Description
1995 Dodge Ram 1500 2500 3500 Truck Service Manual
This is the complete service manual for the 1995 Dodge Ram 1500, 2500, and 3500 trucks. Whether you are servicing a 3.9L V-6, a 5.2L V-8, a 5.9L V-8, an 8.0L V-10, or the 5.9L Cummins diesel, this 1995 Dodge Ram service manual covers every major system with the procedures, specifications, and diagnostic information a professional technician needs. From routine lubrication and maintenance to complete engine overhauls, this Dodge Ram 1500-3500 workshop manual is the single most useful reference you can have for these trucks.
File Details
- Manual Type: Service Manual
- Brand: Dodge
- Model: Ram Truck 1500, 2500, 3500
- Language: English
- File Format: PDF
- Publication Number: 20M0694
- Copyright: 1994 Chrysler Corporation
- Litho in U.S.A.
Chapters Covered
- Introduction
- Lubrication and Maintenance
- Front Suspension and Axle
- Rear Suspension and Axles
- Brakes
- Clutch
- Cooling System
- Electrical
- Engines
- Exhaust System and Intake Manifold
- Frame and Bumpers
- Fuel System
- Propeller Shafts
- Steering
- Transmissions and Transfer Cases
- Wheels and Tires
- Body Components
- Heating and Air Conditioning
- Emission Control Systems
- Index
This 1995 Dodge Ram 1500-3500 service manual is organized by group, with each section containing general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the components involved. The manual covers both 2-wheel drive and 4-wheel drive configurations, and includes detailed coverage of all available engine options: the 3.9L V-6, 5.2L V-8, 5.9L V-8 (both light-duty and heavy-duty versions), 8.0L V-10, and the 5.9L Cummins in-line 6-cylinder diesel. Whether you are working on the front suspension and axle, the rear suspension and axles, the brake system, the clutch, the cooling system, the electrical system, the engine, the exhaust system, the frame and bumpers, the fuel system, the propeller shafts, the steering system, the transmissions and transfer cases, the wheels and tires, the body components, the heating and air conditioning system, or the emission control systems, you will find the information you need in this comprehensive 1995 Dodge Ram service manual.
What This 1995 Dodge Ram Service Manual Enables You to Do
This Dodge Ram 1500-3500 repair manual is not a generic guide. It is the same manual used by professional technicians to service and repair these trucks. With it, you can perform everything from basic maintenance to complex repairs. The lubrication and maintenance section gives you the factory maintenance schedules, fluid capacities, and the correct lubricants and fluids for every system on the truck. The front and rear suspension sections walk you through every procedure for the link/coil suspension, the independent front suspension (IFS), the Dana 44 and Dana 60 front axles, and the 9 1/4, Dana 60, Dana 70, and Dana 80 rear axles, including differential service, axle shaft replacement, and pinion seal replacement. The brake section covers disc brakes, drum brakes, the master cylinder, the power brake booster, the rear wheel anti-lock (RWAL) system, and the all-wheel anti-lock brake system (ABS), with complete diagnostic charts and service procedures. The clutch section covers the hydraulic linkage, the clutch cover and disc, the release bearing, the pilot bearing, and the flywheel. The cooling system section covers the radiator, water pump, thermostat, hoses, fan, and viscous fan drive for all engines. The electrical section covers the battery, starting system, charging system, ignition system, instrument panel and gauges, audio systems, horns, speed control, turn signals, wipers, lamps, and the restraint system. The engine sections cover the 3.9L V-6, the 5.2L V-8, the 5.9L V-8, the 8.0L V-10, and the 5.9L Cummins diesel, with complete disassembly, inspection, and assembly procedures, torque specifications, and clearance specifications. The exhaust system and intake manifold section covers the exhaust manifolds, catalytic converters, mufflers, tailpipes, and intake manifolds. The frame and bumpers section covers the frame, front and rear bumpers, trailer hitch, and snow plow. The fuel system section covers the fuel tank, fuel pump, fuel filter, fuel injectors, fuel rail, and the multi-port fuel injection (MFI) system for gasoline engines, as well as the diesel fuel delivery system. The propeller shaft section covers the front and rear propeller shafts, center bearing, and universal joints. The steering section covers the steering column, steering linkage, power steering pump, and the recirculating ball power steering gear. The transmission and transfer case section covers the NV3500 manual transmission, the NV4500 manual transmission, the 42RH/46RH/47RH automatic transmissions, and the NP231 HD, NP241, and NP241 HD transfer cases. The wheels and tires section covers tire pressure, rotation, and replacement. The body components section covers body mechanisms, lubrication, and service. The heating and air conditioning section covers the heater, air conditioning, and automatic temperature control. The emission control systems section covers the emission control components and vacuum hose routing. The index at the rear of the manual allows you to quickly locate any component or system.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the β1995 Dodge Ram 1500 2500 3500 Truck Service Manual – Complete PDF Workshop Guideβ are as follows:
Table of Contentsp. 4
+Introductionp. 6
+DESIIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTSp. 6
Vehicle Designationp. 6
Vehicle Safety Certification Labelp. 6
Vehicle Identification Number (VIN) Platep. 6
Body Code Platep. 7
Engine and Transmission/Transfer CaseIdentificationp. 7
Major Component Identificationp. 7
Equipment Identification Labelp. 7
International Vehicle Control and Display Symbolsp. 8
+Vehicle Dimensionsp. 8
VEHICLE INTERIOR DIMENSIONSβSTD CABp. 9
VEHICLE INTERIOR DIMENSIONSβCLUB CABp. 9
VEHICLE EXTERIOR DIMENSIONSβSTD CABp. 10
VEHICLE EXTERIOR DIMENSIONSβCLUB CABp. 11
VEHICLE EXTERIOR DIMENSIONSβCHASSIS CABp. 12
+Vehicle Weightsp. 13
GROSS VEHICLE WEIGHT RATINGβ2WD STD CABp. 14
GROSS VEHICLE WEIGHT RATINGβ4WD STD CABp. 15
GROSS VEHICLE WEIGHT RATINGβ2WD CLUB CABp. 16
GROSS VEHICLE WEIGHT RATINGβ4WD CLUB CABp. 17
GROSS VEHICLE WEIGHT RATINGβSTD CAB 8.0L OR DIESELp. 18
GROSS VEHICLE WEIGHT RATINGβCLUB CAB 8.0L OR DIESELp. 19
GROSS VEHICLE WEIGHT RATINGβ2WD CHASSIS GAB 5.9Lp. 20
GROSS VEHICLE WEIGHT RATINGβ4WD CHASSIS CAB S.9Lp. 21
GROSS VEHICLE WEIGHT RATINGβ2WD CHASSIS CAB 8.0L OR DIESELp. 22
GROSS VEHICLE WEIGHT RATINGβ4WD CHASSIS CAB 8.0L OR DIESELp. 23
+Trailer Towing Specificationsp. 24
TRAILER TOWINGβSTD CABp. 25
TRAILER TOWINGβSTD CAB(CONT)p. 26
TRAILER TOWINGβSTD CAB(CONT)p. 27
TRAILER TOWINGβCLUB CAB 4X2p. 28
TRAILER TOWINGβCLUB CAB 4X4p. 29
TRAILER TOWINGβCHASSIS CABp. 30
+MEASUREMENT AND TORQUE SPECIFICATIONSp. 31
SPECIFICATION NOTATIONSp. 31
METRIC AND ENGLISH/SAE CONVERSIONp. 31
+TORQUE SPECIFICATIONSp. 31
TORQUE CHARTSp. 31
+BOLT THREAD AND GRADE/CLASS IDENTIFICATIONp. 31
THREAD IDENTIFICATIONp. 31
SPECIFIED TORQUE FOR STANDARD BOLTSp. 32
THREAD NOTATIONβSAE AND METRICp. 33
GRADE/CLASS IDENTIFICATIONp. 33
METRIC CONVERSIONp. 33
BOLT IDENTIFICATIONp. 34
Bolt Markings and Torque Values – U.S. Customaryp. 34
BOLT STRENGTHp. 35
METRIC CONVERSEp. 36
+0-Lubrication & Maintenancep. 37
+GENERAL INFORMATIONp. 37
INTRODUCTIONp. 37
INTERNATIONAL SYMBOLSp. 37
+Fuel Requirementsp. 37
GASOLINE ENGINESp. 37
DIESEL ENGINESp. 38
Classification of Lubricantsp. 38
Lubrication and Replacement Parts Recommendationp. 38
Components Requiring No Lubricationp. 39
Fluid Capacitiesp. 39
+MAINTENANCE SCHEDULESβLIGHT DUTY VEHICLESp. 40
INTRODUCTIONp. 40
EMISSION CONTROL SYSTEM MAINTENANCEp. 40
+SERVICE INTERVALS FOR 1500 AND 2500 LIGHTDUTY VEHICLESp. 40
SCHEDULEβAp. 40
SCHEDULEβBp. 41
+MAINTENANCE SCHEDULESβHEAVY DUTYp. 44
INTRODUCTIONp. 44
EMISSION CONTROL SYSTEM MAINTENANCEp. 44
+SERVICE INTERVALS FOR 2500 AND 3500 HEAVY DUTY VEHICLESp. 44
SCHEDULEβAp. 44
SCHEDULEβBp. 46
+MAINTENANCE SCHEDULESβDIESEL ENGINE VEHICLEp. 62
INTRODUCTIONp. 49
+SERVICE INTERVALS FOR DIESEL ENGINE VEHICLEp. 49
SCHEDULEβp. 49
SCHEDULEβBp. 50
+JUMP STARTING, TOWING AND HOISTINGp. 53
Jump Startingp. 53
Hoisting Recommendationsp. 54
Towing Recommendationsp. 54
Ground Clearance and Ramp Anglep. 55
Two-Wheel-Drive Vehicle Towingp. 55
Four-Wheel-Drive Vehicle Towingp. 55
Towing When Keys Are Not Availablep. 55
+ENGINE MAINTENANCE-GASOLINEp. 56
BREAK-IN PERIODp. 56
ENGINE OILp. 56
Engine Oil Filterp. 57
Engine Cooling Systemp. 58
Engine Air Cleanerp. 59
Crankcase Ventilation Systemp. 59
Fuel Systemp. 60
Fuel Filterp. 60
Ignition Cables, Distributor Cap, and Rotorp. 60
Spark Plugsp. 60
Batteryp. 61
Rubber and Plastic Component Inspectionp. 61
Emission Control Systemp. 61
Accessory Drive Beltsp. 61
Exhaust SystemβGasolinep. 61
Air-Conditioner Compressorp. 61
+DIESEL ENGINEp. 62
Engine Oilp. 62
Break-In Periodp. 62
Engine Oil Filterp. 63
Engine Cooling Systemp. 64
Engine Air Cleanerp. 64
Batteryp. 64
Rubber and Plastic Component Inspectionp. 65
Exhaust SystemβDieselp. 65
Air-Conditioner Compressorp. 65
+DRIVETRAINp. 66
Clutch and Brake Pedal Bushingsp. 66
Clutch Master Cylinderp. 66
Manual Transmissionsp. 67
Automatic Transmissionp. 67
Transfer Case (4WD Vehicles)p. 68
Front Axie (4WD)p. 68
Rear Axlep. 66
Front Axle U-Joint and Pivot Bearingsp. 69
Drive Shaftsp. 70
Rubber and Plastic Hoses/Tubingp. 70
+CHASSIS AND BODYp. 71
Chassis Component and Wheel Bearing Lubricantsp. 71
Steering Linkagep. 71
Manual Steering Gearp. 71
Power Steering Systemp. 71
Front Wheel Bearingsp. 72
Rear Wheel Bearingsp. 73
Brakesp. 73
Parking Brakep. 74
Tiresp. 74
Body Component Mechanismsp. 75
Headlampsp. 75
Speedometer Cablep. 75
+2-Front Suspension & Axlep. 76
+GENERAL INFORMATIONp. 76
+FRONT SUSPENSIONp. 76
LINK/COIL SUSPENSIONp. 76
INDEPENDENT FRONT SUSPENSIONp. 77
FRONT DRIVE AXLEp. 77
STANDARD DIFFERENTIAL OPERATIONp. 77
+FRONT WHEEL ALIGNMENTp. 79
GENERAL INFORMATIONp. 79
PRE-ALIGNMENT ISPECTION LINK/COIL SUSPENSIONp. 79
ALIGNMENT AND ADJUSTMENTS LINK/COILSUSPENSIONp. 80
PRE-ALIGNMENT INSPECTION IFS SUSPENSIONp. 81
ALIGNMENT AND ADJUSTMENTS IFSSUSPENSIONp. 82
+ALIGNMENT SPECIFICATIONSp. 83
ALIGNMENT SPECIFICATIONS 4X2 AND 4X4p. 83
+LINK/COIL SUSPENSIONp. 84
SERVICE INFORMATIONp. 84
TRACK BARp. 84
STABILIZER BARp. 84
SHOCK DIAGNOSISp. 85
SHOCK ABSORBERp. 85
COIL SPRINGp. 85
LOWER SUSPENSION ARMp. 86
UPPER SUSPENSION ARMp. 86
+INDEPENDENT FRONT SUSPENSION (IFS)p. 87
Service Informationp. 87
Stabilizer Barp. 87
Shock Diagnosisp. 87
Shock Absorberp. 87
Coil Springsp. 88
Lower Suspension Armp. 89
Lower Ball Studp. 89
Upper Suspension Armp. 90
Upper Ball Studp. 90
Wheel Hub and Bearingsp. 90
Steering Knucklep. 91
+AXLE NOISE/VIBRATION DIAGNOSISp. 92
GENERAL INFORMATIONp. 92
+GEAR AND BEARING NOISEp. 92
GEAR NOISEp. 92
BEARING NOISEp. 92
LOW SPEED KNOCKp. 93
VIBRATIONp. 93
DRIVELINE SNAPp. 93
SERVICE DIAGNOSISp. 94
+AXLE SERVICE PROCEDURESp. 96
GENERAL INFORMATIONp. 96
Lubricant Specificationsp. 96
Lubricant Changep. 96
Drive Axle Assembly Replacementp. 97
Pinion Seal Replacementp. 98
Hub Bearing and Axle Shaftp. 99
Axle Shaftβ Cardan U-Jointp. 99
+Vacuum Disconnect 44/60 Axlep. 100
+DISCONNECT AXLE/SHIFT MOTOR DIAGNOSISp. 101
TWO-WHEEL DRIVE OPERATION DIAGNOSISp. 101
FOUR-WHEEL DRIVE OPERATION DIAGNOSISp. 102
SHIFT MOTOR β REMOVAL/DISASSEMBLYp. 103
INTERMEDIATE AXLE SHAFTβREMOVAL/DISASSEMBLYp. 103
+Steering Knuckle and Ball Studsp. 104
knuckle removalp. 104
UPPER BALL STUD REPLACEMENT 44 AXLEp. 104
LOWER BALL STUD REPLACEMENT 44 AXLEp. 104
UPPER BALL STUD REPLACEMENT 60 AXLEp. 106
LOWER BALL STUD REPLACEMENT 60 AXLEp. 106
KNUCKLE INSTALLATION MODEL 44p. 106
KNUCKLE INSTALLATION MODEL 60p. 107
Differential Removalp. 107
Axle Shaft Oil Sealp. 108
Differential Disassemblyp. 108
Pinion Removal/Disassemblyp. 108
Cleaning/Inspectionp. 109
Differential Assemblyp. 110
+Pinion Gear Depth Informationp. 110
PINION GEAR DEPTH VARIANCEp. 112
Differential and Pinion Measurementp. 112
Pinion Gear Assembly/Installationp. 114
Differential Shim Pack Measurement and Adjustmentp. 115
Differential Installationp. 116
+Backlash and Contact Pattern Analysisp. 117
Gear Tooth Contact Patternsp. 118
Final Assemblyp. 119
AXLE SPECIFICATIONSp. 119
TORQUE SPECIFICATIONSp. 120
+3-Rear Suspension & Axlep. 121
+GENERAL INFORMATIONp. 121
SUSPENSIONp. 121
AXLESp. 121
[IDENTIFICATIONp. 121
STANDARD DIFFERENTIAL OPERATIONp. 121
LUBRICANTSp. 123
+REAR SUSPENSIONβ2WD and 4WD VEHICLESp. 124
SPRING AND SHOCK DIAGNOSISp. 124
VEHICLE LOADING AND WEIGHT DISTRIBUTIONp. 124
SHOCK ABSORBERp. 124
SPRINGSp. 124
+AXLE NOISE/VIBRATION DIAGNOSISp. 126
GENERAL INFORMATIONp. 126
GEAR AND BEARING NOISEp. 126
LOW SPEED KNOCKp. 127
VIBRATIONp. 127
DRIVELINE SNAPp. 127
REAR AXLE ALIGNMENTp. 127
LIMITED SLIP DIFFERENTIALp. 127
SERVICE DIAGNOSIS CHARTp. 128
SERVICE DIAGNOSIS (CONT'D}p. 129
+9 1/4 AXLE SERVICE PROCEDURESp. 130
INFORMATIONp. 130
AXLE ASSEMBLY REMOVAL/INSTALLATIONp. 130
LUBRIlCATION CHANGEp. 130
9 1/4 Axle EXPLODED VIEWp. 131
AXLE SHAFT, SEAL AND BEARING SERVICEp. 132
PINION SEAL REPLACEMENTp. 133
+DIFFERENTIAL SERVICEp. 135
SERVICE INFORMATIONp. 135
DIFFERENTIAL CASE REMOVALp. 135
PINION GEAR SHAFT REMOVALp. 136
RING GEARp. 136
CASE FLANGE RUNOUT MEASUREMENTp. 136
DIFFERENTIAL CASE DISASSEMBLYp. 136
CLEANING AND INSPECTIONp. 137
EXCITER RING REPLACEMENTp. 137
DIFFERENTIAL CASE ASSEMBLYp. 137
PINION DEPTH MEASUREMENT AND ADJUSTMENTp. 138
PINION GEAR DEPTH VARIANCEp. 139
DIFFERENTIAL CASE INSTALLATIONp. 140
DIFFERENTIAL BEARING PRELOAD AMD RINGGEAR BACKLASH ADJUSTMENTp. 141
SIDE GEAR CLEARENCE MEASUREMENT AND ADJUSTMENTp. 142
RING GEAR TEETH CONTACT PATTERN ANALYSISp. 142
Gear Teeth Contact Patternsp. 143
+MODEL 60, 70 and 80 AXLE SERVICEPROCEDURESp. 144
+GENERAL INFOMATIONp. 144
Model 70 and 80 Rear Axlep. 145
LUBRICANTp. 144
Axle Assembly Removal/Installationp. 146
Drain and Refillp. 146
Pinion Seal ReplacementβModel 70 and 80p. 147
Pinion Seal ReplacementβModel 60p. 147
Axle Shaft Removal/Installationp. 149
Wheel Bearing Servicep. 149
Differential Disassemblyp. 150
+Pinion Removal/Disassemblyp. 151
CLEANING/INSPECTIONp. 152
+Differential Assemblyp. 153
PINION GEAR DEPTH INFORMATIONp. 155
+Pinion Measurement and Assemblyp. 156
PINION GEAR DEPTH MEASUREMENTp. 156
PINION GEAR DEPTH VARIANCEp. 156
+Ring Gear Backlash and Contact Patternp. 159
RING GEAR BACKLASH MEASUREMENTp. 159
RING GEAR TEETH CONTACT PATTERN ANALYSISp. 161
Gear Teeth Contact Patternsp. 162
+TRAC-LOK/POWER-LOK DIFFERENTIALp. 163
+SERVICE INFORMATIONp. 163
NOISE DIAGNOSISp. 163
TRAC-LOK/POWER-LOK DIFFERENTIAL TESTp. 163
LUBRICANTSp. 164
+TRAC-LOK 9 1 \ AND MODEL 60 AXLESp. 164
DISASSEMBLYp. 164
CLEANING AND INSPECTIONp. 166
PRESOAK PLATES AND DISCp. 166
ASSEMBLYp. 166
+POWER-LOK MODEL 70 AXLE AND TRAC-LOK MODEL 80 AXLEp. 168
DISASSEMBLYp. 168
CLEANING AND INSPECTIONp. 168
ASSEMBLYp. 168
Power-Lok Components Exploded Viewp. 169
AXLE SPECIFICATIONSp. 171
TORQUE SPECIFICATIONSp. 172
+5-Brakesp. 173
+GENERAL INFORMATIONp. 173
SERVICE BRAKE COMPONENTSp. 173
ANTILOCK BRAKE SYSTEMSp. 173
BRAKE WARNING LIGHTSp. 174
BRAKE FLUID/LUBRICANTS/ CLEANING SOLVENTSp. 174
MODEL IDENTIFICATIONp. 174
BRAKE SAFETY PRECAUTIONSp. 174
+SERVICE BRAKE DIAGNOSISp. 175
General Informationp. 175
Service Brake Diagnosis Proceduresp. 175
Brake Warning Lightsp. 175
Low Vacuum SwitchβDiesel Modelsp. 175
Preliminary Brake Checkp. 176
Road Testingp. 176
Component Inspectionp. 176
Pedal Falls Awayp. 176
Low Brake Pedalp. 176
Brake Pedal Has Spongy Feelp. 176
Hard Pedal or High Pedal Effortp. 177
Brake Dragp. 177
Brake Fadep. 177
Brake Pedal Pulsationp. 177
Brake Pullp. 177
Rear Brake Grab or Pullp. 177
Brakes Do Not Hold After Driving Through Deep Water Puddlesp. 178
Brake Noisep. 178
Contaminated Brakeliningp. 178
Brake Fluid Contaminationp. 178
Master Cylinder/Power Booster Testp. 179
Power Booster Check Valve Testp. 179
Power Booster Vacuum Testp. 179
Testing Diesel Engine Vacuum Pump Outputp. 179
Booster Vacuum Test Connectionsp. 180
+MASTER CYLINDERp. 181
Descriptionp. 181
Master Cylinder Serviceabilityp. 181
Master Cylinder Applicationp. 181
Master Cylinder Identification Codesp. 181
Recommended Brake Fluidp. 182
Brake Fluid Levelp. 182
Brake Fluid Contaminationp. 182
Master Cylinder Removalp. 183
Master Cylinder Disassembly and Overhaulp. 184
Master Cylinder Cleaning and Inspectionp. 185
Master Cylinder Reassemblyp. 185
Master Cylinder Bleeding (On Bench)p. 186
Master Cylinder Installationp. 187
+POWER BRAKE BOOSTERβBRAKE PEDAL-BRAKELIGHT SWITCHp. 188
Component Descriptionp. 188
Power Brake Booster Identificationp. 188
Power Brake Booster Serviceabilityp. 189
Power Brake Booster Operationp. 189
Power Brake Booster Removalp. 189
Power Brake Booster Installationp. 190
Brakelight Switch Removalp. 190
Brakelight Switch Test and Diagnosisp. 191
Brakelight Switch Adjustment and Installationp. 191
Brake Pedal Removalp. 191
BRAKE PEDAL INSTALLATIONp. 192
+POWER BRAKE VACUUM PUMP (DIESEL MODELS)p. 193
General Informationp. 193
VACUUM PUMP SERVICEABILITYp. 193
LOW VACUUM WARNING SWITCHp. 193
VACUUM PUMP OPERATIONp. 193
VACUUM PUMP DIAGNOSISp. 194
VACUUMβSTEERING PUMP ASSEMBLY REMOVALp. 194
VACUUM PUMP REPLACEMENTp. 196
PUMP ADAPTER REPLACEMENTp. 196
VACUUMβSTEERING PUMP ASSEMBLY INSTALLATIONp. 197
+REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEMp. 198
General Informationp. 198
+RWAL System Componentsp. 198
Electronic Control Modulep. 199
RWAL VALVEp. 199
Combination Valvep. 199
SPEED SENSOR AND EXCITER RINGp. 199
ANTILOCK WARNING LAMPp. 200
Rear Wheel Antilock System Operationp. 200
Combination Valve Operationp. 200
Rear Wheel Antilock System Diagnosisp. 201
Diagnostic Fault Flash Codesp. 201
Fault Code Capacityp. 201
RWAL Diagnostic Connectorp. 201
Fault Code Identificationp. 201
Clearing A Fault Codep. 201
Fault Condition Causesp. 201
RWAL Antilock System Flash Codesp. 202
Antilock Component Serviceabilityp. 202
RWAL Valve/Combination Valve Removalp. 202
RWAL Valve/Combination Installationp. 203
Control Module Removal/Installationp. 203
Rear Speed Sensor Removal/I nstallationp. 204
Rear Speed Sensor Rear Harness Removal/Installationp. 205
+RWAL System Brake Bleedingp. 205
MANUAL BLEEDING PROCEDUREp. 206
PRESSURE BLEEDINGp. 207
+ALL-WHEEL ANTILOCK BRAKE SYSTEM {ABS}p. 208
+ABS Componentsp. 208
Front Brake ABS Valvep. 208
RWAL Valvep. 208
Combination Valvep. 209
ABS Control Modulep. 209
ABS Diagnostic Connectorp. 209
Wheel Speed Sensors And Tone Wheelsp. 209
Master Cylinder And Power Brake Boosterp. 209
+All Wheel Antilock System (ABS) Operationp. 210
ABS OPERATION IN NORMAL BRAKING MODEp. 210
ABS OPERATION IN ANTILOCK BRAKINGMODEp. 211
Combination Valve Operationp. 211
ABS System Diagnosisp. 211
ABS Diagnostic Connector Locationp. 212
ABS Normal and Fault Conditionsp. 212
ABS Warning Light Displayp. 212
ABS Control Module Diagnosisp. 212
ABS Valve Service and Diagnosisp. 213
Combination Valve Testingp. 213
ABS Valve and Control Module Removalp. 213
ABS Valve and Control Module Installationp. 213
RWAL Valve/Combination Valve Removalp. 214
RWAL Valve/Combination Installationp. 215
Front Speed Sensor Removalp. 215
Front Speed Sensor Installationp. 215
Front Tone Wheel Servicep. 216
Rear Speed Sensor Removal/Installationp. 216
Rear Speed Sensor Installationp. 216
Rear Speed Sensor Harness Replacementp. 216
ABS System Brake Bleedingp. 216
ABS Manual Brake Bleeding Procedurep. 218
+DISC BRAKESp. 220
General Service Informationp. 220
Caliper Operation and Wear Compensationp. 220
Disc Brakeshoe Removalp. 222
Disc Brakeshoe and Caliper Inspectionp. 223
Disc Brakeshoe Installationp. 223
Disc Brake Caliper Removalp. 225
Disc Brake Caliper Disassemblyp. 225
Disc Brake Caliper Cleaning and Inspectionp. 226
Disc Brake Caliper Overhaul and Reassemblyp. 227
Disc Brake Caliper Installationp. 228
Disc Brake Rotor Inspection and Servicep. 229
Disc Brake Rotor Removal (With Tapered Bearings)p. 230
Disc Brake Rotor Installation (With TaperedBearings)p. 231
Wheel Bearing Adjustment (With Tapered Bearings)p. 231
Disc Brake Rotor Removal (With Unit Bearings)p. 232
Disc Brake Rotor Installation (With Unit Bearings)p. 233
Front Wheel Bearing Replacementp. 234
Wheel Nut Tighteningp. 234
+DRUM BRAKESp. 235
General Service Informationp. 235
Drum Brake Operationp. 235
Brakelining Wear Compensationp. 235
Brakeshoe Removal (11-Inch Brake)p. 235
Brakeshoe Installation (11-Inch Brake)p. 237
Brakeshoe Removal (13-Inch Brake)p. 238
Brakeshoe Installation (13-Inch Brake)p. 239
Wheel Cylinder Removal (All)p. 241
Wheel Cylinder Overhaul (All)p. 241
Wheel Cylinder Installation (All)p. 242
Drum Brake Adjustmentp. 243
Brake Support Plate Removalp. 243
Brake Support Plate Installationp. 243
Brake Drum Servicep. 244
Wheel Nut Tighteningp. 244
+PARKING BRAKESp. 245
Front Cable Replacementp. 245
Rear Cable Replacementp. 245
Parking Brake Cable Tensioner Adjustmentp. 246
+Parking Brake Pedal Assembly Replacementp. 247
Parking Brake Pedal Mountingp. 248
SPECIFICATIONSp. 249
+6-Clutchp. 250
CLUTCH COMPONENTSp. 250
CLUTCH DISC APPLICATIONp. 250
CLUTCH COVER APPLICATIONp. 251
CLUTCH PEDAL POSITION SWITCHp. 252
CLUTCH HYDRAULIC LINKAGEp. 252
CLUTCH LINKAGE FLUIDp. 252
CLUTCH COMPONENT LUBRICATIONp. 252
GENERAL DIAGNOSIS INFORMATIONp. 252
CLUTCH PROBLEM CAUSESp. 253
+INSPECTION AND DIAGNOSIS CHARTSp. 254
Clutch Inspection Pointsp. 255
Clutch Inspection Chartsp. 256
Clutch Inspection Charts(Cont.)p. 257
Clutch Inspection Charts(Cont.)p. 258
Clutch Inspection Charts(Cont.)p. 259
Clutch Pedal Position Switch Circuitryp. 260
CLUTCH COVER AND DISC REMOVALp. 261
CLUTCH COVER AND DISC INSTALLATIONp. 261
CLUTCH HOUSING REPLACEMENT (NV4500)p. 263
RELEASE BEARING REPLACEMENTp. 264
PILOT BEARING REPLACEMENTp. 264
CLUTCH LINKAGE SERVICEp. 265
CLUTCH PEDAL REMOVALp. 266
CLUTCH PEDAL INSTALLATIONp. 266
FLYWHEEL SERVICEp. 267
+CHECKING NV4500 CLUTCH HOUSING RUNOUTp. 268
MEASURING CLUTCH HOUSING BORE RUNOUT (NV4S00 ONLY)p. 268
CORRECTING CLUTCH HOUSING BORERUNOUT (NV4S00 GAS ENGINE ONLY)p. 268
MEASURING CLUTCH HOUSING FACE RUNOUT (NV4500)p. 268
CORRECTING CLUTCH HOUSING FACE RUNOUT (NW4500)p. 269
+7-Cooling Systemp. 271
GENERAL INFORMATIONp. 271
+DIAGNOSISp. 274
On-Board Diagnostics (OBD)p. 274
DRB SCAN TOOLp. 275
+PRELIMINARY CHECKSp. 275
COOLING SYSTEM DIAGNOSISβALL EXCEPT DIESELp. 276
COOLING SYSTEM DIAGNOSISβALL EXCEPT DIESEL(CONT.)p. 277
COOLING SYSTEM DIAGNOSISβALL EXCEPT DIESEL(CONT.)p. 278
COOLING SYSTEM DIAGNOSISβALL EXCEPT DIESEL(CONT.)p. 279
COOLING SYSTEM DIAGNOSISβALL EXCEPT DIESEL(CONT.)p. 280
COOLING SYSTEM DIAGNOSISβALL EXCEPT DIESEL(CONT.)p. 281
COOLING SYSTEM DIAGNOSISβDIESEL ENGINEp. 282
COOLING SYSTEM DIAGNOSISβDIESEL ENGINE(CONT.)p. 283
COOLING SYSTEM DIAGNOSISβDIESEL ENGINE(CONT.)p. 284
COOLING SYSTEM DIAGNOSISβDIESEL ENGINE(CONT.)p. 285
COOLING SYSTEM DIAGNOSISβDIESEL ENGINE(CONT.)p. 286
COOLING SYSTEM DIAGNOSISβDIESEL ENGINE(CONT.)p. 287
+SERVICE PROCEDURESp. 288
Water PumpsβExcept Diesel and 8.0L V-10Enginep. 288
Water Pumpβ8.0L V-10 Enginep. 291
Water Pumpβ5.9L Dieselp. 295
Water Pump Bypass Hosep. 296
Thermostatp. 300
Coolantp. 307
DRAINING COOLING SYSTEMp. 308
Refilling Cooling Systemp. 308
Cooling System Cleaning/Reverse Flushingp. 309
Testing Cooling System for Leaksp. 310
Coolant Reserve/Overflow Systemp. 311
Radiator Pressure Capp. 312
Radiatorsp. 313
Cooling System Hosesp. 315
Cooling System FanβGas Enginesp. 316
Cooling System FanβDiesel Enginep. 317
Viscous Fan Drivep. 318
+AUTOMATIC TRANSMISSION OIL COOLERSp. 320
Automatic Transmission Oil CoolersβExcept DieselEnginesp. 320
Automatic Transmission Oil CoolersβDieselEnginep. 322
+ENGINE ACCESSORY DRIVE BELTSp. 324
General Informationp. 324
Belt Diagnosisp. 324
Belt Schematicsp. 324
Belt Tensionp. 324
Belt Removal/Installationp. 324
SERPENTINE DRIVE BELT DIAGNOSISp. 325
Automatic Belt Tensionerp. 328
ENGINE BLOCK HEATERSp. 331
SPECIFICATIONSp. 333
+8-Electricalp. 334
+8A-Battery/Starting/ Charging System Diagnosticsp. 334
GENERAL INFORMATIONp. 334
+BATTERYp. 335
GENERAL INFORMATIONp. 335
BATTERY RATINGSp. 336
+DIAGNOSISp. 336
ABNORMAL BATTERY DISCHARGINGp. 336
BATTERY DIAGNOSISp. 337
BUILT-IN TEST INDICATORp. 338
HYDROMETER TESTp. 338
OPEN CIRCUIT VOLTAGE TESTp. 339
LOAD TESTp. 339
+BATTERY CHARGINGp. 341
BATTERY CHARGING TIME TABLEp. 341
CHARGING TIME REQUIREDp. 341
CHARGING COMPLETELY DISCHARGED BATTERYp. 342
IGNITION-OFF DRAWp. 343
+STARTING SYSTEMp. 344
GENERAL INFORMATIONp. 344
STARTING SYSTEM DIAGNOSISp. 346
COLD CRANKING TESTp. 347
FEED CIRCUIT TESTSp. 347
CONTROL CIRCUIT TESTSp. 348
STARTER RELAY CONNECTIONSp. 349
+CHARGING SYSTEMp. 351
GENERAL INFORMATIONp. 351
+DIAGNOSISp. 351
INSPECTIONp. 351
OUTPUT WIRE RESISTANCE TESTp. 352
CHARGING SYSTEM DIAGNOSISp. 352
CURRENT OUTPUT TESTp. 353
+USING ON-BOARD DIAGNOSTIC SYSTEMp. 355
GENERAL INFORMATIONp. 355
GENERATOR DIAGNOSTIC TROUBLE CODEp. 355
+SPECIFICATIONSp. 356
BATTERY SPECIFICATIONSp. 356
STARTING SYSTEM SPECIFICATIONSp. 356
CHARGING SYSTEM SPECIFICATIONSp. 357
+8B- Battery/Starter/ Generator Servicep. 358
+BATTERYp. 358
GENERAL INFORMATIONp. 358
BATTERY REMOVAL/INSTALLp. 358
+STARTER AND STARTER RELAYp. 362
GENERAL INFORMATIONp. 362
STARTER REMOVE/INSTALLp. 362
STARTER RELAY REMOVE/INSTALLp. 363
+GENERATORp. 365
GENERAL INFORMATIONp. 365
+SPECIFICATIONSp. 366
BATTERY SPECIFICATIONSp. 366
STARTING SYSTEM SPECIFICATIONSp. 366
GENERATOR SPECIFICATIONSp. 367
+8C-Overhead Consolep. 368
GENERAL INFORMATIONp. 368
DIAGNOSISp. 369
+SERVICE PROCEDURESp. 371
COMPASS VARIATION ADJUSTMENTp. 371
COMPASS DEMAGNETIZINGp. 371
OVERHEAD CONSOLE REMOVE/INSTALLp. 372
COMPASS/THERMOMETER MODULE REMOVE/INSTALLp. 373
READING/COURTESY LAMPSp. 373
+8D-Ignition Systemsp. 374
+COMPONENT IDENTIFICATION/SYSTEM OPERATIONp. 374
General Informationp. 374
Automatic Shutdown (ASD) Relayp. 375
Camshaft Position Sensorβ3.9L V-6 OR 5.2/5.9L V-8 Enginesp. 375
Camshaft Position Sensorβ8.OL V-10 Enginep. 376
Crankshaft Position Sensorβ3.9L V-6 or 5.2/5.9LV-8 Enginesp. 376
Crankshaft Position Sensorβ8.0L V-10 Enginep. 377
Distributorsβ3.9L V-6 or 5.2/5.9L V-8 Enginesp. 378
Ignition Coilβ3.9L V-6 or 5.2/5.9L V-8 Enginesp. 378
Ignition Coil Packsβ8.0L V-10 Enginep. 379
Ignition Control Moduleβ8.0L V-10 Enginep. 380
Engine Coolant Temperature Sensorp. 380
Intake Manifold Air Temperature Sensorp. 380
Manifold Absolute Pressure (MAP) Sensorp. 380
Powertrain Control Module (PCM)p. 380
Oxygen Sensor (02S)p. 381
+DIAGNOSTICS/SERVICE PROCEDURESp. 382
GENERAL INFORMATIONp. 382
Automatic Shutdown (ASD) Relay Testp. 382
Camshaft Position Sensor Testβ3.9L V-6 or5.2/5.9L V-8 Enginesp. 382
Camshaft Position Sensor Testβ8.0L V-10 Enginep. 383
Crankshaft Position Sensor Testβ3.9L V-6 or5.2/5.9L V-8 Enginesp. 383
Crankshaft Position Sensor Testβ8.0L V-10Enginep. 384
Distributor Capβ3.9L V-6 or 5.2/5.9L V-8 Enginesp. 384
Distributor Rotorβ3.9L V-6 or 5.2/5.9L V-8Enginesp. 385
DRB Scan Toolp. 385
Ignition Coil Testβ3.9L V-6 or 5.2/5.9L V-8Enginesp. 385
Ignition Coil Pack Testsβ8.0L V-10 Enginep. 385
IGNITION COIL RESISTANCEβEXCEPT 8.0L V-10 ENGINEp. 386
Ignition Control Module Testβ8.0L V-10 Enginep. 386
Engine Coolant Temperature Sensor Testp. 387
Ignition Secondary Circuit Diagnosisp. 388
Ignition Timingp. 389
Intake Manifold Air Temperature Sensor Testp. 389
Manifold Absolute Pressure (MAP) Sensor Testp. 389
Powertrain Control Module (PCM)p. 389
+Spark Plugsp. 390
NORMAL OPERATINGp. 390
COLD F0ULING/CARB01 FOULINGp. 391
WET FOULING OR GAS FOULINGp. 391
OIL OR ASH ENCRUSTEDp. 391
ELECTRODE GAP BRIDGINGp. 391
SCAVENGER DEPOSITSp. 391
CHIPPED ELECTRODE INSULATORp. 391
PREIGNITION DAMAGEp. 392
SPARK PLUG OVERHEATINGp. 392
Spark Plug Secondary Cablesp. 392
Oxygen Sensor (02S) Testsp. 393
On-Board Diagnosticsp. 393
+COMPONENT REMOVAL/INSTALLATIONp. 395
General informationp. 395
Automatic Shutdown (ASD) Relayp. 395
Camshaft Position Sensorβ3.9L V-6 or 5.2/5.9L V-8 Enginesp. 395
CAMSHAFT POSITION SENSORβ8.0L V-10ENGINEp. 396
CRANKSHAFT POSITION SENSORβ3.9L V-6 OR 5.2/5.9L V-8 ENGINESp. 397
CRANKSHAFT POSITION SENSORβ8.0L V-10ENGINEp. 398
ENGINE COOLANT TEMPERATURE SENSORp. 399
DISTRIBUTOR SERVICEp. 399
IGNITION COILβ3.9L V-6 OR 5.2/5.9L V-8ENGINESp. 401
IGNITION COIL PICKSβ8.0L V-10 ENGINEp. 401
IGNITION CONTROL MODULEβ8.OL V-10 ENGINEp. 402
INTAKE MANIFOLD AIR TEMPERATURE SENSORp. 402
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORp. 402
OXYGEN SENSOR (02S)p. 402
POWERTRAIN CONTROL MODULE (PCM)p. 402
SPARK PLUGSp. 403
SPARK PLUG SECONDARY CABLESp. 404
IGNITION SWITCHp. 406
+SPECIFICATIONSp. 409
GENERAL INFORMATIONp. 409
IGNITION TIMINGp. 409
IGHITION COIL RESISTANCEβEXCEPT 8.0L ENGINEp. 409
SPARK PLUGSp. 409
IGNITION COIL PACKSβ8.0L V-10 ENGINEp. 409
SPARK PLUG CABLE RESISTANCEp. 409
ENGINE FIRING ORDERβ3.9L V-6 ENGINEp. 410
ENGINE FIRING ORDERβ5.2L/5.9L V-8 ENGINEp. 410
SPARK PLUG CABLE ORDERβ8.0L V-10ENGINEp. 410
TORQUEp. 410
+8E-Instrument Panel & Guagesp. 411
+GENERAL INFORMATIONp. 411
INSTRUMENT PANELp. 411
NSTRUMENT CLUSTERSp. 411
MESSAGE CENTERp. 412
GAUGESp. 412
COOLANT TEMPERATURE GAUGEp. 413
FUEL GAUGEp. 413
GEAR SELECTOR INDICATORp. 413
OIL PRESSURE GAUGEp. 413
SPEEDOMETER/ODOMETERp. 413
TACHOMETERp. 413
TRIP ODOMETERp. 414
VOLTMETERp. 414
INDICATOR LAMPSp. 414
AIRBAG INDICATOR LAMPp. 414
ANTI-LOCK BRAKE SYSTEM LAMPp. 414
BRAKE WARNING LM$Pp. 414
FOUR-WHEEL DRIVE INDICATOR LAMPp. 414
HAZARD WARNING INDICATOR LAMPp. 414
HEADLAMP HIGH BEAM INDICATOR LAMPp. 414
LOW FUEL WARNING LAMPp. 414
LOW OIL PRESSURE WARNING LAMPp. 415
LOW WASHER FLUID WARNING LAMPp. 415
MAINTENANCE REQUIRED INDICATORp. 415
MALFUNCTION INDICATOR LAMPp. 415
MASTER LIGHTING INDICATOR LAMPp. 415
SEAT BELT REMINDER LAMPp. 415
TRANSMISSION OIL TEMPERATURE WARNING LAMPp. 415
TURN SIGNAL INDICATOR LAMPSp. 415
UPSHIFT INDICATOR LAMPp. 415
WAIT-TO-START LAMPp. 416
WATER-IN-FUEL LAMPp. 416
CLUSTER ILLUMINATION LAMPSp. 416
+DIAGNOSISp. 416
+GAUGESp. 416
COOLANT TEMPERATURE GAUGEp. 416
FUEL GAUGEp. 417
GEAR SELECTOR INDICATORp. 417
OIL PRESSURE GAUGEp. 417
SPEEDOMETER/ ODOMETERp. 418
TACHOMETERp. 419
TRIP ODOMETERp. 419
VOLTMETERp. 419
INSTRUMENT CLUSTER CONNECTIONSp. 420
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD- HIGH LINEp. 421
INSTRUMENT CLUSTER PRINTED CIRCUIT BOAR!- LOW LINEp. 422
+INDICATOR LAMPSp. 423
AIRBAG INDICATOR LAMPp. 423
ANTI-LOCK BRAKE SYSTEM LAMPp. 423
BRAKE WARNING LAMPp. 423
FOUR WHEEL DRIVE INDICATOR LAMPp. 424
HEADLAMP HIGH BEAM INDICATOR LAMPp. 424
LOW FUEL WARNING LAMPp. 424
LOW OIL PRESSURE WARNING LAMPp. 425
LOW WASHER FLUID WARNING LAMPp. 425
MALFUNCTION INDICATOR LAMPp. 426
MAINTENANCE REQUIRED INDICATOR LAMPp. 426
SEAT BELT REMINDER LAMPp. 426
TRANSMISSION OIL TEMPERATURE WARNING LAMPp. 427
TURN SIGNAL INDICATOR LAMPSp. 427
UPSHIFT INDICATOR LAMPp. 427
WAIT-TO-START LAMPp. 428
WATER-IN-FUEL LAMPp. 428
CLUSTER ILLUMINATION LAMPSp. 428
+SERVICE PROCEDURESp. 429
ASH RECEIVER REMOVE/INSTALLp. 429
CUP HOLDER REMOVE/INSTALLp. 429
KNEE BLOCKER REMOVE/INSTALLp. 429
FUSEBLOCK MODULE REMOVE/INSTALLp. 429
INSIDE HOOD RELEASE REMOVAL/INSTALLp. 429
CLUSTER BEZEL REMOVE/INSTALLp. 429
CIGAR LIGHTER/POWER OUTLET REMOVE/INSTALLp. 430
INSTRUMENT CLUSTER REMOVE/INSTALLp. 430
CLUSTER LENS AND MASK REMOVE/INSTALLp. 430
GAUGES REMOVE/INSTALLp. 431
PRND21 INDICATOR REMOVE/INSTALLp. 431
CLUSTER BULBS REMOVE/INSTALLp. 431
LOW FUEL CIRCUIT REMOVE/INSTALLp. 432
PRINTED CIRCUIT REMOVE/INSTALLp. 432
OIL PRESSURE SENDING UNIT REMOVE/INSTALLp. 432
VEHICLE SPEED SENSOR REMOVE/INSTALLp. 433
HEATER – A/C CONTROL/MESSAGE CENTER REMOVE/INSTALLp. 434
HEATER – A/C CONTROL/MESSAGE CENTER LAMP BULBS REMOVE/INSTALLp. 434
HEADLAMP SWITCH REMOVE/INSTALLp. 434
OVERDRIVE LOCKOUT/FOG LAMP SWITCH REMOVE/INSTALLp. 434
GLOVE BOX REMOVE/INSTALLp. 435
GLOVE BOX LAMP/SWITCH/LATCH STRIKER REMOVE/INSTALLp. 435
GLOVE BOX LATCH REMOVE/INSTALLp. 436
INSTRUMENT PANEL ASSEMBLY REMOWE/INSTALLp. 436
SPECIFICATIONSp. 439
+8F-Audio Systemsp. 440
+GENERAL INFORMATIONp. 440
RADIOSp. 440
IGNITION-OFF DRAW FUSEp. 440
SPEAKERSp. 440
FILTER CHOKE/SPEAKER RELAYp. 440
ANTENNAp. 440
RADIO NOISE SUPPRESSIONp. 440
+DIAGNOSISp. 441
RADIOp. 441
SPEAKERSp. 441
FILTER CHOKE/SPEAKER RELAYp. 441
RADIO DIAGNOSIS CHARTp. 442
RADIO AND SPEAKER CONNECTORSp. 443
+ANTENNAp. 444
TEST 1p. 444
TEST 2p. 444
TEST 3p. 444
TEST 4p. 444
RADIO FREQUENCY INTERFERENCEp. 444
+SERVICE PROCEDURESp. 445
RADIO REMOVE/INSTALLp. 445
SPEAKERS REMOVE/INSTALLp. 446
FILTER CHOKE/SPEAKER RELAY REMOVE/INSTALLp. 447
ANTENNA REMOVE/INSTALLp. 448
+8G-Hornsp. 450
GENERAL INFORMATIONp. 450
+DIAGNOSISp. 450
HORN SYSTEMp. 450
HORN SWITCHp. 451
+SERVICE PROCEDURESp. 452
HORN SWITCH REMOVE/INSTALLp. 452
HORN RELAY REMOVE/INSTALLp. 454
+8H-Vehicle Speed Control Systemp. 455
GENERAL INFORMATIONp. 455
+DIAGNOSISp. 457
ROAD TESTp. 457
INSPECTIONp. 457
+USING ON-BOARD DIAGNOSTIC SYSTEMp. 457
DIAGNOSTIC TROUBLE CODESp. 457
RETRIEVING DIAGNOSTIC TROUBLE CODESp. 457
+VEHICLE SPEED SENSORp. 457
DIAGNOSIS CHART 1 – GAS ENGINEp. 458
DIAGNOSIS CHART 2 – GAS ENGINEp. 459
DIAGNOSIS CHART 1 – DIESEL ENGINEp. 460
DIAGNOSIS CHART 2 – DIESEL ENGINEp. 461
SPEED CONTROL DIAGNOSTIC TROUBLE CODEp. 462
SPEED CONTROL SWITCHp. 462
STOP LAMP SWITCHp. 462
VACUUM SUPPLY TESTp. 463
SPEED CONTROL SERVOp. 463
POWERTRAIN CONTROL MODULEp. 463
SERVICE PROCEDURES.p. 465
SPEED CONTROL SERVO REMOVE/INSTALLp. 465
SPEED CONTROL SWITCH REMOVE/INSTALLp. 467
SERVO CABLE REMOVE/INSTALLp. 467
VACUUM RESERVOIR REMOVE/INSTALLp. 469
+8J-TURN SIGNAL AND HAZARD WARNING SYSTEMSp. 470
GENERAL INFORMATIONp. 470
DIAGNOSISp. 471
SERVICE PROCEDURESp. 473
+8K-Wiper & Washer Systemsp. 474
GENERAL INFORMATIONp. 474
+DIAGNOSISp. 475
+WIPER MOTORp. 475
WIPER/WASHER DIAGNOSISp. 476
+SERVICE PROCEDURESp. 480
WIPER BLADES REMOVE/INSTALLp. 480
WIPER ELEMENTS REMOVE/INSTALLp. 480
WIPER ARM REMOVE/INSTALLp. 480
WIPER MOTOR/LINKAGE REMOVE/INSTALLp. 481
MULTI-FUNCTION SWITCH REMOVE/INSTALLp. 482
WASHER RESERVOIR REMOVE/INSTALLp. 482
+8L-Lampsp. 484
+LAMP DIAGNOSISp. 484
GENERAL INFORMATIONp. 484
+HEADLAMP DIAGNOSISp. 484
HEADLAMP DIAGNOSIS CHARTp. 485
FOG LAMP DIAGNOSIS CHARTp. 484
MULTI-FUNCTION SWITCH TESTING PROCEDURESp. 487
DAYTIME RUNNING LAMPSβCANADA ONLYp. 487
+SERVICE PROCEDURESp. 489
HEADLAMP ALIGNMENTp. 489
HEADLAMP ALIGNMENT PREPARATIONp. 489
HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREENp. 489
HEADLAMP MODULEp. 490
HEADLAMP BULBp. 490
FOG LAMPSp. 491
FOG LAMP BULBp. 492
PARK, TURN SIGNAL AND SIDE MARKER LAiPp. 492
PARK AND TURN SIGNAL LAMP BULBp. 492
FRONT SIDE MARKER LAMP BULBp. 492
ROOF CLEARANCE LAMPSp. 492
ROOF CLEARANCE LAMP BULBp. 493
CENTER HIGH MOUNTED STOP LAMP (CHMSL)p. 493
CARGO LAMPp. 493
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULBp. 493
CARGO LAMP BULBp. 493
HEADLAMP SWITCHp. 493
FOG LAMP SWITCHp. 493
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMPS-PICKUPp. 493
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP BULBβPICKUPp. 494
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMPSβCHASSIS CABp. 494
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP BULBβCHASSIS CABp. 494
SIDE IDENTIFICATION (ID) LAMPSp. 494
SIDE IDENTIFICATION (ID) LAMP BULBSp. 495
REAR IDENTIFICATION (ID) LAMPSp. 495
REAR IDENTIFICATION (ID) LAMP BULBSp. 495
LICENSE PLATE LAMP PANELp. 495
LICENSE PLATE LAMP BULBp. 495
DOME LAMPp. 495
OVERHEAD CONSOLEp. 496
OVERHEAD CONSOLE READING LAMP BULBp. 496
BULB APPLICATIONp. 497
+8M-Restraint Systemsp. 498
AIRBAG SYSTEMp. 498
GENERAL INFORMATIONp. 498
DIAGNOSISp. 499
+SERVICE PROCEDURESp. 500
AIR SYSTEM SERVICE (DEPLOYED)p. 500
AIR BAG MODULE HANDLINGp. 500
CLEANUP PROCEDUREp. 500
AIR BAG MODULE REMOVE/ INSTALLp. 500
+IMPACT SENSOR REMOVE/INSTALLp. 501
+LEFT SIDEp. 502
V-6 AND V-8 ENGINEp. 502
V-10 AND DIESEL ENGINEp. 502
+RIGHT SIDEp. 503
V-6 AND V-8 ENGINEp. 503
V-10 AND DIESEL ENGINEp. 504
AIRBAG CONTROL MODULE REMOVE/INSTALLp. 504
CLOCKSPRING REMOVE/INSTALLp. 505
CLOCKSPRING CENTERINGp. 506
+8P-Power Locksp. 507
GENERAL INFORMATIONp. 507
DIAGNOSISp. 507
SERVICE PROCEDURESp. 508
+8R-Power Seatsp. 510
GENERAL INFORMATIONp. 510
DIAGNOSISp. 510
SERVICE PROCEDURESp. 512
+8S-Power Windowsp. 514
GENERAL INFORMATIONp. 514
DIAGNOSISp. 514
SERVICE PROCEDURESp. 516
+8T-Power Mirrorsp. 518
GENERAL INFORMATIONp. 518
DIAGNOSISp. 519
SERVICE PROCEDURESp. 520
+8U- Chime/Buzzer Warning Systemsp. 522
GENERAL INFORMATIONp. 522
DIAGNOSISp. 523
SERVICE PROCEDURESp. 525
+8W- Wiring Diagramsp. 526
+8W-01 GENERAL INFORMATION – WIRING DIAGRAMSp. 527
NOTES, CAUTIONS, and WARNINGSp. 527
WIRE CODE IDENTIFICATIONp. 527
CONNECTORSp. 528
TAKE OUTSp. 528
SYMBOLSp. 528
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICESp. 528
LEGEND OF SYMBOLS USED ON WIRING DIAGRAMSp. 529
TROUBLESHOOTING TOOLSp. 530
INTERMITTENT AND POOR CONNECTIONSp. 530
+TROUBLESHOOTING TESTSp. 530
TESTING FOR VOLTAGEp. 530
TESTING FOR CONTINUITYp. 530
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADSp. 531
TESTING FOR A VOLTAGE DROPp. 531
TROUBLESHOOTING WIRING PROBLEMSp. 531
WIRING REPAIRp. 532
TERMINAL/CONNECTOR REPAIRβMOLEX CONNECTORSp. 532
CONNECTOR REPLACEMENTp. 532
CONNECTOR AND TERMINAL REPLACEMENTp. 533
TERMINAL REPLACEMENTp. 534
DIODE REPLACEMENTp. 534
+8W-10 FUSE/FUSE BLOCKp. 535
GENERAL INFORMATIONp. 535
ABS Control Module 8W-10-6p. 540
Airbag Control Module 8W-10-5, 6p. 539
Buzzer Module 8W-10-7p. 541
Circuit Breaker (Cavity 1, Fuse BLock) 8W-10-6p. 540
Circuit Breaker (Cavity 2, Fuse Block) 8W-10-4p. 538
Fuse 1 (PDC) 8W-10-4, 7, 8p. 538
Fuse 2 (Fuse Block) 8W-10-6p. 540
Fuse 2 (PDC) 8W-10-6p. 540
Fuse 3 (PDC) 8W-10-3, 5p. 537
Fuse 5 (Fuse Block) 8W-10-4p. 538
Fuse 6 (Fuse Block) 8W-10-4p. 538
Fuse 6 (PDC) 8W-10-8p. 542
Fuse 7 (Fuse Block) 8W-10-4p. 538
Fuse 8 (Fuse Block) 8W-10-4p. 538
Fuse 9 (Fuse Block) 8W-10-5p. 539
Fuse 10 (Fuse Block) 8W-10-5p. 539
Fuse 11 (Fuse Block) 8W-10-5p. 539
Fuse 12 (Fuse Block) 8W-10-5p. 539
Fuse 13 (Fuse Block) 8W-10-8p. 542
Fuse 14 (Fuse Block) 8W-10-6p. 540
Fuse 15 (Fuse Block) 8W-10-6p. 540
Fuse 16 (Fuse Block) 8W-10-6p. 540
Fuse 17 (Fuse Block) 8W-10-7p. 541
Fuse 18 (Fuse Block) 8W-10-8p. 542
Fuse 19 (Fuse Block) 8W-10-7p. 541
Fuse 20 (Fuse Block) 8W-10-8p. 542
Fuse Block 8W-10-2, 3p. 536
Headlamp Switch 8W-10-8p. 542
Ignition Switch 8W-10-4, 5p. 538
Ignition Switch 8W-10-6p. 540
Instrument Cluster 8W-10-5p. 539
Message Center 8W-10-5p. 539
RWAL Module 8W-10-6p. 540
+8W-11 POWER DISTRIBUTIONp. 543
A/C Compressor Clutch Relay 8W-11-5p. 547
ABS Control Module 8W-11-6p. 543
ABS Pump Relay 8W-11-6p. 543
ABS Warning Lamp Relay 8W-11-6p. 543
ASD Relay 8W-11-4p. 546
Engine Starter Motor Relay 8W-11-7p. 543
Fuel Pump Relay 8W-11-8p. 548
Fuse 1 (PDC) 8W-11-5p. 547
Fuse 2 (PDC) 8W-11-7p. 543
Fuse 3 (PDC) 8W-11-9p. 549
Fuse 4 (PDC) 8W-11-4p. 546
Fuse 5 (Fuse Block) 8W-11-9p. 549
Fuse 5 (PDC) 8W-11-6p. 543
Fuse 6 (Fuse Block) 8W-11-9p. 549
Fuse 6 (PDC) 8W-11-7p. 543
Fuse 7 (Fuse Block) 8W-11-9p. 549
Fuse 7 (PDC) 8W-11-4p. 543
Fuse 8 (Fuse Block) 8W-11-9p. 549
Fuse 9 (Fuse Block) 8W-11-9p. 549
Fuse 10 (Fuse Block) 8W-11-9p. 549
Fuse 11 (Fuse Block) 8W-11-9p. 549
Fuse 12 (Fuse Block) 8W-11-9p. 549
Fuse A (PDC) 8W-11-5p. 547
Fuse B (PDC) 8W-11-5p. 547
Fuse C (PDC) 8W-11-9p. 549
Horn Relay 8W-11-5p. 547
Ignition Switch 8W-11-9p. 549
Power Distribution Center 8W-11-2, 3p. 544
Powertrain Control Module 8W-11-5, 8p. 547
Trailer Tow Relay 8W-11-4p. 546
+8W-12 JOINT CONNECTORSp. 550
ABS Control Module 8W-12-7p. 556
Daytime Running Lamps (DRL) Module 8W-12-6, 8p. 555
Fuse 1 (PDC) 8W-12-2, 4p. 553
Fuse 2 (PDC) 8W-12-8p. 557
Fuse 3 (PDC) . .8W-12-6p. 555
Fuse 6 (PDC) 8W-12-4p. 553
Fuse 11 (Fuse Block) 8W-12-6p. 555
Fuse 13 (Fuse Block) 8W-12-2, 5p. 551
Fuse 15 (Fuse Block) 8W-12-8p. 557
Fuse 18 (Fuse Block) 8W-12-2, 5p. 551
Headlamp Switch 8W-12-2, 3, 5, 7p. 551
Ignition Switch 8W-12-6, 8p. 555
Instrument Cluster 8W-12-5, 6, 8p. 554
Joint Connector A (C217) 8W-12-2. 3p. 551
Joint Connector B (C231) 8W-12-4p. 553
Joint Connector C (C209) 8W-12-5, 6, 7, 8p. 554
Overhead Console 8W-12-2p. 551
Park Brake Switch 8W-12-6p. 555
Powertrain Control Module 8W-12-5, 7p. 554
RWAL Control Module 8W-12-4, 6, 7, 8p. 553
8W-15 GROUND DISTRIBUTIONp. 558
8W-20 CHARGING SYSTEMp. 566
8W-21 STARTING SYSTEMp. 571
+8W-30 FUEL/IGNITIONp. 573
ABS Control Module 8W-30-15, 24, 34p. 587
Airbag Control Module 8W-30-12p. 584
ASD Relay 8W-30-20, 27, 39p. 592
Camshaft Position Sensor 8W-30-16, 25, 35p. 588
Circuit Breaker (Cavity 1, Fuse Block) 8W-30-12p. 584
Crankshaft Position Sensor 8W-30-18, 27, 37p. 590
Data Link C o n n e c t o r 8W-30-15, 24, 33p. 587
EGR Solenoid 8W-30-17, 26, 36p. 589
Engine Coolant Temperature Sensor 8W-30-16, 25, 35p. 588
EVAP/Purge Solenoid 8W-30-17, 26, 36p. 589
Fuel Pump Relay 8W-30-48p. 620
Fuel Tank Gauge Level Sending Unit 8W-30-48p. 620
Fuse 2 (Fuse Block) 8W-30-12p. 584
Fuse 2 (PDC) 8W-30-10p. 582
Fuse 3 (PDC) 8W-30-10, 21, 30, 40p. 582
Fuse 5 (Fuse Block) 8W-30-10p. 582
Fuse 6 (Fuse Block) 8W-30-10p. 582
Fuse 7 (Fuse Block) 8W-30-10p. 582
Fuse 8 (Fuse Block) 8W-30-10p. 582
Fuse 9 (Fuse Block) 8W-30-11, 21, 30, 40p. 583
Fuse 10 (Fuse Block) 8W-30-11p. 583
Fuse 11 (Fuse Block) 8W-30-11p. 583
Fuse 12 (Fuse Block) 8W-30-11p. 583
Fuse 14 (Fuse Block) 8W-30-12p. 584
Fuse 15 (Fuse Block) 8W-30-12p. 584
Fuse 16 (Fuse Block) 8W-30-12p. 584
Heated Oxygen Sensor(s) 8W-30-20, 27, 39p. 592
Idle Air Control Motor 8W-30-13, 22, 36p. 585
Ignition Coil(s) 8W-30-14, 23, 34p. 586
Ignition Switch 8W-30-11, 12, 21, 30, 40p. 583
Injectors (3.9L) 8W-30-13, 14p. 585
Injectors (5.2L/5.9L) 8W-30-22, 23p. 594
Injectors (8.0L) 8W-30-31, 32p. 603
Intake Air Temperature Sensor 8W-30-16, 25, 35p. 588
Manifold Absolute Pressure (MAP) SensoR 8W-30-18, 27, 37p. 590
Powertrain Control Module 8W-30-13 thru 39p. 585
RWAL Control Module 8W-30-12p. 584
Throttle Position Sensor 8W-30-18, 27, 37p. 590
Vehicle Speed Sensor 8W-30-19, 27, 38p. 591
8W-31 TRANSMISSION CONTROLp. 621
+8W-32 ANTI-LOCK BRAKESp. 626
ABS Control Module 8W-32-9 thru 13p. 634
ABS Pump Relay 8W-32-9p. 634
ABS Warning Lamp Relay 8W-32-9p. 634
Data Link Connector 8W-32-11p. 636
Front Anti-Lock Valve 8W-32-10p. 635
Front Wheel Speed Sensor 8W-32-11p. 636
Fuse 2 (PDC) 8W-32-12p. 637
Fuse 14 (Fuse Block) 8W-32-9, 12p. 634
Ignition Switch 8W-32-9, 12, 13p. 634
Instrument Cluster 8W-32-9p. 634
Rear Anti-Lock Valve 8W-32-9p. 634
Rear Wheel Anti-Lock Brake Sensor 8W-32-11p. 636
Vacuum Sensor 8W-32-12p. 637
8W-33 VEHICLE SPEED CONTROLp. 639
8W-39 VEHICLE THEFT ALARMp. 526
+8W-40 INSTRUMENT CLUSTERp. 642
ABS Control Module 8W-40-6, 8p. 647
ABS Warning Lamp Relay 8W-40-8p. 649
Airbag Control Module 8W-40-4, 12p. 646
Airbag Lamp 8W-40-12p. 653
Brake Warning Lamp 8W-40-6p. 647
Brake Warning Switch 8W-40-7p. 648
Buzzer Module 8W-40-10p. 651
Check Anti-Lock Lamp 8W-40-9p. 650
Check Engine Lamp 8W-40-6p. 647
Daytime Running Lamps Module 8W-40-7, 11p. 648
Engine Coolant Temperature Gauge 8W-40-5p. 646
Engine Coolant Temperature Sensor 8W-40-5p. 646
Engine Oil Pressure Gauge 8W-40-5p. 646
Engine Oil Pressure Sensor 8W-40-5p. 646
Fog Lamp Relays 8W-40-11p. 652
Fuel Gauge 8W-40-5p. 646
Fuel Tank Gauge Level Sending Unit 8W-40-5p. 646
Fuse A 8W-40-11p. 652
Fuse 1 (PDC) 8W-40-10, 11p. 652
Fuse 2 (PDC) 8W-40-8p. 649
Fuse 3 (PDC) 8W-40-4, 6, 8, 12p. 645
Fuse 12 8W-40-4, 6, 8, 12p. 645
Fuse 13 8W-40-10p. 651
Fuse 14 8W-40-8p. 649
Fuse 18 8W-40-10p. 651
4WD Lamp 8W-40-9p. 650
4X4 Switch 8W-40-9p. 650
Headlamp Switch 8W-40-10p. 651
High Beam Indicator 8W-40-11p. 652
Ignition Switch 8W-40-4, 6, 8, 12p. 645
Illumination Lamps 8W-40-10p. 651
Low Washer Fluid Lamp 8W-40-12p. 653
Low Washer Fluid Sensor 8W-40-12p. 653
Maintenance Required Lamp (SRI) 8W-40-12p. 653
Message Center 8W-40-4p. 645
Oil Pressure Gauge 8W-40-5p. 646
Overhead Console 8W-40-10p. 651
Parking Brake Switch 8W-40-7p. 648
Powertrain Control Module 8W-40-4, 6, 12p. 645
PTO Switch 8W-40-9p. 650
RWAL Control Module 8W-40-7, 9p. 648
Seat Belt Lamp 8W-40-10p. 651
Speedometer 8W-40-4p. 645
Tachometer 8W-40-4p. 645
Turn Signal Indicator Lamps 8W-40-11p. 652
Upshift Lamp 8W-40-12p. 653
Voltmeter 8W-40-4p. 645
8W-41 HORNS/CIGAR LIGHTERp. 654
8W-42 AIR CONDITIONING-HEATERp. 657
8W-43 AIRBAG SYSTEMp. 663
8W-44 INTERIOR LIGHTINGp. 666
8W-46 MESSAGE CENTERp. 673
8W-47 AUDIO SYSTEMSp. 675
8W-49 OVERHEAD CONSOLEp. 682
+8W-50 FRONT LIGHTINGp. 686
Daytime Running Lamps 8W-50-9p. 690
Fog Lamp Relays 8W-50-3p. 688
Fog Lamp Switch 8W-50-7p. 686
Fog Lamps 8W-50-7p. 686
Fuse Block Fuses 8W-50-4, 8p. 686
Headlamp Switch 8W-50-4p. 686
Headlamps 8W-50-3, 6p. 686
Ignition Switch 8W-50-8p. 689
Park/Turn Signal Lamps 8W-50-5p. 686
PDC Fuses 8W-50-3, 4, 6, 8p. 688
Roof Clearance Lamps 8W-50-10p. 691
Roof Identification Lamps 8W-50-10p. 691
8W-51 REAR LIGHTINGp. 692
8W-52 TURN SIGNALSp. 701
8W-53 WIPERSp. 704
8W-54 TRAILER TOWp. 707
8W-60 POWER WINDOWSp. 709
8W-61 POWER DOOR LOCKSp. 712
8W-62 POWER MIRRORSp. 715
8W-63 POWER SEATp. 717
+8W-70 SPLICE INFORMATIONp. 719
S101-S104 8W-70-2p. 720
S105-S107 8W-70-3p. 721
S108-S109 8W-70-4p. 722
S110-S111 8W-70-5p. 723
S112-S114 8W-70-6p. 724
S115-S116 8W-70-7p. 725
S117-S119 8W-70-8p. 726
S120-S121 8W-70-9p. 727
S122-S125 8W-70-10p. 728
S126-S128 8W-70-11p. 729
S129-S120 8W-70-12p. 730
S131-S132 8W-70-13p. 731
S133-S134 8W-70-14p. 732
S135 8W-70-15p. 733
S136 8W-70-16p. 734
S137-S138 8W-70-17p. 735
S139 8W-70-18p. 736
S140-S142 8W-70-19p. 737
S143-S146 8W-70-20p. 738
S147 8W-70-21p. 739
S201-S202 8W-70-22p. 740
S203 8W-70-23p. 741
S204 8W-70-24p. 742
S205 8W-70-25p. 743
S206-S207 8W-70-26p. 744
S208-S209 8W-70-27p. 745
S210-S212 8W-70-28p. 746
S213-S215 8W-70-29p. 747
S216-S218 8W-70-30p. 748
S301-S302 8W-70-30p. 748
S303-S305 8W-70-31p. 749
S306-S308 8W-70-32p. 750
S309-S311 8W-70-33p. 751
S312-S313 8W-70-34p. 752
S314-S316 8W-70-35p. 753
S317-S319 8W-70-36p. 754
S320 8W-70-37p. 755
S401-S404 8W-70-37p. 755
S405-S408 8W-70-38p. 756
S409 8W-70-39p. 757
+8W-80 CONNECTOR PIN OUTSp. 758
C101-C105p. 760
C106-C110p. 761
C112-C115p. 762
C116-C120p. 763
C121p. 764
C122-C124p. 765
C125-C127p. 766
C128-C132p. 767
C133p. 768
C133(CONT.)-C134p. 769
C135 3.9L ENGINESp. 770
C135 5.2L & 5.9L ENGINESp. 771
C135 8.0L ENGINEp. 772
C135 DIESEL ENGINEp. 773
C136-C139p. 774
C140-C143p. 775
C144-C147p. 776
C148-C152p. 777
C153-C157p. 778
C158-C181p. 779
C162-C166p. 780
C167-C171p. 781
C172-C176p. 782
C204-C207p. 783
C208-C209p. 784
C210-C212p. 785
C213-C215p. 786
C216-C218p. 787
C219-C222p. 788
C223-C226p. 789
C227-C229p. 790
C230-C232p. 791
C233-C237p. 792
C238-C240p. 793
C241 FUSE BLOCK(SEE 8W-10-2)p. 536
C301-C305p. 794
C306-C310p. 795
C311-C315p. 796
C316-C320p. 797
C321-C325p. 798
C326-C330p. 799
C331-C335p. 800
C336-C339p. 801
C340-C343p. 802
C401p. 802
C402-C406p. 803
C407-C411p. 804
C412-C416p. 805
C417-C421p. 806
C422-C426p. 807
C427-C431p. 808
C431p. 809
8W-90 CONNECTOR LOCATIONSp. 810
8W-95 SPLICE LOCATIONSp. 832
+9-Enginesp. 845
+STANDARD SERVICE PROCEDURESp. 845
Form-ln-Place GasketsβGasoline Enginesp. 845
Engine PerformanceβGasoline Enginesp. 846
Honing Cylinder Boresp. 846
Measuring with Plastigagep. 847
Repair Damaged or Worn Threadsp. 848
Hydrostatic Lockp. 848
+ENGINE DIAGNOSISp. 849
GENERAL INFORMATIONp. 849
INTAKE MANIFOLD LEAKAGE DIAGNOSISp. 849
CYLINDER COMPRESSION PRESSURE TESTp. 849
ENGINE CYLINDER HEAD GASKET FAILURE DIAGNOSISp. 849
CYLINDER COMBUSTION PRESSURE LEAKAGE TESTp. 850
ENGINE OIL PRESSUREp. 851
ENGINE DIAGNOSIS-GASOLINE-PERFORMANCEp. 852
ENGINE DIAGNOSIS-GASOLINE-MECHANICALp. 853
SERVICE DIAGNOSIS-GASOLINE-LUBRICATIONp. 854
SERVICE DIAGNOSIS-DIESEL-PERFORMANCEp. 855
SERVICE DIAGNOSISβDIESEl-PERFORMANCE-CONT.p. 856
SERVICE DIAGNOSISβDIESELβPERFORMANCEβCONT.p. 857
SERVICE DIAGNOSISβDIESELβPERFORMANCEβCONT.p. 858
SERVICE DIAGNOSISβDIESELβPERFORMANCEβCONT.p. 859
SERVICE DIAGNOSISβDIESELβPERFORMANCEβCONT.p. 860
SERVICE DIAGNOSISβDIESELβPERFORMANCEβCONT.p. 861
SERVICE DIAGNOSISβDIESELβMECHANICALp. 862
SERVICE DIAGNOSISβDIESELβMECHANICALβCONT.p. 863
+3.9L ENGINE SERVICE PROCEDURESp. 864
General Informationp. 864
Engine Front Mountsp. 864
Engine Rear Mountp. 865
+Engine Assemblyp. 865
REMOVALp. 865
INSTALLATIONp. 867
Engine Rear Support Cushion Assembliesp. 866
Cylinder Head Coverp. 868
Valve Components ReplaceβCylinder Head Not Removedp. 868
Rocker Arms and Push Rodsp. 868
Valve Stem Seal and Spring Replacementp. 868
Cylinder Headsp. 869
Valves and Valve Springsp. 870
Hydraulic Tappetsp. 872
Valve Timingp. 873
Vibration Damperp. 874
Timing Chain Coverp. 874
Front Crankshaft Oil Seal Replacementp. 876
Camshaftp. 876
Distributorp. 878
Oil Panp. 879
+LUBRICATION SYSTEMp. 881
PISTON AND CONNECTING ROD ASSEMBLYp. 884
CRANKSHAFTp. 887
CRANKSHAFT MAIN BEARINGSp. 888
CRANKSHAFT REAR OIL SEALSp. 889
Cylinder Blockp. 890
Specificationsβ3.9L Enginep. 892
ENGINE SPECIFICATIONS-CONT.p. 893
ENGINE SPECIFICATIONS – CONT.p. 894
TORQUE SPECIFICATIONSp. 895
+5.2L ENGINE SERVICE PROCEDURESp. 896
General INFORMATIONp. 896
Engine Front Mountsp. 896
Engine Rear MOUNTp. 897
Engine Assemblyp. 897
Cylinder HEAD COVERp. 900
Valve Components ReplaceβCylinder Head NotRemovedp. 900
Rocker ARMS AND PUSH Rodsp. 900
Valve Stem Seal and Spring Replacementp. 900
Cylinder HEADSp. 901
Valves and valve Springsp. 902
HYDRAULIC TAPPETSp. 904
Valve Timingp. 905
Vibration Damperp. 906
Timing Chain Coverp. 906
Front CRANKSHAFT OIL SEAL Replacementp. 908
Camshaftp. 908
Distributor BUSHINGp. 910
OIL PANp. 911
LUBRICATION SYSTEMp. 912
CRANKSHAFTp. 915
CRANKSHAFT MAIN BEAR1NSSp. 916
CRANKSHAFT REAR OIL SEALSp. 917
CYLINDER BL0CKp. 918
Specificationsβ5.2L Enginep. 921
ENGINE SPECIFICATIONSβCONT.p. 922
ENGINE SPECIFICATIONSβCONT.p. 923
TORQUE SPECIFICATIONSp. 924
+5.9L ENGINE SERVICE PROCEDURESp. 925
General Informationp. 925
Engine Front Mountsp. 925
Engine Rear Mountp. 926
Engine Assemblyp. 926
Cylinder Head Coverp. 929
Valve Components Replaceβ-Cylinder Head Not Removedp. 929
Rocker Arms and Push Rodsp. 929
Valve Stem Seal and Spring Replacementp. 929
Cylinder Headsp. 930
Valves and Valve Springsp. 931
Hydraulic Tappetsp. 933
Valve Timingp. 934
Vibration Damperp. 935
Timing Chain Coverp. 935
Front Crankshaft Oil Seal Replacementp. 937
Camshaftp. 937
Distributor Bushingp. 939
Oil Panp. 940
LUBRICATION SYSTEMp. 941
OIL PUMPp. 943
PISTON AND CONNECTING ROD ASSEMBLYp. 945
CRANKSHAFTp. 947
CRANKSHAFT MAIN BEARINGSp. 948
CRANKSHAFT REAR OIL SEALSp. 949
CYLINDER BLOCKp. 950
ENGINE SPECIFICATIONSβCONT.p. 952
TORQUE SPECIFICATIONSp. 953
+8.0L ENGINE SERVICE PROCEDURESp. 954
General Informationp. 954
Engine MountsβFrontp. 955
Engine MountβRearp. 955
Engine Assemblyp. 956
Cylinder Head Coverp. 958
Valve Components ReplaceβCylinder Head Not Removedp. 959
Rocker Arms and Push Rodsp. 959
Valve Stem Seal and Spring Replacementp. 959
Cylinder Headsp. 960
Valves and Valve Springsp. 962
Hydraulic Tappetsp. 965
Valve Timingp. 966
Vibration Damperp. 966
Timing Chain Coverp. 967
Timing Chain Cover Oil Sealp. 969
Camshaftp. 970
Oil Panp. 972
LUBRICATION SYSTEMp. 973
OIL PUMPp. 975
PISTON AND CONNECTING ROD ASSEMBLYp. 977
CRANKSHAFTp. 979
CRANKSHAFT MAIN BEARINGSp. 980
CRANKSHAFT REAR SEAL RETAINERp. 981
CYLINDER BLOCKp. 981
ENGINE SPECIFICATIONSp. 983
ENGINE SPECIFICATIONSβCONT.p. 984
ENGINE SPECIFICATIONSβCONT.p. 985
TORQUE SPECIFICATIONSp. 986
+5.9L (DIESEL) ENGINE SERVICE PROCEDURESp. 987
General Informationp. 987
Engine Front Mountsp. 987
Engine Rear Mountp. 988
Engine Assemblyp. 988
Rocker Levers and Push Rodsp. 991
Cylinder Headp. 992
Valves and Valve Springsp. 994
Valve Clearance Adjustmentp. 999
Gear Housing and Coverp. 1000
Timing Pinp. 1002
Tappetp. 1004
Camshaftp. 1006
Cylinder Blockp. 1008
Piston and Connecting Rod Assemblyp. 1012
Crankshaftp. 1016
Oil Pan and Suction Tubep. 1023
LUBRICATION SYSTEMp. 1024
OIL PUMPp. 1026
OIL FILTER BYPASS VALVEp. 1028
OIL PRESSURE REGULATOR VALVE AND SPRINGp. 1029
OIL COOLER ELEMENT AND GASKETp. 1029
ENGINE SPECIFICATIONSp. 1031
ENGINE SPECIFICATIONSβCONT,p. 1032
TORQUE SPECIFICATIONSp. 1033
+11-Exhaust System & Intake Manifoldp. 1034
GENERAL INFORMATIONp. 1034
EXHAUST SYSTEM DIAGNOSISp. 1035
+SERVICE PROCEDURESβENGINESp. 1036
Exhaust Pipep. 1036
Catalytic Convertersp. 1037
Mufflersp. 1037
Exhaust Tailpipep. 1038
Exhaust Heat Shieldsp. 1038
Intake ManifoldβV-6 and V-8 Enginesp. 1038
Intake ManifoldβV-10 Enginep. 1041
Engine Exhaust Manifold-V-6 and V-8 Enginesp. 1043
Engine Exhaust ManifoldβV-10 Enginep. 1044
+SERVICE PROCEDURESβDIESEL ENGINESp. 1045
Exhaust Pipep. 1045
Catalytic Convertersp. 1045
Mufflerp. 1046
Exhaust Tailpipep. 1046
Exhaust Heat Shieldsp. 1047
Engine Exhaust Manifoldp. 1047
Intake Manifold CoverβAir Intake Heaterp. 1048
Turbochargerp. 1049
Wastegate Adjustmentp. 1050
Charge Air CoolerβIntercoolerp. 1051
SPECIFICATIONSp. 1053
+13-Bumpers & Framep. 1054
+BUMPERS AND FRAME COMPONENTSp. 1054
Front Bumperp. 1054
Front Bumper Upper Fasciap. 1054
Front Bumper Lower Fasciap. 1054
Front Bumper Air Damp. 1055
Skid Platep. 1055
Spare Tire Winchp. 1055
Rear Bumperp. 1056
Trailer Hitchp. 1057
+SNOW PLOWp. 1058
Service Informationp. 1058
System Description and Operationp. 1058
Snow Plow Wiring Diagramsp. 1059
+Snow Plow Malfunction Diagnosis and Testsp. 1059
Raise BladeβVoltage Application & Hydraulic Fluid Flowp. 1060
Lower & Fioat BladeβVoLtage Application & Hydraulic Fluid Flowp. 1061
Angle Blade RightβVoltage Application & Hydraulic Fluid Flowp. 1062
Angle Blade LeftβVoltage Application & Hydraulic Fluid Flowp. 1063
SNOW PLOW DIAGNOSIS CHARTp. 1064
Snow Plow Control Wiring Diagramp. 1065
Snow Plow Control Wiring Diagram (Continued)p. 1066
Snow Plow Auxiliary Lighting Wiring Diagramp. 1067
POWER UNITp. 1068
+Power UnitβExploded Viewp. 1069
Insert ValveβExploded Viewp. 1070
Solenoid Valve C/Four-Way ValveβExplodedViewp. 1070
POWER ANGLING CYLINDER SERVICEp. 1071
SNOW PLOW FRAMEp. 1071
SNOW PLOW PIVOT BRACKETp. 1071
SNOW PLOW CONTROL iOitJLEp. 1072
SNOW PLOW SPECIFICATIONSp. 1074
+FRAMEp. 1075
Safety Precautions and Warningsp. 1075
General Informationp. 1075
Frame Straighteningp. 1076
Frame Repairsp. 1076
+Frame Dimensionsp. 1076
BR 1500 and 2500 Rear- Wheel-Drivep. 1077
BR 1500 and 2500 Four-Wheel-Drivep. 1078
BR 3500 Rear-Wheel-Drivep. 1079
BR 3500 Four- Wheel-Drivep. 1080
BR 1500 Club Cab Rear- Wheel-Drivep. 1081
BR 1500 Club Cab Rear-Wheel-Drivep. 1082
+14-Fuel Systemp. 1083
GENERAL INFORMATIONp. 1083
+FUEL DELIVERY SYSTEMβEXCEPT DIESELp. 1084
General Informationp. 1084
Fuel Pump ModuleβAll Gas Powered Enginesp. 1084
Fuel Filter/Fuel Pressure Regulatorp. 1085
Fuel Filterp. 1087
Fuel System Pressure Release Procedurep. 1087
Fuel System Pressure TestβGas PoweredEnginesp. 1087
Fuel Pump Capacity TestβGas Powered Enginesp. 1088
Fuel Pressure Leak Down TestβGas PoweredEnginesp. 1088
Fuel Tubes/Lines/Hoses and Clampsp. 1089
Quick-Connect Fittingsp. 1089
Fuel Line with Latch Clipp. 1092
+FUEL DELIVERY SYSTEMβDIESEL ENGINEp. 1093
General Informationp. 1093
Fuel System ComponentsβDiesel Enginep. 1094
Fuel Tank ModuleβDiesel Enginep. 1095
Fuel Heaterp. 1096
Fuel Heater Relayp. 1096
Fuel Tankp. 1096
Fuel Transfer Pumpp. 1096
Fuel Filter/Water Separatorp. 1097
Fuel Filterp. 1098
Fuel FilterβIn Tankp. 1098
Fuel System Pressure Warningp. 1098
Fuel System Pressure TestβDiesel Enginep. 1098
Fuel Transfer Pump Capacity TestβDiesel Enginep. 1098
Fuel Tubes/Lines/Hoses and ClampsβLow-Pressure Typep. 1098
Quick-Connect Fittingsp. 1098
High-Pressure Fuel Linesp. 1098
Intake Manifold Air Heaterp. 1098
Intake Manifold Air Heater Relaysp. 1098
Intake Manifold Air Temperature Sensorp. 1098
Fuel Injection Pumpp. 1098
Fuel Injectorsp. 1099
Fuel Shutdown Solenoidp. 1100
Fuel Shutdown Solenoid Relayp. 1101
Fuel Drain Manifoldp. 1101
Powertrain Control Modulep. 1101
Diesel Fuel System Operationp. 1101
+FUEL TANKSp. 1102
General Informationp. 1102
Fuel Tanksp. 1102
Fuel Pumpp. 1103
Fuel Gauge Sending Unitp. 1104
Fuel Tank Capacitiesp. 1104
Heat Shieldsp. 1104
Fuel Tank Filler Tube Capp. 1104
No-Lead Fuel Tank Filler Tubep. 1104
Fuel Tank Pressure Relief/Rollover Valvep. 1102
+ACCELERATOR PEDAL AND THROTTLE CABLEp. 1106
General Informationp. 1106
Accelerator Pedalp. 1106
Throttle Cablep. 1107
Throttle Linkage AdjustmentβDiesel Enginep. 1108
+MULTI-PORT FUEL INJECTION (MFI)βCOMPONENT DESCRIPTION/SYSTEM OPERATIONβEXCEPT DIESELp. 1110
GENERAL INFORMATIONp. 1110
Powertrain Control Module (PCM)p. 1111
PCM System SchematicsβExcept Dieselp. 1112
System Schematicβ3.9L (V-6) Enginep. 1113
System Schematicβ5.2L/5.9L LDC (V-8) Enginep. 1114
System Schematic-5.9L HDC (V-8) Enginep. 1115
System Schematicβ8.OL HDC (V-10) Enginep. 1116
Manifold Absolute Pressure (MAP) SensorβPCM Pin #1βPCM Inputp. 1117
Engine Coolant Temperature SensorβPCM Pin#2βPCM Inputp. 1117
Battery VoltageβPCM Pin #3βPCM inputp. 1117
Battery Temperature Sensorp. 1118
Sensor ReturnβPCM Pin #4βPCM Inputp. 1118
Five Volt PowerβPCM Pin #6βPCM Inputp. 1118
Eight Volt PowerβPCM Pin #7βPCM Inputp. 1118
Ignition Circuit SenseβPCM Pin #9βPCM Inputp. 1118
Overdrive/Override SwitchβPCM Pin #10βPCMInputp. 1118
Power GroundβPCM Pin #11p. 1118
Power GroundβPCM Pin #12p. 1118
Fuel InjectorsβPCM Pin #13βPCM Outputp. 1118
Fuel InjectorsβPCM Pin #14βPCM Outputp. 1119
Fuel InjectorsβPCM Pin #15βPCM Outputp. 1119
Fuel InjectorsβPCM Pin #16βPCM Outputp. 1119
Fuel InjectorsβPCM Pin #17βPCMp. 1120
Ignition Coil DriverβPCM Pin #17βPCM Outputp. 1120
Fuel InjectorsβPCM Pin #18βPCM Outputp. 1120
Ignition Coil DriverβPCM Pin #18βPCM Outputp. 1120
Ignition Coil DriverβPCM Pin #19βPCM Outputp. 1120
Generator FieldβPCM Pin #20βPCM Outputp. 1121
Intake Manifold Air Temperature SensorβPCM Pin#21-βPCM Inputp. 1121
Throttle Position SensorβPCM Pin #22βPCM Inputp. 1121
Oxygen (02S) SensorβPCM Pin #23βPCM Inputp. 1122
Crankshaft Position SensorβPCM Pin #24βPCM Inputp. 1123
Data Link ConnectorβPCM Pin #25βPCM Outputp. 1123
CCD Bus(+)βPCM Pin #26βPCM Outputp. 1123
Air Conditioning (A/C) ControlsβPCM Pins #27 and#28βPCM Inputp. 1123
Brake SwitchβPCM Pin #29βPCM inputp. 1123
Park/Neutral SwitchβPCM Pin #30βPCM Inputp. 1123
Transmission Temperature Warning LampβPCM Pin #31βPCM Outputp. 1124
Overdrive LampβPCM Pin #31βPCM Outputp. 1124
Malfunction Indicator LampβPCM Pin #32βPCM Outputp. 1124
Speed ControlβPCM Pins #33 and #53βPCMOutputp. 1124
Air Conditioning RelayβPCM Pin #34βPCMOutputp. 1124
EGR Valve Control SolenoidβPin #35βPCMOutputp. 1125
Transmission Temperature Warning LampβPCM Pin #36βPCM Outputp. 1125
Overdrive LampβPCM Pin #37βPCM Outputp. 1125
Fuel InjectorsβPCM Pin #38βPCM Outputp. 1125
Idle Air Control (IAC) MotorβPin #39βPCM Outputp. 1125
Idle Air Control (IAC) MotorβPin #40βPCM Outputp. 1126
Oxygen (02S) SensorβPCM Pin #41βPCM Inputp. 1126
Transmission Temperature SensorβPCM Pin#42βPCM Inputp. 1126
TachometerβPCM Pin #43βPCM Outputp. 1127
Camshaft Position SensorβPCM Pin #44βPCM Inputp. 1127
Data Link ConnectorβPCM Pin #45βPCM inputp. 1127
CCD Bus(-)βPCM Pin #46βPCM Outputp. 1127
Vehicle Speed SensorβPCM Pin #47βPCM Inputp. 1127
Speed ControlβPCM Pins #48, #49 and #50βPCM Inputp. 1128
Automatic Shutdown (ASD) RelayβPCM Pin#51βPCM Outputp. 1128
Fuel Pump RelayβPCM Pin #51βPCM Outputp. 1128
EVAP Canister Purge SolenoidβPCM Pin#52βPCM Outputp. 1128
Speed ControlβPCM Pins #53 and #33βPCM Outputp. 1129
Torque Convertor Clutch (TCC) SolenoidβPCM Pin#54βPCM Outputp. 1129
Overdrive SolenoidβPCM Pin #55βPCM Outputp. 1129
Sri LampβPCM Pin #56βPCM Outputp. 1129
Automatic Shutdown (ASD) SenseβPCM Pin#57βPCM Inputp. 1130
Fuel InjectorsβPCM Pin #58βPCM Outputp. 1130
Idle Air Control (IAC) MotorβPin #59βPCM Outputp. 1130
Idle Air Control (IAC) MotorβPin #60βPCM Outputp. 1130
Fuel Filterp. 1130
Fuel Pressure Regulatorp. 1130
Throttle Bodyp. 1130
Fuel Railp. 1131
+Open Loop/Closed Loop Modes of Operationp. 1132
MODESp. 1132
GNITION SWITCH MODE (KEY-ON/ENGINEOFF)p. 1132
ENGINE START-UP MODEp. 1132
ENGINE WARM-UP MODEp. 1133
IDLE MODEp. 1133
CRUISE MODEp. 1133
ACCELERATION MODEp. 1133
DECELERATION MODEp. 1134
WIDE OPEN THROTTLE MODEp. 1134
IGNITION SWITCH OFF MODEp. 1134
+MULTI-PORT FUEL INJECTION (MFI)βGENERAL DIAGNOSISβEXCEPT DIESELp. 1135
Visual Inspectionp. 1135
POWERTRAIN CONTROL MODULE (PCM) 60-WAY CONNECTORp. 1139
SYSTEM SCHEMATICSp. 1139
AUTOMATIC SHUTDOWN (ASD) RELAY TESTp. 1139
CAMSHAFT POSITION SENSOR TESTp. 1139
CRANKSHAFT POSITION SENSOR TESTp. 1139
EINGINE COOLANT TEMPERATURE SENSOR TESTp. 1139
TRANSMISSION TEMPERATURE 5ENS0R TESTp. 1140
FUEL PUMP RELAY TESTp. 1141
INTAKE MANIFOLD AIR TEMPERATURE SENSOR TESTp. 1141
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TESTp. 1141
THROTTLE POSITION SENSOR TESTp. 1143
THROTTLE BODY MINIMUM AIR FLOW CHECKp. 1143
VEHICLE SPEED SENSOR TESTp. 1144
OXYGEN (02S) SENSOR HEATING ELEMENT TESTp. 1144
IDLE AIR CONTROL (IAC) MOTOR TESTp. 1145
RELAYS-OPERATION/TESTINGp. 1146
STARTER 10T0R RELAY TESTp. 1147
POWERTRAIN CONTROL MODULE TESTINGp. 1147
FUEL INJECTOR TESTp. 1148
FUEL PUiP PRESSURE TESTp. 1148
+ON-BOARD DIAGNOSTICS (OBD)βGAS POWERED VEHICLESp. 1148
MONITORED CIRCUITSp. 1148
NON-MONITORED CIRCUITSp. 1149
HIGH AND LOW LIMITSp. 1149
ACCESSING DIAGNOSTIC TROUBLE CODESp. 1149
ERASING TROUBLE CODESp. 1150
DRB SCAN TOOLp. 1150
DIAGNOSTIC TROUBLE CODE (DTC)p. 1150
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSp. 1150
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSβCONTINUEDp. 1151
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSβCONTINUEDp. 1152
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSβCONTINUEDp. 1153
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSβCONTINUEDp. 1154
+MULTI-PORT FUEL INJECTION (MFI)βCOMPONENT REMOVAL/ INSTALLATIONβEXCEPT DIESELp. 1155
AIR CLEANER HOUSING/AIR CLEANER ELEMENT(FILTER)p. 1155
ACCELERATOR PEDAL AND THROTTLE CABLEp. 1157
AIR CONDITIONING (A/C) CLUTCH RELAYp. 1157
AUTOMATIC SHUTDOWN (ASD) RELAYp. 1157
BRAKE SWITCHp. 1157
CAMSHAFT POSITION SENSORp. 1157
CRANKSHAFT POSITION SENSORp. 1157
INTAKE MANIFOLD AIR TEMPERATURE SENSORp. 1157
ENGINE COOLANT TEMPERATURE SENSORp. 1158
EVAP CANISTER PURGE SOLENOIDp. 1158
FUEL FILTERp. 1158
FUEL PRESSURE REGULATORp. 1158
FUEL INJECTOR(S)p. 1158
FUEL PUMP MODULEp. 1159
FUEL PUMPp. 1159
FUEL PUMP RELAYp. 1159
FUEL RAILp. 1159
FUEL SYSTEM PRESSURE RELEASE PROCEDUREp. 1162
FUEL TANKSp. 1162
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVEp. 1162
FUEL TUBES/LINES/HOSES AND CLAMPSp. 1162
IDLE AIR CONTROL (IAC) MOTORp. 1162
IGNITION COILp. 1162
INTAKE MANIFOLDp. 1163
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORp. 1163
OXYGEN (02S) SENSOip. 1164
PARK/NEUTRAL SWITCHp. 1165
POWERTRAIN CONTROL MODULE (PCM)p. 1165
QUICK-CONNECT FITTINGSp. 1165
THROTTLE BODYp. 1165
THROTTLE POSITION SENSOR (TPS)p. 1166
TRANSMISSION TEMPERATURE SENSORp. 1167
VEHICLE SPEED SENSORp. 1168
+DIESEL ENGINEβCOMPONENT DESCRIPTION/SYSTEM OPERATIONp. 1169
GENERAL INFORMATIONp. 1169
SYSTEM DIAGNOSISp. 1169
POWERTRAIN CONTROL MODULE (PCM)βDIESELp. 1169
+PCM SYSTEM SCHEMATICSβDIESELp. 1170
System Schematicβ5.9L Diesel Enginep. 1171
WATER-IN-FUEL SENSOR-PCM PIN #1βPCM INPUTp. 1172
BATTERY VOLTAGEβPCM PIN #3βPCM INPUTp. 1172
BATTERY TEMPERATURE SENSORp. 1172
SENSOR RETURNβPCM PIN #4βPCM INPUTp. 1172
FIVE VOLT POWERβPCM PIN #6βPCM INPUTp. 1172
EIGHT VOLT POWERβPCM PIN #7βPCM INPUTp. 1172
IGNITION CIRCUIT SENSEβPCM PIN #9βPCM INPUTp. 1172
POWER GROUNDβPCM PIN #11p. 1172
POWER GROUNDβPCM PIN #12p. 1172
INTAKE MANIFOLD AIR HEATERp. 1172
INTAKE MANIFOLD AIR HEATER RELAYSβPCM PINS # 1 5 AND #16βPCM OUTPUTp. 1173
GENERATOR FIELDβ’PCM PIN #21βPCM OUTPUTp. 1174
INTAKE MANIFOLD AIR TEMPERATURE SENSORβPCM PIN #21βPCM INPUTp. 1174
THROTTLE POSITION SENSORβPCM PIN#22βPCM INPUTp. 1175
ENGINE SPEED SENSORβPCM PIN #24βPCM INPUTp. 1175
DATA LINK CONNECTORβPCM PIN #25βPCM OUTPUTp. 1175
AIR CONDITIONING (A/C) CONTROLSβPCM PIN#27βPCM INPUTp. 1175
BRAKE SWITCHβPCM PIN #29βPCM INPUTp. 1176
PARK/NEUTRAL SWITCHβPCM PIN #30βPCM INPUTp. 1176
TRANSMISSION TEMPERATURE WARNING LAMPβPCM PIN #31βPCM OUTPUTp. 1176
MALFUNCTION INDICATOR LAMPβPCM PIN#32βPCM OUTPUTp. 1176
SPEED CONTROLβPCM PINS #33 AND #53βPCM OUTPUTp. 1177
AIR CONDITIONING RELAYβPCM PIN #34βPCM OUTPUTp. 1177
WATER-IN-FUEL WARNING LAMPβPCM PIN#35βPCM INPUTp. 1177
WAIT-TO-START LAMP WARNING LAMPβPCM PIN #36βPCM OUTPUTp. 1177
OVERDRIVE LAMPβPCM PIN #37βPCM OUTPUTp. 1178
TRANSMISSION TEMPERATURE SENSORβPCM PIN #42βPCM INPUTp. 1178
TACHOMETERβPCM PIN #43βPCM OUTPUTp. 1178
DATA LINK CONNECTORβPCM PIN #45βPCM INPUTp. 1178
CCD BUS(-)βPCM PIN #46βPCM OUTPUTp. 1178
VEHICLE SPEED SENSORβPCM PIN #47βPCM INPUTp. 1178
SPEED CONTROLβPCM PINS #48,#49 AND #50βPCM INPUTp. 1179
AUTOMATIC SHUTDOWN (ASD) RELAYβPCM PIN#51βPCM OUTPUTp. 1179
SPEED CONTROLβPCM PINS #S3 AND #33βPCM OUTPUTp. 1179
TORQUE CONVERTOR CLUTCH (TCC) SOLENOIDβPCM PIN #54βPCM OUTPUTp. 1179
OVERDRIVE SOLENOIDβPCM PIN #55βPCM OUTPUTp. 1179
AUTOMATIC SHUTDOWN (ASD) SENSEβPCM PIN#57βPCM INPUTp. 1179
+DIESEL ENGINEβGENERAL DIAGNOSISp. 1180
GENERAL INFORMATIONp. 1180
Fuel System ComponentsβDiesel Enginep. 1181
VISUAL INSPECTIONp. 1182
POWERTRAIN CONTROL MODULE (PCM) 60-WAY CONNECTORp. 1183
SYSTEM SCHEMATICSp. 1183
AIR IN FUEL SYSTEMp. 1183
AUTOMATIC SHUTDOWN (ASD) RELAY TESTp. 1184
ENGINE SPEED SENSOR TESTp. 1184
FUEL FILTER/WATER SEPARATOR TESTp. 1184
FUEL HEATER TESTp. 1185
FUEL HEATER RELAY TESTp. 1186
FUEL INJECTOR TESTp. 1186
FUEL INJECTION PUMP TESTp. 1187
FUEL SUPPLY RESTRICTIONSp. 1187
FUEL SHUTDOWN SOLENOID TESTp. 1187
FUEL SHUTDOWN SOLENOID RELAY TESTp. 1189
FUEL TRANSFER PUMP PRESSURE TESTp. 1189
HIGH-PRESSURE FUEL LINE LEAK TESTp. 1191
IDLE SPEED ADJUSTMENTp. 1192
INTAKE MANIFOLD AIR HEATER TESTp. 1192
INTAKE MANIFOLD AIR HEATER RELAY TESTp. 1194
INTAKE MANIFOLD AIR TEMPERATURE SENSORTESTp. 1194
POWERTRAIN CONTROL MODULE TESTINGp. 1195
RELAYSβOPERATION/TESTINGp. 1195
STARTER MOTOR RELAY TESTp. 1196
THROTTLE POSITION SENSOR TESTp. 1196
TRANSMISSION TEMPERATURE SENSOR TESTp. 1196
VEHICLE SPEED SENSOR TESTp. 1197
WATER-IN-FUEL WARNING LAMPp. 1197
+0N-B0ARD DIAGNOSTICS (OBD)βDIESEL POWERED VEHICLESp. 1197
MONITORED CIRCUITSp. 1197
NON-MONITORED CIRCUITSp. 1197
HIGH AND LOW LIMITSp. 1198
ACCESSING DIAGNOSTIC TROUBLE CQDESp. 1198
ERASING TROUBLE CODESp. 1198
DRB SCAN TOOLp. 1199
+DIAGNOSTIC TiOtJIlE CODE (DTC)p. 1199
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSp. 1199
DIAGNOSTIC TROUBLE CODE DESCRIPTIONSβCONTINUEDp. 1200
SYSTEM DIAGNOSIS CHARTSp. 1201
FUEL INJECTION PUMP TIMINGp. 1201
+DIESEL ENGINEβCOMPONENT REMOVAL/INSTALLATIONp. 1207
AIR CLEANER HOUSING/AIR CLEANER ELEMENTp. 1207
AIR BLEED PROCEDUREp. 1208
ENGINE SPEED SENSORp. 1209
FUEL DRAIN MANIFOLDp. 1210
FUEL FILTERβIN TANKp. 1211
FUEL FILTER/WATER SEPARATORp. 1211
FUEL GAUGE SENDING UNITp. 1212
FUEL HEATERp. 1212
FUEL HEATER RELAYp. 1213
FUEL INJECTION PUMPp. 1213
FUEL INJECTION PUiP SUPPLY LINEp. 1220
FUEL INJECTORSp. 1220
FUEL SHUTDOWN SOLENOIDp. 1222
FUEL SHUTDOWN SOLENOID RELAYp. 1223
FUEL SYSTEM PRESSURE WARNINGp. 1223
FUEL SYSTEM PRESSURE TESTβDIESEL ENGINEp. 1223
FUEL TANKp. 1224
FUEL TANK MODULEp. 1224
FUEL TRANSFER PUMPp. 1224
HIGH-PRESSURE FUEL LINESp. 1224
lDLE SPEED ADJUSTMENTp. 1225
INTAKE MANIFOLDp. 1225
INTAKE MANEFOLD All TEMPERATURE SENSORp. 1226
INTAKE MANIFOLD AIR HEATERp. 1226
INTAKE MANIFOLD AIR HEATER RELAYSp. 1226
POWERTRAIN CONTROL MODULE (PCM)p. 1227
THROTTLE POSITION SENSORp. 1227
TRANSMISSION TEMPERATURE SENSORp. 1229
VEHICLE SPEED SENSORp. 1229
WASTEGATE (TURBOCHARGER)p. 1229
WATER-IN-FUEL SENSORp. 1229
SPECIFICATIONSp. 1083
+16-Propeller Shaftsp. 1230
+GENERAL INFORMATIONp. 1230
PROPELLER SHAFTSp. 1230
CENTER BEARINGp. 1231
UNIVERSAL JOINTSp. 1231
LUBRICATIONp. 1231
PRECAUTIONSp. 1231
+DIAGNOSIS AND TESTINGp. 1232
VIBRATIONp. 1232
UNBALANCEp. 1232
RUNOUTp. 1233
+SERVICE PROCEDURESp. 1233
UNIVERSAL JOINT ANGLEp. 1233
INSPECTIONp. 1234
PROPELLER SHAFT ANGLE MEASUREMENTp. 1234
MEASUREMENTβTWO-PIECE SHAFTp. 1235
+REMOVAL AND INSTALLATIONp. 1236
FRONT PROPELLER SHAFTp. 1236
REAR PROPELLER SHAFTp. 1236
TWO PIECE PROPELLER SHAFTβREARp. 1237
+DISASSEMBLY AND ASSEMBLYp. 1237
CENTER BEARINGp. 1237
SINGLE CARDANp. 1238
DOUBLE CARDAN (CV)p. 1239
+CLEANING AND INSPECTIONp. 1242
SINGLE AND DOUBLE CARDAN JOINTp. 1242
ADJUSTMENTSp. 1243
SPECIFICATIONSp. 1243
SPECIAL TOOLSp. 1243
+19-Steeringp. 1244
+GENERAL INFORMATIONp. 1244
STEERING SYSTEM COMPONENTSp. 1244
+POWER STEERING SYSTEM DIAGNOSISp. 1246
PUMP PRESSURE TESTp. 1246
+POWER STEERING SYSTEM DIAGNOSISp. 1248
STEERING NOISESp. 1247
STEERING NOISES (C0NT)p. 1247
BINDS STICKS SEIZEDp. 1249
SHAKE SHUDDER VIBRATIONp. 1249
LOW ASSIST, NO ASSIST, OR HARD STEERINGp. 1250
POOR RETURN TO CENTERp. 1250
LOOSE STEERINGp. 1251
VEHICLE LEADS TO THE SIDEp. 1251
FLUID LEAKp. 1252
FOAMY OR MILKY FLUIDp. 1252
PUMP LEAKAGE DIAGNOSISp. 1253
GEAR LEAKAGE DIAGNOSISp. 1254
+POWER STEERING PUMPp. 1255
SERVICE INFORMATIONp. 1255
POWER STEERING HOSEp. 1255
PUMP REPLACEMENTβDIESEL ENGINEp. 1256
PUMP REPLACEMENTβGASOLINE ENGINEp. 1258
PUMP PULLEYp. 1259
PUMP RESERVOIRp. 1259
POWER STEERING PUMPβINITIAL OPERATIONp. 1260
+STEERING LINKAGEp. 1261
SERVICE INFORMATIONp. 1261
STEERING LINKAGEβIFS SUSPENSIONp. 1261
STEERING LINKAGEβLINK/COIL SUSPENSIONp. 1262
+RECIRCULATING BALL POWER STEERING GEARp. 1263
SERVICE INFORMATIONp. 1263
PITMAN SHAFT SEALSβIN CAR REPLACEMENTp. 1263
STEERING GEAR REPLACEMENTp. 1265
STEERING GEAR ADJUSTMENTSp. 1265
+GEAR DISASSEMBLY INFORMATIONp. 1267
Power Steering Gearp. 1268
PITMAN SHAFT AND SIDE COVER REPLACEMENTp. 1269
HOUSING END PLUGp. 1269
ADJUSTER PLUG ASSEMBLY REPLACEMENTp. 1270
VALVE REPLACEMENTp. 1272
RACK PISTON AND WORM SHAFT REPLACEMENTp. 1273
PITMAN SHAFT SEALS AND BEARING REPLACEMENTp. 1275
CHECK VALVE REPLACEMENTp. 1276
POWER STEERING GEAR SPECIFICATIONSp. 1277
+STEERING COLUMNp. 1278
SERVICE INFORMATIONp. 1278
STEERING WHEELp. 1278
CLOCKSPRINGp. 1280
COLUMNβ REMOVAL/INSTALLATIONp. 1280
COLUMN COMPONENT SERVICEp. 1282
TORQUE SPECIFICATIONSp. 1283
+21-Transmission & transfer Casep. 1284
+NV3500 MANUAL TRANSMISSIONp. 1284
GENERAL INFORMATIONp. 1284
NV3500 Manual Transmissionp. 1285
TRANSMISSION LUBRICANTp. 1286
TRANSMISSION LUBRICANT LEVEL AND CAPACITYp. 1286
DRAIN AND FILL PLUG LOCATIONSp. 1286
TRANSMISSION GEAR RATIOSp. 1286
TRANSMISSION CHANGESp. 1287
+TRANSMISSION DIAGNOSISp. 1287
LOW LUBRICANT LEVELp. 1287
HARD SHIFTINGp. 1287
TRANSMISSION NOISEp. 1287
TRANSMISSION REMOVAL (2-WHEEL DRIVE)p. 1287
TRANSMISSION REMOVAL (4-WHEEL DRIVE)p. 1289
TRANSMISSION INSTALLATION (2-WHEEL DRIVE)p. 1290
TRANSMISSION INSTALLATION (4-WHEEL DRIVE)p. 1290
+TRANSMISSION DISASSEMBLY AND OVERHAULp. 1291
FRONT HOUSING REMOVALp. 1291
SHIFT SHAFT, SHIFT FORKS AMD REVERSE IDLER SEGMENT REMOVALp. 1294
REAR HOUSING REMOVAL (2-WHEEL DRIVE TRANSMISSION)p. 1297
REAR ADAPTER MOUSING REMOVAL ( 4 -WHEEL DRIVE TRANSMISSION)p. 1298
REMOVING GEARTRAIN FROM FIXTURE TOOL 6747p. 1299
OUTPUT SHAFT GEARTRAIN DISASSEMBLYp. 1299
REVERSE IDLER DISASSEMBLY )FIG. 52)p. 1303
TRANSMISSION COMPONENT CLEANING AND INSPECTIONp. 1303
Output Shaft And Geartrainp. 1306
+TRANSMISSION ASSEMBLYp. 1307
CORRECT ASSEMBLY OF SYNCHRONIZER COMPONENTSp. 1307
OUTPUT SHAFT AND GEARTRAIN ASSEMBLYp. 1308
REVERSE IDLER ASSEMBLY (FIG. 52)p. 1315
GEARTRAIN BUILDUP (IN ASSEMBLY FIXTURE TOOL)p. 1315
REAR HOUSING INSTALLATION (2-WHEEL DRIVE TRANSMISSION)p. 1318
REAR ADAPTER HOUSING INSTALLATION(4-WHEEL DRIVE TRANSMISSION)p. 1320
REVERSE IDLER SEGMENT INSTALLATIONp. 1320
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET INSTALLATIONp. 1321
FRONT HOUSING AND INPUT SHAFTBEARING RETAINER INSTALLATIONp. 1324
+NV4500 MANUAL TRANSMISSIONp. 1330
GENERAL INFORMATIONp. 1330
NV4500 Manual Transmissionp. 1331
TRANSMISSION IDENTIFICATIONp. 1332
REQUIRED LUBRICANTβCAPACITYβFILL LEVELp. 1332
GEAR RATIOSp. 1332
SHIFT PATTERNp. 1332
+MANUAL TRANSMISSION DIAGNOSISp. 1332
COMMON PROBLEM CAUSESp. 1332
HARD SHIFTINGp. 1332
NOISY OPERATIONp. 1332
SLIPS OUT OF GEARp. 1333
LOW LUBRICANT LEVELp. 1333
CLUTCH PROBLEMSp. 1333
TRANSMISSION REMOVAL (2-WHEEL DRIVE)p. 1333
TRANSMISSION INSTALLATION (2-WHEEL DRIVE)p. 1334
TRANSMISSION REMOVAL (4-WHEEL DRIVE)p. 1334
TRANSMISSION INSTALLATION (4-WHEEL DRIVE)p. 1335
+TRANSMISSION DISASSEMBLY AND OVERHAULp. 1336
SHIFT COVER REMOVALp. 1336
EXTENSION/ADAPTER HOUSING REMOVALp. 1336
MAINSHAFT AND COUNTERSHAFT FIFTH GEAR REMOVALp. 1337
FRONT RETAINER REMOVAL AND DISASSEMBLYp. 1341
DRIVE GEAR REMOVAL AND DISASSEMBLYp. 1342
MAINSHAFT AND GEARTRAIN REMOVALp. 1343
REVERSE IDLER GEAR AND COUNTERSHAFT REMOVAL/DISASSEMBLYp. 1344
GEAR CASE DISASSEMBLYp. 1346
MAINSHAFT DISASSEMBLYp. 1347
TRANSMISSION CLEANING AND INSPECTIONp. 1353
+MAINSHAFT GEARTRAINp. 1357
LEGEND FOR MAINSHAFT GEARTRAINp. 1358
+TRANSMISSION ASSEMBLY AND ADJUSTMENTp. 1358
GEAR CASE ASSEMBLYp. 1358
COUNTERSHAFT AND REVERSE IDLER GEAR INSTALLATIONp. 1358
ADJUSTING COUNTERSHAFT END PLAYp. 1361
SHIFT LUG AND RAIL INSTALLATIONp. 1361
MAINSHAFT AND GEARTRAIN ASSEMBLYp. 1361
MAINSHAFT AND GEARTRAIN INSTALLATIONp. 1369
DRIVE GEAR AND RETAINER INSTALLATIONp. 1370
MAINSHAFT END PLAY ADJUSTMENTp. 1371
MAINSHAFT FIFTH GEAR INSTALLATIONp. 1372
COUNTERSHAFT FIFTH GEAR AND SYNCHRO INSTALLATIONp. 1372
EXTENSION/ADAPTER HOUSING INSTALLATIONp. 1374
SHIFT COVER INSTALLATIONp. 1374
SHIFT COVER SERVICEp. 1375
SHIFT LEVER REPLACEMENTp. 1377
SHIFT COVER REPLACEMENTp. 1379
+42RH/46RH/47RH AUTOMATIC TRANSMISSIONp. 1380
+GENERAL INFORMATIONp. 1380
TRANSMISSION DESCRIPTIONp. 1380
42RH Transmission And Overdrive Unitp. 1381
46RH/47RH Transmission And Overdrive Unitp. 1382
TORQUE CONVERTERp. 1383
GEAR RATIOSp. 1383
RECOMMENDED FLUIDp. 1383
+COMPONENTS UNIQUE TO 47RHp. 1383
Planetary Gearsp. 1383
Gear Casep. 1383
Clutch Packsp. 1383
Rear Band, Lever and Low-Reverse Drump. 1383
Low-Reverse Drum And Overdrive piston retainerp. 1383
Governor Weight Assemblyp. 1383
TEMPERATURE SENSOR AND INDICATOR LAMPp. 1383
TRANSMISSION IDENTIFICATIONp. 1384
FOURTH GEAR OVERDRIVE COMPONENTSp. 1384
TRANSMISSION CHANGES AND PARTSINTERCHANGEABLEp. 1385
+42RH/46RH/47RH TRANSMISSION CONTROLS AND OPERATIONp. 1386
3-4 SHIFT SEQUENCEp. 1386
GEARSHIFT MECHANISMp. 1386
OVERDRIVE SELECTOR SWITCHp. 1386
TRANSMISSION HYDRAULIC CONTROLSp. 1386
PRESSURE REGULATIONp. 1386
SHIFT VALVE FLOW CONTROLp. 1387
CONVERTER DRAINBACK VALVEp. 1387
B00ST VALVE OPERATIONp. 1387
QUICK FILL VALVE OPERATIONp. 1387
CONVERTER CLUTCH CONTROLp. 1387
CLUTCH AND BAND APPLICATIONp. 1388
+42RH/46RH/47RH TRANSMISSION DIAGNOISIS AND TESTINGp. 1389
GENERAL INFORMATIONp. 1389
PRELIMINARY DIAGNOSISp. 1389
CHECKING FLUID LEVEL AND CONDITIONp. 1389
EFFECTS OF INCORRECT FLUID LEVELp. 1390
CAUSES OF BURNED FLUIDp. 1390
FLUID CONTAMINATIONp. 1390
OVERDRIVE FOURTH GEAR ELECTRICAL CONTROLSp. 1391
THROTTLE VALVE CABLE ADJUSTMENTp. 1391
GEARSHIFT LINKAGEp. 1391
ROAD TESTINGp. 1391
ANALYZING THE ROAD TESTp. 1391
Clutch And BAND APPLLICATIONp. 1392
+HYDRAULIC PRESSURE TESTp. 1392
PRESSURE TEST PORT LOCATIONSp. 1392
+HYDRAULIC PRESSURE TEST PROCEDUREp. 1393
Test OneβTransmission In 1 Rangep. 1393
Test TwoβTransmission In 2 Rangep. 1393
Test ThreeβTransmission In D Range Third Gearp. 1393
Test FourβTransmission In Reversep. 1393
Test FiveβGovernor Pressurep. 1394
Test SixβTransmission In Overdrive Fourth Gearp. 1394
CONVERTER STALL TESTp. 1394
STALL TEST ANALYSISp. 1395
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATIONp. 1395
CONVERTER HOUSING FLUID LEAK DIAGNOSISp. 1395
+DIAGNOSIS CHARTSp. 1399
TRANSMISSION DIAGNOSISp. 1400
TRANSMISSION DIAGNOSIS (CONT.)p. 1401
TRANSMISSION DIAGNOSIS (CONT.)p. 1402
TRANSMISSION DIAGNOSIS (CONT.)p. 1403
TRANSMISSION DIAGNOSIS (CONT.)p. 1404
TRANSMISSION DIAGNOSIS (CONT.)p. 1405
TRANSMISSION DIAGNOSIS (CONT.)p. 1406
TRANSMISSION DIAGNOSIS (CONT.)p. 1407
OVERDRIVE DIAGNOSIS(CONT.)p. 1408
OVERDRIVE DIAGNOSIS(CONT.)p. 1409
OVERDRIVE DIAGNOSIS(CONT.)p. 1410
TORQUE CONVERTER DIAGNOSISp. 1411
TORQUE CONVERTER DIAGNOSIS(C0NT.)p. 1412
TORQUE CONVERTER DIAGNOSIS(C0NT.)p. 1413
HYDRAULIC FLOW IN PARK (42RH/46RH/47RH)p. 1414
HYDRAULIC FLOW IN NEUTRAL (42RH/46RH/47RH)p. 1415
HYDRAULIC FLOW IN REVERSE (42RH/46RH/47RH)p. 1416
HYDRAULIC FLOW IN D FIRST GEAR (42RH/46RH/47RH)p. 1417
HYDRAULIC FLOW IN D SECOND GEAR (42RH/46RH/47RHJp. 1418
HYDRAULIC FLOW IN D THIRD GEAR (42RH/46RH/47RH)p. 1419
HYDRAULIC FLOW IN D FOURTH GEAR-CONVERTER CLUTCH NOT APPLIED (42RH/46RH/47RH)p. 1420
HYDRAULIC FLOW IN D FOURTH GEAR-CONVERTER CLUTCH APPLIED (42RH/46RH/47RH)p. 1421
HYDRAULIC FLOW IN MANUAL FIRST GEAR (1) (42RHJ46RH/47RH)p. 1422
HYDRAULIC FLOW IN MANUAL FIRST GEAR (1) (42RHJ46RH/47RH)p. 1423
+42RH/46RH/47RH TRANSMISSION IN-VEHICLE SERVIlCEp. 1424
FLUID LEVEL CHECKp. 1424
+FLUID AND FILTER REPLACEMENTp. 1424
FLUID AND FILTER REPLACEMENT PROCEDUREp. 1424
REFILLING AFTER OVERHAUL OR FLUID/FILTERCHANGEp. 1425
GEARSHIFT LINKAGE ADJUSTMENTp. 1425
GEARSHIFT INDICATOR ADJUSTMENTp. 1425
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENTp. 1426
THROTTLE VALVE CABLE REPLACEMENTp. 1426
FRONT BAND ADJUSTMENTp. 1427
REAR BAND ADJUSTMENTp. 1428
SPEEDOMETER SERVICEp. 1429
PARK/NEUTRAL POSITION SWITCHp. 1429
YOKE SEAL REPLACEMENTp. 1430
GOVERNOR AND PARK LOCK SERVICEp. 1431
VALVE BODY SERVICEp. 1431
TRANSMISSION COOLER LINE AND FITTING SERVICEp. 1432
CONVERTER DRAINBACK CHECK VALVE SERVICEp. 1433
TRANSMISSION COOLER FLOW TESTINGp. 1433
TRANSMISSION COOLER REVERSE FLUSHINGp. 1434
TRANSMISSION COOLER REPLACEMENTp. 1434
ALUMINUM THREAD REPAIRp. 1435
+42RH/46RH/47RH TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATIONp. 1436
GENERAL SERVICE INFORMATIONp. 1436
TRANSMISSION AND CONVERTER REMOVALp. 1436
CONVERTER AND DRIVE PLATE SERVICEp. 1437
STARTER RING GEAR REPLACEMENTp. 1438
PUMP OIL SEAL REPLACEMENTp. 1438
TRANSMISSION INSTALLATIONp. 1438
OVERDRIVE UNIT REMOVALp. 1439
OVERDRIVE UNIT INSTALLATIONp. 1440
+42RH TRANSMISSION OVERHAULp. 1442
TRANSMISSION DISASSEMBLYp. 1442
OVERHAUL SERVICE INFORMATIONp. 1448
TRANSMISSION CASE CLEANING AND INSPECTIONp. 1448
OVERRUNNING CLUTCHβLOW-REVERSE DRUMβOVERDRIVE PISTON RETAINER INSPECTION AND OVERHAULp. 1449
OIL PUMP AND REACTION SHAFT SUPPORT OVERHAULp. 1449
FRONT CLUTCH OVERHAULp. 1453
REAR CLUTCH OVERHAULp. 1456
PLANETARY GEAR TRAIN AND INTERMEDIATE SHAFT OVERHAULp. 1459
FRONT SERVO AND BAND OVERHAULp. 1463
REAR SERVO AND IAN0 OVERHAULp. 1464
VALVE BODY SERVICE AND ADJUSTMENTp. 1465
VALVE BODY CLEANING AND INSPECTIONp. 1473
Upper Housing Componentsp. 1474
VALVE BODY REASSEMBLYp. 1475
TRANSMISSION ASSEMBLY PROCEDUREp. 1477
+46RH/47RH TRANSMISSION OVERHAULp. 1485
TRANSMISSI0N DISASSEMBLYp. 1485
OVERHAUL SERVICE INFORMATIONp. 1494
TRANSMISSION CASE CLEANING AND INSPECTIONp. 1495
LOW-REVERSE DRUM AND REAR BAND SERVICEp. 1495
OVERDRIVE PISTON AND RETAINER SERVICEp. 1495
OVERRUNNING CLUTCH OVERHAULp. 1495
OVERRUNNING CLUTSH ASSEMBLY INSTALLATIONp. 1497
ACCUMULATOR OVERHAULp. 1498
FRONT SERVO AND BAND OVERHAULp. 1498
REAR SERVO AND BAND OVERHAULp. 1499
OIL PUMP AND REACTION SHAFT SUPPORT OVERHAULp. 1499
FRONT CLUTCH OVERHAULp. 1502
REAR CLUTCH OVERHAULp. 1505
PLANETARY GEARTRAIN OVERHAULp. 1507
VALVE BODY SERVICE AND ADJUSTMENTp. 1512
VALVE BODY LOWER HOUSING DISASSEMBLYp. 1518
3-4 ACCUMULATOR HOUSING DISASSEMBLYp. 1520
+VALVE BODY CLEANING AND INSPECTIONp. 1520
Upper Housing Componentsp. 1521
VALVE BODY REASSEMBLYp. 1522
VALVE BODY CONTROL PRESSURE ADJUSTMENTp. 1524
+TRANSMISSION ASSEMBLYp. 1525
FRONT/REAR SERVO INSTALLATIONp. 1526
OVERRUNNING CLUTCH, REAR BAND,LOW-REVERSE DRUM, AND OVERDRIVE PISTON RETAINER INSTALLATIONp. 1527
PLANETARY GEARTRAIN, FRONT/REARCLUTCH, AND FRONT BAND INSTALLATIONp. 1531
OIL PUMP INSTALLATIONp. 1532
OVERDRIVE UNIT AND PISTON INSTALLATIONp. 1534
INPUT SHAFT END PLAY CHECKp. 1534
BAND ADJUSTMENTS AND INSTALLATION OFACCUMULATOR, VALVE BODY, OIL PAN, ANDTORQUE CONVERTERp. 1535
+42RH/46RH/47RH OVERDRIVE UNIT OVERHAULp. 1537
OVERDRIVE UNIT DISASSEMBLYp. 1537
OVERDRIVE GEARTRAIN DISASSEMBLYp. 1539
OVERDRIVE COMPONENT CLEANING AND INSPECTIONp. 1543
GOVERNOR OVERHAULp. 1545
DIRECT CLUTCH AND OEARTRAIN ASSEMBLYp. 1548
Direct Clutch Pack Componentsp. 1552
OVERDRIVE GEARTRAIN AND CASE ASSEMBLYp. 1554
Overdrive Clutch Pack Componentsp. 1557
OVERDRIVE CLUTCH INSTALLATION ANDADJUSTMENTp. 1558
+NP231 HD/NP241/NP241 HD TRANSFER CASEp. 1559
GENERAL DESCRIPTIONp. 1559
TRANSFER CASE APPLICATIONp. 1559
OPERATING RANGESp. 1559
TRANSFER CASE SERVICEp. 1559
PTO CAPABILITYp. 1559
TRANSFER CASE IDENTIFICATIONp. 1559
RECOMMENDED LUBRICANT AND CAPACITYp. 1559
TRANSFER CASE SHIFT MECHANISMp. 1560
TRANSFER CASE CHANGESp. 1560
SERVICE DIAGNOSISp. 1561
CHECKING FLUID LEVELp. 1561
FLUID DRIIN/REFILLp. 1561
IN-VEHICLE SERVICEp. 1561
SPEEDOMETER SERVICEp. 1561
SERVICE DIAGNOSISp. 1562
SHIFT LINKAGE ADJUSTMENTp. 1562
TRANSFER CASE REMOVALp. 1562
TRANSFER CASE INSTALLATIONp. 1564
+TRANSFER CASE DISASSEMBLYp. 1564
REAR EXTENSION, RETAINER AND REARCASE REMOVALp. 1564
GEARTRAIN AND SHIFT COMPONENT REMOVALp. 1568
INPUT GEAR AND PLANETARY REMOVALp. 1569
PLANETARY AND INPUT GEAR DISASSEMBLYp. 1570
MIAINSHAFT DISASSEMBLYp. 1573
FRONT/REAR CASE BEARING AND SEAL REMOVALp. 1573
TRANSFER CASE CLEANING AND INSPECTIONp. 1574
+TRANSFER CASE ASSEMBLYp. 1576
FRONT CASE ASSEMBLYp. 1576
PLANETARY AND INPUT GEAR ASSEMBLY AND INSTALLATIONp. 1578
MAINSHAFT/SHAFT FORK ASSEMBLY AND INSTALLATIONp. 1580
FRONT OUTPUT SHAFT, DRIVE CHAIN AND SPROCKET INSTALLATIONp. 1583
REAR CASE, OIL PUMP AND SPEEDOMETER GEAR INSTALLATIONp. 1584
REAR RETAINER AND EXTENSION INSTALLATIONp. 1586
INPUT RETAINER, DETENT, AND COMPANION FLANGE INSTALLATIONp. 1587
+NV 021 PTO ADAPTERp. 1590
GENERAL INFORMATIONp. 1590
SHIFT LEVER AND LINKAGEp. 1591
PTO ADAPTER OPERATING RANGES AND SHIFTINGp. 1591
PTO ACCESSORY EQUIPMENTp. 1592
RECOMMENDED LUBRICANT AND FILL LEVELp. 1592
ADAPTER IDENTIFICATIONp. 1592
PTO ADAPTER SERVICEp. 1592
ADAPTER SERVICE DIAGNOSISp. 1592
SHIFT LINKAGE ADJUSTMENTp. 1593
SPEEDOMETER SERVICEp. 1593
ADAPTER REMOVALp. 1594
ADAPTER INSTALLATIONp. 1594
ADAPTER DISASSEMBLY AND OVERHAULp. 1595
ADAPTER CLEANING AND INSPECTIONp. 1601
ADAPTER ASSEMBLYp. 1602
+TRANSMISSION/TRANSFER CASE SPECIFICATIONSp. 1609
AUTOMATIC TRANSMISSION GENERAL SPECIFICATIONSp. 1610
SPACER/THRUST PLATE/SNAP RING SPECIFICATIONSp. 1610
AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONSp. 1611
AUTOMATIC TRANSMISSION TORQUE SPECIFICATIONSp. 1611
TRANSFER CASE TORQUE SPECIFICATIONSp. 1612
NV 021 TORQUE SPECIFICATIONSp. 1612
+22-Wheels & Tiresp. 1613
+TIRESp. 1613
GENERAL INFORMATIONp. 1613
CLEANING OF TIRESp. 1614
PRESSURE GAUGESp. 1614
TIRE INFLATION PRESSURESp. 1614
REPLACEMENT TIRESp. 1615
ROTATIONp. 1615
TREAD WEAR INDICATORSp. 1615
REPAIRING LEAKSp. 1615
TIRE NOISE OR VIBRATIONp. 1616
TIRE WEAR PATTERNSp. 1616
LEAD CORRECTION CHARTp. 1617
+WHEELSp. 1618
GENERAL INFORMATIONp. 1618
DUAL REAR WHEELSp. 1619
WHEEL REPLACEMENTp. 1620
WHEEL ORNAMENTATIONp. 1620
TIRE AND WHEEL BALANCEp. 1620
MATCH MOUNTINGp. 1620
TIRE AND WHEEL RUNOUTp. 1622
+VEHICLE VIBRATIONp. 1623
VIBRATION TYPESp. 1623
VIBRATION OIAGNOSISp. 1623
TORQUE SPECIFICATIONSp. 1625
+23-Body Componentsp. 1626
+EXTERIOR COMPONENT SERVICEp. 1626
GRILLEp. 1626
GRILLE FRAMEp. 1626
GRILLE SEALSp. 1627
HOOD SILENCERp. 1627
HOOD SAFETY CATCHp. 1627
HOOD LATCH STRIKERp. 1628
HOODp. 1628
HOOD HINGEp. 1628
HOOD LATCHp. 1629
HOOD SLAM BUMPERp. 1629
COWL COVERp. 1629
FR0NT WHEELHOUSE LINERp. 1630
LEFT FRONT FENDERp. 1630
RIGHT FRONT FENDERp. 1631
SIDE VIEW MIRRORp. 1632
MIRROR FLAG COVERp. 1633
LOW MOUNTED SIDE VIEW MIRRORp. 1633
DOOR LATCH STRIKERp. 1633
DOOR SEALp. 1633
DOOR SECONDARY SEALp. 1634
ROOF RAIL WEATHERSTRIP AND RETAINERp. 1634
ROOF JOINT M0LDINGp. 1634
BODY VENTp. 1635
TAPE STRIPE OVERLAYp. 1635
STICK-ON BODY SIDE MOLDINGSp. 1636
BODY EMBLEMSp. 1637
TAILGATE DECALSp. 1638
FUEL FILL DOORp. 1638
REAR SPLASH SHIELDSp. 1638
REAR WHEELHOUSE LINERp. 1639
REAR FENDER WITH DUAL REAR WHEELSp. 1639
TAILGATE CHECK CABLEp. 1640
TAILGATEp. 1640
TAILGATE HANDLE ESCUTCHEONp. 1640
TAILGATE LATCH HANDLEp. 1640
TAILGATE LATCHp. 1641
TAILGATE LATCH STRIKERp. 1641
TAILGATE PROTECTORp. 1641
TAILGATE SLAM BUMPERp. 1642
CAHGO BOIp. 1642
+DOORSp. 1643
SERVICE INFORMATIONp. 1643
DOORp. 1643
DOOR HINGEp. 1643
DOOR TRIM PANELp. 1644
DOOR WATER DAMp. 1645
INNER DOOR BELT WEATHERSTRIPp. 1645
OUTER DOOR BELT WEATHERSTRIPp. 1645
D00R GLASS RUN WEATHERSTRIPp. 1645
DOOR GLASSp. 1646
DOOR GLASS WIDOW REGULATORp. 1646
DOOR GLASS RUN LOWER CHANNELSp. 1646
OUTSIDE DOOR HANDLEp. 1647
DOOR LOCK CYLINDERp. 1647
DOOR LOCK BUTTONp. 1647
DOOR-LATCH/LOCKp. 1648
+URETHANE SET GLASSp. 1649
SAFETY PRECAUTIONS AND WARNINGSp. 1649
WINDSHIELDp. 1649
QUARTER VENT WINDOWβCLUB CABp. 1651
QUARTER VENT WINDOW WEATHERSTRIP SEALp. 1651
REAR WINDOWβCONVENTIONAL CABp. 1652
SLIDING REAR WINDOWβCONVENTIONAL CABp. 1653
LATCH AND KEEPERβCONVENTIONAL CABp. 1653
REAR WINDOWβCLUB CABp. 1653
SLIDING REAR WINDOWβCLUB CABp. 1654
+CAB INTERIOR COMPONENTSp. 1655
BENCH SEATp. 1655
SEAT REPAIRβBENCH SEATp. 1655
SPLIT BENCH SEATp. 1657
SEAT REPAIRβSPLIT BENCHp. 1657
REAR SEATβCLUB CABp. 1659
INTERIOR TRIM PANELSp. 1660
DOOR SILL AND COWL COVERp. 1660
A-PILLAR GRAB HANDLEp. 1660
A-PILLAR MOLDINGp. 1660
QUARTER TRIM PANELp. 1661
QUARTER TRIM PANELβCLUB CABp. 1661
REAR CLOSURE PANEL TRIMp. 1661
SEAT BELT RETRACTORp. 1662
SEAT BELT RETRACTORSβCLUB CABp. 1662
SEAT BELT BUCKLEp. 1662
REAR SEAT BELT BUCKLEp. 1663
HEADLINERp. 1663
OVERHEAD ASSIST HANDLEp. 1663
COAT HOOKp. 1664
SUN VISORp. 1664
REAR FLOOR STOWAGE TRAYp. 1664
EMERGENCY JACK AND TOOL KITp. 1664
EMERGENCY JACK AND TOOL KITβCLUB CABp. 1665
FLOOR SHIFT BOOTβMANUALp. 1665
FLOOR SHIFT BOOTβ4WD MANUALp. 1665
FLOOR SHIFT BOOTβ4WD AUTOMATICp. 1665
FLOOR CARPET OR MATp. 1666
FLOOR CARPET OR MATβCLUB CABp. 1666
+BODY DIAGNOSTIC AND PAINT PROCEDURESp. 1667
WATER LEAKSp. 1667
WIND NOISEp. 1668
PAINTp. 1668
BASE COAT/CLEAR COAT FINISHp. 1668
WET SANDING,BUFFING AND POLISHINGp. 1668
PAINTED SURFACE TOUCH-UPp. 1668
AFTERMARKET PAINT AND TRIM CODE DESCRIPTIONSp. 1669
+24-Heating & Air Conditioningp. 1670
+GENERAL INFORMATIONp. 1670
HEATER SYSTEMp. 1670
SIDE WINDOW DEMISTERSp. 1670
AIR CONDITIONING SYSTEMp. 1671
SYSTEM AIRFLOWp. 1671
+A/C COMPONENTSp. 1671
ACCUMULATORp. 1671
COMPRESSORp. 1671
CLUTCH PULLEY AND COILp. 1671
AIR CONDITIONING CYCLING SWITCHp. 1671
CONDENSERp. 1672
EVAPORATOR COILp. 1672
FIXED ORIFICE TUBEp. 1672
HIGH PRESSURE RELIEF VALVEp. 1672
HIGH-PRESSURE CUT-OUTp. 1672
REFRIGERANT LINESp. 1672
SPRING LOCK COUPLERp. 1672
SERVICE PORTSp. 1672
REFRIGERANTp. 1672
REFRIGERANT OILp. 1672
REFRIGERANT EQUIPMENTp. 1672
+MANIFOLD GAUGE SETp. 1672
R-134a Manifold Gauge Setp. 1673
WARNINGS, CAUTIONS AND SERVICE PRECAUTIONSp. 1674
+REFRIGERANT SERVICEp. 1676
LEAK TESTING REFRIGERANTp. 1676
RECOVERING REFRIGERANT SYSTEMp. 1676
EVACUATING REFRIGERANT SYSTEMp. 1676
CHARGING REFRIGERANT SYSTEMp. 1676
REFRIGERANT OIL LEVEL CHECKp. 1676
AJC REFRIGERANT OIL CAPACITIESp. 1677
+AIR CONDITIONING AND HEATER REFRIGERANT SERVICE PERFORMANCE TESTp. 1678
A/C PERFORMANCE TESTp. 1678
HEATER OUTPUT TESTp. 1678
A/C PERFORMANCE (TEMPERATURE AND PRESSURE)p. 1679
+PRESSURE DIAGNOSISp. 1679
TEMPERATURE REFERENCE CHARTp. 1680
+HEATING AND AIR CONDITIONING TEST PROCEDURESp. 1681
VACUUM CONTROLp. 1681
BLOWER MOTORp. 1681
AIR CONDITIONING CYCLING SWITCHp. 1682
HIGH PRESSURE RELIEF VALVEp. 1683
HIGH-PRESSURE CUT-OFF SWITCHp. 1683
COMPRESSOR CLUTCH TESTp. 1683
+COMPRESSOR SERVICEp. 1684
COMPRESSOR NOISEp. 1684
COMPRESSOR DRIVE BELTp. 1684
COMPRESSOR REPLACEMENTp. 1684
COMPRESSOR MANIFOLDp. 1685
COMPRESSOR CLUTCH COIL ASSEMBLYp. 1685
+COMPONENT SERVICEp. 1688
REFRIGERANT LINE COUPLERSp. 1688
CONTROL PANELp. 1688
BLOWER MOTOR AND WHEELp. 1689
BLOWER MOTOR RESISTORp. 1690
HEATERβA/C HOUSINGp. 1690
HEATER COREp. 1691
EVAPORATOR COREp. 1692
RECIRCULATING AIR DOOR ACTUATORp. 1692
RECIRCULATING AIR DOORp. 1693
TEMPERATURE / BLEND AIR DOOR CABLEp. 1693
TEMPERATURE / BLEND AIR DOORp. 1693
HEAT / DEFROST DOOR ACTUATORp. 1694
HEAT / DEFROST DOORp. 1694
PANEL / DEFROST DOOR ACTUATORp. 1694
PANEL / DEFROST DOORp. 1695
DEFROSTER DUCTp. 1695
CONDENSERp. 1695
ACCUMULATORp. 1695
FIXED ORIFICE TUBEp. 1695
HIGH PRESSURE CUT-OUT SWITCHp. 1696
VACUUM RESERVOIRp. 1696
TORQUE SPECIFICATIONSp. 1698
+25-Emission Control Systemsp. 1699
+GENERAL INFORMATIONp. 1699
SERVICE REMINDER INDICATOR (SRI) LAMPp. 1699
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABELp. 1700
VACUUM HOSE ROUTING SCHEMATICSp. 1701
ON-BOARD DIAGNOSTICSp. 1701
ENGINE VACUUM SCHEMATICβ3.9L V-6 AND 5.2L/5.9L V-8 LDC ENGINESp. 1702
ENGINE VACUUM SCHEMATICβ5.9L V-8 HDC ENGINEp. 1702
ENGINE VACUUM SCHEMATICβ8.0L V-10 ENGINEp. 1703
ORB SCAN TOOLp. 1703
+EMISSION CONTROLSp. 1704
CATALYTIC C0NVERT0Rp. 1704
EVAP (EVAPORATION) CONTROL SYSTEMp. 1704
EVAP CANISTERp. 1704
EVAP CANISTER PURGE SOLENOIDp. 1704
PRESSURE RELIEF/ROLLOVER VALVEp. 1705
FUEL TANK FILLER TUBE CAPp. 1705
P0SITIVE CRANKCASE VENTILATION (PCV)SYSTEMp. 1706
CRANKCASE VENTILATION SYSTEMβ-8.OL V-10ENGINEp. 1708
CRANKCASE BREATHER/FILTERp. 1708
EGR (EXHAUST GAS RECIRCULATION) SYSTEMSp. 1708
OXYGEN (02S) SENSORp. 1712
INTAKE MANIFOLD AIR HEATERβDIESEL ENGINEp. 1712
INTAKE MANIFOLD AIR HEATER RELAYSβDIESEL ENGINEp. 1712
+AIR INJECTION SYSTEMβHDC-GAS ENGINESp. 1713
GENERAL INFORMATIONp. 1713
AIR INJECTION PUMPp. 1714
ONE-WAY CHECK VALVEp. 1715
+COMPONENT REMOVAL/INSTALLATIONp. 1716
AIR CLEANER HOUSINO/AIR CLEANER ELEMENTp. 1716
AIR INJECTION PUMPp. 1716
AIR INJECTION PUMP AIR FILTER.p. 1716
ONE-WAY CHECK VALVEp. 1717
ENGINE COOLANT TEMPERATURE SENSORp. 1717
EGR VALVEβ3.9/5.2L/5.9L ENGINESp. 1717
EGR VALVEβ8.0L ENGINEp. 1717
EGR VALVE CONTROL (EGR SOLENOID)p. 1718
EGR TUBEβ3.9L/5.2L/5.9L ENGINESp. 1718
EGR TUBEβ8.0L V-10 ENGINEp. 1719
EVAP CANISTERp. 1719
EVAP CANISTER PURGE SOLENOIDβ3.9L/5.2L/5 J L ENGINEp. 1720
EVAP CANISTER PURGE SOLENOID-8 .0L V-10 ENGINEp. 1720
FUEL TANK FILLER TUBE CAPp. 1720
OXYGEN (02S) SENSORp. 1721
POWERTRAIN CONTROL MODULE (PCM)p. 1721
PRESSURE RELIEF/ROLLOVER VALVEp. 1721
Indexp. 1722
Why the Correct 1995 Dodge Ram 1500-3500 Service Manual Matters
Working on a 1995 Dodge Ram without the correct service manual is a recipe for wasted time, incorrect repairs, and damaged components. These trucks are now approaching thirty years old, and finding accurate, model-specific repair information can be difficult. This 1995 Dodge Ram 1500-3500 service manual gives you the exact specifications, torque values, and procedures that Chrysler Corporation published for these vehicles. You get the correct tightening torques for critical fasteners, the correct fluid capacities and types, the correct diagnostic procedures for the engine control system, and the correct disassembly and assembly sequences for major components. Whether you are a professional technician, a serious DIY mechanic, or a fleet maintenance supervisor, having the correct 1995 Dodge Ram service manual saves time and prevents costly mistakes. It is also an invaluable reference for anyone restoring or maintaining a 1995 Dodge Ram 1500, 2500, or 3500 truck.
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