines except 8.0L V-10: Install coolant
HOSE CLAMP HOSE
reserve/overflow tank to fan shroud (fits into T-slots
on shroud).
(13) Connect throttle cable to fan shroud.
(14) Install negative battery cable(s) to battery(s).
(15) Diesel engine: Install positive battery cable to
top of radiator. Tighten radiator-to-battery cable
mounting nuts.
(16) Position heater controls to full heat position.
(17) Fill cooling system with coolant. Refer to Re
filling Cooling System i n this group.
(18) Operate engine until i t reaches normal tem
perature. Check cooling system and automatic trans
mission (if equipped) fluid levels.
J9207-36
COOLING SYSTEM HOSES
Rubber hoses route coolant to and from the radia Fig. 67 Hose Clamp Tool—Typical
tor, intake manifold and heater core. Radiator lower
hoses are spring-reinforced to prevent collapse from COOLING SYSTEM FAN—GAS ENGINES
water pump suction at moderate and high engine Also refer to Viscous Fan Drive i n this group for
speeds. additional information.
TYPICAL F A N BLADE WATER WATER PUMP

CONSTANT ASSEMBLY PUMP
T E N S I O N HOSE PULLEY PULLEY
CLAMP BOLTS
THREADED
NUT
TYPICAL THREADED SHAFT CRANKSHAFT

HOSE (WATER PUMP HUB) PULLEY
CLAMP
NUMBER/LETTER VISCOUS FAN DRIVE
LOCATION J9407-39 J9307-32
' Fig. 68 Clamp Number/Letter Location Fig. 69 Fan Blade/Viscous Fan Drive—Gas
REMOVAL Engines—Typical
(1) Disconnect negative battery cable from battery. CAUTION: Do not remove water pump pulley-to-wa
(2) Remove throttle cable at top of fan shroud. ter pump bolts (Fig. 69). This pulley is under spring
(3) Except 8.0L V-10 Engine: Unsnap coolant re tension.
serve/overflow tank from fan shroud and lay aside.
The tank is held to shroud with T-shaped slots. Do (7) Remove four bolts securing fan blade assembly
not disconnect hose or drain coolant from tank. to viscous fan drive (Fig. 69).
(4) The thermal Viscous Fan Drive/Fan Blade As
sembly is attached (threaded) to water pump hub INSPECTION
shaft (Fig. 69). Remove fan blade/viscous fan drive The fan cannot be repaired. I f fan is damaged, i t
assembly from water pump by turning mounting nut must be replaced. Inspect fan as follows:
counterclockwise as viewed from front. Threads on (1) Remove fan blade and viscous fan drive as an
viscous fan drive are R I G H T H A N D . A Snap-On 36 assembly from the engine. Refer to preceding Re
M M Fan Wrench (number SP346 from Snap-On moval procedure.
Cummins Diesel Tool Set number 2017DSP) can be (2) Remove fan blade assembly from viscous fan
used. Place a bar or screwdriver between water drive unit (four bolts).
pump pulley bolts (Fig. 69) to prevent pulley from ro (3) Lay fan on a flat surface with leading edge fac
tating. ing down. With tip of blade touching flat surface, re
Do not attempt to remove fan/viscous fan drive as place fan i f clearance between opposite blade and
sembly from vehicle at this time. surface is greater than 2.0 mm (.090 inch). Rocking
Do not unbolt fan blade assembly (Fig. 69) from motion of opposite blades should not exceed 2.0 mm
viscous fan drive at this time. (.090 inch). Test all blades i n this manner.
(5) Remove four fan shroud-to-radiator mounting
WARNING: DO NOT ATTEMPT TO BEND OR
bolts.
S T R A I G H T E N FAN B L A D E S IF NOT WITHIN S P E C I
(6) Remove fan shroud and fan blade/viscous fan
FICATIONS.
drive assembly as a complete unit from vehicle.
After removing fan blade/viscous fan drive assem (4) Inspect fan assembly for cracks, bends, loose
bly, do n o t place viscous fan drive i n horizontal po rivets or broken welds. Replace fan i f any damage is
sition. I f stored horizontally, silicone fluid i n the found.
viscous fan drive could drain into its bearing assem
bly and contaminate lubricant.
# COOLING SYSTEM 7 - 45
CAUTION: SI f a n blade assembly is replaced be THREADED

c a u s e of mechanical d a m a g e , w a t e r p u m p a n d v i s
cous fan drive s h o u l d also be inspected. These
c o m p o n e n t s c o u l d h a v e b e e n d a m a g e d due to ex
c e s s i v e vibration.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 69) to 23 N-m (17 ft. lbs.) torque.
drive assembly to vehicle as a complete unit.
(3) Install fan shroud.
(4) Install fan blade/viscous fan drive assembly to
water pump shaft (Fig. 69).
(5) Except 8.0L V-10 Engine: Install coolant re
serve/overflow tank to fan shroud. Snaps into posi
tion.
(6) Install throttle cable to fan shroud.
COOLING SYSTEM FAN—DIESEL ENGINE

Fig. 70 Fan Blades/Viscous Fan Drive—5.9L Diesel
REMOVAL place fan i f clearance between opposite blade and
(1) Disconnect negative battery cable from battery. surface is greater than 2.0 mm (.090 inch). Rocking
(2) Remove the fan shroud mounting bolts. Posi motion of opposite blades should not exceed 2.0 mm
tion fan shroud towards engine. (.090 inch). Test all blades i n this manner.
CAUTION: Do not remove the fan pulley bolts. This WARNING: DO NOT ATTEMPT TO BEND OR
pulley is under spring tension. STRAIGHTEN FAN B L A D E S IF NOT WITHIN S P E C I
FICATIONS.
(3) The thermal viscous fan drive/fan blade assem
bly is attached (threaded) to the fan hub shaft (Fig. (4) Inspect fan assembly for cracks, bends, loose
70). Remove the fan blade/fan drive assembly from rivets or broken welds. Replace fan i f any damage is
fan pulley by turning the mounting nut clockwise (as found.
viewed from front). Threads on the viscous fan drive
are L E F T H A N D . A Snap-On 36 M M Fan Wrench CAUTION: If the fan blade assembly is replaced be
(number SP346 from Snap-On Cummins Diesel Tool c a u s e of mechanical damage, the fan pulley and
Set number 2017DSP) can be used. Place a bar or v i s c o u s fan drive should also be inspected. T h e s e
screwdriver between the fan pulley bolts to prevent components could have been damaged due to ex
pulley from rotating. c e s s i v e vibration.
(4) Remove the fan shroud and the fan blade/vis
cous drive as an assembly from vehicle.
(5) Remove fan blade-to-viscous fan drive mount INSTALLATION
ing bolts. (1) Install fan blade assembly to viscous fan drive.
Inspect the fan for cracks, loose rivets, loose or Tighten mounting bolts to 23 N-m (17 ft. lbs.) torque.
bent fan blades. (2) Position the fan shroud and fan blade/viscous
fan drive to the vehicle as an assembly.
INSPECTION (3) Install viscous fan drive assembly on fan hub
The fan cannot be repaired. I f the fan is damaged, shaft. Tighten mounting nut to 57 N-m (42 ft. lbs.)
it must be replaced. Inspect the fan as follows: torque.
(1) Remove fan blade and thermal viscous fan (4) Install fan shroud bolts.
drive assembly from engine. Refer to the preceding (5) Install battery cable to battery.
Removal procedure.
(2) Remove fan blade assembly from thermal vis VISCOUS FAN DRIVE
cous fan drive unit (four bolts). The thermal viscous fan drive (Figs. 69 or 70) con
(3) Lay fan on a flat surface with leading edge fac sists of the viscous fan drive clutch and a thermo
ing down. With tip of blade touching flat surface, re- static spring coil mounted on its front face (Fig. 71).
The viscous fan drive clutch is a silicone-fluid-filled (Fig. 72). Rotate spring counterclockwise until a stop is
coupling connecting fan blade assembly to water felt. The gap between end of coil and retaining clip
pump shaft. The coupling allows fan to be driven i n a should be approximately 12 mm (0,5 inch) (Fig. 73). Re
normal manner at low engine- speeds. I t will limit top place unit i f shaft does not rotate with coil. After test
speed of fan to a predetermined maximum level at ing, install end of coil in slot of retaining clip.
higher engine speeds.
M O U N T I N G NUT
T O WATER PUMP
Fig. 71 Viscous Fan Drive

The thermostatic spring coil (Fig. 71) reacts to the
temperature of radiator discharge air. I t engages
drive clutch for higher fan speed i f air temperature
from radiator rises above a certain point. Until addi
tional engine cooling is necessary fan will remain at Fig. 72 Disconnecting End of Thermostatic
a reduced rpm regardless of engine speed. Only when Spring—Typical
sufficient heat is present i n the air, will the viscous
fan drive clutch engage. This air flowing through ra
diator core will cause a reaction to thermostatic
spring coil. Fan speed will then increase to provide
necessary additional engine cooling.
CAUTION: If v i s c o u s fan drive is replaced b e c a u s e

of mechanical damage, cooling fan blades should
also be inspected. Inspect for fatigue c r a c k s , loose
blades or loose rivets that could have resulted from
e x c e s s i v e vibration. Replace fan blade assembly if
any of these conditions are found. Also inspect wa
ter pump bearing and shaft assembly for any re
lated damage due to a v i s c o u s drive malfunction.
Regardless of increased engine speed, once the fan

has reached its maximum operating speed, i t will not
rotate any faster. When the necessary engine cooling
has been accomplished causing a reduction i n tem
perature of radiator discharge air, the spring coil
again reacts. This will cause fan speed to be reduced
to its previous disengaged speed.
Fig. 73 TeBimc Sfrmc S l i d Shaft Rotation—Typical
T E S T I N G VISCOUS FAN DRIVE
In case of engine overheating, inspect thermal viscous REHMOVAUIHSTALLATION
fan drive for proper operation. Observe movement of For removal and installation procedures of the
thermostatic spring coil and shaft. Lift end of thermo thermal viscous fan drive, refer to Cooling System
static spring up and out of retaining slot in fan drive Fans in this group.
AUTOMATIC TRANSMISSION OIL COOLERS
INDEX
page page
Automatic Transmission Oil Coolers— Automatic Transmission Oil Coolers—Except Diesel
Diese! Engine . . . 49 Engines 47
AUTOMATIC TRANSMISSION OIL COOLERS— this optional cooler is located between the radiator
EXCEPT DIESEL ENGINES and air conditioning condenser (Fig. 1).
8.0L V-10 Engine: The air-to-oil cooler is located
WKATEH-TO-OJL GAOLER in front of and to the left side of the radiator (Fig. 2).
Ml gas powered models equipped with an auto This secondary cooler is supplied as standard equip
matic transmission are equipped with a transmission ment on models equipped with the 8.0L V-10 engine
oil cooler mounted internally within the radiator side and an automatic transmission.
tank. This internal cooler is supplied as standard UPPER RADIATOR TRANS. O I L
equipment on all gas powered models equipped with SUPPORT BRACKET COOLER
an automatic transmission. BOLT UPPER
RADIATOR MOUNTING
The internal radiator oil cooler is n o t used with BOLTS (2)
SUPPORT
the diesel engine. BRACKET
Transmission oil is cooled when i t passes through
TRANSMISSION
this separate cooler. I n case of a leak i n the internal OIL
radiator mounted transmission oil cooler, engine cool COOLER
ant may become mixed with transmission fluid or
transmission fluid may enter engine cooling system.
Both cooling system and transmission should be
drained and inspected i f the internal radiator
mounted transmission cooler is leaking.
Also refer to the section on Transmission Air-to-Oil
Coolers. This heavy duty air-to-oil cooler is an option
on most engine packages. I t is supplied as standard
equipment on both the 8.0L V-10 and 5.9L diesel en
gines. LOWER RADIATOR
TRANS. OIL
SUPPORT BRACKET
BOLTS (2) COOLER
REPLAClii WATER-TO-OIL COOLER I I RADIATOR SIDE LOWER
TANK MOUNTING
BOLT J9407-40
The internal transmission oil cooler located within
the radiator is not serviceable. I f i t requires service,
Fig. 1 Air-To-Oil Cooler—3.9L V-6 or 5.2/5.9L V-8
the radiator must be replaced.
Engines
Once the repaired or replacement radiator , has
been installed, fill the cooling system and inspect for The oil coolers on all gas powered engines operate
leaks. Refer to the Refilling Cooling System and Test in conjunction with the internal radiator mounted
ing Cooling System For Leaks sections i n this group. main oil cooler. The transmission oil is routed
I f the transmission operates properly after repairing through the main cooler first, then the optional
the leak, drain the transmission and remove the cooler, before returning to the transmission.
transmission oil pan. Inspect for sludge and/or rust.
Inspect for a dirty or plugged inlet filter. I f none of RE10WAL—AIR-TO-OIL COOLER—3 J L / I . 2 L / 5 J L ENGINES
these conditions are found, the transmission and I f a leak should occur i n the internal radiator
torque converter may not require reconditioning. Re mounted transmission air-to-oil cooler (gas engines
fer to Group 21 for automatic transmission servicing. only), engine coolant may become mixed with trans
mission fluid. Transmission fluid may also enter en
Am°m°Q$L COOLER gine cooling system. Both cooling system and
5.2/5.9L V-8 Gas Powered Engines: A n optional transmission should be drained and inspected i n case
air-to-oil transmission oil cooler is available with of oil cooler leakage.
most engine packages. On the 5.2/5.9L V-8 engines, (1) Disconnect negative battery cable at battery.
RADIATOR MOUNTING
SUPPORT BOLTS
OIL COOLER
MOUNTING ALIGNMENT
BOLTS (3) J9407-41 DOWELS (2) J9407-38
Fig. 2 Air-To-Oil Cooler—8.0L ¥-10 Engine Fig. 3 Radiator Mounting Bolts—Typical
(2) Drain cooling system. Refer to Draining Cooling INSTALLATION
System. (1) Install the oil cooler assembly to the A-shaped

(3) Place a drain pan under the oil cooler lines. radiator support bracket using the two upper mount
(4) Disconnect the two transmission oil cooler line ing bolts and mounting straps. Install the bolts but
quick-connect fittings at the radiator. Refer to Group do not tighten at this time.
21, Transmissions for procedures. Plug cooler lines to (2) Install the radiator support bracket and oil
prevent oil leakage. cooler (as an assembly) to the vehicle.
(5) Disconnect the oil cooler quick-connect fitting (3) Install the two lower radiator A-shaped support
at the transmission oil cooler line. Refer to Group 21, bracket bolts. Do not tighten bolts at this time.
Transmissions for procedures. (4) Slide and position the oil cooler on the
(6) Disconnect the windshield washer reservoir A-shaped bracket until its lower mounting hole lines
tank at the fan shroud. Refer to Group 8K, Wind up with the bolt hole on the vehicle body. Tighten the
shield Wiper and Washer Systems for procedures. oil cooler mounting strap bolts to 6 N-m (50 in. lbs.)
(7) Remove the rubber shield at right side of radi torque.
ator. The shield is held to vehicle body with plastic (5) Install the upper radiator A-shaped support
clips. bracket bolt. Tighten all three radiator support
(8) Remove the two radiator upper mounting bolts bracket mounting bolts to 11 N-m (95 in. lbs.) torque.
(Fig. 3). (6) Install the two radiator upper mounting bolts
(9) Position the upper part of radiator towards en (Fig. 1). Tighten bolts to 11 N-m (95 in. lbs.) torque.
gine. (7) Install windshield washer reservoir tank.
(10) Remove the oil cooler lower mounting bolt (oil (8) Install rubber shield to radiator.
cooler-to-vehicle body) (Fig. 1). (9) Install the quick-connect fittings on the two oil
(11) Remove three bolts (radiator support bracket- cooler lines to the radiator. Refer to Group 21, Trans
to-body) (Fig. 1). Remove this A-shaped support missions for procedures.
bracket and the transmission oil cooler as an assem (10) Fill cooling system. Refer to Refilling the Cool
bly from the vehicle. Take care not to damage the ra ing System i n this group.
diator core or A/C condenser fins with the cooling (11) Connect negative battery cable to battery.
lines when removing. (12) Start the engine and check all fittings for
(12) Remove oil cooler from A-phaped support leaks.
bracket by removing two upper mounting strap bolts (13) Check the fluid level i n the automatic trans
and mounting straps at support bracket (Fig. 1). mission. Refer to Group 21, Transmissions for proce
(13) Remove oil cooler from the A-shaped radiator dures.
support bracket.
REMOVAL—AIR-TO-OIL COOLER—8.0L V-10 ENGINE

I f a leak should occur i n the internal radiator
mounted transmission oil cooler (gas engines only),
engine coolant may become mixed with transmission
fluid. Transmission fluid may also enter engine cool
ing system. Both cooling system and transmission
should be drained and inspected i n case of oil cooler
leakage.
(1) Place a drain pan under the oil cooler lines.
(2) Disconnect the two transmission oil cooler line
quick-connect fittings from the transmission oil
cooler lines (Fig. 2). Refer to Group 21, Transmis
sions for procedures. Plug cooler lines to prevent oil
leakage.
(3) Remove three oil cooler-to-radiator support
mounting bolts (Fig. 2).
(4) Remove the oil cooler and line assembly from
the vehicle.
INSTALLATION
(1) Install the oil cooler and cooler line assembly to
the vehicle.
(2) Install three mounting bolts and tighten to 6
N-m (50 i n . lbs.) torque.
(3) Connect the quick-connect fittings. Refer to
Group 21, Transmissions for procedures.
(4) Start the engine and check all fittings for leaks.
(5) Check the fluid level i n the automatic trans
mission. Refer to Group 21, Transmissions for proce
dures.
AUTOMATIC TRANSMISSION OIL COOLERS-

DIESEL ENGINE
All diesel models equipped with an automatic
transmission are equipped with both a main water-
to-oil cooler and a separate air-to-oil cooler. Both cool
ers are supplied as standard equipment on diesel QUICK-
engine powered models when equipped with an auto MOUNTING CONNECT
matic transmission. NUTS (2) FITTINGS (2) J9407-42
Transmission oil is cooled when i t passes through

these coolers. Fig. 5 Air-To-Oil Cooler—Diesel Engine
The main water-to-oil transmission oil cooler is (1) Disconnect both negative battery cables at bat
mounted to a bracket on the turbocharger side of the teries.
engine (Fig. 4). (2) Remove air cleaner assembly and air cleaner
The air-to-oil cooler is located i n front of and to the intake hoses. Refer to Group 25, Emission Control
left side of the radiator (Fig. 5). System for procedures.
The diesel engine is not equipped with an internal (3) Drain cooling system. Refer to Draining Cooling
radiator mounted oil cooler. System.
(4) Disconnect coolant lines from cooler.
REMOVAL—VKATER-TO-OIL COOLER—5.9L (5) Disconnect transmission oil lines from cooler.
DIESEL ENGINE Plug cooler lines to prevent oil leakage.
I f a leak should occur i n the water-to-oil cooler (6) Remove oil cooler mounting straps.
mounted to the side of the engine block, engine cool (7) Lift oil cooler off of mounting bracket.
ant may become mixed with transmission fluid.
Transmission fluid may also enter engine cooling sys INSTALLATION
tem. Both cooling system and transmission should be (1) Position oil cooler on bracket.
drained and inspected i n case of oil cooler leakage. (2) Install mounting straps.
(3) Connect transmission oil lines to cooler. (5) Remove the charge air cooler-to-oil cooler bolt
(4) Connect coolant hoses to cooler. (Fig. 5).
(5) Connect negative battery cables to both batter (6) Remove two mounting nuts.
ies. (7) Remove the oil cooler and line assembly to
(6) Fill cooling system. Refer to Refilling Cooling wards the front of vehicle. Cooler must be rotated
System i n this section. and tilted into position while removing.
(7) Check transmission oil level and fill as neces
sary. INSTALLATION
(8) Install air cleaner assembly and air cleaner in (1) Carefully position the oil cooler assembly to the
take hoses. Refer to Group 25, Emission Control Sys vehicle.
tem for procedures. (2) Install two nuts and one bolt. Tighten to 11
N-m (95 in. lbs.) torque.
REMOVAL—AIR-TO-OIL COOLER—5.9L DIESEL
(3) Connect the quick-connect fittings to the trans
ENGINE
mission cooler lines. Refer to Group 21, Transmis
(1) Remove front bumper. Refer to Group 23, Body.
sions for procedures.
(2) Place a drain pan under the oil cooler.
(4) Install front bumper. Refer to Group 23, Body.
(3) Raise the vehicle.
(4) Disconnect the oil cooler quick-connect fittings (5) Start the engine and check all fittings for leaks.
from the transmission lines. These are located near (6) Check the fluid level i n the automatic trans
the power steering gearbox. Refer to Group 21, mission. Refer to Group 21, Transmissions for proce
Transmissions for procedures. dures.
E N G I N E ACCESSORY D R I V E B E L T S
INDEX
page page
Automatic Belt Tensioner 55 Belt Schematics 51
Belt Diagnosis 51 Belt Tension 51
Belt Removal/Installation 51 General Information 51
GENERAL INFORMATION
All vehicles are available with either a 3.9L V-6, a
5.2L V-8, two different 5.9L V-8 engines, an 8.0L V-10
or a 5.9L in-line 6 cylinder diesel engine.
The accessory drive components are operated by a
single, crankshaft driven, serpentine drive belt on all
engines. An automatic belt tensioner is used to main NORMAL CRACKS
tain correct belt tension at all times. Refer to Auto BELT OK
matic Belt Tensioner proceeding i n this group.
BELT DIAGNOSIS
SERPENTINE DRIVE BELT DIAGNOSIS—ALL
ENGINES
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not a
reason to replace belt. However, cracks running along
a rib (not across) are not normal. Any belt with NOT NORMAL CRACKS
cracks running along a rib must be replaced (Fig. 1). REPLACE BELT J9Q07-44
Also replace belt i f i t has excessive wear, frayed cords
or severe glazing. Fig. 1 Serpentine Accessory Drive Belt Wear
Refer to the Serpentine Drive Belt Diagnosis charts Patterns
for further belt diagnosis. Also refer to Automatic tensioner. The tensioner maintains correct belt ten
Belt Tensioner proceeding i n this group. sion at all times. For other tensioner information and
removal/installation procedures, refer to Automatic
BELT SCHEMATICS Belt Tensioner proceeding i n this group. Due to use
Refer to figures 2, 3, 4, 5 or 6 for belt routing. The of this belt tensioner, do not attempt to use a belt
belt routing schematics are published from the latest tension gauge on any engine.
information available at the time of publication. I f
anything differs between these schematics and BELT REMOVAL/INSTALLATION
the Belt Routing Label, use the schematics on
Belt Routing Label. This label is located i n the en Caution: Do not attempt to check belt tension with
gine compartment. a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
BELT TENSION Tensioner in this group.
ALL ENGINES
Correct accessory drive belt tension is required to 3 . 9 L V-6 O R 5.2/5.9L V-8 LDC-GAS ENGINES
be sure of optimum performance of belt driven engine
accessories. I f specified tension is not maintained, REMOVAL
belt slippage may cause; engine overheating, lack of Drive belts on these engines are equipped with a
power steering assist, loss of air conditioning capac spring loaded automatic belt tensioner (Fig. 7). This
ity, reduced generator output rate and greatly re belt tensioner will be used on all belt configurations,
duced belt life. such as with or without power steering or air condi
I t is not necessary to adjust belt tension on any en tioning. For more information, refer to Automatic
gine. All engines are equipped with an automatic belt Belt Tensioner, proceeding i n this group.
S E R P E N T I N E D R I V E BELT DIAGNOSIS
RIB C H U N K I N G Foreign objects i m b e d d e d in Remove foreign objects from

( O N E O R M O R E RIBS pulley grooves. pulley grooves. Replace belt.
HAS SEPARATED
F R O M BELT B O D Y ) Installation d a m a g e . Replace belt.
RIB O R BELT W E A R Pulley(s) misaligned. A l i g n pulley(s).
Abrasive environment. Clean pulley(s). Replace

belt if necessary.
Rusted pulley(s). Clean rust from pulley(s).
Sharp or j a g g e d pulley g r o o v e tips. Replace pulley.
Rubber deteriorated. Replace belt.
LONGITUDINAL Belt has mistracked from Replace belt.

BELT C R A C K I N G pulley g r o o v e .
{CRACKS BETWEEN
T W O RIBS) Pulley g r o o v e tip has w o r n a w a y Replace belt.
rubber to tensile member.
BELT SLIPS Belt slipping because o f Replace tensioner.

insufficient tension.
Incorrect belt. Replace belt.
Belt o r pulley subjected to Replace belt and clean pulleys.

substance (belt dressing, o i l ,
ethylene glycol) that has
reauced friction.
Driven component b e a r i n g failure. Replace faulty component bearing.
Belt g l a z e d a n d hardened from Replace belt.

heat a n d excessive slippage.
" G R O O V E JUMPING" Belt tension either too Replace tensioner.

(BELT D O E S N O T high o r t o o l o w .
MAINTAIN C O R R E C T
P O S I T I O N O N PULLEY) Incorrect belt. Replace belt.
Pulley(s) not within design Replace pulley(s).

tolerance.
Foreign object(s) in grooves. Remove f o r e i g n objects

from grooves.
Pulley misalignment. Check a n d Replace.
Belt c o r d l i n e is b r o k e n . Replace belt.
BELT B R O K E N Excessive tension. Replace belt a n d

(NOTE: IDENTIFY tensioner.
AND CORRECT
PROBLEM BEFORE Incorrect belt. Replace belt.
N E W BELT IS
INSTALLED) Tensile members d a m a g e d d u r i n g Replace belt.
belt installation.
Severe misalignment. 4) Check a n d replace.
Bracket, pulley, o r b e a r i n g Replace defective component

failure. a n d belt.
NOISE Belt slippage. Replace belt o r belt tensioner.

(OBJECTIONAL
SQUEAL, SQUEAK, Bearing noise. '2) Locate a n d repair.
O R R U M B L E IS
H E A R D O R FELT Belt misalignment. 3) Replace belt.
W H I L E D R I V E BELT
IS I N O P E R A T I O N ) Belt-to-pulley mismatch. Install correct belt.
J9107-74
AUTOMATIC
TENSIONER
*IF VEHICLE IS N O T EQUIPPED WITH POWER

STEERING, THIS WILL BE A N IDLER PULLEY. J9307-26 J9307-56
Fig. 2 Belt Routing—3.9L V-6 or 5.2/5.9L V-8 Fig. 4 Belt Routing—S.9L HDC-Gas Engine and 8.0 L
LDC-Gas Engines V-10—Without A/C
AUTOMATIC •TOWER STEERING PUMP IS NOT BELT DRIVEN

TENSIONER
J9307-55
Fig. 3 Belt Routing—5.9L HDC-Gas Engine and 8.0 L

Fig. 5 Belt Routing—5.9L Diesel Engine—With A/C
V-10—With A/C
INSTALLATION
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 7). CAUTION: When installing serpentine a c c e s s o r y
(2) Rotate tensioner assembly clockwise (as viewed drive belt, belt must be routed correctly. If not, en
from front) until tension has been relieved from belt. gine may overheat due to water pump rotating in
( 3 ) Remove belt from idler pulley first. wrong direction. Refer to (Fig. 2) for correct engine
(4) Remove belt from vehicle. belt routing. The correct belt with correct length
must be used.
(4) Check belt indexing marks. Refer to the pro

POWER STEERING PUMP
IS NOT BELT DRIVEN
ceeding Automatic Belt Tensioner for more belt infor
mation.
S.9L HDC-GAS AND 8.01 ¥-10 ENGINES
REMOVAL
Drive belts are equipped with a spring loaded au
tomatic belt tensioner (Fig. 8). This belt tensioner
will be used on all belt configurations, such as with
or without power steering or air conditioning. For
more information, refer to Automatic Belt Tensioner,
proceeding i n this group.
PULLEY
BOLT
AUTOMATIC
TENSIONER
TENSIONER
MOUNTING
BOLT
J9307-58
Fig. 6 Belt Routing—5.9L Diesel Engine—Without

A/C
J9307-64
Fig. 8 Belt Tensioner—5.9L HDC-Gas and 8.0L V-10

Engines—Typical
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 8). (The threads on this
bolt are left hand).
(2) Relax the tension from the belt by rotating the
tensioner counterclockwise (as viewed from front)
(Fig. 8). When all belt tension has been relaxed, re
move belt from tensioner pulley first and other pul
J9219-15 leys last.
Fig. 7 Belt Tensioner—3.9L V-6 or 5.2/5.9L V-8 INSTALLATION
LDC-Gas Engines
CAUTION: When installing serpentine a c c e s s o r y
(1) Position drive belt over all pulleys except idler drive belt, belt must be routed correctly. If not, en
pulley. This pulley is located between generator and gine may overheat due to water pump rotating in
A/C compressor. wrong direction. Refer to (Figs. 3 or 4) for correct
(2) Attach a socket/wrench to pulley mounting bolt engine belt routing. The correct belt with correct
of automatic tensioner (Fig. 7). length must be used.
(3) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place. Re
move wrench. Be sure belt is properly seated on all CAUTION: if the pulley is to be removed from the
pulleys. tensioner, its mounting bolt has left hand threads.
(1) Position drive belt over all pulleys e x c e p t ten (1) Position drive belt over all pulleys except wa
sioner pulley. ter pump pulley.
(2) Attach a socket/wrench to pulley mounting bolt (2) Attach a 3/8 inch ratchet to tensioner.
of automatic tensioner (Fig. 8). (3) Rotate ratchet and belt tensioner counterclock
(3) Rotate socket/wrench counterclockwise. Install wise. Place belt over water pump pulley. Let ten
belt over tensioner pulley. Let tensioner rotate back sioner rotate back into place. Remove ratchet. Be
into place. Remove wrench. Be sure belt is properly sure belt is properly seated on all pulleys.
seated on all pulleys.
AUTOMATIC BELT TENSIONER
5 . 9 L DIESEL ENGINE Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Figs. 10, 11
REMOVAL or 12). This belt tensioner will be used with all belt
Drive belts on diesel engines are equipped with a configurations, such as with or without power steer
spring loaded automatic belt tensioner (Fig. 9). fig ing or air conditioning.
ure 9 displays the tensioner for vehicles with
out air conditioning. Caution: Do not attempt to check belt tension with
This belt tensioner will be used on all belt configu a belt tension gauge on vehicles equipped with an
rations, such as with or without air conditioning. For automatic belt tensioner.
more information, refer to Automatic Belt Tensioner,
proceeding i n this group.
Fig. 9 Belt Tensioner—5.9L Diesel—Typical (non-A/C

shown)
(1) A 3/8 inch square hole is provided i n the auto
matic belt tensioner (Fig. 9). Attach a 3/8 inch drive- Fig. 10 Belt Tensioner—3.9L V-6 or 5.2/5.9L V-8
LDC-Gas Engines
long handle ratchet to this hole.
(2) Rotate ratchet and tensioner assembly counter On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, the
clockwise (as viewed from front) until tension has tensioner is equipped with an indexing arrow (Fig.
been relieved from belt. 13) on back of tensioner and an indexing mark on
(3) Remove belt from water pump pulley first. tensioner housing. I f a new belt is being installed, ar
(4) Remove belt from vehicle. row must be within approximately 3 mm (1/8 in.) of
indexing mark (Point B-Fig. 13). Belt is considered
INSTALLATION new i f i t has been used 15 minutes or less. I f this
specification cannot be met, check for:
CAUTION: When installing serpentine a c c e s s o r y • The wrong belt being installed (incorrect length/
drive belt, belt must be routed correctly. If not, en width)
gine may overheat due to water pump rotating in • Worn bearings on an engine accessory (A/C com
wrong direction. Refer to (Figs. 5 or 6) for correct pressor, power steering pump, water pump, idler pul
engine belt routing. The correct belt with correct ley or generator)
length must be used. • A pulley on an engine accessory being loose
• Misalignment of an engine accessory
TENSIONER
ASSEMBLY
INDEXING
ARROW
Fig. 11 Belt Tensioner—SSL HDC-Gas and 8.0L V-10

Engines
Fig. 13 Indexing Marks—3.9L V-6 or 5.2/5.9L V-8

LDC-Gas Engines
(3) Remove ignition coil from coil mounting bracket
(two bolts). Do not remove coil mounting bracket
from cylinder head.
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 13).
WARNING: BECAUSE OF HIGH SPRING PRES

SURE, DO N O T ATTEMPT T O DISASSEMBLE AUTO
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
Fig. 12 Belt Tensioner—5.9L Diesel—Typical
(non-A/C shown) (5) Remove pulley bolt. Remove pulley from ten
sioner.
• Belt incorrectly routed. Refer to (Figs. 2, 3, 4, 5 or
6) INSTALLATION
On 3.9L V-6 or 5.2/5.9L V-8 LDC gas engines, a (1) Install pulley and pulley bolt to tensioner.
used belt should be replaced if tensioner indexing ar Tighten bolt to 61 N-m (45 ft. lbs.) torque.
row has moved to point-A (Fig. 13). Tensioner travel
(2) Install tensioner assembly to mounting bracket.
stops at point-A. An indexing tab is located on back of tensioner. Align
this tab to slot in mounting bracket. Tighten nut to
3 . 9 L V - 6 O R S.2/S.9L V-8 LDC-GAS ENGINES
REMOVAL (3) Connect all wiring to ignition coil.
(1) Remove accessory drive belt. Refer to Belt Re (4) Install coil to coil bracket. If nuts and bolts are
moval/Installation in this group. used to secure coil to coil bracket, tighten to 11 N-m
(2) Disconnect wiring and secondary cable from ig (100 in. lbs.) torque. If coil mounting bracket has
nition coil. been tapped for coil mounting bolts, tighten bolts to 5
0 COOLING SYSTEM 7 - 57
CAUTION: To prevent damage to coil case, coil

BELT TENSIONER
mounting bolts must be torqued.
(5) Install drive belt. Refer to Belt Removal/Instal

lation in this group.
(6) Check belt indexing marks (Fig. 13).
S.9L HOC-GAS AND 8.0L ENGINES
REMOVAL
(1) Remove accessory drive belt. Refer to Belt Re
moval/Installation in this group.
(2) Remove tensioner mounting bolt (Fig. 11) and
remove tensioner.
CAUTION: If the pulley is to be removed from the DOWEL PIN J9307-63
tensioner, its mounting bolt h a s left hand threads.
Fig. 14 Tensioner Dowel Pln—5.9L HDC-Gas and
8.0L V-10 Engines
WARNING: BECAUSE OF HIGH SPRING PRES
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO
MATIC TENSIONER. UNIT IS S E R V I C E D A S AN
INSTALLATION
(1) Install pulley and pulley bolt to tensioner (ob
serve the previous CAUTION). Tighten bolt to 88
(2) Install tensioner assembly to mounting bracket.
A dowel pin is located on back of tensioner (Fig. 14).
Align this to dowel hole (Fig. 15) in tensioner mount
ing bracket. Tighten bolt to 41 N-m (30 ft. lbs.)
torque.
(3) Install drive belt. Refer to Belt Removal/Instal
lation in this group.
Fig. 15 Tensioner Dowel Hole—SSL HDC-Gas and
S.9L DIESEL ENGINE 8.0L V-10 Engines
REMOVAL INSTALLATION
(1) Remove accessory drive belt. Refer to Belt Re (1) Install pulley to tensioner.
moval/Installation in this group. (2) Install tensioner assembly to mounting bracket.
(2) Remove tensioner mounting bolt (Fig. 12) and A dowel is located on back of tensioner. Align this
remove tensioner. dowel to hole in tensioner mounting bracket. Tighten
WARNING: BECAUSE OF HIGH SPRING PRES (3) Install drive belt. Refer to Belt Removal/Instal
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO lation in this group.
MATIC TENSIONER. UNIT IS S E R V I C E D A S AN
ENGINE BLOCK HEATERS
DESCRIPTION AND OPERATION
An optional engine block heater is available with for
all models. The heater is equipped with a power cord.
The cord is attached to an engine compartment compo
nent with tie-straps. The heater warms the engine pro
viding easier engine starting and faster warm-up in low
temperatures. The heater is mounted in a core hole of
the engine cylinder block (in place of a freeze plug) with
the heating element immersed in engine coolant. Con
nect the power cord to a grounded 110-120 volt AC elec
trical outlet with a grounded, three wire extension cord.
WARNING: DO NOT OPERATE ENGINE UNLESS

BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS RE
TAINING CLIPS AND ROUTED AWAY FROM EX
HAUST MANIFOLDS AND MOVING PARTS.
The 3.9L/5.2L/5.9L gas powered engine has the HEATER J9407-,

block heater located on the right side of engine next Fig. 2 Engine Block Heater—8.0L V-10 Engine
to the oil filter (Fig. 1).
The 8.0L V-10 engine has the block heater located
on the right side of engine next to the engine oil dip
stick tube (Fig. 2).
Fig. 3 Engine Block Heater—Diesel Engine

(4) Loosen (but do not completely remove) the
screw at center of block heater (Fig. 1 or 2).
(5) Remove block heater from engine. After remov
ing block heater, note direction of heating element
coil (up or down). Element coil must be installed cor
rectly to prevent damage.
INSTALLATION
(1) Thoroughly clean the cylinder block freeze plug
hole and block heater seat.
Fig. 1 Engine Block Heater—3.9U5.2U5.9L Gas
(2) Insert block heater into cylinder block.
Powered Engine
(3) With heater fully seated, tighten center screw.
REMOVAL (4) Fill cooling system with recommended coolant. Re
(1) Disconnect negative battery cable from battery. fer to Refilling Cooling System section in this group.
(2) Drain coolant from radiator and cylinder block. (5) Start and warm the engine.
(3) Remove power cord from heater (Figs. 1 or 2). (6) Check block heater for leaks.
• COOLING SYSTEM 7 - 5S
SPECIFICATIONS
GENERAL INFORMATION COOLANT CAPACITIES

The following specifications are published from the
latest information available at the time of publica
tion. I f a n y t h i n g differs between the specifica
tions found on t h e Vehicle Emission C o n t r o l
I n f o r m a t i o n (VECI) label and the following
specifications, use specifications on V E C I label. 3.9L/5.2L/5.9L 19 yt®n
The VECI label is located in the engine compart G a s Engines (20 Qts. or 5.0 Gals.)
ment.
8.0L Engine 25 Liters
( 2 6 Q t s . or 6 . 5 G a l s . )
DRIVE BELT TENSION
All engines are equipped with a spring loaded au
5.9L Diesel Engine ..... 23 Liters
tomatic belt tensioner. Do not attempt to check belt (24 Qts. or 6.0 Gals.)
tension with a belt tension gauge on vehicles
equipped with an automatic belt tensioner. Refer to * Nominal refill capacities are shown. A variation
Automatic Belt Tensioner i n this group. may be observed from vehicle to vehicle due to
manufacturing tolerances and refill procedures.
* Capacities shown include vehicles with air

conditioning and or heavy-duty cooling
systems.
J9407-21
TORQUE
D«tcription | Torqw Description
Automatic Belt Tensioner Pulley Bolt— Radiator Mounting Bolts 11 N » m ( 9 5 in. lbs.)
3 . 9 L / 5 . 2 L / 5 . 9 L L D C G a s Engine . . . 61 N ^ m ( 4 5 ft. lbs.)
Thermal Viscous Fan-to-Hub-Diesel
Automatic Belt Tensioner Pulley Bolt— Engine 5 7 N^m (42 ft. l b s . ) ,
5 . 9 L H D C Gas ondS.OL
Thermostat Housing Bolts—
V-10 Engine 88 N®m ( 6 5 ft. lbs.)
All G a s Engines Except 8.0L V-10 . 2 3 N * m ( 2 0 0 in. lbs.)
Automatic Belt Tensioner-to-Mounting
Bracket-3.9l/5.2ll5.9l LDC
8.0LV-10. 2 5 N ® m ( 2 2 0 in. lbs.)
Gas Engine . . . . . . . . . . . . . . . . . . 67 N»m (50 ft. lbs.)
Automatic Belt Tensioner-to-Mounting
Diesel Engine 2 4 N « m (18 ft. lbs.)
Bracket—5.9L HDC G a s and 8.0L
V-10 Engines 41 N®m (30 ft. lbs.) Water Pump Mounting Bolts -
All G a s Engines 4 0 N ® m ( 3 0 ft. lbs.)
Fan Shroud-to-Radiator Mounting
Bolts 6 N * m (50 in. lbs.) Water Pump Pulley Bolts —
All G a s Engines 2 2 N * m ( 1 6 f t . lbs.)
Heater Hose Fitting at Water Pump —
8.0L V-10 Engine 16 N « m [UTm. lbs.) Water Pump Mounting Bolts—
Diesel Engine 2 4 N ® m (18 ft. lbs.)
Hose Clamps 4 N»m (34 in. lbs.)
Idler Pulley Mounting Bolt—
All G a s Engines 61 N»m (45 ft. lbs.)
J9407-20
• ELECTRICAL 8A - 1
ELECTRICAL
G R O U P INDEX
group group
AUDIO SYSTEMS 8F POWER MIRRORS 8T

BATTERY/STARTER/GENERATOR SERVICE . . . 8B POWER SEAT ,... 8R
BATTERY/STARTING/CHARGING SYSTEMS POWER WINDOWS ..., 8S
DIAGNOSTICS 8A RESTRAINT SYSTEMS 8M
HORNS . . . 8G TURN SIGNALS AND HAZARD WARNING
IGNITION SYSTEMS 8D FLASHERS 8J
INSTRUMENT PANEL AND GAUGES 8E VEHICLE SPEED CONTROL SYSTEM ,, 8H
LAMPS 8L WARNING BUZZER SYSTEM 8U
OVERHEAD CONSOLE 8C WINDSHIELD WIPERS AND WASHERS 8K
POWER LOCKS . . . 8P WIRING DIAGRAMS . . . 8W
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page page
BATTERY TEST PROCEDURES 3 GENERATOR TEST PROCEDURES 15

ENGINE STARTER MOTOR TEST PROCEDURES .10 SPECIFICATIONS " 20
GENERAL INFORMATION 1 USING ON-BOARD DIAGNOSTIC SYSTEM . . . . 19
GENERAL INFORMATION
The battery, starting, and charging systems operate to on-board diagnostics (OBD) built into the power-
with one another and, therefore, must be thoroughly train control module (PCM). Use of an ammeter, volt/
tested as a complete system. I n order for the vehicle ohmmeter, battery charger, carbon pile rheostat (load
to start and charge properly, i t must have a battery tester), and 12-volt test lamp will be required.
that will perform to specifications. The starter motor, All OBD sensing systems are monitored by the
generator, wiring, and electronics also must perform PCM. The PCM will store a diagnostic trouble code
within specifications. (DTC) i n memory for any detectable failure i n the
Group 8A covers starting (Fig. 1) and charging monitored circuits. Refer to Using On-Board Diagnos
(Fig. 2) system diagnostic procedures. These proce tic System i n this group for more information.
dures include the most basic conventional methods,
8A - 2 ELECTRICAL •
SOLENOID TERMINAL STARTER
NEGATIVE SOLENOID
CABLE
STARTER MALFUNCTION
MOTOR INDICATOR
LAMP
4 STARTER
RELAY
CONNECTOR
DIAGNOSTIC S C A N
TOOL
IGNITION
SWITCH
CLUTCH PEDAL
M O U N T E D STARTER
INTERLOCK SWITCH POWERTRAIN CONTROL
GROUND, MODULE
( M A N . TRANSMISSION ONLY) CIRCUIT
NEUTRAL SAFETY
THIS CIRCUIT GROUNDED
SWITCH ( A U T O .
AT ALL TIMES
TRANS. ONLY)
(AAAN. TRANS. ONLY)
BATTERY
928A-17
J948A-9
Fig. 1 Starting System Components—Typical

Fig. 2 Charging System Components—Typical
ELECTRICAL 8A - 3
BATTERY TEST PROCEDURES
INDEX
page page
Battery Charging 6 Ignition-Off Draw (IOD) Diagnosis .. 4
Battery Load Test 5 State-Of-Charge Test Using Test Indicator 3
Battery Open Circuit Voltage Test 5 Test Indicator 3
General Information 3
GENERAL INFORMATION terminals should be properly cleaned before diagnos

The battery stores, stabilizes, and produces electri tic procedures are performed. Refer to Group 8B -
cal current. A battery must be able to accept a charge Battery/Starter/Generator Service, for additional in
and produce high-amperage current over an extended formation.
period. A chemical reaction takes place between sul
TEST INDICATOR
furic acid solution (electrolyte) and lead positive/neg
A test indicator (hydrometer) built into the top of
ative plates i n each cell of the battery. As the battery
the battery case, provides visual information for bat
discharges, the plates collect acid from the electro
tery testing (Fig. 4). I t is important when using test
lyte. When the charging system charges the battery, indicator that the battery be level and have a clean
water is converted to sulfuric acid i n the battery. A top to see correct indications. Additional light may be
factory installed battery has a built-in test indicator required to view indicator.
to help determine state-of-charge. The factory in
stalled battery is also nonrefillable, water can not be WARNING: DO NOT U S E O P E N F L A M E . E X P L O S I V E
added. The battery is vented to release excess gases G A S E S FORM A B O V E BATTERY.
that are created when the battery is being charged or
discharged. The battery top, posts, and terminals
should be cleaned when other underhood mainte
nance is performed (Fig. 3).
WARNING: DO NOT ATTEMPT TO A S S I S T BOOST,

C H A R G E , OR T E S T BATTERY WHEN E L E C T R O
LYTE L E V E L IS B E L O W T H E T O P O F T H E P L A T E S
( Y E L L O W OR BRIGHT C O L O R IS V I S I B L E IN T E S T
INDICATOR). P E R S O N A L INJURY MAY O C C U R .
Fig. 4 Built-in Test Indicator

STATE-OF-CHARGE TEST USING TEST INDICATOR
The built-in test indicator (hydrometer) measures
the specific gravity of the electrolyte. Specific gravity
(SG) will indicate state-of-charge (voltage); although,
the test indicator will not indicate cranking capacity
of the battery. Refer to Battery Load Test for more
information. Look into the sight glass and note the
color of the indicator (Fig. 5), refer to the following
description as color indicates:
G R E E N - 7 5 to 100% state-of-charge
The battery is adequately charged for further test
ing or return to use. I f the vehicle will not crank for
Fig. 3 Battery Construction and Test Indicator a maximum 15 seconds, refer to Battery Load Test
When the electrolyte level is below the top of the for more information.
plates (yellow or bright test indicator), the battery B L A C K OR DARK—0 to 7 5 % state-of-charge
must be replaced. The battery must be completely The battery is inadequately charged and must be
charged (green test indicator) and the top, posts, and charged until green indicator is visible (12.4 volts or
more) before the battery is tested or returned to use. Excessive battery drain is caused by items left
Refer to Abnormal Battery Discharging for more in turned on, internally shorted generator, or intermit
formation. tent short i n wiring.
YELLOW OR B R I G H T COLOR I f IOD is over 20 milliamperes, the defect must be
A yellow or bright color indicates electrolyte level found and corrected before replacing a battery. I n
in the battery is below test indicator (Fig. 5). Water most cases the battery can be charged and returned
can not be added to a maintenance-free battery. The to service.
battery must be replaced. A low electrolyte level may When a vehicle will not be used for 20 days or
be caused by an over-charging condition. Refer to more (stored), remove IOD fuse from the fuseblock
Generator Test Procedures i n this group. module to reduce battery discharging.
TEST PROCEDURE
WARNING: DO NOT ATTEMPT T O C H A R G E , T E S T ,
OR A S S I S T B O O S T B A T T E R Y WHEN Y E L L O W OR
When testing a diesel-equipped vehicle (dual
batteries), do not check IOD between batteries.
BRIGHT C O L O R IS V I S I B L E IN T E S T INDICATOR.
One battery may be at a higher state-of-charge
P E R S O N A L INJURY MAY O C C U R .
than the other, which will cause a high IOD be
tween the batteries only. Remove negative ca
TEST 1NDICATORESTATE OF CHARGE
ble from passenger side battery negative post
71CO/ o REPLACE BATTERY prior to performing the I O D Test Procedures
>i outlined below.
Testing for higher amperage IOD must be per
IBl
î^^^^^^^^^ ...
GREEN
Jt
(1 \ w /
BLACK
• "
Hi
YELLOW 898A-3
formed first to prevent damage to most milli-
amp meters.
Verify that all electrical accessories are OFF. Turn
off all lamps, remove ignition key, and close all doors.
I f the vehicle is equipped with electronic accessories
(illuminated entry, high line radio), allow the systems
to automatically shut off (time out), up to 3 minutes.
Fig. 5 Test Indicator Sight Glass
(1) Determine that the underhood lamp is operat
ABNORMAL BATTERY DISCHARGING ing properly, then disconnect or remove bulb.
(1) Corroded battery posts and terminals. (2) Disconnect negative cable from battery.
(2) Loose or worn generator drive belt. (3) Connect a typical 12-volt test lamp (low watt
(3) Electrical loads that exceed the output of the age bulb) between the negative cable clamp and the
charging system due to equipment or accessories in battery negative terminal.
stalled after delivery. The test lamp may light brightly for up to 3 min
(4) Slow driving speeds (heavy traffic conditions) or utes, or may not light at all (depending on the elec
prolonged idling with high-amperage draw systems trical equipment). The term brightly being used
in use. throughout the following tests, implies the brightness
(5) Defective electrical circuit or component caus of the test lamp will be the same as i f i t were con
ing excess IOD. Refer to Ignition-Off Draw Diagnosis nected across the battery.
in this group. The test lamp must be securely clamped to the neg
(6) Defective charging system. ative cable and battery terminal. I f the test lamp be
(7) Defective battery. comes disconnected during any of the IOD test, the
electronic timer function will be activated and all
IGNITION-OFF DRAW (IOD) DIAGNOSIS tests must be repeated.
Ignition-off draw refers to power being drained (4) After 3 minutes, the test lamp should turn OFF
from the battery with the ignition switch turned off. or be DIMLY l i t (depending on the electrical equip
A normal vehicle electrical system will draw from 5 ment). I f the test lamp remains brightly l i t , do not
to 20 milliamps. This is with the ignition switch i n disconnect i t . Remove each fuse or circuit breaker
the OFF position, and all non-ignition controlled cir (refer to Group 8 - Wiring Diagrams) until test lamp
cuits i n proper working order. A vehicle that has not is either OFF or DIMLY lit. This will eliminate the
been operated for approximately 20 days, may dis higher amperage draw.
charge the battery to an inadequate level. Battery I f test lamp is still bright after disconnecting each
drain should not exceed approximately 20 MA (20 fuse and circuit breaker, disconnect the wiring har
milliamps = 0.020 amps). ness from the generator. Refer to Generator Test Pro
The 20 MA are needed to supply PCM memory, dig cedures in this group. Do not disconnect the test lamp.
ital clock memory, and ETR (electronically tuned ra After higher amperage IOD has been corrected, low
dio) memory. amperage IOD may be checked.
I t is now safe to install milliamp meter to check for

low amperage IOD.
(5) With test lamp still connected securely, clamp
an ammeter between battery negative terminal and
negative battery cable.
If the test lamp or the milliamp meter circuit
is broken the various timer circuits will start.
Do not open any doors or turn on any electrical
accessories with the test lamp disconnected or
the meter may be damaged.
(6) Disconnect test lamp. The current draw should
not exceed 0.020 amp. I f i t exceeds 20 milliamps iso
late each circuit by removing circuit breakers and
898A7
fuses. The meter reading drops once the high current
problem is found. Repair this section of the circuit, Fig. 6 Testing Open Circuit Voltage
whether i t is a wiring short or component failure.
BATTERY LOAD TEST
BATTERY OPEN CIRCUIT VOLTAGE TEST
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ
A battery voltage (no load) test will show state-of-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO
charge of a battery that will pass the Battery Load
LYTE LEVEL, DO NOT TEST. ACID BURNS OR
Test described i n this section. Before proceeding
EXPLOSIVE CONDITION MAY RESULT.
with this test or the Battery Load Test, com
pletely charge battery as described i n Battery A battery load test will verify cranking ability
Charging in this section. based on the cold crank amperage rating of the bat
I f a battery has a no load voltage reading of 12.4 tery.
volts or greater and will not endure a load test, i t is Before performing battery load test, the bat
defective and should be replaced. Refer to Group 8B - tery must b e FULLY CHARGED.
Battery/Starter/Generator Service for instructions. To (1) Remove both battery cables, negative first. Bat
test battery no load voltage, perform the following tery top and posts should be clean. I f test indicator is
operation: not green, charge the battery. See Battery Charging
(1) Before measuring open circuit voltage, the sur in this group.
face charge must be removed from plates. Turn head (2) Connect a suitable volt-ammeter-load tester
lamps on for 15 seconds then allow up to 5 minutes (Fig. 7) to the battery posts (Fig. 8). Refer to operat
for voltage to stabilize. ing instructions provided with the tester being used.
(2) Remove both battery cables, negative first. On Check the open circuit voltage (no load) of the bat
diesel models with dual batteries, each battery must tery. Voltage should be equal to or greater than 12.4
be disconnected and tested separately from the other. volts (Fig. 7), with a green test indicator.
(3) Using a voltmeter connected to the battery
posts (see instructions provided with voltmeter) mea
sure open circuit voltage (Fig. 6).
This voltage reading will indicate state-of-charge,
but will not reveal cranking capacity. Refer to Bat
tery Open Circuit Voltage chart.
BATTERY OPEN CIRCUIT VOLTAGE
Open Circuit Volts Percent C h a r g e
11.7 volts o r less 0%

12.0 25%
898A-8
12.2 50%
12.4 75% Fig. 7 Volt-Amps-Load Tester—Typical
12.6 o r m o r e 100% (3) Rotate the load control knob (carbon pile rheo
928A-3 stat) to apply a 300 amp load for 15 seconds then re-
(6) Voltage drop will vary according to battery tem
perature at the time of the load test. Battery temper
ature can be estimated by the ambient temperature
over the past several hours. If the battery has been
charged, boosted, or loaded a few minutes prior to
test, the battery would be somewhat warmer. Refer
to Load Test Temperature chart for proper loaded
voltage reading.
(7) If the voltmeter reading fell below 9.6 volts,
with the battery temperature at a minimum of 70°F
(21°C), replace the battery.
J948A-13 LOAD TEST TEMPERATURE

Minimum Vbhoge Temperature
Fig 8 Volt-Ammeter-Load Tester Connections
P C°
turn control knob to O F F (Fig. 9). This will remove 9.6 70 and above 21 and above
the surface charge from the battery.
9.5 60 16
9.4 50 10
9.3 40 4
9.1 30 -1
8.9 20 -7
8.7 10 -12
8.5 0 -18
J908A-4
BATTERY CHARGING
A battery is completely charged when it has:
• an open circuit voltage of 12.4 volts or more.
• has enough cranking capacity (minimum 9.6 volts
898ArlO when loaded for 15 seconds to 50% of cold crank am
Fig. § Remove Surface Charge from Battery perage rating at 21°C (70°F).
A green test indicator on the top of the battery, in
(4) Allow the battery to stabilize to open circuit dicates the battery is charged enough for further
voltage (may take up to 5 minutes). testing. A black indicator means the battery state-of-
(5) Rotate the load control knob to maintain a load charge is below 75%. A yellow or bright indicator
(50% of cold crank amperage rating—see Specifica means the battery has low electrolyte level. The bat
tions) for a minimum of 15 seconds (Fig. 10). After 15 tery cannot be refilled or charged, it must be re
seconds, record the (loaded) voltage reading and re placed.
turn the load control to OFF
WARNING: DO NOT C H A R G E A BATTERY THAT
HAS LOW E L E C T R O L Y T E L E V E L BATTERY MAY
A R C INTERNALLY AND E X P L O D E .
WARNING: E X P L O S I V E G A S E S FORM O V E R BAT

TERY, DO NOT S M O K E , U S E F L A M E , OR C R E A T E
S P A R K S NEAR BATTERY.
WARNING: DO NOT A S S I S T BOOST OR C H A R G E A

F R O Z E N BATTERY, CASING MAY F R A C T U R E .
898Arll
Fig. W Load 50% Cold Crank Rating Note Voltage

WARNING: POISON, CAUSES SEVERE BURNS. holddowns, tray, terminals, posts, and top before
BATTERY CONTAINS SULFURIC ACID, AVOID CON completing service, see Group 8B - Battery/Starter/
TACT WITH SKIN, EYES, OR CLOTHING. IN EVENT Generator Service.
OF CONTACT, FLUSH WITH WATER A N D C A L L
PHYSICIAN IMMEDIATELY. KEEP OUT OF REACH C H A R G I N G TIME REQUIRED
OF CHILDREN. The time required to charge a battery will vary de
pending upon the following factors:
(1) Size o f Battery— A completely discharged
CAUTION: A l w a y s disconnect the battery negative large, heavy-duty battery requires more than twice
cable before charging battery to avoid damage to the recharging time as a completely discharged small
electrical systems. Do not exceed 16.0 volts while capacity battery.
charging battery.
WARNING: N E V E R E X C E E D 20 AMPS WHEN
O n diesel models with dual batteries, each C
CHARGING A C O L D (-1°C/30 F) BATTERY, P E R
battery must be disconnected and charged sep S O N A L INJURY MAY RESULT.
arately from the other. The two batteries are
wired in parallel (positive to positive, negative (2) Temperature— A longer time will be needed
to negative) in this application. to charge a battery at -18°C (0°F) than at 27°C
Battery electrolyte will bubble inside case while be (80°F). When a fast charger is connected to a cold
ing charged properly. I f the electrolyte boils or is dis battery, current accepted by battery will be very low
charged from the vent holes while charging, at first. Then, i n time, the battery will accept a
immediately reduce charging rate or turn OFF higher rate as battery warms.
charger and evaluate battery condition. Battery (3) C h a r g e r C a p a c i t y — A charger that supplies
should not be hot to the touch. I f the battery feels only 5 amperes will require a longer charging time
hot to the touch, turn OFF charger and let cool be than a charger that supplies 20 amperes or more.
fore restarting. (4) S t a t e O f C h a r g e — A completely discharged
Some battery chargers are equipped with polarity battery requires more charging time than a partially
(+ to +/- to -) sensing devices to protect the charger or charged battery. Electrolyte is nearly pure water i n a
battery from being damaged i f improperly connected. completely discharged battery. A t first the charging
I f the battery state-of-charge is too low for the polar current amperage will be low. As the battery charges,
ity sensor to detect, the sensor must be bypassed for the specific gravity of the electrolyte will rise slowly.
charger to operate. Refer to operating instructions
provided with battery charger being used. CHARGING COMPLETELY DISCHARGED
BATTERY
CAUTION: Charge battery until test indicator ap The following procedure should be used to recharge
pears green. Do not overcharge. a completely discharged battery. Unless procedure is
properly followed, a good battery may be needlessly
I t may be necessary to jostle the battery or vehicle
replaced.
to bring the green ball into view i n the test indicator
(1) Measure voltage at battery posts with a voltme
when the state-of-charge has reached 75%.
ter, accurate to 1/10 volt (Fig. 11). I f below 10 volts,
BATTERY CHARGING TIME TABLE then charge current will be low and i t could take
some time before i t accepts a current greater than a
Charging A m p e r a g e 5 Amps 10 A m p s 2 0 A m p s few milliamperes. Such low current may not be de
O p e n Circuit Voltage Hours Charging a t 21°C (70°F) tectable on ammeters built into many chargers.
12.25to12.39 6Hrs. 3Hrs. 1,5 Hr. (2) Connect charger leads. Some chargers feature
12.00to12.24 8Hrs. 4Hrs. 2Hrs. polarity protection circuitry which prevents operation
unless charger is connected to battery posts correctly.
11.95to12.09 12Hrs. 6Hrs. 3Hrs.
A completely discharged battery may not have
10.00to11.95 14Hrs. 7Hrs. 3.5 Hrs. enough voltage to activate this circuitry, even though
10.00 to 0 See Charging Completely leads are connected properly. This makes i t appear
Discharged Battery that battery will not accept charging current. Refer
928A-19 to instructions provided with battery charger being
used.
After the battery has been charged (green test in (3) Battery chargers vary i n the amount of voltage
dicator), perform a load test to determine cranking and current they provide. For time required for bat
capacity. I f the battery will endure a load test, return tery to accept measurable charger current at various
the battery to use. I f battery will not endure a load voltages, refer to Charge Rate chart. I f charge cur
test, i t must be replaced. Clean and inspect battery rent is still not measurable at end of charging times,
Voltage Hours
16.0 v o l t s m a x i m u m u p to 4 h r s .
14.0 to 15.9 v o l t s u p to 8 h r s .
13.9 v o l t s o r l e s s u p to 16 h r s .
J928A-6
measurable during charging time, the battery may be
good and charging should be completed i n the normal
898A-12 manner.
Fig. 11 Voltmeter Accurate to 1/10 Volt Connected
the battery should be replaced. I f charge current is
ELECTRICAL 8A - S
BATTERY D I A G N O S T I C S CHART
STARTER W O N T CRANK VISUAL INSPECTION

CHECK FOR OBVIOUS DAMAGE SUCH AS CRACKED OR
BROKEN CASE THAT SHOWS LOSS OF ELECTROLYTE,
BROKEN/CRACKED TERMINAL DAMAGE, LOOSE OR CORRODED
F. C. = 1 CONNECTIONS, CLEAN A N D TIGHTEN CONNECTORS
REPLACE BATTERY*
X
STARTER STILL W O N T C R A N K
PROCEED TO STARTER TEST N O OBVIOUS DAMAGE
PROCEDURES O N VEHICLE IN THIS GROUP
TEST I N D I C A T O R / O P E N C I R C U I T V O L T A G E TEST
1
CHECK TEST INDICATOR/OPEN CIRCUIT VOLTAGE
1. TURN HEADLAMPS O N FOR 15 SECONDS
2. TURN HEADLAMPS OFF FOR 5 MINUTES TO ALLOW
BATTERY VOLTAGE TO STABILIZE
3. REMOVE NEGATIVE, THEN POSITIVE CABLE.
POSSIBLE CAUSE-I0D-REFER
TO I G N I T I O N OFF DRAW SECTION
YELLOW OR BRIGHT INDICATOR

F. C. = 2
ELIMINATE EXCESS IOD N O EXCESS IOD F O U N D DO NOT CHARGE, BOOST, OR
F. C. = 3 TEST, ELECTROLYTE BELOW
INDICATOR. REPLACE BATTERY,
GREEN BALL S H O W I N G A N D CHECK C H A R G I N G SYSTEM
•CHARGE BATTERY-REFER CHARGE OPEN CIRCUIT VOLTAGE
TO C H A R G I N G BATTERY ACCEPTED ABOVE 12.40 VOLTS**
PROCEED TO STARTER TEST
W O N T ACCEPT C H A R G E PROCEDURES O N VEHICLE I N
F. C. = 4 THIS GROUP
1. N O GREEN BALL S H O W I N G
2. OPEN CIRCUIT VOLTAGE BELOW 12.40
VOLTS. SEE CHARGING COMPLETELY
DISCHARGED BATTERY L O A D TEST V O L T A G E C H A R G E
MINIMUM
ESTIMATED REQUIRED
L O A D TEST ELECTROLYTE VOLTAGE
TEMPERATURE UNDER
DISCHARGE BATTERY AT 300 AMPERES FOR 15 SECONDS. ALLOW BATTERY
TO RECOVER FOR 15 SECONDS. CONNECT VOLTMETER A N D AMPERE LOAD 15 SEC. LOAD
EQUAL TO 1/2 THE COLD C R A N K I N G AMPERE RATING OF THE BATTERY FOR
70° F (21° C) & ABOVE 9.6
15 SECONDS. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD O N .
60° F (16° C 9.5
N O T E : ESTIMATE T E M P E R A T U R E O F BATTERY. 50° F (16° C 9.4
R E F E R TO L O A D TEST V O L T A G E C H A R T . 40° F (4° C 9.3
30° F H°c 9.1
20° F (-7° C 8.9
VOLTAGE AT OR ABOVE VOLTAGE BELOW 10° F (-12°C 8.7
9.6 VOLTS AT R O O M 9.6 VOLTS AT R O O M 0° F (-18°C 8.5
(70 DEG. F) TEMP. (70 DEG. F) TEMP.
VOLTMETER M U S T BE ACCURATE
I TO 1/10 VOLT
FAILED LOAD TEST
PASSED LOAD TEST
F. C = 5
RETURN BATTERY TO USE
•REPLACE BATTERY FAILURE C O D E (FX.) CHART
FAILURE CODE (F. C.)
NUMBER CONDITION
1 BROKEN/CRACKED
PROCEED TO STARTER TEST YELLOW/BRIGHT INDICATOR
2
PROCEDURES O N VEHICLE I N I G N I T I O N OFF DRAW
3
THIS GROUP BATTERY W O N ' T ACCEPT CHARGE
4
5 BATTERY FAILED LOAD TEST
NOTES: " A F T E R C H A R G I N G O R R E P L A C I N G A BATTERY,
C H E C K THE VEHICLE'S C H A R G I N G S Y S T E M , A N D
C L E A N A N D T I G H T E N BATTERY C O N N E C T O R S " C H E C K I N G O P E N CIRCUIT VOLTAGE W I L L
(REFER TO A P P L I C A B L E S E C T I O N S O F T H I S MONITOR " G R E E N BALL" INDICATION
SERVICE MANUAL). FOR ALL 6 CELLS. J938A-22
E N G I N E S T A R T E R MOTOR T E S T P R O C E D U R E S
INDEX
page page
General Information 10 Starter System Diagnostic Inspections 10
Starter Control Circuit Tests 12 Starting System Cold Cranking Test . . . . . . . . . . . . 10
Starter Feed Circuit Tests - (Voltage Drop Method) . 11
GENERAL INFORMATION tion switch, starter relay, and battery (including all
The starting system consists of an: ground connections). Clean and tighten all connec
• ignition switch tions as required.
• starter relay
SOLENOID, RELAY AND IGNITION SWITCH
• park/neutral position switch (automatic transmis
sion) INSPECTION
• clutch switch (manual transmission) Inspect the starter solenoid, starter relay and igni
• wiring harness tion switch to determine their condition. Also, i f
• battery equipped with automatic transmission, inspect condi
• starter motor with an integral solenoid. tion of the park/neutral position switch; and, i f
These components form 2 separate circuits. A high equipped with manual transmission, inspect condi
amperage circuit that feeds the starter motor up to tion of the clutch switch. Testing information can be
375 amps-gas engine; 700 amps-diesel engine, and a found i n the following pages.
control circuit that operates on less than 20 amps
(Fig. 1). STARTING SYSTEM COLD CRANKING TEST
(1) Battery must first pass load and voltage drop
IGNITION SWITCH tests and be fully charged before proceeding. Refer to
OUTCH I
Battery Test Procedures.
SWITCH I
(2) Connect a suitable volt-ampere tester to the
^ f f PARK/NEUTRAL POSITION I
II SWITCH I battery terminals (Fig. 2). Refer to the operating in
structions provided with the tester being used.
STARTER RELAY
MOTOR -
JT POSITIVE NEGATIVE
S 1 E R
ARJ SOtENOIDl CLAMP CLAMP
Fig. 1 Starting System Components INDUCTION

AMMETER
STARTER SYSTEM DIAGNOSTIC INSPECTIONS CLAMP
Before removing any unit from the starter motor 948A-24
system for repair, perform the following inspections:
Fig. 2 Volt-Amps Tester Connections (Typical)
BATTERY INSPECTION
(3) Fully engage parking brake, place manual
To determine condition of the battery, perform the
transmission i n NEUTRAL, automatic transmission
testing procedure outlined i n Battery Test Proce
in PARK.
dures.
(4) Verify that all lamps and accessories are OFF.
WIRING INSPECTION (5) Remove automatic shutdown (ASD) relay from
Inspect wiring for damage. Inspect all connections power distribution center (PDC) on gas engine mod
at the starter motor solenoid, park/neutral position els, or disconnect fuel shutdown solenoid connector
switch (if equipped), clutch switch (if equipped), igni- (Fig. 3) on diesel engine models.
STARTING SYSTEM DIAGNOSIS
TEST CONDITIONS
• PLACE GEAR SELECTOR IN PARK OR NEUTRAL AND SET PARK BRAKE OR EQUIVALENT.
• VERIFY BATTERY STATE-OF-CHARGE AND CRANKING CAPACITY, SEE BATTERY SECTION.
• CLEAN BATTERY TOP, POSTS, A N D TERMINALS.
• VERIFY GENERATOR DRIVE BELT TENSION.
• REMOVE ASD RELAY FROM POWER DISTRIBUTION CENTER (GAS ENGINE).
• DISCONNECT FUEL SHUTDOWN SOLENOID CONNECTOR (DIESEL ENGINE).
SYMPTOM SYMPTOM SYMPTOM SYMPTOM SYMPTOM

STARTER FAILS T O S T A R T E R FAILS T O STARTER E N G A G E S , STARTER E N G A G E S STARTER D O E S N O T
ENGAGE. NO SOUNDS ENGAGE SOLENOID FAILS T O T U R N DRIVE CLUTCH D I S E N G A G E AFTER
O R RELAY C L I C K S E N G I N E . D O M E LIGHT SPINS OUT E N G I N E STARTS
DIMS
POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE C A U S E
STARTER C O N T R O L RESISTANCE T O O RESISTANCE T O O D R I V E C L U T C H FAULTY IGNITION SWITCH

C I R C U I T FAULTY H I G H IN STARTER H I G H IN STARTER FAULTY
FEED CIRCUIT FEED CIRCUIT
BROKEN TEETH
IGNITION SWITCH O N RING GEAR STARTER RELAY
FAULTY STARTER C O N T R O L STARTER A S S E M B L Y FAULTY
C I R C U I T FAULTY FAULTY
STARTER A S S E M B L Y
PARK/NEUTRAL FAULTY STARTER A S S E M B L Y
POSITION STARTER S O L E N O I D ENGINE SEIZED FAULTY
SWITCH FAULTY
(AUTO TRANS.)
FAULTY STARTER
STARTER ASSEMBLY IMPROPERLY
CLUTCH SWITCH FAULTY MOUNTED
FAULTY
( M A N . TRANS.)
REFER TO
APPROPRIATE G R O U P
STARTER R E L A Y
A N D S E C T I O N O F THIS
FAULTY
MANUAL FOR PROPER
SERVICE A N D TEST
PROCEDURES FOR THE
STARTER ASSEMBLY COMPONENTS
FAULTY
INVOLVED
J948A-16
(6) Rotate and hold the ignition switch i n the meter be connected to the terminals that the cables
START position. Note cranking voltage and amper are connected to, instead of to the cables themselves.
age. For example, when testing between the battery and
(a) I f voltage reads above 9.6 volts and amperage solenoid, touch the voltmeter test probes to the bat
draw reads above 300 amps (gas engine), or 700 tery post and the solenoid threaded stud. The follow
amps (diesel engine) go to Starter Feed Circuit ing operation will require a voltmeter, accurate to
Tests. 1/10 of a volt.
(b) I f voltage reads 12.5 volts or greater and am Before performing the tests, assure the following
perage reads below specifications, go to Starter procedures are accomplished:
Control Circuit Tests. • Remove ASD relay from PDC on gas engine mod
A cold engine will increase starter motor cur els.
rent and reduce battery voltage. • Disconnect the fuel shutdown solenoid connector
(Fig. 3) on diesel engine models.
STARTER FEED CIRCUIT TESTS - (VOLTAGE DROP • A l l lamps and accessories are OFF.
• Transmission i n NEUTRAL (manual transmission)
METHOD)
or PARK (automatic transmission).
The voltage drop tests will determine i f there is ex
• Parking brake applied.
cessive resistance i n the high current circuit. When
• Battery is fully charged (refer to Battery Test Pro
performing these tests, i t is important that the volt-
cedures).
8A - 12 ELECTRICAL
FRONT OF ENGINE AIR TEMPERATURE SENSOR BATTERY

SENSOR ELECTRICAL
CONNECTOR
STARTER
MOTOR VOLTMETER 898A20
Fig. 5 Test Positive Battery Cable Resistance

(Typical)
INTAKE rect poor contact at battery cable to solenoid connec
MANIFOLD
(UPPER HALF)
FUEL tion. I f reading is still above 0.2 volt, replace positive
SHUTDOWN SOLENOID
SOLENOID ELECTRICAL battery cable.
J9414-93
CONNECTOR (5) Connect voltmeter to measure between the bat
tery negative post and the engine block (Fig. 6).
Fig. 3 Diesel Engine Fuel Shutdown Solenoid
VOLTMETER
(1) Connect positive lead of voltmeter to battery
negative post. Connect negative lead of voltmeter to
battery negative cable clamp (Fig. 4). Rotate and
hold the ignition switch i n the START position. Ob
serve voltmeter. I f voltage is detected, correct poor
contact between cable clamp and post.
VOLTMETER
ENGINE v
GROUND\ BATTERY 898A-18
Fig. 6 Test Ground Circuit Resistance

BATTERY
(6) Rotate and hold the ignition switch i n the
START position. I f voltage reads above 0.2 volt, cor
rect poor contact at ground cable attaching point.
Voltage reading still above 0.2 volt, replace ground
898A17 cable.
( 7 ) Connect positive voltmeter lead to starter mo
Fig. 4 Test Battery Connection Resistance tor housing. Connect negative lead to battery nega
tive terminal (Fig. 7 ) .
(2) Connect positive lead of voltmeter to battery
(8) Rotate and hold the ignition switch i n the
positive post. Connect negative lead of voltmeter to
START position. I f voltage reads above 0.2 volt, cor
battery cable positive clamp (Fig. 4). Rotate and hold
rect poor starter to engine ground.
the ignition switch i n the START position. Observe
I f resistance tests detect no feed circuit failures, re
voltmeter. I f voltage is detected, correct poor contact move the starter motor and go to Solenoid Testing.
between cable clamp and post.
(3) Connect a voltmeter to measure between the STARTER CONTROL CIRCUIT TESTS
battery positive post and the center of the B+ starter The starter control circuit consists of a:
solenoid stud (Fig. 5). • starter solenoid
(4) Rotate and hold the ignition switch i n the • starter relay
START position. I f voltage reads above 0.2 volt, cor- • ignition switch
• Terminal 87A is connected to terminal 30 i n the

de-energized position.
• The solenoid terminal (87) is connected to the bat
tery terminal (30) i n the energized position, which
supplies battery voltage to the operated device.
• The ignition terminal (86) is connected to the elec
tromagnet and usually connected to a switched power
source.
• The ground terminal (85) is connected to the elec
tromagnet and is usually grounded by a switch or the
PCM.
TESTING
Remove relay from PDC to perform the following
tests.
Fig. 7 Test Starter Motor Ground (Typical) • A relay i n the de-energized position should have
• park/neutral position switch (automatic transmis continuity between terminal 87A and terminal 30.
sion) • Resistance value between terminals 85 and 86
• clutch switch (manual transmission) (electromagnet) is 75 ±5 ohms.
• all their wiring and connections. • Connect a battery to terminals 85 and 86. There
Testing procedures for these components are as fol should be continuity between terminals 30 and 87.
lows and should be followed i n order as described.
CAUTION: Before performing any test, remove A S D

relay from P D C (gas engine) or unplug fuel shut
down solenoid connector (diesel engine) to prevent
engine from starting.
S T A R T E R RELAY CONNECTIONS
Fig. 8 Power Distribution Center

IGNITION SWITCH TEST
After testing starter solenoid and relay and they
check out OK, trouble is probably with ignition
switch or its wiring.
GROUND SOLENOID
Check all wiring for opens and shorts, and connec
(85) TERMINAL tions for being loose or corroded.
(87)
J928B-1
STARTER RELAY OPERATION/TESTING

The starter relay is i n the power distribution cen
ter (PDCXFig. 8). Refer to the underside of the PDC
cover for relay location.
OPERATION
• The battery terminal (30) is usually connected to
battery voltage and can be switched or B + at all
times.
SOLENOID TESTING
Refer to Group 8B - Battery/Starter/Generator Ser
vice for starter removal procedures.
(1) Disconnect field coil wire from field coil termi
nal (Fig. 9).
Fig. 10 Continuity Test Between Solenoid Terminal

and Field Coil Terminal
SOLENOID
Fig. 9 Field Coil Wire Terminal

RR8BD33
(2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. There
Fig. 11 Continuity Test Between Solenoid Terminal
should be continuity (Fig. 10).
and Solenoid Housing
(3) Check for continuity between solenoid terminal (6) Connect field coil wire to field coil terminal
and solenoid housing. There should be continuity (Fig. 9).
(Fig. 11).
(4) I f there is continuity, solenoid is good. I f there PARK/NEUTRAL POSITION SWITCH
is no continuity i n either test, solenoid has an open Refer to Group 21 - Transmissions for diagnostic
circuit and is defective. Replace the starter motor. information.
(5) Install starter as described i n Group 8B - Bat
CLUTCH SWITCH
tery/Starter/Generator Service.
Refer to Group 6 - Clutch for diagnostic informa
tion.
• ELECTRICAL 8A - 1i
GENERATOR TEST PROCEDURES
INDEX
page page
Diagnostic Procedures 15 Generator Output Wire Resistance Test 15
General Information 15 Operational Check with Voltmeter 15
Generator Output Test 16
GENERAL INFORMATION • Inspect connection at generator B+ output. I t

The generator is belt-driven by the engine. All en should be clean and tight. Repair as required.
gines use serpentine drive.
The amount of DC current produced by the gener GENERATOR OUTPUT WIRE RESISTANCE TEST
ator is controlled by the powertrain control module Generator output wire resistance test (Fig. 1) will
(PCM). show amount of voltage drop across generator output
All vehicles are equipped with on-board diagnostics wire between generator battery terminal and battery
(OBD). A l l O B D sensing systems are monitored by positive post.
the PCM. The PCM will store i n electronic memory
any detectable failure within the monitored circuits. PREPARATION
Refer to Using On-Board Diagnostic System i n this (1) Before starting test, make sure vehicle has a
group for more information. fully charged battery. Test and procedures on how to
check for a fully charged battery are shown i n Bat
OPERATIONAL CHECK WITH WOLTMETER tery Test Procedures.
When the ignition switch is turned to the ON posi (2) Turn OFF ignition switch.
tion, battery potential will register on the voltmeter. (3) Disconnect negative cable from battery.
During engine cranking a lower voltage will appear (4) Disconnect generator output wire from genera
on the meter. With the engine running, a voltage tor output battery terminal.
reading higher than the first reading (ignition i n ON) (5) Connect a 0-150 ampere scale D.C. ammeter i n
should register. series between generator battery terminal and dis
connected generator output wire. Connect positive
DIAGNOSTIC PROCEDURES lead to generator battery terminal and negative lead
I f the voltmeter does not give the indications as de
to disconnected generator output wire.
scribed above, or i f an undercharged or overcharged
battery condition occurs, the following procedures (6) Connect positive lead of a test voltmeter (range
may be used to diagnose the charging system. 0-18 volts minimum) to disconnected generator out
Remember that an undercharged battery is often put wire. Connect negative lead of test voltmeter to
caused by: battery positive cable at positive post.
• accessories being left on overnight. (7) Connect one end of a jumper wire to ground
• a defective switch which allows a bulb, such as a and with other end probe K20 lead wire at back of
trunk or glove box lamp, to stay on (refer to Ignition- generator (Fig. 1). This will generate a DTC.
Off Draw Diagnosis).
CAUTION: Do not connect A142 lead of wiring to
VISUAL INSPECTION ground. Refer to Group 8W - Wiring Diagrams for
• Inspect condition of battery cable terminals, bat more information.
tery posts, connections at engine block, starter motor
solenoid and relay. They should be clean and tight. (8) Connect an engine tachometer and connect neg
Repair as required. ative cable to battery.
• Inspect all fuses i n the fuseblock module for tight (9) Connect a variable carbon pile rheostat between
ness in receptacles. They should be properly installed battery terminals. Be sure carbon pile is in OPEN or
and tight. Repair or replace as required. OFF position before connecting leads. See Load Testing
• Inspect generator mounting bolts for tightness. Re in Battery Test Procedures for instructions.
place or torque bolt as required (refer to Torque Spec
ifications). TEST
• Inspect generator drive belt condition and tension. (1) Start engine. Immediately after starting, re
Tension or replace belt as required. Refer to Belt Ten duce engine speed to idle.
sion Specifications.
FIELD
TERMINALS TO POWERTRAIN 10 AMP FUSE
CONTROL MODULE.
TERMINAL 51
-A142- Ail
GROUND
^ ^BATTERY A
= = = CHASSIS "
+ GROUND
J948A-17
Fig. 1 Generator Output Wire Resistance Test (Typical)
(2) Adjust engine speed and carbon pile to main PREPARATION

tain 20 amperes flowing i n circuit. Observe voltmeter (1) Before starting any tests, make sure vehicle
reading. Voltmeter reading should not exceed 0.5 has a fully charged battery. Test and procedures on
volts. how to check for a fully charged battery are shown i n
Battery Test Procedures.
RESULTS (2) Disconnect negative cable from battery.
I f a higher voltage drop is indicated, inspect, clean (3) Disconnect generator output wire at the gener
and tighten all connections between generator bat ator battery terminal.
tery terminal and battery positive post. A voltage (4) Connect a 0-150 ampere scale D.C. ammeter i n
drop test may be performed at each connection to lo series between generator battery terminal and dis
cate connection with excessive resistance. I f resis connected generator output wire (Fig. 2). Connect
tance tested satisfactorily, reduce engine speed, turn positive lead to generator battery terminal and neg
OFF carbon pile and turn OFF ignition switch. ative lead to disconnected generator output wire.
(1) Disconnect negative cable from battery. (5) Connect positive lead of a test voltmeter (range
(2) Remove test ammeter, voltmeter, carbon pile, 0-18 volts minimum) to generator battery terminal.
and tachometer. (6) Connect negative lead of test voltmeter to a
(3) Remove jumper wire. good ground.
(4) Connect generator output wire to generator (7) Connect an engine tachometer and connect bat
battery terminal post. Tighten to 5 to 6 N*m (45 to 75 tery negative cable.
in. lbs.). (8) Connect a variable carbon pile rheostat be
(5) Connect negative cable to battery. tween battery terminals. Be sure carbon pile is i n
(6) Use DRB scan tool to erase DTC. OPEN or OFF position before connecting leads. See
Load Testing i n Battery Test Procedures for instruc
GENERATOR OUTPUT TEST tions.
Generator output test determines whether genera (9) Connect one end of a jumper wire to ground
tor can deliver its rated current output. and with other end probe K20 lead wire at back of
generator (Fig. 2). This will generate a DTC.
CAUTION: Do not connect A142 lead of wiring to RESULTS

ground. Refer to G r o u p 8W - Wiring Diagrams for (1) I f reading is less than specified and generator
more information. output wire resistance is not excessive, the generator
should be replaced. Refer to Group 8B - Battery/
Starter/Generator Service for information.
TEST (2) After current output test is completed reduce
(1) Start engine. Immediately after starting reduce engine speed, turn OFF carbon pile and turn OFF ig
engine speed to idle. nition switch.
(2) Adjust carbon pile and engine speed i n incre (3) Disconnect negative cable from battery.
ments until a speed of 1250 rpm and voltmeter read (4) Remove test ammeter, voltmeter, tachometer
ing of 15 volts is obtained. and carbon pile.
(5) Remove jumper wire (Fig. 2).
CAUTION: Do not allow voltage meter to read above (6) Connect generator output wire to generator
16 volts. battery terminal post. Tighten nut to 5-6 N-m (45-75
in. lbs.).
(3) The ammeter reading must be within rating (7) Connect negative cable to battery.
shown i n Generator Specifications. (8) Use DRB scan tool to erase DTC.
TO POWERTRAIN 10 AMP FUSE

CONTROL MODULE
TERMINAL
51
A142
GROUND
CARBON PILE CHASSIS

RHEOSTAT GROUND
J948A-18
Fig. 2 Generator Current Output Test—Typical

8A - 18 ELECTRICAL
CHARGING SYSTEM DIAGNOSTICS

IMPROPER UNSTEADY NOISY
OR LOW OVER
CHARGING CHARGING ALTERNATOR
CHARGING
CHECK BATTERY
CONDITION TEST GROUNDED WORN OR
SEE BATTERY GENERATOR GENERATOR FIELD FRAYED
SECTION FOR OUTPUT WIRE WIRE, FIELD DRIVE BELT
DETAILS RESISTANCE TERMINAL, OR
CONNECTIONS
CORRODED CHARGING
BATTERY CABLES GENERATOR
RESISTANCE REFER TO MOUNTING
OR TERMINALS TOO HIGH USING ON-BOARD LOOSE
DIAGNOSTIC
SYSTEM
DRIVE BELTS CORRODED OR

LOOSE SHORTED CABLES
OR HIGH FAULTY FAULTY
RESISTANCE GENERATOR GENERATOR
ACROSS FUSIBLE
LOOSE OR LINK
CORRODED
WIRING
CONNECTIONS AT
GENERATOR
RESISTANCE *FOR MORE INFORMATION REFER TO
O.K. THE POWERTRAIN DIAGNOSTIC PROCEDURES
LOOSE OR MANUAL COVERING THE VEHICLE INVOLVED
CORRODED
WIRING •SEE GROUP 8W, WIRING DIAGRAMS FOR
CONNECTIONS AT TEST CIRCUIT AND COMPONENT INFORMATION
TERMINAL BLOCK GENERATOR
CURRENT
OUTPUT
LOOSE
CHASSIS TO
BATTERY GROUND
CABLE CURRENT
OUTPUT
O.K.
LOOSE
GENERATOR
GROUND WIRE
REFER TO
USING ONBOARD
DIAGNOSTIC
LOOSE OR SYSTEM
CORRODED
WIRING
CONNECTIONS AT
BULKHEAD FAULTY
DISCONNECT GENERATOR
CHECK FOR
APPROXIMATELY
12 VOLTS AT FIELD
INPUT BRUSH
TERMINAL WITH
IGNITION SWITCH
J948A-14
"ON"
USING ON-BOARD DIAGNOSTIC S Y S T E M

OPERATION OF ON-BOARD DIAGNOSTIC HOW TO USE MALFUNCTION INDICATOR (CHECK
(OBD) SYSTEM ENGINE) LAMP TO OBTAIN A DTC
The powertrain control module (PCM) monitors To start this function, cycle the ignition switch ON-
critical input and output circuits of the charging sys OFF-ON-OFF-ON within 5 seconds. This will allow
tem making sure they are OK. Some are checked any DTC stored i n the PCM to be displayed. The
continuously and some are only checked under cer malfunction indicator (Check Engine) lamp will dis
tain conditions. play a DTC by flashing on and off. There is a short
I f the OBD system senses that one critical circuit is pause between flashes and a longer pause between
bad, i t will consider this a real problem and put a digits. All codes displayed are two digit numbers with
DTC into memory. Each input and output circuit a four second pause between codes.
monitored by the OBD system has its own DTC. The An example of a code is as follows:
DTC will stay in memory as long as the circuit con (1) Lamp on for 2 seconds, then turns off.
tinues to be bad. I f the problem does not happen (2) Lamp flashes 4 times pauses and then flashes 1
again after the code is put into memory, the PCM time.
will clear the memory after 50 engine starts. (3) Lamp pauses for 4 seconds, flashes 4 times,
pauses and then flashes 7 times.
DIAGNOSTIC TROUBLE CODES
The two codes are 41 and 47. Any number of codes
Diagnostic trouble codes (DTC) are 2 digit numbers
can be displayed, as long as they are i n memory. The
flashed on malfunction indicator (Check Engine)
lamp will flash until all are displayed (55 = end of
lamp that identify which circuit is bad. I n most
test).
cases, they do not identify which component i n a cir
cuit is bad. A DTC description can be read using the CHARGING SYSTEM DIAGNOSTIC TROUBLE
DRB scan tool. Refer to Group 14 - Fuel Systems for CODES
more information. Therefore, a DTC is only a symp See Generator Diagnostic Trouble Code chart for
tom, not necessarily the cause for the problem. I n DTC which apply to the charging system. Refer to
some cases, as a result of the design of the driveabil- the Powertrain Diagnostic Procedures manual to di
ity test procedure, a DTC can be the reason for the agnose an On-Board Diagnostic System, Trouble
problem. I t is important that the test procedure be Code.
followed, i n order to understand what caused the
DTC of the on-board diagnostic system to be set.
GENERATOR DIAGNOSTIC TROUBLE CODE (DTC)
Diagnostic DRB Scan Tool

Trouble Disc-by Description of Diagnostic Trouble Code
Code
12* Battery Disconnect Direct battery input to PCM was disconnected within the last 50 Key-on cycles.
41 ** Generator Field Not An open or shorted condition detected in the generator field control circuit.
Switching Properly
46**...... Charging System Battery voltage sense input above target charging voltage during engine operation.
Voltage Too High
47** Charging System Battery voltage sense input below target charging durina engine operation.
Voltage To© Low Also, no significant change detected in battery voltage during active test of
generator output.
55*. N/A Completion of fault code display on Check Engine lamp.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as
describeain manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
J948A-8
SPECIFICATIONS
BATTERY SPECIFICATIONS
Load Cold
Test Cranking Reserve
(Amps) Rating @ 0 ° F Capacity
300 Amp 600 Amp 120 Minutes
375 A m p 750 Amp 125 Minutes
C R A N K I N G RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts
or greater at specified temperature.
RESERVE CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage
o f 10.5 volts a t 2 7 ° C ( 8 0 ° F ) .
J948B-7
D I E S E L ENGINE STARTER
R E D U C T I O N G E A R STARTER
Manufacturer Nippondenso
Engine Application 8.0L
Engine Application 5.9L DIESEL
Part Number and 56004757
Power Rating 1.4 kw Part Number and 4741012
Power Rating 2.7 kw
12
Voltage 12
No. of Fields 4
No. of Fields 4
No. of Poles 4
No. of Poles 4
4
Brushes 4
Drive Reduction
Gear Train Drive Conventional
Gear Train
Free Running Test
11 Free Running Test
Voltage 11
Amperage Draw 73 Amps
Amperage Draw 200 Amps Max.
Minimum Speed rpm 3601 rpm
Minimum Speed rpm 3000 rpm Min.
Solenoid Closing Voltage 7 5 Volts
Solenoid Closing Voltage 8 Volts
Cranking Amperage Draw Test . . . . 125-250 Amps*
* Engine should be up to operating temperature. Extremely
heavy oil or tight engine will increase starter amperage draw. * Engine should be up to operating temperature. Extremely
heavy oil or tight engine will increase starter amperage draw.
J948B-25 J948B-23
GAS ENGINE STARTERS
5.9L, 5.2L & 3.9L
Part Number a n d 53005984
1.4 Kw
12
4
4
4
Drive Reduction
Gear Train
Free Running Test
11
Amperage Draw 73 A m p s
Minimum Speed rpm 3601 r p m
Solenoid Closing Voltage 7.5 Volts
Cranking Amperage D r a w Test . . . 125-250 A m p s '
* Engine should be up to operating temperature. Extremely heavy

oil or tight engine will increase starter amperage draw.
J948B-26
GENERATOR SPECIFICATIONS
mm PART N U M B E R PULUY GROOVES ENGINE RATING
NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS
NIPPONDENSO 56027221 8 DIESEL 120 AMPS
J948B-24
BATTERY/STARTER/GENERATOR SERVICE 8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY SERVICE PROCEDURES 1 SPECIFICATIONS 9

GENERATOR SERVICE S STARTER SERVICE PROCEDURES 4
BATTERY 8ERW1CE P R O C E D U R E S
GENERAL INFORMATION MOVING A BATTERY BY HAND. SAFETY GLASSES
This section will cover the battery removal and in SHOULD A L S O BE WORN. IF THE BATTERY IS
stallation procedures only. For diagnostic procedures, CRACKED OR LEAKING THE ELECTROLYTE CAN
see Group 8A - Battery/Starting/Charging Systems BURN THE SKIN AND EYES.
Diagnostics.
The maintenance free battery (Fig. 1) does not (3) Remove battery holddown (Figs. 2 and 3) and
have removable battery cell caps. Water can not be remove battery from vehicle.
added to this battery. The battery is sealed, except
for small vent holes i n the top. The chemical compo
sition inside of the battery produces an extremely
small amount of gas at normal charging voltages.
The battery is equipped with a test indicator (Fig. 1)
that displays a colored ball to indicate battery state-
of-charge.
Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required
Fig. 1 Maintenance Free Battery

BATTERY VISUAL INSPECTION AND SERVICE
(1) Make sure ignition switch is in OFF position Fig. 2 Battery Holddown
and all battery feed accessories are OFF.
(2) Disconnect and remove battery cables at bat (4) Clean top of battery with a solution of clean
tery. Remove negative cable first. warm water and baking soda. Scrub area with a stiff
bristle brush and wipe off with a cloth moistened
WARNING: WEAR A SUITABLE PAIR OF RUBBER with ammonia or baking soda and warm water (Fig.
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE 4).
8B - 2 BATTERY/STARTER/GENERATOR SERVICE •
BATTERY HOLD D O W N . BATTERY TRAY
STRAP \ J.
U-NUT
NUT
J948B-13
Fig. 5 Battery Tray—Gas Engine w/o Speed Control

> BATTERY TRAY
J948B-11
Fig. 3 Auxiliary Battery Holddown—Diesel Engine

• C L E A N I N G BRUSH
TEST
INDICATOR W A R M WATER SPEED
A N D BAKING CONTROL
S O D A SOLUTION SERVO
J948B-14
Fig. 6 Battery Tray—Gas Engine with Speed Control

DIESEL RIGHT SIDE
BATTERY TRAY
BATTERY RK108
Fig. 4 Cleaning Battery

CAUTION: Care should be taken to ensure that
solution does not enter vent holes.
(5) Inspect battery case and cover for cracks or

leakage. I f cracks or leaks are present, battery must
be replaced.
J948B-12
(6) Inspect battery tray for damage caused by loss
of acid from battery. I f acid damage is present i t will
Fig. 7 Battery Tray—Diesel Engine Auxiliary Battery
be necessary to clean area with same solution de
scribed i n step 4 (Figs. 5, 6 and 7).
• BATTERY/STARTER/GENERATOR SERVICE 8B - 3
(7) Clean battery post with a suitable battery post

cleaning tool (Fig. 8).
Fig. 9 Cleaning Battery Cable Terminal

(13) Connect cable clamps to battery post, making
Fig. 8 Cleaning Battery Post sure top of clamp is flush with top of post (Fig. 10).
(8) Clean inside surfaces of terminal clamps with a Install negative cable last.
suitable battery terminal cleaning tool (Fig. 9). Re
place damaged or frayed cables and broken terminal
clamps.
(9) Inspect battery for proper or damaged hold-
down ledge.
(10) Install battery in vehicle, making sure that
battery is properly positioned on battery tray (Figs. 2
and 3).
(11) Install battery holddown clamp, making sure
that i t is properly positioned on battery. Tighten bolt
to 12 N-m (100 in. lbs.).
(12) Place oiled felt washer onto battery positive Fig. 10 Battery Cables Disconnected
(+) post. (14) Tighten clamp nut securely.
STARTER SER¥iCE PROCEDURES
INDEX
page page
General Information 4 Starter Motor Removal and Installation Except
Starter Motor Removal and Installation Diesel 4 Diesel 4
GENERAL INFORMATION
This section will cover starter removal and instal
lation. For diagnostic procedures, see Group 8A - Bat
tery/Starting/Charging Systems Diagnostics.
STARTING SYSTEM DESCRIPTION

The starter system circuits consist of:
• battery
• engine starter motor and solenoid
• starter relay
• ignition switch
• park/neutral position switch (automatic transmission)
• clutch switch (manual transmission)
• connecting wires and battery cables.
Turning the ignition switch to the START position
causes the starter relay points to close, allowing cur
rent to energize solenoid windings. This causes sole
noid plunger and clutch shift lever to move, engaging
clutch pinion gear into ring gear. A t the same time,
the solenoid contacts close causing starter motor to
crank. As soon as engine starts, clutch pinion gear
overruns to protect starter armature from damage
due to excessive speed. Once the engine starts, the
ignition switch should be immediately released to the
ON position to prevent starter motor damage.
WARNING: ALWAYS DISCONNECT NEGATIVE CABLE

FROM BATTERY BEFORE SERVICING THE STARTER.
STARTER MOTOR REMOVAL AND INSTALLATION

EXCEPT DIESEL
HARNESS J948B-16
(1) Disconnect negative cable from battery.
(2) Remove wire terminal connector from starter Fig. 2 Remove or Install Starter Wire Connector—V10
motor (Figs. 1 and 2). STARTER MOTOR REMOVAL AND INSTALLATION
(3) Remove mounting hardware securing starter to
DIESEL
bellhousing (Figs. 2 and 3).
(1) Disconnect negative cables from both batteries.
(4) Move starter forward to clear lower mounting
(2) Remove battery cable from starter by pulling
stud (V6/V8) and starter gear housing nose. This allows
rubber boot up and removing nut (Fig. 5).
starter to come down past the exhaust pipe (Fig. 4).
(3) Remove solenoid wire from solenoid.
To install starter motor, reverse removal procedures.
(4) Remove starter motor mounting bolts (Figs. 5
• Torque battery terminal nut to 8-12.5 N-m (70-110
in. lbs). and 6).
• Torque solenoid terminal nut to 5-7 N-m (45-65 in. lbs). INSTALLATION
• Torque mounting bolts to 26-48 N-m (35-65 ft. lbs). (1) Install starter motor. Tighten bolts to 43 N-m
(32 ft. lbs.).
Fig. 4 Remove or Install Starter Motor—V6/V8

(2) Attach solenoid wire. Tighten solenoid nut to 6
N-m (55 in. lbs.).
(3) Attach battery cable to starter motor. Tighten
cable nut to 10 N-m (90 in. lbs.).
Fig. 6 Remove Or Install Starter Motor Mounting Bolt
(4) Connect negative cables to batteries.
GENERATOR S E R V I C E
INDEX
page page
General Information 6 Generator Replacement—5.9L HDC and V-10 Gas
Generator Replacement—3.9L/5.2L/5.9L-LDC Gas Engine 7
Engine 6 Generator Replacement—Diesel Engine 8
GENERAL INFORMATION
This section will cover generator removal and in
stallation. The generator is not serviceable. Informa
tion covering on-vehicle testing can be found i n
Group 8A - Battery/Starting/Charging/System Diag
nostics.
The standard equipment generator is the 75 amp
generator. The optional generator is a 90 amp unit.
When a vehicle is equipped with the heavy duty
package, diesel, or VIO engine option, a 120 amp
generator is used.
GENERATOR REPLACEMENT—3.9L/5.2L/5.9L-LDC
GAS ENGINE
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 1). This
belt tensioner is used on all belt configurations. For
more information, refer to Group 7 - Cooling, Belt
Removal/Installation.
REMOVAL
(1) Disconnect negative cable from battery. Fig. 1 Automatic Belt Tensioner—Belt Removal/
(2) Attach a socket/wrench to pulley mounting bolt Installation
of automatic tensioner (Fig. 1).
(3) Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(4) Remove belt from idler pulley first.
(5) Remove belt from vehicle. ,
(6) Remove lower generator mounting bolt and nut
(Fig. 2).
(7) Remove upper generator mounting bolt and re
move generator.
(8) Remove B+ terminal nut, 2 field terminal nuts,
ground, and wire harness holddown nuts (Fig. 3). Re
move wire connectors.
INSTALLATION
(1) Install harness to generator. Tighten nuts as
follows:
• Ground terminal, B+ terminal and wire harness
holddown 7-10 N-m (60-90 in. lbs.). Fig. 2 Generator Mounting Bolts
• Field terminals 2.5-3 N-m (20-30 in. lbs.). engine may overheat because the water pump will
(2) Install generator. Tighten both bolts to 41 N-m be rotating in the wrong direction if the belt is in
(30 ft. lbs.). stalled incorrectly. Refer to belt routing label in en
gine compartment, or s e e Group 7 - Cooling
CAUTION: When installing a serpentine a c c e s s o r y
drive belt, the belt MUST be routed correctly. The System, Belt Schematics.
Fig. 3 Remove or Install Wire Connector Assembly Fig. 4 Automatic Belt Tensioner—S.9L HDC and V10
- Typical
(3) Position drive belt over all pulleys except the
idler pulley. This pulley is located between the gen
erator and A/C compressor.
(4) Attach a socket or wrench to pulley mounting
bolt of the automatic tensioner (Fig. 1).
(5) Rotate socket or wrench clockwise. Place belt
over idler pulley. Let tensioner rotate back into place.
Remove wrench. Be sure belt is properly seated on
all pulleys.
(6) Check belt indexing marks. Refer to Group 7 -
Cooling, Automatic Belt Tensioner.
(7) Connect negative cable to battery.
GENERATOR REPLACEMENT—5.9L HDC AND V-10

GAS ENGINE
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This Fig. 5 Generator Mounting Bolts
belt tensioner is used on all belt configurations. For (7) Remove upper generator mounting bolt and re
more information, refer to Group 7 - Cooling, Belt move generator.
Removal/Installation. (8) Remove B+ terminal nut, 2 field terminal nuts,
REMOVAL
(2) Attach a socket or wrench to pulley mounting INSTALLATION
bolt of automatic tensioner (Fig. 4). The threads o n (1) Install harness to generator. Tighten nuts as
t h i s b o l t are left-hand. follows:
(3) Rotate tensioner assembly counterclockwise (as • Ground terminal, B+ terminal and wire harness
viewed from front) until tension has been relieved holddown 7-10 N-m (60-90 in. lbs.).
from belt. • Field terminals 2.5-3 N-m (20-30 in. lbs.).
(4) Remove belt from idler pulley first. (2) Install generator. Tighten both bolts to 41 N-m
(5) Remove belt from vehicle. (30 ft. lbs.).
(6) Remove lower generator mounting bolt and nut
(Fig. 5).
sioner rotate back into place. Remove socket. Be sure
belt is properly seated on all pulleys.
GENERATOR REPLACEMENT—DIESEL ENGINE

(1) Remove negative cables from batteries.
(2) Remove generator drive belt. See Group 7 -
Cooling System, for instructions.
(3) Remove B+ terminal nut, 2 field terminal nuts,
(4) Remove upper mounting bolt and nut (Fig. 7).
(5) Remove lower mounting bolt.
(6) Remove generator from the vehicle.
(7) To install generator, first tighten lower mount
ing bolt to 43 N-m (32 ft. lbs.). Tighten upper bolt to
24 N-m (18 ft. lbs.).
Fig. 6 Remove or install Wire Connector Assembly

CAUTION: When installing a serpentine a c c e s s o r y
drive belt, the belt MUST be routed correctly. The
engine may overheat because the water pump will
be rotating in the wrong direction if the belt is in
stalled incorrectly. Refer to belt routing label in en
gine compartment, or see Group 7 - Cooling
System, Belt Schematics.
(3) Position drive belt over all pulleys except wa

ter pump pulley.
(4) Attach a 3/8-inch socket to tensioner.
(5) Rotate socket and belt tensioner counterclock Fig. 7 Remove or Install Generator Mounting Bolts
wise. Place belt over water pump pulley. Let ten
BATTERY/STARTER/GENERATOR SERVICE 8B - 9
SPECIFICATIONS
BATTERY SPECIFICATIONS
load Cold
Test Cranking Reserve
(Amps) Roting @ 0°F Capacity
C R A N K I N G RATING Is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7 . 2 volts
or greater at specified temperature.
RESERVE CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage
of 10.5 volts at 2 7 ° C ( 8 0 ° F ) .
J948B-7
G A S ENGINE STARTERS
Manyfacturer Nippondenso Manufacturer Nippondenso

Engine Application 8.0L
Engine Application 5.9L, 5.2L & 3.9L
Part Number and 53005984 1.4 kw
1.4 Kw 12
12 No. of Fields 4
4 No. of Poles 4
4
No. of Poles 4
Reduction
4 Gear Train
Reduction Free Running Test
Gear Train 11
Amperage Draw ; 73 Amps
Free Running Test 3601 rpm
11 7.5 Volts
Amperage Draw 73 Amps Cranking Amperage Draw Test . . . . 125-250 Amps*
Minimum Speed rpm 3601 rpm
7.5 Volts heavy oil or tight engine will increase starter amperage draw.
Cranking Amperage Draw Test . . . 125-250 Amps*
J948B-25
* Engine should be up to operating temperature. Extremely heavy
oil or tight engine will increase starter amperage draw.
J948B-26
8B - 10 BATTERY/STARTER/GENERATOR SERVICE
DIESEL ENGINE
REDUCTION mm STARTER
Manufacturer Niapandensa
5.9L DIESEL
Power Rating 2.7 kw
12
4
No. of Poles 4
4
Drive Conventional
Gear Train
Free Running Test
Voltage 11
200 Amps Max.
Minimum Speed rpm 3000 rpm Min.
8 Volts
heavy oil or tight engine will increase starter amperage draw.
J948B-23
GENERATOR SPECIFICATIONS
FTPS PHUT N U M M 1 P U U J Y GROOVES ENGINE RATING
NIPPONDENSO 5300864© 7 ALL GASOLINE 75 AMPS
NIPPONDENSO 56027221 8 DIESEL 120 AMPS

• OVERHEAD CONSOLE 8C - 1
OVERHEAD CONSOLE
CONTENTS
page page
COMPASS MODULE REPLACEMENT 9 DIAGNOSTIC PROCEDURES 2

COMPASS REPAIR PROCEDURES 7 LENS/LAMP REPLACEMENT 9
CONSOLE REPAIR PROCEDURES 9 THERMOMETER SENSOR REPLACEMENT 8
DESCRIPTION 1
DESCRIPTION display the headings in actual degrees. This compass is

The overhead console includes: a self-calibrating unit that requires no adjusting.
• reading/courtesy lights I f the direction portion of the compass display
• compass/thermometer blanks out, and only CAL and temperature remain
displayed, then demagnetizing is necessary to remove
residual magnetic fields. Follow the demagnetizing
and calibration procedures to restore the compass
module to proper operation.
Care should be used to avoid putting anything mag
netic on the roof of the vehicle or near the compass.
Magnetic bit drivers used on fasteners that hold the
overhead console assembly to the roof of the vehicle can
also effect operation of the compass. Both a magnet on
the roof or a magnetized fastener can cause the compass
display to blank out.
I f the overhead console assembly is removed and
reinstalled i n the vehicle, then the compass should be
re-calibrated by following the compass calibration
procedure.
I f the front overhead console attaching screw is re
placed, the new screw must be a #8 X 1-1/4-inch
stainless.
If the compass functions, but compass direction accu
racy is off, i t may be necessary to perform a variation
adjustment. A variation adjustment is needed to correct
for the difference between magnetic north and true
north (road map north). Follow the variation adjust
ment procedure to set the variation for the geographical
location the compass is being operated in.
J948C-2 THERMOMETER
The ambient temperature display can be changed
READING AND COURTESY LAMPS
from Fahrenheit to Celsius using the US/METRIC
Both reading/courtesy lamps in the overhead console button. The temperature reported is not an instant
are activated by the door courtesy circuit. When both
reading of conditions but an average temperature. I t
doors are closed the lamps can be activated by depress
may take the unit several minutes to react to a ma
ing the corresponding lens. When either door is open,
jor change such as driving out of a heated garage
the switches are disabled and they will not turn the
into winter temperatures.
lamps off.
When the ignition switch is turned OFF, the last
COMPASS displayed temperature reading stays i n memory.
The compass will display the direction in which the I f the temperature is more than 60°C (140°F) or
vehicle is pointed, using the 8 major compass headings the circuit is shorted to ground, the temperature dis
(Examples: north is "N", northeast is "NE"). It does not play should read SC. I f the temperature message re-
8C - 2 OVERHEAD CONSOLE •
ceived is less than -40°C (-40°F), or an open circuit • Chart 2 describes the procedures for outside tem
exists, the display should read O C . perature measuring problems.
• Chart 3 describes the procedures for illumination
DIAGNOSTIC PROCEDURES lamp problems.
Follow the appropriate diagnostic flow chart:
• Chart 1 describes the procedures for compass and
display problems.
OVERHEAD CONSOLE 8C - 3
COMPLAINTS
WITH COMPASS,
OR DISPLAY
i
ERRATIC COMPASS DISPLAY SEGMENTS ARE

OPERATION OR COMPASS MISSING OR EXTRA
COMPLETELY
DIRECTION PORTION OF
DISPLAY BLANKS OUT DARK SEGMENTS O N
RUN
^-^MAGNETS^\ YES REMOVE PUSH STEP "SELF-DIAGNOSTIC
w
<\ NEARBY 1
MAGNETS SWITCH TEST TO
VERIFY COMPLAINT
Jmo
PERFORM YES
DEGAUSSING
PROCEDURE
PERFORM
CALIBRATION &
VARIANCE CHECK FUSE
PROCEDURE
MOVE VEHICLE
YES TO A
DIFFERENT
LOCATION
PERFORM
NO CALIBRATION &
CHECK FOR LOOSE
VARIANCE
PROCEDURE CONNECTORS
VOLTAGE/GROUND
YES
NO PERFORM
INDICATED
REPAIR
MODULE IS
DEFECTIVE DISPLAY k | _
N O
REPLACE ' NOW UT (TOGGLE \ -

COMP/TEMP
SWITCHI
PERFORM
CALIBRATION &
VARIANCE
PROCEDURE
DONE
J948C-25
Chart 1
4 OVERHEAD CONSOLE
COMPLAINTS
WITH
CONSOLE LAMPS
1
COMPLAINTS COMPLAINTS COMPLAINTS OF
WITH FLICKERING
WITH COURTESY MAP/COURTESY
A M P LAMPS LAMPS LAMPS
I l I
TOGGLE EACH
CLOSE ALL [CONFIRM LAMPS!
SOFT-TOUCH
DOORS FLICKER
SWITCH
REPLACE TOGGLE EACH PERFORM

SUSPECTED SOFT-TOUCH INDICATED
BAD BULB SWITCH REPAIR
REPLACE
ELECTRONICS
SUSPECTED
MALFUNCTION
BAD BULB
REPLACE
REPLACE LAMP
UNIT
YES YES
CHECK TOGGLE
REPLACE LAMP
VOLTAGES SWITCHES SO
ASSEMBLY
& GROUND LAMPS ARE OFF
PERFORM
INDICATED OPEN A DOOR
REPAIR
NO
DOOR SWITCH
OR CIRCUIT
BAD
PERFORM
DOOR SWITCH
INDICATED
GOOD
REPAIR
REPLACE
REPLACE LAMP REPEAT FOR NO/DOORS N
LAMP £HECKEDy
ASSEMBLY NEXT DOOR
ASSEMBLY 7
YES
^ DONE J*
J928C-4
Chart 2
COMPLAINTS WITH COMPASS MODULE

DISPLAYING " S C OR " O C " IN
k TEMPERATURE PORTION O F DISPLAY
I
TURN IGNITION O N
(NOTE: D O NOT START
ENGINE)
I
TOGGLE "COMP/TEMP"
SWITCH (TO UGHT
DISPLAY)
REPAIR WIRING BETWEEN

COMPASS MODULE AND
TEMP SENSOR
DONE
REPLACE TEMPERATURE
SENSOR
DONE
COMPASS MODULE IS
DEFECTIVE ... REPLACE
T
PERFORM COMPASS
CALIBRATION AND
VARIANCE PROCEDURE
T
DONE
J948C-24
Chart 3
O V E R H E A D CONSOLE CIRCUIT SCHEMATIC
IT -Ml-
B2 ^**LPARK 3L
[HEAD AIR TEMP
FUSE #11 SENSOR
(10 AMP) FUSE #17
(15 AMP) * — j
A21 RETURN
FUSE #18 HEAD LAMP G32 Ml
(15 AMP) SWITCH
*2 "ill
OFF FUSE #13 ? G32
LOCK m RUN (5 AMP) L_4_J
IGNITION • I i
-«-
SWITCH m I 1
ACC 1 START
Zll Zll
TE2 L 2 G31
£ 4fe
1 2 7 5 4
ILLUM BATT
(DIM)
Zll TEMP
A7 COMPASS HEAD
GROUND LAMPS
FUSE #5 OVERHEAD GROUND 0 N / 0 f F
(50 AMP) CONSOLE 11

Zll
FUSE #7
(40 AMP) -Z4- J
Zll -M2- -M2—>}
AO
10 M2
BODY
h4 BATTERY
ENGINE -±r •±r
TO
LEFT DOOR TO
I
RIGHT DOOR
GROUND GROUND - JAMB SWITCH J948C-1
JAMB SWITCH
COMPASS REPAIR PROCEDURES CAUTION: DO NOT place any external magnets

s u c h a s magnetic roof mount antennas, in the vicin
VARIATION ADJUSTMENT PROCEDURE ity of the compass.
Variance is the difference between magnetic north
and geographic north. I n some areas the difference Do not attempt to set compass near large metal ob
between magnetic and geographic north is great jects such as other vehicles, large buildings or
enough to cause the compass to give false readings. I f bridges. The compass features an "Auto-Cal" design
this occurs, the variance must be set. which simplifies the calibration procedure. During
To set the variance: turn key to the ON position. normal driving this feature automatically updates
Depress both buttons and hold down until VAR light the compass calibration. This takes into account
appears. This takes about 5 seconds. small changes i n magnetism the vehicle may see over
Release both buttons. its lifetime.
Using the map (Fig. 1) find your geographic loca Calibrate the compass manually as follows:
tion and note the zone number. (1) Start the engine.
Press the US/METRIC button to sequentially go (2) Depress both buttons and hold down until CAL
through the numbers until the zone number for your display appears. This takes about 10 seconds and ap
area appears i n the display. pears about 5 seconds after the VAR display appears.
Press the COMP/TEMP button to enter this zone (3) Release buttons.
number. (4) Drive vehicle on a level surface that is away
Confirm correct directions are indicated. from metal objects through 3 or more complete cir
cles, i n not less than 48 seconds. The CAL display
will go off and the compass is now calibrated.
If C A L display does not go off, either there is
excessive magnetism near the compass or the
unit is defective. Repeat the demagnetizing and
calibration procedures at least one more time.
If the wrong direction is still indicated, the
area selected may be too close to a magnetic
source. Repeat the calibration procedure i n an
other location.
DEMAGNETIZING PROCEDURE
The tool used to demagnetize the forward console
attaching screw and roof panel is the Miller Tool
6029. Equivalent units must be rated as continuous
duty for 110/115 volts and 60Hz. They must also
have a field strength of over 350 gauss at 1/4-inch
beyond the tip of the probe.
I n this procedure the demagnetizing tool is used to
demagnetize both the roof panel and console forward
mounting screw.
(1) Be sure the ignition switch is i n the OFF posi
tion before you begin the demagnetizing procedures.
(2) Plug the demagnetizing tool into a 110/115 volt
outlet while keeping the tool at least 2 inches away
from the compass area.
CONSOLE F0RWAR0 MOUNTING SCREW

Fig. 1 Variance Settings (3) Slowly approach the head of the forward
COMPASS CALIBRATION PROCEDURE mounting screw with the plastic coated tip of the de
magnetizing tool. Contact the head of the screw for
CAUTION: DO NOT u s e magnetic tools when servic about 2 seconds.
ing the overhead console. (4) With the demagnetizing tool still energized,
slowly back i t away from the screw until the tool is
at least 2 inches from the screw head. Unplug the
tool.
ROOF PANEL SELF*DIAGNOSTIC TEST
(5) Place an 8-1/2 X 11 piece of paper on the center The self-diagnostic test is used to confirm that the
of the roof at the windshield, oriented lengthwise display and all of its segments are operating prop
from front to rear. The purpose of the paper is to pro erly. Initiate the self-diagnostic test as follows:
tect the roof panel from scratches and define the area (1) With the ignition switch i n the OFF position si
to be degaussed (Fig. 2). Figure 2 shows the recom multaneously press and hold the COMP/TEMP but
mended sweep pattern of 1/2-inch between passes i n ton and the US/METRIC button.
a sweeping zig-zag pattern. (2) Turn ignition switch to ON.
(3) Continue to hold both buttons until segments
PULL TIP O F D E G A U S S I N G T O O L AWAY on the display light. The module is now i n self diag
nostic test.
C AT LEAST T W O FEET A N D
DISCONNECT The display will respond by cycling through the fol
3
lowing characters:
N 00
NW 11
c W 22
SW 33
S 44
SE 55
C E 66
NE 77
l b repeat test, press the COMP/TEMP button.
Pressing the US/METRIC button will light every seg
C 1/2" ment of the display for 2 seconds. To repeat test,
press the COMP/TEMP button. To exit diagnostics,
press the US/METRIC button. The module will re
turn to compass/thermometer mode.
c Should any segment i n any of the digit posi
tions fail to light, the unit is defective and
should be replaced.
c START B + (AT
ALL TIMES)
LAMPS
GROUND
J908E-27
Fig. 2 Roof Demagnetizing Pattern

PANEL DIMMER
(6) Plug i n the demagnetizing tool. Keep the tool at
least 2 inches away from the compass unit. B + (KEY O N )
(7) Slowly approach the center of the roof panel at

the windshield with the demagnetizing tool plugged HEADLAMPS ON/OFF
in. COURTESY
DOOR SWITCH
INPUT
(8) Contact the roof panel with the tip of the tool GROUND
(be sure template is i n place to avoid scratching the

J948C-19
roof panel). Use slow sweeping motions of 1/2 inch
between sweeps. Move the tool approximately 4 Fig. 3 Compass/Temperature Harness Connector
inches either side of the centerline and at least 11
inches back from the windshield. THERMOMETER SENSOR REPLACEMENT
(9) With the demagnetizing tool still energized, The sensor is mounted to the radiator support on
slowly back i t away from the roof panel until the tip the driver's side just behind the grille (Fig. 1).
is at least 2 inches from the roof. Unplug the tool. (1) Raise hood to access the sensor.
(10) Calibrate the compass and set the variance as
described.
(2) Pull front of console down slightly then move i t

rearward until mounting clips detach from roof panel
(Fig. 3).
Fig. 1 Ambient Temperature Sensor.

(2) Remove screw attaching sensor and bracket.
(3) Unplug electrical connector.
(4) To install new sensor, reverse removal proce
dures. Tighten attaching screw to 5.5 N-m (50 in.
lbs.) torque.
CONSOLE REPAIR PROCEDURES

REMOVAL Fig. 3 Remove/Install Overhead Console
(1) Remove 2 console mounting screws (Fig. 2). (3) Disconnect wire harness from compass module.
INSTALLATION
(1) Connect wire harness to compass module.
(2) While locating front edge of console to indenta
tion of headliner, install 2 screws.
(3) Push up on console housing adjacent to each
reading/courtesy lamp lens until the mounting lips
are felt to seat into position.
COMPASS MODULE REPLACEMENT

(1) Remove overhead console and disconnect wir
ing. Refer to Console Repair Procedures.
(2) Remove 3 screws holding compass module to
console (Fig. 4).
(3) Unplug harness connector from lighting module
(Fig. 5).
(4) Remove compass module.
(5) For installation, reverse the removal proce
dures.
LENS/LAMP REPLACEMENT
(1) Insert a long flat blade tool at the notch on the
curved edge of the lens. Carefully pry the lens from
the housing and pivot the lens down. Slide lens side
ways, away from center of console, to disengage lens
pivots.
J948G5 (2) Remove bulb by pulling straight down.
(3) Install new bulb by pushing firmly into socket.
Fig. 2 Remove Console Mounting Screws'
Fig. 4 Compass Module Removal/Installation
(4) Slide lens toward center of console, to engage
lens pivots. Pivot lens up into position and snap in.
Test by pressing lens for proper operation and light
ing.
• IGNITION SYSTEMS 80 - 1
IGNITION SYSTEMS
CONTENTS
page page
COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES . . . . . . 10

OPERATION ..." 1 IGNITION SWITCH 38
COMPONENT REMOVAL/INSTALLATION 24 SPECIFICATIONS 38
C O M P O N E N T IDENTIFICATION/SYSTEM OPERATION
INDEX
page page
Automatic Shut Down (ASD) Relay 2 General Information . 1
Camshaft Position Sensor—3.9L V-6 or 5.2/5.9L V-8 Ignition Coil Packs—8.0L V-10 Engine 6
Engines 2 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8 Engines .... 5
Camshaft Position Sensor—8.0L V-10 Engine . . . . . 3 Ignition Control Module—8.0L V-10 Engine 7
Crankshaft Position Sensor—3.9L V-6 or 5.2/5.9L Intake Manifold Air Temperature Sensor 8
V-8 Engines 3 Manifold Absolute Pressure (Map) Sensor 9
Crankshaft Position Sensor—8.0L V-10 Engine . . . . 4 Oxygen Sensor (02S) 9
Distributors—3.9L V-6 or 5.2/5.9L V-8 Engines 5 Powertrain Control Module (PCM) 9
Engine Coolant Temperature Sensor 7
GENERAL INFORMATION This section of the group, Component Identifica

Throughout this group, references are made to par tion/System Operation, will discuss ignition system
ticular vehicle models by alphabetical designation or operation and will identify ignition system compo
by the particular vehicle nameplate. A chart showing nents.
a breakdown of alphabetical designations is included For diagnostic procedures and adjustments, refer to
in the Introduction group at the beginning of this the Diagnostics/Service Procedures section of this
manual. group.
All vehicles are equipped with either a 3.9L V-6 en For removal and installation of ignition system
gine, a 5.2L V-8 engine, two different 5.9L V-8 en components, refer to the Component Removal/Instal
gines, an 8.0L V-10 engine or a 5.9L Cummins in-line lation section of this group.
6 cylinder diesel engine. Because the diesel engine For other useful information, refer to On-Board Di
does not have an ignition system, its service proce agnostics i n the General Diagnosis sections of Group
dures can be found i n the Fuel System section of this 14, Fuel System i n this manual.
repair manual. For operation of the DRB Scan Tool, refer to the
The 3.9L V-6 and 5.2L V-8 engines will be referred appropriate Powertrain Diagnostic Procedures ser
to i n this Ignition group as: Light Duty Cycle (LDC) vice manual.
engines. The 5.9L V-8 gas powered engine will be re An Ignition specifications section is included at the
ferred to as either: Light Duty Cycle (LDC) or Heavy end of this group. A general Maintenance Schedule
Duty Cycle (HDC) engine. The 8.0L V-10 engine will (mileage or time intervals) for ignition related items
be referred to as: Heavy Duty Cycle (HDC) engine. can be found i n Group 0, Lubrication and Mainte
Either of the HDC gas powered engines can be eas nance. This schedule can also be found in the Owners
ily identified by the use of an engine mounted air in Manual.
jection pump. The 3.9L V-6 engine, the 5.2/5.9L V-8
IGNITION SYSTEMS
LDC gas engines or the diesel engine will not use an
air injection pump. The ignition systems used on the 3.9L V-6, 5.2L V-8
and both of the 5.9L V-8 engines are basically iden-
8D - 2 IGNITION SYSTEMS •
tical with each engine using a mechanical distributor. AUTOMATIC SHUT DOWN (ASD) RELAY
Similarities and differences between the systems will The ASD relay is located i n the Power Distribution
be discussed. Center (PDC) near the vehicle battery (Fig. 2). For
The ignition system used on the 8.0L V-10 engine the location of this relay within the P D C , refer to
does not use a conventional mechanical distributor. I t PDC cover.
will be referred to as a Direct Ignition System (DIS) As one of its functions, the ASD relay will supply
or, distributor-less ignition system. battery voltage to the ignition coil (or coil packs i f
Basic ignition timing is not adjustable on any equipped with a V-10 engine). The ground circuit for
engine. the ASD relay is controlled by the powertrain control
A sequential multi-port fuel injection system is module (PCM). The PCM regulates ASD relay opera
used on all 3.9L V-6 or 5.2/5.9L V-8 gas powered en tion by switching the ground circuit to the ASD relay
gines. On the 8.0L V-10 engine, a multi-port fuel in on-and-off.
jection system is also used, although the fuel
injectors are operated i n pairs.
The ignition coils on the V-10 are individually fired,
but each coil is a dual output. Refer to Ignition Coil
Packs—8.0L V-10 Engine i n this Ignition System
group for additional information. Also refer to Group
14, Fuel Systems for additional information.
The ignition system is controlled by the powertrain
control module (PCM) on all engines (Fig. 1). The
PCM was formerly referred to as the SBEC or engine
controller.
Fig. 2 Power Distribution Center (PDC) Location

CAMSHAFT POSITION SENSOR—3.9L V-6 OR
5.2/5.9L V-8 ENGINES
The camshaft position sensor is located i n the igni
tion distributor (Fig. 3) on all 3.9L V-6 or 5.2/5.9L V-8
engines.
POWERTRAIN CONTROL
MODULE (PCM) J9414-11
Fig. 1 PCM Location—Typical

An additional ignition control module (ICM) is used
to partially control ignition coil operation on the 8.0L
V-10 engine only. Refer to Ignition Coil Packs—8.0L
V-10 Engine i n this Ignition System group for addi
tional information.
The ignition system consists of:
• Spark Plugs
• Ignition Coil (multiple coils with the 8.0L V-10 en
gine)
• Secondary Ignition Cables
• Ignition distributor. Contains rotor and camshaft
position sensor (3.9L V-6 or 5.2/5.9L V-8 engines
only) Fig. 3 Camshaft Position Sensor—3.9L V-6 or
• Ignition Control Module (8.0L V-10 engine only) 5.2/5.9L V-8 Engines—Typical
• Powertrain Control Module (PCM) SENSOR OPERATION- 3.91 V-6 OR 5.Z5.9L
• Crankshaft Position Sensor V-8 ENGINES
• Camshaft Position Sensor The camshaft position sensor contains a hall effect
• IGNITION SYSTEMS 8D - 3
device called a sync signal generator to generate a spective cylinders. The sensor generates electrical
fuel sync signal. This sync signal generator detects a pulses. These pulses (signals) are sent to the power-
rotating pulse ring (shutter) on the distributor shaft. train control module (PCM). The PCM will then de
The pulse ring rotates 180 degrees through the sync termine crankshaft position from both the camshaft
signal generator. Its signal is used i n conjunction position sensor and crankshaft position sensor.
with the crankshaft position sensor to differentiate The camshaft position sensor detects notches i n the
between fuel injection and spark events. I t is also upper camshaft drive gear (Fig. 5). The face of the
used to synchronize the fuel injectors with their re sensor is positioned next to this gear with a small air
spective cylinders. gap.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
to switch high resulting i n a sync signal of approxi
mately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync sig
nal voltage to switch low to 0 volts.
For component testing, refer to the Diagnostics/Ser
vice Procedures section of this group.
For removal and installation of this component, re
fer to the Component Removal/Installation section of
this group.
CAMSHAFT POSITION SENSOR—8.0L V-10

ENGINE Fig. 5 Sensor Operation—8.0L V-10 Engine
The camshaft position sensor is located i n the tim When the gear is rotating, the sensor will detect
ing chain case/cover on the left-front side of the en one of these notches. Input voltage from the sensor to
gine (Fig. 4). A machined hole is provided i n the the PCM will then switch from a low (approximately
timing chain cover to place the face of the sensor 0.3 volts) to a high (approximately 5 volts). As the
next to the upper camshaft drive gear. A slot and a notch moves away from the sensor, the input voltage
single bolt are provided on the sensor for depth ad switches back low to 0.3 volts.
justment (Fig. 4).
CRANKSHAFT POSITION SENSOR—3.9L ¥-6 OR
5.2/5JL V-8 ENGINES
The sensor is bolted to the top of cylinder block
near the rear of the right cylinder head (Fig. 6).
Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the pow
ertrain control module (PCM). The PCM interprets
the sensor input to determine the crankshaft posi
tion. The PCM then uses this position, along with
other inputs, to determine injector sequence and ig
nition timing.
The sensor is a hall effect device combined with an
internal magnet. I t is also sensitive to steel within a
certain distance from it.
SENSOR OPERATION—3.9L V»6 ENGINE

Fig. 4 Camshaft Position Sensor—8.0L ¥-10
The flywheel/drive plate has groups of notches at
Engine—Typical
its outer edge. On 3.9L V-6 engines, there are three
SENSOR OPERATION—8.0L V-f 0 ENGINE sets of double notches and three sets of single
The camshaft position sensor is used i n conjunction notches (Fig. 7).
with the crankshaft position sensor to differentiate The notches cause a pulse to be generated when
between fuel injection and spark events. I t is also they pass under the sensor. The pulses are the input
used to synchronize the fuel injectors with their re to the PCM.
, CRANKSHAFT SPARK SENSOR OPERATION*^5.2L/5*9L V-8 ENGINES
H POSITION PLUG On 5.2L and 5.9L V-8 engines, the flywheel/drive
M
SENSOR CABLE
LOOM plate has 8 single notches, spaced every 45 degrees,
at its outer edge (Fig. 8).
CRANKSHAF
POSITION
SENSOR
FLYWHEEL
NOTCHES
WIRING
A M HARNESS EGR * . TUBE MOUNTING
J?314^2^ C O N N E C T O R \ TUBE / [ BOLTS (2)
Fig. 6 Crankshaft Position Sensor—3.9L V-6 or

5.2/5.9L V-8 Engines—Typical
CRANKSHAFT J93I4-88
POSITION
SENSOR
Fig. 8 Sensor Operation—5.2L/5.9L V-8 Engines
FLYWHEEL The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM. For each engine revolution, there are 8
pulses generated on V-8 engines.
NOTCHES- The engine will not operate i f the PCM does not re
ceive a crankshaft position sensor input.
this group.
CRANKSHAFT POSITION SENSOR—8 J L V-10

ENGINE
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
J9314-89
right engine mount, just above the oil pan rail (Fig.
9).
Fig. 7 Sensor Operation—3.9L V-6 Engine
The engine will not operate i f the PCM does not re SENSOm OPERATION—8,01 ¥-10 ENGINE
ceive a crankshaft position sensor input. The crankshaft position sensor detects notches ma
For component testing, refer to the Diagnostics/Ser chined into the middle of the crankshaft (Fig. 10).
vice Procedures section of this group. There are five sets of notches. Each set contains
For removal and installation of this sensor, refer to two notches. Basic ignition timing is determined by
the Component Removal/Installation section of this the position of the last notch i n each set of notches.
group. Once the powertrain control module (PCM) senses
the last notch, i t will determine crankshaft position
(which piston will next be at Top Dead Center). An
input from the camshaft position sensor is also
timing advance is controlled by the powertrain con

trol module (PCM). Because ignition timing is con
trolled by the PCM, base ignition timing is not
adjustable on any of these engines*
The distributor is held to the engine i n the conven
tional method using a holddown clamp and bolt. Al
though the distributor can be rotated, it will
have no effect on ignition timing.
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.
this group.
IGNITION COIL—3.9L V-6 OR 5.2/5 J L V-8

Fig. 9 Crankshaft Position Sensor—8.0L V-10
ENGINES
Engine—Typical
3.9L V-6 o r 5.2/5.0L V-8 LDC-Gas Engines; The
coil is mounted to a bracket that is bolted to the
front of the right engine cylinder head (Fig. 11). This
bracket is mounted on top of the automatic belt ten
sioner bracket using common bolts.
5.9L V-8 HDC-Gas Engine: The coil is mounted to
a bracket that is bolted to the air injection pump
(AIR pump) mounting bracket (Fig. 12).
Fig. 10 Sensor Operation—8.0L V-10 Engine

needed. I t may take the module up to one complete
engine revolution to determine crankshaft position
during engine cranking.
The PCM uses the signal from the camshaft posi
tion sensor to determine fuel injector sequence. Once
crankshaft position has been determined, the PCM
begins energizing a ground circuit to each fuel injec Fig. 11 Ignition Coil—3.91 V-6 or 5.2/5.9L ¥-8
tor to provide injector operation. LDC-Gas Engines
The ignition coil is not oil filled. The windings are
DISTRIBUTORS—3.9L V-6 OR 5.2/5.9L V-8 embedded i n an epoxy compound. This provides heat
ENGINES and vibration resistance that allows the ignition coil
For component testing, refer to the Diagnostics/Ser to be mounted on the engine.
vice Procedures section of this group. The automatic shutdown (ASD) relay, after receiv
All 3.9L V-6 and 5.2L/5.9L V-8 engines are ing signals from the crankshaft and camshaft posi
equipped with a camshaft driven mechanical distrib tion sensors, will supply battery voltage to the
utor, containing a shaft driven distributor rotor. They ignition coil positive terminal. I f these signals are not
are equipped with an internal camshaft position (fuel received by the PCM after approximately one second
sync) sensor. This sensor provides fuel injection syn of engine cranking (start-up), the ASD relay will shut
chronization and cylinder identification. off positive voltage to the coil. Coil operation (firing)
Distributors do not have built in centrifugal or vac is then controlled by switching ground circuits (off-
uum assisted advance. Base ignition timing and all and-on) through the PCM. The PCM will determine
8D - 6 ' IGNITION SYSTEMS
ENGINE COIL
COIL \ CYLINDERS "MOUNTING 5
CONNECTOR NUMBER BOLTS (8) J948D-6
Fig. 12 Ignition Coil—5.91 ¥-8 HDC-Gas Engine Fig. 13 Ignition Coil Packs—8.0L ¥-10 Engine
cylinder identification after receiving signals from REAR COIL PACK FRONT COIL PACK
the crankshaft and camshaft position sensors.
Base i g n i t i o n t i m i n g is n o t adjustable o n any
engine. B y controlling the coil ground circuit, the
PCM is able to set the base timing and adjust the ig
nition timing advance. This is done to meet changing
engine operating conditions.
The PCM adjusts ignition timing based on inputs i t
receives from:
• The engine coolant temperature sensor
• The crankshaft position sensor (engine speed)
• The manifold absolute pressure (MAP) sensor
• The throttle position sensor
• Transmission gear selection
this group.
IGNITION COIL PACKS—8 J L ¥-10 ENGINE

The ignition system used on the 8.0L V-10 engine
does not use a conventional mechanical distributor. I t
will be referred to as a Direct Ignition System (DIS)
or, distributor-less ignition system. Because of the RIGHT LEFT
IANK IANK
DIS, basic i g n i t i o n t i m i n g is n o t adjustable o n
any 8.0L V-10 engine. FIRING ORDER
1-10-9-4-3-6-5-8-7-2 J948D-12
Two separate coil packs containing a total of five
independent coils are attached to a common mount
ing bracket located above the right engine valve Fig. 14 Spark Plug Cable Order—8.0L ¥-10 Engine
cover (Fig. 13). The coil packs are not oil filled. The • Number 9 and 8
front coil pack contains three independent epoxy • Number 1 and 6
filled coils. The rear coil pack contains two indepen • Number 7 and 4
dent epoxy filled coils. • Number 3 and 2
When one of the 5 independent coils discharges, i t The ignition system is controlled by the powertrain
fires two paired cylinders at the same time (one cyl control module (PCM) on all engines (Fig. 15). The
inder on compression stroke and the other cylinder PCM was formerly referred to as the SBEC or engine
on exhaust stroke). controller.
Coil firing (Fig. 14) is paired together on cylinders: The automatic shutdown (ASD) relay, after receiv
• Number 5 and 10 ing signals from the crankshaft and camshaft posi-
Base ignition timing is not adjustable on the

8.0L V-10 engine. By controlling all of the coil
ground circuits, the PCM is able to set the base tim
ing and adjust the ignition timing advance. This is
done to meet changing engine operating conditions.
receives from:
• The engine coolant temperature sensor
• The crankshaft position sensor (engine speed)
POWERTRAIN CONTROL vice Procedures section of this group.
For removal and installation of the coil packs, refer
to the Component Removal/Installation section of
this group.
tion sensors, will supply battery voltage to all of the
ignition coil positive terminals. V these signals are IGNITION CONTROL MODULE—8.0L V-10 ENGINE
not received by the PCM after approximately one sec
ond of engine cranking (start-up), the ASD relay will MODULE OPERATION
shut off positive voltage to all of the coils. Coil oper For ignition control module (ICM) operation, refer
ation (firing) is then controlled by switching ground to the previous section on Ignition Coil Packs—8.0L
circuits (off-and-on) through the PCM. The PCM will V-10 Engine.
determine cylinder identification after receiving sig For ICM testing, refer to the appropriate Power-
nals from the crankshaft and camshaft position sen train Diagnostic Procedures manual for operation of
sors. the DRB scan tool.
Ignition coil ground path circuits for paired cylin For removal and installation of the ICM, refer to
ders number 1/6, 3/2 and 9/8 are operated by the the Component Removal/Installation section of this
PCM only. group.
A separate ignition control module (ICM), along
with commands from the PCM, is used to control the ENGINE COOLANT TEMPERATURE SENSOR
ground path circuits for only two of the five paired The engine coolant sensor provides an input volt
coil packs. This will be for paired cylinders number age to the powertrain control module (PCM) relating
4/7 and 5/10. The ICM is located i n the engine com coolant temperature. The PCM uses this input, along
partment. I t is mounted to the right inner fender be with inputs from other sensors, to determine injector
hind the coolant reserve/overflow tank (Fig. 16). pulse width and ignition timing. As coolant tempera
ture varies, the coolant temperature sensor resis
COOLANT
RESERVE/OVERFLOW tance will change, resulting in a different input
voltage to the PCM.
When the engine is cold, the PCM will operate i n
the Open Loop Cycle. I t will demand slightly richer
air-fuel mixtures and higher idle speeds, until nor
mal operating temperatures are reached. Refer to
Modes Of Operation i n Group 14, Fuel System for a
description of Open and Closed Loop operation.
On the 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor
is installed i n the intake manifold near the thermo
stat housing (Fig. 17).
On the 8.0L V-10 engine, the sensor is installed i n
the thermostat housing (Fig. 18).
BOLTS (2) J948D-21 For component testing, refer to the Diagnostics/Ser
Fig. 16 Ignition Control Module Location—8.0L V-10 For removal and installation of this component, re
Engine fer to the Component Removal/Installation section of
this group.
Fig. 17 Coolant Temperature Sensor—3.9L V-6 or Fig. 19 Sensor Location—3.9L V-6 Engine—Typical
Fig. 18 Coolant Temperature Sensor—8.0L V-10

Engine
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
The intake manifold air temperature sensor ele
ment extends into the intake manifold air stream. I t
provides an input voltage to the powertrain control
module (PCM) indicating intake manifold air temper
ature. The input from this sensor is used along with
inputs from other sensors to determine injector pulse
width. As the temperature of the air-fuel stream i n
the manifold varies, the sensor resistance will
change. This will result i n a different input voltage
to the PCM. For more information, refer to Group 14,
Fuel System.
On 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor is
threaded into the right-front side of the intake man
ifold (Figs. 19 or 20). Fig. 21 Sensor Location—8.0L V-10 Engine—Typical
On 8.0L V-10 engines, the sensor is threaded into For removal and installation of this component, re
the left side of the intake manifold near the front of fer to the Component Removal/Installation section of
the throttle body (Fig. 21). this group.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

For information, refer to Group 14, Fuel System.
POWERTRAIN CONTROL MODULE (PCM)

The powertrain control module (PCM) is located i n
the right-rear side of the engine compartment (Fig.
22). The PCM was formerly referred to as the SBEC
or engine controller.
The ignition system is controlled by the PCM.
Base ignition timing (by rotation of distribu
tor) is not adjustable.
The PCM opens and closes the ignition coil ground
circuit to operate the ignition coil (or coils). This is
done to adjust ignition timing, both initial (base) and POWERTRAIN CONTROL
advance, for changing engine operating conditions. MODULE (PCM) J9414.11
receives from: Fig. 22 PCM Location—Typical
• The engine coolant temperature sensor OXYGEN SENSOR (02S)
• The crankshaft position sensor (engine speed) For an operational description, diagnosis and re
moval or installation of the 02S, refer to Group 14,
Fuel Systems i n this manual.
this group.
For diagnostics, refer to the appropriate Powertrain
Diagnostic Procedures service manual for operation
of the DRB scan tool.
8D - 10 IGNITION SYSTEMS
D1AGNOST1CS/SERW1CE PROCEDURES
INDEX
page page
Automatic Shut Down (ASD) Relay Test . . 10 Ignition Coil Pack Tests—8.0L V-10 Engine . . 13
Camshaft Position Sensor Test—3.9L V-6 or Ignition Coil Test—3.9L V-6 or 5.2/5.9L V-8
5.2/5.9L V-8 Engines 10 Engines 13
Camshaft Position Sensor Test—8.0L V-10 Engine . 11 Ignition Control Module Test—8.0L V-10 Engine . . . 14
Crankshaft Position Sensor Test—3.9L V-6 or Ignition Secondary Circuit Diagnosis 16
5.2/5.9LV-8 Engines 11 Ignition Timing 18
Crankshaft Position Sensor Test—8.0L V-10 Intake Manifold Air Temperature Sensor Test . . . . . 18
Engine 12 Manifold Absolute Pressure (MAP) Sensor Test . . . 19
Distributor Cap—3.9L V-6 or 5.2/5.9L V-8 Engines . 12 On-Board Diagnostics (OBD) 23
Distributor Rotor—3.9L V-6 or 5.2/5.9L V-8 Oxygen Sensor (02S) Tests ... 23
Engines 13
Powertrain Control Module (PCM) 19
DRB Scan Tool 13
Spark Plug Secondary Cables 22
Engine Coolant Temperature Sensor Test 15
General Information 10 Spark Plugs 19
GENERAL INFORMATION
This section of the group, Diagnostics/Service Pro
cedures, will discuss basic ignition system diagnostics
and service adjustments.
For system operation and component identification,
refer to the Component Identification/System Opera
tion section of this group.
For removal or installation of ignition system com
ponents, refer to the Component Removal/Installa
For other useful information, refer to On-Board Di
agnostics i n the General Diagnosis sections of Group
14, Fuel System in this manual.
For operation of the DRB Scan Tool, refer to the
appropriate Powertrain Diagnostic Procedures ser
vice manual.
Fig. 1 Camshaft Position Sensor—3.9L V-6 or
AUTOMATIC SHUT DOWN (ASD) RELAY TEST 5.2/5.9L V-8 Engines—Typical
To perform a complete test of this relay and its cir
cuitry, refer to the DRB scan tool. Also refer to the insert them into the backside of the distributor wire
appropriate Powertrain Diagnostics Procedures man harness connector to make contact with the termi
ual. To test the relay only, refer to nals. Be sure that the connector is not damaged
Relays—Operation/Testing i n the Group 14, Fuel Sys when inserting the paper clips. Attach voltmeter
tem section of this service manual. leads to these paper clips.
(1) Connect the positive (+) voltmeter lead into the
CAMSHAFT POSITION SENSOR TEST—3 J L ¥-6 sensor output wire. This is at done the distributor
OR 5.2/5.9L ¥-8 ENGINES wire harness connector. For wire identification, refer
The camshaft position sensor (Fig. 1) is located i n to Group 8W, Wiring Diagrams.
the distributor on all 3.9L V-6 or 5.2L/5.9L V-8 en (2) Connect the negative (-) voltmeter lead into the
gines. ground wire. For wire identification, refer to Group
To perform a complete test of this sensor and its 8W, Wiring Diagrams.
circuitry, refer to the DRB scan tool. Also refer to the (3) Set the voltmeter to the 15 Volt DC scale.
appropriate Powertrain Diagnostics Procedures man (4) Remove distributor cap from distributor (two
ual. To test the sensor only, refer to the following: screws). Rotate (crank) the engine until the distribu
F o r this test, an analog (non-digital) voltme tor rotor is pointed towards the rear of vehicle. The
ter is needed. Do not remove the distributor connec movable pulse ring should now be within the sensor
tor from the distributor. Using small paper clips, pickup.
• ; IGNITION SYSTEMS 80 - 11
(5) Turn ignition key to ON position. Voltmeter

should read approximately 5.0 volts.
(6) I f voltage is not present, check the voltmeter
leads for a good connection.
(7) I f voltage is still not present, check for voltage
at the supply wire. For wire identification, refer to
Group 8W, Wiring Diagrams.
(8) I f voltage is not present at supply wire, check
for voltage at pin-7 of powertrain control module
(PCM) 60-way connector. Leave the PCM connector
connected for this test.
(9) I f voltage is still not present, perform vehicle
test using the DRB scan tool.
(10) I f voltage is present at pin-7, but not at the
supply wire:
(a) Check continuity between the supply wire.
Fig. 2 Camshaft Position Sensor—8.0L V-10
This is checked between the distributor connector
Engine—Typical
and pin-7 at the PCM. I f continuity is not present,
repair the harness as necessary. scale for this test. The meter reading should be
(b) Check for continuity between the camshaft open (no resistance). Replace sensor i f a any resis
position sensor output wire and pin-44 at the PCM. tance is indicated.
I f continuity is not present, repair the harness as
necessary.
(c) Check for continuity between the ground cir
cuit wire at the distributor connector and ground.
I f continuity is not present, repair the harness as
necessary.
(11) While observing the voltmeter, crank the en
gine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the en
gine is cranking. This verifies that the camshaft po
sition sensor i n the distributor is operating properly
and a sync pulse signal is being generated.
I f sync pulse signal is not present, replacement of V I E W L O O K I N G INTO
the camshaft position sensor is necessary. CONNECTOR O N SENSOR
PIGTAIL HARNESS J948D-20
For removal or installation of ignition system com
ponents, refer to the Component Removal/Installa
Fig. 3 Typical Sensor Connector
For system operation and component identification, CRANKSHAFT POSITION SENSOR TEST—3.9L V-8
refer to the Component Identification/System Opera OR 5.2/iJL V-8 ENGINES
tion section of this group. To perform a complete test of this sensor and its
circuitry, refer to the DRB scan tool. Also refer to the
CAMSHAFT POSITION SENSOR TEST—8.01 V-10 appropriate Powertrain Diagnostics Procedures man
ENGINE ual. To test the sensor only, refer to the following:
The camshaft position sensor is located i n the tim The sensor is located on the top of cylinder block
ing chain case/cover on the left-front side of the en near the rear of right cylinder head (Fig. 4).
gine (Fig. 2). (1) Near the rear of intake manifold, disconnect
To perform a complete test of this sensor and its sensor pigtail harness connector from main wiring
circuitry, refer to the DRB scan tool. Also refer to the harness.
appropriate Powertrain Diagnostics Procedures man (2) Place an ohmmeter across terminals B and C
ual. To test the sensor only, refer to the following: (Fig. 3). Ohmmeter should be set to lK-to-lOK
(1) Disconnect the sensor pigtail harness from the scale for this test. The meter reading should be
main engine wiring harness connector. open (no resistance). Replace sensor i f a low resis
(2) Place an ohmmeter across terminals B and C tance is indicated.
(Fig. 3). Ohmmeter should be set to lK-to-10K
(3) Place an ohmmeter across terminals B and C
(Fig. 3). O h m m e t e r s h o u l d b e s e t to IK-to-1 OK
s c a l e f o r t h i s test. The meter reading should be
open (no resistance). Replace sensor i f a low resis
tance is indicated.
DISTRIBUTOR CAP—3 J L V-6 OR 5.2/6 J L V-8

ENGINES
INSPECTION
Remove the distributor cap and wipe i t clean with
a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers, or damaged ro
tor button (Figs. 6 and 7). Also check for white depos
its on the inside (caused by condensation entering
the cap through cracks). Replace any cap that dis
plays charred or eroded terminals. The machined
surface of a terminal end (faces toward rotor) will in
dicate some evidence of erosion from normal opera
tion. Examine the terminal ends for evidence of
mechanical interference with the rotor tip.
CRANKSHAFT POSITION SENSOR TEST—8.0L
V-10 ENGINE
5).
Fig. 5 Crankshaft Position Sensor—8.0L V-10

Engine—Typical
To perform a complete test of this sensor and its
appropriate Powertrain Diagnostics Procedures man
ual. To test the sensor only, refer to the following:
(2) Disconnect the sensor pigtail harness from the
main engine wiring harness connector. Fig. 7 Cap Inspection—Internal—Typical
DISTRIBUTOR ROTOR—3.9L ¥«6 OR 5.2/5 J L ¥-8

LNGINES
Visually inspect the rotor (Fig. 8) for cracks, evi
dence of corrosion, or the effects of arcing on the
metal tip. Also check for evidence of mechanical in
terference with the cap. Some charring is normal on
the end of the metal tip. The silicone-dielectric-var-
nish-compound applied to the rotor tip for radio in
terference noise suppression, will appear charred.
This is normal. Do not remove the charred com
pound. Test the spring for insufficient tension. Re
place a rotor that displays any of these adverse
conditions.
INSUFFICIENT
SPRING
TENSION Fig. 9 Ignition Coil—3.9L V-6 or S.2/5.9L V-8
LDC-Gas Engines
CORRODED EVIDENCE OF
PHYSICAL
CONTACT
WITH CAP J908D-48
Fig. 8 Rotor Inspection—Typical

Fig. 10 Ignition Coil—5.9L V-8 HDC-Gas Engine
DRB SCAN TOOL
Inspect the ignition coil for arcing. Test the coil ac
For operation of the DRB scan tool, refer to the ap
cording to coil tester manufacturer's instructions.
propriate Powertrain Diagnostic Procedures service
Test the coil primary and secondary resistance. Re
manual.
place any coil that does not meet specifications. Refer
IGNITION COIL TEST—3 J L ¥-6 OR 5.2/5 J L ¥-8 to the Ignition Coil Resistance chart.
I f the ignition coil is being replaced, the secondary
ENGINES spark plug cable must also be checked. Replace cable
To perform a complete test of the ignition coil and if i t has been burned or damaged.
its circuitry, refer to the DRB scan tool. Also refer to Arcing at the tower will carbonize the cable boot,
the appropriate Powertrain Diagnostics Procedures which, i f i t is connected to a new ignition coil, will
manual. To test the coil only, refer to the following: cause the coil to fail.
The ignition coil is designed to operate without an I f the secondary coil cable shows any signs of dam
external ballast resistor. age, i t should be replaced with a new cable. Carbon
3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: The tracking on the old cable can cause arcing and the
coil is mounted to a bracket that is bolted to the failure of a new ignition coil.
front of the right engine cylinder head (Fig. 9). This
bracket is mounted on top of the automatic belt ten IGNITION COIL PACI TESTS—8 J L ¥-18 ENGINE
sioner bracket using common bolts. To perform a complete test of the ignition coil packs
5.9L V-8 HDC-Gas Engine: The coil is mounted to and their circuitry, refer to the DRB scan tool. Also
a bracket that is bolted to the air injection pump
(AIR pump) mounting bracket (Fig. 10).
I G N I T I O N COIL R E S I S T A N C E — E X C E P T 8.0L V-10 ENGINE
PRIMARY RESISTANCE S E C 0 N P A R Y RESISTANCE
COIL (MANUFACTURER) 21-27°C (70-80°F) 21-27°C (70-80°F)
Diamond 0.97-1.18 Ohms 11,300- 15,300 O h m s
Toyodenso 0 . 9 5 - 1.20 O h m s 11,300- 13.300 O h m s
J918D-2
refer to the appropriate Powertrain Diagnostics Pro and either the right (cylinders 9/8) or left (cylinders
cedures manual. To test the coil packs only, refer to 5/10) coil terminals (Fig. 15). Refer to figure 16 for
the following procedure: resistance specifications.
OHMMETER
ing bracket located above the right engine valve
cover (Fig. 11). The coil packs are not oil filled. The
front coil pack contains three independent epoxy M A K E OHMMETER
filled coils that will fire six cylinders. The rear coil C O N N E C T I O N S AT
C O R R E S P O N D I N G CYLINDERS
pack contains two independent epoxy filled coils that e(l/6, 7/4 OR 3/2).
will fire four cylinders.
! = u l r 1 r l
< Q ® ® - >
FRONT
OF
TTJ. TNGINE
© ©
I J948D-14
^ BOLTS (8)
Fig. 12 Checking Coil Secondary Resistance—Front
J948D-6
Coils—8.0L V-10 Engine
Fig. 11 Ignition Coil Packs—8.0L V-10 Engine IGNITION CONTROL MODULE TEST—8.0L V-10
To test the secondary resistance of each individual ENGINE
paired coil, attach an ohmmeter across the coil tow The I C M is located i n the engine compartment. I t
ers (Figs. 12 or 13). This must be done between cor is mounted to the right inner fender behind the cool
responding cylinders number 3/2, 7/4, 1/6, 9/8 or 5/10 ant reserve/overflow tank.
(Fig. 11). Refer to figure 16 for resistance specifica Ignition coil ground path circuits for paired cylin
tions. ders number 1/6, 3/2 and 9/8 are operated by the
To test the primary resistance of the front coil PCM only.
pack, attach an ohmmeter between the B+ coil termi A separate ignition control module (ICM) (Fig. 17),
nal and either the right (cylinders 3/2), center (cylin along with commands from the PCM, is used to con
ders 7/4) or left coil (cylinders 1/6) terminals (Fig. trol the ground path circuits for only two of the five
14). Refer to figure 16 for resistance specifications. paired coil packs. This will be for paired cylinders
To test the primary resistance of the rear coil pack, number 4/7 and 5/10.
attach an ohmmeter between the B+ coil terminal For I C M testing, refer to the appropriate Power-
train Diagnostic Procedures manual for operation of
the DRB scan tool.
• — — — — IGNITION SYSTEMS 80 - 15
OHMMETER TO LIFT TO RIGHT

COIL COIL
M A K E OHMMETER
C O N N E C T I O N S AT
C O R R E S P O N D I N G CYLINDERS
(5/10 OR 9/8). FRONT
OF
ENGINE
FRONT
OF B+
ENGINE TERMINAL J948D-17
Fig. 15 Checking Coil Primary Resistance—Rear

Coils—8.0L V-10 Engine
* P r i m a r y Resistance: 0 . 5 3 t o 0 . 6 5 ohms
J948D 15 * * S e c o n d a r y Resistance: 1 0 . 9 t o 14 7 K o h m s
Fig. 13 Checking Coil Secondary Resistance—Rear * Test across the p r i m a r y c o n n e c t o r .

Coils—8*01 V-10 Engine Refer t o text f o r test p r o c e d u r e s .
* * Test across the i n d i v i d u a l c o i l t o w e r s .

TO B+ TERMINAL
Refer t o text f o r test p r o c e d u r e s .
J948D-13
Fig. 16 Ignition Coil Resistance Specifications—8.0L

V-10 Engine
FRONT
OF COOLANT
ENGINE RESERVE/OVERFLOW
TANK
I G N I T I O N CONTROL
MODULE (ICM)
TO TO
CENTER- RIGHT
COIL COIL J948D-16
Fig. 14 Checking Coil Primary Resistance—Front

Coils—8.0L V-10 Engine TANK
MOUNTING
For removal and installation of the ICM, refer to BOLTS (3)
the Component Removal/Installation section of this ICM M O U N T I N G
group. BOLTS (2) J948D-21
ENGINE COOLANT TEMPERATURE SENSOR TEST Fig. 17 Ignition Control Module Location—8.0L V-10
To perform a complete test of this sensor and its Engine
circuitry, refer to the DRB scan tool. Also refer to the (1) Disconnect wire harness connector from sensor.
appropriate Powertrain Diagnostics Procedures man On 3.9L V-6 or 5.2/5.9L V-8 engines with air
ual. To test the sensor only, refer to the following: conditioning, do not pull directly on wiring harness.
On the 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor Fabricate an L-shaped hook tool from a coat hanger
is installed i n the intake manifold near the thermo (approximately eight inches long). Place the hook
stat housing (Fig. 18). part of tool under the connector for removal. The con
On the 8.0L V-10 engine, the sensor is installed i n nector is snapped onto the sensor. I t is not equipped
the thermostat housing (Fig. 19). with a lock type tab.
COOLANT SENSOR RESISTANCE (OHMSI

—= GENERATOR
TEMPERATURE
SENSOR
TEMPERATURE RESISTANCE (OHMS)
C F MIN MAX
-40 -40 291,490 381,710

-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
Fig. 18 Coolant Temperature Sensor—8.9L V-6 or 70 158 1,630 1,870
80 176 1,170 1,340
5.2/5.9L V-8 Engines—Typical 90 194 860 970
TEMP. G A U G E 100 212 640 720
SENSOR (FOR TEMP.: 110 230 480 540
ENGINE C O O L A N T TEMP. SENSOR
(FOR PCM OPERATION) G A U G E OPERATION) 120 248 370 410
J928D-4
IGNITION SECONDARY CIRCUIT DIAGNOSIS

CHECKING FOR SPARK—EXCEPT 8.0L V-IO
ENGINE
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.
Grasp the boot (not the cable) and pull it off with a
J948D-9 steady, even force.
Fig. 19 Coolant Temperature Sensor—8.0L V-10 (1) Disconnect the ignition coil secondary cable
Engine from center tower of the distributor cap. Hold the ca
(2) Test the resistance of the sensor with a high in ble terminal approximately 12 mm (1/2 in.) from a
put impedance (digital) volt-ohmmeter. The resis good engine ground (Fig. 20).
tance should be less than 1340 ohms at normal
engine operating idle temperature. For resistance
values, refer to the Sensor Resistance chart. Replace
the sensor if it is not within the range of resistance
specified in the chart.
(3) Test continuity of the wire harness. This is
done between powertrain control module (PCM) wire
harness connector terminal-2 and the sensor connec
tor terminal. Also check continuity between PCM
wire harness terminal-4 to the sensor connector ter
minal. Repair the wire harness if an open circuit is
indicated.
CHECK HERE IGNITION
FOR SPARK COIL 918D-18
Fig. 20 Checking for Spark—Typical

IGNITION SYSTEMS 80 - 17
WARNING: B E V E R Y C A R E F U L WHEN T H E ENGINE

IS CRANKING. DO NOT PUT Y O U R HANDS NEAR
THE P U L L E Y S , BELTS OR T H E FAN. DO NOT W E A R
L O O S E FITTING CLOTHING.
(2) Rotate (crank) the engine with the starter mo

tor and observe the cable terminal for a steady arc. If
steady arcing does not occur, inspect the secondary
coil cable. Refer to Spark Plug Cables in this group.
Also inspect the distributor cap and rotor for cracks
or burn marks. Repair as necessary. If steady arcing
occurs, connect ignition coil cable to the distributor
cap.
(3) Remove a cable from one spark plug.
(4) Using insulated pliers and taking care to pre
vent damage to the cable, boot and terminal, hold the
cable terminal approximately 12 mm (1/2 in.) from Fig. 22 Coil Harness Connector—5.9L V-8 HDC-Gas
Engine
the engine cylinder head or block. Do this while ro
tating the engine with the starter motor. Observe the (2) Connect a set of small jumper wires (18 gauge
spark plug cable terminal for an arc. If steady arcing or smaller) between the ignition coil and the discon
occurs, it can be expected that the ignition secondary nected coil electrical connector (Fig. 23).
system is operating correctly. If steady arcing occurs
JUMPER
at the spark plug cables, but the engine will not
start, connect the DRB scan tool. Refer to the Power-
train Diagnostic Procedures service manual.
FAILURE TO START TEST—EXCEPT 8.0L V-10

ENGINE
To prevent unnecessary diagnostic time and wrong
test results, the previous Checking For Spark test
should be performed prior to this test.
WARNING: S E T PARKING B R A K E OR B L O C K T H E
DRIVE W H E E L S B E F O R E P R O C E E D I N G WITH THIS
TEST.
(1) Unplug the ignition coil harness connector at

the coil (Figs. 21 or 22). Fig. 23 Coil Terminals—3.9L V-6 or 5.2/5.9L V-8
Engines—Typical
(3) Determine that sufficient battery voltage (12.4
volts) is present for the starting and ignition sys
tems.
(4) Connect the positive lead of the voltmeter to
the ignition coil (Fig. 23). Connect the negative lead
of the voltmeter to a good ground on the engine
block. Crank the engine for 5 seconds while monitor
ing the voltage at the coil positive terminal (Fig. 23):
• If the voltage remains near zero during the entire
period of cranking, refer to On-Board Diagnostics in
Group 14, Fuel Systems. Check the powertrain con
trol module and auto shut down relay.
• If voltage is at near battery voltage and drops to
zero after 1-2 seconds of cranking, check the power-
Fig. 21 Coil Harness Connector—3.9L V-6 or
train control module circuit. Refer to On-Board Diag
5.2/5.9L LDC-Gas Engines
nostics in Group 14, Fuel Systems.
• I f voltage remains at near battery voltage during appropriate Powertrain Diagnostics Procedures ser
the entire 5 seconds, turn the key off. Remove the 60- vice manual for operation of the DRB Scan Tool.
way connector (Fig. 24) from the powertrain control
module (PCM). Check 60-way connector 'for any INTAKE MANIFOLD AIR TEMPERATURE SENSOR
spread terminals. TEST
ifold (Figs. 26 or 27).
S
oooooooooo oooooooooo
On 8.0L V-10 engines, the sensor is threaded into
ôoooooo |11 o o o o o o o20
5 i ? i oo; the left side of the intake manifold near the front of
^QPOOOOOOO
ôooooooooo i OOOOOOOOO
O ' the throttle body (Fig. 28).
CONNECTOR SUPPORT BRACKET INTAKE
TERMINAL SIDE MANIFOLD
SHOWN J908D-42 AIR
TEMPERATURE
SENSOR
Fig. 24 PCM 60-Way Connector
(5) Remove test lead from the coil positive termi
nal. Connect an 18 gauge jumper wire between the
battery positive terminal and the coil positive termi
nal.
(6) Make the special jumper shown i n Figure 25.
Using the jumper, momentarily ground terminal-19
of the 60-way connector. A spark should be generated
at the coil cable when the ground is removed.
CAPACITOR > CONNECT THIS-
J9414-12
CLIP TO COIL
NEGATIVE / Fig. 26 Sensor Location—3.9L V-6 Engine—Typical
ALLIGATOR
GROUND
r r ^ * * ^ ^ CLIP
THIS : 3 M F INTAKE MANIFOLD
^ . '. (MOMENTARILY
CLIP : : 1 AIR TEMPERATURE
— — " ' G R O U N D THIS
1
SENSOR
CLIP T O COIL
NEGATIVE
ALLIGATOR CLIP RBI003
Fig. 25 Special Jumper Ground-to-Coil Negative

Terminal
(7) I f spark is generated, replace the powertrain
control module (PCM).
(8) I f spark is not seen, use the special jumper to
ground the coil negative terminal directly.
(9) I f spark is produced, repair wiring harness for
an open condition. J9314-162
• (10) I f spark is not produced, replace the ignition

coil. Fig. 27 Sensor Location—5.2L/5.9L V-8 Engines-
Typical
IGNITION TIMING To perform a complete test of the intake manifold
Base (initial) ignition timing is NOT adjust air temperature sensor and its circuitry, refer to the
able on any engine. On a 3.9L V-6 or a 5.2/5.9L DRB scan tool. Also refer to the appropriate Power-
V-8 engine, do not attempt to adjust ignition train Diagnostics Procedures manual. To test the sen
timing by rotating the distributor. sor only, refer to the following:
All ignition timing functions are controlled by the (1) Disconnect the wire harness connector from the
powertrain control module (PCM). Refer to On-Board sensor.
Diagnostics in the Multi-Port Fuel (2) Test the resistance of the sensor with a input
Injection—General Diagnosis section of Group 14, impedance (digital) volt-ohmmeter. Do not remove
Fuel Systems for more information. Also refer to the the sensor from the engine for testing. For resistance
IGNITION SYSTEMS 80 - 11

TEST
To perform a complete test of MAP sensor and its
circuitry, refer to DRB scan tool and appropriate
Powertrain Diagnostics Procedures manual. To test
the MAP sensor only, refer to MAP Sensor i n Group
14, Fuel System.
POWERTRAIN CONTROL MODULE (POM)

29). The PCM was formerly referred to as the SBEC
or engine controller.
Fig. 28 Sensor Location—8.0 V-10 Engine—Typical

values, refer to the Sensor Resistance chart. Replace
the sensor i f i t is not within the range of resistance
specified i n the chart.
SENSOR RESISTANCE (OHMS)
C F MIN MAX
-40 -40 291,490 381,710 POWERTRAIN CONTROL

-20 -4 85,850 108,390 MODULE (PCM) J9414-11
-10 14 49,250 61,430
0 32 29,330 35,990 Fig. 29 PCM Location—Typical
10 50 17,990 21,810
20 68 11,370 13,610 The ignition system is controlled by the PCM.
25 77 9,120 10,880 For removal and installation of this component, re
30 86 7,370 8,750 fer to the Component Removal/Installation section of
40 104 4,900 5,750
50 122 3,330 3,880 this group.
60 140 2,310 2,670 For diagnostics, refer to the appropriate Powertrain
70 158 1,630 1,870 Diagnostic Procedures service manual for operation
80 176 1,170 1,340 of the DRB scan tool.
90 194 860 970
100 212 640 720
110 230 480 540 SPARK PLUGS
120 248 370 410 For spark plug removal, cleaning, gap adjustment
and installation, refer to the Component Removal/In
J928D-4 stallation section of this group.
(3) Test the resistance of the wire harness. This is On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug ca
done between the powertrain control module (PCM) ble boot heat shields are pressed into the cylinder
head to surround each cable boot and spark plug
wire harness connector terminal-2 and the sensor
(Fig. 30). These shields protect the spark plug boots
connector terminal. Also check continuity between
from damage (due to engine heat generated by the
terminal-4 to the sensor connector terminal. Repair
exhaust manifolds) and should not be removed. After
the wire harness as necessary i f the resistance is
the spark plug cable has been installed, the lip of the
greater than 1 ohm.
cable boot should have a small air gap to the top of
the heat shield (Fig. 30).
Faulty carbon and/or gas fouled plugs generally
this group.
cause hard starting, but they will clean up at higher
engine speeds. Faulty plugs can be identified i n a
NORMAL DRY BLACK COLD (CARBON) FOULING
J908D-15
Fig. 30 Heat Shields—3.9L ¥-6 or 5.2/5.9L ¥-8 Fig. 31 Normal Operation and Cold (Carbon) Fouling
Engines
COLD FOULING/CARBON FOULING
number of ways: poor fuel economy, power loss, de
Cold fouling is sometimes referred to as carbon
crease i n engine speed, hard starting and, i n general,
fouling. The deposits that cause cold fouling are ba
poor engine performance. sically carbon (Fig. 31). A dry, black deposit on one or
Remove the spark plugs and examine them for two plugs i n a set may be caused by sticking valves
burned electrodes and fouled, cracked or broken por or defective spark plug cables. Cold (carbon) fouling
celain insulators. Keep plugs arranged i n the order of the entire set of spark plugs may be caused by a
in which they were removed from the engine. A n iso clogged air filter or repeated short operating times
lated plug displaying an abnormal condition indicates (short trips).
that a problem exists i n the corresponding cylinder.
Replace spark plugs at the intervals recommended i n WET FOULING OR GAS FOULING
the maintenance chart i n Group 0, Lubrication and A spark plug coated with excessive wet fuel or oil is
Maintenance. wet fouled. I n older engines, worn piston rings, leak
Spark plugs that have low mileage may be cleaned ing valve guide seals or excessive cylinder wear can
and reused i f not otherwise defective. Refer to the cause wet fouling. I n new or recently overhauled en
following Spark Plug Condition section of this group. gines, wet fouling may occur before break-in (normal
oil control) is achieved. This condition can usually be
CONDITION resolved by cleaning and reinstalling the fouled
plugs.
10RMAL OPEiATlie
The few deposits present on the spark plug will OIL OR ASH ENCRUSTED
probably be light tan or slightly gray i n color. This is I f one or more spark plugs are oil or oil ash en
evident with most grades of commercial gasoline crusted (Fig. 32), evaluate engine condition for the
(Fig. 31). There will not be evidence of electrode cause of oil entry into that particular combustion
burning. Gap growth will not average more than ap chamber.
proximately 0.025 mm (.001 in) per 1600 k m (1000
miles) of operation. Spark plugs that have normal ELECTRODE GAP BRIDGING
wear can usually be cleaned, have the electrodes Electrode gap bridging may be traced to loose de
filed, have the gap set and then be installed. posits i n the combustion chamber. These deposits ac
Some fuel refiners i n several areas of the United cumulate on the spark plugs during continuous stop-
States have introduced a manganese additive (MMT) and-go driving. When the engine is suddenly
for unleaded fuel. During combustion, fuel with MMT subjected to a high torque load, deposits partially liq
uefy and bridge the gap between electrodes (Fig. 33).
causes the entire tip of the spark plug to be coated
This short circuits the electrodes. Spark plugs with
with a rust colored deposit. This rust color can be
electrode gap bridging can be cleaned using standard
misdiagnosed as being caused by coolant i n the com
procedures.
bustion chamber. Spark plug performance is not af
fected by MMT deposits. SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel
low (Fig. 34). They may appear to be harmful, but
GROUND
ELECTRODE
COVERED
J908D-12
Fig. 34 Scavenger Deposits

GROUND
J908D-13
Fig. 35 Chipped Electrode Insulator

PREIGNITION DAMAGE
Preignition damage is usually caused by excessive
combustion chamber temperature. The center elec
J908D-11
trode dissolves first and the ground electrode dis
solves somewhat latter (Fig. 36). Insulators appear
Fig. 33 Electrode Gap Bridging
relatively deposit free. Determine i f the spark plug
this is a normal condition caused by chemical addi has the correct heat range rating for the engine. De
tives i n certain fuels. These additives are designed to termine i f ignition timing is over advanced, or i f
change the chemical nature of deposits and decrease other operating conditions are causing engine over
spark plug misfire tendencies. Notice that accumula heating. (The heat range rating refers to the operat
tion on the ground electrode and shell area may be ing temperature of a particular type spark plug.
heavy, but the deposits are easily removed. Spark Spark plugs are designed to operate within specific
plugs with scavenger deposits can be considered nor temperature ranges. This depends upon the thick
mal i n condition and can be cleaned using standard ness and length of the center electrodes porcelain in
procedures. sulator.)
CHIPPED ELECTRODE INSULATOR SPARK PLUG OVERHEATING

A chipped electrode insulator usually results from Overheating is indicated by a white or gray center
bending the center electrode while adjusting the electrode insulator that also appears blistered (Fig.
spark plug electrode gap. Under certain conditions, 37). The increase i n electrode gap will be consider
severe detonation can also separate the insulator ably i n excess of 0.001 inch per 1000 miles of opera
from the center electrode (Fig. 35). Spark plugs with tion. This suggests that a plug with a cooler heat
this condition must be replaced. range rating should be used. Over advanced ignition
SB - 22 IGNITION SYSTEMS •
GROUND
ELECTRODE
STARTING
TO DISSOLVE
CENTER
ELECTRODE
DISSOLVED
J908D-14 J9314-94
Fig. 36 Preignition Damage Fig. 38 Heat Shields—3.9L ¥-6 or 5.2/5.9L ¥-8

timing, detonation and cooling system malfunctions Engines
can also cause spark plug overheating. Check the high-tension cable connections for good
contact at the ignition coil, distributor cap towers
BLISTERED
WHITE OR
and spark plugs. Terminals should be fully seated.
GRAY The terminals and spark plug covers should be i n
COLORED good condition. Terminals should fit tightly to the ig
INSULATOR
nition coil, distributor cap and spark plugs. The
spark plug cover (boot) of the cable should fit tight
around the spark plug insulator. Loose cable connec
tions can cause corrosion and increase resistance, re
sulting i n shorter cable service life.
Clean the high tension cables with a cloth moist
ened with a nonflammable solvent and wipe dry.
Check for brittle or cracked insulation.
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
J908D-16 manufacturer. Note that 8.0L V-10 engines equipped
with distributor-less ignition (DIS) will display oppo
Fig. 37 Spark Plug Overheating site polarity spikes for paired cylinders.
SPARK PLUG SECONDARY CA1LES I f an oscilloscope is not available, spark plug cables
On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug may be tested as follows:
heat shields are pressed into the cylinder head to
CAUTION: Do not leave any one spark plug cable
surround each spark plug cable boot and spark plug
disconnected for longer than necessary during test
ing. This may c a u s e possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
cable boot should have a small air gap to the top of With the engine running, remove spark plug cable
the heat shield (Fig. 38). from spark plug (one at a time) and hold next to a
good engine ground. I f the cable and spark plug are
TESTING in good condition, the engine rpm should drop and
Spark plug cables are sometimes referred to as sec the engine will run poorly. I f engine rpm does not
ondary ignition cables or secondary wires. The cables drop, the cable and/or spark plug may not be operat
transfer electrical current from the distributor to in ing properly and should be replaced. Also check en
dividual spark plugs at each cylinder. The spark plug gine cylinder compression.
cables are of nonmetallic construction and have a With the engine not running, connect one end of a
built i n resistance. The cables provide suppression of test probe to a good ground. Start the engine and run
radio frequency emissions from the ignition system. the other end of the test probe along the entire
length of all spark plug cables. I f cables are cracked
or punctured, there will be a noticeable spark jump a Diagnostic Trouble Code (DTC) number 11 can be
from the damaged area to the test probe. The cable observed at the Check Engine Lamp.
running from the ignition coil to the distributor cap I f the problem is sensed i n a monitored circuit of
can be checked i n the same manner. Cracked, dam ten enough to indicate an actual problem, a DTC is
aged or faulty cables should be replaced with resis stored. The DTC will be stored i n the PCM memory
tance type cable. This can be identified by the words for eventual display to the service technician. I f the
ELECTRONIC SUPPRESSION printed on the cable problem is repaired or ceases to exist, the PCM can
jacket. cels the DTC after 51 engine starts.
3.9L/5.2L/5.9L Engines: Use an ohmmeter to test Certain criteria must be met for a DTC to be en
for open circuits, excessive resistance or loose termi- tered into PCM memory. The criteria may be a spe
. nals. Remove the distributor cap from the distributor. cific range of engine rpm, engine temperature and/or
Do n o t remove cables from cap. Remove cable input voltage to the PCM.
from spark plug. Connect ohmmeter to spark plug A DTC indicates that the PCM has recognized an
terminal end of cable and to corresponding electrode abnormal signal i n a circuit or the system. A DTC
in distributor cap. Resistance should be 250 to 1000 may indicate the result of a failure, but never iden
Ohms per inch of cable. I f not, remove cable from dis tify the failed component directly.
tributor cap tower and connect ohmmeter to the ter It is possible that a DTC for a monitored circuit
minal ends of cable. I f resistance is not within may not be entered into memory even though a mal
specifications as found i n the Spark Plug Cable Re function has occurred. Refer to On-Board Diagnostics
sistance chart, replace the cable. Test all spark plug (OBD) i n Group 14, Fuel Systems for additional in
cables i n this manner. formation.
S P A R K P L U G CABLE RESISTANCE
ACCESSING DIAGNOSTIC TROUBLE CODES
MINIMUM MAXIMUM A stored Diagnostic Trouble Code (DTC) can be dis
played by cycling the ignition key On-Off-On-Off-On
2 5 0 O h m s Per Inch 1 0 0 0 Ohms Per Inch
within three seconds and observing the Malfunction
3 0 0 0 O h m s Per Foot 1 2 , 0 0 0 O h m s Per Foot Indicator Lamp. This lamp was formerly referred to
as the Check Engine Lamp. The lamp is located on
J908D-43
the instrument panel.
To test ignition coil-to-distributor cap cable, do not They can also be displayed through the use of the
remove the cable from the cap. Connect ohmmeter to Diagnostic Readout Box (DRB) scan tool. The DRB
rotor button (center contact) of distributor cap and connects to the data link connector i n the engine
terminal at ignition coil end of cable. I f resistance is compartment (Fig. 39). For operation of the DRB, re
not within specifications as found i n the Spark Plug fer to the appropriate Powertrain Diagnostic Proce
Cable Resistance chart, remove the cable from the dures service manual.
distributor cap. Connect the ohmmeter to the termi
nal ends of the cable. I f resistance is not within spec
ifications as found i n the Spark Plug Cable
Resistance chart, replace the cable. Inspect the igni
tion coil tower for cracks, burns or corrosion.
For removal and installation of spark plug cables,
refer to Spark Plug Secondary Cables i n the Compo
nent Removal/Installation section.
OXYGEN SENSOR (02S) TESTS

For an operational description, diagnosis and re
0N-B0ARD DIAGNOSTICS (OBD) POWERTRAIN CONTROL

F O R IGNITION SYSTEM COMPONENTS

Fig. 39 PCM and Data Link Connector—Typical
The powertrain control module (PCM) has been
programmed to monitor certain ignition system cir EIAMPLES:
cuits: • I f the lamp flashes 1 time, pauses and flashes 1
I f a reference signal is not being detected during more time, a flashing Diagnostic Trouble Code (DTC)
engine cranking from the crankshaft position sensor, number 11 is indicated.
• I f the lamp flashes 3 times, pauses and flashes 5 ERASING T R O U B L E CODES
more times, a flashing Diagnostic Trouble Code After the problem has been repaired, the DRB scan
(DTC) number 35 is indicated. tool must be used to erase a DTC. Refer to the ap
After any stored DTC information has been ob propriate Powertrain Diagnostic Procedures service
served, the display will end with a flashing DTC manual for operation of the DRB scan tool.
number 5 5 . This will indicate the end of all stored in
formation.
COMPONENT REMOVAL/INSTALLATION
INDEX
page page
Automatic Shut Down (ASD) Relay 24 Ignition Coil Packs—8.0L V-10 Engine 31
Camshaft Position Sensor—3.9L V-6 or 5.2/5.9L V-8 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8 Engines . . . 30
Engines 24 Ignition Control Module—8.0L V-10 Engine . . . . . . 32
Camshaft Position Sensor—8.0L V-10 Engine . . . . 25 Intake Manifold Air Temperature Sensor . . . . . . . . . 32
Crankshaft Position Sensor—3.9L V-6 or 5.2/5.9L Manifold Absolute Pressure (MAP) Sensor 33
V-8 Engines 26 Oxygen Sensor (02S) 33
Crankshaft Position Sensor—8.0L V-10 Engine . . . 27 Powertrain Control Module (PCM) 33
Distributor Service . 29 Spark Plug Secondary Cables 34
Engine Coolant Temperature Sensor 28 Spark Plugs 33
General Information 24 Throttle Position Sensor (TPS) 35
GENERAL INFORMATION
This section of the group, Component Removal/In
stallation, will discuss the removal and installation
of ignition system components.
For basic ignition system diagnostics and service
adjustments, refer to the Diagnostics/Service Proce
dures section of this group.
For system operation and component identification,
refer to the Component Identification/System Opera
AUTOMATIC SHUT DOWN (ASD) RELAY

The automatic shut down (ASD) relay is located i n
the power distribution center (PDC). The PDC is lo
cated next to the battery i n the engine compartment
(Fig. 1). For the location of the relay within the PDC,
Fig. 1 Power Distribution Center (PDC)
refer to PDC cover.
CAMSHAFT POSITION SENSOR—3.9L V-6 OR
REMOVAL 5.2/5.9L V-8 ENGINES
The camshaft position sensor is located in the dis
(2) Remove the cover at PDC.
tributor (Fig. 2).
(3) Remove the relay from the PDC by pulling
straight up. REMOVAL
Distributor removal is not necessary to remove
INSTALLATION
camshaft position sensor.
(1) Check the relay terminals i n the PDC connec (1) Disconnect negative battery cable at battery.
tor for corrosion or damage before installing relay. (2) Remove the air cleaner assembly and connect
Repair as necessary. ing air tubes.
(2) Push the relay into the connector on the PDC.
(3) Connect negative battery cable at battery.
• — ^ — — — — — IGNITION SYSTEMS 80 - 25
Fig. 2 Camshaft Position Sensor—SSL V-6 or Fig. 3 Camshaft Position Sensor—8.0L V-10 Engine
5.2/5.9L V-8 Engines—Typical some of the rib material may still be observed after
(3) Remove coil high-tension cable and all spark removal.
plug cables at distributor cap. Note and mark posi CAMSHAFT P O S I T I O N
tion of cables before removal. SENSOR
(4) Remove distributor cap from distributor (two
screws).
(5) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(6) Remove distributor rotor from distributor shaft.
(7) Lift the camshaft position sensor assembly
from the distributor housing (Fig. 2).
INSTALLATION
(1) Install camshaft position sensor to distributor.
Align sensor into notch on distributor housing.
(2) Connect wiring harness connectors.
(3) Install rotor.
POSITIONING) J948D-11
(4) Install distributor cap. Tighten mounting
screws. Fig. 4 Sensor Depth Positioning Rih—8.0L V-10
(5) Install spark plug cables i n correct firing order
Engine
to distributor cap. Refer to the Specifications section
at the end of this group for spark plug cable order. One of two different procedures must be followed
Be sure all spark plug cables are firmly connected for replacement of this sensor. Refer to the following:
into distributor cap towers. Sensor Replacement—Old Sensor or Sensor
(6) Install air cleaner assembly and connecting air Replacement—New Sensor.
tubes.
(7) Connect negative battery cable to battery. SENSOR REPLACEMENT—OLD SENSOR
I f the original camshaft position sensor is to be re
CAMSHAFT POSITION SENSOR—8 J L ¥-10 moved and installed, such as 'when servicing the tim
ENGINE ing chain, timing gears or timing chain cover, use
The camshaft position sensor is located i n the tim this procedure.
ing chain case/cover on the left-front side of the en
gine (Fig. 3). REMOWAL
A thin plastic rib is molded into the face of the sen (1) Disconnect the sensor harness connector from
sor (Fig. 4) to position the depth of sensor to the up the engine harness connector.
per cam gear (sprocket). This rib can be found on (2) Remove the sensor mounting bolt (Fig. 3).
both the new replacement sensors and sensors that (3) Carefully pry the sensor from the timing chain
were originally installed to the engine. The first time case/cover i n a rocking action with two small screw
the engine has been operated, part of this rib may be drivers.
sheared (ground) off. Depending on parts tolerances, (4) Remove the sensor from vehicle.
(5) Check condition of sensor O-ring (Fig. 5). (11) Install sensor mounting bolt and tighten to 6
(12) Connect engine wiring harness to sensor har
ness.
SENSOR REPLACEMENT—NEW SENSOR

I f a new replacement camshaft position sensor is to
be installed, use this procedure.
HEMOWAL
(1) Disconnect the sensor wiring harness connector
from the engine harness connector.
(2) Remove the sensor mounting bolt (Fig. 3).
(3) Carefully pry the sensor from the timing chain
case/cover i n a rocking action with two small screw
J948D-4 drivers.
(4) Remove the sensor from vehicle.
Fig. 5 Camshaft Sensor O-Ring—8.0L ¥-10 Engine
INSTALLATION
INSTALLATION
(1) Apply a small amount of engine oil to the sen
When installing a used camshaft position sensor,
the sensor depth must be adjusted to prevent contact sor O-ring (Fig. 5).
with the camshaft gear (sprocket). (2) Install the sensor into the timing case/cover
(1) Observe the face of the sensor. I f any of the with a slight rocking action. Do not twist the sensor
original rib material remains (Fig. 4), i t must be cut into position as damage to the O-ring may result.
down flush to the face of the sensor with a razor Push the sensor all the way into the cover until the
knife. Remove only enough of the rib material until rib material on the sensor (Fig. 4) contacts the cam
the face of the sensor is flat. Do not remove more shaft gear.
material than necessary as damage to sensor may re (3) Install the mounting bolt and tighten to 6 N*m
sult. Due to a high magnetic field and possible elec (50 in. lbs.) torque.
trical damage to the sensor, never use an electric (4) Connect sensor wiring harness to engine har
grinder to remove material from sensor. ness.
(2) From the parts department, obtain a peel-and-
stick paper spacer (Fig. 4). These special paper spac CRANKSHAFT POSITION SENSOR—3JL V-B OR
ers are of a certain thickness and are to be used as a 1.2/5 J L ¥-8 ENGINES
tool to set sensor depth.
(3) Clean the face of sensor and apply paper spacer REMOVAL
(Fig. 4). The sensor is bolted to the top of the cylinder block
(4) Apply a small amount of engine oil to the sen near the rear of right cylinder head (Fig. 6).
sor O-ring (Fig. 5). (1) Remove the air filter assembly and its and
(5) Install the sensor into the timing case/cover plastic air intake tube. Refer to A i r Filter/Filter
with a slight rocking action until the paper spacer Housing—3.9L/5.2L/5.9L Gas Engines i n Group 25,
contacts the camshaft gear. Do not install the sensor Emission Control Systems for additional information.
mounting bolt. Do not twist the sensor into position
(2) Remove the spark plug cable loom and spark
as damage to the O-ring or tearing of the paper
plug cables from valve cover mounting stud at rear of
spacer may result.
right valve cover (Fig. 6). Position spark plug cables
(6) Scratch a scribe line into the timing chain case/
to top of valve cover.
cover to indicate depth of sensor (Fig. 5).
(7) Remove the sensor from timing chain case/ (3) Disconnect 2 hoses at Exhaust Gas Recircula
cover. tion (EGR) valve. Note position of hoses at EGR
(8) Remove the paper spacer from the sensor. This valve before removal.
step must be followed to prevent the paper spacer (4) Disconnect electrical connector and hoses at
from getting into the engine lubrication system. electric EGR transducer (EET). Note position of
(9) Again, apply a small amount of engine oil to hoses at EET before removal.
sensor O-ring. (5) Remove 2 EGR valve mounting bolts and re
(10) Again, install the sensor into the timing case/ move EGR valve. Discard old EGR gasket.
cover with a slight rocking action until the sensor is (6) Disconnect electrical connector at engine oil
aligned to scribe line. pressure sending unit.
(10) Disconnect crankshaft position sensor pigtail

harness from main wiring harness.
(11) Remove 2 sensor (recessed hex head) mount
ing bolts (Fig. 6) and remove sensor.
INSTALLATION
(1) Position crankshaft position sensor to engine
and install mounting bolts. Tighten bolts to 8 N-m
(70 i n . lbs.) torque.
(2) Connect main harness electrical connector to
sensor.
(3) Clean the EGR tube and exhaust manifold (at
EGR tube mounting point) of any old gasket mate
rial.
(4) Install a new gasket to exhaust manifold end of
EGR tube and install EGR tube to both manifolds.
Tighten mounting nut at intake manifold. Tighten 2
mounting bolts at exhaust manifold to 23 N-m (204
in. lbs.) torque.
(5) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the
thread sealant to get into the sending unit opening,
5.2/5.9L V-8 Engines—Typical or the opening at the engine. Install sending unit to
engine and tighten to 14 N-m (130 in. lbs.) torque. In
(7) To prevent damage to oil pressure sending unit, stall electrical connector to sending unit.
a special tool, such as number C-4597 must be used (6) Clean the intake manifold and EGR valve of
(Fig. 7). Remove sending unit from engine. any old gasket material.
(7) Install a new EGR valve gasket at intake man
ifold.
(8) Install EGR valve to intake manifold. Tighten 2
bolts to 23 N-m (200 in. lbs.) torque.
(9) Position EET and install its electrical connec
tor. Connect hoses between EGR valve and EET.
Connect hose between main vacuum harness and
EET.
(10) Install spark plug cable loom and spark plug
cables to valve cover mounting stud.
(11) Install the air filter housing and plastic air in
take tube.
CRANKSHAFT POSITION SENSOR—8 J L ¥-10

ENGINE
8).
REMOVAL
Fig. 7 Oil Pressure Sending Unit—Removal/
Installation
(2) Disconnect the sensor harness connectors.
(8) Loosen EGR tube mounting nut at intake man (4) Carefully pry the sensor from the cylinder block
ifold. in a rocking action with two small screwdrivers.
(9) Remove 2 EGR tube mounting bolts at exhaust (5) Remove the sensor from vehicle.
manifold (Fig. 6) and remove EGR tube. Discard old (6) Check condition of sensor O-ring (Fig. 10).
gasket at exhaust manifold.
(2) Install the sensor into the cylinder block with a

slight rocking action. Do not twist the sensor into po
sition as damage to the O-ring may result.
CAUTION: Before tightening the sensor mounting

bolt, be sure the sensor is completely flush to the
cylinder block (Fig. 9). If sensor is not flush, dam
age to the sensor mounting tang may result.
(3) Install the mounting bolt and tighten to 8 N*m

(70 in. lbs.) torque.
(4) Connect sensor wiring harness and lower the
vehicle.
ENGINE COOLANT TEMPERATURE SENSOR
Fig 8 Crankshaft Position Sensor—8.0L ¥-10 WARNING: HOT, P R E S S U R I Z E D C O O L A N T CAN

Engine—Typical C A U S E INJURY B Y S C A L D I N G . C O O L I N G S Y S T E M
MUST B E PARTIALLY DRAINED B E F O R E REMOV
ING T H E C O O L A N T T E M P E R A T U R E S E N S O R . R E
F E R TO G R O U P 7, COOLING S Y S T E M .
R E M O V A L — 3 . 9 L V-6 O R 5 . W 5 . 9 L V-8 ENGINES

The engine coolant sensor is located i n the intake
manifold next to the thermostat housing (Fig. 11).
SENSOR POSITIONED
FLUSH TO CYLINDER BLOCK J948D-2
Fig. 9 Sensor Removal/Installation—8.0L ¥-10

Engine
CRANKSHAFT
POSITION
Fig. 11 Coolant Temperature Sensor—3.9L ¥-6 or

5.2/5.9L ¥-8 Engines—Typical
(1) Partially drain cooling system. Refer to Group
7, Cooling System.
(2) Disconnect electrical connector from sensor
(Fig. 11).
Engines w i t h a i r conditioning:When removing
the connector from sensor, do not pull directly on wir
J948D-3 ing harness. Fabricate an L-shaped hook tool from a
coat hanger (approximately eight inches long). Place
Fig. 10 Sensor O-Ring—8.0L ¥-10 Engine the hook part of tool under the connector for removal.
INSTALLATION The connector is snapped onto the sensor. I t is not
(1) Apply a small amount of engine oil to the sen equipped with a lock type tab.
sor O-ring (Fig. 10). (3) Remove sensor from intake manifold.
INSTALLATION (1) Disconnect negative battery cable at battery.

(1) Install sensor to intake manifold. (2) Remove air cleaner assembly and connecting
(2) Tighten sensor to 7 N-m (62 in. lbs.) torque. tubes.
(3) Connect electrical connector to sensor. (3) Remove the spark plug cables and secondary
The sensor connector is symmetrical (not indexed). ignition coil cable at distributor cap. Mark position of
It can be installed to the sensor i n either direction. cables before removal. Position spark plug cables to
(4) Replace any lost engine coolant. Refer to Group the side of engine.
7, Cooling System. (4) Remove distributor cap from distributor (two
screws).
REMOWAL—8.0L V-10 ENGINE (5) Mark the position of distributor housing in
The engine coolant sensor is located i n the thermo relationship to engine or dash panel. This is done
stat housing (Fig. 12). to aid i n installation.
Before distributor is removed, the number one cyl
inder must be brought to the top dead center (TDC)
firing position.
(6) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(7) Slowly rotate engine clockwise, as viewed from
front, until indicating mark on crankshaft vibration
damper is aligned to 0 degree (TDC) mark on timing
chain cover (Fig. 13).

Engine—Typical
7, Cooling System.
(2) Disconnect electrical connector from sensor
(Fig. 12).
(3) Remove sensor from thermostat housing.
INSTALLATION
(1) Install sensor to thermostat housing. Fig. 13 Damper-To-Cover Alignment Marks—Typical
(2) Tighten sensor to 7 N-m (65 in. lbs.) torque. (8) The distributor rotor should now be aligned to
(3) Connect electrical connector to sensor. the CYL. NO. 1 alignment mark (stamped) into the
(4) Replace any lost engine coolant. Refer to Group camshaft position sensor (Fig. 14). I f not, rotate the
7, Cooling System.
crankshaft through another complete 360 degree
turn. Note the position of the number one cylinder
DISTRIBUTOR SERVICE
spark plug cable (on the cap) i n relation to rotor. Ro
3 J L V-6 OR 5 . 2 / 5 J L V-8 ENGINES tor should now be aligned to this position.
(9) Disconnect camshaft position sensor wiring
REMOWAL harness from main engine wiring harness.
(10) Remove distributor rotor from distributor
CAUTION: B a s e ignition timing is not adjustable on shaft.
any engine. Distributors do not have built in centrif (11) Remove distributor holddown clamp bolt and
ugal or vacuum assisted advance. B a s e ignition clamp (Fig. 15). Remove distributor from vehicle.
timing and timing advance are controlled by the
powertrain control module (PCM). B e c a u s e a con CAUTION: Do not crank engine with distributor re
ventional timing light can not be used to adjust dis moved. Distributor/crankshaft relationship will be
tributor position after installation, note position of lost
distributor before removal.
(6) Rotate the distributor housing until rotor is
aligned to CYL. NO. 1 alignment mark on the cam
shaft position sensor (Fig. 14).
(7) Tighten clamp holddown bolt (Fig. 15) to 22.5
(8) Connect camshaft position sensor wiring har
ness to main engine harness.
(9) Install distributor cap. Tighten mounting
screws.
(10) Install all spark plug cables i n correct firing
order to distributor cap. Refer to the Specifications
section at the end of this group for spark plug cable
order. Be sure all spark plug cables are firmly con
nected into distributor cap towers.
DISTRIBUTOR J9314-81
(11) Install air cleaner assembly and connecting
Fig. 14 Rotor Alignment Mark
tubes.
IGNITION COIL—3.9L V-6 OR 5.2/5.9L V-8

ENGINES
The ignition coil is an epoxy filled type. I f the coil
is replaced, i t must be replaced with the same type.
REMOVAL
3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: The coil
is mounted to a bracket that is bolted to the front of
the right engine cylinder head (Fig. 16). This bracket
is mounted on top of the automatic belt tensioner
bracket using common bolts.
5.9L V-8 HDC-Gas Engine: The coil is mounted to a
bracket that is bolted to the air injection pump (AIR
pump) mounting bracket (Fig. 17).
Fig. 15 Distributor Holddown Clamp
INSTALLATION
I f engine has been cranked while distributor is re
moved, establish the relationship between distributor
shaft and number one piston position as follows:
Rotate crankshaft i n a clockwise .direction, as
viewed from front, until number one cylinder piston
is at top of compression stroke (compression should
be felt on finger with number one spark plug re
moved). Then continue to slowly rotate engine clock
wise until indicating mark (Fig. 9) is aligned to 0
degree (TDC) mark on timing chain cover.
(1) Clean top of cylinder block for a good seal be
tween distributor base and block.
(2) Lightly oil the rubber O-ring seal on the dis
tributor housing.
Fig. 16 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8
(3) Install rotor to distributor shaft.
LDC-Gas Engines
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot (1) Disconnect the primary wiring from the igni
in distributor oil pump drive gear. Position rotor to tion coil (Figs. 16 or 17).
the number one spark plug cable position. (2) Disconnect the secondary spark plug cable from
(5) Install distributor holddown clamp and clamp the ignition coil (Figs. 16 or 17).
bolt. Do not tighten bolt at this time.
ENGINE
COIL "\ CYLINDER^
CONNECTOR ^ S ^ M NUMBER BOLTS (8) J948D-6
Fig. 17 ignition Coil—5.9L V-8 HDC-Gas Engine Fig. 18 Ignition Coil Packs—8.0L V-10 Engine
WARNING: (3.9L V - 6 OR 5.2/5.9L V-8 LDC-GAS EN (2) Install coil pack mounting bolts.
GINES) DO NOT REMOVE THE COIL MOUNTING (3) Install coil pack-to-engine mounting bracket (if
BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS. necessary).
THE COIL MOUNTING BRACKET IS UNDER ACCES
(4) Connect primary wiring connectors to coil
SORY DRIVE BELT TENSION. IF THIS BRACKET IS
packs (four wire connector to front coil pack and
TO BE REMOVED FOR ANY REASON, A L L BELT
three wire connector to rear coil pack).
TENSION MUST FIRST BE RELIEVED. REFER TO
(5) Connect secondary spark plug cables to coil
THE BELT SECTION OF GROUP 7, COOLING SYS
packs. Refer to figure 19 for correct cable order.
TEM.
REAR COIL PACK FRONT COIL PACK
(3) Remove ignition coil from coil mounting bracket
(two bolts).
INSTALLATION
(1) Install the ignition coil to coil bracket. I f nuts
and bolts are used to secure coil to coil bracket,
tighten to 11 N-m (100 in. lbs.) torque. I f the coil
mounting bracket has been tapped for coil mounting
bolts, tighten bolts to 5 N-m (50 in. lbs.) torque.
(2) Connect all wiring to ignition coil.
IGNITION COIL PACKS—8 J L ¥-10 ENGINE

REMOVAL
ing bracket located above the right engine valve
cover (Fig. 18). The front and rear coil packs can be
serviced separately.
(1) Remove the secondary spark plug cables from
the coil packs. Note position of cables before removal.
(2) Disconnect the primary wiring harness connec
tors at coil packs.
(3) Remove the four (4) coil pack-to-coil mounting RIGHT LEFT
bracket bolts for the coil pack being serviced (Fig. IANK BANK
18). F I R I N G ORDER
(4) Remove coil(s) from mounting bracket. 1-10-9-4-3-6-5-8-7-2 J 948D-12
INSTALLATION Fig. 19 Spark Plug Cable Order—8.0L V-10 Engine

(1) Position coil packs to mounting bracket (prima
ry wiring connectors face downward).
IGNITION CONTROL MODULE—8.0L V-10 ENGINE
The ignition control module (ICM) is located i n the
engine compartment. I t is mounted to the right inner
fender behind the coolant reserve/overflow tank.
REMOVAL
(1) Disconnect the negative battery cable at bat
tery.
(2) Remove the three bolts retaining the coolant re
serve/overflow tank to the inner fender (Fig. 20). Po
sition the tank to the side. Do not drain coolant from
tank.
(3) Disconnect the electrical connector at the ICM.
(4) Remove the ICM from inner fender (two bolts)
(Fig. 20).
COOLANT Fig. 21 Sensor Location—3.9L V-6 Engine—Typical
RESERVE/OVERFLOW
BOLTS (2) J948D-21
Fig. 20 Ignition Control Module Mounting—8.0L V-10

Engine
INSTALLATION
(1) Position the I C M to the inner fender. Install
two mounting bolts.
(2) Connect the electrical connector to ICM.
(3) Position the coolant reserve/overflow tank to
the inner fender. Install and tighten three mounting
bolts.
(4) Connect the negative battery cable.

ALL GAS POWERED ENGINES
REMOVAL
3.9L V-6 o r 5.2/5.9L V-8 Engines: The intake
manifold air temperature sensor is threaded into the
right-front side of intake manifold (Figs. 21 or 22).
8.0L V-10 Engine: The sensor is threaded into the Fig. 23 Sensor Location—8.0L V-10 Engine—Typical
left side of the intake manifold near the front of the INSTALLATION
throttle body (Fig. 23).
(1) Install sensor to intake manifold.
(1) Disconnect electrical connector at sensor (Figs.
(2) Tighten the sensor to 13 N-m (10 ft. lbs.)
21, 22 or 23).
torque.
(2) Remove sensor from intake manifold.
(3) Install electrical connector.

PCM
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR MOUNTING
For removal and installation, refer to MAP Sensor

in Group 14, Fuel System.
OXYGEN SENSOR (02S)

For an operational description, diagnosis and re

REMOVAL
24). I t is mounted the dash panel cowl with three
bolts (Fig. 25). The PCM was formerly referred to as
the SBEC or engine controller. PCM CONNECTOR
CONNECTOR M O U N T I N G
BOLT J9414-9
Fig. 25 PCM Mounting

age (due to engine heat generated by the exhaust
manifolds) and should not be removed. After the
spark plug cable has been installed, the lip of the ca
ble boot should have a small air gap to the top of the
heat shield (Fig. 26).
POWERTRAIN CONTROL

(2) Remove 60-way electrical connector from PCM
(one bolt) (Fig. 25).
(3) Remove the three PCM mounting bolts (Fig.
25).
(4) Remove PCM from vehicle.
INSTALLATION
(1) Check pins i n PCM 60-way connector for dam Fig. 26 Heat Shields—3.9L V-6 or 5.2/5.9L V-8
age. Repair as necessary. Engines
(2) Position PCM and install mounting bolts.
Tighten bolts to 1 N-m (9 in. lbs.) torque. I f removal of the heat shield(s) is necessary, remove
(3) Connect 60-way electrical connector to PCM. the spark plug cable and compress the sides of shield
Tighten bolt to 4 N-m (35 in. lbs.) torque. for removal. Each shield is slotted to allow for com
(4) Connect negative battery cable to battery. pression and removal. To install the shields, align
shield to machined opening i n cylinder head and tap
SPARK PLUGS into place with a block of wood.
On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug ca
ble heat shields are pressed into the cylinder head to
surround each cable boot and spark plug (Fig. 26).
These shields protect the spark plug boots from dam-
PLUG REMOVAL SPARK PLUG GAP
3.9L V-6 Engines .89 mm (.035 in)
ALL ENGINES 5.2L/5.9L V-8 Engines= .89 mm (.035 in)
(1) Always remove spark plug or ignition coil ca 8.0L V-10 Engines 1.14 mm (.045 in)
bles by grasping at the cable boot. Turn the cable Also refer to the specifications section at the back
boot 1/2 turn and pull straight back i n a steady mo of this group for additional spark plug information.
tion. Never pull directly on the cable. Internal dam
age to cable will result. PLUG INSTALLATION
(2) Prior to removing the spark plug, spray com Always tighten spark plugs to the specified torque.
pressed air around the spark plug hole and the area Over tightening can cause distortion resulting i n a
around the spark plug. This will help prevent foreign change i n the spark plug gap.
material from entering the combustion chamber. When replacing the spark plug and ignition coil ca
(3) Remove the spark plug using a quality socket bles, route the cables correctly and secure them i n
with a rubber or foam insert. the appropriate retainers. Failure to route the cables
(4) Inspect the spark plug condition. Refer to properly can cause the radio to reproduce ignition
Spark Plugs i n the Diagnostics/Service Procedures noise. I t could cause cross ignition of the spark plugs,
section of this group. or short circuit the cables to ground.
(1) Start the spark plug into the cylinder head by
PLUG CLEANING
hand to avoid cross threading.
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After clean (2) Tighten spark plugs to 35-41 N-m (26-30 ft.
ing, file the center electrode flat with a small point lbs.) torque.
file or jewelers file before adjusting gap. (3) Install spark plug cables over spark plugs.
CAUTION: Never u s e a motorized wire wheel brush SPARK PLUG SECONDARY CABLES
to clean the spark plugs. Metallic deposits will re
main on the spark plug insulator and will c a u s e CAUTION: When disconnecting a high voltage cable
plug misfire. from a spark plug, distributor c a p or ignition coil,
twist the rubber boot slightly (1/2 turn) to break it
loose. Grasp the boot (not the cable) and pull it off
PLUG GAP ADJUSTMENT with a steady, even force.
Check the spark plug gap with a gap gauge tool. I f
the gap is not correct, adjust i t by bending the Install cables into their proper order (Figs. 28, 29
ground electrode (Fig. 27). Never attempt t o adjust or 30).
the gap by b e n d i n g the center electrode.
GAUGE
CLOCKWISE ROTATION
FRONT 1-6-5-4-3-2
OF
ENGINE
SPARK J9314-80
PLUG
Fig. 28 Engine Firing Order—3.9L V-6 Engine

When replacing the spark plug and coil cables,
route the cables correctly and secure i n the proper
retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise. I t could
J908D-10
also cause cross ignition of the plugs, or short circuit
the cables to ground.
Fig. 27 Setting Spark Plug Gap—Typical
On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug ca

ble boot heat shields are pressed into the cylinder
head to surround each cable boot and spark plug
cable boot should have a small air gap to the top of
the heat shield (Fig. 31).
J9314-79
Fig. 29 Engine Firing Order—5.2U5.9L V-8 Engines
Fig. 31 Heat Shields—3.9L V-6 or 5.2/5.91 V-8

Engines
THROTTLE POSITION SENSOR (TPS)

For removal and installation, refer to Throttle Po
sition Sensor i n the Component Removal/Installation
section of Group 14, Fuel Systems.
RIGHT LEFT
IANK BANK
F I R I N G ORDER
1-10-9-4-3-6-5-8-7-2 J 948D-12
Fig. 30 Spark Plug Cable Order—8.0L V-10 Engine

When installing new cables, make sure a positive
connection is made. A snap should be felt when a
good connection is made between the plug cable and
the distributor cap tower.
IGNITION SWITCH
INDEX
page page
General Information 36 Ignition Switch and Key Cylinder Service 36
GENERAL INFORMATION
The ignition switch is located i n the steering col
umn. The Key-In- Switch and Halo Light are integral
with the ignition switch. Refer to Group 8U for Key-
In-Switch and Halo Light diagnosis.
IGNITION SWITCH AND KEY CYLINDER SERVICE

REMOVAL
(1) Disconnect negative battery cable(s).
(2) Tilt column: Remove tilt lever (counterclock
wise).
(3) Remove upper and lower shrouds (Fig. 1).
WHEEL
STEERING LEVER
TILT SHROUD
UPPER BRACKET
PANEL
Fig. 2 Ignition Switch Screw Removal
KEY-IN SWITCH & MULTI-FUNCTION
SHROUD NUT J928J-2 Fig. 3 Key in Switch and Halo Lamp Connector
Fig. 1 Shroud Removal/Installation—Typical

(7) Remove the key cylinder from the ignition
switch as follows:
(4) Remove ignition switch mounting screws (Snap- (a) With the key inserted and the ignition switch
on torx bit tool TTXR20B0 or equivalent in the lock position, proceed as follows: Use a small
required—Fig. 2). screwdriver to depress the key cylinder retaining
(5) Gently pull switch away from the column. Re pin flush with the key cylinder surface (Fig. 4).
lease two connector locks on the 7-terminal wiring (b) Rotate the key clockwise to the OFF position.
connector. Remove the connector from the ignition The key cylinder should now be unseated from the
switch (Fig. 3). ignition switch assembly (Fig. 5).
(6) Release connector lock on the Key-In-Switch
CAUTION: Do not remove key cylinder at this time.
and Halo Light 4-terminal connector (Fig. 3).
(c) With key cylinder in unseated position (key
cylinder bezel about 1/8 inch above ignition switch
SMALL
SCREWDRIVER
Fig. 6 Key Cylinder Removal

Park-lock dowel pin on ignition switch assembly
must engage with column park-lock slider linkage
(Fig. 8). Verify ignition switch is i n lock position (flag
is parallel with the ignition switch terminals) (Fig.
6). Apply a dab of grease to flag and pin. Position
park-lock link and slider to mid-travel. Position igni
tion switch against lock housing face. Be sure pin is
inserted into park-lock link contour slot. Tighten re
taining screws to 2 N-m (17 in. lbs.) torque.
908D-18
Fig. 7 Ignition Switch View From Column

HALO LIGHT
RING 908D-16 (3) Assemble cover to the column (3 screws).
Tighten retaining screws to 2 N-m (17 in. lbs.)
Fig. 5 Unseated Key Cylinder torque.
halo light ring), proceed as follows: Rotate the key (4) Tilt column: Install t i l t lever (clockwise).
counterclockwise to the Lock position and remove (5) Install negative battery cable(s).
the key. (6) Install key cylinder.
(d) Remove key cylinder (Fig. 6). (a) With key cylinder and ignition i n lock posi
tion, gently insert key cylinder into ignition switch
INSTALLATION assembly until i t bottoms.
(1) Install electrical connectors to switch. Make (b) Insert key. While gently pushing on the key
sure that the switch locking tabs are fully seated i n cylinder (inward) toward the ignition switch, rotate
the wiring connectors. key clockwise to end of travel.
(2) Mount ignition switch to the column (Fig. 7).
(7) Check for proper operation of push-to-lock, halo
lighting, Accessory, Lock, Off, Run, Start, column lock
and shift lock (if applicable).
Refer to Group 8W, Wiring for ignition switch cir
cuits.
Fig. 8 Ignition Switch Mounting Pad
SPECIFICATIONS
GENERAL INFORMATION IGNITION COIL PACKS—8.0L V-10 ENGINE
latest information available at the time of publica * p n m a r y Resistance: 0.53 to 0.65 ohms
tion. I f anything differs between the specifica * * Secondary Resistance: 10.9 to 14.7 K ohms
tions found on the Vehicle Emission Control
Information (VECI) label and the f o l l o w i n g * Test across the primary connector.
specifications, use specifications on V E C I label. Refer to text for test procedures.
The VECI label is located i n the engine compart * * Test across the individual coil towers.
ment. Refer to text for test procedures.
J948D-13
IGNITION TIMING
Ignition timing is not adjustable on any engine. Re
fer to Ignition Timing i n the Diagnostics/Service Pro
cedures section of this group for more information.
SPARK PLUGS
Spark Plug
Engine Original Application Gap Tightening Size

Replacement Torque
Equipment
3.9L RC12YC RC12YC All .035" 41 N»m 14 mm Thread

V-6 (0.9 mm) (30 ft. lbs.) 3/4" Reach
5.2/5.9L RC12YC RC12YC All .035" 41 N»m 14 mm Thread

V-8 (0.9 mm) (30 ft. lbs.) 3 / 4 " Reach
8.0L RC9MC4 RC9MC4 All .045" 41 N»m 14 mm Thread

V-10 (1.14 mm) (30 ft. lbs.) 3 / 4 " Reach
J948D-19
SPARK PLUG CABLE RESISTANCE ENGINE FIRING ORDER—S.ZL/S.9L V-8

ENGINES
MINIMUM MAXIMUM
250 O h m s Per Inch 1000 O h m s Per Inch
3000 O h m s Per Foot 12,000 O h m s Per Foot
J908D-43
, '0®©',
a CLOCKWISE ROTATION
1-8-4-3-6-5-7-2 ©fo ©'
ENGINE FIRING ORDER—3.9L V-6 ENGINE FRONT
OF .©©©,
ENGINE
J9314-79
<=] CLOCKWISE ROTATION

FRONT 1-6-5-4-3-2
OF
ENGINE
J9314-80
SPARK P L U G CABLE ORDER—8.0L V-10 TORQUE

ENGINE
Description | Torque
Camshaft Position Sensor Bolt —
8 . 0 L V-10 E n g i n e . 6 N » m ( 5 0 i n . lbs.)
Crankshaft Position S e n s o r -
A l l G a s P o w e r e d Engines 8 N » m ( 7 0 i n . lbs.)
D i s t r i b u t o r H o l d D o w n Bolt 2 3 N » m (17 ft. lbs.)
Engine C o o l a n t Temp. S e n s o r -
A l l Engines 7 N » m ( 6 2 i n . lbs.)
I g n i t i o n C o i l M o u n t . Bolts —
3 . 9 L / 5 . 2 L / 5 . 9 L Engines
(nuts a n d bolts) 11 N » m ( 1 0 0 i n . lbs.)
(bolts o n l y 5 N * m ( 5 0 i n . lbs.)
I g n i t i o n C o i l M o u n t . Bolts —
8 . 0 L V-10 Engine 10 N * m ( 9 0 i n . lbs.)
Intake M a n i f o l d A i r Temp. Sensor —
A l l Engines 13 N « m (10 ft. lbs.)
M A P Sensor-To-Throttle B o d y
Mounting Bolts—
3 . 9 L / 5 . 2 L / 5 . 9 L Engine . 3 N * m ( 2 5 i n . lbs.)
M A P Sensor-To-lnt. M a n . B o l t s —
8 . 0 L V-10 Engine 2 N * m ( 2 0 i n . lbs.)
P C M M o u n t i n g Screws 1 N « m (9 i n . lbs.)
P C M 6 0 - W a y Elect. C o n n e c t o r 4 N » m ( 3 5 i n . lbs.)
RIGHT LEFT S p a r k Plugs — A l l Engines 4 1 N » m ( 3 0 ft. lbs.)

BANK BANK J948D-18
FIRING ORDER
1-10-9-4-3-6-5-8-7-2 J948D-12
IGNITION COIL RESISTANCE—EXCEPT 8.0L V-10 ENGINE
PRIMARY RESISTANCE S E C O N P H R Y RESISTANCE
COIL (MANUFACTURER) 21-27°C (70-80°F) 21-27°C (70-80°F)
Diamond 0 . 9 7 - 1.18 O h m s 11,300- 15,300 O h m s
Toyodenso 0 . 9 5 - 1.20 O h m s 11,300- 13,300 O h m s
J918D-2
• INSTRUMENT PANEL AND GAUGES 8E - 1
INSTRUMENT PANEL AND G A U G E S
CONTENTS
page page
CLUSTER AND GAUGE SERWiCE GENERAL INFORMATION 1

PROCEDURES 20 MESSAGE CENTER 5
CLUSTER AND GAUGE TEST PROCEDURES ... 6 SWITCH AND PANEL COMPONENT SERVICE . 25
FUSEBLOCK MODULE AND FLASHERS 6
GENERAL INFORMATION
INDEX
page page
Electronic Digital Clock 4 Warning Lamps 3
Gauges 2
With the ignition switch i n the ON or START posi The low line instrument cluster includes gauges for
tion, voltage is supplied to the instrument cluster in (Fig. 1):
dicator lamps by fuse #12. Voltage for the • speedometer
illumination lamps is supplied through fuse #13. The • fuel level
voltage supplied to the instrument cluster is supplied • coolant temperature
to all the gauges and indicators through the instru • oil pressure
ment cluster printed circuit. • electrical system voltage.
With the ignition switch i n the OFF position, volt
age is not supplied to the instrument cluster.
J948E-43
Fig. 1 Low Line Cluster—Typical

8E - 2 INSTRUMENT PANEL AND GAUGES •
The low line cluster also includes warning lamps OIL PRESSURE GAUGE
for: The oil pressure gauge pointer position is con
• low oil pressure warning trolled by a magnetic field created by electrical cur
• four-wheel drive indicator rent flow through the coils within the gauge. A
• malfunction indicator (Check Engine) change i n current flow will change the magnetic field
• airbag warning which changes the pointer position. The oil pressure
• seat belt reminder sender is a variable resistor that changes electrical
• maintenance required (emissions maintenance - resistance with a change i n oil pressure (calibration
HDC 5.9L V8 & 8.0L VIO) values shown i n Specifications chart).
• upshift indicator In the oil pressure indicating system, changes i n
• brake indicator sending unit resistance are actuated by a diaphragm
• anti-lock brake system indicator that moves as the oil pressure increases or decreases.
• turn signal indicators Low oil pressure causes high resistance. High pres
• high beam indicator sure causes low resistance.
The high line cluster has all the gauges of the low
line cluster and includes a 0-6000 rpm tachometer COOLANT TEMPERATURE GAUGE
(Fig. 2) The coolant temperature gauge pointer position is
The high line cluster also includes warning lamps controlled by a magnetic field. This field is created by
for: electrical current flowing through the coils within the
• low fuel warning gauge. A change in current flow will change the mag
• low washer fluid indicator netic field which changes the pointer position. The
coolant temperature sending unit is a thermistor that
GAUGES changes electrical resistance with a change i n coolant
A l l the gauges are the electro-magnetic type. When temperature. As the resistance changes, the current
the ignition switch is i n the OFF position each gauge changes and the pointer moves to a new position (cal
will show a reading, except the speedometer and ta ibration values shown i n Specifications chart).
chometer. The readings are only accurate when the When the engine coolant is cold, the resistance of
ignition switch is i n the ON position. the sending unit is high. When the engine coolant is
hot, the resistance of the sending unit is low.
VOLTMETER
The voltmeter measures battery or generator out FUEL GAUGE
put voltage, whichever is greater. The fuel gauge pointer position is controlled by a
magnetic field created by electrical current flow
through the coils within the gauge. A change i n cur-
Fig. 2 High Line Cluster—Typical

• INSTRUMENT PANEL AND GAUIES 8E - 3
rent flow will change the magnetic field which MALFUNCTION INDICATOR (CHECK ENGINE)
changes the pointer position. LAMP
A hinged float arm i n the fuel tank raises or lowers The malfunction indicator (Check Engine) lamp i l
depending on the fuel level. The float arm contacts a luminates each time the ignition switch is turned
variable resistor i n the gauge sending unit. This pro ON. I t will stay on for 3 seconds as a bulb test.
vides a change of resistance i n the fuel gauge circuit I f the PCM receives an incorrect signal or no signal
with any up or down movement of the float. As the from certain sensors or emission related systems, the
resistance changes, the current changes and the lamp is turned on (pin 32 of PCM). This is a warning
pointer moves to a new position (calibration values that the PCM has recorded a system or sensor mal
shown in Specifications chart). function. I n some cases, when a malfunction of a
Sending unit resistance is high when the fuel level monitored circuit occurs, the PCM will go into a
in the tank is low and the float arm drops. Sending limp-in mode of operation i n an attempt to keep the
unit resistance is low when the tank is full and the system operating (except diesel). I t signals an imme
float arm is raised. diate need for service.
The lamp can also be used to display diagnostic
SPEEDOMETER/ODOMETER trouble codes (DTC). Cycle the ignition switch ON-
The speedometer/odometer system consists of an OFF-ON-OFF-ON within 3 seconds. This will allow
electric speedometer/odometer and pushbutton reset any DTC's stored in the PCM to be displayed i n a se
trip odometer mounted i n the cluster. The system ries of flashes representing digits. Refer to Group 14
also includes the wire harness from the cluster to the - General Diagnosis Sections for a listing of the
vehicle speed sensor at the transmission, and the codes.
adapter and pinion i n the transmission. The electric
speedometer/odometer has the same appearance as a AIRRAG WARNING
mechanical version, but i t eliminates the drive cable. This lamp monitors the airbag system. This lamp
A signal is sent from a transmission mounted vehicle will come on when the ignition switch is turned to
speed sensor to the speedometer/odometer circuitry the ON position and should stay l i t for 6 to 8 sec
through the w r i n g harness. Refer to Group 21 - onds.
I f the a i r b a g w a r n i n g l a m p e i t h e r fails t o
Transmission for selecting the proper pinion, and se
l i g h t , o r goes o n a n d stays on, there is a system
lecting and indexing the proper adapter.
malfunction. Refer t o the a p p r o p r i a t e Diagnos
tic Test Procedures m a n u a l t o diagnose the
TACHOMETER
problem.
The tachometer displays the engine speed (RPM).
With the engine running, the tachometer receives an SEAT BELT REMINDER
engine speed signal from the PCM pin 43 (calibration This lamp is illuminated i f the ignition switch is
values shown i n Specifications chart). ON and the driver's seat belt is not buckled. The
lamp will go off after 4 to 8 seconds.
WARNING LAMPS For testing of this system refer to Group 8U -
Chime/Buzzer Warning Systems.
LOW OIL PRESSURE
The oil pressure warning switch, mounted on the MAINTENANCE REQUIRED—HDC S.9L V8/8.0L
engine, is controlled by engine oil pressure. The lamp V-10
should only light when the engine is first started. This system is designed to act as a reminder that
When engine oil pressure is normal, the switch is scheduled vehicle emissions maintenance must be
held i n the off or open position. This stops current performed, as required by federal emissions laws. I t
from flowing to the low oil pressure warning lamp on is n o t i n t e n d e d to indicate a w a r n i n g o r t h a t a
the instrument panel. state o f emergency exists w h i c h m u s t be cor
When the engine oil pressure is low, the switch is rected t o insure safe vehicle operation. When
in the on or closed position. This allows current to the lamp has been activated, certain service/mainte
flow to the low oil pressure warning lamp i n the in nance must be performed. For required service/main
strument cluster causing the warning lamp to illumi tenance, stated in time or mileage, refer to Group 0 -
nate. Lubrication and Maintenance. Also refer to Group 25
- Emission Control System for information.
FOUR-WHEEL DRIVE INDICATOR
UPSHIFT INDICATOR
Indicates that the transfer case is i n a four-wheel
Vehicles equipped with manual transmissions have
drive mode of operation.
an upshift indicator lamp. The lamp is controlled by
the PCM. The lamp illuminates to indicate when the
driver should shift to the next highest gear for best • The vacuum sensor (diesel engines) senses low
fuel economy. The engine controller will turn the vacuum, or
lamp off after 3 to 5 seconds i f the upshift is not per • The ABS or RWAL system has a malfunction.
formed. The lamp will remain off until the vehicle
stops accelerating and is brought back to the range of LOW FUEL WARNING
lamp operation, or is shifted into another gear. The low fuel warning indicator lights when the fuel
The indicator lamp is normally illuminated when level i n the tank is less than approximately 1/8 of ca
the ignition switch is turned ON, and is turned OFF pacity. A low fuel warning module controls when the
when the engine is started. The lamp will be lighted indicator will light. When the module senses approx
during engine operation according to engine speed imately 65 ohms or more from the fuel level sender
and load. Refer to Group 14 - Fuel System for addi for 10 to 20 continuous seconds, the indicator will
tional information. light. The indicator will remain on until the module
senses approximately 65 ohms or less from the fuel
ANTI LOOK B R A K E S Y S T E M (ABS)
sender for 10 to 20 continuous seconds (exact calibra
This lamp monitors the anti-lock brake system
tion values shown i n Specifications chart).
(ABS), or rear wheel anti-lock (RWAL) system, de
pending upon vehicle equipment. This lamp will LOW WASHER FLUID
come on when the ignition key is turned to the ON
The low washer fluid indicator lights when the
position, and may stay on for as long as 30 seconds.
windshield washer reservoir is less than approxi
I f the ABS lamp remains on or comes on during driv
mately 1/8 full.
ing, i t indicates that the ABS or RWAL brake system
is not functioning. Refer to Group 5 - Brakes for fur
ther information. ELECTRONIC DIGITAL CLOCK
The electronic digital clock is i n the radio. The
BRAKE INDICATOR clock and radio each use the display panel built into
The brake indicator lamp warns the driver that the the radio. A digital readout indicates the time i n
parking brake is applied or that the hydraulic pres hours and minutes whenever the ignition switch is i n
sure i n the split brake system is unequal. the ON or ACCESSORY position.
Voltage is supplied through the brake indicator When the ignition switch is i n the OFF position or
bulb to up to 5 switches. A path to ground for the when the radio frequency is being displayed, time
current is supplied if: keeping is accurately maintained.
• The brake warning switch is closed (with unequal The procedure for setting the clock varies slightly
brake system hydraulic pressures), or with each radio. The correct procedure is described
• The ignition switch is i n the START position (to under the individual radio operating instructions re
test the bulb), or ferred to i n the owner's manual supplied with the ve
• The park brake switch is closed (with the parking hicle.
brake applied), or
INSTRUMENT PANEL AND GAUGES 8E - 5
MESSAGE CENTER
The message center (Fig. 1), located below the
heater-A/C controls, includes warning lamps for:
• transmission temperature (V-10 and diesel)
• hazard flasher indicator
• water i n fuel (diesel)
• wait to start (diesel)
• master illumination (export)
HAZARD WARNING FLASHER INDICATOR

Illuminates when the hazard warning flasher is en
gaged.
TRANSMISSION TEMPERATURE
Refer to Group 21 - Transmission and Transfer
Cases for operating parameters of the warning lamp.
WATER IN FUEL—DIESEL
The water-in-fuel lamp is connected to a sensor lo
O
cated i n the fuel filter. I f water collects i n the fuel/
water separator filter, the water-in-fuel indicator will
light.
WAIT TO START—DIESEL
The wait-to-start indicator is connected to a sensor
that monitors intake air temperature i n the intake
manifold. I f intake air temperature is low and igni
tion switch is i n ON position, the PCM sends current
to the intake manifold air heaters and the wait-to- J948E-37
start indicator. This intake manifold preheat cycle is
controlled by an electronic air heater control module. Fig. 1 Message Center
MASTER ILLUMINATION—EXPORT
This indicator is used only on models intended for
export to countries that require this feature.
FUSEBLOCK MODULE AND FLASHERS

The fuseblock module is located on the driver's end 30 amp circuit breakers,
of the instrument panel. Open the driver's door and turn signal flasher,
remove the fuseblock module cover. Refer to Group horn relay.
8W - Wiring Diagrams for fuse amperage and circuit hazard warning flasher,
information. chime module,
The following components plug into the fuseblock ignition-off draw fuse (#17).
module. fuse puller.
• fuses.
8E - 6 INSTRUMENT PANEL AND GAUGES
CLUSTER AND G A U G E TEST PROCEDURES
INDE1
page page
Coolant Temperature Gauge Diagnosis 9 Oil Pressure Gauge Diagnosis 7

Fuel Gauge Diagnosis , 6 Specifications 19
Instrument Cluster Connectors 17 Speedometer/Odometer Diagnosis 10
Instrument Cluster Printed Circuit Board—High Tachometer Diagnosis 12
Line . 17 Vehicle Speed Sensor 12
Instrument Cluster Printed Circuit Board—Low Voltmeter Diagnosis 10
Line . . . . . . . . 18 Warning Lamp System Tests 13
Low Fuel Warning Diagnosis 7
CAUTION: Disconnect battery negative cable(s), in Sending Unit Test. I f not OK, turn ignition switch
engine compartment, before servicing instrument OFF and continue to next step.
panel. When power is required for test purposes, (4) Pull instrument cluster from dash. Do not un
connect battery cable (for test only). plug cluster connectors. Refer to Instrument Cluster
Replacement for removal procedures.
D i s c o n n e c t b a t t e r y negative cable(s) after test (5) Check for continuity i n wire between un
and before continuing service procedures. plugged fuel tank sending unit connector input to
gauge cavity (Fig. 1) and fuel gauge input terminal
FUEL GAUGE DIAGNOSIS (Figs. 3 or 4). I f OK, continue to next step. I f not OK,
I f all gauges and warning lamps are inoperative, repair open circuit as required.
check battery feed from ignition switch to fuse #12, (6) Unplug instrument cluster connector B (black).
then check wiring from fuse to cavity #8 of cluster Check for continuity between unplugged fuel tank
connector B (black). sending unit connector input to gauge cavity (Fig. 1)
and a good ground. There should be no continuity. I f
FUEL GAUGE CIRCUIT TEST
OK, reinstall cluster connector B and continue to
(1) Unplug connector from fuel tank sending unit. next step. I f not OK, repair short circuit as required.
Check sending unit ground cavity of connector (Fig.
(7) With ignition switch i n ON position, check for
1) for continuity to ground. I f OK, go to next step. I f
battery voltage across fuel gauge B+ terminal and
not OK, repair circuit to ground.
ground terminal (Figs. 3 or 4). I f OK, replace gauge.
FUEL PUMP SUPPLY I f not OK, continue to next step.
battery voltage at cavity #8 of cluster connector B
INPUT T O G A U G E (black). With ignition switch i n OFF position, check
for continuity to ground at cavity #9 of cluster con
SENDING UNIT G R O U N D nector B (black). I f both OK, replace cluster printed
circuit board. I f not OK, repair ground or feed circuit
FUEL PUMP G R O U N D
as required.
J928E-49
F U E L T A N K SENDING UNIT TEST
Fig. 1 Fuel Tank Sending Unit Connector (1) I f the fuel gauge passes tests i n steps (1)
through (3) above, check fuel tank sending unit as
(2) With sending unit connector unplugged, turn
follows:
ignition switch to ON. Gauge should read EMPTY. I f
OK, continue to next step. I f not OK, go to step (4). (a) Carefully remove fuel tank sending unit from
tank. Refer to Group 14 - Fuel System.
CAUTION: When connecting an input terminal to (b) Check for correct resistance measurements as
ground, DO NOT leave the connection grounded for shown i n Specifications. I f not OK, replace sending
more than a few s e c o n d s . unit (Fig. 2).
(2) I f fuel gauge and sending unit are operating,
(3) With ignition switch ON, connect a jumper wire but sending unit accuracy is suspect, check the fol
between input to gauge cavity and sending unit lowing:
ground cavity of sending unit connector (Fig. 1). (a) Fuel tank bottom deformed causing improper
Gauge should read FULL. I f OK, see Fuel Tank positioning of sending unit pick up tube or float
arm. Replace or repair tank and recheck sending LOW FUEL WARNING DIAGNOSIS
unit. Refer to Group 14 - Fuel System. For diagnosis refer to Warning Lamps - Low Fuel
(b) Sending unit improperly installed, restricting Warning.
float arm travel. Install properly.
(c) Float arm deformed. Make sure sending unit OIL PRESSURE GAUGE DIAGNOSIS
float arm moves freely and pick up tube is not bent When a problem occurs with an individual cluster
so that i t contacts bottom of tank. Inspect float for gauge, before disassembling the cluster to check the
any signs of damage or leaks. gauge, check for a defective sending unit (sensor) or
(d) Fuel tank mounting flange for sending unit wiring. I f all gauges and warning lamps are inopera
deformed. Feel for interference fit of sending unit tive, check battery feed from ignition switch through
to bottom of tank. I t is permissible to bend pick up fuse #12 and wiring to cavity #8 of cluster connector
tube down a little near mounting flange to gain in B (black).
terference fit.
FUEL GAUGE SYSTEM DIAGNOSIS
FUEL G A U G E SYSTEM DIAGNOSIS
FUEL G A U G E FUEL G A U G E FUEL G A U G E

rUEL GAUGE
DOES NOT INOPERATIVE DOES NOT
INACCURATE
MAD F U L L O R ERRATIC READ EMPTY
CHECK FAULTY W I R I N G OR TANK DEFORMED TANK N O T EMPTY

T A N K N O T FULL COMPONENTS CHECK CHECK
i i
PROPER A L I G N M E N T
CHECK ALL W I R I N G O F PICKUP A N D
INCLUDING SENDER ASSEMBLY.
GROUND REFER T O G R O U P 14
FAULTY PRINTED FAULTY FUEL G A U G E FAULTY FUEL

CIRCUIT B O A R D S E N D I N G UNIT GAUGE
J908E-74
FUEL G A U G E LOCKING
FLOAT SENDING UNIT TABS
ELECTRIC
FUEL PUMP
FUEL GAUGE
INPUT
MOUNTING IN-TANK
SCREWS FUEL FILTER J9414-33
Fig. 2 Fuel Tank Sending Unit Fig. 3 Fuel Gauge Terminals—High Line Cluster
SENDING UNIT
(GAUGE)
SWITCH
(LIGHT)
898E-2
Fig. 5 Combination Oil Pressure Sending Unit

Terminals
? J948E-57
(2) Using a jumper wire, ground switch cavity of
connector (Fig. 5) to engine. The lamp should light. I f
Fig. 4 Fuel Gauge Terminals—Low Line Cluster
OK, check sending unit. I f not OK, turn ignition
COMBINATION OIL PRESSURE SENDING UNIT switch OFF, remove jumper wire and continue with
The combination oil pressure sending unit has 2 next step.
functions: (3) Pull instrument cluster from dash. Do not un
(1) Lamp function. The sending unit provides a low- plug cluster connectors. Refer to Instrument Cluster
resistance that keeps the low oil pressure warning Replacement for removal procedures.
lamp on until there is oil pressure. (4) Check continuity between sending unit connec
(2) Gauge function. The sending unit provides a re tor switch cavity (Fig. 5) and oil pressure lamp
sistance that varies with oil pressure for gauge oper ground terminal (Figs. 9 or 10) on back of cluster.
ation. There should be continuity. I f OK, continue to next
step. I f not OK, go to step (6).
COMBINATION SENDING UNIT LAMP FUNCTION TEST (5) With ignition switch i n ON position, check for
To test the combination oil pressure sending unit battery voltage at oil pressure lamp B+ terminal
lamp function, unplug the connector. Measure the re (Figs. 9 or 10) on back of cluster. I f OK, replace bulb.
sistance between the sending unit switch terminal I f not OK, continue to next step.
(Fig. 5 ) and the metal housing (Figs. 6, 7 and 8). The (6) Unplug cluster connector B (black). With igni
ohmmeter should read 0 ohms. Now, start the engine. tion switch i n OFF position and jumper wire from
I f there is oil pressure, the ohmmeter reading should step (2) installed, check for continuity to ground at
increase. I f sending unit fails either test, replace cluster connector cavity #4. I f OK, remove jumper
sending unit. wire and continue to next step. I f not OK, repair
open circuit to sending unit.
COMBINATION SENDING UNIT GAUGE FUNCTION TEST (7) Turn ignition switch to ON. Check for battery
To test the combination oil pressure sending unit voltage at cluster connector B, cavity #8. I f OK, re
gauge function, unplug the connector. Measure the place cluster printed circuit board. I f not OK, repair
resistance between the sending unit sending unit ter circuit to fuse #12.
minal (Fig. 5) and the metal housing (Figs. 6, 7 and
8). The ohmmeter should read higher than 65 ohms. OIL PRESSURE GAUGE CIRCUIT TEST
Now, start the engine. The ohmmeter should read be Perform Combination Sending Unit Gauge Func
tween 24.5 and 65 ohms, depending on engine speed, tion Test before proceeding with circuit test.
oil temperature, and oil viscosity. I f sending unit fails
CAUTION: When connecting an input terminal to
either test, replace sending unit.
ground, DO NOT leave the connection grounded for
more than a few seconds.
LOW OIL PRESSURE WARNING LAMP
CIRCUIT TEST (1) Unplug connector from sending unit (Figs. 6, ^,
Perform Combination Sending Unit Lamp Function and 8) and turn ignition switch to ON. Gauge should
Test before proceeding with circuit test. read at or below minimum. I f OK, continue to next
(1) Unplug connector from sending unit (Figs. 6, 7, step. I f not OK, go to step (3).
and 8) and turn ignition switch to ON. Lamp should (2) Using a jumper wire, ground sending unit cav
be off. I f OK, continue to next step. I f not OK, repair ity of sending unit connector (Fig. 5) to engine. The
circuit for short to ground. gauge should read at or above maximum. I f OK,
EGR VALVE
Fig. 6 Oil Pressure Sending Unit—V6 and V8
STEERING
PUMP ENGINE BLOCK J9119-74
Fig. 8 Oil Pressure Sending Unit—Diesel
J948E-55
J948E-38
Fig. 9 Oil Pressure Lamp—High Line Cluster
Fig. 7 Oil Pressure Sending Unit—V10 (6) With ignition switch i n ON position, check for
check sending unit. I f not OK, turn ignition switch battery voltage across oil pressure gauge B+ terminal
OFF, remove jumper wire and continue with next and ground terminal (Fig. 11). I f OK, replace gauge.
step. I f not OK, continue with next step.
(3) Pull instrument cluster from dash. Do not un (7) Unplug cluster connector B (black). With igni
plug cluster connectors. Refer to Instrument Cluster tion switch i n ON position, check for battery voltage
Replacement for removal procedures. at cavity #8. I f OK, continue to next step. I f not OK,
repair circuit to fuse #12.
(4) Check continuity between sending unit connec
(8) Turn ignition switch to OFF and check for con
tor sending unit cavity (Fig. 5) and oil pressure sen
tinuity to ground at cluster connector B, cavity #9. I f
sor input terminal (Fig. 11) on back of cluster. There
OK, replace cluster printed circuit board. I f not OK,
should be continuity. I f OK, continue with next step. repair open circuit to ground.
I f not OK, repair open circuit as required.
(5) Check continuity between oil pressure sensor COOLANT TEMPERATURE GAUGE DIAGNOSIS
input terminal (Fig. 11) and ground. There should be When a problem occurs with an individual cluster
no continuity. I f OK, go to next step. I f not OK, re gauge, before disassembling the cluster to check the
pair short circuit as required. gauge, check for a defective sending unit (sensor) or
wiring. I f all gauges and warning lamps are inopera-
(1) Unplug connector from sending unit (Figs. 12,
13 or 14) and turn ignition switch to ON. Gauge
should read at or below minimum. I f OK, continue to
next step. I f not OK, go to step (3).
(2) Using a jumper wire, ground sending unit con
nector to engine. The gauge should read at or above
maximum. I f OK, check sending unit. I f not OK, turn
ignition switch to OFF, remove jumper wire and con
tinue with next step.
(3) Pull instrument cluster from dash. Do not un
plug cluster connectors. Refer to Instrument Cluster
(4) Check continuity between sending unit connec
tor and temperature gauge input terminal (Figs. 15
or 16) on back of cluster. There should be continuity.
Fig. 10 Oil Pressure Lamp—Low Line Cluster
I f OK, continue with next step. I f not OK, repair
open circuit as required.
(5) Check continuity between temperature gauge
input terminal (Figs. 15 or 16) and ground. There
should be no continuity. I f OK, go to next step. I f not
OK, repair short circuit as required.
battery voltage across temperature gauge B+ termi
nal and ground terminal (Figs. 15 or 16). I f OK, re
place gauge. I f not OK, continue with next step.
(7) Unplug cluster connector B (black). With igni
tion switch i n ON position, check for battery voltage
at cavity #8. I f OK, continue to next step. I f not OK,
(8) Turn ignition switch to OFF and unplug cluster
connector A (white). Check for continuity to ground
at cavity #6. I f OK, replace cluster printed circuit
Fig. 11 Oil Pressure Gauge Terminals board. I f not OK, repair open circuit to ground.
tive, check battery feed from ignition switch through VOLTMETER DIAGNOSIS
fuse #12 and wiring to cavity #8 of cluster connector (1) Pull instrument cluster from dash. Do not un
B (black). plug connectors. Refer to Instrument Cluster Re
placement for removal procedures.
COOLANT TEMPERATURE SENDING UNIT
(2) With the ignition switch i n the ON position,
TEST
check for battery voltage across the B+ pin and the
(1) Unplug connector from sending unit (Figs. 12,
ground pin (Fig. 17) on back of cluster. I f OK, replace
13 or 14).
gauge. I f not OK, continue to next step.
(2) Connect an ohmmeter between the sending
unit terminal and the engine block. There should be (3) Unplug cluster connector A (white). With igni
a reading on the ohmmeter. Refer to Specifications tion switch i n OFF position, check for continuity be
for the range. I f there is no reading, replace sending tween connector cavity #6 and ground. There should
unit. I f OK, continue with Coolant Temperature be continuity. I f OK, continue to next step. I f not OK,
Gauge Circuit Test. repair open circuit to ground.
COOLANT TEMIPEHATURE GAUGE CIRCUIT tion switch i n ON position, check for battery voltage
TEST at connector cavity #8. I f OK, replace cluster printed
Perform Coolant Temperature Sending Unit Test circuit board. I f not OK, repair circuit to fuse #12.
before proceeding with circuit test.
SPEEDOMETER/ODOMETER DIAGNOSIS
CAUTION: When connecting an input terminal to When a problem occurs with speedometer/odometer
ground, Do Not leave the connection grounded for operation, before disassembling the cluster to check
more than a few s e c o n d s . the gauge, check for a defective vehicle speed sensor
Fig. 14 Coolant Temperature Sending Unit—Diesel
Fig. 12 Coolant Temperature Sending Unit—V6 and

V8
Fig. 15 Temperature Gauge Terminals—High Line

Cluster
Fig. 13 Coolant Temperature Sending Unit—V-10

or speedometer pinion. Refer to the Powertrain Diag
nostic Test Procedures manual for the appropriate
tests.
plug cluster connectors. Refer to Instrument Cluster Fig. 16 Temperature Gauge Terminals—Low Line
Replacement for removal procedures. Cluster
(2) Disconnect vehicle speed sensor and check for
continuity i n G7 circuit between vehicle speed sensor next step. I f not, repair open circuit from vehicle
connector and speedometer speed sensor input termi speed sensor.
nal (Fig. 18). There should be continuity. I f OK, go to
8E - 12 i i S T i U i E i T PANEL AND IAUIES •
Fig. 17 Voltmeter Terminals

(3) Check for continuity between speedometer
speed sensor input terminal (Fig. 18) and ground.
There should be no continuity. I f OK, continue to J948E-32
next step. I f not OK, repair short i n circuit from ve
hicle speed sensor. Fig. 18 Speedometer Terminals
battery voltage across speedometer B+ terminal and tinuity. I f OK, continue to next step. I f not OK,
ground terminal (Fig. 18). I f OK, replace speedome repair short i n circuit from PCM.
ter/odometer. I f not OK, continue to next step. (4) With ignition switch i n ON position, check for
battery voltage across tachometer B+ terminal and
ground terminal (Fig. 19). I f OK, replace tachometer.
I f not OK, continue with next step.
repair circuit to fuse #12. (5) Unplug cluster connector B (black). With igni
(6) Turn ignition switch to OFF and unplug cluster
at cavity #6. I f OK, replace cluster printed circuit
board. I f not OK, repair open circuit to ground. (6) Turn ignition switch to OFF and unplug cluster
VEHICLE SPEED SENSOR at cavity #6. I f OK, replace cluster printed circuit
For testing of the vehicle speed sensor and related board. I f not OK, repair open circuit to ground.
components, refer to the Powertrain Diagnostic Test
Procedures manual.
TACHOMETER
When a problem occurs with the tachometer opera
tion, before disassembling the cluster to check the
gauge, check for a good tach signal from the power-
train control module (PCM). Refer to the Powertrain
Diagnostic Test Procedures manual for the appropri
ate tests.
(2) Check continuity between PCM connector cav
ity 43 and tachometer input terminal (Fig. 19). There
should be continuity. I f OK, continue to next step. I f
not OK, repair open circuit as required. Fig. 19 Tachometer Terminals
(3) Check continuity between tachometer input ter
minal (Fig. 19) and ground. There should be no con-
WARNING LAMP SYSTEM TESTS • from splice joint connector C, check the suspected
faulty switch and its circuit. Also see Group 5 -
BRAKE SYSTEM WARNING LAMP Brakes for additional information.
The brake warning lamp illuminates when the
parking brake is applied with the ignition switch LOW OIL PRESSURE
turned ON. The same lamp will also illuminate Refer to Oil Pressure Gauge Diagnosis
should one of the two service brake systems (RWAL
or ABS) fail when the brake pedal is applied. Refer to FOUR-WHEEL DRIVE
Group 5 - Brakes for diagnosis of these components. The four-wheel drive indicator lamp should illumi
The lamp also lights when the ignition switch is nate any time the front axle disconnect is connected
turned to the START position, as a bulb check. (engaged) in the four-wheel drive mode. I f the indica
tor lamp bulb is good, check the circuit from the in
Diesel Models — The brake warning lamp is
strument cluster to the switch. Refer to Group 2 -
also connected to a sensor that monitors vac
Front Suspension and Axle for more information.
uum i n the brake booster system. O n these
models, an illuminated brake warning lamp can
also indicate a low vacuum condition. Refer to
Group 5 - Brakes for more information.
The bulb location is labeled on the cluster
I f brake warning lamp fails to light during bulb printed circuit. Refer to Group 8W - Wiring Di
check (ignition switch i n START position), proceed as agrams for more information.
follows: (2) With transfer case shifted to a four-wheel drive
(1) Pull instrument cluster from dash. Do not un mode, turn ignition switch to ON position. Check for
plug cluster connectors. Refer to Instrument Cluster battery voltage between B+ terminal and ground ter
Replacement for removal procedures. minal of bulb. I f OK, replace bulb. I f not OK, con
The bulb location is labeled on the cluster tinue to next step.
printed circuit board. Refer to Group 8W - Wir (3) With ignition switch i n ON position, check for
ing Diagrams for more information. battery voltage between B+ terminal of bulb and a
(2) Replace brake warning lamp bulb with a known good ground. I f OK, go to step (5). I f not OK,
known good unit. Check for lamp operation by turn continue to next step.
ing ignition switch to START position. I f OK, rein (4) Unplug cluster connector B (black). With igni
stall cluster. I f not OK, continue to next step. tion switch in ON position, check for battery voltage
(3) Turn ignition switch to ON position. Check for at connector cavity #8. I f OK, replace cluster printed
battery voltage at B+ terminal of bulb. I f OK, go to circuit board. I f not OK, repair open circuit to fuse
step (5). I f not OK, continue to next step. #12 as required.
(4) Unplug cluster connector B (black). With igni (5) With ignition switch i n OFF position, check for
tion switch i n ON position, check for battery voltage continuity between ground terminal of bulb and clus
at connector cavity #8. I f OK, replace cluster printed ter connector B (black), cavity #13. There should be
circuit board. I f not OK, repair open circuit to fuse continuity. I f OK, continue to next step. I f not OK,
#12 as required. replace cluster printed circuit board.
(6) Check for continuity from cluster connector B
(5) Disconnect battery negative cable. Hold ignition
(black), cavity #13 to switch at front axle disconnect
switch i n START position while checking for continu
housing. I f not OK, repair circuit as required. I f OK,
ity to ground at ground terminal of bulb. I f OK, re
refer to Group 2 - Front Suspension and Axles and/or
place bulb. I f not OK, continue to next step.
Group 21 - Transmission and Transfer Case for diag
(6) Unplug cluster connector A (white). Hold igni nosis of four-wheel drive axle disconnect and con
tion switch in START position while checking connec trols.
tor cavity #4 for continuity to ground. I f OK, replace
cluster printed circuit board. I f not OK, repair open MALFUNCTION INDICATOR (CHECK ENGINE) -
ground circuit from ignition switch. (1) Pull instrument cluster from dash. Do not un
I f brake warning lamp lights during bulb check, plug cluster connectors. Refer to Instrument Cluster
but does not light to indicate a brake system mal Replacement for removal procedures.
function, check the circuit as follows: The bulb location is labeled on the cluster
• from ground terminal at bulb to cluster connector printed circuit. Refer to Group 8W - Wiring Di
A, cavity #5. agrams for terminal information.
• from cluster connector A, cavity #5 to splice joint (2) Check for battery voltage between bulb B+ and
connector C. Refer to Group 8W - Wiring Diagrams ground terminals within 3 seconds after turning igni
for more information. tion switch to ON position. I f OK, replace bulb. I f not
OK, continue to next step.
(3) With ignition switch i n ON position, check for (2) Check for battery voltage between bulb B+ and
battery voltage between B + terminal of bulb and a ground terminals within 4 seconds after turning igni
known good ground. I f OK, go to step (5). I f not OK, tion switch to ON position. I f OK, replace bulb. I f not
continue to next step. OK, continue to next step.
(4) Unplug cluster connector B (black). With igni (3) With ignition switch i n ON position, check for
tion switch i n ON position, check for battery voltage battery voltage between B+ terminal of bulb and a
at connector cavity #8. I f OK, replace cluster printed known good ground. I f OK, go to step (5). I f not OK,
circuit board. I f not OK, repair open circuit to fuse continue to next step.
#12 as required. (4) Unplug cluster connector B (black). With igni
(5) With ignition switch i n OFF position, check for tion switch i n ON position, check for battery voltage
continuity between ground terminal of bulb and clus at connector cavity #8. I f OK, replace cluster printed
ter connector B (black), cavity #6. There should be circuit board. I f not OK, repair open circuit to fuse
continuity. I f OK, continue to next step. I f not OK, #12 as required.
replace cluster printed circuit board. (5) With ignition switch i n OFF position, check for
(6) Check for continuity from cluster connector B continuity between ground terminal of bulb and clus
(black), cavity #6 to powertrain control module ter connector A (white), cavity #1. There should be
(PCM) connector, cavity #32. I f not OK, repair circuit continuity. I f OK, continue to next step. I f not OK,
as required. I f OK, refer to Powertrain Diagnostic replace cluster printed circuit board.
Test Procedures manual for diagnosis of PCM.
(6) Check for continuity from cluster connector A
AIRBAG (white), cavity #1 to terminal #57 of buzzer i n fuse-
(1) Pull instrument cluster from dash. Do not un block module. I f not OK, repair circuit as required. I f
plug cluster connectors. Refer to Instrument Cluster OK, refer to Group 8U - Chime/Buzzer Warning Sys
Replacement for removal procedures. tem for diagnosis of buzzer.
• The bulb location is labeled on the cluster
printed circuit. Refer to Group 8W - Wiring Di MAINTENANCE REQUIRED (EMISSIONS
agrams for terminal information. MAINTENANCE HDC 5.9L ¥8 & 8 . 0 L V10)
(2) Check for battery voltage between bulb B+ and The maintenance required lamp is controlled
ground terminals within 6 seconds after turning igni b y the PCM.
tion switch to ON position. I f OK, replace bulb. I f not (1) Pull instrument cluster from dash. Do not un
OK, continue to next step. plug cluster connectors. Refer to Instrument Cluster
(3) With ignition switch i n ON position, check for Replacement for removal procedures.
battery voltage between B + terminal of bulb and a The bulb location is labeled on the cluster
known good ground. I f OK, go to step (5). I f not OK, printed circuit. Refer to Group 8W - Wiring Di
continue to next step. agrams for terminal information.
(4) Unplug cluster connector B (black). With igni (2) Disconnect black 60-way connector at PCM,
tion switch i n ON position, check for battery voltage and install a jumper wire from cavity #56 to a good
at connector cavity #8. I f OK, replace cluster printed ground. Turn ignition switch to ON position and
circuit board. I f not OK, repair open circuit to fuse check for battery voltage between bulb B+ and
#12 as required. ground terminals.If OK, replace bulb. I f not OK, con
(5) With ignition switch i n OFF position, check for tinue to next step.
continuity between ground terminal of bulb and clus (3) With ignition switch i n ON position, check for
ter connector A (white), cavity #9. There should be
battery voltage between B+ terminal of bulb and a
continuity. I f OK, continue to next step. I f not OK,
known good ground. I f OK, go to step (5). I f not OK,
replace cluster printed circuit board.
continue to next step.
(6) Check for continuity from cluster connector A
(white), cavity #9 to airbag control module (ACM) (4) Unplug cluster connector B (black). With igni
connector 1 (13 way), cavity #7. I f not OK, repair cir tion switch i n ON position, check for battery voltage
cuit as required. I f OK, refer to Group 8M - Restraint at connector cavity #8. I f OK, replace cluster printed
System for diagnosis of ACM. circuit board. I f not OK, repair open circuit to fuse
#12 as required.
SEAT BELT WARNING (5) With ignition switch i n OFF position, check for
(1) Pull instrument cluster from dash. Do not un continuity between ground terminal of bulb and clus
plug cluster connectors. Refer to Instrument Cluster ter connector B (black), cavity #5. There should be
Replacement for removal procedures. continuity. I f OK, continue to next step. I f not OK,
The bulb location is labeled on the cluster replace cluster printed circuit board.
printed circuit. Refer to Group 8W - Wiring Di (6) Check for continuity from cluster connector B
agrams for terminal information. (black), cavity #5 to cavity #56 of PCM 60-way con-
nector. I f not OK, repair circuit as required. I f OK, (4) Unplug cluster connector B (black). With igni
refer to Powertrain Diagnostic Test Procedures man tion switch i n ON position, check for battery voltage
ual for diagnosis of PCM. at connector cavity #8. I f OK, replace cluster printed
circuit board. I f not OK, repair open circuit to fuse
UPSHIFT INDICATOR #12 as required.
The upshift indicator lamp is controlled by (5) With ignition switch i n OFF position, check for
the P C M . continuity between ground terminal of bulb and clus
(1) Pull instrument cluster from dash. Do not un ter connector B (black), cavity #14. There should be
plug cluster connectors. Refer to Instrument Cluster continuity. I f OK, continue to next step. I f not OK,
Replacement for removal procedures. replace cluster printed circuit board.
The bulb location is labeled on the cluster (6) Check for continuity from cluster connector B
printed circuit. Refer to Group 8W - Wiring Di (black), cavity #14 to RWAL module connector cavity
agrams for terminal information.
#2, or ABS module connector cavity #24. I f not OK,
(2) Disconnect black 60-way connector at PCM,
repair circuit as required. I f OK, refer to Group 5 -
and install a jumper wire from cavity #54 to a good
Brakes for diagnosis of RWAL or ABS module.
ground. Turn ignition switch to ON position and
check for battery voltage between bulb B+ and L E F T AND RIGHT TURN SIGNAL INDICATORS
ground terminals.If OK, replace bulb. I f not OK, con
The turn signals are controlled by the multi-func
tinue to next step.
tion switch, attached to the steering column.
battery voltage between B+ terminal of bulb and a
known good ground. I f OK, go to step (5). I f not OK,
continue to next step.
(4) Unplug cluster connector B (black). With igni The bulb location is labeled on the cluster
tion switch i n ON position, check for battery voltage printed circuit. Refer to Group 8W - Wiring Di
at connector cavity #8. I f OK, replace cluster printed agrams for terminal information.
circuit board. I f not OK, repair open circuit to fuse (2) With ignition switch i n ON position, and multi
#12 as required. function switch i n position (right or left, depending
(5) With ignition switch in OFF position, check for upon indicator being tested), check for battery volt
continuity between ground terminal of bulb and clus age between B+ terminal and ground terminal of
ter connector A (white), cavity #3. There should be bulb. I f OK, replace bulb. I f not OK, continue to next
continuity. I f OK, continue to next step. I f not OK, step.
replace cluster printed circuit board. (3) With ignition switch i n OFF position, check for
(6) Check for continuity from cluster connector A continuity between ground terminal of bulb and clus
(white), cavity #3 to cavity #54 of PCM 60-way con ter connector A, cavity #10. I f OK, continue to next
nector. I f not OK, repair circuit as required. I f OK, step. I f not OK, replace cluster printed circuit board.
refer to Powertrain Diagnostic Test Procedures man (4) Unplug cluster connector A (white) and check
ual for diagnosis of PCM. for continuity between cavity #10 and a good ground.
There should be continuity. I f OK, continue to next
ABS (CHECK ANTI-LOCK) step. I f not OK, repair open circuit to ground as re
The A B S lamp is controlled by the rear wheel quired.
anti-lock (RWAL) module or the anti-lock brake (5) With ignition switch i n ON position, and multi
system (ABS) module, depending upon vehicle function switch i n position (right or left, depending
equipment. upon indicator being tested), check for battery volt
(1) Pull instrument cluster from dash. Do not un age at cluster connector A (white), cavity #14 (right)
plug cluster connectors. Refer to Instrument Cluster or cavity #12 (left). I f OK, continue to next step. I f
Replacement for removal procedures. not OK, go to step (7).
The bulb location is labeled on the cluster (6) With ignition and multi-function switches still
printed circuit. Refer to Group 8W - Wiring Di positioned as i n step (5), check for battery voltage at
agrams for terminal information. B+ terminal of bulb. I f not OK, replace cluster
(2) Check for battery voltage between bulb B+ and printed circuit board.
ground terminals within 30 seconds after turning ig (7) With ignition switch i n OFF position, check
nition switch to ON position. I f OK, replace bulb. I f continuity between cluster connector A (cavity #14 -
not OK, continue to next step. right, cavity #12 - left) and multi-function switch con
(3) With ignition switch i n ON position, check for nector (cavity #11 - right, cavity #16 - left). I f not OK,
battery voltage between B+ terminal of bulb and a repair open circuit as required. I f OK, refer to Group
known good ground. I f OK, go to step (5). I f not OK, 8J - Turn Signals for diagnosis of multi-function
continue to next step. switch.
HIGH BEAM (3) With ignition switch i n OFF position, unplug
(1) Pull instrument cluster from dash. Do not un cluster connector A (white). Check for continuity be
plug cluster connectors. Refer to Instrument Cluster tween connector A, cavity #6 and ground. Then re
Replacement for removal procedures, peat continuity check between connector A, cavity
The b u l b l o c a t i o n is labeled o n the cluster #10 and ground. There should be continuity. I f OK,
printed circuit. Refer to Group 8W - Wiring Di continue to next step. I f not OK, repair open circuit
agrams for terminal information. to ground as required.
(2) With headlamps on high beam, check for bat (4) I f above tests have not revealed a problem, re
tery voltage between B+ terminal and ground termi place low fuel warning circuit and module assembly.
nal of bulb. I f OK, replace bulb. I f not OK, continue
LOW WASHER FLUID
to next step.
(3) With headlamp switch i n OFF position, check plug cluster connectors. Refer to Instrument Cluster
for continuity between ground terminal of bulb and Replacement for removal procedures.
cluster connector A, cavity #10. I f OK, continue to The bulb location is labeled on the cluster
next step. I f not OK, replace cluster printed circuit printed circuit. Refer to Group 8W - Wiring Di
board. agrams for terminal information.
(4) Unplug cluster connector A (white) and check (2) Unplug low washer level sensor connector and
for continuity between cavity #10 and a good ground. install a jumper wire between connector and ground.
There should be continuity. I f OK, continue to next With ignition switch i n ON position, check for bat
step. I f not OK, repair open circuit to ground as re tery voltage between bulb B+ and ground terminals.
quired. I f OK, replace bulb. I f not OK, continue to next step.
(5) With headlamps on high beam, check for bat (3) With ignition switch i n ON position, check for
tery voltage at cluster connector A (white), cavity battery voltage between B+ terminal of bulb and a
#13. I f OK, continue to next step. I f not OK, go to known good ground. I f OK, go to step (5). I f not OK,
step (7). continue to next step.
(6) With headlamps still on high beam, check for (4) Unplug cluster connector B (black). With igni
battery voltage at B+ terminal of bulb. I f not OK, re tion switch i n ON position, check for battery voltage
place cluster printed circuit board. at connector cavity #8. I f OK, replace cluster printed
(7) With headlamp switch i n OFF position, check circuit board. I f not OK, repair open circuit to fuse
continuity between cluster connector A, cavity #13 #12 as required.
and L3 splice i n headlamp and dash wiring harness. (5) With ignition switch i n OFF position, check for
I f not OK, repair open circuit as required. I f OK, re continuity between ground terminal of bulb and clus
fer to Group 8J - Turn Signals for diagnosis of multi ter connector B (black), cavity #7. There should be
function switch. continuity. I f OK, continue to next step. I f not OK,
replace cluster printed circuit board.
LOW FUEL (6) Check for continuity from cluster connector B
The low fuel warning lamp is controlled by the low (black), cavity #7 to low washer level sensor. I f not
fuel warning lamp circuit and module assembly. This OK, repair circuit as required. I f OK, replace faulty
circuit relies upon a properly functioning fuel gauge sensor. Refer to Group 8K - Windshield Wiper and
for operation. Therefore, make all necessary repairs Washer Systems for service of sensor.
to fuel gauge and fuel tank sending unit circuits be
fore attempting repair or diagnosis of the low fuel
warning.
The bulb location is labeled on the cluster
printed circuit. Refer to Group 8W - Wiring Di
agrams for terminal information.
(2) Fuel level must be below 1/8 full (as indicated
on fuel gauge) or, a 100 ohm resistor must be in
stalled between fuel tank sending unit connector "in
put to gauge" cavity and ground. Turn ignition switch
in ON position and wait for 30 seconds. Then check
for battery voltage between B+ terminal and ground
terminal of bulb. I f OK, replace bulb. I f not OK, con
tinue to next step.
• INSTRUMENT PANEL AND IAUGES 8E - 17
INSTRUMENT CLUSTER CONNECTORS

CONNECTOR A CONNECTOR B
(WHITE) B S S S S S Q S S S S S S S : 14 SSSSSgil (BLACK)
14'
9~
i | ® ^ ^
BP IS? UP Iff
it 6 6 h o 6 o 6 o o 6 6
LB14J LB13J |A5J B6 1 B4 IA9I B7 B5 [A3 I LA4^ B1 AT fAlsl [Al2l [AT4]
u u < Z
1 UJ z
o 2*
< 8§ ^2 to
X
u zi < a:
3
OS
55 o£ S « < 3 a.
0=f UJ _
X flD
UJ
CO
2
LU
PIN NUMBER IN J948E-23
s
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD—HIGH LINE
SPEEDOMETER TACHOMETER
SCREWS SCREWS
VOLTMETER
SCREWS
OIL PRESSURE
GAUGE SCREWS
COOLANT FUEL G A U G E
TEMPERATURE SCREWS
GAUGE
© AIR BAG
SCREWS
© ILLUMINATION
© TURN S I G N A L INDICATORS
® HIGH BEAM INDICATOR
© L O W FUEL
J948E-22
INSTRUMENT CLUSTER PRINTED CIRCUIT
BOARD—LOW LINE
VOLTMETER SPEEDOMETER FUEL GAUGE
SCREWS SCREWS SCREWS
OIL PRESSURE
GAUGE SCREWS
7. UPSHIFT INDICATOR
1. ILLUMINATION 8. SEAT BELT WARNING LAMP
2. TURN SIGNAL INDICATORS 9. MALFUNCTION INDICATOR
3. HIGH BEAM INDICATOR (CHECK ENGINE)
4. ABS 10. LOW OIL INDICATOR
5. MAINTENANCE INDICATOR 11. AIR BAG
6. BRAKE 12. 4WD INDICATOR J948E-45
SPECIFICATIONS
O I L PRESSURE GAUGE CALIBRATION VOLTMETER CALIBRATION

POINTER POSITION RESISTANCE VOLTAGE INPUT POINTER POSITION
Low Normal ± 3 ° 65 ohms Low Normal 11.75 Grad. ±3°
High Normal ±4° 24.5 ohms High Normal 15.8 Grad. ±4°
TEMPERATURE GAUGE CALIBRATION TACHOMETER CALIBRATION

GASOLINE E N G I N E S
ENGINE FREQUENCY INDICATION
POINTER POSITION RESISTANCE
V6
Low Normal ±3° 361.7 ohms V8 100 HZ 3000 RPM ± 200
Diesel
High Normal ±3° 77 ohms
VIO 125 HZ 3000 RPM ±200
TEMPERATURE GAUGE CALIBRATION SPEEDOMETER CALIBRATION

DIESEL ENGINE
FREQUENCY INDICATION
POINTER POSITION RESISTANCE
41.1 HZ 20 mph ±3.0
L o w N o r m a l ±3° 155 ohms
118.8 HZ 55 mph ±2.5
High N o r m a l ±4® 80.9 ohms
163.2 HZ 75 mph ±2.5
FUEL GAUGE CALIBRATION LOW FUEL INDICATOR
POINTER POSITION RESISTANCE SENDER RESISTANCE (ohms) BULB DELAY TIME

Empty Grad. ±2.5° 97 ohms £e A + 53 8to30
6 5 4 ON or OFF
-5.0 seconds
1/2 Full Grad. ±5° 32.5 ohms
Full Grad. ±2.5° 9 ohms
J948E-44
8E - 20 INSTRUMENT PANEL AND GAUGES
CLUSTER A N D GAUGE SERWICE PROCEDURES
INDEX
page page
Cluster Bezel 20 Low Fuel Warning Circuit 23
Gauge Replacement—Cluster Removed 23 Printed Circuit Board 21
Instrument Cluster Replacement 20 PRND21 Indicator 23
Lamp Bulb Replacement—Instrument Cluster . . . . 24 Vehicle Speed Sensor 23
Lamp Bulb Replacement—Message Center 24
CLUSTER BEZEL
REMOWAL
(2) Remove 2 screws from cup holder (Fig. 1) and
remove cup holder assembly.
J948E-46
J948E-8 Fig. 3 Instrument Bezel Removal/Installation

Fig. 1 Cup Holder Removal ELECTRICAL
CONNECTOR
(3) Remove 2 screws from ash receiver (Fig. 2) and CLIPS
remove ash receiver assembly.
o
J
I 1
V*
J948E-9
J948E-10
Fig. 2 Ash Receiver Removal
Fig. 4 Cigar Lighter Removal
(4) Carefully pry bezel away from instrument
panel to disengage clips (Fig. 3). (2) Remove cluster bezel. Refer to Cluster Bezel
(5) Unplug connector from cigar lighter (Fig. 4). Removal.
(6) Unplug connector from auxiliary power outlet. (3) Remove knee blocker (Fig. 5).
(7) Reverse removal procedures to install bezel. (4) Pull PRND21 cable and twist to remove from
(8) Connect negative cable to battery. position arm (Fig. 6) i f equipped.
(5) Push tab on bottom of cable retainer up then
INSTRUMENT CLUSTER REPLACEMENT squeeze sides to remove retainer from column.
(6) Remove 4 screws that hold cluster (Fig. 7).
REMOVAL (7) Pull cluster rearward and unplug 2 electrical
(1) Disconnect negative cable from battery. connectors (Fig. 8).
INSTRUMENT CLUSTER
J948E-12
Fig. 8 Unplug Electrical Connectors

(3) I f equipped, connect PRND21 actuator to steer
ing column.
(4) Place shift selector i n PARK position. Indicator
Fig. 5 Knee Blocker Remowal should be properly positioned. I f not, adjust indicator
by turning recessed hex head (9/64-inch hex key
wrench) underneath cable retainer (Fig. 9).
INDICATOR
PRND21 SCREW
ADJUSTING
J948E-66
STEERING
PUSH TAB COLUMN
UP Fig. 9 PRND21 Indicator Adjustment
J948E-4
(5) Install knee blocker.
Fig. 6 PRND21 Cable Removal (6) Plug connectors onto cigar lighter and auxiliary
power outlet attached to bezel.
(7) Install bezel.
(8) Install cup holder and ash receiver assemblies.
Be certain that center clips on metal track housings
catch tabs on instrument panel. Tighten screws to
2.2 N-m (20 in. lbs.) torque.
(10) Check to see that all instruments are func
tioning properly.
PRINTED CIRCUIT BOARD

REMOVAL (FIGS. 10 AND 11)
(1) Remove instrument cluster. See cluster re
J948E-11 moval.
(2) Remove lamp socket assemblies.
Fig. 7 Instrument Cluster Removal (3) Remove gauge mounting screws and remove
(8) Remove cluster. gauges.
(4) Remove low fuel warning circuit connector, i f
INSTALLATION equipped.
(1) Connect 2 large connectors to cluster. (5) Remove printed circuit board from cluster hous
(2) Position cluster to instrument panel and install ing.
4 screws.
SPEEDOMETER TACHOMETER
SCREWS SCREWS
VOLTMETER
SCREWS
OIL PRESSURE
GAUGE SCREWS
COOLANT FUEL GAUGE

TEMPERATURE SCREWS
GAUGE
© AIR BAG
SCREWS
(D I L L U M I N A T I O N
(5) TURN S I G N A L INDICATORS
0 H I G H BEAM INDICATOR
( 5 ) L O W FUEL
J948E-22
Fig. 10 instrument Cluster Printed Circuit Board—High Line/Diesel
VOLTMETER SPEEDOMETER FUEL GAUGE

SCREWS SCREWS SCREWS
PRESSURE
GAUGE SCREWS
7. UPSHIFT INDICATOR
1. ILLUMINATION 8. SEAT BELT WARNING LAMP
2. TURN SIGNAL INDICATORS 9. MALFUNCTION INDICATOR
3. HIGH BEAM INDICATOR (CHECK ENGINE)
4. ABS 10. LOW OIL INDICATOR
5. MAINTENANCE INDICATOR 1 1 . AIR BAG
6. BRAKE 1 2 . 4 W D INDICATOR J948E-45
Fig. 11 Instrument Cluster Printed Circuit Board—Low Line

INSTALLATION (4) Remove required gauge screws from rear of

mounting bezel. Remove gauge from front.
CAUTION: Do not overtighten mounting s c r e w s or For Installation, reverse Removal procedures.
damage to circuit board and/or cluster housing will
occur. LOW FUEL WARNING CIRCUIT
(1) Pull instrument cluster from dash. Refer to In
(1) Position printed circuit board on cluster hous strument Cluster Replacement.
ing. (2) Remove connector from cluster (Fig. 14).
(2) Install gauges.
(3) Install lamp socket assemblies.
(4) Install instrument cluster. See cluster installa
tion.
GAUGE REPLACEMENT—CLUSTER REMOVED

(1) Remove cluster. Refer to Instrument Cluster
Replacement.
(2) Remove 7 screws and lens (Fig. 12).
REMOVE SCREWS
FUEL CIRCUIT
CONNECTOR J948E-59
Fig. 14 Low Fuel Warning Connector

(3) Remove left turn signal bulb and illumination
REMOVE SCREWS "J948E-13 bulb.
Fig. 12 Instrument Cluster Lens
(4) Pull flexible printed circuit back.
(5) Remove low fuel circuit.
(3) Remove gauge bezel (Fig. 13). (6) Reverse removal procedures to install new low
fuel circuit.
LENS
VEHICLE SPEED SENSOR

GAUGE (1) Remove harness connector from sensor. Be sure
BEZEL weather seal stays on harness connector.
(2) Remove sensor by loosening sensor coupling
nut from the pinion gear adapter until sensor is free
M O U N T I N G BEZEL
A N D GAUGES (Fig. 15).
(3) To install the sensor, reverse the removal pro
cedures. Tighten coupling nut to 17 N-m (150 in. lbs.)
PRND21 PRND21 INDICATOR

CABLE (1) Remove cluster assembly. Refer to Instrument
RETAINER
Cluster Removal.
(2) Remove screws attaching PRND21 mechanism
to cluster housing (Fig. 16).
(3) Remove PRND21 mechanism.
(4) To install PRND21 indicator, reverse removal
procedures
(5) To adjust PRND21 indicator, place shift selector
J948E-14
in PARK position. Now adjust indicator by turning
Fig. 13 Instrument Cluster recessed hex head screw (9/64-inch hex key wrench)
underneath cable retainer (Fig. 17).
CAUTION: Do not touch the face of a gauge or the
back of the lens with your finger. It will leave a per
manent finger print.
SPEEDOMETER
PINION GEAR
Fig. 17 PRND21 Indicator Adjustment

(2) Remove instrument cluster. See cluster re
moval.
(3) Twist lamp socket assembly and remove from
printed circuit board.
(4) Remove bulb from socket.
INSTALLATION
(1) Install bulb into socket.
(2) Install socket assembly into printed circuit
board.
(3) Position cluster into place i n panel. See cluster
installation.
LAMP BULB REPLACEMENT—MESSAGE CENTER

The message center is located i n the lower portion
of the heater control. Refer to Heater/ A/C Control
Removal i n this section.
(3) Twist lamp socket assembly and remove from
printed circuit board.
(5) To install message refer to Heater A/C Control
Installation
Fig. 16 PRND21 Housing Removal

LAMP BULB REPLACEMENT—INSTRUMENT
CLUSTER
REMOWAL
SWITCH A N D P A N E L C O M P O N E N T S E R V I C E
INDEX
page page
Cigar Lighter 27 Heater A/C Control 25
Fuseblock Module 27 Inside Hood Release 27
Glove Box 28 Instrument Panel Replacement 28
Glove Box Lamp Switch 26 Message Center Module 27
Headlamp Switch 25 Overdrive Lockout Switch 26
DISCONNECT NEGATIVE CABLE F E O M BAT-

TEEY I N E N G I N E COMPARTMENT BEFOHE
SERVICING I N S T R U M E N T PANEL.
HEATER A/C CONTROL

REMOVAL
(1) Remove cluster bezel (refer to Cluster Bezel Re
moval).
(2) Remove 4 control attaching screws (Fig. 1).
Fig. 2 Heater—A/C Control Connections

(4) Push control into panel.
(5) Install 4 control mounting screws.
(6) Install cluster bezel.
HEADLAMP SWITCH
(1) Remove cluster bezel (refer to Cluster Bezel Re
moval).
(2) Remove 3 screws and headlamp switch from in
strument panel (Fig. 3).
Fig. 1 Heater—A/C Control Remowal

(4) Pull control rearward.
(5) Unplug 2 wiring harness connectors (Fig. 2).
(6) Push i n on red cable connector to release. Re
move cable end from control unit.
(7) Remove control.
INSTALLATION
(1) Position control near panel.
(2) Connect control cables to control (see Heater
A/C Section).
Fig. 3 Headlamp Switch and Bezel Removal
(3) Connect illumination lamp, and wire connec
tors. (3) Unplug 2 electrical connectors (Fig. 4).
Fig. 4 Headlamp Switch Removal

(4) Pull knob and stem assembly to stop. Depress
button on bottom of switch and remove knob and
stem from housing.
(5) Remove 2 screws and bezel from housing.
(6) Reverse removal procedures to install head
Fig. 6 Glove Box Lamp and Switch—Typical
lamp switch.
OVERDRIVE LOCKOUT SWITCH
GLOVE BOX LAMP SWITCH
(1) Open glove box until stops i n bin rest against REMOVAL
instrument panel. (1) Remove cluster bezel (refer to Cluster Bezel Re
(2) Grasp switch by plunger and pull firmly out moval).
ward. Switch and lamp assembly are retained i n (2) Remove 3 screws and switch and bezel assem
mounting hole by a light snap fit (Fig. 5). bly (Fig. 7).
OVERDRIVE LOCKOUT
REMOVE
SCREWS
Fig. 5 Glove Box Lamp Switch—Typical Fig. 7 Overdrive Lockout Switch and Bezel
(3) Disconnect wires to switch and lamp (Fig. 6). (3) Pull up on retaining tab and unplug electrical
(4) Remove bulb from socket. connector.
(5) Reverse removal procedures to install switch INSTALLATION
and lamp.
(1) Position lockout switch into module and push
(6) Tuck any wiring that was exposed by lamp re
until retaining tabs lock into place.
moval back into recess behind lamp. Do not leave
(2) Connect switch connector.
wires exposed i n glove box latch area.
(3) Install instrument cluster bezel to panel.
MESSAGE CENTER MODULE INSIDE HOOD RELEASE

The message center is located i n the lower portion
of the heater control. Refer to Heater/A/C Control Re REMOVAL
moval, i n this section. (1) Disengage cable from hood latch i n engine com
partment.
FUSEBLOCK MODULE (2) Remove 2 screws holding handle assembly to
(1) Disconnect negative cable from battery. instrument panel.
(2) Remove 5 screws and knee blocker from lower (3) Remove assembly by pulling cable rearward
instrument panel (Fig. 8). through dash panel grommet.
INSTALLATION
(1) Feed cable assembly forward through dash
panel grommet.
(2) Mount handle assembly to instrument panel
with 2 screws.
(3) Connect cable to hood latch.
CIGAR LIGHTER
REMOVAL
remove cup holder assembly.
Fig. 8 Knee Blocker Removal

(3) Remove 2 screws holding fuseblock module to
instrument panel (Fig. 9).
Fig. 10 Cup Holder Removal

(2) Remove 2 screws from ash receiver (Fig. 11)
and remove ash receiver assembly.
J948E-9

panel to disengage clips.
Fig. 9 Fuseblock Module Removal (4) Unplug connector from cigar lighter (Fig. 12).
(4) Pull fuseblock module back far enough to gain (5) Unscrew cigar lighter from cluster bezel.
access to buzzer module. INSTALLATION
(5) Reverse removal procedure to install. (1) Screw cigar lighter into cluster bezel.
(2) Plug connector onto cigar lighter.
Fig. 12 Cigar Lighter Remowal Fig. 14 Glove Box and Bin
(3) Install bezel to instrument panel. GLOVE BOX LATCH

(4) Install cup holder and ash receiver assemblies. (1) Open glove box door.
Be certain that center clips on metal track housings (2) Remove latch retaining clip.
catch tabs on instrument panel. Tighten screws to (3) Remove latch.
2.2 N-m (20 in. lbs.) torque.
(4) Reverse removal procedure to install.
GLOVE BOX CATCH
DOOR AND BIN
REMOVAL
REMOVAL (1) Open glove box door.
(1) Open door. Depress right side of bin enough to (2) Remove glove box lamp and switch assembly.
allow stop to clear opening (Fig. 13). Refer to Glove Box Lamp Switch, i n this section.
(3) Remove catch mounting screws.
(4) Remove catch.
INSTALLATION
(1) Position catch into place, install mounting
screws and tighten securely.
(2) Install glove box switch and lamp assembly.
(3) Close glove box door.
INSTRUMENT PANEL REPLACEMENT

REMOVAL
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPT
ING TO REMOVE OR INSTALL THE AIRBAG SYS
TEM COMPONENTS YOU MUST FIRST
DISCONNECT AND ISOLATE THE BATTERY NEGA
Fig. 13 Glove Box Door Release
TIVE (GROUND) CABLE. ALLOW SYSTEM CAPACI
(2) From inside glove, push on stem of button hold TOR TO DISCHARGE FOR 2 MINUTES THEN BEGIN
ing strap at left end of door. Button will push out al AIRBAG REMOVAL. FAILURE TO DO SO COULD
lowing strap to be removed. RESULT IN ACCIDENTAL DEPLOYMENT AND POS
(3) The door and bin are removed by lifting door SIBLE PERSONAL INJURY.
off hinges (Fig. 14).
INSTALLATION (2) Remove left and right kick panel trim.
(1) Snap bin onto door assembly. (3) Remove 5 screws and knee blocker (Fig. 15).
(2) Push strap and retaining button into hole. (4) Remove 4 screws and instrument panel support
(3) Close glove box door. (Fig. 16).
(7) Push tab on bottom of cable retainer up then

squeeze sides to remove retainer from column.
(8) Remove t i l t lever (Tilt column only).
(9) Remove both upper and lower shrouds from col
umn (Fig. 18).
STEERING TILT UPPER PANEL
WHEEL LEVER SHROUD BRACKET
NUT
SPACER
J948E-1
Fig. 15 Knee Blocker Remowal
CLOCK SPRING
LOWER
SHROUD NUT J928J-2
INSTRUMENT
PANEL SUPPORT Fig. 18 Steering Column Shrouds
(10) Remove lower fixed column shroud.
(11) Loosen connector screw. The screw will remain
in the connector. Remove switch connectors (Figs. 19
J948E-2 and 20).
Fig. 16 Instrument Panel Support STEERING
COLUMN
(5) Unplug Squib at lower left corner of instrument ASSY.
panel.
(6) Pull PRND21 cable and twist to remove from
position arm (Fig. 17).
POSITION
ARM
TURN S I G N A L
MULTI SWITCH A N D
FUNCTION LEVER
SWITCH
J918J-1 CONNECTOR
Fig. 19 Multifunction Switch Connector

(12) Remove squib harness from wiring trough.
STEERING
PUSH TAB COLUMN (13) Remove wiring trough from steering column.
UP (14) Remove 3 toe plate nuts and washers (Fig.
J948E-4
21).
Fig. 17 PRND21 Cable Remowal (15) Remove 2 nuts and washers attaching steer
ing column bracket to instrument panel steering col
umn support bracket (Fig. 22).
H A L O LIGHT SWITCH
TURN S I G N A L
SWITCH & LEVER
.INSTRUMENT
PANEL TRANSMISSION
IGNITION SPEED
SWITCH CONTROL J918J-2 TUNNEL - J94SM-1
Fig. 20 Steering Column Connectors Fig. 23 Airbag Control Module Cover Screws
AIRBAG
CONTROL
MODULE
TOE PLATE
M O U N T I N G NUTS (3) J948M-2
J948E-3
/ #
Fig. 24 Airbag Control Module (ACM)

Fig. 21 Steering Column Toe Plate
(19) Disconnect wiring at ACM.
(20) Disconnect left side wiring.
(21) Remove 2 screws holding brake release to bot
tom of instrument panel.
(22) Disconnect right side wiring. There are:
• 2 connectors attached to the heater A/C housing.
• courtesy lamp connector
• antenna cable
• 2 body connectors
(23) Remove 5 screws holding instrument panel to
dash.
(24) Loosen lower instrument panel pivot bolts.
(25) Roll instrument panel down.
(26) Disconnect vacuum harness for heater A/C
J948E-5 , system.
(27) Using a screwdriver or pointed tool, push
Fig. 22 Steering Column Mounting through plastic flashing to release locking tab on
(16) Allow column to lower and rest on seat. heater-A/C control cable (Fig. 25).
(17) Remove 2 screws from bottom of airbag con (28) Pull cable from top of heater core housing.
trol module (ACM) cover (Fig. 23). (29) Remove instrument panel from vehicle.
(18) Remove 4 screws holding ACM to transmis
sion tunnel (Fig. 24).
(4) Tighten instrument panel pivot bolts to 12 N-m

LOCKING (110 in. lbs.) torque.
(5) Assemble shrouds to the column with 3 screws.
Torque screws to 2 N-m (17 in. lbs.).
(6) Raise steering column assembly against the in
strument panel support bracket.
(7) Install 2 steering column bracket washers and
nuts (Finger Tighten Only).
CAUTION: C h e c k that all wiring is clear and not

pinched.
(8) Tighten the 2 steering column bracket nuts to

12 N-m (110 i n . lbs.) torque.
(9) Tighten 3 toe plate nuts and washers (Fig. 21)
to 23 N-m (200 i n . lbs.) torque.
(10) Install multi-function switch connector to
switch and tighten connector retaining screw to 17
in. lbs.
(11) Tilt column only—install tilt lever (clockwise).
(12) Connect right side connectors.
(13) Install instrument panel lower support (Fig.
16) with 4 screws.
(14) Install knee blocker (Fig. 15) with 5 screws.
(15) Install brake release to bottom of instrument
panel with 2 screws.
(16) Connect left side wiring.
Fig. 25 Heater-A/C Cable Remowal From Housing (17) Connect wiring at ACM.
(18) Install ACM. Tighten bolts to 11 N-m (105 i n .
INSTALLATION lbs.).
(1) Install instrument panel on pivot bolts. (19) Install ACM cover.
(2) Connect heater A/C cable and vacuum harness. Refer to Group 8M - Restraint Systems before con
(3) Roll instrument panel into place and install* 5 necting negative cable to battery.
screws along top edge. Torque screws to 3 N-m (28 in.
lbs.).
AUDIO SYSTEMS
CONTENTS
page
SERVICE PROCEDURES 11 TEST PROCEDURES
GENERAL INFORMATION
For operation of the factory installed radios, refer
to the owner's manual supplied with the vehicle.
When installing or removing the ignition-off draw
(IOD) fuse, i t is important that the ignition switch be
in the OFF position.
Failure to place the ignition switch i n the OFF po
sition can cause the radio display to become scram
bled when the IOD fuse is removed. Replacing the
IOD fuse will correct the scrambled display.
8F - 2 AUDIO SYSTEMS •
TEST PROCEDURES
AM/PM STEREO—CASSETTE TAPE
RADIO CONNECTORS
BLACK GRAY
JL VIEW FROM
0 0 0 0 0 0 0 WIRE END
LEGEND: 1 - AMP ON-OFF SIGNAL/ANT UP SIGNAL 1 - RADIO MUTE

2 - LEFT REAR SPEAKER FEED (+) 2 - LEFT FRONT SPEAKER RETURN (-)
3 - RIGHT REAR SPEAKER FEED (+) 3 - RIGHT FRONT SPEAKER RETURN (-)
4 - LEFT FRONT SPEAKER FEED (+) 4 - MARKER — (HEAD/PARK LAMPS)
5 - RIGHT FRONT SPEAKER FEED (+) 5 - DIMMER — (PANEL, LAMPS, VARIABLE)
6 - LEFT REAR SPEAKER RETURN (-) 6 - ACCESSORY — (SWITCHED B+)
7 - RIGHT REAR SPEAKER RETURN (-) 7 - BATTERY — (MEMORY)
TURN IGNITION KEY

TO ACCESSORY
POSITION
TUNE RADIO TO KNOWN

STRONG STATION & SET
VOLUME TO LISTENING LEVEL
NO YES
TAPE ONLY
NOISE ONLY AM FM
INOPERATIVE
STATIC INOPERATIVE? INOPERATIVE
AM-FM OK
AM-TAPE
OK
RUN STATIC RUN ONLY AM 1

NOISE CHECK INOPERATIVE RUN TAPE
CHECK FUSE(S) ANTENNA EXCHANGE
SYSTEM
IGNITION SYSTEM CHECK RADIO
CHECK
MEMORY
FEED
REPLACE
YES
(D
BLOWN
FUSES ONLY ONE
SPEAKER
ONE CHANNEL
(LEFT OR RIGHT)
(FRONT OR REAR)
NO
CHECK FOR
SHORT
CIRCUIT IN CHECK THAT
SPEAKERS IN MOUNTING
THE BAD AND TRIM
CHANNEL PANELS ARE
SECURED
EXCHANGE IF SPEAKER IS
RADIO DAMAGED,
REPLACE SPEAKER
948F-14
• AUDIO SYSTEMS 8F - 3
C H A R T A AND B—NON-INFINITY
I
CHECK RADIO
CONNECTOR FOR:
(A) LOOSE CONNECTIONS
(I) CORROSION
USING A VOLTMETER,
CHECK FOR BATTERY VOLTAGE
AT TERMINAL 6 A W 7 OF THE
GRAY RADIO CONNECTOR
EXCHANGE REPAIR AS
RADIO NECESSARY
CHECK RADIO
CONNECTOR FOR:
(AHOOSE CONNECTIONS
(B) BROKEN WIRES
(Q CORROSION
USING AN OHMMETER, CHECK SPEAKER WIRES FOR

SHORT TO GROUND. REFER TO ABOVE DIAGRAM FOR
SPEAKER PLUS AND MINUS TERMINALS. PIACE ONE
LEAD OF THE OHMMETER TO PLUS TERMINAL AND THE
OTHER LEAD TO GROUND. SWITCH THE LEAD TO THE
MINUS TERMINAL.
TEST RESISTANCE BETWEEN

THE SPEAKER PLUS AND REPAIR AS
MINUS TERMINALS FOR A NECESSARY
READING OF 3 TO 8 OHMS.
SF - 4 AUDIO SYSTEMS •
CHART A—INFINITY
CHECK FOR BATTERY CHECK RADIO

VOLTAGE AT THE PIN 1 OF CONNECTOR FOR:
BLACK CONNECTOR (A) LOOSE CONNECTIONS
(B) BROKEN WIRES
(C) CORROSION
WITH IGNITION
CHECK FUSE ^YES CHECK RADIO O N USING A
OR REPAIR AS FOR GOOD VOLTMETER,
NECESSARY GROUND REPAIR AS CHECK FOR
NECESSARY BATTERY VOLTAGE
y AT TERMINAL 1
AND 2 OF THE
CHECK THAT RADIO CHOKE/ GRAY RADIO
RELAY (P-BODY) IS CONNECTED CONNECTOR
r
1
CHECK THAT GROUND WIRE IS
ATTACHED TO GROUND LOG
O N REAR OF RADIO
REPAIR AS EXCHANGE
r NECESSARY RADIO
SUBSTITUTE CHOKE/RELAY
(P-BODY) WITH A KNOWN
GOOD ONE
YES REPLACE
CHOKE/RELAY
CHECK RADIO
CONNECTOR FOR:
(B) BROKEN WIRES
(C) CORROSION
WITH IGNITION O N
USING A VOLTMETER,
REPAIR AS CHECK FOR BATTERY
NECESSARY VOLTAGE AT PIN 1 OF
BLACK CONNECTOR
EXCHANGE REPAIR AS
RADIO NECESSARY
948F-19
AUDIO SYSTEMS 8F
CHART B—INFINITY
¥
CHECK RADIO
CONNECTOR FOR:
(B) BROKEN WIRES
(C) CORROSION
USING A N OHMMETER, CHECK SPEAKER WIRES

FOR SHORT TO GROUND. REFER TO RADIO
CONNECTORS DIAGRAM FOR SPEAKER PLUS
REPAIR AS
AND MINUS TERMINALS. PLACE ONE LEAD OF
NECESSARY
THE OHMMETER TO PLUS TERMINAL A N D THE
OTHER LEAD TO GROUND. SWITCH THE LEAD
TO THE MINUS TERMINAL
DISCONNECT SPEAKER A N D
CHECK CONNECTOR FOR:
(A) LOOSE CONNECTIONS REPAIR AS
(B) BROKEN WIRES NECESSARY
(C) CORROSION
REPAIR AS
NECESSARY
REPLACE
SPEAKER
EXCHANGE
REPAIR AS
NECESSARY RADIO
J948F-15
8F - 8 AUilO SYSTEMS •
CHART C AND D—ALL RADIOS
USE DIRECT FEED FROM

BATTERY.
CHECK FOR NOISE WITH THE
IGNITION IN ACCESSORY
POSITION, WITH ALL ELECTRICAL
ACCESSORIES OFF.
START ENGINE. WITH ENGINE

RUNNING, IF THERE IS STATIC/NOISE,
CHECK THE FOLLOWING: YES EXCHANGE
(A) ELECTRIC FUEL PUMP RADIO
(B) IGNITION SYSTEM FAULTS
(C) CHECK GROUND CONNECTIONS
(D) CHECK ANTENNA MOUNTING
CHECK ANTENNA
CONNECTIONS
REPAIR AS
NECESSARY
REPLACE OR REPAIR
DEFECTIVE ANTENNA
OR LEAD
948F-16
C H A R T E—ALL CASSETTE TAPE PLAYERS
TURN RADIO ON & INSERT TAPE*
POOR
TAPE
PERFORMANCE
INOPERATIVE
EATS TAPES.
DIRTY CAPSTAN
TRYAKI MOWN
CHECK PLAYER FOR AND DRIVE
GOOD TAPE
OBSTRUCTION SYSTEM
BEHIND DOORS
CLEAN WITH WET

HEAD CLEANER
NO
NO YES
IF NOT OK,
EXCHANGE UNIT
LOSS OF HIGH ADVISE OWNER
TRY A KNOWN REPAIR AS FREQUENCY. OF WORN OR
GOOD TAPE
^ NECESSARY CLEAN WITH WET DEFECTIVE TAPE
HEAD CLEANER
EXCHANGE
UNIT
YES
•NO EJECT
Do Not Force Rem o val
EXCHANGE ADVISE OWNER of J a m m e d Cassette
UNIT OF WORN OR EXCHANGE UNIT
DEFECTIVE TAPE
948F-17
8F - 8 AUDIO SYSTEMS
RADIO SCHEMATICS INFINITY RADIO

o
00
o
ozS!
O O 3 O I CO
L I
W/O POWER SEATS
STANDARD REAR
RIGHT SPEAKER
6 x 9 STANDARD STANDARD REAR

SPEAKER LEFT SPEAKER J948F-14
ANTENNA TIP OF MAST

TEST POINT
ANTENNA DIAGNOSIS
Turn Ign. Key to

ACC.
Tune to Known
Strong AM Station
Check Antenna
Connections
No
Oieck for Repair as

Reception Using Required*
A Test Antenna RY684
*Be Sure Antenna is
Properly Grounded to Car. Fig. 1 Antenna Test Points
(Poor Grounding of Antenna
May Cause Engine Noise or BENCH T E S T F O R ANTENNA MALFUNCTION
Static Especially on AM) (1) With test lamp and battery i n circuit;
Yes
(a) attach one test lead to concentric pin on
lead-in connector
Replace or Repair (b) other test lead to tip of mast (Fig. 2).
Remove Radio Defective Antenna The lamp should light indicating continuity.
For Service Or Lead in J928M
TESTING
Antenna performance may be tested by substitut
ing a known good antenna. Check short or open cir
cuits with an ohmmeter or test lamp, once the
antenna cable is disconnected from the radio, as fol PR519
lows: Fig. 2 Antenna Bench Test Points
(1) Continuity should be observed between the tip
(2) Keeping one lead on connector pin, clip other
of the mast and radio end pin (Fig. 1).
lead on antenna body assembly. The lamp should
(2) No continuity or a very high resistance of sev
NOT light. I f i t does, look for a short circuit i n the
eral megaohms should be observed between the body or i n the cable, probably at the connector.
ground shell of the connector and radio end pin. (3) Remove clip lead from connector pin and clip on
(3) Continuity should be observed between the outer shell of connector. Connect other clip lead to
ground shell of the connector and the mounting hard antenna body assembly. The lamp should light again.
ware on the fender. I f i t does not light, antenna shielding has an open
circuit.
Wiggle cable over its entire length to reveal
intermittent short or open circuits during steps
1, 2 and 3.
SERVICE PROCEDURES
RADIO REPLACEMENT ELECTRICAL
CONNECTOR
REMOVAL CLIPS
remove assembly.
J948E-10
J948E-8 Fig. 4 Cigar Lighter Removal

Fig. 1 Cup Holder Removal (6) Unplug connector from auxiliary power outlet.
(7) Remove 2 mounting screws from front of radio
(3) Remove 2 screwsfromash receiver (Fig. 2) and (Fig. 5).
remove assembly.
v. J
J948I-9

J948FS
panel to disengage clips (Fig. 3).
Fig. 5 Radio to Instrument Panel Mounting
(8) Pull radio out of instrument panel and discon
nect wiring and antenna (Fig. 6).
(9) Remove screw from ground strap (Fig. 6).
INSTALLATION
(1) Install ground strap.
(2) Install wiring and antenna.
(3) Insert radio into panel and install mounting
screws.
(4) Connect auxiliary power outlet and cigarette
lighter.
(5) Install instrument cluster bezel.
(6) Install cup holder assembly.
J948E-46 (7) Install ash receiver assembly.
Fig. 3 Instrument Bezel Removal/Installation
(5) Unplug connector from cigar lighter (Fig. 4). ANTENNA REPLACEMENT
(5) Lower antenna assembly down far enough to

gain access to antenna body (Fig. 9).
Fig. 6 Radio Connectors

(2) Remove 5 screws holding right side kick panel/
sill trim. Remove kick panel/sill trim.
(3) Remove antenna mast from antenna body (Fig.
Fig. 9 Antenna Mounting

(6) Remove antenna lead and body by pulling an
tenna cable out of cowl and through opening i n cowl
reinforcement.
INSTALLATION
(1) Route antenna cable between fender and cowl
panel to A pillar area.
(2) Insert antenna body through hole i n fender.
(3) Install adapter making sure tab indexes with
Fig. 7 Antenna Mast Removal and Installation opening i n fender and antenna body.
(4) Install cap nut and tighten securely with tool
(4) Remove cap nut using antenna nut wrench C-4816.
C-4816 (Fig. 8). (5) Install mast to antenna body.
(6) From inside vehicle pull cable i n far enough to
connect cable.
(7) Install kick panel/sill trim.
DOOR MOUNTED SPEAKERS

REMOVAL
(1) Remove 2 screws and door pull cup (Fig. 10).
(2) Remove power window/lock switch by reaching
through door pull cup opening and depressing rear
switch retaining tab (Fig. 11).
(3) Pull rear of switch up and away from door.
(4) Unplug connectors from switch (Fig. 12).
(5) Pull power mirror switch control knob rearward
ADAPTER PR517 A to remove from switch (Fig. 13).
(6) Remove switch retaining nut from switch (Fig.
Fig. 8 Cap Nut and Adapter 14).
REMOVE 2 SCREWS
J948S-2
Fig. 10 Door Pull Cup
Fig. 11 Switch Bezel Rear Retaining Tab
Fig. 14 Power Mirror Switch Retaining Nut

Fig. 12 Door Switch Connectors
(3) Install door trim panel by starting with re
To aid in removal of the trim panel, start at tainer closest to the outside mirror. Press retainers
the bottom of the panel. in working around door toward lock button. On high-
(7) Using a device such as a trim stick, pry trim line door panel, continue with fasteners along belt
panel away from door around perimeter and remove line.
trim panel.
(8) Remove screws holding speaker (Fig. 15). REAR SPEAKERS
(9) Disconnect speaker leads. (1) Remove rear screw from sill trim.
(10) Remove speaker. (2) Remove 2 screws holding B pillar trim (Fig.
16).
INSTALLATION (3) Remove B pillar t r i m by:
(1) Connect leads to speaker. (a) gently unhooking top 2 retainer clips by pull
(2) Position speaker into place, install mounting ing inward and forward.
screws and tighten securely. (b) Remove 2 plastic push-in fasteners from bot
tom of panel.
8F - 14 AUDIO SYSTEMS •
RELAY/CHOKE—INFINITY SPEAKERS
I f the audio system is lacking bass, check for con
tinuity across the relay and choke connectors. I f no
continuity, replace relay/choke assembly.
The relay/choke is located behind the instrument
panel, to the right of the RWAL module, i f equipped
(Fig. 17).
Fig. 17 Relay/Choke Assembly

(1) Remove knee blocker (Fig. 18).
Fig. 16 B Pillar Interior Trim

(c) Loosen rear screws of cowl/sill trim.
(d) Slide B pillar t r i m out from under cowl/sill Fig. 18 Knee Blocker Removal
trim. (2) Remove 2 screws holding bottom of RWAL mod
(4) Move t r i m panel far enough to access speaker ule bracket to instrument panel brace (Fig. 19).
screws. (3) Remove screw holding top of RWAL module
(5) Remove screws holding speaker. bracket to instrument panel (Fig. 20) and remove
(6) Pull speaker out and unplug wiring. module.
(7) Reverse removal procedures to install speaker. (4) Remove relay from connector or remove 2
screws and relay/choke assembly (Fig. 17).
(5) Reverse removal procedures to install.
Fig. 19 RWAL Module Lower Mounting Screws Fig. 20 RWAL Module Upper Mounting Screw
• HORNS 8G ~ 1
HORNS
CONTENTS
page page
GENERAL INFORMATION . 1 TEST PROCEDURES 1

SERVICE PROCEDURES 2
The horn system consists of a horn switch, horn re- (PDC) and grounded i n the horn switch. When the
lay (located i n the power distribution center), horns, horn switch on the steering column is pressed, the
and all their wiring and connections. The circuit volt- ground circuit is completed, energizing the relay, and
age is supplied from the power distribution center supplying power to the horns.
TEST PROCEDURES
HORNS WILL NOT SOUND resistance). I f OK, replace relay. I f not, repair open i n
I f the horns do not sound, check for a blown horn circuit between relay and horn.
fuse i n cavity B of the PDC. I f the fuse is blown, re
HORN
place i t with the same type fuse.
• Measure the resistance between the horn connector
HORN R E L A Y pin with black wire and chassis ground. The meter
(1) Remove horn relay from PDC. should read zero ohms. I f not, repair open to ground.
(2) Check for battery voltage at relay cavities 86 and 87. • Disconnect horn connector. Depress horn switch.
There should be battery voltage at the horn connec
If OK, go to next step. I f not, repair open circuit to PDC.
tor pin with dark green with red tracer wire. I f OK,
(3) Depress horn switch. Measure resistance be
replace horn assembly. I f not, repair open to relay.
tween relay cavity 85 and ground. Meter should read
zero ohms. I f not, repair open to horn switch ground. HORNS SOUND CONTINUOUSLY
(4) Measure resistance between relay cavity 30 and
ground. Meter should read almost zero ohms (horn CAUTION: Continuous sounding of horns may
c a u s e relay to fail.
HORN
HI NOTE
RELAY HORN
i ( I N PDC)
r FUSE!
X2-DG/RD
A7 (20 AMP) -Zl BK-i
(IN PDC)
TO
A / C CLUTCH
RELAY
A7 TO HORN
SWITCH
FUSEJM LONOTE
(50 AMP) HORN
(INPDC) T O
HORNS FBSY X2 DG/RD
i
AO CLOCK SPRING
HORN —Zl BK
I N COLUMN
RELAY CONNECTOR
Zl
HORN*
BATTERY SWITCH
= STEERING
COLUMN
1• FRAME
GROUND GROUND J948G-7
8G - 2 HORNS •
(1) Unplug horn relay from connector inside PDC. TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
Plug in a known good relay. If horns stop blowing, re B A G DEPLOYMENT AND POSSIBLE INJURY
lay is defective and must be replaced. If horns still WAIT 2 MINUTES FOR THE RESERVE CAPACITOR
sound, replace original relay and proceed as follows: TO DISCHARGE BEFORE REMOVING OR WORKING
(a) Connect one lead of test lamp to relay termi ON ANY AIRBAG SYSTEM COMPONENTS.
nal 86 (battery) on the relay bank.
(b) Connect the other lead to relay terminal 85 (2) Disconnect and isolate the battery negative ca
(switch) on the relay bank. Should the lamp illumi ble.
nate, either the wire from the horn switch is (3) Gain access to the horn switch connectors as
shorted to ground or the horn switch is defective. described in Horn Switch Replacement.
Continue to next step. (4) Disconnect horn wires located in the lower por
tion of steering wheel.
WARNING: BEFORE BEGINNING ANY AIRBAG SYS
(5) Repeat the previous test and if the test lamp
TEM COMPONENT REMOVAL OR INSTALLATION,
still illuminates, wire is shorted and should be re
REMOVE AND ISOLATE THE NEGATIVE (-) C A B L E
FROM THE BATTERY THIS IS THE ONLY SURE
paired. If test lamp does not illuminate, horn switch
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE is defective and must be replaced.
SERVICE PROCEDURES
HORN SWITCH REPLACEMENT
WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S
TEM COMPONENT REMOVAL OR INSTALLATION,
R E M O V E AND ISOLATE T H E NEGATIVE (-) C A B L E
FROM T H E BATTERY. THIS IS T H E ONLY S U R E
WAY TO D I S A B L E T H E A I R B A G S Y S T E M . F A I L U R E
TO DO THIS C O U L D R E S U L T IN A C C I D E N T A L AIR-
B A G D E P L O Y M E N T AND P O S S I B L E INJURY.
WAIT 2 MINUTES F O R T H E R E S E R V E CAPACITOR
TO D I S C H A R G E B E F O R E REMOVING OR WORKING
ON ANY A I R B A G S Y S T E M OOMPONENTS.
REMOVAL
(2) From underside of steering wheel, remove
speed control switch mounting screws (Fig. 1), i f
equipped.
Fig. 1 Speed Control Switch Removal

(3) Pull switches from wheel and unplug connector
(Fig. 2).
(4) Using a small screwdriver remove right rear
steering wheel cover (Fig. 3).
Fig. 3 Right Rear Steering Wheel Cover
• HORNS 8G - 3
(5) Remove 4 nuts attaching airbag module (Fig.

4).
J948G-2 Fig. 6 Horn Button Removal
Fig. 4 Airbag Module Removal

(6) Remove airbag module from steering wheel.
There are 2 l o c k i n g tabs h o l d i n g h o r n b u t t o n
to steering wheel (Fig. 5).
HORN
CIRCUIT
.CONNECTORS J94SG-S
LOCKING
TABS Fig. 7 Horn Button Connectors
INSTALLATION
(1) Connect electrical leads to horn button termi
nals.
(2) Snap horn buttons into place i n steering wheel.
(3) Position airbag module into place on steering
wheel. Install attaching nuts and tighten to 1.5 N*m
(15 in. lbs.).
(4) Install right rear steering wheel cover.
(5) Plug electrical connector to speed control
J948G-4
switches.
(6) Install speed control switches with 2 screws.
Fig. 5 Horn Button Locking Tabs
(7) Using a small screwdriver pry horn button HORN REPLACEMENT
from steering wheel (Fig. 6). The horn(s) is/are located on the driver's side
(8) Unplug electrical connectors and remove horn bumper support (Fig. 8).
buttons from steering wheel (Fig. 7). (1) Raise vehicle.
(2) Disconnect horn(s) electrical connector.
8G - 4 HORNS •
(3) Remove bolt holding horn bracket to bumper HORN RELAY
support and remove horn. The horn relay is located i n the power distribution
center (PDC) (Fig. 9). Refer to the label on the PDC
cover for relay location.
Fig. 8 Horn Removal and Installation

(4) To install horn(s), reverse the removal proce
dures. Tighten bolt to 20 ft. lbs. Fig. 9 Power Distribution Center
• VEHICLE SPEED CONTROL SYSTEM 8H - 1
WEHiCLE S P E E D CONTROL SYSTEM
CONTENTS
page page
SERVICE PROCEDURES .... 11 TEST PROCEDURES 6
GENERAL INFORMATION the OFF button to unlatch the ON position or turn

The vehicle speed control system (Fig. 1) is electri ing off the ignition erases the memory.
cally actuated and vacuum operated. The electronic con TO SET SPEED: When the vehicle has reached
trol is integrated into the powertrain control module the desired speed push the SET/COAST button to en
(PCM). The PCM is located on the passenger side of the gage system which will then automatically maintain
dash panel in the engine compartment. The controls are the desired speed.
located on the steering wheel and consist of the OFF, TO DECELERATE: When speed control is en
ON/CRUISE, RESUME/ACCEL and SET/COAST but gaged, holding the SET/COAST button depressed al
tons. The system is designed to operate at speeds be lows the vehicle to coast to a lower speed setting.
tween 35 mph (50 km/h) and 85 mph (142 km/h). TO RESUME: After disengaging the speed control
system by tapping the brake or clutch pedal, push
WARNING: THE USE O F VEHICLE SPEED CON the RESUME/ACCEL button to return vehicle to the
TROL IS NOT RECOMMENDED WHEN DRIVING
previously set speed.
CONDITIONS DO NOT PERMIT MAINTAINING A
CONSTANT SPEED, SUCH AS I N HEAVY TRAFFIC TO ACCELERATE: While speed control is en
OR ON ROADS THAT ARE W I N D I N G , ICY, SNOW gaged, hold the RESUME/ACCEL button depressed
COVERED, OR SLIPPERY and release at a new desired speed. This will allow
the vehicle to continuously accelerate and set at a
TO ACTIVATE: By pushing the ON/CRUISE but higher speed setting.
ton to the depressed latched position, ON, the speed TAP-UP: When the speed control system is en
control function is now ready for use. gaged, tapping the RESUME/ACCEL button will in
TO DEACTIVATE: A soft tap of the brake pedal, crease the speed setting by 2 mph (3 km/h). The
normal brake use or clutch pedal use while the sys system will respond to multiple tap-ups.
tem is engaged will disengage speed control without TO ACCELERATE for PASSING: Depress the acceler
erasing memory. A sudden increase i n engine speed ator as you would normally. When the pedal is released the
may be experienced i f the clutch pedal is depressed vehicle will return to the speed setting in memory.
while the speed control system is engaged. Pushing
SH - 2 VEHICLE SPEED CONTROL SYSTEM
OAS ENGINE
WARNING: THE USE OF THI SPEED CONTROL START ENGINE

IS NOT RECOMMENDED WHEN DRIVING
C O N D I T I O N S DO NOT PERMIT M A I N T A I N I N G
A C O N S T A N T SPEED, SUCH A S HEAVY
TRAFFIC O R O N M A D S THAT ARE WINDING, ' ' 1
ICY, SNOW COVERED OR SLIPPERY. SPEED CONTROL
ACCELERATE VEHICLE
ENGAGES WHEN
T O DESIRED SPEED
ENGINE IS STARTED
I
PUSH ON BUTTON FAULTY
TO "ON" POSITION. ELECTRICAL CIRCUIT*
i
SPEED CONTROL ENGAGES
WITHOUT PUSHING THE
i
PUSH AND RELEASE
DEFECTIVE SERVO
"SET/COAST" BUTTON
"SET/COAST" BUTTON
FAULTY ELECTRICAL CIRCUIT* REMOVE FOOT FROM

ACCELERATOR. SPEED
SHOULD BE CONTROLLED
DEFECTIVE SERVO
r
1 f
- NO SPEED CONTROL WHEN J HUNTING SURGE OR EXCESSIVE SAG SPIED SETTING AFTER
SET/COAST BUTTON IS SPEED VARIATIONS O N HILLS OR LOCK-IN, TOO HIGH
PRESSED AND RELEASED AT LOW SPEEDS IN TRAILER T O W I N G OR TOO LOW
f \ 1<
FUSE BLOWN
TORQUE CONVERTER
CLUTCH
ENGINEi
PERFORMANCE
V A C U U M LEAK
ROUGHNESS
f t
AMPLIFICATION
N O V A C U U M AT OF ENGINE VACUUM DEFECTIVE SERVO
SERVO SURGE LEAK
i f f
SPEED CONTROL EXCESSIVE L O A D AAAY
DEFECTIVE
THROTTLE CABLE DEFECTIVE SERVO REQUIRE AAANUAL
CABLE
DISCONNECTED ASSISTANCE ON HILLS
f
DEFECTIVE V A C U U M
IMPROPER STOP LAMP DEFECTIVE DEFECTIVE
RESERVOIR
SWITCH ADJUSTMENT CABLE V A C U U M RESERVOIR
(CHECK VALVE)
1 f
DEFECTIVE
FAULTY ELECTRICAL
POWERTRAIN
CIRCUIT* CONTROL MODULE
"TESTS AND ADJUSTMENTS ARE DESCRIBED

DEFECTIVE SERVO IN APPROPRIATE SECTION OF SERVICE
MANUAL.
DEFECTIVE V A C U U M
RESERVOIR
J938H-8
VEHICLE SPEED CONTROL SYSTEM 8H - 3
DIAGNOSIS CHART 2
DRIVE VEHICLE OVER

ROUGH ROADS
1
UNIT DISENGAGES TAP BRAKE PEDAL
ON ROUGH R O A D S LIGHTLY, SPEED
CONTROL SHOULD
I
IMPROPER
DISENGAGE
i N O SYSTEM
ADJUSTMENT O F STOP DISENGAGEMENT
SPEED C O N T R O L W H E N BRAKE PEDAL
LAMP A N D SPEED
CONTROL SWITCH* DIESENGAGES IS DEPRESSED
I I
DEFECTIVE O R
FAULTY IMPROPERLY ADJUSTED
ELECTRICAL STOP LAMP A N D
PUSH RESUME/ACCEL
CIRCUIT SPEED C O N T R O L
SWITCH VEHICLE
S H O U L D RESUME SWITCH
1
PREVIOUSLY
M E M O R I Z E D SPEED
I
ENGINE DOES
NOT RETURN TO
NORMAL IDLE
I SPEED C O N T R O L
THROTTLE CABLE
KINKED OR DAMAGED
i VEHICLE RESUMES
SPEED
i
I
FAULTY ELECTRICAL
SPEED C O N T R O L
CIRCUIT*
THROTTLE CABLE
KINKED OR D A M A G E D
DEPRESS BRAKE
PEDAL, SPEED
CONTROL
I
DEFECTIVE SERVO
S T A N D A R D THROTTLE SHOULD DISENGAGE
L I N K A G E FAULTS
SPEED C O N T R O L N O SYSTEM
1
RESUME S P E E D
DISENGAGES DISENGAGE IS P O S S I B L E
W H E N BRAKE PEDAL IS B E L O W 20 M . P . H .
DEPRESSED
N O RESUME W H E N
BUTTON IS P R E S S E D
T T
I DEFECTIVE BRAKE
SWITCH
DEFECTIVE VEHICLE
SPEED SENSOR
DEFECTIVE SWITCH
I
FAULTY ELECTRICAL SPEED CONTROL
FAULTY ELECTRICAL
CIRCUIT*
DEFECTIVE
E N G I N E CONTROLLER
CIRCUIT* SYSTEM O K
DEFECTIVE POWERTRAIN
CONTROL MODULE J948H-21
8H - 4 WEH1GLE SPEED CONTROL SYSTEM
DIESEL ENGINE
WARNINGS THE USE OF THE SPEED CONTROL

IS NOT RECOMMENDED WHEN D R I V I N G START ENGINE
CONDITIONS DO N O T PERMIT MAINTAINING
A CONSTANT SPEED, SUCH AS HEAVY
i
TRAFFIC OR ON ROADS THAT ARE WINDING, SPEED CONTROL
ICY, SNOW COVERED OR SUPPERY. ACCELERATE VEHICLE
ENGAGES WHEN
T O DESIRED S P E E D
ENGINE IS STARTED
PUSH ON/CRUISE
FAULTY
BUTTON TO "ON"
ELECTRICAL CIRCUIT*
POSITION
SPEED CONTROL DEFECTIVE SERVO

ENGAGES WITHOUT PUSH AND RELEASE
PUSHING THE "SET/DECEL" BUTTON
"SET/DECEL" BUTTON
X
FAULTY ELECTRICAL CIRCUIT*
I
REMOVE FOOT FROM
ACCELERATOR. SPEED
SHOULD BE CONTROLLED
DEFECTIVE SERVO
I
NO SPEED CONTROL HUNTING SURGE OR
SPEED VARIATIONS
I
EXCESSIVE SAG
O N HILLS OR
SPEED SETTING AFTER
LOCK-IN, TOO HIGH
WHEN SET/DECEL BUTTON
IS PRESSED AND RELEASED AT LOW SPEEDS IN TRAILER TOWING OR TOO LOW
I I
TORQUE CONVERTER ENGINE "INSUFFICIENT
FUSE BLOWN
CLUTCH ROUGHNESS PERFORMANCE VACUUM AT SERVO
X X X
"INSUFFICIENT AMPLIFICATION OF ••INSUFFICIENT
DEFECTIVE SERVO
VACUUM AT SERVO ENGINE SURGE VACUUM AT SERVO
SPEED CONTROL X X
EXCESSIVE LOAD MAY
t
THROTTLE CABLE DEFECTIVE SERVO REQUIRE MANUAL DEFECTIVE CABLE
DISCONNECTED ASSISTANCE ON HILLS
IMPROPER STOP LAMP

X **REFER TO GROUP 5 - BRAKES
DEFECTIVE CABLE
SWITCH ADJUSTMENT FOR VACUUM PUMP DIAGNOSIS.
X I
DEFECTIVE
FAULTY ELECTRICAL
POWERTRAIN
CIRCUIT* CONTROL MODULE
I TEST AND ADJUSTMENTS ARE DESCRIBED

DEFECTIVE SERVO IN APPROPRIATE SECTION OF SERVICE
MANUAL
X
DEFECTIVE ENGINE
SPEED SENSOR
J948H-28
VEHICLE SPEED CONTROL SYSTEM 8H - 5
DIESEL ENGINE CONTINUED
DRIVE VEHICLE OVER

ROUGH ROAD
TAP BRAKE PEDAL

UNIT DISENGAGES LIGHTLY, SPEED
O N ROUGH ROAD CONTROL SHOULD
DISENGAGE
T
IMPROPER
ADJUSTMENT O F SPEED CONTROL N O SYSTEM
STOP LAMP SWITCH* DISENGAGES DISENGAGEMENT
W H E N BRAKE PEDAL
IS DEPRESSED
FAULTY
ELECTRICAL
CIRCUIT
DEFECTIVE OR
IMPROPERLY ADJUSTED
STOP LAMP SWITCH
PUSH RESUME/ACCEL
SWITCH VEHICLE
SHOULD RESUME 11
PREVIOUSLY
SPEED CONTROL
MEMORIZED SPEED
E N G I N E DOES THROTTLE CABLE
N O T RETURN T O KINKED OR DAAAAGED
N O R M A L IDLE
1
VEHICLE RESUMES FAULTY ELECTRICAL

SPEED CONTROL CIRCUIT*
THROTTLE CABLE SPEED
KINKED OR DAAAAGED
r
DEPRESS BRAKE
DEFECTIVE SERVO
STANDARD THROTTLE PEDAL, SPEED
LINKAGE FAULTS CONTROL
SHOULD DISENGAGE
*
i
SPEED CONTROL N O SYSTEM RESUME SPEED
N O RESUME W H I N
DISENGAGE IS POSSIBLE
B U T T O N IS PRESSED DISENGAGES
WHEN BRAKE PEDAL IS BELOW 2 0 M . P . H .
DEPRESSED
DEFECTIVE SWITCH DEFECTIVE DEFECTIVE VEHICLE

POWERTRAIN SPEED SENSOR
CONTROL MODULE
SPEED CONTROL DEFECTIVE

FAULTY ELECTRICAL
SYSTEM O K POWERTRAIN
CIRCUIT* FAULTY ELECTRICAL
CONTROL MODULE
CIRCUIT*
STICKY BRAKE SWITCH J948H-27

8H - 6 VEHICLE SPEED CONTROL SYSTEM •
TEST PROCEDURES
INDEX
page page
Checking for Diagnostic Trouble Code 6 Stop Lamp Switch Test 8
General Information 6 Vacuum Supply Test 8
Inoperative System 6 Vehicle Speed Control Switch Test 8
Road Test 6 Vehicle Speed Control System Electrical Tests 6
Speed Control Cable Attachment 8 Vehicle Speed Sensor Test . . . . . . . . . . . . . . . . . . . 6
Speed Control Cable Attachment—Servo 9
GENERAL INFORMATION strument cluster. I f a DTC is present, the code will

Before starting diagnosis and repair procedures for be displayed i n a series of flashes representing dig
a speed control malfunction, verify that the speed its. Three flashes i n rapid succession, a slight
control wire harness is properly connected to all con pause, then 4 flashes i n rapid succession would in
nectors. Refer to Diagnosis Chart. dicate DTC 34.
(2) I f a DTC 34 is observed, perform the tests i n
ROAD TEST the sections Electrical Tests at Servo and, Electrical
Road test vehicle to verify reports of speed control Tests at Powertrain Control Module.
system malfunction. The road test should include at I f a DTC 15 is observed, perform the test for a
tention to the speedometer. Speedometer operation faulty vehicle speed sensor.
should be smooth and without flutter at all speeds. (3) I f a fault code 11 is observed (diesel only), per
Flutter i n the speedometer indicates a problem form the test for a faulty engine speed sensor. Refer
which might cause surging i n the speed control sys to the Powertrain Diagnostic Procedures manual.
tem. The cause of any speedometer deficiencies (4) Correct any problems found when performing
should be corrected before proceeding. these tests and recheck for DTC i f changes were
made.
INOPERATIVE SYSTEM
I f road test verifies a system problem and the VEHICLE SPEED SENSOR TEST
speedometer operates properly, check for: For testing of the vehicle speed sensor and related
• loose electrical and vacuum connections at the components refer to the Powertrain Diagnostic Proce
servo. dures manual.
• check for correct installation of the vacuum check
valve i n the hose from servo to vacuum source (gas VEHICLE SPEED CONTROL SYSTEM ELECTRICAL
engine only). The word VAC on the valve must point TESTS
toward the vacuum source. Vehicle speed control systems may be tested using
• corrosion that should be removed from electrical two different methods. One involves the use of the
terminals and a light coating of Mopar Multi-Purpose DRB scan tool. I f this test method is desired, refer
Grease, or equivalent, applied. to the Powertrain Diagnostic Procedures manual.
• secure attachment of both ends of speed control ca The other test method uses a voltmeter. The volt
ble.
meter method is described i n the following tests.
I f any information is needed concerning wiring, re
CHECKING FOR DIAGNOSTIC TROUBLE CODE
fer to Group 8W - Wiring Diagrams.
(1) When trying to verify a speed control system
electrical problem, use a DRB scan tool to find the CAUTION: When test probing for voltage or conti
cause. Refer to Powertrain Diagnostic Procedures nuity at electrical connectors, care must be taken
manual. not to damage connector, terminals, or s e a l s . If
I f the DRB scan tool is not available, the diagnostic these components are damaged, intermittent or
trouble code (DTC) may be determined with the fol complete system failure may occur.
lowing method:
(a) With key inserted i n ignition switch, cycle
switch ON-OFF-ON-OFF-ON. On third cycle, leave ELECTRICAL TESTS AT SERVO
switch i n ON position. Refer to Service Procedures for access to servo.
(b) After switch has been cycled, observe mal (1) Turn ignition switch to ON position.
function indicator lamp (Check Engine) on in- (2) Push speed control switch to ON position.
(3) Connect negative lead of a voltmeter to a good

chassis ground near servo,
(4) Disconnect 4-way connector going to servo
(Figs. 1 and 2). Pin 2 of the main harness 4-way con
nector should read approximately battery voltage. I f
not, check for loose connections, brake switch adjust
ment or, repair the main harness as necessary.
(5) Connect a jumper wire between pin 2 of the
4-way servo connector of the main harness and pin 2
of the servo. The other 3 terminals from the servo
should show battery voltage. I f not, replace the servo.
(6) Turn ignition OFF. Using an ohmmeter, connect
one lead to a good body ground. Touch the other lead
to pin 1 i n the 4-way connector of the main harness.
The meter should show continuity. I f not, repair
ground circuit as necessary.
PIN 2 PIN 3
898H-5
Fig. 2 Servo Harness Connector
Location
With the speed control switch i n the OFF position,
the voltmeter should read zero volts. With the speed
control switch i n the ON position, the voltmeter
should read battery voltage. I f not, repair the main
harness as necessary.
Fig. 1 Servo And Harness Connector

ELECTRICAL TESTS AT POWEKTRAIN
CONTROL MODULE
(1) Unplug 60-way connector from powertrain con
trol module, located on the passenger side dash panel
i n the engine compartment (Fig. 3).
(2) Connect negative lead of voltmeter to a good
body ground near the module.
Fig. 4 Powertrain Control Module 60-Way Connector
(3) For the following tests, the ignition switch
Shown from Terminal End
must be i n the ON position. Refer to Fig. 4 for con
troller terminal locations. Touch the positive lead of (4) Touch the positive lead of the voltmeter to the
the voltmeter to the terminal i n cavity number 33. terminal i n cavity number 53. As i n step (3), the volt-
meter should read zero volts with the switch i n the SPEED CONTROL SWITCH CONTINUITY
OFF position, and battery voltage with the switch i n CHART
the ON position.
(5) Touch the positive lead of the voltmeter to the C O N N E C T O R TERMINAL E N D
terminal i n cavity number 48. With the speed control
switch i n the OFF position, the voltmeter should
JE El
read zero volts. With the switch i n the ON position,
the voltmeter should read battery voltage. Pressing
the SET button should cause the voltmeter to change
from battery voltage to zero volts for as long as the
switch is held. I f not, perform the speed control
switch test. I f the switch is not at fault, then check
the main harness and repair as necessary.
(6) Touch the positive lead of the voltmeter to the
terminal i n cavity number 50. The voltmeter should
read zero volts with the speed control switch i n ei
ther the OFF or ON position. With switch i n either
SWITCH
RESUME or SET position, the voltmeter should read
battery voltage. I f not, perform the speed control SPEED CONTftOL SWITCH
switch test. I f the switch is not at fault, then check CONTINUITY
the main harness and repair as necessary.
mmnmsmmi CONTINUITY K T W K N
(7) Touch the positive lead of the voltmeter to the OFF PIN 1 A N D PIN 4
terminal i n cavity number 49. The voltmeter should
PIN 1 A N D PIN 4
read zero volts with the switch i n the OFF position. ON PIN 1 A N D PIN 2
With the switch i n the ON position, the voltmeter PIN 2 A N D PIN 4
should read battery voltage. The voltmeter will con ON AND SET PIN 1 A N D PIN 2
tinue to read battery voltage when either the SET or PIN 1 A N D PIN 3
O N A N D RESUME
RESUME switch is pressed. I f not, perform the speed
control switch test. I f the switch is not at fault, then J948H-30
check the main harness and repair as necessary . (a) With switch plunger released, there should be
(8) Turn ignition switch OFF. Using an ohmmeter, continuity between pin 5 and pin 6.
connect one lead to a good body ground and touch the (b) With switch plunger depressed, there should
other lead to the terminal i n cavity number 29. With be continuity between pin 1 and pin 2.
the brake pedal released, the meter should show con
(c) With switch plunger still depressed, there
tinuity. When the pedal is depressed, the meter
should be continuity between pin 3 and pin 4.
should show open circuit.
(4) I f the switch fails the above continuity tests, i t
(9) DIESEL ONLY. The diesel engine PCM re
is defective. Replace switch. I f switch is OK, reinstall
quires a signal from the engine speed sensor to cav
and check adjustment. Refer to Service Procedures -
ity number 24. To diagnose the engine speed sensor,
refer to the appropriate Powertrain Diagnostic Proce Stop Lamp Switch for correct installation and adjust
dures manual. ment procedures.
VEHICLE SPEED CONTROL SWITCH TEST VACUUM SUPPLY TEST

To check the switch, remove the switch from its (1) Disconnect vacuum hose at the servo and in
mounting position. Refer to Service Procedures for stall a vacuum gauge i n the hose.
access to switch. Use an ohmmeter and refer to the (2) Start engine and observe gauge at idle. Vacuum
Switch Continuity Chart to determine i f continuity is gauge should read at least ten inches of mercury.
correct. I f there is no continuity at any one of the (3) I f vacuum does not meet this requirement,
switch positions, replace the switch. check for vacuum leaks or poor engine performance.
F o r diesel engine refer to Group 5 - Brakes
STOP LAMP SWITCH TEST for vacuum pump diagnosis.
(1) Remove the stop lamp switch from the mount
ing bracket. Refer to Service Procedures - Stop Lamp SPEED CONTROL CABLE ATTACHMENT
Switch. Attach the speed control cable to the throttle body
(2) Disconnect switch from wiring harness. lever as follows:
(3) Using an ohmmeter, check switch continuity (1) Open throttle lever to completely expose nail
(Fig. 5) as follows: head.
wii PLUNGER
INDEX KEY 948H-6
Fig. 5 Stop Lamp Switch

(2) Position cable end fitting over nail head, then
allow throttle to close.
(3) Hold throttle closed and apply pressure to cable
J948H-23
until end fitting snaps onto nail head.
SPEED CONTROL CABLE ATTACHMENT—SERVO Fig. 6 Speed Control Cable Attachment at Servo
The speed control cable is attached to the servo verify that the clip is in place. I f the clip is missing
with a hair-pin clip (Fig. 6). A check should be made to the speed control system will be inoperative.
VEHICLE SPEED CONTROL SYSTEM SCHEMATIC
POWERTRAIN CONTROL SPEED

CONTROL
SPEED 2
1 -V36-
-V35-
33
zr
MODULE
53 29 49 48 50 Z
—tl SPEED
SWITCH
SWITCH
CONTROL RESUME/
SERVO 3 -V30- OFF# |iJON
ON ACCEL.
lACC
4 -Zl- -Zl- [SET
1Zl COAST,7 O N / O ON N
"#12 V30 V 4 0 3? V31 ^
f
\ c c _ - A c e — mJI
jj—OFF-+-OFF-+J
2^
-A21- rill
#10
1 V32 V33
OFF
RUN V34
IGNITION CLOCK SPRING
SWITCH ACC t <S *!S
1 4
FUSE #10
1 START
(2 AMP) h
L-V33- X3
1 R !-V31
Al •V32
L A3 A3
A; L-V40-
2
FUSE#6 it
1 L50
J
V32 150
i
(40 AMP) u3
FUSE#3 FUSE #20

(40 AMP) (15 AMP)
Zll
i
T
AO
T t Zll
TO ABS TO
MODULE CHMSL
TO HORN
RELAY
F32 Zll
Z0 -L50-
1 TO HEADLAMP
STOP LAMP AND SPEED
CONTROL SWITCH
.
BODY BATTERY SWITCH J
GROUND 330 OHM 2 WATT J948H-1
8H - 10 VEHICLE SPEED CONTROL SYSTEM
SPEED CONTROL DIAGNOSTIC TROUBLE CODE (DTC)
Diagnostic D l i Scan Tool

Trouble Display Description of Diagnostic Trouble Code
Glide
11 * No Crank Reference No crank reference signal detected during engine cranking.

Signal at PCM
15"........ No Vehicle Speed No vehicle distance (speed) sensor signal detected during road load conditions.
Sensor Signal
34* Speed Control An open or shorted condition detected in the Speed Control vacuum or vent solenoid
Solenoid Circuits circuits.
or
Speed Control
Switch Always Low Speed Control switch input below the minimum acceptable voltage.
or
Speed Control
Switch Always High Speed Control switch input above the maximum acceptable voltage.
55V N/A
Completion of fault code display on Check Engine lamp.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described
in manualand observe code flashed by Check Engine Lamp.
*'Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
J948H-26
SERWiCE PROCEDURES
INDEX
page page
Engine Speed Sensor—Diesel Engine .......... 16 Speed Control Vacuum Reservoir Replacement—
Servo Throttle Cable Assembly 13 Gas Engines 15
Servo Unit—V-10 and Diesel Engines .......... 11 Stop Lamp Switch Replacment 16
Servo Unit—V-6 and V-8 Engines 11 Vacuum Pump—Diesel Engine 16
Speed Control Switch Replacement 15
SERVO UNIT—V-6 AND V-8 ENGINES (2) With throttle blocked to full open position,
align hole i n cable sleeve with hole i n servo pin and
REMOVAL install hairpin clip.
(1) Disconnect vacuum hose at servo (Fig. 1). (3) Insert servo studs through holes i n cable
(2) Disconnect electrical'connector at servo. sleeve.
(4) Install 2 attaching nuts and tighten to 6 N-m
(50 in. lbs.).
(5) Connect vacuum hose to servo.
(6) Connect electrical connector to servo terminals.
SERVO UNIT—V-10 AND DIESEL ENGINES
REMOVAL
(1) Disconnect both battery cables, negative cable
first.
(2) Remove 2 bolts and battery holddown (Fig. 2).
Fig. 2 Battery Holddown

Fig. 1 Servo Mounting
(3) Pull up on battery heatshield (if equipped) to
(3) Remove 2 nuts from cable sleeve. remove i t (Fig. 3).
(4) Pull speed control cable away from servo to ex (4) Remove battery from vehicle.
pose cable hairpin clip. (5) From under left front wheel opening remove 2
(5) Remove hairpin clip attaching cable to servo. forward battery tray nuts (Fig. 4).
(6) Pull servo away from mounting bracket. (6) Remove 2 nuts and 2 bolts holding battery tray
to vehicle (Fig. 5).
INSTALLATION (7) Lift battery tray up far enough for access to
(1) Insert servo studs through holes i n servo speed control servo electrical connector (Fig. 6).
mounting bracket. (8) Unplug electrical connector.
(9) Remove 2 nuts from cable sleeve.
Fig. 3 Battery Heatshield
Fig. 4 Forward Battery Tray Nuts—Viewed From Fig. 6 Speed Control Servo Mounting
Under Vehicle (2) With throttle blocked to full open position,
(10) Pull speed control cable away from servo to align hole i n cable sleeve with hole i n servo pin and
expose cable hairpin clip (Fig. 7). install hairpin clip.
(11) Remove hairpin clip attaching cable to servo. (3) Insert servo studs through holes i n cable
(12) Pull servo away from mounting bracket. sleeve.
(4) Install 2 attaching nuts and tighten to 6 N-m
INSTALLATION (50 i n . lbs.).
(1) Insert servo studs through holes i n servo (5) Connect vacuum hose to servo.
mounting bracket. (6) Connect electrical connector to servo terminals.
SERVO THROTTLE CABLE ASSEMBLY

REMOVAL
(1) Remove air cleaner (except V-10 and diesel).
(2) Using finger pressure only, remove speed con
trol cable connector at bell crank by PUSHING con
nector off the bell crank (Fig. 8, 9 or 10). DO NOT
try to pull connector off perpendicular to the bell
crank.
(3) Squeeze tabs on speed control cable and push
out of locking plate.
(4) Remove servo cable from servo as described un
der Servo Unit - Removal.
Fig. 7 Speed Control Cable Attachment at Servo

(7) Install battery tray. Tighten all battery tray
mounting hardware to 16 N-m (140 in. lbs.).
(8) Install battery i n vehicle making sure that bat
tery is properly positioned on battery tray.
(9) Install battery heat shield, i f equipped.
that i t is properly positioned on battery. Tighten bolt
to 4 N-m (35 i n . lbs.).
Fig. 8 Speed Control Cable—V6/V8 Typical

Fig. 10 Speed Control Cable—Diesel
INSTALLATION SPEED CONTROL VACUUM RESERVOIR

(1) Install cable as described under Servo Unit - REPLACEMENT-GAS ENGINES
Installation. The vacuum reservoir is located i n the cowl area
(2) Route cable from servo, through cable support near the windshield wiper linkage.
bracket, and install cable on nail head stud.
(3) Install air cleaner (except V-10 and diesel). REMOVAL
SPEED CONTROL SWITCH REPLACEMENT CAUTION: The use of a screwdriver or other prying
(1) Disconnect negative cable from battery. tool to remove a wiper arm may distort it. This dis
tortion could allow the arm to come off the pivot
WARNING: TO AVOID AN ACCIDENTAL A I R B A G D E shaft, regardless of how carefully it is installed.
PLOYMENT A L L O W S Y S T E M CAPACITOR T O DIS
C H A R G E FOR 2 MINUTES B E F O R E P E R F O R M I N G (1) Lift wiper arm to permit the latch (Fig. 13) to
SERVICE PROCEDURES.
be pulled out to the holding position. Remove arm
from pivot using a rocking motion.
speed control switch mounting screws (Fig. 11).
Fig. 13 Removing Wiper Arm

(2) Remove weatherstrip along front edge of cowl
grille (Fig. 14).

(3) Pull switches from wheel and unplug connector
(Fig. 12).
Fig. 14 Cowl Grille Weatherstrip
Fig. 12 Speed Control Switches

(4) Plug electrical connector into new switches.
(5) Install new switches with 2 screws.
(3) Release plastic anchor screws (Fig. 15). (4) Position cowl grille on vehicle. Push plastic
screw anchors into place.
PLASTIC /
/
(5) Install wiper arms (refer to Group 8K - Wind
SCREW A N C H O R
shield Wiper and Washers).
STOP LAMP SWITCH REPLACMENT

REMOVAL
(1) Pull connector from switch.
(2) Remove switch from bracket by depressing
brake pedal and rotating switch in a counterclock
wise direction 1/8 turn (Fig. 8).
(3) Pull switch rearward and remove from bracket.
INSTALLATION
PULL PLUNGER
J948K-4
Fig. 15 Plastic Anchor Screws

(4) Lift cowl grille from vehicle and lay aside.
(5) Remove 2 pushnuts and slide vacuum reservoir
off studs (Fig. 16).
VACUUM INDEX KEY 948H-6

RESERVOIR
Fig. 17 Stop Lamp Switch

(1) Before installing switch, ensure adjustable
switch plunger is completely extended. Pull plunger
out until i t reaches the end of its travel, approxi
mately 3/4 inch from collar to end of plunger. A click
ing sound will be heard during this procedure.
(2) With brake pedal depressed, align key on
switch locking collar to slot i n switch mounting
bracket square hole. Press switch forward into
bracket until collar is seated flush to bracket. Rotate
switch clockwise 1/8 turn.
J948H4 (3) Release brake pedal. Switch plunger will adjust
to correct setting.
Fig. 16 Vacuum Reservoir (4) Plug connector into switch.
(6) Disconnect all hoses. VACUUM PUMP—DIESEL ENGINE
Refer to Group 5 - Brakes for removal and instal
INSTALLATION
lation of the vacuum pump.
(1) Connect hoses to vacuum reservoir.
(2) Install vacuum reservoir onto bracket studs. ENGINE SPEED SENSOR—DIESEL ENGINE
(3) Install 2 pushnuts on studs. Refer to Group 14 - Fuel System; Diesel Engine
section, for removal and installation procedures.
• TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1
TURN SIGNALS AND HAZARD WARNING FLASHER
CONTENTS
page page
GENERAL INFORMATION 1 MULTI-FUNCTION SWITCH TESTING

MULTI-FUNCTION SWITCH SERVICE PROCEDURES ... 2
PROCEDURES 3
WARNING: BEFORE SERVICING A STEERING COL
UMN EQUIPPED WITH A N A I R B A G , REFER TO
GROUP 8M - RESTRAINT SYSTEMS FOR PROPER
AND SAFE SERVICE PROCEDURES.
BUZZER
TURN SIGNALS MODULE
DESCRIPTION
The turn signals are actuated with a lever on the
left side of the steering column just behind the steer
ing wheel. The signals are turned off by a canceling
cam (two lobes molded to the clockspring mecha
nism). The cam comes in contact with the cancel ac INSTRUMENT
... ...fANEL.......
tuator on the turn signal (multi-function) switch
assembly. Either cam lobe, pushing on the cancel ac
tuator, returns the switch to the off position. Fig. 1 Fuse Block/Flasher Location
With the ignition switch ON, and the multi-func
tery voltage at the fuse side of the turn signal flasher
tion lever i n its up or down position, current flows
(top terminal). I f not, repair open circuit in wiring
through the.
between fuse and flasher.
• turn signal flasher canister
• multi-function switch (4) Replace turn flasher with 2 lamp 12-volt rated
• turn indicator lamp flasher, that is known to be good. With ignition
• front and rear turn signal bulbs. switch in ON position, and turn stalk moved up or
The selected turn signal indicator with front and down, the lamps should flash. I f not, replace with
rear turn signal bulbs will flash. original flasher and go to next step.
(5) Locate the multi-function switch connector. Re
DIAGNOSIS—TURN SIGNAL INOPERATIVE fer to Multi-Function Switch Testing Procedures.
High generator output voltage can burn out Measure voltage at the multi-function switch connec
lamps rapidly. tor cavity 17. Meter should read battery voltage. I f
(1) Turn ignition switch to ON position. Place turn OK, replace multi-function switch. I f not, repair open
stalk in up or down position. Observe the turn indi circuit in wiring between flasher and multi-function
cator arrow on instrument cluster. I f the arrow re switch connector cavity 17.
mains lit, check for burned out exterior turn signal
bulb, replace as required. Turn indicator should now HAZARD WARNING SYSTEM
flash, i f not go to next step.
(2) Remove and inspect fuse i n cavity #6 of fuse- DESCRIPTION
block module. Replace i f necessary. The fuseblock The hazard warning flashers are actuated by a
module is located in the left end of the instrument push button located on the top of the steering column
panel (Fig. 1). between the steering wheel and the instrument
(3) With ignition switch in ON position, return panel. The hazard switch is identified with a double
turn stalk to neutral position. There should be bat-
8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER
triangle. Push and release the button to turn the (1) Measure voltage at fuse side of flasher (top ter
hazard function ON and OFF. The button will move minal). Meter should read battery voltage. I f not, re
out from the steering column i n the ON position, and pair open circuit in wiring to fuse.
will remain i n (toward the column) in the OFF posi (2) Replace hazard flasher with known good
tion, flasher. With hazard switch ON, lamps should flash.
With the hazard switch OUT, current flows through I f not, replace with original flasher and go to next
the: step.
• hazard flasher (3) Locate the multi-function switch connector. Re
• multi-function switch fer to Multi-Function Switch Testing Procedures.
• two front turn signal bulbs With hazard switch OFF, measure voltage at the
multi-function switch connector cavity 13. Meter
• two rear turn signal bulbs
should read battery voltage. I f not, repair open cir
• both indicator bulbs.
cuit in wiring to hazard flasher.
All of the turn lamps and both indicators will flash.
DIAGNOSIS—HAZARD FLASHER
TURN SIGNAL AND HAZARD WARNING FLASHER
INOPERATIVE LOCATION
Hazard switch in ON. The park and stop lamps The turn signal and hazard warning flashers are
should light. I f not replace the 15 amp hazard lamps both located on the fuseblock module (Fig. 1). The
fuse i n power distribution center. fuseblock module is located in the left end of the in
strument panel.
MULTI-FUNCTION SWITCH T E S T I N G PROCEDURES
The multi-function switch contains electrical cir STEERING
cuitry for: COLUMN
ASSY.
• turn signal
• hazard warning
• headlamp beam select
• headlamp optical horn
• windshield wiper
• pulse wipe
• windshield washer.
This integrated switch assembly is mounted to the
left-hand side of the steering column. Should any
TURN S I G N A L
function of the switch fail, the entire switch assembly SWITCH A N D
MULTI
must be replaced. FUNCTION LEVER
To test the switch: SWITCH
J918J-1 CONNECTOR
(2) Remove upper and lower column covers to gain
Fig. 2 Multi-Function Switch Connector—Typical
access to the switch connector.
(3) Remove switch connector (Figs. 2 and 3).
(4) Using an ohmmeter, test for continuity (no re SWITCH
H A L O LIGHT
sistance) between the terminals of the switch, as
shown i n the following continuity chart (Fig. 4).
TURN S I G N A L
SWITCH & LEVER
IGNITION SPEED
SWITCH CONTROL J918J-2
Fig. 3 Steering Column Connectors

• TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3
VIEW FROM TERMINAL CASE
SWITCH POSITIONS
TURN SIONAl HAZARD WARNING CONTINUITY BETWEEN
NEUTRAL OFF 12 AND 14 AND 15
LEFT OFF 15 AND 16 AND 17
LEFT OFF 12 AND 14
LEFT OFF 22 AND 23 WITH OPTIONAL CORNER LAMPS
RIGHT OFF 11 AND 12 AND 17
RIGHT OFF 14 AND 15
RIGHT OFF 23 AND 24 WITH OPTIONAL CORNER LAMPS
NEUTRAL ON 11 AND 12 AND 13 AND 15 AND 16
908J-4
Fig. 4 Turn Signal and Hazard Switch Continuity Chart
MULTI-FUNCTION SWITCH S E R V I C E P R O C E D U R E S
REMOVAL HAZARD WARNING
(2) Remove tilt lever (tilt column only).
(3) Remove both upper and lower steering column
covers.
(4) Remove multi-function switch tamper proof
mounting screws (tamper proof torx bit Snap On
TTXR20B2 or equivalent required).
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remain i n the con
nector.
(6) Remove wiring connector from multi-function
switch (Fig. 5).
908J-9
INSTALLATION
(1) Install wiring connector to switch and tighten Fig. 5 Multi-Function Switch
connector retaining screw to 2 N-m (17 in. lbs.)
torque. (4) Install tilt lever (tilt column only).
(2) Attach multi-function switch to column and (5) Install negative cable to battery.
torque retaining screws to 2 N-m (17 in. lbs.). (6) Check all functions of switch for proper opera
(3) Install steering column covers. Torque retaining tion.
screws to 2 N-m (17 in. lbs.).
• WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 1
WINDSHIELD WIPER AND WASHER SYSTEMS
CONTENTS
page page
WINDSHIELD WASHERS 11 WINDSHIELD WIPER SYSTEM SERVICE

WINDSHIELD WIPER FUNCTION AND SWITCH PROCEDURES .. 8
TESTING PROCEDURES 5
WINDSHIELD WIPER MOTOR TESTING
PROCEDURES 1
GENERAL INFORMATION has a range of 2 to 15 seconds. This is accomplished

The windshield wipers can be operated with the by a variable resistor i n the wiper switch and is con
windshield wiper switch only when the ignition trolled electrically by a control module.
switch is i n the ACCESSORY or ON position. Fuse The wiper system completes the wipe cycle when
cavity 3, located i n the fuseblock module, protects the the switch is turned OFF. The blades park in the
circuitry of the wiper system. lowest portion of the wipe pattern.
The wiper motor has permanent magnet fields. The Depressing the washer knob while the system is i n
speeds are determined by current flow to the appro the OFF position,
priate set of brushes. • turns the wiper motor on
The intermittent wipe system i n addition to low • allows the motor to operate through 3-4 wipe cy
and high speed, has a delay mode. The delay mode cles and then turn OFF.
WINDSHIELD WIPER MOTOR TESTING PROCEDURES
The following is a list of general wiper motor sys- only the delay mode, switch, or wiring, refer to the
tern problems. I t contains the tests that are to be Intermittent Windshield Wiper Function Testing Pro-
performed to locate the faulty part, and the correc- cedures.
tive action to be taken. I f the malfunction involves
8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS
MOTOR RUNS
I MOTOR RUNS I BLADES SLAP

BLADES DO AGAINST
NOT PARK i U T OUTPUT BLADES
CRANK DOES WINDSHIELD CHATTER
NOT TURN MOULDINGS
I O N DRY GLASS
I MOTOR STOPS I MOTOR STOPS! MOTOR WILL
IN ANY NOT STOP LINKAGE N O T FOREIGN
BLADES DO
POSITION [ WHEN SWITCH | FASTENED A R M S LOOSE SUBSTANCE SUCH
| WHEN SWITCH NOT PARK
PROPERLY
IS TURNED PROPERLY TO O N PIVOT SHAFT AS BODY POLISH
IS TURNED "Off" MOTOR OUTPUT O N GLASS OR
"Off"
SHAFT X BLADES
A R M SET A T
DEFECTIVE
t ARM
TWISTED A R M
OPEN PARK INCORRECT IMPROPERLY
WIRING CIRCUIT POSITION MOTOR DEFECTIVE POSITIONED O N HOLDS BLADE A T
MOTOR PIVOT SHAFT W R O N G ANGLE
t f TO GLASS
A R M S LOOSE LOOSENESS OF
FAULTY SWITCH BENT OR
O N PIVOT SHAFT THE MOTOR
MOTOR WILL DAMAGED
CRANK OR OTHER
HOT RUN BLADES
DRIVE PARTS
LOOSE LINKAGE | A ¥ A N Y SPEEDl
DEFECTIVE DEFECTIVE
AT MOTOR
MOTOR MOTOR
CONNECTION
I WIPER BLADES |
WIPER OPERATING
KNOCK PROPERLY
MOTOR
WILL NOT
WIPER KNOCK
RUN WIPER KNOCKS
AT OTHER
AT EXTREME
T H A N EXTREME
WIPE
CHECK WIPE
VOLTAGE t
AT MOTOR A X I A L OR W O R N ARMATURE
— T ~ OUT FREEPLAY END PLAY
IN LINKAGE IN MOTOR
I
VOLTAGE
PRESENT REPLACE
MOTOR
I
DEFECTIVE
MOTOR CHECK i 5 * l REMOVE
FUSE §-*» MOTOR
SWITCH
BLOWS 1 CONNECTOR
CHECK
GROUND REPLACE
FUSE
I MOTOR RUNS |
BLADES DO
NOT MOVE
REPLACE FUSE
MOTOR BLOWS
JL
OUTPUT OUTPUT
SHAFT SHAFT f
STATIONARY ROTATES CHECK CHECK
WIRING SWITCH
REPLACE LOOSE BAD

A R M S LOOSE
MOTOR MOTOR LINKAGE
CRANK CONNECTION
ON PIVOT SHAFT
CONDITION (a) If fuse does not blow, motor is defective.

Motor will not ran in any switch position. (b) If fuse blows, switch or wiring is at fault.
PROCEDURE CONDITION
(1) Check for a blown fuse in the fuseblock module. Motor runs slowly at all speeds.
(a) If fuse is good, proceed to step (2).
PROCEDURE
(b) If fuse is defective, replace and check motor (1) Disconnect wiring harness connector at motor.
operation in all switch positions. Remove wiper arms and blades. Connect an ammeter
(c) If motor is still inoperative and the fuse does between battery and terminal "L" on motor (Fig. 2).
not blow, proceed to step (2).
(d) If replacement fuse blows, proceed to step (5).
(2) Place switch in low speed position.
(3) Listen to motor. If you cannot hear it running,
proceed to step (4). If you hear it running, check mo
tor output shaft. If output shaft is not turning, re
place motor assembly. If it is turning, crank arm or
drive link is not properly connected. Replace worn
parts and/or properly connect drive link to the motor
output shaft.
(4) Connect a voltmeter between motor terminal
"IT and ground strap (Fig. 1). If there is no voltage or
very little voltage (less than one volt) present, move
negative test lead from the ground strap to battery
negative terminal. Fig. 2 Ammeter Between Terminal "L" and Battery
VOLTMETER WIPER (a) If motor runs and average ammeter reading

is more than 6 amps, proceed to step (2).
(b) If motor runs and average ammeter reading
is less than 6 amps, proceed to step (3).
(2) Check to see if wiper linkage or pivots are bind
ing or caught. Disconnect drive linkfrommotor.
(a) If motor now runs and draws less than 3
amps, repair linkage system.
(b) If motor continues to draw more than 3 amps,
replace motor assembly.
(3) Check motor wiring harness for shorting be
tween high and low speed wires as follows:
(a) Connect a voltmeter or test lamp to motor
ground strap.
(b) Set wiper switch to LOW position.
(c) Connect other lead of voltmeter (test lamp) to
Fig. 1 Voltmeter Between Terminal "L" and Ground terminal "W of the wiring harness.
(d) If voltage is present, there is a short in the
(a) If an increase in voltage is noticed, the prob wiring or wiper switch. If no voltage is present?pro-
lem is a bad ground circuit. Make sure the motor ceed to step (e).
mounting is free of paint and that nuts or bolts are (e) Set wiper switch to HIGH position.
tight. (f) Move voltmeter (test lamp) leadfromterminal
(b) If there is still no indication of voltage, the a
H" to terminal "IT of the wiring harness.
problem is an open circuit in the wiring harness or (g) If voltage is present, there is a short in the
wiper switch. wiring or wiper switch.
(c) If no noticeable increase (greater than 3 volts)
in voltage is observed, the problem is a faulty mo CONDITION
tor assembly. Motor will r u n at high speed, but not at low
(5) Disconnect motor wiring connector and replace speed. Motor will r u n at low speed, but not at
fuse. high speed.
8K - 4 WINDSHIELD WIPER AND WASHER SYSTEMS •
PROCEDURE
(1) I f motor will not run on high speed, put switch TERMINALS
in HIGH position and connect a test lamp between
motor terminal "H" and ground (Fig. 3).
TERMINAL
"H"
WIPER
MOTOR
/
J948K-26
WIPER Fig. 4 One Jumper Wire Between Terminal "P2" and

MOTOR GROUND J948K-25
"L". One Jumper Wire Between Terminal "PI"and
"B+"
Fig. 3 Test Lamp Between Terminal "H" and Ground
nector. Connect a voltmeter or test lamp to the motor
I f motor will not run on low speed, put switch i n ground strap. Connect the other lead to terminal "PI"
LOW position and connect a test lamp between motor of wiring connector.
terminal "L" and ground. (a) I f voltage is not present, check for an open
(2) I f test lamp does not light at motor terminal, circuit i n the wiring harness or wiper control
there is an open i n wiring or switch. I f test lamp switch or fuse.
lights at motor terminal, replace motor assembly. (b) I f voltage is present, proceed to step (3).
(3) Remove wiper motor from vehicle and connect
CONDITION an ohmmeter or continuity tester between terminals
Motor will keep running with switch i n O F F "L" and "P2" (Fig. 5).
position. OHMMETER TERMINALS
PROCEDURE
(1) Remove wiring harness. Connect jumper from
terminal P2 to terminal "L" of wiper motor (Fig. 4).
(2) Connect second jumper from terminal " P I " to
battery. I f motor runs to PARK position and stops,
wiper switch is faulty. I f motor keeps running and
does not park, replace motor assembly.
CONDITION
Motor will stop wherever it is, when column
switch is put in O F F position. (Wipers do not
continue running to PARK position). J948K-27
PROCEDURE Fig. 5 Ohmmeter Between Terminal "V and "P2"

(1) Remove motor wiring connector and clean ter
(a) I f there is continuity between these termi
minals. Reconnect connector and test motor. I f prob
nals, the problem is a defective motor.
lem persists, proceed to step (2). (b) I f there is no continuity, the problem is an
(2) Put wiper switch to OFF and ignition switch to open circuit i n the wiper control switch or wiring
ACCESSORY position. Disconnect motor wiring con- harness.
WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 5
WINDSHIELD WIPER FUNCTION AND SWITCH TESTING PROCEDURES

MULTI-FUNCTION SWITCH TESTING PROCEDURES STEERING
The multi-function switch contains circuitry for: COLUMN
ASSY.
• turn signal
• hazard warning
• headlamp beam select
• headlamp optical horn
• windshield wiper
• pulse wipe
• windshield washer.
This integrated switch assembly is mounted to the
left-hand side of the steering column. Should any
TURN S I G N A L
function of the switch fail, the entire switch assembly MULTI- SWITCH A N D
must be replaced. FUNCTION LEVER
To test the switch: SWITCH
J918J-1 CONNECTOR
(2) Remove tilt lever (tilt column only). Fig. 2 Multi-Function Switch Connector
(3) Remove upper and lower column covers to gain
access to the switch connector (Fig. 1). KEY-IN SWITCH & MULTI-FUNCTION
H A L O LIGHT SWITCH
UPPER SHROUD GROUND UPPER
FIXED SHROUD
SUPPORT BRACKET
TURN S I G N A L
SWITCH & LEVER
WIRE HARNESS
CONNECTOR
IGNITION SPEED
SWITCH CONTROL J918J-2
WASHER
Fig. 3 Steering Column Connectors
INTERMITTENT WIPER FUNCTION TESTING
PROCEDURES
LOWER These tests involve disconnecting the intermittent
LOWER FIXED wipe control module. The module is located on the in
SHROUD SHROUD J9119-22
strument panel support bracket behind the knee
blocker (Fig. 4).
Fig. 1 Steering Column Cowers
(4) Remove lower fixed column cover. CONDITION
(5) Loosen steering column upper bracket nuts. Do Excessive delay (more than 30 seconds) or in
Not remove nuts. adequate variation in delay.
(6) Move upper fixed column cover to gain access
to rear of multi-function switch. PROCEDURE
(7) Remove switch connector (Figs. 2 and 3). Variations i n delay should be as follows:
(8) Using an ohmmeter, test for continuity (no re (1) Minimum delay (delay control to extreme coun
sistance) between the terminals of the switch as terclockwise position before first detent) 1/2 to 2 sec
shown i n the continuity chart. onds.
(9) Refer to Service Procedures for assembly. (2) Maximum delay (delay control to extreme clock
wise position before off detent) 10 to 30 seconds.
(3) I f there is excessive delay or no variations i n
delay proceed to intermittent wipe switch test.
I N T E R M I T T E N T WIPE SWITCH CONTINUITY
CHART
JT i I i= i)
INTERMITTENT
J
= = £ I WIPER MODULE
^ 5^4 3 2 1
1 JT
1L
MULTIFUNCTION SWITCH PINS
SWITCH CONTINUITY
POSITION iETWEiN
OFF PIN 6 AND PIN 7
PIN 8 AND PIN 9
PIN 2 AND PIN 4
DELAY PIN 1 AND PIN 2
PIN 1 AND PIN 4
LOW PIN 4 AND PIN 6
HIGH PIN 4 AND PIN 5
WASH PIN 3 AND PIN 4
'RESISTANCE AT AAAXIMUM DELAY POSITION SHOULD BE
BETWEEN 270,000 OHMS AND 330,000 OHMS.
J948K-1
'RESISTANCE AT MINIMUM DELAY POSITION SHOULD BE
ZERO WITH OHMMETER SET ON HIGH OHM SCALE.
Fig. 4 Intermittent Wipe Module Location
918J-4
(2) Verify that the motor ground strap is making
CONDITION good contact and that the motor mounting bolts are
I n D E L A Y mode wipers r u n continually when tight.
wash is operated but do not provide an extra (3) Verify that the wiring ground connections for
wipe when the wash control is released.
the intermittent wipe control unit and the wiper
PROCEDURE switch are tight.
Replace the control unit. (4) If condition is not corrected, replace control
unit.
CONDITION
Wipers start erratically during D E L A Y mode. INTERMITTENT WIPE MODULE LOCATION
The module is located on the instrument panel sup
PROCEDURE port bracket behind the knee blocker (Fig. 4).
(1) Verify that the ground connection at the instru
ment panel is making good connection (free from
paint) and is tight.
INTERMITTENT WIPER SYSTEM SCHEMATIC
INTERMITTENT
WIPER SWITCH
5 !' ° WASHER A ^
• ® SWITCH/ ^ TO
CLUSTER G29
i
LOW WASHER
FLUID LEVEL
SENSOR
GROUND 5
PARK 6
INTERMITTENT 7
DELAY 1
DELAY INPUT 8
WASHER 2
FEED (B+) 4
WIPER MOTOR 3
FRAME
INTERMITTENT GROUND
WIPER CONTROL
MODULE
FUSE #8
(20 AMP)
INTERMITTENT
WIPER MOTOR
10 IGNITION
SWITCH
BODY -L
GROUNDT J948K-2
WINDSHIELD WIPER S Y S T E M S E R V I C E P R O C E D U R E S
INDEX
page page
Installation 11 Wiper Blade Replacement 8
Linkage Replacement 10 Wiper Blades ..... 8
Pivot Assemblies 10 Wiper Motor Replacement 9
Wiper Arm Replacement . . . 8 Wiper Switch Replacement 10
Wiper Blade Element Replacement 8
WIPER BLADES (5) For installation reverse above procedures.

Wiper blades exposed to the weather for a long pe When complete turn ignition switch ON. Turn wiper
riod of time tend to lose their wiping effectiveness. switch OFF allowing the wiper blades to PARK, then
Periodic cleaning of the wiper blade is suggested to turn ignition switch OFF.
remove the accumulation of salt and road film. The
wiper blades, arms and windshield should be cleaned WIPER BLADE ELEMENT REPLACEMENT
with a sponge or cloth and a mild detergent or non- (1) Lift wiper arm to raise blade off glass.
abrasive cleaner. I f the blades continue to streak or (2) Remove blade assembly from arm by pushing
smear, they should be replaced. release tab under arm tip and slide blade away from
arm tip (Figs. 1 and 2).
WIPER BLADE REPLACEMENT (3) To remove wiping element from blade assembly:
(1) Turn wiper switch ON. Turn ignition switch • Grasp end of element at locating claw and pull el
ON. When blades are i n a convenient position turn ement and metal rails out of claw (Fig. 3).
ignition OFF.
CLAW
(2) Lift wiper arm to raise blade off glass.
(3) Remove blade assembly from arm by pushing
release tab under arm tip and slide blade away from
arm tip (Figs. 1 and 2).
Fig. 3 Wiper Blade Element Removal

• Remove wiper element by sliding out of the claws.
VER1ABRA ELEMENT 938K-31 (4) For installation, reverse removal procedures.
Fig. 1 Wiper Blade and Element—Typical WIPER ARM REPLACEMENT

REMOVAL
CAUTION: T h e use of a screwdriver or other prying

tool to remove an arm may distort it. T h i s distortion
could allow the arm to come off the pivot shaft, re
gardless of how carefully it is installed.
(1) Lift the arm to permit the latch (Fig. 4) to be

pulled out to the holding position. Remove arm from
pivot using a rocking motion.
INSTALLATION
Fig. 2 Wiper Blade Removal
(1) With wiper motor i n PARK position, position
(4) Gently place wiper arm tip on glass surface. arms to pivot shafts.
(4) Release plastic anchor screws (Fig. 7).
PLASTIC /
UNLOCKED SCREW A N C H O R
POSITION
LOCKED
POSITION
J948K-21
Fig. 4 Removing Wiper Arm

(2) Rotate arm until tip of wiper blade is ±22MM
to edge of black out (Fig. 5).
(3) Install arm onto pivot shaft.
(4) Grasp wiper arm with left hand and push lock
toward front of vehicle.
(5) Operate wipers with glass wet.
(6) PARK wipers. I f blades are not i n PARK posi
tion remove arms and reposition on pivots.
J948K-4
BLACK OUT
AREA
Fig. 7 Plastic Anchor Screws
(5) Lift cowl grille from vehicle.
(6) Remove washer hoses from supply hose at Y fit
ting (Fig. 8). Set cowl grille aside.
TIP OF BLADE ± 2 2 M M FROM EDGE OF BLACK OUT J948K-22
Fig. 5 Adjusting Wiper Arms

WIPER MOTOR REPLACEMENT
REMOVAL
(2) Remove wiper arms. J948K-5
(3) Remove weatherstrip along front edge of cowl

grille (Fig. 6). Fig. 8 Washer Hoses
( 7 ) Remove wiper linkage mounting bolts (Fig. 9).
J948K-3
Fig. 6 Cowl Grille Weatherstrip

Fig. 9 Linkage Mounting Bolts
(8) Turn linkage over. Unplug harness connector (6) Install motor and linkage.
from wiper motor (Fig. 10). (7) Connect washer hoses.
\ \ \ \ / / / (8) Install cowl grille.
GROUND TAB WIPER MOTOR
CONNECTOR CONNECTOR
(9) Install weatherstrip.
(10) Install wiper arms, refer to Wiper A r m Re
placement. Be sure to lock wiper arm into position.
LINKAGE REPLACEMENT
Refer to Wiper Motor Replacement.
PIW0T ASSEMBLIES
The pivot assemblies are not serviceable. Replace
the linkage assembly i f a pivot is damaged. Refer to
Wiper Motor Replacement.
J948K-7 WIPER SWITCH REPLACEMENT

Fig. 10 Wiper Motor Connector (2) Remove tilt lever (tilt column only).
(9) Unplug ground tab connector (Fig. 10). (3) Remove upper and lower column covers (Fig.
(10) Remove crank arm from drive link by prying 12).
retainer bushing from crank arm pin with a suitable UPPER SHROUD GROUND UPPER
size screwdriver (Fig. 11). CUP FIXED SHROUD
SUPPORT BRACKET
REMOVE
3 SCREWS
^ LEVER MASK
/
WIRE HARNESS
CONNECTOR
WASHER
J948K-17
Fig. 11 Motor Removal LOWER

LOWER FIXED
(11) Remove 3 screws and motor. SHROUD SHROUD J9119-22
(12) Remove nut attaching crank arm to motor
drive shaft. Fig. 12 Steering Column Covers
(13) Remove crank arm from motor.
(4) Remove both upper and lower fixed shrouds.
INSTALLATION (5) Loosen steering column upper bracket nuts. Do
(1) Position crank arm on motor drive shaft, mak Not remove nuts.
ing sure slot is indexed properly. Install mounting (6) Remove multi-function switch tamper proof
nut and tighten to 14 N-m (11 ft. lbs.) torque. mounting screws.
(2) Install crank arm pin i n drive link retainer (7) Gently pull switch away from column.
bushing by snapping together with channel lock pli (8) Loosen connector screw. The screw will remain
ers. in the connector.
(3) Position motor into place, install mounting (9) Remove wiring connector from multi-function
screws, and tighten to 6 N*m (55 in. lbs.) torque. switch (Fig. 13).
(4) Plug harness connector to wiper motor.
(5) Plug ground connector to ground tab.
HAZARD WARNING (2) Mount multi-function switch to column and

torque retaining screws to 2 N*m (17 in, lbs.).
(3) Install steering column covers. Torque retaining
screws to 2 N*m (17 i n . lbs.).
(4) Install tilt lever (tilt column only).
(5) Install battery cable.
(6) Check all functions of switch for proper opera
tion.
908J-9
Fig. 13 Multi-Function Switch

INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 2 N*m (17 in. lbs.).
WINDSHIELD W A S H E R S
GENERAL INFORMATION CLAMPS. ALWAYS W E A R S A F E T Y G L A S S E S WHEN
All models are equipped with electric operated SERVICING CONSTANT TENSION CLAMPS.
windshield washer pumps.
The electric pump assembly is mounted directly to
CAUTION: A number or letter is stamped into the
the reservoir. A permanently lubricated, sealed motor
is coupled to a rotor type pump. Fluid, gravity fed
from the reservoir, is forced by the pump through
ment clamp with a matching number or letter.
rubber hoses to the nozzles which direct the streams
to the windshield. HOSE CLAMP HOSE
TOOL 6 0 9 4 CLAMP
These vehicles are equipped with plastic washer
nozzles. Because they are inserted directly into the
cowl grille, there is no adjustment required.
WINDSHIELD WASHER PUMP REPLACEMENT/LOW

FLUID LEVEL SENSOR
REMOWAL
WARNING: DO NOT LOOSEN THE RADIATOR

DRAINCOCK WITH THE SYSTEM HOT AND PRES
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
J9207-36
DO NOT WASTE reusable coolant. I f the solution

is clean, drain the coolant into a clean container for
reuse. (1) Remove upper radiator hose at radiator (Fig. 3)
(2) Pull reservoir up and out of radiator shroud
WARNING: CONSTANT TENSION HOSE CLAMPS (Fig. 4).
ARE USED ON COOLING SYSTEM HOSES. WHEN (3) Pull hose off of pump/level sensor and drain
REMOVING OR INSTALLING THIS TYPE OF CLAMP, solvent into a clean container.
ONLY USE TOOLS DESIGNED FOR SERVICING (4) Disconnect electrical lead from pump/sensor.
THIS CLAMP SUCH AS SPECIAL CLAMP TOOL (5) Gently pry pump/sensor away from reservoir
(NUMBER 6094) (FIG. 1). SNAP-ON CLAMP TOOL and out of grommet. Care must be taken not to punc
(NUMBER HPC-20) MAY BE USED FOR LARGER ture reservoir.
8K - 12 WINDSHIELD WIPER AND WASHER SYSTEMS
WASHER PUMP J948K-18
Fig. 4 Washer Fluid Reservoir Removal

TYPICAL
HOSE INSTALLATION
CLAMP (1) Install new rubber grommet into place on res
NUMBER/LETTER ervoir.
LOCATION J9407-39
(2) Position pump/sensor into place and push i n
Fig. 2 Clamp Number/Letter Location firmly until i t locks into grommet.
(3) Connect electrical lead and hose to pump/sen
sor.
(4) Install reservoir onto radiator fan shroud.
(5) Fill reservoir with water and/or washer fluid,
inspect for leaks and test system.
(6) Install radiator hose.
(7) Fill cooling system. Refer to Group 7 - Refilling
Cooling System.
WASHER NOZZLES
(1) To replace a washer nozzle, gently pry nozzle
out of cowl grille.
(2) Remove hose from nozzle.
(3) Attach hose to new nozzle.
(4) Push nozzle into grille.
Fig. 3 Upper Radiator Hose Removal

(6) Remove rubber grommet from reservoir and
throw away.
WINDSHIELD WASHER DIAGNOSIS
WASHER D O E S MOTOR R U N S SYSTEM OPERATES

PUMP MOTOR
NOT PUMP P U M P I N G WITHOUT
RUNS
OPERATE PROPERLY FLUID INTERRUPTION
T T T
±
PUMP R U N S -
PUMP MOTOR SYSTEM OPERATES SYSTEM OUTPUT
PUMP NOT INTERMITTENTLY LOW
D O E S NOT R U N
P U M P I N G FLUID
T
LOOSE WIRING, N O FLUID IN LOOSE WIRING NOZZLES
TERMINALS, C O R R O D E D RESERVOIR CONNECTIONS AIMED L O W
TERMINALS.
NOZZLE JET U N D E R PINCHED O R

BROKEN WIRES FAULTY SWITCH LEAKY H O S E S
C O W L PANEL
t
LEAKY O R RESTRICTED
NOZZLE JETS
POOR G R O U N D FAULTY MOTOR PLASTIC H O S E
PLUGGED
CONNECTOR
i
BROKEN OR P O O R ELECTRICAL
FAULTY SWITCH LOOSE HOSE CONNECTIONS
FAULTY MOTOR FAULTY PUMP DEFECTIVE MOTOR
J908K-27
• LAMPS 8L - 1
LAMPS
CONTENTS
page page
BULB APPLICATION 10 LAMP BULB SERVICE 4

EXTERIOR LAMPS .. . .
a B B 6 LAMP DIAGNOSIS 1
HEADLAMP ALIGNMENT . 2 LAMP SYSTEMS 9
LAMP DIAGNOSIS
GENERAL INFORMATION CAUTION: Do not touch the glass of halogen bulbs
BR vehicles use lighting on the interior and exte with fingers or other possibly oily surface, reduced
rior of the vehicle for illuminating and indicating bulb life will result.
purposes. Lighting circuits are protected by fuses or Do not u s e bulbs with higher candle power than
circuit breakers. Lighting circuits require an overload indicated in the Bulb Application table at the end of
protected power source, on/off device, lamps and body this group. Damage to lamp c a n result.
ground to operate properly. Plastic lamps require a Do not u s e fuses, circuit breakers or relays hav
wire i n the harness to supply body ground to the ing greater amperage value than indicated on the
lamp socket. Lamp sockets that are exposed to mois fuse panel or in the Owners Manual.
ture should be coated with Mopar, Multi-purpose
Grease or equivalent to avoid corrosion. I f a socket When i t is necessary to remove components to ser
has become corroded, clean socket and bulb base with vice another, i t should not be necessary to apply ex
abrasive fiber sanding pad or metallic bristle brush. cessive force or bend a component to remove i t .
Replace sockets and bulbs that are deformed from Before damaging a trim component, verify hidden
corrosion that could prevent continuous body ground. fasteners or captured edges are not holding the com
ponent i n place.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors, in
spect the terminals inside the connector. Male termi
HEADLAMP DIAGNOSIS
nals should not be bent or disengaged from the BR vehicles built for use i n Canada are equipped
with a Daytime Running Lamp (DRL) system. The
insulator. Female terminals should not be sprung
DRL system operates the headlamps at 50% illumi
open or disengaged from the insulator. Bent and
nation with the headlamp switch OFF and the en
sprung terminals can be repaired using needle nose
gine running. The DRL system is controlled by the
pliers and pick tool. Corroded terminals appear Daytime Running Lamp Module located on radiator
chalky or green. Corroded terminals should be re closure panel on the right side of the engine compart
placed to avoid recurrence of the problem symptoms. ment. The DRL module overrides the headlamp
Wire connector terminals should be coated with Mo switch when the headlamps are turned OFF. The
par, Multi-purpose Grease or equivalent to avoid cor headlamps operate normally when the headlamps are
rosion. turned ON.
Begin electrical system failure diagnosis by testing When a vehicle experiences problems with the
related fuses and circuit breakers i n the fuse block headlamp system, verify the condition of the battery
and engine compartment. Verify that bulbs are i n connections, charging system, headlamp bulbs, wire
good condition and test continuity of the circuit connectors, relay, high beam dimmer switch and
ground. Refer to Group 8W, Wiring Diagrams for headlamp switch. Refer to Group 8W, Wiring Dia
component location and circuit information. grams for component locations and circuit informa
tion.
SAFETY PRECAUTIONS
SYMPTOM
WARNING: EYE PROTECTION SHOULD BE USED Headlamps are dim when engine is idling of
WHEN SERVICING GLASS COMPONENTS,. PER with ignition turned O F F . Canada cars must
SONAL INJURY CAN RESULT. have lamps ON.
8L - 2 LAMPS •
ACTION • Test for high resistance i n headlamp circuits.
• Clean battery terminal clamps and posts. Refer to • Defective headlamp bulb.
Group 8B, Battery/Starter/Generator Service for
proper procedures. SYMPTOM
• Test charging system output. Refer to Group 8A, Headlamps flash randomly.
Battery/Starting/Charging Systems Diagnostics for
proper testing procedures. ACTION
• Test for high resistance i n headlamp circuits. • Test for poor circuit ground.
• Defective headlamp bulb. • Test for high resistance i n headlamp circuits.
• Test condition of headlamp relay.
SYMPTOM • Check for loose or corroded connector terminals or
Bulbs burn out frequently. splices i n headlamp circuits. Refer to Group 8W, Wir
ing Diagrams for component and splice locations.
ACTION
• Test charging system output. Refer to Group 8A, SYMPTOM
Battery/Starting/Charging Systems Diagnostics for Headlamps do not illuminate.
proper testing procedures.
• Check for loose or corroded connector terminals or ACTION
splices i n headlamp circuits. Refer to Group 8W, Wir • Test for voltage at headlamp bulbs connectors.
ing Diagrams for component and splice locations. • Test headlamp relay.
• Test headlamp switch.
SYMPTOM
• Test high-beam headlamp dimmer switch.
Headlamps are dim with engine running
above idle. Canada cars must have lamps ON. • Check for loose or corroded connector terminals or
splices i n headlamp circuits. Refer to Group 8W, Wir
ACTION ing Diagrams for component and splice locations.
• Test charging system output. Refer to Group 8A,
Battery/Starting/Charging Systems Diagnostics for
proper testing procedures.
HEADLAMP ALIGNMENT
HEADLAMP ALIGNMENT HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN
Headlamps can be aligned using the screen method
provided i n this section. Alignment Tool C4466-A or ALIGNMENT SCREEN PREPARATION
equivalent can also be used. Refer to instructions (1) Position vehicle on a level surface perpendicu
provided with the tool for proper procedures. The lar to a flat wall 7.62 meters (25 ft) away from front
preferred headlamp alignment setting is 0 for of headlamp lens.
the left/right adjustment and 1" down for the (2) I f necessary, tape a line on the floor 7.62
up/down adjustment. meters (25 ft) away from and parallel to the wall.
(3) Up 1.27 meters (5 feet) from the floor, tape a
HEADLAMP ALIGNMENT PREPARATION line on the wall at the centerline of the vehicle. Sight
(1) Verify headlamp dimmer switch and high beam along the centerline of the vehicle (from rear of vehi
indicator operation. cle forward) to verify accuracy of the line placement.
(2) Correct defective components that could hinder (4) Rock vehicle side-to-side three times to allow
proper headlamp alignment. suspension to stabilize.
(3) Verify proper tire inflation. (5) Jounce front suspension three times by pushing
(4) Clean headlamp lenses. downward on front bumper and releasing.
(5) Verify that luggage area is not heavily loaded. (6) Measure the distance from the center of head
(6) Fuel tank should be FULL. Add 2.94 kg (6.5 lamp lens to the floor. Transfer measurement to the
lbs.) of weight over the fuel tank for each estimated alignment screen (with tape). Use this line for up/
gallon of missing fuel. down adjustment reference.
(7) Measure distance from the centerline of the ve
hicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
right adjustment reference.
• LAMPS 8L - 3
HEADLAMP ADJUSTMENT T h e p r e f e r r e d headlamp a l i g n m e n t is 0 for the

A properly aimed low beam headlamp will project u p / d o w n adjustment a n d 1" d o w n f o r t h e left/
top edge of high intensity pattern on screen from 50 r i g h t adjustment* The high beam pattern should be
mm (2 in.) above to 50 mm (2 in.) below headlamp correct when the low beams are aligned properly.
centerline. The side-to-side outboard edge of high i n To adjust headlamp aim, rotate alignment screws
tensity pattern should be from 50 mm (2 in.) left to to achieve the specified high intensity pattern.
50 mm (2 in.) right of headlamp centerline (Fig. 1).
CENTER OF LOW B E A M HOT FLOOR T O

VEHICLE T O SPOT AREA CENTER OF
CENTER OF , HEADLAMP
HEADLAMP LENS
LENS
VEHICLE
CENTERLINE'
PREFERRED
HOT SPOT
LOCATION
7.62 METERS
(25 FEET)
W—T- /
FRONT OF
HEADLAMP 938L-61
Fig. 1 Headlamp Alignment Screen—Typical

8L - 4 LAMPS
LAMP BULB 5ERW1CE
INDEX
page page
Cargo Lamp Bulb 1 Roof Clearance Lamp Bulb 2
Center High Mounted Stop Lamp (Chmsl) 1 Tail, Stop, Turn Signal and Back-Up Lamp
Front Side Marker Lamp Bulb 1 Bulb—Chassis Cab 2
Headlamp Bulb 1 Tail, Stop, Turn Signal and Back-Up Lamp
License Plate Lamp Bulb 2 Bulb—Pickup 2
Park and Turn Signal Lamp Bulb . . . . . . . . . . . . . . . 1
HEADLAMP BULB INSTALLATION

On driver side and on vehicles with dual batteries, Reverse the preceding operation.
the headlamp assemble must be removed to service
the headlamp bulb. PARK AND TURN SIGNAL LAMP BULB
REMOVAL (FIG. 1) REMOVAL

(1) Release hood latch and open hood. (1) Remove park and turn signal lamp.
(2) Remove headlamp assembly on drivers side or (2) Remove park and turn Signal lamp socket from
passenger side when equipped with dual batteries. back of lamp.
Refer to Headlamp Removal paragraph of Exterior (3) Pull park and turn signal lamp bulb from
Lamps section. socket.
(3) Disengage wire connector from headlamp bulb. INSTALLATION
(4) Remove retaining ring holding bulb to head Reverse the preceding operation.
lamp.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
(5) Pull bulb from headlamp.
REMOVAL (FIG. 2|
INSTALLATION
(1) Remove screws holding CHMSL to roof panel.
CAUTION: Do not touch the glass of halogen bulbs (2) Separate CHMSL from roof.
with fingers or other possibly oily surface, reduced (3) Remove socket from lamp.
bulb life will result. (4) Pull bulb from socket.
Reverse the preceding operation. INSTALLATION
BULB BULB
Reverse the preceding operation.
SOCKET RETAINING
RING CARGO LAMP BULB
ELECTRICAL REMOVAL (FIG. 2)

CONNECTOR (1) Remove screws holding cargo lamp to roof
panel.
(2) Separate cargo lamp from roof.
(3) Remove socket from lamp.
PLASTIC (4) Pull bulb from socket.
LENS/ BASE UNLOCK
REFLECTOR 918L-34
INSTALLATION
Fig. 1 Headlamp Bulb Reverse the preceding operation.
FRONT SIDE MARKER LAMP BULB ROOF CLEARANCE LAMP BULB
REMOVAL REMOVAL
(1) Remove park and turn signal lamp. (1) Remove roof clearance lamp lens.
(2) Remove side marker lamp socket from back of (2) Pull bulb from lamp.
lamp.
(3) Pull side marker lamp bulb from socket. INSTALLATION
• LAMPS 8L -
SCREW \ ( ^
Fig. 2 Cargo or Center High Mounted Stop Lamp

Bulbs
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP

BULB—PICKUP RETAINING
STUDS J948L-6
REMOVAL (FIG. 3)
(1) Remove tail lamp from cargo box. Fig, 3 Tail, Stop, Turn Signal and Back-up Lamp
(2) Remove socket from tail lamp. Bulb—Pickup
(3) Pull bulb from socket. INSTALLATION
INSTALLATION
LICENSE PLATE LAMP BULB
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP REMOVAL
BULB—CHASSIS CAB (1) Remove license plate lamp lens.
(2) Pull bulb from license plate lamp.
REMOVAL
(1) Remove screws holding tail lamp lens to lamp INSTALLATION
body. Reverse the preceding operation.
(2) Separate lens from lamp.
SL - e LAMPS
EXTERIOR LAMPS
INDEX
page page
Cargo Lamp . 7 Roof Clearance Lamps 6
Center High Mounted Stop Lamp (CHMSL) 6 Side Identification (ID) Lamps 7
Headlamp Module 6 Tail, Stop, Turn Signal and Back-Up Lamps—
License Plate Lamp Panel 9 Chassis Cab 8
Park, Turn Signal and Side Marker Lamp 6 Tail, Stop, Turn Signal and Back-Up Lamps—Pickup . . 7
Rear Identification (ID) Lamps 7
PARK, TURN SIGNAL AND SIDE MARKER LAMP

REMOWAL
HEADLAMP
(1) Remove screw holding park lamp to headlamp SOCKET
module.
(2) Disengage clip holding park lamp to headlamp
SCREW
module.
(3) Separate park lamp headlamp module.
(4) Remove park and turn signal socket from back
of lamp.
(5) Remove side marker socket from back of lamp.
(6) Separate park and turn signal lamp from vehi
cle.
CARRIER
INSTALLATION
BRACKET
HEADLAMP MODULE H E A D LAMP

SIDE MARKER
HOUSING
BULB
REMOVAL (FIG 1)
TURN A N D PARK
(1) Release hood latch and open hood. LAMP H O U S I N G
(2) Remove park and turn signal lamp. J948L-8
Fig. 1 Headlamp
(3) Remove screws holding top of headlamp module
to radiator closure panel. (4) Remove screws holding clearance lamp to roof
(4) From behindfrontbumper, remove screws hold panel.
ing bottom of headlamp module to radiator closure (5) Disengage wire connector from body wire har
panel. ness.
(5) Separate headlamp module from radiator clo (6) Separate roof clearance lamp from vehicle.
sure panel.
(6) Disengage wire connector from headlamp bulb. INSTALLATION
(7) Separate headlamp module from vehicle. Reverse the preceding operation.
INSTALLATION CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL fFIG® 3)
ROOF CLEARANCE LAMPS (1) Remove screws holding CHMSL to roof panel.
(2) Separate CHMSL from roof.
REMOVAL (FIG. 2J (3) Disengage wire connector from body wire har
(1) Insert a flat blade screw driver into slot at the ness.
base of the clearance lamp lens. (4) Separate CHMSL from vehicle.
(2) Pry upward to disengage clips holding lens to
clearance lamp. INSTALLATION
(3) Separate lens from clearance lamp. Reverse the preceding operation.
• LAMPS 8L - 7
LENS REMOVAL (FIG. 4 |

(1) Using a flat blade screw driver, disengage clips
holding I D lamp to retainer.
(2) Separate I D lamp from retainer.
(3) Disengage wire connector from body wire har
ness.
(4) Separate lamp from vehicle.
(5) Remove screws holding lamp retainer to rear
fender.
(6) Separate retainer from rear fender.
INSTALLATION
Fig. 2 Roof Clearance Lamps
Fig. 4 Side Identification Lamps

REAR IDENTIFICATION (ID) LAMPS
The bulbs i n the side ID lamps can not be replaced.
I f a bulb should fail, the entire lamp would require
replacement.
REMOVAL (FIGm Si
(1) Remove screws holding rear ID lamps to cargo
box.
(2) Separate I D lamps from cargo box.
(3) Disengage I D lamp wire connector from body
wire harness.
(4) Separate I D lamp from vehicle.
J948L-4 INSTALLATION
Fig. 3 Center High Mounted Stop Lamp
TAIL, STOP, TURN SIGNAL AND BACK-UP
CARGO LAMP LAMPS—PICKUP
The cargo lamp is incorporated into the CHMSL, i f
equipped. Refer to Center High Mounted Stop Lamp REMOVAL (FIG. 6)
paragraph for proper procedures. (1) Release tailgate latch and open tailgate.
(2) Remove screws holding tail lamp to cargo box.
SIDE IDENTIFICATION (ID) LAMPS (3) Disengage clips holding tail lamp to cargo box.
The bulbs i n the side I D lamps can not be replaced. (4) Separate tail lamp from cargo box.
I f a bulb should fail, the entire lamp would require (5) Disengage tail lamp wire connector from body
replacement. wire harness.
(6) Separate tail lamp from vehicle.
8L - 8 LAMPS
TAIL, STOP, TURN SIGNAL AND BACK-UP

LAMPS—CHASSIS CAB
REMOVAL (FIG. 7)
(1) Remove nuts holding tail lamp to mounting
bracket.
(2) Disengage tail lamp wire connector from body
BUMPER
wire harness.
(3) Separate tail lamp[fromvehicle.
INSTALLATION
<»i m ilium
SCREW LICENCE
TAILGATE PLATE BRACKET
MARKER LAMPS J948L-10
TAILLAMP-BRAKE LAMP-
BACKUP LAMP
HOUSING
Fig. 5 Rear Identification Lamps
INSTALLATION
SCREW
FRAME
TAILLAMP M O U N T I N G
BRACKET J948L-9
TAILLAMP
Fig. 7 Tail, Stop, Turn Signal and Back-up Lamps-
Chassis Cab
RETAINING
CLIP
RETAINING
STUDS J948L-6
Fig. 6 Tail, Stop, Turn Signal and Back-up Lamps-

Pickup
• LAMPS 8L - 9
LICENSE PLATE LAMP PANEL
REMOVAL (FIG. 8)
(1) Remove screws holding license plate panel to
cargo box.
(2) Disengage license plate lamp wire connector
from body wire harness.
(3) Separate license plate lamp from vehicle.
INSTALLATION
LICENSE
PLATE
LAMP
Fig. 8 License Plate Lamp Panel
LAMP S Y S T E M S
DAYTIME RUNNING LAMPS—CANADA ONLY (3) Remove screw holding DRLR to engine com
The daytime running lamps are controlled by the partment dash panel.
Daytime Running Lamp Relay (DRLR). The DRLR is (4) Separate DRLR from dash panel.
located i n the engine compartment on the left fender
wheelhouse (Fig. 9). The DRLR allows the high beam INSTALLATION
headlamps to illuminate at 50% of the switched ON Reverse the preceding operation.
brightness when the engine is running with the
headlamp switch OFF. The Daytime running lamps
will go out when the headlamp switch is pulled out.
The passing light feature will flash bright high
beams while the daytime running lamps are acti
vated.
DAYTIME RUNNING LAMP DIAGNOSTICS

The daytime running lamp system shears fuse 24,
in the fuse panel, with the back-up lamp circuit. The
DRLR is controlled by inputs received from the
Speed Sensor, Headlamp Switch and the Engine Con
troller (SBEC). Refer to Group 8W, Wiring Diagrams
for component location and circuit information.
DAYTIME R U N N I N G LAMP RELAY REMOWAL

(FIG. 9)
(1) Release hood latch an open hood. Fig. 9 Daytime Running Lamp Relay (DRLR)
(2) Disconnect wire connector from DRLR.
8L - 10 LAMPS •
B U L B APPLICATION
GENERAL INFORMATION A/C Heater Control..... ..........158
The following Bulb Applications list the lamp title Ash Receiver................................. .....................161
on the left side of the column and trade number or Cigar Lighter 161
part number on the right. Headlamp Switch......... 158
Heater Control ....158
CAUTION: Do not u s e bulbs that have a higher c a n Instrument Cluster .....PC194
dle power than the bulb listed in the Bulb Applica Radio ASC
tions. Damage to lamp c a n result.
Do not touch halogen bulbs with fingers or other INDICATOR LAMPS
possibly oily surfaces. Bulb life will be reduced. Service procedures for most of the lamps i i i the in
strument panel, instrument cluster and switches are
located i n Group 8E, Instrument Panel and Gauges.
EXTERIOR LAMPS Airbag High Line PC194
Back-up 3157 Airbag low Line PC74
Cargo........ 921 Anti-lock Brake PC74
Center High Mounted Stop ......................921 Battery Voltage PC194
Clearance ......194 Brake Warning PC194
Headlamp 9004 Check Engine PC74
License Plate 1155 Engine Oil Pressure ..PC74
License Plate—Step Bumper................. .168 Four Wheel Drive PC194
Message Center .........PC194 High Beam PC194
Park/Turn Signal..... .....3157NA Low Fuel PC194
Snow Plow Control ..161 Low Washer Fluid............. ...PC74
Tail/Stop/Turn Signal. 3157 Maintenance Required PC74
Seat Belt PC74
INTERIOR LAMPS Turn Signal. ...........PC194
Upshift.... ......PC74
D I M M E R CONTROLLED LAMPS
Service procedures for most of the lamps i n the i n NON-DIMMING LAMPS
strument panel, Instrument cluster and switches are Service procedures for most of the lamps i n the fol
located i n Group 8E, Instrument Panel and Gauges. lowing list can be found i n Group 23, Body. Some
Some components have lamps that can only be ser components have lamps that can only be serviced by
viced by a Authorized Service Center (ASC) after the a Authorized Service Center (ASC) after the compo
component is removed from the vehicle. Contact local nent is removed from the vehicle. Contact local
dealer for location of nearest ASC. When illumination dealer for location of nearest ASC.
goes out i n the Electronic Instrument Cluster (EIC) Dome 1004
the complete button module must be replaced. The Glove Compartment.... ..1891
Mechanical Instrument Cluster (MIC) uses PC194 Ignition Lock 1445
bulbs for illumination.
• RESTRAINT SYSTEMS 8M - 1
RESTRAINT SYSTEMS
CONTENTS
page page
AIRBAG SYSTEM 1 AIRBAG SYSTEM SERVICE 5

AIRBAG SYSTEM GENERAL INFORMATION . . . . 2
AIRBAG SYSTEM
WARNING: THIS S Y S T E M IS A S E N S I T I V E , COM WARNING: R E P L A C E A I R B A G S Y S T E M COMPO

P L E X E L E C T R O - M E C H A N I C A L UNIT. B E F O R E AT NENTS WITH C H R Y S L E R MOPAR® S P E C I F I E D R E
TEMPTING TO DIAGNOSE, R E M O V E OR INSTALL P L A C E M E N T P A R T S ONLY. S U B S T I T U T E P A R T S
T H E A I R B A G S Y S T E M COMPONENTS YOU MUST MAY A P P E A R I N T E R C H A N G E A B L E , BUT INTERNAL
F I R S T DISCONNECT AND ISOLATE T H E B A T T E R Y D I F F E R E N C E S MAY R E S U L T IN INFERIOR O C C U
NEGATIVE (GROUND) C A B L E . F A I L U R E TO DO S O PANT PROTECTION.
C O U L D R E S U L T IN ACCIDENTAL D E P L O Y M E N T T H E F A S T E N E R S , S C R E W S , AND B O L T S , ORIGI
AND P O S S I B L E P E R S O N A L INJURY. NALLY U S E D FOR T H E A I R B A G COMPONENTS,
WHEN AN U N D E P L O Y E D A I R B A G A S S E M B L Y IS HAVE S P E C I A L COATINGS AND A R E S P E C I F I
TO B E REMOVED FROM THE S T E E R I N G W H E E L , C A L L Y DESIGNED FOR T H E A I R B A G S Y S T E M .
DISCONNECT BATTERY NEGATIVE C A B L E AND T H E Y MUST N E V E R B E R E P L A C E D WITH ANY S U B
I S O L A T E . A L L O W S Y S T E M CAPACITOR TO DIS S T I T U T E S . ANYTIME A NEW F A S T E N E R IS
C H A R G E FOR 2 MINUTES B E F O R E BEGINNING N E E D E D , R E P L A C E WITH T H E C O R R E C T F A S T E N
COMPONENT REMOVAL. E R S PROVIDED IN T H E S E R V I C E P A C K A G E OR
F A S T E N E R S L I S T E D IN THE P A R T S BOOK.
To inspect system use Passive Restraint System Di
agnostic Procedures Manual.
I f the airbag module assembly is defective and non-
deployed, refer to Chrysler Corporation current re
turn list for proper handling procedures.
8M - 2 RESTRAINT SYSTEMS
AIRBAG SYSTEM G E N E R A L INFORMATION
NDEX
page page
Airbag Clean-Up Procedure 3 Airbag Module Handling (Undeployed) 2
Airbag Clockspring 2 Airbag Module Storage 2
Airbag Control Module , 2 Airbag Service (Deployed) 3
Airbag Impact Sensors . . . . . . . . . . . . . . . . . . . . . . 2 Airbag System Check 3
Airbag Module 2 Airbag System Schematic 4
Airbag Module Handling (Deployed) .. 2
AIRBAG MODULE AIRBAG CONTROL MODULE

The airbag module is the most visible part of the The airbag control module (ACM), contains the saf
system. I t contains the airbag cushion and its sup ing sensor, and monitors the system to determine the
porting components. The airbag module contains a readiness of the system. The ACM contains on-board
housing to which the cushion and inflator are at diagnostics (OBD), and will illuminate the airbag
tached and sealed. warning lamp i n the instrument cluster when a fault
The inflator assembly is mounted to the back of the occurs.
module. I t seals the hole so i t can discharge the gas
it produces directly into the cushion when supplied AIRBAG MODULE STORAGE
with the proper electrical signal. A protective cover is The airbag module must be stored i n its original
fitted to the front of the airbag module and forms a special container until used for service. Additionally,
decorative cover i n the center of the steering wheel. it must be stored in a clean, dry environment, away
from sources of extreme heat, sparks, and high elec
The airbag module is mounted directly to the steer
trical energy. Always place or store the module on a
ing wheel.
surface with the trim cover facing up to minimize
movement i n case of accidental deployment.
AIRBAG IMPACT SENSOR
The airbag system is a safety device designed to AIRBAG MODULE HANDLING (UNDEPLOYED)
protect the driver from serious injury, caused by a At no time should any source of electricity be per
frontal impact of the vehicle. mitted near the inflator on the back of the module.
The impact sensors provide verification of the di When carrying an undeployed module, the trim cover
rection and severity of the impact. Three impact sen should be pointed away from the body to minimize
sors are used. One is called a safing sensor. The injury i n the event of accidental deployment. I f the
safing sensor is located inside the airbag control module is placed on a bench or other surface, the
module (ACM), which is below the center of the in plastic trim cover should be face up to minimize
strument panel on the transmission tunnel. The movement i n case of accidental deployment.
other two sensors are mounted on the inner fender
extensions behind the grille opening reinforcement WARNING: WHEN A STEERING COLUMN HAS AN
on the left and right side of the vehicle. AIRBAG MODULE ATTACHED, NEVER PLACE THE
The impact sensors are threshold sensitive COLUMN ON THE FLOOR OR OTHER SURFACE
switches that complete an electrical circuit when an WITH THE STEERING WHEEL OR AIRBAG MODULE
impact provides a sufficient deceleration force to FACE DOWN.
close the switch. The sensors are calibrated for the AIRBAG MODULE HANDLING (DEPLOYED)
specific vehicle and react to the severity and direc The vehicle interior will contain sodium hydroxide
tion of the impact. powder, a chemical byproduct of the generant used
for airbag deployment. Since this powder can irritate
AIRBAG CLOCKSPRING the skin, eyes, nose or throat, be sure to wear safety
The clockspring is mounted on the steering column glasses, rubber gloves and a long-sleeved shirt during
behind the steering wheel. I t is used to maintain a cleanup (Fig. 1).
continuous electrical circuit between the wiring har I f you experience skin irritation during cleanup,
ness and the driver's side airbag module. This assem run cool water over the affected area. Also, i f you ex
bly consists of a flat, ribbon-like electrically perience irritation of the nose and throat, exit the ve
conductive tape which winds and unwinds with the hicle for fresh air until the irritation ceases. I f
steering wheel rotation. irritation continues, see a physician.
Fig. 1 Wear Safety Glasses and Rubber Gloves Fig. 3 Vacuum Heater and A/C Outlets
AIRBAG CLEANUP PROCEDURE and cannot be reused. Other airbag system compo
Begin the cleanup by putting tape over the airbag nents are replaced as required by the extent of dam
exhaust vent (Fig. 2) so that no additional powder age.
will find its way into the vehicle interior. Then re
move the airbag and airbag modulefromthe vehicle. AIRBAG SYSTEM CHECK
Use a vacuum cleaner to remove any residual pow- (1) Disconnect battery negative cable and isolate.
(2) Connect DRB scan tool to ACM diagnostic
6-way connector, clipped to lower left corner of in
strument panel.
(3) From right side of vehicle (awayfromairbag in
case of accidental deployment), turn ignition switch
to ON position. Exit vehicle with DRB. Use the latest
version of the proper DRB cartridge.
(4) After checking that no one is inside the vehicle,
reconnect negative battery cable.
(5) Using the DRB, read and record active diagnos
tic trouble code (DTC) data.
(6) Read and record any stored DTC.
(7) Refer to the Diagnostic Test manual if any DTC
is found in steps 5 or 6.
(8) Erase stored DTC, if there are no active codes.
If problems remain, DTC will not erase.
(9) With ignition switch in ON position, make sure
Fig. 2 Airbag Exhaust Vent Sealing no one is in the vehicle.
der from the vehicle interior. Work from the outside (10) From passenger side of vehicle, turn ignition
in as you do, so that you avoid kneeling or sitting on switch to OFF then ON. Observe the instrument
an uncleaned area. cluster airbag lamp. It should go on for 6 to 8 sec
Be sure to vacuum the heater and A/C outlets as onds, then go out; indicating system is functioning
well (Fig. 3). Run the blower on low and vacuum any normally.
powder expelled from the plenum. You may need to I f airbag warning lamp fails to light, or goes
vacuum the interior of the car a second time to re on and stays on, there is a system malfunction.
cover all of the powder. Refer to the Passive Restraint Diagnostic Test
Place the deployed airbag and module in your ve manual to diagnose the problem.
hicular scrap pile.
AIRBAG SERVICE (DEPLOYED)

Any vehicle which is to be returned to use after an
airbag deployment, must have the airbag module and
clockspring replaced. These are one-time components
8M - 4 RESTRAINT SYSTEMS •
AIRBAG SYSTEM SCHEMATIC
IGNITION FUSE #12

SWITCH ACC I (15 AMP)
TO
5 CLUSTER
TO
5 MESSAGE CENTER
TO
•J CLUSTER
TWISTED
PAIR AIR BAG
2 1 7 3 — R43- 1 + SQUIB
6 RUN RUN/
5
START 4 — R45- I
FUSE#3 2 -SQUIB
(40 AMP) PASSENGER 1 TWISTED
AIR BAG 2 PAIR
FUSE#2 13 3 + —Dl- CCD +
(40 AMP)
12 CCD
11 AIR BAG 4
-D2- CCD -
DIAGNOSTIC MODULE -Dll- RECEIVE
-D12- TRANSMIT
-D10- GROUND
ABS POWER
Ml- 11 10 23
MODULE AIRBAG/ABS
DIAGNOSTIC
-MI- CONNECTOR
BODY
GROUND
J948M-3
• RESTRAINT SYSTEMS 8M - i
AIRBAG SYSTEM SERWiCE
INDEX
page page
Airbag Control Module (ACM) . 9 Clockspring Centering Procedure 10
Airbag Module 5 Impact Sensors—V-10 and Diesel Engines 7
Clockspring 9 Impact Sensors—V-6 and V-8 6
AIRBAG MODULE
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
(-) C A B L E FROM THE VEHICLE BATTERY THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM FAILURE TO DO THIS COULD RESULT IN
B
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI

BLE PERSONAL INJURY
A L L O W SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES BEFORE BEGINNING COMPONENT
REMOVAL
REMOVAL
When removing a deployed airbag module, rubber Fig. 2 Speed Control Switches
gloves, eye protection and long-sleeved shirt should
be worn. There may be deposits on the surface i n
large doses that could irritate the skin and eyes.
(1) Disconnect battery negative cable and isolate.
speed control switch mounting screws (Fig. 1), i f
equipped.

(5) Remove 4 nuts attaching airbag module (Fig.
4).
(3) Pull switches from wheel and unplug connector (6) Remove airbag module from steering wheel.
(Fig. 2). (7) Unplug electrical connector from airbag mod
(4) Using a small screwdriver remove right rear ule.
PASSENGER SIDE
REMOVAL
(1) Disconnect negative cable from battery and iso
late.
(2) Remove 3 screws holding sensor to front wheel-
house extension. Remove sensor (Fig. 5).
. ^ ^ 'W
FORWARD ' r^' <r
RIGHT IMPACT
SENSOR
J94SG-2
J948M-5
Fig. 4 Airbag Module Remowal
(8) I f replacing a deployed module, the clockspring Fig. 5 Right Impact Sensor
must also be replaced. Refer to Clockspring Removal
Do not remove tape holding harness to con
and Installation for proper procedure.
nector.
INSTALLATION (3) Unplug connector from sensor and remove sen
(1) Connect clockspring wiring connector to the sor (Fig. 6).
module, by pressing straight i n on the connector. The SENSOR
connector should latch securely beneath module lock CONNECTOR
ing clip to assure positive connection.

(2) Install 4 nuts and torque to 9 to 11 N-m (80 to
100 in. lbs.).
(3) Do not connect negative battery cable. Refer to
Airbag System Check for proper procedure.
IMPACT SENSORS—V»i AND ¥-8

WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S
TEM REMOVAL OR INSTALLATION P R O C E D U R E S ,
R E M O V E AND I S O L A T E T H E B A T T E R Y NEGATIVE
(-) C A B L E FROM T H E V E H I C L E BATTERY. THIS IS
THE ONLY S U R E WAY TO D I S A B L E THE A I R B A G J948M-8
S Y S T E M . F A I L U R E TO DO THIS C O U L D R E S U L T IN
A C C I D E N T A L A I R B A G D E P L O Y M E N T AND P O S S I Fig. 6 Impact Sensor Connector—Typical
B L E P E R S O N A L INJURY. INSTALLATIOI
A L L O W S Y S T E M CAPACITOR T O D I S C H A R G E (1) Connect sensor wiring lead from harness to
F O R 2 MINUTES B E F O R E BEGINNING COMPONENT connector on body of sensor.
REMOVAL. (2) Mount sensor (arrow pointed forward) using 3
screws provided with new sensor. Torque screws to 4
The impact sensors are located on the inner
to 5 N-m (35 - 45 in. lbs.).
fender extensions behind the grille opening re
inforcement.
Airbag Systems Check for proper procedure.
DRIVER'S SIDE S Y S T E M . F A I L U R E T O DO THIS C O U L D R E S U L T IN

ACCIDENTAL A I R B A G D E P L O Y M E N T AND P O S S I
REMOVAL B L E P E R S O N A L INJURY.
(1) Disconnect negative cable from battery and iso A L L O W S Y S T E M CAPACITOR T O D I S C H A R G E
late. FOR 2 MINUTES B E F O R E BEGINNING COMPONENT
(2) Remove plastic retainers holding rubber air REMOVAL.
dam to radiator support on driver's side.
(3) Working through air dam opening remove 3 The impact sensors are located on the inner
screws holding sensor to front wheelhouse extension. fender extensions behind the grille opening re
Remove sensor (Fig. 7). inforcement.
PASSENGER SIDE
REMOVAL
(1) Disconnect negative cable from battery and iso
late.
(2) Remove 3 screws holding sensor to front wheel-
house extension. Remove sensor (Fig. 5).
Do not remove tape holding harness to con
nector.
(3) Unplug connector from sensor and remove sen
sor (Fig. 6).
INSTALLATION
(1) Connect sensor wiring lead from harness to
connector on body of sensor.
(2) Mount sensor (arrow pointed forward) using 3
to 5 N-m (35 - 45 in. lbs.).
DRIVER'S SIDE
• Do not remove tape holding harness to con REMOVAL

nector. (1) Disconnect negative cable from battery and iso
(4) Unplug connector from sensor and remove sen late.
sor (Fig. 6). (2) Remove 2 battery holddown bolts (Fig. 8).
INSTALLATION
(1) Connect sensor wiring lead from harness to
to 5 N-m (35 - 45 in. lbs.).
(3) Install rubber air dam across opening.
IMPACT SENSORS—V-10 AND DIESEL ENGINES

WARNING: B E F O R E BEGINNING ANY AIRBAG S Y S
R E M O V E AND ISOLATE T H E B A T T E R Y NEGATIVE
(-) C A B L E FROM T H E V E H I C L E BATTERY. THIS IS Fig. 8 Battery Holddown
T H E ONLY S U R E WAY TO D I S A B L E T H E AIRBAG (3) Pull up on battery heatshield (if equipped) to
remove i t (Fig. 9).
(4) Remove battery from vehicle.
(5) From under left front wheel opening remove 2
Fig. 9 Battery Heatshield
Fig. 10 Forward Battery Tray Nuts—Viewed From Fig. 12 Speed Control Servo Mounting
Under Vehicle (10) Remove 3 screws holding sensor to front
(6) Remove 2 nuts and 2 bolts holding battery tray wheelhouse extension. Remove sensor (Fig. 7).
to vehicle (Fig. 11). Do not remove tape holding harness to con
(7) Lift battery tray up far enough for access to nector.
speed control servo electrical connector (Fig. 12). (11) Unplug connector from sensor and remove
(8) Unplug electrical connector from speed control sensor (Fig. 6).
servo.
(9) Move battery tray enough to access impact sen INSTALLATION
sor. (1) Connect sensor wiring lead from harness to

to 5 N-m (35 - 45 in. lbs;).
(3) Plug harness connector into speed control
servo.
(4) Install battery tray. Tighten all battery tray
mounting hardware to 16 N-m (140 in. lbs.).
(5) Install battery i n vehicle making sure that bat
tery is properly positioned on battery tray.
(6) Install battery heat shield, i f equipped.
that i t is properly positioned on battery, use holes 1 1 J CONTROL I J 1
across from each other. Tighten holddown bolts to 4 MODULE
N-m (35 in. lbs.).
J948M-2
Airbag Systems Check for proper procedure. Fig. 14 Airbag Control Module
AIRBAG CONTROL MODULE (ACM) (5) Remove ACM.
WARNING: T H E ACM CONTAINS O N E O F THE IM INSTALLATION

PACT S E N S O R S WHICH E N A B L E T H E S Y S T E M T O (1) Position the ACM with the arrow pointing for
F I R E T H E A I R B A G . TO AVOID A C C I D E N T A L D E ward.
PLOYMENT, R E M O V E AND I S O L A T E T H E B A T T E R Y (2) Connect wiring at ACM, making sure both con
NEGATIVE (-) C A B L E FROM T H E V E H I C L E BAT nectors are seated and locking tabs engaged.
T E R Y . THIS IS T H E ONLY S U R E WAY T O D I S A B L E (3) Attach ACM to the transmission tunnel with
T H E A I R B A G S Y S T E M . F A I L U R E T O DO THIS the 4 screws. Torque to 9.5 to 14 N-m (85-125 in.
C O U L D R E S U L T IN ACCIDENTAL A I R B A G D E P L O Y lbs.).
MENT, AND P O S S I B L E P E R S O N A L INJURY. (4) Install ACM cover.
ALLOW S Y S T E M CAPACITOR TO D I S C H A R G E (5) Do not connect negative battery cable. Refer to
F O R 2 MINUTES B E F O R E BEGINNING COMPONENT Airbag System Check for proper procedure.
REMOVAL.
CLOCKSPRING
REMOVAL
WARNING: B E F O R E BEGINNING ANY AIRBAG S Y S
(2) Remove 2 screws and cover from bottom of cen
R E M O V E AND ISOLATE T H E B A T T E R Y NEGATIVE
ter console (Fig. 13).
(-) C A B L E FROM T H E V E H I C L E BATTERY. THIS IS
T H E ONLY S U R E WAY TO D I S A B L E T H E A I R B A G
S Y S T E M . F A I L U R E TO DO S O C O U L D R E S U L T IN
ACCIDENTAL A I R B A G DEPLOYMENT, AND POSSI
B L E INJURY.
A L L O W S Y S T E M CAPACITOR T O D I S C H A R G E
FOR 2 MINUTES B E F O R E BEGINNING COMPONENT
REMOVAL.
REMOVAL
(1) Place front wheels in straight-ahead position
before starting repair.
(3) Wait 2 minutes for the reserve capacitor to dis
charge before removing undeployed module.
(4) Remove airbag module. Refer to Airbag Module
Fig. 13 Airbag Control Module Cover Screws
Removal.
(3) Remove 4 screws holding ACM to transmission (5) Disconnect horn terminal.
tunnel (Fig. 14). (6) Remove steering wheel. Refer to Group 19 -
(4) Disconnect wiring at ACM. Steering Wheel Removal.
8M - 10 RESTRAINT SYSTEMS •
(7) Remove lower steering column shroud to gain INSTALLATION
access to clockspring wiring (Fig. 15). (1) Snap clockspring onto the steering column. I f
the clockspring is not properly positioned, follow the
UPPER SHROUD GROUND UPPER
CLIP FIXED SHROUD clockspring centering procedure before installing
SUPPORT BRACKET steering wheel.
(2) Connect the clockspring assembly to the instru
ment panel wiring harness. Make sure wiring locator
clips are properly seated on the outside of the wiring
trough and locking tabs are engaged.
(3) Install knee blocker.
(4) Install steering column shrouds. Be sure airbag
wire is inside of shrouds.
WIRE HARNESS (5) Road wheels should still be i n the straight-
CONNECTOR
ahead position. Install steering wheel making sure to
fit the flats on the hub of the steering wheel with the
formations on the inside of clockspring. Pull the horn
WASHER
lead through the wheel. The airbag and speed control
leads go through the bottom larger hole i n the steer
ing wheel. Make sure not to pinch them between the
steering wheel and nut. Refer to Group 19 - Steer
LOWER ing Wheel Installation for proper steering
LOWER FIXED wheel nut torque.
SHROUD SHROUD J9119-22
(6) Connect airbag lead wire to the airbag module.
To assure complete connection, latching arms must
Fig. 15 Steering Column Shrouds
be visibly on top of connector housing.
(8) Remove lower fixed shroud. (7) Install airbag module, and torque nuts to 9 to
(9) Remove knee blocker (Fig. 16). 11 N-m (80 to 100 in. lb.).
CLOCKSPRING CENTERING PROCEDURE

I f the rotating tape within the clockspring is not
positioned properly with the steering wheel and the
front wheels, the clockspring may fail during use.
The clockspring MUST be centered i f i t is not known
to be properly positioned, or i f the front wheels were
moved from the straight-ahead position.

(-) C A B L E FROM THE VEHICLE BATTERY. THIS IS
THE ONLY SURE WAY TO DISABLE THE A I R B A G
Fig. 16 Knee Blocker Removal SYSTEM. FAILURE TO DO THIS COULD RESULT IN
(10) Disconnect the 2-way connector between the ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI
clockspring and the instrument panel wiring harness BLE INJURY.
at lower left corner of instrument panel. A L L O W SYSTEM CAPACITOR TO DISCHARGE
(11) To remove clockspring, pull assembly from FOR 2 MINUTES BEFORE BEGINNING COMPONENT
steering column by lifting locating fingers as neces REMOVAL.
sary. The clockspring cannot be repaired, and must
be replaced i f faulty. (1) Place front wheels i n the straight ahead posi
tion.
(2) Remove airbag module, and steering wheel. Re
fer to Airbag Module and Clockspring for procedures.
(3) Depress the 2 plastic locking pins (Fig. 17).
(5) From the end of travel, rotate the rotor 2 full

turns and a half i n the counterclockwise direction.
The horn wire should end up at the top and the
squib wire at the bottom.
(6) Install steering wheel. Refer to Group 19 Steer
ing Column Installation for procedures and steering
wheel nut torque.
(7) Install airbag module. Tbrque nuts to 9 to 11
N-m (80 to 100 i n . lbs.).
(8) Do not connect battery negative cable. Refer to
Fig. 17 Clockspring (Auto-Locking)

(4) Keeping locking mechanism disengaged, rotate
the clockspring rotor i n the clockwise direction to the
end of travel. Do not apply excessive torque.
f
i
• POWER DOOR LOCKS 8P - 1
POWER DOOR L O C K S
CONTENTS
page page
SERVICE PROCEDURES ... 3 TEST PROCEDURES ... 1
GENERAL INFORMATION Both doors can also be unlocked by using the inside
The door lock motors are controlled by two-way remote door handles. Both doors can also be opened
switches. Tb lock the doors, push either switch to the with the inside door handle without first lifting the
rear. Tb unlock doorsfrominside the vehicle push ei plunger.
ther switch forward.
The power door locks do not lock or unlock the
doors from outside the vehicle. Insert key into lock
cylinder to lock or unlock each individual door.
TEST PROCEDURES
DESCRIPTION
The door locks are operated by reversible motors. SWITCH CONTINUITY
The voltage supply comesfromthe 50 amp fuse, cav POSITION BETWEEN
ity 5, in the power distribution center (PDC) to the PINS 1 & 4
OFF
20 amp fuse located in cavity 19 of the fuseblock PINS 2 & 5
module. Power then goes to both door switches. With
the left door switch in LOCK position, voltage travels
® LOCK PINS 2 & 3
3 PINS 1 & 4
from the left switch to the right door switch. Voltage
is then applied to both lock motors. Ground is found
through the right door switch then the left door
switch (Fig. 2).
The right door lock/window switch operates the
same as the driver's door switch. The voltage and
its
PIN IDENTIFICATION
PIN SIDE OF SWITCH
UNLOCK
PINS 3 & 4
PINS 2 & 5
898P-5
ground paths are reversed to unlock the doors.
The power door lock operates with battery power Fig. 1 Door Lock Switch Continuity
and, therefore, is independent of the ignition switch. (2) Measure voltage at lock terminal (cavity 3) of
door switch connectors. Meter should read battery
SWITCH TEST voltage. If not, repair open circuit between fuse cav
(1) For switch testing, remove the switchfromits ity 19 and switch.
mounting location as described in the Service Proce (3) Remove left door switch. Measure resistance at
dures section of this group. cavities 2 and 4 of left door switch connector to
(2) Using an ohmmeter, refer to Fig. 1 to deter ground. Meter should read zero ohms. If not, repair
mine if continuity is correct in the lock and unlock open in circuit to ground. If OK, install left door
switch positions. If these results are not obtained, re switch.
place the switch. (4) Remove right door switch. Measure resistance
between cavities 2 and 4 of right door switch connec
DIAGNOSING POWER DOOR LOCKS tor to ground. Meter should read zero ohms. If not,
For complete circuit diagrams refer to Group repair open in circuit between switches. If OK, install
8W - Wiring Diagrams. right door switch.
Check fuse i n cavity 5 of P D C and cavity 19 of (5) At the motor connector, check for battery volt
fuseblock module. Replace as required. age at either terminal with a door switch moved to
(1) Measure voltage at output side of fuses. Meter lock or unlock position. If OK, replace motor. If not,
should read battery voltage. If not, repair open in cir repair open in circuit to motor.
cuit to fuse.
8P - 2 POWER DOOR LOCKS •
LEFT DOOR RIGHT DOOR
LOCK SWITCH LOCK SWITCH
I—•UNLOCK I—•UNLOCK
tr
RIGHT DOOR
5
fr-<( « « P36—(f^ -» P34 LOCK MOTOR
Z3
tt~<( ft « P35 «- *) P33
KOCK -« F35 (f
Z3
-F35 » F35-
Z3
F35
1 <s ^
LEFTSIDE
COWL GROUND FUSE #19
(20 AMP) LEFT DOOR
LOCK MOTOR
A7 FUSE #5 P33-
(50 AMP)
X A7 • A7—« >> -AO
zo
BODY —
GROUND J948P-1
Fig. 2 Power Door Lock Circuit Schematic

LOCK MOTOR STALL TEST exceeds 8 amps at room temperature or i f the motor
l b test the lock motor, attach an ammeter i n series does not complete its travel i n less than one second,
with the motor and operate the door switch. Replace Refer to Service Procedures,
the lock motor and latch assembly i f current draw
• POWER DOOR LOCKS 8P - 3
SERVICE PROCEDURES
SWITCH REPLACEMENT LOCK MOTOR AND LATCH ASSEMBLY
(1) Remove 2 screws and door pull cup (Fig. 1). REPLACEMENT
(1) Remove switch as described in Switch Replace
REMOVE 2 SCREWS
ment.
( 2 ) Pull power mirror switch control knob rearward
to remove from switch (Fig. 4 ) i f equipped.
DOOR TRIM
PANEL
SWITCH CONTROL
KNOB
J948S-2

J948T-6
Fig. 4 Power Mirror Switch Control Knob Removal/

SWITCH BEZEL Installation
RETAINING TAB
5).
SWITCH RETAINING
J948S-3 NUT

( 3 ) Pull rear of switch up and away from door.
DOOR TRIM'
PANEL
CONNECTOR
LOCKING SWITCH PANEL POWER MIRROR
TABS FRONT CLIP J948S-8 SWITCH J948T-5
Fig. 3 Door Switch Connectors Fig. 5 Power Mirror Switch Retaining Nut
(5) Plug connector onto new switch. To aid in removal of the trim panel, start at
(6) Install a new switch by inserting front of the bottom of the panel.
switch into trim panel then pushing down rear of
switch.
8P - 4 POWER DOOR LOCKS
(4) Using a device such as a trim stick, pry trim

panel away from door around perimeter and remove
trim panel.
(5) Roll door watershield away from bottom of door
to allow access to lock motor (Fig. 6).
(6) Remove 3 screws holding lock motor and latch
assembly to door.
(7) Disconnect linkage rods.
(8) Pull motor and latch out far enough to unplug
electrical connector and remove moti ~ and latch from
door.
(9) To install a motor and latch, reverse the re
moval procedures. Tighten screws to 10.5 N*m (95 in.
lbs.).
J948P-3
Fig. 6 Lock Motor And Latch Removal/Installation
i
POWER SEATS
CONTENTS
page page
DIAGNOSIS 1 POWER SEAT SWITCH REPLACEMENT 2

GENERAL 1 SWITCH TESTING 2
POWER SEAT MOTOR REPLACEMENT 2
GENERAL motor. The motor is grounded and the motor runs to

The power seat can be adjusted i n 6 different direc drive the seat forward until the switch is released.
tions (Fig. 1). The control switch is on the lower out With the switch i n the REAR position, the polarity
board side of the seat. is reversed and causes the motor to run i n the oppo
The front lever on the switch raises or lowers the site direction and drive the seat backward.
front of the seat cushion; the center lever raises or The front motor works i n a similar way when the
lowers the complete seat by moving the switch up or front height switch is operated.
down. I t also moves i t forward or rearward by mov To raise the entire seat, the center position seat
ing the switch forward or rearward. The rear lever switch is held i n the UP position. This applies bat
raises or lowers the rear of the seat cushion. tery voltage to both the front and rear motors. Both
motors run to drive the entire seat up. A similar ac
tion occurs to move the entire seat down.
Each motor contains a self-resetting circuit breaker
to protect i t from overload. Consecutive or frequent
resetting must not be allowed to continue. Make nec
essary repairs.
DIAGNOSIS
Refer to Group 8W-Wiring Diagrams for a complete
circuit diagram.
Before any testing is attempted the battery should
be fully charged and all connections and pins cleaned
and tightened to insure proper continuity and
grounds.
With the dome lamp on, apply switch i n direction
of the failure. I f the dome lamp dims, the seat may
be jamming. Check for binding. I f the dome lamp
1. SEAT UP A N D D O W N
2. SEAT FORWARD A N D REARWARD
does not dim, then proceed with the following electri
3. SEAT TILT (FRONT UP A N D D O W N ) cal tests.
4. SEAT TILT (REAR UP A N D D O W N )
J938R-4 S E A T MOTOR ASSEMBLY
• Position seat switch to move all 3 seat motors. The
Fig. 1 Power Seat Switch seat should move i n all directions. I f not, go to No
There are 3 reversible motors that operate the Seat Motors Operate. I f one or more motors operate,
power seat. The front and rear of the seat cushion refer to Switch Testing.
are operated by different motors. They can be raised Test seat switch. I f OK, replace defective motor.
or lowered independently of each other. Moving the
center position seat switch to either the UP or NO SEAT MOTORS OPERATE
DOWN position, runs both the front and rear motors 30 amp circuit breaker #2 (fuseblock module)
at the same time. installed.
The forward-rearward motor is operated by the • Probe circuit breaker, on fuseblock module. I f bat
center position seat switch. When the switch is held tery voltage is present, replace circuit breaker.
in the FORWARD position, battery voltage is applied
through the switch contacts to the forward-rearward
POWER SEAT CIRCUIT SCHEMATIC
CIRCUIT BREAKER #2
(30 AMP)
BODY • =
GROUND BATTERY
J948R-1
• Remove switch, refer to Seat Switch Replacement.

Measure voltage at red wire at switch. Meter should
read battery voltage. I f not, repair open to circuit
breaker.
• Measure resistance at black wire at switch. Meter
should read zero ohms. I f OK, replace switch. I f not,
repair open to ground.
SWITCH TESTING
POWER SEAT SWITCH REPLACEMENT

(1) Remove 2 screws holding switch and bezel to
seat (Fig. 2). 7^
(2) Remove 2 screws holding switch to bezel (Fig.
3). J948R-2
(3) Pull switch from seat far enough to access con

nector, and unplug. Fig. 2 Seat Switch and Bezel Remowal
(4) To install switch, reverse removal procedures. (4) Unplug power seat wire harness connector lo
cated under seat.
POWER SEAT MOTOR REPLACEMENT (5) Remove driver's seat from vehicle.
The seat motors are not serviced separately. Re (6) Remove 4 screws attaching seat track to seat
place the power seat track assembly i f a motor is (Fig. 6).
faulty. (7) To install power seat track and seat, reverse
(1) Remove 3 bolts attaching seat frame to floor the removal procedures. Torque seat mounting
pan.
screws to 20 N-m (15 ft. lbs.).
(2) Remove 1 nut from stud locating seat frame to
floor pan.
(3) Remove 2 bolts holding power seat to center
seat section (Figs. 4 and 5).
Fig. 4 Driver's Power Seat Removal
Fig. 5 Center Seat Section Attachment

POWER WINDOWS 8S • 1
POWER WINDOWS
CONTENTS
page page
SERVICE PROCEDURES ... 3 TEST PROCEDURES .. 1
GENERAL INFORMATION I t is necessary that the window be free to slide up

A permanent magnet motor moves each power win and down i n the glass channels or tubes and tracks.
dow. Each motor raises or lowers the glass when volt I f the window is not free to move up and down, the
age is supplied to the motor. The direction the motor window motor will not be able to move the glass.
turns depends on the polarity of the supply voltage. Tb determine i f the glass is free, disconnect the
The door switches control the supply voltage polarity. electric window regulator glass channel from the
Each motor is protected by a built-in circuit glass. Slide window up and down by hand.
breaker. I f a window switch is held on too long with A less positive method is to shake the glass i n the
the window obstructed or after the window is fully door, (with glass positioned between the up and down
up or down, the circuit breaker opens the circuit. The stop positions). I f the glass will move slightly from
circuit breaker resets automatically as i t cools. Do side to side, front to rear, and up and down, the win
not allow frequent or consecutive resetting of the cir dow is probably not bound tight i n the tracks.
cuit breaker to continue.
TEST PROCEDURES
DESCRIPTION
With ignition switch i n ON, voltage supply comes SWITCH POSITION CONTINUITY BETWEEN
from the 40 amp fuse, cavity 2, i n the power distri PINS1,2,3,5&6
bution center (PDC) to the 30 amp circuit breaker, i n OFF Note: Pin 4 should not have
cavity 1 of the fuseblock module. Power then goes to continuity with a n y of the other
the driver's door switch terminal 4 and passenger pins in the O F F position.
door switch terminal 3. Current flow for the pas
DRIVER'S PINS 1 & 4
senger door motor must go through b o t h the PINS2&3
passenger door switch and the driver's door
PASSENGER PINS4&5
switch to reach ground. P1NS3&6
Both motors are grounded through the driver's door
DRIVER'S PINS 1 & 3
window switch by a black wire attached to a ground
PINS2&4
stud. The stud is located on the driver's side cowl.
PASSENGER HNS3&5
PINS4&6
SWITCH TEST
For switch testing, remove the switch from its
mounting location. Using an ohmmeter, refer to Figs.
1 and 2 to determine i f continuity is correct i n the up
and down switch positions. I f continuity is correct
perform window lift motor test.
DIAGNOSING POWER DOOR LOCKS

For complete circuit diagrams refer to Group 1
8W - Wiring Diagrams.
Check fuse i n cavity 2 of P D C . Replace as re 6 2
quired.
(1) Locate circuit breaker i n cavity 1 of fuseblock
4
J J948S-9
module. Pull out slightly but be sure that circuit
breaker terminals still contact terminals i n fuseblock
Fig. 1 Driver's Door Power Window Switch
module. Connect ground wire of voltmeter to a good
Continuity
ground. With probe of voltmeter positive wire, check
8S - 2 POWER WINDOWS
(3) Carefully separate multiple terminal block on

wiring harness from switch body.
SWITCH CONTINUITY (4) Turn ignition switch to ON position. Connect
POSHION eewEEN
one lead of test lamp to black (BK) wire terminal
OFF
PINS 1 St 4 (cavity 3). Touch other test lamp lead to tan (TN)
PINS 2 & 5
wire terminal (cavity 4). I f test lamp comes on, the
® DOWN
PINS 2 & 3 wiring circuit between the battery and switch is func
3 PINS 1 & 4 tional. I f lamp does not come on, check for an open
circuit or poor ground. I f OK, install left door switch.
PINS 3 &4 (5) Remove passenger door switch as described i n
UP PINS 2 & 5 the Service Procedures section of this group.
(6) Measure voltage at lock terminal (cavity 3) of
PIN IDENTIFICATION right door switch connector. Meter should read bat
PIN SIDE O F SWITCH J948S-10
tery voltage. I f not, repair open circuit between cir
cuit breaker and switch.
Fig. 2 Passenger's Door Power Window Switch (7) Turn ignition switch to OFF. Measure resis
Continuity tance between cavities 2 and 4 of right door switch
both terminals of circuit breaker for battery voltage. connector to ground. Meter should read zero ohms. I f
I f only one terminal checks at battery voltage, circuit not, repair open i n circuit between switches. I f OK,
breaker is defective and must be replaced. I f neither install right door switch.
terminal shows battery voltage, check for open or (8) A t the motor connector, check for battery volt
shorted circuit to circuit breaker. age at either terminal with a door switch moved to
(2) Remove driver's door switch as described i n the up or down position. I f OK, replace motor. I f not, re
Service Procedures section of this group. pair open i n circuit to motor.
5 -F21-
-Z3-
-Qll-
4>-
LEFT WINDOW
LEFTSIDE LIFT MOTOR
LEFT
= COWL GROUND
2
_?2
4h -Q21-
DOWN
i«
UP 5
-Q16- 4> >h
2 UP
r Q12
E
I* - RIGHT WINDOW
RIGHT LIFT MOTOR
IN ' ®
6
-Q26- 4>—>y
•F21-
4
11DOWN
1
4>- -Q22
3
DOWN RIGHT DOOR
LEFT DOOR POWER WINDOW
POWER WINDOW SWITCH
SWITCH F21
A2-
IGNITION
SWITCH
START t ACC
* • ^1 CIRCUIT
ICB#1 BREAKER 1
RUN 1 • Y | (30 AMP)
OFF LOCK
55
< 1
BODY BATTERY =^^f Y
GROUND GROUND J948S-1

\
Fig. 3 Power Window Circuit Schematic

POWER WINDOWS 88 - 3
SERVICE P R O C E D U R E S
SWITCH REPLACEMENT REGULATOR AND MOTOR REPLACEMENT
(1) Remove 2 screws and door pull cup (Fig. 1).
REMOVAL
REMOVE 2 SCREWS To repair or inspect the entire electric window reg
ulator, remove from door as follows:
(1) Remove switch as described i n Switch Replace
ment.
(2) Pull power mirror switch control knob rearward
to remove from switch (Fig. 4), i f equipped.
DOOR TRIM
PANEL
J948S-2
SWITCH CONTROL
KNOB
J948T-6
SWITCH BEZEL
RETAINING TAB
Fig. 4 Power Mirror Switch Control Knob Removal/
Installation
J948S-3
5).
Fig. 2 Switch Bezel Rear Retaining Tab SWITCH RETAINING
NUT
DOOR TRIM-
PANEL
CONNECTOR
LOCKING SWITCH PANEL
TABS FRONT CLIP
J948S-8
Fig. 3 Door Switch Connectors POWER MIRROR

SWITCH J948T-5
(5) Plug connector onto new switch.
(6) Install a new switch by inserting front of Fig. 5 Power Mirror Switch Retaining Nut
switch into t r i m panel then pushing down rear of
switch.
8S - 4 POWER WINDOWS •
To a i d i n removal o f the trim panel, start at
the bottom of the panel.
(4) Using a device such as a trim stick, pry trim panel
away from door around perimeter and remove trim panel.
(5) Roll door watershield away from bottom of door
to allow access to regulator screws (Fig. 6).
Fig. 6 Window Regulator Mounting Screws

(6) Move glass to allow access to glass channel at
taching screws Figs. 7 and 8).
J948S-7
Fig. 9 Window Regulator Removal

(2) Install remaining 4 screws.
(3) Tighten 4 regulator screws to 12 N-m (105 in.
lbs.) torque.
(4) Move glass as far rearward into channel as pos
sible and pushed down. Tighten 2 window track
screws to 12 N-m (105 in. lbs.) torque.
(5) Attach door glass by sliding 2 nuts into the
slots on the channel (Figs. 7 and 8). Tighten door
Fig. 7 Glass Channel Front Attaching Nut glass nuts to 12 N-m (105 in. lbs.) torque.
(7) Slide the glass rearward to remove nuts from (6) Connect wire harness connector to regulator.
door panel. (7) Using 3M 08044 or 3M 08041 adhesive/sealant,
(8) Pull glass to full up position and tape to door. install plastic water dam sheet.
(9) Unplug wiring connector from motor. (8) Install power mirror switch into t r i m panel us
(10) Remove 2 window track and 2 regulator ing retaining nut (Fig. 5), i f equipped.
screws (Fig. 6). (9) Install switch to trim panel.
(11) Loosen 2 regulator screws (Fig. 6). (10) Place trim panel i n the installation position
(12) Remove window regulator from door (Fig. 9). and press i n nylon retainers.
(11) Install door pull cup and trim panel attaching
INSTALLATION screws.
(1) Place regulator inside door by sliding 2 loose (12) Install switch panel.
screws i n slots i n door.
• POWER MIRRORS 8T - 1
POWER MIRRORS
CONTENTS
page page
AUTOMATIC DAY/NIGHT MIRROR .. 6 TEST PROCEDURES 1

SERVICE PROCEDURES .. 4
GENERAL INFORMATION
Electrically-operated remote control mirrors are
available as an option. The mirrors are controlled by
a single switch assembly located on the door panel
(Fig. 1).
The mirror switch is a toggle-type switch. Rotate
the switch clockwise (Right mirror) or counterclock
wise (Left mirror) for mirror selection, and moved up,
down, right, or left for mirror movement direction.
The motors that operate the mirrors are part of the
mirror assembly and cannot be serviced separately.
Fig. 1 Power Mirror Switch
T E S T PROCEDURES
MIRROR MOTOR TEST PROCEDURE MIRROR SWITCH TEST PROCEDURE
(1) Remove power mirror switch from mounting po (1) Remove power mirror switch from mounting po
sition (refer to Service Procedures - Mirror Switch sition, refer to Service Procedures.
Replacement). (2) Disconnect wiring harness at switch connector.
(2) Disconnect wiring harness at switch connector. (3) Test for continuity (no resistance) between the
(3) Connect 2 jumper wires as follows and refer to terminals of the switch as shown i n the Mirror
the Mirror Test Chart for wire hookups at the switch Switch Continuity Chart.
connector (harness side, not switch side). (4) I f results shown i n the chart are not obtained,
• connect one to a 12-volt source replace the switch.
• connect the other to a good body ground.
I f results shown i n chart are not obtained, check
for broken or shorted circuit, or replace mirror as
sembly as necessary.
8T - 2 POWER MIRRORS •
MIRROR SWITCH CONTINUITY CHART MIRROR TEST CHART
Mirror Selector Knob in "I" Position MIRROR REACTION

MOVE LEVER CONTINUITY B E T W E E N 12 Volts Ground Right Left
YL/BK a n d PK, YL/PK a n d BK YL/BK WT UP
YL a n d PK YL YL/PK UP
YL/PK a n d PK, DB a n d IK WT YL/BK DOWN
D B / W T a n d BK YL/PK YL DOWN
YL/PK a n d PK, YL a n d BK WT DB RIGHT
YL/BK a n d BK YL/PK DB/WT RIGHT
YL/PK a n d B K , D B a n d PK
4 D B / W T a n d PK
DB
DB/WT
WT
YL/PK
LEFT
LEFT
Mirror Selector Knob in " R " Position
MOVE LEVER CONTINUITY B E T W E E N J928T-4
W T a n d B K , YL a n d PK
YL/BK a n d PK
W T a n d PK, D B a n d BK
D B / W T a n d BK
WT a n d PK, YL a n d BK
Y L / B K a n d BK
W T a n d BK, DB a n d PK
D B / W T a n d PK
J928T-5
POWER MIRRORS 8T - 3
POWER MIRROR CIRCUIT SCHEMATIC
POWER MIRROR SWITCH

FEED
-Ml-
GND
4
n U.I #
1UP
*—-#
1,11
LTJ
4 4
L
•
RT
RT
W/POWER MIRROR MIRROR
LOCKS
5 ^ 2 # 7d* 34* 1#
Z3 Z3
FUSE #17 X W ^ O POWER

(15 AMP) LOCKS
P75 P7J P73 P70 P72 P74
W/POWER SEATS-*
> W / 0 POWERi
SEATS
LEFT SIDE
COWL GROUND
I
T
A7
FUSE #1
A7
r
¥75
75 P71 P73 P70 P72
1
P74
P7
I 1
FUSE
(50 AMP) 1
I I
„ P I
AO
DOWN OS
LEFT 3
LEFT
RIGHT DOWNJp
• U P mu
LEFT
RIGHT
ppfRi
RIGHT
BATTERY
MIRROR
I MIRROR
1948T-2
SERVICE PROCEDURES
MIRROR SWITCH REPLACEMENT DOOR TRIM*
PANEL
(1) Remove 2 screws and door pull cup (Fig. 2)
REMOVE 2 SCREWS

Fig. 5 Power Mirror Switch Control Knob ,
Installation
SWITCH RETAINING
NUT
SWITCH BEZEL
RETAINING TAB
DOOR TRIM-
PANEL
J948S-3

POWER MIRROR
SWITCH J948T-5
Fig. 6 Power Mirror Switch Retaining Nut

To aid in removal of the trim panel, start at
the bottom of the panel.
(7) Using a device such as a trim stick, pry trim
panel away from door around perimeter and remove
trim panel.
CONNECTOR (8) Unplug power mirror switch connector (Fig. 7).
LOCKING SWITCH PANEL
TABS FRONT CLIP J948S-8
INSTALLATION
Fig. 4 Door Switch Connectors (1) Install switch into trim panel using retaining
(5) Pull power mirror switch control knob rearward nut (Fig. 6).
to remove from switch (Fig. 5). (2) Plug switch connector together (Fig. 7).
(6) Remove switch retaining nut from switch (Fig. (3) Place trim panel in position and press in nylon
6). retainers.
• POWER MIRRORS 8T - S
Fig. 7 Power Mirror Switch Connector

(4) Install power switch control knob by pushing
onto control stem.
(5) Place front of door switch panel into opening. Fig. 8 Power Mirror Removal/Installation
Press rear of switch panel into place. (2) Unplug mirror motor connector (Fig. 8).
(6) Install door pull cup. (3) Remove 3 nuts holding mirror to door.
(7) Install door panel attaching screws. (4) For installation, reverse removal procedure.
MIRROR ASSEMBLY REPLACEMENT
(1) Remove door trim panel as described i n Mirror
Switch Replacement.
AUTOMATIC DAY/NIGHT MIRROR
GENERAL DIAGNOSIS
The automatic day/night mirror automatically Light sensor must be covered completely so
changes its reflectance to reduce glare i n all types of that no light reaches the sensor. Use one finger
driving conditions. A thin layer of electrochromic ma pressed tightly against the sensor, or cover sen
terial between two pieces of conductive glass make sor completely with electrical tape.
up the face of the mirror. As light conditions change, • Cover the forward facing sensor to keep out any
two photocell sensors adjust the reflectance while re ambient light.
ducing glare from headlamps approaching from the • Shine a light into the rear facing sensor. Watch to
rear. see i f the mirror darkens.
With the mirror darkened, place the vehicle i n re
SENSORS verse, the mirror should return to its normal condi
tion.
The mirror incorporates 2 sensors. The ambient
I f the above conditions are met the mirror is oper
sensor (forward facing) detects normal outside light
ating properly.
levels. The headlamp sensor (rear facing) detects
I f the above conditions are not met, perform the
light levels received at the rear window side of the following voltage tests (Fig. 1).
mirror. When the difference between the two levels Test 3 way connector harness.
becomes too great (light level received at rear of mir (1) Pin 1 - Ignition Switch i n RUN position, should
ror is much higher than front of mirror), the mirror have battery voltage.
begins to darken. (2) Pin 2 - Should have continuity to ground.
(3) Pin 3 - When the transmission is i n reverse,
SWITCH should have battery voltage.
The mirror switch controls whether the automatic (4) I f test is OK, replace Mirror.
dimming feature is ON or OFF. When ON is selected, (5) I f not, refer to 8W - Wiring Diagrams to test
the switch is lighted by an integral LED. the circuits.
To test the operation:
• Turn ignition switch to the ON position. REPLACEMENT
• Place mirror switch i n ON (switch lighted) position (1) Unplug connector behind mirror (Fig. 2).
(Fig. 1).
REAR FACING SENSOR
l
MmM--^^ RELEASE
^ mfcf TAB
ON/OFF ELECTRICAL
SWITCH CONNECTOR J948T-8
FORWARD FACING SENSOR J948T-9
Fig. 2 Automatic Mirror Removal
Fig. 1 Automatic Day/Night Mirror (2) Remove screw holding mirror to windshield.
(3) Push mirror up far enough to clear the support
and remove mirror.
(4) To install mirror, reverse removal procedures
• BUZZER WARNING SYSTEMS 8U - 1
BUZZER WARNING SYSTEMS
CONTENTS
page page
BUZZER MODULE REPLACEMENT 5 KEY-IN SWITCH REPLACEMENT 4

DIAGNOSIS 1 OPERATION 1
GENERAL INFORMATION 1
GENERAL INFORMATION This occurs when the seat belt switch is closed be
The buzzer module is located i n the left end of the cause the driver's seat belt is not buckled. The Fas
instrument panel (Fig. 1) behind the fuseblock mod ten Belt lamp will also turn on, along with the
ule cover. The buzzer sounds an audible warning warning sound.
tone i n any of the following conditions:
• Vehicle lights are ON when the driver's door is KEY4N4GNITION
opened. To sound the key-in-ignition alarm, the module
• The key is in the ignition and the driver's door is needs:
open. • the ignition key warning switch must be closed.
• The ignition is switched ON and the driver's seat • the driver's door jamb switch must be closed.
belt is not buckled. Buzzer will quit after 4 to 8 sec These conditions ground pin 6 of the module. These
onds. I n addition to the buzzer, a seat belt indicator switches are closed when the driver's door is open
lamp turns on for 4-8 seconds as a reminder to fasten and the key is i n the ignition.
seat belt.
L I G H T S ON
To sound the lights-on warning, the module needs:
• the headlamp switch must be closed.
• the driver's door jamb switch must be closed.
These conditions ground pin 6 of the module. These
switches are closed when the driver's door is open
BUZZER and the headlamp switch is ON.
MODULE
DIAGNOSIS
I f the buzzer unit does not operate as described,
check the two fuses for pins 1 and 7 (Figs. 2, 3 and 4)
and replace as required. I f the fuses are not defec
tive, perform the following tests to determine i f the
problem is i n the module or in the wiring. Remove
buzzer module, refer to Buzzer Module Replacement.
Plug i n a known good module and check its opera
tion. I f the problem is not corrected by replacing the
Fig. 1 Buzzer Module Location module, remove the module and continue as follows:
OPERATION
VOLTAGE T E S T S
Battery voltage for module operation is supplied to
Ignition i n ON, measure between the follow
two pins. Battery voltage is present at pin 7 at all
ing pins and vehicle ground.
times (Figs. 2 and 3). Pin 1 receives voltage when the • Measure voltage at buzzer module connector pin 1.
ignition switch is turned ON. Meter should read battery voltage. I f not, repair open
to ignition switch.
S E A T BELT WARNING
Turn ignition O F F and remove key from igni
To sound the seat belt warning, the module needs:
tion.
• battery voltage at the ignition switch input (pin 1).
• Measure voltage at buzzer module connector pin 7.
• a ground at the seat belt switch. Meter should read battery voltage. I f not, repair open
• a ground at pin 3 to activate the timer. to fuse. Battery voltage is present at pin 7 at all
times, regardless of ignition switch position.
8U - 2 BUZZER WARNING SYSTEMS •
• Buzzer module connector pin 4. Drivers seat belt
not buckled. Meter should read zero ohms. I f not, re
SEAT BELT
pair open to ground (or buckle switch may be defec
SWITCH tive). Meter should read open circuit i f drivers seat
belt is buckled. I f not, repair short to ground (or
buckle switch may be defective).
• Buzzer module connector pin 6. Open driver's door,
key i n ignition, (in OFF position). Meter should read
zero ohms. I f not, repair open to ground.
• Buzzer module connector pin 6. Open driver's door,
headlamp switch ON, meter should read zero ohms. I f
GROUND not, repair open to ground.
SEAT BELTl J—I DOOR SW
WARNING - 7 (SHOWN DOOR CLOSED)
LIGHT
•KEYSW*
vc. OTM UGHTSSW
IGNITION
(SHOWN KEY OUT) (J (SHOWN UGfflS OFF)
L
B+
TO DOOR SWITCH
- KEY I N SWITCH A N D
HEAD LAMP O N SWITCH J948U-3
Fig. 2 Buzzer Module Connector Terminal

Identification—Front View SEAT BELT SW
(SHOWN
IGNSW
LIGHTS-ON/KEY-IN-IGNITION BUCKLED)
(SHOWN IGN OFF)
WARNING
(? PIN VIEW (SAME AS REAR SIDE [WIRE SIDE]
CONNECTOR VIEW)
BATTERY ( + ) X = DoNotCare
I)
SEAT DRIVER'S HEAD
FUNCTION DESCRIPTION IGN. KEY
BELT DOOR LAMPS
4 to 8 Second ^ O n Not
Tone and X X X
Seat Lamp Output O P Bckld
Belt
Reminder 4 to 8 Second
LamjÔutput Bckld X X X
OP
Key and Continuous, In X

Head Lamp Steady X X Open
SEAT BELT Reminder* Tone X On
SWITCH
IGNITION SEAT BELT GROUND
WARNING LIGHT J928U-9 J948U-9
Fig. 3 Buzzer Module Terminal Identification—Front Fig. 4 Buzzer Module Schematic

View
RESISTANCE TESTS
IO Q O O
CAUTION: Before making resistance measurements, 4 3 2 1
turn ignition switch O F F and disconnect negative WIRE CONTINUITY
cable from battery to avoid damaging ohmmeter. CAVITY APPLICATION SETWIEN
1 Hab lamp 1 & 2 Almost zero ohms
2 Hab bmp (bulb fibment)
Measure between the following pins and vehi
cle ground. 3 Key-in warning switch 3 & 4 with key in ignition
4 Key-in warning switch
• Buzzer module connector pin 2. Meter should read
J918M-3
almost zero ohms (bulb filament). I f not, replace seat
belt indicator bulb.
Fig. 5 Halo Lamp And Key-In Warning Switch
• Buzzer module connector pin 3. Meter should read
Continuity Chart
zero ohms. I f not, repair open to ground.
BUZZER WARNING SYSTEMS 8U - 3
K 00 CM
«0 «0
5
i
I
q>
E
.§
8U - 4 BUZZER WARNING SYSTEMS
KEY-IN SWITCH REPLACEMENT (7) Remove key cylinder from ignition switch as
follows:
REMOVAL (a) Insert key i n ignition switch and move switch
(1) Disconnect negative cable from battery. to LOCK position.
(2) Tilt column only—remove tilt lever (counter (b) Use a small screw driver to depress key cyl
clockwise). inder retaining pin flush with key cylinder surface
(3) Carefully remove both upper and lower steering (Fig. 9).
column covers. Requires removal of 3 screws (torx
T-20).
(4) Remove 3 ignition switch mounting screws I G N I T I O N SWITCH
MOUNTING
(tamper proof torx bit Snap On TTXR15A2 or equiv SCREWS (3)
alent required) (Fig. 7).
STEERING
IGNITION
COLUMN
SWITCH 938D-1
Fig. 9 Key Cylinder Pin
STEERING (c) Rotate key clockwise to OFF position. The key

IGNITION
COLUMN
SWITCH
cylinder should now be unseated from ignition
908D-14
switch assembly.
Fig. 7 Ignition Switch Screw Removal CAUTION: Do not try to remove key cylinder at this
(5) Gently pull switch away from column. Release time.
2 connector locks on 7 terminal wiring connector,
then remove connector from ignition switch. (d) The key cylinder is unseated and the key cyl
(6) Release connector lock on 4-terminal key-in inder bezel should be about 1/8-inch above ignition
and halo lamp connector then remove connector from switch halo lamp ring (Fig. 10). Rotate key counter
ignition switch (Fig. 8). clockwise to LOCK position and remove key.
(e) Remove key cylinder (Fig. 11).
INSTALLATION
(1) Install 2 wiring connectors to the switch. Make
KEY-IN SWITCH & MULTI-FUNCTION sure that switch locking tabs are fully seated in the
SWITCH
H A L O LIGHT wiring connectors.
(2) Mount ignition switch to column with 3 screws.
When equipped with column shift:
• the shifter must be i n PARK position
• the park lock dowel pin on the ignition switch as
sembly must engage with column park lock slider
linkage (Figs. 12 and 13).
Verify ignition switch is i n LOCK position (flag is
TURN S I G N A L parallel with ignition switch terminals). Apply a daub
SWITCH & LEVER
of grease to flag and pin. Position park lock link and
slider to mid-travel. Position ignition switch against
lock housing face, making sure pin is inserted into
SPEED
park lock link contour slot. Torque retaining screws
IGNITION
SWITCH CONTROL J918J-2 to 2 N-m (17 in. lbs.).
(3) Assemble cover to the column with 3 screws.
Fig. 8 Key-In Switch And Halo Lamp Connector Torque screws to 2 N-m (17 in. lbs.).
• BUZZER WARNING SYSTEMS 8U - 5
908D-18
Fig. 12 Ignition Switch—View From Column
1
RING 908D-16
Fig. 10 Unseated Key Cylinder
Fig. 13 Ignition Switch Mounting Pad

(2) Remove 5 screws and knee blocker from lower
Fig. 11 Key Cylinder Removal

(4) Tilt column only—install tilt lever (clockwise).
(5) Install negative cable to battery.
(6) Install key cylinder as follows:
(a) With key cylinder and ignition in the LOCK
position, gently insert key cylinder into the ignition
switch assembly until it bottoms.
(b) Insert key, while gently pushing on key cylin
der inward toward the ignition switch, rotate key
clockwise to the ON position.
(7) Check for proper operation of push-to-lock, halo Fig. 14 Knee Blocker
lamp, ACCESSORY, LOCK, OFF, ON, START, col
umn lock and shift lock (if applicable). (3) Remove 2 screws holding fuseblock module to
BUZZER MODULE REPLACEMENT (4) Pull fuseblock module back far enough to gain
(1) Disconnect negative cable from battery. access to buzzer module.
8U - 8 BUZZER WARNING SYSTEMS
(5) Pull buzzer module out of fuseblock module.

(6) Tb install a new buzzer module, reverse re
moval procedures.
Fig. 15 Fuseblock Module Removal

• WIRING DIAGRAMS 8W - 1
WIRING DIAGRAMS
CONTENTS
page page
COMPONENT IDENTIFICATION 10 SPLICE LOCATIONS 31

GENERAL INFORMATION 1 WIRING DIAGRAMS 43
INDEX
page page
Circuit Identification 2 Secondary Ignition Wiring 1
Component Identification 2 Splice Locations 3
Connector and Terminal Assembly Replacement ... 4 Symbols Identification 5
Connector Replacement 4 Terminal Replacement 5
Connectors 3 Troubleshooting Wiring Problems 3
Controller and Module Locations 5 Wire Code Identification 2
Fuse Identification 5 Wiring Diagram Sheets and Indexes 1
Ground Identification 5 Wiring Harness Routing 5
Locating A System or Component . . 2 Wiring Repair 3
Power Distribution Center Identification 5
The wiring diagrams contain the latest information SPARK PLUGS

available at time of publication. Throughout out this RIGHT BANK
group references may be made to a particular vehicle
by letter or number designation. A chart showing the
breakdown of these designations is included i n the
Introduction Section of this service manual.
SECONDARY IGNITION WIRING

Secondary ignition wiring is shown i n Figures 1, 2
and 3. For information on ignition systems or distrib SPARK PLUGS
utor operation refer to Group 8D Ignition Systems. LEFT BANK
EIGHT CYLINDER DISTRIBUTOR-CLOCKWISE ROTATION
FOR 318 CUBIC INCH ENGINES
FIRING ORDER-1-84-3-6-&7-2 RP899
Fig. 2 Secondary Ignition Wiring 5.2L and 5.9L

Engine
WIRING DIAGRAM SHEETS AND INDEXES
The wiring diagram sheets are organized so that
systems relating to the basic vehicle and all of its op
tions are shown. Add-on or non-factory options are
not covered. The diagram pages are identified by a
sheet number which is located at'the lower right or
3.9L SIX-CYLINDER ENGINE
DISTRIBUTOR—CLOCKWISE R O T A T I O N
left hand corner of each sheet. Page numbers at
FIRING ORDER 1 - 6 - 5 - 4 - 3 - 2 RN755 the top of each page do not apply to diagram
sheets.
Fig. 1 Secondary Ignition Wiring 3.9L Engine
8W - 2 WIRING DIAGRAMS •
18 LB/YL*
0 0 © £>i0
FRONT
OF COLOR O F WIRE
ENGINE (Light Blue w i t h Yellow Tracer)
. G A U G E O F WIRE
(18 G a u g e )
10) (8
©nr© 0 PART O F AAAIN CIRCUIT
5 1 LI
5
10
9
8
7 3
2
(Varies Depending o n Equipment)
. 6 AAAIN CIRCUIT IDENTIFICATION
T J948W-20 918W-16
Fig. 4 Wire Color Code Identification

Fig. 3 Secondary Ignition Wiring 8.0L Engine
Diagram sheets show all information relating to COLOR COLOR
STANDARD
COLOR
STANDARD
TRACER COLOR TRACER
the system. This includes feeds, grounds, switch in CODE CODE
COLOR CODE
ternal circuity, connectors, splices, and pin identifica
tion for controllers and modules. A l l connectors, BL BLUE WT OR ORANGE BK
switches, and relays are shown i n the at rest position
with the ignition switch removed and the doors BK BLACK WT PK PINK B K O R WT
closed. BR BROWN WT RD RED WT

In certain instances a wire may be referenced to
DB DARK WT TN TAN WT
another sheet. When this happens, the wire will be
BLUE
identified as to where i t is going.
The index used for the diagrams is located at the DG DARK WT VT VIOLET WT
beginning of the diagrams. I t covers all systems GREEN
shown i n the diagrams and is i n alphabetical order.
GY GRAY BK WT WHITE BK
WIRE CODE IDENTIFICATION LB LIGHT BK YL YELLOW BK

Each wire shown i n the diagrams contains a code BLUE
(Fig. 4) which identifies the main circuit, part of the
LIGHT BK * WITH TRACER
main circuit, gauge of wire, and color. The color is LG
GREEN
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 5). I f the 918W-136
wire has a tracer and i t is a standard color an aster
isk will follow the main wire color. I f the tracer is Fig. 5 Wire Color Code Chart
non-standard the main wire color will have a slash (/) The diagram index identifies the main system and
after i t followed by the tracer color. all components that relate to that system. There are
also sections of the index that identify specific com
CIRCUIT IDENTIFICATION
ponents only (for example modules, lamps, etc.). Re
A l l circuits i n the diagrams use an alpha/numeric
fer to a components name i n the index i f you are
code to identify the wire and its function. To identify
unclear as to what a system may be called.
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows Diagram pages are arranged starting with the bat
the main circuits only and does not show the second tery and fuses. Then working into charging, starting,
ary codes that may apply to some models. and ignition systems. After this they start at the
front of the vehicle and work to rear. The diagrams
LOCATING A SYSTEM OR COMPONENT end with connector identification pages.
To locate a system or component i n the diagrams,
refer to the alphabetical index at the front of the di COMPONENT IDENTIFICATION
agrams. Determine the diagram sheet number. Sheet l b find a components location on the vehicle refer
numbers are located at the lower right or left hand to the wiring and components section index. This sec
corner of each sheet. Page numbers at the top of tion shows the wire harness routing and the compo
the page do not apply to diagram sheets. nents location i n the vehicle. When using this section
M A I N CIRCUIT IDENTIPICATION
CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION
A Battery Feed: Fused a n d Unfused P Power Assist System: Locks, Mirrors

B A B S System Q Power Assist System: Windows
C Air Conditioning System R Airbag System
D CCD (+), CCD H S Air Suspension, Automatic Load Leveling
E Interior Lamp Illumination T Electronic Automatic Transaxle
F Battery Feed; Fused and Unfused V Windshield Wipers and Washers,
G Sensors, Sending Units, Switches Vehicle Speed Control System
K Powertrain Central Module W Power Assist System: Windows
L Exterior Lighting, Stop Lamp Switch X Horn, Radio, Radio Speakers, Power Locks
M Interior Lamps Z Ground Circuits: Includes power and signal
grounds for PCM
938W-17
refer to the wiring diagrams for the general location (1) Verify the problem.
of the component. Then use the component identifi (2) Verify any related symptoms. Perform opera
cation index to locate the proper figure number. tional checks on components in the same circuit as
the problem area. Refer to the wiring diagram fuse
SPLICE LOCATIONS application chart for circuit information.
Splices are indicated in the wiring diagrams by a (3) Analyze the symptoms. Use the wiring dia
diamond with splice circuit code within it (Fig. 6 ex grams to determine what the circuit is doing, where
ample 1). If there is more than one splice per circuit the problem most likely is occurring and where the
splice code a small box will be connected to the dia diagnosis will continue.
mond with the splice number in it (Fig. 6 example 2). (4) Isolate the problem area.
To locate a splice in the wire harness, determine (5) Repair the problem.
the splice number from the wiring diagrams, then re (6) Verify proper operation. For this step check for
fer to the splice location index. This section shows proper operation of all items on the circuit repaired.
the general location of the splice in the harness. Refer to the wiring diagram fuse application chart.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wir
ing diagrams. The wires must also be held securely
EXAMPLE 1 EXAMPLE 2 in place to prevent damage to the insulation.
918W-18 (1) Disconnect battery negative cable.
Fig. 6 Wiring Splice Examples
(2) Remove 1 inch of insulation from each end the
wire.
CONNECTORS (3) Place a piece of heat shrink tubing over one
The connectors shown in the diagram are viewed side of the wire. Make sure the tubing will be long
from the terminal end unless otherwise specified. For enough to cover and seal the entire repair area.
viewing bulkhead and engine controller connectors (4) Spread the strands of the wire apart on each of
refer to the back of the wiring diagrams. This area the exposed wires (Fig. 7 example 1).
shows major connectors for pin and cavity identifica (5) Push the two ends of wire together until the
tion. strands of wire are close to the insulation (Fig. 7 ex
ample 2).
TROUBLESHOOTING WIRING PROBLEMS
(6) Twist the wires together (Fig. 7 example 3).
When troubleshooting wiring problems there are
(7) Solder the connection together using rosin core
six steps which can aid in the procedure. The steps
type solder only. Do not use acid core solder.
are listed and explained below.
(8) Center the heat shrink tubing over the joint (6) Insert the removed wire i n the same cavity on
and heat using a heat gun. Heat the joint until the the repair connector.
tubing is tightly sealed and sealant comes out of both (7) Repeat steps four through six for each wire i n
ends of the tubing. the connector. Check that all wires are inserted into
(9) Secure the wire to the existing ones to prevent the proper cavities. For connector pin out identifica
chafing or damage to the insulation. tion refer to the wiring diagrams.
(10) Connect battery and test all affected systems. (8) Insert the connector locking wedge into the re
paired connector.
(9) Connect connector to its mating half.
(10) Connect battery and test affected systems.
CONNECTOR
CONNECTOR LOCKING
FINGER
LOCKING WEDGE
a 928W-144
Fig. 9 Connector Locking Finger and Locking

Wedge (Typical)
918W-20
CONNECTOR AND TERMINAL ASSEMBLY
Fig. 7 Wire Repair REPLACEMENT
CONNECTOR REPLACEMENT (1) Disconnect battery.
(1) Disconnect battery. (2) Disconnect the connector being repaired from
(2) Disconnect the connector that is to be repaired its mating half.
from its mating half. (3) Cut off the existing wire connector directly be
(3) Remove connector locking wedge (Fig. 8). hind the insulator and remove six inches of tape from
the harness.
CONNECTOR (4) Stagger cut all wires on the harness side about
1/2 inch apart (Fig. 10).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly i n the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall har
ness length is the same as the original (Fig. 10).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
CONNECTOR LOCKING (9) Spread the strands of the wire apart on each of
92BW-143
WEDGE TAB the exposed wires (Fig. 7 example 1).
(10) Push the two ends of wire together until the
Fig. 8 Connector Locking Wedge Tab (Typical) strands of wire are close to the insulation (Fig. 7 ex
(4) Position the connector locking finger away from ample 2).
the terminal. Pull on the wire to remove the terminal (11) Twist the wires together (Fig. 7 example 3).
from the connector (Fig. 9). (12) Solder the connection together using rosin
(5) Reset the terminal locking tang, i f i t has one. core type solder only. Do not use acid core solder.
• WIRING DIAGRAMS 8W - i
REPAIR SIDE STAGER CUTS (12) Twist the wires together (Fig. 7 example 3).
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge and recon
nect the connector to its mating half.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
HARNESS WIRES 928W-145
SYMBOLS IDENTIFICATION
Fig. 10 Stagger Cutting Wires (Typical) Various symbols are used throughout wiring dia
grams. These symbols can be identified by referring
(13) Center the heat shrink tubing over the joint
to symbol identification chart (Fig. 11).
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. FUSE IDENTIFICATION
(14) Repeat steps 8 through 13 for each wire. For fuse block information refer to (Fig. 12).
(15) Re-tape the wire harness starting 1-1/2 inches
CAUTION; When replacing a blown fuse, it is impor
behind the connector and 2 inches past the repair.
tant to replace it with a fuse having the correct am
(16) Reconnect the repaired connector.
perage rating. The u s e of a fuse with a rating other
than indicated may result in a dangerous electrical
TERMINAL REPLACEMENT overload. If a proper rated fuse continues to blow, it
(1) Disconnect battery. indicates a problem that should be corrected.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge (Fig. 8). CONTROLLER AND MODULE LOCATIONS
(4) Position the connector locking finger away from To identify the general locations of controllers and
the terminal. Pull on the wire to remove the terminal modules used in this vehicle refer to (Fig. 13).
from the connector (Fig. 9).
(5) Cut the wire 6 inches from the back of the con WIRING HARNESS ROUTING
nector. To identify a wiring harness and its approximate
(6) Remove 1 inch of insulation from the wire on routing refer to (Fig. 13). This chart shows all of the
the harness side. vehicles wiring harnesses and how they are routed.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired. GROUND IDENTIFICATION
(8) Cut the repair wire to the proper length and re To identify ground locations and there functions re
move 1 inch of insulation. fer to (Fig. 14).
(9) Place a piece of heat shrink tubing over one of
side of the wire. Make sure the tubing will be long POWER DISTRIBUTION CENTER IDENTIFICATION
enough to cover and seal the entire repair area. For power distribution center fuse and relay iden
(10) Spread the strands of the wire apart on each tification refer to the wiring diagrams or the power
of the exposed wires (Fig. 7 example 1). distribution center cover.
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex
ample 2).
LEGEND OF SYMBOLS USED O N W I R I N G D I A G R A M S
+ POSITIVE CONNECTOR
— NEGATIVE — > MALE C O N N E C T O R
GROUND > FEMALE C O N N E C T O R
FUSE — s DENOTES WIRE C O N T I N U E S ELSEWHERE

DENOTES WIRE G O E S T O O N E OF T W O
G A N G FUSES W I T H BUSS BAR
CIRCUITS
CIRCUIT BREAKER
-K- SPLICE
CAPACITOR SPLICE I D E N T I F I C A T I O N
n OHMS cFfcP THERMAL ELEMENT
• A A A - * RESISTOR | TIMER | TIMER
•-VN£A-«
1 4f ^ ^!
VARIABLE RESISTOR MULTIPLE C O N N E C T O R
'YYY'
WIRING WITH
SERIES RESISTOR OPTIONAL
oJ WIRING WITHOUT
•-JUL-* COIL " Y " WINDINGS
-viuL—<•
^0000 J
STEP UP COIL
BBSS DIGITAL READOUT
OPEN CONTACT -0- SINGLE FILAMENT LAMP
CLOSED C O N T A C T DUAL FILAMENT LAMP
CLOSED SWITCH L.E.D. - LIGHT EMITTING DIODE
O P E N SWITCH -@- THERMISTOR
CLOSED G A N G E D SWITCH GAUGE
O P E N G A N G E D SWITCH SENSOR
T W O POLE SINGLE T H R O W S W I T C H FUEL INJECTOR
3b
PRESSURE SWITCH flR * DENOTES WIRE GOES THROUGH
BULKHEAD DISCONNECT
DENOTES WIRE G O E S T H R O U G H
S O L E N O I D SWITCH S r o
8
~ ~ " COLUMN """""* STEERING C O L U M N C O N N E C T O R
i I#14 DENOTES WIRE G O E S T H R O U G H
I n MERCURY SWITCH INST

PANEL INSTRUMENT PANEL C O N N E C T O R
( 1#7 DENOTES WIRE G O E S T H R O U G H G R O M M E T

DIODE OR RECTIFIER ENG
TO ENGINE COMPARTMENT
o 0
BY-DIRECTIONAL ZENER DIODE
MOTOR
ARMATURE A N D BRUSHES
—
fm
DENOTES WIRE G O E S T H R O U G H G R O M M E T
HEATED GRID ELEMENTS
908W-191
Fig. 11 Symbol Identification

CAVITY AMP ITEMS FUSED CAVITY AMP ITEMS F U S E D
1 Not Used 18 15 Headlamp Switch
2 Not Used 19 20 Power Door Locks
3 Not Used 20 15 Stop Lamp Switch
4 Not Used FI Not Used
5 20 Power Outlet, Cigar Lighter F2 30 Blower Motor
30
6 15 Turn Signals CB1 Power Windows
C/Brkr
30
7 10 Radio CB2 Power Seat
C/Brkr
8 20 Windshield Wipers
Automatic Shut Down Relay, A / C

9 10
Compressor Clutch Relay, Fuel Pump Relay
10 2 Vehicle Speed Control

BBBB
Buzzer, Overdrive Switch, .20.19.18.17j
11 10
Overhead Console
BBBB
12 15 Cluster, Air Bag Module, Message Center B 16J5.14.ia .
13 5
Cluster Illumination, Radio Illumination, BBBB I
HE VAC Switch, Overhead Console •12-11-10-9=
A B S Module and Relays, Vacuum Sensor BBBB EE

14 20
(Diesel Only) 4-3-2-1
o
15 10 Transmission Range
>
o
16 15 Air Bag Module HAZARD WARNING >
FLASHER 2
Radio, Buzzer, Glove Box, Dome Lamp, Power m
17 15 J948W-16
Mirrors, Overhead Console, Time'Delay Relay
s
Fig. 12 Fuse Block ami Relay Bank
CRANKSHAFT POSITION
SENSOR STOP/TURN LAMP
ABS FRONT WHEEL SENSOR
A/C COMPRESSOR
>
a
33
HEADLAMP
TURN SIGNAL
POWER SEAT SW
SIDE MARKER
SEAT SELT SWITCH
STOP/TURN LAMP
POWER LOCK SW
HORNS POWER WINDOW SW
POWER MIRROR SW
JUNCTION BLOCK
J948W-17
Fig. 13 Controller and Module Locations

G R O U N D B: GROUND G: G R O U N D P: BRAKE G R O U N D :
ABS MODULE FUEL T A N K , ABS POWER FUEL T A N K ,
RADIO CLUSTER, V A C U U M SENSOR,
ROOF G R O U N D : WIPER MOTOR,
OVERHEAD CONSOLE,
G R O U N D C: OVERHEAD CONSOLE, UNDERHOOD LAMP
BRAKE LAMP SWITCH,
LEFT HEADLAMP, DAY-NIGHT MIRROR
GLOVE BOX LAMP, GENERATOR GROUND:
TRAILER RELAY, POWER OUTLET, LEFT C O W L G R O U N D :
ABS YELLOW LAMP RELAY, GENERATOR
CIGAR LIGHTER, POWER SEAT,
L O W WASHER SWITCH, HE VAC SWITCH, SEAT BELT SWITCH, FRAME G R O U N D :
LEFT PARK & TURN LAMP, FOG LAMP RELAY 1 & 2, CENTER HIGH MOUNTED RIGHT TURN, STOP & TAIL LAMP,
WASHER PUMP RIGHT DOOR JAMB SWITCH, STOP LAMPS RIGHT BACK-UP LAMP,
G R O U N D D: FOG LAMP SWITCH, I EFT TURN, STOP & TAIL LAMP,
OVERDRIVE SWITCH, ENGINE G R O U N D : I EFT BACK-UP LAMP,
RIGHT HEADLAMP
WIPER MODULE P.C.M. IICENSE LAMPS,
RIGHT PARK & TURN LAMP,
A/C COMPRESSOR CLUTCH TRAILER T O W ,
VEHICLE SPEED CONTROL SERVO, G R O U N D H: DATA LINK CONNECTOR FENDER & TAILGATE LAMPS
4 x 4 SWITCH, AIRBAG MODULE
RIGHT FOG LAMP, BODY G R O U N D : (DUAL REAR WHEELS ONLY)
LEFT FOG LAMP, G R O U N D I: BATTERY TERMINAL ( - )
HI & LO NOTE HORNS W A R N I N G BUZZER,
HEADLAMP CARGO G R O U N D BATTERY G R O U N D :
IGNITION SWITCH BATTERY TERMINAL ( - )
FRAME LEFT C O W L
GROUND GROUND
Fig. 14 Ground Identification

COMPONENT IDENTIFICATION
Caption Fig. Caption Fig^
Battery Wiring 13 Four Wheel Drive Wiring 20
Cab Wiring 3 Frame Wiring 2
Door Wiring 5 Instrument Panel Wiring 6, 7
Engine Compartment Wiring 9, 10, 11, 12 Rear Lamp Wiring 1
Engine Wiring 3.9L 16 Roof Wiring 4
Engine Wiring 5.2L, 5.9L 17 Steering Column Wiring 8
Engine Wiring 8.0L 18 Transmission Wiring (Automatic) 14
Engine Wiring 5.9L Diesel 19 Transmission Wiring (Manual) 15
Fig. 1 Rear Lamp Wiring
CHASSIS REAR WHEEL
WIRING SPEED SENSOR
HARNESS
0
o
>
0
33
FRAME >
ASSEMBLY
FUEL TANK s
X-MEMBER
TO LEFT
TAIL LAMP
CHASSIS WIRING
HARNESS
TO ENGINE
COMPARTMENT J948W-33
WIRING
Fig. 2 Frame Wiring

Fig. 4 Roof Wiring
INTERMITTENT
WIPER MODULE
01
S
z
m
o
INSTRUMENT CLUSTER a
CONNECTORS 2D
T O HVAC 3
CONTROL
RWAL MODULE
RADIO CONNECTORS
T O HEADLAMP
INSTRUMENT PANEL SWITCH
T O INTERMITTENT
WIPER MODULE
(SEE V I E W Y |
FUSE BLOCK
A N D RELAY INSTRUMENT
BANK PANEL
ASSEMBLY
INSTRUMENT PANEL T O
GROUND
HEADLAMP A N D DASH
W I R I N G CONNECTOR
y i c w I N DIRFCTION OF
TO GLOVE BOX RADIO CHOKE A N D

LAMP A N D RELAY ASSEMBLY
SWITCH
T O A l t BAG
SQUIB
T O DOOR
WIRING INSTRUMENT
T O DOOR PANEL SUPPORT
WIRING
TO CIGAR
LIGHTER TO BODY
WIRING V I F W I N DIRECTION
rfr ARROW L
T O RWAL T O HEADLAMP A N D TO INSTRUMENT J948W-37
DASH WIRING PANEL W I R I N G
(SE^VIEWYl (SEE V I E W X)
Fig. 6 instrument Panel Wiring

INSTRUMENT PANEL AIR BAG/ABS •
HARNESS DATA LINK CONNECTOR
ROUS TEST CONNECTOR

ASSEMBLY PLANT USE
ONLY
INSTRUMENT PANEL
HARNESS
yiiw IN PWBCTQN
OF A R R O W Y
OF ARROW X
TO MESSAGE TO FUSE BLOCK
CENTER TO TRANSMISSION
OVERDRIVE SWITCH
ROOF W I R I N G
CONNECTOR
INSTRUMENT PANEL
TO PARK BRAKE HARNESS
SWITCH
GROUND
^ GROUND
(SEE VIEW Z)
VIEW I N DIRECTION
Of ARROW Z
TO STOP
LAMP SWITCH
TO MULTI-FUNCTION
TO BLOWER MOTOR SWITCH
TO
TO CLOCKSPRING FUSE BLOCK
22
INSTRUMENT
PANEL HARNESS
TO IGNITION SWITCH
0
RWAL TEST
CONNECTOR >
2
m
VIEW I N DIRECTION
OF A R R O W Z
J948W-38
Fig. 7 Instrument Panel Wiring

J948W-39
Fig. 8 Steering Column Wiring

GROUND LOT FENDER POWER DISTRIBUTION
SIDE SHIELD CENTER
HYDRAULIC
HEADLAMP A N D DASH CONTROL

W I R I N G HARNESS
HAZARD HARNESS
CONNECTOR POWER DISTRIBUTION
CENTER
ABS CONTROL UNIT

POWER DISTRIBUTION
CONNECTOR CENTER
OF A R R O W Y
BRAKE MASTER
CYLINDER
BRAKE G R O U N D OF A R R O W 7
ABS FRONT WHEEL

SENSOR CONNECTOR
OF A R R O W V
BRAKE W A R N I N G
LAMP SWITCH
CONNECTOR
HEADLAMP AND DASH
PRESSURE LIMITING
WIRING HARNESS
VALVE CONNECTOR
OF A R R O W X so
POWERTRAIN 0
CONTROL MODULE
0
30
>
3
m
J948W40 m
3=
Fig. 9 Engine Compartment Wiring
UNDERHOOD LAMP
AND CONNECTOR
HEADLAMP AND
DASH WIRING
HARNESS
>
a
••a
>
m
LEFT FENDER
SIDE SHIELD
VIEW IN DIRECTION
QF ARROW Z
VEHICLE SPEED CONTROL
AMBIENT AIR SERVO
TEMPERATURE HARNESS VACUUM SENSOR
SENSOR CONNECTORS (DIESEL ONLY)
BATTERY
HEADLAMP AND DASH

WIRING HARNESS
LEFT FENDER
POWER DISTRIBUTION
VIEW IN DIRECTION CENTER VIEW IN DIRECTION
OF ARROW X VIEW IN DIRECTION OF ARROW T
OF ARROW Y
J948W41

HEADLAMP A N D DASH WINDSHIELD WASHER
W I R I N G HARNESS RESERVOIR
DAYTIME R U N N I N G
LAMP MODULE
TO RIGHT SIDE
OF ENGINE
COMPARTMENT WINDSHIELD WASHER PUMP
MOTOR
VIEW I N DIRECTION OF
ARROW Y
GROUND
VIEW I N DIRECTION OF
ARROW Z
TO HEADLAMP
PARK A N D
TURN SIGNAL LAMP
CONNECTOR
FRONT VIEW I N DIRECTION -

TO ENGINE COMPARTMENT
BUMPER OF A R R O W Y
WIRING
ASSEMBLY HORNS
HEADLAMP A N D LEFT FENDER

DASH W I R I N G SIDE SHIELD
HARNESS
22
o
o
>
CHASSIS
WIRING VIEW I N DIRECTION
HARNESS ARROW *
Q F
V I E W I N DIRECTION
OF ARROW V FRAME RAIL J948W42

POWER DISTRIBUTION CENTER
FEED
AIR CLEANER
GROUND ASSEMBLY
BATTERY
E N G I N E STARTER MOTOR
BATTERY
T O LEFT BATTERY
BATTERY
POWER DISTRIBUTION
CENTER
POWER DISTRIBUTION
CENTER FEED LINE TO ENGINE
STARTER
GROUND MOTOR
EE
o
>
2
m
T O ENGINE DIESEL AIR HEATER

J948W44
STARTER W I R I N G BATTERY RELAYS
Fig. 13 Battery Wiring

TO ENGINE TRANSMISSION HEATED OXYGEN
WIRING RANGE SWITCH SENSOR
1\»
TRANSMISSION OVERDRIVE
SOLENOID TO ENGINE
WIRING
>
VEHICLE SPEED 0
TRANSMISSION ) SENSOR 39
TEMPERATURE SENSOR >
CO
TRANSMISSION VEHICLE SPEED
TEMPERATURE SENSOR
SENSOR
TRANSMISSION
RANGE SWITCH 3.9L, 5.21 AND 5.9L
HEATED OXYGEN JUMPER HARNESS CONNECTOR
HEATED OXYGEN
SENSOR
SENSOR
TRANSMISSION RANGE
SWITCH TRANSFER
CASE
TRANSMISSION
TEMPERATURE
SENSOR"
5.2L AND 5.9L HEAVY DUTY VEHICLE SPEED VEHICLE SPEED

HEATED OXYGEN J948W-45
SENSOR SENSOR SENSOR
Fig. 14 Transmission Wiring (Automatic)

TO ENGINE BACK-UP JUMPER HARNESS CONNECTOR
WIRING LAMP SWITCH
HEATED OXYGEN
SENSOR
TRANSFER
CASE
VEHICLE SPEED
SENSOR
3.9L, 5.2L AND 5.9L
TO ENGINE
WIRING TO HEATED OXYGEN
SENSOR
TO ENGINE BACK-UP LAMP
WIRING SWITCH
BACK-UP
LAMP SWITCH VEHICLE SPEED
SENSOR
VEHICLE SPEED
SENSOR
0
HEATED OXYGEN
O
SENSOR
>
a
DIEfEL ENGINE
5.9L HD >
3
m
J948W46 m
Fig. 15 Transmission Wiring (Manual)

J948W-47
Fig. 16 Engine Wiring 3.9L

FUEL THROTTLE POSITION MAP SENSOR ENGINE OIL •
Fig. 17 Engine Wiring S.2L, 5.9L

m
J948W-49
Fig. 18 Engine Wiring 8.0L

ENGINE OIL PRESSURE ENGINE WIRING THROTTLE
ENGINE WIRING GENERATOR HARNESS POSITION
HARNESS SENDING UNIT
(SENSOR)
POWER STEERING
PUMP
FUEL
HEATER
VIEW IN DIRECTION
OF ARROW X Til I
VIEW IN DIRECTION
OF ARROW T
VIEW IN DIRECTION
OF ARROW Z
ENGINE
GROUNDS
ENGINE SPEED
SENSOR AIR HEATER
CONNECTOR ASSEMBLY
ENGINE WIRING
HARNESS
WATER-IN
FUEL SENSOR INTAKE CHARGE AIR
CONNECTOR TEMPERATURE SENSOR ENGINE COOLANT
TEMPERATURE SENSOR
TO TRANSMISSION
VIEW IN DIRECTION WIRING
OF ARROW Y
0
O
VIEW IN DIRECTION
OF ARROW T
FUEL SHUT OFF >
SOLENOID 0
VIEW IN DIRECTION
OF ARROW X
TO TRANSMISSION J948W-50
Fig. 19 Engine Wiring Diesel

Fig. 20 Four Wheel Drive Wiring
WIRING DIAGRAMS 8W - 31
S P L I C E LOCATIONS
Splice Number Fjp^ Splice Number FJJL.
AO 7 L7 . . . . 8
A2 7 L7-2 1
A3 6 L7-3 3
A3-1 8 L10 8
A6 7 L50 5
A7 6 L62 1
A7-1 7 L63 1
A20 7 M1 5
A22 6 M1-1 2
A142 Diesel 8 M1-2 3
A142 V-6, V-8 .9 P33 RT Door 4
A142 V-10 10 P34 RT Door 4
A142-1 V-6, V-8 9 T40 7
A142-1 V-10 10 T41 8
A142-2 V-10 10 V6 5
B120 ; 7 V40 7
C7 6 X2 8
F14 6 X13 6
F18 7 X13-1 2
F18-1 Diesel 11 X53 LT Door . . . 4
F18-1 V-6, V-8 9 X54 RT Door 4
F18-1 V-10 10 X55 LT Door 4
F21 6 X56 RT Door 4
F35 5 Z1 7
G7-1 8 Z1-1 7
G9 7 Z1-2 8
G107 8 Z1-3 8
K4 8 Z2 .7
K4-1 V-6, V-8 9 Z2-1 6
K4-1 V-10 10 Z2-2 2
K6 V-6, V-8 9 Z3 5
K6 V-10 10 Z3-1 5
K7 Diesel 11 Z3-2 4
K7 V-6, V-8 9 Z4 3
K7 V-10 10 Z4-1 3
K20 Diesel 11 Z11 5
K20 V-6, V-8 9 Z11-1 Diesel 11
K113 V-10 10 Z11-1 V-6, V-8 9
K114 V-10 10 Z11-1 V-10 10
K115 V-10 10 Z11-2 8
K116 V-10 10 Z12 8
K158 V-10 10 Z12-1 . .8
L1-1 .1 Z13 1
L3 8 Z13-1 1
L4 8
WIRING DIAGRAMS
Wiring Diagram Sheet Name Sheet Number Wiring Diagram Sheet Name Sheet Number
ABS Controller 59, 60, 61, 62 Bypass Jumper 9
ABS Controller Connector. 134 Camshaft Position Sensor. 37
ABS Pump Relay 60 Cargo Lamps 79
ABS Pump/Valve Assembly -59 Center High Mounted Stop Lamps 115
ABS 2-Way Power Feed . .59 Charge Air Temperature Sensor 18, 28, 38, 45
ABS Yellow Lamp Relay 60 Charging System (Diesel Engine) 6
A/C Compressor Clutch 98 Battery 6
A/C Compressor Clutch Relay . .98 Fuse C 6
Airbag System 53, 54 Generator 6
Clockspring . 53 Charging System (Gas Engine) 5
Data Link Connector 53 Battery 5
Sensors 54 Fuse C 5
Squib (Igniter) .53 Generator . .5
System Control Module 53 Chime 107, 108
Air Conditioning And Heater System 97, 98 Cigar Lighter 78
Bi-Directional Zener Diode 98 Circuit Breakers
Blower Motor 97 Circuit Breaker 1 .1, 7, 100
Blower Motor Resistor 97 Circuit Breaker 2 3, 73, 105
Compressor Clutch 98 Clearance And Identification Lamps 65
Compressor Clutch Relay .98 Clockspring 52, 53, 64
Fan Switch -97 Cluster A 87
High Pressure Cut Out Switch . .97 Cluster B 88
HVAC Switch . .97 Clutch Pedal Position (Switch) 9
Illumination Lamps .97 Controller, ABS 59, 60, 61, 62
Low Pressure Cut Out Switch . . .97 Crankshaft Position Sensor 18, 28, 38
Air Temperature Sensor .82 Data Link Connector 15, 25, 39, 44, 53, 61
Anti-Lock Brake System (ABS) 59, 60, 61, 62 Day/Night Mirror 106
Brake Warning Switch 62 Daytime Running Lamps Jumper 71
Controller 59, 60, 61, 62 Daytime Running Lamps Module 71
Data Link Connector 61 Diesel Engine Control System 43-50
Left Front Wheel Sensor 61 Automatic Shut Down Relay 44
Pump Relay .60 Charge Air Temperature Sensor . . . .45
Pressure Limiting Valve 60 Data Link Connector 44
Pump/Valve Assembly .59 Engine Speed Sensor .45
Rear Wheel Anti-Lock Brake Sensor . .61 Fuel Heater . .48
Right Front Wheel Sensor 61 Fuel Heater Relay 47
2-Way Power Feed .59 Fuel Shut Down Relay 47
Vacuum Sensor. 62 Fuel Shut Down Solenoid . . 48
Yellow Lamp Relay 60 Heated Intake Air System 43
Automatic Day/Night Mirror 106 Heated Intake Air System Relays 43
Automatic Shut Down Relay 22, 25, 36, 44 Powertrain Control Module 43-50
Back-Up Lamps 111, 112 Throttle Position (Sensor) 45
Back-Up Lamp Switch 12 Vehicle Speed Sensor 46
Battery . 3, 5, 6 Water-In Fuel Sensor 45
Bi-Directional Zener Diode 98 Dimmer Switch, Headlamp 73
Blower Motor 96, 97 Diode, Zener 98
Blower Motor Resistor 96, 97 Distributor .17, 27
Body Connector 136 Dome Lamp 79, 81
Brake Sensor, RWAL . .56, 58, 61 Door Jamb Switch. .80, 82
Brake Warning Switch 56, 57, 62 Door Lock Motors .102
Bulkhead Connector 123, 124, 125, 126 Door Lock Switch 101, 102
Buss Bar 4 Door Speakers 92, 93, 94
Buzzer 109, 110 Electric Brake Provision 113
Engine Coolant Temperature Sensor 16, 26, 42, 51 Heated Oxygen Sensors 31, 32
Engine Data Link Connector .15, 25, 39, 44 Idle Air Control Motor . .29
Engine Oil Pressure and Engine Coolant Temperature System.51 Ignition Coil 23
Engine Coolant Temp Sensor .51 Injectors 23, 24
Engine Oil Pressure Sending Unit 51 MAP Sensor 27
Engine Speed Sensor 45 Powertrain Control Module (PCM) 23-32
Engine Starter System. .9 Throttle Position (Sensor). .28
Bypass Jumper 9 Vehicle Speed Sensor 30
Clutch Pedal Position (Switch) . .9 Fuel Injection Ignition System (8.0L Engine) . 33-42
Starter Motor 9 Automatic Shut Down Relay 36
Starter Relay . .9 Camshaft Position Sensor 37
Engine Connector- A 127 Charge Air Temperature Sensor 38
Engine Connector- B 128 Crankshaft Position Sensor .38
Engine Connector- C . . . .129 Data Link Connector . . . 39
EVAP/Purge Solenoid 19, 29, 41 Engine Coolant Temperature Sensor 42
Exhaust Gas Recirculation (EGR) Solenoid. . . . . . . .19, 29, 41 EVAP/Purge Solenoid .41
Fan Switch 96, 97 Exhaust Gas Recirculation (EGR) Solenoid 41
Fender and Tailgate Lamps . .66 Heated Oxygen Sensors 35
Four Wheel Drive (4X4) Switch 11 Idle Air Control Motor 40
Front End Lighting w/o Daytime Running Lamps . . . . . .67, 68 Ignition Coil 4-Pack .40
Left Headlamp 67 Ignition Coil 6-Pack 40
Left Park and Turn signal Lamp 67 Ignition Module 39
Right Headlamp 68 Injectors 33, 34
Right Park and Turn Signal Lamp 68 MAP Sensor. .37
Front End Lighting With Daytime Running Lamps 69, 70 Powertrain Control Module (PCM). . ; 33-42
Left Headlamp 69 Throttle Position (Sensor) 38
Left Park and Turn Signal Lamp 69 Vehicle Speed Sensor 36
Right Headlamp 70 Fuel Injectors 13, 14, 23, 24, 33, 34
Right Park and Turn Signal Lamp. 70 Fuel Pump .90
Fuel Gauge Sensor 90 Fuel Pump Relay 90
Fuel Heater 48 Fuel Shut Down Relay 47
Fuel Heater Relay , 47 Fuel Shut Down Solenoid 48
Fuel Injection Ignition System (3.9L Engine) 13-22 Fuel Tank S y s t e m . . . . . ....... 90
Automatic Shut Down Relay 22 Fuel Tank Level Gauge Sending Unit 90
Charge Air Temperature Sensor 18 Fuse Application Chart .1, 2, 3
Crankshaft Position Sensor .18 Fuse block 117, 118
Data Link Connector 15 Fuses
Distributor .17 Fuse 5. 2, 8, 78
Engine Coolant Temperature Sensor 16 Fuse 6 2, 8, 85
EVAP/Purge Solenoid .19 Fuse 7 . .2, 8, 91, 93
Exhaust Gas Recirculation (EGR) Solenoid 19 Fuse 8 2, 8, 84
Heated Oxygen Sensors 21 Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 7, 90, 98
Idle Air Control Motor 19 Fuse 10. 1, 7, 64
Ignition Coil . .13 Fuse 11 .1, 7, 76
Injectors. . .13, 14 Fuse 12 1, 7, 86
MAP Sensor 17 Fuse 13 • 3, 73, 77
Powertrain Control Module (PCM) .13-22 Fuse 14 .2, 8, 55, 57, 62
Throttle Position (Sensor) .18 Fuse 15 .2, 8
Vehicle Speed Sensors .20 Fuse 16. 2, 8, 53
Fuel Injection Ignition System (5.2L/5.9L Engines) 23-32 Fuse 17 3, 107, 109
Automatic Shut Down Relay . .25 Fuse 18 . . . . .3, 73
Charge Air Temperature Sensor 28 Fuse 19 3, 101
Crankshaft Position Sensor 28 Fuse 20 3, 75
Data Link Connector 25 Fuse B 52
Distributor 27 Fuse C. . . .5, 6, 85
Engine Coolant Temperature Sensor 26 Fuse F2 1, 7, 96, 98
EVAP/Purge Solenoid .29 Fusible Links. 4
Exhaust Gas Recirculation (EGR) Solenoid 29 Generator 5, 6
•
Glove Box Lamp And Switch. . 78 Identification Lamps 65
Ground Joint 114 Ignition Switch Lamp .108, 110
Hazard Flasher 85 Illumination Lamps 96, 97
Headlamps 67, 68, 69, 70 License Lamp .66, 111, 112
Headlamp Switch 73 Overhead Map Lamp 80
Dimmer Switch 3, 73 Parking Lamp-Left 67, 69
Headlamp Switch. 73 Parking Lamp-Right 68, 70
Headlamp Switch Connector .116 Reading Lamps 81
Heated Intake Air System 43 Stop Lamp-Left 111
Heated Intake Air System Relays 43 Stop Lamp-Right 112
Heated Oxygen Sensor 21, 31, 32, 35 Tailgate Lamps 66
Heater System • -96 Tail Lamp-Left - 111
Blower Motor 96 Tail Lamps-Right 112
Blower Motor Resistor 96 Turn Signal Lamp-Left 67, 69, 111
Fan Switch 96 Turn Signal Lamp-Right 68, 70, 112
Heater Switch • -96 Underhood Lamp 72
Horn System 52 Left Door Connector- 1 137
Clockspring 52 Left Door Connector- 2 138
Fuse B 52 MAP Sensor 17, 27, 37
Horn Relay 52 Mercury Switch 72
Horns .52 Message Center 86
Horn Switch 52 Modules
HVAC Switch 97 Airbag System Control 53
Idle Air Control Motor 19, 29, 40 Daytime Running Lamps 71
Ignition Coil 13, 23, 40 Ignition Module 39
Ignition Key-In Switch 108, 110 Intermittent Wiper Control 83
Ignition Module • 39 Powertrain Control Module (PCM) 10, 13-42, 63
Ignition Switch 1, 7, 8 Rear Wheel Anti-Lock Control .55, 56, 57, 58
Ignition Switch Lamp 108, 110 Motors
Infinity Stereo Radio System .93, 94 Blower-A/C. 97
Door Speakers 94 Blower-Heater 96
Door Tweeter Speakers. • .93 Door Locks 102
Radio Choke 94 Engine Starter 9
Rear Speakers .94 Idle Air Control . 19, 29, 40
Stereo Radio . 93 Power Mirror 103, 104
Injectors 13, 14, 23, 24, 33, 34 Power Seat 105
Intermittent Wiper Module 83 Washer Pump. 83
Intermittent Wiper System 83, 84 Window Lift 99, 100
Control Module • -83 Windshield Washer Pump 83
Low Washer Fluid Level Sensor 83 Windshield Wiper-Intermittent .84
Park Switch 84 Multi-Function Switch Connector 135
Washer Pump Motor 83 Oil Pressure And Temp System . .51
Wiper Motor 84 Overhead Console . 81, 82
Wiper/Washer Switch 84 Overhead Console Connector 141
Joint Connector-A-Wiring 74, 130 Overhead Map Lamp 80
Joint Connector-B-Wiring 75, 131 Park Brake Switch .77
Joint Connector-C-Wiring 7, 76, 77, 132 Power Distribution Center 3, 4, 142
Key-In Switch 108, 110 Power Door Locks 101, 102
Lamps Left Door Lock Switch .101
Back-Up Lamps 111, 112 Left Front Door Motor 102
Cargo Lamps , 79 Right Door Lock Switch 102
Center High Mounted Stop Lamps . .115 Right Front Door Motor 102
Clearance Lamps 65 Power Mirror Switch Connector .143
Dome Lamps 79, 81 Power Mirror System 103, 104
Fender Lamps 66 Left Motor .103
Glove Box Lamps 78 Right Motor . .104
Headlamp-Left 67, 69 Switch 103
Headlamp-Right 68, 70 Power Outlet. . 78
Power Seat System .105 RAWL Control Module Connector 133
Motors 105 RAWL Rolls Test Connector 56, 58
Switch. 105 RAWL Service Connector . .56, 58
Power Take-Off (PTO) Switch 11 Seatbelt Warning and Buzzer System (BUX Only) 109, 110
Powertrain Control Module Connector (3.9L Engines) 119 Buzzer 109, 110
Powertrain Control Module Connector (5.2L/5.9L Engines). .120 Ignition Switch Lamp 110
Powertrain Control Module Connector (8.0L Engines) 121 Key-In Switch 110
Powertrain Control Module Connector (Diesel Engine) 122 Seatbelt Switch . 110
Power Window System 99, 100 Time Delay Relay 110
Left Window Lift Motor .99 Seatbelt Warning and Chime System 107, 108
Right Window Lift Motor. . 100 Chime 107, 108
Switch 99, 100 Ignition Switch Lamp 108
Pressure Limiting Valve . .55, 57, 60 Key-In Switch 108
Printed Circuit Board 89 Seatbelt Switch 108
Pump/Valve Assembly (ABS) 59 Time Delay Relay 108
Radio AM/FM Stereo 91, 92, 93, 94 Sensors
Radio And Sensor Ground 95 Airbag. 54
Radio Choke 94 Air Temperature .82
Radio Speakers 92, 93, 94 Camshaft Position 37
Reading Lamps 81 Charge Air Temperature 18, 28, 38, 45
Rear Lighting .111, 112 Crankshaft Position .18, 28, 38
Back-Up Lamps 111, 112 Engine Coolant Temperature 16, 26, 42, 51
License Lamp 111, 112 Engine Speed 45
Tail, Stop and Turn Signal Lamp 111, 112 Fuel Gauge 90
Rear Speakers 92, 94 Heated Oxygen 21, 31, 32, 35
Rear Wheel Anti-Lock Brake System (Diesel). . . . . . . . .57, 58 Low Washer Fluid Level 83
Brake Sensor 58 MAP Sensor .17, 27, 37
Brake Warning Switch 57 RAWL Brake 56, 58, 61
Control Module 57, 58 Throttle Position 18, 28, 38, 45
Pressure Limiting Valve .57 Transmission Temperature 10
Rolls Test Connector 58 Vacuum Sensor 57, 62
Service Connector 58 Vehicle S p e e d . . . . . . . 20, 30, 36, 46
Vacuum Sensor. 57 Water-ln-Fuel 45
Rear Wheel Anti-Lock Brake System (Gas) 55, 56 Wheel Sensor 61
Brake Sensor 56 Windshield Washer Low Fluid Level 83
Brake Warning Switch 56 Service Connector, RWAL . . . . . . . . . . . . . . . . . . . . .56, 58
Control Module .55, 56 Solenoids
Pressure Limiting Valve 55 EVAP/Purge . . . . . . . . . . . . . . . . . .19, 29, 41
Rolls Test Connector 56 Exhaust Gas Recirculation 19, 29, 41
Service Connector .56 Fuel Shut Down .48
Rear Wheel Anti-Lock Control Module Connector 133 Transmission Overdrive. 10
Relays Speakers, Stereo Radio 92, 93, 94
ABS Pump Relay 60 Splices
ABS Yellow Lamp Relay .60 Splice AO .5, 6
A/C Compressor Clutch Relay 98 Splice A2 9
Automatic Shut Down Relay. . . . . . . . . . . . .22, 25, 36, 44 Splice A3. .3, 75
Engine Starter Relay 9 Splice A3-1 .71
Fuel Heater Relay .47 Splice A6 4
Fuel Pump Relay 90 Splice A7 3, 73
Fuel Shut Down Relay . .47 Splice A7-1 .3, 52
Heated Intake Air System Relays 43 Splice A8 43
Horn Relay. .52 Splice A12. .47
Time Delay Relay 108, 110 Splice A18 47
Trailer Tow Relay .113 Splice A19 .43
Resistors, Blower M o t o r . . . . . . . . . . . . . . . . . . . . . .96, 97 Splice A20 62
Right Door Connector- 1 139 Splice A22. .1, 7
Right Door Connector- 2 . 140 Splice A142 14, 24, 34, 40, 44
Rolls Test Connector 56, 58 Splice A142-1 ......... . .13, 21, 23, 32, 34
Splice A142-2 33 Splice Z2-2 95
Splice B120 59 Splice Z3 83
Splice C7 96, 97 Splice Z3-1 78
Splice F14 86 Splice Z3-2 99, 101, 103
Splice F18 44, 90, 98 Splice Z4 65
Splice F18-1 19, 29, 39, 41, 43 Splice Z4-1 81
Splice F21 100 Splice Z11 82
Splice F35 101 Splice Z11-1 21, 31, 35, 48, 98
Splice G7 46 Splice Z11-2 82
Splice G7-1 20, 30, 36, 46 Splice Z12 48
Splice G9 57, 62 Splice Z12-1 15, 25, 39, 42, 47
Splice G107 11, 62 Splice Z13 111
Splice K4 17, 20, 27, 30, 32, 36, 37, 45 Splice Z13-1 111
Splice K4-1 18, 28, 38 Splice Z13-2 66
Splice K6 17, 27, 37 Splice Z13-3 111
Splice K7 17, 27, 37, 46 Splice Z13-4 66
Splice K20 5, 6 Splice Z13-5 112
Splice K113 33 Squib (Igniter) 53
Splice K114 33 Starter Relay, Engine 9
Splice K115 34 Starter System, Engine 9
Splice K116 33 Stereo Radio 91, 93
Splice K158 34 Stereo Radio System 91, 92
Splice L1 12 Case Ground 91
Splice L1-1 112 Door Speakers 92
Splice L3 67, 69 Rear Speakers 92
Splice L4 67, 69 Stereo Radio 91
Splice L7 67, 69 Stop Lamp Switch 64
Splice L7-1 68, 70 Stop/Turn And Hazard Flasher System 85
Splice L7-2 112 Hazard Flasher .85
Splice L7-3 65, 81 Turn Signal And Hazard Flasher Switch 85
Splice L7-4 66 Turn Signal Flasher 85
Splice L7-5 66 Switches
Splice L10 8 A/C High Pressure Cut-Out 97
Splice L50 64 A/C Low Pressure Cut-Out 97
Splice L60 68, 70, 85 Back-Up Lamp 12
Splice L61 67, 69, 85 Brake Warning Switch 56, 57, 62
Splice L62 112 Clutch Pedal Position 9
Splice L63 111 Door Jamb . . 80, 82
Splice M1 107, 109 Door Lock 101, 102
Splice M M 79 Fan 96, 97
Splice M1-2 81 Four Wheel Drive (4X4) 11
Splice P33 102 Glove Box Lamp 78
Splice P34 102 Hazard Flasher 85
Splice T40 9 Headlamp 3, 73
Splice T41 16, 26, 42, 48 Headlamp Dimmer 73
Splice V6 84 Heater 96
Splice V40 76 Horn 52
Splice X13 94 HVAC 97
Splice X13-1 94 Ignition 1, 7
Splice X53 94 Intermittent Wiper 84
Splice X54 94 Key-In 108, 110
Splice X55 94 Left Door Lock 101
Splice X56 94 Mercury 72
Splice Z1 114 Park Brake 77
Splice Z1-1 72 Park Switch 84
Splice Z1-3 68, 70 Power Door Locks 101, 102
Splice Z2 95 Power Mirrors 103
Splice Z2-1 92, 95 Power Seat 105
8W - 48 WIRING DIAGRAMS
Power Take-off (PTO) . . .11 Turn Signal Flasher 85
Power Windows 99, 100 Two-Way (2-Way) Power Feed. 59
Right Door Lock .102 Underhood Lamp .72
Seatbelt .108.110 Vacuum Sensor. 57, 62
Stop Lamp. .64 Valve-Pressure Limiting 55, 57, 60
Transmission Overdrive . 10 Valve-ABS Pump/Valve . .59
Transmission Range 12 Vehicle Speed Control System . 63, 64
Turn Signal 85 Clockspring 64
Vehicle Speed Control .64 Powertrain Control Module . 63
Windshield Washer 84 Servo 63
Windshield Wiper .84 Stop Lamp Switch. . .64
Throttle Position (Sensor) 18, 28, 38, 45 Vehicle Speed Control Switch. 64
Time Delay Relay 108, 110 Vehicle Speed Sensor 20, 30, 36, 46
Trailer Tow Connector 113 Washer Pump Motor. 83
Trailer Tow Relay 113 Washer Switch 84
Trailer Tow System 113 Water-ln-Fuel Sensor .45
Connector • • 113 Wheel Sensors .61
Electric Brake Provision 113 Windshield Wiper System (Intermittent) 83, 84
Relay 113 Low Washer Fluid Level Sensor 83
Transmission Overdrive System 10, 11, 12 Washer Pump Motor 83
Back-Up Lamp Switch .12 Washer Switch 84
4X4 Switch 11 Wiper Control Module 83
Powertrain Control Module . -10 Wiper Motor 84
PTO Switch .11 Wiper/Washer Switch 84
Trans O/D Solenoid .10 Wiper Switch 84
Trans O/D Switch .10 Zener Diode .98
Transmission Range Switch 12
Transmission Temperature Sensor .10
Turn Signal/Hazard Switch . .85
I G N I T I O N SWITCH - A 3 1 12BK/WT*-
A21 12DB-
SH 7
A22 Al
T
12BK 12RD
OR*
POWER
DISTRIBUTION
CENTER
SH 4
A22 12BK/0R*-
A22 A22
12BK 12BK
OR* OR*
FUSE#F2 CIRCUIT
30 AMP BREAKER 1
( L I G H T GREEN) 30 AMP
F21
14TN
a.
BLOWER L E F T DOOR
MOTOR POWER WINDOW
SH 9 6 , 9 7 SWITCH
SH 9 9
=3 RIGHT DOOR
1
FUSE* 9 " " J FUSE # 1 0 FUSE 11 11 FUSE # 1 2
10 AMP POWER WINDOW
2 AMP 10 AMP 15 AMP
If"
(RED) SWITCH
H (GRAY) (RED) IGHT B L U E )
SH 100
3
F18 V34
F12
22LG 22WT 22DB
BK* RD* WT*
X CLOCKSPRING
F U E L PUMP RELAY SH 64
SH 90 VEHICLE
A / C COMPRESSOR S P E E D CONTROL
CLUTCH RELAY SWITCH
SH 98 SH 64 MESSAGE
JOINT
AUTOMATIC CENTER
CONNECTOR C
SHUT DOWN RELAY SH 86
SH 7 6
SH 2 2 , 2 5 , 3 6 , 4 4 CLUSTER B
OVERHEAD
TRANSMISSION SH 88
CONSOLE
OVERDRIVE SOLENOID
SH 10
SH 81 , AIRBAG
CHIME SYSTEM
ENGINE DATA L I N K BUX
MODULE CONTROL
CONNECTOR ONLY
SH 1 5 , 2 5 . 3 9 . 4 4
SH 107 I MODULE
BUZZER SH 5 3
EXHAUST GAS
SH 109
RECIRCULATION
SOLENOID
SH 1 9 . 2 9 . 4 1
E V A P / P U R G E SOLENOID 3
SH 1 9 . 2 9 . 4 1
POWERTRAIN CONTROL
i3
MODULE
SH 1 9 . 2 9 . 4 1 , 4 3
I G N I T I O N MODULE
fl 3
l
SH 39 —
F U E L HEATER RELAY 4
SH 47
F U E L SHUT DOWN DIESEL
ONLY
ill
SOLENOID
SH 48
INTAKE A I R HEATER
RELAYS F U S E S NOT USED
SH 43
BR 1 FUSE APPLICATION CHART J948W-9

• WIRING DIAGRAMS 8W - SI
-A31 12BK/WT*-
-A22 12BK/0R*-i
FUSE # 5 FUSE* 6 FUSE* 7 FUSE* 8
4
20 AMP 15 AMP 10 AMP 15 AMP
(YELLOW) (LIGHT BLUE) (RED) .(LIGHT BLUE)
F30
V6
IBRD
16DB
OR*
BK*
x
POWER OUTLET TURN x
SH 78 SIGNAL RADIO WIPER CONTROL
CIGAR L I G H T E R FLASHER SH 9 1 , 9 3 MODULE
SH 78 SH 85 SH 83
WIPER MOTOR
SH 84
WIPER SWITCH
SH 84
F U S E * 14 3 FUSE #15 FUSE # 1 6

20 AMP 10 AMP 15 AMP
13
(YELLOW) R E (LIGHT BLUE)
3 ( °)
A20 L10
18RD 22BR
DB* LG*
J, JOINT
REAR WHEEL
CONNECTOR C
A N T I - L O C K MODULE
SH 7
SH 5 5 . 5 7
AUTOMATIC
VACUUM SENSOR
DAY/NIGHT
SH 5 7 , 6 2
MIRROR AIRBAG
A N T I - L O C K BRAKE
SH 106 SYSTEM
SYSTEM CONTROLLER
BACK-UP CONTROL
SH 6 2
LAMP SWITCH MODULE
ABS POWER
SH 12 SH 53
RELAY
DAYTIME RUNNING
SH 60
LAMPS MODULE
SH 71
J948W-9 F U S E A P P L I C A T I O N C H A R T B R 2
•AO 6RD- POWER D I S T R I B U T I O N

CENTER SH 4
H A3 12RD/LG*-
zo
6BK AO
20 6BK
10BK
BATTERY
J,
4
ENGINE
STARTER
AO MOTOR
OBRD SH 9
BATTERY
GROUND
A7
12RD
BODY BK*
GROUND
CIRCUIT I FUSE # 1 7 ! FUSE #18 19* FUSE # 1 9
9
BREAKER 2 15 AMP , 8 15 AMP 20 AMP
DIESEL 30 AMP I (LIGHT BLUE) 3 (LIGHT BLUE) (YELLOW)
ONLY
F37 F35
Ml
14RD 16RD
18PK
LB*
x
F33
x
POWER
UNDERHOOD
20PK
RD* 1
L E F T DOOR
LAMP
SEAT LOCK SWITCH
SH 72
SWITCH SH 101
POWER MIRROR
SH 105 RIGHT DOOR
SWITCH
,— SH 103 LOCK SWITCH
BUX SH 102
CHIME MODULE
ONLY L — SH 107 HEADLAMP
BUZZER SWITCH A3 12RD/LG*
SH 109 SH 73
JOINT
CONNECTOR B
SH 75
RADIO
SH 9 1 , 9 3
GLOVE.BOX
LAMP AND SWITCH
SH 78
RADIO CHOKE 13< FUSE # 1 3
SH 94 5 AMP
OVERHEAD MAP (TAN)
LAMP
AO SH 80
OBRD OVERHEAD FUSE # 2 0
CONSOLE 15 AMP
SH 81 (LIGHT BLUE)
TIME DELAY
RELAY JOINT CONNECTOR C F32
SH 1 0 8 , 1 1 0 SH 77 18PK
OVERHEAD CONSOLE DB*
SH 81 v k
HEATER SWITCH
3
JOINT
SH 96 CONNECTOR B
RIGHT BATTERY
HVAC SWITCH SH 75
(DIESEL ONLY) SH 97
ENGINE BRAKE
CLUSTER B
BLOCK SWITCH
SH 88
SH 64
RADIO
REAR WHEEL
SH 9 1 , 9 3
-== (ON ENGINE) ANTI-LOCK
MODULE
BODY
SH 5 6 . 5 8
GROUND
BR 3 FUSE APPLICATION CHART J948W-9

TO TO
IGNITION
TO
SWITCH
( S E E SH 7 )
TO
SPLICE AUTOMATIC
( S E E SH 5 2 ) SPLICE SHUT DOWN RELAY
( S E E SH 9 ) ( S E E SH 2 2 , 2 5 , 3 6 , 4 4 )
TO
BATTERY FEED FEED
POSITIVE T- A16
TERMINAL A2
14GY
( S E E SH 5 , 6 12PK
WT*
BK*
FEED
FUSIBLE FUSIBLE FUSIBLE •FUSIBLE
LINK 1 LINK 2 LINK 3 LINK 4
|}K'
AO ( 3 0 AMP)
50 AMP) ( 4 0 AMP) ( 4 0 AMP)
6RD
A2 A16
12PK 14GY
BK* WT*
A10
All BUSS BAR 12RD
6BK DG*
GY*
FUSIBLE FUSIBLE
-FUSIBLE LINK 6 LINK 5
LINK ( 4 0 AMP) ( 4 0 AMP)
ft ( 1 2 0 AMP)
All A10
6BK 12RD
GY* DG*
FEED
J. FEED
TO GENERATOR TO A N T I - L O C K
( S E E SH 5 . 6 ) BRAKE SYSTEM
(SH 1 2 4 )
POWER RELAY
( S E E SH 60)
iNOTEi
FOR LOCATIONS
S E E SH 142
TO
TRAILER
TOW SYSTEM
TO ( S E E SH 1 1 3 ) SPLICE
POWERTRAIN ( S E E SH 7 5 )
CONTROL
MODULE
CAVITY 3
( S E E SH 1 6 , 2 6 , 4 1 , 4 8 )
J948W-9 POWER DISTRIBUTION CENTER BR 4

FEED < TO ENGINE

-AO 6RD i STARTER MOTER
(SEE SH 9)
FEED, TO POWER
\ DISTRIBUTION
CENTER
(SEE SH 4)
ZO
6BK
BATTERY
GROUND
(LEFT FRONT BODY
OF GROUND
ENGINE) (LEFT FENDER
B L A C K
SHIELD)
FEED
TO POWER
DISTRIBUTION
CENTER
(SEE SH 4)
(SH 124)
TO
HAZARD 1 FEED L9 18BK/VT*
FLASHER C
(SEE SH 85)
TO
POWERTRAIN
CONTROL MODULE
CAVITY 20
SPLICE (SEE SH 14.24.41)
(SEE SH 14.24.34)
CHARGING SYSTEM
(GAS ENGINE) J948W-9
BR 5
FEED f TO E N G I N E
AO 6BK- "1 STARTER MOTER
( S E E SH 9 )
ENGINE
BLOCK
(LEFT SIDE
OF E N G I N E )
ENGINE
BLOCK
(RIGHT S I D E
OF E N G I N E ) BODY
GROUND
(RIGHT S I D E
SHIELD) FEED
TO POWER
DISTRIBUTION
CENTER
( S E E SH 4 )
(SH 1 2 4 )
TO FEED
t t U
HAZARD V L9 18BK/VT*
:i A e
FLASHER u r o
( S E E SH 8 5 )
TO
POWERTRAIN
CONTROL MODULE
CAVITY 20
SPLICE ( S E E SH 4 3 )
( S E E SH 4 4 )
CHARGING SYSTEM
J948W-9 (DIESEL ENGINE) BR 6
>—F14 18LG/YL*—
TO >—F12 22DB/WT*—
POWER DISTRIBUTION
CENTER >—V34 2 2 W T / R D * —
( S E E SH 4 )
I G N I T I O N SWITCH FEED
>—F18 22LG/BK*-
(ON S T E E R I N G COLUMN)
(SH 123) TO
Al FUSE # 1 2 CLOCKSPRING
12RD ( 1 5 AMP) 30 ( S E E SH 6 4 )
F U S E * 11 F18
(SH 124) ( 1 0 AMP) 20LG
F U S E * 10 TO BK*
4 2
E I ( 2 AMP)
FEED
« - A l 12RD FUSE* 9
( 1 0 AMP)
SPLICE
(SH 123) ( S E E SH 9 8 )
H>— A31 12BK/WT*-

I—« A41 18YL INST/
PNL
A41
18YL
JFEED
TO ENGINE
-A2 12PK/BK*-<( A22 12BK/0R* A22 12BK/0R*-
STARTER
SYSTEM
( S E E SH 9 )
43
F U S E * F2 CIRCUIT
(SH 124) ( 3 0 AMP) BREAKER 1
( 3 0 AMP)
( I N FUSE BLOCK)
A2
12PK
Y
BK *
F21
FEED
1 TO
TO
14TN FEED^TO <f2^> S L I C E
( S E E SH 100)
BLOWER
•L10 2 2 B R / L G *
3>
SPLICE
-A41
-A21
-G9
18YL
12DB
22GY/BK* 25
MOTOR
( S E E SH 9 G . 9 8 )
28
( S E E SH 9 ) -A2 12PK/BK* JOINT
(CONNECTOR
23 CONNECTOR
-A22 12BK/0R* S E E SH 132)
C
G9
9 30 | — » - L 1 0 2 2 B R / L G * -
-A31 12BK/WT* 29
22GY
Bm
K* W/0 DRL-
-Al 12RD
1 FEED
TO
T L10 / — L10 18BR/LG*
CLUSTER A 22BR /
( S E E SH 8 7 ) LG* /
TO REAR WHEEL , L-)/-L10 20BR/LG* —
A N T I - L O C K MODULE \
J
( S E E SH 5 6 . 5 8 ) FEED 62
[SH 124)
TO BRAKE
WARNING S W I T C H ) G9 18GY/BK*
( S E E SH 5 6 . 5 7 ) FEED F E E D ^ TO <G9> S P L I C E
( S E E SH 62)
BR 7 IGNITION SWITCH J948W-9

FI4 18L6/YL* ^ 4 T O < W > SPLICE

F E E D
F12 22DB/WT* ( TO J O I N T CONNECTOR C , >^
F E E D ^ TO < V 6 ) > S P L I C E
V6 16DB/BK*'
( S E E SH 84)
FEED < TO RADIO
-A31 12BK/WT*- X12 18RD/WT*
i ( S E E SH 9 1 , 9 3 )
F U S E #5
( 2 0 AMP) F E E D f TO TURN S I G N A L FLASHER
L 5 20BK
F U S E #6 > ( S E E SH 8 5 )
( I S AMP)
FUSE # 7 F E E D < TO POWER OUTLET
F30 18RD/0R*
( 1 0 AMP) > ( S E E SH 7 8 )
FUSE # 8
( 2 0 AMP)
WITH-
ABS
F U S E * 14
( 2 0 AMP)
A22
F U S E * 15 -A20 18RD/DB*-
12BK
( 1 0 AMP)
OR*
F U S E * 16
( 1 5 AMP) Y—m 18RD/DB*-
-A20 18RD/DB*
» 1 FEED WITH ABS

L10
TO REAR WHEEL
22BR
A N T I - L O C K MODULE
LG* - T
F23 ( S E E SH 5 5 . 5 7 )
18DB A20 2Q
18RD
Zl
A
YL*
TO AIRBAG . n r r n
FEED |
TO
SYSTEM C O N T R O L L E D J FEED
BLACK X VACUUM
MODULE ) >
TO O 2 0 > S P L I C E SENSOR
( S E E SH 5 3 )
( S E E SH 5 7 )
• L10 2 2 B R / L G * - ( S E E SH 62)
DD
L10 2 2 B R / L G * - p p .10 2 2 B R / L G * -
JFEED
DD 1J t - a a l
DD
TO AUTOMATIC
L10 1 8 B R / L G * •L10 18BR/LG* • DAY/NIGHT MIRROR
(LEFT S I D E COWL)
10 ( S E E SH 1 0 6 )
"| ENG |- FEED

(SH 128)
TO
BACK-UP
LAMP SWITCH
HD/LP ( S E E SH 12)
DASH
TO
F E E D „ DAYTIME RUNNING
L10 2 0 B R / L G * L10 1 8 B R / L G * - \ LAMP MODULE
( S E E SH 7 1 )
J948W-9 IGNITION SWITCH BR 8

•
BLACK- 7 » - AO 6RD
ENGINE STARTER MOTOR
]3— T40 12BR
T0
FEED BATTERY
-» AO 6RD- { POSITIVE TERMINAL
(SEE SH 5.6)
T0<Z122J
PULL-ON SPLICE SPLICE
(SEE SH 15. (SEE SH 16.
6 -» T40 12BR
25.42.47)
^TGND
26.42.48)
GND
—UUUUUJ (LEFT
HOLD-ON FENDER Z12 T41
SIDE BLACK 20BK 20BK
SHIELD) TN* WT*
HO/LP
DASH
•T40 12BR- GAS
ONLY
DIESEL T40
ONLY -T40 12BR- 12BR
T40
12BR DIESEL 22BK INGT}-
10 ONLY WT
* (SH 127) TO
IGNITION
-ENG i
(SH L27
SWITCH
T40 > (SEE SH 7)
12BR
ENGINE (IN POWER TnFEED
J , FEED STARTER DISTRIBUTION
CENTER) A41
TO FUEL RELAY (SEE SH 142) 18YL
SHUT DOWN
RELAY 23
(SEE SH 47)
A2 A41 (SH 123)
HD/LP 12PK 14YL

DASH BK*
TO
POWER FEED
DISTRIBUTION \ A2 12PK/BK* GREEN
CENTER
SEE SH 4) in? •A41 18YL
-A2 12PK/BK* 3G=F
43
(SH 124)
A2
12PK GREEN
BK* A41 GREEN A41
BYPASS 18YL
J*IFEED JUMPER CLUTCH
18YL MANUAL
TRANSMISSION
TO IGNITION A41 20YL PEDAL POSISION
, SWITCH (SWITCH)
(SEE SH 7) AUTOMATIC
A
(ON CLUTCH ROD)
%
TRANSMISSION
BR 9 ENGINE STARTER SYSTEM J948W-9

WIRING DIAGRAMS 8W - i t
BLACK
T18 22LG/0R*- •Z3 2 0 B K / 0 R *

G54 2 2 0 R / B K * ^ l q •TS 2 2 0 R / W T *
•F12 22DB/WT* 8.0L ONLY-
FEED r T O CLUSTER A
G54 220R/BK*
> (SEE SH 8 7 ) —T18 20LG/0R*-*~i
T18 22LG/0R* T18 2 2 L G / 0 R * — T 1 8 20LG/OR*—,

(SH 123) 7 3-JENG Ah
•D>-T6 220R/WT*—))- -T6 220R/WT* (SH 127)
3.9L.
TRANSMISSION
t £ J 6
5.2L.
(SH 123) 5.9L
OVERDRIVE
SWITCH
ONLY
-JENG A h
(ON INSTRUMENT
PANEL RIGHT (SH 127)
TO JOINT TO OF STEERING
CONNECTOR C COLUMN)
(SEE SH 7 6 ) G54
T6
20OR 200R
SPLICE
(SEE SH 7 8 )
WT* BK*
K54 200R/BK*-
TRANSMISSION
OVERDRIVE
SOLENOID
10 54 37
wmLm
31
(MOUNTED
ON -T60 20BR 55 POWERTRAN I CONTROL MODULE
TRANSMISSION) (CONNECTOR SEE SH 1 1 9 . 1 2 0
121.122)
— » — F18 2 0 L G / B K * — i
TO (RIGHT SIDE
COWL) 42
SPLICE
(SEE SH 20, 30
36.45) T54
18VT
"JGND TRANSMISSION
K4 TEMPERATURE
18BK SENSOR
LB*
FEED
TO
(IN
<R8> 1 TRANSMISSION
COOLER L I N E )
SLICE
(SEE SH 1 9 . 2 9 K4 1 8 B K / L B *
41.43)
BLACK
T54 18VT
J948M-9 TRANSMISSION OVERDRIVE SYSTEM BR 10

WT
I H FOUR WHEEL DRIVE WT
I H POWER TAKE OFF
BUCK" "BLACK ~"
8BK -Zl 1
8BK
G107 18BK/GY*
4X4 SWITCH PTO SWITCH
ON FRONT AXLE) (RIGHT SIDE OF PTO)
G107
18BK
GY*
BLACK
Zl
20BK G107
20BK
JGND G107 GY*
20BK
TO
GY*
Zl> 3
SPLICE SPLICE
(SEE SH 68,70) (SEE SH 68.70) I
6107 G107 26 G107
20BK HD/LP 20BK (SH 123) 20BK
GY* DASH GY* GY*
i
i
G107 G107
WT
IH 22BK WT
IH 22BK
ABS GY* ABS GY*
G107 G107
20BK 20BK
GY* GY*
FEED FEED
TO ANTI-LOCK TO ANTI-LOCK
BRAKE SYSTEM BRAKE SYSTEM
MODULE MODULE
(SEE SH 62) (SEE SH 62)
TO CLUSTER B cfi i-6107 22BK/GY*—-y-

E
TO CLUSTER B FEED
(SEE SH 88) / (SEE SH 88)
W I
1TH- —6107 22BK/6Y*—-y
WITH-
G107 "ABS G107 ABS
20BK 20BK
GY* GY*
l_
X ÊD "V FEED
TO REAR WHEEL TO REAR WHEEL
ANTI-LOCK BRAKE ANTI-LOCK BRAKE
MODULE MODULE
(SEE SH 55,57) (SEE SH 55.57)
BR 11 TRANSMISSION OVERDRIVE SYSTEM J948W-9

AUTOMATCI
TRANSMISSION
(ON TRANSMISSION)
GND f TO <J41> SPLICE

T41 18BK/WT*-^-£ \ y
(SEE SH 16.
26.42.48)
MANUAL
, TRANSMISSION
(RIGHT SIDE OF
TRANSMISSION)
TO JOINT
CONNECTOR C
(SEE SH 7)
FEED
LIO
22BR
LG*
LIO 18BR/LG* (SH 124)
(SH 128) A-630

MANUAL LI
O
TRANSMISSION 18LG*
(5.2L&5.9L
ONLY)
BR
(SH 128)
^-LIO
WTIH
18BR/
L G J
LIO
20BR
62
DRL LG*
(RIGHT SID)EEOF * \
TRANSMISS"
ION) 1 I
FEED
TO <qjo> SPLICE
(SEE SH 8)
SPLICE
(SEE SH 112)
i—BLACK
LI 22VT/BK* f TO
2 2
|pD||f] rw AUTOMATC
I
(SH 123) lb cjj Jq y[
a|
,
(LEFT SIDE
(SEE SH 106)
dk KICK PANEL)
J948W-9 TRANSMISSION OVERDRIVE SYSTEM BR 12
8W - S2 WIRING DIAGRAMS •
r .—. — , r
p A142 16DG/0R* A142 16DG/0R* A142 16DG/0R* A142 16DG/0R*

BLACK b-i-BLACK in*-BLACK
L-Kll 18WT/DB* K 1 2 18TN K13 18YL/WT* K14 1 8 L B / B R *
INJECTOR # 4
T T T T A142
T T T T
Kll Al42 K12 K13 A 1 4 2 K14 A 1 4 2
18WT 16DG 16DG 18YL 16DG 18LB 160G
18TN
OB* O R * OR* WT* O R * BR* O R *
-A142 16DG/0R*-
-A142 16DG/0R*-
-A142 14DG/0R*-
(REAR OF
ENGINE)
IGNITION
COIL
i i A142
14DG
K19
T T
A142
OR*
16BK 14DG
GY* OR*
•A142 16DG/0R* A142 16DG/0R*
•A142 16DG/0R*
Kll K12 K19 K13 K14

18WT 18TN 16BK 18YL 18LB
OB* GY* WT* BR*
1
A . T A .
16 15 19 14 13
INJ #1 INJ # 2 COIL INJ # 3 INJ #4
DRIVER #1
POWERTRAIN CONTROL MODULE
( R I G H T S I D E COWL) (CONNECTOR S E E SH 1 1 9 )
FUEL INJECTION IGNITION SYSTEM

BR 13 (3.9L ENGINE) J948W-9
TO
GENERATOR A142 16DG/0R* r-A142 16DG/0R*
( S E E SH S )
j i - * - BLACK BLACK
FEED §r
~^K38 18GY* L-K58 18BR/DB*
INJECTOR # 6
A142
HOB TO
TRANSMISSION
T T T T OVERDRIVE
, SWITCH %
TO F U E L
PUMP RELAY
K38 A142 K58 A142
S E E SH 10) ( S E E SH 9 0 )
18GY 16DG 18BR 16DG
OR* OB* OR* FEED FEED
-A142 16DG/0R*
-A142 16DG/0R*
-A142 14DG/OR* T6 K51

220R 22DB
WT* YL*
-A 142 14DG/0R*
A142
160G
OR*
8
- ENG A
TO (SH 123) (SH 127)

TRANSMISSION
OVERDRIVE
SOLENOID
( S E SH 1 0 )
T6
220R
FEED
WT*
TO
GENERATOR
( S E E SH 5 )
-JENG A|-
FEED
•A142 16DG/0R*- (SH 127)
A142 K58 TG K51

16DG K38 T60 18BR K20 200R 20DB
O R * 18GY 20BR DB* 18DG WT* YL*
T
57
T
38 55
i
58
± 20 10
JL
JL
± 51
FEED INJ TRANS INJ # 6 VOLTAGE TRANS SW A.S.D.
#5 OD REG INPUT
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE (CONNECTOR S E E SH 119)
F U E L I N J E C T I O N I G N I T I O N S Y S T E M .
J948W-9 ( 3 . 9 L E N G I N E ) B R 1 4
TO
TRANSMISSION
OVERORIVE
SWITCH
(SEE SH 10)
FEEO
T18
22LG
OR*
Z12 20BK/TN*-
(SH 123)
T18
22L6
OR*
-QNG}
(SH 127)
654
200R
BK* TO
T18 Z12
20L6 SPLICE
20BK
OR* (SEE SH 2 1 )
TN*
ENGINE
DATA LINK lu
CONNECTOR
(RIGHT SIDE
COWL)
SPLICE
Z12 14BK/TN* SEE SH 19)
ENGINE FEED
GROUND
f | ( L E F T FRONT
OF ENGINE)
TO
TRANSMISSION
OVERDRIVE
SOLENOID
(SEE SH 1 0 )
FEED
Z12 Z12 D21
16BK 16BK 20PK
TN* TN*
37
TRANS
54
TRANS
12,
1 11 25
\ + 45
DATA LINK
CONTROL CONTROL POWER GROUND DT
AR
TA
ANSLMT
I RECEIVE
(RIGHT SIDE COWL) POWERTRAN
I CONTROL MODULE (CONNECTOR SEE SH 119)

TO ENGINE 6 N D
H ENG Y ( S H 127)
STARTER RELAY V—-^—- -T41 22BK/WT*
( S E E SH 9 )
TO J O I N T , FEED
CONNECTOR C V
( S E E SH 76)
Z12 T41
20BK 20BK
TN* WT*
•Z12 20BK/TN *
REAR WHEEL
ANTI-LOCK
ONLY
TO TO
CLUSTER B TRANSMISSION
( S E E SH 8 8 ) TO RANGE SWITCH
MESSAGE ( S E E SH 1 2 )
FEED CENTER
( S E E SH 8 6 ) TGND
T41
FEED
18BK
WT*
G3 G14
22BK 20PK
PK* BK*
15
TO SPLICE K2 18TN/BK*
(SH 1 2 3 ) POWER ( S E E SH 7 6 )
BLACK
67
DI STRIBUTION
CENTER
S E E SH 4 ) 18BK/LB*
G3
22BK
(SH 1 2 4 )
FEED
PK* V40
ENGINE
22WT
COOLANT
8 PK*
r TEMPERATURE
HENGBh I SENSOR
A14 I
16RD (FRONT OF
(SH 1 2 8 ) G14 ENGINE)
WT*
18PK
BK*
1 - ENG B
H ENG A
(SH 1 2 8 )
(SH 1 2 7 )
G3 614 A14
20BK 18PK 16RD
PK* BK* WT*
i.
32
A. ±
31
TRANS TEMP F U E L PUMP
29
STOP LAMP
30
ENGINE
2
ECT
MIL
LAMP RELAY SW STARTER RLY
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE (CONNECTOR S E E SH 1 1 9 )

J948W-9 (3.9L ENGINE) BR 16
K6 18VT/WT*
-Kl 18DG/RD*
BLACK
K4 18BK/LB*
(CENTER REAR
OF E N G I N E )
MAP (MOUNTED ON
DISTRIBUTOR THROTTLE BODY)
SENSOR
K44 K4 K7
20TN 20BK 200R
YL* L B *
J
TO V E H I C L E
S P E E D CONTROL K44 Kl K6 K4
SERVO 20TN 18DG 18VT 18BK
( S E E SH 6 3 ) YL* LB* RD* WT* L B *
FEED FEEO
K4 2 0 B K / L B *
K4 18BK/LB*
K6 18VT/WT*
ENG
K6 K4
20VT 18BK
WT* L B *
-K7 200R- K7 200R-

V36 V35
20TN 20LG
RD* RD*
K4 18BK/LB*
i E N G - B k * A ENG B h TO
(SH 1 2 8 ) (SH 1 2 8 ) TRANSMISSION
TEMPERTURE
TO SENSOR
VEHICLE ( S E E SH 1 0 )
SPEED
V36
20TN
V3S
20LG
K44
20TN
SENSOR
( S E E SH 2 0 ) K7 Kl
18DG
K6
20VT
T
200R T54
RD* RD* YL* RD* WT* 18VT
33
i
VACUUM
A
53
VENT
±
44
CAM P O S I T I O N
i 7
8V
i_
1
MAP
JL6
5V
42
TRANS
SENS SUPPLY SENSOR OUTPUT TEMP

CRANKSHAFT
POSITION
SENSOR
( R I G H T REAR
THROTTLE OF E N G I N E )
POSITION
(SENSOR)
(ON THROTTLE
BODY)
BLACK
K4 K7
20BK 200R
LB*
K4 2 0 B K / L B *
K4 18BK/LB*
K6 18VT/WT* TO
ENGINE
COOLANT
TEMPERATURE
K22 SENSOR
180R ( S E E SH 1 6 )
DB*
K7 200R
K4 18BK/LB*-
K22
180R K24
DB* 20GY
BK*
22 24 4 21
TP(S) B-h SIGNAL CHARGE
REF AIR
SENSE

J948W-9
(3.9L ENGINE) BR 18
SW - 08 WIRING DIAGRAMS •
TO < R 8 > S P L I C E
( S E E SH 9 8 )
FEED
TO
ENGINE
DATA L I N K
CONNECTOR
TO ( S E E SH 1 5 )
CLUSTER B
( S E E SH 8 8 ) FEED
FEED F18 20LG/BK*— 1
TO
F n
F F TRANSMISSION
F18 2 0 L G / B K * ^ ^ W OVERDRIVE
SOLENOID
G21 ( S E E SH 1 0 )
22GY
LB*
(SH 1 2 3 )
IDLE AIR
CONTROL MOTOR F18
20LG
BK*
(ON THROTTLE
BODY)
G21
22GY EVAP/PURGE
LB* SOLENOID
( R I G H T S I D E COWL)
BLACK
-BLACK
HENG C h
(SH 1 2 9 )
G21 K59 K40 K60 K39 F 1 8 K52 K35 EXHAUST GAS

20GY 18VT 18BR 1 8 Y L 18GY 2 0 L G 20PK 20GY RECIRCULATION
LB* BK* WT* B K * R D * B K * BK* YL* SOLENOID
( R I G H T REAR
OF I N T A K E )
43 159 40 60 391 9 52 35
TACH m EVAP/ EGR
IAC
PURGE

BR 19 (3.9L ENGINE) J948U-9
TO
TRANSMISSION TO
TEMPERATURE CRANKSHAFT
SENSOR P O S I T I O N SENSOR
( S E E SH 1 0 ) ( S E E SH 1 8 )
TO
GNO GNO
TO
THROTTLE
POSITION SPLICE
(SENSOR) ( S E E SH 1 8 )
( S E E SH 1 8 )
K4 18BK/LB*
K7 180R VEHICLE
K4 18BK/LB* SPEED
SENSOR
G7 18WT/0R* —«—I
(REAR OF
67 ( L E F T S I D E OF TRANSMISSION)
20WT TRANSMISSION)
OR*
TO HEATED TO MAP
OXYGEN SENSOR
SENSOR ( S E E SH 1 7 )
( S E E SH 2 1 )
T0<K7> S P L I C E ^ F E E D K7 180R
( S E E SH 1 7 )
-<f-G7 22WT/0R* —<f-G7 20WT/0R*-
20 9H ENG Ch
UJ (SH 1 2 9 )
(SH 1 2 3 )
G7
22WT
OR*
FEED 47 VSS
TO
CLUSTER A
( S E E SH 8 7 ) ( R I G H T S I D E COWL) (CONNECTOR S E E SH 119)

J948W-9
(3.9L ENGINE) BR 20
T0<Z12>T
I N J E C T O R S 1 . 3 AND 5
SPLICE ( S E E SH 1 3 . 1 4 )
( S E E SH 1 5 )
GND FEED
Z12
14BK
A142 14DG/QR*-
Zll 14BK/WT*
ENGINE GROUND
( L E F T FRONT
OF E N G I N E )
TO A I R
CONDITIONING AND
HEATER SYSTEM
( S E E SH 9 8 ) SPLICE
( S E E SH 1 4 )
(RIGHT S I D E COWL) (CONNECTOR S E E SH 1 1 9 )

TO TO
FEED FEED. POWER
<9>f F18 20LG/BK*- A16 14GY/WT* —-—-A DISTRIBUTION
CENTER
SPLICE (SEE SH 4)
(SEE SH 98)
AUTOMATIC
SHUT DOWN RELAY
(IN POWER
DISTRIBUTION
CENTER) TO
(SEE SH 142) VEHICLE SPEED
CONTROL SYSTEM
(SEE SH 63)
FEED FEED FEED
FEED
V31 V32 V33
TO 22BR 22YL 22WT
FUEL PUMP
RELAY
RD* RD* LG*
SEE SH 90)
-|ENG Af- 79 80 81
(SH 127)
-A142 14DG/0R* » (SH 124) (SH 124) (SH 124)
TO A/C TO A/C V31 V32 V33

LOW PRESSURE COMPRESSOR 20BR 20YL 20WT
CUT-OUT SWITCH CLUTCH RELAY RD* RD* LG*
(SEE SH 97) SEE SH 98)
FEED ^JGND
3
C13
22DB * HENG Bf-
OR*
(SH 128)
HENG A|- ENG B|- Bh

(SH 127) (SH 128) (SH 128)
C20 C13 V31 V32 V33
20DB 20BR 20YL 20WT
18BR OA * RD* LG*
RD*
27 34 48 49 50
A/C DAMPED A/C COMP SET IGN RESUME
PRESS CLUTCH
(RIGHT SIDE COWL) (CONNECTOR SEE SH 119)

(3.9L ENGINE) I B R 2 2
r A142 16DG/0R* AI42 16DG/0R* A142 16DG/0R* A142 16DG/0R*

ji-^—BLACK BLACK -BLACK BLACK
"t-Kll 18WT/DB* K12 18TN K14 18LB/BR *
\ INJECTOR # 2
INJECTOR U 4
T T T I T T T T
K l l A142 A142 K13 A142 K B A142
K12
18WT 160G 18TN
16DG 18YL 16DG 18LB 16DG
DB* O R * OR* WT* OR* BR* OR*
-A142 160G/OR*-
-A142 16DG/0R*-
-A142 14DG/0R*-
(RIGHT F R O N T \
OF ENGINE) V
IGNITION
COIL
TO
TRANSMISSION
IT T
A142
1406
OVERDRIVE OR*
K19 A142
SOLENOID 14DG
16BK
( S E E SH 1 0 ) OR*
GY*
FEED
A142 16DG/0R*- A142 16DG/0R*
-A142 16DG/0R*- A142 16DG/0R*
K19 K13 K14

Kll K12
T60 18LB
18WT 18TN 16BK 18YL
20BR BR*
DB* GY* WT*
16
INJ #1
A 55
TRANS
#«
y
15
INJ # 2
K
19
JL
T
COIL
14
A
T
INJ # 3
13
INJ #4
OD DRIVER

BR 23 (5.2L AND 5.9L ENGINES) J948W-9
r A142 16DG/0R* A142 16DG/0R* pA142 16DG/QR* P-A142 16DG/0R*

W-BLACK BLACK p|jN*-BLACK l||-*-BLACK
•K38 18GY K58 18BR/DB* L-K17 18DB/TN* L-K18 18RD/YL*
INJECTOR * 8 /
TO
GENERATOR
( S E E SH 5)
T T T T T T T T
K38 A 1 4 2 K58 A 1 4 2 K17 A 1 4 2 K18 A 1 4 2
18GY 160G 18BR 16DG 18DB 16DG 18RD 16DG
OR* OB* OR* TN* OR* YL* OR*
A142 16DG/0R*
A142 16DG/0R*
A142 14DG/0R* TO
TRANSMISSION
OVERDRIVE
A142 14DG/0R* , SWITCH
S E E SH 1 0 )
"ypEED
T6
220R
A142 WT*
160G TO F U E L
OR* PUMP RELAY
( S E E SH 9 0 )
(SH 1 2 3 ) FEED
T6
K51
220R
TO 22DB
WT*
GENERATOR YL*
( S E E SH 5 )
FEED
-|ENG A|- :-|ENG A[-
A142 16DG/0R*- (SH 1 2 7 ) (SH 1 2 7 )
A142 16DG/0R*-
A142 K58 T6 K17 K51 K18

16DG K38 K20 18BR 200R 18DB 20DB 18RD
OR* 18GY 18DG DB* WT* TN* YL* YL*
X
T
57
X
T
38
'A
T
20
X
T
58
X
r
10 17
*
*
51
± 18
FEED INJ # 5 VOLTAGE INJ # 6 TRANS INJ # 7 ASD RLY INJ # 8
REG OD
( R I G H T S I D E COWL) POWERTRAIN CONTROL MODULE (CONNECTOR S E E SH 1 2 0 )

J948W-9
(5.2L AND 5.9L ENGINES) BR 24
TO TO
TO :FIS: FEED FEEO r POWER
TRANSMISSION F18 2 0 L G / B K * 1 A16 14GY/WT* — — - t DISTRIBUTION
OVERDRIVE CENTER
SWITCH SPLICE -A.
( S E E SH 4 )
(SEE SH 10) ( S E E SH 9 8 )
AUTOMATIC
FEED
SHUT DOWN RELAY
( I N POWER
T18 DISTRIBUTION
22LG CENTER)
OR* ( S E E SH 1 4 2 )
Z12 20BK/TN*
(SH 1 2 3 )
T18
22LG
OR* TO
F U E L PUMP
RELAY
( S E E SH 9 0 )
ENG A h
(SH 1 2 7 ) TO
G54 .FEED
200R AMOT] A142 14DG/0R*
BK* TO
SPLICE
( S E E SH 3 2 )
T18
20LG
OR* SPLICE
( S E E SH 3 1 )
ENGINE
TGND DATA L I N K
Zll CONNECTOR
16BK
WT* Z12 14BK/TN * Z12 20BK/TN*—N (RIGHT SIDE
COWL)
314
ENGINE
I 51 6
TO
GROUND
(LEFT SIDE
OF E N G I N E )
F18
20LG
r 020
20LG
TRANSMISSION 6K*
OVERDRIVE
SOLENOID
( S E E SH 1 0 ) FEEC
T18
G54
200R
BK* T
K54
FEED
Z12 Z12
D12
A
TO
D20
16BK
20PK LF18
i
20LG 200R 16BK
20LG
OR* BK* TN* TN* SPLICE
i
( S E E SH 2 9 )
JL T
37 S4
I 1 1 25 12 45
TRANS TRANS DATA DATA
CONTROL CONTROL
POWER GROUND LINK LINK
TRANSMIT RECEIVE
BR 25 (5.2L AND 5.9L ENGINES) J948U-9
- ENG A - ( S H 127)
L 1
TO ENGINE m —
Z ! ! H
STARTER R E L A Y 5 - -T41 228K/WT*-),
( S E E SH 9 )
TO J O I N T , FEED
CONNECTOR C \
( S E E SH 7 6 ) Z12 T4I
20BK 20BK
TN* WT*
•Z12 20BK/TN * -
(SH 1 2 3 )
REAR WHEEL
ANT I - L O C K
ONLY
TO TO
CLUSTER B TRANSMISSION
( S E E SH 8 8 ) TO RANGE SWITCH
MESSAGE ( S E E SH 1 2 ) K2 18TN/BK*
FEED CENTER
( S E E SH 8 6 ) GND BLACK
FEED K4 18BK/LB* J
r •• •
T41 T41 I
G3 G14 18BK 20BK
22BK 20PK WT* WT*
PK* BK* ENGINE
COOLANT
15 TEMPERATURE
SENSOR
TO SPLICE (FRONT OF
(SH 1 2 3 ) POWER ( S E E SH 7 6 ) ENGINE)
DISTRIBUTION
67 CENTER
( S E E SH 4 )
G3
22BK FEED
(SH 1 2 4 ) K4 K2
PK*
18BK 18TN
LB* BK*
8 A14
G14 V40
16RD
H ENG B 18PK
BK* WT*
20WT JGN
(SH 1 2 8 ) PK*
TO
^ ENG A -
H ENG B h
- ENG A | - ^ (SH 1 2 7 )
(SH 1 2 8 ) SPLICE
(SH 1 2 7 ) ( S E E SH 2 8 )
A14 V40 K2
G3 G14
16RD 20WT 18TN
20BK 18PK
PK* WT* PK* BK*
BK*
i i i
32 31 3 29 30 2
MIL TRANS F U E L PUMP STOP LAMP STARTER ECT
LAMP RLY SW RLY

J948W-9 (5.2L AND 5.9L ENGINES) BR 26
K6 18VT/WT*
-Kl 18DG/RD *
BLACK
K4 18BK/LB*
(CENTER REAR
OF E N G I N E )
MAP (MOUNTED ON
*^ DISTRIBUTOR THROTTLE BODY)
SENSOR
K44 K4 K7
20TN
YL*
20BK 200R
L B *
T
J
TO V E H I C L E
S P E E D CONTROL K44 K4 Kl K6 K4
SERVO K7
20TN 20BK 18DG 18VT 18BK
( S E E SH 6 3 ) 200R
YL* L B * RD* WT* L B *
FEED FEED
K4 20BK/LB*
K4 18BK/LB*
K6 18VT/WT*
K7 200R-
V36 V35
20TN 20LG
RD* RD*
« — K4 18BK/LB*
K4 20BK/LB*
-ENG B - ENG B -
TO
(SH 1 2 8 ) (SH 1 2 8 ) TRANSMISSION
TO TEMPERTURE
VEHICLE SENSOR
SPEED ( S E E SH 1 0 )
V36
20TN
V35
20LG
K44
20TN
SENSOR
( S E E SH 3 0 ) T
T54
RD* RD* YL*
18VT
A i
T33 53
T 7 1 6 42
44
VACUUM VENT CAM 8V MAP 5V TRANS
POSITION SUPPLY SENSOR OUTPUT TEMP

CRANKSHAFT
POSITION
SENSOR
( R I G H T REAR
THROTTLE OF E N G I N E )
POSITION
(SENSOR)
(ON THROTTLE
BODY)
BLACK
BLACK
K24
K 4
20GY
OK* 20BK
B K
* L B *
K4 2 0 B K / L B *
K4 i 8 B K / L B *
K6 18VT/WT* TO
ENGINE
COOLANT
TEMPERATURE
K22 SENSOR
180R ( S E E SH 2 6 )
DB*
K7 200R
K4 18BK/LB*-
K4 2 0 B K / L B * •
K22
180R K24
DB* 20GY
BK*
22 24 4 21
TP(S) BH- SIGNAL CHARGE
REF AIR
SENSE

J948W-9 (5.2L AND 5 9L ENGINES) BR 28
TO < ^ 1 8 > SPLICE

(SEE SH 98)
'FEED
TO
ENGINE
DATA LINK
TO CONNECTOR
CLUSTER B (SEE SH 25)
(SEE SH 88)
FEED
FEED FEED F18 20LG/BK*
TO
n TRANSMISSION
F F F
LE
F18 20LG/BK*- ^4 OVERDRIVE
G21 G24 SOLENOID
22GY 22GY
LB* PK* (SEE SH 10)
10
(SH 123) (SH 123) IDLE AIR

CONTROL MOTOR
F18
(ON 20LG
THROTTLE BK*
G21 G24 BODY)
22GY 22GY EVAP/PURGE (RIGHT SIDE
LB* PK* SOLENOID COWL)
BLACK
-BLACK
HENG C
(SH 129)
HENG C
(SH 129)
G21 G24 K59 K40 K60 K39 F18 K52 K35
20GY 20GY 18VT 18BR 18YL 18GY 20LG 20PK 20GY REXHAUST GAS
LB* PK* BK* WT* BK* RD* BK* BK* YL* EC IRCULATION
SOLENOID
(RIGHT REAR
s. •s. OF INTAKE)
s. s.
43 56 159 40 60 39 9 52 35
TACH EMR EVAP/
I.A.C. B+ PURGE EGR
TO
LEFT HEATED
TO OXYGEN SENSOR
TRANSMISSION (SEE SH 32)
TEMPERATURE
SENSOR
(SEE SH 10)
TO
THROTTLE T0<(K7>SPLICE
POSITION
(SENSOR) (SEE SH 27)
(SEE SH 28)
^JGND FEED
K4
18BK
LB*
TO VEHICLE
RIGHT RWN K4 18BK/LB*—«— SSEPNESEODR
888 J 3 1
" 1 8 B K
' L B
* G7 18WT/0R*—«—
SENSOR (LEFT SIDE
(SEE SH 31) OF TRANSMISSION)
TO TO MAP 67
CRANKSHAFT SENSOR 18MT
POSITION (SEE SH 2 7 ) OR*
SENSOR
(SEE SH 28)
20
(SH 123) ENG C
I (SH 129)
G7 22WT/0R* —(f-G7 20WT/0R*-
G7
22WT
OR*
VSS
47
FEED POWERTRANI CONTROL MODULE
TO (RIGHT SIDE COWL) (CONNECTOR SEE SH 120)
CLUSTER A
(SEE SH 87)
( 5 . 2 L AND 5 . 9 L ENGINES) BR 30
J948W-9
RIGHT
HEATED
OXYGEN
SENSOR
186K
BLACK
Zll 18BK/WT*
A142
14DG
OR*
• A142 14DG/0R*-
K41 K4 1 8 B K / L B * K4 18BK/LB* —
18BK
DG*
K41 18BK/DG* •
Zll 18BK/WT* Zll 18BK/WT*
TO A / C
GND< COMPRESSOR
TO A / C CLUTCH RELAY
LOW P R E S S U R E C13 ( S E E SH 9 8 )
CUT-OUT SWITCH 22DB K41
( S E E SH 9 7 ) OR* 18BK
i l DG*
FEED ^ -fJNG
T- (SH 1 2 7 )
TO C20 CI 3
A I R CONDITIONING 18BR 20DB
AND HEATER SYSTEM OR*
( S E E SH 9 8 )
ENGINE
GROUND
Z12
14BK 27 34 41
TN* A/P
CRES
DSAMP RLY GROUND °2
JGND
TO
SPLICE
(SEE SH 25) FUEL INJECTION IGNITION SYSTEM
LEFT
HEATED
OXYGEN
SENSOR
BLACK
TO V E H I C L E
SPEED CONTROL SYSTEM
( S E E SH 6 3 )
FEED FEED FEED
V32 V33
22YL 22WT
A142 14DG/0R* RD* LG*
-K4 18BK/LB*
80 81
(SH 1 2 4 ) (SH 1 2 4 )
( S E E SH 3 0 )
V32 V33
20YL 20WT
Zll 18BK/WT* RD* LG*
- ENG 8 — ss
(SH 1 2 8 )
2 4
ENG B - ENG B
(SH 1 2 8 ) (SH 1 2 8 )
K141
V31 V32 V33
18TN
20BR 20YL 20WT
WT*
RD* RD * LG*
23 48 49 50
°2 SET IGN RESUME

J948W-9
SW - 82 WIRING DIAGRAMS •
INJECTOR #I INJECTOR 02 INJECTOR #3 INJECTOR # 4 INJECTOR # 5
r A142 16DG/0R* j — A142 16DG/0R* A142 16DG/0R* r A142 16DG/0RX A142 16DG/0R*
b-^-BLACK BLACK BLACK [j-——BLACK BLACK
•Kl16 18WT/DB* ~^-K158 18LG/BK* Kl14 18YL/WT* K l 15 18TN K l 13 18LB/BR*

i
T
K l 16
T
AH2
T T Kl14 A142 A142
T T
K158 A142 K l 15 Kl13 A142
18MT 16DG 18LG 16DG 18YL 16DG
18TN
16DG 18LB 16DG cur
DB* OR* BK* OR* WT* OR* OR* BR* OR* t m
K115 18TN —
Kl14 18YL/WT*
K158 18LG/BK*
ENG
Kl14 A142 K l 13
20YL 16DG 20LB
WT* OR* BR*
•A142 16DG/0R*
-A142 16DG/0R*
•A142 14DG/0R* A142 16DG/0R*
A142 14DG/0R*
K l 16 18WT/DB*
A142 14DG/0R*
A142 A142
14DG 14DG A142 16DG/0R*
OR* OR*
K l 16 FEED FEED K l 14 K l 13
18WT 20YL 20LB
DB* TO WT* BR*
TO
L E F T HEATED RIGHT HEATED
OXYGEN SENSOR OXYGEN SENSOR
( S E E SH 3 5 ) ( S E E SH 3 5 )
16 14 13
INJ INJ # 3 . #6 INJ # 5 , #8
# 1 . #10

BP 33 I (8.0L ENGINE)
INJECTOR # 6 INJECTOR # 1 INJECTOR # 9 INJECTOR # 1 0

INJECTOR U 8
A142 16DG/0R* 16DG/0R * i

-BLACK

J948W-9
(8.0L ENGINE) BR 34
LEFT
HEATED
OXYGEN
SENSOR 2
23 41
02
02

BR 35 (J3.0L ENGINE) J948W-9
TO
CAMSHAFT
P O S I T I O N SENSOR
TO ( S E E SH 3 8 )
TRANSMISSION
TEMPERATURE
SENSOR
( S E E SH 1 0 )
TO
THROTTLE
POSITION
(SENSOR)
( S E E SH 3 8 )
K4
188K
L&*
RIGHT S I D E COWL)
47 V.S.S.
(CONNECTOR S E E SH 1 2 1 )

J948W-9
(8.0L ENGINE) BR 36
CAMSHAFT P O S I T I O N
BLACK
SENSOR
K4 18BK/LB *
(ON TIMING
Kl 18DG/RD*
COVER)
K6 18VT/WT*
(ON THROTTLE
BODY)
•sU nU
T T T
Kl K6 K4
18DG 18VT 18BK
RD* WT* L B *
K4 18BK/LB*- K4 18BK/LB*-
K6 18VT/WT*•
TO K6 K4
V E H I C L E SPEED 20VT 18BK
CONTROL SERVO WT* L B *
( S E E SH 6 3 )
K7 200R K7 200R
K7 180R -
FEED FEED
V36 V35
20TN 20LG
RD* RD* K4 18BK/LB*-
TO
VEHICLE K7
-ENG B|-: SPEED 180R
SENSOR TO
(SH 1 2 8 ) ( S E E SH 3 6 ) TRANSMISSION
TEMPERATURE
ENG B h SENSOR
FEED
( S E E SH 1 0 )
(SH 1 2 8 )
TO
V36 V35 K44 IGNITION Kl K6 FEED
20TN 20LG 18TN MODULE 18DG 20VT T54
K7
RD* RD* YL*
200R ( S E E SH 39) RD* WT* 18VT
i
33 53 44 7 1 6 42
VACUUM VENT CAM 8V MAP 5V TRANS
POSITION SUPPLY SENSOR OUTPUT TEMP
(RIGHT SIDE COWL) POWERTRAIN CONTROL MODULE (CONNECTOR S E E SH 1 2 1 )

WIRING DIAGRAMS SW - 87
CRANKSHAFT
POSITION
SENSOR
( R I G H T S I D E OF
THROTTLE ENGINE NEAR
POSITION MOTOR MOUNT)
(SENSOR)
(ON THROTTLE
BODY)
BLACK
BLACK
K24 K4
K7
20GY 20BK
K4 18BK/LB* 20OR
BK* L B *
K6 18VT/WT*
TO
K22 ENGINE
180R COOLANT
DB* TEMPERATURE
SENSOR
( S E E SH 4 2 )
K7 200R
GND
1
K4 18BK/LB* —
L-K4 20BK/LB*
•K4 18BK/LB* K4 18BK/LB* — -K4 16BK/LB*—. ,

JL ( R I G H T FRONT
-T OF I N T A K E )
CHARGE A I R
TEMPERATURE
SENSOR
K22 K4
I80R K24 20BK K21
20GY K21 16BK/RD*
DB* LB* 16BK
BK* RD* K4 1 6 B K / L B *
GRAY
22 24 4 21
TP(S) B+ SIGNAL CHARGE
REF AIR

J948U-9
(8.0L ENGINE) BR 38
K7 180R DARK GRAY

F18 20LG/BKK* K32 18YL/GY*
K137 20WT/BK*
K138 20BR/OR* K17 20DB/TN*
Z12 18BK/TN*
(RIGHT FENDER SIDE SHIELD)

IGNITION MODULE
10 6
K138 K137 K17 20DB/TN*

20BR 20WT K7 K32 18YL/GY*
OR* BK* 180R
TO
MESSAGE
CENTER
(SEE SH 86)
FEED
GH SPLICE
20PK (SEE SH 37) (SEE SH 41)
BK*
ENGINE
DATA LINK
67 Z12 20BK/TN* CONNECTOR
•021 20PK
(SH 124) (RIGHT D20
SIDE 20LG
COWL)
G14 Z12
18PK 14BK
BK* Z12 TN*
16BK TO
TN* L-Zll 1GBK/WT*—I TRANSMISSION
ENGINE OVERDRIVE
GROUND GND SOLENOID
-|ENG A|- (SEE SH 1 0 )
(LEFT SIDE
(SH 127) OF ENGINE) TO
G14 K138 K137 Z12
D21 D20 FEED
18PK 20BR 20WT 16BK
20PK 20LG K54
BK* OR* BK* TN* SPLICE 200R
(SEE SH 35) BK*
36 45
i 54
_
TRANS 138 37 I I" 121 D25
ATA DATA LINK TRANS
PWR NK RECEIVE CONTROL
LAMP IGN MOD GRNDTRLI
ANSMIT
—K18 20RD/YL* •A142 14DG/0R*
BLACK-
BLACK K19 20BK/GY*
§ - A 1 4 2 14DG/0R*
K32 18YL/GY*
— K17 20DB/TN*
•K43 20DG/GY*
U _ ™ — _ _ _ J
IGNITION COIL IGNITION COIL

4-PACK 6-PACK
(REAR OF CYLINDER HEAD) (REAR OF CYLINDER HEAD)
T
N,
K18 A142
A142 K43 K19
20RD 14DG
1406 20D6 20BK
YL* OR*
OR* 6Y* G Y *
K17 20DB/TN*
K32 18YL/GY*
A142 14DG/0R* TO
TO VEHICLE SPEED
CLUSTER B CONTROL S Y S T E M
( S E E SH 8 8 ) ( S E E SH 6 3 )
^JFEED ^FEED ^ F E E D ^JF^ 13

FEEDp
621 624 V31 V32 V33

226Y 22GY IDLE AIR 22BR 22YL 22WT
LB* PK* C O N T R O L MOTOR RD* RD* LG*
TTmnr|
10 79 80 81
(ON THROTTLE
• H I **
• Ml/ BODY)
(SH 1 2 3 ) (SH 1 2 3 ) (SH 1 2 4 ) (SH 1 2 4 ) [SH 1 2 4 )
V31
621 624 TO 20BR V32 V33
BLACK
226Y 22GY TRANSMISSION RD* 20YL 20WT
0
LB* PK* OVERDRIVE 1 i———i R O * LG*

SOLENOID ^:-|EN6 B|-
( S E E SH 10)
-|ENG C | - : (SH 128) -JENG B | - :
FEED
(SH 1 2 9 ) (SH 1 2 8 )
-JENG C [ - : -ENG B -
(SH 1 2 9 ) (SH 1 2 8 )
K59 K40 K60 K39
621 K18 T60 K43 K19 V31 V32
624 18VT 18BR 18YL 18GY V33
206Y 20RD 20BR 20DG 20BK 20BR 20YL
206Y BK* WT* B K * R D * 20WT
LB* PK* YL* OY* G Y * RD* RD* LG*
JL 1
T
43
TACH
T
56
EMR
i
T17
COIL
40 60 39 | 55
TRANS
T
18
T
19 48
SET
49
IGN
i 50
AIS COIL RESUME
HOD
(RIGHT SIDE COWL) POWERTRAIN CONTROL MODULE (CONNECTOR S E E SH 121)

J948W-9
(8.0L ENGINE) BR 40
TO < R 8 > SPLICE
( S E E SH 9 8 )
TO
TRANSMISSION TO
OVERDRIVE ENGINE
SOLENOID DATA L I N K
TO ( S E E SH 1 0 ) CONNECTOR
TRANSMISSION ( S E E SH 3 9 )
OVERDRIVE T nF E E D
SWITCH F18
20LG
BK*
FEED F18 20LG/BK*— 1
TO
IGNITION
F18 20LG/BK*
MODULE
T6 ( S E E SH 3 9 )
TO 220R
POWER WT*
DISTRIBUTION
CENTER
( S E E SH 4 )
FEED
F18
TO F U E L 20LG
PUMP RELAY BK*
( S E E SH 9 0 )
(SH 1 2 3 )
FEED
K51
22D8
A14 T6 TO YL*
16RD 220R GENERATOR EVAP/PURGE
WT* WT* ( S E E SH 5 ) SOLENOID
(RIGHT S I D E
COWL)
FEED
K51 F18
22DB 20LG
YL* BK*
8
HENG B HENG A h ENG A
(SH 1 2 8 ) (SH 1 2 7 ) (SH 1 2 7 )
A14 T6 K51 F18 K52 2 G EXHAUST GAS
16RD
WT*
200R
WT*
K20
18DG
20DB
YL*
20LG
BK*
20PK
BK*
S, IY L
RECIRCULATION
* SOLENOID
( R I G H T REAR
OF E N G I N E )
3 10 20 51 9 52 35
RELAY SWITCH VOLTAGE ASD IGN EVAP EGR
FEED FEED REG SOL SOL
(RIGHT SIDE COWL) POWERTRAIN CONTROL MODULE (CONNECTOR S E E SH 1 2 1 )

4 (SH 127)
TO ENGINE , GND
STARTER RELAY r — — T41 22BK/WTX Z12 20BK/TN*
( S E E SH 9 )
TO J O I N T fFEED TO
CONNECTOR C >
( S E E SH 7 6 )
TO
SPLICE
TRANSMISSION
T41 ( S E E SH 3 5 )
TO OVERDRIVE
CLUSTER B SWITCH 20BK
WT* GND
( S E E SH 8 8 ) ( S E E SH 1 0 )
FEED FEED
TO
TRANSMISSION
RANGE SWITCH
G3 T18 ( S E E SH 1 2 )
22BK 22LG
PK* OR*
(LEFT SIDE
REAR WHEEL OF E N G I N E )
ANTI-LOCK T41
ONLY V
O 1°T 13BK
20WT U T *
15 ENGINE
PK* *
GROUND
(SH 1 2 3 ) (SH 1 2 3 )
ENGINE COOLANT
TEMPERATURE
TO SENSOR
GRAY
G3 T18 K2 18TN/BK* i
22BK 22LG
PK* OR* SPLICE K4 18BK/LB*
( S E E SH 3 8 ) J
— -i
GND
(FRONT OF
ENGINE)
8 K4
18BK
HENG B h HENG A h LB*
(SH 1 2 8 ) (SH 1 2 7 )
G3 T18 K2
20BK 20LG 18TN
PK* OR* BK*
32 31 29 30 2
MIL TRANS STOP LAMP STARTER ECT
LAMP SW RELAY

J948W-9
(8.0L ENGINE) BR 42
AIR AIR
TO BATTERY P O S I T I V E TERMINAL TO F U E L FEED
"HEATER HEATER f
(o) SHUT DOWN SOLENOID

( S E E SH 4 8 )
y—
F18
20LG
BK*
TO
TRANSMISSION
F18 20LG/BK* OVERDRIVE
SOLENOID
( S E E SH 10)
F18 2 0 L G / B K * —i
FEED
HEATED HEATED
INTAKE INTAKE
AIR ( L E F T FENDER AIR
SYSTEM SIDE SHIELD) SYSTEM
RELAY RELAY
1 2
F18 18LG/BK* *
•F18 20LG/BK* -
TO CLUSTER B TO CLUSTER B
( S E E SH 88) ( S E E SH 8 8 )
A122
6BK FEED
"JFEED
G3 G21
20BK 22GY
TO F U E L
PK* BK*
HEATER
RELAY
(SH 123) ( S E E SH 4 7 )
lslBl:
G3 (SH 123) 62i
HEATED 22GY
INTAKE 20BK
PK* BK*
AIR
SYSTEM
HENG Bh HENG Ch
(SH 128) (SH 129)
(LOCATED ON TO GENERATOR
INTAKE MANIFOLD) ( S E E SH 6 )
FEED
S21 G3 S22 F18 G21

K20 18LG
20YL 20BK 200R 20GY
18DG
BK* PK* BK* BK* LB*
16 20 32 15 9 43
HEATER GENERATOR MIL HEATER IGNITION TACH
m RELAY FIELD Ml R E L A Y FEED
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE 11 (CONNECTOR S E E SH 122)
BR 43 DIESEL ENGINE CONTROL SYSTEM 9

J
4
8W9
-
TO
POWER DISTRIBUTION
CENTER TO
( S E E SH 4 ) MESSAGE
CENTER
FEED ( S E E SH 8 6 )
FEED FEED
G86 G85
20TN 200R
1 (SH 128)
OR* BK*
ENG B h
-F18 18LG/BK* F18 18LG/BK*—w—F18 20LG/BK*
-F18 2 0 L G / B K *
TO
68 71
:zi2;
AUTOMATIC
SPLICE SHUT DOWN (SH 124) (SH 124)
S E E SH 4 8 ) RELAY
( I N POWER
DISTRIBUTION G86 G85
ENGINE CENTER) 18TN 180R
DATA L I N K ( S E E SH 1 4 2 ) OR* BK*
CONNECTOR
(RIGHT S I D E
COWL)
10 1
- ENG C ENG C h
TO F U E L
PUMP RELAY (SH 129) (SH 129)
( S E E SH 9 0 ) -ENG A-
(SH 127)
K51 A142
D20 021 22DB
20LG 14DG
20PK
OR*
ENG A - ^y ENG
(SH 127)
>
A142J
A142 14DB
FEED K51 A142 G86 G85
20DB 16DG 18TN 180R
TO YL* OR* OR* BK*
GENERATOR
( S E E SH 6 )
45 25 51 57 35 36
DATA DATA ASD B+ KNOCK WAIT
LINK LINK SENSOR TO
RECEIVE TRANSMIT START
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE I I (CONNECTOR S E E SH 122)
J948H-9 DIESEL ENGINE CONTROL SYSTEM BR 44

BW - 94 WIRING DIAGRAMS
THROTTLE
DIESEL POSITION
W A T E R - I N - F U E L SENSOR (SENSOR)
I N FUEL F I L T E R ) (TOP OF
INJECTION
#AAA# PUMP)
AUTOMATIC
TRANSMISSION
TO ONLY
TRANSMISSION
TEMPERATURE
SENSOR
(SEE SH 1 0 )
K22
K6 200R
20VT DB*
WT* |
Kl
20DG
RD*
K4 2 0 B K / L B * K4 18BK/LB* •
K4 2 0 B K / L B * •
K4 16BK/LB* K7 200R K7 200R
K4
1SBK
LB*
CHARGE A I R
TEMPERATURE
SENSOR (FRONT OF
(REAR OF ENGINE
INTAKE) ON T I M I N G
COVER)
BLACK
K4 16BK/LB* K4 2 0 B K / L B * K24 K6
20GY 20VT
K21 16BK/RD*! BK* WT*
-BLACK
Kl i . ~ — —-
20DG K4 K22
K24 20GY/BK* 20BK 200R
RD*
LB* DB*
1
1 21 24 4 6 22
WATER I N CHARGE IGN SIG 5V TP(S)
FUEL AIR SENSE REF OUT
(RIGHT SIDE COWL) POWERTRAIN CONTROL MODULE I I (CONNECTOR SEE SH 122)
BR 45 DIESEL ENGINE CONTROL SYSTEM J948W-9

r - B BLACK
LACK
VEHICLE (REAR OF
67 18WT/0R* SPEED
TRANSMISSION)
Bp
SENSOR
-K4 18BK/LB*
K4
-K7 200R 18BK
LB*
K7 G7
200R 18WT
OR*
( L E F T REAR
BLACK OF ENGINE)
K7 200R
- ENG C [ - :
(SH 129)
TO CLUSTER A FEED
(SEE SH 8 7 )
67
20WT
OR*
G7
K7 20WT TO
200R OR*
JBUX MODULE
7
i 47
ONLY) ( S E E SH 107)
8V VEHICLE SPEED
SUPPLY SENSOR
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE I I (CONNECTOR SEE SH 122)
J948W-9 DIESEL ENGINE CONTROL SYSTEM BR 46

TO ENGINE DATA r u n Z12 14BK/TN*

G N D
L I N K CONNECTOR <
( S E E SH 44) AUTOMATIC-
TRANSMISSION
ONLY
FUEL
HEATER F E E D
"IN POWER FUEL T41
DISTRIBUTION SHUT DOWN 112 20BK/TN*—| 20BK
CENTER) WT*
FEED
4
© ( I N POWER
DISTRIBUTION
CENTER)
HE
N T
T] MANUAL
- TRANSMISSION
Zi2
Z12 Z12 © 18BK (SH 1 2 7 ) ONLY
T 4 l
I6BK 16BK TN*

A12 22BK
TN* TN*
200R WT*
JGND
ENG A18
ENG 16DB TO ENGINE
STARTER RELAY
A12;
Z12 A12
<8>-t ( S E E SH 9 )
A18
20BK 14RD FUEL iORD
TN* TN* SHUT BK*
1 Js.
DOWN
RELAY
F U E L HEATER RELAY
(LEFT SIDE SHIELD) u
TO A I R CONDITIONING
AND HEATER SYSTEM
T
F18
"
[T A93
(LEFT
SIDE
20LG 14RD
( S E E SH 9 7 , 9 8 ) SHIELD) T40
BK* BK* 12BR TO
r n A123
GND FEED FEED 10RD
•T40
VT*
C13
TO 10 , SPLICE
C20 ( S E E SH 9 )
22DB HENG Ah
18BR CF18>1
OR*
(SH 127)
SPLICE
( S E E SH 43) -A 123 10RD/VT*-
HENG A h
(SH 127) -A93 14RD/BK*-
HENG A
S
(
-
[H 127)
Z12
p»—614 1 8 P K / B K * - » - G i 4 2 0 P K / BIK*
K* -i 2
0
B K
67 f E E
TN*
C13
20DB
C20
Z12
16BK
Z12 G14
16BK 18PK T
O
i
OR*
18BR TN* TN* BK*
(SH 124) M ES
AGE
C
ENTE
R
S(EE SH 8 6 )
34 27 1 11 12 | 31
R
L
Y P
RESSW
S WPR G
R
ND L R
ANS
G
RND A
MP
R
(
G
IH TS
D
IE COWL
)P
OWE
R
T
RN
AI C O
N
TROLM O
D
UL
ECO
(
IIN
NE
C
T
OR S
E
E SH 122)
•Z12 14BK/TN*- Z12 14BK/TN*
TO A / C
Z12 14BK/TN* COMPRESSOR
-41 2
T 0BKW
/ T
*- Zll 1
6
BK
W * —i
/T CLUTCH
( S E E SH 9 8 )
TO
T
G
ND
czn>2
(LEFT S I D E OF E N G I N E )
SPLICE
( S E E SH 8 2 )
Q ~ F 1 8 20LG/BK* GND
[}—A123 10RD/VT*
T-Z11 16BK/WT* — < f - Z l i 16BK/WTJI
HENG Ah
Q-—Z12 10BK/TN* (SH 127) TO
T R A
N S
MOS
SI
N
R ANGES WT
C
I
H
S(EE SH 12)
GND
T41 18BK/WT*
FUEL M
(OUND T
T
E -41 2
0
BK
W/T
*
SHUT DOWN O
N
SOLENOID N
I
EJ
CT
OIN TO O
J
NIT
P
UM P
) C
ONNE
C
T
ORC
( S E E SH 7 6 )
TO
POWER
DISRTIBUTION TO F
E
E
D
CENTER
( S E E SH 4 ) CV40^
V40
S
PLC
IE 22WT
FEED
S(EE SH 7 6 ) P K * (SH 123)
FEED
Piss
F
UEL A14 V40 V40
SPLICE S
HU
TD O
WN 16RD 20WT 22WT
( S E E SH 4 3 ) S
OLE
NO
DI WT* PK* PK*
G
R
OUN
D
,O(N N
I
E
JCT
O
IN -W/O
ABS
dzr P UMP
)
A123 1
0RV
D/T
*
- ENG B h HENG A
J [_J [_J L|—»— Z13 1 6 B K / T N * —' (SH 1 2 8 ) (SH 1 2 7 )

A
9
3 14RD/BKX—<f
FUEL
HEATER / (NEAR F U E L F I L T E R )
Z12 16BK/TNX A14 T41 V40

16RD 2
0
B
K 20WT
WT* WT* PK*
h^f- BLACK
Z
•12 2
0BT
/N
K *
3 14RD/BK*
A
9
3 30 29
RLY B + STARTER STOP LAMP
-Z12 2
0BT
K/N*
-
MANUAL-
TRANSMISSION
7 POWERTRAIN CONTROL MODULE I I
(RIGHT S I D E COWL) (CONNECTOR S E E SH 122)

ONLY
9
J
4
8W9
- DIESEL ENGINE CONTROL SYSTEM BR 48
TO
TRANSMISSION
OVERDRIVE
SWITCH
10)
( S E E SH
FEED FEED
T6 T18
220R 22LG
WT* OR*
TO
TRANSMISSION
OVERDRIVE
SOLENOID
( S E E SH 10)
(SH 123) (SH 123)
FEED FEED
TO
T6 T18 TRANSMISSION
220R 22LG K54
TEMPERATURE T60
WT* OR* 200R
SENSOR 20BR
( S E E SH 1 0 ) BK*
FEED
ENG A h ^ HENG Ah
(SH 127) (SH 127)
TG T18 T54 T60

K54
200R 20L6 16VT
200R
WT* OR*
20BR BK*
110 37 | 42 | 55 54 |
TRANS TEMP TRANSMISSION
OVERDRIVE SWITCH
SOLENOID
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE II (CONNECTOR S E E SH 122)

TO
CLOCKSPRING/VEHICLE
SPEED CONTROL SWITCH
( S E E SH 6 4 )
FEED FEED FEED

TO J O I N T
CONNECTOR C
( S E E SH 7 7 )
V32
r
22YL
FEED FEED RD*
TO
VEHICLE SPEED
CONTROL SERVO V32 V31 V33
( S E E SH 6 3 ) 22YL 22BR 22WT
RD* RD* LG*
FEED FEED
80
El 40J79 El 81
(SH 124) (SH 124) (SH 124)
V35 V36 V32 V31 V33

20LG 20TN 20YL 20BR 20WT
RD* RD* RD* RD* LG*
-ENG B- - ENGJj- -ENG B|- -ENG B^ -ENG B-
(SH 128) (SH 128) (SH 128) (SH 128) (SH 128)
V35 V36 V32 V31 V33

20LG 20TN 20YL 20BR 20WT
RD* RD* RD* RD* LG*
53 33 49 48 50
VENT VACUUM IGN SET RESUME
(RIGHT S I D E COWL) POWERTRAIN CONTROL MODULE II (CONNECTOR S E E SH 122)
J948W-9 DIESEL ENGINE CONTROL SYSTEM BR 50

8W 100 WIRING DIAGRAMS •
TO
CLUSTER B
( S E E SH 8 8 )
FEED
FEED
TO
CLUSTER A
( S E E SH 8 7 ) G60
G6 22GY
"JFEED 22GY YL*
020 19
22VT 18
YL*
(SH 1 2 3 )
(SH 1 2 3 )
660
(SH 1 2 3 ) G6 226Y
22GY YL*
G20
22VT
YL*
- ENG C -
(SH 1 2 9 )
8
HENG C h
^ HENG C h
(SH 1 2 9 )
(SH 1 2 9 )
G60
GS 16GY
16GY YL*
G20
18VT V6 - V8 -
YL* -BLACK CENTER REAR
OF ENGINE
VIO -
ENGINE ENGINE O I L RIGHT FRONT
COOLANT
TEMPERATURE
PRESSURE
SENDING UNIT r4 OF TIMING
COVER
SENSOR
DIESEL -
LEFT
SIDE
GAS E N G I N E S - FRONT OF ENGINE OF ENGINE
ON THERMOSTAT
HOUSING
G6 16GY-
DIESEL ENGINES - L E F T S I D E OF ENGINE
ENGINE OIL PRESSURE AND

BR 51 ENGINE COOLANT TEMPERATURE SYSTEM J948W-9
WIRING DIAGRAMS I W - 111
HD/LP
FEED
—•» A7 12RD/BK*- •$T0<A7)> SPLICE
48
_._ n TO POWER
EsJ (SEE SH 73)
FEED DISTRIBUTION
r
[SH 124)
A7 10RD/BK*- > CENTER
(SEE SH 4) HIGH NOTE
HORN)
FUSE B (LEFT SIDE

(20 AMP) SHIELD)
(IN POWER
DISTRIBUTION BLACK
CENTER)
(SEE SH 142) HORN
RELAY
F31 18VT
X2 18DG/RDX-
-Zl 18BK
(LOW NOTE
(IN POWER HORN)
DISTRIBUTION CENTER)
(SEE SH 142)
V y y
^ - (LEFT SIDE
F31 X2 g^p^g SHIELD)
20VT 18DG
RD* BLACK
FEED SH 123)
TO
A/C COMPRESSOR
CLUTCH RELAY
(SEE SH 98)
WITH
POWER
GROUP Zl
18BK
GND GND
TO GROUND
JOINT
(SEE SH 114)
^HORN SWITCH
J948W-9 HORN SYSTEM BR 52

I
A-TWISTED (BASE OF STEERING COLUMN)
y\ P
A
RI
r — A — RR43
45 18DG/LBXH
I
r 1-
YELLOW
CLOCK
SPRING
TWISTED
PAIR
P A R T OF
STEERING
R43 R45 COLUMN
20BK 20DG
SQUIB DRIVER
(AIRBAG SIDE
p-26 18BK/0R* » - Z6 18BK/0R*-
IGNITER) AIRBAG
(SH 123) QjJ

36
1-11
AIRBAG SYSTEM CONTROL MODULE (CENTER REAR OF I.P.)
1-1 1-2 1-7 1-13 1-6 1-12 1-5
R49 18LB-
I TWISTED
PAIR
R48 18TN-
R47 18DB/LB*-
D2 F14 F23 R41

18WT 18LG 18DB 18BK
BK* YL* YL* TN*
R46 18BR/LB*-
FEED
TO
CLUSTER A
(SEE SH 87)
BLUE
FEED FUSE #16
(15 AMP)
TO
TO
FEED
» A22 12BK/BR* 5 <A22
AIRBAG/ABS
SPLICE
DATA LINK
( S E E SH 8 6 )
CONNECTOR SPLICE
(RIGHT OF STEERING (SEE SH 7)
COLUMN NEAR MODULE)
BR 53 AIRBAG SYSTEM J498W-9

BLACK
BLACK R47- 1 8 D B / L B *
R46 18BR/LBX R49 18LB
R48 18TN
D2 18WT/BK*
Z6 18BK/0R*
R43 18BK/LB*—•
R45 18DG/LB*
la 1
Dl
F23
18VT/BR*
18DB/YL*
R41 18BK/TN*
— H
F14 18LG/YL*
Z6 18BK/0R*-
GROUND A
^ ( L E F T REAR
O FENDER
SIDE SHIELD)
58 [oj (SH 124)

R49 18LB- - » R49 18LB-
57 pjj (SH 124)
•R48 18TN - » R48 18TN
56 (SH l 2 4 )
-R47 18DB/LB*
GJ
» R47 18DB/LB*
55 (SH l24)
R46 18BR/LB*
El
)> R46 18BR/LBX
i INTERFACE GROMMET
( L E F T DASH PANEL)
RIGHT AIRBAG LEFT AIRBAG

SENSOR SENSOR
BLACK
J498W-9 AIRBAG SYSTEM BR 54

BLACK TO
B108 18WT
B i l l 18LB/BK* SPLICE
Z8 1 6 B K / P K X ( S E E SH 9 5 )
B101 18LG/WT*
PRESSURE L I M I T I N G VALUE
(NEAR MASTER C Y L I N D E R )
Z8 16BK/PK*
O ( L E F T REAR FENDER
SIDE SHIELD)
TO
IGNITION
SWITCH GROUND
( S E E SH 7 ) B
Z8 16BK/PK * •
TO 4X4
OR PTO SWITCH
FUSE # 1 4
( S E E SH 1 1 )
( 2 0 AMP)
TO FEED
CLUSTER B
( S E E SH 8 8 )
FEED G107
TO
20BK
CLUSTER B GY*
52 46 51
( S E E SH 8 8 )
26
A20 FEED
(SH 1 2 4 ) [SH 1 2 4 ) (SH 1 2 4 )
18RD
OB* (SH 1 2 3 )
G19 G107 G107

22LG 20BK 20BK
Bill B101 GY*
RD* B108 GY*
22LB 18LG
18WT
BK* WT*
3 2 11 8 1 4
IGN LAMP RESET DUMP I S O SOL 4WD LAMP
(REAR OF INSTRUMENT P A N E L - REAR WHEEL A N T I - L O C K

RIGHT OF S T E E R I N G COLUMN) CONTROL MODULE (CONNECTOR S E E SH 1 3 3 )
REAR WHEEL ANTI-LOCK BRAKE SYSTEM

BR 55 (GAS ENGINE) J948W-9
--B113 20RD/VT* - -
BLACK
B114 20WT/VT*
i — B l 14 2 0 W T / V T * —
(RIGHT SIDE REAR WHEEL - B 1 13 2 0 R D / V T *
BLACK FRAME FORWARD ANTI-LOCK
OF SHOCK) TWISTED
BRAKE SENSOR
PAIR
( I N REAR
I DIFFERENTIAL)
I
B l 13 B l 14
20RD 20WT
VT* VT*
TWISTED
PAIR
(LEFT SIDE G9 BRAKE WARNING SWITCH

COWL) 18GY (LEFT SIDE
BK* FRAME R A I L )
BLACK
SPLICE
(SEE SH 8 3
28
TWISTED
PAIR
(SH 1 2 3 )
TO J O I N T
G9
CONNECTOR C
20GY
(SEE SH 7,78,77)
BK*
(SH 1 2 4 ) (SH 1 2 4 )
GROUND
8113 TWISTED I
22RD PAIR (LEFT SIDE
VT* B l 14 REAR OF
i INSTRUMENT
i 22WT
VT* PANEL)
ROLLS J (ASSEMBLY i
TEST / PLANT USE !
ONLY) TO J O I N T
REAR WHEEL CONNECTOR B
ANTI-LOCK (SEE SH 7 5 )
SERVICE CONNECTOR
FEED
BLACK BLACK
(NEAR
TWISTED MODULE)
PAIR F32
20PK
B l 13 Z3 DB*
22RD B l 12 16BK
VT* 20BK OR*
1 1
1 1
1 1
S
t f s. s.
13 14 12 10 9 7 5 6
SENSOR SENSOR DIAG GROUND STOP STOP PARK BRAKE
LOW HIGH LAMP SW LAMP SW BRAKE WARNING
SW
(REAR OF INSTRUMENT PANEL- REAR WHEEL A N T I - L O C K
RIGHT OF STEERING COLUMN) CONTROL MODULE (CONNECTOR SEE SH 133)
REAR WHEEL ANTI-LOCK BRAKE SYSTEM

J948W-9
(GAS ENGINE) BR 56
BLACK
TO
B I O S 18WT
B i l l 18LB/BK*
Z8 1 6 B K / P K * SPLICE
B101 18LG/WT* ( S E E SH 9 5 )
( L E F T FENDER VACUUM
SIDE SHIELD) SENSOR
GND
PRESSURE L I M I T I N G VALVE
(NEAR MASTER C Y L I N D E R )
T 0
GND „
7 t
Zl ™f GROUND
18BK > JOINT
( S E E SH 1 1 4 )
A20 TO J O I N T
IBRD CONNECTOR C
DB* ( S E E SH 7 )
FEED
?
^ DASH
G9
22GY
P K
28 *
(SH 123)
( L E F T REAR
_ FENDER
O SIDE
SHIELD)
BRAKE WARNING
SWITCH
(LEFT SIDE
Bill B101
FRAME R A I L ) B108
TO 18LB 18LG TO 4X4
18WT
z±=r FEED
IGNITION BK* WT* OR PTO SWITCH
A20 SWITCH ( S E E SH 1 1 )
18RD ( S E E SH 7 ) TO
DB* CLUSTER B FEED
( S E E SH 8 8 )
FEED
TO
CLUSTER B 52 G107
46 51
( S E E SH 8 8 ) 20BK
GY*
FEED 26
(SH 124) (SH 124) (SH 124)
A20
18RD
DB* G19 G107 (SH 123)
22LG 20BK
Bill B101 GY* G107
RD* B108
22LB 18LG 20BK
18WT
BK* WT* GY*
3 2 11 8 1 4
4 W D L A M P
IGN WARN L P RESET DUMP ISO SOL
REAR WHEEL ANTI-LOCK
C 0 N T R 0 L M 0 D U L E
(REAR OF INSTRUMENT PANEL-RIGHT OF S T E E R I N G COLUMN) (CONNECTOR S E E SH 1 3 3 )
REAR WHEEL ANT I-LOCK BRAKE SYSTEM

BR 57 (DIESEL ENGINE) J948W-9
B1 13 2 0 R D / V T * —
BLACK
Bl14 20WT/VT*
r— B U 4 2GWT/VT* \ -j—{{
(RIGHT S I D E REAR WHEEL B1 13 20RD/VT*
BLACK FRAME FORWARD - _ « T
ANTI-LOCK
OF SHOCK) TWISTED BRAKE SENSOR
i i
( I N REAR
DIFFERENTIAL)
TWISTED
PAIR
(LEFT
SIDE TO
COWL)
BLACK
SPLICE
( S E E SH 8 3 )
TWISTED
PAIR
B l 13 B l 14
20RD 20WT TO J O I N T
VT* VT* CONNECTOR C
i
53 I i 54 ( S E E SH 7 . 7 6 . 7 7 )
1
' (SH 1 214 )
GROUND
TWISTED I
PAIR ( L E F T OF
STEERING
COLUMN
REAR OF
INSTRUMENT
PANEL)
REAR WHEEL
ANTI-LOCK
TO J O I N T
S E R V I C E CONNECTOR
CONNECTOR B
( S E E SH 7 5 )
BLACK BLACK
FEED
TWISTED
PAIR
F32
20PK
Z3 DB*
B l 12 16BK
20BK OR*
13 14 12 10 9 7 5 6
SENSOR SENSOR DIAG GROUND STOP STOP PARK BRAKE
LOW HIGH LAMP SW LAMP SW SW WARN
REAR WHEEL A N T I - L O C K
(REAR OF INSTRUMENT P A N E L - R I G H T OF S T E E R I N G COLUMN) CONTROL MODULE (CONNECTOR S E E SH 1 3 3 )
REAR WHEEL ANT I-LOCK BRAKE SYSTEM

J948W-9
(DIESEL ENGINE) BR 58
DARK GRAY
B120 1 2 B R / W T X B120 12BR/WT *
15 2 0 V T / R D * B18 2 0 V T / L G *
B243 18DG/BK * B248 16DG/WT *
B245 18WT/LG * B249 18WT/TN*
B120 12BR/WT* B60 1 2 L B / B K *
A N T I - L O C K BRAKE SYSTEM
PUMP/VALVE ASSEMBLY
TO <^Z2> S P L I C E
B249 B248 B18 B245 B243 B5 B 6 0 B120 B120
18WT 16DG 20VT 18WT 16DG 20VT 1 2 L B (SEE SH 9 5 ) 12BR 12BR
TN* WT* L G * L G * B K * R D * BK* WT* WT*
HD/LP
DASH
(LEFT FENDER S I D E S H I E L D ) A N T I - L O C K BRAKE SYSTEM CONTROLLER (CONNECTOR S E E SH 1 3 4 )
BR 59 ANT I-LOCK BRAKE SYSTEM J948W-9

TOO P
WE
R
5
0 D
S
T
IR
BI
U T
O
IN
CE
NT
ER
S
(
EES H4)
T
O. F
E
E
D (
SH«
4)
CL
US
T
E
RB 7 G 1
922
LGR/D
* <
(- T
O<A
20
>SP
LC
IE F
EE
D
S
(
EESH8 8)
S(
EES
H6 2
)
A20 019 (
I
NO P
WE
R
1
8
RD 2 0
LG D
ST
IR
BI
U T
O
IN
DB* R
D* C E
NTE
R)
G
9
I 2
0
LG
R/D
* S
(
EES H 14
2
N
I OP
WE
R AB
S
A
BSY
E
L
OW D
ST
IR
B
I
U T
O
IN U
P
MP
L
A
MPR
E
LA
Y C
E
NT
ER R
E
L
AY
S
(
EES H 14
2)
8
7
A 8
7
B
12
0
TO 1
2
B
R WT
F
E
ED B
11
6 *
2
0
GY
S
P
LC
I
E
S(
EES H 1
14
)
B
1
20 1
2
BR
W/T
*
B
1
20 1
2
BR
W * P
/T RE
S
SUR
EL
V
A LU E
M
IT
N
IIG
L
(
EFTSD
IE C
O
W L
)
B
LA
C
K
B2
5
2 18BR
T
/
N *
B1
2
0 12
BR
W/T* 1 RR
B1
92 0
L
B RR IT R
ESE
T
B2
5
4 16DG
0R
/* a SO Lv
B
25
2 a\o B2
5
4 B4
7 G1
9 1
1
8
B
R lil 16
D
G 2
0
R
D G6
2
0
L 2
0
G
Y
1
6
TN* *, OLB
R* LB
* R
D*
2
8 1
9 2
6 1
3 2
4
L
(
EFTF
E
ND
ERS
D
IE S
HE
I
LD) A
N
LO
-
T
ICKB
R
AK
ESY
S
T
EMC
O
NT
RO
L
L
ERC
O
(N
NE
C
T
OR
ANT I-LOCK BRAKE SYSTEM BR 60

9
J
4
8W9
-
R
E
ARW HE
L (IN R
E
ARD F
I
F
ERE
N T
AIL
)
AN
LO
-
TICK T
O
B
R
AKES E
N
S
OR O
JN
IT
B
LA CK C ON
NE
CT
ORB
S(EE S
H 75)
nnrroi Bl 1
420WV
T/
T*
Bl 1
32 0R
D
V/T *
F
E
E
D
T
WS
T
E
ID A
R
I
BAG
A
/B
S
P
AR
I D
A
TAL N
IK
C
O
NNE
C
T
OR
T O <zn> S P
L
CI
E y—BLUE
B l 13
2
0
RD GND * R
(
G
IHTO F
VT* \X Zll 2
0
BK
W/T
* ST
EE
R
NI
GC O
L
UMN
N
E
ARA R
B
IAG
M OD
UL
E
)
S(EE S
H 82)
D12 W
2T
Dll
R
(
G
IH TRF
A
M E 2
20R RD*
B
L
AC
K RAL
I O
F
R
WAR
D
O
FSHO
CK
)
T
WS
T
E
ID
P
AR
I
B l 13
2
0
RD
VT* Dll
R
G
IH
T L
EF
T 012
W
2T
F
R
ONT F
R
ONT 2
2
R
0. RD*
WHE
L WH
EL
S
E
NS
O
R S
E
NS
O
R
L
(
E F
T
S
DIE nmnrs nmnr\ S(H 124) S(H 124)
—« S
H E
L
ID)
N
T
WS
T
E
ID T
WS
T
E
ID D12 Dll
P
AR
I P
AR
I 2
00R W
2T
1 I i
1 j ! 1
I I i
i
B113 B 1*14 i
B7 W B6 B
9 B 8
2
0
R D W0
2T W
0
2 0
2 T
T DB* 2
0
RD20
RD
V•T* ViT* i ! GY*
i i• 1 i i
i i i 1 i
! i i
1 s
Ti T t T t T s,
14 I 2
15 3 16, ,10 11,
S
E
NSORS
E
NS
O R
H
GIH O
L
W W HEL
S
E
N S
O
R D
A
T
ALN
IK
L
(
E FTF
E
ND E
RSD
IE S
H A
EI
LN
D
LT
I
O
-
)CKBRAKE
SYSTEM CONTROLLER (CONNECTOR S E E SH 1 3 4 )
BR 61 ANTI-LOCK BRAKE SYSTEM J948W-9

TO
/ \ VACUUM ( L E F T FENDER
SENSOR SIDE SHIELD)
D I E S E L ONLY
SPLICE
( S E E SH 7 )
TFEED
TO
A20 18RD/DB* f GROUND
Zl 18BK }
JOINT
( S E E SH 1 1 4 )
TO
G9 JOINT
FUSE # 1 4
20GY SPLICE CONNECTOR C
( 2 0 AMP)
BK* ( S E E SH 9 5 ) ( S E E SH 7 )
FEED
A20
18RD G9
OB* 22GY
BK* BRAKE J 1
WARNING
SWITCH \
TO
(LEFT \
1f
41
CLUSTER B
28 FRAME
( S E E SH 8 8 )
0 RAIL) Y
(SH 1 2 4 ) G9
FEED (SH 123 ) 16GY
•=• Z7 BK*
TO ABS " 18BK
PUMP RELAY 6107 GROUND R D *
( S E E SH 6 0 ) 22BK B
GY*
( L E F T REAR
FENDER S I D E
SHIELD)
L-G9 20GY/BK* G9 16GY/BK *
(SH 1 2 3 )
HD/LP
A20 DASH TO
18RD
DB*
<V40)>
SPLICE
( S E E SH 7 6 )
FEED
G107 V40
20BK FEED 20WT
A20 A20 GY* PK*
18RD 18RD
TO 4X4 OR
DB* DB*
PTO SWITCH
1 JL ( S E E SH 1 1 )
T T 8 9 20 25
1 »2 1 7
1
4WD STOP L P GRND WARNING
IGNITION LAMP SW SW
(LEFT FENDER S I D E S H I E L D ) ANTI-LOCK BRAKE SYSTEM CONTROLLER (CONNECTOR S E E SH 1 3 4 )
J948W-9
ANTI-LOCK BRAKE SYSTEM BR 62
(RIGHT S I D E COWL)
-ENG B -
(SH 128)
I G N I T I O N 49 V32 20YL/RD* « V32 2 0 Y L / R D *
SET 48 V31 20BR/RD*

POWERTRAIN
CONTROL 2 - ENG B (SH 1 2 8 ) 80
MODULE RESUME 50 V33 20WT/LG*
(SH 1 2 4 )
VACUUM 3 3 V36 20TN/RD*
ENG B
(SH 1 2 8 ) — V32 22YL/RD*

VENT 5 3 V35 20LG/RD*
— V31 20BR/RD*
(CONNECTOR
S E E SH 1 1 9 , 1 2 0 . 1 2 1 , 1 2 2 )
-JENG B -
— V33 20WT/LG*
(SH 128)
V30 20DB/RD *
V30 20DB/RD* ))-
31
Zl 20BK
(SH 123)
TO
DIRECT
CONNECTION BLACK
SPLICE TO SERVO
( S E E SH 1 1 4 )
V E H I C L E SPEED CONTROL SERVO

( L E F T FENDER S I D E S H I E L D )
BR 63 VEHICLE SPEED CONTROL SYSTEM J948W-9

] • WIRING DIAGRAMS 8W - 113
VEHICLE SPEED
FEED CONTROL SWITCH
L50 TO CENTER
18WT HIGH MOUNTED
TN* STOP LAMP SYSTEM
10 (SEE SH 1 1 5 )
TO
TURN SIGNAL
AND HAZARD
FLASHER SWITCH
- BODY -
(SH 1 3 6 )
{
L50 INST/
(SEE SH 8 5 ) 18WT PNL
TN*
FEED
L50;
L50 18WT/TN*
TO J O I N T "V
CONNECTOR C
(SEE SH 7 7 ) L50 NATURAL—]
T T
18WT V32 V33 V31
I A W • / I 22YL 22WT 22BR
TN*
FEED FEED RD* LG* RD*
V32 2 2 Y L / R D *
V32 2 2 Y L / R D *
V31
79fnl(SH 124)
20BR Kf V31 22BR/RD*
RD*
8 1 | O j | ( S H 124)
V33
20WT - « V33 2 2 W T / L G *
LG*
.FEED CLOCK SPRING
TO J O I N T
CONNECTOR C ) V40 2 0 W T / P K * 1
—V34 22WT/RD*
(SEE SH FEED
76,77) L 5 V32 2 0 Y L / R D *
— Z l l 20BK/WT* •
— — V30 2 0 D B / R D * • GND
F32 1 8 P K / D B *
FEED
TO
V34
TO J O I N T
BLACK -BLACK 22WT
CONNECTOR B ;zn; RD*
(SEE SH 7 5 ) 7 FUSE # 1 0
( 2 AMP)
(DIRECT N SPLICE
• • • • • • CONNECTION TO v BLACK (SEE SH 8 2 )
SWITCH)
5 io:
V
N
A21
12DB
FEED
TO
IGNITION
SWITCH
(SEE SH 7 )
STOP LAMP AND VEHICLE SPEED STOP LAMP SWITCH

CONTROL SWITCH WITH WITHOUT VEHICLE SPEED CONTROL
VEHICLE SPEED CONTROL
J948W-9
VEHICLE SPEED CONTROL SYSTEM BR 64
8W - 114 WIRING DIAGRAMS • I
£
TO J O I N T BLACK
CONNECTOR A
( S E E SH 7 4 )
ID
L7 18BK/YL*
Z4 18BK an
L E F T OUTBOARD
CLEARANCE LAMP
£
BLACK
L7 18BK/YL *
Z4 18BK
L E F T OUTBOARD
I D E N T I F I C A T I O N LAMP
£
BLACK
L7 18BK/YL* an^rx
Z4 18BK
cm ID
CENTER
IDENTIFICATION
LAMP
£
BLACK
L7 18BK/YL*
TO
OVERHEAD
CONSOLE
Z4 18BK an ID
RIGHT OUTBOARD
( S E E SH 8 1 ) I D E N T I F I C A T I O N LAMP
£
BLACK
L7 18BK/YL*
Z4 18BK an ID
RIGHT OUTBOARD
CLEARANCE LAMP
GROUND
(FORWARD CENTER OF ROOF P A N E L )
BR 65 CLEARANCE AND IDENTIFICATION LAMPS J948W-9

! • WIRING DIAGRAMS 8W - 11S
L E F T FORWARD
FENDER LAMP
RIGHT FORWARD
FENDER LAMP
L E F T REAR
FENDER LAMP
an
an
RIGHT REAR
FENDER LAMP
an
an
I—L7 18BK/YL*
LEFT
TAILGATE
LAMP
Z13 18BK
1
—L7 18BK/YL*
RIGHT
ILGATE
LAMP
Z13 I8BK
L7 18BK/YL*
-J T0<L7>T| SPLICE Z13 18BK

"3)'
<f
ft
ICENSE
LAMP
( S E E SH 1 1 1 )
FENDER AND TAILGATE LAMPS

J948W-9
(DUAL REAR WHEELS) BR 66
8W - 116 WIRING DIAGRAMS • I
TO
HEADLAMP
TO DIMMER SWITCH
CLUSTER A ( S E E SH 7 3 )
( S E E SH 8 7 }
L4 16VT/WT*
L3 16RD/0R* L3 16RD/0R*
LEFT
HEADLAMP
L4 16VT/WT*
FEED, TO J O I N T
L7 18BK/YL* ( CONNECTOR A
( S E E SH 7 4 )
Zl 128 A T 0
^ K J SPLICE
40
S E E S H 7 2 )
Q GROUND C ( TO
(SH 124)
_ J _ ( L E F T FENDER GROUND
SIDE SHIELD) JOINT
( S E E SH 1 1 4 )
GND
L E F T PARK Z l 18BK —
AND TURN L7 2 0 B K / Y L *
SIGNAL LAMP
L7 2 0 B K / Y L *
FE E D
. L E F T FENDER TRAILER
SIDE SHIELD) TOW RELAY
( S E E SH 1 1 4 )
TO TURN TO
S I G N A L SWITCH $ FEED
( S E E SH 8 5 ) L7 1 8 B K / Y L *
SPLICE
( S E E SH 1 1 2 )
FRONT END LIGHTING
BR 67 WITHOUT DAYTIME RUNNING LAMPS J948W-9
Zl 20BK
BLUE RIGHT
HEADLAMP
L3 16RD/0RX L3 16RD/0RX
TO GROUND
JOINT
( S E E SH 1 1 4 )
L4 16VT/WTX
4X4 OR PTO ^ GND

Zl 18BK
SWITCH
( S E E SH 1 1 )
BLACK
Q GROUND D
= ( R I G H T FRONT
~~ FENDER S I D E S H I E L D )
Zl 18BK RIGHT PARK
L7 2 0 B K / Y L X L7 1 8 B K / Y L X - AND TURN
-L60 18LG/TNX- SIGNAL LAMP
L60;
HD/LP
DASH
L60 HD/LP
20TN DASH
BKX
70
(SH 124) FEED > TO TURN

L60 18TN/BK X — S I G N A L SWITCH
( S E E SH 8 5 )
FRONT END LIGHTING

J948W-9
WITHOUT DAYTIME RUNNING LAMPS BR 68
SW - 118 WIRING DIAGRAMS
TO
HEADLAMP
TO
DIMMER SWITCH
CLUSTER A
( S E E SH 7 3 )
( S E E SH 8 7 )
FEED FEED FEED TO

DAYTIME
RUNNING
LAMPS
L4
MODULE
16VT
(SEE SH 7 1 )
WT*
FEED
TO
DAYTIME F E E D
RUNNING 5 G34 20RD/GYX

LAMPS
MODULE 5 FEED
L3 16RD/0R*
( S E E SH 7 1 )
L4 16VT/WT*
L3 16RD/0R*
BLUE
LEFT
HEADLAMP
L4 16VT/WT*
FEED „ TO J O I N T
L7 18BK/YL* — 4 CONNECTOR A
GND
Zl 12BK
J TO < Z l > 1 | S P L I C E 4 0 (SEE SH 7 4 )
(SEE SH 7 2 )
TO
GROUND
= " ( L E F T FENDER
JOINT
SIDE SHIELD)
( S E E SH 1 1 4 )
BLACK GND
LEFT PARK Zl 18BK Zl 1 8 B K —

AND TURN L7 1 8 B K / Y L * L7 2 0 B K / Y L *
SIGNAL LAMP L61 18LG/TN* — i
L7 2 0 B K / Y L * .
FEED
:L61 1 TO
HD/LP L61 TRAILER
DASH 20LG BLACK TOW RELAY
YL* ( L E F T FENDER ( S E E SH 1 1 4 )
69 SIDE SHIELD)
TO TURN FEED TO
(SH 124)
SIGNAL SWITCH £ L61 18LG/YL*- FEED
S E E SH 8 5 ) L7 1 8 B K / Y L *
SPLICE
( S E E SH 1 1 2 )
FRONT END LIGHTING
BR 69 WITH DAYTIME RUNNING LAMPS J948W-9
RIGHT
HEADLAMP
L3 16RD/0R*
TO GROUND
JOINT
( S E E SH 1 1 4 )
GND
L4 16VT/WT*
G N D
4X4 OR PTO ^
Zl 18BK
SWITCH
( S E E SH 1 1 )
O GROUND D
~br ( R I G H T FRONT FENDER
SIDE SHIELD)
Zl 18BK RIGHT PARK

L7 2 0 B K / Y L * L7 18BK/YL* AND TURN
SIGNAL LAMP
BLACK
HD/LP
DASH
L60 HD/LP
20TN DASH
BK*
70
feu io \ I
4 FEED s TO TURN
[bH U 4 ;I — L 6 0 i 8 T N / B K 5 l c — E E £ J S I G N A L SWITCH
( S E E SH 8 5 )
FRONT END LIGHTING

J948W-9
WITH DAYTIME RUNNING LAMPS BR 70
TO TO
CLUSTER A
DAYTIME RUNNING
( S E E SH 8 7 )
<y> LAMPS MODULE
SPLICE
FEED
( S E E SH 6 9 )
FEED G34
18RD BLACK
TO GY*
TO 634
18RD (LOCATED ON
o
27
GY* L E F T FENDER
SIDE SHIELD)
SPLICE SPLICE
( S E E SH 8 ) (SH 123)
( S E E SH 6 9 )
FEED
DAYTIME RUNNING
LAMPS JUMPER
G34
20RD
GY*
BLACK
Gil
20WT
BK*
32
FEED (SH 123)
Gil
22WT
TO
BK*
SPLICE
<«> ( S E E SH 6 9 )
SPLICE
FEEO TO J O I N T
CONNECTOR C
( S E E SH 7 7 )
A3
12R0 47
LG*
TO
(SH 124)
FEED POWER
» A3 1 2 R D / L G * A3 1 2 R D / L G * -C DISTRIBUTION
CENTER
( S E E SH 4 )
BR 71 DAYTIME RUNNING LAMPS MODULE J948W-9

TO
Z13;
SPLICE
(SEE SH 111)
GND GND
•WITH
TRAILER
TOW
Z13 Z13
16BK 12BK
TO
WINDSHIELD
WASHER
PUMP MOTOR
(SEE SH 83)
GND f TO GROUND
JOINT
(SEE SH 114)
BRAKE
GROUND O
(RWAL)
SPLICE
(SEE SH 107.109)
TO LEFT
HEADLAMP
(SEE SH 67.69)
J948W-9 UNDERHOOD LAMP BR 72

HEADLAMP
DIMMER SWITCH
HEADLAMP SWITCH
TO
(CONNECTOR
S E E SH 1 1 6 )
SPLICE
( S E E SH 7 5 )
FEED
•A3 12RD/LG*
TO J O I N T GND
CONNECTOR C — G16 22BK/LB*—<(
( S E E SH 7 6 )
F33 20PK/RD*
FUSE #18
( 1 5 AMP)
TO CARGO
(SH 136) AND DOME
LAMP SYSTEM
( S E E SH 7 9 )
SPLICE 48
( S E E SH 8 3 )
W/O INFINITY-x
RADIO \ (SH 124)
FEED
> > — — A7 12RD/BK* •5 TO <A77T| SPLICE TO POWER
SEAT SYSTEM
(SEE SH 52) ( S E E SH 1 0 5 )
J-
A7 12RD/BK*
FEED
A7 12RD/BK* F37 14RD/LB* » F37 14RD/LB*
1
C I R C U I T BREAKER 2 H BODY h
(CB2) ( 3 0 AMP)
(IN FUSEBLOCK) (SH 136)
( S E E SH 1 1 7 . 1 1 8 )
BR 73 HEADLAMP SWITCH J948W-9

TO < L 7 > SPLICE
( S E E SH 6 7 . 6 9 )
FEED TO
TO MAP LAMP
RADIO OR OVERHEAD
( S E E SH 9 1 . 9 3 ) CONSOLE
( S E E SH 8 0 . 8 1 )
FEED (LEFT K I C K PANEL)
L7
18BK
^
J
GND
M2 2 2 Y L
YL*
L7 18BK/YL*
FEED
40 L7
20BK
YL* TO
(SH 124)
L7
SPLICE
18BK
( S E E SH 6 5 . 8 1 )
YL*
L7 20BK/YL* 10
J O I N T CONNECTOR A
(CONNECTOR S E E SH 130) 8
( L E F T S I D E OF BODY -
INSTRUMENT PANEL)
(SH 136)
GND TO
M2 20YL M2 2 2 Y L » — M2 20YL f DOME LAMP
^ ( S E E SH 7 9 )
M2 M2 M2
22YL 22YL 22YL
GND , TO TIME
- J DELAY RELAY
( S E E SH 1 0 8 . 1 1 0 )
LT RT
DOOR 1 DOOR 1
(SH 137) (SH 139)
M2 M2
18YL 18YL
TO
GND
L E F T DOOR r
JAMB SWITCH > GND
( S E E SH 8 0 . 8 2 )
TO
RIGHT DOOR
JAMB SWITCH
( S E E SH 8 0 . 8 2 )
J948W-9
JOINT CONNECTOR A WIRING BR 74
47
HI TO
INST/ (SH 124)
FEED . POWER
PNL A3 1 2 R D / L G * ^_ A3 1 2 R D / L G * — — f DISTRIBUTION
CENTER
A3 (SEE SH 4 )
FEED . TO
A3 1 2 R D / L G * — — 4 HEADLAMP SWITCH
(SEE SH 7 3
TO
FEED
A3 - — - A3 1 2 R D / L G * Â3>H
12RD
WITH DRL-
SPLICE
(SEE SH 7 1 )
TO
TO REAR WHEEL
BRAKE SWITCH A N T I - L O C K MODULE
FUSE # 2 0 20 (SEE SH 6 4 ) (SEE SH 5 6 . 5 8 )
( 1 5 AMP)
FEED FEED
F32 F32 F32

18PK 18PK 20PK
DB* DB* DB*
J O I N T CONNECTOR B
( L E F T S I D E OF INSTRUMENT PANEL) (CONNECTOR SEE SH 131)
1 2 6 7 8
Ml Ml Ml Ml Ml
20PK 20PK 18PK 20PK 18PK
FEED FEED FEED

j
TO TO TO
RADIO RADIO CHOKE
(SEE SH 9 1 , 9 3 ) (SEE SH 9 4 )
SPLICE
( S E E SH 1 0 7 , 1 0 9 )
FEED FEED
TO TO
GLOVE BOX AIRBAG/ABS
LAMP AND SWITCH DATA L I N K
(SEE SH 7 8 ) CONNECTOR
(SEE SH 6 1 )
BR 75 JOINT CONNECTOR B WIRING

TO
POWERTRAIN FEED TO ABS
CONTROL MODULE CONTROLLER
CAVITY 2 9 (SEE SH 6 2 )
(SEE SH 1 8 , 2 6 , 4 2 , 4 8 )
V40 FEED
20WT
TO PK* HD/LP
L E F T DOOR V40 DASH
JAMB SWITCH 20WT
[ S E E SH 8 0 . 8 2 ) r K*
ENG A -
GND (SH 1 2 7 ) -V40 20WT/PK*
W/O ABS •V40 20WT/PK*

G16 V40
20BK TO 22WT TO
TO LB* K E Y - I N SWITCH PK* TO REAR WHEEL
HEADLAMP ( S E E SH 1 0 8 . 1 1 0 ) BRAKE ANTI-LOCK
SWITCH SWITCH MODULE
( S E E SH 7 3 ) GND ( S E E SH 6 4 ) ( S E E SH 5 6 , 5 8 )
LT
DOOR 1
TGND FEED FEED
(SH 1 3 7 ) (SH 1 2 3 )
G16 G16 G16 V40 V40 V40

22BK 22BK 22BK 22WT 20WT 22WT
LB* LB* LB* PK* PK* PK*
21 20 22 31 32 33
J O I N T CONNECTOR C
(LEFT S I D E OF INSTRUMENT PANEL) (CONNECTOR S E E SH 1 3 2 )
12 15 13 14
BUX ONLY
F12 F12
22DB 22DB
WT* WT* F12
20DB
WT*
3 D €hlS (LEFT KICK

dJO QQ PANEL)
9 *) 1 0 * > i5
r 123 ^-BLACK
FEED
TO TO
CHIME TRANSMISSION
MODULE OVERDRIVE
FUSE # 1 1 ( S E E SH 1 0 7 ) SWITCH
( 1 0 AMP) (BUX ONLY) ( S E E SH 1 0 )
EE0
r
FEED
TO
TO BUZZER
I G N I T I O N SWITCH ( S E E SH 1 0 9 )
( S E E SH 7 ) OVERHEAD CONSOLE
( S E E SH 8 1 )
J948W-9
JOINT CONNECTOR C WIRING BR 76
TO TO
OVERHEAD CONSOLE FEED POWERTRAIN
( S E E SH 8 1 ) TO , ? CONTROL MODULE
HEADLAMP C A V I T Y 49
FEED SWITCH ( S E E SH 2 2 . 3 2 . 4 0 . 5 0 . 6 3 )
( S E E SH 7 3 ) V32
T
20YL
FEED RD*
(LEFT KICK
PANEL) El
20TN -ENG B
OR*
BLACK (SH 128)
TO TO
CLUSTER 6 BRAKE
( S E E SH 8 8 ) V32 SWITCH
20YL ( S E E SH 6 4 )
TO FUSE # 1 3
( 5 AMP) RD*
FEED HEATER SWITCH TO FEED
TO OR CLOCKSPRING
RADIO HVAC SWITCH 80
( S E E SH 6 4 )
( S E E SH 9 1 , 9 3 ) ( S E E SH 9 6 . 9 7 )
FEEO
FEED E2 FEED E2 (SH 124)
220R 220R
M v;32 v :\1
E2 E2 E2 V :
YL 22 YL 20 YL
2 2
22 OR 22 OR 22 OR
RD * RD* R D*
* N, S s. s
N. y s, s
Si S N.
S,
1 2 3 4 5 18 19 17
(LEFT S I D E OF INSTRUMENT PANEL) JOINT CONNECTOR C (CONNECTOR S E E SH 132)
9 11 10 8
N yS N
51 ^ 1> N
Gil Gil Gil Gil

22WT 22WT 22WT 20WT
BK* BK* BK* BK*
32
FEED FEED
(SH 123)
TO TO
REAR WHEEL Gil CLUSTER A %
A N T I - L O C K MODULE 20WT
9
( S E E SH 8 7 )
( S E E SH 5 6 , 5 8 ) BK*
(LOCATED ON
FEED BRAKE B R A C K E T )
m
TO
DAYTIME RUNNING
T
LAMPS MODULE
( S E E SH 7 1 ) PARK BRAKE
SWITCH
BR 77 JOINT CONNECTOR C WIRING J948W-9

FEED TO JOINT
GLOVE
BOX LAMP
C3 C BLACK
Ml 20PK — — C CONNECTOR B
^ (SEE SH 75)
AND
SWITCH r~o| [ [ ~\ Z3 16BK/0RX
TO
TRANSMISSION
OVERDRIVE
SWITCH
(SEE SH 10)
GND
BLACK Z3 20BK/0R*
TO
CIGAR GND, HEATER SWITCH
LIGHTER Z3 18BK/0RX Z3 12BK/0R* ——( OR
CGE£ F30 18RD/0R*

HVAC SWITCH
(SEE SH 96,97)
Z3 12BK/0R*-
Z3
18BK GND
OR*
TO
SPLICE
(SEE SH 83)
POWER Z3 18BK/0R*
OUTLET Z l l 18BK/WTX
(RIGHT SIDE
OF INSTRUMENT (REAR OF
PANEL) 1 _ INSTRUMENT GND
)^F30 IBRD/OR* —
© PANEL
, ON CENTER TO
•=r SUPPORT)
F30 GROUND G
18RD
OR* SPLICE
(SEE SH 82)
BLACK F30 18RD/0R*
F30 18RD/0R*
FUSE MS
(20 AMP)
Z3 18BK/0R*
L . .— _ — — — J
FEED TO
A31 12BK/WTX i IGNITION SWITCH
(SEE SH 7)
J948W-9
CIGAR LIGHTER AND GLOVE BOX LAMP BR 78
M3 18PK/DB*
BLACK
•M3 18PK/DB* Ml 18PK
y— •—. • • -»
k ) CARGO LAMP 1
M3 18PK/DB*
Ml 18PK
BLACK
\C3
M3 18PK/DB* Ml 18PK
. J
M3
18PK CARGO LAMP 2
DB*
Ml 18PK
Ml 18PK
Iff
(CENTER
REAR OF
H BODY h
ROOF P A N E L )
TO
(SH 136)
FEED
Ml 18PK - — » Ml 18PK
SPLICE
( S E E SH 1 0 7 , 1 0 9 )
0
^ - | BODY - Ml 18PK
I (SH 136) DOME LAMP

GRAY
M3
22PK
M2 20YL
DB*
M2
J^GND 20YL
TO
HEADLAMP SWITCH
• BODY -
( S E E SH 7 3 )
(SH 136)
M2
22YL
JGND
TO J O I N T
CONNECTOR A
( S E E SH 7 4 )
CARGO AND DOME LAMPS

BR 79 J948W-9
T
O
T
O OJ
NI T C
ON N E
C
T
ORA T
O
R C S(EE SH 74)
O
J
NIT C ON N
S(EE SH 76)
E
C
T
O
G
N
D GNo'J' G
N
D 1"ND
G
o
SPL
CI
E
S(EE SH 107
1
,0
9)
M2
G16 22YL
22BK
LB* M2
2
YL
LT
D
O
OR 1
SH 137) G ; 6
2
0
BK
LB*
S
PLC
IE
S(EE SH 65)
G
N
D
R
O
OF
GR
O
UN
D
C
(
E
N T
E
R OF
R
OOFPANEL
)
J948W-9
OVERHEAD MAP LAMP BR 80
FEED
TO F12 22DB/WT* — , L7 20BK/YL*
JOINT CONNECTOR C FEED
( S E E SH 7 6 , 7 7 ) Ml 20PK
— E 2 220R —
M2 2 2 Y L
10
BLACK- Zll 20BK/WTX
632 22BK/LB*
G31 22VT/LG X
Zll 20BK/WTX
G31 22VT/LGX
632 22BK/LBX
BLACK
6
E2 220R
F12 22DB/WTX
L7 18BK/YL X
W/0
L7 20BK/YLX
CLEARANCE
LAMPS
READING
LAMPS
G N D
AUTOMATIC 7
DAY/NIGHT MIRROR C
( S E E SH 1 0 6 )
ROOF
GROUND
(CENTER OF
ROOF P A N E L )
OVERHEAD CONSOLE J948W-9

TO < M i > S P L I C E FEED
J O I N T CONNECTOR A TO
( S E E SH 1 0 7 . 1 0 9 ) AIRBAG/ABS
( S E E SH 7 4 )
DATA L I N K
L7 20BK/YLX — i
CONNECTOR
Ml 20PK ( S E E SH 6 1 )
TO
CLUSTER B
( S E E SH 8 8 )
J O I N T CONNECTOR C
RIGHT DOOR ( S E E SH 7 6 ) SPLICE
JAMB SWITCH ( S E E SH 3 5 . 4 8 , 9 8 )
J948W-9
OVERHEAD CONSOLE BR 82
(BEHIND S T E E R I N G COLUMN
COVER RIGHT OF COLUMN)
INTERMITTENT WIPER CONTROL MODULE
DELAY
GROUND FEED MOTOR INPUT DELAY INT PARK
5 4 3 8 1 7 6
x
T
13
18BK
OR*
V5
18DG
YL*
i
T
I
T
V6
18DG
BK*
TV8
18VT
T
T
V9
18WT
T V17
18DG
V7
18DG
WT*
T
VIO BK*
18BR
66
V17 18DG
(SH 1 2 4 ) V9 18WT/BK*
V8 18VT
VIO
18BR
VIO 18BR —
V6 18DG/BK*
V5 18DG/YL*
TO „ FEED
CLUSTER B (
( S E E SH 8 8 )
TO
SPLICE
J
( S E E SH 7 2 )
VIO (SH 1 2 3 )
TO 18BR GND
CHIME
MODULE
( S E E SH 1 0 7 ) Zl 20BK
IN WASHER
LOW WASHER RESERVOIR)
FLUID LEVEL
Wll WINDSHIELD WASHER SENSOR
P N L
PUMP MOTOR GND. X \
( I N WASHER R E S E R V O I R )
TO < V > :S P L I C E
GND TO
F
( S E E SH 1 1 4 )
Z3 20BK/0R* —A HEADLAMP SWITCH
BUX ( S E E SH 7 3 )
TO
ONLY
Z3 12BK/0R* • 73
U 1l o6 B
BKK // 0uRR**
G N D R E A R W
f } A N T I - L O C K MODULE H E E L
G N D
^ TO <Z3TT| SPLICE ( S E E SH 5 6 , 5 8 )
Z3 12BK/0R*
( S E E SH 7 8 )
GND,
Z3 20BK/0R* K TO CLUSTER A * - ± z , 1
>
( S E E SH 8 7 ) ( L E F T S I D E REAR
V ;
TO X TO OF INSTRUMENT
BUZZER > I G N I T I O N SWITCH LAMP PANEL)
( S E E SH 1 0 9 ) ( S E E SH 1 0 8 , 1 1 0 )
BR 83 INTERMITTENT WIPER SYSTEM J948W-9

INTERMITTENT WIPER SWITCH

FOR CONNECTOR S E E SH 1 3 5 )
/ • HI
O F F # D E L A Y # L O
9 DELA
O F F 9#
:
DDEELLAA Y # -
.HI
LO
OFF w D E L A Y # LO
L
HI
WASHER 1
OFF*
,~»~
SWITCH/ ^ r K
#ON
MULT I - MULT I - MULT I - MULT I - MULT I - JMULTI- MULT I -

FUNIC FUNC FUNC FUNC FUNC 1 FUNC FUNC
V7 MULT I - V9 V6
V17 VIO
18DG FUNC 18WT 16DB
18DG I8BR
WT* BK* BK*
V3
18BR
WT*
V17 18DG
V9 18WT/BK*
V8 18VT
VIO 18BR
V6 18DB/BK* V6 16DB/BK*-
V5 18DG/YL * V6 16DG/BK*- VG 16DG/BK*
(SH 1 2 4 )
V6 V5 V3 V4 LI Lj
18DB 18DG 18BR 18RD I G N I T I O N SWITCH
2 3
BK * Y L * WT* YL* ( S E E SH 7 )
r 1
V5 V6
18DG 18DB
YL* BK*
; _. i
PARK \ — —--{ M1 1
SWITCH \ GND
WIPERS WIPERS -> c Zl 18BK i TO <nJT| SPLICE
UP DOWN ( S E E SH 7 2 )
INTERMITTENT WIPER MOTOR
J948W-9
INTERMITTENT WIPER SYSTEM BR 84
TO L E F T PARK AND TO
TO
TURN SIGNAL LAMP FEED CHARGING
I G N I T I O N SWITCH C
( S E E SH 6 7 . 6 9 ) SYSTEM
( S E E SH 7 ) >
( S E E SH 5 . 6 )
A31
FEED 12BK FEED
TO RIGHT
WT* A15
PARK AND
TURN SIGNAL 16PK
LAMP
( S E E SH
68.70) L9
FUSE C
18BK
HD/LP ( 1 5 AMP)
L61 VT*
DASH TFEED FUSE # 6 ( I N POWER
:L61
18LG
TN*
L60
I8LG
TN*
HD/LP
DASH
:L60
( 1 5 AMP)
V T
L5
L9
44
(SH 1 2 4 )
DISTRIBUTION
CENTER)
( S E E SH 1 4 2 )
20BK
L60 18BK
L61
20TN TURN SIGNAL VT*
20LG 4 HAZARD
YL* BK* FLASHER
FLASHER
( I N FUSE
BLOCK)
d ( I N FUSE
70
( S E E SH 1 1 7 ) BLOCK)
L6 L19
69 20RD 18PK
(SH 1 2 4 ) ( S E E SH 1 1 7 )
GY* WT*
(SH 1 2 4 ) L60 17 13
18TN MULT I - MULT I -
L61 BK* 11 FUNC FUNC
18LG MULT I -
YL* FUNC HAZARD
SWITCH
14
FEED f NORMAL 1 1 1
L60 20TN/BK*- MULT I -
FUNC
TO
CLUSTER A
16
MULT I -
FUNC
f * ' T T I
( S E E SH 8 7 )
1
F E E P m m m m RIGHT
5 L61 20LG/YL*-
TURN L E F T 1
TURN SIGNAL
MULT I - MULT I - AND HAZARD
FUNC FUNC FLASHER SWITCH
15 12 (CONNECTOR
S E E SH 1 3 5 )
TO
REAR L63 L50
LIGHTING 18DG L62
18WT
( S E E SH 1 1 1 . 1 1 2 ) RD* 18BR
TN*
PK*
(SH 123 FEED
(SH 1 2 3 )
sin 1
IROn TO
CLSO)
BLACK L63
18DG L62 SPLICE
( L E F T FENDER 18BR
RD* ( S E E SH 6 4 )
SIDE SHIELD) PK*
BR 85 STOP/TURN AND HAZARD FLASHER SYSTEM J948W-9

TO
IGNITION SWITCH
(SEE SH 7)
FEED
A21
12DB
S
TO
AIRBAG
SYSTEM FUSE #12
TO POWERTRAIN CONTROL
MODULE
(15 AMP) C9 C io C 1 l ri2
<
CONTROL MODULE I I
CAVITY 36 ( S E E J $ 53)
(SEE SH 44) FEED
FEED
TO
POWERTRAIN
TO CONTROL MODULE
POWERTRAIN CAVITY 31
G85 (SEE SH 1 6 , 2 6 . 4 7 )
CONTROL MODULE I I 180R
CAVITY 35 CAVITY 36 F14 1 8 L G / Y L *
BK* (SEE SH 39)
(SEE SH 44)
FEED
FEED
FEED s TO CLUSTER B
F14 2 0 L G / Y L * ( (SEE SH 88)
G14
G86
18PK
18TN
OR* BK*
1 1 INST/
10
HENG C h ENG A PNL
-JENG c|-
(SH 129) (SH 129) (SH 127)
BLACK
G85 G14
G86
180R 18PK
18TN
BK* BK* •
OR*
20TN/0R*
(SH 124) (SH 124) 20LG/YL*
(SH 124)
68 fpl- 71 GO: 67 rsi •G85 200R/BK*
G86 G85 G14 F14 -G14 20PK/BK*

20TN 200R 20PK 20LG —r
BK* YL* /
OR* BK*
/
/
/
/
* s.
s. 2 /
/
/
I i1 8 :
KNOCK WAIT TO TRANS FUSED IGNITION
SENSOR START LAMP
MESSAGE CENTER
(ON INSTRUMENT PANEL RIGHT OF STEERING COLUMN)
MESSAGE CENTER BR 86
9
J
4
8W9
-
/
I
- ^ - L $ 0 2 0 T N / B K * ( S E E SH 85)
(RIGHT TURN INDICATOR)
(HIGH BEAM INDICATOR) . 14

c c n
FEED
G34 1 8 R D / G Y * ( S E E SH 67.69J\)JJ±!L G7 22WT/0R* (SEE SH 2 0 . 3 0 . 3 6 . 4 8 )
FEED (VEHICLE SPEED)
L61 2 0 L G / Y L * (SEE SH 85)
(LEFT TURN INDICATOR)
GND
-L FEED
67 20UT/0R % (SEE SH 46)
13 2 0 B K / O R * (SEE SH 83)
(GROUND) FEED
R41 18BK/TN * (SEE SH 53)
(AIRBAG LAMP)
FEED
G20 2 2 V T / Y L * (SEE SH 51)
GND (ENGINE COOLANT TEMP)
Z l l 20BK/WT* (SEE SH 82)
(GROUND) FEED
G i l 22UT/BK* (SEE SH 77)
FEED (BRAKE LAMP)
G9 2 2 G Y / B K * ( S E E SH 7 )
(LAMP CK) FEED
G54 220R/8K * ( S E E SH 10)
(UPSHIFT LAMP)
FEED
G13 2 2 D B / R D * ( S E E SH 109)
(SEAT BELT LAMP)
BUX ONLY WHITE

"1 FEED
613 2 0 D B / R D * ( S E E SH 107)
(SEAT BELT LAMP)
(SEE SH 89 FOR CLUSTER SCHEMATIC)
BR 87 CLUSTER CONNECTOR-A J948W-9

FEED
FEED G19 22LG/RD*(SEE SH 60)
G107 22BK/GY* (SEE SH 11.55.57) (ANTI-LOCK LAMP)
(4UD INDICATOR) G19 22LG/RD* (SEE SH 55.57)
G107 20BK/GY* (SEE SH 11.62)
FEED
G4 22DB (SEE SH 90)
(FUEL GAU6E) FEED G60 22GY/YL* (SEE SH 51)
GND (ENGINE OIL PRESSURE)
Zll 22BK/WT* (SEE SH 82)
(GROUND) 2
•E^ - F14 20LG/YL* (SEE SH 86)
FEED (IGNITION)
G29 22BK/TN* (SEE SH 83)
(HASHER FLUID LAMP)
FEED G3 22BK/PK* (SEE SH 16.26.42.43)
FEED (CHECK ENGINE LAMP)
G24 22GY/PK* (SEE SH 29.40)
(MAINTENANCE LAMP) FEED
G6 22GY (SEE SH 51)
FEED (ENGINE OIL PRESSURE)
G21 22GY/LB* (SEE SH 19,29.40.43)
(TACH)
FEED E2 220R (SEE SH 77)
(ILLUMINATION)
BLACK
(SEE SH 89 FOR CLUSTER SCHEMATIC)
J948U-9 CLUSTER CONNECTOR-B BR 88

CHECK | O f 4] 0
ANTI-LOCK
o l B8 I IGNITION
4WD B13 o
BRAKE AS
o [ A6 I GROUND
CHECK ENGINE B6
OIL B4
PRESSURE
o|AU| SP PULSE
SPARE o
AIRBAG A9
o\jT\ TA PULSE
LOW WASHER B7
MAINTENANCE B5
REQUIRED
BIO OIL PRESSURE
SENDER
UPSHIFT A3
LAMP CHECK I A4 | o
^ r m TEMPERATURE
A 7
°l I SENDER
GENERAL fFT\
L B ± J
o
ILLUMINATION
SEAT BELT I Al I a
Bll FUEL SENDER

HIGH BEAM A13 0
oflFI GROUND
LEFT TURN |A12| 0
RIGHT TURN A14 0

o A10 GROUND
BR 89 PRINTED CIRCUIT BOARD J948W-9

(SH 1 2 3 ) FUSE # 9
( 1 0 AMP)
30 fill
•F18 20LG/BK* » F18 22LG/BK*
( S E E SH 9 8 )
F18
20LG
BK* FEED r TO POWER
AH 16RD/WT* , DISTRIBUTION
CENTER
( S E E SH 4 )
FEED
86: 30:
i—Zll 22BK/WT *
( I N POWER TO < Z U > 21 S P L I C E
FUEL TO
DISTRIBUTION IGNITION
PUMP
CENTER S E E ( S E E SH 8 2 ) SWITCH
RELAY
SH 1 4 2 ) G4 22DB ( S E E SH 7 )
85:
87 3
—K51 22DB/YL*- IEJ
A61 16DG/BK*- (SH 1 2 3 )
FEED K51
22DB
-BLACK
TO YL* G4
AUTOMATIC ( L E F T FENDER 22DB
SHUT DOWN 8 SIDE SHIELD)
RELAY ENG A FEED
( S E E SH 2 2 ,
25,36.44) (SH 1 2 7 )
TO
CLUSTER B
r-K51 20DB/YL* ( S E E SH 8 8 )
FEED
TO
POWERTRAIN Zll
CONTROL 18BK
MODULE WT*
CAVITY 51
( S E E SH 1 4 .
24,41.44)
-»-
(TOP OF F U E L
TANK)
F U E L TANK
L E V E L GAUGE
SENDING UNIT
TO 0.13> S P L I C E
GND . \y
Z13 16BK
* ( S E E SH 1 1 1 )
J948W-9 FUEL TANK SYSTEM BR 90

RT
(SH 1 3 9 )
DOOR 1
X56 20DB/RD * • — — - X 5 6 20DB/RD * •
S H l 3 ?
" DOOR 1 " ( )
X55 2 0 B R / R D * X55 2 0 B R / R D % -
(SH 1 3 6 ) - BODY -
X58 20DB/0R* -X58 18DB/0R * •

TO J O I N T
< FEED
CONNECTOR A ) L7 2 0 B K / Y L X I X57 2 0 B R / L B % » - -X57 18BR/LB %
( S E E SH 7 4 )
(SH 1 3 6 ) - BODY -
TO J O I N T FEED
CONNECTOR C t — — E2 220R X54 20VT
>
( S E E SH 7 7 )
TO
IGNITION
SWITCH X53 20DG
( S E E SH 7 )
X52 20DB/WT *
X51 20BR/YL %
FUSE # 7
10 AMP)
X12 18RD/WT %
TO J O I N T FEED
CONNECTOR B ( Ml 2 0 P K -
>
( S E E SH 7 5 )
j a • • • • • oTI 1 joo
GRAY BLACK
I — Z2 1 8 B K / L G X
—©CO-
RADIO
CASE
STEREO RADIO GROUND
( D I R E C T ATTACHMENT
TO RADIO)
BR 91 STEREO RADIO SYSTEM J948W-9

X56 20DB/RD* X56 20DB/RD * RIGHT

DOOR
X54 20VT SPEAKER
X54
20VT
X55 20BR/RD* X55 20BR/RD* LEFT

DOOR
X53 20DG SPEAKER
X58 18DB/0R*
X57 18BR/LB*
(SH 139)-DOOR
8J 1 nn
-X54 20VT X52 18DB/WT* RIGHT
REAR
X53 X58 18DB/0R * SPEAKER
20DG
(SH 137)- D Q LT ^
X53 20D6
X52
12 18DB EQUIPPED
(SH 1 3 5 ) - ] BODY |-
X52 2 0 D B / W T * — ) )
• X51 18BR/YL * LEFT
REAR
-X57 18BR/LB * SPEAKER
(SH 1 3 5 ) - ] BODY [•
X51 20BR/YL * »—X51 1 8 B R / Y L * —'
TO
ABS 2-WAY
POWER FEED
( S E E SH 5 9 )
WITH HIGH- GND

L I N E CLUSTER TO
12 18BK/LG * 12 18BK/LG * • » -Z2 18BK/LG*

6ND R
GND
491_ _ SPLICE
( S E E SH 9 5 )
Z8
10BK
(SH 1 2 4 ) PK*
L-Z2 18BK/LG*
( L E F T FRONT
GROUND (p)
FENDER
SIDE SHIELD)
J948W-9 STEREO RADIO SYSTEM BR 92

TO SPLICE
LEFT RIGHT
DOOR TWEETER DOOR TWEETER
( S E E SH 9 5 )
r 1
"JGND
Z2 Z2
18BK 18BK
LG* LG*
RT LT
DOOR 1 DOOR 1
(SH 139 (SH 137

BLACK BLACK
'— Z2 1 8 B K / L G *
X56 • Z2 1 8 B K / L G *
X55 X54 I8DB
X53
18BR 18VT RD*
18DG
RD* I X54 18VT -
X56 18DB/RD*
X53 18DG •
•X55 18BR/RD* •
TO J O I N T FEED
f
CONNECTOR A \ L7 20BK/YL* X56 20DB/RD*

( S E E SH 7 4 )
TO X55 20BR/RD*
IGNITION
SWITCH
( S E E SH 7 )
X58 20DB/0R*-
TO J O I N T
CONNECTOR C
X57 2 0 B R / L B * -
( S E E SH 7 7 )
FEED X54 20VT

E2
220R
F U S E Ml
X53 20DG
( 1 0 AMP)
- X52 20DB/WT*
X12 18RD/WT * -X51 20BR/YL* -
-Ml 20PK
FEED BLACK-
X60 22DG/RD* -
JL
TO J O I N T • •••
CONNECTOR B GRAY
( S E E SH 7 5 )
RADIO
CASE
GROUND
-—-Cm-n
Z2
DIRECT isBK
STEREO RADIO ATTACHMENT i *
G
TO RADIO ,
BR 93 INFINITY STEREO RADIO SYSTEM J948W-9

LEFT RIGHT LEFT RIGHT

DOOR SPEAKER DOOR SPEAKER REAR SPEAKER REAR SPEAKER
W 7
BLACK i—era-
vL-
I
X13 Z2 — I X13 12 12
l
fc*
L G * 18BR
X 5 5
X53 18BK 18BK
18DG R D * L G * 1
X
8
5
D
r
6
B
X54 18BK
18VT R D *
18BK
LG*
r i
X57 X51
X13
18BK
RD*
18BK J
LG* X 5 8
^
I
X13
18BK
X52 R D *
GN
IL
J RD* RD* 18BR 18BR 18DB 18DB
LB* YL* OR* WT*
<Z2S
SPLICE
( S E E SH 9 5 )
X13 18BK/RD*
-X55 2 0 B R / R D * — ) ) — X 5 5 18BR/RD *
H
S (SH
< 137
HD00R ll" 8 (
i ^-JBODY]-7
X58 20DB/0R* -X58 18DB/0R*
(SH 136)-|B0PY|-2
-X57 20BR/LB*- -X57 18BR/LB*
(SH 139)- D Q Qp 1 h2
-X54 20VT » — -X54 18VT
(SH 1 3 7 ) - pQQp i - 3 (SH 1 3 6 )
X53 20DG » — X53 18DG BODY - 1 2
X52 20DB/WT * • X52 18DB/WT *

(SH 1 3 6 ) ~ | BODY |~5
X51 2 0 B R / Y L * » X51 1 8 B R / Y L *
X13 18BK/RD*
(REAR OR RADIO)
INST/
PNL
TO
JOINT 12
T CONNECTOR B 18BK
^ ( S E E SH 7 5 ) LG*
18PK FEED
GND
TO
GND
12 18BK/LG *
" SPLICE
( S E E SH 9 5 )
J948W-9 INFINITY STEREO RADIO SYSTEM BR 94

TO
TO RADIO
RIGHT REAR , CHOKE
, SPEAKER ( S E E SH 9 4 )
(INFINITY)
( S E E SH 9 4 ) TO
RADIO CASE
, GROUND
( S E E SH 9 1 , 9 3 )
TO
GND
L E F T DOOR
SPEAKER
(INFINITY)
Z2 18BK/LG* ( S E E SH 9 4 )
(SH 136) 4
-)BQDY|- GND
Z2 18BK/LG* (i— 12 18BK/LG * -»- Z2 18BK/LG*
iDOOR i H S H 1 3 7 )
12
18BK
LG*
Z2 18BK/LG* -Z2 18BK/LG *
GND HDOOR iHSH 139)

GND
(SH 124)
TO
L E F T REAR TO
SPEAKER RIGHT DOOR
,(INFINITY) SPEAKER
S E E SH 9 4 ) (INFINITY)
Z2 18BK/LG * •
(SEE SH 94)
WITH HIGH
L I N E CLUSTER
Z2 18BK/LG *
GROUND (p Z8
10BK
PK*
Z8 16BK/PK* Z7 18BK/RD * ( L E F T FRONT J^GND

FENDER S I D E
GND GND SHIELD)
GROUND TO
TO B ABS 2-WAY
TO
PRESSURE POWER F E E D
ABS
LIMITING ( S E E SH 5 9 )
CONTROLLER
VALVE ( S E E SH 6 2 )
( L E U REAR
( S E E SH 5 5 , 5 7 )
FENDER S I D E
SHIELD)
BR 95 RADIO AND SENSOR GROUND J948W-9

r BLACK
E2 220R
C5 1 6 L G / Y L *
C4 16TN
C7 12BK/TN*
C i 120G
Z3 12BK/0R *
CI
I2DG
INST/
)) C7 1 2 B K / T N * - PNL
FUSE F 2 F2
)> :
C7
( 3 0 AMP)
C4 C5 C7
A22
•??» 12BK
OR*
„ i i
•IS Xfs. Xfs. FEED
M H
T0<A22> SPLICE
BLOWER MOTOR ( S E E SH 7 )
RESISTER
FEED f TO J O I N T
— — ( CONNECTOR C
* ( S E E SH 7 7 )
SPLICE
( S E E SH 7 8 )
J948W-9 HEATER SYSTEM BR 96

r BLACK
E2 220R
C90 2 2 L G
C5 16LG/YL*
C4 16TN
C6 14LB
C7 12BK/TN *
CI 12DG
13 1 2 B K / 0 R *
BLOWER
MOTOR
FAN HI
SWITCH C7 12BK/TN * -
INST/
C 7 > PNL
Ml
LOW
OEF
HEAT C4 C5 C6 C7
16TN 1BLG 14LB 12BK
HI/LO YL* TN*
A/C
MAX A / C
OFF
LO Ml M2 HI
DEF
- BLOWER MOTOR
#HEAT RESISTER
HI/LO
OFF* MAX
MAX AA
/ C/ TO
GND
C9Q (Gl/)" •41—1- -»- Z3 12BK/OR *
22LG
ILLUMINATION SPLICE
( S E E SH 7 8 )
CD
HVAC SWITCH
E2
220R
F E E D < TO J O I N T A/C A/C
\ CONNECTOR C HIGH PRESSURE LOW P R E S S U R E TO
( S E E SH 7 7 ) CUT OUT CUT OUT POWERTRAIN
SWITCH SWITCH CONTROL
MODULE
C A V I T Y 27
(SH 1 2 3 ) ( S E E SH 2 2 , 3 1 ,
34.47)
C90
18LG
FEED
ENG C h
( S E E SH 1 2 9 )
C90 18LG a C90 18LG/WT * C20 18BR

))
(MOUNTED ON (IN A / C LINE
COMPRESSOR) RIGHT S I D E OF
ENGINE COMPARTMENT)
AIR CONDITIONING AND

BR 97 HEATER SYSTEM J948W-9
HD/LP
TO HORN
DASH
RELAY
TO
( S E E SH 5 2 )
AUTOMATIC f FEED
F18 20LG/BK * F18 20LG/BK * -
SHUT DOWN RELAY >
( S E E SH 2 2 , 2 5 . 3 6 )
FEED
- F18 20LG/BK *
30 F31
20VT
(SH 1 2 3 )
30 A/C
FEED
COMPRESSOR
F18 -ENG B -
•CI 12DG- CLUTCH
22LG RELAY
(SH 1 2 8 )
BK* TO F U E L
PUMP RELAY
( I N POWER
F18 DISTRIBUTION
( S E E SH 9 0 )
18LG CENTER)
BK* ( S E E SH 1 4 2 )
FUSE F 2 FEED
( 3 0 AMP)
FUSE* 9 TO
C13
( 1 0 AMP) 22DB
:FIS OR*
SPLICE
A22 ( S E E SH 1 9 , 2 9 . 4 1 , 4 3 )
12BK ENG C h
OR* TO I G N I T I O N
C C f r n (SH 1 2 9 )
FEED S A P I 12DB ( SWITCH
} H I L L D M
> (SEE SH 7 )
C3
18DB
TO < A 2 2 > S P L I C E BK*
ENG A h
( S E E SH 7 )
TO (SH 1 2 7 )
TO POWERTRAIN
CONTROL MODULE f GND
GND C A V I T Y 34 y—— C13 20DB/OR*
Zil>2l fZ!!!L.zil 16BK/WT * — , ( S E E SH 2 2 ,
31,34.47)
SPLICE
( S E E SH 8 2 )
A / C COMPRESSOR
CLUTCH
TO
<n2Hl ( S E E SH 2 1 .
31,35,48)
SPLICE
( S E E SH 1 5 , 2 5 )
GND Zll 18BK/WT *

Z12 14BK/TN * C3 18DB/BK*
ENGINE [ L E F T FRONT
GROUND OF E N G I N E )
BI-DIRECTIONAL
ZENER DIODE
AIR CONDITIONING AND

J948W-9 HEATER SYSTEM BR 98
L E F T DOOR
B + B — r Oil MLB
POLARITY POLARITY WINDOW AND MOVEMENT % %
4
LB WT LEFT FRONT UP F21 14TN-
Z3 14BK/0R *
W
WT LB LEFT FRONT DOWN
026 14VT/WT*- nHi fiiii -Q16 I4BR/WT *
BR/WT VT/WT RIGHT FRONT UP 7* 5 * ^
VT/WT BR/WT RIGHT FRONT DOWN
TN BK/OR F E E D AND GROUND
UP LEFT DOOR SWITCH CONNECTOR
FORWARD m* MASTER SWITCH
TO GND . TO POWER
L E F T DOOR i MIRROR SWITCH
LOCK SWITCH ( S E E SH 1 0 3 ) Q21 14WT
( S E E SH 1 0 1 )
GND GND
LEFT
Z3 Z3 Z3 WINDOW
14BK 14BK 18BK LIFT
OR* OR* OR* MOTOR
Q21 O i l
14WT 14LB
Oil 14LB
•F21 14TN
LT
- (SH 138)
DOOR 2
LEFT SIDE
COWL GROUND F21 14TN
•JpoJJ - ( S H 140)
2
1—016 14BR/WT* • -))—Q16 14BR/WT*-
3
L E F T OOOR
POWER WINDOW
RT (SH 140)
SWITCH
DOOR 2
SH 138) -Q26 14VT/WT*-
Q26
14VT
LT WT*
(SH 138) -
DOOR 2
Q26 14VT/WT* —
BR 99 POWER WINDOW SYSTEM J948W-9

RIGHT DOOR
RED
B+ B— FORWARD I N CAR
POLARITY POLARITY WINDOW MOVEMENT AND SWITCH
VT BR DOWN FROM DOOR SWITCH Q22 14VT Q16 14BR/WT*

BR VT UP FROM DOOR SWITCH
F21 I4TN
VT/WT BR/WT DOWN FROM MASTER SWITCH
BR/WT VT/WT UP FROM MASTER SWITCH Q26 14VT/WT X Q12 14BR
UP
TN
— FEED
RIGHT FRONT WINDOW L I F T SWITCH CONNECTOR
TO
FEED
A22 12BK/OR*
SPLICE
(SEE SH 7 )
CIRCUIT
BREAKER 1
( 3 0 AMP)
( I N FUSE BLOCK)
Q22 14VT
RIGHT
WINDOW
LIFT
MOTOR
F21 14TN
Q12 14BR
016 14BR/WTX
•Q26 14VT/WT X
RIGHT DOOR
POWER WINDOW SWITCH
J948W-9
POWER WINDOW SYSTEM BR 100
8W - ISO WIRING DIAGRAMS
LEFT DOOR SWITCH CONNECTOR
P35 160R/VTX- 13 14BK/0R*

(LOCK)
F35 14RD
(FEED)
Z3 14BK/0R* P36 16PK/VT*
(UNLOCK)
FORWARD
T UP
TERMINAL END
U . . . , „ J
LEFT DOOR ,
LOCK SWITCH /
LT
(SH 138) DOOR S H
'UNLOCK 2 D00R2"( "°>
-<f
K -P36 16PK/VT* • -» P36 16PK/VT * )) P36 16PK/VT*
10
(SH 138) IpoQR 2 ~ DOOR 2 h ( S HH 0 )
<f •P35 160R/VTX )> P35 160R/VT * » P35 160R/VT*

LOCK — F35 16RD » F35 16RD
13
14BK RT
OR* DOOR 2 " (SH 140)
F35:
F35 14R0 F35 16RD
LT INST/
(SH 138)- DOOR 2 PNL
FUSE #19
(20 AMP)
FEED TO SPLICE
Z3 18BK/0R *•
A7 12RD/BKX
(SEE SH 73)
,TO POWER MIRROR
-f SWITCH
GND (SEE SH 103)
LEFT TO LEFT DOOR JAMB

SIDE >
{ SWITCH
COWL GND (SEE SH 80.82)
GROUND
BR 101 POWER DOOR LOCKS J948W-9

RIGHT DOOR SWITCH CONNECTOR
-BLUE
P33 16QR/BK* P36 16PK/VT*

(LOCK)
0 F 3 5 IBRD
P35 160R/VT* -0 m~ P34 1 6 P K / B K *

(UNLOCK)
FORWARD
T UP
TERMINAL END
RIGHT DOOR / RIGHT

LOCK SWITCH / DOOR
BLACK
UNLOCK
P36 16PK/VT* (f
rr - » - P34 16PK/BK* P34 16PK/BK * — i
P35 160R/VT*- L - » — P33 160R/BK* P33 160R/BK*

RIGHT FRONT
F35 16RD LOCK DOOR MOTOR
RIGHT
DOOR P33 P34
160R 16PK
BK* B K *
8
RT RT
DOOR 2 DOOR 2
(SH 140) (SH 140)

P34
P33 16PK
160R B K *
BK*
LT
LT DOOR 2
DOOR 2
(SH 138)
(SH 138) BLACK
P33 P34
160R 1GPK
BK* B K *
L E F T FRONT
DOOR MOTOR
J948W-9
POWER DOOR LOCKS BR 1 0 2
T
O
<$>
SPLICE
(SEE SH 1 0 7 . 1 0 9 )
"pFEED
POWER MIRROR SWITCH
Ml
20PK
Ml 20PK
LT
DOOR 1
(SH 137)
I
J
Z3 Z3
18BK 18BK
OR* OR*
-W/0
i '— P74 20DB-
POWER P72
P75 P71 P73 P70
WINDOWS 20YL
20DB 20YL 20YL 20WT
AND LOCKS BK*
WT* PK*
P72 20YL/BK*
SH 13?)
( S E E SH 9 9 )
GRAY D(AT MIRROR) JOOR lH
Z3>2
a- P70 20WT
LT
- (SH 137)
DOOR 1
P75 P73
20DB VERTICAL 20YL
WT* PK*
P73
LEFT O
P71
20YL* 1 1
V
20YL
PK*
SIDE UP — ^ nDN
COWL
GROUND
TO L E F T HORIZONTAL
DOOR JAMB
SWITCH
( S E E SH 8 0 . 8 2 )
L E F T MIRROR
MOTORS
BR 103 POWER MIRROR SYSTEM J948W-9

•GRAY
T J l T h r
139)
DOOR i
P74 20DB
P74
20DB
10 P70
P70
LT 20WT 20HT
DOOR 1
(SH 137)
- P74 20DB — l
RT
DOOR 1 HORIZONTAL
(SH 139)
P72 20YL/BK*
LT R
RT
P70 20WT
RT
DOOR 1 VERTICAL
(SH 139)
RIGHT MIRROR
MOTORS
RIGHT
LEFT
MIRROR
MIRROR
POWER MIRROR SWITCH FUNCTION
LEVER MIRROR
RT('B) POSITION
CIRCUIT
DIRECTION
A SK.TL.PB UP
B NG.VF.RC RIGHT
C SD.TE.PH DOWN
D NA.VM.RJ LEFT
VIEW OF SWITCH INDEXING

FROM FRONT OF SWITCH
J948W-9
POWER MIRROR SYSTEM BR 104
TO P17 14DB/RD*
<$> PIS 14YL/LB*

SPLICE BLACK FORWARD/
(SEE SH 73) BACKWARD
SEAT
MOTOR
FEED P17 14DB/RD*
•— , i
P15 14YL/LB* •
A7
12RD Pll 14YL/WT*-
BK*
P13 14RD/WT*
RED REAR
VERTICAL
SEAT
CIRCUIT MOTOR
BREAKER Pll 14YL/WT*
2 L « « _ . « .
(30 AMP) P13 14RD/WT*-

(IN
FUSE BLOCK)
P19 14YL/LG *
F37 P2l 14RD/LG*

14RD RED FRONT
LB* VERTICAL
SEAT
^ -|BODY|-
MOTOR
(SH 136) P19 14YL/LG*
F37 14RD/LB*
(UNDER SEAT)
P19 Pll P17
14YL 14YL 14DB
P21 LG* WT * RD *
Z3 14BK/0R*- 14RD
7 P13 P15
1 * 14RD 14YL
LEFT „ 14RD * L G
BODY z: I D *
Li
L B
WT* LB *
O GROUND 14BK
4E *
(LEFT REAR BLACK OR*
= ^ OF CAB)
Z3 14BK/0R* P19
14YL
P17 14DB/RD * LG*
F37 14RD/LB *
J
Pll 14YL/WT *•
FRT FRT REAR REAR
DOWN UP DOWN UP
I BLACK
VERT VERT
& &} ^ DOWN UP
P13 14RD/WT*- P21

14RD
I
P15 14YL/LB *- LG*
POWER SEAT SWITCH
BR 105 POWER SEAT SYSTEM J948W-9

FEED R TO
— — \ JOINT CONNECTOR C
(SEE SH 7)
LIO
22BR
LG*
SPLICE
LI 22VT/BK* LI 18VT/BK *
(SEE SH 12)
22
III
(SH 1 2 3 )
r TO SPLICE
(SEE SH 8 0 . 8 1 )
LI 22VT/BK*
FUSED BACK-UP GROUND Z4 22BK

FEED LPS
LIO 22BR/LG*
AUTOMATIC
DAY/NIGHT MIRROR ^-BLACK
i j
J948W-9
AUTOMATIC DAY/NIGHT MIRROR BR 106
Ml G26
20PK 20LB
(RIGHT OF G26 G7
CHIME COLUMN) 20LB 20WT
BLACK OR*
1-•3 I-•7 2-'I
1 1-5
1-•1 1 -2 1
N y %
1 it
N S
N y s. y
y N
cp CP CP
pjEpCJ
F12 G13 Z3 Ml G7 BLACK
1-4 1-1
20DB 20DB 20BK 20PK 20WT
WT* RD* OR* OR*
G10 G13
FEED GND FEED 20LG 20DB
RD* RD*
TO JOINT TO
CONNECTOR C Z3 F12
(SEE SH 76)
FEED
%
SPLICE SPLICE
20BK
OR*
20DB
W T
*
(SEE SH 83) (SEE SH 4 6 )
TO CLUSTER A
(SEE SH 87)
TO JOINT
CONNECTOR B
(SEE SH 75)
SPLICE TO POWER
(SEE SH 79) MIRROR SWITCH
(SEE SH 103)
FEED
Ml 20PK •Ml 20PK-
Ml 20PK Ml 20PK
(SH 136HB0DYJ-
-BLACK
Ml Ml Ml
20PK 18PK 20PK
Ml 20PK
FEED
Ml 20PK- —<^ Ml 20PK
0034 FUSE # 1 7 ,
TO UNDERHOOD (15 AMP) (LEFT KICK PANEL)
LAMP (SH 123)
(SEE SH 72) 48
00 (SH 124)
FEED
TO
TO SPLICE y FEED
) — A 7 12RD/BK*- A7 12RD/BK * — ) ) — A7 12RD/BK*- i <ATZD
(SEE SH 73)
SPLICE
SEATBELT WARNING (SEE SH 52)
AND CHIME SYSTEM

BR 107 (BUX ONLY) J948W-9
CHIME
1 4 1-6
FEED f TO
L
G26 20LB - ( H E A D L A M P SWITCH
>
G10 ( S E E SH 7 3
20LG
RD* TO J O I N T TO J O I N T 6ND
ONNECTOR C
CONNECTOR CONNECTOR A i
-|BODY|- S E E SH 7 6 ) ( S E E SH 7 4 ) I
(SH 136) G26 [GND
20LB
616
L - G I O 20LG/RD* —i KEY-IN 22BK
SWITCH LB*
Z3 20BK/0R*
TIME DELAY
- Z3 18BK/0R* SEATBELT RELAY
SWITCH (IN FUSEBLOCK)
(IN BUCKLE) ( S E E SH
GIO 20LG/RD*
117,118)
•M50 22YL/RD *
BLACK
-Z3 20BK/0R*
M50
-G26 20LB 22YL
Ml
20PK
RD*
G16 22BK/LB*
-GRAY
TO C E N T E R H I G H BODY GND G N 0 r - Z 3 20BK/0R*—VAX

MOUNTED S T O P LAMP GROUND Ss IGNITION
AND CARGO LAMP ( L E F T REAR S W I T C H LAMP
( S E E SH 1 1 5 ) TO POWER
OF C A B ) T0^Z3> SPLICE
SEAT SYSTEM
( S E E SH 1 0 5 )
(SEE SH 8 3 )
Ml 20PK
TO OVERHEAD
MAP LAMP
( S E E SH 8 0 )
FEED
Ml 20PK-
FEED
TO <MQ2| SPLICE
Ml 20PK-
(SEE SH 8 1 )
SEATBELT WARNING
AND CHIME SYSTEM
J948W-9
(BUX ONLY) BR 108
(SEE SH
BUZZER 117.118)
(IN FUSEBLOCK)
. 56 57 58 62
F12 G13 Z3 Ml
22DB 22DB 20BK 20PK
WT* RD * OR*
FEED GND
TO JOINT TO
CONNECTOR C
(SEE SH 76)
FEED SPLICE
(SEE SH 83)
TO
CLUSTER A
(SEE SH 87)
TO JOINT
CONNECTOR B
(SEE SH 75)
SPLICE TO POWER
(SEESH 79) MIRROR SWITCH
(SEE SH 103)
LT 137) FEED
DOOR 1 h ( S H
Ml 20PK -Ml 20PK-
Ml 20PK Ml 20PK
(SH 136HB0DYh
•BLACK
(LEFT KICK PANEL)
Ml Ml Ml
20PK 18PK 20PK
Ml 20PK
Ml 20PK-
FEED Ml 20PK
DQ34 FUSE #17
TO UNDERHOOD (15 AMP)
LAMP (SH 123)
(SEE SH 72) 48
Oil (SH 124) TO

FEED
TO V 7 S P L I C E r FEED
7
A7 12RD/BK*• A7 12RD/BK * — ) ) — A 7 12RD/BK*-

(SEE SH 73)
SPLICE
(SEE SH 5 2 )
SEATBELT WARNING
BR 109 AND BUZZER SYSTEM J948H-9
j
(SEE SH
BUZZER 117.118)
(IN FUSEBLOCK)
59 61
1 0
FEED
r
G26 2 0 L B l^Lf HEADLAMP SWITCH
GiO S E E SH 7 3
22LG
TO J O I N T TO JOINT
CONNECTOR C .ONNECTOR .. GND (
S E E SH 7 6 ) CO
(SEN
ENEC
SHTOR
74)A
M2
(SH 1 3 6 ) G26 GNO 22YL
22LB
-GIO 20LG/RD* G16 54 53
KEY-IN 22BK
SWITCH LB* 55
—
r —
— Ulf>»n
Z3 20BK/0R*
-<f
Z3 18BK/0R* TIME DELAY
RELAY
SEATBELT
-GRAY (IN FUSEBLOCK)
610 20L6/RD* SWITCH (SEE SH 117.118)
(IN SEATBELT M50 22YL/RD*
BLACK BUCKLE)
•13 20BK/0R* M50
-G26 22LB 22YL Ml
20PK
G16 22BK/LB* RD*
TO CENTER HIGH BODY GND£~~Z3 20BK/0R*-I G N I T I O N

MOUNTED STOP LAMP G RO UND V-K
AND CARGO LAMP SWITCH
(SEE SH 115) EAT SYSTEMT0<^> SPLICE
E FT E R T 0 P 0 M E R
YA
CABR ARF
AREAA\ J S LAMP
(SEE SH 105) (SEE SH 83)

Ml 20PK
TO
OVERHEAD
MAP LAMP
( S E E SH 8 0 )
FEED
Ml 20PK-
FEED TO <M^H SPLICE

Ml 20PK-
( S E E SH 8 1 )
SEATBELT WARNING
J948W-9 AND BUZZER SYSTEM BR 1 1 0
TO TRAILER f GND
LEFT LICENSE TOW y-
LAMP (IF EQUIPPED)
(SEE SH 113)
BLACK Z13
L7 18BK/YL* 12BK
L7 18BK/YL *
Z13 18BK
Z13 18BK Z13 18BK
(RIGHT REAR
LEFT FRAME RAIL)
TAIL, L7 18BK/YL*-
STOP I
TURN
SIGNAL L63 18DG/BR*
LAMP Z13
16BK
L7 18BK/YL*- L7 18BK/YL*-
Z13 18BK-
8VT/BK*- •Ll 18VT/BK *
L63 L63 Z13 Z13

LEFT 18DG 18DG 16BK 12BK
BACK-UP RD* RD*
LAMP -WITH
TRAILER TOW
W/0
Z
TRAILER TOW
L63 18DG/RD*
L63 18DG/RD* •
L62 18BR/PK* •
LI 18VT/BK* -
L63 L62 LI
18DG 18BR 18VT Z13 12BK'
RD* PK* BK* Xj}
Z13 16BK
CHASSIS
FEED FEED FEED Z13
16BK
TO GND
TRAILER TOW
SYSTEM
(IF EQUIPPED) TO
(SEE SH 113) FUEL TANK
LEVEL GAUGE
SENDING UNIT
(SEE SH 90)
BR 111 REAR LIGHTING J948W-9

RIGHT LICENSE
BLACK
LAMP
ZI3 18BK- Z13 18BK
L7 18BK/YL *
L7 18BK/YL*
L7 18BK/YL*
CHASSIS RIGHT
Z13 18BK - L7 1 8 B K / Y L * TAIL
f ^ STOP I
I TURN
L7 BLACK L62 180G/BR *: — S I G N A L
L7 L7 LAMP
18BK 18BK 18BK
YL* YL* YL*
Z13
Z13 18BK 18BK
L7 18BK/YL *
RIGHT
BACK-UP
LAMP
/—w/u
W TOW FEED , TO TRANSMISSION
w
TRAILER r-Li I8VT/BK* — — ( O V E R D R I V E SYSTEM
(SEE SH 12)
LI LI L62 L62
18VT 18VT 18BR 18BR
BK* BK* PK* PK*
FEED ^TO SPLICE
•L7 18BK/YL*
(SEE SH 6 7 . 6 9 )
(LEFT FENDER SIDE
L63 18DG/RD * SHIELD)
L63 18DG/RD * L63 18DG/RD* »
L62 18BR/PK* (SH 123)
W H
LI 18VT/BK * TR A V L ER L63
18DG
RD*
Z13 12BK
Z13 16BK
SPLICE FEED
(SEE SH 72)
WITH TRAILER TOW TO TURN SIGNAL SWITCH

(SEE SH 85)
J948W-9
REAR LIGHTING BR 112
i
, SPLICE
,SEE SH 112)
A6 14RD/TN»-«-fJf~) _ 0
BLACK
L7 20BK/YL*-(f
TRAILER TOW SPLICE ( I N POWER

CONNECTOR (SEE SH 6 7 . 6 9 ) DISTRIBUTION
CENTER)
(SEE SH 1 4 2 )
BR 113 TRAILER TOW SYSTEM J948W-9

TO
LOW WASHER
F L U I D LEVEL SWITCH
TO ABS YELLOW „ ^
(SEE SH 8 3 )
L I G H T RELAY f ^ E ^
2 l 2 0 , B
(SEE SH 6 0 J — Zl 20BK Zl 188K-™4

TO DAYTIME
RUNNING LIGHT
TO MODULE
VEHICLE SPEED G N D
f
SEE SH 7 1 )
CONTROL S E R V O ) Z l 20BK Zl 18BK^4
(SEE SH 6 3 )
Z l 18BK
Z l 12BK
Z l 14BK
* r Z l 18BK
O — Z l 18BK
-Zl 12BK
•Zl 14BK
-Zl 18BK
-Zl 18BK
Zl 20BK-
BLACK
Z l 12BK
TO
TO VACUM
Zl SENSOR
12BK (SEE SH 57.62) S PILK
ICE
(SEE SH 6 8 , 7 0 )
;H (
T-
TO
LEFT PARK
AND TURN
SI6NAL
LAMP
(SEE SH 6 7 . 6 9 )
TO HORNS
(SEE SH 5 2 )
TO<ZjTnSPLlCE
(SEE SH 7 2 )
J948W-9
GROUND JOINT BR 114
GNO , TO
— \ SEATBELT SWITCH
(SEE SH 108.110)
10
(SH 136) -J BODY f-
L50 18WT/TN * «
FEED
TO
<8>
SPLICE \ BLACK
(SEE SH 64) (CENTER REAR ROOF
PANEL)
Z3 L50
Z3 L50 18BK 18WT
18BK 18WT OR* TN*
OR* TN*
0
1 MOUNTED STOP LAMP 1
/
i
CENTER HIGH
MOUNTED STOP LAMP 2
I
Z3 18BK/0R* Z3 18BK/0R*
BLACK BLACK
L50 18WT/TN* L50 18WT/TN*

i— , ,—i
CENTER HIGH
BR 115 MOUNTED STOP LAMP J948W-9
BLACK
1
5
VIEWED FROM
r
TERMINAL END
CAV CIRCUIT FUNCTION SHEET
Bl A3 12RD/LGX HEADLAMP SWITCH F E E D 73
B2 F33 20PK/RD* PARK LAMP F E E D 73
B3 G26 2 0 L B K E Y - I N BUZZER/CHIME 73
B3 G26 2 0 L B K E Y - I N BUZZER/CHIME 73
D M3 22PK/DBX CARGO LAMP GROUND 73
H L2 16LG HEADLAMP DIMMER SWITCH F E E D 73
I El 20TN/0R* HEADLAMP DIMMER SWITCH 73
P L20 16LG/WT* HEADLAMP DIMMER SWITCH FEED 73
R L7 2 0 B K / Y L * TAIL,LICENSE.SIDE MARKER LAMPS 73
U G16 2 2 B K / L B X BUZZER/CHIME 73
J948W-9 HEADLAMP SWITCH CONNECTOR BR 116

@
CB1
CB2
TIME DELAY
54
49 50 51 52
55
45 46 47 48
©@©0
53 41 42 44
37 38 40
33 34 36
j 59
fW 63
29 30 32
[58
m 62
25
21
26
22
27 28
|57 61
1
[56 60
• Ml 17 18 19
13 15
1
BUZZER
© @ (19) (20)
VIEWED FROM TERMINAL END

(LOCATED L E F T S I D E OF
INSTRUMENT PANEL)
BR 117 FUSEBLOCK J948W-9

FUSE AMPS COLOR SHEET
5 20 YELLOW 2.8.78
6 15 LIGHT BLUE 2.8.85
7 10 REO 2.8.91.93
8 20 YELLOW 2.8.84
9 10 RED 1.7.90.98
10 2 GRAY 1.7.64
11 10 RED 1.7.76
12 15 LIGHT BLUE 1.7.86
13 5 TAN 73.77
14 20 YELLOW 2.8.55.57.62
!S 10 RED 2.8
16 15 LIGHT BLUE 2.8.53
17 15 LIGHT BLUE 3.107.109
18 15 LIGHT BLUE 3.73
19 20 YELLOW 3.101
20 15 LIGHT BLUE 3.75
FI
F2 30 LIGHT GREEN 1 .7.96.98
C81 30 1.7.100
CB2 30 3.73.105
J948W-9 FUSEBLOCK BR 118

CAV CIRCUIT ACTION SHEET

1 Kl 18D6/RD* MAP SENS . 17 j
2 K2 1 8 T N / B K * ENGINE COOLANT TEMPERATURE SENSOR 16 1
3 A14 16RD/WT* FUEL PUMP RELAY F E E
4 K4 2 0 B K / L B * SIGNAL REFERE
— —
5 —•
6 K6 2 0 V T / M T * 5 VOLT OUTPi 17
7
8
K7 200R 8 VOLT SUPP!
.... _
17
9 F18 2 0 L G / B K * I s ? : ; ; ; F E F - 19
10 T6 2 0 0 R / W T * TRANSMISSION OVERDRIVE SWITCH FEED 10,14
11 Z12 1 6 B K / T N * POWER GROUNI 15
12 112 illK/TNl POWER GROUNI
13 K14 1 i l l / I I * FUEL INJECT!
14 K13 1 8 Y L / W T * FUEL I N J E C T * :
15 !<12 1C7N FUEL INJECT! )3
16 K l l 18WT/0B* FUEL I N J E C T S 13
17 ™- —
18
19 K19 16BK/GY * I^'.;T-I-M C O I L D R I v - : ; -
;
13
20 K20 18DG VOLTAGE REGULA7 .•'J
21 K21 18BK/RD * INTAKE AIR TEMP E M W I E N S W EC;
22 K22 180R/DB* THROTTLE P O S I T I O N [SENSORl 1 HI
23 — — —
24 K24 2 0 G Y / B K * OlSfRliUTOR IGNITION SENSOR (BO 18
25 0 2 1 20PK SERIAL COMMUNICATION INTERFACE 15
......
26 —
27 rC20 18BR 17TDAMPED"PRESSURE SWITCH '
28 .—. —
29 V 4 0 20WT/PK * STOP LAMP S W I T C ! : IB
30 T41 2 0 B K / W T * ENGINE STARTER RELAY 16
31 6 1 4 20PK/BK * TRANSMISSION TEMPERATURE LAMP 16
32 "Gl 2 0 I K / P K * MALFUNCTION INDICATOR LAMP 16
33 V36 20TN/RD * VEHICLE SPEED CONTROL {VACUUM) 17.63
34 C13 20DB/0R * A/C COMPRESSOR CLUTCH RELAY GROUND 22 1
35 K35 20GY/YL * EXHAUST GAS RECIRCULATION SOLENOID 13 j
—
36
37 T18 2 0 L G / 0 R * TRANSMISSION FEED 10(15
38 K38 18GY FUEL I N J E C T S f; C H
VIEHED FROM
39 K39 20GY/RD * IDLE A I R CONTROL MOTOR T O P E N T 19
TERMINAL END
40 K40 18BR/WT * IDLE A I R CONTROL MOTOR (CLOSE) 19
41 K41 1 8 B K / D G * HEATED OXYGEN SENS ' 1 ?l
42 T54 18VT TRANSMISSION TEMP SENS • C J7
f
43 G21 2 0 G Y / L B * TACHOMET . 13
44 K44 2 0 T N / Y L * CAMSHAFT P O S I T I O N SENSOR 17
45 020 20LG "SERIAL COMMUNICATION INTERFACE (RECETVET ID
46 — —
47 G7 2 0 W T / 0 R * VEHICLE SPEED SENSOR 20
48 "731 2 0 I R / R D * T E H I CLE SPEED CONTROL (TETF~ 22,63
4 9 V32 2 0 Y L / R D * VEHICLE S P E E D T O N T R O L ( I G N I T T O N T 22,83
50 V 3 3 2 0 W T / L G * VEHI CLE S P E E D T O N T R O L ( RESUME) 22,63
51 K51 2 0 D B / Y L * AUT0HA1IC SHUT DOWN RELAY 14
52 K52 2 0 P K / 8 K * EVAP/PURGE SOLE;: 19
53 V35 2 0 L G / R D * VEHICLE SPEED C0NTR0L"ToTT~ 17,63
54 K54 2 0 0 R / B K * TRANSMISSION OVERDRIVE SOLENOID 10,15
54 "654 2 0 0 R / B K * SHIFT INDICATOR LAMP 10.15
55
56
T 6 0 20BR
—
TRANSMISSION OVERDRIVE SOLENOID
_
10,14
57 A142 1 6 D 6 / 0 R * INJECTOR/SENSE/GENERATOR FEED .•»
58 K58 18BR/DB* FUEL INJECT' 14

59 K59 18VT/BK * "IDLE A I R CONTROL MOTOR (CLOSET 19
60 K60 18YL/BK * II • 'CONTROL MOTOR (CLOSE) 19

BR 119 (3.9L ENGINE) J948W-9
CAV CIRCUIT : ; ,
: NCTI0N SHEET
1 Kl 18DG/RD* MAP SENSOR 27
2 K2 18TN/BK* ENGINE COOLANT TEMPERATURE SENSOR 26
3 U14 1 6 R D / W T * i T M T U M T R F L A Y FEED ~ 26
4 K4 2 0 B K / L B t 28
5 ----- —
6 K6 20VT/WT* 5 VOLT OUTPUT 27

7 K7 200R 8 VOLT SUPPLY 27
8 ...... —
9 F18 20LG/BK t ;
I -:i^;\0i! FEED 29
11 212 1 6 B K / T N * POWER GROUND 25
12 Z12 1 6 B K / T N % POWER GROUND 25
13 717 1 8 L B / B R * " FUEL INJECTOR 23
14 K13 njvv/yT* FUEL INJECTOR # 3 23
15 K12 18TN FUEL INJECTOR Ul 23
16 Kll 18WT/DB X FUEL INJECTS #1 23
17 !(17 130LJ/TN* FUEL INJECTOR ul 24
18 xi 3 n ; u / Y L * 24
19 K19 1 6 B K / G Y X I * M i T I O N C O I L D R I V E R U\ 23
20 K20 18DG VOLTAGE REGULATOR 24
21 K21 1 8 B K / R D X INTAKE AIR TEMPERATURE SENSOR 28
22 K22 200R/DB* THROTTLE P O S I T I O N T S E N S O R ) 28
23 K141 18TN/WTX HEATED OXYGEN SENSOR 32
24 K24 2 0 G Y / B K X DISTRIBUTOR IGNITION SENSOR ( E H 28
25 D21 2 0 P K S E R I A L COMMUNICATION INTERFACE 25
—
26
27 C20 1 8 B R
-
A / C DAMPED P R E S S U R E SWITCH 31
28 — - - —
29 V40 20WT/PK* STOP LAMP SWITCH 26

30 74! 20BK/WT X ENGINE STARTER RELAY 26
31 •314 18PK/BK* TRANSMISSION TEMPERATURE LAMP 26
32 63 2 0 B K / P K X MALFUNCTION INDICATOR LAMP 26
33 V36 20TN/RD* VEHICLE SPEED CONTROL (VACUUM) 27.63
34 C13 2 0 D B / 0 R * A/C COMPRESSOR CLUTCH RELAY GROUND 31
35 K35 2 0 6 Y / Y L X EXHAUST GAS RECIRCULATION SOLENOID 29
36 —
37 T18 2 0 L G / 0 R X TRANSMISSION F E E D 25
38 K 3 8 18GY FUEL INJECTOR
#5 24
39 K39 2 0 G Y / R D X I D L E AIR CONTROL MOTOR
(OPTNT 29 VIEWED FROM
40 K40 18BR/WT X IDLE AIR CONTROL
MOTOR ( C L O S E ) 29 TERMINAL END
41 K41 18BK/DG * HEATED OXYGEN SENSOR 31
42 T54 1 8 V T TRANSMISSION TEMP SENSOR 10.27
43 G21 2 0 G Y / L B X TACHOMETER 29
44 K44 2 0 T N / Y L X CAMSHAFT P O S I T I O N SENSOR 27
45 D20 2V, SERIAL COMMUNICATION INTERFACE [RECEIVE) 25
46 — — —
47 G7 2 0 W T / 0 R X V E H I C L E SPEED SENSOR 30
48 V31 2 0 B R / R D * V E H I C L E SPEED CONTROL ( S E T ) 32.63
49 V 3 2 20YL/RDX VEHICLE SPEED CONTROL (IGNITION) 32.63
50 V33 20WT/LG X VEHICLE SPEED CONTROL (RESUME) 32,63
51 K51 20DB/YLX AUTOMATIC SHUT DOWN RELAY 24
52 K52 20PK/BKX EVAP/PURGE SOLENOID 29
53 V35 20LG/RDX VEHICLE SPEED CONTROL (VENT) 27,63
54 K54 200R/BKX TRANSMISSION OVERDRIVE SOLENOID 10,25
54 654 200R/BKX SHIFT INDICATOR LAMP 10,25
55 T60 2 0 B R TRANSMISSION OVERDRIVE SOLENOID 10,23
56 6 2 4 2 0 G Y / P K X EMISSION MAINTENANCE LAMP 29
57 A142 1 6 D G / 0 R X I N J E C T O R / S E N S E / G E N E R A T O R F E E D 24
58 K58 1 8 B R / D B X F U E L INJECTOR U 6 24
59 K59 1 8 V T / B K X IDLE A I R CONTROL MOTOR LCLOSE, 29
60 K60 1 8 Y L / B K X IDLE AIR CONTROL MOTOR I CLOSE, 29

J948U-9

I Kl 18D6/RD* MAP SENSOR 37
2 K2 1 8 T N / B K X ENGINE COOLANT TEMPERATURE SENSOR 42
3 A14 16RD/WT* FUEL PUMP RELAY FEED 41
4 K4 2 0 B K / L B * SIGNAL REFERENCE 38
5
6 —
K6 2 0 V T / W T X —
5 VOLT OUTPUT —
37
8 — — —
9 F18 2 0 L 6 / B K X I G N I T I O N FEED 41
11 Z12 16BK/TN X POWER GROUND 39
12 111 1 6 B K / T N * POWER GROUND 39
13 K l 13 2 0 L B / B R X FUEL INJECTORS # 5 AND # 8 33
14 K l 14 2 0 Y L / W T * FUEL INJECTORS # 3 AND U 6 33
15 K l 1 5 20TN FUEL INJECTORS # 4 AND # 9 34
16 K l 1 6 20WT/DB X FUEL INJECTORS # 1 AND u 10 33
17 K18 1 8 R D / Y L * I G N I T I O N COIL ( 4 - P A C K ) 40
18 K43 2 0 D G / 6 Y * I G N I T I O N COIL ( 6 - P A C K ) 40
19 K19 2 0 B K / 6 Y * I G N I T I O N COIL ( 6 - P A C K ) 40
20 K20 18D6 VOLTAGE REGULATOR 41
21 K 2 1 16BK/RD X INTAKE A I R TEMPERATURE SENSOR 38
22 Kll 180R/DB* THROTTLE P O S I T I O N (SENSOR) 38
23 K141 18TN/WT* HEATED OXYGEN SENSOR 35
24 K24 2 0 6 Y / B K X DISTRIBUTOR IGNITION SENSOR ( B O 38
25 dll 20PK SERIAL COMMUNICATION INTERFACE 39
26
27 —
CIO 18BR
—
A / C DAMPED PRESSURE SWITCH —
34
28
29 —
V40 20WT/PK * —
STOP LAMP SWITCH —
42
30 T 4 1 20BK/WT * ENGINE STARTER RELAY 42
31 T18 2 0 L 6 / 0 R * TRANSMISSION TEMPERATURE LAMP 10,42
32 63 2 0 B K / P K X MALFUNCTION INDICATOR LAMP 42
33 V36 2 0 T N / R D * VEHICLE SPEED CONTROL (VACUUM) 37,63
34 C13 2 0 D B / 0 R X A/C COMPRESSOR CLUTCH RELAY GROUND 34
35 K35 2 0 6 Y / Y L * EXHAUST GAS RECIRCULATION SOLENOID 41
36 6 1 4 18PK/BK X TRANSMISSION TEMPERATURE LAMP 39
37 K137 20WT/BKX I G N I T I O N MODULE 39
38 K138 20BR/0RX I G N I T I O N MODULE 39
VIEWED FROM
39 K39 1 8 6 Y / R D X IDLE AIR CONTROL MOTOR (OPEN) 40
TERMINAL END
40 K40 18BR/WT X IDLE AIR CONTROL MOTOR (CLOSE) 40
41 K 4 1 18BK/DG X HEATED OXYGEN SENSOR 35
42 T 5 4 18VT TRANSMISSION TEMP SENSOR 10.37
43 621 2 0 6 Y / L B X TACHOMETER 40
44 K44 1 8 T N / Y L X CAMSHAFT P O S I T I O N SENSOR 37
45 D20 2 0 L 6 SERIAL COMMUNICATION INTERFACE (RECEIVE) 39
46
47 —
67 2 0 W T / O R X —
VEHICLE SPEED SENSOR —
36
48 V31 2 0 B R / R D X VEHICLE SPEED CONTROL ( S E T ) 40,63
49 V32 2 0 Y L / R D X VEHICLE SPEED CONTROL ( I G N I T I O N ) 40,63
50 V33 2 0 W T / L 6 X VEHICLE SPEED CONTROL (RESUME) 40,63
51 K51 2 0 D B / Y L X AUTOMATIC SHUT DOWN RELAY 41
52 K52 2 0 P K / B K X EVAP/PURGE SOLENOID 41
53 V35 2 0 L 6 / R D X VEHICLE SPEED CONTROL (VENT) 37,63
54 K54 2 0 0 R / B K X TRANSMISSION OVERDRIVE SOLENOID 10,39
55 T60 20BR TRANSMISSION OVERDRIVE SOLENOID 10,40
56 624 206Y/PK X EMISSION MAINTENANCE LAMP 40
57 A142 16DG/0RX INJECTOR/SENSE/GENERATOR FEED 34
58 K158 2 0 L 6 / B K X FUEL INJECTORS # 2 AND Ul 34
59 K59 18VT/BK X IDLE AIR CONTROL MOTOR | CLOSE) 40
60 K60 1 8 Y L / B K X IDLE AIR CONTROL MOTOR [CLOSE 40

BR 121 (8.0L ENGINE) J948W-9
CAV F CIRCUIT FUNCTION SHEET

1 Kl 20DG/RD* WATER I N FUEL SENSOR 45
2
— — —
3 AM 18RD/WT* FUEL PUMP RELAY FEED
4 K4 2 0 B K / L B * SIGNAL REFERENCE 45
5
6
—
K6 2 0 V T / W T * —
5 VOLT OUTPUT —
45
8 —
9 F 1 8 18LG/BK * I G N I T I O N FEED 43
10 T6 2 0 0 R / W T * TRANSMISSION OVERDRIVE SWITCH FEED 10.49
11 Z12 1 6 B K / T N * POWER GROUND 47
12 Z12 1 6 8 K / T N * POWER GROUND 47
13
14
—
—
—
— —
—
15 S22 2 0 0 R / B K * HEATED INTAKE RELAY U 2 43
IS S21 2 0 Y L / B K X HEATED INTAKE R E L A Y # 1 43
17
18 —
19 — — —
20 K20 18DG VOLTAGE REGULATOR 43
21 K21 16BK/RDX INTAKE AIR TEMPERATURE SENSOR 45
22 K22 200R/DB* THROTTLE P O S I T I O N (SENSOR) 45
23 — — —
24 K24 2 0 6 Y / B K t IGNITION SENSOR (B*) 45
25 0 2 1 20PK SERIAL COMMUNICATION INTERFACE 44
—
26
27 C20 — 18BR A / C DAMPED PRESSURE SWITCH
—
47
—
28
29 —
V40 20MT/PK t STOP LAMP SWITCH —
48
30 T 4 1 20BK/WT * ENGINE STARTER RELAY 48
30 Z12 20BK/TN * ENGINE STARTER RELAY 48
31 G14 18PK/BK t TRANSMISSION TEMPERATURE LAMP 47
32 63 2 0 B K / P K t MALFUNCTION INDICATOR LAMP 43
33 V36 2 0 T N / R D * VEHICLE SPEED CONTROL (VACUUM) 50.63
34 C13 2 0 D B / 0 R * A/C COMPRESSOR CLUTCH RELAY GROUND 47
35 686 18TN/0R* KNOCK SENSOR GROUND 44
36 685 180R/BK* WAIT TO START 44
37 T18 2 0 L 6 / 0 R X TRANSMISSION OVERHEATING LAMP 10.49
—
38 VIEWED FROM
39 — — TERMINAL END
40
41 — — —
42 T54 16VT TRANSMISSION TEMP SENSOR 10.49

43 G21 20GY/LB* TACHOMETER 43
44
45 D20
—
20LG —
SERIAL COMMUNICATION INTERFACE (RECEIVE) —
44
—
46
47 G7 2 0 W T / 0 R X
—
VEHICLE SPEED SENSOR —
46
48 V31 2 0 B R / R D X VEHICLE SPEED CONTROL ( S E T ) 50,63
49 V32 2 0 Y L / R D * VEHICLE SPEED CONTROL ( I G N I T I O N ) 50.63
50 V33 2 0 W T / L G * VEHICLE SPEED CONTROL (RESUME) 50.63
51 K51 2 0 D B / Y L * AUTOMATIC SHUT DOWN RELAY 44
52 — — —
53 V35 20L6/RD* VEHICLE SPEED CONTROL (VENT) 50.63
54 K54 200R/BK* TRANSMISSION OVERDRIVE SOLENOID 10.49
55 T60 20BR TRANSMISSION OVERDRIVE SOLENOID 10 4 9
56
57 A142 —
1 6 D G / 0 R * INJECTOR/SENSE/GENERATOR FEED
—
44
58
59
—
—
—
—
—
60
— —
—
J948W-9
(DIESEL ENGINE) BR 122

1 — — —
I
2 i
—
3 64 22DB FUEL TANK LEVEL GAUGE SENDING UNIT 90

4 L62 18BR/PK* RI6HT REAR STOP AND TURN LAMP 8 5 , 1 1 2
5 L63 18DG/RD t LEFT REAR STOP AND TURN LAMP 85,112
6 T6 220R/WT* TRANSMSSION OVERDRIVE SWITCH FEED 1 0 . 1 4 , 2 4 , 4 1 . 4 9
7 T18 22L6/0R* TRANSMISSION FEED j10.15.25.42.49
8 G20 2 2 V T / Y L * ENGINE COOLANT TEMPERATURE SENDING UNIT 51
9 621 226Y/LB* TACHOMETER 19.29.40.43
10 G24 226Y/PK* EMISSION MAINTENANCE LAMP 29.40
-BLACK
11 — —
12 — — —
13 — — —
14 C90 22L6 A/C SELECT 97
12- - 1 15 G3 22BK/PK* MALFUNCTION INDICATOR LAMP 16.26.42.43

24- -13
16 X3 20BK/RD* HORN RELAY COIL SWITCH 52
36- -25
16 X3 22BK/RD* HORN RELAY COIL SWITCH 52
— — —
40- -37 17
18 66 226Y ENGINE OIL PRESSURE SWITCH (LOW) 51
19 660 22GY/YL* ENGINE OIL PRESSURE SENDING UNIT 51
44- O -41
20 G7 22WT/0R* VEHICLE SPEED SENSOR 20.30.36
48- -45 20 67 20WT/0R* VEHICLE SPEED SENSOR 46

21 — — —
60- -49 22 LI 22VT/BK* BACK-UP LAMPS 12.106

72- -61
84- -73 23 A41 18YL ENGINE STARTER RELAY 7,9
— — —
24
25 — —
VIEWED FROM 26 6107 20BK/6YX 4WD LAMP 11,55.57

TERMINAL END 26 6107 22BK/GYX 4WD LAMP i ; . C2
( L E F T S I D E COWL 27 634 18RD/GYX HEADLAMP INDICATOR (HIGH BEAM) 6 7 . 6 9 . 7 1
REAR OF
INSTRUMENT PANEL) 28 69 226Y/BKX BRAKE WARNING LAMP SWITCH .,56,57.62
29 629 22BK/TN* WASHER FLUID LEVEL INDICATOR (LOW) 83
30 F18 22LG/BKX IGNITION FEED 7/JO,98
31 V30 20DB/RDX VEHICLE SPEED CONTROL FEED 63
32 Gil 22WT/BKX PARK BRAKE SWITCH 71.77
33 Zll 18BK/WT* SENSE GROUND 82
34 Ml 20PK DOME AND COURTESY LAMP 72.107.109
35 V40 22WT/PK* STOP LAMP SWITCH 16,26.42,48,76
36 Z6 18BK/0RX AIRBAG GROUND 53

37 V3 18BR/WTX WINDSHIELD WIPER (LOW SPEED) 84
38 L3 16RD/0RX HEADLAMP ( H I G H BEAM) 67.69,73
39 L4 16VT/WTX HEADLAMP (LOW BEAM) 67.69,73
84 WAY CONNECTOR INSTRUMENT PANEL

BR 123 TO HEADLAMP AND DASH WIRING J948W-9
\

40 L7 18BK/YL X TAIL.LICENSE,SIDE MARKER LAMPS 67.69,74
41 A20 18RD/DB X I G N I T I O N RUN 8.57.62
41 A20 18RD/DB X I G N I T I O N RUN 8
42 Al 12RD I G N I T I O N SWITCH FEED 4,7
43 A2 12PK/BK X I G N I T I O N SWITCH FEED 7,9
44 L9 18BK/VT X HAZARD FLASHER F E E D 5.6.85
45 V4 16RD/YL X WINDSHIELD WIPER (HIGH SPEED) 84
46 B108 18WT RWAL DUMP SOLENOID 55,57
47 A3 12RD/L6X HEADLAMP SWITCH FEED 4.71.75
48 A7 12RD/BK X FUSEBLOCK FEED 52.73,107,109
48 A7 12RD/BK X FUSEBLOCK FEED 73
49 12 18BK/L6X SENSOR GROUND 59.92.94,95
49 12 18BK/L6X SENSOR GROUND 59,92.94,95
50 619 22L6/RD X A N T I - L O C K BRAKE WARNING LAMP 60
51 8101 18L6/WTX RWAL I S O L A T E SOLENOID 55.57
52 Bill 22LB/BKX RWAL R E S E T SWITCH 55.57
X 53 Bl13 22RD/VT X REAR WHEEL SENSOR ( H I G H ) 56.58
X 54 B l 14
R46
22WT/VTX
18BR/LB X
REAR WHEEL SENSOR
FRONT RIGHT
(LOW)
IMPACT SENSOR
56,58
55 54
56 R47 18DB/LB X FRONT L E F T IMPACT SENSOR 54
57 R48 18TN FRONT RIGHT IMPACT SENSOR 54
58 R49 18LB FRONT L E F T IMPACT SENSOR 54
X TWISTED
INDICATES
PAIR
59 631 22VT/L6X INTAKE A I R TEMPERATURE SENSOR 82
60 632 22BK/LBX INTAKE AIR TEMPERATURE SENSOR (RETURN) 82
61 12 18BK/L6X SENSOR GROUND 95
62 LIO 22BR/L6X BACK-UP LAMP SWITCH FEED 7.12
63 — — —
64 V6 18DB/BK X WINDSHIELD WIPER MOTOR 84

65 V5 18D6/YLX WINDSHIELD WIPER MOTOR FEED 84
66 VIO 18BR WINDSHIELD WASHER 83
67 614 20PK/BK X TRANSMISSION TEMPERATURE LAMP 16.26.39.47.86
68 686 20TN/0RX SENSOR GROUND 44,86
69 L61 18L6/YLX L E F T FRONT TURN SIGNAL 67,69.85
70 L60 18TN/BKX RIGHT FRONT TURN SIGNAL 68.70.85
71 685 200R/BKX WAIT TO START 44.86
72 — — —
73 — — —
74 — — —
75 — — —
76 D12 220R ABS DATA L I N K (TXD) 61

77 Dll 22WT/RDX ABS DATA L I N K (RDX) 61
78 — — —
79 V31 22BR/RD X V E H I C L E SPEED CONTROL ( S E T ) 22.32.40.50,64

80 V32 22YL/RD X V E H I C L E SPEED CONTROL (IGNITION) 22.32.40.50,63.77
81 V33 22WT/L6X V E H I C L E S P E E D CONTROL (RESUME) 22.32.40.50.64
82 — — —
83 — — —
84 — — —
84 WAY CONNECTOR INSTRUMENT PANEL ,

J948W-9 TO HEADLAMP AND DASH WIRING I BR 124
f
1
2 —
—
—
—
—
3 64 22DB FUEL TANK LEVEL GAUGE SENDING UNIT 90

4 L62 18BR/PK* RI6HT REAR STOP AND TURN LAMP 8 5 . 1 1 2
5 L63 18DG/RDX L E F T REAR STOP -AND TURN LAMP 85 112
6 T6 220R/WTX TRANSMSSION OVERDRIVE SWITCH FEED 1 0 . 1 4 . 2 4 . 4 1 . 4 9

7 T18 22L6/0R* TRANSMISSION FEED 10.15.25.42.49
8 620 22VT/YL* ENGINE COOLANT TEMPERATURE SENDING UNIT 51

9 621 226Y/LB* TACHOMETER 19.29.40.43
10 624 226Y/PKX E M I S S I O N MAINTENANCE LAMP 29.40
11 — —
—
I -
13-
z •BLACK
12
24
12
13
14
15
—
—
C90 18L6
63 2 2 B K / P K *
—
—
A/C SELECT
MALFUNCTION INDICATOR LAMP
97
—
—
16.26.42.43
16 X3 2 2 B K / R D * HORN RELAY C O I L SWITCH 52

25- 36
17
18 66
—
22GY
—
ENGINE OIL PRESSURE SWITCH (LOW) 51

—
37- 40
19 660 226Y/YL* ENGINE OIL PRESSURE SENDING UNIT 51
20 67 22WT/0RX V E H I C L E SPEED SENSOR 20.30.36.46

41- O 44
45-
21
22
—
LI 18VT/BK*
—
BACK-UP LAMPS 12,106

—
48
23 A41 18YL ENGINE STARTER RELAY 7.9
49
61
60
72
24
— —
—
73 84 25
26
—
6107 20BK/6Y*
—
4WD LOCK LAMP
—
11.55.57
26 G107 20BK/6Y* 4WD LOCK LAMP 11.62
VIEWED FROM 27 634 18RD/6Y* HEADLAMP INDICATOR (HIGH BEAM) 6 7 . 6 9 , 7 1

TERMINAL END 27 634 20RD/6Y* HEADLAMP INDICATOR (HIGH BEAM) 6 9 . 7 1
( L E F T S I D E COWL 28 69 186Y/BK* 7.57
BRAKE WARNING LAMP SWITCH
REAR OF
INSTRUMENT P A N E L ) 28 69 206Y/BK* BRAKE WARNING LAMP SWITCH 7.56,62
29 629 18BK/TN* WASHER FLUID LEVEL INDICATOR (LOW) 83
30 F18 20L6/BKX IGNITION FEED 7,90,98
31 V30 20DB/RD* V E H I C L E S P E E D CONTROL F E E D 63
32 Gil 20WT/BK* PARK BRAKE SWITCH 71,77
33 Zll 18BK/WT* SENSE GROUND 82
34 Ml 20PK DOME AND COURTESY LAMP 72,107,109
35 V40 20WT/PK* STOP LAMP SWITCH 16.26,42.76
35 V40 22WT/PK* STOP LAMP SWITCH 16,26,42,48.76
36 Z6 18BK/0R* AIRBAG GROUND 53

37 V3 18BR/WT* WINDSHIELD WIPER (LOW SPEED) 84
38 L3 16RD/0R* HEADLAMP (HIGH BFAM) 67.69.73
39 L4 16VT/WT* HEADLAMP (LOW BEAM) 67,69,73
84 WAY CONNECTOR HEADLAMP AND DASH

BR 125 TO INSTRUMENT PANEL WIRING J948W-9

40 L7 18BK/YL* TAIL.LICENSE.SIDE MARKER LAMPS 67.69.74
41 A20 18RD/DB* I G N I T I O N RUN 8.57.62
41 A20 18RD/DB* I G N I T I O N RUN 8
42 Al 12RD I G N I T I O N SWITCH FEED 4.7
43 A2 12PK/BK* I G N I T I O N SWITCH FEED 7.9
44 L9 18BK/VT* HAZARD FLASHER F E E D 5,6.85
45 V4 18RD/YL* WINDSHIELD WIPER (HIGH SPEED) 84
46 8108 18WT RWAL DUMP SOLENOID 55,57
47 A3 12RD/L6X HEADLAMP SWITCH FEED 4,71,75
47 A3 12RD/L6* HEADLAMP SWITCH FEED 75
48 A7 12RD/BKX FUSEBLOCK FEED 52,73,107.109
49 Z2 18BK/L6* SENSOR GROUND 59.92.94.95
49 Z2 18BK/L6* SENSOR GROUND 59.92.94.95
50 619 20L6/RD X A N T I - L O C K BRAKE WARNING LAMP 60
51 B101 18L6/WTX RWAL I S O L A T E SOLENOID 55,57
52 Bill 18LB/BK X RWAL R E S E T SWITCH 55,57
X 53 Bl13 20RD/VT X REAR WHEEL SENSOR ( H I G H ) 56,58

54 Bl14 20WT/VT X REAR WHEEL SENSOR (LOW) 56,58
55 R46 18BR/LB X FRONT RIGHT IMPACT SENSOR 54
56 R47 18DB/LB X FRONT L E F T IMPACT SENSOR 54
57 R48 18TN FRONT RIGHT IMPACT SENSOR 54
58 R49 18LB FRONT L E F T IMPACT SENSOR 54
% INDICATES 631 18VT/L6X
59 INTAKE A I R TEMPERATURE SENSOR 82
TWISTED P A I R
60 632 18BK/LBX INTAKE AIR TEMPERATURE SENSOR (RETURN) 82
61 Z2 18BK/L6X SENSOR GROUND 95
62 LIO 20BR/L6X BACK UP LAMP SWITCH FEED 7,12
62 LIO 18BR/LGX BACK UP LAMP SWITCH FEED 7,12
—
63
64
—
V6 18DB/BKX
_—
WINDSHIELD WIPER MOTOR 84
65 V5 18DG/YLX WINDSHIELD WIPER MOTOR FEED 84
67 614 18PK/BK X - TRANSMISSION TEMPERATURE LAMP 16,26,39,47,86
68 686 18TN/0RX KNOCK SENSOR GROUND 44,86
69 L61 20L6/YLX L E F T FRONT TURN S I G N A L 67,69.85
70 L60 20TN/BKX RIGHT FRONT TURN SIGNAL 68,70.85
71 685 180R/BKX WAIT TO START 44,86
72 — —
—
73 — —
—
74 —
— —
75
76
—
D12 200R
—
ABS DATA L I N K (TXD)
—
61
77 Dll 20WT/RDX ABS DATA L I N K (RDX) 61
78
79
—
V31 20BR/RD X V E H I C L E SPEED CONTROL (SET)
—
22.32.40.50.64
80 V32 2 0 Y L / R D X V E H I C L E SPEED CONTROL (IGNITION) 22.32.40.50.63.77
81 V33 20WT/L6X V E H I C L E SPEED CONTROL (RESUME) 22.32.40.50.64
82 —
— —
83
— —
84 — —
—
84 WAY CONNECTOR HEADLAMP AND DASH
J948W-9 TO INSTRUMENT PANEL WIRING BR 126
HENG A | -
1
•1? Th
/ *r—u " T ^ y LIGHT GRAY
V I E W E D FROM
0 ooo O
(LEFT SIDE COWL)
T E R M I N A L END
1 1 4
\O o o o O
i G14 18PK/BKX TRANSMISSION LAMP 16,26,39,47,86
2 T6 200R/WTX TRANSMISSION OVERDRIVE SWITCH FEED 10,14.24.41,49
3 T18 20LG/0R* TRANSMISSION FEED 10.15,25,42,49
3.9L.5.2L.
3 G54 200R/BKX SHIFT INDICATOR LAMP 10.15.25
5 . 9 L ONLY
4 T41 20BK/WT* ENGINE STARTER RELAY 9,16,26.42.47
4 Z12 20BK/TN X POWER GROUND 9,16,26.42.47
5 Zll 16BK/WT X SENSE GROUND 35.48.82,98
6 A142 14DG/0RX INJECTOR/SENSE/GENERATOR FEED 22,25.32.34,36.44
7 C13 20DB/0RX A/C COMPRESSOR CLUTCH RELAY GROUND 22.31.34.47.98
8 K51 20DB/YLX AUTOMATIC SHUT DOWN R E L A Y 14.24.41.44.90
9 V40 20WT/PK X STOP LAMP SWITCH 16.26.42.48.76
10 T40 12BR ENGINE STARTER RELAY 9,47 DIESEL ONLY
U " "
^r— LIGHT GRAY
V I E W E D FROM 0 ooo O
T E R M I N A L END 1 1
O ooo O
V
10 6
1 G14 18PK/BKX TRANSMISSION LAMP 16,26,39.47,86
2 T6 220R/WTX TRANSMISSION OVERDRIVE SWITCH FEED 10.14,24.41,49
3 T18 22LG/0RX TRANSMISSION FEED 10,15,25.42,49
4 T41 22BK/WTX ENGINE STARTER RELAY 9.16.26.42.47
5 Zll 16BK/WT X SENSE GROUND 35,48,82,98
6 A142 14DG/0RX INJECTOR/SENSE/GENERATOR FEED 22,25,32.34.36.44
7 C13 22DB/0R X A/C COMPRESSOR CLUTCH RELAY GROUND 2 2 , 3 1 , 3 4 . 4 7 . 9 8
8 K51 22DB/YL X AUTOMATIC SHUT DOWN R E L A Y 14.24.41.44,90
9 V40 20WT/PK X STOP LAMP SWITCH 16.26.42,48.76
9 V40 22WT/PK X STOP LAMP SWITCH 16,26,42,48,76
10 T40 12BR ENGINE STARTER RELAY 9.47
BR 127 ENGINE CONNECTOR-A J948W-9

10 6
r? s i DARK GRAY ENG B -
VIEWED FROM
O ooo O
(LEFT SIDE COWL)
TERMINAL END
O oo o O
1 F18 18LG/BKX I G N I T I O N FEED 19,29.41.44,98
2 V31 20BR/RD * VEHICLE SPEED CONTROL (SET) 22.32.40.50,63
3 V32 2 0 Y L / R D * VEHICLE SPEED CONTROL ( I G N I T I O N ) 2 2 , 3 2 , 4 0 . 5 0 . 6 3 , 7 7
4 V33 20WT/LG* VEHICLE SPEED CONTROL (RESUME) 2 2 . 3 2 . 4 0 . 5 0 , 6 3
5 A14 16RD/WT* FUEL PUMP RELAY FEED 4.16,26,41.48
6 LI 18VT/BK* BACK-UP LAMPS 12
6 LI 18VT/BKX BACK-UP LAMPS 12
6 LI 18VT/BK* BACK-UP LAMPS 12 5.2L.5.9L ONLY
7 V35 20LG/RDX VEHICLE SPEED CONTROL. ( V E N T ) 1 7 , 2 7 , 3 7 , 5 0 . 6 3
8 G3 2 0 B K / P K X MALFUNCTION INDICATOR LAMP 16.26,42,43
9 V36 20TN/RDX VEHICLE SPEED CONTROL (VACUUM) 1 7 . 2 7 . 3 7 . 5 0 . 6 3
10 LIO 18BR/LG X BACK-UP LAMP SWITCH FEED 8,12
10 LIO 18BR/LG X BACK-UP LAMP SWITCH FEED 12
10 LIO 18BR/LG X BACK-UP LAMP SWITCH FEED 12 5.2L.5.9L ONLY
I* y •DARK GRAY
VIEWED FROM O ooo O
TERMINAL END
O ooo O
_. JT
10 6
1 F18 18LG/BKX I G N I T I O N FEED 19,29,41 44.98
2 V31 20BR/RD X VEHICLE SPEED CONTROL (SET) 22.32.40.50.63
3 V32 2 0 Y L / R D X VEHICLE SPEED CONTROL (IGNITION) 2 2 , 3 2 , 4 0 , 5 0 . 6 3 . 7 7
4 V33 20WT/LG X VEHICLE SPEED CONTROL (RESUME) 2 2 . 3 2 . 4 0 . 5 0 . 6 3
5 A14 16RD/WT X FUEL PUMP RELAY FEED 4,16,26.41.48
7 V35 20LG/RDX VEHICLE SPEED CONTROL (VENT) 1 7 , 2 7 , 3 7 , 5 0 . 6 3
8 G3 22BK/PKX MALFUNCTION INDICATOR LAMP 16,26,42,43
9 V36 20TN/RD X VEHICLE SPEED CONTROL (VACUUM) 1 7 . 2 7 . 3 7 . 5 0 . 6 3
10 L10 18BR/LG X BACK-UP LAMP SWITCH FEED 8.12
10 L10 18BR/LG X BACK-UP LAMP SWITCH FEED 12
J948W-9 ENGINE CONNECTOR-B BR 128

8W - 178 WiilNG DIAGRAMS
ENG C - 10 r? TI BLACK
O ooo O
(LEFT S I D E COWL) VIEWED FROM
TERMINAL END
^
O ooo O
u
1 G85 180R/BKX WAIT TO START 44.86 DIESEL ONLY
2 G21 20GY/LB % TACHOMETER 19.29.40.43

5.2L.5.9L.
3 G24 20GY/PK* EMISSION MAINTENANCE LAMP 29.40 8 . 0 L ONLY
4 G60 16GY/YL % ENGINE O I L PRESSURE SENDING UNIT 51
5 C90 18LG A/C SELECT 97
6 C3 18DB/BKX A / C COMPRESSOR CLUTCH F E E D 98
7 G20 18VT/YL* ENGINE COOLANT TEMPERATURE SENDING UNIT 51
8 G6 16GY ENGINE O I L PRESSURE SWITCH (LOW) 51
9 G7 20WT/0RX V E H I C L E SPEED SENSOR 20.30.36.46
10 G86 18TN/0R* SENSOR GROUND 44.86 DIESEL ONLY
O ooo O •BLACK
VIEWED FROM
TERMINAL END
O ooo O
n
10
1 685 180R/BK* WAIT TO START 44.86
2 621 22GY/LB* TACHOMETER 19.29.40,43
3 G24 226Y/PK* EMISSION MAINTENANCE LAMP 29.40
4 660 226Y/YLX ENGINE O I L PRESSURE SENDING UNIT 51
5 C90 18L6 A/C SELECT 97
6 C3 18DB/BK* A / C COMPRESSOR CLUTCH F E E D 98
7 620 22VT/YL* ENGINE COOLANT TEMPERATURE SENDING UNIT 51
8 66 22GY ENGINE O I L PRESSURE SWITCH (LOW) 51
9 67 22WT/0R* V E H I C L E S P E E D SENSOR 20.30.36.46
10 686 18TN/0RX SENSOR GROUND 44.86
BR 129 ENGINE CONNECTOR-C J948W-9

1 M2 2 0 Y L DOOR SWITCH GROUNDS 74
4 L7 18BK/YL * TAIL,LICENSE.SIDE MARKER LAMPS 74
5 L7 2 0 B K / Y L * TAIL.LICENSE.SIDE MARKER LAMPS 74
J948W-9 JOINT CONNECTOR A BR 130

V I E U E D FROM TERMINAL END

( L E F T S I D E COWL)
1 Ml 20PK DOME AND COURTESY LAMP 75
3 — —
4 F32 18PK/DB* STOP LAMP SWITCH FEED 75
10 — . —•
BR 131 JOINT CONNECTOR B J948W-9

BLACK 11
1
12 22
23 33

(LEFT SIDE COWL)

1 E2 220R DIMHABLE LAMP 77
2 E2 220R DIMMABLE LAMP 77
6 — —
7 — —
8 Gil 20WT/BK* PARK BRAKE SWITCH 77

9 Gil 22WT/BK * PARK BRAKE SWITCH 77
10 Gil 22WT/BK* PARK BRAKE SWITCH 77
11 Gil 22WT/BK * PARK BRAKE SWITCH 77
12 F12 22DB/WT* IGNITION RUN/START 76
16 — —
17 V32 20YL/RD* VEHICLE SPEED CONTROL (IGNITION) 77

20 G16 22BK/LB* BUZZER/CHI ME/PASSIVE RESTRAINT 76
21 G16 22BK/LB* BUZZER/CHIME/PASSIVE RESTRAINT 76
22 G16 22BK/LB * BUZZER/CHIME/PASSIVE RESTRAINT 76
23 G9 22GY/BK * BRAKE WARNING LAMP SWITCH 7
27 — —
28 LIO 22BR/LG* BACK-UP LAMP SWITCH FEED 7

29 LIO 22BR/LG* BACK-UP LAMP SWITCH FEED 7
30 LIO 22BR/L<5* BACK-UP LAMP SWITCH FEED 7
J948W-9 JOINT CONNECTOR C BR 132

i—GRAY
(RIGHT OF STEERING COLUMN

REAR OF INSTRUMENT PANEL)
1 B101 18LG/WT* RWAL ISOLATE SOLENOID 55.57
2 G19 22LG/RD* WARNING LAMP 55.57
3 A20 18RD/DBX I G N I T I O N RUN 55.57
3 A20 18RD/DBX I G N I T I O N RUN 55
4 G107 20BK/GYX 4WD LAMP 55.57
4 G107 20BK/GY* 4WD LAMP 55.57
5 Gil 22WT/BK* PARK BRAKE SWITCH 56,58
6 G9 2 2 G Y / B K X BRAKE WARNING LAMP SWITCH 56,58
7 V40 22WT/PK t STOP LAMP SWITCH 56,58
8 8 1 0 8 18WT RWAL DUMP SOLENOID 55.57
9 F32 20PK/DB * STOP LAMP SWITCH FEED 56.58
10 13 16BK/0R* INSTRUMENT PANEL GROUND 56.58
11 Bill 22LB/BKX RWAL RESET SWITCH 55.57
12 Bl12 20BK RWAL SERVICE TEST 56.58
13 B114 22WT/VT* REAR WHEEL SENSOR (LOW) 56.58
14 Bl13 22RD/VT* REAR WHEEL SENSOR (HIGH) 56.58
)j( I N D I C A T E S TWISTED PAIR
REAR WHEEL ANTI-LOCK CONTROL

BR 133 MODULE CONNECTOR j94 w-9
8
1 Bl13 20RD/VTX REAR WHEEL SENSOR (HIGH) 61
2 87 20WT RI6HT WHEEL SENSOR 61
3 B9 20RD L E F T WHEEL SENSOR 61

4 B1 IB 20GY PUMP RELAY 60
5 B5 2 0 V T / R D X PUMP/VALVE 59
6
—
X
7
8 G107 20BK/6YX
.
4WD LAMP
—
62
X 9 V40 20WT/PK X STOP LAMP SWITCH 62
X 10 012 200R DATA L I N K 61
11 Dll 20WT/RD X DATA L I N K 61
13 B47 2 0 R D / L B X YELLOW LAMP RELAY C O I L ( - ) 60
14 Bl14 20WT/VTX REAR WHEEL SENSOR (LOW) 61
lb B6 20WT/DBX RIGHT WHEEL SENSOR 61
IB B8 20RD/6YX LEFT WHEEL SENSOR 61
18 B18 20VT/L6X PUMP/VALVE 59
19 B19 2 0 L B PRESSURE LIMIT VALVE 60
20 11 1 8 B K / R D X GROUND 62
21
—
22
—
23
24 619 20L6/RDX WARNING LAMP
—
60
26
14 ~ep cga ega cjp ega ega cp eg- 25 69 2 0 G Y / B K X BRAKE WARNING LAMP SWITCH 62
1 26 B254 16D6/0RX P R E S S U R E L I M I T VALVE 60
LT 27
28
—
B252 18BR/TNX P R E S S U R E L I M I T VALVE

—
60
VIEWED FROM TERMINAL END 29
30 B248 16D6/WTX PUMP/VALVE

—
59
(LEFT FENDER S I D E S H I E L D )
31
• —
32
33 B249 18WT/TNX PUMP/VALVE

—
59
34 B120 14BR/WTX PUMP MOTOR F E E D 59

35 B243 16D6/BKX PUMP/VALVE 59
36
37 B245
•
18WT/L6X
•
PUMP/VALVE
—
59
% I N D I C A T E S TWISTED P A I R
ANTI-LOCK BRAKE
J948W-9 SYSTEM CONTROLLER BR 134
BLACK-
MULTF" I 1
FUNC
( B A S E OF
HHHHHLTlCElLl]
STEERING
COLUMN)
17 16
U LTH (^~^) LUI UB 0 nn
24 23 22 21 20 19 18
1 V9 18WT/BKX WINDSHIELD WIPER 84
2 V8 18VT WINDSHIELD WIPER 84
4 V6 16DB/BK* WINDSHIELD WIPER MOTOR 84
5 V4 16RD/YL* WINDSHIELD WIPER (HIGH S P E E D ) 84
7 V7 18D6/WT* WINDSHIELD WIPER (PARK) 84
8 V17 18D6 WINDSHIELD WIPER (INTERMITTENT) 84
9 V3 18BR/WT* WINDSHIELD WIPER (LOW S P E E D ) 84
10
11 L60 20TN/BKX RIGHT FRONT TURN S I 6 N A L 85
11 L60 18TN/BK * RI6HT FRONT TURN SIGNAL 85
12 L62 18BR/PK % RIGHT REAR STOP AND TURN LAMP 85
13 L19 18PK/WT X HAZARD FLASHER 85
14 L50 18WT/TN* STOP LAMP SWITCH 85
15 L63 18DG/RD * LEFT REAR STOP AND TURN LAMP 85
16 L61 20L6/YL* LEFT FRONT TURN SIGNAL 85
16 L61 18L6/YL* LEFT FRONT TURN SIGNAL 85
17 L6 20RD/6Y* TURN SIGNAL FLASHER 85
18 L4 16VT/WT* HEADLAMP (LOW BEAM) 73
19 L2 16L6 HEADLAMP DIMMER SWITCH F E E D 73
20 L3 16RD/0R* HEADLAMP (HIGH BEAM) 73
21 L20 16L6/WTX HEADLAMP DIMMER SWITCH F E E D 73
MULT I-FUNCTION
BR 135 SWITCH CONNECTOR J948W-9
WIRING DIAGRAMS 8W - 18i

TO BODY
1 F37 14RD/LB* POWER SEAT FEED 73,105
2 X57 20BR/LB* L E F T REAR SPEAKER (B — ) 91,94
3 Ml 18PK DOME AND COURTESY LAMP 7S.107.10f
4 12 1 8 B K / L G X SENSOR GROUND 95
BLACK
5 X51 2 0 B R / Y L * L E F T REAR SPEAKER (B+) 92.94
6 M3 2 2 P K / D B * CARGO LAMP GROUND 73.79
7 X58 20DB/0R* RIGHT REAR SPEAKER (B—). 91,94
8 M2 2 2 Y L DOOR AND L I F T GROUND SWITCHES 74.79
9 G10 2 0 L G / R D * S E A T B E L T WARNING SWITCH 108
9 G10 2 2 L G / R D X S E A T B E L T WARNING SWITCH 110
10 L50 18WT/TN* STOP LAMP SWITCH 64,115
11 X13 18BK/RD* NAME BRAND SPEAKER A M P L I F I E R B 94

VIEWED FROM TERMINAL END X52 20DB/WT* RIGHT REAR SPEAKER (B + ) 92,94
12
( L E F T S I D E OF
INSTRUMENT PANEL)

TO INSTRUMENT PANEL
1 F37 14RD/LBX POWER SEAT FEED 73.105
2 X57 18BR/LB* LEFT REAR SPEAKER (B—) 91.94

OH 3 Ml 18PK DOME AND COURTESY LAMP 79,107,109
-BLACK
12- OD 4 12 1 8 B K / L G X SENSOR GROUND 95
DD 5 X51 18BR/YL* L E F T REAR SPEAKER (B + ) 92.94
6 M3 2 0 P K / D B * CARGO LAMP GROUND 73.79

L
D 7 X58 18DB/0R* RIGHT REAR SPEAKER (B-) 91.94
DD 8 M2 2 0 Y L DOOR AND L I F T GROUND SWITCHES 74.79
9 G10 20L6/RD* S E A T B E L T WARNING SWITCH 108.110

OD
10 L50 18WT/TN % STOP LAMP SWITCH 64.115
11 X13 18BK/RD % NAME BRAND SPEAKER A M P L I F I E R B 94
12 X52 18DB/WT % RIGHT REAR SPEAKER (B + ) 92.94

J948W-9
BODY CONNECTOR BR 136
8W 186 WIRING DIAGRAMS
LT
DOOR 1 CAV CIRCUIT FUNCTION SHEET
1 G16 18BK/LB* BUZZER/CHIME 76.80.82
2 X13 18BK/RD* NAME BRAND SPEAKER AMPLIFIER 94
3 X53 18DG LEFT FRONT DOOR SPEAKER ( B + ) 94
3 X53 20DG LEFT FRONT DOOR SPEAKER (B + ) 92
TO INSTRUMENT PANEL
4 Ml 20PK DOME AND COURTESY LAMP 103.107.109
BLACK
5 P70 20WT POWER MIRROR MOTOR (RIGHT) 103
a
6 M2 18YL DOOR SWITCH GROUND 74.80.82
5 -p Q Q 3 - i
7 12 18BK/LG* SENSOR GROUND 93.95
8 X55 18BR/RD* LEFT FRONT DOOR SPEAKER ( B — ) 94
^ — ^
8 X55 20BR/RD* LEFT FRONT DOOR SPEAKER ( B — ) 91
9 P72 20YL/BK* POWER MIRROR MOTOR (RIGHT) 103
10 P74 20DB POWER MIRROR MOTOR (RIGHT) 104
(LEFT S I D E COWL)

TO LEFT DOOR 1 76.80.82
G16 22BK/LB* BUZZER/CHIME
BLACK
2 X13 18BK/RD* NAME BRAND SPEAKER AMPLIFIER B 94
3 X53 20DG LEFT FRONT DOOR SPEAKER (B + ) 92.94
10 .—j
O O 4 Ml 20PK DOME AND COURTESY LAMP 103.107.109
5-
O O 5 P70 20WT POWER MIRROR MOTOR (RIGHT) 103
6 M2 22YL DOOR SWITCH GROUND 74.80.82
7 Z2 18BK/LG* SENSOR GROUND 93.95
VIEWED FROM TERMINAL END 8 X55 20BR/RD* LEFT FRONT DOOR SPEAKER ( B - ) 91.94
9 P72 20YL/BKX POWER MIRROR MOTOR (RIGHT) 103
LEFT DOOR 1
BR 137 CONNECTOR J948W-9
LT
DOOR 2

TO INSTRUMENT PANEL
1 F35 16RD POWER DOOR LOCK SWITCH FEED 101
F21 14TN POWER WINDOW SWITCH 99 BLACK

2
3 016 14BR/WTX POWER WINDOW MASTER SWITCH 99
4 026 14VT/WT* POWER WINDOW MASTER SWITCH 99

q - i
5 P33 160R/BK X POWER DOOR LOCK MOTOR (LOCK) 102
6 P34 16PK/BK * POWER DOOR LOCK MOTOR (UNLOCK) 102 Q - 5

7 P35 160R/VT * POWER DOOR LOCK SWITCH (LOCK) 101 v v
8 P36 16PK/VT* POWER DOOR LOCK SWITCH (UNLOCK) 101
(LEFT SIDE COWL)
TO LEFT DOOR
BLACK
2 F21 14TN POWER WINDOW SWITCH 99
3 016 14BR/WT X POWER WINDOW MASTER SWITCH 99
4 Q26 14VT/WT* POWER WINDOW MASTER SWITCH 99
5 P33 160R/BK* POWER DOOR LOCK MOTOR (LOCK) 102
6 P34 16PK/BK X POWER DOOR LOCK MOTOR (UNLOCK) 102
7 P35 160R/VT X POWER DOOR LOCK SWITCH (LOCK) 101

8 P36 16PK/VT* POWER DOOR LOCK SWITCH (UNLOCK) 101
LEFT DOOR 2
J948W-9 CONNECTOR BR 138
RT
DOOR 1

TO INSTRUMENT PANEL
1 X13 18BK/RDX NAME BRAND SPEAKER A M P L I F I E R B 94
2 X54 18VT RIGHT FRONT DOOR SPEAKER (B+) 94
2 X54 20VT RIGHT FRONT DOOR SPEAKER (B+) 92
4 P72 2 0 Y L / B K * POWER MIRROR MOTOR (RIGHT) 104
18BK/LGX 93,95
i — D O Q Q-- 5 12 SENSOR GROUND
6 X56 18DB/RD* RIGHT FRONT DOOR SPEAKER (B-) 94
6 X56 20DB/RD* RIGHT FRONT DOOR SPEAKER (B—) 91

7 M2 18YL DOOR SWITCH GROUND 74,80,82
(RIGHT S I D E COWL)
TO RIGHT DOOR
BLACK
1 X13 18BK/RD* NAME BRAND SPEAKER A M P L I F I E R B 94
2 X54 20VT RIGHT FRONT DOOR SPEAKER (B + ) 92.94
4 P72 2 0 Y L / B K * POWER MIRROR MOTOR (RIGHT) 104
5 12 18BK/LG* SENSOR GROUND 93.95
6 X56 20DB/RD* RIGHT FRONT DOOR SPEAKER (B—) 91.94

VIEWED FROM TERMINAL END 7 M2 2 2 Y L DOOR SWITCH GROUND 74.80,82
RIGHT DOOR 1
BR 139 CONNECTOR J948W-9
RT
OOOR 2
2 — TO INSTRUMENT PANEL
BLACK
4 016 14BR/WT* POWER WINDOW MASTER SWITCH 99
5 Q26 14VT/WT* POWER WINDOW MASTER SWITCH 99
8 P36 16PK/VTX POWER DOOR LOCK SWITCH (UNLOCK) 101
7 F35 16R0 POWER DOOR LOCK SWITCH FEED 101
8 P33 160R/BK* POWER DOOR LOCK MOTOR (LOCK) 102 VIEWED FROM TERMINAL END
9 P34 16PK/BK* POWER DOOR LOCK MOTOR (UNLOCK) 102
10 P35 160R/VT X POWER DOOR LOCK SWITCH (LOCK) 101
CAV CIRCUIT FUNCTION SHEET TO R I 6 H T DOOR
1 BLACK
4 016 14BR/WTX POWER WINDOW MASTER SWITCH 99
5 026 14VT/WTX POWER WINDOW MASTER SWITCH 99
6 P36 16PK/VT X POWER DOOR LOCK SWITCH (UNLOCK) 101
8 P33 160R/BK* POWER DOOR LOCK MOTOR (LOCK) 102

9 P34 16PK/BK* POWER DOOR LOCK MOTOR (UNLOCK) 102
10 P35 160R/VT X POWER DOOR LOCK SWITCH ( L O C K ) 101
RIGHT DOOR 2
J948W-9 CONNECTOR BR 140
13 BLACK
A.
•ooooo
• • • • • •
•••••••
I n n n n n n n

( D I R E C T CONNECT TO CONSOLE)
2 L7 2 0 B K / Y L X TAIL, LICENSE. S I D E MARKER LAMPS 81
2 L7 1 8 B K / Y L * TAIL, LICENSE. S I D E MARKER LAMPS 81
3 —
4 G32 22BK/LB* AIR TEMP SENSOR (RETURN) 81
5 G31 22VT/LG* A I R TEMPERATURE SENSOR 81
6 M2 2 2 Y L DOOR SWITCH GROUND 81
8 —
9 Zll 20BK/WTX S E N S E GROUND 81
10 —
11 Z4 18BK ROOF GROUND 81
OVERHEAD CONSOLE
BR 141 CONNECTOR J948M-9
o
FUSES
B FUSELINK ALT ( 1 2 0 AMP TYPE C)
BATTERY ALT C FUSELINK 1 ( 5 0 AMP)
O FL ALT O FUSELINK 2 ( 4 0 AMP)
FUSELINK 3 ( 4 0 AMP)
TRAILER
FL 1
PARK
FL
ABS
5 1 85 1 FUSELINK 5 ( 4 0 AMP)
1 30 | 7 "si
7 FUSELINK 6 ( 4 0 AMP)
FL 2 FL 6
AJ
IGN RUN HD/LP 1 8G | FUSELINK 7 ( 3 0 AMP)
FL 3 FL 7 HORN
IGN ACC TRAILER
~85l
FUSE B ( 2 0 AMP)
FL 4 FL 8 30 7 FUSE C ( 1 5 AMP)
ENG FUEL A.
"861
ABS PUMP ABS YELLOW LP A / C CLUTCH
E3D 1 85 I 1 85 1
1
30
l7
AJLJ
1 30 | 7
A.
1 1 7
30 | A 7j
m LJBJ 1 86 |
STARTER FUEL PUMP ASD
[ 851 •El
30 30 W 30
1
JLAJLJ Ail
861 3D "^861
J948W-9 POWER DISTRIBUTION CENTER BR 142

VIEWED FROM
TERMINAL END

2 P72 20YL/BKX POWER MIRROR MOTOR (RIGHT) 103

5 P75 20DB/WT* POWER MIRROR MOTOR (LEFT) 103
6 P71 20YL POWER MIRROR MOTOR (LEFT) 103
7 P73 20YL/PK* POWER MIRROR MOTOR (LEFT) 103
8 13 18BK/0R* INSTRUMENT PANEL GROUND 103

8 Z3 18BK/0R* INSTRUMENT PANEL GROUND 103
POWER MIRROR
BR 143 SWITCH CONNECTOR J948W-9
• ENGINES 9 - 1
ENGINES
CONTENTS
page page
3.9L ENGINE SERVICE PROCEDURES 17 5.9L ENGINE SERVICE PROCEDURES 71

5.2L ENGINE SERVICE PROCEDURES 44 8.0L ENGINE SERVICE PROCEDURES 97
5.9L (DIESEL) ENGINE SERVICE ENGINE DIAGNOSIS 5
PROCEDURES 123 STANDARD SERVICE PROCEDURES 1
STANDARD S E R V I C E P R O C E D U R E S
INDEX
page page
Engine Performance (Gasoline Engines) 2 Hydrostatic Lock 4
Form-ln-Place Gaskets (Gasoline Engines) 1 Measuring with Plastigage 3
Honing Cylinder Bores 2 Repair Damaged or Worn Threads ............. 4
FORM-IN-PLACE GASKETS (GASOLINE ENGINES) between smooth machined metallic surfaces. I t will
There are several places where form-in-place gas not cure i f left i n the uncovered tube. DO NOT use
kets are used on the engine. DO NOT use form-in- on flexible metal flanges.
place gasket m a t e r i a l unless specified. Care
SURFACE PREPARATION
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor Parts assembled with form-in-place gaskets may be
tance. Too thin a bead can result i n leakage while too disassembled without unusual effort. I n some in
much can result i n spill-over. A continuous bead of stances, i t may be necessary to lightly tap the part
the proper width is essential to obtain a leak-free with a mallet or other suitable tool to break the seal
joint. between the mating surfaces. A flat gasket scraper
Two types of form-in-place gasket materials are may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
used i n the engine area (Mopar Silicone Rubber Ad
hesive Sealant and Mopar Gasket Maker). Each have Scrape or wire brush all gasket surfaces to remove
different properties and cannot be used interchange all loose material. Inspect stamped parts to ensure
ably. gasket rails are flat. Flatten rails with a hammer on
a flat plate, i f required. Gasket surfaces must be free
MOPAR SILICONE RUBBER A D H E S I V E of oil and dirt. Make sure the old gasket material is
SEALANT removed from blind attaching holes.
Mopar Silicone Rubber Adhesive Sealant, normally
GASKET APPLICATION
black i n color, is available in 3 ounce tubes. Moisture
in the air causes the sealant material to cure. This Assembling parts using a form-in-place gasket re
material is normally used on flexible metal flanges. quires care.
It has a shelf life of 1 year and will not properly cure Mopar Silicone Rubber Adhesive Sealant should be
if over aged. Always inspect the package for the ex applied i n a continuous bead approximately 3 mm
piration date before use. (0.12 inch) i n diameter. A l l mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
MOPAR GASKET MAKER inch) drop is placed i n the center of the gasket con
Mopar Gasket Maker, normally red i n color, is tact area. Uncured sealant may be removed with a
available i n 6 cc tubes. This anaerobic type gasket shop towel. Components should be torqued i n place
material cures i n the absence of air when squeezed while the sealant is still wet to the touch (within 10
9 - 2 ENGINES •
minutes). The use of a locating dowel is recom (k) I f the same cylinder(s) repeat an abnormally
mended during assembly to prevent smearing the low reading, i t could indicate the existence of a
material off location. problem i n the cylinder.
Mopar Gasket Maker should be applied sparingly The recommended compression pressures are
to one gasket surface. The sealant diameter should to be used only as a guide to diagnosing engine
be 1.00 mm (0.04 inch) or less. Be certain the mate problems. A n engine should NOT be disassem
rial surrounds each mounting hole. Excess material bled to determine the cause of low compression
can easily be wiped off. Components should be unless some malfunction is present.
torqued i n place within 15 minutes. The use of a lo (4) Clean or replace spark plugs as necessary. Ad
cating dowel is recommended during assembly to pre just gap (refer to Group 8D, Ignition System for gap
vent smearing the material off location. adjustment and torque).
(5) Test resistance of spark plug cables (refer to
ENG11E PERFORMANCE (GASOLINE ENGINES) Group 8D, Ignition System).
To provide best vehicle performance and lowest ve (6) Inspect the primary wire. Test coil output volt
hicle emissions, i t is most important that the tune-up age, primary and secondary resistance. Replace parts
be done accurately. Use the specifications listed on as necessary (refer to Group 8D, Ignition System and
the Vehicle Emission Control Information label found make necessary adjustment).
on the engine compartment hood.
(7) Set ignition timing to specifications (refer to
(1) Test cranking amperage draw (refer to Group
Specification Label on engine compartment hood).
8B, Battery/Starter/Generator Service for the proper
procedures). This step does not apply to 8.0L engine.
(2) Tighten the intake manifold bolts (refer to (8) Perform a combustion analysis.
Group 11, Exhaust System and Intake Manifold for (9) Test fuel pump for pressure and vacuum (refer
the proper specifications). to Group 14, Fuel System for the proper specifica
(3) Perform cylinder compression test: tions).
(a) Check engine oil level and add oil, i f neces (10) Inspect air filter element (refer to Group 0,
sary. Lubrication and Maintenance for the proper proce
(b) Drive the vehicle until engine reaches normal dure).
operating temperature. (11) Inspect crankcase ventilation system (refer to
(c) Select a route free from traffic and other Group 0, Lubrication and Maintenance for the proper
forms of congestion, observe all traffic laws and procedure).
briskly accelerate through the gears several times. (12) For emission controls, refer to Group 25,
The higher engine speed may help clean out valve Emission Controls System for service procedures.
seat deposits which can prevent accurate compres (13) Inspect and adjust accessory belt drives (refer
sion readings. to Group 7, Cooling System for the proper adjust
ments).
CAUTION: DO NOT overspeed the engine. (14) Road test vehicle as a final test.
(d) Remove all spark plugs from engine. As spark HONING CYLINDER BORES
plugs are being removed, check electrodes for ab Before honing, stuff plenty of clean shop towels un
normal firing indicators—fouled, hot, oily, etc. der the bores and over the crankshaft to keep abra
Record cylinder number of spark plug for future sive materials from entering the crankshaft area.
reference. (1) Used carefully, the Cylinder Bore Sizing Hone
(e) Disconnect coil wire from distributor or from C-823 equipped with 220 grit stones, is the best tool
both coil packs (V-10) and secure to good ground to for this job. I n addition to deglazing, i t will reduce
prevent a spark from starting a fire. taper and out-of-round as well as removing light
(f) Be sure throttle blades are fully open during scuffing, scoring or scratches. Usually a few strokes
the compression check. will clean up a bore and maintain the required lim
(g) Insert compression gage adaptor into the its.
No.l spark plug hole. Crank engine until maximum
pressure is reached on gauge. Record this pressure CAUTION: DO NOT u s e rigid type hones to remove
as N o . l cylinder pressure. cylinder wall glaze.
(h) Repeat Step 3g for all remaining cylinders.
(i) Compression should not be less than 689 kPa (2) Deglazing of the cylinder walls may be done i f
(100 psi) and not vary more than 172 kPa (25 psi) the cylinder bore is straight and round. Use a cylin
from cylinder to cylinder. der surfacing hone, Honing Tool C-3501, equipped
(j) I f cylinder(s) have abnormally low compres with 280 grit stones (C-3501-3810). 20-60 strokes, de
sion pressures, repeat steps 3a through 3h. pending on the bore condition, will be sufficient to
• ENGINES 9-3
provide a satisfactory surface. Using honing oil and the crankshaft. Place a minimum of 0.254 mm
C-3501-3880 or a light honing oil available from ma (0.010 inch) shim between the bearing shell and the
jor oil distributors. adjacent bearing cap. Tighten the bolts to 18 N-m (13
ft. lbs.) torque.
CAUTION: DO NOT use engine or t r a n s m i s s i o n oil, • CHECK N O . l BEARING? Shim No.2 main bear
mineral spirits or kerosene. ing.
• CHECK NO.2 B E A R I N G ; Shim N o . l and No.3
(3) Honing should be done by moving the hone up main bearing.
and down fast enough to get a Crosshatch pattern. • CHECK NO.3 BEARINGs Shim No.2 and No.4
The hone marks should INTERSECT at 50° to 60° main bearing.
for proper seating of rings (Fig. 1). • CHECK NO.4 BEARINGs Shim No.3 main bear
ing (3.9L). Shim No.3 and No.5 main bearing (5.2L,
5.9L, 8.0L and 5.9L-Diesel).
• CHECK NO.5 BEARINGs Shim No.4 main bear
ing (5.2L and 5.9L). Shim No.4 and No.6 main bear
ing (8.0L and 5.9L-Diesel).
• CHECK NO.6 B E A R I N G : Shim No.5 main bear
ing (8.0L). Shim No.5 and No.7 main bearing (5.9L-
Diesel).
• C H E C K NO.7 B E A R I N G : Shim No.6 main bear
ing (5.9L-Diesel).
R e m o v e a l l s h i m s before a s s e m b l i n g e n g i n e .
M E T H O D - 2 (ALTERNATIVE)—The weight of
the crankshaft is supported by a jack under the coun
terweight adjacent to the bearing being checked.
(3) Place a piece of Plastigage across the entire
width of the bearing cap shell (Fig. 2). Position the
Fig. 1 Cylinder Bore Crosshatch Pattern
Plastigage approximately 6.35 mm (1/4 inch) off cen
(4) A controlled hone motor speed between 200 and ter and away from the oil holes. I n addition, suspect
300 RPM is necessary to obtain the proper cross- areas can be checked by placing the Plastigage i n
hatch angle. The number of up and down strokes per that area. Tighten the bearing cap bolts of the bear
minute can be regulated to get the desired 50° to 60° ing being checked to 115 N-m (85 ft. lbs.) torque. D O
angle. Faster up and down strokes increase the cross- N O T rotate t h e c r a n k s h a f t o r t h e P l a s t i g a g e
hatch angle. may be smeared, giving inaccurate results.
(5) After honing, i t is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
MEASURING WITH PLASTIGAGE

CRANKSHAFT MAIN BEARING CLEARANCE
Engine crankshaft bearing clearances can be deter
mined by use of Plastigage, or equivalent. The follow L90
ing is the recommended procedures for the use of
Plastigage: Fig. 2 Placement of Plastigage in Bearing Shell
(1) Remove oil film from surface to be checked. (4) Remove the bearing cap and compare the width
Plastigage is soluble i n oil. of the flattened Plastigage with the scale provided on
(2) The total clearance of the main bearings can the package (Fig. 3). Plastigage generally comes i n 2
only be determined by removing the weight of the scales (one scale is i n inches and the other is a met
crankshaft. This can be accomplished by either of two ric scale). Locate the band closest to the same width.
methods: This band shows the amount of clearance. Differ
M E T H O D - 1 (PREFERRED)—Shim the bear ences i n readings between the ends indicate the
ings adjacent to the bearing to be checked. This will amount of taper present. Record all readings taken
remove the clearance between upper bearing shell (refer to Engine Specifications).
I - 4 ENGINES •
• Tapping the hole with a special Heli-Coil Tap, or
equivalent.
• Installing an insert into the tapped hole.
This brings the hole back to its original thread
size.
CAUTION: B e sure that the tapped holes maintain

the original center line.
Heli-Coil tools and inserts are readily available

RN861 from automotive parts jobbers.
Fig. 3 Clearance Measurement
HYDROSTATIC LOCK
(5) Plastigage is available i n a variety of clearance When an engine is suspected of hydrostatic lock
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range (regardless of what caused the problem), follow the
is usually the most appropriate for checking engine steps below.
bearing clearances. (1) Perform the Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be (2) Disconnect the negative cable from the battery.
determined by use of Plastigage, or equivalent. The (3) Inspect air cleaner, induction system and in
following is the recommended procedures for the use take manifold to ensure system is dry and clear of
of Plastigage: foreign material.
(1) Remove oil film from surface to be checked. (4) Place a shop towel around the spark plugs or
Plastigage is soluble i n oil. fuel injectors (diesel engine) to catch any fluid that
(2) Place a piece of Plastigage across the entire may possibly be under pressure i n the cylinder head.
width of the bearing cap shell (Fig. 2). Position the Remove the spark plugs or fuel injectors (diesel en
Plastigage approximately 6.35 mm (1/4 inch) off cen gines).
ter and away from the oil holes. I n addition, suspect
areas can be checked by placing the Plastigage i n the CAUTION: DO NOT u s e the starter motor to rotate
suspect area. the crankshaft. Severe damage could occur.
(3) The crankshaft must be turned until the con
necting rod to be checked starts moving toward the (5) With all spark plugs and injectors (diesel en
top of the engine. Only then should the rod cap with gine) removed, rotate the crankshaft using a breaker
Plastigage i n place be assembled. Tighten the rod cap bar and socket.
nut to 61 N-m (45 ft. lbs.) torque. DO NOT rotate (6) Identify the fluid i n the cylinder(s).
the crankshaft or the Plastigage may be (7) Make sure all fluid has been removed from the
smeared, giving inaccurate results. cylinders.
(4) Remove the bearing cap and compare the width (8) Repair engine or components as necessary to
of the flattened Plastigage with the scale provided on prevent this problem from occurring again.
the package (Fig. 3). Plastigage generally comes i n 2 (9) Squirt engine oil into the cylinders to lubricate
scales (one scale is i n inches and the other is a met the walls. This will prevent damage on restart.
ric scale). Locate the band closest to the same width. (10) Install new spark plugs or fuel injectors (die
This band shows the amount of clearance. Differ sel engine). Tighten the spark plugs to 41 N-m (30 ft.
ences i n readings between the ends indicate the lbs.) torque. Tighten the fuel injector nuts to 60 N-m
amount of taper present. Record all readings taken (44 ft. lbs.) torque.
(refer to Engine Specifications). (11) Drain engine oil. Remove and discard the oil
(5) Plastigage is available i n a variety of clearance filter.
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range (12) Install the drain plug. Tighten the plug to 34
is usually the most appropriate for checking engine N-m (25 ft. lbs.) torque.
bearing clearances. (13) Install a new oil filter.
(14) Fill engine crankcase with the specified
REPAIR DAMAGED OR WORN THREADS amount and grade of oil (refer to Group 0, Lubrica
Damaged or worn threads can be repaired. Essen tion and Maintenance).
tially, this repair consists of: (15) Connect the negative cable to the battery.
• Drilling out worn or damaged threads. (16) Start the engine and check for any leaks.
ENGINES 9- 5
E N G I N E DIAGNOSIS
Engine diagnosis is helpful i n determining the Refer to the Service Diagnosis—Performance chart
causes of malfunctions not detected and remedied by- and the Service Diagnosis—Mechanical chart for pos
routine tune-ups. sible causes and corrections of malfunctions. Refer to
These malfunctions may be classified as either per Group 14, Fuel System for the fuel system diagnosis.
formance (e.g., engine idles rough and stalls) or me
chanical (e.g., a strange noise).
SERVICE DIAGNOSIS (GASOLINE ENGINES} - PERFORMANCE
CONDITION POSS1MJ CAUSiS CORRECTION
ENGINE WILL N O T START 1. Weak battery. 1. Test battery specific gravity. Charge or replace as necessary.
2. Corroded or loose battery 2. Clean and tighten battery connections. Apply a coat of light
connections. mineral grease to the terminals.
. 3. Faulty starter. 3. Refer to Group 8A, Battery/Starter/Charging System
Diagnostics.
4. Moisture on ignition wires and 4. Wipe wires and cap clean and dry.
distributor cap.
5. Faulty ignition cables. 5. Replace any cracked or shorted cables.
6. Faulty coil or control unit. 6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. Incorrect spark plug gap. 7. Set gap (refer to Group 8D, Ignition System).
8. Incorrect ignition timing. 8. RefertoGroup 8D, Ignition System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel filter.
10. Faulty fuel pump. 10. Install new fuel pump (refer to Group 14, Fuel System).
11. Faulty connectors for crankshaft 11. Rebuild or replace the connectors.
or camshaft position sensors.
ENGINE STALLS OR 1. Idle speed set too low. 1. RefertoGroup 14, Fuel System.
ROUGH IDLE 2. Idle mixture too lean or too rich. 2. RefertoGroup 14, Fuel System.
3. Leak in intake manifold. 3. Inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 11, Exhaust System & Intake
Manifold).
4. Worn or burned distributor rotor. 4. Install new distributor rotor.
5. Incorrect ignition wiring. 5. Install correct wiring.
6. Faulty coil. 6. Test and replace, if necessary (refertoGroup 8D, Ignition
System).
7. EGR valve leaking. 7. Test and replace, if necessary (refertoGroup 25, Emissions
Control System).
J9409-91
9 - 6 ENGINES
SERVICE DIAGNOSIS (GASOLINE ENGINES) - PERFORMANCE (CONT.)
CONOITION POSSIBLE CAUSES CORRECTION
E N G I N E LOSS OF POWER 1. Incorrect ignition timing. 1. Refer to G r o u p 8 D , Ignition System,

2. W o r n or burned distributor rotor. 2. Install new distributor rotor.
3. W o r n distributor shaft. 3. Remove a n d repair distributor (refer to G r o u p 8 D , Ignition
System).
4 . Dirty or incorrectly gapped spark 4. Clean plugs a n d set g a p (refer to G r o u p 8 D , Ignition System).
plugs.
5. Dirt or water in fuel system. 5. Clean system a n d replace fuel filter.
6. Faulty fuel pump. 6. Install new fuel pump.
7. Incorrect valve timing. 7. Correct valve timing.
8. Blown cylinder head gasket. 8. Install new cylinder head gasket.
9. Low compression. 9. Test compression o f each cylinder.
10. Burned, w a r p e d or pitted valves. 10. Install new valves.
11. Plugged or restricted exhaust 11. Install new parts, as necessary.
system.
12. Faulty ignition cables. 12. Replace any cracked or shorted cables.
13. Faulty coil. 13. Test a n d replace, as necessary (refer to G r o u p 8 D , Ignition
14. Faulty crankshaft or camshaft System).
sensor. 14. Replace sensor.
E N G I N E MISSES O N 1. Dirty or g a p set too w i d e in spark 1. Clean spark plugs and set g a p (refer to G r o u p 8 D , Ignition
ACCELERATION plug. System).
2. Incorrect ignition timing. 2. Refer to G r o u p 8 D , Ignition System.
3. Dirt in fuel system. 3. Clean fuel system.
4 . Burned, w a r p e d or pitted valves. 4. Install new valves.
5. Faulty coil. 5. Test a n d replace, if necessary, (refer to G r o u p 8 D , Ignition
System).
E N G I N E MISSES AT HIGH 1. Dirty or gap set too w i d e in spark 1. Clean spark plugs a n d set g a p (refer to G r o u p 8 D , Ignition
SPEED plug. System).
2. W o r n distributor shaft. 2. Remove a n d repair distributor (refer to G r o u p 8 D , Ignition
System).
3. W o r n or burned distributor rotor. 3. Install new distributor rotor.
4 . Faulty coil. 4 . Test a n d replace, as necessary (refer to G r o u p 8 D , Ignition
System).
5. Incorrect ignition timing. 5. Refer to G r o u p 8 D , Ignition System.
6. Dirty injector in throttle body. 6. Clean injector.
7. Dirt or water in fuel system. 7. Clean system and replace fuel filter.
J9409-92
• ENGINES 9 - 7
SERVICE DIAGNOSIS (GASOLINE ENGINES) - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION

NOISY VALVES 1. High or low oil level in 1. Check for correct oil level (refer to Group 0, Lubrication and
crankcase. Maintenance).
2. Thin or diluted oil. 2. Change oil (refer to Group 0, Lubrication and Maintenance).
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash adjusters. 4. Clean hydraulic tappets/hydraulic lash adjusters.
5. Bent push rods. 5. Install new push rods.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new hydraulic tappets/hydraulic lash adjusters.
8. Worn valve guides. 8. Ream and install new valves with oversize stems.
9. Excessive runout of valve seats on 9. Grind valve seats and valves.
valve faces.
CONNECTING ROD 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0, Lubrication and
NOISE Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct clearance. Repair as necessary.
5. Connecting rod journal out-of- 5. Replace crankshaft or grind journals.
round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0, Lubrication and
Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
4. Excessive bearing clearance. 4. Measure bearings for correct clearance. Repair as necessary.
5. Excessive end play. 5. Check No. 3 main bearing for wear on flanges.
6. Crankshaft journal out-of-round, 6. Grind journals or replace crankshaft.
worn.
7. Loose flywheel or torque 7. Tighten to correct torque.
converter.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and check main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
7. Excessive bearing clearance. 7. Measure bearings for correct clearance.
8. Oil pump relief valve stuck. 8. Remove valve and inspect, clean and install.
9. Oil pump suction tube loose, bent 9. Remove oil pan and install new tube, if necessary.
or cracked.
10. Oil pump cover warped or 10. Install new oil pump.
cracked.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace the gasket.
gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the part.
metal part.
OIL PUMPING AT RINGS; 1. Worn, scuffed or broken rings. 1. Hone cylinder bores and install new rings.
SPARK PLUGS FOULING 2. Carbon in oil ring slot. 2. Install new rings.
3. Rings fitted too tightly in grooves. 3. Remove the rings. Check grooves. If grooves are not proper
width, replace piston.
4. Worn valve guides. 4. Ream guides and replace valves with oversize valves and seals.
5. Replace gasket and tighten intake manifold to proper torque.
5. Leaking intake gasket.
6. Replace seals.
6. Leaking valve guide seals.
7. Seat valve guide seals or replace, as needed
7. Dislodged valve guide seals.
J9209-58
9 - 8 ENGINES — •
S E R V I C E DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE
CONDBTICM POSSIBLE CAUSES CORRECTION
ENGINE WILL N O T Starting motor operating, but R e m o v e t h e s t a r t e r m o t o r . Check f o r b r o k e n f l y w h e e l t e e t h o r

C R A N K OR CRANKS not cranking the engine. a broken storting motor spring.
SLOWLY
Crankshaft rotation restricted. Rotate the engine to check for rotational resistance.
Starting circuit connections Clean and tighten connections.

loose or corroded.
N e u t r a l safety switch or starter C h e c k s t a r t e r r e l a y f o r s u p p l y v o l t a g e a n d p r o p e r o p e r a t i o n of

relay inoperative. neutral safety. Replace defective parts.
Battery charge l o w . C h e c k b a t t e r y v o l t a g e . R e p l a c e b a t t e r y if a c h a r g e c a n n o t b e
held.
No voltage to starter solenoid. C h e c k v o l t a g e t o s o l e n o i d . If n e c e s s a r y , r e p l a c e t h e s o l e n o i d .
Solenoid or starting motor Replace starter m o t o r .

inoperative.
ENGINE CRANKS, No fuel in supply tank. Fill fuel supply.

BUT WILL N O T Electrical fuel shutdown solenoid Check for loose wires and verify that the fuel shutdown solenoid is
START—NO SMOKE not open. functioning.
FROM EXHAUST
Air intake or exhaust plugged. Remove the obstruction.
Fuel filter plugged. Drain fuel/water separator and replace fuel filter.
Excessive fuel inlet restriction. Check fuel inlet restriction. Correct cause.
Injection pump not getting fuel or Check fuel flow/bleed fuel system.
fuel is aerated.
Inoperative lift pump. Check fuel flow and pressure.
One or more injectors worn or not Check/replace bad improperly operating injectors.
operating properly.
Worn or inoperative injection pump. Visually check fuel delivery with an externally connected injector to one of
the pump outlets. Repair or replace the pump if fuel is not being delivered.
Internal pump timing incorrect. Time the pump (refer to Group 14, Fuel System).
Camshaft out of time. Check/correct gear train timing alignment.
ENGINE H A R D T O Incorrect starting procedure. The fuel shutoff solenoid control must be in the run position. Ensure proper
procedure is being used.
START, OR WILL
N O T START—SMOKE Cranking speed too slow. (a) V e r i f y t h a t t h e t r a n s m i s s i o n is n o t e n g a g e d .
FROM EXHAUST
(b) C h e c k t h e b a t t e r y , s t a r t i n g m o t o r a n d l o o k f o r l o o s e o r
corroded w i r i n g connections.
(c) R o t a t e t h e e n g i n e w i t h a b a r r i n g t o o l (Snap-On T o o l SP371,

MTE N o . 3377462, o r e q u i v a l e n t ) t o check f o r i n t e r n a l
rotational resistance.
Cold starting aids not working Verify the aids are o p e r a t i n g . Repair/replace inoperative
or are needed. parts.
Intake heater system not V e r i f y s y s t e m is w o r k i n g . R e p a i r / r e p l a c e i n o p e r a t i v e p a r t s .

working.
Insufficient i n t a k e air. Inspect or replace filter and check for obstructions to the air
supply tube.
A i r in the fuel s y s t e m or the Check the f l o w t h r o u g h the filter and b l e e d the s y s t e m . Locate
f u e l s u p p l y is i n a d e q u a t e . and eliminate the air source.
J9409-109
• ENGINES 9 - 9
S E R V I C E DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)
CONDITION POSSIBLE CAUSES COMMOTION
ENGINE H A R D TO Fuel list pump Inoperative. Measure lift pump outlet pressure. If needed repair or replace pump.
START, OR WILL
N O T START—SMOKE Injection p u m p t h r o t t l e l i n k a g e Visually check the l i n k a g e . T i g h t e n / r e p l a c e l i n k a g e .
FROM EXHAUST loose o r d a m a g e d .
(Cont'd)
Contaminated fuel. Verify by operating the engine w i t h clean fuel from a
t e m p o r a r y t a n k . Check for presence of gasoline. Drain and
flush fuel supply tanks. Replace f u e l / w a t e r s e p a r a t o r filter.
Fuel screen plugged. Check fuel screen.
One or more injectors worn or not Check/replace bad improperly operating injectors.
operating properly.
Worn or inoperative injection pump. Visually check fuel delivery with an externally connected injector to one of
the pump outlets. Repair or replace the pump if fuel is not being delivered.
Injection p u m p o u t o f t i m e . C h e c k / t i m e t h e p u m p ( r e f e r t o G r o u p 14, F u e l S y s t e m ) .
Valves incorrectly adjusted. Adjust valves.
Engine compression low. Check compression to identify the problem.
E N G I N E STARTS, Idle s p e e d t o o l o w f o r t h e Adjust the idle speed.

BUT WILL N O T accessories.
KEEP R U N N I N G
Intake air or exhaust system Visually check for exhaust restriction a n d inspect t h e air i n t a k e .
restricted. Repair/replace restricting parts.
A i r in the fuel system or the Check t h e f l o w t h r o u g h the filter a n d b l e e d t h e s y s t e m . Locate

f u e l s u p p l y is i n a d e q u a t e . and eliminate the air source.
Fuel w a x i n g d u e t o e x t r e m e l y Verify by inspecting the fuel filter. Clean t h e s y s t e m a n d use

cold w e a t h e r . c l i m a t i z e d fuel. Replace f u e l / w a t e r s e p a r a t o r f i l t e r . Check fuel
heater for proper operation.
Contaminated fuel. Verify by operating the engine w i t h clean fuel f r o m a temporary

supply t a n k . Check for presence of gasoline. Replace f u e l / w a t e r
separator filter.
S U R G I N G (SPEED If t h e c o n d i t i o n occurs a t i d l e , Adjust the idle.

CHANGE) t h e i d l e s p e e d is s e t t o o l o w f o r
the accessories.
High pressure fuel leak. Inspect/correct leaks in the high pressure lines. Fittings a n d
delivery valve sealing washers.
O n e or more injectors w o r n o r C h e c k / r e p l a c e the i n o p e r a t i v e injectors.

not o p e r a t i n g p r o p e r l y .
Improperly o p e r a t i n g injection Repair or replace the injection pump.

pump.
ROUGH IDLE Cold engine. Refer t o t r o u b l e s h o o t i n g logic f o r i n t a k e m a n i f o l d h e a t e r s y s t e m

(IRREGULARLY FIRING (see G r o u p 1 1 , E x h a u s t S y s t e m I I n t a k e M a n i f o l d )
OR ENGINE S H A K I N G )
I d l e s p e e d too l o w f o r t h e
Adjust idle speed.
accessories.
Engine mounts damaged o r

Repair or replace mounts.
loose.
J9409-110
9 - 10 ENGINES •
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)
mmmnm POSSIBLE CAUSES CORRECTION
ROUGH IDLE High pressure fuel leaks. Correct leaks in t h e high pressure lines, fittings o r d e l i v e r y
(IRREGULARLY FIRING valves.
OR ENGINE SHAKING)
(Cont'd) A i r in t h e fuel s y s t e m . Bleed t h e fuel s y s t e m a n d e l i m i n a t e t h e source of t h e air.
Sticking n e e d l e v a l v e i n a n Check a n d replace t h e injector w i t h the s t i c k i n g n e e d l e v a l v e .

injector.
ENGINE RUNS ROUGH Fuel injection lines l e a k i n g . Correct leaks in t h e high pressure lines, fittings, injector sealing
OR MISFIRING w a s h e r s o r d e l i v e r y valves.
A i r in t h e fuel o r t h e fuel Check t h e f l o w t h r o u g h t h e filter a n d b l e e d t h e s y s t e m . Locate

supply is i n a d e q u a t e . a n d e l i m i n a t e t h e a i r source.
C o n t a m i n a t e d fuel. Verify b y o p e r a t i n g t h e e n g i n e w i t h clean fuel f r o m a t e m p o r a r y

supply t a n k . Check f o r presence of gasoline. Replace f u e l / w a t e r
s e p a r a t o r filter.
Incorrect v a l v e adjustment. Check f o r a b e n t push r o d a n d adjust valves. Replace push r o d ,

if necessary.
Injection p u m p t i m i n g incorrect. C h e c k / t i m e p u m p (refer t o G r o u p 14, Fuel System).
I m p r o p e r l y o p e r a t i n g injectors. Replace i n o p e r a t i v e injectors.
Defective injection p u m p Repair or replace injection pump.

(delivery valves).
Camshaft o u t of t i m e . Check/correct gear train timing alignment.
D a m a g e d camshaft o r t a p p e t s . Inspect camshaft v a l v e lift. Replace camshaft a n d t a p p e t s .
ENGINE RPM WILL N O T Engine o v e r l o a d e d . Verify h i g h idle s p e e d w i t h o u t l o a d . I n v e s t i g a t e o p e r a t i o n t o b e

REACH RATED SPEED sure correct g e a r is b e i n g used.
Improperly operating Verify e n g i n e s p e e d w i t h h a n d t a c h o m e t e r — c o r r e c t as r e q u i r e d .

tachometer.
Throttle linkage w o r n or Adjust l i n k a g e for stop-to-stop fuel c o n t r o l l e v e r t r a v e l . Replace

incorrectly adjusted. l i n k a g e if necessary.
Partially e n g a g e d mechanical A d j u s t a n d place s h u t d o w n l e v e r in t h e r u n p o s i t i o n .

shutdown lever.
I n a d e q u a t e fuel s u p p l y . Check t h e fuel f l o w t h r o u g h t h e s y s t e m t o locate t h e reason for

i n a d e q u a t e fuel s u p p l y — c o r r e c t as r e q u i r e d .
Air-fuel control leak. Check and repair leak. Check AFC tubing for obstruction.
I m p r o p e r l y o p e r a t i n g injection Repair or replace injection pump.
pump.
LOW POWER Fuel c o n t r o l l e v e r not m o v i n g t o C h e c k / c o r r e c t for stop-to-stop t r a v e l .

full t h r o t t l e .
Shutdown lever Check t o see if t h e s h u t d o w n l e v e r is i n r u n p o s i t i o n .

partially engaged.
High o i l l e v e l . Check/correct oil level.
Engine o v e r l o a d e d . Check f o r a d d e d l o a d i n g f r o m accessories o r d r i v e n units, b r a k e s

d r a g g i n g a n d o t h e r changes i n v e h i c l e l o a d i n g . R e p a i r / r e p l a c e as
needed.
J9409-111
+ ENGINES 9 - 11
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)
CONDITION P O S S I B L E CAUSES €OBtftE€TION
LOW POWER Slow throttle response caused by Check for leaks and obstructions. Tighten the fittings. Repair or replace
(Cont'd) leaking or obstructed air fuel control the pump if the controls are not functioning.
tube or improperly operating
control in the pump.
Inadequate intake air flow. Inspect/replace air cleaner element. Look for other restrictions.
High pressure fuel leak. Inspect/correct leaks in the high pressure lines, fittings injector sealing
washers or delivery valve seals.
Inadequate fuel supply. Air in Check the flow through the filter to locate the source of the restriction.
the fuel. Check fuel pressure and inlet restriction.
Excessive exhaust restriction. Check/correct the restriction in the exhaust system.
High fuel temperature. Verify that fuel heater is off during warm weather. Check for a restricted
fuel drain manifold. Repair/replace as needed.
Poor quality fuel or fuel Verify by operating from a temporary tank with good fuel. Check for
contaminated with gasoline. presence of gasoline. Replace fuel/water separator filter.
Air leak between the turbocharger Check/correct leaks in hoses, gaskets, charge air cooler and around
and the intake manifold. mounting cap screws or through holes in the manifold cover.
Exhaust leak at the manifold or Check/correct leaks in the manifold or turbocharger gaskets. If manifold
turbocharger. is cracked, replace manifold.
Improperly operating turbocharger. Inspect/replace turbocharger.
Valve clearance incorrect. Check/adjust valves.
Worn or improperly operating Check/replace injectors.

injectors.
Incorrect injection pump timing. Verify injection pump timing (see Group 14, Fuel System).
Improperly operating injection pump. Repair or replace injection pump.
EXCESSIVE EXHAUST Engine running too cold (white Refer to troubleshooting logic for coolant temperature below normal
SMOKE smoke). (refer to Group 7, Cooling System). Inspect intake manifold heater for
proper operation.
Improper starting procedure Use proper starting procedure.

(white smoke).
Fuel supply inadequate. Check fuel supply pressure and inlet restriction.
Injection pump timing. Check and time pump (refer to Group 14, Fuel System.
Inadequate intake air. Inspect/change air cleaner. Look for other restriction. Check charge air
cooler for obstructions.
Air leak between turbocharger and Check/correct leaks in the air crossover tube, hoses, gaskets, mounting
intake manifold. capscrews or through holes in the manifold cover.
Exhaust leak at the manifold or Check/correct leaks in the manifold or turbocharger gaskets. If cracked
turbocharger. replace manifold.
Improperly operating turbocharger. Inspect/replace turbocharger.
J9409-112
9 - 12 ENGINES
SERVICE DIAGNOSIS (DIESEL ENGINE) • PERFORMANCE (CONT.)
CONDITIO!! POSSIBLE C A U S E S CORRECTION
EXCESSIVE EXHAUST More than one sealing washer Check a n d r e m o v e e x t r a washer.

SMOKE ( C o n t ' d ) under a n injector.
Improperly operating injectors. Check a n d replace inoperative injectors.
Improperly operating or over- Repair or replace injection pump.

fueled injection p u m p .
Piston r i n g s n o t s e a l i n g P e r f o r m b l o w - b y c h e c k . C o r r e c t as r e q u i r e d .
(blue smoke).
E N G I N E WILL N O T Fuel shutoff solenoid inoperative. Stop the engine mechanically with lever on the fuel pump. Check/replace
SHUT-OFF fuel shutoff solenoid.
Engine r u n n i n g o n fumes d r a w n C h e c k t h e a i r i n t a k e ducts f o r t h e s o u r c e o f t h e f u m e s .
into the air intake. W A R N I N G : In case o f e n g i n e r u n a w a y d u e t o f l a m m s b l e fumes
f r o m g a s o l i n e s p i l l s o r t u r b o c h a r g e r o i i l e a k s b e i n g sucked i n t o t h e
e n g i n e , s h u t o f f e n g i n e i g n i t i o n s w i t c h first t h e n us© ® C 0 2 ©r d r y
c h e m i c a l t y p e f i r e e x t i n g u i s h e r and direct the spray under the front -
b u m p e r t o r e m o v e o x y g e n s u p p l y . T h e e n g i n e a i r i n t a k e is o n t h e
p a s s e n g e r s i d e b e h i n d the b u m p e r . T h e fire e x t i n g u i s h e r must b e
d i r e c t e d a t this location f o r e m e r g e n c y shutdown conditions.
Fuel injection pump malfunction. Repair or replace fuel pump.
C O O L A N T TEMPERA Low c o o l a n t l e v e l . (a) C h e c k c o o l a n t l e v e l . A d d c o o l a n t , if n e c e s s a r y .

TURE A B O V E N O R M A L
(b) L o c a t e a n d c o r r e c t t h e s o u r c e o f t h e c o o l a n t l e a k . Refer t o
t r o u b l e s h o o t i n g l o g i c f o r c o o l a n t loss.
Incorrect/improperly operating R e p l a c e c a p w i t h t h e c o r r e c t r a t i n g for t h e s y s t e m .

pressure cap.
High lube oil level. C h e c k / d r a i n oil t o correct level.
Loose d r i v e b e l t o n w a t e r Check/replace belt or belt tensioner.

pump/fan.
Inadequate air flow t o the C h e c k / r e p a i r r a d i a t o r c o r e , f a n s h r o u d a n d f a n c l u t c h as

radiator. required.
Radiator fins plugged. Blow debris from fins.
Collapsed radiator hose. Replace t h e hose.
Improperly operating tempera Verify that t h e gauge a n d temperature sensor a r e accurate.

ture sensor/gauge. R e p l a c e g a u g e / s e n s o r , if b a d .
Improperly operating, incorrect Check a n d replace t h e thermostat.

or n o t h e r m o s t a t .
Air in the cooling system. (a) M a k e s u r e t h e f i l l r a t e is n o t b e i n g e x c e e d e d a n d t h e c o r r e c t

v e n t e d t h e r m o s t a t is i n s t a l l e d .
(b) C h e c k f o r l o o s e h o s e c l a m p s . T i g h t e n if l o o s e .
(c) If a e r a t i o n c o n t i n u e d , c h e c k f o r a c o m p r e s s i o n l e a k t h r o u g h
the head gasket.
Inoperative w a t e r pump. Check a n d replace t h e w a t e r pump.
Incorrect injection p u m p timing. Verify p u m p timing marks a r e aligned. C h e c k / t i m e t h e injector

p u m p ( r e f e r t o G r o u p 7, C o o l i n g S y s t e m ) .
J9409-113
• ENGINES 9 - 13
SERVICE DIAGNOSIS (DIESEL ENGINE) • PERFORMANCE (CONT.)
C O O L A N T TEMPERA O v e r f u e l e d injection p u m p . Repair or replace the injection pump.

TURE A i O V E N O R M A L
(Cont'd) Plugged cooling passages in Flush t h e s y s t e m a n d f i l l w i t h c l e a n c o o l a n t .
radiator, head, head gasket or
block.
Engine o v e r l o a d e d . V e r i f y t h a t t h e e n g i n e l o a d r a t i n g is n o t b e i n g e x c e e d e d .
C O O L A N T TEMPERA Too m u c h a i r f l o w a c r o s s t h e C h e c k / r e p a i r v i s c o u s f a n as r e q u i r e d .
TURE BELOW N O R M A L radiator.
Incorrect thermostat, b r o k e n Check a n d replace thermostat.

thermostat jiggle pin or
contamination in thermostat.
T e m p e r a t u r e sensor or g a u g e V e r i f y t h a t t h e g a u g e a n d s e n s o r a r e a c c u r a t e . If n o t , r e p l a c e
inoperative. gauge/sensor.
C o o l a n t n o t f l o w i n g by Check a n d clean coolant passages.

t e m p e r a t u r e sensor.
J9409-114
9 - 14 ENGINES •
SERVICE DIAGNOSIS (DIESEL ENGINE) - MECHANICAL
LUBRICATING OIL Low oil level. (a) C h e c k a n d f i l l w i t h c l e a n e n g i n e oil.

PRESSURE L O W
(b) C h e c k f o r a s e v e r e e x t e r n a l o i l l e a k t h a t c o u l d r e d u c e t h e
pressure.
O i l viscosity thin, d i l u t e d o r V e r i f y t h e c o r r e c t o i l is b e i n g u s e d . C h e c k for o i l d i l u t i o n . Refer

w r o n g specification. to C o n t a m i n a t e d Lube O i l (Engine Diagnosis—Mechanical).
Improperly operating pressure V e r i f y t h e p r e s s u r e s w i t c h is f u n c t i o n i n g c o r r e c t l y . If n o t ,

switch/gauge. replace switch/gauge.
Relief valve stuck open. Check/replace valve.
Plugged oil filter. Change oil filter. O i l filter change interval may need to be
revised.
If cooler was r e p l a c e d , s h i p p i n g C h e c k / r e m o v e shipping plugs.

p l u g s left i n c o o l e r .
If p u m p r e p l a c e d , f o u r c y l i n d e r V e r i f y t h a t t h e c o r r e c t p u m p is i n s t a l l e d . If n o t , i n s t a l l a n o i l
oil p u m p installed in a six p u m p for a six c y l i n d e r engine.
cylinder engine.
Loose o r m i s s i n g c u p p l u g s . Check a n d r e p l a c e c u p p l u g s .
Worn oil pump. Check a n d r e p l a c e o i l p u m p .
Suction t u b e l o o s e o r s e a l Check a n d replace seal.

leaking.
Loose m a i n b e a r i n g c a p . Check a n d i n s t a l l n e w b e a r i n g s a n d t i g h t e n c a p t o p r o p e r t o r q u e .
W o r n bearings or w r o n g Inspect a n d r e p l a c e c o n n e c t i n g r o d o r m a i n b e a r i n g s . C h e c k a n d
bearings installed. replace piston cooling nozzles.
J9109-237
1
• ENGINES 9-15
S E R V I C E DIAGNOSIS (DIESEL ENGINE) - MECHANICAL (CONT.)
LUBRICATING OIL Pressure s w i t c h / g a u g e not Verify the pressure switch is functioning correctly. If not,
PRESSURE T O O HIGH operating properly. replace s w i t c h / g a u g e .
Engine r u n n i n g t o o cold. Refer t o Coolant T e m p e r a t u r e Below N o r m a l (Engine Diagnosis—

Performance)
O i l viscosity too thick. M a k e sure the correct oil is b e i n g used. Refer t o G r o u p O ,

Lubrication a n d M a i n t e n a n c e .
O i l pressure r e g u l a t o r valve Check a n d replace valve, a n d / o r oil cooler cover.

stuck closed or binding.
LUBRICATING OIL LOSS External leaks. Visually inspect for o i l leaks. Repair as r e q u i r e d .
Crankcase being overfilled. Verify t h a t t h e correct dipstick is b e i n g used.
Incorrect oil specification or (a) M a k e s u r e t h e correct o i l is b e i n g used.

viscosity.
(b) Look for reduced viscosity f r o m dilution w i t h f u e l .
(c) R e v i e w / r e d u c e t h e o i l change intervals.
O i l cooler leak. Check a n d replace t h e oil cooler.
High b l o w - b y forcing o i l o u t Check t h e b r e a t h e r t u b e a r e a for signs of o i l loss. Perform t h e

the breather. r e q u i r e d repairs.
Turbocharger l e a k i n g oil to t h e Inspect t h e a i r ducts for evidence of o i l transfer.

air intake. Repair as r e q u i r e d .
Worn valve seals. Inspect a n d replace t h e v a l v e seals.
Piston rings not sealing (oil Perform b l o w - b y check. Repair as r e q u i r e d .

b e i n g consumed b y the engine).
COMPRESSION Air in the fuel system. Bleed t h e fuel s y s t e m (refer t o G r o u p 14, Fuel System).
KNOCKS
Poor q u a l i t y fuel. Verify b y o p e r a t i n g f r o m a t e m p o r a r y tank w i t h g o o d fuel. Clean
a n d flush t h e fuel supply tanks. Replace f u e l / w a t e r s e p a r a t o r
filter.
Engine o v e r l o a d e d . Verify that e n g i n e l o a d r a t i n g is not b e i n g e x c e e d e d .
Incorrect injection p u m p t i m i n g . Check a n d t i m e injection p u m p (refer to G r o u p 14, Fuel System).
I m p r o p e r l y o p e r a t i n g injectors. Check a n d r e p l a c e i n o p e r a t i v e injectors.
J9109-266
9 - 16 ENGINES •
S E R V I C E DIAGNOSIS (DIESEL ENGINE) • MECHANICAL (CONT.)
EXCESSIVE V I B R A T I O N Loose o r b r o k e n e n g i n e m o u n t s . Replace e n g i n e m o u n t s .
Damaged fan or improperly Check a n d replace the v i b r a t i n g components.

o p e r a t i n g accessories.
Improperly operating vibration Inspect/replace the vibration damper.

damper.
Improperly operating fan hub. Inspect/replace the fan hub.
Worn or damaged alternator Check/replace the alternator.

bearing.
Flywheel housing misaligned. Check/correct flywheel alignment.
Loose o r b r o k e n p o w e r I n s p e c t t h e c r a n k s h a f t a n d rods f o r d a m a g e t h a t causes a n

component. u n b a l a n c e . R e p a i r / r e p l a c e as r e q u i r e d .
Worn or unbalanced driveline Check/repair driveline components.

components.
EXCESSIVE E N G I N E D r i v e belt squeal, insufficient Check the tensioner a n d inspect the d r i v e belt. M a k e sure w a t e r
NOISES tension or abnormally high pump, tensioner pulley, fan hub and alternator turn freely.
loading.
Intake air or exhaust leaks. Refer t o E x c e s s i v e E x h a u s t S m o k e ( E n g i n e D i a g n o s i s —

Performance).
E x c e s s i v e v a l v e lash A d j u s t v a l v e s . M a k e s u r e t h e p u s h rods a r e n o t b e n t a n d r o c k e r
levers or adjusting s c r e w s a r e not severely w o r n . Replace bent
or severely w o r n pads.
Turbocharger noise. Check turbocharger i m p e l l e r and t u r b i n e w h e e l for housing

c o n t a c t . R e p a i r / r e p l a c e as r e q u i r e d .
Gear train noise. V i s u a l l y i n s p e c t a n d m e a s u r e g e a r b a c k l a s h . Replace g e a r s as

required.
Power function knock. Check/replace rod and main bearings.
ALTERNATOR N O T Loose o r c o r r o d e d b a t t e r y Clean/tighten battery connection.

C H A R G I N G OR I N connections.
SUFFICIENT C H A R G I N G
Alternator belt slipping. Check/replace belt tensioner. Check/replace belt.
A l t e r n a t o r pulley loose on Tighten pulley.

shaft.
Improperly operating Check/replace alternator.

alternator.
J9109-253
3.9L E N G I N E S E R V I C E P R O C E D U R E S
INDEX
page page
Camshaft 29 General Information 17
Crankshaft 34 Hydraulic Tappets . 25
Crankshaft Main Bearings 35 Oil Pan . 32
Crankshaft Rear Oil Seals 36 Oil Pump 32
Cylinder Block 37 Piston / Connecting Rod Assembly 33
Cylinder Head Cover 20 Rocker Arms 21
Cylinder Heads 21 Specifications—3.9L Engine 40
Distributor 31 Timing Chain Cover . 27
Engine Assembly 19 Valve Stem Seal / Spring Replacement 25
Engine Front Mounts 17 Valve Timing . 26
Engine Rear Mount 18 Valves / Valve Springs . 23
Front Crankshaft Oil Seal Replacement 29 Vibration Damper 26
GENERAL INFORMATION
The 3.9 Liter (238 CID) six-cylinder engine is a V-
Type, lightweight, single cam, overhead valve engine
with hydraulic roller tappets (Fig. 1). 000
Engine Type.... . . . . W V-6 OHV
Bora a n d Stroke.. 9 9 . 3 x 8 4 . 0 mm (3.91 x 3.31 in.)
Displacement 3.9L ( 2 3 8 c u . in.)
Compression Ratio ....9.1:1
Torque 312 N®m (230 ft. lbs.) O 3 200 rpm
#
Firing Order ......1-6-5-4-3-2

Uibrication Pressure Feed - Full Flow Filtration
Engine O i l Capacity 3.8L (4.0 Qts) with Filter
Cooling System Liquid Cooled - Forced Circulation J9309-26
Cooling Capacity 14.3L(15.1 Qts)
Cylinder Block C a s t Iron Fig. 2 Firing Order
Crankshaft .Nodular Iron
Cylinder H e a d C a s t Iron
X M 3,91 T XXXX XXXXXXXX
Combustion Chambers "Fast Bum" Design
Camshaft Nodular C a s t Iron
Pistons ....Aluminum Alloy w / S f r u t
X = Last Digit of Model Year
Connecting Rods Forged Steel M = Plant - M Mound Road
S Saltillo
J9409-9 T Trenton
K Toluca
3.9L = Engine Displacement
Fig. 1 Engine Description
T - Usage - T Truck
This engine is designed for unleaded fuel. XXXX • Month/Day
Engine lubrication system consists of a rotor type XXXXXXXX - Serial Code - Last 8 Digits of VIN No.
oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
J9209-72
3, 5 on the left bank and 2, 4, 6 on the right bank.
The firing order is 1-6-5-4-3-2 (Fig. 2). Fig. 3 Engine identification Number
The engine serial number is stamped into a ma
chined pad located on the left, front corner of the cyl ENGINE FRONT MOUNTS
inder block. When component part replacement is
REMOVAL
necessary, use the engine type and serial number for
(1) Disconnect the negative cable from the battery.
reference (Fig. 3).
(2) Position fan to assure clearance for radiator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake

manifold.
(3) Install engine support/lifting fixture.

(5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut (Fig. 4).
(6) Remove engine support bracket/cushion bolts
(Fig. 4). Remove the support bracket/cushion and
heat shields.
CUSHION
BRACKET
J9409-54
Fig. 5 Positioning Engine Front Mounts
J9409-52
Fig. 4 Engine Front Mounts

'INSTALLATION
(1) With engine raised SLIGHTLY, position the en
gine support bracket/cushion and heat shields to the
block. Install new bolts and tighten to 81 N-m (60 ft.
lbs.) torque.
(2) Install the thru-bolt into the engine support
bracket/cushion.
(3) Lower engine with support/lifting fixture while
guiding the engine bracket/cushion and thru-bolt into
support cushion brackets (Fig. 5).
(4) Install thru-bolt nuts and tighten the nuts to
(5) Lower the vehicle.
(6) Remove lifting fixture.
ENGINE REAR MOUNT Fig. 6 Engine Rear Support Cushion

(6) I f necessary, remove the bolts holding the
REMOVAL transmission support bracket to the transmission
(1) Raise the vehicle on a hoist. (Fig. 7).
(2) Position a transmission jack i n place.
(3) Remove support cushion stud nuts (Fig. 6). INSTALLATION
(4) Raise rear of transmission and engine (1) I f removed, position the transmission support
SLIGHTLY. bracket to the transmission. Install new attaching
(5) Remove the bolts holding the support cushion bolts and tighten to 88 N-m (65 ft. lbs.) torque.
to the transmission support bracket. Remove the sup
port cushion.
(15) Remove radiator (refer to Group 7, Cooling
System).
(16) Remove the generator with the wire connec
tions (refer to Group 8B, Battery/Starter/Generator
Service).
(17) Remove the air cleaner box.
(18) Disconnect the throttle linkage.
(19) Remove throttle body.
(20) Remove the intake manifold (refer to Group
11, Exhaust System and Intake Manifold).
(21) Remove the distributor cap and wiring.
(22) Disconnect the heater hoses.
(23) Disconnect the power steering hoses, i f
equipped.
(24) Disconnect the transmission cooler lines.
(25) Disconnect the fuel lines.
(26) On Manual Transmission vehicles, remove the
shift lever (refer to Group 21, Transmissions).
(27) Raise and support the vehicle on a hoist.
(28) Remove the drain plug and drain the engine
oil.
(29) Remove engine front mount thru-bolt nuts.
Fig. 7 Transmission Support Bracket (30) Remove the transmission cooler line brackets
(2) Position support cushion to transmission sup from oil pan.
port bracket. Install stud nuts and tighten to 41 N-m (31) Disconnect exhaust pipe at manifold.
(30 ft. lbs.) torque. (32) Disconnect the starter wires. Remove starter
motor (refer to Group 8B, Battery/Starter/Generator
(3) Using the transmission jack, lower the trans
Service).
mission and support cushion onto the crossmember
(33) Remove the dust shield and transmission
(Fig. 6).
cover.
(4) Install the support cushion bolts and tighten to (34) AUTOMATIC TRANSMISSION:
41 N-m (30 ft. lbs.) torque. (a) Support transmission. This will assure that
(5) Remove the transmission jack. the torque converter will remain i n proper position
(6) Lower the vehicle. in the transmission housing.
(b) Remove torque converter bolts.
ENGINE ASSEMBLY (c) Remove transmission bolts.
(35) M A N U A L TRANSMISSION?
REMOVAL (a) Remove the prop shaft (refer to Group 16,
(1) Remove the battery. Propeller Shaft).
(2) Drain cooling system (refer to Group 7, Cooling (b) Support transmission.
System for the proper procedure). (c) Remove rear transmission support.
(3) Remove the upper crossmember and top core (d) Remove the crossmember.
support. (e) Remove the clutch assembly and slave cylin
(4) Remove the transmission oil cooler. der.
(5) Discharge the air conditioning system, i f (f) Disconnect all wiring and connectors.
equipped (refer to Group 24, Heating and A i r Condi (g) Remove transmission bolts. Remove the
tioning for service procedures). transmission.
(6) Remove the serpentine belt (refer to Group 7, (h) Remove the bell housing.
Cooling System).
(i) Remove clutch assembly.
(7) Remove the A/C compressor with the lines at
(j) Remove flywheel and ring gear.
tached. Set aside.
(8) I f equipped, remove the condenser.
(37) Install a jack stand under the automatic
(9) Remove the washer bottle. transmission.
(10) Remove the radiator overflow bottle.
(11) Disconnect the top radiator hose. CAUTION: DO NOT lift the engine by the intake
(12) Remove the fan. manifold.
(13) remove the fan shroud.
(14) Disconnect the lower radiator hose. (38) Install an engine lifting fixture.
(39) Remove engine from vehicle and install engine (27) Install the fan shroud.
assembly on a repair stand. (28) Install the fan.
(29) Connect the top radiator hose.
INSTALLATION (30) Install the radiator overflow bottle.
(1) Remove engine from the repair stand and posi (31) Install the washer bottle.
tion i n the engine compartment. Position the thru- (32) I f equipped, install the condenser.
bolt into the support cushion brackets. (33) Install the A/C compressor with the lines at
(2) Install an engine support fixture. tached.
(34) Install the serpentine belt (refer to Group 7,
(4) AUTOMATIC TRANSMISSION:
Cooling System).
(a) Install transmission bolts.
(35) Evacuate and charge the air conditioning sys
(b) Install torque converter bolts. Tighten the
tem, i f equipped (refer to Group 24, Heating and Air
bolts to 31 N-m (270 i n . lbs.) torque.
(c) Remove the support from transmission. Conditioning for service procedures).
(5) M A N U A L TRANSMISSION: (36) Install the transmission oil cooler.
(a) Install flywheel and ring gear. (37) Install the upper crossmember and top core
(b) Install clutch assembly. support.
(c) Install bell housing. (38) Add coolant to the cooling system (refer to
(d) Install transmission and bolts. Group 7, Cooling System for the proper procedure).
(e) Connect all wiring and connectors. (39) Install the battery.
(f) Install clutch assembly and slave cylinder. (40) Warm engine and adjust.
(g) Install the crossmember. (41) Road test vehicle.
(h) Install rear transmission support.
(i) Remove support from transmission. CYLINDER HEAD COVER
(j) Install the prop shaft (refer to Group 16, Pro A steel backed silicon gasket is used with the cyl
peller Shaft). inder head cover (Fig. 1). This gasket can be used
(6) Install the dust shield and transmission cover. again.
(7) Install the starter and connect the starter wires
CYLINDER HEAD
(refer to Group 8B, Battery/Starter/Generator Ser COVER GASKET \
vice).
(8) Install exhaust pipe to manifold.
(9) Install the transmission cooler line brackets
from oil pan.
(10) Install engine front mount thru-bolt nuts.
Tighten the nuts.
(11) Install the drain plug and tighten to 34 N-m
(12) Lower the vehicle. J9209-104
(13) Remove engine lifting fixture.
(14) On Manual Transmission vehicles, install the Fig. 1 Cylinder Head Cover Gasket
shift lever (refer to Group 21, Transmissions). REMOVAL
(15) Connect the fuel lines. (1) Disconnect the negative cable from the battery.
(16) Connect the transmission cooler lines. (2) Disconnect closed ventilation system and evap
(17) Connect the power steering hoses, i f equipped. oration control system from cylinder head cover.
(18) Connect the heater hoses. (3) Remove cylinder head cover and gasket. The
(19) Install the distributor cap and wiring.
gasket may be used again.
(20) Install the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold). CLEANING
(21) Using a new gasket, install throttle body. Clean cylinder head cover gasket surface.
Tighten the throttle body bolts to 23 N-m (200 i n . Clean head rail, i f necessary.
lbs.) torque.
(22) Connect the throttle linkage. INSPECTION
(23) Install the air cleaner box. Inspect cover for distortion and straighten, i f nec
(24) Install the generator and wire connections (re essary.
fer to Group 8B, Battery/Starter/Generator Service). Check the gasket for use i n head cover installation.
(25) Install radiator (refer to Group 7, Cooling Sys I f damaged, use a new gasket.
tem).
(26) Connect the lower radiator hose.
INSTALLATION (3) Install rocker arm and pivot assemblies i n the
(1) The cylinder head cover gasket can be used same order as removed. Tighten the rocker arm bolts
again. Install the gasket onto the head rail. to 28 N-m (21 ft. lbs.) torque.
(2) Position the cylinder head cover onto the gas (4) Install cylinder head cover.
ket. Tighten the bolts to 11 N-m (95 i n . lbs.) torque. (5) Connect spark plug wires.
(3) Install closed crankcase ventilation system and
evaporation control system. CYLINDER HEADS
(4) Connect the negative cable to the battery. The alloy cast iron cylinder heads (Fig. 3) are held
i n place by 8 bolts. The spark plugs are located i n
ROCKER ARMS the peak of the wedge between the valves.
REMOVAL SPARK SPARK INTAKE

PLUGS PLUG VALVE
(1) Disconnect spark plug wires by pulling on the
boot straight out i n line w i t h plug.
(2) Remove cylinder head cover and gasket.
(3) Remove the rocker arm bolts and pivots (Fig.
2). Place them on a bench i n the same order as re
moved.
(4) Remove the push rods and place them on a
bench i n the same order as removed.
ROCKER
ARMS
EXHAUST INTAKE EXHAUST

VALVE VALVES VALVES J9309-35
Fig. 3 Cylinder Head Assembly

REMOVAL
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures).
(3) Remove the heat shields (Fig. 4).
J9209-66
Fig. 2 Rocker Arms

INSTALLATION
(1) Rotate the crankshaft until the "V6" mark lines
up with the TDC mark on the timing chain case
cover. This mark is located 147° ATDC from the N o . l
firing position.
CAUTION: DO NOT rotate or crank the engine dur Fig. 4 Exhaust Manifold Heat Shields
ing or immediately after rocker arm installation. Al
(4) Remove the intake manifold-to-generator
low the hydraulic roller tappets adequate time to
bracket support rod. Remove the generator.
bleed down (about 5 minutes).
(5) Remove closed crankcase ventilation system.
(2) Install the push rods i n the same order as re (6) Disconnect the evaporation control system.
moved. (7) Remove the air cleaner.
(9) Disconnect accelerator linkage and i f so PERFECT SEALANT N O . 5 PERFECT SEALANT N O . 5
equipped, the speed control and transmission kick- (OR EQUIVALENT) (OR EQUIVALENT)
down cables.
(10) Remove the return spring.
(11) Remove distributor cap and wires.
(12) Disconnect the coil wires.
(13) Disconnect heat indicator sending unit wire.
(14) Disconnect heater hoses and bypass hose.
(15) Remove cylinder head covers and gaskets.
(16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(17) Remove exhaust manifolds.
CYLINDER
(18) Remove rocker arm assemblies and push rods. HEAD GASKET J9309-39
Identify to ensure installation i n original locations.
(19) Remove the head bolts from each cylinder Fig. 5 Sealant Location on Cylinder Head Gasket
head and remove cylinder heads. Discard the cylin
der head gasket. (7) ® © FOUNDRY ©
^ ^ ^ MARK ^
(20) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge i f there is
any reason to suspect leakage. I f out-of-flatness ex
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length i n any direction, either replace head or
J9309-43
lightly machine the head surface.
FOR EXAMPLE:—A 305 mm (12 inch) span is
Fig. 6 Cylinder Head Bolt Tightening Sequence
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 CAUTION: When tightening the rocker arm bolts,
mm (0.009 inch). This amount of out-of-flat is accept make sure the piston in that cylinder is NOT at
able. T D C . Contact between the valves and piston could
The cylinder head surface finish should be occur.
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods. (5) Install push rods and rocker arm assemblies i n
their original position. Tighten the bolts to 28 N-m
INSTALLATION (21 ft. lbs.) torque.
(1) Apply Perfect Sealant No.5, or equivalent, to (6) Install the intake manifold and throttle body
both sides of the gasket (Fig. 5). assembly (refer to Group 11, Exhaust System and I n
(2) Position the new cylinder head gaskets onto the take Manifold).
cylinder block. (7) Install exhaust manifolds. Tighten the bolts
(3) Position the cylinder heads onto head gaskets and nuts to 34 N-m (25 ft. lbs.) torque.
and cylinder block. (8) Adjust spark plugs to specifications (refer to
(4) Starting at top center, tighten all cylinder head Group 8D, Ignition System). Install the plugs and
bolts, i n sequence, to 68 N-m (50 ft. lbs.) torque (Fig. tighten to 41 N-m (30 ft. lbs.) torque.
6). Repeat procedure, tighten all cylinder head bolts (9) Install coil wires.
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to (10) Connect heat indicator sending unit wire.
confirm that all bolts are at 143 N-m (105 ft. lbs.) (11) Connect the heater hoses and bypass hose.
torque. (12) Install distributor cap and wires.
(13) Hook up the return spring.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel lines.
(16) Install the generator and drive belt. Tighten
generator mounting bolt to 4 1 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys
tem for adjusting the belt tension.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi Fig. 7 Positioning Valve with Tool C-3973
tion and install cylinder head covers. Tighten the
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Install the heat shields. Tighten the bolts to
(23) Fill cooling system (refer to Group 7, Cooling
System for proper procedure).
(24) Connect the negative cable to the battery.
VALVES / VALVE SPRINGS
The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are
cast integral with the heads.
This procedure requires the removal of the cylinder
head.
Fig. 8 Measuring Valve Guide Wear
REMOVAL (c) Move valve to and from the indicator. The to
(1) Remove the cylinder head. tal dial indicator reading should not exceed 0.432
(2) Compress valve springs using Valve Spring mm (0.017 inch). Ream the guides for valves with
Compressor Tool MD-998772A. oversize stems if dial indicator reading is excessive
(3) Remove valve retaining locks, valve spring re or if the stems are scuffed or scored.
tainers, valve stem seals and valve springs. Service valves with oversize stems are available
(4) Before removing valves, remove any burrs from (Fig. 9).
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in Reamer O / S Valve Guide Size
original location.
0.076 mm 8.026 - 8.052 mm
VALVE CLEANING (0.003 in.) ( 0 . 3 1 6 - 0 . 3 1 7 in.)
Clean valves thoroughly. Discard burned, warped
and cracked valves. 0.381 mm 8 . 3 3 1 - 8 . 3 5 7 mm
Remove carbon and varnish deposits from inside of (0.015 in.) ( 0 . 3 2 8 - 0 . 3 2 9 in.)
valve guides with a reliable guide cleaner.
VALVE INSPECTION
Measure valve stems for wear. If wear exceeds J9309-30
0.051 mm (0.002 inch), replace the valve.
Measure valve stem guide clearance as follows: Fig. 9 Reamer Sizes
(a) Install Valve Guide Sleeve Tool C-3973 over Slowly turn reamer by hand and clean guide thor
valve stem and install valve (Fig. 7). The special oughly before installing new valve. Ream the valve
sleeve places the valve at the correct height for guides from standard to 0.381 mm (0.015 inch).
checking with a dial indicator. Use a 2 step procedure so the valve guides are
(b) Attach dial indicator Tool C-3339 to cylinder reamed true in relation to the valve seat:
head and set it at right angle of valve stem being • Step 1-Ream to 0.0763 mm (0.003 inch).
measured (Fig. 8). • Step 2 - R e a m to 0.381 mm (0.015 inch).
9 - 24 3 J L ENGINE •
REFACING VALVES I VALVE SEATS
The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig. 10).
CONTACT
POINT 3
4574° - 45 A°
VALVE SEAT ^ ^ R K 6 3 5
Fig. 12 Refacing Valve Seats

(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat
ing stones. A true and complete surface must be ob
A - SEAT WIDTH - INTAKE 1 . 0 1 6 - 1 . 5 2 4 mm (0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
tained.
1 3 e
B - FACE ANGLE (INTAKE & EXHAUST) 4 3 / 4 ° ~ 4 3 / 4 (2) Measure the concentricity of valve seat using a
C - SEAT ANGLE (INTAKE & EXHAUST) 4474° - 44%° dial indicator. Total runout should not exceed 0.051
D - CONTACT SURFACE
mm (0.002 inch) total indicator reading.
J9309-95 (3) Inspect the valve seat with Prussian blue to de
termine where the valve contacts the seat. To do this,
Fig. 10 Valve Face and Seat Angles coat valve seat LIGHTLY with Prussian blue then set
VALVES valve in place. Rotate the valve with light pressure.
Inspect the remaining margin after the valves are If the blue is transferred to the center of valve face,
refaced (Fig. 11). Valves with less than 1.190 mm contact is satisfactory. If the blue is transferred to
(0.047 inch) margin should be discarded. the top edge of valve face, lower valve seat with a 15°
stone. If the blue is transferred to bottom edge of
r.
valve face raise valve seat with a 60° stone.
\—»—-?m
INTAKE
T \ MARGIN / ^
EXHAUST
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
VALVE VALVE
\ A C E ' inch). The width of the exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).
VALVE SPRING INSPECTION
"STEM* Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
VALVE SPRING Valve Spring Tester Tool C-647 until surface is in line
RETAINER LOCK
GROOVE with the 1-5/16 inch mark on the threaded stud. Be
sure the zero mark is to the front (Fig. 13). Place
spring over stud on the table and lift compressing le
J9209-127 ver to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
Fig. 11 Intake and Exhaust Valves instant. Multiply this reading by 2. This will give the
VALVE SEATS spring load at test length. Fractional measurements
are indicated on the table for finer adjustments. Re
CAUTION: DO NOT un-shroud valves during valve fer to specifications to obtain specified height and al
seat refacing (Fig. 12). lowable tensions. Discard the springs that do not
meet specifications.
(9) Install seals on the exhaust valve stem and po
sition down against valve guides.
(10) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(11) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-6-5-4-3-2. Make
sure piston in cylinder is at TDC on the valve spring
that is being removed.
(12) Remove adapter from the No.l spark plug
hole.
(13) Install rocker arms.
(14) Install covers and coil wire to distributor.
Fig. 13 Testing Valve Spring for Compressed
(15) Install air cleaner.
Length with Tool C-647
(16) Road test vehicle.
INSTALLATION HYDRAULIC TAPPETS

(1) Coat valve stems with lubrication oil and insert Before disassembling any part of the engine to cor
them in cylinder head. rect tappet noise, check the oil pressure. If vehicle
(2) If valves or seats are reground, check valve has no oil pressure gauge, install a reliable gauge at
stem height. If valve is too long, replace cylinder the pressure sending unit. The pressure should be
head. between 207-552 kPa (30-80 psi) at 3,000 RPM.
(3) Install new seals on all valve guides. Install Check the oil level after the engine reaches normal
valve springs and valve retainers. operating temperature. Allow 5 minutes to stabilize
(4) Compress valve springs with Valve Spring oil level, check dipstick.
Compressor Tool MD-998772A, install locks and re The oil level in the pan should never be above the
lease tool. If valves and/or seats are ground, measure F U L L mark or below the ADD OIL mark on dipstick.
the installed height of springs. Make sure the mea Either of these 2 conditions could be responsible for
surement is taken from bottom of spring seat in cyl noisy tappets.
inder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer. OIL LEVEL
If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun- HIGH
terbore. This should bring spring height back to nor If oil level is above the F U L L mark, it is possible
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
VALVE STEM SEAL / SPRING REPLACEMENT the oil pan. Foam in oil pan would be fed to the hy
This procedure is done with the cylinder head in draulic tappets by the oil pump causing them to lose
stalled. length and allow valves to seat noisily.
(1) Set engine basic timing to Top Dead Center
(TDC). LOW
(2) Remove the air cleaner.
Low oil level may allow oil pump to take in air.
(3) Remove cylinder head covers and spark plugs.
When air is fed to the tappets, they lose length which
(4) Remove coil wire from distributor and secure to
allows valves to seat noisily. Any leaks on intake side
good ground to prevent engine from starting.
(5) Using suitable socket and flex handle at crank of oil pump through which air can be drawn will cre
shaft retaining bolt, turn engine so the No.l piston is ate the same tappet action. Check the lubrication
at Top Dead Center on the compression stroke. system from the intake strainer to the pump cover,
(6) Remove rocker arms. including the relief valve retainer cap. When tappet
(7) With air hose attached to an adapter installed noise is due to aeration, it may be intermittent or
in No.l spark plug hole, apply 620-689 kPa (90-100 constant, and usually more than 1 tappet will be
psi) air pressure. noisy. When oil level and leaks have been corrected,
(8) Using Valve Spring Compressor Tool operate the engine at fast idle. Run engine for a suf
MD-998772A, compress valve spring and remove re ficient time to allow all of the air inside the tappets
tainer valve locks and valve spring. to be bled out.
TAPPET NOISE DIAGNOSIS INSTALLATION
(1) Tb determine source of tappet noise, operate en (1) Lubricate tappets.
gine at idle with cylinder head covers removed. (2) Install tappets and push rods i n their original
(2) Feel each valve spring or rocker arm to detect positions. Ensure that the oil feed hole i n the side of
noisy tappet. The noisy tappet will cause the affected the tappet body faces up (away from the crankshaft).
spring and/or rocker arm to vibrate or feel rough i n (3) Install aligning yokes with ARROW toward
operation. camshaft.
W o r n valve guides o r c o c k e d s p r i n g s a r e (4) Install yoke retainer. Tighten the bolts to 23
sometimes mistaken for noisy tappets. I f such is N-m (200 in. lbs.) torque. Install intake manifold.
the c a s e , n o i s e m a y b e d a m p e n e d b y a p p l y i n g (5) Install push rods i n original positions.
side thrust o n t h e valve s p r i n g . I f noise i s n o t (6) Install rocker arms.
appreciably r e d u c e d , i t can b e assumed the (7) Install cylinder head cover.
n o i s e is i n the tappet. I n s p e c t the r o c k e r arm (8) Start and operate engine. Warm up to normal
push rod sockets a n d p u s h rod ends for wear. operating temperature.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces CAUTION: To prevent damage to valve mechanism,
sive leak down around the unit plunger or by the engine must not be run above fast idle until all hy
plunger partially sticking i n the tappet body cylinder. draulic tappets have filled with oil and have become
The tappet should be replaced. A heavy click is quiet.
caused by a tappet check valve not seating or by for
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
WAIVE TIMING
stick i n the down position. This heavy click will be (1) Turn crankshaft until the No.6 exhaust valve is
accompanied by excessive clearance between the closing and No.6 intake valve is opening.
valve stem and rocker arm as valve closes. I n either (2) Insert a 6.350 mm (1/4 inch) spacer between
case, tappet assembly should be removed for inspec rocker arm pad and stem tip of No.l intake valve. A l
tion and cleaning. low spring load to bleed tappet down giving i n effect
a solid tappet.
The valve train generates a noise very much like a
(3) Install a dial indicator so plunger contacts
light tappet noise during normal operation. Care
valve spring retainer as nearly perpendicular as pos
must be taken to ensure that tappets are making the
sible. Zero the indicator.
noise. I n general, i f more than one tappet seems to
be noisy, its probably not the tappets. (4) Rotate the crankshaft clockwise (normal run
ning direction) until the valve has lifted 0.254 mm
REMOVAL (0.010 inch). The timing of the crankshaft should
(1) Remove the air cleaner. now read from 10° before top dead center to 2° after
(2) Remove cylinder head cover. top dead center. Remove spacer.
(3) Remove rocker assembly and push rods. Iden
tify push rods to ensure installation i n original loca CAUTION: DO NOT turn crankshaft any further
tion. clockwise a s valve spring might bottom and result
(4) Remove intake manifold. in serious damage.
(5) Remove yoke retainer and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool (5) I f reading is not within specified limits:
C-4129-A through opening i n cylinder head and seat (a) Check sprocket index marks.
tool firmly i n the head of tappet. (b) Inspect timing chain for wear.
(7) Pull tappet out of bore with a twisting motion. (c) Check accuracy of DC mark on timing indica
I f all tappets are to be removed, identify tappets to tor.
ensure installation i n original location.
(8) I f the tappet or bore i n cylinder block is scored, VIBRATION DAMPER
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet. REMOVAL
CAUTION: T h e plunger and tappet bodies are not (2) Remove fan shroud retainer bolts and set
interchangeable. T h e plunger and valve must al shroud back over engine.
ways be fitted to the original body. It is advisable to (3) Remove the cooling system fan.
work on one tappet at a time to avoid mixing of (4) Remove the serpentine belt (refer to Group 7,
parts. Mixed parts are not compatible. DO NOT dis Cooling System).
assemble a tappet on a dirty work bench. (5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from (2) Drain cooling system (refer to Group 7, Cooling
end of crankshaft. System).
(7) Install bar and screw from Puller Tool Set (3) Remove the serpentine belt (refer to Group 7,
C-3688. Install 2 bolts with washers through the Cooling System).
puller tool and into the vibration damper (Fig. 1). (4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys
tem).
(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using ex
treme caution to avoid damaging oil pan gasket.
Fig. 1 Vibration Damper Assembly
(11) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
(8) Pull vibration damper off of the crankshaft. damage the crankshaft seal surface of cover (Fig. 3).
INSTALLATION
(1) Position the vibration damper onto the crank
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2).
Fig. 3 Removal of Front Crankshaft Oil Seal

TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam
shaft sprocket attaching bolt. Apply torque i n the di
Fig. 2 Installing Vibration Damper rection of crankshaft rotation to take up slack; 41
N-m (30 ft. lbs.) torque with cylinder head installed
(3) Install the crankshaft bolt and washer. Tighten or 20 N-m (15 ft. lbs.) torque with cylinder head re
the bolt to 183 N-m (135 ft. lbs.) torque. moved. With a torque applied to the camshaft
(4) Install the crankshaft pulley. Tighten the pul sprocket bolt, crankshaft should not be permitted to
ley bolts to 23 N-m (200 in. lbs.) torque. move. I t may be necessary to block the crankshaft to
(5) Install the serpentine belt (refer to Group 7, prevent rotation.
Cooling System). (3) Hold a scale with dimensional reading even
(6) Install the cooling system fan. Tighten the bolts with the edge of a chain link. With cylinder heads in
to 23 N-m (17 ft. lbs.) torque. stalled, apply 14 N-m (30 ft. lbs.) torque in the re
(7) Position the fan shroud and install the bolts. verse direction. With the cylinder heads removed,
Tighten the retainer bolts to 11 N-m (95 in. lbs.) apply 20 N-m (15 ft. lbs.) torque i n the reverse direc
torque. tion. Note the amount of chain movement (Fig. 4).
(8) Connect the negative cable to the battery. (4) Install a new timing chain, i f its movement ex
ceeds 3.175 mm (1/8 inch).
TIMING CHAIN COVER
(5) I f chain is not satisfactory, remove camshaft
REMOVAL
sprocket attaching bolt and remove timing chain with
(1) Disconnect the negative cable from the battery. crankshaft and camshaft sprockets.
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal i n the groove of the tool.
(3) Position the seal and tool onto the crankshaft
(Fig. 7).
CRANKSHAFT. INSTALL THIS

FRONT OIL END INTO
J9409-96 SEAL SPECIAL TOOL
6635
Fig. 4 Measuring Timing Chain Wear and Stretch

(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location i n crankshaft sprocket and i n cam
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
J9309-44
against the chain i n position as described).
(10) Slide both sprockets evenly over their respec
tive shafts and use a straightedge to check alignment Fig. 6 Placing Oil Seal on Installation Tool 6635
of timing marks (Fig. 5).
SPECIAL TOOL \ | OIL
SEAL
TIMING
J9409-97
MARKS
Fig. 5 Alignment of Timing Marks
(11) Install the camshaft bolt. Tighten the bolt to
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
TIMING'
used thrust plate. I f not within these limits install a CHAIN
new thrust plate. COVER J9309-45-
CLEANING Fig. 7 Position Tool and Seal onto Crankshaft

Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs. (4) Using the vibration damper bolt, tighten the
The water pump mounting surface must be bolt to draw the seal into position on the crankshaft
cleaned. (Fig. 8).
(5) Tighten chain case cover bolts to 41 N-m (30 ft.
INSTALLATION lbs.) torque. Tighten oil pan bolts to 24 N-m (215 in.
(1) Using a new cover gasket, carefully install lbs.) torque.
chain case cover to avoid damaging oil pan gasket. (6) Remove the vibration damper bolt and seal in
Use a small amount of Mopar Silicone Rubber Adhe stallation tool.
sive Sealant, or equivalent, at the joint between tim (7) Install vibration damper.
(Fig. 7).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 8).
(8) Remove the vibration damper bolt and seal in
stallation tool.
(9) Install the vibration damper.
CAMSHAFT
This procedure requires that the engine is removed
from the vehicle.
The camshaft has an integral oil pump and distrib
utor drive gear (Fig. 9).
CHAIN
SPROCKET
J9309-46
Fig. 8 Installing Oil Seal

(8) Install fuel lines (refer to Group 14, Fuel Sys
tem).
(9) Install water pump and housing assembly us
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque. Fig. 9 Camshaft and Sprocket Assembly
(10) Install power steering pump (refer to Group REMOVAL
19, Steering). (1) Remove intake manifold.
(11) Install the serpentine belt (refer to Group 7, (2) Remove cylinder head covers.
Cooling System). (3) Remove timing case cover and timing chain.
(12) Install the cooling system fan. Tighten the (4) Remove rocker arms.
bolts to 23 N-m (17 ft. lbs.) torque. (5) Remove push rods and tappets. Identify each
(13) Position the fan shroud and install the bolts. part so i t can be installed i n the original location.
Tighten the bolts to 11 N-m (95 i n . lbs.) torque. (6) Remove distributor and lift out the oil pump
(14) Fill cooling system (refer to Group 7, Cooling and distributor drive shaft.
System for the proper procedure). (7) Remove camshaft thrust plate; note location of
(15) Connect the negative cable to the battery. oil tab (Fig. 10).
(8) Install a long bolt into front of camshaft to fa
FRONT CRANKSHAFT OIL SEAL REPLACEMENT cilitate removal of the camshaft. Remove camshaft,
The oil seal can be replaced without removing the
being careful not to damage cam bearings with the
timing chain cover provided the cover is not mis
cam lobes.
aligned.
(1) Disconnect the negative cable from the battery. REMOVAL—BEARING
(2) Remove vibration damper. (1) With engine completely disassembled, drive out
(3) I f front seal is suspected of leaking, check front
rear cam bearing core hole plug.
oil seal alignment to crankshaft. The Seal Installa
(2) Install proper size adapters and horseshoe
tion/Alignment Tool 6635, should fit with minimum
washers (part of Camshaft Bearing Remover/Installer
interference. I f tool does not fit, the cover must be re
moved and installed properly. Tool C-3132-A) at back of each bearing shell. Drive
(4) Place a suitable tool behind the lips of the oil out bearing shells (Fig. 11).
INSTALLATION—BEARING
damage the crankshaft seal surface of cover.
(1) Install new camshaft bearings with Camshaft
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat Bearing Remover/Installer Tool C-3132-A by sliding
the oil seal i n the groove of the tool. the new camshaft bearing shell over proper adapter.
for a minimum of 805 k m (500 miles). Drain at
the next normal oil change.
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
Fig. 12 Camshaft Holding Tool C-3509 (Installed

Position)
(3) Hold tool i n position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed i n too far and prevent knocking out the welch
Fig. 10 Timing Chain Oil Tab Installation plug i n rear of cylinder block. Tool should remain
installed u n t i l the camshaft a n d crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole i n
thrust plate. Tighten bolts to 24 N-m (210 i n . lbs.)
torque. Top edge of tab should be flat against thrust
plate i n order to catch oil for chain lubrication.
crankshaft bores.
Fig. 11 Camshaft Bearings Remowal and Installation (7) Turn crankshaft and camshaft to line up with
with Tool C-3132-A keyway location i n crankshaft sprocket and i n cam
(2) Position rear bearing i n the tool. Install shaft sprocket.
horseshoe lock and by reversing removal procedure, (8) Lift sprockets and chain (keep sprockets tight
carefully drive bearing shell into place. against the chain i n position as described).
(3) Install remaining bearings i n the same manner.
tive shafts and use a straightedge to check alignment
Bearings must be carefully aligned to bring oil holes
into full register with oil passages from the main
(10) Install the camshaft bolt/cup washer. Tighten
bearing. I f the camshaft bearing shell oil holes are bolt to 68 N-m (50 ft. lbs.) torque.
not i n exact alignment, remove and install them cor
rectly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position i n cylinder block.
Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv
alent. The oil mixture should be left i n engine
(11) Measure camshaft end play. Refer to Specifica (3) As the burnisher is pulled through the bushing,
tions for proper clearance. If not within limits install the bushing is expanded tight i n the block and bur
a new thrust plate. nished to correct size (Fig. 16). DO NOT r e a m t h i s
(12) Each tappet reused must be installed in the bushing.
same position from which it was removed. When
camshaft is replaced, a l l o f the tappets must be
replaced,
DISTRIBUTOR
REMOVAL
Refer to Group 8D, Ignition Systems for the proper
procedure.
REMOVAL—DRIVE SHAFT BUSHING

(1) Remove the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold). Fig. 16 Burnishing Distributor Driveshaft Bushing
(2) Insert Distributor Drive Shaft Bushing Puller (4) Install the intake manifold (refer to Group 11,
Tool C - 3 0 5 2 into old bushing and thread down until a Exhaust System and Intake Manifold).
tight fit is obtained (Fig. 14).
(3) Hold puller screw and tighten puller nut until DISTRIBUTOR TIMING
bushing is removed. Before installing the distributor and oil pump drive
shaft, time engine as follows:
(1) Rotate crankshaft until N o . l cylinder is at top
dead center on the firing stroke.
(2) When i n this position, the timing mark on v i
bration damper should be under "0" on the timing in
dicator.
(3) Coat shaft and drive gear with engine oil. In
stall the shaft so that after the gear spirals into
place, i t will index with the oil pump shaft. The slot
on top of drive gear should be aligned towards left
front intake manifold attaching bolt hole (Fig. 17).
Fig. 14 Distributor Driveshaft Bushing Removal
INSTALLATION—DRIVE SHAFT BUSHING
(1) Slide new bushing over burnishing end of Dis
tributor Drive Shaft Bushing Driver/Burnisher Tool
C - 3 0 5 3 . Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 15).
Fig. 17 Position of Installed Distributor Drive Gear

INSTALLATION
Fig. 15 Distributor Driveshaft Bushing Installation procedure.
OIL PAN DOWEL DOWEL
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Loosen the right side engine support bracket
cushion thru-bolt nut and raise the engine slightly.
Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film i n the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots. DOWEL J9309-78
I f present, trim excess sealant from inside the en

gine. Fig. 2 Position of Dowels in Cylinder Block
Clean oil pan i n solvent and wipe dry with a clean (6) Install the oil pan bolts. Tighten the bolts to 24
cloth. N-m (215 in. lbs.) torque.
Clean oil screen and pipe thoroughly i n clean sol (7) Remove the dowels. Install the remaining oil
vent. Inspect condition of screen. pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
torque.
INSPECTION
(8) Lower the engine into the support cushion
Inspect oil drain plug and plug hole for stripped or
brackets and tighten the thru-bolt nut to the proper
damaged threads. Repair as necessary.
torque.
Inspect oil pan mounting flange for bends or distor
tion. Straighten flange, i f necessary. (9) Install the drain plug. Tighten drain plug to 34
INSTALLATION (10) Install the engine to transmission strut.
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 (11) Install exhaust pipe.
inch bolts. Cut the head off the bolts and cut a slot (12) Lower vehicle.
into the top of the dowel. This will allow easier in (13) Install dipstick.
stallation and removal with a screwdriver (Fig. 1). (14) Connect the negative cable to the battery.
(15) Fill crankcase with oil to proper level.
17 " x 5 / 1 6 " BOLT
2
OIL PUMP
OIL PUMP PRESSURE
J
The M I N I M U M oil pump pressure is 41.4 kPa (6
^ DOWEL
psi) at curb idle. The MAXIMUM oil pump pressure
is 207-552 kPa (30-80 psi) at 3,000 RPM or more.
CAUTION: If oil pressure is Z E R O at curb idle, DO

A
SLOT J9209-106 NOT run engine at 3,000 RPM.
Fig. 1 Fabrication of Alignment Dowels

REMOVAL
(2) Install the dowels i n the cylinder block (Fig. 2). (1) Remove the oil pan.
(3) Apply small amount of Mopar Silicone Rubber (2) Remove the oil pump from rear main bearing
Adhesive Sealant, or equivalent i n the corner of the cap.
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and INSTALLATION
onto the block. (1) Install oil pump. During installation slowly ro
(5) Position the oil pan over the dowels and onto tate pump body to ensure driveshaft-to-pump rotor
the gasket. shaft engagement.
(2) Hold the oil pump base flush against mating DIAMETER (D)
surface on No.4 main bearing cap. Finger tighten SHOULD BE 98.704-98.831 mm
0.0000-0.0152 mm -(3.886-3.891 i n . ) -
pump attaching bolts. Tighten attaching bolts to 41 (0.0000-0.0006 in. •98.577-98.704 mm -
N-m (30 ft. lbs.) torque. LARGER THAN (C). (3.881-3.886 in.)
(3) Install the oil pan.
PISTON / CONNECTING ROD ASSEMBLY

62.230 mm
The pistons are elliptically turned so that the di (2.45 in,
ameter at the pin boss is less than its diameter
across the thrust face. This allows for expansion un i
der normal operating conditions. Under operating
temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more
nearly round shape.
A l l pistons are machined to the same weight, re
gardless of size, to maintain piston balance. ELLIPTICAL SHAPE OF THE PISTON
The piston pin rotates i n the piston only and is re SKIRT SHOULD BE 0.254-0.304 mm
(0.010-0.012 in.) LESS AT DIAMETER
tained by the press interference fit of the piston pin (A) THAN ACROSS THE THRUST
in the connecting rod. FACES AT DIAMETER (B).
J9309-9
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head. Fig. 3 Piston Measurements
(3) Remove the oil pan. FITTING RINGS
(4) Remove top ridge of cylinder bores w i t h a reli (1) Measurement of end gaps:
able ridge reamer before removing pistons from cyl (a) Measure piston ring gap 2 inches from bot
inder block. Be sure to keep tops of pistons covered tom of cylinder bore. A n inverted piston can be
during this operation. used to push the rings down to ensure positioning
(5) Be sure the connecting rod and connecting rod rings squarely i n the cylinder bore before measur
cap are identified with the cylinder number. Remove ing.
connecting rod cap. Install connecting rod bolt guide
(b) Insert feeler gauge i n the gap. The top com
set on connecting rod bolts.
pression ring gap should be between 0.254-0.508
(6) Pistons and connecting rods must be removed
mm (0.010-0.020 inch). The second compression
from top of cylinder block. When removing piston and
ring gap should be between 0.508-0.762 mm (0.020-
connecting rod assemblies, rotate crankshaft center
the connecting rod i n the cylinder bore and at BDC. 0.030 inch). The oil ring gap should be 0.254-1.270
Be careful n o t t o n i c k crankshaft j o u r n a l s . mm (0.010-0.050 inch).
(7) After removal, install bearing cap on the mat (c) Rings with insufficient end gap may be prop
ing rod. erly filled to the correct dimension. Rings with ex
cess gaps should not be used.
INSPECTION (2) Install rings and confirm ring side clearance:
Check the crankshaft connecting rod journal for ex (a) Install oil rings being careful not to nick or
cessive wear, taper and scoring. scratch the piston.
Check the cylinder block bore for out-of-round, (b) Install the compression rings using Installa
taper, scoring and scuffing. tion Tool C-4184. The top compression may be in
Check the pistons for taper and elliptical shape be stalled with either side up. The second compression
fore they are fitted into the cylinder bore (Fig. 3). ring must be installed with the identification mark
face up (toward top of piston) and the chamfer
FITTING PISTONS
should face down. A n identification mark on the
Piston and cylinder wall must be clean and dry.
ring is a drill point, a stamped letter "O", an oval
Specified clearance between the piston and the cylin
depression or the word TOP.
der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at the top of (c) Measure side clearance between piston ring
skirt, 90° to piston pin axis. Cylinder bores should be and ring land (Fig. 4). Clearance should be 0.038-
measured halfway down the cylinder bore and trans 0.076 mm (0.0015-0.0030 inch) for the compression
verse to the engine crankshaft center line. rings. The steel rail oil ring should be free in
Pistons and cylinder bores should be measured at groove, but should not exceed 0.203 mm (0.0080
normal room temperature, 21°C (70°F). inch) side clearance.
FEELER GAUGE Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch).
Bearings are available i n 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size. Install the bearings in pairs. DO NOT use a
new bearing half with an o l d bearing half. DO
NOT file the rods or bearing caps.
INSTALLATION
(1) Be sure that compression ring gaps are stag
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
J9209-136 sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 5).
Fig. 4 Measuring Piston Ring Side Clearance (3) Immerse the piston head and rings i n clean en
(d) Pistons with insufficient or excessive side gine oil. Slide Piston Ring Compressor Tool C-385
clearance should be replaced. over the piston and tighten with the special wrench
(3) Orient the rings: (part of Tool C-385). Be sure position of rings
(a) Arrange top compression ring 90° counter does not change during this operation.
clockwise from the oil ring rail gap (Fig. 5). (4) Install connecting rod bolt protectors on rod
(b) Arrange second compression ring 90° clock bolts, the long protector should be installed on the
wise from the oil ring rail gap (Fig. 5). numbered side of the connecting rod.
OIL RING
(5) Rotate crankshaft so that the connecting rod
SPACER GAP journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
SECOND (6) Tap the piston down in cylinder bore, using a
COMPRESSION
TOP hammer handle. A t the same time, guide connecting
RING GAP
COMPRESSION
OIL RING RAIL rod into position on crankshaft journal.
RING GAP
GAP (TOP) (7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con
OIL RING RAIL
necting rod cap and cylinder bore number are the
GAP (BOTTOM) J9309-80 same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N-m (45 ft. lbs.) torque.
Fig. S Proper Ring Installation (9) Install the oil pan.
CONNECTING ROD BEARINGS (10) Install the cylinder head.
Fit all rods on a bank until completed. DO NOT al (11) Install the engine into the vehicle.
ternate from one bank to another, because connecting
rods and pistons are not interchangeable from one CRANKSHAFT
bank to another. A crankshaft which has undersize journals will be
The bearing caps are not interchangeable and stamped with 1/4 inch letters near the notch of the
should be marked at removal to ensure correct as No.6 crankshaft counterweight (Fig. 6).
sembly. F O R E X A M P L E : R2 stamped on the No.6 crank
Each bearing cap has a small V-groove across the shaft counterweight indicates that the No.2 rod jour
parting face. When installing the lower bearing shell, nal is 0.025 mm (0.001 in) undersize. M4 indicates
make certain that the V-groove i n the shell is i n line that the No.4 main journal is 0.025 mm (0.001 in)
with the V-groove i n the cap. This provides lubrica undersize. R3 M2 indicates that the No.3 rod journal
tion of the cylinder wall i n the opposite bank. and the No.2 main journal are 0.025 mm (0.001 in)
The bearing shells must be installed so that the undersize.
tangs are i n the machined grooves i n the rods and When a crankshaft is replaced, all main and con
caps. necting rod bearings should be replaced with new
• 3.9L ENGINE 9 - 35
I d e n t i f i c a t i o n Stamp
INSTALLATION
Undersize Journal
(1) Lightly oil the new upper seal lips with engine
ROD - 0.025mm (0.001 in.) Rl -R2-R3-Etc. oil.
M A I N - 0.025mm (0.001 in.) M 1 - M 2 - M 3 or M 4 (2) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en
STEEL STAMP IDENTIFICATION gine.
R (ROD) A N D / O R M (MAIN) F O L L O W E D (3) Position the crankshaft into the cylinder block.
BY THE R O D OR M A I N NUMBER
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
#1
#5 #4 #3 # 2 - ^
J9209-134 (Fig. 7). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
Fig. 6 Location of Crankshaft Identification cap to cylinder block immediately after sealant appli
cation.
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are t MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTSs
replaced. ^ L O C T I T E 515 (OR EQUIVALENT)^
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear-
ing cap.
(3) Remove the vibration damper, CAP
(4) Remove the timing chain cover. ALIGNMENT
SLOT
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time,
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals. REAR M A I N
BEARING C A P J9309-72
(8) Remove and discard the front crankshaft oil
seal. Fig. 7 Sealant Application to Bearing Cap
INSPECTION OF J O U R N A L S (7) To align the bearing cap, use cap slot, align
The crankshaft connecting rod and main journals ment dowel and cap bolts. DO NOT remove excess
should be checked for excessive wear, taper and scor material after assembly. DO NOT strike rear cap
ing. The maximum taper or out-of-round on any more than 2 times for proper engagement.
crankshaft journal is 0.025 mm (0.001 inch). (8) Clean and oil all cap bolts. Install all main
Journal grinding should not exceed 0.305 mm bearing caps. Install all cap bolts and alternately
(0.012 inch) under the standard journal diameter. DO tighten to 115 N-m (85 ft. lbs.) torque.
NOT grind thrust faces of No.3 main bearing. DO (9) Install oil pump.
(10) Install the timing chain cover.
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
(12) Apply Mopar Silicone Rubber Adhesive Seal
clean out all oil passages.
ant, or equivalent, at bearing cap to block joint to
CAUTION: After any journal grind, it is important provide cap to block and oil pan sealing (Fig. 8). Ap
that the final paper or cloth polish be in the same ply enough sealant until a small amount is squeezed
direction a s the engine rotates. out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(13) Install new front crankshaft oil seal.
CLEANING (14) Immediately install the oil pan.
Clean Loctite 515 residue and sealant from the cyl
inder block and rear cap mating surface. Do this be CRANKSHAFT MAIN BEARINGS
fore applying the Loctite drop and the installation of Bearing caps are not interchangeable and should
rear cap. be marked at removal to ensure correct assembly.
9 - 36 3.9L ENGINE •
MOPAR SILICONE SEALANT
RUBBER ADHESIVE APPLIED
Fig. 8 Apply Sealant to Bearing Cap to Block Joint

Fig. 10 Upper Main Bearing Removal and
Upper and lower bearing halves are NOT inter Installation with Tool C-3059
changeable. Lower main bearing halves of N o . l and 3
are interchangeable. INSTALLATION
Upper and lower No.2 bearing halves are flanged Only one main bearing should be selectively fitted
to carry the crankshaft thrust loads. They are NOT while all other main bearing caps are properly tight
interchangeable with any other bearing halves i n the ened. A l l bearing capbolts removed during service
engine (Fig. 9). Bearing shells are available i n stan procedures are to be cleaned and oiled before instal
dard and the following undersizes: 0.25 mm (0.001 lation.
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), When installing a new upper bearing shell, slightly
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). chamfer the sharp edges from the plain side.
Never install an undersize bearing that will reduce (1) Start bearing i n place, and insert Crankshaft
clearance below specifications. Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 10).
(2) Slowly rotate crankshaft counterclockwise slid
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N-m (85 ft. lbs.)
torque.
(4) Install the oil pump.
CRANKSHAFT REAR OIL SEALS

The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
Fig. 9 Main Bearing Identification The lower seal half can only be installed with the
rear main bearing cap removed.
REMOVAL
(1) Remove the oil pan. U P P E R SEAL REPLACEMENT (CRANKSHAFT
(2) Remove the oil pump from the rear main bear REMOVED)
ing cap. (1) Remove the crankshaft. Discard the old upper
(3) Identify bearing caps before removal. Remove seal.
bearing caps one at a time. (2) Clean the cylinder block rear cap mating sur
(4) Remove upper half of bearing by inserting face. Make sure the seal groove is free of debris.
Crankshaft Main Bearing Remover/Installer Tool (3) Lightly oil the new upper seal lips with engine
C-3059 into the oil hole of crankshaft (Fig. 10). oil.
(5) Slowly rotate crankshaft clockwise, forcing out (4) Install the new upper rear bearing oil seal with
upper half of bearing shell. the yellow paint facing towards the rear of the en
gine.
(5) Position the crankshaft into the cylinder block.
• 3.9L ENGINE 9 - 37
(6) Lightly oil the new lower seal lips with engine cap to cylinder block immediately after sealant appli
oil. cation. Be sure the yellow paint faces toward the rear
(7) Install the new lower rear bearing oil seal into of the engine.
the bearing cap with the yellow paint facing towards (10) To align the bearing cap, use cap slot, align
the rear of the engine. ment dowel and cap bolts. DO NOT remove excess
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or material after assembly. DO NOT strike rear cap
equivalent, on each side of the rear main bearing cap more than 2 times for proper engagement.
(Fig. 7). DO NOT over apply sealant or allow the (11) Install the rear main bearing cap with cleaned
sealant to contact the rubber seal. Assemble bearing and oiled cap bolts. Alternately tighten A L L cap bolts
cap to cylinder block immediately after sealant appli to 115 N-m (85 ft. lbs.) torque.
cation. (12) Install oil pump.
(9) To align the bearing cap, use cap slot, align (13) Apply Mopar Silicone Rubber Adhesive Seal
ant, or equivalent, at bearing cap to block joint to
ment dowel and cap bolts. DO NOT remove excess
provide cap to block and oil pan sealing (Fig. 8). Ap
material after assembly. DO NOT strike rear cap
ply enough sealant until a small amount is squeezed
more than 2 times for proper engagement.
out. Withdraw nozzle and wipe excess sealant off the
(10) Clean and oil all cap bolts. Install all main oil pan seal groove.
bearing caps. Install all cap bolts and alternately (14) Immediately install the oil pan.
tighten to 115 N-m (85 ft. lbs.) torque.
(11) Install oil pump. LOWER SEAL REPLACEMENT
(12) Apply Mopar Silicone Rubber Adhesive Seal (1) Remove the oil pan.
ant, or equivalent, at bearing cap to block joint to (2) Remove the oil pump from the rear main bear
provide cap to block and oil pan sealing (Fig. 8). Ap ing cap.
ply enough sealant until a small amount is squeezed (3) Remove the rear main bearing cap and discard
out. Withdraw nozzle and wipe excess sealant off the the old lower seal.
oil pan seal groove. (4) Clean the rear main cap mating surfaces i n
(13) Install new front crankshaft oil seal. cluding the oil pan seal grooves.
(14) Immediately install the oil pan. (5) Carefully install a new upper seal (refer to Up
per Seal Replacement - Crankshaft Installed proce
UPPER SEAL REPLACEMENT (CRANKSHAFT dure above).
INSTALLED! (6) Lightly oil the new lower seal lips with engine
(1) Remove the oil pan. oil.
(2) Remove the oil pump from the rear main bear (7) Install a new lower seal i n bearing cap with
ing cap. yellow paint facing the rear of engine.
(3) Remove the rear main bearing cap. Remove (8) Apply 5 mm (0.20 in) drop of Loctite 515, or
and discard the old lower oil seal. equivalent, on each side of the rear main bearing cap
(4) Carefully remove and discard the old upper oil (Fig. 7). DO NOT over apply sealant or allow the
seal. sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli
(5) Clean the cylinder block mating surfaces before
cation.
oil seal installation.
(9) To align the bearing cap, use cap slot, align
oil. To allow ease of installation of the seal, loosen at material after assembly. DO NOT strike rear cap
least the 2 main bearing caps forward of the rear more than 2 times for proper engagement.
bearing cap. (10) Install the rear main bearing cap with cleaned
(7) Rotate the new upper seal into the cylinder and oiled cap bolts. Alternately tighten the cap bolts
block being careful not to shave or cut the outer sur to 115 N-m (85 ft. lbs.) torque.
face of the seal. To assure proper installation, use the (11) Install oil pump.
installation tool provided with the kit. Install the (12) Apply Mopar Silicone Rubber Adhesive Seal
new seal with the yellow paint facing towards the ant, or equivalent, at bearing cap to block joint to
rear of the engine. provide cap to block and oil pan sealing (Fig. 8). Ap
(8) Install the new lower rear bearing oil seal into ply enough sealant until a small amount is squeezed
the bearing cap with the yellow paint facing towards out. Withdraw nozzle and wipe excess sealant off the
the rear of the engine. oil pan seal groove.
(9) Apply 5 mm (0.20 in) drop of Loctite 515, or (13) Immediately install the oil pan.
(Fig. 7). DO NOT over apply sealant or allow the CYLINDER BLOCK
sealant to contact the rubber seal. Assemble bearing Remove the engine assembly from the vehicle.
DISASSEMBLE RIGHT OIL GALLERY
(1) Remove the cylinder head.
(3) Remove the piston/connecting rod assembly.
© \ CYLINDER
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
• The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
• The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
• The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely co
ordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures i n the begin
ning of this Group for the proper honing of cylinder
bores.
OIL LINE PLUG

The oil line plug is located i n the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 11). Improper installa
tion or plug missing could cause erratic, low or no oil
pressure.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 192.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
11). I f plug is too high, use a suitable flat dowel drift
to position properly.
(4) I f plug is off position, remove oil pan and rear Fig. 12 Location of Cup Plugs in Oil Galleries
main bearing cap. Use suitable flat dowel to remove REMOVAL
plug. Coat outside diameter of new plug with Mopar (1) Using a blunt tool such as a drift or a screw
(stud and bearing mount adhesive), or equivalent. driver and a hammer, strike the bottom edge of the
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 cup plug (Fig. 13).
inches) from bottom of the block. (2) With the cup plug rotated, grasp firmly with
(5) Assemble engine and check oil pressure. pliers or other suitable tool and remove plug (Fig.
13).
ENGINE COItE OIL I CAMSHAFT PLUGS
Engine core plugs have been pressed into the oil CLEANING
galleries behind the camshaft thrust plate (Fig. 12). Thoroughly clean inside of cup plug hole i n cylinder
This will reduce internal leakage and help maintain block or head. Be sure to remove old sealer.
higher oil pressure at idle. Make certain the new plug is cleaned of all oil or
grease.
3.9L ENGINE 9 - 39
CYLINDER INSTALLATION
BLOCK (1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION: DO NOT drive c u p plug Into the casting

SECOND
REMOVE PLUG a s restricted coolant flow c a n result and c a u s e s e
WITH PLIERS. rious engine problems.
(2) Using proper drive plug, drive plug into hole.

FIRST
STRIKE HERE The sharp edge of the plug should be at least 0.50
WITH HAMMER mm (0.020 inch) inside the lead-in chamfer.
I t is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed i n service immediately.
DRIFT 9209-41 ASSEMBLE
(1) Install the piston/connecting rod assembly.
Fig. 13 Core Hole Plug Removal (2) Install the oil pan.
(3) Install the cylinder head.
(4) Install the engine into the vehicle.
SPECIFICATIONS—3 J L ENGINE
ENGINE SPECIFICATIONS
Camshaft
Bearing Diameter End Play 0.051-0.178 mm
No. 1 50.800-50.825 mm (0.002-0.007 in)
(2.000-2.001 in) Max. Allowable 0.254 mm
No. 2 50.394-50.419 mm (0.010 in)
(1.984-1.985 in) Main Bearing Journals
No. 3 49.606-49.632 mm Diameter 63.487-63.513 mm
(1.953-1.954 in) (2.4995-2.5005 in)
No. 4 39.688-39.713 mm Out-of-Round (Max.) 0.0254 mm
(1.5625-1.5635 in) (0.001 in)
Diametrical Clearance 0.0254-0.0762 mm Taper (Max.) 0.0254 mm
(0.001-0.003 in) (0.001 in)
Max. Allowable . . . . . . . . . . . . . . . . 0.127 mm
(0.005 in) Cylinder Black
End Play . 0.051-0.254 mm Cylinder Bore
(0.002-0.010 in) Diameter 99.314-99.365 mm
Bearing Journal Diameter (3.910-3.912 in)
No. 1 50.749-50.775 mm Out-of-Round (Max.) 0.127 mm
(1.998-1.999 in) (0.005 in)
No. 2 50.343-50.368 mm Taper (Max.) 0.254 mm
(1.982-1.983 in) (0.010 in)
No. 3 49.555-49.581 mm Oversize (Max.) 1.016 mm
(1.951-1.952 in) (0.040 in)
No. 4 39.637-39.662 mm Distributor Lower Drive Shaft
(1.5605-1.5615 in) Bushing (Press Fit in Block) 0.0127-0.3556 mm
(0.0005-0.0140 in)
Connecting Rods Shaft-to-Bushing Clearance . . . . 0.0178-0.0686 mm
Bearing Clearance 0.0127-0.0559 mm (0.0007-0.0027 in)
(0.0005-0.0022 in) Tappet Bore Diameter 22.99-23.01 mm
Piston Pin Bore Diameter 24.940-24.978 mm (0.9051-0.9059 in)
(0.9819-0.9834 in)
Side Clearance (Two Rods) 0.152-0.356 mm Cylinder Head
(0.006-0.014 in) Compression Pressure 689 kPa
Total Weight (Less Bearing) . . . . . 726 grams (100 psi)
(25.61 oz) Gasket Thickness (Compressed) 1.2065 mm
(0.0475 in)
Crankshaft Valve Seat
Connect Rod Journal Angle.... 4 4 . 2 5 ° - 44.75°
Diameter 53.950-53.975 mm Runout (Max.) 0.0762 mm
(2.124-2.125 in) (0.003 in)
Out-of-Round (Max.) 0.0254 mm Width (Finish) - Intake 1.016-1.542mm
(0.001 in) (0.040-0.060 in)
Taper (Max.) 0.0254 mm Width (Finish) - Exhaust. 1.524-2.032 mm
(0.001 in) (0.060-0.080 in)
Diametrical Clearance Hydraulic Tappets

No. 1 0.0127-0.0381 mm Body Diameter 22.949-22.962 mm
(0.0005-0.0015 in) (0.9035-0.9040 in)
Nos. 2, 3, and 4 0.0127-0.0508 mm Clearance in Block 0.0279-0.0610 mm
(0.0005-0.0020 in) (0.0011-0.0024 in)
Max. Allowable (Nos. 2 , 3, & 4) . . . 0.0635 mm Dry Lash 1.524-5.334 mm
(0.0025 in) (0.060-0.210 in)
Push Rad Length 175.64-176.15 mm
(6.915-6.935 in)
J9409-25
ENGINE SPECIFICATIONS (CONT.)
O i l Pump Piston Pins

Clearance Over Rotors (Max.) 0.1016 mm Clearance
(0.004 in) In Piston 0.00635-0.01905 mm
Cover Out-of-Flat ( M a x . ) . . 0.0381 mm (0.00025-0.00075 in)
(0.0015 in) In Rod (Interference) 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter 24.996-25.001 mm
Outer Rotor (0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm End Play NONE
(0.014 in) Length 75.946-76.454 mm
Diameter (Min.) 62.7126 mm (2.990-3.010 in)
(2.469 in)
Thickness (Min.) 20.955 mm Piston Rings
(0.825 in) Ring G a p
Tip Clearance Between Rotors (Max).. 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) 0.254-1.270 mm
O i l Pressure (0.010-0.050 in)
At Curb Idle Speed* 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
At 3000 rpm 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) 34.5-48.3 kPa Ring Width
(5-7 psi) Compression Rings 1.971-1.989 mm
(0.0776-0.0783 in)
• C A U T I O N : If pressure is Z E R O at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
D O N O T run engine at 3,000 rpm. (0.1515-0.1565 in)
O i l Filter Valves
Bypass Valve Setting 62-103 kPa Face Angle 43.25° - 43.75°
(9-15 psi) Head Diameter
Intake 4 8 . 6 6 6 mm
Pistons (1.916 in)
Clearance at Top of Skirt 0.0127-0.0381 mm Exhaust 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake 124.28-125.92 mm
Piston Length 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) 10.973 mm
(0.180-0.190 in) (0.432 in)
No. 3 3.810-4.064 mm Stem Diameter 7.899-7.925 mm
(0.150-0.160 in) (0.311-0.312 in)
Weight 592.6-596.6 grams Stem-to-Guide Clearance 0.0254-0.0762 mm
(20.90-21.04 oz) (0.001-0.003 in)
Max. Allowable (Rocking Method).. 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950-7.976 mm
(0.313-0.314 in)
J9309-32
Valve S p r i n g s Valv® Timing

Free Length (Approx.) 49.962 mm Exhaust Valve
(1.967 in) Closes (ATC) 25°
Spring Tension @ 41.66 mm = 378 N Opens (BBC) .. 56°
(Valve Closed) (@ 1.64 in = 85 lbs) Duration 264°
Spring Tension @ 30.89 mm * 890 N Intake Valve
(Valve Open) (@ 1.212 in - 200 lbs) Closes (ABC) 65°
Number of Coils 6.8 Opens (BTC) 8°
Installed Height 41.66 mm Duration 250°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 31°
Wire Diameter . 4.50 mm
(0.177 in)
J9409-98
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION LOCATION O F IDENTIFICATION
CRANKSHAFT JOURNALS RorM Steel stamped (near notch) on no. 6 crankshaft

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing counterweight.
0.0254 mm (0.001 in.) journal)
and/or
R-1-4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS • Diamond-shaped stamp

(OVERSIZE) Top pad - front of engine and flat ground on
0.2032 mm (0.008 in.) outside surface of each O/S tappet bore.
VALVE STEMS (OVERSIZE) X Milled pad adjacent to two tapped holes

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head.
J9309-81
TORQUE DESCRIPTION TORQUE

DESCRIPTION
Adjusting Strap Bolt 2 3 N®m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 41 N®m (30 ft. lbs.)
Camshaft Bolt 6 8 N®m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts 2 4 N®m ( 2 1 0 in. lbs.) Trans. Support Bracket Nuts 41 N®m (30 ft. lbs.)
Chain Case Cover Bolts 41 N®m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts 61 N®m (45 ft. lbs.) Bracket Bolts 6 8 N®m (50 ft. lbs.)
Crankshaft Main Bearing Cap Bolts .... 115 N®m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N®m (30 ft. lbs.)
1 st Step 68 N®m (50 ft. lbs.) Rocker Arm Bolts 23 N®m (200 in. lbs.)
2nd Step 1 4 3 N®m ( 1 0 5 ft. lbs.)
Cylinder Head Cover Bolts 11 N®m (95 in. lbs.) Spark Plugs 41 N®m (30 ft. lbs.)
Starter Mounting Bolts 68 N®m (50 ft. lbs.)
Exhaust Manifold-to-Cylinder
34 N»m (25 ft. lbs.) Throttle Body Bolts 23 N®m (200 in. lbs.)
Torque Converter Drive Plate
02 N»m (75 ft. lbs.) Bolts 31 N®m ( 2 7 0 in. lbs.)
Front Mount - Engine Support Transfer Case-to-lnsulator
41 N»m (30 ft. lbs.) Mounting Plate Nuts 204 N®m (150 ft. lbs.)
41 N»m (30 ft. lbs.) Vibration Damper Retainer

Bolt 183 N®m (135 ft. lbs.)
Intake Manifold Bolts Refer to Procedure
in Service Manual. Water Pump-to-Chain Case
Cover Bolt 41 N®m (30 ft. lbs.)
Oil Pan Bolts 23 N®m (200 in. lbs.)
Oil Pan Drain Plug 34 N®m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N®m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N®m (95 in. lbs.) J9409-82
9 - 44 S.2L ENGINE
INOEX
page page
Camshaft 56 General Information . 44
Crankshaft 61 Hydraulic Tappets 52
Crankshaft Main Bearings 62 Oil Pan ..... ....... 58
Crankshaft Rear Oil Seals 63 Oil Pump 59
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Specifications—5.2L Engine 67
Distributor 57 Timing Chain Cover 54
Engine Assembly 46 Valve Stem Shield / Spring Replacement 52
Engine Front Mounts 44 Valve Timing 53
Engine Rear Mount . . . . . . . . . . . . . . . . . . . . . . . . 45 Valves / Valve Springs 50
Front Crankshaft Oil Seal Replacement . . . . . . . . . 56 Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . 53
GENERAL INFORMATION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. 1).
Eng it* Type.... .90° V-8 OHV

Bore and Stroke 99.3 x 84.0 mm (3.91 x 3.31 in.)
Displacement .....5.21 (318 cu. in.)
Compression Ratio 9.1:1
Torque .....407 N®m (300 ft. lb.) © 3,200 rpm
Firing Oder .1-8-4-3-6-5-7-2
Lubrication Pressure Feed - Full Flow Filtration
Engine Oil Capacity 4.7L (5.0 Qts) with Filter
Cooling System ....Liquid Cooled - Forced Circulation
Ceding Capacity. 16.1 L (17.0 Qts) J908D-49
Cylinder Block Cast Iron
Crankshaft .....Nodular Iron
Fig. 2 Firing Order
Cylinder Head ..Cast Iron
Combustion Chambers Wedge-High Swirl Valve Shrouding X M 5 J L T XXXX XXXXXXXX
Camshaft Nodular Cast Iron
Pistons.... ...Aluminum Alloy w/Strut
Connecting Rods ....Forged Steel X = Last Digit of Model Year
M = Plant - M Mound Road
S Saltillo
T Trenton
J9409-10
K Toluca
5.2L = Engine Displacement
Fig. 1 Engine Description T = Usage - T Truck
This engine is designed for unleaded fuel. XXXX = Month/Day
Engine lubrication system consists of a rotor type XXXXXXXX « Serial Code - Last 8 Digits of VIN No.
The cylinders are numbered from front to rear; 1, J9209-73
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2). Fig. 3 Engine Identification Number
The engine serial number is stamped into a ma ENGINE FRONT MOUNTS
chined pad located on the left, front corner of the cyl
inder block. When component part replacement is REMOVAL
necessary, use the engine type and serial number for (1) Disconnect the negative cable from the battery.
reference (Fig. 3).
tank and hose.

manifold.

(€) Remove engine support bracket/cushion bolts
heat shields.
CUSHION
BRACKET
J9409-54
J9409-52

INSTALLATION
lbs.) torque.
bracket/cushion.
(4) Install thru-bolt nuts and tighten the huts to
ENGINE REAR MOUNT Fig. 6 Engine Rear Support Cushion

REMOVAL transmission support bracket to the transmission
port cushion.
System).
Service).
equipped.
oil.
port bracket. Install stud nuts and tighten to 41 N-m (31) Disconnect exhaust pipe at manifold.
(32) Disconnect the starter wires. Remove starter
Service).
(Fig. 6). cover.
(4) Install the support cushion bolts and tighten to (34) AUTOMATIC TRANSMISSION;
(35) M A N U A L TRANSMISSION:
REMOVAL (a) Remove the prop shaft (refer to Group 16,
(3) Remove the upper crossmember and top core (d) Remove the crossmember.
support. (e) Remove the clutch assembly and slave cylin
(4) Remove the transmission oil cooler. der.
(5) Discharge the air conditioning system, i f (f) Disconnect all wiring and connectors.
equipped (refer to Group 24, Heating and A i r Condi (g) Remove transmission bolts. Remove the
tioning for service procedures). transmission.
(6) Remove the serpentine belt (refer to Group 7, (h) Remove the bell housing.
Cooling System). (i) Remove clutch assembly.
(7) Remove the A/C compressor with the lines at (j) Remove flywheel and ring gear.
tached. Set aside. (36) Lower the vehicle.
(8) I f equipped, remove the condenser. (37) Install a jack stand under the automatic
(9) Remove the washer bottle. transmission.
(4) AUTOMATIC TRANSMISSION:
Cooling System).
bolts to 31 N-m (270 i n . lbs.) torque. tem, i f equipped (refer to Group 24, Heating and Air
(refer to Group 8B, Battery/Starter/Generator Ser CYLINDER HEAD
vice).
from oil pan.
Tighten the nuts.
shift lever (refer to Group 21, Transmissions). REMOVAL
(15) Connect the fuel lines.
(16) Connect the transmission cooler lines.
(2) Disconnect closed ventilation system and evap
(17) Connect the power steering hoses, i f equipped.
oration control system from cylinder head cover.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring. (3) Remove cylinder head cover and gasket. The
(20) Install the intake manifold (refer to Group 11, gasket may be used again.
Exhaust System and Intake Manifold).
CLEANING
(21) Using a new gasket, install throttle body.
Clean cylinder head cover gasket surface.
Tighten the throttle body bolts to 23 N-m (200 i n .
lbs.) torque. Clean head rail, i f necessary.
(23) Install the air cleaner box.
Inspect cover for distortion and straighten, i f nec
(24) Install the generator and wire connections (re
essary.
fer to Group 8B, Battery/Starter/Generator Service).
(25) Install radiator (refer to Group 7, Cooling Sys Check the gasket for use i n head cover installation.
tem). I f damaged, use a new gasket.
INSTALLATION EXHAUST SPARK EXHAUST SPARK EXHAUST
(1) The cylinder head cover gasket can be used VALVE PLUGS VALVES PLUGS VALVE
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
evaporation control system.
ROCKER ARMS
REMOVAL
boot straight out i n line with plug. INTAKE INTAKE
VALVES VALVES J9309-37
moved. REMOVAL
(4) Remote the push rods and place them on a (1) Disconnect the negative cable from the battery.
bench i n the same order as removed. (2) Drain cooling system (refer to Group 7, Cooling
ROCKER CYLINDER System for the proper procedures).
J9209-65
Fig. 2 Rocker Arms
INSTALLATION
firing position.
ing or immediately after rocker arm installation. Al (4) Remove the intake manifold-to-generator
low the hydraulic roller tappets adequate time to bracket support rod. Remove the generator.
(3) Install rocker arm and pivot assemblies i n the (8) Disconnect the fuel lines.
same order as removed. Tighten the rocker arm bolts (9) Disconnect accelerator linkage and i f so
to 28 N-m (21 ft. lbs.) torque. equipped, the speed control and transmission kick-
(4) Install cylinder head cover. down cables.
(5) Connect spark plug wires. (10) Remove the return spring.
CYLINDER HEADS (12) Disconnect the coil wires.
The alloy cast iron cylinder heads (Fig. 3) are held (13) Disconnect heat indicator sending unit wire.
in place by 10 bolts. The spark plugs are located i n (14) Disconnect heater hoses and bypass hose.
the peak of the wedge between the valves. (15) Remove cylinder head covers and gaskets.
The 5.2L cylinder head is identified by the foundry
mark N H .
(16) Remove intake manifold and throttle body as (4) Starting at top center, tighten all cylinder head
an assembly. Discard the flange side gaskets and the bolts, i n sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
front and rear cross-over gaskets. 6). Repeat procedure, tighten all cylinder head bolts
(17) Remove exhaust manifolds. to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
(18) Remove rocker arm assemblies and push rods. confirm that all bolts are at 143 N-m (105 ft. lbs.)
Identify to ensure installation i n original locations. torque.
(19) Remove the head bolts from each cylinder
der head gasket.
CLEANING
heads.
INSPECTION
Inspect all surfaces with a straightedge i f there is
any reason to suspect leakage. I f out-of-flatness ex
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length i n inches i n any direction, either replace
head or lightly machine the head surface. Fig. 6 Cylinder Head Bolt Tightening Sequence
FOR EXAMPLES A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out- CAUTION: When tightening the rocker arm bolts,
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 make sure the piston in that cylinder is NOT at
mm (0.009 inch). This amount of out-of-flat is accept T D C . Contact between the valves and piston could
able. occur.
The cylinder head surface finish should be
(5) Install push rods and rocker arm assemblies i n
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION (6) Install the intake manifold and throttle body
(1) Apply Perfect Sealant No.5, or equivalent, to assembly (refer to Group 11, Exhaust System and In
both sides of the gasket (Fig. 5). take Manifold).
(7) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
(8) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
(9) Install coil wires.
(10) Connect heat indicator sending unit wire.
(11) Connect the heater hoses and bypass hose.
(12) Install distributor cap and wires.
(14) Connect the accelerator linkage and i f so
down cables.
generator mounting bolt to 41 N-m (30 ft. lbs.)
Fig. 5 Sealant Location on Cylinder Head Gasket torque. Tighten the adjusting strap bolt to 23 N-m
(2) Position the new cylinder head gaskets onto the tem for adjusting the belt tension.
cylinder block.
(3) Position the cylinder heads onto head gaskets
bracket support rod. Tighten the bolts.
and cylinder block.
9 - 50 5.2L ENGINE •
(18) Place the cylinder head cover gaskets i n posi
tion and install cylinder head covers. Tighten the
(22) Install the heat shields. Tighten the bolts to

The rocker pivot support- and the valve guides are
cast integral with the heads.
This procedure requires the removal of the cylinder Fig, 8 Measuring Waive Guide Wear
head. head and set i t at right angle of valve stem being
REMOWAL measured (Fig. 8).
(1) Remove the cylinder head. (c) Move valve to and from the indicator. The to
(2) Compress valve springs using Valve Spring tal dial indicator reading should not exceed 0.432
Compressor Tool MD-998772A. mm (0.017 inch). Ream the guides for valves with
(3) Remove valve retaining locks, valve spring re oversize stems i f dial indicator reading is excessive
tainers, valve stem seals and valve springs. or i f the stems are scuffed or scored.
(4) Before removing valves, remove any burrs from Service valves with oversize stems are available
valve stem lock grooves to prevent damage to the (Fig. 9).
valve guides. Identify valves to ensure installation i n
original location. learner O / S Valve Guide Size
VALVE CLEANING 0.076 mm 8.026 - 8.052 mm

Clean valves thoroughly. Discard burned, warped (0.003 in.) ( 0 . 3 1 6 - 0 . 3 1 7 in.)
and cracked valves.
Remove carbon and varnish deposits from inside of 0.381 mm 8 . 3 3 1 - 8 . 3 5 7 mm
valve guides with a reliable guide cleaner. (0.015 in.) ( 0 . 3 2 8 - 0 . 3 2 9 in.)
WALWE INSPECTION
Measure valve stems for wear. I f wear exceeds
J9309-30
0.051 mm (0.002 inch), replace the valve.
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig.. 7). The special Slowly turn reamer by hand and clean guide thor
sleeve places the valve at the correct height for oughly before installing new valve. Ream the valve
checking with a dial indicator. guides from standard to 0.381 mm (0.015 inch).
Use a 2 step procedure so the valve guides are
reamed true in relation to the valve seat:
• Step 1-Ream to 0.0763 mm (0.003 inch).
• Step 2—Ream to 0.381 mm (0.015 inch).
REFACING WALWES / WALWE SEATS

(Fig. 10).
WALWES
Inspect the remaining margin after the valves are
Fig, 7 Positioning Waive with Too! C-3973 refaced (Fig. 11). Valves with less than 1.190 mm
(b) Attach Dial Indicator Tool C-3339 to cylinder (0.047 inch) margin should be discarded.
§.2L ENGINE I - 51
CONTACT
POINT 3
REFACING STONE i
4574° - 45 A° MUST NOT CUT
VALVE SHROUD
A - SEAT WIDTH - INTAKE 1.016 - 1.524 mm (0.040 - 0.060 in.)

EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 m.)
B - FACE ANGLE (INTAKE & EXHAUST) 4374° - 43 A° 3
valve i n place. Rotate the valve with light pressure.

C - SEAT ANGLE (INTAKE & EXHAUST) 4474° - 44%°
D - CONTACT SURFACE
I f the blue is transferred to the center of valve face,
contact is satisfactory. I f the blue is transferred to
J9309-95
the top edge of valve face, lower valve seat with a 15°
stone. I f the blue is transferred to bottom edge of
Fig. 10 Valve Face and Seat Angles
INTAKE EXHAUST inch). The width of the exhaust seats should be
VALVE VALVE 1.524-2.032 mm (0.060-0.080 inch).
VALVE SPRING INSPECTION

Whenever valves have been removed for inspection,
* STEM-
Valve Spring Tester Tool C-647 until surface is i n line
VALVE SPRING with the 1-5/16 inch mark on the threaded stud. Be
RETAINER LOCK sure the zero mark is to the front (Fig. 13). Place
GROOVE
spring over stud on the table and lift compressing le
ver to set tone device. Pull on torque wrench until
J9209-127 ping is heard. Take reading on torque wrench at this
k=0 instant. Multiply this reading by 2. This will give the
Fig. 11 Intake and Exhaust Valves spring load at test length. Fractional measurements
are indicated on the table for finer adjustments. Re
VALVE SEATS
fer to specifications to obtain specified height and al
lowable tensions. Discard the springs that do not
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 12).
INSTALLATION
(1) When refacing valve seats, i t is important that
(1) Coat valve stems with lubrication oil and insert
the correct size valve guide pilot be used for reseat them i n cylinder head.
ing stones. A true and complete surface must be ob (2) I f valves or seats are reground, check valve
tained. stem height. I f valve is too long, replace cylinder
(2) Measure the concentricity of valve seat using a head.
dial indicator. Total runout should not exceed 0.051 (3) Install new seals on all valve guides. Install
mm (0.002 inch) total indicator reading. valve springs and valve retainers.
(3) Inspect the valve seat with Prussian blue to de (4) Compress valve springs with Valve Spring
termine where the valve contacts the seat. To do this, Compressor Tool MD-998772A, install locks and re
coat valve seat LIGHTLY with Prussian blue then set lease tool. I f valves and/or seats are ground, measure
(12) Remove adapter from the N o . l spark plug
hole.
(13) Install rocker arms.
(14) Install covers and coil wire to distributor.
(16) Road test vehicle.
HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor
rect tappet noise, check the oil pressure. I f vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick.
Fig. 13 Testing Waive Spring for Compressed The oil level i n the pan should never be above the
Length with Tool C-647 FULL mark or below the ADD OIL mark on dipstick.
the installed height of springs. Make sure the mea Either of these 2 conditions could be responsible for
surement is taken from bottom of spring seat i n cyl noisy tappets.
inder head to the bottom surface of spring retainer. I f
spacers are installed, measure from the top of spacer. OIL LEVEL
I f height is greater than 42.86 mm (1-11/16 inches), HIGH
install a 1.587 mm (1/16 inch) spacer i n head coun-
I f oil level is above the FULL mark, i t is possible
terbore. This should bring spring height back to nor
for the connecting rods to dip into the oil. With the
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). engine running this condition could create foam i n
the oil pan. Foam i n oil pan would be fed to the hy
VALVE STEM SHIELD / SPRING REPLACEMENT draulic tappets by the oil pump causing them to lose
This procedure is done with the cylinder head i n length and allow valves to seat noisily.
stalled.
(1) Set engine basic timing to Top Dead Center LOW
(TDC). Low oil level may allow oil pump to take i n air.
(2) Remove the air cleaner. When air is fed to the tappets, they lose length which
(3) Remove cylinder head covers and spark plugs. allows valves to seat noisily. Any leaks on intake side
(4) Remove coil wire from distributor and secure to of oil pump through which air can be drawn will cre
good ground to prevent engine from starting. ate the same tappet action. Check the lubrication
(5) Using suitable socket and flex handle at crank system from the intake strainer to the pump cover,
shaft retaining bolt, turn engine so the N o . l piston is including the relief valve retainer cap. When tappet
at TDC on the compression stroke. noise is due to aeration, i t may be intermittent or
(6) Remove rocker arms. constant, and usually more than 1 tappet will be
(7) With air hose attached to an adapter installed noisy. When oil level and leaks have been corrected,
in N o . l spark plug hole, apply 620-689 kPa (90-100 operate the engine at fast idle. Run engine for a suf
psi) air pressure. ficient time to allow all of the air inside the tappets
(8) Using Valve Spring Compressor Tool to be bled out.
MD-998772A, compress valve spring and remove re
tainer valve locks and valve spring. TAPPET NOISE DIAGNOSIS
(9) Install seals on the exhaust valve stem and po (1) TB determine source of tappet noise, operate en
sition down against valve guides. gine at idle with cylinder head covers removed.
(10) The intake valve stem seals should be pushed (2) Feel each valve spring or rocker arm to detect
firmly and squarely over the valve guide using the noisy tappet. The noisy tappet will cause the affected
valve stem as a guide. DO NOT force seal against top spring and/or rocker arm to vibrate or feel rough i n
of guide. When installing the valve retainer locks, operation.
compress the spring only enough to install the locks. Worn valve guides or cocked springs are
(11) Follow the same procedure on the remaining 7 sometimes mistaken for noisy tappets. I f such is
cylinders using the firing sequence 1-8-4-3-6-5-7-2. the case, noise may be dampened by applying
Make sure piston i n cylinder is at TDC on the valve side thrust on the valve spring. I f noise is not
spring that is being removed. appreciably reduced, it can be assumed the
noise is i n the tappet. Inspect the rocker arm (7) Install cylinder head cover.
push rod sockets and push rod ends for wear. (8) Start and operate engine. Warm up to normal
(3) Valve tappet noise ranges from light noise to a operating temperature.
heavy click. A light noise is usually caused by exces
sive leak-down around the unit plunger or by the CAUTION: To prevent damage to valve mechanism,
plunger partially sticking i n the tappet body cylinder. engine must not be run above fast idle until all hy
The tappet should be replaced. A heavy click is draulic tappets have filled with oil and have become
caused by a tappet check valve not seating or by for quiet.
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
stick i n the down position. This heavy click will be VALVE TIMING
accompanied by excessive clearance between the (1) Turn crankshaft until the No.6 exhaust valve is
valve stem and rocker arm as valve closes. I n either closing and No.6 intake valve is opening.
case, tappet assembly should be removed for inspec (2) Insert a 6.350 mm (1/4 inch) spacer between
tion and cleaning. rocker arm pad and stem tip of No.l intake valve. A l
The valve train generates a noise very much like a low spring load to bleed tappet down giving i n effect
light tappet noise during normal operation. Care a solid tappet.
must be taken to ensure that tappets are making the (3) Install a dial indicator so plunger contacts
noise. I n general, i f more than one tappet seems to valve spring retainer as nearly perpendicular as pos
be noisy, its probably not the tappets. sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run-
REMOVAL niiig direction) until the valve has lifted 0.254 mm
(1) Remove the air cleaner. (0.010 inch). The timing of the crankshaft should
(2) Remove cylinder head cover. now read from 10° before top dead center to 2° after
(3) Remove rocker assembly and push rods. Iden top dead center. Remove spacer.
tify push rods to ensure installation i n original loca
tion. CAUTION: DO NOT turn crankshaft any further
(4) Remove intake manifold. clockwise a s valve spring might bottom and result
(5) Remove yoke retainer and aligning yokes. in serious damage.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening i n cylinder head and seat (5) I f reading is not within specified limits:
tool firmly i n the head of tappet. (a) Check sprocket index marks.
(7) Pull tappet out of bore with a twisting motion. (b) Inspect timing chain for wear.
I f all tappets are to be removed, identify tappets to (c) Check accuracy of DC mark on timing indica
ensure installation i n original location. tor.
(8) I f the tappet or bore i n cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to VIBRATION DAMPER
next oversize. Replace with oversize tappet.
REMOVAL
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must al
(2) Remove fan shroud retainer bolts and set
ways be fitted to the original body. It is advisable tb
shroud back over engine.
work on one tappet at a time to avoid mixing of
(3) Remove the cooling system fan.
parts. Mixed parts are not compatible. DO NOT dis
assemble a tappet on a dirty work bench.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
INSTALLATION (6) Remove vibration damper bolt and washer from
(1) Lubricate tappets. end of crankshaft.
(2) Install tappets and push rods i n their original (7) Install bar and screw from Puller Tool Set
positions. Ensure that the oil feed hole i n the side of C-3688. Install 2 bolts with washers through the
the tappet body faces up (away from the crankshaft). puller tool and into the vibration damper (Fig. 1).
(3) Install aligning yokes with ARROW toward (8) Pull vibration damper off of the crankshaft.
camshaft. (
(4) Install yoke retainer. Tighten the bolts to 23 INSTALLATION
N-m (200 in. lbs.) torque. Install intake manifold. (1) Position the vibration damper onto the crank
(5) Install push rods i n original positions. shaft.
(6) Install rocker arm.
at each side.
damage the crankshaft seal surface of cover (Fig. 3).
Fig. 1 Vibration Damper Assembly

(2) Place installing tool, part of Puller Tool Set
C-3688 i n position and press the vibration damper
onto the crankshaft (Fig. 2).
Fig. 3 Removal of Front Crankshaft Oil Seal

(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam
rection of crankshaft rotation to take up slack; 41
Fig. 2 Installing Vibration Damper N-m (30 ft. lbs.) torque with cylinder head installed
or 20 N-m (15 ft. lbs.) torque with cylinder head re
(3) Install the crankshaft bolt and washer. Tighten moved. With a torque applied to the camshaft
the bolt to 183 N-m (135 ft. lbs.) torque. sprocket bolt, crankshaft should not be permitted to
(4) Install the crankshaft pulley. Tighten the pul move. I t may be necessary to block the crankshaft to
ley bolts to 23 N-m (200 in. lbs.) torque. prevent rotation.
(5) Install the serpentine belt (refer to Group 7, (3) Hold a scale with dimensional reading even
Cooling System). with the edge of a chain link. With cylinder heads in
(6) Install the cooling system fan. Tighten the bolts stalled, apply 14 N-m (30 ft. lbs.) torque i n the re
to 23 N-m (17 ft. lbs.) torque. verse direction. With the cylinder heads removed,
(7) Position the fan shroud and install the bolts. apply 20 N-m (15 ft. lbs.) torque i n the reverse direc
Tighten the retainer bolts to 11 N-m (95 in. lbs.) tion. Note the amount of chain movement (Fig. 4).
torque.
TIMING CHAIN C0¥ER

REMOVAL
System).
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
Fig. 4 Measuring Timing Chain Wear and Stretch
System).
(5) Remove power steering pump (refer to Group (4) Install a new timing chain, i f its movement ex
19, Steering). ceeds 3.175 mm (1/8 inch).
(6) Remove vibration damper. (5) I f chain is not satisfactory, remove camshaft
(7) Remove fuel lines (refer to Group 14, Fuel Sys sprocket attaching bolt and remove timing chain with
tem). crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft CRANKSHAFT. INSTALL THIS
sprocket on the bench with timing marks on exact FRONT OIL END INTO
imaginary center line through both camshaft and SEAL SPECIAL TOOL
crankshaft bores. 6635

shaft sprocket.
J9309-44
Fig. 6 Placing Oil Seal on Installation Tool 6635
SPECIAL TOOL
TIMING
J9409-97
MARKS

used thrust plate. I f not within these limits install a
new thrust plate.
CLEANING
Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs. TIMING'
The water pump mounting surface must be CHAIN
COVER J9309-45*-
cleaned.
INSTALLATION Fig. 7 Position Tool and Seal onto Crankshaft

(1) Using a new cover gasket, carefully install (6) Remove the vibration damper bolt and seal in
chain case cover to avoid damaging oil pan gasket. stallation tool.
Use a small amount of Mopar Silicone Rubber Adhe (7) Install vibration damper.
sive Sealant, or equivalent, at the joint between tim (8) Install fuel lines (refer to Group 14, Fuel Sys
ing chain cover gasket and the oil pan gasket. Finger tem).
tighten the timing chain cover bolts at this time. (9) Install water pump and housing assembly us
(2) Place the smaller diameter of the oil seal over ing new gaskets (refer to Group 7, Cooling System).
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(10) Install power steering pump (refer to Group
19, Steering).
(Fig. 7).
bolt to draw the seal into position on the crankshaft Cooling System).
(Fig. 8). (12) Install the cooling system fan. Tighten the
(5) Tighten chain case cover bolts to 41 N-m (30 ft. bolts to 23 N-m (17 ft. lbs.) torque.
lbs.) torque. Tighten oil pan bolts to 24 N-m (215 in. (13) Position the fan shroud and install the bolts.
lbs.) torque. Tighten the bolts to 11 N-m (95 i n . lbs.) torque.
The camshaft has an integral oil pump and distrib
utor drive gear (Fig. 9).
THRUST
PLATE
PUMP A N D
DISTRIBUTOR DRIVE
GEAR INTEGRAL
WITH CAMSHAFT
•CAMSHAFT SPROCKET
J9309-71
Fig. 9 Camshaft and Sprocket Assembly

REMOVAL
(1) Remove intake manifold.
(2) Remove cylinder head covers.
(3) Remove timing case cover and timing chain.
(4) Remove rocker arms.
J9309-46 (5) Remove push rods and tappets. Identify each
part so i t can be installed i n its original location.
Fig. 8 Installing Oil Seal (6) Remove distributor and lift out the oil pump
(14) Fill cooling system (refer to Group 7, Cooling and distributor drive shaft.
System for the proper procedure). (7) Remove camshaft thrust plate, note location of
(15) Connect the negative cable to the battery. oil tab (Fig. 10).
FRONT CRANKSHAFT OIL SEAL REPLACEMENT

The oil seal can be replaced without removing the
aligned.
oil seal alignment to crankshaft. The seal installa
tion/alignment tool 6635, should fit with minimum
moved and installed properly.
the oil seal i n the groove of the tool. THRUST PLATE
(6) Position the seal and tool onto the crankshaft REAR SIDE
(Fig. 7).
J9209-132
bolt to draw the seal into position on the crankshaft
(Fig. 8). Fig. 10 Timing Chain Oil Tab installation
(8) Remove the vibration damper bolt and seal in (8) Install a long bolt into front of camshaft to fa
stallation tool. cilitate removal of the camshaft. Remove camshaft,
(9) Install the vibration damper. being careful not to damage cam bearings with the
(10) Connect the negative cable to the battery. cam lobes.
CAMSHAFT REMOVAL—BEARING
This procedure requires that the engine is removed (1) With engine completely disassembled, drive out
from the vehicle. rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell, Drive
out bearing shells (Fig. 11).
Fig. 12 Camshaft Holding Tool C-3509 (Installed

Position)
Fig. 11 Camshaft Bearings Removal and Installation imaginary center line through both camshaft and
with Tool C-3132-A crankshaft bores.
INSTALLATION—BEARING (6) Place timing chain around both sprockets.
(1) Install new camshaft bearings with Camshaft (7) Turn crankshaft and camshaft to line up with
Bearing Remover/Installer Tool C-3132-A by sliding keyway location i n
the new camshaft bearing shell over proper adapter. crankshaft sprocket and i n camshaft sprocket.
(2) Position rear bearing i n the tool. Install horse (8) Lift sprockets and chain (keep sprockets tight
shoe lock and by reversing removal procedure, care against the chain i n position as described).
fully drive bearing shell into place. (9) Slide both sprockets evenly over their respec
(3) Install remaining bearings i n the same manner. tive shafts and use a straightedge to check alignment
Bearings must be carefully aligned to bring oil holes of timing marks (Fig. 13).
bearing. I f the camshaft bearing shell oil holes are
camshaft. Be sure this p l u g does n o t leak.
INSTALLATION
Whenever a n engine has been r e b u i l t , a new
camshaft and/or new tappets installed, a d d 1
p i n t o f M o p a r Crankcase Conditioner, o r equiv
alent. The o i l m i x t u r e should be left i n engine (10) Install the camshaft bolt/cup washer. Tighten
for a m i n i m u m o f 805 k m (500 miles). D r a i n at bolt to 68 N-m (50 ft. lbs.) torque.
t h e next n o r m a l o i l change. (11) Measure camshaft end play. Refer to Specifica
(2) Install Camshaft Gear Installer Tool C-3509 tions for proper clearance. I f not within limits install
with tongue back of distributor drive gear (Fig. 12). a new thrust plate.
(3) Hold tool i n position with a distributor lock- (12) Each tappet reused must be installed i n the
plate bolt. This tool will restrict camshaft from being same position from which i t was removed. When
pushed i n too far and prevent knocking out the welch camshaft is replaced, a l l o f the tappets must be
plug i n rear of cylinder block. Tool should r e m a i n replaced.
installed u n t i l the camshaft a n d crankshaft
sprockets a n d t i m i n g c h a i n have been installed. DISTRIBUTOR
REMOVAL
M a k e sure t a n g enters l o w e r r i g h t hole i n
t h r u s t plate. Tighten bolts to 24 N-m (210 i n . lbs.)
procedure.
REMOVAL—DRIVE SHAFT BUSHING (4) Install the intake manifold (refer to Group 11,
(1) Remove the intake manifold (refer to Group 11, Exhaust System and Intake Manifold).
(2) Insert Distributor Drive Shaft Bushing Puller DISTRIBUTOR TIMING
Tool C-3052 into old bushing and thread down until a Before installing the distributor and oil pump drive
tight fit is obtained (Fig. 14). shaft, time engine as follows:
(1) Rotate crankshaft until N o . l cylinder is at top
(3) Hold puller screw and tighten puller nut until
dead center on the firing stroke.
bushing is removed.
(2) When in this position, the timing mark on v i
bration damper should be under "0" on the timing in
dicator.
(3) Coat shaft and drive gear with engine oil. I n
stall the shaft so that after the gear spirals into
i n top of drive gear should be aligned towards left

INSTALLATION—DRIVE SHAFT BUSHING
(1) Slide new bushing over burnishing end of Dis
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert the tool and bushing into the bore.
hammer (Fig. 15).
Fig. 17 Position or Installed Distributor Drive Gear
INSTALLATION
procedure.
OIL PAN
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
Fig. 15 Distributor Driveshaft Bushing Installation (4) Drain engine oil.
(3) As the burnisher is pulled through the bushing, (6) Remove left engine to transmission strut.
the bushing is expanded tight i n the block and bur (7) Loosen the right side engine support bracket
nished to correct size (Fig. 16). D O NOT ream this cushion thru-bolt nut and raise the engine slightly.
bushing. Remove oil pan by sliding backward and out.
CLEANING
the sealant inside the rear main cap slots.
I f present, t r i m excess sealant from inside the en
gine.
Clean oil pan i n solvent and wipe dry with a clean
cloth.
Fig. 16 Burnishing Distributor Driveshaft Bushing

Clean oil screen and pipe thoroughly i n clean sol (5) Position the oil pan over the dowels and onto
vent. Inspect condition of screen. the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
INSPECTION N-m (215 i n . lbs.) torque.
Inspect oil drain plug and plug hole for stripped or (7) Remove the dowels. Install the remaining oil
damaged threads. Repair as necessary. pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
Inspect oil pan mounting flange for bends or distor torque.
tion. Straighten flange, i f necessary. (8) Lower the engine into the support cushion
brackets and tighten the thru bolt nut to the proper
INSTALLATION torque.
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 (9) Install the drain plug. Tighten drain plug to 34
inch bolts. Cut the head off the bolts and cut a slot N-m (25 ft. lbs.) torque.
into the top of the dowel. This will allow easier in (10) Install the engine to transmission strut.
stallation and removal with a screwdriver (Fig. 1). (11) Install exhaust pipe.
1V " x 5 / 1 6 " BOLT
2
(12) Lower vehicle.
(13) Install dipstick.
(15) Fill crankcase with oil to proper level.
OIL P U M P
DOWEL
OIL PUMP PRESSURE
The M I N I M U M oil pump pressure is 41.4 kPa (6
Ai
SLOT J9209-106
Fig. 1 Fabrication of Alignment Dowels CAUTION: If oil pressure is Z E R O at curb idle, DO
(2) Install the dowels i n the cylinder block (Fig. 2). NOT run engine at 3,000 RPM.
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent i n the corner of the
REMOVAL
cap and the cylinder block. (1) Remove the oil pan.
(4) Slide the one-piece gasket over the dowels and (2) Remove the oil pump from rear main bearing
onto the block. cap.
DOWEL DOWEL
INSTALLATION
(1) Install oil pump. During installation slowly ro
tate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
PISTON / CONNECTING R O DA S S E M B
The pistons are elliptically turned so that the di
across the thrust face. This allows for expansion un
nearly round shape.
All pistons are machined to the same weight, re
DOWEL \ \ ©//DOWEL// J9309-79 gardless of size, to maintain piston balance.
The piston pin rotates i n the piston only and is re
Fig. 2 Position of Dowels in Cylinder Block tained by the press interference fit of the piston pin
in the connecting rod.
REMOWAL measured halfway down the cylinder bore and trans
(1) Remove the engine from the vehicle. verse to the engine crankshaft center line.
(2) Remove the cylinder head. Pistons and cylinder bores should be measured at
(3) Remove the oil pan. normal room temperature, 21°C (70°F).
(4) Remove top ridge of cylinder bores with a reli
able ridge reamer before removing pistons from cyl FITTING RINGS
inder block. Be sure to keep tops of pistons covered (1) Measurement of end gaps:
during this operation. (a) Measure piston ring gap 2 inches from bot
(5) Be sure the connecting rod and connecting rod tom of cylinder bore. A n inverted piston can be
cap are identified with the cylinder number. Remove used to push the rings down to ensure positioning
connecting rod cap. Install connecting rod bolt guide rings squarely i n the cylinder bore before measur
ing.
set on connecting rod bolts.
(b) Insert feeler gauge i n the gap. The top com
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
connecting rod assemblies, rotate crankshaft center ring gap should be between 0.508-0.762 mm (0.020-
the connecting rod i n the cylinder bore and at BDC. 0.030 inch). The oil ring gap should be 0.254-1.270
Be careful n o t t o n i c k crankshaft j o u r n a l s . mm (0.010-0.050 inch).
INSPECTION
(2) Install rings and confirm ring side clearance:
DIAMETER (D) face up (toward top of piston) and the chamfer
SHOULD BE 98.704-98.831 mm should face down. A n identification mark on the
0.0000-0.0152 mm (3.886-3.891 in.] ring is a drill point, a stamped letter "O", an oval
(0.0000-0.0006 in.
LARGER THAN (C). depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 4). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression
rings. The steel rail oil ring should be free i n
groove, but should not exceed 0.203 mm (0.0080
inch) side clearance.
FEELER GAUGE
ELLIPTICAL SHAPE OF THE PISTON

SKIRT SHOULD BE 0.254-0.304 mm
(A) THAN ACROSS THE THRUST
FACES AT DIAMETER (B).
J9309-9
RING
GROOVE
Fig. 3 Piston Measurements
FITTING PISTONS J9209-136
Specified clearance between the piston and the cylin Fig. 4 Measuring Piston Ring Side Clearance
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). (d) Pistons with insufficient or excessive side
Piston diameter should be measured at the top of clearance should be replaced.
skirt, 90° to piston pin axis. Cylinder bores should be (3) Orient the rings:
(a) Arrange top compression ring 90° counter (4) Install connecting rod bolt protectors on rod
clockwise from the oil ring rail gap (Fig. 5). bolts, the long protector should be installed on the
(b) Arrange second compression ring 90° clock numbered side of the connecting rod.
wise from the oil ring rail gap (Fig. 5). (5) Rotate crankshaft so that the connecting rod
OIL RING journal is on the center of the cylinder bore. Be sure
SPACER GAP connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down i n cylinder bore, using a
SECOND hammer handle. A t the same time, guide connecting
COMPRESSION
TOP rod into position on crankshaft journal.
RING GAP
COMPRESSION (7) The notch or groove on top of piston must be
OIL RING RAIL
RING GAP
GAP (TOP) pointing toward front of engine. The larger chamfer
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con
necting rod cap and cylinder bore number are the
OIL RING RAIL same. Install nuts on cleaned and oiled rod bolts and
GAP (BOTTOM) J9309-80 tighten nuts to 61 N-m (45 ft. lbs.) torque.
Fig. 5 Proper Ring Installation (10) Install the cylinder head.
CONNECTING ROD BEARINGS (11) Install the engine into the vehicle.
Fit all rods on a bank until completed. DO NOT al
ternate from one bank to another, because connecting CRANKSHAFT
rods and pistons are not interchangeable from one A crankshaft which has undersize journals w i l l be
bank to another. stamped with 1/4 inch letters on the milled flat on
The bearing caps are not interchangeable and the No.8 crankshaft counterweight (Fig. 6).
should be marked at removal to ensure correct as F O R E X A M P L E : R2 stamped on the No.8 crank
sembly. shaft counterweight indicates that the No.2 rod jour
Each bearing cap has a small V-groove across the nal is 0.025 mm (0.001 in) undersize. M4 indicates
parting face. When installing the lower bearing shell, that the No.4 main journal is 0.025 mm (0.001 in)
make certain that the V-groove i n the shell is i n line undersize. R3 M2 indicates that the No.3 rod journal
with the V-groove i n the cap. This provides lubrica and the No.2 main journal are 0.025 mm (0.001 in)
tion of the cylinder wall i n the opposite bank. undersize.
The bearing shells must be installed so that the
tangs are i n the machined grooves i n the rods and Undersize Journal Identification Stamp
caps.
0.025 mm (0.001 in.! (Rod) R1-R2-R3 orR4
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch). 0.025 mm (0.001 in.) (Main) M1-M2-M3-M4 or M 5
Bearings are available i n 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
#8 CRANKSHAFT
mm (0.010 inch) and 0.305 mm (0.012 inch) under COUNTERWEIGHT
(ROD)
(MAIN)
size. Install the bearings i n pairs. DO NOT use a
new b e a r i n g half with a n old bearing half. DO
NOT file the rods o r b e a r i n g caps.
INSTALLATION
gered so that neither is in-line with oil ring rail gap.
3="
(2) Before installing the ring compressor, make J9209-138
sure the oil ring expander ends are butted and the
Fig. 6 Location of Crankshaft Identification
(3) Immerse the piston head and rings i n clean en When a crankshaft is replaced, all main and con
gine oil. Slide Piston Ring Compressor Tool C-385 necting rod bearings should be replaced with new
over the piston and tighten with the special wrench bearings. Therefore, selective fitting of the bearings
(part of Tool C-385). Be sure position o f rings is not required when a crankshaft and bearings are
does not change during this operation. replaced.
REMOWAL
(2) Remove the oil pump from the rear main bear
ing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
seal.
INSPECTION OF JOURNALS BEARING CAP J9309-72
The crankshaft connecting rod and main journals

Fig. 7 Sealant Application to Bearing Cap
should be checked for excessive wear, taper and scor
ing. The maximum taper or out-of-round on any material after assembly. DO NOT strike rear cap
crankshaft journal is 0.025 mm (0.001 inch). more than 2 times for proper engagement.
Journal grinding should not exceed 0.305 mm (8) Clean and oil all cap bolts. Install all main
(0.012 inch) under the standard journal diameter. DO bearing caps. Install all cap bolts and alternately
NOT grind thrust faces of No.3 main bearing. DO tighten to 115 N*m (85 ft. lbs.) torque.
NOT nick crank pin or bearing fillets. After grinding, (9) Install oil pump.
remove rough edges from crankshaft oil holes and (10) Install the timing chain cover.
clean out all oil passages. (11) Install the vibration damper.
(12) Apply Mopar Silicone Rubber Adhesive Seal
CAUTION: After any journal grind, it is important ant, or equivalent, at bearing cap to block joint to
that the final paper or cloth polish be in the s a m e provide cap to block and oil pan sealing (Fig. 8). Ap
direction a s the engine rotates. ply enough sealant until a small amount is squeezed
CLEANING
(13) Install new front crankshaft oil seal.
(14) Immediately install the oil pan.
inder block and rear cap mating surface. Do this be
fore applying the Loctite drop and the installation of MOPAR SILICONE SEALANT
rear cap. RUBBER ADHESIVE APPLIED
INSTALLATION
oil.
(2) Install the new upper rear bearing oil seal with
gine.
oil.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or Fig. 8 Apply Sealant to Bearing Cap to Block Joint
CRANKSHAFT MAIN BEARINGS
(Fig. 7). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing Bearing caps are not interchangeable and should
cap to cylinder block immediately after sealant appli be marked at removal to ensure correct assembly.
cation. Upper and lower bearing halves are NOT inter
(7) To align the bearing cap, use cap slot, align changeable. Lower main bearing halves of No.2 and 4
ment dowel and cap bolts. DO NOT remove excess are interchangeable.
Upper and lower No.3 bearing halves are flanged INSTALLATION
to carry the crankshaft thrust loads. They are NOT Only one main bearing should be selectively fitted
interchangeable with any other bearing halves i n the while all other main bearing caps are properly tight
engine (Fig. 9). Bearing shells are available i n stan ened. A l l bearing capbolts removed during service
dard and the following undersizes: 0.25 mm (0.001 procedures are to be cleaned and oiled before instal
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), lation.
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). When installing a new upper bearing shell, slightly
Never install an undersize bearing that will reduce chamfer the sharp edges from the plain side.
clearance below specifications. (1) Start bearing i n place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 10).
(2) Slowly rotate crankshaft counterclockwise slid
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N-m (85 ft. lbs.)
torque.
(4) Install the oil pump.

The lower seal half can only be installed with the
Fig. 9 Main Beating Identification
UPPER SEAL REPLACEMENT (CRANKSHAFT
REMOWAL
REMOWED)
(1) Remove the oil pan. (1) Remove the crankshaft. Discard the old upper
(2) Remove the oil pump from the rear main bear seal.
ing cap. (2) Clean the cylinder block rear cap mating sur
(3) Identify bearing caps before removal. Remove face. Make sure the seal groove is free of debris.
bearing caps one at a time. (3) Lightly oil the new upper seal lips with engine
(4) Remove upper half of bearing by inserting oil.
Crankshaft Main Bearing Remover/Installer Tool • (4) Install the new upper rear bearing oil seal with
C-3059 into the oil hole of crankshaft (Fig. 10). the yellow paint facing towards the rear of the en
(5) Slowly rotate crankshaft clockwise, forcing out gine.
upper half of bearing shell. (5) Position the crankshaft into the cylinder block.
oil.
cation.
material after assembly. DO NOT strike rear cap
(10) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
Fig. 10 Upper Main Bearing Removal and
Installation with Tool C-3059
(11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Seal (2) Remove the oil pump from the rear main bear
ant, or equivalent, at bearing cap to block joint to ing cap.
provide cap to block and oil pan sealing (Fig. 8). Ap (3) Remove the rear main bearing cap and discard
ply enough sealant until a small amount is squeezed the old lower seal.
out. Withdraw nozzle and wipe excess sealant off the (4) Clean the rear main cap mating surfaces in
oil pan seal groove. cluding the oil pan seal grooves.
(13) Install new front crankshaft oil seal. (5) Carefully install a new upper seal (refer to Up
(14) Immediately install the oil pan. per Seal Replacement - Crankshaft Installed proce
dure above).
UPPER SEAL REPLACEMENT (CRANKSHAFT (6) Lightly oil the new lower seal lips with engine
INSTALLED) oil.
(1) Remove the oil pan. (7) Install a new lower seal i n bearing cap with
(2) Remove the oil pump from the rear main bear yellow paint facing the rear of engine.
ing cap. (8) Apply 5 mm (0.20 in) drop of Loctite 515, or
(3) Remove the rear main bearing cap. Remove equivalent, on each side of the rear main bearing cap
and discard the old lower oil seal. (Fig. 7). DO NOT over apply sealant or allow the
(4) Carefully remove and discard the old upper oil sealant to contact the rubber seal. Assemble bearing
seal. cap to cylinder block immediately after sealant appli
(5) Clean the cylinder block mating surfaces before cation.
oil seal installation. (9) To align the bearing cap, use cap slot, align
(6) Lightly oil the new upper seal lips with engine ment dowel and cap bolts. DO NOT remove excess
oil. To allow ease of installation of the seal, loosen at material after assembly. DO NOT strike rear cap
least the 2 main bearing caps forward of the rear more than 2 times for proper engagement.
bearing cap. (10) Install the rear main bearing cap with cleaned
(7) Rotate the new upper seal into the cylinder and oiled cap bolts. Alternately tighten the cap bolts
block being careful not to shave or cut the outer sur to 115 N-m (85 ft. lbs.) torque.
face of the seal. To assure proper installation, use the (11) Install oil pump.
installation tool provided with the kit. Install the (12) Apply Mopar Silicone Rubber Adhesive Seal
new seal with the yellow paint facing towards the ant, or equivalent, at bearing cap to block joint to
rear of the engine. provide cap to block and oil pan sealing (Fig. 8). Ap
(8) Install the new lower rear bearing oil seal into ply enough sealant until a small amount is squeezed
the bearing cap with the yellow paint facing towards out. Withdraw nozzle and wipe excess sealant off the
the rear of the engine. oil pan seal groove.
(9) Apply 5 mm (0.20 in) drop of Loctite 515, or (13) Immediately install the oil pan.
(Fig. 7). DO NOT over apply sealant or allow the CYLINDER BLOCK
sealant to contact the rubber seal. Assemble bearing Remove the engine assembly from the vehicle.
cation. Be sure the yellow paint faces toward the rear DISASSEMBLE
of the engine. (1) Remove the cylinder head.
(10) To align the bearing cap, use cap slot, align (2) Remove the oil pan.
material after assembly. DO NOT strike rear cap (3) Remove the piston/connecting rod assembly.
(11) Install the rear main bearing cap with cleaned CLEANING
and oiled cap bolts. Alternately tighten A L L cap bolts Clean cylinder block thoroughly and check all core
to 115 N-m (85 ft. lbs.) torque. hole plugs for evidence of leaking.
(12) Install oil pump. INSPECTION
(13) Apply Mopar Silicone Rubber Adhesive Seal Examine block for cracks or fractures.
ant, or equivalent, at bearing cap to block joint to The cylinder walls should be checked for out-of-
provide cap to block and oil pan sealing (Fig. 8). Ap bound and taper with Cylinder Bore Indicator Tool
ply enough sealant until a small amount is squeezed C-119. The cylinder block should be bored and honed
out. Withdraw nozzle and wipe excess sealant off the with new pistons and rings fitted if:
oil pan seal groove. • The cylinder bores show more than 0.127 mm
(14) Immediately install the oil pan. (0.005 inch) out-of-round.
LOWER SEAL REPLACEMENT 0.254 mm (0.010 inch).
(1) Remove the oil pan. • The cylinder walls are badly scuffed or scored.
bores.
OIL LINE PLUG

The oil line plug is located i n the vertical passage
at the rear of the block between the Oil-Tb-Filter and
Oil-From-Filter passages (Fig. 11). Improper installa
tion or plug missing could cause erratic, low or no oil
pressure.
(1) Remove oil pressure sending unit from back of
block.
Fig. 12 Location of Cup Plugs in OH Galleries
to position properly. REMOVAL
(1) Using a blunt tool such as a drift or a screw
RIGHT OIL GALLERY
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 13).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
13).
CYLINDER
^ BLOCK ' /
CRANKSHAFT FROM OIL PUMP J9209-147
Fig. 11 Oil Line Plug

Fig. 13 Core Hole Plug Removal
(4) I f plug is off location, remove oil pan and rear
main bearing cap. Use suitable flat dowel to remove CLEANING
plug. Coat outside diameter of plug with Mopar (stud Thoroughly clean inside of cup plug hole i n cylinder
and bearing mount adhesive), or equivalent. Plug block or head. Be sure to remove old sealer.
should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches) Make certain the new plug is cleaned of all oil or
from bottom of the block. grease.
(5) Assemble engine and check oil pressure.
INSTALLATION
ENGINE CORE OIL / CAMSHAFT PLUGS (1) Coat edges of plug and core hole with Mopar
Engine core plugs have been pressed into the oil Gasket Maker, or equivalent.
galleries behind the camshaft thrust plate (Fig. 12).
This will reduce internal leakage and help maintain
higher oil pressure at idle.
9 - 06 5.2L ENGINE •
CAUTION: DO NOT drive cup plug into the casting ASSEMBLE
a s restricted coolant flow c a n result and c a u s e s e (1) Install the piston/connecting rod assembly.
rious engine problems. (2) Install the oil pan.
(2) Using proper drive plug, drive plug into hole. ( 4 ) I n g t a l l t h e hicle.
e n g i n e i n t o t h e ve
The sharp edge of the plug should be at least 0.50

mm (0.020 inch) inside the lead-in chamfer.
I t is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed i n service immediately.
SPECIFICATIONS—5.2L ENGINE
Camshaft
B e a r i n g Diameter End Play 0 . 0 5 1 - 0 . 1 7 8 mm
No. 1 5 0 . 8 0 0 - 5 0 . 8 2 5 mm ( 0 . 0 0 2 - 0 . 0 0 7 in)
( 2 . 0 0 0 - 2 . 0 0 1 in) Max. Allowable 0 . 2 5 4 mm
No. 2 5 0 . 3 9 4 - 5 0 . 4 1 9 mm ( 0 . 0 1 0 in)
( 1 . 9 8 4 - 1 . 9 8 5 in) Main Bearing Journals
No. 3 5 0 . 0 1 3 - 5 0 . 0 3 8 mm Diameter 6 3 . 4 8 7 - 6 3 . 5 1 3 mm
( 1 . 9 6 9 - 1 . 9 7 0 in) ( 2 . 4 9 9 5 - 2 . 5 0 0 5 in)
No. 4 4 9 . 6 0 6 - 4 9 . 6 3 2 mm Out-of-Round (Max.) 0 . 0 2 5 4 mm
( 1 . 9 5 3 - 1 . 9 5 4 in) (0.001 in)
No. 5 3 9 . 6 8 8 - 3 9 . 7 1 3 mm Taper (Max.) 0 . 0 2 5 4 mm
( 1 . 5 6 2 5 - 1 . 5 6 3 5 in) ( 0 . 0 0 1 in)
Diametrical C l e a r a n c e 0 . 0 2 5 4 - 0 . 0 7 6 2 mm
( 0 . 0 0 1 - 0 . 0 0 3 in) C y l i n d e r Block
Max. Allowable 0 . 1 2 7 mm C y l i n d e r Bore
( 0 . 0 0 5 in) Diameter 9 9 . 3 1 4 - 9 9 . 3 6 5 mm
End Play 0 . 0 5 1 - 0 . 2 5 4 mm ( 3 . 9 1 0 - 3 . 9 1 2 in)
( 0 . 0 0 2 - 0 . 0 1 0 in) Out-of-Round (Max.) 0 . 1 2 7 mm
B e a r i n g J o u r n a l Diameter ( 0 . 0 0 5 in)
No. 1 5 0 . 7 4 9 - 5 0 . 7 7 5 mm Taper (Max.) 0 . 2 5 4 mm
( 1 . 9 9 8 - 1 . 9 9 9 in) ( 0 . 0 1 0 in)
No. 2 5 0 . 3 4 3 - 5 0 . 3 6 8 mm Oversize (Max.) 1.016 mm
( 1 . 9 8 2 - 1 . 9 8 3 in) ( 0 . 0 4 0 in)
No. 3 4 9 . 9 6 2 - 4 9 . 9 8 7 mm Distributor L o w e r Drive S h a f t
( 1 . 9 6 7 - 1 . 9 6 8 in) Bushing (Press Fit in Block) 0 . 0 1 2 7 - 0 . 3 5 5 6 mm
No. 4 49.555-49.581 mm ( 0 . 0 0 0 5 - 0 . 0 1 4 0 in)
( 1 . 9 5 1 - 1 . 9 5 2 in) Shaft-to-Bushing C l e a r a n c e 0 . 0 1 7 8 - 0 . 0 6 8 6 mm
No. 5 3 9 . 6 3 7 - 3 9 . 6 6 2 mm ( 0 . 0 0 0 7 - 0 . 0 0 2 7 in)
( 1 . 5 6 0 5 - 1 . 5 6 1 5 in) T a p p e t Bore D i a m e t e r 2 2 . 9 9 - 2 3 . 0 1 mm
( 0 . 9 0 5 1 - 0 . 9 0 5 9 in)
Connecting R e d s
Bearing Clearance 0 . 0 1 2 7 - 0 . 0 5 5 9 mm Cylinder Head
( 0 . 0 0 0 5 - 0 . 0 0 2 2 in) C o m p r e s s i o n Pressure 6 8 9 kPa
Piston Pin Bore Diameter 2 4 . 9 6 6 - 2 4 . 9 7 8 mm (100 psi)
( 0 . 9 8 2 9 - 0 . 9 8 3 4 in) G a s k e t Thickness ( C o m p r e s s e d ) 1 . 2 0 6 5 mm
S i d e C l e a r a n c e (Two Rods) 0 . 1 5 2 - 0 . 3 5 6 mm ( 0 . 0 4 7 5 in)
( 0 . 0 0 6 - 0 . 0 1 4 in) Valve S e a t
Total Weight (Less B e a r i n g ) 7 2 6 grams Angle 44.25° - 44.75°
(25.61 o z ) Runout ( M a x . ) 0 . 0 7 6 2 mm
( 0 . 0 0 3 in)
Crankshaft W i d t h (Finish) - Intake 1 . 0 1 6 - 1 . 5 2 4 mm
Connect Rod Journal ( 0 . 0 4 0 - 0 . 0 6 0 in)
Diameter 5 3 . 9 5 0 - 5 3 . 9 7 5 mm W i d t h (Finish) - E x h a u s t 1 . 5 2 4 - 2 . 0 3 2 mm
( 2 . 1 2 4 - 2 . 1 2 5 in) ( 0 . 0 6 0 - 0 . 0 8 0 in)
Out-of-Round (Max.) 0 . 0 2 5 4 mm
( 0 . 0 0 1 in) H y d r a u l i c Tappets
Taper (Max.) 0 . 0 2 5 4 mm B o d y Diameter 2 2 . 9 4 9 - 2 2 . 9 6 2 mm
( 0 . 0 0 1 in) ( 0 . 9 0 3 5 - 0 . 9 0 4 0 in)
C l e a r a n c e in Block 0 . 0 2 7 9 - 0 . 0 6 1 0 mm
Diametrical C l e a r a n c e ( 0 . 0 0 1 1 - 0 . 0 0 2 4 in)
No. 1 0 . 0 1 2 7 - 0 . 0 3 8 1 mm Dry Lash 1 . 5 2 4 - 5 . 3 3 4 mm
( 0 . 0 0 0 5 - 0 . 0 0 1 5 in) ( 0 . 0 6 0 - 0 . 2 1 0 in)
Nos. 2, 3, 4 and 5 0 . 0 1 2 7 - 0 . 0 5 0 8 mm Push R o d Length 1 7 5 . 6 4 - 1 7 6 . 1 5 mm
( 0 . 0 0 0 5 - 0 . 0 0 2 0 in) ( 6 . 9 1 5 - 6 . 9 3 5 in)
M a x . A l l o w a b l e ( N o s . 2 , 3 , 4 & 5 ) . . . . 0 . 0 6 3 5 mm
( 0 . 0 0 2 5 in)
J9409-26
ENGINE SPECIFICATIONS (CONT.J
O i l Pump Piston Pins

Clearance Over Rotors (Max.) 0.1016 mm Clearance
(0.004 in) In Piston 0.00635-0.01905 mm
Cover Out-of-Flat (Max.) 0.0381 mm (0.00025-0.00075 in)
(0.0015 in) In Rod (Interference) 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) . . . . . . 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter.... 24.996-25.001 mm
Outer Rotor (0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm End Play. NONE
(0.014 in) Length 75.946-76.454 mm
(2.469 in)
Thickness (Min.) 20.955 mm Piston Rings
(0.825 in) Ring G a p
Tip Clearance Between Rotors (Max).. 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) . . . . 0.254-1.270 mm
Oil Pressure (0.010-0.050 in)
At Curb Idle Speed* 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings . 0.038-0.076 mm
At 3000 rpm 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) 34.5-48.3 kPa Ring Width
(5-7 psi) Compression Rings 1.971-1.989 mm
(0.0776-0.0783 in)
* C A U T I O N : If pressure is Z E R O at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
D O NOT run engine at 3,000 rpm. (0.1515-0.1565 in)
Oil Filter Valves

Bypass Valve Setting 62-103 kPa Face Angle 43.25° - 43.75°
(9-15 psi) Head Diameter
Intake 4 8 . 6 6 6 mm
Pistons (1.916 in)
Clearance at Top of Skirt 0.0127-0.0381 mm Exhaust 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) . . . . . 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake 124.28-125.92 mm
Piston Length 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) 10.973 mm
(0.180-0.190 in) (0.432 in)
No. 3 . 3.810-4.064 mm Stem Diameter 7.899-7.925 mm
(0.150-0.160 in) (0.311-0.312 in)
Weight 592.6-596.6 grams Stem-to-Guide Clearance 0.0254-0.0762 mm
(20.90-21.04 oz) (0.001-0.003 in)
Max. Allowable (Rocking Method).. 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) . . . . . . . 7.950-7.976 mm
(0.313-0.314 in)
J9309-32
E N G I N E SPECIFICATIONS (CON%)
Valve S p r i n g s Valve Timing

Free Length (Approx.) . . 49.962 mm Exhaust Valve
Spring Tension . . . . . . . . . . . . . . . . @ 41.66 mm = 378 N Opens (BBC) . . . . . . . . . 60°
(Valve Closed) (@ 1.64 in » 85 lbs) Duration 264°
Spring Tension @ 30.89 mm = 890 N Intake Valve
(Valve Open) (@ 1.212 in « 200 lbs) Closes (ABC) 61°
Number of Coils 6.8 Opens (BTC) . .10°
Installed Height. 41.66 mm Duration 250°
(Spring Seat to Retainer) (1.64 in) Valve Overlap. . . 31 0
Wire Diameter .... 4.50 mm

(0.177 in)
J9409-99
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDINTlflCATlON LOCATION OF 1PINTIMCATION
CRANKSHAFT JOURNALS RorM Milled flat on no. 8 crankshaft counterweight.

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing
0.0254 mm (0.001 in.) journal)
and/or
R-l -4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS • Diamond-shaped stamp top pad - front of

(OVERSIZE) engine and flat ground on outside surface of
0.2032 mm (0.008 in.) each O / S tappet bore.
VALVE STEMS (OVERSIZE) X Milled pad adjacent to two tapped holes

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head.
J930§-S2
DESCRIPTION TORQUE DESCRIPTION TORQUE
Adjusting Strap Bolt 23 N»m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 41 N®m (30 ft. lbs.)
Camshaft Bolt 68 N*m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts 24 N-m (210 in. lbs.) Trans. Support Bracket Nuts 41 N®m (30 ft. lbs.)
Chain Case Cover Bolts 41 N»m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts 61 N-m (45 ft. lbs.) Bracket Bolts 68 N«m (50 ft. lbs.)
Crankshaft Main Bearing Cap Bolts .... 115 N«m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N®m (30 ft. lbs.)
1st Step 68 N*m (50 ft. lbs.) Rocker Arm Bolts 23 N-m (200 in. lbs.)
2nd Step 143 N«m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N-m (95 in. lbs.) Spark Plugs 41 N*m (30 ft. lbs.)
Starter Mounting Bolts 68 N*m (50 ft. lbs.)
Exhaust Manifold-to-Cylinder
34 N«m (25 ft. lbs.) Throttle Body Bolts 23 N-m (200 in. lbs.)
02 N»m (75 ft. lbs.) Bolts 31 N®m (270 in. lbs.)
41 N»m (30 ft. lbs.) Mounting Plate Nuts 204
N®m (150 ft. lbs.)
41 N»m (30 ft. lbs.) Vibration Damper Retainer
Bolt 183
Intake Manifold Bolts Refer to Procedure N*m(135 ft. lbs.)
Cover Bolt 41
Oil Pan Bolts 23 N»m (200 in. lbs.) N®m (30 ft. lbs.)
Oil Pan Drain Plug 34 N*m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N-m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N*m (95 in. lbs.) J9409-82
INDEX
page page
Camshaft . 83 General Information . . . . . . . . . . . . . . . . . . . . . . . 71
Crankshaft Main Bearings 89 Oil Pan 85
Crankshaft Rear Oil Seals . . . . . . 90 Oil Pump . 86
Cylinder Heads 75 Specifications—5.9L Engine 93
Distributor 84 Timing Chain Cover 81
Engine Rear Mount 72 Valves / Valve Springs 76
Front Crankshaft Oil Seal Replacement 83 Vibration Damper 80
GENERAL INFORMATION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. 1).
90°V-8OHV
101.6 x 9 0 . 9 mm (4.00 x 3.58 in.)
5 . 9 L ( 3 6 0 c u . in.)
9.1:1
4 4 8 N « m ( 3 3 0 ft. lbs.) 9 3 , 2 5 0 rpm
1-8-4-3-6-5-7-2
Pressure Feed - Full Flow Filtration
4.71 (5.0 Q h ) w / f i h w
Liquid Cooled - Forced Circulation
14.7L(15.5Qls) J908D-49
Cylinder Block
Fig. 2 Firing Order
Combustion Chambers. ...Wedge-High Swirl Valve Shrouding X M 5.9L T XXXX XXXXXXXX
Pistons
X • Last Digit of Model Year
M = Plant-M Mound Road
S Saltillo
T Trenton
J9409-11
K Toluca
5.9L » Engine Displacement
Fig. 1 Engine Description T - Usage - T Truck
This engine is designed for unleaded fuel. XXXX - Month/Day
XXXXXXXX - Serial Cede - Last 8 Digits of VIN No.
Engine lubrication system consists of a rotor type
The cylinders are numbered from front to rear; 1, J9209-74
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2). Fig. 3 Engine Identification Number
The engine serial number is stamped into a ma
ENGINE FRONT MOUNTS
chined pad located on the left, front corner of the cyl
inder block. When component part replacement is REMOVAL
necessary, use the engine type and serial number for (1) Disconnect the negative cable from the battery.
reference (Fig. 3).
tank and hose.

manifold.

(6) Remove engine support bracket/cushion bolts
heat shields.
CUSHION
BRACKET
J9409-54
J9409-52

INSTALLATION
lbs.) torque.
bracket/cushion.
Fig. 6 Engine Rear Support Cushion
ENGINE REAR MOUNT
REMOWAL transmission support bracket to the transmission
port cushion.
System).
Service).
equipped.
J9409-56 oil.
port bracket. Install stud nuts and tighten to 41 N-m (31) Disconnect exhaust pipe at manifold,
(30 ft. lbs.) torque. (32) Disconnect the starter wires. Remove starter
Service).
(Fig. 6).
cover.
(4) Install the support cushion bolts and tighten to (34) AUTOMATIC TRANSMISSION:
(35) M A N U A L TRANSMISSION!
REMOVAL
(a) Remove the prop shaft (refer to Group 16,
(3) Remove the upper crossmember and top core
(d) Remove the crossmember.
support.
(e) Remove the clutch assembly and slave cylin
(4) Remove the transmission oil cooler.
der.
(5) Discharge the air conditioning system, i f
(f) Disconnect all wiring and connectors.
equipped (refer to Group 24, Heating and A i r Condi
(g) Remove transmission bolts. Remove the
tioning for service procedures).
transmission.
(h) Remove the bell housing.
Cooling System).
(i) Remove clutch assembly.
(7) Remove the A/C compressor with the lines at
(j) Remove flywheel and ring gear.
tached. Set aside.
(37) Install a jack stand under the automatic
(9) Remove the washer bottle.
transmission.
(3) Raise and support the vehicle on a hoist. (34) Install the serpentine belt (refer to Group 7,
(4) AUTOMATIC TRANSMISSION: Cooling System).
(refer to Group 8B, Battery/Starter/Generator Ser CYLINDER HEAD
vice).
from oil pan.
Tighten the nuts.
shift lever (refer to Group 21, Transmissions). REMOWAL
(15) Connect the fuel lines. (1) Disconnect the negative cable from the battery.
(16) Connect the transmission cooler lines.
(2) Disconnect closed ventilation system and evap
(17) Connect the power steering hoses, i f equipped.
oration control system from cylinder head cover.
(18) Connect the heater hoses.
(3) Remove cylinder head cover and gasket. The
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (refer to Group 11, gasket may be used again.
CLEANING
(21) Using a new gasket, install throttle body.
Clean cylinder head cover gasket surface.
Tighten the throttle body bolts to 23 N-m (200 i n .
lbs.) torque. Clean head rail, i f necessary.
Inspect cover for distortion and straighten, i f nec
(24) Install the generator and wire connections (re
essary.
fer to Group 8B, Battery/Starter/Generator Service).
Check the gasket for use i n head cover installation.
(25) Install radiator (refer to Group 7, Cooling Sys
tem). I f damaged, use a new gasket.
INSTALLATION EXHAUST SPARK EXHAUST SPARK EXHAUST
(1) The cylinder head cover gasket can be used VALVE PLUGS VALVES PLUGS VALVE
again. Install the gasket onto the head rail.
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
evaporation control system.
ROCKER ARMS
REMOVAL
boot straight out i n line with plug. INTAKE INTAKE
(2) Remove cylinder head cover and gasket. VALVES VALVES J9309-37

moved. REMOVAL
(4) Remove the push rods and place them on a (1) Disconnect the negative cable from the battery.
bench i n the same order as removed. (2) Drain cooling system (refer to Group 7, Cooling
ROCKER CYLINDER System for the proper procedures).
J9209-65
Fig. 2 Rocker Arms

INSTALLATION
firing position.
ing or immediately after rocker arm installation. Al (4) Remove the intake manifold-to-generator
low the hydraulic roller tappets adequate time to bracket support rod. Remove the generator.
(3) Install rocker arm and pivot assemblies i n the (8) Disconnect the fuel lines.
same order as removed. Tighten the rocker arm bolts (9) Disconnect accelerator linkage and i f so
to 28 N-m (21 ft. lbs.) torque. equipped, the speed control and transmission kick-
(4) Install cylinder head cover. down cables.
(5) Connect spark plug wires. (10) Remove the return spring.
CYLINDER HEADS (12) Disconnect the coil wires.
The alloy cast iron cylinder heads (Fig. 3) are held (13) Disconnect heat indicator sending unit wire.
in place by 10 bolts. The spark plugs are located i n (14) Disconnect heater hoses and bypass hose.
the peak of the wedge between the valves. (15) Remove cylinder head covers and gaskets.
The 5.9L cylinder head is identified by the foundry
mark CF.
(16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Remove rocker arm assemblies and push rods.
der head gasket.
CLEANING
heads.
Fig, 5 Cylinder Head Bolt Tightening Sequence
INSPECTION (7) Adjust spark plugs to specifications (refer to
Inspect all surfaces with a straightedge i f there is Group 8D, Ignition System). Install the plugs and
any reason to suspect leakage. I f out-of-flatness ex tighten to 41 N-m (30 ft. lbs.) torque.
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the (8) Install coil wires.
span length i n inches i n any direction, either replace (9) Connect heat indicator sending unit wire.
head or lightly machine the head surface. (10) Connect the heater hoses and bypass hose.
F O R E X A M P L E : A 305 mm (12 inch) span is (11) Install distributor cap and wires.
0.102 mm (0.004 inch) out-of-flat. The allowable out- (12) Hook up the return spring.
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 (13) Connect the accelerator linkage and i f so
mm (0.009 inch). This amount of out-of-flat is accept equipped, the speed control and transmission kick-
able. down cables.
The cylinder head surface finish should be (14) Install the fuel lines.
1.78-4.57 microns (70-180 microinches). (15) Install the generator and drive belt. Tighten
Inspect push rods. Replace worn or bent rods. generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
INSTALLATION (200 in. lbs.) torque. Refer to Group 7, Cooling Sys
(1) Position the new cylinder head gaskets onto the tem for adjusting the belt tension.
cylinder block. (16) Install the intake manifold-to-generator
(2) Position the cylinder heads onto head gaskets bracket support rod. Tighten the bolts.
and cylinder block. (17) Place the cylinder head cover gaskets i n posi
(3) Starting at top center, tighten all cylinder head tion and install cylinder head covers. Tighten the
bolts, i n sequence, to 68 N-m (50 ft. lbs.) torque (Fig. bolts to 11 N-m (95 in. lbs.) torque.
5). Repeat procedure, tighten all cylinder head bolts (18) Install closed crankcase ventilation system.
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to (19) Connect the evaporation control system.
confirm that all bolts are at 143 N-m (105 ft. lbs.) (20) Install the air cleaner.
torque. (21) Install the heat shields. Tighten the bolts to
CAUTION; When tightening the rocker arm bolts, (22) Fill cooling system (refer to Group 7, Cooling
make sure the piston in that cylinder is NOT at System for proper procedure).
TDC. Contact between the valves and piston could (23) Connect the negative cable to the battery.
occur.
(4) Install push rods and rocker arm assemblies i n The valves are arranged in-line and inclined 18°.
their original position. Tighten the bolts to 28 N-m The rocker pivot support and the valve guides are
(21 ft. lbs.) torque. cast integral with the heads.
(5) Install the intake manifold and throttle body This procedure requires the removal of the cylinder
assembly (refer to Group 11, Exhaust System and I n head.
take Manifold).
(6) Install exhaust manifolds. Tighten the bolts REMOVAL
and nuts to 34 N-m (25 ft. lbs.) torque. (1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring (c) Move valve to and from the indicator. The to
Compressor Tool MD-998772A. tal dial indicator reading should not exceed 0.432
(3) Remove valve retaining locks, valve spring re mm (0.017 inch). Ream the guides for valves with
tainers, valve stem seals and valve springs. oversize stems i f dial indicator reading is excessive
(4) Before removing valves, remove any burrs from or i f the stems are scuffed or scored.
valve stem lock grooves to prevent damage to the Service valves with oversize stems are available
valve guides. Identify valves to ensure installation i n (Fig. 8).
original location.
Reamer O / S Valve Guide Size
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped 0.076 mm 8.026 - 8.052 mm
and cracked valves. (0.003 in.) (0.316-0.317in.)
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner. 0.381 mm 8.331 - 8.357 mm
(0.015 in.) ( 0 . 3 2 8 - 0 . 3 2 9 in.)
VALVE INSPECTION
0.051 mm (0.002 inch), replace the valve. J9309-30
Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over Fig. 8 Reamer Sizes
valve stem and install valve (Fig. 6). The special Slowly turn reamer by hand and clean guide thor
sleeve places the valve at the correct height for oughly before installing new valve. Ream the valve
reamed t r u e i n r e l a t i o n t o the valve seat:
REFACING VALVES / VALVE SEATS

(Fig. 9).
CONTACT
Fig. 6 Positioning Valve with Tool C-3973

(b) Attach Dial Indicator Tool C-3339 to cylinder
head and set i t at right angle of valve stem being
measured (Fig. 7).
A - SEAT WIDTH - INTAKE 1 . 0 1 6 - 1 . 5 2 4 mm (0.040 - 0.060 in.)

EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
3
B - FACE ANGLE (INTAKE & EXHAUST) 4374° - 43 A°
1
C - SEAT ANGLE (INTAKE & EXHAUST) 44 A° - 4 4 / 4 ° 3
D - CONTACT SURFACE
J9309-95

Fig. 7 Measuring Valve Guide Wear
¥AL¥ES contact is satisfactory. I f the blue is transferred to
Inspect the remaining margin after the valves are the top edge of valve face, lower valve seat with a 15°
refaced (Fig. 10). Valves with less than 1.190 mm stone. I f the blue is transferred to bottom edge of
(0.047 inch) margin should be discarded.
INTAKE
T \
i
MARGIN / >
- EXHAUST
inch). The width of the exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).
VALVE VALVE
\FACE'
WALVE SPUING INSPECTION
* STEM*
Valve Spring Tester Tool C-647 until surface is i n line
with the 1-5/16 inch mark on the threaded stud. Be
VALVE SPRING sure the zero mark is to the front (Fig. 12). Place
RETAINER LOCK spring over stud on the table and lift compressing le
GROOVE
ver to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
J9209-127
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
Fig. 10 Intake and Exhaust Valves are indicated on the table for finer adjustments. Re
fer to specifications to obtain specified height and al
VALVE SEATS lowable tensions. Discard the springs that do not
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 11).
REFACING STONE
MUST NOT CUT
VALVE SHROUD
SPECIAL
TOOL C-647
9209-37
Fig. 12 Testing Valve Spring for Compressed

INSTALLATION
(1) When refacing valve seats, i t is important that (1) Coat valve stems with lubrication oil and insert
the correct size valve guide pilot be used for reseat them i n cylinder head.
ing stones. A true and complete surface must be ob (2) I f valves or seats are reground, check valve
tained. stem height. I f valve is too long, replace cylinder
(2) Measure the concentricity of valve seat using a head.
dial indicator. Total runout should not exceed 0.051 (3) Install new seals on all valve guides. Install
mm (0.002 inch) total indicator reading. valve springs and valve retainers.
(3) Inspect the valve seat with Prussian blue to de (4) Compress valve springs with Valve Spring
termine where the valve contacts the seat. To do this, Compressor Tool MD-998772A, install locks and re
coat valve seat LIGHTLY with Prussian blue then set lease tool. I f valves and/or seats are ground, measure
valve i n place. Rotate the valve with light pressure. the installed height of springs. Make sure the mea
I f the blue is transferred to the center of valve face, surement is taken from bottom of spring seat i n cyl-
inder head to the bottom surface of spring retainer. I f OIL LEVEL
spacers are installed, measure from the top of spacer.
I f height is greater than 42.86 mm (1-11/16 inches), HIGH
install a 1.587 mm (1/16 inch) spacer i n head coun- I f oil level is above the FULL mark, i t is possible
terbore. This should bring spring height back to nor for the connecting rods to dip into the oil. With the
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). engine running this condition could create foam i n
the oil pan. Foam i n oil pan would be fed to the hy
VALVE STEM SHIELD / SPRING REPLACEMENT draulic tappets by the oil pump causing them to lose
This procedure is done with the cylinder head i n length and allow valves to seat noisily.
stalled.
(1) Set engine basic timing to Top Dead Center LOW
(TDC) and remove air cleaner. Low oil level may allow oil pump to take i n air.
(2) Remove cylinder head covers and spark plugs. When air is fed to the tappets, causes them to lose
(3) Remove coil wire from distributor and secure to length and allows valves to seat noisily. Any leaks on
good ground to prevent engine from starting. intake side of oil pump through which air can be
(4) Using suitable socket and flex handle at crank drawn will create the same tappet action. When tap
shaft retaining bolt, turn engine so the N o . l piston is pet noise is due to aeration, i t may be intermittent or
at TDC on the compression stroke. constant, and usually more than 1 tappet will be
(5) Remove rocker arms. noisy. When oil level and leaks have been corrected,
(6) With air hose attached to an adapter installed engine should be operated at fast idle for sufficient
in N o . l spark plug hole, apply 620-689 kPa (90-100 time. This allows all of the air inside of the tappets
psi) air pressure. to be bled out.
(7) Using Valve Spring Compressor Tool
MD-$98772A, compress valve spring and remove re T A P P E T NOISE DIAGNOSIS
tainer valve locks and valve spring. (1) To determine source of tappet noise, operate en
(8) Install seals on the exhaust valve stem and po gine at idle with cylinder head covers removed.
sition down against valve guides. (2) Feel each valve spring or rocker arm to detect
(9) The intake valve stem seals should be pushed noisy tappet. The noisy tappet will cause the affected
firmly and squarely over the valve guide using the spring and/or rocker arm to vibrate or feel rough i n
valve stem as a guide. DO NOT force seal against top operation.
of guide. When installing the valve retainer locks, Worn valve guides or cocked springs are
compress the spring only enough to install the locks. sometimes mistaken for noisy tappets. I f such is
(10) Follow the same procedure on the remaining 7 the case, noise may be dampened by applying
cylinders using the firing sequence 1-8-4-3-6-5-7-2. side thrust on the valve spring. I f noise is not
Make sure piston i n cylinder is at TDC on the valve appreciably reduced, it can be assumed the
spring that is being removed. noise is i n the tappet. Inspect the rocker arm
(11) Remove adapter from the N o . l spark plug push rod sockets and push rod ends for wear.
hole. (3) Valve tappet noise ranges from light noise to a
(12) Install rocker arms. heavy click. A light noise is usually caused by exces
(13) Install covers and coil wire to distributor. sive leak-down around the unit plunger or by the
(14) Install air cleaner. plunger partially sticking i n the tappet body cylinder.
(15) Road test vehicle. The tappet should be replaced. A heavy click is
HYDRAULIC TAPPETS eign particles becoming wedged between the plunger
Before disassembling any part of the engine to cor and the tappet body. This will cause the plunger to
rect tappet noise, check the oil pressure. I f vehicle stick i n the down position. This heavy click will be
has no oil pressure gauge, install a reliable gauge at accompanied by excessive clearance between the
the pressure sending unit. The pressure should be valve stem and rocker arm as valve closes. I n either
between 207-552 kPa (30-80 psi) at 3,000 RPM. case, tappet assembly should be removed for inspec
Check the oil level after the engine reaches normal tion and cleaning.
operating temperature. Allow 5 minutes to stabilize The valve train generates a noise very much like a
oil level, check dipstick. light tappet noise during normal operation. Care
The oil level i n the pan should never be above the must be taken to ensure that tappets are making the
FULL mark or below the ADD OIL mark on dipstick. noise. I n general, i f more than one tappet seems to
Either of these 2 conditions could be responsible for be noisy, its probably not the tappets.
noisy tappets.
REMOVAL CAUTION: DO NOT turn crankshaft any further
(1) Remove the air cleaner. clockwise a s valve spring might bottom and result
(2) Remove cylinder head cover. in serious damage.
(3) Remove rocker assembly and push rods. Iden
tify push rods to ensure installation i n original loca (5) I f reading is not within specified limits:
tion. (a) Check sprocket index marks.
(4) Remove intake manifold. (b) Inspect timing chain for wear.
(5) Remove yoke retainer and aligning yokes. (c) Check accuracy of DC mark on timing indica
(6) Slide Hydraulic Tappet Remover/Installer Tool tor.
C-4129-A through opening i n cylinder head and seat
VIBRATION DAMPER
tool firmly i n the head of tappet.
(7) Pull tappet out of bore with a twisting motion. REMOVAL
I f all tappets are to be removed, identify tappets to (1) Disconnect the negative cable from the battery.
ensure installation i n original location. (2) Remove fan shroud retainer bolts and set
(8) I f the tappet or bore i n cylinder block is scored, shroud back over engine.
scuffed, or shows signs of sticking, ream the bore to (3) Remove the cooling system fan.
next oversize. Replace with oversize tappet. (4) Remove the serpentine belt (refer to Group 7,
Cooling System).
CAUTION: The plunger and tappet bodies are not (5) Remove the vibration damper pulley.
interchangeable. The plunger and valve must al (6) Remove vibration damper bolt and washer from
w a y s be fitted to the original body. It is advisable to end of crankshaft.
work on one tappet at a time to avoid mixing of (7) Install bar and screw from Puller Tool Set
parts. Mixed parts are not compatible. DO NOT dis C-3688. Install 2 bolts with washers through the
assemble a tappet on a dirty work bench. puller tool and into the vibration damper (Fig. 1).
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods i n their original
positions. Ensure that the oil feed hole i n the side of
the tappet body faces up (away from the crankshaft).
(3) Install rocker arm and shaft assembly.
(4) Install vent cover.
(5) Install distributor, start engine and reset tim
ing. J9209-81
CAUTION: To prevent damage to valve mechanism, Fig. 1 Vibration Damper Assembly

engine must not be run above fast idle until all hy (8) Pull vibration damper off of the crankshaft.
draulic tappets have filled with oil and have become
quiet. INSTALLATION
(1) Position the vibration damper onto the crank
shaft.
¥AL¥E TIMING (2) Place installing tool, part of Puller Tool Set
(1) Turn crankshaft until the No.6 exhaust valve is C-3688 i n position and press the vibration damper
closing and No.6 intake valve is opening. onto the crankshaft (Fig. 2).
(2) Insert a 6.350 mm (1/4 inch) spacer between (3) Install the crankshaft bolt and washer. Tighten
rocker arm pad and stem tip of No.l intake valve. A l the bolt to 183 N-m (135 ft. lbs.) torque.
low spring load to bleed tappet down giving i n effect (4) Install the crankshaft pulley. Tighten the pul
a solid tappet. ley bolts to 23 N-m (200 i n . lbs.) torque.
(3) Install a dial indicator so plunger contacts (5) Install the serpentine belt (refer to Group 7,
valve spring retainer as nearly perpendicular as pos Cooling System).
sible. Zero the indicator. (6) Install the cooling system fan. Tighten the bolts
(4) Rotate the crankshaft clockwise (normal run to 23 N-m (17 ft. lbs.) torque.
ning direction) until the valve has lifted 0.863 mm (7) Position the fan shroud and install the bolts.
(0.034 inch). The timing of the crankshaft should Tighten the retainer bolts to 11 N-m (95 in. lbs.)
now read from 10° before top dead center to 2° after torque.
top dead center. Remove spacer. (8) Connect the negative cable to the battery.
moved. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. I t may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads i n
stalled, apply 14 N-m (30 ft. lbs.) torque i n the re
verse direction. With the cylinder heads removed,
apply 20 N-m (15 ft. lbs.) torque i n the reverse direc
tion. Note the amount of chain movement (Fig. 4).
Fig. 2 installing Vibration Damper
TIMING CHAIN COVER

REMOVAL
System).
Cooling System).
System). Fig. 4 Measuring Timing Chain Wear and Stretch
(4) Install a new timing chain, i f its movement ex
19, Steering).
ceeds 3.175 mm (1/8 inch).
(5) I f chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
tem).
crankshaft and camshaft sprockets.
at each side.
crankshaft bores.
damage the crankshaft seal surface of cover (Fig. 3).
shaft sprocket.
used thrust plate. I f not within these limits install a
Fig. 3 Removal of Front Crankshaft Oil Seal new thrust plate.
TIMING CHAIN S T R E T C H
(1) Place a scale next to the timing chain so that CLEANING
any movement of the chain may be measured. Be sure mating surfaces of chain case cover and
(2) Place a torque wrench and socket over cam cylinder block are clean and free from burrs.
N-m (30 ft. lbs.) torque with cylinder head installed
or 20 N-m (15 ft. lbs.) torque with cylinder head re
The water pump mounting surface must be
cleaned.
INSTALLATION
(1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
TIMING
Use a small amount of Mopar Silicone Rubber Adhe CHAIN
sive Sealant, or equivalent, at the joint between tim COVER J9309-45-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time. Fig. 7 Position Tool and Seal onto Crankshaft
CRANKSHAFT. INSTALL THIS

FRONT OIL END INTO
SEAL SPECIAL TOOL
6635
J9309-44
Fig. 6 Placing Oil Seal on Installation Tool 6635

J9309-46
(Fig. 7). Fig. 8 Installing Oil Seal
(4) Using the vibration damper bolt, tighten the (9) Install water pump and housing assembly us
bolt to draw the seal into position on the crankshaft ing new gaskets (refer to Group 7, Cooling System).
(Fig. 8). Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(5) Tighten chain case cover bolts to 41 N-m (30 ft.
(10) Install power steering pump (refer to Group
lbs.) torque. Tighten oil pan bolts to 24 N-m (215 i n . 19, Steering).
lbs.) torque. (11) Install the serpentine belt (refer to Group 7,
(6) Remove the vibration damper bolt and seal in Cooling System).
stallation tool. (12) Install the cooling system fan. Tighten the
(7) Install vibration damper. bolts to 23 N-m (17 ft. lbs.) torque.
(8) Install fuel lines (refer to Group 14, Fuel Sys (13) Position the fan shroud and install the bolts.
tem). Tighten the bolts to 11 N-m (95 i n . lbs.) torque.
(14) Fill cooling system (refer to Group 7, Cooling (7) Remove camshaft thrust plate, note location of
System for the proper procedure). oil tab (Fig. 10).
(15) Connect the negative cable to the battery. (8) Install a long bolt into front of camshaft to fa
cilitate removal of the camshaft. Remove camshaft,
FRONT CRANKSHAFT OIL SEAL REPLACEMENT being careful not to damage cam bearings with the
The oil seal can be replaced without removing the cam lobes.
aligned.
oil seal alignment to crankshaft. The seal installa
tion/alignment tool 6635, should fit w i t h minimum
moved and installed properly.
(Fig. 7).
bolt to draw the seal into position on the crankshaft THRUST PLATE
(Fig. 8). REAR SIDE
(8) Remove the vibration damper bolt and seal in

J9209-132
stallation tool.
Fig. 10 Timing Chain Oil Tab Installation
REMOVAL—REARING
CAMSHAFT (1) With engine completely disassembled, drive out
This procedure requires that the engine is removed rear cam bearing core hole plug.
from the vehicle. (2) Install proper size adapters and horseshoe
The camshaft has an integral oil pump and distrib washers (part of Camshaft Bearing Remover/Installer
utor drive gear (Fig. 9). Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 11).
THRUST \ SPECIAL TOOL C-3132-A,
PLATE
OIL PUMP A N D
DISTRIBUTOR DRIVE
GEAR INTEGRAL
WITH CAMSHAFT
-CAMSHAFT SPROCKET
J9309-71
Fig. 9 Camshaft and Sprocket Assembly 'J9209-93

REMOVAL Fig. 11 Camshaft Bearings Removal and Installation
(1) Remove intake manifold. with Tool C-3132-A
(2) Remove cylinder head covers.
(3) Remove timing case cover and timing chain. INSTALLATION—BEARING
(4) Remove rocker arms. (1) Install new camshaft bearings with Camshaft
(5) Remove push rods and tappets. Identify each Bearing Remover/Installer Tool C-3132-A by sliding
part so i t can be installed i n its original location. the new camshaft bearing shell over proper adapter.
(6) Remove distributor and lift out the oil pump (2) Position rear bearing i n the tool. Install horse
and distributor drive shaft. shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place. (9) Slide both sprockets evenly over their respec
(3) Install remaining bearings i n the same manner. tive shafts and use a straightedge to check alignment
Bearings must be carefully aligned to bring oil holes of timing marks (Fig. 13).
camshaft. Be sure this p l u g does not leak.
INSTALLATION
Whenever a n engine has been rebuilt, a new
pint of Mopar Crankcase Conditioner, or equiv Fig. 13 Alignment of Timing Marks
alent. The oil mixture should be left i n engine (10) Install the camshaft bolt/cup washer. Tighten
for a m i n i m u m of 805 k m (500 miles). Drain at bolt to 68 N-m (50 ft. lbs.) torque.
the next n o r m a l o i l change. (11) Measure camshaft end play. Refer to Specifica
(2) Install Camshaft Gear Installer Tool C-3509 tions for proper clearance. I f not within limits, install
with tongue back of distributor drive gear (Fig. 12). a new thrust plate.
(12) Each tappet reused must be installed i n the
same position from which i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
DISTRIBUTOR
REMOVAL
procedure.
R E M O V A L — D R I V E SHAFT BUSHING
Fig. 12 Camshaft Holding Tool C-3509 (Installed (1) Remove the intake manifold (refer to Group 11,
Position) Exhaust System and Intake Manifold).
(2) Insert Distributor Drive Shaft Bushing Puller
(3) Hold tool i n position with a distributor lock-
Tool C-3052 into old bushing and thread down until a
plate bolt. This tool will restrict camshaft from being tight fit is obtained (Fig. 14).
pushed i n too far and prevent knocking out the welch (3) Hold puller screw and tighten puller nut until
plug i n rear of cylinder block. Tool should remain bushing is removed.
i n s t a l l e d u n t i l the camshaft and crankshaft
sprockets a n d timing c h a i n have been installed.
Make sure tang enters lower right hole i n
thrust plate. Tighten bolts to 24 N-m (210 in. lbs.)
crankshaft bores.
keyway location i n crankshaft sprocket and i n cam INSTALLATION—DRIVE SHAFT BUSHING
shaft sprocket. (1) Slide new bushing over burnishing end of Dis
(8) Lift sprockets and chain (keep sprockets tight tributor Drive Shaft Bushing Driver/Burnisher Tool
against the chain i n position as described). C-3053. Insert the tool and bushing into the bore.
• 5.9L ENGINE 9 - 85

hammer (Fig. 15).
Fig. 17 Position of Installed Distributor Drive Gear

OIL PAN
Fig. 15 Distributor Driveshaft Bushing Installation
(3) As the burnisher is pulled through the bushing, REMOVAL
the bushing is expanded tight i n the block and bur (1) Disconnect the negative cable from the battery.
nished to correct size (Fig. 16). D O NOT r e a m t h i s (2) Remove engine oil dipstick.
bushing. (3) Raise vehicle.
(4) Drain engine oil.
(6) Remove left engine to transmission strut.
(7) Loosen the right side engine support bracket
cushion thru-bolt and raise the engine slightly. Re
move oil pan by sliding backward and out.
CLEANING
Fig. 16 Burnishing Distributor Driveshaft Bushing the sealant inside the r e a r m a i n cap slots.
I f present, t r i m excess sealant from inside the en
(4) Install the intake manifold (refer to Group 11, gine.
Exhaust System and Intake Manifold). Clean oil pan i n solvent and wipe dry with a clean
cloth.
DISTRIBUTOR TIMING Clean oil screen and pipe thoroughly i n clean sol
Before installing the distributor and oil pump drive vent. Inspect condition of screen.
shaft, time engine as follows:
(1) Rotate crankshaft until N o . l cylinder is at top INSPECTION
dead center on the firing stroke. Inspect oil drain plug and plug hole for stripped or
(2) When i n this position, the timing mark on v i damaged threads. Repair as necessary.
bration damper should be under "0" on the timing in Inspect oil pan mounting flange for bends or distor
dicator. tion. Straighten flange, i f necessary.
(3) Coat shaft and drive gear with engine oil. I n
stall the shaft so that after the gear spirals into INSTALLATION
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
on top of drive gear should be aligned towards left
into the top of the dowel. This will allow easier in
stallation and removal with a screwdriver (Fig. 1).
INSTALLATION (2) Install the dowels i n the cylinder block (Fig. 2).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent i n the corner of the
procedure.
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
.17 " x 5 / 1 6 " BOLT
2
OIL PUMP
O I L PUMP PRESSURE
The MINIMUM oil pump pressure is 41.4 kPa (6
DOWEL
CAUTION: If oil pressure is Z E R O at curb idle, DO
' NOT run engine at 3,000 RPM.
SLOT J9209-106
REMOVAL
Fig. 1 Fabrication of Alignment Dowels (1) Remove the oil pan.
DOWEL ^ ^ ^ ^ DOWEL (2) Remove the oil pump from rear main bearing
cap.
INSTALLATION
(1) Install oil pump. During installation slowly ro
tate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41

J9309-79
nearly round shape.
Fig. 2 Position of Dowels in Cylinder Block
All pistons are machined to the same weight, re
gardless of size, to maintain piston balance.
(6) Install the oil pan bolts. Tighten the bolts to 2 4 The piston pin rotates in the piston only and is re
N-m (215 in. lbs.) torque. tained by the press interference fit of the piston pin
(7) Remove the dowels. Install the remaining oil in the connecting rod.
pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
torque. REMOVAL
(8) Lower the engine into the support cushion (1) Remove the engine from the vehicle.
brackets and tighten the thru-bolt to the proper (2) Remove the cylinder head.
torque. (3) Remove the oil pan.
(9) Install the drain plug. Tighten drain plug to 34 (4) Remove top ridge of cylinder bores with are li
N-m (25 ft. lbs.) torque. able ridge reamer before removing pistons from cyl
(10) Install the engine to transmission strut. inder block. Be sure to keep tops of pistons covered
(11) Install exhaust pipe. during this operation.
(12) Lower vehicle. (5) Be sure the connecting rod and connecting rod
(13) Install dipstick. cap are identified with the cylinder number. Remove
(14) Connect the negative cable to the battery. connecting rod cap. Install connecting rod bolt guide
(15) Fill crankcase with oil to proper level. set on connecting rod bolts.
connecting rod assemblies, rotate crankshaft center
the connecting rod in the cylinder bore and at BDC.
Be careful not to nick crankshaft journals.
INSPECTION (2) Install rings and confirm ring side clearance:
DIAMETER (D) face up (toward top of piston) and the chamfer
SHOULD BE 98.704-98.831 mm should face down. An identification mark on the
0.0000-0.0152 mm (3.886-3.891 in.)
(0.0000-0.0006 in.
ring is a drill point, a stamped letter "O", an oval
LARGER THAN (C) depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 4). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression
rings. The steel rail oil ring should be free in
groove, but should not exceed 0.203 mm (0.0080
inch) side clearance.
FEELER G A U G E

SKIRT SHOULD BE 0.254-0.304 mm
FACES AT DIAMETER (B).
J9309-9
Fig. 3 Piston Measurements GROOVE
FITTING PISTONS
J9209-136
Specified clearance between the piston and the cylin Fig. 4 Measuring Piston Ring Side Clearance
der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at the top of (d) Pistons with insufficient or excessive side
skirt, 90° to piston pin axis. Cylinder bores should be clearance should be replaced.
measured halfway down the cylinder bore and trans (3) Arrange ring gaps 90° apart as shown in Fig. 5.
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at CONNECTING ROD BEARINGS
normal room temperature, 21°C (70°F). Fit all rods on a bank until completed. DO NOT al
ternatefromone bank to another, because connecting
FITTING RINGS rods and pistons are not interchangeable from one
(1) Measurement of end gaps: bank to another.
(a) Measure piston ring gap 2 inches from bot The bearing caps are not interchangeable and
tom of cylinder bore. An inverted piston can be should be marked at removal to ensure correct as
used to push the rings down to ensure positioning sembly.
rings squarely in the cylinder bore before measur Each bearing cap has a small V-groove across the
ing. parting face. When installing the lower bearing shell,
(b) Insert feeler stock in the gap. The compres make certain that the V-groove in the shell is in line
sion ring gap should be between 0.254-0.508 mm with the V-groove in the cap. This provides lubrica
(0.010-0.020 inch). The second compression ring tion of the cylinder wall in the opposite bank.
gap should be between 0.508-0.762 mm (0.020- The bearing shells must be installed so that the
0.030 inch). The oil ring gap should be 0.254-1.270 tangs are in the machined grooves in the rods and
mm (0.010-0.050 inch). caps.
OIL RING (11) Install the engine into the vehicle.
SPACER GAP
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on
SECOND
COMPRESSION
the No.3 crankshaft counterweight (Fig. 6).
TOP F O R EXAMPLE? R2 stamped on the No.3 crank
RING GAP
COMPRESSION
RING GAP
OIL RING RAIL shaft counterweight indicates that the No.2 rod jour
GAP (TOP) nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.
OIL RING RAIL
GAP (BOTTOM) J9309-80
Undersize Journal Identification Stamp

Fig. 5 Proper Ring Installation R1-R2-R3 or R4
0.025 mm (0.001 inch) (Rod)
Limits of taper or out-of-round on any crankshaft 0.025 mm (0.001 inch) (Main) M1-M2-M3-M4 or M5
journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 Z * - (ROD)
mm (0.010 inch) and 0.305 mm (0.012 inch) under 4-(MAIN)

size. Install the bearings in pairs. D O N O T use a
new bearing half with an old bearing half. D O
NOT file the rods or bearing caps.
INSTALLATION
U LJ J9309-52
gered so that neither is in line with oil ring rail gap.
(2) Before installing the ring compressor, make Fig. 6 Location of Crankshaft Identification
sure the oil ring expander ends are butted and the
When a crankshaft is replaced, all main and con
necting rod bearings should be replaced with new
(3) Immerse the piston head and rings in clean en bearings. Therefore, selective fitting of the bearings
gine oil. Slide Piston Ring Compressor Tool C-385 is not required when a crankshaft and bearings are
over the piston and tighten with the special wrench replaced.
(part of Tool C-385). Be sure position of rings
does not change during this operation. REMOVAL
(4) Install connecting rod bolt protectors on rod (1) Remove the oil pan.
bolts, the long protector should be installed on the (2) Remove the oil pump from the rear main bear-
numbered side of the connecting rod. ing cap.
(5) Rotate crankshaft so that the connecting rod (3) Remove the vibration damper,
journal is on the center of the cylinder bore. Be sure (4) Remove the timing chain cover,
connecting rod and cylinder bore number are the (5) Identify bearing caps before removal. Remove
same. Insert rod and piston into cylinder bore and bearing caps and bearings one at a time,
guide rod over the crankshaft journal. (6) Lift the crankshaft out of the block,
(6) Tap the piston down in cylinder bore, using a (7) Remove and discard the crankshaft rear oil
hammer handle. At the same time, guide connecting seals.
rod into position on crankshaft journal. (8) Remove and discard the front crankshaft oil
(7) The notch or groove on top of piston must be seal.
of the connecting rod bore must be installed toward INSPECTION OF JOURNALS
crankshaft journal fillet. The crankshaft connecting rod and main journals
(8) Install rod caps. Install nuts on cleaned and should be checked for excessive wear, taper and scor
oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.) ing. The maximum taper or out-of-round on any
torque. crankshaft journal is 0.025 mm (0.001 inch).
(9) Install the oil pan. Journal grinding should not exceed 0.305 mm
(10) Install the cylinder head. (0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO (8) Clean and oil all cap bolts. Install all main
NOT nick crank pin or bearing fillets. After grinding, bearing caps. Install all cap bolts and alternately
remove rough edges from crankshaft oil holes and tighten to 115 N-m (85 ft. lbs.) torque.
clean out all oil passages. (9) Install oil pump.
CAUTION: After any journal grind, it is important (11) Install the vibration damper.
that the final paper or cloth polish be in the s a m e (12) Apply Mopar Silicone Rubber Adhesive Seal
direction a s the engine rotates. ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 8). Ap
ply enough sealant until a small amount is squeezed
CLEANING
inder block and rear cap mating surface. Do this be
fore applying the Loctite drop and the installation of (13) Install new front crankshaft oil seal.
rear cap. (14) Immediately install the oil pan.
MOPAR SILICONE SEALANT
INSTALLATION RUBBER ADHESIVE APPLIED
oil.
(2) Install the new upper rear bearing oil seal with
gine.
oil.
(Fig. 7). DO NOT over apply sealant or allow the Fig. 8 Apply Sealant to Bearing Cap to Block Joint
Bearing caps are not interchangeable and should
cation.
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter
changeable. Lower main bearing halves of No.2 and 4
are interchangeable.
Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves i n the
engine (Fig. 9). Bearing shells are available i n stan
dard and the following undersizes: 0.25 mm (0.001
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.
REMOVAL
BEARING CAP J9309-72
Fig. 7 Sealant Application to Bearing Cap
ing cap.
(7) To align the bearing cap, use cap slot, align (3) Identify bearing caps before removal. Remove
ment dowel and cap bolts. DO NOT remove excess bearing caps one at a time.
material after assembly. DO NOT strike rear cap (4) Remove upper half of bearing by inserting
more than 2 times for proper engagement. Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 10).
9 - 90 § J L ENGINE •
The lower seal half can only be installed with the
U P P E R SEAL REPLACEMENT (CRANKSHAFT

REMOWED).
(1) Remove the crankshaft. Discard the old upper
seal.
(2) Clean the cylinder block rear cap mating sur
face. Make sure the seal groove is free of debris.
oil.
Fig. 9 Main Bearing Identification (4) Install the new upper rear bearing oil seal with
gine.
oil.
cation.
Fig. 10 Upper Main Bearing Removal and material after assembly. DO NOT strike rear cap
Installation with Tool C-3059 more than 2 times for proper engagement.
(5) Slowly rotate crankshaft clockwise, forcing out (10) Clean and oil all cap bolts. Install all main
upper half of bearing shell. bearing caps. Install all cap bolts and alternately
INSTALLATION (11) Install oil pump.
Only one main bearing should be selectively fitted (12) Apply Mopar Silicone Rubber Adhesive Seal
while all other main bearing caps are properly tight ant, or equivalent, at bearing cap to block joint to
ened. A l l bearing capbolts removed during service provide cap to block and oil pan sealing (Fig. 8). Ap
procedures are to be cleaned and oiled before instal ply enough sealant until a small amount is squeezed
lation. out. Withdraw nozzle and wipe excess sealant off the
When installing a new upper bearing shell, slightly oil pan seal groove.
chamfer the sharp edges from the plain side. (13) Install new front crankshaft oil seal.
(1) Start bearing i n place, and insert Crankshaft (14) Immediately install the oil pan.
Main Bearing Remover/Installer Tool C-3059 into oil U P P E R SEAL REPLACEMENT (CRANKSHAFT
hole of crankshaft (Fig. 10). INSTALLED)
(2) Slowly rotate crankshaft counterclockwise slid (1) Remove the oil pan.
ing the bearing into position. Remove Tool C-3059. (2) Remove the oil pump from the rear main bear
(3) Install the bearing cap. Clean and oil the bolts. ing cap.
Tighten the capbolts to 115 N-m (85 ft. lbs.) torque. (3) Remove the rear main bearing cap. Remove
(4) Install the oil pump. and discard the old lower oil seal.
(5) Install the oil pan. (4) Carefully remove and discard the old upper oil
seal.
(5) Clean the cylinder block mating surfaces before sealant to contact the rubber seal. Assemble bearing
oil seal installation. cap to cylinder block immediately after sealant appli
(6) Lightly oil the new upper seal lips with engine cation.
oil. To allow ease of installation of the seal, loosen at (9) To align the bearing cap, use cap slot, align
least the 2 main bearing caps forward of the rear ment dowel and cap bolts. DO NOT remove excess
bearing cap. material after assembly. DO NOT strike rear cap
(7) Rotate the new upper seal into the cylinder more than 2 times for proper engagement.
block being careful not to shave or cut the outer sur (10) Install the rear main bearing cap with cleaned
face of the seal. To assure proper installation, use the and oiled cap bolts. Alternately tighten the cap bolts
installation tool provided with the k i t . Install the to 115 N-m (85 ft. lbs.) torque.
new seal with the yellow paint facing towards the (11) Install oil pump.
rear of the engine. (12) Apply Mopar Silicone Rubber Adhesive Seal
(8) Install the new lower rear bearing oil seal into ant, or equivalent, at bearing cap to block joint to
the bearing cap with the yellow paint facing towards provide cap to block and oil pan sealing (Fig. 8). Ap
the rear of the engine. ply enough sealant until a small amount is squeezed
(9) Apply 5 mm (0.20 in) drop of Loctite 515, or out. Withdraw nozzle and wipe excess sealant off the
equivalent, on each side of the rear main bearing cap oil pan seal groove.
(Fig. 7). DO NOT over apply sealant or allow the (13) Immediately install the oil pan.
cap to cylinder block immediately after sealant appli CYUNiER BL0CI
cation. Be sure the yellow paint faces toward the rear Remove the engine assembly from the vehicle.
of the engine.
(10) To align the bearing cap, use cap slot, align DISASSEMBLE
ment dowel and cap bolts. DO NOT remove excess (1) Remove the cylinder head.
material after assembly. DO NOT strike rear cap (2) Remove the oil pan.
more than 2 times for proper engagement. (3) Remove the piston/connecting rod assembly.
(11) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten A L L cap bolts CLEANING
to 115 N-m (85 ft. lbs.) torque. Clean cylinder block thoroughly and check all core
(12) Install oil pump. hole plugs for evidence of leaking.
(13) Apply Mopar Silicone Rubber Adhesive Seal INSPECTION
ant, or equivalent, at bearing cap to block joint to Examine block for cracks or fractures.
provide cap to block and oil pan sealing (Fig. 8). Ap The cylinder walls should be checked for out-of-
ply enough sealant until a small amount is squeezed round and taper with Cylinder Bore Indicator Tool
out. Withdraw nozzle and wipe excess sealant off the C-119. The cylinder block should be bored and honed
oil pan seal groove. with new pistons and rings fitted if:
(14) Immediately install the oil pan. • The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
LOWER SEAL REPLACEMENT
0.254 mm (0.010 inch).
ing cap.
(3) Remove the rear main bearing cap and discard
the old lower seal.
(4) Clean the rear main cap mating surfaces in
cluding the oil pan seal grooves.
(5) Carefully install a new upper seal (refer to Up
bores.
per Seal Replacement - Crankshaft Installed proce
dure above). OIL L I N E P L U G
(6) Lightly oil the new lower seal lips with engine The oil line plug is located i n the vertical passage
oil. at the rear of the block between the Oil-To-Filter and
(7) Install a new lower seal in bearing cap with Oil-From-Filter passages (Fig. 11). Improper installa
yellow paint facing the rear of engine. tion or plug missing could cause erratic, low or no oil
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or pressure.
equivalent, on each side of the rear main bearing cap (1) Remove oil pressure sending unit from back of
(Fig. 7). DO NOT over apply sealant or allow the block.
9 - 92 5.9L ENGINE •
to position properly.
RIGHT OIL GALLERY
PASSAGE
TO CAMSHAFT
REAR BEARING
OIL FROM FILTER
TO SYSTEM
PLUG
OIL TO FILTER
^RH157p
FROM OIL PUMP Fig. 12 Location of Cup Plugs in Oil Galleries
CRANKSHAFT
J9109-229
Fig. 11 Oil Line Plug

(4) I f plug is off position, remove oil pan and rear
main bearing cap. Use suitable flat dowel to remove SECOND
REMOVE PLUG
plug. Coat outside diameter of plug with Mopar (stud WITH PLIERS
and bearing mount adhesive), or equivalent. Plug
should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches) FIRST
from bottom of the block. STRIKE HERE
(5) Assemble engine and check oil pressure. WITH HAMMER
ENGINE CORE, OIL AND CAMSHAFT PLUGS

Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 12). DRIFT 9209-41
This will reduce internal leakage and help maintain
higher oil pressure at idle. Fig. 13 Core Hole Plug Removal
INSTALLATION
REMOVAL (1) Coat edges of plug and core hole with Mopar
(1) Using a blunt tool such as a drift or a screw Gasket Maker, or equivalent.
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 13). CAUTION: DO NOT drive cup plug into the casting
a s restricted coolant flow can result and cause s e
(2) With the cup plug rotated, grasp firmly with
rious engine problems.
pliers or other suitable tool and remove plug (Fig.
13). (2) Using proper drive plug, drive plug into hole.
CLEANING mm (0.020 inch) inside the lead-in chamfer.
Thoroughly clean inside of cup plug hole i n cylinder I t is not necessary to wait for curing of the sealant.
block or head. Be sure to remove old sealer. The cooling system can be filled and the vehicle
Make certain the new plug is cleaned of all oil or placed i n service immediately.
grease.
ASSEMBLE
(1) Install the piston/connecting rod assembly.
(4) Install the engine into the vehicle.
• 5 J L ENGINE 9 - 93
SPECIFICATIONS—5 J L ENGINE
Camshaft
Bearing Diameter End Play 0.051 -0.178 mm

No.l 50.800 - 50.825 mm (0.002 - 0.007 in)
(2.000 - 2.001 in) Max. Allowable 0.254 mm
No.2 50.394 - 50.419 mm (0.010 in)
(1.984-1.985 in) Main Bearing Journals
No.3 50.013 - 50.038 mm Diameter 71.361 -71.387 mm
(1.969-1.970 in) (2.8095-2.8105 in)
No.4 49.606 - 49.632 mm Out-of-Round (Max.) 0.0254 mm
(1.953- 1.954 in) (0.0)1 in)
No.5 39.688 - 39.713 mm Taper (Max.) 0.0254 mm
(1.5625-1.5635 in) (0.0)1 in)
Diametrical Clearance 0.0254 - 0.0762 mm
Cylinder Mock
(0.001 -0.003 in)
Max. Allowable 0.127 mm
Cylinder Bore
(0.005 in)
End Play 0.051 - 0.254 mm Diameter 101.60- 101.65 mm
(0.002-0.010 in) (4.000 - 4.002 in)
Bearing Journal Diameter Out-of-Round (Max.) 0.127 mm
No.l 50.749 - 50.775 mm (0.005 in)
(1.998-1.999 in) Taper (Max.) 0.254 mm
No.2 50.343 - 50.368 mm (0.010 in)
(1.982-1.983 in) Distributor Lower Drive Shaft
No.3 49.962 - 49.987 mm Bushing (Press Fit in Block) 0.0127 - 0.3556 mm
(1.967-1.968 in) (0.0005 - 0.0140 in)
No.4 49.555 - 49.581 mm Shaft-to-Bushing Clearance 0.0178 - 0.0686 mm
(1.951 -1.952 in) (0.0007 - 0.0027 in)
No.5 39.637 - 39.662 mm Tappet Bore Diameter 22.99 - 23.01 mm
(1.5605 -1.5615 in) (0.9051 -0.9059 in)
Connecting Rods
Cylinder Head
Compression Pressure 689 kPa

Bearing Clearance 0.0127 - 0.0559 mm
(0.0005 - 0.0022 in) (100 psi)
Piston Pin Bore Diameter 24.966 - 24.978 mm Gasket Thickness (Compressed) ............................. 1.2065 m m
(0.9829 - 0.9834 in) (0.0475 in)
Side Clearance (Two Rods) 0.152-0.356 mm Valve Seat
(0.006 -0.014 in) Angle 44.25° - 44.75°
Total Weight (Less Bearing) 758 grams Runout (Max.) 0.0762 mm
(25.74 oz) (0.003 in)
Width (Finish) - Intake 1.016-1.524 mm
Crankshaft
(0.040-0.060 in)
Connecting Rod Journal Width (Finish) - Exhaust 1.524-2.032 m m
Diameter 53.950 - 53.975 mm (0.060-0.080 in)
(2.124-2.125 in)
Out-of-Round (Max.) 0.0254 mm Hydraulic Tappets
(0.001 in)
Taper (Max.) 0.0254 mm Body Diameter 22.949 - 22.962 mm
(0.001 in) (0.9035 - 0.9040 in)
Diametrical Clearance Clearance in Block 0.0279 - 0.0610 mm
No.l 0.0127-0.0381 mm (0.0)11 -0.0024 in)
( 0 . 0 0 ) 5 - 0 . 0 0 1 5 in) Dry Lash 1.524 - 5.334 mm
Max.Alb*able(No.l) 0.0381 mm (0.060 - 0.210 in)
(0.0015 in) Push Rod Length 175.64 - 176.15 mm
Nos.2, 3, 4 and 5 0.0127 - 0.0508 mm (6.915 - 6.935 in)
(0.0005 - 0.0020 in)
Max. Allowable (Nos.2, 3, 4 & 5) 0.0635 mm
(0.0025 in) J9409-27
9 - 94 5.9L ENGINE
•
O i l Pump Piston Rings
Clearance over Rotors (Max.) 0.1016 mm Ring Gap

(0.004 in) Compression Ring (Top) 0.30 - 0.55 mm
Cover Out-of-Flat (Max.) 0.0381 mm (0.012-0.022 in)
(0.0015 in) Compression Rings (2nd) 0.55 - 0.80 mm
Inner Rotor Thickness (Min.) 20.955 mm (0.022 - 0.031 in)
(0.825 in) Oil Control (Steel Rails) 0.381 -1.397 mm
Outer Rotor (0.015 - 0.055 in)
Clearance (Max.) 0.3556 mm Ring Side Clearance
(0.014 in) Compression Rings 0.040 - 0.085 mm
(2.469 in) Oil Ring (Steel Rails) 0.05 - 0.21 mm
Thickness (Min.) 20.955 mm (0.002 - 0.008 in)
(0.825 in) Ring Width
Tip Clearance between Rotors (Max.) 0.2032 mm Compression Rings 1.530 - 1.555 mm
(0.008 in) (0.060 - 0.061 in)
Oil Ring (Steel Rails) - Max. 0.447 - 0.473 mm
O i l Pressure (0.018-0.019 in)
At Curb Idle Speed* 41.4 kPa Valves
(6
psi)
Face Angle 43.25° - 43.75°
At 3000 rpm 207 - 552 kPa
(30 - 80 psi) Head Diameter
Switch Actuating Pressure (Min.) 34.5 - 48.3 kPa Intake 47.752 mm
(5-7 psi) (1.88 in)
* CAUTION: If pressure is ZERO at curb idle, DO NOT Exhaust 41.072 mm
run engine at 3,000 rpm. (1.617 in)
Length (Overall)
O i l Filter Intake 126.21 - 126.85 mm
Bypass Valve Setting 62 -103 kPa (4.969 - 4.994 in)
(9-15 psi) Exhaust 126.44 - 127.30 mm
(4.978 - 5.012 in)
Pistons Lift (Zero Lash) 10.414 mm
(0.410 in)
Clearance at Top of Skirt 0.0127 - 0.0381 mm Stem Diameter
(0.0005 - 0.0015 in) Intake 9.449 - 9.474 mm
Land Clearance (Diametrical) 0.508 - 0.660 mm (0.372-0.373 in)
(0.020 - 0.026 in) Exhaust 9.423 - 9.449 mm
Piston Length 81.03 mm (0.371 - 0.372 in)
(3.19 in) Stem-to-Guide Clearance
Piston Ring Groove Depth Intake 0.0254 - 0.0762 mm
Nos.l and 2 4.761 -4.912 mm (0.001 - 0.003 in)
Exhaust 0.0508 - 0.1016 mm
(0.187-0.193 in)
No.3 3.996 - 4.177 mm (0.002 - 0.004 in)
(0.157-0.164 in) Max. Allowable (Rocking Method) 0.4318 mm
Weight 582 - 586 grams (0.017 in)
(20.53-20.67 oz) Guide Bore Diameter (Std) 9.500 - 9.525 mm
(0.374-0.375 in)
Piston Pins
Clearance In Piston 0.006 - 0.019 mm

(0.00023 - 0.00074 in)
Diameter 25.007 - 25.015 mm
(0.9845 - 0.9848 in)
End Play NONE
Length 67.8 - 68.3 mm
(2.67 - 2.69 in) J9309-103
Valve Springs V a l v e Timing

Free Length (Approx.) 49.962 mm Exhaust Valve
Spring Tension @ 41.66 mm =* 3 7 8 N Opens (BBC) 61°
(Valve Closed) (@ 1.64 in - 85 lbs) Duration 264°
Spring Tension @ 30.89 mm « 890 N Intake Valve
(Valve Open) (@ 1.212 in - 2 0 0 lbs) Closes (ABC) 80°
Number of Coils 6.8 Opens (BTC) 130
Installed Height 41.66 mm Duration 274°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 36©
Wire Diameter 4 . 5 0 mm
(0.177 in)
J9409-100
O V E R S I Z E AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION LOCATION O F IDENTIFICATION
0.025 mm (0.001 inch) RorM Milled flat on number three crankshaft

U/S Crankshaft M-2-3 etc. (Indicating No. 2 & 3 main counterweight
bearing journal)
and/or
R-l-4 etc. (Indicating No. 1 & 4 connecting
rod journal)
0.508 mm (0.020 inch) A Following engine serial number.

O/S Cylinder Bores
0.203 mm (0.008 inch) 3/8" diamond-shaped stamp Top pad — Front

O/S Tappets • of engine and flat ground on outside surface of
each O/S tappet bore.
0.127 mm (0.005 inch) X Milled pad adjacent to two 3/8" tapped holes
O/S Valve Stems on each end of cylinder head.
J9209-120

Adjusting Strap Bolt 23 N*m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 41 N*m (30 ft. lbs.)
Camshaft Bolt 68 N«m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts 24 N*m (210 in. lbs.) Trans. Support Bracket Nuts 41 N®m (30 ft. lbs.)
Chain Case Cover Bolts 41 N«m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts 61 N«m (45 ft. lbs.) Bracket Bolts 68 N®m (50 ft. lbs.)
Crankshaft Main Bearing Cap Bolts .... 115 N*m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N«m (30 ft. lbs.)
1st Step 68 N*m (50 ft. lbs.) Rocker Arm Bolts 23 N»m (200 in. lbs.)
2nd Step 143 N*m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N»m (95 in. lbs.) Spark Plugs 41 N«m (30 ft. lbs.)
Starter Mounting Bolts 68 N«m (50 ft. lbs.)
Head Bolts/Nuts 34 N»m {25 ft. lbs.) Throttle Body Bolts ............................. 23 N®m (200 in. lbs.)
Front Mount - Thru-Bolt Nut 102 N»m (75 ft. lbs.) Bolts 31 N®m (270 in. lbs.)
Bracket/Cushion Bolts 41 N»m (30 ft. lbs.) Mounting Plate Nuts 204 N«m (150 ft. lbs.)
Generator Mounting Bolt 41 N»m (30 ft. lbs.) Vibration Damper Retainer
Bolt 183 N»m (135 ft. lbs.)
Intake Manifold Bolts Refer to Procedure
Cover Bolt 41 N»m (30 ft. lbs.)
Oil Pan Bolts 23 N«m (200 in. lbs.)
Oil Pan Drain Plug 34 N*m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N«m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N*m (95 in. lbs.) J9409-82
8.0L ENGINE SERVICE PROCEDURES
page page
Camshaft 110 General Information 97
Crankshaft Main Bearings , 116 Oil Pan 111
Crankshaft Pulley / Damper . . 108 Oil Pump 112
Crankshaft Rear Seal Retainer 117 Piston / Connecting Rod Assembly 114
Cylinder Block 118 Rocker Arms 101
Cylinder Head Cover 100 Specifications—8.0L Engine 119
Cylinder Heads 102 Timing Chain Cover 109
Engine Rear Mount 98 Valves / Valve Springs 104
GENERAL INFORMATION REAR COIL PACK FRONT COIL PACK

The 8.0 Liter (488 CID) ten-cylinder engine is a V -
Type lightweight, single cam, overhead valve engine
with hydraulic roller tappets (Fig. 1).
Engine Type ...90° V-10OHV

Bore and Stroke .........101.6 x 98.6 mm (4.00 x 3.88 in.)
Displacement ......8.01 (488 cu. in.)
Compression Ratio 8.6:1
Torque 617 N*m (450ft.lis.) • 2.400 rpm
Firing Order 1-10-9-4-3-6-5-8-7-2
Lubrication Pressure Feed - FuH Flow Filtration
(Direct Crankshaft Driven Pump)
Engine Oil Capacity... .A.6L 7 0 Qts) w/fiher
Coding System Liquid Cooled - Forced GrcubKon
Coding Capacity 20.5L (21.75 Qts)
Crankshaft Cost Iron
Cylinder Head Cast Iron
Combustion Chambers • • Wedge-High SwiH
Camshaft. ......Nodular Cast Iron
Pistons Die Cast Aluminum Alloy
Connecting Rods... ....Forged Steel
J9409-3 RIGHT LEFT

SANK BANK
FIRING ORDER
Fig. 1 Engine Description 1-10-9-4-3-6-5-8-7-2 J 948D-12
This engine is designed for unleaded fuel.
Engine lubrication system consists of a gerotor type Fig. 2 Firing Order
oil pump mounted i n the timing chain cover and mount (Fig. 3). When component part replacement is
driven by the crankshaft. The V-10 uses a full flow necessary, use the engine type and serial number for
oil filter. reference.
The cylinders are numbered from front to rear; 1,
3, 5, 7, 9 on the left bank and 2 , 4, 6, 8, 10 on the ENGINE FRONT MOUNTS
right bank. The firing order is 1-10-9-4-3-6-5-8-7-2
(Fig. 2). REMOVAL
The engine serial number is located on the lower (1) Disconnect the negative cable from the battery.
left front of the cylinder block i n front of the engine (2) Position fan to assure clearance for radiator top
tank and hose.
9 - 98 8.0L ENGINE •
Fig. 3 Engine identification

manifold. CUSHION
BRACKET
(3) Install engine support/lifting fixture. J9409-54
(5) Lift the engine SLIGHTLY and remove the Fig. 5 Positioning Engine Front Mounts
thru-bolt and nut (Fig. 4). (5) Lower the vehicle.
(6) Remove engine support bracket/cushion bolts (6) Remove lifting fixture.
heat shields. ENGINE REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(3) Remove support cushion stud nuts (Fig. 6).
J9409-52

INSTALLATION
lbs.) torque.
bracket/cushion.
(4) Install thru-bolt nuts and tighten the nuts to Fig. 6 Engine Rear Support Cushion
(4) Raise rear of transmission and engine (5) Discharge the air conditioning system, i f
SLIGHTLY. equipped (refer to Group 24, Heating and Air Condi
(5) Remove the bolts holding the support cushion tioning for service procedures).
to the transmission support bracket. Remove the sup (6) Remove the serpentine belt (refer to Group 7,
port cushion. Cooling System).
(6) I f necessary, remove the bolts holding the (7) Remove the A/C compressor with the lines at
transmission support bracket to the transmission tached. Set aside.
(Fig. 7). (8) I f equipped, remove the condenser.
(11) Disconnect the top radiator hose.
(12) Remove the fan.
(13) Remove the fan shroud.
(14) Disconnect the lower radiator hose.
System).
Service).
(20) Remove the upper intake manifold (refer to
Group 11, Exhaust System and Intake Manifold).
(21) Remove the coil assemblies with the ignition
cables.
equipped.
Fig. 7 Transmission Support Bracket (25) Disconnect the fuel lines.
INSTALLATION (26) On Manual Transmission vehicles, remove the
(1) I f removed, position the transmission support shift lever (refer to Group 21, Transmissions).
bracket to the transmission. Install new attaching (27) Raise and support the vehicle on a hoist.
bolts and tighten to 88 N-m (65 ft. lbs.) torque. (28) Remove the drain plug and drain the engine
(2) Position support cushion to transmission sup oil.
port bracket. Install stud nuts and tighten to 41 N-m (29) Remove engine front mount thru-bolt nuts.
(30 ft. lbs.) torque. (30) Remove the transmission cooler line brackets
from oil pan.
(31) Disconnect exhaust pipe at manifold.
(32) Disconnect the starter wires. Remove starter
(Fig. 6).
(4) Install the support cushion bolts and tighten to
Service).
(5) Remove the transmission jack. cover.
(6) Lower the vehicle. (34) AUTOMATIC TRANSMISSION:
(a) Support transmission. This will assure that
ENGINE ASSEMBLY the torque converter will remain i n proper position
in the transmission housing.
REMOVAL
(1) Remove the battery.
(c) Remove transmission bolts.
(35) M A N U A L TRANSMISSIONS
System for the proper procedure). (a) Remove the prop shaft (refer to Group 16,
(3) Remove the upper crossmember and top core Propeller Shaft).
support. (b) Support transmission.
(4) Remove the transmission oil cooler. (c) Remove rear transmission support.
(d) Remove the crossmember.
(e) Remove the clutch assembly and slave cylin (16) Connect the transmission cooler lines.
der. (17) Connect the power steering hoses, i f equipped.
if) Disconnect all wiring and connectors. (18) Connect the heater hoses.
(g) Remove transmission bolts. Remove the (19) Remove the coil assemblies with the ignition
transmission. cables.
(h) Remove the bell housing. (20) Install the upper intake manifold (refer to
(i) Remove clutch assembly. Group 11, Exhaust System and Intake Manifold).
(j) Remove flywheel and ring gear. (21) Using a new gasket, install throttle body.
(36) Lower the vehicle. Tighten the throttle body bolts to 23 N-m (200 in.
(37) Install a jack stand under the automatic lbs.) torque.
transmission. (22) Connect the throttle linkage.
CAUTION: DO NOT lift the engine by the intake (24) Install the generator and wire connections (re
manifold. fer to Group 8B, Battery/Starter/Generator Service).
(25) Install radiator (refer to Group 7, Cooling Sys
(38) Install an engine lifting fixture.
tem).
(39) Remove engine from vehicle and install engine
assembly on a repair stand. (26) Connect the lower radiator hose.
(27) Install the fan shroud.
INSTALLATION (28) Install the fan.
(1) Remove engine from the repair stand and posi (29) Connect the top radiator hose.
tion i n the engine compartment. Position the thru- (30) Install the radiator overflow bottle.
bolt into the support cushion brackets. (31) Install the washer bottle.
(2) Install an engine support fixture. (32) I f equipped, install the condenser.
(3) Raise and support the vehicle on a hoist. (33) Install the A/C compressor with the lines at
(4) AUTOMATIC TRANSMISSION: tached.
(a) Install transmission bolts. (34) Install the serpentine belt (refer to Group 7,
(b) Install torque converter bolts. Tighten the Cooling System).
bolts to 31 N-m (270 in. lbs.) torque. (35) Evacuate and charge the air conditioning sys
(c) Remove the support from transmission. tem, i f equipped (refer to Group 24, Heating and Air
(5) M A N U A L TRANSMISSION: Conditioning for service procedures).
(a) Install flywheel and ring gear. (36) Install the transmission oil cooler.
(b) Install clutch assembly. (37) Install the upper crossmember and top core
(c) Install bell housing. support.
(d) Install transmission and bolts.
(38) Add coolant to the cooling system (refer to
(e) Connect all wiring and connectors.
Group 7, Cooling System for the proper procedure).
(f) Install clutch assembly and slave cylinder.
(g) Install the crossmember. (39) Install the battery.
(h) Install rear transmission support. (40) Warm engine and adjust.
(i) Remove support from transmission. (41) Road test vehicle.
(j) Install the prop shaft (refer to Group 16, Pro
peller Shaft). CYLINDER HEAD COVER
(6) Install the dust shield and transmission cover. Die-cast magnesium cylinder head covers (Fig. 1)
(7) Install the starter and connect the starter wires reduce noise and provide a good sealing surface. A
(refer to Group 8B, Battery/Starter/Generator Ser steel backed silicon gasket is used with the cylinder
vice). head cover (Fig. 2). This gasket can be used again.
(9) Install the transmission cooler line brackets REMOVAL
from oil pan. (1) Disconnect the negative cable from the battery.
(10) Install engine front mount thru-bolt nuts. (2) Disconnect closed ventilation system and evap
Tighten the nuts. oration control system from cylinder head cover.
(11) Install the drain plug and tighten to 34 N-m Identify each system for installation.
(25 ft. lbs.) torque. (3) Remove the upper intake manifold to remove
(12) Lower the vehicle. the right side head cover (refer to Group 11, Exhaust
(13) Remove engine lifting fixture. System and Intake Manifold).
(14) On Manual Transmission vehicles, install the (4) Remove cylinder head cover bolts and stud
shift lever (refer to Group 21, Transmissions). bolts. Remove the covers and gaskets. The gasket
(15) Connect the fuel lines. may be used again.
CAUTION: T h e cylinder head cover fasteners have a
special plating. DO NOT u s e alternative fasteners.

ket. Install the stud bolts and hex head bolts i n the
proper positions (Fig. 1). Tighten the stud bolts and
the bolts to 16 N-m (144 in. lbs.) torque.
(3) I f removed, install the upper intake manifold
(refer to Group 11, Exhaust System and Intake Man
ifold).
evaporation control system onto the proper head
cover. DO NOT switch the systems.
ROCKER ARMS
REMOVAL
(1) Disconnect spark plug wires by pulling the boot
straight out i n line with plug.
(3) Remove the rocker arm bolts and the rocker
arm assembly (Fig. 3). Place rocker arm assemblies
on a bench i n the same order as removed.
(4) Remove the push rods and place them on a
bench i n the same order as removed.
Fig. 1 Cylinder Head Covers
J9409-58
Fig. 2 Cylinder Head Cover Gaskets

CLEANING Fig. 3 Rocker Arm Assembly
Clean cylinder head cover gasket surface. INSTALLATION
Clean head rail, i f necessary.
CAUTION: DO NOT rotate or crank the engine dur
INSPECTION ing or immediately after rocker arm installation. Al
Inspect cover for distortion and straighten, i f nec low the hydraulic roller tappets adequate time to
essary. bleed down (about 5 minutes).
Check the gasket for use i n head cover installation.
I f damaged, use a new gasket. (1) Install the push rods i n the same order as re
moved.
INSTALLATION (2) Install rocker arm assemblies i n the same order
(1) The cylinder head cover gasket can be used as removed. Tighten the rocker arm bolts to 28 N-m
again. Install the gasket onto the head rail. Be sure (21 ft. lbs.) torque.
the word TOP is facing up. (3) Install cylinder head cover and gasket.
(4) Connect spark plug wires.
9 - 102 8 . 0 L ENGINE •
CYLINDER HEADS COIL PACKS
A N D BRACKET
The alloy cast iron cylinder heads (Fig. 4) are held
in place by 12 bolts. The spark plugs are located i n
the peak of the wedge between the valves.
INTAKE VALVES INTAKE VALVES INTAKE VALVE
MOUNTING
BOLTS (4)
EXHAUST ' EXHAUST

VALVES VALVE
J9409-1
FRONT O F E N G I N E J9414-55
REMOVAL Fig. 6 Coil Pack and Bracket
(1) Disconnect the negative cable from the battery. (12) Disconnect the coil wires.
(2) Drain cooling system (refer to Group 7, Cooling (13) Disconnect heat indicator sending unit wire.
System for the proper procedures). (14) Disconnect heater hoses and bypass hose.
(3) Remove the heat shields (Fig. 5). (15) Remove upper intake manifold and throttle
body as an assembly.
(16) Remove cylinder head covers and gaskets.
(17) Remove the EGR tube. Discard the gasket.
(18) Remove lower intake manifold. Discard the
flange side gaskets and the front and rear cross-over
gaskets.
(20) Remove rocker arm assemblies and push rods.
der head gasket.
CLEANING
Fig. 5 Spark Plug Wire Heat Shields (Left Side heads. Be sure material does not fall into the lifters
Shown) and surrounding valley.
(4) Remove the intake manifold-to-generator Clean cylinder block front and rear gasket surfaces
bracket support rod. Remove the generator. using a suitable solvent.
(5) Remove closed crankcase ventilation system. Clean the exhaust manifold to cylinder head mat
(6) Disconnect the evaporation control system. ing areas.
(8) Disconnect the fuel lines. INSPECTION
(9) Disconnect accelerator linkage and i f so Inspect all surfaces with a straightedge i f there is
equipped, the speed control and transmission kick- any reason to suspect leakage. The out-of-flatness
down cables. specifations are 0.0007 mm/mm (0.0007 inch/inch),
(10) Remove the return spring. 0.127 mm/152 mm (0.005 inch/6 inches) any direction
(11) Remove coil pack and bracket (Fig. 6).
o r 0.254 mm (0.010 inch) overall across head. I f e x (6) Insert dowels into cylinder block locator holes.
ceeded, either replace h e a d o r lightly machine the Peel off the protective paper (blue - rear and brown -
head surface. front) and press firmly onto the block (Fig. 9).
The cylinder h e a d surface f i n i s h should b e
INTAKE MANiroLD-TO-BLOCK SEALS (FRONT)
1.78-4.57 microns (70-180 microinches). (BROWN PEEL-OFF)
Inspect push r o d s . Replace worn or bent rods.
INSTALLATION
(1) Position t h e n e w cylinder h e a d gaskets o n t o t h e
cylinder block.
(2) Position the cylinder heads o n t o head gaskets
and cylinder block.
(3) Tighten t h e cylinder head bolts in two steps
(Fig. 7):
• Step 1—Tighten all cylinder h e a d bolts, i n se
quence, to 58 N-m (43 ft. lbs.) torque.
• Step 2—Tighten all cylinder head bolts, i n se INTAKE MANIFOLD-TO-BLOCK SEALS (REAR)"
quence, to 143 N-m (105 ft. lbs.) torque. (BLUE PEEL-OFF) J9409-63
CYLINDER HEAD
© T© © Fig. 9 Intake Manifold-to-Block Seals and
Dowel Holes
Locator
(7) Apply Mopar Silicone Rubber Adhesive Sealant,

or equivalent, into the four corner spaces (Fig. 10).
Fill the pocket, but DO NOT overfill.
INTAKE MANIFOLD SEALANT

®i M © © GASKET
© © © @
J9409-14
Fig. 7 Cylinder Head Bolt Tightening Sequence

CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
T D C . Contact between the valves and piston could
occur.
(4) Install push rods and rocker arm assemblies i n

(5) Install the side intake manifold gaskets. Be
sure that the locator dowels are positioned i n the
head (Fig. 8).
J9409-65
Fig. 10 Mopar Silicone Rubber Adhesive Sealant

•INTAKE MANIFOLD GASKETS^
Application Locations
(8) The lower intake manifold MUST be installed
within 3 minutes of sealant application. Carefully
lower intake manifold into position on the cylinder
LOCATOR DOWELS'' J9409-64 block and cylinder heads. After intake manifold is i n
place, inspect to make sure seals and gaskets are in
Fig. 8 Intake Manifold Flange Gasket Alignment place.
(9) Tighten the lower intake manifold bolts to 54
(10) Using a new gasket, position the upper intake (2) Special studs must be used to adapt the Valve
manifold onto the lower intake manifold. Spring Compressor Tool to the V-10 cylinder head
(11) Tighten upper intake manifold bolts to 22 N-m (Fig. 11). Install the 5/16 end into the Special Tool
(16 ft. lbs.) torque. MD998772A and the metric end into the cylinder
(12) Install the exhaust manifolds using sealant. head.
Tighten the bolts and stud bolts to 22 N-m (16 ft.
lbs.) torque. FITS INTO TOOL MD 9 9 8 7 7 2 A
(13) Using a new gasket, position the EGR tube to
the intake manifold and the exhaust manifold.
Tighten the EGR tube nut to 34 N-m (25 ft. lbs.)
torque. Tighten the bolts to 20 N-m (174 in. lbs.)
torque.
(14) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
(15) Install coil wires.
(16) Connect heat indicator sending unit wire.
(18) Install coil packs and bracket. Tighten the
bracket bolts to 21 N-m (190 in. lbs.) torque. Connect
the coil wires.
down cables.
FITS INTO CYLINDER HEAD
(21) Install the fuel lines. J9409-95
generator mounting bolt to 41 N-m (30 ft. lbs.) Fig. 11 Special Studs (6715) for ¥-16 Engine
torque. Tighten the adjusting strap bolt to 23 N-m (3) Compress valve springs using Valve Spring
Compressor Tool MD-998772A with Adapter 6716A
tem for adjusting the belt tension.
and Screw 6765 (Fig. 12). Tap the retainer using a
brass drift and ball peen hammer to loosen locks
bracket support rod. Tighten the bolts to 41 N-m (30
away from retainer.
ft. lbs.) torque.
(24) Place the cylinder head cover gaskets i n posi
tion (tab marked TOP facing you) and install cylinder
head covers. Tighten the bolts to 16 N-m (144 in. lbs.)
torque.
(28) Install the heat shields and the washers.
Tighten the nuts to 20 N-m (175 in. lbs.) torque.
(31) Check for leaks (fuel, oil, antifreeze, etc.).
The rocker pivot support and the valve guides are Fig. 12 Valve Spring Compressor (MD998772A) with
cast integral with the heads. Adaptor (6716A) and Screw 6765
This procedure requires the removal of the cylinder (4) Remove valve retaining locks, valve spring re
head.
tainers and valve springs. Check for abnormal wear,
REMOVAL replace as required.
(1) Remove the cylinder head. (5) Remove the valve stem seals.
(6) Before removing valves, remove any burrs from Service valves with oversize stems are available
valve stem lock grooves to prevent damage to the (Fig. 15).
valve guides. Identify valves to ensure installation i n
original location. Reamer O / S Valve Guide Size
VALVE CLEANING 0.076 mm 8.026 - 8.052 mm

Clean valves thoroughly. Discard burned, warped (0.003 in.) (0.316-0.317 in.)
and cracked valves.
Remove carbon and varnish deposits from inside of 0.381 mm 8.331 - 8.357 mm
valve guides with a reliable guide cleaner. (0.015 in.) (0.328 -0.329 in.)
VALVE INSPECTION
0.051 mm (0.002 inch), replace the valve. J9309-30
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 13). The special Slowly turn reamer by hand and clean guide thor
sleeve places the valve at the correct height for oughly before installing new valve. Ream t h e valve
reamed true i n relation to the valve seat:
• Step 1-Ream to 0.0763 m m (0.003 inch).
REFACING VALVES I VALVE SEATS

The intake and exhaust valves have a 45° face an
gle and a 44 1/2° seat angle (Fig. 16).
CONTACT
POINT
Fig. 13 Positioning Valve with Tool C-3973

(b) Attach Dial Indicator Tool C-3339 to cylinder
head and set i t at right angle of valve stem being
measured (Fig. 14).
A - SEAT WIDTH - INTAKE 1.016-1.524 mm ( 0 . 0 4 0 - 0 . 0 6 0 in.)

EXHAUST 1.016-1.524 mm ( 0 . 0 4 0 - 0 . 0 6 0 in.)
B - FACE A N G L E (INTAKE & EXHAUST)
C - SEAT A N G L E (INTAKE & EXHAUST)
D - CONTACT SURFACE
J9409-80

VALWES
Fig. 14 Measuring Valve Guide Wear Inspect the remaining margin after the valves are
(c) Move valve to and from the indicator. The to refaced (Fig. 17). Valves with less than 1.190 mm
tal dial indicator reading should not exceed 0.432 (0.047 inch) margin should be discarded.
mm (0.017 inch). Ream the guides for valves with
oversize stems i f dial indicator reading is excessive
or i f the stems are scuffed or scored.
I - 111 8.0L ENGINE •
INTAKE EXHAUST
VALVE VALVE
FACE
SPECIAL
TOOL C-647
•STEM-
VALVE SPRING
R E T A I N E R LOCK
GROOVE
9209-37
J9209-127 Fig. 18 Testing Waive Spring for Compressed

Fig. 17 Intake and Exhaust Waives
INSTALLATION
VALWE SEATS
(1) Make sure there are no burrs on valve stems.
(1) When refacing valve seats, i t is important that (2) Coat valve stems with lubrication oil. Insert
the correct size valve guide pilot be used for reseat valves into valve guides i n cylinder head.
ing stones. A true and complete surface must be ob (3) Install new seals on all valve guides (BLACK
tained. on intake and BROWN on exhaust). Install valve
(2) Measure the concentricity of valve seat using a springs and valve retainers.
dial indicator. Total r U f i o u t should not exceed 0.038 (4) Compress valve springs with Valve Spring
mm (0.0015 inch) total indicator reading. Compressor Tool MC-998772A and adapter 6716A, in
(3) Inspect the valve seat with Prussian blue to de stall locks and release tool. Tap the retainer with a
termine where the valve contacts the seat. To do this, brass or heavy plastic hammer to ensure locks have
coat valve seat LIGHTLY with Prussian blue then set been seated.
valve i n place. Rotate the valve with light pressure. (5) I f valves and/or seats were ground, measure
I f the blue is transferred to the center of valve face, the installed height of springs. Make sure the mea
contact is satisfactory. I f the blue is transferred-to surement is taken from bottom of spring seat i n cyl
the top edge of valve face, lower valve seat with a 15° inder head to the bottom surface of spring retainer. I f
stone. I f the blue is transferred to bottom edge of spacers are installed, measure from the top of spacer.
valve face raise valve seat with a 60° stone. I f height is greater than 42.86 mm (1-11/16 inches),
(4) When seat is properly positioned the width of install a 1.587 mm (1/16 inch) spacer i n head coun-
valve seats should be 1.016-1.524 mm (0.040-0.060 terbore. Ensure this brings spring height back to nor
inch). mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
VALVE SPRING INSPECTION VALVE STEM SHIELD / SPRING REPLACEMENT
This procedure is done with the cylinder head in
stalled.
Valve Spring Tester Tool C-647 until surface is i n line (2) Set engine basic timing to Top Dead Center
with the 1-5/16 inch mark on the threaded stud. Be (TDC) and remove air cleaner.
sure the zero mark is to the front (Fig. 18). Place (3) Remove cylinder head covers and spark plugs.
spring over stud on the table and lift compressing le (4) Using suitable socket and flex handle at crank
ver to set tone device. Pull on torque wrench until shaft retaining bolt, turn engine so the N o . l piston is
ping is heard. Take reading on torque wrench at this at TDC on the compression stroke.
instant. Multiply this reading by 2. This will give the (5) Remove rocker arms.
spring load at test length. Fractional measurements (6) With air hose attached to an adapter installed
are indicated on the table for finer adjustments. Re in N o . l spark plug hole, apply 620-689 kPa (90-100
fer to specifications to obtain specified height and al psi) air pressure.
lowable tensions. Discard the springs that do not
(7) Using Valve Spring Compressor Tool engine should be operated at fast idle for sufficient
MD-998772A with adapter 6716A, compress valve time. This allows all of the air inside of the tappets
spring and remove retainer valve locks and valve to be bled out.
spring.
(8) Install seals on the exhaust valve stem and po TAPPET NOISE DIAGNOSIS
sition down against valve guides. The exhaust valve (1) To determine source of tappet noise, operate en
stem seal is brown. gine at idle with cylinder head covers removed.
(9) The black intake valve stem seals should be (2) Feel each valve spring or rocker arm to detect
pushed firmly and squarely over the valve guide us noisy tappet. The noisy tappet will cause the affected
ing the valve stem as a guide. DO NOT force seal spring and/or rocker arm to vibrate or feel rough i n
against top of guide. When installing the valve re operation.
tainer locks, compress the spring only enough to in Worn valve guides or cocked springs are
stall the locks. sometimes mistaken for noisy tappets. I f such is
(10) Follow the same procedure on the remaining 7 the case, noise may be dampened by applying
cylinders using the firing sequence 1-10-9-4-3-6-5-8- side thrust on the valve spring. If noise is not
7-2. Make sure piston i n cylinder is at TDC on the appreciably reduced, it can be assumed the
valve spring that is being removed. noise is i n the tappet. Inspect the rocker arm
(11) Remove adapter from the N o . l spark plug push rod sockets and push rod ends for wear.
hole. (3) Valve tappet noise ranges from light noise to a
(12) Install rocker arms. heavy click. A light noise is usually caused by exces
(13) Install air cleaner. sive leak-down around the unit plunger or by the
(14) Connect the negative cable to the battery. plunger partially sticking i n the tappet body cylinder.
(15) Road test vehicle and check for leaks. The tappet should be replaced. A heavy click is
HYDRAULIC TAPPETS eign particles becoming wedged between the plunger
Before disassembling any part of the engine to cor and the tappet body. This will cause the plunger to
rect tappet noise, check the oil pressure. I f vehicle stick i n the down position. This heavy click will be
has no oil pressure gauge, install a reliable gauge at accompanied by excessive clearance between the
the pressure sending unit. The pressure should be valve stem and rocker arm as valve closes. I n either
between 207-552 kPa (30-80 psi) at 3,000 RPM. case, tappet assembly should be removed for inspec
Check the oil level after the engine reaches normal tion and cleaning.
operating temperature. Allow 5 minutes to stabilize The valve train generates a noise very much like a
oil level, check dipstick. The oil level i n the pan light tappet noise during normal operation. Care
should never be above the FULL mark or below the must be taken to ensure that tappets are making the
ADD OIL mark on dipstick. Either of these 2 condi noise. I n general, i f more than one tappet seems to
tions could be responsible for noisy tappets. be noisy, its probably not the tappets.
OIL LEVEL REMOVAL

HIGH (2) Remove the air cleaner.
I f oil level is above the FULL mark, i t is possible (3) Remove cylinder head cover.
for the connecting rods to dip into the oil. With the (4) Remove rocker arm assembly and push rods.
engine running this condition could create foam i n Identify push rods to ensure installation i n original
the oil pan. Foam i n oil pan would be fed to the hy location.
draulic tappets by the oil pump causing them to lose (5) Remove intake manifold.
length and allow valves to seat noisily. (6) Remove the cylinder head i f the end tappets
are to be removed.
LOW (7) Remove yoke retainer spider and tappet align
Low oil level may allow oil pump to take i n air. ing yokes (Fig. 1).
When air is fed to the tappets, causes them to lose (8) Pull tappet out of bore with a twisting motion.
length and allows valves to seat noisily. Any leaks on I f all tappets are to be removed, identify tappets to
intake side of oil pump through which air can be ensure installation i n original location.
drawn will create the same tappet action. When tap (9) I f the tappet or bore i n cylinder block is scored,
pet noise is due to aeration, i t may be intermittent or scuffed, or shows signs of sticking, ream the bore to
constant, and usually more than 1 tappet will be next oversize. Replace with oversize tappet.
noisy. When oil level and leaks have been corrected, (10) Check camshaft lobes for abnormal wear.
9 - 108 8.0L ENGINE •
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos
sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run
ning direction) until the valve has lifted 0.863 mm
(0.034 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Use a protractor as there are no tim
ing marks on the engine.
CAUTION; DO NOT t u r n crankshaft any further

c l o c k w i s e as valve s p r i n g m i g h t b o t t o m a n d result
in serious damage.
(5) I f reading is not within specified limits:

(a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of TDC mark on timing indi
cator.
CRANKSHAFT PULLEY / DAMPER

REMOVAL
Fig. 1 Tappets, Aligning Yoke and Yoke Retaining (1) Disconnect the negative cable from the battery.
Spider (2) Remove fan shroud retainer bolts and set
INSTALLATION shroud back over engine.
(1) Lubricate tappets. (3) Remove the cooling system fan.
(2) Install tappets i n their original positions. En (4) Remove the serpentine belt (refer to Group 7,
sure that the oil bleed hole (if so equipped) faces for Cooling System).
ward. (5) Remove crankshaft pulley/damper bolt and
(3) Install tappet aligning yokes. Position the yoke washer from end of crankshaft (Fig. 2).
retainer spider over the tappet aligning yokes (Fig.
1). Install the yoke retaining spider bolts and tighten
(4) Install cylinder head.
(5) Install the push rods i n their original location.
(6) Position the rocker arm assembly on the pedes
tal and align to the push rods. Install the bolts and
(7) Install intake manifold.
(8) Install cylinder head cover.
CAUTION: To prevent damage to valve mechanism,

e n g i n e m u s t not be r u n above fast idle until all hy
draulic tappets have filled w i t h oil a n d h a v e become
quiet.
Fig. 2 Crankshaft Pulley / Damper
(11) Road test vehicle and check for leaks. (6) Using a 3-prong puller tool, pull pulley/damper
off of the crankshaft.
VALVE TIMING (7) Inspect crankshaft oil seal (Fig. 3).
(1) Turn crankshaft until the No.6 exhaust valve is
INSTALLATION
closing and No.6 intake valve is opening.
(1) Position the crankshaft pulley/damper onto the
(2) Insert a 6.350 mm (1/4 inch) spacer between
crankshaft.
rocker arm pad and stem tip of N o . l intake valve. A l
(2) Install the crankshaft bolt and washer. Pull the
low spring load to bleed tappet down giving i n effect
pulley/damper onto the crankshaft. Tighten the bolt
a solid tappet.
(3) Install the serpentine belt (refer to Group 7, N-m (30 ft. lbs.) torque with cylinder head installed
Cooling System). or 20 N-m (15 ft. lbs.) torque with cylinder head re
(4) Install the cooling system fan. moved. With a torque applied to the camshaft
(5) Position the fan shroud and install the bolts. sprocket bolt, crankshaft should not be permitted to
(6) Connect the negative cable to the battery. move. I t may be necessary to block the crankshaft to
prevent rotation.
TIMING CHAIN COVER (3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads in
REMOWAL stalled, apply 14 N-m (30 ft. lbs.) torque i n the re
(1) Disconnect the negative cable from the battery. verse direction. With the cylinder heads removed,
(2) Drain cooling system (refer to Group 7, Cooling apply 20 N-m (15 ft. lbs.) torque i n the reverse direc
System). tion. Note the amount of chain movement (Fig. 4).
Cooling System).
System).
19, Steering).
(6) Remove crankshaft pulley/damper.
tem).
(8) Loosen oil pan bolts and remove the front oil
pan bolts that mount the pan to the timing chain
cover.
(9) Remove the cover bolts. Fig. 4 Measuring Timing Chain Wear and Stretch
(10) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket. (4) Install a new timing chain, i f its movement ex
(11) Place a suitable tool behind the lips of the oil ceeds 3.175 mm (1/8 inch).
seal to pry the oil seal outward. Be careful not to (5) I f chain is not satisfactory, remove camshaft
damage the crankshaft seal surface of the cover (Fig. sprocket attaching bolt and remove timing chain with
3). crankshaft and camshaft sprockets.
crankshaft bores.
shaft sprocket.
J9409-68 47 N-m (35 ft. lbs.) torque.
Fig. 3 Timing Chain Cover and Oil Seal be 0.051-0.152 mm (0.002-0.006 inch) with a new
(12) Inspect surface of cover. Remove any burrs or thrust plate and up to 0.254 mm (0.010 inch) with a
high spots. used thrust plate. I f not within these limits install a
new thrust plate.
(1) Place a scale next to the timing chain so that CLEANING
any movement of the chain may be measured. Be sure mating surfaces of timing chain cover and
(2) Place a torque wrench and socket over, cam cylinder block are clean and free from burrs.
g - 110 8JL ENGINE •
(5) Remove timing chain cover and timing chain.
CAMSHAFT (6) Remove camshaft thrust plate (Fig. 6).
SPROCKET
C A M SHAFT
TIMING
MARKS
CRANKSHAFT -THRUST PLATE

SPROCKET J9409-70
J9409-69 Fig. 6 Camshaft

(7) Install a long bolt into front of camshaft to fa
Fig. 5 Alignment of Timing Marks cilitate removal of the camshaft. Remove camshaft,
INSTALLATION being careful not to damage cam bearings with the
(1) Using a new cover gasket, carefully install tim cam lobes.
ing chain cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe REMOVAL—BEARING
sive Sealant, or equivalent, at the joint between tim (1) With engine completely disassembled, drive out
ing chain cover gasket and the oil pan gasket. Finger rear cam bearing core hole plug.
tighten the timing chain cover bolts at this time. (2) Install proper size adapters and horseshoe
(2) Tighten timing chain cover bolts to 47 N-m (35 washers (part of Camshaft Bearing Remover/Installer
ft. lbs.) torque. Tighten oil pan bolts to 24 N-m (215 Tool C-3132-A) at back of each bearing shell. Drive
in. lbs.) torque. out bearing shells (Fig. 7).
(3) Position the crankshaft front oil seal onto seal
installer special tool 6806. Use the vibration damper
bolt to draw seal into timing chain cover.
(4) Install vibration damper.
(5) Install fuel lines (refer to Group 14, Fuel Sys
tem).
(6) Install water pump and housing assembly us
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(7) Install power steering pump (refer to Group 19,
Steering). 09209-93
Cooling System). Fig. 7 Camshaft Bearings Removal and Installation
(9) Install the cooling system fan. Tighten the bolts with Tool C-3132-A
INSTALLATION—BEARING
(10) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N-m (95 in. lbs.) torque. (1) Install new camshaft bearings with Camshaft
(11) Fill cooling system (refer to Group 7, Cooling Bearing Remover/Installer Tool C-3132-A by sliding
System for the proper procedure). the new camshaft bearing shell over proper adapter.
(12) Connect the negative cable to the battery. (2) Position rear bearing i n the tool. Install horse
(13) Road test vehicle and check for leaks. shoe lock and by reversing removal procedure, care
fully drive bearing shell into place.
C A M S H A F T (3) Install remaining bearings i n the same manner.
This procedure requires that the engine is removed Bearings must be carefully aligned to bring oil holes
from the vehicle. into full register with oil passages from the main
REMOVAL not i n exact alignment, remove and install them cor
(1) Remove cylinder head covers. rectly. Install a new core hole plug at the rear of
(2) Remove rocker arm assemblies. camshaft. Be sure this plug does not leak.
(3) Remove push rods and tappets. Identify each
part so i t can be installed i n its original location.
(4) Remove intake manifold.
INSTALLATION PICK-UP
(1) Lubricate camshaft lobes and camshaft bearing TUBE
journals. Using a long bolt, insert the camshaft into
the cylinder block.
Whenever an engine has been rebuilt, a new
pint of Mopar Crankcase Conditioner, o r equiv SEALANT AT
alent. The o i l m i x t u r e should be left i n engine SPLIT-LINE
for a m i n i m u m of 805 k m (500 miles). Drain at

the next normal oil change.
(2) Install camshaft thrust plate. Tighten the torx
bolts to 22 N-m (16 ft. lbs.) torque.
imaginary center line through both camshaft and J9409-76
crankshaft bores.
(4) Place timing chain around both sprockets. Fig. 1 Oil Pick-Up Tube
Clean oil pan i n solvent and wipe dry with a clean
keyway location i n crankshaft sprocket and the dowel
cutaway i n camshaft sprocket. cloth.
(6) Lift sprockets and chain (keep sprockets tight Clean oil screen and pipe thoroughly i n clean sol
against the chain i n position as described). vent. Inspect condition of screen.
INSPECTION
of timing marks. Inspect oil drain plug and plug hole for stripped or
(8) Install the camshaft bolt. Tighten bolt to 75 damaged threads. Repair as necessary.
N-m (55 ft. lbs.) torque. Inspect oil pan mounting flange for bends or distor
(9) Measure camshaft end play. Refer to Specifica tion. Straighten flange, i f necessary.
tions for proper clearance. I f not within limits, install
INSTALLATION
a new thrust plate.
(10) Each tappet reused must be installed i n the (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
same position from which i t was removed. When inch bolts. Cut the head off the bolts and cut a slot
camshaft is replaced, all o f the tappets must be into the top of the dowel. This will allow easier in
replaced. stallation and removal with a screwdriver (Fig. 2).
(11) Install tappets and push rods i n their original
17 " x 5 / 1 6 " BOLT
2
location.
(12) Install the rocker arms.
(14) Install the crankshaft pulley/damper. i
(15) Install the intake manifolds.
(16) Install the cylinder head covers. DOWEL
OIL PAN
REMOWAL SLOT J9209-106

(2) Raise vehicle. Fig. 2 Fabrication of Alignment Dowels
(3) Drain engine oil. (2) Install the dowels i n the cylinder block at the
(4) Remove left engine to transmission strut. four corners.
(5) Remove oil pan and one-piece gasket. The en (3) Apply small amount of Mopar Silicone Rubber
gine may have to be raised slightly on 2WD vehicles. Adhesive Sealant, or equivalent at the split lines.
(6) Remove the oil pick-up tube assembly (Fig. 1). The split lines are between the cylinder block, the
Discard the gasket. timing chain cover and the rear crankshaft seal as
CLEANING
sembly (Fig. 1). After the sealant is applied you
Clean the block and pan gasket surfaces. have 3 minutes to install the gasket and oil pan.
I f present, t r i m excess sealant from inside the en (4) Slide the one-piece gasket over the dowels and
gine. onto the block.
(5) Position the oil pan over the dowels and onto
OUTER INNER
the gasket. The engine may have to be slightly raised ROTOR ROTOR
on 2WD vehicles.
(6) Install the oil pan bolts (Fig. 3). Tighten the 1/4
inch bolts to 11 N-m (96 in. lbs.) torque. Tighten the
stud bolts to 16 N-m (144 in. lbs.) torque. Tighten the
5/16 inch bolts to 16 N-m (144 in. lbs.) torque.
TIMING CHAIN
Fig. 3 Oil Pan Bolt Location
COVER J 9 4 0 9 . 7 1
(7) Remove the dowels. Install the remaining 5/16

inch oil pan bolts. Tighten these bolts to 16 N-m (144 Fig. 5 Oil Pump
in. lbs.) torque. CLEANING
(8) Install the drain plug. Tighten drain plug to 34 Wash all parts i n a suitable solvent and inspect
N-m (25 ft. lbs.) torque. carefully for damage or wear.
(9) Install the engine to transmission strut.
(10) Lower vehicle. INSPECTION
(11) Connect the negative cable to the battery. Mating surface of the oil pump cover should be
(12) Fill crankcase with oil to proper level. smooth. Replace pump cover i f scratched or grooved.
Lay a straightedge across the pump cover surface
OIL PUMP (Fig. 6). I f a 0.076 mm (0.003 inch) feeler gauge can
be inserted between cover and straightedge, cover
REMOVAL
should be replaced.
(1) Remove the timing chain cover.
(2) Remove the relief valve plug, gasket, spring
and valve (Fig. 4). Discard the gasket.
PLUG TIMING
>-68
Fig. 6 Checking Oil Pump Cover Flatness

Measure thickness (Figs. 7 and 8) and diameter of
Fig. 4 Oil Pressure Relief Valve rotors. I f either rotor thickness measures 18.92 mm
(3) Remove oil pump cover (Fig. 5).
(4) Remove pump rotors (Fig. 5).
9309-70 Fig. 10 Measuring Inner Rotor Clearance in Cover
Fig. 8 Measuring inner Rotor Thickness

Slide outer rotor into timing chain cover pump
body. Press rotor to the side with your fingers and
measure clearance between rotor and pump body
(Fig. 9). I f clearance is 0.19 mm (0.007 inch) or more,
and outer rotor is within specifications, replace tim
ing chain cover.
Install inner rotor into timing chain cover pump
body (Fig. 10). Inner rotor should be positioned with
chamfer up or toward engine when cover is installed. FEELER
GAUGE STRAIGHT
This allows easy installation over crankshaft. I f EDGE
clearance between inner and outer rotors is 0.150
mm (0.006 inch) or more, replace both rotors.
9309-73
Place a straightedge across the face of the timing
chain cover pump body, between bolt holes (Fig. 11).
Fig. 11 Measuring Clearance Over Rotors
I f a feeler gauge of 0.077 mm (0.003 inch) or more
can be inserted between rotors and the straightedge, Inspect oil pressure relief valve plunger for scoring
and the rotors are within specifications, replace tim and free operation i n its bore. Small marks may be
ing chain cover. removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx
imately 49.5 mm (1.95 inches). The spring should
§ - 114 8.0L ENGINE
test between 100 and 109 N (22.5 and 24.5 pounds) NOT try to remove black coating on skirt. This
when compressed to 34 mm (1-11/32 inches). Replace is the dry film lubricant.
spring that fails to meet these specifications. (7) After removal, install bearing cap on the mat
I f oil pressure was low and pump is within specifi ing rod.
cations, inspect for worn engine bearings or other
reasons for oil pressure loss. INSPECTION
Check the crankshaft connecting rod journal for ex
INSTALLATION cessive wear, taper and scoring.
(1) Lubricate the pump rotors i n engine oil and in Check the cylinder block bore for out-of-round,
stall i n the timing chain cover. Use new parts as re taper, scoring and scuffing.
quired. Check the pistons for taper and elliptical shape be
(2) Position the oil pump cover onto the timing fore they are fitted into the cylinder bore (Fig. 12).
chain cover. Tighten cover bolts to 14 N-m (125 in.
DIAMETER (D)
lbs.) torque. SHOULD BE 98.704-98.831 mm
(3) Install the relief valve and spring. 0.0000-0.0152 mm (3.886-3.891 in.)
(0.0000-0.0006 in.
(4) Using a new pressure relief valve gasket, in LARGER THAN (C)
stall the relief valve plug. Tighten the plug to 20 N-m

nearly round shape.
A l l pistons are machined to the same weight, re SKIRT SHOULD BE 0.254-0.304 mm
gardless of size, to maintain piston balance. (0.010-0.012 in.) LESS AT DIAMETER
The piston pin rotates i n the piston only and is re FACES AT DIAMETER (B).
tained by the press interference fit of the piston pin
J9309-9
in the connecting rod.
The pistons have a unique dry-film lubricant coat
ing baked onto the skirts to reduce friction. The lu Fig. 12 Piston Measurements
bricant is particularly effective during engine break- FITTING PISTONS
in, but with time, the material becomes embedded Piston and cylinder wall must be clean and dry.
into cylinder bore walls and continues to reduce fric Specified clearance between the piston and the cylin
tion. der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at the top of
REMOVAL
skirt, 90° to piston pin axis. Cylinder bores should be
(1) Remove the engine from the vehicle.
measured halfway down the cylinder bore and trans
(3) Remove the oil pan and oil pump pick-up tube. verse to the engine crankshaft center line.
(4) Remove top ridge of cylinder bores with a reli Pistons and cylinder bores should be measured at
able ridge reamer before removing pistons from cyl normal room temperature, 21°C (70°F).
inder block. Be sure to keep tops of pistons covered
during this operation. FITTING RINGS
(5) Be sure the connecting rod and connecting rod (1) Measurement of end gaps:
cap are identified with the cylinder number. Remove (a) Measure piston ring gap 2 inches from bot
connecting rod cap. Install connecting rod bolt guide tom of cylinder bore. An inverted piston can be
set on connecting rod bolts. used to push the rings down to ensure positioning
(6) Pistons and connecting rods must be removed rings squarely i n the cylinder bore before measur
from top of cylinder block. When removing piston and ing.
connecting rod assemblies, rotate crankshaft center (b) Insert feeler stock i n the gap. Gap for com
the connecting rod i n the cylinder bore and at BDC. pression rings should be between 0.254-0.508 mm
Be careful not to nick, crankshaft journals. D O (0.010-0.020 inch).
The oil ring gap should be 0.381-1.397 mm (0.015- The bearing shells must be installed so that the
0.055 inch). tangs are i n the machined grooves i n the rods and
(c) Rings with insufficient end gap may be prop caps.
erly filed to the correct dimension. Ends should be Limits of taper or out-of-round on any crankshaft
stoned smooth after filing with Arkansas White journals should be held to 0.025 mm (0.001 inch).
Stone. Rings with excess gaps should not be used. Bearings are available i n 0.025 mm (0.001 inch),
(2) Install rings and confirm ring side clearance: 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
(a) Install oil rings being careful not to nick or mm (0.010 inch) and 0.305 mm (0.012 inch) under
scratch the piston. size. Install the bearings in pairs. DO NOT use a
(b) Install the compression rings using Installa new bearing h a l f with an old bearing half. DO
tion Tool C-4184. The compression rings must be NOT file the rods or bearing caps.
installed with the identification mark face up (to
ward top of piston). An identification mark on the INSTALLATION
ring is a drill point, a stamped letter "O", an oval (1) Be sure that compression ring gaps are stag
depression or the word TOP. gered so that neither is i n line with oil ring rail gap.
(c) Measure side clearance between piston ring (2) Before installing the ring compressor, make
and ring land. Clearance should be 0.074-0.097 mm sure the oil ring expander ends are butted and the
(0.0029-0.0038 inch) for the compression rings. The rail gaps located properly (Fig. 13).
steel rail oil ring should be free i n groove, but (3) Immerse the piston head and rings i n clean en
should not exceed 0.246 mm (0.0097 inch) side gine oil. Slide Piston Ring Compressor Tool C-385
clearance. over the piston and tighten with the special wrench
(d) Pistons with insufficient or excessive side (part of Tool C-385). Be sure position of rings
clearance should be replaced. does not change during this operation.
(3) Arrange ring gaps 90° apart as shown i n Fig. (4) Install connecting rod bolt protectors on rod
13. bolts, a long protector should be installed on the
numbered side of the connecting rod.
TOP COMPRESSION RING GAP (5) Rotate crankshaft so that the connecting rod
UPPER OIL RING GAP
journal is on the center of the cylinder bore i n the
bottom dead center position. Be sure connecting rod
and cylinder bore number are the same. Insert rod
and piston into cylinder bore. Be sure the piston and
rod assemblies are installed i n the proper orientation
SPACER (Fig. 14).
GAP (6) While tapping the piston down i n cylinder bore
with the handle of a hammer, guide the connecting
rod over the crankshaft journal.
(7) The notch or groove on top of piston must be
2ND COMPRESSION RING GAP crankshaft journal fillet.
LOWER OIL RAIL GAP J9409-77 (8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.)
Fig. 13 Proper Ring Installation torque.
CONNECTING ROD BEARINGS (9) Install the oil pump pick-up tube and oil pan.
Fit all rods on a bank until completed. DO NOT al (10) Install the cylinder head.
ternate from one bank to another, because connecting (11) Install the engine into the vehicle.
rods and pistons are not interchangeable from one
bank to another. CRANKSHAFT
The bearing caps are not interchangeable and When a crankshaft is replaced, all main and con
should be marked at removal to ensure correct as necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
sembly.
is not required when a crankshaft and bearings are
Each bearing cap has a small V-groove across the
replaced.
parting face. When installing the lower bearing shell,
make certain that the V-groove i n the shell is i n line REMOWAL
with the V-groove i n the cap. This provides lubrica (1) Remove the oil pan.
tion of the cylinder wall i n the opposite bank. (2) Remove the oil pickup tube.
9 - 116 8.0L ENGINE •
FRONT I D . M A I N BEARING
TOWARDS THIS SIDE CAP
LOWER M A I N
BEARINGS
CRANKSHAFT'
UPPER M A I N
BEARINGS
ORIENTATION BUTTON ORIENTATION BUTTON J9409-72

TOWARDS FRONT TOWARDS REAR
( L H . ONLY) (R.H. ONLY)
1,3, 5, 7 , 9 2, 4, 6, 8 , 10 Fig. 15 Main Bearing Identification
INSTALLATION
(1) Lubricate crankshaft main bearings with clean
engine oil.
J9409-78
(2) Install the crankshaft into the cylinder block.
(3) Lubricate the main journals with clean engine
Fig. 14 Piston and Rod Orientation
oil. Install main bearing caps and bolts. Follow the 2
(3) Remove the timing chain cover and gasket. Re step tightening sequence.
move and discard the front crankshaft oil seal and • Step 1—Starting with bearing cap N o . l , tighten
cover gasket. the bolts to 27 N-m (20 ft. lbs.) torque.
(4) Remove the rear seal retainer. Remove and dis • Step 2—Starting with bearing cap N o . l , tighten
card the crankshaft rear oil seal and retainer gasket. the bolts to 115 N-m (85 ft. lbs.) torque.
(5) Identify main bearing caps before removal (Fig. (4) Lubricate the connecting rod bearings and jour
15). Remove bearing caps and bearings one at a time. nals with clean engine oil. Carefully install connect
(6) Remove the connecting rod bearing caps. ing rods to the crankshaft.
(7) Lift the crankshaft straight out of the block. (5) Install the rear seal retainer with a new gasket
and oil seal. Use seal installer 6687 when installing
JOURNALS the oil seal.
The crankshaft connecting rod and main journals (6) Install the timing chain cover with a new gas
should be checked for excessive wear, taper and scor ket and oil seal.
ing. The maximum taper or out-of-round on any (7) Apply a rearward axial load of 667 N (150 lbs-f)
crankshaft journal is 0.025 mm (0.001 inch). on crankshaft centerline, driving No.3 main cap and
Journal grinding should not exceed 0.305 mm thrust bearing against No.3 bulkhead. Repeat proce
(0.012 inch) under the standard journal diameter. DO dure, driving crankshaft forward to align rear flange
NOT grind thrust faces of No.3 main bearing. DO of thrust bearings i n a common plane. Front face of
NOT nick crank pin or bearing fillets. After grinding, No.l main cap must not extend forward i n front of
remove rough edges from crankshaft oil holes and face of No.l bulkhead.
(8) Install the oil pickup tube. Tighten the bolts to
clean out all oil passages.
16 N-m (144 in. lbs.) torque.
CAUTION: After any journal grind, it is important (9) Install the oil pan.
that the final paper or cloth polish be in the s a m e
direction a s the engine rotates.
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. A l l lower main bearing halves are inter • Step 1—Starting with bearing cap N o . l , tighten
changeable. Upper main bearing halves of No.l, 2, 4, the bolts to 27 N-m (20 ft. lbs.) torque.
5 and 6 are interchangeable. • Step 2—Starting with bearing cap N o . l , tighten
Upper No.3 main bearing is flanged to carry the the bolts to 115 N-m (85 ft. lbs.) torque.
crankshaft thrust loads. This bearing is NOT inter (4) Apply a rearward axial load of 667 N (150 Ibs-f)
changeable with any other bearing halves i n the en on crankshaft centerline, driving No.3 main cap and
gine. Bearing shells are available i n standard and thrust bearing against No.3 bulkhead. Repeat proce
the following undersizes: 0.25 mm (0.001 inch), 0.051 dure, driving crankshaft forward to align rear flange
mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm of thrust bearings i n a common plane. Front face of
(0.010 inch) and 0.305 mm (0.012 inch). Never install No.l main cap must not extend forward i n front of
an undersize bearing that will reduce clearance be face of No.l bulkhead.
low specifications. (5) Install the oil pump pick-up tube and oil pan.
REMOVAL CRANKSHAFT REAR SEAL RETAINER

(1) Remove the oil pan and oil pump pick-up tube.
(2) Identify bearing caps before removal. Remove REMOVAL
bearing caps one at a time. (1) Remove the transmission.
(3) Remove upper half of bearing by inserting (2) Remove the flywheel and clutch or the torque
Crankshaft Main Bearing Remover/Installer Tool converter and drive plate assemblies.
C-3059 into the oil hole of crankshaft (Fig. 16). (3) Remove the oil pan.
(4) Slowly rotate crankshaft clockwise, forcing out (4) Remove the rear seal retainer. Discard the oil
upper half of bearing shell. seal and the gasket (Fig. 17).
Fig. 16 Upper Main Bearing Removal and Fig. 17 Crankshaft Rear Seal Retainer
Installation with Tool C-3059 CLEANING
INSTALLATION Wash all parts i n a suitable solvent and inspect
Only one main bearing should be selectively fitted carefully for damage or wear.
while all other main bearing caps are properly tight
ened. A l l bearing capbolts removed during service INSTALLATION
procedures are to be cleaned and oiled before instal (1) Position the rear seal i n the retainer.
lation. (2) Using Special Tool 6687, position the retainer
When installing a new upper bearing shell, slightly and oil seal over the crankshaft. Install the bolts and
chamfer the sharp edges from the plain side. tighten to 22 N-m (16 ft. lbs.) torque.
(1) Start bearing i n place, and insert Crankshaft (3) The seal face surface must be within 0.508 mm
Main Bearing Remover/Installer Tool C-3059 into oil (0.020 in) full indicator movement relative to rear
hole of crankshaft (Fig. 16). face of crankshaft. I f out of limits, gently tap the
(2) Slowly rotate crankshaft counterclockwise slid high side into the retainer.
ing the bearing into position. Remove Tool C-3059. (4) Add a small amount of Mopar Silicone Rubber
(3) Lubricate the main journals with clean engine Adhesive Sealant at split-line.
oil. Install main bearing caps and bolts. Follow the 2 (5) Install the oil pan.
step tightening sequence.
9 - 118 8.0L ENGINE
(6) Add Teflon sealer to threads of flex plate or fly (2) With the cup plug rotated, grasp firmly with
wheel bolts to crankshaft. Install the flywheel and pliers or other suitable tool and remove plug (Fig.
clutch or the torque converter and drive plate assem 18).
blies. CYLINDER
(7) Install the transmission. ^ BLOCK
/
CYLINDER BLOCK
Remove the engine assembly from the vehicle.
r i
SECOND
REMOVE PLUG
DISASSEMBLE WITH PLIERS
FIRST
(3) Remove the piston/connecting rod assemblies. STRIKE HERE
WITH HAMMER
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
DRIFT 9209-41
INSPECTION
Examine block for cracks or fractures.
Fig. 18 Core Hole Plug Removal
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool CLEANING
C-119. The cylinder block should be bored and honed Thoroughly clean inside of cup plug hole i n cylinder
with new pistons and rings fitted if: block or head. Be sure to remove old sealer.
• The cylinder bores show more than 0.127 mm Make certain the new plug is cleaned of all oil or
(0.005 inch) out-of-round. grease.
INSTALLATION
0.254 mm (0.010 inch).
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
ordinated with the fitting of pistons and rings so CAUTION: DO NOT drive cup plug into the casting
specified clearances may be maintained. a s restricted coolant flow c a n result and c a u s e s e
Refer to Standard Service Procedures i n the begin rious engine problems.
bores. (2) Using proper drive plug, drive plug into hole.
ENGINE CORE OIL / CAMSHAFT PLUGS mm (0.020 inch) inside the lead-in chamfer.
Engine core plugs have been pressed into the oil I t is not necessary to wait for curing of the sealant.
galleries behind the camshaft thrust plate. This will The cooling system can be filled and the vehicle
reduce internal leakage and help maintain higher oil placed i n service immediately.
pressure at idle.
ASSEMBLE
HEiOWAL (1) Install the piston/connecting rod assembly.
(1) Using a blunt tool such as a drift or a screw (2) Install the oil pan.
driver and a hammer, strike the bottom edge of the (3) Install the cylinder head.
cup plug (Fig. 18). (4) Install the engine into the vehicle.
SPECIFICATIONS—S.OL ENGINE
Camshaft Crankshaft (Cant.)
Bore Diameter Main Bearing Diametrical Clearance

No.l 5 3 . 1 6 - 53.19 mm No.l - No.6 ...0.0)51 - 0 . 0 5 8 mm
(2.093 - 2.094 in) (0.0002 - 0.0023 in)
No.2 52.76 - 52.78 mm Max. Allowable ...0.071 mm
(2.077 - 2.078 in) (0.0028 in)
No.3 52.35 - 52.37 mm End Play 0.051 - 0 . 4 3 2 mm
(2.061 - 2.062 in) ( 0 . 0 ) 2 - 0 . 0 1 7 in)
No.4 5 1 . 9 4 - 5 1 . 9 7 mm Max. Allowable ....0.559 mm
(2.045 - 2.046 in) (0.022 in)
No.5 51.54 - 51.56 mm Main Bearing Journals
(2.029 - 2.030 in) Diameter 76.187 - 76.213 mm
No.6 ..48.74 - 48.77 mm (2.9995 - 3.0005 in)
( 1 . 9 1 9 - 1 . 9 2 0 in) Out-of-Round (Max.) 0.0254 mm
Diametrical Clearance (0.0)1 in)
Taper (Max.) ...0.0254 mm
No.l & No.3 - No.6 0.0254 - 0.0762 mm (0.001 in)
(0.001 - 0.003 in)
No.2 0.0381 - 0.0889 mm Cylinder Block
(0.0015 - 0.0035 in)
End Play 0.127-0.381 mm Cylinder Bore
( 0 . 0 0 5 - 0 . 0 1 5 in) Diameter ...101.60- 101.61 mm
Bearing Journal Diameter (4.0000 - 4 . 0 0 ) 5 in)
Out-of-Round (Max.) 0.127 mm
No.l 53.11 - 5 3 . 1 4 mm (0.0)5 in)
(2.091 - 2.092 in) Taper (Max.) 0.254 mm
No.2 52.69 - 52.72 mm (0.010 in)
(2.0745 - 2.0755 in) Tappet Bore Diameter 22.982 - 23.010 mm
No.3 52.30 - 52.32 mm (0.9048 - 0.9059 in)
(2.059 - 2.060 in)
No.4 51.89 - 51.92 mm Cylinder Head
(2.043 - 2.044 in)
No.5 51.49-51.51 mm Compression Pressure 1172 - 1310 kPa
(2.027 - 2 . 0 2 8 in) ( 1 7 0 - 1 9 0 psi)
No.6 .48.69 - 48.72 mm Gasket Thickness (Compressed) 0.991 - 1.118 mm
(1.917- 1.918 in) (0.039 - 0.044 in)
Valve Seat
Connecting Rods Angle 44.5°
Runout (Max.) 0.076 mm
Bearing Clearance 0.005 - 0.074 mm (0.003 in)
(0.0002 - 0.0029 in) Width (Finish)
Piston Pin Bore Diameter 24.940 - 24.978 mm Intake & Exhaust ....1.02 - 1.52 mm
(0.9819 - 0.9834 in) (0.040 - 0.060 in)
Side Clearance (Two Rods) 0.25 - 0.46 mm Guide Bore Diameter (Std.) 7.95 - 7.98 mm
(0.010-0.018 in) ( 0 . 3 1 3 - 0 . 3 1 4 in)
Total Weight (Less Bearing) 744 grams
(26.24 oz) Hydraulic Tappets
Crankshaft Body Diameter 22.949 - 22.962 mm

(0.9035 - 0.9040 in)
Connecting Rod Journal Clearance in Block (Diametrial) 0.2030 - 0.0610 mm
Diameter 53.950 - 53.975 mm (0.0008 - 0.0)24 in)
( 2 . 1 2 4 - 2 . 1 2 5 in) Plunger Travel Minimum (Dry) 4.24 mm
Out-of-Round (Max.) 0.0254 mm (0.167 in)
(0.001 in) Push Rod Length 195.52 - 196.02 mm
Taper (Max.) 0.0254 mm ( 7 . 6 9 8 - 7 . 7 1 7 in)
(0.001 in)
J9409-121
O i l Pump Piston Rings
Clearance over Rotors (Max.) 0.1906 mm Ring G a p

(0.0075 in) Compression Rings 0.254 - 0.508 mm
Cover Out-of-Flat (Max.) 0.051 mm (0.010 - 0.020 in)
(0.002 in) Oil Control (Steel Rails) 0.381 - 1.397 mm
Inner Rotor Thickness (Min.) 14.925 • 14.950 mm ( 0 . 0 1 5 - 0 . 0 5 5 in)
(0.5876 - 0.5886 in) Ring Side Clearance
Outer Rotor Compression Rings 0.074 - 0.097 mm
Clearance (Max.) 0.1626 mm (0.0029 - 0.0038 in)
(0.006 in) Oil Ring (Steel Rails) 0.185 - 0.246 mm
Diameter (Min.) 82.461 mm (0.0073 - 0.0097 in)
(3.246 in) Ring Width
Thickness (Min.) 14.925 mm Compression Rings 4.115 - 4.369 mm
(0.5876 in) (0.162 - 0.172 in)
Tip Clearance between Rotors (Max.) 0.584 mm Oil Ring (Steel Rails) 2.591 - 2.743 mm
(0.0230 in) (0.102 - 0.108 in)
O i l Pressure (Engine Hot) Valves
At Curb Idle Speed * 83 - 172 kPa Face Angle 45°

( 1 2 - 2 5 psi) Head Diameter
At 3000 rpm 345-414kPa Intake 48.640 - 48.900 mm
(50 - 60 psi) ( 1 . 9 1 5 - 1 . 9 2 5 in)
Exhaust 4 1 . 1 2 3 - 4 1 . 3 7 7 mm
•CAUTION: If pressure is ZERO at curb idle, DO NOT (1.619-1.629 in)
run engine at 3,000 rpm. Length (Overall)
Intake 145.19-145.82 mm
Pistons (5.716-5.741 in)
Exhaust 145.54 - 146.18 mm
Land Clearance (Diametrical) 0.013 - 0.038 mm (5.730 - 5.755 in)
(0.0005 - 0.0015 in) Lift (Zero Lash)
Piston Length 82.5 mm Intake 9.91 mm
(3.25 in) (0.390 in)
Piston Ring Groove Diameter Exhaust 10.34 mm
No. 1 & No.2 9 1 . 3 0 - 9 1 . 5 5 mm (0.407 in)
(3.594 - 3.604 in) Valve Stem Tip Height 4 7 . 5 0 - 4 8 . 1 3 mm
No.3 9 2 . 9 0 - 9 3 . 1 5 mm ( 1 . 8 7 0 - 1 . 8 9 5 in)
(3.657 - 3.667 in) Stem Diameter 7.900 - 7.920 mm
Weight 463 - 473 grams (0.311 -0.312 in)
(16.33- 16.68 oz) Stem-to-Guide Clearance
Intake & Exhaust 0.025 - 0.076 mm
Piston Pins (0.001 - 0.003 in)
Max. Allowable (Rocking Method) 0.4318 mm
Clearance (0.017 in)
In Piston 0.2489 - 0.5537 mm
(0.0098-0.0218 in) J9409-83
In Rod (Interference) 0.018 - 0.061 mm
(0.0007 - 0.0024 in)
Diameter 24.996 - 25.001 mm
(0.9841 - 0.9843 in)
End Play NONE
Length 67.818 - 68.326 mm
(2.670 - 2.690 in)
E N G I N E SPECIFICATIONS (CONT)
V a l v e Springs V a l v e Timing
Free Length (Approx.) ..............49.962 mm Exhaust Valve (degrees)

(1.967 in) Closes (ATC) 25
Spring Tension Opens (BBC) 60
Valve Closed 369 - 405 N @41.66 mm Duration 265
(81 - 89 lbs @1.640 in) Intake Valve (degrees)
Valve Open 865 - 956 N ©30.89 mm Closes (ABC) 6.1
(190-210lbs@1.216in) Opens (BTC) 6
Number of Coils 6.79 Duration 246
Wire Diameter ..4.496 mm Valve Overlap (degrees) ...31
(0.177 in)
J9409-84
9 - 122 5.9L (DIESEL) ENGINE •
| Description I Torque Description | Torque |

75 N T n (55 ft. lbs.) Intake Manifold Bolts (Upper) 22 N*m (16 ft. lbs.)
Camshaft Thrust Plate Torx Bolts . . . . 22 N*m (16ft. lbs.) Oil Filter 9 N*m (80 in. lbs.)
Coil Pack Bracket Bolts 21 N*m(190in. lbs.) +45°
Connecting Rod Cap Bolts . . . . . . . . 61N*m(45ft. lbs.) Oil Filter Connector 46 N»m (34 ft. lbs.)
Crankshaft Main Bearing Cap Bolts Oil Pan Bolts (1/4-20) 11 N*m (96 in. lbs.)
1st Step ............ 27N*m(20 ft. lbs.)
2nd Step 115 N^m (85 ft. lbs.) Oil Pan Stud Bolts . 16 N*m (144 in. lbs.)
Crankshaft Pulley/Damper Bolt 183N*m(135 ft. lbs.) Oil Pan Bolts (5/16-18) 16 N*m (144 in. lbs.)
Crankshaft Rear Seal Retainer Bolts . . . . 22N«m(16fr. lbs.) Oil Pan Drain Plug 34 N*m (25 ft. lbs.)
Cylinder Head Bolts Oil Pan Pick-Up Tube Bolts 16 N*m (144 in. lbs.)
1st Step 58N*m(43 ft. lbs.) Oil Pump Attaching Bolts 41 N*m (30 ft. lbs.)
2nd Step 143N«m(105 ft. lbs.)
Oil Pump Cover Bolts 14 N«m (125 in. lbs.)
Cylinder Head Cover Bolts/Studs . . . 16N«m(144in. lbs.)
Oil Pump Pressure Relief Plug 20 N*m (15 ft. lbs.)
Drive Plate-to-Crankshaft Bolts . . . . . . 75N*m(55ft. lbs.) Rear Oil Seal Retainer Bolts . 22 N*m (16 ft. lbs.)
Drive Plate-to-Torque Converter Bolts . . . .75 N*m (55 ft. lbs.) Rocker Arm Bolts . . . . . . . . 28 N*m (21 ft. lbs.)
EGR Tube Nut. 34N*m(25 ft. lbs.) Spark Plugs 41 N*m (30 ft. lbs.)
EGR Bolts 20N*m(174in. lbs.) Starter Mounting Bolts 68 N«m (50 ft. lbs.)
Engine Support Bracket/Cushion
Thru-Bolt 102N*m(75 ft. lbs.) Timing Chain Cover Bolts 47 N»m (35 ft. lbs.)
Engine Support Bracket/Cushion Thermostat Housing Bolts 25 N»m (220 in. lbs.)
41 N*m(30ft. lbs.) Throttle Body Nuts 11 N«m (96 in. lbs.)
Exhaust Manifold-to-Cylinder Torque Converter Drive Plate Bolts 31 N«m (270 in. lbs.)
22N*m(16ft. lbs.)
Transfer Case-to-lnsulator Mounting
Flywheel-to-Crankshaft Bolts . . . . . . . 75N#m(55 ft. lbs.) Plate Nuts . 2 0 4 N « m (150 ft. lbs.)
41 N*m(30ft. lbs.) Transmission Support Bracket Bolts 68 N«m (50 ft. lbs.)
Generator-to-intake Manifold Transmission Support Cushion Bolts 41 N»m (30 ft. lbs.)
Bracket Bolts 41 N«m(30ft. lbs.) Transmission Support Cushion
Stud Nuts .41 N » m (30 ft. lbs.)
20N«m(175 in. lbs.)
hydraulic Tappet Yoke Retaining Water Pump-to-Chain Case Cover Bolt . . 41 N*m (30 ft. lbs.)
22N*m(16ft. lbs.) Water Pump Pulley Bolts . . . . . . . . . . . . 22 N*m (16 ft. lbs.)
Intake Manifold Bolts (Lower) 54N*m(40ft. lbs.) J9409-130
• 5.9L (DIESEL) ENGINE 9 - 123
5.9L ( D I E S E L ) E N G I N E S E R V I C E PROCEDURES
INDEX
page page
Camshaft 141 Oil Filter Bypass Valve 163
Crankshaft 153 Oil Pan / Suction Tube 161
Cylinder Block 143 Oil Pressure Regulator Valve / Spring 164
Cylinder Head 128 Oil Pump 161
Engine Assembly 125 Piston / Connecting Rod Assembly . 148
Engine Front Mounts 123 Rocker Levers / Push Rods 127
Engine Rear Mount 124 Specifications—5.9L Diesel Engines . . . . . . . . . . 165
Gear Housing / Cover 136 Tappet 140
General Information 123 Timing Pin . . . 137
Oil Cooler Element / Gasket 164 Valve Clearance Adjustment 135
Oil Filter 162 Valves and Valve Springs 130
GENERAL INFORMATION
The 5.9 Liter (359 CID) six-cylinder diesel engine is
an In-line valve-in head type (Fig. 1).
Engine Type In-line 6 (Diesel-Turbo)

Bore and Stroke. 102.0 x 120.0 mm (4.02 x 4.72 in.)
Displacement... 5.9L (359 cu. in.)
Compression Ratio ...17.5:1
Torque (Automatic) 542 N®m (400 ft. lbs.) @ 1600 rpm
(Manual) 569 N-m (420 ft. lbs.) @ 1600 rpm
Firing Order 1-5-3-6-2-4
Lubrication Pressure Feed - Full Flow
Filtration w/Bypass Valve
Engine Oil Capacity 9.5L (10.0 Qts) w/Filter
Cooling System Liquid Cooled - Forced Circulation J9409-107
Cooling Capacity 23L (24 Qts)
Fig. 2 Firing Order
Crankshaft Induction Hardened Forged Steel ENGINE FRONT MOUNTS
Cylinder Head Cast Iron
Combustion Chambers High Swirl Bowl REMOVAL
Camshaft Chilled Ductile Iron (1) Disconnect the negative cable from the battery.
Pistons Cast Aluminum (2) Position fan to assure clearance for radiator top
Connecting Rods Forged Steel tank and hose.
J9409-12 (4) Raise vehicle on hoist.
Fig. 1 Diesel Engine Description
This engine is designed for No.2 Diesel Fuel. Only (6) Remove engine support bracket/cushion bolts
use N o . l Diesel Fuel where extended arctic condi (Fig. 3). Remove the support bracket/cushion.
tions exist (below -23°C or -10°F).
INSTALLATION
Engine lubrication system consists of a gerotor type
oil pump and a full flow oil filter with a bypass valve.
gine support bracket/cushion to the block. Install new
The cylinders are numbered from front to rear; 1 to bolts and tighten to 81 N-m (60 ft. lbs.) torque.
6. The firing order is 1-5-3-6-2-4 (Fig. 2). (2) Install the thru-bolt into the engine support
The engine data plate is located on the driver side bracket/cushion.
of the engine forward of the fuel injection pump. (3) Lower engine with support/lifting fixture while
J9409-53
ENGINE
SUPPORT
BRACKET/
CUSHION
Fig. 5 Engine Rear Support Cushion
BRACKET J9409-122

ENGINE REAR MOUNT

REMOVAL
(1) Raise the vehicle on a hoist.
(3) Remove support cushion stud nuts (Fig. 5).
(4) Raise rear of transmission and engine Fig. 6 Transmission Support Bracket
SLIGHTLY. INSTALLATION
(5) Remove the bolts holding, the support cushion (1) I f removed, position the transmission support
to the transmission support bracket. Remove the sup bracket to the transmission. Install new attaching
port cushion. bolts and tighten to 88 N-m (65 ft. lbs.) torque.
(6) I f necessary, remove the bolts Holding the (2) Position support cushion to transmission sup
transmission support bracket to the transmission port bracket. Install stud nuts and tighten to 41 N-m
(Fig. 6). (30 ft. lbs.) torque.
(Fig. 5).
• 5 J L (DIESEL) ENGINE 9 - 125
(4) Install the support cushion bolts and tighten to (17) Disconnect the heater hoses at the dash panel
41 N-m (30 ft. lbs.) torque. and at the water valve (Fig. 8).
(5) Remove the transmission jack.
ENGINE ASSEMBLY
REMOVAL
(1) Remove the battery.
System for the proper procedure).
(3) Remove the upper crossmember and top core
support.
(4) Remove the transmission oil cooler.
Fig. 8 Heater Hoses
(5) Discharge the air conditioning system, i f
equipped (refer to Group 24, Heating and Air Condi (18) Disconnect the air inlet tube from the turbo
tioning for service procedures). charger (Fig. 9) and the air intake housing. Remove
(6) Remove the serpentine belt (refer to Group 7, the tube.
Cooling System). (19) Remove the exhaust pipe from the turbo
(7) Remove the A/C compressor with the lines at charger outlet flange (Fig. 9).
tached. Set aside.
(11) Disconnect the top radiator hose.
(12) Remove the fan.
(14) Disconnect the lower radiator hose.
System).
(16) Remove the generator (Fig. 7) with the wire
connections (refer to Group 8B, Battery/Starter/Gen
erator Service).
Fig. 9 Air Inlet Tube and Exhaust Pipe Connection

(20) Disconnect the intercooler inlet duct from the
turbocharger and the intercooler. Remove the inlet
duct.
(21) Disconnect the intercooler outlet duct from the
air inlet housing and the intercooler. Remove the out
let duct.
(22) Disconnect the accelerator linkage, the speed
control linkage and the throttle valve linkage.
equipped.
Fig. 7 Generator Removal
9 126 5.9L (DIESEL) ENGINE •
(25) Disconnect ail electrical connections from the (4) Position the engine i n the chassis with the
engine. Put tags on the connections to identify their thru-bolt installed.
locations. (5) Remove the covers or tape covering the engine
(26) Disconnect the fuel lines to the lift pump and openings.
fuel return. Use tags to identify the lines. (6) Remove the jack stand from under the auto
(27) On Manual Transmission vehicles, remove the matic transmission.
shift lever (refer to Group 21, Transmissions). (7) Raise and support the vehicle.
(28) Raise and support the vehicle on a hoist. (8) AUTOMATIC TRANSMISSION;
(29) Drain the engine lubricating oil. Dispose of (a) Install and tighten the transmission bolts.
the oil according to all applicable regulations. (b) Install and tighten the torque converter bolts.
(30) Remove the oil pan. (c) Remove the support from the transmission.
(31) Remove engine front mount thru-bolt nuts. (9) M A N U A L TRANSMISSIONS
(32) Remove the transmission cooler line brackets (a) Install flywheel and ring gear.
from oil pan. (b) Install clutch assembly.
(33) Disconnect exhaust pipe at manifold. (c) Install the bell housing.
(34) Disconnect the starter wires. Remove starter (d) Install the transmission and bolts.
motor (refer to Group 8B, Battery/Starter/Generator (e) Connect all wiring and connectors.
Service). (f) Install the clutch assembly and slave cylinder.
(35) Remove the dust shield and transmission (g) Install the crossmember.
cover. (h) Install rear transmission support.
(36) AUTOMATIC TRANSMISSION: (i) Remove the support from the transmission,
(a) Support transmission. This will assure that (j) Install the prop shaft (refer to Group 16, Pro
the torque converter will remain i n proper position peller Shaft).
in the transmission housing. (10) Install the dust shield and transmission cover.
(b) Remove torque converter bolts. (11) Install the starter motor (refer to Group 8B,
(c) Remove transmission bolts. Battery/Starter/Generator Service). Connect the
(37) M A N U A L TRANSMISSION! starter wires.
(a) Remove the prop shaft (refer to Group 16, (12) Install the transmission cooler line brackets to
Propeller Shaft). oil pan.
(b) Support transmission. (13) Install and tighten engine front mount thru-
(c) Remove rear transmission support. bolt nuts.
(d) Remove the crossmember. (14) Install the oil pan. Install the drain plug.
(e) Remove the clutch assembly and slave cylin (15) Lower the vehicle.
der. (16) On Manual Transmission vehicles, install the
(f) Disconnect all wiring and connectors. shift lever (refer to Group 21, Transmissions).
(g) Remove transmission bolts. Remove the (17) Connect the fuel lines to the lift pump and
transmission. fuel return. Use tags to identify the lines.
(h) Remove the bell housing. (18) Connect all electrical connections to the en
(i) Remove clutch assembly. gine. Use tags to identify their locations.
(j) Remove flywheel and ring gear. (19) Connect the transmission cooler lines.
(38) Lower the vehicle. (20) Connect the power steering hoses, i f equipped.
(39) Install a jack stand under the automatic (21) Connect the accelerator linkage, the speed
transmission. control linkage and the throttle valve linkage.
(40) Put a cover or tape over all engine openings.
(22) Install the outlet duct. Connect the intercooler
(41) Lift the engine out of the vehicle.
outlet duct to the air inlet housing and the inter
(42) Install the engine on a suitable stand.
cooler.
(43) Remove all accessories and brackets not previ
(23) Install the inlet duct. Connect the intercooler
ously removed for use with the replacement engine.
inlet duct to the turbocharger and the intercooler.
INSTALLATION (24) Install the exhaust pipe to the turbocharger
(1) Check the data plate to verify that the replace outlet flange.
ment engine is the same model and rating as the en (25) Install the air inlet tube. Connect the air inlet
gine that was removed. tube to the turbocharger and the air intake housing.
(2) Install all accessories and brackets that had (26) Connect the heater hoses at the dash panel
been removed from the previous engine. and at the water valve.
(3) Use the lifting brackets to lift the engine off of (27) Install the generator and wire connections (re
the stand. fer to Group 8B, Battery/Starter/Generator Service).
(28) Install the radiator (refer to Group 7, Cooling

LOCKNUT ADJUSTING
System).
(30) Install the fan shroud.
(31) Install the fan.
(33) Install the radiator overflow bottle.
(34) Install the washer bottle.
(35) I f equipped, install the condenser.
(36) Install the A/C compressor with the lines at
tached.
Conditioning for service procedures).
J9109-31
(38) Install the transmission oil cooler.
(39) Install the upper crossmember and top core
Fig. 1 Location of Rocker Lever Components
support.
(40) Install the serpentine belt (refer to Group 7, powdered metal and may continue to show wetness
Cooling System). after they have been cleaned and dried.
(41) Fill the cooling system with a mixture of 50% (6) Inspect for excessive wear i n the bore and the
water and 50% ethylene-glycol base antifreeze (refer contact surface for the valve stem.
Group 7, Cooling System for the proper procedure). (7) Measure the rocker lever bore diameter. The
(42) Fill the engine with the required amount of maximum diameter is 19.05 mm (0.75 inch). Replace
clean engine lubricating oil (refer to Group 0, Lubri i f out of limits.
cation and Maintenance). (8) Inspect the pedestal and shaft.
(43) Install the battery and connect the battery ca (9) Measure the shaft diameter. The minimum di
bles. ameter is 18.94 mm (0.746 inch). Replace i f out of
(44) Check the oil level after the engine has run limits.
for 2 or 3 minutes. Oil held i n the oil filter and oil
passages will cause the oil level i n the pan to be ASSEMBLE—ROCKER LEVERS
lower. (1) Install the adjusting screw and locknut.
(45) Operate the engine at idle for 5 to 10 minutes (2) Lubricate the shaft with clean engine oil. Be
and check for leaks and loose parts. sure to assemble the intake and exhaust rocker le
vers i n the correct location.
ROCKER LEVERS / PUSH RODS (3) Position the levers on the rocker shaft. Install
the thrust washers.
REMOVAL (4) Clean the push rods i n the hot soapy water.
(1) Remove the valve covers. (5) Inspect the push rod ball and socket for signs
(2) Loosen the adjusting screw locknuts. Loosen of scoring or cracks where the ball and the socket are
the adjusting screws until they stop (Fig. 1). pressed into the tube.
(3) Remove the bolts from the rocker lever pedes (6) Check the push rods for roundness and
tals. Remove the pedestals and rocker lever assem straightness.
blies (Fig. 1). (7) Install the push rods into the sockets of the
(4) Remove the push rods. The rear two push rods valve tappets. Lubricate the push rod sockets with
must be raised through holes i n cab overhang. clean engine oil.
(8) Make sure the rocker lever adjusting screws
DISASSEMBLE—ROCKER LEVERS are completely backed out.
(1) Remove the retaining rings and thrust washers
(Fig. 1). INSTALLATION
(2) Remove the rocker levers (Fig. 1). DO NOT dis (1) Make sure the dowel rings i n the pedestals are
assemble the rocker lever shaft and pedestal. The installed into the dowel bores i n the cylinder head.
pedestal and shaft must be replaced as an assembly. (2) I f the push rod is holding pedestal off head, bar
(3) Remove the locknut and adjusting screw (Fig. the engine until the pedestal will set on the head
1). surface without interference.
(4) Clean all parts i n a strong solution of laundry (3) Use clean engine oil to lubricate the cylinder
detergent i n hot water. head bolt threads and under the bolt heads.
(5) Use compressed air to dry the parts after rins (4) Install the long bolts (12 mm) into the rocker
ing i n clean hot water. The pedestals are made from lever pedestals. Tighten the bolts as follows:
• Step 1—Tighten the bolts, i n sequence (Fig. 2), to
90 N-m (66 ft. lbs.) torque. Check the torque. I f lower
than 90 N-m (66 ft. lbs.), tighten to this torque.
• Step 2—Tighten the bolts, i n sequence (Fig. 2), to
120 N-m (89 ft. lbs.) torque. Check the torque. I f
lower than 120 N-m (89 ft. lbs.), tighten to this
torque.
• Step 3—Tighten the bolts, i n sequence (Fig. 2), an
additional 90°.
<C=M FRONT
Fig. 3 Exhaust Manifold

FUEL TEMPERATURE SENSOR
J9109-32
Fig. 2 Rocker Lever (Head Bolts) Tightening

Sequence
(5) Tighten the 8 mm bolts to 24 N-m (18 ft. lbs.)
torque.
(6) Install the valve cover. Tighten the valve cover
CYLINDER HEAD
These cylinder heads can only be used on engines
with an intercooler. DO NOT interchange with ear
lier models.
REMOVAL
(1) Drain the coolant. DO NOT waste reusable
coolant. I f the solution is clean, drain the coolant into
a clean container for reuse.
(2) Drain the engine oil. Dispose of the used oil
properly.
(3) Disconnect the radiator and heater hoses (refer
Fig. 4 Fuel/Water Separator Filter
to Group 7, Cooling System).
(4) Remove the turbocharger. INSPECTION
(5) Remove the exhaust manifold (Fig. 3). Remove the cup plugs and inspect the coolant pas
(6) Remove the fuel lines and injector nozzles (re sages. A large build up of rust and lime will require
fer to Group 14, Fuel System). removal of the cylinder block for cleaning i n a hot
(7) Remove the valve covers. tank.
(8) Remove the rocker levers and push rods. Inspect the cylinder bores for damage or excessive
(9) Remove the fuel filter/water separator (Fig. 4). wear. Rotate the crankshaft so the piston is at Bot
Refer to Group 14, Fuel System, for the proper pro tom Dead Center (BDC) to inspect the bores.
cedures. Remove the remote fuel filter/water separa Measure the cylinder bores (Fig. 6). DO NOT pro
tor head. ceed with in-chassis repair i f the bores are damaged
(10) I f the engine is hot, remove the cylinder head or worn beyond the limits (refer to Cylinder Bore Re
bolts i n the sequence shown i n Fig. 5. The removal pair - Cylinder Block).
sequence is not important i f the engine is cold. There Check the top surface for damage caused by the
are 3 sizes of head bolts. Note the position of each
cylinder head gasket leaking between cylinders.
bolt for future installation.
Inspect the block and head surface for nicks, ero
(11) Remove the cylinder head and gasket from the
sion, etc.
cylinder block.
5JL (DIESEL) ENGINE 9 - 129
Fig. 7 Cylinder Head Combustion Deck Face

J9109-36 Measurement
corner of the rear face (Fig. 8). Check valve protru
Fig. 5 Cylinder Head Bolt Removal Sequence-
sion after head surface refacing.
Cylinder Head Hot
Surface finish requirements are 1.5-3.2 microme
ters (60-126 microinch).
REFERENCE
MIN. 102.0 mm (4.0157 inch)

MAX. 102.116 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch) STOCK TOTAL (MAX.)
Taper 0.76 mm (0.003 inch) 1.00 mm (0.03937 inch)
REFERENCE HEIGHT (MIN.)
Oversize pistons and rings are 94.00 ±0.25 mm
available for bored cylinder blocks. (3.7008 ±0.0010 inch)
SURFACE FINISH
J9109-75 1.5 to 3.2 micrometers
(60 to 128 microinches)
Fig. 6 Cylinder Bore Diameter J9109-134
Check the head distortion (Fig. 7). The distortion of
the combustion deck face is not to exceed 0.010 mm Fig. 8 Cylinder Head Stock Removal
(0.0004 inch) in any 50.8 mm (2.00 inch) diameter. CLEANING
Overall variation end to end or side to side 0.30 mm Clean the carbon from the injector nozzle seat with
(0.012 inch). a nylon or brass brush.
D O NOT proceed with the in-chassis overhaul if Scrape the gasket residue from all gasket surfaces.
the cylinder head or block surface is damaged or not Wash the cylinder head in hot soapy water solution
flat (within specifications). (88°C or 140°F).
After rinsing, use compressed air to dry the cylin
REFACING HEAD SURFACE der head.
The cylinder head combustion deck may be refaced Polish the gasket surface with 400 grid paper. Use
in whatever increments necessary to clean up the an orbital sander or sanding block to maintain a flat
surface and maintain the surface finish and flatness surface.
tolerances. The combined total of stock removed must
not exceed 1.00 mm (0.03937 inch). The amount of INSTALLATION
stock removed each time must be steel stamped (1) The cylinder block and head must be clean and
above combustion deck edge, on the lower right hand dry.
(2) Position the gasket onto the dowels (Fig. 9). (7) Be sure to lubricate the push rod sockets with
Make sure the gasket is correctly aligned with the clean engine oil.
holes i n the cylinder block. (8) Install the rocker lever pedestal bolts and
(3) Carefully put the cylinder head onto the gasket tighten to 24 N-m (18 ft. lbs.) torque.
and cylinder block. Make sure the cylinder head is (9) Adjust the valve clearance.
installed onto the dowels i n the cylinder block (Fig. (10) Install the valve covers. Tighten the bolts to
9). 24 N-m (18 ft. lbs.) torque.
(11) Install the injector nozzles and fuel lines (refer
CYLINDER HEAD to Group 14, Fuel System).
(12) Install the remote fuel filter/water separator
head. Install the fuel filter/water separator (refer to
Group 14, Fuel System for the proper procedures).
(13) Install the exhaust manifold (refer to Group
(14) Install the turbocharger.
(15) Connect the radiator and heater hoses.
(16) Fill the engine with new coolant or the clean
drained coolant (refer to Group 7, Cooling System for
the proper procedure).
(17) Fill the engine with clean lubricating oil (refer
to Group 0, Lubrication and Maintenance).
VALVES AND VALVE SPRINGS

Fig. 9 Cylinder Head/Gasket Alignment REMOVAL
(4) Install the push rods and rocker levers. (1) Remove the cylinder head.
(5) Use clean engine oil to lubricate the cylinder (2) Mark the valves to identify their position.
head bolt threads and under the bolt heads. (3) Compress the valve spring and remove the
(6) The cylinder head bolts are 3 different sizes. valve stem collets (Fig. 1).
Install the bolts i n the proper hole. Tighten the bolts (4) Release valve spring and remove the retainer
as follows: and spring (Fig. 1).
• Step 1—Tighten all bolts, i n sequence (Fig. 10), to (5) Remove the remaining collets, retainers,
springs and valves. Keep the valves i n a labeled rack.
90 N*m (66 ft. lbs.) torque. Check the torque. I f lower
(6) Remove the valve stem seals (Fig. 1).
than 90 N-m (66 ft. lbs.), tighten to this torque.
• Step 2—Tighten all long 12 mm bolts (Nos. 4, 5,
12, 13, 20 and 21), i n sequence (Fig. 10), to 120 N-m
(89 ft. lbs.) torque. Check the torque. I f lower than
120 N-m (89 ft. lbs.), tighten to this torque.
• Step 3—Tighten all bolts, i n sequence (Fig. 10), an
additional 90°.
Fig. 1 Valve Removal

VALVES
J9109-36 CLEANING AND INSPECTION

Before cleaning, note the valve number. Clean the
Fig. 10 Cylinder Head Tightening Sequence
valve heads with a soft wire wheel. Mark the valve
with the number noted above.
• 5JL (DIESEL) ENGINE 9 - 131
Polish the valve stems with crocus cloth. VALVE RIM

Inspect for abnormal wear on the valve heads and THICKNESS
stems. Replace badly worn valves.
Check for bent valves. Replace bent valves.
Measure the valve stem diameter (Fig. 2). The
valve stem diameter should be 7.935-7.960 mm
(0.3126-0.3134 inch). I f out of limits, replace the
valve. Mark the new valves with the replacement lo
cation.
J9109-146
Fig. 4 Valve Rim Thickness

J !
J
MEASURE AT THESE POINTS
J9109-144
Fig. 2 Measure Valve Stem Diameter

Inspect the end of the valve stem for flatness.
I f required, resurface the valve end.
WALWE GRINDING
The valve seat angle should be 30° (Intake Valve)
and 45° (Exhaust Valve) - (Fig. 3). .
INTAKE EXHAUST N E W DIAMETER LIMITS

8.019-8.029 mm (0.3157-0.3165 inch)
W O R N LIMIT
8.090 mm (0.3185 inch)
J9109-135
Fig. 5 Valve Guide Bore

0 (
0 0 O r / 0 I f the valve guide bores are larger than the worn
limit, the cylinder head must be machined for service
valve guides. New valve guides must be reamed to
00° 0c size after they are installed.
I f the cylinder head needs service valve guides and
O
J9109-41 valve seat inserts, the valve guides should be in
stalled first.
Fig. 3 Valve Seat Angle
INSTALLATION
Measure the r i m thickness (Fig. 4). The minimum
T H I N WALL-SERVICE GUIDES
valve r i m thickness is 0.79 mm (0.031 inch).
Machine the cylinder head valve guide bores to
Grind the face of valves to be reused.
Check the valve stem tip for flatness. I f required, 11.125 ±0.013 mm (0.4380 ±0.0005 inch) i n diameter
re-surface the tip. (Fig. 6).
Service valve guides must be centered with valve
WALWE GUIDES seats within 0.35 mm (0.01378 inch) diameter. They
must also be square with the combustion face within
INSPECTION 0.10 mm (0.004 inch) at 50.0 mm (1.9685 inch) ra
Inspect the valve guides for scuffing or scoring. dius.
Measure the valve guide bore (Fig. 5). The bore di Lubricate the valve guides with oil and press the
ameter should be 8.019-8.089 mm (0.3157-0.3185 guides flush to the bottom of the bosses.
inch).
Trim off the top of the valve guides flush to top of VALVE GUIDE BORES
guide bosses, i f necessary. CYLINDER
Machine the valve guide bores to 8.029 ±0.010 mm HEAD
(0.3161 ±0.0004 inch) - (Fig. 6).
The valve guide bore must be centered with the
valve seat within 0.35 mm (0.0138 inch) diameter. I t
also must be square with the combustion face within
0.010 mm (0.0004 inch) at 50.0 mm (2.0 inch) radius.
THICK WALL-SERVICE GUIDES
VALVE GUIDE BORES CYLINDER EXHAUST INTAKE
HEAD
CYLINDER HEAD VALVE GUIDE BORES

14.000 ± 0 . 0 1 3 mm (0.5512 ± 0.0005 in)
EXHAUST VALVE GUIDE BORES

8.029 ± 0 . 0 1 0 mm (0.3161 ± 0 . 0 0 0 4 in)
J9109-137
INTAKE
r^7 Fig. 7 Service Valve Guides—Thick Wall
WALWE SEATS
11.125 ± 0 . 0 1 3 mm (0.438 ± 0.0005 in)
INSPECTION
VALVE GUIDE BORES

Cylinder head with integral valve seats can be
8.029 ± 0 . 0 1 0 mm (0.3161 ± 0 . 0 0 0 4 in)
ground only once. Previously ground integral seats
must be replaced with service seats.
One X stamped into the head casting identify seats
J9109-136
that have been ground previously (Fig. 8).
Fig. 6 Service Valve Guides—Thin Wall Two X's stamped on the head indicate service seats
have been installed (Fig. 8). Service seats can be
Machine the cylinder head valve guide bores to
ground.
14.000 ±0.013 mm (0.5512 ±0.0005 inch) diameter
(Fig. 7). SERVICE SEATS
Valve guides must be centered with valve seats INSTALLED
within 0.35 mm (0.01378 inch) diameter. Valve
guides must also be square with the combustion face
within 0.10 mm (0.004 inch) at 50.0 mm (2.0 inch)
radius.
Lubricate the valve guides with oil and press i n the
guides to 12.25 ±0.50 mm (0.4823 ±0.020 inch) pro
trusion above the cylinder head.
Ream the bores to 8.029 ±0.010 mm (0.3161
±0.0004 inch) - (Fig. 7).
WALWE SPRINGS
Measure the valve spring length. The approximate
J9109-138
free length is 55.63 mm (2.190 inch) with the maxi
mum inclination of 1.0 mm (0.039 inch).
Measure the valve spring force. 289.32 N (65 lbs.) Fig. 8 Reworked Cylinder Head Seats- -Stamped
Identification .
is the minimum acceptable load required to compress
the spring to a height of 49.25 mm (1.94 inch). On the integral seat head, i f 0.254 mm (0.010 inch)
I f the valve spring does not meet the limits above, or more has been removed from the head combustion
replace the spring. surface, service seats must be installed.
To determine if the head has been previously resur Identify ground valve seats by stamping the cylin
faced, before calculating valve depth, process as fol der head.
lows: Install the valves i n their designated locations and
(1) Check the rear lower right corner of the head measure the depth of each. The valve depth limit (In
for a stamping that would indicate previous resurfac tegral and Inserted Seats) is 0.99 mm to 1.52 mm
ing (e.g. .003). (0.039 inch to 0.060 inch). Replace the valve i f the
(2) To verify the information, or i f no amount is in depth is over this limit.
dicated, measure the head height (Fig. 9). Apply a light coat of valve lapping compound to
(3) I f the head height is 94.75 mm (3.730 inch) or each valve and lap each valve to its mating seat.
greater, the valve seats may be ground, i f they have Remove the valves and clean lapping compound
not been ground previously. from the valves and seats.
Measure the valve seat width indicated by the lap
ping surface. The valve seat width limit is 1.50-2.00
mm (0.060-0.080 inch).
I f required, grind the areas with a 60° stone and a
15° stone to center the seat on the valve face. Main
tain the valve seat width limits (Fig. 11).
Fig. 9 Cylinder Head Height

INTEGRAL VALVE SEAT GRINDING
After resurfacing the valves and determining that
all valves meet specifications, install the valves i n
their designated locations and measure valve depth
(Fig. 10). The valve depth is the distance from the
valve face to the head deck. Record the depth of each J9109-141
valve.
Fig. 11 Grind Valve Seat
SERVICE VALVE SEAT INSTALLATION
Inspect the valve guide bores as described i n the
valve guide section of this manual. I f i t is necessary
to install valve guides, install the guides before i n
stalling the service seats.
Replacement valve seat inserts must be installed i f
the valve seats have been ground previously. The i l
lustrated marks indicate valve seats have been
ground previously.
Machine the cylinder head to install the service
Fig. 10 Valve Depth valve seats (Figs. 12 and 13).
Press service seats into the machined pockets.
Grind the valve seats to remove scores, scratches Stake the valve seats into the pockets.
and burns. The seat angle should be—Intake 30° and
Exhaust 45°. SERVICE VALVE SEAT GRINDING
Install the valves i n their respective bores and
Install the valves i n their designated location and
measure the depth again (Fig. 10). Record the depth
measure the valve depth. The valve depth is the dis
of each valve.
tance from the valve face to the head deck.
The grinding depth is the difference between the
measurement before grinding and the measurement Record the depth of each valve (Fig. 14). The depth
after grinding. The grinding depth maximum limit is 0.99-1.52 mm (0.039-0.060 inch).
(integral seats only) is 0.254 mm (0.010 inch). Service Grind the valve seats to remove scores, scratches
valve seats are available for over limit integral valve and burns. The valve seat angle is 30° (Intake) and
seats. 45° (Exhaust).
COMBUSTION
VALVE SEAT DEPTH VALVE SEAT DEPTH
10.40 ±0.10 mm (0.4094 ± 0.004 inch) 10.20 ±0.10 mm (0.4015 ± 0.004 inch)
VALVE SEAT WIDTH VALVE SEAT WIDTH
47.0 ±0.013 mm (1.8504 ±0.0005 in) 43.65 ±0.013 mm (1.7185 ±0.0005 in)
M A X I M U M RADIUS M A X I M U M RADIUS
0.40 mm (0.0157 inch) M A X . 0.40 mm (0.0157 inch) M A X .
SURFACE FINISH SURFACE FINISH
3.2 micrometers (128.0 mkrotnch) 3.2 micrometers (128.0 microinch)
J9409-115 J9409-116
Fig. 12 Machining for Service Valve Seats—Intake Fig. 13 Machining for Service Valve Seats—Exhaust
Valve Valve
Install the valves i n their respective bores and

measure the depth again (Fig. 14). The valve depth
limit is 0.99-1.52 mm (0.039-0.060 inch). Replace the
valve i f the depth is over the limit.
Apply a light coat of valve lapping compound to
each valve and lap each valve to its companion seat.
Remove the valves and clean the lapping compound
from the valve and seats.
Measure the valve seat width indicated by the
lapped surface (Fig. 15). The width limits are 1.5-2.0
MIN. - 0 . 9 9 0 mm ( 0 . 0 3 9 inch)
mm (0.060-0.080 inch). I f required, grind lower area MAX. - 1.520 mm ( 0 . 0 6 0 inch)
with 60° stone and upper area with 15° stone (Fig.
15). Be sure to center the seat on the valve face.
Maintain the valve seat within limits. J9109-44
SERVICE VALVE SEAT REPLACEMENT Fig. 14 Valve Depth with Seat Insert
To replace service seat inserts, machine the insert (3) Lubricate the stems with SAE 90W oil before
in the same manner as i f machining out the internal installing the valves. Install the valves i n the same
seat. Hold the same tolerances and follow the same positions as removed.
installation procedures. (4) Compress the valve spring after installing the
INSTALLATION
spring and retainer (Fig. 17).
(1) Clean all cylinder head components before as (5) Install new valve collets and release the spring
tension (Fig. 17).
sembling.
(2) Install the valve stem seals (Fig. 16). The in
take and exhaust valve seals are the same.
MAXIMUM VALVE CLEARANCE ADJUSTMENT

MINIMUM 2.0 mm Use the timing pin to locate Top Dead Center
1.5 mm (0.080 inch) (TDC) for cylinder N o . l (Fig. 18). The timing pin is
( 0 . 0 6 0 inch)
located at the back of the gear housing and below the
injection pump. Be sure to disengage the timing pin
after locating top dead center.
J9109-45
Fig. 15 Waive Seat Width

VALVE STEM
SEAL
J9109-33
Fig. 18 Locating TDC using Timing Pin

Adjust the valves when the engine is cold, below
60°C (140°P).
J9109-148 STEP 1
Adjust the clearance for the valves shown i n Fig.
Fig. 16 Waive Stem Seal installation 19. The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment
COLLETS VALVE
SPRING is 0.508 mm (0.020 inch) for the exhaust valve.
ESSOR Tighten the valve adjusting nuts to 24 N-m (18 ft.
lbs.) torque.
Be sure timing pin is disengaged before rotating
the crankshaft. Mark the pulley and rotate the
crankshaft 360°.
J9109-147
Fig. 17 Waive, Waive Spring and Collet Installation

WARNING: W E A R PROTECTIVE EQUIPMENT AND
DO NOT STAND IN LINE WITH T H E VALVE S T E M © © © © © ©
WHEN TAPPING THE VALVES.
J9109-34 FRONT
(6) Tap the ends of the valve stems with a mallet
to verify the collets are seated. Fig. 19 Adjust Waive Clearance—Step 1
(7) Install the cylinder head. STEP 2
(8) Check the valve clearance adjustment. Adjust the clearance for the valves shown i n Fig.
20. The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment INSTALLATION
is 0.508 mm (0.020 inch) for the exhaust valve. (1) Install a new gasket and the gear housing.
Tighten the bolts to 24 N-m (18 ft. lbs.) torque. Tighten the bolts to 24 N-m (18 ft. lbs.) torque.
(2) Install the camshaft. Make sure the alignment
I = INTAKE E = EXHAUST
marks on the camshaft and crankshaft gears are
aligned (Fig. 2).
E l I E I E
© © © © © ©
J9109-35 FRONT O
Fig. 20 Adjust Valve Clearance—Step 2
GEAR HOUSING / C0¥ER

GEAR HOUSING
Fig. 2 Camshaft/Crankshaft Gear Alignment
REMOVAL (3) I f a new housing is installed, the timing pin as
(1) Remove the engine assembly from the vehicle. sembly must be accurately located.
(2) Remove the front end components and the gear (4) Install the following:
housing cover (refer to Gear Housing Cover Removal • Fan hub assembly (refer to Group 7, Cooling Sys
for the proper procedures). tem)
(3) Remove the following: • Fuel injection pump (refer to Group 14, Fuel Sys
• Camshaft tem)
• Gear driven accessories • Gear driven accessories
• Fuel injection pump (refer to Group 14, Fuel Sys (5) Install the gear housing cover (refer to Gear
tem) Housing Cover Installation for the proper proce
• Fan hub assembly (refer to Group 7, Cooling Sys dures).
tem) (6) Install the front end components.
(4) Remove the gear housing and gasket (Fig. 1). (7) Install the engine assembly into the vehicle.
(5) Clean the gasket material from the cylinder
block. G E A R HOUSING COVER
REMOVAL
(1) Remove fan drive assembly.
(2) Remove the fan belt (Fig. 3).
(3) Remove belt tensioner (Fig. 3).
(4) Remove oil fill tube and adaptor (Fig. 4).
(6) Remove the bolts that hold the gear cover to
the gear housing.
(7) Gently pry the cover away from the housing,
taking care not to mar the gasket surfaces (Fig. 5).
(8) Clean the old gasket residue from the back of
the gear cover and front of the gear housing.
INSTALLATION
(1) Lubricate the front gear train with clean en
Fig. 1 Gear Housing/Gasket
gine oil.
Fig. 6 Alignment/installation Tool

(6) Tighten the gear housing cover bolts to 24 N-m
(7) Remove the alignment/installation tool. Always
use a seal pilot when you install a seal.
(8) Apply a bead of Loctite 277 to the outside di
ameter of the seal. Install the pilot from the seal k i t
onto the crankshaft. Install the seal onto the pilot
and start into the gear housing cover. Remove the pi
lot.
(9) Use the alignment/installation tool and a plas
tic hammer to install the seal to the correct depth. To
prevent damage to the seal carrier, hit the align
ment/installation tool alternately at the 12, 3, 6 and
9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N-m (32 ft. lbs.) torque.
Fig. 4 Oil Fill Tube (11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve at this time.
(12) Install the belt tensioner. Tighten the mount
ing bolts to 43 N-m (32 ft. lbs.) torque.
(13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125 N-m
(92 ft. lbs.) torque. Use an engine barring tool to
keep the engine from rotating during tightening op
eration.
TIMING PIN
TIMING PIN REPLACEMENT
The timing pin can be replaced without removing
the assembly from the gear housing.
(1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the retain
Fig. 5 Gear Housing and Cower ing ring i f i t is damaged during removal.
(2) I f timing pin assembly is removed from gear
(2) Thoroughly clean the front seal area of the housing, i t must be precisely reset to obtain exact
crankshaft. The seal lip and the sealing surface on TDC.
the crankshaft must be free from all oil residue to (3) Install a new O-Ring, lubricate the pin and po
prevent seal leaks. sition i n the housing (Fig. 7). Install the new retain
(3) Install the gear housing cover and a new gas ing ring to 1.5 mm (0.059 inch).
ket.
(4) Install the bolts but DO NOT tighten them at TIMING PIN HOUSING. ASSEMBLY I GASKET
this time.
(5) Use the alignment/installation tool from the REMOVAL
seal k i t to align the cover to the crankshaft (Fig. 6). (1) Locate TDC for cylinder N o . l .
Fig. 7 Engine Timing Pin Location

Fig. 8 Fabricated Wire Pointer
(2) Remove the timing pin housing assembly and
gasket.
(3) Clean any gasket material from the gear hous
ing and from the timing pin housing assembly.
INSTALLATION (CYLINDER HEAD ON)

The location of the timing pin assembly on the gear
housing is critical for correct engine adjustment. Fol
low this procedure to install the assembly so that i t
corresponds to TDC for cylinder N o . l .
(1) Look through the hole i n the gear housing and
rotate the engine until the hole i n the cam gear can
be seen.
(2) Remove the injector nozzles from all of the cyl
inders. This step is important to vent the cylinders so
the crankshaft can be rotated smoothly to locate TI)C
for cylinder N o . l .
Fig. 9 Locate and Mark Vibration Damper—First
(3) Temporarily install the vibration damper.
Mark
(4) Fabricate and install a wire pointer (Fig. 8).
This can be done by forming a piece of wire that can touches the intake valve with approximately
be tighten under one of the gear housing capscrews. the same amount of force as i n the previous
The wire should extend from the gear cover to a step (Fig* 10).
place on the crankshaft vibration damper that is eas (10) Mark the vibration damper at the wire pointer
ily seen. (Fig. 10).
(5) Rotate the crankshaft one-quarter rotation i n (11) Measure the distance and mark the vibration
the direction of engine rotation. damper at one-half that distance between the two
(6) Tighten the adjusting screw for the N o . l intake marks. This mark is the TDC mark (Fig. 11).
valve to zero lash plus 5 turns. (12) Completely loosen the intake valve adjusting
screw. I f not done, damage to the intake valve or
CAUTION: U s e extreme care when rotating the
push rod could occur when the crankshaft is rotated.
crankshaft. U s e of too much force could damage
(13) Rotate the crankshaft i n the direction of nor
the valve or push rod (Fig. 9).
mal engine rotation until the pointer is aligned with
(7) Rotate the crankshaft slowly i n the opposite di the TDC mark. Rotate crankshaft one additional
rection of normal engine rotation until the piston turn.
touches the intake valve (Fig. 9). (14) The timing pin hole i n the cam gear should be
(8) Mark the vibration damper at the wire pointer visible or felt through the back side of the gear hous
(Fig. 9). ing. I f not, the crankshaft must be rotated one revo
(9) Rotate the crankshaft i n the direction of nor lution i n the direction of engine rotation.
mal engine rotation until the piston touches the in
take valve (Fig. 10). Make sure that the piston
between the pointer and gear housing to prevent

EXHAUST'^T^ damage to the gear housing.
=pVALVE / 2 N D MARK
(2) Fabricate a steel plate (Fig. 13).
FABRICATED
5 ) ) ) / ROTATE WIRE
VIBRATION POINTER
HAMPER
'J9409-119
VIBRATION
Fig. 10 Mark Vibration Damper—Second Mark DAMPER
TDC J9109-107
1ST
MARK Fig. 12 Fabricated Wire Pointer
2ND MARK
1 4 . 2 8 8 mm ( . 5 6 2 5 inch)
12.7 mm
(.5 inch)
J9109-50 1 5 3 . 9 8 8 mm
( 6 . 0 6 2 5 inch)
Fig. 11 Location of Top Dead Center (TDC)
(15) Apply a coat of Loctite™ 59241 (Liquid Te
flon), or equivalent to the threads of the Torx head
bolts. Install the timing pin assembly and new
5 0 . 8 mm
O-ring. (2 inch)
(16) Hold the timing pin i n the hole to align the J9109-105
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N-m (44 i n . lbs.) torque. Fig. 13 Fabricated Steei Plate
(17) Install the remaining rocker lever pedestal as (3) Use two flywheel housing bolts to assemble the
semblies. Tighten the rocker lever pedestal mounting plate over N o . l cylinder (Fig. 14).
capscrews. (4) Rotate the crankshaft i n the direction of rota
(18) Adjust the valves. tion until the piston contacts the plate.
(19) Install the injectors and bleed the fuel system (5) Mark the vibration damper (Fig. 11).
(refer to Group 14, Fuel System).
(20) Install the fuel pump (refer to Group 14, Fuel FLYWHEEL
System). HOUSING
(21) Install the gear cover. BOLT
(22) Remove the pointer. Install the crankshaft v i
bration damper.
FABRICATE
INSTALLATION (CYLINDER HEAD OFF) PLATE
The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated i f the
gear housing is interchanged.
(1) Temporarily install the vibration damper and a Fig. 14 Fabricated Plate Location on No.1 Cylinder
fabricated wire pointer (Fig. 12). Put a flat washer
(6) Rotate the engine i n the opposite direction un
t i l the piston contacts the plate.
(7) Mark the vibration damper (Fig. 11).
(8) Mark the vibration damper for TDC. TDC will TROUGH
be one-half the distance between the first two marks

(Fig. 11).
(9) Remove the plate and rotate the engine i n the
direction of rotation until the pointer aligns with the
TDC mark.
(10) Look for the timing pin hole i n the camshaft
gear. I f i t is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with a
new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or Fig. 1 Tappet Remowal using a Trough
equivalent to the threads of the torx head bolts. The minimum tappet stem diameter is 15.925 mm
(13) Push the pin into the hole i n the cam gear to (0.627 inch) - (Fig. 2). I f the tappet is out of limits,
align the timing pin housing. replace the tappet.
(14) Hold the pin i n while tightening the torx head
bolts to 5 N-m (44 in. lbs.) torque. Be sure timing pin
is disengaged before rotating the engine. NORMAL
(15) Remove the vibration damper and wire WEAR
pointer.
TIPPET
REMOWAL
(1) Remove the camshaft.
ABNORMAL
(2) Insert a trough the full length of the cam bore WEAR
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job. STEM DIAMETER-
(3) Make sure the trough is positioned so i t will J9109-152
catch the tappet when the wooden dowel is removed.
(4) Identify the location of each tappet as i t is re Fig. 2 Tappet Inspection
moved. The tappets must be installed i n their origi INSTALLATION
nal locations. (1) Insert the trough the full length of the cam
(5) Only remove one tappet at a time. Remove the bore.
rubber band from the two companion tappets, secur (2) Feed the installation tool down the tappet bore
ing the tappet not to be removed with the rubber and into the trough (Fig. 3).
band. (3) Feed the installation tool cord through the cam
(6) Pull the wooden dowel from the tappet bore al bores. Carefully pull the trough and installation tool
lowing the tappet to fall into the trough (Fig. 1). out the front. The barrier at the rear of the trough
(7) Normally the tappet will fall over when i t drops will assure the tool will be pulled out with i t .
into the trough. Use a flashlight to determine this. I f
(4) Lubricate the tappets with Lubriplate 105, or
the tappet does not fall over, shake the trough gently
equivalent.
to get i t to do so.
(5) Insert the installation tool into the tappet (Fig.
(8) Special care should be taken, when removing
4). To aid i n removing the installation tool after the
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough. tappets is installed, work the tool i n and out of the
(9) Carefully pull the trough and tappet from the tappet several times before installing the tappets.
cam bore and remove the tappet. Repeat the process (6) Place the tappet and tool i n the trough and
until all tappets are removed. slide the trough back into the cam bore (Fig. 4).
(7) Pull the tool/tappet through the cam bore and
INSPECTION up into the tappet bore (Fig. 5).
Inspect the tappet socket, stem and face for exces (8) Difficulty could be experienced i n getting the
sive wear, cracks and other damage (Fig. 2). tappet to make the bend from the trough up to the
• 5.9L (DIESEL) ENGINE i - 141
tate i t 1/2 turn. This will position the round side of

the trough up, which will hold the tappet i n place.
(10) Remove the installation tool from the tappet.
(11) Install a wooden dowel into the top of the tap
pet and secure i t with a rubber band.
(12) Repeat this process until all tappets have
been installed.
(13) Install the camshaft.
CAMSHAFT
REMOVAL
(1) Remove the following parts:
• Valve covers
• Rocker lever assemblies
• Push rods
• Drive belt
• Fan hub assembly
• Vibration damper
• Gear housing cover
• Lift pump
(2) Insert the dowels through the push tube holes
and into the top of each tappet. When properly in
stalled, the dowels can be used to pull the tappets up
(Fig. 6).
(3) Pull the tappets up and wrap a rubber band
around the top of the dowel rods (Fig. 6). This will
prevent the tappets from dropping down.
DOWEL TOOL
Fig. 4 insert installation Tool into Tappet
Fig. 6 Holding Tappets in Place (Cummins Tool

3822513)
(4) Rotate the crankshaft to align the crankshaft to
camshaft timing marks (Fig. 7).
(5) Remove the bolts from the thrust plate (Fig. 8)
Fig. 5 Pull Tappet/Tool into Position (6) Remove the camshaft, gear and thrust plate.
tappet bore (due to the webbing of the block). I f this
INSPECTION
occurs, pull the trough out enough to allow the tap
pet to drop down and align itself. Now pull the tap Inspect the lift pump lobe, valve lobes and bearing
journals for wear, cracking, pitting and other dam
pet up into the bore carefully.
age.
(9) After the tappet has been pulled up into posi
Clean the camshaft and gear with solvent and a
tion, slide the trough back into the cam bore and ro lint free cloth.
9 • 142 5.9L (DIESEL) ENGINE •
J9109-51
Fig. 7 Align Crankshaft to Camshaft

CAMSHAFT JOURNAL DIAMETER (MIN.)
53.962 mm (2.1245 inch)
VALVE LOBE HEIGHT (MIN.)

INTAKE - 47.040 mm (1.852 inch)
EXHAUST - 46.770 mm (1.841 inch)
LIFT PUMP LOBE DIAMETER (MIN.)

35.500 mm (1.398 inch)
J9109-53
Fig. 9 Bearing Journal/Valve Lobe Measurements

(5) Use a universal cam bushing installation tool
and install the bushing so that i t is even with the
front face of the cylinder block. The oil hole must be
Fig. 8 Thrust Plate Bolt Location aligned. A 3.2 mm (0.128 inch) diameter rod must be
able to pass through the hole (Fig. 10).
Inspect the gear teeth for wear and damage. Look (6) Measure the installed bushing. The limit of the
for cracks at the root of the teeth. inside diameter is 54.133 mm (2.1312 inch).
Measure the bearing journals, lift pump lobe and
valve lobes (Fig. 9).
CAMSHAFT BUSHING—REPLACEMENT
(1) Measure the diameter of each bore. (The limit
for the bushing i n the N o . l bore is the same as for
the other bores without bushings). The limit of the
inside diameter is 54.133 mm (2.1312 inch). I f the
camshaft bore for the first cam bushing is worn be
yond the limit, install a new service bushing. Inspect
the rest of the camshaft bores for damage or exces
sive wear.
(2) I f the bores without a bushing are worn beyond Fig. 10 Oil Hole Alignment
the limit, the engine must be removed for machining
CAMSHAFT GEAR—REPLACEMENT
and installation of service bushings. I f badly worn,
(1) Press the camshaft out of the gear.
replace the cylinder block.
(2) Remove all burrs and smooth any rough sur
(3) Remove the bushing from the N o . l bore, using
faces caused by removing the gear.
a universal cam bushing tool.
(3) Install the camshaft key.
(4) Mark the cylinder block so you can align the oil
(4) Lubricate the camshaft surface with Lubriplate
hole i n the cylinder block with the oil hole i n the
105, or equivalent.
bushing.
• S J L (DIESEL) ENGINE 9 - 143
CAUTION: The camshaft gear w i l l be p e r m a n e n t l y • Fan hub assembly

d i s t o r t e d . If overheated. The o v e n t e m p e r a t u r e • Drive belt
s h o u l d never exceed 177°C (350°F). • Push rods
• Rocker lever assemblies
(5) Heat the gear i n an oven at 177°C (350°F) for • Valve covers
45 minutes. (7) Install the engine i n the vehicle.
(8) Operate the engine at idle for five to ten min
WARNING: WEAR PROTECTIVE GLOVES TO H A N
utes and check for leaks and loose parts.
DLE THE HOT GEAR.
(6) Install the gear with the timing marks visible. CYLINDEH BL0CI
Be sure the gear is seated against the camshaft
shoulder. REMOVAL
(7) I f the camshaft is not to be used immediately, (1) Remove the engine assembly from the vehicle.
lubricate the lobes and journals to prevent rust. (2) Remove the cylinder head from the block.
(3) Remove the camshaft.
INSTALLATION (4) Remove the piston/connecting rod assemblies.
(1) Apply a coat of Lubriplate 105 to the camshaft
bores. INSPECTION
(2) Lubricate the camshaft lobes, journals and Measure the combustion deck face using a straight
thrust washer with Lubriplate 105, or equivalent. edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm
CAUTION: W h e n Installing t h e camshaft, DO NOT (0.0004 inch) i n any 50.00 mm (2.0 inch) diameter.
p u s h it in farther t h a n it w i l l g o w i t h t h e t h r u s t Overall variation end to end or side to side is 0.075
washer in place. Pushing it t o o far can d i s l o d g e t h e mm (0.003 inch).
p l u g in t h e rear of t h e camshaft bore a n d c a u s e an I f the surface exceeds the limit, refer to Cylinder
o i l leak. Block Refacing.
(3) Install the camshaft/thrust washer. Align the
timing marks as illustrated (Fig. 7).
(4) Install the thrust washer bolts and tighten to
(5) Verify the camshaft has the correct amount of
backlash and end clearance (Fig. 11).
Fig. 1 Combustion Deck Face Measurement

Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). I f the cylinder
bores exceeds the limit, refer to Cylinder Bore Re
pair.
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Fig. 3). Limit for the
BACKLASH - 0 . 0 8 0 - 0 . 3 3 0 mm No.l bore applies to the ID of the bushing.
( 0 . 0 0 3 - 0 . 0 1 3 inch)
I f a bore exceeds the limit, refer to Camshaft Bore
C L E A R A N C E - 0 . 1 5 2 - 0 . 2 5 4 mm Repair.
( 0 . 0 0 6 - 0 . 0 1 0 inch)
Inspect the tappet bores for scoring or excessive
wear (Fig. 4).
Fig. 11 Camshaft Backlash and End Clearance
I f out of limits, replace the cylinder block.
(6) Install the following parts:
• Lift pump CYLINDER BORES—DE-GLAZE
• Gear housing cover (1) New piston rings may not seat i n glazed cylin
• Vibration damper der bores.
MIN. 102.0 mm (4.0157 inch)

MAX. 102.116 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch) TAPPET BORE DIAMETER
Taper 0.0 76 mm (0.003 inch)
Oversize pistons and rings are MAX. 16.055 mm (0.632 inch)
available for bored cylinder blocks.
J9209-167 J9109-79
Fig. 2 Cylinder Bore Diameter Fig. 4 Tappet Bore Diameter
TOP OF BLOCK
J9109-124
Fig. 5 Cylinder Bore Crosshatch Pattern

(5) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.
CAMSHAFT BORE DIAMETER (6) The C r o s s h a t c h angle is a function of drill speed
and how fast the hone is moved vertically (Fig. 6).
(7) Vertical strokes MUST be smooth continuous
MAX. 54.133 mm (2.1312 inch)
passes along the full length of the bore (Fig. 6).
(8) Inspect the bore after 10 strokes.
J9109-78
(9) Use a strong solution of hot water and laundry
Fig. 3 Camshaft Bores detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
(2) De-glazing gives the bore the correct surface
(10) Rinse the bores until the detergent is removed
finish required to seat the rings. The size of the bore
and blow the block dry with compressed air.
is not changed by proper de-glazing.
(11) Check the bore cleanliness by wiping with a
(3) Cover the lube holes i n the top of the block
white, lint free, lightly oiled cloth. I f grit residue is
with waterproof tape.
still present, repeat the cleaning process until all res
(4) A correctly honed surface will have a cross- idue is removed. Wash the bores and the complete
hatch appearance with the lines at 15° to 25° angles block assembly with solvent and dry with compressed
(Fig. 5). For the rough hone, use 80 grit honing air.
stones. To finish hone, use 280 grit honing stones.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.
stamped beside the first when the block is refaced to

0.50 mm (0.0197 inch) - (Fig. 8),
1 STROKE (f+|)/PER SECOND
Fig. 6 De-Glazing Drill Speed and Vertical Speed

CYLINDER BLOCK REFACING Fig. 8 Stamp Block after Reface
(1) The combustion deck can be refaced twice. The (3) Consult the parts catalog for the proper head
first reface should be 0.25 mm (0.0098 inch). If addi gaskets which must be used with refaced blocks to
tional refacing is required, an additional 0.25 mm ensure proper piston-to-valve clearance.
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 7). CYLINDER BORE REPAIR
Cylinder bore(s) can be repaired by one of two
methods:
• Method 1:—Over boring and using oversize pistons
and rings.
• Method 2:—Boring and installing a repair sleeve
to return the bore to standard dimensions.
METHOD 1—OVERSIZE BORE

Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
1st REFACE 0.25 mm (0.0098 inch) Method 2—Repair Sleeve).
2nd REFACE 0.25 mm (0.0098 inch)
Cylinder block bores may be bored twice before use
® Total 0.50 mm (0.0197 inch) of a repair sleeve is required (Fig. 9). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
® Standard 323.00 mm ±0.10 mm 1.00 mm (0.0393 inch) oversize.
(12.7165 inch ±0.0039 inch)
After boring to size, use a honing stone to chamfer
1st REFACE 3 2 2 . 7 5 mm ±0.10 mm
the edge of the bore (Fig. 9).
(12.7067 inch ±0.0039 inch)
A correctly honed surface will have a Crosshatch
2nd REFACE 322.50 mm ±0.10 mm
appearance with the lines at 15° to 25° angles with
(12.6968 inch ±0.0039 inch)
the top of the cylinder block (Fig. 10). For the rough
J9409-123 hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
Fig. 7 Refacing Dimensions of the Cylinder Block A maximum of 1.2 micrometer (48 microinch) sur
face finish must be obtained.
(2) The upper right corner of the rear face of the After finish honing is complete, immediately clean
block must be stamped with a X when the block is the cylinder bores with a strong solution of laundry
refaced to 0.25 mm (0.0098 inch). A second X must be detergent and hot water.
After rinsing, blow the block dry.
METHOD 2 — R E P A I R S L E E V E
BORING A N D
H O N I N G DIAMETERS I f more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored
and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 11).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl
inder bore beyond the oversize limit.
BORING DIAMETER DIMENSION
1st REBORE - 102.469 mm

(4.0342 inch)
2nd REBORE - 102.969 mm
(4.0539 inch)
H O N I N G DIAMETER DIMENSIONS
STANDARD 102.020 ±0.020 mm BLOCK REBORE FOR REPAIR SLEEVE

(4.0165 ±0.0008 inch)
1st REBORE 102.520 ± 0.020 mm BORE DIA. - 104.500 + 0.015 mm
(4.0362 ± 0.0008 inch) (4.1142 + 0.0006 inch)
2nd REBORE 103.020 ±0.020 mm STEP DIM. - 6.35 mm (0.25 inch)
(4.0559 ±0.0008 inch)
J9109-120
CHAMFER DIMENSIONS
Fig. 11 Block Bore for Repair Sleeve Dimensions

Approx. 1.25 mm (0.049 inch)
by 15° After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
J9109-119
debris and oil residue before installing the sleeve.
Fig. 9 Cylinder Bore Dimensions Cool the repair sleeve(s) to a temperature of -12°C
(10°F) or below for a minimum of one hour. Be ready
TOP OF BLOCK to install the sleeve immediately after removing i t
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until i t contacts the step at the bottom of the bore
(Fig. 12).
A sleeve driver can be constructed as follows (Fig.
Fig. 10 Crosshatch Pattern of Repaired Sleeve(s) 13) .
Set up a boring bar and machine the sleeve to
Check the bore cleanliness by wiping with a white,
101.956 mm (4.014 inch) - (Fig. 14).
lint-free, lightly-oiled cloth. There should be no grit
After removing the boring bar, use a honing stone
residue present.
to chamfer the corner of the repair sleeve(s) - (Fig.
I f the block is not to be used right away, coat i t
14) .
with a rust-preventing compound.
A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
SLEEVE DIAMETER - 101.956 mm

(4.014 inch)
SLEEVE PROTRUSION
M I N . - FLUSH WITH BLOCK
Fig. 12 Sleeve Installation MAX. - 0.050 mm (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 mm (0.049 inch)
BY 15°
J9109-123
Fig. 14 Sleeve Machining Dimensions

A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
CAM BORE REPAIR

The front cam bushing bore can be bored to 57.740
HANDLE - STEEL
Mm ±0.018 mm (2.273 inch ±0.0007 inch) oversize.
DO NOT bore the intermediate or rear cam bore to
A = 127 mm (5 inch) the front cam bore oversize dimensions. Intermediate
B = 38 mm (1.5 inch) and rear cam bores may be bored to 57.240 mm
C = 6.35 mm (0.25 inch) ±0.018 mm (2.253 inch ±0.0007 inch) oversize.
D = 25.4 mm (1 inch) A surface finish of 2.3 micrometers (92 microinch)
E = 101 mm (3.976 inch) must be maintained. Not more than 20% of an area
F = 107.343 mm (4.226 inch) of any one bore may be 3.2 micrometers (126 micro-
inch).
J9109-122
Camshaft bores can be repaired individually. I t is
Fig. 13 Sleeve Driver Construction not necessary to repair undamaged cam bores i n or
der to repair individually damaged cam bores. The
the top of the cylinder block. For the rough hone, use standard front bushing cannot be used to repair in
80 grit honing stones. To finish hone, use 280 grit termediate or rear bores.
honing stones. Install all cam bushings flush or below the front
Finished bore inside dimension is 102.020 ±0.020 cam bore surface. The oil hole must align to allow a
mm (4.0165 ±0.0008 inch). 3.2 mm (0.125 inch) rod to pass through freely (Fig.
A maximum of 1.2 micrometer (48 microinch) sur 15).
face finish must be obtained.
After finish honing is complete, immediately clean CUP PLUG—REPLACEMENT
the cylinder bores with a strong solution of laundry (1) Remove the cup plugs from the oil passages
detergent and hot water. (Fig. 16).
After rinsing, blow the block dry with compressed (2) Apply a bead of Loctite 277 around the outside
air. diameter of the oil passage cup plugs.
Wipe the bore with a white, lint-free, lightly oiled (3) Drive the cup plugs in until they bottom i n the
cloth. Make sure there is no grit residue present. bore (Fig. 16).
Apply a rust-preventing compound i f the block will (4) Fill the engine with oil. Run the engine and
not be used immediately. check for leaks.
I - 148 i J L (DIESEL) ENGINE • •
(7) Remove the connecting rod bolts and rod caps.

Use care so the cylinder bores and connecting rods
are not damaged.
(8) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder
bore.
(9) Store the piston/rod assemblies in a rack.
(10) If a piston must be replaced, replace with the
same part number (grading) that was removed.
DISJkSSEMBLE
Fig. 15 Oil Hole Alignment
(1) Remove the retainer rings from the piston (Fig.
1).
(5) Stop the engine and check the oil level with the (2) Remove the piston pin. Heating the piston is
dipstick. not required.
(3) Remove the piston rings (Fig. 1).
Fig. 16 Cup Plug Locations in Cylinder Block

INSTALLATION Fig. 1 Retainer Rings
(1) Install the cylinder head onto the block.
(2) Install the engine assembly into the vehicle. CLEANING
CAUTION: DO NOT u s e bead blast to clean the pis

PISTON / CONNECTING ROD ASSEMBLY tons. DO NOT clean the pistons and rods in an acid
The turbocharged intercooler piston has a Ni-Resist tank.
insert with a keystone profile for the top compression
ring. The new piston has a new design bowl and a 7 Soak the pistons in cold parts cleaner. Soaking the
mm longer piston pin. These pistons can not be inter pistons overnight will usually loosen the carbon de
changed with earlier models. posits.
Wash the pistons and rods in a strong solution of
REMOVAL laundry detergent and hot water.
(1) Remove the engine assembly from the vehicle. Clean the remaining deposits from the ring grooves
(2) Remove the cylinder head from the block. with the square end of a broken ring. DO NOT use a
(3) Remove the oil pan and suction pump. ring groove cleaner and be sure not to scratch the
(4) If the cylinder bores have ridges, use a ridge ring sealing surface in the piston groove.
reamer to cut the ridge from the top of the cylinder Wash the pistons again in a detergent solution or
bore before removing the piston. Make sure the ridge solvent.
reamer does not make a deep cut into the bore. DO Rinse the pistons. Use compressed air to dry.
NOT remove more metal than is necessary to remove
the ridge. INSPECTION
(5) If cylinders have ridges, the cylinders are over Inspect the rod journals for deep scratches, indica
size and will need boring. tion of overheating and other damage.
(6) Use a hammer and a steel stamp to mark the Inspect the pistons for damage and excessive wear.
cylinder number onto each connecting rod cap. Mark Check top of the piston, ring grooves, skirt and pin
the cylinder number onto the top of each piston. bore.
Measure the piston skirt diameter (Fig. 2). I f the PISTON

piston is out of limits, replace the piston.
12 mm (1/2 inch)
Mllll'lll!
_H
m
MIN. DIAMETER
101.823 mm
4.0088 inch
J9109-63
Fig. 2 Piston Skirt Diameter J9109-65

The upper groove only needs to be inspected for
Fig. 4 Piston Pin Bore
damage.
Use a new piston ring to measure the clearance i n PISTON
the intermediate ring groove (Fig. 3). I f the clearance PIN
of the intermediate ring exceeds 0.152 mm (0.006
inch), replace the piston.
Use a new oil ring to measure the clearance i n the
oil groove (Fig. 3). I f the clearance exceeds 0.127 mm
(0.005 inch), replace the piston.
FEELER GAUGE
J9109-66
Fig. 5 Piston Pin Diameter

CONNECTING
ROD
PISTON
J9109-64
Fig. 3 Intermediate and Oil Ring Clearances

Measure the pin bore (Fig. 4). The maximum diam
eter is 40.025 mm (1.5758 inch). I f the bore is over
limits, replace the piston.
Inspect the piston pin for nicks, gouges and exces
sive wear.
Measure the pin diameter (Fig. 5). The minimum
diameter is 39.990 mm (1.5744 inch). I f the diameter J9109-67
is out of limits, replace the pin.
Inspect the rod for damage and wear. The I-Beam Fig. 6 Connecting Rod Pin Bore
section of the connecting rod cannot have dents or CONNECTING R O D BEARING / CRANKSHAFT
other damage. Damage to this part can cause stress JOURNAL CLEARANCE
risers which will progress to breakage. Measure the connecting rod bore with the bearings
Measure the connecting rod pin bore (Fig. 6). The installed and the bolts tightened to 100 N«m (73 ft.
maximum diameter is 40.042 mm (1.5764 inch). I f lbs.) torque.
out of limits, replace the connecting rod. Record the smaller diameter.
9 - 150 5 . 9 L (DIESEL) ENGINE
Measure the diameter of the rod journal at the lo (2) Install the upper bearing shell i n the connect
cation shown (Fig. 7). Calculate the average diameter ing rod with the tang of the bearing i n the slot of the
for each side of the journal. connecting rod. The connecting rod bearing shells
The clearance is the difference between the con must be installed i n the original connecting rod and
necting rod bore (smallest diameter) and the average cap. Use clean lubricating oil to coat the inside diam
diameter for each side of the crankshaft journal. eter of the connecting rod bearing shell.
(3) Install the bearing shell i n the connecting rod
cap with the tang of the bearing i n the slot to the
cap. Use clean lubricating oil to coat the inside diam
eter of the bearing shell.
(4) The four digit number stamped on the connect
ing rod and cap at the parting line must match and
be installed on the oil cooler side of the engine. I n
stall the connecting rod cap and capscrews. Tighten
the capscrews to 3 5 N-m (26 ft. lbs.) torque.
(5) Use a fine grit home to remove any burrs from
the cylinder block head deck. Zero the dial indicator
to the cylinder block head deck.
(6) Move the dial indicator over the piston directly
over the piston pin to eliminate any side-to-side
movement.
MIN. 6 8 . 9 6 2 mm ( 2 . 7 1 5 inch) (7) Rotate the crankshaft to top dead center (TDC).
MAX. 6 9 . 0 1 3 mm ( 2 . 7 1 7 inch) Rotate the crankshaft clockwise and counterclockwise
to find the highest dial indicator reading. Record the
Out-of-Round - Max. reading.
0 . 0 5 0 mm ( 0 . 0 0 2 inch) (8) Remove the piston and connecting rod assembly
from the N o . l cylinder and install the assembly into
Taper - Max. the No.2 cylinder. Repeat the procedure for every cyl
0 . 0 1 3 mm ( 0 . 0 0 0 5 inch) inder using the same piston and connecting rod as
Bearing Clearance - Max.
sembly.
0 . 0 8 9 mm ( 0 . 0 0 3 5 inch) (9) Determine the grade of the piston being used
by referring to the Piston Grading Chart. Four digits
J9109-91 on top of the piston are the last four digits of the
part number.
Fig. 7 Connecting Rod Journal Diameter Limits
ASSEMBLE
I f the crankshaft is within limits, replace the bear (1) Be sure the FRONT marking on the piston and
ing. I f the crankshaft is out of limits, grind the the numbers on the rod and cap are oriented (Fig. 8).
crankshaft to the next smaller size and use oversize Install the retaining ring into the pin groove on the
rod bearings. FRONT side of the piston.
(2) Lubricate the pin and bore with engine oil.
PISTON GRADING
(3) Install the piston pin i n the opposite side of the
When rebuilding an engine with the original cylin
installed retaining pin. Pistons do not require heat
der block, crankshaft and pistons, make sure the pis
ing to install the pin, however, the piston does need
tons are installed i n the original cylinder. I f replacing
to be at room temperature or above.
the piston(s), make sure the replacement piston(s)
(4) Determine the piston diameter and obtain the
are the same grade as the original piston. I f a new
appropriate ring set. The piston rings can be identi
cylinder block or crankshaft is used, the piston grad
fied as shown i n Fig. 9.
ing procedure MUST be performed to determine the
proper piston grade for each cylinder. (5) Position each ring i n the cylinder and use a pis
ton to square i t with the bore at a depth of 89.0 mm
(1) Install the connecting rod and piston assembly
(3.5 inch) - (Fig. 10).
into the N o . l cylinder. DO NOT install the piston
rings.
PISTON GRADING CHART
MEASURING USE
PISTON PROTRUSION GRADE PART N O .
A 0.609-0.711 mm (0.024-0.028 in.) A 3922571
A 0.508-0.609 mm (0.020-0.024 in.) B 3922572
A 0.406-0.508 mm (0.016-0.020 in.) C 3922573
B 0.711-0.813 mm (0.028-0.032 in.) A 3922571
B 0.609-0.711 mm (0.024-0.028 in.) B 3922572
B 0.508-0.609 mm (0.020-0.024 in.) C 3922573
C 0.813-0.914 mm (0.032-0.036 in.) A 3922571
C 0.711-0.813 mm (0.028-0.032 in.) B 3922572
C 0.609-0.711 mm (0.024-0.028 in.) C 3922573
J9409-108
PISTON
VI, //CONNECTING
J9109-68 J9109-70
Fig. 8 Proper Markings on the Piston and Fig. 10 Position of Ring in Cylinder Bore
Connecting Rod (7) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem
TOP RING TOP ble the rings with the word TOP or the supplier's
MARK up.
(8) Position the oil ring expander i n the oil control
INTERMEDIATE ring groove (bottom groove).
RING (9) Install the oil control ring with the end gap OP
POSITE the ends on the expander (Fig. 12).
(10) Install the intermediate piston ring i n the sec
OIL C O N T R O L ond groove (Fig. 13).
RING J9109-69 (11) Install the top piston ring i n the top groove
(Fig. 13).
Fig. 9 Piston Ring identification (12) Position the rings as shown i n Fig. 14.
(6) Use a feeler gauge to measure the piston ring (13) Install the original bearings as removed or i n
gap (Fig. 11). stall new bearings. I f new bearings are used, be sure
to obtain the proper bearing clearance (Fig. 15).
(14) DO NOT lubricate the side of the bearing that
is against the connecting rod or cap. Apply a coat of
9 - 152 5.9L (DIESEL) ENGINE
FEELER GAUGE
TOP
RING
INTERMEDIATE
RING
OIL CONTROL
RING
0.400 mm 0.700 mm J9109-73

TOP
(0.0160 inch) (0.0275 inch)
INTERMEDIATE 0.250 mm 0.550 mm Fig. 14 Piston Ring Positioning
(0.0100 inch) (0.0215 inch)
OIL CONTROL 0.250 mm 0.550 mm
(0.0100 inch) (0.0215 inch)
J9109-71
Fig. 11 Piston Ring Gap 0.250 mm (.0098 in.)

0.500 mm (.0197 in.)
OIL CONTROL 0.750 mm (.0295 in.)
RING 1.000 mm (.0394 in.)
J9109-82
Fig. 15 Connecting Rod Bearing Size Location

INSTALLATION
( 1 ) Lubricate the cylinder bore with clean engine
oil.
EXPANDER
(2) Generously lubricate the rings and piston skirts
PISTON with clean engine oil.
(3) Compress the rings using a piston ring com
pressor tool (Fig. 16). If using a strap-type ring com
pressor, make sure the inside end of the strap does
J9109-72 not hook on a ring gap and break the ring.
Fig. 12 Oil Control Ring/Expander Location in

Groove
PISTON
RING
COMPRESSOR TOOL J9109-83
PISTON RING
INSTALLATION Fig. 16 Piston Ring Compressor Tool
TOOL J9109-74 (4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen
Fig. 13 Piston Ring Installation Tool ter) - (Fig. 17).
Lubriplate 105, or equivalent to the new upper and (5) Be sure the FRONT marking on the piston and
lower connecting rod bearings. the numbers on the rod and cap are oriented as illus
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the word FRONT on the piston to-
J9109-86
SIDE CLEARANCE LIMITS

MIN. 0.100 mm (0.004 inch)
0.300 mm (0.012 inch)
J9109-84 MAX.
Fig. 17 Piston/Rod Assembly at BDC Fig. 19 Side Clearance between Connecting
Rod/Crankshaft
wards the front of the cylinder block. Use care when
you install the piston and connecting rod so the cyl (14) Install the cylinder head onto the block.
inder bore is not damaged.
(15) Install the engine assembly into the vehicle.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the CRANKSHAFT
top of the block. Carefully pull the connecting rod
onto the crankshaft journal. REMOVAL
(8) Use clean engine oil to lubricate the threads (1) Remove the rear crankshaft seal housing.
and under the heads of the connecting rod bolts. (2) Remove the gear housing.
(9) The 4 digit number stamped on the rod cap at (3) Rotate the engine to a horizontal position and
the parting line must match and be installed towards remove the main bearing bolts.
the oil cooler side of the engine (Fig. 18). (4) The main bearing caps should be numbered. If
they are not, be sure to mark them, beginning with
number one at the front and ending with number
seven at the rear (Fig. 1).
MAIN
BEARING
CAP
J9109-85
Fig. 18 Correct Rod Cap Installation

(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
• Tighten the bolts to 35 N-m (26 ft. lbs.) torque. J9109-87
• Tighten the bolts to 70 N-m (51 ft. lbs.) torque.
Fig. 1 Numbering Main Bearing Caps
• Tighten the bolts to 100 N-m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for CAUTION: DO NOT pry on the main c a p s to free
freedom of rotation as the caps are installed. If the them from the cylinder block.
crankshaft does not rotate freely, check the installa
tion of the rod bearing and the bearing size. (5) Use two of the main bearing cap bolts to "wig
(12) Measure the side clearance between the con gle" the main cap loose, being careful not to damage
necting rod and the crankshaft (Fig. 19). DO NOT the bolt threads (Fig. 2). Remove the caps.
measure the clearance between the cap and crank
WARNING: U S E A HOIST T O AVOID INJURY.
shaft.
(13) Install the suction tube and oil pan.
Clean the crankshaft oil galley holes with a nylon
brush.
Rinse in clean solvent and dry with compressed air.
Inspect the front and rear seal contact areas of the
crankshaft for scratches or grooving.
The service seal k i t will position the seal slightly
deeper into the seal bore so i t will contact the crank
shaft at a different location. I f this has already been
done and the crankshaft has two worn areas, install
a wear sleeve to provide a new contact surface for
the seal.
Inspect the rod and main journal for deep scores,
J9109-88 signs of overheating and other abnormal marks.
Fig. 2 Main Bearing Cap Removal CRANKSHAFT REWORK
(6) Lift the crankshaft and gear from the cylinder Crankshaft main and rod journals may be ground
block (Fig. 3). in increments of 0.25 mm (0.0098 inch) up to a total
of 1.00 mm (0.0394 inch).
CAUTION: Crankshaft must be lifted straight off the The only exception is the main journal thrust
bearings to prevent damage to the thrust bearings. width surface. This journal must be ground i n incre
ments of 0.50 mm (0.019/7 inch) up to a total of 1.00
CRANKSHAFT mm (0.0394 inch). The thrust surface is located on
the No.6 main bearing. When the thrust surface re
quires grinding, the main journal must be ground to
the same undersize dimension.
MAIN JOURNAL
A l l main journals are to be ground i n the opposite
direction of engine rotation (clockwise as viewed from
the front of crankshaft). Polish the journals i n the
same direction as engine rotation.
The main bearing grinding specifications are shown
i n Fig. 5.
J9109-89
STANDARD MAIN. JOURNAL DIAMETER
Fig. 3 Lifting Crankshaft out of Cylinder Block 83.000 +0.013 mm
(3.2677 ± 0.0005 inch)
( 7 ) Remove the main bearings from the block and
W O R N MAIN J O U R N A L DIAMETER LIMIT
the main caps. 82.962 (3.2662 inch)
(8) Remove the piston cooling nozzles by using a
3/16 inch pin punch to push them out (Fig. 4). UNDERSIZES REGRIND T O
0.25 mm 82.750 ± 0 . 0 1 3 mm
(0.0098 inch) (3.2579 ± 0.0005 inch)
PISTON
0.50 mm 82.500 + 0 . 0 1 3 mm
COOLING (0.0197 inch) (3.2480 ± 0.0005 inch)
NOZZLE 0.75 mm 82.250 + 0 . 0 1 3 mm
(0.0295 inch) (3.2381 ± 0 . 0 0 0 5 inch)
1.00 mm 82.000 + 0 . 0 1 3 mm
(0.0394 inch) (3.2283 + 0 . 0 0 0 5 inch)
O U T - O F R O U N D & TAPER (MAX.)

0.005 mm (0.0002 inch)
ALL M A I N J O U R N A L S ARE T O BE PARALLEL
TO THE FRONT AND REAR M A I N S WITHIN:
0.030 mm (0.001 inch)
Fig. 4 Piston Cooling Nozzles J9109-125
Fig. 5 Crankshaft Main Journal Dimensions

Thrust journals can be ground i n the same incre ORIGINAL RADIUS

ments and using the same specifications as all other
main journals. The main journal radius may be
ground using either the preferred or the alternative
procedure providing the thrust surface width is not
being ground. The preferred procedure must be used
when the main bearing thrust width surface is
ground. When the thrust surface width requires
grinding, the main journal must be ground to the
same undersize dimension (Fig. 6).
THRUST JOURNAL WIDTH

37.500 ±0.025 mm
(1.4764 ±0.001 inch)
UNDERSIZES REGRIND WIDTH TO
0.50 mm 38.000 ±0.025 mm
(0.0197 inch) (1.4961 ±0.001 inch JOURNAL SURFACE
1.00 mm 38.500 ±0.025 mm SURFACE FINISH
(0.0394 inch) (1.5158 ±0.001 inch)
® 0.8 micrometer (32.0 microinch)
J9109-127 for a minimum of 45° into the
fillet beyond journal surface
Fig. 6 Crankshaft Thrust Journal Width Dimensions 1.6 micrometer (64.0 microinch)
for remainder of fillet
The thrust surface is to be ground on center within
0.10 mm (0.004 inch). I t also must be perpendicular © 0.4 micrometer (16.0 microinch)
to the front and rear mains within 0.0015 mm

J9109-129
(0.00006 inch) per radial inch on the thrust area
(Fig. 7). The surface finish requirement is 0.04 mi
Fig. 8 Grind Crankshaft Main Journal—Preferred
crometer (16.0 microinch).
Method
JOURNAL ROD JOURNAL
All rod journals are to be ground i n the opposite di
rection of engine rotation (clockwise as viewed from
the front of crankshaft). Polish the journals i n the
same direction as engine rotation.
The rod bearing grinding specifications are shown
in Fig. 10.
PREFERRED PROCEDURE:
Smoothly blend a 4.00 ±0.020 (0.1575 ±0.0008
inch) radius to the ground diameters and side faces
(Fig. 11).
A L T E R N A T I V E PROCEDURE:
Smoothly blend a 1.25 ±0.020 mm (0.0492 ±0.0008
J9109-128 inch) radius to the ground journals (Fig. 12).
Fig. 7 Crankshaft Thrust Surface CRANKSHAFT FRONT SEAL

PREFERRED PROCEDURE: REMOVAL
Smoothly blend a 4.20 ±0.020 mm (0.1654 ±0.0008
(1) Remove the drive belt.
inch) radius to the ground diameters (Fig. 8).
(2) Remove the vibration damper.
CAUTION: DO NOT use the Alternative Procedure (3) Drill two l/8th inch holes into the seal face,
when the thrust surface width is ground. 180° apart.
(4) Use a slide hammer tool with a #10 metal
ALTERNATIVE PROCEDURE: screw. Pull alternating from side-to-side until the
Smoothly blend a 1.25 ±0.020 mm (0.0492 ±0.0008 seal is free.
inch) radius to the ground diameters (Fig. 9).
ORIGINAL RADIUS ORIGINAL RADIUS
N E W UNDERCUT RADIUS
N E W UNDERCUT RADIUS^
JOURNAL SURFACE.
JOURNAL SURFACE
SURFACE FINISH
0.8 micrometer (32.0 microinch) SURFACE FINISH
for a minimum of 45° into the
fillet beyond journal surface ® 0.8 micrometer (32.0 microinch)
1.6 micrometer (64.0 microinch)
^ fillet beyond journal surface
for remainder of fillet CD 1.6 micrometer (64.0 microinch)
© 0.4 micrometer (16.0 microinch) for remainder of fillet
WIDTH O F REGRIND/UNDERCUT RADIUS v£/ 0.4 micrometer (16.0 microinch)
® 34.5 ±0.025 mm (1.358 ±0.001 in)

J9109-130 J9109-131
Fig. 9 Grind Crankshaft Main Journal—Alternative Fig. 11 Crankshaft Rod Journal Grind—Preferred
Method Method
(2) If the gear cover was replaced, use the align

S T A N D A R D R O D J O U R N A L DIAMETER ment tool from the seal kit to make sure the cover is
69.000 + 0 . 0 1 3 mm aligned with the crankshaft.
(2.7165 ± 0 . 0 0 0 5 inch)
(3) Apply a bead of Loctite 277 to the outside di
W O R N R O D J O U R N A L DIAMETER LIMIT ameter of the seal.
68.962 (2.7150 inch) (4) Install the pilot from the seal kit onto the
UNDERSIZES REGRIND TO crankshaft.
0.25 mm 68.750 + 0 . 0 1 3 mm (5) Install the seal onto the pilot and start it into
(0.0098 inch) (2.7067 ± 0 . 0 0 0 5 inch) the gear housing cover seal bore.
0.50 mm 68.500 ± 0 . 0 1 3 mm (6) Remove the pilot.
(0.0197 inch) (2.6969 ± 0.0005 inch)
0.75 mm 68.250 + 0 . 0 1 3 mm
(7) Use the alignment/installation tool and a plas
(0.0295 inch) (2.6870 ± 0.0005 inch) tic hammer to install the seal to the correct depth.
1.00 mm 68.000 + 0.013 mm (8) Install the vibration damper, but DO NOT
(0.0394 inch) (2.6772 ± 0 . 0 0 0 5 inch) tighten the damper bolt until the belt is installed.
O U T - O F R O U N D & TAPER (MAX.) (9) Install the drive belt.
0.005 mm (0.0002 inch) (10) Tighten the vibration damper bolts to 125 N-m
(92 ft. lbs.) torque. Use the engine barring tool to
ALL M A I N J O U R N A L S A R E T O BE PARALLEL
T O THE F R O N T A N D REAR M A I N S W I T H I N : keep the engine from rotating during torquing oper
0.030 mm (0.001 inch) ation.
J9109-126
CRANKSHAFT REAR SEAL HOUSING AND
Fig. 10 Crankshaft Rod Journal Dimensions SEAL
INSTALLATION
REMOVAL
(1) The sealing surface on the crankshaft must be
(1) Remove the rear seal housing and gasket (Fig.
free from all oil residue to prevent seal leaks.
13).
ORIGINAL RADIUS (2) Assemble the rear seal housing and gasket to
N E W UNDERCUT RADIUS the cylinder block with the bolts.
JOURNAL S U R F A C E , (3) Align the seal housing to the crankshaft with
the alignment tool provided i n the seal k i t (Fig. 14).
Make sure the seal housing is level with both sides of
the block oil pan rail. Tighten the bolts to 9 N-m (7
ft. lbs.) torque.
(4) Remove the alignment tool and t r i m the gasket
even with the oil pan mounting surface (Fig. 14).
ALIGNMENT
TOOL
SURFACE FINISH
® 0.8 micrometer (32.0 microinch)

^ fillet beyond journal surface
( § / 1.6 micrometer (64.0 microinch)
for remainder of fillet
(Q 0.4 micrometer (16.0 microinch)
WIDTH O F REGRIND/UNDERCUT RADIUS J9109-100
® 34.79 ±0.025 mm (1.369 ±0.001 in)
Fig. 14 Crankshaft Rear Seal Housing Alignment
J9109-132
Tool
Fig. 12 Grind Crankshaft Rod Journal—Alternative (5) The rubber O . D . rear crankshaft seals are l u
Method bricated with soapy water. Seals without rubber O . D .
(2) Support the seal area of the rear seal housing use Loctite 277, or equivalent.
and press/drive out the seal using a hammer and a (6) Install the seal pilot (provided with the replace
pin pinch. ment kit) onto the crankshaft. Push the seal onto the
(3) Clean the rear seal housing. crankshaft (Fig. 15).
(7) Remove the seal pilot.
CRANKSHAFT
REAR SEAL
HOUSING
GASKET
J9109-99
J9109-101
Fig. 13 Crankshaft Rear Seal Housing/Gasket
Fig. 15 Crankshaft Rear Seal Pilot
INSTALLATION
(1) Clean and dry the rear crankshaft sealing sur (8) Use alignment and installation tool packaged
face. The seal lip and the sealing surface on the in the seal k i t (Fig. 16). Alternately, drive the seal at
crankshaft must be free from all oil residue to pre the 12, 3, 6 and 9 o'clock positions to prevent bending
vent seal leaks. the seal carrier during installation.
9 - 158 5.9L (DIESEL) ENGINE #
(1) Install the seal pilot, provided i n the replace
ment kit, on the crankshaft. Push the seal on the pi
lot and crankshaft.
(2) Remove the seal pilot.
(3) Seal O.D. lubricant/sealant:
• Rubber O.D. rear crankshaft seals are lubricated
with soapy water.
• Seals without rubber O.D. use Loctite 277 or
equivalent sealant.
(4) Use the alignment tool to install the seal to the
correct depth i n the housing. Use a hammer to drive
the seal into the housing until the alignment tool
stops against the housing (Fig. 18).
(5) H i t the tool at the 12, 3, 6 and 9 o'clock posi
tions to drive the seal evenly and prevent bending
Fig. 16 Crankshaft Rear Seal Alignment/Installation
the seal housing.
Tool
CRANKSHAFT REAR SEAL
REMOVAL
(1) Remove the transmission (refer to Group 21,
Transmission for the proper procedure).
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
(5) Drill holes 180° apart into the seal. Be careful
not to get the drill against the crankshaft.
(6) Install #10 sheet metal screws i n the drilled
holes and remove the rear seal with a slide hammer
(Fig. 17).
Fig. 18 Seal Installation using Alignment Tool

FLYWHEEL RING GEAR
REMOVAL
(1) Remove the transmission.
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
WARNING: W E A R E Y E P R O T E C T I O N WHEN Y O U
DRIVE T H E G E A R FROM T H E F L Y W H E E L DO NOT
U S E A S T E E L DRIFT PIN.
(5) Use a drift pin to drive the ring gear from the
flywheel (Fig. 19). Strike the gear at several points
Fig. 17 Crankshaft Rear Seal Removal
around the wheel until i t is off.
INSTALLATION (6) Heat the new ring for 20 minutes i n an oven
preheated to 127°C (250°F).
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to WARNING: W E A R P R O T E C T I V E G L O V E S WHEN
prevent seal leaks. Y O U INSTALL T H E HEATED G E A R .
The crankshaft and seal must be dry when the seal (7) Install the gear. The gear must be installed so
is installed. the bevel on the teeth is towards the crankshaft side
of the flywheel (Fig. 19).
Fig. 19 Flywheel/Ring Gear Position

INSTALLATION MIN. 82.962 mm (3.2662 inch)
MAX. 83.103 mm (3.2682 inch)
CAUTION: Never u s e the timing pin to hold the
crankshaft in position. J9109-93
(1) Use the engine barring tool to hold the crank Fig. 21 Crankshaft Main Journal Diameter
shaft when the flywheel bolts are being tightened. limits, replace the main bearings. I f not within spec
(2) Tighten the bolts i n a criss-cross pattern to 137 ifications, grind the crankshaft to next size and use
N-m (101 ft. lbs.) torque. oversize bearings.
MAIN BEARING CLEARANCE CRANKSHAFT GEAR - REPLACEMENT
Inspect the main bearing bores for damage or ab Remove the crankshaft gear using a heavy duty
normal wear. puller.
Install the crankshaft main bearings and measure Remove all burrs and make sure the gear surface
main bearing bore diameter with the main bolts on the end of the crankshaft is smooth.
tightened to 176 N-m (130 ft. lbs.) torque (Fig. 20). I f removed, install a new alignment pin. Drive the
pin i n using a ball-peen hammer, leaving i t protrud
ing 1.60 mm (0.063 inch) to 2.39 mm (0.094 inch)
above the crankshaft (Fig. 22).
MAX. 83.106 mm (3.2719 inch)
J9109-92
Fig. 22 Installing Alignment Pin
Fig. 20 Crankshaft Main Bearing Bore Diameter Heat the crankshaft gear for 45 minutes at a tem
Measure the diameter of the main journal at the perature of 121°C (250°F).
locations shown (Fig. 21). Calculate the average di
CAUTION: DO NOT heat the gear longer than 4 5
ameter for each side of the journal.
minutes.
Calculate the main bearing journal to bearing
clearance, the clearance specifications are 0.119 mm
(0.00475 inch). I f the crankshaft journal is within WARNING: W E A R P R O T E C T I V E GLOVES T O P R E
VENT INJURY.
Position the gear with the timing mark out and in (12) Tighten the bolts evenly in the sequence
stall it on the crankshaft using the alignment pin. shown using the following torque steps (Fig. 24).
Make sure the gear contacts the shoulder. • STEP 1-Tighten all bolts in sequence to 60 N-m
INSTALLATION • STEP 2-Tighten all bolts in sequence to 119 N-m
CAUTION: U s e only hand force to push the nozzle
• STEP 3-Tighten all bolts in sequence to 176 N-m
in place. If driven with a hammer, the nozzle will be
damaged.
(1) Use a center punch to push the piston cooling

nozzle into place. Install nozzles so they are even
with or slightly below the saddle surface.
(2) Make sure the saddle surface is clean and dry.
Install the upper main bearings.
(3) Install the combination thrust/main bearing in
the number six main bearing location.
(4) Lubricate the bearings with Lubriplate 105, or
equivalent.
WARNING: T O AVOID INJURY, U S E A HOIST TO IN

STALL T H E CRANKSHAFT.
(5) Install the crankshaft.

Fig. 24 Main Bearing Bolt Tightening Sequence
CAUTION: Crankshaft must be lowered onto the
bearings straight to prevent damage to thrust bear (13) Turn the crankshaft to determine that it will
ings. rotate freely all 360°. Check the main bearing cap in
stallations and/or the bearing sizes if the shaft does
(6) Install the ring dowels in the main bearing not turn easily.
caps (Fig. 23). (14) Push the crankshaft towards one end of its
thrust and place a dial indicator as shown (Fig. 25).
J9109-95
Fig. 23 Install Ring Dowels

(7) Install the lower main bearings in the caps. Fig. 25 Position of Dial Indicator
(8) Lubricate the bearings with Lubriplate, or (15) Zero the indicator needle and push the crank
equivalent. shaft towards the other end of its thrust and record
(9) Numbers on the main bearings caps face the oil the crankshaft end clearance (Fig. 26).
cooler side of the engine with number one at the
front of the engine.
(10) Place the caps in their respective positions.
(11) Lubricate the main bearing bolt threads and
underside of the bolt head with clean engine oil.
(2) Install the suction tube and gasket. Tighten the

(3) Fill the joint between the pan rail/gear housing
and pan rail/rear cover with sealant. Use Three Bond
1207-C, or equivalent.
(4) Install the pan and gasket (Fig. 1). Tighten the
(5) Install the drain plug with a new sealing
washer and tighten to 80 N-m (60 ft. lbs.) torque.
(6) Install the engine assembly into the vehicle.
(7) Fill the engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance). Run the
MIN. 0.100 mm (0.004 inch)
MAX. 0.430 mm (0.017 inch) engine and check for leaks.
(8) Stop the engine and let it set for five minutes.
J9409-120
Check the oil level, and add oil if needed.
Fig. 26 Crankshaft End Clearance
OIL PUMP
OIL P A N / SUCTION TUBE The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL
(1) Remove the engine from the vehicle and mount REMOVAL
on an engine stand. (1) Remove the radiator (refer to Group 7, Cooling
WARNING: HOT OIL CAN CAUSE PERSONAL IN (2) Loosen the crankshaft vibration damper and re
JURY. move the drive belt.
(3) Remove the fan clutch assembly.
(2) Drain the used engine oil. Dispose of the used (4) Remove the fan hub.
oil properly. (5) Remove the oil fill tube.
(3) Remove the oil pan and gasket (Fig. 1). Be sure (6) Remove the crankshaft vibration damper.
to connect the support bracket. (7) Remove the gear housing cover.
(4) If required, remove the suction tube and gasket (8) Remove the four mounting bolts and pull the
(Fig. 1). pump from the bore in the cylinder block (Fig. 2).
GASKET
Fig. 2 Oil Pump Removal

CLEAN AND INSPECT
Visually inspect the lube pump gears for chips,
cracks or excessive wear.
Remove the back plate (Fig. 3).
Fig. 1 Oil Pan, Suction Tube and Gasket Mark TOP on the gerotor planetary using a felt tip
INSTALLATION pen (Fig. 3).
(1) Clean the sealing surface. Remove the gerotor planetary (Fig. 3).
Measure the clearance of the gerotor planetary to
the body bore (Fig. 6). Maximum clearance is 0.381
mm (0.015 inch). If the oil pump is out of limits, re
place the pump.
Fig. 3 Gerotor Planetary and Gerotor

Inspect for excessive wear or damage. Fig. 6 Gerotor Planetary to Body Bore Clearance
Clean all parts in solvent and dry with compressed
Measure the gears backlash (Fig. 7). The limits of a
air.
used pump is 0.080-0.380 mm (0.003-0.015 inch). If
Inspect the pump housing and gerotor drive for
the backlash is out of limits, replace the oil pump.
damaged and excessive wear.
Install the gerotor planetary in the original posi Install the back plate.
tion. The chamfer must be on the O.D. and down. OIL PUMP
Measure the tip clearance (Fig. 4). Maximum clear
ance is 0.1778 mm (0.007 inch). If the oil pump is out
of limits, replace the pump.
FEELER
GAUGE
J9109-24
Fig. 7 Measure Gear Backlash

INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill
J9109-21 ing the pump with clean engine oil during installa
tion will help to prime the pump at engine start up.
Fig. 4 Tip Clearance Make sure the idler gear pin is installed in the lo
Measure the clearance of the gerotor drive/gerotor cating bore in the cylinder block.
planetary to port plate (Fig. 5). Maximum clearance (2) Install the pump. Tighten the oil pump mount
is 0.127 mm (0.005 inch). If the oil pump is out of ing bolts in two steps and in the sequence shown
limits, replace the pump. (Fig. 2).
• Step 1—Tighten to 5 N-m (44 in. lbs.) torque.
• Step 2-Tighten to 24 N-m (18 ft. lbs.) torque.
(3) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
(4) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back
lash (Fig. 8). The backlash should be 0.080-0.330 mm
(0.003-0.013 inch). If the backlash is out of limits, re
place the oil pump drive gear and the idler gear.
(5) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 5 Gerotor to Port Plate Clearance
OIL FILTER
When replacing the oil filter, Chrysler Corporation
(5) Install the drain plug using a new sealing

washer. Tighten the plug to 80 N-m (60 ft. lbs.)
torque.
(6) Use only High-Quality Multi-Viscosity lubricat
ing oil i n the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions outlined i n
Group 0, Lubrication and Maintenance.
(7) Fill the engine with the correct grade of new
oil. The engine capacity is 8.5 liters (9 quarts) i n the
crankcase and 0.95 liters (1 quart) i n the lubricating
oil filter.
(8) Start the engine and operate i t at idle for sev
eral minutes. Check for leaks at the filter and drain
Fig. 8 Idler Gear to Pump Drive Gear and plug.
Crankshaft Gear Backlash (9) Stop the engine. Wait approximately 5 minutes
recommends use of the replacement filter specified i n to let the oil i n the upper parts of the engine to drain
back to the oil pan. Check the oil level again. Add oil
your Operator's Manual.
as necessary to bring the level to the " H " (High)
CAUTION: The internal filtering medium of some fil mark on the dipstick.
ters has been known to disintegrate. Debris from
failed filters may plug the piston oil cooling noz
OIL FILTER 1YPASS WALWE
zles, resulting in scuffed pistons and eventual en REMOVAL
gine failure. (1) Remove the oil cooler cover (Fig. 9).
(2) Remove the valve from the cooler cover (Fig. 9).
REMOVAL
WARNING: HOT OIL C A N C A U S E P E R S O N A L IN

JURY.
(1) Operate the engine until the water temperature

reaches 60°C (140°F). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of some engine problems
that might exist.
• Thin, black oil indicates fuel dilution. Fig. 9 Removing Filter Bypass Valve
• Milky discoloration indicates coolant dilution. INSTALLATION
(4) Clean the area around the lubricating oil filter (1) Drive the new valve i n until i t bottoms against
head. Remove the filter using a 90-95 mm filter the step i n the bypass valve bore (Fig. 10).
wrench. (2) Install the oil cooler cover.
(5) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
FILTER
head. Make sure i t is removed. BYPASS
,VALVE
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter as specified by the filter man
ufacturer.
(4) Clean the drain plug and the sealing surface of J9109-15
the pan. Check the condition of the threads and seal
ing surface on the oil pan and drain plug. Fig. 10 Installing New Filter Bypass Valve
OIL PRESSURE REGULATOR VALVE / SPRING (2) Remove the oil filter.
When oil pressure from the oil pump exceeds 448 (3) Clean around the oil cooler cover.
kPa (65 psi), the regulator valve opens to allow oil to (4) Disconnect the turbocharger supply line (Fig.
drain back into the pan. 13).
(5) Remove the oil cooler cover, gaskets and cooler
REMOVAL element.
(1) Remove the threaded plug, gasket, spring and
valve (Fig. 11).
PLUG GASKET
OIL
FILTER
SPRING
J9109-17
9 Fig. 13 Turbocharger Supply Line

Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. I f the element leaks, replace the
J9109-14
element.
Fig. 11 Oil Pressure Regulator INSTALLATION
(2) Check the spring for height and load limita (1) I f a new oil cooler is being installed, remove the
tions (Fig. 12). Replace the spring i f out of limits. shipping plugs (Fig. 14).
(2) Assemble the oil cooler, gaskets and the cover
VALVE OPEH (Fig. 14). Tighten the bolts to 24 N-m (18 ft. lbs.)
• HEIGHT: 3 9 . 9 8 m m (1.574 inch) torque.
• L O A D : 91 N (20.5 lb)
COVER
MSEMILEP
• HEIGHT: 4 4 . 9 8 m m (1.77 inch)
• L O A D : 60 N (13.5 lb)
J9109-13
GASKETS
Fig. 12 Oil Pressure Regulator Spring Check
SHIPPING
PLUG J9109-18
INSTALLATION
(1) Clean and inspect the plunger, bore and seat Fig. 14 Oil Cooler
before assembly. The plunger must move freely i n the
valve bore. (3) Connect the turbocharger oil oil supply line.
(2) Install the valve, spring, gasket and plug. Tighten the nut to 15 N-m (11 ft. lbs.) torque.
Tighten the plug to 80 N-m (60 ft. lbs.) torque. (4) Fill the filter with clean lubricating oil and ap
ply a light coat of oil to the sealing gasket. Install
OIL COOLER ELEMENT / GASKET the oil filter.
The non-intercooled turbocharged engine filter (5) Fill the coolant system and operate the engine
head/coolers can not be used on intercooled engines. to check for leaks. Stop the engine and check the
coolant and oil level.
REMOVAL
(1) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
5JL (DIESEL) ENGINE 9 - 165
•
SPECIFICATIONS—5 J L DIESEL ENGINES
Camshaft C r a n k s h a f t (Cont.)
Journal Diameter (Min.) 53.962 mm Gear Backlash 0 . 0 8 0 - 0 . 3 3 0 mm

(2.1245 in) ( 0 . 0 0 3 - 0 . 0 3 in)
Valve Lobes (Min. Diameter @ Peak of Lobe) Cylinder Black
Intake 47.040 mm Cylinder Bore
(1.852 in)
Exhaust .. 4 6 7 7 0 mm Diameter. 102.116 mm
(1.841 in)
(4.0203 in)
Lift Pump Lobe (Min. Diameter @ Peak of Lobe) . . 35.500 mm Out-of-Round (Max.) 0.038 mm
(1.398 in) (0.0015 in)
End Clearance . . . 0 . 1 5 2 - 0 . 2 5 4 mm Taper (Max.) 0.076 mm
(0.006-0.010 in) (0.003 in)
G e a r Backlash . 0 . 0 8 0 - 0 . 3 3 0 mm Tappet Bore Diameter 16.055 mm
(0.003-0.013 in) (0.632 in)
Connecting Rods Top Surface Flatness (Max. Overall Variation) 0.075 mm
(0.003 in)
Pin Bore Diameter (Max.) 40.042 mm Max. Variation any 5 0 mm (2 in) Diameter Area . . . 0.010 mm
(1.5764 in) (0.0004 in)
Side Clearance 0.100-0.300 mm Refacing Combustion Deck
(0.004-0.012 in)
First Reface 0.250 mm
Crankshaft (0.0098 in)
Second Reface 0.250 mm
Main Bearing Journal Diameter (0.0098 in)
Total Reface 0.500 mm
Standard 82.962 mm (0.0197 in)
(3.2662 in) Surface Finish , . 1.50-3.20 micrometers
Machined 0.25 mm 82.712 mm (60-126 microinches)
(0.0098 in) (3.2564 in) Main Bearing Bore Diameter (Max.) 83.106 mm
Machined 0.50 mm 82.462 mm with Bearing Installed (3.2719 in)
(0.0197 in) (3.2465 in)
Machined 0.75 mm 82.212 mm Camshaft Bore Diameter (Max.)
(0.0295 in) (3.2367 in)
Machined 1.00 mm . . . 81.962 mm No. 1 without Bushing 57.258 mm
0.0394 in) (3.2269 in) (2.2543 in)
Out-of-Round (Max.) 0.050 mm Nos. 1-7 with Bushing .54.133 mm
(0.002 in) (2.1312 in)
Taper (Max.) 0.013 mm
(0.0005 in) Cylinder H e a d
Oil Clearance (Max.) 0.119 mm
(0.0047 in) Flatness Max. Overall 0.030 mm
Connecting Rod Journal Diameter (0.012 in)
Max. Variation within 0.01 mm (0.0004 in) in any
Standard 68.962 mm 50.8 mm (2.00 in) diameter area.
(2.7150 in)
Machined 0.25 mm 68.712 mm Valve Seat Angle
(0.0098 in) (2.7052 in)
Machined 0.50 mm 68.462 mm Intake.......... ........30°
(0.0197 in) (2.6954 in)
Machined 0.75 mm 68.212 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 °
(0.0295 in) (2.6855 in)
Machined 1.00 mm 67.962 mm Valve Seat Width
(0.0394 in) (2.6757 in)
Out-of-Round (Max.) 0.050 mm Minimum 1.52 mm
(0.002 in) (0.060 in)
Taper (Max) 0.013 mm Maximum • 2.03 mm
(0.0005 in) (0.080 in)
Oil Clearance 0.089 mm Tappets
(0.0035 in)
End Clearance 0.100-0.430 mm Stem Diameter 15.925 mm
(0.004-0.017 in) (0.627 in)
J9409-4
ENGINE SPECIFICATIONS (CONT)
OH Pump Piston Pins
Tip Clearance (Max.) 0.1778 mm Diameter (Min.) . 39.990 mm

(0.007 in) (1.5744 in)
Gerotor Drive/Planetary to Port 0.127 mm Bore Diameter (Max.) 40.025 mm
Plate Clearance (Max) (0.005 in) (1.5758 in)
Gerotor Planetary to Body 0.381 mm Piston Rings
Clearance (Max.) (0.015 in)
G e a r Backlash (Used Pump) . 0 . 0 8 0 - 0 . 3 8 0 mm Ring End G a p
(0.003-0.015 in)
Top Ring 0 . 4 0 0 - 0 . 7 0 0 mm
Oil Pressure (0.016-0.0275 in)
Intermediate Ring 0 . 2 5 0 - 0 . 5 5 0 mm
At Idle Speed* 69kPa (0.010-0.0215 in)
(10 psi) Oil Control Ring 0 . 2 5 0 - 0 . 5 5 0 mm
At 2,500 rpm .207kPa (0.010-0.0215 in)
(30 psi)
Regulating Valve Opening Pressure 448 kPa
Valves
(65 psi)
Clearance — Intake 0.25 mm
(0.010 in)
Exhaust. . 0.51 mm
* CAUTIONs If pressure is Z E R O at curb idle, (0.020 in)
DO NOT run engine at 2,500 r p m .
Guide Diameter 8.019-8.089 mm
(0.3157-0.3185 in)
Stem Diameter . . . 7 . 9 3 5 - 7 . 9 6 0 mm
Oil Filter (0.3126-0.3134 in)
Depth (Installed) 0.99-1.52 mm
Differential Pressure to Open Filter 138 kPa (0.039-0.060 in)
(20 psi)
Valve Springs
Pistons
Free Standing Length 55.63 mm
Skirt Diameter 101.880-101.823 mm (2.19 in)
(4.0110-4.0088 in) Inclination (Max.) 1.00 mm
Ring Groove Depth (0.039 in)
Minimum Load @49.25 mm-289.32 N
Intermediate • 0.150 mm (@1.94 in-65 lbs)
(0.006 in)
Oil Control 0.130 mm
(0.005 in)
J9409-5
Description 1 Torque 1 [ Description Torque 1

Air Fuel Control Fitting (In Head) . . . . . . . . 8 N®m (6 ft. lbs.) Intercooler Attaching Bolts . . . . . . . . . . . . 2 N®m (17 in. lbs.)
Battery Cable (Negative) Intercooler Duct Clamp Nuts 8 N»m (72 in. lbs.)
Mounting to Block . 7 7 N*m (57 ft. lbs.)
Lifting Bracket (Rear) 7 7 N®m (57 ft. lbs.)
Belt Tensioner Mounting . 4 3 N ® m (32 ft. lbs.)
Block Heater Mounting . . . 1 2 N * m ( 9 f t . lbs.) Oil Cooler Assembly 24 N®m (18 ft. lbs.)
Oil Fill Tube Bracket Bolt 43 N « m (32 ft. lbs.)

C a b Heater Hose Clamp . . 4 N * m ( 3 5 in. lbs.)
Oil Filter . . ... ..... 3/4 Turn After Contact
C a b Heater Tubing Clamp Mounting . . . . 9 N « m ( 7 f t . lbs.)
Oil Pan Drain Plug 80 N « m (60 ft. lbs.)
Camshaft Thrust Plate Bolts . . . 24 N®m (210 in. lbs.)
Oil Pan Bolts 24 N*m (18 ft. lbs.)
Clutch Cover Mounting to
Flywheel Bolts . . . . . . . 2 3 N « m ( 1 7 f t . lbs.) Oil Pressure Regulator Plug 80 N*m (60 ft. lbs.)
Connecting Rod Bolts Oil Pressure Sender/Switch 16 N « m (12 ft. lbs.)
Step 1 (Alternately Tighten) 35 N*m (26 ft. lbs.
Step 2 (Alternately Tighten) 7 0 N « m ( 5 1 ft. lbs. Oil Pump Mounting Bolts . 24 N « m (18 ft. lbs.)
Step 3 (Alternately Tighten). .... 100 N « m (73 ft. lbs.
Oil Suction Tube (Flange) 24 N®m (18 ft. lbs.)
Cooling Fan Mounting to Fan Clutch . . . . 20 N « m (15 ft. lbs.)
Oil Suction Tube Brace Bolt . 24 N®m (18 ft. lbs.)
Crankshaft Main Bearing Bolts Oil Supply Fitting for Vacuum Pump . . . . 1
10 N*m (7 /? ft. lbs.)
Step 1 . . 6 0 N * m ( 4 5 f t . lbs.)
Step 2 . 1 1 9 N * m ( 8 8 ft. lbs Rear Mount — Support
Step 3 . . . 1 7 6 N * m ( 1 2 9 ft. lbs, Cushion-to-Crossmember Nut 41 N®m (30 ft. lbs.)
Cylinder Head Bolts Rear Mount — Support Cushion-to-Trans.
All Bolts. . . 9 0 N » m ( 6 6 f t . lbs.) Support Bracket Nuts 41 N»m (30 ft. lbs.)
All Long Bolts 1 2 0 N ® m ( 8 9 ft. lbs.)
Tighten All Bolts an Additional .90° Rear Mount — Transmission Support
Bracket Bolts 68 N®m (50 ft. lbs.)
Exhaust Manifold Bolts 43 N*m (32 ft. lbs.)
Rear Support Plate-to-Transfer
Fan Clutch Mounting/Fan Hub Case Bolts 41 N*m (30 ft. lbs.)
(Left Hand Threads) . . 5 7 N » m (42 ft. lbs.)
Rocker Arm Bolts 23 N » m (200 in. lbs.)
Fan Hub Bracket Mounting . . 2 4 N * m ( 1 8 f t . lbs.)
SparkPlugs 41 N*m (30 ft. lbs.)
Fan Hub Bearing Retaining Capscrew . . 77 N » m (57 ft. lbs.)
Starter Mounting Bolts 68 N»m (50 ft. lbs.)
Fan Pulley to Fan Hub . . . 9 N * m ( 7 f t . lbs.)
Throttle Body Bolts (MPI) 23 N*m (200 in. lbs.)
Fan Pulley Crankshaft . . . 9 N « m ( 7 f t . lbs.)
Torque Converter Drive Plate Bolts . . . . 31 N « m (270 in. lbs.)
Fan Shroud Mounting Nuts .11 N»m(95in.lbs.)
Transfer Case-to-lnsulator Mounting
Flywheel Bolts 137 N*m (101 ft. lbs.)
Plate Nuts 204 N » m (150 ft. lbs.)
Flywheel Housing Adaptor . 7 7 N » m (57 ft. lbs.)
Transmission Support Bracket Bolts
Front Mount — Thru-Bolt Nut . 102 N*m (75 ft. lbs.) (2WD) 68 N®m (50 ft. lbs.)
Front Mount — Engine Support Transmission Support Spacer Bolts

Bracket/Cushion Bolts . 41 N * m ( 3 0 ft. lbs.) (4WD) 68 N*m (50 ft. lbs.)
Transmission Support Spacer-to-lnsulator
Generator Mounting Bolts . . 41 N * m ( 3 0 f t . lbs.)
Mounting Plate Nuts (4WD) 204 N*m (150 ft. lbs.)
Generator Pulley . 8 0 N * m ( 5 9 f t . lbs.)
Vacuum Pump Oil Supply Line . . . . 10 N®m (7Vi ft. lbs.)
Generator Support (Upper) . . 2 4 N * m ( 1 8 f t . lbs.)
Vibration Damper Retainer Bolt . 183 N®m (135 ft. lbs.)
G e a r Cover . . 2 4 N « m ( 1 8 f t . lbs.)
. 2 4 N ® m ( 1 8 f t . lbs.) Water Pump-to-Chain Case Cover Bolt . . 41 N « m (30 ft. lbs.)

G e a r Housing Bolts
Intake Manifold Cover Bolts . 24 N*m (18 ft. lbs.) J9409-6

* EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
EXHAUST SYSTEM DIAGNOSIS 3 SERVICE PROCEDURES (GASOLINE ENGINES) . 4

GENERAL INFORMATION 1 SPECIFICATIONS 24
SERVICE PROCEDURES (DIESEL ENGINES) .. 13
EXHAUST SYSTEM occur. If a converter is heat-damaged, correct the
The gasoline engine exhaust system consists of en cause of the damage at the same time the converter
gine exhaust manifolds, exhaust pipes, catalytic con is replaced. Also, inspect all other components of the
verters), extension pipe (if needed), exhaust heat exhaust system for heat damage.
shields, muffler and exhaust tailpipe (Fig. 1). Unleaded gasoline must be used in gas engines to
The diesel engine exhaust system consists of an en avoid contaminating the catalyst core.
gine exhaust manifold, turbocharger, exhaust pipe,
catalytic converter, extension pipe (if needed), muffler EXHAUST HEAT SHIELDS
and exhaust tailpipe (Fig. 2). Exhaust heat shields are needed to protect both the
The engine exhaust manifolds on gasoline engines vehicle and the environment from the high tempera
are equipped with ball flange outlets to assure a tures developed by the catalytic converter. The com
tight seal and strain free connections. bustion reaction facilitated by the catalyst releases
The exhaust system must be properly aligned to additional heat in the exhaust system. Under severe
prevent stress, leakage and body contact. If the sys operating conditions, the temperature increases in
tem contacts any body panel, it may amplify objec the area of the reactor. Such conditions can exist
tionable noises from the engine or body. when the engine misfires or otherwise does not oper
When inspecting an exhaust system, critically in ate at peak efficiency. DO NOT remove spark plug
spect for cracked or loose joints, stripped screw or wires from plugs or by any other means short out
bolt threads, corrosion damage and worn, cracked or cylinders. Failure of the catalytic converter can occur
broken hangers. Replace all components that are due to a temperature increase caused by unburned
badly corroded or damaged. DO NOT attempt to re fuel passing through the converter.
pair. DO NOT allow the engine to operate at fast idle for
When replacement is required, use original equip extended periods (over 5 minutes). This condition
ment parts (or their equivalent). This will assure may result in excessive temperatures in the exhaust
proper alignment and provide acceptable exhaust system and on the floor pan.
noise levels.
EXHAUST GAS RECIRCULATION (EGR)—
CAUTION: Avoid application of rust prevention com
pounds or undercoating materials to exhaust s y s (GASOLINE ENGINES)
tem floor pan exhaust heat shields. Light overspray Tb assist in the control of oxides of nitrogen (NOx)
near the edges is permitted. Application of coating in engine exhaust, all engines are equipped with an
will result in excessive floor pan temperatures and exhaust gas recirculation system. The use of exhaust
objectionable fumes. gas to dilute incoming air/fuel mixtures lowers peak
flame temperatures during combustion, thus limiting
the formation of NOx.
CATALYTIC CONVERTER Exhaust gases are taken from openings in the ex
The stainless steel catalytic converter body is de haust gas crossover passage in the intake manifold.
signed to last the life of the vehicle. Excessive heat Refer to Group 25, Emission Control Systems for
can result in bulging or other distortion, but exces complete description, diagnosis and service proce
sive heat will not be the fault of the converter. If un- dures of the exhaust gas recirculation system and
burned fuel enters the converter, overheating may components.
11-2 EXHAUST SYSTEM AND INTAKE MANIFOLD •
CATALYTIC
CONVERTER
3.91, 5.2L
5.9L (LIGHT DUTY)
MUFFLER
TAILPIPE
CATALYTIC
CONVERTERS
5.9L (HEAVY DUTY)

8.0L
J9411-27
Fig. 1 Exhaust System—Gasoline Engines (Typical)
TURBOCHARGER (5.9L DIESEL ENGINE) Supplying increased air flow to the engine
A turbocharger is used to force more air into the provides:
engine cylinders. Exhaust gas energy is used to turn • Improved engine performance
the turbine wheel and shaft. At the other end of the • Lower exhaust smoke density
shaft is the compressor wheel. The compressor wheel • Improved operating economy
draws air in and forces it into the engine cylinders • Altitude compensation
through the intake manifold. • Noise reduction.
• EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
J9411-28
Fig. 2 Exhaust System—Diesel Engines (Typical)
E X H A U S T S Y S T E M DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST N O I S E 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.

2. Burned or blown-out muffler. 2. Replace muffler assembly. Check
exhaust system.
3. Burned or rusted-out exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold flange. 4. Tighten connection attaching nuts.
5. Exhaust manifold cracked or broken. 5. Replace exhaust manifold.
6. Leak between exhaust manifold and 6. Tighten exhaust manifold to cylinder
cylinder head. head stud nuts or bolts.
7. Restriction in muffler or tail pipe. 7. Remove restriction, if possible. Replace
muffler or tail pipe, as necessary.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Damaged or improperly installed gaskets. 2. Replace gaskets, as necessary.
ENGINE HARD TO WARM UP 1. Blocked crossover passage in intake 1. Remove restriction or replace intake
OR WILL NOT RETURN TO manifold. manifold.
NORMAL IDLE 2. Thermostat broken. 2. Replace thermostat.
J9211-3
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD •
SERWICE PROCEDURES {GASOLINE ENGINES}
INDEX
page page
Catalytic Converters 4 Exhaust Tailpipe 6
Engine Exhaust Manifold—V-10 Engine 11 Intake Manifold—V-10 Engine 9
Engine Exhaust Manifold—V-6 and V-8 Engines . . . 11 Intake Manifold—V-6 and V-8 Engines . . . . . . . . . . . 6
Exhaust Heat Shields 6 Mufflers 5
Exhaust Pipe 4
RETAINERS RIGHT SIDE

EXHAUST PIPE EXHAUST PIPE
REMOVAL
(2) Saturate the bolts and nuts with heat valve lu
bricant. Allow 5 minutes for penetration.
(3) Remove exhaust manifold bolts, retainers and
nuts (Fig. 1 or 2).
(4) Remove the clamp nuts (Fig. 1 or 3).
(5) Disconnect the exhaust pipe from the support
hangers on the 5.9L (Heavy Duty) and the 8.0L en
gines (Fig. 2).
(6) Remove the exhaust pipe.
J9411-23
RETAINERS
Fig. 2 Exhaust Pipe for 5.9L (Heavy Duty) and 8.0L
INSTALLATION
(1) Connect the exhaust pipe support hangers on
the 5.9L (Heavy Duty) and the 8.0L engine (Fig. 2).
(2) Position the exhaust pipe for proper clearance
with underbody parts.
(3) Position the exhaust pipe to manifold. Install
the bolts, retainers and nuts. Tighten the nuts to 34
(4) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)
torque.
EXHAUST
PIPE (6) Start the engine and inspect for exhaust leaks
J9411-24
and exhaust system contact with the body panels.
Fig. 1 Exhaust Pipe for 3.9L, S.2L and 5.9L (Light Adjust the alignment, i f needed.
Duty)
CATALYTIC CONVERTERS
CLEANING
Clean ends of pipes to assure mating of all parts. REMOVAL
INSPECTION (2) Saturate the bolts and nuts with heat valve lu
Discard rusted clamps, broken or worn supports bricant. Allow 5 minutes for penetration.
and attaching parts. Replace a component with orig (3) Remove clamps and nuts (Fig. 1, 3 and 4).
inal equipment parts, or equivalent. This will assure (4) Disconnect the catalytic converter from the sup
proper alignment with other parts i n the system and port hanger on the 3.9L, 5.2L and 5.9L (Light Duty)
provide acceptable exhaust noise levels. engines (Fig. 1).
• EXHAUST SYSTEM AND INTAKE MANIFOLD 11-5
INSTALLATION
(1) Connect the support hanger on the 3.9L, 5.2L
and 5.9L (Light Duty) engines (Fig. 1).
(2) Assemble converter and clamps loosely to per
mit proper clearance with exhaust heat shields and
underbody parts.
(3) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
torque.
(5) Start the engine and inspect for exhaust leaks
Adjust the alignment, i f needed.
MUFFLERS
REMOVAL
(2) Saturate the clamp nuts with heat valve lubri
cant. Allow 5 minutes for penetration.
(3) Disconnect the muffler hanger (Fig. 4 or 5).
(4) Remove clamps and nuts (Fig. 4 or 5).
(5) Remove the muffler.
Fig. 3 Exhaust Pipe Clamp Location for 5.9L (Heavy
Duty) and 8.0L
W/CLAMP J9411-20
Fig. 5 Muffler for 3.9L 5.2L and 5.9L (Light Duty)
9
Engines
Fig. 4 Catalytic Converter Clamp Location for 5.9L CLEANING
(Heavy Duty) and 8.0L Clean ends of pipes and muffler to assure mating
(5) Remove the catalytic converter. of all parts.
CLEANING INSPECTION
Clean ends of pipes and muffler to assure mating Discard rusted clamps, broken or worn hangers,
of all parts. supports and attaching parts. Replace a component
with original equipment parts, or equivalent. This
INSPECTION will assure proper alignment with other parts i n the
Discard rusted clamps, broken or worn supports system and provide acceptable exhaust noise levels.
and attaching parts. Replace a component with orig
inal equipment parts, or equivalent. This will assure INSTALLATION
proper alignment with other parts i n the system and (1) Assemble muffler and clamps loosely to permit
provide acceptable exhaust noise levels. proper alignment of all parts.
(2) Connect the muffler hanger.
(3) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)
torque.
11-6 EXHAUST SYSTEM AND INTAKE MANIFOLD •
(4) Lower the vehicle. CLEANING
(5) Start the engine and inspect for exhaust leaks Clean ends of pipes and muffler to assure mating
and exhaust system contact with the body panels. of all parts.
INSPECTION
EXHAUST TAILPIPE Discard rusted clamps, broken or worn hangers,
supports and attaching parts. Replace a component
REMOVAL with original equipment parts, or equivalent. This
(1) Raise and support the vehicle. will assure proper alignment with other parts i n the
(2) Saturate the clamp nuts with heat valve lubri system and provide acceptable exhaust noise levels.
cant. Allow 5 minutes for penetration.
(3) Disconnect the exhaust tailpipe support hanger INSTALLATION
(Fig. 6). I f used, disconnect the extension pipe sup (1) Loosely assemble exhaust tailpipe and exten
port hanger (Fig. 7). sion pipe, i f used, to permit proper alignment of all
(4) Remove clamps and nuts (Fig. 6). parts.
(5) Remove the exhaust tailpipe and extension (2) Connect the support hangers (Fig. 6 and 7).
pipe, i f used. (3) Position the exhaust tailpipe and extension
pipe, if used, for proper clearance with the underbody
parts.
torque.
EXHAUST HEAT SHIELDS
REMOVAL
(2) Remove the nuts or bolts holding the exhaust
CLAMP J9411-22
heat shield to the floor pan, crossmember or bracket.
Fig. 6 Exhaust Tailpipe (3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts.
INTAKE MANIFOLD—V-6 and V-8 ENGINES

The aluminum intake manifold is a single plane
design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear
cross-over gaskets. The intake manifold has internal
EGR.
REMOVAL
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(3) Remove the generator.
Fig. 7 Extension Pipe
(6) Disconnect the accelerator linkage and if so Inspect mating surfaces of manifold for flatness
equipped, the speed control and transmission kick- with a straightedge.
down cables.
(7) Remove the return spring. INSTALLATION
(8) Remove the distributor cap and wires. (1) Install the plenum pan, if removed, as follows:
(9) Disconnect the coil wires. (a) Turn the intake manifold upside down. Sup
(10) Disconnect the heat indicator sending unit port the manifold.
wire. (b) Place a new plenum pan gasket onto the seal
(11) Disconnect the heater hoses and bypass hose. rail of the intake manifold. Position the pan over
(12) Remove the closed crankcase ventilation and the gasket. Align all the gasket and pan holes with
evaporation control systems. the intake manifold.
(13) Remove intake manifold bolts. (c) Hand start all bolts.
(14) Lift the intake manifold and throttle body out (d) Tighten the bolts, in sequence (Fig. 2), as fol
of the engine compartment as an assembly. lows:
(15) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets. V-6 V-8
(16) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 1). Discard
the gasket.
THROTTLE
Fig. 2 Plenum Pan Bolt Tightening Sequence

• Step 1-Tighten bolts to 2.7 N-m (24 in. lbs.)
J9209-68 torque.
• Step 2-Tighten bolts to 5.4 N-m (48 in. lbs.)
Fig. 1 Throttle Body Assembly torque.
(17) Remove the plenum pan as follows: • Step 3-Tighten bolts to 9.5 N-m (84 in. lbs.)
(a) Turn the intake manifold upside down. Sup torque.
port the manifold. • Step 4—Check that all bolts are tighten to 9.5 N-m
(b) Remove the bolts and lift the pan off the (84 in. lbs.) torque.
manifold. Discard the gasket. (2) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N-m
CLEANING (200 in. lbs.) torque.
Clean manifold in solvent and blow dry with com (3) Place the 4 plastic locator dowels into the holes
pressed air. in the block Fig. 3).
Clean cylinder block front and rear gasket surfaces (4) Apply Mopar Silicone Rubber Adhesive Sealant,
using a suitable solvent. or equivalent, to the four corner joints. An excessive
The plenum pan rail must be clean and dry (free of amount of sealant is not required to ensure a leak
all foreign material). proof seal. However, an excessive amount of sealant
may reduce the effectiveness of the flange gasket.
INSPECTION The sealant should be slightly higher than the cross
Inspect manifold for cracks. over gaskets, approx. 5 mm (0.2 in).
(5) Install the front and rear cross-over gaskets FLANGE GASKET
onto the dowels (Fig. 3).
\
FRONT CROSS-OVER GASKET
REAR CROSS-OVER GASKET J9209-99
Fig. 3 Cross-Over Gaskets and Locator Dowels

(6) Install the flange gaskets. Ensure that the ver
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
/
CYLINDER
HEAD GASKET J9209-101
in position with the mating cylinder head gasket tabs
Fig. 4 Intake Manifold Flange Gasket Alignment
(Fig. 4). The words MANIFOLD SIDE should be vis
ible on the center of each flange gasket. INTAKE
MAN
(7) Carefully lower intake manifold into position on
the cylinder block and cylinder heads. Use the align
ment dowels in the cross-over gaskets to position the
intake manifold. After intake manifold is in place, in
spect to make sure seals are in place.
(8) Install the intake manifold bolts and tighten as
follows:
V-6 ENGINE—(Fig. 5)
• Step 1-Tighten bolts 1 and 2 to 8 N-m (72 in. lbs.)
torque. Tighten in alternating steps 1.4 N-m (12 in.
lbs.) torque at a time.
• Step 2—Tighten bolts 3 through 12, in sequence,
to 8 N-m (72 in. lbs.) torque.
• Step 3—Check that all bolts are tighten to 8 N-m
• Step 4—Tighten all bolts, in sequence, to 16 N-m
• Step 5—Check that all bolts are tighten to 16 N-m
(12 ft. lbs.) torque. FRONT OF ENGINE
V-8 ENGINE—(Fig. 6) J9209-59
• Step 1—Tighten bolts 1 through 4, in sequence, to Fig. S Intake Manifold Bolt Tightening Sequence
8 N-m (72 in. lbs.) torque. Tighten in alternating (V-6)
steps 1.4 N-m (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 5 through 12, in sequence, • Step 4—Tighten all bolts, in sequence, to 16 N-m
to 8 N-m (72 in. lbs.) torque. (12 ft. lbs.) torque.
• Step 3—Check that all bolts are tighten to 8 N-m • Step 5—Check that all bolts are tighten to 16 N-m
(72 in. lbs.) torque. (12 ft. lbs.) torque.
J9209-60
Fig. 6 Intake Manifold Bolt Tightening Sequence

(V-8) Fig. 7 Generator and A/C Compressor Braces
(9) Install closed crankcase ventilation and evapo

ration control systems.
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(13) Install distributor cap and wires.
down cables.
generator mounting bolt to 41 N*m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N*m
tem for the proper adjusting of belt tension.
Fig. 8 Air Intake Housing
(19) Fill cooling system (refer to Group 7, Cooling (7) Disconnect the fuel lines.
System for the proper procedure). (8) Disconnect the accelerator linkage and i f so
(20) Connect the negative cable to the battery. equipped, the speed control and transmission kick-
down cables.
INTAKE MANIFOLD—V-10 ENGINE (9) Remove the coil assemblies with the ignition
The aluminum intake manifold has two plenum cables.
chambers which supply air to five runners each. Pas (10) Disconnect the vacuum lines.
sages across the longitudinal center of the manifold (11) Disconnect the heater hoses and bypass hose.
feed air from the throttle body to the plenum cham (12) Remove the closed crankcase ventilation and
bers. evaporation control systems.
(13) Remove the throttle body bolts and lift the
REMOVAL
(1) Disconnect the negative cable from the battery. throttle body off the upper intake manifold (Fig. 9).
(2) Drain the cooling system (refer to Group 7, Discard the gasket.
Cooling System for the proper procedures). (14) Remove upper intake manifold bolts.
(3) Remove the accessory drive belt (refer to Group (15) Lift the upper intake manifold out of the en
7, Cooling System for the proper procedures). gine compartment (Fig. 9). Discard the gasket.
(4) Remove the generator brace and generator (Fig. (16) Remove the lower intake manifold bolts and
7). remove the manifold (Fig. 10).
(5) Remove the A/C compressor brace (Fig. 7). Re (17) Discard the lower intake manifold gaskets
move the compressor and set aside. (Fig. 11).
(6) Remove the air cleaner cover and filter. Remove
the air cleaner housing (Fig. 8). Discard the gasket.
UPPER INTAKE THROTTLE LOWER
Fig. 11 Lower Intake Manifold Gaskets
Fig. 10 Lower intake Manifold

CLEANING Fig. 12 Intake Manifold Flange Gasket Alignment
Clean manifolds i n solvent and blow dry with com
pressed air.
INSPECTION
Inspect manifolds for cracks.
Inspect mating surfaces of the manifolds for flat
ness with a straightedge.
INSTALLATION
(1) Install the intake manifold side gaskets. Be
sure that the locator dowels are positioned i n the
head (Fig. 12).
(2) Insert two dowels into the locator holes. Peel
the protective paper off and align the seal with the (BLUE PEEL-OFF) J9409-63
sticky side down. Press firmly onto the block (Fig.
13). Repeat for the other end. Front seal is BROWN Fig. 13 Intake Manifold-to-Block Seals and Locator
and rear seal is BLUE. Dowel Holes
(3) Apply Mopar Silicone Rubber Adhesive Sealant, (4) The lower intake manifold MUST be installed
or equivalent, into the four corner pockets (Fig. 11). within 3 minutes of sealant application. Carefully
Fill the pocket, but DO NOT overfill. lower intake manifold into position on the cylinder
• EXHAUST SYSTEM AND INTAKE MANIFOLD 11 11
block and heads. After intake manifold is i n place, in INSPECTION

spect to make sure seals and gaskets are i n place. Inspect manifold for cracks.
(5) Tighten the lower intake manifold bolts i n se Inspect mating surfaces of manifold for flatness
quence to 54 N-m (40 ft. lbs.) torque (Fig. 10). with a straight edge. Gasket surfaces must be flat
(6) Using a new gasket, position the upper intake within 0.2 mm per 300 mm (0.008 inch per foot).
manifold onto the lower intake manifold.
(7) Tighten upper intake manifold bolts i n se INSTALLATION
quence to 22 N-m (16 ft. lbs.) torque (Fig. 9).
CAUTION: If the studs came out with the nuts when
(8) Using a new gasket, install the throttle body
removing the engine exhaust manifold, install new
onto the upper intake manifold. Tighten the bolts to
studs. Apply sealer on the coarse thread ends. Wa
23 N-m (200 in. lbs.) torque.
ter leaks may develop at the studs if this precaution
(9) Install closed crankcase ventilation and evapo
is not taken..
ration control systems.
(10) Connect the heater hoses and bypass hose. (1) Position the engine exhaust manifolds on the
(11) Connect the vacuum lines. two studs located on the cylinder head. Install coni
(12) Install the coil assemblies and the ignition ca cal washers and nuts on these studs (Fig. 14 or 15).
bles. (2) Install two bolts and conical washers at the in
(13) Connect the accelerator linkage and i f so ner ends of the engine exhaust manifold outboard
equipped, the speed control and transmission kick- arms. Install two bolts WITHOUT washers on the
down cables. center arm of engine exhaust manifold (Fig. 14 or
(14) Install the fuel lines. 15). Starting at the center arm and working outward,
(15) . Using a new gasket, install the air cleaner tighten the bolts and nuts to 34 N-m (25 ft. lbs.)
housing. Tighten the nuts to 11 N-m (96 in. lbs.) torque.
torque. Install the air cleaner filter and cover. (3) Install the exhaust heat shields.
(16) Install the A/C compressor. Position the com (4) Raise and support the vehicle.
pressor brace and install the bolts. Tighten the brace (5) Assemble exhaust pipe to manifold and secure
bolts to 41 N-m (30 ft. lbs.) torque. with bolts, nuts and retainers. Tighten the bolts and
(17) Install the generator. Position the generator nuts to 26 N-m (19 ft. lbs.) torque.
brace and install the bolts. Tighten the brace bolts to (6) Lower the vehicle.
41 N-m (30 ft. lbs.) torque. (7) Connect the negative cable to the battery.
(18) Install the accessory drive belt (refer to Group
7, Cooling System).
ENGINE EXHAUST MANIFOLD—V-6 and V-8

ENGINES
Engine exhaust manifolds are LOG type with port
ing for air injection into the LOG.
REMOVAL
(3) Remove the bolts and nuts attaching the ex
haust pipe to the engine exhaust manifold.
(4) Lower the vehicle. . Fig. 14 Engine Exhaust Manifold Installation—3.9L
(5) Remove the exhaust heat shields. Engine
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
ENGINE EXHAUST MANIFOLD—V-10 ENGINE
(7) Remove manifold from the cylinder head. Engine exhaust manifolds are made of high molyb
denum ductile cast iron. A special ribbed design helps
CLEANING control permanent dimensional changes during heat
Clean mating surfaces on cylinder head and mani cycles.
fold. Wash with solvent and blow dry with com
pressed air.
J9311-11
Fig. 15 Engine Exhaust Manifold Installation—5.2U

5.9L Engines
REMOVAL
(1) Disconnect the negative cable from the battery. SHIELD J941H4
(3) Remove the bolts and nuts attaching the ex
Fig. 17 Left Engine Exhaust Manifold
haust pipe to the engine exhaust manifold.
(4) Lower the vehicle. (9) Remove manifold from the cylinder head. Dis
(5) Remove the exhaust heat shields (Figs. 16 ajid card the gasket.
17).
(6) Right exhaust manifold—Remove the EGR tube CLEANING
and gasket (Fig. 16). Discard the gasket. Clean mating surfaces on cylinder head and manifold.
Wash with solvent and blow dry with compressed air.
EXHAUST
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
(1) Using a new gasket position the engine exhaust
manifold onto the cylinder head. Refer to Figs. 16 and
17 to install bolts and stud bolts in the proper position.
Tighten the bolts to 22 N-m (16 ft. lbs.) torque.
(2) Right side exhaust manifold—Install the EGR
tube using a new gasket (Fig. 16). Tighten the tube
assembly nut to 34 N-m (25 ft. lbs.) torque. Tighten
the two EGR nuts to 20 N-m (175 in. lbs.) torque.
(3) Right exhaust manifold—Install the dipstick
bracket to the manifold.
HEAT (4) Position washers and exhaust heat shields onto
SHIELD J9411-13 the manifold stud bolts (Figs. 16 and 17). Be sure the
tabs on the heat shields align with slots i n the gas
Fig. 16 Right Engine Exhaust Manifold and EGR ket. Install the nuts and tighten to 20 N-m (175 in.
Tube lbs.) torque.
(7) Right exhaust manifold—Remove the dipstick (6) Assemble exhaust pipe to manifold and secure with
bracket from the manifold. bolts. Tighten the bolts to 34 N-m (25 ft. lbs.) torque.
(8) Remove bolts attaching manifold to cylinder (7) Lower the vehicle.
head. (8) Connect the negative cable to the battery.
SERVICE PROCEDURES ( D I E S E L ENGINES)
INDEX
page page
Catalytic Converters 13 Exhaust Tailpipe 14
Charge Air Cooler (Intercooler) 22 Intake Manifold Cover / Air Intake Heater . . . . . . . . 16
Engine Exhaust Manifold 15 Muffler . 14
Exhaust Heat Shields 15 Turbocharger 17
Exhaust Pipe 13 Wastegate Adjustment 22
EXHAUST PIPE (3) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)
torque.
REMOVAL (4) Install the exhaust pipe support clamps and
(1) Raise and support the vehicle on a hoist. nuts. Tighten the nuts to 54 N-m (40 ft. lbs.) torque.
(2) Saturate the bolts and nuts with heat valve lu (5) Lower the vehicle.
bricant. Allow 5 minutes for penetration. (6) Start the engine and inspect for exhaust leaks
(3) Remove the bolts and nuts from the exhaust and exhaust system contact with the body panels.
pipe to turbocharger exhaust pipe (Fig. 1). Adjust the alignment, if needed.
(4) Remove the clamp nuts.
(5) Disconnect the exhaust pipe support hanger. CATALYTIC CONVERTERS
REMOVAL
(2) Saturate the bolts and nuts with heat valve lu
bricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts (Fig. 2).
J9411-18
Fig. 1 Exhaust Pipe Mounting

CLEANING
Clean ends of pipes to assure mating of all parts.
INSPECTION
Discard rusted clamps, broken or worn supports Fig. 2 Catalytic Converter
and attaching parts. Replace a component with orig
inal equipment parts, or equivalent. This will assure (4) Remove the catalytic converter.
proper alignment with other parts in the system and CLEANING
provide acceptable exhaust noise levels. Clean ends of pipes and muffler to assure mating
of all parts.
INSTALLATION
(1) Connect the exhaust pipe support hangers (Fig. INSPECTION
Discard rusted clamps and attaching parts. Replace
(2) Align the exhaust pipe with the turbocharger a component with original equipment parts, or equiv
exhaust pipe and the catalytic converter. Install the alent. This will assure proper alignment with other
bolts and nuts. Tighten the nuts to 34 N-m (25 ft. parts in the system and provide acceptable exhaust
lbs.) torque. noise levels.
INSTALLATION EXHAUST TAILPIPE
(1) Assemble converter and clamps loosely to per
mit proper clearance with exhaust heat shields and REMOVAL
underbody parts. (1) Raise and support the vehicle.
(2) Tighten all clamp nuts to 43 N-m (32 ft. lbs.) (2) Saturate the clamp nuts with heat valve lubri
torque. cant. Allow 5 minutes for penetration.
(3) Lower the vehicle. (3) Disconnect the exhaust tailpipe support hanger
(4) Start the engine and inspect for exhaust leaks (Fig. 4). I f used, disconnect the extension pipe sup
and exhaust system contact with the body panels. port hanger (Fig. 5).
Adjust the alignment, i f needed. (4) Remove clamps and nuts (Fig. 4).
(5) Remove the exhaust tailpipe and extension
MUFFLER pipe, i f used.
REMOVAL
(2) Remove the clamps and nuts (Fig. 3).
(3) Disconnect the support hanger (Fig. 3).
(4) Remove the muffler.
CLAMP J9411-22
Fig. 4 Exhaust Tailpipe
W/CLAMP J9411-20
Fig. 3 Muffler
CLEANING
Clean ends of pipes and muffler to assure mating
of all parts.
INSPECTION
Discard rusted clamps, broken or worn hangers,
will assure proper alignment with other parts i n the
system and provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the support hanger (Fig. 3).
(2) Install the clamps and nuts. Tighten the nuts
(3) Lower the vehicle. Fig. 5 Extension Pipe (Typical)
(4) Start the engine and inspect for exhaust leaks CLEANING
and exhaust system contact with the body panels. Clean ends of pipes and muffler to assure mating
Adjust the alignment, i f needed. of all parts.
• EXHAUST SYSTEM AND INTAKE MANIFOLD . 1 1 - 1 5
INSPECTION
Discard rusted clamps, broken or worn hangers,
will assure proper alignment with other parts in the
system and provide acceptable exhaust noise levels.
INSTALLATION
(1) Loosely assemble exhaust tailpipe and exten
sion pipe, if used, to permit proper alignment of all
parts.
(2) Connect the support hangers (Fig. 4 and 5).
(3) Position the exhaust tailpipe and extension
pipe, if used, for proper clearance with the underbody
parts.
torque.
Adjust the alignment, if needed.
Fig. 6 Air Intake Pipe, Exhaust Pipe and
EXHAUST HEAT SHIELDS Turbocharger
REMOVAL
(2) Remove the nuts or bolts holding the exhaust
heat shield to the floor pan, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts.
ENGINE EXHAUST MANIFOLD

REMOVAL
(1) Disconnect the air intake and exhaust pipes
(Fig. 6).
(2) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 7).
(3) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 7).
(4) Remove the turbocharger and gasket. Fig. 7 Oil Supply Line and Charge Air Cooler
(5) Remove the cab heater supply and return lines. (Intercooler) Inlet Duct
(6) Remove the engine exhaust manifold and gas (3) Position the charge air cooler (intercooler) inlet
kets (Fig. 8). duct to the turbocharger. With the clamp in position,
(7) Clean the sealing surfaces. tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(4) Position the air intake pipe and the exhaust
INSTALLATION
pipe onto the turbocharger. Tighten the clamps to 8
(1) Install the engine exhaust manifold and gas
kets. Tighten the exhaust manifold bolts in sequence
to 43 N-m (32 ft. lbs.) torque (Fig. 9). (5) Install the oil drain tube and oil supply line to
(2) Install the turbocharger. Tighten the turbo the turbocharger. Tighten the drain tube bolts to 24
charger mounting nuts to 32 N-m (24 ft. lbs.) torque.
11 • 16 EXHAUST SYSTEM AND INTAKE MANIFOLD ^ ^ — ^— ^ ^ •
Fig. 10 Air inlet Tube and Heater Ground Wire
F/g. 9 Engine Exhaust Manifold Bolt Tightening

Sequence
N-m (18 ft. lbs.) torque. Tighten the oil supply line
fitting nut to 15 N-m (11 ft. lbs.) torque.
75^ "J9HM1
(6) Connect the cab heater supply and return lines.
Tighten the line nuts to 24 N-m (18 ft. lbs.) torque. Fig. 11 Air Intake Heater
(7) Operate the engine to check for leaks.
(7) Disconnect the fuel heater ground wire from in
INTAKE MANIFOLD COVER / AIR INTAKE HEATER take manifold cover (Fig. 13).
(8) Remove the manifold intake cover and gasket
REMOVAL (Fig. 13). Keep the gasket material and any other
(1) Remove the charge air cooler (intercooler) out material out of the air intake.
let duct from the air inlet tube (Fig. 10). (9) Clean the sealing surface.
(2) Remove the high pressure fuel lines.
(3) Disconnect and remove the air intake heater INSTALLATION
ground wire (Fig. 10). (1) Using a new gasket, install the intake manifold
(4) Disconnect the air intake heater power supply cover.
lines (Fig. 11). Remove the air intake heater and gas (2) Install the fuel heater ground wire. Tighten the
kets (Fig. 11). Clean the mounting surface of the in bolt to 12 N-m (110 in. lbs.) torque.
take manifold cover. (3) Connect the air temperature switch to the in
(5) Disconnect the charge air temperature sensor take manifold cover.
from the intake manifold cover (Fig. 12). (4) Connect the charge air temperature sensor to
(6) Disconnect the air temperature switch from the the intake manifold cover.
intake manifold cover (Fig. 12).
EXHAUST SYSTEM AND INTAKE MANIFOLD 11-17
TURBOCHARGER
REMOVAL
(2) Disconnect the air intake pipe and exhaust pipe
(Fig. 14).
Fig. 12 Charge Air Temperature Sensor and Air

Temperature Switch
MANIFOLD FUEL HEATER
Fig. 14 Air Intake Pipe, Exhaust Pipe and

Turbocharger
(3) Remove the oil drain tube bolts.
(4) Remove the oil supply line (Fig. 15).
(5) Disconnect the charge air cooler (intercooler)
Fig. 13 Manifold Intake Cower and Fuel Heater
inlet duct from the turbocharger (Fig. 15).
Ground Wire
(6) Remove the turbocharger mounting nuts and
the turbocharger.
(5) Some of the intake manifold bolt holes are (7) I f the turbocharger is not to be installed imme
drilled through and must be sealed. Apply liquid te diately, cover the opening to prevent material from
flon sealant to the bolts. Install the intake manifold entering into the manifold.
cover bolts. Tighten the bolts to 24 N-m (18 ft. lbs.) (8) Clean and inspect the sealing surface.
torque.
(6) Install a new gasket between the air intake DISASSEMBLY
heater and the intake manifold cover. Install a new (1) Scribe the housing so they can be assembled i n
gasket on top of the air intake heater. the same position.
(7) Install the air inlet tube. Tighten the air inlet (2) Clamp the turbocharger i n a bench vise.
tube bolts to 24 N-m (18 ft. lbs.) torque. (3) Remove the compressor housing V-Band clamps
(8) Connect the intake manifold heater ground (Fig. 16).
wire. (4) Remove the compressor housing and inspect for
(9) Install and tighten the air intake heater power impeller contact (Fig. 16).
supply nuts to 14 N-m (10 ft. lbs.) torque. (5) Remove the square cut O-ring (Fig. 16).
(10) Position the charge air cooler (intercooler) out (6) Remove the impeller nut (Fig. 16). Turn the im
let duct onto the air inlet tube. Tighten the charge peller nut to the right to loosen. The nut and shaft
air cooler (intercooler) outlet duct clamps to 8 N-m have left hand threads.
(74 in. lbs.) torque. (7) Remove the impeller and inspect the blades for
(11) Install and bleed the high pressure fuel lines. damage. The wheel and shaft assembly is balanced
Tighten the high pressure fuel line nuts to 24 N-m as a unit. I f the impeller is damaged the complete as
(18 ft. lbs.) torque. sembly must be replaced.
j^HHgtt in i i DIFFUSER
^^^^^^^k^J^WV" EXHAUST 'Jl

/ MANIFOLD
TURBINE
HOUSING LOCKPLATE J9111-9
Fig. 17 Diffuser and Lockplate

O-RING OIL
SLINGER
Fig. 15 0#7 Supply Line and Charge Air Cooler

(Intercooler) Inlet Duct
IMPELLER
O-RING
J9111-10
Fig. 18 Diffuser, O-ftlng and Oil Slinger
V-BAND THRUST
CLAMP COLLAR
COMPRESSOR H O U S I N G
J9111-8
Fig. 16 Compressor Housing and Impeller

OIL
(8) Remove the diffuser bolts and lockplate (Fig. BAFFLE
17).
(9) Remove the diffuser and discard the O-ring
(Fig. 18).
(10) Remove the oil slinger and discard the piston
ring (Fig. 18).
(11) Inspect for cracks and excessive wear.
(12) Remove the oil baffle (Fig. 19). J9111-11
(13) Remove the thrust bearing and retainer
screws (Fig. 19). Do not reuse the thrust bearing. Fig. 19 Oil Baffle, Thrust Bearing and Collar
(14) Remove the thrust collar (Fig. 19). (18) Remove the turbine shaft and heat shield (Fig.
(15) Inspect the collar for excessive wear. 21).
(16) Remove the turbine housing lock plates and (19) Inspect the turbine blades and the shaft for
clamp plates (Fig. 20). excessive wear.
(17) Remove the bearing housing (Fig. 20).
Fig. 20 Turbine Housing Lock Plates and Clamp

Plates
(20) Remove and discard the piston ring type seal
(Fig. 21).
J9111-14
CAUTION: The w h e e l a n d shaft assembly is bal
anced a s a unit. If t h e t u r b i n e blades or shaft are Fig. 22 Snap Rings and Shaft Bearing
damaged, t h e c o m p l e t e a s s e m b l y m u s t be replaced. Measure the shaft bearing diameter (Fig. 23). The
(21) Remove and discard the outer retainer rings minimum diameter should be 10.97 mm (0.432 inch).
(Fig. 22).
(22) Remove and discard the turbocharger shaft ASSEMBLE
bearings (Fig. 22), SHAFT BEARING
(23) Remove and discard the inner snap rings (Fig.
| J9111-15
Fig. 23 Shaft Bearing Diameter

The balance marks must be aligned to make sure
the wheel and shaft assembly is balanced.
Fig. 21 Turbine Wheel Shaft and Heat Shield (1) Install the piston ring and lubricate the groove
with engine oil.
CLEANING (2) Install the heat shield (Fig. 24).
Use a stiff bristle nylon brush and solvent to clean (3) Clamp a socket i n a soft jawed vice and posi
all parts. Do not use a wire brush on the compressor tion the shaft i n the socket.
wheel. Do not bead blast the parts. (4) Install the inner retainer rings. The beveled
Remove the carbon build up from the housing with face must be towards the bearing (Fig. 25).
a scraper and a 240 grit emery cloth.
(5) Lubricate the turbocharger bearing with engine
Polish the bearing surfaces with crocus and kero
oil and install the bearings i n the housing.
sene or diesel fuel.
(6) Install the outer retainer ring. The beveled face
After rinsing i n clean solvent, use compressed air
must be towards the bearings (Fig. 26).
to dry the parts.
(7) Assemble the turbine shaft and heat shield to
INSPECTION the bearing housing. Rotating the housing as you
I n addition to the inspection specified during disas press downward will assist i n properly seating the
sembly, inspect all parts after cleaning. piston ring.
11 - 2 0 EXHAUST SYSTEM AND INTAKE MANIFOLD •
HEAT SHIELD (10) Install the oil baffle. Check the balance mark
alignment.
(11) Install the piston ring type seal on the oil
slinger (Fig. 27).
Fig. 24 Turbine Shaft/Heat Shield to Bearing

Housing
Fig. 27 Piston Ring Type Seal

(12) Mark the top surface of the oil slinger line
with the balance mark.
(13) Lubricate the oil slinger with engine oil and
install it into the diffuser.
(14) Install the O-ring into the diffuser.
(15) Install the diffuser. Align the balance marks
on the shaft and the oil slinger (Fig. 28).
Fig. 25 Beveled Face of Inner Retainer Ring
Fig. 28 Align Balance Marks—Shaft and Oil Slinger

(16) Align the balance mark and install the impel
ler (Fig. 29). Be careful not to move the bearing
housing.
(17) Do not allow the impeller to turn when in
stalling the nut. The impeller nut and the shaft have
Fig. 26 Beveled Face of Outer Retainer Ring
L E F T hand threads. Tighten the nut to 14 N-m (129
(8) Install the thrust collar. Align the balance in. lbs.) torque.
mark with the balance mark on the shaft. Mark the (18) Install the bearing housing assembly into the
top surface with a marker pen so alignment can be turbine housing (Fig. 30).
verified after installing the thrust bearing. (19) Align the scribe marks (Fig. 30).
(9) Lubricate the thrust bearing with engine oil (20) Apply anti-seize compound to the bolt threads.
and install it on the housing. Tighten the torx bolts (21) Install the clamp plates, lock plates and bolts
to 4.5 N-m (40 in. lbs.) torque. (Fig. 31). Tighten the bolts to 11.3 N-m (100 in. lbs.)
torque.
Fig. 32 Diffuser and Lockplate

(24) Measure the end play (Fig. 33). For turbo
charger with a serial number before 840638 the end
play should be 0.102-0.152 mm (0.004-0.006 inch).
For turbocharger with a serial number of 840638 and
after the end play should be 0.026-0.076 mm (0.001-
0.003 inch).
(25) Measure radial clearance of the shaft (Fig.
33). The clearance should be 0.300-0.460 mm (0.012-
0.018 inch).
Fig. 33 End Play/Radial Clearance of Shaft

(26) Install the square cut O-ring.
(27) Be sure the scribe marks are aligned. Install
the compressor housing and V-Band clamp. Apply an-
ti-seize compound to the V-Band bolt threads.
Tighten the clamp to 8 N-m (72 in. lbs.) torque. Tap
against the clamp on 4 places around its circumfer
Fig. 31 install Clamp Plates/Lock Plates ence. Again tighten the clamp to 8 N-m (72 in. lbs.)
(22) Install the lock plates and bolts into the dif torque.
fuser (Fig. 32).
INSTALLATION
(23) After tightening the bolts to 5.7 N-m (50 i n .
(1) Install a new gasket and apply anti-seize com
lbs.) torque, bend the lockplate tabs to lock the bolts.
pound to the mounting studs.
Be sure the scribe marks are aligned.
(2) Install the turbocharger. Tighten the turbo
charger mounting nuts to 32 N-m (24 ft. lbs.) torque.
(3) Use a new gasket and connect the drain line.
Tighten the drain line connection bolts to 24 N-m (18
ft. lbs.) torque.
(4) New turbocharger must be pre-lubricated with
clean engine lubricating oil before start up. Pour
50-60 cc (2-3 ounces) of oil into supply fitting.
WARNING: DO NOT U S E Y O U R FINGER TO TURN

T H E TURBINE W H E E L .
(5) Rotate the turbine wheel to allow oil to enter

the turbocharger.
(6) Install the oil supply line. Tighten the oil sup
ply line fitting nut to 15 N-m (11 ft. lbs.) torque.
(7) Position the Charge air cooler (intercooler) inlet
duct to the turbocharger. With the clamp i n position,
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(8) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8
(9) Connect the negative cable to the battery. Fig. 34 Wastegate Turbocharger
(10) Operate the engine and check for leaks.
WASTEGATE ADJUSTMENT
The wastegate turbocharger provides additional
low speed boost without over-boost at high speeds.
This increases low speed torque and better driveabil-
ity.
Proper adjustment of the wastegate assembly is
critical to the operation of the wastegate turbo
charger (Fig. 34). The control rod is set at the factory
and no adjustment should be necessary, unless
wastegate assembly is damaged.
CAUTION: DO NOT adjust the wastegate s o that

higher pressures are required to open the waste-
gate valve. The turbocharger speed will be in
creased and can c a u s e damage to the turbocharger Fig. 35 Wastegate and Dial Indicator
and c a u s e a loss of engine performance.
(4) Adjust the length of the clevis end of the con
(1) Connect regulated air pressure to the waste- trol rod to align the clevis pin hole to the wastegate
gate actuator (Fig. 35). Install a dial indicator to lever. Install the adjusting link and retaining clip
measure the control rod movement. Apply 103 - 138 (Fig. 36).
kPa (15 - 20 psi) to seat the components and take
any slack out of the control rod. Release the air pres CAUTION: DO NOT pull, push or force the align
sure and zero the dial indicator gauge. ment of the clevis pin.
(2) Apply 133 kPa (19.3 psi) air pressure to the ac
tuator. The control rod should move 0.33 - 1.27 mm (5) After the adjustment is complete, tighten the
(0.013 - 0.050 in) total travel. I f the rod travel is out actuator rod jam nut (Fig. 36).
of limits, the wastegate linkage must be adjusted. (6) Recheck the travel on the wastegate control
(3) To adjust the wastegate linkage, apply air pres rod. Adjust, i f necessary.
sure to the actuator to release the spring tension on
the lever. Remove the control rod from the wastegate CHARGE AIR COOLER (INTERCOOLER)
lever (Fig. 36). Pull the wastegate lever toward the Intake air is drawn through the air cleaner and
actuator (closed position). into the turbocharger compressor housing. Pressur-
WASTEGATE ACTUATOR J9411-17
Fig. 36 Adjustment of Wastegate Actuator

ized air from the turbocharger then flows forward
through the charge air cooler (intercooler) located i n
front of the radiator. From the charge air cooler (in
tercooler) the air flows back into the intake manifold.
The charge air cooler (intercooler) is a heat ex
changer that uses air flow to dissipate heat from the
intake air. As the turbocharger increases air pres
sure, the air temperature increases. Lowering the in
take air temperature increases engine efficiency and
power.
REMOVAL
WARNING: IF T H E ENGINE WAS J U S T TURNED

OFF, T H E INTAKE AND O U T L E T D U C T S MAY B E
HOT
(1) Remove the grille (refer to Group 23, Body for Fig. 38 Charge Air Cooler (Intercooler) Ducts
(2) Install the inlet and outlet ducts to the charge
(2) Remove the front support bracket (Fig. 37).
(3) I f the vehicle is equipped with air conditioning, air cooler (intercooler)—(Fig. 38). With the clamps i n
remove the condenser as follows: position, tighten the clamp nut to 8 N-m (72 in. lbs.)
(a) Discharge the air conditioning system (refer torque.
to Group 24, Heating and Air Conditioning for the (3) I f the vehicle is equipped with air conditioning,
proper procedures). install the condenser as follows:
(b) Remove the bolt from the sealing plate (Fig. (a) Position the condenser and sealing plate as
37). sembly onto the charge air cooler (intercooler)
(c) Remove the nuts holding the condenser to the studs. Install the nuts and tighten.
charge air cooler (intercooler) (Fig. 37). Lift the (b) Connect the halves of the sealing plate (Fig.
condenser and sealing plate assembly away from 37). Install the bolt and tighten.
the charge air cooler (intercooler). (c) Charge the air conditioning system (refer to
(4) Remove the inlet and outlet ducts from the Group 24, Heating and Air Conditioning for the
charge air cooler (intercooler)—(Fig. 38). proper procedures).
(5) Remove the charge air cooler (intercooler) bolts. (4) Install the front support bracket (Fig. 37). In
Pivot the charge air cooler (intercooler) forward and stall and tighten the bolts.
up to remove. (5) Install the grille (refer to Group 23, Body for
INSTALLATION
(1) Position the charge air cooler
(intercooler)—(Fig. 37). Install the bolts and tighten
SPECIFICATIONS
TURBOCHARGER SPECIFICATIONS
COMPONENT DIMENSIONS
635 mm Water (25 in. Water) Max.
0 . 3 0 0 - 0 . 4 6 0 mm (0.012-0.018 inch)
Turbo Rotor Assembly End Play
Before S/N 840638 0.102-0.152 mm ( 0 . 0 0 4 - 0 . 0 0 6 inch)

S/N 840638 A N D AFTER 0 . 0 2 6 - 0 . 0 7 6 mm (0.001-0.003 inch)
10.97 (0.432 inch)
J9111-26
Adjusting Strap Bolt 23 N-m (200 in. lbs.) Muffler-to-Tail Pipe Clamp Nuts 43 N-m (32 ft. lbs.)
Air Heater Power Supply Nuts 14 N-m (10 ft. lbs.)
Plenum Pan Bolts (3.9L & 5.2L)
Cab Heater Supply/Return Line Nuts 24 N-m (18 ft. lbs.) 1st Step 2.7 N-m (24 in. lbs.)
Catalytic Converter-to-Muffler 2nd Step 5.4 N-m (48 in. lbs.)
Clamp Nuts 43 N-m (32 ft. lbs.) 3rd Step.. 9.5 N-m (84 in. lbs.)
Exhaust Manifold-to-Cylinder Throttle Body (MPI) Bolts.. 23 N-m (200 in. lbs.)
Head Bolts (5.9L Diesel) 43 N-m (32 ft. lbs.) Throttle Control Bracket
Exhaust Manifold-to-Cylinder Mounting Bolts 24 N-m (18 ft. lbs.)
Head Bolts/Nuts 34 N-m (25 ft. lbs.) Thrust Bearing Torx Bolts 4.5 N-m (40 in. lbs.)
Exhaust Pipe-to-Catalytic Turbocharger Bearing Housing/
Converter Clamp Nuts 43 N-m (32 ft. lbs.) Diffuser Bolts 5.7 N-m (50 in. lbs.)
Exhaust Pipe-to-Exhaust Turbocharger Bearing Housing/
Manifold Bolts/Nuts 26 N-m (19 ft. lbs.) Turbine Housing Bolts 11.3 N-m (100 in. lbs.)
Fuel Heater Ground Bolt 12 N-m (110 in. lbs.) Turbocharger Impeller Nut 14 N-m (129 in. lbs.)
Fuel Line Nuts 24 N-m (18 ft. lbs.) Turbocharger Mounting Nuts 32 N-m (24 ft. lbs.)
Turbocharger Oil Drain Tube Bolts 24 N-m (18 ft. lbs.)
Generator Mounting Bolt 41 N-m (30 ft. lbs.) Turbocharger Oil Supply Line Fitting Nut 15 N-m (11 ft. lbs.)
Turbocharger V-Band Clamp 8.5 N-m (75 in. lbs.)
Intake Manifold Capbolts Refer to Procedure in
Service Manual.
Intake Manifold Cover Bolts 24 N-m (18 ft. lbs.) J9311-12
Intercooler Attaching Bolts. 2 N-m (17 in. lbs.)
Intercooler Duct Clamp Nuts 8 N-m (72 in. lbs.)
• BUMPERS AND FRAME 13 - 1
BUMPERS AND FRAME
CONTENTS
page page
BUMPERS AND FRAME COMPONENTS 1 SNOW PLOW 5

FRAME 23
B U M P E R S AND FRAME COMPONENTS
INDEX
page page
Front Bumper 1 Rear Bumper 3

Front Bumper Air D a m 2 Skid Plate 2
Front Bumper Lower F a s c i a 1 S p a r e Tire Winch 3
Front Bumper Upper F a s c i a 1 Trailer Hitch 4
FRONT BUMPER
REMOWAL (FIG. 1)
(1) Support front bumper on a suitable lifting de
vice.
(2) Remove bolt holding front bumper brace to
frame rail.
(3) Remove nuts and stud plates holding front
bumper to end of frame rail.
(4) Disengage wire connectors from horns.
(5) Separate front bumper from vehicle.
INSTALLATION
FRONT BUMPER UPPER FASCIA
REMOWAL (FIG. 2)
(1) Remove bumper.
(2) Disengage clips holding upper fascia to bumper
face bar.
(3) Separate fascia from bumper.
Fig. 1 Front Bumper
INSTALLATION (3) Disengage clips holding lower fascia to bumper
Reverse the preceding operation. face bar.
(4) Separate lower fascia from bumper.
FRONT BUMPER LOWER FASCIA
INSTALLATION
REMOWAL (FIG. 3) Reverse the preceding operation.
(1) Remove bumper.
(2) Disengage clips holding end of upper fascia to
bumper face bar.
13 - 2 BUMPERS AND FRAME •
RETAINING UPPER BUMPER
LOWER RETAINING
FASCIA CLIP J9413-3 AIR DAM SCREW J9413-4
Fig. 2 Front Bumper Upper Fascia Fig. 4 Front Bumper Air Dam
SKID PLATE
REMOVAL (FIG* 5)
(1) Hoist and support vehicle on safety stands.
(2) Remove bolts holding skid plate to frame rails.
(3) Separate skid plate from vehicle.
INSTALLATION
J9413-2
Fig. 3 Front Bumper Lower Fascia

FRONT BUMPER AIR DAM
Fig. 5 Skid Plate
REMOVAL (FIG. 4)
(1) Remove Pin-type fasteners holding air dam to
bottom of front bumper.
(2) Remove screws holding air dam to bottom of
front bumper.
(3) Separate air dam from vehicle.
INSTALLATION
SPARE TIRE WINCH

REMOVAL (FIG. 6)
(1) Remove spare tire from under vehicle.
(2) Remove bolts holding spare tire winch to spare
tire bracket.
(3) Separate spare tire winch from vehicle.
INSTALLATION
REAR BUMPER
REMOWAL (FIG. 7)
(1) Support rear bumper on a suitable lifting de
vice.
(2) Remove bolts holding rear bumper braces to
frame rails.
(3) Disengage license plate lamp wire connector
from body wire harness, i f equipped.
(4) Separate rear bumper from vehicle.
INSTALLATION
Reverse the preceding operation. Fig. 6 Spare Tire Winch
J9413-8
Fig. 7 Rear Bumper

13 - 4 BUMPERS AND FRAME
TRAILER HITCH
REMOVAL (FIG. 8)
(1) Support trailer hitch on a suitable lifting de
vice.
(2) Remove fasteners holding trailer wiring connec
tor to trailer hitch, i f equipped.
(3) Remove bolts holding trailer hitch to frame
rails.
(4) Separate trailer hitch from vehicle.
INSTALLATION
HITCH
Fig. 8 Trailer Hitch

SNOW PLOW
INDEX
page page
Power Angling Cylinder Service 19 Snow Plow Malfunction Diagnosis and Tests ...... 6
Power Unit 16 Snow Plow Pivot Bracket 19
Service Information 5 Snow Plow Wiring Diagrams 6
Snow Plow Control Module 20 System Description and Operation 5
Snow Plow Frame 19
SERVICE INFORMATION If the Made impacts obstructions, t h e p i n will

The snow plow option is available on four wheel drive shear to protect the snow plow a n d the vehicle
BR vehicles. Refer to figure 1 for primary mechanical from damage. The pin is not used with power
components. angle plowing.
• Power Angling Cylinders—Enable the operator to
LIFT A R M move the moldboard either straight ahead or to the side.
• Hinge Pins—Allows the A-Frame to pivot up and
down. The pins act as moldboard attaching points.
• Cutting Edge—Replaceable blade edge extends
the life of the blade.
• Runners—Adjustable runners retain the cutting
edge at the proper height.
• Sno-Flo Paint—Specially developed high-visibil
ity, yellow paint provides fast, smooth snow-rolling
action.
• Hydraulic Pump/Motor—Hydraulically lifts,
lowers and angles the snow plow.
• A-frame—Provides the means for attaching the
snow plow to the vehicle.
• L i f t Arm—Raises and lowers the snow plow.
SYSTEM DESCRIPTION AND OPERATION

H Y D R A U L I C CYLINDER AND MOTOR
The hydraulic cylinder and motor unit is designed
to raise, lower and angle the blade.
The power unit is a high torque, 12-volt motor that
is coupled to a gear-type hydraulic pump.
The toggle switches operate the solenoid valves.
The following components control the snow plow
RUNNERS J9001-2
blade positioning:
Fig. 1 Snow Plow Components • Solenoid valves designated A,B, and C.
• Mechanical hydraulic check valves.
COMPONENT D E S C R I P T I O N • Pilot check valve.
The primary snow plow components are described • Crossover relief valve.
within the following list:
• Moldboard—Snow blade constructed from high SOLENOID (ELECTRO-MECHANICAL) VALVES
tensile steel. Three solenoid valves are used for snow plow con
• Trip Springs—Allow the moldboard to tilt forward trol. Each valve is comprised of two components:
and slide over obstructions without losing the snow load. • Cartridge—Comprised of a valve and a solenoid.
• Sector—Used for positioning the moldboard • Coil—The electrical component that retracts the
• straight ahead or angling i t to the right or left. cartridge solenoid.
• Sector Shear Pin—Self-locking pin that locks the With power applied, the solenoid retracts and pulls
moldboard i n either a straight ahead or an angled the poppet valve into the OPEN position.
plowing position. When power is turned off, the spring forces the so
lenoid back to its normal, CLOSED position.
SOLENOID VALWE A PILOT CHECK VALVE
The solenoid valve A cartridge contains a poppet A pilot check valve has a piston i n addition to a
valve. This valve is normally de-energized i n the ball seat and spring. A pilot check valve is located be
CLOSED position. When closed, the valve retains tween solenoid valve C and the reservoir. I t has two
pressure i n the lift cylinder. When i t is energized functions:
(valve opened), i t allows the fluid to flow from the lift • Prevents the hydraulic fluid in either angling cyl
cylinder back to the reservoir. This enables the plow inder from leaking back to the reservoir.
blade to lower via gravity. • Allows the hydraulic fluid from a retracting an
Solenoid valve A is designed to remain energized gling cylinder to return to the reservoir.
(valve open) during plowing to provide a floating The valve action is done by fluid moving the piston,
blade position. This ensures that the plow blade is which forces the check ball off its seat.
guided up-down by the surface deviations.
CROSSOVER RELIEF VALVE
SOLENOID VALVE B
This valve protects against damage by a sudden
The solenoid valve B cartridge contains a spool
impact against the end of the blade. This will cause
valve. This valve is normally in the de-energized
CLOSED position. This allows the fluid to flow to the high hydraulic pressure to accumulate i n one of the
C solenoid. I n the energized OPEN position, the fluid angling cylinders.
is diverted to the lift cylinder. This causes the plow The hydraulic pressure increases enough to open
blade to be raised. the crossover relief valve. The valve allows the highly
pressurized hydraulic fluid to flow to the other cylin
SOLENOID VALVE C der. This cushions the impact and changes the posi
The solenoid valve C cartridge contains a spool tion of the blade.
valve that is normally in the de-energized CLOSED
position. This allows the fluid to flow to the right- SYSTEM OPERATION
side power angling cylinder. This angles the blade to Refer to Figures 2 through 5 for voltage application
the left. A t the same time, i t allows the fluid from and hydraulic fluid flow for each snow plow function.
the retracting left-side power angling cylinder to re Each figure shows the components that are actuated
turn to the pump reservoir. for each function.
Energizing the solenoid valve will route fluid to the
left side angling cylinder. This angles the plow blade SNOW PLOW WIRING DIAGRAMS
to the right. Also, the fluid is forced from the retract Refer to Figures 6, 7 and 8 for wiring diagrams.
ing right side cylinder. I t flows through the C car Refer to Specifications chart at the end of this
tridge valve and returns to the pump reservoir. group.
MECHANICAL HYDRAULIC VALVES SNOW PLOW MALFUNCTION DIAGNOSIS AND
The mechanical hydraulic valves all have the same
TESTS
function: they control the direction of the hydraulic
Refer to the charts and illustrations for proper di
fluid flow.
agnosis.
CHECK VALVES
SOLENOID VALVE COIL FUNCTIONAL TEST
Check valves allow fluid to flow freely i n one direc
Test the coils for proper operation, according to the
tion while preventing fluid from flowing i n the oppo
site direction. following procedure.
A pump check valve is used to prevent fluid from (1) Hold a screwdriver blade about 0.125 inch
leaking back through the pump to the reservoir. above the nut on the coil to be tested.
Two additional check valves are necessary because (2) Have a helper operate the control switch that
solenoid valves B and C have some leakage. energizes the applicable coil.
One check valve is located between solenoid valve
CAUTION: Do not connect an ohmmeter to a coil
B and the lift cylinder. I t prevents fluid i n the lift
cylinder from leaking back through solenoid valve B. when it is applied. This c a n c a u s e internal damage
I f fluid leaks back, i t could angle the blade to the to the ohmmeter.
left. This would force fluid through solenoid valve C
into the right side cylinder. (3) I f the coil is working, the electromagnetic ac
The other check valve is located between valve B tion will pull the screwdriver down to the retaining
and valve C. I t prevents fluid from being forced nut. I f this does not occur, use an ohmmeter to check
through solenoid valve B. the coil for continuity.
BUMPERS AND FRAME 13 -
TAN- O R A N G E WITH IGNITION SWITCH

WHITE
TRACER
SWITCH
6 0
SWITCH ANGLE
RAISE
| AND I 0 ORANGE BATTERY
WITH
i LOWER i WHITE TRACER
BLACK < TAN
FUSE
LIGHT -O
'GREEN
RED«
n n
SOLENOID SWITCH
• MOTOR
ENERGIZED: MOTOR A N D " B " COIL
"C" SOLENOID
A N G L I N G CYLINDER
B OPERATING PRESSURE
EXHAUST
ESS3 INTAKE OR DRAIN
METERED FLOW
RB52S
Fig. 2 Raise Blade—Voltage Application & Hydraulic Fluid Flow

- 8 BUMPERS AND FRAME
TAN IGNITION SWITCH
ORANGE
WITH
j SWITCH WHITE
TRACER
RAISE A N D
LOWER
BATTERY
ORANGE WITH
t
F U S E
WHITE TRACER /
TAN
BLACK -o
LIGHT GREEN
RED
N MOTOR
_L
ENERGIZED: " A " COIL
SOLENOID SWITCH
C" SOLENOID
POWER
ANGLING
CYLINDER
LOWER A N D FLOAT
(FORCE APPLIED AGAINST LIFT RAM)
OPERATING PRESSURE
EXHAUST
INTAKE OR DRAIN
mmm METERED FLOW
RB526
Fig. 3 Lower & Float Blade—Voltage Application & Hydraulic Fluid Flow
BUMPERS AND FRAME 13 -
TT
TAN
IGNITION SWITCH
t
ORANGE
SWITCH WITH
WHITE
TRACER
o o
RAISE A N D
LOWER
BATTERY
ORANGE WITH FUSE
0 WHITE TRACER jf_ ±
BLACK
ENERGIZED: MOTOR A N D " C " COIL
Fig. 4 Angle Blade Right—Voltage Application & Hydraulic Fluid Flow

13-10 BUMPERS AND FRAME
ORANGE
TAN* ORANGE WITH WHITE
WITH WHITE
TRACER
TRACER
. IGNITION SWITCH
SWITCH
6 f =5
O O SWITCH j ANGLE
RAISE
AND LOWER BATTERY
FUSE
BLACK-
O
TAN
LIGHT
RED- " GREEN
P—q
-SOLENOID SWITCH
MOTOR
ENERGIZED; MOTOR
Fig. 5 Angle Blade Left—Voltage Application & Hydraulic Fluid Flow

SNOW PLOW DIAGNOSIS
Condition P o s s i b l e Cows® Correction
P L O W B L A D E W I L L H O T LIFT O R a) Low h y d r a u l i c f l u i d level, (a) A d d fluid t o p r o p e r l e v e l .

LIFTS S L O W L Y b) Discharged b a t t e r y . (b) Recharge b a t t e r y .
c) L e a k i n g or o p e n " A " c a r t r i d g e . (c) Clean o r replace " A " c a r t r i d g e .
d) No v o l t a g e a t " B " c o i l . (d) Locate m a l f u n c t i o n a n d r e p a i r .
e) I n o p e r a t i v e " B " c o i l . (e) Replace " B " c o i l .
f) M a l f u n c t i o n i n g m o t o r . (f) Repair o r replace m o t o r .
g) M a l f u n c t i o n i n g p u m p . (g) Replace p u m p .
P L O W BLADE WILL NOT A N G L E RIGHT- a) I m p r o p e r c o u p l e r e n g a g e m e n t . (a) Engage coupler p r o p e r l y .

M O T O R IS O P E R A T I O N A L b) M e c h a n i c a l b i n d o r interference. (b) Eliminate mechanical b i n d or
interference.
c) Malfunctioning coupler. (c) Repair o r replace coupler.
d) No v o l t a g e at "C" c o i l . (d) Locate m a l f u n c t i o n a n d r e p a i r .
e) I n o p e r a t i v e "C" c o i l . (e) Replace "C" coil.
f) I n o p e r a t i v e "C" c a r t r i d g e . (f) Clean o r replace "C" c a r t r i d g e .
P L O W BLADE WILL NOT A N G L E LEFT- a) I m p r o p e r coupler e n g a g e m e n t . (a) Engage coupler p r o p e r l y .

M O T O R IS O P E R A T I O N A L b) M e c h a n i c a l b i n d o r interference. (b) Eliminate mechanical b i n d o r
interference.
c) M a l f u n c t i o n i n g c o u p l e r . (c) Repair or replace coupler.
d) L e a k i n g or o p e n crossover relief (d) Clean or replace crossover relief
valve. valve.
P L O W BLADE WILL N O T ANGLE- a) I m p r o p e r c o u p l e r e n g a g e m e n t . (a) Engage coupler p r o p e r l y .

M O T O R IS O P E R A T I O N A L b) M e c h a n i c a l b i n d o r interference. (b) Eliminate mechanical b i n d o r
interference.
c) L e a k i n g or o p e n crossover relief (c) Clean or replace crossover relief
valve. valve.
P L O W WILL NOT REMAIN IN a) A i r in cylinders a n d hoses. (a) Purge cylinders a n d hoses.

ANGLED POSITION b) L e a k i n g "C" c a r t r i d g e O - r i n g seals. (b) Replace O - r i n g seals.
c) L e a k i n g or o p e n p i l o t check v a l v e . (c) Clean or replace p i l o t check v a l v e .
d) L e a k i n g crossover relief v a l v e . (d) Clean or replace crossover relief
valve.
i) Crossover relief v a l v e o p e n i n g (e) Replace crossover relief v a l v e .
pressure t o o l o w .
MOTOR DOES NOT OPERATE a) Discharged o r defective b a t t e r y . (a) Recharge or replace b a t t e r y .

b) Loose o r c o r r o d e d electrical (b) Clean a n d t i g h t e n electrical
connections. connections.
c) I n o p e r a t i v e s o l e n o i d s w i t c h . (c) Replace s o l e n o i d s w i t c h .
d) M a l f u n c t i o n i n g c o n t r o l s w i t c h . (d) Replace c o n t r o l s w i t c h .
e) M a l f u n c t i o n i n g m o t o r . (e) Repair o r replace m o t o r .
P L O W BLADE WILL NOT LOWER a) No v o l t a g e a t " A " c o i l . (a) Locate m a l f u n c t i o n a n d r e p a i r .

b) " A " c a r t r i d g e j a m m e d i n closed
position. (b) Clean or replace " A " c a r t r i d g e .
c) I n o p e r a t i v e " A " c o i l .
(c) Replace " A " c o i l .
P L O W BLADE CREEPS D O W N W A R D a) Leaking " A " cartridge.
b) Leaking " A " c a r t r i d g e O - r i n g seal. (a) Clean or replace " A " c a r t r i d g e .
c) Leaking B-Check V a l v e . (b) Replace O - r i n g seal.
d) L e a k i n g Ram Packing Cup. (c) Clean or replace Pump Check V a l v e .
e) Leaking O - r i n g seal a t b o t t o m of (d) Replace Ram Packing Cup.
cylinder. (e) Replace O - r i n g seal.
P L O W BLADE WILL NOT a) Runner h e i g h t incorrect. (a) A d j u s t runners.

CLEAN SURFACE b) C u t t i n g e d g e u n e v e n l y w o r n . (b) Replace.
BLADE WILL NOT FOLLOW a) Not in " L o w e r Float Position". (a) Position s w i t c h a t " L o w e r Float"
SURFACE DEVIATIONS b) Insufficient slack i n lift c h a i n . (b) A d j u s t lift c h a i n .
S N O W STICICS T O F A C E (a) Sno-Flo paint w o r n off. (a) Refinish.

O F BLADE
J90O1-3
TO TURN FUSE # 5
SIGNAL FLASHER < (20 AMP)
T
- D l 18RD/YL*
(SEE SHEET 27)
D l 18RD/YL*
TO R.W.A.L.
j MODULE
(SEE SH 5 1 , 53)
BLACK
TO
IGNITION
SWITCH
(SEE SH 10)
-SP4 18WT/BR*- -SP4 18WT/BR*-
-SP4 18WT/BR*
-SP4 18WT/BR*
UP
h
- D l 18RD/YL*- DOWN
-SP1 18WT/BK*
PLOW
UP
CONTROL D l 18RD/YL*
DOWN SWITCH
-SP3 18 WT/RD*
UP & D O W N
-SP3 18WT/RD*-
-SP1 18WT/BK*-
- S P 4 18WT/BR*-
Dl -SP4liwf/BR*]
18RD -SP4 18WT/BR*- -SP4 18WT/BR* !
YL*
- D l 18RD/YL*-
PLOW — S P 4 18WT/BR* I
CONTROL
SWITCH D l 18RD/YL*
LEFT TO
—SP5 18WT/LG* I
RIGHT
t— . .—. . J
-SP4 18WT/BR* SP5 18WT/LG*-
- D l 18RD/YL*- -T2 18LG/RD*-
TRANSMISSION OIL
TEMPERATURE LAMP
8901-3
Fig. 6 Snow Plow Control Wiring Diagram

S N O W PLOW
UP SOLENOID
(FRONT S N O W
PLOW FRAME)
16RD—fW\
S N O W PLOW D O W N
SOLENOID (FRONT
S N O W PLOW FRAME)
S N O W PLOW
RIGHT SOLENOID
(FRONT S N O W
PLOW FRAME)
, , TRANSMISSION OIL
H-^^HL TEMPERATURE SWITCH
~ (RIGHT SIDE
TRANSMISSION OIL BELOW RADIATOR) 8901-4
TEMPERATURE LAMP
Fig. 7 Snow Plow Control Wiring Diagram

TO FRONT
TO FRONT
END WIRING
END WIRING
TO HEADLAMP j " -L2 14LG (SEE SH 22)
(SEE SH 21)
SWITCH
T T
17 L9
18BK 18BK
BLACK BLACK
(RIGHT
SIDE
RADIATOR
YOKE
PANEL)
BLACK
(RIGHT
UPPER
SNOW
PLOW
FRAME)
BLACK
BLACK
LEFT AUXILIARY
RIGHT AUXILIARY
PARK A N D TURN
LEFT AUXILIARY PARK A N D TURN
SIGNAL LAMP RIGHT AUXILIARY
HEADLAMP SIGNAL LAMP
HEADLAMP
8901-2
Fig. 8 Snow Plow Auxiliary Lighting Wiring Diagram

• BUMPERS AND FRAME 13 - 1S
POWER UNIT (23) Disassemble the three-way valve (Fig. 9). Dis
card the O-ring seal.
DISASSEMBLY/INSPECTION (24) Remove and clean solenoid valve C with spe
(1) Remove the drain plug (Fig. 9). Drain the unit. cial tool J-25399 (Fig. 9). Inspect the solenoid valve
(2) Extend the ram and piston rod completely. for external damage.
Drain the remaining oil from the cylinder. (25) Disassemble the four-way valve (Fig. 12). Dis
(3) Remove the cover lock nuts (Fig. 9). Remove card the O-ring seals (Fig. 12).
the cover. (26) Test solenoid valve B and C coils for electrical
(4) Inspect the casting for damage and cracks. In continuity. The normal coil DC resistance is 3.7 ohms.
spect the seal for cuts (Fig. 9). (27) Remove the pilot check valve plug, the spring
(5) Remove the ram and the piston. Inspect the ny and the ball from the bottom of the valve block.
lon sleeve, the piston, and the piston follower for ex (28) Inspect the spring for damage and the ball
cessive wear (Fig. 10). seat for nicks.
(6) Inspect the cylinder for pitting and scoring i n (29) Remove the acorn nut for access to the cross
the bore (Fig. 10). over valve components (Fig. 9).
(7) Inspect the ram for nicks, scratches, and corro (30) Remove the crossover valve components (Fig. 13).
sion (Fig. 10). Inspect for external damage. Discard the O-ring seals.
(8) Inspect the piston packing cup for wear (Fig. 10). (31) Clean the block with compressed air to remove
(9) Clean and inspect the base strainer. all foreign material.
(10) Replace all the O-ring seals during assembly.
(11) Loosen the motor bolts. Do not remove the ASSEMBLY
bolts from the motor. Retain the motor end plate dur Verify that all components are clean, free of foreign
ing removal. Temporarily install two nuts on the mo material. Use replacement gaskets and seals during
tor bolts to retain the motor intact. assembly. Petroleum jelly should used for installing
B o t h Prestolite a n d A m e r i c a n Bosch motors the rubber O-ring seals.
are used i n snow p l o w power units. A Prestolite (1) Install the crossover valve components in the
m o t o r can be identified by a domed t o p cover valve block with replacement O-ring seals (Fig. 13)
a n d the trade name stamped o n the body. Amer (2) Install the ball, spring and pressure plug with
i c a n Bosch motors have a flat t o p cover a n d no a replacement O-ring seal i n the bottom of the valve
i d e n t i f y i n g name o r marks. block (Fig. 13)
(12) Remove the pump drive shaft seal. (3) Assemble solenoid valve C with replacement O-
(13) Verify the seal k i t components are correct for ring seals and nylon retainer rings (Fig. 12).
the unit. (4) Install solenoid valve C with Tool J-25399 (Fig. 9).
(14) Dip the new seal i n oil. Install i t over the (5) Assemble solenoid valve B with replacement O-
pump shaft with the seal lip facing down. ring seals.
(15) Position the seal i n the pump housing slightly (6) Install the ball, spring and solenoid valve B
below the boss face. with Tool J-25399 (Fig. 9).
(16) Remove solenoid valve A coil from the base. (7) Install the valve block and the replacement O-
Test i t for continuity. The normal coil DC resistance ring seals on the pump base.
is 9.0 ohms ±10%. (8) Install the retainer, the spring, the ball, the in
(17) Remove solenoid valve A cartridge. Inspect for sert valve and the pump housing with replacement
external damage. O-ring seals (Fig. 11). Tighten the pump housing
(18) Remove the filters. Clean the screens with base nuts to 11.3 N-m (100 in. lbs.) torque.
cleaning solvent and compressed air. Discard the O- (9) Install the filters and the plugs with replace
ring seals and the nylon retaining rings. ment O-ring seals (Fig. 9).
(19) Remove the pump housing (Fig. 9). Remove the in (10) Install solenoid valve A cartridge i n the pump
sert valve, the ball, the spring, and the retainer from the base with replacement O-ring seals (Fig. 9).
pump housing (Fig. 11). Inspect all the components for (11) Install solenoid valve A coil (Fig. 9).
damage and contamination. Discard the O-ring seals. (12) Install the motor on the pump housing (Fig.
(20) Remove the socket-head screws. Remove the 9). Engage the gear shaft tang with the notch i n the
valve block from the pump housing (Fig. 9). Discard motor output shaft. Tighten the motor housing cap
the O-ring seals. screws to 5 N-m (45 in. lbs.) torque.
(21) Remove solenoid valve B with special tool (13) Install the ram and piston with replacement
J-25399 (Fig. 9). O-ring seals (Fig. 9).
(22) Remove the ball and spring from the valve (14) Position the cover on the reservoir. Secure i t
block (Fig. 9). Clean the solenoid valve. Inspect i t for with lock nuts (Fig. 9). Tighten the lock nuts to 11.3
external damage. N-m (100 i n . lbs.) torque.
L E G E N D FOR F I G . 9
1. Plastic Washer 16. Pump Housing 31. V a l v e Block 46. 3-Way Coil
2. Locknut 17. Poppet 32. Socket H e a d Cap Screw 47. Cap Plug
3. Pressure Relief V a l v e 18. Spring 33. Filter 48. Check Spring
4 . Filler Plug 19. G u i d e 34. Plug 49. C y l i n d e r Tank
5. Caver a n d Seal 20. Retainer 35. Strainer 50. V a l v e Block
6. O-Ring Seal 21. Setscrew 36. Check V a l v e Retainer 51. Cage
7. Sleeve 22. Aluminum Washer 37. Ball 52. O - R i n g S e a l / G l i d e Ring
8. Washer 23. Jamnut 38. Insert V a l v e 53. Crossover V a l v e
9. Ram 24. Acorn N ut 39. C y l i n d e r Tank 54. Pilot Check V a l v e
10. Piston 25. Stud 40. Cylinder 55. Spacer
11. Packing Cup 26. Brass W a s h e r 41. 4-Way Solenoid 56. Disc
12. Piston Follower 27. 2-Way Solenoid 42. 4-Way V a l v e 57. A d j u s t m e n t Screw
13. Locknut 28. 2-Way Coil 43. 4-Way Coil 59. D r a i n Plug
14. M o t o r 29. 2-Way V a l v e 44. 3-Way Solenoid
15. Shaft Seal 30. Base a n d Strainer 45. 3-Way V a l v e
J9001-6
• BUMPERS AND FRAME 13-17
COVER TANK
ASSEMBLY RESERVOIR BRASS NUT LOCK NUT
CYLINDER
COIL
- V A L V E CARTRIDGE
RAM O-RINGS
PISTON
FOLLOWER
RB531
Fig. 10 Lift Cylinder Components
SNAP RING
N Y L O N WASHER
O-RINGS
N Y L O N WASHER
O-RING
NOTE: N Y L O N WASHERS N Y L O N WASHER

A N D O-RINGS SHOULD
TAPER D O W N TO VALVE SHAPE
FROM VALVE D O W N . RB533
BASE
RETAINER
Fig. 12 Solenoid Valve C/Four-Way Valve—Exploded
View
O-RING SPRING
INSERT
VALVE
O-RING
RB532
Fig. 11 Insert Valve—Exploded View

• B U M P E R S AND FRAME 1
SNOW PLOW FRAME

REMOVAL
(1) Support the snow plow frame.
(2) Remove the nuts and bolts that attach the
bumper brackets to the snow plow frame (Fig. 15).
(3) Remove the nuts and bolts that attach the sup
port straps to the snow plow frame (Fig. 15).
(4) Remove the nuts, washers and bolts that attach
the snow plow frame to the vehicle frame side rails
and front crossmember (Fig. 15).
(5) Remove the snow plow frame and support from
the front of the vehicle frame (Fig. 15).
INSTALLATION
(1) Position and support the snow plow frame at
RB534 the front of the vehicle frame with the bolt holes
aligned (Fig. 15).
Fig. 13 Crossover Relief Valve—Disassembled (2) Install the snow plow frame attaching bolts,
washers and nuts finger-tight (Fig. 15).
POWER ANGLING CYLINDER SERVICE
(3) Install the support strap attaching bolts and
I f angling cylinder fluid leakage occurs, the cause nuts finger-tight (Fig. 15).
could be a loose gland nut (Fig. 14). Tighten the (4) Install the bumper bracket attaching bolts and
gland nut. nuts finger-tight (Fig. 15).
CAUTION; Over-tightening the gland nut c a n lock (5) Tighten all the attaching nuts to 68 N-m (50 ft.
the cylinder. Leakage will not c e a s e immediately be lbs.) torque.
c a u s e fluid h a s accumulated between the packing (6) Remove the support from under the snow plow
and the gland nut. If the leakage persists, replace frame.
the rod packing (Fig. 14).
SNOW PLOW PIWOT BRACKET
REMOVAL
(1) Support the snow plow pivot bracket.
' G L A N D NUT
PACKING
POWER A N G L I N G CYLINDER
WASHER
WIPER P A C K I N G
SPLIT BEARING
RN886
Fig. 14 Angling Cylinder—Exploded View

FRAME
SNOW
PLOW FRAME
BUMPER
BRACKET
BUMPER
BRACKET
J9101-2
Fig. 15 Snow Plow Frame Removal/Installation
(2) Remove the nuts and bolts that attach the sup FRAME FRAME
port straps to the pivot bracket (Fig. 15). BOLT
(3) Remove the nuts, washers and bolts that attach

the pivot bracket to the vehicle frame side rails (Fig.
BOLT
16).
(4) Remove the pivot bracket from the vehicle
frame rails (Fig. 16).
INSTALLATION
(1) Position and support the pivot bracket at the
vehicle frame rails with the bolt holes aligned (Fig. BRACE»ACE
16).
(2) Install the pivot bracket attaching bolts, wash
ers and nuts finger-tight (Fig. 16).
(3) Install the support strap attaching bolts and
nuts (Fig. 15). Tighten the nuts to 68 N-m (50ft.lbs.)
torque. PIVOT
(4) Tighten the pivot bracket attaching nuts to 68 BRACKET A D 8
N-m (50 ft. lbs.) torque. BOLT BOLT
(5) Remove the support from under the pivot J9101-1

bracket.
Fig. 16 Snow Plow Pivot Bracket Removal/
SNOW PLOW CONTROL MODULE Installation
REMOVAL/DISASSEMBLY (2) Remove the control module from the instru

(1) Remove the screws and module retainers from ment panel (Fig. 17).
the instrument panel (Fig. 17). (3) Remove the module housing attaching screws
(Fig. 18).
(4) Separate the switch cover from the housing

(Fig. 18). INSTRUMENT
(5) Detach the lamp holders from the switch cover. PANEL
Disconnect the wire harness connectors from the
switches (Fig. 18).
(6) Remove the nut, ring washer and lock washer WIRE
from each toggle switch (Fig. 18). HARNESS
(7) Remove the toggle switches from the switch
AUXILIARY
cover (Fig. 18). HEADLAMP
(8) Carefully pry the auxiliary headlamp switch SWITCH
outward from the switch cover face. Remove it from
the switch cover (Fig. 18).
ASSEMBLY/INSTALLATION
SWITCH
(1) Insert the auxiliary headlamp switch in the COVER AND BEZEL
switch cover opening. Carefully push inward until it BLADE HOUSING
is completely seated against the cover face (Fig. 18). RAISE/LOWER
(2) Position the toggle switches in the switch cover SWITCH BLADE
ANGLE
openings. Install the lock washers, ring washers and SWITCH
nuts (Fig. 18). Tighten the nuts with 5 N-m (45 in. RETAINER J9123-424
lbs.) torque.
(3) Insert the lamp holders in the switch cover Fig. 17 Snow Plow Control Module Removal/
openings. Connect the wire harness connectors to the Installation
switches (Fig. 18).
(4) Mate the switch cover with the module hous
ing. Install the housing attaching screws (Fig. 18).
Tighten the screws until the screw heads are seated
against the housing.
(5) Position the control module on the instrument
panel with the slots aligned with the holes. Install
the retainers and screws (Fig. 17). Tighten the
screws until the module is tightly attached to the in
strument panel.
BLADE SWITCH AUXILIARY

ANGLE COVER HEADLAMP
SWITCH SWITCH
TRANS OIL NUT

TEMP LAMP
(AUTO TRANS)
RING
WASHER
TO AUXILIARY
H/LAMP SWITCH
LOCKWASHER
YELLOW DOT
WIRE
HARNESS
5
'ILLUMINATION
HOUSING LAMP' \
SCREW, BLADE
RAISE/LOWER
SWITCH
TO SNO-PLOW CONTROL
SWITCH
(ANGLE)
TO S N O PLW CONTROL SWITCH
(RAISE/LOWER) J9123-425
Fig. 18 Snow Plow Control Module Disassembled

SNOW PLOW SPECIFICATIONS
ELECTRICAL SPECIFICATIONS S O L E N O I D V A L V E S A . 1, A N D C SPECIFICATIONS

MOTOR SPECIFICATIONS A Coll
American Bos€§t M05S1046A A p p l i e d V o l t a g e — 12 V o l t s DC
No load (motor not attached to pump) operation: C u r r e n t — 0.83 A m p e r e s
C A U T I O N : D o n o t o p e r a t e m o t o r continuously f o r m o r e N o m i n a l resistance (one o h m m e t e r p r o b e t o coil w i r e , o t h e r
t h a n 3 0 seconds. t o m e t a l coil cover)—9.0 ± 1 0 % o h m s .
A p p l i e d V o l t a g e — 12 V o l t s DC S and C Colls
M a x . C u r r e n t — 24 A m p e r e s A p p l i e d V o l t a g e — 12 V o l t s DC
Speed ( M i n . ) — 5900 r p m C u r r e n t — 1.24 A m p e r e s
With load (pump operating): N o m i n a l resistance (one o h m m e t e r p r o b e t o coil w i r e , o t h e r
C A U T I O N : D o n o t o p e r a t e m o t o r continuously f o r m o r e t o m e t a l coil cover)—3.5 ± 1 0 % o h m s .
t h a n 5 seconds.
A p p l i e d V o l t a g e — 12 V o l t s DC S O L E N O I D SWITCH _
M a x . C u r r e n t — 230 A m p e r e s A p p l i e d V o l t a g e — 12 V o l t s DC
M a x . Current — 5 Amperes
Prestolite M6L4105
No load (motor not attached to pump) operation: N o m i n a l resistance (one o h m m e t e r p r o b e t o coil w i r e , o t h e r
C A U T I O N : D o n o t o p e r a t e m o t o r continuously f o r m o r e t o m e t a l foot)—2.65-4.5 o h m s .
t h a n 3 0 seconds.
H Y D R A U L I C FLUID C A P A C I T Y
A p p l i e d V o l t a g e — 10 V o l t s DC
M a x . C u r r e n t — 45 A m p e r e s NOTE: 1 Q u a r t = 32 Fluid O u n c e s
Speed ( M i n . ) — 10,000 r p m A Reservoir a n d Pump 28 o z .
U n d e r Load ( p u m p o p e r a t i n g ) : Hoses & 1-1/2 x 10 C y l i n d e r s 16 o z .
C A U T I O N : D o n o t o p e r a t e m o t o r continuously f o r m o r e Total 1 q t . , 12 o z .
t h a n 5 seconds. (44 o z . )
A p p l i e d V o l t a g e — 12 V o l t s DC B Reservoir a n d P u m p 28 o z .
M a x . C u r r e n t — 230 A m p e r e s Hoses & 1-1/2 x 12 C y l i n d e r s 19 o z .
Total 1 q t . , 15 o z .
(47 o z . )
HYDRAULIC SPECIFICATIONS
PUMP
C Reservoir a n d P u m p 1
q t . , 4.5 o z .
(36.5 o z . )
Pressure O u t p u t ( p u m p relief v a l v e o p e n i n g p r e s s u r e Hoses 12x12 Cylinders 28 o z .
1650 ± 5 0 psi Total 2qt„ 5oz.
(64.5 o z . )
C R O S S O V E R RELIEF VALVE
O p e n i n g Pressure 3800 ± 400 psi J9001-4
FRAME
INDEX
page page
Frame Dimensions 24 General Information 23
Frame Repairs 24 Safety Precautions and Warnings 23
Frame Straightening 24
SAFETY PRECAUTIONS AND WARNINGS
WARNING: U S E E Y E P R O T E C T I O N WHEN GRIND

ING OR WELDING METAL, S E R I O U S E Y E INJURY
CAN RESULT.
B E F O R E P R O C E E D I N G WITH F R A M E REPAIR IN
VOLVING GRINDING OR WELDING, V E R I F Y THAT
V E H I C L E F U E L S Y S T E M IS NOT L E A K I N G OR IN
CONTACT WITH REPAIR A R E A , P E R S O N A L INJURY
CAN RESULT.
DO NOT A L L O W O P E N F L A M E TO CONTACT
P L A S T I C BODY P A N E L S . F I R E OR E X P L O S I O N CAN
RESULT.
WHEN W E L D E D F R A M E C O M P O N E N T S A R E R E
P L A C E D , 100% PENETRATION W E L D MUST B E
A C H I E V E D DURING INSTALLATION. IF NOT, DAN
Fig. 1 Frame
G E R O U S OPERATING CONDITIONS C A N RESULT.
STAND C L E A R O F C A B L E S OR CHAINS ON with rubber load cushions (Fig. 2) with through-bolts.
PULLING EQUIPMENT DURING F R A M E STRAIGHT The cargo box or bed is attached to the frame with
ENING OPERATIONS, P E R S O N A L INJURY CAN R E bolts. Refer to Group 23, Body for cargo box service
SULT. procedures.
DO NOT V E N T U R E UNDER A HOISTED V E H I C L E
THAT IS NOT S U P P O R T E D ON S A F E T Y STANDS,
P E R S O N A L 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 3 bolts to replace
production fasteners, loosening or failure can re
sult.
When using heat to straighten frame components
do not exceed 566°C (1050°F), metal fatigue can re
sult.
Welding the joints around riveted c r o s s members
and frame side rails can weaken frame
Fig. 2 Cab Mounts
The frame is designed to absorb and dissipate flex
GENERAL INFORMATION ing and twisting due to acceleration, braking, corner
BR trucks have a ladder-type frame (Fig. 1) with ing and road surface variances without bending when
Box-section front rails, dropped center section and subjected to normal driving conditions. The frame is
open-channel side rails i n the rear. the mounting platform for the following systems and
Cross members attached to the frame side rails components.
with rivets, welds or bolts form a ladder-type con • Front and rear suspension systems.
struction (Fig. 1). The cab is isolated from the frame • Engine, transmission, and transfer case.
• Steering gear and linkage. (4) If necessary when a side rail is repaired, grind
• Fuel cell and fuel line tubing. the weld smooth and install a reinforcement channel
• Front end sheet metal and radiator closure panel. (Fig. 3) over the repaired area.
• Passenger cab. If a reinforcement channel is required, the
• Cargo box or bed. top and bottom flanges should be 0.250 inches
• Front and rear bumper systems. narrower than the side rail flanges. Weld only
i n the areas indicated (Fig. 3).
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566°C (1050°F).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
Fig. 3 Frame Reinforcement
FRAME REPAIRS
FRAME FASTENERS
DRILLING HOLES Bolts, nuts and rivets can be used to repair frames
Do not drill holes in frame side rail top and bottom or to install a reinforcement section on the frame.
flanges, metal fatigue can result causing frame fail Bolts can be used in place of rivets. When replacing
ure. Holes drilled in the side of the frame rail must rivets with bolts, install the next larger size diameter
be at least 38 mm (1.5 in.) from the top and bottom bolt to assure proper fit. If necessary, ream the hole
flanges. out just enough to sufficiently receive the bolt.
Additional drill holes should be located away from Conical-type washers are preferred over the split-
existing holes. ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair. Grade-3 bolts or softer
WELDING should not be used. Tightening bolts/nuts with the
Use MIG, TIG or arc welding equipment to repair correct torque, refer to the Introduction Group at the
welded frame components. Gas welding is not recom front of this manual for tightening information.
mended. Gas welding transmits excessive heat to
frame components causing possible metal fatigue. FRAME DIMENSIONS
Frame components that have been damages should Frame dimensions are listed in inch scale. All di
mensions are from center to center of Principal Lo
be inspected for cracks before returning the vehicle
cating Point (PLP), or from center to center of PLP
to use. If cracks are found in accessible frame com
and fastener location.
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3 VEHICLE PREPARATION
mm (0.125 in.) diameter drill bit. Position the vehicle on a level work surface. Using
(2) Using a suitable die grinder with 3 inch cut off screw or bottle jacks, adjust the vehicle PLP heights
wheel, V-groove the crack to allow 100% weld pene to the specified dimension above a level work surface.
tration. Vertical dimensions can be taken from the work sur
(3) Weld the crack. face to the locations indicated (Fig. 4, 5, 6 or 7).
BUMPERS AND FRAME 13 - 25
WB A B
118.7 39.66 83.76
134.7 55.66 99.76
ALL DIMENSIONS ARE SHOWN IN INCHES
-r- 12.54
4—r 17.8S
I _ | — — 27.23
r
BR 1500 and 2500

119" and 135"
WHEELBASE
REAR-WHEEL-DRIVE
REAR SPRING HANGER

DOWN BRKT SPRING HANGER
REAR TRANS C MEMBER
REAR FRAME SECTION J9413-15

Fig. 4 BR 1500 and 2500 Rear-Wheel-Drive

Fig. 5 BR 1500 and 2500 Four-Wheel-Drive
BUMPERS AND FRAME 13 27
3565
75.
79.34
REAR
WHEELS

Fig. 6 BR 3500 Rear-Wheel-Drive
- 28 BUMPERS AND FRAME
BR 3500
135",139"andl63"
WHEELBASE
FOUR-WHEEL-DRIVE
REAR FRAME SECTION

J9413-18
Fig. 7 BR 3500 Four-Wheel-Drive
F U E L SYSTEM
CONTENTS
page page
ACCELERATOR PEDAL AND THROTTLE GENERAL INFORMATION 1

CABLE 21 MULTI-PORT FUEL INJECTION (MFI)—
DIESEL ENGINE—COMPONENT DESCRIPTION/ COMPONENT DESCRIPTION/SYSTEM
SYSTEM OPERATION 84 OPERATION—EXCEPT DIESEL 2S
DIESEL ENGINE—COMPONENT REMOVAL/ MULTI-PORT FUEL INJECTION (MFI)—
INSTALLATION 11 i COMPONENT REMOVAL/INSTALLATION—
DIESEL ENGINE—GENERAL DIAGNOSIS . . . . . 94 EXCEPT DIESEL 72
FUEL DELIVERY SYSTEM—EXCEPT DIESEL . . . 3 MULTI-PORT FUEL INJECTION (MFI)—
FUEL DELIVERY SYSTEM—DIESEL ENGINE . . 12 GENERAL DIAGNOSIS—EXCEPT DIESEL . . . 53
FUEL TANKS 25 SPECIFICATIONS 140
INDEX
page page
Fuel Requirements—Diesel Engine 2 Fuel Usage Statement—Gas Powered Engines .... 2
Throughout this group, references are made to par filter. It also consists of fuel tubes/lines/hoses and fit
ticular vehicle models by alphabetical designation or tings, vacuum hoses, throttle body and fuel injec
by the particular vehicle nameplate. A chart showing tors).
a breakdown of the alphabetical designations is in The Fuel Delivery System consists of: the electric
cluded i n the Introduction section at the beginning of fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail,
this manual. fuel injectors and fuel pressure regulator.
A l l vehicles are equipped with either a 3.9L (V-6) A Fuel Return System is used on all vehicles (all
engine, a 5.2L (V-8) engine, two different 5.9L (V-8) engines). On gas powered engines, fuel is returned
engines, an 8.0L (V-10) engine or a 5.9L (Cummins through the fuel pump module and back to the fuel
in-line 6 cylinder diesel) engine. tank. A separate fuel return line from the tank to the
The 3.9L (V-6) and 5.2L (V-8) engines will be re engine is no longer used on any gas powered engine.
ferred to i n this group as: LDC (Light Duty Cycle) On diesel powered engines, a separate fuel return
engines. The 5.9L (V-8) gas powered engine will be line from the tank to the engine is used.
referred to as either: LDC (Light Duty Cycle) or HDC The Fuel Tank Assembly consists of: the fuel
(Heavy Duty Cycle) engine. The 8.0L (V-10) and die tank, filler tube, fuel gauge sending unit/electric fuel
sel engines will be referred to as: HDC (Heavy Duty pump module (electric fuel pump on gas powered en
Cycle) engine. gines only), a pressure relief/rollover valve and a
Either of the HDC gas powered engines can be eas pressure-vacuum filler cap.
ily identified by the use of an engine mounted air in Also to be considered part of the fuel system is the
jection pump. The 3.9L/5.2L/5.9L LDC gas engines or Evaporation Control System. This is designed to
the diesel engine will not use an air injection pump. reduce the emission of fuel vapors into the atmo
The F u e l System consists of: the fuel tank, an sphere. The description and function of the Evapora
electric fuel tank mounted fuel pump (gas powered tive Control System is found i n Group 25, Emission
engines), a fuel injection pump (diesel engine), a me Control Systems.
chanical fuel transfer (lift) pump (diesel) and a fuel
FUEL USAGE STATEMENT—GAS POWERED MTBE/ETBE
ENGINES Gasoline and MTBE (Methyl Tertiary Butyl Ether)
Your vehicle was designed to meet all emission reg blends are a mixture of unleaded gasoline and up to
ulations and provide excellent fuel economy using 15 percent MTBE. Gasoline and ETBE (Ethyl Ter
high quality unleaded gasoline. Only use unleaded tiary Butyl Ether) are blends of gasoline and up to
gasolines having a minimum posted octane of 87. 17 percent ETBE. Gasoline blended with MTBE or
I f your vehicle develops occasional light spark ETBE may be used i n your vehicle.
knock (ping) at low engine speeds, this is not harm
ful. However, c o n t i n u e d heavy k n o c k at h i g h CLEAN AIR GASOLINE
speeds can cause damage a n d should be re Many gasolines are now being blended that con
p o r t e d to y o u r dealer immediately. Engine dam tribute to cleaner air, especially i n those areas of the
age as a result of heavy knock operation may not be country where air pollution levels are high. These
covered by the new vehicle warranty. new blends provide a cleaner burning fuel and some
I n addition to using unleaded gasoline with the are referred to as Reformulated Gasoline.
proper octane rating, those t h a t c o n t a i n deter I n areas of the country where carbon monoxide lev
gents, corrosion a n d s t a b i l i t y additives are rec els are high, gasolines are being treated with oxygen
ommended. Using gasolines that have these ated materials such as MTBE, ETBE and ethanol.
additives will help improve fuel economy, reduce
Chrysler Corporation supports these efforts toward
emissions and maintain vehicle performance. Gener
cleaner air and recommends that you use these gaso
ally, premium unleaded gasolines contain more addi
tive than regular unleaded gasolines. lines as they become available.
Poor q u a l i t y gasoline can cause problems such
FUEL REQUIREMENTS—DIESEL ENGINE
as hard starting, stalling and stumble. I f you experi
ence these problems, use another brand of gasoline WARNING: DO NOT USE ALCOHOL OR GASOLINE
before considering service for the vehicle.
AS A FUEL BLENDING AGENT. THEY CAN BE UN
GASOLINE/OXYGENATE BLENDS STABLE UNDER CERTAIN CONDITIONS AND HAZ
Some fuel suppliers blend unleaded gasoline with ARDOUS OR EXPLOSIVE WHEN MIXED WITH
materials that contain oxygen such as alcohol, MTBE DIESEL FUEL
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are generally Use good quality diesel fuel from a reputable sup
used i n gasoline blends: plier i n your Dodge diesel powered truck. For most
year-round service, number 2 (No. 2) diesel fuel
ETHANOL meeting ASTM specification D-975 will provide good
Ethanol (Ethyl or Grain Alcohol) properly blended, performance.
is used as a mixture of 10 percent ethanol and 90 I f the vehicle is exposed to extreme cold (below
percent gasoline. Gasoline w i t h ethanol may be -18°C - 0°F), or for any reason is required to operate
used i n y o u r vehicle. at colder than normal conditions for prolonged peri
ods, use climitized No. 2 diesel fuel. A dilution of No.
METHANOL 2 diesel fuel with 50 percent kerosine may also be
used. This fuel will provide better protection from
CAUTION: DO NOT USE GASOLINES CONTAINING fuel gelling or wax-plugging of the fuel filters.
METHANOL. Use of methanol/gasoline blends may re Diesel fuel is seldom completely free of water. To
sult in starting and driveability problems. In addition, prevent fuel system trouble, including fuel tube (line)
damage may be done to critical fuel system compo
freezing i n winter, drain the accumulated water reg
nents.
ularly using the water drain provided. For proce
Methanol (Methyl or Wood Alcohol) is used i n a va dures, refer to Draining Water from Filter under the
riety of concentrations blended with unleaded gaso Fuel Filter/Water Separator heading. This can be
line. You may encounter fuels containing 3 percent or found i n the Diesel Engine—Component Removal/In
more methanol along with other alcohols called cosol- stallation section of this group.
vents.
Problems that are the result of using methanol/gas
oline blends are not the responsibility of Chrysler
Corporation. They may not be covered by the vehicle
warranty.
FUEL DELIVERY SYSTEM—EXCEPT DIESEL
INDEX
page page
Fuel Filter 6 Fuel System Pressure Release 6
Fuel Filter/Fuel Pressure Regulator 4 Fuel System Pressure Test—Gas Powered
Fuel Pressure Leak Down Test—Gas Powered Engines 6
Engines 7 Fuel Tubes/Lines/Hoses and Clamps 8
Fuel Pump Capacity Test—Gas Powered Engines . . 7 General Information 3
Fuel Pump Module—All G a s Powered Engines . . . . 3 Quick-Connect Fittings 8
GENERAL INFORMATION PIASTIC FUEL FILTER/ FUEL

The fuel delivery system used on gas powered en LOCKNUT FUEL PRESSURE SUPPLY TOP OF
REGULATOR CONNECTION FUEL TANK
gines of previous years is no longer used. This con
sisted of a fuel return line that routed excess fuel
pressure back to the fuel tank. The new system will
n o t have a separate fuel return line. PRESSURE REUEF/
A separate frame mounted fuel filter will not be ROLLOVER VALVE
used with any gas powered engine.
The Fuel Delivery System for gas powered engines
is controlled by the powertrain control module
(PCM). For additional information, also refer to Pow
ertrain Control Module (PCM) i n the Multi-Port Fuel PUMP/GAUGE
AUXILIARY ELEC. CONNECTION
Injection (MFI) sections of this group. FUEL SUPPLY
FITTING
The fuel pump module contains a combination fuel {SOME ENGINES) J94I4-32
pressure regulator and fuel filter. Refer to the follow
ing Fuel Pump Module—All Gas Powered Engines Fig. 1 Top View Fuel Pump Module—Gas Powered
for additional information. Engines—Typical
FUEL PUMP MODULE—ALL GAS POWERED FUEL GAUGE LOCKING
FLOAT SENDING UNIT TABS
ENGINES
The fuel pump module on all gas powered engines
is installed i n the top of the fuel tank (Fig. 1). The
fuel pump module (Figs. 1 or 2) contains the follow
ing:
• A combination fuel filter/fuel pressure regulator
• Electric fuel pump
• Fuel pump reservoir
• A separate in-tank fuel filter
• Pressure relief/rollover valve
• Fuel gauge sending unit
• Fuel supply line connection MOUNTING IN-TANK
• Auxiliary fuel supply fitting (not all engines) SCREWS FUEL FILTER J9414-33
ELECTRIC FUEL PUMP Fig. 2 Fuel Pump Module Components—Gas

The electric fuel pump is located i n and is part of, Powered Engines—Typical
the fuel pump module (Fig. 2). I t is equipped with a FUEL PUMP ELECTRICAL CONTROL
permanent magnet electric motor. The fuel pump
Voltage to operate the electric pump is supplied
module is suspended i n fuel i n the fuel tank. Fuel is
through the fuel pump relay. For an electrical opera
drawn i n through a separate filter (located on bottom
tional description of the fuel pump, refer to Fuel
of module) and pushed through the electric motor to
Pump Relay-PCM Pin #51—PCM Output. This can
the fuel filter/fuel pressure regulator.
be found i n the Multi-Port Fuel Injection (MFI) regulator, the pressure relief/rollover valve and the
System—Component Description/System Operation fuel pump electrical connector should all be pointed
section of this group. to the drivers side of the vehicle before tightening
locknut.
FUEL PUMP REPLACEMENT (2) Position new locknut over top of fuel pump
The electric fuel pump is not serviceable. I f the fuel module.
pump needs replacement, the complete fuel pump (3) Tighten locknut.
module must be replaced. Refer to Fuel Pump Mod (4) Install fuel tank. Refer to Fuel Tank Installa
ule Removal for procedures. Perform the Fuel System tion i n this section.
Pressure Release procedure before servicing the fuel
AUXILIARY FUEL SUPPLY FITTING
pump.
An auxiliary (capped) fuel supply fitting is located
F U E L PUMP MODULE REMOWAL on the top of the fuel pump module (Fig. 1). This fit
ting will be available only on diesel powered models,
WARNING: T H E F U E L S Y S T E M IS UNDER A CON models with either a 5.9L V-8 heavy duty or 8.0L
STANT P R E S S U R E (EVEN WITH T H E ENGINE O F F ) . V-10 engine and all cab-chassis models. This fitting
B E F O R E SERVICING T H E F U E L PUMP MODULE, supplies a non-pressurized auxiliary fuel source.
F U E L S Y S T E M P R E S S U R E MUST B E R E L E A S E D .
FUEL FILTER/FUEL PRESSURE REGULATOR
A combination fuel filter and fuel pressure regula
CAUTION: Whenever the fuel pump module Is ser tor is used on all gas powered engines. I t is pressed
viced, the locknut and gasket must be replaced. into a rubber grommet located on the top of the fuel
pump module (Fig. 1). A separate frame mounted fuel
(1) Drain the fuel tank. Refer to Draining Fuel
filter is not used with gas powered engines.
Tank i n the Fuel Tank section of this group.
F u e l Pressure Regulator Operation: The pres
(2) Remove fuel tank. Refer to the Fuel Tank sec
sure regulator is a mechanical device that is not con
tion of this group.
trolled by the powertrain control module (PCM) or
(3) Note the direction of the fuel filter/fuel pres
engine vacuum.
sure regulator, the pressure relief/rollover valve and
The regulator is calibrated to maintain fuel system
the fuel pump electrical connector. These should all
operating pressure of approximately 241-310 kPa
be pointed to the drivers side of the vehicle.
(35-45 psi) at the fuel injectors. I t contains a dia
(4) The fuel pump module locknut is threaded onto
phragm, calibrated springs and a fuel return valve.
the fuel tank. Remove the fuel pump module locknut
The internal fuel filter (Fig. 3) is also part of the as
(Fig. 1). The fuel pump module will spring up when
sembly.
the locknut is removed.
Fuel is supplied to the filter/regulator by the elec
(5) Remove module from fuel tank.
tric fuel pump through an opening tube at the bot
DISASSEMBLY—FUEL GAUGE SENDING UNIT tom of filter/regulator (Fig. 3).
The filter/regulator contains a check valve to main
(1) Remove sending unit mounting screws (Fig. 1).
tain some fuel pressure when the engine is not oper
(2) Mark the sending unit electrical wires before
ating. This will help to start the engine.
removal for correct installation. Carefully disconnect
I f fuel pressure at the pressure regulator exceeds
electrical wires from sending unit. Remove sending
approximately 45 psi, an internal diaphragm closes
unit.
and excess fuel pressure is routed back into the tank
(3) Reverse order of removal for installation.
through the pressure regulator. A separate fuel re
IN-TANK FUEL FILTER turn line is not used with any gas powered engine.
The in-tank filter is attached to the bottom of the REMOVAL—FUEL FILTER OR FUEL PRESSURE
fuel pump module (Fig. 2). REGULATOR
(1) Pry the mounting tabs back and remove the in-
tank fuel filter. WARNING: T H E F U E L S Y S T E M IS UNDER A CON
(2) Install new fuel filter into retaining tabs. STANT P R E S S U R E , E V E N WITH ENGINE OFF. B E
FORE SERVICING THE FUEL FILTER/FUEL
FUEL PUMP MODULE INSTALLATION P R E S S U R E REGULATOR, THE FUEL SYSTEM
P R E S S U R E MUST B E R E L E A S E D .
CAUTION: Whenever the fuel pump module is ser
viced, the locknut and gasket must be replaced.
Refer to Fuel System Pressure Release i n the Fuel
(1) Using a new gasket, position fuel pump module Delivery System section of this group.
into opening i n fuel tank. The fuel filter/fuel pressure The fuel filter/fuel pressure regulator is located on
the top of fuel pump module (Fig. 4).
INTERNAL
FUEL FILTER
FUEL FLOW TO FUEL

INJECTORS
RUBBER FUEL FILTER/FUEL

GROMMET PRESSURE REGULATOR
RUBBER
AT PUMP
MODULE
GROMMET J9314-173
CALIBRATED
Fig. 5 Filter/Regulator Removal and Installation
SPRINGS
X EXCESS FUEL BACK
FUEL FILTER/FUEL
TO TANK PRESSURE REGULATOR
FUEL INLET J9314-170
Fig. 3 Side View—Filter/Regulator

PLASTIC
WASTIC FUEL FILTER/ FUEL TUBE
LOCKNUT FUEL PRESSURE " SUPPLY TOP OF
FUEL TANK (COVER)
REGULATOR CONNECTION
PRESSURE RELIEF/
ROLLOVER VALVE
J9314-174
Fig. 6 Plastic Tube and Snap Ring

PUMP/GAUGE
AUXILIARY ELEC. CONNECTION (4) Gently cut the old fuel tube (line) clamp (Fig. 7)
FUEL SUPPLY
FITTING taking care not to damage the plastic fuel tube. Re
(SOME ENGINES) J9414-32 move and discard the old fuel tube clamp.
Fig. 4 Filter/Regulator Location FUEL FILTER/FUEL

PRESSURE REGULATOR
Fuel pump module removal is not necessary.
(1) Drain fuel tank and remove tank. Refer to Fuel
Tanks in this group.
(2) The fuel filter/regulator is pressed into a rubber
grommet. Remove by twisting and pulling straight up
(Fig. 5).
CAUTION: Do not pull the filter/regulator more than

three inches from the fuel pump module. Damage to
the coiled fuel tube (line) may result.
(3) Remove the snap ring retaining the convoluted

tube (cover) to the filter/regulator (Fig. 6). Slide the J9314-175
plastic tube down the fuel tube to clear the fuel tube
clamp. Fig. 7 Fuel Tube and Clamp
(5) Remove the plastic fuel tube from the filter/reg (2) Remove the fuel tank filler tube cap to release
ulator by gently pulling downward. Remove filter/reg fuel tank pressure.
ulator from fuel pump module. (3) Remove (unscrew) the protective plastic cap
from the pressure test port on the fuel rail (Fig. 9).
INSTALLATION On the 8.0L V-10 engine, this test port is located at
(1) Install a new clamp over the plastic fuel tube. the front of the engine.
(2) Install filter/regulator to fuel tube. Rotate the
filter/regulator i n the fuel tube (line) until i t is
pointed to the drivers side of vehicle.
(3) Tighten line clamp to fuel line using special
Hose Clamp Pliers number C-4124 or equivalent
(Fig. 8). Do not use conventional side cutters to
tighten this type of clamp.
Fig. 9 Typical Fuel Pressure Test Port

WARNING: DO NOT A L L O W FUEL TO SPILL ONTO
THE ENGINE INTAKE OR EXHAUST MANIFOLDS.
PLACE SHOP TOWELS UNDER AND AROUND THE
PRESSURE PORT TO ABSORB FUEL WHEN THE
PRESSURE IS RELEASED FROM THE FUEL RAIL.
Fig. 8 Tightening Fuel Tube Clamp

WARNING: WEAR PROPER EYE PROTECTION
(4) Slide the convoluted plastic tube (cover) up to
WHEN RELEASING FUEL SYSTEM PRESSURE.
the bottom of filter/regulator and install snap ring
(Fig. 6). (4) Obtain the fuel pressure gauge/hose assembly
(5) Press the filter/regulator (by hand) into the from fuel pressure gauge tool set 5069. Remove the
rubber grommet. The assembly should be pointed to gauge from the hose.
the drivers side of the vehicle. (5) Place one end of hose (gauge end) into an ap
(6) Install fuel tank. Refer to Fuel Tanks i n this proved gasoline container.
group. (6) Place a shop towel under the test port. On the
8.0L V-10 engine, this test port is located at the front
FUEL FILTER of the engine.
Refer to Fuel Filter/Fuel Pressure Regulator for in (7) To release fuel pressure, screw the other end of
formation. hose onto the fuel pressure test port.
(8) After fuel pressure has been released, remove
FUEL SYSTEM PRESSURE RELEASE the hose from the test port.
(9) Install protective cap to fuel test port.
ALL GAS POWERED ENGINES
The fuel system is under constant fuel pressure
FUEL SYSTEM PRESSURE TEST—GAS POWERED
(even with the engine off).
ENGINES
WARNING: BECAUSE THE FUEL SYSTEM IS UN Fuel systems on gas powered engines are equipped
DER CONSTANT FUEL PRESSURE, THIS PRES with a fuel tank module mounted, combination fuel
SURE MUST BE RELEASED BEFORE SERVICING filter/fuel pressure regulator (Fig. 10). The fuel pres
ANY FUEL SUPPLY OR FUEL RETURN SYSTEM sure regulator is a mechanical device that is not con
COMPONENT. THIS DOES NOT APPLY TO THROT trolled by the powertrain control module (PCM) or
TLE BODY REMOVAL. engine vacuum.
With engine at idle speed, system fuel pressure
(1) Disconnect negative battery cable. should be approximately 241-310 kPa (35-45 psi).
PLASTIC FUEL FILTER/ FUEL FUEL PUMP CAPACITY TEST—GAS POWERED
SUPPLY TOP OF
LOCKNUT FUEL PRESSURE ENGINES
REGULATOR CONNECTION FUEL TANK
Before performing this test, verify fuel pump pres
sure by performing the previous tests.
(1) Release the fuel system pressure from fuel sys
PRESSURE RELIEF/ tem. Refer to the previous Fuel Pressure Release
ROLLOVER VALVE Procedure i n this group.
(2) Disconnect the fuel supply line at fuel rail.
On the 8.0L V-10 engine, the fuel line-to-fuel rail
connection is made at the rear of the engine. Refer to
Fuel Tubes/Lines/Hoses and Clamps i n this section of
PUMP/GAUGE
AUXILIARY RUBBER GROMMET ELEC. CONNECTION the group for procedures. Remove air cleaner housing
FUEL SUPPLY
FRONT OF before tool connection.
FITTING
(SOME ENGINES) TANK J9414-32 (3) Connect Fuel Line Pressure Test Adapter Tool
number 6631 (3/8 in.), or number 6539 (5/16 in.) into
Fig. 10 Fuel Filter/Fuel Pressure Regulator—Typical the disconnected fuel supply line (tube). Insert the
other end of Adapter Tool 6631 or 6539 into an ap
(1) Remove (unscrew) the protective plastic cap proved gasoline container.
from the pressure test port on the fuel rail (Fig. 9). (4) To activate the fuel pump and pressurize the
On the 8.0L V-10 engine, this test port is located at system, obtain the DRB scan tool. Refer to the appro
the front of the engine. Connect the 0-414 kPa (0-60 priate Powertrain Diagnostic Procedures service
psi) fuel pressure gauge (from Gauge Set 5069) to manual for DRB operation.
test port pressure fitting on fuel rail (Fig. 11). (5) A good fuel pump will deliver approximately 2
FUEL PRESSURE
liters of fuel per minute.
TEST G A U G E
FUEL PRESSURE LEAI DOWN TEST—GAS
POWERED ENGINES
ENGINE OFF
Abnormally long periods of cranking to restart a
hot engine that has been shut down for a short pe
riod of time may be caused by:
• Fuel pressure bleeding past a fuel injector(s).
• Fuel pressure bleeding past the check valve i n the
fuel filter/fuel pressure regulator.
(1) Disconnect the fuel inlet line at fuel rail. On
the 8.0L V-10 engine, the fuel line-to-fuel rail connec
tion is made at the rear of the engine. Refer to Fuel
Tubes/Lines/Hoses and Clamps i n this section of the
group for procedures. Remove air cleaner housing be
fore tool connection.
(2) Connect Fuel Line Pressure Test Adapter Tool
number 6539 (5/16 in.), or Adapter Tool number 6631
J9214-28 (3/8 in.) between the disconnected fuel line and fuel
rail (Fig. 12).
Fig. 11 Fuel Pressure Test—Typical Adapter Tool connection on the 8.0L V-10 engine is
made at rear of engine.
(2) Note pressure gauge reading. Fuel pressure (3) Connect the 0-414 kPa (0-60 psi) fuel pressure
should be approximately 241-310 kPa (35-45 psi) at test gauge (from Gauge Set 5069) to the test port on
idle. either tool 6631 or 6539. The fittings on both tools
(3) I f pressure is at O psi, connect DRB scan tool must be in good condition and free from any
and refer to operating instructions i n the appropriate small leaks before performing the proceeding
Powertrain Diagnostics Procedures service manual. test.
I f operating pressure is above 45 psi, fuel pump is (4) Start engine and bring to normal operating
OK. Replace fuel filter/fuel pressure regulator assem temperature.
bly. (5) Observe test gauge. Normal operating pressure
should be 241-310 kPa (35-45 psi).
S U R E MUST B E R E L E A S E D . R E F E R TO T H E F U E L
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
Inspect all hose connections such as clamps, cou

plings and fittings to make sure they are secure and
leaks are not present. The component should be re
placed immediately i f there is any evidence of degra
dation that could result i n failure.
Never attempt to repair a plastic fuel line/tube. Re
place as necessary.
Avoid contact of any fuel tubes/hoses with other ve
hicle components that could cause abrasions or scuff
ing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
Fig. 12 Connecting Adapter Tool—Typical The lines/tubes/hoses used on fuel injected vehicles
(6) Shut engine off. are of a special construction. This is due to the
(7) Pressure should not fall below 24 psi for five higher fuel pressures and the possibility of contami
minutes. nated fuel i n this system. I f i t is necessary to replace
(8) I f pressure falls below 24 psi, i t must deter these lines/tubes/hoses, only those marked EFM/EFI
mined i f a fuel injector, the fuel module mounted fuel may be used.
pressure regulator or a fuel tube/line is leaking. The hose clamps used to secure rubber hoses on
(9) Again, start engine and bring to normal operat fuel injected vehicles are of a special rolled edge con
ing temperature. struction. This construction is used to prevent the
(10) Shut engine off. edge of the clamp from cutting into the hose. Only
(11) Checking for fuel injector leakage: Clamp these rolled edge type clamps may be used i n this
off the rubber hose portion of either tool 6539 or 6631 system. A l l other types of clamps may cut into the
between the disconnected fuel tube (line) and test hoses and cause high-pressure fuel leaks.
port inlet. I f pressure now holds at or above 24 psi, a Use new original equipment type hose clamps.
fuel injector or the fuel rail is leaking. Tighten hose clamps to 1 N-m (15 i n . lbs.) torque.
Checking for fuel pressure regulator o r fuel
tube leakage: Clamp off the rubber hose portion of QUICK-CONNECT FITTINGS
either tool 6539 or 6631 between the fuel rail and Also refer to the previous Fuel Tubes/Lines/Hoses
test port inlet. I f pressure now holds at or above 24 and Clamps section.
psi, a leak can be found at a fuel tube/line. I f no Different types of quick-connect fittings are used to
leaks are found at fuel tubes or lines, replace the fuel attach various fuel system components. These are: a
filter/fuel pressure regulator. single-tab type, a two-tab type or a plastic retainer
ring type.
MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diag SINGLE-TAB TYPE
nose with this system. The powertrain control mod This type of fitting is equipped with a single pull
ule (PCM) has been programmed to compensate for tab (Fig. 13). The tab is removable. After the tab is
some mechanical malfunctions such as incorrect cam removed, the quick-connect fitting can be separated
timing, vacuum leaks, etc. I f engine performance from the fuel system component.
problems are encountered and a diagnostic trouble
code (DTC) is not displayed, the problem may be me CAUTION: The interior components (O-rings, s p a c
chanical rather than electronic. ers) of this type of quick-connect fitting are not ser
viced separately, but new pull tabs are available. Do
FUEL TUBES/LINES/HOSES AND CLAMPS not attempt to repair damaged fittings or fuel lines/
Also refer to the proceeding section on Quick-Con tubes. If repair is necessary, replace the complete
nect Fittings. fuel tube/quick-connect fitting assembly.
WARNING: T H E F U E L S Y S T E M IS UNDER A CON
STANT P R E S S U R E ( E V E N WITH T H E ENGINE O F F ) .
B E F O R E SERVICING ANY F U E L S Y S T E M H O S E S ,
FITTINGS O R L I N E S , T H E F U E L S Y S T E M P R E S
INSERTED TO REMOVE QUICK-CONNECT
TUBE E N D PULL TAB J9414-24 FITTING J9414-25
Fig. 13 Single-Tab Type Fitting Fig. 14 Disconnecting Single-Tab Type Fitting

WARNING: T H E F U E L S Y S T E M IS UNDER A CON FUEL TUBE OR PULL QUICK-CONNECT
STANT P R E S S U R E (EVEN WITH T H E ENGINE O F F ) . FUEL SYSTEM TAB FITTING
FITTINGS OR LINES, T H E F U E L S Y S T E M P R E S
S U R E MUST B E R E L E A S E D . R E F E R T O T H E F U E L
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
DISCONNECTION/CONNECTION
(1) Disconnect negative battery cable from battery.
(2) Perform the fuel pressure release procedure.
Refer to the Fuel Pressure Release Procedure i n this FUEL
section. TUBE
(3) Clean the fitting of any foreign material before STOP J9414-26
disassembly.
(4) Press the release tab on the side of fitting to re Fig. 15 Removing Pull Tab
lease pull tab (Fig. 13). (11) Obtain a new pull tab. Push the new tab down
until i t locks into place i n the quick-connect fitting.
CAUTION: If this release tab is not pressed prior to (12) Verify a locked condition by firmly pulling on
releasing the pull tab, the pull tab will be damaged. fuel tube and fitting (15-30 lbs.).
(5) While pressing the release tab on the side of (13) Connect negative cable to battery.
the fitting, use a screwdriver to pry up the pull tab (14) Start engine and check for leaks.
(Fig. 14).
(6) Raise the pull tab until i t separates from the T W O - T A B TYPE FITTING
quick-connect fitting (Fig. 15). Discard the old pull This type of fitting is equipped with tabs located on
tab. both sides of the fitting (Fig. 16). These tabs are sup
(7) Disconnect the quick-connect fitting from the plied for disconnecting the quick-connect fitting from
fuel system component being serviced. component being serviced.
(8) Inspect the quick-connect fitting body and fuel
system component for damage. Replace as necessary. CAUTION: The interior components (O-rings, s p a c
(9) Prior to connecting the quick-connect fitting to ers) of this type of quick-connect fitting are not ser
component being serviced, check condition of fitting viced separately, but new plastic retainers are
and component. Clean the parts with a lint-free available. Do not attempt to repair damaged fittings
cloth. Lubricate them with clean engine oil. or fuel lines/tubes. If repair is necessary, replace
(10) Insert the quick-connect fitting into the fuel the complete fuel tube/quick-connect fitting a s s e m
tube or fuel system component until the built-on stop bly.
on the fuel tube or component rests against back of
fitting.
14 - 10 FUEL SYSTEM •
(7) Insert the quick-connect fitting to the compo
nent being serviced and into the plastic retainer.
When a connection is made, a click will be heard.
(8) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(10) Start engine and check for leaks.
PLASTIC R E T A I N E R R I N G TYPE FITTING

This type of fitting can be identified by the use of a
full-round plastic retainer ring (Fig. 17) usually black
in color.
Fig. 16 Typical Two-Tab Type Quick-Connect Fitting

STANT P R E S S U R E ( E V E N WITH T H E ENGINE O F F ) .
FITTINGS OR L I N E S , T H E F U E L S Y S T E M P R E S
S U R E MUST B E R E L E A S E D . R E F E R TO T H E F U E L
PRESSURE RELEASE P R O C E D U R E IN THIS
GROUP.
INSTALLATION
(1) Disconnect negative battery cable from the bat
tery.
(2) Perform the fuel pressure release procedure.
Refer to the Fuel Pressure Release Procedure i n this
section.
PLASTIC
(3) Clean the fitting of any foreign material before
RETAINER J9314-100
disassembly.
(4) To disconnect the quick-connect fitting, squeeze
Fig. 17 Plastic Retainer Ring Type Fitting
the plastic retainer tabs against the sides of the
quick-connect fitting with your fingers. Tool use is CAUTION: The interior components (O-rings, s p a c
not required for removal and may damage plastic re ers, retainers) of this type of quick-connect fitting
tainer. Pull the fitting from the fuel system compo are not serviced separately. Do not attempt to repair
nent being serviced. The plastic retainer will remain damaged fittings or fuel lines/tubes. If repair is nec
on the component being serviced after fitting is dis essary, replace the complete fuel tube/quick-con
connected. The O-rings and spacer will remain i n the nect fitting assembly.
quick-connect fitting connector body.
(5) Inspect the quick-connect fitting body and com
ponent for damage. Replace as necessary. WARNING: T H E F U E L S Y S T E M IS UNDER A CON
STANT P R E S S U R E (EVEN WITH T H E ENGINE O F F ) .
CAUTION: When the quick-connect fitting w a s dis B E F O R E S E R V I C I N G ANY F U E L S Y S T E M H O S E S ,
connected, the plastic retainer will remain on the FITTINGS OR L I N E S , T H E F U E L S Y S T E M P R E S
component being serviced. If this retainer must be S U R E MUST B E R E L E A S E D . R E F E R T O T H E F U E L
removed, very carefully release the retainer from PRESSURE RELEASE P R O C E D U R E IN THIS
the component with two small screwdrivers. After GROUP.
removal, inspect the retainer for c r a c k s or any dam
age.
(8) Prior to connecting the quick-connect fitting to (1) Disconnect negative battery cable from the bat
component being serviced, check condition of fitting tery.
and component. Clean the parts with a lint-free
cloth. Lubricate them with clean engine oil.
(2) Perform the fuel pressure release procedure. After disconnection, the plastic retainer ring will
Refer to the Fuel Pressure Release Procedure in this remain with the quick-connect fitting connector body.
section. (5) Inspect fitting connector body, plastic retainer
(3) Clean the fitting of any foreign material before ring and fuel system component for damage. Replace
disassembly. as necessary.
(4) To release the fuel system component from the (6) Prior to connecting the quick-connect fitting to
quick-connect fitting, firmly push the fitting towards component being serviced, check condition of fitting
the component being serviced while firmly pushing and component. Clean the parts with a lint-free
the plastic retainer ring into the fitting (Fig. 17). cloth. Lubricate them with clean engine oil.
With the plastic ring depressed, pull the fitting from (7) Insert the quick-connect fitting into the compo
the component. The plastic retainer ring must be nent being serviced until a click is felt.
pressed squarely into the fitting body. I f this re
(8) Verify a locked condition by firmly pulling on
tainer is cocked during removal, it may be dif
fuel tube and fitting (15-30 lbs.).
ficult to disconnect fitting. Use an open-end
wrench on the shoulder of the plastic retainer (9) Connect negative battery cable to battery.
ring to aid in disconnection. (10) Start engine and check for leaks.
F U E L DEL1WERY S Y S T E M — D I E S E L E N G I N E
INDEX
page page
Diesel Fuel System Operation 20 Fuel Tank 15
Fuel Drain Manifold . 20 Fuel Tank Module—Diesel Engine 12
Fuel Filter 16 Fuel Transfer Pump 15
Fuel Filter—In Tank . 16 Fuel Transfer Pump Capacity Test—Diesel Engine . 17
Fuel Filter/Water Separator 16 Fuel Tubes/Lines/Hoses and Clamps—Low-
Fuel Heater 14 Pressure Type 17
Fuel Heater Relay 15 General Information 12
Fuel Injection Pump 17 High-Pressure Fuel Lines 17
Fuel Injectors 18 Intake Manifold Air Heater 17
Fuel Shutdown Solenoid 19 Intake Manifold Air Heater Relays 17
Fuel Shutdown Solenoid Relay 19 Intake Manifold Air Temperature Sensor 17
Fuel System Pressure Test—Diesel Engine 16 Powertrain Control Module 20
Fuel System Pressure Warning 16 Quick-Connect Fittings 17
GENERAL INFORMATION FUEL TANK MODULE—DIESEL ENGINE

This section of the group will cover diesel An electric fuel pump is not used i n the fuel tank
fuel delivery components not controlled by the module for diesel powered engines. Fuel is supplied
powertrain control module (PCM), Various com by the fuel transfer pump and the fuel injection
ponents, relays and switches are operated by pump.
the PCM. Refer to the Diesel Engine sections of The fuel tank module is installed in the top of the
this group for components that are operated by fuel tank (Fig. 2). The fuel tank module (Figs. 2 or 3)
the PCM. contains the following components:
Diesel fuel delivery (except for operation of • Fuel reservoir
the intake manifold air heater and manifold air • A separate in-tank fuel filter
heater relays) is not directly regulated by the • Pressure relief/rollover valve
PCM. • Fuel gauge sending unit
The fuel delivery system of the 5.9L turbo-diesel • Fuel supply line connection
engine consists of the: • Fuel return line connection
• Fuel tank • Auxiliary fuel supply fitting
• Fuel tank module
• Low and high-pressure fuel supply lines E L E C T R I C F U E L PUMP
The electric fuel pump, normally mounted i n the
• Low-pressure, mechanical, fuel transfer pump (fuel
fuel pump module on gas powered engines, is not
lift pump)
used with diesel powered engines.
• High-pressure fuel injection pump The low-pressure, fuel transfer pump (fuel lift
• Fuel heater pump) and high- pressure fuel injection pump are
• Fuel heater relay mechanically operated. Refer to either: Fuel Transfer
• Fuel shutdown solenoid Pump or Fuel Injection Pump for information.
• Fuel shutdown solenoid relay
• High-pressure fuel injectors FUEL T A N K MODULE REMOVAL
• Fuel return line
• Fuel filter/water separator CAUTION: Whenever the fuel tank module is ser
• In-tank fuel filter viced, the plastic locknut and rubber gasket must
• Pre-filter (in fuel heater) be replaced.
• Fuel drain manifold
(1) Drain the fuel tank. Refer to Draining Fuel
For information regarding fuel requirements of the
Tank in the Fuel Tank section of this group.
5.9L turbo diesel engine, refer to the Fuel
(2) Remove fuel tank. Refer to the Fuel Tank sec
Requirements—Diesel Engines paragraph at the tion of this group.
front of this group. (3) Note the direction of the: fuel line connectors,
the pressure relief/rollover valve and the fuel gauge
electrical connector. These should all be pointed to
the drivers side of the vehicle.
FUEL SYSTEM 14 - 13
WASTEGATED TURBOCHARGER
TURBOCHARGER OIL SUPPLY
HIGH PRESSURE
FUEL TUBES
FUEL DRAIN
UNE (MANIFOLD)
FUEL INJECTORS (6)
TURBOCHARGER
RIGHT SIDE WASTEGATE
OF ENGINE
FUEL SUPPLY INTAKE AIR INTAKE MANIFOLD

UNE (TO SENSOR
INJECTION PUMP)
WATER TEMPERATURE
SENSOR (FOR I.R GAUGE)
HIGH PRESSURE FUEL FILTER/

FUEL LINES WATER SEPARATOR
FUEL/WATER
SEPARATOR AND
DRAIN VALVE
HIGH PRESSURE
FUEL INJECTION
PUMP
RUBBER PRIMER
BUTTON
THROTTLE POSITION
SENSOR (AUTO. FUEL TRANSFER
TRANS. ONLY) PUMP (FUEL
LIFT PUMP)
STARTER
FUEL MOTOR
SHUTDOWN
SOLENOID FUEL HEATER
TEMP. SENSOR
OIL PRESSURE ' (THERMOSTAT) LEFT SIDE DRAIN
SENSOR OF ENGINE TUBE J9414-69
Fig. 1 Fuel System Components—Diesel Engine

PRESSURE RELIEF/ FUEL TANK MODULE INSTALLATION
ROLLOVER VALVE AUX. FUEL
SUPPLY FITTING
CAUTION: Whenever the fuel tank module is ser
viced, the locknut and rubber gasket must be re
PLASTIC
LOCKNUT placed.
FUEL
SUPPLY (1) Using a new gasket, position the fuel tank
UNE module into the opening i n fuel tank. The fuel line
FUEL connectors, the pressure relief/rollover valve and the
RETURN
UNE fuel gauge electrical connector should all be pointed
FRONT FUEL GAUGE
OF TANK to the drivers side of the vehicle before tightening
SENDING
UNIT locknut.
ELECTRICAL (2) Position new locknut over top of fuel tank mod
CONNECTOR ule.
J9414-70 (3) Tighten locknut.
(4) Install fuel tank. Refer to Fuel Tank Installa
Fig. 2 Top View of Fuel Tank Module—Diesel tion i n this section.
FUEL G A U G E LOCKING
FLOAT SENDING UNIT TABS AUXILIARY FUEL SUPPLY FITTING
ELECTRIC An auxiliary (capped) fuel supply fitting is located
FUEL PUMP on the top of the fuel tank module (Fig. 2). This fit
ting will be available only on: diesel powered models,
models with either a 5.9L V-8 heavy duty or 8.0L
V-10 engine and all cab-chassis models. This fitting
supplies a non-pressurized auxiliary fuel source.
FUEL HEATER
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation. The fuel
heater is located on the left side of the engine above
MOUNTING IN-TANK the starter motor (Fig. 4).
SCREWS FUEL FILTER J9414-33 The heater assembly is equipped with a built-in
sensor (thermostat) (Fig. 4) that senses fuel temper
Fig. 3 Fuel Gauge Sending Unit—Typical
ature. When the temperature is below 40 degrees F,
(4) The plastic locknut on the fuel tank module is the built-in sensor allows current to flow to the
threaded onto the fuel tank. Remove the locknut built-in heater element warming the fuel. When the
(Fig. 2). The tank module will spring up when the temperature is above 80 degrees F, the sensor stops
locknut is removed. current flow to the heater element.
(5) Remove module from fuel tank. Voltage to operate the fuel heater is supplied from
the ignition switch and through the fuel heater relay
DISASSEMBLY—FUEL GAUGE SENDING UNIT (Fig. 5) (also refer to Fuel Heater Relay).
(1) Remove sending unit mounting screws (Fig. 3). The fuel heater and fuel heater relay are not con
(2) Mark the sending unit electrical wires before trolled by the powertrain control module (PCM).
removal for correct installation. Carefully disconnect The built-in heater element operates on 12 volts,
electrical wires from sending unit. Remove sending 300 watts at 0 degrees F.
unit. The fuel heater assembly contains a pre-filter to
(3) Reverse order of removal for fuel gauge unit in prevent contaminants from entering the fuel transfer
stallation. pump.
For diagnosis, refer to the Diesel Engine—General
IN-TANK FUEL FILTER
Diagnosis section of this group.
The in-tank filter is attached to the bottom of the For removal and installation procedures, refer to
fuel tank module (Fig. 3). the Diesel Engine—Component Removal/Installation
(1) Pry the mounting tabs back and remove the in- section of this group.
tank fuel filter.
(2) Install new fuel filter into retaining tabs.
FUEL TEMPERATURE SENSOR For removal and installation procedures, refer to
the Diesel Engine—Component Removal/Installation
FUEL TANK
Refer to the Fuel Tank section of this group for in
formation.
FUEL TRANSFER PUMP

The fuel transfer pump (fuel lift pump) is located
on the left-rear side of the engine cylinder block
above the starter motor (Fig. 1). The mechanically
operated pump is not controlled by the powertrain
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source of approximately
FUEL 172 Kpa (25 psi) to the injection pump and fuel filter/
TRANSFER
PUMP water separator from the fuel tank. Here, the low-
ELECTRICAL pressure is raised by the fuel injection pump for
CONNECTOR
FUEL operation of the high-pressure fuel injectors. The
HEATER J9414-94
transfer pump is driven by an eccentric on the engine
camshaft that actuates a spring loaded piston within
Fig. 4 Fuel Heater and Temperature Sensor Location
the pump (Fig. 6). Check valves within the pump,
FUEL HEATER RELAY control direction of fuel flow and prevent fuel bleed-
Voltage to operate the fuel heater is supplied from back during engine shut down.
the ignition switch through the fuel heater relay. The The fuel transfer pump should never be operated
powertrain control module (PCM) is not used to con without the pre-filter installed.
trol this relay. The fuel volume of the transfer pump will vary
The fuel heater relay is located i n the engine com with engine rpm, but will always provide more fuel
partment near the brake master cylinder (Fig. 5). than the fuel injection pump requires. Excess fuel is
FUEL SHUT-OFF returned to the fuel tank through an overflow valve.
FUEL HEATER S O L E N O I D RELAY The valve is located on the side of the injection pump
RELAY (Fig. 7) and is used to connect the fuel return line to
BRAKE MASTER the side of the injection pump. This valve opens at
CYLINDER
approximately 152 kPa (22 psi) and returns fuel to
the fuel tank through the fuel return line.
CHECK LOW PRESSURE
VALVES SUPPLY UNE RUBBER
A B C PRIMER PUMP
BUTTON
FUEL UNE
ENGINE INLET J9414-71
J9414-31 CAMSHAFT
Fig. 5 Fuel Heater Relay—Diesel Fig. 6 Transfer Pump Operation

For diagnosis, refer to the Diesel Engine—General MANUAL OPERATION OF TRANSFER PUMP
Diagnosis section of this group. The transfer pump has a primer button (Fig. 8).
This rubber primer button is located on the pump
FUEL RETURN LINE
For removal and installation procedures of the
transfer pump, refer to Fuel Transfer Pump i n the
Diesel Engine—Component Removal/Installation sec
tion of this group.
OVERFLOW
VALVE For diagnosis, refer to the Diesel Engine—General
FUEL FILTER/WATER SEPARATOR

The fuel filter/water separator protects the fuel in
jection pump by removing water and contaminants
from the fuel. The separator filter construction allows
fuel to pass through it, but prevents moisture (water)
from doing so. Moisture collects at the bottom of the
separator filter.
The fuel filter/water separator is located on the left
side of the engine above the starter motor (Fig. 1).
Refer to the maintenance schedules i n Group 0 i n
this manual for the recommended fuel filter/water
separator replacement intervals.
FUEL INJECTION For diagnosis, refer to the Diesel Engine—General
J9414-102
PUMP Diagnosis section of this group.
Fig. 7 Injection Pump Overflow Valve For removal and installation procedures, refer to
the Diesel Engine —Component Removal/Installation
housing. The purpose of the button is to prime and
bleed air from the fuel system i f the vehicle has run
For draining of water, refer to the Diesel
out of fuel. To prime the system up to the fuel injec
Engine—Component Removal/Installation section of
tor pump, continually press on the button (Fig. 8) un
this group. See Fuel Filter/Water Separator.
t i l resistance is felt. This resistance will indicate that
priming is completed and air has been removed. FUEL FILTER
I f the primer button feels as i f i t is not pumping, Refer to Fuel Filter/Water Separator for informa
rotate (crank) the engine approximately 90 degrees.
tion.
Continue pumping until air is removed.
FUEL FILTER—IN TANK
FUEL Refer to Fuel Tank Module—Diesel Engine for re
TRANSFER moval and installation. This can be found i n the Fuel
PUMP N
Delivery—Diesel Engine section of this group.
FUEL SYSTEM PRESSURE WARNING
WARNING: H I G H - P R E S S U R E F U E L LINES D E L I V E R
D I E S E L F U E L UNDER E X T R E M E P R E S S U R E FROM
T H E INJECTION PUMP TO T H E F U E L I N J E C T O R S .
THIS MAY B E A S HIGH A S 120,000 KPA (17,405 PSI)
. U S E E X T R E M E CAUTION WHEN INSPECTING F O R
HIGH-PRESSURE FUEL L E A K S . INSPECT FOR
H I G H - P R E S S U R E F U E L L E A K S WITH A S H E E T O F
C A R D B O A R D . HIGH F U E L INJECTION P R E S S U R E
C A N C A U S E P E R S O N A L INJURY IF CONTACT IS
MADE WITH T H E SKIN.
RUBBER
PRIMER
BUTTON FUEL SYSTEM PRESSURE TEST—DIESEL ENGINE
J9414-72 For fuel pressure tests, refer to the Diesel
Engine—General Diagnosis section of this group.
Fig. 8 Fuel Transfer Pump—Manual Operation
• FUEL SYSTEM 14 - 17
FUEL TRANSFER PUMP CAPACITY TEST—DIESEL INTAKE MANIFOLD AIR HEATER RELAYS
ENGINE The relays for the intake manifold air heater are
For fuel pump capacity tests, refer to the Diesel controlled by the powertrain control module (PCM).
Engine —General Diagnosis section of this group. Refer to the Diesel Engine—Component Description/
System Operation section of this group for an opera
FUEL TUBES/LINES/HOSES AND CLAMPS—LOW- tional description. Refer to the Diesel
Engine—General Diagnosis section for diagnosis. Re
PRESSURE TYPE fer to the Diesel Engine—Component Removal/Instal
Refer to Fuel Tubes/Lines/Hoses and Clamps. Also lation section for removal/installation procedures.
refer to the section on Quick-Connect Fittings. These
can be found i n the Fuel Delivery—Except Diesel sec INTAKE MANIFOLD AIR TEMPERATURE SENSOR
tion of this group. The intake manifold air temperature sensor is con
trolled by the powertrain control module (PCM). Re
QUICK-CONNECT FITTINGS fer to the Diesel Engine sections of this group for an
Refer to Quick-Connect Fittings. These can be operational description, diagnosis and removal/instal
found i n the Fuel Delivery—Except Diesel section of lation procedures.
this group.
FUEL INJECTION PUMP
HIGH-PRESSURE FUEL LINES The fuel injection pump is a Bosch P7100 series in
line type (Fig. 9). The injection pump is driven by the
CAUTION: The high-pressure fuel lines must be engine camshaft. A gear on the end of the pump shaft
held securely in place in their holders. The lines meshes with the camshaft gear. The pump is timed
cannot contact each other or other components. Do to the engine. Fuel injection occurs near the end of
not attempt to weld high-pressure fuel lines or to the compression stroke for each cylinder.
repair lines that are damaged. Only u s e the recom
mended lines when replacement of high-pressure DEUVERY OIL FILL PLUG
fuel line is necessary.
High-pressure fuel lines deliver fuel under pressure

of up to approximately 120,000 kPa (17,405 PSI)
from the injection pump to the fuel injectors. The
lines expand and contract from the high-pressure
fuel pulses generated during the injection process. All
high-pressure fuel lines are of the same length and
inside diameter. Correct high-pressure fuel line usage
and installation is critical to smooth engine opera
tion.
WARNING; U S E E X T R E M E CAUTION WHEN IN

S P E C T I N G F O R H I G H - P R E S S U R E F U E L L E A K S . IN
S P E C T F O R H I G H - P R E S S U R E F U E L L E A K S WITH A
S H E E T O F C A R D B O A R D . HIGH F U E L INJECTION
P R E S S U R E CAN C A U S E P E R S O N A L INJURY IF
CONTACT IS MADE WITH T H E SKIN.
For removal and installation procedures, refer to

section of this group. Fig. 9 Fuel Injection Pump
The RQV-K governor (Fig. 10) has a pump timing
INTAKE MANIFOLD AIR HEATER feature. This will allow the pump shaft to be oriented
The intake manifold air heater is controlled by the in a position corresponding to top dead center (TDC)
powertrain control module (PCM). Refer to the Diesel for the compression stroke of cylinder number one.
Engine—Component Description/System Operation Indexing the governor flyweight assembly to the
section of this group for an operational description. shaft during assembly establishes pump timing.
Refer to the Diesel Engine—General Diagnosis sec As engine speed increases, the internal pump pres
tion for diagnosis. Refer to the Diesel sure increases. An air-flow control (AFC) (Fig. 10) on
Engine—Component Removal/Installation section for the governor ensures that regulated fuel delivery is
removal/installation procedures. matched to intake manifold pressure (turbocharger
boost) for emission control. FUEL INJECTORS
The fuel injectors are mounted on the left side of
the cylinder head (Fig. 11). The injectors are con
nected to the fuel injection pump by the high-pres
sure fuel lines. A separate injector is used for each
cylinder.
FUEL INJECTION
™™ J9414-104
Fig. 10 injection Pump Governor and AFC Fig. 11 Fuel Injectors—Typical
The mechanical fuel transfer pump delivers fuel The injectors consist of the nozzle holder, O-ring
under a low- pressure of approximately 172 Kpa (25 water seal, shims, spring, needle valve and nozzle
psi) to the injection pump through the fuel filter/wa (Fig. 12). Fuel enters the injector at the fuel inlet
ter separator. The injection pump then supplies high- (top of injector) and is routed to the needle valve
pressure fuel of approximately 120,000 kPa (17,400 bore. When fuel pressure rises to approximately
psi) to each injector i n precise metered amounts at "25,500 kPa (3,700 psi)-to-26,900 kPa (3,900 psi), the
the correct time. needle valve spring tension is overcome. The needle
Excess fuel is returned to the fuel tank by an over valve rises and fuel flows through the spray holes i n
flow valve (Fig. 7) on the injection pump. This vent the nozzle tip into the combustion chamber. The
opens at approximately 152 kPa (22 psi) and returns pressure required to lift the needle valve is the oper
fuel to the fuel tank through the fuel return line. ating pressure setting. This is sometimes referred to
Diesel fuel and engine oil are used to cool the fuel as the POP pressure setting.
injection pump. A separate oil feed line from the en
gine supplies engine oil to the pump. The oil returns
to the engine through an opening at the front of
pump.
The KSB (cold start) solenoid is no longer used.
The injection pump high idle speed is factory-
sealed and is not adjustable. The low idle speed is
adjustable. Refer to Idle Speed Adjustment i n the
Diesel Engine—General Diagnosis section of this
group for procedures.
For diagnosis, refer to the Diesel Engine—General
J9114-82
For injection pump timing, refer to Fuel Injection
Fig. 12 Typical Fuel Injector Operation
Pump Timing i n the Diesel Engine—General Diagno
sis section of this group. Fuel pressure i n the injector circuit decreases after
injection. The injector needle valve is immediately
closed by the needle valve spring and fuel flow into
• FUEL SYSTEM 14-19
the combustion chamber is stopped. Exhaust gases jection pump lever. The injection pump shutdown le
are prevented from entering the injector nozzle by ver is then positioned to the run position (Fig. 14).
the needle valve. When the ignition key is released to the ON posi
For diagnosis, refer to the Diesel Engine—General tion, a low-amperage current is supplied to the other
Diagnosis section of this group. coil i n the solenoid. This is used to hold the solenoid
For removal and installation procedures, refer to shaft i n the up position. Accelerator pedal position
the Diesel Engine —Component Removal/Installation then controls fuel lever control for fuel control at the
section of this group. injection pump.
FUEL SHUTDOWN SOLENOID

SHUTDOWN
The fuel s h u t d o w n solenoid a n d fuel shut POSITION RUN POSITION
d o w n solenoid relay are n o t c o n t r o l l e d b y the
p o w e r t r a i n c o n t r o l module (PCM).
The fuel shutdown (shut-off) solenoid is used to
electrically shut off the diesel fuel supply to the high-
pressure fuel injection pump. The solenoid is
mounted to the side of the pump and is connected to
the pump with a lever (Figs. 1 or 13).
FRONT OF ENGINE AIR TEMPERATURE SENSOR
SENSOR ELECTRICAL
CONNECTOR
FUEL
SHUTDOWN
SOLENOID
J9414-80
Fig. 14 Fuel Shutdown Solenoid Positions

Voltage to operate the solenoid is supplied from the
ignition switch and through the fuel shutdown sole
noid relay (Fig. 15) (also refer to Fuel Shutdown So
lenoid Relay).
INTAKE For solenoid diagnosis, refer to Fuel Shutdown So
MANIFOLD lenoid i n the Diesel Engine—General Diagnosis sec
(UPPER HALF) fpQ SOLENOID
S H U
SOLENOID
W N
ELECTRICAL tion of this group.

CONNECTOR J9414-93 I f the shutdown solenoid is being replaced, its shaft
length must be adjusted. For fuel shutdown solenoid
Fig. 13 Fuel Shutdown Solenoid Location removal, installation and solenoid shaft adjustment
The solenoid controls starting and stopping of the procedures, refer to the Diesel Engine—Component
engine regardless of the position of the accelerator Removal/Installation section of this group.
pedal. When the ignition switch is off, the solenoid
plunger is spring loaded (down) i n the 'shutdown po FUEL SHUTDOWN SOLENOID RELAY
sition (Fig. 14) and fuel is shut off to the injection Voltage to operate the fuel shutdown (shut-off) so
pump. lenoid is supplied from the ignition switch and
Two different coils are located within the solenoid through the fuel shutdown solenoid relay. The fuel
and a three-wire pigtail wire harness is attached to shutdown solenoid relay is located i n the engine com
the solenoid. partment near the brake master cylinder (Fig. 15).
When the ignition switch is turned to the CRANK For diagnosis, refer to the Diesel Engine—General
(starter engaged) position, high-amperage current Diagnosis section of this group.
(approximately 40 amps at 12 volts) is supplied to For removal and installation procedures, refer to
one of the coils i n the shutdown solenoid from the the Diesel Engine—Component Removal/Installation
fuel shutdown solenoid relay. This high-amperage section of this group.
current allows the solenoid shaft to pull up on the in
14 - 20 FUEL SYSTEM
FUEL SHUT-OFF
FUEL HEATER SOLENOID RELAY
Fig. 16 Fuel Drain Manifold—Typical

Fig. 15 Fuel Shutdown Solenoid Relay—Diesel

Refer to the Diesel Engine sections of this group for
FUEL DRAIN MANIFOLD information.
Some fuel is continually vented from the fuel injec
tion pump to cool the pump and the fuel injectors. DIESEL FUEL SYSTEM OPERATION
During injection, a small amount of fuel flows past Refer to this section (Fuel Delivery—Diesel Engine)
the injector nozzle and is not injected into the com for components not operated by the powertrain con
bustion chamber. This fuel drains into the fuel drain trol module (PCM). Refer to the Diesel
manifold (Fig. 16). Fuel i n the drain manifold is then Engine—Component Description/System Operation
routed back to the fuel filter/water separator. section for components operated by the PCM.
A C C E L E R A T O R P E D A L AND T H R O T T L E C A B L E
INDEX
page page
Accelerator Pedal 21 Throttle Cable 22
General Information 21 Throttle Linkage Adjustment—Diesel Engine . . . . . 23
GENERAL INFORMATION PEDAL

RETURN
All gas powered engines are equipped with torsion SPRING
return springs located on the throttle body shaft. On THROTTLE
( M A N U A L TRANS.
BODY
the diesel powered engine, the torsion springs are lo ONLY)
cated on the fuel injection pump lever (Fig. 1). 3.9IV

5.2L and 5.9L gas powered engines equipped with a
manual transmission have an additional pedal return
spring (Fig. 2). All of these springs are designed to
give positive throttle return while meeting safety re
quirements.
FRONT O F VEHICLE
CABLE SJ^> RUBBER
CABLE
SOCKET GROMMET
MOUNTING
BRACKET CABLE
PIN
THROTTLE
BODY C A M
THROTTLE
CABLE J9414-45
Fig. 2 Throttle Return Spring—3.9U5.2U5.9L Gas

Engines with Man. Trans.
(2) Insert a small screwdriver into the square holes
located on the pivots/bushings (Fig. 4). Twist the
FUEL screwdriver to disengage the pivot locks from the
INJECTION
PUMP
pivot pin. Pivots will be damaged when removing.
Discard old pivots.
TORSION
(3) Remove pedal/bracket assembly from vehicle.
SPRING J9414-43
INSTALLATION
Fig. 1 Throttle Cable at Injection Pump—Diesel- (1) Position pedal/bracket assembly over the pivot
Typical pin (Fig. 4).
(2) Install two new pivots/bushings. Using large
ACCELERATOR PEOAL pliers, press both of the bushings together until they
bottom on the sides of the pedal/bracket assembly.
REMOVAL Bushing retaining ears will snap into position when
CAUTION: Be careful not to damage or kink the c a properly installed.
ble core wire (within the cable sheathing) while ser (3) From inside the vehicle, hold up the accelerator
vicing accelerator pedal or cables. pedal. Install the throttle cable core wire and plastic
cable retainer into and through the upper end of the
(1) From inside the vehicle, hold up the accelerator pedal arm (the plastic retainer is snapped into the
pedal. Remove the plastic cable retainer and throttle pedal arm). When installing the plastic retainer to
cable core wire from upper end of pedal arm (Fig. 3). the accelerator pedal arm, note the index tab on the
The plastic cable retainer snaps into pedal the arm. pedal arm (Fig. 3). Align the index slot on the plastic
cable retainer to this index tab.
CABLE ^ FRONT OF cable core wire from upper end of pedal arm (Fig. 3).
STOP The plastic cable retainer snaps into pedal the arm.
C^-v VEHICLE (2) Remove the cable core wire at the pedal arm.
PINCH T W O
TABS (3) A l l Gas Powered Engines: Remove the air
FOR cleaner housing.
CABLE REMOVAL (4) From inside the vehicle, pinch both sides of the
plastic cable housing retainer tabs at the dash panel
(Fig. 3).
(5) Remove cable housing from dash panel and pull
the cable into the engine compartment.
(6) 3.9L/5.2L/5.9L Gas Powered Engines: Dis
connect the cable from the routing/holddown clip at
the radiator fan shroud.
(7) 8.0L V-10 Engine and/or Diesel Engine: Re
move the throttle cable socket at fuel injection lever
ball (Fig. 1-Diesel) or throttle body lever ball (Fig.
6-8.0L V-10) (snaps off).
3.9L/5.2L/5.9L Gas Powered Engines: Operate
the throttle body cam (by hand) to the full open
THROTTLE
throttle position. Slip the pin on the end of cable
PEDAL
ARM J9414-42
from the hole i n the throttle body cam (Fig. 5). Re
move cable from cam.
Fig. 3 Cable Removal/Installation TORSION
SPRING
PEDAL M O U N T I N G
BRACKET
THROTTLE
CABLE
PIVOTS/
BUSHINGS
PEDAL/
BRACKET
J9414-40
Fig. 4 Accelerator Pedal—Removal or Installation ROTATE
V I E W OF W I D E
THROTTLE CA1LE O P E N THROTTLE
J9414-41
CAUTION: B e careful not to damage or kink the c a
ble core wire (within the cable sheathing) while ser Fig. 5 Throttle Cable at Throttle Body—3.9U5.2U
vicing, accelerator pedal o r cables. 5.9L Gas Engines—Typical
(8) A l l Gas Powered Engines: Remove cable
REMOVAL housing at throttle body mounting bracket by press
(1) From inside the vehicle, hold up the accelerator ing on release tab with a small screwdriver (Figs. 5
pedal. Remove the plastic cable retainer and throttle or 6). To prevent cable housing breakage, press
on the tab only enough to release the cable
PRESS TAI FOR (4) Install the remaining cable housing end into
CABLE REMOVAL and through the dash panel opening (snaps into po
sition). The two plastic pinch tabs (Fig. 3) should lock
the cable to dash panel.
(5) From inside the vehicle, hold up the accelerator
CABLE
SOCKET
pedal. Install the throttle cable core wire and plastic
cable retainer into and through the upper end of the
pedal arm (the plastic retainer is snapped into the
pedal arm). When installing the plastic retainer to
the accelerator pedal arm, note the index tab on the
pedal arm (Fig. 3). Align the index slot on the plastic
cable retainer to this index tab.
THROTTLE LINKAGE ADJUSTMENT—DIESEL

LEVER ENGINE
BALL
The linkage rod (Fig. 7) connecting the throttle le
ver to the fuel injection pump lever is adjustable.
CAUTION: Before adjusting the fuel injection pump

MOUNTING
J9414-44
throttle linkage, verify that engine is set at correct
BRACKET
low idle speed. Refer to Idle Speed Adjustment.
Fig. 6 Throttle Cable at Throttle Body—8.0L This can be found in the Diesel Engine—General Di
Engine agnosis section of this group.
from the bracket. Lift the cable housing straight (1) Verify low idle speed.
up from bracket while pressing on release tab. Re (2) Disconnect throttle cable socket from lever ball
move throttle cable from vehicle. stud on throttle lever (Fig. 8).
(9) Diesel Engine: A rubber/plastic grommet is
molded to the cable (Fig. 1). This grommet is pressed THROTTLE LEVER-TO-
THROTTLE
into the back of the cable mounting bracket. Apply LEVER
INJECTION PUMP LEVER
LINKAGE ROD
lubricant to the rubber grommet (Fig. 1) on both BALL
sides of the cable mounting bracket. Work the rubber
grommet (rearward) through the mounting bracket
with two small screwdrivers. Remove throttle cable
from vehicle.
INSTALLATION
(1) 3.9L/5.2L/5.9L Gas Engines:
(a) Rotate and hold the throttle cam i n the full
wide open position. Fit the pin on the end of cable
into the hole on the throttle body cam (Fig. 5).
(b) Connect cable to throttle body mounting
bracket (push down and lock).
(c) Connect cable to fan shroud routing clip.
(2) 8.0L V-10 Engine:
(a) Connect cable end socket to throttle body le
ver ball (snaps on) (Fig. 6).
(b) Connect cable to throttle body mounting THROTTLE
LEVER
bracket (push down and lock).
(3) Diesel Engine:
RIGHT-HAND-
(a) Feed the cable through the rear of its mount THREADED
ing bracket (Fig. 1) until the rubber/plastic grom THROTTLE FLAT NUT
POSITION LEFT-HAND-
met locks into position on the bracket. SENSOR THREADED
(b) Connect cable end socket to the fuel injection NUT J9414-67
pump lever ball (snaps on).
Fig. 7 Throttle Lever Linkage Adjustment—Diesel
14 - 24 FUEL SYSTEM
FRONT OF VEHICLE
CABLE RUBBER
CABLE
SOCKET GROMMET
MOUNTING
BRACKET
LEVER
BALL
FUEL
INJECTION
PUMP
TORSION
SPRING J9414-43
Fig. 8 Throttle Cable at Injection Pump—Diesel-

Typical
(3) Measure the distance between the center of the
lever ball and the rear face of the cable mounting CENTER REAR FACE
OF BALL OF BRACKET J9414-68
bracket (Fig. 9). Dimension should be 126.5 mm (5.0
inches.) I f not, proceed to linkage adjustment.
(4) To prevent damage to ends of linkage, attach Fig. 9 Linkage Measurement—Diesel
locking-type pliers to the flat (Fig. 7) located on the throttle lever and throttle lever-to-injection pump
linkage rod before loosening locknuts. lever linkage rod (Fig. 7) should be observed.
(5) Loosen the right-hand-threaded nut (Fig. 7). (c) Continue to press the accelerator pedal to the
(6) Loosen the left-hand-threaded nut (Fig. 7). floor. I f throttle lever breakover is operating cor
(7) Rotate the flat on the linkage rod (lengthen or rectly, the throttle lever-to-injection pump lever
shorten) to achieve proper linkage adjustment (Fig. linkage rod should have stopped moving while the
9). Tighten both nuts after adjustment. throttle lever continues to move towards the rear of
(8) With the engine OFF, operate the throttle from vehicle.
accelerator pedal and check for throttle lever action (10) Again, check and verify low idle speed. Adjust
and binding. Re sure throttle lever stop is against
i f necessary.
the low idle speed screw after throttle is released.
(11) Diesel engines equipped w i t h a n auto
(9) Re sure of wide open throttle (WOT) when ac
matic transmission: A throttle position sensor
celerator pedal is pressed to the floor. This is checked
by observing throttle lever breakover position. Pro (TPS) is used with this driveline combination. TPS
ceed to the following: voltage must now be tested. Refer to Throttle Posi
(a) Key OFF and engine OFF for this test. tion Sensor. This can be found i n the Diesel
(b) Two people are needed for this test. From in Engine—Component Removal/Installation section of
side of the vehicle, press the accelerator pedal this group.
about half-way to the floor. Movement of both the
F U E L TANKS
INDEX
page page
Fuel Gauge Sending Unit 27 Fuel Tanks 25
Fuel Pump 27 General Information 25
Fuel Tank Capacities . . . . . . . . . . . . . . . . . . . . . . . 27 Heat Shields 27
Fuel Tank Filler Tube Cap 27 No-Lead Fuel Tank Filler Tube 27
Fuel Tank Pressure Relief/Rollover Valve . 27
GENERAL INFORMATION FUEL TANKS

All Dodge trucks pass a full 360 degree rollover
without fuel leakage. To accomplish this, fuel and va DRAINING FUEL TANK
por flow controls are required for all fuel tank con (1) Remove fuel tank filler tube cap to release fuel
nections. tank pressure.
All models have a pressure relief/rollover valve (2) Perform Fuel System Pressure Release proce
mounted i n the top of the fuel tank. I n addition to dure as described i n this group.
the valve, improved flow control is used i n the fuel (3) Raise vehicle on hoist.
pump. Fuel flow is controlled i f pump is subjected to (4) While working over the left rear tire/wheel, dis
higher than normal pressure during rollover. For the connect the rubber fuel fill hose and clamp at fuel
same reason, a fuel tank filler tube cap (gas cap) tank (Fig. 1). Position fuel siphoning/drain hose into
with higher pressure setting is used to control fuel this opening at tank.
flow on vehicles with side fill.
An evaporation control system is used to reduce FUEL
PUMP
emissions of fuel vapors into atmosphere by evapora MODULE, VENT TUBE
tion and to reduce unburned hydrocarbons emitted AND HOSE
by vehicle engine. When the fuel evaporates from
fuel tank, vapors pass through vent hoses or tubes to
a charcoal canister. The are temporarily held i n the
canister. When the engine is running, the vapors are
drawn into intake manifold. Refer to Group 25, Emis
sion Control System for additional information.
Inspect all hose connections to make sure they are
secure and not leaking. Fuel tank hoses, tubes and
lines should be replaced immediately i f there is any
evidence of degradation that could result i n failure.
Avoid contact with clamps or other components
that cause abrasions or scuffing. Be sure that the
rubber hoses are properly routed to prevent pinching CLAMPS (4)
FUEL TANK
and to avoid heat sources. FILLER TUBE
The hoses used on fuel injected vehicles are of a CAP FUEL FILL
special construction due to higher fuel pressures in TUBE AND HOSE
volved i n system. I f hoses need replacement, only use DRIVER'S SIDE
hoses marked EFM/EFI. Of VEHJCLf J9414-36
The hose clamps used on fuel injected vehicles have
a special rolled edge construction. This prevents the Fig. 1 Fuel Tank Fill and Vent Hoses
edge of the clamp from cutting into the hose. Only (5) Drain fuel into an approved portable holding
these rolled edge type clamps may be used on this
tank or a properly labeled gasoline safety container.
system. Other clamps may cut into the hoses. This
could cause high- pressure fuel leaks. Refer to Fuel TANK REMOVAL
Tubes/Lines/Hoses and Clamps i n this group for ad (1) Disconnect negative battery cable at battery.
ditional information. Also refer to Quick-Connect Fit
(2) Remove fuel tank filler tube cap.
tings i n this group.
14 - 2S FUEL SYSTEM •
FUEL LINE (3) Drain fuel tank. Refer to the previous Draining
ELECTRICAL
(TO FUEL RAIL) Fuel Tank section.
WtSVER'SSIDE CONNECTOR
(4) Disconnect both the fuel fill and fuel vent rub
ber hoses at the fuel tank (Fig. 1).
EVAP (5) Gas Powered Engines: While working over
HOSE the left rear tire/wheel:
(a) Disconnect the electrical connector from the
fuel pump module (Fig. 2).
(b) Disconnect the EVAP hose at the pressure re
lief/rollover valve (Fig. 2).
(c) Disconnect the fuel supply line at the fuel fil
ter/fuel pressure regulator (Fig. 2). Refer to Fuel
Tubes/Lines/Hoses and Clamps i n this group for ad
ditional information about fuel line removal and in
stallation. Also refer to Quick-Connect Fittings i n
this group.
FUEL FILTER/ Diesel Powered Engines: While working over the
FUEL PRESSURE
REGULATOR left rear tire/wheel:
(a) Disconnect the electrical connector from the
FUEL TANK fuel tank module (Fig. 3).
(GAS POWERED) J9414-37
(b) Disconnect the fuel supply and fuel return
lines at the fuel tank module (Fig. 3). Refer to Fuel
Fig. 2 Fuel Tank Connections—Gas Powered
Engines
FUEL RETURN stallation. Also refer to Quick-Connect Fittings i n
AND SUPPLY UNES DRIVER'S SIDE this group.
OF VEHICLE ELECTRICAL (6) Place a transmission jack under the center of
CONNECTOR the fuel tank. Apply a slight amount of pressure to
fuel tank with transmission jack.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(7) Remove the fuel tank mounting strap nuts at

the mounting straps (Fig. 4). I f equipped, remove the
fuel tank heat shield bolts (Fig. 4).
(8) Lower fuel tank for removal.
TANK INSTALLATION
(1) Place fuel tank on top of transmission jack.
(2) Raise tank into position i n the frame cross-
members.
(3) Connect the two mounting straps and mounting
FUEL
strap nuts.
TANK (4) Remove transmission jack. Tighten strap nuts
(DIESEL) J9414-38 to 9 N-m (80 in. lbs.) torque. Do not over tighten re
taining strap nuts.
Fig. 3 Fuel Tank Connections—Diesel Powered (5) Gas Powered Engines:
Engines (a) Connect the electrical connector to the fuel
pump module (Fig. 2).
WARNING: THE FUEL SYSTEM IS UNDER A CON
(b) Connect the EVAP hose at the pressure relief/
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
rollover valve (Fig. 2).
BEFORE SERVICING THE FUEL TANK, FUEL SYS (c) Connect the fuel supply line at the fuel filter/
TEM PRESSURE MUST BE RELEASED. REFER TO fuel pressure regulator (Fig. 2). Refer to Fuel
THE FUEL SYSTEM PRESSURE RELEASE PROCE Tubes/Lines/Hoses and Clamps in this group for ad
DURE BEFORE SERVICING THE FUEL TANK. ditional information about fuel line removal and in
this group.
sel powered engines. Refer to either of the Fuel De
livery System sections of this group for fuel gauge
sending unit service.
FUEL TANK CAPACITIES

Refer to the Specifications section at the end of this
group.
HEAT SHIELDS
Some fuel line components are covered by sheet
metal heat shields. They may have to be removed
when servicing the fuel tank, fuel tubes/lines or va
por vent line. It is very important that these heat
shields be reinstalled after service. They are
used to protect lines and tank from heat of exhaust
system. See Group 11 i n this manual for proper in
stallation.
FUEL TANK FILLER TUBE CAP

STRAP MOUNTING The loss of any fuel or vapor out of filler neck is
NUTS J9414-39 prevented by the use of a pressure-vacuum fuel tank
filler tube cap. Relief valves inside cap will release
Fig. 4 Fuel Tank Mounting—Typical only under significant pressure of 6.58 to 8.44 kPa
Diesel Powered Engines: (1.95 to 2.5 psi). The vacuum release for all gas caps
(a) Connect the electrical connector to the fuel is between .97 and 2.0 kPa (.14 and .29 psi). This cap
tank module (Fig. 3). must be replaced by a similar unit i f replacement is
(b) Connect the fuel supply and fuel return lines necessary. This is i n order for the system to remain
at the fuel tank module (Fig. 3). Refer to Fuel effective.
CAUTION: Remove fuel tank filler tube cap before
servicing any fuel system component. This is done
to help relieve tank pressure.
this group.
(6) Install the rubber fill and vent lines to tank.
Tighten hose clamps to 2.3 N-m (20 in. lbs.) torque. NO-LEAD FUEL TANK FILLER TUBE
(7) Refill fuel tank and inspect all hoses and lines
for leaks. I A S P 0 W E R E 0 ENGINES
(8) Connect negative battery cable to battery. All catalyst equipped vehicles have a special fuel
tank filler tube. The fuel filler opening is smaller i n
FUEL PUMP diameter than those used for non-catalyst vehicles to
Gas Powered Engines: A n electric in-tank mounted permit entry of only the smaller no-lead fuel nozzles.
fuel pump is used with gas powered engines. Refer to A deflector is installed i n the fuel filler opening. The
Fuel Pump Module i n the Fuel Delivery deflector is opened by the no-lead fuel nozzle.
System—Except Diesel section of this group. The fuel filler tube on these models has a one-way
Diesel Powered Engines: A mechanically operated ball check valve. The valve is designed to prevent
low-pressure fuel transfer pump and a mechanically fuel back splash which may occur while filling the
operated high-pressure fuel injection pump are used tank.
to supply fuel for the diesel engine. Refer to the Fuel A label is attached to instrument panel under fuel
Delivery—Diesel Engine section of this group for in gauge that reads UNLEADED FUEL ONLY as a re
minder to driver. A similar label is located near fuel
formation on the fuel injection pump and fuel trans
tank filler.
fer pump.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
FUEL GAUGE SENDING UNIT The fuel tanks of all vehicles have a pressure relief/
The fuel gauge sending unit is attached to the side rollover valve. The valves relieve fuel tank pressure
of the fuel pump module on gas powered engines. I t and prevent fuel flow through fuel tank vent hoses
is attached to the side of the fuel tank module on die during rollover. A l l vehicles pass a full 360 degree
rollover without fuel leakage.
The pressure relief/rollover valve (Figs. 5 or 6) is FUEL LINE ELECTRICAL
mounted at the top of fuel pump module (gas pow (TO FUEL RAIL) DRIVER'S SIDE CONNECTOR
ered engines), or fuel tank module (diesel powered
engines).
On gas powered engines, the valve is connected to EVAP
HOSE
the EVAP canister with a rubber hose. On diesel
powered engines, the top of the valve is open to at
mosphere. Refer to Group 25, Emission Control Sys
tems for more information.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tanks section
in this group.
(2) Wedge the blade of a straight screwdriver be
tween the rubber valve grommet and fuel pump mod
ule where support rib is located. Do not wedge FUEL FILTER/
between valve and grommet or damage to valve FUEL PRESSURE
may result upon removal. REGULATOR
(3) Use a second screwdriver as a support to pry FUEL TANK
(GAS POWERED) J9414-37
valve and grommet assembly from tank.
(4) To remove grommet from valve, place valve up
Fig. 5 Pressure Relief/Rollover Valve—Gas Powered
right on a flat surface. Push down on the grommet.
Engines
Peel the grommet off the valve.
FUEL RETURN
INSTALLATION AND SUPPLY LINES DRIVER'S SIDE
(1) Install the rubber grommet in fuel tank and OF VEHICLE ELECTRICAL
work it around the curled lip. CONNECTOR
(2) Lubricate the grommet with power steering
fluid and push valve downward into grommet. Twist
the valve until it is pointed to the drivers side of ve
hicle.
(3) Install fuel tank. Refer to Fuel Tank Installa
tion.
FUEL
TANK
(DIESEL) J9414-38
Fig. 6 Pressure Relief/Rollover Valve—Diesel

Powered Engines
MULTI-PORT FUEL INJECTION {MFI}—COMPONENT DESCRIPTION/SYSTEM
OPERATION—EXCEPT DIESEL
INDEX
page page
Air Conditioning (A/C) Controls—PCM Pins #27 and Idle Air Control (IAC) Motor—Pin #60—PCM
#28—PCM Input 42 Output 48
Air Conditioning Relay—PCM Pin #34—PCM Ignition Circuit Sense—PCM Pin #9—PCM Input . . 37
Output 43 Ignition Coil Driver—PCM Pin #17—PCM Output . . 38
Automatic Shut Down (ASD) Relay—PCM Pin Ignition Coil Driver—PCM Pin #18—PCM Output . . 39
#51—PCM Output 47 Ignition Coil Driver—PCM Pin #19—PCM Output . . 39
Automatic Shut Down (ASD) Sense—PCM Pin Intake Manifold Air Temperature Sensor—PCM Pin
#57—PCM Input . . 48 #21—PCM Input . 39
Battery Temperature Sensor 37 Malfunction Indicator Lamp—PCM Pin #32—PCM
Battery Voltage—PCM Pin #3—PCM Input 36 Output 43
Brake Switch—PCM Pin #29—PCM Input 42 Manifold Absolute Pressure (MAP) Sensor—PCM
Camshaft Position Sensor—PCM Pin #44—PCM
Pin #1—PCM Input 36
Input 45
CCD Bus(+)—PCM Pin #26—PCM Output 42 Open Loop/Closed Loop Modes of Operation 50
CCD Bus(-)—PCM Pin #46—PCM Output 46 Overdrive Lamp—PCM Pin #31—PCM Output 43
Crankshaft Position Sensor—PCM Pin #24—PCM Overdrive Lamp—PCM Pin #37—PCM Output 44
Input 41 Overdrive Solenoid—PCM Pin #55—PCM Output . 48
Data Link Connector—PCM Pin #25—PCM Output 42 Overdrive/Override Switch—PCM Pin #10—PCM
Data Link Connector—PCM Pin #45—PCM Input . 46 Input 37
Eight Volt Power—PCM Pin #7—PCM Input . 37 Oxygen (02S) Sensor—PCM Pin #23—PCM Input . 40
Electric Exhaust Gas Recirculation Transducer Oxygen (02S) Sensor—PCM Pin #41—PCM Input . 45
Solenoid—Pin #35—PCM Output 44 Park/Neutral Switch—PCM Pin #30—PCM Input . . 42
Engine Coolant Temperature Sensor—PCM Pin PCM Schematics—Except Diesel 3
#2—PCM Input 36 Power Ground—PCM Pin #11 37
Evap Canister Purge Solenoid—PCM Pin Power Ground—PCM Pin #12 37
#52—PCM Output 47 Powertrain Control Module (PCM) 2
Five Volt Power—PCM Pin #6—PCM Input 37 Sensor Return—PCM Pin #4—PCM Input . 37
Fuel Fi ter 48 Speed Control—PCM Pins #33 and #53—PCM
Fuel In ectors—PCM Pin #13—PCM Output 37 Output 43
Fuel In ectors—PCM Pin #14—PCM Output 38 Speed Control—PCM Pins #48, #49 and # 5 0 —
Fuel In ectors—PCM Pin #15—PCM Output 38 PCM Input 46
Fuel In' ectors—PCM Pin #16—PCM Output 38 Speed Control—PCM Pins #53 and #33—PCM
Fuel In ectors—PCM Pin #17—PCM Output . . . . . . 38 Output 47
Fuel In ectors—PCM Pin #18—PCM Output 39 SRI Lamp—PCM Pin #56—PCM Output 48
Fuel In ectors—PCM Pin #38—PCM Output 44 Tachometer—PCM Pin #43—PCM Output 45
Fuel In ectors—PCM Pin #58—PCM Output 48 Throttle Body 49
Fuel Pressure Regulator 48 Throttle Position Sensor—PCM Pin #22—PCM
Fuel Pump Relay—PCM Pin #51—PCM Output . . . 47 Input 40
Fuel Rail 49 Torque Convertor Clutch (TCC) Solenoid—PCM Pin
General Information 29 #54—PCM Output 47
Generator Field—PCM Pin #20—PCM Output . . . . 39 Transmission Temperature Sensor—PCM Pin
Idle Air Control (IAC) Motor—Pin #39—PCM #42—PCM Input 45
Output 44 Transmission Temperature Warning Lamp—PCM
Idle Air Control (IAC) Motor—Pin #40—PCM Pin #31—PCM Output . 42
Output 45 Transmission Temperature Warning Lamp—PCM
Idle Air Control (IAC) Motor—Pin #59—PCM Pin #36—PCM Output 44
Output . 48 Vehicle Speed Sensor—PCM Pin #47—PCM Input . 46
GENERAL INFORMATION as either: LDC (Light Duty Cycle) or HDC (Heavy

All vehicles are equipped with either a 3.9L V-6 en Duty Cycle) engine. The 8.0L V-10 engine will be re
gine, a 5.2L V-8 engine, two different 5.9L V-8 en ferred to as: HDC (Heavy Duty Cycle) engine.
gines, an 8.0L V-10 engine or a 5.9L Cummins in-line Either of the HDC gas powered engines can be eas
6 cylinder diesel engine. Refer to the Diesel sections ily identified by the use of an engine mounted air in
of this group for diesel information. jection pump. The 3.9L V-6, 5.2/5.9L V-8 L D C gas
The 3.9L V-6 and 5.2L V-8 engines will be referred engines or the diesel engine will not use an air injec
to in this group as: L D C (Light Duty Cycle) engines. tion pump.
The 5.9L V-8 gas powered engine will be referred to
A sequential multi-port fuel injection (MFI) system the air conditioning clutch switch and brake switch.
is used on all 3.9L V-6 or 5.2/5.9L V-8 gas powered Based on inputs that i t receives, the PCM adjusts
engines. On the 8.0L V-10 engine, a multi-port fuel ignition coil(s) dwell. The PCM also adjusts the gen
injection system is also used, although the fuel injec erator charge rate through control of the generator
tors are simultaneously fired i n pairs. field and provides speed control operation.
The MFI system provides precise air/fuel ratios for The PCM contains a voltage convertor. This con
all driving conditions. verts battery voltage to a regulated 8.0 volts. I t is
used to power the crankshaft position sensor, cam
POWERTRAIN CONTROL MODULE (PCM) shaft position sensor and vehicle speed sensor. The
The powertrain control module (PCM) is located i n PCM also provides a five (5) volt supply for the man
the right-rear side of the engine compartment (Fig. ifold absolute pressure (MAP) sensor and throttle po
1). I t is mounted to the dash panel cowl with three sition sensor (TPS).
bolts. The PCM was formerly referred to as the
The P C M Inputs represent the instantaneous en
SBEC or engine controller.
gine operating conditions. Air-fuel mixture and igni
tion timing calibrations for various driving and
atmospheric conditions are pre-programmed into the
PCM. The PCM monitors and analyzes various in
puts. I t then computes engine fuel and ignition tim
ing requirements based on these inputs. Fuel
delivery control and ignition timing will then be ad
justed accordingly.
Other inputs to the PCM are provided by the brake
switch, air conditioning select switch and the speed
control switches. All inputs to the PCM are converted
into signals.
Electrically operated fuel injectors spray fuel i n
precise metered amounts into the intake port directly
POWERTRAIN CONTROL above the intake valve. The injectors are fired i n a
MODULE (PCM) J9414-11 specific sequence by the PCM. I n the Closed Loop
mode, the PCM maintains an air/fuel ratio of 14.7 to
1 by constantly adjusting injector pulse width. Injec
The PCM operates the fuel system. The PCM is a tor pulse width is the length of time that the injector
pre-programmed, dual microprocessor digital com opens and sprays fuel into the chamber. The PCM
puter. I t regulates ignition timing, air-fuel ratio, adjusts injector pulse width by opening and closing
emission control devices, charging system, speed con the ground path to the injector.
trol, A/C compressor clutch engagement, overdrive Manifold absolute pressure and engine rpm (speed)
operation, torque convertor clutch and idle speed. are the primary inputs that determine fuel injector
The PCM can adapt its programming to meet chang pulse width. The PCM also monitors other inputs
ing operating conditions. when adjusting air-fuel ratio.
The PCM receives input signals from various The PCM adjusts ignition timing by controlling ig
switches and sensors. Based on these inputs, the nition coil operation. The ignition coil(s) receives bat
PCM regulates various engine and vehicle operations tery voltage when the ignition key is i n the run or
through different system components. These compo start (crank) position. The PCM provides a ground
nents are referred to as P C M Outputs. The sensors for the ignition coil. The coil(s) discharges when the
and switches that provide inputs to the PCM are con PCM removes a ground. By switching the ground
sidered P C M Inputs. path on and off, the PCM regulates ignition timing.
The PCM adjusts ignition timing based upon in Refer to Group 8D, Ignition System for more infor
puts i t receives from sensors that react to: engine mation.
crankshaft position, manifold absolute pressure, en P C M Inputs That Effect Fuel Injector Pulse
gine coolant temperature, throttle position, transmis Widths
sion gear selection (automatic transmission), vehicle
• Battery voltage
speed, intake manifold air temperature and the
• EGR
brake switch.
• Engine coolant temperature
The PCM adjusts idle speed based on inputs i t re
• Engine speed (rpm)
ceives from sensors that react to: throttle position,
• Evaporative emissions purge
vehicle speed, transmission gear selection, engine
• Exhaust gas oxygen content from oxygen (02S)
coolant temperature and from inputs i t receives from
sensor
• Intake manifold air temperature • Generator field (charging system operation)
• Manifold absolute pressure (MAP) • Idle air control (IAC) motor
• Throttle position (TPS) • Ignition coil(s) and ignition timing
• Transmission gear selection (auto, trans.) • Malfunction indicator lamp (Check Engine Lamp)
Other P C M Inputs: • Overdrive solenoid electrical operation (auto,
• A/C request (if equipped with factory A/C) trans, only)
• Auto shut down (ASD) sense • Overdrive warning lamp (auto, trans, only)
• Brake switch • SCI transmit (DRB scan tool connection)
• Camshaft position sensor signal • Service reminder indicator lamp (EMR lamp)
• Crankshaft position sensor • Shift indicator lamp (manual transmission only)
• Engine coolant temperature sensor • Speed control vacuum solenoid
• Ignition circuit sense (ignition switch i n r u n posi • Speed control vent solenoid
tion)
• Tachometer (on instrument panel, i f equipped)
• Manifold absolute pressure (MAP) sensor
• Torque convertor clutch electrical operation (auto,
• Overdrive/override switch
trans, only)
• Park/neutral switch (auto, trans, only)
• SCI receive (DRB scan tool connection) • Transmission oil temperature warning lamp (cer
• Speed control resume switch tain HD models with auto, trans, only)
• Speed control set switch
SYSTEM DIAGNOSIS
• Speed control on/off switch
The powertrain control module (PCM) tests many
• Vehicle speed sensor
Powertrain Control Module (PCM) Outputs: of its own input and output circuits. I f a diagnostic
After inputs are received by the PCM, certain com trouble code (DTC) is found i n a major system, this
ponents are controlled by the PCM. These are consid information is stored i n the PCM memory. Refer to
ered P C M Outputs. These outputs are for: On-Board Diagnostics i n the Multi-Port Fuel
• A/C clutch relay (A/C clutch operation) Inj ection—General Diagnosis—Except Diesel section
• Auto shut down (ASD) relay of this group for DTC information.
• Data link connectors (for DRB and MDS test
equipment) PCM SCHEMATICS—EXCEPT DIESEL
• EGR valve control solenoid (EET) Powertrain control system schematics for gas pow
• EVAP canister purge solenoid ered fuel injected engines are shown i n figures 2, 3, 4
• Fuel injectors (pulse width) and 5. After the schematics, a description is given for
• Fuel pump relay (electric fuel pump) each circuit (pin) of the PCM 60-way connector.
EVAP PURGE
TRANSMISSION ELECTRIC EGR CO

OVERDRIVE TRANSDUCER
SWITCH
SWITCH • Ats! TRANSMISSION OVERDRIVE
INST PNL r — " - 1 | 1 A > ' i INDICATOR LAMP TRANS. TEMP. LAMP
AUTO. HPS TRANS. ONLY) /
m
CO
-<
CO
' FNGTNE"" BODY ENGINE

GROUND GROUND - GENERATOR
STARTER J9414-49
Fig. 2 System Schematic—SSL (V-6) Engine

m
-<
m
' GENERATOR
J9414-50
Fig. 3 System Schematic—5.2U5.9L LDC (V-8) Engine

EVAP PURGE
TRANSMISSION
OVERDRIVE ELECTRIC EGR
SWITCH TRANSDUCER I
A/C
SWITCH "f |3 ( ^TRANSMISSIONOVERDRIVE
% TRANS. TEMP. LAMP
INST PNL 1 i\ K
' • INDICATOR LAMP (AUTO. HPS TRANS. ONLY) Q
MALFUNCTION
A/C INPICATOR LAMP
PRESS m
SW SERVICE REMINPER -<
INDICATOR LAMP CO
THROTTLE
POSITION ENGINE COOLANT
SENSOR TEMP. SENSOR
SHIFT INPICATORr'© -
INTAKE AIR LAMP
TEMP. SENSOR •MANUAL TRANS. ONLY 3 SPEED
So 58 w
AUTO. ONLY
TRANSMISSION
TEMP. SENSOR i£§ y y y y DATA I
21 ECT ;
85
(AUTO. HPS'
22 INTAKE TEMP. u »i=3< <DATA
.1 ?*£o < <<LINK LINK
TRANS
CCD +
REC 186
TRANS. ONLY) TPS v HISS CCD -
87]
TRANS TEMP. EVAP PURGE SOL 8 fx
5 VOLTS
MAP
EETS
TRANS TEMP LAMP
1 4
TRANSMISSION
SENSOR RETURN TCC
47 SRI
VSS SOLENOID
VEHICLE
SPEED SENSOR
CMP PCM SIL/TCC SOL
OVERDR SOL
8 VOLTS
CKP AC RELAY
CRANKSHAFT POSITION POWERTRAIN INJECTOR 2
CAMSHAFT
POSITION SENSOR. . -12 02S(LEFT) CONTROL INJECTOR 7
41 0 2 S (RIGHT) MODULE
SENSOR INJECTOR 5
HEATED, 30 WN SWITCH INJECTOR 6
OXYGEN 29 BRAKE SWITCH INJECTOR 3
1SENSOR SPEED CONTROL SPEED CONTROL INJECTOR 4
I - ~ - RESUME JACCEL INJECTOR •
LEFT ON i ON/OFF INJECTOR 1
START
^RT f COAST/SET Z >. 2 31=5
RUN <A
z *~ c£ VACUUM
OFF OFF HEATED, It VENT
CLUTCH
JgJ
SW
OXYGEN
IGNITION SENSOR \ j m ili'Fi lis
RIGHT BRAKE
PEDAL SWITCH
POSITION l#3 £j>#5 Ej±*2
4
SWITCH f
MANUAL! <
TRANS.
ONLY
TO
R.W.A.L TO
STOP*-* -"
LAMPS
1 sin #4 #6
FUEL INJECTORS
# 7
BAT"
ENGINE A/C COMPRESSOR

STARTER CLUTCH RELAY
[86
SOL
RELAY
FUEL PUMP
RELAY
m •87A
87
AUTO. 851 86
TRANS. ONLY A/C
§7j 87A-—*i COMPRESSOR
30 %--87A 30 CLUTCH
Z«/> 185
PARK/NEUTRAL
|<z POSITION SWITCH BATTERY
L ENGINE
flJ BOPY ENGINE
AUTOMATIC
SHUT-POWN FUEL
GROUNP GROUNP RELAY PUMP IGNITION " GENERATOR
STARTER COIL J9414-51
Fig. 4 System Schematic—S.9L HDC (V-8) Engine

Tl
m
r—
CO
«<
CO
L *_j
ENGINE - GENERATOR
STARTER J9414-52
Fig. 5 System Schematic—8.0L HDC (V-10) Engine

MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR—PCM PIN #1—PCM INPUT
The MAP sensor reacts to absolute pressure in the
intake manifold and provides an input voltage to the
powertrain control module (PCM). As engine load
changes, manifold pressure varies, causing the MAP
sensor voltage to change. This change results in a
different input voltage to the PCM. The input voltage
level supplies the PCM with information. This relates
to ambient barometric pressure before engine start
up, during engine start-up (cranking) and to engine
load while the engine is running. The PCM uses this
input, along with inputs from other sensors, to adjust
air-fuel mixture.
3.9L V-6 or 5.2/5.9L V-8 Engines: The MAP sen
sor is mounted to the throttle body (Fig. 6). It is con Fig. 7 MAP Sensor—8.0L V-10 Engine—Typical
nected to the throttle body with an L-shaped rubber
fitting and to the PCM electrically. changes. At cold coolant temperatures, its resistance
8.0L V-10 Engine: The MAP sensor is mounted is high. As temperatures increase, its resistance will
into the right side of the intake manifold (Fig. 7). decrease.
The coolant sensor provides an input voltage to the
powertrain control module (PCM) relating engine
coolant temperature. The PCM uses this input, along
with inputs from other sensors, to determine injector
pulse width and ignition timing. As coolant tempera
ture varies, the coolant temperature sensor resis
tance will change, resulting in a different input
voltage to the PCM.
When the engine is cold, the PCM will operate in
the Open Loop Mode. It will demand slightly richer
air-fuel mixtures and higher idle speeds, until nor
mal operating temperatures are reached. Refer to
Open Loop/Closed Loop Modes Of Operation in this
group for a description of operation.
is installed in the intake manifold near the thermo
On the 8.0L V-10 engine, the sensor is installed in
Fig. 6 MAP Sensor—3.9L V-6 or S.2/5.9L V-8 fer to the Component Removal/Installation section of
Engines—Typical this group.
vice Procedures section of this group. BATTERY VOLTAGE—PCM PIN #3—PCM INPUT
For removal and installation of this component, re The battery voltage input provides power to the
fer to the Component Removal/Installation section of powertrain control module (PCM). It also informs the
this group. PCM what voltage level is supplied to the ignition
coil(s) and fuel injectors.
ENGINE COOLANT TEMPERATURE SENSOR—PCM If battery voltage is low, the PCM will increase in
PIN #2—PCM INPUT jector pulse width (period of time that the injector is
The engine coolant temperature sensor is a vari energized). This is done to compensate for the re
able, thermistor type. It reacts to temperature duced flow through injector caused by the lowered
voltage.
IGNITION CIRCUIT SENSE—PCM PIN #i—PCM
INPUT
The ignition circuit sense input tells the powertrain
control module (PCM) the ignition switch has ener
gized the ignition circuit. Refer to the wiring dia
grams for circuit information.
OVERDRIVE/OVERRIDE SWITCH—PCM PIN

#10—PCM INPUT
On vehicles equipped with overdrive, the power-
train control module (PCM) regulates the 3-4 over
drive up-shift and 4-3 down-shift through the
overdrive solenoid. An overdrive/override switch is lo
cated on the instrument panel.
The overdrive/override switch is normally closed
Fig. 8 Coolant Temperature Sensor—3.9L V-6 or and will allow overdrive operation. I t opens when the
5.2/5.9L ¥-8 Engines—Typical operator presses the switch (lamp will illuminate).
The transmission will not enter overdrive when the
operator presses the override switch and the lamp is
illuminated. The transmission downshifts i f the oper
ator presses the override switch while i n overdrive.
Also refer to Overdrive Solenoid—PCM Pin
#55—PCM Output for additional information.
Refer to Group 21 for more transmission informa
tion.
POWER GROUND—PCM PIN #11

Provides a common ground for power devices (sole
noid and relay devices).

Provides a common ground for power devices (sole
noid and relay devices).
Fig. 9 Coolant Temperature Sensor—8.0L V-10 FUEL INJECTORS—PCM PIN #13—PCM OUTPUT
Engine
3BL/5.2U5.9L ENGINES
BATTERY TEMPERATURE SENSOR
Pin #13 is used as the ground control circuit for the
This input is internal to the powertrain control
fuel injector on cylinder #4 on 3.9L/5.2L/5.9L engines.
module (PCM). A thermistor located within the
The injectors (Fig. 10) are energized individually in
PCM's printed circuit board is used to sense under- a sequential order by the powertrain control module
hood temperature. This temperature is used to vary (PCM). The PCM will adjust injector pulse width by
the battery charging rate i n relationship to the tem switching the ground path to each individual injector
perature. on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
SENSOR RETURN—PCM PIN #4—PCM INPUT injector pulse width based on various inputs i t re
Sensor Return provides a low noise ground refer ceives.
ence for all system sensors. During start up, battery voltage is supplied to the
injectors through the ASD relay. When the engine is
FIVE VOLT POWER—PCM PIN #6—PCM INPUT operating, voltage is supplied by the charging sys
This circuit supplies approximately 5 volts to power tem. The PCM determines injector pulse width based
the MAP and TPS sensors. on various inputs.
The fuel injectors are attached to the fuel rail (Fig.
FIGHT VOLT POWER—PCM PIN #7—PCM INPUT 11). 3.9L V-6 engines use six injectors. 5.2L and 5.9L
This circuit supplies approximately 8 volts to power V-8 engines use eight injectors.
the vehicle speed, camshaft position and crankshaft The nozzle ends of the injectors are positioned into
position sensors. openings i n the intake manifold just above the intake
14 - 38 FUEL SYSTEM : •
Refer to Fuel Injectors-PCM Pin # 1 3 - P C M Output

for information.
8.0L V-f 0 ENGINE

fuel injectors on cylinders #3 and #6 on the 8.0L V-10
engine (both injectors are fired simultaneously—one
cylinder on compression stroke and one cylinder on
exhaust stroke).
FUEL INJECTORS—PCM PIN #15—PCM OUTPUT

3.9L/5.2L/5.BL ENGINES
Fig. 10 Fuel Injector Internal Components—Typical for information.
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped 8.0L V«f 0 ENGINE
with an attached numerical tag (INJ 1, I N J 2 etc.). Pin #15 is used as the ground control circuit for the
This is used to identify each fuel injector with its re fuel injectors on cylinders #9 and #4 on the 8.0L V-10
spective cylinder number. engine (both injectors are fired simultaneously—one
exhaust stroke).

3.9L/5.2UB/BL ENGINES
for information.
8.0L V - f 0 ENGINE
fuel injectors on cylinders #1 and #10 on the 8.0L
V-10 engine (both injectors are fired
simultaneously—one cylinder on compression stroke
and one cylinder on exhaust stroke).
FUEL 5.2L/5.9L ENGINES

INJECTOR J9214-30 Pin #17 is used as the ground control circuit for the
fuel injector on cylinder #7 on 5.2L/5.9L engines. Re
Fig. 11 Fuel Injectors—Typical fer to Fuel Injectors-PCM Pin # 1 3 - P C M Output for
8.01 V-f 0 ENGINE information.
fuel injectors on cylinders #5 and #8 on the 8.0L V-10 IGNITION COIL DRIVER—PCM PIN #17—PCM
engine (both injectors are fired simultaneously—one OUTPUT
exhaust stroke). 8.0L V-f 0 ENGINE
FUEL INJECTORS—PCM PIN #14—PCM OUTPUT ignition coils operating cylinders #8 and #9 on the
8.0L V-10 engine (both coils are fired simultaneous
3.9L/5.2L/5.9L ENGINES ly).
Pin #14 is used as the ground control circuit for the Two separate coil packs containing a total of five
fuel injector on cylinder #3 on 3.9L/5.2L/5.9L engines. independent coils are attached to a common mount-
ing bracket located above the right engine valve Refer to Group 8D, Ignition System for additional
cover (Fig. 12). The coil packs are not oil filled. The information.
front coil pack contains three independent epoxy
filled coils. The rear coil pack contains two indepen
dent epoxy filled coils.
Refer to Group 8D, Ignition System for additional
information.
Fig. 13 Ignition Coil—3.9U5.2U5.9L LDC-Gas

Engine
Fig. 12 Ignition Coil Packs—8.0L ¥-10 Engine
5.2L/5.9L ENGINES
fuel injector on cylinder #8 on 5.2L/5.9L engines. Re
fer to Fuel Injectors-PCM Pin # 1 3 - P C M Output for
information.
IGNITION COIL DRIVER—PCM PIN #18—PCM

OUTPUT
8.0L V-10 ENGINE Fig. 14 Ignition Coil—5.9L HDC-Gas Engine

ignition coils operating cylinders #2 and #3 on the 8.0L V - f 0 ENGINE
8.0L V-10 engine (both coils are fired simultaneous- Pin #19 is used as the ground control circuit for the
ly). ignition coils operating cylinders #1 and #6 on the
8.0L V-10 engine (both coils are fired simultaneous-
IGNITION COIL DRIWER—PCM PIN #11—PCM ly).
OUTPUT Refer to Group 8D, Ignition System for additional
information.
3.9L/5.2L/SML ENGINES
Pin #19 is used as the ground control circuit for the GENERATOR FIELD—PCM PIN #20—PCM OUTPUT
ignition coil. The powertrain control module (PCM) regulates the
System voltage is supplied to the ignition coil pos charging system voltage within a range of 12.9 to
itive terminal. The powertrain control module (PCM) 15.0 volts. Refer to Group 8A for charging system in
then operates the ignition coil through an on/off formation.
ground signal. Base (initial) ignition timing is
not adjustable. The PCM adjusts ignition timing to INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
meet changing engine operating conditions. PCM PIN #21—PCM INPUT
The ignition coil is located near the front of the The intake manifold air temperature sensor is a
right cylinder head (Fig. 13 or 14). variable, thermistor type. It reacts to temperature
14-40 FUEL SYSTEM •
changes. A t cold air temperatures, its resistance is
high. As temperatures increase, its resistance will de
crease.
The air temperature sensor element extends into
the intake manifold air stream. I t provides an input
voltage to the powertrain control module (PCM) indi
cating intake manifold air temperature. The input
from this sensor is used along with inputs from other
sensors to determine injector pulse width. As the
temperature of the air-fuel stream i n the manifold
varies, the sensor resistance will change. This will
result i n a different input voltage to the PCM.
Fig. 17 Sensor Location—8.0L V-10 Engine—Typical
the left side of the intake manifold near the front of
the throttle body (Fig. 17). THROTTLE POSITION SENSOR—PCM PIN
#22—PCM INPUT
The throttle position sensor (TPS) is located on the
left side of the throttle body on the 3.9L V-6 or 5.2/
5.9L V-8 engines (Fig. 18).
The TPS is located on the rear of the throttle body
just below the idle air control motor on the 8.0L V-10
engine (Fig. 19).
The TPS is connected to the throttle blade shaft
and is a variable resistor. I t provides the powertrain
control module (PCM) with an input signal (voltage)
that represents throttle blade position. As the posi
tion of the throttle blade changes, the resistance of
the sensor changes.
The PCM supplies approximately 5 volts to the
sensor. The sensor output voltage (input signal to the
PCM) represents the throttle blade position. The
Fig. 15 Sensor Location—3.9L V-6 Engine—Typical PCM receives an input signal voltage from the sen
sor. This will vary i n an approximate range of from 1
volt at minimum throttle opening (idle), to 4 volts at
wide open throttle. Along with inputs from other sen
sors, the PCM uses the TPS sensor output to deter
mine current engine operating conditions. I t also will
adjust fuel injector pulse width and ignition timing.
Group 14, Fuel Systems.
OXYGEN (02S) SENSOR—PCM PIN #23—PCM

INPUT
PCM PINS #23 O R #41
Fig. 16 Sensor Location—5.2U5.9L V-8. Engines— 3 J L / i . 2 L / i . S L LDC ENGINE
Typical
A single, heated 02S sensor is used on the 3.9L V-6
and the 5.2L/5.9L V-8 light duty cycle (LDC) engines.
I t is located i n the exhaust down pipe (Fig. 20). The
02S sensor provides an input voltage to the power-
correct sensor temperature at all times allows the

system to enter into Closed Loop operation sooner.
In Closed Loop operation, the powertrain control
module (PCM) monitors the 02S sensor input (along
with other inputs). I t then adjusts the injector pulse
width accordingly. During Open Loop operation, the
PCM ignores the 02S sensor input and adjusts injec
tor pulse width to a preprogrammed value (based on
other sensor inputs).
Refer to Open Loop/Closed Loop Modes of Opera
tion i n this group for additional information.
Fig. 18 Sensor Location—3.9L ¥-6 or 5.2/5.9L ¥-8

Engines—Typical
mi c A I D INTAKE M A N I F O L D EXHAUST
PIPE J9214^
Fig. 20 Oxygen Sensor Location—3.9U5.2U5.9L

LDC Engine
8.0L V-10 AND 5.9L V-8 HDC ENGINES
Dual, heated 02S sensors are used on both the
8.0L V-10 and 5.9L V-8 heavy duty cycle (HDC) en
gines (Fig. 21). Each sensor will monitor the oxygen
content i n each exhaust downpipe.
On the 5.9L HDC V-8 engine, the left 02S sensor
monitors the odd numbered cylinders (1-3-5-7) and
fuel is controlled on the left side (bank) of the engine.
The right sensor monitors the even numbered cylin
ders (2-4-6-8) and fuel is controlled on the right side
Fig. 19 Sensor Location—8.0L ¥-10 Engine—Typical (bank) of the engine.
On the 8.0L V-10 engine, pairs of fuel injectors are
train control module (PCM) relating the oxygen con
tent of the exhaust gas. The PCM uses this fired (one on each side of the engine). Because of
information to fine tune the air-fuel ratio by adjust this, both 02S sensor readings are averaged by the
ing injector pulse width. powertrain control module (PCM). This will deter
The 02S sensor produces voltages from 0 to 1 volt. mine a common fuel injection rate for all ten cylin
This voltage will depend upon the oxygen content of ders.
the exhaust gas i n the exhaust manifold. When a For additional sensor operational information, refer
large amount of oxygen is present (caused by a lean to the paragraphs i n the previous 3.9L/5.2/5.9L LDC
air-fuel mixture), the sensor produces a low voltage. oxygen sensor section.
When there is a lesser amount present (rich air-fuel
mixture) i t produces a higher voltage. By monitoring CRANKSHAFT POSITION S E N S O R — P C M P I N
the oxygen content and converting i t to electrical # 2 4 — P C M INPUT
voltage, the sensor acts as a rich-lean switch. Refer to Group 8D, Ignition System for informa
The oxygen sensor is equipped with a heating ele tion.
ment that keeps the sensor at proper operating tem
perature during all operating modes. Maintaining
AIR CONDITIONING (A/C) CONTROLS—PCM PINS
#27 AND #28—PCM INPUT
The A/C control system information applies to fac
tory installed air conditioning units.
A/C BEQUEST SIGNAL? Once A/C has been se
lected, the powertrain control module (PCM) receives
the A/C request signal from the evaporator switch.
The input indicates that the evaporator temperature
is i n the proper range for A/C application. The PCM
uses this input to cycle the A/C compressor clutch
(through the A/C relay). I t will also determine the
correct engine idle speed through the idle air control
(IAC) motor position.
I f the A/C low-pressure switch opens (indicating a
low refrigerant level), the PCM will not receive an
A/C select signal. The PCM will then remove the
Fig. 21 02S Location—8.0L/5.9L HDC Engine- ground from the A/C relay. This will deactivate the
Typical A/C compressor clutch.
DATA LINK CONNECTOR—PCM PIN #25—PCM I f the evaporator switch opens, (indicating that
OUTPUT evaporator is not i n proper temperature range), the
PCM will not receive the A/C request signal. The
The data link connector (diagnostic scan tool con
PCM will then remove the ground from the A/C relay,
nector) links the Diagnostic Readout Box (DRB) scan
deactivating the A/C compressor clutch.
tool or the Mopar Diagnostic System (MDS) with the
powertrain control module (PCM). The data link con BRAKE SWITCH—PCM PIN #29—PCM INPUT
nector is located i n the engine compartment (Fig. 22). When the brake light switch is activated, the pow
For operation of the DRB scan tool, refer to the ap ertrain control module (PCM) receives an input indi
propriate Powertrain Diagnostic Procedures service cating that the brakes are being applied. After
manual. receiving this input, the PCM maintains idle speed to
The data link connector uses two different pins on a scheduled rpm through control of the idle air con
the PCM. Pin #25 is for Data Link Transmit and pin trol (IAC) motor. The brake switch input is also used
#45 is for Data Link Receive. to control the speed control system and electrical op
eration of the transmission torque converter.
PARK/NEUTRAL SWITCH—PCM PIN #30—PCM

INPUT
The park/neutral switch provides an input to the
powertrain control module (PCM). This will indicate
that the automatic transmission is i n Park, Neutral
or a Drive gear selection. This input is used to deter
mine idle speed (varying with gear selection), fuel in
jector pulse width and ignition timing advance. Refer
to Group 21, Transmissions, for testing, replacement
and adjustment information.
TRANSMISSION TEMPERATURE WARNING

POWERTRAIN CONTROL
M O D U L E (PCM) J9414-11
LAMP—PCM PIN #31—PCM OUTPUT
Fig. 22 PCM and Data Link Connector—Typical 9.M/5.21/5.9L ENGINES—AUTOMATIC

TRANSMISSIONS ONLY
CCD BUS(+)—PCM PIN #26—PCM OUTPUT An instrument panel mounted lamp (Fig. 23) is
Various modules exchange information through a used to warn of a possible transmission overheating
communications port called the CCD BUS(+). condition. When transmission temperature has been
determined to be above approximately 280 degrees F
by the transmission temperature sensor, a signal is
sent to the powertrain control module (PCM). The
PCM will then control warning lamp operation. The
lamp will illuminate for about two seconds each time

the ignition key is turned ON as a bulb check.
Also refer to Transmission Temperature
Sensor-PCM Pin # 4 2 - P C M Input for additional in
formation.
Fig. 24 Check Engine Lamp—Typical Location

trouble code (DTC). Cycle the ignition switch On-Off-
On-Off-On within three seconds and any codes stored
in the PCM memory will be displayed. This is done
in a series of flashes representing digits. Refer to On-
Fig. 23 Transmission Temperature Warning Board Diagnostics i n the General Diagnosis section
Lamp—Typical Location of this group for more information.
8»0L V-10 ENGINE—AUTOMATIC
TRANSMISSIONS ONLY SPEED CONTROL—PCM PINS #33 AND #53—PCM
On the 8.0L V-10 engine, pin #36 performs the OUTPUT
same function as pin #31 on 3.9L/5.2L/5.9L engines. These two circuits control vent and vacuum opera
Also refer to Transmission Temperature tion of the speed control solenoids.
Sensor-PCM Pin # 4 2 - P C M Input for additional in
formation. AIR CONDITIONING RELAY—PCM PIN #34—PCM
OUTPUT
OVERDRIVE LAMP—PCI P l i #31—PCM OUTPUT This circuit controls a ground signal for operation
of the A/C clutch relay. Also refer to Air Conditioning
8 . 0 L ¥-10 ENGINE—AUTOMATIC
(A/C) Controls-PCM Pins # 2 7 and # 2 8 - P C M Input
TRANSMISSIONS ONLY
for additional information.
This circuit controls a signal for the operation of The A/C relay is located in the power distribution
the instrument panel mounted overdrive lamp. On center (PDC). The PDC is located next to the battery
3.9L/5.2L/5.9L engines, this circuit is controlled by in the engine compartment (Fig. 25). For the location
pin #37. When the lamp is illuminated, the overdrive of the relay within the PDC, refer to PDC cover.
is disengaged.
MALFUNCTION INDICATOR LAMP—PCM PIN

#32—PCM OUTPUT
The malfunction indicator lamp (formerly referred
to as the check engine lamp—Fig. 24) illuminates on
the instrument panel each time the ignition key is
turned on. I t will stay on for about three seconds as
a bulb test.
I f the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, the lamp is turned on. This
is a warning that the PCM has recorded a system or
sensor malfunction. I n some cases, when a problem is
declared, the PCM will go into a limp-in mode. This
is an attempt to keep the system operating. I t signals
an immediate need for service.
The lamp can also be used to display a diagnostic Fig. 25 Power Distribution Center (PDC) Location
E L E C T R I C E X H A U S T G A S R E C I R C U L A T I O N I D L E A I RC O N T R O L ( I A C ) M O T O R — P I N #3S—PCM
T R A N S D U C E R S O L E N O I D — P I N # 3 5O —U PT CP UM T
OUTPUT Pin #39 controls one of the circuits for operation of
This circuit controls operation of the EET solenoid. the IAC motor.
Refer to Group 25, Emission Control System for in The IAC motor is mounted to the throttle body
formation. See Electric Exhaust Gas Recirculation (Figs. 26 or 27) and is controlled by the powertrain
Transducer (EET) Solenoid. control module (PCM).
T R A N S M I S S I O N T E M P E R A T U R E W A R N I N G
L A M P — P C M P I N #36—PCM O U T P U T
8 . 0 L ENGINE—AUTOMATIC TRANSMISSIONS
ONLY
An instrument panel mounted lamp (Fig. 23) is
used to warn of a possible transmission overheating
condition. When transmission temperature has been
determined to be above approximately 280 degrees F
by the transmission temperature sensor, a signal is
PCM will then control lamp operation. The lamp will
illuminate for about two seconds each time the igni
tion key is turned ON as a bulb check.
On 3.9L/5.2L/5.9L engines, pin #31 performs the
same function.
Also refer to Transmission Temperature
Sensor-PCM Pin #42-PCM Input for additional in
formation.
OVERDRIVE L A M P — P C M P I N #37—PCM O U T P U T
3.9L/5.2U5.9L ENGINES—AUTOMATIC
TRANSMISSIONS ONLY
This circuit controls a signal for the operation of
the instrument panel mounted overdrive lamp. On
the 8.0L V-10 engine, this circuit is controlled by pin
#31. When the lamp is illuminated, the overdrive is
disengaged.
8,0L V - 1 0 E N G I N E
Pin #37 is used to supply a dwell gate signal for
operation of the ignition control module. The dwell
gate signal selects which coil is to be fired.
FUEL I N J E C T O R S — P C M P I N #38—PCM O U T P U T
3.9L/5.2U5.9L ENGINES
Pin #38 is used as the ground control circuit for the Fig. 27 IAC Motor—8.0L Engine—Typical
fuel injector on cylinder #5 on 3.9L/5.2L/5.9L engines. The throttle body has an air control passage that
Refer to Fuel Injectors-PCM Pin # 1 3 - P C M Output provides air for the engine at idle (the throttle plate
for information. is closed). The IAC motor pintle protrudes into the
air control passage (Figs. 28 or 29) and regulates air
8.0IL V-10 ENGINE flow through i t . Based on various sensor inputs, the
Pin #38 is used to supply a dwell signal for opera powertrain control module (PCM) adjusts engine idle
tion of the ignition control module to energize the ig speed by moving the IAC motor pintle i n and out of
nition coil. the air control passage. The IAC motor is positioned
when the ignition key is turned to the ON position.
A (factory adjusted) set screw is used to mechani TRANSMISSION TEMPERATURE SENSOR—PCM
cally limit the position of the throttle body throttle PIN #42—PCM INPUT
plate. Never attempt to adjust the engine Idle
speed using this screw. All idle speed functions are AUTOMATIC TRANSMISSIONS ONLY
controlled by the PCM. The transmission temperature sensor is a variable,
thermistor type. I t reacts to temperature changes. A t
MOUNTING SCREWS cold transmission oil temperatures, its resistance is
MAP SENSOR
high. As temperatures increase, its resistance will de
crease.
The transmission temperature sensor is used on
RUBBER FITTING models equipped with certain heavy-duty options and
an automatic transmission. Its purpose is to help
control transmission overheating. I f transmission
overheating has been determined by this sensor
(temp, above approximately 280 degrees F), an input
is sent to the powertrain control module (PCM). The
AIR PCM will then force a 4-3 downshift. Once transmis
PASSAGE sion temperature has cooled below specifications, a
3-4 upshift will be allowed. An instrument panel
VIEW FROM BOTTOM
mounted transmission temperature warning lamp
J9314-87
(Fig. 23) is also used.
This sensor is located i n the transmission cooling
Fig. 28 Air Control Passage—3.9U5.2U5.9L Engines
line on the side of the transmission (Fig. 30).
VACUUM TRANSMISSION C O O L I N G
FITTING LINE
THROTTLE
POSITION
SENSOR
TRANSMISSION
TEMPERATURE S E N S O R J9414-46
THROTTLE
BODY
Fig. 30 Transmission Temperature Sensor
IDLE AIR
Location—Typical
IDLE AIR
C O N T R O L (IAC)
PASSAGE
MOTOR
TACHOMETER—PCM PIN #43—PCM OUTPUT
V I E W FROM BOTTOM The powertrain control module (PCM) supplies en
J9414-48
gine rpm values to the instrument cluster mounted
Fig. 29 Air Control Passage—8.0L ¥-10 Engine tachometer (if equipped). Refer to Group 8E for ta
chometer information.
IDLE AIR CONTROL (IAC) MOTOR—PIN #40—PCM
OUTPUT CAMSHAFT POSITION SENSOR—PCM PIN
Pin #40 controls one of the circuits for operation of #44—PCM INPUT
the IAC motor. Refer to Idle Air Control (IAC) A fuel sync signal is provided by the camshaft po
M o t o r - P i n #39—PCM Output for information. sition sensor. The sync signal from this sensor works
in conjunction with the crankshaft position sensor to
OXYGEN ( 0 2 S ) SENSOR—PCM PIN #41—PCM provide the powertrain control module (PCM) with
INPUT inputs. This is done to establish and maintain correct
Refer to Oxygen (02S) Sensor-PCM Pin injector firing order. The sensor is located-in the ig
#23—PCM Input for information. nition distributor (Fig. 31—3.9L/5.2L/5.9L engine), or
in the timing chain case/cover on the left-front side of input is used by the powertrain control module
the engine (Fig. 3 2 - 8 . 0 L V-10 engine). (PCM) to determine vehicle speed and distance trav
Refer to Camshaft Position Sensor i n Group 8D, Ig eled.
nition System for more information. The speed sensor generates 8 pulses per sensor
revolution. These signals, i n conjunction with a
closed throttle signal from the throttle position sen
sor, indicate a closed throttle deceleration to the
PCM. When the vehicle is stopped at idle, a closed
throttle signal is received by the PCM (but a speed
sensor signal is not received).
Under deceleration conditions, the PCM adjusts the
idle air control (IAC) motor to maintain a desired
MAP value. Under idle conditions, the PCM adjusts
the IAC motor to maintain a desired engine speed.
I n addition to determining distance and vehicle
speed, the output from the sensor is used to help con
trol:
• Speed control operation
• Transmission overdrive operation
• Transmission torque converter electrical operation
• Idle air control (IAC) motor for engine idle speed
• Fuel injector pulse width
SENSOR
ELECTRICAL
CONNECTOR
Fig. 32 Camshaft Position Sensor—8.0L V-10 Engine
DATA LINK CONNECTOR—PCM PIN #45—PCM

INPUT
J9414-60
Refer to Data Link Connector—PCM PIN
# 2 5 - P C M Output for information.
Fig. 33 Vehicle Speed Sensor—Typical
CCD BUS(-)—PCM PIN #46—PCM OUTPUT SPEED CONTROL—PCM PINS #48 #4S AND
Various modules exchange information through a #50—PCM INPUT
communications port called the CCD BUS(-).
The speed control system provides three separate
inputs to the powertrain control module (PCM); On/
VEHICLE SPEED SENSOR—PCM PIN #47—PCM
Off, Set and Resume. The On/Off input informs the
INPUT PCM that the speed control system has been acti
The speed sensor (Fig. 33) is located i n the exten vated. The Set input informs the PCM that a fixed
sion housing of the transmission (2WD) or on the vehicle speed has been selected. The Resume input
transfer case extension housing (4WD). The sensor indicates to the PCM that the previous fixed speed is
requested.
The speed control operating range is from 50 km/h Refer to Automatic Shut Down Relay—PCM Pin
to 142 km/h (35 to 85 mph). Inputs that effect speed #51—PCM Output for additional information.
control operation are: The fuel pump will operate for approximately one
• Park/neutral switch second unless the engine is operating or the starter
• Vehicle speed sensor motor is engaged.
• Throttle position sensor The fuel pump relay is located i n the power distri
Refer to Group 8H for further speed control infor bution center (PDC). The PDC is located next to the
mation. battery i n the engine compartment (Fig. 34). For the
location of the relay within the PDC, refer to PDC
AUTOMATIC SHUT DOWN (ASD) RELAY—PCM PIN cover.
#51—PCM OUTPUT
This circuit (pin #51) controls operation of both the EVAP CANISTER PURGE SOLENOID—PCM PIN
ASD and fuel pump relays. #52—PCM OUTPUT
The ASD relay is located i n the power distribution This circuit controls a ground signal for operation
center (PDC). The PDC is located next to the battery of the EVAP Canister Purge Solenoid.
in the engine compartment (Fig. 34). For the location Refer to Group 25, Emission Control System. See
of the relay within the PDC,- refer to PDC cover. EVAP Canister Purge Solenoid.
SPEED CONTROL—PCM PINS #53 AND #33—PCM

OUTPUT
These two circuits control vent and vacuum opera
tion of the speed control solenoids.
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID—

PCM PIN #54—PCM OUTPUT
AUTOMATIC TRANSMISSION
This circuit (Fig. 35) controls operation of the
transmission mounted torque convertor (TCC) sole
noid used for torque convertor engagement.
TORQUE CONVERTER CLUTCH
AND OVERDRIVE SOLENOID
ELECTRICAL CONNECTOR
The ASD relay, after receiving signals from the
crankshaft and camshaft position sensors, will supply
battery voltage to the fuel injectors, ignition coil(s),
generator field winding and oxygen (02S) sensor(s)
heating element. I f these signals are not received by
the PCM after approximately one second of engine
cranking (start-up), the ASD relay will be shut down.
The ground circuit for the coil i n the ASD relay is
controlled by the powertrain control module (PCM). VEHICLE
The PCM operates the relay by switching the ground SPEED
SENSOR J9414-59
circuit ON and OFF.
Also refer to Fuel Pump Relay-PCM Pin Fig. 35 Electrical Connections at Transmission—
#51—PCM Output for additional information. TCC and Overdrive Solenoids
FUEL PUMP RELAY—PCM PIN #51—PCM The powertrain control module (PCM) will deter
OUTPUT mine when to engage and disengage the solenoid by
monitoring vehicle miles per hour (mph) versus the
The PCM energizes the electric fuel pump through
output voltage of the throttle position sensor. Also
the fuel pump relay. Battery voltage is applied to the
needed are various inputs from:
fuel pump relay when the ignition key is ON. The re
lay is energized when a ground signal is provided by
pin #51 on the PCM.
• Engine coolant temperature located in the power distribution center (PDC). The
• Module timer PDC is located next to the battery i n the engine com
• Engine rpm partment (Fig. 34). For the location of the relay
• MAP sensor within the PDC, refer to PDC cover.
This relay is used to connect the oxygen sensor(s)
MANUAL TRANSMISSION heater element, ignition coil(s), generator field wind
I f equipped with a manual transmission, pin #54 ing and fuel injectors to the 12 volt + power supply.
will control operation of the shift indicator lamp (if The ASD relay is controlled by the PCM through
equipped with lamp). The lamp is controlled by the same circuit that the fuel pump relay is controlled.
powertrain control module (PCM). The lamp illumi This input is used only to sense that the ASD relay
nates on the instrument panel to incicate when the is energized. I f the powertrain control module (PCM)
driver should shift to the next highest gear for best does not see 12 volts + at this input when the ASD
fuel economy. The PCM will turn the lamp OFF after should be activated, i t will set a diagnostic trouble
3 to 5 seconds i f the shift of gears is not performed. code (DTC).
The lamp will remain off until vehicle stops acceler
ating and is brought back to range of up-shift lamp FUEL INJECTORS—PCM PIN #58—PCM OUTPUT
operation. This will also happen i f vehicle is shifted
into fifth gear. 3.9I/5.21/S.9L ENGINES
The indicator lamp is normally illuminated when Pin #58 is used as the ground control circuit for the
the ignition switch is turned on and i t is turned off fuel injector on cylinder #6 on 3.9L/5.2L/5.9L engines.
when the engine is started up. With the engine run Refer to Fuel Injectors-PCM Pin # 1 3 - P C M Output
ning, the lamp is turned ON/OFF depending upon for information.
engine speed and load.
8 . 0 L V-10 ENGINE
OWERDRIVE SOLENOID—PCM PIN #§§—PCM Pin #58 is used as the ground control circuit for the
OUTPUT fuel injectors on cylinders #2 and #7 on the 8.0L V-10
engine (both injectors are fired simultaneously—one
AUTOMATIC TRANSMISSION cylinder on compression stroke and one cylinder on
This circuit controls operation of the transmission exhaust stroke).
mounted overdrive solenoid (Fig. 35) used for over
drive operation. The powertrain control module IDLE A I R CONTROL (IAC) M O T O R — P I N # 5 9 — P C M
(PCM) will determine when to engage and disengage OUTPUT
the solenoid by monitoring engine rpm versus output Pin #59 controls one of the circuits for operation of
voltage of the throttle position sensor. Also needed the IAC motor. Refer to Idle A i r Control (IAC)
are various inputs from: Motor—Pin #39—PCM Output for information.
• Engine coolant temperature
• Module timer IDLE AIR CONTROL (IAC) MOTOR—PIN #60—PCM
• Vehicle speed
• MAP sensor OUTPUT
Pin #60 controls one of the circuits for operation of
SRI LAMP—PCM PIN #56—PCM OUTPUT the IAC motor. Refer to Idle A i r Control (IAC)
This circuit controls operation of the SRI lamp. M o t o r - P i n # 3 9 - P C M Output for information.
The instrument panel mounted service reminder
indicator (SRI) lamp was formerly referred to as the FUEL FILTER
emission maintenance reminder (EMR) lamp. I t is A fuel tank mounted, combination, fuel filter/fuel
used only on vehicles equipped with 5.9L V-8 or 8.0L pressure regulator is used for all gasoline powered
V-10 heavy duty cycle (HDC) engines. When the lamp engines. For information, refer to Fuel Filter/Fuel
has been activated, certain service/maintenance must Pressure Regulator i n the Fuel Delivery
be performed. For required service/maintenance System—Except Diesel section of this group.
stated i n time or mileage, refer to Group 0, Lubrica
tion and Maintenance. Also refer to Group 25, Emis FUEL PRESSURE REGULATOR
sion Control System for information. A fuel tank mounted, combination, fuel filter/fuel
pressure regulator is used for all gasoline powered
AUTOMATIC S H U T D O W N ( A S D ) S E N S E — P C M P I N engines. For information, refer to Fuel Filter/Fuel
# 5 7 — P C M INPUT Pressure Regulator in the Fuel Delivery
A 12 volt signal at this input indicates to the PCM System—Except Diesel section of this group.
that the ASD has been activated. The ASD relay is
The fuel pressure regulator is a mechanical device INTAKE M A N I F O L D

not controlled by the powertrain control module UPPER HALF
(PCM).
THROTTLE BODY
Filtered air from the air cleaner enters the intake
manifold through the throttle body. Fuel does not en
ter the intake manifold through the throttle body.
Fuel is sprayed into the intake manifold by the fuel
injectors.
The throttle body is mounted on the top of the in
take manifold on 3.9L/5.2L/5.9L engines (Fig. 36). On
the 8.0L V-10 engine, a two-barrel side-mounted type
throttle body is mounted to the upper half of the in
take manifold (Fig. 37).
THROTTLE
NUTS (4) J9414-57
Fig. 37 Throttle Body—8.0L Engine
THROTTLE BODY
M O U N T I N G BOLTS
Fig. 36 Throttle Bo6y-3.9U5.2US.9L Engines

The throttle body contains an air control passage
(Figs. 38 or 39) controlled by the idle air control Fig. 38 Air Control Passage—3.9U5.2U5.9L Engines
(IAC) motor. The air control passage is used to sup A (factory adjusted) set screw is used to mechani
ply air for idle conditions. A throttle valve (plate) is cally limit the position of the throttle body throttle
used to supply air for above idle conditions. Refer to plate. Never attempt to adjust the engine idle
Idle Air Control (IAC) M o t o r - P i n # 3 9 - P C M Output speed using this screw. A l l idle speed functions are
in this group for more information. controlled by the PCM.
On the 3.9L V-6 and 5.2L/5.9L V-8 engines, the
throttle position sensor (TPS), idle air control (IAC) FUEL RAIL
motor and manifold absolute pressure (MAP) sensor The fuel rail supplies the necessary fuel to each in
are attached to the throttle body. On the 8.0L V-10 dividual fuel injector and is mounted to the intake
engine, the TPS and IAC motor are attached to the manifold (Figs. 40 or 41). The fuel pressure regulator
throttle body. The MAP sensor on the 8.0L engine is is no longer mounted to the fuel rail on any gas pow
attached to the intake manifold. ered engines. I t is now located on the fuel tank
The accelerator pedal cable, speed control cable and mounted fuel pump module. Refer to Fuel Filter/Fuel
transmission control cable (when equipped) are con Pressure Regulator in the Fuel Delivery
nected to the throttle arm. System—Except Diesel section of this group.
VACUUM ELECTRICAL MOUNTING BOLTS
FITTING'
PASSAGE CONTROL (IAC)

MOTOR
VIEW FROM BOTTOM ,
I O A A A Q
Fig. 39 Air Control Passage—8.0L V-10 Engine Fig. 41 Fuel RailS.OL V-10 Engine—Typical
different injector pulse width and ignition timing for
idle than i t does for wide open throttle (WOT). There
are several different modes of operation that deter
mine how the PCM responds to the various input sig
nals.
MODES
• Open Loop
• Closed Loop
During Open Loop modes, the powertrain control
module (PCM) receives input signals and responds
only according to preset PCM programming. Input
from the oxygen (02S) sensor(s) is not monitored
during Open Loop modes.
During Closed Loop modes, the PCM will monitor
J9414-53 the oxygen (02S) sensor input. This input indicates
Fig. 40 Fuel Rail-3.91J5.2IJ5.9L Engines—Typical to the PCM whether or not the calculated injector
pulse width results i n the ideal air-fuel ratio. This
CAUTION: 3.9L/5.2U5.9L ENGINES. The left and ratio is 14.7 parts air-to-1 part fuel. By monitoring
right sections of the fuel rail are connected with a the exhaust oxygen content through the 02S sensor,
flexible connecting hose. Do not attempt to sepa the PCM can fine tune the injector pulse width. This
rate the rail halves at this connecting hose (Fig. 40). is done to achieve optimum fuel economy combined
Due to the design of this connecting hose, they do with low emission engine performance.
not use any clamps. Never attempt to install a The fuel injection system has the following modes
clamping device of any kind to the hose. When re of operation:
moving the fuel rail assembly for any reason, be • Ignition switch ON
careful not to bend or kink the connecting hose. • Engine start-up (crank)
• Engine warm-up
• Idle
OPEN LOOP/CLOSED LOOP MODES OF • Cruise
OPERATION • Acceleration
As input signals to the powertrain control module • Deceleration
(PCM) change, the PCM adjusts its response to the • Wide open throttle (WOT)
• Ignition switch OFF
output devices. For example, the PCM must calculate The ignition switch On, engine start-up (crank), en-
gine warm-up, acceleration, deceleration and wide ENGINE WAHM-UP MODE

open throttle modes are Open Loop modes. The idle This is an Open Loop mode. During engine warm-
and cruise modes, (with the engine at operating tem up, the powertrain control module (PCM) receives in
perature) are Closed Loop modes. puts from:
• Battery voltage
IGNITION SWITCH (KEY-ON) MODE • Crankshaft position sensor
This is an Open Loop mode. When the fuel system • Engine coolant temperature sensor
is activated by the ignition switch, the following ac • Intake manifold air temperature sensor
tions occur: • Manifold absolute pressure (MAP) sensor
• The powertrain control module (PCM) pre-posi- • Throttle position sensor (TPS)
tions the idle air control (IAC) motor. • Camshaft position sensor signal (in the distribu
• The PCM determines atmospheric air pressure tor)
from the MAP sensor input to determine basic fuel • Park/Neutral Switch (Gear indicator signal—auto,
strategy. trans, only)
• The PCM monitors the engine coolant temperature • A i r conditioning request signal (if equipped)
sensor input. The PCM modifies fuel strategy based Based on these inputs the following occurs:
on this input. • Voltage is applied to the fuel injectors with the
• Intake manifold air temperature sensor input is powertrain control module (PCM). The PCM will
monitored. then control the injection sequence and injector pulse
• Throttle position sensor (TPS) is monitored. width by turning the ground circuit to each individ
• The auto shut down (ASD) relay is energized by ual injector on and off.
the PCM for approximately three seconds. • The PCM adjusts engine idle speed through the
• The fuel pump is energized through the fuel pump idle air control (IAC) motor and adjusts ignition tim
relay by the PCM. The fuel pump will operate for ap ing.
proximately one second unless the engine is operat • The PCM operates the A/C compressor clutch
ing or the starter motor is engaged. through the clutch relay. This is done i f A/C has been
• The 02S sensor(s) heater element is energized selected by the vehicle operator and requested by the
through the fuel pump relay. The 02S sensor(s) input A/C thermostat.
is not used by the PCM to calibrate air-fuel ratio dur • I f the vehicle has a manual transmission, the up
ing this mode of operation. shift lamp is operated by the PCM.
• The up-shift indicator lamp is illuminated (manual • When engine has reached operating temperature,
transmission only). the PCM will begin monitoring 02S sensor(s) input.
The system will then leave the warm-up mode and go
ENGINE START-UP MODE into closed loop operation.
This is an Open Loop mode. The following actions
occur when the starter motor is engaged. IDLE MODE
The powertrain control module (PCM) receives in When the engine is at operating temperature, this
puts from: is a Closed Loop mode. A t idle speed, the powertrain
• Battery voltage control module (PCM) receives inputs from:
• Engine coolant temperature sensor • A i r conditioning request signal (if equipped)
• Crankshaft position sensor • Battery voltage
• Intake manifold air temperature sensor • Crankshaft position sensor
• Manifold absolute pressure (MAP) sensor • Engine coolant temperature sensor
• Throttle position sensor (TPS) • Intake manifold air temperature sensor
• Starter motor relay • Manifold absolute pressure (MAP) sensor
• Camshaft position sensor signal • Throttle position sensor (TPS)
The PCM monitors the crankshaft position sensor. • Camshaft position sensor signal (in the distribu
I f the PCM does not receive a crankshaft position tor)
sensor signal within 3 seconds of cranking the en • Battery voltage
gine, i t will shut down the fuel injection system. • Park/Neutral Switch (Gear indicator signal—Auto,
The fuel pump is activated by the PCM through trans, only)
the fuel pump relay. • Oxygen sensor
Voltage is applied to the fuel injectors with the Based on these inputs, the following occurs:
PCM. The PCM will then control the injection se • Voltage is applied to the fuel injectors with the
quence and injector pulse width by turning the powertrain control module (PCM). The PCM will
ground circuit to each individual injector on and off. then control injection sequence and injector pulse
The PCM determines the proper ignition timing ac width by turning the ground circuit to each individ
cording to input received from the crankshaft posi ual injector on and off.
tion sensor.
• The PCM monitors the 02S sensor(s) input and • Intake manifold air temperature sensor
adjusts air-fuel ratio by varying injector pulse width. • Manifold absolute pressure (MAP) sensor
It also adjusts engine idle speed through the idle air • Throttle position sensor (TPS)
control (IAC) motor. • Camshaft position sensor signal (in the distribu
• The PCM adjusts ignition timing by increasing tor)
and decreasing spark advance. • Park/Neutral switch (gear indicator signal—auto,
• The PCM operates the A/C compressor clutch trans, only)
through the clutch relay. This happens if A/C has If the vehicle is under hard deceleration with the
been selected by the vehicle operator and requested proper rpm and closed throttle conditions, the PCM
by the A/C thermostat. will ignore the oxygen sensor input signal. The PCM
will enter a fuel cut-off strategy in which it will not
C R U I S E MODE
supply battery voltage to the injectors. If a hard de
When the engine is at operating temperature, this
is a Closed Loop mode. At cruising speed, the power- celeration does not exist, the PCM will determine the
train control module (PCM) receives inputs from: proper injector pulse width and continue injection.
• Air conditioning request signal (if equipped) Based on the above inputs, the PCM will adjust en
• Battery voltage gine idle speed through the idle air control (IAC) mo
• Engine coolant temperature sensor tor.
• Crankshaft position sensor The PCM adjusts ignition timing by turning the
• Intake manifold air temperature sensor ground path to the coil(s) on and off.
• Manifold absolute pressure (MAP) sensor The PCM opens the ground circuit to the A/C
• Throttle position sensor (TPS) clutch relay to disengage the A/C compressor clutch.
• Camshaft position sensor signal (in the distribu This is done until the vehicle is no longer under de
tor) celeration (if the A/C system is operating).
• Park/Neutral switch (gear indicator signal—auto,
trans, only) WIDE OPEN THROTTLE MODE
• Oxygen (02S) sensor(s) This is an Open Loop mode. During wide open
• Transmission temperature sensor (certain HD throttle operation, the powertrain control module
models with auto, trans.) (PCM) receives the following inputs.
Based on these inputs, the following occurs: • Battery voltage
• Voltage is applied to the fuel injectors with the • Crankshaft position sensor
PCM. The PCM will then adjust the injector pulse • Engine coolant temperature sensor
width by turning the ground circuit to each individ •• Intake manifold air temperature sensor
ual injector on and off. • Manifold absolute pressure (MAP) sensor
• The PCM monitors the 02S sensor(s) input and • Throttle position sensor (TPS)
adjusts air-fuel ratio. It also adjusts engine idle
• Camshaft position sensor signal (in the distribu
speed through the idle air control (IAC) motor.
tor)
• The PCM adjusts ignition timing by turning the
ground path to the coil(s) on and off. During wide open throttle conditions, the following
• The PCM operates the A/C compressor clutch occurs:
through the clutch relay. This happens if A/C has • Voltage is applied to the fuel injectors with the
been selected by the vehicle operator and requested powertrain control module (PCM). The PCM will
by the A/C thermostat. then control the injection sequence and injector pulse
width by turning the ground circuit to each individ
ACCELERATION MODE ual injector on and off. The PCM ignores the oxygen
This is an Open Loop mode. The powertrain control sensor input signal and provides a predetermined
module (PCM) recognizes an abrupt increase in amount of additional fuel. This is done by adjusting
throttle position or MAP pressure as a demand for injector pulse width.
increased engine output and vehicle acceleration. The • The PCM adjusts ignition timing by turning the
PCM increases injector pulse width in response to in ground path to the coil(s) on and off.
creased throttle opening. • The PCM opens the ground circuit to the A/C
clutch relay to disengage the A/C compressor clutch.
DECELERATION MODE This will be done for approximately 15 seconds (if the
When the engine is at operating temperature, this air conditioning system is operating).
is an Open Loop mode. During hard deceleration, the If the vehicle has a manual transmission, the up
powertrain control module (PCM) receives the follow shift lamp is operated by the PCM.
ing inputs.
• Air conditioning request signal (if equipped) IGNITION SWITCH OFF MODE
• Battery voltage When ignition switch is turned to O F F position,
• Engine coolant temperature sensor the PCM stops operating the injectors, ignition
• Crankshaft position sensor coil(s), ASD relay and fuel pump relay.
MULTI-PORT FUEL INJECTION (MFI)—GENERAL D I A G N O S I S — E X C E P T D I E S E L
INDEX
page page
Automatic Shut Down (ASD) Relay Test 57 Oxygen (02S) Sensor Heating Element Test 62
Camshaft Position Sensor Test .... 57 Powertrain Control Module (PCM) 60-Way
Crankshaft Position Sensor Test 57 Connector 56
Diagnostic Trouble Code (DTC) 68 Powertrain Control Module Testing 65
DRB Scan Tool 68 Relays—Operation/Testing 64
Engine Coolant Temperature Sensor Test . . . . . . . 57 Starter Motor Relay Test 65
Fuel Injector Test 66 System Schematics 57
Fuel Pump Pressure Test 66 Throttle Body Minimum Air Flow Check 61
Fuel Pump Relay Test 59 Throttle Position Sensor Test 61
Idle Air Control (IAC) Motor Test 63 Transmission Temperature Sensor Test 58
Intake Manifold Air Temperature Sensor Test 59
Vehicle Speed Sensor Test 62
Manifold Absolute Pressure (MAP) Sensor Test . . . 59
Visual Inspection 53
On-Board Diagnostics (OBD)—Gas Powered
Vehicles 66
VISUAL INSPECTION (2) Inspect the battery cable connections. Be sure

A visual inspection for loose, disconnected, or incor that they are clean and tight.
rectly routed wires and hoses should be made. This (3) Inspect fuel pump relay and air conditioning
should be done before attempting to diagnose or ser compressor clutch relay (if equipped). Inspect the
vice the fuel injection system. A visual check will A S D relay connections. Inspect starter motor relay
help spot these faults and save unnecessary test and connections. Inspect relays for signs of physical dam
age and corrosion. The relays are located in the
diagnostic time. A thorough visual inspection will in
power distribution center (PDC). The PDC is located
clude the following checks:
in the engine compartment (Fig. 2). For the location
(1) Verify that the 60-way connector is fully in of this relay within the PDC, refer to PDC cover.
serted into the connector of the powertrain control
module (PCM) (Fig. 1). Verify that the connector
mounting screw is tightened to 4 N-m (35 in. lbs.)
torque.
PCM
MOUNTING

(4) Inspect ignition coil connections. Verify that coil
secondary cable(s) is firmly connected to coil (Fig. 3,
4 or 5).
(5) 3.9L/5.2L/5.9L Engines: Verify that distributor
cap is correctly attached to distributor. Be sure that
PCM CONNECTOR
CONNECTOR MOUNTING spark plug cables are firmly connected to the distrib
BOLT j94] „94
utor cap and the spark plugs are in their correct fir
ing order. Be sure that coil cable is firmly connected
Fig. 1 Powertrain Control Module (PCM) to distributor cap and coil. Be sure that camshaft po
sition sensor wire connector (at the distributor) is
14 - §4 FUEL SYSTEM
(6) Verify that generator output wire, generator

connector and ground wire are firmly connected to
the generator.
(7) Inspect the system body grounds for loose or
dirty connections. Refer to Group 8, Wiring for
ground locations.
(8) 3.9L/5.2L/5.9L Engines: Verify positive crank
case ventilation (PCV) valve operation. Refer to
Group 25, Emission Control System for additional in
formation. Verify PCV valve hose is firmly connected
to PCV valve and manifold (Fig. 6).
8.0L V-10 Engine: Verify firm connections at fixed
orifice fitting and connecting tube (Fig. 7).
Fig. 3 Ignition Coil—3.9U5.2U5.9L LDC-Gas Engine
Fig. 6 PCV Valve and Hose Connections—3.9U5.2U

COIL "\
J9314-160
5.9L Engines—Typical
CONNECTOR
VACUUM
Fig. 4 Ignition Coil—5.9L HDC-Gas Engine JBE
COILS
J9414-64
Fig. 7 Fixed Orifice Fitting Hose Connections—8.0L

J948D-6 V-10 Engine—Typical
Fig. 5 Ignition Coil Packs—8.0L V-10 Engine (9) Verify that the fuel line, vacuum hose and elec
firmly connected to harness connector. Inspect spark trical connector are firmly connected to the fuel
plug condition. Refer to Group 8D, Ignition. Connect pump module. These can be inspected from over the
vehicle to an oscilloscope and inspect spark events top of the left-rear wheel.
for fouled or damaged spark plugs or cables.
(10) Inspect fuel line quick-connect fitting-to-fuel
rail connection. On the 8.0L V-10 engine, the fuel
line-to-fuel rail connection is made at the rear of the
engine.
(11) Verify that hose connections to all ports of vac
uum fittings on intake manifold are tight and not
leaking.
(12) Inspect accelerator cable, transmission throt
tle cable (if equipped) and cruise control cable con
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or re
strictions.
(13) I f equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit
ting on intake manifold. Also check connection to
brake vacuum booster.
(14) Inspect the air cleaner inlet and air filter ele
ment for dirt or restrictions.
(15) Inspect radiator grille area, radiator fins and
air conditioning condenser for restrictions.
(16) Verify that the intake manifold air tempera
ture sensor wire connector is firmly connected to har
ness connector (Figs. 8, 9 or 10).

(22) Verify that oxygen sensor wire connector (or
connectors) are firmly connected to the sensor (or
sensors). Inspect sensor(s) and connector(s) for dam
Fig. 8 Sensor Location—3.9L V-6 Engine—Typical age (Figs. 16 or 17).
(17) Verify that MAP sensor electrical connector is (23) Inspect for pinched or leaking fuel lines/tubes.
firmly connected to MAP sensor (Figs. 11 or 12). On Inspect for pinched, cracked or leaking fuel hoses.
3.9L/5.2L/5.9L engines, also verify that rubber (24) Inspect for exhaust system restrictions such
L-shaped fitting from MAP sensor to the throttle as pinched exhaust pipes, collapsed muffler or
body is firmly connected (Fig. 13). plugged catalytic convertor.
(18) Verify that fuel injector wire harness connec (25) I f equipped with automatic transmission, ver
tors are firmly connected to injectors i n the correct ify that electrical harness is firmly connected to park/
order. Each harness connector is numerically tagged neutral switch. Refer to Automatic Transmission
with the injector number (INJ 1, I N J 2 etc.) of its section of Group 21.
corresponding fuel injector and cylinder number. (26) Verify that the harness connector is firmly
(19) Verify harness connectors are firmly connected connected to the vehicle speed sensor (Fig. 18).
to idle air control (IAC) motor, throttle position sen (27) Verify that electric fuel pump/gauge sender
sor (TPS) and manifold absolute pressure (MAP) sen unit wire connector is firmly connected to harness
sor (Fig. 11). connector. These can be inspected from over the top
(20) Verify that wire harness connector is firmly of the left-rear wheel.
connected to the engine coolant temperature sensor (28) Inspect fuel hoses at fuel pump/gauge sender
(Figs. 14 or 15). unit for cracks or leaks.
14 - IS FUEL SYSTEM •
Fig. 13 Rubber Fitting—MAP Sensor-to-Throttle

Body— 3.9U5.2U5.9L Engines
Fig. 11 MAP Sensor—3.9L/5.2U5.9L Engines-

Typical
Fig. 14 Coolant Temperature Sensor—3.9US.2U5.9L

Engines—Typical
Fig. 12 MAP Sensor—8.0L ¥-10 Engine—Typical

(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to timing ring on drive
plate/flywheel.
(30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components.
POWERTRAIN CONTROL MODULE (PCM) 60-WAY

CONNECTOR
For PCM 60-way connector wiring schematics, refer Fig. 15 Coolant Temperature Sensor—8.0L V-10
to Group S W , Wiring Diagrams. Engine
SENSOR
ELECTRICAL
CONNECTOR
EXHAUST
PIPE J9214-5
Fig. 16 Single Oxygen Sensor Location—3.9U5.2U

5.9L LDC Engines—Typical
J9414-60
Fig. 18 Vehicle Speed Sensor—Typical

ENGINE COOLANT TEMPERATURE SENSOR TEST
the sensor only, refer to the following:
(1) Disconnect wire harness connector from coolant
temperature sensor (Figs. 19 or 20).
3.9L/5.2L/5.9L Engines with A i r C o n d i t i o n i n g :
When removing the connector from sensor, do not
pull directly on wiring harness. Fabricate an
L-shaped hook tool from a coat hanger (approximate
Fig. 17 Dual Oxygen Sensor Location—5.9L and ly eight inches long). Place the hook part of tool un
8.0L HDC Engines—Typical der the connector for removal. The connector is
SYSTEM SCHEMATICS snapped onto the sensor. I t is not equipped with a
Refer to PCM Schematics—Except Diesel i n the lock type tab.
Multi-Port Fuel Injection (MFI)—Component De
scription/System Operation—Except Diesel section of
this group.
AUTOMATIC SHUT DOWN (ASD) RELAY TEST

To perform a complete test of the ASD relay and its
circuitry, refer to the DRB scan tool and appropriate
the relay only, refer to Relays—Operation/Testing i n
this section of the group.
CAMSHAFT POSITION SENSOR TEST

Refer to Group 8D, Ignition Systems, for Camshaft
Position Sensor testing.
CRANKSHAFT POSITION SENSOR TEST

Refer to Group 8D, Ignition Systems, for Crank Fig. 19 Coolant Temperature Sensor—3.9L V-6 or
shaft Position Sensor testing. 5.2/5.9L V-8 Engines—Typical
TEMP. GAUGE minal 4 to the sensor connector terminal. Repair the
ENGINE COOLANT TEMP. SENSOR SENSOR (FORTEMP. ^ 1 wire harness i f an open circuit is indicated.
(FOR PCM OPERATION) GAUGE OPERATION)
(4) After tests are completed, connect electrical
connector to sensor. The sensor connector is symmet
rical (not indexed). I t can be installed to the sensor
in either direction.
TRANSMISSION TEMPERATURE SENSOR TEST

4-SPEED AUT01ATIC TRANSMISSIONS ONLY
J948D-9 The transmission temperature sensor is used on
models equipped with certain heavy-duty options and
Fig. 20 Coolant Temperature Sensor—8.0L V-10 a 4-speed automatic transmission. Its purpose is to
Engine
help control transmission overheating. I f transmis
(2) Test the resistance of the sensor with a high in sion overheating has been determined by this sensor,
put impedance (digital) volt-ohmmeter. The resis an input is sent to the powertrain control module
tance (as measured across the sensor terminals) (PCM). The PCM will then force a 4-3 downshift.
should be less than 1340 ohms with the engine Once transmission temperature has cooled below
warm. Refer to the Sensor Resistance specifications, a 3-4 upshift will be allowed. An in
(OHMS)—Engine Coolant, Intake A i r and Transmis strument panel mounted transmission temperature
sion Temperature Sensors resistance chart. Replace warning lamp (Fig. 21) is also used.
the sensor i f i t is not within the range of resistance
specified i n the chart. INSTRUMENT
PANEL
SENSOR RESISTANCE (OHMS)—ENGINE
COOLANT, INTAKE AIR AND TRANSMISSION
TEMPERATURE SENSORS

TRANSMISSION
C F MIN MAX TEMPERATURE
WARNING LAMP
J
-40 -40 291,490 381,710
-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810 J9414-61
20 68 11,370 13,610
25 77 9,120 10,880 Fig. 21 Transmission Temperature Warning
30 86 7,370 8,750
40 104 4,900 5,750 Lamp—Typical Location
50 122 3,330 3,880 This sensor is located in the transmission cooling
60 140 2,310 2,670
70 158 1,630 1,870 line on the side of the transmission (Fig. 22).
80 176 1,170 1,340 Test the resistance of the sensor with a high input
90 194 860 970 impedance (digital) volt-ohmmeter. The resistance (as
100 212 640 720 measured across the sensor terminals) should be less
no 230 480 540
120 248 370 410 than 1340 ohms with the engine and transmission
warm. Refer to the Sensor Resistance
J928D-4 (OHMS)—Engine Coolant, Intake Air and Transmis
sion Temperature Sensors resistance chart. Replace
(3) Test continuity of the wire harness. Do this be the sensor i f i t is not within the range of resistance
tween the powertrain control module (PCM) wire specified i n the chart.
harness connector terminal 2 and the sensor connec
tor terminal. Also test continuity of wire harness ter
TEMPERATURE SENSOR J9414-46

Location—Typical
FUEL PUMP RELAY TEST
To perform a complete test of this relay and its cir
cuitry, refer to the DRB scan tool and appropriate

TEST
(1) Disconnect the wire harness connector from the
intake air temperature sensor (Figs. 23, 24 or 25).
tance chart. Replace the sensor i f i t is not within the
range of resistance specified i n the chart.
(3) Test the resistance of the wire harness. Do this
between the powertrain control module (PCM) wire
harness connector terminal 21 and the sensor con
nector terminal. Also check between terminal 4 to the
sensor connector terminal. Repair the wire harness
as necessary i f the resistance is greater than 1 ohm.

TEST
To perform a complete test of MAP sensor and its
Fig. 23 Sensor Location—3.9L V-6 Engine—Typical the MAP sensor only, refer to the following:
(2) Test the resistance of the sensor with an input 3.9L V-6 or 5.2/5.9L V-8 Engines: The MAP sen
impedance (digital) volt-ohmmeter. The resistance (as sor is mounted to the throttle body (Fig. 26). I t is
measured across the sensor terminals) should be less connected to the throttle body with an L-shaped rub
than 1340 ohms with the engine warm. Refer to the ber fitting and to the PCM electrically.
Sensor Resistance (OHMS)—Engine Coolant, Intake
Air and Transmission Temperature Sensors resis-
Fig. 28 Rubber Fitting—MAP Sensor-to-Throttle

Body—Except 8.0L ¥-10 Engine
tion switch ON and the engine OFF, output voltage
should be 4-to-5 volts. The voltage should drop to 1.5-
to-2.1 volts with a hot, neutral idle speed condition.
Fig. 26 MAP Sensor—3.9L ¥-6 or 5.2/5.9L ¥-8
Engines—Typical
8.0L V-10 Engine: The MAP sensor is mounted
into the right side of the intake manifold (Fig. 27). I t
senses direct manifold vacuum and is connected to
the PCM electrically.
A. Ground
B. Output Voltage
C. 5 Volts
J8914-91
Fig. 29 MAP Sensor Connector Terminals—3.91 ¥-6

or 5.2/5.9L ¥-8 Engines
(3) Test powertrain control module (PCM) termi
Fig. 27 MAP Sensor—8.0L ¥-10 Engine—Typical
nal-1 for the same voltage described above to verify
(1) 3.9L V-6 or 5.2/5.9L V-8 Engines: Inspect the the wire harness condition. Repair as necessary.
rubber fitting from the MAP sensor to the throttle (4) Test MAP sensor supply voltage at sensor con
body (Fig. 28). Repair as necessary. nector between terminals A and C (Fig. 29) with the
ignition ON. The voltage should be approximately 5
CAUTION: When testing the MAP sensor, be sure volts (±0.5V). Five volts (±0.5V) should also be at
that the harness wires are not damaged by the test terminal-6 of the PCM wire harness connector. Re
meter probes,, pair or replace the wire harness as necessary.
(5) Test the MAP sensor ground circuit at sensor
(2) 3.9L V-6 or 5.2/5.9L V-8 Engines: Test the MAP connector terminal-A (Fig. 29) and PCM connector
sensor output voltage at the MAP sensor connector terminal-4. Repair the wire harness i f necessary.
between terminals A and B (Fig. 29). With the igni- (6) Test the MAP sensor ground circuit at the PCM
connector between terminal-4 and terminal-11 with
an ohmmeter. I f the ohmmeter indicates an open cir
cuit, inspect for a defective sensor ground connection.
Refer to Group 8W, Wiring for location of this connec
tion. I f the ground connection is good, replace the
PCM. I f terminal-4 has a short circuit to 12 volts +,
correct this condition before replacing the PCM.
THROTTLE POSITION SENSOR TEST

ual. To test the sensor only, refer to the following:
The throttle position sensor (Figs. 30 or 31) can be
tested with a digital voltmeter. The sensor must be
checked on the vehicle with its three wire connector
engaged to the sensor. The center terminal wire of
the sensor connector is the output terminal.
(1) Remove the air filter housing assembly. Refer
to Group 25, Emission Control Systems for proce
dures.
(2) Carefully attach a paper clip into the center Fig. 31 Throttle Position Sensor—3.9L V-6 or
terminal of the sensor harness. 5.2/5.9L V-8 Engines—Typical
(3) Attach the positive (+) lead of the voltmeter to
this paper clip. THROTTLE BODY MINIMUM AIR FLOW CHECK
(4) Attach the negative (-) lead of the voltmeter to
a good ground. 3.9L V-6 AND 5 . 2 1 / S . 9 L V-8 ENGINES
The following test procedure has been developed to
With the ignition key i n the ON position and en
check throttle body calibrations for correct idle condi
gine not running, check the sensor output voltage at
tions. The procedure should be used to diagnose the
the center terminal wire of the connector. Check this
throttle body for conditions that may cause idle prob
at idle (throttle plate closed) and at wide open throt lems. This procedure should be used only after
tle (WOT). A t idle, sensor output voltage should be normal diagnostic procedures have failed to
greater than 200 millivolts. A t wide open throttle, produce results that indicate a throttle body re
sensor output voltage must be less than 4.8 volts. lated problem. Be sure to check for proper op
The output voltage should increase gradually as the eration of the idle air control motor before
throttle plate is slowly opened from idle to WOT. performing this test.
A special fixed orifice tool (number 6714) (Fig. 32)
must be used for the following test.
SPECIAL TOOL 6714
J9414-7
Fig. 32 Fixed Orifice Tool
(1) Start the engine and bring to operating temper
Fig. 30 Throttle Position Sensor—8.0L V-10 ature. Be sure all accessories are off before perform
Engine—Typical ing this test.
(2) Shut off the engine and remove the air filter el
ement housing.
(3) Disconnect the vacuum line at the PCV valve
(Fig. 33).
POWERTRAIN CONTROL
MODULE (PCM) J9414-U
Fig. 35 Data Link Connector

(8) Using the DRB scan tool, scroll through the
Fig. 33 Install Orifice Tool menus as follows: select—System, select—Engine,
(4) Install the 0.185 inch orifice tool (number 6714) select—Fuel and Ignition, select—Actuator Tests,
into the disconnected vacuum line i n place of the select—Engine rpm and select—Minimum Air Flow.
PCV valve (Fig. 33). The DRB scan tool will count down to stabilize the
(5) Disconnect the idle purge vacuum line from fit idle rpm and display the minimum air flow idle rpm.
ting at throttle body. This vacuum line is located on The idle rpm should be between 500 and 900 rpm.
the front of throttle body next to the MAP sensor I f the idle speed is outside of these specifications, re
(Fig. 34). Cap the fitting at throttle body after vac place the throttle body. Refer to Throttle Body i n the
uum line has been removed. Component Removal/Installation section of this
group.
<4i FRONT OF ENGINE
(9) Disconnect the DRB scan tool from the vehicle.
(10) Remove cap from idle purge fitting at throttle
body and install vacuum line.
(11) Remove orifice tool and connect vacuum line
to PCV valve.
(12) Install air filter element housing.
VEHICLE SPEED SENSOR TEST

To perform a complete test of the sensor and its cir
cuitry, refer to DRB scan tool and appropriate Pow
ertrain Diagnostics Procedures manual.
OXYGEN (02S) SENSOR HEATING ELEMENT TEST

To perform a complete test of single or dual 02S
sensor(s) and circuitry, refer to DRB scan tool and
ual. To test the 02S sensor only, refer to the follow
ing:
On 3.9L V-6 and 5.2/5.9L V-8 LDC engines, the sin
THROTTLE gle 02S sensor is located on the right exhaust down
BODY J9414-6 pipe (Fig. 36).
On both the 5.9L V-8 HDC and 8.0L V-10 engines,
Fig. 34 Idle Purge Line the dual 02S sensors are located on each (left and
(6) Connect the DRB scan tool to the data link con right) exhaust down pipe (Fig. 37).
nector (Fig. 35) on the vehicle. Refer to the appropri The 02S heating element can be tested with an
ate Powertrain Diagnostic Procedures service manual ohmmeter as follows:
for DRB operation. Disconnect the 02S sensor connector. Connect the
(7) Start the engine. ohmmeter test leads across the white wire terminals
of the sensor connector. Resistance should be be-
FUEL SYSTEM 14 - 63
tween 5 and 7 ohms. Replace the sensor i f the ohm

meter displays an infinity (open) reading.
EXHAUST
PIPE J9214-5
Fig. 36 Single Oxygen Sensor—3.9L V-6 or 5.2/5.9L

V-8 LDC Engines
Fig. 38 IAC Motor—3.9L/5.2U5.9L Engines—Typical
Fig. 37 Dual Oxygen Sensors—5.9U8.0L HDC

Engines—Typical
IDLE AIR CONTROL (IAC) MOTOR TEST Fig. 39 IAC Motor—8.0L V-10 Engine—Typical
To perform a complete test of IAC motor (Figs. 38 (1) With the ignition OFF, disconnect the IAC mo
or 39) and its circuitry, refer to DRB scan tool and tor wire connector at throttle body.
appropriate Powertrain Diagnostics Procedures man (2) Plug the exerciser tool (7558) harness connector
ual. To test the IAC motor only, special IAC motor into the IAC motor. A typical tool hook-up is shown
exerciser tool number 7558 (Fig. 40) may be used. in figure 40.
(3) Connect the red clip of exerciser tool (7558) to
CAUTION: Proper safety precautions must be taken battery positive terminal. Connect the black clip to
when testing the IAC motor. negative battery terminal. The red lamp on the exer
ciser tool will be illuminated when the exerciser is
• Set the parking brake and block the drive wheels properly connected to battery.
• Route all tester cables away from the cooling fans, (4) Start engine.
drive belt, pulleys and exhaust components When the switch is i n the HIGH or LOW position,
• Provide proper ventilation while operating the en the lamp on the exerciser tool will flash. This indi
gine cates that voltage pulses are being sent to the IAC
• Always return the engine idle speed to normal be stepper motor.
fore disconnecting the exerciser tool (5) Move the switch to the HIGH position. The en
gine speed should increase. Move the switch to the
1 4 - S 4 F U E L S Y S T E M
IAC WIRE HARNESS

IAC IDLE AIR
MOTOR MOTOR CONNECTION
CONTROL STEPPER
TOOL MOTOR
CONNECTOR
IAC
MOTOR
CONNECTOR
PINTLE J9314-116
Fig. 41 IAC Stepper Motor Pintle—Typical

TO
SPECIAL RELAYS—OPERATION/TESTING
BATTERY
TOOL 7558 To perform a complete test of a relay and its cir
J9314-H5 cuitry, refer to DRB scan tool and appropriate Pow
ertrain Diagnostics Procedures manual. To test the
Fig. 40 IAC Motor Testing—Typical Tool Hook-Up relay only, refer to the following:
LOW position. The engine speed should decrease. OPERATION
(a) I f the engine speed changes while using the The f o l l o w i n g operations/tests apply to these
exerciser tool, the IAC motor is functioning prop relays only: Automatic Shut Down (ASD) and Fuel
erly. Disconnect the exerciser tool and connect the Pump. For operations/tests on all other relays, refer
IAC stepper motor wire connector to the stepper to the appropriate section of this service manual.
motor. These relays are located i n the power distribution
(b) I f the engine speed does not change, turn the center (PDC). The PDC is located i n the engine com
ignition OFF and proceed to step (6). Do not dis partment (Fig. 42). For the location of this relay
connect exerciser from the IAC stepper motor. within the PDC, refer to PDC cover.
(6) Remove the IAC stepper motor from the throt
POWER
tle body. DISTRIBUTION
CENTER
CAUTION: W h e n c h e c k i n g IAC motor o p e r a t i o n w i t h (PDC)
the motor removed from the throttle body, d o not
e x t e n d t h e pintle (Fig. 41) more t h a n 6.35 mm (.250
in). If the pintle is extended more than this amount, it
may separate from the IAC stepper motor. The IAC mo
tor must be replaced if the pintle separates from the
motor.
(7) With the ignition OFF, cycle the exerciser tool

switch between the HIGH and LOW positions. Ob
serve the pintle. The pintle should move in-and-out
of the motor. J9414-10
(a) I f the pintle does not move, replace the IAC
motor. Start the engine and test the replacement
motor operation as described i n step (5).
(b) I f the pintle operates properly, check the IAC The relay terminal numbers (Fig. 43) can be found
motor bore i n the throttle body bore for blockage on the bottom of the relay.
and clean as necessary. Install the IAC motor and • Terminal number 30 is connected to battery volt
retest. I f blockage is not found, refer to the DRB age and can be switched or B+ (hot) at all times.
scan tool and the appropriate Powertrain Diagnos • The center terminal number 87A is connected (a
tics Procedures service manual. circuit is formed) to terminal 30 i n the de-energized
(normally OFF) position.
BOTTOM VIEW RELAY

OF RELAY CONNECTOR
DE-ENERGIZED ENERGIZED
RELAY RELAY
9214-157
Fig. 43 Relay Terminals

• Terminal number 87 is connected (a circuit is CAUTION: Do not allow the ohmmeter to contact
formed) to terminal 30 i n the energized (ON) posi terminals 85 or 86 during these tests. Damage to
tion. Terminal number 87 then supplies battery volt ohmmeter may result.
age to the component being operated.
• Terminal number 86 is connected to a switched (+) (7) Attach the other jumper wire (12V +) to termi
power source. nal number 86. This will activate the relay. Continu
• Terminal number 85 is grounded by the power- ity should now be present between terminals number
train control module (PCM). 87 and 30. Continuity should not be present between
terminals number 87A and 30.
TESTING (8) Disconnect jumper wires from relay and 12 Volt
(1) Remove relay before testing. power source.
(2) Using an ohmmeter, perform a resistance test I f continuity or resistance tests did not pass, re
between terminals 85 and 86. Resistance value place relay. I f tests passed, refer to Group 8W, Wiring
(ohms) should be 75 ±5 ohms for resistor equipped Diagrams for (fuel system) relay wiring schematics
relays. and for additional circuit information.
(3) Connect the ohmmeter between terminals num
ber 87A and 30. Continuity should be present at this STARTER MOTOR RELAY TEST
time. Refer to Group 8A, Battery/Starting/Charging Sys
(4) Connect the ohmmeter between terminals num tem Diagnostics, for starter motor relay testing.
ber 87 and 30. Continuity should not be present at
this time. POWERTRAIN CONTROL MODULE TESTING
(5) Use a set of jumper wires (16 gauge or small Operation of the powertrain control module (PCM)
er). Connect one jumper wire between terminal num is tested with the DRB scan tool. Refer to the appro
ber 85 (on the relay) to the ground side (-) of a 12 priate Powertrain Diagnostic Procedures service
Volt power source. manual for tests.
(6) Attach the other jumper wire to the positive
side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
FUEL INJECTOR TEST ON-BOARD DIAGNOSTICS (OBD)—GAS POWERED
To perform a complete test of the fuel injectors and VEHICLES
their circuitry, refer to DRB scan tool and appropri The powertrain control module (PCM) has been
ate Powertrain Diagnostics Procedures manual. To programmed to monitor many different circuits of the
test the injector only, refer to the following: fuel injection system. I f a problem is sensed i n a
Disconnect the fuel injector wire harness connector monitored circuit often enough to indicate an actual
from the injector (Figs. 44 or 45). Place an ohmmeter problem, a diagnostic trouble code (DTC) is stored.
across the injector terminals. Resistance reading The DTC will be stored i n the PCM memory for even
should be approximately 14.5 ohms ±1.2 ohms at tual display to the service technician. I f the problem
20°C (68°F). is repaired or ceases to exist, the PCM cancels the
DTC after 51 engine starts.
Certain criteria must be met for a diagnostic trou
ble code (DTC) to be entered into PCM memory. The
criteria may be a specific range of engine rpm, engine
temperature and/or input voltage to the PCM.
I t is possible that a DTC for a monitored circuit
may not be entered into memory even though a mal
function has occurred. This may happen because one
of the DTC criteria for the circuit has not been met.
Example: assume that one of the criteria for the
MAP sensor circuit is that the engine must be oper
ating between 750 and 2000 rpm to be monitored for
a DTC. I f the MAP sensor output circuit shorts to
ground when the engine rpm is above 2400 rpm, a 0
volt input will be seen by the PCM. A DTC will not
be entered into memory because the condition does
not occur within the specified rpm range.
A DTC indicates that the powertrain control mod
ule (PCM) has recognized an abnormal signal i n a
FUEL
circuit or the system. A DTC may indicate the result
INJECTOR J9214-30
of a failure, but never identify the failed component
Fig. 44 Typical Fuel Injector Wiring Connector directly.
There are several operating conditions that the
PCM does not monitor and set a DTC for. Refer to
the following Monitored Circuits and Non-Monitored
Circuits i n this section.
MONITORED C I R C U I T S
The powertrain control module (PCM) can detect
certain problems i n the fuel injection system.
Open o r Shorted Circuit - The PCM can deter
mine i f sensor output (which is the input to PCM) is
within proper range. I t also determines i f the circuit
is open or shorted.
O u t p u t Device C u r r e n t Flow - The PCM senses
whether the output devices are hooked up.
I f there is a problem with the circuit, the PCM
senses whether the circuit is open, shorted to ground
Fig. 45 Fuel Injector Internal Components—Typical (-), or shorted to (+) voltage.
Oxygen Sensor - The PCM can determine i f the
FUEL PUMP PRESSURE TEST oxygen sensor is switching between rich and lean.
Refer to Fuel Pump Pressure Test i n the Fuel De This is, once the system has entered Closed Loop. Re
livery System section of this group. fer to Open Loop/Closed Loop Modes Of Operation i n
the Component Description/System Operation section
for an explanation of Closed (or Open) Loop opera
tion.
NON*MONITORED CIRCUITS tablish high and low limits that are programmed into
The PCM does not monitor the following circuits, it for that device. I f the input voltage is not within
systems or conditions that could have malfunctions specifications and other diagnostic trouble code
that result i n driveability problems. A diagnostic (DTC) criteria are met, a DTC will be stored i n mem
trouble code (DTC) may not be displayed for these ory. Other DTC criteria might include engine rpm
conditions. limits or input voltages from other sensors or
Fuel Pressure: Fuel pressure is controlled by the switches. The other inputs might have to be sensed
fuel pressure regulator. The PCM cannot detect a by the PCM when i t senses a high or low input volt
clogged fuel pump inlet filter, clogged in-line fuel fil age from the control system device i n question.
ter, or a pinched fuel supply or return line. However,
these could result i n a rich or lean condition causing ACCESSING DIAGNOSTIC TROUBLE CODES
an oxygen sensor DTC to be stored i n the PCM. A stored diagnostic trouble code (DTC) can be dis
Secondary Ignition Circuit: The PCM cannot played by cycling the ignition key ON-OFF-ON-
detect an inoperative ignition coil, fouled or worn OFF-ON within three seconds and observing the
spark plugs, ignition cross firing, or open circuited malfunction indicator lamp. This lamp was formerly
spark plug cables. referred to as the check engine lamp. The lamp is lo
Engine Timing: The PCM cannot detect an incor cated on the instrument panel (Fig. 46).
rectly indexed timing chain, camshaft sprocket or
crankshaft sprocket. The PCM also cannot detect an
incorrectly indexed distributor. However, these could
result in a rich or lean condition causing an oxygen
sensor DTC to be stored i n the PCM.
Cylinder Compression: The PCM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust System: The PCM cannot detect a
plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions: The PCM cannot de
termine i f the fuel injector is clogged, or the wrong
injector is installed. However, these could result i n a
rich or lean condition causing an oxygen sensor DTC
to be stored i n the PCM.
Excessive Oil Consumption: Although the PCM
monitors exhaust stream oxygen content through ox
ygen sensor (closed loop), i t cannot determine exces
sive oil consumption. Fig. 46 Check Engine Lamp—Typical Location
Throttle Body A i r Flow: The PCM cannot detect They can also be displayed through the use of the
a clogged or restricted air cleaner inlet or air filter Diagnostic Readout Box (DRB scan tool). The DRB
element.
scan tool connects to the data link connector i n the
Evaporative System: The PCM will not detect a
engine compartment (Fig. 47). For operation of the
restricted, plugged or loaded EVAP canister.
DRB, refer to the appropriate Powertrain Diagnostic
Vacuum Assist: Leaks or restrictions in the vac
uum circuits of vacuum assisted engine control sys Procedures service manual.
tem devices are not monitored by the PCM. However,
EXAMPLES
a vacuum leak at the MAP sensor will be monitored
and a diagnostic trouble code (DTC) will be gener • I f the lamp (Fig. 46) flashes 4 times, pauses and
ated by the PCM. flashes 1 more time, a diagnostic trouble code (DTC)
Powertrain Control Module (PCM) System number 41 is indicated.
Ground: The PCM cannot determine a poor system • I f the lamp flashes 4 times, pauses and flashes 6
ground. However, a DTC may be generated as a re more times, a diagnostic trouble code (DTC) number
sult of this condition. 46 is indicated.
Powertrain Control Module (PCM) Connector • I f the lamp flashes 1 time, pauses and flashes 2
Engagement: The PCM cannot determine spread or more times, a diagnostic trouble code (DTC) number
damaged connector pins. However, a DTC may be 12 is indicated. I f the sequence of codes begins with a
generated as a result of this condition. DTC number 12, this indicates direct battery input to
the PCM was disconnected within the last 50 key-on
HIGH AND LOW LIMITS cycles. Old codes may have been erased.
The powertrain control module (PCM) compares in
put signal voltages from each input device. I t will es
DATA LINK
CONNECTOR
=3= •=§=> D-l GROUND
D-2 N/C
D-3 SCI TRANS
D-4 SCI RECEIVE
D-5 IGNITION
J9214-20 D-6 NOT USED
Fig. 48 Data Link Connector Schematic
POWERTRAIN CONTROL Refer to the appropriate Powertrain Diagnostic Pro
MODULE (PCM) J9414-11 cedures service manual for operation of the DRB
scan tool.
Fig. 47 Data Link Connector Location—Typical
After any stored DTC information has been ob DRB SCAN TOOL
served, the display will end with a flashing DTC For operation of the DRB scan tool, refer to the ap
number 55. This will indicate the end of all stored in propriate Powertrain Diagnostic Procedures service
formation. manual.
Refer to the Diagnostic Trouble Code (DTC) charts
for DTC identification. DIAGNOSTIC TROUBLE CODE (DTC)
I f the problem is repaired or ceases to exist, the On the following pages, a list of diagnostic trouble
powertrain control module (PCM) cancels the DTC codes is provided for all gas powered engines. A DTC
after 51 engine starts. indicates that the powertrain control module (PCM)
Diagnostic trouble codes indicate the results of a has recognized an abnormal signal i n a circuit or the
failure, but never identify the failed component di system. A DTC may indicate the result of a failure,
rectly. but never identify the failed component directly.
The circuits of the data link connector are shown i n
(Fig. 48).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRB
scan tool to erase a Diagnostic Trouble Code (DTC).
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
Diagnostic
DRB Scan Tool
Trouble Description of Diagnostic Trouble Code
Display
Code
11* No Crank Reference No crank reference signal detected during engine cranking.
Signal at PCM
12* Battery Disconnect Direct battery input to PCM was disconnected within the last 50 Key-on
cycles.
13** No Change in MAP From No difference recognized between the engine MAP reading and the
Start to Run barometric (atmospheric) pressure reading at start-up.
14** MAP Sensor Voltage Too MAP sensor input below minimum acceptable voltage.
Low
or
MAP Sensor Voltage Too MAP sensor input above maximum acceptable voltage.
High
15* No Vehicle Speed Sensor No vehicle distance (speed) sensor signal detected during road load
Signal conditions.
17* Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures
during vehicle travel (thermostat).
21* 02S Stays at Center Neither rich or lean condition detected from the oxygen sensor input. If
equipped with dual 02S sensors, the DRB scan tool will specify left or right
sensor.
or
02S Shorted to Voltage Oxygen sensor input voltage maintained above the normal operating range.
If equipped with dual 02S sensors, the DRB scan tool will specify left or right
sensor.
22* ECT Sensor Voltage Too Engine coolant temperature sensor input above maximum acceptable
High voltage.
or
ECT Sensor Voltage Too Engine coolant temperature sensor input below minimum acceptable voltage.
Low
23* Intake Air Temp Sensor Intake air manifold temperature sensor input below the minimum acceptable
Voltage Low voltage.
or
Intake Air Temp Sensor Intake manifold air temperature sensor input above the maximum acceptable
Voltage High voltage.
24* Throttle Position Sensor Throttle position sensor input above the maximum acceptable voltage.
Voltage High
or
Throttle Position Sensor Throttle position sensor input below the minimum acceptable voltage.
Voltage Low
25* Idle Air Control Motor A shorted condition detected in one or more of the idle air control motor
Circuits circuits.
described in manual and observe code flashed by Check Engine lamp.
14 - 70 FUEL SYSTEM
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED
Diagnostic
DRB Scan Tool
Display
Code
27* Injector #1 Control Circuit Injector #1 output driver does not respond properly to the control signal.
or
Injector #2 Control Circuit Injector #2 output driver does not respond properly to the control signal.
or
or
or
or
or
or
31* EVAP Solenoid Circuit An open or shorted condition detected in the EVAP solenoid circuit.
32* EGR Solenoid Circuit An open or shorted condition detected in the EGR solenoid circuit.
33* A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch relay circuit.
34* Speed Control Solenoid An open or shorted condition detected in the Speed Control vacuum or vent
Circuits solenoid circuits.
or
Speed Control Switch Speed Control switch input below the minimum acceptable voltage.
Always Low
or
Speed Control Switch Speed Control switch input above the maximum acceptable voltage.
Always High
37* Torque Converter Clutch An open or shorted condition detected in the CKT circuit.
Solenoid CKT
or
Trans Temp Sensor Voltage Low at Trans Temp Sensor
Voltage Too Low
or
Trans Temp Sensor Voltage High at Trans Temp Sensor
Voltage Too High
41* Generator Field Not An open or shorted condition detected in the generator field control circuit.
Switching Properly
42* Auto Shut Down Relay An open or shorted condition detected in the auto shut down relay circuit.
Control Circuit
DIAGNOSTIC T R O U B L E CODE DESCRIPTIONS—CONTINUED
Diagnostic
DRB S c a n T o o l
Display
Code
43* Ignition Coil Circuit # 1 An open or shorted condition detected in the # 1 coil circuit.
or
Ignition Coil Circuit #2 An open or shorted condition detected in the # 2 coil circuit.
or
Ignition Coil Circuit # 3 An open or shorted condition detected in the # 3 coil circuit.
or
Ignition Coil Circuit #4 An open or shorted condition detected in the # 4 coil circuit.
or
Ignition Coil Circuit # 5 An open or shorted condition detected in the # 5 coil circuit.
44* Battery Temp Sensor Volts An open or shorted condition exists in the engine coolant temperature sensor
out of Limit circuit or a problem exists in the PCM's battery temperature voltage circuit.
45* Trans Overdrive Solenoid An open or shorted condition exists in the transmission overdrive solenoid
Circuit circuit.
46* Charging System Voltage Battery voltage sense input above target charging voltage during engine
Too High operation.
47* Charging System Voltage Battery voltage sense input below target charging during engine operation.
Too Low Also, no significant change detected in battery voltage during active test of
generator output.
51* System Lean L-ldle Adap Oxygen sensor signal input indicates lean air/fuel ratio condition at the left
at Rich Limit 02S sensor during engine operation. If equipped with dual 02S sensors, the
DRB scan tool will specify left or right sensor.
or
System Lean R-ldle Adap Oxygen sensor signal input indicates lean air/fuel ratio condition at the right
at Rich Limit 02S sensor during engine operation. If equipped with dual 02S sensors, the
52** System Rich L-ldle Adap Oxygen sensor signal input indicates rich air/fuel ratio condition at the left
at Lean Limit 02S sensor during engine operation. If equipped with dual 02S sensors, the
or
System Rich R-ldle Adap Oxygen sensor signal input indicates rich air/fuel ratio condition at the right
at Lean Limit 02S sensor during engine operation. If equipped with dual 0 2 S sensors, the
53* Internal PCM Failure PCM Internal fault condition detected.

or
PCM Failure SPI PCM Internal fault condition detected.
Communications
54* No Cam Sync Signal at No fuel sync (camshaft signal) detected during engine cranking.
PCM
55* N/A A DTC # 5 5 is used to end all DTC messages. This code indicates a
completion of all DTC's displayed on the Malfunction Indicator Lamp (Check
Engine Lamp).
62* PCM Failure SPI miles not

stored Unsuccessful attempt to update SPI miles in the PCM EEPROM.
63* PCM Failure EEPROM

Write Denied Unsuccessful attempt to write to an EEPROM location by the PCM.
Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as
Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
MULTI-PORT F U E L I N J E C T I O N (MFI)—COMPONENT REMOVAL/INSTALLATION—
EXCEPT DIESEL
INDEX
page page
Accelerator Pedal and Throttle Cable . . . . . . . . . . . 72 Fuel Tank Pressure Relief/Rollover Valve 78
Air Conditioning (A/C) Clutch Relay 72 Fuel Tanks 78
Air Filter/Filter Housing 72 Fuel Tubes/Lines/Hoses and Clamps 78
Automatic Shut Down (ASD) Relay 72 Idle Air Control (IAC) Motor 78
Brake Switch 72 Ignition Coil 78
Camshaft Position Sensor 72 Intake Manifold 78
Crankshaft Position Sensor 72 Intake Manifold Air Temperature Sensor 72
Engine Coolant Temperature Sensor 73 Manifold Absolute Pressure (MAP) Sensor 79
EVAP Canister Purge Solenoid 74 Oxygen (02S) Sensor 79
Fuel Filter 74 Park/Neutral Switch 80
Fuel Injector(s) 74
Powertrain Control Module (PCM) 80
Fuel Pressure Regulator 74
Quick-Connect Fittings 81
Fuel Pump 74
Fuel Pump Module 74 Throttle Body 81
Fuel Pump Relay 74 Throttle Position Sensor (TPS) 81
Fuel Rail 74 Transmission Temperature Sensor 82
Fuel System Pressure Release Procedure . . . . . . . 78 Vehicle Speed Sensor 83
ACCELERATOR PEDAL AND THROTTLE CABLE AUTOMATIC SHUT DOWN (ASD) RELAY
Refer to the Accelerator Pedal and Throttle Cable The relay is located i n the power distribution cen
section of this group for removal/installation proce ter (PDC). The PDC is located next to the battery i n
dures. the engine compartment (Fig. 1). For the location of
the relay within the PDC, refer to PDC cover.
AIR CONDITIONING (A/C) CLUTCH RELAY
The A/C clutch relay is located i n the power distri BRAKE SWITCH
bution center (PDC). The PDC is located i n the en Refer to Group 5, Brakes for removal/installation
gine compartment (Fig. 1). For the location of this procedures.
relay within the PDC, refer to PDC cover.
CAMSHAFT POSITION SENSOR
For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
CRANKSHAFT POSITION SENSOR

Refer to Group 8D, Ignition System for removal/in
stallation procedures.

the left side of the intake manifold near the front of
the throttle body (Fig. 4).
Fig. 1 Power Distribution Center (PDC) Location REMOVAL

(1) Remove air cleaner assembly.
AIR FILTER/FILTER HOUSING (2) Disconnect electrical connector at sensor (Figs.
Refer to Air Filter/Filter Housing—Gas Engines i n 2, 3 or 4).
Group 25, Emission Control System for removal/in (3) Remove sensor from intake manifold.
ENGINE COOLANT TEMPERATURE SENSOR

is installed i n the intake manifold near the thermo
On the 8.0L V-10 engine, the sensor is installed i n
Fig. 5 Coolant Temperature Sensor—3.9L V-6 or


Engine
REMOVAL
WARNING; HOT P R E S S U R I Z E D COOLANT CAN

5
C A U S E INJURY B Y S C A L D I N G . COOLING S Y S T E M
MUST B E PARTIALLY DRAINED B E F O R E REMOV
ING T H E C O O L A N T T E M P E R A T U R E S E N S O R . R E
Fig. 4 Sensor Location—8.0L V-10 Engine—Typical F E R TO G R O U P 7, COOLING.
INSTALLATION
(1) Install sensor to intake manifold. Tighten to 28
7, Cooling.
(2) Disconnect electrical connector from sensor.
3.9L/5.2L/5.9L Engines with air conditionings
When removing the connector from sensor, do not
pull directly on wiring harness. Fabricate an
L-shaped hook tool from a coat hanger (approximate CUP
ly eight inches long). Place the hook part of tool un
der the connector for removal. The connector is
snapped onto the sensor. I t is not equipped with a
lock type tab.
(3) Remove sensor from intake manifold or thermo
stat housing.
INSTALLATION
(1) Install sensor.
(2) Tighten to 11 N-m (8 ft. lbs.) torque. INJECTOR J9214-24
(3) Connect electrical connector to sensor.

Fig. 7 Fuel Injector and Retaining Clip
The sensor connector is symmetrical (not indexed).
I t can be installed to the sensor i n either direction. (4) Remove injector(s) from fuel rail.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System. INSTALLATION
(1) Apply a small amount of engine oil to each fuel
EVAP CANISTER PURGE SOLENOID injector O-ring. This will help i n fuel rail installation.
Refer to Group 25, Emission Control System for re (2) Install injector(s) and injector clip(s) to fuel
moval/installation procedures. rail.
(3) Install fuel rail assembly. Refer to Fuel Rail in
FUEL FILTER stallation.
The fuel filter and fuel pressure regulator are one (4) Install air cleaner.
combined part. A separate in-line fuel filter is not (5) Start engine and check for leaks.
used. Refer to Fuel Filter/Fuel Pressure Regulator i n
the Fuel Delivery System—Except Diesel section of FUEL PUMP MODULE
this group for removal and installation procedures. Refer to Fuel Pump Module i n the Fuel Delivery
System section of this group for removal/installation
FUEL PRESSURE REGULATOR procedures.
The fuel filter and fuel pressure regulator are one
combined part. Refer to Fuel Filter/Fuel Pressure FUEL PUMP
Regulator i n the Fuel Delivery System—Except Die The electric fuel pump is not serviced separately.
sel section of this group for removal and installation
The fuel pump module must be replaced. Refer to
procedures.
Fuel Pump Module i n the Fuel Delivery System sec
FUEL INJECTOR(S) tion of this group for removal/installation procedures.
WARNING: THE FUEL SYSTEM IS UNDER A CON FUEL PUMP RELAY

STANT PRESSURE (EVEN WITH THE ENGINE The relay is located i n the power distribution cen
TURNED OFF). BEFORE SERVICING THE FUEL IN ter (PDC). The PDC is located next to the battery i n
JECTOR^), THE FUEL SYSTEM PRESSURE MUST the engine compartment (Fig. 8). For the location of
BE RELEASED. the relay within the PDC, refer to PDC cover.
To release fuel pressure, refer to the Fuel Delivery FUEL RAIL

System section of this group. See Fuel System Pres
sure Release. WARNING; THE FUEL SYSTEM IS UNDER A CON
To remove one or more fuel injectors, the fuel rail STANT PRESSURE (EVEN WITH THE ENGINE
assembly must be removed from engine. TURNED OFF). BEFORE SERVICING THE FUEL
RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE
REMOWAL MUST BE RELEASED.
(1) Remove air cleaner assembly.
(2) Remove fuel rail assembly. Refer to Fuel Rail To release fuel pressure, refer to the Fuel Delivery
removal i n this section. System section of this group. See Fuel System Pres
(3) Remove the clip(s) retaining the injector(s) to sure Release.
fuel rail (Fig. 7).
FUEL SYSTEM 14 - 75
Fig. 10 A/C Compressor Support Bracket—3.9U5.2U

Fig, 8 Power Distribution Center (PDC) Location
5.9L Engines—Typical
mEmOWAL-3.9m-2m.9L ENGINES ness is numerically tagged (INJ 1, I N J 2, etc.) for
injector position identification.
CAUTION; The left and right fuel rails are replaced
a s an assembly. Do not attempt to separate the rail
halves at the c o n n e c t i n g hose (Fig. 9). Due to the
design of this c o n n e c t i n g hose, it does not u s e a n y
clamps. Never attempt to install a c l a m p i n g device
of any kind to the hose. W h e n r e m o v i n g the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
FUEL
INJECTOR J9214-30
J9414-53 Fig. 11 Injector Connectors—3.9U5.2U5.9L

Engines—Typical
Fig. 9 Fuel Rail—3.9L/5 2U5 9L Engines—Typical
(7) 3.9L (V-6) engine only: Disconnect electrical
(1) Remove negative battery cable at battery. connector at intake manifold air temperature sensor.
(2) Remove air cleaner tube and housing. Do not remove sensor.
(3) Perform the fuel pressure release procedure. (8) Remove EVAP canister purge solenoid/bracket
Refer to the Fuel Delivery System section of this assembly (Fig. 12) from intake manifold (one nut on
group. 3.9L, one bolt on 5.2L/5.9L).
(4) Remove throttle body from intake manifold. Re (9) Disconnect the main fuel line at side of fuel rail
fer to Throttle Body removal i n this group. (Fig. 13). Refer to Fuel Tubes/Lines/Hoses and
(5) I f equipped with air conditioning, remove the Clamps i n the Fuel Delivery System section of this
A/C compressor-to-intake manifold support bracket group for procedures.
(three bolts) (Fig. 10). (10) Remove the remaining fuel rail mounting
(6) Disconnect electrical connectors at all fuel i n - . bolts (Fig. 9).
jectors (Fig. 11). The factory fuel injection wiring har- (11) Gently rock and pull the left fuel rail until
14 76 • FUEL SYSTEM •
CLIP
Fig. 14 Fuel Injector Clip—Typical

Fig. 12 EVAP Canister Purge Solenoid—3.9U5.2U (5) Push the right fuel rail down until fuel injec
5.9L Engines—Typical tors have bottomed on injector shoulder. Push the
left fuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install fuel rail mounting bolts.
(7) Install EVAP canister purge solenoid to intake
manifold.
(8) Connect electrical connector to intake manifold
air temperature sensor.
(9) Connect wiring to all fuel injectors. The injector
wiring harness is numerically tagged.
(10) Install the A/C support bracket (if equipped).
(11) Install throttle body to intake manifold. Refer
to Throttle Body installation i n this section of the
group.
(12) Install main fuel line at fuel rail (Fig. 13). Re
fer to Fuel Tubes/Lines/Hoses and Clamps i n the
Fuel Delivery System section of this group for proce
Fig. 13 Fuel Line at Fuel Raii—3.9U5.2U5.9L dures.
Engines—Typical (13) Install air cleaner tube and housing.
the fuel injectors just start to clear the intake mani (14) Connect battery cable to battery.
fold. Gently rock and pull the right fuel rail until (15) Start engine and check for leaks.
the fuel injectors just start to clear the intake mani
fold. Repeat this procedure (left/right) until all fuel REMOVAL—&OL V-10 E N G I N E
injectors have cleared the intake manifold. (1) Remove negative battery cable at battery.
(12) .Remove fuel rail (with injectors attached) from (2) Remove air cleaner housing and tube.
engine. (3) Perform the fuel pressure release procedure.
(13) Remove the clip(s) retaining the injector(s) to Refer to the Fuel Delivery System section of this
fuel rail (Fig. 14). group.
(4) Disconnect throttle body linkage and remove
INSTALLATION—3.9I/5.2L/5.9L ENGINES throttle body from intake manifold. Refer to Throttle
(1) Apply a small amount of engine oil to each fuel Body removal i n this group.
injector O-ring. This will help i n fuel rail installation. (5) Remove ignition coil pack and bracket assembly
(2) Install injector(s) and injector clip(s) to fuel (Fig. 15) at intake manifold and right engine valve
rail. cover (four bolts).
(3) Position the fuel rail/fuel injector assembly to (6) Remove upper half of intake manifold. Refer to
the injector openings on the intake manifold. Group 11, Exhaust System and Intake Manifold for
(4) Guide each injector into the intake manifold. procedures.
Be careful not to tear the injector O-ring.
COIL PACKS ELECTRICAL MOUNTING BOLTS
AND BRACKET
MOUNTING
BOLTS (4)
FRONT OF ENGINE J9414-55
Fig. 15 Ignition Coil Pack and Mounting Bracket— Fig. 16 Fuel Rail Mounting Bolts—8.0L V-10
8.0L V-10 Engine Engine—Typical
(7) Disconnect electrical connectors at all fuel in (4) Guide each injector into the intake manifold.
jectors. The factory fuel injection wiring harness is Be careful not to tear the injector O-ring.
numerically tagged (INJ 1, I N J 2, etc.) for injector (5) Push the right fuel rail down until fuel injec
position identification. tors have bottomed on injector shoulder. Push the
(8) Disconnect main fuel line at fuel rail. On the left fuel rail down until fuel injectors have bottomed
8.0L V-10 engine, the fuel line-to-fuel rail connection on injector shoulder.
is made at the rear of the engine. Refer to Fuel (6) Install the six fuel rail mounting bolts into the
Tubes/Lines/Hoses and Clamps in the Fuel Delivery lower half of intake manifold. Tighten bolts to 15
System section of this group for procedures. N-m (136 in. lbs.) torque.
(9) Remove the six fuel rail mounting bolts from (7) Connect wiring to all fuel injectors. The injector
the lower half of intake manifold (Fig. 16). wiring harness is numerically tagged.
(10) Gently rock and pull the left fuel rail until (8) Install upper half of intake manifold. Refer to
the fuel injectors just start to clear the intake mani Group 11, Exhaust System and Intake Manifold for
fold. Gently rock and pull the right fuel rail until procedures.
the fuel injectors just start to clear the intake mani (9) Connect main fuel line at fuel rail. Refer to
fold. Repeat this procedure (left/right) until all fuel Fuel Tubes/Lines/Hoses and Clamps i n the Fuel De
injectors have cleared the intake manifold. livery System section of this group for procedures.
(11) Remove fuel rail (with injectors attached) from (10) Install ignition coil pack and bracket assembly
engine. (Fig. 15) at intake manifold and right engine valve
(12) Remove the clip(s) retaining the injector(s) to cover (four bolts).
fuel rail (Fig. 14). (11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
INSTALLATION—8.0L V-f 0 ENGINE (12) Install throttle body linkage to throttle body.
(1) Apply a small amount of engine oil to each fuel (13) Install air cleaner tube and housing.
injector O-ring. This will help i n fuel rail installation. (14) Install negative battery cable at battery.
(2) Install injector(s) and injector clip(s) to fuel (15) Start engine and check for leaks.
rail.
The fuel injector electrical connectors on all
10 injectors should be facing to the right (pas
senger) side of the vehicle (Fig. 16).
(3) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE

STANT P R E S S U R E ( E V E N WITH T H E ENGINE
TURNED O F F ) . B E F O R E S E R V I C I N G T H E F U E L
PUMP, F U E L LINES ( T U B E S ) , F U E L FILTER, F U E L
P R E S S U R E R E G U L A T O R OR F U E L INJECTOR(S),
T H E F U E L S Y S T E M P R E S S U R E MUST B E R E
LEASED.
To release fuel pressure, refer to the Fuel Delivery

System section of this group. See Fuel System Pres
sure Release Procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re
Fig. 18 IAC Motor—8.0L Engine—Typical
moval/installation procedures.
REMOWAL
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE (1) Remove air cleaner housing and tube assembly.
Refer to the Fuel Tank section of this group for re (2) Disconnect electrical connector from IAC motor.
moval/installation procedures. (3) Remove two mounting bolts (screws) (Fig. 19).
FUEL TUBES/LINES/HOSES AND CLAMPS

Refer to Fuel Tubes/Lines/Hoses and Clamps i n the
Fuel Delivery System section of this group for remov
al/installation procedures.
Also refer to Quick-Connect Fittings i n the Fuel
Delivery System section of this group for removal/in
IDLE AIR CONTROL (IAC) MOTOR

The idle air control (IAC) motor is mounted to the
throttle body (Figs. 17 or 18).
J9214-23
Fig. 19 Typical Mounting Bolts (Screws)—IAC Motor

(4) Remove IAC motor from throttle body.
INSTALLATION
(1) Install IAC motor to throttle body.
(2) Install and tighten two mounting bolts (screws)
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.
Fig. 17 IAC Motor—3.9U5.2U5.9L Engines—Typical


REMOVAL—3.9L V-6 Oft 5.2/5.9L V-8 ENGINES
The MAP sensor is located on the front of the
throttle body (Fig. 17). A n L-shaped rubber fitting is
used to connect the MAP sensor to throttle body (Fig.
20).
M O U N T I N G SCREWS
MAP SENSOR
RUBBER FITTING
~ , J9414-1
Fig. 21 MAP Sensor Location—8.0L V-10 Engine-

Typical
(2) Clean the area around the sensor before re
moval.
(3) Remove the two sensor mounting bolts.
VIEW FROM BOTTOM J9314-87 (4) Remove the sensor from the intake manifold.
INSTALLATION
Fig. 20 MAP Sensor L-Shaped Rubber Fitting—3.9U
(1) Check the condition of the sensor seal. Clean
5.2U5.9L Engines
the sensor and lubricate the rubber gasket with clean
The throttle body must be removed from the engine oil.
intake manifold for MAP sensor removal. (2) Clean the sensor opening i n the intake mani
(1) Remove air cleaner assembly and tube. fold.
(2) Remove throttle body. Refer to Throttle Body (3) Install the sensor into the intake manifold.
removal i n this section. (4) Install sensor mounting bolts. Tighten bolts to
(3) Remove two MAP sensor mounting bolts 2 N-m (20 in. lbs.) torque.
(screws) (Fig. 20). (5) Install the electrical connector to sensor.
(4) While removing MAP sensor, slide the rubber
L-shaped vacuum fitting (Fig. 20) from the throttle OXYCEN (02S) SENSOR
body fitting. On 3 . 9 L / 5 . 2 L / 5 . 9 L LDC engines, the single 0 2 S
(5) Remove rubber L-shaped fitting from MAP sen sensor is located on the right exhaust down pipe (Fig.
sor. 22). On 5.9L V-8 HDC and 8.0L V-10 HDC engines,
the dual 0 2 S sensors are located on each (left and
INSTALLATION right) exhaust down pipe (Fig. 23).
(1) Install rubber L-shaped fitting to MAP sensor.
(2) Position sensor to throttle body while guiding REMOVAL
rubber fitting over throttle body vacuum fitting.
(3) Install MAP sensor mounting bolts (screws). WARNING: T H E E X H A U S T MANIFOLD B E C O M E S
Tighten screws to 3 N-m (25 in. lbs.) torque. V E R Y HOT DURING ENGINE OPERATION. A L L O W
(4) Install throttle body. Refer to Throttle Body in ENGINE TO C O O L B E F O R E REMOVING O X Y G E N
stallation i n this section. SENSOR.
REMOVAL—S.OL V-f 0 ENGINE (2) Disconnect the wire connector(s) from the 0 2 S
The MAP sensor is mounted into the right upper sensor(s).
side of the intake manifold (Fig. 21). A rubber gasket
is used to seal the sensor to the intake manifold. The CAUTION: When disconnecting the sensor electrical
rubber gasket is part of the sensor and is not ser connector, do not pull directly on wire going into
viced separately. sensor.
(1) Remove the electrical connector at the sensor.
14 - 80 FUEL SYSTEM

REMOVAL
24). I t is mounted to the dash panel cowl with three
bolts (Fig. 25). The PCM was formerly referred to as
the SBEC or engine controller.
EXHAUST
PIPE J9214-5
POWERTRAIN CONTROL
PCM
MOUNTING
Fig. 23 Dual Oxygen Sensors—5.9L and 8.0L HDC

Engine—Typical
(3) Remove the 02S sensor from the exhaust man
ifold. Snap-On oxygen sensor wrench (number YA
8 8 7 5 ) may be used for removal and installation.
INSTALLATION
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid i n removal. DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor. PCM CONNECTOR
CONNECTOR M O U N T I N G
I f threads i n exhaust pipe are damaged, they may BOLT j94 „9
14
be rethreaded with an 18 mm x 1.5 pitch +6E tap.

Blow off metal material i n exhaust pipe before in
Fig. 25 PCM Mounting
stalling 02S sensor.
(1) Install the 02S sensor into the exhaust mani (1) Disconnect negative battery cable at battery.
fold. Tighten to 30 N-m (22 ft. lbs.) torque. (2) Remove 60-way electrical connector from PCM
(2) Connect the 02S sensor wire connector. (one screw) (Fig. 25).
(3) Lower the vehicle. (3) Remove the three PCM mounting bolts (Fig.
25).
PARK/NEUTRAL SWITCH (4) Remove PCM from vehicle.
Refer to Group 21, Transmission and Transfer Case
for removal/installation procedures.
• FUEL SYSTEM 14 •- 81
INSTALLATION INTAKE M A N I F O L D
(1) Check pins i n PCM 60-way connector for dam UPPER HALF
age. Repair as necessary.

(2) Position PCM and install mounting bolts.
Tighten bolts to 1 N-m (9 in. lbs.) torque.
(3) Connect 60-way electrical connector to PCM.
Tighten bolt to 4 N-m (35 in. lbs.) torque.
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
THROTTLE BODY
A (factory adjusted) set screw is used to mechani
cally limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle
speed using t h i s screw. All idle speed functions are
controlled by the powertrain control module (PCM).
The throttle body is mounted on the top of the in
NUTS (4) J9414-57
take manifold on 3.9L/5.2L/5.9L engines (Fig. 26). On
the 8.0L V-10 engine, a two-barrel side-mounted type
Fig. 27 Throttle Body Mounting—8.0L V-10 Engine
throttle body is mounted to the upper half of the in
take manifold (Fig. 27). (4) Remove (unsnap) all control cables from throt
tle body (lever) arm. Refer to the Accelerator Pedal
THROTTLE and Throttle Cable section of this group for addi
tional information.
(5) 3.9L/5.2L/5.9L Engines: Remove the four
throttle body mounting bolts (Fig. 26). 8.0L V-10 E n
gine: Remove the four throttle body mounting nuts
(Fig. 27).
(6) Remove throttle body from intake manifold.
(7) Discard old throttle body-to-intake manifold
gasket.
INSTALLATION
(1) Clean the mating surfaces of the throttle body
and the intake manifold.
(2) Install new throttle body-to-intake manifold
gasket.
(3) Install throttle body to intake manifold.
(4) 3.9L/5.2L/5.9L Engines:Install four mounting
bolts. Tighten bolts to 23 N-m (200 in. lbs.) torque.
8.0L V-10 Engine: Install four mounting nuts and
THROTTLE BODY
M O U N T I N G BOLTS
tighten to 11 N-m (96 in. lbs.) torque.
(5) Install control cables.
(6) Install vacuum line to throttle body.
Fig. 26 Throttle Body Mounting—3.9U5.2U5.9L (7) Install electrical connectors.
Engines (8) Install air cleaner assembly.
REMOWAL
(1) Remove the air cleaner assembly. THROTTLE POSITION SENSOR (TPS)
(2) 3.9L/5.2L/5.9L Engines: Disconnect throttle The throttle position sensor (TPS) is located on the
body electrical connectors at MAP sensor, IAC motor left side of the throttle body on the 3.9L V-6 or 5.2/
and TPS. 8.0L V-10 Engine: Disconnect throttle 5.9L V-8 engines (Fig. 28).
body electrical connectors at IAC motor and TPS. The TPS is located on the rear of the throttle body
(3) 3.9L/5.2L/5.9L Engines: Remove vacuum line just below the idle air control motor on the 8.0L V-10
at throttle body. engine (Fig. 29).
THROTTLE
POSITION
THROTTLE
J9414-2 SENSOR J9414-3
BODY
Fig. 29 TPS Location—8.0L ¥-10 Engine—Typical Fig. 31 TPS Mounting Bolts—8.0L V-10 Engine-
Typical
REMOVAL
(1) Remove the air filter housing assembly. Refer (2) Tighten bolts to 7 N-m (60 i n . lbs.) torque.
to Group 25, Emission Control Systems for proce (3) Manually operate the throttle control lever by
dures. hand to check for any binding of the TPS.
(2) Disconnect TPS electrical connector. (4) Connect TPS electrical connector to TPS.
(3) Remove two TPS mounting bolts (Figs. 30 or (5) Install air cleaner. Refer to Group 25, Emission
31). Control Systems for procedures.
(4) Remove TPS from throttle body.
TRANSMISSION TEMPERATURE SENSOR
INSTALLATION This sensor is located i n the transmission cooling
The throttle shaft end of the throttle body slides line on the side of the transmission (Fig. 33).
into a socket i n the TPS (Fig. 32). The TPS must be
installed so that i t can be rotated a few degrees. I f REMOVAL
the sensor will not rotate, install the sensor with the (1) Raise and support the vehicle.
throttle shaft on the other side of the socket tangs. (2) Place a drain pan below the sensor.
The TPS will be under slight tension when rotated. (3) Clean the area around sensor before removal.
(1) Install the TPS and two retaining bolts. (4) Disconnect the electrical connector at sensor.
FUEL SYSTEM 14 - 83
THROTTLE THROTTLE
BODY POSITION
SENSOR
ELECTRICAL
CONNECTOR
THROTTLE SOCKET LOCATING

SHAFT TANGS J9214-52
Fig. 32 TPS Installation—Typical
J9414-60
Fig. 34 Vehicle Speed Sensor Location—Typical
SPEEDOMETER
PINION GEAR

Location—Typical
(5) Remove (unthread) the sensor from transmis
sion cooling line. To prevent twisting and damage
to cooling line, be sure to use a backup wrench
on cooling line*
INSTALLATION
(1) Install the sensor into the transmission cooling
line. Tighten sensor to 11 N*m (8 ft. lbs.) torque.
(2) Connect the electrical connector at sensor. SENSOR J9314-188
(4) Check and adjust automatic transmission fluid Fig. 35 Sensor Removal/Installation—Typical
level.
VEHICLE SPEED SENSOR (5) Pull the sensor from the speedometer pinion
The vehicle speed sensor (Fig. 34) is located on the gear adapter for removal.
extension housing of the transmission on 2WD mod
els. It is located on the transfer case on 4WD models. INSTALLATION
(1) Install new sensor into speedometer gear
REMOVAL adapter.
(1) Raise and support vehicle. (2) Tighten sensor mounting bolt. To prevent dam
(2) Clean the area around the sensor before re age to sensor or speedometer adapter, be sure the
moval. sensor is mounted flush to the adapter before tight
(3) Disconnect the electrical connector from the ening.
sensor (Fig. 35). (3) Connect electrical connector to sensor.
D I E S E L ENGINE—COMPONENT DESCRIPTION/SYSTEM OPERATION
INDEX
page page
Air Conditioning (A/C) Controls—PCM Pin Park/Neutral Switch—PCM Pin #30—PCM Input . . 90
#27—PCM input 90 PCM Schematics—Diesel 85
Air Conditioning Relay—PCM Pin #34—PCM Power Ground—PCM Pin #11 . . 87
Output 91 Power Ground—PCM Pin #12 87
Automatic Shut Down (ASD) Relay—PCM Pin Powertrain Control Module (PCM)—Diesel 84
#51—PCM Output 93 Sensor Return—PCM Pin #4—PCM Input 87
Automatic Shut Down (ASD) Sense—PCM Pin Speed Control—PCM Pins #33 and #53—PCM
#57—PCM Input 93 Output . . 91
Battery Temperature Sensor 87 Speed Control—PCM Pins #48, #49 and # 5 0 —
Battery Voltage—PCM Pin #3—PCM Input 87 PCM Input 93
Brake Switch—PCM Pin #29—PCM Input 90 Speed Control—PCM Pins #53 and #33—PCM
CCD Bus(-)—PCM Pin #46—PCM Output 92 Output 93
Data Link Connector—PCM Pin #25—PCM Output . 90 System Diagnosis 84
Data Link Connector—PCM Pin #45—PCM Input . . 92 Tachometer—PCM Pin #43—PCM Output 92
Eight Volt Power—PCM Pin #7—PCM Input .87 Throttle Position Sensor—PCM Pin #22—PCM
Engine Speed Sensor—PCM Pin #24—PCM Input . 90 Input . 89
Five Volt Power—PCM Pin #6—PCM Input 87 Torque Convertor Clutch (TCC) Solenoid—PCM Pin
General Information 84 #54—PCM Output 93
Generator Field—PCM Pin #20—PCM Output . . . . 88 Transmission Temperature Sensor—PCM Pin
Ignition Circuit Sense—PCM Pin #9—PCM Input . . 87 #42—PCM Input 92
Intake Manifold Air Heater Relays—PCM Pins #15 Transmission Temperature Warning Lamp—PCM
and #16—PCM Output 87 Pin #31—PCM Output 90
Intake Manifold Air Temperature Sensor—PCM Pin Vehicle Speed Sensor—PCM Pin #47—PCM Input . 92
# 2 1 — PCM Input 88 Wait-To-Start Lamp Warning Lamp—PCM Pin
Malfunction Indicator Lamp—PCM Pin #32—PCM #36—PCM Output 91
Output 91 Water-ln-Fuel Sensor—PCM Pin #1—PCM Input . . 87
Overdrive Lamp—PCM Pin #37—PCM Output 92 Water-ln-Fuel Warning Lamp—PCM Pin #35—PCM
Overdrive Solenoid—PCM Pin #55—PCM Output . 93 Input .. 91
GENERAL INFORMATION • Fuel filter (strainer)

Various components, relays and switches are • Fuel drain manifold
operated by the powertrain control module
(PCM). This section of the group will cover a SYSTEM DIAGNOSIS
description and operation of components con The powertrain control module (PCM) tests many
trolled by the P C M for vehicles equipped with of its own input and output circuits. If a diagnostic
diesel powered engines. trouble code (DTC) is found in a major system, this
Diesel fuel injection system components (except for information is stored in the PCM memory. Refer to
the intake manifold air heater) are not directly regu On-Board Diagnostics in the Diesel Engine—General
lated by the PCM. Diagnosis section of this group for DTC information.
Refer to the Fuel Delivery—Diesel Engine section For components not operated by the PCM, refer to
of this group for fuel components not operated or reg the Fuel Delivery—Diesel Engine section of this
ulated by the PCM. These components are the: group.
• Fuel tank
• Fuel tank module POWERTRAIN CONTROL MODULE (PCM)—DIESEL
• Low and high-pressure fuel supply lines The powertrain control module (PCM) is located in
• Low-pressure, mechanical, fuel transfer pump (fuel the right-rear side of the engine compartment (Fig.
lift pump) 1). It is mounted to the dash panel cowl with three
• High-pressure fuel injection pump
bolts. The PCM was formerly referred to as the
• Fuel filter/water separator
SBEC or engine controller. Except for operation of
• Fuel heater
the intake manifold air heater, the PCM does not
• Fuel heater relay
• Fuel shutdown solenoid regulate or control fuel system operation on the die
• Fuel shutdown solenoid relay sel engine.
• High-pressure fuel injectors The PCM is a pre-programmed, dual micro-proces
• Fuel return line sor digital computer. Although it does not regulate or
• Intake manifold air temperature sensor
• Overdrive/override switch
• Park/neutral switch (auto, trans, only)
• Power ground
• SCI receive (DRB scan tool connection)
• Sensor return
• Throttle position sensor (auto, trans, only)
• Transmission temperature sensor (auto, trans,
only)
• Vehicle speed sensor
• Water-in-fuel sensor
• Ignition switch sense
P C M Outputs:
POWERTRAIN CONTROL After inputs are received by the PCM, certain sen
MODULE (PCM) J9414-11 sors, switches and components are controlled or reg
ulated by the PCM. These are considered P C M
Outputs. These outputs are for:
control the fuel system on the diesel powered engine, • A/C clutch relay (A/C clutch operation)
it does operate or regulate the: • Auto shut down (ASD) relay
• Speed control system • Data link connectors (for DRB and MDS test
• Charging system equipment)
• Certain warning lamps • Generator field (charging system operation)
• Transmission overdrive solenoid • Malfunction indicator lamp (Check Engine Lamp)
• Torque convertor engagement • Overdrive solenoid electrical operation (auto,
• ASD relay trans, only)
• Air conditioning operation
• Overdrive/Override warning lamp (auto, trans,
• Tachometer
only)
• Intake manifold air heater
The PCM can adapt its programming to meet • SCI transmit (DRB scan tool connection)
changing operating conditions. • Speed control vacuum solenoid
The PCM receives input signals from various • Speed control vent solenoid
switches and sensors. Based on these inputs, the • Tachometer
PCM regulates various engine and vehicle operations • Torque convertor electrical operation (auto, trans,
through different system components. These compo only)
nents are referred to as P C M Outputs. The sensors • Transmission oil temperature warning lamp (auto,
and switches that provide inputs to the PCM are con trans, only)
sidered P C M Inputs. • Wait-to-start lamp
P C M Inputs: • Water-in-fuel lamp
• Air conditioning selection • Intake manifold air heater #1
• Battery voltage • Intake manifold air heater #2
• Brake light switch
• Engine speed sensor (rpm) PCM SCHEMATICS—DIESEL
• Speed control switch position Powertrain control module (PCM) schematics for
• Auto shut down (ASD) sense diesel powered vehicles are shown in figure 2. After
• Battery voltage input used to measure generator the schematics, a description is given for each circuit
output (pin) of the PCM 60-way connector.
01
m
m
-<
m
THROTTLE HI
POSITION
SENSOR
m
{AUTO. TRANS.
OILY)
A/C •
COMPRESSOR
CLUTCH
J9414-84
Fig. 2 System Schematic—5.9L Diesel Engine

WATER-IN-FUEL SENSOR—PCM PIN #1—PCM in the ON position. The PCM continues to monitor
INPUT the input at the end of the intake manifold air heater
The water-in-fuel (WIF) sensor is located at the post-heat cycle.
bottom of the fuel filter/water separator (Fig. 3).
BATTERY WOLTAGE—PCM PIN #3—PCM INPUT
The battery voltage input provides power to the
FUEL FILTER/
WATER SEPARATOR powertrain control module (PCM). I t also informs the
PCM what voltage level is being supplied by the gen
erator once the vehicle is running.
The battery input also provides the voltage that is
needed to keep the PCM memory alive. The memory
stores diagnostic trouble code (DTC) messages, mini
mum and maximum TPS value from the previous
key-on and speed control adaptive memory.
DRAIN
WATER-IN- VALVE
FUEL S E N S O R BATTERY TEMPERATURE SENSOR
This input is internal to the powertrain control
module (PCM). A thermistor located within the
J9414-90 PCM's printed circuit board is used to sense under-
hood temperature. This temperature is used to vary
Fig. 3 Water-in-Fuel Sensor the battery charging rate i n relationship to the tem
perature.
WAIT-TO-
START
W A R N I N G LAMP SENSOR RETURN—PCM PIN #4—PCM INPUT
Sensor Return provides a low noise ground refer
ence for all system sensors.
FIVE VOLT POWER—PCM PIN #6—PCM INPUT

This circuit supplies approximately 5 volts to power
HEAT-A/C
TEMPERATURE the throttle position sensor (TPS) sensor.
CONTROL
KNOB EIGHT WOLT POWER—PCM PIN #7—PCM INPUT
This circuit supplies approximately 8 volts to power
the vehicle speed and engine speed sensors.
IGNITION CIRCUIT SENSE—PCM PIN #9—PCM

INPUT
The ignition circuit sense input tells the powertrain
control module (PCM) the ignition switch has been
turned to the ON position. Refer to the wiring dia
TRANSMISSION
WATER-IN-FUEL TEMPERATURE grams for circuit information.
W A R N I N G LAMP W A R N I N G LAMP J9414-63
Fig. 4 Wait-to-Start and Water-in-Fuel Warning Lamp Provides a common ground for power devices (sole
Location noid and relay devices).
The sensor sends an input to the powertrain con
trol module (PCM) when i t senses water in the fuel POWER GROUND—PCM PIN #12
filter/water separator. As the water level i n the filter/ Provides a common ground for power devices (sole
separator increases, the resistance across the WIF noid and relay devices).
sensor decreases. This decrease i n resistance is sent
as a signal to the PCM and compared to a high water
INTAKE MANIFOLD AIR HEATER RELAYS—PCM
standard value. Once the value reaches 30 to 40 k i - PINS #15 AND #16—PCM OUTPUT
lohms, the PCM will activate the instrument panel The PCM operates the intake manifold air heater
mounted, water-in-fuel warning lamp (Fig. 4). This through the intake manifold air heater relays. The
all takes place when the ignition key is initially put relays are located i n the engine compartment below
the left battery (Fig. 5).
BATTERY
(LEFT SIDE)
Fig, 5 Intake Manifold Ait Heater Relays

The relays may be energized before and after
cranking, depending upon intake manifold air tem
UPPER PART OF
perature. The PCM monitors intake manifold air INTAKE MANIFOLD J9414-105
temperature through the intake manifold air temper
ature sensor. Also refer to Intake Manifold A i r Fig. 6 Air Heater
Heater i n this section.
illuminated. The heater is energized for a specific
The relays are not energized during engine crank
amount of time. Refer to the Air Heater Cycle Chart.
ing. When they are energized they make a clicking
Once the heater has cycled, the wait-to-start warn
noise.
ing lamp goes out. While the engine is cranked, the
CAUTION: When testing, do not energize the air heater is not energized.
heater relays more than once per 15 minutes with
POST-HEAT CYCLE
out running and operating the engine. Due to the
high amperage needed to operate the heater, the
After engine has been started, the post-heat cycle
batteries may not have enough time to recharge.
will begin i f intake manifold air temperature was
Wait 15 minutes before turning the key back to the
15°C (59°F) or below when ignition switch was
ON position.
turned on. Depending upon intake manifold temper
ature, either: the heater is energized, or they are cy
cled on and off (when one is energized, the other is
INTAKE MANIFOLD AM HEATER not). The time the heater is energized depends upon
When energized, the air heater will warm incoming intake manifold air temperature. Refer to the A i r
air as i t enters the intake manifold. The air heater Heater Cycle Chart.
(Fig. 6) is energized by the PCM through the air
heater relays. Intake manifold air temperature deter GENERATOR FIELD—PCM PIN #20—PCM OUTPUT
mines when the heater is energized. They may be en The powertrain control module (PCM) regulates the
ergized before cranking and after cranking, or both. charging system voltage within a range of 12.9 to
Refer to Pre-Heat Cycle and Post-Heat Cycle. The 15.0 volts. Refer to Group 8A for charging system in
heater is not energized during cranking. formation.
PREHEAT CYCLE INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
The PCM powers up when the ignition key is PCM PIN #21—PCM INPUT
turned to the On position. I f intake manifold air tem This pin provides an input signal to the powertrain
perature is 15°C (59°F) or below, the air heater is en
ergized and the wait-to-start warning lamp is
AIR HEATER C Y C L E CHART FRONT OF ENGINE AIR TEMPERATURE SENSOR
SENSOR ELECTRICAL
NTAKEMANffOU) PRE-HEATCYOJTIME POST-HEAT CYCU- CONNECTOR
TEMPERATURE- HGNmON ON, ENGME IGNmONON,
KEY ON POSITION N0TRUNNM6 ENGINE RUNNWO
Above 15° C 0 seconds No

(59° F)
-10°Cto 15° C 10 seconds Yes

(15° Fto59° F)
-18°Cto-10°F 15 seconds Yes

(0°Ftol5° F)
Below-18° C 30 seconds Yes

(0°F)
INTAKE
MANIFOLD
FUEL
(UPPER HALF) SOLENOID
SHUTDOWN
SOLENOID ELECTRICAL
CONNECTOR J9414-93
J9414-133
Fig. 7 Air Temperature Sensor Location—Diesel
The intake manifold air temperature sensor is a idle position). The PCM uses the TPS input, along
variable, thermistor type. I t reacts to temperature with vehicle speed sensor and engine speed sensor
changes. At cold air temperatures, its resistance is inputs to determine 3-4 upshift (overdrive) and 4-3
high. As temperatures increase, its resistance will de downshift. I t is also used with the vehicle speed sen
crease. sor and engine speed sensor inputs to engage and
The air temperature sensor element extends into disengage the torque convertor solenoid. This sole
the intake manifold air stream. I t provides an input noid is used for torque convertor engagement.
voltage to the PCM indicating intake manifold air The TPS is a linear potentiometer. The PCM sup
temperature. The input from this sensor is used by plies 5 volts to the sensor. TPS output to the PCM
the PCM to determine i f and how long to activate the varies from approximately 1.0 volt at idle to 3.5 volts
intake manifold air heater relays. When the relays at wide open throttle (WOT).
are activated, current will flow through the relays to
the intake manifold air heater.
As the temperature of the air-fuel stream i n the
manifold varies, the sensor resistance will change.
This will result i n a different input voltage to the
PCM.
The sensor is located on the top of the intake man
ifold and to the rear of the intake manifold air heater
(Fig. 7).
Also refer to Intake Manifold Heater Relays—PCM ELECTRICAL THROTTLE
Pin #15—PCM Output for additional information. CONNECTOR POSITION
SENSOR
Refer to the Diesel Engine—General Diagnosis sec
tion of this group for diagnostic procedures.
THROTTLE POSITION SENSOR—PCM PIN

#22—PCM INPUT
The throttle position sensor (TPS) is used only on
vehicles equipped with an automatic transmission i f
equipped with a diesel engine. I t is not used with the
manual transmission. CENTER TERMINAL MOUNTING
The TPS is mounted on the side of the fuel injec IS OUTPUT WIRE BOLTS (2) J9414-91
tion pump (Fig. 8). The TPS provides an input to the
PCM. I t senses how far the throttle is open (past the Fig. 8 Throttle Position Sensor Location—Diesel
14 - 90 FUEL SYSTEM
ENGINE SPEED SENSOR—PCM PIN #24—PCM DATA LINK

CONNECTOR
INPUT
The engine speed (rpm) sensor is mounted to the
front of engine (Fig. 9). I t generates an rpm signal to
the PCM. The engine speed sensor input is used
along with the vehicle speed sensor and throttle po
sition sensor (TPS) inputs to determine when to shift
the automatic transmission into and out of overdrive.
The speed sensor signal is also used as an input for
the ASD relay (for control of generator field), vehicle
speed control, torque convertor electrical engagement
and instrument panel mounted tachometer.
SENSOR M O U N T I N G BOLTS
POWERTRAIN CONTROL
0^ MODULE (PCM) J9414-11
Fig. 10 PCM and Data Link Connector—Typical

PCM uses this input to cycle the A/C compressor
through the A/C relay.
I f the A/C low or high-pressure switch opens, the
PCM will not receive an A/C request signal. The
PCM will then remove the ground from the A/C relay.
This will deactivate the A/C compressor clutch.
BRAKE SWITCH—PCM PIN #29—PCM INPUT

When the brake light switch is activated, the pow
ertrain control module (PCM) receives an input indi
cating that the brakes are being applied. After
receiving this input, the PCM is used to control the
speed control system and electrical operation of the
VIBRATION
transmission torque converter.
DAMPER J9214-69
PARK/NEUTRAL SWITCH—PCM PIN #30—PCM
Fig. 9 Engine Speed Sensor—Diesel INPUT
DATA LINK CONNECTOR—PCM PIN #25—PCM The park/neutral switch provides an input to the
OUTPUT powertrain control module (PCM). This will indicate
The data link connector (diagnostic scan tool con that the automatic transmission is i n Park, Neutral
nector) links the Diagnostic Readout Box (DRB) scan or a Drive gear selection. This input is used to deter
tool or the Mopar Diagnostic System (MDS) with the mine speed control strategy and electrical operation
powertrain control module (PCM). The data link con of both the overdrive and torque convertor solenoids.
nector is located i n the engine compartment (Fig. 10). Refer to Group 21, Transmissions, for testing, re
For operation of the DRB scan tool, refer to the ap placement and adjustment information.
manual. TRANSMISSION TEMPERATURE WARNING
The data link connector uses two different pins on LAMP—PCM PIN #31—PCM OUTPUT
the PCM. Pin #25 is for Data Link Transmit and pin
#45 is for Data Link Receive. A U T O M A T I C TRANSMISSION ONLY
An instrument panel mounted lamp (Fig. 11) is
AIR CONDITIONING (A/C) CONTROLS—PCM PIN used to warn of a possible transmission fluid over
#27—PCM INPUT heating condition. When transmission fluid tempera
The A/C control system information applies to fac ture has been determined to be above approximately
tory installed air conditioning units. 280 degrees F by the transmission temperature sen
A/C R E Q U E S T SIGNAL? When either the A/C or sor, a signal is sent to the powertrain control module
Defrost mode has been selected and the A/C low and (PCM). The PCM will then control warning lamp op-
high-pressure switches are closed, an input signal is
eration. The lamp will illuminate for about two sec On-Off-On within three seconds and any codes stored
onds each time the ignition key is turned O N as a in the PCM memory will be displayed. This is done
bulb check. in a series of flashes representing digits. Refer to On-
Also refer to Transmission Temperature Board Diagnostics i n the General Diagnosis section
Sensor—PCM Pin #42—PCM Input for additional in of this group for more information.
formation.
SPEED CONTROL—PCM PINS #33 AND #53—PCM
INSTRUMENT
OUTPUT
AIR CONDITIONING RELAY—PCM PIN #34—PCM

OUTPUT
This circuit controls a ground signal for operation
of the A/C clutch relay. Also refer to Air Conditioning
(A/C) Controls-PCM Pin # 2 7 - P C M Input for addi
tional information.
The A/C relay is located i n the power distribution
center (PDC). The PDC is located next to the battery
in the engine compartment (Fig. 13). For the location
of the relay within the PDC, refer to PDC cover.
Fig. 11 Transmission Temperature Warning
Lamp—Typical Location
MALFUNCTION INDICATOR LAMP—PCM PIN
#32—PCM OUTPUT
The malfunction indicator lamp (formerly referred
to as the check engine lamp—Fig. 12) illuminates on
the instrument panel each time the ignition key is
turned on. I t will stay on for about three seconds as
a bulb test.

WATER-IN-FUEL WARNING LAMP—PCM PIN
#35—PCM INPUT
The PCM turns the water-in-fuel indicator lamp to
the ON position i f water is detected i n the fuel. The
water-in-fuel indicator lamp is located i n the instru
ment panel (Fig. 14). The lamp will illuminate for
about two seconds each time the ignition key is
turned ON as a bulb check.
Also refer to Water-ln-Fuel Sensor—PCM Pin
Fig. 12 Check Engine Lamp—Typical Location #1—PCM Input for additional information.
I f the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or WAIT-TO-START LAMP WARNING LAMP—PCM
components, the lamp is turned on. This is a warning PIN #36—PCM OUTPUT
that the PCM has recorded a system or sensor mal The wait-to-start warning lamp is turned on and
function. I t signals an immediate need for service. off by the PCM based on the intake manifold air tem
The lamp can also be used to display a diagnostic perature sensor input. The lamp is located on the in
trouble code (DTC). Cycle the ignition switch On-Off- strument (Fig. 14).
14 - §2 FUEL SYSTEM •
WAIT-TO- warning lamp (Fig. 11) is also used.
START This sensor is located in the transmission cooling
W A R N I N G LAMP
line on the side of the transmission (Fig. 15).
TRANSMISSION C O O L I N G
LINE
HEATA/C
TEMPERATURE
CONTROL
KNOB
TRANSMISSION
TRANSMISSION
WATER-IN-FUEL TEMPERATURE Fig. 15 Transmission Temperature Sensor
W A R N I N G LAMP W A R N I N G LAMP J9414-63 Location—Typical
Fig. 14 Wait-to-Start and Water-in-Fuel Warning TACHOMETER—PCM PIN #43—PCM OUTPUT

Lamp Location The powertrain control module (PCM) supplies en
gine rpm values to the instrument cluster mounted
The lamp is turned on when the ignition is first ac tachometer (if equipped). Refer to Group 8E for ta
tivated. It will remain on for two seconds as a bulb chometer information.
test. If the PCM reads intake manifold air tempera
ture below 15°C (59°F), it will turn the wait-to-start DATA LINK CONNECTOR—PCM PIN #4i—PCM
warning lamp on for the air heater preheat cycle.
The lamp stays on until the preheat cycle is over. INPUT
The wait-to-start lamp will flash on and off if the Refer to Data Link Connector-PCM PIN
intake manifold air temperature sensor input to the #25—PCM Output for information.
PCM is below minimum value or above maximum
value. The PCM stores a DTC when these conditions CCD BUSH—PCM PIN #46—PCM OUTPUT
occur. Various modules exchange information through a
communications port called the CCD BUS(-).
OVERDRIVE LAMP—PCM PIN #37—PCM OUTPUT
This circuit controls a signal for the operation of VEHICLE SPEED SENSOR—PCM PIN #47—PCM
the instrument panel mounted overdrive lamp. When INPUT
the lamp is illuminated, the overdrive is disengaged. The speed sensor (Fig. 16) is located in the exten
sion housing of the transmission (2WD) or on the
TRANSMISSION TEMPERATURE SENSOR—PCM transfer case extension housing (4WD). The sensor
PIN #42—PCM INPUT input is used by the powertrain control module
(PCM) to determine vehicle speed and distance trav
AUTOMATIC TRANSMISSIONS ONUf eled.
The transmission temperature sensor is a variable, The speed sensor generates 8 pulses per sensor
thermistor type. It reacts to temperature changes. At revolution. These signals, in conjunction with a
cold transmission oil temperatures, its resistance is
high. As temperatures increase, its resistance will de closed throttle signal from the throttle position sen
crease. sor (auto, trans, only), indicate a closed throttle de
The transmission temperature sensor is used on celeration to the PCM. When the vehicle is stopped
models equipped with an automatic transmission. Its at idle, a closed throttle signal is received by the
purpose is to help control transmission fluid over PCM (but a speed sensor signal is not received).
heating. If transmission overheating has been deter In addition to determining distance and vehicle
mined by this sensor (temp, above approximately 280 speed, the output from the sensor is used to help con
degrees F), an input is sent to the powertrain control trol:
module (PCM). The PCM will then force a 4-3 down • Speed control operation
shift. Once transmission temperature has cooled be • Transmission overdrive operation
low specifications, a 3-4 upshift will be allowed. An • Transmission torque converter electrical operation
instrument panel mounted trai^smission temperature
SENSOR
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID—
ELECTRICAL PCM PIN #54—PCM OUTPUT
CONNECTOR
AUTOMATIC TRANSMISSION
This circuit (Fig. 17) controls operation of the
transmission mounted torque convertor (TCC) sole
noid used for torque convertor engagement.
TORQUE CONVERTER CLUTCH
A N D OVERDRIVE SOLENOID
ELECTRICAL CONNECTOR
J9414-60 VEHICLE
SPEED
Fig. 16 Vehicle Speed Sensor—Typical SENSOR J9414-59
SPEED CONTROL—PCM PINS #48, # 4 9 AND Fig. 17 Electrical Connections at Transmission—

TCC and Overdrive Solenoids
#50—PCM INPUT
The speed control system provides three separate The powertrain control module (PCM) will deter
inputs to the powertrain control module (PCM); On/ mine when to engage and disengage the solenoid by
Off, Set and Resume. The On/Off input informs the monitoring vehicle miles per hour (mph). Also needed
PCM that the speed control system has been acti are various inputs from the module timer, engine
vated. The Set input informs the PCM that a fixed rpm and throttle position sensor.
vehicle speed has been selected. The Resume input
indicates to the PCM that the previous fixed speed is OVERDRIVE SOLENOID—PCM PIN #55—PCM
requested.
The speed control operating range is from 50 km/h OUTPUT
to 142 km/h (35 to 85 mph). Inputs that effect speed AUTOMATIC TRANSMISSION
control operation are: This circuit controls operation of the transmission
• Park/neutral switch mounted overdrive solenoid (Fig. 17) used for over
• Vehicle speed sensor drive operation. The powertrain control module
• Engine speed sensor (PCM) will determine when to engage and disengage
• Throttle position sensor (auto, trans, only) the solenoid by monitoring engine rpm and vehicle
Refer to Group 8H for further speed control infor speed, versus output voltage of the throttle position
mation.
sensor. Also needed are various inputs from the mod
AUTOMATIC SHUT DOWN (ASD) RELAY—PCM PIN ule timer.
#51—PCM OUTPUT
This circuit controls operation of the ASD relay. It AUTOMATIC SHUT DOWN (ASD) SENSE—PCM PIN
provides the necessary power to operate the genera #57—PCM INPUT
tor field control for charging system operation. A 12 volt signal at this input indicates to the PCM
The ASD relay is located in the power distribution that the ASD has been activated. The ASD relay is
center (PDC). The PDC is located next to the battery located in the power distribution center (PDC). The
in the engine compartment (Fig. 13). For the location PDC is located next to the battery in the engine com
of the relay within the PDC, refer to PDC cover. partment (Fig. 13). For the location of the relay
The ground circuit for the coil in the ASD relay is within the PDC, refer to PDC cover.
controlled by the powertrain control module (PCM). This input is used only to sense that the ASD relay
The PCM operates the relay by switching the ground is energized. If the powertrain control module (PCM)
circuit ON and OFF. does not see 12 volts + at this input when the ASD
should be activated, it will set a diagnostic trouble
SPEED CONTROL—PCM PINS #53 AND #33—PCM code (DTC).
OUTPUT
DIESEL ENGINE—GENERAL DIAGNOSIS
INDEX
page page
Air in Fuel System 97 Intake Manifold Air Heater Relay Test 106
Automatic Shut Down (ASD) Relay Test . 97 Intake Manifold Air Heater Test 105
Diagnostic Trouble Code (DTC) 111 Intake Manifold Air Temperature Sensor Test . . . . 106
DRB Scan Tool 111 On-Board Diagnostics (OBD)—Diesel Powered
Engine Speed Sensor Test 97 Vehicles 109
Fuel Filter/Water Separator Test . 97 Powertrain Control Module (PCM) 60-Way
Fuel Heater Relay Test 99 Connector 96
Fuel Heater Test 98 Powertrain Control Module Testing 107
Fuel Injection Pump Test 100 Relays—Operation/Testing 107
Fuel Injector Test 99 Starter Motor Relay Test 108
Fuel Shutdown Solenoid Relay Test 101
System Schematics 96
Fuel Shutdown Solenoid Test 100
Throttle Position Sensor Test 108
Fuel Supply Restrictions 100
Fuel Transfer Pump Pressure Test 101 Transmission Temperature Sensor Test 108
General Information 94 Vehicle Speed Sensor Test . 109
High-Pressure Fuel Line Leak Test 104 Visual Inspection 94
Idle Speed Adjustment 104 Water-ln-Fuel Warning Lamp 109
GENERAL INFORMATION (5) Verify that the electrical connector is firmly

This section of the group will cover a general diag connected to the intake manifold air temperature
nosis of diesel engine fuel system components. For an sensor. Inspect the connector for corrosion or dam
operational description, refer to the Diesel aged wires. The sensor is located on the top of the in
Engine—Component Description/System Operation take manifold (Fig. 4).
section of this group. For component removal and in (6) Verify that the water-in-fuel (WIF) sensor elec
stallation procedures, refer to the Diesel trical connector is firmly attached to the sensor (Fig.
Engine—Component Removal/Installation section of 5). Inspect the connector for corrosion or damaged
this group. wires.
Although various components, relays and switches (7) Check for water i n the fuel filter/water separa
are operated by the powertrain control module tor. A water drain is supplied on the filter/separator.
(PCM), the diesel fuel injection system (Fig. 1) is not Refer to Fuel Filter/Water Separator i n the Diesel
directly regulated by the PCM. Refer to Powertrain Engine—Component Removal/Installation section of
Control Module (PCM) for additional information. this group for draining water.
(8) Verify that the electrical connector is firmly
VISUAL INSPECTION
connected to the fuel shutdown solenoid on the injec
A visual inspection for loose, disconnected, or incor
tion pump (Fig. 4). Inspect the connector for corro
rectly routed wires and hoses should be made before
sion or damage.
attempting to diagnose or service the diesel fuel in
jection system. A visual check will help find these (9) Be sure that the intake manifold air heater
conditions. I t also saves unnecessary test and diag electrical cable connections at the intake manifold
nostic time. A thorough visual inspection of the fuel are tight and free of corrosion (Fig. 6).
injection system includes the following checks: (10) Inspect the throttle linkage and accelerator
(1) Be sure that the battery connections (on both linkage for binding.
batteries) are tight and not corroded. (11) Be sure that the throttle return spring is con
(2) Be sure that the 60-way connector is fully en nected.
gaged with the powertrain control module (PCM). (12) Inspect all fuel supply and return lines for
Verify that the connector mounting screw is tight signs of leakage.
(Fig. 2). (13) Be sure that the ground connections are tight
(3) Be sure that the electrical connections at the and free of corrosion. Refer to Group 8, Wiring for lo
intake manifold air heater relays (Fig. 3) are tight cations of ground connections.
and not corroded. (14) Inspect the air cleaner element for restrictions
(4) Inspect the starter motor and starter solenoid by using the built-on Filter Minder™. Do not remove
connections for tightness and corrosion. the top of air cleaner housing to inspect condition of
FUEL SYSTEM 14 - 9i
WASTEGATED TURBOCHARGER
TURBOCHARGER OIL SUPPLY
HIGH PRESSURE
FUEL TUBES
FUEL DRAIN
LINE (MANIFOLD)
FUEL INJECTORS (6)
TURBOCHARGER
RIGHT SIDE WASTEGATE
OF ENGINE
FUEL SUPPLY INTAKE AIR INTAKE MANIFOLD

UNE {TO TEMP. SENSOR
INJECTION PUMP)
WATER TEMPERATURE
SENSOR (FOR LP. GAUGE)
HIGH PRESSURE FUEL FILTER/

FUEL LINES WATER SEPARATOR
FUEL/WATER
SEPARATOR AND
DRAIN VALVE
HIGH PRESSURE
FUEL INJECTION
PUMP
RUBBER PRIMER
BUTTON
THROTTLE POSITION
SENSOR (AUTO. FUEL TRANSFER
TRANS. ONLY) PUMP (FUEL
LIFT PUMP)
STARTER
FUEL MOTOR
SHUTDOWN
SOLENOID FUEL HEATER
TEMP. SENSOR
OIL PRESSURE (THERMOSTAT) DRAIN
LEFT SIDE
SENSOR OF ENGINE TUBE J9414-69
Fig. 1 Fuel System Components—Diesel Engine

14 - SB FUEL SYSTEM •
DATA LINK FRONT OF ENGINE AIR TEMPERATURE SENSOR
CONNECTOR SENSOR ELECTRICAL
CONNECTOR
POWERTRAIN CONTROL
MODULE (PCM) J9414.11

INTAKE
BATTERY MANIFOLD
(LEFT SIDE) (UPPER HALF) SHUTDOWN SOLENOID '
CABLES TO SOLENOID ELECTRICAL
J9414-93
BATTERY H CONNECTOR
Fig. 4 Air Temperature Sensor and Fuel Shutdown

Solenoid
FILTER -at- FUEL FILTER/

[HOUSING X \ 1 WATER SEPARATOR
INTAKE AIR
HEATER RELAYS (2)
RELAY
TRIGGER RELAY M O U N T I N G 1
WIRES (4) BOLTS (3) J9414-85 ELECTRICAL /

CONNECTOR J9414-87
Fig. 3 intake Manifold Air Heater Relays

Fig. 5 Water-in-Fuel (WIF) Sensor
air filter. Refer to A i r Filter/Filter Housing—Diesel
Engines i n Group 25, Emission Control System for (19) Automatic Transmission Only: Be sure the
Filter Minder™ information. electrical connector is firmly connected to the plug
(15) Be sure that the turbocharger output hose is leading to the overdrive solenoid i n the transmission.
connected to the charge air cooler (intercooler) inlet
tube. Verify that the charge air cooler output hose is POWERTRAIN CONTROL MODULE (PCM) 60-WAY
connected to the cooler and the intake manifold. CONNECTOR
(16) Be sure that the vacuum pump-to-brake For PCM 60-way connector wiring schematics, refer
booster hose is connected and not damaged. to Group 8W, Wiring Diagrams.
(17) Be sure that the accessory drive belt is not
damaged or slipping. SYSTEM SCHEMATICS
(18) Automatic Transmission Only: Raise the vehi Refer to PCM Schematics — Diesel i n the Diesel
cle and check the electrical connection at the trans Engine—Component Description/System Operation
mission temperature sensor (Fig. 7). section of this group.
Inspect the fuel system from the fuel transfer
pump to the injectors for loose connections. Leaking
fuel is an indicator of loose connections or defective
seals. Air can also enter the fuel system between the
fuel tank and the transfer pump. Inspect the fuel
tank and fuel lines for damage that might allow air
into the system.
For air bleeding, refer to the A i r Bleed Procedure
i n the Diesel Engine—Component Removal/Installa
AUTOMATIC SHUT DOWN (ASD) RELAY TEST

To perform a complete test of the ASD relay and its
circuitry, refer to the DRB scan tool and appropriate
ENGINE SPEED SENSOR TEST

circuitry, refer to the appropriate Powertrain Diag
nostic Procedures manual.
FUEL FILTER/WATER SEPARATOR TEST

A blocked or clogged fuel filter/water separator can
cause starting problems and prevent the engine from
revving up. I t can also cause, low power and blue or
white fog like exhaust.
The maximum allowable fuel pressure drop across
the fuel filter/water separator is 35 kPa (5 psi). This
can be checked with a fuel pressure gauge.
(1) Attach the gauge to the inlet side (Fig. 8) of fil
ter/separator at the fuel line leading from the fuel
transfer pump. Measure pressure with the engine
running.
(2) Attach the gauge to the outlet side (Fig. 8) of
the filter/separator at the fuel line leading to the fuel
injection pump. Measure pressure with the engine
running.
(3) Compare the pressures. I t must not exceed the
previous specification.
I f the instrument panel mounted water-in-fuel
TEMPERATURE SENSOR J9414-46 warning lamp is illuminated with the ignition key
ON, i t indicates that excess water has collected i n
Fig. 7 Transmission Temperature Sensor Location— the fuel filter/water separator. Excess water can be
Typical drained. Refer to Fuel Filter/Water Separator i n the
AIR IN FUEL SYSTEM Diesel Engine—Component Removal/Installation sec
Air will enter the fuel system whenever fuel supply tion of this group for water draining procedures.
lines, separator filters, injection pump, high-pressure I f excess water gathers i n the filter/separator i n a
lines or injectors are removed or disconnected. Air short period of time, the fuel tank must be removed,
trapped i n the fuel system can result i n hard start drained and cleaned.
ing, a rough running engine, engine misfire, low For removal and installation procedures, refer to
power, excessive smoke and fuel knock. After service the Diesel Engine—Component Removal/Installation
is performed, air must be bled from the system be section of this group.
fore starting the engine.
Fig. 9 Fuel Heater Location
Fig. 8 Fuel Pressure Gauge Attaching Points

FUEL HEATER TEST
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
Tjie fuel heater element, relay and tempera
ture sensor are not controlled by the power-
train control module (PCM).
A malfunctioning fuel heater can cause a wax
build-up i n the fuel filter/water separator. Wax
build-up i n the filter/separator can cause engine
starting problems and prevent the engine from rev Fig. 10 Fuel Heater Assembly
ving up. I t can also cause blue or white fog-like ex heater relay (Fig. 11) (also refer to Fuel Heater Re
haust. I f the heater is not operating i n cold lay), to the fuel temperature sensor and on to the
temperatures, the engine may not operate due to fuel fuel heater element.
waxing. The built-in heater element operates on 12 volts,
The fuel heater is located on the left side of the en 300 watts at 0 degrees F. As temperature increases,
gine above the starter motor (Fig. 9). power requirements decrease.
The heater assembly is equipped with a built-in The fuel heater assembly contains a pre-filter (Fig.
fuel temperature sensor (thermostat) (Figs. 9 or 10) 10) to prevent contaminants from entering the fuel
that senses fuel temperature. When the fuel temper transfer pump.
ature is below 40 degrees F, the sensor allows cur A minimum of 7 volts is required to operate the fuel
rent to flow to the built-in heater element to warm heater. The resistance value of the heater element is
the fuel. When the fuel temperature is above 80 de less than 1 ohm (cold) and up to 1000 ohms warm.
grees F, the sensor stops current flow to the heater
element (circuit is open). TESTING
Voltage to operate the fuel heater element is sup (1) Remove the electrical connector at the side of
plied from the ignition switch, through the fuel the fuel heater (Fig. 9).
FUEL SHUT-OFF FUEL INJECTOR TEST
FUEL HEATER SOLENOID RELAY A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and
rough engine idle. If the fuel injector needle valve
does not operate properly, the engine may misfire
and produce low power.
A leak in the injection pump-to-injector high-pres
sure fuel line can cause many of the same symptoms
as a malfunctioning injector. Inspect for a leak in the
high-pressure lines before checking for a malfunc
tioning fuel injector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-

PRESSURE FUEL OF UP TO APPROXIMATELY
1 2 0 , 0 0 0 KPA ( 1 7 , 4 0 0 PSI) TO EACH INDIVIDUAL IN
JECTOR THROUGH THE HIGH-PRESSURE LINES.
FUEL UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE THE SKIN AND CAUSE PERSONAL IN
JURY. WEAR SAFETY GOGGLES AND ADEQUATE
PROTECTIVE CLOTHING. AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE
FUEL LINES.
Fig. 11 Fuel Heater Relay—Diesel
(2) Using an ohmmeter, check the resistance across
the two terminals on the side of the heater. Resis WARNING: DO NOT BLEED AIR FROM THE FUEL
tance should be approximately 1 ohm (cold) to 1000 SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
ohms (warm). TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
(3) With the electrical connector still unplugged BLEEDING AIR FROM THE FUEL SYSTEM.
from the fuel heater, check the electrical operation of
the fuel temperature sensor (Fig. 10). Proceed to next To determine which fuel injector is malfunctioning,
step: run the engine and loosen the high-pressure fuel line
(4) Using an ohmmeter, check the resistance across nut at the injector (Fig. 12). Listen for a change in
the two terminals in the pigtail wire harness coming engine speed. After testing, tighten the line nut to 30
from the fuel temperature sensor. The sensor circuit N-m (22 ft. lbs.) torque. If engine speed drops, the in
should be open if the fuel temperature is above 80 jector was operating normally. If engine speed re
degrees. The sensor circuit should be closed if the mains the same, the injector is malfunctioning. Test
fuel temperature is below 40 degrees. all injectors in the same manner one at a time.
(5) Check for 12 volts at the disconnected temper
ature sensor connector with the ignition key ON. Re
fer to Group 8W, Wiring for electrical schematics.
(6) With ignition ON, check for 12 volts at the fuel
heater relay connector. Refer to Group 8W, Wiring for
electrical schematics.
(7) Check operation of the fuel heater relay (Fig.
11). Refer to Relays—Operation/Testing in this sec
tion of the group.
FUEL HEATER RELAY TEST
The fuel heater relay is located in the engine com
partment near the brake master cylinder (Fig. 11).
To test the relay only, refer to Relays—Operation/
Testing in this section of the group. Fig. 12 Inspecting Injector Operation
To test the fuel heater, refer to Fuel Heater Test in Once an injector has been found to be malfunction
this section of the group. ing, remove it from the engine and replace it. Refer
to the Diesel Engine—Component Removal/Installa sure fuel lines with the correct replacement line.
tion section of this group for procedures.
CAUTION: The high-pressure fuel lines must be
FUEL INJECTION PUMP TEST clamped securely in place in the holders. The lines
The fuel shutdown solenoid is the only serviceable cannot contact each other or other components. Do
component of the fuel injection pump. The injection not attempt to weld high-pressure fuel lines or to
pump is not to be serviced or the warranty may repair lines that are damaged. Only u s e the recom
be voided. I f the injection pump requires ser mended lines when replacement of high-pressure
vice, the complete assembly must be replaced. fuel line is necessary.
Incorrect injection pump timing can cause poor per
formance, excessive smoke and emissions and poor
fuel economy. FUEL SHUTDOWN SOLENOID TEST
A defective fuel injection pump or misadjusted For an operational description (electrical and me
pump timing can cause starting problems or prevent chanical) of the solenoid, refer to the Diesel
the engine from revving up. It can also cause: Engine—Component Description/System Operation
• Engine surge at idle section of this group.
• Rough idle (warm engine) The fuel shutdown (shut-off) solenoid (Fig. 13)
• Low power and fuel shutdown solenoid relay (Fig. 15) are
• Excessive fuel consumption not controlled by the powertrain control mod
• Poor performance ule (PCM).
• Low power
• Black smoke from the exhaust FRONT OF ENGINE AIR TEMPERATURE SENSOR
SENSOR ELECTRICAL
• Blue or white fog like exhaust
CONNECTOR
• Incorrect idle or maximum speed
Engine power is also effected by the governor set
ting and performance. Do not attempt to adjust
the governor. I f the governor seals on the exter
nal adjustment screw are broken, the fuel rate
may be out of adjustment. The warranty of the
injection pump and the engine may be void if
the seals have been tampered with or removed.
FUEL SUPPLY RESTRICTIONS

LOW-PRESSURE LINES
Fuel supply line restrictions or a defective fuel INTAKE
MANIFOLD
transfer pump can cause starting problems and pre (UPPER HALF)
FUEL
SHUTDOWN SOLENOID
vent the engine from revving up. The starting prob SOLENOID ELECTRICAL
J9414-93
lems include; low power and blue or white fog like CONNECTOR
exhaust. Test all fuel supply lines for restrictions or
blockage. Flush or replace as necessary. Bleed the Fig. 13 Fuel Shutdown Solenoid Location
fuel system of air once a fuel supply line has been re (1) With the ignition switch off, the solenoid shaft
placed. Refer to the Air Bleed Procedure section of should be down and the injection pump lever should
this group for procedures. Also refer to the Fuel be in the shutdown position (no fuel supply to injec
Transfer Pump Pressure Test section of this group for tion pump) (Fig. 14).
restriction tests. (2) Turn the ignition switch to the CRANK (starter
engage) position and observe the solenoid shaft and
HIGH-PRESSURE LINES
injection pump lever. The shaft should pull up (shaft
Restricted (kinked or bent) high-pressure lines can retracted into the solenoid) and the pump lever
cause starting problems, poor engine performance
should be in the run position (fuel being supplied to
and black smoke from exhaust.
injection pump) (Fig. 14).
Examine all high-pressure lines for any damage.
(3) Release the ignition key from the CRANK to
Each radius on each high-pressure line must be
smooth and free of any bends or kinks. the ON position. The shaft should remain in the up
Replace damaged, restricted or leaking high-pres position and the pump lever should remain in the
this circuit when the key is in the CRANK position,
SHUTDOWN check the fuel shutdown solenoid relay. Refer to
POSITION RUN POSITION Relays—Operation/Testing in this section of the
group. Also check the wiring between the relay and
the solenoid.
(6) If the solenoid shaft moves up when the igni
tion switch is in the CRANK position, but moves
down when the key is released from the CRANK to
the ON position, check the circuit coming from the
ignition switch for 12 volts. Refer to Group 8W, for
wire connector pin location and circuit identification.
If the shutdown solenoid is being replaced, its shaft
length must be adjusted. For fuel shutdown solenoid
removal, installation and solenoid shaft adjustment
procedures, refer to the Diesel Engine—Component
Removal/Installation section of this group.
FUEL FUEL SHUTDOWN SOLENOID RELAY TEST

SHUTDOWN
SOLENOID Voltage to operate the fuel shutdown solenoid is
J9414-80 supplied from the ignition switch and through the
fuel shutdown solenoid relay. The fuel shutdown so
Fig. 14 Fuel Shutdown Solenoid Positions lenoid relay is located in the engine compartment
FUEL SHUT-OFF near the brake master cylinder (Fig. 15).
FUEL HEATER SOLENOID RELAY To test the relay, refer to Relays—Operation/Test
RELAY ing in this section of the group.
BRAKE MASTER For removal and installation procedures, refer to
CYLINDER
FUEL TRANSFER PUMP PRESSURE TEST

For operation of the fuel transfer pump primer but
ton, refer to Fuel Transfer Pump in the Fuel
The fuel transfer pump is located on the left side of
the engine and above the starter motor (Fig. 16).
An improperly operating fuel transfer pump can
cause low engine power and/or hard engine starting.
Inspect the fuel supply line to the pump for restric
tions, kinks or leaks.
Fuel leaking from the weep hole in the pump cas
ing indicates a leaking pump. The transfer pump
must then be replaced or rebuilt.
J9414-31 Do not operate the fuel system with a fuel line or
component suction restriction of more than 100 MM
Fig. 15 Fuel Shutdown Solenoid Relay Location
Hg (4.0 inch Hg).
run position (fuel being supplied to injection pump) Low transfer pump output can be caused by a worn
(Fig, 14). If the solenoid shaft is not moving, refer to eccentric on the engine camshaft.
the following; The maximum allowable fuel pressure drop across
(4) Disconnect the solenoid three-wire pigtail wire the fuel filter/water separator is 35 kPa (5 psi). As
harness from the main engine harness. the filter removes contaminants in the fuel, the pres
(5) If the solenoid shaft did not move up when the sure drop across the fuel filter/water separator will
ignition switch was in the CRANK position, check for increase. Frequent replacement of the filter/separator
12 volts at the three-way connector. This will be the may indicate a worn transfer pump. The filter/sepa
circuit coming from the fuel shutdown solenoid relay. rator can be checked with a fuel pressure gauge. For
Refer to Group 8W, for wire connector pin location procedures, refer to Fuel Filter/Water Separator
and circuit identification. If 12 volts is not present at Tests in this section of the group.
1 4 - 1 0 2 FUEL SYSTEM •
FUEL
PRESSURE
GAUGE
'TEED I N "
IEL
TRANSFER
PUMP
ELECTRICAL
CONNECTOR
FUEL
J9414-94 J9414-108
HEATER
Fig. 16 Fuel Transfer Pump Location Fig. 18 Fuel Pressure Gauge Connection
Refer to Group 0, Lubrication and Maintenance at (3) Start the engine and measure the output pres
the front of this manual for recommended replace sure. Minimum pressure is 172 k P a (25 psi).
ment intervals. (4) Proceed to the Fuel Volume Test.
OUTPUT PRESSURE TEST F U E L VOLUME TEST

(1) Disconnect the fuel line fitting on the top of the Fuel volume-versus-engine cranking rpm are used
fuel transfer pump (Fig. 17). Remove fuel line from for the test.
pump at this point.
WARNING: TO PREVENT THE ENGINE FROM
FUEL UNE FOR PRESSURE FUEL UNE STARTING, DISCONNECT THE PIGTAIL HARNESS
TO FUEL TANK TESTS: TO FUEL FILTER/
RUBBER DISCONNECT WATER SEPARATOR
AT THE FUEL SHUTDOWN SOLENOID (FIG. 1 9 ) .
FUEL HOSE FUEL UNE AT USE CAUTION AS RESIDUAL FUEL IN THE FUEL
THIS POINT
INJECTOR PUMP MAY CAUSE THE ENGINE TO
START AND RUN R A R I L Y . CONTINUE TO
T E M P 0
RUN THE ENGINE UNTIL IT QUITS BEFORE PER

FORMING THE FUEL VOLUME TEST.
(1) Connect a hand held tachometer to the engine.

Use Cummins part number 3377462 or an equiva
lent.
(2) Connect a temporary rubber fuel hose at the
top (output) side of the fuel transfer pump. (Fig. 20).
(3) Place the other end of this hose into a gradu
ated container (Fig. 20).
(4) Crank the engine for 30 seconds. Measure the
FUEL TRANSFER
fuel volume in the container after 30 seconds of en
PUMP gine cranking time. Do not crank the engine for
HOSE more than 30 seconds at a time. Starter motor
CLAMPS (2) FUEL
HEATER J9414-107 damage may result.
(5) To determine the correct fuel volume, refer to
Fig. 17 Transfer Pump Fuel Line Locations figure 21—Fuel Volume Specification. To use the
(2) Attach (Tee in) a fuel pressure gauge at this chart in figure 21, refer to the following procedure:
point (Fig. 18). • Draw a straight vertical line at the measured rpm.
FRONT OF ENGINE AIR TEMPERATURE SENSOR ml

SENSOR ELECTRICAL 625
CONNECTOR
600
575
T > 550
C
O 525
v 500
JS
o 475
450
E 425
O 400
>
15 375
350
325
INTAKE 300
MANIFOLD
(UPPER HALF)
p u E L
SHUTDOWN SOLENOID 275

SOLENOID ELECTRICAL 200 225 250 275 300 400
CONNECTOR J9414-93 Engine Cranking Speed (RPM) j9414.no
Fig. 19 Fuel Shutdown Solenoid Electrical Fig. 21 Fuel Volume Specifications

Connector
between the disconnected fitting and the transfer
TEMPORARY pump inlet. Connect vacuum gauge to T-fitting as
RUBBER HOSE shown in figure 22. The vacuum gauge will not indi
cate a vacuum until the transfer pump begins to op
erate at full capacity.
VACUUM
GAUGE
GRADUATED
CONTAINER
FUEL
TRANSFER
PUMP
J9414-109
Fig. 20 Performing Volume Test

• Draw a straight horizontal line at the measured
fuel volume. FUEL TRANSFER
PUMP J9414-111
• If these two lines intersect below the flow line
(Fig. 21), this indicates a defective transfer pump or Fig. 22 Vacuum Gauge Connection
a line restriction.
• If these two lines intersect above the flow line Inlet restriction must not exceed 100 mm Hg
(Fig. 21), this indicates acceptable fuel flow. (4 i n Hg),
(6) If fuel volume falls below specifications, test for
fuel line inlet restrictions before condemning the fuel
transfer pump. This is done by installing a T-fitting
I f the restriction is higher than the specifications, IDLE SPEED ADJUSTMENT
check for a kinked fuel line or a plugged fuel tank The high-speed idle screw is factory sealed and
vent. A partially clogged in-tank fuel filter can also cannot be adjusted. Low-speed idle can be adjusted.
cause excess vacuum. (1) Use an optical tachometer such as Snap-on No.
MT139 or MTE (Cummins tool division) No. 3377462
HIGH-PRESSURE FUEL LINE LEAK TEST to read the engine rpm.
High-pressure fuel line leaks can cause starting (2) Bring the engine to normal operating tempera
problems and poor engine performance. ture.
(3) Adjust the low idle speed at the low idle speed
WARNING; DO TO EXTREME FUEL PRESSURES OF
screw. The screw and locknut are located at the rear
UP TO 120,000 KPA (17,400 PSI), USE EXTREME
of the fuel injection pump (Fig. 24).
CAUTION WHEN INSPECTING FOR HIGH-PRES
SURE FUEL LEAKS. DO NOT GET YOUR HAND LEVER STOP
NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-
PRESSURE FUEL LEAKS WITH A SHEET OF CARD
BOARD. HIGH FUEL INJECTION PRESSURE CAN
CAUSE PERSONAL INJURY IF CONTACT IS MADE
WITH THE SKIN.
Start the engine. Move the cardboard over the

high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 23). I f a high- pressure line con
nection is leaking, bleed the system and tighten the
connection. Refer to the Air Bleed Procedure i n this
group for procedures. Replace damaged, restricted or
leaking high-pressure fuel lines with the correct re
placement line.
HIGH-PRESSURE CARDBOARD
LINE
LOW IDLE
ADJUSTING
SCREW
FACTORY HIGH IDLE LOCKNUT
SEAL STOP SCREW J9414-103
Fig. 24 Low Idle Speed Screw

(4) Loosen the idle screw lock nut (Fig. 24). Adjust
idle screw to obtain specified rpm. Refer to the Idle
Speed—Diesel Engine specifications chart for idle
rpm.
(5) Tighten the locknut after adjustment.
I D L E SPEEDS—DIESEL ENGINES
I O W SDH S K I D HIGH IDLE SPIED
With automatic transmission... Do not attempt to adjust

high idle speed. High idle
FITTING •750-800 RPM with transmission speed adjustment screw
J9414-130 in drive and air conditioning on. is factory sealed. Breaking
seal will void injection pump
Fig. 23 Typical Test for Leaks with Cardboard With manual transmission... warranty.
CAUTION; T h e high-pressure fuel lines must be *780 RPM with transmission in

clamped securely in place in the holders. T h e lines neutral and air conditioning on.
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to • With engine at normal operating temperature. Refer to text
for idle adjustment procedures.
J9414-66
mended lines when replacement of high-pressure
INTAKE MANIFOLD AIR HEATER TEST BATTERY

The intake manifold air heater (Fig. 25) is con (LEFT SIDE)
trolled by the powertrain control module (PCM)
through the intake manifold air heater relays (Fig.
26). This is done after a specified signal is sent to the
PCM from the intake manifold air temperature sen
sor.
Two heating elements are located within the air
heater assembly. A separate cable is connected to a
separate terminal to supply power for each element
(Fig. 25).
Fig. 26 Intake Manifold Air Heater Relays

out running and operating the engine. Due to the
high amperage needed to operate the heater, the
batteries may not have enough time to recharge.
Wait 15 minutes before turning the key back to the
ON position.
(1) With the engine not running and ambient air

temperature below 16°C (60°F), turn the ignition key
to the ON position.
(2) The wait-to-start warning lamp will come on
and the air heater relays should click ON signaling
the start of the preheat cycle.
(3) Check for battery voltage at both air heater ter
UPPER PART OF minals (Fig. 25). The heater w i l l o n l y be ener
INTAKE MANIFOLD J9414-105 gized for 10 t o 20 seconds. Refer to the Preheat
Cycle Time Interval Chart.
Fig. 25 Intake Manifold Air Heater
PREHEAT/POST-HEAT CYCLE HEATER TEST
The PCM provides a ground path for the intake (1) Disconnect both negative battery cables at both
manifold air heater relays. The ground path is pro batteries.
vided i f intake manifold air temperature is 15°C (2) Lift the rubber shields from each of the cable
(59°F) when the ignition key is initially placed i n the connectors at the intake manifold air heater (Fig. 25)
ON position. When the ground is provided, the air to expose the cable terminals. Do not disconnect ca
heater is energized to start the preheat cycle. ble nuts.
The preheat-cycle can be tested with a voltmeter or (3) Use an ohmmeter to test the resistance be
test light. I f the intake manifold air temperature is tween the cable terminal (not the mounting stud)
above 15°C (59°F), the wait-to-start warning lamp and a ground. The resistance should be zero (0). I f
will not illuminate and the air heater will not be en not, inspect for corroded or dirty cable connections.
ergized. Note that the warning lamp will illuminate Clean or repair the connections and retest before re
for approximately two seconds each time the key is placing heater. Also check both ends of the ground
turned ON. This feature is used as a bulb check. cable at the rear of the heater for corroded or dirty
connections. I f resistance is now anything other than
CAUTION: When testing, do not energize the air
zero (0), proceed to next step.
heater relays more than once per 15 minutes with-
AIR HEATER CYCLE CHART ohmmeter should show a closed circuit across the
large terminals. I f not, replace relay and bracket as
NTAKEMANVOU) PRE-HEAT CYCLE TIME POST-HEAT CYCLE- sembly.
TEMPERATURE- -tGNFTIONON,ENGME IGNmONON, (7) Repeat the same test on the opposite relay.
KEY ON POSITION N0TRUNNM6 ENGftS RUNNftiG (8) After testing and repairing, connect battery ca
bles to both batteries.
Above 15° C 0 seconds No
(59° F) For removal and installation procedures, refer to
-10°Cto 15° C 10 seconds Yes section of this group.
(15° Fto59° F)
-18° Cto-10°F 15 seconds Yes

(0° Flo 15° F) TEST
Below-18° C 30 seconds Yes circuitry, refer to DRB scan tool and appropriate
(0°F)
(1) Disconnect the wire harness connector from the
intake manifold air temperature sensor. The sensor
is located on the top of the intake manifold and to
the rear of the air heater (Fig. 27).

J9414-133 SENSOR ELECTRICAL
CONNECTOR
(4) Disconnect both cables from the intake mani
fold heater (two nuts) (Fig. 25).
(5) Measure the resistance from each of the air
heater terminal threaded studs to a ground. The re
sistance should be zero (0). I f the ohmmeter is still
reading anything other than zero (0), replace the in
take manifold air heater.
(6) After testing and repairing, connect battery ca
bles to both batteries.
Intake Manifold A i r Heater i n the Diesel
Engine—Component Removal/Installation section of
this group.
INTAKE MANIFOLD AIR HEATER RELAY TEST INTAKE

MANIFOLD FUEL
To test the intake manifold air heater, refer to the (UPPER HALF) SOLENOID
SHUTDOWN
previous Intake Manifold A i r Heater Test. SOLENOID ELECTRICAL
CONNECTOR J9414-93
To test the intake manifold air heater relays, refer
to the following:
(1) Disconnect both negative battery cables at both Fig. 27 Air Temperature Sensor Location—Diesel
batteries. (2) Test the resistance of the sensor with an input
(2) Disconnect the four small relay trigger wires at impedance (digital) volt-ohmmeter. The resistance (as
both relays (Fig. 26). Note position of wires before re measured across the sensor terminals) should be less
moval. than 1340 ohms with the engine warm. Refer to the
(3) Disconnect the four large cables at each of the Sensor Resistance (OHMS)—Intake Manifold A i r
relay terminals (four nuts—Fig. 26). Note position of Temperature resistance chart. Replace the sensor i f i t
cables before removal. is not within the range of resistance specified i n the
(4) Attach an ohmmeter across two of the large chart.
studs on one of the relays. (3) Test the resistance of the wire harness. Do this
(5) Attach a jumper wire (+ and -) to each of the between the powertrain control module (PCM) wire
small terminals on one of the relays. Polarity is not harness connector terminal 21 and the sensor con
important. nector terminal. Also check between terminal 4 to the
(6) Momentarily touch the jumper wires to the ve sensor connector terminal. Repair the wire harness
hicle battery (+ and -). The relay should click and the as necessary i f the resistance is greater than 1 ohm.
SENSOR RESISTANCE (OHMS)—INTAKE

MANIFOLD AIR TEMPERATURE SENSOR
C F MEN MAX
-40 -40 291,490 381,710

-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
110 230 480 540
120 248 370 410
J928D-4
P O W E R T R A I N C O N T R O L MODULE T E S T I N G
Operation of the powertrain control module (PCM)
is tested with the DRB scan tool. Refer to the appro
priate Powertrain Diagnostic Procedures service
manual for tests.
RELAYS—OPERATION/TESTING
Tb perform a complete test of a relay and its cir
cuitry, refer to DRB scan tool and appropriate Pow
ertrain Diagnostics Procedures manual. To test the
relay only, refer to the following:
OPERATION
The following operations/tests apply to these
relays only: automatic shut down (ASD), fuel shut
down solenoid and fuel heater. For operations/tests Fig. 29 Fuel Heater and Fuel Shutdown Solenoid
on all other relays, refer to the appropriate section of Relays—Diesel
this service manual. • Terminal number 87 is connected (a circuit is
The ASD relay is located i n the power distribution formed) to terminal 30 i n the energized (ON) posi
center (PDC). The PDC is located i n the engine com tion. Terminal number 87 then supplies battery volt
partment (Fig. 28). For the location of this relay age to the component being operated.
within the PDC, refer to PDC cover. • Terminal number 86 is connected to a switched (+)
The fuel heater and fuel shutdown relays are lo power source.
cated i n the engine compartment near the brake • Terminal number 85 is grounded by the power-
master cylinder (Fig. 29). train control module (PCM).
The relay terminal numbers (Fig. 30) can be found
on the bottom of the relay. TESTING
• Terminal number 30 is connected to battery volt (1) Remove relay before testing.
age and can be switched or B+ (hot) at all times. (2) Using an ohmmeter, perform a resistance test
• The center terminal number 87A is connected (a between terminals 85 and 86. Resistance value
circuit is formed) to terminal 30 i n the de-energized (ohms) should be 75 ±5 ohms for resistor equipped
(normally OFF) position. relays.
BOTTOM VIEW RELAY

OF RELAY CONNECTOR
DE-ENERGIZED ENERGIZED
RELAY RELAY
9214-157
Fig. 30 Relay Terminals

(3) Connect the ohmmeter between terminals num Diagrams for (fuel system) relay wiring schematics
ber 87A and 30. Continuity should be present at this and for additional circuit information.
time.
(4) Connect the ohmmeter between terminals num STARTER MOTOR RELAY TEST
ber 87 and 30. Continuity should not be present at Refer to Group 8A, Battery/Starting/Charging Sys
this time. tem Diagnostics, for starter motor relay testing.
(5) Use a set of jumper wires (16 gauge or small
er). Connect one jumper wire between terminal num THROTTLE POSITION SENSOR TEST
ber 85 (on the relay) to the ground side (-) of a 12 The throttle position sensor (TPS) is used on diesel
Volt power source. engines only when equipped with an automatic
(6) Attach the other jumper wire to the positive transmission.
side (+) of a 12V power source. Do not connect this To test and adjust the TPS, refer to Throttle Posi
jumper wire to relay at this time. tion Sensor Testing. See Throttle Position Sensor i n
CAUTION: Do not allow the ohmmeter to contact section of this group for procedures.
terminals 85 or 86 during these tests. Damage to
ohmmeter may result. TRANSMISSION TEMPERATURE SENSOR TEST
(7) Attach the other jumper wire (12V +) to termi AUTOMATIC TRANSMISSION ONLY
nal number 86. This will activate the relay. Continu To perform a complete test of this sensor and its
ity should now be present between terminals number circuitry, refer to DRB scan tool and appropriate
87 and 30. Continuity should not be present between Powertrain Diagnostics Procedures manual. To test
terminals number 87A and 30. the sensor only, refer to the following:
(8) Disconnect jumper wires from relay and 12 Volt (1) Disconnect the wire harness connector from the
power source. temperature sensor. The sensor is located on the side
I f continuity or resistance tests did not pass, re of the transmission in the transmission cooling line
place relay. I f tests passed, refer to Group 8W, Wiring (Fig. 31).
FUEL SYSTEM 14 - 109
SENSOH RESISTANCE
(OHMS)^TRANSMISSION TEMPERATURE
SENSOR
C F MIN MAX
-40 -40 291,490 381,710

-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
TEMPERATURE SENSOR J9414-46 30 86 7,370 8>750
40 104 4,900 5,750
Fig. 31 Transmission Temperature Sensor 50 122 3,330 3,880
Location—Typical 60 140 2,310 2,670
70 158 1,630 1,870
(2) Test the resistance of the sensor with an input 80 176 1,170 1,340
impedance (digital) volt-ohmmeter. The resistance (as 90 194 860 970
measured across the sensor terminals) should be less 100 212 640 720
than 1340 ohms with the engine warm. Refer to the 110 230 480 540
120 248 370 410
Sensor Resistance (OHMS)—Transmission Tempera
ture Sensor resistance chart. Replace the sensor i f i t
J928D-4
is not within the range of resistance specified i n the
chart. tual display to the service technician. I f the problem
(3) Test the resistance of the wire harness. Do this is repaired or ceases to exist, the PCM cancels the
between the powertrain control module (PCM) wire DTC after 51 engine starts.
harness connector terminal 42 and the sensor con Certain criteria must be met for a diagnostic trou
nector terminal. Also check between terminal 4 to the ble code (DTC) to be entered into PCM memory. The
sensor connector terminal. Repair the wire harness criteria may be a specific range of engine rpm, engine
as necessary i f the resistance is greater than 1 ohm. temperature and/or input voltage to the PCM.
It is possible that a DTC for a monitored circuit
VEHICLE SPEED SENSOR TEST may not be entered into memory even though a mal
To perform a complete test of the sensor and its cir function has occurred. This may happen because one
cuitry, refer to DRB scan tool and appropriate Pow of the DTC criteria for the circuit has not been met.
ertrain Diagnostics Procedures manual. A DTC indicates that the powertrain control mod
ule (PCM) has recognized an abnormal signal i n a
WATER-IN-FUEL WARNING LAMP
circuit or the system. A DTC may indicate the result
I f this warning lamp remains illuminated when the
of a failure, but never identify the failed component
ignition key is ON, i t indicates that excess water has
directly.
collected i n the fuel filter/water separator. (Note that
the lamp will be illuminated for approximately two There are several operating conditions that the
seconds when the ignition key is initially placed i n PCM does not monitor and set a DTC for. Refer to
the ON position for a bulb check). Excess water can the following Monitored Circuits and Non-Monitored
be drained. Refer to Fuel Filter/Water Separator i n Circuits i n this section.
section of this group for water draining procedures. MONITORED CIRCUITS
The powertrain control module (PCM) can detect
ON-BOARD DIAGNOSTICS (OBD)—DIESEL certain problems i n the electrical system.
POWERED WEHICLES Open or Shorted Circuit - The PCM can deter
The powertrain control module (PCM) has been mine i f sensor output (which is the input to PCM) is
programmed to monitor many different circuits for within proper range. I t also determines i f the circuit
diesel powered vehicles. I f a problem is sensed i n a is open or shorted.
monitored circuit often enough to indicate an actual Output Device Current Flow - The PCM senses
problem, a diagnostic trouble code (DTC) is stored. whether the output devices are hooked up.
The DTC will be stored in the PCM memory for even-
I f there is a problem with the circuit, the PCM
senses whether the circuit is open, shorted to ground
(-), or shorted to (+) voltage.
NON-MONITORED CIRCUITS
The PCM does not monitor the following circuits,
systems or conditions that could have malfunctions
that result i n driveability problems. A diagnostic
trouble code (DTC) will not be displayed for these
conditions.
Fuel Pressure: Fuel pressure is controlled by the
fuel transfer pump and fuel injection pump. The
PCM cannot detect problems i n these components.
Cylinder Compression: The PCM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust System: The PCM cannot detect a
plugged, restricted or leaking exhaust system. Fig. 32 Check Engine Lamp—Typical Location
Fuel Injector Malfunctions: The PCM cannot de DRB, refer to the appropriate Powertrain Diagnostic
termine i f the fuel injector is clogged, or the wrong Procedures service manual.
injector is installed. The fuel injectors on the diesel
engine are not controlled by the PCM.
Vacuum Assist: Leaks or restrictions i n the vac
uum circuits of vacuum assisted engine control sys
tem devices are not monitored by the PCM.
Powertrain Control Module (PCM) System
Ground: The PCM cannot determine a poor system
ground. However, a DTC may be generated as a re
sult of this condition.
Powertrain Control Module (PCM) Connector
Engagement: The PCM cannot determine spread or
damaged connector pins. However, a DTC may be
generated as a result of this condition.
POWERTRAIN CONTROL
HIGH AND LOW LIMITS MODULE (PCM) J9414-11
The powertrain control module (PCM) compares in
put signal voltages from each input device. I t will es Fig. 33 Data Link Connector Location—Typical
tablish high and low limits that are programmed into
EXAMPLES
it for that device. I f the input voltage is not within
specifications and other diagnostic trouble code • I f the lamp (Fig. 32) flashes 4 times, pauses and
(DTC) criteria are met, a DTC will be stored i n mem flashes 1 more time, a diagnostic trouble code (DTC)
ory. Other DTC criteria might include engine rpm number 41 is indicated.
limits or input voltages from other sensors or • I f the lamp flashes 4 times, pauses and flashes 6
switches. The other inputs might have to be sensed more times, a diagnostic trouble code (DTC) number
by the PCM when i t senses a high or low input volt 46 is indicated.
age from the control system device i n question. • I f the lamp flashes 1 time, pauses and flashes 2
more times, a diagnostic trouble code (DTC) number
ACCESSING DIAGNOSTIC TROUBLE CODES 12 is indicated. I f the sequence of codes begins with a
A stored diagnostic trouble code (DTC) can be dis DTC number 12, this indicates direct battery input to
played by cycling the ignition key ON-OFF-ON- the PCM was disconnected within the last 50 key-on
OFF-ON within three seconds and observing the cycles. Old codes may have been erased.
malfunction indicator lamp. This lamp was formerly After any stored DTC information has been ob
referred to as the check engine lamp. The lamp is lo served, the display will end with a flashing DTC
cated on the instrument panel (Fig. 32). number 55. This will indicate the end of all stored in
They can also be displayed through the use of the formation.
Diagnostic Readout Box (DRB scan tool). The DRB
Refer to the Diagnostic Trouble Code (DTC) charts
scan tool connects to the data link connector i n the
for DTC identification.
engine compartment (Fig. 33). For operation of the
I f the problem is repaired or ceases to exist, the ERASING TROUBLE CODES
powertrain control module (PCM) cancels the DTC After the problem has been repaired, use the DRB
after 51 engine starts. scan tool to erase a Diagnostic Trouble Code (DTC).
Diagnostic trouble codes indicate the results of a Refer to the appropriate Powertrain Diagnostic Pro
failure, but never identify the failed component di cedures service manual for operation of the DRB
rectly. scan tool.
Typical circuits of the data link connector are
shown i n (Fig. 34). DRB SCAN TOOL
For operation of the DRB scan tool, refer to the ap
D-l GROUND manual.
D-2 N/C DIAGNOSTIC TROUBLE CODE (DTC)
D-3 SCI TRANS On the following pages, a list of diagnostic trouble
codes is provided for all diesel powered vehicles. A
D-4 SCI RECEIVE DTC indicates that the powertrain control module
D-5 IGNITION (PCM) has recognized an abnormal signal i n a circuit
or the system. A DTC may indicate the result of a
J9214-20
D-6 NOT USED failure, but never identify the failed component di
rectly.
Fig. 34 Data Link Connector Schematic
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
Diagnostic
DRB Scan Tool
Display
Code
11* No Crank Reference No crank reference signal detected during engine cranking.
Signal at PCM
12* Battery Disconnect Direct battery input to PCM was disconnected within the last 50 Key-on
cycles.
15** No Vehicle Speed Sensor No vehicle distance (speed) sensor signal detected during road load
Signal conditions.
23** Intake Air Temp Sensor Intake manifold air temperature sensor input below the minimum acceptable
Voltage Low voltage.
or
Intake Air Temp Sensor Intake manifold air temperature sensor input above the maximum acceptable
Voltage High voltage.
24* Throttle Position Sensor Throttle position sensor input above the maximum acceptable voltage
Voltage High (automatic transmission only).
or
Throttle Position Sensor Throttle position sensor input below the minimum acceptable voltage
Voltage Low (automatic transmission only).
33* A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch relay circuit.
14 - 112 FUEL SYSTEM
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED
Diagnostic
DRB Scan Tool
Display
Code
34* Speed Control Solenoid An open or shorted condition detected in the Speed Control vacuum or vent
Circuits solenoid circuits.
or
Speed Control Switch Speed Control switch input below the minimum acceptable voltage.
Always Low
or
Speed Control Switch Speed Control switch input above the maximum acceptable voltage.
Always High
37* Torque Converter Clutch An open or shorted condition detected in the CKT circuit.
Solenoid CKT
or
Trans Temp Sensor Voltage Low at Trans Temp Sensor
Voltage Too Low
or
Trans Temp Sensor Voltage High at Trans Temp Sensor
Voltage Too High
41** Generator Field Not An open or shorted condition detected in the generator field control circuit.
Switching Properly
42* Auto Shut Down Relay An open or shorted condition detected in the auto shut down relay circuit.
Control Circuit
44* Battery Temp Sensor Volts An open or shorted condition exists in the engine coolant temperature sensor
out of Limit circuit or a problem exists in the PCM's battery temperature voltage circuit.
45* Trans Overdrive Solenoid An open or shorted condition exists in the transmission overdrive solenoid
Circuit circuit.
46** Charging System Voltage Battery voltage sense input above target charging voltage during engine
Too High operation.
47** Charging System Voltage Battery voltage sense input below target charging during engine operation.
Too Low Also, no significant change detected in battery voltage during active test of
generator output.
53* Internal PCM Failure PCM Internal fault condition detected.

or
PCM Failure SPI PCM Internal fault condition detected.
Communications
55* N/A A DTC #55 is used to end all DTC messages. This code indicates a
completion of all DTC's displayed on the Malfunction Indicator Lamp (Check
Engine Lamp).
62* PCM Failure SPI miles not Unsuccessful attempt to update SPI miles in the PCM EEPROM.
stored
63* PCM Failure EEPROM Unsuccessful attempt to write to an EEPROM location by the PCM.
Write Denied
DIESEL FUEL INJECTION SYSTEM DIAGNOSIS
SYMPTOM CAUSE ACTION
Stuffing p r o b l e m Improper fuel Drain fuel tank, flush system, fill with proper
fuel. Change filter
Empty fuel tank or fuel tank vent blocked Fill tank, bleed system, check tank vent
Air in fuel system Bleed fuel system
Voltage not supplied to fuel shutdown Correct voltage supply problem or

solenoid or fuel shutdown solenoid replace solenoid
inoperative
Voltage not supplied from fuel shutdown Refer to text for testing
solenoid relay
Clogged fuel filter Replace fuel filter
Restricted or blocked fuel supply lines Remove restriction or replace lines
Leaking injection lines, damaged lines or Replace damaged lines or tighten

loose connections connections as necessary.
Bleed fuel system
Wax buildup in fuel filter (cold weather Replace fuel filter, use recommended
only) diesel fuel
Incorrect injection pump to engine timing Adjust injection pump timing
Malfunctioning intake manifold air heating Repair air heating system

system
Injection sequence does not correspond Install fuel injection lines in correct order
with firing order
Low or uneven engine compression Repair as necessary
Restricted or blocked fuel injection lines Remove restriction or replace lines
Fuel injection pump malfunction or Replace fuel injection pump

not adjustable
Engine surge e t idle Empty fuel tank or fuel tank vent blocked Fill tank, bleed system, check tank vent
Low idle speed Adjust idle speed

J9414-122
14 - 114 FUEL S Y S T E M •
DIESEL FUEL INJECTION SYSTEM DIAGNOSIS—CONTINUED
Engine surges at idle (cant.) Fuel injection pump malfunction or Replace fuel injection pump
not adjustable
Rough idle w h e n engine Improper fuel Drain fuel tank, flush system, fill with
is w a r m proper fuel
Low idle speed Adjust idle speed - see Air Bleed Procedure
Injection pump rear support bracket loose Repair as necessary
Restricted or damaged injector nozzle Repair or replace as necessary
Injection sequence does not correspond Install injection lines in correct order
withfiringorder
Leaking high or low pressure fuel line Repair as necessary
Fuel injection pump malfunctioning Replace fuel injection pump

or not adjustable
Engine misses under load Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Restricted or blocked fuel injection lines Remove restrictions or replace lines
Restricted or blocked fuel supply lines Remove restrictions or replace lines

loose connection connections as necessary.
Bleed fuel system
J9414-123
Engine misses under b o d Fuel transfer pump defective Test and repair as necessary
Incorrect injection pump timing Adjust injection pump timing
Restricted or damaged injector nozzle Replace or repair as necessary
Restricted or blocked fuel injection lines Install fittings proper positions

not adjustable
Low power Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Control lever not going to full throttle Adjust throttle linkage

position
Intercooler internally blocked or leaking Check pressure drop across intercooler.

If pressure drop is more than 4 in. Hg,
clean or replace as necessary

loose connections connections as necessary.
Bleed fuel system
Incorrect injection pump-to-engine timing Adjust injection pump timing
Clogged or restricted air filter Remove restrictions or replace filter if

necessary
Air fuel control tube broken or leaking Repair or replace as necessary
Low manifold pressure Check and repair turbocharger operation.

Check intercooler and air pipes for blockage
Injection sequence does not correspond Install fuel injection lines in correct
with firing order order
Incorrect injection pump to engine timing Check injection pump to engine timing

not adjustable
J9414-124
Excessive fuel consumption Improper diesel fuel Use correct fuel for conditions. Refer to
owner's manual
Clogged or restricted air filter Remove restrictions or replace air filter if

necessary
with firing order

Low idle misadjusted Adjust idle stop screw
Incorrect injection pump to engine timing Adjust injection pump to engine timing

not adjustable
Unoble to shut engine off Voltage to fuel shutdown solenoid Correct voltage supply problem or replace
interrupted or fuel solenoid inoperative solenoid
Injection pump linkage damaged Repair as necessary
Either poor performance, Improper fuel Drain fuel tank, flush system, fill with
block smoke or low power proper fuel for conditions. Refer to owner's
manual

Clogged or restricted air filter Remove restrictions or replace filter if

necessary
Air fuel control tube leaking or broken Repair or replace as necessary
Low manifold pressure Check and repair turbocharger operation
with firing order
J9414-125
D I E S E L F U E L INJECTION SYSTEM DIAGNOSIS—CONTINUED
Either poor performance, Injection pump to engine timing Check injection pump to engine timing
black smoke or l o w power

not adjustable
White or U u e fog-like Improper fuel Drain fuel tank,flushsystem,fillwith proper

exhaust in full-load range fuel, change filter
Restricted or blocked fuel injection lines Remove restriction or replace lines
Restricted or blocked fuel supply lines Remove restriction or replace lines
Wax buildup in fuel filter (cold weather Replace fuelfilter,use recommended

only) diesel fuel. Inspect fuel heater
electrical connector for damage
Incorrect injection pump to engine timing Adjust injection pump timing

not adjustable
Incorrect idle speed Low idle misadjusted Adjust idle stop screw - see Idle Speed
Adjustment

not adjustable
Engine does not rev up Improper fuel Drain fuel tank, flush system,fillwith proper
fuel, change filter
Fuel transfer pump defective Test and repair as necessary
Empty fuel tank or fuel tank Fill tank, bleed system, check
vent clocked tank vent
J9414-126
Engine does not rev up Control lever not going to full throttle Adjust throttle linkage
position

Clogged fuel filler Replace fuel filter
Fuel shutdown solenoid out of adjustment Adjust as necessary
Wax buildup in fuelfiber(cold weather Inspect fuel heater electrical connector

only) for damage. Replace fuel filter, use
recommended diesel fuel
Fuel injection pump malfunction or Replace injection pump

not adjustable
Injection pump runs hot Overflowfitting(to fuel return line) on Cban overflow orifice or replace fitting
side of injection pump is defective
Oil supply line to pump is restricted Repair restriction
J9414-127
D I E S E L ENGINE—COMPONENT REMOWAL/INSTALLATION
INDEX
page page
Air Bleed Procedure . 119 Fuel Tank 134
Engine Speed Sensor 120 Fuel Tank Module 134
Fuel Drain Manifold 121 Fuel Transfer Pump 134
Fuel Filter—In Tank 122 High-Pressure Fuel Lines 135
Fuel Filter/Water Separator 122 Idle Speed Adjustment 136
Fuel Gauge Sending Unit 123 Intake Manifold . 136
Fuel Heater 123 Intake Manifold Air Heater 137
Fuel Heater Relay 124 Intake Manifold Air Heater Relays 137
Fuel Injection Pump 124 Intake Manifold Air Temperature Sensor 136
Fuel Injection Pump Supply Line 130 Powertrain Control Module (PCM) 138
Fuel Injectors 131 Throttle Position Sensor 138
Fuel Shutdown Solenoid . 132 Transmission Temperature Sensor 139
Fuel Shutdown Solenoid Relay 133 Vehicle Speed Sensor 139
Fuel System Pressure Test—Diesel Engine 134 Wastegate (Turbocharger) 139
Fuel System Pressure Warning 134 Water-ln-Fuel Sensor 139
AIR BLEED PROCEDURE

A certain amount of air becomes trapped in the fuel
system when fuel system components are serviced or
replaced. Bleed the system after fuel system service
according to the following procedures.
WARNING: DO NOT B L E E D AIR FROM T H E F U E L

S Y S T E M O F A HOT ENGINE. DO NOT A L L O W F U E L
TO S P R A Y ONTO T H E E X H A U S T MANIFOLD WHEN
B L E E D I N G AIR FROM T H E F U E L S Y S T E M .
MANUAL BLEEDING
Some air enters the fuel system when the filters or
injection pump supply line are changed. This small
amount of air is vented automatically from the injec
tion pump through the fuel drain manifold. This is if
the filter was changed according to instructions.
The system will have to be bleed manually if:
• The fuel filter is not filled before installation
• The fuel injection pump is replaced
• High-pressure fuel line connections are loosened or
lines replaced
• Initial engine start-up or start-up after an ex
tended period of no engine operation.
(1) Loosen the low-pressure bleed bolt (Fig. 1).
(2) Operate the rubber push-button primer on the
fuel transfer pump (Fig. 2). Do this until the fuel ex
iting the low-pressure bleed bolt is free of air.
Fig. 1 Low-pressure Bleed Bolt
If the primer button feels as if it is not pumping,
rotate (crank) the engine approximately 90 degrees. CRANKING TO B L E E D AIR FROM T H E INJECTION
Continue pumping until air is removed. PUMP. P L A C E T H E TRANSMISSION IN N E U T R A L
(3) Tighten low-pressure bleed screw to 8 N-m (6 ft. OR PARK AND S E T PARKING B R A K E B E F O R E E N
lbs.) torque. GAGING T H E S T A R T E R MOTOR.
FUEL INJECTION PUMP BLEEDING
WARNING: THE ENGINE MAY START WHEN

14 - 120 F U E L S Y S T E M •
FUEL
TRANSFER
PUMP
J9114-69
Fig. 3 Bleeding High-Pressure Fuel Lines

RUBBER (2) Crank the engine until all air is bled from the
PRIMER
BUTTON line. Do not operate the s t a r t e r m o t o r for longer
J9414-72
t h a n 30 seconds. Wait t w o minutes between
cranking intervals.
Fig. 2 Fuel Transfer Pump—Manual Operation (3) Start the engine and bleed one injector at a
time until the engine runs smoothly.
CAUTION: Do not engage the starter motor for more
(4) Tighten fuel line(s) at injector(s) to 30 N-m (22
than 30 seconds at a time. Allow two minutes be
ft. lbs.) torque.
tween cranking intervals.
(1) Perform the previous procedure: Manual Bleed

ENGINE SPEED SENSOR
The engine speed (rpm) sensor is located on the
ing.
front of engine (Fig. 4). Spacers located behind the
(2) Crank the engine for 30 seconds at a time to al
low air trapped i n the injection pump to vent out the sensor are used to position sensor over the vibration
drain manifold. Observe the previous WARNING and damper.
CAUTION. SENSOR M O U N T I N G BOLTS *
HIGH PRESSURE FUEL LINE BLEEDING
WARNING: T H E F U E L INJECTION PUMP S U P P L I E S

H I G H - P R E S S U R E F U E L O F AS HIGH A S 120,000
KPA (17,405 PSI) TO E A C H INDIVIDUAL INJECTOR
THROUGH T H E H I G H - P R E S S U R E LINES. F U E L UN
D E R THIS AMOUNT OF P R E S S U R E CAN P E N E
T R A T E T H E SKIN AND C A U S E P E R S O N A L INJURY.
W E A R S A F E T Y G O G G L E S AND A D E Q U A T E P R O
T E C T I V E CLOTHING AND AVOID C O N T A C T WITH
F U E L S P R A Y WHEN B L E E D I N G H I G H - P R E S S U R E
F U E L LINES.
WARNING: DO NOT B L E E D AIR FROM T H E F U E L

S Y S T E M O F A HOT ENGINE. DO NOT A L L O W F U E L
T O S P R A Y ONTO T H E E X H A U S T MANIFOLD WHEN
B L E E D I N G AIR FROM T H E F U E L S Y S T E M .
VIBRATION
DAMPER J9214-69
Bleed air from one injector at time.
(1) Loosen the high-pressure fuel line fitting at the Fig. 4 Engine Speed Sensor—Diesel
injector (Fig. 3).
REMOVAL FUEL DRAIN MANIFOLD

Before removing the sensor, note the position and
routing of the sensor wiring harness. This routing REMOVAL
must be maintained to prevent wiring from contact (1) Remove the two nuts retaining the nameplate/
ing belt or pulleys. cover to the top of the six engine valve covers (Fig.
(1) Disconnect the speed sensor pigtail harness 6). Remove nameplate/cover from engine.
from the main engine wiring harness near the front/
NAMEPLATE/COVER
top of engine. NAMEPLATE/COVER
NUTS (2)
(2) Remove the clip bolts from the sensor pigtail
# 6 CYLINDER
wiring harness. VALVE COVER
(3) Remove the two speed sensor mounting nuts
(Fig. 4).
(4) Remove the speed sensor and its mounting
spacers from the vehicle.
INSTALLATION/ADJUSTMENT
The engine speed sensor uses a slotted hole on one
side (Fig. 5) to adjust its depth. A brass (non-magnet
ic) feeler gauge must be used to adjust the sensor.
RUBBER
METAL ADAPTER
CLAMPS (2)
INTAKE
TUBE
J9414-73
Fig. 6 Nameplate/Cover—Diesel
(2) Remove drain manifold fitting screws (bolts) at
each of the six injectors (Fig. 7).
INJECTOR
J9214-70
Fig. 5 Engine Speed Sensor—Installation

Sensor-to-vibration damper air gap is: 1.25 MM
(.049 in.) minimum to 1.30 MM (.051 in.) maximum.
(2) Position speed sensor, its mounting spacers and
two mounting nuts to the engine. Install mounting
nuts finger tight.
(3) Route sensor wiring harness behind engine pul
leys. Install and tighten wiring harness clip bolts.
(4) Place the feeler gauge between the sensor and DRAIN MANIFOLD
the vibration dampener. FITTING
SCREW J9114-44
(5) Gently seat (push down) the sensor until it con
tacts the feeler gauge. Be sure the sensor is not
Fig. 7 Fuel Drain Manifold Fittings—Typical
near either of the notches (Fig. 4) on the vibra
tion damper. I f sensor is adjusted at or near (3) Remove the fuel drain manifold holddown
these notches, it will be damaged when engine clamp mounting bolt at the top/rear of intake mani
is started. fold.
(6) Tighten sensor mounting nuts to 24 N-m (18 ft. (4) Remove the fuel drain manifold banjo fitting at
lbs.) torque. the top of fuel filter/water separator (one bolt) (Fig.
(7) Remove feeler gauge. 8).
(8) Connect the sensor electrical connector to the (5) Remove fuel drain manifold fitting washers at
main engine wiring harness. each fuel injector.
(6) Remove manifold from engine. following: Draining Water from Filter.
D R A I N I N G WATER F R O M F I L T E R ? The filter
FUEL
DRAIN should be drained whenever the water-in-fuel warn
MANIFOLD ing lamp remains illuminated. (Note that the lamp
BOLT
will be illuminated for approximately two seconds
when the ignition key is initially placed i n the ON
position for a bulb check). The drain valve can also
be used to drain excess fuel from the filter when re
placement of the filter is necessary.
There is a drain valve and drain hose located at
the bottom of the water-in-fuel (WIF) sensor (Fig. 9).
Place a drain pan under the drain hose. With the
engine not running, push up on the drain valve
1
(Fig. 9) to remove the water from the filter/separator.
Hold the drain valve open until all water and con
taminants have been removed and clean fuel exits
the drain. Dispose of mixture i n drain pan according
to applicable regulations.
FUEL FILTER/
WATER SEPARATOR
FUEL DRAIN
MANIFOLD
WIF
SENSOR
HOUSING
FUEL FILTER/
J9414-86
WATER SEPARATOR
Fig. 8 Drain Manifold and Fuel Filter/Water

Separator
INSTALLATION DRAIN
(1) Using new seals/washers on all fittings, assem HOSE J9414-89
ble fuel drain manifold i n reverse order of disassem
bly. Fig. 9 Drain Valve at Fuel Filter/Water Separator
(2) Tighten drain manifold fitting screws (bolts) at (2) Remove the drain hose at the drain valve (Fig.
the injectors to 8 N-m (6 ft. lbs.) torque. 9).
(3) Tighten drain manifold holddown clamp screws (3) Disconnect the electrical connector from the
(bolts) to 13 N-m (10 ft. lbs.) torque. WIF sensor at the bottom of the filter (Fig. 10).
(4) Install nameplate/cover.
FILTER FUEL FILTER/ -
FUEL FILTER—IN TANK [HOUSING WATER SEPARATOR
Refer to Fuel Tank Module—Diesel Engine for re
moval and installation. This can be found i n the Fuel
FUEL FILTER/WATER SEPARATOR

Refer to the maintenance schedules i n Group 0 i n
this manual for the recommended fuel filter/water
separator replacement intervals.
The combination water-in-fuel sensor and fuel fil
ter/water separator is screwed onto a metal housing
located on the left/rear side of the engine and below
the intake manifold (Fig. 8). ELECTRICAL /
CONNECTOR 1 ^ ^ ^ = ^ \J9414-87
REMOVAL
(1) Partially drain the filter/separator. Refer to the Fig. 10 Electrical Connector—WIF Sensor
(4) Remove (unscrew) the filter/separator and WIF (3) Fill filter/separator with clean fuel.
sensor as one assembly from the filter housing (Fig. (4) Apply a light film of clean unused engine oil to
10). the filter/separator seal.
(5) Remove the O-ring seal from the filter housing (5) Install a new O-ring seal to the filter/separator
(Fig. 11). housing (Fig. 11).
(6) Install filter/separator to housing. Tighten fil
O-RING FILTER ter/separator one-half turn after it makes contact
SEAL HOUSING
with the housing.Tighten by hand only.
(7) Connect electrical connector to WIF sensor.
(8) Connect drain hose to drain valve.
FUEL GAUGE SENDING UNIT

Refer to the Fuel Delivery- Diesel Engine section
of this group for procedures.
FUEL HEATER
The fuel heater element assembly is located inside
of the fuel heater housing and above the pre-filter
(Fig. 13). The fuel temperature sensor is located at
the top of the fuel heater housing (Fig. 13).
Fig. 11 Fuel Filter/Water Separator O-Ring
(6) Drain the filter/separator.
(7) Remove the WIF sensor, O-ring and drain valve
assembly from the filter/separator (Fig. 12).
(8) Inspect the WIF sensor probes. Clean contami
nants from sensor probes if necessary. Replace sensor
if probes will not clean up.
FUEL FILTER/
WATER SEPARATOR
EL
TRANSFER
PUMP
DRAIN ELECTRICAL
WATER-IN- VALVE CONNECTOR
FUEL SENSOR FUEL
HEATER J9414-94
Fig. 13 Fuel Heater and Temperature Sensor

J9414-90 Location
REMOVAL
Fig. 12 WIF Sensor and Drain Valve Assembly (1) Disconnect both negative battery cables at both
INSTALLATION batteries.
(1) Install a new O-ring seal on WIF sensor. (2) Remove starter motor. Refer to Group 8B for
(2) Install WIF sensor/drain valve assembly into procedures.
new filter/separator. (3) Disconnect the electrical connector at the front
If the new fuel filter/water separator is not of fuel heater housing (Fig. 13).
filled with clean fuel before it is installed, man (4) Place a drain pan below the fuel heater.
ual air bleeding of the fuel system may be nec (5) A machined hex is located on the bottom of the
essary (temporary rough engine running may pre-filter housing (Fig. 14). From under the vehicle,
occur). I f necessary, refer to the A i r Bleed Pro attach a socket to this hex and remove (unscrew) the
cedure i n this section of the group for proce pre-filter.
dures. (6) Remove the fuel heater assembly from housing.
INSTALLATION (3) Connect battery cables to both batteries.
FUEL INJECTION PUMP

REMOVAL
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect electrical connector at throttle posi
tion sensor on side of injection pump (if equipped
with automatic transmission) (Fig. 16).
Fig. 14 Fuel Heater and Pre-Filter

Reverse the removal procedure for heater element
installation.
FUEL HEATER RELAY

The fuel heater relay is located in the engine com
partment near the brake master cylinder (Fig. 15).
FUEL SHUT-OFF
B U L , b
IS OUTPUT WIRE W J94U-91
Fig. 16 Throttle Position Sensor—Diesel

(3) Disconnect the electrical connector at fuel shut
down solenoid. (Fig. 17).
(4) Disconnect the main engine wiring harness at
top of injection pump and position to the side.
(5) Remove the metal intake manifold-to-inter-
cooler connecting tube.
(6) Remove the engine oil dipstick tube mounting
clamp and bolt (Fig. 18). Position dipstick tube to the
side.
(7) Disconnect the air heater cables (two
nuts—Fig. 18) and remove the air heater assembly at
intake manifold (five bolts—Fig. 18). Discard both of
the old air heater base gaskets.
(8) Remove the throttle control bracket, cables and
Fig. 15 Fuel Heater Relay—Diesel linkage assembly from the side of pump (three bolts).
REMOVAL Position the assembly to the side.
(1) Disconnect both negative battery cables at both (9) Disconnect turbocharger wastegate line and
batteries. vacuum line from air flow control (AFC) valve at rear
(Si) Disconnect the electrical connector at the relay. of injection pump (Fig. 19).
(3) Remove the relay from the mounting bracket. (10) Remove the fuel supply line at both ends (in
jection pump and fuel filter/water separator) (Fig.
INSTALLATION 20). For procedures, refer to Fuel Injection Pump
(1) Install the relay to the mounting bracket. Supply Line in this group. Place a rag beneath the
(2) Connect the electrical connector. fitting to catch excess fuel.

SENSOR ELECTRICAL
CONNECTOR
INTAKE
MANIFOLD Fl IPI
(UPPER HALF) SHUTDOWN SOLENOID

SOLENOID ELECTRICAL
CONNECTOR
Fig. 17 Fuel Shutdown Solenoid Location Fig, 19 Wastegate and Vacuum Lines
AIR CABLE INTAKE MANIFOLD
HEATER NUTS (2) BOLTS (5)
ASSEMBLY
LOWER PART
OF INTAKE
MANIFOLD
CABLES (2)
CABLE
MOUNTING
STUDS (2)
FUEL
INJECTION
PUMP J9414-114
Fig. 20 Fuel Injection Pump Supply Line

DIPSTICK TUBE jection pump. For procedures, refer to High-Pressure
HOLT
UPPER PART OF Fuel Lines in this group. Place a rag beneath the fit
INTAKE MANIFOLD J9414-105 tings to catch excess fuel.
(13) Disconnect the engine oil supply line at side of
Fig. 18 Intake Manifold Air Heater pump (Fig. 23).
(11) Remove the overflow valve and fuel return (14) Remove the oil fill tube bracket mounting bolt
line at pump (Fig. 21). Place a rag beneath the fitting (Fig. 24).
to catch excess fuel. (15) Remove oil fill tube from tube-to-gear housing
(12) Disconnect the six (6) high-pressure fuel lines adapter (Fig. 24). Tube is removed by screwing coun
from the fuel delivery valve holders at the top of in- terclockwise from adapter.
FUEL INJECTION
PUMP J9414-102 J9414-112
Fig. 21 Injection Pump Overflow Valve Fig. 23 Engine Oil Supply Line—Pump Mounting
Nuts
HIGH-PRESSURE FUEL DEUVERY
FUEL LINES (6) FITTINGS (6) VALVE HOLDERS (6)
OIL FILL
TUBE
J9114-54
Fig. 24 Oil Fill Tube, Adapter and Mounting Bracket

to position the engine to TDC (Top Dead Center) on
the compression stroke of number 1 cylinder.
INJECTION PUMP (17) Remove the rubber air tube connecting the
J9414-116
turbocharger to the air filter housing.
Fig. 22 Fuel Delivery Valve Holders and Pressure The engine can be rotated with a barring tool such
Lines as Snap-On No. SP371, MTE No. 3377462 (Cummins
(16) Remove oil fill tube adapter from gear housing Tool Division), or an equivalent.
(Fig. 24). Adapter is removed by screwing counter (18) The opening for the barring tool is located i n
clockwise from gear housing. the rear flange of engine on exhaust manifold side
The engine is equipped with a built-on move (Fig. 27). Remove the rubber access plug covering
able timing pin. This pin is located above the power this opening.
steering pump, below and to the inside of the fuel in (19) Insert the barring tool into the flywheel hous
jection pump, on the rear of the cam gear housing ing opening (Fig. 27).
(Fig. 25). The pin will engage into a machined hole i n (20) While holding tension on the timing pin (to
the back of the camshaft gear (Fig. 26). I t is designed wards front of engine), very slowly rotate the engine
(counter-clockwise as viewed from front) with the
Fig. 27 Rotating Engine with Barring Tool—Typical

Before proceeding to the next step, and to
prevent shearing of the timing pin, temporarily
remove the timing pin from the back of the
gear.
(21) Remove the nut and washer retaining the in
Fig. 25 Timing Pin and Location jection pump gear to the injection pump shaft (Fig.
28).
MACHINED HOLE
Place a shop towel below the retainer nut i n the
gear housing cover opening to prevent the nut or
washer from falling into the gear housing.
CAUTION: If the gear retainer nut or washer drops

into gear housing, cover must be removed to re
trieve them before engine is started.
INJECTION
PUMP
Fig. 26 Back of Camshaft Gear—Typical

barring tool. Rotating the barring tool counter-clock
wise will rotate the crankshaft clockwise. Continue to
rotate until the timing pin drops into the machined
hole i n the back of the camshaft gear. When the pin
aligns to the gear, the engine is now at the TDC po TIMING GEAR
sition (compression stroke) at cylinder number 1. COVER J9414-4
CAUTION: When installing the fuel injection pump Fig. 28 Injection Pump Gear Washer and Nut
and to achieve proper injection pump timing, the (22) Use a T-bar type puller (Fig. 29) to separate
engine MUST be in the T D C position (compression the injection pump gear from the injection pump
stroke) at cylinder number 1 . shaft. Attach two M8 X 1.24 M M (metric) screws
through the puller and into the two threaded holes (26) Clean the injection pump O-ring mounting
supplied in the pump gear. Pull the injection pump surfaces on both the gear housing and pump.
gear forward until it loosens from the injection pump
shaft. P u l l on the gear only enough to loosen it INSTALLATION
from the injection pump shaft. Pulling the gear
CAUTION: Before installing the injection pump, be
to far may cause damage or breakage to the
sure that number 1 cylinder is at the Top Dead C e n
gear cover.
ter (compression stroke) position. Engage the tim
ing pin on the rear of the gear cover (Fig. 25) into
the rear of the camshaft gear. Rotate crankshaft if
T-BAR
necessary.
Before injection pump installation, it must be set

(pump shaft rotated) to a certain position to attain
accurate pump timing. Remove the access plug from
the side of pump (Fig. 31). Stored behind this access
plug is a plastic timing pin tool (Fig. 32). This tool is
used to align the injection pump timing tooth (Fig.
33) to the center of access hole.
DEUVERY OIL FILL PLUG

VALVES
J9114-60
AFC
Fig. 29 Separating Injection Pump Gear from Pump
Shaft
(23) Remove the two (2) injection pump-to-lower
mounting bracket bolts (Fig. 30).
P7100 INLINE
FUEL INJECTION
PUMP ACCESS
PLUG J9414-75
Fig. 31 Injection Pump Access Plug

Installing Original Pump: If the original pump
PUMP-TO-
is being reinstalled, the pin tool should already be
LOWER BRACKET mounted with the slotted end facing outward (Fig.
MOUNTING BOLTS (2) 32). When the position of this tool has been reversed,
with the slotted end facing inward, it is used as a
J9414-113 pump timing pin tool.
Installing New or Rebuilt Pump; If a new or re
Fig. 30 Pump Mounting Bolts built pump is being installed, the pump should have
been shipped with the slotted end of the timing pin
(24) Remove the four (4) injection pump-to-gear tool engaged to the timing tooth in the pump.
housing mounting nuts (Fig. 23). To set injection pump timing on an original pump
(25) Remove the injection pump from gear housing. or when checking timing on a new pump, rotate the
Take care not to nick the injection pump shaft pump shaft until the timing tooth appears in the cen
on the aluminum gear housing when removing ter of the plug opening (Fig. 33). Install the slotted
pump. end of the timing pin tool over the timing tooth. The
Fig. 32 Injection Pump Timing Pin Tool

should be clean and free of any oil. This will en
sure of proper gear-to-shaft tightening.
INJECTION
PUMP
GEAR
J9414-77
Fig. 33 Injection Pump Timing Tooth

pump shaft may have to be rotated slightly to align
the tool to the tooth. Do not force the slots in the tool
over the timing tooth.
After the tool has been temporarily installed to
the timing tooth, install and loosely tighten the ac PUMP MOUNTING
cess plug. New pumps should have been shipped with FLANGE J9414-5
this tool already engaged.
(1) If the original pump is being installed, check Fig. 34 Apply Oil to Gear Cover
the condition of the rubber O-ring at pump mounting (3) Position the pump assembly to the mounting
area. flange on gear cover while aligning the injection
(2) Apply clean engine oil to the injection pump pump shaft through the back of injection pump gear.
mounting flange opening in gear cover housing to al (4) Install the four pump mounting nuts finger
low easier pump installation (Fig. 34). Also apply en tight. Do not attempt to tighten (pull) the pump
gine oil to the pump O-ring seal at pump mounting to the gear cover using the mounting nuts.
area. The injection pump shaft and its mounting Damage to pump or gear cover may occur. The
area i n the center of the injection pump gear,
pump must be positioned flat to its mounting (15) Install the low-pressure fuel supply line to
flange before attempting to tighten mounting pump.
nuts. (16) Install the turbocharger wastegate line and
(5) Install two (vertical) pump mounting bracket AFC sensing line at the pump.
bolts finger tight. (17) New or rebuilt P7100 series fuel injection
(6) Tighten the four pump mounting nuts to 24 pumps must be pre-lubricated before operation. Fail
N-m (18 ft. lbs.) torque. Tighten the two pump ure to do so may result in pre-mature governor wear.
mounting bracket bolts. To prevent damage to (a) Remove the 10 mm hex plug (oil fill plug) on
pump and mounting flange, tighten the pump the top of the injection pump governor (Fig. 31).
mounting nuts first. (b) Add 750 ml (25 ounces) of clean engine oil
(7) Install injection pump drive shaft-to-injection through this opening.
pump gear retaining nut and washer. Do a prelim (c) Install oil fill plug and tighten to 28 N-m (21
inary tightening of this nut to 10 to 15 N-m (7 to ft. lbs.) torque.
11 ft. lbs.) torque. Do not over tighten. This is (18) Install the throttle linkage assembly to pump.
not the final tightening torque. To prevent dam Tighten bolts to 24 N-m (18 ft. lbs.) torque.
age to the timing pin, do not exceed this (19) Connect electrical connector to fuel solenoid.
torque. (20) Connect the main engine wiring harness at
(8) Disengage the timing pin (Fig. 25) from the top of injection pump.
rear of camshaft gear by pulling it straight back. (21) Install the engine oil dipstick tube mounting
(9) Remove the access plug from injection pump clamp and bolt at the opening to the intake manifold.
(Fig. 31) and remove timing pin tool from pump. (22) Install oil fill tube and tube adapter.
(10) Do a final tightening of the injection pump (23) Install oil fill tube bracket and mounting bolt.
gear-to-inj ection pump shaft nut. Tighten to 165 N-m (24) Install electrical connector to throttle position
(122 ft. lbs.) torque. Use the barring tool to prevent sensor (if equipped).
the engine from rotating when tightening gear. (25) Install air filter housing-to-turbocharger tube
(11) After the injection pump gear has received a at air filter housing.
final tightening, verify injection pump timing. (26) Using a new gasket, install air heater assem
(a) Rotate the engine counter-clockwise with the bly (five bolts).
barring tool (clockwise as observed at the crank (27) Install intake manifold-to-intercooler tube.
shaft from the front of vehicle). Continue rotating (28) Check and adjust throttle linkage. Refer to
engine until the timing pin aligns into hole at rear Throttle Position Sensor in this group.
of camshaft gear (Fig. 26). The engine is now at (29) Bleed air from fuel system. Refer to the Air
TDC of number cylinder. Bleed Procedure in this section of the group.
(b) With the timing pin aligned into the rear of (30) Adjust the low idle speed if required. Refer to
the camshaft gear, the timing tooth should also be Idle Speed Adjustment.
centered in the access hole on the side of the injec (31) Inspect throttle linkage to be sure that the
tion pump (Fig. 33). Install timing pin tool (Fig. 32) control lever is opening to the full open position.
to verify. (32) Some engine oil was lost when removing
(c) If the timing pin tool will not fit into the tim pump. Check and adjust engine oil level.
ing tooth in the pump, the pump gear nut must be
removed. Loosen the pump gear from the pump FUEL INJECTION PUMP SUPPLY LINE
shaft with the T-bar puller tool. With the gear loos The fuel injection pump supply line is located be
ened, rotate the injection pump shaft until it aligns tween the injection pump and the fuel filter/water
to the center of access hole on side of pump. separator housing (Fig. 35). It is attached at each
Tighten injection gear nut and remove barring tool. end with copper/or rubber sealed banjo fittings and
(12) Remove the timing pin tool from the pump. bolts.
Reverse the position of this tool (Fig. 32). The slotted
part of tool should be facing outward and will be REMOVAL
stored in pump in this direction. Place tool back into (1) Clean the area around the line.
pump. Install access plug and its sealing washer. (2) Remove the banjo fitting bolts at each end of
Tighten plug to 15 N-m (11 ft. lbs.) torque. the supply line (Fig. 35).
(13) Install the engine oil supply line and fuel re (3) Remove line from engine.
turn line/overflow valve to pump.
(14) Install the six high-pressure fuel lines to the INSTALLATION
top of pump. Tighten lines to 30 N-m (22 ft. lbs.) (1) Install new copper/or rubber washers to the
torque. banjo fittings at each end of the line.
J9414-97
Fig. 36 Loosening Injector Nut
FUEL
INJECTION
PUMP J9414-114
Fig. 35 Fuel Injection Pump Supply Line

(2) Install the line to the injection pump and fuel
filter. Tighten the injection pump end to 33 N-m (24
ft. lbs.). Tighten the filter end to 24 N-m (18 ft. lbs.).
(3) Bleed the line of air. Refer to the Air Bleed Pro
cedure at the beginning of this group.
FUEL INJECTORS
REMOVAL
J9414-98
(1) Disconnect both negative battery cables from
both batteries. Fig. 37 Loosening Injector Body
(2) Remove the high-pressure fuel lines. Refer to I I
High-Pressure Fuel Lines in this section. ADJUSTABLE
(3) Remove the fuel drain manifold. Refer to Fuel WRENCH
Drain Manifold in this section.
(4) Thoroughly clean the area around the injector.
CAUTION; When rust h a s formed on the fuel injec
tor nut {Fig. 36), the injector (when being removed)
can rotate in the cylinder head. This may c a u s e
damage to the cylinder head bore. U s e a rust pen
etrating solvent before attempting to loosen a
rusted holddown nut.
(5) Hit the injector body with a brass drift to

loosen it (Fig. 37).
(6) Hold the injector body with one wrench while J9414-99
removing the injector nut with another (Fig. 38).
Fig. 38 Loosening Injector
(7) It may be necessary to tap the injector with an
injector puller tool (Fig. 39). (2) Install a new copper washer on injector (Fig.
41).
INSTALLATION (3) Apply a coating of anti-seize compound to the
(1) Clean the injector cylinder head bore with spe threads of the injector holddown nut and between the
cial Cummins wire brush tool or equivalent (Fig. 40). top of the nut and injector body (Fig. 42).
J9414-100 J9414-101
Fig. 39 Removing Injector with Puller Tool Fig. 42 Apply Anti-Seize Compound
tightening the injector, push the o-ring into the
groove on the top of the injector.
Fig. 40 Cleaning Cylinder Head Injector Bore
Fig. 43 Installing Injector

(5) Tighten the injector holddown nut to 60 N*m
(6) Connect the fuel drain manifold to the injec
tors. Refer to Fuel Drain Manifold in this section.
(7) Connect the high-pressure fuel lines. Refer to
High-Pressure Fuel Lines in this section.
(8) Connect the negative battery cables to both
batteries.
(9) Bleed the air from the high-pressure lines. Re
fer to High- Pressure Line Bleeding in the Air Bleed
Procedure section at the front of this section of the
J9114-50 group.
Fig. 41 Injector Washer
FUEL SHUTDOWN SOLENOID
(4) Install the injector into the cylinder head. Align
the tab on the injector to the notch in the cylinder REMOVAL
bore (Fig. 43). Certain types of injectors may have an The fuel shutdown solenoid is mounted to a bracket
o-ring located above the holddown nut (Fig. 43). After located on the side of the fuel injection pump (Fig.
44).
FRONT O F ENGINE AIR TEMPERATURE SENSOR

(2) Install clip at injection pump lever.
SENSOR ELECTRICAL (3) Install and tighten two mounting bolts.
CONNECTOR (4) Check and adjust the shaft length of the sole
noid. Refer to the following procedure:
SOLENOID SHAFT ADJUSTMENT

After replacing the fuel shutdown solenoid, the so
lenoid shaft length must be checked and (if neces
sary) adjusted.
(1) Turn the ignition switch ON.
(2) Pull up (by hand) and hold on the solenoid le
ver (Fig. 46). I f the solenoid is operating cor
rectly, it should remain i n the U P position with
the key i n the O N position.
FUEL
SHUTDOWN
SOLENOID
INTAKE
MANIFOLD
(UPPER HALF) SHUTPOWN SOLENOID
SOLENOID ELECTRICAL
CONNECTOR
J9414-93
Fig. 44 Fuel Shutdown Solenoid Location

(1) Disconnect the solenoid electrical connector
(Fig. 44).
FUEL S H U T D O W N MOUNTING
SOLENOID BOLTS
HOLD SOLENOID
SHUTDOWN LEVER IN
LEVER "UP" P O S I T I O N J9414-81
Fig. 46 Fuel Shutdown Solenoid Lever in Up

Position
(3) Take a measurement from the bottom of the so
lenoid mounting bracket to the top of the injection
pump shutdown lever pin (Fig. 47).
(4) Dimension should be 66.9 mm (2.64 inches).
(5) If adjustment is necessary, loosen the shaft
locknut and rotate the adjustment nut (Fig. 48) to at
LOCKNUTS CLIP tain dimension.
J9414-92
FUEL SHUTDOWN SOLENOID RELAY
Fig. 45 Fuel Shutdown Solenoid The fuel shutdown solenoid relay is located in the
Removal/Installation
engine compartment near the brake master cylinder
(2) Disconnect clip at injection pump shutdown le (Fig. 49).
ver (Fig. 45).
(3) Remove two solenoid mounting bolts. REMOVAL
(4) Remove solenoid from mounting bracket. (1) Disconnect both negative battery cables at both
batteries.
INSTALLATION (2) Disconnect the electrical connector at the relay.
(1) Position solenoid to mounting bracket and in (3) Remove the relay from the mounting bracket.
jection pump lever.
FUEL SHUT-OFF
BOTTOM OF BRACKET RELAY
BRAKE MASTER
CYLINDER
J9414-31
Fig. 49 Fuel Shutdown Solenoid Relay—Diesel

TOP OF LEVER
PIN PIN FUEL SYSTEM PRESSURE WARNING
J9414-131 WARNING: H I G H - P R E S S U R E F U E L LINES D E L I V E R

D I E S E L F U E L UNDER E X T R E M E P R E S S U R E FROM
Fig. 47 Solenoid Measurement THE INJECTION PUMP TO T H E F U E L I N J E C T O R S .
THIS MAY B E A S HIGH A S 120,000 KPA (17,405 PSI)
ADJUSTMENT . U S E E X T R E M E CAUTION WHEN INSPECTING FOR
NUT
gfe^ H I G H - P R E S S U R E F U E L L E A K S . INSPECT F O R
H I G H - P R E S S U R E F U E L L E A K S WITH A S H E E T O F
C A R D B O A R D . HIGH F U E L INJECTION P R E S S U R E
CAN C A U S E P E R S O N A L INJURY IF CONTACT IS
MADE WITH T H E SKIN.
FUEL SYSTEM PRESSURE TEST—DIESEL ENGINE

For fuel pressure tests, refer to the Diesel
FUEL TANK
Refer to the Fuel Tank section of this group for pro
cedures.
FUEL TANK MODULE

Refer to Fuel Tank Module—Diesel Engine. This
can be found i n the Fuel Delivery—Diesel Engine
LOCKNUT J9414-132
FUEL TRANSFER PUMP
Fig. 48 Solenoid Adjustment
For operation of the fuel transfer pump primer but
INSTALLATION ton, refer to Fuel Transfer Pump i n the Fuel
(1) Install the relay to the mounting bracket. Delivery—Diesel Engine section of this group.
(2) Connect the electrical connector. The fuel transfer pump is located on the left side of
(3) Connect battery cables to both batteries. the engine and above the starter motor (Fig. 50). The
mounting bracket/spacer for the fuel heater assembly
is located between the engine block and the fuel (7) Remove the fuel pump and fuel heater assem
transfer pump (Fig. 51). The fuel heater housing and bly from the engine as one unit.
its bracket assembly must also be removed when re
moving fuel pump. PUMP INSTALLATION
(1) Clean the mating surfaces of the fuel heater
FUEL T
EMP
ERA
TUR
E SENSOR mounting bracket, the fuel pump and the engine
block of any gasket material.
(2) Position the new gaskets, the fuel heater hous
ing mounting bracket and the fuel pump to the en
gine.
(3) Install the two mounting bolts into the engine.
Tighten to 24 N-m (18 ft. lbs.) torque. As these bolts
are tightened, the plunger within the fuel pump
is being compressed. Tighten these two bolts al
t e r n a t e l y to prevent damage to the fuel pump
housing.
(4) Install fuel line fittings to pump and fuel
heater. Tighten to 24 N-m (18 ft. lbs.) torque.
(5) Install starter motor. Refer to Group 8B for
procedures.
(6) Connect battery cables at both batteries.
(7) Bleed air from fuel system. Refer to the A i r
Bleed Procedure at the beginning of this section of
the group.
HIGH-PRESSURE FUEL LINES

Fig. 50 Fuel Transfer Pump Location A l l high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine op
eration.
CAUTION: The high-pressure fuel lines must be

clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
mended lines when replacement of high-pressure
REMOVAL
(1) Disconnect both negative battery cables from
both batteries.
Fig. 51 Pump Removal/Installation (2) Remove the nameplate/cover from the top of
the six engine valve covers (two nuts) (Fig. 52).
PUMP REMOVAL
(3) Remove the necessary clamps holding the lines
to the engine.
batteries.
(4) Clean the area around each line. Disconnect
(2) Remove starter motor. Refer to Group 8B for
each line at the top of each fuel injector (Fig. 53).
procedures.
(5) Disconnect each high-pressure line fitting at
(3) Place a drain pan below the pump.
each fuel injection pump delivery valve holder (Fig.
(4) Remove the fuel line fittings at the top of both
54).
the fuel pump and fuel heater housing (Fig. 51).
(6) Very carefully remove each line from the en
(5) Remove the fuel hose clamps and rubber fuel
gine. Do not bend the line while removing.
hose (fuel heater housing-to-fuel pump) (Fig. 51).
(6) Remove the two mounting bolts (Fig. 51).
Fig. 52 Nameplate/Cover—Diesel Fig. 54 Fuel Delivery Valve Holders and Pressure

Lines
FUEL HIGH-PRESSURE valve holder i n the correct firing order. Also position
DRAIN FITTING FUEL UNE
MANIFOLD each line in the correct line holder.
(2) Loosely install the line clamp isolator and
bracket holder bolts.
(3) Tighten each line at the delivery valve holder
(4) Tighten each line at the fuel injector to 30 N-m
Be sure the lines are not contacting each
other or any other component.
(5) Tighten the clamp bracket bolts to 24 N-m (18
ft. lbs.) torque.
(6) Bleed air from the fuel system. Refer to High-
Pressure Fuel Line Bleeding i n the A i r Bleed Proce
dure portion of this section.
IDLE SPEED ADJUSTMENT

Refer to the Diesel Engine - -General Diagnosis sec-
FUEL INJECTOR tion for procedures.
J94U-H7
Fig. 53 Fuel Lines at Fuel Injectors INTAKE MANIFOLD

Refer to Group 11, Exhaust System and Intake
CAUTION: Be sure that the high-pressure fuel lines
Manifold for procedures.
are installed in the same order that they were re
moved. Prevent the injection p u m p delivery valve INTAKE MANIFOLD AIR TEMPERATURE SENSOR
holders from turning when removing or installing The intake manifold air temperature sensor is lo
high- pressure lines from injection pump. cated on the top of intake manifold and to the rear of
the intake manifold heater (Fig. 55).
INSTALLATION
REMOVAL
(1) Carefully position each high-pressure fuel line
(1) Disconnect the electrical connector at the sen
to the fuel injector and fuel injection pump delivery
sor.
FRONT OF ENGINE AIR TEMPERATURE SENSOR AIR CABLE INTAKE MANIFOLD
SENSOR ELECTRICAL HEATER NUTS (2) BOLTS (5)
CONNECTOR ASSEMBLY
LOWER PART
OF INTAKE
MANIFOLD
CABLE
MOUNTING
STUDS (2)
INTAKE
MANIFOLD F U E L
(UPPER HALF) TJ0WN

SHUT SOLENOID
SOLENOID ELECTRICAL
CONNECTOR J9414-93
Fig. 55 Air Temperature Sensor Location—Diesel

(2) Remove the sensor (Fig. 55) the from intake DIPSTICK TUBE
manifold. BOLT
UPPER PART OF
INSTALLATION INTAKE MANIFOLD J9414-105
(1) Install sensor to intake manifold. Tighten to 28
N-m (20 ft. lbs.) torque. Fig. 56 Intake Manifold Air Heater
(2) Install electrical connector. (3) Position the air heater to the intake manifold.
(4) Install and tighten five bolts to the intake man
INTAKE MANIFOLD AIR HEATER ifold. Tighten to 24 N-m (18 ft. lbs.) torque. (The
The intake manifold air heater assembly (with in ground cable for the air heater is connected to one of
ternal heating elements) is located between the up the intake manifold bolts).
per and lower portions of the intake manifold (Fig. (5) Connect the two cables to the air heater.
56). If the heating coils (elements) within the assem
bly have failed, the entire heater assembly must be INTAKE MANIFOLD AIR HEATER RELAYS
replaced. The relays are located in the engine compartment,
bolted to the left inner fender below the left battery
REMOVAL (Fig. 57).
batteries. REMOVAL
(2) Remove the engine oil dipstick tube mounting The mounting bracket and both relays are replaced
bracket bolt at the side of the intake manifold (Fig. as an assembly.
56). (1) Disconnect both negative battery cables at both
(3) Remove the two cable nuts and remove cables batteries.
at the air heater electrical studs (Fig. 56). (2) Disconnect the four relay trigger wires at both
(4) Remove the five bolts retaining the upper half relays (Fig. 57). Note the position of wiring before re
of the intake manifold to the lower half of the intake moving.
manifold (Fig. 56). (3) Lift the four rubber shields from the four cables
(5) Position the intake manifold and manifold con (Fig. 57).
necting tube to the side. (4) Remove the four nuts at the cable connectors
(6) Remove the air heater from the intake mani (Fig. 57). Note the position of wiring before removing.
fold. (5) Remove the three relay mounting bracket bolts
(Fig. 57) and remove relay assembly.
INSTALLATION
(1) Clean the mating surfaces of the air heater and INSTALLATION
intake manifold. (1) Install the relay assembly to the inner fender.
(2) Install a new lower and upper gasket to the air Tighten mounting bolts to 4.5 N-m (40 in. lbs.)
heater. torque.
14 - 138 FUEL SYSTEM
BATTERY
(LEFT SIDE)
IS OUTPUT WIRE BUU&UI J9414-91
Fig. 57 Intake Manifold Air Heater Relays Fig. 58 Throttle Position Sensor—Diesel
(2) Connect the eight electrical connectors to the (5) The TPS voltage must now be tested and (if
relays. necessary) adjusted. Refer to the following: Throttle
(3) Connect battery cables to both batteries. Position Sensor Testing.
POWERTRAIN CONTROL MODULE (PCM) T H R O T T L E POSITION SENSOR TESTING

Refer to the Multi-Port Fuel Injection CAUTION: Before attempting to test the T P S , verify
(MFI)—Component Removal/Installation—Except the linkage adjustment dimension shown in figure
Diesel section of this group for procedures. 59. This dimension MUST be 126.5 mm (5.0 inches)
B E F O R E testing. For linkage adjustment proce
THROTTLE POSITION SENSOR dures, refer to Throttle Linkage Adjustment—Diesel
Engine. This can be found in the Accelerator Pedal
AUTOMATIC TRANSMISSION ONLY and Throttle Cable section of this group.
The throttle position sensor (TPS) is used on
the diesel powered engine only when equipped
with an automatic transmission. I f the TPS is to CAUTION: Before testing the T P S , verify that the
be replaced on a diesel engine, it must be engine is set at correct low idle speed. Refer to Idle
tested after replacement. Speed Adjustment This can be found in the Diesel
REMOVAL
(1) Disconnect the electrical connector on bottom of (1) After confirming the correct linkage adjustment
TPS (Fig. 58). and idle speed, proceed to the following:
(2) Remove the two TPS mounting bolts. (2) Attach a paper clip into the center terminal
(3) Remove the sensor from bracket. (Fig. 58) of the TPS electrical connector. Do not re
move the connector from the TPS for this test.
INSTALLATION (3) Attach the positive lead of a voltmeter to this
(1) Position the TPS to the mounting bracket. The paper clip and the negative lead to a good ground.
electrical connector should be facing downward. (4) Turn the ignition switch to the ON position. Do
not start engine.
The T P S is spring loaded. After positioning
(5) The voltage at the TPS center terminal should
the TPS to its mounting bracket, rotate the TPS be 1.0 volt ( ± .2 volt) with linkage at idle position.
on the bracket i n a counter-clockwise direction The voltage at the wide open throttle position should
until the two bolt holes align. be 3.5 volts ( ± .4 volts). I f voltage is not correct, pro
(2) Install and tighten two bolts. ceed to adjusting linkage.
(3) Connect the electrical connector on bottom of (6) The linkage rod (Fig. 60) connecting the throt
TPS. tle lever to the fuel injection pump lever is adjust
(4) Operate the throttle by hand to check for bind able. To prevent damage to the ends of linkage,
ing. attach locking-type pliers to the flat (Fig. 60) located
THROTTLE LEVER-TO-
THROTTLE
INJECTION PUMP LEVER
LEVER
LINKAGE ROD
BALL
THROTTLE
LEVER
RIGHT-HAND-
THREADED
THROTTLE FLAT NUT
POSITION LEFT-HAND-
CENTER REAR FACE
SENSOR THREADED
O F BALL O F BRACKET J9414-68 NUT J9414-67
Fig. 59 Linkage Measurement—Diesel Fig. 60 Throttle Lever Linkage Adjustment—Diesel

on the linkage rod before loosening locknuts. rectly, the throttle lever-to-injection pump lever
(7) Loosen the right-hand-threaded nut (Fig. 60). linkage rod should have stopped moving while the
(8) Loosen the left-hand-threaded nut (Fig. 60). throttle lever continues to move towards the rear of
(9) Slowly rotate the flat (Fig. 60) on the linkage vehicle.
rod (lengthen or shorten) to achieve 1.0 volt (± .2 (13) Again, check and verify low idle speed. Adjust
volts) on the voltmeter with the linkage in the idle if necessary.
position. With the throttle in the wide open position,
voltage should be 3.5 volts ( ± .4 volts). DO NOT TRANSMISSION TEMPERATURE SENSOR
lengthen or shorten the linkage rod more than
1 mm from the dimension shown i n figure 59. I f Refer to the Multi-Port Fuel Injection
voltage requirements cannot b e met b y linkage (MFI) — Component Removal/Installation—Except
adjustment (125.6 to 127.6 mm), replace the Diesel section of this group for removal and installa
TPS. tion procedures.
(10) Tighten both nuts after adjustment.
(11) With the engine OFF, operate the throttle VEHICLE SPEED SENSOR
from accelerator pedal and check for throttle lever Refer to the Multi-Port Fuel Injection
action and binding. Be sure throttle lever stop is (MFI)—Component Removal/Installation—Except
against the low idle speed screw after throttle is re Diesel section of this group for removal and installa
leased. tion procedures.
(12) Be sure of wide open throttle (WOT) when ac
celerator pedal is pressed to the floor. This is checked WASTEGATE (TURBOCHARGER)
by observing throttle lever breakover position. Pro Refer to Group 11, Exhaust System and Intake
ceed to the following: Manifold for procedures.
(a) Key OFF and engine OFF for this test.
(b) Two people are needed for this test. From in WATER-IN-FUEL SENSOR
side of the vehicle, press the accelerator pedal The water-in-fuel sensor is located at the bottom of
about half-way to the floor. Movement of both the the fuel filter/water separator. Refer to Fuel Filter/
throttle lever and throttle lever-to-injection pump Water Separator in this section of the group for re
lever linkage rod (Fig. 60) should be observed.
moval and installation procedures.
(c) Continue to press the accelerator pedal to the
floor. If throttle lever breakover is operating cor-
SPECIFICATIONS
GENERAL INFORMATION IDLE SPEEDS—DIESEL ENGINES
latest information available at the time of publica LOW IDLE SPEED HIGH IDLE SPEED
tion. I f anything differs between the specifica
Wilh automatic transmission... Do not attempt to adjust
t i o n s f o u n d o n t h e Vehicle E m i s s i o n Control
high idle speed. High idle
Information ( V E C I ) l a b e l a n d the following •750-800 RPM with transmission speed adjustment screw
specifications, use specifications o n V E C I l a b e l . in drive and air conditioning on. is factory sealed. Breaking
The VECI label is located i n the engine compart seal will void injection pump
ment. On diesel powered engines, refer to the Engine With manual transmission... warranty.
Data Plate. This can be found on the left (drivers)
side of the engine timing gear cover. *780 RPM with transmission in
neutral and air conditioning on.
F U E L TANK C A P A C I T I E S
* With engine at normal operating temperature. Refer to text
for idle adjustment procedures.
TANK: L1TI1S GALLONS r
J9414-66
118' Wheelbose 98 26
All Other Models 132 35
T O R Q U E — C A S POWERED ENGINES
Nominal refill capacities are shown. A variation may be observed
from vehicle to vehicle due t o manufacturing tolerances and refill
procedures. Description Torque
Camshaft position sensor bolt:

J9414-65 8.0L V-10 engine 6 N*m (50 in. lbs.)
Crankshaft position sensor
mount. bolt(s) 8N»m (70 in. lbs.)
SENSOR RESISTANCE (OHMS)—ENGINE
Engine coolant temperature
COOLANT, INTAKE AIR AND TRANSMISSION
sensor 11 N*m(8ft. lbs.)
TEMPERATURE SENSORS Fuel hose (tube) clamps 1 N*m(10in. lbs.)
Fuel tank nuts 9 N*m (80 in. lbs.)
TEMPERATURE RESISTANCE (OHMS) IAC motor-to-throttle body...... 7N*m (60 in. lbs.)
Intake manifold air
temperature sensor 28 N»m (20ft.lbs.)
C F MIN MAX
MAP sensor mounting screws;
3.9L/5.2L/5.9L engine 3 N t m (25 in. lbs.)
-40 -40 291,490 381,710 8.0L engine 2N»m(20 in. lbs.)
-20 -4 85,850 108,390 Oxygen (O2S) s e n s o r 30N»m (22ft.lbs.)
-10 14 49,250 61,430 PCM 60-way connector
0 32 29,330 35,990 mounting screw 4 N»m (35 in. lbs.)
10 50 17,990 21,810 Throttle body mounting bolts
20 68 11,370 13,610 or nuts:
25 77 9,120 10,880 3.9L/5.2L/5.9L engine.... 23 N*m (200 in. lbs.)
30 86 7,370 8,750
8.0L V-10 engine 11 N»m (96 in. lbs.)
40 104 4,900 5,750
50 122 3,330 3,880 Throttle position sensor
60 140 2,310 2,670 mount, bolts 7N«m (60 in. lbs.)
70 158 1,630 1,870 Transmission temp, sensor....... 11 N*m(8ft. lbs.)
80 176 1,170 1,340
90 194 860 970
100 212 640 720 J9414-118
110 230 480 540
120 248 370 410
J928D-4
TORQUE—DIESEL ENGINES
Description Torque Description Torque
Air fuel control (AFC) Fuel transfer pump

line fitting 24 N-m (18 ft. lbs.) mounting bolts . . . . . . . . . . . . . . . 24 N-m (18 ft. lbs.)
Banjo fitting at top of High-pressure fuel lines at delivery
filter/separator . 24 N-m (18 ft. lbs.) valve clamp isolator bolts 30 N-m (22 ft. lbs.)
Banjo fitting at side of High-pressure fuel lines
fuel injector 8 N-m (6 ft. lbs.) at fuel injector 30 N-m (22 ft. lbs.)
Banjo fitting (fuel supply line High-pressure fuel line
at side of injector pump) . 30 N-m (22 ft. lbs.) clamp holders . . . . . . . . . . . . . . . 6 N-m (4 ft. lbs.)
Engine speed sensor bolts/ Injector pump access plug 15 N-m (11 ft. lbs.)
nuts 24 N-m (18 ft. lbs.) Injection pump-to-injection pump
Fuel drain manifold fitting gear nut 165 N-m (122 ft. lbs.)
bolts at injectors 8 N-m (6 ft. lbs.) Injector pump mounting nuts 24 N-m (18 ft. lbs.)
Fuel filter . 1/2 turn after contact Intake manifold air
Fuel hose clamps temperature sensor 28 N-m (20 ft. lbs.)
(low pressure) 1 N-m (15 in. lbs.) Intake manifold air
Fuel injector retaining nut . . . . . . . . 60 N-m (44 ft. lbs.) heater relay bolts. . . . . . . . . . . . . 4.5 N-m (40 in. lbs.)
Fuel tank nuts 9 N-m (80 in. lbs.) Low-pressure bleed screw 8 N-m (6 ft. lbs.)
J9414-119
F U E L SYSTEM PRESSURES—GAS POWERED FUEL SYSTEM PRESSURES—DIESEL

ENGINES ENGINES
• Fuel System Operating Pressure: • Fuel pressure drop across

.241-310 kPa (35-45 psi) fuel filter . . . 35 kPa (5 psi) maximum
• Fuel return line or component

restriction (vacuum) 100 mm (4 in Hg) maximum
• Fuel transfer pump
pressure . . . . . . . . . . Will vary. See text for procedures.
• Fuel injector "pop off" pressure 3500 psi

J9414-120
• Maximum injection pump
pressure 120,000 kPa (17,405 psi)
J9414-121
• PROPELLER SHAFTS 16 - 1
P R O P E L L E R SHAFTS
CONTENTS
page page
GENERAL INFORMATION 1 TORQUE SPECIFICATIONS 13
PROPELLER SHAFT REPLACEMENT 8 UNIVERSAL JOINT REPLACEMENT 10
SERVICE DIAGNOSIS/PROCEDURES 3
PROPELLER SHAFTS
The basic function of a propeller shaft is to trans
mit power from one point to another. The shaft is de
signed to send torque through an angle from the
transmission (transfer case on 4WD vehicles) to the
axle.
The propeller shaft must operate through con
stantly changing relative angles between the trans
mission and axle. I t also must be capable of changing
length while transmitting torque. The axle rides sus
pended by springs i n a floating motion. This means
the propeller shaft must change operating angles and
contract or expand. This is accomplished through
universal joints and slip joints (or yokes). The TYPE 2 TYPE 1
U-joints permit the propeller shaft to operate at dif ~ J9416-2
ferent angles. The slip joints (or yokes) permit the Fig. 1 Center Bearing
shaft to contract or expand.
Tubular propeller shafts are balanced by the man UNIVERSAL JOINTS
ufacturer with weights spot welded to the tube. The front prop shaft uses a 7290 series universal
The propeller shaft is designed and built with the joints. The rear prop shaft uses a 7290 series univer
yoke lugs in line with each other. This is called phas sal joint with a 9 1/4 axle. A 1410 series universal
joint is used with the Dana 60, 70 and 80 rear axles.
ing. This design produces the smoothest running con
Shaft with 7290 series universal joints use external
dition. An out of phase shaft can cause a vibration.
snap rings. Shafts with 1410 series universal joints
Before undercoating a vehicle, the propeller
use internal snap rings.
shaft and the U-joints should be covered. This
will prevent the undercoating from causing an
unbalanced condition and vibration.
CAUTION: U s e exact replacement hardware for at

taching the propeller shafts. Exact replacement will
ensure safe operation. The specified torque must
always be applied when tightening the fasteners.
CENTER BEARINGS
The two-piece propeller shaft uses two types of cen
ter bearings. Type 1 is used with the 9 1/4 axle. Type
2 is used with the Dana axles (Fig. 1). Both types are
mounted i n the same location.
16 - 2 PROPELLER SHAFTS •
FLANGE
YOKE J9416-4
Fig. 3 Double Cardan Universal Joint (Typical)

LUBRICATION
RETAINER J9416-11
All U-joints should be inspected for leakage and
Fig. 2 Single Cardan Universal Joint (Typical) damage each time the vehicle is serviced. If seal
leakage or damage exists, the U-joint should be re
Two different types of universal joints systems are placed.
used:
• Single cardan universal joint (Fig. 2)
• Double cardan universal joint (Fig. 3)
• PROPELLER SHAFTS 16-3
SERWICE DIAGNOSIS/PROCEDURES
INDEX
page page
Precautions . 3 Universal Joint Angle Measurement 4
Runout 4 Vibration 3
Unbalance 3
PRECAUTIONS Driveline vibration can also result from loose or

Propeller shafts are balanced by the manufacturer damaged engine mounts. Refer to Group 21, Trans
to prevent vibration. Before undercoating a vehicle, missions for additional information.
the propeller shaft and the U-joints should be cov Propeller shaft vibration will increase as the vehi
ered. This will prevent the undercoating from caus cle speed is increased. A vibration that occurs within
ing an unbalanced condition and vibration. a specific speed range is n o t caused by propeller
Aluminum graphite propeller shaft should be in shaft unbalance. Defective U-joints or an incorrect
spected. The graphite must be securely attached to propeller shaft angle are usually the cause.
the aluminum tubing. I f there is any relative move
ment between the two materials the assembly must UNBALANCE
be replaced. I f propeller shaft unbalance is suspected, i t can be
Use exact replacement hardware for attaching the verified with the following procedure.
propeller shafts. The specified torque must always be Removing a n d re-indexing the p r o p e l l e r shaft
applied when tightening the fasteners. 180° may e l i m i n a t e some v i b r a t i o n s .
VIBRATION (2) Clean all foreign material from propeller shaft
Tires that are out-of-round or wheels that are un and U-joints.
balanced will cause a low frequency vibration. Refer (3) Inspect propeller shaft for missing balance
to Group 2 2 , Tires And Wheels for service informa weights, broken welds, and bent areas. I f the pro
tion. peller shaft is bent, i t must be replaced.
Brake drums that are unbalanced will cause harsh, (4) Ensure the U-joints are not worn and are prop
low frequency vibration. Refer to Group 5, Brakes for erly installed.
service information. (5) Check the U-joint clamp screws torque.
DRIVELINE VIBRATION
D r i v e Condition Possible C a u s e Correction
PROPELLER SHAFT a. Undercoating or other foreign material a. Clean exterior of shaft and wash with
on shaft. solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or excessive c. Install replacement yoke.
runout.
d. Incorrect drive line angularity. d. Correct angularity
e. Rear spring center bolt not in seat. e. Loosen spring U-bolts and seat center
bolts.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent tube) or g. Install replacement propeller shaft.
out of balance.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced i. Reindex propeller shaft 180°, test and
condition. correct as necessary.
j. Excessive drive pinion gear shaft yoke j. Reindex propeller shaft 180° and
runout. evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified torque.
b. Lack of lubrication. b. Replace U-joint.
J9216-7
16-4 PROPELLER SHAFTS •
(6) Remove wheels and tires. Install wheel lug
nuts to retain brake drums i n place.
(7) Mark and number the shaft at four positions
90° apart, six inches from the yoke weld end.
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration oc
curred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 1).
RF489
Fig. 3 Clamp Screws Separated

the lowest level. Bend the slack end of the clamps so
the screws will not loosen.
(15) Install the wheel and tire. Remove supports
and lower the vehicle.
(16) I f the vibration remains unacceptable, apply
the procedures at the front end of propeller shaft.
Fig. 1 Clamp Screw At Position 1 RUNOUT

(1) Remove dirt, rust, paint, and undercoating
(10) Start the engine and re-check for vibration. I f
from the propeller shaft surface. Areas where the dial
there is little or no change i n vibration, move the
indicator will contact the shaft must be clean.
clamp to one of the other three positions. Repeat the
(2) The dial indicator must be installed perpendic
vibration test. ular to the shaft surface.
(11) I f there is no difference, the vibration may not (3) Measure runout at the center and ends.
be caused by propeller shaft unbalance. (4) Refer to Runout Specifications chart.
(12) I f the vibration decreased, install a second (5) Replace the propeller shaft i f the runout ex
clamp (Fig. 2) and repeat the vibration test. ceeds the limit.
RUNOUT SPECIFICATIONS
Front of shaft 0.03 in. (0.76 mm)

Center of shaft 0.035 in. (0.89 mm)
Rear of shaft 0.03 in. (0.76 mm)
NOTE: Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the shaft tube for
tube lengths over 30 inches. Under 30 inches the max. runout
is 0.03 inch for full length of the tube.
J9416-15
UNIVERSAL JOINT ANGLE MEASUREMENT

RF483
INFORMATION
Fig. 2 Two Clamp Screws At The Same Position
When two shafts intersect, the bend that is formed
(13) I f vibration increased, separate the clamp is called the working angle. The larger the angle, the
screws (1/4 inch above and 1/4 inch below the mark). larger the amount of acceleration and deceleration of
Repeat the vibration test (Fig. 3). the joint. This speeding up and slowing down of the
(14) Increase distance between the clamp screws. joint must be cancelled. This will produce a smooth
Repeat the test until the amount of vibration is at power flow. This is done through phasing and proper
universal joint working angles.
A propeller shaft is properly phased when the yoke (2) Place Inclinometer on yoke bearing (A) parallel
ends are on the same plane or i n line. A twisted shaft to the shaft (Fig. 5). Center bubble i n sight glass and
will throw the yokes out of phase and cause a notice record measurement.
able vibration. This measurement will give you the transmis
When taking universal joint angle measurements sion or O U T P U T Y O K E A N G L E (A).
or checking phasing with two piece shafts, consider
each shaft separately.
Ideally the driveline system should have:
• Angles that are in equal or opposite within 1
degree of each other
• Have a 3 degree maximum operating angle
• Have at least a 1/2 degree continuous operat
ing (propeller shaft) angle
Engine R.P.M. is the main factor i n determining
maximum allowable operating angles. As a guide to
maximum normal operating angles refer to the chart
(Fig. 4).
PROPELLER SHAFT MAX. NORMAL

it.PÎVt. OPERATING ANGLES
5000 3°
4500 3°
4000 4°
3500 5°
3000 5°
2500 7°
2000 8°
Fig. 5 Front (Output) Angle Measurement (A)
1500 11°
J9316-4 (3) Rotate propeller shaft 90 degrees. Place Incli
nometer on yoke bearing parallel to the shaft (Fig. 6).
Fig. 4 Maximum Angles and R.P.M. Center bubble i n sight glass and record measure
INSPECTION
ment. This measurement can also be taken at the
Before measuring universal joint angles, the rear end of the shaft.
following must done. This measurement will give y o u the PROPEL
• Inflate all tires to correct pressure. L E R SHAFT A N G L E (C).
• Check angles in the same loaded or unloaded
condition as when the vibration occurred. Prop
shaft angles will change according to the
amount of load in the vehicle. Always check an
gles in loaded and unloaded conditions.
• Check the condition of all suspension components.
Verify all fasteners are torqued to specifications.
• Check the condition of the engine and transmis
sion mounts. Verify all fasteners are torqued to spec
ifications.
MEASUREMENT ONE—PIECE SHAFT

To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
universal joint so protractor base sits flat.
(1) Rotate the shaft until transmission/transfer J9216-9
case output yoke bearing is facing downward.
Always make measurements from front to Fig. 6 Propeller Shaft Angle Measurement (C)
rear.
18 - 6 PROPELLER SHAFTS •
This measurement will give you the pinion
shaft or I N P U T Y O K E A N G L E (B).
(6) Subtract smaller figure from larger (C minus
B) to obtain axle INPUT OPERATING ANGLE.
Refer to rules given below and the example in (Fig.
8) for additional information.
• Good cancellation of u-joint operating angles (with
in 1°)
• Operating angles less than 3°
• At least 1/2 of one degree continuous operating
(propeller shaft) angle
MEASUREMENT TWO-PIECE SHAFT

A rear propeller shaft U-joint angle can be easily
PINION YOKE
BEARING CAP measured with Special Tool 7663.
The front half-shaft must be parallel to the rear
axle pinion gear shaft. The front and rear half-shafts
SPECIAL must be offset by a minimum of 1/2 of a degree. From
TOOL the transmission/transfer case output shaft and from
7663
(J-23498A) J9216-12 each other.
To accurately check driveline alignment, raise and
Fig. 7 Rear (Input) Angle Measurement (B) support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
(4) Subtract smaller figure from larger (C minus A)
any external bearing snap rings (if equipped) from
to obtain transmission OUTPUT OPERATING AN universal joint so protractor base sits flat.
GLE. (1) Rotate the shaft until transmission/transfer
(5) Rotate propeller shaft 90 degrees. Place Incli case output yoke bearing is facing downward.
nometer on pinion yoke bearing parallel to the shaft (2) Place Inclinometer on yoke bearing (A) parallel
(Fig. 7). Center bubble in sight glass and record mea to the shaft (Fig. 9). Center bubble in sight glass and
surement. record measurement.
Horizontal Level
C
(A) Output Yoke = 3.0° f 4.9° (B) Axle Input Yoke = 3.2 4.9
(C) Prop. Shaft or
(C) Prop. Shaft = 4.9° Or
-3.0 o
= 4.9° -3.2°
Transmission Output 1.9° Axle Input 1.7°
Operating Angle Operating Angle
Trans. Output Operating Angle 1.9°

Axle Input Operating Angle -1.7°
C
Amount of U-Jdint Cancellation 0.2
J9316-3
Fig. 8 Universal Joint Angle Example

J9016-26
Fig. 9 Universal Joint \gle Two—Piece Shaft

(3) Repeat measurement procedure on bearing cap ADJUSTMENT AT CENTER BEARING WITH
B and C. Record these measurements. TWO-PIECE SHAFT
(4) Excessive variation in measurement angles of Drive away shudder is the vibration that occurs at
A, B or C indicate propeller mis-alignment. Vertical first acceleration from a stop. Shudder vibration usu
alignment of a two-piece shaft at the yokes ally peaks at the engines highest torque output.
Shudder is a symptom associated on vehicles using a
should be greater than one-half degree and as
two-piece prop shaft. To decreased shudder lowering
close to one degree as possible.
the center bearing in 1/8 inch increments. Use shim
stock or fabricated plates (Fig. 11). Plate stock must
ADJUSTMENT AT AXLE WITH LEAF SPRINGS
be used to maintain compression of the rubber insu
Adjust the pinion shaft angle at the springs with lator around the bearing. Do not use washers. Re
tapered shims (Fig. 10). Install tapered shims be place the original bolts with the appropriate
tween the springs and axle pad to correct the angle. increased length bolts.
Refer to Group 3, Rear Suspension and Axle for ad
ditional information.
Fig. 10 Adjustment at Leaf Springs (Typical)
J9316-25
Fig. 11 Angle Adjustment at Center Bearing

16-8 PROPELLER SHAFTS •
PROPELLER SHAFT REPLACEMENT
PRECAUTIONS TRANSFER
Use exact replacement hardware for attaching the
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be ap
plied when tightening the fasteners.
Mark the propeller shaft yoke and axle or trans
mission yoke before service (Fig. 1). This will assure
correct phasing and eliminate possible vibration.
REFERENCE MARKS
STRAP
SLIP YOKE AXLE

BOOT YOKE J9416-1
Fig. 2 Front Propeller Shaft

J9316-2
Replacement U-joint straps and bolts must be
Fig. 1 Reference Marks on Yokes installed.
CAUTION: Do not allow the propeller shaft to drop (2) Tighten the U-joint strap bolts at the pinion
or hang from either universal joint during removal. shaft to 19 N-m (14 ft. lbs.) torque.
Attach it to the vehicle underside with wire to pre Tighten the transfer case bolts to 88 N-m (65 ft.
vent damage to the universal joints. lbs.) torque.
(3) Install skid plates (if equipped), refer to Group
13, Frames. Remove support and lower the vehicle.
CAUTION: Protect the machined, external surface of
the slip yoke from damage after propeller shaft re REAR PROPELLER SHAFT
moval. If damaged, the transmission extension seal
could be damaged. REMOVAL
(1) Shift the transmission and transfer case (if ap
FRONT PROPELLER SHAFT plicable) to their Neutral positions. Raise and sup
port vehicle.
REMOVAL (2) Scribe alignment marks on the pinion yoke.
(1) Shift the transmission and transfer case to their (3) Remove the U-joint strap bolts at pinion shaft
neutral positions. Raise and support vehicle. Remove yoke.
skid plates (if equipped), refer to Group 13 Frames. (4) Slide the slip yoke off of the transmission/
(2) Scribe alignment mark on transfer case and transfer case output shaft and remove the propeller
propeller shaft flanges. Scribe mark on pinion shaft shaft (Fig. 3).
yoke and propeller shaft. These marks will be used
for installation reference (Fig. 2). INSTALLATION
(3) Remove the U-joint strap bolts at the pinion (1) Slide the slip yoke on the transmission/transfer
shaft yoke. case output shaft. Align the installation reference
(4) Remove bolts from transfer case yoke flange marks at the axle yoke and install the propeller shaft
and remove the propeller shaft. (Fig. 3).
Replacement U-joint straps and bolts must be
INSTALLATION installed.
(1) Position the propeller shaft with the yoke refer (2) Tighten the U-joint strap bolts to;
ence marks aligned. Install the propeller shaft (Fig. • Dana Axle: 29 N-m (22 ft. lbs.) torque.
2). • 9 1/4 Axle: 19 N-m (14 ft. lbs.) torque.
f ^ ^ . _ ^ ^ _ . PROPELLER SHAFTS 16 - I
SLIDING (5) Slide the slip yoke off transmission output

shaft and remove the propeller shaft.
INSTALLATION
(1) Slide the slip yoke on transmission output
shaft. Align the installation reference marks at the
axle yoke.
(2) Align and install the center bearing to the sup
port bracket. Install the bolts and tighten to 68 N-m
Replacement U - j o i n t straps a n d bolts must be
installed.
(3) Tighten the U-joint strap bolts to;
• Dana Axle: 29 N-m (22 ft. lbs.) torque.
• 9 1/4 Axle: 19 N-m (14 ft. lbs.) torque.
CENTER BEARING SERVICE

SCREW Vehicles equipped with a two-piece rear propeller
19 N-m shaft have a rubber insulated center bearing. The
(14 ft-lbs). CLAMP J9216-6 bearing supports the shafts where they join together.
Thh two-piece propeller shaft uses two types of center
Fig. 3 Rear Propeller Shaft bearings. Type 1 is used with the 9 1/4 axle. Type 2
(3) Remove support and lower the vehicle. is used with the Dana axles. Both types are mounted
in the same location and service the same.
REAR—TWO PIECE PROPELLER SHAFT
The two piece shaft has a center bearing which sup REMOVAL
ports the shafts where they are joined together (Fig. 4). (1) Remove rear two-piece shaft. Refer to two-piece
removal.
REMOVAL (2) Remove slip joint boot clamp and separate the
(1) Shift the transmission/transfer case to their two shafts. The slip joints are master splined.
Neutral positions. Raise and support vehicle. (3) Use hammer and punch to tap slinger away
(2) Scribe alignment marks on the pinion yoke. from shaft to provide room for bearing splitter.
(3) Remove the universal joint strap bolts at the (4) Position Bearing Splitter Tool 1130 between
pinion shaft yoke. slinger and shaft.
(4) Scribe alignment marks on the frame crossmem
ber for center bearing reference. Remove bolts that at C a u t i o n : Do not damage shaft s p l i n e d u r i n g re
tach the center bearing to the support bracket (Fig. 4). m o v a l of center bearing.
(5) Set shaft in press and press bearing off the shaft.
INSTALLATION
(1) Install new slinger on shaft and drive into po
sition with 2 1/2 in. I.D. pipe for type 1 center bear
ing. For type 2 center bearing use 2 1/4 in. I.D. pipe
to install slinger.
(2) Install new center bearing on shaft' with Bear
ing Installer Tool 6052. Drive on shaft with hammer
until bearing is seated.
(3) Clean shaft splines and apply a coat of multi
purpose grease.
(4) Align master splines and slide front and rear
shafts together. Reposition slip yoke boot and install
TYPE 2 TYPE 1 new clamp.
J9416-2
(5) Install two-piece shaft in vehicle. Refer to in
Fig. 4 Center Bearing stallation two-piece shaft.
1 i - 10 PROPELLER SHAFTS •
UNIVERSAL J O I N T REPLACEMENT
PRECAUTIONS
Shaft with 7290 series universal joints use internal
snap rings. Shafts with 1410 series universal joints
use external snap rings.
Always make reference marks on the yokes before
removal or component service (Fig. 1). This will en
sure correct phasing.
REFERENCE MARKS
J9316-19
Fig. 2 External Snap Ring
J9316-2
Fig. 1 Reference Marks on Yokes
SINGLE CARDAN U-JOINT
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
I f worn or leaking, they must be replaced as a unit.
The joints may have either inside or outside snap
rings. Some will use both types.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement i n this group.
(2) Paint or score alignment marks on the yokes
for installation reference.
(3) Using a soft drift, tap the outside of the bear
ing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke (Fig.
2).
J9316-21
(5) Set the yoke i n an arbor press or vise with a
large socket beneath i t . Place a smaller socket on the Fig. 3 Press Out Bearing
upper bearing assembly and press i t through to re
CAUTION: If the c r o s s or bearing assembly are
lease the lower bearing assembly (Fig. 3).
cocked when being pressed, the bearing assembly
(6) I f the bearing assembly will not pull out by
will s c o r e the walls of the yoke bore and ruin the
hand after pressing, tap the base of the lug near i t to
yoke.
dislodge.
(7) To remove the opposite bearing, turn the yoke
over and straighten the cross i n the open hole. Then CLEANING AND INSPECTION
carefully press the end of the cross until the remain (1) Clean all the universal joint yoke bores with
ing bearing can be removed (Fig. 4). cleaning solvent and a wire brush.
worn bearing assembly bores.
BEARING
J9316-24
Fig. 4 Press Out Remaining Bearing Fig. 6 install Bearing

ASSEMBLY/INSTALLATION (4) Press the bearing assembly into the cross hole
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 enough to install snap ring. Install a internal snap
or 2 grease to aid i n installation. ring on 7290 series or external snap ring on 1410 se
(2) Position the cross i n the yoke (Fig. 5). ries universal joint.
(5) Repeat steps 3 and 4 to install the opposite
CROSS bearing assembly. I f the joint is stiff, strike the yoke
with a soft hammer to seat the needle bearings. In
stall a snap ring.
(6) Install the propeller shaft. Refer to Propeller
Shaft Replacement i n this group.
DOUBLE CARDAN U-JOINT

REMOVAL/DISASSEMBLY
Double cardan universal joints are not serviceable.
I f worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Front Pro
peller Shaft Removal.
(2) Paint or score alignment marks on the yoke
flange, link yoke and propeller shaft yoke for instal
lation reference.
(3) Remove all external snap rings (Fig. 7).
(4) Press bearing assembly out of the flange yoke,
enough to grasp the bearing with vise jaws (Fig. 8).
(5) Grasp the protruding bearing with vise jaws.
J9416-13 Tap the flange yoke with a plastic hammer to remove
the bearing (Fig. 9).
Fig. 5 Install Cross In Yoke
(3) Place a bearing assembly over the trunnion and CAUTION: Do not strike bearing holes, this may
align i t with the cross hole (Fig. 6). Keep the needle damage s n a p ring grooves.
bearings upright i n the bearing assembly. A needle
(6) Repeat steps 4 and 5 to remove the opposite
roller lying at the bottom will prevent proper assem side bearing.
bly. (7) Press bearing assembly out of the link yoke
and remove bearings as described above.
16 - 12 PROPELLER SHAFTS

(1) Clean all the U-joint yoke bores with cleaning
SNAP RING solvent and a wire brush.
worn bearing assembly bores.
(3) Inspect the centering ball, spring and bearing
for wear.
(4) Inspect the centering ball boot for tears or
cracks.
ASSEMBLY/INSTALLATION
During installation, ensure that all yokes are
aligned to the reference marks.
(1) Fit a cross into propeller shaft yoke.
J9416-5 (2) Press bearings into propeller shaft yoke and in
stall snap rings. Keep the needle bearings upright i n
Fig, 7 Remove Snap Rings
the bearing assembly (Fig. 10). A needle roller lying
at the bottom will prevent proper installation.
PRESS
•S3 PROPELLER SHAFT
YOKE
BEARING
J9416-8
Fig. 8 Press Out Bearing
Fig. 10 Press In Bearings Assembly
(3) Press bearings into link yoke at propeller shaft
end (Fig. 11). Install snap rings.
FLANGE
YOKE UNK
YOKE
PROPELLER SHAFT
YOKE
J9416-7
Fig. 9 Remove Bearing From Yoke

(8) Remove flange yoke from link yoke.
J9416-9
(9) Press remaining bearings out of link yoke and
propeller shaft yoke. Fig. 11 Press In Bearings Assembly
(4) Install spring i n centering ball. Install cross
into link yoke and flange yoke.
• PROPELLER SHAFTS 16 -
(5) Press bearings into link yoke and flange yoke

(Fig. 12). Install snap ring. FLANGE
(6) Verify all snap rings are seated into the YOKE
grooves.
(7) Install the propeller shaft. Refer to Propeller
Shaft Replacement in this group.
J9416-10
Fig. 12 Press In Bearings Assembly
P R O P E L L E R SHAFT AND U-JOINT
I Description | Torqu® H
Center Bearing to Support Bracket Bolts . . 68 N«m (50 ft. lbs.)

Center Bearing Bracket to Frame Bolts . . 68 N«m (50 ft. lbs.)
Double Cardan to Transfer Case
Flange Bolts 88 N*m (65 ft. lbs.)
Prop Shaft to Yoke Bolts . 19 N*m (14 ft. lbs.)
Prop Shaft to Yoke Bolts
(Dana Rear Axle) 30 N*m (22 ft. lbs.)
J9416-3
STEERING
• 19 - 1
STEERING
CONTENTS
page page
GENERAL INFORMATION 1 STEERING COLUMN 34

POWER STEERING PUMP 11 STEERING LINKAGE 17
POWER STEERING SYSTEM DIAGNOSIS 2 TORQUE SPECIFICATIONS 39
RECIRCULATING BALL POWER STEERING
GEAR 19
STEERING SYSTEM COMPONENTS toe and steering wheel alignment. For additional
Dodge Trucks use a power assisted recirculating- wheel alignment information refer to Group 2, Front
ball type steering gear (Fig. 1). The gear is used with Suspension.
four wheel drive and two wheel drive vehicles.
RECIRCULATINGBALL POWER STEERING
Power steering systems use;
GEARS
• Steering gear
The recirculating ball system acts as a rolling
• Steering linkage
thread between the worm shaft and rack piston. The
• Pressure and return fluid hoses and fittings
worm shaft is supported by a thrust bearing at the
• Belt driven hydraulic steering pump with fluid res
lower end and a bearing assembly at the upper end.
ervoir
When the worm shaft is turned the rack piston
moves. The rack piston teeth mesh with the pitman
(sector) shaft. Turning the worm shaft turns the pit
man shaft, which turns the steering linkage.
Two different type steering gears are used, variable
ratio and fixed ratio. The fixed ratio is used on all
Dodge Ram Trucks 8,800 lbs. GVW to 11,000 lbs.
GVW. The variable ratio gear is used on 6,010 lbs.
GVW to 7,500 lbs. GVW trucks. The steering gears
can be adjusted and internally serviced.
An identification code H F on the upper adjustment
cover designates 13-16:1 variable ratio. The identifi
cation code BN designates 17.5:1 fixed ratio.
POWER STEERING PUMP
The Saginaw P-Series pump (Fig. 1) is used on
Dodge Ram Truck vehicles.
Hydraulic pressure is provided by a belt driven
power steering pump. The power steering pump is a
constant flow rate and displacement, vane-type
pump. The internal parts that are inside the housing
J9219-65 operate submerged in fluid. The flow control orifice is
part of the pressure line union. The pressure relief
Fig. 1 Power Steering Systems valve inside the flow control valve limits the pump
The 4X2 steering linkage consists of a pitman arm, pressure.
idler arm, tie rods, and center link. The 4X4 steering The power steering pump is connected to the steer
linkage consists of pitman arm, drag link and tie ing gear via the pressure hose and the return hose.
rods. Adjustment sleeves are used on the tie rods for The pump shaft has a pressed-on pulley that is belt
driven by the crankshaft pulley.
19 - 2 STEERING •
Trailer tow option vehicles are equipped with a STEERING COLUMNS
power steering pump oil cooler. The oil cooler is Two steering columns are used on Dodge Ram
mounted to the left front side of the radiator closure Truck vehicles. A fixed or non-tilt column and a tilt
panel. column. Both types have anti-theft provisions. When
The power steering pump on the D O D G E T U R B O in the LOCK position, the ignition switch and steer
D I E S E L engine is bolted onto the rear of the vac ing shaft cannot be operated. The lock mechanism
uum pump. The pump is driven by the accessory also prevents operation of the automatic transmis
drive through a common shaft. sion gear shift lever. Both columns are energy-ab
Dodge R a m Truck power steering pumps are sorbing (collapse from impact in the event of a front-
not interchangeable with pumps installed i n end collision).
other vehicles.
POWER STEERING SYSTEM DIAGNOSIS
PUMP PRESSURE TEST (7) Gauge should read below 862 kPa (125 psi). If
The following procedure is used to test the opera reading is above inspect hoses for restrictions and re
tion of the power steering system on the vehicle. pair as necessary. The initial pressure should be in
(1) Check belt tension and adjust as necessary. the range of 345-552 kPa (50-80 psi).
(2) Disconnect high pressure hose at gear or pump. CAUTION: The following test procedure involves
Use a container for dripping fluid. testing maximum pump pressure output and flow
(3) Connect Gauge C-3309-E to both hoses using control valve operation. Do not leave valve closed
adapter fitting (Fig. 1). Connect spare pressure hose for more than five s e c o n d s a s the pump could be
to gear or pump. damaged.
SPECIAL (8) Close valve fully three times and record highest
TOOL
C-3309E^ ^_ , pressure indicated each time. A l l three readings
must be above specifications and within 345
k P a (50 psi) of each other.
• Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
• Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
CAUTION: Do not force the pump to operate against

the stops for more than 2 to 4 s e c o n d s at a time be
c a u s e , pump damage will r e s u l t
1 Pressure Hose to Steering Gear
2 Shut-Off Vblve (9) Open the test valve, turn steering wheel ex
3 Pressure Hose From f\jmp J9219-44 treme left and right positions against the stops.
Record the highest indicated pressure at each posi
Fig. 1 Pressure Test Gauge tion. Compare readings to specifications. If highest
(4) Open the test valve completely. output pressures are not the same against either
(5) Start engine and warm up to operating temper stop, the gear is leaking internally and must be re
paired.
ature.
The steering pump relief pressure for all en
(6) Check fluid level, add fluid as necessary. gines is 1400 p.s.i. ± 50.
STEERING 19 • 3
PUMP LEAKAGE DIAGNOSIS
J9419-33
19-4 STEERING •
STEERING NOISES
There is some noise in oil power steering systems. One of the most common is a hissing sound evident at standstill parking.
Hiss is a high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve
and results from high velocity fluid passing valve orifice edges. There is no relationship between this noise and performance of
the steering. Hiss may be expected when steering wheel is at end of travel or when slowly turning at standstill.
OBJECTIONALHISSOR 1. Noisy valve in gear 1. Check for proper seal between

WHISTLE steering column coupling and
dash seal.
2. Ensure steering column lower
coupling has no metal-to-metal
contact within the coupling
by performing an electrical
continuity check. (Remove
coupling for check.)
3. If hiss is still extremely
objectionable, replace
steering gear.
RATTLE OR CLUNK 1. Gear loose on front crossmember. 1. Check gear-to-crossmember

mounting bolts. Tighten to
specification.
2. Crossmember-to-frame bolts or studs loose 2. Torque bolts and studs to
specifications.
3. Tie rod looseness (outer or inner) 3. Check tie rod pivot points for
wear. Replace if necessary.
4. Pressure hose touching other parts of vehicle 4. Adiust hose to proper position
by loosening, repositioning,
and retightening fitting.
Do not bend tubing.
5. Noise internal to gear 5. Replace gear.
CHIRP OR SQUEAL 1. Loose belt 1. Check tensioner at end of

(IN THE AREA OF PUMP) travel, replace belt
PARTICULARLY NOTICEABLE 9 M 8 w i || n n - M i 2. Check pulley alignment.
2 ulU
AT FULL WHEEL TRAVEL * M , s a l j
9 n e d
P »ys Move pulley inward or outward
AND DURING STANDSTILL 0.5 mm (0.020 in.)
PARKING
J9419-26
• STEERING 19-5
P O W E R S T E E R I N G SYSTEM DIAGNOSIS
P U M P 0ROWL
Pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be
objectionable. Abnormal situations, such as a low oil level causing aeration or hoses touching the vehicle oody, can create a noise
level that could bring complaints.
CONDITION P O S S I B L E CAUSE CORRECTION
WHINE OR GROWL 1. Low fluid level 1. Fill to proper level and perform leakage
(PUMP NOISE) diagnosis. (Recheck after system is free
of aeration.)
2. Hose touching vehicle body or frame 2. Reposition hose. Replace hose if tube
ends are bent.
3. Extreme wear of pump internal parts 3. Replace pump and flush system.
SUCKING AIR SOUND 1. Loose return line clamp 1. Tighten or replace clamp.
2. Inspect connection and replace o-ring as
2. Missing O-ring on hose connection required.
3. Fill to proper level and perform leakage
3. Low fluid level diagnosis.
4. Inspect and replace reservoir as required.
4. Air leak between reservoir and pump
SQUEAK OR RUB SOUND 1. Sound from steering column 1. Check for squeak in steering column.
Inspectforcontact between shroud
intermediate shaft, column, and wheel.
(Realign if necessary.)
2. Sound internal to steering gear 2. Replace gear.
SCRUBBING/KNOCKING 1. Incorrect tire size 1. Verify tire size is the same as originally
supplied.
2. Check clearance between tires and other
vehicle components, through full travel 2. Correct as necessary.
3. Checkforinterference between steering gear
and other components 3. Correct as necessary.
4. Incorrect gear supplied
4. Replace gear.
9119-3
19-6 STEERING •
B I N D S STICKS SEIZED
C A T C H E S , STICKS IN 1. Low fluid level 1 Fill to proper level and perform leakage
CERTAIN POSITIONS O R diagnosis.
DIFFICULT T O T U R N
2. Tires not properly inflate! 2. Inflate tires to proper pressure.
3. Lock of lube in ball joints 3. Lubricate where possible.
4. Lack of lube in outer tie rod ends 4. Lubricate where possible
5. Loose pump belt 5. Tighten or replace belt.
6. Faulty pumpflowcontrol (Verify cause 6. Replace pump.
using Pump Test Procedure)
7. Excessive friction in steering column or ' 7. Correct condition. (See Steering Column
intermediate shaft Service Procedure.)
8. Steering column coupling binding 8. Realign as necessary.
9. Excessive friction in gear 9. Replace gear.
SHAKE SHUDDER VIBRATION
V I B R A T I O N OF THE 1. Air in the power steering system 1. Check for leaks and bleed air
S T E E R I N G W H E E L AND/ from system.
OR D A S H DURING DRY
2. Tires not properly inflated 2. Inflate tires to proper pressure.
PARK OR LOW SPEED
STEERING MANEUVERS 3. Excessive engine vibration 3. Make sure that engine is running
properly.
4. Faulty accessory drive belt tensioner 4. Check dynamic belt tensioner for
(Poly-V belt systems only) abnormal vibration. (See Drive Belt
Adjustments.)
5. Overcharged air conditioner 5. Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis.)
J9419-34
• STEERING 19 - 7
L O W ASSIST, N O ASSIST, OR HARD STIIR1NO
STIFF, HARD TO TURN, 1. Tires not properly inflated 1. Inflate tires to proper pressure.
SURGES, MOMENTARY 2. Low fluid level 2. Add power steering fluid as required and
INCREASE IN EFFORT perform leakage diagnosis.
WHEN TURNING
3. Loose belt 3. Tighten or replace belt.
4. Lack of ball joint lubrication 4. Lubricate or replace as required.
5. Low pressure pump (Verify using Pump Test 5. Verify cause using Pump Test Procedure.
Procedure) Replace pump if necessary.
6. High internal leak gear 6. Check steering system using test
procedure. If steering gear is at fault,
replace steering gear.
POOR RETURN TO CINTIR
CONDITION POSSIBLE CAUSI CORRECTION
STEERING WHEEL DOES 1. Tires not properly inflated 1. Inflate tires to proper pressure.
NOT WANT TO RETURN 2. Improper front wheel alignment 2. Check and adjust as necessary.
TO CENTER POSITION
3. Lack of lubrication in ball joint 3. Replace as required or lubricate.
4. Steering column U-joints misaligned 4. Realign steering column U-joints.
5. Mispositioned dash cover 5. Reposition dash cover.
To evaluate items 6 and 7, disconnect the
intermediate steering shaft. Turn the steering
wheel and listen for internal rubbing in
column.
6. Steering wheel rubbing 6. Adjust covers.
7. Tight steering shaft bearings 7. Replace bearings.
8. Excessive friction coupling universal joint 8. Replace U-joints.
9. High friction in the steering gear 9. Replace steering gear.
9119-5
19-8 STEERING •
LOOSE STEERING
CONDITION POSSIBLE CAUSE - CORRECTION
EXCESSIVE WHEEL 1. Air in system 1. Add fluid.

KICKBACK OR TOO 2. Gear loose on crossmember 2. Check gear to crossmember mounting
MUCH STEERING WHEEL bolts. Tighten to specification.
PLAY
3. Worn/broken intermediate shaft 3. Check for worn universal joint and broken
isolator. Replace intermediate shaft if
worn.
4. Free play in steering column 4. Check and replace as required.
5. Loose ball joints 5. Check and replace as required.
6. Front wheel bearings loose or worn 6. Tighten hub nut or replace with new parts
as necessary.
7. Loose outer tie rod ends 7. Check and replace as required.
8. Loose inner tie rod ends 8. Replace gear.
9. Defective steering gear rotary valve 9. Replace gear.
VEHICLE LEADS TO THE SIDE
WHEEL DOES NOT 1. Radial tire lead 1. Rotate tires as recommended in Tire
WANT TO RETURN TO Service.
CENTER POSITION 2. Front end misaligned 2. Align front end as recommended in
Wheel Alignment Service Procedure.
3. Wheel braking 3. Check for dragging brakes as directed in
Brake Service Procedure.
4. Unbalanced steering gear valve. (If this is the 4. Checking for pull with outer tie rod end
cause, the steering efforts will be very light in disconnected. If verified, replace gear.
direction of lead and heavier in the opposite
direction)
9119-6
• STEERING 19-9
FLUID L E A K
LOW FLUID LEVEL WITH: 1. Overfilled reservoir 1. Adjust fill level.

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

COVER BOLTS TO 61 N»m (45 FT. QUE THE HOSE FITTING NUT TO
LBS.). REPLACE THE SIDE COVER 31N«m (23 FT. LBS.). IF LEAKAGE
SEAL IF THE LEAKAGE PERSISTS. PERSISTS, REPLACE THE SEAL.
2. ADJUSTER PLUG SEAL - REPLACE 4. PITMAN SHAFT SEALS - REPLACE

THE ADJUSTER PLUG SEALS. THE SEALS.
5. TOP COVER SEAL - REPLACE THE

SEAL.
J9419-35
POWER STEERING PUMP
1N0EX
page page
Power Steering Hose 11 Pump Replacement—Gasoline Engine 14
Power Steering Pump—Initial Operation 16 Pump Reservoir 15
Pump Pulley 15 Service Information . . 11
Pump Replacement—Diesel Engine 12
SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. I f a malfunction or internal
fluid leak occurs, the complete unit must be replaced.
POWER STEERING HOSE

Max. cool, vehicles are equipped with a power
steering auxiliary fin oil cooler. The oil cooler is
mounted to the left front side of the radiator closure
panel Fig. 1).
Fig. 2 Power Steering Hose Diesel Engine
Fig. 1 Power Steering Cooler

Cap hose open ends and pump/steering gear fit
tings to prevent entry of foreign material.
WARNING: P O W E R S T E E R I N G FLUID (AND PUMP

COMPONENTS) AND T H E E X H A U S T S Y S T E M CAN
B E E X T R E M E L Y HOT IF T H E ENGINE HAS B E E N
R E C E N T L Y OPERATING. DO NOT START T H E E N
GINE WITH ANY L O O S E OR D I S C O N N E C T E D
H O S E S . DO NOT A L L O W T H E H O S E S TO TOUCH A
HOT E X H A U S T MANIFOLD OR T H E CATALYTIC
CONVERTER,
REMOWAL Fig. 3 Power Steering Hose Gas Engine

(1) Remove fasteners from hose retaining brackets (3) Disconnect pressure and return hose from the
at all locations. pump. Remove hoses from vehicle (Fig. 2, 3).
(2) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser INSTALLATION
voir (Fig. 2, 3). (1) Wipe hose ends, pump and gear unions clean.
19 - 12 STEERING •
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks. The
hose must be kept away from exhaust system
components. Do not distort hose tube ends by bend
ing, kinking or over tightening.
(3) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
(4) Tighten fittings at pump and gear to 31 N-m
(5) Install clamps on return hose on gear and
pump.
(6) After installation, inspect and test for fluid
leaks.
PUMP REPLACEMENT—DIESEL ENGINE

REMOWAL
(1) Place a drain pan under the power steering
pump.
(2) Disconnect and cap the vacuum and steering
pump hoses.
(3) Disconnect the electrical connector on the oil Fig. 5 Oil Feed Line Removal/Installation
pressure sender unit (Fig. 4). Remove sender unit
from engine block and plug hole i n block.
PUMP ENGINE BLOCK
Fig. 4 Oil Pressure Sending Unit Fig. 6 Pump Assembly Upper Bolt
(4) Disconnect and cap the oil feed line from the (8) Drain the fluid from the steering pump.
bottom of the vacuum pump (Fig. 5). (9) Remove the steering pump to vacuum pump
(5) Remove the lower bolt that attaches the vacu bracket attaching nuts (Fig. 8).
um/steering pump assembly to the engine block. Re (10) Slide the steering pump from the bracket. Use
move the nut from the steering pump attaching care not to damage the internal oil seal i n the vac
bracket (Fig. 5). uum pump (Fig. 9).
(6) Remove upper bolt from the pump assembly (11) Remove the two pump body spacers (Fig. 9),
(Fig. 6). Remove the assembly from the engine (Fig. for pump installation.
7).
(7) Remove the gasket from the mounting surfaces INSTALLATION
on engine block and pump assembly. (1) Install the two pump body spacers (Fig. 9).
• STEERING 19 - 13
PUMP BRACKET
SPACERS J9119-69
Fig. 9 Steering Pump Removal/Installation

Fig. 7 Pump Assembly Removal/Installation
PUMP
J9119-78
Fig. 10 Steering/Vacuum Pump Assembly
Fig. 8 Bracket Nut Removal/Installation
(4) Position new gasket on vacuum pump assem
(2) Rotate the drive gear until the steering pump
bly. Use sealer if necessary to retain the gasket.
and vacuum pump drive dogs align. Install the steer
(5) Align and install the pump assembly on the en
ing pump onto the vacuum pump bracket. Use care
gine. Ensure the steering pump stud is inserted into
to avoid damaging the oil seal in the vacuum pump
the block bracket. Tighten the pump-to-engine block
during installation. The steering pump housing
attaching bolts to 77 N-m (57 ft. lbs.) torque.
and spacers must mate completely with the
(6) Install the steering pump to attaching bracket
vacuum pump bracket (Fig. 10).
nut and tighten to 24 N-m (18 ft. lbs.) torque.
(3) Install the three (3) vacuum pump bracket to
(7) Remove plug and install the oil pressure send
steering pump nuts. Tighten to 24 N-m (18 Ft. lbs.)
ing unit and electrical connector.
torque.
19-14 STEERING •
(8) Install the oil feed line to the vacuum pump. (2) Clamp the fluid return hose and disconnect the
Tighten the oil line connection to 7 N-m (60 in. lbs./ 5 hoses from the power steering pump. Cap the fit
ft. lbs.) torque. tings.
(9) Install the fluid hoses to the power steering (3) Remove battery ground cable and nut at stud.
pump. Tighten the pressure fitting at the pump to 31 Unthread stud from cylinder head, do not remove
N-m (23 ft. lbs.) torque. from bracket. Loosen upper bracket bolt. Remove the
(10) Install and clamp the hose on the vacuum lower bracket to engine block bolts. Pivot the pump
pump. assembly past the coolant tube. Remove the upper
(11) Fill the reservoir with power steering fluid stud. Remove upper bolt from cylinder head. The
only. I f necessary, refer to Pump Initial Operation steering pump and mounting bracket will be removed
for detailed instructions. from engine as an assembly.
(12) Start and run the engine. Check the operation (4) Remove the pump pulley, refer to the procedure
of the brakes, i f necessary refer to Group 5, Brakes below. This will allow access to the pump attaching
for additional information. screws.
(5) Remove the pump bracket (Fig. 12). On 8.0L
PUMP REPLACEMENT—GASOLINE ENGINE engine remove rear pump bracket (Fig. 13).
REMOVAL
WARNING: DO NOT R E M O V E T H E WATER PUMP

COOLANT T U B E UNLESS THE COOLANT SYSTEM
HAS B E E N DEPRESSUR1ZED AND DRAINED.
WARNING: DO NOT ATTEMPT TO R E M O V E T H E

PUMP WITHOUT REMOVING T H E B E L T FIRST. T H E
AUTOMATIC T E N S I O N E R IS UNDER A HIGH
SPRING LOAD.
(1) Remove the serpentine drive belt. Rotate ten

sioner clock-wise and hold i n place, and remove belt
(Fig. 11). O n 5.9L H . D . and 8.0L engines rotate
tensioner counter clock-wise.
Fig. 12 Pump Mounting 3.9L, 5.2L and 5.9L

INSTALLATION
(1) Install the bracket to pump (Fig. 12). Tighten
bolts to 47 N-m (35 ft. lbs.). On 8.0L engine install
rear pump bracket (Fig. 13). Tighten nut to 47 N-m
(35 ft. lbs.). Tighten bolts to 24 N-m (18 ft. lbs.).
(2) Install the pump pulley, refer to the procedure
below.
(3) Position the steering pump (with pulley) and
mounting bracket on the engine block. Install the up
per stud and bolt i n bracket. Pivot the pump down
past the coolant tube. Install the lower bolts i n
bracket (Fig. 12).
(4) Install bracket and pump assembly to engine
block. Tighten the bolts and nut to 41 N-m (30 ft.
lbs.).
(5) Connect the fluid hoses to the pump.
Fig. 11 Belt Removal 3.9L, 5.2L and 5.9L Light Duty (6) Install the serpentine drive belt. Rotate ten
sioner clock-wise and hold i n place, slip the belt over
• STEERING 19 - 1§
FRONT BRACKET HUB SPECIAL

TOOL
C-4333
REAR
BRACKET
STEERING
PUMP
FRONT OF ENGINE
PULLEY PULLEY © J9219-83
Fig. 13 Pump Mounting 8.0L Fig. 14 Pulley Removal (Typical)
the pulleys. Refer to Group 7, Cooling for belt rout HUB

ing. On 5.9L H D . a n d 8.0L r o t a t e tensioner
counter clock-wise.
CAUTION: Do not use automatic transmission fluid

to fill t h e reservoir.
(7) Fill the reservoir with power steering fluid only.

If necessary, refer to P u m p i n i t i a l Operation for
detailed instructions.
PUMP PULLEY
REMOVAL
(1) Remove the pulley with Puller C-4333 (Fig. 14),
Do n o t hammer o n p u l l e y because this w i l l
damage i t and the p u m p .
(2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install the pulley with Installer C-4063A (Fig. PULLEY J9219-84
15). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain Fig. 15 Pulley Installation (Typical)
aligned with the pump shaft. Prevent the pulley from PUMP RESERVOIR
being cocked on the shaft.
(3) Force pulley flush with the end of the shaft. REMOWAL
With Serpentine Belts; Run engine until warm (5 Discard a l l O-ring seals d u r i n g disassembly,
min.) and note any belt chirp. I f chirp exists, move they are n o t re-usable.
pulley outward approximately 0.5 mm (0.020 in.). I f (1) Remove the filler cap and drain the fluid from
noise is increases, press on 1.0 mm (0.040 in.). Be reservoir before removing parts.
careful t h a t p u l l e y does not contact m o u n t i n g (2) Remove mounting studs and pressure fitting
bolts. (Fig. 16). Rock reservoir by hand or use a soft face
mallet to remove.
19 - 16 STEERING
CAP
EXPANSION PLUG - DO NOT REMOVE; RESERVOIR

IF DEFORMED OR DISLODGED,
REPLACE PUMP
FITTING
SEALS 75N*m
(55 FT. LBS.)
J9419-32
Fig. 16 Pump and Reservoir
(3) Remove O-ring seals from housing and reser (2) Install new O-ring seals in housing (Fig. 17).
voir. Tighten mounting studs to 48 N-m (35 ft. lbs.) torque.
(4) Remove flow control valve and spring from (3) Install fitting in flow control valve bore.
housing. Tighten the fitting to 75 N-m (55 ft. lbs.) torque.
INSTALLATION POWER STEERING PUMP—INITIAL OPERATION

Clean all parts before installation. Lubricate Follow this procedure to remove air from the sys
new O-ring seals with M O P A R ® Power Steering tem.
F l u i d or an equivalent product.
(1) Install flow control valve and spring (Fig. 17). CAUTION: The fluid level should be checked with en
gine off to prevent injury from moving components.
VALVE AND
SPRING Use only MOPAR® Power Steering Fluid. Do not use
automatic transmission fluid. Do not overfill.
Wipe filler cap clean, then check the fluid level.

The dipstick should indicate F U L L COLD when the
fluid is at normal temperature.
(1) Raise front wheels off the ground and turn
steering wheel full left.
(2) Fill the pump fluid reservoir to the F U L L
COLD level.
(3) With engine off turn the steering wheel lock-to-
lock 20 times.
(4) Check fluid level and check for bubbles in fluid.
If bubbles are found check all connections and repeat
step 3.
(5) Lower front wheels and start the engine. Let
engine run for two minutes.
(6) Turn the steering wheel slowly from lock-to-
lock several times.
J8919-101 (7) Stop the engine. Check the fluid level and refill
Fig. 17 Flow Control Valve/Spring Installation
as required.
(8) If fluid is foamy, allow vehicle to stand a few
minutes and repeat the above procedure.
STEERING LINKAGE
SERVICE INFORMATION
The tie-rod end ball stud seals should be inspected
during all oil changes.
Check for ball stud wear, corrosion or damaged
seal. If these conditions exist, replace the tie-rod. Lu
bricate the tie-rod end with MOPAR® Multi-Mileage
Lubricant, or equivalent.
STEERING LINKAGE—IFS SUSPENSION

Heavy duty steering linkage will be use on 8,800
and 10,500 GVW vehicles. The 10,500 GVW steering
linkage will have a steering damper mounted from a LINK
frame bracket to the centerlink.
Torque specification are the same for standard or J9419-37
heavy duty linkage.
Use Puller tool for tie rod removal. Failure to Fig. 2 Steering Linkage—IFS Vehicles
use this tool could damage the tie rod and seal
(Fig. 1). (7) Mark the pitman arm and shaft positions for
reference. Remove pitman arm with Puller C-4150A
(Fig. 3).
Fig. 1 Tie Rod Removal

REMOVAL Fig. 3 Pitman Arm Removal
(1) Remove the cotter pin and nut from the tie-rod. INSTALLATION
(2) Remove the tie-rod end ball studs from steering Replace all damaged or worn steering linkage com
knuckle arms (Fig. 1 and 2). ponents.
Use care to avoid damaging the seals.
(1) Position idler arm on the frame side rail. In
(3) Remove inner tie-rod ends from center link
stall stud plate and tighten nuts to 108 N-m (80 ft.
(Fig. 2).
lbs.) torque.
(4) If equipped remove steering damper from cen
ter link and frame bracket. (2) Center steering gear to alignment marks and
(5) Remove idler arm ball stud from center link. install pitman arm.
Remove idler arm stud plate from frame side rail (3) Install the lock washer and retaining nut on
(Fig. 2). the pitman shaft. Tighten the nut to 251 N-m (185 ft.
(6) Remove pitman arm ball stud from center link. lbs.) torque.
(4) Install center link to ball studs (Fig. 2). Install (3) Mark the pitman arm and shaft positions for
and tighten retaining nuts to 88 N-m (65 ft. lbs.) reference. Remove the nut and washer from the pit
torque. Install new cotter pins. man arm. Remove the pitman arm with Puller
(5) Install tie-rod ends into center link (Fig. 2). C-4150A (Fig. 5).
Tighten the nuts to 88 N-m (65 ft. lbs.) torque. Install
new cotter pins.
(6) Install steering damper to frame bracket and
center link if equipped. Tighten nuts to 68 N-m (50
ft. lbs.) torque. Install new cotter pins.
(7) Insert tie-rod ends into steering knuckle arm
(Fig. 2). Tighten the nuts to 88 N-m (65 ft. lbs.)
torque. Install new cotter pins.
(8) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to
the Alignment Specifications chart within Group 2,
Front Suspension).
SPECIAL TOOL
Position the clamp on the sleeve so retaining C4150A
bolt is located on the bottom side of the sleeve.
(9) After adjustment, tighten the tie-rod adjust
ment sleeve clamp bolt to 54 N-m (40 ft. lbs.) torque.
STEERING LINKAGE—LINK/COIL SUSPENSION

Use Puller C-4150A to remove drag link steer
J9419-23
ing damper or pitman arm (Fig. 5). Use Puller
tool to remove tie rod ends (Fig. 1). Failure to Fig. 5 Pitman Arm Removal
use these tools could cause damage to the seals.
(4) Remove tie rod from steering knuckle.
REMOVAL
INSTALLATION
(1) Remove tie rod and steering damper from drag
Replace all damaged or worn steering linkage com
link.
ponents.
(2) Remove drag link tie-rod end from steering (1) Center steering gear to alignment marks and
knuckle and pitman arm (Fig. 4). install pitman arm.
STEERING STEERING (2) Install the lock washer and retaining nut on
DAMPER GEAR the pitman shaft. Tighten the nut to 251 N-m (185 ft.
lbs.) torque.
DRAG LINK (3) Install drag-link ball studs to steering knuckle
and pitman arm. Install the retaining nuts and
PITMAN tighten to 88 N-m (65 ft. lbs.) torque. Install new cot
ARM
ter pins.
(4) Install tie-rod on steering knuckle and drag-
link. Tighten the nuts to 88 N-m (65 ft. lbs.) torque.
Install new cotter pins.
(5) Install steering damper on drag-link and
(6) Remove the supports and lower the vehicle to
TIE ROD TIE ROD the surface. Adjust the wheel toe position (refer to
END
J9419-24
the Alignment Specifications chart within Group 2,
Front Suspension).
Fig. 4 Steering Linkage—Link/Coil Position the clamp on the sleeve so retaining
bolt is located on the bottom side of the sleeve.
Use care to avoid damaging the seals. (7) After adjustment tighten tie-rod adjustment
sleeve clamp bolts to 54 N-m (40 ft. lbs.) torque.
STEERING 19-19
R E C I R C U L A T I N G B A L L POWER S T E E R I N G G E A R
I N D E X
page page
Adjuster Plug Assembly Replacement 26 Pitman Shaft Seals—In Car Replacement 19
Check Valve Replacement 32 Rack Piston and Worm Shaft Replacement 29
Gear Disassembly Information 23 Service Information 19
Housing End Plug 25 Steering Gear Adjustments 21
Pitman Shaft and Side Cover Replacement 25 Steering Gear Replacement 21
Pitman Shaft Seals and Bearing Replacement . . . . 31 Valve Replacement 28
SERVICE INFORMATION SPECIAL TOOL

A recirculating-ball steering gear is used with the C-4171
power (assisted) steering system. The power steering TOP OF TOOL

gear can be adjusted and internally serviced. FLUSH WITH
HOUSING
PITMAN SHAFT S E A L S — I N CAR REPLACEMENT

SPECIAL TOOL
REMOVAL G4328
(1) Remove pitman arm from gear. Refer to Pitman

Arm Removal i n Steering Linkage.
(2) Clean exposed end of pitman shaft and hous
ing. Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers.
CAUTION: U s e care not to score the housing bore

when prying out seals a n d washers.
(4) Remove backup washer and double lip seal

with screwdriver.
• Start the engine and turn the steering wheel fully
to the LEFT to force out the seals and washers.
J9119-42
• Stop the engine.
(5) Remove backup washer and single lip seal with Fig. 1 Pitman Shaft Seal Installation
screwdriver.
(3) Install the backup washer.
(6) Inspect the housing for burrs and remove i f
necessary. Inspect the pitman shaft seal surface for (4) Install the double lip seal.
roughness and pitting. I f pitted replace shaft. (5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
INSTALLATION (7) Center the steering gear.
(1) Coat seal with white petroleum grease. Install (8) Install the pitman arm. Refer to Pitman A r m
single lip seal with Installer or a suitable size deep Installation i n Steering Linkage.
socket (Fig. 1). (9) Add power steering fluid. Refer to Power Steer
(2) Coat the double lip seal and washer with white ing Initial Operation.
petroleum grease.
Fig. 2 Power Steering Gear
• STEERING -19-21
STEERING GEAR REPLACEMENT INSTALLATION

(1) Position the steering gear on the frame rail and
REMOVAL install the bolts. Tighten mounting bolts to 190 N-m
(1) Place the front wheels i n a straight-ahead posi (140 ft. lbs.) torque.
tion. (2) Align steering coupler on gear shaft. Install
(2) Disconnect and cap the fluid hoses from steer pinch bolt and tighten to 49 N-m (36 ft. lbs.) torque.
ing gear. (3) Align and install the pitman arm.
(3) Remove coupler pinch bolt at the steering gear (4) Install the washer and retaining nut on the pit
and slide shaft off gear (Fig. 3). man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque.
(5) Connect fluid hoses to steering gear, tighten to
31 N-m (23 ft. lbs.). Add fluid, refer to Power Steering
Pump Initial Operation.
STEERING GEAR ADJUSTMENTS
SERVICE INFORMATION
CAUTION: Steering gear must be adjusted a s out

lined. Failure to adhere to the procedure may result
in gear damage or improper steering response.
Remove the gear from the vehicle and mount i n a

vise. Drain the power steering fluid and make the
J9419-20 following adjustments i n this order:
• FIRST - worm thrust bearing preload
Fig. 3 Column Shaft Removal • SECOND - over-center preload adjustment
(4) Mark the pitman shaft and pitman arm for in
stallation reference. Remove the pitman arm from WORM THRUST REARING PRELOAD
the shaft with Puller C-4150A (Fig. 4). ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 5).
WRENCH BL
J9419-23
Fig. 4 Pitman Arm Removal

Fig. 5 Loosening the Adjuster Plug Locknut
(6) Remove steering gear retaining bolts and nuts.
(2) Turn the adjuster i n with Spanner Wrench
Remove the steering gear from the vehicle.
C-4381. Tighten the plug and thrust bearing i n the
housing until firmly bottomed i n housing.
(3) Place an index mark on the housing even with FIRST
one of the holes in adjuster plug (Fig. 6). MARK
J9219-30
J8919-58
Fig. 8 Aligning To The Second Mark
Fig. 6 Alignment Marking On,Housing OVER-CENTER ADJUSTMENT

(1) Rotate the stub shaft from stop to stop and
(4) Measure back (counterclockwise) 13 mm (0.50
count the number of turns.
in) and mark housing (Fig. 7).
(2) Starting at either stop turn the stub shaft back
1/2 the total number of turns. This is the center of
the gear travel (Fig. 9).
Fig. 7 Remarking The Housing

(5) Rotate adjustment plug back (counterclockwise)
with spanner wrench until hole is aligned with the
second mark (Fig. 8).
Fig. 9 Steering Gear Centered
(6) Install and tighten locknut to 109 N-m (80 ft.
lbs.) torque. Be sure adjustment plug does not turn (3) Turn the pitman shaft adjuster screw back
while tightening the locknut. (COUNTERCLOCKWISE) until extended, then turn
back in (CLOCKWISE) one half turn.
• STEERING 19 -
(4) Place the torque wrench in the vertical position CENTER

on the stub shaft. Rotate wrench 45 degrees each
side of center and record the highest rotational
torque on center (Fig. 10).
(5) Turn the adjuster in until torque to turn stub
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more than
reading in Step 4.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 58 N-m (43 ft. lbs.).
GEAR DISASSEMBLY INFORMATION

CAUTION: Cleanliness is extremely important when
repairing a power steering gear. Keep the bench,
tools and components clean at all times. Thor
oughly clean the exterior of the gear with cleaning
solvent before disassembly. Drain as much of the
fluid as possible. Use protective vise jaws at all
times when clamping components. During assem
bly, lubricate all components with power steering J8919-63
fluid except when instructed otherwise (Fig. 11).
Fig. 10 Checking Over-center Rotation Torque
I
—s
m
m
1 - HOUSING, STEERING GEAR BEARING ASSY., NEEDLE (PlTAAAN SHAFT)

2 - RACE THRUST BEARING (WORM)
f SEAL, PITMAN SHAFT (SINGLE LIP)
3 - BEARING ASSY., ROLLER THRUST (WORM) WASHER, SEAL BACK-UP (PITMAN SHAFT)
RACE, THRUST BEARING (WORM) SEAL, PITMAN SHAFT (DOUBLE LIP)
WORM, STEERING WASHER, SEAL BACK-UP (PlTAAAN SHAFT)
SEAL "O" RING (STUB SHAFT) RING, RETAINING (PlTAAAN SHAFT SEAL)
SHAFT, STUB WASHER. PlTAAAN SHAFT LOCK
SPOOL, VALVE NUT, PlTAAAN SHAFT
9 - SEAL, "O" RING (SPOOL) NUT, RACK PISTON
10 - BODY, VALVE BALL
RING, VALVE BODY (3) GUIDE, BALL RETURN (2)
12 - SEAL, "O" RING (VALVE BODY) (3) 36 - CLAMP, BALL RETURN GUIDE
13 - RETAINER, BEARING (ADJUSTER) 37 - SCREW ASSY., LOCKWASHER & (2)
14 - SPACER, THRUST BEARING 38 - PLUG, RACK PISTON
1 5 - RACE, UPPER THRUST BEARING (SAAALL) 39- SEAL, "O" RING (RACK PISTON)
16- BEARING, UPPER THRUST 40- RING, RACK PISTON
17- RACE, UPPER THRUST BEARING (LARGE) 41 - SEAL, "O" RING (HOUSING END PLUG)
18 - SEAL, "O" RING (ADJUSTER) 42- PLUG, HOUSING END
19- PLUG, ADJUSTER 4 3 - RING, RETAINING (HOUSING END PLUG)
2 0 - BEARING, NEEDLE 44 - GEAR ASSY., PlTAAAN SHAFT
21 - SEAL, STUB SHAFT 45- SEAL ASSY., GASKET
2 2 - SEAL, STUB SHAFT DUST 46- COVER ASSY., HOUSING SIDE
2 3 - RING, RETAINING 47 - BOLT, HEX. HEAD (SIDE COVER) (4)
24 - NUT, ADJUSTER PLUG LOCK 48 - NOT, LASH ADJUSTER
J9219-64
Fig. 11 Power Steering Gear

PITMAN SHAFT AND SIDE COVER REPLACEMENT (3) Install gasket to side cover and bend tabs
around edges of side cover.
REMOVE (4) Install pitman shaft assembly and side cover to
(1) Remove steering gear from vehicle. Refer to housing.
Power Steering Gear Replacement in this section. (5) Install side cover bolts and tighten to 61 N-m
(2) Remove pitman arm from steering gear. Refer (45 ft. lbs.).
to Pitman Arm Removal in the Steering Linkage sec (6) Adjust pitman shaft, refer to Over-Center Ad
tion. justment.
(3) Rotate stub shaft back and forth to drain power
INSTALL
steering fluid.
(1) Install steering gear. Refer to Power Steering
DISASSEMBLE Gear Replacement in this section.
• Clean exposed end of pitman shaft and housing. (2) Install pitman arm onto steering gear. Refer to
• Clean pitman shaft spline with a wire brush. Steering Linkage in this group.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear. HOUSING END PLUG
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as REMOVE
an assembly. (1) Remove steering gear from vehicle. Refer to
(4) Remove pitman shaft from the side cover (Fig. Power Steering Gear Replacement in this section.
12). (2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
• Rotate stub shaft back and forth to drain fluid.
(1) Rotate retaining ring until one end is under the
hole in the housing. Unseat and force ring from
groove (Fig. 13).
Fig. 12 Side Cover and Pitman Shaft

ASSEMBLE Fig. 13 End Plug Retaining Ring
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover. (2) Rotate stub shaft slowly COUNTER-CLOCK
(2) Install preload adjuster nut. Do not tighten WISE to remove end plug out from housing (Fig. 14).
nut until after pitman shaft adjustment has
been made.
CAUTION: Do not turn stub shaft any further than INSTALL
necessary. The recirculating balls will drop out of (1) Install steering gear. Refer to Power Steering
the rack piston circuit and fall inside the rack pis Gear Replacement in this section.
ton chamber. This will require complete d i s a s s e m (2) Install pitman arm onto steering gear. Refer to
bly of the gear. Steering Linkage in this group.
(3) Remove O-ring seal (Fig. 14). ADJUSTER PLUG ASSEMBLY REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span
ner Wrench C - 4 3 8 1 (Fig. 16).
SPECIAL TOOL
C-4381 OR J-7624
HOUSING ASSEMBLY
HOUSING END PLUG

O-RING SEAL
HOUSING END PLUG
RETAINING RING J9319-30
Fig. 14 End Plug Components

ASSEMBLE
• Lubricate O-ring seal with power steering fluid.
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 mm (1 J9119-27
inch) from access hole (Fig. 15).
Fig. 16 Remove/install Adjustment Plug
RING GAP (3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 17).
(4) Remove bearing spacer, races and thrust bear
PUNCH ing (Fig. 18).
ACCESS HOLE (5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
with an appropriate tool (Fig. 19).
RETAINER
RING ASSEMBLE
CAUTION: Needle bearing must be installed with

identification on bearing facing tool to prevent dam
age to bearing.
J9219-32
(1) Install needle bearing into adjuster plug with
Fig. 15 Installing The Retaining Ring an appropriate tool.
(2) Apply white petroleum grease on lip seal. In
stall lip seal into adjuster plug appropriate tool.
Fig. 18 Adjustment Plug (Cap) Components

(3) Apply white petroleum grease to dust seal cav J9219-10
ity and install dust seal into adjuster plug with an
appropriate tool. Fig. 20 Install Retainer
(4) Install retaining snap ring. punch (drift) i n a notch, tighten securely (Fig. 21).
(5) Install O-ring seal to adjuster plug. Hold adjuster plug to maintain alignment of the
(6) Install large bearing race, thrust bearing, small marks.
bearing race and bearing spacer to adjuster plug.
(11) Adjust pitman shaft. Refer to Over-Center Ad
(7) Install thrust washer bearing retainer to ad
justment.
juster plug (Fig. 2 0 ) .
INSTALL
CAUTION: When installing adjuster plug, care
should be taken NOT to cut the seals.
Gear Replacement in this section.
(8) Install adjuster plug into housing with Spanner
Wrench C-4381.
(9) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(10) Install adjuster plug lock nut, and using a
19-28 STEERING •
GEAR, MAKE SURE ANGLE OF

THRUST RACES ARE AS SHOWN. J9319-32
Fig. 22 Bearing, Worm and Valve Assembly
Fig. 21 Tighten Lock Nut

VALVE REPLACEMENT
REMOVE
Power Steering Gear Replacement i n this section.
DISASSEMBLE
(1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement.
CAUTION: When removing valve, do not rotate

valve until it h a s separated from worm shaft tangs.
Rotation may c a u s e recirculating balls to drop out
of the rack piston circuit. This will require complete
J9319-36
disassembly of the gear.
Fig. 23 Remove and Install Stub Shaft
(2) Remove stub shaft and valve assembly (Fig.
22). (2) Lubricate valve spool and O-ring seal with
(3) Remove stub shaft from valve assembly, i f nec power steering fluid.
essary. (3) Install valve spool to valve body by pushing
• Tap stub shaft lightly on a block of wood to loosen and rotating. Hole i n valve spool for stub pin must be
shaft cap. accessible from opposite end of valve body.
• Pull cap and valve body and disengage stub shaft (4) Assemble stub shaft to valve spool, i f necessary
pin from hole i n valve body (Fig. 23). and insert pin (Fig. 26).
(4) Remove valve assembly i f necessary. • Notch i n stub shaft cap MUST fully engage valve
• Remove valve spool by pulling and rotating from body pin and seat against valve body shoulder.
valve body (Fig. 24). (5) Install O-ring seals and teflon rings to valve
• Remove valve spool O-ring seal. body.
• Remove valve body teflon rings and O-ring seals (6) Lubricate O-ring seals and teflon rings with
(Fig. 25). power steering fluid.
(7) Install stub shaft and valve assembly to worm
ASSEMBLE shaft. Line up worm shaft to slot i n the valve assem
(1) Install valve spool O-ring seal to valve spool. bly.
• STEERING 19-29
SPOOL VALVE NOTCH IN CAP
VALVE BODY PIN

ROTATE
VALVE TO
REMOVE
VALVE BODY J9319-37
Fig. 24 Remove and Install Spool
J9319-38
Fig. 26 Stub Shaft Installation

DISASSEMBLE
(1) Remove pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement i n this
section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement i n this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 27).
EXTENSION END PLUG
J8919-48
Fig. 25 Remove and Install Valve Seals

(8) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment. Refer to Steering Gear Ad
justments i n this section.
INSTALL
RACK PISTON AND WORM SHAFT REPLACEMENT

REMOVE
Fig. 27 Remove and Install Rack Piston End Plug

(5) Insert Arbor C-4175 into bore of rack piston (2) Check for scores, nicks or burrs on the rack pis
(Fig. 28). Hold tool tightly against worm shaft while ton finished surface. Slight wear is normal on the
turning the stub shaft COUNTERCLOCKWISE. worm gear surfaces.
The rack piston will be forced onto the tool and
hold the rack piston balls i n place. ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align
worm shaft spiral groove with rack piston ball guide
hole (Fig. 30).
INSTALL BALLS IN THIS HOLE
WHILE SLOWLY ROTATING
WORM COUNTERCLOCKWISE
Fig. 28 Remove and install Rack Piston

(6) Remove the rack piston, rack balls, and tool to
gether from housing.
(7) Remove valve. Refer to Valve Replacement i n
this section. J9319-39
(8) Remove worm shaft.

(9) Remove thrust bearing and races. Fig. 30 Installing Balls in Rack Piston
(10) Remove arbor tool from rack piston. WARNING: MAKE S U R E A L L R A C K PISTON B A L L S
(11) Remove rack piston balls. A R E R E I N S T A L L E D IN T H E R A C K PISTON. IM
(12) Remove screws, clamp and ball guide. P R O P E R INSTALLATION MAY R E S U L T IN P E R
(13) Remove teflon ring and O-ring seal (Fig. 29). S O N A L INJURY.
There are 24 balls in the rack piston circuit,

12 are black and 12 are silver (Chrome). The
black rack piston balls are smaller than the sil
ver balls. T H E B L A C K A N D SILVER - B A L L S
M U S T BE I N S T A L L E D ALTERNATELY I N T O
T H E RACK P I S T O N A N D B A L L GUIDE. This
procedure will maintain worm shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning worm shaft COUN
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold i n place (Fig. 31).
(5) Install guide onto rack piston and retain with
clamp and bolt. Tighten bolt to 58 N-m (43 in. lbs.)
torque.
(6) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly against worm shaft while turning
J9219-12 the stub shaft COUNTERCLOCKWISE.
The rack piston will be forced onto the tool and
Fig. 29 Remove and Install Seal on Rack Piston hold the rack piston balls i n place.
CLEAN AND INSPECTION (7) Install the races and thrust bearing to worm
(1) Wash all components i n clean solvent and dry shaft (Fig. 32).
with compressed air. (8) Install worm shaft to housing.
• STEERING 19 <- 31
GUIDE WARNING: M A K E SURE A L L RACK PISTON BALLS

ARE REINSTALLED IN THE RACK PISTON. IM
PROPER INSTALLATION MAY RESULT IN PER
SONAL INJURY.
(11) Install rack piston plug and tighten to 149

(12) Install housing end plug. Refer to Housing
End Plug Replacement i n this section.
(13) Install pitman shaft and side cover. Refer to
section.
(14) Adjust steering gear. Refer to Steering Gear
Adjustments i n this section.
INSTALL
Gear Replacement i n this section.
PITMAN SHAFT SEALS AND BEARING

BALLS J9319-40
REPLACEMENT
Fig. 31 Balls in the Return Guide
REMOVE
WORM SHAFT THRUST RACES (1) Remove steering gear from vehicle. Refer to
DISASSEMBLE
(1) Remove pitman arm from gear. Refer to Pitman
Arm Removal i n Steering Linkage.
(2) Clean exposed end of pitman shaft and hous
ing. Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers.
CAUTION: Use care n o t t o s c o r e t h e h o u s i n g bore

w h e n p r y i n g o u t seals a n d w a s h e r s .
(4) Remove backup washer and double lip seal

with screwdriver.
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove i f
necessary.
MAKE SURE ANGLE OF THRUST (7) Remove needle bearing from side cover area of
RACES ARE AS SHOWN
housing (Fig. 33).
Fig. 32 Worm Shaft and Bearing ASSEMBLE

(1) Install needle bearing into housing (Fig. 34).
(9) Install valve. Refer to Valve Replacement i n (2) Install single lip seal with Installer or a suit
this section. able size socket (Fig. 35).
(10) Install rack piston to worm shaft from tool, (3) Coat the double lip seal and washer with
compress seals. grease.
Hold Arbor tightly against worm shaft and turn (4) Install the backup washer.
stub shaft CLOCKWISE until rack piston is seated (5) Install the double lip seal.
on worm shaft. (6) Install the backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Install the pitman shaft and side cover. Refer to
section.
19 - 32 STEERING
REMOVER SIDE COVER SPECIAL TOOL

AREA C-4171
TOP O F TOOL
FLUSH WITH
HOUSING
SPECIAL TOOL
C4328
J9319-42 J9119-42
Fig. 33 Needle Bearing Removal Fig. 35 Pitman Shaft Seal Installation
SPECIAL T O O L . CHECK VALVE REPLACEMENT

C-4171
REMOVE
D O NOT
BOTTOM BEARING
IN HOUSING Power Steering Gear Replacement in this section.
WHEN TOOL
BOTTOMS O N DISASSEMBLE
HOUSING, BEARING IS
FULLY INSTALLED
CAUTION: U s e care not to damage the threads of
the housing when prying out check valve.
(1) Remove valve by prying from housing with a

SPECIAL TOOL
C-4178 small screwdriver.
ASSEMBLE
(1) Install the valve into the housing with a 3/8-
inch diameter piece of tubing 100 mm (4 inches) long.
INSTALL
Fig. 34 Pitman Shaft Bearing Installation

INSTALL
POWER STEERING GEAR SPECIFICATIONS
S t o r i n g G e a r Type Recirculating ball with Storing Gear Adjustments:

hydraulic assist. Wormshaft Bearing Preload Torque ....0.45-1.13 N«m
(10 to 15 in.-lbs.)
Ration C o d e (Top of G e a r )
BN ..17.5:1 Pitman Shaft Overcenter Drag Torque:
HF 13-16:1 New Gear
(less than 400 miles/640 km) 0.45-0.90 N*m
S t o r i n g G e a r Hydraulic Fluid Use M o p a r Power (6 to 10 in.-lbs.) in addition to wormshaft
Swing Fluid, or equivalent. bearing preload but not to exceed
combined total of 2 N*m (18 in.-lbs.).
S t o r i n g G e a r lubricants .Lubricate pitman shaft
seals, bearings races, a n d rack Used Gear
piston recirculating bails with (over 400 mites/640 km) 0.5-0.6 N-m (4 to 5 in.-lbs.)
petroleum jelly. Lubricate all other in addition to wormshaft bearing
parts with power s t o r i n g fluid. preload but not to exceed
combined total of 2 N*m (25 in.-lbs.).
Caution: Gears must be adjusted exactly as outlined in Storing

Gear Adjustments-On Bench. Failure to adhere to the
recommended procedures may result in gear damage
or improper storing response.
J9419-36
19-34 STEERING •
S T E E R I N G COLUMN
SERVICE INFORMATION nition locking link, shaft lock plate or shaft lock
The Acustar columns (Fig.l) have been designed to plate retainer (Fig. 2, 3). Damage will occur.
be serviced as an assembly; less wiring, switches,
shrouds, steering wheel, etc. Most steering column
components can be serviced without removing the
column from the vehicle. For additional information
refer to Group 8 H , Electrical.
UPPER
SHROUD
Fig. 2 Observe Cautions
LOWER
SHROUD J9419-17
Fig. 1 Acustar Steering Column

WARNING: BEFORE BEGINNING ANY A I R B A G SYS
(-) C A B L E FROM THE VEHICLE BATTERY. THIS IS
THE ONLY SURE WAY TO DISABLE THE A I R B A G Fig. 3 Observe Caution
SYSTEM. FAILURE TO DO THIS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT A N D POSSI
STEERING WHEEL
B L E PERSONAL INJURY.
REMOWAL
When removing a deployed airbag module Refer to
WARNING: WHEN A STEERING COLUMN HAS A N Group 8M.
A I R B A G MODULE ATTACHED, NEVER PLACE THE (1) Make sure the front wheels are in the straight
COLUMN ON THE FLOOR OR OTHER SURFACE ahead position.
WITH THE STEERING WHEEL OR MODULE FACE (2) Disconnect battery negative cable and isolate.
DOWN. (3) From underside of steering wheel, remove
speed control switch mounting screws if equipped
(Fig. 4).
CAUTION: Bumping, jolting and hammering on (4) Pull switches from wheel and unplug connector
steering column shaft and gear shift tube must be (Fig. 5).
avoided during service procedures. (5) Using a small screwdriver remove right rear
CAUTION: Do not attempt to remove pivot pins to (6) Remove 4 nuts attaching AirBag Module (Fig.
dissemble the tilting mechanism. Do not remove ig 7).
• STEERING .19 - 35
Fig. 5 Speed Control Switches

(7) Remove AirBag Module from steering wheel
and unplug squib connector from airbag module.
(8) Remove the steering wheel retaining nut.
Steering wheel and shaft are master splined for in
(9) Remove the steering wheel with puller. Do not
hammer or jolt steering column or shaft during
removal of wheel.
INSTALLATION
(1) Pull speed control and airbag wires through the
lower hole i n the steering wheel. Pull the horn wire Fig. 7 AirBag Module Removal
through the smaller hole at the top (Fig. 8). Ensure (5) Connect clockspring wiring connector to the
the wires are NOT pinched. module, by pressing straight i n on the connector. The
(2) Install the steering wheel with the scored connector should latch securely beneath module lock
marks or master splines aligned. ing clip to assure positive connection.
(3) Install the retaining nut and tighten to 61 N-m ( 6 ) Mount airbag module, install 4 nuts and torque
(45 ft. lbs.) torque. Force the steering wheel down to 9 to 11 N-m (80 to 100 in. lbs.).
on the shaft with the retaining nut only. Do not (7) Do not connect negative battery cable. Refer to
hammer or shock the column with sudden im Airbag System Check for proper procedure.
pact to install the wheel.
(4) Connect the wires to the horn buttons, speed
control switch and air bag module.
19-36 STEERING •
(2) Depress the 2 locking tabs to disengage the
locking mechanism (Fig. 9).
CONNECTOR J9419-19
Fig. 8 Steering Wheel Installation

CLOCKSPRING
REMOWAL
(1) Place the front wheels i n the straight ahead po
sition before starting the repair.
(3) Remove the steering wheel, refer to Steering Fig. 9 Clockspring (Auto-Locking)
Wheel Removal. (3) Keeping mechanism disengaged, rotate clock-
(4) Remove upper and lower steering column spring rotor i n CLOCKWISE DIRECTION to end of
shrouds to gain access to the clockspring wiring. travel. Do not apply excessive torque.
(5) Release wire connector at clockspring. (4) From the end of travel, rotate the rotor 2 1/2
(6) Pull clockspring assembly from column by lift full turns i n the COUNTER CLOCKWISE direction.
ing locking fingers as necessary. The clockspring can The horn wire should end up at the top and the
not be repaired, and must be replaced i f faulty. squib wire at the bottom (Fig. 9).
(5) Install the steering wheel, refer to Steering
INSTALLATION Wheel Installation.
(1) Snap clockspring assembly onto column. I f
clockspring is not properly positioned, follow the cen COLUMN— REMOVAL/INSTALLATION
tering procedures before installing steering wheel.
(2) Connect the wire connector to the clockspring. WARNING: WHEN A S T E E R I N G COLUMN HAS AN
A I R B A G MODULE ATTACHED, N E V E R P L A C E T H E
WARNING: E N S U R E C L O C K S P R I N G WIRE CON COLUMN ON T H E F L O O R OR OTHER S U R F A C E
NECTION IS C O M P L E T E L Y S E A T E D . T H E LATCHING WITH T H E S T E E R I N G W H E E L OR MODULE F A C E
C L I P ARMS MUST B E P R O P E R L Y E N G A G E D ON DOWN.
T H E MODULE.
CAUTION: Bumping, jolting and hammering on
(3) Install upper and lower steering column
steering column shaft and gear shift tube must be
shrouds. Be sure wiring is inside of shrouds and not
avoided during service procedures.
pinched.
(4) Install the steering wheel and air bag module,
refer to Steering Wheel Installation. REMOWAL
(1) Make sure the front wheels are i n the straight
CENTERING PROCEDURE ahead position.
I f the rotating tape within the clockspring is not £2) Disconnect the negative (ground) cable from the
positioned properly, the clockspring may fail during battery.
use. The following procedures MUST BE USED to (3) Remove steering wheel from column, refer to
center the clockspring. Steering Wheel-Removal.
(1) Place the front wheels in the straight ahead po (4) Vehicles equipped with column shift, disconnect
sition before starting the procedure. link rod i n engine compartment. Pry rod out from
• STEERING 19-37
grommet i n the shift lever (Fig. 10). STEERING

(5) Paint installation alignment marks on the col COLUMN
ASSY.
umn shaft-to-coupler. This will aid i n column shaft to
wheel alignment. Remove the steering column shaft-
to-coupler bolt (Fig. 10).
STEERING
COLUMN
STEERING
COUPLER
TURN SIGNAL
MULTI SWITCH AND
FUNCTION LEVER
SWITCH
J918J-1 CONNECTOR
Fig. 12 Multi-function Switch Wiring

HALO LIGHT SWITCH
SHIFT
LEVER J9419-2I
Fig. 10 Couplet Screw Removal

(6) Remove the dash panel cover under column.
(7) For column shift vehicles, make sure shift lever
is i n P a r k position. Pull cable and twist to remove
from position arm. Push tab on bottom of cable re
TURN SIGNAL
tainer, then squeeze sides to remove retainer from SWITCH & LEVER
column.
PRNDL
CABLE IGNITION SPEED
POSITION SWITCH CONTROL J918J-2
ARM
Fig. 13 Steering Column Wiring
(13) Remove the wiring harness from the column
by prying out the plastic retainer buttons.
(14) Remove lower dash panel and toe plate fasten
ers (Fig. 1).
(15) Remove column from vehicle. Use care to
avoid damaging the paint or trim.
STEERING
PUSH TAB COLUMN INSTALLATION
UP
J948E-4 CAUTION: Bumping, jolting and hammering on
steering column shaft and gear shift tube must be
Fig. 11 PRNDL Drive Cable
avoided during service procedures.
(8) Remove tilt lever (if equipped) from column.
(9) Remove the upper and lower lock housing (1) Column shift vehicles, install a new grommet.
shroud (Fig. 1). Remove the lower fixed shroud. Use MOPAR® Multipurpose Lubricant, or equivalent,
(10) Remove the turn signal multi-function switch to aid installation of the grommet. A new grommet
with a 7mm socket (Fig. 12). should be used when ever the rod is discon
(11) Loosen the upper Support Bracket nuts to al nected from the lever.
low some slack. This will aid i n removal of the upper (2) Install the ground clip on the left spacer slot
fixed shroud. (Fig. 14).
(12) Remove electrical connections from Key-in (3) Remove the shipping lock pin (Fig. 1), i f neces
light, Ignition Switch, Horn and Clock Spring (Speed sary.
Control) (Fig. 13). (4) Install column through floor pan.
19-38 STEERING •
J948E-66
Fig. 15 PRNDL Adjuster

(16) Column shift vehicles, connect the shift link
RN832 rod to the transmission shift lever. Use MOPAR®
Multipurpose Lubricant, or an equivalent product, to
Fig. 14 Ground Clip & Spacer installation aid the installation.
(5) Position the column bracket shear pins on the (17) Check operation of the transmission shift link
attaching studs. Install, but loose assemble the two age and adjust as necessary. Refer to Group 21,
upper bracket washers and nuts. Transmission for the shift linkage adjustment.
(6) With the front wheels i n the straight-ahead po (18) Connect the battery ground (negative) cable.
sition. Align steering column shaft to the coupler. In
stall pinch bolt and tighten to 49 N-m (36 ft. lbs.)
COLUMN COMPONENT SERVICE
The Acustar tilt and standard columns (Fig.l) have
torque.
been designed to be serviced as an assembly; less
(7) Clip the wiring harness on the steering column. wiring, switches, shrouds, steering wheel, etc. Most
Connect the multi-function switch wiring and tighten steering column components can be serviced without
with 7mm socket. removing the column from the vehicle. For additional
(8) Install the upper fixed shroud. information, refer to Group 8H, Electrical.
(9) Be sure both breakaway capsules are fully The gear shift lever (if equipped) can be serviced.
seated i n the slots i n the column support bracket. Use a drift and a suitable size socket to drive out pin
Tighten the two upper bracket nuts to 12 N-m (105 (Fig. 16).
in. lbs.) torque. HAMMER
(10) Tighten the toe plate to floor pan attaching
nuts to 22.5 N-m (200 in. lbs.) torque.
(11) Install the wiring connections to the column.
Install the lower fixed shroud.
(12) Column shift vehicles, install the PRNDL
driver cable. Place shifter i n Park position. I f indica
tor needs adjusting turn recessed hex head screw un
derneath cable retainer (Fig. 15).
(13) Install the lock housing shrouds. Install the
tilt lever (if equipped).
(14) Install the lower dash panel column cover.
(15) Install steering wheel on column, refer to
Steering Wheel-Installation.
Fig. 16 Gear Shift Removal

STEERING COLUMN STEERING PUMP
Description Torque Description Torque
Steering Wheel to Shaft Flow Control Valve 75 N-m ft. lbs.)

High Pressure Fluid Line 31 N-m ft. lbs.
Retaining Nut 61 N«m (45 ft. lbs.) Oil Cooler Bolt 20 N-m ft. lbs.
Coupler Bolt 47 N®m (35 ft. lbs.) Pump Bracket to Engine 41 N-m ft. lbs.
Upper Column Bracket Pump to Brocket 47 N-m ft. lbs.
Pump to Rear Bracket Nuts
Support Nuts..... 12N«m(105in. lbs.) (8.0 L.) 47 N-m (35 ft. lbs.)
Toe Plate Attaching Rear Bracket to Front Bracket
Bolts/Nuts 23 N»m (200 in. lbs.) (8.0 L.) 24 N-m (18 ft. lbs.)
PumptoVacuum Pump Nuts
J9319-61 (Diesel Engine) 24 N-m (18 ft. lbs.)
Pump Assembly to Engine
Block (Diesel Enginef , 77 N-m (57 ft. lbs.)
PumptoSupport Bracket
Nut (Diesel Engine) 24 N-m (18 ft. lbs.)
ReservoirtoBody Bolts 56 N-m 42 ft. lbs.)
J9419-31
STEERING GEAR
Description Torque
Adjustment Plug Locknut... 108 N-m (80ft.lbs.)
Adjustment Screw Locknut 58 N-m (43ft.lbs.)
Gear to Frame Bolts 190 N-m (140ft.lbs.)
Intermediate Shaft Pinch
Bolts (Upper and Lower) . 49 N-m (36ft.lbs.)
Pitman Shaft Nut 251 N-m (185ft.lbs.)
High Pressure Fluid Line ... 31 N-m (23ft.lbs.)
Return Pressure Fluid Line . 31 N-m (23ft.lbs.)
Rack-Piston Plug 149 N-m (110ft.lbs.)
Side Cover Bolts 61 N-m (45ft.lbs.)
J9419-30
STEERING LINKAGE
Description Torque
Drag Link Ball Stud Nuts
Link/Coil 88 N-m (65ft.lbs.)
Idler Arm to Frame Bolts ... 108 N-m (80ft.lbs.)
Pitman Shaft Nut 251 N-m (185ft.lbs.)
Tie -Rod Clamp Nut 54 N-m (40ft.lbs.)
Tid-Rod Nut 88 N-m (65ft.lbs.)
Tie-Rod Adjuster Clamps
4X2 and 4X4 54 N-m (40ft.lbs.)
DampertoCenterlink Nut. 68 N-m (50ft.lbs.)
Damper to Frame Nut 68 N-m (50ft.lbs.)
J9419-28
# _ TRANSMISSION AND TRANSFER CASE 21 - 1
TRANSMISSION AND TRANSFER C A S E
CONTENTS
page page
AUTOMATIC TRANSMISSION—32RH/36RH/ NV4I00 MANUAL TRANSMISSION 48

37RH/42RH/46RH/47RH 96 NV 021 PTO ADAPTER .402
NV3500 MANUAL TRANSMISSION 1 NP241 TRANSFER CASE 372
NV3500 MANUAL TRANSMISSION
INDEX
page page
Drain and Fill Plug Locations 1 Transmission Installation (2-Wheel Drive) 6
General Information 1 Transmission Installation (4-Wheel Drive) . . . . . . . . 7
Transmission Assembly 22 Transmission Lubricant 1
Transmission Component Cleaning and Inspection . 20 Transmission Lubricant Level and Capacity 1
Transmission Diagnosis 3 Transmission Removal (2-Wheel Drive) 4
Transmission Disassembly and Overhaul 8 Transmission Removal (4-Wheel Drive) 5
Transmission Gear Ratios 1
GENERAL INFORMATION TRANSMISSION LUBRICANT LEVEL AND

The NV3500 is a medium-duty, 5-speed, constant CAPACITY
mesh, fully synchronized manual transmission. Fifth The correct transmission lubricant level is to the
gear is an overdrive range with a ratio of 0.0729:1. bottom edge of the fill plug hole.
The NV3500 is used with 3.9L and 5.2L engines and The transmission must be level to obtain an accu
is available in two and four-wheel drive configura rate lubricant level check. A drive-on type of hoist is
tions. recommended for this purpose.
The transmission gear case consists of two alumi Lubricant capacity of the NV3500 is approximately
num housings (Fig. 1). The clutch housing is not a re 1.98 liters (4.2 pints). This represents the approxi
movable component. It is an integral part of the mate quantity needed to refill the transmission after
transmission front housing. a lubricant change or overhaul.
Roller bearings are used to support the transmis
sion shafts in the two housings. The transmission DRAIN AND FILL PLUG LOCATIONS
gears all rotate on caged type needle bearings. The NV3500 fill and drain plugs are both located
The NV3500 has a single shaft shift mechanism. in the front housing. The fill plug is at the passenger
The three shift forks are all mounted on a one shift side of the housing. The drain plug is at the bottom
shaft. The shaft is supported in the front and rear of the housing (Fig. 3).
housings by bushings and one bearing. Internal shift
components consist of the forks, shaft, shift lever TRANSMISSION GEAR RATIOS
socket, anti-rotation bracket, bias spring and detent NV3500 gear ratios are:
components (Fig. 2). first 4.016:1
second 2.318:1
TRANSMISSION LUBRICANT third 1.401:1
Required lubricant for the NV3500 is Mopar man fourth 1:1
ual transmission lubricant P/N 4761526. This is the fifth 0.729:1
only lubricant recommended for use in NV3500 reverse 3.55:1
transmissions.
2 ' NV3500 MANUAL TRANSMISSION
J9421-1
Fig. I NV3500 Manual Transmission
• NV3500 MANUAL TRANSMISSION 21 - 3
Fig. 2 NV3500 iff Mechanism

TRANSMISSION DIAGNOSIS
LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor
rect lubricant level check.
Leaks can occur at the mating surfaces of the hous
ings, or from the front/rear seals. A suspected leak
could also be the result of an overfill condition.
Leaks at component mating surfaces will probably
be the result of inadequate sealer, gaps i n the sealer,
incorrect bolt tightening, or use of a non-recom
mended sealer.
A leak at the front of the transmission will be from
either a loose or damaged, front bearing retainer or
retainer seal. Lubricant may also drip from the
transmission clutch housing after extended opera
tion. I f the leak is severe, i t will contaminate the
clutch disc causing slip, grab and chatter.
Transmissions filled from air or electrically pow
ered lubricant containers can be underfilled. This
Fig. 3 Drain and Fill Plug Locations generally happens when the container delivery mech
anism is improperly calibrated. Always check the lu
bricant level after filling to avoid an under fill
condition.
A correct lubricant level check can only be
made when the vehicle is level; use a drive-on
hoist to ensure this. Also allow the lubricant to
21 - 4 NV3500 MANUAL TRANSMISSION •
settle for a minute or so before cheeking. These
recommendations will ensure an accurate
check a n d avoid an under-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, transmis
sion component damage, clutch linkage malfunction,
or by a damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
component, synchro and bearing damage. I f a leak
goes undetected for an extended period, the first in
dications of a problem are usually hard shifting and
noise.
Incorrect or contaminated lubricants can also con
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. I f
the clutch problem is advanced, gear clash during
Fig. 4 Shift Lever
shifts can result.
Worn or damaged synchro rings can cause gear ISOLATOR
clash when shifting into any forward gear. I n some
new or rebuilt transmissions, new synchro rings may
tend to stick slightly causing stiff and/or noisy shifts.
In most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds. Fig. 5 Shift Lever Reaction Plate Removal
Severe, obviously audible transmission noise is (6) Remove rollers from anti-rotation bracket with
generally the result of a lubricant problem. Insuffi pencil magnet (Fig. 6). Retain rollers as they are re
cient, improper, or contaminated lubricant can pro usable parts i f i n good condition.
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVAL (2-WHEEL DRIVE)

(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove bolts attaching shift tower, lever, and
lever extension and remove assembly (Fig. 4). Shift
lever reaction plate can also be removed at this time
if plate sealer bead has broken loose.
(5) Remove reaction plate from shift lever opening
in rear housing (Fig. 5). Reaction plate is one-way
fit. Note position of plate for installation refer
ence before removal. Narrow side of plate goes Fig. 6 Removing Anti-Rotation Bracket Rollers
toward driver side of transmission.

(8) Remove crankshaft position sensor. Retain sen
sor attaching bolts.
(9) Remove skid plate, i f equipped.
(10) Drain transmission lubricant i f transmission
will be disassembled for service.
(11) Mark propeller shaft and U-joint for installa
tion reference. Then disconnect and remove propeller
shaft.
(12) Disconnect vehicle speed sensor wires.
(13) Disengage harness from clips on transmission
housing.
(14) Support engine with adjustable jack stand.
(15) Remove nuts attaching insulator to crossmem
ber. Then remove insulator from extension housing i f
necessary.
(16) Remove bolts and nuts attaching crossmember
to frame rails. Rotate crossmember diagonally and
remove crossmember.
(17) Disconnect exhaust pipes at manifold and at
converter or muffler connections as needed. Then re
move Y-pipe, converter and tailpipe.
(18) Remove slave cylinder attaching nuts and re
move cylinder from clutch housing.
(19) Remove starter motor.
(20) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(21) Remove nuts/bolts attaching clutch housing to Fig. 7 Removing Shift Lever Extension With Tool
engine. 6783
(22) Move transmission and clutch housing rear (3) Remove screws attaching shift boot bezel and
ward until clear of engine. Then lower jack and re slide boot upward on shift lever extension. Then
move transmission from under vehicle. loosen extension locknut and unscrew extension from
(23) Remove transmission from jack and position shift lever.
transmission on workbench. (4) Remove bolts attaching shift tower and lever
(24) I f transmission will be overhauled, remove re assembly and remove assembly (Fig. 4). Shift lever
lease bearing, and fork and remove clutch housing reaction plate can also be removed at this time i f
from transmission. plate sealer bead has broken loose.
(25) I f shift lever extension is press-on style and (5) Remove reaction plate from shift lever opening
must be removed from shift lever, refer to following in rear housing (Fig. 5). Reaction plate is one-way
procedure: fit. Note position of plate for installation refer
(a) Obtain Remover/Installer Tool 6783. ence before removal. Narrow side of plate goes
(b) Scribe mark position of extension on shank of toward d r i v e r side of transmission.
shift lever. (6) Remove rollers from anti-rotation bracket with
(c) Position notched, lower end of tool just under pencil magnet (Fig. 6). Retain rollers as they are re
square shank of shift lever (Fig. 7). usable parts i f i n good condition.
(d) Position tool upper jaws under flange on (7) Remove crankshaft position sensor. Retain sen
shift lever extension (Fig. 7). sor attaching bolts.
(e) Tighten tool screw to pull extension off (8) Raise vehicle on hoist.
square shank of shift lever. (9) Remove skid plate, i f equipped.
(f) Remove lever extension and tool. (10) Drain transmission lubricant i f transmission
will be disassembled for service.
TRANSMISSION REMOVAL (4-WHEEL DRIVE) (11) Mark propeller shafts and U-joints for instal
(1) Disconnect battery negative cable. lation reference. Then disconnect and remove propel
(2) Shift transmission into Neutral. ler shafts.
(12) Disconnect vehicle speed sensor wires.
(13) Disconnect transfer case shift linkage at (2) Lubricate release fork pivot ball, release fork,
transfer case range lever. release bearing hub and transmission bearing re
(14) Remove bolts attaching shift linkage bracket tainer surface with Mopar high temperature grease.
to transfer case and move linkage and bracket aside. (3) Mount transmission on jack. Secure transmis
(15) Remove nuts attaching transfer case to trans sion to jack with safety chains.
mission adapter housing. (4) Lubricate transmission input shaft pilot hub
(16) Remove transfer case with aid of helper. Sup and splines with light coat of Mopar high tempera
port transfer case with transmission jack. Move ture grease.
transfer case rearward, tilt i t away from fixed (weld (5) Align transmission input shaft with release
ed) rear crossmember and work i t out from between bearing and clutch disc. Then slide transmission into
transmission and crossmember. place on engine block.
(17) Support engine with adjustable jack stand. (6) Install and tighten transmission clutch housing
(18) Remove nuts and bolts attaching support bolts to 68 N-m (50 ft. lbs.) torque. Be sure housing is
bracket and cushions to fixed crossmember. fully seated before tightening bolts. Install housing
(19) Remove nuts and bolts attaching removable dust cover after tightening housing bolts.
crossmember to frame rails. Rotate crossmember di (7) Fill transmission with recommended Mopar
agonally to remove it. gear lubricant. Correct fill level is to bottom edge of
(20) Disconnect exhaust pipes at manifold and at fill plug hole.
converter or muffler connections as needed. Then re (8) Connect backup light switch wires.
move Y-pipe, converter and tailpipe. (9) Connect transmission harnesses to clips on
(21) Remove slave cylinder attaching nuts and re case.
move cylinder from clutch housing. Move cylinder (10) Install crossmember. Tighten crossmember-to-
aside for working clearance. frame bolts to 68 N-m (50 ft. lbs.) torque.
(22) Remove clutch housing dust cover. (11) Tighten crossmember-to-transmission insula
(23) On some models, i t may be necessary to re tor nuts to 68 N-m (50 ft. lbs.) torque.
move front axle struts and oil filter for access and re (12) Install slave cylinder. Tighten cylinder nuts to
moval clearance. Remove these components i f 23 N-m (200 in. lbs.) torque.
necessary. (13) Remove jack used to support transmission.
(24) Support transmission with transmission jack. (14) Install strut bolts/nuts, i f removed. Also in
Secure transmission to jack with safety chains. stall oil filter i f removal was necessary.
(25) Remove bolts attaching transmission clutch (15) Connect vehicle speed sensor wires.
housing to engine block. (16) Install and connect exhaust system. Align ex
(26) Move transmission rearward until transmis haust components before tightening clamp and
sion clutch housing is clear of engine. Then lower bracket bolts and nuts. Be sure exhaust components
jack and remove transmission from under vehicle. are clear of all chassis and driveline components.
(27) Remove transmission from jack and position (17) Align and install propeller shaft. Tighten
transmission on workbench. U-joint clamp bolts to 19 N-m (170 in. lbs.) torque.
(28) I f transmission will be disassembled for ser (18) Verify that all linkage components, hoses and
vice, remove release bearing and fork. electrical wires have been connected.
(29) I f shift lever extension is press-on style and (19) Remove any remaining support stands and
must be removed from shift lever, refer to following lower vehicle.
procedure: (20) Install crankshaft position sensor.
(a) Obtain Remover/Installer Tool 6783. (21) Connect battery negative cable.
(b) Scribe mark position of extension on shank of (22) Apply Mopar Gasket Maker, or Loctite 518 to
shift lever. mounting surface of shift tower, shift lever reaction
(c) Position notched, lower end of tool just under plate and transmission front case.
square shank of shift lever (Fig. 7). (23) Install reaction plate and shift lever assembly.
(d) Position tool upper jaws u n d e r flange on Tighten shift tower bolts to 7-10 N-m (5-7 ft. lbs.)
shift lever extension (Fig. 7). torque. Reaction plate is one-way fit. N a r r o w
(e) Tighten tool screw to pull extension off side goes t o w a r d d r i v e r side o f transmission.
square shank of shift lever. (24) I f shift lever extension was removed from shift
(f) Remove lever extension and tool. lever, reinstall with Tool 6783 as follows:
(a) Reposition upper jaw of Remover/Installer
TRANSMISSION INSTALLATION (2-WHEEL DRIVE) Tool 6783 above flange on lever extension (Fig. 8).
(1) Make sure transmission clutch housing mount Tool will now be used to press extension back onto
ing surface is clean before installation. shift lever.
(b) Tighten tool screw to press extension back (7) Fill transmission with recommended Mopar
onto lever. Press extension to scribe mark made gear lubricant. Correct fill level is to bottom edge of
during removal. fill plug hole.
(c) Remove special tool. (8) Connect backup light switch wires.
(9) Connect transmission harnesses and vent line
to retainer clips on housing.
(10) Install center crossmember. Tighten cross-
member-to-frame bolts to 67 N-m (50 ft. lbs.) torque.
(11) Tighten crossmember-to-insulator nuts to
54-61 N-m (40-45 ft. lbs.) torque.
(12) Install slave cylinder in transmission clutch
housing. Tighten cylinder attaching nuts to 23 N-m
(13) Remove jack used to support transmission.
(14) Install strut bolts/nuts, if removed.
SPECIAL (15) Install transfer case. Align and position trans
TOOL fer case with transmission jack or aid of helper. Tilt
6783
case upward and work into position on transmission
mounting studs.
(16) Install and tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque.
(17) Install and connect transfer case shift linkage.
(18) Connect distance sensor wires.
(19) Align and connect exhaust system compo
nents. Be sure exhaust components are clear of all
chassis and driveline components.
(20) Align and install front and rear propeller
shafts. Tighten U-joint clamp bolts to 19 N-m (170 in.
lbs.) torque.
(21) Verify that all linkage components, hoses and
•206 electrical wires have been connected.
(22) Check transfer case fluid level. Add Mopar
Fig. 8 installing Shift Lever Extension With Tool
Dexron I I if necessary. Correct level is to edge of fill
6783
plug hole. Be sure transfer case is level before check
(25) Install shift boot and bezel. ing or adding fluid.
(23) Check and adjust transfer case shift linkage if
TRANSMISSION INSTALLATION (4-WHEEL DRIVE) necessary.
(1) Make sure transmission clutch housing and en (24) Install transfer case skid plate, if equipped.
gine block contact surfaces are clean. (25) Install new oil filter, if original was removed.
(2) Lubricate release fork pivot ball, release fork, (26) Remove any remaining support stands and
release bearing hub and transmission bearing re lower vehicle.
tainer surface with Mopar high temperature grease. (27) Install crankshaft position sensor.
(3) Mount transmission on jack. Secure transmis (28) If new oil filter was installed, add engine oil
sion to jack with safety chains. as needed to bring level to full mark on dipstick.
(4) Lubricate transmission input shaft pilot hub (29) Connect battery negative cable.
and splines with light coat of Mopar high tempera (30) Apply Mopar Gasket Maker, or Loctite 518 to
ture grease. mounting surfaces of shift tower, shift lever reaction
(5) Align transmission input shaft with release plate, and lever mounting surface on transmission
bearing and clutch disc. Then slide clutch housing front housing.
into place on engine block. (31) Install reaction plate and shift lever assembly
(6) Install and tighten transmission clutch housing (Fig. 4). Tighten shift tower bolts to 7-10 N-m (5-7 ft.
bolts to 54-61 N-m (40-45 ft. lbs.) torque. Be sure lbs.) torque. Reaction plate is one-way fit. Nar
housing is fully seated before tightening bolts. If row side goes to driver side of transmission.
equipped, install dust cover after tightening housing (32) If vehicle has press-on style shift lever exten
bolts. sion and it was removed from shift lever, reinstall ex
tension with Tool 6783 as follows:
Tool 6783 above flange on lever extension (Fig. 8).
Tool will now be used to press extension back onto
shift lever.
(b) lighten tool screw to press extension back
onto lever. Press extension to scribe mark made
during removal.
(c) Remove special tool.
(33) Install shift boot and bezel.
TRANSMISSION DISASSEMBLY AND OVERHAUL

Fig. 3 Shift Lever isolator And Plate Assembly
FRONT HOUSING REMOWAL Removal
(1) I f necessary, t e m p o r a r i l y r e i n s t a l l isolator (6) Remove rollers from anti-rotation bracket with
plate assembly, rollers, a n d shift lever assembly. pencil magnet (Fig. 4). Retain rollers as they are re
T h e n shift transmission i n t o N e u t r a l . usable parts i f i n good condition.
(2) I f lubricant was not drained out of transmis
sion during removal, remove drain plug and drain lu
bricant into container at this time.
(3) Remove backup light switch. Switch is located
on driver side of rear housing (Fig. 1).
Fig. 4 Removing Anti-Rotation Bracket Rollers

Fig. 1 Backup Light Switch Location
(7) Remove shift shaft lock bolt (Fig. 5). Bolt is lo
(4) Remove shift tower bolts and remove shift lever cated . at top of front housing just forward of shift
assembly (Fig. 2). tower. Bolt is a hex head, shoulder-type bolt that se
cures shift shaft bushing and lever. Use 13 mm
socket to remove bolt.
(8) Remove bolts attaching input shaft bearing re
tainer i n front housing (Fig. 6). Use 10 mm socket to
remove bolts.
(9) Remove input shaft bearing retainer. Use pry
tool to carefully lift retainer and break sealer bead
(Fig. 7).
(10) Remove bearing retainer from input shaft
(Fig. 8). Note position of retainer lube channel for in
Fig. 2 Shift Lever Assembly Removal
(11) Remove snap ring that secures input shaft i n
front bearing (Fig. 9).
(5) Remove isolator and plate assembly from shift
lever opening i n rear housing (Fig. 3). Plate assem
bly is one-way fit. Note p o s i t i o n o f plate f o r i n
stallation reference before removal. N a r r o w
side o f plate goes t o w a r d d r i v e r side o f trans
mission a n d r u b b e r coated side faces u p w a r d .
4 NV3500 MANUAL TRANSMISSION 21 - 9
t I 13 mm
Fig. 8 input Shaft Bearing Retainer Removal
Fig. 5 Shift Shaft Lock Bolt Removal
Fig. 9 Input Shaft Snap Ring Removal

HAMMER
Fig. 6 Input Shaft Bearing Retainer Bolt Removal
Fig. 10 Shift Shaft Detent Plug Removal
Fig. 7 Loosening Bearing Retainer Sealer Bead

(12) Remove shift shaft detent plug (Fig. 10). Use
crowfoot bar and hammer to lightly pry and tap plug
out of housing.
21-10 NV3500 MANUAL TRANSMISSION •
(13) Remove shift shaft detent plunger and spring
(Fig. 11). Use pencil magnet to remove spring then
plunger.
Fig. 11 Detent Plunger And Spring Remowal

Fig. 13 Front Housing Removal
(14) Remove bolts that attach front housing to rear
housing (Fig. 12). Three bolts at extreme r e a r o f handle to tap input shaft bearing out of case. Coun
housing are actually for the o u t p u t shaft bear tershaft bearing can be removed by hand.
i n g retainer. I t is n o t necessary to remove a l l
three bolts at t h i s t i m e . Leave at least one b o l t
i n place u n t i l r e a r case is ready t o be removed.
(15) Separate front housing from rear housing (Fig.
RETAINER
Fig. 14 Input Shaft And Countershaft Front Bearing

Location
(17) Note position of input shaft, shift shaft and
forks, and geartrain components i n housing (Fig. 15).
S H I F T SHAFT, SHIFT F O R K S AND R E V E R S E

IDLER S E G M E N T REMOVAL
(1) Place shop towel over shaft lever and bushing
to contain lever detent ball and spring. Then rotate
lever and bushing upward out of shift forks and
catch ball and spring as they exit shaft lever (Fig.
16).
(2) Disengage bias spring from anti-rotation
bracket (Fig. 17). Use screwdriver and length of steel
brake tube to unseat spring. Slip brake tube over
Fig. 12 Housing And Bearing Retainer Bolt spring end and rotate spring away from bracket.
Locations Then use screwdriver to move spring end off bracket
tab.
13). Use plastic mallet to tap front housing off align
(3) Unseat roll pin that secures shift socket to shift
ment dowels.
(16) Remove input shaft bearing and countershaft shaft as follows:
front bearing from front case (Fig. 14). Use hammer
• NW3500 MANUAL TRANSMISSION 21-11
SHIFT BUSHING REAR UNSEAT SHORT

USE STEEL
SHAFT HOUSING E N D WITH
TUBE T O
UNSEAT L O N G PRY TOOL
END OF SPRING
3-4
FORK
J9421-18
Fig. 17 Disengaging Anti-Rotation Bracket Bias

REVERSE Spring
OUTPUT IDLER A N D
SHAFT
SUPPORT (b) Remove reverse idler segment (but leave gear
COUNTERSHAFT A N D GEARS J942M5
in case).
(c) Remove input shaft, bearing, and 3-4 synchro
Fig. 15 Geartrain And Shift Component ring.
Identification (d) Remove 3-4 shift fork and 3-4 synchro sleeve
simultaneously. Use shop rag to catch struts, balls,
SHAFT and springs as sleeve comes off hub.
LEVER DETENT (e) Slide shift shaft bushing off shaft lever. Then
BALL A N D rotate lever out of shift fork arms and catch ball
SPRING
and spring as lever clears notches.
(f) Push shift shaft rearward, tap out pin (if
needed) and pull shaft out of rear housing and shift
forks. Use plastic mallet to assist shaft removal.
PIN
PUNCH SHIFT
SOCKET
J942M9
Fig. 16 Removing Shift Shaft Lever Detent Ball And

Spring
(a) Tilt socket toward passenger side of case.
This places roll pin at slight angle to avoid trap Fig. 18 Driving Roll Pin Out Of Shift Socket
ping pin between gear teeth when i t is tapped (4) Drive out roll pin that secures bushing and le
downward. ver to shift shaft (Fig. 19).
(b) Tap roll pin downward with pin punch. Roll (5) Pull shift shaft out of rear housing, shift socket,
pin does not have to come completely out of shift anti-rotation bracket, fifth-reverse fork and 1-2 fork
shaft. I t only has to clear the socket. (Fig. 20). Tap shift socket rearward with mallet to
(c) I f roll pin accidentally becomes jammed help move shaft out of socket.
between gear teeth locking socket and shaft (6) Remove bias spring, shift socket and anti-rota
i n place, proceed to alternate disassembly tion bracket from rear housing (Fig. 21).
method i n step (1A). (7) Remove lever and bushing from shift shaft (Fig.
(1A) I f socket roll pin becomes jammed, alternate 22).
disassembly method is as follows: (8) Remove shift shaft (Fig. 23). Pull shaft straight
(a) Remove rear bearing retainer bolts. out of fork.
(9) Remove 3-4 fork. Rotate 3-4 fork around syn-
21 - 12 N¥3i00 MANUAL TRANSMISSION
PIN
PUNCH SHAFT -
SHIFT LEVER r
SHAFT
AND
BUSHING ~
BUSHING
AND
LEVER
3-4
FORK
. J9421-17 J9421-41:
Fig. 19 Removing Shift Shaft Lever Roil Pin Fig. 22 Removing Shift Shaft Lever And Bushing
PLASTIC SHIFT
MALLET SHAFT
SHIFT
SOCKET
SHAFT
DETENT
NOTCHES
J9421-40: J9421-42
Fig. 2 0 Pulling Shift Shaft Out Of Housing, Socket, Fig. 23 Removing Shift Shaft
Bracket Fifth-Reverse Fork and 1-2 Fork
3-4 1-2 A N D
FORK 5TH-REVERSE
MAS FORK ARMS
SPUING
3-4
SYNCHRO
SLEEVE
SHIFT ANTI-liOWIOf*
X1t=L
J9421-44"
SOCKET BRACKET
J9421-148
Fig. 24 Removing 3-4.Shi ft Fork
Fig. 2 1 Shift Lever Control Components (a) Adjust height of reverse idler pedestal rod to
chro sleeve fork clears shift arms on 1-2 and fifth-re 18.42 cm (7-1/4 in.) Then position Adapters 6747-1
verse forks. Then remove 3-4 fork (Fig. 24). and 6747-2 on Assembly Fixture 6747.
(10) Support geartrain and rear housing on Assem
bly Fixture Tool 6747 (with aid of helper) as follows:
• NV3500 MANUAL TRANSMISSION 2 1 - 1 3
(b) Slide fixture tool onto input shaft, counter (11) Remove bolts attaching reverse idler shaft and
shaft and idler gear (Fig. 25). T h e pedestal rod shaft support segment to rear housing (Fig. 27).
on the fixture tool is used to support the re
verse idler.
(c) Stand geartrain and rear housing upright on
fixture (Fig. 26). Have helper hold fixture tool i n
place while housing and geartrain is being rotated
into upright position.
(d) Position 5 x 10 cm (2 x 4 in.) wood blocks un
der legs of fixture tool. Blocks are needed to raise
fixture high enough for input shaft to clear work
bench surface.
SPECIAL SPECIAL
TOOL TOOL
Fig. 27 Removing/Installing Reverse Idler Shaft

Bolts
PEDESTAL J9421-45
(12) Remove reverse idler shaft support segment
by sliding i t straight out of housing (Fig. 28).
Fig. 25 Installing Assembly Fixture On Geartrain
INPUT SHAFT
Fig. 26 Geartrain And Housing Mounted On Fixture Fig. 28 Reverse Idler Shaft Support Segment
Tool Removal/Installation
R E A R HOUSING REMOVAL (2-WHEEL DRIVE
TRANSMISSION!
(1) On 2-wheel drive transmission, remove three
bolts that attach output shaft bearing retainer to
rear case (Fig. 29). Bolts are to rear of shift tower
opening.
J9421-50
Fig. 30 Unseating Rear Housing From Output Shaft
Fig. 29 Removing/Installing Output Shaft. Bearing Bearing (2-Wheel Drive Transmission)
Retainer Bolts (2-Wheel Drive Transmission)
(2) Unseat output shaft bearing from bearing bore
in rear housing. Use plastic or rawhide mallet to tap
rear housing upward and off output shaft bearing as
shown (Fig. 30).
(3) Lift rear housing up and off geartrain (Fig. 31).
(4) Remove countershaft rear bearing from rear
housing (Fig. 32).
(5) Examine condition of oil tube, bearing bore and
idler shaft notch i n rear housing (Fig. 32). Replace
housing i f any of these components are damaged.
R E A R ADAPTER HOUSING REMOVAL

(4-WHEEL DRIVE TRANSMISSION)
(1) A tool is required to remove the rear seal from
the adapter housing. Use either a dent puller, or fab
ricate a remover tool from 5/16 x 1-1/2 in. long lag
screw and appropriate size hex nut. Use hex nut that
will fit on a slide hammer. Tack weld, braze or silver
solder nut to lag screw (Fig. 33).
(2) Install fabricated seal remover tool on slide
hammer shaft (Fig. 33).
Fig. 31 Rear Housing Removal (2-Wheel Drive
(3) Locate dimples i n face of rear seal (Fig. 34).
Transmission)
Fabricated seal remover tool will be threaded into
one of these dimples. (5) Remove rear seal with slide hammer. Seal
(4) Thread fabricated seal remover tool into one of should only require 2-3 light bumps with slide ham
the dimples i n the seal face (Fig. 35). mer to remove it.
FABRICATED SUDE HAMMER

SEAL
REMOVER
TOOL
J942M98
Fig. 35 Remover Tool Threaded into Seal
(4-Wheel Drive Transmission)
REAR SUDE REMOVER

HOUSING HAMMER TOOL
J9421-52
Fig. 32 Rear Housing Components
mm
mmm immm
mm
L
J9421-200
Fig. 36 Rear Seal Removal
WBDVMAZE (4-Wheel Drive Transmission)
mum
immsw (6) Remove rear bearing snap ring from output
shaft with heavy duty snap ring pliers (Fig. 37).
J942M99
Fig. 33 Rear Seal Remover Tool HEAVY
(4-Wheel Drive Transmission) DUTY
SNAP
RING
LOCATION PLIERS
OF
DIMPLES
J9421-201
37 Rear Bearing Snap Ring Removal (4-Wheel

J942M97 Drive Transmission)
Fig. 34 Location Of Dimples In Seal Face
(7) Lift rear adapter housing upward and off (4) Remove output shaft bearing retainer from rear
geartrain (Fig. 38). surface of fifth gear (retainer will drop onto gear af
ter bolts are removed).
(5) Lift and remove output shaft and gears off in
put shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from assembly fixture tool.
OUTPUT SHAFT GEARTRAIN DISASSEMBLY

The synchronizer hubs and sleeves are differ
ent and must not be intermixed. It is recom
mended that each synchronizer unit be
removed as an assembly to avoid intermixing
parts. It is also recommended that each syn
Fig, 38 Rear Adapter Housing Removal (4-Wheel chro hub and sleeve be marked with a scriber
Drive Transmission) or paint for correct assembly reference.
(8) Remove bearing retainer bolts and remove rear (1) Remove snap ring that secures 3-4 synchro hub
bearing retainer and rear bearing (Fig. 39). Use ham on output shaft.
mer handle to push or tap bearing out of housing i f (2) Remove 3-4 synchro assembly and third speed
needed. synchro ring with shop press and Remover Tool 1130
(9) Examine condition of bearing bore, counter (Fig. 40).
shaft rear bearing race and idler shaft notch i n rear (a) I f remover tool has fairly thick jaws, position
housing. Replace housing i f race, bore or notch are tool jaws behind third speed synchro ring. Inspect
worn or damaged. synchro ring afterward as remover tool may dam
age ring during removal.
(b) I f remover tool has fairly thin jaws, position
tool jaws behind third gear. Then remove synchro
assembly and gear simultaneously.
KI1NW7 J9421-21
Fig, 40 Removing 3-4 Synchro Assembly
Fig. 39 Rear Adapter Housing Components (4-Wheel (3) Remove third gear and needle bearing (Fig. 41).
Drive Transmission) (4) Remove retaining ring that secures two-piece
thrust washer on shaft (Fig. 42). Use small pry tool
REMOVING GEARTRAIN FROM FIXTURE TOOL
to remove retaining ring.
6747
(5) Remove two-piece thrust washer (Fig. 43). Note
(1) Slide reverse idler gear assembly off assembly position of washer locating lugs i n shaft notches for
fixture pedestal. installation reference.
(2) Remove 1-2 and fifth-reverse forks from syn (6) Remove second gear and needle bearing (Fig.
chro sleeves. 44).
(3) Slide countershaft out of fixture tool. (7) Remove second speed synchro ring. Then re
move 1-2 synchro hub snap ring (Fig. 45).
N¥3500 MANUAL TRANSMISSION 21-17
SECOND
THIRD SECOND GEAR
GEAR GEAR NEEDLE
THIRD NEEDLE BEARING
BEARING
GEAR
J9421-22 J94?l-25
Fig. 41 Third Gear And Needle Bearing Remowal Fig. 44 Second Gear And Needle Bearing Remowal
SYNCHRO
SECOND HUB
GEAR SNAP
SYNCHRO RING
RING
-2
SYNCHRO
HUB
AND
THRUST WASHER SLEEVE
RETAINING
RING J9421-26
J9421-23
Fig. 45 Second Speed Synchro Ring And Synchro
Fig. 42 Thrust Washer Retaining Ring Remowal
Hub Snap Ring Remowal
(8) Remove 1-2 synchro hub and sleeve from out
SECOND put shaft with shop press and Remover Tool 1130
GEAR (Fig. 46).
THRUST
WASHER 1-2
(2-PIECE) SYNCHRO
HUB
AND
SLEEVE
J9421-24 SPECIAL
TOOL
Fig. 43 Two-Piece Thrust Washer Remowal 1130
J9421-27
Fig. 46 1-2 Synchro Hub And Sleewe Remowal

21-18 NV3500 MANUAL TRANSMISSION
(9) Remove first gear and needle bearing (Fig. 47).

PRESS
RAM
FIRST SPACER
FIRST (AS REQUIRED)
GEAR GEAR
NEEDLE
BEARING
OUTPUT
SHAFT
J9421-28
Fig. 47 First Gear And Needle Bearing Remowal SHAFT. SPECIAL

BEARING' TOOL
(10) Remove output shaft bearing snap ring (Fig. 1130
48).
OUTPUT
SHAFT
BEARING
PRESS,
PLATES J9421-30
i i
Fig. 49 Output Shaft Bearing Remowal (2-Wheel Driwe)

SNAP
RING
PLIERS BEARING
SNAP FIFTH
RING GEAR
AND
SYNCHRO
J9421-29
Fig. 48 Output Shaft Bearing Snap Ring Remowal

(11) On 2-wheel drive models, remove output shaft
bearing with Remover Tool 1130 and shop press (Fig. J9421-31
49).
(12) Remove fifth gear (Fig. 50). Fig. 50 Fifth Gear Remowal
(13) Remove fifth gear needle bearing. Spread (3) Remove idler gear needle bearing from shaft.
bearing apart just enough to clear shoulder on output
shaft (Fig. 51). SHIFT L E V E R DISASSEMBLY (FIG. 56)
(14) Remove fifth-reverse synchro hub snap ring The shift lever assembly can be disassembled
(Fig. 52). for cleaning and inspection if desired. However,
(15) Remove fifth reverse synchro hub and sleeve the only serviceable part on the assembly is the
with shop press and standard type remover tool (Fig. shift lever outer boot (Fig. 56). The tower, lever,
53) . and remaining components are NOT available
(16) Remove reverse gear and needle bearing (Fig. separately; these components are only serviced
54) . as a complete assembly.
R E V E R S E IDLEm DISASSEMBLY (FIG. SSI
(1) Remove outer boot from groove i n shift tower.
(1) Remove idler gear snap rings. Then slide boot up and off shift lever.
(2) Remove thrust washer, wave washer, thrust (2) Remove screws attaching shift lever retainer to
plate and idler gear from shaft. shift tower. Then remove retainer.
NV3500 MANUAL TRANSMISSION 21 - 19
FIFTH SPECIAL
GEAR TOOL
NEEDLE 1130
BEARING
(SPREAD
BEARING TO
CLEAR
SHOULDER
ON
SHAFT)
MARK HUB
J9421-32 FOR INSTALLATION REFERENCE
J9421-34
Fig. 51 Fifth Gear Needle Bearing Remowal Fig. 53 Fifth-Rewerse Synchro Hub And Sleeve
Remowal
FIFTH-REVERSE
SYNCHRO REVERSE GEAR
HUB AND SLEEVE AND NEEDLE
BEARING
SYNCHRO
HUB
SNAP
RING J9421-35
SNAP
RING
PLIERS Fig. 54 Rewerse Gear And Needle Bearing Remowal
J9421-33
Fig. 52 Fifth-Rewerse Synchro Hub Snap Ring

Remowal
REVERSE
IDLER
GEAR IDLER
SNAP FLAT WAVE THRUST GEAR IDLER THRUST SNAP
RING WASHER WASHER WASHER BEARING SHAFT WASHER RING
THRUST
WASHER
LOCK BALLS
J9421-53
Fig. 55 Rewerse Idler Components

21 - 20 NW3500 MANUAL TRANSMISSION
SHIFT
TOWER AND
INNER BOOT
OUTER
BOOT
GUIDE
J9421-38
Fig. 56 Shift Lever Components

(3) Remove seal plate from shift tower. hibiting wear or damage i n these areas. Do not at
(4) Slide inner boot off ball end of shift lever. tempt to salvage shift forks.
(5) Pull shift lever up and out of tower. Inspect the shift shaft bushings and front
(6) Remove plastic seat and guides from shift lever. bearing carefully. The bushings and bearing are
(7) Obtain replacement not serviceable items. The front or rear housing
will have to be replaced if these components
TRANSMISSION COMPONENT CLEANING AND are damaged i n any way.
INSPECTION Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
Component Cleaning nicks, or scores. The plunger spring should be
Clean the gears, shafts, shift components and straight and not collapsed, or distorted. Minor
transmission housings with a standard parts clean scratches, or nicks on the plunger can be smoothed
ing solvent. Do not use acid or corrosive base sol with 320/400 grit emery soaked i n oil. Replace the
vents. Dry all parts except bearings with compressed plunger and spring i f i n doubt about condition.
air. Inspect the shift shaft, the shaft lever and the le
Clean the shaft bearings with a mild solvent such ver bushing that fits over the lever. Replace the shaft
as Mopar degreasing solvent, Gunk, or similar sol i f bent, cracked, or severely scored. Minor burrs,
vents. Do not dry the bearings with compressed air. nicks, or scratches can be smoothed off with 320/400
Allow the bearings to either air dry, or wipe them dry grit emery cloth followed by polishing with crocus
with clean shop towels. cloth.
Replace the shaft lever and bushing i f either part
Shift Lever Assembly
is deformed, or worn. Do not attempt to salvage these
The shift lever assembly can be disassembled for
parts as shift fork binding will occur. Replace the
cleaning and inspection i f desired. However, the only
small detent ball and spring that goes i n the lever i f
serviceable part of the assembly is the shift lever
outer boot (Fig. 56). The tower, lever, and remaining the ball is worn, or i f the spring is bent or collapsed.
components are NOT available separately; these com Replace the roll pin that secures the lever to the
ponents are only serviced as a complete assembly. shaft.
Replace the shift lever assembly i f the tower, lever, or
Front/Rear Housings And Bearing Retainers
internal components are worn, or damaged.
Inspect the housings carefully. Look for cracks,
Shift Shaft And Forks stripped threads, scored mating surfaces, damaged
Inspect the shift fork interlock arms and synchro bearing bores, or worn dowel pin holes. Minor nicks
sleeve contact surfaces (Fig. 57). Replace any fork ex on mating surfaces can be dressed off with a fine file,
NV3I00 MANUAL TRANSMISSION 21 - 21
SHIFT SHAFT
SHAFT LEVER
SHAFT
LEVER
BUSHING
FIFTH-REVERSE SHIFT 1-2 SHIFT 3-4 SHIFT

FORK FORK FORK
J9421-54
Fig. 57 Shift Forks And Shaft

or emery cloth. Damaged threads can be renewed by Countershaft Bearings And Races
either re-tapping or installing Helicoil inserts. The countershaft bearings and races are machine
Check condition of the oil tube in the rear housing. lapped during manufacture to form matched sets.
The tube must not be bent or loose. The housing will The bearings and races should not be interchanged.
have to be replaced if the tube is loose or damaged. The bearing races are a permanent press fit
Pay particular attention to the bushings and in the housings and are NOT serviceable. I f a
bearings in the front and rear housings. The bearing race becomes damaged, it will be nec
front housing contains the shift shaft front essary to replace the front or rear housing as
bearing and bushing, the countershaft front necessary. I n addition, if a countershaft bearing
bearing race and the detent plunger bushing. becomes damaged, it will be necessary to re
The rear housing contains the shift shaft rear place not only the bearing but the applicable
bushing and the countershaft rear bearing housing as well. A new countershaft bearing
race. Be advised that these components are will be supplied with each new housing for ser
NOT serviceable items. The front housing will vice use.
have to be replaced if the shift shaft bearing The countershaft bearings can be installed back
and bushing, detent plunger bushing, or coun wards if care is not exercised. The bearing roller cage
tershaft bearing race is loose, worn, or dam is a different diameter on each side. Be sure the
aged. The rear housing will have to be replaced bearing is installed so the large diameter side
if the shift shaft rear bushing, or the counter of the cage is facing the countershaft gear (Fig.
shaft rear bearing race is loose, worn, or dam 58). The small diameter side goes in the bearing
aged. race.
Inspect the input shaft bearing retainer. Be sure Reverse Idler Components
the release bearing slide surface of the retainer is in
Inspect the idler gear, bearing, shaft, thrust
good condition. Minor nicks on the surface can be
washer, wave washer and thrust plate (Fig. 56). Re
smoothed off with 320/420 grit emery cloth and final
place the bearing if any of the needle bearing rollers
polished with oil coated crocus cloth. Replace the re are worn, chipped, cracked, flat-spotted, or brin-
tainer seal if necessary. nelled. Also replace the bearing if the plastic bearing
Inspect the output shaft bearing retainer. Be sure cage is damaged or distorted.
the U-shaped retainer is flat and free of distortion. Replace the thrust washer, wave washer, or thrust
Replace the retainer if the threads are damaged, or if plate if cracked, chipped, or worn. Replace the idler
the retainer is bent, or cracked. gear if the teeth are chipped, cracked or worn thin.
Replace the shaft if worn, scored, or the bolt threads
are damaged beyond repair. Replace the support seg-
COUNTERSHAFT
BRACKET
ROLLERS
ANTI-ROTATION BRACKET
J9421-55 J9421-43
Fig. 58 Correct Countershaft Bearing installation Fig, 59 Shift Lever Components

ment i f cracked, or chipped and replace the idler at TRANSMISSION ASSEMBLY
taching bolts i f the threads are damaged.
Assembly Information
Shift Lever Controls Gaskets are not used i n the NV3500 transmission.
Inspect the bias spring, shift socket, anti-rotation Sealers are used at all flange joints. Recommended
bracket, and bracket rollers (Fig. 59). sealers are Mopar Gasket Maker (or Loctite 518) for
Replace the socket i f worn, cracked, or i f the pin is all flange joints and Loctite Ultra, heavy body sili
loose or damaged. Replace the spring i f broken or cone (black) sealer (or Mopar equivalent) for the in
distorted. Replace the anti-rotation bracket i f bent, put shaft bearing retainer. Apply these products as
broken, or worn. The bracket rollers can be reused i f indicated i n the reassembly procedures.
they are i n good condition but should be replaced i f It is very important that the transmission
worn, or chipped. shift components be i n Neutral position during
The original shift socket roll pin should not be re assembly. This is necessary i n preventing dam
used. Install a new pin during reassembly. The age to synchro and shift components when the
socket roll pin is approximately is approximately 33 housings are installed.
mm (1-1/4 in.) long. Transmission gears, shafts, and synchro compo
nents should all be lubricated with recommended
Output Shaft And Gears gear lubricant during assembly operations. Petro
Inspect all of the gears (Fig. 60) for worn, cracked, leum jelly can be used to prelubricate bearings and
to hold parts i n place during assembly. Only petro
chipped, or broken teeth. Also check condition of the
leum jelly should be used. Do not use chassis or
bearing bore i n each gear. The bores should be
bearing grease. This type of heavy grease will
smooth and free of surface damage. Discoloration of
plug oil channels i n the housings and gears re
the gear bores is a normal occurrence and is not a sulting in failure.
reason for replacement. Replace gears only when
The 3-4, 1-2 and fifth-reverse synchro hub snap
tooth damage has occurred, or i f the bores are brin- rings can be fitted selectively. New snap rings are
nelled or severely scored. available i n 0.05 mm (0.0019 in.) thickness incre
Inspect the shaft splines and bearings surfaces. M i ments. Use the thickest snap ring that will fit i n
nor nicks on the bearings surfaces can be smoothed each snap ring groove.
with 320/420 grit emery and final polished with cro Proper reassembly of the NV3500 requires some
cus cloth. Replace the shaft i f the splines are dam special service tools. Geartrain Assembly Fixture
aged or bearing surfaces are deeply scored, worn, or 6747 is especially important. The entire geartrain
brinnelled. and shift mechanism must be assembled i n this fix
ture before either transmission housing can be prop-
0 INPUT SHAFT 0 FIRST SPEED SYNCHRO RING

0 FOURTH SPEED SYNCHRO RING 0 FIRST GEAR
0 OUTPUT SHAFT PILOT BEARING 0 FIRST GEAR NEEDLE BEARING
0 SNAP RING, 3-4 SYNCHRO HUB @ OUTPUT SHAFT
0 SLEEVE, 3-4 SYNCHRO @ REVERSE GEAR NEEDLE BEARING
0 HUB, 3-4 SYNCHRO 0 REVERSE GEAR
0 STRUT, SPRING, DETENT BALL (3 SETS), 3-4 SYNCHRO 0 REVERSE SYNCHRO RING (SOLID BRASS)
0 THIRD SPEED SYNCHRO RING 0 FIFTH-REVERSE SYNCHRO HUB
0 THIRD GEAR @ STRUT, SPRING, DETENT BALL (3 SETS), FIFTH-REVERSE SYNCHRO
® THIRD GEAR NEEDLE BEARING 0 SLEEVE, FIFTH-REVERSE SYNCHRO
0 RETAINING RING 0 SNAP RING, FIFTH-REVERSE SYNCHRO HUB
® THRUST WASHER (2-PIECE) 0 FIFTH SPEED SYNCHRO RING
® SECOND GEAR NEEDLE BEARING 0 FIFTH GEAR NEEDLE BEARING
0 SECOND GEAR 0 FIFTH GEAR
® SECOND SPEED SYNCHRO RING @ BEARING RETAINER (IN HOUSING)
0 SLEEVE, 1-2 SYNCHRO 0 OUTPUT SHAFT BEARING
0 SNAP RING, 1-2 SYNCHRO HUB 0 SNAP RING, SHAFT BEARING
0 STRUT, SPRING, DETENT BALL (3 SETS), 1-2 SYNCHRO J9421-37
Fig. 60 Output Shaft Geartrain

erly installed. The tools are needed to avoid Fifth-Reverse Synchro Position
damaging the gears, housing, or shift components. The fifth-reverse synchro hub has raised shoulders
on one side of the spline bore. This side of the hub
CORRECT ASSEMBLY OF SYNCHRONIZER must face the rear of the output shaft after installa
COMPONENTS, tion.
The synchronizer sleeves, hubs and struts are dif The fifth-reverse sleeve has a large taper on one
ferent and must be kept i n sets. Only the synchro de side. Be sure the sleeve is installed so the taper faces
tent balls and springs are interchangeable. toward front of the output shaft.
The 5-4 and 1-2 synchro rings are all made of cast
metal and are interchangeable. However, the reverse Synchro Component Assembly
gear synchro ring is made of solid brass and must The easiest method of assembling each synchro is
not be interchanged. to install the springs, struts and detent balls one at a
A total of three detent springs, struts and balls are time as follows:
used i n all three synchro assemblies. The balls and (1) Slide the sleeve part way onto the hub. Leave
springs are interchangeable. enough room to install the spring i n the hub and the
The synchro sleeves and hubs must also be cor strut i n the hub groove.
rectly positioned on the shaft i n order to operate (2) Install the first spring i n the hub. Then install
properly. Assemble and install each synchro accord a strut over the spring. Be sure the spring is seated
ing to the following instructions. in the spring bore i n the strut.
(3) Slide the sleeve onto the hub just far enough to
3-4 Synchro Position
hold the first strut and spring i n place.
Some 3-4 synchro hubs may have a raised shoulder (4) Place the detent ball i n the top of the strut.
on one side of the spline bore. I f so, this side of the Then carefully work the sleeve over the ball to hold
hub must face the front of the output shaft after in it i n place. A small flat blade screwdriver can be used
stallation. However, i f both hub sides are the same, to press the ball into place while moving the sleeve
the hub can be installed i n either direction. over i t .
The 3-4 synchro sleeve has grooves machined on (5) Repeat the procedure for the remaining
one side. Be sure this side also faces the front of the springs, struts and balls. Tape, or a rubber band can
output shaft. be used to temporarily secure each strut and ball as
they are installed.
1-2 Synchro Position
(6) Verify synchro assembly. Be sure the three
The 1-2 synchro hub has raised shoulders on one springs, struts and detent balls are all i n place (Fig.
side of the spline bore. This side of the hub must face 62).
the rear of the output shaft after installation.
The top surface of the 1-2 synchro sleeve is marked
HUB
for correct installation (Fig. 61). One side of the
sleeve is marked "first gear side". Be sure this side is
facing the first gear after installation.
CORRECT POSITION
IS MARKED ON
SLEEVE
J9421-56
J9421-57
Fig. 61 Location Of Position Marks On 1-2 Synchro
Sleeve Fig. 62 Assembled View Of Synchro Components
O U T P U T SHAFT AND GEARTRAIN ASSEMBLY

Because the synchro hubs and rear bearing
must be pressed onto the output shaft, it is eas
ier (and faster), to assemble the entire
geartrain while mounted i n a shop press. This
method of reassembly is demonstrated i n the
following procedure.
(1) Lubricate shaft, gears and bearings (Fig. 60)
with recommended lubricant during assembly. Petro
leum jelly can be used to hold parts i n place.
(2) Check bearing surfaces of output shaft for nicks
or scratches. Smooth surfaces with 320/400 grit em Fig. 65 Reverse Gear Synchro Ring installation
ery cloth i f necessary. Apply ATF to emery cloth and
shaft surface before polishing. (8) Assemble fifth-reverse synchro hub, sleeve,
struts, springs and detent balls, i f not previously
(3) Inspect and replace any synchro ring that ex
done.
hibits wear or damage. Completely immerse each
synchro ring i n lubricant before installation. CAUTION: The fifth-reverse s y n c h r o hub a n d sleeve
(4) Recheck needle bearings once again before as c a n be installed backwards if care is n o t exercised.
sembly, replace any bearing exhibiting wear, or dam On© side of the hub has s h o u l d e r s a r o u n d t h e h u b
age to the bearing rollers or plastic bearing cage. bore. Make sure this side of t h e h u b is f a c i n g t h e
Petroleum jelly can be used to prelubricate bearings rear of t h e shaft- I n addition, o n e s i d e of t h e sleeve
i f desired. is tapered. B e sure the sleeve is installed s o the ta
(5) Lubricate and install reverse gear needle bear pered side will be facing the front of the shaft.
ing on shaft (Fig. 63). Slide bearing up against shoul
der on output shaft as shown. (9) Start fifth-reverse synchro assembly on output
REVERSE shaft splines by hand. Then seat synchro onto shaft
with shop press and suitable size pipe tool (Fig. 66).
Fig. 63 Reverse Gear Bearing Installation

(6) Install reverse gear over needle bearing (Fig.
64).
J9421-61
Fig. 66 Fifth-Reverse Synchro Assembly Installation

(10) Install new fifth-reverse hub snap ring (Fig.
67) as follows:
Fig. 64 Reverse Gear installation
(a) Snap rings are available i n thicknesses from
(7) Install solid brass synchro ring on reverse gear 2.00 mm to 2.20 mm (0.078 to 0.086 in.).
(Fig. 65). (b) Install thickest snap ring that will fit i n shaft
groove.
(c) Verify that snap ring is completely seated i n
groove before proceeding.
Fig. 69 Installing Fifth Gear Bearing
Fig. 67 Installing Fifth-Reverse Synchro Hub Snap

Ring
(11) Install fifth speed synchro ring i n synchro hub
and sleeve (Fig. 68).
Fig, 70 Fifth Gear Installation
Fig. 68 Installing Fifth Speed Synchro Ring

(12) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 69). Be
sure bearing is properly seated after installation.
(13) Install fifth gear on shaft and onto bearing
(Fig. 70).
(14) Install output shaft bearing with shop press
and suitable size pipe tool (Fig. 71).
(15) Install output shaft bearing snap ring (Fig.
72). Use heavy duty snap ring pliers and spread snap
ring only enough to install it. Be sure snap ring is
completely seated i n shaft groove before proceeding.
(16) Turn output shaft over so i t is supported on
press blocks by output shaft bearing (Fig. 73). Re
mainder of geartrain can now be installed on shaft
while i t is still mounted i n shop press.
Fig. 71 Output Shaft Bearing Installation
BEARING
SNAP
RING FIRST
GEAR
BEARING
Fig. 72 installing Output Shaft Bearing Snap Ring

Fig, 74 First Gear installation
(17) Install first gear bearing on output shaft (Fig.
73). Be sure bearing is seated on shaft shoulder and
is properly joined.
FIRST
Fig. 75 First Speed Synchro Ring installation

(21) Start 1-2 synchro assembly on shaft by hand
(Fig. 76). Be sure synchro sleeve is properly positioned.
Side marked first side must be facing first gear.
Fig. 73 First Gear Bearing Installation

(18) Install first gear on shaft and over bearing
(Fig. 74). Make sure bearing synchro cone is facing
up as shown.
(19) Install first speed synchro ring (Fig. 75).
(20) Assemble 1-2 synchro hub sleeve, springs,
struts and detent balls.
CAUTION: The 1-2 synchro hub and sleeve can be

installed backwards if care is not exercised. One
side of the hub has a small diameter shoulder
around the hub bore. Make sure this side of the hub
faces the forward end of the output shaft. In addi
Fig. 78 Starting 1-2 Synchro On Shaft
tion, one side of the synchro sleeve is marked "first
gear side" (Figs. 61 and 76). Be sure this side of the
sleeve will face the first gear after installation.
(22) Press 1-2 synchro onto output shaft using (24) Install second speed synchro ring i n 1-2 syn
suitable size pipe tool and shop press (Fig. 77). chro hub and sleeve (Fig. 79). Be sure synchro ring is
properly seated i n sleeve.
CAUTION: Take t i m e to align the s y n c h r o r i n g a n d
p p n i i i j i
sleeve as h u b t h e is b e i n g p r e s s e d o n t o t h e shaft.
The s y n c h r o ring c a n be c r a c k e d if it b e c o m e s m i s SECOND
aligned.
Fig. 79 Second Speed Synchro Ring Installation

(25) Install second gear needle bearing on shaft
(Fig. 80).
Fig. 77 Pressing 1-2 Synchro Assembly Onto Output

Shaft
(23) Install new 1-2 synchro hub snap ring (Fig.
78) as follows:
(a) Snap rings are available i n thicknesses from
1.80 mm to 2.00 mm (0.070 to 0.078 in.).
(b) Install thickest snap ring that will fit i n shaft
groove.
groove before proceeding. Fig. 80 Second Gear Bearing Installation
(26) Install second gear onto shaft and bearing
(Fig. 81).
(27) Install two-piece thrust washer (Fig. 82). Be
sure washer halves are seated i n shaft groove and
that washer lugs are seated i n shaft lug bores.
(28) Start retaining ring around two-piece thrust
washer (Fig. 83).
(29) Seat thrust washer retaining ring with plastic
mallet (Fig. 84).
(30) Install third gear needle bearing on shaft (Fig.
85) .
(31) Install third gear on shaft and bearing (Fig.
86) .
(32) Install third speed synchro ring on third gear
(Fig. 87).
Fig. 78 Installing 1-2 Synchro Hub Snap Ring
Fig. 81 Second Gear installation Fig. 83 Starting Retaining Ring Over Two-Piece
Thrust Washer
Fig. 84 Seating Thrust Washer Retaining Ring
J9421 -77
Fig. 82 Installing Two-Piece Thrust Washer

(33) Assemble 3-4 synchro hub, sleeve, springs,
struts and detent balls.
CAUTION: The 3-4 s y n c h r o h u b a n d sleeve can be

installed backwards if care is not exercised. One
side of t h e h u b has s h o u l d e r s a r o u n d the h u b bore. Fig. 85 Third Gear Bearing Installation
Make sure this side of the h u b is facing the f r o n t of
(34) Start 3-4 synchro hub on output shaft splines
the shaft. In a d d i t i o n , one side of the sleeve has
by hand (Fig. 88).
g r o o v e s in it. Be sure t h i s side of sleeve is also fac
(35) Press 3-4 synchro assembly onto output shaft
ing the f r o n t of the shaft.
with shop press and suitable size pipe tool (Fig. 89).
21 - 30 NW3S00 MANUAL TRANSMISSION
Fig. 86 Installing Third Gear
THIRD
SPEED
Fig. 89 Pressing 3-4 Synchro Assembly On Output

Shaft
(b) Install thickest snap ring that will fit i n shaft
groove. Use heavy duty snap ring pliers to install
new ring.
groove before proceeding.
3-4
SYNCHRO
Fig. 87 Third Speed Synchro Ring Installation
Fig. 90 Installing 3-4 Synchro Hub Snap Ring

(37) Verify correct position of synchro sleeves be
fore proceeding with assembly operations (Fig. 91).
Grooved side of 3-4 sleeve should be facing forward.
First gear side of 1-2 sleeve should be facing first
Fig. 88 Starting 3-4 Synchro Hub On Output Shaft
gear. Tapered side of fifth-reverse sleeve should be
(36) Install 3-4 synchro hub snap ring (Fig. 90) as facing forward.
follows:
(a) Snap rings are available i n thicknesses from R E V E R S E IDLER ASSEMBLY (FIG. SS)
2.00 mm to 2.30 mm (0.078 to 0.090 in.). (1) Lubricate idler components with gear lube.
N¥3i00 MANUAL TRANSMISSION 21 - 31
GROOVED SIDE "FIRST GEAR TAPERED

FORWARD SIDE" F A C I N G SIDE
GEAR FORWARD
3-4 1-2 5TH REV.

SYNCHRO SYNCHRO SYNCHRO
SLEEVE SLEEVE SLEEVE J942M45
Fig. 91 Correct Synchro Sleeve Position

(2) Slide idler gear bearing on shaft (Fig. 92). (6) Install snap ring i n groove at rear of shaft (Fig.
Bearing fits either way on shaft. 93).
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 92).
(4) Place first lock ball i n dimple at rear end of
idler shaft (Fig. 92). Petroleum jelly can be used to
hold ball i n place i f desired.
IDLER
GEAR
BEARING SNAP
RING
GROOVE
THRUST
WASHER
J9421-89
Fig. 93 Idler Gear Rear Thrust Washer Installation

(7) Install lock ball i n dimple at front of shaft.
REAR OF Hold ball i n place with petroleum jelly i f desired.
SHAFT J9421-87 (8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 94).
Fig. 92 Idler Gear And Bearing Installation (9) Install wave washer, flat washer and remaining
(5) Slide thrust rear thrust washer onto shaft and snap ring on idler shaft (Fig. 94). Be sure snap ring
over lock ball (Fig. 93). is fully seated.
21 - 82 NV3500 MANUAL TRANSMISSION
(2) Position wood block under each leg of assembly

REAR GEAR THRUST fixture (Fig. 96). Blocks are needed to provide clear
OF SHAFT I WASHER
I AND BALL ance for input shaft and can be made from 2 x 4 lum
ber.
(3) Install input shaft i n fixture tool (Fig. 96).
Make sure Adapter Tool 6747-1 is positioned under
shaft as shown.
SNAP RING
J9421-90
Fig. 94 Idler Gear And Shaft Assembly

GEARTRAIN BUILDUP IN ASSEMBLY FIXTURE
TOOL
(1) Install Adapter 6747-1 on input shaft hub of
fixture tool (Fig. 95). Then install Adapter 6747-2 on
front bearing hub of countershaft. Adapter 6747-2
has a raised shoulder on one side. Be sure the
shoulder is seated against the countershaft. Fig. 96 Installing Input Shaft In Assembly Fixture
(4) Install pilot bearing i n input shaft (Fig. 97).
Fig. 97 Installing Pilot Bearing In Input Shaft

(5) Install fourth speed synchro ring on input shaft
(Fig. 98).
(6) Adjust height of idler gear pedestal on assem
Fig. 95 Preparing Assembly Fixture For Geartrain bly fixture (Fig. 99). Start with a basic height of
Buildup 18.4 cm (7-1/4 in.). F i n a l adjustment can be
made after gear is positioned on pedestal.
FOURTH
SPEED
SYNCHRO
RING
OUTPUT
SHAFT
AND
GEARTRAIN
SPECIAL
INPUT TOOL
SHAFT 6747
J9421-93
Fig. 98 installing Fourth Speed Synchro Ring On INPUT

input Shaft SHAFT
REVERSE
IDLER
PEDESTAL
J9421-95
Fig. 100 Output Shaft And Geartrain Installed In

Input Shaft
J9421-94 OUTPUT
SHAFT
AND
Fig. 99 Idler Pedestal Basic Height Adjustment
GEARTRAIN
(7) Install assembled output shaft and geartrain in COUNTERSHAFT
(SLIDE INTO
input shaft (Fig. 100). Carefully rotate output shaft PLACE ON
until fourth speed synchro ring seats in synchro hub FIXTURE TOOL)
and sleeve.
(8) Install Adapter 6747-2 on front bearing
hub of countershaft, if not previously done. The
adapter has a shoulder on one side. The shoul
der goes toward the countershaft.
(9) Slide countershaft (and adapter) into fixture
slot. Verify that countershaft and output shaft gears
are fully meshed before proceeding (Fig. 101).
(10) Check alignment of countershaft and output
shaft gear teeth. Note that gears may not align per
fectly. A difference in height of 1.57 to 3.18 mm (1/16
to 1/8 in.) will probably exist. This difference will not
J9421-96
interfere with assembly. However, if the difference is
greater than this, the countershaft adapter tool is
probably upside down. Remove countershaft, reverse Fig. 101 Countershaft Installed On Fixture Tool
adapter tool, reinstall countershaft and check align meshed and aligned with shaft gear teeth and
ment again. that bolt holes are facing out and not toward
(11) Position reverse idler on pedestal of assembly
fixture (Fig. 102). Be sure idler gear is properly
geartrain. Adjust pedestal up or down i f necessary. INSERT ARM
Also be sure that short end of idler shaft is facing up THROUGH
1-2 FORK
as shown.
COUNTERSHAFT
REVERSE
IDLER FIFTH-REVERSE
ASSEMBLY
(ON PEDESTAL) FORK
OUTPUT
SHAFT
AND
GEARTRAIN
Fig. 104 Assembling 1-2 And Fifth-Reverse Shift

TOOL Forks
PEDESTAL (14) Install assembled shift forks in synchro
sleeves (Fig. 105). Be sure forks are properly seated
in sleeves.
J9421-97
Fig. 102 Reverse Idler Assembly Positioned On

Assembly Fixture Pedestal
(12) On 2-wheel drive transmission, thread one Pi
lot Stud C-3288-B in center or passenger side hole of
output shaft bearing retainer. Then position retainer SHIFT u
SYNCHRO
on fifth gear as shown (Fig. 103). Cut a screwdriver FORKS SLEEVES
slot at the end of the pilot stud with a hacksaw i f
necessary (slot makes for easy stud removal after
housing is installed).
FORK
J9421-100
SPECIAL ARMS
TOOL
C-3288-B Fig. 105 Shift Forks installed In Synchro Sleeves
REAR HOUSING INSTALLATION [2-WHEEL
DRIVE TRANSMISSION)
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 106).
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
OUTPUT race (Fig. 107).
SHAFT
BEARING
CAUTION: The countershaft bearings can be in
RETAINER J9421-98
stalled backwards if care is not exercised. Be sure
the large diameter side of the roller retainer faces
Fig. 103 Positioning Output Shaft Bearing Retainer
the countershaft and the small diameter side faces
For Rear Housing Installation
the race and housing (Fig. 108).
(13) Assemble 1-2 and fifth reverse-shift forks (Fig.
104). A r m of fifth-reverse fork goes through slot i n (4) Apply extra petroleum jelly to hold counter
1-2 fork. shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
Fig. 108 Countershaft Rear Bearing Seated In

Seated in Race
(7) Install rear housing onto geartrain (Fig. 109).
Be sure b e a r i n g retainer p i l o t stud is in correct
bolt hole i n housing. Also be sure countershaft
Fig. 106 Preparing Rear Housing Dowels For and output shaft bearings are aligned in hous
Installation ing and on countershaft.
bushing/bearing in rear housing (Fig. 108).
(6) Reach into countershaft rear bearing with fin
ger, ' and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place. This avoids having rollers becoming dis
placed during housing installation. This will result i n
misalignment between bearing and countershaft
bearing hub.
COUNTERSHAFT
REAR
BEARING
Fig. 109 Rear Housing Installation (2-Wheel Drive

Transmission Shown)
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
PETROLEUM JELLY
(APPLY TO BEARING (9) Install three bolts that secure rear bearing re
AND RACE) J9421-103 tainer to rear housing as follows:
(a) Apply Mopar Gasket Maker, or Loctite 518 to
Fig. 107 Lubricating Countershaft Rear Bearing bolt threads, bolt shanks and under bolt heads
(Fig. 110).
(b) Start first two bolts i n retainer (Fig. 111). I t
may be necessary to move retainer rearward (with
pilot stud) i n order to start bolts i n retainer.
(c) Remove pilot stud C-3288-B and install last
retainer bolt (Fig. 111). Use screwdriver to remove
pilot stud.
(d) Tighten all three retainer bolts to 30-35 N-m
RACE J9421-203
Fig. 112 Preparing Adapter Housing For Installation

Fig. 110 Applying Sealer To Retainer And Housing
countershaft rear bearing and bearing race.
Bolts
(5) Install countershaft rear bearing i n bearing
race (Fig. 108).
CAUTION: The countershaft bearings c a n be in

stalled backwards if care is not exercised. Be sure
the large diameter side of the roller retainer faces
the countershaft and the small diameter side faces
the race and housing (Fig. 108).
(6) Apply extra petroleum jelly to hold counter

shaft rear bearing i n place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing i n adapter housing (Fig. 108).
(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 113).
(10) Lubricate lip of new rear seal (Fig. 114) with
Mopar Door Ease, or transmission fluid.
Fig. 111 Removing Pilot Stud Tool And Installing (11) Install new rear seal i n adapter housing bore
Retainer Bolts (2-Wheel Drive Transmission) with suitable size tool. Be sure seal is fully seated i n
REAR ADAPTER HOUSING INSTALLATION housing bore (Fig. 114).
(4-WHEEL DRIVE TRANSMISSION)
REVERSE IDLER SEGMENT INSTALLATION
(1) Install rear bearing i n adapter housing. Use (1) Apply Mopar Gasket Maker, or Loctite 518
wood hammer handle or wood dowel to tap bearing sealer to underside of idler shaft bolt heads, bolt
into place. shanks and bolt threads (Fig. 110).
(2) Position rear bearing retainer i n adapter hous (2) Align idler shaft and rear housing bolt holes
ing (Fig. 112). with drift, pin punch, or phillips screwdriver.
(3) Apply Mopar Gasket Maker, or Loctite 518 to (3) Work segment upward into housing and onto
threads, bolt shanks and under hex heads of bearing idler shaft (Fig. 115).
retainer bolts (Fig. 110). (4) Verify that idler shaft is seated i n housing
notch before proceeding. Segment and housing can be
Fig. 113 installing Rear Bearing Snap Ring (4-Wheel

Drive Transmission)
Fig. 115 Installing Reverse Idler Shaft Support

Segment
Fig. 114 Rear Seal Installation (4-Wheel Drive

Transmission)
damaged i f idler shaft is misaligned.
(5) Insert idler shaft retaining bolts through hous
ing and segment and into shaft. Long bolt goes
through segment and short bolt goes through housing
and directly into rear of shaft (Fig. 116). Start both Fig. 116 Installing Reverse Idler Shaft Bolts
bolts by hand to avoid cross threading. (2) Before proceeding, verify that all synchro are i n
(6) Tighten idler shaft bolts to 19-25 N-m (14-18 ft. Neutral position (centered on hub). Move sleeves into
lbs.) torque. neutral i f necessary.
CAUTION: Make sure the idler shaft and support CAUTION: The transmission synchros must all be
segment are properly seated and held firmly in in Neutral position for proper reassembly. Other
place while tightening the shaft bolts. The segment, wise, the housings, shift forks and gears can be
housing or shaft threads can be damaged if the damaged during installation of the two housings.
idler shaft is allowed to shift out of position in the
housing. (3) Install 3-4 shift fork i n synchro sleeve (Fig.
117). Verify that groove i n fork arm is aligned with
grooves i n 1-2 and fifth-reverse fork arms as shown.
SHIFT SHAFT, SHAFT LEVER AND BUSHING (4) Check surface of shift shaft before proceeding.
AND SHIFT SOCKET INSTALLATION Small nicks or scratches can be smoothed off with oil
(1) Remove geartrain and housing assembly from soaked 320-400 grit emery cloth i f necessary.
fixture with aid of helper.
3-4 ALIGN LEVER
FORK GROOVES SHAFT
LEVER BUSHING
IN
FORK
ARMS
J9421-107 J9421-88
Fig. 117 Installing 3-4 Shift Fork Fig. 119 Assembling Shift Shaft Lever And Bushing
(5) Slide shift shaft through 3-4 shift fork (Fig SHAFT -
118). Be sure shaft detent notches are to front. LEVER f
& AND
BUSHING ~
SHAFT
DETENT
NOTCHES
Fig. 120 Installing Shift Shaft Lever And Bushing

J9421-42
Fig. 118 Shift Shaft Installation

(6) Assemble shift shaft shift lever and bushing BIAS
SPRING
(Fig. 119). Be sure slot i n bushing is facing up
and roll pin hole for lever is aligned with hole
in shaft. SHIFT
(7) Install assembled lever and bushing on shift SHAFT
shaft (Fig. 120).
(8) Slide shift shaft through 1-2 fork and part way
into shift lever opening i n rear housing (Fig. 121).
(9) Slide bias spring on shift shaft. Be sure spring
ends are facing rearward as shown (Fig. 121).
(10) Assemble anti-rotation bracket and shift
socket. Be sure pin on socket and tab on bracket are J9421-108
both facing forward (Fig. 122).
(11) Align shift socket and anti-rotation bracket
Fig. 121 Bias Spring Positioned On Shift Shaft
with shift shaft. Then slide shaft through socket and
bracket (Fig. 123). Be sure socket pin and bracket (13) Rotate shift shaft so detent notches in shaft
tab are both facing forward. are facing driver side of housing.
(12) Push shift shaft through fifth-reverse fork and
into bushing i n rear housing. Use plastic mallet to
tap shaft into place i f necessary.
NW3500 MANUAL TRANSMISSION 21 - 3S
SHAFT
LEVER
J9421-86
Fig. 124 Roil Pin Identification (Shaft Lever And

Shift Socket)
Fig. 122 Assembling Shift Socket And Anti-Rotation

Bracket
ANTI-ROTATION
BRACKET
Fig. 125 Starting Roll Pin In Shift Shaft Lever

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.
(17) Before proceeding, verify that lock pin slot i n

lever bushing is positioned as shown (Fig. 126).
Fig. 123 Shift Socket And Anti-Rotation Bracket

Installation
CAUTION: Correct positioning of the shift shaft de
tent 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 disas
sembled againto correct shaft alignment.
(14) Select correct new roll pin for shift shaft lever
(Fig. 124). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi
mately 33 mm (1-1/4 in.) long.
(15) Align roll pin holes i n shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 125). Fig. 126 Correct Seating Of Shift Shaft Lever Roll
(16) Seat shaft lever roll pin with pin punch (Fig. Pin
126).
(18) Align roll pin holes in shift socket and shift SHIFT
shaft. Then start roll pin into shift shaft by hand FORK
(Fig. 127). ARMS
J942U15
Fig. 129 Shaft Lever Positioned For Detent Ball and

Spring Installation
LEVER
Fig. 127 Starting Roll Pin In Shift Socket DETENT
BORE
(19) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket after installation
(Fig. 129).
J942M16
Fig. 130 Installing Detent Spring In Shaft Lever
Fig. 128 Seating Shift Socket Roll Pin

(20) Verify that notches in shift fork arms are
aligned (Fig. 129). Realign arms if necessary.
(21) Rotate shaft lever and bushing downward (out
of fork arms), to expose detent bore in lever (Fig.
129). Fig. 131 Installing Detent Ball In Shaft Lever
(22) Insert detent spring in lever bore with pencil (24) Press and hold detent ball in lever with mag
magnet (Fig. 130). net. Then carefully rotate lever upward into fork arm
(23) Install detent ball on top of spring in lever notches. Be sure ball is seated in fork arms before
bore (Fig. 131). Use pencil magnet to hold ball in proceeding (Fig. 132).
place.
N¥3500 MANUAL TRANSMISSION 2 1 - 41
SHIFT FORK
ARMS
SHIFT
SHAFT
SHAFT
LEVER
BALL
AND
SPRING J9421-117
Fig. 132 Correct Seating Of Lever Detent Bali in

Shift Fork Arms
(25) Engage bias spring ends on socket pin and an
ti-rotation bracket tab as follows:
(a) Push short end of spring against pin on shift
socket. Use screwdriver to hold this end of spring
in place. Fig. 134 Positioning Long End Of Bias Spring In
(b) Slide 10-13 cm (4-5 in.) length of steel tubing Tab Notch
over longest end of bias spring (Fig. 133). Tubing 90° angle. Short spring end should be seated
can be made from scrap piece of steel brakeline or against shift socket pin and ling end should be
similar size tubing. seated i n tab notch.
SHORT TAB
END OF
SPRING
AGAINST
PIN
SOCKET
PIN
SHIFT
SOCKET
STEEL
TUBE
ON
LONG BIAS
END OF SPRING
SPRING
ANTI-
\ \ \ ROTATION
J942M18
BRACKET J9421-120
Fig. 133 Positioning Short End Of Bias Spring Fig. 135 Correct Installed Position Of Bias Spring
Against Pin
FRONT HOUSING AND INPUT SHAFT
(c) Grasp brakeline and pry long end of spring BEARING RETAINER INSTALLATION
around tab on anti-rotation bracket. Then seat (1) Before proceeding, verify that all synchro are i n
spring end i n tab notch (Fig. 134). Neutral position (centered on hub). Move sleeves into
(d) Verify correct bias spring installation (Fig. neutral i f necessary.
135). Both springs should be facing straight up at a
CAUTION: The t r a n s m i s s i o n s y n c h r o s m u s t all be
in Neutral p o s i t i o n d u r i n g reassembly. Otherwise,
t h e h o u s i n g s , shift forks and gears can be d a m a g e d
d u r i n g installation of the h o u s i n g s .

countershaft front bearing. Then insert bearing in
front housing race (Fig. 136). Large diameter side
of bearing cage goes toward countershaft (Fig.
137). Small diameter side goes toward bearing
race in housing.
Fig. 137 Input Shaft Bearing And Countershaft Front

Bearing Installation
Fig. 136 Lubricating/Positioning Countershaft Front

Bearing
(3) Reach into countershaft front bearing with fin
ger, and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place. This avoids having rollers becoming dis
placed during housing installation. This will result in
misalignment between bearing and countershaft
bearing hub.
(4) Install input shaft bearing in front housing MAKER
bore (Fig. 137). Use plastic mallet to seat bearing. (OR LOCTITE 518) J9421-123
Bearing goes in from front side of housing only.
(5) Apply small amount of petroleum jelly to shift Fig. 138 Applying Sealer To Front/Rear Housings
shaft bushing in front housing (Fig. 138). (9) Tap rear housing alignment dowels back into
(6) Apply 1/8 in. wide bead of Mopar Gasket place with hammer and pin punch (Fig. 140). Both
Maker, or Loctite 518 to mating surfaces of front and dowels should be fairly flush fit in each housing.
rear housings (Fig. 138). Have helper hold transmission upright while dowels
(7) Have helper hold rear housing and geartrain in are tapped back into place.
upright position. Then install front housing on rear (10) Place transmission in horizontal position.
housing and geartrain (Fig. 139). (11) Apply Mopar Gasket Maker, or Loctite 518 to
(8) Work front housing downward onto geartrain housing attaching bolts. Apply sealer material sealer
until seated on rear housing. to underside of bolt heads and to bolt shanks and
threads (Fig. 110).
CAUTION: If t h e f r o n t h o u s i n g w i l l not seat o n t h e (12) Install and start housing attaching bolts by
rear h o u s i n g , either t h e shift c o m p o n e n t s are not in hand (Fig. 141). Then tighten bolts to 30-35 N-m
Neutral, or one or m o r e c o m p o n e n t s are m i s (22-26 ft. lbs.) torque.
aligned. Do not force the f r o n t h o u s i n g into place.
T h i s w i l l o n l y result in damaged c o m p o n e n t s .
• NV3500 MANUAL T R A N S M I S S I O
FRONT HOUSING
HOUSING ATTACHING
BOLTS
f (APPLY SEALER
* BEFOREHAND)
J9421-126
Fig. 141 Installing Housing Attaching Bolts
SHIFT
SHAFT
BUSHING
J9421-124 LOCK BOLT
Fig. 139 Front Housing Installation
FRONT
HOUSING
J942M27
Fig. 142 Installing Shift Shaft Bushing Lock Bolt
FRONT
HOUSING
REAR
HOUSING
J942M25
Fig. 140 Reseating Housing Alignment Dowels

(13) Install shift shaft bushing lock bolt (Fig. 142).
Apply Mopar Gasket Maker, or Loctite 518 to bolt
II
threads, shank and underside of bolt head before in
stallation.
J9421-128
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift Fig. 143 Correct Alignment Of Lock Bolt And Shaft
shaft is not in Neutral. Or, the shaft bushing (or le Bushing
ver) is misaligned (Fig. 143).
(14) Lubricate then install shift shaft detent (16) Install detent plug (Fig. 146). Start plug in
plunger in housing bore (Fig. 144). Lubricate plunger bore by hand. Then seat plug with brass punch.
with petroleum jelly or gear lubricant. Be sure
plunger is fully seated i n detent n o t c h i n shift
shaft.
Fig. 144 installing Shift Shaft Detent Plunger

(15) Install detent spring inside plunger (Fig. 145).
Fig. 146 Detent Plug installation
(17) Install backup light switch (Fig. 147).
Fig. 147 Installing Backup Light Switch

Fig. 145 Installing Detent Plunger Spring (18) Install input shaft snap ring (Fig. 148).
Fig. 148 installing input Shaft Snap Ring

• NV3500 MANUAL TRANSMISSION 2 1 - 45
(19) Install new oil seal i n front bearing retainer

with Installer Tool 6448 (Fig. 149).
Fig. 151 Installing Input Shaft Bearing Retainer
Fig. 149 installing Oil Seal In Front Bearing Retainer

(20) Apply bead of Loctite Ultra (heavy body),
black silicone sealer (or Mopar equivalent), to flange
surface of front bearing retainer. Then apply bead of
same sealer to retainer mounting surface of front
housing (Fig. 150).
Fig. 152 Installing Input Shaft Bearing Retainer Bolts
Fig. 150 Applying Sealer To Bearing Retainer And

Housing
(21) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
151). Although retainer is one-way fit on hous
ing, be sure bolt holes are aligned before seat
ing retainer.
(22) Install and tighten bearing retainer bolts to
7-10 N-m (5-7 ft. lbs.) torque (Fig. 152).
(23) Apply petroleum jelly to anti-rotation bracket
rollers. Install roller i n each side of bracket and se
cure rollers with plastic clips (Fig. 153).
Fig. 153 Installing Rollers And Clips In Anti-Rotation

Bracket
21 - 46 NV3500 MANUAL TRANSMISSION v
SHIFT LEVER INSTALLATION (3) Apply 1/8 to 3/16 in. wide bead of Mopar Gas
O n some models, i t may be necessary to h o l d ket Maker, or Loctite 518 to metal side of isolator
off i n s t a l l i n g the shift lever u n t i l after the and plate assembly (Fig. 156).
transmission is back i n the vehicle. Refer t o the
f o l l o w i n g procedures f o r shift lever assembly
and installation.
(1) Apply 1/8 to 3/16 in. wide bead of Mopar Gas
ket Maker, or Loctite 518 to isolator and plate mat
ing surface of rear housing (Fig. 154).
Fig. 156 Applying Sealer To Mounting Surface Of

Isolator And Plate Assembly
(4) Install isolator and plate assembly on housing.
(5) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(6) Align and install shift lever assembly on isola
tor plate and i n housing (Fig. 157). Be sure ball end
of lever is properly seated i n shift socket.
Fig. 154 Applying Sealer To Isolator And Plate

Assembly Mounting Surface
(2) Align and position isolator and plate assembly
on rear housing mounting surface. Plate assembly
is a one-way f i t . N a r r o w side o f plate goes o n
d r i v e r side o f h o u s i n g m o u n t i n g surface a n d
r u b b e r coated side faces u p w a r d (Fig. 155).
NARROW
Fig. 157 Shift Lever Installation

(7) Install and tighten shift lever attaching bolts to
7-10 N-m (5-7 ft. lbs.) torque.
(8) Slide short length of rubber hose over shift le
ver threads. Hose will protect threads during trans
mission installation.
Fig. 155 Correct Positioning Of isolator And Plate

Assembly
(9) Fill transmission to bottom edge of fill plug

hole with required lubricant.
(10) Install and tighten fill plug to 19-27 N-m
(11) Check transmission vent (Fig. 158). Be sure
vent is open and not restricted i n any way.
Fig. 158 Transmission Vent Location

NW4500 MANUAL TRANSMISSION
INDEX
page page
Gear Ratios 48 Transmission Disassembly and Overhaul 53
General Information 48 Transmission Identification 48
Manual Transmission Diagnosis 49 Transmission Installation—2-Wheel Drive 51
NV4500 Changes for 1994 48 Transmission Installation—4-Wheel Drive 53
Shift Cover Service 91 Transmission Lubricant—Capacity—Fill Level . . . . . 48
Shift Pattern 48 Transmission Removal—2-Wheel Drive 50
Transmission Assembly and Adjustment 74 Transmission Removal—4-Wheel Drive 52
Transmission Cleaning and Inspection 69
GENERAL INFORMATION TRANSMISSION LUBRICANT—CAPACITY—FILL

The NV4500 is a five-speed, constant mesh manual LEVEL
transmission (Fig. 1). A l l gear ranges including re Required lubricant for the NV4500 is Mopar Man
verse are synchronized. Fifth gear is an overdrive ual Transmission Lubricant, P/N 4637579, or Castrol
range with a ratio of 0.74:1. The transmission has a Syntorq. Both are synthetic gear lubricants with an
cast iron gear case and aluminum shift cover. API grade rating of GL 4 and a viscosity rating of
Two versions of the NV4500 are used i n 1994 mod SAE 75W-90.
els. A standard duty version is used for 5.2L and 5.9L The Mopar and Castrol lubricants are the only lu
bricants recommended for use in NV4500 transmis
applications and a heavy duty version is used for
sions.
VIO, Cummins diesel, and some V8 heavy duty
Dry fill lubricant capacity is approximately 3.78 l i
engine applications. The main differences between ters (8 pints).
the two versions concern the larger input and output Correct lubricant fill level is to the bottom edge of
shafts used i n the heavy duty version. Other than the fill plug hole (Fig. 3). Check fill level only when
this, the two versions are serviced exactly alike. the transmission is level.
The NV4500 is a top loader style transmission. The The transmission lubricant is drained through the
shift lever is located i n the shift cover and operates PTO cover bottom bolt hole (Fig. 3). I t will be neces
the shift forks and rails directly. The shift forks and sary to apply sealer to the bolt threads before install
rails are all located within the aluminum cover ing i t during a lubricant change.
which is bolted to the top of the gear case.
A reverse gear inhibitor mechanism prevents re GEAR RATIOS
verse gear engagement when shifting into forward NV4500 gear ratios are:
First gear: 5.61:1
gear ranges. The inhibitor mechanism is located i n
Second gear: 3.04:1
the shift cover.
Third gear: 1.67:1
Tapered roller bearings support the drive gear, Fourth gear: 1.00:1
mainshaft and countershaft i n the gear case. Pilot Fifth gear: 0.74:1
roller bearings i n the drive gear hub support the for Reverse gear: 5.61:1
ward end of the mainshaft. The mainshaft gears are
all supported on caged type roller bearings. Drive SHIFT PATTERN
gear thrust reaction is controlled by a needle type The NV4500 shift pattern is i n a modified H pat
thrust bearing. The bearing is located at the forward tern (Fig. 4). Overdrive fifth and reverse gears are i n
end of the mainshaft. line and outboard of the first through fourth gear po
sitions.
TRANSMISSION IDENTIFICATION
The NV<*500 transmission identification tag is at NV4500 CHANGES FOR 1994
tached to the driver side PTO cover (Fig. 2). The gear case and shift lever have been changed on
The tag provides the transmission model number, all 1994 transmissions. This applies to both the stan
build date and part number. Be sure to reinstall the dard and heavy duty versions of the NV4500.
I.D. tag i f removed during service. The information The gear case change involves deletion of the drain
on the tag is essential to correct parts ordering. plug. The transmission is now drained through one of
4WD
VERSION
J9221-15
Fig. 1 NV4500 Manual Transmission

the bottom PTO cover bolt holes. Refer to the lubri MANUAL TRANSMISSION DIAGNOSIS
cant change procedure in this section for details.
A single, reversible shift lever is used for all appli COMMON PROBLEM CAUSES
cations. The lever is offset and must be indexed for The majority of transmission malfunctions are a re
proper fit and position. Refer to the service proce sult of:
dures for details on installation position. • insufficient lubricant
The shift lever extension is also new. The lever is • incorrect lubricant
now a press fit on the shift lever. A new service tool • misassembled or damaged internal components
for removal/installation is required and is described • improper operation.
in the transmission removal/installation procedures.
The new shift lever is a two-way fit and requires cor HARD SHIFTING
rect positioning. A low lubricant level, loose or worn shift lever, or
loose, damaged shift housing components are com-
PTO Misassembled synchro components will also cause
COVER shift problems. Incorrectly installed synchro sleeves,
struts, or springs will all cause shift problems.
NOISY OPERATION
Transmission noise is most often a result of worn
or damaged components. Chipped, broken gear or
synchronizer teeth and brinnelled, spalled bearings
all cause noise.
Abnormal wear and damage to internal compo
nents is frequently the end result of insufficient lu
bricant, non-recommended lubricants, or improper
operation.
SLIPS OUT OF GEAR

Transmission disengagement may be caused by
ijiisaligned or damaged shift components, or worn
teeth on the mainshaft gears or synchro components.
Incorrect assembly will also contribute to gear disen
gagement.
J9221-14
LOW LUBRICANT LEVEL
Fig. 2 NV4500 Identification Tag Location
Insufficient transmission lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method.
Leaks will be evident by the presence of gear oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill condi
PILL tion.
PLUG PTO If air powered lubrication equipment is used to fill
COVER a transmission, be sure the equipment is properly
calibrated. Equipment out of calibration can lead to
DRAIN an underfill condition.
BOLT J9421-210
CLUTCH PROBLEMS
Fig. 3 NV450Q Fill Plug And Drain Bolt Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
0 0 © A damaged pilot bearing will cause noise. If bear
ing damage is severe, drive gear misalignment and
hard shifting can also occur.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
Damaged or worn clutch hydraulic components, or
0.0® J9221-13
leaks in the fluid lines or cylinders will cause hard
shifting and gear clash. Failure of one of the clutch
hydraulic cylinders can result in incomplete clutch
Fig. 4 NV4S00 Shift Pattern release or engagement.
mon causes of hard shifting. If hard shifting is also Verify that clutch components are all in good con
accompanied by gear clash, synchronizer clutch and dition before removing the transmission for repair.
stop rings, or mainshaft gear teeth may be worn or
damaged. TRANSMISSION REMOVAL—2-WHEEL DRIVE
Hard shifting may also be caused by a loose, or (1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
misaligned shift cover, or alignment dowels. Worn, or
(3) Remove screws attaching shift boot to floorpan.
damaged shift cover components will also cause hard
Then slide boot upward on lever extension.
shifting. Any of the foregoing faults will cause com
(4) Remove shift lever extension with Remover/In
ponent bind and high shift efforts. staller Tool 6783 as follows:
(a) Scribe mark position of extension on shank of (14) Support transmission with a transmission
shift lever. jack. Secure transmission to jack with safety chains.
(b) Position notched, lower end of tool just under (15) Remove rear crossmember.
square shank of shift lever (Fig. 5). (16) Remove bolts attaching clutch slave cylinder
(c) Position tool upper jaws u n d e r flange on to clutch housing. Then move cylinder aside for work
shift lever extension (Fig. 5). ing clearance.
(d) Tighten tool screw to pull extension off (17) Remove transmission harness wires from clips
square shank of shift lever. on transmission shift cover.
(e) Remove lever extension and tool. (18) Remove bolts attaching transmission to clutch
housing.
(19) Slide transmission and jack rearward until
drive gear clears clutch housing.
(20) Lower transmission jack and remove trans
mission from under vehicle.
(21) I f transmission will be overhauled, clean
transmission exterior with solvent or with steam
gun.
TRANSMISSION INSTALLATION—2-WHEEL DRIVE

(1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com
ponents:
• drive gear splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bearing
• release bearing bore
• release fork
• release fork ball stud
• propeller shaft slip yoke
(2) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(3) Mount transmission on jack and position trans
mission under vehicle.
(4) Raise transmission until drive gear is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start drive gear
in release bearing, clutch disc and pilot bushing.
Fig. 5 Removing Shift Lever Extension With Tool
(6) Work transmission forward until seated against
6783
clutch housing. Do not allow transmission to remain
(5) Raise and support vehicle. unsupported after drive gear has entered clutch disc.
(6) Mark propeller shaft and axle yokes for align (7) Install and tighten transmission-to-clutch hous
ment reference. Use paint, scriber, or chalk to mark ing bolts to 108 N-m (80 ft. lbs.) torque.
yokes. (8) Install clutch slave cylinder.
(7) Remove U-joint clamp strap screws and remove (9) Connect speed sensor and backup light switch
clamps. wires.
(8) Remove propeller shaft. (10) Position transmission harness wires i n clips
(9) Disconnect and remove exhaust system Y-pipe. on shift cover.
(10) Disconnect wires at speed sensor and backup (11) Install transmission mount on transmission or
light switch. rear crossmember.
(11) Support engine with adjustable safety stand (12) Install rear crossmember.
and wood block. (13) Remove transmission jack and engine support
(12) I f transmission is to be disassembled for re fixture.
pair, remove drain bolt at bottom of PTO cover and (14) Align and connect propeller shaft.
drain lubricant from transmission. (15) Fill transmission with required lubricant, i f
(13) move bolts/nuts attaching transmission to rear necessary.
mount. (16) Lower vehicle.
(17) Install lever extension on shift lever with Tool (e) Remove lever extension and tool.
6783 as follows: (5) Raise vehicle.
(a) Reposition upper jaw of Remover/Installer (6) Remove skid plate if equipped.
Tool 6783 above flange on lever extension (Fig. 6). (7) If transmission will be disassembled for repair,
Tool will now be used to press extension back onto remove drain bolt at bottom of PTO cover and drain
shift lever. lubricant from transmission.
(b) Tighten tool screw to press extension back (8) Mark propeller shafts and yokes for assembly
onto lever. Install extension to scribe mark made reference.
during removal. (9) Disconnect propeller shafts and remove propel
(c) Remove special tool. ler shafts.
(10) Disconnect and remove exhaust system Y-pipe.
Then disconnect and lower remaining exhaust pipes
for clearance as necessary.
(11) Support engine with adjustable safety stand.
(12) Disconnect speed sensor wires and disconnect
speedometer cable, if equipped.
(13) Disconnect backup light switch wires.
(14) Disconnect transfer case shift linkage at
transfer case range lever. Then remove transfer case
shift mechanism from transmission (Fig. 7).
SPECIAL
TOOL
6783
1-206
Fig. 7 Transfer Case Shift Mechanism
Fig. 6 Installing Shift Lever Extension With Tool
6783 (15) Remove bolts/nuts attaching transmission to
rear support.
(18) Install shift boot and bezel.
(16) Remove crossmember bolts/nuts and remove
(19) Connect battery negative cable.
crossmember.
TRANSMISSION REMOVAL—4-WHEEL DRIVE (17) Support transfer case with transmission jack.
(1) Disconnect battery negative cable. Secure transfer case to jack with safety chains.
(2) Shift transmission into Neutral. (18) Remove transfer case attaching nuts.
(3) Remove shift lever boot and bezel. (19) Move transfer case rearward until input gear
(4) Remove shift lever extension with Remover/In clears transmission mainshaft.
staller Tool 6783 as follows: (20) Lower transfer case assembly and move it
(a) Scribe mark position of extension on shank of from under vehicle.
shift lever. (21) If transmission is being removed for repair, re
(b) Position notched, lower end of tool just under move drain bolt at bottom of PTO cover and drain lu
square shank of shift lever (Fig. 5). bricant from transmission.
(c) Position tool upper jaws under flange on (22) Support transmission with transmission jack.
shift lever extension (Fig. 5). Secure transmission to jack with safety chains.
(d) Tighten tool screw to pull extension off (23) Remove transmission harness from retaining
square shank of shift lever. clips on transmission shift cover.
(24) Remove bolts/nuts attaching transmission (14) Remove transmission jack and engine support
mount to rear crossmember. fixture.
(25) Remove rear crossmember. (15) Install transfer case on transmission jack. Se
(26) Remove clutch slave cylinder splash shield, if cure transfer case to jack with safety chains.
equipped. (16) Install new gasket on transmission adapter, or
(27) Loosen clutch slave cylinder attaching nuts coat adapter sealing surface with Mopar Gasket
until cylinder piston rod is clear of release lever. This Maker, or silicone adhesive sealer.
reduces pressure on lever and release bearing mak (17) Raise jack and align transfer case input gear
ing transmission removal/installation easier. Cylinder with transmission mainshaft.
does not have to be removed completely. (18) Move transfer case forward and seat it on
(28) Remove bolts attaching transmission to clutch adapter.
housing. (19) Install and tighten transfer case attaching
(29) Move transmission rearward until drive pin nuts. Tighten nuts to 41-47 N-m (30-35 ft. lbs.) if case
ion clears clutch disc and release bearing. has 3/8 studs, or 30-41 N-m (22-30 ft. lbs.) if case has
(30) Lower transmission and remove it from under 5/16 studs.
vehicle. (20) Connect transfer case shift lever to range le
ver on transfer case.
(31) If transmission will be overhauled, thoroughly
(21) Align and connect propeller shafts. Tighten U-
clean transmission exterior with solvent or steam
joint clamp strap bolts to 19 N-m (170 in. lbs.)
gun. torque.
(22) Check lubricant levels in transmission and
TRANSMISSION INSTALLATION—4-WHEEL DRIVE transfer case. Add lubricant if necessary.
(1) Apply light coat of Mopar high temperature (23) Install transfer case skid plate and crossmem
bearing grease to contact surfaces of following com ber. Tighten attaching bolts/nuts to 41 N-m (30 ft.
ponents: lbs.) torque.
• drive gear splines and pilot bearing hub (24) Install exhaust system components.
• release bearing slide surface of front retainer (25) Lower vehicle.
• pilot bearing (26) Install lever extension on shift lever with Tool
• release bearing bore 6783 as follows:
• release fork (a) Reposition upper jaw of Remover/Installer
• release fork ball stud Tool 6783 above flange on lever extension (Fig. 6).
• propeller shaft slip yoke Tool will now be used to press extension back onto
(2) Fill transmission with recommended lubricant. shift lever.
Correct level is to bottom edge of fill plug hole. (b) Tighten tool screw to press extension back
(3) Mount transmission on jack and position trans onto lever. Press extension to scribe mark made
mission under vehicle. Secure transmission to jack during removal.
with safety chains. (c) Remove special tool.
(4) Raise transmission until drive gear is centered (27) Install shift lever boot and bezel.
in release bearing and clutch disc hub. (28) Connect battery negative cable.
(5) Move transmission forward and start drive gear
in release bearing and clutch disc. TRANSMISSION DISASSEMBLY AND OVERHAUL
(6) Work transmission forward until seated against SHIFT C O V E R REMOVAL
clutch housing. Do not allow transmission to remain (1) Remove shift cover bolts (Fig. 1).
unsupported after drive gear has entered clutch disc. (2) Loosen shift cover with pry tool. To avoid dam
(7) Install and tighten transmission-to-clutch hous aging cover seal surface, insert pry tool only in slots
ing bolts to 108 N-m (80 ft. lbs.) torque. provided in cover (Fig. 2).
(8) Connect speed sensor and backup light switch (3) Raise cover enough to disengage it from align
wires. ment dowels in gear case (Fig. 3).
(9) Position transmission harness wires in clips on (4) Raise front of shift cover and lift cover up and
shift cover. off gear case (Fig. 3).
(10) Tighten slave cylinder attaching nuts and in (5) Set cover assembly aside for inspection. If cover
stall slave cylinder shield, if equipped. components are damaged, refer to shift cover service
(11) Install transmission mount on transmission or information.
rear crossmember.
(12) Install transfer case shift mechanism on EXTENSION/ADAPTER HOUSING REMOVAL
transmission (Fig. 7). (1) Remove bolts attaching extension/adapter hous
(13) Install rear crossmember. ing to gear case (Fig. 4). Use 10 mm, 12 point socket
bolt s p l i n e s are easily damaged if the w r o n g t o o l is
u s e d t o loosen a n d remove t h e m . Use a 10 m m , 12
p o i n t s o c k e t or box e n d w r e n c h only.
Fig. 1 Shift Cover Bolt Removal/installation

SHIR
COVER
SLOT
Fig. 4 Extension/Adapter Housing Bolts

(2) Remove extension/adapter housing (Fig. 5). Tap
housing with rubber mallet to loosen it. Then break
sealer bead with putty knife and work housing off
alignment dowels with two pry tools. One alignment
dowel is i n case. Other dowel is i n housing.
Fig. 2 Loosening Shift Cover

SHIFT
GEAR
CASE J9221-85
Fig. 5 Extension/Adapter Housing Removal/

Installation
Fig. 3 Shift Cover Removai/lnstallation
(3) Remove spline seal from end of mainshaft (Fig.
to remove housing bolts. Loosen bolts 4-5 threads
6). The seal can be reused or discarded as de
with socket and ratchet first. An air wrench can then
sired. The seal is not an essential part and can
be used to complete removal but only after bolts are
be reused or discarded as desired. The seal is
loose.
mainly used to prevent lubricant loss during
CAUTION: Spline head bolts are used to attach the shipping and does not have to be replaced if
extension or adapter h o u s i n g to the gear c a s e . The damaged.
quire service, remove them individually. Proce

dures for both removal methods are provided
below.
Removing Countershaft Fifth Gear Components As Assembly

(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 9).
CLUTCH
Fig. 6 Mainshaft Spline Seal

(4) On 2-wheel drive models, remove extension
housing seal (Fig. 7). Seal can be removed by collaps
ing one side with punch then prying seal out with
suitable tool.
(5) Note that 4-wheel drive adapter housing
does not have a seal (Fig. 8).
SEAR J9221-89
Fig. 9 Removing Countershaft Fifth Speed Clutch

Gear Snap Ring
(2) Remove roll pins that secure countershaft fifth
gear shift fork to shift rail with pin punch (Fig. 10).
R o l l pins are driven out f r o m b o t t o m o f f o r k
and not from top.
FIFTH GEAR
SHIFT FORK J9221-94
Fig. 10 Removing Fifth Gear Shift Fork Roll Pins

(3) Remove shift fork and fifth gear components as
assembly. Rotate mainshaft as needed to allow coun
Fig. 8 Adapter Housing (4-Wheel Drive Models) tershaft fifth gear to clear mainshaft fifth gear.
MAINSHAFT AND COUNTERSHAFT FIFTH Removing Countershaft Fifth Gear Components Individually
GEAR REMOWAL (1) Remove snap ring that secures fifth speed
The fifth gear components can be removed indi clutch gear on countershaft (Fig. 9).
vidually or as an assembly. If the fifth gear com (2) Remove countershaft fifth speed clutch gear,
ponents are only being removed for access to stop ring and bearing spacer (Fig. 11).
another component, remove them as an assembly. (3) Remove three struts and strut springs from
However, if any of the fifth gear components re countershaft fifth gear hub and sleeve (Fig. 11).
SYNCHRO SLEEVE SPECIAL STRIKE

TOOL TOOL
6443 HERE
OR 6743 TO
LOOSEN
NUT
FIFTH
GEAR FIFTH
SHIFT SPRINGS GEARN
FORK NUT J9421-207
BEARING Fig. 12 Installing Nut Wrench On Mainshaft Fifth

SPACER
Gear
FIFTH
SYNCHRO SPECIAL
FIFTH
CLUTCH TOOL
GEAR
J9221-90 GEAR 6443
NUT
OR 6743
Fig. 11 Removing Countershaft Fifth Gear Synchro
Components
SPECIAL
(4) Remove mainshaft fifth gear nut and washer as
TOOL
follows: 6441
(a) Install nut wrench on fifth gear nut (Fig. 12). OR
Use Nut Wrench 6443 on standard duty models 6442
and Wrench 6743 on heavy duty models. -
(b) Note that wrench only fits one way on nut.
Be sure wrench is fully engaged in nut slots and is
not cocked.
(c) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel
drive models, install Socket Wrench 6442 on main-
shaft splines. Then install breaker bar in socket
wrench (Fig. 13). Wedge breaker bar handle BREAKER
BAR
against workbench. Purpose of socket wrench and
RATCHET
breaker bar is to prevent mainshaft from turning WRENCH
while nut is loosened. J9421-208
(d) Position small end of Nut Wrench 6443 at ap
Fig. 13 Removing Mainshaft Fifth Gear Nut From
proximately 10 o'clock position (Fig. 12).
Shaft Threads
(e) Strike small end of nut wrench with heavy
copper hammer to break nut loose. Nut is secured sembly (Fig. 15). Remove fork by tapping it off rail
by interference fit thread plus Loctite adhesive and with plastic mallet. Leave sleeve engaged i n fork
will require several firm blows to loosen it (nut or note position of sleeve for assembly refer
torque is in 300 ft. lb. range). ence.
(f) Once nut is loose, it can be removed by hold (7) Remove countershaft fifth gear and hub assem
ing nut wrench with breaker bar and rotating out bly (Fig. 16).
put shaft with socket wrench and ratchet. (8) Remove countershaft fifth gear needle bearing
(g) Remove fifth gear nut and coned washer from assemblies (Fig. 17).
shaft (Fig. 14). Note position of washer for assem (9) Remove cone shaped rear bearing thrust
bly reference (coned side of washer faces rear). washer from end of countershaft (Fig. 18). Note posi
(5) Remove roll pins that secure countershaft fifth tion of washer for assembly reference. Also note that
gear shift fork to shift rail with pin punch (Fig. 10). washer bore has notch for locating pin.
Roll pins are driven out from bottom of fork (10) Remove and retain thrust washer locating pin
and not from top. from countershaft (Fig. 19).
(6) Remove fifth gear shift fork and sleeve as as-
•
THRUST THRUST
SYNCHRO WASHER WASHER
SLEEVE J9221-95 PIN (CONE SHAPED) J9221-98
Fig. 15 Fifth Gear Shift Fork And Sleeve Removal Fig. 18 Countershaft Rear Bearing Thrust Washer
Removal
FIFTH
GEAR (a) Position first Puller Jaw 6459 on gear (Fig.
SYNCHRO
HUB 19).
COUNTERSHAFT
FIFTH
GEAR
J9221-96
Fig. 16 Removing Countershaft Fifth Gear And

Synchro Hub Assembly
I MAINSHAFT J9221-99
(11) Remove mainshaft fifth gear with Puller Tool
Set 6444. Note that puller set can be used on Fig. 19 Installing First Puller Jaw On Mainshaft Fifth
both standard and heavy duty transmissions. Gear
Gear removal procedure is as follows:
(b) Assemble Puller Flange 6444-1 and Puller SPECIAL TOOL
Rods 6444-3 (Fig. 20). 6444-8
Fig. 20 Seating Puller Flange In First Puller Jaw

(c) Slide assembled puller flange and rods onto
WRENCH J9221-190
output shaft. Then seat flange in notch of puller
jaw (Fig. 20). Fig. 22 Removing Fifth Gear From Mainshaft
(d) Position second Puller Jaw 6459 on gear and Splines
in notch of puller flange (Fig. 21).
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 21).
Fig. 23 Removing Mainshaft Fifth Gear, Bearing

Plate, Bearing Shims And Rear Bearing Cup
Fig. 21 Installing Retaining Collar Over Puller Jaws

(f) Install Puller and Bolt 6444 on puller rods.
Then secure puller to rods with retaining nuts (Fig.
22).
(g) Tighten puller bolt to remove gear from shaft
splines (Fig. 22).
(12) Remove bolts attaching mainshaft rear bear
ing plate to gear case and remove fifth gear, plate,
end play shims and bearing cup (Fig. 23).
FRONT RETAINER REMOVAL AND

Fig. 24 Removing Front Bearing Retainer Bolts
DISASSEMBLY
(1) Remove front retainer bolts (Fig. 24).
• N¥4500 MANUAL TRANSMISSION 21 - 5S
(2) Remove front retainer by lightly tapping i t (c) Install assembled tools i n front retainer (Fig.
back and forth with plastic mallet to loosen i t . Then 27). Be sure puller jaws are seated under bearing
rock retainer back and forth by hand to work i t out cup.
of gear case. Note that retainer flange extends into (d) Place Insert Tool 6453-2 i n center of puller
and is fairly snug fit i n case bore. jaws (Fig. 27). Insert tool is used to hold puller
(3) Remove seal from front retainer (Fig. 25). Use jaws i n place.
small chisel to collapse one side of seal then pry i t
SPECIAL SPECIAL
out with suitable tool. TOOL TOOL
6453-1 6453-2
FRONT
RETAINER J9221-179
SEAL
Fig. 27 Installing Puller Tools In Front Retainer
(e) Install Puller 6444 on puller rods (Fig. 28).
Then install retaining nuts on puller rods.
(f) Tighten puller bolt to draw bearing cup out of
retainer (Fig. 28). Use holding wrench on puller
FRONT BEARING and turn puller bolt with adjustable wrench.
RETAINER J9221-104
TIGHTENING HOLDING
Fig. 25 Removing Bearing Retainer Seal WRENCH WRENCH
(4) Remove bearing cup from front retainer as fol
lows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 26).
(b) Insert Puller Jaws 6453-1 i n puller flange
(Fig. 26). Narrow lip of puller jaws will go under
bearing cup.
SPECIAL
TOOL
6444-6
SPECIAL
TOOL
6453-2
SPECIAL
TOOL
6444-1
FRONT
RETAINER J9221-180
Fig. 28 Removing Bearing Cup From Front Retainer

SPECIAL
TOOL DRIVE GEAR REMOVAL AND DISASSEMBLY
6453-1 ^ ^ ^ ^ ^ J9221-178 (1) Remove drive gear. Tilt gear downward and out
of case (Fig. 29).
Fig. 26 Assembling Puller Rods, Flange And Jaws (2) Remove pilot bearing from drive gear (Fig. 30).
(3) Remove bearing from drive gear as follows:
J9221-105
Fig. 29 Drive Gear Removal
Fig. 31 Removing Front Bearing From Drive Gear

MAINSHAFT AND GEARTRAIN REMOVAL
(1) Remove countershaft rear bearing plate (Fig.
32).
Fig. 30 Pilot Bearing Removal/Installation

(a) Note that puller tool assembly and setup is
similar to that used for removing fifth gear from
mainshaft (Figs. 19-23).
(b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-4. Then position first Puller Jaw 6447
on gear (Fig. 31).
(c) Slide assembled puller flange and rod tools
onto output shaft. Then seat flange in notch of
puller jaw (Fig. 31).
(d) Position second Puller Jaw 6447 on gear and Fig. 32 Removing Countershaft Rear Bearing Plate
in notch of puller flange (Fig. 31). (2) Remove countershaft end play shim and rear
(e) Slide Retaining Collar 6444-8 over puller bearing cup (Fig. 33).
jaws to hold them in place (Fig. 31). (3) Remove reverse idler shaft. Thread a shift
(f) Install Puller 6444 on puller rods. Then se cover bolt into shaft and withdraw shaft from case
cure puller to rods with retaining nuts (Fig. 31). (Fig. 34).
(g) Tighten puller bolt to remove bearing cone (4) Move 1-2 and 3-4 synchro sleeves into Neutral,
from drive gear (Fig. 31). if necessary.
•
Fig. 36 Fourth Speed Clutch Gear Stop Ring

Removal
(9) Remove mainshaft assembly as follows (Fig.
37):
Fig. 33 Countershaft End Play Shim And Rear (a) Lift front end of mainshaft slightly.
Bearing Cup Removal (b) Grasp mainshaft rear splines. Then turn
spline end of mainshaft i n counterclockwise direc
tion to rotate shaft and geartrain out of case.
(c) Once mainshaft gears roll clear of counter
shaft gears, shaft and gear assembly can be tilted
outward and removed from gear case (Fig. 37).
Fig. 34 Removing Reverse idler Shaft

(5) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 35).
Fig. 37 Mainshaft And Geartrain Removal

(10) Refer to mainshaft disassembly procedures i f
any gears or synchro components must be replaced.
R E V E R S E I D L E R G E A R AND COUNTERSHAFT
REMOVAL/DISASSEMBLY
(1) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 38).
(2) Remove idler gear through drive gear bore at
Fig. 35 Drive Gear Thrust Bearing Removal front of case (Fig. 39).
(3) Keep reverse idler gear bearings and spacer to
(6) Remove fourth speed clutch gear and synchro
gether for cleaning and inspection (Fig. 40). Insert
stop ring from mainshaft (Fig. 36).
idler shaft through gear and bearings to keep them
(7) Roll gear case onto left side (Fig. 37). in place.
(8) Reach into gear case and push reverse idler (4) Remove idler gear thrust washers from gear
gear away from mainshaft gears. case. Install washers on idler shaft to keep them to
gether for cleaning and inspection.
(d) Install second Puller Jaw 6449 on bearing

and in notch of puller flange (Fig. 41).
jaws to hold them in place (Fig. 41). Note that re
taining collar has small lip on one end and only fits
one way over jaws.
(f) Install Puller 6444 on puller rods. Then se
cure puller to rods with retaining nuts (Fig. 41).
(g) Tighten puller bolt to remove bearing from
shaft (Fig. 41). If bearing is exceptionally tight, tap
end of puller bolt with copper mallet to help loosen
bearing.
Fig. 38 idler Gear Moved Away From Countershaft
Fig. 41 Removing Countershaft Rear Bearing

(6) Remove bearing puller tools.
J922M14 (7) Rotate countershaft out of gear case (Fig. 42).
Fig. 39 Reverse Idler Gear Removal

REVERSE
Fig. 40 Reverse Idler Gear Components

(5) Remove countershaft rear bearing. Shaft can
not be removed from case until rear bearing has been Fig. 42 Removing Countershaft From Gear Case
removed. Bearing removal procedure is as follows: (8) Remove countershaft front bearing as follows:
(a) Assemble Puller Flange 6444-1 and Puller (a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 41). Bolts 6444-6 (Fig. 43).
(b) Position first Puller Jaw 6449 on bearing (b) Position first Puller Jaw 6451 on bearing.
cone (Fig. 41). (c) Seat puller flange in notch of puller jaw.
(c) Seat puller flange in notch of puller jaw just (d) Install second Puller Jaw 6451 on bearing
installed on bearing cone (Fig. 41). and in notch of puller flange.

one way over jaws.
(f) Install Puller Bridge And Bolt Assembly 6444
on puller bolts. Then secure bridge to bolts with re
taining nuts (Fig. 43).
(g) Tighten puller bolt to remove bearing from shaft
(Fig. 43). If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(10) Set countershaft and idler gear aside for
cleaning and inspection.
J9221-159 6444.6
Fig. 43 Removing Countershaft Front Bearing

GEAR CASE DISASSEMBLY
(1) Remove countershaft front bearing cap. Use
mallet or hammer to remove cap from inside case
(Fig. 44).
Fig. 46 Removing Shift Lug Roll Pin
Fig. 44 Countershaft Front Bearing Cap Removal

(2) Remove countershaft front bearing cup with
Remover Tool 6454 and Tool Handle C-4171 (Fig. 45).
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 46). A small pin punch can be mod
ified by putting a slight bend in it to drive pin com
pletely out of shift rail (Fig. 46).
(4) Remove shift lug rail by tapping it out of case
and shift lug with tapered punch (Fig. 47). Note po
sition of rail and lug for assembly reference.
Fig. 47 Removing Shift Lug Rail
(5) Remove lug rail bushings from gear case with stack the geartrain parts in order of removal.
Special Tool 6456 (Fig. 48). This practice will help avoid incorrect assem
bly and lost time.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Remove fourth gear synchro struts and springs
from 3-4 hub and sleeve (Fig. 50). Three struts and
springs are used. Keep springs and struts together
for inspection and cleaning. Store parts in a paper
cup to avoid losing them.
(3) Remove 3-4 sleeve from 3-4 synchro hub (Fig.
51).
Fig. 48 Removing Shift Lug Rail Bushings

(6) Unclip and remove magnet from bottom of gear
case (Fig. 49).
Fig. 51 Removing 3-4 Sleeve From Hub

Fig. 49 Gear Case Magnet Location (4) Remove 3-4 synchro hub from mainshaft
splines with suitable size bearing splitter, or with
MAINSHAFT DISASSEMBLY
two tapered drifts. Position splitter or drifts between
Not all of the mainshaft gear and synchro
third gear stop ring to start moving hub off shaft.
components are a one-way fit. Some gear and Then complete hub removal by tapping it off shaft
synchro components can be installed back with plastic mallet. Tap hub at 6-8 different points to
wards. To avoid reassembly problems, mark the remove hub evenly.
speed gears, clutch gears, synchro hubs, and (5) Remove 3-4 synchro hub, third gear stop ring
sleeves for reference during teardown. Use and third gear (Fig. 52).
paint or a scriber for marking purposes. Then (6) Remove third gear bearing assemblies from
mainshaft (Fig. 53).
(7) Remove third gear bearing spacer (Fig. 54).
(8) Remove snap ring that retains second gear
thrust washer on mainshaft (Fig. 54).
(9) Remove second gear thrust washer (Fig. 55).
Note that washer is notched for locating pin.
(10) Remove second gear (Fig. 56).
Fig. 50 3-4 Synchro Strut And Spring Removal

SECOND
GEAR THRUST
WASHER
THRUST
WASHER
SNAP R I N G
THIRD
GEAR
THIRD GEAR
BEARING
SPACER
THIRD
GEAR
STOP J922M22
RING
Fig. 54 Bearing Spacer And Snap Ring Location

SECOND
GEAR
3-4
SYNCHRO
HUB
THRUST
WASHER
J922M20
Fig. 52 Third Gear, Stop Ring And 3-4 Hub Removal
SECOND
GEAR
BEARING J922M23
Fig. 55 Second Gear Thrust Washer Removal

SECOND
GEAR
THIRD
GEAR
NEEDLE
BEARING
ASSEMBLIES
J922M21 J922M24
Fig. 56 Second Gear Removal

Fig. 53 Third Gear Needle Bearing Removal
J9221-127
Fig. 59 Removing Second Speed Clutch Gear Snap

J922M25
Ring
Fig. 57 Second Gear Bearing Removal 1-2
SLEEVE
(12) Remove thrust washer locating pin (Fig. 58). AND
Use needle nose pliers to grip and remove pin. HUB SYNCHRO
STOP
SECOND RING
GEAR
THRUST CLUTCH
WASHER RING
LOCATING
PIN (REMOVE
WITH NEEDLE
SECOND
NOSE PLIERS)
SPEED
CLUTCH
GEAR
J922M28
Fig. 60 Second Speed Clutch Gear, Clutch Ring And

Stop Ring Removal
J922M26
Fig. 58 Thrust Washer Locating Pin Removal

(13) Remove snap ring that retains second speed
clutch gear (Fig. 59). Snap ring is seated in main-
shaft synchro hub groove.
(14) Remove second speed clutch gear, synchro
clutch ring and synchro stop ring (Fig. 60).
(15) Remove 1-2 synchro hub snap ring (Fig. 61).
(16) Mark position of 1-2 synchro sleeve and hub
for assembly reference. Side of hub with flat hub
spring goes toward front (Fig. 62). Note that tapered
side of sleeve also goes toward front.
(17) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 62). It is not necessary J922M29
to disassemble synchro components unless worn, or
damaged. Fig. 61 Removing 1-2 Sleeve And Hub Snap Ring
(18) Remove first gear synchro stop ring and clutch
(20) Remove first speed clutch gear (Fig. 65).
ring (Fig. 63).
(19) Remove first speed clutch gear front snap ring
from mainshaft hub (Fig. 64).
1-2 CLUTCH GEAR

SLEEVE SNAP RING (REAR)
AND HUB
(MARK
'POSITION FOR
ASSEMBLY
REFERENCE)
FIRST
SPEED
HUB SPRING J922I-130 CLUTCH
GEAR J9221-133
Fig. 62 Removing 1-2 Synchro Sleeve And Hub

Fig. 65 First Speed Clutch Gear Removal
FIRST GEAR
CLUTCH RING (22) Remove mainshaft rear bearing as follows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 66).
(b) Position first Puller Jaw 6445 on bearing
cone (Fig. 66).
(c) Seat Puller Flange 6444-1 in notch of first
puller jaw (Fig. 66).
(d) Install second Puller Jaw 6445 on bearing
cone and on puller flange (Fig. 66).
one way over jaws.
FIRST GEAR (f) Install Puller 6444 on puller rods. Then se
STOP RING J922M31
cure puller to rods with retaining nuts (Fig. 67).
(g) Place holding wrench on hex at top of puller
Fig. 63 First Gear Stop And Clutch Ring Removal
(Fig. 67). Then tighten puller bolt with adjustable
FIRST wrench to remove bearing from shaft (Fig. 67). If
SPEED
CLUTCH
bearing proves difficult to remove, tap end of puller
GEAR bolt with copper hammer after each turn of bolt.
This will help loosen bearing on shaft and ease re
moval.
(24) Remove reverse gear thrust washer (Fig. 68).
CLUTCH
GEAR
SNAP
RING
(FRONT)
J9221-132
Fig. 64 First Speed Clutch Gear Front Snap Ring

Removal
(21) Remove first speed clutch gear rear snap ring
from mainshaft hub (Fig. 65). It is not really neces
sary to remove this snap ring unless it, or the main-
shaft is to be replaced.
21 - 68 N¥4560 MANUAL TRANSMISSION •
Fig. 66 Assembling Mainshaft Rear Bearing Puller Tools

SPECIAL REVERSE
Fig. 67 Removing Mainshaft Rear Bearing

(25) Remove reverse gear thrust washer locating (30) Remove first gear snap ring (Fig. 71). Tension
pin (Fig. 69). of this snap ring is considerable. Heavy duty snap
ring pliers will be required to spread the ring far
enough to remove i t .
Fig. 69 Removing Thrust Washer Locating Pin

(26) Remove reverse gear and synchro components
Fig. 71 Reverse Gear Bearing Spacer And First Gear
as assembly (Fig. 70). It is not necessary to re
Snap Ring Removal
move or disassemble synchro components un
less they are damaged and need t o be replaced. (31) Remove reverse clutch gear (Fig. 72).
I f synchro sleeve or struts require service,
m a r k position o f sleeve o n hub before removal.
Correct sleeve position is important as sleeve
can be installed backwards causing shift prob
lems.
(27) Remove reverse gear bearing assembly from
mainshaft (Fig. 70).
(28) Remove reverse gear synchro stop ring and
clutch gear (Fig. 70).
FIRST REVERSE
J922M51
Fig. 72 Removing Reverse Clutch Gear

(32) Remove first gear from bearing and mainshaft
(Fig. 73).
(33) Remove first gear bearing from mainshaft
(Fig. 74).
TRANSMISSION CLEANING AND INSPECTION

Clean the gears, bearings shafts, extension/adapter
housing and gear case with solvent. Dry all parts ex
cept the bearings with compressed air. Allow the
Fig. 70 Reverse Gear, Bearing And Stop Ring bearings to either air dry or wipe them dry with
Removal clean shop towels.
(29) Remove reverse gear bearing spacer from Inspect the reverse idler gear, bearings, shaft and
mainshaft (Fig. 71). thrust washers (Fig. 75). Replace the bearings i f the
rollers are worn, chipped, cracked, flat-spotted, or
brinnelled. Or i f the bearing cage is damaged or dis
torted. Replace the thrust washers i f cracked,
FIRST Replace the gear if any teeth, splines, or bearing sur
GEAR faces are also worn or damaged.
MAINSHAFT FRONT
PILOT BEARING
BEARING
J9221-152
Fig. 73 Removing First Gear
DRIVE
MAINSHAFT FIRST GEAR J922M81
Fig. 76 Drive Gear Components
Inspect the front bearing retainer and bearing cup
(Fig. 77). Replace the bearing cup if scored, cracked,
brinnelled, or rough. Check the release bearing slide
surface of the retainer carefully. Minor corrosion,
nicks, or pitting can be smoothed with 400 grit emery
and polished out with crocus cloth. Wet the abrasive
paper and crocus cloth with oil when smoothing/pol
J922M53 ishing. Replace the retainer if worn or damaged in
Fig. 74 Removing First Gear Bearing any way.
chipped, or worn. Replace the gear if the teeth are
chipped, cracked or worn thin.
FRONT IDLER BEARINGS REAR
Fig. 77 Front Bearing Retainer Components

Inspect the countershaft and bearings (Fig. 78). Re
place the bearings if worn, rough, flat spotted, or
heat checked. Check the countershaft gear teeth
carefully. Small nicks, scratches, or burrs can be re
moved with an oil stone and 400 grit paper wetted
with oil. However, replace the shaft as an assembly if
SPACER SHAFT J922M83 the forward gear is loose, or any of the teeth are
Fig. 75 Reverse Idler Components worn, cracked, broken, or severely chipped.
Inspect the drive gear and bearings (Fig. 76). Mi Be sure to check condition of the countershaft bearing
nor scratches and burrs on the gear surfaces can be cups. Replace either bearings cup if worn, or damaged.
reduced with an oil stone and 400 grit paper wetted Check condition of the mainshaft. Inspect all the bear
with oil. Replace either bearing if worn, or damaged. ing surfaces, splines and threads. Also check condition
of the snap ring grooves in the hub area and the speed-
REAR COUNTERSHAFT FRONT GEAR EXTENSION

BEARING BEARING CASE HOUSING
(2-WHEEL
J922M84
Fig. 78 Countershaft And Bearings
ometer drive gear teeth (Fig. 79). Minor scratches or
burrs, can be removed with an oil stone and polished
ADAPTER
with crocus cloth. However, replace the shaft if any sur HOUSING
faces exhibit considerable wear or damage. (4-WHEEL
DRIVE) - J922M86
BEARING HUB BEARING NUT SPEEDOMETER
SURFACES SURFACES THREADS TEETH Fig. 80 Gear Case And Extension/Adapter Housings
are excessively worn, or damaged. The synchro sleeve
should also be replaced if worn or damaged in any way.
Do not reuse synchro struts that are worn, or springs
that are collapsed or severely distorted. Replace worn
distorted synchro parts to avoid shift problems after as
sembly and installation.
The shift fork should be inspected for evidence of
wear and distortion. Check fit of the sleeve in the
fork to be sure the two parts fit and work smoothly.
SPLINES Replace the fork if the roll pin holes are worn over
size or damaged. Do not attempt to salvage a worn
SPLINES SPLINES J9221-185
fork. It will cause shift problems later on. Replace
the shift fork roll pins if necessary, or if doubt exists
Fig. 79 Mainshaft Bearing And Spline Surfaces
about their condition.
Check condition of the gear case and extension or The bearings should be examined carefully for
adapter housing (Fig. 80). Be sure the alignment wear, roughness, flat spots, pitting, or other damage.
dowels in the case top surface and in the housing/ Replace the bearings if necessary.
adapter are tight and in good condition. Inspect the stop ring and clutch gear, replace either
Run a tap through the gear case bolt holes if the
part if worn or damaged in any way. Also be sure replace
threads need minor cleanup. Helicoil inserts can be used
ment parts fit properly before proceeding with assembly.
to repair seriously damaged threaded holes if necessary.
Be sure all case and housing/adapter sealing and mat Inspect the 1-2 synchro components (Fig. 82). The hub
ing surfaces are free of burrs and nicks. This is espe weights and retainer springs are reusable if in good con
cially important as gaskets are not used in the NV4500. dition. However, replace the springs if distorted, or bro
Minor nicks and scratches on the sealing surfaces can ken and replace the weights if worn or damaged.
be dressed off with a fine tooth file or oil stone. Examine the hub and sleeve for wear or damage.
Replace the gear case or housing/adapter if cracked Replace the sleeve and hub if the splines are worn,
or broken. Do not attempt to repair this type of dam chipped or damaged.
age by welding or brazing. Replace the synchro struts if worn, or chipped. Also
Check condition of the countershaft fifth gear com replace the springs if collapsed, distorted, or broken.
ponents (Fig. 81). This includes the shift lug and rail Inspect the mainshaft geartrain components (Fig.
located in the gear case and the rail bushings. 83). Check the teeth on all gears, hubs, clutch gears,
Inspect the gear and hub assembly. Minor burrs can stop rings and clutch rings. The teeth must be in
be cleaned up with an oil stone. However, the gear and good condition and not worn, cracked, or chipped. Re
hub assembly should be replaced if the teeth or splines place any component that exhibits wear or damage.
21-72 NV4500 MANUAL TRANSMISSION
THRUST BEARINGS BEARING COUNTERSHAFT SYNCHRO SYNCHRO
ROLL
PINS J9221-187
Fig. 81 Countershaft Fifth Gear Components
Examine the synchro stop rings, clutch rings and Check condition of the synchro struts and springs,
clutch gears. Replace any part that exhibits wear, Replace these parts if worn, cracked, or distorted,
distortion, or damage. Replace the clutch rings if the
friction material is burned, flaking off, or worn.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent, or worn. Replace the wash
ers if worn, or the locating pin notches are distorted.
Fig, 82 1-2 Synchro Components

LEGEND FOR FT GEARTRAIN
1. MAINSHAFT 25. SYNCHRO HUB SNAP RING

2. FIRST GEAR BEARING 26. FIRST GEAR SYNCHRO STOP RING
3. FIRST GEAR 27. 1-2 SYNCHRO SLEEVE
4. CLUTCH GEAR 28. SYNCHRO STRUTS AND SPRINGS (4 EACH)
5. SYNCHRO STOP RING 29. 1 -2 SYNCHRO HUB (INC. RETAINER SPRINGS AND WEIGHTS)
6. FIRST GEAR SNAP RING 30. SYNCHRO HUB SNAP RING
7. REVERSE GEAR BEARING SPACER 31. SECOND GEAR SYNCHRO STOP RING
8. REVERSE GEAR BEARING 32. SECOND SPEED CLUTCH GEAR
9. REVERSE SYNCHRO SLEEVE 33. SECOND GEAR SYNCHRO CLUTCH RING
10. SYNCHRO STRUTS AND SPRINGS (3 EACH) 34. CLUTCH GEAR SNAP RING
11. REVERSE GEARUNES 35. SECOND GEAR BEARING
12. THRUST WASHER 36. SECOND GEAR
13. THRUST WASHER LOCATING PIN 37. THRUST WASHER AND LOCATING PIN
14. MAINSHAFT REAR BEARING 38. THRUSTWASHER SNAP RING
15. MAINSHAFT REAR BEARING CUP 39. THIRD GEAR BEARING SPACER
16. MAINSHAFT END PLAY SHIMS 40. THIRD GEAR
17. MAINSHAFT REAR BEARING PLATE 41. THIRD GEAR BEARING ASSEMBLIES (2)
18. MAINSHAFT FIFTH GEAR 42. THIRD GEAR SYNCHRO STOP RING
19. THRUST WASHER 43. 3-4 SYNCHRO SLEEVE
20. FIFTH GEAR NUT 44. SYNCHRO STRUTS AND SPRINGS (3 EACH)
21. MAINSHAFT SPUNE SEAL 45. 3-4 SYNCHRO HUB
22. CLUTCH GEAR SNAP RING 46. FOURTH GEAR SYNCHRO STOP RING
23. FIRST SPEED CLUTCH GEAR 47. FOURTH SPEED CLUTCH GEAR
24. FIRST GEAR SYNCHRO CLUTCH RING 48. DRIVE GEAR THRUST BEARING
J9321-98
TRANSMISSION ASSEMBLY AND ADJUSTMENT • Mainshaft End Play: 0.051-0.15 mm (0.002-0.006

in.)
Assembly Information
Gaskets are not used i n the NV4500 transmis GEAR CASE ASSEMBLY
sion. Use Mopar Gasket Maker, silicone adhe (1) Install countershaft front bearing cup in case
sive/sealer, or Loctite 518 on all gear case and with Tool Handle C-4171 and Installer Tool 6061-1 or
extension housing sealing surfaces. C-4340 (Fig. 84).
(2) Install new bushings in shift lug rail bores with
Adjustment Specifications Tool 6456 (Fig. 85). Seat bushings flush with bores.
• Countershaft End Play: 0.051-0.15 mm (0.002-
0.006 in.)
SPECIAL TOOL SPECIAL TOOL
Fig. 85 Installing Shift Lug Rail Bushings

(3) If case magnet was removed, install and secure
magnet in clip at bottom of case (Fig. 86).
COUNTERSHAFT AND REVERSE IDLER GEAR

INSTALLATION
(1) Install front bearing on countershaft with In
staller Tool 6446 (Fig. 87).
(2) Lubricate countershaft front bearing cup and
cone with petroleum jelly.
(3) Position gear case on end with rear of case fac
ing up (Fig. 88).
Fig. 84 Installing Countershaft Front Bearing Cup
(5) Lubricate reverse idler gear bearings with pe

troleum jelly and install first bearing, bearing spacer
and second bearing (Fig. 89).
(6) Install idler gear front thrust washer on boss in
gear case (Fig. 89). Coat thrust washer with liberal
quantity of petroleum jelly to hold i t i n place.
POSITION
IDLER
GEAR
FRONT
PJ9221-149 THRUST "
WASHER
ON
Fig. 86 Gear Case Magnet installation BOSS
FRONT
BEARING
SPECIAL
TOOL 0
6446
J9221-162
Fig. 89 Positioning Idler Gear Front Thrust Washer

In Case
(7) Install reverse idler gear i n case (Fig. 90).
COUNTERSHAFT
(8) Install idler gear rear thrust washer between
J9221-160 idler gear and case boss (Fig. 90).
REAR
Fig. 87 Countershaft Front Bearing installation THRUST
WASHER- REVERSE
(4) Install countershaft in gear case (Fig. 88). Do IDLER
n o t i n s t a l l rear b e a r i n g on countershaft r e a r at GEAR
this time.
GEAR
CASE
FRONT
THRUST
WASHER
I
J9221-163
Fig. 90 Idler Gear And Thrust Washer Installation

COUNTERSHAFT
(9) Align idler gear bearings and thrust washers
a with drift.
(10) Install reverse idler shaft (Fig. 91). Be sure
notched end of shaft is facing countershaft as shown.
Use shift cover bolt to hold and insert shaft i n case
bore.
(11) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 92).
IJ922M61
(12) Install rear bearing cone on countershaft with
Installer Tool C-4040 or 6446 (Fig. 93).
Fig. 88 Positioning Countershaft In Gear Case
COUNTERSHAFT SHIFT REVERSE

SPECIAL
COVER IDLER
TOOL
BOLT SHAFT
6446
COUNTERSHAFT REAR
BEARING
J922M 66
Fig. 91 Rewerse Idler Shaft Installation Fig. 93 Installing Countershaft Rear Bearing
FRONT
BEARING
CAP
(SEAT
WITH
WOOD
BLOCK)
COUNTERSHAFT
Fig. 94 Countershaft Front Bearing Cap Installation
COUNTERSHAFT
REAR
BEARING
CUP
WOOD,.
BLOCK
J9221-165
Fig. 92 Supporting Countershaft With Wood Block

(13) Remove wood block from under countershaft
and lower countershaft front bearing into front bear
ing cup.
(14) Install new front bearing cap i n gear case
(Fig. 94). Apply Mopar silicone adhesive/sealer to J9221-167
flange and lip of new cap. Then seat cap i n case bore
Fig. 95 Countershaft Rear Bearing Cup Installation
with wood block and mallet.
(15) Lubricate countershaft rear bearing cup and (2) Rotate countershaft 4-5 times to seat bearings.
cone with petroleum jelly. (3) Mount dial indicator on case. Then position in
(16) Install countershaft rear bearing cup i n gear dicator plunger on end of countershaft and zero indi
case and over rear bearing (Fig. 95). Tap cup into cator dial needle (Fig. 97).
place with plastic mallet i f necessary. (4) Raise countershaft with screwdriver and note
end play reading on dial indicator. End play should
ADJUSTING COUNTERSHAFT END PLAY be 0.051 - 0.15 mm (0.002 - 0.006 in.).
(1) Install countershaft rear bearing plate (Fig. (5) Remove countershaft rear bearing plate.
96). Be sure plate is seated i n notch i n reverse idler (6) Select and install end play shim that will pro-
shaft before tightening bearing plate bolts.
COUNTERSHAFT REAR (7) Reinstall countershaft rear bearing plate (Fig.

96). Be sure plate is seated i n reverse idler shaft
notch before installing bolts. Also be sure end play
shims are still in position before tightening bearing
plate bolts.
(8) Apply 1-2 drops Mopar Loc W Seal or Loctite
242 to threads of rear bearing plate bolts. Then in
stall and tighten bearing plate bolts to 23 N*m (200
in. lbs.) torque.
SHIFT L U G AND RAIL INSTALLATION

(1) Lubricate shift lug, rail and bushings with Cas
trol Syntorq.
(2) Insert shift lug rail part way into case.
J9221-168
(3) Install shift lug on rail. Note position of
Fig. 96 Countershaft Rear Bearing Plate Installation (4) Position shift rail so roll pin notches are at ap
proximately 5 o'clock position (Fig. 99).
(5) Install roll pin that secures lug to rail (Fig. 99).
NOTCHES LUG ROLL SHIFT
Fig. 99 Shift Lug And Rail Installation

MAINSHAFT AND GEARTRAIN ASSEMBLY
CAUTION: The reverse, 1-2 and 3-4 synchro com

Fig. 97 Measuring Countershaft End Play ponents can be assembled and installed incorrectly
if care is not exercised. Some components can be
vide minimum countershaft end play. Position shim
installed backwards resulting in shift problems. Re
on rear bearing cup (Fig. 98).
fer to the assembly procedures for component iden
REAR END tification and location.
(1) Lubricate mainshaft bearing surfaces and all

bearing assemblies with Castrol Syntorq or with pe
troleum jelly.
(2) Install first snap ring i n rearmost groove of
mainshaft hub (Fig. 100). This snap ring locates first
speed clutch gear on shaft. A total of four of these
snap rings are used to secure various components on
the mainshaft 1-2 synchro hub. The snap rings are
all the same size and are interchangeable.
Fig. 98 Installing Countershaft End Play Shim (3) Install first gear bearing assembly on main-
shaft (Fig. 100).
SNAP FIRST REVERSE GEAR

RING 'GEAR STOP RING
BEARING
WOOD BLOCKS .CLUTCH GEAR
.FIRST GEAR
\~ ~
-S"
^ ^ ^ ^ ^ ^ ^ ^
i ,
r •- A
MAINSHAFT
SYNCHRO
HUB J9221-176
u . - - • \
J9221-191
i
Fig. 100 First Gear Bearing and Snap Ring
Installation Fig. 102 Clutch Gear Stop Ring Installation
(4) If desired, mainshaft can be placed in upright (10) Install reverse, gear bearing on mainshaft (Fig.
(vertical) position and supported with wood blocks 103).
(Fig. 101). Reverse gear components are easier to in REVERSE GEAR
stall with shaft upright. BEARING
(5) Install first gear and bearing on shaft (Fig.
101). Clutch hub side of gear faces front of shaft. BEARING
SPACER
(6) Install clutch gear on first gear (Fig. 101). Be
sure clutch gear is seated on shaft splines.
(7) Install first gear snap ring (Fig. 101). Use FIRST
heavy duty snap ring pliers to install this snap ring GEAR
as ring tension is considerable. Do not overspread
snap ring and make sure it is fully seated i n J9221-192
groove. Reverse gear will not fit properly if
snap ring is not fully seated.
Fig. 103 Reverse Gear Bearing And Spacer
FIRST FIRST Installation
GEAR GEAR
SNAP (11) If reverse gear sleeve and struts were disas
RING sembled for service, reassemble sleeve, struts and
springs as follows:
CAUTION: The reverse sleeve will fit either way

on the hub. This means the sleeve c a n be installed
backwards if care is not exercised. Be sure the ta
pered side of the sleeve faces rearward after instal
REVERSE
CLUTCH lation.
GEAR
(a) Position sleeve on hub so tapered side of
sleeve faces rearward. Sleeve will fit either way
but will cause shift problems if installed backwards
J9221-177
(Fig. 104).
(b) Rotate sleeve to align teeth on sleeve and
Fig. 101 First Gear, Clutch Gear And Snap Ring
hub. Sleeve will slide easily into place on hub when
Installation
properly aligned.
(8) Install stop ring on clutch gear (Fig. 102). Be (c) Install springs in gear hub (Fig. 104). Use pe
sure stop ring is fully seated on gear taper. troleum jelly to hold springs in place if desired.
(9) Install reverse gear bearing spacer on main- (d) Compress first spring with flat blade screw
shaft (Fig. 103). Bearing spacer seats against first driver and slide strut into position in hub slot.
gear snap ring. Then work spring into seat in strut with small
hooked tool, or screwdriver.
(e) Install second and third struts in same man THRUST

ner as described in step (d). WASHER
(f) Work sleeve upward on hub until struts are PIN
centered and seated in sleeve. Sleeve should be in
neutral position after seating struts. MAINSHAFT
REVERSE SLEEVE SPRING (3) REVERSE

GEAR GEAR
STRUT (3)
J9221-194
Fig. 106 Thrust Washer Pin installation
THRUST WASHER REVERSE GEAR
HUB J922H89
Fig. 104 Reverse Gear Synchro Assembly J9221-195

(12) Install reverse gear and synchro assembly on
mainshaft (Fig. 105). Rotate assembly until stop ring Fig. 107 Reverse Gear Thrust Washer Installation
lugs engage in hub slots and gear drops into fully SPECIAL
seated position. TOOL
6446
REVERSE GEAR
AND
SYNCHRO ASSEMBLY MAINSHAFT
REAR
BEARING
J922M93
Fig. 105 Reverse Gear Installation J9221-175
(13) Install reverse gear thrust washer pin in

Fig. 108 Installing Mainshaft Rear Bearing
mainshaft (Fig. 106). Use needle nose pliers to install
pin. (16) Turn mainshaft over and place it in horizontal
(14) Install reverse gear thrust washer (Fig. 107). position on workbench.
Be sure locating pin is seated in thrust washer notch. (17) Install first speed clutch gear on mainshaft
(15) Install rear bearing on mainshaft. Use In 1-2 synchro hub (Fig. 109). Recessed side of gear
staller Tool 6446 to seat bearing on shaft and against faces front. Be sure gear is seated against snap ring
thrust washer (Fig. 108). If bearing is not fully previously installed on hub.
seated on shaft, seat bearing by tapping inner race (18) Install snap ring on mainshaft 1-2 synchro
with small brass punch and hammer. Bearing inner hub to secure clutch gear (Fig. 110). Be sure snap
race should be flush with shaft.
21 - 80 NW4I00 MANUAL TRANSMISSION •
clutch ring are aligned and seated i n first gear
hub. 1-2 synchro hub will not seat properly if
clutch ring tabs are misaligned.
Fig. 109 installing First Speed Clutch Gear

ring is fully seated in hub groove and against clutch
gear. Note that this is second of four snap rings used
to secure synchro components on shaft hub. Fig. 112 First Speed Clutch And Stop Ring
Installation
(21) Support mainshaft in upright position (Fig.
113). Remaining gears, snap rings and synchro com
ponents are easier to install with shaft in upright po
sition. Shaft can be supported in gear case as shown,
or hole can be cut in workbench to support shaft.
Fig. 110 Installing First Speed Clutch Gear Snap MAINSHAFT

Ring
(19) Assemble first speed clutch ring and stop ring
(Fig. 111).
Fig. 113 Mainshaft Positioned For Gear And

Synchro Installation
(22) If 1-2 synchro hub and sleeve were disassem
Fig. 111 Assembling First Speed Clutch And Stop bled for service, reassemble hub, sleeve, struts and
Rings springs as follows:
(a) Install weights in hub (Fig. 114). Use petro
(20) Install assembled first speed clutch and stop leum jelly to hold weights in place if desired.
rings on clutch gear (Fig. 112). Be sure tabs on
HUB SYNCHRO
Fig. 114 Installing Weights In 1-2 Synchro Hub

(b) Install weight retainer springs. Flat spring
goes at front side of hub (Fig. 115). Be sure re
tainer spring ends are securely engaged in weight
slots as shown.
Fig. 116 Installing 1-2 Synchro Sleeve On Hub
sleeve upward until struts are started in sleeve.
Verify that struts are engaged in sleeve before pro
ceeding.
(g) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated
and springs are not displaced during assembly.
J9221-207
STRUTS AND
Fig. 115 Installing Weight Retainer Springs In 1-2 SPRINGS (4 EACH) J9221-209
Synchro Hub
(c) Place synchro hub on bench so side of hub Fig. 117 Installing 1-2 Synchro Struts And Springs
with square spring is facing up (Fig. 116). (23) Install first speed stop ring in 1-2 synchro hub
(d) Align and install sleeve on hub. Be sure ta and sleeve (Fig. 118). Be sure stop ring is fully seated
pered side of sleeve faces upward (toward front). and engaged in hub and sleeve.
Rotate sleeve until it slides onto hub. Sleeve only (24) Install 1-2 synchro assembly and stop ring on
fits one way and will easily slide onto hub when mainshaft. Rotate sleeve to align it with stop ring
long slot in sleeve, aligns with long shoulder on lugs if necessary. Then seat assembly on shaft (Fig.
hub (Fig. 116). 119) .
(e) Place wood blocks under hub that will raise (25) Check position of 1-2 and reverse synchro
hub about 3.5 cm (1-3/8 in.) above surface of work sleeves. Be sure tapered side of 1-2 sleeve faces front
bench. Then allow sleeve to drop down on hub (Fig. and tapered side of reverse sleeve faces rear (Fig.
117). 120) . Also be sure square spring is visible at forward
(f) Install springs and struts in hub (Fig. 117). side of 1-2 synchro hub. Do not skip this check as
Use lots of petroleum jelly to hold them in place. transmission will not shift properly if either
Then compress struts with your fingers and move synchro sleeve is installed backwards.
(27) Install snap ring that secures 1-2 synchro on

mainshaft hub (Fig. 121). Be sure snap ring is fully
seated i n ring groove i n mainshaft hub. I f snap ring
will not seat in groove, round weight spring at
rear of 1-2 synchro hub is probably not seated
in recess at front of first speed clutch gear. O r
first speed clutch gear is slightly misaligned.
Realign as needed to fully seat snap ring.
Fig. 118 Installing First Speed Stop Ring In Synchro

Hub
Fig. 121 Installing 1-2 Synchro Snap Ring

(28) Reinstall flat weight spring i n 1-2 synchro hub
(Fig. 122). Be sure spring ends are securely engaged
in weight slots.
Fig. 119 1-2 Synchro Installation
Fig. 122 Reinstalling Flat Weight Spring

(29) Assemble second speed clutch gear, clutch ring
and stop ring (Fig. 123).
(30) Install assembled second speed clutch gear
and rings on mainshaft and i n 1-2 synchro hub (Fig.
124).
(31) Install snap ring that secures second speed
clutch gear on mainshaft (Fig. 125). Use narrow
blade screwdriver to work snap ring into hub groove
as shown. Be sure snap ring is fully engaged i n
Fig. 120 Correct Position Of Rewerse And 1-2 mainshaft groove before proceeding. I f snap
Synchro Sleewes ring will not fit i n groove, clutch gear is
(26) Temporarily remove flat weight spring from slightly misaligned. Or, flat weight spring at
front side of 1-2 synchro hub. Removing spring
makes installation of 1-2 hub snap ring easier.
STOP RING SCREWDRIVER MAINSHAFT

HUB
CLUTCH RING
SNAP
RING
CLUTCH GEAR
SECOND
SPEED
CLUTCH
GEAR
J9221-215
J9221-200
Fig. 123 Assembling Second Speed Clutch Gear, Fig. 125 Installing Second Speed Clutch Gear Snap
Clutch Ring And Stop Ring Ring
CLUTCH SECOND
GEAR GEAR
BEARING
STOP
RING
CLUTCH
RING J9221-214 J9221-217
Fig. 124 Second Speed Clutch Gear, Clutch Ring Fig. 126 Second Gear Bearing Installation
And Stop Ring Installation
SECOND
front of 1-2 synchro hub is probably not seated GEAR
in recess i n front of second speed clutch gear.
(32) Install second gear bearing on mainshaft (Fig.
126).
CLUTCH
(33) Install second gear on mainshaft and bearing. RING TABS
Rotate gear until tabs of second speed clutch ring are
fully seated in tab slots in gear (Fig. 127).
(34) Install thrust washer pin in shaft (Fig. 128).
Use needle nose pliers to insert pin in shaft hole.
(35) Install second gear thrust washer. Be sure TAB
washer is seated on gear and pin (Fig. 129). SLOTS
(IN GEAR)
(36) Install second gear thrust washer snap ring
(Fig. 130). Be sure snap ring is fully seated in main-
shaft groove. J9221-218
(37) Install third gear bearing spacer on shaft and
Fig. 127 Second Gear Installation
seat it against thrust washer snap ring (Fig. 130).
(38) Install third gear bearings on mainshaft (Fig. ther bearing spacer or snap ring was not in
131). Upper bearing should be flush with mainshaft stalled. Check and correct if necessary.
hub. I f upper bearing is not flush with hub, ei-
THRUST THIRD
WASHER GEAR
PIN BEARINGS
SECOND
GEAR
J9221-225
Fig. 131 Third Gear Bearing Installation
J9221-223 THIRD
GEAR
Fig. 128 Thrust Washer Pin Installation
SECOND SECOND
GEAR GEAR
THRUST
WASHER LOCATING
PIN
IN WASHER
NOTCH ,^\/\.râ -\ \ II J9221-226
Fig. 132 Third Gear Installation
SYNCHRO THIRD
STOP 'GEAR
RING
J9221-224
Fig. 129 Second Gear Thrust Washer Installation

SECOND
GEAR THRUST J9221-227
WASHER
Fig. 133 Third Gear Stop Ring Installation
THRUST (41) If 3-4 synchro was disassembled for service,

WASHER reassemble synchro components as follows:
SNAP RING (a) Align and install synchro sleeve on hub (Fig.
134). Front side of hub has a narrow groove
machined i n it.
(b) Insert all three synchro struts in slots ma
THIRD GEAR chined in sleeve and hub (Fig. 134).
BEARING
SPACER (c) Install and seat synchro springs (Fig. 134).
Use flat blade or phillips screwdriver to compress
springs and seat them in struts and hub as shown.
J922M22 (42) Remove mainshaft and geartrain from gear
case or from workbench.
Fig. 130 Installing Snap Ring And Third Gear
(43) Start 3-4 synchro assembly on mainshaft. Tap
Bearing Spacer
assembly onto shaft splines until hub is about 3 mm
(39) Install third gear over bearings and on main- (1/8 in.) away from third speed stop ring. Then align
shaft (Fig. 132). stop ring with synchro sleeve and hub and seat syn
(40) Install synchro stop ring on third gear (Fig. chro assembly with Tool C-4040 (Fig. 135).
133). Be sure stop ring is fully seated on gear taper.
STRUT (3) SPRING (3) 3-4 3-4
Fig. 137 Fourth Speed Clutch Gear Installation

MAINSHAFT AND GEARTRAIN INSTALLATION
(1) Position gear case so case opening is facing up
(Fig. 138).
Fig. 134 3-4 Synchro Assembly (2) Grip mainshaft at pilot bearing hub and just
behind rear bearing. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
(3) Continue holding front of shaft but switch grip
at rear to shaft output splines. Lift mainshaft assem
bly slightly, align gears and seat assembly in case. Be
sure fourth speed clutch gear and stop ring were not
displaced during installation (Fig. 138).
MAINSHAFT
Fig. 135 Seating 3-4 Synchro Assembly On

Mainshaft
(44) Verify that 3-4 synchro hub is fully seated on
shaft. Approximately 3 mm (1/8 in.) of shaft spline
should be visible. If hub is not seated, stop ring lugs
are misaligned. Rotate ring until lugs are fully en
gaged in 3-4 hub slots.
(45) Install fourth speed stop ring in 3-4 synchro
sleeve (Fig. 136).
Fig. 138 Mainshaft And Geartrain Installed In Case

(4) Install drive gear thrust bearing on mainshaft
(Fig. 139). Use plenty of petroleum jelly to hold bear
ing in place.
(5) Check alignment and mesh of mainshaft gears.
If gears are not aligned, roll case on side and realign
shaft and gears in case.
DRIVE GEAR AND RETAINER INSTALLATION

(1) Install bearing on drive gear with Installer Tool
Fig. 136 Fourth Speed Stop Ring Installation 6448 (Fig. 140).
(2) Lubricate pilot bearing with petroleum jelly
(46) Install fourth speed clutch gear in stop ring
and install it in drive gear bore.
(Fig. 137).
(3) Install drive gear on mainshaft. Work gear
rearward until mainshaft hub is fully seated in pilot
bearing.
MAINSHAFT DRIVE GEAR

THRUST BEARING^. SPECIAL TOOL
6052
RETAINER
U922M10
Fig. 139 Drive Gear Thrust Bearing installation
SPECIAL
-TOOL
6448 WOOD BLOCK J9221-202
Fig. 142 Installing Bearing Retainer Oil Seal

(7) Apply Mopar Gasket Maker to flange surface of
front bearing retainer (Fig. 143).
BEARING (8) Install front bearing retainer over drive gear
and start it into case.
(9) Start front bearing retainer in gear case. Ver
ify that retainer lube channel is at top-center
DRIVE GEAR (12 O'clock) position (Fig. 143). Adjust retainer
position before proceeding, if necessary.
LUBE
J9221-204
CHANNEL
(INSTALL AT
Fig. 140 Installing Front Bearing On Drive Gear 12 O'CLOCK
POSITION)
(4) Install bearing cup in front retainer with
Driver Handle C-4171 and Installer C-4308 (Fig.
141).
SPECIAL SPECIAL
TOOL TOOL
C-4308 C-4171
FRONT
APPLY RETAINER
GASKET
AAAKER
HERE J9221-231
WOOD
BLOCKS
Fig. 143 Location Of Front Retainer Lube Channel
(10) Align front bearing retainer bolt holes and tap
retainer into place with plastic mallet. Install and
RETAINER tighten retainer bolts to 30 N-m (265 in. lbs.) torque
(Fig. 144).
J9221-203
MAINSHAFT END PLAY ADJUSTMENT
Fig. 141 Installing Front Bearing Cup In Retainer (1) Install mainshaft rear bearing cup in case and
over bearing. Tap bearing cup into place with plastic
(5) Install new oil seal in front bearing retainer mallet.
with Tool C-4595 or 6052 (Fig. 142). Use one or two (2) Install rear bearing plate to hold mainshaft
wood blocks to support retainer as shown. Lubricate and rear bearing in position (Fig. 145). Do not install
seal lip with petroleum jelly after installation. any end play shims at this time.
(6) Clean contact surfaces of gear case and front (3) Tighten rear bearing plate bolts securely.
bearing retainer with a wax and grease remover.
BEARING MAINSHAFT
PLATE REAR
OIL HOLE BEARING
(AT TOP) PLATE
FRONT BEARING — 3 ^ 1 1 1 A —^1 y m 7 , JW 1 0, 3,W

RETAINER V W /\ "-
Fig. 144 installing Front Bearing Retainer
(4) Place gear case in upright position on bench. E i
ther cut hole in bench to accept drive gear and front re
tainer, or use C-clamps to secure transmission on bench. J9221-233
Do not leave transmission unsupported.
Fig. 146 Rear Bearing Plate Installation
(5) Mount dial indicator on rear of gear case and
position indicator plunger against inner race of rear MAINSHAFT
bearing (Fig. 145). FIFTH
(6) Move mainshaft forward to remove all play. GEAR
Then zero dial indicator.
(7) Move mainshaft upward and observe dial indi
cator reading. Move mainshaft with pry tool posi
tioned between drive gear and case.
(8) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play if
necessary.
DIAL REAR
INDICATOR BEARING
AND SPECIAL
BASE TOOL
6446 J9221-220
Fig. 147 Installing Mainshaft Fifth Gear

(2) Install fifth gear nut washer (Fig. 148). Coned
side of washer faces end of shaft.
(3) Apply 3-4 drops Mopar Lock N' Seal, or Loctite
242 to nut threads on mainshaft.
(4) Install fifth gear nut on mainshaft (Fig. 148).
FIFTH NUT
GEAR WASHER
'(CONED)
J9221-232
Fig. 145 Checking Mainshaft End Play FIFTH
GEAR
(9) If end play adjustment is required, remove NUT
bearing plate and install necessary shim.
(10) Reinstall rear bearing plate (Fig. 146).
(11) Apply Mopar Lock W Seal or Loctite 242 to
bearing plate bolt threads. Then install and tighten
bolts to 23 N-m (200 in. lbs.) torque. Be sure oil
hole in bearing plate is at top as shown.
MAINSHAFT FIFTH GEAR INSTALLATION

(1) Install mainshaft fifth gear. Use Installer Tool J9221-93
6446 to seat gear on shaft (Fig. 147). Gear is seated Fig. 148 Installing Fifth Gear Nut And Washer
when it contacts rear bearing.
(5) Tighten fifth gear nut as much as possible with (2) Install thrust washer on countershaft. Turn
Nut Wrench 6443 or 6743, long handle ratchet, breaker washer until pin engages in washer notch (Fig. 151).
bar and Socket Wrench 6441 or 6442 (Fig. 149). Flat side of washer faces rear and cone side to front
SPECIAL FIFTH
as shown.
Fig. 151 Installing Fifth Gear Thrust Washer

(3) Lubricate and install fifth gear bearings on
countershaft (Fig. 152).
(4) Install bearing spacer on countershaft and seat
it against bearings (Fig. 152). Coat spacer with petro
RATCHET leum jelly to hold it in place.
WRENCH J9221-92
Fig. 149 Fifth Gear Nut Installation
(6) Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
(7) Position Spline Socket Wrench 6441 or 6442 on
mainshaft splines. Then install breaker bar in socket
wrench and wedge bar against workbench.
(8) Tighten fifth gear nut with Nut Wrench 6443
and high capacity torque wrench. Required torque on
nut is 339-475 N-m (250-350 ft. lbs.). Have helper
hold transmission steady if necessary. Nut can also
be tightened by striking Wrench 6443 with heavy
copper mallet then checking with torque wrench. BEARINGS J9221-236
COUNTERSHAFT FIFTH GEAR AND SYNCHRO Fig. 152 Countershaft Fifth Gear Bearing And
INSTALLATION Spacer Installation
(1) Install thrust washer pin in countershaft (Fig. (5) Install synchro sleeve on hub of countershaft
150). fifth gear. Tapered side of sleeve faces front and flat
side faces rear (Fig. 153).
Fig. 150 Installing Fifth Gear Thrust Washer Pin

Fig. 153 Installing Synchro Sleeve On Countershaft
Fifth Gear Hub
(6) Install shift fork in synchro sleeve (Fig. 154).

FIFTH
GEAR
SYNCHRO HUB
SLEEVE
SHIFT
FORK
J9221-238
Fig. 154 Installing Fifth Gear Shift Fork In Synchro SYNCHRO

Sleeve STRUT (3) J9221-240
(7) Install assembled fifth gear, synchro sleeve and
Fig. 156 Installing Fifth Gear Synchro Struts And
shift fork (Fig. 155). Align fork with shift lug rail and
Springs
align gear with bearings and countershaft. Start
components onto shaft and rail. Then tap gear and
STOP
fork into place with plastic or rawhide mallet. RING
(8) Align roll pin holes in shift fork with notches in CLUTCH
GEAR
shift lug rail. Then install roll pins from top side of
fork (Fig. 155). Note that roll pins are one way fit
due to small shoulder at one end of each pin.
SHIFT
FORK
AND
SLEEVE
J9221-241
Fig. 157 Fifth Synchro Clutch Gear And Stop Ring

Installation
CLUTCH
GEAR ,
RINGV rz^J
SHIFT FIFTH
> FORK ROLL GEAR
PINS HUB J9221-239
Fig. 155 Installing Assembled Countershaft Fifth

Gear, Shift Fork And Synchro Sleeve
(9) Install synchro struts and springs in fifth gear
FIFTH
hub (Fig. 156). Install struts in hub slots first. Then SYNCHRO
install springs by compressing them with screwdriver CLUTCH
and working springs into hub and struts. GEAR J9221-89
(10) Assemble and install fifth synchro clutch gear Fig. 158 Installing Fifth Synchro Clutch Snap Ring
and stop ring in fifth gear hub (Fig. 157). Make sure
both parts are seated in fifth gear hub. (2) If extension housing bushing must be replaced,
(11) Install clutch gear snap ring (Fig. 158). collapse old bushing with tapered drift (Fig. 159). Po
sition drift in slot provided at end of housing. Then
EXTENSION/ADAPTER HOUSING tap drift into slot and against bushing to collapse
INSTALLATION and remove it.
(1) If extension housing seal needs replacement, (3) Remove any burrs from housing bushing bore
remove it collapsing with a punch and chisel. Then with a file and emery cloth.
pry seal out of housing with crowfoot pry bar.
TAPERED .SPECIAL TOOL
C-4660-3
PUNCH
BUSHING
EXTENSION
HOUSING
EXTENSION HOUSING
J9221-251
Fig. 159 Removing Extension Housing Bushing

(4) Install new bushing in extension housing (Fig.
160). Use Tool Handle C-4171 and Installer Tool
SP5559 to install bushing. Note that installer tool J9221-201
SP5559 is part of tool set C-4469.
Fig. 161 Installing Extension Housing Seal
m SPECIAL
-TOOL
C-4171 EXTENSION
HOUSING
SPECIAL
-TOOL
C-4660-3
EXTENSION
HOUSING
J9221-252
GEAR
CASE J9221-85
Fig. 160 Installing Extension Housing Bushing
Fig. 162 Installing Extension/Adapter Housing
(5) Install extension housing seal with Tool
C-4660-3 (Fig. 161). socket and do not use an impact wrench.
(6) Clean mating surfaces of extension/adapter Splines on bolt heads can be damaged if impact
housing and gear case with a wax and grease re wrench or wrong type of socket is used for
mover. tightening purposes.
(7) Check alignment dowels in gear case and hous
ing or adapter. Be sure dowels are in position and S H I F T COVER INSTALLATION
seated. (1) Clean mating surfaces of shift cover and gear
(8) Apply Mopar Gasket Maker to gear case and case with a wax and grease remover.
housing mating surfaces. (2) Apply Mopar Gasket Maker, or Loctite 518 to
(9) Align and install extension/adapter housing on sealing surface of shift cover or gear case. Do not
gear case (Fig. 162). overapply sealer material. Excess can be squeezed
(10) Apply Mopar Lock N' Seal or Loctite 242 to into gear case and could block lubricant feed holes in
threads of extension/adapter housing bolts. time.
(11) Install and tighten housing bolts to 54 N- (40 (3) Lubricate synchro sleeves with Castrol Syntorq
ft. lbs.) torque. Use a twelve point 10 mm socket, gear lubricant. Then apply light coat of petroleum
a ratchet wrench and necessary extensions to jelly to shift fork contact surfaces.
install bolts. Do not use any other type of
(4) Verify that 1-2 and 3-4 synchro sleeves are in Shift Cover Inspection
neutral position. Also verify that forks in shift cover Inspect the cover and shift components whenever
are in neutral position. the cover is removed from the gear case. Or, when
(5) Align and install shift cover (Fig. 163). If cover ever diagnosis indicates inspection is necessary.
will not seat, it is either not aligned on gear case Check the forks for wear, distortion, cracks, or be
dowels, or shift forks are not aligned with sleeves ing loose on the shift rails. Also check fit of the shift
and shift lug. rails in the cover. Replace the cover assembly if the
SHIFT rails are loose in the cover bores.
Inspect and replace the pads on the fifth-reverse
shift fork if worn. The reverse inhibitor should also
be replaced if worn, or faulty. The expansion plugs at
the rear of the cover can be replaced if loose or leak
ing.
A gasket is not used between the shift cover
and gear case. Use Mopar Gasket Maker, or
Loctite 518 to seal the cover.
Procedures for the serviceable components in the
shift cover as follows:
Fifth-Reverse Shift Fork Pad Replacement

The plastic shift fork pads are held in place by a
combination of tension and a small locating tang.
Fig. 163 Installing Shift Cover Assembly Three pads are used on the fork (Fig. 164).
The pads can be removed either by hand or with a
(6) Apply Mopar Lock N' Seal or Loctite 242 to narrow blade screwdriver. To remove the pads by
threads of shift cover bolts. hand, grasp each pad and tilt it out and off the fork.
(7) Install and tighten shift cover bolts to 30 N-m If the pads prove difficult to remove by hand, insert a
(265 in. lbs.) torque. screwdriver blade between the pad and fork and pry
(8) Install backup light switch and vent in shift the pad off.
cover. Apply sealer to switch threads before installa
tion and tighten switch to 30 N-m (265 in. lbs.).
(9) On 2-wheel drive models, install and index
speedometer adapter in extension housing.
(10) Install and tighten drain bolt (at bottom of
PTO cover).
(11) Fill transmission to bottom edge of fill plug
hole with Mopar Manual Transmission Lubricant,
P/N 4637579, or Castrol Syntorq. Both are synthetic,
GL 4 grade 75W-90 lubricants.
(12) Install and tighten fill plug to 40 N-m (30 ft.
lbs.) torque.
SHIFT COVER SERVICE

The only serviceable shift cover components are:
• fifth-reverse shift fork pads
• reverse inhibitor
Fig. 164 Shift Fork Pad Locations
• vent components
• backup light switch Reverse Inhibitor Replacement
• expansion plugs The reverse inhibitor mechanism should be checked
• shift lever components for wear or damage whenever diagnosis indicates this
The shift cover, shift forks, shift rails and detent is necessary.
components are not serviced individually. The cover The inhibitor mechanism is attached to the cover
must be replaced as an assembly if the cover, or any with two screws (Fig. 165). Attaching screw torque is
shift components are worn or damaged. 8-14 N-m (75-115 in. lbs.).
Expansion Plug Replacement
The expansion plugs at the rear of the shift rail
bores (Fig. 168) can be replaced if loose and/or leak
ing. Replacement procedure is as follows:
(1) Drill 6 mm (1/4 in.) diameter hole in each plug
to be removed.
(2) Pry plug out of cover with tapered punch.
(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
(4) Apply small bead of sealer to outer edge of each
Fig. 165 Reverse Inhibitor Mounting new plug. Use Mopar silicone adhesive/sealer, or
equivalent.
Vent Component Replacement
(5) Position each new plug in bore and tap into
The shift cover vent assembly consists of the vent place with hammer and suitable size punch or socket.
tube, connecting hose, hose clamps, and vent valve
(Fig. 166). Shift Lever Replacement
If the vent tube is removed for replacement or ser
vice access, apply Mopar silicone adhesive/sealer to
the tube to help secure it in the cover.
Fig. 168 Expansion Plug Location

TUBE CLAMP J9221-256 (1) If transmission is in vehicle, remove shift lever
boot. Then remove shift lever extension with Remov
Fig. 166 Shift Cover Vent Components er/Installer Tool 6783 as follows:
Backup Light Switch Replacement (a) Position notched, lower end of tool just under
The backup light switch is located at the left (driv square shank of shift lever (Fig. 169).
er) side of the cover (Fig. 167). The switch plunger is (b) Position tool upper jaws under flange on
operated by the fifth-reverse shift rail. shift lever extension (Fig. 169).
The switch can be replaced with the transmission (c) Tighten tool screw to pull extension off square
in, or out of the vehicle. A gasket may, or may not be shank of shift lever.
used with the switch. (d) Remove lever extension and tool.
Apply sealer to the switch threads before installa (2) If transmission is out of vehicle, temporarily
tion. Tightening torque for the switch is 22-34 N-m mount cover on gear case.
(192-300 in. lbs.). (3) Remove shift lever lower boot. Unseat boot
from shift tower and slide it off shift lever.
(4) Unlock shift lever retainer with two long screw
drivers for leverage. Press lever retainer downward
with screwdrivers. Then turn retainer counterclock
wise to release retainer from locking pins in shift
tower (Fig. 170).
(5) Lift shift lever upward and remove lever, re
tainer and spring as assembly (Fig. 171).
(6) Lubricate shift lever and retainer contact sur
faces with petroleum jelly or Castrol Syntorq.
(7) If transmission is out of vehicle, temporarily
mount shift cover on gear case.
Fig. 167 Backup Light Switch Location (8) Install shift lever as follows:
SHIFT SPRING RETAINER

LEVER
LOWER
BOOT
FLANGE
O N LEVER
EXTENSION
TOOL
UPPER JAW J9221-259
(UNDER
FLANGE) Fig. 171 Shift Lever Components
must be positioned differently in standard
and heavy duty transmissions.
(b) On heavy duty transmissions, install lever so
SQUARE
"heavy" mark on lever shank is facing forward.
SHANK (c) On standard duty transmissions, install lever
OF SHIFT SPECIAL
TOOL so "standard" mark on lever shank is facing for
LEVER
6783 ward.
CAUTION: Verify correct lever installation before

proceeding. T h i s is important because if the shift
lever is mispositioned, it will also misalign the lever
extension causing interference and bind.
TOOL
LOWER
JAW J9421-205 LEVER H.D. POSITION
SHANK MARK
(TO FRONT)
Fig. 169 Removing Shift Lever Extension With Tool
6783
RETAINER
STD. DUTY
LEVER POSITION
SHANK MARK
(TO FRONT)
PIN
SLOT
J9421-209
Fig. 172 Shift Lever Position Marks

(9) Lock lever retainer in shift tower with two long
J9221-253
screwdrivers. Use screwdrivers to push and turn re
tainer until it engages both locking pins in tower.
Fig. 170 Unlocking Shift Lever Retainer (10) Install lower boot on shift lever. Seat boot se
curely on shift tower.
(a) Note position information on square shank of (11) If transmission is in vehicle, install lever ex
shift lever (Fig. 172). Although one shift lever is tension on shift lever with Tool 6783 as follows:
used for all applications, lever is offset and
Tool 6783 above flange on lever extension (Fig.
173). Tool will now be used to press extension back
onto shift lever.
(b) Tighten tool screw to press extension back
onto lever.
(c) Remove special tool.
(d) Install shift lever boot and bezel.
Fig. 174 Shift Cover Bolt Removal/Installation

SHIR
COVER
SLOT
Fig. 175 Loosening Shift Cover

SHIFT
Fig. 173 installing Shift Lever Extension With Tool

6783
Shift Cover Replacement
(1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 174).
(3) Loosen shift cover with pry tool. To avoid dam
aging cover seal surface, insert pry tool only i n slots
provided i n cover (Fig. 175).
(4) Raise cover enough to disengage i t from align
ment dowels i n gear case (Fig. 176).
(5) Raise front of shift cover and lift cover up and
off gear case (Fig. 176).
(6) Set cover assembly aside for inspection. I f cover Fig. 176 Shift Cover Removal/Installation
components are damaged, refer to shift cover service overapply sealer material. Excess can be squeezed
information. into gear case and could block lubricant feed holes i n
(7) Clean mating surfaces of shift cover and gear time.
case with wax and grease remover. (9) Lubricate synchro sleeves with Castrol Syntorq
(8) Apply Mopar Gasket Maker, or Loctite 518 to gear lubricant. Then apply light coat of petroleum
sealing surface of shift cover or gear case. Do not jelly to shift fork contact surfaces.
(10) Verify that 1-2 and 3-4 synchro sleeves are in (13) Install and tighten shift cover bolts to 27-31
neutral position. Also verify that forks in shift cover N-m (216-276 in. lbs.) torque.
are i n neutral position. (14) Install backup light switch i n cover. Apply
(11) Align and install shift cover (Fig. 176). I f cover sealer to switch threads before installation and
will not seat, i t is either not aligned on gear case tighten switch to 22-34 N-m (193-265 i n . lbs.).
dowels, or shift forks are not aligned with sleeves (15) Install vent assembly, i f removed. Apply an
and shift lug. adhesive/sealer to vent tube to help secure i t i n cover.
(12) Apply Mopar Lock 1ST Seal or Loctite 242 to
threads of shift cover bolts.
21 - 96 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH/47RH •
AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH/47RH
CONTENTS
page page
32RH TRANSMISSION OVERHAUL 175 GENERAL INFORMATION—42RH/46RH/

36RH/37RH TRANSMISSION OVERHAUL . . . . 216 47RH 100
42RH TRANSMISSION OVERHAUL 257 OVERDRIVE UNIT OVERHAUL—42RH/46RH/
46RH/47RH TRANSMISSION OVERHAUL . . . . 303 47RH 353
AUTOMATIC TRANSMISSION DIAGNOSIS AND TRANSMISSION, CONVERTER, OVERDRIVE
TESTING 108 REMOVAL/INSTALLATION 169
AUTOMATIC TRANSMISSION IN-VEHICLE TRANSMISSION/TRANSFER CASE
SERVICE (ALL) 154 SPECIFICATIONS 421
GENERAL INFORMATION—32RH/36RH . . . . . . 96
G E N E R A L INFORMATION—32RH/36RH
INDEX
page page
Components Unique to 37RH Transmission 96 Transmission Controls and Components 99
Recommended Fluid 96 Transmission Description 96
Torque Converter 96 Transmission Identification 99
TRANSMISSION DESCRIPTION RECOMMENDED FLUID

The Chrysler 32RH, 36RH and 37RH are three Mopar ATF Plus, Type 7176 is the recommended
speed, fully automatic transmissions (Figs. 1 and 2). and preferred fluid for Chrysler automatic transmis
They are used in 1500, 2500 and 3500 models. The sions. Dexron II fluid should only be used in situa
32RH is used for 3.9L and 5.2L engine applications. tions where Mopar ATF Plus is not available.
The 36RH is used for heavy duty 5.2L and 5.9L en
gine applications. The 37RH is used for diesel and COMPONENTS UNIQUE TO 37RH TRANSMISSION
V10 engine applications.
Planetary Gears
TORQUE CONVERTER The transmission and overdrive planetary gear car
A three element torque converter is used. The con riers in the 37RH are heavy duty components. The
verter used with 32RH transmissions has a converter transmission planetary carriers have four pinion
clutch. The converter used with 36RH and 37RH gears. The carrier in the overdrive compounder has
transmissions is also equipped with a converter five pinion gears.
clutch.
A 241 or 273 mm (9.5 or 10.75 in.) converter is Governor Weight Assembly
used for 3.9L, 5.2L and 5.9L gas engine applications.
The governor weight assembly is made of alloyed
A 310 mm (12.2 in.) converter is used for diesel and
brass. The diesel weight assembly is easily identified
V10 engine applications.
by the distinctive gold color of the alloyed material.
The converter used with 1993 and later model
32RH transmissions is new. The converter hub was, The heavier weight assembly provides the shift
changed to accept the new style drive flats on the oil points needed to offset lower operating speeds of a
pump inner gear. The new style converter is not in diesel engine.
terchangeable with previous designs. The alloyed weight assembly is unique to the
The converter is a welded assembly. It is not a re 37RH. It is not interchangeable with the weight as
pairable component and is serviced as an assembly. semblies used in gas engine versions.
FRONT PLANETARY GEAR SET
TURBINE FRONT CLUTCH / REAR PLANETARY GEAR SET
STATOR
LOW AND REVERSE (REAR) BAND
IMPELLER
LOCK-UP
CLUTCH^
BUSHING
L
IS*
EXTENSION HOUSING
ENGINE 39
CRANKSHAFT
39
KICKDOWN (FRONT) BAND SUN GEAR DRIVING SHELL m

39
FLEXIBLE DRIVE PLATE
39
1S3
PR225 -*
Fig, 1 32RH Automatic Transmission
IMPELLER
FLEXIBLE DRIVE PLATE

ENGINE CRANKSHAFT
Fig. 2 36RH/37RH Automatic Transmission

• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH/47RH 21 - 99
TRANSMISSION IDENTIFICATION Flow Control And Lubrication

Transmission identification numbers are stamped The manual valve is operated by the gearshift link
on the left side of the case just above the oil pan gas age and provides the operating range selected by the
ket surface (Fig. 3). Refer to this information when driver.
ordering replacement parts. The 1-2 shift valve provides automatic 1-2 or 2-1
shifts and the 2-3 shift valve provides automatic 2-3
or 3-2 shifts.
The kickdown valve provides forced 3-2 or 3-1
downshifts depending on vehicle speed. Downshifts
occur when the throttle is opened beyond downshift
detent position which is just before wide open throt
tle.
The 2-3 valve throttle pressure plug provides 3-2
downshifts with varying throttle openings and de
pending on vehicle speed.
The 1-2 shift control valve transmits 1-2 shift pres
sure to the accumulator piston to control kickdown
band capacity on 1-2 upshifts and 3-2 downshifts.
The limit valve determines maximum speed at
which a 3-2 part throttle kickdown can be made.
Some transmissions do not have the limit valve and
maximum speed for a 3-2 kickdown is at the detent
Fig. 3 Transmission Identification Numbers position.
TRANSMISSION CONTROLS AND COMPONENTS The shuttle valve has two functions. First is fast
The transmission hydraulic control system provides front band release and smooth engagement during
fully automatic operation. The system performs five "lift foot" 2-3 upshifts. Second is to regulate front
basic functions, which are: clutch release and band application during 3-2 down
• pressure supply shifts.
• pressure regulation The converter clutch valve applies the converter
• flow control modulated clutch when supplied with line pressure
through the converter clutch solenoid. The solenoid is
• clutch and band application
controlled by and connected to the powertrain control
• lubrication.
module through a connector in the transmission case.
Pressure Supply
Electronic control of converter clutch engagement
includes disengagement at closed throttle during
The oil pump develops fluid pressure for clutch/ warmup and during part throttle acceleration. Non-
band application and for lubrication. The pump is converter clutch transmissions have a threaded plug
driven by the torque converter. at the rear of the transmission case in place of the
solenoid wiring connector.
Pressure Regulation The fail safe valve restricts feed to the converter
The pressure regulator valve maintains transmis clutch if front clutch pressure drops. It permits
sion line pressure. The amount of pressure developed clutch engagement only in direct (third) gear and
is controlled by throttle pressure. Throttle pressure is provides fast clutch release during kickdown.
dependent on the degree of throttle opening. The reg The switch valve directs apply fluid pressure to the
ulator valve is located in the valve body. converter clutch in one position and releases it in the
The throttle valve determines line pressure and opposite position. It also directs oil to the cooling and
shift speed. The throttle valve also controls upshift lube circuits. The switch valve regulates oil pressure
and downshift speeds by regulating pressure accord to the torque converter by limiting maximum oil
ing to throttle position. pressure to 130 psi.
Pressure developed by the governor valve works Clutch/Band Application
with throttle pressure to determine shift points. Gov
The front/rear clutch pistons and servo pistons are
ernor pressure is the speed signal that indicates actuated by line pressure. When line pressure is re
when a shift should take place. In operation, gover moved, the pistons are released by spring tension.
nor pressure increases at a rate approximately the On 2-3 upshifts, the front servo piston is released
same as vehicle speed. by spring tension and hydraulic pressure. The accu
mulator controls hydraulic pressure on the apply side
of the front servo during 1-2 upshifts and at all
throttle openings.
21 - 100 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/48RH/47RH •
G E N E R A L INFORMATION—42RH/46RH/47RH
INDEX
page page
Components Unique to 47RH 103 Recommended Fluid 103
Fourth Gear Overdrive Components 104 Temperature Sensor and Indicator Lamp 103
Fourth Gear Overdrive Operation 105 Torque Converter 103
Gear Ratios . . . . 103 Transmission Description . . . . . . . . . . . . . . . . . . . 100
Hydraulic Controls 106 Transmission Identification 104
TRANSMISSION DESCRIPTION clutch. The overdrive clutch is applied in fourth gear

The Chrysler 42RH, 46RH and 47RH are 4-speed only. The direct clutch is applied in all ranges except
automatic transmissions. Fourth gear is an overdrive fourth gear.
range. The governor and park lock assemblies are located
The 42RH is used with 3.9L engines. The 46RH is inside the overdrive unit. The unit must be removed
used with 5.2L and 5.9L gas engines. The 47RH is a and disassembled for service access to the park lock
heavy duty transmission for use with V10 and diesel and governor components.
engines only. Fourth gear is controlled by a manually operated
The 42RH/46RH/47RH are all dual unit designs. switch in the instrument panel. The switch is in cir
The assembly consists of an automatic transmission cuit with the overdrive solenoid (on the valve body)
with an overdrive unit attached at the rear (Figs. 1 and the powertrain control module. In the On posi
and 2). First through third gear ranges are provided tion, current flows through the switch to the solenoid
by the clutches, bands, overrunning clutch and plan for the 3-4 shift sequence. The transmission must be
etary gear set in the transmission. Fourth gear range in third gear before a 3-4 upshift will occur.
is provided by the overdrive unit. Overdrive ratio is The overdrive solenoid will not be energized and a
0.69:1.
3-4 upshift will not occur when the control switch is
The overdrive unit contains an overdrive clutch, di
in the OFF position.
rect clutch, planetary gear set and overrunning
VALVE
BODY
J9321-2G5
Fig. 2 46RH/47RH Transmission And Overdrive Unit

• AUTOMATIC TiANSMISSION—32RH/36RH/37RH/42RH/48RH/47RH 21 - 103
TORQUE CONVERTER Gear Case

A three element torque converter is used for all ap The 47RH transmission case is readily identifiable
plications. The converter consists of the impeller, sta- by the extra reinforcing ribs around the rear servo
tor and turbine. The converter also contains an area of the case.
overrunning clutch and a converter clutch mecha The converter housing bolt pattern is unique for
nism. diesel and gas engine versions of the 47RH.
The converter used with 1993 and later 42RH
transmissions is new. The converter hub was Clutch Packs
changed to accept new style drive flats on the oil Clutch packs used in the diesel version of the con
pump inner gear. The new style converter is not in tain the following number of discs and plates:
terchangeable with previous designs. • transmission front/rear clutch has 4 discs and 5
The converter modulated clutch consists of a slid steel plates
ing clutch piston, clutch springs and the clutch disc • overdrive clutch has 5 discs and 6 steel plates
friction material. The clutch provides optimum • overdrive direct clutch has 9 discs and 10 steel
torque transfer and economy when engaged. • plates
The clutch disc is attached to the converter front
Rear Band, Lever and Low-Reverse Drum
cover. The clutch piston and clutch springs are at
tached to the turbine hub. The springs dampen en The 47RH has a special, extra wide, double wrap
gine firing impulses and loads during the initial rear band, and a heavy duty band lever and pins.
phase of converter clutch engagement. The double wrap band is positively retained on the
Converter clutch engagement is controlled by the low-reverse drum. A shoulder machined on the for
converter clutch valve and solenoid. Both are located ward end of the drum secures the band and main
on the transmission valve body. Clutch engagement tains band location during severe operation. The
occurs in drive range at speeds above approximately band lever screw acts directly against the band. A
30-35 mph. strut and second lever is not used.
The converter clutch provides reduced engine speed
Governor Weight Assembly
and greater fuel economy when engaged. Clutch en
gagement also provides reduced transmission fluid The governor weight assembly in the diesel version
temperatures. is made of alloyed brass. The diesel weight assembly
is easily identified by the distinctive gold color of the
GEAR RATIOS alloyed material. The heavier weight assembly pro
42RH forward gear ratios are: vides the shift points needed to offset lower operating
• First gear = 2.74:1 speeds of a diesel engine.
• Second gear = 1.54:1 The alloyed weight assembly is unique. It is not in
• Third gear = 1.00:1 terchangeable with the weight assemblies used in
• Fourth gear = 0.69:1. gas engine versions.
46RH/47RH forward gear ratios are:
• First gear = 2.45:1 TEMPERATURE SENSOR AND INDICATOR LAMP
• Second gear = 1.45:1 Fourth gear and converter clutch operation in the
• Third gear = 1.00:1 47RH is also controlled by a temperature sensor. The
• Fourth gear = 0.69:1. sensor is located in a cooler line (Fig. 3).
The sensor constantly monitors transmission fluid
RECOMMENDED FLUID temperature. The sensor is in circuit with overdrive
The recommended and preferred fluid for 42RH/ and converter clutch solenoid through the power
46RH/47RH transmissions is Mopar ATF Plus, type train controller.
7176. Dexron II fluid should only be used when ATF The temperature sensor prevents overdrive and
Plus is not available. converter clutch engagement when fluid temperature
is below 60°F for the overdrive clutch; and below
COMPONENTS UNIQUE TO 47RH 70°F for the converter clutch.
The sensor will also downshift the transmission to
Planetary Gears third gear, or prevent a 3-4 upshift when fluid tem
The transmission and overdrive planetary gear car perature exceeds 270-275° F.
riers in the 47RH are heavy duty components. The The fluid temperature switch is located in a boss
transmission planetary carriers have five pinion built into the cooler outlet line. The boss and switch
gears. The carrier in the overdrive compounder has are located approximately 2-3 inches from the outlet
five pinion gears. line fitting in the transmission case.
21 104 AUTOMATIC T R A N S M I S S I O N — 3 2 R H / 3 6 R H / 3 7 R H / 4 2 R H / 4 6 R H / 4 7 R H •
The fluid temperature indicator lamp is i n the in
strument cluster adjacent to the heater/defroster con
trols (Fig. 4).
Fig. 5 Identification Number And Code Location (All)

the input and output shafts. The output shaft is i n
the overdrive unit. The intermediate shaft is sup
Fig, 3 Temperature Sensor Location ported by the overdrive piston retainer and piloted i n
the output shaft.
The overdrive piston and retainer are located at
the rear of the transmission case. The retainer serves
as both the rear support and pressure chamber for
the overdrive piston. The intermediate shaft is
splined to the overdrive direct clutch sliding hub,
planetary assembly and overrunning clutch.
The governor components and speedometer drive
are located on the output shaft i n the overdrive unit.
Two bearings are used to support the output shaft. A
longer park rod assembly is also required.
There are no rotating seal rings or pressurized oil
TRANSMISSION for the direct clutch. The clutch is applied by spring
FLUID pressure and released by movement of the overdrive
TEMPERATURE
' INDICATOR
clutch piston during the 3-4 upshift.
LAMP The governor is operated by fluid pressure supplied
through pressure tubes. The tubes are permanently
attached to the governor support. Governor fluid
pressure is transmitted through the intermediate
shaft to the tubes.
J9421-241 Governor pressure and overdrive clutch pressure
taps are provided i n the transmission case for pres
Pig. 4 Fluid Temperature indicator Lamp Location sure testing purposes.
TRANSMISSION IDENTIFICATION The overdrive unit contains a direct clutch, an
Transmission identification numbers and codes are overdrive clutch and an overrunning clutch. Fourth
stamped on the left side of the case just above the oil gear range is provided by an additional planetary
pan gasket surface (Fig. 5). gear set I n the overdrive unit.
The first letter/number group is the assembly part The direct clutch is applied by spring pressure. A
number. The next number group the transmission high pressure spring rated at approximately 830
build date. The last number group is the transmis pounds (5530 kPa) tension, holds the clutch i n en
sion serial number. Refer to this information when gagement. The sun gear, direct clutch sliding hub
ordering replacement parts. and drum are splined to the annulus gear for direct
drive. For coasting or reverse gear, power flows only
FOURTH GEAR OVERDRIVE COMPONENTS through the direct clutch.
42RH746RH/47RH models have three transmission
shafts. An intermediate shaft is positioned between
• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH/47RH 21 - 111
A timing valve disengages the torque converter and during fourth gear operation. The amount of
clutch prior to a 4-3 downshift. The clutch solenoid, boost is determined by throttle opening and line
engagement valve, and timing valve are actuated i n pressure.
fourth gear range. The overdrive piston engages the overdrive clutch
The fourth gear shift valves and plugs are located by pressing directly against the clutch pressure plate.
in the valve body lower housing. The components in The overdrive clutch also disengages the direct clutch
clude: during 3-4 upshifts. As fluid pressure extends the
• a separate housing for the overdrive valves and overdrive piston, the piston contacts the direct clutch
plugs hub pressing i t rearward. This action compresses the
• an overdrive solenoid direct clutch spring relieving spring load on the
• a converter clutch solenoid clutch pack. The clutch is disengaged once spring
• a 3-4 shift valve load is relieved.
• a 3-4 timing valve The 3-4 accumulator cushions overdrive clutch en
• a 3-4 accumulator gagement to smooth the transition into fourth gear.
• a 3-4 shuttle valve The accumulator is charged at the same time as ap
• an overdrive separator plate. ply pressure acts against the overdrive piston.
• a boost valve and connecting tube Converter clutch engagement i n overdrive fourth
gear is controlled by switch and sensor inputs to the
FOURTH GEAR OVERDRIVE OPERATION powertrain control module (PCM). I n third gear
above 25 mph, inputs that determine clutch engage
3-4 Shift Sequence ment and shift timing are:
The overdrive clutch is applied i n fourth gear only. • transmission fluid temperature
The direct clutch is applied i n all ranges except • engine speed
fourth gear. • vehicle speed
Fourth gear overdrive range is electronically con • throttle position
trolled and hydraulically activated. Various sensor in • manifold vacuum
puts are supplied to the powertrain control module to
operate the overdrive solenoid on the valve body. The • overdrive off (control) switch position
solenoid contains a check ball that opens and closes a
vent port i n the 3-4 shift valve feed passage. Gearshift Mechanism
The overdrive solenoid (and check ball) are not en • The gear shift mechanism provides the same shift
ergized i n first, second, third or reverse gear. The positions used with other Chrysler transmissions (P-
vent port remains open diverting line pressure from R-N-D-2-1).
the 2-3 shift valve away from the 3-4 shift valve. The shift into overdrive fourth gear range occurs
The overdrive switch must be i n the On position to only after the transmission has completed the shift
transmit signals to the solenoid. A 3-4 upshift occurs into D third gear range. No further movement of the
only when the overdrive solenoid is energized by an shift mechanism is required to complete the 3-4 shift.
electrical signal from the powertrain control module. The fourth gear upshift occurs automatically when
The solenoid is energized upon receiving a signal. the overdrive control switch is i n the ON position.
This causes the check ball to close the vent port. Shift timing is determined by sensor inputs to the
Closing the vent port allows line pressure from the engine controller.
2- 3 shift valve to act directly upon the 3-4 upshift
Overdrive Off Switch
valve.
Line pressure acting on the 3-4 shift valve over The overdrive off (or control) switch is located in
comes valve spring tension moving the valve to the the instrument panel. I n the normal on position, au
upshift position. This action exposes the feed pas tomatic shifts into fourth gear overdrive will occur. I n
sages to the 3-4 timing valve, 3-4 shuttle valve, 3-4 the Off position, the switch overrides the engine con
accumulator and ultimately to the overdrive piston. troller preventing a shift to overdrive fourth gear
Line pressure through the timing and shuttle range.
valves move the overdrive piston into simultaneous The switch has an indicator light that illuminates
contact with the overdrive clutch and the direct when overdrive is turned off. The switch also resets
clutch hub. when the ignition key is turned to the OFF position
The overdrive clutch is engaged and the direct so that the automatic overdrive feature is restored.
clutch is disengaged simultaneously to complete the The use of fault codes is employed to help diagnose
3- 4 upshift. the electronic components that operate the overdrive
The boost valve provides increased fluid apply pres unit and converter clutch. The codes are accessible
sure to the overdrive clutch during the 3-4 upshift through the DRB I I scan tool.
21-106 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH/47iH
H Y D R A U L I C C O N T R O L S ing lift-foot 2-3 upshifts. The second is to regulate

The 42RH/46RH/47RH hydraulic control system front clutch and band application during 3-2 down
shifts.
provides fully automatic operation. The system per
The 3-4 shuttle valve uses a combination of throttle
forms five basic functions which are: pressure supply,
and governor pressure to control the rate of overdrive
pressure regulation, flow control, clutch/band applica
piston apply and release. This is done to maintain
tion, and lubrication. shift quality at varying throttle openings.
Transmission operation is similar to that described The 3-4 timing valve is moved by line pressure
in the 32RH/36RH/37RH General Information sec coming through the 3-4 shift valve. The timing valve
tion. The main difference being fourth gear operation holds the 2-3 shift valve in an upshift position. The
which is covered here. purpose is to prevent the 2-3 valve from up or down
shifting before the 3-4 valve.
Pressure Regulation
The 3-4 accumulator is mounted on the overdrive
The pressure regulator valve maintains line pres housing. It performs the same function as the 2-3 ac
sure. The amount of pressure developed is controlled cumulator. It is used to smooth engagement during
by throttle pressure which is dependent on the de the 3-4 shift.
gree of throttle opening. The regulator valve is lo On models with a converter clutch, the clutch valve
cated in the valve body. applies the converter clutch when supplied with line
The throttle valve determines line pressure and pressure through the converter clutch solenoid.
shift speed. Governor pressure increases in propor The converter clutch solenoid is mounted on the
tion to vehicle speed. The throttle valve controls up valve body. It is energized by an electrical signal
shift and downshift speeds by regulating pressure from the powertrain control module. Electronic con
according to throttle position. trol of converter clutch engagement includes disen
gagement at closed throttle during warmup and
Flow Control And Lubrication during part throttle acceleration.
The manual valve is operated by the gearshift link The switch valve directs apply fluid pressure to the
age and provides the operating range selected by the converter clutch in one position and releases it in the
driver. opposite position. It also directs oil to the cooling and
The 1-2 shift valve provides 1-2 or 2-1 shifts and lube circuits. The switch valve regulates oil pressure
the 2-3 shift valve provides 2-3 or 3-2 shifts. to the torque converter by limiting maximum oil
The kickdown valve provides forced 3-2 or 3-1 pressure to 130 psi.
downshifts depending on vehicle speed. Downshifts
Quick Fill Valve Function
occur when the throttle is opened beyond downshift
detent position which is just before wide open throt The 3-4 shuttle valve has been replaced by a 3-4
tle. quick fill valve. The valve maintains a prefill pres
sure of approximately 5 psi in the overdrive clutch.
The 2-3 valve throttle pressure plug provides 3-2
Prefill pressure is maintained in all drive (D) ranges.
downshifts at varying throttle openings depending on
The purpose of the valve is faster engagement of the
vehicle speed.
overdrive clutch during 3-4 upshifts.
The 1-2 shift control valve transmits 1-2 shift pres In operation, the valve temporarily bypasses the
sure to the accumulator piston. This controls kick- clutch piston feed orifice at the start of a 3-4 upshift.
down band capacity on 1-2 upshifts and 3-2 This exposes a larger passage into the piston retainer
downshifts. resulting in a much faster clutch fill and apply se
The 3-4 shift valve, shuttle valve, timing valve and quence.
accumulator are only actuated when the overdrive The valve does not bypass the regular clutch feed
solenoid is energized. orifice throughout the 3-4 upshift. Instead, once a
The solenoid contains a check ball that controls a predetermined pressure develops within the clutch,
vent port to the 3-4 valve. The check ball either di the valve closes the bypass. Clutch fill is then com
verts line pressure away from or directly to, the 3-4 pleted through the regular feed orifice.
shift valve. Energizing the solenoid causes the check
ball to close the vent port allowing line pressure to Boost Valve Function
act upon the 3-4 upshift valve. The boost valve provides increased fluid apply pres
The limit valve determines maximum speed at sure for converter clutch and overdrive clutch en
which a 3-2 part throttle kickdown can be made. On gagement.
transmissions ndt having a limit valve, maximum The boost valve is connected to the overdrive clutch
speed for 3-2 kickdown is at the detent position. circuit via a tube connected between the valve body
The 2-3 shuttle valve has two functions. First is upper and lower housings. The valve is connected to
fast front band release and smooth engagement dur the converter clutch circuit via the regulator valve,
• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH/47RH 21 -107
switch valve and 3-4 shift and timing valves. The switch valve directs fluid apply pressure to the
Hydraulic circuitry for the boost valve is shown in converter clutch in one position and releases it in the
the hydraulic flow diagrams. The diagrams are lo opposite position. It also directs oil to the cooling and
cated at the end of the transmission diagnosis and lube circuits. The switch valve regulates oil pressure
test section. to the torque converter by limiting maximum oil
During converter clutch engagement in fourth gear, pressure to 130 psi.
the valve supplies full line pressure directly to the
clutch. The increased pressure available at the clutch Clutch/Band Application
provides smooth shifting and positive engagement. The clutch and servo pistons are actuated by line
The 3-4 upshift causes the boost valve to increase pressure. When fluid pressure is released, the pistons
line pressure to the overdrive clutch. Pressure also are released by spring pressure.
increases with throttle opening. This ensures positive On 2-3 upshifts, the front servo piston is released
clutch engagement during periods of high throttle by spring tension and hydraulic pressure. The accu
opening acceleration.
mulator controls hydraulic pressure on the apply side
Converter Clutch Control of the front servo during 1-2 upshifts and all throttle
openings.
The converter clutch valve applies the converter
clutch when supplied with line pressure through the The overdrive direct clutch is applied by spring
converter clutch solenoid. The solenoid is mounted on pressure. The direct clutch is applied in all ranges
the valve body and energized by an electrical signal except fourth gear.
from the powertrain control module. Electronic con The overdrive clutch is applied in fourth gear only.
trol of converter clutch operation includes clutch re The clutch is applied by the overdrive piston which is
lease at closed throttle during warmup and during actuated by line pressure through the 3-4 shift valve.
part throttle acceleration. The boost valve provides
additional apply pressure for converter clutch appli
cation.
21-108 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING •
AUTOMATIC TRANSMISSION DIAGNOSIS A N D TESTING
INDEX
page page
Air Testing Transmission Clutch and Band Gearshift Linkage 110
Operation 114 General Information . 108
Analyzing the Road Test 110 Hydraulic Pressure Test 111
Checking Fluid Level and Condition 108 Overdrive Fourth Gear Electrical Controls . . . . . . 109
Converter Housing Fluid Leak Diagnosis . . . . . . . 115 Preliminary Diagnosis 108
Converter Stall Test 113 Road Test 110
Diagnosis Charts 118 Stall Test Analysis 114
Fluid Contamination 109 Throttle Valve Cable 110
GENERAL INFORMATION (4) Perform stall test if complaint is based on slug

The diagnosis procedures in this section apply to gish acceleration or if abnormal throttle opening is
both 3 and 4-speed transmissions equally. Any differ needed to maintain normal speeds with a properly
ences in diagnostic technique or method are noted tuned engine.
wherever applicable. (5) Perform hydraulic pressure test if shift prob
Automatic transmission problems can be a result of lems were noted during road test.
poor engine performance, incorrect fluid level, incor (6) Perform air pressure test to check clutch-band
rect linkage adjustment, band or hydraulic control operation.
pressure adjustments, hydraulic system malfunctions
or electrical/mechanical component malfunctions. VEHICLE IS DISABLED
(1) Check fluid level and condition.
Begin diagnosis by checking the easily accessible
(2) Check for broken, disconnected gearshift and
items such as: fluid level and condition, linkage ad
throttle linkage.
justments and electrical connections on 4-speed mod (3) Check for cracked, leaking cooler lines, or loose,
els. A road test will determine if further diagnosis is missing pressure port plugs.
necessary. (4) Raise vehicle, start engine, shift transmission
Procedures outlined in this section should be per into gear and note following:
formed in the following sequence to realize the most (a) If propeller shaft turns but wheels do not,
accurate results: problem is with differential or axle shafts.
• Preliminary diagnosis (b) If propeller shaft does not turn and transmis
• Fluid Level and condition sion is noisy, stop engine. Remove oil pan, and
• Leak tests (if fluid level is low) check for debris. If pan is clear, remove transmis
• Linkage Adjustments sion and check for damaged drive plate, converter,
• Overdrive off switch test oil pump or input shaft.
• Road test (c) If propeller shaft does not turn and transmis
• Stall test sion is not noisy, perform hydraulic pressure test to
• Hydraulic pressure test determine if problem is a hydraulic or mechanical.
• Air pressure tests
• Analyze test results and consult diagnosis charts CHECKING FLUID LEVEL AND CONDITION
(1) Place vehicle on level surface. This is important
PRELIMINARY DIAGNOSIS for an accurate reading.
Two basic procedures are required. One procedure (2) Do not check level until fluid is at normal op
for vehicles that are driveable and an alternate pro erating temperature of approximately 82°C (180°F).
cedure for disabled vehicles (will not back up or move This is necessary to avoid false readings which could
forward). produce under or over fill condition,
(3) Fully apply parking brakes.
VEHICLE IS DRIVEABLE (4) Start and run engine at curb idle speed. Then
(1) Check fluid level and condition. shift transmission through all gear ranges and back
(2) Adjust throttle valve cable and gearshift link to Neutral.
age if complaint was based on delayed, erratic, or (5) Clean top of filler tube and dipstick to keep dirt
harsh shifts. out of tube.
(3) Road test and note how transmission upshifts, (6) Remove dipstick and check fluid l e v e l as fol
downshifts and engages. lows:
• AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21 - 109
(a) Dipstick has three fluid level indicating • failure to clean dipstick and fill tube when check
marks which are a MIN dot mark, an OK mark ing level
and a MAX fill arrow mark: • engine coolant entering the fluid
(b) Correct level is to MAX arrow nark on dip • internal failure that generates debris
stick. This is correct maximum hot fluid level. Ac • overheat that generates sludge (fluid breakdown)
ceptable level is between O K mark and max arrow • failure to reverse flush cooler and lines after re
mark on dipstick. pair
(c) If level is at, or below MIN level dot on dip • failure to replace contaminated converter after re
stick, add only enough fluid to restore correct level. pair
Mopar ATF Plus, type 7176 is the preferred fluid. The use of non recommended fluids can result in
(d) If transmission is overfilled, excess fluid can transmission failure. The usual results are erratic
be removed with suction gun and 1/8 to 3/16 inch shifts, slippage, abnormal wear and eventual failure
diameter tubing. The tubing will have to be due to fluid breakdown and sludge formation. Avoid
adapted to the gun nozzle and be long enough to this condition by using recommended fluids only.
extend through the fill tube into the oil pan. The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
CAUTION: Do not overfill the transmission. Overfill other foreign material on the cap and tube could fall
ing may cause leakage out the pump vent which
into the tube if not removed beforehand. Take the
can be mistaken for a pump seal leak. In addition,
time to wipe the cap and tube clean before withdraw
overfilling will also cause fluid aeration and foam
ing the dipstick.
ing a s the e x c e s s fluid is picked up and churned by
Engine coolant in the transmission fluid is gener
the gear train. This will significantly reduce fluid life
ally caused by a cooler malfunction. The only remedy
and even prevent upshiftlng.
is to replace the radiator as the cooler in the radiator
(7) Check and note fluid condition as follows: is not a serviceable part. If coolant has circulated
(a) Fluid should be dark to light red in color and through the transmission for some time, an overhaul
free of particles and sludge. may also be necessary; especially if shift problems
(b) If fluid is orange, brown, or smells slightly had developed.
burned, flow test and reverse flush cooler and lines. The transmission cooler and lines should be reverse
Then change fluid and filter and road test again to flushed whenever a malfunction generates sludge
confirm proper operation. and/or debris. The torque converter should also be re
(c) If fluid is black, dark brown, turned to sludge, placed at the same time.
contains extensive amount of metal or friction ma Failure to flush the cooler and lines will result in
terial particles, transmission will need overhaul. re-contamination and a shop comeback. Flushing ap
Main and auxiliary coolers will have to be flow plies to auxiliary coolers as well. The torque con
tested and reverse flushed as well. verter should also be replaced whenever a failure
generates sludge and debris. This is necessary be
EFFECTS OF INCORRECT FLUID LEVEL cause normal converter flushing procedures will not
A low fluid level allows the pump to take in air remove al of the contaminants.
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal. OVERDRIVE FOURTH GEAR ELECTRICAL
If the transmission is overfilled, the gears churn CONTROLS
the fluid into foam. This aerates the fluid and caus The electrical controls governing the shift into
ing the same conditions occuring with a low level. In fourth gear consist of the control switch on the in
either case, air bubbles cause fluid overheating, oxi strument panel and the overdrive solenoid on the
dation and varnish buildup which interferes with valve body. The control switch is in circuit with the
valve, clutch and servo operation. solenoid and must be in the On position to energize
Foaming also causes fluid expansion which can re the solenoid. The transmission must also have
sult in fluid overflow from the transmission vent or reached third gear range before the shift to fourth
fill tube. Fluid overflow can easily be mistaken for a gear will occur.
leak if inspection is not careful. Serious aeration can The control switch, valve body solenoid, case con
even prevent upshifts if overfill quantity exceeds one nectors and related wiring can all be tested with a 12
2 pints, or morequart. volt test lamp or a volt/ohmmeter. Check continuity
of each component when diagnosis indicates this is
FLUID CONTAMINATION necessary.
Transmission fluid contamination is generally a re Switch and solenoid continuity should be checked
sult of: whenever the transmission fails to shift into fourth
• adding incorrect fluid gear range.
21 - 1 1 0 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING •
If the fluid temperature indicator lamp comes on,
Gearshift Lever Position
fluid temperature is either at, or above 285°F. This
P R N D 2 1
indicates an approaching overheat condition. The DRIVE
ELEMENTS 1
sensor will downshift the transmission to third gear i
1 2 3 2
and possibly disengage the converter clutch. At this i —-
FRONT • •
point, it will be necessary to determine the cause of CLUTCH
the overheat condition (e.g. cooler restricted, blocked,
vehicle overloaded, not equipped for towing, etc.). FRONT
BAND • •
(KICKDOWN)
THROTTLE VALVE CABLE
REAR
Throttle valve cable adjustment is important to CLUTCH
proper operation. This adjustment positions the
throttle valve which controls shift speed, quality and REAR
BAND • •
part throttle downshift sensitivity. (LOW-REV.)
If cable setting is too short, early shifts and slip
page between shifts may occur. If the setting is too OVER
RUNNING • • •
long, shifts may be delayed and part throttle down CLUTCH
shifts may be very sensitive. Refer to the In-Vehicle
Service section for adjustment procedure. J9021-33
GEARSHIFT LINKAGE Fig. 1 Clutch And Band Application (32RH/36RH/

Gearshift linkage adjustment is important because 37RH)
it positions the valve body manual valve. Incorrect is applied in first gear (D, 2 and 1 ranges) only. The
adjustment will cause creeping in Neutral, prema rear band is applied in 1 and R range only.
ture clutch wear, delayed engagement in any gear, or Note that the overdrive clutch is applied only in
a no-start in Park or Neutral position. fourth gear and the overdrive direct clutch and over
Proper operation of the park/neutral position running clutch are applied in all ranges except fourth
switch will provide a quick check of linkage adjust gear.
ment. Refer to the In-Vehicle Service section for ad For example: If slippage occurs in first gear in D
justment procedure. and 2 range but not in 1 range, the transmission
overrunning clutch is faulty. Similarly, if slippage oc
ROAD TEST curs in any two forward gears, the rear clutch is slip
Before road testing, be sure the fluid level and all ping.
linkage adjustments have been checked and adjusted Applying the same method of analysis, note that
if necessary. Observe engine performance during the the front and rear clutches are applied simulta
road test. A poorly tuned engine will not allow an ac neously only in D range third and fourth gear. If the
curate analysis of transmission operation. transmission slips in third gear, either the front
Operate the transmission in all gear ranges. Check clutch or the rear clutch is slipping.
for shift variations and engine flare, which indicates If the transmission slips in fourth gear but not in
slippage. Note if shifts are harsh, spongy, delayed, third gear, the overdrive clutch is slipping. By select
early, or if part throttle downshifts are sensitive. ing another gear which does not use these clutches,
Slippage indicated by engine flare, usually means the slipping unit can be determined. For example, if
clutch, band or overrunning clutch problems. If the the transmission also slips in Reverse, the front
condition is advanced, an overhaul may be necessary clutch is slipping. If the transmission does not slip in
to restore normal operation. Reverse, the rear clutch is slipping.
A slipping clutch or band can often be determined If slippage occurs during the 3-4 shift or only in
by comparing which internal units are applied in the fourth gear, the overdrive clutch is slipping. Simi
various gear ranges. The Clutch and Band Applica larly, if the direct clutch were to fail, the transmis
tion charts (Figs. 1 and 2) provide a basis for analyz sion would lose both reverse gear and overrun
ing road test results. braking in 2 position (manual second gear). If the
transmission slips in any other two forward gears,
ANALYZING THE ROAD TEST the transmission rear clutch is probably slipping.
Refer to the Clutch and Band Application charts If the transmission will not shift to fourth gear, the
(Figs. 1 and 2) and note which elements are in use in control switch, overdrive solenoid or related wiring
the various gear ranges. may also be the problem cause.
Note that the rear clutch is applied in all forward This process of elimination can be used to identify
ranges (D, 2, 1). The transmission overrunning clutch a slipping unit and check operation. Proper use of
TRANSMISSION CLUTCHES A N D BANDS OVERDRIVE CLUTCHES

SHIFT
LEVER FRONT FRONT REAR REAR OVERRUN. OVERDRIVE DIRECT OVERRUN.
POSITION CLUTCH BAND CLUTCH BAND CLUTCH CLUTCH CLUTCH CLUTCH
Reverse X X X
Drive Range
First X X X X
Second X X X X
Third X X X X
Fourth X X X
2-Range
(Manual)
Second) X X X X X
1-Range
(Manual
Low) X X X X X
J9421-218
Fig. 2 Clutch And Band Application (42RH/46RH/47RH)
the Clutch and Band Application Chart is the key. The rear servo and governor pressure ports are at
Although road test analysis will help determine the the right rear of the transmission case. The overdrive
slipping unit, the actual cause of a malfunction usu clutch pressure port is at the left rear of the case.
ally cannot be determined until hydraulic and air An accurate tachometer and two test gauges are re
pressure tests are performed. Practically any condi quired for the pressure test. Test Gauge C-3292 has a
tion can be caused by leaking hydraulic circuits or 100 psi range and is used at the accumulator, gover
sticking valves. nor, front servo, and overdrive pressure ports. Test
Unless a malfunction is obvious, such as no Gauge C-3293 has a 300 psi range and is used at the
drive i n D range first gear, do not disassemble rear servo port where pressures range from 250 to
the transmission. Perform the hydraulic and 290 psi. In cases where two test gauges are required,
air pressure tests to help pinpoint the problem the 300 psi gauge can be used at any of the other
cause. test ports.
HYDRAULIC PRESSURE TEST

Hydraulic test pressures range from a low of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port in reverse. Use
100 psi Gauge C-3292 to check pressure at the accu
mulator, front servo and governor. Use 300 psi Gauge
C-3293 to check pressure at the rear servo and at the
overdrive port in fourth gear.
PRESSURE TEST PORT LOCATIONS

There are pressure test ports at the accumulator,
Fig. 3 Pressure Test Ports At Side Of Case
front servo, and rear servo (Figs. 3, 4 and 5).
Governor and overdrive clutch pressure test ports HYDRAULIC PRESSURE TEST PROCEDURE
are located at the left and right rear sides of the Connect a tachometer to the engine. Position the
case. tachometer so it can be observed from under the ve
Line pressure is checked at the accumulator port hicle. Raise the vehicle on hoist that will allow the
on the right side of the case. The front servo pressure wheels to rotate freely.
port is at the right side of the case just behind the
Test One—Transmission in 1 Range
filler tube opening.
This test checks pump output, pressure regu
lation, and condition of the rear clutch and
21 - 112 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING
GOVERNOR (6) Move transmission throttle valve lever from full

PRESSURE PORT forward to full rearward position and note pressures
on both gauges.
(7) Line pressure at accumulator port should be
54-60 psi (372-414 kPa) with throttle lever forward
and gradually increase to 90-96 psi (621-662 kPa) as
kver is moved rearward.
(8) Rear servo pressure should be same as line
pressure within 3 psi (20.68 kPa).
Test Two—Transmission In 2 Range

This test checks pump output and pressure
Fig. 4 Pressure Test Ports At Rear Of Case
regulation. Use 100 psi Test Gauge C-3292 for
this test.
(1) Connect test gauge to accumulator pressure
port.
(2) Start and run engine at 1000 rpm.
(3) Move transmission shift lever (on valve body)
one detent rearward from full forward position. This
is 2 range.
(4) Move transmission throttle lever from full for
ward to full rearward position and read pressure at
both gauges.
(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually in
crease to 90-96 psi (621-662 kPa) as lever is moved
rearward.
Test Three—Transmission in D Range

This test checks pressure regulation and con
dition of the clutch circuits. Use both pressure
Test Gauges C-3292 and C-3293 for this test.
(1) Connect test gauges to accumulator and front
servo ports (Fig. 5). Use either test gauge at the two
ports.
(2) Start and run engine at 1600 rpm for this test.
(3) Move selector lever two detents rearward from
full forward position. This is D range.
(4) Read pressures on both gauges as transmission
throttle lever is moved from full forward to full rear
ward position.
Fig. 5 Pressure Test Port Locations (42RH/46RH/ (5) Line pressure should be 54-60 psi (372-414
47RH) kPa) with throttle lever forward and gradually in
servo circuit. Test Gauges C-3292 and C-3293 crease as lever is moved rearward.
are required for this test. Gauge C-3292 has a (6) Front servo is pressurized only in D range and
should be same as line pressure within 3 psi (21 kPa)
100 psi range. Gauge C-3293 has a 300 psi range.
up to downshift point.
(1) Connect 100 psi Gauge C-3292 to accumulator
port. Test Four—Transmission In Reverse
(2) Connect 300 psi Gauge C-3293 to rear servo This test checks pump output, pressure regu
port. lation and the front clutch and rear servo cir
(3) Disconnect throttle valve cable and gearshift cuits. Use 300 psi Test Gauge C-3293 for this
rod from transmission levers. test.
(4) Start and run engine at 1000 rpm. (1) Connect 300 psi gauge to rear servo port.
(5) Move transmission shift lever (on manual lever (2) Start and run engine at 1600 rpm for test.
shaft) all the way forward into 1 range. (3) Move transmission shift lever four detents rear
ward from full forward position. This is Reverse
range.
AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21 - 113
(4) Move transmission throttle lever all way for

ward then all way rearward and note gauge read TEST CONDITION INDICATION
ings. Line pressure OK during Pump and regulator valve OK
(5) Pressure should be 145 - 175 psi (1000-1207 any one test
kPa) with lever forward and increase to 230 - 280 psi
Line Pressure OK in R Leakage in rear dutch area (servo,
(1586-1931 kPa) as lever is moved rearward. but bw in D, 2, 1 dutch seals governor support
/
seal rings)
Test Five-—Governor Pressure
Pressure OK in 1, 2 but Leakage in front dutch area (servo,
This test checks governor operation by mea low in D3 and R dutch seals, retainer bore, pump
s u r i n g governor pressure response to changes seal rings)
i n engine speed. It is usually not necessary to
Pressure OK in 2 but low in Leakage in rear servo
check governor operation unless shift speeds R and 1
are incorrect or if the transmission w i l l not
downshift, o r upshift. Front servo pressure in 2 Leakage in servo; broken servo
(1) Connect 100 psi Test Gauge C-3292 to governor ring or cracked servo piston
pressure port. Pressure low in all positions Cogged filter, stuck pressure
(2) Move transmission shift lever to D range. regulator valve, worn or
(3) Start and r u n engine at curb idle speed and defective pump
note pressure. At idle and with vehicle stopped, pres Governor pressure too high at Governor valve sticking open
sure should be zero to 1-1/2 psi maximum. I f pres idle speed:
sure exceeds this figure, governor valve or weights
Governor pressure low at all Governor valve sticking dosed
are sticking open. mph figures
(4) Slowly increase engine speed and observe
speedometer and pressure test gauge. Governor pres Lubrication pressure low at all Cogged oil cooler or lines, seal
throttle positions rings leaking, output shaft
sure should increase i n proportion to vehicle speed.
plugged with debris, worn
Or approximately 1 psi for every 1 mph. bushings in pump or dutch
(5) Pressure rise should be smooth and drop back retainer J9021-34
to 0 to 1-1/2 psi when wheels stop rotating.
(6) Compare results of pressure tests with analysis Fig. 6 Pressure Test Analysis Chart (32RH/36RH)
charts (Figs. 9 and 10).
locked and the transmission i n D range. This test
Test Six—42RH/46RH/47RH Transmission In Overdrive checks the holding ability of the the converter over
Fourth Gear running clutch and both of the transmission clutches.
This test checks line pressure at the over When stall testing is completed, refer to the Stall
drive clutch i n fourth gear range. Use 300 psi Speed Specifications chart and Stall Speed Diagnosis
Test Gauge C-3292 for this test. guides.
(1) Raise vehicle and connect test gauge to over
drive clutch pressure port (Fig. 4). WARNING: NEVER A L L O W ANYONE TO STAND DI
(2) Lower vehicle to enough to allow entry into RECTLY IN LINE WITH THE VEHICLE FRONT OR
drivers seat. Leave vehicle wheels approximately one REAR DURING A STALL TEST. ALWAYS B L O C K
foot off shop floor. THE WHEELS A N D APPLY THE SERVICE A N D
(3) Secure test gauge where i t can be viewed from PARKING BRAKES DURING THE TEST.
drivers seat.
(4) Verify that overdrive control switch is i n ON
position. STALL T E S T P R O C E D U R E
(5) Start engine and shift into D range. (1) Connect tachometer to engine. Position tachom
(6) Increase engine rpm gradually until 3-4 shift eter so i t can be viewed from driver seat.
occurs and note gauge pressure. (2) Check transmission fluid level. Add fluid i f nec
(7) Pressure should be 469-496 kPa (68-72 psi) essary.
with closed throttle and increase to 620-827 kPa (90- (3) Start and run engine until transmission fluid
120 psi) at 1/2 to 3/4 throttle. Note that pressure will reaches normal operating temperature.
increase to 896 kPa (130 psi) or more at full throttle. (4) Block front wheels.
(8) Refer to pressure test charts (Figs. 6 and 7) for (5) Fully apply service and parking brakes.
pressure diagnosis. (6) Open throttle completely for no more than five
seconds and record maximum engine rpm registered
CONVERTER STALL TEST on tachometer.
Stall testing involves determining maximum engine
rpm obtainable at full throttle with the rear wheels
STALL S P E E D T O O L O W
TEST C O N D I T I O N INDICATION
Low stall speeds with a properly tuned engine in
Line pressure OK during Pump and regulator valve OK dicate a torque converter overrunning clutch prob
any one test
lem. The condition should be confirmed by road
Line Pressure OK in R Leakage in rear clutch area (servo, testing prior to converter replacement.
but low in D, 2, 1 clutch seals, governor support The converter overrunning clutch is slipping when:
seal rings)
Stall speeds are 250 to 350 rpm below specified min
Pressure Low in D Overdrive clutch piston seal, or imum and the vehicle operates properly at highway
Fourth G e a r Range check ball problem speeds but has poor low speed acceleration.
Pressure OK in 1, 2 but Leakage in front clutch area (servo,
low in D3 and R clutch seals, retainer bore, pump STALL SPEED NORMAL
seal rings) If stall speeds are normal but abnormal throttle
opening is required to maintain highway speeds, the
Pressure OK in 2 but low Leakage in rear servo
in R and 1 converter overrunning clutch is seized and the torque
converter must be replaced.
Front servo pressure low Leakage in servo; broken servo
in 2 ring or cracked servo piston ' CONVERTER NOISE DURING TEST
Pressure low in all positions Clogged filter, stuck regulator A whining noise caused by fluid flow is normal dur
valve, worn or faulty pump, ing a stall test. However, loud metallic noises indi
plugged fluid cooler cate a damaged converter. To confirm that noise is
Governor pressure too high Governor valve sticking open originating from the converter, operate the vehicle at
at idle speed light throttle in Drive and Neutral on a hoist and lis
ten for noise coming from the converter housing.
Governor pressure low Governor valve sticking closed
at all mph figures
AIR TESTING TRANSMISSION CLUTCH AND BAND
Lubrication pressure low at Clogged oil cooler or lines, seal OPERATION
all throttle positions rings leaking, output shaft plugged
with debris, worn bushings in Air pressure testing can be used to check transmis
pump or clutch retainer sion front/rear clutch and band operation with the
J9321-165 transmission either in the vehicle, or on the work
bench as a final check after overhaul.
Fig. 7 Pressure Test Analysis Chart (42RH/46RH/ Air pressure testing requires that the oil pan and
47RH) valve body be removed from the transmission. The
servo and clutch apply passages are shown in Figure
CAUTION: Stall testing c a u s e s a rapid increase in
8.
transmission fluid temperature. Do not hold the
throttle open any longer than five s e c o n d s . If more FRONT SERVO APPLY. FRONT
than one stall test is required, run the engine at REAR SERVO APPLY SERVO
.RELEASE
1000 rpm with the transmission in Neutral for at
least 20 s e c o n d s to cool the fluid.
LINE PRESSURE T O PUMP
(7) If engine speed exceeds maximum shown in ACCUMULATOR SUCTION
stall speed chart, release accelerator immediately. PUMP

This indicates that transmission clutch slippage is PRESSURE
occurring.
FRONT
(8) Shift transmission into Neutral. Operate engine CLUTCH
for 20 seconds. Stop engine, shift transmission into APPLY
Park and release brakes. REAR
(9) Stall speeds should be in 1800-2100 rpm range. CLUTCH
APPLY
STALL TEST ANALYSIS TO TORQUE

GOVERNOR CONVERTOR
PRESSURE /
S T A L L S P E E D TOO H I G H FROM TORQUE
If the stall speed exceeds specifications by more CONVERTER
TO
than 200 rpm, transmission clutch slippage is indi GOVERNOR TO COOLER tS*H252
cated.
Fig. 8 Air Pressure Test Passages
F R O N T CLUTCH AIR T E S T
Place one or two fingers on the clutch housing and
apply air pressure through front clutch apply passage
(Fig. 11). Piston movement can be felt and a soft
thump heard as the clutch applies.
R E A R CLUTCH AIR T E S T
Place one or two fingers on the clutch housing and
apply air pressure through rear clutch apply passage
(Fig. 11). Piston movement can be felt and a soft
thump heard as the clutch applies.
F R O N T S E R V O AIR T E S T
Apply air pressure to the front servo apply passage.
The servo rod should extend and cause the band to
tighten around the drum. Spring tension should re
lease the servo when air pressure is removed. Fig. 9 Converter Housing Leak Paths
(4) Fabricate test probe (Fig. 10). Attach probe to
R E A R S E R V O AIR T E S T
converter housing with a dust shield bolt.
Apply air pressure to the rear servo apply passage.
(5) Have a helper run engine at 2500 rpm (with
The servo rod should extend and cause the band to
transmission i n Neutral) for two minutes; then stop
tighten around the drum. Spring tension should re
engine.
lease the servo when air pressure is removed.
(6) Inspect test probe and converter housing. I f a
leak is evident, note color of fluid. Transmission fluid
CONVERTER HOUSING FLUID LEAK DIAGNOSIS
is red. Engine oil ranges i n color from brown to
When diagnosing converter housing fluid leaks, two
green, or to black when oil is dirty.
items must be established before repair. First, i t
(7) I f probe upper surface is, the converter and
must be verified that a leak condition actually exists.
seal are not at fault. A path of fluid across probe up
And second, the true source of the leak must be de
per surface indicates a converter or seal leak. Fluid
termined.
leaking under the probe is coming from pump hous
Some suspected converter housing fluid leaks may
ing area (Fig. 11).
not be leaks at all. They may only be the result of
(8) Fluid leaking under the probe could be from:
residual fluid i n the converter housing, or excess
pump seal and/or bushing, pump vent, kickdown le
fluid spilled during factory fill or refill after repair.
ver shaft access plug, pump bolts, or porous spots i n
Converter housing leaks have several potential
pump body or transmission case (Fig. 11).
sources. Through careful observation, a leak source
(9) I f porous spots i n the transmission case or
can be identified before removing the transmission
pump body are the suspected leak source, pressurize
for repair.
transmission as described i n Leak Testing With A i r
Pump seal leaks tend to move along the drive hub
Pressure.
and onto the rear of the converter. Pump O-ring or
pump body leaks follow the same path as a seal leak
(Fig. 12).
Pump vent or pump attaching bolt leaks are gener
ally deposited on the inside of the converter housing
and not on the converter itself (Fig. 9).
Pump seal or gasket leaks usually travel down the
inside of the converter housing.
Front band lever pin plug leaks are generally de
posited on the housing and not on the converter.
L E A K DIAGNOSIS P R O C E D U R E
SHIELD MATERIAL: 5-1/2" X 1-1/2" X 1/32"
(1) Raise rear of vehicle and allow accumulated BOLT SHEET METAL RN778
fluid to drain out of converter housing.
(2) Check and adjust transmission fluid level. Fig. 10 Leak Test Probe
(3) Raise vehicle. Remove converter housing dust
cover and wipe as much fluid as possible from con
verter housing.
The converter hub seal cup is made from thin wall

tube and a 3.17 mm (1/8 in.) thick disc (Figs. 13 and
14).
A retaining strap is needed to secure the seal cup
for testing. The strap can be made from 31.75 mm (1-
1/4 in.) wide stock (Fig. 15). The strap attaching hole
positions are approximate only. Measure hole position
on the converter housing before drilling.
The pump vent tool is made from 6.35 mm (1/4 in.)
rod and 4.76 mm (3/16 in.) plate (Figs. 16 and 17).
The fabricated tools can all be made from mild
steel or aluminum stock.
WELD OR BREAK EDGE 1/16"
BRAZE MIN.
RH253
Fig. 11 Pump Area Inspection Points
TORQUE C O N V E R T E R L E A K POINTS
Possible sources of converter leaks are: (a) leaks at
the weld joint around the outside diameter weld (Fig.
12) and (b) leaks at the converter hub weld (Fig. 12).
OUTSIDE OF OPEN
LEAK T E S T I N G WITH AIR PRESSURE MATERIAL: 1-7/8 INCH O.D. KANTP^ TURF
THIN WALLED STEEL TUBING DISTANCE ON TUBE
OUTSIDE TORQUE CONVERTER AND 1/8 INCH STEEL DISC RN779
DIAMETER HUB WELD
WELD Fig. 13 Converter Hub Seal Cup (36RH/37RH/46RH/
47RH)
WELD BREAK EDGE 1/16" MIN.
OR BRAZE
POLISH
'LUG OUTSIDE
STARTER RING GEAR
RH254 OF OPEN
"END FOR 1.498
Fig. 12 Typical Converter Leak Points THIS DISTANCE
ON TUBE
This test involves closing off all openings and pres MATERIAL: 1-1/2 INCH O.D. THIN
WALLED STEEL TUBING AND
surizing the transmission to 8 psi with Air Pump 1/8 INCH STEEL DISC RN780
7700. Fig. 14 Converter Hub Seal Cup (32RH/42RH)
A soapy water solution is applied to suspected leak
points before and during the pressure test. Leaks will 15/32 INCH DRILL 4 HOLES
be indicated by the presence of air bubbles coming
through the solution.
Some transmission openings such as the fill tube
and front cooler line fitting can be closed off with a
rubber plug or similar device. Plugs can secured with
wire or duct tape.
The transmission rear output shaft opening is
closed off simply by leaving the transfer case bolted
in place. However, if the transfer case has been re
moved, a shipping plug can used to close off this
opening. MATERIAL: 1/4 INCH STEEL STOCK
The torque converter hub opening in the pump and 1-1/4 INCH WIDE RN781
the pump vent require special tools to close them off. Fig. 15 Seal Cup Retaining Strap
(3) Attach Air Pump 7700 to rear cooler line fit

ting. Connect a length of copper tube to fitting. Then
attach pump hose to tube with hose clamp (Fig. 19).
(4) Apply a thick soapy water solution to suspected
leak areas.
CAUTION: The recommended test pressure is 8 psi.

The maximum allowable test pressure is 10 psi. Do
not exceed specified pressure.
(5) Pressurize transmission to 8 psi with air pump.

(6) Observe suspected leak areas. Air bubbles ap
pearing in soapy water solution indicate leak points.
(7) Remove test tools and plugs after test comple
tion and make necessary repairs as described in Leak
Correction procedure.
MATERIAL: 3/16 INCH STEEL STOCK
Fig. 16 Pump Vent Plug (36RH/37RH/46RH/47RH)
13/32" DRILL 2 HOLES
MATERIAL: 3/16 INCH STEEL STOCK
Fig. 17 Pump Vent Plug (32RH/42RH)

AIR P R E S S U R E LEAK T E S T P R O C E D U R E
(1) Install vent plug, converter hub seal cup and
cup retaining strap (Fig. 18).
CAUTION: B e sure the surfaces of the hub seal cup

are smooth and free of nicks, scratches, or burrs.
Surface irregularities on the cup will damage the
COOLER LINE FITTING RY254
pump seal if not removed. Sand and/polish the cup
with 400 grit sandpaper or crocus cloth to smooth Fig. 19 Typical Method Of Pressurizing
the surface if necessary. Transmission
(2) Close off remaining transmission openings with C O N V E R T E R HOUSING AREA LEAK
rubber plugs, or stoppers or similar devices. Do not CORRECTION
close off rear cooler line fitting. Hand operated (1) Remove converter.
air pump will be attached to this fitting.
21 - 118 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING •
(2) Tighten front band adjusting screw until band (8) Lubricate pump seal and converter hub with
is tight around front clutch retainer. This prevents transmission fluid or petroleum jelly and install con
front/rear clutches from coming out when oil pump is verter.
removed. (9) Install transmission and converter housing
(3) Remove oil pump and remove pump seal. In dust shield.
spect pump housing drainback and vent holes for ob (10) Lower vehicle.
structions. Clear holes with solvent and wire.
(4) Inspect pump bushing and converter hub. If DIAGNOSIS CHARTS
bushing is scored, replace it. If converter hub is The diagnosis charts provide additional reference
scored, either polish it with crocus cloth or replace when diagnosisng a transmission fault. The charts
converter if scoring is severe. provide general information on a variety of transmis
(5) Install new pump seal, O-ring, gasket, bushing. sion, overdrive unit and lockup torque converter fault
Replace oil pump if cracked, porous or damaged in conditions.
any way.
The hydraulic flow charts outline fluid flow and hy
(6) Loosen kickdown lever pin access plug three
draulic circuitry. Circuit operation is provided for
turns. Apply Permatex No. 2 or equivalent to plug
threads and tighten plug to 17 N-m (150 in-lbs) neutral, third, fourth and reverse gear ranges. Nor
torque. mal working pressures are also supplied for each of
(7) Adjust front band. the gear ranges.
HARSH E N G A G E M E N T (FROM 1. Engine idle speed too high 1. Check/adjust idle speed
N E U T R A L T O DRIVE O R
2 . Driver "riding" accelerator pedal during shift 2 . Advise owner/operator
REVERSE)
3 . Throttle cable or linkage misadjusted 3. Adjust cable or linkage; setting is either too
long or too short
4 . Band adjustment needed 4. Adjust front/rear bands
5 . Loose mounting bolts 5. Check engine, transmission, propeller shaft,
crossmember, and axle bolt torque; tighten
loose bolts and replace missing bolts
6 Worn or damaged U-joints 6. Remove propeller shaft and replace U-joints

7 Loose axle pinion nut 7. Replace nut and check pinion threads before
installing new nut; replace pinion gear if
threads are damaged
8. Hydraulic pressure is incorrect 8. Check pressures; remove, overhaul, or adjust
valve body as needed; repair oil pump if
necessary
Note: The shift from neutral to
reverse is normally quite firm. 9 . Accumulator piston spring, or seal worn or 9 . Remove valve body and replace piston,
Hydraulic pressure at the rear damaged seal, or spring as needed
servo can approach 3 0 0 psi in
10. Faulty converter clutch (if equipped) 10. Replace converter and flush cooler and lines
reverse gear. Do not confuse a
before installing new converter
firm engagement with a truly
harsh engagement 11. Clutch, band, or planetary component is damaged 11. Remove, disassemble, and repair
transmission as necessary
DELAYED E N G A G E M E N T 1. Engine idle speed too low 1. Adjust idle speed

(FROM N E U T R A L TO DRIVE
O R REVERSE) 2. Low fluid level 2 . Correct level and check for leaks
3. Gearshift linkage out of adjustment 3. Adjust cable or linkage and repair linkage if
worn or damaged
4. Rear band out of adjustment 4. Adjust band
5. Valve body filter plugged 5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary
6. Oil pump gears worn or damaged or pump 6 . Remove transmission and replace oil pump
body or seal is damaged, allowing pump to
take in air, causing fluid aeration
7. Reaction shaft seal rings worn or broken . 7. Remove transmission, remove oil pump, and
replace seal rings
8. Governor valve stuck or valve shaft is loose or 8. Remove and inspect governor components;
damaged replace worn or damaged parts
9. Low hydraulic pressure 9 . Perform pressure test, remove transmission,
and repair as needed
10. Clutch, band, or servo damage 10. Remove and disassemble transmission and
repair as necessary
J9321-255
21 - 120 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING — •
Condition PossiMo Canto Correction
SHIFTS DELAYED OR ERRATIC 1. Lowfluidlevel 1. Correct fluid level and check for leaks
(SHIFTS ALSO HARSH AT
2. Throttle linkage out of adjustment 2. Adjust linkage as described in service section
TIMES)
3. Throttle linkage is binding 3. Disassemble, clean, and adjust linkage; replace
linkage grommets if removea or if worn or
cracked
4. Gearshift linkage out of adjustment 4. Adjust linkage as described in service section
5. Fluid filter partially clogged 5. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary
6. A i r in fluid due to overfill condition or air leakage 6. Drain fluid to correct level if overfilled. If fluid is
into pump suction passages highly aerated (full of bubbles and foamy), oil
pump gasket or seal may have failed, or pump
body is porous or cracked
7. Clutch or servo problem 7. Remove valve body and air test clutch, band and
servo operation; disassemble and repair
transmission as needed
8. Front band out of adjustment (may cause harsh 8. Adjust band
1-2 shift)
NO REVERSE (D RANGES OK) 1. Gearshift linkage is either out of adjustment or 1. Repair or replace linkage parts as needed
damaged
2. Rear band is out of adjustment 2. Adjust band
3. Valve body malfunction (stuck/damaged manual 3. Remove and service valve body; replace valve
valve, regulator valve, or check ball) body if any valves or valve bores are worn or
damaged
4. Rear servo or front clutch malfunction 4. Remove and disassemble transmission; replace
worn, damaged servo and clutch parts as
necessary
HAS FIRST-REVERSE ONLY 1. Governor valve, shaft, weights, or body damaged 1. Remove governor assembly and repair as
( N O 1-2 OR 2-3 UPSHIFT) necessary
J9121-440
Condition Possiblo Cavso Corroction
N O DRIVE RANGE 1. Gearshift linkage either loose, damaged or out of 1. Repair or replace linkage components
(REVERSE OK) adjustment
2. Low fluid level 2. Correct fluid level and check for leaks
3. Valve body malfunction (manual valve or shaft 3. Remove and disassemble valve body; replace as
damaged or 1 -2 shift valve stuck) assembly if any valves or bores are damaged
4. Rear clutch failure 4. Remove and disassemble transmission and rear
clutch; repair/replace worn, damaged parts as
needed
5. Transmission overrunning clutch failure 5. Remove and disassemble transmission; replace
overrunning clutch
6. Input shaft seal rings worn or damaged 6. Remove and disassemble transmission; replace
seal rings and any other worn or damaged parts
N O DRIVE OR REVERSE 1. Low fluid level 1. A d d fluid and check for leaks if drive is restored
(VEHICLE WILL NOT MOVE)
2. Gearshift linkage loose, damaged, or misassembled 2. Inspect, adjust, and reassemble linkage as needed;
replace worn, damaged parts
3. Failure of driveline component, such as U-joint, axle 3. Perform preliminary inspection procedure for
shaft, transfer case component, etc. vehicle that will not move; refer to procedure in
diagnosis section
4. Low fluid pressure due to worn or damaged oil 4. Perform pressure test to confirm low pressure;
pump replace pump body and/or gears if necessary
5. Transmission internal component damaged 5. Remove and disassemble transmission; repair or
replace failed components as needed
6. Valve body malfunction (seized valve, damaged 6. Remove, disassemble, and inspect valve body;
manual lever, valve body screws loose or replace valve body (as assembly) if any valve or
overtightened causing distortion and bind) bore is damaged; clean and reassemble correctly
if all parts are in good condition
J9121-443
21 - 122 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING - •
Condition Posslblo Couso Correction
MOVES IN 2ND OR 3RD 1. Governor valve sticking 1. Remove, clean, and inspect; replace faulty parts
G E A R , ABRUPTLY
2. Valve body malfunction 2 . Remove, clean, and inspect; look for stuck
DOWNSHIFTS TO L O W
1 -2 valve or governor plug
SLIPS IN LOW GEAR D O N L Y , 1. Overrunning clutch faulty, not holding 1. Replace overrunning clutch
BUT N O T IN 1 POSITION
S U P S IN F O R W A R D D R I V E 1. Low fluid level 1. Add fluid and check for leaks

RANGES 2. Check for bad pump gasket or seals, dirt
2. Air in fluid (fluid is foamy, full of bubbles), shifts are
spongy, caused by air getting into pump suction between pump halves, and loose pump bolts o r
passages defective O-ring at filler tube
3. Gearshift or throttle linkage out of adjustment 3. Adjust linkage
4. Low hydraulic pressures due to worn pump, 4. Perform hydraulic and air pressure tests to
incorrect control pressure adjustments, valve body determine cause
warpage or malfunction, sticking governor, leaking
seal rings, clutch seals leaking, servo leaks, clogged
filter, or cooler lines
5. Accumulator piston cracked, spring broken or 5. Inspect and repair as necessary
seal worn
6. Clutch or servo malfunction, leaking seals or 6. Air pressure check clutch-servo operation and
worn plates repair as required
7. Overrunning clutch worn, not holding (slips in 7. Replace clutch
1 only)
S L I P S I N REVERSE O N L Y 1. Low fluid level 1. A d d fluid and check for leaks

2. Aerated fluid; see Slips in Forward Drive Ranges 2. See Slips in Forward Drive Ranges
3. Gearshift linkage out of adjustment 3. Adjust linkage
5. Hydraulic pressure too low due to worn pump, worn 5. Perform hydraulic pressure tests to determine
seal rings, clutch or servo seal leakage cause
6. W o r n front clutch, leaking rear servo, or worn 6. Air pressure check clutch-servo operation and
rear band repair as required
7. Band-linkage binding 7. Inspect and repair as required
J9121-444
• AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21-123
N O KICKDOWN OR 1. Incorrect throttle linkage or cable adjustment 1. Adjust linkage or cable

NORMAL DOWNSHIFT
2. Incorrect gear shift linkage or cable adjustment 2 . Adjust linkage or cable
3. Front band out of adjustment 3. Adjust band
4. Hydraulic pressures too high or too low due to 4. Perform hydraulic pressure tests to determine
sticking governor, valve body malfunction, or cause and repair as required. Correct valve
incorrect hydraulic control pressure adjustments body pressure adjustments as required
5. Front servo, band, or linkage malfunction 5. Air pressure test operation and repair as
necessary
6. Clutch or servo malfunction
6. Air pressure test operation and repair as
necessary
STUCK IN L O W G E A R (Y, ILL 1. Gearshift or throttle linkage or cable out of 1. Adjust linkage or cable. Repair linkage of
N O T UPSHIFT) adjustment worn or damaged. Relace damaged cable.
2. Front band out of adjustment 2. Adjust band
3. Governor valve stuck closed; loose output shaft 3. Check line and governor pressures to
support or governor housing bolts, worn pump, determine cause; correct as required
leaking seal rings, or valve body problem (i.e.,
stuck 1-2 shift valve or governor plug)
4. Clutch or servo malfunction 4. Air pressure check operation of clutches and
bands; repair faulty component
N O L O W G E A R (MOVES IN 1. Governor valve sticking in partially open position 1. Remove governor; clean, inspect, and repair
2 N D O R 3RD G E A R ONLY) as required
2. Valve body malfunction 2. Remove, clean, and inspect. Look for sticking
1-2 valve, 2-3 valve, governor plug, or
broken springs
3. Front servo piston cocked in bore 3. Inspect servo and repair as required
4. Front band linkage malfunction 4. Inspect linkage and look for bind in linkage
5. Incorrect throttle or gearshift linkage or cable 5 . Adjust linkage or cable
adjustment
J9321-256
Condition Possible C a m Correction
CREEPS IN NEUTRAL 1. Gearshift linkage out of adjustment 1. Adjust linkage

2. Valve body malfunction (warped body, cross 2. Perform hydraulic pressure test to determine
leakage) cause ana repair as required
3. Clutch dragging 3. Air pressure check operation of clutches and
repair as required
4. Converter lockup clutch dragging 4. O i l pump worn; replace pump
DRAGS OR LOCKS UP 1. Front or rear band out of adjustment 1. Adjust bands

2. Servo band or linkage malfunction (i.e., binding 2. A i r pressure check servo operation and repair
linkage, warped band, servo piston stuck) as required
3. Air pressure check clutch operation and repair
3. Dragging clutch (does not release fully) as required
4. Remove, inspect, and repair as required (look
4. Broken or seized planetary gears for debris in oil pan)
5. Remove and inspect clutch, repair as required
5. Overrunning clutch worn, broken, or seized
GROWLING, GRATING, OR 1 . Planetary gear set broken or seized 1. Check for debris in oil pan and repair as
SCRAPING NOISES required
2. Overrunning clutch worn, seized, or broken 2. Inspect and check for debris in oil pan; repair as
required
3. O i l pump components scored, binding, or broken 3. Remove, inspect, and repair as required
4. Output shaft bearing or bushing damaged 4. Remove, inspect, and repair as required
5. Faulty clutch operation 5. Perform air pressure check and repair as
required
6. Governor support (park gear) binding or seal rings 6. Remove, inspect, and repair as required
broken
7. Front and rear bands out of adjustment 7. Adjust bands
BUZZING NOISE 1. Low fluid level 1. A d d fluid and check for leaks
2. A i r being drawn into pump suction passages 2. Check pump for porous casting, scores on
mating surfaces, and excess rotor clearance;
repair as required
3. Overrunning clutch damaged 3. Replace clutch
4. Valve body misassembled, bolts loose, weak spring, 4. Remove, disassemble, inspect valve body;
or mispositioned valve or check ball reassemble correctly if necessary; replace
assembly if valves or springs are damaged
J9121-446
OIL COMES OUT FILLER TUBE 1. Transmission overfilled 1. Drain fluid to correct level; remove neutral
switch and drain through switch hole with
suction gun
2. Breather vent in oil pump blocked 2. Inspect and clear blockage
3. Fluid cooler or cooler lines plugged 3. Flush cooler and lines
4. A i r in fluid (aerated) 4. See "Slips In Forward Drive Ranges"
5. O i l filter clogged 5. Replace filter; determine the reason for clogged
condition and repair
6. Rear servo piston or seal failure 6. Check hydraulic pressure at servo in reverse
(will register low or fluctuate rapidly)
7. Valve body switch valve sticking 7. Remove and clean valve
OIL LEAKS (ITEMS LISTED 1. Speedometer adapter 1. Replace both adapter seals
REPRESENT POSSIBLE LEAK 2. Tighten pan screws to 150 inch-pounds; if
2. Pan gasket
POINTS A N D SHOULD ALL BE leaks persist, replace gasket; do not
CHECKED) overtighten screws
3. Filler tube (where tube enters case) 3. Replace O-ring seal
4. Fluid lines and fittings 4. Tighten fittings; if leaks persist, replace fittings
and lines if necessary
5. Valve body manual lever shaft seal 5. Replace shaft seal
6. Pressure port plug loose 6. Tighten to correct torque; replace plug if leak
persists
7. Rear bearing access plate 7. Replace gasket
8. Gasket damaged or bolts are loose 8. Replace bolts or gasket or tighten bolts
9. Adapter/extension gasket damaged 9. Replace gasket
10. Neutral switch 10. Replace switch and gasket
11. Converter housing area 11. Check for leaks at seal caused by worn seal or
burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing, or hole plugged. Check for leaks past
O-ring seal on pump, or past pump-to-case
bolts; pump housing porous, oil coming out
vent due to overfill or leak past front band shaft
access plug
12. Cooler line fittings and hoses 12. Replace fittings and hoses
13. Pump seal 13. Replace seal
14. Torque converter 14. Replace converter
J9121-448
Condition Possibi® €mmm Correction
OVERHEAT DURING 1. Vehicle not properly equipped for trailer towing or 1. Be sure vehicle is equipped with recommended
COMMERCIAL OPERATION commercial use optional components (i.e., HD springs,
OR WHILE TRAILER TOWING transmission, axle, larger CID engine, auxiliary
(FLUID DARK AND BURNED cooler, correct axle ratio, etc.). If vehicle is not so
WITH SOME SLUDGE equipped, it should not be used for severe
FORMATION) service operation
2. Vehicle not equipped with auxiliary fluid cooler 2. Drain fluid, change filter, and install auxiliary
cooler
3. Extensive idling time or operation in heavy traffic in 3. Cut down on idling time; shift into neutral every
hot weather so often and run engine at 1000 rpm to help
circulatefluidthrough cooler
4. Tow vehicle overloaded (exceeding vehicle tow 4. Be sure vehicle is properly equipped to handle
capacity) load; do not tow Class Ill-type loads with a
vehicle that is only rated for Class 1 or II
operation
5. Air flow to auxiliary cooler blocked by snow plow, 5. Remove or reposition item causing air flow
front mounted spare tire, bug screen, or similar item blockage
OVERHEAT DURING NORMAL 1. Low fluid level 1. Add fluid and check for leaks
OPERATION (FLUID 2. Flush cooler and lines and replace radiator if
2. Fluid cooler, lines blocked, or cooler cracked (oil in
DISCOLORED, SMELLS
engine coolant) transmission fluid has entered coolant
BURNED)
3. Switch valve sticking 3. Remove, disassemble, clean valve body
4. Clutch pack clearance incorrect (too tight) 4. Check and correct as required
5. Bands too tight 5. Adjust bands
J9121-450
N O START IN PARK OR 1. Gearshift linkage out of adjustment 1. Adjust linkage

NEUTRAL 2. Neutral switch wire broken or open 2. Check continuity with test lamp; repair as
required
3. Faulty neutral switch 3. Refer to service section for test and replacement
procedure
4. Valve body manual lever assembly bent, worn, 4. Inspect lever assembly and replace if damaged
broken, or not aligned with switch
SLUGGISH ACCELERATION AT 1. Poor engine performance 1. Check engine and repair as required
LOW SPEEDS OR REQUIRES 2. Adjust linkage
2. Gearshift or throttle linkage out of adjustment
EXCESSIVE THROTTLE
OPENING TO MAINTAIN 3. Transmission clutches slipping 3. Perform stall test and repair as required
HIGHWAY SPEEDS 4. Overrunning clutch in converter not holding 4. Perform stall test and replace converter if clutch
has failed
5. Converter overrunning clutch stuck 5. Replace converter
FLUID CONTAMINATED 1. If contamination occurred shortly after overhaul, 1. If contamination is severe, cooler flushing,
(DISCOLORED, FULL OF fluid cooler and lines were not flushed and flow converter replacement, and another overhaul
SLUDGE A N D / O R METAL tested. This is especially true when original overhaul may be necessary; particularly so if shift
AND FRICTION MATERIAL was to correct a problem that generated a large problems were also present
PARTICULAR) amount of debris, such as a gear failure or a clutch
pack failure
Note: Flushing the cooler and lines is mandatory after
a failure of the converter lockup clutch
2. Incorrect fluid used in transmission 2. If transmission is operating properly, drain fluid,
reverse flush cooler and lines, and change fluid
and filter. However, if shift problem has
developed, converter replacement and
transmission overhaul may be required
3. Main cooler in radiator is cracked, allowing engine 3. Replace radiator (and cooler) and flush lines. If
coolant to enter transmission problem was diagnosed early enough, fluid and
filter change may only be necessary. If
contamination perioa was prolonged, overhaul
and converter replacement may be required
4. Severe overload results in overheat, fluid break 4. Repair transmission, flush cooler, and lines.
down, and accelerated wear, especially in high Replace converter if necessary. Install auxiliary
ambient temperatures. Most frequent causes are: cooler if needed. Also install HD cooling system
• Vehicle is not properly equipped for heavy duty if needed. If tow vehicle and unit being towed
are both overloaded, the only repair is to reduce
service
the load to rated limits. However, if trailer or
• Tow vehicle and boat or trailer are both boat is too large for tow vehicle, the only option
overloaded is for the owner to move up to properly-
• Trailer or boat are too large for tow vehicle (load equipped and load-rated tow vehicle
exceeds rated capacity of tow vehicle)
J9121-449
42RH/46RH/47RH OVERDRIVE DIAGNOSIS
Condition P o s s i b l e Cause Correction
N O 3-4 UPSHIFT 1. Fourth gear overdrive switch (on dash) in OFF 1. Turn control switch to O N position
position
2 . Replace fuse; determine why fuse failed
2 . Overdrive circuit fuse blown and repair as necessary (i.e., shorts,
grounds in circuit)
3. Fourth gear overdrive switch shorted, open, 3. Replace switch if shorted or open and
wires loose repair loose or d a m a g e d wires
4 . Overdrive solenoid or circuit wire loose, 4 . Check wires/connections with 12V test lamp
shorted, open and voltmeter; repair d a m a g e d or loose
wires/connections as necessary
5. Solenoid feed orifice in valve b o d y is blocked 5. Remove, disassemble, clean valve b o d y
thoroughly
6. Fourth gear overdrive solenoid failure 6. Verify solenoid failure with test lamp and
replace solenoid
7. Sensor failure (vehicle speed sensor or coolant 7 . Test both sensors with test lamp or volt/
sensor) ohmmeter and replace faulty sensor
8. Park/neutral switch open or shorted or switch 8. Test switch as described in service section
wire to powertrain control module is d a m a g e d and replace if necessary
(loss of park/neutral input)
9 . Powertrain control module faulty 9. Check with DRB II scan tool and replace if
necessary
10. T.P.S. fault 10. Adjust or replace T.P.S.
11. Transmission fluid temperature sensor fault (if 11. Replace sensor
equipped)
12. Replace both seals
12. Overdrive piston seal failure
13. Remove unit, check end play, and install
13. W r o n g overdrive piston spacer correct spacer
14. Pressure test transmission to determine
14. Low hydraulic pressure cause '
15. Set-reset module faulty 15. Replace module (if equipped)
SUPS I N OVERDRIVE 1. Low fluid level 1. A d d fluid and check for leaks
FOURTH GEAR
2 . Overdrive piston or seal malfunction 2 . Remove overdrive unit; replace piston seals
if worn; replace piston if d a m a g e d , if piston
retainer is d a m a g e d , it will be necessary to
remove and disassemble the transmission
3. Overdrive clutch pack worn 3. Remove overdrive unit and rebuild clutch pack
4 . 3-4 shift valve, timing valve, or accumulator 4 . Remove and overhaul valve body. Replace
malfunction accumulator seals. Make sure all valves operate
freely in bores, and d o not bind or stick. Make
sure valve b o d y screws are correctly tightened
and separator plates are properly positioned
5. Overdrive piston retainer bleed orifice blown out 5. Disassemble transmission, remove retainer,
and replace orifice
6. Overdrive unit thrust bearing failure 6. Disassemble overdrive unit and replace
thrust bearing (No. 1 thrust bearing is
between overdrive piston and clutch hub;
N o . 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; No. 3 thrust bearing is between
overrunning clutch hub and output shaft)
J9321-252
• — — AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21 - 129
42RH/46RH OVERDRIVE DIAGNOSIS
DELAYED 3-4 UPSHIFT 1. Low fluid level 1. A d d fluid a n d check for leaks
(SLOW TO ENGAGE)
2. Overdrive solenoid or wiring is faulty 2. Test solenoid and check wiring for loose/
corroded connections, or shorts/ground; replace
solenoid if faulty and repiar wiring if necessary
3. Overdrive piston spacer too thin 3. Remove unit; measure end p l a y and select
proper spacer
4. Overdrive clutch pack worn 4. Remove unit and rebuild clutch pack
5. T.P.S. faulty 5. Replace T.P.S.
6. Overdrive clutch bleed orifice plugged 6. Disassemble transmission a n d replace orifice
3-4 UPSHIFT OCCURS BEFORE 1. Overdrive solenoid connector or wiring problem 1. Test connector and wiring for loose connections,
COMPLETION OF 2-3 UPSHIFT shorts, or ground, and repair as needed
2. Overdrive solenoid malfunction 2. Replace solenoid
3. Coolant temperature or T.P.S. malfunction 3. Test each sensor for continuity, short, ground,
a n d replace as necessary
4. Valve b o d y malfunction 4. Remove, disassemble, clean, and inspect
valve b o d y components; make sure all valves
a n d plugs slide freely in bores; polish valves
with crocus cloth if needed
5. Powertrain control module malfunction 5. Test with DRB II scan tool and replace
controller if faulty
J9321-253
42RH/46RH OVERDRIVE DIAGNOSIS
N O 4-3 D O W N S H I F T 1. Circuit wiring and/or connectors shorted 1. Test wiring a n d connectors, with test lamp
and volt/ohmmeter; repair wiring as
necessary; replace connectors and/or
harnesses as required
2. Converter clutch solenoid not venting 2. Remove valve b o d y and replace solenoid if
seized or shorted
3. Overdrive solenoid not venting 3. Remove valve b o d y and replace solenoid if
seized or shorted
4. 3-4 shift, shuttle, timing valve, or accumulator 4. Remove valve b o d y ; remove and disassemble
malfunction lower housing a n d 3-4 accumulator housing;
replace seals a n d clean valves as necessary;
be sure a l l valves slide freely in bores
5. Powertrain control module malfunction 5. Check operation with DRB II scan tool;
replace controller only if faulty
6. T.P.S. malfunction 6. Replace T.P.S.
7. Sensor or sensor w i r i n g problem 7. Check coolant a n d transmission temperature
sensors, speed sensor, a n d overdrive control
switch
N O 4-3 D O W N S H I F T W H E N 1. Control switch open-shorted 1. Test a n d replace switch if faulty

C O N T R O L SWITCH IS
TURNED OFF 2 . Overdrive solenoid w i r i n g or connectors faulty 2. Check solenoid w i r i n g a n d connections for
shorts/grounds; repair as necessary
3. Overdrive or converter clutch solenoid not 3. Test solenoids a n d replace if seized or shorted
venting
4. Powertrain control module malfunction 4. Test with DRB II scan tool; replace module if
faulty
J9321-254
HARSH 1-2, 2-3, OR 3-2 1. Lockup solenoid failure 1. Remove valve body and replace solenoid
SHIFTS (A500)
TORQUE CONVERTER LOCKS 1. Lockup solenoid, relay, or wiring problem 1. Test solenoid, relay, and wiring for continuity,
UP IN SECOND A N D / O R shorts, or grounds; replace solenoid and relay if
THIRD GEAR (A500) faulty; repair wiring and connectors as
necessary
NOISY OPERATION IN 1. Overdrive clutch discs, plates, or snap rings 1. Remove unit and rebuild clutch pack
FOURTH GEAR ONLY damaged
2. Overdrive piston or planetary thrust bearing 2. Remove and disassemble unit; replace either
brinnelled, installed wrong, or damaged thrust bearing if damaged
3. Output shaft bearings brinnelled, scored, damaged 3. Remove and disassemble unit; replace either
bearing if damaged
4. Planetary gears worn, chipped, damaged 4. Remove and overhaul overdrive unit
5. Overdrive unit overrunning clutch rollers rough, 5. Remove and overhaul overdrive unit
scored, or output bushings are worn
J9121-455
21-132 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING •
Condition Possible C a u s e Correction
N O REVERSE (OR SUPS IN 1. Direct clutch spring collapsed or broken 1. Remove and disassemble unit; check clutch pack
REVERSE) and replace spring
2. Direct clutch pack worn 2. Disassemble unit and rebuild clutch pack
4. Front clutch malfunction 4. Air pressure test clutch operation; remove and
rebuild if necessary
5. Overdrive thrust bearing failure 5 . Disassemble geartrain and replace bearings
N O 1-2 OR 2-3 UPSHIFT (HAS 1. Governor component loose, worn, or damaged 1. Remove and disassemble unit; replace worn or
LOW AND REVERSE ONLY) damaged governor components as needed
J9121-456
TORQUE CONVERTER CLUTCH DIAGNOSIS
POSSIBLE CAUSE
FAULTY OIL PUMP X X X X X
STICKING GOVERNOR VALVE X X X
PLUGGED COOLER, LINES OR FITTINGS X X X
VALVE BODY MALFUNCTION X X X X X X X
STUCK SWITCH VALVE X X X X X X
STUCK CONVERTER CLUTCH VALVE X X X
STUCK CONVERTER CLUTCH SOLENOID X X
SOLENOID WIRING DISCONNECTED X
FAILED CONVERTER CLUTCH SOLENOID X
FAILED CONVERTER CLUTCH RELAY X X
FAULTY TORQUE CONVERTER: X X X X X
OUT OF BALANCE X
FAILED CONVERTER CLUTCH X X X
LEAKING TURBINE HUB SEAL X X
ALIGN EXHAUST SYSTEM X X
TUNE ENGINE X X X
FAULTY INPUT SHAFT OR SEAL RING X X
THROTTLE CABLE MISADJUSTED X X
OUT OF FILL TUBE OR PUMP SEAL

DURING CLUTCH ENGAGEMENT
VIBRATION WHEN "REVVED"
OVERHEATING: OIL COMING

LOW A SPEED IN 4th GEAR
VIBRATION AFTER CLUTCH

CHATTER DURING CLUTCH
VIBRATION OR SHUDDER
SHUDDER AFTER CLUTCH

LOCKS UP OR DRAGS IN
STAYS ENGAGED AT TOO
STALLS OR IS SLUGGISH
ENGAGEMENT-(COLD)
CONVERTER CLUTCH
WILL NOT ENGAGE
LOW OR SECOND
5
Z Z
ENGAGEMENT
ENGAGEMENT
IN NEUTRAL
IN REVERSE
0
Q y z
z t—UJ
0
J9321-206
HYDRAULIC FLOW IN PARK POSITION (32RH/36RH/37RH)
OIL FILTER ENGINE RUNNING

+ AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21 - 135
HYDRAULIC FLOW IN DSEGOMD GEAR (32RH/36RH/37RH)
GOVERNOR VALVE
ACCUMULATOR
LOCK-UP ONLY
SELECTOR LEVER IN TORQUE CONVERTER-

DRIVE (SECOND)
HALF THROTTLE J9021-162
HYDRAULIC FLOW IN D-THIRD GEAR (32RH/36RH/37RH)
HYDRAULIC FLOW IN D-THIRD GEAR—AFTER CONVERTER CLUTCH ENGAGEMENT (32RH/36RH/37RH)
GOVERNOR VALVE
REAR SERVO
ACCUMULATOR
© °E^SJO ©
o © M{ © ©
O © O ©
LOCK-UP ONLY
TO
LUBRICATION
FRONT
-.CLUTCH
IMBRICATION
SELECTOR LEVER IN TORQUE CONVERTER
DRIVE (LOCK-UP)
J9Q21-164
H Y D R A U L I C F L O W D U R I N G F U L L T H R O T T L E 3-2 KICKDOWN (32RH/36RH/37RH)
GOVERNOR VALVE REAR SERVO FRONT , SERVO ACCUMULATOR
LOCK-UP ONLY
TO
LUBRICATION
FRONT
CLUTCH
UBRICATION
1-2 SHIFT CONTROL

55-70 n\f////
GOVERNOR 30-73 PSI f"
SELECTOR LEVER IN DRIVE TORQUE CONVERTER"
(FULL THROTTLE KICKDOWN)
J9021-166
HYDRAULIC FLOW IN 2-POSITION MANUAL SECOND (32RH/36RH/37RH)
GOVERNOR VALVE
ACCUMULATOR
y
LOCK-UP ONLY
SELECTOR LEVER IN TORQUE CONVERTER-

TWO (MANUAL SECOND)
CLOSED THROTTLE J902M67
HYDRAULIC FLOW' IN f-POSITION MANUAL LOW (32RH/36RH/37RH)
GOVERNOR VALVE
REAR SERVO ^ „ , , FRONT ^ SERVO
/ REAR CLUTCH r n 1 T 1 W
FRONT CLUTCH ACCUMULATOR
LOCK-UP ONLY
TO
.UBRICATION
FRONT
i CLUTCH
.UBRICATION
hv. OIL FILTER

SELECTOR LEVER I N
O N E ( M A N U A L LOW)
CLOSED THROTTLE M902M68
HYDRAULIC FLOW IN R E V E R S E (32BH/36HH/37mH)
GOVERNOR VALVE REAR SERVO FRONT SERVO

REAR CLUTCH ÂCCUMULATOR
SELECTOR LEVER
IN REVERSE
HYDRAULIC FLOW IN NEUTRAL (42RH/46RH/47RH)
J9421-156
H Y D R A U L I C PLOW IN R E V E R S E (42RH/46RH/4TRH)
UNE PRESSURE
( 1 6 0 - 2 7 0 psi)
THROTTLE
PRESSURE
( 0 - 9 4 psi)
1-2 SHIFT
CONTROL
( 2 5 - 7 0 psi)
UNE PRESSURE
T O THROTTLE
VALVE
( 5 0 - 1 0 0 psi)
CONVERTER/
LUBE PRESSURE
( 9 5 - 1 3 0 psi)
PUMP
SUCTION
SELECTOR LEVB1 IN REVERSE
J9421-157
HYDRAULIC FLOW IN D FIRST GEAR (42RH/46RH/47RH)
ACCUMULATOR OVERDRIVE
CLUTCH
LINE P R E S S U R E
( 7 0 - 7 8 psi)
I
GOVERNOR
PRESSURE
( 0 - 7 5 psi)
THROTTLE
PRESSURE
(To 4 0 psi)
CONVERTER/
LUBE P R E S S U R E
( 5 - 7 5 psi)
PUMP
SUCTION
OVERDRIVE
PRE-FILL
PRESSURE
( 0 - 5 psi)
SELECTOR LEVER IN DRIVE

FtiSTGEAR
PART THROTTLE
J9421-158
-4
HYDRAULIC FLOW IN D SECOND GEAR (42RH/46RH/47RH)
ACCUMULATOR OVERORIVf
CLUTCH
LINE P R E S S U R E
(57-94 psi)
•GOVERNOR
PRESSURE
( 0 - 5 7 psi)
THROTTLE
PRESSURE
(0-94 psi)
1-2 SHIFT
PRESSURE
( 2 5 - 7 0 psi)
CONVERTER/
LUBE PRESSURE
( 5 - 7 5 psi)
PUMP
SUCTION
OVERDRIVE
PRE-FILL
PRESSURE
( 0 - 5 psi)
SECOND GEAR
PART THROTTLE
J9421-159
HYDRAULIC FLOW I N D THIRD GEAR (42RH/46RH/47RH)
U N E PRESSURE
( 5 7 - 9 4 psi)
GOVERNOR
PRESSURE
( 0 - 6 0 psi)
THROTTLE
PRESSURE
( 0 - 9 4 psi)
CONVERTER/
LUBE PRESSURE
( 5 - 5 7 psi)
PUMP
SUCTION
OVERDRIVE
PRE-FILL
PRESSURE
( 0 - 5 psi)

THIRD GEAR
(CONVERTER CLUTCH NOT APPLIED) ro
J9421-160
CD
HYDRAULIC FLOW IN D FOURTH GEAR-CONVERTER CLUTCH NOT APPLIED (42RH/46RH/47RH) ro
CJI
OVERDRIVE
CLUTCH
UNE PRESSURE
(57-94 psi)
THROTTLE
PRESSURE
(0-94 psi)
1-2 SHIFT
CONTROL
(25-70 psi)
GOVERNOR
PRESSURE
(0-57 psi)
PUMP
SUCTION
OVERDRIVE
PRE-FILL
PRESSURE
(0-5 psi)
OVERDRIVE 4TH GEAR
(CONVERTER CLUTCH NOT APPLIED)
J9421-161
HYDRAULIC FLOW IN D FOURTH GEAR-CONVERTER CLUTCH APPLIED (42RH/46RH/47RH)
UNE PRESSURE
( 9 5 - 1 3 0 psi)
GOVERNOR
PRESSURE
(0-60 psi)
THROTTLE
PRESSURE
( 0 - 1 0 0 psi)
CONVERTER/
LUBE PRESSURE
(5-60 psi)
PUMP
SUQION
z
Gi
(CONveneaurcH AmjED)
to
J9421-162 cn
HYDRAULIC FLOW IN MANUAL F I R S T G E A R f I J f42RH/46RH/47RH|
CLUTCH
tmmm
LINE PRESSURE
(55-62 psi)
1-2 SHIFT
CONTROL
(25-35 psi)
GOVERNOR
PRESSURE
(0-30 psi)
CcJvERiER/
LUBE PRESSURE
(5-57 psi)
PUMP
SUCTION
OVERDRIVE
PRE-FILL
PRESSURE
(0-5 psi)
SELECTOR LEVER EN MANUAL 1

HRSTGEAR
CLOSED THROTTLE
J942M63
HYDRAULIC FLOW IN MANUAL SECOND GEAR (2) (42RH/46RH/47RH)
CLUTCH
UNE PRESSURE
( 5 5 6 2 psi)
1-2 S H I F T
CONTROL
( 2 5 - 3 5 psi)
GOVERNOR
PRESSURE
( 6 - 5 7 psi)
CONVERTER/
LUBE PRESSURE
( 5 - 5 7 psi)
PUMP
SUCTION
OVERDRIVE
PRE-FILL
PRESSURE
( 0 - 5 psi)
SELECTOR LEVER Bî MANUAL 2

SECOND GEAR
CLOSED THROTTLE
J9421-164 CJl
w
21-154 AUTOMATIC TRANSMISSIOI IN-VEHICLE SERVICE (ALL)
A U T O M A T I C T R A N S M I S S I O N I N - V E H I C L E SERVICE (ALL}
INDEX
page page
Aluminum Thread Repair 168 Park Lock Service—32RH/36RH/37RH 162
Extension Housing Bushing and Output Shaft Park/Neutral Position Switch 158
Bearing—32RH/36RH/37RH 160 Rear Band Adjustment 158
Extension Housing Yoke Seal 159 Servicing Transmission Cooler Lines and Fittings . 165
Fluid and Filter Replacement 154 Speedometer Service 158
Fluid Level Check 154 Throttle Cable Replacement 156
Front Band Adjustment . . . . . . . . . . . . . . . . . . . . 157 Transmission Cooler Service 166
Gearshift Linkage Adjustment 154 Transmission Throttle Valve Cable Adjustment . . . 155
Governor and Park Gear Service—32RH/36RH/ Valve Body Control Pressure Adjustments 164
37RH 161 Valve Body Service 163
Governor and Park Lock Service—42RH/46RH/
47RH ...... 162
FLUID LEVEL CHECK Recommended Fluid

(1) Transmission fluid should be at normal operat The recommended (and preferred) fluid for all
ing temperature. Drive vehicle i f necessary to bring Chrysler automatic transmissions is Mopar ATF
temperature to normal range of 82°C (180°F). Plus, type 7176. Dexron I I fluid should only be used
(2) Position vehicle on level surface. This is ex when ATF Plus is not available.
tremely important for an accurate check.
(3) Apply parking brakes and run engine at curb Severe Usage Change Interval
idle speed. Under severe usage, the fluid and filter should be
(4) Shift transmission momentarily into all gear changed and the bands adjusted at 12,000 mile (19
ranges. Then shift back to Neutral. 000 Km) intervals.
(5) Clean top of filler tube and dipstick (to avoid Severe usage is defined as:
dirt entry) and check fluid level. (a) More than half of vehicle operation occurs i n
(6) Correct level is to MAX or Full mark on dip heavy city traffic during hot weather (above 90° F).
stick. (b) Vehicle is used for Taxi, Police, Limousine, or
(7) I f fluid level is low, add only enough fluid to similar commercial operations.
correct level. (c) Vehicle is used for trailer/boat towing or
heavy load hauling.
CAUTION: Do not overfill the transmission. Overfill
ing may c a u s e leakage from the pump vent which FLUID AND FILTER REPLACEMENT
can be mistaken for a pump seal leak. In addition, PROCEDURE
overfilling will also c a u s e fluid aeration and foam (1) Raise vehicle, remove oil pan and drain fluid.
ing a s the e x c e s s fluid is picked up and churned by (2) Remove three filter screws and remove filter.
the gear train. This will c a u s e shift problems and (3) Position new filter on valve body and install fil
reduce the life of the fluid significantly. ter screws finger tight.
(4) Tighten filter screws to (4 N*m (35 in. lbs.).
(8) I f fluid level is too high, excess fluid can be (5) Position new gasket on oil pan and install pan
drained with suction gun and flexible tubing. Tubing on transmission. Tighten pan bolts to 17 N-m (150 in.
will have to be adapted to suction gun nozzle and be lbs.) torque.
long enough to extend through fill tube into trans (6) Lower vehicle and refill transmission with rec
mission oil pan. Tubing diameter should be 1/8 to ommended fluid.
3/16 inch diameter.
GEARSHIFT LINKAGE ADJUSTMENT
FLUID AND FILTER REPLACEMENT Check linkage adjustment by starting the engine i n
Park and Neutral.
Normal Change Interval Adjustment is OK i f the engine starts only i n Park
The fluid and filter should be changed (and the and Neutral.
bands adjusted) at recommended maintenance inter Adjustment is incorrect i f the engine starts i n any
vals. Or whenever the transmission has been disas other position, or does not start i n either Park or
sembled for any reason. Neutral.
• AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL) 21 - 155
I f the engine starts i n any position other than Park position. Proper adjustment will allow simultaneous
or Neutral, or i f the engine will not start at all, the movement without causing the transmission throttle
park/neutral position switch may be faulty. lever to either move ahead of, or lag behind the ac
celerator lever.
G E A R S H I F T LINKAGE ADJUSTMENT Throttle cable adjustment can be checked on the
PROCEDURE vehicle. I t is recommended that cable adjustment
(1) Shift transmission into Park. condition be verified before proceeding to the cable
(2) Raise vehicle. adjustment procedure.
(3) Check condition of shift rod, levers, grommets,
and torque shaft (Fig. 1). Tighten, repair, or replace Checking Throttle Cable Adjustment
worn or damaged parts. "(1) Turn ignition key to OFF position.
(4) Loosen shift rod adjusting swivel lock screw. Be (2) Remove air cleaner on gas engines.
sure swivel turns freely on rod.
(3) On diesel engines, verify that fuel injection
(5) Verify that valve body shift control lever is in
pump accelerator linkage is at curb idle position (Fig.
Park detent. Move lever fully rearward to check.
2 and 3).
(6) Adjust swivel position on the shift rod to a ob
tain free pin fit i n torque shaft lever (Fig. 1). Then (4) On gas engines, verify that lever on throttle
tighten swivel lock screw to 10 N-m (90 in. lbs.) body is at curb idle position. Then verify that trans
torque. mission throttle lever (Figs. 4 and 5) is also at idle
(7) Check adjustment by starting engine i n Park position.
and Neutral. Engine should start i n these positions (5) Slide cable off attachment stud on throttle body
only. If engine starts in any position other than or injection pump lever (Figs. 2, 4 and 5 ) .
Park or Neutral, adjustment is incorrect or (6) Compare position of cable end to attachment
park/neutral position switch is faulty. stud on throttle body lever (Fig. 6):
(a) Cable end and attachment stud should be
TORQUE SHAFT
SHAFT LEVER aligned (or centered on one another) to within 1
mm (0.039 in.) i n either direction.
(b) I f cable end and attachment stud are mis
aligned (off center), cable will have to be adjusted
as described i n following adjustment procedure.
(7) Reconnect cable end to attachment stud. Then
with aid of a helper, observe movement of transmis
sion throttle lever and lever on throttle body.
(a) I f both levers move simultaneously from idle
to half-throttle and back to idle position, adjust
ment is correct.
GROMMET
SHAFT
LEVER
J9421-242
RETAINER
Fig. 1 Column Shift Linkage Components AND
BUTTON
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT THROTTLE
VALVE
The transmission throttle lever is operated by an CABLE
adjustable cable (Figs. 2, 3, 4). The cable adjustment
lock button is located i n the retainer portion of the CONTROL
cable (engine-end). The adjustment procedure for gas LEVER LINKAGE
and diesel engines is the same. STUD BRACKET J9421-243
A correctly adjusted throttle valve cable will cause
the throttle lever on the transmission to move simul Fig. 2 Throttle Valve Cable Attachment At Engine
taneously with the throttle control lever from the idle (Cummins Diesel)
21 - 156 AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL) •
(b) I f transmission throttle lever moves ahead of, ACCELERATOR
or lags behind throttle body lever, cable adjustment CABLE THROTTLE
VALVE
will be necessary. Or, i f throttle body lever prevents STUD T.V. CABLE CABLE
transmission lever from returning to closed posi STUD
tion, cable adjustment will be necessary.
CABLE ENGINE RETAINER

BRACKET BRACKET AND
ACCELERATOR
CABLE BUTTON
J9421-245
Fig. 5 Throttle Valve Cable Attachment At Engine

(V10 Engine)
(7) Center cable end on attachment stud to within
1 mm (0.039 in.) and release lock button (Fig. 6).
J9421-247 (8) Check cable adjustment. Be sure transmission
throttle lever and lever on throttle body (Fig. 6),
Fig. 3 Cable Identification (Cummins Diesel) move simultaneously and as described in cable ad
ENGINE justment checking procedure.
BRACKET
CABLE CABLE
LOCK BRACKET
BUTTON
THROTTLE
BODY LEVER
RETAINER
AND THROTTLE
BUTTON VALVE
CABLE
THROTTLE
VALVE
CABLE CONTROL
LEVER
STUD ALIGN CABLE
J9421-244 AND STUD TO
WITHIN 1 MM (0.039 IN.)
OF CENTER
Fig. 4 Throttle Valve Cable Attachment At Engine
(V6/V8 Gas Engine)
Throttle Valve Cable Adjustment Procedure
(1) Turn ignition switch to OFF position. J9321-415
(2) Remove air cleaner on gas engines.
Fig. 6 Throttle Cable Adjustment Components (Gas
(3) Disconnect cable end from attachment stud on
Engine Shown)
control lever (Figs. 2, 4, 5).
(4) Verify that transmission throttle lever is i n THROTTLE CABLE REPLACEMENT
fully closed position. Then be sure lever on throttle (1) Raise vehicle.
body is at curb idle position. (2) Disconnect throttle valve (T.V.) cable at trans
(5) Locate cable lock button. Button is part of cable mission lever (Figs. 8 and 9).
retainer at engine end of cable.
(6) Press cable lock button inward to release cable.
Lock button only has to move about 2 mm (0.070 in.)
to release cable i n adjuster head.
THROTTLE
(11) Check and adjust throttle valve cable. Refer to
BODY procedures i n this section.
T.V. LEVER BRACKET J9421-250

TRANSMISSION
SHIFT Fig. 9 V10/Diesel Throttle Valve Cable Attachment
LEVER J9421-246 (At Transmission)
Fig. 7 Throttle Cable Control Levers (Gas Engine

Shown)
(3) Rotate cable out of transmission bracket (Figs.
8 and 9).
(4) Disengage cable from body clips.
(5) Lower vehicle.
(6) Disengage cable at engine bracket and from le
ver stud on throttle body or fuel injection pump.
(7) Remove cable from engine compartment.
(8) Position new cable in engine compartment.
Connect cable to engine bracket but do not connect
cable to throttle lever stud on throttle body or injec
tion pump at this time.
(9) Raise vehicle and secure cable in body clips.
SPRING T.V. LEVER J9421-249
(10) Attach cable to transmission T.V. lever (Figs. 8
and 9). Be sure T.V. lever return spring is attached Fig. 10 Throttle Lever Spring Attachment
(Fig. 10). Transmission will not shift properly i f
spring is not connected. FRONT BAND ADJUSTMENT
The front (kickdown) band adjusting screw is lo
cated on the left side of the transmission case above
the manual valve and throttle valve levers.
(1) Raise vehicle.
(2) Loosen band adjusting screw locknut. Then
back locknut off 3-5 turns. Be sure adjusting screw
turns freely i n case. Apply lubricant to screw threads
if necessary.
(3) Tighten band adjusting screw to 8 N-m (72 in.
lbs.) torque. I f adapter extension C-3705 must be
used to reach adjuster screw, tighten screw to
only 5 N-m (47-50 in. lbs.) torque (Fig. 11).
(4) Back off adjusting screw 2-1/2 turns on all
transmission models.
T.V. LEVER BRACKET J9421-250
Fig. 8 V6/V8 Throttle Valve Cable Attachment (At

Transmission)
(5) Hold adjuster screw i n position and tighten SPEEDOMETER SERVICE
locknut to 41 N-m (30 ft. lbs.) torque. Rear axle gear ratio and tire size determine speed
(6) Lower vehicle. ometer pinion requirements. I f the pinion must be re
placed, refer to the parts catalogue information for
the correct part.
SPEEDOMETER ASSEMBLY REMOWAL

(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 13).
(4) Remove speed sensor and speedometer adapter
as assembly.
(5) Remove speed sensor retaining screw and re
move sensor from adapter.
(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 13).
Remove and discard O-rings i f worn or damaged.
Fig. 11 Front Band Adjustment Screw Location (8) Inspect terminal pins i n speed sensor. Clean
pins with Mopar electrical spray cleaner i f dirty or
REAR BAND ADJUSTMENT oxidized. Replace sensor i f faulty, or pins are loose,
The transmission oil pan must be removed for ac severely corroded, or damaged.
cess to the rear band adjusting screw.
(1) Raise vehicle. SPEEDOMETER INSTALLATION AND
(2) Remove transmission oil pan and drain fluid. INDEXING
(3) Loosen band adjusting screw locknut 5-6 turns. (1) Thoroughly clean adapter flange and adapter
Be sure adjusting screw turns freely i n lever. mounting surface i n housing. Surfaces must be clean
(4) Tighten adjusting screw to 8 N-m (72 in. lbs.) for proper adapter alignment and speedometer oper
torque (Fig. 12). ation.
(5) Complete band adjustment as follows: (2) Install new O-rings on speed sensor and speed
• On 32RH/42RH, back off adjusting screw four ometer adapter i f necessary.
turns. (3) Lubricate sensor and adapter O-rings with
• On 36RH/37RH/46RH/47RH, back off adjusting transmission fluid.
screw two turns. (4) Install vehicle speed sensor i n speedometer
(6) Hold adjusting screw i n place and tighten lock- adapter. Tighten sensor attaching screw to 2-3 N-m
nut to 34 N-m (25 ft. lbs.) torque. (15-27 in. lbs.) torque.
(7) Position new gasket on oil pan and install pan (5) Install speedometer pinion i n adapter.
on transmission. Tighten pan bolts to 17 N-m (13 ft. (6) Count number of teeth on speedometer pinion.
lbs.) torque. Do this before installing assembly i n housing. Then
lubricate pinion teeth with transmission fluid.
(8) Lower vehicle and refill transmission with Mo
(7) Note index numbers on adapter body (Fig. 14).
par ATF Plus, Type 7176 fluid.
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly i n housing.
(9) Rotate adapter until required range numbers
are at 6 o-clock position. Be sure range index num
bers correspond to number of teeth on pinion gear.
(10) Install speedometer adapter clamp and retain
ing screw. Tighten clamp screw to 10-12 N-m (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level i f necessary.
PARK/NEUTRAL POSITION SWITCH

The center terminal of the park/neutral position
switch is the starter circuit terminal. I t provides the
Fig, 12 Rear Band Adjustment Screw Location ground for the starter solenoid circuit through the se-
AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL) 21 - 159
Fig. 13 Speedometer Components

SPEEDOMETER INDEX Check gearshift linkage adjustment before replac
NUMBER ing a switch that tests bad.
LOCATION
SWITCH REPLACEMENT
(1) Raise vehicle and position drain pan under
switch.
(2) Disconnect switch wires.
(3) Remove switch from case.
(4) Move shift lever to Park and Neutral positions.
Verify that switch operating lever fingers are cen
tered in switch opening in case (Fig. 15).
(5) Install new seal on switch and install switch in
case. Tighten switch to 34 N-m (25 ft. lbs.) torque.
(6) Test continuity of new switch with 12V test
J9321-386 lamp.
(7) Connect switch wires and lower vehicle.
Fig. 14 Location Of Index Numbers On Speedometer (8) Top off transmission fluid level.
Adapter
lector lever in Park and Neutral positions only. The EXTENSION HOUSING YOKE SEAL
outer terminals on the switch are for the backup
lamp circuit. YOKE SEAL REPLACEMENT
(1) Raise vehicle.
S W I T C H TCST (2) Mark propeller and axle yokes for alignment
To test the switch, remove the wiring connector. reference. Then disconnect shaft at yoke and remove
Then test continuity between the center terminal and shaft.
(3) Remove old seal with Seal Remover C-3985
the transmission case. Continuity should exist only
(Fig. 16).
when the transmission is in Park or Neutral.
(4) Install new seal. Start seal in housing. Then
Shift the transmission into reverse and test conti tap seal into place with Seal Installer C-3995 or
nuity at the switch outer terminals. Continuity C-3972 (Fig. 17).
should exist only when the transmission is in Re (5) Carefully guide propeller shaft slip yoke into
verse. Continuity should not exist between the outer housing and onto output shaft splines. Align marks
terminals and the case. made at removal and connect propeller shaft to rear
axle pinion yoke.
21-160 AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL) •
(8) Remove extension housing-to-transmission
bolts.
(9) Verify that transmission is in 1 position. Park
lock rod is easier to disengage/engage with sprag i n
this position.
(10) Remove access plate and gasket from under
side of extension housing. Plate must be removed for
access to rear bearing locating ring.
(11) Insert parallel jaw snap ring pliers into access
plate opening and spread bearing locating ring (Fig.
18).
(12) Hold snap ring in a spread position and work
extension housing off rear bearing.
Fig. 18 Releasing Rear Bearing Locating Ring

(13) Carefully pull extension housing rearward to
move park lock rod past sprag.
(14) Remove housing.
OUTPUT SHAFT REAR BEARING

REPLACEMENT
Fig. 17 installing Extension Housing Yoke Seal (1) Remove snap ring that retains rear bearing on
output shaft (Fig. 19).
EXTENSION HOUSING BUSHING AND OUTPUT
SHAFT BEARING—32RH/3IRH/37RH
EXTENSION HOUSING REMOVAL

(1) Shift transmission into manual low (1) position.
(2) Raise vehicle.
(3) Mark propeller shaft and axle yokes for align
ment reference. Then disconnect and remove shaft.
(4) Remove vehicle speed sensor, speedometer
adapter and speedometer pinion (Fig. 13).
(5) Remove bolts attaching extension housing to Fig. 19 Rear Bearing Location
rear support.
(6) Raise transmission slightly with jack stand or (2) Remove bearing from output shaft. Note that
floor jack. 36RH/37RH transmissions have a second snap ring
(7) Remove crossmember and rear support as as at the front of the shaft bearing. 32RH transmissions
sembly. do not have this second snap ring.
• AUTOMATIC TRANSMISSION IN-WEHICLE SERWICE (ALL) 21-111
(3) Install new bearing on shaft. Be sure locating SPECIAL TOOL

ring groove i n outer circumference of bearing is to
ward front (Fig. 13).
(4) Install rear bearing retaining snap ring (Fig.
13). However, do not install the locating ring on the
bearing. The locating ring goes i n the extension hous
ing. The ring is not seated i n the rear bearing until
the housing is installed.
EXTENSION HOUSING BUSHING Fig. 22 Installing Extension Housing Seal

REPLACEMENT (5) Spread locating ring with parallel jaw snap
(1) Remove housing oil seal with Special Tool ring pliers.
C-3985-B (Fig. 20). (6) Hold locating i n spread position. Tap or work
housing into place and release locating ring. Be very
sure locating ring is fully seated i n rear bearing.
(7) Install and tighten housing-to-transmission
(8) Install gasket and access plate on underside of
housing.
(9) Install crossmember and rear mount assembly.
(10) Remove jack used to support transmission.
(11) Install and tighten housing-to-rear mount
(12) Install speedometer pinion and adapter.
Fig. 20 Hemming Extension Housing Seal (13) Align and install propeller shaft.
(14) Lower vehicle.
(2) On 32RH, remove housing bushing with Bush (15) Top off transmission fluid level i f necessary.
ing Remover C-4470. On 36RH/37RH, remove bush
ing with Remover C-4469 (Fig. 21). G0WERN0R AND PARI GEAR SERWICE—32RH/
(3) On 32RH, slide new bushing on installing end
of Tool C-4470. On 36RH/37RH, slide bushing on Tool 3IRH/37RH
C-4469 (Fig. 21).
G O V E R N O R AND PARK GEAR REMOWAL
(4) Align bushing oil hole with oil slot i n extension
housing. Then press or tap bushing into place (Fig. (1) Remove extension housing and output shaft
21). rear bearing. Refer to procedure i n this section.
(5) Install new oil seal i n housing (Fig. 22). On (2) Carefully remove snap ring from weight end of
32RH use Seal Installer C-3995. On 36RH/37RH, use governor valve shaft (Fig. 23).
Seal Installer C-3972. (3) Slide governor valve and shaft out of governor
body.
(4) Remove large snap ring from weight end of gov
ernor body and remove governor weight assembly
(Fig. 24).
(5) Remove snap ring from governor weight and re
move inner weight and spring from outer weight.
(6) Remove snap ring retaining governor body and
park gear on output shaft (Fig. 23).
(7) Slide governor body and park gear assembly off
output shaft.
(8) Remove bolts attaching governor body to gear
Fig. 21 Extension Housing Bushing Replacement
and separate body from gear.
EXTENSION HOUSING INSTALLATION (9) Remove filter screen from governor body.
(1) Position new gasket on housing. Use petroleum
jelly to hold gasket in place. CLEANING AND INSPECTION
(2) Install locating ring i n extension housing, i f re Thoroughly clean all the governor parts in a suit
moved. able cleaning solution but do not use any type of
(3) Slide housing onto output shaft. caustic cleaning agents.
(4) Work park rod past sprag and install housing The weights and valves should fall freely i n their
on shaft. bores when clean and dry.
(7) Assemble governor weights and spring. Secure
inner weight and spring in outer weight with snap
ring.
(8) Install weight assembly in governor body and
install retaining snap ring.
(9) Place governor valve on valve shaft. Insert
shaft in governor body, through governor weights and
output shaft. Be sure valve is properly seated in
body.
(10) Secure valve shaft with small snap ring.
(11) Install output shaft bearing and extension
housing. Refer to procedure in this section.
GOVERNOR AND PARK LOCK SERVICE—42RH/

46RH/47RH
The governor and park lock components are located
within the overdrive unit and cannot be serviced in
Fig. 23 Governor Snap Ring Locations the vehicle.
Minor surface scratches and burrs can be removed The overdrive unit must be removed and disassem
with crocus cloth. Inspect the governor weight spring bled for access to the governor and park lock compo
for distortion. Replace the spring, if damaged. nents.
Clean the filter in solvent and dry it with com Refer to the 42RH/46RH overdrive unit section for
pressed air. Replace the filter if damaged. repair procedures.
Inspect the park gear for chipped or worn gear
teeth or damaged ring grooves. Replace the gear, if PARK LOCK SERVICE—32RH/36RH/37RH
damaged.
P A R K LOCK COMPONENT REMOWAL
SPRING (1) Raise vehicle and remove propeller shaft.
(2) Remove extension housing. Refer to procedure
in this section.
(3) Slide sprag shaft out of extension housing and
remove sprag and spring (Fig. 25).
(4) Remove snap ring and slide reaction plug and
pin assembly out of housing.
(5) If park rod requires service, it will be necessary
to remove valve body. Refer to Valve Body Service
procedures in this section.
Fig. 24 Governor Components

GOVERNOR/PARK GEAR ASSEMBLY AND
INSTALLATION
(1) Assemble governor body, filter screen and park
gear.
(2) Install and tighten gear-to-body bolts finger
tight. Make sure oil passage in governor body aligns
with matching passage in gear.
(3) Install assembled governor body and gear on
output shaft.
(4) Position governor body so valve shaft hole in
body aligns with matching hole in output shaft. Then J922M39
slide body and park gear into place.
(5) Install snap ring securing governor and park Fig. 25 Park Lock Components
gear to output shaft.
(6) Tighten bolts attaching governor body to park
gear to 11 N-m (95 in. lbs.) torque.
COMPONENT INSPECTION (6) Disconnect 3-speed solenoid wire from case con
Inspect the sprag shaft for scores and free move nector.
ment in the housing and sprag. Inspect the sprag (7) Remove valve body attaching screws.
and control rod springs for distortion and loss of ten (8) Push 4-speed solenoid connector downward to
sion. start i t out of case.
Inspect the square lug on the sprag for broken (9) Lower valve body enough to remove accumula
edges. Check the lugs on the park gear for damage. tor piston and piston spring (Fig. 26). Note number
Inspect the ball on the end of the control rod for of accumulator springs removed. Some trans
nicks and burrs. Also be sure the ball rotates freely. missions (like 47RH), have one spring while
Replace any park lock components exhibiting wear or others have two.
damage. (10) Pull valve body forward to disengage park rod.
(11) Push manual lever shaft and solenoid case
PARK LOCK COMPONENT INSTALLATION connector out of transmission case. Then lower valve
(1) Install reaction plug and pin assembly i n hous body, rotate i t away from case, pull park rod out of
ing and secure with new snap ring (Fig. 25). sprag and remove valve body (Fig. 26).
(2) Position sprag and spring i n housing and insert ACCUMULATOR OUTER
sprag shaft. Be sure square lug on sprag is toward PISTON SPRING
park gear. Also be sure spring is positioned so i t
moves sprag away from gear.
(3) Replace park rod i f necessary.
(4) Install extension housing as described i n this
section.
(5) Install propeller shaft and lower vehicle.
(6) Check transmission fluid level. Add fluid i f nec INNER SEAL
essary. SPRING RINGS J932M87
VALVE BODY SERVICE Fig. 26 Accumuiator Piston And Springs (42RH/

46RH)
GENERAL SERVICE INFORMATION UPPER
The valve body can be removed for service without HOUSING
having to remove the entire transmission assembly.
The valve body can be disassembled for cleaning \
and inspection of the individual components. Refer to
the procedures i n the appropriate transmission over
haul section.
The only serviceable valve body components are
the:
• manual lever
• manual lever washer/seal/E-clip and shaft seal
• manual lever detent ball and spring
• throttle lever
• fluid filter
• solenoid and connector assembly
• switch valve, spring and adjusting screw bracket
• park rod and E-clip
• transfer plate solenoid
• overdrive/converter solenoid and harness assembly
The remaining valve body components are serviced PLATE LOWER VALVE
HOUSING HOUSING J9321-164
only as part of a complete valve body assembly
VALVE BODY REMOVAL Fig. 27 Valve Body Assembly (4-Speed Shown)
(1) Raise vehicle. VALVE BODY INSTALLATION
(2) Remove oil pan and drain fluid. (1) Verify that park/neutral position switch has
(3) Loosen clamp bolts and remove throttle valve NOT been installed. Valve body cannot be installed
and shift levers from valve body manual lever shaft. with switch i n place. Remove switch i f necessary.
(4) Remove park/neutral position switch. (2) Install new seals on accumulator piston and in
(5) Remove filter from valve body. stall piston i n case.
21-164 AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL)
(3) Place valve body manual lever i n low (1 posi The 1-5/16 in. (33.4 mm) setting is an approximate
tion) to ease inserting park rod into sprag. setting only. Because of manufacturing tolerances, i t
(4) Use screwdriver to push park sprag into en may be necessary to vary from this dimension to ob
gagement with park gear. This allows knob on rod to tain desired pressure.
move past sprag when valve body is installed. Rotate One complete turn of the adjusting screw changes
output shaft to verify sprag engagement. line pressure approximately 1-2/3 psi (9 kPa). Turn
(5) Position accumulator spring between accumula ing the adjusting screw counterclockwise increases
tor piston and valve body. pressure while turning the screw clockwise decreases
(6) Position valve body on transmission and work pressure.
park rod past sprag. Be sure accumulator piston and
spring remain in position.
(7) Hold valve body i n position and install valve
body attaching screws finger tight only.
(8) Install neutral start and backup lamp switch i n
case.
(9) Tighten valve body attaching screws alternately
and evenly to 11 N-m (100 in. lbs.) torque.
(10) Install new fluid filter on valve body. Install
and tighten filter screws to 4 N-m (35 in. lbs.) torque.
(11) Connect solenoid wire to case connector.
(12) Install manual and throttle levers on throttle
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket. Tighten pan
Fig. 28 Line Pressure Adjustment
(14) Connect park/neutral position switch and con THROTTLE PRESSURE ADJUSTMENT
verter clutch solenoid wires. Insert Gauge Tool C-3763 between the throttle le
(15) Install speedometer pinion gear, adapter and ver cam and kickdown valve (Fig. 29).
speed sensor. Push the tool inward to compress the kickdown
(16) Lower vehicle. valve against the spring and bottom the throttle
(17) Fill transmission with Mopar ATF Plus, Type valve.
7176 fluid. Maintain pressure against kickdown valve spring.
(18) Adjust gearshift and throttle cable i f neces Turn throttle lever stop screw until the screw head
sary. touches throttle lever tang and the throttle lever cam
touches gauge tool.
VALVE BODY CONTROL PRESSURE ADJUSTMENTS The kickdown valve spring must be fully com
There are two control pressure adjustments on the
pressed and the kickdown valve completely
valve body which are: Line pressure and throttle
bottomed to obtain correct adjustment.
pressure.
The valve body must be removed from the trans
mission i n order to perform the adjustments. Refer to
the valve body removal/installation procedures i n
this section.
Because line and throttle pressures are interdepen
dent (each affects shift quality and timing), both ad
justments must be performed properly and in the
correct sequence. Adjust line pressure first and throt
tle pressure last.
LINE PRESSURE ADJUSTMENT

Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 28).
Distance should be 1-5/16 in. (33.4 mm).
I f adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting. Fig. 29 Throttle Pressure Adjustment
• AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL) 2 1 - 1 Si
SERVICING TRANSMISSION COOLER LINES AND TRANSMISSION

FITTING COOLER
FITTINGS UNE
Fitting Types
The transmission cooler lines are attached with
quick disconnect fittings.
A flange on the cooler line serves as the sealing
mechanism. The wire retainer clip (Fig. 30), secures
the cooler line i n the fitting by this flange. The clip METAL
COVER
fits behind the flange to hold the line i n place. J942H74
Three different fitting styles may be used. Type 1
Fig. 32 Type 3 Quick Disconnect fitting
fittings have the retainer clip exposed (Fig. 30). Type
2 fittings have the retainer clip and fitting body en tings. The tool spreads the wire retainer clip to per
cased i n a shrink wrap material (Fig. 31). Type 3 fit mit release of the cooler line.
tings have the retainer clip covered by a metal* sleeve Fittings swedged into cooler line hoses (Fig. 33) are
crimped onto the fitting body (Fig. 32). serviced only as part of the entire cooler line.
COOLER LINE AND FITTING SERVICE TRANSMISSION

FITTING
The cooler lines and quick disconnect fittings
are NOT serviceable. Damaged fittings or lines
are to be replaced as assemblies.
RETAINING SEAT FITTING
CUP
COOLER
HOSE FITTING
J9321-257
J9321-245
Fig. 33 Transmission And Cooler Line Fitting
Fig. 30 Type 1 Quick Disconnect Fitting Placement
FITTING SHRINK RELEASE COOLER DISCONNECTING COOLER LINES WITH
BODY WRAP TOOL LINE
QUICK DISCONNECT FITTINGS
MATERIAL
(1) I f fitting and cooler line are encrusted with
dirt, mud, or grease, clean fitting and cooler line with
Mopar spray type cleaner/degreaser. Plastic release
tool will not fit into retainer clip i f fitting is full of
foreign material.
(2) Slide small plastic release tool into fitting until
tool bottoms against flange on cooler line (Fig. 34).
(3) Push and turn tool to spread retainer clip and
pull cooler line out of fitting (Fig. 34).
(4) Cover open ends of cooler lines and fittings to
prevent dirt entry.
J9321-452 (5) Inspect condition of fitting. Replace transmis
sion fitting as an assembly i f fitting body or retainer
Fig. 31 Type 2 Quick Disconnect fitting clip is damaged. Replace cooler line as assembly, i f
Fitting Release Tool fitting swedged into cooler line hose, is damaged.
A release tool is needed to disconnect each type of
fitting. A plastic tool is clipped directly to one of the
cooler lines on models with the type 2 and 3 fittings.
This tool can also be used to disconnect type 1 fit-
CAUTION: The wire retainer clips must secure the
cooler lines in the fittings. If the clips are deformed,
or distorted, normal fluid pressure could unseat the
cooler lines resulting in fluid loss a n d transmission
damage. Be very sure the cooler lines are firmly s e
cured by the retainer clip a s described in step (4)
above.
TRANSMISSION COOLER SERVICE
FLUSHING COOLERS AND LINES

I f a transmission malfunction contaminates the
fluid, the cooler and lines must be reverse flushed
thoroughly. This is necessary to prevent sludge and
particles from flowing back into the transmission af
Fig. 34 Disconnecting Cooler Line With Release ter repair. The flushing procedure applies to stan
Tool (Type 2 Fitting Shown) dard and auxiliary coolers.
REATTACHING COOLER LIMES WITH QUICK Pressure equipment is preferred for cooler reverse
DISCONNECT FITTINGS flushing. However, reverse flushing can be performed
(1) I f transmission or radiator fittings require re with hand operated equipment as follows.
placement, apply Mopar Lock N ' Seal, or Loctite 242
to fitting threads before installation. Flushing Procedure
(2) Wipe off cooler line and fitting with clean, dry (1) Identify and disconnect cooler pressure and re
cloth. turn lines at transmission (Figs. 35 and 36).
(3) Insert cooler line into fitting. Then push line (2) Position drain pan under cooler pressure line to
inward until retainer clip secures line. A snap or catch material flushed through cooler and lines.
click sound will be heard and felt through the line (3) Reverse flush cooler using hand operated suc
when the retainer clip seats behind the cooler line tion gun filled with mineral spirits. Insert gun nozzle
flange. (or hose) into cooler return line. Then force mineral
(4) P u l l o u t w a r d o n cooler lines to verify t h a t spirits into line and through cooler.
they are properly secured. (4) Continue reverse flushing until fluid exiting
cooler pressure line is clear and free from debris. Re
place cooler if fluid cannot be pumped through.
J9421-251
Fig. 35 Cooler Line Identification (Gas Engine)

AUTOMATIC TRANSMISSION IN-VEHICLE SERVICE (ALL) 2 1 - 1 6 7
AUXILIARY RETURN
COOLER
TEMPERATURE
SENSOR
J9421-252
Fig, 36 Cooler Line Identification (Diesel Engine)

(5) Clear flushing materials from cooler and lines (3) Remove brackets securing cooler to radiator
with short pulses of compressed air. Insert air gun and radiator support (Figs. 37-38).
nozzle into cooler return line and continue short air (4) Mark or tag cooler hoses for installation refer
pulses until all fluid is cleared from cooler and lines. ence (Figs. 35-36).
(6) Pump one quart of fresh automatic transmis (5) Position drain pan under cooler lines.
sion fluid through cooler and lines before reconnect (6) Loosen cooler lines and remove auxiliary cooler
ing lines. (7) Connect cooler lines to replacement auxiliary
cooler and position cooler on radiator, or support.
CHECKING COOLER FLUID FLOW Then install cooler brackets and attaching fasteners.
Cooler flow is checked, by measuring the amount of Tighten cooler line fittings and hose clamps securely.
fluid pumped through the cooler in a specified time (8) If condenser was removed, install condenser
by the transmission oil pump. and evacuate and recharge air conditioning system.
(1) Disconnect cooler return line from transmission (9) Install bumper assembly.
and place it in one quart test container. (10) Add transmission fluid as necessary.
(2) Add extra quart of fluid to transmission.
(3) Use stopwatch to check test time.
' (4) Shift into Neutral.
(5) Start and run engine at curb idle speed and
note cooler flow. A minimum of one quart (0.9 liter) of
fluid should flow into test container in 20 seconds.
(6) If fluid flow is intermittent, flows less than one
quart in 20 seconds, or fails to flow at all, cooler is
plugged or damaged and should be replaced.
MAIN COOLER REPLACEMENT

The main transmission cooler is located in the ra
diator lower tank. The cooler is not a serviceable
component. If the cooler is damaged in any way, the
radiator will have to be replaced. J9421-253
AUXILIARY COOLER REPLACEMENT Fig. 37 Auxiliary Cooler Mounting (Side Mount)

(1) Remove front bumper assembly.
(2) If cooler is behind air conditioning condenser,
remove condenser and receiver-drier if necessary.
ALUMINUM THREAD REPAIR

Damaged or worn threads i n the aluminum trans
mission case and i n the valve body can be repaired
with stainless steel thread inserts. Repair consists of
drilling out the worn or damaged threads, tapping
the hole with a special tap and installing a thread in
sert i n the tapped hole. The procedure returns the
hole threads to original size. Heli-Coil, or equivalent
quality, inserts are readily available from most auto
motive parts suppliers.
Fig. 38 Auxiliary Cooler Mounting (Center Mount)

• T R A N S M I S S I O N , CONVERTER, OVERDRIVE REMOVAL/INSTALLATION 21 - 169
TRANSMISSION, C O N V E R T E R , O V E R D R I V E REMOVAL/INSTALLATION
INDEX
page page
Converter and Drive Plate Service 171 Pump Oil Seal Replacement 171
General Service Information 169 Starter Ring Gear Replacement 170
Overdrive Unit Installation 174 Transmission Installation 172
Overdrive Unit Removal 173 Transmission Removal . 169
GENERAL SERVICE INFORMATION ENGINE

The overdrive unit can be removed and serviced BLOCK
separately. It is not necessary to remove the entire

transmission assembly to perform overdrive unit re
pairs.
The entire transmission assembly must be removed
in order to service the torque converter, driveplate,
ring gear and oil pump. Refer to the transmission re
moval and installation procedures in this section.
If only the overdrive unit requires service, refer to
the overdrive unit removal and installation proce
dures.
CAUTION: The transmission and torque converter

must be removed a s an assembly to avoid compo
nent damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the con
verter is left attached to the driveplate during re
moval. Be sure to remove the transmission and
converter a s an assembly.
J9421-255
TRANSMISSION REMOWAL Fig. 1 Transmission-To-Engine Strut Attachment

(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary ex x 4 models, it will also be necessary to remove bolt
haust components. attaching transfer case vent tube to converter hous
(3) Remove engine-to-transmission struts, if ing (Fig. 2).
equipped (Fig. 1). TRANSFER
(4) Disconnect fluid cooler lines at transmission.
( 5 ) Remove starter motor.
(6) Disconnect and remove crankshaft position sen
sor. Retain sensor attaching bolts.
CAUTION: The crankshaft position s e n s o r will be

damaged if the transmission is removed (or in
stalled) with the sensor still bolted to the engine
block. To avoid damage, remove the sensor before
removing the transmission.
(7) Remove torque converter access cover.

(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan. J9421-256
(9) Remove fill tube bracket bolts and pull tube out
Fig. 2 Fill Tube Attachment
of transmission. Retain fill tube O-ring (Fig. 1). On 4
21 170 TRANSMISSION, CONVERTER, OVERDRIVE REMOVAL/INSTALLATION •
(10) Mark torque converter and drive plate for as (24) Carefully work transmission and torque con
sembly alignment. Note that bolt holes in crankshaft verter assembly rearward off engine block dowels
flange, drive plate and torque converter all have one and disengage torque converter hub from end of
offset hole. crankshaft. Attach a small C-clamp to edge of bell
(11) Rotate crankshaft i n clockwise direction until housing to hold torque converter i n place during
converter bolts are accessible. Then remove bolts one transmission removal.
at a time. Rotate crankshaft with socket wrench on (25) Lower transmission and remove assembly
dampener bolt. from under the vehicle.
(12) Mark propeller shaft and axle yokes for as (26) To remove torque converter, remove C-clamp
sembly alignment. Then disconnect and remove pro from edge of bell housing and carefully slide torque
peller shaft. ON 4 x 4 models, remove both propeller converter out of the transmission.
shafts.
(13) Disconnect wires from park/neutral position STARTER RING GEAR REPLACEMENT
switch, transmission solenoid, and vehicle speed sen The starter ring gear on torque converters without
sor. a modulated clutch can be replaced. Torque convert
(14) Disconnect gearshift rod and torque shaft as ers with a clutch must be replaced as an assembly i f
sembly from transmission.
the ring gear is damaged. The heat from welding
(15) Disconnect throttle valve cable from transmis
would damage the converter clutch friction material.
sion bracket and throttle valve lever.
The starter ring gear is mounted directly on the
(16) On 4 x 4 models, disconnect shift rod from
transfer case shift lever. Or remove shift lever from outer diameter of the torque converter front cover.
transfer case and tie rod and lever to chassis compo Gear replacement is as follows:
nent with wire.
R I N G GEAR REMOVAL
(17) Disconnect transmission fluid cooler lines at
transmission fittings. Remove lines from retaining (1) Cut through weld material at rear side of ring
clips and tie lines to chassis with wire. gear with cut-off wheel or grinding wheel. Avoid cut
(18) Support rear of engine with safety stard or ting or grinding into converter front cover.
jack. (2) Scribe heavy line on front cover next to front
(19) Raise transmission slightly with service jack face of ring gear. Line is needed to properly locate
to relieve load on crossmember and supports. new gear on converter.
(20) Remove bolts securing rear support and cush (3) Support torque converter on front cover with
ion to transmission and crossmember. Raise trans blocks of wood (Fig. 4) Position blocks adjacent to
mission slightly, slide exhaust hanger arm from converter lugs to avoid altering lug position. The
bracket (Figs. 3 and 4), and remove rear support. torque converter must not rest on the front
cover hub during this operation.
EXHAUST /
PIPE ARM (4) Using blunt chisel or drift and hammer, tap
AND BRACKET downward on ring gear near welded areas to break
any remaining weld material (Fig. 4).
(5) Tap around ring gear until i t comes off con
verter.
(6) Smooth weld areas on converter with a mill
file.
RING GEAR INSTALLATION
(1) Heat and expand new ring gear for installation
on converter. Any of the following methods are ac
ceptable:
REAR SUPPORT
(a) OVEN: Place gear i n oven and set tempera
:AND CUSHION "J9421-257 ture at 200° F (93° C) Allow ring gear to remain i n
oven for 15 to 20 minutes.
Fig. 3 Rear Support Cushion (b) BOILING WATER: Place ring gear i n shallow
(21) Remove bolts attaching crossmember to frame container. Add water and heat for approximately
and remove crossmember. eight minutes after water has come to a boil.
(22) On 4 x 4 models, disconnect speed sensor (c) STEAM: Place ring gear on a flat surface and
wires and vent hose from transfer case. Then remove direct steam flow around gear for approximately 2
transfer case with transmission jack or aid of helper. minutes.
(23) Remove all converter housing bolts.
• TRANSMISSION, CONVERTER, OVERDRIVE REMOVAL/INSTALLATION 21-171
To use the remover tool, First start the tool into

the seal by hand. Next, thread the tool into the seal
as far as it will go. Use a wrench on the tool hex to
turn the tool. Continue tightening until all the tool
threads firmly grip the metal part of the seal. Then
tighten the tool puller screw to withdraw the seal
from the pump body.
Fig. 4 Removing Starter Ring Gear

(2) After ring gear is expanded by heating, imme
diately place gear in position on converter front
Fig. 5 Pump Seal Removal (32RH/42RH)
cover. Wear thick leather work gloves when han
dling the hot ring gear.
(3) Quickly tap gear onto converter evenly with
plastic or rawhide mallet. Continue tapping gear un
til face of gear is even with scribe line on front cover.
(4) Before proceeding, make sure gear is even with
scribed line around full circumference of the front
cover.
(5) The following suggestions are offered as an aid
in tack welding the new ring gear to the converter:
• Do not weld with oxy-acetylene equipment
• Use a D.C. arc welder set at straight polarity, or
an A.C. welder if the proper electrode is available
• Use a 1/8 inch diameter welding rod and a welding Fig. 6 Pump Seal Removal (36RH/37RH/46RH/47RH)
current of 80 to 125 amps
• Direct the arc at the intersection of the gear and Seal Installation
front cover at an angle of 45° from the rear face of On 32RH/42RH pumps, use Installer Tool C-4193
the gear. to install the new seal (Fig. 6).
(6) Tack weld new ring gear to torque converter On 36RH/37RH/46RH/47RH pumps, use Installer
front cover. Take care to place same amount of Tool C-3860-A (Fig. 7).
weld material (or as nearly as possible) in orig To use the tool, place the seal in the pump opening
inal weld locations. This is essential in main with the seal lip facing inward. Then tap the seal
taining converter balance. Position welds into place with the installer tool (Fig. 7). Tool Handle
alternately on opposite sides of converter and C-4171 may be used with the installer tool if desired.
ring gear to minimize distortion.
(7) Inspect gear teeth and remove any nicks, raised CONVERTER AND DRIVE PLATE SERVICE
metal, weld spatter, or rough surfaces. After the transmission has been removed, the drive
plate and torque converter can be replaced or re
PUMP OIL SEAL REPLACEMENT moved for service access.
The torque converter is not a serviceable part. If
Seal Removal the converter is contaminated or damaged in any
On 32RH/42RH pumps, remove the seal with Spe way, it must be replaced as an assembly. Do not at
cial Tool C-3981B (Fig. 5). tempt to flush a converter contaminated by
On 36RH/37RH/46RH/47RH pumps, remove the metal or clutch facing particles. Flushing will
seal with Special Tool C-3861 (Fig. 6). not remove these contaminants.
21 - 172 TRANSMISSION, CONVERTER, OVERDRIVE REMOVAL/INSTALLATION •
J932M80
Fig. 7 Pump Seal Installation

TRANSMISSION INSTALLATION
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks. Fig. 8 Typical Method Of Checking Converter
Polish the hub and notches with 320/400 grit paper Seating
and crocus cloth i f necessary. The hub must be
smooth to avoid damaging pump seal at installation.
(2) Lubricate converter drive hub and oil pump
seal lip with transmission fluid.
(3) Lubricate converter pilot hub with transmission
fluid.
(4) Align and install converter i n oil pump.
(5) Carefully install converter i n oil pump. Be sure
converter is fully seated i n pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 8). Surface of converter lugs should
be 1/2 in. to rear of straightedge when converter is
fully seated.
(7) Temporarily secure converter with C-clamp at
tached to housing or with metal strap attached
across converter housing.
(8) Position transmission on jack and secure i t
with chains.
(9) Check condition of converter driveplate. Re
place the plate i f cracked, distorted or damaged. I f
driveplate replacement was necessary, be sure
transmission dowel pins are seated i n engine
block and protrude far enough to held trans Fig. 9 Torque Converter And Driveplate Markings
mission i n alignment. (14) Install bolts attaching converter housing to
(10) Raise transmission and align converter with engine.
drive plate. (15) Install rear support. Then lower transmission
(11) Move transmission forward. Then raise, lower onto crossmember and install bolts attaching trans
or t i l t transmission to align converter housing with mission mount to crossmember.
engine block dowels. (16) Remove engine support fixture.
(12) Rotate converter so alignment marks scribed (17) Install crankshaft position sensor.
on converter are aligned with mark on driveplate.
(18) Install vehicle speed sensor and speedometer
The offset holes i n plate are next to 1/8 inch hole i n
adapter.
inner circle of plate (Fig. 9).
(19) Install new plastic retainer grommet on any
(13) Carefully work transmission forward and over
shift linkage rod or lever that was disconnected.
engine block dowels until converter hub is seated i n
crankshaft. Grommets should not be reused. Use pry tool to re-
• TRANSMISSION, CONVERTER, OVERDRIVE REMOVAL/INSTALLATION 21 - 173
move rod from grommet and cut away old grommet.

Use pliers to snap new grommet into lever and to
snap rod into grommet at assembly.
(20) Connect gearshift and throttle cable to trans
mission.
(21) Connect wires to park/neutral position switch,
transmission solenoid(s) and oxygen sensor. Be sure
transmission harnesses are properly 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 lockup surface
within the converter. If new bolts are required, u s e
the bolts specified in this procedure and in the
parts book only.
(22) Verify converter bolt length. Bolt measure

ment is from bottom (underside) of bolt head to end
of bolt threads. Fig. 1 Mark Propeller Shaft And Yoke For Alignment
• On 9.5 in., 3-lug converter, bolts should be 11.7 Reference
mm (0.46 in.) long.
• On 9.5 in., 4-lug converter, bolts should be 13.2 (7) Support transmission with transmission jack.
mm (0.52 in.) long. (8) Remove rear crossmember.
• On 10.0 in., 4-lug converter, bolts should be 13.2 (9) Remove vehicle speed sensor and speedometer
mm (0.52 in.) long. adapter.
• On 10.75 in., 4-lug converter, bolts should be 11.2 (10) Remove bolts attaching overdrive unit to
transmission (Fig. 2).
mm (0.44 in.) long.
(23) Install torque converter-to-driveplate bolts. CAUTION: Support the overdrive unit with a jack
• On models with 9.5 in., 3-lug converter, tighten before moving it rearward. This is necessary to pre
bolts to 54 N-m (40 ft. lbs.). vent damaging the intermediate shaft. Do not allow
• On models with 9.5 in., 4-lug converter, tighten the shaft to support the entire weight of the over
bolts to 74 N-m (55 ft. lbs.). drive unit.
• On models with 10.0 in., 4-lug converter, tighten
bolts to 74 N-m (55 ft. lbs.).
• On models with 10.75 in., 4-lug converter, tighten
bolts to 31 N-m (270 in. lbs.).
(24) Install converter housing access cover.
(25) Install starter motor and cooler line bracket.
(26) Connect cooler lines to transmission.
(27) Install transmission fill tube (Fig. 12). Install
new seal on tube before installation.
(28) Install exhaust components.
(29) Align and install propeller shaft.
(30) Adjust gearshift linkage and throttle valve ca
ble i f necessary.
(31) Lower vehicle.
(32) Fill transmission with Mopar ATF Plus, Type
7176 fluid. Mopar Dexron I I can be used when ATF
Plus is not readily available.
OVERDRIVE UNIT REMOVAL Fig. 2 Removing/Installing Overdrive Unit Attaching

(1) Shift transmission into Park.
Bolts
(2) Raise vehicle.
(3) Remove transmission oil pan, remove gasket, (11) Carefully work overdrive unit off intermediate
drain oil and reinstall pan. shaft. Do not tilt compounder during removal. Keep
(4) I f overdrive unit had malfunctioned, or i f fluid it as level as possible.
is contaminated, remove entire transmission. I f diag (a) I f overdrive unit does not require service, im
nosis indicated overdrive clutch or governor problems mediately insert Alignment Tool 6227-2 in
only, remove overdrive unit only. splines of planetary gear and overrunning
(5) Mark propeller shaft universal joint and axle clutch to prevent splines from rotating out of
pinion yoke for alignment reference at installation alignment. I f misalignment occurs, overdrive
(Fig. 1). unit will have to be disassembled in order to
(6) Disconnect and remove propeller shaft. realign splines.
21 - 174 TRANSMISSION, CONVERTER, OVERDRIVE REMOVAL/INSTALLATION
(b) If overdrive unit requires service, refer to (6) Install selective spacer on intermediate shaft, i f
Overdrive Unit Overhaul procedures. removed. Spacer goes i n groove just rearward of
(12) Remove and retain overdrive piston thrust shaft rear splines (Fig. 4).
bearing. Bearing may remain on piston or in clutch
hub during removal.
(13) Position drain pan on workbench.
(14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal
fragments. I f fluid contains these items, overhaul will
be necessary.
(16) I f overdrive unit does not require any service,
leave alignment tool in position. Tool will prevent ac
cidental misalignment of planetary gear and overrun
ning clutch splines.
Fig. 4 Intermediate Shaft Selective Spacer Location
OVERDRIVE UNIT INSTALLATION (7) Install overdrive piston i n retainer (If re
(1) Be sure overdrive unit Alignment Tool 6227-2 is moved). Lubricate piston seals with Ru-Glyde, Door-
fully seated before moving unit. I f tool is not seated Eze or petroleum jelly to ease installation. Be sure
and gear splines rotate out of alignment, overdrive piston locating lugs are aligned in piston retainer.
unit may have to be disassembled in order to realign (8) Install thrust bearing i n overdrive unit sliding
splines. hub. Use petroleum jelly to hold bearing i n position.
(2) I f overdrive piston retainer was not removed CAUTION: Be sure the shoulder on the inside diam
during service and original case gasket is no longer eter of the bearing is facing forward.
reusable, prepare new gasket by trimming i t as de
scribed i n steps (2) through (4). However, i f original (9) Verify that splines i n overdrive planetary gear
gasket is in good condition, proceed to step (5). and overrunning clutch hub are aligned with Align
(3) Cut out old case gasket around piston retainer ment Tool 6227-2. Overdrive unit cannot be in
with razor knife (Fig. 3). stalled if splines are not aligned. I f splines have
(4) Use old gasket as template and trim new gas rotated out of alignment, unit may have to be
ket to fit. disassembled to realign splines.
(5) Position new gasket over piston retainer and on (10) Carefully slide Alignment Tool 6227-2 out of
overdrive planetary gear and overrunning clutch
transmission case. Use petroleum jelly to hold gasket splines.
in place i f necessary. Do not use any type of (11) Raise overdrive unit and carefully slide i t
sealer to secure gasket. Use petroleum jelly straight onto intermediate shaft. Insert park rod into
only. park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could
cause planetary gear and overrunning clutch
splines to rotate out of alignment. I f this oc
curs, it will be necessary to remove and disas
semble overdrive unit to realign splines.
(12) Align slip-fit governor tubes and work over
drive unit forward on intermediate shaft until seated
against transmission case.
(13) Install bolts attaching overdrive unit to trans
mission unit. Tighten bolts in diagonal pattern to 34
N-m (25 ft-lbs).
(14) Install crossmember.
(15) Install speed sensor and speedometer adapter.
Be sure to index adapter.
(16) Connect speed sensor and overdrive wires.
(17) Align and install propeller, shaft.
(18) I f valve body was also removed, adjust bands,
install valve body and install transmission oil pan
Fig. 3 Trimming Overdrive Case Gasket and gasket.
(19) Lower vehicle and refill transmission with Mo
par ATF Plus, Type 7176 transmission fluid. Mopar
Dexron I I can be used i f ATF Plus is not readily
available.
• 32RH TRANSMISSION OVERHAUL 21-175
3 2 R H TRANSMISSION OWERHAUL
INDEX
page page
Extension Housing and Park Lock Component Planetary Gear Train—Output Shaft Overhaul . . . 193
Overhaul 182 Rear Clutch Overhaul 190
Front Clutch Overhaul 188 Rear Servo and Band Overhaul 198
Front Servo and Band Overhaul 198 Transmission Assembly and Adjustment 207
Governor and Park Gear Overhaul 183 Transmission Case Cleaning and Inspection . . . . 181
Oil Pump and Reaction Shaft Support Overhaul . . 185 Transmission Disassembly 175
Overhaul Service Information 180 Valve Body Service and Adjustment . . . . . . . . . . . 199
Overrunning Clutch—Low-Reverse Drum—Rear
Support Overhaul 181
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process.
(2) Remove throttle and shift levers from valve
body manual shaft (Fig. 1).
(3) Mount transmission in repair stand C-3750-B
or similar type stand.
THROTTLE
Fig. 2 Extension Housing Removal (32RH)
J9421-260
Fig. 1 Throttle Valve And Shift Lever

(4) Remove bolts attaching extension housing to
transmission case. Then remove rear bearing locating
ring access cover from housing (Fig. 2)
Fig. 3 Output Shaft Rear Bearing Position (32RH)
(5) Spread rear bearing locating ring with parallel
jaw snap ring pliers (Fig. 2). Then work extension (10) Disconnect solenoid wire from case connector
housing off rear bearing and output shaft. Remove (Fig. 6).
housing gasket after removing housing. (11) Lift valve body upward, guide park rod out of
(6) Remove rear bearing and snap ring from out case opening and remove valve body (Fig. 5).
put shaft (Fig. 3). (12) Remove accumulator spring and piston (Fig.
(7) Remove oil pan bolts and remove pan and gas 8).
ket. (13) Remove front band reaction pin access plug
(8) Remove park/neutral position switch and seal (Fig. 9). Plug is accessible through converter housing.
(Fig. 4). Use 1/4 inch drive extension to remove plug as
(9) Remove hex head valve body attaching bolts shown.
(Fig. 5). (14) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until band
21 176 32RH TRANSMISSION OVERHAUL
VALVE
BODY
ASSEMBLY
J9121-114
Fig. 4 Park/Neutral Position Switch Removal/

installation J9121-117
Fig. 7 Removing/Installing Valve Body (32RH)
ACCUMULATOR PISTON
PISTON SPRING
VALVE BODY VALVE BODY _ 0
ATTACHING BOLTS ATTACHING BOLTS
Fig. 5 Valve Body Attaching Bolt Locations (32RH)

J9121-118
SOLENOID
WIRE Fig. 8 Removing/Installing Accumulator Piston And
Spring (32RH)
FRONT
BAND
REACTION
PIN
ACCESS
PLUG
SIJ9121-119
J9121-116
Fig. 9 Removing/Installing Front Band Reaction Pin
Fig. 6 Solenoid Wire Connection (32RH) Access Plug (32RH)
is tight around front clutch retainer. This prevents (18) Loosen front band adjusting screw until band
front/rear clutches from coming out with pump and is completely loose.
possibly damaging clutch or pump components. (19) Squeeze front band together and remove band
(15) Remove oil pump bolts. strut (Fig. 11).
(16) Thread bolts of Slide Hammer Tools C-3752 (20) Remove front band reaction pin with pencil
into threaded holes i n pump body flange (Fig. 10). magnet. Pin is accessible from converter housing side
(17) Bump slide hammer weights outward to re of case (Fig. 12).
move pump and reaction shaft support assembly (21) Remove front band lever (Fig. 13)
from case (Fig. 10).
• 32RH TRANSMISSION OVERHAUL 21 - 177
Fig. 10 Removing Oil Pump/Reaction Shaft Support Fig. 13 Removing/Installing Front Band Lever
Assembly (32RH) (32RH)
(23) Remove front and rear clutch units as assem
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 14).
Fig. 11 Removing/Installing Front Band Strut (32RH)
J9121-124
Fig. 14 Removing Front/Rear Clutch Assemblies

(32RH)
(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch units aside for overhaul.
Fig. 12 Removing Front Band Reaction Pin (32RH) (25) Remove output shaft thrust washer from out
(22) Slide front band rearward and onto driving put shaft (or from rear clutch hub).
shell. Band will not be removed until after front/rear (26) Remove output shaft thrust plate from output
clutch removal. shaft hub (Fig. 16).
2 1 - 178 32RH TRANSMISSION OVERHAUL
Fig. 17 Front Band Removal/Installation (32RH)
Fig. 15 Separating Front/Rear Clutch Assemblies

(32RH)
Fig. 18 Removing/Installing Governor Body Snap

Ring(32RH)
Fig. 16 Removing/Installing Output Shaft Thrust

Plate (32RH)
(27) Slide front band, off driving shell (Fig. 17) and
remove band from case.
(28) Remove governor body snap ring (Fig. 18).
(29) Remove E-clip from one end of governor valve
shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing i t .
(30) Loosen bolts attaching governor body to park
gear.
(31) Mark position of governor body on park gear
with center punch or scriber.
(32) Remove governor body and park gear as as
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft. Fig. 19 Removing Governor Valve And Shaft (32RH)
• 32RH TRANSMISSION OVERHAUL 21 - 17S
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
Fig. 20 Removing/installing Governor And Park

Gear (32RH)
(33) Remove planetary geartrain as assembly (Fig.
21). Support geartrain with both hands during re
moval. Do not allow machined surfaces on output
shaft to become nicked or scratched.
Fig. 21 Planetary Geartrain Removal (32RH)

(34) Loosen rear band adjusting screw 4-5 turns.
(35) Remove snap ring that secures low-reverse
drum to rear support hub, however do not remove
drum at this time (Fig. 22).
(36) Remove rear band lever pins with parallel jaw
snap ring pliers (Fig. 23). Spread plier jaws in pin
bore to grip pin. Then twist and pull pins to remove
them as shown.
(37) Remove rear band lever, link and strut.
(38) Mark position of rear support for assembly
reference (Fig. 24). Use scriber or center punch to
mark case and support.
(39) Remove rear support bolts and remove sup
port from low-reverse drum and case (Fig. 25). Keep Fig. 24 Marking Rear Support For Assembly Reference
21 - 180 32RH TRANSMISSION OVERHAUL
rear support bolts together for assembly reference.
Fig. 25 Removing Rear Support

(40) Remove bolts attaching overrunning clutch Fig. 27 Compressing Front Servo Rod Guide (32RH)
cam to case (Fig. 26).
(46) Compress rear servo spring retainer about
1/16 in. with C-clamp and Tool C-4470 or SP-5560
(Fig. 28). Valve Spring Compressor C-3422-A can also
be used to compress spring retainer.
(47) Remove rear servo spring retainer snap ring.
Then remove compressor tools and remove rear servo
spring and piston.
Fig. 26 Overrunning Clutch Cam Bolt Locations

(32RH)
(41) Remove low-reverse drum and overrunning
clutch as assembly. Slide drum and clutch through
rear band and out of case. Set drum and clutch as
sembly aside for cleaning and inspection.
(42) Remove rear band from case.
Fig. 28 Compressing Rear Servo Spring (32RH)
(43) Compress front servo rod guide about 1/8 in.
with valve spring compressor tool C-3422-B (Fig. 27). OVERHAUL SERVICE INFORMATION
A C-clamp and tool C-4470 can also be used to com Inspect all the transmission bushings during over
press rod guide. haul. Bushing condition is important as worn, scored
(44) Remove front servo rod guide snap ring (Fig. bushings contribute to low pressures, clutch slip and
27). Exercise caution when removing snap ring. accelerated wear of other components. Do not replace
Servo bore can be scratched or nicked if care is bushings as a matter of course. Replace bushings
not exercised. only when actually worn or scored.
(45) Remove compressor tools and remove front Use recommended tools to replace bushings. The
servo rod guide, spring and servo piston. tools are sized and designed to remove, install and
seat bushings correctly. The bushing replacement OVERRUNNING CLUTCH—LOW-REVERSE

tools are included in Bushing Tool Set C-3887-B. The DRUM—REAR SUPPORT OVERHAUL
tool set is manufactured by the Miller Tool Co. and is
available through the dealer tool program. DISASSEMBLING OVERRUNNING CLUTCH/
Pre-sized service bushings are available for replace L O W - R E V E R S E DRUM
ment purposes. Only the sun gear bushings are not If the clutch assembly came out with the low-re
serviced. Low cost of the sun gear assembly makes it verse drum, thread two clutch cam bolts into the
easier to simply replace the gear and bushings as an cam. Then lift the cam out of the drum with the bolts
assembly. (Fig. 29). Rotate the cam back and forth to ease re
Heli-Coil inserts are recommended for repairing moval if necessary. Remove the clutch roller and
damaged, stripped or worn threads in aluminum spring assembly from the race afterward.
parts. These inserts are available from most automo
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces
sary, providing it is used carefully. When used on
valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve
bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or E -
clips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with Mopar ATF
Plus, Type 7176, or Dexron II transmission fluid dur
ing overhaul and assembly.
Use Mopar Door Ease, or Ru-Glyde to lubricate
Fig. 29 Removing Overrunning Clutch From
clutch piston seals. Use petroleum jelly to lubricate
Low-Reverse Drum (32RH)
O-rings and thrust washers. Petroleum jelly can also
be used to hold parts in place during reassembly. CLEANING AND INSPECTION
Clean the overrunning clutch assembly, clutch cam,
TRANSMISSION CASE CLEANING AND low-reverse drum and rear support in solvent. Dry
INSPECTION them with compressed air after cleaning.
Clean the case in a solvent tank. Flush the case Inspect condition of each clutch part after cleaning.
bores and fluid passages thoroughly with solvent. Replace the overrunning clutch roller and spring as
Dry the case and all fluid passages with compressed sembly if any rollers or springs are worn or damaged,
air. Be sure all solvent is removed from the case and or if the roller cage is distorted, or damaged. Replace
that all fluid passages are clear. the cam if worn, cracked or damaged.
Do not use shop towels or rags to dry the ease Replace the low-reverse drum if the clutch race,
(or any other transmission component) unless roller surface or inside diameter is scored, worn or
they are made from lint-free materials. Lint damaged. Do not remove the clutch race from
will readily adhere to case surfaces and trans
the low-reverse drum under any circumstances.
mission components and will circulate through
Replace the drum and race as an assembly if ei
out the transmission after assembly. A sufficient
ther component is damaged.
quantity of lint can block fluid passages and in
terfere with valve body operation. Examine the rear support carefully for wear,
Inspect the case for cracks, porous spots, worn cracks, scoring or other damage. Be sure the support
bores, or damaged threads. Damaged threads can be hub is a snug fit in the case and drum. Replace the
repaired with Helicoil thread inserts. However, the support if worn or damaged.
case will have to be replaced if it exhibits any type of
ASSEMBLING OVERRUNNING CLUTCH/LOW-
damage or wear.
Lubricate the front band adjusting screw threads R E V E R S E DRUM
with petroleum jelly and thread the screw part-way (1) Assemble clutch rollers and springs in retainer
into the case. Be sure the screw turns freely. if necessary (Fig. 30).
Remount the case in Repair Stand C-3750-B after (2) Install overrunning clutch roller, spring and re
cleaning and inspection. tainer assembly in clutch cam (Fig. 31).
21 - 182 32RH TRANSMISSION OVERHAUL •
RETAINER LOW-REVERSE CLUTCH
DRUM RACE ( O N
HUB O F DRUM)
J9121-139
OVERRUNNING
Fig. 30 Overrunning Clutch Rollers, Springs, CLUTCH
Retainer (32RH) J9121-135
CLUTCH Fig. 32 Temporary Assembly Of Clutch And Drum

ROLLER
ASSEMBLY To Check Operation (32RH)
(5) Remove rear support, overrunning clutch and
low-reverse drum. Set components aside for final as
sembly. I f overrunning clutch will be installed
before final assembly, install cam only as de
scribed in Transmission Assembly And Adjust
ment section. Clutch cam must be properly
indexed in case to fit and operate properly.
LOW-REVERSE DRUM OVERRUNNING
CLUTCH
CAM
CLUTCH C A M
ROLLER
AND
S P R I N G ASSEMBLY
J9121-138
Fig. 31 Assembling Overrunning Clutch And Cam

(32RH) CLUTCH
RACE
(3) Temporarily assemble and check overrunning
clutch operation as follows:
(a) Assemble cam and clutch.
(b) Install clutch assembly on low-reverse drum
with twisting motion (Fig. 32). HUB O F
(c) Install drum-clutch assembly i n case and in LOW-REVERSE
stall clutch cam bolts. DRUM
(d) Install rear support and support attaching

bolts.
J9121-140
(e) Check low-reverse drum rotation. D r u m
should rotate freely in clockwise direction
Fig. 33 Assembled Overrunning Clutch Components
and lock when turned in counterclockwise di (32RH)
rection (as viewed from front of case).
(4) Note component position for assembly refer EXTENSION HOUSING AND PARK LOCK
ence. Bolt holes i n clutch cam are countersunk on COMPONENT OVERHAUL
one side, Be sure this side of cam will face rearward Clean the housing and park lock components i n sol
when installed (Fig. 33). vent and dry them with compressed air.
Inspect the housing bushing, seal and bearing snap shown (Fig. 37). The sprag may not retract i f the
ring (Fig. 34). Replace the bushing i f scored, worn or spring is improperly installed.
damaged. Replace the seal i f cut, torn or distorted.
Replace the snap ring i f distorted or broken.
BEARING
SNAP EXTENSION
RING HOUSING BUSHING
J9121-250
Fig. 34 Extension Housing Components (32RH)

Examine the park lock components i n the housing.
I f replacement is necessary, remove the shaft with
parallel jaw snap ring pliers (Fig. 35) and remove the
sprag and spring. Then remove the spring clip and
reaction plug (Fig. 38).
Compress the reaction p l u g s p r i n g c l i p only
enough to remove or i n s t a l l i t . The c l i p is easily
d i s t o r t e d i f overcompressed. Replace the c l i p i f
it becomes bent or distorted. Do n o t straighten
and reuse the clip i f this occurs.
Be sure a replacement sprag is installed so the
sprag locking lug will face the park gear (Fig. 37).
Also be sure the spring is correctly positioned as
J9121-47
Fig. 37 Correct Position Of Sprag And Spring

(32RH)
GOVERNOR AND PARK GEAR OVERHAUL

GOVERNOR/PARK GEAR DISASSEMBLY
(1) Loosen bolts attaching governor to park gear.
(2) Remove governor snap ring and locating snap
Fig. 35 Park Sprag, Shaft And Spring Remowal
(32RH)
ring from output shaft (Fig. 38).
(8) Remove E-clip securing governor valve shaft SPRJNG
and remove shaft and valve from governor body.
OUTER WEIGHT
(4) Slide governor and park gear off output shaft.
(5) Remove governor retaining bolts and separate
governor from park gear. VALVE SHAFT
(6) Remove governor filter from park gear. Keep SNAP'
RINGS VALVE
filter with governor body.
(7) Remove governor weight snap ring and remove INNER WEIGHT SNAP
weight assembly from governor body. Remove inner RING
snap ring and separate governor weights.
GOVERNOR/PARK GEAR CLEANING AND FILTER SCREEN

INSPECTION
Clean the governor and park gear components i n
solvent and dry with compressed air.
Examine the governor components carefully (Fig.
38). Discard any snap rings or E-clips i f distorted, or
worn. Be sure the governor weights operate freely in
the bores and do not bind. Also verify that the gov
ernor valve slides freely on the shaft and i n the bore.
Minor scratches, or burrs on governor components J9221-51
can be cleaned up with oil-soaked crocus cloth. How
ever, do not attempt to salvage components that are Fig. 38 Governor Components (32RH)
severely worn or scored. REAR FRONT
PARK
There are two governor component changes GEAR SEAL SEAL
on current transmissions that affect service RING RING
procedures. The first change involves the gov
ernor valve. The valve is now made of alumi
num. The second change involves the output
shaft which has been spotfaced for governor
valve end clearance. The new aluminum valve
must only be used with an output shaft that has
a spotface. I n addition, the governor body and
spotfaced side of the valve shaft hole in the out
put shaft must be indexed.
Check condition of the park gear seal rings, ring
grooves and gear teeth (Fig. 39). Replace the gear as
an assembly i f the teeth or ring grooves are worn, or
damaged.
Replace the park gear front and rear seal rings i f
cracked, or worn. The production style front ring is a
plain type and the rear ring is a hook style. I f re
placement rings are both hook-style, be sure the ring
ends are properly hooked together.
ASSEMBLING GOVERNOR AND PARK GEAR

(1) Coat governor body bores and valves with
transmission fluid.
(2) Assemble governor weights and springs. Then
J9121-48
install weight assembly i n governor body but do not
install valve and shaft at this time. These parts are Fig. 39 Park Gear And Seal Rings (32RH)
not installed until after governor and park gear are
ger tight only. Bolts will not be final tightened until
in place on output shaft.
after governor and park gear are mounted on output
(3) Install new seal rings on park gear i f necessary. shaft.
(4) Insert filter screen i n park gear and install gov
ernor body on park gear. Tighten attaching bolts fin-
OIL PUMP AND REACTION SHAFT SUPPORT REACTION

SHAFT
OVERHAUL SUPPORT INNER OUTER
GEAR GEAR
PUMP AND SUPPORT DISASSEMBLY
(1) Remove seal from around pump housing (Fig.
40).
PUMP
HOUSING
SEAL
RING J9321-214
Fig. 43 Pump Gear Removal (32RH)

(6) I f pump seal was not removed during transmis
sion disassembly, remove seal with punch and ham
mer.
(7) Remove front clutch thrust washer from sup
J9321-211
port hub (Fig. 44).
Fig. 40 Hemming Pump Housing Seal (32RH)
OIL PUMP AND REACTION SHAFT SUPPORT
(2) Mark pump housing and support assembly for CLEANING AND INSPECTION
alignment reference. Clean pump and reaction shaft support components
(3) Loosen bolts that attach pump body to support with solvent and dry them with compressed air.
(Fig. 41). Inspect the pump housing and support components.
Replace the housing or support i f the seal ring
SUPPORT grooves or machined surfaces are worn, scored, pit
TO ted, or damaged.
PUMP
BOLTS (6) Replace the pump gears i f pitted, worn chipped, or
damaged. Inspect the thrust washer for wear or dam
age. Replace the washer i f necessary. Note that the
inner gear used in 1993 and later 32RH oil
pumps has a new design drive lug. The new de
sign incorporates drive flats instead of the
square lug used previously. The torque con
J9321-212 verter hub has also been redesigned to accept
the new drive. I f pump gear replacement is nec
Fig. 41 Loosening Pump Support Bolts
essary, be very sure to order and install the
(4) Remove pump-to-support bolts and separate new style gears.
support from pump housing (Fig. 42). Inspect the pump and reaction shaft support bush
ings. Minor bushing wear is acceptable. Replace the
* REACTION PUMP
SHAFT HOUSING bushings only i f scored, or severely worn.
SUPPORT Install the gears i n the pump housing and measure
end clearance with a feeler gauge and straightedge
(Fig. 45). Clearance should be 0.010 - 0.06 mm
(0.0004 - 0.0025 in.).
Measure clearance between the outer gear and the
pump body (Fig. 46). Clearance should be 0.08 - 0.19
mm (0.0035 - 0.0075 in.).
Measure gear tooth clearance with a feeler gauge.
J9321-213
Align one tooth of the outer gear i n inner gear and
Fig. 42 Separating Pump Housing From Reaction measure clearance (Fig. 47). Clearance should be
Shaft Support (32RH) 0.08 - 0.19 mm (0.0035 - 0.0075 in.).
(5) Remove inner and outer gears from reaction R E P L A C I N G OIL PUMP BUSHING
shaft support (Fig. 43). (1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 (Fig. 48).
REACTION SHAFT GASKET

SUPPORT
OIL SEAL
O-RING
SEAL
PUMP HOUSING THIUST
WASHII
J942H51
Fig. 44 Oil Pump And Reaction Shaft Support Components (32RH)
-STRAIGHT EDGE
INNER
GEAR
FEELER
GAUGE
OUTER
GEAR
J9321-215 J9321-217
Fig. 45 Measuring Pump Gear End Clearance (32RH) Fig. 47 Measuring Pump Gear Tooth Clearance
FEELER
(2) Install new pump bushing with Tool Handle
GAUGE C-4171 and Bushing Installer SP-5117 (Fig. 48).
INNER Bushing should be flush with pump housing bore.
GEAR (3) Stake new pump bushing i n two places with
blunt punch (Fig. 49). Remove burrs from stake
points with knife blade afterward.
REPLACING REACTION SHAFT SUPPORT

BUSHING
(1) Assemble Bushing Remover Tools SP-1191,
J9321-216
3633 and 5324 (Fig. 50). Do not clamp any part of
Fig. 46 Measuring Pump Housing-To-Inner Gear reaction shaft or support in vise.
Clearances (2) Hold Cup Tool SP-3633 Firmly against reaction
shaft and thread remover SP-5324 into bushing as
+ 32RH TRANSMISSION OVERHAUL 21 - 187
SPECIAL BUSHING SPECIAL SPECIAL

TOOL REMOVAL TOOL TOOL
C-4171 SP-1191 C-4171
SPECIAL TOOL
PUMP HOUSING SP-3551
SPECIAL
T O O L
BUSHING
A— SP-5325
SPECIAL
TOOL SPECIAL
C-4171 BUSHING
TOOL INSTALLATION
SP-5117
J9221-243
Fig. 50 Replacing Reaction Shaft Support Bushing

(32RH)
BUSHING ASSEMBLING OIL PUMP AND REACTION
SHAFT SUPPORT
J9221-242
(1) Lubricate gear bore i n pump housing with
Fig. 48 Removing Oil Pump Bushing (32RH) transmission fluid.
(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig.
51).
(4) Install outer gear i n pump housing (Fig. 51).
Gear can be installed either way (it is not a one-way
fit).
OUTER
GEAR
PUMP
^/HOUSING
Fig. 49 Staking Oil Pump Bushing

far as possible by hand. Then thread remover tool 3-4
additional turns into bushing with a wrench.
(3) Turn remover tool hex nut down against re WOOD
mover cup to pull bushing from shaft. Clean all chips BLOCKS
from shaft after bushing removal. J9321-219
(4) Lightly grip old bushing in vise or with pliers
Fig. 51 Supporting Pump And Installing Outer Gear
and back remover tool out of bushing. (32RH)
(5) Assemble Bushing Installer Tools C-4171 and
SP-5325 (Fig. 50). (5) Install pump inner gear (Fig. 52).
(6) Slide new bushing onto Installer Tool SP-5325.
CAUTION: The gear is a one-way fit. One side of the
(7) Position reaction shaft support upright on a
gear bore i s chamfered. Install the gear s o the
clean smooth surface. chamfered side faces front.
(8) Align bushing in bore. Then tap bushing into
place until Bushing Installer SP-5325 bottoms. (6) Install new thrust washer on hub of reaction
(9) Clean reaction shaft support thoroughly after shaft support. Lubricate washer with transmission
installing bushing. fluid or petroleum jelly. Thrust washer I.D. is
chamfered on one side. Install washer so cham
fered side faces front.
INNER REACTION
OUTER GEAR SHAFT
PUMP SUPPORT
GEAR HOUSING'
H9321-221
Fig. 54 Assembling Reaction Shaft Support And

Pump Housing (32RH)
J9321-465
(c) Tighten support-to-pump bolts to 20 N-m (15
Fig. 52 Pump Inner Gear installation (32RH) ft. lbs.).
(d) Remove pump assembly from transmission
(7) I f reaction shaft seal rings are being replaced,
case.
install new seal rings on support hub (Fig. 53). Lu
(12) Install new oil seal i n pump with Special Tool
bricate seal rings with transmission fluid or petro C-4193 and Tool Handle C-4171 (Fig. 55). Be sure
leum jelly after installation. Squeeze each ring until seal lip faces inward.
ring ends are securely hooked together. (13) Install new seal ring around pump housing.
Be sure seal is properly seated i n groove.
CAUTION: The reaction shaft support seal rings will
(14) Lubricate lip of pump oil seal with petroleum
break if overspread, or twisted. If new rings are be jelly. Lubricate pump seal with Ru-Glyde or petro
ing installed, spread them only enough for installa leum jelly.
tion. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
SPECIAL
during installation. TOOL
C-4193
SEAL PUMP
RINGS BODY
PUMP
SEAL
J932M83
Fig. 55 Pump Oil Seal Installation (32RH)
SUPPORT
HUB J9321-218
FRONT CLUTCH OVERHAUL
Fig. 53 Huh Seal Ring Position (32RH)

FRONT C L U T C H DISASSEMBLY
(1) Remove waved snap ring and remove pressure
(8) Install reaction shaft support on pump housing plate, clutch plates and clutch discs (Fig. 56).
(Fig. 54). (2) Compress clutch piston spring with Compressor
(9) Align reaction support on pump housing. Use Tool C-3575-A (Fig. 57). Be sure legs of tool are
alignment marks made at disassembly. Or, rotate seated squarely on spring retainer before compress
support until bolt holes i n support and pump housing ing spring.
are all aligned (holes are offset for one-way fit). (3) Remove retainer snap ring and remove com
(10) Install all bolts that attach support to pump pressor tool.
housing. Then tighten bolts finger tight. (4) Remove spring retainer and clutch spring.
(11) Tighten support-to-pump bolts to required (5) Remove clutch piston from clutch retainer.
torque as follows: (6) Remove seals from clutch piston and clutch re
(a) Reverse pump assembly and install i t i n tainer hub. Discard both seals as they are not reus
transmission case. Position pump so bolts are fac able.
ing out and are accessible.
(b) Secure pump assembly i n case with 2 or 3 FRONT CLUTCH INSPECTION
bolts, or with pilot studs. Clean the front clutch components i n solvent and
# _ , 32RH TRANSMISSION OVERHAUL 21 - 189
CLUTCH SPRING
'PISTON RETAINER SNAP RING
SNAP RING (WAVED)
FRONT CLUTCH RETAINER
J9121-144 CLUTCH PLATES'
Fig. 56 Front Clutch Components (32RH)

damaged. Also check action of the check ball i n the
FRONT COMPRESSOR piston retainer. The ball must move freely and not
CLUTCH TOOL C-3575-A
SPRING stick.
Replace the retainer bushing i f worn, scored, or
there is any doubt about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer i f the seal surfaces are seriously scored. I n
spect the retainer check ball (Fig. 58). Be the check
ball moves freely i n its seat.
RETAINER
CHECK BALL
SPRING RETAINER
RETAINER \ ^ SNAP RING
Fig. 57 Compressing Front Clutch Piston Spring

(32RH)
dry them with compressed air only. Do not use rags
or shop towels to dry any of the clutch parts. Lint
from such materials will adhere to the component
surfaces and could restrict or block fluid passages af
ter assembly. J9121-368
Replace the clutch discs i f warped, worn, scored,
burned or charred, or i f the facing is flaking off. Re Fig. 58 Front Clutch Retainer Check Ball Location
place the steel plates i f heavily scored, warped, or (32RH)
broken. Be sure the driving lugs on the plates are i n
REPLACING FRONT CLUTCH RETAINER
good condition. The lugs must not be bent, cracked or
damaged i n any way. BUSHING
Replace the clutch spring and spring retainer i f ei (1) Assemble Tool Handle C-4171 and Bushing Re
ther is distorted, warped or broken. mover SP-3627 (Fig. 59).
Check the lug grooves i n the clutch piston retainer. (2) Insert remover tool i n bushing and drive old
The steel plates should slide freely i n the slots. Re bushing out of retainer (Fig. 59).
place the piston retainer i f the grooves are worn or
(3) Mount Bushing Installer SP-3626 on Tool Han

FRONT
dle C-4171. Then slide new bushing onto installer CLUTCH
tool. RETAINER
(4) Align and install new bushing. Tap bushing
into retainer until installer tool bottoms against re
tainer (Fig. 59).
(5) Remove bushing replacement tools and clean
retainer thoroughly.
SPECIAL SPECIAL SPECIAL SPECIAL
TOOL TOOL TOOL TOOL
C-4171 SP-3627 C-4171 SP-3626
FRONT
CLUTCH J912M46
RETAINER BUSHING
\ Fig. 60 Installing Front Clutch Piston (32RH)
FEELER GAUGE
BUSHING BUSHING
REMOVAL INSTALLATION
J9221-246
Fig. 59 Replacing Front Clutch Retainer Bushing

(32RH)
ASSEMBLING FRONT CLUTCH
(1) Lubricate clutch plates and soak clutch discs i n
transmission fluid.
(2) Install new seals on piston and i n hub of re
tainer. Be sure lip of each seal faces interior of clutch
retainer.
(3) Lubricate lip of piston and retainer seals with
liberal quantity of Door Eze, or petroleum jelly. Then
J /L
lubricate retainer hub, bore and piston with trans
mission fluid. f 1
(4) Install clutch piston i n retainer (Fig. 60). Use
twisting motion to seat piston in bottom of retainer.
Do not attempt to push the piston straight in.
This could fold the seals over causing leakage
7
FEELER GAUGE RH288
and clutch slip.
(5) Position spring on clutch piston. Then place Fig. 61 Measuring Front Clutch Pack Clearance
spring retainer on top of spring. REAR CLUTCH OVERHAUL
(6) Compress return spring and spring retainer
with Compressor Tool C-3575-A. Then install new R E A R CLUTCH DISASSEMBLY
snap ring to secure spring retainer. (1) Remove fiber thrust washer from forward side
(7) Install clutch plates and discs (Fig. 56). Install of clutch retainer.
steel plate then disc until all plates and discs are in (2) Remove selective clutch pack snap ring (Fig.
stalled. 4 clutch discs are required. 62).
(8) Install pressure plate and waved snap ring (3) Remove top pressure plate, clutch discs, steel
(Fig. 56). plates, bottom pressure plate and wave spring (Fig.
(9) Check clutch pack clearance (Fig. 61). Clear 62).
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.) (4) Remove clutch piston with rotating motion.
with 4-disc clutch. I f clearance is incorrect, clutch (5) Remove and discard piston seals.
pack components may have to be changed. (6) Remove input shaft snap ring (Fig. 63).
32RH TRANSMISSION OVERHAUL 21 - 191
Fig. 62 Rear Clutch Components (32RH)
J912M50
Fig. 64 Pressing Input Shaft Out Of Rear Clutch

Retainer (32RH)
Fig. 63 Removing/installing Input Shaft Snap Ring
materials will adhere to component surfaces and
(32RH)
could restrict or block fluid passages after assembly.
(7) Press input shaft out of retainer with shop Replace the clutch discs i f warped, worn, scored,
press and suitable size press tool (Fig. 64). burned/charred, the lugs are damaged, or i f the fac
(8) Remove input shaft front/rear seal rings. ing is flaking off. Replace the top and bottom pres
sure plates i f scored, warped, or cracked. Be sure the
REAR C L U T C H INSPECTION driving lugs on the pressure and clutch plates are
Clean the clutch components with solvent and dry also i n good condition. The lugs must not be bent,
them with compressed air. Do not use rags or shop cracked or damaged i n any way.
towels to dry any of the clutch parts. Lint from such Replace the piston spring and wave spring i f either
part is distorted, warped or broken.
Check the lug grooves i n the clutch retainer. The that ends of rear ring are securely hooked together.
clutch and pressure plates should slide freely i n the Lubricate both rings with light coat of petroleum
slots. Replace the retainer i f the grooves are worn or jelly after installation.
damaged. Also check action of the check balls i n the
retainer and piston. Each check ball must move
freely and not stick.
Replace the retainer bushing i f worn, scored, or
doubt exists about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer i f the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer i f worn or damaged.
Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
i f worn, distorted, or damaged. The input shaft front
seal ring is teflon with chamfered ends. The rear ring
is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace
the shaft i f worn, scored or damaged i n any way.
ASSEMBLING REAR CLUTCH J9121-151

(1) Soak clutch discs and steel plates i n transmis
sion fluid. Fig. 66 Input Shaft Seal Ring Identification (32RH)
(2) Install new seal rings on clutch retainer hub (3) Lubricate splined end of input shaft and clutch
and input shaft (Fig. 65). retainer with transmission fluid. Then press input
(a) Be sure clutch hub seal ring is fully seated i n shaft into retainer (Fig. 67).
groove and is not twisted. (4) Install input shaft snap ring (Fig. 63).
(b) Note that input shaft front seal ring is teflon
and rear seal ring is metal (Fig. 66). Be sure cham
fered ends of teflon ring are properly joined and
Fig. 67 Pressing Input Shaft Into Rear Clutch

J9121-538 Retainer (32RH)
Fig. 65 Rear Clutch Retainer And Input Shaft Seal
Ring Installation (32RH)
(5) Install new seals on clutch piston. Be sure lip

of each seal faces interior of clutch retainer.
(6) Lubricate lip of piston seals with liberal quan
tity of Door Eze, or petroleum jelly. Then lubricate
retainer hub and bore with transmission fluid.
(7) Install clutch piston i n retainer. Use twisting
motion to seat piston i n bottom of retainer. Do n o t
attempt to push the p i s t o n s t r a i g h t in. This
c o u l d fold the-seals over causing leakage a n d
c l u t c h slip.
(8) Install piston spring i n retainer and on top of
piston (Fig. 68). Concave side of spring faces down
ward (toward piston).
(9) Install wave spring i n retainer (Fig. 68). Be
sure spring is completely seated i n retainer groove.
FigB 69 Typical Method Of Checking Rear Clutch

Pack Clearance
Fig. 68 Piston And Wave Spring Position (32RH)

(10) Install bottom pressure plate (Fig. 62). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.
(11) Install first clutch disc i n retainer on top of
bottom pressure plate. Then install a clutch plate fol
lowed by a clutch disc until entire clutch pack is in
stalled. Total of 4 discs and. 3 plates are required
(Fig. 62). Fig, 70 Installing Rear Clutch Thrust Washer (32RH)
(12) Install top pressure plate (Fig. 62). PLANETARY GEAR TRAIN—OUTPUT SHAFT
(13) Install selective snap ring (Fig. 62), Be sure
snap ring is fully seated i n retainer groove.
OVERHAUL
(14) Measure clutch pack clearance (Fig. 69). P L A N E T A R Y G E A R T R A I N D I S A S S E M B L Y (FIO.
Clearance should be 0.81 - 1.40 mm (0.032 - 0.055 71) .
in.). I f clearance is incorrect, steel plates, discs, snap (1) Remove snap ring, tabbed thrust washer and
ring and pressure plates may have to be changed. thrust plate from front of output shaft.
(15) Coat rear-clutch fiber thrust washer with pe (2) Remove front annulus gear and support assem
troleum jelly and install washer over input shaft and bly.
into clutch retainer (Fig. 70). Use enough petroleum (3) Remove front planetary front thrust washer.
jelly to hold washer in place. (4) Remove front planetary gear.
(16) Set rear clutch aside for installation during fi (5) Remove front planetary rear thrust washer.
nal assembly. (6) Remove sun gear and driving shell.
SELECT FRONT SUPPORT ANNULUS GEAR FRONT SUN SUN DRIVING SHELL FRONT DRIVING
FIT ANNULUS SNAP RING SUPPORT PLANETARY GEAR GEAR THRUST PLATE SHELL
PLANETARY SNAP THRUST SPACER
SNAP RING WASHERS
RING
(4 TAB)
FRONT
ANNULUS
THRUST
WASHER
DRIVING
SHELL
REAR
THRUST
PLATE
OUTPUT
SHAFT
THRUST OUTPUT SHAFT J942M65
PLATE (4X2 VERSION)
Fig. 71 Planetary Geartrain Components (32RH)

(7) Remove snap ring that retains sun gear in driv Inspect the output shaft carefully. Pay particular
ing shell and remove sun gear and thrust plates. attention to the machined bushing/bearing surfaces
Note thrust plate position for assembly reference. on the shaft and the governor valve shaft bore at the
(8) Remove tabbed thrust washer from rear plane shaft rear.
tary gear. Replace the output shaft if the machined surfaces
(9) Remove rear planetary gear from rear annulus are scored, pitted, or damaged in any way. Also re
gear and remove annulus gear from output shaft. place the shaft if the splines are damaged, or exhib
(10) Remove snap rings that secure annulus gears its cracks at any location (especially at the governor
to supports and separate each gear from the support. valve shaft bore).
PLANETARY GEARTRAIN INSPECTION ASSEMBLING PLANETARY GEARTRAIN

Clean the planetary components in solvent and dry (1) Lubricate output shaft and planetary compo
them with compressed air. nents with transmission fluid. Use petroleum jelly to
Check sun gear and driving shell condition. Re lubricate and hold thrust washers and plates in posi
place the gear if damaged or if the bushings are tion.
scored or worn. The bushings are not serviceable. Re (2) Assemble rear annulus gear and support if dis
place the driving shell if worn, cracked or damaged. assembled. Be sure support snap ring is seated and
Replace planetary gear sets if gears, pinion pins, or that shoulder-side of support faces rearward (Fig.
carrier are damaged in any way. Replace the annulus 72).
gears and supports if either component is worn or (3) Install rear thrust washer on rear planetary
damaged. gear (Fig. 72). Use enough petroleum jelly to hold
Inspect the geartrain spacers, thrust plates, snap washer in place. Also be sure washer tabs are prop
rings, and thrust washers. Replace any of these parts erly engaged in gear slots.
that are worn, distorted or damaged. Do not attempt (4) Install rear annulus over and onto rear plane
tary gear (Fig. 72).
to reuse these parts.
(5) Install assembled rear planetary and annulus
gear on output shaft (Fig. 73). Verify that assembly is
fully seated on shaft.
• 32RH TRANSMISSION OVERHAUL
(7) Install spacer on sun gear (Fig. 75).
Fig. 72 Assembling Rear Annulus And Planetary

Gear (32RH)
Fig. 75 Installing Spacer On Sun Gear (32RH)
(8) Install thrust plate on sun gear (Fig. 76). Note
that driving shell thrust plates are interchangeable.
Use either plate on sun gear and at front/rear of
shell.
Fig. 73 installing Assembled Rear Annulus And

Planetary Gear On Output Shaft (32RH)
(6) Install front thrust washer on rear planetary

gear (Fig. 74). Use enough petroleum jelly to hold
washer on gear.
Fig. 76 Installing Driving Shell Front Thrust Plate
On Sun Gear (32RH)
(9) Hold sun gear in place and install thrust plate
over sun gear at rear of driving shell (Fig. 77).
(10) Position wood block on bench and support sun
gear on block (Fig. 78). This makes it easier to align
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.
(11) Align rear thrust plate on driving shell and in
stall sun gear lock ring. Be sure ring is fully seated
in sun gear ring groove (Fig. 79).
(12) Install assembled driving shell and sun gear
on output shaft (Fig. 80).
Fig. 74 Installing Rear Planetary Front Thrust

Washer (32RH)
SUN SUN GEAR/

DRIVING GEAR DRIVING SHELL
SHELL ASSEMBLY
REAR OUTPUT
THRUST SHAFT
PLATE J912M62 J9121-165
Fig. 77 Installing Driving Shell Rear Thrust Plate Fig. 80 Installing Assembled Sun Gear And Driving
(32RH) Shell On Output Shaft (32RH)
(13) Install rear thrust washer on front planetary
washer on gear and be sure washer tabs are all prop
SUN erly seated.
GEAR
FRONT
PLANETARY
REAR GEAR
TABBED
THRUST
WASHER
WOOD
BLOCK
DRIVING
SHELL J912M63
Fig. 78 Supporting Sun Gear On Wood Block (32RH)
SUN J912M66
LOCK GEAR
RING LOCK
GROOVE RING Fig. 81 Installing Rear Thrust Washer On Front
Planetary Gear (32RH)
(14) Install front planetary gear on output shaft
REAR
THRUST and i n driving shell (Fig. 82).
PLATE (15) Install front thrust washer on front planetary
washer i n place on gear and be sure washer tabs are
seated.
(16) Assemble front annulus gear and support. Be
sure support snap ring is seated.
DRIVING
SHELL (17) Position thrust plate on front annulus gear
J912VI64_ support (Fig. 83). Use enough petroleum jelly to hold
thrust plate i n place.
Fig. 79 Installing Sun Gear Lock Ring (32RH) (18) Install front annulus assembly on front plane
tary gear (Fig. 82).
(19) Install front annulus thrust washer (Fig. 84).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
• 32RH TRANSMISSION OVERHAUL 21 197
(20) Install front annulus snap ring (Fig. 85). Use

snap ring pliers to avoid distorting ring during in
stallation. Also be sure ring is fully seated.
Fig. 82 Installing Front Planetary And Annulus

Gears (32RH)
Fig. 85 Installing Front Annulus Snap Ring (32RH)

(21) Install planetary selective snap ring with snap
ring pliers (Fig. 86). Be sure ring is fully seated.
SELECTIVE
Fig. 83 Positioning Thrust Plate On Annulus

Support (32RH)
Fig. 86 Installing Planetary Selective Snap Ring

(32RH)
(22) Turn planetary geartrain assembly over so
driving shell is facing workbench. Then support
geartrain on wood block positioned under forward
end of output shaft. This allow geartrain components
to move forward for accurate end play check.
(23) Check planetary geartrain end play with
feeler gauge (Fig. 87). Gauge goes between shoulder
on output shaft and end of rear annulus support.
(24) Geartrain end play should be 0.127 to 1.22
mm (0.005 to 0.048 in.). I f end play is incorrect, snap
ring (or thrust washers) may have to be replaced.
Fig. 84 Installing Front Annulus Thrust Washer
Snap ring is available i n three different thicknesses
(32RH) for adjustment purposes.
SERVO
PISTON
RING J912M72
Fig. 87 Checking Planetary Geartrain End Play Fig. 88 Front Servo Components (32RH)
(32RH) REAR SERVO AND BAND OVERHAUL
FRONT SERVO AND BAND OVERHAUL
R E A R S E R V O PISTON DISASSEMBLY
F R O N T S E R V O DISASSEMBLY (FIG. 88) (1) Remove seal from servo piston. Note which way
(1) Remove small snap ring from servo piston. seal lip faces for assembly reference.
(2) Remove piston, rod, springs and guide. (2) Compress cushion spring in vise only enough to
(3) Remove and discard servo piston rings and O- allow piston plug snap ring removal (Fig. 89). Use
ring. wood block between vise jaws and end of piston plug
to keep plug aligned and in position.
F R O N T S E R V O AND BAND INSPECTION (3) Remove snap ring from end of piston plug (Fig.
Clean the servo components with solvent and dry 89).
them with compressed air. (4) Open vise and remove wood block, piston plug,
Inspect the servo components. Replace the springs cushion spring and servo piston.
if collapsed, distorted or broken. Replace the guide,
rod and piston if cracked, bent, or worn. Discard the
servo snap ring if distorted or warped.
Replace the front band if distorted, the lining is
burned or flaking off, or excessively worn.
Check the servo piston bore for wear. Replace the
piston and rod as an assembly if either part is worn
or damaged.
Replace any servo component if doubt exists about
its condition. Do not reuse suspect parts.
ASSEMBLING F R O N T S E R V O PISTON
(1) Lubricate seal rings and O-rings with petro
leum jelly. Lubricate other servo parts with transmis
sion fluid.
(2) Install new O-ring on servo piston rod.
(3) Install new seal on piston rod guide and install Fig. 89 Removing/Installing Servo Piston Plug Snap
new seal rings on piston. Ring (32RH)
(4) Assemble rod, piston, servo springs and snap
ring (Fig. 88).
REAR SERVO INSPECTION BE SURE

Clean the servo components with solvent and dry SEAL LIP
IS TOWARD
them with compressed air. SERVO BORE
Check rear band condition. Eeplace the band i f dis
torted, the lining is burned or flaking off, or the lin
ing is excessively worn.
Check the band reaction pins. Replace the O-rings REAR
on both pins. Minor pin scoring can be cleaned up SERVO
with crocus cloth. However, replace the pins if worn, PISTON
severely scored, or cracked. J9121-175
Inspect the servo components (Fig. 90). Replace the
servo and cushion springs if collapsed, distorted or Fig. 91 Installing Rear Servo Piston Seal (32RH)
broken. Replace the plug or piston if cracked, bent, or
worn. Discard the servo snap ring and spring re not u s e force at any time. The valves and valve
tainer if distorted or warped. body will be damaged if force is used. Also tag or
mark the valve body springs for reference a s they
If doubt exists about the condition of any servo
are removed. Do not allow them to become inter
component, replace it. Do not reuse suspect parts.
mixed.
SPRING
RETAINER MANUAL CONVERTER
LEVER CLUTCH
SERVO MODULE
SPRING AND TUBE
PISTON
PLUG
SERVO
SNAP
CUSHION RING
SPRING
PISTON MANUAL
PLUG VALVE
SNAP
RING
CONVERTER
SOLENOID CLUTCH
WIRE SOLENOID
SERVO
PISTON J912M73
PARK
ROD
Fig. 90 Rear Servo Components (32RH) J932M25
ASSEMBLING REAR SERVO PISTON

Fig. 92 Valve Body Assembly (32RH)
(1) Assemble piston plug, cushion spring and pis
ton (Fig. 90). (1) Remove screws attaching adjusting screw
(2) Compress cushion spring in vise and install pis bracket to valve body and transfer plate. Hold
ton plug snap ring (Fig. 90). bracket firmly against spring force while removing
(3) Install new seal on piston. Be sure seal lip is last screw.
toward servo bore (Fig. 91). (2) Remove adjusting screw bracket, line pressure
(4) Lubricate piston seal with petroleum jelly. Lu adjusting screw, pressure regulator spring and switch
bricate other servo parts with transmission fluid. valve spring (Fig. 93). Do not remove throttle
pressure adjusting screw from bracket and do
VALVE BODY SERVICE AND ADJUSTMENT not disturb adjusting screw settings during re
moval.
VALVE BODY DISASSEMBLY
(3) Secure detent ball and spring in housing with
CAUTION: Do not clamp any part of the valve body Retainer Tool 6583 (Fig. 94).
assembly (Fig. 92) in a vise. This practice will dis (4) Remove manual shaft E-clip and washer (Fig.
tort the valve body and transfer plate resulting in 95).
valve bind. Slide valves and plugs out carefully. Do
UNE THROTTLE (8) Remove park rod E-clip and separate rod from
PRESSURE PRESSURE manual lever (Fig. 96).
REGULATOR ADJUSTING
VALVE SCREW A N D MANUAL
SPRING BRACKET LEVER
LINE
PRESSURE
ADJUSTING
SCREW
SWITCH
VALVE
SPRING J9121-176
Fig. 93 Adjusting Screw Bracket And Spring PARK

ROD J9121-81
Removal (32RH)
SPECIAL
Fig. 96 Park Rod Removal (32RH)
TOOL 6583 (9) Remove screws attaching converter clutch mod
ule to valve body and remove module and connecting
tube (Fig. 97).
MODULE
A N D CONNECTING TUBE
DETENT BALL A N D SPRING HOUSING J932M21
Fig. 94 Securing Detent Ball And Spring With

Retainer Tool
(5) Pull manual shaft and park rod assembly up
J9121-178
ward out of valve body and off throttle lever (Fig.
95). Fig. 97 Converter Clutch Module And Connecting
(6) Remove retainer tool and remove detent ball Tube Removal/Installation (32RH)
and spring (Fig. 95).
(7) Remove throttle lever (Fig. 95). (10) Turn valve body over so transfer plate is fac
ing upward (Fig. 98). With valve body in this posi
SHUTTLE tion, valve body check balls will remain in place and
VALVE PARK
END PLATE ROD
not fall out when transfer plate is removed.
(11) Remove screws attaching transfer plate to
valve body (Fig. 98).
(12) Remove transfer plate and separator plate
THROTTLE from valve body. Note position of filter and converter
MANUAL
LEVER
LEVER clutch solenoid for reference (Fig. 99).
(13) Position transfer plate on bench so separator
plate, filter and clutch solenoid are facing up. This
will avoid having rear clutch and rear servo check
balls fall out when plates are separated.
(14) Remove screws attaching separator plate to
transfer plate.
MANUAL 1/ LEVER
LEVER K WASHER
DETENT BALL A N D E-CLIP
A N D SPRING
J912M77
Fig. 95 Removing Manual And Throttle Levers
32RH TRANSMISSION OVERHAUL 21 201
VALVE
BODY CONVERTER
VALVE SCREWS CLUTCH
BODY SOLENOID
SCREWS
VALVE
BODY
SCREWS
J932M22
VALVE
Fig. 100 Removing Converter Clutch Solenoid (32RH)
BODY
SEPARATOR
PLATE
TRANSFER
PLATE J912M81
Fig. 98 Valve Body-To-Transfer Plate Screw

Locations (32RH)
TRANSFER
PLATE
TRANSFER
PLATE
CONVERTER
CLUTCH
SOLENOID
VALVE REAR CLUTCH
BODY J9321-124 CHECK BALL
Fig. 99 Transfer Plate Removal/Installation (32RH)

(15) Remove converter clutch solenoid from separa
tor plate (Fig. 100).
(16) Note position of filter, clutch solenoid and rear J9121-182
clutch/rear servo check balls for assembly reference
(Fig. 101). Fig. 101 Transfer And Separator Plates (32RH)
(17) Remove shuttle valve end plate (Fig. 102). (22) Remove 1-2 and 2-3 shift valve governor plugs
(18) Remove shuttle valve E-clip and remove secondary from valve body (Fig. 103).
spring and spring guides from end of valve (Fig. 102). (23) Remove shuttle valve throttle plug, primary
spring and shuttle valve from valve body (Fig. 103).
(24) Remove 1-2 shift control valve and spring
from valve body (Fig. 104).
(25) Remove 2-3 shift valve and spring from valve
body (Fig. 104).
(26) Remove 1-2 shift valve and spring from valve
body (Fig. 104).
(27) Remove regulator valve end plate (Fig. 104).
(28) Remove regulator valve line pressure plug,
pressure plug sleeve, throttle pressure plug and
spring (Fig. 104).
VALVE BODY CLEANING AND INSPECTION

The only serviceable valve body components are:
• park lock rod and E-clip
• switch valve and spring
Fig. 102 Shuttle Valve E-C//p And Secondary Spring • pressure adjusting screw bracket
Location (32RH) • throttle valve lever
(19) Remove governor valve end plate (Fig. 103). • manual shaft
(20) Remove switch valve and pressure regulator • manual shaft seal, washer, E-clip and detent ball
valve from valve body (Fig. 103). • fluid filter.
(21) Remove throttle valve and spring, kickdown valve • converter clutch solenoid
and detent and manual valve from valve body (Fig. 103). The remaining valve body components are serviced
only as part of a complete valve body assembly.
END PLATE J9121-50
Fig. 103 Control Valves And Governor Plugs (32RH)

REGULATOR
REGULATOR VALVE
VALVE SPRING
THROTTLE
PRESSURE
PLUG
SLEEVE
LINE
PRESSURE
PLUG
REGULATOR
VALVE
END
PLATE
2-3 SHIFT
SHIFT VALVE VALVE AND
SPRING J9121-180
END PLATE
Fig. 104 Shift Valves And Pressure Regulator Plugs (32RH)
Clean the valve body components in a parts clean (or by testing with a magnet). DO NOT polish or
ing solution only. Do not use gasoline, kerosene, or sand aluminum valves or plugs with any type of
any type of caustic solution. Dry the parts with com material, or under any circumstances. This practice
pressed air. Make sure all passages are clean and will remove the special coating and c a u s e the
free from obstructions. valves and plugs to stick and bind.
Do not use rags or shop towels to wipe off
valve body components. Lint from these materi Inspect the valves and plugs for scratches, burrs,
als will adhere to the valve body components. nicks, or scores. Also inspect the coating on the alu
Lint will interfere with valve operation and minum valves and plugs (Fig. 105). If the coating is
may clog filters and fluid passages. damaged or worn through, the valve (or valve body)
Inspect the throttle and manual valve levers and should be replaced.
shafts. Do not attempt to straighten a bent shaft or Aluminum valves and plugs must not be sanded or
correct a loose lever. Replace these components if polished under any circumstances. However, minor
worn, bent, loose or damaged in any way. burrs or scratches on steel valves and plugs can be
Inspect all of the valve body mating surfaces for removed with crocus cloth but do not round off the
scratches, nicks, burrs, or distortion. Use a straightedge valve or plug edges. Squareness of these edges is vi
to check surface flatness. Minor scratches may be re tally important. These edges prevent foreign matter
moved with crocus cloth using only very light pressure. from lodging between the valves, plugs and bore.
Minor distortion of a valve body mating surface Inspect all the valve and plug bores in the valve body.
may be corrected by smoothing the surface with cro Use a penlight to view the bore interiors. Replace the
cus cloth. The cloth should be in sheet form and be valve body if any bores are distorted or scored. Inspect
positioned on a surface plate, sheet of plate glass, or all of the valve body springs. The springs must be free
equally flat surface. However, if distortion is severe of distortion, warpage or broken coils.
or any surfaces are heavily scored, the valve body
Trial fit each valve and plug in its bore to check free
will have to be replaced.
dom of operation. When clean and dry, the valves and
CAUTION: The throttle valve, shuttle valve plug, 1-2 plugs should drop freely into the bores. Valve body bores
shift valve and 1-2 governor plug are made of do not change dimensionally with use. If the valve body
coated aluminum. These components are identified functioned correctly when new, it will continue to oper
in Figure 105 with the abbreviation (Alum.). Alumi ate properly after cleaning and inspection. It should not
num components can be identified by the dark be necessary to replace a valve body assembly unless it
color of the special coating applied to the surface is damaged in handling.
SHIFT VALVE 2-3 SHIFT SHUTTLE VALVE
END PLATE VALVE AND SECONDARY SPRING,
SPRING GUIDES, E-CLIP
1-2 SHIFT
CONTROL VALVE
AND SPRING
REGULATOR
VALVE
END PLATE
SHUTTLE VALVE
COVER
REGULATOR
VALVE
PRESSURE
PLUG
SLEEVE
2-3 SHIFT
VALVE GOVERNOR
PLUG
REGULATOR
VALVE THROTTLE
PRESSURE PLUG
SHUTTLE VALVE
PLUG (ALUM.)
GOVERNOR
VALVE END
PLATE
MODULE
AND
CONNECTING
TUBE
MANUAL LEVER
DETENT BALL
PRESSURE AND SPRING
LINE THROTTLE SWITCH REGULATOR
PRESSURE ADJUSTING PRESSURE VALVE VALVE
ADJUSTING SCREW ADJUSTING AND AND
SCREW BRACKET SCREW SPRING SPRING J9121-369
Fig. 105 Valve Body Components (32RH) (Alum. Indicates Aluminum Part)
V A L V E BODY ASSEMBLY 1/4" CHECK BALLS (6)
CAUTION; Do not force the 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 s c r e w s during reassembly.
Overtightening can distort the valve body resulting
in valve sticking, c r o s s leakage and unsatisfactory
operation. Tighten valve body s c r e w s to recom
mended torque only.
(1) Lubricate valve body bores, valves and plugs

with transmission fluid.
(2) Insert rear clutch and rear servo check balls i n
transfer plate (Fig. 100).
(3) Install filter screen in separator plate (Fig.
100).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep 11/32" CHECK BALL (1) J912M83
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid Fig. 107 Correct Position Of Valve Body Check Balls
and insert solenoid in separator plate (Fig. 106). (32RH)
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 104).
(11) Install 1-2 shift control valve and spring (Fig.
104)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve i n bore.
(b) Insert plastic guides i n shuttle valve second
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve i n place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 103).
Tighten end plate screws to 4 N-m (35 in. lbs.)
Fig. 106 Installing Converter Clutch Solenoid (32RH)
torque.
(6) Position valve body so internal passages and (14) Install 1-2 and 2-3 valve governor plugs i n
check ball seats are facing upward. Then install valve body (Fig. 103). Then install shuttle valve pri
check balls in valve body (Fig. 107). There are a total mary spring and throttle plug.
of seven check balls; The one large check ball is ap (15) Align and install governor plug end plate on
proximately 11/32 inch i n diameter. The remaining valve body and install end plate screws. Tighten
check balls are approximately 1/4 inch i n diameter.
screws to 4 N-m (35 in. lbs.) torque.
(7) Align and install assembled transfer and sepa
(16) Install manual valve (Fig. 103).
rator plates on valve body. Install and tighten valve
(17) Install throttle valve and spring. Then install
body screws alternately in a diagonal pattern to 4
N-m (35 in. lbs.) torque. kickdown valve and detent (Fig. 103).
(8) Assemble converter clutch module and valves. (18) Install pressure regulator valve and switch
Then install assembly on valve body (Fig. 108). valve in valve body.
(9) Assemble regulator valve line pressure plug, (19) Install manual lever detent spring i n housing.
sleeve, throttle plug and spring (Fig. 104). Insert as Place detent ball on end of spring and push ball and
sembly i n valve body and install end plate. Tighten spring into housing. Secure ball and spring with De
end plate screws to 4 N*m (35 in. lbs.) torque. tent Retainer 7684 or C-3765 (Fig. 94).
MODULE
J932M23
Fig. 108 Converter Clutch Module Components (32RH)

(20) Insert line pressure adjusting screw i n adjust
ing screw bracket (Fig. 93).
(21) Install spring on end of line pressure regula
tor valve.
(22) Install switch valve spring on tang at end of
adjusting screw bracket (Fig. 94).
(23) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify that valve springs and
bracket are properly aligned. Then tighten all three
bracket screws to 4 N-m (35 in. lbs.) torque.
(24) Install converter clutch module and connect
ing tube. Be sure long end of tube goes to module
(Fig. 97). Tighten module screws to 4 N-m (35 i n .
lbs.) torque.
Fig. 109 Manual And Throttle Lever Alignment
(25) Install throttle lever i n valve body. Then in (32RH)
stall manual lever over throttle lever and start man
ual lever into valve body. (30) I f line pressure and/or throttle pressure ad
(26) Align manual lever detent with detent ball justment screw settings were not disturbed, continue
and align lever arm with manual valve. Hold throttle with overhaul or reassembly. However, i f adjustment
lever upward. Then press down on manual lever un screw settings w e r e moved or changed, readjust as
t i l lever is fully seated. described i n Valve Body Control Pressure Adjustment
(27) Install manual lever seal, washer and retain procedure.
ing E-clip.
(28) Lubricate shaft of manual lever with light V A L V E BODY CONTROL PRESSURE
coat of petroleum jelly. This will help protect seal lip ADJUSTMENTS
when manual shaft seal is installed. There are two control pressure adjustments on the
(29) Verify that throttle lever is aligned with end valve body which are, line pressure and throttle pres
of kickdown valve stem and that manual lever arm is sure.
engaged i n manual valve (Fig. 109).
32RH TRANSMISSION OVERHAUL 21 - 207
The two pressures are interdependent because each

affects shift quality and timing. Each pressure ad
justment must be performed properly and i n the cor
rect sequence. The correct sequence is line pressure
adjustment first and throttle pressure adjustment
last.
Line Pressure Adjustment

Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 110).
Distance should be 33.4 mm (1-5/16 in.).
I f adjustment is required, t u r n the adjusting screw
in, or out, to obtain required distance setting.
The 33.4 m m (1-5/16 in.) s e t t i n g is an approxi
mate setting. Because o f m a n u f a c t u r i n g toler Fig. 111 Throttle Pressure Adjustment (32RH)
ances, i t may be necessary t o v a r y from this
dimension to o b t a i n desired pressure. TRANSMISSION ASSEMBLY AND ADJUSTMENT
One complete turn of the adjusting screw changes
Assembly Tips
line pressure approximately 1-2/3 psi (9 kPa). Turn
ing the adjusting screw counterclockwise increases Do not allow dirt, grease, or foreign material to en
pressure while turning the screw clockwise decreases ter the case or transmission components during as
pressure. sembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for assembly are equally clean.
Shop towels used for wiping off your hands and
service tools must be made of lint free materials.
Lint will adhere to transmission parts and could in
terfere with valve operation, or even restrict fluid
passages.
Lubricate the transmission components with ATF
Plus, or Dexron II™ during reassembly. Use petro
leum jelly, Door Eze, or Ru-Glyde on seals and
O-rings to ease installation.
Petroleum jelly can also be used to hold thrust
washers and plates i n position during assembly oper
ations. However, do not use chassis grease, bearing
grease, white grease, or similar lubricants on any
transmission. part. These types of lubricants can
Fig. 110 Line Pressure Adjustment (32RH) eventually block or restrict fluid passages and valve
operation. Use petroleum jelly only.
Throttle Pressure Adjustment
Do not force parts into place. Most of the transmis
Insert Gauge Tool C-3763 between the throttle le sion components are easily installed by hand when
ver cam and the kickdown valve stem (Fig. 111). properly aligned. I f a part seems extremely difficult
Push the gauge tool inward to compress the kick- to install, i t is either misaligned or incorrectly assem
down valve against the spring and bottom the throt bled. Also verify that thrust washers, thrust plates
tle valve. and seal rings are correctly positioned before assem
Maintain pressure against kickdown valve spring. bly. These parts can interfere with proper assembly i f
Turn throttle lever stop screw until the screw head mispositioned or "left out" by accident.
touches throttle lever tang and the throttle lever cam
touches gauge tool. TRANSMISSION ASSEMBLY PROCEDURE
The kickdown valve spring must be fully com (1) Install rear servo piston, spring and spring re
pressed and the kickdown valve completely tainer. Compress rear servo spring and retainer with
bottomed to obtain correct adjustment. Compressor Tool C-3422-A or a large C-clamp.
(2) Install front servo piston, spring and rod guide.
Compress front servo rod guide with Valve Spring
Compressor C-3422-B and install servo snap ring.
(3) Examine bolt holes in overrunning clutch cam. bolts to 17 N-m (150 in. lbs.) torque.
Note that one hole is not threaded (Fig. 112 This (9) Lubricate overrunning clutch rollers with
hole must align with blank area i n clutch cam bolt transmission fluid.
circle (Fig. 113). (10) Install rear band reaction pin (Fig. 105). Be
sure pin is fully seated in case.
Fig. 112 Location Of -Non-Threaded Hole in Clutch

Cam (32RH)
Fig. 114 Overrunning Clutch And Rear Band Pin
Installation (32RH)
(11) Install rear band i n case (Fig. 115). Twin lugs
on band seat against reaction pin and single lug
faces band lever.
(12) Install low-reverse drum as follows (Fig. 115):
(a) Lubricate overrunning clutch race (on hub of
drum) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start clutch race into
overrunning clutch rollers.
(d) Rotate drum in clockwise direction and push
drum inward until i t seats i n overrunning clutch.
Fig. 113 Location Of Blank Area In Clutch Cam Seat

(In Case) (32RH)
(4) Mark location of non threaded hole in clutch
cam and blank area of case with paint stripe or
grease pencil (Fig. 114).
(5) Install overrunning clutch roller and spring as
sembly i n clutch cam (Fig. 114).
(6) Align and install overrunning clutch i n case
(Fig. 114). Be sure cam is correctly installed.
Bolt holes i n cam are slightly countersunk o n
one side. This side o f cam faces r e a r w a r d (to
w a r d r e a r support).
(7) Verify that non threaded hole i n clutch cam is
properly aligned (Fig. 114). Check alignment by Fig. 115 Installing Rear Band And Low-Reverse
threading a clutch cam bolt into each hole. Adjust Drum (32RH)
cam position i f necessary before proceeding. (13) Install rear band lever and pivot pin (Fig.
(8) Install clutch cam bolts. Note that cam bolts 116). Be sure pin is fully seated i n case.
are shorter than rear support bolts. Tighten cam
Fig. 116 Installing Rear Band Lever And Pivot Pin

Fig. 118 Installing Output Shaft/Planetary Geartrain
(32RH)
(32RH)
(14) Hold low-reverse drum i n position and install
rear support. Align support with punch marks made
during disassembly.
(15) Install and tighten rear support bolts to 17
N-m (150 in. lbs. or 13 ft. lbs.) torque.
(16) Install snap ring that retains low-reverse
drum to hub of rear support (Fig. 117).
Fig. 119 Aligning/Seating Rear Planetary In

Low-Reverse Drum (32RH)
(21) Install governor filter in park gear and install
governor body on gear (Fig. 120). Align governor body
on gear using marks made at disassembly.
(22) Install new seal rings on hub of park gear
(Fig. 120). Be sure ring (or rings) with hooked ends
Fig. 117 Installing Low-Reverse Drum Snap Ring are properly connected.
(32RH) (23) Install governor weight assembly i n governor
(17) Lubricate output shaft, rear support bore and body. Be sure governor weight snap rings are se
low-reverse drum hub with transmission fluid. curely seated.
(18) Install assembled output shaft and planetary (24) Align and install governor/park gear assembly
geartrain in case (Fig. 118). on output shaft. Note that output shaft i n current
(19) Align drive lugs on rear planetary gear with transmission is spotfaced for governor valve
slots i n low-reverse drum (Fig. 119). Then seat plan end clearance (Fig. 120). Shaft must be indexed
etary assembly in drum. so that small end of governor valve will seat in
(20) Lubricate governor components and park gear this spotface. Install governor body and park as
seal rings with transmission fluid. follows to ensure proper alignment and opera
tion.
(a) Rotate output shaft until spotface (at gover i n valve and in output shaft. I f valve shaft
nor valve shaft hole) is facing upward (Fig. 120). binds, governor/park gear is misaligned.
(b) Position valve bore i n governor body over
spotface on output shaft (Fig. 120). Then align
valve shaft holes i n governor body and output
shaft.
(c) Align splines i n output shaft and park gear
hub.
(d) Carefully push assembly into place i n rear
support (Fig. 121).
(e) Verify that governor valve shaft holes in out
put shaft and governor body are still i n alignment.
Reposition governor body and park gear i f align
ment is not correct.
(f) Tighten bolts attaching governor body to park
gear to 11 N-m (95 in. lbs.) torque.
Fig. 122 Installing Governor Valve And Shaft (32RH)

(26) Rotate output shaft until opposite end of gov
ernor valve shaft is facing upward. Then install re
maining E-clip on governor valve shaft (Fig. 123). Be
very sure both E-clips are firmly seated on
shaft.
J9221-52
Fig. 120 Governor Valve And Output Shaft Spotface

Alignment (32RH)
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
Fig. 123 Securing Governor Valve Shaft (32RH)

(27) Install snap ring that retains governor body
on output shaft (Fig. 124).
(28) Install output shaft thrust plate on shaft hub
(Fig. 125). Use petroleum jelly to hold thrust plate i n
place.
(29) Check input shaft seal rings (Fig. 126). Verify
that diagonal-cut ends of teflon seal ring are properly
joined and ends of metal ring are correctly hooked to
Fig. 121 Installing Governor Body And Park Gear gether. Also be sure ringp are installed sequence
(32RH) shown.
(30) Check rear clutch thrust washer. Use addi
(25) Install first E-clip on governor valve shaft.
tional petroleum jelly to hold washer i n place i f nec
Then install governor valve and shaft i n governor
essary.
body (Fig. 122). Be sure valve shaft moves freely
Fig. 127 Assembling Front And Rear Clutch Units

(32RH)
(32) Coat output shaft thrust washer with petro
leum jelly. Then install washer i n rear clutch hub
(Fig. 128). Use enough petroleum jelly to hold washer
i n place. Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also
note that washer only fits one way in clutch
hub.
Fig. 125 Installing Output Shaft Thrust Plate (32RH)
Fig. 128 Installing Output Shaft Thrust Washer

(32RH)
(33) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 129). This will make installa
tion on front planetary easier.
(34) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to in
stall i f transmission is as close to upright position as
Fig. 126 Input Shaft Seal Ring Location (32RH) possible.
(35) Install front and rear clutch units as assembly
(31) Align clutch discs in front clutch and install (Fig. 130). Align rear clutch with front annulus gear
front clutch on rear clutch (Fig. 127). Rotate front and install assembly i n driving shell. Be sure out
clutch retainer back and forth until completely put shaft thrust washer and thrust plate are
seated on rear clutch. not displaced during installation.
Fig. 129 Aligning Rear Clutch Disc Lugs (32RH) Fig. 131 Installing Front Band And Reaction Pin
(36) Carefully work assembled clutches back and (32RH)
forth to engage and seat rear clutch discs on front
BAND BAND
annulus gear. Verify that front clutch drive lugs are
fully engaged i n slots of driving shell after installa
tion.
Fig. 132 Front Band Linkage Installation (32RH)

(41) Coat band lever pin access plug with sealer
and install plug i n converter housing (Fig. 133).
J9121-124
Fig. 130 Installing Front/Rear Clutch Assemblies

(32RH)
(37) Slide front band over front clutch retainer
(Fig. 131).
(38) Insert front band reaction pin part way into
Fig. 133 Installing Front Band Reaction Pin Access
case (Fig. 131).
Plug (32RH)
(39) Install front band lever, strut, lever pin and
adjusting screw (Fig. 132). (42) Check reaction shaft support hub. Verify that
(40) Tighten front band adjusting screw until band seal rings are hooked together and that front clutch
just grips clutch retainer. Verify that front/rear thrust washer is properly positioned (Fig. 134).
clutches are still seated before continuing. Thrust washer I.D. is chamfered on one side.
Install washer so chamfer is facing front. Use

extra petroleum jelly to hold thrust washer in place
if necessary.
SEAL
RINGS J9121-194
Fig. 134 Reaction Shaft Support Seal Rings And Fig. 136 Installing Oil Pump And Reaction Shaft
Front Clutch Thrust Washer Position (32RH) Support (32RH)
(43) Thread two Pilot Stud Tools C-3288-B into (48) Measure input shaft end play (Fig. 137). At
bolt holes in oil pump flange (Fig. 135). tach dial indicator to converter housing. Position in
(44) Align and install oil pump gasket (Fig. 135). dicator plunger against input shaft and zero
indicator. Move input shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 -
0.091 in.). If end play is incorrect, change output
shaft thrust washer if end play is incorrect. Washer
is located in hub of rear clutch retainer.
Fig. 135 Installing Pilot Studs And Oil Pump Gasket

(32RH)
Fig. 137 Checking Input Shaft End Play (32RH)
(45) Lubricate oil pump seals with transmission
fluid, petroleum jelly, or Ru-Glyde. (49) Make sure neutral switch has not been in
(46) Install oil pump (Fig. 136). Align and position stalled in case. Remove switch if necessary as it will
interfere with valve body installation.
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then (50) Install new seal rings on accumulator piston
install two or three pump bolts to hold pump in (Fig. 138). Lubricate accumulator piston, seals and
accumulator bore with transmission fluid.
place.
(51) Install accumulator piston and spring (Fig.
(47) Remove pilot stud tools and install remaining
138) in case.
oil pump bolts. Tighten bolts alternately in diagonal
(52) Place valve body manual lever in low to move
pattern to 20 N-m (15 ft-lbs).
park lock rod rearward.
(60) Adjust front/rear bands as follows:
(a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 N-m (72
in. lbs.).
(c) Back off front band adjusting screw 2-1/2
turns and rear band adjusting screw 4 turns.
(d) Hold each adjusting screw i n position and
tighten locknuts to 34 N-m (25 ft. lbs.).
(61) Install new pan gasket on transmission and
install oil pan. Tighten pan bolts to 17 N-m (13 ft.
Fig. 138 Installing Accumulator Piston And Spring lbs.).
(32RH) (62) Turn transmission over.
(63) Install grommet i n shift lever i f necessary
(53) Position valve body on case. Work park rod (Fig. 140).
past sprag and install valve body-to-case bolts finger
tight. GROMMET
(54) Install neutral switch i n case. Tighten switch
(55) Align valve body on case (Fig. 139). Tighten
valve body-to-case bolts alternately and evenly to 12
N-m (105 in. lbs.) torque. Start at center and work
outward when tightening bolts. Do not o v e r t i g h t e n
valve body bolts. This c o u l d result i n d i s t o r t i o n
a n d cross leakage after installation..
VALVE
J9421-259
Fig. 140 Shift Lever Grommet .

(64) Install shift transmission lever on manual le
ver shaft (Fig. 141).
Fig. 139 Installing Valve Body (32RH)

(56) Install new filter on valve body. Tighten filter
screws to 4 N-m (35 in. lbs.).
(57) Position new extension housing gasket on
transmission case. Use petroleum jelly to hold gasket
in place.
(58) Install rear bearing and snap ring on output Fig. 141 Transmission Shift Lever Installation
shaft. (65) Install throttle valve lever on throttle shaft
(59) Install extension housing on transmission (Fig. 1).
case. Tighten housing fasteners to 33 N-m (24 ft. (66) Position new extension adapter housing gas
lbs.). Be sure park lock rod is properly engaged i n ket on transmission case. Use petroleum jelly to hold
sprag before tightening fasteners. gasket in place.
32RH TRANSMISSION OVERHAUL. 21 - 215
(67) Install new rear seal i n extension housing i f CAUTION: T h e transmission cooler and lines must
required. be reverse flushed if overhaul corrected a malfunc
(68) Install extension/adapter housing on transmis tion that generated sludge, metal particles, or
sion case. Tighten housing fasteners to 33 N-m (24 ft. clutch friction material. The torque converter should
lbs.). Be sure park lock rod is properly engaged in also be replaced if contaminated by the same mal
sprag before tightening fasteners. function. Debris and residue not flushed from the
(69) Lubricate converter hub with transmission cooler and lines will flow back into the transmission
fluid and carefully install converter. Turn converter and converter. T h e result could be a repeat failure
back and forth until seated. Be sure converter hub and shop comeback.
slots are fully seated in oil pump gear lugs.
(70) Secure converter i n oil pump before mounting (63) Install new manual lever shaft seal i n case.
transmission on jack and before moving transmission Use 15/16 deep well socket to install seal.
back under vehicle. Use metal strapping, C-clamp, or
locking pliers to hold converter i n place. Attach hold
ing tool to converter housing.
21 - 216 36RH/37RH TRANSMISSION OVERHAUL
36RH/37RH T R A N S M I S S I O N O V E R H A U L
INDEX
page page
Extension Housing and Park Lock Components . . 226 Rear Clutch Overhaul 236
Front Clutch Overhaul 234 Rear Servo and Band Overhaul 231
Front Servo and Band Overhaul 231 Rear Support and Low-Reverse Drum Service . . . 228
Governor and Park Gear Overhaul 226 Transmission Assembly and Adjustment 248
Oil Pump and Reaction Shaft Support Overhaul . . 232 Transmission Case Cleaning and Inspection . . . . 226
Overhaul Service Information 226 Transmission Disassembly 216
Overrunning Clutch Overhaul 228 Valve Body Service and Adjustment 241
Planetary Gear Train and Output Shaft Overhaul . 237
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with steam gun or
solvent. Wear safety goggles while cleaning transmis
sion.
(2) Mount transmission on Repair Stand C-3750-B.
(3) Remove bolts attaching extension housing to
transmission case. Then remove rear bearing snap
ring access cover from housing (Fig. 1)
(4) Spread rear bearing locating ring with parallel
jaw snap ring pliers (Fig. 1). Then work extension
housing off bearing and output shaft. Remove hous
ing gasket after removing housing.
(5) Remove rear bearing and snap rings from out
put shaft (Fig. 2). Note that two snap rings are used
to retain bearing.
J9421-260
Fig. 3 Transmission Shift And Throttle Valve Levers
Fig. 1 Extension Housing Removal (36RH/37RH)

(6) Remove throttle and manual valve levers from
valve body manual shaft.
(7) Remove oil pan bolts and remove pan (Fig. 4)
and gasket (Fig. 5). Oil pan magnet can be removed
or left i n pan as needed (Fig. 6). Exercise care when
removing pan to avoid distorting or bending pan
flange.
Fig. 4 Removing/Installing Oil Pan (36RH/37RH)

36RH/37RH TRANSMISSION OVERHAUL 21 - 217
FLUID
FILTER
PAN
GASKET J9121-6
Fig. 5 Removing/Installing Pan Gasket (36RH/37RH) Fig. 8 Fluid Filter Removal/Installation (36RH/37RH)
MAGNET'
MAGNET
MOUNTING
BOSS J9121-7J VALVE BODY VALVE BODY _ | n i o l 0
J
\ , ATTACHING BOLTS ATTACHING BOLTS jJJlf

Fig. 6 Oil Pan Magnet Location (36RH/37RH)
Fig. 9 Valve Body Attaching Bolt Locations
(8) Remove park/neutral position switch (Fig. 7). I f (36RH/37RH)
switch gasket is i n good condition, retain gasket and
keep i t with switch.
Fig. 7 Park/Neutral Position Switch Removal/

Installation
(9) Remove three fluid filter attaching screws and J9121-10
remove filter (Fig. 8).

(10) Remove hex head valve body attaching bolts Fig. 10 Valve Body Removal/Installation (36RH/
37RH)
(Fig. 9).
(11) Lift valve body upward, guide park rod out of (13) Remove front band lever pin access plug (Fig.
case opening and remove valve body (Fig. 10). 12). Square end of 1/4 inch drive extension can be
(12) Remove accumulator spring and piston (Fig. used to remove plug as shown.
11). Note position of piston and spring for assembly (14) Remove oil pump and reaction shaft support
reference. Remove and discard piston seals i f worn or assembly as follows:
cut. (a) Tighten front band adjusting screw until
band is tight around front clutch retainer (Fig. 13).
21 - 218 36RH/37RH TRANSMISSION OVERHAUL •
(b) Remove oil pump bolts.
(c) Thread Slide Hammer Tools C-3752 into
threaded holes i n flange of oil pump housing (Fig.
14).
Fig. 11 Removing/installing Accumulator Piston And

Spring (36RH/37RH)
Fig. 14 Installing Oil Pump Remover Tools

(36RH/37RH)
(d) Remove oil pump and reaction shaft support
by bumping slide hammers outward alternately to
pull pump from case (Fig. 15).
Fig. 12 Removing/Installing Front Band Lever Pin

Access Plug (36RH/37RH)
This will prevent retainer from coming out with
pump and possibly damaging clutch or pump com
ponents.
Fig. 15 Removing Oil Pump (36RH/37RH)
Fig. 13 Tightening Front Band To Hold Front Clutch

In Place (36RH/37RH)
• 36RH/37RH TRANSMISSION OVERHAUL 21 - 219
(15) Remove oil pump gasket (Fig. 16). Note gasket

position i n case for assembly reference.
Fig. 18 Removing Front Band (36RH/37RH)
Fig. 16 Removing Oil Pump Gasket (36RH/37RH)

(16) Loosen front band adjusting screw until band
is completely loose.
(17) Remove front band strut and anchor (Fig. 17).
LEVER STRUT
Fig. 19 Removing Front And Rear Clutch

Assemblies (36RH/37RH)
clutch removal (Fig. 21). Or remove washer from in
J9121-18 put shaft hub i n rear clutch i f washer remained i n
hub during removal.
Fig. 17 Front Band Linkage (36RH/37RH)
(22) Remove thrust plate from output shaft hub
(18) Squeeze front band together slightly and slide (Fig. 22).
band over front clutch retainer and out of case (Fig. (23) I f the output shaft or planetary geartrain
18). components must be disassembled for service,
(19) Remove front and rear clutch assemblies as a continue on to step (24). However, if the shaft
unit (Fig. 19). Set assemblies aside for disassembly and geartrain components do not need servic
and inspection after removal. ing, the shaft and geartrain can be removed as
(20) Remove front band reaction pin and lever. a unit (Fig, 23). I n this case, simply remove the
Start pin through lever and out of case bore. Use governor valve shaft, governor and park gear
pencil magnet to complete pin removal (Fig. 20). and remove the complete assembly.
(21) Remove triangular shaped thrust washer from
output shaft hub i f washer remained on hub during
Fig. 20 Removing Front Band Lever And Pin

(36RH/37RH)
ASSEMBLY
Fig. 23 Removing Output Shaft And Planetary

Geartrain (36RH/37RH)
(24) Remove planetary gear retaining snap ring
from output shaft (Fig. 24). Retain snap ring i f i n
good condition (it is reusable).
Fig. 21 Removing Output Shaft Thrust Washer

(36RH/37RH)
Fig. 24 Removing Planetary Snap Ring (36RH/37RH)

(25) Remove front planetary gear and front annu
lus gear from output shaft as assembly (Fig. 25).
(26) Remove front planetary gear and thrust
washer from front annulus gear (Fig. 26). Note
thrust washer position for assembly reference.
Fig. 22 Removing Output Shaft Thrust Plate

(36RH/37RH)
3SRH/37RH TRANSMISSION OVERHAUL 21 - 221
(27) Remove tabbed thrust washer from driving

shell (Fig. 27). Note washer position for assembly ref-
erence.
DRIVING
SHELL
DRIVING
SHELL
FRONT
ANNULUS GEAR J9121-26
\
Fig. 27 Removing Driving Shell Thrust Washer

J9121-25 (36RH/37RH)
(28) Remove sun gear and driving shell (Fig. 28).
Fig. 25 Removing Front Planetary And Annulus
Gears (36RH/37RH) FRONT
PLANETARY
FRONT GEAR
PLANETARY
GEAR
TABBED
THRUST
TABBED WASHER
THRUST
WASHER
FRONT
ANNULUS
FRONT GEAR
ANNULUS
GEAR
J9121-27
J9121-27 Fig. 28 Removing Sun Gear And Driving Shell

(36RH/37RH)
Fig. 26 Disassembling Front Planetary And Annulus
Gears (36RH/37RH)
(29) Remove tabbed thrust washer from rear plan (31) Remove rear planetary thrust plate from rear
etary gear (Fig. 29). Note washer position on gear for annulus gear (Fig. 31).
assembly reference.
J9121-29
Fig. 29 Removing Rear Planetary Thrust Washer

(36RH/37RH)
(30) Remove rear planetary gear from annulus J9121-31 \
gear (Fig. 30).
Fig. 31 Removing Rear Planetary Thrust Plate
(36RH/37RH)
(32) Remove rear annulus gear from output shaft
(Fig. 32).
J9121-30
Fig. 30 Removing Rear Planetary Gear (36RH/37RH)
J9121-32
Fig. 32 Removing Rear Annulus Gear (36RH/37RH)

3IRH/37RH TRANSMISSION OVERHAUL 21 - 223
(33) Remove output shaft, park gear and governor (36) Slide low-reverse drum off rear support hub
assembly from rear of case (Fig. 38), and out of rear band (Fig. 1).
PARK GOVERNOR REAR
OUTPUT
GEAR ASSEMBLY BAND
AND LINK
LOCATING
SNAP RING J9121-33 J9221-7
Fig. 33 Removing Output Shaft, Park Gear And Fig. 35 Removing Low-Reverse Drum (36RH/37RH)
Governor Assembly (36RH/37RH) (37) Note that overrunning clutch race will remain
(34) Loosen rear band adjusting screw. on splines of low-reverse drum after removal (Fig.
(35) Remove snap ring securing low-reverse drum 36). The race is a permanent press fit on the
to rear support (Fig. 34). hub splines. Do not attempt to remove the race.
OVERRUNNING LOW-REVERSE
REAR LOW-REVERSE CLUTCH DRUM
BAND DRUM RACE
REAR
SUPPORT
DRUM
RETAINING
SNAP
RING
J9121-34 J9221-8
Fig. 36 Overrunning Clutch Race Position (36RH/

Fig. 34 Removing Low-Reverse Drum Snap Ring 37RH)
(36RH/37RH)
(38) -Remove overrunning clutch assembly (Fig. REAR

37). Assembly can be removed without displacing BAND ADJUSTING
rollers and springs i f care is exercised. Note position LEVER
of rollers and springs for assembly reference.
, ^CLUTCH
REAR
BAND
REACTION
Fig. 37 Removing Overrunning Clutch (36RH/37RH) PIN y/ J9121-37
(39) Start rear band reaction pin out of case with
Fig. 39 Removing Rear Band Levers And Reaction
punch or drift (Fig. 38).
Pin (36RH/37RH)
(40) Remove band adjusting lever, reaction lever
and reaction pin (Fig. 39).
SELECT FRONT SUPPORT ANNULUS GEAR FRONT SUN SUN DRIVING SHELL FRONT DRIVING
FIT ANNULUS SNAP RING SUPPORT PLANETARY GEAR GEAR THRUST PLATE SHELL
PLANETARY SNAP THRUST SPACER
SNAP RING WASHERS
RING
FRONT
ANNULUS-
THRUST
WASHER
DRIVING
SHELL
REAR
THRUST
PLATE
OUTPUT
SHAFT
THRUST OUTPUT
PLATE SHAFT J9221-17
Fig. 38 Starting Rear Band Reaction Pin Out Of Case (36RH/37RH)

(41) Remove strut from rear band. Keep strut with (47) Remove servo piston snap ring (Fig. 42). Start
levers and pin for cleaning, inspection and assembly one end of ring out of bore. Then carefully work re
reference. moval tool around back of snap ring until free of ring
(42) Remove rear band and link (Fig. 40). groove. Exercise caution when removing snap
ring. Servo bore can be scratched or nicked if
care is not exercised.
(48) Remove tools and remove rear servo retainer,
spring and piston assembly.
Fig. 40 Removing Rear Band And Link (36RH/37RH)

(43) Compress front servo rod guide with C-clamp
and Tool C-4470, or Valve Spring Compressor
C-3422-B (Fig. 41). Compress guide only enough to
Fig. 42 Removing Rear Servo Retaining Snap Ring
permit snap ring removal (about 3 mm or 1/8 in.).
(36RH/37RH)
(44) Remove servo piston snap ring (Fig. 41). Un
seat one end of ring. Then carefully work removal (49) Inspect rear support. I f support has arrow and
tool around back of ring until free of ring groove. E x word "pan" on it, note position for assembly refer
ercise caution when removing snap ring. Servo ence. However, i f support does not have arrow or
bore can be scratched or nicked if care is not word, mark position of support with center punch
exercised. (Fig. 43).
(45) Remove tools and remove servo piston and
spring.
Fig. 43 Marking Rear Support For Assembly

Reference (36RH/37RH)
Fig. 41 Removing Front Servo Retaining Snap Ring

(36RH/37RH)
(46) Compress rear servo piston with C-clamp and
Tool C-4470, or Valve Spring Compressor C-3422-B
(Fig. 42). Compress servo spring retainer only
enough to permit snap ring removal.
(50) Remove rear support bolts and remove sup Use Mopar Door Ease, or Ru-Glyde to lubricate
port from case (Fig. 44). Use a twisting motion to re seals, O-rings, and thrust washers. Petroleum jelly
move support i f necessary. can also be used to hold parts i n place during reas
sembly.
TRANSMISSION CASE CLEANING AND

INSPECTION
Clean the case i n a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
Do not use shop towels or rags to dry the ease
(or any other transmission component) unless
they are made from lint-free materials. Lint
will readily adhere to case surfaces and trans
mission components and will circulate through
out the transmission after assembly. A sufficient
quantity of lint can block fluid passages and in
Fig. 44 Removing Rear Support (36RH/37RH) terfere with valve body operation.
OVERHAUL SERVICE INFORMATION Inspect the case for cracks, porous spots, worn
Inspect all the transmission bushings during over servo bores, or damaged threads. Damaged threads
haul. Bushing condition is important as worn, scored can be repaired with Helicoil thread inserts. How
bushings contribute to low pressures, clutch slip and ever, the case will have to be replaced i f i t exhibits
accelerated wear of other components. Replace worn, damage or wear.
or scored bushings, or i f doubt exists about bushing Lubricate the front band adjusting screw with pe
condition. troleum jelly and thread i t part way into the case. Be
Use recommended tools to replace bushings. The sure the screw turns freely and does not bind.
tools are sized and designed to remove, install and Remount the transmission case i n Repair Stand
seat bushings correctly. The bushing replacement C-3750-B after cleaning and inspection.
tools are included i n Bushing Tool Set C-3887-B. EXTENSION HOUSING AND PARK LOCK
Pre-sized service bushings are available for replace
COMPONENTS
ment purposes. Only the sun gear bushings are not
Clean the housing and park lock components i n sol
serviced. Low cost of the sun gear assembly makes i t
vent and dry them with compressed air.
easier to simply replace the gear and bushings as an
Examine the park lock components i n the housing.
assembly.
I f replacement is necessary, remove the shaft with
Heli-Coil inserts are recommended for repairing parallel jaw snap ring pliers (Fig. 45) and remove the
damaged, stripped or worn threads in aluminum sprag and spring. Then remove the spring clip and
parts. These inserts are available from most automo reaction plug (Fig. 46). Compress the reaction
tive jobbers. Stainless steel inserts are preferred. plug spring clip only enough to remove and in
The use of crocus cloth is permissible where neces stall it. Do not distort the clip during removal
sary, providing i t is used carefully. When used on or installation.
valves, use extreme care to avoid rounding off sharp Be sure a replacement sprag is installed so the
edges. Sharp edges are vital as they prevent foreign sprag locking lug will face the park gear (Fig. 47).
matter from getting between the valve and valve Also be sure the spring is correctly positioned as
bore. shown (Fig. 47). The sprag may not retract i f the
Do not reuse oil seals, gaskets, seal rings, or spring is improperly installed.
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or E- GOVERNOR AND PARK GEAR OVERHAUL
clips that are bent or distorted. Replace these parts
as well. GOVERNOR/PARK GEAR DISASSEMBLY
Lubricate transmission parts with Mopar ATF (1) Loosen bolts attaching governor to park gear.
Plus, Type 7176 transmission fluid during assembly. (2) Remove governor snap ring from output shaft
This is the preferred fluid for use i n 36RH transmis (Fig. 48).
sions. Use Mopar Dexron I I only when ATF Plus is (3) Remove E-clip securing governor valve shaft
not readily available. and remove shaft and valve from governor body.
Fig. 45 Park Sprag, Shaft And Spring Remowal

(36RH/37RH)
Fig. 48 Governor Snap Rings (36RH/37RH)

Clean the governor and park gear components in
solvent and dry with compressed air.
Fig. 46 Park Sprag Reaction Plug And Spring Examine the governor components carefully (Fig.
Location (36RH/37RH) 49). Discard any snap rings or E-clips if distorted, or
(4) Slide governor and park gear off output shaft. worn. Be sure the valve and weights operate freely in
(5) Remove governor retaining bolts and separate the bores and do not bind. Also be sure the valve
governor from park gear. slides freely on the shaft. Minor scratches or burrs
(6) Remove governor filter from park gear. Keep can be reduced with crocus cloth soaked in transmis
filter with governor body. sion fluid. However, do not attempt to salvage com
(7) Remove governor weight snap ring and remove ponents that are severely worn or scored.
weight assembly from governor body. Remove inner There are t w o governor component changes
snap ring and separate governor weights. on 1992 and later 36RH transmissions t h a t af
fect service procedures, The f i r s t change i n -
SPRING PARK REAR FRONT

GEAR SEAL SEAL
OUTER WEIGHT RING RING
VALVE SHAFT
SNAP*
RINGS VALVE
INNER WEIGHT SNAP
^ R I N G
FILTER SCREEN
GOVERNOR
VALVE
SPOTFACE J9221-51
Fig. 49 Governor Components (36RH/37RH)

volves the governor valve which is now made of
aluminum. The second change involves the out
put shaft which has been spotfaced for gover J9121-48
nor valve end clearance. The new aluminum
valve must only be used with an output shaft Fig. 50 Park Gear And Seal Rings (36RH/37RH)
that has a spotface. The governor body and (5) Install governor body-to-park gear bolts
spotfaced side of the output shaft must be in finger tight only. Bolts are fully tightened only
dexed during assembly. after installation on output shaft. This is neces
Check condition of the park gear seal rings, ring sary to ensure proper alignment of park gear
grooves and gear teeth (Fig. 50). Replace the gear as and governor body.
an assembly i f the teeth or ring grooves are worn, or
damaged. REAR SUPPORT AND LOW-REVERSE DRUM
Replace the park gear front and rear seal rings i f SERVICE
cracked, or worn. The production style front ring is a Clean the drum and support i n parts cleaning sol
plain type and the rear ring is a hook style. I f re vent and dry them with compressed air.
placement rings are both hook-style, be sure the ring Inspect the drum and support for evidence of wear,
ends are properly hooked together as shown (Fig. 50). scoring, or cracks. Assemble the support, drum and
overrunning clutch race and check fit of the compo
ASSEMBLING GOVERNOR AND PARK GEAR
nents.
The alloyed brass governor weight assembly
Examine the overrunning clutch race. The race is a
is designed for exclusive use in 37RH diesel
permanent press fit on the hub splines of the low-re
transmissions. Do not interchange this weight
verse drum. The drum and race are replaced as an
assembly.
assembly i f either part is worn or damaged. Also
(1) Coat governor body bores governor components check fit of the race on the drum. Replace the assem
with transmission fluid. bly i f the race is loose on the hub splines.
(2) Assemble and install governor weights and
spring i n governor body but do not install shaft and OVERRUNNING CLUTCH OVERHAUL
valve at this time. These parts will not be installed
Inspect condition of the clutch cam, cage-type re
until after governor and park gear are installed on
tainer, rollers, springs and clutch race.
output shaft.
Replace the clutch cam i f worn or damaged. Also
(3) Install new seal rings on park gear if necessary.
check fit of the cam i n the transmission case. I f the
(4) Insert filter screen i n park gear and install gov
cam is loose, the case may be worn, or cracked.
ernor body on park gear.
• 3 6 R H / 3 7 R H T R A N S M I S S I O N OVERHAUL 21 - 229
The clutch race is permanently pressed onto the (4) Install rear support in case. Align support with
low-reverse drum hub. If either the drum or race are reference marks made at disassembly.
worn or damaged, replace the drum and race as an (5) Align and start new clutch cam and spring re
assembly. Check fit of the race on the low-reverse tainer in case. Be sure serrations on cam and in case
drum hub splines. Replace the drum and race as an are aligned (Fig. 53). Then tap cam into case just
assembly if the race is loose on the hub splines. enough to hold it in place.
Examine the overrunning clutch assembly care (6) Verify that cam is correctly positioned be
fully. Replace the assembly if the rollers, springs, or fore proceeding any further. Narrow ends of
cage-type retainer are worn, or damaged. cam ramps should be to left when cam is
If the clutch cam requires replacement, install a viewed from front end of case (Fig. 53).
new cam as described in the following procedure.
OVERRUNNING CLUTCH CAM REPLACEMENT

(1) Remove clutch cam setscrew (Fig. 51).
Fig. 53 Positioning Replacement Clutch Cam And

Spring Retainer
(7) Insert Adapter Tool SP-5124 into piston re
tainer (Fig. 54).
Fig. 51 Removing/Installing Clutch Cam Setscrew
(2) Tap old cam and spring retainer out of case
with pin punch. Insert punch through bolt holes at
rear of case (Fig. 52). Alternate position of punch to
avoid cocking cam during removal.
Fig. 54 Positioning Adapter Tool In Overdrive Piston

Retainer
(8) Assemble Puller Bolt SP-3701 and Press Plate
SP-3583-A (Fig. 55).
(9) Install assembled puller plate and bolt (Fig.
Fig. 52 Removing Overrunning Clutch Cam 56). Insert bolt through cam, case and adapter tool.
Be sure plate is seated squarely on cam.
(3) Clean clutch cam bore and case. Be sure to re
move all chips/shavings generated during cam re (10) Hold puller plate and bolt in place and install
moval. puller nut SP 3701 on puller bolt (Fig. 57).
Fig. 55 Assembling Clutch Cam Puller Bolt And Fig. 57 Installing Overrunning Clutch Cam
Press Plate INSTALLING OVERRUNNING CLUTCH
ASSEMBLY
(1) Lubricate overdrive piston retainer hub, clutch
race, clutch cam, and overrunning clutch rollers with
transmission fluid.
(2) If any overrunning clutch rollers or springs
came out of retainer, reinstall them as follows: Install
and seat spring in retainer first. Then insert roller
between spring and retainer stop as shown (Fig. 58).
Verify that each roller and spring are fully seated be
fore proceeding.
Fig. 56 Positioning Puller Plate On Clutch Cam

(11) Tighten puller nut to draw clutch cam into
case (Fig. 57). Be sure earn is drawn into case
evenly and does not become cocked.
(12) Install clutch cam setscrew (Fig. 51).
(13) Remove clutch cam installer tools and piston
retainer.
(14) Stake case i n 12 places around clutch
cam to help secure cam i n case. Use blunt
punch or chisel to stake case.
(15) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are
removed from case.
Fig. 58 Clutch Roller, Spring And Retainer Assembly

• 36RH/37RH TRANSMISSION OVERHAUL 21 - 2 3 1
(3) Install and seat clutch assembly in cam (Fig. (3) Remove and discard servo component O-ring
59). The retainer is a one-way fit i n the earn* and seal rings.
The flanged side of the retainer should be fac (4) Lubricate new O-ring and seal rings with petro
ing outward. The r e t a i n e r a n d rollers will slip leum jelly and install them on piston, guide and rod.
easily into the c a m w h e n p r o p e r l y positioned. (5) Install rod in piston. Install spring and washer
on rod. Compress spring and install snap ring.
O ÔVERRUNNING
CLUTCH (6) Set servo components aside for installation dur
SEATED ing transmission reassembly.
26
2-RH307
M
Fig. 60 Front Servo Components
REAR SERVO AND BAND OVERHAUL
S E R V O AND BAND INSPECTION

Clean the servo components with solvent and dry
them with compressed air.
Inspect the servo components. Replace the spring if
collapsed, distorted or broken. Replace the plug and
piston if cracked, bent, or worn. Discard the servo
Fig. 59 Overrunning Clutch Seated in Cam snap ring if distorted or warped.
Check rear band condition. Replace the band if dis
(4) Install low-reverse drum. Tilt drum slightly
torted, the lining is burned or flaking off, or the lin
and carefully engage clutch race (on drum hub) in
overrunning clutch rollers. Raise drum to level posi ing is worn (grooves no longer visible at any point on
tion. Then rotate the drum in clockwise direction un the lining material).
til fully seated. If doubt exists about the condition of any servo
(5) Check overrunning clutch operation. Low-re component, replace it. Do not reuse suspect parts.
verse drum should rotate freely in clockwise direction
REAR SERVO PISTON OVERHAUL (FIG. 61)
and lock in counterclockwise direction.
(6) Align and reinstall overdrive piston retainer. (1) Remove small snap ring and remove plug and
Tighten retainer bolts to 11 N»m (95 in. lbs.) torque. spring from servo piston.
(2) Remove and discard servo piston seal ring.
FRONT SERVO AND BAND OVERHAUL (3) Lubricate piston and guide seals with petro
leum jelly. Lubricate other servo parts with transmis
SERVO AND BAND INSPECTION sion fluid.
Clean the servo piston components with solvent (4) Install new seal ring on servo piston.
and dry them with compressed air. Wipe the band (5) Assemble piston, plug, spring and snap ring.
clean with lint free shop towels. (6) Lubricate piston seal lip with petroleum jelly.
Replace the front band if distorted, lining is (7) Set servo components aside for assembly instal
burned, flaking off, or worn to the point where the lation.
grooves in the lining material are no longer visible.
Inspect the servo components. Replace the springs SNAP PISTON PISTON SPRING SNAP
SEAL RETAINER RING
if collapsed, distorted or broken. Replace the guide, RING PLUG
rod and piston if cracked, bent, or worn. Discard the

servo snap ring if distorted or warped.
Check the servo piston bore for wear. If the bore is
severely scored, or damaged, it will be necessary to
replace the case.
Replace any servo component if doubt exists about
CUSHION PISTON
its condition. Do not reuse suspect parts. SPRING J9121-64
PISTON SPRING
FRONT SERVO PISTON OVERHAUL (FIG. 60) Fig. 61 Rear Servo Components
(1) Remove seal ring from rod guide.
(2) Remove small snap ring from servo piston rod.
Then remove piston rod, spring and washer from pis
ton.
Fig. 62 Oil Pump And Reaction Shaft Components (36RH/37RH)

OIL PUMP AND REACTION SHAFT SUPPORT Install the gears in the pump body and measure
OVERHAUL end clearance with a feeler gauge and straightedge
(Fig. 63). Clearance should be 0.010 to 0.06 mm
DISASSEMBLING PUMP AND SUPPORT (FIG. (0.0004 to 0.0025 in.).
82) Measure side clearances with feeler gauge (Fig.
(1) Mark position of support with scriber. 64). Clearance between gear teeth and between outer
(2) Remove support bolts and separate support and gear and pump body should be 0.08 to 0.19 mm
pump body (Fig. 62). (0.0035 to 0.0075 in.).
(3) Remove O-ring seal from pump body. STRAIGHTEDGE PUMP
(4) Remove seal rings and thrust washer from re
action shaft support.
(5) Clean pump and support components with sol
vent and dry them with compressed air.
INSPECTING PUMP AND SUPPORT

Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or ma
chined surfaces are worn, scored, pitted, or damaged.
Replace the pump gears if pitted, worn chipped, or
damaged. Inspect the fiber thrust washer. Replace
the washer if worn or damaged.
Inspect the pump and reaction shaft bushings. Re
place the bushings only if heavily worn, scored or
damaged. It is not necessary to replace the bushings
unless they are actually damaged or worn. Fig. 63 Checking Pump Gear End Clearance
SPECIAL BUSHING
J9221-244
Fig. 65 Oil Pump Bushing Replacement (36RH/
37RH)
J8921-388
Fig. 64 Checking Pump Gear Side Clearances

Fig. 66 Staking And Deburring Oil Pump Bushing
REPLACING OIL PUMP BUSHING
(1) Position pump housing on clean, smooth sur REPLACING REACTION SHAFT SUPPORT
face with gear cavity facing down. BUSHING
(2) Remove bushing with Tool Handle C-4171 and (1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushing Remover SP-3550 (Fig. 65). Bushing Remover SP-5301 (Fig. 67).
(3) Assemble Tool Handle C-4171 and Bushing In (2) Hold cup tool firmly against reaction shaft.
staller SP-5118 (Fig. 65). Thread remover tool into bushing as far as possible
(4) Place bushing on installer tool and start bush by hand.
ing into shaft (Fig. 65). (3) Using wrench, thread remover tool an addi
(5) Tap bushing into place until Installer Tool SP- tional 3-4 turns into bushing to firmly engage tool.
3550 bottoms in pump cavity (Fig. 65). Keep tool and (4) Tighten tool hex nut against cup tool to pull
bushing square with bore. Do not allow bushing to bushing from shaft. Clean all chips from shaft and
become cocked during installation. support after bushing removal.
(6) Stake pump bushing in two places with blunt (5) Place reaction shaft support upright on a clean,
punch. Remove burrs from stake points with knife smooth surface.
blade (Fig. 66).
(6) Assemble Bushing Installer Tools C-4171 and ASSEMBLING OIL PUMP AND REACTION
SP-5302 (Fig. 67). Then slide new bushing onto in SHAFT SUPPORT
staller tool. (1) Lubricate pump gears with transmission fluid
(7) Start bushing in shaft. Tap bushing into shaft and install them i n pump body.
until installer tool bottoms against support flange (2) Install new thrust washer and seal rings on re
(Fig. 66). action shaft support. Lubricate seal rings with trans
(8) Clean reaction shaft support thoroughly after mission fluid or petroleum jelly.
bushing replacement (to remove any chips). (3) Align and install reaction shaft support on
SPECIAL pump body.
SPECIAL
TOOL TOOL (4) Install bolts attaching reaction shaft support to
SP-1191 C-4171 pump. Tighten bolts to 20 N-m (175 in. lbs.) torque.
(5) Install new pump seal with Seal Installer
SPECIAL C-3860-A and Tool Handle C-4171.
TOOL
SP-5302 (6) Install new O-ring on pump body. Lubricate oil
seal and O-ring with transmission fluid or petroleum
jelly.
(7) Set pump and support aside for assembly in
stallation.
BUSHING
FRONT CLUTCH OVERHAUL
BUSHING
FRONT CLUTCH DISASSEMBLY
(1) Remove waved snap ring and remove pressure
X REACTION plate, clutch plates and driving discs (Fig. 68).
SHAFT (2) Compress clutch piston retainer and springs
with Compressor Tool C-3863-A (Fig. 69).
BUSHING
REMOVAL BUSHING (3) Remove piston snap ring and spring retainer
INSTALLATION (Fig. 6 9 ) .
J9221-245 (4) Remove piston springs. Note number and po
sition of piston springs for assembly reference.
Fig. 67 Reaction Shaft Bushing Replacement
(5) Remove compressor tool and remove clutch pis
(36RH/37RH)
ton.
(6) Remove and discard clutch piston seals. Also
discard spring retainer snap ring.
INNER CLUTCH CLUTCH PISTON CLUTCH CLUTCH

PISTON SEAL PISTON SPRING RETAINER PLATES PACK
CLUTCH RETAINER PISTON SEAL SPRINGS (9) SNAP RING CLUTCH DISCS REACTION PLATE J9321-129
Fig. 68 Front Clutch Components (36RH/37RH)
SPECIAL (5) Install new bushing until installer head bot
TOOL toms against retainer (Fig. 70).
C-3863-A
(6) Remove installer tools and clean retainer thor
oughly.
SPECIAL SPECIAL
TOOL TOOL
C-4171 SP-3629
FRONT CLUTCH
RETAINER
SPECIAL SPECIAL
TOOL TOOL
C-4171 SP-5511
mm
Fig. 69 Removing Front Clutch Spring Retainer
Snap Ring (36RH/37RH)
FRONT CLUTCH CLEANING AND INSPECTION J9221-247
Clean and inspect the front clutch components. Re
place the clutch discs if warped, worn, scored, burned Fig. 70 Front Clutch Retainer Bushing Replacement
or charred, the lugs are damaged, or if the facing is (36RH/37RH)
flaking off. Replace the steel plates if heavily scored, ASSEMBLING FRONT CLUTCH
warped, or broken. Be sure the driving lugs on the (1) Soak clutch discs in transmission fluid.
discs and plate are also in good condition. The lugs (2) Lubricate new inner and outer piston seals
must not be bent, cracked or damaged in any way. with Ru-Glyde, or Door Ease.
Replace the piston springs and spring retainer if ei (3) Install new seals on clutch piston. Be sure seal
ther are distorted, warped or broken. lips face interior of retainer.
Check the lug grooves in the clutch piston retainer. (4) Install clutch piston in retainer. Use twisting
The steel plates should slide freely in the slots. Re motion to seat piston in retainer. Do not force pis
place the piston retainer if the grooves are worn or ton straight in. This could fold seals over caus
damaged. Also check action of the check ball in the ing leakage and clutch slip.
piston retainer. The ball must move freely and not (5) Install clutch piston springs. If clutch has nine
stick. springs, position springs as shown (Fig. 71).
Replace the retainer bushing if worn, scored, or (6) Install retainer on piston springs.
there is any doubt about bushing condition. (7) Compress spring retainer and piston springs
Inspect the piston and retainer seal surfaces for with Compressor Tool C-3863-A.
nicks or scratches. Minor scratches can be removed (8) Install new spring retainer snap ring and re
with crocus cloth. However, replace the piston and/or move compressor tool.
retainer if the seal surfaces are seriously scored. (9) Lubricate clutch plates and pressure plate with
REPLACING FRONT CLUTCH RETAINER transmission fluid.
BUSHING (10) Install clutch plates and discs. Install steel
(1) Assemble Tool Handle C-4171 and Bushing Re plate followed by a disc until 4 plates and discs are
mover SP-3629 (Fig. 70). installed.
(2) Insert remover tool in bushing and drive bush (11) Install pressure plate and waved snap ring.
ing straight out of piston retainer. (12) Check clutch pack clearance (Fig. 72). Clear
(3) Mount Bushing Installer SP-5511 on tool han ance between waved spring and pressure plate
dle (Fig. 70). should be 1.78 to 3.28 mm (0.070 to 0.129 in.) for 3
(4) Slide new bushing onto installer head and start disc clutch, or 2.08 to 3.83 mm (0.082 to 0.151 in.) for
bushing in retainer.
9 SPRING
CLUTCH
11 SPRING
CLUTCH
13 SPRING
CLUTCH
FEELER G A U G E RH288
Fig. 72 Measuring Front Clutch Pack Clearance

J9221-260 (Typical)
Fig. 71 Front Clutch Spring Position (36RH/37RH) Replace the steel plates and the pressure plate i f
heavily scored, warped, or broken. Be sure the driv
4 disc clutch. I f clearance is incorrect, clutch plates, ing lugs on the discs and plates are also i n good con
discs, snap ring and/or pressure plate will have to be dition. The lugs must not be bent, cracked or
changed. damaged i n any way.
Replace the piston spring and wave spring i f either
REAR CLUTCH OVERHAUL part is distorted, warped or broken.
Check the lug grooves i n the clutch retainer. The
R E A R CLUTCH DISASSEMBLY (FIG. 73) steel plates should slide freely in the slots. Replace
(1) Remove clutch pack select fit snap ring. the retainer i f the grooves are worn or damaged. Also
(2) Remove outer pressure plate and steel plates check action of the retainer check ball. The ball must
and discs. move freely and not stick.
(3) Remove inner pressure plate, wave spring, Inspect the piston and retainer seal surfaces for
spacer ring and piston spring. nicks or scratches. Minor scratches can be removed
(4) Remove clutch piston and piston retainer from with crocus cloth. However, replace the piston and/or
clutch retainer. Bump clutch retainer on a wood retainer i f the seal surfaces are seriously damaged.
block to dislodge piston and retainer. Check thrust washer condition. Washer thickness
(5) Remove input shaft thrust washer. should be 1.55 to 1.60 mm (0.061 to 0.063 in.). Re
(6) Remove input shaft snap ring and press shaft place the washer i f worn or damaged.
out of clutch retainer. Check condition of the two seal rings on the input
(7) Remove and discard clutch piston seals. shaft and the single seal ring on the piston retainer.
(8) Do not remove shaft seal rings unless they are Replace the seal rings i f worn or damaged.
obviously damaged (broken, cracked). Check the input shaft for wear, or damage. Replace
the shaft i f worn, scored or damaged i n any way.
R E A R CLUTCH CLEANING AND INSPECTION
Clean the clutch components with solvent and dry
them with compressed air.
Replace the clutch discs i f warped, worn, scored,
burned/charred, the lugs are damaged, or i f the fac
ing is flaking off.
Fig. 73 Rear Clutch C ponents (36RH/37RH)

ASSEMBLING REAR CLUTCH (FIG. 73) (6) Install thrust washer on retainer (Fig. 73). Use
(1) Soak clutch discs i n transmission fluid. petroleum jelly to hold thrust washer i n place.
(2) Install new seal rings on input shaft and piston (7) Install assembled piston retainer i n clutch re
retainer (Fig. 7 4 ) . tainer (Fig. 73).
(8) Install piston spring, spacer ring and wave
spring i n clutch retainer. Be sure wave spring is fully
seated. Tap spring into place i f necessary.
(9) Lubricate clutch plates with transmission fluid.
(10) Install inner pressure plate.
(11) Install first clutch disc followed by a steel
plate until all discs and plates are installed.
(12) Install outer pressure plate and snap ring.
(13) Check clutch pack clearance with feeler gauge
(Fig. 75). Clearance should be 0.6 to 1.14 mm (0.025
to 0.045 in.). A low limit clearance is preferred.
(14) I f clutch pack clearance is incorrect, clutch
pack snap ring, pressure plate, steel plates and discs
will have to be replaced.
PLANETARY GEAR TRAIN AND OUTPUT SHAFT

Fig. 74 Input Shaft And Retainer Seal Ring OVERHAUL
Locations (36RH/37RH)
G E A R T R A I N AND SHAFT INSPECTION
(3) Press input shaft into retainer. Secure shaft
Clean the output shaft and geartrain components
with snap ring. Use new snap ring i f old one is dis
(Fig. 76). Use parts cleaning solvent and dry with
torted, or damaged.
compressed air.
(4) Install new seals on clutch piston. Lubricate Remove one of the snap rings that retain the sun
piston seals with Ru-Glyde, or Door Ease. Be sure gear i n the driving shell. Then remove the sun gear
seal lips face input shaft. and thrust plate.
(5) Install clutch piston i n retainer. Use twisting Check sun gear and driving shell condition. Re
motion to seat piston i n retainer. Do not push pis place the sun gear as an assembly i f the gear teeth
ton straight in. This could d i s t o r t seals causing are chipped or worn. Also replace the gear as an as
leakage and clutch slip. sembly i f the bushings are scored or worn. The sun
gear bushings are not serviceable. Replace the thrust
SELECTIVE Inspect the machined surfaces of the output shaft.

SNAP RING Be sure the oil passages are open and clear. Replace
the shaft i f scored, pitted, or damaged.
PLANETARY GEARTRAIN ASSEMBLY AND

ADJUSTMENT
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to hold parts i n place and to lubricate output
shaft bushing surfaces, thrust washers and thrust
plates.
(2) Install front snap ring on sun gear and install
gear i n driving shell. Then install thrust plate over
sun gear and against rear side of driving shell. In
stall rear snap ring to secure sun gear and thrust
plate i n driving shell.
(3) Install rear annulus gear on output shaft (Fig.
77).
FEELER
GAUGE
RH295
Fig. 75 Measuring Rear Clutch Pack Clearance

(Typical)
plate i f worn, or severely scored. Replace the driving
shell i f distorted, cracked, or damaged i n any way.
Inspect the planetary gear sets and annulus gears.
The pinion gears, pinion shafts, pinion washers and
shaft retaining pins are all serviceable and can be re
placed i f worn or damaged. However, i f a pinion car
rier is damaged, the entire planetary gear set must
be replaced as an assembly.
Replace the annulus gears i f the teeth are chipped, OUTPUT
SHAFT J9121-68
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash Fig. 77 Installing Rear Annulus Gear On Output
ers i f cracked, scored or worn. Shaft (36RH/37RH)
SNAP RING
(SELECTIVE) THRUST REAR
FRONT THRUST REAR ANNULUS
WASHER DRIVING SHELL PLANETARY GEAR
ANNULUS G E A R PLATE GEAR
ASSEMBLY
FRONT
PLANETARY G E A R
ASSEMBLY
THRUST
PLATE
LOW-REVERSE
OUTPUT SHAFT
DRUM
J9121-67
Fig. 76 Planetary Geartrain Components (36RH/37RH)

• ^ 36RH/37RH TRANSMISSION OVERHAUL 21 - 239
(4) Install thrust plate in annulus gear (Fig. 78).

Be sure plate is seated on shaft splines and against
gear.
Fig. 78 Installing Rear Annulus Thrust Plate

(36RH/37RH)
(5) Install rear planetary gear in rear annulus
gear (Fig. 79). Be sure planetary carrier is seated
against annulus gear.
Fig. 81 Installing Sun Gear And Driving Shell

(38RH/37RH)
(10) Install tabbed thrust washer on front plane
tary gear (Fig. 83). Seat washer tabs in matching
slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
Fig. 79 Installing Rear Planetary Gear (36RH/37RH) (11) Install front annulus gear over and onto front
planetary gear (Fig. 84). Be sure gears are fully
(6) Install tabbed thrust washer on front face of meshed and seated.
rear planetary gear (Fig. 80). Seat washer tabs in (12) Install front planetary and annulus gear as
matching slots in face of gear carrier. Use extra pe sembly (Fig. 85). Hold gears together and slide them
troleum jelly to hold washer in place if desired. onto shaft. Be sure planetary pinions are seated on
(7) Lubricate sun gear bushings with petroleum sun gear and that planetary carrier is seated on out
jelly or transmission fluid. put shaft.
(8) Install sun gear and driving shell on output (13) Place geartrain in upright position. Rotate
shaft (Fig. 81). Seat shell against rear planetary gears to be sure all components are seated and prop
gear. Verify that thrust washer on planetary gear erly assembled. Snap ring groove at forward end of
was not displaced during installation. output shaft will be completely visible when compo
(9) Install tabbed thrust washer in driving shell nents are correctly assembled.
(Fig. 82). be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
21 240 36RH/37RH TRANSMISSION OVERHAUL •
TAB DRIVING
Fig. 84 Assembling Front Planetary And Annulus

Fig. 82 Installing Driving Shell Thrust Washer
Gears (36RH/37RH)
(36RH/37RH)
Fig. 85 Installing Front Planetary And Annulus Gear

Fig. 83 Installing Thrust Washer On Front Planetary Assembly (36RH/37RH)
Gear (36RH/37RH)
(14) Install planetary snap ring i n groove at end of VALVE 10DY SERVICE AID ADJUSTMENT
output shaft (Fig. 86).
WALVE BODY DISASSEMBLY
CAUTION: Do not clamp any part of the valve body

in a vise. This practice will distort the valve body
and transfer plate resulting in valve bind. Slide
valves and plugs out carefully. Do not u s e force at
any time. The valves and valve body will be dam
aged if force is used. Also tag or mark the valve
body springs for reference a s they are removed. Do
not allow them to become intermixed.
(1) Remove screws attaching adjusting screw

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1 9 9 4

To order the special service tools used and

NO PART OF THIS PUBLICATION MAY BE

Chrysler Corporation reserves the right to make changes In design or to

Litho In U.S.A. Copyright © 1993 Chrysler Corporation 20M0793

"f 1 Exhaust System a n d Intake Manifold

Service Manual C o m m e n t Forms (Rear of Manual)

VEHICLE IDENTIFICATION NUMBER (VIN) • Equipment Identification Plate

BODY CODE PLATE

VEHICLE SAFETY CERTIFICATION LABEL

• Month and year of vehicle manufacture

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS

REAR W I N D O W ENGINE COOLANT BATTERY CHARGING

VEHICLE INTERIOR DIMENSIONS

A Head Room 40.2

1500/ 2500/ 3500/

G R O S S VEHICLE WEIGHT RATING—2WD PICKUP

—Rear 1,670 1,695 — —

—Total 4,010 4,035 — — —

- M A G N U M 5.2L V 8 _ 2,065 2,845 — —

— M A G N U M 5.9L V 8 —• 1,980 2,810 4,100 5,290

G R O S S V E H I C L E WEIGHT RATING—4WD PICKUP

G R O S S VEHICLE WEIGHT RATING—PICKUP 8.0L O R DIESEL

G R O S S VEHICLE WEIGHT RATING—2WD CHASSIS CAB S.9L

1 6 3 " W B (84" CA)

G R O S S VEHICLE WEIGHT RATING—4WD CHASSIS CAB S.9L

1 3 9 " W B (60" CA)

163" W B (84" CA)

G R O S S V E H I C L E WEIGHT RATING—2WD CHASSIS CAB 8.0L OR DIESEL

8.0L V10 A N D 5 . 9 L DIESEL — 4 x 2

—Total 4,975 5,280 — —

8.0L V10 A N D 5 . 9 L DIESEL — 4 x 4

—Total 5,415 5,710 — —

F A S T E N E R T O R Q U E INFORMATION AND METRIC C O N V E R S I O N

CONWERSION FORMULAS AND EQUIWALENT WALUES

Inches H g (60°F) x 3.377 « Kilopascals (kPaj kPa x 0.2961 = Inches H g

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

mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

1 Inch « 25 Millimeters 1 Cubic Inch « 16 Cubic Centimeters

STANDARD TORQUE SPECIFICATIONS

THREAD NUMBER THREAD DISTANCE

METRIC BOLTS—IDENTIFICATION CLASS NUMBERS

in-lbs to N«m N»m to in-lbs

ft-lbs to N«m N«m to ft-lbs

LUBRICATION AND MAINTENANCE

CHASSIS AND BODY 28 JUMP STARTING, TOWING AND HOISTING . . . 12

INTRODUCTION • Lubricate parking brake ratio lever pivot.

112,500 MILES (181 OOO KM) OR A T 90 • Replace spark plugs.

42,000 MILES (67 OOO KM) OR A T 42 MONTHS • Lubricate steering linkage.

MAINTENANCE SCHEDULES DIESEL ENGINE VEHICLE

SEVERE SERVICE ' 24,000 MILES (38 OOO KM) OR AT 24 MONTHS

48,000 MILES (77 OOO KM) OR AT 48 MONTHS • Replace fuel filter.

JUMP STARTING (2) When using another vehicle as a booster

CAUTION: When using another vehicle a s a

DISCONNECT CABLE CLAMPS AS FOLLOWS: • A n axle tube

TWO-WHEEL-DRIVE VEHICLE TOWING

APPLIED NEUTRAL POSITION

@ SLING TYPE/WHEEL LIFT

OIL P R O P E R L Y . CONTACT YOUR D E A L E R OR GOV ANTICIPATED TEMPERATURE RANGE

Ml rubber and plastic components should be in

(3) Connect the stabilizer bar links and shock ab

CAUTION: All suspension components that use rub