2000 Dodge Dakota Service Manual – PDF DOWNLOAD

Description

2000 Dodge Dakota Service Manual – PDF DOWNLOAD

FILE DETAILS:

2000 Dodge Dakota Service Manual – PDF DOWNLOAD

Language : English
Pages : 2128
Downloadable : Yes
File Type : PDF
Size: 85.1 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

2000 Dodge Dakota Service Manual – PDF DOWNLOAD

VEHICLE IDENTIFICATION NUMBER (VIN) PLATE:

The Vehicle Identification Number (VIN) plate is attached to the top left side of the instrument panel (Fig. 1). The VIN contains 17 characters that provide data concerning the vehicle. Refer to the decoding chart to determine the identification of a vehicle.

TABLE OF CONTENTS:

2000 Dodge Dakota Service Manual – PDF DOWNLOAD

00AN_0 1
LUBRICATION AND MAINTENANCE 1
LUBRICANTS AND CAPACITIES 1
SERVICE PROCEDURES 1
DESCRIPTION 1
PARTS AND LUBRICANT RECOMMENDATIONS 1
RECOMMENDATIONS 1
INTERNATIONAL SYMBOLS 1
CLASSIFICATION OF LUBRICANTS 1
ENGINE OIL 2
SPECIALIZED LUBRICANTS AND OILS 2
FLUID CAPACITIES 2
Fuel Tank 2
Engine Oil W/Filter change 2
Cooling System 2
Automatic Transmission 2
Manual Transmission 3
Transfer Case 3
Front Axle 3
Rear Axle 3
Power Steering 3
MAINTENANCE SCHEDULES 4
SERVICE PROCEDURES 4
MAINTENANCE SCHEDULES 4
EMISSION CONTROL SYSTEM MAINTENANCE 4
FLUID FILL LOCATIONS AND LUBRICATION POINTS 4
SCHEDULE “A” 4
SCHEDULE “B” 6
JUMP STARTING, TOWING AND HOISTING 10
SERVICE PROCEDURES 10
JUMP STARTING PROCEDURE 10
TO JUMP START A DISABLED VEHICLE: 10
TOWING RECOMMENDATIONS 11
SAFETY PRECAUTIONS 11
GROUND CLEARANCE 11
RAMP ANGLE 11
TOWING WHEN KEYS ARE NOT AVAILABLE 11
TWO WHEEL DRIVE VEHICLE TOWING 12
TOWING-REAR END LIFTED 12
TOWING-FRONT END LIFTED 12
TWO WHEEL DRIVE-MANUAL AND AUTOMATIC TRANSMISSION 12
FOUR-WHEEL-DRIVE VEHICLE TOWING 12
FOUR WHEEL DRIVE TOWING-REAR END LIFTED 12
FOUR WHEEL DRIVE TOWING-FRONT END LIFTED 12
HOISTING RECOMMENDATIONS 13
FLOOR JACK 13
HOIST 13
00AN_2 15
SUSPENSION 15
ALIGNMENT 15
DESCRIPTION AND OPERATION 15
WHEEL ALIGNMENT 15
DESCRIPTION 15
OPERATION 15
DIAGNOSIS AND TESTING 16
PRE-ALIGNMENT INSPECTION 16
SERVICE PROCEDURES 17
SUSPENSION HEIGHT- 4×4 17
HEIGHT MEASUREMENT 17
HEIGHT ADJUSTMENT 17
WHEEL ALIGNMENT 18
CAMBER AND CASTER ADJUSTMENT 18
CASTER 18
CAMBER 18
TOE ADJUSTMENT 18
SPECIFICATIONS 19
ALIGNMENT 19
FRONT SUSPENSION – 4×2 20
DESCRIPTION AND OPERATION 20
FRONT SUSPENSION – 4X2 20
DESCRIPTION 20
SHOCK ABSORBERS 20
DESCRIPTION 20
OPERATION 20
COIL SPRINGS 21
DESCRIPTION 21
OPERATION 21
STEERING KNUCKLE 21
DESCRIPTION 21
OPERATION 21
SUSPENSION ARMS 21
DESCRIPTION 21
STABILIZER BAR 21
DESCRIPTION 21
OPERATION 21
DIAGNOSIS AND TESTING 21
LOWER BALL JOINT 21
UPPER BALL JOINT 22
SHOCK DIAGNOSIS 22
REMOVAL AND INSTALLATION 22
SHOCK ABSORBER 22
REMOVAL 22
INSTALLATION 22
COIL SPRING 22
REMOVAL 22
INSTALLATION 23
STEERING KNUCKLE 23
REMOVAL 23
INSTALLATION 24
LOWER SUSPENSION ARM 24
REMOVAL 24
INSTALLATION 24
UPPER SUSPENSION ARM 24
REMOVAL 24
INSTALLATION 24
STABILIZER BAR 25
REMOVAL 25
INSTALLATION 25
HUB/BEARING 25
REMOVAL 25
INSTALLATION 25
WHEEL MOUNTING STUDS 26
REMOVAL 26
INSTALLATION 26
SPECIFICATIONS 26
TORQUE CHART 26
SPECIAL TOOLS 27
FRONT SUSPENSION 27
FRONT SUSPENSION – 4×4 28
DESCRIPTION AND OPERATION 28
FRONT SUSPENSION – 4×4 28
DESCRIPTION 28
SHOCK ABSORBERS 28
DESCRIPTION 28
OPERATION 29
TORSION BARS 29
DESCRIPTION 29
OPERATION 29
STEERING KNUCKLE 29
DESCRIPTION 29
OPERATION 29
SUSPENSION ARMS 29
DESCRIPTION 29
STABILIZER BAR 29
DESCRIPTION 29
OPERATION 29
DIAGNOSIS AND TESTING 29
LOWER BALL JOINT 29
UPPER BALL JOINT 29
SHOCK DIAGNOSIS 30
SERVICE PROCEDURES 30
LUBRICATION 30
REMOVAL AND INSTALLATION 30
SHOCK ABSORBER 30
REMOVAL 30
INSTALLATION 30
TORSION BAR 31
REMOVAL 31
INSTALLATION 31
STEERING KNUCKLE 31
REMOVAL 31
INSTALLATION 32
LOWER SUSPENSION ARM 32
REMOVAL 32
INSTALLATION 33
UPPER SUSPENSION ARM 33
REMOVAL 33
INSTALLATION 33
STABILIZER BAR 34
REMOVAL 34
INSTALLATION 34
HUB/BEARING 35
REMOVAL 35
INSTALLATION 35
WHEEL MOUNTING STUDS 35
REMOVAL 35
INSTALLATION 35
SPECIFICATIONS 36
TORQUE CHART 36
SPECIAL TOOLS 36
FRONT SUSPENSION 36
REAR SUSPENSION 37
DESCRIPTION AND OPERATION 37
REAR SUSPENSION 37
DESCRIPTION 37
SHOCK ABSORBERS 37
DESCRIPTION 37
OPERATION 37
STABILIZER BAR 37
DESCRIPTION 37
OPERATION 37
LEAF SPRINGS 37
DESCRIPTION 37
OPERATION 37
DIAGNOSIS AND TESTING 38
SPRING AND SHOCK 38
REMOVAL AND INSTALLATION 38
SHOCK ABSORBER 38
REMOVAL 38
INSTALLATION 38
STABILIZER BAR 38
REMOVAL 38
INSTALLATION 38
LEAF SPRINGS 39
REMOVAL 39
INSTALLATION 40
SPECIFICATIONS 40
TORQUE CHART 40
00AN_3 41
DIFFERENTIAL AND DRIVELINE 41
PROPELLER SHAFTS 41
DESCRIPTION AND OPERATION 41
PROPELLER SHAFT 41
DESCRIPTION 41
OPERATION 42
CENTER BEARING 42
DESCRIPTION 42
OPERATION 42
PROPELLER SHAFT JOINTS 44
DESCRIPTION 44
PROPELLER SHAFT JOINT ANGLE 44
DESCRIPTION 44
OPERATION 44
DIAGNOSIS AND TESTING 45
VIBRATION 45
UNBALANCE 46
RUNOUT 46
SERVICE PROCEDURES 47
DRIVELINE ANGLE MEASUREMENT PREPARATION 47
PROPELLER SHAFT ANGLE MEASUREMENT 47
ONE-PIECE PROPELLER SHAFT 47
TWO-PIECE PROPELLER SHAFT 48
REMOVAL AND INSTALLATION 50
FRONT PROPELLER SHAFT 50
REMOVAL 50
INSTALLATION 50
REAR PROPELLER SHAFT 50
REMOVAL 50
INSTALLATION 50
CENTER BEARING 51
REMOVAL 51
INSTALLATION 51
DISASSEMBLY AND ASSEMBLY 51
SINGLE CARDAN UNIVERSAL JOINT 51
DISASSEMBLY 51
ASSEMBLY 52
DOUBLE CARDAN JOINT 53
DISASSEMBLY 53
ASSEMBLY 54
CLEANING AND INSPECTION 57
PROPELLER SHAFT 57
ADJUSTMENTS 57
ADJUSTMENT AT AXLE WITH LEAF SPRINGS 57
CENTER BEARING ADJUSTMENT 57
SPECIFICATIONS 57
TORQUE 57
SPECIAL TOOLS 57
PROPELLER SHAFT 57
FRONT AXLE DRIVESHAFTS 58
DESCRIPTION AND OPERATION 58
FRONT AXLE DRIVESHAFTS 58
DESCRIPTION 58
OPERATION 60
DIAGNOSIS AND TESTING 60
VEHICLE INSPECTION 60
NOISE AND/OR VIBRATION IN TURNS 60
CLUNKING NOISE DURING ACCELERATION 60
SHUDDER OR VIBRATION DURING ACCELERATION 60
VIBRATION AT HIGHWAY SPEEDS 60
REMOVAL AND INSTALLATION 61
FRONT DRIVESHAFT 61
REMOVAL 61
INSTALLATION 62
C/V JOINT BOOTS 62
REMOVAL 62
INSTALLATION 62
DISASSEMBLY AND ASSEMBLY 63
INNER C/V JOINT 63
DISASSEMBLY 63
ASSEMBLY 63
OUTER C/V JOINT 64
DISASSEMBLY 64
ASSEMBLY 66
CLEANING AND INSPECTION 68
C/V JOINT 68
C/V JOINT BOOTS 70
SPECIFICATIONS 70
TORQUE 70
SPECIAL TOOLS 70
C/V JOINT DRIVESHAFT 70
C205F AXLE 71
DESCRIPTION AND OPERATION 71
C205F AXLE 71
DESCRIPTION 71
OPERATION 71
LUBRICANT 71
DESCRIPTION 71
STANDARD DIFFERENTIAL 72
DESCRIPTION 72
OPERATION 72
DIAGNOSIS AND TESTING 72
GENERAL INFORMATION 72
GEAR NOISE 75
BEARING NOISE 75
LOW SPEED KNOCK 75
VIBRATION 75
DRIVELINE SNAP 76
SERVICE PROCEDURES 76
LUBRICANT CHANGE 76
REMOVAL AND INSTALLATION 76
FRONT AXLE 76
REMOVAL 76
INSTALLATION 77
PINION SHAFT SEAL 77
REMOVAL 77
INSTALLATION 77
AXLE SHAFT 79
REMOVAL 79
INSTALLATION 79
AXLE SHAFT SEAL AND BEARING 79
REMOVAL 79
INSTALLATION 80
DIFFERENTIAL 80
REMOVAL 80
INSTALLATION 80
DIFFERENTIAL SIDE BEARINGS 81
REMOVAL 81
INSTALLATION 81
RING GEAR 81
REMOVAL 81
INSTALLATION 82
PINION GEAR 82
REMOVAL 82
INSTALLATION 84
FINAL ASSEMBLY 86
DISASSEMBLY AND ASSEMBLY 87
STANDARD DIFFERENTIAL 87
DISASSEMBLY 87
ASSEMBLY 87
CLEANING AND INSPECTION 88
AXLE COMPONENTS 88
ADJUSTMENTS 88
PINION GEAR DEPTH 88
GENERAL INFORMATION 88
PINION DEPTH MEASUREMENT AND ADJUSTMENT 89
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 90
SHIM SELECTION 90
GEAR CONTACT PATTERN ANALYSIS 93
SPECIFICATIONS 95
C205F AXLE 95
C205F AXLE 95
SPECIAL TOOLS 95
C205F AXLE 95
8 1/4 AND 9 1/4 AXLE 99
DESCRIPTION AND OPERATION 99
8 1/4 AXLE 99
DESCRIPTION 99
OPERATION 100
9 1/4 AXLES 101
DESCRIPTION 101
OPERATION 103
LUBRICANT 103
DESCRIPTION 103
STANDARD DIFFERENTIAL 104
DESCRIPTION 104
OPERATION 104
TRAC-LOK OPERATION 104
DESCRIPTION 104
OPERATION 104
DIAGNOSIS AND TESTING 105
GENERAL INFORMATION 105
GEAR NOISE 107
BEARING NOISE 108
LOW SPEED KNOCK 108
VIBRATION 108
DRIVELINE SNAP 108
TRAC-LOK DIFFERENTIAL NOISE 108
TRAC-LOK TEST 108
SERVICE PROCEDURES 109
LUBRICANT CHANGE 109
REMOVAL AND INSTALLATION 109
REAR AXLE 109
REMOVAL 109
INSTALLATION 110
AXLE SHAFT 110
REMOVAL 110
INSTALLATION 111
8 1/4 AND 9 1/4 AXLE SEAL AND BEARING 111
REMOVAL 111
INSTALLATION 111
PINION SEAL 112
REMOVAL 112
INSTALLATION 112
DIFFERENTIAL 114
REMOVAL 114
INSTALLATION 114
DIFFERENTIAL SIDE BEARINGS 115
REMOVAL 115
INSTALLATION 115
RING GEAR AND EXCITER RING 115
REMOVAL 116
INSTALLATION 116
PINION GEAR 117
REMOVAL 117
INSTALLATION 119
FINAL ASSEMBLY 121
DISASSEMBLY AND ASSEMBLY 122
STANDARD DIFFERENTIAL 122
DISASSEMBLY 122
ASSEMBLY 122
8 1/4 TRAC-LOK DIFFERENTIAL 122
DISASSEMBLY 123
ASSEMBLY 126
9 1/4 TRAC-LOK DIFFERENTIAL 127
DISASSEMBLY 128
ASSEMBLY 130
CLEANING AND INSPECTION 131
8 1/4 AND 9 1/4 AXLES 131
TRAC-LOK 132
PRESOAK PLATES AND DISC 132
ADJUSTMENTS 132
8 1/4 AXLE PINION GEAR DEPTH 132
GENERAL INFORMATION 132
PINION DEPTH MEASUREMENT AND ADJUSTMENT 132
9 1/4 AXLE PINION GEAR DEPTH 133
GENERAL INFORMATION 133
PINION DEPTH MEASUREMENT AND ADJUSTMENT 134
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 136
GEAR CONTACT PATTERN ANALYSIS 137
SIDE GEAR CLEARANCE 139
SPECIFICATIONS 139
8 1/4 INCH AXLE 139
9 1/4 INCH AXLE 139
8 1/4 and 9 1/4 INCH AXLE 140
SPECIAL TOOLS 140
8 1/4 AND 9 1/4 AXLES 140
00AN_5 145
BRAKES 145
BASE BRAKE SYSTEM 145
DESCRIPTION AND OPERATION 146
BRAKE SYSTEM 146
DESCRIPTION 146
SERVICE WARNINGS & CAUTIONS 146
DESCRIPTION 146
BRAKE PEDAL 146
DESCRIPTION 146
OPERATION 146
STOP LAMP SWITCH 146
DESCRIPTION 146
OPERATION 146
RED BRAKE WARNING LAMP 147
DESCRIPTION 147
OPERATION 147
POWER BRAKE BOOSTER 147
DESCRIPTION 147
OPERATION 147
MASTER CYLINDER 147
DESCRIPTION 147
OPERATION 147
COMBINATION VALVE 147
DESCRIPTION 147
OPERATION 147
FRONT DISC BRAKES 148
DESCRIPTION 148
OPERATION 148
DRUM BRAKES 148
DESCRIPTION 148
OPERATION 148
PARKING BRAKES 149
DESCRIPTION 149
OPERATION 149
BRAKE HOSES AND LINES 149
DESCRIPTION 149
OPERATION 149
DIAGNOSIS AND TESTING 149
BASE BRAKE SYSTEM 149
PRELIMINARY BRAKE CHECK 149
ROAD TESTING 150
BRAKE NOISES 151
BRAKE LAMP SWITCH 152
SWITCH CIRCUIT IDENTIFICATION 152
SWITCH CONTINUITY TEST 152
RED BRAKE WARNING LAMP 152
MASTER CYLINDER/POWER BOOSTER 152
POWER BOOSTER VACUUM TEST 152
POWER BOOSTER CHECK VALVE TEST 152
COMBINATION VALVE 153
Pressure Differential Switch 153
DISC BRAKE ROTOR 153
ROTOR MINIMUM THICKNESS 153
ROTOR RUNOUT 153
ROTOR THICKNESS VARIATION 154
BRAKE DRUM 154
BRAKE DRUM RUNOUT 154
BRAKE LINE AND HOSES 154
BRAKE FLUID CONTAMINATION 154
SERVICE PROCEDURES 155
BRAKE FLUID LEVEL 155
MASTER CYLINDER BLEEDING 155
BLEEDING PROCEDURE 155
BASE BRAKE BLEEDING 155
MANUAL BLEEDING 155
PRESSURE BLEEDING 156
DISC ROTOR MACHINING 156
BRAKE DRUM MACHINING 156
BRAKE TUBE FLARING 156
DOUBLE INVERTED FLARING 156
ISO FLARING 157
REMOVAL AND INSTALLATION 157
BRAKE LAMP SWITCH 157
REMOVAL 157
INSTALLATION 158
BRAKE PEDAL 158
REMOVAL 158
INSTALLATION 158
COMBINATION VALVE 158
REMOVAL 158
INSTALLATION 158
MASTER CYLINDER 159
REMOVAL 159
INSTALLATION 159
POWER BRAKE BOOSTER 159
REMOVAL 159
INSTALLATION 159
DISC BRAKE CALIPER 160
REMOVAL 160
INSTALLATION 160
DISC BRAKE SHOES 161
REMOVAL 161
INSTALLATION 161
DISC BRAKE ROTOR 163
REMOVAL 163
INSTALLATION 163
REAR BRAKE SHOES 163
REMOVAL 163
INSTALLATION 164
WHEEL CYLINDER 165
REMOVAL 165
INSTALLATION 165
BRAKE SUPPORT PLATE 165
REMOVAL 165
INSTALLATION 165
FRONT PARK BRAKE CABLE 165
REMOVAL 165
INSTALLATION 165
REAR PARK BRAKE CABLES 166
REMOVAL 166
INSTALLATION 166
PARK BRAKE PEDAL ASSEMBLY 166
Removal 166
Installation 167
DISASSEMBLY AND ASSEMBLY 167
MASTER CYLINDER RESERVOIR 167
REMOVAL 167
INSTALLATION 167
DISC BRAKE CALIPER 168
DISASSEMBLY 168
ASSEMBLY 169
WHEEL CYLINDER 169
DISASSEMBLY 169
ASSEMBLY 170
CLEANING AND INSPECTION 171
REAR DRUM BRAKE 171
CLEANING 171
INSPECTION 171
CALIPER 171
CLEANING 171
INSPECTION 172
WHEEL CYLINDER 172
CLEANING 172
INSPECTION 172
ADJUSTMENTS 172
REAR DRUM BRAKE 172
ADJUSTMENT WITH BRAKE GAUGE 172
ADJUSTMENT WITH ADJUSTING TOOL 173
PARK BRAKE CABLE TENSIONER 173
SPECIFICATIONS 174
BRAKE FLUID 174
BASE BRAKES 175
TORQUE CHART 175
SPECIAL TOOLS 175
BASE BRAKES 175
REAR WHEEL ANTILOCK BRAKES 176
DESCRIPTION AND OPERATION 176
REAR WHEEL ANTILOCK 176
DESCRIPTION 176
OPERATION 176
RWAL COMPONENT LOCATION 177
DESCRIPTION 177
CONTROLLER REAR WHEEL ANTILOCK BRAKES 177
DESCRIPTION 177
OPERATION 178
RWAL VALVE 178
DESCRIPTION 178
OPERATION 178
REAR WHEEL SPEED SENSOR AND EXCITER RING 178
DESCRIPTION 178
OPERATION 179
BRAKE WARNING LAMPS 179
DESCRIPTION 179
OPERATION 180
BRAKE LAMP SWITCH 180
DESCRIPTION 180
OPERATION 180
DIAGNOSIS AND TESTING 180
REAR WHEEL ANTILOCK 180
SERVICE PROCEDURES 180
RWAL SERVICE PRECAUTIONS 180
REAR WHEEL ANTILOCK BRAKE BLEEDING 181
MANUAL BLEEDING 181
PRESSURE BLEEDING 181
REMOVAL AND INSTALLATION 181
CONTROLLER 181
REMOVAL 181
INSTALLATION 181
RWAL VALVE 182
REMOVAL 182
INSTALLATION 182
REAR WHEEL SPEED SENSOR 182
REMOVAL 182
INSTALLATION 182
EXCITER RING 183
SPECIFICATIONS 183
TORQUE CHART 183
FOUR WHEEL ANTILOCK BRAKES 184
DESCRIPTION AND OPERATION 184
ANTILOCK BRAKE SYSTEM 184
DESCRIPTION 184
OPERATION 184
CONTROLLER ANTILOCK BRAKES 185
DESCRIPTION 185
OPERATION 185
HYDRAULIC CONTROL UNIT 185
DESCRIPTION 185
OPERATION 185
WHEEL SPEED SENSOR 186
DESCRIPTION 186
OPERATION 186
ABS WARNING LAMP 187
DESCRIPTION 187
OPERATION 187
DIAGNOSIS AND TESTING 187
ANTILOCK BRAKES 187
SERVICE PROCEDURES 187
BLEEDING ABS BRAKE SYSTEM 187
REMOVAL AND INSTALLATION 188
CONTROLLER ANTILOCK BRAKES 188
REMOVAL 188
INSTALLATION 188
ANTILOCK CONTROL ASSEMBLY 188
REMOVAL 188
INSTALLATION 189
FRONT WHEEL SPEED SENSOR – 4×2 189
REMOVAL 189
INSTALLATION 189
FRONT WHEEL SPEED SENSOR – 4×4 190
REMOVAL 190
INSTALLATION 190
TONE WHEEL 190
REAR WHEEL SPEED SENSOR 191
REMOVAL 191
INSTALLATION 191
EXCITER RING 191
SPECIFICATIONS 191
TORQUE CHART 191
00AN_6 193
CLUTCH 193
DESCRIPTION AND OPERATION 193
CLUTCH 193
DESCRIPTION 193
OPERATION 193
FLYWHEEL 194
DESCRIPTION 194
OPERATION 194
CLUTCH DISC 194
DESCRIPTION 194
OPERATION 194
CLUTCH PRESSURE PLATE 194
DESCRIPTION 194
OPERATION 195
CLUTCH RELEASE BEARING 195
DESCRIPTION 195
OPERATION 195
HYDRAULIC CLUTCH LINKAGE 196
DESCRIPTION 196
OPERATION 196
CLUTCH DISC APPLICATION 196
DESCRIPTION 196
OPERATION 197
CLUTCH PEDAL POSITION SWITCH 197
DESCRIPTION 197
OPERATION 197
DIAGNOSIS AND TESTING 197
SAFETY PRECAUTIONS 197
INSTALLATION METHODS AND PARTS USAGE 197
CLUTCH DIAGNOSTIC INFORMATION 197
CLUTCH CONTAMINATION 197
IMPROPER CLUTCH RELEASE OR ENGAGEMENT 199
CLUTCH MISALIGNMENT 199
CLUTCH HOUSING MISALIGNMENT 199
CLUTCH FLYWHEEL RUNOUT 199
CLUTCH COVER AND DISC RUNOUT 199
CLUTCH DIAGNOSIS CHARTS 200
SERVICE PROCEDURES 202
CLUTCH COMPONENT LUBRICATION 202
RECOMMENDED LUBRICANTS 202
CLUTCH HYDRAULIC FLUID 203
CLUTCH FLUID LEVEL 203
FLYWHEEL 203
REMOVAL AND INSTALLATION 204
CLUTCH COVER AND DISC 204
REMOVAL 204
INSTALLATION 204
CLUTCH HOUSING REPLACEMENT 205
REMOVAL 205
INSTALLATION 205
RELEASE BEARING 206
REMOVAL 206
INSTALLATION 206
PILOT BEARING 206
REMOVAL 206
INSTALLATION 206
CLUTCH HYDRAULIC LINKAGE 207
REMOVAL 207
INSTALLATION 207
CLUTCH PEDAL 208
REMOVAL 208
INSTALLATION 208
SPECIFICATIONS 208
TORQUE 208
00AN_7 209
COOLING SYSTEM 209
DESCRIPTION AND OPERATION 210
COOLING SYSTEM 210
DESCRIPTION 210
COOLANT RESERVE/OVERFLOW SYSTEM 213
DESCRIPTION 213
OPERATION 213
ENGINE ACCESSORY DRIVE BELTS 213
DESCRIPTION 213
RADIATOR 213
DESCRIPTION 213
OPERATION 213
WATER PUMP 214
DESCRIPTION 214
OPERATION 214
WATER PUMP BYPASS-4 7L 214
DESCRIPTION 214
OPERATION 214
WATER PUMP BYPASS-3 9/5 9L ENGINES 214
DESCRIPTION 214
OPERATION 215
THERMOSTAT-3 9L/5 9L ENGINES 215
DESCRIPTION 215
OPERATION 215
THERMOSTAT-4 7L ENGINE 215
DESCRIPTION 215
OPERATION 216
AUTOMATIC TRANSMISSION OIL COOLERS 216
DESCRIPTION 216
AUTOMATIC BELT TENSIONER 216
DESCRIPTION 216
OPERATION 217
BLOCK HEATER 217
DESCRIPTION 217
OPERATION 217
RADIATOR PRESSURE CAP 218
DESCRIPTION 218
OPERATION 218
HOSE CLAMPS 218
DESCRIPTION 218
OPERATION 218
VISCOUS FAN DRIVE 219
DESCRIPTION 219
OPERATION 219
COOLING SYSTEM FAN 219
DESCRIPTION 219
OPERATION 220
DIAGNOSIS AND TESTING 220
ON-BOARD DIAGNOSTICS (OBD) 220
FOR CERTAIN COOLING SYSTEM COMPONENTS 220
ACCESSING DIAGNOSTIC TROUBLE CODES 221
ERASING TROUBLE CODES 221
DRB SCAN TOOL 221
WATER PUMP TESTS 221
LOOSE IMPELLER-4 7L 221
INSPECTING FOR INLET RESTRICTIONS 221
PRELIMINARY CHECKS 222
ENGINE COOLING SYSTEM OVERHEATING 222
COOLING SYSTEM 223
ELECTRIC COOLING FAN 228
RADIATOR FAN MOTOR INOPERATIVE 229
RADIATOR COOLANT FLOW CHECK 229
COOLING SYSTEM-TESTING FOR LEAKS 229
ULTRAVIOLET LIGHT METHOD 229
PRESSURE TESTER METHOD 229
INTERNAL LEAKAGE INSPECTION 230
COMBUSTION LEAKAGE TEST-WITHOUT PRESSURE TESTER 231
VISCOUS FAN DRIVE-3 9L/4 7L and 5 9L ENGINES 231
ACCESSORY DRIVE BELT DIAGNOSIS 232
VISUAL DIAGNOSIS 232
NOISE DIAGNOSIS 232
THERMOSTAT 234
RADIATOR CAP-TO-FILLER NECK SEAL-PRESSURE RELIEF CHECK 234
RADIATOR CAP-PRESSURE TESTING 234
COOLANT-LOW LEVEL AERATION 235
COOLING SYSTEM-DEAERATION 235
SERVICE PROCEDURES 235
COOLANT-ROUTINE LEVEL CHECK 235
COOLANT SERVICE 235
COOLANT-ADDING ADDITIONAL 236
COOLANT LEVEL CHECK 236
COOLING SYSTEM-DRAINING AND FILLING 236
DRAINING 236
REFILLING 236
REFILLING 4 7L ENGINE 237
COOLING SYSTEM-CLEANING/REVERSE FLUSHING 237
CLEANING 237
REVERSE FLUSHING 237
REVERSE FLUSHING RADIATOR 237
REVERSE FLUSHING ENGINE 237
CHEMICAL CLEANING 237
COOLANT 238
DESCRIPTION 238
OPERATION 238
COOLANT SELECTION AND ADDITIVES 238
REMOVAL AND INSTALLATION 238
COOLANT RESERVE/OVERFLOW TANK 238
WATER PUMP-2 5L ENGINE 238
REMOVAL 238
INSTALLATION 239
WATER PUMP-3 9L/5 9L ENGINES 240
REMOVAL 240
INSTALLATION 242
WATER PUMP 4 7L ENGINES 243
REMOVAL 243
INSTALLATION 244
WATER PUMP BYPASS HOSE-3 9/5 9L ENGINES 245
REMOVAL WITHOUT AIR CONDITIONING 245
INSTALLATION 245
REMOVAL WITH AIR CONDITIONING 246
INSTALLATION 247
THERMOSTAT-3 9L/5 9L ENGINES 247
REMOVAL 247
INSTALLATION 249
THERMOSTAT-2 5L ENGINE 250
REMOVAL 250
INSTALLATION 250
THERMOSTAT- 4 7L ENGINE 251
REMOVAL 251
INSTALLATION 252
TRANSMISSION OIL COOLER LINES 252
REMOVAL 252
INSTALLATION 252
RADIATOR 252
REMOVAL 252
INSTALLATION 253
ENGINE BLOCK HEATER 254
REMOVAL 254
INSTALLATION 254
ACCESSORY DRIVE BELT-2 5L ENGINE 255
REMOVAL 255
INSTALLATION 255
ACCESSORY BELT REPLACEMENT-4 7L ENGINE 256
REMOVAL 256
INSTALLATION 256
ACCESSORY DRIVE BELT-3 9L/5 9L ENGINES 257
REMOVAL 257
INSTALLATION 257
ACCESSORY DRIVE BELT TENSIONER-2 5L 258
REMOVAL 258
INSTALLATION 258
AUTOMATIC BELT TENSIONER 3 9L/5 9L ENGINES 258
REMOVAL 258
INSTALLATION 258
AUTOMATIC BELT TENSIONER-4 7L ENGINE 259
REMOVAL 259
INSTALLATION 259
IDLER PULLEY-2 5L/3 9L/5 9L ENGINES 259
REMOVAL 259
INSTALLATION 259
IDLER PULLEY-4 7L ENGINE NON A/C 260
REMOVAL 260
INSTALLATION 260
RADIATOR DRAINCOCK 260
REMOVAL 260
INSTALLATION 260
VISCOUS FAN DRIVE 261
REMOVAL 261
INSTALLATION 262
ELECTRIC FAN 262
REMOVAL 262
INSTALLATION 262
CLEANING AND INSPECTION 263
RADIATOR CAP 263
CLEANING 263
INSPECTION 263
RADIATOR 263
CLEANING 263
INSPECTION 263
WATER PUMP 263
CLEANING 263
INSPECTION 263
FAN BLADE 263
CLEANING 263
INSPECTION 263
SPECIFICATIONS 264
COOLING SYSTEM CAPACITIES 264
ACCESSORY DRIVE BELT TENSION-2 5L ENGINE 264
TORQUE SPECIFICATIONS 264
SPECIAL TOOLS 265
COOLING 265
00AN_8A 267
BATTERY 267
DESCRIPTION AND OPERATION 267
BATTERY 267
DESCRIPTION 267
OPERATION 268
BATTERY CABLES 269
DESCRIPTION 269
OPERATION 269
BATTERY HOLD DOWNS 270
DESCRIPTION 270
OPERATION 270
BATTERY TRAY 270
DESCRIPTION 270
OPERATION 271
DIAGNOSIS AND TESTING 271
BATTERY 271
DIAGNOSIS 271
TESTING 275
BATTERY CABLES 280
DIAGNOSIS 280
TESTING 281
SERVICE PROCEDURES 282
BATTERY CHARGING 282
CHARGING A COMPLETELY DISCHARGED BATTERY 283
CHARGING TIME REQUIRED 283
REMOVAL AND INSTALLATION 284
BATTERY HOLD DOWNS 284
REMOVAL 284
INSTALLATION 284
BATTERY 285
REMOVAL 285
INSTALLATION 285
BATTERY TRAY 286
REMOVAL 286
INSTALLATION 286
CLEANING AND INSPECTION 287
BATTERY 287
CLEANING 287
INSPECTION 288
SPECIFICATIONS 288
BATTERY 288
00AN_8B 289
STARTING SYSTEMS 289
DESCRIPTION AND OPERATION 289
STARTING SYSTEM 289
DESCRIPTION 289
OPERATION 290
STARTER MOTOR 290
DESCRIPTION 290
OPERATION 291
STARTER RELAY 291
DESCRIPTION 291
OPERATION 291
DIAGNOSIS AND TESTING 291
STARTING SYSTEM 291
DIAGNOSIS 291
TESTING 293
STARTER MOTOR 296
STARTER SOLENOID 296
STARTER RELAY 296
RELAY TEST 297
RELAY CIRCUIT TEST 297
REMOVAL AND INSTALLATION 298
STARTER MOTOR 298
REMOVAL 298
INSTALLATION 299
STARTER RELAY 300
REMOVAL 300
INSTALLATION 301
SPECIFICATIONS 301
STARTING SYSTEM 301
00AN_8C 303
CHARGING SYSTEM 303
DESCRIPTION AND OPERATION 303
CHARGING SYSTEM 303
DESCRIPTION 303
OPERATION 303
GENERATOR 303
DESCRIPTION 303
OPERATION 303
BATTERY TEMPERATURE SENSOR 304
DESCRIPTION 304
OPERATION 304
ELECTRONIC VOLTAGE REGULATOR 304
DESCRIPTION 304
OPERATION 304
DIAGNOSIS AND TESTING 304
CHARGING SYSTEM 304
INSPECTION 304
ON-BOARD DIAGNOSTIC TEST FOR CHARGING SYSTEM 305
REMOVAL AND INSTALLATION 305
GENERATOR 305
REMOVAL 305
INSTALLATION 306
BATTERY TEMPERATURE SENSOR 307
REMOVAL 307
INSTALLATION 307
SPECIFICATIONS 308
GENERATOR RATINGS 308
TORQUE CHART 308
00AN_8D 309
IGNITION SYSTEM 309
DESCRIPTION AND OPERATION 309
IGNITION SYSTEM 309
DESCRIPTION 309
OPERATION 309
DISTRIBUTOR 310
DESCRIPTION 310
OPERATION 310
SPARK PLUGS 310
DESCRIPTION 310
OPERATION 310
SPARK PLUG CABLES 310
DESCRIPTION 310
OPERATION 310
IGNITION COIL (EXCEPT 4 7L ENGINE) 310
DESCRIPTION 310
OPERATION 311
IGNITION COIL-4 7L ENGINE 311
DESCRIPTION 311
OPERATION 311
CRANKSHAFT POSITION SENSOR-2 5L ENGINE 311
DESCRIPTION 311
OPERATION 311
CRANKSHAFT POSITION SENSOR-3 9L V-6 ENGINE 312
DESCRIPTION 312
OPERATION 312
CRANKSHAFT POSITION SENSOR-5 2/5 9L V-8 ENGINE 312
DESCRIPTION 312
OPERATION 312
CRANKSHAFT POSITION SENSOR-4 7L ENGINE 313
DESCRIPTION 313
OPERATION 313
CAMSHAFT POSITION SENSOR 313
DESCRIPTION 313
OPERATION 313
CAMSHAFT POSITION SENSOR-4 7L ENGINE 314
DESCRIPTION 314
OPERATION 314
IGNITION SWITCH AND KEY LOCK CYLINDER 314
DESCRIPTION 314
OPERATION 314
DIAGNOSIS AND TESTING 315
DISTRIBUTOR CAP 315
DISTRIBUTOR ROTOR 315
SPARK PLUG CABLES 316
TESTING 316
SPARK PLUG CONDITIONS 317
NORMAL OPERATING 317
COLD FOULING/CARBON FOULING 317
WET FOULING OR GAS FOULING 317
OIL OR ASH ENCRUSTED 318
ELECTRODE GAP BRIDGING 318
SCAVENGER DEPOSITS 318
CHIPPED ELECTRODE INSULATOR 318
PREIGNITION DAMAGE 318
SPARK PLUG OVERHEATING 319
IGNITION SWITCH AND KEY LOCK CYLINDER 319
ELECTRICAL DIAGNOSIS 319
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) 319
REMOVAL AND INSTALLATION 320
SPARK PLUG CABLES 320
SPARK PLUGS 321
REMOVAL 321
CLEANING 321
GAP ADJUSTMENT 321
INSTALLATION 322
IGNITION COIL-2 5L ENGINE 322
REMOVAL 322
INSTALLATION 322
IGNITION COIL-3 9/5 2/5 9L ENGINES 322
REMOVAL 322
INSTALLATION 323
IGNITION COIL-4 7L ENGINE 323
REMOVAL 323
INSTALLATION 324
CRANKSHAFT POSITION SENSOR-2 5L ENGINE 324
REMOVAL 324
INSTALLATION 324
CRANKSHAFT POSITION SENSOR-3 9/5 2/5 9L ENGINES 324
REMOVAL 324
INSTALLATION 325
CRANKSHAFT POSITION SENSOR-4 7L V-8 ENGINE 325
REMOVAL 325
INSTALLATION 325
CAMSHAFT POSITION SENSOR 325
REMOVAL 325
INSTALLATION 326
CAMSHAFT POSITION SENSOR-4 7L ENGINE 326
REMOVAL 326
INSTALLATION 326
DISTRIBUTOR-2 5L ENGINE 326
REMOVAL 327
INSTALLATION 328
DISTRIBUTORS-3 9/5 2/5 9L ENGINES 329
REMOVAL 329
INSTALLATION 330
CHECKING DISTRIBUTOR POSITION 331
IGNITION SWITCH AND KEY CYLINDER 331
KEY CYLINDER REMOVAL 331
IGNITION SWITCH REMOVAL 331
IGNITION SWITCH AND KEY CYLINDER INSTALLATION 332
COLUMN SHIFT INTERLOCK 334
REMOVAL/INSTALLATION 334
SPECIFICATIONS 335
IGNITION TIMING 335
ENGINE FIRING ORDER-2 5L 4-CYLINDER ENGINE 335
ENGINE FIRING ORDER-3 9L V-6 ENGINE 335
ENGINE FIRING ORDER-4 7L V-8 ENGINE 335
ENGINE FIRING ORDER-5 2L/5 9L V-8 ENGINES 335
SPARK PLUGS 336
SPARK PLUG CABLE RESISTANCE 336
IGNITION COIL RESISTANCE-EXCEPT 4 7L ENGINE 336
IGNITION COIL RESISTANCE-4 7L V-8 ENGINE 336
TORQUE CHART 336
00AN_8E 337
INSTRUMENT PANEL SYSTEMS 337
DESCRIPTION AND OPERATION 337
INSTRUMENT PANEL SYSTEM 337
DESCRIPTION 337
INSTRUMENT PANEL 337
DESCRIPTION 337
INSTRUMENT CLUSTER 338
DESCRIPTION 338
OPERATION 339
CENTRAL TIMER MODULE 340
DESCRIPTION 340
OPERATION 340
CIGAR LIGHTER 340
DESCRIPTION 340
OPERATION 340
GEAR SELECTOR INDICATOR 341
DESCRIPTION 341
OPERATION 341
POWER OUTLET 341
DESCRIPTION 341
OPERATION 341
DIAGNOSIS AND TESTING 342
INSTRUMENT CLUSTER 342
PRELIMINARY DIAGNOSIS 342
SELF-DIAGNOSTIC TEST 343
HARD WIRED LAMP DIAGNOSIS 344
CIGAR LIGHTER 347
POWER OUTLET 348
REMOVAL AND INSTALLATION 348
CLUSTER BEZEL 348
REMOVAL 348
INSTALLATION 349
HEADLAMP SWITCH 349
REMOVAL 349
INSTALLATION 349
INSTRUMENT CLUSTER 349
REMOVAL 349
INSTALLATION 350
INSTRUMENT CLUSTER COMPONENTS 350
REMOVAL 350
INSTALLATION 352
STEERING COLUMN OPENING COVER 352
REMOVAL 352
INSTALLATION 353
GEAR SELECTOR INDICATOR 353
REMOVAL 353
INSTALLATION 353
PARK BRAKE RELEASE HANDLE 354
REMOVAL 354
INSTALLATION 354
INSTRUMENT PANEL LOWER REINFORCEMENT 355
REMOVAL 355
INSTALLATION 355
INSTRUMENT PANEL CENTER SUPPORT BRACKET 355
REMOVAL 355
INSTALLATION 356
INSTRUMENT PANEL ASH RECEIVER 356
REMOVAL 356
INSTALLATION 356
INSTRUMENT PANEL LOWER BEZEL 357
REMOVAL 357
INSTALLATION 357
CIGAR LIGHTER AND POWER OUTLET 358
REMOVAL 358
INSTALLATION 358
GLOVE BOX LAMP AND SWITCH 359
REMOVAL 359
INSTALLATION 359
GLOVE BOX LATCH STRIKER 359
REMOVAL 359
INSTALLATION 360
GLOVE BOX 360
ROLL DOWN 360
REMOVAL 360
INSTALLATION 361
GLOVE BOX COMPONENTS 361
REMOVAL 361
INSTALLATION 361
CENTRAL TIMER MODULE 361
REMOVAL 362
INSTALLATION 362
INSTRUMENT PANEL ASSEMBLY 363
REMOVAL 363
INSTALLATION 364
INSTRUMENT PANEL TOP COVER 366
REMOVAL 366
INSTALLATION 367
00AN_8F 369
AUDIO SYSTEMS 369
DESCRIPTION AND OPERATION 369
AUDIO SYSTEM 369
DESCRIPTION 369
OPERATION 369
RADIO RECEIVER 370
DESCRIPTION 370
OPERATION 370
REMOTE RADIO SWITCH 370
DESCRIPTION 370
OPERATION 370
SPEAKER SYSTEM 371
DESCRIPTION 371
OPERATION 371
POWER AMPLIFIER 371
DESCRIPTION 371
OPERATION 371
ANTENNA 372
DESCRIPTION 372
RADIO NOISE SUPPRESSION 372
DESCRIPTION 372
DIAGNOSIS AND TESTING 372
AUDIO SYSTEM 372
RADIO RECEIVER 373
REMOTE RADIO SWITCH 374
SPEAKER 375
POWER AMPLIFIER 376
ANTENNA 376
TEST 1 376
TEST 2 377
TEST 3 377
TEST 4 377
RADIO FREQUENCY INTERFERENCE 377
REMOVAL AND INSTALLATION 378
RADIO RECEIVER 378
REMOVAL 378
INSTALLATION 378
REMOTE RADIO SWITCH 379
REMOVAL 379
INSTALLATION 379
SPEAKER 379
REMOVAL 379
INSTALLATION 381
POWER AMPLIFIER 382
REMOVAL 382
INSTALLATION 382
ANTENNA 383
REMOVAL 383
INSTALLATION 385
RADIO NOISE SUPPRESSION COMPONENTS 386
REMOVAL 386
INSTALLATION 387
SPECIAL TOOLS 389
AUDIO SYSTEMS 389
00AN_8G 391
HORN SYSTEMS 391
DESCRIPTION AND OPERATION 391
HORN SYSTEM 391
DESCRIPTION 391
OPERATION 391
HORN 391
DESCRIPTION 391
OPERATION 392
HORN RELAY 392
DESCRIPTION 392
OPERATION 392
HORN SWITCH 392
DESCRIPTION 392
OPERATION 392
DIAGNOSIS AND TESTING 393
HORN RELAY 393
RELAY CIRCUIT TEST 393
HORN SWITCH 394
HORN 394
REMOVAL AND INSTALLATION 394
HORN RELAY 394
REMOVAL 394
INSTALLATION 395
HORN 395
REMOVAL 395
INSTALLATION 395
00AN_8H 397
SPEED CONTROL SYSTEM 397
DESCRIPTION AND OPERATION 397
SPEED CONTROL SYSTEM 397
DESCRIPTION 397
OPERATION 397
SPEED CONTROL SERVO 398
DESCRIPTION 398
OPERATION 398
SPEED CONTROL SOLENOID CIRCUITS 398
OPERATION 398
SPEED CONTROL SWITCHES 398
DESCRIPTION 398
OPERATION 398
BRAKE LAMP SWITCH 399
DESCRIPTION 399
OPERATION 399
SERVO CABLE 399
DESCRIPTION 399
OPERATION 399
VACUUM RESERVOIR 399
DESCRIPTION 399
OPERATION 399
VEHICLE SPEED INPUT 399
OPERATION 399
DIAGNOSIS AND TESTING 400
ROAD TEST 400
VACUUM SUPPLY TEST 400
REMOVAL AND INSTALLATION 400
SPEED CONTROL SERVO 400
REMOVAL 400
INSTALLATION 400
SPEED CONTROL SWITCHES 401
REMOVAL 401
INSTALLATION 401
SERVO CABLE (EXCEPT 4 7L ENGINE) 402
REMOVAL 402
INSTALLATION 402
SERVO CABLE-4 7L V-8 ENGINE 402
REMOVAL 402
INSTALLATION 403
VACUUM RESERVOIR 404
REMOVAL 404
INSTALLATION 404
SPECIFICATIONS 405
TORQUE CHART 405
00AN_8J 407
TURN SIGNAL AND HAZARD WARNING SYSTEMS 407
DESCRIPTION AND OPERATION 407
TURN SIGNAL SYSTEM 407
DESCRIPTION 407
OPERATION 407
HAZARD WARNING SYSTEM 407
DESCRIPTION 407
OPERATION 407
TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH 408
DESCRIPTION 408
OPERATION 408
TURN SIGNAL CANCELLING CAM 408
DESCRIPTION 408
OPERATION 409
COMBINATION FLASHER 409
DESCRIPTION 409
OPERATION 409
DIAGNOSIS AND TESTING 410
TURN SIGNAL AND HAZARD WARNING SYSTEMS 410
TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH 411
REMOVAL AND INSTALLATION 411
COMBINATION FLASHER 411
REMOVAL 411
INSTALLATION 411
TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH 412
REMOVAL 412
INSTALLATION 413
00AN_8K 415
WIPER AND WASHER SYSTEMS 415
GENERAL INFORMATION 415
INTRODUCTION 415
WINDSHIELD WIPER SYSTEM 415
WINDSHIELD WASHER SYSTEM 415
DESCRIPTION AND OPERATION 416
WIPER ARM AND BLADE 416
WIPER LINKAGE AND PIVOT 416
WIPER MOTOR 416
WIPER SWITCH AND WASHER SWITCH 416
CENTRAL TIMER MODULE 417
INTERMITTENT WIPE RELAY 417
WASHER RESERVOIR 418
WASHER PUMP 418
WASHER FLUID LEVEL SENSOR 418
WASHER NOZZLE AND PLUMBING 418
DIAGNOSIS AND TESTING 418
WIPER SYSTEM 418
WASHER SYSTEM 419
WIPER SWITCH AND WASHER SWITCH 420
INTERMITTENT WIPE RELAY 421
RELAY TEST 421
RELAY CIRCUIT TEST 421
REMOVAL AND INSTALLATION 422
WIPER BLADE 422
WIPER ARM 422
WIPER LINKAGE AND PIVOT 423
WIPER MOTOR 423
INTERMITTENT WIPE RELAY 425
WIPER SWITCH AND WASHER SWITCH 425
WASHER SYSTEM 426
WASHER RESERVOIR 426
WASHER PUMP 426
WASHER FLUID LEVEL SENSOR 427
WASHER NOZZLE 427
00AN_8L 429
LAMPS 429
LAMP SYSTEMS 429
DESCRIPTION AND OPERATION 429
LAMP SYSTEMS 429
HEADLAMPS 429
HEADLAMP SWITCH 429
TAIL/TURN SIGNAL/STOP/BACK-UP LAMP 429
FRONT TURN SIGNAL/PARKING LAMP 430
CHMSL LAMP (CENTER HIGH MOUNTED STOP LAMP) 430
DAYTIME RUNNING LAMPS 430
SAFETY PRECAUTIONS 430
LAMP DIAGNOSIS 431
DIAGNOSIS AND TESTING 431
SYSTEM DIAGNOSIS 431
HEADLAMP 431
FOG LAMP 433
HEADLAMP ALIGNMENT 435
ADJUSTMENTS 435
HEADLAMP ALIGNMENT 435
LAMP ALIGNMENT SCREEN PREPARATION 435
VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT 435
HEADLAMP ALIGNMENT 435
FOG LAMP ALIGNMENT 437
SPECIAL TOOLS 438
HEADLAMP ALIGNMENT 438
LAMP BULB SERVICE 439
REMOVAL AND INSTALLATION 439
HEADLAMP BULB 439
REMOVAL 439
INSTALLATION 439
FOG LAMP BULB 439
REMOVAL 439
INSTALLATION 439
PARK AND TURN SIGNAL LAMP BULBS 440
REMOVAL 440
INSTALLATION 440
FRONT SIDE MARKER LAMP BULB 440
REMOVAL 440
INSTALLATION 440
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB 440
REMOVAL 440
INSTALLATION 440
CARGO LAMP BULB 440
TAIL, BRAKE, TURN SIGNAL AND BACK-UP LAMP BULBS 440
REMOVAL 440
INSTALLATION 440
LICENSE PLATE LAMP BULB 441
REMOVAL 441
INSTALLATION 441
UNDERHOOD LAMP BULB 441
REMOVAL 441
INSTALLATION 441
DOME LAMP BULB 441
REMOVAL 441
INSTALLATION 441
OVERHEAD CONSOLE READING LAMP BULB 441
REMOVAL 441
INSTALLATION 441
LAMP SERVICE 442
REMOVAL AND INSTALLATION 442
HEADLAMP 442
REMOVAL 442
INSTALLATION 442
FOG LAMP 442
REMOVAL 442
INSTALLATION 442
PARK, TURN SIGNAL AND SIDE MARKER LAMP 442
REMOVAL 442
INSTALLATION 443
CENTER HIGH MOUNTED STOP LAMP (CHMSL) 443
REMOVAL 443
INSTALLATION 444
CARGO LAMP 444
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP 444
REMOVAL 444
INSTALLATION 444
LICENSE PLATE LAMP 444
REMOVAL 444
INSTALLATION 444
UNDERHOOD LAMP 444
REMOVAL 444
INSTALLATION 444
DOME LAMP 445
REMOVAL 445
INSTALLATION 445
OVERHEAD CONSOLE READING LAMP 445
LAMP SYSTEMS 446
GENERAL INFORMATION 446
DAYTIME RUNNING LAMP MODULE (DRLM) 446
REMOVAL AND INSTALLATION 446
DAYTIME RUNNING LAMP MODULE (DRLM) 446
REMOVAL 446
INSTALLATION 446
BULB APPLICATION 447
SPECIFICATIONS 447
EXTERIOR LAMPS 447
INTERIOR LAMPS 447
DIMMER CONTROLLED LAMPS 447
INDICATOR LAMPS 447
NON-DIMMING LAMPS 447
00AN_8M 449
PASSIVE RESTRAINT SYSTEMS 449
DESCRIPTION AND OPERATION 449
AIRBAG SYSTEM 449
DESCRIPTION 449
OPERATION 449
DRIVER SIDE AIRBAG MODULE 450
DESCRIPTION 450
OPERATION 450
PASSENGER SIDE AIRBAG MODULE 451
DESCRIPTION 451
OPERATION 451
PASSENGER SIDE AIRBAG ON/OFF SWITCH 451
DESCRIPTION 451
OPERATION 451
AIRBAG CONTROL MODULE 451
DESCRIPTION 451
OPERATION 452
CLOCKSPRING 452
DESCRIPTION 452
OPERATION 452
DIAGNOSIS AND TESTING 452
AIRBAG SYSTEM 452
SERVICE PROCEDURES 453
AIRBAG SYSTEM 453
NON-DEPLOYED 453
DEPLOYED 453
STORAGE 453
CLEANUP PROCEDURE 454
REMOVAL AND INSTALLATION 454
DRIVER SIDE AIRBAG MODULE 454
REMOVAL 455
INSTALLATION 456
DRIVER SIDE AIRBAG MODULE TRIM COVER 456
REMOVAL 456
INSTALLATION 457
PASSENGER SIDE AIRBAG MODULE 457
REMOVAL 458
INSTALLATION 459
PASSENGER SIDE AIRBAG ON/OFF SWITCH 460
REMOVAL 460
INSTALLATION 460
AIRBAG CONTROL MODULE 460
REMOVAL 460
INSTALLATION 461
CLOCKSPRING 461
REMOVAL 461
INSTALLATION 462
ADJUSTMENTS 463
CLOCKSPRING CENTERING 463
SPECIAL TOOLS 464
PASSIVE RESTRAINT SYSTEMS 464
00AN_8N 465
ELECTRICALLY HEATED SYSTEMS 465
GENERAL INFORMATION 465
INTRODUCTION 465
REAR WINDOW DEFOGGER SYSTEM 465
HEATED MIRROR SYSTEM 465
DESCRIPTION AND OPERATION 466
REAR GLASS HEATING GRID 466
OUTSIDE MIRROR HEATING GRID 466
DEFOGGER SWITCH 466
DIAGNOSIS AND TESTING 466
DEFOGGER SYSTEM 466
REAR GLASS HEATING GRID 467
DEFOGGER SWITCH 467
SERVICE PROCEDURES 468
REAR GLASS HEATING GRID REPAIR 468
REMOVAL AND INSTALLATION 469
DEFOGGER SWITCH 469
REMOVAL 469
INSTALLATION 469
00AN_8O 471
POWER DISTRIBUTION SYSTEMS 471
DESCRIPTION AND OPERATION 471
POWER DISTRIBUTION SYSTEM 471
DESCRIPTION 471
OPERATION 471
POWER DISTRIBUTION CENTER 471
DESCRIPTION 471
OPERATION 472
GENERATOR CARTRIDGE FUSE 472
DESCRIPTION 472
OPERATION 472
JUNCTION BLOCK 472
DESCRIPTION 472
OPERATION 473
IGNITION-OFF DRAW FUSE 473
DESCRIPTION 473
OPERATION 473
RELAY AND FUSE BLOCK 474
DESCRIPTION 474
OPERATION 474
REMOVAL AND INSTALLATION 474
POWER DISTRIBUTION CENTER 474
REMOVAL 474
INSTALLATION 475
GENERATOR CARTRIDGE FUSE 476
REMOVAL 476
INSTALLATION 476
JUNCTION BLOCK 476
REMOVAL 476
INSTALLATION 477
IGNITION-OFF DRAW FUSE 477
REMOVAL 478
INSTALLATION 478
RELAY AND FUSE BLOCK 478
REMOVAL 478
INSTALLATION 479
00AN_8P 481
POWER LOCK SYSTEMS 481
GENERAL INFORMATION 481
INTRODUCTION 481
POWER LOCK SYSTEM 481
REMOTE KEYLESS ENTRY SYSTEM 481
DESCRIPTION AND OPERATION 482
CENTRAL TIMER MODULE 482
POWER LOCK SWITCH 483
POWER LOCK MOTOR 483
REMOTE KEYLESS ENTRY TRANSMITTER 483
REMOTE KEYLESS ENTRY RECEIVER 484
DRIVER UNLOCK RELAY 484
HEADLAMP RELAY 484
HORN RELAY 484
DIAGNOSIS AND TESTING 484
POWER LOCK SYSTEM AND REMOTE KEYLESS ENTRY SYSTEM 484
POWER LOCK SWITCH 485
CONVENTIONAL CAB AND CLUB CAB 485
QUAD CAB 485
CENTRAL TIMER MODULE 486
POWER LOCK MOTOR 487
REMOTE KEYLESS ENTRY TRANSMITTER 488
RELAYS 488
SERVICE PROCEDURES 488
REMOTE KEYLESS ENTRY TRANSMITTER BATTERY REPLACEMENT 488
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING 489
REMOVAL AND INSTALLATION 489
POWER LOCK SWITCH 489
CONVENTIONAL CAB AND CLUB CAB 489
QUAD CAB 489
POWER LOCK MOTOR 489
DRIVER UNLOCK RELAY 490
HEADLAMP RELAY 490
HORN RELAY 490
00AN_8Q 493
VEHICLE THEFT/SECURITY SYSTEMS 493
GENERAL INFORMATION 493
INTRODUCTION 493
VEHICLE THEFT SECURITY SYSTEM 493
ENABLING 493
ARMING 493
DISARMING 494
POWER-UP MODE 494
TAMPER ALERT 494
DESCRIPTION AND OPERATION 494
CENTRAL TIMER MODULE 494
DOOR AJAR SWITCH 495
DOOR LOCK CYLINDER SWITCH 495
DESCRIPTION 495
OPERATION 495
HEADLAMP RELAY 495
HORN RELAY 495
SECURITY LAMP 495
DIAGNOSIS AND TESTING 496
VEHICLE THEFT SECURITY SYSTEM 496
DOOR LOCK CYLINDER SWITCH 496
RELAYS 496
REMOVAL AND INSTALLATION 496
DOOR AJAR SWITCH 496
DOOR LOCK CYLINDER SWITCH 496
HEADLAMP RELAY 497
HORN RELAY 498
00AN_8R 499
POWER SEAT SYSTEMS 499
GENERAL INFORMATION 499
INTRODUCTION 499
POWER SEAT SYSTEM 499
DESCRIPTION AND OPERATION 499
POWER SEAT SWITCH 499
POWER SEAT ADJUSTER AND MOTORS 499
CIRCUIT BREAKER 500
DIAGNOSIS AND TESTING 500
POWER SEAT SYSTEM 500
CIRCUIT BREAKER 500
POWER SEAT ADJUSTER AND MOTORS 500
POWER SEAT SWITCH 500
REMOVAL AND INSTALLATION 500
POWER SEAT SWITCH 500
POWER SEAT ADJUSTER AND MOTORS 501
00AN_8S 503
POWER WINDOW SYSTEMS 503
GENERAL INFORMATION 503
INTRODUCTION 503
POWER WINDOW SYSTEM 503
DESCRIPTION AND OPERATION 503
POWER WINDOW SWITCH 503
POWER WINDOW MOTOR 504
CIRCUIT BREAKER 504
DIAGNOSIS AND TESTING 504
POWER WINDOW SYSTEM 504
ALL WINDOWS INOPERATIVE 504
ONE WINDOW INOPERATIVE 504
CIRCUIT BREAKER 505
POWER WINDOW SWITCH 505
CONVENTIONAL CAB AND CLUB CAB 505
QUAD CAB 505
POWER WINDOW MOTOR 506
REMOVAL AND INSTALLATION 507
POWER WINDOW SWITCH 507
CONVENTIONAL CAB AND CLUB CAB 507
QUAD CAB 507
POWER WINDOW MOTOR 508
00AN_8T 509
POWER MIRROR SYSTEMS 509
EXTERIOR MIRRORS 509
GENERAL INFORMATION 509
INTRODUCTION 509
POWER MIRROR SYSTEM 509
DESCRIPTION AND OPERATION 509
POWER MIRROR 509
POWER MIRROR SWITCH 510
DIAGNOSIS AND TESTING 510
POWER MIRROR SYSTEM 510
REMOVAL AND INSTALLATION 511
POWER MIRROR SWITCH 511
POWER MIRROR 512
INTERIOR MIRRORS 513
GENERAL INFORMATION 513
INTRODUCTION 513
AUTOMATIC DAY/NIGHT MIRROR SYSTEM 513
DESCRIPTION AND OPERATION 513
AUTOMATIC DAY/NIGHT MIRROR 513
DIAGNOSIS AND TESTING 513
AUTOMATIC DAY/NIGHT MIRROR 513
REMOVAL AND INSTALLATION 514
AUTOMATIC DAY/NIGHT MIRROR 514
00AN_8U 515
CHIME/BUZZER WARNING SYSTEMS 515
GENERAL INFORMATION 515
INTRODUCTION 515
CHIME WARNING SYSTEM 515
DESCRIPTION AND OPERATION 515
CENTRAL TIMER MODULE 515
INSTRUMENT CLUSTER 516
DRIVER DOOR AJAR SWITCH 516
KEY-IN IGNITION SWITCH 516
HEADLAMP SWITCH 516
DRIVER SEAT BELT SWITCH 516
DIAGNOSIS AND TESTING 517
CENTRAL TIMER MODULE 517
DRIVER DOOR AJAR SWITCH 517
KEY-IN IGNITION SWITCH 518
HEADLAMP SWITCH 518
DRIVER SEAT BELT SWITCH 519
INSTRUMENT CLUSTER 519
REMOVAL AND INSTALLATION 519
CHIME WARNING SYSTEM SWITCHES 519
00AN_8V 521
OVERHEAD CONSOLE SYSTEMS 521
DESCRIPTION AND OPERATION 521
OVERHEAD CONSOLE SYSTEM 521
DESCRIPTION 521
OVERHEAD CONSOLE 521
DESCRIPTION 521
COMPASS MINI-TRIP COMPUTER 522
DESCRIPTION 522
OPERATION 523
OVERHEAD CONSOLE READING AND COURTESY LAMP 523
DESCRIPTION 523
OPERATION 523
GARAGE DOOR OPENER STORAGE BIN 523
DESCRIPTION 523
OPERATION 524
PAPERCLIP 524
DESCRIPTION 524
SUNGLASSES STORAGE BIN 524
DESCRIPTION 524
OPERATION 524
AMBIENT TEMPERATURE SENSOR 524
DESCRIPTION 524
OPERATION 524
DIAGNOSIS AND TESTING 525
COMPASS MINI-TRIP COMPUTER 525
SELF-DIAGNOSTIC TEST 525
AMBIENT TEMPERATURE SENSOR 525
SENSOR TEST 526
SENSOR CIRCUIT TEST 526
SERVICE PROCEDURES 526
COMPASS VARIATION ADJUSTMENT 526
COMPASS CALIBRATION 526
COMPASS DEMAGNETIZING 527
REMOVAL AND INSTALLATION 528
OVERHEAD CONSOLE READING AND COURTESY LAMP LENS 528
REMOVAL 528
INSTALLATION 528
OVERHEAD CONSOLE 529
REMOVAL 529
INSTALLATION 529
PAPERCLIP 530
REMOVAL 530
INSTALLATION 530
COMPASS MINI-TRIP COMPUTER 531
REMOVAL 531
INSTALLATION 531
OVERHEAD CONSOLE READING AND COURTESY LAMP HOUSING 531
REMOVAL 531
INSTALLATION 531
SUNGLASSES STORAGE BIN 532
REMOVAL 532
INSTALLATION 532
GARAGE DOOR OPENER STORAGE BIN DOOR 532
REMOVAL 532
INSTALLATION 532
AMBIENT TEMPERATURE SENSOR 533
REMOVAL 533
INSTALLATION 533
SPECIAL TOOLS 533
OVERHEAD CONSOLE SYSTEMS 533
00AN_8W 535
WIRING DIAGRAMS 535
8W-01 GENERAL INFORMATION 537
DESCRIPTION AND OPERATION 537
INTRODUCTION 537
CIRCUIT INFORMATION 540
CIRCUIT FUNCTIONS 540
SECTION IDENTIFICATION 541
SYMBOLS 541
CONNECTOR INFORMATION 543
IDENTIFICATION 543
LOCATIONS 543
SPLICE LOCATIONS 543
NOTES, CAUTIONS, and WARNINGS 543
TAKE OUTS 543
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 544
DIAGNOSIS AND TESTING 544
TROUBLESHOOTING TOOLS 544
INTERMITTENT AND POOR CONNECTIONS 544
TROUBLESHOOTING TESTS 545
TESTING FOR VOLTAGE POTENTIAL 545
TESTING FOR CONTINUITY 545
TESTING FOR A SHORT TO GROUND 545
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 545
TESTING FOR A VOLTAGE DROP 545
TROUBLESHOOTING WIRING PROBLEMS 545
SERVICE PROCEDURES 546
WIRING REPAIR 546
TERMINAL/CONNECTOR REPAIR-MOLEX CONNECTORS 546
TERMINAL/CONNECTOR REPAIR-THOMAS AND BETTS CONNECTORS 546
CONNECTOR REPLACEMENT 547
CONNECTOR AND TERMINAL REPLACEMENT 548
TERMINAL REPLACEMENT 549
DIODE REPLACEMENT 550
SPECIAL TOOLS 551
WIRING/TERMINAL 551
8W-02 COMPONENT INDEX 553
8W-10 POWER DISTRIBUTION 555
8W-11 FUSE/RELAY BLOCK 593
8W-12 JUNCTION BLOCK 601
8W-15 GROUND DISTRIBUTION 619
8W-20 CHARGING SYSTEM 633
8W-21 STARTING SYSTEM 637
8W-30 FUEL/IGNITION SYSTEMS 641
8W-31 TRANSMISSION CONTROL SYSTEM 669
8W-33 VEHICLE SPEED CONTROL 681
8W-34 REAR WHEEL ANTI-LOCK BRAKES 685
8W-35 ALL-WHEEL ANTI-LOCK BRAKES 689
8W-39 VEHICLE THEFT SECURITY SYSTEM 693
8W-40 INSTRUMENT CLUSTER 703
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 713
8W-42 AIR CONDITIONING/HEATER 717
8W-43 AIRBAG SYSTEM 725
8W-44 INTERIOR LIGHTING 729
8W-45 CENTRAL TIMER MODULE 743
8W-47 AUDIO SYSTEM 759
8W-49 OVERHEAD CONSOLE 767
8W-50 FRONT LIGHTING 771
8W-51 REAR LIGHTING 781
8W-52 TURN SIGNALS 789
8W-53 WIPERS 793
8W-54 TRAILER TOW 797
8W-60 POWER WINDOWS 801
8W-61 POWER DOOR LOCKS 809
8W-62 POWER MIRRORS 815
8W-63 POWER SEAT 817
8W-70 SPLICE INFORMATION 819
8W-80 CONNECTOR PIN-OUTS 823
8W-90 CONNECTOR LOCATIONS 895
DESCRIPTION AND OPERATION 895
INTRODUCTION 895
CONNECTOR/GROUND LOCATIONS 895
8W-95 SPLICE LOCATIONS 927
DESCRIPTION AND OPERATION 927
INTRODUCTION 927
SPLICE LOCATIONS 927
00AN_9 939
ENGINE 939
2 5L ENGINE 939
DESCRIPTION AND OPERATION 940
ENGINE 940
DESCRIPTION 940
LUBRICATION SYSTEM 940
DESCRIPTION 940
OPERATION 940
EXHAUST MANIFOLD 941
DESCRIPTION 941
OPERATION 941
INTAKE MANIFOLD 941
DESCRIPTION 941
CYLINDER HEAD 941
DESCRIPTION 941
OPERATION 941
CRANKSHAFT 941
DESCRIPTION 941
OPERATION 941
CRANKSHAFT MAIN BEARINGS 943
DESCRIPTION 943
OPERATION 943
CRANKSHAFT OIL SEALS 943
DESCRIPTION 943
OPERATION 943
DIAGNOSIS AND TESTING 944
ENGINE DIAGNOSIS-INTRODUCTION 944
SERVICE DIAGNOSIS-PERFORMANCE 944
SERVICE DIAGNOSIS-MECHANICAL 946
SERVICE DIAGNOSIS-LUBRICATION 947
INTAKE MANIFOLD LEAKAGE DIAGNOSIS 947
CYLINDER COMPRESSION PRESSURE TEST 947
CYLINDER HEAD GASKET FAILURE DIAGNOSIS 948
CYLINDER-TO-CYLINDER LEAKAGE TEST 948
CYLINDER-TO-WATER JACKET LEAKAGE TEST 948
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 948
ENGINE OIL LEAK INSPECTION 949
Air Leak Detection Test Method 949
INSPECTION FOR REAR SEAL AREA LEAKS 949
REAR SEAL AREA LEAKS-INSPECTION 950
HYDRAULIC TAPPETS 950
OIL LEVEL 950
TAPPET NOISE DIAGNOSIS 951
LEAK-DOWN TEST 951
ENGINE OIL PRESSURE 951
SERVICE PROCEDURES 952
FORM-IN-PLACE GASKETS 952
MOPAR SILICONE RUBBER ADHESIVE SEALANT 952
MOPAR GASKET MAKER 952
SURFACE PREPARATION 952
GASKET APPLICATION 952
ENGINE OIL 952
ENGINE OIL SPECIFICATION 952
API SERVICE GRADE CERTIFIED 952
SAE VISCOSITY 953
ENERGY CONSERVING OIL 953
OIL LEVEL INDICATOR (DIPSTICK) 953
CRANKCASE OIL LEVEL INSPECTION 953
ENGINE OIL CHANGE 953
ENGINE OIL FILTER CHANGE 954
REPAIR DAMAGED OR WORN THREADS 954
CYLINDER BORE-HONING 954
HYDROSTATIC LOCK 955
VALVE TIMING 955
VALVE, GUIDE AND SEAL 955
VALVE REFACING 956
VALVE SEAT REFACING 956
VALVE STEM OIL SEAL REPLACEMENT 956
VALVE GUIDES 956
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT 956
PISTON-FITTING 957
BORE GAUGE METHOD 957
PISTON RING-FITTING 958
CONNECTING ROD BEARINGS-FITTING 960
CRANKSHAFT MAIN BEARINGS-FITTING 963
INSPECTION 963
FITTING BEARINGS (CRANKSHAFT INSTALLED) 963
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) 965
REMOVAL AND INSTALLATION 966
ENGINE MOUNTS-FRONT 966
REMOVAL 966
INSTALLATION 966
ENGINE REAR SUPPORT 967
REMOVAL 967
INSTALLATION 967
ENGINE 967
REMOVAL 967
INSTALLATION 969
INTAKE MANIFOLD 969
REMOVAL 969
INSTALLATION 970
EXHAUST MANIFOLD 971
REMOVAL 971
INSTALLATION 971
CYLINDER HEAD COVER 971
REMOVAL 971
INSTALLATION 972
ROCKER ARMS AND PUSH RODS 972
REMOVAL 972
INSTALLATION 973
VALVE SPRING AND SEAL 973
REMOVAL 973
INSTALLATION 973
CYLINDER HEAD 974
REMOVAL 974
INSTALLATION 974
HYDRAULIC TAPPETS 976
REMOVAL 976
INSTALLATION 976
VIBRATION DAMPER 977
REMOVAL 977
INSTALLATION 977
TIMING CASE COVER OIL SEAL 977
REMOVAL 977
INSTALLATION 977
TIMING CASE COVER 978
REMOVAL 978
INSTALLATION 978
TIMING CHAIN AND SPROCKETS 978
REMOVAL 979
INSTALLATION 979
CAMSHAFT 980
REMOVAL 980
INSTALLATION 980
CAMSHAFT PIN REPLACEMENT 981
REMOVAL 981
INSTALLATION 982
CAMSHAFT BEARINGS 983
CRANKSHAFT MAIN BEARINGS 983
REMOVAL 983
INSTALLATION 984
OIL PAN 985
REMOVAL 985
INSTALLATION 985
OIL PUMP 986
REMOVAL 986
INSTALLATION 987
PISTON AND CONNECTING ROD 987
REMOVAL 987
INSTALLATION 987
REAR MAIN OIL SEAL 988
REMOVAL 988
INSTALLATION 988
DISASSEMBLY AND ASSEMBLY 989
CYLINDER HEAD 989
DISASSEMBLY 989
ASSEMBLY 989
CLEANING AND INSPECTION 989
ROCKER ARMS AND PUSH RODS 989
CLEANING 989
INSPECTION 989
HYDRAULIC TAPPETS 989
CLEANING 989
INSPECTION 989
ENGINE CYLINDER HEAD 990
CLEANING 990
INSPECTION 990
CYLINDER BLOCK 990
CLEANING 990
INSPECTION 990
INTAKE MANIFOLD 990
CLEANING 990
INSPECTION 991
EXHAUST MANIFOLD 991
CLEANING 991
INSPECTION 991
SPECIFICATIONS 991
2 5L ENGINE SPECIFICATIONS 991
SPECIFICATIONS-TORQUE 994
SPECIAL TOOLS 995
2 5L ENGINE 995
3 9L ENGINE 997
DESCRIPTION AND OPERATION 998
ENGINE 998
DESCRIPTION 998
ENGINE LUBRICATION SYSTEM 998
DESCRIPTION 998
OPERATION 998
CYLINDER HEAD COVER GASKET 1001
DESCRIPTION 1001
OPERATION 1001
EXHAUST MANIFOLD 1001
DESCRIPTION 1001
OPERATION 1001
INTAKE MANIFOLD 1001
DESCRIPTION 1001
OPERATION 1001
CYLINDER HEAD 1002
DESCRIPTION 1002
OPERATION 1002
VALVES AND VALVE SPRINGS 1002
DESCRIPTION 1002
TIMING CHAIN TENSIONER 1002
DESCRIPTION 1002
OPERATION 1002
PISTON AND CONNECTING ROD 1002
DESCRIPTION 1002
CRANKSHAFT 1002
DESCRIPTION 1002
OPERATION 1002
CRANKSHAFT MAIN BEARINGS 1003
DESCRIPTION 1003
OPERATION 1003
CRANKSHAFT OIL SEALS 1003
DESCRIPTION 1003
OPERATION 1003
DIAGNOSIS AND TESTING 1003
ENGINE DIAGNOSIS-INTRODUCTION 1003
SERVICE DIAGNOSIS-GASOLINE ENGINES 1004
INTAKE MANIFOLD LEAKAGE DIAGNOSIS 1008
CYLINDER COMPRESSION PRESSURE TEST 1008
CYLINDER HEAD GASKET FAILURE DIAGNOSIS 1008
CYLINDER-TO-CYLINDER LEAKAGE TEST 1008
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1008
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1008
INSPECTION (ENGINE OIL LEAKS IN GENERAL) 1009
REAR SEAL AREA LEAKS-INSPECTION 1009
HYDRAULIC TAPPETS 1010
OIL LEVEL 1010
TAPPET NOISE DIAGNOSIS 1010
LEAK-DOWN TEST 1010
ENGINE OIL PRESSURE 1011
SERVICE PROCEDURES 1011
FORM-IN-PLACE GASKETS 1011
MOPAR SILICONE RUBBER ADHESIVE SEALANT 1011
MOPAR GASKET MAKER 1011
SURFACE PREPARATION 1011
GASKET APPLICATION 1012
ENGINE OIL 1012
ENGINE OIL SPECIFICATION 1012
API SERVICE GRADE CERTIFIED 1012
SAE VISCOSITY 1012
ENERGY CONSERVING OIL 1012
OIL LEVEL INDICATOR (DIPSTICK) 1012
CRANKCASE OIL LEVEL INSPECTION 1012
ENGINE OIL CHANGE 1013
ENGINE OIL FILTER CHANGE 1013
REPAIR DAMAGED OR WORN THREADS 1014
CYLINDER BORE-HONING 1014
HYDROSTATIC LOCK 1014
VALVE TIMING 1015
VALVES, GUIDES AND SPRINGS 1015
VALVE CLEANING 1015
VALVE GUIDES 1015
VALVE GUIDES 1016
REFACING VALVES AND VALVE SEATS 1016
VALVES 1016
VALVE SEATS 1016
VALVE SPRINGS 1017
TIMING CHAIN STRETCH-MEASURING 1017
PISTON-FITTING 1017
PISTON RINGS-FITTING 1018
CONNECTING ROD BEARINGS-FITTING 1019
CRANKSHAFT MAIN BEARINGS-FITTING 1020
REMOVAL AND INSTALLATION 1020
ENGINE FRONT MOUNTS 1020
REMOVAL-2WD 1020
INSTALLATION-2WD 1020
REMOVAL-4WD 1021
INSTALLATION-4WD 1022
ENGINE REAR SUPPORT 1022
REMOVAL-2WD 1022
INSTALLATION-2WD 1023
REMOVAL-4WD 1024
INSTALLATION-4WD 1024
EXHAUST MANIFOLD 1025
REMOVAL 1025
INSTALLATION 1025
ENGINE ASSEMBLY 1026
REMOVAL 1026
INSTALLATION 1026
CYLINDER HEAD COVER 1027
REMOVAL 1027
INSTALLATION 1027
CYLINDER HEAD COMPONENTS-IN VEHICLE SERVICE 1027
ROCKER ARMS AND PUSH RODS 1027
VALVE STEM SHIELDS AND SPRINGS 1028
CYLINDER HEADS 1028
REMOVAL 1028
INSTALLATION 1029
VALVES AND VALVE SPRINGS-CYLINDER HEAD REMOVED 1029
REMOVAL 1029
INSTALLATION 1029
HYDRAULIC TAPPETS 1030
REMOVAL 1030
INSTALLATION 1030
INTAKE MANIFOLD 1030
REMOVAL 1030
INSTALLATION 1030
DISTRIBUTOR DRIVE SHAFT BUSHING 1032
REMOVAL 1032
INSTALLATION 1032
DISTRIBUTOR INSTALLATION 1033
VIBRATION DAMPER 1033
REMOVAL 1033
INSTALLATION 1034
TIMING CHAIN COVER 1034
REMOVAL 1034
INSTALLATION 1034
TIMING CHAIN AND TENSIONER 1035
REMOVAL 1035
INSTALLATION 1035
CAMSHAFT 1036
REMOVAL 1036
INSTALLATION 1036
CAMSHAFT BEARINGS 1038
REMOVAL 1038
INSTALLATION 1038
CRANKSHAFT MAIN BEARINGS 1038
REMOVAL 1038
INSTALLATION 1038
OIL PAN 1038
REMOVAL2WD 1038
INSTALLATION2WD 1039
OIL PUMP 1040
REMOVAL 1040
INSTALLATION 1040
PISTON AND CONNECTING ROD ASSEMBLY 1040
REMOVAL 1040
INSTALLATION 1040
CRANKSHAFT 1041
REMOVAL 1041
INSTALLATION 1041
CRANKSHAFT FRONT OIL SEAL 1041
REMOVAL 1041
INSTALLATION 1042
CRANKSHAFT REAR OIL SEALS 1042
UPPER SEAL -CRANKSHAFT REMOVED 1042
UPPER SEAL-CRANKSHAFT INSTALLED 1043
LOWER SEAL 1044
ENGINE CORE OIL AND CAMSHAFT PLUGS 1044
REMOVAL 1044
INSTALLATION 1044
DISASSEMBLY AND ASSEMBLY 1045
OIL PUMP 1045
DISASSEMBLE 1045
ASSEMBLE 1045
CLEANING AND INSPECTION 1046
CYLINDER HEAD COVER 1046
CLEANING 1046
INSPECTION 1046
CYLINDER HEAD 1046
CLEANING 1046
INSPECTION 1046
PISTON AND CONNECTING ROD INSPECTION 1046
CLEANING 1046
INSPECTION 1046
OIL PUMP 1046
CLEANING 1046
INSPECTION 1046
OIL PAN 1047
CLEANING 1047
INSPECTION 1048
CYLINDER BLOCK 1048
CLEANING 1048
INSPECTION 1048
INTAKE MANIFOLD 1048
CLEANING 1048
INSPECTION 1049
EXHAUST MANIFOLD 1049
CLEANING 1049
INSPECTION 1049
SPECIFICATIONS 1049
3 9L ENGINE SPECIFICATIONS 1049
TORQUE SPECIFICATIONS 1053
SPECIAL TOOLS 1054
3 9L ENGINE 1054
4 7L ENGINE 1056
DESCRIPTION AND OPERATION 1057
ENGINE 1057
DESCRIPTION 1058
ENGINE LUBRICATION SYSTEM 1058
DESCRIPTION 1058
OPERATION 1060
CYLINDER BLOCK 1060
DESCRIPTION 1060
CRANKSHAFT 1060
DESCRIPTION 1060
PISTON AND CONNECTING ROD 1061
DESCRIPTION 1061
CYLINDER HEAD 1061
DESCRIPTION 1061
VALVE GUIDES 1061
DESCRIPTION 1061
VALVES 1061
DESCRIPTION 1061
VALVE STEM SEAL 1061
DESCRIPTION 1061
VALVE SPRING 1061
DESCRIPTION 1061
HYDRAULIC LASH ADJUSTER 1061
DESCRIPTION 1061
TIMING DRIVE SYSTEM 1061
DESCRIPTION 1061
OPERATION 1061
CAMSHAFT 1062
DESCRIPTION 1062
ROCKER ARM 1062
DESCRIPTION 1062
CYLINDER HEAD COVER 1062
DESCRIPTION 1062
OIL PAN 1062
DESCRIPTION 1062
STRUCTURAL DUST COVER 1062
DESCRIPTION 1062
OPERATION 1062
INTAKE MANIFOLD 1062
DESCRIPTION 1062
EXHAUST MANIFOLD 1062
DESCRIPTION 1062
DIAGNOSIS AND TESTING 1063
ENGINE DIAGNOSIS-INTRODUCTION 1063
SERVICE DIAGNOSIS-PERFORMANCE 1063
SERVICE DIAGNOSIS-MECHANICAL 1065
SERVICE DIAGNOSIS-LUBRICATION 1066
INTAKE MANIFOLD LEAKAGE DIAGNOSIS 1066
CYLINDER COMPRESSION PRESSURE TEST 1066
CYLINDER HEAD GASKET FAILURE DIAGNOSIS 1067
CYLINDER-TO-CYLINDER LEAKAGE TEST 1067
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1067
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1067
ENGINE OIL LEAK INSPECTION 1068
Air Leak Detection Test Method 1068
INSPECTION FOR REAR SEAL AREA LEAKS 1068
REAR SEAL AREA LEAKS-INSPECTION 1069
HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS 1069
CHECKING ENGINE OIL PRESSURE 1070
SERVICE PROCEDURES 1070
FORM-IN-PLACE GASKETS 1070
MOPAR SILICONE RUBBER ADHESIVE SEALANT 1070
MOPAR GASKET MAKER 1070
SURFACE PREPARATION 1070
GASKET APPLICATION 1070
ENGINE OIL 1071
ENGINE OIL SPECIFICATION 1071
API SERVICE GRADE CERTIFIED 1071
SAE VISCOSITY 1071
ENERGY CONSERVING OIL 1071
CONTAINER IDENTIFICATION 1071
OIL LEVEL INDICATOR (DIPSTICK) 1071
CRANKCASE OIL LEVEL INSPECTION 1072
ENGINE OIL CHANGE 1072
ENGINE OIL FILTER CHANGE 1072
REPAIR DAMAGED OR WORN THREADS 1073
CYLINDER BORE-HONING 1073
HYDROSTATIC LOCK 1074
VALVE SERVICE 1074
REFACING 1074
ENGINE TIMING-VERIFICATION 1075
SINGLE CAMSHAFT TIMING 1075
TIMING CHAIN-MEASURING WEAR 1077
PISTONS-FITTING 1077
PISTON RINGS-FITTING 1078
CONNECTING ROD BEARINGS-FITTING 1080
CRANKSHAFT MAIN BEARINGS 1082
INSPECTION 1082
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) 1083
CRANKSHAFT MAIN BEARING SELECTION 1083
REMOVAL AND INSTALLATION 1083
ENGINE MOUNTS-LEFT AND RIGHT 1083
REMOVAL 1083
INSTALLATION 1084
ENGINE MOUNT-REAR 1084
REMOVAL 1084
INSTALLATION 1085
STRUCTURAL COVER 1085
REMOVAL 1085
INSTALLATION 1085
ENGINE ASSEMBLY 1086
REMOVAL 1086
INSTALLATION 1089
INTAKE MANIFOLD 1090
REMOVAL 1090
INSTALLATION 1091
EXHAUST MANIFOLDS 1091
RIGHT EXHAUST MANIFOLD 1091
LEFT EXHAUST MANIFOLD 1093
CYLINDER HEAD COVER 1093
REMOVAL 1093
INSTALLATION 1093
REMOVAL 1093
INSTALLATION 1094
ROCKER ARMS 1095
REMOVAL 1095
INSTALLATION 1095
CYLINDER HEADS 1096
CYLINDER HEAD-LEFT 1096
CYLINDER HEAD-RIGHT 1099
INSTALLATION 1099
VALVE SPRINGS AND SEALS 1101
REMOVAL 1101
INSTALLATION 1101
HYDRAULIC LASH ADJUSTER 1102
REMOVAL 1102
INSTALLATION 1102
CRANKSHAFT DAMPER 1102
REMOVAL 1102
INSTALLATION 1102
TIMING CHAIN COVER 1103
REMOVAL 1103
INSTALLATION 1103
TIMING CHAIN AND SPROCKETS 1104
REMOVAL 1104
INSTALLATION 1107
IDLER SHAFT-TIMING DRIVE 1110
REMOVAL 1110
INSTALLATION 1111
CAMSHAFTS-IN VEHICLE 1111
LEFT CAMSHAFT 1111
RIGHT CAMSHAFT 1114
CRANKSHAFT MAIN BEARINGS 1118
CRANKSHAFT MAIN BEARING SELECTION 1118
CHECKING CRANKSHAFT END PLAY 1118
OIL PAN 4X2 VEHICLE 1118
REMOVAL 1118
INSTALLATION 1119
OIL PAN 4X4 VEHICLE 1120
REMOVAL 1120
INSTALLATION 1120
PISTON AND CONNECTING ROD 1120
REMOVAL 1120
INSTALLATION 1121
CRANKSHAFT 1123
REMOVAL 1123
INSPECTION 1123
INSTALLATION 1124
FLEXPLATE 1125
REMOVAL 1125
INSTALLATION 1125
OIL PUMP 1125
REMOVAL 1125
INSTALLATION 1126
ENGINE OIL PRESSURE SENDING UNIT 1126
REMOVAL 1126
INSTALLATION 1126
CRANKSHAFT OIL SEAL-FRONT 1127
REMOVAL 1127
INSTALLATION 1128
CRANKSHAFT OIL SEAL-REAR 1129
REMOVAL 1129
INSTALLATION 1129
ENGINE CORE PLUGS 1129
REMOVAL 1129
INSTALLATION 1129
DISASSEMBLY AND ASSEMBLY 1130
OIL PUMP 1130
DISASSEMBLE 1130
ASSEMBLE 1130
CLEANING AND INSPECTION 1130
INTAKE MANIFOLD 1130
CLEANING 1130
INSPECTION 1130
EXHAUST MANIFOLD 1131
CLEANING 1131
INSPECTION 1131
CYLINDER HEADS 1131
CLEANING 1131
INSPECTION 1131
PISTON AND CONNECTING ROD 1131
CLEANING 1131
INSPECTION 1131
OIL PAN 1131
CLEANING 1131
INSPECTION 1131
OIL PUMP 1132
CLEANING 1132
INSPECTION 1132
CYLINDER BLOCK 1133
CLEANING 1133
INSPECTION 1133
SPECIFICATIONS 1134
4 7L ENGINE 1134
TORQUE 1137
SPECIAL TOOLS 1138
4 7L ENGINE 1138
5 9L ENGINE 1142
DESCRIPTION AND OPERATION 1143
ENGINE 1143
DESCRIPTION 1143
ENGINE LUBRICATION SYSTEM 1143
DESCRIPTION 1143
OPERATION 1143
EXHAUST MANIFOLD 1146
DESCRIPTION 1146
OPERATION 1146
INTAKE MANIFOLD 1146
DESCRIPTION 1146
OPERATION 1146
CYLINDER HEAD COVER GASKET 1147
DESCRIPTION 1147
OPERATION 1147
CYLINDER HEAD 1147
DESCRIPTION 1147
OPERATION 1147
VALVES AND VALVE SPRINGS 1147
DESCRIPTION 1147
ENGINE OIL PAN 1147
DESCRIPTION 1147
OPERATION 1147
CRANKSHAFT OIL SEALS 1147
DESCRIPTION 1147
OPERATION 1147
PISTON AND CONNECTING ROD 1148
DESCRIPTION 1148
CRANKSHAFT MAIN BEARINGS 1148
DESCRIPTION 1148
OPERATION 1148
CRANKSHAFT 1148
DESCRIPTION 1148
OPERATION 1148
DIAGNOSIS AND TESTING 1148
ENGINE DIAGNOSIS-INTRODUCTION 1148
SERVICE DIAGNOSIS-GASOLINE ENGINES 1149
INTAKE MANIFOLD LEAKAGE DIAGNOSIS 1153
CYLINDER COMPRESSION PRESSURE TEST 1153
CYLINDER HEAD GASKET FAILURE DIAGNOSIS 1153
CYLINDER-TO-CYLINDER LEAKAGE TEST 1153
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1153
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1154
INSPECTION (ENGINE OIL LEAKS IN GENERAL) 1154
REAR SEAL AREA LEAKS-INSPECTION 1155
HYDRAULIC TAPPETS 1155
OIL LEVEL 1155
TAPPET NOISE DIAGNOSIS 1155
LEAK-DOWN TEST 1156
ENGINE OIL PRESSURE 1156
SERVICE PROCEDURES 1156
FORM-IN-PLACE GASKETS 1156
MOPAR SILICONE RUBBER ADHESIVE SEALANT 1157
MOPAR GASKET MAKER 1157
SURFACE PREPARATION 1157
GASKET APPLICATION 1157
ENGINE PERFORMANCE 1157
ENGINE OIL 1157
ENGINE OIL SPECIFICATION 1157
API SERVICE GRADE CERTIFIED 1158
SAE VISCOSITY 1158
ENERGY CONSERVING OIL 1158
OIL LEVEL INDICATOR (DIPSTICK) 1158
CRANKCASE OIL LEVEL INSPECTION 1158
ENGINE OIL CHANGE 1158
ENGINE OIL FILTER CHANGE 1159
REPAIR DAMAGED OR WORN THREADS 1159
CYLINDER BORE-HONING 1159
HYDROSTATIC LOCK 1160
VALVE TIMING 1160
VALVE SERVICE 1161
VALVE CLEANING 1161
VALVE INSPECTION 1161
VALVE GUIDES 1161
REFACING VALVES AND VALVE SEATS 1161
VALVE SPRING INSPECTION 1162
MEASURING TIMING CHAIN STRETCH 1163
PISTONS-FITTING 1163
PISTON RINGS-FITTING 1164
CONNECTING ROD BEARINGS-FITTING 1165
CRANKSHAFT MAIN BEARINGS-FITTING 1165
REMOVAL AND INSTALLATION 1166
ENGINE FRONT MOUNTS 1166
REMOVAL-2WD 1166
INSTALLATION-2WD 1166
REMOVAL-4WD 1167
INSTALLATION-4WD 1167
ENGINE REAR SUPPORT 1168
REMOVAL-2WD 1168
INSTALLATION-2WD 1168
REMOVAL-4WD 1168
INSTALLATION-4WD 1168
ENGINE ASSEMBLY 1169
REMOVAL 1169
INSTALLATION 1170
INTAKE MANIFOLD 1170
REMOVAL 1170
INSTALLATION 1170
EXHAUST MANIFOLD 1172
REMOVAL 1172
INSTALLATION 1172
CYLINDER HEAD COVER 1173
REMOVAL 1173
INSTALLATION 1173
ROCKER ARMS AND PUSH RODS 1173
REMOVAL 1173
INSTALLATION 1173
VALVE SPRING AND STEM SEAL REPLACEMENT-IN VEHICLE 1174
CYLINDER HEAD 1174
REMOVAL 1174
INSTALLATION 1174
VALVES AND VALVE SPRINGS 1175
REMOVAL 1175
INSTALLATION 1175
HYDRAULIC TAPPETS 1175
REMOVAL 1175
INSTALLATION 1175
VIBRATION DAMPER 1176
REMOVAL 1176
INSTALLATION 1176
TIMING CHAIN COVER 1176
INSTALLATION 1176
TIMING CHAIN 1178
REMOVAL 1178
INSTALLATION 1178
CAMSHAFT 1178
REMOVAL0 – 2 AN (Continued) 1178
INSTALLATION 1179
CAMSHAFT BEARINGS 1180
REMOVAL 1180
INSTALLATION 1180
DISTRIBUTOR DRIVE SHAFT BUSHING 1180
REMOVAL 1180
INSTALLATION 1180
DISTRIBUTOR INSTALLATION 1180
CRANKSHAFT MAIN BEARINGS 1181
REMOVAL 1181
INSTALLATION 1181
OIL PAN 1182
REMOVAL 1182
4WD 1182
INSTALLATION2WD 1182
4WD 1183
PISTON AND CONNECTING ROD ASSEMBLY 1183
REMOVAL 1183
INSTALLATION 1183
CRANKSHAFT 1184
REMOVAL 1184
INSPECTION OF JOURNALS 1184
CLEANING 1184
INSTALLATION 1184
OIL PUMP 1185
REMOVAL 1185
INSTALLATION 1185
CRANKSHAFT OIL SEAL-FRONT 1185
CRANKSHAFT OIL SEALS-REAR 1186
UPPER SEAL -CRANKSHAFT REMOVED 1186
UPPER SEAL -CRANKSHAFT INSTALLED 1187
LOWER SEAL 1187
ENGINE CORE OIL AND CAMSHAFT PLUGS 1188
REMOVAL 1188
INSTALLATION 1188
DISASSEMBLY AND ASSEMBLY 1188
OIL PUMP 1188
DISASSEMBLE 1188
ASSEMBLE 1189
CLEANING AND INSPECTION 1189
CYLINDER HEAD COVER 1189
CLEANING 1189
INSPECTION 1189
CYLINDER HEAD ASSEMBLY 1189
CLEANING 1189
INSPECTION 1189
PISTON AND CONNECTING ROD ASSEMBLY 1190
INSPECTION 1190
OIL PAN 1190
CLEANING 1190
INSPECTION 1190
OIL PUMP 1190
INSPECTION 1190
CYLINDER BLOCK 1192
CLEANING 1192
INSPECTION 1192
INTAKE MANIFOLD 1192
CLEANING 1192
INSPECTION 1192
EXHAUST MANIFOLD 1192
CLEANING 1192
INSPECTION 1192
SPECIFICATIONS 1193
5 9L ENGINE SPECIFICATIONS 1193
SPECIAL TOOLS 1197
5 9L ENGINE 1197
00AN_11 1201
EXHAUST SYSTEM 1201
DESCRIPTION AND OPERATION 1201
EXHAUST SYSTEM 1201
DESCRIPTION 1201
CATALYTIC CONVERTER 1201
DESCRIPTION 1201
OPERATION 1201
MUFFLER 1201
DESCRIPTION 1201
TAILPIPE 1201
DESCRIPTION 1201
OPERATION 1201
EXHAUST HEAT SHIELDS 1201
DESCRIPTION 1201
DIAGNOSIS AND TESTING 1203
EXHAUST SYSTEM DIAGNOSIS 1203
REMOVAL AND INSTALLATION 1203
EXHAUST PIPE 1203
REMOVAL 1203
INSTALLATION 1205
CATALYTIC CONVERTER 1205
REMOVAL 1205
INSTALLATION 1205
EXTENSION PIPE 1206
REMOVAL 1206
INSTALLATION 1206
MUFFLER 1206
REMOVAL 1206
INSTALLATION 1206
TAILPIPE 1207
REMOVAL 1207
INSTALLATION 1207
HEAT SHIELDS 1207
REMOVAL 1207
INSTALLATION 1207
CLEANING AND INSPECTION 1210
EXHAUST PIPE 1210
CLEANING 1210
INSPECTION 1210
CATALYTIC CONVERTER 1210
CLEANING 1210
INSPECTION 1210
SPECIFICATIONS 1210
TORQUE SPECIFICATIONS 1210
00AN_13 1211
FRAME AND BUMPERS 1211
BUMPERS 1211
DESCRIPTION AND OPERATION 1211
BUMPERS 1211
DESCRIPTION 1211
OPERATION 1211
REMOVAL AND INSTALLATION 1211
FRONT BUMPER 1211
REMOVAL 1211
INSTALLATION 1211
FRONT BUMPER FASCIA 1211
REMOVAL 1211
INSTALLATION 1212
REAR BUMPER 1212
REMOVAL 1212
INSTALLATION 1212
VALANCE PANEL 1213
REMOVAL 1213
INSTALLATION 1213
FRAME 1214
DESCRIPTION AND OPERATION 1214
FRAME 1214
DESCRIPTION 1214
OPERATION 1217
SERVICE PROCEDURES 1217
FRAME SERVICE 1217
SAFETY PRECAUTIONS AND WARNINGS 1217
FRAME STRAIGHTENING 1218
FRAME REPAIRS 1218
FRAME FASTENERS 1218
REMOVAL AND INSTALLATION 1218
FRONT AXLE SKID PLATE 1218
REMOVAL 1218
INSTALLATION 1219
TRANSFER CASE SKID PLATE 1219
REMOVAL 1219
INSTALLATION 1219
FUEL TANK SKID PLATE-4WD VEHICLES 1219
REMOVAL 1219
INSTALLATION 1219
SPARE TIRE WINCH 1220
REMOVAL 1220
INSTALLATION 1220
TRAILER HITCH 1220
REMOVAL 1220
INSTALLATION 1220
SPECIFICATIONS 1221
FRAME DIMENSIONS 1221
4X4 FRAME TOP VIEW 1222
4X4 FRAME SIDE VIEW 1223
4X2 FRAME TOP VIEW 1224
4X2 FRAME SIDE VIEW 1225
TORQUE SPECIFICATIONS 1226
00AN_14 1227
FUEL SYSTEM 1227
FUEL DELIVERY SYSTEM 1227
DESCRIPTION AND OPERATION 1227
PCM VIN REPROGRAMMING 1227
OPERATION 1227
FUEL DELIVERY SYSTEM 1227
DESCRIPTION 1227
OPERATION 1228
FUEL PUMP MODULE 1228
DESCRIPTION 1228
OPERATION 1228
FUEL PUMP 1228
DESCRIPTION 1228
OPERATION 1228
FUEL GAUGE SENDING UNIT 1229
DESCRIPTION 1229
OPERATION 1229
FUEL FILTER/FUEL PRESSURE REGULATOR 1230
DESCRIPTION 1230
OPERATION 1230
FUEL TANK 1230
DESCRIPTION 1230
OPERATION 1230
FUEL INJECTORS 1230
DESCRIPTION 1230
OPERATION 1230
FUEL RAIL-3 9/5 2/5 9L ENGINES 1231
DESCRIPTION 1231
OPERATION 1231
FUEL INJECTOR RAIL-4 7L ENGINE 1231
DESCRIPTION 1231
OPERATION 1231
FUEL INJECTOR RAIL/FUEL DAMPER-2 5L ENGINE 1232
DESCRIPTION 1232
OPERATION 1232
FUEL TANK FILLER TUBE CAP 1233
DESCRIPTION 1233
OPERATION 1233
FUEL TUBES/LINES/HOSES AND CLAMPS 1233
DESCRIPTION 1233
QUICK-CONNECT FITTINGS 1233
DESCRIPTION 1233
DIAGNOSIS AND TESTING 1233
FUEL PUMP PRESSURE TEST 1233
FUEL PUMP CAPACITY TEST 1234
FUEL PRESSURE LEAK DOWN TEST 1234
FUEL PUMP AMPERAGE TEST 1235
FUEL GAUGE SENDING UNIT 1236
FUEL INJECTOR TEST 1237
SERVICE PROCEDURES 1237
FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1237
QUICK-CONNECT FITTINGS 1237
DISCONNECTING 1238
CONNECTING 1240
REMOVAL AND INSTALLATION 1240
FUEL PUMP MODULE 1240
REMOVAL 1240
INSTALLATION 1241
FUEL PUMP INLET FILTER 1242
REMOVAL 1242
INSTALLATION 1242
FUEL GAUGE SENDING UNIT 1242
REMOVAL 1243
INSTALLATION 1243
FUEL INJECTOR RAIL-3 9/5 2/5 9L ENGINES 1244
REMOVAL 1244
INSTALLATION 1245
FUEL INJECTOR RAIL/FUEL DAMPER-2 5L ENGINE 1245
REMOVAL 1245
INSTALLATION 1246
FUEL INJECTOR RAIL-4 7L V-8 ENGINE 1246
REMOVAL 1247
INSTALLATION 1247
FUEL INJECTOR(S) 1248
REMOVAL 1248
INSTALLATION 1248
FUEL TANK 1248
REMOVAL 1248
INSTALLATION 1249
FUEL TANK FILLER TUBE CAP 1250
REMOVAL/INSTALLATION 1250
ACCELERATOR PEDAL 1250
REMOVAL 1250
INSTALLATION 1251
THROTTLE CABLE 1251
REMOVAL 1251
INSTALLATION 1252
THROTTLE CABLE-4 7L V-8 ENGINE 1253
REMOVAL 1253
INSTALLATION 1253
SPECIFICATIONS 1253
FUEL TANK CAPACITY 1253
FUEL SYSTEM PRESSURE 1253
FUEL REQUIREMENTS 1253
REFORMULATED GASOLINE 1254
GASOLINE/OXYGENATE BLENDS 1254
MMT IN GASOLINE 1254
SULFUR IN GASOLINE 1254
MATERIALS ADDED TO FUEL 1255
FUEL SYSTEM CAUTIONS 1255
TORQUE CHART 1255
FUEL INJECTION SYSTEM 1256
DESCRIPTION AND OPERATION 1257
POWERTRAIN CONTROL MODULE (PCM) 1257
DESCRIPTION 1257
OPERATION 1257
MODES OF OPERATION 1258
OPERATION 1258
AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT 1260
DESCRIPTION 1260
OPERATION 1260
BATTERY VOLTAGE-PCM INPUT 1260
OPERATION 1260
BRAKE SWITCH-PCM INPUT 1260
OPERATION 1260
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT 1261
DESCRIPTION 1261
OPERATION 1261
FIVE VOLT SENSOR SUPPLIES-PRIMARY AND SECONDARY 1261
DESCRIPTION 1261
OPERATION 1261
FUEL LEVEL SENSOR-PCM INPUT 1261
DESCRIPTION 1261
OPERATION 1261
IGNITION CIRCUIT SENSE-PCM INPUT 1261
DESCRIPTION 1261
OPERATION 1261
INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT 1261
DESCRIPTION 1261
OPERATION 1262
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT 1262
DESCRIPTION 1262
OPERATION 1262
OIL PRESSURE SENSOR-PCM INPUT 1263
DESCRIPTION 1263
OPERATION 1263
OXYGEN SENSOR (O2S)-PCM INPUT 1263
DESCRIPTION 1263
OPERATION 1263
POWER GROUNDS 1264
OPERATION 1264
POWER STEERING PRESSURE SWITCH-PCM INPUT 1264
DESCRIPTION 1264
OPERATION 1265
SENSOR RETURN-PCM INPUT 1265
OPERATION 1265
SIGNAL GROUND-PCM INPUT 1265
OPERATION 1265
THROTTLE POSITION SENSOR (TPS)-PCM INPUT 1265
DESCRIPTION 1265
OPERATION 1265
VEHICLE SPEED AND DISTANCE-PCM INPUT 1266
OPERATION 1266
AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT 1266
DESCRIPTION 1266
OPERATION 1266
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS 1266
OPERATION 1266
DATA LINK CONNECTOR-PCM INPUT AND OUTPUT 1266
DESCRIPTION 1266
OPERATION 1266
FUEL INJECTORS-PCM OUTPUT 1266
DESCRIPTION 1266
OPERATION 1266
FUEL PUMP RELAY-PCM OUTPUT 1266
DESCRIPTION 1266
OPERATION 1266
IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT 1267
DESCRIPTION 1267
OPERATION 1267
OXYGEN SENSOR HEATER RELAYS-PCM OUTPUT 1267
DESCRIPTION 1267
OPERATION 1268
RADIATOR COOLING FAN RELAY-PCM OUTPUT 1268
DESCRIPTION 1268
OPERATION 1268
THROTTLE BODY 1268
DESCRIPTION 1268
OPERATION 1268
DIAGNOSIS AND TESTING 1268
VISUAL INSPECTION-3 9/5 2/5 9L ENGINES 1268
VISUAL INSPECTION-2 5L ENGINE 1272
ASD AND FUEL PUMP RELAYS 1275
OPERATION 1275
TESTING 1275
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE 1276
3 9/5 2/5 9L ENGINES 1276
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE 1277
REMOVAL AND INSTALLATION 1277
AUTOMATIC SHUTDOWN (ASD) RELAY 1277
REMOVAL 1277
INSTALLATION 1278
FUEL PUMP RELAY 1278
REMOVAL 1278
INSTALLATION 1278
OXYGEN SENSOR HEATER RELAYS 1278
REMOVAL 1278
INSTALLATION 1278
THROTTLE BODY-3 9/5 2/5 9L ENGINES 1278
REMOVAL 1278
INSTALLATION 1278
THROTTLE BODY-2 5L ENGINE 1279
REMOVAL 1279
INSTALLATION 1279
THROTTLE BODY-4 7L V-8 ENGINE 1279
REMOVAL 1279
INSTALLATION 1279
THROTTLE POSITION SENSOR (TPS)-3 9/5 2/5 9L ENGINES 1280
REMOVAL 1280
INSTALLATION 1280
THROTTLE POSITION SENSOR (TPS)-4 7L V-8 ENGINE 1280
REMOVAL 1280
INSTALLATION 1281
THROTTLE POSITION SENSOR-2 5L ENGINE 1281
REMOVAL 1281
INSTALLATION 1282
IDLE AIR CONTROL (IAC) MOTOR-3 9/5 2/5 9L ENGINES 1282
REMOVAL 1282
INSTALLATION 1282
IDLE AIR CONTROL (IAC) MOTOR-4 7L V-8 ENGINE 1282
REMOVAL 1282
INSTALLATION 1282
IDLE AIR CONTROL (IAC) MOTOR-2 5L ENGINE 1282
REMOVAL 1283
INSTALLATION 1283
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-3 9/5 2/5 9L ENGINES 1283
REMOVAL 1283
INSTALLATION 1283
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-4 7L V-8 ENGINE 1284
REMOVAL 1284
INSTALLATION 1284
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-2 5L ENGINE 1284
REMOVAL 1285
INSTALLATION 1285
POWERTRAIN CONTROL MODULE (PCM) 1285
REMOVAL 1285
INSTALLATION 1285
OXYGEN SENSOR-EXCEPT 2 5L ENGINE 1285
REMOVAL 1285
INSTALLATION 1286
OXYGEN SENSOR-2 5L ENGINE 1287
REMOVAL 1287
INSTALLATION 1287
AIR CLEANER ELEMENT (FILTER) 1288
REMOVAL 1288
INSTALLATION 1288
ENGINE COOLANT TEMPERATURE SENSOR-3 9/5 2/5 9L ENGINES 1288
REMOVAL 1288
INSTALLATION 1289
ENGINE COOLANT TEMPERATURE SENSOR-4 7L V-8 ENGINE 1289
REMOVAL 1289
INSTALLATION 1289
ENGINE COOLANT TEMPERATURE SENSOR-2 5L ENGINE 1289
REMOVAL 1289
INSTALLATION 1290
INTAKE MANIFOLD AIR TEMPERATURE SENSOR-3 9/5 2/5 9L ENGINES 1290
REMOVAL 1290
INSTALLATION 1290
INTAKE MANIFOLD AIR TEMPERATURE SENSOR-4 7L V-8 ENGINE 1290
REMOVAL 1290
INSTALLATION 1290
INTAKE MANIFOLD AIR TEMPERATURE SENSOR-2 5L ENGINE 1290
REMOVAL 1290
INSTALLATION 1290
POWER STEERING PRESSURE SWITCH 1291
REMOVAL 1291
INSTALLATION 1291
SPECIFICATIONS 1292
TORQUE CHART 1292
SPECIAL TOOLS 1292
FUEL SYSTEM 1292
00AN_19 1295
STEERING 1295
POWER STEERING 1295
DESCRIPTION AND OPERATION 1295
STEERING SYSTEM 1295
DESCRIPTION 1295
OPERATION 1295
DIAGNOSIS AND TESTING 1296
POWER STEERING SYSTEM 1296
POWER STEERING FLOW AND PRESSURE 1298
FLOW AND PRESSURE TEST 1298
POWER STEERING PUMP 1300
DESCRIPTION AND OPERATION 1300
POWER STEERING PUMP 1300
DESCRIPTION 1300
OPERATION 1300
DIAGNOSIS AND TESTING 1301
PUMP LEAKAGE 1301
SERVICE PROCEDURES 1301
POWER STEERING PUMP – INITIAL OPERATION 1301
REMOVAL AND INSTALLATION 1301
POWER STEERING PUMP – 2 5L 1301
REMOVAL 1301
INSTALLATION 1302
PUMP RESERVOIR – 2 5L ENGINE 1302
REMOVAL 1302
INSTALLATION 1302
POWER STEERING PUMP – 3 9L & 5 9L ENGINES 1302
REMOVAL 1302
INSTALLATION 1303
POWER STEERING PUMP – 4 7L 1303
REMOVAL 1303
INSTALLATION 1303
DISASSEMBLY AND ASSEMBLY 1303
PUMP PULLEY 1303
DISASSEMBLY 1303
ASSEMBLY 1303
SPECIFICATIONS 1304
TORQUE CHART 1304
SPECIAL TOOLS 1304
POWER STEERING PUMP 1304
RACK & PINION STEERING GEAR 1305
DESCRIPTION AND OPERATION 1305
RACK & PINION STEERING GEAR 1305
DESCRIPTION 1305
OPERATION 1305
REMOVAL AND INSTALLATION 1305
TIE ROD END 1305
REMOVAL 1305
INSTALLATION 1305
RACK & PINION STEERING GEAR – 4×2 1306
REMOVAL 1306
INSTALLATION 1306
RACK & PINION STEERING GEAR – 4×4 1307
REMOVAL 1307
INSTALLATION 1307
DISASSEMBLY AND ASSEMBLY 1308
BOOT SEAL 1308
REMOVAL 1308
INSTALLATION 1308
SPECIFICATIONS 1308
TORQUE CHART 1308
SPECIAL TOOLS 1308
RACK & PINION STEERING GEAR 1308
STEERING COLUMN 1309
DESCRIPTION AND OPERATION 1309
STEERING COLUMN 1309
SERVICE PRECAUTIONS 1309
DIAGNOSIS AND TESTING 1310
IGNITION SWITCH 1310
TEST AND REPAIR 1310
REMOVAL AND INSTALLATION 1310
STEERING COLUMN 1310
REMOVAL 1310
INSTALLATION 1312
GEAR SHIFT LEVER 1312
REMOVAL 1312
INSTALLATION 1312
SPECIFICATIONS 1313
TORQUE CHART 1313
00AN_21 1315
TRANSMISSION AND TRANSFER CASE 1315
NV1500 MANUAL TRANSMISSION 1315
DESCRIPTION AND OPERATION 1315
NV1500 MANUAL TRANSMISSION 1315
DESCRIPTION 1315
OPERATION 1316
LUBRICANT 1317
DESCRIPTION 1317
DIAGNOSIS AND TESTING 1317
LOW LUBRICANT LEVEL 1317
HARD SHIFTING 1318
TRANSMISSION NOISE 1318
REMOVAL AND INSTALLATION 1318
TRANSMISSION 1318
REMOVAL 1318
INSTALLATION 1319
SHIFT TOWER 1319
REMOVAL 1319
INSTALLATION 1319
OUTPUT SHAFT SEAL 1320
REMOVAL 1320
INSTALLATION 1320
OUTPUT SHAFT BUSHING 1320
REMOVAL 1320
INSTALLATION 1320
DISASSEMBLY AND ASSEMBLY 1321
TRANSMISSION 1321
DISASSEMBLY 1321
ASSEMBLY 1328
CLEANING AND INSPECTION 1346
TRANSMISSION COMPONENTS 1346
SHIFT LEVER ASSEMBLY 1346
SHIFT SHAFT AND FORKS 1346
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1346
COUNTERSHAFT BEARINGS AND RACES 1346
REVERSE IDLER COMPONENTS 1347
SHIFT SOCKET 1347
OUTPUT SHAFT AND GEARTRAIN 1347
SPECIFICATIONS 1348
TORQUE 1348
SPECIAL TOOLS 1348
NV1500 MANUAL TRANSMISSION 1348
NV3500 MANUAL TRANSMISSION 1350
DESCRIPTION AND OPERATION 1350
NV3500 MANUAL TRANSMISSION 1350
DESCRIPTION 1350
OPERATION 1352
LUBRICANT 1353
DESCRIPTION 1353
DIAGNOSIS AND TESTING 1353
LOW LUBRICANT LEVEL 1353
HARD SHIFTING 1353
TRANSMISSION NOISE 1354
REMOVAL AND INSTALLATION 1354
TRANSMISSION-2WD 1354
REMOVAL 1354
INSTALLATION 1354
TRANSMISSION-4WD 1355
REMOVAL 1355
INSTALLATION 1355
SHIFT TOWER 1356
REMOVAL 1356
INSTALLATION 1356
YOKE SEAL-2WD 1357
REMOVAL 1357
INSTALLATION 1357
REAR HOUSING YOKE BUSHING 1357
REMOVAL 1357
INSTALLATION 1357
DISASSEMBLY AND ASSEMBLY 1358
TRANSMISSION 1358
FRONT HOUSING REMOVAL 1358
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT REMOVAL 1360
REAR HOUSING REMOVAL-2WD 1363
REAR ADAPTER HOUSING REMOVAL-4WD 1364
GEARTRAIN DISASSEMBLY FROM FIXTURE 1364
OUTPUT SHAFT DISASSEMBLY 1365
REVERSE IDLER DISASSEMBLY 1368
ASSEMBLY 1368
OUTPUT SHAFT ASSEMBLY 1369
REVERSE IDLER ASSEMBLY 1377
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS 1378
GEARTRAIN ASSEMBLY IN FIXTURE 1379
REAR HOUSING INSTALLATION-2WD 1382
ADAPTER HOUSING INSTALLATION-4WD 1384
REVERSE IDLER SEGMENT INSTALLATION 1385
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET INSTALLATION 1385
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER INSTALLATION 1388
SHIFT TOWER AND LEVER ASSEMBLY INSTALLATION 1392
CLEANING AND INSPECTION 1392
TRANSMISSION COMPONENTS 1392
SHIFT TOWER AND LEVER ASSEMBLY 1393
SHIFT SHAFT AND FORKS 1393
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1393
COUNTERSHAFT BEARINGS AND RACES 1394
REVERSE IDLER COMPONENTS 1394
Shift Socket 1394
Output Shaft And Geartrain 1394
SPECIFICATIONS 1395
TORQUE 1395
SPECIAL TOOLS 1395
NV3500 MANUAL TRANSMISSION 1395
42RE AUTOMATIC TRANSMISSION 1398
DESCRIPTION AND OPERATION 1399
42RE AUTOMATIC TRANSMISSION 1399
DESCRIPTION 1399
OPERATION 1401
FLUID 1406
DESCRIPTION 1407
OPERATION 1407
TORQUE CONVERTER 1407
DESCRIPTION 1407
OPERATION 1410
OIL PUMP 1411
DESCRIPTION 1411
OPERATION 1411
VALVE BODY 1412
DESCRIPTION 1412
OPERATION 1416
ACCUMULATOR 1431
DESCRIPTION 1431
OPERATION 1431
PISTONS 1431
DESCRIPTION 1431
OPERATION 1432
FRONT CLUTCH 1433
DESCRIPTION 1433
OPERATION 1434
REAR CLUTCH 1434
DESCRIPTION 1434
OPERATION 1435
OVERDRIVE CLUTCH 1436
DESCRIPTION 1436
OPERATION 1436
OVERRUNNING CLUTCH 1436
DESCRIPTION 1436
OPERATION 1436
PLANETARY GEARSET 1437
DESCRIPTION 1437
OPERATION 1437
BANDS 1437
DESCRIPTION 1437
OPERATION 1437
SERVOS 1438
DESCRIPTION 1438
OPERATION 1438
GEARSHIFT MECHANISM 1439
DESCRIPTION 1439
OPERATION 1439
CONVERTER DRAINBACK VALVE 1439
DESCRIPTION 1439
OPERATION 1439
POWERTRAIN CONTROL MODULE (PCM) 1439
DESCRIPTION 1439
OPERATION 1439
ELECTRONIC GOVERNOR 1440
DESCRIPTION 1440
OPERATION 1441
GOVERNOR PRESSURE CURVES 1442
DESCRIPTION 1442
OPERATION 1442
OVERDRIVE OFF SWITCH 1443
DESCRIPTION 1443
OPERATION 1443
DIAGNOSIS AND TESTING 1443
AUTOMATIC TRANSMISSION DIAGNOSIS 1443
EFFECTS OF INCORRECT FLUID LEVEL 1443
CAUSES OF BURNT FLUID 1443
FLUID CONTAMINATION 1443
PRELIMINARY DIAGNOSIS 1444
VEHICLE IS DRIVEABLE 1444
VEHICLE IS DISABLED 1444
PARK/NEUTRAL POSITION SWITCH 1444
SWITCH TEST 1444
OVERDRIVE ELECTRICAL CONTROLS 1444
GEARSHIFT CABLE 1444
ROAD TESTING 1445
ANALYZING ROAD TEST 1445
HYDRAULIC PRESSURE TEST 1446
Pressure Test Port Locations 1446
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION 1448
Front Clutch Air Test 1448
Rear Clutch Air Test 1448
Front Servo Apply Air Test 1448
Rear Servo Air Test 1449
CONVERTER HOUSING FLUID LEAK DIAGNOSIS 1449
TORQUE CONVERTER LEAK POINTS 1449
CONVERTER HOUSING AREA LEAK CORRECTION 1449
DIAGNOSIS TABLES AND CHARTS-RE TRANSMISSION 1450
SERVICE PROCEDURES 1461
FLUID LEVEL CHECK 1461
FLUID LEVEL CHECK PROCEDURE 1461
FLUID AND FILTER REPLACEMENT 1461
REMOVAL 1461
INSPECTION 1461
CLEANING 1462
INSTALLATION 1462
TRANSMISSION FILL PROCEDURE 1462
CONVERTER DRAINBACK CHECK VALVE SERVICE 1462
OIL PUMP VOLUME CHECK 1463
FLUSHING COOLERS AND TUBES 1463
COOLER FLUSH USING TOOL 6906A 1463
ALUMINUM THREAD REPAIR 1464
REMOVAL AND INSTALLATION 1464
TRANSMISSION 1464
REMOVAL 1464
INSTALLATION 1465
TORQUE CONVERTER 1466
REMOVAL 1466
INSTALLATION 1466
YOKE SEAL REPLACEMENT 1466
REMOVAL 1466
INSTALLATION 1466
PARK/NEUTRAL POSITION SWITCH 1467
REMOVAL 1467
INSTALLATION 1467
GEARSHIFT CABLE 1467
REMOVAL 1467
INSTALLATION 1468
GOVERNOR SOLENOID AND PRESSURE SENSOR 1468
REMOVAL 1468
INSTALLATION 1468
VALVE BODY 1469
REMOVAL 1470
INSTALLATION 1470
OVERDRIVE UNIT 1471
REMOVAL 1471
INSTALLATION 1472
OVERDRIVE HOUSING BUSHING 1473
REMOVAL 1473
INSTALLATION 1473
OUTPUT SHAFT REAR BEARING 1473
REMOVAL 1473
INSTALLATION 1473
OUTPUT SHAFT FRONT BEARING 1473
REMOVAL 1473
INSTALLATION 1474
DISASSEMBLY AND ASSEMBLY 1474
VALVE BODY 1474
DISASSEMBLY 1474
ASSEMBLY 1481
TRANSMISSION 1492
DISASSEMBLY 1492
ASSEMBLY 1497
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER 1503
DISASSEMBLY 1503
ASSEMBLY 1503
FRONT SERVO PISTON 1505
DISASSEMBLY 1505
ASSEMBLY 1505
REAR SERVO PISTON 1506
DISASSEMBLY 1506
ASSEMBLY 1506
OIL PUMP AND REACTION SHAFT SUPPORT 1506
DISASSEMBLY 1506
ASSEMBLY 1508
FRONT CLUTCH 1509
DISASSEMBLY 1510
ASSEMBLY 1510
REAR CLUTCH 1511
DISASSEMBLY 1511
ASSEMBLY 1513
PLANETARY GEARTRAIN/OUTPUT SHAFT 1514
DISASSEMBLY 1514
ASSEMBLY 1515
OVERDRIVE UNIT 1520
DISASSEMBLY 1520
ASSEMBLY 1527
CLEANING AND INSPECTION 1536
VALVE BODY 1536
TRANSMISSION 1537
GENERAL INFORMATION 1537
TRANSMISSION CASE CLEANING AND INSPECTION 1537
OVERRUNNING CLUTCH/LOW-REVERSE DRUM/OVERDRIVE PISTON RETAINER 1537
ACCUMULATOR 1537
FRONT SERVO 1538
REAR SERVO 1538
OIL PUMP AND REACTION SHAFT SUPPORT 1538
FRONT CLUTCH 1539
REAR CLUTCH 1539
PLANETARY GEARTRAIN 1539
OVERDRIVE UNIT 1540
ADJUSTMENTS 1540
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT 1540
THROTTLE VALVE CABLE ADJUSTMENT CHECK 1541
GEARSHIFT CABLE 1541
Gearshift Adjustment Procedure 1541
BAND ADJUSTMENTS 1542
FRONT BAND ADJUSTMENT 1542
REAR BAND ADJUSTMENT 1542
VALVE BODY 1543
CONTROL PRESSURE ADJUSTMENTS 1543
SCHEMATICS AND DIAGRAMS 1543
HYDRAULIC SCHEMATICS 1543
SPECIFICATIONS 1556
TRANSMISSION 1556
GENERAL 1556
GEAR RATIOS 1556
TORQUE 1556
THRUST WASHER/SPACER/SNAP RING DIMENSIONS 1557
PRESSURE TEST 1557
SPECIAL TOOLS 1557
RE TRANSMISSIONS 1557
46RE AUTOMATIC TRANSMISSION 1561
DESCRIPTION AND OPERATION 1562
46RE TRANSMISSION 1562
DESCRIPTION 1562
OPERATION 1564
FLUID 1569
DESCRIPTION 1570
OPERATION 1570
TORQUE CONVERTER 1570
DESCRIPTION 1570
OPERATION 1573
OIL PUMP 1575
DESCRIPTION 1575
OPERATION 1575
VALVE BODY 1575
DESCRIPTION 1575
OPERATION 1578
ACCUMULATOR 1592
DESCRIPTION 1592
OPERATION 1593
PISTONS 1594
DESCRIPTION 1594
OPERATION 1594
FRONT CLUTCH 1595
DESCRIPTION 1595
OPERATION 1596
REAR CLUTCH 1596
DESCRIPTION 1596
OPERATION 1597
OVERDRIVE CLUTCH 1598
DESCRIPTION 1598
OPERATION 1598
OVERRUNNING CLUTCH 1598
DESCRIPTION 1598
OPERATION 1598
PLANETARY GEARSET 1599
DESCRIPTION 1599
OPERATION 1599
BANDS 1599
DESCRIPTION 1599
OPERATION 1600
SERVOS 1600
DESCRIPTION 1600
OPERATION 1600
GEARSHIFT MECHANISM 1601
DESCRIPTION 1601
OPERATION 1601
CONVERTER DRAINBACK VALVE 1601
DESCRIPTION 1601
OPERATION 1601
POWERTRAIN CONTROL MODULE (PCM) 1601
DESCRIPTION 1601
OPERATION 1601
ELECTRONIC GOVERNOR 1602
DESCRIPTION 1602
OPERATION 1603
GOVERNOR PRESSURE CURVES 1604
DESCRIPTION 1604
OPERATION 1604
OVERDRIVE OFF SWITCH 1605
DESCRIPTION 1605
OPERATION 1605
DIAGNOSIS AND TESTING 1605
AUTOMATIC TRANSMISSION DIAGNOSIS 1605
EFFECTS OF INCORRECT FLUID LEVEL 1605
CAUSES OF BURNT FLUID 1605
FLUID CONTAMINATION 1605
PRELIMINARY DIAGNOSIS 1606
VEHICLE IS DRIVEABLE 1606
VEHICLE IS DISABLED 1606
PARK/NEUTRAL POSITION SWITCH 1606
SWITCH TEST 1606
OVERDRIVE ELECTRICAL CONTROLS 1606
GEARSHIFT CABLE 1606
ROAD TESTING 1607
ANALYZING ROAD TEST 1607
HYDRAULIC PRESSURE TEST 1608
Pressure Test Port Locations 1608
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION 1610
Front Clutch Air Test 1610
Rear Clutch Air Test 1610
Front Servo Air Test 1611
Rear Servo Air Test 1611
CONVERTER HOUSING FLUID LEAK DIAGNOSIS 1611
TORQUE CONVERTER LEAK POINTS 1611
CONVERTER HOUSING AREA LEAK CORRECTION 1611
DIAGNOSIS TABLES AND CHARTS-RE TRANSMISSION 1612
SERVICE PROCEDURES 1623
FLUID LEVEL CHECK 1623
FLUID LEVEL CHECK PROCEDURE 1623
FLUID AND FILTER REPLACEMENT 1623
REMOVAL 1623
INSPECTION 1623
CLEANING 1624
INSTALLATION 1624
TRANSMISSION FILL PROCEDURE 1624
CONVERTER DRAINBACK CHECK VALVE SERVICE 1624
OIL PUMP VOLUME CHECK 1625
FLUSHING COOLERS AND TUBES 1625
COOLER FLUSH USING TOOL 6906A 1625
ALUMINUM THREAD REPAIR 1626
REMOVAL AND INSTALLATION 1626
TRANSMISSION 1626
REMOVAL 1626
INSTALLATION 1627
TORQUE CONVERTER 1628
REMOVAL 1628
INSTALLATION 1628
YOKE SEAL REPLACEMENT 1629
REMOVAL 1629
INSTALLATION 1629
PARK/NEUTRAL POSITION SWITCH 1629
REMOVAL 1629
INSTALLATION 1629
GEARSHIFT CABLE 1630
REMOVAL 1630
INSTALLATION 1630
GOVERNOR SOLENOID AND PRESSURE SENSOR 1631
REMOVAL 1631
INSTALLATION 1631
VALVE BODY 1631
REMOVAL 1632
INSTALLATION 1632
OVERDRIVE UNIT 1633
REMOVAL 1633
INSTALLATION 1634
OVERDRIVE HOUSING BUSHING 1635
REMOVAL 1635
INSTALLATION 1635
OUTPUT SHAFT REAR BEARING 1635
REMOVAL 1635
INSTALLATION 1635
OUTPUT SHAFT FRONT BEARING 1636
REMOVAL 1636
INSTALLATION 1636
DISASSEMBLY AND ASSEMBLY 1636
VALVE BODY 1636
DISASSEMBLY 1636
ASSEMBLY 1647
TRANSMISSION 1655
DISASSEMBLY 1655
ASSEMBLY 1661
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER 1669
DISASSEMBLY 1669
ASSEMBLY 1669
FRONT SERVO PISTON 1671
DISASSEMBLY 1671
ASSEMBLY 1672
REAR SERVO PISTON 1672
DISASSEMBLY 1672
ASSEMBLY 1672
OIL PUMP AND REACTION SHAFT SUPPORT 1672
DISASSEMBLY 1672
ASSEMBLY 1673
FRONT CLUTCH 1676
DISASSEMBLY 1676
ASSEMBLY 1676
REAR CLUTCH 1678
DISASSEMBLY 1678
ASSEMBLY 1679
PLANETARY GEARTRAIN/OUTPUT SHAFT 1682
DISASSEMBLY 1682
ASSEMBLY 1684
OVERDRIVE UNIT 1686
DISASSEMBLY 1686
ASSEMBLY 1693
CLEANING AND INSPECTION 1702
VALVE BODY 1702
TRANSMISSION 1705
GENERAL INFORMATION 1705
TRANSMISSION CASE CLEANING AND INSPECTION 1705
OVERRUNNING CLUTCH/LOW-REVERSE DRUM/OVERDRIVE PISTON RETAINER 1705
ACCUMULATOR 1706
FRONT SERVO 1706
REAR SERVO 1706
OIL PUMP AND REACTION SHAFT SUPPORT 1706
FRONT CLUTCH 1707
REAR CLUTCH 1707
PLANETARY GEARTRAIN/OUTPUT SHAFT 1707
OVERDRIVE UNIT 1708
ADJUSTMENTS 1708
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT 1708
THROTTLE VALVE CABLE ADJUSTMENT CHECK 1709
GEARSHIFT CABLE 1709
Gearshift Adjustment Procedure 1710
FRONT BAND ADJUSTMENT 1710
REAR BAND ADJUSTMENT 1710
VALVE BODY 1710
CONTROL PRESSURE ADJUSTMENTS 1710
SCHEMATICS AND DIAGRAMS 1711
HYDRAULIC SCHEMATICS 1711
SPECIFICATIONS0 – 2 AN (Continued) 1724
RE TRANSMISSION 1724
GENERAL 1724
TORQUE 1724
THRUST WASHER/SPACER/SNAP RING DIMENSIONS 1725
PRESSURE TEST 1725
SPECIAL TOOLS 1726
RE TRANSMISSION 1726
45RFE AUTOMATIC TRANSMISSION 1730
DESCRIPTION AND OPERATION 1731
45RFE AUTOMATIC TRANSMISSION 1731
DESCRIPTION 1731
OPERATION 1731
FLUID 1732
DESCRIPTION 1732
OPERATION 1732
TORQUE CONVERTER 1732
DESCRIPTION 1732
OPERATION 1735
ELECTRONICALLY MODULATED CONVERTER CLUTCH ENGAGEMENT 1737
DESCRIPTION 1737
OPERATION 1737
OIL PUMP 1737
DESCRIPTION 1737
OPERATION 1737
VALVE BODY 1738
DESCRIPTION 1738
OPERATION 1738
PISTONS 1741
DESCRIPTION 1741
OPERATION 1741
INPUT CLUTCHES 1742
DESCRIPTION 1742
OPERATION 1742
HOLDING CLUTCHES 1745
DESCRIPTION 1745
OPERATION 1745
PLANETARY GEARTRAIN 1747
DESCRIPTION 1747
OPERATION 1747
GEARSHIFT MECHANISM 1749
DESCRIPTION 1749
OPERATION 1749
OVERDRIVE OFF SWITCH 1749
DESCRIPTION 1749
OPERATION 1749
TRANSMISSION CONTROL MODULE 1749
DESCRIPTION 1749
OPERATION 1749
CLUTCH VOLUME INDEXES 1750
SHIFT SCHEDULES 1751
SOLENOID AND PRESSURE SWITCH ASSEMBLY 1752
DESCRIPTION 1752
OPERATION 1752
BATTERY FEED (TCM) 1752
DESCRIPTION 1752
OPERATION 1752
TRANSMISSION CONTROL RELAY 1752
DESCRIPTION 1752
OPERATION 1752
PRESSURE SWITCHES 1752
DESCRIPTION 1752
OPERATION 1752
INPUT AND OUTPUT SPEED SENSORS 1753
DESCRIPTION 1753
OPERATION 1753
LINE PRESSURE CONTROL 1753
DESCRIPTION 1753
OPERATION 1753
THROTTLE POSITION SENSOR 1753
OPERATION 1753
TRANSMISSION RANGE SENSOR 1753
DESCRIPTION 1753
OPERATION 1753
TRANSMISSION TEMPERATURE SENSOR 1754
DESCRIPTION 1754
OPERATION 1754
SOLENOIDS 1754
DESCRIPTION 1754
OPERATION 1754
SOLENOID SWITCH VALVE 1754
DESCRIPTION 1754
OPERATION 1754
DIAGNOSIS AND TESTING 1754
EFFECTS OF INCORRECT FLUID LEVEL 1754
CAUSES OF BURNT FLUID 1755
FLUID CONTAMINATION 1755
45RFE AUTOMATIC TRANSMISSION GENERAL DIAGNOSIS 1755
PRELIMINARY DIAGNOSIS 1755
VEHICLE IS DRIVABLE 1755
VEHICLE IS DISABLED 1756
GEARSHIFT CABLE 1756
ROAD TESTING 1756
HYDRAULIC PRESSURE TEST 1757
Pressure Test Port Locations 1757
TEST PROCEDURE 1757
AIR TESTING TRANSMISSION CLUTCH OPERATION 1758
CONVERTER HOUSING FLUID LEAK DIAGNOSIS 1758
TORQUE CONVERTER LEAK POINTS 1758
SERVICE PROCEDURES 1759
FLUID LEVEL CHECK 1759
FLUID LEVEL CHECK PROCEDURE 1759
FLUID AND FILTER REPLACEMENT 1759
REMOVAL 1759
INSPECTION 1759
CLEANING 1760
INSTALLATION 1760
TRANSMISSION FILL PROCEDURE 1760
OIL PUMP VOLUME CHECK 1761
FLUSHING COOLERS AND TUBES 1761
COOLER FLUSH USING TOOL 6906A 1761
TRANSMISSION QUICK LEARN PROCEDURE 1761
ALUMINUM THREAD REPAIR 1762
REMOVAL AND INSTALLATION 1762
INPUT SPEED SENSOR 1762
REMOVAL 1762
INSTALLATION 1762
OUTPUT SPEED SENSOR 1762
REMOVAL 1762
INSTALLATION 1762
LINE PRESSURE SENSOR 1763
REMOVAL 1763
INSTALLATION 1763
VALVE BODY 1763
REMOVAL 1763
INSTALLATION 1764
SOLENOID AND PRESSURE SWITCH ASSEMBLY 1764
REMOVAL 1764
INSTALLATION 1764
TRANSMISSION 1764
REMOVAL 1764
INSTALLATION 1766
TORQUE CONVERTER 1767
REMOVAL 1767
INSTALLATION 1767
OIL PUMP FRONT SEAL 1767
REMOVAL 1767
INSTALLATION 1767
ADAPTER HOUSING SEAL 1767
REMOVAL 1767
INSTALLATION 1767
GEARSHIFT CABLE 1768
REMOVAL 1768
INSTALLATION 1768
DISASSEMBLY AND ASSEMBLY 1769
TRANSMISSION 1769
DISASSEMBLY 1769
ASSEMBLY 1773
VALVE BODY 1778
DISASSEMBLY 1778
ASSEMBLY 1780
OIL PUMP 1781
DISASSEMBLY 1781
ASSEMBLY 1783
INPUT CLUTCH ASSEMBLY 1784
DISASSEMBLY 1784
ASSEMBLY 1785
4C RETAINER/BULKHEAD 1788
DISASSEMBLY 1788
ASSEMBLY 1789
PLANETARY GEAR SET 1790
DISASSEMBLY 1790
ASSEMBLY 1790
LOW/REVERSE CLUTCH 1792
DISASSEMBLY 1792
ASSEMBLY 1792
CLEANING AND INSPECTION 1793
VALVE BODY 1793
TRANSMISSION 1794
GENERAL INFORMATION 1794
TRANSMISSION CASE CLEANING AND INSPECTION 1795
LOW/REVERSE CLUTCH ASSEMBLY 1795
ACCUMULATOR 1795
OIL PUMP AND REACTION SHAFT SUPPORT 1795
PLANETARY GEARTRAIN 1795
ADJUSTMENTS 1796
GEARSHIFT CABLE 1796
Gearshift Adjustment Procedure 1796
SCHEMATICS AND DIAGRAMS 1796
HYDRAULIC SCHEMATICS 1796
SPECIFICATIONS 1816
TRANSMISSION 1816
GENERAL 1816
GEAR RATIOS 1816
TORQUE 1816
SPECIAL TOOLS 1816
45RFE TRANSMISSION 1816
NV231 TRANSFER CASE 1820
DESCRIPTION AND OPERATION 1820
NV231 TRANSFER CASE 1820
DESCRIPTION 1820
OPERATION 1820
LUBRICANT AND FILL LEVEL 1821
DESCRIPTION 1821
DIAGNOSIS AND TESTING 1821
NV231 DIAGNOSIS 1821
REMOVAL AND INSTALLATION 1822
TRANSFER CASE 1822
REMOVAL 1822
INSTALLATION 1822
TRANSFER CASE SHIFTER 1823
REMOVAL 1823
INSTALLATION 1823
FRONT OUTPUT SHAFT SEAL 1823
REMOVAL 1823
INSTALLATION 1823
REAR RETAINER BUSHING AND SEAL 1823
REMOVAL 1823
INSTALLATION 1824
DISASSEMBLY AND ASSEMBLY 1825
NV231 TRANSFER CASE 1825
DISASSEMBLY 1825
ASSEMBLY 1831
CLEANING AND INSPECTION 1841
NV231 TRANSFER CASE 1841
MAINSHAFT/SPROCKET/HUB INSPECTION 1841
INPUT GEAR AND PLANETARY CARRIER 1841
SHIFT FORKS/HUBS/SLEEVES 1843
REAR RETAINER AND EXTENSION HOUSING 1843
FRONT OUTPUT SHAFT/YOKE/DRIVE CHAIN 1843
LOW RANGE ANNULUS GEAR 1844
FRONT-REAR CASES AND FRONT RETAINER 1844
OIL PUMP/OIL PICKUP 1844
ADJUSTMENTS 1844
SHIFTER ADJUSTMENT 1844
SPECIFICATIONS 1845
TORQUE 1845
SPECIAL TOOLS 1845
NV231 1845
NV242 TRANSFER CASE 1847
DESCRIPTION AND OPERATION 1847
NV242 TRANSFER CASE 1847
DESCRIPTION 1847
LUBRICANT AND FILL LEVEL 1848
DESCRIPTION 1848
DIAGNOSIS AND TESTING 1848
NV242 DIAGNOSIS 1848
REMOVAL AND INSTALLATION 1849
TRANSFER CASE 1849
REMOVAL 1849
INSTALLATION 1849
TRANSFER CASE SHIFTER 1849
REMOVAL 1849
INSTALLATION 1850
FRONT OUTPUT SHAFT SEAL 1850
REMOVAL 1850
INSTALLATION 1850
REAR RETAINER BUSHING AND SEAL 1850
REMOVAL 1850
INSTALLATION 1850
DISASSEMBLY AND ASSEMBLY 1852
NV242 TRANSFER CASE 1852
DISASSEMBLY 1852
ASSEMBLY 1860
CLEANING AND INSPECTION 1872
NV242 TRANSFER CASE 1872
MAINSHAFT/SPROCKET/HUB INSPECTION 1872
INPUT GEAR AND PLANETARY CARRIER 1872
SHIFT FORKS/HUBS/SLEEVES 1873
REAR RETAINER AND EXTENSION HOUSING 1873
FRONT OUTPUT SHAFT/YOKE/DRIVE CHAIN 1873
LOW RANGE ANNULUS GEAR 1874
FRONT-REAR CASES AND FRONT RETAINER 1874
OIL PUMP/OIL PICKUP 1874
ADJUSTMENTS 1874
SHIFTER ADJUSTMENT 1874
SPECIFICATIONS 1875
TORQUE 1875
SPECIAL TOOLS 1875
NV242 1875
00AN_22 1879
TIRES AND WHEELS 1879
TIRES 1879
DESCRIPTION AND OPERATION 1879
TIRES 1879
DESCRIPTION 1879
RADIAL-PLY TIRES 1880
DESCRIPTION 1880
SPARE TIRE-TEMPORARY 1880
DESCRIPTION 1880
TIRE INFLATION PRESSURES 1880
DESCRIPTION 1880
TIRE PRESSURE FOR HIGH SPEED 1881
DESCRIPTION 1881
REPLACEMENT TIRES 1881
DESCRIPTION 1881
DIAGNOSIS AND TESTING 1881
PRESSURE GAUGES 1881
TREAD WEAR INDICATORS 1881
TIRE WEAR PATTERNS 1881
TIRE NOISE OR VIBRATION 1882
SERVICE PROCEDURES 1882
ROTATION 1882
MATCH MOUNTING 1882
REPAIRING LEAKS 1883
CLEANING AND INSPECTION 1884
CLEANING TIRES 1884
SPECIFICATIONS 1884
TIRE REVOLUTION PER MILE 1884
WHEELS 1885
DESCRIPTION AND OPERATION 1885
WHEEL 1885
DESCRIPTION 1885
DIAGNOSIS AND TESTING 1885
WHEEL INSPECTION 1885
TIRE AND WHEEL RUNOUT 1885
METHOD 1 (RELOCATE WHEEL ON HUB) 1886
METHOD 2 (RELOCATE TIRE ON WHEEL) 1886
SERVICE PROCEDURES 1886
WHEEL INSTALLATION 1886
WHEEL REPLACEMENT 1887
TIRE AND WHEEL BALANCE 1887
SPECIFICATIONS 1889
TORQUE CHART 1889
00AN_23 1891
BODY 1891
PAINT 1891
DESCRIPTION AND OPERATION 1891
PAINT CODE 1891
BASE COAT/CLEAR COAT FINISH 1891
DESCRIPTION 1891
OPERATION 1891
FINESSE SANDING, BUFFING, AND POLISHING 1891
PAINTED SURFACE TOUCH-UP 1892
DESCRIPTION 1892
AFTERMARKET REPAIR PRODUCTS 1892
STATIONARY GLASS 1894
DESCRIPTION AND OPERATION 1894
STATIONARY GLASS 1894
DESCRIPTION 1894
OPERATION 1894
SERVICE PROCEDURES 1894
WINDSHIELD SAFETY PRECAUTIONS 1894
REMOVAL AND INSTALLATION 1894
WINDSHIELD 1894
REMOVAL 1894
INSTALLATION 1895
BACKLITE 1896
REMOVAL 1896
INSTALLATION-SLIDING BACKLITE 1896
INSTALLATION-FIXED BACKLITE 1897
SEATS 1898
DESCRIPTION AND OPERATION 1898
SEAT SYSTEMS 1898
DESCRIPTION 1898
OPERATION 1898
REMOVAL AND INSTALLATION 1898
BENCH SEAT 1898
REMOVAL 1898
INSTALLATION 1898
BENCH SEAT TRACK 1899
REMOVAL 1899
INSTALLATION 1899
BENCH SEAT BACK 1899
REMOVAL 1899
INSTALLATION 1899
BENCH SEAT BACK PAD/COVER 1900
REMOVAL 1900
INSTALLATION 1900
BENCH SEAT CUSHION/COVER 1900
REMOVAL 1900
INSTALLATION 1900
BUCKET SEAT 1900
REMOVAL 1900
INSTALLATION 1901
BUCKET SEAT TRACK 1901
REMOVAL 1901
INSTALLATION 1901
BUCKET SEAT BACK 1901
BUCKET SEAT BACK PAD/COVER 1901
REMOVAL 1901
INSTALLATION 1901
BUCKET SEAT CUSHION/COVER 1901
REMOVAL 1901
INSTALLATION 1902
CENTER SEAT/CONSOLE 1902
REMOVAL 1902
INSTALLATION 1902
CENTER ARMREST/CONSOLE LATCH 1902
REMOVAL 1902
INSTALLATION 1902
CENTER ARMREST UPPER INERTIA LATCH COVER 1903
REMOVAL 1903
INSTALLATION 1903
CONSOLE LID/SEAT BACK 1903
REMOVAL 1903
INSTALLATION 1903
CENTER SEAT CUSHION/COVER 1903
REMOVAL 1903
INSTALLATION 1904
REAR SEAT BACK-CLUB CAB 1904
REMOVAL 1904
INSTALLATION 1905
REAR SEAT CUSHION-CLUB CAB 1905
REMOVAL 1905
INSTALLATION 1905
REAR SEAT QUAD CAB 1906
Removal 1906
Installation 1906
QUAD CAB REAR SEAT CUSHION COVER 1906
Removal 1906
Installation 1906
BODY COMPONENT SERVICE 1907
DESCRIPTION AND OPERATION 1908
BODY COMPONENTS 1908
DESCRIPTION 1908
OPERATION 1908
INTERIOR TRIM PANELS 1908
DIAGNOSIS AND TESTING 1908
WATER LEAKS 1908
VISUAL INSPECTION BEFORE WATER LEAK TESTS 1908
WATER LEAK TESTS 1908
WATER LEAK DETECTION 1909
WIND NOISE 1909
VISUAL INSPECTION BEFORE TESTS 1909
SERVICE PROCEDURES 1910
BODY LUBRICATION 1910
HEAT STAKING 1910
REMOVAL AND INSTALLATION 1910
GRILLE 1910
REMOVAL 1910
INSTALLATION 1910
HOOD 1911
REMOVAL 1911
INSTALLATION 1911
HOOD SILENCER PAD 1911
REMOVAL 1911
INSTALLATION 1911
HOOD HINGE 1911
REMOVAL 1911
INSTALLATION 1911
HOOD SAFETY LATCH 1912
REMOVAL 1912
INSTALLATION 1912
HOOD LATCH STRIKER 1912
HOOD LATCH 1912
REMOVAL 1912
INSTALLATION 1912
HOOD RELEASE CABLE 1913
REMOVAL 1913
INSTALLATION 1913
COWL GRILLE 1913
REMOVAL 1913
INSTALLATION 1913
COWL SEAL 1914
REMOVAL 1914
INSTALLATION 1914
HOOD SEAL 1914
REMOVAL 1914
INSTALLATION 1914
FRONT WHEELHOUSE LINER 1914
REMOVAL 1914
INSTALLATION 1914
LEFT FRONT FENDER 1914
REMOVAL 1914
INSTALLATION 1915
RIGHT FRONT FENDER 1916
REMOVAL 1916
INSTALLATION 1917
EXTERIOR NAMEPLATES 1917
REMOVAL 1917
INSTALLATION 1918
SIDE VIEW MIRROR 1918
REMOVAL 1918
INSTALLATION 1918
FRONT DOOR TRIM PANEL 1919
REMOVAL 1919
INSTALLATION 1920
FRONT DOOR WATERDAM 1920
REMOVAL 1920
INSTALLATION 1921
FRONT DOOR 1921
REMOVAL 1921
INSTALLATION 1921
FRONT DOOR HINGE 1921
REMOVAL 1921
INSTALLATION 1921
FRONT DOOR OUTSIDE HANDLE 1922
REMOVAL 1922
INSTALLATION 1922
FRONT DOOR LOCK CYLINDER 1923
REMOVAL 1923
INSTALLATION 1923
LOCK CYLINDERS 1923
FRONT DOOR LATCH 1923
REMOVAL 1923
INSTALLATION 1923
FRONT DOOR LATCH STRIKER 1924
REMOVAL 1924
INSTALLATION 1924
FRONT DOOR INSIDE HANDLE ACTUATOR 1924
FRONT DOOR INNER BELT WEATHERSTRIP 1924
REMOVAL 1924
INSTALLATION 1924
FRONT DOOR OUTER BELT WEATHERSTRIP 1924
REMOVAL 1924
INSTALLATION 1924
FRONT DOOR GLASS 1924
REMOVAL 1924
INSTALLATION 1925
FRONT DOOR WINDOW REGULATOR 1925
REMOVAL 1925
INSTALLATION 1925
FRONT DOOR LOWER GLASS RUN CHANNELS 1926
REMOVAL 1926
INSTALLATION 1926
FRONT DOOR GLASS RUN WEATHERSTRIP 1926
REMOVAL 1926
INSTALLATION 1926
FRONT DOOR SEAL 1926
REMOVAL 1926
INSTALLATION 1927
FRONT DOOR SECONDARY SEAL 1927
REMOVAL 1927
INSTALLATION 1927
REAR DOOR 1927
Removal 1927
Installation 1927
REAR DOOR HINGE 1927
REMOVAL 1927
INSTALLATION 1927
REAR DOOR TRIM PANEL 1927
REMOVAL 1927
INSTALLATION 1927
REAR DOOR WATERDAM 1928
REMOVAL 1928
INSTALLATION 1928
REAR DOOR LATCH STRIKER 1929
REMOVAL 1929
INSTALLATION 1929
REAR DOOR LATCH 1929
REMOVAL 1929
INSTALLATION 1929
REAR DOOR OUTSIDE HANDLE 1929
REMOVAL 1929
INSTALLATION 1929
REAR DOOR INSIDE HANDLE ACTUATOR 1930
REAR DOOR GLASS RUN CHANNELS 1930
REMOVAL 1930
INSTALLATION 1930
REAR DOOR GLASS RUN WEATHERSTRIP 1930
REMOVAL 1930
INSTALLATION 1930
REAR DOOR INNER BELT WEATHERSTRIP 1930
REMOVAL 1930
INSTALLATION 1931
REAR DOOR OPENING WEATHERSTRIP 1931
REMOVAL 1931
INSTALLATION 1931
REAR DOOR OUTER BELT WEATHERSTRIP 1931
REMOVAL 1931
INSTALLATION 1931
REAR DOOR SECONDARY SEAL 1931
REMOVAL 1931
INSTALLATION 1931
REAR DOOR GLASS 1931
REMOVAL 1931
INSTALLATION 1931
REAR DOOR QUARTER GLASS 1932
REMOVAL 1932
INSTALLATION 1932
REAR DOOR WINDOW REGULATOR 1932
REMOVAL 1932
INSTALLATION 1932
ROOF RAIL WEATHERSTRIP AND RETAINER 1933
REMOVAL 1933
INSTALLATION 1933
ROOF JOINT MOLDING 1933
REMOVAL 1933
INSTALLATION 1933
QUARTER VENT WINDOW 1933
REMOVAL 1933
INSTALLATION 1933
QUARTER VENT WINDOW WEATHERSTRIP 1934
REMOVAL 1934
INSTALLATION 1934
AIR EXHAUSTER 1934
REMOVAL 1934
INSTALLATION 1934
AIR EXHAUSTER-CAB 1934
REMOVAL 1934
INSTALLATION 1935
BODY SIDE MOLDINGS 1935
REMOVAL 1935
INSTALLATION 1935
WHEEL OPENING MOLDING 1935
REMOVAL 1935
INSTALLATION 1935
FUEL FILLER DOOR 1935
REMOVAL 1935
INSTALLATION 1935
REAR SPLASH SHIELD 1936
REMOVAL 1936
INSTALLATION 1936
TAILGATE CHECK CABLE 1936
REMOVAL 1936
INSTALLATION 1937
TAILGATE 1937
REMOVAL 1937
INSTALLATION 1937
TAILGATE LATCH RELEASE HANDLE 1937
REMOVAL 1937
INSTALLATION 1937
TAILGATE LATCH 1938
REMOVAL 1938
INSTALLATION 1938
TAILGATE LATCH STRIKER 1938
REMOVAL 1938
INSTALLATION 1938
CARGO BOX 1938
REMOVAL 1938
INSTALLATION 1938
CARGO BOX SEAL 1939
REMOVAL 1939
INSTALLATION 1939
COWL TRIM COVER 1939
REMOVAL 1939
INSTALLATION 1939
A-PILLAR TRIM 1940
REMOVAL 1940
INSTALLATION 1940
DOOR SILL TRIM COVER 1940
REMOVAL 1940
INSTALLATION 1940
B-PILLAR TRIM 1940
REMOVAL 1940
INSTALLATION 1941
QUARTER TRIM PANEL 1941
REMOVAL 1941
INSTALLATION 1941
REAR CAB BACK PANEL TRIM 1941
REMOVAL 1941
INSTALLATION 1941
BACKLITE SLIDING VENT GLASS 1942
REMOVAL 1942
INSTALLATION 1942
FRONT SEAT BELT RETRACTOR 1942
REMOVAL 1942
INSTALLATION 1942
SEAT BELT RETRACTOR-QUAD CAB 1942
REMOVAL 1942
INSTALLATION 1942
SEAT BELT BUCKLE 1943
REMOVAL 1943
INSTALLATION 1943
REAR SEAT BELT/BUCKLE-CLUB CAB 1943
REMOVAL 1943
INSTALLATION 1943
REAR SEAT BELT RETRACTOR-CLUB CAB 1944
REMOVAL 1944
INSTALLATION 1944
FLOOR SHIFT BOOT 1944
REMOVAL0 – 2 AN (Continued) 1944
INSTALLATION 1944
SHIFT BEZEL 1945
REMOVAL 1945
INSTALLATION 1945
FLOOR CONSOLE 1946
REMOVAL 1946
INSTALLATION 1946
REAR STORAGE BOX 1946
REMOVAL 1946
INSTALLATION 1946
FLOOR CARPET OR MAT 1947
REMOVAL 1947
INSTALLATION 1947
REARVIEW MIRROR 1947
REMOVAL 1947
INSTALLATION 1947
REARVIEW MIRROR SUPPORT BRACKET 1947
INSTALLATION 1947
SUNVISORS 1948
REMOVAL 1948
INSTALLATION 1948
COAT HOOK 1948
REMOVAL 1948
INSTALLATION 1948
QUAD CAB ASSIST HANDLE 1949
REMOVAL 1949
INSTALLATION 1949
HEADLINER 1949
REMOVAL 1949
INSTALLATION 1949
ADJUSTMENTS 1949
HOOD 1949
HOOD LATCH STRIKER 1949
HOOD LATCH 1950
FRONT DOOR LATCH 1950
FRONT DOOR IN/OUT 1950
FRONT DOOR UP/DOWN 1951
REAR DOOR ADJUSTMENT 1951
In and Out 1951
Up and Down 1951
SPECIFICATIONS 1952
WELD LOCATIONS 1952
FRONT FENDER AND INNER WHEELHOUSE 1952
ROOF PANEL-REGULAR CAB 1953
ROOF PANEL-CLUB CAB 1954
BODY SIDE APERTURE-REGULAR CAB 1955
BODY SIDE APERTURE-REGULAR CAB 1956
BODY SIDE APERTURE-REGULAR CAB 1957
BODY SIDE APERTURE-REGULAR CAB 1958
BODY SIDE APERTURE-CLUB CAB 1959
BODY SIDE APERTURE-CLUB CAB 1960
BODY SIDE APERTURE-CLUB CAB 1961
BODY SIDE APERTURE-CLUB CAB 1962
CAB BACK PANEL-REGULAR CAB 1963
CAB BACK PANEL-CLUB CAB 1964
FLOOR PAN-REGULAR CAB 1965
FLOOR PAN-REGULAR CAB 1965
FLOOR PAN-REGULAR CAB 1966
FLOOR PAN-CLUB CAB 1967
FLOOR PAN-CLUB CAB 1968
FLOOR PAN-CLUB CAB 1969
COWL AND DASH PANEL 1970
COWL AND DASH PANEL 1971
CARGO BOX OUTER SIDE PANEL 1972
CARGO BOX INNER SIDE PANEL 1973
CARGO BOX INNER SIDE PANEL 1974
CARGO BOX INNER SIDE PANEL 1975
CARGO BOX FRONT PANELS 1976
CARGO BOX FLOOR 1977
CARGO BOX FLOOR 1978
STRUCTURAL ADHESIVE LOCATIONS 1979
ROOF-EXTENDED CAB 1979
ROOF-REGULAR CAB 1980
REAR QUARTER PANEL-REGULAR CAB 1981
REAR QUARTER PANEL-EXTENDED CAB 1982
CARGO BOX INNER AND OUTER PANEL 1983
SEALER LOCATIONS 1984
APPLICATION METHODS 1984
SEALER LOCATION 1985
APPLICATION CUT-AWAY 1986
COWL AND DASH PANEL 1987
COWL AND DASH PANEL 1988
FLOOR PAN 1989
CAB REAR PANEL 1990
CAB REAR PANEL 1991
ROOF PANEL 1992
CARGO BOX 1993
CARGO BOX 1994
DOORS 1995
BODY GAP AND FLUSH MEASUREMENTS 1996
BODY GAP AND FLUSH – REGULAR CAB 1996
BODY GAP AND FLUSH 1997
BODY GAP AND FLUSH – EXTENDED CAB 1998
BODY GAP AND FLUSH- QUAD CAB 1999
BODY GAP AND FLUSH- QUAD CAB 2000
BODY GAP AND FLUSH – CARGO BOX 2001
BODY GAP AND FLUSH – CARGO BOX 2002
BODY OPENING DIMENSIONS 2003
WINDSHIELD OPENING 2003
DOOR OPENING 2003
QUARTER WINDOW OPENING 2004
ENGINE COMPARTMENT OPENING 2004
BACKLITE OPENING 2005
TORQUE SPECIFICATIONS 2006
SPECIAL TOOLS 2006
BODY 2006
00AN_24 2007
HEATING AND AIR CONDITIONING 2007
DESCRIPTION AND OPERATION 2008
ACCUMULATOR 2008
DESCRIPTION 2008
OPERATION 2008
BLOWER MOTOR 2008
DESCRIPTION 2008
OPERATION 2008
BLOWER MOTOR RELAY 2008
DESCRIPTION 2008
OPERATION 2008
BLOWER MOTOR RESISTOR 2009
DESCRIPTION 2009
OPERATION 2009
BLOWER MOTOR SWITCH 2009
DESCRIPTION 2009
OPERATION 2009
COMPRESSOR 2010
DESCRIPTION 2010
OPERATION 2010
COMPRESSOR CLUTCH 2010
DESCRIPTION 2010
OPERATION 2010
COMPRESSOR CLUTCH RELAY 2010
DESCRIPTION 2010
OPERATION 2010
CONDENSER 2011
DESCRIPTION 2011
OPERATION 2011
EVAPORATOR COIL 2011
DESCRIPTION 2011
OPERATION 2011
FIXED ORIFICE TUBE 2011
DESCRIPTION 2011
OPERATION 2011
HEATER AND AIR CONDITIONER 2011
DESCRIPTION 2011
OPERATION 2012
HEATER AND AIR CONDITIONER CONTROL 2012
DESCRIPTION 2012
OPERATION 2012
HEATER CORE 2013
DESCRIPTION 2013
OPERATION 2013
HIGH PRESSURE CUT-OFF SWITCH 2013
DESCRIPTION 2013
OPERATION 2013
HIGH PRESSURE RELIEF VALVE 2013
DESCRIPTION 2013
OPERATION 2013
LOW PRESSURE CYCLING CLUTCH SWITCH 2013
DESCRIPTION 2013
OPERATION 2013
REFRIGERANT 2014
DESCRIPTION 2014
OPERATION 2014
REFRIGERANT LINES 2014
DESCRIPTION 2014
OPERATION 2014
REFRIGERANT LINE COUPLERS 2014
DESCRIPTION 2014
OPERATION 2014
REFRIGERANT OIL 2014
DESCRIPTION 2014
OPERATION 2015
REFRIGERANT SYSTEM SERVICE PORTS 2015
DESCRIPTION 2015
OPERATION 2015
VACUUM CHECK VALVE 2015
DESCRIPTION 2015
OPERATION 2015
VACUUM RESERVOIR 2015
DESCRIPTION 2015
OPERATION 2015
DIAGNOSIS AND TESTING 2016
A/C PERFORMANCE 2016
BLOWER MOTOR 2019
VIBRATION 2019
NOISE 2019
BLOWER MOTOR RELAY 2019
RELAY TEST 2019
RELAY CIRCUIT TEST 2019
ADDITIONAL RELAY CIRCUIT TESTING 2020
BLOWER MOTOR RESISTOR 2020
BLOWER MOTOR SWITCH 2021
COMPRESSOR 2021
COMPRESSOR CLUTCH COIL 2022
COMPRESSOR CLUTCH RELAY 2022
RELAY TEST 2022
RELAY CIRCUIT TEST 2022
HEATER-A/C CONTROL 2023
HEATER PERFORMANCE 2023
MAXIMUM HEATER OUTPUT 2023
OBSTRUCTED COOLANT FLOW 2024
MECHANICAL PROBLEMS 2024
TEMPERATURE CONTROL 2024
DUAL FUNCTION HIGH PRESSURE SWITCH/HIGH PRESSURE CUT-OFF SWITCH 2024
LOW PRESSURE CYCLING CLUTCH SWITCH 2024
REFRIGERANT SYSTEM LEAKS 2025
SYSTEM EMPTY 2025
SYSTEM LOW 2025
SERVICE PROCEDURES 2025
REFRIGERANT OIL LEVEL 2025
REFRIGERANT RECOVERY 2026
REFRIGERANT SYSTEM CHARGE 2026
REFRIGERANT CHARGE CAPACITY 2026
REFRIGERANT SYSTEM EVACUATE 2026
REFRIGERANT SYSTEM SERVICE EQUIPMENT 2026
MANIFOLD GAUGE SET CONNECTIONS 2027
LOW PRESSURE GAUGE HOSE 2027
HIGH PRESSURE GAUGE HOSE 2027
RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE 2027
REMOVAL AND INSTALLATION 2028
SERVICE WARNINGS AND PRECAUTIONS 2028
COOLING SYSTEM REQUIREMENTS 2028
REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS 2029
ACCUMULATOR 2029
REMOVAL 2029
INSTALLATION 2029
BLOWER MOTOR 2030
REMOVAL 2030
INSTALLATION 2031
BLOWER MOTOR RELAY 2031
REMOVAL 2031
INSTALLATION 2031
BLOWER MOTOR RESISTOR 2031
REMOVAL 2031
INSTALLATION 2032
COMPRESSOR 2032
REMOVAL 2032
INSTALLATION 2032
COMPRESSOR CLUTCH 2033
REMOVAL 2033
INSPECTION 2035
INSTALLATION 2035
CLUTCH BREAK-IN 2036
COMPRESSOR CLUTCH RELAY 2036
CONDENSER 2037
REMOVAL 2037
INSTALLATION 2038
DUCTS AND OUTLETS 2038
PANEL AND DEFROSTER DUCTS 2038
PANEL OUTLET BARRELS 2038
FLOOR DUCT 2038
DEMISTER DUCT ADAPTER 2038
DEMISTER HOSE 2039
DEMISTER DUCTS AND OUTLETS 2039
HEATER-A/C HOUSING PLENUM ADAPTER 2040
EVAPORATOR COIL 2040
REMOVAL 2040
INSTALLATION 2040
FIXED ORIFICE TUBE 2041
REMOVAL 2041
INSTALLATION 2041
HEATER-A/C CONTROL 2041
REMOVAL 2041
INSTALLATION 2042
HEATER-A/C HOUSING 2042
REMOVAL 2043
DISASSEMBLY 2044
ASSEMBLY 2045
INSTALLATION 2046
HEATER-A/C HOUSING DOOR 2046
BLEND-AIR DOOR 2046
FLOOR-DEFROST DOOR 2046
PANEL-DEFROST DOOR 2046
RECIRCULATION AIR DOOR 2047
HEATER CORE 2047
REMOVAL 2048
INSTALLATION 2048
HIGH PRESSURE CUT-OFF SWITCH 2048
REMOVAL 2048
INSTALLATION 2048
LIQUID LINE 2049
REMOVAL 2049
INSTALLATION 2049
LOW PRESSURE CYCLING CLUTCH SWITCH 2049
REMOVAL 2049
INSTALLATION 2049
MODE DOOR VACUUM ACTUATOR 2050
FLOOR-DEFROST DOOR ACTUATOR 2050
PANEL-DEFROST DOOR ACTUATOR 2050
RECIRCULATION AIR DOOR ACTUATOR 2051
REFRIGERANT LINE COUPLER 2051
REMOVAL 2051
INSTALLATION 2052
SUCTION AND DISCHARGE LINE 2052
REMOVAL 2052
INSTALLATION 2053
TEMPERATURE CONTROL CABLE 2053
REMOVAL 2053
INSTALLATION 2054
VACUUM CHECK VALVE 2054
VACUUM RESERVOIR 2054
VACUUM SYSTEM 2056
VACUUM CHECK VALVE 2057
HEATER-A/C CONTROLS 2057
LOCATING VACUUM LEAKS 2057
ADJUSTMENTS 2061
TEMPERATURE CONTROL CABLE 2061
SPECIFICATIONS 2061
A/C APPLICATION TABLE 2061
00AN_25 2063
EMISSION CONTROL SYSTEMS 2063
ON-BOARD DIAGNOSTICS 2063
DESCRIPTION AND OPERATION 2063
EMISSION SYSTEM 2063
OPERATION 2063
MALFUNCTION INDICATOR LAMP (MIL) 2064
DESCRIPTION 2064
OPERATION 2064
STATE DISPLAY TEST MODE 2064
OPERATION 2064
CIRCUIT ACTUATION TEST MODE 2064
OPERATION 2064
DIAGNOSTIC TROUBLE CODES 2064
OPERATION 2064
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS 2065
TASK MANAGER-GASOLINE POWERED ENGINES ONLY 2078
DESCRIPTION 2078
OPERATION 2078
MONITORED SYSTEMS 2081
OPERATION 2081
TRIP DEFINITION 2083
OPERATION 2083
COMPONENT MONITORS 2083
OPERATION 2083
NON-MONITORED CIRCUITS 2084
OPERATION 2084
HIGH AND LOW LIMITS 2084
OPERATION 2084
LOAD VALUE 2084
OPERATION 2084
EVAPORATIVE EMISSION CONTROLS 2085
DESCRIPTION AND OPERATION 2085
EVAPORATION CONTROL SYSTEM 2085
OPERATION 2085
ROLLOVER VALVE(S) 2086
DESCRIPTION 2086
OPERATION 2086
EVAPORATION (EVAP) CANISTER 2086
DESCRIPTION 2086
OPERATION 2086
DUTY CYCLE EVAP CANISTER PURGE SOLENOID 2087
OPERATION 2087
LEAK DETECTION PUMP (LDP) 2087
OPERATION 2087
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM-3 9/5 2/5 9L ENGINE 2088
DESCRIPTION 2088
OPERATION 2088
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM-4 7L ENGINE 2089
DESCRIPTION 2089
OPERATION 2090
CRANKCASE VENTILATION (CCV) SYSTEM-2 5L ENGINE 2091
DESCRIPTION 2091
OPERATION 2091
CRANKCASE BREATHER/FILTER 2091
DESCRIPTION 2091
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL 2091
DESCRIPTION 2091
OPERATION 2092
DIAGNOSIS AND TESTING 2092
PCV VALVE TEST-3 9/5 2/5 9L ENGINE 2092
PCV VALVE/PCV SYSTEM TEST-4 7L V-8 ENGINE 2093
VACUUM SCHEMATICS 2094
LEAK DETECTION PUMP (LDP) 2094
REMOVAL AND INSTALLATION 2094
PCV VALVE-4 7L V-8 ENGINE 2094
REMOVAL 2094
INSTALLATION 2094
EVAPORATION (EVAP) CANISTER 2095
REMOVAL 2095
INSTALLATION 2095
DUTY CYCLE EVAP CANISTER PURGE SOLENOID 2095
REMOVAL 2096
INSTALLATION 2096
ROLLOVER VALVE(S) 2096
LEAK DETECTION PUMP (LDP) 2096
REMOVAL 2096
INSTALLATION 2097
SPECIFICATIONS 2097
TORQUE CHART 2097
00AN_FR 2099
00AN_IN 2101
INTRODUCTION 2101
DESCRIPTION AND OPERATION 2101
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE 2101
BODY CODE PLATE 2102
LOCATION AND DECODING 2102
BODY CODE PLATE-LINE 4 2102
BODY CODE PLATE-LINE 3 2102
BODY CODE PLATE-LINE 2 2103
BODY CODE PLATE-LINE 1 2103
EQUIPMENT IDENTIFICATION PLATE 2103
INTERNATIONAL SYMBOLS 2103
DESCRIPTION 2103
FASTENER IDENTIFICATION 2104
DESCRIPTION 2104
FASTENER USAGE 2107
THREADED HOLE REPAIR 2107
METRIC SYSTEM 2107
DESCRIPTION 2107
TORQUE REFERENCES 2107
DESCRIPTION 2107
00AN_IX 2111

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