2001 Dodge Ram BR-BE Service Manual – PDF DOWNLOAD

Description

2001 Dodge Ram BR-BE Service Manual – PDF DOWNLOAD

FILE DETAILS:

2001 Dodge Ram BR-BE Service Manual – PDF DOWNLOAD

Language : English
Pages : 2889
Downloadable : Yes
File Type : PDF
Size: 68 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

2001 Dodge Ram BR-BE Service Manual – PDF DOWNLOAD

BODY CODE PLATE:
DESCRIPTION:

• The Body Code Plate is located on the floor pan under the passenger seat or attached to the front face of the radiator closure panel. There are seven lines of information on the body code plate. Lines 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 4 in the center of the plate to line 1 at the bottom of the plate. The last code imprinted on a vehicle code plate will be followed by the imprinted word END.
• When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued). When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap.

TABLE OF CONTENTS:

FOREWORD 0
GROUP TAB LOCATOR 1
in-INTRODUCTION 2
BODY CODE PLATE 2
DESCRIPTION 2
BODY CODE PLATE—LINE 4 2
BODY CODE PLATE—LINE 3 3
BODY CODE PLATE—LINE 2 3
BODY CODE PLATE—LINE 1 3
FASTENER IDENTIFICATION 4
DESCRIPTION 4
FASTENER USAGE 7
DESCRIPTION – FASTENER USAGE 7
DESCRIPTION – THREADED HOLE REPAIR 7
INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS 7
DESCRIPTION – INTERNATIONAL SYMBOLS 7
METRIC SYSTEM 7
DESCRIPTION – METRIC SYSTEM 7
TORQUE REFERENCES 10
DESCRIPTION 10
VECI LABEL 11
DESCRIPTION 11
OPERATION 11
VEHICLE IDENTIFICATION NUMBER 11
DESCRIPTION 11
VIN CODING/LOCATIONS 11
VEHICLE SAFETY CERTIFICATION LABEL 13
DESCRIPTION 13
EQUIPMENT IDENTIFICATION PLATE 13
DESCRIPTION 13
0-LUBRICATION & MAINTENANCE 14
LUBRICATION & MAINTENANCE 14
DESCRIPTION 14
DESCRIPTION – FUEL REQUIREMENTS – GAS ENGINES 14
REFORMULATED GASOLINE 14
GASOLINE/OXYGENATE BLENDS 14
MMT IN GASOLINE 14
SULFUR IN GASOLINE 15
MATERIALS ADDED TO FUEL 15
FUEL SYSTEM CAUTIONS 15
DESCRIPTION – FUEL REQUIREMENTS – DIESEL ENGINE 15
DESCRIPTION 15
INTERNATIONAL SYMBOLS 16
DESCRIPTION 16
DESCRIPTION 16
PARTS & LUBRICANT RECOMMENDATION 16
STANDARD PROCEDURE 16
STANDARD PROCEDURE – CLASSIFICATION OF LUBRICANTS 16
FLUID TYPES 16
DESCRIPTION 16
DESCRIPTION – ENGINE OIL 16
API SERVICE GRADE CERTIFIED 16
SAE VISCOSITY 16
ENERGY CONSERVING OIL 17
CONTAINER IDENTIFICATION 17
DESCRIPTION—ENGINE OIL 17
API SERVICE GRADE CERTIFIED 17
SAE VISCOSITY 17
DESCRIPTION 18
DESCRIPTION – TRANSFER CASE FLUID 18
DESCRIPTION – AUTOMATIC TRANSMISSION FLUID 18
FLUID ADDITIVES 18
OPERATION 18
OPERATION – AUTOMATIC TRANSMISSION FLUID 18
FLUID CAPACITIES 19
SPECIFICATIONS 19
FLUID CAPACITIES 19
MAINTENANCE SCHEDULES 20
DESCRIPTION 20
LIGHT DUTY ENGINE (1500 AND 2500 MODELS EXCEPT 8 0L) MAINTENANCE SCHEDULES 20
EMISSION CONTROL SYSTEM MAINTENANCE 20
FLUID FILL LOCATIONS AND LUBRICATION POINTS 20
LIGHT DUTY SCHEDULE “A” 20
LIGHT DUTY SCHEDULE “B” 22
DESCRIPTION – MEDIUM DUTY TRUCK MAINTENANCE SCHEDULE (8 0L 2500 & 3500 MODELS — CALIFORNIA ONLY) 26
EMISSION CONTROL SYSTEM MAINTENANCE 26
FLUID FILL LOCATIONS AND LUBRICATION POINTS 27
MEDIUM DUTY SCHEDULE “A” 27
MEDIUM DUTY SCHEDULE “B” 28
DESCRIPTION – HEAVY DUTY ENGINE (FEDERAL ONLY – 2500 8 0L HD AND 3500 5 9L& 8 0L MODELS) MAINTENANCE SCHEDULES 30
EMISSION CONTROL SYSTEM MAINTENANCE 30
FLUID FILL LOCATIONS AND LUBRICATION POINTS 30
HEAVY DUTY SCHEDULE “A” 30
HEAVY DUTY SCHEDULE “B” 32
DESCRIPTION – MAINTENANCE SCHEDULES — 24–VALVE CUMMINS TURBO DIESEL 35
EMISSION CONTROL SYSTEM MAINTENANCE 35
FLUID FILL LOCATIONS AND LUBRICATION POINTS 36
SCHEDULE “A” 36
SCHEDULE “B” 37
JUMP STARTING 40
STANDARD PROCEDURE 40
STANDARD PROCEDURE 40
TO JUMP START A DISABLED VEHICLE: 40
HOISTING 41
STANDARD PROCEDURE 41
STANDARD PROCEDURE 41
FLOOR JACK 41
HOIST 41
TOWING 42
STANDARD PROCEDURE 42
STANDARD PROCEDURE 42
SAFETY PRECAUTIONS 42
GROUND CLEARANCE 43
RAMP ANGLE 43
TOWING WHEN KEYS ARE NOT AVAILABLE 43
FOUR-WHEEL-DRIVE VEHICLE TOWING 43
2-SUSPENSION 44
WHEEL ALIGNMENT 44
WHEEL ALIGNMENT 44
DESCRIPTION 44
OPERATION 45
DIAGNOSIS AND TESTING – PRE-ALIGNMENT 45
STANDARD PROCEDURES – ALIGNMENT I F S 45
STANDARD PROCEDURES – CASTER CORRECTION MEASUREMENT 46
STANDARD PROCEDURES – ALIGNMENT LINK/COIL SUSPENSION 48
SPECIFICATIONS 49
ALIGNMENT 49
FRONT – 2WD 50
FRONT – 2WD 50
DESCRIPTION 50
DESCRIPTION 51
SPECIFICATIONS 51
TORQUE CHART 51
SPECIAL TOOLS 52
INDEPENDENT FRONT SUSPENSION 52
HUB / BEARING 52
REMOVAL 52
INSTALLATION 52
JOUNCE BUMPER 52
DESCRIPTION 52
OPERATION 52
KNUCKLE 52
DESCRIPTION 52
OPERATION 53
REMOVAL 53
INSTALLATION 53
LOWER BALL JOINT 53
DIAGNOSIS AND TESTING – LOWER BALL JOINT 53
LOWER CONTROL ARM 53
REMOVAL 53
INSTALLATION 53
SHOCK 54
DESCRIPTION 54
OPERATION 54
DIAGNOSIS AND TESTING – SHOCK 54
REMOVAL 54
INSTALLATION 54
SPRING 54
DESCRIPTION 54
OPERATION 54
REMOVAL 54
INSTALLATION 55
STABILIZER BAR 55
DESCRIPTION 55
OPERATION 55
REMOVAL 55
INSTALLATION 55
UPPER BALL JOINT 55
DIAGNOSIS AND TESTING – UPPER BALL JOINT 55
UPPER CONTROL ARM 56
REMOVAL 56
INSTALLATION 56
FRONT – 4WD 57
FRONT – 4WD 57
DESCRIPTION 57
DESCRIPTION 57
SPECIFICATIONS 58
TORQUE CHART 58
SPECIAL TOOLS 59
LINK/COIL SUSPENSION 59
HUB / BEARING 59
REMOVAL – 2500/3500 59
REMOVAL – 1500 60
INSTALLATION – 2500/3500 61
INSTALLATION – 1500 62
KNUCKLE 63
DESCRIPTION 63
OPERATION 63
REMOVAL 63
REMOVAL 63
INSTALLATION 63
INSTALLATION 63
LOWER CONTROL ARM 63
REMOVAL 63
INSTALLATION 63
SHOCK 64
DESCRIPTION 64
OPERATION 64
DIAGNOSIS AND TESTING – SHOCK 64
REMOVAL 64
INSTALLATION 64
SPRING 65
DESCRIPTION 65
OPERATION 65
REMOVAL 65
INSTALLATION 65
STABILIZER BAR 65
DESCRIPTION 65
OPERATION 65
REMOVAL 65
INSTALLATION 66
TRACK BAR 66
DESCRIPTION 66
OPERATION 66
DIAGNOSIS AND TESTING – TRACK BAR 66
REMOVAL 66
INSTALLATION 66
UPPER CONTROL ARM 66
REMOVAL 66
INSTALLATION 67
LOWER BALL JOINT 67
REMOVAL – 67
INSTALLATION 68
UPPER BALL JOINT 68
REMOVAL – 68
INSTALLATION 68
REAR 69
REAR 69
DESCRIPTION 69
DIAGNOSIS AND TESTING – SPRING AND SHOCK 69
SPECIFICATIONS 70
TORQUE CHART 70
SPECIAL TOOLS 71
SUSPENSION-REAR 71
BUSHINGS 71
REMOVAL 71
INSTALLATION 71
JOUNCE BUMPER 71
DESCRIPTION 71
OPERATION 71
SHOCK 71
DESCRIPTION 71
OPERATION 71
REMOVAL 71
INSTALLATION 71
SPRING 71
DESCRIPTION 71
OPERATION 71
REMOVAL 71
INSTALLATION 72
STABILIZER BAR 73
DESCRIPTION 73
OPERATION 73
REMOVAL 73
INSTALLATION 73
3-DIFFERENTIAL & DRIVELINE 74
PROPELLER SHAFT 74
PROPELLER SHAFT 74
DESCRIPTION 74
OPERATION 74
DIAGNOSIS AND TESTING – PROPELLER SHAFT 76
VIBRATION 76
BALANCE 77
RUNOUT 78
STANDARD PROCEDURES 78
TWO-PIECE PROPELLER SHAFT 79
SPECIFICATIONS 81
PROPELLER SHAFT 81
SPECIAL TOOLS 81
PROPELLER SHAFT 81
PROPELLER SHAFT – FRONT 81
REMOVAL 81
INSTALLATION 81
PROPELLER SHAFT – REAR 82
REMOVAL 82
INSTALLATION 82
CENTER BEARING 83
DESCRIPTION 83
OPERATION 83
REMOVAL 83
INSTALLATION 83
CENTER BEARING ADJUSTMENT 83
SINGLE CARDAN UNIVERSAL JOINTS 84
DISASSEMBLY 84
FRONT AXLE – 216FBI 85
FRONT AXLE – 216FBI 85
DESCRIPTION 85
OPERATION 85
DIAGNOSIS AND TESTING – AXLE 86
GEAR NOISE 86
BEARING NOISE 87
LOW SPEED KNOCK 87
VIBRATION 87
DRIVELINE SNAP 87
REMOVAL 89
INSTALLATION 90
ADJUSTMENTS 90
PINION DEPTH MEASUREMENT AND ADJUSTMENT 91
DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH 93
SHIM SELECTION 93
GEAR CONTACT PATTERN 96
SPECIFICATIONS 98
FRONT AXLE – 216FBI 98
SPECIAL TOOLS 98
FRONT AXLES 98
AXLE SHAFTS 101
REMOVAL 101
INSTALLATION 101
AXLE SHAFTS – INTERMEDIATE 101
REMOVAL 101
INSTALLATION 101
AXLE SHAFT SEALS 102
REMOVAL 102
INSTALLATION 102
AXLE VACUUM MOTOR 102
DESCRIPTION 102
OPERATION 103
DIAGNOSIS AND TESTING – VACUUM MOTOR 104
REMOVAL 106
DISASSEMBLY 106
ASSEMBLY 106
INSTALLATION 106
SINGLE CARDAN UNIVERSAL JOINTS 106
REMOVAL 106
INSTALLATION 107
PINION SEAL 107
REMOVAL 107
INSTALLATION 107
DIFFERENTIAL 109
REMOVAL 109
DISASSEMBLY 109
ASSEMBLY 110
INSTALLATION 110
DIFFERENTIAL CASE BEARINGS 112
REMOVAL 112
INSTALLATION 112
PINION GEAR/RING GEAR 113
REMOVAL 113
INSTALLATION 115
FRONT AXLE – 248FBI 118
FRONT AXLE – 248FBI 118
DESCRIPTION 118
OPERATION 118
DIAGNOSIS AND TESTING – AXLE 119
GEAR NOISE 119
BEARING NOISE 120
LOW SPEED KNOCK 120
VIBRATION 120
DRIVELINE SNAP 120
REMOVAL 123
INSTALLATION 123
ADJUSTMENTS 123
PINION DEPTH MEASUREMENT AND ADJUSTMENT 124
DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH 126
SHIM SELECTION 126
GEAR CONTACT PATTERN 129
SPECIFICATIONS 131
FRONT AXLE – 248FBI 131
SPECIAL TOOLS 131
FRONT AXLE 131
AXLE SHAFTS 133
REMOVAL 133
INSTALLATION 133
AXLE SHAFTS – INTERMEDIATE 133
REMOVAL – INTERMEDIATE AXLE 133
INSTALLATION – INTERMEDIATE AXLE 134
AXLE SHAFT SEALS 134
REMOVAL 134
INSTALLATION 134
AXLE VACUUM MOTOR 135
DESCRIPTION 135
OPERATION 135
DIAGNOSIS AND TESTING – VACUUM MOTOR 136
REMOVAL 138
DISASSEMBLY 138
ASSEMBLY 138
INSTALLATION 138
SINGLE CARDAN UNIVERSAL JOINTS 138
REMOVAL 138
INSTALLATION 139
PINION SEAL 139
REMOVAL 139
INSTALLATION 139
DIFFERENTIAL 141
REMOVAL 141
DISASSEMBLY 141
ASSEMBLY 142
INSTALLATION 142
DIFFERENTIAL CASE BEARINGS 144
REMOVAL 144
INSTALLATION 144
PINION GEAR/RING GEAR 145
REMOVAL 145
INSTALLATION 147
REAR AXLE – 9 1/4 150
REAR AXLE – 9 1/4 150
DESCRIPTION 150
AXLE IDENTIFICATION 150
OPERATION 150
STANDARD DIFFERENTIAL 152
TRAC-LOK DIFFERENTIAL 153
DIAGNOSIS AND TESTING – AXLE 153
GEAR NOISE 153
BEARING NOISE 154
LOW SPEED KNOCK 154
VIBRATION 154
DRIVELINE SNAP 154
REMOVAL 156
INSTALLATION 157
ADJUSTMENTS 157
PINION DEPTH MEASUREMENT 158
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 159
GEAR CONTACT PATTERN 160
SIDE GEAR CLEARANCE 160
SPECIFICATIONS 163
REAR AXLE – 9 1/4 163
SPECIAL TOOLS 163
REAR AXLE – 9 1/4 163
AXLE SHAFTS 166
REMOVAL 166
INSTALLATION 166
AXLE SHAFT SEALS 167
REMOVAL 167
INSTALLATION 167
AXLE BEARINGS 167
REMOVAL 167
INSTALLATION 168
PINION SEAL 168
REMOVAL 168
INSTALLATION 168
DIFFERENTIAL 169
REMOVAL 169
DISASSEMBLY 170
ASSEMBLY 171
INSTALLATION 171
DIFFERENTIAL – TRAC-LOK 171
DIAGNOSIS AND TESTING – TRAC-LOK 171
DIFFERENTIAL TEST 171
DISASSEMBLY 172
ASSEMBLY 174
DIFFERENTIAL CASE BEARINGS 176
REMOVAL 176
INSTALLATION 176
PINION GEAR/RING GEAR/TONE RING 176
REMOVAL 176
INSTALLATION 178
REAR AXLE – 248RBI 182
REAR AXLE – 248RBI 182
DESCRIPTION 182
OPERATION 182
STANDARD DIFFERENTIAL 182
TRAC-LOK DIFFERENTIAL 183
DIAGNOSIS AND TESTING – AXLE 184
GEAR NOISE 184
BEARING NOISE 184
LOW SPEED KNOCK 184
VIBRATION 184
DRIVELINE SNAP 184
REMOVAL 186
INSTALLATION 187
ADJUSTMENTS 187
PINION DEPTH MEASUREMENT AND ADJUSTMENT 188
DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH 189
SHIM SELECTION 189
GEAR CONTACT PATTERN 193
SPECIFICATIONS 195
REAR AXLE – 248RBI 195
SPECIAL TOOLS 195
REAR AXLE – 248RBI 195
AXLE SHAFTS 198
REMOVAL 198
INSTALLATION 198
AXLE BEARINGS 198
REMOVAL 198
INSTALLATION 198
PINION SEAL 198
REMOVAL 198
INSTALLATION 198
DIFFERENTIAL 200
REMOVAL 200
DISASSEMBLY 201
ASSEMBLY 201
INSTALLATION 202
DIFFERENTIAL – TRAC-LOK 203
DIAGNOSIS AND TESTING – TRAC-LOK 203
DIFFERENTIAL TEST 203
DISASSEMBLY 203
ASSEMBLY 205
DIFFERENTIAL CASE BEARINGS 207
REMOVAL 207
INSTALLATION 207
PINION GEAR/RING GEAR/TONE RING 208
REMOVAL 208
INSTALLATION 210
REAR AXLE – 267RBI 213
REAR AXLE – 267RBI 213
DESCRIPTION 213
OPERATION 213
STANDARD DIFFERENTIAL 213
POWR-LOK DIFFERENTIAL 214
DIAGNOSIS AND TESTING – AXLE 215
GEAR NOISE 215
BEARING NOISE 215
LOW SPEED KNOCK 215
VIBRATION 215
DRIVELINE SNAP 215
REMOVAL 217
INSTALLATION 218
ADJUSTMENTS 218
PINION DEPTH MEASUREMENT AND ADJUSTMENT 219
DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH 220
SHIM SELECTION 220
GEAR CONTACT PATTERN 224
SPECIFICATIONS 226
REAR AXLE – 267RBI 226
SPECIAL TOOLS 226
REAR AXLE – 267RBI 226
AXLE SHAFTS 229
REMOVAL 229
INSTALLATION 229
AXLE BEARINGS 229
REMOVAL 229
INSTALLATION 229
PINION SEAL 229
REMOVAL 229
INSTALLATION 230
DIFFERENTIAL 231
REMOVAL 231
DISASSEMBLY 231
ASSEMBLY 232
INSTALLATION 232
DIFFERENTIAL – POWR-LOK 234
DIAGNOSIS AND TESTING – POWR-LOK TEST 234
DISASSEMBLY 234
ASSEMBLY 236
DIFFERENTIAL CASE BEARINGS 237
REMOVAL 237
INSTALLATION 237
PINION GEAR/RING GEAR/TONE RING 238
REMOVAL 238
INSTALLATION 239
REAR AXLE – 286RBI 242
REAR AXLE – 286RBI 242
DESCRIPTION 242
OPERATION 242
STANDARD DIFFERENTIAL 242
TRAC-LOK DIFFERENTIAL 243
DIAGNOSIS AND TESTING – AXLE 244
GEAR NOISE 244
BEARING NOISE 244
LOW SPEED KNOCK 244
VIBRATION 244
DRIVELINE SNAP 244
REMOVAL 246
INSTALLATION 247
ADJUSTMENTS 247
PINION DEPTH MEASUREMENT AND ADJUSTMENT 248
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 249
SHIM SELECTION 249
GEAR CONTACT PATTERN ANALYSIS 253
SPECIFICATIONS 255
REAR AXLE – 286RBI 255
SPECIAL TOOLS 255
REAR AXLE – 286 RBI 255
AXLE SHAFTS 258
REMOVAL 258
INSTALLATION 258
AXLE BEARINGS 258
REMOVAL 258
INSTALLATION 258
PINION SEAL 258
REMOVAL 258
INSTALLATION 258
DIFFERENTIAL 260
REMOVAL 260
DISASSEMBLY 261
ASSEMBLY 261
INSTALLATION 261
DIFFERENTIAL – TRAC-LOK 263
DIAGNOSIS AND TESTING – TRAC-LOK 263
DIFFERENTIAL TEST 263
DISASSEMBLY 263
ASSEMBLY 263
DIFFERENTIAL CASE BEARINGS 265
REMOVAL 265
INSTALLATION 265
PINION GEAR/RING GEAR/TONE RING 266
REMOVAL 266
INSTALLATION 268
5-BRAKES 272
BRAKES – BASE 273
SPECIFICATIONS 273
BASE BRAKE 273
TORQUE CHART 274
SPECIAL TOOLS 275
BASE BRAKES 275
HYDRAULIC/MECHANICAL 275
DESCRIPTION 275
DESCRIPTION 275
WARNING 276
DIAGNOSIS AND TESTING 276
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 276
PRELIMINARY BRAKE CHECK 276
ROAD TESTING 276
BRAKE NOISES 278
STANDARD PROCEDURE 278
STANDARD PROCEDURE – MANUAL BLEEDING 278
STANDARD PROCEDURE – PRESSURE BLEEDING 279
BRAKE LINES 279
STANDARD PROCEDURE 279
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 279
STANDARD PROCEDURE – ISO FLARING 279
COMBINATION VALVE 280
DESCRIPTION 280
DESCRIPTION 280
OPERATION 280
OPERATION 280
PRESSURE DIFFERENTIAL SWITCH 280
METERING VALVE (1500 Model)(and early 2500/3500 models with rear drum brakes) 280
PROPORTIONING VALVE (1500 Model)(and early 2500/3500 models with rear drum brakes) 280
DIAGNOSIS AND TESTING 280
DIAGNOSIS AND TESTING – COMBINATION VALVE 280
Pressure Differential Switch 280
REMOVAL 281
REMOVAL 281
INSTALLATION 281
INSTALLATION 281
DISC BRAKE CALIPERS 281
REMOVAL 281
REMOVAL – REAR 281
REMOVAL – FRONT 281
DISASSEMBLY 281
DISASSEMBLY 282
CLEANING 283
CLEANING 283
INSPECTION 283
INSPECTION 283
ASSEMBLY 283
ASSEMBLY 283
INSTALLATION 284
INSTALLATION – REAR 284
INSTALLATION – FRONT 285
FLUID 285
DIAGNOSIS AND TESTING 285
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 285
STANDARD PROCEDURE 285
STANDARD PROCEDURE – BRAKE FLUID LEVEL 285
SPECIFICATIONS 286
BRAKE FLUID 286
FLUID RESERVOIR 286
REMOVAL 286
REMOVAL 286
INSTALLATION 286
INSTALLATION 286
PEDAL 287
DESCRIPTION 287
DESCRIPTION 287
OPERATION 287
OPERATION 287
REMOVAL 287
REMOVAL 287
INSTALLATION 288
INSTALLATION 288
POWER BRAKE BOOSTER 288
DIAGNOSIS AND TESTING 288
DIAGNOSIS AND TESTING – HYDRAULIC BOOSTER 288
NOISES 288
BOOSTER FUNCTION TEST 288
ACCUMULATOR LEAKDOWN 288
SEAL LEAKAGE 289
STANDARD PROCEDURE 290
STANDARD PROCEDURE – BLEEDING 290
REMOVAL 290
REMOVAL 290
INSTALLATION 291
INSTALLATION 291
ROTORS 291
DIAGNOSIS AND TESTING 291
DIAGNOSIS AND TESTING—DISC BRAKE ROTOR 291
ROTOR MINIMUM THICKNESS 291
ROTOR RUNOUT 291
ROTOR THICKNESS VARIATION 291
REMOVAL 291
REMOVAL – REAR – 2500/3500 292
REMOVAL – 1500/2500 FRONT 292
REMOVAL – 3500 FRONT 293
INSTALLATION 293
INSTALLATION – REAR – 2500/3500 293
INSTALLATION – 1500/2500 FRONT 293
INSTALLATION – 3500 FRONT 293
BRAKE PADS/SHOES 294
REMOVAL0 – 2 BR/BE (Continued) 294
REMOVAL – REAR 294
REMOVAL – FRONT 295
REMOVAL – REAR BRAKE SHOES-11 inch 296
REMOVAL – 12 1/8 INCH 297
INSTALLATION 297
INSTALLATION – REAR 297
INSTALLATION – FRONT 298
INSTALLATION – REAR BRAKE SHOES-11 inch 298
INSTALLATION – 12 1/8 INCH 299
MASTER CYLINDER 300
DESCRIPTION 300
DESCRIPTION 300
OPERATION 300
OPERATION 300
DIAGNOSIS AND TESTING 300
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 300
POWER BOOSTER VACUUM TEST 300
POWER BOOSTER CHECK VALVE TEST 300
STANDARD PROCEDURE 301
STANDARD PROCEDURE—MASTER CYLINDER BLEEDING 301
REMOVAL 301
REMOVAL 301
INSTALLATION 301
INSTALLATION 301
WHEEL CYLINDERS 302
REMOVAL 302
REMOVAL 302
DISASSEMBLY 302
DISASSEMBLY 302
CLEANING 302
CLEANING 302
INSPECTION 302
INSPECTION 302
ASSEMBLY 302
ASSEMBLY 302
INSTALLATION 302
INSTALLATION 303
SUPPORT PLATE 303
REMOVAL 303
REMOVAL 303
INSTALLATION 303
INSTALLATION 303
DRUM 303
DESCRIPTION 303
DESCRIPTION 303
OPERATION 303
OPERATION 303
DIAGNOSIS AND TESTING 304
DIAGNOSIS AND TESTING – BRAKE DRUM 304
BRAKE DRUM RUNOUT 304
STANDARD PROCEDURE 304
STANDARD PROCEDURE – BRAKE DRUM MACHINING 304
CLEANING 304
CLEANING 304
INSPECTION 304
INSPECTION 304
ADJUSTMENTS 305
ADJUSTMENT – REAR BRAKE DRUM 305
ADJUSTMENT WITH BRAKE GAUGE 305
ADJUSTMENT WITH ADJUSTING TOOL 306
PARKING BRAKE 306
DESCRIPTION 306
DESCRIPTION – 2500/3500 WITH REAR DISC BRAKES 306
DESCRIPTION – (1500 Models)(Early 2500/3500 models with rear drum brakes) 306
OPERATION 306
OPERATION – 2500/3500 WITH REAR DISC BRAKES 307
OPERATION – (1500 models) (Early 2500/3500 models with rear drum brakes) 307
PEDAL 307
REMOVAL 307
REMOVAL 307
INSTALLATION 307
INSTALLATION 307
CABLES 308
REMOVAL 308
REMOVAL – REAR PARK BRAKE CABLE – 2500/3500 WITH REAR DISC BRAKES 308
REMOVAL – FRONT PARKING BRAKE CABLE 308
REMOVAL – REAR PARK BRAKE CABLES – 1500 SERIES 308
REMOVAL – REAR PARK BRAKE CABLES 2500/3500 SERIES WITH DRUM BRAKES 309
INSTALLATION 309
INSTALLATION – REAR PARK BRAKE CABLE – 2500/3500 WITH REAR DISC BRAKES 309
INSTALLATION – FRONT PARKING BRAKE CABLE 310
INSTALLATION – REAR PARK BRAKE CABLES – 1500 SERIES 310
INSTALLATION – REAR PARK BRAKE CABLE 2500/3500 SERIES WITH DRUM BRAKES 310
CABLE TENSIONER 311
ADJUSTMENTS 311
ADJUSTMENT 311
RELEASE 311
REMOVAL 311
REMOVAL 311
INSTALLATION 312
INSTALLATION 312
SHOES 312
REMOVAL 312
REMOVAL – REAR DRUM IN HAT PARK BRAKE SHOES – 2500/3500 312
INSTALLATION 313
INSTALLATION – REAR DRUM IN HAT PARK BRAKE SHOES – 2500/3500 313
6-CLUTCH 314
CLUTCH 314
DESCRIPTION 314
OPERATION 314
WARNING 315
DIAGNOSTIC AND TESTING – CLUTCH 315
CLUTCH CONTAMINATION 315
IMPROPER RELEASE OR CLUTCH ENGAGEMENT 317
CLUTCH MISALIGNMENT 317
CLUTCH COVER AND DISC RUNOUT 317
CLUTCH FLYWHEEL RUNOUT 317
DIAGNOSIS CHART 317
SPECIFICATIONS 320
SPECIFICATIONS – CLUTCH 320
CLUTCH DISC 320
DESCRIPTION 320
OPERATION 321
REMOVAL 321
INSTALLATION 322
CLUTCH HOUSING 324
DIAGNOSIS AND TESTING – CLUTCH HOUSING 324
CHECKING RUNOUT 324
CORRECTING CLUTCH HOUSING FACE RUNOUT 326
REMOVAL 326
INSTALLATION 326
CLUTCH RELEASE BEARING 327
DESCRIPTION 327
OPERATION 327
REMOVAL 328
INSTALLATION 328
PRESSURE PLATE 328
DESCRIPTION 328
OPERATION 329
FLYWHEEL 329
DESCRIPTION 329
OPERATION 329
DIAGNOSIS AND TESTING – FLYWHEEL 330
DISASSEMBLY 330
ASSEMBLY 330
PILOT BEARING 330
DESCRIPTION 330
OPERATION 331
REMOVAL 331
INSTALLATION 331
CLUTCH PEDAL 331
REMOVAL 331
INSTALLATION 332
LINKAGE 332
DESCRIPTION 332
OPERATION 333
REMOVAL 333
INSTALLATION 333
CLUTCH PEDAL POSITION SWITCH 335
DESCRIPTION 335
OPERATION 335
7-COOLING 336
COOLING 336
DESCRIPTION 336
DESCRIPTION—COOLING SYSTEM FLOW – 3 9L/5 2L/5 9L ENGINE 336
DESCRIPTION—COOLING SYSTEM FLOW – 5 9L DIESEL 336
DESCRIPTION—HOSE CLAMPS 337
OPERATION 337
OPERATION—HOSE CLAMPS 337
OPERATION—COOLING SYSTEM 339
DIAGNOSIS AND TESTING – PRELIMINARY CHECKS 339
ENGINE COOLING SYSTEM OVERHEATING 339
DIAGNOSIS AND TESTING—ON-BOARD DIAGNOSTICS (OBD) 339
COOLING SYSTEM RELATED DIAGNOSTICS 339
ACCESSING DIAGNOSTIC TROUBLE CODES 340
ERASING TROUBLE CODES 340
DIAGNOSIS AND TESTING—COOLING SYSTEM LEAKS 340
ULTRAVIOLET LIGHT METHOD 340
PRESSURE TESTER METHOD 340
INTERNAL LEAKAGE INSPECTION 341
COMBUSTION LEAKAGE TEST—WITHOUT PRESSURE TESTER 341
DIAGNOSIS AND TESTING – COOLING SYSTEM GAS ENGINE 342
DIAGNOSIS AND TESTING – COOLING SYSTEM DIESEL ENGINE 347
STANDARD PROCEDURE—DRAINING COOLING SYSTEM 3 9L/5 2L/5 9L/8 0L ENGINES 350
STANDARD PROCEDURE—DRAINING COOLING SYSTEM 5 9L DIESEL ENGINE 350
STANDARD PROCEDURE—REFILLING COOLING SYSTEM 3 9L/5 2L/5 9L/8 0L ENGINES 350
STANDARD PROCEDURE—REFILLING COOLING SYSTEM 5 9L DIESEL ENGINE 350
STANDARD PROCEDURE—ADDING ADDITIONAL COOLANT 351
STANDARD PROCEDURE—COOLANT LEVEL CHECK 351
STANDARD PROCEDURE—COOLING SYSTEM CLEANING/REVERSE FLUSHING 351
CLEANING 351
REVERSE FLUSHING 351
REVERSE FLUSHING RADIATOR 351
REVERSE FLUSHING ENGINE 352
CHEMICAL CLEANING 352
STANDARD PROCEDURE—COOLANT SELECTION-ADDITIVES 352
SPECIFICATIONS 352
TORQUE 352
SPECIAL TOOLS 353
COOLING 353
ACCESSORY DRIVE 354
BELT TENSIONERS – 3 9L/5 2L/5 9L 354
DESCRIPTION 354
DESCRIPTION 354
OPERATION 354
OPERATION 354
REMOVAL 354
REMOVAL 355
INSTALLATION 355
INSTALLATION 355
BELT TENSIONERS – 8 0L 355
DESCRIPTION 355
DESCRIPTION 355
OPERATION 355
OPERATION 355
REMOVAL 356
REMOVAL 356
INSTALLATION 357
INSTALLATION 357
BELT TENSIONERS – 5 9L DIESEL 358
DESCRIPTION 358
DESCRIPTION 358
OPERATION 358
OPERATION 358
REMOVAL 358
REMOVAL 358
INSTALLATION 358
INSTALLATION 358
DRIVE BELTS – 3 9L/5 2L/5 9L 359
DIAGNOSIS AND TESTING—ACCESSORY DRIVE BELT 359
VISUAL DIAGNOSIS 359
NOISE DIAGNOSIS 359
REMOVAL 361
REMOVAL 361
INSTALLATION 361
INSTALLATION 362
DRIVE BELTS – 8 0L 362
DIAGNOSIS AND TESTING—ACCESSORY DRIVE BELT 362
VISUAL DIAGNOSIS 362
NOISE DIAGNOSIS 363
REMOVAL 365
REMOVAL 365
INSTALLATION 365
INSTALLATION 365
DRIVE BELTS – 5 9L DIESEL 366
DIAGNOSIS AND TESTING—ACCESSORY DRIVE BELT 366
VISUAL DIAGNOSIS 366
NOISE DIAGNOSIS 366
REMOVAL 368
REMOVAL 368
INSTALLATION 368
INSTALLATION 369
VACUUM PUMP – 5 9L DIESEL 369
DESCRIPTION 369
DESCRIPTION 369
OPERATION 370
OPERATION 370
DIAGNOSIS AND TESTING—VACUUM PUMP OUTPUT 370
DIAGNOSING LOW VACUUM OUTPUT CONDITION 370
REMOVAL 370
REMOVAL 370
INSTALLATION 371
INSTALLATION 372
ENGINE 374
COOLANT 375
DESCRIPTION 375
DESCRIPTION 375
ETHYLENE-GLYCOL MIXTURES 375
PROPYLENE-GLYCOL MIXTURES 375
OPERATION 375
OPERATION 375
COOLANT RECOVERY CONTAINER – 3 9L/5 2L/5 9L/5 9L DIESEL 376
DESCRIPTION 376
DESCRIPTION 376
OPERATION 376
OPERATION 376
REMOVAL 376
REMOVAL 376
INSTALLATION 376
INSTALLATION 376
COOLANT RECOVERY CONTAINER – 8 0L 377
DESCRIPTION 377
DESCRIPTION 377
OPERATION 377
OPERATION 377
RADIATOR FAN – 3 9L/5 2L/5 9L/8 0L 377
REMOVAL 377
REMOVAL 377
CLEANING 378
CLEANING 378
INSPECTION 378
INSPECTION 378
INSTALLATION 378
INSTALLATION 378
RADIATOR FAN – 5 9L DIESEL 379
REMOVAL 379
REMOVAL 379
CLEANING 379
CLEANING 379
INSPECTION 379
INSPECTION 379
INSTALLATION 380
INSTALLATION 380
ENGINE BLOCK HEATER – 3 9L/5 2L/5 9L 380
DESCRIPTION 380
DESCRIPTION 380
OPERATION 380
OPERATION 380
REMOVAL 380
REMOVAL 380
INSTALLATION 380
INSTALLATION 380
ENGINE BLOCK HEATER – 8 0L 381
DESCRIPTION 381
DESCRIPTION 381
OPERATION 381
OPERATION 381
REMOVAL 381
REMOVAL 381
INSTALLATION 381
INSTALLATION 381
ENGINE BLOCK HEATER – 5 9L DIESEL 382
DESCRIPTION 382
DESCRIPTION 382
OPERATION 382
OPERATION 382
REMOVAL 382
REMOVAL 382
INSTALLATION 382
INSTALLATION 382
ENGINE COOLANT TEMP SENSOR – 3 9L/5 2L/5 9L 383
DESCRIPTION 383
DESCRIPTION 383
OPERATION 383
OPERATION 383
REMOVAL 383
REMOVAL 383
INSTALLATION 383
INSTALLATION 383
ENGINE COOLANT THERMOSTAT – 3 9L/5 2L/5 9L 384
DESCRIPTION 384
DESCRIPTION 384
OPERATION 384
OPERATION 384
DIAGNOSIS AND TESTING—THERMOSTAT 384
ON-BOARD DIAGNOSTICS 384
REMOVAL 384
REMOVAL 384
INSTALLATION 385
INSTALLATION 385
ENGINE COOLANT THERMOSTAT – 8 0L 387
DESCRIPTION 387
DESCRIPTION 387
OPERATION 387
OPERATION 387
DIAGNOSIS AND TESTING—THERMOSTAT 387
ON-BOARD DIAGNOSTICS 387
REMOVAL 387
REMOVAL 387
INSTALLATION 388
INSTALLATION 388
ENGINE COOLANT THERMOSTAT – 5 9L DIESEL 389
DESCRIPTION 389
DESCRIPTION 389
OPERATION 389
OPERATION 389
DIAGNOSIS AND TESTING—THERMOSTAT 389
REMOVAL 390
REMOVAL 390
INSTALLATION 390
INSTALLATION 390
FAN DRIVE VISCOUS CLUTCH – 3 9L/5 2L/5 9L/8 0L 391
DESCRIPTION 391
DESCRIPTION 391
OPERATION 391
OPERATION 391
DIAGNOSIS AND TESTING—VISCOUS FAN DRIVE 391
NOISE 391
LEAKS 391
VISCOUS DRIVE 391
FAN DRIVE VISCOUS CLUTCH – 5 9L DIESEL 392
DESCRIPTION 392
DESCRIPTION 392
OPERATION 392
OPERATION 392
DIAGNOSIS AND TESTING—VISCOUS FAN DRIVE 393
NOISE 393
LEAKS 393
VISCOUS DRIVE 393
RADIATOR – 3 9L/5 2L/5 9L 394
DESCRIPTION 394
DESCRIPTION 394
OPERATION 394
OPERATION 394
DIAGNOSIS AND TESTING—RADIATOR COOLANT FLOW 394
REMOVAL 394
REMOVAL 394
CLEANING 395
CLEANING 395
INSPECTION 396
INSPECTION 396
INSTALLATION 396
INSTALLATION 396
RADIATOR – 8 0L 396
DESCRIPTION 396
DESCRIPTION 396
OPERATION 396
OPERATION 396
DIAGNOSIS AND TESTING—RADIATOR COOLANT FLOW 396
REMOVAL 396
REMOVAL 397
CLEANING 397
CLEANING 397
INSPECTION 397
INSPECTION 397
INSTALLATION 398
INSTALLATION 398
RADIATOR – 5 9L DIESEL 398
DESCRIPTION 398
DESCRIPTION 398
OPERATION 398
OPERATION 398
DIAGNOSIS AND TESTING—RADIATOR COOLANT FLOW 398
REMOVAL 398
REMOVAL 398
CLEANING 400
CLEANING 400
INSPECTION 400
INSPECTION 400
INSTALLATION 400
INSTALLATION 400
RADIATOR PRESSURE CAP 400
DESCRIPTION 400
DESCRIPTION 400
OPERATION 400
OPERATION 400
DIAGNOSIS AND TESTING—RADIATOR CAP-TO-FILLER NECK SEAL 401
DIAGNOSIS AND TESTING—RADIATOR CAP 401
CLEANING 401
CLEANING 401
INSPECTION 401
INSPECTION 401
WATER PUMP – 3 9L/5 2L/5 9L 402
DESCRIPTION 402
DESCRIPTION 402
OPERATION 402
OPERATION 402
DIAGNOSIS AND TESTING—WATER PUMP 402
REMOVAL 402
REMOVAL 402
CLEANING 403
CLEANING 404
INSPECTION 404
INSPECTION 404
INSTALLATION 404
INSTALLATION 405
WATER PUMP – 8 0L 405
DIAGNOSIS AND TESTING—WATER PUMP 405
REMOVAL 405
REMOVAL 405
CLEANING 407
CLEANING 407
INSPECTION 407
INSPECTION 407
INSTALLATION 407
INSTALLATION 407
WATER PUMP – 5 9L DIESEL 408
DESCRIPTION 408
DESCRIPTION 408
OPERATION 408
OPERATION 408
DIAGNOSIS AND TESTING—WATER PUMP 408
REMOVAL 408
REMOVAL 408
CLEANING 408
CLEANING 408
INSPECTION 408
INSPECTION 408
INSTALLATION 409
INSTALLATION 409
WATER PUMP INLET TUBE – 3 9L/5 2L/5 9L 409
REMOVAL 409
REMOVAL—WATER PUMP BYPASS HOSE WITH AIR CONDITIONING 409
REMOVAL—WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING 412
INSTALLATION 412
INSTALLATION—WATER PUMP BYPASS HOSE WITH AIR CONDITIONING 412
INSTALLATION—WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING 413
TRANSMISSION 414
TRANS COOLER – 3 9L/5 2L/5 9L 414
DESCRIPTION 414
DESCRIPTION 414
OPERATION 414
OPERATION 414
STANDARD PROCEDURE – FLUSHING COOLERS AND TUBES – WITH RADIATOR IN-TANK TRANSMISSION OIL COOLER 414
STANDARD PROCEDURE – FLUSHING COOLER AND TUBES – WITHOUT RADIATOR IN-TANK TRANSMISSION OIL COOLER 415
REMOVAL 416
REMOVAL 416
DISASSEMBLY 416
DISASSEMBLY 416
ASSEMBLY 417
ASSEMBLY 417
INSTALLATION 417
INSTALLATION 417
TRANS COOLER – 8 0L 417
DESCRIPTION 417
DESCRIPTION 417
OPERATION 417
OPERATION 417
STANDARD PROCEDURE – FLUSHING COOLERS AND TUBES – WITH RADIATOR IN-TANK TRANSMISSION OIL COOLER 418
STANDARD PROCEDURE – FLUSHING COOLER AND TUBES – WITHOUT RADIATOR IN-TANK TRANSMISSION OIL COOLER 418
REMOVAL 419
REMOVAL 419
INSTALLATION 419
INSTALLATION 420
TRANS COOLER – 5 9L DIESEL 420
DESCRIPTION 420
DESCRIPTION 420
OPERATION 420
OPERATION 420
STANDARD PROCEDURE – FLUSHING COOLERS AND TUBES – WITH RADIATOR IN-TANK TRANSMISSION OIL COOLER 420
STANDARD PROCEDURE – FLUSHING COOLER AND TUBES – WITHOUT RADIATOR IN-TANK TRANSMISSION OIL COOLER 421
REMOVAL 422
REMOVAL—AIR TO OIL COOLER 422
REMOVAL—WATER TO OIL COOLER 422
INSTALLATION 423
INSTALLATION—AIR TO OIL COOLER 423
INSTALLATION 423
8a-AUDIO 424
AUDIO 424
DESCRIPTION 424
DESCRIPTION 424
OPERATION 425
OPERATION 425
CENTRAL TIMER MODULE 425
DIAGNOSIS AND TESTING – AUDIO 425
SPECIAL TOOLS 427
AUDIO SYSTEMS 427
ANTENNA BODY & CABLE 427
DESCRIPTION 427
DESCRIPTION 427
OPERATION 427
OPERATION 427
DIAGNOSIS AND TESTING 428
DIAGNOSIS AND TESTING – ANTENNA 428
TEST 1 429
TEST 2 429
TEST 3 429
TEST 4 429
REMOVAL 429
REMOVAL 429
INSTALLATION 430
INSTALLATION 430
RADIO CHOKE RELAY 431
DESCRIPTION 431
DESCRIPTION 431
OPERATION 431
OPERATION 431
DIAGNOSIS AND TESTING – RADIO CHOKE RELAY 431
REMOVAL 432
REMOVAL 432
INSTALLATION 432
INSTALLATION 432
INSTRUMENT PANEL ANTENNA CABLE 432
REMOVAL 432
REMOVAL 432
INSTALLATION 433
INSTALLATION 433
RADIO 433
DESCRIPTION 433
DESCRIPTION 433
OPERATION 433
OPERATION 433
DIAGNOSIS AND TESTING 433
DIAGNOSIS AND TESTING – RADIO 433
REMOVAL 434
REMOVAL 434
INSTALLATION 435
INSTALLATION 435
RADIO NOISE SUPPRESSION COMPONENTS 435
DESCRIPTION 435
DESCRIPTION 435
DIAGNOSIS AND TESTING 435
DIAGNOSIS AND TESTING – RADIO NOISE SUPPRESSION COMPONENTS 435
ENGINE-TO-BODY GROUND STRAP 436
REMOVAL 436
REMOVAL 436
INSTALLATION 436
INSTALLATION 436
CAB-TO- BED GROUND STRAP 437
REMOVAL 437
REMOVAL 437
INSTALLATION 437
INSTALLATION 437
HEATER CORE GROUND STRAP 437
REMOVAL 437
REMOVAL 437
INSTALLATION 438
INSTALLATION 438
REMOTE SWITCHES 438
DESCRIPTION 438
DESCRIPTION 438
OPERATION 438
OPERATION 438
DIAGNOSIS AND TESTING 439
DIAGNOSIS AND TESTING – REMOTE SWITCHES 439
REMOVAL 439
REMOVAL 439
INSTALLATION 440
INSTALLATION 440
SPEAKER 440
DESCRIPTION 440
DESCRIPTION 440
STANDARD 440
PREMIUM 440
OPERATION 440
OPERATION 440
STANDARD 440
PREMIUM 441
DIAGNOSIS AND TESTING – SPEAKER 441
A-PILLAR TWEETER SPEAKER 442
REMOVAL 442
REMOVAL 442
INSTALLATION 442
INSTALLATION 442
FRONT DOOR SPEAKER 443
REMOVAL 443
REMOVAL 443
INSTALLATION 443
INSTALLATION 443
REAR CAB SIDE PANEL SPEAKER 443
REMOVAL 443
REMOVAL 443
INSTALLATION 444
INSTALLATION 444
REAR DOOR SPEAKER 444
REMOVAL 444
REMOVAL 444
INSTALLATION 444
INSTALLATION 444
8b-CHIME/BUZZER 446
CHIME WARNING SYSTEM 446
DESCRIPTION 446
DESCRIPTION 446
OPERATION 446
OPERATION 446
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEM 447
8e-ELECTRONIC CONTROL MODULES 452
BODY CONTROL/CENTRAL TIMER MODULE 452
DESCRIPTION 452
DESCRIPTION 452
OPERATION 454
OPERATION 454
DIAGNOSIS AND TESTING 455
DIAGNOSIS AND TESTING – CENTRAL TIMER MODULE 455
REMOVAL 456
REMOVAL 456
INSTALLATION 456
INSTALLATION 457
COMMUNICATION 457
DESCRIPTION 457
DESCRIPTION – CCD DATA BUS 457
OPERATION 458
OPERATION – CCD DATA BUS 458
BUS (+) AND BUS (–) CIRCUITS 458
CCD CHIPS 458
BUS BIAS AND TERMINATION 459
BUS MESSAGING 459
BUS MESSAGE CODING 460
DIAGNOSIS AND TESTING 462
DIAGNOSIS AND TESTING – CCD DATA BUS 462
CCD BUS FAILURE 462
BUS FAILURE VISUAL SYMPTOM DIAGNOSIS 462
CONTROLLER ANTILOCK BRAKE 462
DESCRIPTION 462
DESCRIPTION 462
OPERATION 462
OPERATION 462
SYSTEM SELF-TEST 462
CAB INPUTS 462
CAB OUTPUTS 462
REMOVAL 463
REMOVAL 463
INSTALLATION 463
INSTALLATION 463
DATA LINK CONNECTOR 463
DESCRIPTION 463
DESCRIPTION – DATA LINK CONNECTOR 463
OPERATION0 – 4 BR/BE (Continued) 463
OPERATION – DATA LINK CONNECTOR 463
ENGINE CONTROL MODULE 464
DESCRIPTION 464
DESCRIPTION – ECM 464
OPERATION 464
OPERATION – ECM 464
REMOVAL 465
REMOVAL 465
INSTALLATION 465
INSTALLATION 465
POWERTRAIN CONTROL MODULE 465
DESCRIPTION 465
DESCRIPTION – PCM 465
DESCRIPTION – MODES OF OPERATION 465
DESCRIPTION – 5 VOLT SUPPLIES 468
DESCRIPTION – IGNITION CIRCUIT SENSE 468
DESCRIPTION – POWER GROUNDS 468
DESCRIPTION – SENSOR RETURN 468
DESCRIPTION – SIGNAL GROUND 468
OPERATION 468
OPERATION – PCM – GAS ENGINES 468
OPERATION – DIESEL 469
OPERATION – 5 VOLT SUPPLIES 470
OPERATION – IGNITION CIRCUIT SENSE 470
REMOVAL 470
REMOVAL 470
INSTALLATION 471
INSTALLATION 471
8f-ENGINE SYSTEMS 472
BATTERY SYSTEM 472
BATTERY SYSTEM 472
DESCRIPTION 472
DESCRIPTION 472
OPERATION 473
OPERATION 473
DIAGNOSIS AND TESTING 473
DIAGNOSIS AND TESTING – BATTERY SYSTEM 473
ABNORMAL BATTERY DISCHARGING 475
CLEANING 476
CLEANING 476
INSPECTION 476
INSPECTION 476
SPECIFICATIONS 477
BATTERY 477
BATTERY 477
DESCRIPTION 477
DESCRIPTION 477
OPERATION 478
OPERATION 478
DIAGNOSIS AND TESTING 478
DIAGNOSIS AND TESTING – BATTERY 478
STANDARD PROCEDURE 479
STANDARD PROCEDURE – CHECKING BATTERY ELECTROLYTE LEVEL 479
STANDARD PROCEDURE – BATTERY CHARGING 480
CHARGING A COMPLETELY DISCHARGED BATTERY 481
CHARGING TIME REQUIRED 481
STANDARD PROCEDURE – BUILT-IN INDICATOR TEST 482
STANDARD PROCEDURE – HYDROMETER TEST 483
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 484
STANDARD PROCEDURE – LOAD TEST 485
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 486
REMOVAL 488
REMOVAL 488
INSTALLATION 488
INSTALLATION 488
BATTERY HOLDDOWN 489
DESCRIPTION 489
DESCRIPTION 489
OPERATION 489
OPERATION 489
REMOVAL 489
REMOVAL 489
INSTALLATION 489
INSTALLATION 489
BATTERY CABLE 490
DESCRIPTION 490
DESCRIPTION 490
GASOLINE ENGINE 490
DIESEL ENGINE 491
OPERATION 491
OPERATION 491
GASOLINE ENGINE 491
DIESEL ENGINE 491
DIAGNOSIS AND TESTING 491
DIAGNOSIS & TESTING – BATTERY CABLES 491
REMOVAL 494
POSITIVE CABLE REMOVAL – GASOLINE 494
NEGATIVE CABLE REMOVAL – GASOLINE 494
INSTALLATION 494
POSITIVE CABLE INSTALLATION – GASOLINE 494
NEGATIVE CABLE INSTALLATION – GASOLINE 495
BATTERY TRAY 495
DESCRIPTION 495
DESCRIPTION 495
OPERATION 495
OPERATION 496
REMOVAL 496
REMOVAL 496
INSTALLATION 496
INSTALLATION 496
CHARGING 498
CHARGING 498
DESCRIPTION 498
DESCRIPTION 498
OPERATION 498
OPERATION 498
DIAGNOSIS AND TESTING 498
DIAGNOSIS AND TESTING – CHARGING SYSTEM 498
INSPECTION 499
SPECIFICATIONS 499
GENERATOR RATINGS 499
SPECIFICATIONS – TORQUE – GENERATOR/CHARGING SYSTEM 499
BATTERY TEMPERATURE SENSOR 500
DESCRIPTION 500
DESCRIPTION 500
OPERATION 500
OPERATION 500
REMOVAL 500
REMOVAL 500
INSTALLATION 500
INSTALLATION 500
GENERATOR 500
DESCRIPTION 500
DESCRIPTION 500
OPERATION 500
OPERATION 500
REMOVAL 501
REMOVAL 501
INSTALLATION 501
INSTALLATION 501
VOLTAGE REGULATOR 502
DESCRIPTION 502
DESCRIPTION 502
OPERATION 502
OPERATION 502
STARTING 503
STARTING 503
DESCRIPTION 503
DESCRIPTION 503
OPERATION 503
OPERATION 503
DIAGNOSIS AND TESTING 504
DIAGNOSIS AND TESTING – STARTING SYSTEM 504
TESTING 505
SPECIFICATIONS 509
STARTING SYSTEM 509
SPECIFICATIONS – TORQUE – STARTING SYSTEM 509
ENGINE STARTER MOTOR 510
DESCRIPTION 510
DESCRIPTION 510
OPERATION 510
OPERATION 510
DIAGNOSIS AND TESTING 510
DIAGNOSIS AND TESTING – STARTER MOTOR 510
STARTER MOTOR SOLENOID 510
REMOVAL 510
REMOVAL 511
INSTALLATION 512
INSTALLATION 512
ENGINE STARTER MOTOR RELAY 513
DESCRIPTION 513
DESCRIPTION 513
OPERATION 513
OPERATION 513
DIAGNOSIS AND TESTING 513
DIAGNOSIS AND TESTING – STARTER RELAY 513
REMOVAL 514
REMOVAL 514
INSTALLATION 514
INSTALLATION 514
8g-HEATED SYSTEMS 516
HEATED MIRRORS 516
HEATED MIRRORS 516
DESCRIPTION 516
DESCRIPTION – HEATED MIRROR SYSTEM 516
OPERATION 516
OPERATION – HEATED MIRROR SYSTEM 517
DIAGNOSIS AND TESTING 517
DIAGNOSIS AND TESTING – HEATED MIRROR SYSTEM 517
MIRROR SWITCH 518
DESCRIPTION 518
DESCRIPTION 518
OPERATION 518
OPERATION 518
DIAGNOSIS AND TESTING 518
DIAGNOSIS AND TESTING – HEATED MIRROR SWITCH 518
HEATED MIRROR GRID 519
DESCRIPTION 519
DESCRIPTION 519
OPERATION 519
OPERATION 519
DIAGNOSIS AND TESTING 519
DIAGNOSIS AND TESTING – HEATED MIRROR GRID 519
HEATED SEAT SYSTEM 520
HEATED SEAT SYSTEM 520
DESCRIPTION 520
DESCRIPTION 520
OPERATION 520
OPERATION 521
DIAGNOSIS AND TESTING 521
DIAGNOSIS & TESTING – HEATED SEAT SYSTEM 521
SELF-DIAGNOSIS 521
TESTING 521
DRIVER SEAT HEATER SWITCH 522
DESCRIPTION 522
DESCRIPTION 522
OPERATION 522
OPERATION 522
DIAGNOSIS AND TESTING 523
DIAGNOSIS & TESTING – HEATED SEAT SWITCH 523
REMOVAL 524
REMOVAL 524
INSTALLATION 524
INSTALLATION 524
HEATED SEAT ELEMENT 525
DESCRIPTION 525
DESCRIPTION 525
OPERATION 525
OPERATION 525
DIAGNOSIS AND TESTING 525
DIAGNOSIS & TESTING – HEATED SEAT ELEMENT AND SENSOR 526
HEATED SEAT ELEMENT 526
HEATED SEAT SENSOR 526
HEATED SEAT RELAY 526
DESCRIPTION 526
DESCRIPTION 526
OPERATION 527
OPERATION 527
DIAGNOSIS AND TESTING 527
DIAGNOSIS & TESTING – HEATED SEAT RELAY 527
RELAY TEST 527
RELAY CIRCUIT TEST 527
REMOVAL 528
REMOVAL 528
INSTALLATION 528
INSTALLATION 528
PASSENGER SEAT HEATER SWITCH 528
DESCRIPTION 528
DESCRIPTION 528
OPERATION 529
OPERATION 529
DIAGNOSIS AND TESTING 529
DIAGNOSIS & TESTING – HEATED SEAT SWITCH 529
REMOVAL 530
REMOVAL 530
INSTALLATION 531
INSTALLATION 531
8h-HORN 532
HORN 532
DESCRIPTION 532
DESCRIPTION 532
OPERATION 532
OPERATION 532
CENTRAL TIMER MODULE 532
HORN 533
DESCRIPTION 533
DESCRIPTION 533
OPERATION 533
OPERATION 533
DIAGNOSIS AND TESTING 533
DIAGNOSIS AND TESTING – HORN 533
REMOVAL 533
REMOVAL 533
INSTALLATION 533
INSTALLATION 534
HORN RELAY 534
DESCRIPTION 534
DESCRIPTION 534
OPERATION 534
OPERATION 534
DIAGNOSIS AND TESTING 534
DIAGNOSIS AND TESTING – HORN RELAY 534
RELAY CIRCUIT TEST 534
REMOVAL 535
REMOVAL 535
INSTALLATION 535
INSTALLATION 535
HORN SWITCH 535
DESCRIPTION 535
DESCRIPTION 535
OPERATION 536
OPERATION 536
DIAGNOSIS AND TESTING 536
DIAGNOSIS AND TESTING – HORN SWITCH 536
REMOVAL 536
REMOVAL 536
8i-IGNITION CONTROL 538
IGNITION CONTROL 538
DESCRIPTION 538
DESCRIPTION – 8 0L V-10 538
DESCRIPTION – V-6/V-8 538
OPERATION 538
OPERATION – 8 0L V-10 538
OPERATION – V-6/V-8 538
SPECIFICATIONS 539
SPECIFICATIONS – TORQUE – IGNITION 539
SPARK PLUG CABLE ORDER—8 0L V-10 ENGINE 539
ENGINE FIRING ORDER—5 2L/5 9L V-8 ENGINES 539
ENGINE FIRING ORDER—3 9L V-6 ENGINE 539
SPARK PLUG CABLE RESISTANCE 540
SPARK PLUGS 540
IGNITION COIL RESISTANCE—3 9L/5 2L/5 9L ENGINES 540
IGNITION COIL RESISTANCE—8 0L V-10 ENGINE 540
IGNITION TIMING 540
AUTOMATIC SHUT DOWN RELAY 540
DESCRIPTION 540
DESCRIPTION – PCM OUTPUT 540
OPERATION 540
OPERATION – PCM OUTPUT 540
OPERATION – ASD SENSE – PCM INPUT 540
DIAGNOSIS AND TESTING 540
DIAGNOSIS AND TESTING – ASD AND FUEL PUMP RELAYS 540
REMOVAL 541
REMOVAL 541
INSTALLATION 541
INSTALLATION 542
CAMSHAFT POSITION SENSOR 542
DESCRIPTION 542
DESCRIPTION – DIESEL 542
DESCRIPTION – 3 9L/5 2L/5 9L 542
DESCRIPTION – 8 0L 542
OPERATION 542
OPERATION – DIESEL 542
OPERATION – 3 9L/5 2L/5 9L 543
OPERATION – 8 0L 543
REMOVAL 543
REMOVAL – DIESEL 544
REMOVAL – 3 9L/5 2L/5 9L 544
REMOVAL – 8 0L 545
INSTALLATION 545
INSTALLATION – DIESEL 545
INSTALLATION – 3 9L/5 2L/5 9L 546
INSTALLATION – 8 0L 546
DISTRIBUTOR 547
DESCRIPTION 547
DESCRIPTION 547
OPERATION 547
OPERATION 548
REMOVAL 548
REMOVAL 548
INSTALLATION 548
INSTALLATION 548
DISTRIBUTOR CAP 549
DIAGNOSIS AND TESTING 549
DIAGNOSIS AND TESTING – DISTRIBUTOR CAP 549
DISTRIBUTOR ROTOR 550
DIAGNOSIS AND TESTING 550
DIAGNOSIS AND TESTING – DISTRIBUTOR ROTOR 550
IGNITION COIL 550
DESCRIPTION 550
DESCRIPTION – 3 9L/5 2L/5 9L 550
DESCRIPTION – 8 0L 550
OPERATION 551
OPERATION – 3 9L/5 2L/5 9L 551
OPERATION – 8 0L0 – 6 BR/BE (Continued) 551
REMOVAL 551
REMOVAL – 3 9L/5 2L/5 9L 551
REMOVAL – 8 0L 552
INSTALLATION 552
INSTALLATION – 3 9L/5 2L/5 9L 552
INSTALLATION – 8 0L 552
SPARK PLUG 553
DESCRIPTION 553
DESCRIPTION 553
OPERATION 553
OPERATION 553
DIAGNOSIS AND TESTING 553
DIAGNOSIS AND TESTING – SPARK PLUG CONDITIONS 553
NORMAL OPERATING 553
COLD FOULING/CARBON FOULING 554
WET FOULING OR GAS FOULING 554
OIL OR ASH ENCRUSTED 554
ELECTRODE GAP BRIDGING 554
SCAVENGER DEPOSITS 554
CHIPPED ELECTRODE INSULATOR 555
PREIGNITION DAMAGE 555
SPARK PLUG OVERHEATING 555
REMOVAL 555
REMOVAL 555
CLEANING 555
CLEANING 556
INSTALLATION 556
INSTALLATION 556
SPARK PLUG CABLE 556
DESCRIPTION 556
DESCRIPTION 556
OPERATION 556
OPERATION 556
DIAGNOSIS AND TESTING 556
DIAGNOSIS AND TESTING – SPARK PLUG CABLES 556
REMOVAL 557
REMOVAL 557
INSTALLATION 557
INSTALLATION 557
8j-INSTRUMENT CLUSTER 560
INSTRUMENT CLUSTER 561
DESCRIPTION 561
DESCRIPTION 561
OPERATION 562
OPERATION 562
DIAGNOSIS AND TESTING 565
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER 565
REMOVAL 569
REMOVAL 569
DISASSEMBLY 569
DISASSEMBLY 570
ASSEMBLY 571
ASSEMBLY 572
INSTALLATION 572
INSTALLATION 573
ABS INDICATOR 573
DESCRIPTION 573
DESCRIPTION 573
OPERATION 573
OPERATION 573
AIRBAG INDICATOR 574
DESCRIPTION 574
DESCRIPTION 574
OPERATION 574
OPERATION 574
BRAKE/PARK BRAKE INDICATOR 575
DESCRIPTION 575
DESCRIPTION 575
OPERATION 575
OPERATION 575
DIAGNOSIS AND TESTING 575
DIAGNOSIS AND TESTING – BRAKE INDICATOR 575
CHECK GAUGES INDICATOR 576
DESCRIPTION 576
DESCRIPTION 576
OPERATION 576
OPERATION 576
CRUISE INDICATOR 577
DESCRIPTION 577
DESCRIPTION 577
OPERATION 577
OPERATION 577
ENGINE TEMPERATURE GAUGE 578
DESCRIPTION 578
DESCRIPTION 578
OPERATION 578
OPERATION 578
FUEL GAUGE 579
DESCRIPTION 579
DESCRIPTION 579
OPERATION 579
OPERATION 579
GEAR SELECTOR INDICATOR 580
DESCRIPTION 580
DESCRIPTION 580
OPERATION 580
OPERATION 580
HIGH BEAM INDICATOR 580
DESCRIPTION 580
DESCRIPTION 580
OPERATION 581
OPERATION 581
DIAGNOSIS AND TESTING 581
DIAGNOSIS AND TESTING – HIGH BEAM INDICATOR 581
LOW FUEL INDICATOR 582
DESCRIPTION 582
DESCRIPTION 582
OPERATION 582
OPERATION 582
MALFUNCTION INDICATOR LAMP (MIL) 583
DESCRIPTION 583
DESCRIPTION 583
OPERATION 583
OPERATION 583
ODOMETER 583
DESCRIPTION 583
DESCRIPTION 583
OPERATION 584
OPERATION 584
OIL PRESSURE GAUGE 584
DESCRIPTION 584
DESCRIPTION 584
OPERATION 585
OPERATION 585
OVERDRIVE OFF INDICATOR 586
DESCRIPTION 586
DESCRIPTION 586
OPERATION 586
OPERATION 586
SEATBELT INDICATOR 586
DESCRIPTION 586
DESCRIPTION 586
OPERATION 586
OPERATION 586
SERVICE REMINDER INDICATOR 587
DESCRIPTION 587
DESCRIPTION 587
OPERATION 587
OPERATION 587
SHIFT INDICATOR (TRANSFER CASE) 588
DESCRIPTION 588
DESCRIPTION 588
OPERATION 588
OPERATION 588
DIAGNOSIS AND TESTING 588
DIAGNOSIS AND TESTING – FOUR-WHEEL DRIVE INDICATOR 588
SPEEDOMETER 589
DESCRIPTION 589
DESCRIPTION 589
OPERATION 589
OPERATION 589
TACHOMETER 589
DESCRIPTION 589
DESCRIPTION 589
OPERATION 590
OPERATION 590
TRANSMISSION OVERTEMP INDICATOR 590
DESCRIPTION 590
DESCRIPTION 590
OPERATION 590
OPERATION 590
TURN SIGNAL INDICATORS 591
DESCRIPTION 591
DESCRIPTION 591
OPERATION 591
OPERATION 591
DIAGNOSIS AND TESTING 591
DIAGNOSIS AND TESTING – TURN SIGNAL INDICATORS 591
UPSHIFT INDICATOR 592
DESCRIPTION 592
DESCRIPTION 592
OPERATION 592
OPERATION 592
VOLTAGE GAUGE 592
DESCRIPTION 592
DESCRIPTION 592
OPERATION 593
OPERATION 593
WAIT-TO-START INDICATOR 593
DESCRIPTION 593
DESCRIPTION 593
OPERATION 594
OPERATION 594
WASHER FLUID INDICATOR 594
DESCRIPTION 594
DESCRIPTION 594
OPERATION 594
OPERATION 594
DIAGNOSIS AND TESTING 595
DIAGNOSIS AND TESTING – WASHER FLUID INDICATOR 595
WATER-IN-FUEL INDICATOR 595
DESCRIPTION 595
DESCRIPTION 595
OPERATION 595
OPERATION 596
8l-LAMPS 598
LAMPS/LIGHTING – EXTERIOR 598
LAMPS/LIGHTING – EXTERIOR 599
DESCRIPTION 599
DESCRIPTION – TURN SIGNAL & HAZARD WARNING SYSTEM 599
OPERATION 599
OPERATION – TURN SIGNAL & HAZARD WARNING SYSTEM 599
DIAGNOSIS AND TESTING 600
DIAGNOSIS AND TESTING – TURN SIGNAL & HAZARD WARNING SYSTEM 600
SPECIFICATIONS 601
601
SPECIAL TOOLS 601
HEADLAMP ALIGNMENT 601
BRAKE LAMP SWITCH 601
DESCRIPTION 601
DESCRIPTION 601
OPERATION 601
OPERATION 601
DIAGNOSIS AND TESTING 602
DIAGNOSIS AND TESTING – BRAKE LAMP SWITCH 602
SWITCH CIRCUIT IDENTIFICATION 602
SWITCH CONTINUITY TEST 602
REMOVAL 602
REMOVAL 602
INSTALLATION 602
INSTALLATION 602
CENTER HIGH MOUNTED STOP LAMP 603
REMOVAL 603
REMOVAL 603
INSTALLATION 603
INSTALLATION 603
CENTER HIGH MOUNTED STOP LAMP UNIT 603
REMOVAL 603
REMOVAL 603
INSTALLATION 603
INSTALLATION 603
CLEARANCE LAMP 603
REMOVAL 603
REMOVAL 603
INSTALLATION 603
INSTALLATION 603
COMBINATION FLASHER 604
DESCRIPTION 604
DESCRIPTION 604
OPERATION 604
OPERATION 604
REMOVAL 605
REMOVAL 605
INSTALLATION 605
INSTALLATION 605
DAYTIME RUNNING LAMP MODULE 606
DESCRIPTION 606
DESCRIPTION 606
OPERATION 606
OPERATION 606
REMOVAL 606
REMOVAL 606
INSTALLATION 606
INSTALLATION 606
FOG LAMP 606
DIAGNOSIS AND TESTING 606
DIAGNOSIS AND TESTING – FOG LAMP 606
REMOVAL 608
REMOVAL 608
INSTALLATION 608
INSTALLATION 608
FOG LAMP UNIT 608
REMOVAL 608
REMOVAL 608
SLT 608
SPORT 609
INSTALLATION 609
INSTALLATION 609
SLT 609
SPORT 609
ADJUSTMENTS 609
ADJUSTMENTS 609
HEADLAMP 610
DESCRIPTION 610
DESCRIPTION 610
OPERATION 610
OPERATION 610
DIAGNOSIS AND TESTING 610
DIAGNOSIS AND TESTING – HEADLAMP 610
REMOVAL 613
REMOVAL 613
INSTALLATION 613
INSTALLATION 613
HEADLAMP RELAY 613
DESCRIPTION 613
DESCRIPTION 613
OPERATION 614
OPERATION 614
DIAGNOSIS AND TESTING 614
DIAGNOSIS AND TESTING – HEADLAMP RELAY 614
REMOVAL 615
REMOVAL 615
INSTALLATION 615
INSTALLATION 615
HEADLAMP SWITCH 615
DESCRIPTION 615
DESCRIPTION 615
OPERATION 615
OPERATION 615
DIAGNOSIS AND TESTING 615
DIAGNOSIS AND TESTING – HEADLAMP SWITCH 615
REMOVAL 616
REMOVAL 616
INSTALLATION 616
INSTALLATION 617
HEADLAMP UNIT 617
REMOVAL 617
REMOVAL 617
INSTALLATION 617
INSTALLATION 617
ADJUSTMENTS 618
ADJUSTMENTS 618
LAMP ALIGNMENT SCREEN PREPARATION 618
VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT 618
HEADLAMP ADJUSTMENT 619
LICENSE PLATE LAMP 619
REMOVAL 619
REMOVAL 619
INSTALLATION 619
INSTALLATION 619
LICENSE PLATE LAMP UNIT 619
REMOVAL 619
REMOVAL 619
INSTALLATION 619
INSTALLATION 619
MARKER LAMP 619
REMOVAL 619
REMOVAL 619
INSTALLATION 620
INSTALLATION 620
MULTI-FUNCTION SWITCH 620
DESCRIPTION 620
DESCRIPTION 620
OPERATION 621
OPERATION 621
DIAGNOSIS AND TESTING 622
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCH 622
REMOVAL 624
REMOVAL 624
INSTALLATION0 – 8 BR/BE (Continued) 624
INSTALLATION 625
OUTBOARD IDENTIFICATION LAMP 625
REMOVAL 625
REMOVAL 625
INSTALLATION 625
INSTALLATION 626
PARK/TURN SIGNAL LAMP 626
REMOVAL 626
REMOVAL 626
INSTALLATION 626
INSTALLATION 626
PARK/TURN SIGNAL LAMP UNIT 626
REMOVAL 626
REMOVAL 626
INSTALLATION 626
INSTALLATION 626
TAIL LAMP 626
DESCRIPTION 626
DESCRIPTION 626
OPERATION 626
OPERATION 626
REMOVAL 626
REMOVAL 626
CHASSIS CAB 626
PICKUP 627
INSTALLATION 627
INSTALLATION 627
CHASSIS CAB 627
PICKUP 627
TAIL LAMP UNIT 627
REMOVAL 627
REMOVAL 627
CAB CHASSIS 627
PICKUP 627
INSTALLATION 627
INSTALLATION 627
CAB CHASSIS 627
PICKUP 627
TURN SIGNAL CANCEL CAM 627
DESCRIPTION 627
DESCRIPTION 627
OPERATION 628
OPERATION 628
UNDERHOOD LAMP 628
REMOVAL 628
REMOVAL 628
INSTALLATION 629
INSTALLATION 629
UNDERHOOD LAMP UNIT 629
REMOVAL 629
REMOVAL 629
INSTALLATION 629
INSTALLATION 629
LAMPS/LIGHTING – INTERIOR 630
LAMPS/LIGHTING – INTERIOR 630
SPECIFICATIONS 630
630
DOME LAMP 630
REMOVAL 630
REMOVAL 630
INSTALLATION 630
INSTALLATION 630
DOOR AJAR SWITCH 631
DESCRIPTION 631
DESCRIPTION 631
DIAGNOSIS AND TESTING 631
DIAGNOSIS AND TESTING – DOOR AJAR SWITCH 631
REMOVAL 631
REMOVAL 632
INSTALLATION 632
INSTALLATION 632
GLOVE BOX LAMP AND SWITCH 632
REMOVAL 632
REMOVAL 632
INSTALLATION 632
INSTALLATION 632
READING LAMP 633
DESCRIPTION 633
DESCRIPTION 633
OPERATION 633
OPERATION 633
REMOVAL 633
REMOVAL 633
INSTALLATION 633
INSTALLATION 633
VANITY LAMP 634
REMOVAL 634
REMOVAL 634
INSTALLATION 634
INSTALLATION 634
8m-MESSAGE SYSTEMS 636
OVERHEAD CONSOLE 636
DESCRIPTION 636
DESCRIPTION 636
GARAGE DOOR OPENER STORAGE BIN 636
SUNGLASS STORAGE BIN 638
COMPASS 638
THERMOMETER 638
STANDARD PROCEDURE 639
STANDARD PROCEDURE – COMPASS CALIBRATION 639
STANDARD PROCEDURE – COMPASS VARIATION ADJUSTMENT 639
ZONE METHOD 639
DIRECT METHOD 639
STANDARD PROCEDURE – COMPASS DEMAGNETIZING 640
REMOVAL 641
REMOVAL 641
DISASSEMBLY 642
OVERHEAD CONSOLE DISASSEMBLY 642
GARAGE DOOR OPENER STORAGE BIN REMOVAL 642
SUNGLASS STORAGE BIN REMOVAL 642
COMPASS MINI-TRIP LENS REMOVAL 642
ASSEMBLY 642
OVERHEAD CONSOLE ASSEMBLY 642
GARAGE DOOR OPENER STORAGE BIN 642
SUNGLASS STORAGE BIN 643
MINI-TRIP COMPUTER LENS 643
INSTALLATION 643
INSTALLATION 643
SPECIAL TOOLS 643
OVERHEAD CONSOLE SYSTEMS 643
COMPASS/MINI-TRIP COMPUTER 643
DESCRIPTION 643
DESCRIPTION 643
OPERATION 644
OPERATION 644
DIAGNOSIS AND TESTING 644
DIAGNOSIS & TESTING – COMPASS MINI-TRIP COMPUTER 645
SELF-DIAGNOSTIC TEST 645
REMOVAL 646
REMOVAL 646
INSTALLATION 646
INSTALLATION 646
AMBIENT TEMP SENSOR 646
DESCRIPTION 646
DESCRIPTION 646
OPERATION 646
OPERATION 646
DIAGNOSIS AND TESTING 646
DIAGNOSIS & TESTING – AMBIENT TEMPERATURE SENSOR 647
SENSOR TEST 647
SENSOR CIRCUIT TEST 647
REMOVAL 647
REMOVAL 647
INSTALLATION 647
INSTALLATION 648
8n-POWER SYSTEMS 650
POWER LOCKS 650
POWER LOCKS 650
DESCRIPTION 650
DESCRIPTION – POWER LOCK SYSTEM 650
DESCRIPTION – REMOTE KEYLESS ENTRY SYSTEM 651
OPERATION 651
OPERATION – POWER LOCK SYSTEM 652
OPERATION – REMOTE KEYLESS ENTRY SYSTEM 652
DIAGNOSIS AND TESTING 653
DIAGNOSIS AND TESTING – POWER LOCK SYSTEM 653
DIAGNOSIS AND TESTING – POWER LOCK & REMOTE KEYLESS ENTRY SYSTEM 653
DOOR CYLINDER LOCK SWITCH 654
DESCRIPTION 654
DESCRIPTION 654
OPERATION 654
OPERATION 654
DIAGNOSIS AND TESTING 654
DIAGNOSIS & TESTING – DOOR CYLINDER LOCK SWITCH 654
REMOVAL 655
REMOVAL 655
INSTALLATION 655
INSTALLATION 655
POWER LOCK MOTOR 655
DESCRIPTION 655
DESCRIPTION 655
OPERATION 655
OPERATION 655
DIAGNOSIS AND TESTING 655
DIAGNOSIS AND TESTING – POWER LOCK MOTOR 656
REMOTE KEYLESS ENTRY TRANSMITTER 656
DESCRIPTION 656
DESCRIPTION 656
OPERATION 656
OPERATION 656
DIAGNOSIS AND TESTING 656
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY TRANSMITTER 656
STANDARD PROCEDURE 657
STANDARD PROCEDURE – RKE TRANSMITTER PROGRAMMING 657
STANDARD PROCEDURE – RKE TRANSMITTER BATTERIES 657
POWER LOCK SWITCH 657
DESCRIPTION 657
DESCRIPTION 657
OPERATION 657
OPERATION 657
DIAGNOSIS AND TESTING 657
DIAGNOSIS AND TESTING – POWER LOCK SWITCH 657
POWER MIRRORS 659
POWER MIRRORS 659
DESCRIPTION 659
DESCRIPTION 659
AUTOMATIC DAY / NIGHT MIRROR 659
OUTSIDE REAR VIEW MIRROR 659
OPERATION 659
OPERATION 659
AUTOMATIC DAY / NIGHT MIRROR 659
OUTSIDE REAR VIEW MIRROR 659
AUTOMATIC DAY / NIGHT MIRROR 659
DESCRIPTION 659
DESCRIPTION 659
OPERATION 659
OPERATION 660
DIAGNOSIS AND TESTING 660
DIAGNOSIS AND TESTING – AUTOMATIC DAY/NIGHT MIRROR 660
REMOVAL 660
REMOVAL 661
INSTALLATION 661
INSTALLATION 661
POWER MIRROR SWITCH 661
DESCRIPTION 661
DESCRIPTION 661
OPERATION 661
OPERATION 661
REMOVAL 661
REMOVAL 661
INSTALLATION 662
INSTALLATION 662
SIDEVIEW MIRROR 662
DESCRIPTION 662
DESCRIPTION 662
OPERATION 662
OPERATION 662
DIAGNOSIS AND TESTING 662
DIAGNOSIS AND TESTING – SIDEVIEW MIRROR 662
REMOVAL 663
REMOVAL 663
POWER SEAT SYSTEM 664
POWER SEAT SYSTEM 664
DESCRIPTION 664
DESCRIPTION 664
OPERATION 664
OPERATION 664
DIAGNOSIS AND TESTING 664
DIAGNOSIS & TESTING – POWER SEAT SYSTEM 664
DRIVER POWER SEAT SWITCH 665
DESCRIPTION 665
DESCRIPTION 665
OPERATION 665
OPERATION 665
DIAGNOSIS AND TESTING 665
DIAGNOSIS & TESTING – DRIVER POWER SEAT SWITCH 665
REMOVAL 666
REMOVAL 666
INSTALLATION 666
INSTALLATION 666
LUMBAR CONTROL SWITCH 666
DESCRIPTION 666
DESCRIPTION 666
OPERATION 666
OPERATION 667
REMOVAL 667
REMOVAL 667
LUMBAR MOTOR 667
DESCRIPTION 667
DESCRIPTION 667
OPERATION 667
OPERATION 667
DIAGNOSIS AND TESTING 667
DIAGNOSIS & TESTING – POWER LUMBAR ADJUSTER 667
PASSENGER POWER SEAT SWITCH 668
DESCRIPTION 668
DESCRIPTION 668
OPERATION 668
OPERATION 668
DIAGNOSIS AND TESTING 668
DIAGNOSIS & TESTING – PASSENGER POWER SEAT SWITCH 668
REMOVAL 669
REMOVAL 669
INSTALLATION 669
INSTALLATION 669
RECLINER MOTOR 669
DESCRIPTION 669
DESCRIPTION 669
OPERATION 670
OPERATION 670
DIAGNOSIS AND TESTING 670
DIAGNOSIS & TESTING – POWER SEAT RECLINER 670
POWER SEAT TRACK 670
DESCRIPTION 670
DESCRIPTION 670
OPERATION 670
OPERATION 670
DIAGNOSIS AND TESTING 670
DIAGNOSIS & TESTING – POWER SEAT TRACK 670
REMOVAL 671
REMOVAL 671
INSTALLATION 671
INSTALLATION 671
POWER WINDOWS 672
POWER WINDOWS 672
DESCRIPTION 672
DESCRIPTION 672
OPERATION 672
OPERATION 672
DIAGNOSIS AND TESTING 672
DIAGNOSIS AND TESTING – POWER WINDOWS 672
ALL WINDOWS INOPERATIVE 672
ONE WINDOW INOPERATIVE 672
POWER WINDOW SWITCH 673
DESCRIPTION 673
DESCRIPTION 673
OPERATION 673
OPERATION 673
DIAGNOSIS AND TESTING 673
DIAGNOSIS AND TESTING – POWER WINDOW SWITCH 673
REMOVAL 674
REMOVAL 674
INSTALLATION 674
INSTALLATION 675
WINDOW MOTOR 675
DESCRIPTION 675
DESCRIPTION 675
DIAGNOSIS AND TESTING 675
DIAGNOSIS AND TESTING – WINDOW MOTOR 675
REMOVAL 675
REMOVAL 675
8o-RESTRAINTS 676
RESTRAINTS 676
DESCRIPTION 676
DESCRIPTION 676
OPERATION 677
OPERATION 677
WARNING 678
WARNING 678
DIAGNOSIS AND TESTING 678
DIAGNOSIS AND TESTING – AIRBAG SYSTEM 679
STANDARD PROCEDURE 679
STANDARD PROCEDURE – HANDLING NON-DEPLOYED AIRBAGS 679
STANDARD PROCEDURE – SERVICE AFTER AN AIRBAG DEPLOYMENT 679
STANDARD PROCEDURE – VERIFICATION TEST 680
SPECIAL TOOLS 681
SPECIAL TOOLS – AIRBAG SYSTEM 681
AIRBAG CONTROL MODULE 681
DESCRIPTION 681
DESCRIPTION0 – 10 BR/BE (Continued) 681
OPERATION 681
OPERATION 681
REMOVAL 682
REMOVAL 682
INSTALLATION 683
INSTALLATION 683
CHILD TETHER 684
REMOVAL 684
REMOVAL 684
INSTALLATION 684
INSTALLATION 684
CLOCKSPRING 685
DESCRIPTION 685
DESCRIPTION 685
OPERATION 685
OPERATION 685
STANDARD PROCEDURE 685
STANDARD PROCEDURE – CLOCKSPRING CENTERING 686
REMOVAL 686
REMOVAL 686
INSTALLATION 687
INSTALLATION 688
DRIVER AIRBAG 689
DESCRIPTION 689
DESCRIPTION 689
OPERATION 689
OPERATION 689
REMOVAL 689
REMOVAL 689
DISASSEMBLY 690
DISASSEMBLY 690
ASSEMBLY 691
ASSEMBLY 692
INSTALLATION 692
INSTALLATION 693
FRONT SEAT BELT & RETRACTOR 693
REMOVAL 693
REMOVAL – STANDARD CAB 693
REMOVAL – CLUB/QUAD CAB 694
INSTALLATION 694
INSTALLATION – STANDARD CAB 694
INSTALLATION – CLUB/QUAD CAB 695
FRONT SEAT BELT BUCKLE 695
REMOVAL 695
REMOVAL 695
INSTALLATION 695
INSTALLATION 695
PASSENGER AIRBAG 696
DESCRIPTION 696
DESCRIPTION 696
OPERATION 696
OPERATION 696
REMOVAL 696
REMOVAL 696
INSTALLATION 697
INSTALLATION 698
PASSENGER AIRBAG ON/OFF SWITCH 698
DESCRIPTION 698
DESCRIPTION 698
OPERATION 699
OPERATION 699
REMOVAL 699
REMOVAL 699
INSTALLATION 700
INSTALLATION 700
REAR SEAT BELT & RETRACTOR 701
REMOVAL 701
REMOVAL 701
INSTALLATION 701
INSTALLATION 701
REAR SEAT BELT BUCKLE 702
REMOVAL 702
REMOVAL 702
INSTALLATION 702
INSTALLATION 702
SEAT BELT SWITCH 703
DESCRIPTION 703
DESCRIPTION 703
OPERATION 703
OPERATION 703
DIAGNOSIS AND TESTING 703
DIAGNOSIS AND TESTING – SEAT BELT SWITCH 703
SEAT BELT TURNING LOOP ADJUSTER 704
REMOVAL 704
REMOVAL 704
INSTALLATION 704
INSTALLATION 704
TURNING LOOP HEIGHT ADJUSTER KNOB 705
REMOVAL 705
REMOVAL 705
INSTALLATION 705
INSTALLATION 705
8p-SPEED CONTROL 706
SPEED CONTROL 706
DESCRIPTION 706
DESCRIPTION – SPEED CONTROL SYSTEM 706
DESCRIPTION – VEHICLE SPEED INPUT 706
OPERATION 706
OPERATION – SPEED CONTROL SYSTEM 707
DIAGNOSIS AND TESTING 707
DIAGNOSIS AND TESTING – VACUUM SUPPLY 707
DIAGNOSIS AND TESTING – ROAD TEST 708
SPECIFICATIONS 709
TORQUE – SPEED CONTROL SYSTEM 709
CABLE 709
DESCRIPTION 709
DESCRIPTION 709
OPERATION 709
OPERATION 709
REMOVAL 709
REMOVAL – GAS ENGINES 709
REMOVAL – DIESEL WITH AUTO TRANS 709
INSTALLATION 709
INSTALLATION – GAS ENGINES 709
INSTALLATION – DIESEL WITH AUTO TRANS 709
SPEED CONTROL SERVO 710
DESCRIPTION 710
DESCRIPTION 710
OPERATION 710
OPERATION 710
REMOVAL 711
REMOVAL 711
REMOVAL – DIESEL WITH AUTO TRANS 713
INSTALLATION 715
INSTALLATION 715
INSTALLATION – DIESEL WITH AUTO TRANS 716
SWITCH 717
DESCRIPTION 717
DESCRIPTION 717
OPERATION 717
OPERATION 717
REMOVAL 718
REMOVAL 718
INSTALLATION 718
INSTALLATION 718
VACUUM RESERVOIR 718
DESCRIPTION 718
DESCRIPTION 718
REMOVAL 718
REMOVAL 718
INSTALLATION 719
INSTALLATION 719
8q-VEHICLE THEFT SECURITY 720
VEHICLE THEFT SECURITY 720
DESCRIPTION 720
DESCRIPTION 720
OPERATION 721
OPERATION 721
DIAGNOSIS AND TESTING 722
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITY SYSTEM 722
VTSS INDICATOR 722
DESCRIPTION 722
DESCRIPTION 722
OPERATION 722
OPERATION 722
DIAGNOSIS AND TESTING 722
DIAGNOSIS AND TESTING – VTSS INDICATOR 722
8r-WIPERS/WASHERS 724
WIPERS/WASHERS 724
DESCRIPTION 724
DESCRIPTION 724
OPERATION 725
OPERATION 725
DIAGNOSIS AND TESTING 726
DIAGNOSIS AND TESTING – WIPER & WASHER SYSTEM 726
CLEANING 729
CLEANING – WIPER & WASHER SYSTEM 729
INSPECTION 729
INSPECTION – WIPER & WASHER SYSTEM 729
WASHER FLUID LEVEL SWITCH 730
DESCRIPTION 730
DESCRIPTION 730
OPERATION 730
OPERATION 730
REMOVAL 731
REMOVAL 731
INSTALLATION 731
INSTALLATION 731
WASHER HOSES/TUBES 731
DESCRIPTION 731
DESCRIPTION 731
OPERATION 731
OPERATION 731
WASHER NOZZLE 732
DESCRIPTION 732
DESCRIPTION 732
OPERATION 732
OPERATION 732
REMOVAL 732
REMOVAL 732
INSTALLATION 732
INSTALLATION 732
WASHER PUMP/MOTOR 732
DESCRIPTION 732
DESCRIPTION 732
OPERATION 732
OPERATION 732
REMOVAL 732
REMOVAL 733
INSTALLATION 733
INSTALLATION 733
WASHER RESERVOIR 733
DESCRIPTION 733
DESCRIPTION 733
OPERATION 733
OPERATION 733
REMOVAL 733
REMOVAL 733
INSTALLATION 734
INSTALLATION 734
WIPER ARM 734
DESCRIPTION 734
DESCRIPTION 734
OPERATION 734
OPERATION 735
REMOVAL 735
REMOVAL 735
INSTALLATION 735
INSTALLATION 735
WIPER BLADE 735
DESCRIPTION 735
DESCRIPTION 735
OPERATION 736
OPERATION 736
REMOVAL 736
REMOVAL 736
INSTALLATION 736
INSTALLATION 736
WIPER MODULE 737
DESCRIPTION 737
DESCRIPTION 737
OPERATION 737
OPERATION 737
REMOVAL 737
REMOVAL 737
INSTALLATION 738
INSTALLATION 738
WIPER RELAY 738
DESCRIPTION 738
DESCRIPTION 738
OPERATION 738
OPERATION 738
DIAGNOSIS AND TESTING 739
DIAGNOSIS AND TESTING – WIPER RELAY 739
REMOVAL 740
REMOVAL 740
INSTALLATION 740
INSTALLATION 740
8w-WIRING 742
8W-01 WIRING DIAGRAM INFORMATION 744
WIRING DIAGRAM INFORMATION 744
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 744
SYMBOLS 744
TERMINOLOGY 748
WARNINGS – GENERAL 748
DIAGNOSIS AND TESTING – WIRING HARNESS 748
TROUBLESHOOTING TOOLS 748
INTERMITTENT AND POOR CONNECTIONS 749
TROUBLESHOOTING WIRING PROBLEMS 749
STANDARD PROCEDURE – TESTING FOR VOLTAGE POTENTIAL 749
STANDARD PROCEDURE – TESTING FOR CONTINUITY 749
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 749
STANDARD PROCEDURE – TESTING FOR SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 750
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 750
SPECIAL TOOLS 751
SPECIAL TOOLS – WIRING/TERMINAL 751
CONNECTOR – AUGAT 751
REMOVAL 751
INSTALLATION 751
CONNECTOR – MOLEX 752
REMOVAL 752
INSTALLATION 752
CONNECTOR – THOMAS AND BETTS 752
REMOVAL 752
INSTALLATION 753
DIODE 753
REMOVAL 753
INSTALLATION 753
TERMINAL 754
REMOVAL 754
INSTALLATION 754
WIRE 755
STANDARD PROCEDURE – WIRE SPLICING 755
8W-02 COMPONENT INDEX 756
8W-10 POWER DISTRIBUTION 758
8W-12 JUNCTION BLOCK 786
8W-15 GROUND DISTRIBUTION 808
8W-18 BUS COMMUNICATIONS 826
8W-20 CHARGING SYSTEM 830
8W-21 STARTING SYSTEM 834
8W-30 FUEL/IGNITION SYSTEM 838
8W-31 TRANSMISSION CONTROL SYSTEM 880
8W-33 VEHICLE SPEED CONTROL 886
8W-34 REAR WHEEL ANTILOCK BRAKES 890
8W-35 ALL WHEEL ANTILOCK BRAKES 894
8W-39 VEHICLE THEFT SECURITY SYSTEM 898
8W-40 INSTRUMENT CLUSTER 902
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 910
8W-42 AIR CONDITIONING-HEATER 914
8W-43 AIRBAG SYSTEM 920
8W-44 INTERIOR LIGHTING 924
8W-45 CENTRAL TIMER MODULE 930
8W-47 AUDIO SYSTEM 940
8W-49 OVERHEAD CONSOLE 950
8W-50 FRONT LIGHTING 956
8W-51 REAR LIGHTING 970
8W-52 TURN SIGNALS 976
8W-53 WIPERS 980
8W-54 TRAILER TOW 984
8W-60 POWER WINDOWS 988
8W-61 POWER DOOR LOCKS 990
8W-62 POWER MIRRORS 994
8W-63 POWER SEATS 998
8W-70 SPLICE INFORMATION 1006
8W-80 CONNECTOR PIN-OUTS 1014
8W-90 CONNECTOR/GROUND LOCATIONS 1092
8W-CONNECTOR/GROUND LOCATIONS 1092
DESCRIPTION 1092
8W-95 SPLICE LOCATIONS 1124
DESCRIPTION 1124
SPLICE LOCATIONS 1124
8W-97 POWER DISTRIBUTION 1136
POWER DISTRIBUTION 1136
DESCRIPTION 1136
OPERATION 1136
SPECIAL TOOLS 1137
POWER DISTRIBUTION SYSTEMS 1137
CIGAR LIGHTER OUTLET 1137
DESCRIPTION 1137
OPERATION 1137
DIAGNOSIS & TESTING – CIGAR LIGHTER 1137
REMOVAL 1138
INSTALLATION 1138
CIRCUIT BREAKER 1139
DESCRIPTION 1139
DIAGNOSIS & TESTING – CIRCUIT BREAKER 1139
GENERATOR CARTRIDGE FUSE 1139
DESCRIPTION 1139
OPERATION 1139
REMOVAL 1139
INSTALLATION 1139
IOD FUSE 1139
DESCRIPTION 1139
OPERATION 1140
REMOVAL 1140
INSTALLATION 1140
JUNCTION BLOCK 1141
DESCRIPTION 1141
OPERATION 1141
REMOVAL 1141
INSTALLATION 1142
POWER DISTRIBUTION CENTER 1142
DESCRIPTION 1142
OPERATION 1143
REMOVAL 1143
INSTALLATION 1143
POWER OUTLET 1144
DESCRIPTION 1144
OPERATION 1145
DIAGNOSIS & TESTING – POWER OUTLET 1145
REMOVAL 1145
INSTALLATION 1146
9-ENGINE 1148
ENGINE 3 9L 1148
ENGINE 3 9L 1150
DESCRIPTION 1150
DESCRIPTION 1150
DIAGNOSIS AND TESTING 1150
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS – INTRODUCTION 1150
DIAGNOSIS AND TESTING—PERFORMANCE 1151
DIAGNOSIS AND TESTING— MECHANICAL 1153
DIAGNOSIS AND TESTING—LUBRICATION 1155
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE 1156
DIAGNOSIS AND TESTING—CYLINDER COMBUSTION PRESSURE LEAKAGE 1156
DIAGNOSIS AND TESTING—REAR SEAL AREA LEAKS 1157
STANDARD PROCEDURE 1157
STANDARD PROCEDURE—CYLINDER BORE HONING 1157
STANDARD PROCEDURE—HYDROSTATIC LOCK 1158
STANDARD PROCEDURE—REPAIR DAMAGED OR WORN THREADS 1158
STANDARD PROCEDURE—FORM-IN-PLACE GASKETS & SEALERS 1158
FORM-IN-PLACE GASKET AND SEALER APPLICATION 1159
REMOVAL 1159
REMOVAL 1159
INSTALLATION 1160
INSTALLATION 1160
SPECIFICATIONS 1161
3 9L ENGINE 1161
TORQUE 1165
SPECIAL TOOLS 1166
ENGINE—3 9L 1166
AIR CLEANER ELEMENT 1168
REMOVAL 1168
REMOVAL – 3 9L/5 2L/5 9L 1168
INSTALLATION 1168
INSTALLATION – 3 9L/5 2L/5 9L 1168
CYLINDER HEAD 1169
DESCRIPTION 1169
DESCRIPTION—CYLINDER HEAD 1169
DESCRIPTION—CYLINDER HEAD COVER GASKET 1169
OPERATION 1169
OPERATION—CYLINDER HEAD 1169
OPERATION—CYLINDER HEAD COVER GASKET 1169
DIAGNOSIS AND TESTING 1169
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE 1169
CYLINDER-TO-CYLINDER LEAKAGE TEST 1169
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1169
REMOVAL 1170
REMOVAL 1170
CLEANING 1170
CLEANING 1170
INSPECTION 1170
INSPECTION 1170
INSTALLATION 1170
INSTALLATION 1170
CYLINDER HEAD COVER(S) 1171
REMOVAL 1171
REMOVAL 1171
CLEANING 1171
CLEANING 1171
INSPECTION 1171
INSPECTION 1171
INSTALLATION 1171
INSTALLATION 1171
INTAKE/EXHAUST VALVES & SEATS 1172
DESCRIPTION 1172
DESCRIPTION 1172
STANDARD PROCEDURE 1172
STANDARD PROCEDURE—VALVES, GUIDES AND SPRINGS 1172
VALVE CLEANING 1172
VALVE GUIDES 1172
VALVE GUIDES 1172
REFACING VALVES AND VALVE SEATS 1173
VALVES 1173
VALVE SEATS 1173
VALVE SPRINGS 1174
REMOVAL 1174
REMOVAL 1174
CLEANING 1174
CLEANING 1174
INSPECTION 1174
INSPECTION 1174
INSTALLATION 1174
INSTALLATION 1175
ENGINE BLOCK 1175
CLEANING 1175
CLEANING 1175
INSPECTION 1175
INSPECTION 1175
CAMSHAFT & BEARINGS (IN BLOCK) 1176
REMOVAL 1176
REMOVAL—CAMSHAFT BEARINGS 1176
REMOVAL—CAMSHAFT 1176
INSTALLATION 1176
INSTALLATION—CAMSHAFT BEARINGS 1176
INSTALLATION—CAMSHAFT 1176
CONNECTING ROD BEARINGS 1178
STANDARD PROCEDURE 1178
STANDARD PROCEDURE-CONNECTING ROD BEARING FITTING 1178
CRANKSHAFT 1178
DESCRIPTION 1178
DESCRIPTION 1178
OPERATION 1178
OPERATION 1178
REMOVAL 1178
REMOVAL 1178
INSTALLATION 1179
INSTALLATION 1179
CRANKSHAFT MAIN BEARINGS 1179
DESCRIPTION 1179
DESCRIPTION 1179
OPERATION 1179
OPERATION 1179
STANDARD PROCEDURE 1179
STANDARD PROCEDURE—MAIN BEARING FITTING 1180
REMOVAL 1180
REMOVAL 1180
INSTALLATION 1181
INSTALLATION 1181
CRANKSHAFT OIL SEAL – FRONT 1181
DESCRIPTION 1181
DESCRIPTION 1181
OPERATION 1181
OPERATION 1181
REMOVAL 1181
REMOVAL 1181
INSTALLATION 1181
INSTALLATION 1181
CRANKSHAFT OIL SEAL – REAR 1181
DESCRIPTION 1181
DESCRIPTION 1181
OPERATION 1181
OPERATION 1181
REMOVAL 1181
REMOVAL 1182
UPPER SEAL —CRANKSHAFT REMOVED 1182
UPPER SEAL—CRANKSHAFT INSTALLED 1182
LOWER SEAL 1182
INSTALLATION 1182
INSTALLATION 1182
UPPER SEAL —CRANKSHAFT REMOVED 1182
UPPER SEAL—CRANKSHAFT INSTALLED 1183
LOWER SEAL 1184
DISTRIBUTOR BUSHING 1184
REMOVAL 1184
REMOVAL 1184
INSTALLATION 1184
INSTALLATION 1184
HYDRAULIC LIFTERS (CAM IN BLOCK) 1185
DIAGNOSIS AND TESTING 1185
DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS 1185
OIL LEVEL 1185
TAPPET NOISE DIAGNOSIS 1185
LEAK-DOWN TEST 1185
REMOVAL 1186
REMOVAL 1186
CLEANING 1186
CLEANING 1186
INSTALLATION 1186
INSTALLATION 1186
PISTON & CONNECTING ROD 1187
DESCRIPTION 1187
DESCRIPTION 1187
STANDARD PROCEDURE 1187
STANDARD PROCEDURE—PISTON FITTING 1187
REMOVAL 1187
REMOVAL 1187
CLEANING 1188
CLEANING 1188
INSPECTION 1188
INSPECTION 1188
INSTALLATION 1188
INSTALLATION 1188
PISTON RINGS 1188
STANDARD PROCEDURE 1188
STANDARD PROCEDURE—PISTON RING FITTING 1188
VIBRATION DAMPER 1189
REMOVAL 1189
REMOVAL 1189
INSTALLATION 1189
INSTALLATION 1189
FRONT MOUNT 1190
REMOVAL 1190
REMOVAL 1190
INSTALLATION 1190
INSTALLATION 1190
REAR MOUNT 1191
REMOVAL 1191
REMOVAL 1191
INSTALLATION 1191
INSTALLATION 1191
LUBRICATION 1192
DESCRIPTION 1192
DESCRIPTION 1192
OPERATION 1192
OPERATION 1192
DIAGNOSIS AND TESTING 1194
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE 1194
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS 1194
OIL 1194
STANDARD PROCEDURE 1194
STANDARD PROCEDURE—ENGINE OIL 1194
OIL LEVEL INDICATOR (DIPSTICK) 1194
CRANKCASE OIL LEVEL INSPECTION 1194
ENGINE OIL CHANGE: 1195
OIL FILTER 1195
REMOVAL 1195
REMOVAL 1195
INSTALLATION 1195
INSTALLATION 1195
OIL PAN 1195
REMOVAL 1195
REMOVAL 1195
CLEANING 1195
CLEANING 1196
INSPECTION 1196
INSPECTION 1196
INSTALLATION 1196
INSTALLATION 1196
OIL PRESSURE SENSOR/SWITCH 1196
DESCRIPTION 1196
DESCRIPTION 1196
OPERATION 1196
OPERATION 1196
OIL PUMP 1197
REMOVAL 1197
REMOVAL 1197
DISASSEMBLY 1197
DISASSEMBLE 1197
CLEANING 1197
CLEANING 1197
INSPECTION 1197
INSPECTION 1197
ASSEMBLY 1198
ASSEMBLY 1198
INSTALLATION 1199
INSTALLATION 1199
INTAKE MANIFOLD 1199
DESCRIPTION 1199
DESCRIPTION 1199
OPERATION 1199
OPERATION 1199
DIAGNOSIS AND TESTING 1200
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE 1200
REMOVAL 1200
REMOVAL 1200
CLEANING 1200
CLEANING 1200
INSPECTION 1200
INSPECTION 1200
INSTALLATION 1200
INSTALLATION 1200
EXHAUST MANIFOLD 1202
DESCRIPTION 1202
DESCRIPTION 1202
OPERATION 1202
OPERATION 1202
REMOVAL 1202
REMOVAL 1202
CLEANING 1202
CLEANING 1202
INSPECTION 1202
INSPECTION 1202
INSTALLATION 1202
INSTALLATION 1202
TIMING BELT / CHAIN COVER(S) 1203
REMOVAL 1203
REMOVAL 1203
INSTALLATION 1203
INSTALLATION 1203
TIMING BELT/CHAIN TENSIONER 1204
DESCRIPTION 1204
DESCRIPTION 1204
OPERATION 1204
OPERATION 1204
TIMING BELT/CHAIN AND SPROCKETS 1204
REMOVAL 1204
REMOVAL 1204
INSPECTION 1204
INSPECTION—MEASURING TIMING CHAIN STRETCH 1205
INSTALLATION 1205
INSTALLATION 1205
ENGINE 5 2L 1206
ENGINE 5 2L 1207
DESCRIPTION 1207
DESCRIPTION 1207
DIAGNOSIS AND TESTING 1208
DIAGNOSIS AND TESTING-ENGINE DIAGNOSIS – INTRODUCTION 1208
DIAGNOSIS AND TESTING—PERFORMANCE 1208
DIAGNOSIS AND TESTING— MECHANICAL 1210
DIAGNOSIS AND TESTING—LUBRICATION 1213
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE 1214
DIAGNOSIS AND TESTING—CYLINDER COMBUSTION PRESSURE LEAKAGE 1214
STANDARD PROCEDURE 1215
STANDARD PROCEDURE—FORM-IN-PLACE GASKETS & SEALERS 1215
FORM-IN-PLACE GASKET AND SEALER APPLICATION 1215
STANDARD PROCEDURE—REPAIR DAMAGED OR WORN THREADS 1215
STANDARD PROCEDURE—HYDROSTATIC LOCK 1215
STANDARD PROCEDURE—CYLINDER BORE HONING 1216
REMOVAL 1216
REMOVAL 1216
INSTALLATION 1217
INSTALLATION 1217
SPECIFICATIONS 1219
5 2L ENGINE 1219
TORQUE 1223
SPECIAL TOOLS 1224
5 2L ENGINE 1224
CYLINDER HEAD 1226
DESCRIPTION 1226
DESCRIPTION—CYLINDER HEAD 1226
DESCRIPTION—CYLINDER COVER GASKET 1226
OPERATION 1226
OPERATION—CYLINDER HEAD 1226
OPERATION 1226
DIAGNOSIS AND TESTING 1226
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE 1226
CYLINDER-TO-CYLINDER LEAKAGE TEST 1226
CYLINDER-TO-WATER JACKET LEAKAGE TEST0 – 14 BR/BE (Continued) 1226
REMOVAL 1227
REMOVAL 1227
CLEANING 1227
CLEANING 1227
INSPECTION 1227
INSPECTION 1227
INSTALLATION 1227
INSTALLATION 1227
CYLINDER HEAD COVER(S) 1228
REMOVAL 1228
REMOVAL 1228
CLEANING 1228
CLEANING 1228
INSPECTION 1228
INSPECTION 1228
INSTALLATION 1228
INSTALLATION 1228
INTAKE/EXHAUST VALVES & SEATS 1228
DESCRIPTION 1228
DESCRIPTION 1228
STANDARD PROCEDURE 1228
STANDARD PROCEDURE—VALVES, GUIDES AND SPRINGS 1229
VALVE CLEANING 1229
VALVE GUIDES 1229
VALVE GUIDES 1229
REFACING VALVES AND VALVE SEATS 1230
VALVES 1230
VALVE SEATS 1230
VALVE SPRINGS 1231
REMOVAL 1231
REMOVAL 1231
CLEANING 1231
CLEANING 1231
INSPECTION 1231
INSPECTION 1231
INSTALLATION 1231
INSTALLATION 1232
ROCKER ARM / ADJUSTER ASSEMBLY 1232
REMOVAL 1232
REMOVAL 1232
INSTALLATION 1232
INSTALLATION 1232
ENGINE BLOCK 1233
CLEANING 1233
CLEANING 1233
INSPECTION 1233
INSPECTION 1233
CAMSHAFT & BEARINGS (IN BLOCK) 1233
REMOVAL 1233
REMOVAL—CAMSHAFT BEARINGS 1233
REMOVAL—CAMSHAFT 1233
INSTALLATION 1234
INSTALLATION—CAMSHAFT BEARINGS 1234
INSTALLATION—CAMSHAFT 1234
CONNECTING ROD BEARINGS 1235
STANDARD PROCEDURE 1235
STANDARD PROCEDURE—CONNECTING ROD BEARING FITTING 1235
CRANKSHAFT 1235
DESCRIPTION 1235
DESCRIPTION 1235
OPERATION 1235
OPERATION 1235
REMOVAL 1235
REMOVAL 1235
INSTALLATION 1236
INSTALLATION 1236
CRANKSHAFT MAIN BEARINGS 1237
DESCRIPTION 1237
DESCRIPTION 1237
OPERATION 1237
OPERATION 1237
STANDARD PROCEDURE 1237
STANDARD PROCEDURE—CRANKSHAFT MAIN BEARING FITTING 1237
REMOVAL 1237
REMOVAL 1237
INSTALLATION 1237
INSTALLATION 1237
CRANKSHAFT OIL SEAL – FRONT 1238
DESCRIPTION 1238
DESCRIPTION 1238
OPERATION 1238
OPERATION 1238
REMOVAL 1238
REMOVAL 1238
INSTALLATION 1238
INSTALLATION 1238
CRANKSHAFT OIL SEAL – REAR 1238
DESCRIPTION 1238
DESCRIPTION 1238
OPERATION 1238
OPERATION 1239
REMOVAL 1239
REMOVAL 1239
UPPER SEAL —CRANKSHAFT REMOVED 1239
UPPER SEAL—CRANKSHAFT INSTALLED 1239
LOWER SEAL 1239
INSTALLATION 1239
INSTALLATION 1239
UPPER SEAL —CRANKSHAFT REMOVED 1239
UPPER SEAL—CRANKSHAFT INSTALLED 1240
LOWER SEAL 1241
DISTRIBUTOR BUSHING 1241
REMOVAL 1241
REMOVAL 1241
INSTALLATION 1241
INSTALLATION 1241
HYDRAULIC LIFTERS (CAM IN BLOCK) 1242
DIAGNOSIS AND TESTING 1242
DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS 1242
OIL LEVEL 1242
TAPPET NOISE DIAGNOSIS 1242
LEAK-DOWN TEST 1242
REMOVAL 1243
REMOVAL 1243
CLEANING 1243
CLEANING 1243
INSTALLATION 1243
INSTALLATION 1243
PISTON & CONNECTING ROD 1244
DESCRIPTION 1244
DESCRIPTION 1244
STANDARD PROCEDURE 1244
STANDARD PROCEDURE—PISTON FITTING 1244
REMOVAL 1244
REMOVAL 1244
CLEANING 1245
CLEANING 1245
INSPECTION 1245
INSPECTION 1245
INSTALLATION 1245
INSTALLATION 1245
PISTON RINGS 1245
STANDARD PROCEDURE 1245
STANDARD PROCEDURE—PISTON RING FITTING 1245
VIBRATION DAMPER 1246
REMOVAL 1246
REMOVAL 1246
INSTALLATION 1246
INSTALLATION 1246
FRONT MOUNT 1247
REMOVAL 1247
REMOVAL 1247
INSTALLATION 1247
INSTALLATION 1247
REAR MOUNT 1248
REMOVAL 1248
REMOVAL 1248
INSTALLATION 1248
INSTALLATION 1248
LUBRICATION 1249
DESCRIPTION 1249
DESCRIPTION 1249
OPERATION 1249
OPERATION 1249
DIAGNOSIS AND TESTING 1251
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS 1251
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE 1251
OIL 1251
STANDARD PROCEDURE 1251
STANDARD PROCEDURE—ENGINE OIL 1251
OIL LEVEL INDICATOR (DIPSTICK) 1251
CRANKCASE OIL LEVEL INSPECTION 1251
ENGINE OIL CHANGE 1252
OIL FILTER 1252
REMOVAL 1252
REMOVAL 1252
INSTALLATION 1252
INSTALLATION 1252
OIL PAN 1252
REMOVAL 1252
REMOVAL 1252
CLEANING 1252
CLEANING 1253
INSPECTION 1253
INSPECTION 1253
INSTALLATION 1253
INSTALLATION 1253
OIL PUMP 1254
REMOVAL 1254
REMOVAL 1254
DISASSEMBLY 1254
DISASSEMBLE 1254
INSPECTION 1254
INSPECTION 1254
ASSEMBLY 1256
ASSEMBLE 1256
INSTALLATION 1256
INSTALLATION 1256
INTAKE MANIFOLD 1256
DESCRIPTION 1256
DESCRIPTION 1256
OPERATION 1256
OPERATION 1256
DIAGNOSIS AND TESTING 1256
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE 1257
REMOVAL 1257
REMOVAL 1257
CLEANING 1257
CLEANING 1257
INSPECTION 1257
INSPECTION 1257
INSTALLATION 1257
INSTALLATION 1258
EXHAUST MANIFOLD 1259
DESCRIPTION 1259
DESCRIPTION 1259
OPERATION 1259
OPERATION 1259
REMOVAL 1259
REMOVAL 1259
CLEANING 1259
CLEANING 1259
INSPECTION 1259
INSPECTION 1259
INSTALLATION 1260
INSTALLATION 1260
TIMING BELT / CHAIN COVER(S) 1260
REMOVAL 1260
REMOVAL 1260
INSTALLATION 1260
INSTALLATION 1260
TIMING BELT/CHAIN AND SPROCKETS 1261
REMOVAL 1261
REMOVAL 1261
INSPECTION 1261
INSPECTION—MEASURING TIMING CHAIN STRETCH 1261
INSTALLATION 1261
INSTALLATION 1262
ENGINE 5 9L 1263
ENGINE 5 9L 1264
DESCRIPTION 1264
DESCRIPTION 1264
DIAGNOSIS AND TESTING 1264
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS – INTRODUCTION 1265
DIAGNOSIS AND TESTING—PERFORMANCE 1265
DIAGNOSIS AND TESTING— MECHANICAL 1267
DIAGNOSIS AND TESTING—LUBRICATION 1270
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE 1271
DIAGNOSIS AND TESTING—CYLINDER COMBUSTION PRESSURE LEAKAGE 1271
STANDARD PROCEDURE 1272
STANDARD PROCEDURE—FORM-IN-PLACE GASKETS & SEALERS 1272
FORM-IN-PLACE GASKET AND SEALER APPLICATION 1272
STANDARD PROCEDURE—REPAIR DAMAGED OR WORN THREADS 1272
STANDARD PROCEDURE—HYDROSTATIC LOCK 1272
STANDARD PROCEDURE—CYLINDER BORE HONING 1273
REMOVAL 1273
REMOVAL 1273
INSTALLATION 1274
INSTALLATION 1274
SPECIFICATIONS 1276
5 9L ENGINE 1276
TORQUE 1280
SPECIAL TOOLS 1281
5 9L ENGINE 1281
CYLINDER HEAD 1283
DESCRIPTION 1283
DESCRIPTION—CYLINDER HEAD 1283
DESCRIPTION 1283
OPERATION 1283
OPERATION—CYLINDER HEAD 1283
OPERATION 1283
DIAGNOSIS AND TESTING 1283
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE 1283
CYLINDER-TO-CYLINDER LEAKAGE TEST 1283
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1283
REMOVAL 1284
REMOVAL 1284
CLEANING 1284
CLEANING 1284
INSPECTION 1284
INSPECTION 1284
INSTALLATION 1284
INSTALLATION 1284
CYLINDER HEAD COVER(S) 1285
REMOVAL 1285
REMOVAL 1285
CLEANING 1285
CLEANING 1285
INSPECTION 1285
INSPECTION 1285
INSTALLATION 1285
INSTALLATION 1285
INTAKE/EXHAUST VALVES & SEATS 1285
DESCRIPTION 1285
DESCRIPTION 1285
STANDARD PROCEDURE 1285
STANDARD PROCEDURE—VALVES, GUIDES AND SPRINGS 1285
VALVE CLEANING 1285
VALVE GUIDES 1285
VALVE GUIDES 1286
REFACING VALVES AND VALVE SEATS 1286
VALVES 1287
VALVE SEATS 1287
VALVE SPRINGS 1287
REMOVAL 1287
REMOVAL 1287
CLEANING 1287
CLEANING 1287
INSPECTION 1287
INSPECTION 1288
INSTALLATION 1288
INSTALLATION 1288
ROCKER ARM / ADJUSTER ASSY 1289
REMOVAL 1289
REMOVAL 1289
INSTALLATION 1289
INSTALLATION 1289
ENGINE BLOCK 1289
CLEANING 1289
CLEANING 1289
INSPECTION 1289
INSPECTION 1289
CAMSHAFT & BEARINGS (IN BLOCK) 1290
REMOVAL 1290
REMOVAL—CAMSHAFT BEARINGS 1290
REMOVAL—CAMSHAFT 1290
INSTALLATION 1290
INSTALLATION—CAMSHAFT BEARINGS 1291
INSTALLATION—CAMSHAFT 1291
CONNECTING ROD BEARINGS 1291
STANDARD PROCEDURE 1291
STANDARD PROCEDURE—CONNECTING ROD BEARING FITTING 1291
CRANKSHAFT 1292
DESCRIPTION 1292
DESCRIPTION 1292
OPERATION 1292
OPERATION 1292
REMOVAL 1292
REMOVAL 1292
INSTALLATION 1292
INSTALLATION 1292
CRANKSHAFT MAIN BEARINGS 1293
DESCRIPTION 1293
DESCRIPTION 1293
OPERATION 1293
OPERATION 1293
STANDARD PROCEDURE 1293
STANDARD PROCEDURE—CRANKSHAFT MAIN BEARING FITTING 1293
REMOVAL0 – 16 BR/BE (Continued) 1294
REMOVAL 1294
INSTALLATION 1294
INSTALLATION 1294
CRANKSHAFT OIL SEAL – FRONT 1294
DESCRIPTION 1294
DESCRIPTION 1294
OPERATION 1294
OPERATION 1294
REMOVAL 1294
REMOVAL 1294
INSTALLATION 1295
INSTALLATION 1295
CRANKSHAFT OIL SEAL – REAR 1295
DESCRIPTION 1295
DESCRIPTION 1295
OPERATION 1295
OPERATION 1295
REMOVAL 1295
REMOVAL 1296
UPPER SEAL —CRANKSHAFT REMOVED 1296
UPPER SEAL—CRANKSHAFT INSTALLED 1296
LOWER SEAL 1296
INSTALLATION 1296
INSTALLATION 1296
UPPER SEAL —CRANKSHAFT REMOVED 1296
UPPER SEAL—CRANKSHAFT INSTALLED 1296
LOWER SEAL 1297
DISTRIBUTOR BUSHING 1297
REMOVAL 1297
REMOVAL 1297
INSTALLATION 1297
INSTALLATION 1297
HYDRAULIC LIFTERS 1298
DIAGNOSIS AND TESTING 1298
DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS 1298
OIL LEVEL 1298
TAPPET NOISE DIAGNOSIS 1298
LEAK-DOWN TEST 1299
REMOVAL 1299
REMOVAL 1299
CLEANING 1299
CLEANING 1299
INSTALLATION 1299
INSTALLATION 1299
PISTON & CONNECTING ROD 1300
DESCRIPTION 1300
DESCRIPTION 1300
STANDARD PROCEDURE 1300
STANDARD PROCEDURE—PISTON FITTING 1300
REMOVAL 1300
REMOVAL 1301
CLEANING 1301
CLEANING 1301
INSPECTION 1301
INSPECTION 1301
INSTALLATION 1301
INSTALLATION 1301
PISTON RINGS 1301
STANDARD PROCEDURE 1301
STANDARD PROCEDURE—PISTON RING FITTING 1301
VIBRATION DAMPER 1302
REMOVAL 1302
REMOVAL 1302
INSTALLATION 1303
INSTALLATION 1303
FRONT MOUNT 1303
REMOVAL 1303
REMOVAL 1303
INSTALLATION 1303
INSTALLATION 1303
REAR MOUNT 1304
REMOVAL 1304
REMOVAL 1304
INSTALLATION 1305
INSTALLATION 1305
LUBRICATION 1305
DESCRIPTION 1305
DESCRIPTION 1305
OPERATION 1305
OPERATION 1305
DIAGNOSIS AND TESTING 1305
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS 1307
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE 1307
OIL 1307
STANDARD PROCEDURE 1307
STANDARD PROCEDURE—ENGINE OIL 1307
OIL LEVEL INDICATOR (DIPSTICK) 1307
CRANKCASE OIL LEVEL INSPECTION 1307
ENGINE OIL CHANGE 1308
OIL FILTER 1308
REMOVAL 1308
REMOVAL 1308
INSTALLATION 1308
INSTALLATION 1308
OIL PAN 1308
REMOVAL 1308
REMOVAL 1308
CLEANING 1308
CLEANING 1309
INSPECTION 1309
INSPECTION 1309
INSTALLATION 1309
INSTALLATION 1309
OIL PUMP 1309
REMOVAL 1309
REMOVAL 1309
DISASSEMBLY 1309
DISASSEMBLE 1310
INSPECTION 1310
INSPECTION 1310
ASSEMBLY 1312
ASSEMBLE 1312
INSTALLATION 1312
INSTALLATION 1312
INTAKE MANIFOLD 1312
DESCRIPTION 1312
DESCRIPTION 1312
OPERATION 1312
OPERATION 1312
DIAGNOSIS AND TESTING 1312
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE 1312
REMOVAL 1313
REMOVAL 1313
CLEANING 1313
CLEANING 1313
INSPECTION 1313
INSPECTION 1313
INSTALLATION 1313
INSTALLATION 1313
EXHAUST MANIFOLD 1315
DESCRIPTION 1315
DESCRIPTION 1315
OPERATION 1315
OPERATION 1315
REMOVAL 1315
REMOVAL 1315
CLEANING 1315
CLEANING 1315
INSPECTION 1315
INSPECTION 1315
INSTALLATION 1315
INSTALLATION 1315
TIMING BELT / CHAIN COVER(S) 1316
REMOVAL 1316
REMOVAL 1316
INSTALLATION 1316
INSTALLATION 1316
TIMING BELT/CHAIN AND SPROCKETS 1317
REMOVAL 1317
REMOVAL 1317
INSPECTION 1317
INSPECTION—MEASURING TIMING CHAIN STRETCH 1317
INSTALLATION 1317
INSTALLATION 1317
ENGINE 8 0L 1318
ENGINE 8 0L 1319
DESCRIPTION 1319
DESCRIPTION 1319
DIAGNOSIS AND TESTING 1319
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS – INTRODUCTION 1320
DIAGNOSIS AND TESTING—PERFORMANCE 1320
DIAGNOSIS AND TESTING— MECHANICAL 1322
DIAGNOSIS AND TESTING—LUBRICATION 1325
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE 1326
DIAGNOSIS AND TESTING—CYLINDER COMBUSTION PRESSURE LEAKAGE 1326
STANDARD PROCEDURE 1327
STANDARD PROCEDURE—CYLINDER BORE HONING 1327
STANDARD PROCEDURE—FORM-IN-PLACE GASKETS & SEALERS 1327
FORM-IN-PLACE GASKET AND SEALER APPLICATION 1328
STANDARD PROCEDURE—REPAIR DAMAGED OR WORN THREADS 1328
STANDARD PROCEDURE—HYDROSTATIC LOCK 1328
REMOVAL 1328
REMOVAL 1328
INSTALLATION 1329
INSTALLATION 1329
SPECIFICATIONS 1331
8 OL ENGINE 1331
TORQUE 1334
SPECIAL TOOLS 1335
8 0L ENGINE 1335
AIR CLEANER ELEMENT 1337
REMOVAL 1337
REMOVAL – 8 0L 1337
INSTALLATION 1337
INSTALLATION – 8 0L 1337
CYLINDER HEAD 1338
DESCRIPTION 1338
DESCRIPTION 1338
DIAGNOSIS AND TESTING 1338
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE 1338
CYLINDER-TO-CYLINDER LEAKAGE TEST 1338
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1338
REMOVAL 1339
REMOVAL 1339
CLEANING 1340
CLEANING 1340
INSPECTION 1340
INSPECTION 1340
INSTALLATION 1340
INSTALLATION 1340
CYLINDER HEAD COVER(S) 1341
DESCRIPTION 1341
DESCRIPTION 1341
REMOVAL 1341
REMOVAL 1341
CLEANING 1341
CLEANING 1341
INSPECTION 1341
INSPECTION 1341
INSTALLATION 1341
INSTALLATION 1341
INTAKE/EXHAUST VALVES & SEATS 1342
DESCRIPTION 1342
DESCRIPTION 1342
STANDARD PROCEDURE 1342
VALVE SERVICE 1342
VALVE GUIDES 1342
REFACING VALVES AND VALVE SEATS 1343
VALVE SPRING INSPECTION 1344
REMOVAL 1344
REMOVAL—VALVE STEM SEALS 1344
REMOVAL—VALVES AND VALVE SPRINGS 1344
CLEANING 1345
CLEANING 1345
INSPECTION 1345
INSPECTION 1345
INSTALLATION 1345
INSTALLATION—VALVE STEM SEAL 1345
INSTALLATION—VALVES AND VALVE SPRINGS 1346
ROCKER ARM / ADJUSTER ASSY 1347
REMOVAL 1347
REMOVAL 1347
INSTALLATION 1347
INSTALLATION 1347
ENGINE BLOCK 1347
CLEANING 1347
CLEANING 1347
INSPECTION 1347
INSPECTION 1347
CAMSHAFT & BEARINGS (IN BLOCK) 1347
REMOVAL 1347
REMOVAL—CAMSHAFT BEARINGS 1347
REMOVAL—CAMSHAFT 1348
INSTALLATION 1348
INSTALLATION—CAMSHAFT BEARINGS 1348
INSTALLATION—CAMSHAFT 1348
CONNECTING ROD BEARINGS 1349
STANDARD PROCEDURE 1349
STANDARD PROCEDURE—CONNECTING ROD BEARING FITTING 1349
CRANKSHAFT 1349
REMOVAL 1349
REMOVAL 1349
INSTALLATION 1350
INSTALLATION 1350
CRANKSHAFT MAIN BEARINGS 1350
STANDARD PROCEDURE 1350
STANDARD PROCEDURE—MAIN BEARING FITTING 1350
REMOVAL 1350
REMOVAL 1351
INSTALLATION 1351
INSTALLATION 1351
CRANKSHAFT OIL SEAL – FRONT 1351
REMOVAL 1351
REMOVAL—FRONT OIL SEAL – FRONT COVER INSTALLED 1351
REMOVAL—FRONT OIL SEAL – FRONT COVER REMOVED 1351
INSTALLATION 1351
INSTALLATION—FRONT OIL SEAL – FRONT COVER INSTALLED 1352
INSTALLATION—FRONT OIL SEAL – FRONT COVER REMOVED 1352
CRANKSHAFT OIL SEAL – REAR 1353
REMOVAL 1353
REMOVAL 1353
INSTALLATION 1353
INSTALLATION 1353
CRANKSHAFT REAR OIL SEAL RETAINER 1353
REMOVAL 1353
REMOVAL 1353
INSTALLATION 1353
INSTALLATION 1353
HYDRAULIC LIFTERS 1353
DIAGNOSIS AND TESTING 1353
DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS 1353
OIL LEVEL 1353
TAPPET NOISE DIAGNOSIS 1353
LEAK-DOWN TEST 1354
REMOVAL 1354
REMOVAL 1354
CLEANING 1354
CLEANING 1355
INSTALLATION 1355
INSTALLATION 1355
PISTON & CONNECTING ROD 1355
DESCRIPTION 1355
DESCRIPTION 1355
STANDARD PROCEDURE 1355
STANDARD PROCEDURE—PISTON FITTING 1355
REMOVAL 1356
REMOVAL 1356
CLEANING 1356
CLEANING 1356
INSPECTION 1356
INSPECTION 1356
INSTALLATION 1357
INSTALLATION 1357
PISTON RINGS 1358
STANDARD PROCEDURE 1358
STANDARD PROCEDURE—FITTING PISTON RINGS 1358
VIBRATION DAMPER 1359
REMOVAL 1359
REMOVAL 1359
INSTALLATION 1359
INSTALLATION 1359
FRONT MOUNT 1360
REMOVAL 1360
REMOVAL 1360
INSTALLATION 1360
INSTALLATION 1360
REAR MOUNT 1360
REMOVAL 1360
REMOVAL 1360
INSTALLATION 1360
INSTALLATION 1360
LUBRICATION 1361
DESCRIPTION 1361
DESCRIPTION 1361
OPERATION 1361
OPERATION 1361
DIAGNOSIS AND TESTING 1362
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS 1362
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE 1362
OIL 1364
STANDARD PROCEDURE 1364
STANDARD PROCEDURE—ENGINE OIL 1364
OIL LEVEL INDICATOR (DIPSTICK) 1364
CRANKCASE OIL LEVEL INSPECTION 1364
ENGINE OIL CHANGE 1364
OIL FILTER 1365
REMOVAL 1365
REMOVAL 1365
INSTALLATION0 – 18 BR/BE (Continued) 1365
INSTALLATION 1365
OIL PAN 1365
REMOVAL 1365
REMOVAL 1365
CLEANING 1365
CLEANING 1365
INSPECTION 1365
INSPECTION 1366
INSTALLATION 1366
INSTALLATION 1366
OIL PUMP 1366
REMOVAL 1366
REMOVAL 1366
CLEANING 1367
CLEANING 1367
INSPECTION 1367
INSPECTION 1367
INSTALLATION 1368
INSTALLATION 1368
INTAKE MANIFOLD 1369
DESCRIPTION 1369
DESCRIPTION 1369
DIAGNOSIS AND TESTING 1369
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE 1369
REMOVAL 1369
REMOVAL 1369
CLEANING 1370
CLEANING 1370
INSPECTION 1370
INSPECTION 1370
INSTALLATION 1370
INSTALLATION 1370
EXHAUST MANIFOLD 1371
DESCRIPTION 1371
DESCRIPTION 1371
OPERATION 1371
OPERATION 1371
REMOVAL 1372
REMOVAL 1372
CLEANING 1372
CLEANING 1372
INSPECTION 1372
INSPECTION 1372
INSTALLATION 1372
INSTALLATION 1372
TIMING BELT / CHAIN COVER(S) 1372
REMOVAL 1372
REMOVAL 1372
INSTALLATION 1373
INSTALLATION 1373
TIMING BELT/CHAIN AND SPROCKETS 1373
REMOVAL 1373
REMOVAL 1373
INSPECTION 1374
INSPECTION—MEASURING TIMING CHAIN STRETCH 1374
INSTALLATION 1374
INSTALLATION 1374
ENGINE 5 9L DIESEL 1376
ENGINE 5 9L DIESEL 1378
DESCRIPTION 1378
DESCRIPTION 1378
DIAGNOSIS AND TESTING 1378
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS – MECHANICAL 1379
DIAGNOSIS AND TESTING—SMOKE DIAGNOSIS CHARTS 1381
STANDARD PROCEDURE 1384
STANDARD PROCEDURE—FORM-IN-PLACE GASKETS & SEALERS 1384
FORM-IN-PLACE GASKET AND SEALER APPLICATION 1385
STANDARD PROCEDURE—REPAIR DAMAGED OR WORN THREADS 1385
STANDARD PROCEDURE—HYDROSTATIC LOCK 1385
REMOVAL 1385
REMOVAL—ENGINE 1385
REMOVAL—CRANKCASE BREATHER VAPOR CANISTER 1388
INSTALLATION 1388
INSTALLATION—ENGINE 1388
INSTALLATION—CRANKCASE BREATHER VAPOR CANISTER 1389
SPECIFICATIONS 1389
5 9L DIESEL 1389
TORQUE 1390
SPECIAL TOOLS 1391
5 9L DIESEL ENGINE 1391
ENGINE DATA PLATE 1391
DESCRIPTION 1391
DESCRIPTION 1391
AIR CLEANER ELEMENT 1391
REMOVAL 1391
REMOVAL 1391
INSTALLATION 1392
INSTALLATION 1392
CYLINDER HEAD 1393
DESCRIPTION 1393
DESCRIPTION 1393
REMOVAL 1393
REMOVAL 1393
CLEANING 1395
CLEANING—CYLINDER HEAD 1395
CLEANING—CROSSHEADS 1396
CLEANING—PUSHRODS 1396
INSPECTION 1396
INSPECTION—CYLINDER HEAD 1397
INSPECTION—CROSSHEADS 1397
INSPECTION—PUSHRODS 1397
INSTALLATION 1397
INSTALLATION 1397
CYLINDER HEAD COVER(S) 1400
REMOVAL 1400
REMOVAL 1400
CLEANING 1400
CLEANING 1400
INSPECTION 1400
INSPECTION 1400
INSTALLATION 1400
INSTALLATION 1400
INTAKE/EXHAUST VALVES & SEATS 1400
DESCRIPTION 1400
DESCRIPTION 1400
STANDARD PROCEDURE 1400
STANDARD PROCEDURE-VALVES,GUIDES AND SPRINGS 1400
REMOVAL 1400
CLEANING 1402
INSPECTION 1402
INSTALLATION 1403
STANDARD PROCEDURE—VALVE LASH ADJUSTMENT AND VERIFICATION 1403
REMOVAL 1405
REMOVAL 1405
INSTALLATION 1406
INSTALLATION 1407
ROCKER ARM / ADJUSTER ASSY 1408
DESCRIPTION 1408
DESCRIPTION 1408
REMOVAL 1408
REMOVAL 1408
CLEANING 1408
CLEANING 1409
INSPECTION 1409
INSPECTION 1409
Rocker Arms 1409
Push Rods 1410
Crossheads 1410
INSTALLATION 1410
INSTALLATION 1410
ENGINE BLOCK 1410
STANDARD PROCEDURE 1410
STANDARD PROCEDURE-CYLINDER BLOCK REFACING 1410
STANDARD PROCEDURE-CYLINDER BORE – DE-GLAZE 1411
STANDARD PROCEDURE—CYLINDER BORE REPAIR 1412
METHOD 1—OVERSIZE BORE 1412
METHOD 2—REPAIR SLEEVE 1412
STANDARD PROCEDURE—CAM BORE REPAIR 1414
INSPECTION 1414
INSPECTION 1414
CAMSHAFT & BEARINGS (IN BLOCK) 1415
REMOVAL 1415
REMOVAL—CAMSHAFT BEARINGS 1415
REMOVAL—CAMSHAFT 1415
INSPECTION 1419
INSPECTION 1419
Camshaft 1419
Camshaft Bushing/Bores 1419
Camshaft Gear 1420
Thrust Plate 1420
INSTALLATION 1420
INSTALLATION—CAMSHAFT BEARINGS 1420
INSTALLATION—CAMSHAFT 1420
CONNECTING ROD BEARINGS 1421
STANDARD PROCEDURE 1421
STANDARD PROCEDURE—CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE 1421
CRANKSHAFT 1422
DESCRIPTION 1422
DESCRIPTION 1422
CRANKSHAFT MAIN BEARINGS 1422
STANDARD PROCEDURE 1422
STANDARD PROCEDURE—MAIN BEARING CLEARANCE 1422
CRANKSHAFT OIL SEAL – FRONT 1423
REMOVAL 1423
REMOVAL 1423
INSTALLATION 1423
INSTALLATION 1424
CRANKSHAFT OIL SEAL – REAR 1425
REMOVAL 1425
REMOVAL 1425
INSTALLATION 1425
INSTALLATION 1425
CRANKSHAFT REAR OIL SEAL RETAINER 1425
REMOVAL 1425
REMOVAL 1425
INSTALLATION 1426
INSTALLATION 1426
SOLID LIFTERS/TAPPETS 1427
REMOVAL 1427
REMOVAL 1427
CLEANING 1428
CLEANING 1428
INSPECTION 1428
INSPECTION 1428
INSTALLATION 1428
INSTALLATION 1428
PISTON & CONNECTING ROD 1429
DESCRIPTION 1429
DESCRIPTION 1429
STANDARD PROCEDURE 1429
STANDARD PROCEDURE—PISTON GRADING 1429
REMOVAL 1432
REMOVAL 1432
CLEANING 1432
CLEANING 1432
INSPECTION 1432
INSPECTION 1432
Connecting Rods 1433
CLEANING 1433
INSPECTION 1433
INSTALLATION 1434
INSTALLATION 1434
PISTON RINGS 1435
STANDARD PROCEDURE 1435
STANDARD PROCEDURE-PISTON RING FITTING 1435
VIBRATION DAMPER 1436
REMOVAL 1436
REMOVAL 1436
INSPECTION 1436
INSPECTION 1436
INSTALLATION 1436
INSTALLATION 1436
FRONT MOUNT 1437
REMOVAL 1437
REMOVAL 1437
INSTALLATION 1437
INSTALLATION 1437
REAR MOUNT 1438
REMOVAL 1438
REMOVAL 1438
INSTALLATION 1438
INSTALLATION 1438
LUBRICATION 1439
DESCRIPTION 1439
DESCRIPTION 1439
OPERATION 1439
OPERATION 1439
DIAGNOSIS AND TESTING 1442
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE 1442
OIL 1442
STANDARD PROCEDURE 1442
STANDARD PROCEDURE-ENGINE OIL LEVEL 1442
STANDARD PROCEDURE-ENGINE OIL SERVICE 1442
USED ENGINE OIL DISPOSAL 1443
OIL COOLER & LINES 1443
CLEANING 1443
CLEANING AND INSPECTION 1443
OIL FILTER 1443
REMOVAL 1443
REMOVAL 1443
INSTALLATION 1443
INSTALLATION 1443
OIL PAN 1443
REMOVAL 1443
REMOVAL 1443
CLEANING 1443
CLEANING 1444
INSPECTION 1444
INSPECTION 1444
INSTALLATION 1444
INSTALLATION 1444
OIL PRESSURE RELIEF VALVE 1444
REMOVAL 1444
REMOVAL 1444
CLEANING 1444
CLEANING 1444
INSPECTION 1444
INSPECTION 1444
INSTALLATION 1444
INSTALLATION 1445
OIL PRESSURE SENSOR/SWITCH 1445
DESCRIPTION 1445
DESCRIPTION 1445
OPERATION 1445
OPERATION 1445
REMOVAL 1445
REMOVAL 1445
INSTALLATION 1445
INSTALLATION 1446
OIL PUMP 1446
REMOVAL 1446
REMOVAL 1446
CLEANING 1446
CLEANING 1446
INSPECTION 1446
INSPECTION 1446
INSTALLATION 1447
INSTALLATION 1447
INTAKE MANIFOLD 1448
REMOVAL 1448
REMOVAL 1448
CLEANING 1448
CLEANING 1449
INSPECTION 1449
INSPECTION 1449
INSTALLATION 1449
INSTALLATION 1449
EXHAUST MANIFOLD 1450
REMOVAL 1450
REMOVAL 1450
CLEANING 1451
CLEANING 1451
INSPECTION 1451
INSPECTION 1451
INSTALLATION 1451
INSTALLATION 1451
GEAR HOUSING 1451
REMOVAL 1451
REMOVAL 1451
INSTALLATION 1452
INSTALLATION 1452
GEAR HOUSING COVER 1453
REMOVAL 1453
REMOVAL 1453
INSTALLATION 1454
INSTALLATION 1454
11-EXHAUST SYSTEM 1456
EXHAUST SYSTEM 1456
DESCRIPTION—3 9L/5 2L/5 9/8 0L 1456
DESCRIPTION—5 9L DIESEL 1458
DIAGNOSIS AND TESTING – GAS ENGINE 1459
DIAGNOSIS AND TESTING – DIESEL ENGINE 1459
SPECIFICATIONS 1460
TORQUE 1460
CATALYTIC CONVERTER – 3 9L/5 2L/5 9L 1460
DESCRIPTION 1460
OPERATION 1460
REMOVAL 1460
INSPECTION 1460
INSTALLATION 1460
CATALYTIC CONVERTER – 5 9L HEAVY DUTY/8 0L 1461
DESCRIPTION 1461
OPERATION 1461
REMOVAL 1461
INSPECTION 1462
INSTALLATION 1462
EXHAUST PIPE – 3 9L/5 2L/5 9L 1462
REMOVAL 1462
INSPECTION 1462
INSTALLATION 1462
EXHAUST PIPE – 5 9L HEAVY DUTY/8 0L 1463
REMOVAL 1463
INSPECTION 1464
INSTALLATION 1464
EXHAUST PIPE – 5 9L DIESEL 1464
REMOVAL 1464
INSPECTION 1464
INSTALLATION 1465
HEAT SHIELDS 1465
DESCRIPTION 1465
REMOVAL 1465
INSTALLATION 1465
MUFFLER – 3 9L/5 2L/5 9L/8 0L 1465
REMOVAL 1465
INSTALLATION 1466
MUFFLER – 5 9L DIESEL 1466
REMOVAL 1466
INSTALLATION 1466
TAILPIPE – 3 9L/5 2L/5 9L 1466
REMOVAL 1466
INSPECTION 1466
INSTALLATION 1467
TAILPIPE – 5 9L HEAVY DUTY/8 0L 1467
REMOVAL 1467
INSPECTION 1467
INSTALLATION 1467
TAILPIPE – 5 9L DIESEL 1467
REMOVAL 1467
INSPECTION 1467
INSTALLATION 1467
RESONATOR 1468
REMOVAL 1468
INSTALLATION 1468
TURBOCHARGER 1468
DESCRIPTION 1468
OPERATION 1468
REMOVAL 1470
CLEANING 1471
INSPECTION 1471
INSTALLATION 1471
CHARGE AIR COOLER AND PLUMBING 1472
DESCRIPTION 1472
OPERATION 1472
REMOVAL 1472
CLEANING 1473
INSPECTION 1473
INSTALLATION 1473
13-FRAME & BUMPERS 1476
BUMPERS 1476
DESCRIPTION 1476
FRONT AIR DAM 1476
REMOVAL 1476
INSTALLATION 1477
FRONT FASCIA 1477
REMOVAL 1477
INSTALLATION 1477
ADJUSTMENT 1477
FRONT LOWER FASCIA 1478
REMOVAL 1478
INSTALLATION 1478
FRONT FASCIA—SPORT 1478
REMOVAL 1478
INSTALLATION 1478
FRONT BUMPER 1478
REMOVAL 1478
INSTALLATION 1479
FRONT BUMPER—SPORT 1479
REMOVAL 1479
INSTALLATION 1479
REAR BUMPER 1480
REMOVAL 1480
INSTALLATION 1480
FRAME 1481
DESCRIPTION 1481
FRAME SERVICE 1481
SAFETY PRECAUTIONS AND WARNINGS 1481
FRAME STRAIGHTENING 1482
FRAME REPAIRS 1482
FRAME FASTENERS 1482
SPECIFICATIONS 1482
FRAME DIMENSION 1482
TORQUE SPECIFICATIONS 1484
CAB CHASSIS ADAPTER BRACKET 1484
REMOVAL 1484
INSTALLATION 1484
FRONT TOW HOOK 1484
REMOVAL 1484
Installation 1485
SPARE TIRE WINCH 1485
REMOVAL 1485
INSTALLATION 1485
TRAILER HITCH 1485
REMOVAL 1485
INSTALLATION 1485
TRANSFER CASE SKID PLATE 1486
REMOVAL 1486
INSTALLATION 1486
14-FUEL SYSTEM 1488
FUEL DELIVERY – GASOLINE 1488
FUEL DELIVERY – GASOLINE 1489
DESCRIPTION 1489
DESCRIPTION – FUEL DELIVERY SYSTEM 1489
OPERATION 1489
OPERATION – FUEL DELIVERY SYSTEM 1489
DIAGNOSIS AND TESTING 1489
DIAGNOSIS AND TESTING – FUEL PRESSURE LEAK DOWN TEST 1489
STANDARD PROCEDURE 1490
STANDARD PROCEDURE – FUEL SYSTEM PRESSURE RELEASE 1490
SPECIFICATIONS 1491
SPECIFICATIONS – FUEL SYSTEM PRESSURE – GAS ENGINES 1491
SPECIFICATIONS – TORQUE – FUEL DELIVERY 1491
SPECIAL TOOLS 1491
FUEL SYSTEM 1491
FUEL FILTER/PRESSURE REGULATOR 1492
DESCRIPTION 1492
DESCRIPTION 1492
OPERATION 1492
OPERATION 1492
REMOVAL 1492
REMOVAL 1492
INSTALLATION 1493
INSTALLATION 1493
FUEL LEVEL SENDING UNIT / SENSOR 1494
DESCRIPTION 1494
DESCRIPTION 1494
OPERATION 1494
OPERATION 1494
DIAGNOSIS AND TESTING 1495
DIAGNOSIS AND TESTING – FUEL GAUGE SENDING UNIT 1495
REMOVAL 1495
REMOVAL 1495
INSTALLATION 1495
INSTALLATION 1496
FUEL LINES 1496
DESCRIPTION 1496
DESCRIPTION 1496
FUEL PUMP 1496
DESCRIPTION 1496
DESCRIPTION 1496
OPERATION 1496
OPERATION 1496
DIAGNOSIS AND TESTING 1496
DIAGNOSIS AND TESTING – FUEL PUMP CAPACITY TEST 1496
DIAGNOSIS AND TESTING – FUEL PUMP PRESSURE TEST 1497
DIAGNOSIS AND TESTING – FUEL PUMP AMPERAGE TEST 1497
FUEL PUMP MODULE 1499
DESCRIPTION 1499
DESCRIPTION 1499
OPERATION 1499
OPERATION 1500
REMOVAL 1500
REMOVAL 1500
INSTALLATION 1500
INSTALLATION 1500
FUEL RAIL 1502
DESCRIPTION 1502
DESCRIPTION – 3 9L/5 2L/5 9L 1502
DESCRIPTION – 8 0L 1502
OPERATION 1502
OPERATION – 3 9L/5 2L/5 9L 1502
OPERATION – 8 0L 1502
REMOVAL 1503
REMOVAL – 3 9L/5 2L/5 9L 1503
REMOVAL – 8 0L 1504
INSTALLATION 1505
INSTALLATION – 3 9L/5 2L/5 9L 1505
INSTALLATION – 8 0L 1506
FUEL TANK 1506
DESCRIPTION 1506
DESCRIPTION 1506
OPERATION 1506
OPERATION 1506
REMOVAL 1506
REMOVAL 1506
INSTALLATION 1507
INSTALLATION 1507
INLET FILTER 1509
REMOVAL 1509
REMOVAL 1509
INSTALLATION 1509
INSTALLATION 1509
QUICK CONNECT FITTING 1509
DESCRIPTION 1509
DESCRIPTION 1509
STANDARD PROCEDURE 1509
STANDARD PROCEDURES – QUICK-CONNECT FITTINGS 1509
DISCONNECTING 1509
CONNECTING 1512
ROLLOVER VALVE 1512
DESCRIPTION 1512
DESCRIPTION 1512
REMOVAL 1512
REMOVAL 1513
INSTALLATION 1514
INSTALLATION 1514
FUEL INJECTION – GASOLINE 1515
FUEL INJECTION – GASOLINE 1515
DIAGNOSIS AND TESTING 1515
VISUAL INSPECTION—3 9L/5 2L/5 9L ENGINES 1515
VISUAL INSPECTION—8 0L ENGINE 1519
SPECIFICATIONS 1522
SPECIFICATIONS – TORQUE – GAS FUEL INJECTION 1522
SPECIAL TOOLS 1523
FUEL SYSTEM 1523
ACCELERATOR PEDAL 1524
REMOVAL 1524
REMOVAL 1524
INSTALLATION 1524
INSTALLATION 1524
CRANKSHAFT POSITION SENSOR 1525
DESCRIPTION 1525
DESCRIPTION – 3 9L 1525
DESCRIPTION – 5 2L/5 9L 1525
DESCRIPTION – 8 0L 1525
OPERATION 1525
OPERATION – 3 9L 1525
OPERATION – 5 2L/5 9L 1525
OPERATION – 8 0L 1526
REMOVAL 1526
REMOVAL – 3 9L/5 2L/5 9L 1526
REMOVAL – 8 0L 1527
INSTALLATION 1527
INSTALLATION – 3 9L/5 2L/5 9L 1527
INSTALLATION – 8 0L 1527
FUEL PUMP RELAY 1528
DESCRIPTION 1528
DESCRIPTION 1528
OPERATION 1528
OPERATION 1528
REMOVAL 1528
REMOVAL 1528
INSTALLATION 1528
INSTALLATION 1528
IDLE AIR CONTROL MOTOR 1528
DESCRIPTION 1528
DESCRIPTION 1528
OPERATION 1528
OPERATION 1528
REMOVAL 1529
REMOVAL – 3 9L/5 2L/5 9L 1529
REMOVAL – 8 0L 1529
INSTALLATION 1529
INSTALLATION – 3 9L/5 2L/5 9L 1529
INSTALLATION – 8 0L 1530
INTAKE AIR TEMPERATURE SENSOR 1530
DESCRIPTION 1530
DESCRIPTION – 3 9L/5 2L/5 9L/8 0L 1530
OPERATION 1530
OPERATION – 3 9L/5 2L/5 9L/8 0L 1530
REMOVAL 1530
REMOVAL – 3 9L/5 2L/5 9L 1530
REMOVAL – 8 0L 1530
INSTALLATION 1530
INSTALLATION – 3 9L/5 2L/5 9L 1530
INSTALLATION – 8 0L 1531
MANIFOLD ABSOLUTE PRESSURE SENSOR 1531
DESCRIPTION 1531
DESCRIPTION – 3 9L/5 2L/5 9L/8 0L 1531
OPERATION 1531
OPERATION – 3 9L/5 2L/5 9L/8 0L 1531
REMOVAL 1531
REMOVAL – 3 9L/5 2L/5 9L 1532
REMOVAL – 8 0L 1532
INSTALLATION 1532
INSTALLATION – 3 9L/5 2L/5 9L 1532
INSTALLATION – 8 0L 1533
O2 SENSOR 1533
DESCRIPTION 1533
DESCRIPTION 1533
OPERATION 1533
OPERATION 1533
REMOVAL 1534
REMOVAL 1534
INSTALLATION 1535
INSTALLATION 1535
PTO SWITCH 1535
DESCRIPTION 1535
DESCRIPTION 1535
OPERATION 1535
OPERATION 1535
THROTTLE BODY 1535
DESCRIPTION 1535
DESCRIPTION 1535
OPERATION 1535
OPERATION 1535
REMOVAL 1535
REMOVAL – 3 9L/5 2L/5 9L 1535
REMOVAL – 8 0L 1536
INSTALLATION 1536
INSTALLATION – 3 9L/5 2L/5 9L 1536
INSTALLATION – 8 0L 1536
THROTTLE CONTROL CABLE 1537
REMOVAL 1537
REMOVAL 1537
INSTALLATION 1537
INSTALLATION 1537
THROTTLE POSITION SENSOR 1538
DESCRIPTION 1538
DESCRIPTION 1538
OPERATION 1538
OPERATION 1538
REMOVAL 1538
REMOVAL – 3 9L/5 2L/5 9L 1538
REMOVAL – 8 0L 1539
INSTALLATION 1539
INSTALLATION – 3 9L/5 2L/5 9L 1539
INSTALLATION – 8 0L 1539
FUEL INJECTOR 1540
DESCRIPTION 1540
DESCRIPTION 1540
OPERATION 1540
OPERATION 1540
OPERATION – PCM OUTPUT 1540
DIAGNOSIS AND TESTING 1540
DIAGNOSIS AND TESTING – FUEL INJECTOR TEST 1540
REMOVAL 1540
REMOVAL 1540
INSTALLATION 1540
INSTALLATION 1540
FUEL DELIVERY – DIESEL 1541
FUEL DELIVERY – DIESEL 1541
DESCRIPTION 1541
DESCRIPTION – DIESEL FUEL DELIVERY SYSTEM 1541
OPERATION 1543
DIAGNOSIS AND TESTING 1543
DIAGNOSIS AND TESTING – AIR IN FUEL SYSTEM 1543
DIAGNOSIS AND TESTING – FUEL SUPPLY RESTRICTIONS 1543
LOW-PRESSURE LINES 1543
HIGH-PRESSURE LINES 1543
STANDARD PROCEDURE 1543
STANDARD PROCEDURES – WATER DRAINING AT FUEL FILTER 1543
STANDARD PROCEDURES – CLEANING FUEL SYSTEM PARTS 1544
STANDARD PROCEDURE – AIR BLEED 1544
SPECIFICATIONS 1545
FUEL SYSTEM PRESSURES—DIESEL ENGINES 1545
FUEL INJECTOR FIRING ORDER—DIESEL 1545
SPECIAL TOOLS 1546
DIESEL FUEL SYSTEM0 – 22 BR/BE (Continued) 1546
FUEL FILTER / WATER SEPARATOR 1546
DESCRIPTION 1546
DESCRIPTION 1546
OPERATION 1546
OPERATION 1546
REMOVAL 1546
REMOVAL 1547
INSTALLATION 1548
INSTALLATION 1548
FUEL HEATER 1549
DESCRIPTION 1549
DESCRIPTION 1549
OPERATION 1549
OPERATION 1549
DIAGNOSIS AND TESTING 1549
DIAGNOSIS AND TESTING – FUEL HEATER 1549
TESTING 1550
REMOVAL 1550
REMOVAL/INSTALLATION 1550
FUEL HEATER RELAY 1550
DESCRIPTION 1550
DESCRIPTION 1550
OPERATION 1550
OPERATION 1550
DIAGNOSIS AND TESTING 1550
DIAGNOSIS AND TESTING – FUEL HEATER RELAY 1551
TESTING 1551
REMOVAL 1552
REMOVAL 1552
INSTALLATION 1552
INSTALLATION 1552
FUEL INJECTION PUMP 1552
DESCRIPTION 1552
DESCRIPTION—FUEL PUMP 245 H P 1552
DESCRIPTION—FUEL PUMP 235 H P 1553
OPERATION 1553
OPERATION 1553
DIAGNOSIS AND TESTING 1553
DIAGNOSIS AND TESTING—FUEL INJECTION PUMP TIMING 1553
REMOVAL 1555
REMOVAL 1555
INSTALLATION 1558
INSTALLATION 1558
FUEL INJECTION PUMP DATA PLATE 1560
SPECIFICATIONS 1560
FUEL INJECTION PUMP DATA PLATE 1560
FUEL LEVEL SENDING UNIT / SENSOR 1560
DESCRIPTION 1560
DESCRIPTION 1560
OPERATION 1560
OPERATION 1560
FUEL LINES 1560
DESCRIPTION 1560
DESCRIPTION 1560
DESCRIPTION—HIGH PRESSURE FUEL LINES 1561
OPERATION 1561
OPERATION—HIGH PRESSURE FUEL LINES 1561
DIAGNOSIS AND TESTING 1561
DIAGNOSIS AND TESTING – HIGH-PRESSURE FUEL LINE LEAKS 1561
REMOVAL 1562
REMOVAL 1562
INSTALLATION 1564
INSTALLATION 1564
FUEL TANK 1565
DESCRIPTION 1565
DESCRIPTION – DIESEL FUEL TANK 1565
FUEL TANK MODULE 1565
DESCRIPTION 1565
DESCRIPTION 1565
OPERATION 1565
OPERATION 1565
REMOVAL 1565
REMOVAL 1565
INSTALLATION 1566
INSTALLATION 1566
FUEL TRANSFER PUMP 1566
DESCRIPTION 1566
DESCRIPTION 1566
OPERATION 1566
OPERATION 1566
DIAGNOSIS AND TESTING 1567
DIAGNOSIS AND TESTING – FUEL TRANSFER PUMP PRESSURE 1567
REMOVAL 1569
REMOVAL 1570
INSTALLATION 1570
INSTALLATION 1570
OVERFLOW VALVE 1570
DESCRIPTION 1570
DESCRIPTION 1570
OPERATION 1570
OPERATION 1570
DIAGNOSIS AND TESTING 1571
DIAGNOSIS AND TESTING – OVERFLOW VALVE 1571
REMOVAL 1571
REMOVAL 1571
INSTALLATION 1572
INSTALLATION 1572
WATER IN FUEL SENSOR 1572
DESCRIPTION 1572
DESCRIPTION 1572
OPERATION 1572
OPERATION 1572
REMOVAL 1572
REMOVAL 1572
FUEL DRAIN MANIFOLD 1573
DESCRIPTION 1573
DESCRIPTION 1573
OPERATION 1573
OPERATION 1573
REMOVAL 1573
REMOVAL 1573
INSTALLATION 1573
INSTALLATION 1573
FUEL INJECTION – DIESEL 1574
FUEL INJECTION – DIESEL 1574
DESCRIPTION 1574
DESCRIPTION – DIESEL FUEL INJECTION SYSTEM 1574
DIAGNOSIS AND TESTING 1574
DIAGNOSIS AND TESTING – BOOST PRESSURE 1576
SPECIFICATIONS 1577
TORQUE – DIESEL ENGINE 1577
ACCELERATOR PEDAL POSITION SENSOR 1578
DESCRIPTION 1578
DESCRIPTION 1578
OPERATION 1578
OPERATION 1578
REMOVAL 1578
REMOVAL 1578
INSTALLATION 1580
INSTALLATION 1580
FUEL INJECTOR 1580
DESCRIPTION 1580
DESCRIPTION 1580
OPERATION 1580
OPERATION 1581
DIAGNOSIS AND TESTING 1582
DIAGNOSIS AND TESTING—FUEL INJECTOR TEST 1582
REMOVAL 1583
REMOVAL 1583
INSTALLATION 1584
INSTALLATION 1585
FUEL INJECTION PUMP RELAY 1586
DESCRIPTION 1586
DESCRIPTION 1586
OPERATION 1586
OPERATION 1586
FUEL TEMPERATURE SENSOR 1586
DESCRIPTION 1586
DESCRIPTION 1586
OPERATION 1586
OPERATION 1587
INTAKE AIR HEATER 1587
DESCRIPTION 1587
DESCRIPTION 1587
OPERATION 1587
OPERATION 1587
REMOVAL 1587
REMOVAL 1587
INSTALLATION 1587
INSTALLATION 1588
INTAKE AIR HEATER RELAY 1588
DESCRIPTION 1588
DESCRIPTION 1588
OPERATION 1588
OPERATION 1589
REMOVAL 1589
REMOVAL 1589
INSTALLATION 1589
INSTALLATION 1589
INTAKE AIR TEMPERATURE SENSOR 1589
DESCRIPTION 1589
DESCRIPTION – DIESEL 1589
OPERATION 1589
OPERATION – DIESEL 1589
REMOVAL 1590
REMOVAL – DIESEL 1590
INSTALLATION 1590
INSTALLATION – DIESEL 1590
MAP SENSOR 1590
DESCRIPTION 1590
DESCRIPTION – DIESEL 1590
OPERATION 1590
OPERATION – DIESEL 1590
REMOVAL 1590
REMOVAL – DIESEL 1591
INSTALLATION 1591
INSTALLATION 1591
PTO SWITCH 1591
DESCRIPTION 1591
OPERATION 1591
THROTTLE CONTROL CABLE 1591
REMOVAL 1591
REMOVAL 1591
INSTALLATION 1592
INSTALLATION 1592
19-STEERING 1594
STEERING 1594
DESCRIPTION 1594
OPERATION 1594
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM 1595
DIAGNOSIS AND TESTING – POWER STEERING FLOW AND PRESSURE 1597
POWER STEERING ANALYZER INSTALLATION 1597
FLOW AND PRESSURE TEST 1597
COLUMN 1599
COLUMN 1599
DESCRIPTION 1599
SERVICE PRECAUTIONS 1599
REMOVAL 1600
INSTALLATION 1601
SPECIFICATIONS 1602
TORQUE CHART 1602
KEY-IN IGNITION SWITCH 1602
DESCRIPTION 1602
DIAGNOSIS AND TESTING – IGNITION SWITCH AND KEY LOCK CYLINDER 1603
ELECTRICAL DIAGNOSIS 1603
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) 1603
LOCK CYLINDER HOUSING 1603
REMOVAL 1603
INSTALLATION 1604
IGNITION SWITCH 1604
DESCRIPTION 1604
OPERATION 1604
DIAGNOSIS AND TESTING – IGNITION SWITCH 1604
TEST AND REPAIR 1604
REMOVAL 1605
INSTALLATION 1605
GEAR SHIFT LEVER 1606
REMOVAL 1606
INSTALLATION 1606
STEERING WHEEL 1606
REMOVAL 1606
INSTALLATION 1606
GEAR 1607
GEAR 1607
DESCRIPTION 1607
OPERATION 1607
DIAGNOSIS AND TESTING – POWER STEERING GEAR LEAKAGE 1607
REMOVAL 1609
INSTALLATION 1609
ADJUSTMENTS 1609
WORM THRUST BEARING PRELOAD 1610
PITMAN SHAFT OVER-CENTER PRELOAD 1610
SPECIFICATIONS 1612
POWER STEERING GEAR 1612
TORQUE CHART 1612
SPECIAL TOOLS 1613
POWER STEERING GEAR 1613
PITMAN BEARING 1613
REMOVAL 1613
INSTALLATION 1614
PITMAN SHAFT 1615
REMOVAL 1615
INSTALLATION 1616
PITMAN SHAFT SEAL 1616
REMOVAL 1616
INSTALLATION 1617
SPOOL VALVE 1617
REMOVAL 1617
INSTALLATION 1619
STEERING GEAR HOUSING PLUG 1620
REMOVAL 1620
INSTALLATION 1620
WORM SHAFT 1620
REMOVAL 1620
INSTALLATION 1622
PUMP 1624
PUMP 1624
DESCRIPTION 1624
OPERATION 1624
DIAGNOSIS AND TESTING – PUMP LEAKAGE 1624
STANDARD PROCEDURE – POWER STEERING PUMP – INITIAL OPERATION 1624
STANDARD PROCEDURE – FLUSHING POWER STEERING SYSTEM 1625
REMOVAL – GASOLINE ENGINE 1626
REMOVAL – DIESEL ENGINE 1626
INSTALLATION – GASOLINE ENGINE 1628
INSTALLATION – DIESEL ENGINE 1628
SPECIAL TOOLS 1629
POWER STEERING PUMP 1629
PULLEY 1629
REMOVAL 1629
INSTALLATION 1629
HOSES – PRESSURE 1630
DESCRIPTION 1630
OPERATION 1630
HOSES – RETURN 1630
DESCRIPTION 1630
OPERATION 1630
LINKAGE – 2WD 1631
LINKAGE – 2WD 1631
DESCRIPTION 1631
STANDARD PROCEDURE – LUBRICATION 1631
REMOVAL 1631
INSTALLATION 1632
SPECIFICATIONS 1632
TORQUE CHART 1632
SPECIAL TOOLS 1632
STEERING LINKAGE 1632
LINKAGE – 4WD 1633
LINKAGE – 4WD 1633
DESCRIPTION 1633
STANDARD PROCEDURE – LUBRICATION 1633
REMOVAL 1633
INSTALLATION 1634
SPECIFICATIONS 1634
TORQUE CHART 1634
SPECIAL TOOLS 1635
STEERING LINKAGE 1635
21-TRANSMISSION AND TRANSFER CASE 1636
MANUAL – NV3500 1636
MANUAL – NV3500 1636
DESCRIPTION 1636
DESCRIPTION 1636
GEAR RATIOS 1636
OPERATION 1636
OPERATION 1636
DIAGNOSIS AND TESTING 1638
DIAGNOSIS AND TESTING – MANUAL TRANSMISSION 1638
LOW LUBRICANT LEVEL 1638
HARD SHIFTING 1638
TRANSMISSION NOISE 1638
REMOVAL 1638
REMOVAL 1638
TWO WHEEL DRIVE 1639
FOUR WHEEL DRIVE 1639
DISASSEMBLY 1639
DISASSEMBLY 1640
FRONT HOUSING 1640
SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT 1642
REAR HOUSING – 2WD 1644
REAR ADAPTER HOUSING – 4WD 1646
GEARTRAIN FROM FIXTURE 1647
OUTPUT SHAFT 1647
REVERSE IDLER 1650
CLEANING 1650
CLEANING 1650
INSPECTION 1650
INSPECTION 1650
SHIFT LEVER ASSEMBLY 1650
SHIFT SHAFT AND FORKS0 – 24 BR/BE (Continued) 1650
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1650
COUNTERSHAFT BEARINGS AND RACES 1652
REVERSE IDLER COMPONENTS 1652
Shift Socket 1652
Output Shaft And Geartrain 1652
ASSEMBLY 1652
ASSEMBLY 1652
SYNCHRONIZER 1653
OUTPUT SHAFT 1653
REVERSE IDLER ASSEMBLY 1660
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS 1662
GEARTRAIN ASSEMBLY 1662
REAR HOUSING – 2WD 1666
ADAPTER HOUSING – 4WD 1667
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET 1668
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER 1671
SHIFT TOWER AND LEVER 1674
INSTALLATION 1675
INSTALLATION 1675
TWO WHEEL DRIVE 1675
FOUR WHEEL DRIVE 1675
SPECIFICATIONS 1676
MANUAL – NV3500 1676
SPECIAL TOOLS 1676
MANUAL – NV3500 1676
MANUAL – NV4500 1679
MANUAL – NV4500 1679
DESCRIPTION 1679
DESCRIPTION 1679
SHIFT PATTERN 1681
GEAR RATIOS 1681
IDENTIFICATION 1681
OPERATION 1681
OPERATION 1681
DIAGNOSIS AND TESTING 1681
DIAGNOSIS AND TESTING – MANUAL TRANSMISSION 1681
LOW LUBRICANT LEVEL 1681
HARD SHIFTING 1682
TRANSMISSION NOISE 1682
REMOVAL 1682
REMOVAL 1682
TWO WHEEL DRIVE 1682
FOUR WHEEL DRIVE 1682
DISASSEMBLY 1683
DISASSEMBLY 1683
CLEANING 1699
CLEANING 1699
INSPECTION 1699
INSPECTION – TRANSMISSION 1699
ASSEMBLY 1700
ASSEMBLY 1700
INSTALLATION 1716
INSTALLATION 1717
TWO WHEEL DRIVE 1717
FOUR WHEEL DRIVE 1717
SPECIFICATIONS 1718
SPECIFICATIONS – NV4500 1718
SPECIAL TOOLS 1718
MANUAL – NV4500 1718
ADAPTER HOUSING SEAL 1722
REMOVAL 1722
REMOVAL 1722
INSTALLATION 1722
INSTALLATION 1722
EXTENSION HOUSING SEAL 1722
REMOVAL 1722
REMOVAL 1722
INSTALLATION 1722
INSTALLATION 1722
SHIFT MECHANISM 1723
REMOVAL 1723
REMOVAL 1723
FIFTH-REVERSE SHIFT FORK PADS 1723
EXPANSION PLUG 1724
INSTALLATION 1724
INSTALLATION 1724
EXPANSION PLUG 1724
FIFTH-REVERSE SHIFT FORK PADS 1724
SHIFT COVER 1724
SHIFT COVER 1725
REMOVAL 1725
REMOVAL 1725
INSTALLATION 1725
INSTALLATION 1725
MANUAL – NV5600 1726
MANUAL – NV5600 1726
DESCRIPTION 1726
DESCRIPTION 1726
SHIFT PATTERN 1728
GEAR RATIOS 1728
IDENTIFICATION 1728
OPERATION 1728
OPERATION 1728
DIAGNOSIS AND TESTING 1728
DIAGNOSIS AND TESTING – MANUAL TRANSMISSION 1728
LOW LUBRICANT LEVEL 1728
HARD SHIFTING 1729
TRANSMISSION NOISE 1729
REMOVAL 1729
REMOVAL 1729
TWO WHEEL DRIVE 1729
FOUR WHEEL DRIVE 1730
DISASSEMBLY 1730
DISASSEMBLY 1730
CLEANING 1744
CLEANING – TRANSMISSION 1744
INSPECTION 1744
INSPECTION – TRANSMISSION 1744
ASSEMBLY 1745
ASSEMBLY 1745
INSTALLATION 1760
INSTALLATION 1760
TWO WHEEL DRIVE 1760
FOUR WHEEL DRIVE 1761
SPECIFICATIONS 1761
SPECIFICATIONS – NV5600 1761
SPECIAL TOOLS 1762
NV5600 MANUAL TRANSMISSION 1762
ADAPTER HOUSING SEAL 1767
REMOVAL 1767
REMOVAL 1767
INSTALLATION 1767
INSTALLATION 1767
EXTENSION HOUSING SEAL 1767
REMOVAL 1767
REMOVAL 1767
INSTALLATION 1767
INSTALLATION 1767
SHIFT COVER 1767
REMOVAL 1767
REMOVAL 1767
INSTALLATION 1768
INSTALLATION 1768
AUTOMATIC TRANSMISSION – 42RE 1769
AUTOMATIC TRANSMISSION – 42RE 1770
DESCRIPTION 1770
DESCRIPTION 1770
IDENTIFICATION 1772
GEAR RATIOS 1772
OPERATION 1772
OPERATION 1772
PARK POWERFLOW 1773
NEUTRAL POWERFLOW 1773
REVERSE POWERFLOW 1774
FIRST GEAR POWERFLOW 1775
SECOND GEAR POWERFLOW 1776
DIRECT DRIVE POWERFLOW 1777
FOURTH GEAR POWERFLOW 1778
DIAGNOSIS AND TESTING 1778
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 1778
DIAGNOSIS AND TESTING – PRELIMINARY 1778
VEHICLE IS DRIVEABLE 1778
VEHICLE IS DISABLED 1778
DIAGNOSIS AND TESTING – ROAD TESTING 1778
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TEST 1779
Pressure Test Port Locations 1780
DIAGNOSIS AND TESTING – AIR CHECKING TRANSMISSION CLUTCH AND BAND OPERATION 1782
Front Clutch Air Test 1782
Rear Clutch Air Test 1782
Front Servo Apply Air Test 1783
Rear Servo Air Test 1783
DIAGNOSIS AND TESTING – CONVERTER HOUSING FLUID LEAK 1783
TORQUE CONVERTER LEAK POINTS 1783
CONVERTER HOUSING AREA LEAK CORRECTION 1783
DIAGNOSIS AND TESTING – DIAGNOSIS CHARTS 1784
STANDARD PROCEDURE 1794
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 1794
REMOVAL 1794
REMOVAL 1794
DISASSEMBLY 1795
DISASSEMBLY 1795
CLEANING 1800
CLEANING 1800
INSPECTION 1800
INSPECTION 1800
ASSEMBLY 1801
ASSEMBLY 1801
INSTALLATION 1807
INSTALLATION 1808
SCHEMATICS AND DIAGRAMS 1809
HYDRAULIC SCHEMATICS 1809
SPECIFICATIONS 1821
TRANSMISSION 1821
SPECIAL TOOLS 1823
RE TRANSMISSIONS 1823
ACCUMULATOR 1826
DESCRIPTION 1826
DESCRIPTION 1826
OPERATION 1826
OPERATION 1826
INSPECTION 1826
INSPECTION 1827
BANDS 1827
DESCRIPTION 1827
DESCRIPTION 1827
KICKDOWN (FRONT) BAND 1827
LOW/REVERSE (REAR) BAND 1827
OPERATION 1827
OPERATION 1827
KICKDOWN (FRONT) BAND 1827
LOW/REVERSE (REAR) BAND 1828
ADJUSTMENTS 1828
ADJUSTMENT – BANDS 1828
FRONT BAND 1828
REAR BAND 1828
ELECTRONIC GOVERNOR 1829
DESCRIPTION 1829
DESCRIPTION 1829
GOVERNOR PRESSURE SOLENOID VALVE 1829
GOVERNOR PRESSURE SENSOR 1829
GOVERNOR BODY AND TRANSFER PLATE 1829
GOVERNOR PRESSURE CURVES 1829
OPERATION 1829
OPERATION 1829
GOVERNOR PRESSURE SOLENOID VALVE 1830
GOVERNOR PRESSURE SENSOR 1830
GOVERNOR BODY AND TRANSFER PLATE 1830
GOVERNOR PRESSURE CURVES 1830
REMOVAL 1830
REMOVAL 1831
INSTALLATION 1831
INSTALLATION 1832
EXTENSION HOUSING BUSHING 1833
REMOVAL 1833
REMOVAL 1833
INSTALLATION 1833
INSTALLATION 1833
EXTENSION HOUSING SEAL 1833
REMOVAL 1833
REMOVAL 1833
INSTALLATION 1833
INSTALLATION 1833
FLUID AND FILTER 1834
DIAGNOSIS AND TESTING 1834
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 1834
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 1834
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 1834
STANDARD PROCEDURE 1834
STANDARD PROCEDURE – FLUID LEVEL CHECK 1834
PROCEDURE ONE 1835
PROCEDURE TWO 1835
STANDARD PROCEDURE – FLUID AND FILTER REPLACEMENT 1836
STANDARD PROCEDURE – TRANSMISSION FILL 1836
FRONT CLUTCH 1837
DESCRIPTION 1837
DESCRIPTION 1837
OPERATION 1837
OPERATION 1837
DISASSEMBLY 1837
DISASSEMBLY 1837
INSPECTION 1840
INSPECTION 1840
ASSEMBLY 1841
ASSEMBLY 1841
FRONT SERVO 1841
DESCRIPTION 1841
DESCRIPTION 1841
OPERATION 1841
OPERATION 1842
DISASSEMBLY 1842
DISASSEMBLY 1842
CLEANING 1842
CLEANING 1842
INSPECTION 1842
INSPECTION 1842
ASSEMBLY 1842
ASSEMBLY 1843
OIL PUMP 1843
DESCRIPTION 1843
DESCRIPTION 1843
OPERATION 1843
OPERATION 1843
STANDARD PROCEDURE 1843
STANDARD PROCEDURE – OIL PUMP VOLUME CHECK 1844
DISASSEMBLY 1844
DISASSEMBLY 1844
OIL PUMP BUSHING REPLACEMENT 1845
REACTION SHAFT SUPPORT BUSHING REMOVAL 1846
CLEANING 1846
CLEANING 1846
INSPECTION 1846
INSPECTION 1846
ASSEMBLY 1846
ASSEMBLY 1847
OUTPUT SHAFT FRONT BEARING 1848
REMOVAL 1848
REMOVAL 1848
INSTALLATION 1848
INSTALLATION 1848
OUTPUT SHAFT REAR BEARING 1848
REMOVAL 1848
REMOVAL 1848
INSTALLATION 1848
INSTALLATION 1848
OVERDRIVE CLUTCH 1849
DESCRIPTION 1849
DESCRIPTION 1849
OPERATION 1849
OPERATION 1849
OVERDRIVE OFF SWITCH 1850
DESCRIPTION 1850
DESCRIPTION 1850
OPERATION 1850
OPERATION 1850
DIAGNOSIS AND TESTING 1850
DIAGNOSIS AND TESTING – OVERDRIVE ELECTRICAL CONTROLS 1850
REMOVAL 1850
REMOVAL 1850
INSTALLATION 1850
INSTALLATION 1850
OVERDRIVE UNIT 1851
REMOVAL 1851
REMOVAL 1851
DISASSEMBLY 1851
DISASSEMBLY 1852
OVERDRIVE PISTON 1852
OVERDRIVE CLUTCH PACK 1853
OVERDRIVE GEARTRAIN 1854
DIRECT CLUTCH, HUB AND SPRING 1855
GEARTRAIN 1857
GEAR CASE AND PARK LOCK 1859
CLEANING 1859
CLEANING 1859
INSPECTION 1859
INSPECTION 1859
ASSEMBLY 1859
ASSEMBLY 1860
GEARTRAIN AND DIRECT CLUTCH 1860
GEAR CASE 1865
OVERDRIVE CLUTCH 1866
INTERMEDIATE SHAFT SPACER SELECTION 1867
OD THRUST PLATE SELECTION 1867
OVERDRIVE PISTON 1868
INSTALLATION 1869
INSTALLATION 1869
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER 1870
DESCRIPTION 1870
DESCRIPTION 1870
OPERATION0 – 26 BR/BE (Continued) 1870
OPERATION 1870
DISASSEMBLY 1870
DISASSEMBLY 1870
CLEANING 1870
CLEANING 1871
INSPECTION 1871
INSPECTION 1871
ASSEMBLY 1871
ASSEMBLY 1871
PARK/NEUTRAL POSITION SWITCH 1872
DIAGNOSIS AND TESTING 1872
DIAGNOSIS AND TESTING – PARK/NEUTRAL POSITION SWITCH 1872
SWITCH TEST 1872
REMOVAL 1872
REMOVAL 1873
INSTALLATION 1873
INSTALLATION 1873
PISTONS 1873
DESCRIPTION 1873
DESCRIPTION 1873
OPERATION 1873
OPERATION 1873
PRESSURE 1873
PRESSURE ON A CONFINED FLUID 1873
FORCE MULTIPLICATION 1874
PISTON TRAVEL 1874
PLANETARY GEARTRAIN/OUTPUT SHAFT 1875
DESCRIPTION 1875
DESCRIPTION 1875
OPERATION 1875
OPERATION 1875
DISASSEMBLY 1875
DISASSEMBLY 1875
INSPECTION 1876
INSPECTION 1876
ASSEMBLY 1876
ASSEMBLY 1876
REAR CLUTCH 1881
DESCRIPTION 1881
DESCRIPTION 1881
OPERATION 1881
OPERATION 1881
DISASSEMBLY 1882
DISASSEMBLY 1882
CLEANING 1882
CLEANING 1882
INSPECTION 1883
INSPECTION 1883
ASSEMBLY 1883
ASSEMBLY 1883
REAR SERVO 1885
DESCRIPTION 1885
DESCRIPTION 1885
OPERATION 1885
OPERATION 1885
DISASSEMBLY 1885
DISASSEMBLY 1886
CLEANING 1886
CLEANING 1886
ASSEMBLY 1886
ASSEMBLY 1886
SHIFT MECHANISM 1886
DESCRIPTION 1886
DESCRIPTION 1886
OPERATION 1886
OPERATION 1886
ADJUSTMENTS 1887
ADJUSTMENT 1887
LINKAGE ADJUSTMENT 1887
SOLENOID 1887
DESCRIPTION 1887
DESCRIPTION 1887
OPERATION 1888
OPERATION 1888
SPEED SENSOR 1888
DESCRIPTION 1888
DESCRIPTION 1888
OPERATION 1888
OPERATION 1888
THROTTLE VALVE CABLE 1888
DESCRIPTION 1888
DESCRIPTION 1888
ADJUSTMENTS 1889
ADJUSTMENTS – TRANSMISSION THROTTLE VALVE CABLE 1889
ADJUSTMENT VERIFICATION 1889
ADJUSTMENT PROCEDURE 1890
TORQUE CONVERTER 1891
DESCRIPTION 1891
DESCRIPTION 1891
IMPELLER 1892
TURBINE 1893
STATOR 1894
TORQUE CONVERTER CLUTCH (TCC) 1894
OPERATION 1894
OPERATION 1895
TURBINE 1895
STATOR 1895
TORQUE CONVERTER CLUTCH (TCC) 1895
REMOVAL 1896
REMOVAL 1896
INSTALLATION 1896
INSTALLATION 1896
TORQUE CONVERTER DRAINBACK VALVE 1897
DESCRIPTION 1897
DESCRIPTION 1897
OPERATION 1897
OPERATION 1897
STANDARD PROCEDURE 1897
STANDARD PROCEDURE – TORQUE CONVERTER DRAINBACK VALVE 1897
TRANSMISSION TEMPERATURE SENSOR 1897
DESCRIPTION 1897
DESCRIPTION 1897
OPERATION 1897
OPERATION 1897
VALVE BODY 1898
DESCRIPTION 1898
DESCRIPTION 1898
OPERATION 1898
OPERATION 1902
CHECK BALLS 1902
REGULATOR VALVE 1903
KICKDOWN VALVE 1906
KICKDOWN LIMIT VALVE 1907
1-2 SHIFT VALVE 1908
1-2 SHIFT CONTROL VALVE 1909
2-3 SHIFT VALVE 1909
3-4 SHIFT VALVE 1911
3-4 TIMING VALVE 1911
3-4 QUICK FILL VALVE 1911
THROTTLE VALVE 1912
SWITCH VALVE 1913
MANUAL VALVE 1915
CONVERTER CLUTCH LOCK-UP VALVE 1915
CONVERTER CLUTCH LOCK-UP TIMING VALVE 1915
SHUTTLE VALVE 1915
BOOST VALVE 1916
REMOVAL 1916
REMOVAL 1916
DISASSEMBLY 1916
DISASSEMBLY 1917
VALVE BODY UPPER HOUSING 1924
VALVE BODY LOWER HOUSING 1927
3-4 ACCUMULATOR HOUSING 1928
CLEANING 1928
CLEANING 1928
INSPECTION 1928
INSPECTION 1928
ASSEMBLY 1929
ASSEMBLY 1929
LOWER HOUSING 1929
3-4 ACCUMULATOR 1929
TRANSFER PLATE 1929
UPPER AND LOWER HOUSING 1930
UPPER HOUSING VALVE AND PLUG 1931
BOOST VALVE TUBE AND BRACE 1935
3-4 ACCUMULATOR 1936
VALVE BODY FINAL 1936
GOVERNOR BODY, SENSOR AND SOLENOID 1937
INSTALLATION 1938
INSTALLATION 1938
ADJUSTMENTS 1938
ADJUSTMENTS – VALVE BODY 1939
CONTROL PRESSURE ADJUSTMENTS 1939
AUTOMATIC TRANSMISSION – 44RE 1940
AUTOMATIC TRANSMISSION – 44RE 1941
DESCRIPTION 1941
DESCRIPTION 1941
IDENTIFICATION 1943
GEAR RATIOS 1943
OPERATION 1943
OPERATION 1943
PARK POWERFLOW 1944
NEUTRAL POWERFLOW 1944
REVERSE POWERFLOW 1945
FIRST GEAR POWERFLOW 1946
SECOND GEAR POWERFLOW 1947
DIRECT DRIVE POWERFLOW 1948
FOURTH GEAR POWERFLOW 1949
DIAGNOSIS AND TESTING 1949
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 1949
DIAGNOSIS AND TESTING – PRELIMINARY 1949
VEHICLE IS DRIVEABLE 1949
VEHICLE IS DISABLED 1949
DIAGNOSIS AND TESTING – ROAD TESTING 1949
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TEST 1950
Pressure Test Port Locations 1950
DIAGNOSIS AND TESTING – AIR CHECKING TRANSMISSION CLUTCH AND BAND OPERATION 1953
Front Clutch Air Test 1953
Rear Clutch Air Test 1953
Front Servo Apply Air Test 1954
Rear Servo Air Test 1954
DIAGNOSIS AND TESTING – CONVERTER HOUSING FLUID LEAK 1954
TORQUE CONVERTER LEAK POINTS 1954
CONVERTER HOUSING AREA LEAK CORRECTION 1954
DIAGNOSIS AND TESTING – DIAGNOSIS CHARTS 1955
STANDARD PROCEDURE 1965
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 1965
REMOVAL 1965
REMOVAL 1965
DISASSEMBLY 1966
DISASSEMBLY 1966
CLEANING 1971
CLEANING 1971
INSPECTION 1972
INSPECTION 1972
ASSEMBLY 1972
ASSEMBLY 1972
INSTALLATION 1978
INSTALLATION 1979
SCHEMATICS AND DIAGRAMS 1980
HYDRAULIC SCHEMATICS 1980
SPECIFICATIONS 1992
SPECIFICATIONS 1992
SPECIAL TOOLS 1994
RE TRANSMISSIONS 1994
ACCUMULATOR 1997
DESCRIPTION 1997
DESCRIPTION 1997
OPERATION 1997
OPERATION 1997
INSPECTION 1997
INSPECTION 1998
BANDS 1998
DESCRIPTION 1998
DESCRIPTION 1998
KICKDOWN (FRONT) BAND 1998
LOW/REVERSE (REAR) BAND 1999
OPERATION 1999
OPERATION 1999
KICKDOWN (FRONT) BAND 1999
LOW/REVERSE (REAR) BAND 1999
ADJUSTMENTS 1999
ADJUSTMENT – BANDS 1999
FRONT BAND 1999
REAR BAND 1999
ELECTRONIC GOVERNOR 2000
DESCRIPTION 2000
DESCRIPTION 2000
GOVERNOR PRESSURE SOLENOID VALVE 2000
GOVERNOR PRESSURE SENSOR 2000
GOVERNOR BODY AND TRANSFER PLATE 2000
GOVERNOR PRESSURE CURVES 2000
OPERATION 2000
OPERATION 2000
GOVERNOR PRESSURE SOLENOID VALVE 2001
GOVERNOR PRESSURE SENSOR 2001
GOVERNOR BODY AND TRANSFER PLATE 2001
GOVERNOR PRESSURE CURVES 2001
REMOVAL 2002
REMOVAL 2002
INSTALLATION 2002
INSTALLATION 2002
EXTENSION HOUSING BUSHING 2004
REMOVAL 2004
REMOVAL 2004
INSTALLATION 2004
INSTALLATION 2004
EXTENSION HOUSING SEAL 2004
REMOVAL 2004
REMOVAL 2004
INSTALLATION 2004
INSTALLATION 2004
FLUID AND FILTER 2005
DIAGNOSIS AND TESTING 2005
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 2005
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 2005
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 2005
STANDARD PROCEDURE 2005
STANDARD PROCEDURE – FLUID LEVEL CHECK 2005
PROCEDURE ONE 2006
PROCEDURE TWO 2006
STANDARD PROCEDURE – FLUID AND FILTER REPLACEMENT 2007
STANDARD PROCEDURE – TRANSMISSION FILL 2007
FRONT CLUTCH 2008
DESCRIPTION 2008
DESCRIPTION 2008
OPERATION 2008
OPERATION 2008
DISASSEMBLY 2008
DISASSEMBLY 2008
INSPECTION 2011
INSPECTION 2011
ASSEMBLY 2011
ASSEMBLY 2011
FRONT SERVO 2012
DESCRIPTION 2012
DESCRIPTION 2012
OPERATION 2012
OPERATION 2012
DISASSEMBLY 2013
DISASSEMBLY 2013
CLEANING 2013
CLEANING 2013
INSPECTION 2013
INSPECTION 2013
ASSEMBLY 2014
ASSEMBLY 2014
OIL PUMP 2014
DESCRIPTION 2014
DESCRIPTION 2014
OPERATION 2014
OPERATION 2014
STANDARD PROCEDURE 2014
STANDARD PROCEDURE – OIL PUMP VOLUME CHECK 2014
DISASSEMBLY 2015
DISASSEMBLY 2015
OIL PUMP BUSHING REPLACEMENT 2016
REACTION SHAFT SUPPORT BUSHING REMOVAL 2016
CLEANING 2016
CLEANING 2016
INSPECTION 2016
INSPECTION 2017
ASSEMBLY 2017
ASSEMBLY 2017
OUTPUT SHAFT FRONT BEARING 2019
REMOVAL 2019
REMOVAL 2019
INSTALLATION 2019
INSTALLATION 2019
OUTPUT SHAFT REAR BEARING 2019
REMOVAL 2019
REMOVAL 2019
INSTALLATION 2019
INSTALLATION 2019
OVERDRIVE CLUTCH 2020
DESCRIPTION 2020
DESCRIPTION 2020
OPERATION 2020
OPERATION 2020
OVERDRIVE SWITCH 2020
DESCRIPTION 2020
DESCRIPTION 2020
OPERATION 2020
OPERATION 2020
DIAGNOSIS AND TESTING 2020
DIAGNOSIS AND TESTING – OVERDRIVE ELECTRICAL CONTROLS 2021
REMOVAL 2021
REMOVAL 2021
INSTALLATION0 – 28 BR/BE (Continued) 2021
INSTALLATION 2021
OVERDRIVE UNIT 2022
REMOVAL 2022
REMOVAL 2022
DISASSEMBLY 2022
DISASSEMBLY 2022
OVERDRIVE PISTON 2023
OVERDRIVE CLUTCH PACK 2024
OVERDRIVE GEARTRAIN 2024
DIRECT CLUTCH, HUB AND SPRING 2026
GEARTRAIN 2027
GEAR CASE AND PARK LOCK 2029
CLEANING 2029
CLEANING 2029
INSPECTION 2029
INSPECTION 2029
ASSEMBLY 2030
ASSEMBLY 2030
GEARTRAIN AND DIRECT CLUTCH 2030
GEAR CASE 2036
OVERDRIVE CLUTCH 2037
INTERMEDIATE SHAFT SPACER SELECTION 2037
OD THRUST PLATE SELECTION 2038
OVERDRIVE PISTON 2038
INSTALLATION 2039
INSTALLATION 2039
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER 2040
DESCRIPTION 2040
DESCRIPTION 2040
OPERATION 2040
OPERATION 2040
DISASSEMBLY 2040
DISASSEMBLY 2040
CLEANING 2041
CLEANING 2041
INSPECTION 2041
INSPECTION 2041
ASSEMBLY 2041
ASSEMBLY 2041
PARK/NEUTRAL POSITION SWITCH 2043
DIAGNOSIS AND TESTING 2043
DIAGNOSIS AND TESTING – PARK/NEUTRAL POSITION SWITCH 2043
SWITCH TEST 2043
REMOVAL 2043
REMOVAL 2043
INSTALLATION 2043
INSTALLATION 2043
PISTONS 2043
DESCRIPTION 2043
DESCRIPTION 2043
OPERATION 2043
OPERATION 2044
PRESSURE 2044
PRESSURE ON A CONFINED FLUID 2044
FORCE MULTIPLICATION 2044
PISTON TRAVEL 2045
PLANETARY GEARTRAIN/OUTPUT SHAFT 2045
DESCRIPTION 2045
DESCRIPTION 2045
OPERATION 2045
OPERATION 2045
DISASSEMBLY 2045
DISASSEMBLY 2046
INSPECTION 2046
INSPECTION 2046
ASSEMBLY 2047
ASSEMBLY 2047
REAR CLUTCH 2052
DESCRIPTION 2052
DESCRIPTION 2052
OPERATION 2052
OPERATION 2052
DISASSEMBLY 2053
DISASSEMBLY 2053
CLEANING 2053
CLEANING 2053
INSPECTION 2053
INSPECTION 2054
ASSEMBLY 2054
ASSEMBLY 2054
REAR SERVO 2056
DESCRIPTION 2056
DESCRIPTION 2056
OPERATION 2056
OPERATION 2056
DISASSEMBLY 2056
DISASSEMBLY 2056
CLEANING 2057
CLEANING 2057
ASSEMBLY 2057
ASSEMBLY 2057
SHIFT MECHANISM 2057
DESCRIPTION 2057
DESCRIPTION 2057
OPERATION 2057
OPERATION 2057
ADJUSTMENTS 2057
ADJUSTMENT 2058
LINKAGE ADJUSTMENT 2058
SOLENOID 2058
DESCRIPTION 2058
DESCRIPTION 2058
OPERATION 2059
OPERATION 2059
SPEED SENSOR 2059
DESCRIPTION 2059
DESCRIPTION 2059
OPERATION 2059
OPERATION 2059
THROTTLE VALVE CABLE 2059
DESCRIPTION 2059
DESCRIPTION 2059
ADJUSTMENTS 2060
ADJUSTMENTS – TRANSMISSION THROTTLE VALVE CABLE 2060
ADJUSTMENT VERIFICATION 2060
ADJUSTMENT PROCEDURE 2061
TORQUE CONVERTER 2062
DESCRIPTION 2062
DESCRIPTION 2062
IMPELLER 2063
TURBINE 2063
STATOR 2064
TORQUE CONVERTER CLUTCH (TCC) 2065
OPERATION 2065
OPERATION 2065
TURBINE 2065
STATOR 2066
TORQUE CONVERTER CLUTCH (TCC) 2067
REMOVAL 2067
REMOVAL 2067
INSTALLATION 2067
INSTALLATION 2067
TORQUE CONVERTER DRAINBACK VALVE 2067
DESCRIPTION 2067
DESCRIPTION 2067
OPERATION 2067
OPERATION 2067
STANDARD PROCEDURE 2067
STANDARD PROCEDURE – TORQUE CONVERTER DRAINBACK VALVE 2067
TRANSMISSION TEMPERATURE SENSOR 2068
DESCRIPTION 2068
DESCRIPTION 2068
OPERATION 2068
OPERATION 2068
VALVE BODY 2068
DESCRIPTION 2068
DESCRIPTION 2068
OPERATION 2068
OPERATION 2073
CHECK BALLS 2073
REGULATOR VALVE 2073
KICKDOWN VALVE 2077
KICKDOWN LIMIT VALVE 2077
1-2 SHIFT VALVE 2078
1-2 SHIFT CONTROL VALVE 2079
2-3 SHIFT VALVE 2079
3-4 SHIFT VALVE 2081
3-4 TIMING VALVE 2082
3-4 QUICK FILL VALVE 2082
THROTTLE VALVE 2082
SWITCH VALVE 2083
MANUAL VALVE 2085
CONVERTER CLUTCH LOCK-UP VALVE 2085
CONVERTER CLUTCH LOCK-UP TIMING VALVE 2086
SHUTTLE VALVE 2086
BOOST VALVE 2086
REMOVAL 2086
REMOVAL 2087
DISASSEMBLY 2087
DISASSEMBLY 2088
VALVE BODY UPPER HOUSING 2095
VALVE BODY LOWER HOUSING 2099
3-4 ACCUMULATOR HOUSING 2099
CLEANING 2100
CLEANING 2100
INSPECTION 2100
INSPECTION 2100
ASSEMBLY 2101
ASSEMBLY 2101
LOWER HOUSING 2101
3-4 ACCUMULATOR 2101
TRANSFER PLATE 2101
UPPER AND LOWER HOUSING 2102
UPPER HOUSING VALVE AND PLUG 2103
BOOST VALVE TUBE AND BRACE 2107
3-4 ACCUMULATOR 2107
VALVE BODY FINAL 2108
GOVERNOR BODY, SENSOR AND SOLENOID 2109
INSTALLATION 2109
INSTALLATION 2110
ADJUSTMENTS 2110
ADJUSTMENTS – VALVE BODY 2111
CONTROL PRESSURE ADJUSTMENTS 2111
AUTOMATIC TRANSMISSION – 46RE 2112
AUTOMATIC TRANSMISSION – 46RE 2113
DESCRIPTION 2113
DESCRIPTION 2113
IDENTIFICATION 2115
GEAR RATIOS 2115
OPERATION 2115
OPERATION 2115
PARK POWERFLOW 2116
NEUTRAL POWERFLOW 2116
REVERSE POWERFLOW 2117
FIRST GEAR POWERFLOW 2118
SECOND GEAR POWERFLOW 2119
DIRECT DRIVE POWERFLOW 2120
FOURTH GEAR POWERFLOW 2121
DIAGNOSIS AND TESTING 2121
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 2121
DIAGNOSIS AND TESTING – PRELIMINARY 2121
VEHICLE IS DRIVEABLE 2121
VEHICLE IS DISABLED 2121
DIAGNOSIS AND TESTING – ROAD TESTING 2121
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TEST 2122
Pressure Test Port Locations 2122
DIAGNOSIS AND TESTING – AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION 2125
Front Clutch Air Test 2125
Rear Clutch Air Test 2125
Front Servo Air Test 2125
Rear Servo Air Test 2125
DIAGNOSIS AND TESTING – CONVERTER HOUSING FLUID LEAK 2126
TORQUE CONVERTER LEAK POINTS 2126
CONVERTER HOUSING AREA LEAK CORRECTION 2126
DIAGNOSIS AND TESTING – DIAGNOSIS CHARTS 2127
STANDARD PROCEDURE 2137
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 2137
REMOVAL 2137
REMOVAL 2137
DISASSEMBLY 2138
DISASSEMBLY 2138
CLEANING 2144
CLEANING 2144
INSPECTION 2145
INSPECTION 2145
ASSEMBLY 2145
ASSEMBLY 2145
FRONT/REAR SERVO 2145
OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE DRUM 2147
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH, AND FRONT BAND 2148
OIL PUMP 2151
INPUT SHAFT END PLAY CHECK 2152
ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE CONVERTER 2152
BAND ADJUSTMENT AND FINAL 2153
INSTALLATION 2153
INSTALLATION 2153
SCHEMATICS AND DIAGRAMS 2155
HYDRAULIC SCHEMATICS 2155
SPECIFICATIONS 2167
TRANSMISSION 2167
SPECIAL TOOLS 2169
RE TRANSMISSION 2169
ACCUMULATOR 2172
DESCRIPTION 2172
DESCRIPTION 2172
OPERATION 2172
OPERATION 2172
INSPECTION 2172
INSPECTION 2173
BANDS 2173
DESCRIPTION 2173
DESCRIPTION 2173
KICKDOWN (FRONT) BAND 2173
LOW/REVERSE (REAR) BAND 2173
OPERATION 2173
OPERATION 2174
KICKDOWN (FRONT) BAND 2174
LOW/REVERSE (REAR) BAND 2174
ADJUSTMENTS 2174
ADJUSTMENT – BANDS 2174
FRONT BAND 2174
REAR BAND 2175
ELECTRONIC GOVERNOR 2175
DESCRIPTION 2175
DESCRIPTION 2175
GOVERNOR PRESSURE SOLENOID VALVE 2175
GOVERNOR PRESSURE SENSOR 2175
GOVERNOR BODY AND TRANSFER PLATE 2175
GOVERNOR PRESSURE CURVES 2175
OPERATION 2176
OPERATION 2176
GOVERNOR PRESSURE SOLENOID VALVE 2176
GOVERNOR PRESSURE SENSOR 2176
GOVERNOR BODY AND TRANSFER PLATE 2176
GOVERNOR PRESSURE CURVES 2176
REMOVAL 2177
REMOVAL 2177
INSTALLATION 2177
INSTALLATION 2178
EXTENSION HOUSING BUSHING 2179
REMOVAL 2179
REMOVAL 2179
INSTALLATION 2179
INSTALLATION 2179
EXTENSION HOUSING SEAL 2179
REMOVAL 2179
REMOVAL 2179
INSTALLATION 2179
INSTALLATION 2179
FLUID AND FILTER 2180
DIAGNOSIS AND TESTING 2180
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 2180
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 2180
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 2180
STANDARD PROCEDURE 2180
STANDARD PROCEDURE – FLUID LEVEL CHECK 2180
PROCEDURE ONE 2181
PROCEDURE TWO 2181
STANDARD PROCEDURE – FLUID AND FILTER REPLACEMENT 2182
STANDARD PROCEDURE – TRANSMISSION FILL 2182
FRONT CLUTCH 2183
DESCRIPTION 2183
DESCRIPTION 2183
OPERATION 2183
OPERATION 2183
DISASSEMBLY 2183
DISASSEMBLY 2184
INSPECTION 2184
INSPECTION 2185
ASSEMBLY 2185
ASSEMBLY 2185
FRONT SERVO 2186
DESCRIPTION 2186
DESCRIPTION 2186
OPERATION 2186
OPERATION 2187
DISASSEMBLY 2187
DISASSEMBLY 2187
CLEANING 2187
CLEANING 2187
INSPECTION 2187
INSPECTION 2188
ASSEMBLY 2188
ASSEMBLY 2188
OIL PUMP 2189
DESCRIPTION 2189
DESCRIPTION 2189
OPERATION 2189
OPERATION0 – 30 BR/BE (Continued) 2189
STANDARD PROCEDURE 2189
STANDARD PROCEDURE – OIL PUMP VOLUME CHECK 2189
DISASSEMBLY 2190
DISASSEMBLY 2190
OIL PUMP BUSHING REMOVAL 2192
REACTION SHAFT SUPPORT BUSHING REMOVAL 2192
CLEANING 2192
CLEANING 2192
INSPECTION 2192
INSPECTION 2192
ASSEMBLY 2193
ASSEMBLY 2193
OIL PUMP BUSHING 2193
REACTION SHAFT SUPPORT BUSHING 2193
OIL PUMP BODY 2194
OUTPUT SHAFT FRONT BEARING 2194
REMOVAL 2194
REMOVAL 2194
INSTALLATION 2194
INSTALLATION 2195
OUTPUT SHAFT REAR BEARING 2195
REMOVAL 2195
REMOVAL 2195
INSTALLATION 2195
INSTALLATION 2195
OVERDRIVE CLUTCH 2195
DESCRIPTION 2195
DESCRIPTION 2195
OPERATION 2195
OPERATION 2195
OVERDRIVE UNIT 2195
REMOVAL 2195
REMOVAL 2195
DISASSEMBLY 2196
DISASSEMBLY 2197
OVERDRIVE PISTON 2197
OVERDRIVE CLUTCH PACK 2198
OVERDRIVE GEARTRAIN 2198
DIRECT CLUTCH, HUB AND SPRING 2200
GEARTRAIN 2201
GEAR CASE AND PARK LOCK 2203
CLEANING 2203
CLEANING 2203
INSPECTION 2204
INSPECTION 2204
ASSEMBLY 2204
ASSEMBLY 2204
GEARTRAIN AND DIRECT CLUTCH 2204
GEAR CASE 2209
OVERDRIVE CLUTCH 2210
INTERMEDIATE SHAFT SPACER SELECTION 2211
OD THRUST PLATE SELECTION 2212
OVERDRIVE PISTON 2212
INSTALLATION 2212
INSTALLATION 2212
OVERDRIVE SWITCH 2213
DESCRIPTION 2213
DESCRIPTION 2213
OPERATION 2213
OPERATION 2214
DIAGNOSIS AND TESTING 2214
DIAGNOSIS AND TESTING – OVERDRIVE ELECTRICAL CONTROLS 2214
REMOVAL 2214
REMOVAL 2214
INSTALLATION 2214
INSTALLATION 2214
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER 2215
DESCRIPTION 2215
DESCRIPTION 2215
OPERATION 2215
OPERATION 2215
DISASSEMBLY 2215
DISASSEMBLY 2215
CLEANING 2215
CLEANING 2215
INSPECTION 2215
INSPECTION 2215
ASSEMBLY 2216
ASSEMBLY 2216
PARK/NEUTRAL POSITION SWITCH 2218
DIAGNOSIS AND TESTING 2218
DIAGNOSIS AND TESTING – PARK/NEUTRAL POSITION SWITCH 2218
SWITCH TEST 2218
REMOVAL 2218
REMOVAL 2218
INSTALLATION 2218
INSTALLATION 2218
PISTONS 2219
DESCRIPTION 2219
DESCRIPTION 2219
OPERATION 2219
OPERATION 2219
PRESSURE 2219
PRESSURE ON A CONFINED FLUID 2219
FORCE MULTIPLICATION 2219
PISTON TRAVEL 2220
PLANETARY GEARTRAIN/OUTPUT SHAFT 2220
DESCRIPTION 2220
DESCRIPTION 2220
OPERATION 2220
OPERATION 2220
DISASSEMBLY 2221
DISASSEMBLY 2221
INSPECTION 2222
INSPECTION 2222
ASSEMBLY 2223
ASSEMBLY 2223
REAR CLUTCH 2226
DESCRIPTION 2226
DESCRIPTION 2226
OPERATION 2226
OPERATION 2227
DISASSEMBLY 2227
DISASSEMBLY 2227
CLEANING 2227
CLEANING 2228
INSPECTION 2228
INSPECTION 2228
ASSEMBLY 2228
ASSEMBLY 2228
REAR SERVO 2229
DESCRIPTION 2229
DESCRIPTION 2229
OPERATION 2229
OPERATION 2229
DISASSEMBLY 2229
DISASSEMBLY 2229
CLEANING 2229
CLEANING 2229
ASSEMBLY 2230
ASSEMBLY 2230
SHIFT MECHANISM 2230
DESCRIPTION 2230
DESCRIPTION 2230
OPERATION 2230
OPERATION 2230
ADJUSTMENTS 2230
ADJUSTMENT 2231
LINKAGE ADJUSTMENT 2231
SOLENOID 2231
DESCRIPTION 2231
DESCRIPTION 2231
OPERATION 2232
OPERATION 2232
SPEED SENSOR 2232
DESCRIPTION 2232
DESCRIPTION 2232
OPERATION 2232
OPERATION 2232
THROTTLE VALVE CABLE 2232
DESCRIPTION 2232
DESCRIPTION 2232
ADJUSTMENTS 2233
ADJUSTMENTS – TRANSMISSION THROTTLE VALVE CABLE 2233
ADJUSTMENT VERIFICATION 2233
ADJUSTMENT PROCEDURE 2234
TORQUE CONVERTER 2235
DESCRIPTION 2235
DESCRIPTION 2235
IMPELLER 2236
TURBINE 2237
STATOR 2238
TORQUE CONVERTER CLUTCH (TCC) 2238
OPERATION 2238
OPERATION 2239
TURBINE 2239
STATOR 2239
TORQUE CONVERTER CLUTCH (TCC) 2239
REMOVAL 2239
REMOVAL 2240
INSTALLATION 2240
INSTALLATION 2240
TORQUE CONVERTER DRAINBACK VALVE 2240
DESCRIPTION 2240
DESCRIPTION 2240
OPERATION 2240
OPERATION 2240
STANDARD PROCEDURE 2240
STANDARD PROCEDURE – TORQUE CONVERTER DRAINBACK VALVE 2241
TRANSMISSION TEMPERATURE SENSOR 2241
DESCRIPTION 2241
DESCRIPTION 2241
OPERATION 2241
OPERATION 2241
VALVE BODY 2242
DESCRIPTION 2242
DESCRIPTION 2242
OPERATION 2246
OPERATION 2246
CHECK BALLS 2246
REGULATOR VALVE 2247
KICKDOWN VALVE 2250
KICKDOWN LIMIT VALVE 2251
1-2 SHIFT VALVE 2252
1-2 SHIFT CONTROL VALVE 2253
2-3 SHIFT VALVE 2253
3-4 SHIFT VALVE 2255
3-4 TIMING VALVE 2255
3-4 QUICK FILL VALVE 2255
THROTTLE VALVE 2256
SWITCH VALVE 2257
MANUAL VALVE 2259
CONVERTER CLUTCH LOCK-UP VALVE 2259
CONVERTER CLUTCH LOCK-UP TIMING VALVE 2259
SHUTTLE VALVE 2259
BOOST VALVE 2260
REMOVAL 2260
REMOVAL 2260
DISASSEMBLY 2260
DISASSEMBLY 2261
VALVE BODY UPPER HOUSING 2268
VALVE BODY LOWER HOUSING 2271
3-4 ACCUMULATOR HOUSING 2272
CLEANING 2272
CLEANING 2272
INSPECTION 2272
INSPECTION 2272
ASSEMBLY 2273
ASSEMBLY 2273
LOWER HOUSING 2273
3-4 ACCUMULATOR 2273
TRANSFER PLATE 2273
UPPER AND LOWER HOUSING 2274
UPPER HOUSING VALVE AND PLUG 2275
BOOST VALVE TUBE AND BRACE 2278
3-4 ACCUMULATOR 2278
VALVE BODY FINAL 2279
GOVERNOR BODY, SENSOR AND SOLENOID 2280
INSTALLATION 2280
INSTALLATION 2280
ADJUSTMENTS 2281
ADJUSTMENTS – VALVE BODY 2281
CONTROL PRESSURE ADJUSTMENTS 2281
AUTOMATIC TRANSMISSION – 47RE 2283
AUTOMATIC TRANSMISSION – 47RE 2284
DESCRIPTION 2284
DESCRIPTION 2284
IDENTIFICATION 2286
GEAR RATIOS 2286
OPERATION 2286
OPERATION 2286
PARK POWERFLOW 2287
NEUTRAL POWERFLOW 2287
REVERSE POWERFLOW 2288
FIRST GEAR POWERFLOW 2289
SECOND GEAR POWERFLOW 2290
DIRECT DRIVE POWERFLOW 2291
FOURTH GEAR POWERFLOW 2292
DIAGNOSIS AND TESTING 2292
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 2292
DIAGNOSIS AND TESTING – PRELIMINARY 2292
VEHICLE IS DRIVEABLE 2292
VEHICLE IS DISABLED 2292
DIAGNOSIS AND TESTING – ROAD TESTING 2292
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TEST 2293
Pressure Test Port Locations 2293
DIAGNOSIS AND TESTING – AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION 2296
Front Clutch Air Test 2296
Rear Clutch Air Test 2296
Front Servo Air Test 2296
Rear Servo Air Test 2296
DIAGNOSIS AND TESTING – CONVERTER HOUSING FLUID LEAK 2297
TORQUE CONVERTER LEAK POINTS 2297
CONVERTER HOUSING AREA LEAK CORRECTION 2297
DIAGNOSIS AND TESTING – DIAGNOSIS CHARTS 2298
STANDARD PROCEDURE 2308
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 2308
REMOVAL 2308
REMOVAL 2308
DISASSEMBLY 2309
DISASSEMBLY 2309
CLEANING 2315
CLEANING 2315
INSPECTION 2316
INSPECTION 2316
ASSEMBLY 2316
ASSEMBLY 2316
FRONT/REAR SERVO 2316
OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE DRUM 2318
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH, AND FRONT BAND 2318
OIL PUMP 2320
INPUT SHAFT END PLAY CHECK 2322
ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE CONVERTER 2322
BAND ADJUSTMENT AND FINAL 2322
INSTALLATION 2323
INSTALLATION 2323
SCHEMATICS AND DIAGRAMS 2325
HYDRAULIC SCHEMATICS 2325
SPECIFICATIONS 2337
TRANSMISSION 2337
SPECIAL TOOLS 2339
RE TRANSMISSION 2339
ACCUMULATOR 2342
DESCRIPTION 2342
DESCRIPTION 2342
OPERATION 2342
OPERATION 2343
INSPECTION 2343
INSPECTION 2343
BANDS 2344
DESCRIPTION 2344
DESCRIPTION 2344
KICKDOWN (FRONT) BAND 2344
LOW/REVERSE (REAR) BAND 2344
OPERATION 2344
OPERATION 2344
KICKDOWN (FRONT) BAND 2344
LOW/REVERSE (REAR) BAND 2344
ADJUSTMENTS 2344
ADJUSTMENT – BANDS 2344
FRONT BAND 2344
REAR BAND 2345
ELECTRONIC GOVERNOR 2345
DESCRIPTION 2345
DESCRIPTION 2345
GOVERNOR PRESSURE SOLENOID VALVE 2345
GOVERNOR PRESSURE SENSOR 2345
GOVERNOR BODY AND TRANSFER PLATE 2345
GOVERNOR PRESSURE CURVES 2345
OPERATION 2346
OPERATION 2346
GOVERNOR PRESSURE SOLENOID VALVE 2346
GOVERNOR PRESSURE SENSOR 2346
GOVERNOR BODY AND TRANSFER PLATE 2346
GOVERNOR PRESSURE CURVES 2346
REMOVAL 2347
REMOVAL 2347
INSTALLATION 2348
INSTALLATION 2348
EXTENSION HOUSING BUSHING 2349
REMOVAL 2349
REMOVAL 2349
INSTALLATION 2349
INSTALLATION 2349
EXTENSION HOUSING SEAL 2349
REMOVAL 2349
REMOVAL 2349
INSTALLATION 2349
INSTALLATION0 – 32 BR/BE (Continued) 2350
FLUID AND FILTER 2350
DIAGNOSIS AND TESTING 2350
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 2350
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 2350
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 2350
STANDARD PROCEDURE 2350
STANDARD PROCEDURE – FLUID LEVEL CHECK 2350
PROCEDURE ONE 2351
PROCEDURE TWO 2351
STANDARD PROCEDURE – FLUID AND FILTER REPLACEMENT 2352
STANDARD PROCEDURE – TRANSMISSION FILL 2353
FRONT CLUTCH 2353
DESCRIPTION 2353
DESCRIPTION 2353
OPERATION 2353
OPERATION 2353
DISASSEMBLY 2354
DISASSEMBLY 2354
INSPECTION 2356
INSPECTION 2356
ASSEMBLY 2356
ASSEMBLY 2356
FRONT SERVO 2357
DESCRIPTION 2357
DESCRIPTION 2357
OPERATION 2358
OPERATION 2358
DISASSEMBLY 2358
DISASSEMBLY 2358
CLEANING 2358
CLEANING 2358
INSPECTION 2358
INSPECTION 2358
ASSEMBLY 2358
ASSEMBLY 2358
OIL PUMP 2359
DESCRIPTION 2359
DESCRIPTION 2359
OPERATION 2359
OPERATION 2359
STANDARD PROCEDURE 2359
STANDARD PROCEDURE – OIL PUMP VOLUME CHECK 2359
DISASSEMBLY 2359
DISASSEMBLY 2361
OIL PUMP BUSHING REMOVAL 2363
REACTION SHAFT SUPPORT BUSHING REMOVAL 2363
CLEANING 2363
CLEANING 2363
INSPECTION 2363
INSPECTION 2363
ASSEMBLY 2364
ASSEMBLY 2364
OIL PUMP BUSHING 2364
REACTION SHAFT SUPPORT BUSHING 2365
OIL PUMP BODY 2365
OUTPUT SHAFT FRONT BEARING 2365
REMOVAL 2365
REMOVAL 2365
INSTALLATION 2365
INSTALLATION 2365
OUTPUT SHAFT REAR BEARING 2366
REMOVAL 2366
REMOVAL 2366
INSTALLATION 2366
INSTALLATION 2366
OVERDRIVE CLUTCH 2366
DESCRIPTION 2366
DESCRIPTION 2366
OPERATION 2366
OPERATION 2366
OVERDRIVE SWITCH 2367
DESCRIPTION 2367
DESCRIPTION 2367
OPERATION 2367
OPERATION 2367
DIAGNOSIS AND TESTING 2367
DIAGNOSIS AND TESTING – OVERDRIVE ELECTRICAL CONTROLS 2367
REMOVAL 2367
REMOVAL 2368
INSTALLATION 2368
INSTALLATION 2368
OVERDRIVE UNIT 2368
REMOVAL 2368
REMOVAL 2368
DISASSEMBLY 2369
DISASSEMBLY 2369
OVERDRIVE PISTON 2370
OVERDRIVE CLUTCH PACK 2370
OVERDRIVE GEARTRAIN 2371
DIRECT CLUTCH, HUB AND SPRING 2372
GEARTRAIN 2374
GEAR CASE AND PARK LOCK 2376
CLEANING 2376
CLEANING 2376
INSPECTION 2376
INSPECTION 2376
ASSEMBLY 2377
ASSEMBLY 2377
GEARTRAIN AND DIRECT CLUTCH 2377
GEAR CASE 2382
OVERDRIVE CLUTCH 2383
INTERMEDIATE SHAFT SPACER SELECTION 2384
OD THRUST PLATE SELECTION 2384
OVERDRIVE PISTON 2385
INSTALLATION 2385
INSTALLATION 2385
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER 2386
DESCRIPTION 2386
DESCRIPTION 2386
OPERATION 2386
OPERATION 2386
DISASSEMBLY 2386
DISASSEMBLY 2386
CLEANING 2387
CLEANING 2387
INSPECTION 2387
INSPECTION 2387
ASSEMBLY 2387
ASSEMBLY 2387
PARK/NEUTRAL POSITION SWITCH 2390
DIAGNOSIS AND TESTING 2390
DIAGNOSIS AND TESTING – PARK/NEUTRAL POSITION SWITCH 2390
SWITCH TEST 2390
REMOVAL 2390
REMOVAL 2390
INSTALLATION 2390
INSTALLATION 2390
PISTONS 2390
DESCRIPTION 2390
DESCRIPTION 2390
OPERATION 2390
OPERATION 2390
PRESSURE 2391
PRESSURE ON A CONFINED FLUID 2391
FORCE MULTIPLICATION 2391
PISTON TRAVEL 2391
PLANETARY GEARTRAIN/OUTPUT SHAFT 2392
DESCRIPTION 2392
DESCRIPTION 2392
OPERATION 2392
OPERATION 2392
DISASSEMBLY 2392
DISASSEMBLY 2392
INSPECTION 2395
INSPECTION 2395
ASSEMBLY 2395
ASSEMBLY 2395
REAR CLUTCH 2399
DESCRIPTION 2399
DESCRIPTION 2399
OPERATION 2399
OPERATION 2399
DISASSEMBLY 2399
DISASSEMBLY 2400
CLEANING 2400
CLEANING 2400
INSPECTION 2400
INSPECTION 2400
ASSEMBLY 2401
ASSEMBLY 2401
REAR SERVO 2402
DESCRIPTION 2402
DESCRIPTION 2402
OPERATION 2402
OPERATION 2402
DISASSEMBLY 2403
DISASSEMBLY 2403
CLEANING 2403
CLEANING 2403
ASSEMBLY 2403
ASSEMBLY 2403
SHIFT MECHANISM 2403
DESCRIPTION 2403
DESCRIPTION 2403
OPERATION 2403
OPERATION 2403
ADJUSTMENTS 2404
ADJUSTMENT 2404
LINKAGE ADJUSTMENT 2404
SOLENOID 2404
DESCRIPTION 2404
DESCRIPTION 2404
OPERATION 2405
OPERATION 2405
SPEED SENSOR 2405
DESCRIPTION 2405
DESCRIPTION 2405
OPERATION 2405
OPERATION 2405
THROTTLE VALVE CABLE 2405
DESCRIPTION 2405
DESCRIPTION 2405
ADJUSTMENTS 2406
ADJUSTMENTS – TRANSMISSION THROTTLE VALVE CABLE 2406
ADJUSTMENT VERIFICATION 2406
ADJUSTMENT PROCEDURE 2407
TORQUE CONVERTER 2408
DESCRIPTION 2408
DESCRIPTION 2408
IMPELLER 2409
TURBINE 2410
STATOR 2411
TORQUE CONVERTER CLUTCH (TCC) 2411
OPERATION 2412
OPERATION 2412
TURBINE 2412
STATOR 2412
TORQUE CONVERTER CLUTCH (TCC) 2413
REMOVAL 2413
REMOVAL 2413
INSTALLATION 2413
INSTALLATION 2413
TORQUE CONVERTER DRAINBACK VALVE 2413
DESCRIPTION 2413
DESCRIPTION 2413
OPERATION 2413
OPERATION 2413
STANDARD PROCEDURE 2413
STANDARD PROCEDURE – TORQUE CONVERTER DRAINBACK VALVE 2413
TRANSMISSION TEMPERATURE SENSOR 2414
DESCRIPTION 2414
DESCRIPTION 2414
OPERATION 2414
OPERATION 2414
VALVE BODY 2415
DESCRIPTION 2415
DESCRIPTION 2415
OPERATION 2418
OPERATION 2418
CHECK BALLS 2419
REGULATOR VALVE 2419
KICKDOWN VALVE 2422
KICKDOWN LIMIT VALVE 2422
1-2 SHIFT VALVE 2424
1-2 SHIFT CONTROL VALVE 2425
2-3 SHIFT VALVE 2425
3-4 SHIFT VALVE 2427
3-4 TIMING VALVE 2428
3-4 QUICK FILL VALVE 2428
THROTTLE VALVE 2429
SWITCH VALVE 2429
MANUAL VALVE 2430
CONVERTER CLUTCH LOCK-UP VALVE 2431
CONVERTER CLUTCH LOCK-UP TIMING VALVE 2431
SHUTTLE VALVE 2432
BOOST VALVE 2432
REMOVAL 2432
REMOVAL 2433
DISASSEMBLY 2433
DISASSEMBLY 2434
VALVE BODY UPPER HOUSING 2441
VALVE BODY LOWER HOUSING 2443
3-4 ACCUMULATOR HOUSING 2443
CLEANING 2443
CLEANING 2443
INSPECTION 2444
INSPECTION 2444
ASSEMBLY 2445
ASSEMBLY 2445
LOWER HOUSING 2445
3-4 ACCUMULATOR 2446
TRANSFER PLATE 2446
UPPER AND LOWER HOUSING 2447
UPPER HOUSING VALVE AND PLUG 2447
BOOST VALVE TUBE AND BRACE 2449
3-4 ACCUMULATOR 2451
VALVE BODY FINAL 2451
GOVERNOR BODY, SENSOR AND SOLENOID 2452
INSTALLATION 2453
INSTALLATION 2453
ADJUSTMENTS 2453
ADJUSTMENTS – VALVE BODY 2453
CONTROL PRESSURE ADJUSTMENTS 2453
TRANSFER CASE – NV231HD 2455
TRANSFER CASE – NV231HD 2455
DESCRIPTION 2455
DESCRIPTION 2455
IDENTIFICATION 2455
OPERATION 2455
OPERATION 2455
OPERATING RANGES 2455
SHIFT MECHANISM 2456
SHIFTING 2456
DIAGNOSIS AND TESTING 2456
DIAGNOSIS AND TESTING – TRANSFER CASE 2456
REMOVAL 2457
REMOVAL 2457
DISASSEMBLY 2457
DISASSEMBLY 2457
REAR EXTENSION, RETAINER, AND REAR CASE 2458
COMPANION FLANGE AND SHIFT LEVER 2458
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2459
SHIFT FORKS AND MAINSHAFT 2461
MAINSHAFT 2463
INPUT AND PLANETARY GEAR 2464
INPUT AND PLANETARY GEAR 2465
CLEANING 2465
CLEANING 2466
INSPECTION 2467
INSPECTION 2467
MAINSHAFT/SPROCKET/HUB 2467
INPUT GEAR AND PLANETARY CARRIER 2467
SHIFT FORKS/HUBS/SLEEVES 2467
REAR RETAINER COMPONENTS 2467
DRIVE CHAIN 2468
LOW RANGE ANNULUS GEAR 2469
FRONT-REAR CASES AND FRONT RETAINER 2469
OIL PUMP/OIL PICKUP 2469
ASSEMBLY 2469
ASSEMBLY 2469
BEARINGS AND SEALS 2469
INPUT AND PLANETARY GEAR 2471
SHIFT FORKS AND MAINSHAFT 2473
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2478
OIL PUMP AND REAR CASE 2479
COMPANION FLANGE 2481
REAR RETAINER AND EXTENSION 2481
INSTALLATION 2482
INSTALLATION 2482
SPECIFICATIONS 2483
TRANSFER CASE 2483
SPECIAL TOOLS 2484
TRANSFER CASE – NV231HD 2484
EXTENSION HOUSING BUSHING AND SEAL 2485
REMOVAL 2485
REMOVAL 2485
INSTALLATION 2485
INSTALLATION 2485
FLUID 2486
STANDARD PROCEDURE 2486
STANDARD PROCEDURE – FLUID DRAIN AND REFILL 2486
FRONT OUTPUT SHAFT SEAL 2486
REMOVAL 2486
REMOVAL 2486
INSTALLATION 2486
INSTALLATION 2487
SHIFT LEVER 2487
REMOVAL 2487
REMOVAL0 – 34 BR/BE (Continued) 2487
INSTALLATION 2487
INSTALLATION 2488
ADJUSTMENTS 2488
ADJUSTMENT – SHIFT LEVER 2488
TRANSFER CASE – NV241LD 2490
TRANSFER CASE – NV241LD 2490
DESCRIPTION 2490
DESCRIPTION 2490
IDENTIFICATION 2490
OPERATION 2490
OPERATION 2490
OPERATING RANGES 2490
SHIFT MECHANISM 2491
SHIFTING 2491
DIAGNOSIS AND TESTING 2491
DIAGNOSIS AND TESTING – TRANSFER CASE 2491
REMOVAL 2492
REMOVAL 2493
DISASSEMBLY 2493
DISASSEMBLY 2493
REAR EXTENSION, RETAINER, AND REAR CASE 2493
COMPANION FLANGE AND SHIFT LEVER 2494
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2494
SHIFT FORKS AND MAINSHAFT 2496
MAINSHAFT 2498
INPUT AND PLANETARY GEAR 2500
INPUT AND PLANETARY GEAR 2501
CLEANING 2501
CLEANING 2501
INSPECTION 2501
INSPECTION 2502
MAINSHAFT/SPROCKET/HUB 2502
INPUT GEAR AND PLANETARY CARRIER 2502
SHIFT FORKS/HUBS/SLEEVES 2503
REAR RETAINER COMPONENTS 2504
DRIVE CHAIN 2504
LOW RANGE ANNULUS GEAR 2504
FRONT-REAR CASES AND FRONT RETAINER 2504
OIL PUMP/OIL PICKUP 2504
ASSEMBLY 2504
ASSEMBLY 2504
BEARINGS AND SEALS 2504
INPUT AND PLANETARY GEAR 2507
SHIFT FORKS AND MAINSHAFT 2508
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2513
OIL PUMP AND REAR CASE 2514
COMPANION FLANGE 2516
REAR RETAINER AND EXTENSION 2516
INSTALLATION 2517
INSTALLATION 2517
SPECIFICATIONS 2518
TRANSFER CASE 2518
SPECIAL TOOLS 2519
TRANSFER CASE – NV241LD 2519
EXTENSION HOUSING BUSHING AND SEAL 2520
REMOVAL 2520
REMOVAL 2520
INSTALLATION 2520
INSTALLATION 2520
FLUID 2520
STANDARD PROCEDURE 2520
STANDARD PROCEDURE – FLUID DRAIN AND REFILL 2520
FRONT OUTPUT SHAFT SEAL 2521
REMOVAL 2521
REMOVAL 2521
INSTALLATION 2521
INSTALLATION 2521
SHIFT LEVER 2522
REMOVAL 2522
REMOVAL 2522
INSTALLATION 2523
INSTALLATION 2523
ADJUSTMENTS 2523
ADJUSTMENT – SHIFT LEVER 2523
TRANSFER CASE – NV241HD 2525
TRANSFER CASE – NV241HD 2525
DESCRIPTION 2525
DESCRIPTION 2525
PTO CAPABILITY 2527
IDENTIFICATION 2527
OPERATION 2527
OPERATION 2527
OPERATING RANGES 2527
SHIFT MECHANISM 2527
SHIFTING 2527
DIAGNOSIS AND TESTING 2527
DIAGNOSIS AND TESTING – TRANSFER CASE 2527
REMOVAL 2529
REMOVAL 2529
DISASSEMBLY 2529
DISASSEMBLY 2529
EXTENSION HOUSING 2529
COMPANION FLANGE AND SHIFT LEVER 2529
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2530
SHIFT FORK AND MAINSHAFT 2531
MAINSHAFT 2534
INPUT AND PLANETARY GEAR 2535
INPUT AND PLANETARY GEAR 2535
CLEANING 2537
CLEANING 2537
INSPECTION 2537
INSPECTION 2537
ASSEMBLY 2539
ASSEMBLY 2539
BEARINGS AND SEALS 2539
INPUT AND PLANETARY GEAR 2543
INPUT AND PLANETARY GEAR 2544
MAINSHAFT 2545
SHIFT FORKS AND MAINSHAFT 2547
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2550
OIL PUMP AND REAR CASE 2551
COMPANION FLANGE 2553
EXTENSION HOUSING AND PTO COVER 2553
INSTALLATION 2554
INSTALLATION 2554
SPECIFICATIONS 2554
TRANSFER CASE 2554
SPECIAL TOOLS 2555
TRANSFER CASE – NV241HD 2555
EXTENSION HOUSING BUSHING AND SEAL 2556
REMOVAL 2556
REMOVAL 2556
INSTALLATION 2556
INSTALLATION 2556
FLUID 2557
STANDARD PROCEDURE 2557
STANDARD PROCEDURE – FLUID DRAIN AND REFILL 2557
FRONT OUTPUT SHAFT SEAL 2557
REMOVAL 2557
REMOVAL 2557
INSTALLATION 2557
INSTALLATION 2557
SHIFT LEVER 2559
REMOVAL 2559
REMOVAL 2559
INSTALLATION 2559
INSTALLATION 2559
ADJUSTMENTS 2559
ADJUSTMENT – SHIFT LEVER 2560
22-TIRES/WHEELS 2562
TIRES/WHEELS 2562
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT 2562
METHOD 1 (RELOCATE WHEEL ON HUB) 2562
METHOD 2 (RELOCATE TIRE ON WHEEL) 2563
STANDARD PROCEDURES – TIRE ROTATION 2563
STANDARD PROCEDURES – MATCH MOUNTING 2563
STANDARD PROCEDURES – TIRE AND WHEEL BALANCE 2565
TIRES 2566
DESCRIPTION 2566
DESCRIPTION 2566
TIRE IDENTIFICATION 2566
TIRE CHAINS 2566
DESCRIPTION 2567
DESCRIPTION 2567
DESCRIPTION 2567
DESCRIPTION 2567
DIAGNOSIS AND TESTING – PRESSURE GAUGES 2568
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS 2568
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS 2568
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATION 2569
STANDARD PROCEDURES – REPAIRING LEAKS 2569
SPECIFICATIONS 2570
TIRE REVOLUTIONS PER MILE 2570
SPARE TIRE 2570
DESCRIPTION 2570
WHEELS 2570
DESCRIPTION 2570
OPERATION 2571
DIAGNOSIS AND TESTING – WHEEL INSPECTION 2571
STARDARD PROCEDURE – DUAL REAR WHEEL INSTALLATION 2571
SPECIFICATIONS 2572
TORQUE CHART 2572
STUDS 2573
REMOVAL 2573
INSTALLATION 2573
WHEEL COVER 2573
REMOVAL 2573
INSTALLATION – REAR 2573
INSTALLATION – FRONT 2573
23-BODY 2574
BODY 2574
DESCRIPTION 2574
DESCRIPTION – PUSH-IN FASTENERS 2574
DESCRIPTION – LOCK CYLINDERS 2574
WARNING 2574
SAFETY PRECAUTIONS AND WARNINGS 2574
DIAGNOSIS AND TESTING 2574
DIAGNOSIS AND TESTING – WATER LEAKS 2575
VISUAL INSPECTION BEFORE WATER LEAK TESTS 2575
WATER LEAK TESTS 2575
WATER LEAK DETECTION 2575
DIAGNOSIS AND TESTING – WIND NOISE 2576
VISUAL INSPECTION BEFORE TESTS 2576
SPECIFICATIONS 2577
WELD LOCATIONS 2577
STRUCTURAL ADHESIVE LOCATIONS 2617
BODY SEALER LOCATIONS 2620
BODY GAP AND FLUSH MEASUREMENTS 2629
REGULAR CAB 2629
CLUB CAB 2630
QUAD CAB 2631
CARGO BOX 2632
BODY OPENING DIMENSIONS 2633
TORQUE SPECIFICATIONS 2634
BODY COMPONENTS 2634
DECKLID/HATCH/LIFTGATE/TAILGATE 2635
APPLIQUE 2635
REMOVAL 2635
REMOVAL 2635
INSTALLATION 2635
INSTALLATION 2635
CHECK CABLE 2635
REMOVAL 2635
REMOVAL 2635
INSTALLATION 2635
INSTALLATION 2636
DECALS 2636
REMOVAL 2636
REMOVAL 2636
INSTALLATION 2636
INSTALLATION 2636
HANDLE ESCUTCHEON 2636
REMOVAL 2636
REMOVAL 2636
INSTALLATION 2636
INSTALLATION 2636
LATCH 2637
REMOVAL 2637
REMOVAL 2637
INSTALLATION 2637
INSTALLATION 2637
LATCH HANDLE 2638
REMOVAL 2638
REMOVAL 2638
INSTALLATION 2638
INSTALLATION 2638
LATCH STRIKER 2638
REMOVAL 2638
REMOVAL 2638
INSTALLATION 2638
INSTALLATION 2638
SLAM BUMPER 2639
REMOVAL 2639
REMOVAL 2639
INSTALLATION 2639
INSTALLATION 2639
TAILGATE 2639
REMOVAL 2639
REMOVAL 2639
INSTALLATION 2639
INSTALLATION 2639
DOOR – FRONT 2640
APPLIQUE 2640
REMOVAL 2640
REMOVAL 2640
INSTALLATION 2640
INSTALLATION 2640
DOOR 2641
REMOVAL 2641
REMOVAL 2641
INSTALLATION 2641
INSTALLATION 2641
ADJUSTMENTS 2641
ADJUSTMENT – FRONT DOOR FORE/AFT 2641
ADJUSTMENT – FRONT DOOR UP/DOWN 2642
ADJUSTMENT – FRONT DOOR IN/OUT 2642
DOOR GLASS 2642
REMOVAL 2642
REMOVAL 2642
INSTALLATION 2642
INSTALLATION 2642
EXTERIOR HANDLE 2643
REMOVAL 2643
REMOVAL 2643
INSTALLATION 2643
INSTALLATION 2643
GLASS RUN CHANNEL 2643
REMOVAL 2643
REMOVAL 2643
INSTALLATION 2643
INSTALLATION 2643
HINGE 2643
REMOVAL 2643
REMOVAL 2643
INSTALLATION 2644
INSTALLATION 2644
INSIDE HANDLE ACTUATOR 2644
REMOVAL 2644
REMOVAL 2644
INSTALLATION 2644
INSTALLATION 2644
LATCH 2645
REMOVAL 2645
REMOVAL 2645
INSTALLATION 2645
INSTALLATION 2645
ADJUSTMENTS 2645
ADJUSTMENT – FRONT DOOR LATCH 2645
LATCH STRIKER 2646
REMOVAL 2646
REMOVAL 2646
INSTALLATION 2646
INSTALLATION 2646
LOCK CYLINDER 2646
REMOVAL 2646
REMOVAL 2646
INSTALLATION 2646
INSTALLATION 2646
SIDE VIEW MIRROR FLAG 2647
REMOVAL 2647
REMOVAL 2647
INSTALLATION 2647
INSTALLATION 2647
TRIM PANEL 2647
REMOVAL 2647
REMOVAL 2647
INSTALLATION 2647
INSTALLATION 2647
WATERDAM 2648
REMOVAL 2648
REMOVAL 2648
INSTALLATION 2648
INSTALLATION 2648
WINDOW REGULATOR 2648
REMOVAL 2648
REMOVAL 2648
INSTALLATION 2649
INSTALLATION 2649
DOOR – CARGO 2650
AIR EXHAUSTER 2650
REMOVAL 2650
REMOVAL 2650
INSTALLATION 2650
INSTALLATION 2650
CHECK 2651
REMOVAL 2651
REMOVAL 2651
INSTALLATION 2651
INSTALLATION0 – 36 BR/BE (Continued) 2651
DOOR 2651
REMOVAL 2651
REMOVAL 2651
INSTALLATION 2651
INSTALLATION 2651
ADJUSTMENTS 2651
ADJUSTMENT – CARGO DOOR 2651
CARGO DOOR FORE/AFT AND UP/DOWN 2651
CARGO DOOR IN/OUT 2652
EXHAUST VENT 2652
REMOVAL 2652
REMOVAL 2652
INSTALLATION 2652
INSTALLATION 2652
HINGE 2652
REMOVAL 2652
REMOVAL 2652
INSTALLATION 2652
INSTALLATION 2652
INSIDE HANDLE ACTUATOR 2653
REMOVAL 2653
REMOVAL 2653
INSTALLATION 2653
INSTALLATION 2653
LATCH – LOWER 2653
REMOVAL 2653
REMOVAL 2653
INSTALLATION 2653
INSTALLATION 2653
LATCH – UPPER 2654
REMOVAL 2654
REMOVAL 2654
INSTALLATION 2654
INSTALLATION 2654
LATCH STRIKER – LOWER 2655
REMOVAL 2655
REMOVAL 2655
INSTALLATION 2655
INSTALLATION 2655
LATCH STRIKER – UPPER 2655
REMOVAL 2655
REMOVAL 2655
INSTALLATION 2655
INSTALLATION 2655
RELEASE CABLE 2655
REMOVAL 2655
REMOVAL 2655
INSTALLATION 2655
INSTALLATION 2656
SHUTFACE HANDLE 2656
REMOVAL 2656
REMOVAL 2656
INSTALLATION 2656
INSTALLATION 2656
TRIM PANEL 2657
REMOVAL 2657
REMOVAL 2657
INSTALLATIONCARGO DOOR TRIM PANEL 2657
INSTALLATION 2657
VENT WINDOW 2658
REMOVAL 2658
REMOVAL 2658
INSTALLATION 2658
INSTALLATION 2658
WATERDAM 2658
REMOVAL 2658
REMOVAL 2658
INSTALLATION 2658
INSTALLATION 2658
EXTERIOR 2659
EXTERIOR 2659
DESCRIPTION 2659
DESCRIPTION 2659
OPERATION 2659
OPERATION 2659
BODY SIDE MOLDINGS 2660
REMOVAL 2660
REMOVAL 2660
INSTALLATION 2660
INSTALLATION 2660
BODY STRIPES AND DECALS 2660
REMOVAL 2660
REMOVAL 2660
INSTALLATION 2660
INSTALLATION 2660
TAPE STRIPE 2661
REMOVAL 2661
REMOVAL 2661
INSTALLATION 2661
INSTALLATION 2661
EXTERIOR NAME PLATES 2662
REMOVAL 2662
REMOVAL 2662
INSTALLATION 2662
INSTALLATION 2662
COWL GRILLE 2663
REMOVAL 2663
REMOVAL 2663
INSTALLATION 2663
INSTALLATION 2663
ROOF JOINT MOLDING 2664
REMOVAL 2664
REMOVAL 2664
INSTALLATION 2664
INSTALLATION 2664
GRILLE 2664
REMOVAL 2664
REMOVAL 2664
INSTALLATION 2664
INSTALLATION 2664
GRILLE FRAME 2664
REMOVAL 2664
REMOVAL 2664
INSTALLATION 2665
INSTALLATION 2665
FRONT END SPLASH SHIELDS 2665
REMOVAL 2665
REMOVAL 2665
INSTALLATION 2665
INSTALLATION 2665
LEFT FRONT FENDER 2665
REMOVAL 2665
REMOVAL 2665
INSTALLATION 2666
INSTALLATION 2666
RIGHT FRONT FENDER 2667
REMOVAL 2667
REMOVAL 2667
INSTALLATION 2667
INSTALLATION 2667
FUEL FILL DOOR 2668
REMOVAL 2668
REMOVAL 2668
INSTALLATION 2668
INSTALLATION 2668
REAR FENDER 2668
REMOVAL 2668
REMOVAL 2668
INSTALLATION 2668
INSTALLATION 2668
REAR SPLASH SHIELD 2669
REMOVAL 2669
REMOVAL 2669
INSTALLATION 2669
INSTALLATION 2669
REAR WHEELHOUSE LINER 2669
REMOVAL 2669
REMOVAL 2669
INSTALLATION 2669
INSTALLATION 2669
CARGO BOX 2669
REMOVAL 2669
REMOVAL 2669
INSTALLATION 2670
INSTALLATION 2670
SIDE VIEW MIRROR 2670
REMOVAL 2670
REMOVAL 2670
INSTALLATION 2670
INSTALLATION 2670
SIDE VIEW MIRROR – LOW MOUNTED 2671
REMOVAL 2671
REMOVAL 2671
INSTALLATION 2671
INSTALLATION 2671
SIDE VIEW MIRROR GLASS 2671
REMOVAL 2671
REMOVAL 2671
INSTALLATION 2671
INSTALLATION 2671
HOOD 2672
HINGE 2672
REMOVAL 2672
REMOVAL 2672
INSTALLATION 2672
INSTALLATION 2672
HOOD 2673
REMOVAL 2673
REMOVAL 2673
INSTALLATION 2673
INSTALLATION 2673
ADJUSTMENTS 2673
ADJUSTMENT 2673
LATCH 2673
REMOVAL 2673
REMOVAL 2673
INSTALLATION 2673
INSTALLATION 2673
ADJUSTMENTS 2673
ADJUSTMENT 2673
LATCH RELEASE CABLE 2674
REMOVAL 2674
REMOVAL 2674
INSTALLATION 2674
INSTALLATION 2674
LATCH STRIKER 2675
REMOVAL 2675
REMOVAL 2675
INSTALLATION 2675
INSTALLATION 2675
ADJUSTMENTS 2675
ADJUSTMENT 2675
SAFETY LATCH 2675
REMOVAL 2675
REMOVAL 2675
INSTALLATION 2675
INSTALLATION 2675
SILENCER PAD 2676
REMOVAL 2676
REMOVAL 2676
INSTALLATION 2676
INSTALLATION 2676
INSTRUMENT PANEL SYSTEM 2677
INSTRUMENT PANEL SYSTEM 2677
DESCRIPTION 2677
DESCRIPTION 2677
OPERATION 2678
OPERATION 2678
REMOVAL 2678
REMOVAL 2679
INSTALLATION 2679
INSTALLATION 2680
ASH RECEIVER 2681
REMOVAL 2681
REMOVAL 2681
INSTALLATION 2681
INSTALLATION 2682
CLUSTER BEZEL 2682
REMOVAL 2682
REMOVAL 2682
INSTALLATION 2683
INSTALLATION 2683
CUBBY BIN 2683
REMOVAL 2683
REMOVAL 2683
INSTALLATION 2683
INSTALLATION 2683
CUP HOLDER 2683
REMOVAL 2683
REMOVAL 2683
INSTALLATION 2684
INSTALLATION 2684
GLOVE BOX 2685
REMOVAL 2685
REMOVAL 2685
DISASSEMBLY – GLOVE BOX 2685
ASSEMBLY 2685
ASSEMBLY – GLOVE BOX 2685
INSTALLATION 2686
INSTALLATION 2686
GLOVE BOX LATCH STRIKER 2686
REMOVAL 2686
REMOVAL 2686
INSTALLATION 2686
INSTALLATION 2686
GLOVE BOX OPENING UPPER TRIM 2687
REMOVAL 2687
REMOVAL 2687
INSTALLATION 2687
INSTALLATION 2687
INSTRUMENT PANEL TOP COVER 2687
REMOVAL 2687
REMOVAL 2687
INSTALLATION 2688
INSTALLATION 2688
STEERING COLUMN OPENING COVER 2688
REMOVAL 2688
REMOVAL 2688
INSTALLATION 2689
INSTALLATION 2689
STORAGE BIN 2689
REMOVAL 2689
REMOVAL 2689
INSTALLATION 2689
INSTALLATION 2689
INTERIOR 2691
INTERIOR 2691
DESCRIPTION 2691
CAUTION 2691
A-PILLAR GRAB HANDLE 2692
REMOVAL 2692
REMOVAL 2692
INSTALLATION 2692
INSTALLATION 2692
A-PILLAR TRIM 2692
REMOVAL 2692
REMOVAL 2692
INSTALLATION 2692
INSTALLATION 2692
COWL TRIM COVER 2692
REMOVAL 2692
REMOVAL 2692
INSTALLATION 2692
INSTALLATION 2693
B-PILLAR TRIM 2693
REMOVAL 2693
REMOVAL 2693
INSTALLATION 2693
INSTALLATION 2693
REAR CLOSURE PANEL TRIM 2693
REMOVAL 2693
REMOVAL 2693
INSTALLATION 2693
INSTALLATION 2694
REAR FLOOR STOWAGE TRAY 2694
REMOVAL 2694
REMOVAL 2694
INSTALLATION 2694
INSTALLATION 2694
DOOR SILL TRIM 2694
REMOVAL 2694
REMOVAL 2694
INSTALLATION 2694
INSTALLATION 2694
SHIFT BOOT – MANUAL TRANSMISSION 2695
REMOVAL 2695
REMOVAL 2695
INSTALLATION 2695
INSTALLATION 2695
4WD FLOOR SHIFT BOOT 2695
REMOVAL 2695
REMOVAL 2695
INSTALLATION 2695
INSTALLATION 2695
CENTER CONSOLE 2695
REMOVAL 2695
REMOVAL 2695
INSTALLATION 2695
INSTALLATION 2695
CARPETS AND FLOOR MATS 2696
REMOVAL 2696
REMOVAL 2696
STANDARD CAB 2696
QUAD/CLUB CABS 2696
INSTALLATION 2696
INSTALLATION 2696
STANDARD CAB 2696
QUAD/CLUB CABS 2697
ASSIST HANDLE0 – 38 BR/BE (Continued) 2697
REMOVAL 2697
REMOVAL 2697
INSTALLATION 2697
INSTALLATION 2697
COAT HOOK 2697
REMOVAL 2697
REMOVAL 2697
INSTALLATION 2697
INSTALLATION 2698
HEADLINER 2698
REMOVAL 2698
REMOVAL 2698
INSTALLATION 2698
INSTALLATION 2698
BODY VENT 2699
REMOVAL 2699
REMOVAL 2699
INSTALLATION 2699
INSTALLATION 2699
REAR VIEW MIRROR 2699
REMOVAL 2699
REMOVAL 2699
INSTALLATION 2699
INSTALLATION 2699
INSTALLATION – REARVIEW MIRROR SUPPORT BRACKET 2699
SUN VISOR 2700
REMOVAL 2700
REMOVAL 2700
INSTALLATION 2700
INSTALLATION 2700
QUARTER TRIM PANEL 2700
REMOVAL 2700
REMOVAL 2700
INSTALLATION 2700
INSTALLATION 2701
C-PILLAR TRIM 2701
REMOVAL 2701
REMOVAL 2701
INSTALLATION 2701
INSTALLATION 2701
PAINT 2702
PAINT 2702
SPECIFICATIONS 2702
2001 BR PAINT COLOR CODES 2702
BASE COAT/CLEAR COAT FINISH 2702
DESCRIPTION 2702
DESCRIPTION 2702
OPERATION 2702
OPERATION 2702
PAINT CODE 2702
DESCRIPTION 2702
DESCRIPTION 2702
PAINT TOUCH-UP 2702
DESCRIPTION 2702
DESCRIPTION 2702
OPERATION 2703
WET SANDING/BUFFING & POLISHING 2703
DESCRIPTION 2703
DESCRIPTION 2703
SEATS 2704
SEATS 2704
DESCRIPTION 2704
DESCRIPTION 2704
OPERATION 2704
OPERATION 2704
CENTER CONSOLE LID 2704
REMOVAL 2704
REMOVAL 2704
INSTALLATION 2704
INSTALLATION 2705
CENTER SEAT ARMREST/CONSOLE 2705
REMOVAL 2705
REMOVAL 2705
INSTALLATION 2705
INSTALLATION 2705
CENTER SEAT ARMREST/LATCH COVER 2705
REMOVAL 2705
REMOVAL 2705
INSTALLATION 2705
INSTALLATION 2705
LUMBAR SUPPORT 2706
REMOVAL 2706
REMOVAL 2706
INSTALLATION 2706
INSTALLATION 2706
SEAT – BENCH SEAT 2706
REMOVAL 2706
REMOVAL 2706
INSTALLATION 2706
INSTALLATION 2706
SEAT – SPLIT BENCH 2707
REMOVAL 2707
REMOVAL 2707
STANDARD CAB 2707
QUAD CAB 2707
INSTALLATION 2707
INSTALLATION 2707
STANDARD CAB 2707
QUAD CAB 2707
SEAT BACK – BENCH SEAT 2708
REMOVAL 2708
REMOVAL 2708
INSTALLATION 2708
INSTALLATION 2708
SEAT BACK – SPLIT BENCH 2708
REMOVAL 2708
REMOVAL 2708
STANDARD CAB 2708
QUAD CAB 2708
INSTALLATION 2709
INSTALLATION 2709
STANDARD CAB 2709
QUAD CAB 2710
SEAT BACK COVER 2710
REMOVAL 2710
REMOVAL 2710
INSTALLATION 2710
INSTALLATION 2710
SEAT BACK COVER – SPLIT BENCH 2710
REMOVAL 2710
REMOVAL 2710
INSTALLATION 2711
INSTALLATION 2711
SEAT BACK RECLINER 2711
REMOVAL 2711
REMOVAL 2711
INSTALLATION 2711
INSTALLATION 2711
SEAT CUSHION 2711
REMOVAL 2711
REMOVAL 2711
INSTALLATION 2711
INSTALLATION 2711
SEAT CUSHION COVER 2712
REMOVAL 2712
REMOVAL 2712
INSTALLATION 2712
INSTALLATION 2712
SEAT CUSHION COVER – SPLIT BENCH 2712
REMOVAL 2712
REMOVAL 2712
STANDARD CAB 2712
QUAD CAB 2713
INSTALLATION 2713
INSTALLATION 2713
STANDARD CAB 2713
QUAD CAB 2714
SEAT RISER 2714
REMOVAL 2714
REMOVAL 2714
INSTALLATION 2714
INSTALLATION 2714
SEAT TRACK 2714
REMOVAL 2714
REMOVAL 2714
INSTALLATION 2714
INSTALLATION 2714
SEAT TRACK – SPLIT BENCH 2715
REMOVAL 2715
REMOVAL 2715
INSTALLATION 2715
INSTALLATION 2715
EASY ENTRY SEAT TRACK 2715
REMOVAL 2715
REMOVAL 2715
INSTALLATION 2715
INSTALLATION 2715
SEAT TRACK ADJUSTER 2716
REMOVAL 2716
REMOVAL 2716
INSTALLATION 2716
INSTALLATION 2716
STANCHION COVER 2716
REMOVAL 2716
REMOVAL 2716
INSTALLATION 2716
INSTALLATION 2716
REAR SEAT 2717
REMOVAL 2717
REMOVAL 2717
INSTALLATION 2717
INSTALLATION 2717
STATIONARY GLASS 2718
STATIONARY GLASS 2718
DESCRIPTION 2718
DESCRIPTION 2718
OPERATION 2718
OPERATION 2718
BACKLITE 2718
REMOVAL 2718
REMOVAL 2718
INSTALLATION 2718
INSTALLATION 2718
BACKLITE LATCH AND KEEPER 2719
REMOVAL 2719
REMOVAL 2719
INSTALLATION 2719
INSTALLATION 2719
BACKLITE VENT GLASS 2720
REMOVAL 2720
REMOVAL 2720
INSTALLATION 2720
INSTALLATION 2720
WINDSHIELD 2721
DESCRIPTION 2721
DESCRIPTION 2721
OPERATION 2721
REMOVAL 2721
REMOVAL 2721
INSTALLATION 2721
INSTALLATION 2721
QUARTER WINDOW 2724
REMOVAL 2724
REMOVAL 2724
INSTALLATION 2724
INSTALLATION 2724
WEATHERSTRIP/SEALS 2725
B-PILLAR DOOR SEAL 2725
REMOVAL 2725
REMOVAL 2725
INSTALLATION 2725
INSTALLATION 2725
COWL WEATHERSTRIP 2726
REMOVAL 2726
REMOVAL 2726
INSTALLATION 2726
INSTALLATION 2726
DOOR OPENING SEAL 2726
REMOVAL 2726
REMOVAL 2726
INSTALLATION 2726
INSTALLATION 2726
FRONT DOOR GLASS RUN WEATHERSTRIP 2726
REMOVAL 2726
REMOVAL 2726
INSTALLATION 2726
INSTALLATION 2727
FRONT DOOR INNER BELT WEATHERSTRIP 2727
REMOVAL 2727
REMOVAL 2727
INSTALLATION 2727
INSTALLATION 2727
FRONT DOOR OUTER BELT WEATHERSTRIP 2727
REMOVAL 2727
REMOVAL 2727
INSTALLATION 2727
INSTALLATION 2727
FRONT DOOR UPPER CORNER SEAL 2727
REMOVAL 2727
REMOVAL 2727
INSTALLATION 2727
INSTALLATION 2727
FRONT DOOR SECOND WEATHERSTRIP 2727
REMOVAL 2727
REMOVAL 2727
INSTALLATION 2728
INSTALLATION 2728
24-HEATING & AIR CONDITIONING 2730
HEATING & AIR CONDITIONING 2730
HEATING & AIR CONDITIONING 2730
DESCRIPTION – HEATER AND AIR CONDITIONER 2730
DESCRIPTION – COOLING SYSTEM REQUIREMENTS 2730
DESCRIPTION – REFRIGERANT SYSTEM SERVICE PORT 2730
OPERATION – HEATER AND AIR CONDITIONER 2730
OPERATION – REFRIGERANT SYSTEM SERVICE PORT 2731
DIAGNOSIS AND TESTING – A/C PERFORMANCE 2731
DIAGNOSIS AND TESTING – HEATER PERFORMANCE 2735
MAXIMUM HEATER OUTPUT 2735
TEMPERATURE CONTROL 2735
STANDARD PROCEDURE – DIODE REPLACEMENT 2736
SPECIFICATIONS 2737
A/C APPLICATION TABLE 2737
TORQUE SPECIFICATIONS 2737
CONTROLS 2738
CONTROLS 2739
DIAGNOSIS AND TESTING – VACUUM SYSTEM 2739
VACUUM CHECK VALVE 2739
A/C HEATER CONTROLS 2739
LOCATING VACUUM LEAKS 2740
A/C COMPRESSOR CLUTCH 2742
DESCRIPTION 2742
OPERATION 2742
DIAGNOSIS AND TESTING – A/C COMPRESSOR CLUTCH COIL 2742
STANDARD PROCEDURE – A/C COMPRESSOR CLUTCH BREAK-IN 2742
REMOVAL 2743
INSPECTION 2745
INSTALLATION 2745
A/C COMPRESSOR CLUTCH RELAY 2746
DESCRIPTION 2746
OPERATION 2746
DIAGNOSIS AND TESTING – A/C COMPRESSOR CLUTCH RELAY 2746
RELAY TEST 2746
RELAY CIRCUIT TEST 2746
REMOVAL 2747
INSTALLATION 2747
A/C HEATER CONTROL 2747
DESCRIPTION 2747
OPERATION 2747
DIAGNOSIS AND TESTING – A/C HEATER CONTROL 2748
REMOVAL 2748
INSTALLATION 2749
A/C HIGH PRESSURE SWITCH 2749
DESCRIPTION 2749
OPERATION 2749
DIAGNOSIS AND TESTING – A/C HIGH PRESSURE SWITCH 2749
REMOVAL 2750
INSTALLATION 2750
A/C LOW PRESSURE SWITCH 2750
DESCRIPTION 2750
OPERATION 2750
DIAGNOSIS AND TESTING – A/C LOW PRESSURE SWITCH 2750
REMOVAL 2750
INSTALLATION 2751
BLOWER MOTOR RELAY 2751
DESCRIPTION 2751
OPERATION 2751
DIAGNOSIS AND TESTING – BLOWER MOTOR RELAY 2751
RELAY TEST 2751
RELAY CIRCUIT TEST 2751
REMOVAL 2752
INSTALLATION 2752
BLOWER MOTOR RESISTOR BLOCK 2752
DESCRIPTION 2752
OPERATION 2752
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR BLOCK 2753
REMOVAL 2753
INSTALLATION 2753
BLOWER MOTOR SWITCH 2753
DESCRIPTION 2753
OPERATION 2754
DIAGNOSIS AND TESTING – BLOWER MOTOR SWITCH 2754
REMOVAL 2754
BLEND DOOR ACTUATOR 2754
REMOVAL 2754
INSTALLATION 2755
MODE DOOR ACTUATOR 2755
REMOVAL – HEAT/DEFROST DOOR ACTUATOR 2755
REMOVAL – PANEL/DEFROST DOOR ACTUATOR 2756
INSTALLATION – HEAT/DEFROST DOOR ACTUATOR 2756
INSTALLATION – PANEL/DEFROST DOOR ACTUATOR0 – 40 BR/BE (Continued) 2756
RECIRCULATION DOOR ACTUATOR 2756
REMOVAL 2756
INSTALLATION 2757
VACUUM CHECK VALVE 2757
DESCRIPTION 2757
OPERATION 2757
REMOVAL 2758
INSTALLATION 2758
VACUUM RESERVOIR 2758
DESCRIPTION 2758
OPERATION 2758
REMOVAL 2759
INSTALLATION 2759
DISTRIBUTION 2760
DISTRIBUTION 2760
DESCRIPTION – HVAC SYSTEM AIRFLOW 2760
AIR OUTLETS 2760
REMOVAL – DEMISTER GRILLES 2760
REMOVAL – PANEL OUTLET BARRELS 2761
INSTALLATION – DEMISTER GRILLES 2761
INSTALLATION – PANEL OUTLET BARRELS 2761
BLOWER MOTOR 2761
DESCRIPTION 2761
OPERATION 2761
DIAGNOSIS AND TESTING – BLOWER MOTOR 2762
VIBRATION 2762
NOISE 2762
REMOVAL 2762
INSTALLATION 2762
DEFROSTER DUCTS 2763
REMOVAL – DEFROSTER AND DEMISTER DUCTS 2763
REMOVAL – DEFROSTER AND DEMISTER DUCT ADAPTER 2764
INSTALLATION – DEFROSTER AND DEMISTER DUCTS 2764
INSTALLATION – DEFROSTER AND DEMISTER DUCT ADAPTER 2764
HVAC HOUSING 2764
REMOVAL 2764
REMOVAL – HVAC HOUSING INLET BAFFLE 2765
DISASSEMBLY 2765
ASSEMBLY 2765
INSTALLATION 2766
INSTALLATION – HVAC HOUSING INLET BAFFLE 2766
INSTRUMENT PANEL DEMISTER DUCTS 2766
REMOVAL 2766
INSTRUMENT PANEL DUCTS 2766
REMOVAL 2766
BLEND DOOR 2767
REMOVAL 2767
INSTALLATION 2767
MODE DOOR 2767
REMOVAL – HEAT/DEFROST DOOR 2767
REMOVAL – PANEL/DEFROST DOOR 2767
INSTALLATION – HEAT/DEFROST DOOR 2768
INSTALLATION – PANEL/DEFROST DOOR 2768
RECIRCULATION DOOR 2768
REMOVAL 2768
INSTALLATION 2768
PLUMBING 2769
PLUMBING 2769
DESCRIPTION – A/C LINE COUPLERS 2769
DESCRIPTION 2769
OPERATION – A/C LINE COUPLERS 2770
OPERATION 2770
CAUTION – REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS 2771
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM LEAKS 2772
SYSTEM EMPTY 2772
SYSTEM LOW 2772
STANDARD PROCEDURE – A/C LINE COUPLERS 2772
REMOVAL 2772
INSTALLATION 2773
STANDARD PROCEDURE – REFRIGERANT SYSTEM SERVICE EQUIPMENT 2773
MANIFOLD GAUGE SET CONNECTIONS 2773
STANDARD PROCEDURE – REFRIGERANT RECOVERY 2774
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATE 2774
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGE 2775
SPECIFICATIONS 2775
SPECIFICATIONS 2775
A/C COMPRESSOR 2775
DESCRIPTION – A/C COMPRESSOR 2775
DESCRIPTION – HIGH PRESSURE RELIEF VALVE 2775
OPERATION – A/C COMPRESSOR 2775
OPERATION – HIGH PRESSURE RELIEF VALVE 2775
DIAGNOSIS AND TESTING – A/C COMPRESSOR 2775
REMOVAL 2776
INSTALLATION 2776
A/C CONDENSER 2777
DESCRIPTION 2777
OPERATION 2777
REMOVAL 2778
INSTALLATION 2778
SUCTION AND DISCHARGE LINE 2779
REMOVAL 2779
INSTALLATION 2780
LIQUID LINE 2781
REMOVAL 2781
INSTALLATION 2781
A/C EVAPORATOR 2781
DESCRIPTION 2781
OPERATION 2782
REMOVAL 2782
INSTALLATION 2782
A/C ORIFICE TUBE 2782
DESCRIPTION 2782
OPERATION 2782
DIAGNOSIS AND TESTING – FIXED ORIFICE TUBE 2783
REMOVAL 2783
ACCUMULATOR 2783
DESCRIPTION 2783
OPERATION 2783
REMOVAL 2783
INSTALLATION 2784
HEATER CORE 2784
DESCRIPTION 2784
OPERATION 2784
REMOVAL 2785
INSTALLATION 2785
REFRIGERANT 2785
DESCRIPTION 2785
OPERATION 2785
REFRIGERANT OIL 2785
DESCRIPTION 2785
OPERATION 2785
STANDARD PROCEDURE – REFRIGERANT OIL LEVEL 2786
25-EMISSIONS CONTROL 2788
EMISSIONS CONTROL 2788
DESCRIPTION 2788
DESCRIPTION – DIESEL 2788
DESCRIPTION – STATE DISPLAY TEST MODE 2788
DESCRIPTION – CIRCUIT ACTUATION TEST MODE 2788
DESCRIPTION – DIAGNOSTIC TROUBLE CODES 2789
DESCRIPTION – TASK MANAGER 2802
DESCRIPTION – MONITORED SYSTEMS 2802
OXYGEN SENSOR (O2S) MONITOR 2802
OXYGEN SENSOR HEATER MONITOR 2803
LEAK DETECTION PUMP MONITOR (IF EQUIPPED) 2803
MISFIRE MONITOR 2804
FUEL SYSTEM MONITOR 2804
CATALYST MONITOR 2804
DESCRIPTION – TRIP DEFINITION 2805
DESCRIPTION – COMPONENT MONITORS – GAS ENGINES 2805
DESCRIPTION – COMPONENT MONITORS – DIESEL ENGINES 2805
OPERATION 2805
OPERATION – GAS ENGINES 2805
OPERATION – DIESEL 2806
OPERATION – TASK MANAGER 2806
Test Sequence 2807
MIL Illumination 2807
Diagnostic Trouble Codes (DTCs) 2807
DTC Self Erasure 2808
Trip Indicator 2808
Freeze Frame Data Storage 2808
Similar Conditions Window 2809
OPERATION – NON-MONITORED CIRCUITS – GAS ENGINES 2809
OPERATION – NON-MONITORED CIRCUITS – DIESEL 2810
AIR INJECTION 2812
AIR INJECTION 2812
DESCRIPTION 2812
DESCRIPTION – AIR INJECTION SYSTEM 2812
OPERATION 2814
OPERATION – AIR INJECTION SYSTEM 2814
SPECIFICATIONS 2815
TORQUE – AIR INJECTION SYSTEM 2815
AIR INJECTION PUMP 2815
DESCRIPTION 2815
DESCRIPTION 2815
OPERATION 2815
OPERATION 2815
DIAGNOSIS AND TESTING 2815
DIAGNOSIS AND TESTING – AIR INJECTION PUMP 2815
REMOVAL 2816
REMOVAL 2816
INSTALLATION 2816
INSTALLATION 2816
AIR PUMP FILTER 2816
REMOVAL 2816
REMOVAL 2816
INSTALLATION 2816
INSTALLATION 2816
ONE WAY CHECK VALVE 2817
DESCRIPTION 2817
DESCRIPTION 2817
OPERATION 2817
OPERATION 2817
DIAGNOSIS AND TESTING 2817
DIAGNOSIS AND TESTING – ONE-WAY CHECK VALVE 2817
REMOVAL 2817
REMOVAL 2817
INSTALLATION 2817
INSTALLATION 2817
EVAPORATIVE EMISSIONS 2818
EVAPORATIVE EMISSIONS 2818
DESCRIPTION 2818
DESCRIPTION – EVAP SYSTEM 2818
SPECIFICATIONS 2818
TORQUE – EVAP SYSTEM 2818
CCV HOSE 2819
DESCRIPTION 2819
DESCRIPTION – 8 0L 2819
OPERATION 2819
OPERATION – 8 0L 2819
CRANKCASE VENT HOSE 2819
DESCRIPTION 2819
OPERATION 2819
EVAP/PURGE SOLENOID 2819
DESCRIPTION 2819
DESCRIPTION 2819
REMOVAL 2819
REMOVAL 2819
INSTALLATION 2819
INSTALLATION 2819
FUEL FILLER CAP 2820
DESCRIPTION 2820
DESCRIPTION 2820
OPERATION 2820
OPERATION 2820
REMOVAL 2820
REMOVAL/INSTALLATION 2820
LEAK DETECTION PUMP 2820
DESCRIPTION 2820
DESCRIPTION 2820
REMOVAL 2820
REMOVAL 2821
INSTALLATION 2821
INSTALLATION 2821
PCV FILTER 2822
DESCRIPTION 2822
DESCRIPTION 2822
PCV VALVE 2822
DESCRIPTION 2822
DESCRIPTION – V-6/V-8 ENGINES 2822
OPERATION 2822
OPERATION – V-6/V-8 ENGINES 2822
DIAGNOSIS AND TESTING 2822
DIAGNOSIS AND TESTING – PCV VALVE – V–6/V–8 ENGINES 2823
VACUUM LINES 2824
DIAGNOSIS AND TESTING 2824
DIAGNOSIS AND TESTING – VACUUM SCHEMATICS 2824
VAPOR CANISTER 2824
DESCRIPTION 2824
DESCRIPTION 2824
OPERATION 2824
OPERATION 2824
REMOVAL 2824
REMOVAL 2824
INSTALLATION 2824
INSTALLATION 2825
30-NEW VEHICLE PREPARATION 2826
INTRODUCTION 2826
DESCRIPTION 2826
DESCRIPTION – THE IMPORTANCE OF CAREFUL NEW VEHICLE PREPARATION 2826
USING THE MANUAL 2826
RECEIVING 2828
INSPECTION 2828
INSPECTION 2828
EXTERIOR 2828
INTERIOR 2828
MAJOR INSPECTION POINTS 2828
UNDER HOOD 2829
INSPECTION 2829
INSPECTION – HOOD LATCH/SAFETY CATCH 2829
INSPECTION – FLUID LEVELS 2829
ENGINE OIL 2829
AUTOMATIC TRANSMISSION 2829
CLUTCH MASTER CYLINDER 2829
BRAKE MASTER CYLINDER 2830
POWER STEERING RESERVOIR 2830
WINDSHIELD WASHER RESERVOIR 2830
COOLING SYSTEM RESERVOIR 2831
INSPECTION – LINES/HOSES 2831
INSPECTION – BATTERY 2832
INSPECTION – WIRING 2832
UNDER VEHICLE 2833
INSPECTION 2833
INSPECTION – TIRE PRESSURES 2833
INSPECTION – VISUAL 2833
INSTALLATION 2833
INSTALLATION – WHEEL COVERS 2835
EXTERIOR 2835
INSPECTION 2835
INSPECTION—BODY SEALING 2835
INSPECTION – FIT AND FINISH 2835
INSPECTION – KEYLESS ENTRY 2836
INSPECTION – DOORS AND DOOR LOCKS 2836
BODY INTERIOR 2837
INSPECTION 2837
INSPECTION – COMPASS 2837
INSPECTION – FIT AND FINISH 2837
INSPECTION – LIGHTS AND SWITCHES 2837
INSPECTION – SEAT BELTS, SHOULDER BELTS, RETRACTORS AND HEAD RESTRAINTS 2837
INSPECTION – SEATS 2838
INSPECTION – WINDOWS, DOORS AND LOCKS 2839
INSTALLATION 2839
INSTALLATION – SHIPPED LOOSE ITEMS 2839
ROAD TEST 2840
DESCRIPTION 2840
DESCRIPTION – ROAD TEST INSPECTION 2840
INSPECTION 2840
INSPECTION – FUEL 2840
INSPECTION – OTHER 2840
INSPECTION – SQUEAKS, RATTLES AND WIND NOISE 2840
INSPECTION – STEERING AND HANDLING 2840
INSPECTION – TRANSMISSION/TRANSFER CASE 2840
AUTOMATIC TRANSMISSION 2840
MANUAL TRANSMISSION 2840
4X4 TRANSFER CASE 2841
INSPECTION – ENGINE PERFORMANCE 2841
INSPECTION – PARKING BRAKE 2842
INSPECTION – SERVICE BRAKES 2842
INSPECTION – SPEED CONTROL 2842
INSPECTION – TRIP COMPUTER/MAINTENANCE REMINDER 2842
INSPECTION – RADIO 2842
INSPECTION – HEATER/AIR CONDITIONER 2842
INSPECTION WINDSHIELD WIPERS/WASHERS 2843
INSPECTION – MIRROR 2844
INSPECTION – TURN AND EMERGENCY SIGNALS 2844
INSPECTION – HORN 2844
INSPECTION – GAUGES/WARNING LIGHTS 2844
INSPECTION – SHIFT/CLUTCH INTERLOCK SYSTEM 2844
INSPECTION – NEUTRAL SAFETY SWITCH 2844
PRE DELIVERY STORAGE 2844
DESCRIPTION 2844
DESCRIPTION 2844
STANDARD PROCEDURE – PRE DELIVERY STORAGE 2845
PROGRAMMABLE ELECTRONIC FEATURES 2845
DESCRIPTION 2845
DESCRIPTION 2845
OPERATION 2845
OPERATION 2845
ROLLING POWER DOOR LOCKS 2845
HORN CHIRP 2845
HEADLAMP FLASH 2846
LOW FUEL CHIME 2846
REMOTE KEYLESS ENTRY (RKE) DOOR UNLOCK SEQUENCE 2846
HEADLIGHTS ON AUTOMATICALLY WITH WIPERS 2846
12V POWER OUTLET 2846
TURN SIGNAL CHIME 2846
REMOTE UNLOCK 2846
REMOTE LINKED TO MEMORY 2846
HEADLAMP DELAY 2846
SERVICE INTERVAL0 – 42 BR/BE (Continued) 2846
EASY EXIT SEAT 2846
APPEARANCE TIPS 2846
CLEANING 2846
CLEANING 2846
FINAL STEPS 2847
STANDARD PROCEDURE – OWNER CHECK OUT 2847
STANDARD PROCEDURE – INSPECTION – INFORMATION LABELS 2847
NEW VEHICLE PREPARATION FORM 2847
INDEX 2848
SERVICE MANUAL COMMENTS 2888

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