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VEHICLEIDENTIFICATIONNUMBER
VEHICLEIDENTIFICATIONNUMBER
DESCRIPTION
TheVehicleIdentificationNumber(VIN)plateis attachedtothetopleftsideoftheinstrumentpanel. TheVINcontains17charactersthatprovidedataconcerningthevehicle.Refertothedecodingchartto determinetheidentificationofavehicle.
Toprotecttheconsumerfromtheftandpossiblefraud themanufacturerisrequiredtoincludeaCheckDigit attheninthpositionoftheVehicleIdentificationNumber.Thecheckdigitisusedbythemanufacturerand governmentagenciestoverifytheauthenticityofthe vehicleandofficialdocumentation.Theformulatouse thecheckdigitisnotreleasedtothegeneralpublic.
VEHICLEIDENTIFICATIONNUMBERDECODINGCHART
POSITIONINTERPRETATIONCODE=DESCRIPTION
1CountryofOrigin1=ManufacturedByDaimlerChrysler Corporation
2MakeJ=Jeep
3VehicleType4=MPVLessSideAirBags
8=MPVWithSideAirBags
4GrossVehicleWeightRatingG=5001-6000lbs.
5VehicleLine(WK)S=GrandCherokee4X2 R=GrandCherokee4X4
5VehicleLine(WH)C=GrandCherokee4X4(LHD) D=GrandCherokee4X4(RHD)
6Series4=GrandCherokeeLAREDO 5=GrandCherokeeLIMITED E=5SpeedAuto
7BodyStyle8=SportUtility4Door
8EngineK=3.7K6cyl.MPIGasoline N=4.7L8cyl.MPIGasoline 2=5.7L8cyl.HEMIMultipleDisplacement Gasoline M=3.0L6cyl.TurboDiesel
9CheckDigit0through9orX
10ModelYear5=2005
11AssemblyPlantC=JeffersonNorthAssembly Y=ChryslerSteyerAssembly 12thru17VehicleBuildSequence
DESCRIPTION
Allvehiclesareequippedwithacombinedvehicleemissioncontrolinformation(VECI)label(s).Thelabelislocated intheenginecompartmentonthevehiclehood.Twolabelsareusedforvehiclesbuiltforsaleinthecountryof Canada.
TheVECIlabel(s)containthefollowing:
• Enginefamilyanddisplacement
• Evaporativefamily
• Emissioncontrolsystemschematic
• Certificationapplication
• Sparkplugandgap
Thelabelalsocontainsanenginevacuumschematic. Thereareuniquelabelsforvehiclesbuiltforsalein thestateofCaliforniaandthecountryofCanada. CanadianlabelsarewritteninboththeEnglishand Frenchlanguages.Theselabelsarepermanently attachedandcannotberemovedwithoutdefacing informationanddestroyinglabel.
AvehiclecertificationlabelisattachedtoeveryDaimlerChryslerCorporationvehicle.Thelabelcertifiesthatthe vehicleconformstoallapplicableFederalMotorVehicleStandards.Thelabelalsolists:
• Monthandyearofvehiclemanufacture.
• GrossVehicleWeightRating(GVWR).Thegrossfrontandrearaxleweightratings(GAWR’s)arebasedona minimumrimsizeandmaximumcoldtireinflationpressure.
• VehicleIdentificationNumber(VIN).
• Typeofvehicle.
• Typeofrearwheels.
• Barcode.
• Month,DayandHour(MDH)offinalassembly.
• PaintandTrimcodes.
• Countryoforigin.
Thelabelislocatedonthedriver-sidedoorshut-face.
TheSAEboltstrengthgradesrangefromgrade2tograde8.Thehigherthegradenumber,thegreaterthebolt strength.Identificationisdeterminedbythelinemarksonthetopofeachbolthead.Theactualboltstrengthgrade correspondstothenumberoflinemarksplus2.Themostcommonlyusedmetricboltstrengthclassesare9.8and 10.9.Themetricstrengthclassidentificationnumberisimprintedontheheadofthebolt.Thehighertheclass number,thegreatertheboltstrength.Somemetricnutsareimprintedwithasingle-digitstrengthclassonthenut face.RefertotheFastenerIdentificationandFastenerStrengthCharts.
BoltMarkingsandTorques-Metric BoltMarkings8.8/8.910.912.9
BoltMarkingsandTorques-U.S.Customary BoltMarkingsGrade5Grade8 BoltDia.N·mFt.LbsN·mFt.Lbs 1/4-201095*14125* 1/4-281095*17150* 5/16-1822200*30270* 5/16-2426240*33300* 3/8-1640305540 3/8-2447356045 7/16-1468508865 7/16-2074559570 1/2-1310175135100 1/2-2011585150110 9/16-12135105182135 9/16-18155115202150 5/8-11202150263195 5/8-18215160284210 3/4-10230170297220 3/4-16236175304225 7/8-14405300540400 *InchLbs.
DESCRIPTION
FASTENERUSAGE
WARNING:Useofanincorrectfastenermayresultincomponentdamageorpersonalinjury.
FastenersandtorquespecificationsreferencesinthisServiceManualareidentifiedinmetricandSAEformat. Duringanymaintenanceorrepairprocedures,itisimportanttosalvageallfasteners(nuts,bolts,etc.)forreassembly.Ifthefastenerisnotsalvageable,afastenerofequivalentspecificationmustbeused.
DESCRIPTION
THREADEDHOLEREPAIR
MoststrippedthreadedholescanberepairedusingaHelicoil .FollowthevehicleorHelicoil recommendationsfor applicationandrepairprocedures.
DESCRIPTION-INTERNATIONALSYMBOLS
ThegraphicsymbolsillustratedinthefollowingInternationalControlandDisplaySymbolsChartareusedtoidentify variousinstrumentcontrols.Thesymbolscorrespondtothecontrolsanddisplaysthatarelocatedontheinstrument panel.
Themetricsystemisbasedonquantitiesofone,ten,onehundred,onethousandandonemillion. ThefollowingchartwillassistinconvertingmetricunitstoequivalentEnglishandSAEunits,orviseversa.
MULTIPLYBYTOGETMULTIPLYBYTOGET
in-lbsx 0.11298 =NewtonMeters (N·m) N·mx8.851=in-lbs
ft-lbsx 1.3558 =NewtonMeters (N·m) N·mx 0.7376 =ft-lbs
InchesHg(60°F)x3.377=Kilopascals(kPa)kPax 0.2961 =InchesHg
psix6.895=Kilopascals(kPa)kPax0.145=psi
Inchesx25.4=Millimeters(mm)mmx 0.03937 =Inches
Feetx 0.3048 =Meters(M)Mx3.281=Feet
Yardsx 0.9144 =MetersMx 1.0936 =Yards mphx 1.6093 =Kilometers/Hr. (Km/h) Km/hx 0.6214 =mph
Feet/Secx 0.3048 =Meters/Sec(M/S)M/Sx3.281=Feet/Sec
mphx 0.4470 =Meters/Sec(M/S)M/Sx2.237=mph
Kilometers/Hr.(Km/h)x 0.27778 =Meters/Sec(M/S)M/Sx3.600Kilometers/Hr.(Km/h)
1inch=25Millimeters1CubicInch=16CubicCentimeters
1Foot=0.3Meter1CubicFoot=0.03CubicMeter
1Yard=0.9Meter1CubicYard=0.8CubicMeter
1Mile=1.6Kilometers
RefertotheMetricConversionCharttoconverttorquevalueslistedinmetricNewton-meters(N·m).Also,usethe charttoconvertbetweenmillimeters(mm)andinches(in.).
IndividualTorqueChartsappearwithinmanyortheGroups.RefertotheStandardTorqueSpecificationsChartfor torquereferencesnotlistedintheindividualtorquecharts.
DESCRIPTION
DaimlerChryslerCorporationusesinternationalsymbolstoidentifyenginecompartmentlubricantandfluid inspectionandfilllocations.
DESCRIPTION
LUBRICANTRECOMMENDATIONS
Chassis
ComponentFluid,Lubricant,orGenuinePart
SteeringGear&Linkage,Ball Joints,PropShafts&Yokes, WheelBearings
Body
Mopar Multi-PurposeLubricantNLGIGrade2EP,GC-LB
ComponentFluid,Lubricant,andGenuinePart Hinges:
Door&HoodMopar EngineOil
SwingGateMopar Multi-PurposeLubeNLGIGrade2EP,GC-LB
Latches:Door,Hood/Safety Catch,SwingGate
Mopar Multi-PurposeLubeNLGIGrade2EP,GC-LB
SeatRegulator&TrackMopar Multi-PurposeLubeNLGIGrade2EP,GC-LB
LockCylindersMopar LockCylinderLube
Whenserviceisrequired,DaimlerChryslerCorporationrecommendsthatonlyMopar brandparts,lubricantsand chemicalsbeused.Mopar providesthebestengineeredproductsforservicingDaimlerChryslerCorporationvehicles.
OnlylubricantsbearingdesignationsdefinedbythefollowingorganizationshouldbeusedtoserviceaChrysler Corporationvehicle.
• SocietyofAutomotiveEngineers(SAE)
• AmericanPetroleumInstitute(API)
• NationalLubricatingGreaseInstitute(NLGI)
Thissymbolonthefrontofanoilcontainermeans thattheoilhasbeencertifiedbytheAmericanPetroleumInstitute(API)tomeetallthelubricationrequirementsspecifiedbyDaimlerChryslerCorporation.
SAEratingsalsoapplytomultigradegearlubricants.Inaddition,APIclassificationdefinesthelubricantsusage. SuchasAPIGL-5andSAE75W-90.
WARNING:NEWORUSEDENGINEOILCANBEIRRITATINGTOTHESKIN.AVOIDPROLONGEDOR REPEATEDSKINCONTACTWITHENGINEOIL.CONTAMINANTSINUSEDENGINEOIL,CAUSEDBYINTERNALCOMBUSTION,CANBEHAZARDOUSTOYOURHEALTH.THOROUGHLYWASHEXPOSEDSKINWITH SOAPANDWATER.DONOTWASHSKINWITHGASOLINE,DIESELFUEL,THINNER,ORSOLVENTS, HEALTHPROBLEMSCANRESULT.DONOTPOLLUTE,DISPOSEOFUSEDENGINEOILPROPERLY.CONTACTYOURDEALERORGOVERNMENTAGENCYFORLOCATIONOFCOLLECTIONCENTERINYOUR AREA.
Whenserviceisrequired,DaimlerChryslerCorporationrecommendsthatonlyMopar brandparts,lubricantsand chemicalsbeused.Mopar providesthebestengineeredproductsforservicingDaimlerChryslerCorporationvehicles.
Onlylubricantsbearingdesignationsdefinedbythefollowingorganizationshouldbeused.
• SocietyofAutomotiveEngineers(SAE)
• AmericanPetroleumInstitute(API)
• NationalLubricatingGreaseInstitute(NLGI)
• AssociationdesConstructeursEuropéensd’Automobiles(EuropeanAutomobileManufacturersAssociation) (ACEA)
UseanengineoilthatisAPICertified.MOPAR providesengineoils,thatmeetorexceedthisrequirement.
AnSAEviscositygradeisusedtospecifytheviscosity ofengineoil.Useonlyengineoilswithmultipleviscositiessuchas5W-30or10W-30.Thesearespecified withadualSAEviscositygradewhichindicatesthe cold-to-hottemperatureviscosityrange. For3.7L/4.7L enginesSAE5W-30engineoilisrecommendedfor alloperatingtemperatures.For5.7Lengines,SAE 5W-20engineoilisrecommendedforalloperating temperatures.Vehicleswith5.7Lenginesequipped withMultipleDisplacementSystem,(MDS),must useSAE5W-20oil.Failuretodosomayresultin improperoperationoftheMultipleDisplacement System(MDS).Theseengineoilsimprovelowtemperaturestartingandvehiclefueleconomy.Refer toyourengineoilfillercapfortherecommendedengineoilviscosityforyourvehicle.
ForcountriesthatusetheACEAEuropeanOilCategoriesforServiceFillOils,useengineoilsthatmeettherequirementsofACEAA1/B1,A2/B2,orA3/B3.
AnEnergyConservingtypeoilisrecommendedforgasolineengines.ThedesignationofENERGYCONSERVING islocatedonthelabelofanengineoilcontainer.
Standardengineoilidentificationnotationshavebeen adoptedtoaidintheproperselectionofengineoil. Theidentifyingnotationsarelocatedonthefrontlabel ofengineoilplasticbottlesandthetopofengineoil cans.
Thissymbolmeansthattheoilhasbeencertifiedby theAmericanPetroleumInstitute(API).DiamlerChrysleronlyrecommendAPICertifiedengineoils. UseMopar engineoilorequivalent.
Thereareanumberofengineoilsbeingpromotedaseithersyntheticorsemi-synthetic.Ifyouchosetousesuch aproduct,use only thoseoilsthatmeettheAmericanPetroleumInstitute(API)andSAEviscositystandard.Follow theserviceschedulethatdescribesyourdrivingtype.
Themanufacturer doesnotrecommend theadditionofanyengineoiladditives/supplementstothespecified engineoil.Engineoiladditives/supplementsshouldnotbeusedtoenhanceengineoilperformance.Engineoiladditives/supplementsshouldnotbeusedtoextendengineoilchangeintervals.Noadditiveisknowntobesafefor enginedurabilityandcandegradeemissioncomponents.Additivescancontainundesirablematerialsthatharmthe longtermdurabilityofenginesby:
• DoublingthelevelofPhosphorusintheengineoil.TheILSAC(InternationalLubricantStandardApproval Committee)GF-2andGF-3standardsrequirethatengineoilcontainnomorethan0.10%Phosphorustoprotectthevehiclesemissionsperformance.Additionofengineoiladditives/supplementscanpoison,fromthe addedsulfurandphosphorus,catalystsandhindereffortstoguaranteeemissionsperformanceto80,000 miles.
• Alteringtheviscositycharacteristicsoftheengineoilsothatitnolongermeetstherequirementsofthespecifiedviscositygrade.
• Creatingpotentialforanundesirableadditivecompatibilityinteractionintheenginecrankcase.Generallyitis notdesirabletomixadditivepackagesfromdifferentsuppliersinthecrankcase;therehavebeenreportsof lowtemperatureenginefailurescausedbyadditivepackageincompatibilitywithsuchmixtures.
SAEratingsalsoapplytomultigradegearlubricants.Inaddition,APIclassificationdefinesthelubricantsusage. SuchasAPIGL-5andSAE75W-90.
CAUTION:Richerantifreezemixturescannotbemeasuredwithnormalfieldequipmentandcancauseproblemsassociatedwith100percentethylene-glycol.
Therequiredethylene-glycol(antifreeze)andwatermixturedependsupontheclimateandvehicleoperatingconditions.Therecommendedmixtureof50/50ethylene-glycolandwaterwillprovideprotectionagainstfreezingto-37° C(-35°F).Theantifreezeconcentration mustalways beaminimumof44percent,year-roundinallclimates. If percentageislowerthan44percent,enginepartsmaybeerodedbycavitation,andcoolingsystemcomponentsmaybeseverelydamagedbycorrosion. Maximumprotectionagainstfreezingisprovidedwitha68 percentantifreezeconcentration,whichpreventsfreezingdownto-67.7°C(-90°F).Ahigherpercentagewillfreeze atawarmertemperature.Also,ahigherpercentageofantifreezecancausetheenginetooverheatbecausethe specificheatofantifreezeislowerthanthatofwater.
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Useof100percentethylene-glycolwillcauseformationofadditivedepositsinthesystem,asthecorrosioninhibitive additivesinethylene-glycolrequirethepresenceofwatertodissolve.Thedepositsactasinsulation,causingtemperaturestorisetoashighas149°C(300°F).Thistemperatureishotenoughtomeltplasticandsoftensolder. Theincreasedtemperaturecanresultinenginedetonation.Inaddition,100percentethylene-glycolfreezesat22° C(-8°F).
It’soveralleffectivetemperaturerangeissmallerthanthatofethylene-glycol.Thefreezepointof50/50propyleneglycolandwateris-32°C(-26°F).5°Chigherthanethylene-glycol’sfreezepoint.Theboilingpoint(protection againstsummerboil-over)ofpropylene-glycolis125°C(257°F)at 96.5kPa(14psi),comparedto128°C(263° F)forethylene-glycol.Useofpropylene-glycolcanresultinboil-overorfreeze-uponacoolingsystemdesignedfor ethylene-glycol.Propyleneglycolalsohaspoorerheattransfercharacteristicsthanethyleneglycol.Thiscan increasecylinderheadtemperaturesundercertainconditions.
Propylene-glycol/ethylene-glycolMixturescancausethedestabilizationofvariouscorrosioninhibitors,causingdamagetothevariouscoolingsystemcomponents.Also,onceethylene-glycolandpropylene-glycolbasedcoolantsare mixedinthevehicle,conventionalmethodsofdeterminingfreezepointwillnotbeaccurate.Boththerefractiveindex andspecificgravitydifferbetweenethyleneglycolandpropyleneglycol.
WARNING:ANTIFREEZEISANETHYLENE-GLYCOLBASECOOLANTANDISHARMFULIFSWALLOWEDOR INHALED.IFSWALLOWED,DRINKTWOGLASSESOFWATERANDINDUCEVOMITING.IFINHALED,MOVE TOFRESHAIRAREA.SEEKMEDICALATTENTIONIMMEDIATELY.DONOTSTOREINOPENORUNMARKED CONTAINERS.WASHSKINANDCLOTHINGTHOROUGHLYAFTERCOMINGINCONTACTWITHETHYLENEGLYCOL.KEEPOUTOFREACHOFCHILDREN.DISPOSEOFGLYCOLBASECOOLANTPROPERLY,CONTACTYOURDEALERORGOVERNMENTAGENCYFORLOCATIONOFCOLLECTIONCENTERINYOUR AREA.DONOTOPENACOOLINGSYSTEMWHENTHEENGINEISATOPERATINGTEMPERATUREORHOT UNDERPRESSURE,PERSONALINJURYCANRESULT.AVOIDRADIATORCOOLINGFANWHENENGINE COMPARTMENTRELATEDSERVICEISPERFORMED,PERSONALINJURYCANRESULT.
CAUTION:UseofPropylene-Glycolbasedcoolantsisnotrecommended,astheyprovidelessfreezeprotectionandlesscorrosionprotection.
Thecoolingsystemisdesignedaroundthecoolant.Thecoolantmustacceptheatfromenginemetal,inthecylinder headareaneartheexhaustvalvesandengineblock.Thencoolantcarriestheheattotheradiatorwherethetube/ finradiatorcantransfertheheattotheair.
Theuseofaluminumcylinderblocks,cylinderheads,andwaterpumpsrequiresspecialcorrosionprotection. Mopar Antifreeze/Coolant,5Year/100,000MileFormula(MS-9769),ortheequivalentethylene-glycolbasecoolant withorganiccorrosioninhibitors(calledHOAT,forHybridOrganicAdditiveTechnology)isrecommended.Thiscoolantoffersthebestenginecoolingwithoutcorrosionwhenmixedwith50%ethylene-glycoland50%distilledwaterto obtainafreezepointof-37°C(-35°F).Ifitlosescolororbecomescontaminated,drain,flush,andreplacewithfresh properlymixedcoolantsolution.
CAUTION:Mopar Antifreeze/Coolant,5Year/100,000MileFormula(MS-9769)maynotbemixedwithany othertypeofantifreeze.Mixingofcoolantsotherthanspecified(non-HOATorotherHOAT),mayresultin enginedamagethatmaynotbecoveredunderthenewvehiclewarranty,anddecreasedcorrosionprotection.
Therequiredethylene-glycol(antifreeze)andwatermixturedependsuponclimateandvehicleoperatingconditions. Thecoolantperformanceofvariousmixturesfollows:
PureWater- Watercanabsorbmoreheatthanamixtureofwaterandethylene-glycol.Thisisforpurposeofheat transferonly.Wateralsofreezesatahighertemperatureandallowscorrosion.
100percentEthylene-Glycol- Thecorrosioninhibitingadditivesinethylene-glycolneedthepresenceofwaterto dissolve.Withoutwater,additivesformdepositsinsystem.Theseactasinsulationcausingtemperaturetorisetoas
highas149°C(300°F).Thistemperatureishotenoughtomeltplasticandsoftensolder.Theincreasedtemperature canresultinenginedetonation.Inaddition,100percentethylene-glycolfreezesat-22°C(-8°F).
50/50Ethylene-GlycolandWater- Istherecommendedmixture,itprovidesprotectionagainstfreezingto-37°C (-34°F).Theantifreezeconcentration mustalways beaminimumof44percent,year-roundinallclimates.Ifpercentageislower,enginepartsmaybeerodedbycavitation.Maximumprotectionagainstfreezingisprovidedwitha 68percentantifreezeconcentration,whichpreventsfreezingdownto-67.7°C(-90°F).Ahigherpercentagewill freezeatawarmertemperature.Also,ahigherpercentageofantifreezecancausetheenginetooverheatbecause specificheatofantifreezeislowerthanthatofwater.
CAUTION:Richerantifreezemixturescannotbemeasuredwithnormalfieldequipmentandcancauseproblemsassociatedwith100percentethylene-glycol.
Theuseofaluminumcylinderblocks,cylinderheadsandwaterpumpsrequiresspecialcorrosionprotection.Only Mopar Antifreeze/Coolant,5Year/100,000MileFormula(glycolbasecoolantwithcorrosioninhibitorscalledHOAT, forHybridOrganicAdditiveTechnology)isrecommended.Thiscoolantoffersthebestenginecoolingwithoutcorrosionwhenmixedwith50%distilledwatertoobtaintoobtainafreezepointof-37°C(-35°F).Ifitlosescoloror becomescontaminated,drain,flush,andreplacewithfreshproperlymixedcoolantsolution.
CAUTION:Donotusecoolantadditivesthatareclaimedtoimproveenginecooling.
NOTE:DaimlerChryslerrecommendsusingMopar lubricantsorlubricantsofequalquality
FRONTAXLE
• 200MM-Mopar SyntheticGearLubricant75W-140
REARAXLE
• 213MM-Mopar SyntheticGearLubricant75W-140
NOTE:Vari-lok equippedaxlesrequire118ml(4ounces)ofLimitedSlipAdditivebeaddedtothelubricant.
RecommendedlubricantfortheNV140transfercaseisMopar ATF+4,AutomaticTransmissionFluid.RecommendedlubricantfortheNV245transfercaseisMopar NV245/247TransferCaseFluid.
NOTE:RefertoServiceProceduresinthisgroupforfluidlevelcheckingprocedures.
Mopar ATF+4,AutomaticTransmissionFluidistherecommendedfluidforDaimlerChryslerautomatictransmissions.
DexronIIfluidISNOTrecommended.Clutchchattercanresultfromtheuseofimproperfluid.
Mopar ATF+4,AutomaticTransmissionFluidwhennewisredincolor.TheATFisdyedredsoitcanbeidentified fromotherfluidsusedinthevehiclesuchasengineoilorantifreeze.Theredcolorisnotpermanentandisnotan indicatoroffluidcondition.Asthevehicleisdriven,theATFwillbegintolookdarkerincolorandmayeventually becomebrown. Thisisnormal. ATF+4alsohasauniqueodorthatmaychangewithage.Consequently,odorand colorcannotbeusedtoindicatethefluidconditionortheneedforafluidchange.
DaimlerChryslerstronglyrecommendsagainsttheadditionofanyfluidstothetransmission,otherthanthoseautomatictransmissionfluidslistedabove.Exceptionstothispolicyaretheuseofspecialdyestoaidindetectingfluid leaks.
Various“special”additivesandsupplementsexistthatclaimtoimproveshiftfeeland/orquality.Theseadditivesand othersalsoclaimtoimproveconverterclutchoperationandinhibitoverheating,oxidation,varnish,andsludge. TheseclaimshavenotbeensupportedtothesatisfactionofDaimlerChryslerandtheseadditives mustnotbe used. Theuseoftransmission“sealers”shouldalsobeavoided,sincetheymayadverselyaffecttheintegrityof transmissionseals.
Thissystemrequirestheuseofhydraulicsystem/powersteeringfluidwhichmeetsDaimlerChryslerspecification MS-10838,suchasMoparpartnumber05142893AA,orequivalent,DONOTMIXPOWERSTEERINGFLUID TYPES.Damagemayresulttothepowersteeringpumpandsystemifanyotherfluidisused,andDONOTOVERFILL.
Theautomatictransmissionfluidisselectedbaseduponseveralqualities.Thefluidmustprovideahighlevelof protectionfortheinternalcomponentsbyprovidingalubricatingfilmbetweenadjacentmetalcomponents.Thefluid mustalsobethermallystablesothatitcanmaintainaconsistentviscositythroughalargetemperaturerange.Ifthe viscositystaysconstantthroughthetemperaturerangeofoperation,transmissionoperationandshiftfeelwillremain consistent.Transmissionfluidmustalsobeagoodconductorofheat.Thefluidmustabsorbheatfromtheinternal transmissioncomponentsandtransferthatheattothetransmissioncase.
EngineOil-withFilter-3.7L4.7L(5.0qts.)
EngineOil-withFilter-4.7L5.6L(6.0qts.)
EngineOil-withFilter-5.7L6.6L(7.0qts.)
CoolingSystem-3.7L10.0L(9qts.)***
CoolingSystem-4.7L13.7L(14.5qts.)*** CoolingSystem-5.7L13.7L(14.5qts.)***
Powersteeringfluidcapacitiesaredependentonengine/chassisoptionsaswellassteeringgear/cooleroptions. Dependingontypeandsizeofinternalcooler,lengthandinsidediameterofcoolerlines,oruseofanauxiliary cooler,thesecapacitiesmayvary.Referto19,Steeringforproperfillandbleedprocedures.
ServiceFill-545RFE
2WD-5.2L(11pts.)
4WD-6.2L(13pts.)
ServiceFill-NAG15.0L(10.6pts.)
O-haulFill-545RFE13.33L(28.0pts.)
O-haulFill-NAG17.7L(16.3pts)
DryfillcapacityDependingontypeandsizeofinternalcooler,lengthandinsidediameterofcoolerlines,oruseof anauxiliarycooler,thesefiguresmayvary.(Refertoappropriate21-TRANSMISSION/AUTOMATIC/FLUIDSTANDARDPROCEDURE).
TRANSFERCASE
NV1400.65L(1.4pts.)
NV2451.8L(3.8pts.)
FRONTAXLE±0.3L(2oz.)
C200F1.7L(57.5oz.)
C200FE1.7L(57.5oz.)
REARAXLE±0.3L(2oz.)
C213R2.07L(70oz.)* C213RE2.24L(75.5oz.)
*Vari-Lok,add0.07L(2.5oz.)ofFrictionModifier. ***Includes0.9L(1.0qts.)forcoolantreservoir.
****Nominalrefillcapacitiesareshown.Avariationmaybeobservedfromvehicletovehicleduetomanufacturing toleranceandrefillprocedure.
INSPECTION-FLUIDFILL/CHECKLOCATIONS
Thefluidfill/checklocationsandlubricationpointsarelocatedineachapplicablegroup.
Therearetwomaintenanceschedulesthatshowthe required serviceforyourvehicle. FirstisSchedule B .Itisforvehiclesthatareoperatedundertheconditionsthatarelistedbelowandatthebeginningoftheschedule.
• Dayornighttemperaturesarebelow32°F(0°C)
• Stopandgodriving
• Excessiveengineidling
• Drivingindustyconditions
• Shorttripsoflessthan10miles(16.2km)
• Morethan50%ofyourdrivingisatsustainedhighspeedsduringhotweather,above90°F(32°C)
• Trailertowing
• Taxi,police,ordeliveryservice(commercialservice)
• Off-roadordesertdriving
• IfequippedforandoperatedwithE-85(ethanol)fuel.
NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule“B.”
NOTE:IfANYoftheseapplytoyou,changeyourengineoilevery3,000miles(5000km)or3months, whichevercomesfirst,andfollowthemaintenancerecommendationsin“MaintenanceScheduleB.”
NOTE:IfANYoftheseapplytoyouthenflushandreplaceyourenginecoolantevery102,000miles(163000 km)or60months,whichevercomesfirst,andfollow“ScheduleB”ofthe“MaintenanceSchedules”section ofthismanual.
SecondisSchedule “A”.ItisforvehiclesthatarenotoperatedunderanyoftheconditionslistedunderSchedule “B.”
Usetheschedulethatbestdescribesyourdrivingconditions.Wheretimeandmileagearelisted,followtheinterval thatoccursfirst.
CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.
AtEachStopforFuel
• Checktheengineoillevelabout5minutesafterafullywarmedengineisshutoff.Checkingtheoillevelwhile thevehicleisonlevelgroundwillimprovetheaccuracyoftheoillevelreading.Addoilonlywhenthelevelis atorbelowtheADDorMINmark.
• Checkthewindshieldwashersolvent,addasrequired.
OnceaMonth
• Checkthetirepressureandlookforunusualwearordamage.
• Inspectthebatteryandcleanandtightentheterminalsasrequired.
• Checkthefluidlevelsofthecoolantreservoir,brakemastercylinder,andtransmission,andaddasneeded.
• Checkalllightsandallotherelectricalitemsforcorrectoperation.
AtEachOilChange
• Changetheengineoilfilter.
• Inspecttheexhaustsystem.
• Inspectbrakehoses.
• Checktheenginecoolant/anti-freezelevel,hoses,andclamps.
• Aftercompletionofoff-roadoperation,theundersideofthevehicleshouldbethoroughlyinspected.Examine threadedfastenersforlooseness.
Followthisscheduleifyouusuallyoperateyourvehicleunderoneormoreofthefollowingconditions.
• Dayornighttemperaturesarebelow32°F(0°C)
• Stopandgodriving
• Excessiveengineidling
• Drivingindustyconditions
• Shorttripsoflessthan10miles(16.2km)
• Morethan50%ofyourdrivingisatsustainedhighspeedsduringhotweather,above90°F(32°C)
• Trailertowing
• Taxi,police,ordeliveryservice(commercialservice)
• Off-roadordesertdriving
• IfequippedforandoperatedwithE-85(ethanol)fuel.
NOTE:IfANYoftheseapplytoyou,changeyourengineoilevery3,000miles(5000km)or3months, whichevercomesfirst,andfollowthemaintenancerecommendationsin“MaintenanceScheduleB.”
NOTE:IfANYoftheseapplytoyouthenflushandreplaceyourenginecoolantevery102,000miles(163000 km)or60months,whichevercomesfirst,andfollow“ScheduleB”ofthe“MaintenanceSchedules”section ofthismanual.
Miles3,0006,0009,00012,00015,000 (Kilometers)(5000)(10000)(14000)(19000)(24000) Changetheengineoilandengineoilfilter,ifnot replacedat3months.
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Drainandrefillthefrontandrearaxles.X Inspectthebrakelinings. X Cleanandlubricatethebrakecaliperpins.X
Miles18,00021,00024,00027,00030,000 (Kilometers)(29000)(34000)(38000)(43000)(48000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XXX
Drainandrefillthefrontandrearaxles.X
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainthetransfercaseandrefill. X
Miles33,00036,00039,00042,00045,000 (Kilometers)(53000)(58000)(62000)(67000)(72000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Drainandrefillthefrontandrearaxles.X
Inspectthebrakelinings.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Cleanandlubricatethebrakecaliperpins.X
Miles48,00051,00054,00057,00060,000 (Kilometers)(77000)(82000)(86000)(91000)(96000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceifnecessary (5.7LOnly). X
Inspectdrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XXX
Cleanandlubricatebrakecaliperpins.XX
Inspectthebrakelinings.XX
Drainandrefillthefrontandrearaxles.XX
Drainandrefilltheautomatictransmissionfluid,and replacemainsumpfilter(4.7L/5.7LOnly).‡ X
Miles48,00051,00054,00057,00060,000 (Kilometers)(77000)(82000)(86000)(91000)(96000)
Drainandrefillthetransfercasefluid. X
Flushandreplaceenginecoolant/anti-freezeat60 months,ifnotdoneat102,000miles(163000km). X
NOTE:‡Appliesonlyifvehicleisusedforfrequenttrailertowing,orfleet/commercialservice.
Miles63,00066,00069,00072,00075,000 (Kilometers)(101 000) (106000)(110
Changetheengineoilandengineoilfilter,ifnot replacedat3months.
Inspecttheengineaircleanerfilter,replaceif necessary. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Inspectthebrakelinings. X
Cleanandlubricatethebrakecaliperpins.X
Drainandrefillthefrontandrearaxlefluid.X
Miles78,00081,00084,00087,00090,000 (Kilometers)(125 000) (130000)(134 000) (139 000) (144 000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months.
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints.
Drainandrefillthetransfercasefluid. X
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainandrefillthefrontandrearaxlefluid.X
Miles93,00096,00099,000102,000105,000 (Kilometers)(149000)(154000)(158000)(163000)(168000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months.
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering &suspensionballjoints. XX
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainandrefillthefrontandrearaxlefluid.X
Flushandreplacetheenginecoolant/anti-freeze, ifnotdoneat60months. X
Miles108,000111,000114,000117,000120,000 (Kilometers)(173000)(178000)(182000)(187000)(192000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceif necessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceif necessary(5.7LOnly). X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering &suspensionballjoints. XXX
Inspectthebrakelinings.XX
Cleanandlubricatethebrakecaliperpins.XX
Drainandrefillthefrontandrearaxlefluid.XX
Drainandrefilltheautomatictransmissionfluid, replacemainsumpfilter,andspin-oncooler returnfilter(ifequipped).(4.7L/5.7LOnly).‡
Drainandrefillthetransfercasefluid.X
Flushandreplacetheenginecoolant/anti-freeze at120months,ifnotreplacedat102,000miles (163000km).
NOTE:‡Appliesonlyifvehicleisusedforfrequenttrailertowing,orfleet/commercialservice.
Inspectionandserviceshouldalsobeperformedanytimeamalfunctionisobservedorsuspected.Retainall receipts.
Thismaintenanceisrecommendedbythemanufacturertotheowner,butisnotrequiredtomaintainemissions warranty.
Miles6,00012,00018,00024,00030,000 (Kilometers)(10000)(19000)(29000)(38000)(48000) [Months][6][12][18][24][30]
Changetheengineoilandengineoilfilter.XXXXX
Rotatethetires.XXXXX
Inspecttheengineaircleanerfilter,andreplaceif necessary. X
Replacethesparkplugs. X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainthetransfercaseandrefill. X
Miles36,00042,00048,00054,000 (Kilometers)(58000)(67000)(77000)(86000) [Months][36][42][48][54]
Changetheengineoilandengineoilfilter.XXXX
Rotatethetires.XXXX
Inspectthebrakelinings.XX
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Cleanandlubricatethebrakecaliperpins.XX
Miles60,00066,00072,00078,000 (Kilometers)(96000)(106000)(115000)(125000) [Months][60][66][72][78]
Changetheengineoilandengineoilfilter.XXXX
Rotatethetires.XXXX
Inspecttheengineaircleanerfilter,andreplaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceifnecessary(5.7L Only). X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Flushandreplacetheenginecoolant/anti-freeze,at60 monthsifnotdoneat102,000miles(163000km). X
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainthetransfercaseandrefill.X
Miles84,00090,00096,000102,000 (Kilometers)(134000)(144000)(154000)(163000)
[Months][84][90][96][102]
Changetheengineoilandengineoilfilter.XXXX Rotatethetires.XXXX
Inspecttheengineaircleanerfilter,andreplaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints.
Cleanandlubricatethebrakecaliperpins.X
Inspectthebrakelinings.X
Flushandreplacetheenginecoolant/anti-freezeifnot replacedat60months. X
Drainthetransfercaseandrefill.X
Miles108,000114,000120,000 (Kilometers)(173000)(182000)(192000) [Months][108][114][120]
Changetheengineoilandengineoilfilter.XXX Rotatethetires.XXX
Inspecttheengineaircleanerfilter,andreplaceifnecessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceifnecessary(5.7LOnly). X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering&suspensionball joints.
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Flushandreplacetheenginecoolant/anti-freezeifnotdoneat 102,000miles(163000km). X
Drainthetransfercaseandrefill. X
Inspectionandserviceshouldalsobeperformedanytimeamalfunctionisobservedorsuspected.Retainall receipts.
Thismaintenanceisrecommendedbythemanufacturertotheowner,butisnotrequiredtomaintainemissions warranty.
WARNING:Youcanbebadlyinjuredworkingonoraroundamotorvehicle.Doonlythatserviceworkfor whichyouhavetheproperequipment.Ifyouhaveanydoubtaboutyourabilitytoperformaservicejob, takeyourvehicletoacompetentmechanic.
Therearetwomaintenanceschedulesthatshowthe required serviceforyourvehicle.
FirstisSchedule B .Itisforvehiclesthatareoperatedundertheconditionsthatarelistedbelowandatthebeginningoftheschedule.
• Dayornighttemperaturesarebelow32°F(0°C)
• Stopandgodriving
• Excessiveengineidling
• Drivingindustyconditions
• Shorttripsoflessthan10miles(16.2km)
• Morethan50%ofyourdrivingisatsustainedhighspeedsduringhotweather,above90°F(32°C)
• Trailertowing
• Taxi,police,ordeliveryservice(commercialservice)
• Off-roadordesertdriving
• IfequippedforandoperatedwithE-85(ethanol)fuel.
NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule“B.”
NOTE:IfANYoftheseapplytoyou,changeyourengineoilevery3,000miles(5000km)or3months, whichevercomesfirst,andfollowthemaintenancerecommendationsin“MaintenanceScheduleB.”
NOTE:IfANYoftheseapplytoyouthenflushandreplaceyourenginecoolantevery102,000miles(163000 km)or60months,whichevercomesfirst,andfollow“ScheduleB”ofthe“MaintenanceSchedules”section ofthismanual.
SecondisSchedule “A”.ItisforvehiclesthatarenotoperatedunderanyoftheconditionslistedunderSchedule “B.”
Usetheschedulethatbestdescribesyourdrivingconditions.Wheretimeandmileagearelisted,followtheinterval thatoccursfirst.
CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.
AtEachStopforFuel
• Checktheengineoillevelabout5minutesafterafullywarmedengineisshutoff.Checkingtheoillevelwhile thevehicleisonlevelgroundwillimprovetheaccuracyoftheoillevelreading.Addoilonlywhenthelevelis atorbelowtheADDorMINmark.
• Checkthewindshieldwashersolvent,addasrequired.
OnceaMonth
• Checkthetirepressureandlookforunusualwearordamage.
• Inspectthebatteryandcleanandtightentheterminalsasrequired.
• Checkthefluidlevelsofthecoolantreservoir,brakemastercylinder,andtransmission,andaddasneeded.
• Checkalllightsandallotherelectricalitemsforcorrectoperation.
AtEachOilChange
• Changetheengineoilfilter.
• Inspecttheexhaustsystem.
• Inspectbrakehoses.
• Checktheenginecoolant/anti-freezelevel,hoses,andclamps.
• Aftercompletionofoff-roadoperation,theundersideofthevehicleshouldbethoroughlyinspected.Examine threadedfastenersforlooseness.
Schedule“B”
Followthisscheduleifyouusuallyoperateyourvehicleunderoneormoreofthefollowingconditions.
• Dayornighttemperaturesarebelow32°F(0°C)
• Stopandgodriving
• Excessiveengineidling
• Drivingindustyconditions
• Shorttripsoflessthan10miles(16.2km)
• Morethan50%ofyourdrivingisatsustainedhighspeedsduringhotweather,above90°F(32°C)
• Trailertowing
• Taxi,police,ordeliveryservice(commercialservice)
• Off-roadordesertdriving
• IfequippedforandoperatedwithE-85(ethanol)fuel.
NOTE:IfANYoftheseapplytoyou,changeyourengineoilevery3,000miles(5000km)or3months, whichevercomesfirst,andfollowthemaintenancerecommendationsin“MaintenanceScheduleB.”
NOTE:IfANYoftheseapplytoyouthenflushandreplaceyourenginecoolantevery102,000miles(163000 km)or60months,whichevercomesfirst,andfollow“ScheduleB”ofthe“MaintenanceSchedules”section ofthismanual.
Miles3,0006,0009,00012,00015,000 (Kilometers)(5000)(10000)(14000)(19000)(24000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints.
Miles18,00021,00024,00027,00030,000 (Kilometers)(29000)(34000)(38000)(43000)(48000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceifnecessary. X Replacethesparkplugs. X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints.
Drainandrefillthefrontandrearaxles.X
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainthetransfercaseandrefill. X
Miles33,00036,00039,00042,00045,000 (Kilometers)(53000)(58000)(62000)(67000)(72000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Drainandrefillthefrontandrearaxles.X
Inspectthebrakelinings.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Cleanandlubricatethebrakecaliperpins.X
Miles48,00051,00054,00057,00060,000 (Kilometers)(77000)(82000)(86000)(91000)(96000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceifnecessary (5.7LOnly). X
Inspectdrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XXX
Cleanandlubricatebrakecaliperpins.XX
Inspectthebrakelinings.XX
Drainandrefillthefrontandrearaxles.XX
Drainandrefilltheautomatictransmissionfluid,and replacemainsumpfilter(4.7L/5.7LOnly).‡ X
Drainandrefillthetransfercasefluid. X
Flushandreplaceenginecoolant/anti-freezeat60 months,ifnotdoneat102,000miles(163000km).
NOTE:‡Appliesonlyifvehicleisusedforfrequenttrailertowing,orfleet/commercialservice.
Miles63,00066,00069,00072,00075,000 (Kilometers)(101000)(106000)(110000)(115000)(120000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering &suspensionballjoints. XX
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainandrefillthefrontandrearaxlefluid.X
Miles78,00081,00084,00087,00090,000 (Kilometers)(125000)(130000)(134000)(139000)(144000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceif necessary. X
Replacethesparkplugs. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering &suspensionballjoints. XXX
Drainandrefillthetransfercasefluid.X
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainandrefillthefrontandrearaxlefluid.X
Miles93,00096,00099,000102,000105,000 (Kilometers)(149000)(154000)(158000)(163000)(168000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XX
Inspecttheengineaircleanerfilter,replaceif necessary. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering &suspensionballjoints. XX
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainandrefillthefrontandrearaxlefluid.X
Flushandreplacetheenginecoolant/anti-freeze, ifnotdoneat60months. X
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Miles108,000111,000114,000117,000120,000 (Kilometers)(173000)(178000)(182000)(187000)(192000)
Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,replaceif necessary. X
InspectthePCVValve,replaceif necessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceif necessary(5.7LOnly). X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering &suspensionballjoints. XXX
Inspectthebrakelinings.XX
Cleanandlubricatethebrakecaliperpins.XX
Drainandrefillthefrontandrearaxlefluid.XX
Drainandrefilltheautomatictransmissionfluid, replacemainsumpfilter,andspin-oncooler returnfilter(ifequipped).(4.7L/5.7LOnly).‡ X
Drainandrefillthetransfercasefluid.X
Flushandreplacetheenginecoolant/anti-freeze at120months,ifnotreplacedat102,000miles (163000km). X
NOTE:‡Appliesonlyifvehicleisusedforfrequenttrailertowing,orfleet/commercialservice.
Inspectionandserviceshouldalsobeperformedanytimeamalfunctionisobservedorsuspected.Retainall receipts.
Thismaintenanceisrecommendedbythemanufacturertotheowner,butisnotrequiredtomaintainemissions warranty.
Schedule“A
Miles6,00012,00018,00024,00030,000 (Kilometers)(10000)(19000)(29000)(38000)(48000) [Months][6][12][18][24][30]
Changetheengineoilandengineoilfilter.XXXXX
Rotatethetires.XXXXX
Inspecttheengineaircleanerfilter,andreplaceif necessary. X
Replacethesparkplugs. X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainthetransfercaseandrefill. X
Miles36,00042,00048,00054,000 (Kilometers)(58000)(67000)(77000)(86000)
[Months][36][42][48][54]
Changetheengineoilandengineoilfilter.XXXX
Rotatethetires.XXXX
Inspectthebrakelinings.XX
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Cleanandlubricatethebrakecaliperpins.XX
Miles60,00066,00072,00078,000 (Kilometers)(96000)(106000)(115000)(125000)
[Months][60][66][72][78]
Changetheengineoilandengineoilfilter.XXXX
Rotatethetires.XXXX
Inspecttheengineaircleanerfilter,andreplaceif necessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceifnecessary(5.7L Only). X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Flushandreplacetheenginecoolant/anti-freeze,at60 monthsifnotdoneat102,000miles(163000km). X
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Drainthetransfercaseandrefill.X
Miles84,00090,00096,000102,000 (Kilometers)(134000)(144000)(154000)(163000)
[Months][84][90][96][102]
Changetheengineoilandengineoilfilter.XXXX
Rotatethetires.XXXX
Inspecttheengineaircleanerfilter,andreplaceif necessary. X
InspectthePCVValve,replaceifnecessary. X Replacethesparkplugs. X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering& suspensionballjoints. XX
Cleanandlubricatethebrakecaliperpins.X
Inspectthebrakelinings.X
Flushandreplacetheenginecoolant/anti-freezeifnot replacedat60months. X
Drainthetransfercaseandrefill.X
Miles108,000114,000120,000 (Kilometers)(173000)(182000)(192000)
[Months][108][114][120]
Changetheengineoilandengineoilfilter.XXX
Rotatethetires.XXX
Inspecttheengineaircleanerfilter,andreplaceifnecessary. X
InspectthePCVValve,replaceifnecessary. X
Replacethesparkplugs. X
Inspecttheignitioncables,replaceifnecessary(5.7LOnly). X
Inspectthedrivebelt,replaceifnecessary.X
Lubricatetheupperknuckleballstudatsteering&suspensionball joints. XX
Inspectthebrakelinings.X
Cleanandlubricatethebrakecaliperpins.X
Flushandreplacetheenginecoolant/anti-freezeifnotdoneat 102,000miles(163000km). X
Drainthetransfercaseandrefill. X
Inspectionandserviceshouldalsobeperformedanytimeamalfunctionisobservedorsuspected.Retainall receipts.
Thismaintenanceisrecommendedbythemanufacturertotheowner,butisnotrequiredtomaintainemissions warranty.
WARNING:Youcanbebadlyinjuredworkingonoraroundamotorvehicle.Doonlythatserviceworkfor whichyouhavetheknowledgeandtherightequipment.Ifyouhaveanydoubtaboutyourabilitytoperform aservicejob,takeyourvehicletoacompetentmechanic.
DESCRIPTION
NOTE:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight.Itisimportanttohave thespringssupportingtheweightofthevehicle whenthefastenersaretorqued.Ifspringsarenot attheirnormalrideposition,vehicleridecomfort couldbeaffectedandprematurebushingwear mayoccur.
Wheelalignmentinvolvesthecorrectpositioningofthe wheelsinrelationtothevehicle.Thepositioningis accomplishedthroughsuspensionandsteeringlinkageadjustments.Analignmentisconsideredessential forefficientsteering,gooddirectionalstabilityandto minimizetirewear.Themostimportantmeasurements ofanalignmentarecaster,camberandtoe.
CAUTION:Neverattempttomodifysuspensionorsteeringcomponentsbyheatingorbending.
• CASTER(1) istheforwardorrearwardtiltofthe steeringknucklefromvertical.Tiltingthetopof theknuckleforwardprovideslesspositivecaster. Tiltingthetopoftheknucklerearwardprovides morepositivecaster.Positivecasterpromotes directionalstability.Thisangleenablesthefront wheelstoreturntoastraightaheadpositionafter turns.
• CAMBER(2) istheinwardoroutwardtiltofthe wheelrelativetothecenterofthevehicle.Tilting thetopofthewheelinwardprovidesnegative camber.Tiltingthetopofthewheeloutwardprovidespositivecamber.Incorrectcamberwill causewearontheinsideoroutsideedgeofthe tire.
• TOE(4) isthedifferencebetweentheleading insideedgesandtrailinginsideedgesofthefronttires.Wheeltoepositionoutofspecificationcause’sunstable steering,uneventirewearandsteeringwheeloff-center.Thewheeltoepositionisthe final frontwheelalignmentadjustment.
• THRUSTANGLE(3) istheangleoftherearaxlerelativetothecenterlineofthevehicle.Incorrectthrustangle cancauseoff-centersteeringandexcessivetirewear.Thisangleisnotadjustable,damagedcomponent(s) mustbereplacedtocorrectthethrustangle.
Beforestartingwheelalignment,thefollowinginspectionandnecessarycorrectionsmustbecompleted.Referto SuspensionandSteeringSystemDiagnosisChartbelowforadditionalinformation.
1.Inspecttiresforsize,airpressureandtreadwear.
2.Inspectfrontwheelbearingsforwear.
3.Inspectfrontwheelsforexcessiveradialorlateralrunoutandbalance.
4.Inspectballstuds,linkagepivotpointsandsteeringgearforlooseness,roughnessorbinding.
5.Inspectsuspensioncomponentsforwearandnoise.
6.Checksuspensionrideheight.
7.Roadtestthevehicle.
SUSPENSIONANDSTEERINGSYSTEMDIAGNOSIS
CONDITIONPOSSIBLECAUSESCORRECTION
FRONTENDNOISE1.Looseorwornwheelbearing.1.Replacewheelbearing.
2.Looseorwornsteeringor suspensioncomponents.
3.Looseorwornsteeringor suspensioncomponents.
EXCESSIVEPLAYIN STEERING
2.Tightenorreplacecomponentsas necessary.
3.Tightenorreplacecomponentsas necessary.
1.Looseorwornwheelbearing.1.Replacewheelbearing.
2.Looseorwornsteeringor suspensioncomponents.
2.Tightenorreplacecomponentsas necessary.
3.Looseorwornsteeringgear.3.Replacesteeringgear.
FRONTWHEELSSHIMMY1.Looseorwornwheelbearing.1.Replacewheelbearing.
2.Looseorwornsteeringor suspensioncomponents.
2.Tightenorreplacecomponentsas necessary.
3.Tireswornoroutofbalance.3.Replaceorbalancetires.
4.Alignment.4.Alignvehicletospecifications.
VEHICLEINSTABILITY1.Looseorwornwheelbearing.1.Replacewheelbearing.
2.Looseorwornsteeringor suspensioncomponents.
2.Tightenorreplacecomponentsas necessary.
3.Tirepressure.3.Adjusttirepressure.
4.Alignment.4.Alignvehicletospecifications.
EXCESSIVESTEERING EFFORT
VEHICLEPULLSTOONE SIDE
1.Looseorwornsteeringgear.1.Replacesteeringgear.
2.Columncouplerbinding.2.Replacecoupler.
3.Tirepressure.3.Adjusttirepressure.
4.Alignment.4.Alignvehicletospecifications.
1.Tirepressure.1.Adjusttirepressure.
2.Tire.2.Criss-CrossFrontTires.
3.Alignment.3.Alignvehicletospecifications.
4.Looseorwornsteeringor suspensioncomponents. 4.Tightenorreplacecomponentsas necessary.
5.Radialtirelead.5.Rotateorreplacetireasnecessary.
6.Brakepull.6.Repairbrakeasnecessary.
8.Rideheight.8.Measureandadjustrideheight.
NOTE:SUSPENSIONHEIGHTMEASUREMENTMUSTBEPERFORMEDBEFOREANALIGNMENT.
Camberandcasterangleadjustmentsinvolvechangingthepositionofthelowercontrolarmwiththeslotsinthe framebracketstomovethelowercontrolarminwardsoroutwardsforproperadjustment. Thiscanbeachievedby usingalongprybarwithacurvedtipandinsertingtheprybarintothelowercontrolarmframebrackets andpryinginwardsoroutwards.
NOTE:CamberandcasteradjustmentsmustbemadeatthelowercontrolarmDonotusetheuppercontrol armforCamberandCasteradjustments.
NOTE:Whenthelowercontrolarmpivotboltsareloosenedthelowercontrolarmwillnormallygooutwards automaticallywiththeweightofthevehicle.
Movingtherearpositionofthelowercontrolarmattheframeinorout,willchangethecasteranglesignificantly andcamberangleonlyslightly.Tomaintainthecamberanglewhileadjustingcaster,movetherearofthelower controlarminorout.Thenmovethefrontofthelowercontrolarmslightlyintheoppositedirection.
Moveboththefrontandrearofthelowercontrolarmtogetherinorout.Thiswillchangethecamberanglesignificantlyandcasterangleslightly.
Afteradjustmentismadetightenthelowercontrolarmbolt&nutsto FRONT169N·m(125ft.lbs.)andthe REAR 88N·m(65ft.lbs.).
Thewheeltoepositionadjustmentisthefinaladjustment.
1.Starttheengineandturnwheelsbothwaysbefore straighteningthewheels.Securethesteering wheelwiththefrontwheelsinthestraight-ahead position.
2.Loosenthetierodjamnuts(3).
NOTE:Eachfrontwheelshouldbeadjustedfor one-halfofthetotaltoepositionspecification. Thiswillensurethesteeringwheelwillbecenteredwhenthewheelsarepositionedstraightahead.
3.Adjustthewheeltoepositionbyturningtheinner tierod(4)asnecessary.
4.Tightenthetierodjamnut(3)to75N·m(55ft.lbs.).
5.Verifythespecifications.
6.Turnoffengine.
SUSPENSIONHEIGHTMESUREMENTMUSTBE PERFORMEDBEFOREANALIGNMENT.
Thewheeltoepositionadjustmentisthefinaladjustment.
1.Starttheengineandturnwheelsbothwaysbefore straighteningthewheels.Securethesteering wheelwiththefrontwheelsinthestraight-ahead position.
2.Loosenthetierodjamnuts(3).
NOTE:Eachfrontwheelshouldbeadjustedfor one-halfofthetotaltoepositionspecification. Thiswillensurethesteeringwheelwillbecenteredwhenthewheelsarepositionedstraightahead.
3.Adjustthewheeltoepositionbyturningtheinnertierod(4)asnecessary. 4.Tightenthetierodjamnut(3)to75N·m(55ft.lbs.).
5.Verifythespecifications.
6.Turnoffengine.
SPECIFICATIONS
ALIGNMENT
NOTE:Specificationsareindegrees.
SPECIFICATIONS
REARAXLE
SPECIFICATIONS
NOTE:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethespringssupportingtheweightofthevehiclewhenthefasteners aretorqued.Ifspringsarenotattheirnormalrideposition,vehicleridecomfortcouldbeaffectedandprematurebushingwearmayoccur.
Thefrontsuspensionisdesignedtoalloweachwheeltoadapttodifferentroadsurfacesindependently.Thewheels aremountedtohubbearingsonthesteeringknucklespindles.Thedouble-rowhubbearingsaresealedandlubricatedforlife.Thesteeringknucklesturn(pivot)onballjointsintegraltotheoutboardportionoftheuppercontrol armsandpressedintothelowersteeringknuckle.Theballjointsarelubricatedforlife.
TORQUECHART
TORQUESPECIFICATIONS
DESCRIPTIONN·mFt.Lbs.In.Lbs. ShockAbsorberUpperNuts9570— ShockAbsorberClevisBracket8160— ClevisBrackettoLowerControlArm169125— UpperControlArmBolt/NuttoBody12290— LowerControlArmBolt142105— LowerControlArmBolt/Nut FrontPivot 169125— UpperBallJointNut7555— LowerBallJointNut9570— StabilizerBarRetainerBolts142105— StabilizerBarLinkUpperNut135100— StabilizerBarLinkLowerBolt11585— HubBearingKnuckleBolts136100—
CLEVISBUSHING-9653
PULLER-8677
BALLJOINT-9654
BALLJOINT-C-4212-3
Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight. Itisimportanttohavethespringssupportingtheweightofthevehiclewhenthefastenersaretorqued.Ifspringsare notattheirnormalrideposition,vehicleridecomfortcouldbeaffectedandprematurebushingwearmayoccur.
1.Raiseandsupportthevehicle.
2.Removethefrontsplashshield.
3.Removethetwostabilizerbarretainerbracketbolts (2).
4.Removethebushingclamp(2).
5.Removethestabilizerbarbushing(3).
1.Removetheclevisbracket(3)fromtheshock(1) (Referto2-SUSPENSION/FRONT/CLEVIS BRACKET-REMOVAL).
NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsure properoperationduringtheremovalandinstallationprocess.
2.PressthebushingoutusingspecialtoolsC-4212-F (Press)(1),9653–1(driver)(4)and9653–2 (Receiver)(2)fromthelowercontrolarm(3).
1.Installthestabilizerbarbushing(3)tothebar(1).
2.Installthestabilizerbarbushingreatainerbracket (2)boltsandtightenthetwomountingbolts.
3.Installthefrontsplashshield.
4.Lowerthevehicle.
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NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsure properoperationduringtheremovalandinstallationprocess.
1.Installthenewclevisbracketbushing(3)intothe lowercontrolarm(5)usingtoolsC-4212-F(Press) (1),9653–3(driver)(2),9653–4(Depthgauge)(4) thedepthgaugewillautomaticallysetthedepthof thebushing(3)inthecontrolarm(5).
2.Installtheclevisbracket(3)totheshock(1)(Refer to2-SUSPENSION/FRONT/CLEVISBRACKETINSTALLATION).
Thebearingusedonthefronthubofthisvehicleisthecombinedhubandbearingunittypeassembly.Thisunit assemblycombinesthefrontwheelmountinghub(flange)andthefrontwheelbearingintoaonepieceunit.The wheelmountingstudsaretheonlyreplaceablecomponentofthehub/bearingassembly.
Thehub/bearingassemblyismountedtothesteeringknuckleandisretainedbythreemountingboltsaccessible fromthebackofthesteeringknuckle.Thehub/bearingunitisnotserviceableandmustbereplacedasanassembly ifthebearingorthehubisdeterminedtobedefective.
1.Raiseandsupportthevehicle.
2.Removethewheelandtireassembly. Supportthecaliper,Donotletthecaliperhangby thehose.
3.Removethediscbrakecaliper(1)(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS-REMOVAL).
4.Removethebrakecaliperadaptor(1)(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERADAPTER-REMOVAL).
5.Removeanddiscardtheo-ring(2)andthen removethediscbrakerotor(1)(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSREMOVAL).
6.Removethewheelspeedsensornut(2).
7.Removethewheelspeedsensor(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-REMOVAL).
8.Removethe3hubbearingmountingboltsfromthe backofthesteeringknuckle.Removehubbearing (3)fromthesteeringknuckle.
1.Installthehubbearing(3)totheknuckle.
2.Installthehubbearingtoknuckleandthe3bolts thentightento136N·m(100ft.lbs.).
3.Installthewheelspeedsensor(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-INSTALLATION).
4.Installthewheelspeedsensornut(2).
5.Installthebrakerotor(1)(Referto5-BRAKES/ HYDRAULIC/MECHANICAL/ROTORSINSTALLATION).
6.Installthebrakecaliperadaptor(1)(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERADAPTER-INSTALLATION).
7.Installthecaliper(1)(Referto5-BRAKES/HYDRAULIC/MECHANICAL/DISCBRAKECALIPERS -INSTALLATION).
8.Installthewheelandtireassembly(Referto22-TIRES/WHEELS-STANDARDPROCEDURE).
9.Removethesupportandlowerthevehicle.
Theknuckleisasinglecastingwithlegsmachinedfortheupperandlowerballjoints.Theknucklealsohas machinedmountinglocationsforthefrontbrakecalipersandhubbearing.
Thesteeringknucklepivotbetweentheupperandlowerballjoint.Steeringlinkageattachedtotheknuckleallows thevehicletobesteered.
1.Raiseandsupportthevehicle.
2.Removethetireandwheelassembly.
CAUTION:Neverallowthediscbrakecaliperto hangfromthebrakehose.Damagetothebrake hosewillresult.Provideasuitablesupportto hangthecalipersecurely.
3.Removethebrakecaliper(1).
4.Removethecaliperadapter(1).(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERADAPTER-REMOVAL).
5.Removetheo-ring(2)anddiscardthenremove discbrakerotor(1).(Referto5-BRAKES/HYDRAULIC/MECHANICAL/ROTORS-REMOVAL).
6.Removethewheelspeedsensor(2).(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-REMOVAL).
7.Removetheaxleshaftnut.(ifequippedwithfour wheeldrive)
8.Removethehub/bearing(3).(Referto2-SUSPENSION/FRONT/HUB/BEARING-REMOVAL).
9.Removetheoutertierodendretainingnut.
10.Seperatetheoutertierodend(3)fromthesteeringknuckleusingspecialtool8677(5).(Referto 19-STEERING/LINKAGE/TIERODENDREMOVAL).
11.Removethelowerballjointnut.
12.Seperatethelowerballjointfromtheknuckle(1) usingtoolC–4150A(2).
13.Removetheupperballjointnut.
14.Seperatetheupperballjoint(2)fromtheknuckle (3)usingtool8677(1).
15.Removetheknuckle(3)fromthevehicle.
1.Installtheknuckle(1)tothevehicle.
2.Installthelowerballjointintotheknuckle.
3.Installthelowerballjointnut.Tightenthenutto81 N·m(60ft.lbs.).
4.Installtheupperballjoint(2)intotheknuckle(3)
5.Installtheupperballjointnut(4).Tightenthenutto 81N·m(60ft.lbs.).
6.Installtheoutertierodendtothesteeringknuckle. (Referto19-STEERING/LINKAGE/TIERODEND -INSTALLATION).
7.Installthehub/bearing(3),Tightento136N·m(100 ft.lbs.).(Referto2-SUSPENSION/FRONT/HUB/ BEARING-INSTALLATION).
8.Installtheaxleshaftnut.Tightenthenutto135 N·m(96ft.lbs.).(ifequippedwithfourwheeldrive).
9.Installthewheelspeedsensor(2).(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-INSTALLATION).
10.Installthediscbrakerotor(1).(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSINSTALLATION).
11.Installthecaliperadapter(1).(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERADAPTER-INSTALLATION).
12.Installthetireandwheelassembly.(Referto22TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).
13.Performwheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).
NOTE:Iftheballjointisequippedwithalubricationfitting,greasethejointthenroadtestthevehiclebefore performingtest.
1.Raisethefrontofthevehicle.Placesafetyfloorstandsunderbothlowercontrolarmsasfaroutboardaspossible.Lowerthevehicletoallowthestandstosupportsomeorallofthevehicleweight.
2.Mountadialindicatorsolidlytothetopsideofthelowercontrolarmandthenzerothedialindicator.
3.Positiontheindicatorplungeragainstthebottomsurfaceofthesteeringknuckle.
NOTE:Thedialindicatorplungermustbeperpendiculartothemachinedsurfaceofthesteeringknuckle.
4.Positionaprybarunderthetireassembly.Pryupwardsonthetireassembly.
5.Ifthetravelexceeds0.5mm(0.020in.),replacethelowerballjoint(Referto2-SUSPENSION/FRONT/LOWER BALLJOINT-REMOVAL).
1.Removethetireandwheelassembly.
2.Removethebrakecaliperandrotor(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSREMOVAL).
3.Disconnectthetierod(1)fromthesteeringknuckle usingspecialtoolC-3894-A(1)(Referto19STEERING/LINKAGE/TIERODEND-REMOVAL).
4.Separatetheupperballjoint(2)fromtheknuckle (3)usingspecialtool8677(1).
5.Separatethelowerballjoint(3)fromthesteering knuckle(1)usingspecialtool8677(2).
6.Removethesteeringknuckle(Referto2-SUSPENSION/FRONT/KNUCKLE-REMOVAL).
7.Movethehalfshafttothesideandsupportthehalfshaftoutoftheway 4X4only 8.Chiselouttheballjointstakes.
NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsure properoperationduringtheremovalandinstallationprocess.
9.Presstheballjointfromthelowercontrolarm(3) usingspecialtoolsC-4212-F(PRESS)(1), C–4212–3(Driver)(2)and9654–3(Receiver)(4).
NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsure properoperationduringtheremovalandinstallationprocess.
1.Installtheballjoint(4)intothecontrolarm(3)and pressinusingspecialtoolsC-4212-F(press)(1), 9654–1(Driver)(5)and9654–2(Receiver)(2).
2.Staketheballjointflangeinfourevenlyspacedplacesaroundtheballjointflange,usingachiselandhammer.
3.Removethesupportforthehalfshaftandinstallintoposition 4X4only
4.Installthesteeringknuckle(Referto2-SUSPENSION/FRONT/KNUCKLE-INSTALLATION).
5.Installthetierodendintothesteeringknuckle(Referto19-STEERING/LINKAGE/TIERODEND-INSTALLATION).
6.Installandtightenthehalfshaftnutto251N·m(185ft.lbs.).(IfEquipped).
7.Installthebrakecaliperandrotor(Referto5-BRAKES/HYDRAULIC/MECHANICAL/ROTORS-INSTALLATION).
8.Installthetireandwheelassembly(Referto22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).
9.Checkthevehiclerideheight(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARDPROCEDURE).
10.Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARDPROCEDURE).
Thefrontlowersuspensionarmsarecastiron.
Thebushingsprovideisolationfromtheroad.Thearmsmounttothecradlebracketandtheknuckle.Thearmand bushingsprovidelocationandreacttoloadsfromtheroad.
1.Raiseandsupportthevehicle.
2.Removethetireandwheelassembly.
3.Removethesteeringknuckle(3).(Referto2SUSPENSION/FRONT/KNUCKLE-REMOVAL).
4.Removetheshockclevisbracket(2)fromthelower controlarm.
5.Removethenutandboltfromthefrontofthelower controlarm.
6.Removetherearboltsandflagnutsfromthelower controlarm.
7.Removethelowercontrolarmfromthevehicle.
1.Positionthelowersuspensionarmintotheframe railbracket.
2.Installtherearboltsforthelowercontrolarmtothe frame,Tightento142N·m(105ftlbs).
3.Installthenutandboltforthefrontofthelower controlarmTightento169N·m(125ftlbs).
4.Installthelowerclevisbolt(2)atthelowercontrol armandtightento88N·m(65ft.lbs.).
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5.Installthesteeringknuckle(3)andtightenthenut to75N·m(55ft.lbs.)(Referto2-SUSPENSION/ FRONT/KNUCKLE-INSTALLATION).
6.Installthetireandwheelassembly.
7.Lowerthevehicle.
8.Performwheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARDPROCEDURE).
Thetopoftheshockabsorbersareboltedtothebody.Thebottomoftheshocksareboltedtothelowercontrol arm.Thestandardshockshaveconventionaltwintubeconstructionandarelowpressuregascharged.Gaschargingpreventscavitationduringroughroadoperation.
Theshockabsorbersdampenjounceandreboundmotionofthevehicleovervariousroadconditionsandlimitsuspensionreboundtravel.
1.Removetheairboxcoverandairintakehose.
2.Disconnectthecruisecontrolservoelectricalconnector.
3.Removethecoolantreservoirmountingboltandmovethecoolantreservoirofftotheside.
4.Removethefouruppershockmountingnuts(1).
5.Raiseandsupportthevehicle.
6.Removethetire.
7.Removethetwobrakecaliperadapterbolts.
8.Supportthebrakecaliperadaptorandcaliper. Donotallowthecalipertohangbythebrakehose.
9.Removethediscbrakerotor.
10.Removetheupperballjointnut.
11.Separatetheupperballjoint(2)fromtheknuckle (3)usingspecialtool8677(1).
12.Removethelowerclevisbolt(2)atthelowercontrolarm.
13.Removethelowerstabilizerbolt(3)atthelower controlarm.
14.Removetheshockfromthevehicle.
15.Removethespringifnecessary(Referto2SUSPENSION/FRONT/SPRING-REMOVAL).
1.Removetheairboxcoverandairintakehose.
2.Removethe3PDCbracketnuts(1).
3.MovethePDC(1)offtothesidetoaccessthefour uppershockmountnuts(2).
4.Removethefouruppershockmountnuts(2).
5.Raiseandsupportthevehicle.
6.Removethetire.
7.Removethetwobrakecaliperadapterbolts.
8.Supportthebrakecaliperadaptorandcaliper. Donotallowthecalipertohangbythebrakehose.
9.Removethediscbrakerotor.
10.Removetheupperballjointnut.
11.Separatetheupperballjoint(2)fromtheknuckle (3)usingspecialtool8677(1).
12.Removethelowerclevisbolt(2)atthelowercontrolarm.
13.Removethelowerstabilizerbolt(3)atthelower controlarm.
14.Removetheshock(3)fromthevehicle.
15.Removethespringifnecessary(Referto2SUSPENSION/FRONT/SPRING-REMOVAL).
1.Installtheclevisbracket(4)totheshock(3)and tightento122N·m(90ft.lbs.)..
2.Installtheshockassembly(3)tothevehicle.
3.Installthefouruppershocknuts(1),Tightento95 N·m(70ft.lbs.).
4.Installthecoolantreservoirbolt.
5.Reconnectthecruisecontrolservowiringconnector.
6.Installtheairboxcoverandairintakehose.
7.Raisethevehicleup.
8.Installthelowerstabilizerbolt(2)atthelowercontrolarm.
9.Installthelowerclevisbolt(3)atthelowercontrol armandtightento169N·m(125ft.lbs.).
10.Installtheupperballjointintotheknuckle(1)and tightenthenutto75N·m(55ft.lbs.).
11.Installthediscbrakerotor.
12.Installthecaliperadaptormountingboltsto176N·m(130ft.lbs.).
13.Installthetireandwheelassembly.
14.Lowerthevehicle.
1.Installtheclevisbracket(4)totheshock(3)and tightento122N·m(90ft.lbs.)..
2.Installtheshockassembly(3)tothevehicle.
3.Installthefouruppershocknuts(2),Tightento95 N·m(70ft.lbs.).
4.Installthe3PDC(1)bracketnuts.
5.Raisethevehicleup.
6.Installthelowerstabilizerbolt(2)atthelowercontrolarmandtightento115N·m(85ft.lbs.).
7.Installthelowerclevisbolt(3)atthelowercontrol armandtightento169N·m(125ft.lbs.).
8.Installtheupperballjointintotheknuckle(1)and tightenthenutto75N·m(55ft.lbs.).
9.Installthediscbrakerotor.
10.Installthecaliperadaptormountingboltsto176N·m(130ft.lbs.).
11.Installthetireandwheelassembly. 12.Lowerthevehicle.
1.Removetheshock(Referto2-SUSPENSION/ FRONT/SHOCK-REMOVAL).
2.InstalltheshockassemblyintheBranick7200 springremoval/installationtoolorequivalent(1).
3.Compressthespring(2).
4.Removetheuppershocknut(2).
NOTE:Thenub(1)intheuppershockmount(3) mustbe180°fromthecenterlineofthelower bracket(9)ontheshock(8)forproperinstallation.
5.Removetheshock(8).
6.Removetheshockuppermountingplate(3).
7.Removeandinspecttheupper(5)andlower(7) springisolators.
1.Compressthespring(2).
2.Installthelowerisolator(7).
3.Positiontheshock(8)intothecoilspring(6) make surethejouncebumper(4)isontheshockrod
4.Installtheupperisolator(5).
NOTE:Forproperorientationthenubhole(1)in theuppershockplate(3)mustbe180°inacenterlinefromthebracket(9)atthebottomofthe shock(8).
5.Installtheuppershockmountingplate(3).
6.Installtheshockuppermountingnut(2)Tightento 39N·m(25ft.lbs.).
7.Decompressthespring.
8.Removetheshockassemblyfromthespringcompressortool(1).
9.Installtheshockassembly(Referto2-SUSPENSION/FRONT/SHOCK-INSTALLATION).
Thebarextendsacrossthefrontundersideofthechassisandismountedtothecradle.Linksareconnectedfrom thebartothelowercontrolarms.Thestabilizerbarandlinksareisolatedbyrubberbushings.
Thestabilizerbarisusedtocontrolvehiclebodyswayduringturns.Thespringsteelbarhelpstocontrolthevehicle bodyinrelationshiptothesuspension.
1.Raiseandsupportthevehicle.
2.Removethefrontsplashshield.
3.Removethestabilizerbarlinkuppernut(1)&bolt (2).
4.Removethetwostabilizerbushingclampbolts(2).
5.Removethestabilizerbar(1).
1.Installthestabilizerbar(1)tothevehicle.
2.Installthestabilizerbushingclamp(2)andtighten theboltsto142N·m(105ft.lbs.).
3.Installtheupperstabilizerlink(3)andtightennut (1)&bolt(2)to135N·m(100ft.lbs.).
4.Installthefrontsplashshield.
5.Lowerthevehicle.
1.Raiseandsupportthevehicle.
2.Removethetireandwheelassembly.
3.Removetheupperlinkbolt/nut(1&2).
4.Removethelowerlinkbolt(6).
5.Removethestabilizerlink(3).
1.Installthestabilizerlink(3)tothevehicle.
2.Installthelowerlinkbolt(6)andtightento115N·m (85ft.lbs.)
3.Installtheupperlinkbolt/nut(1&2)andtightento 135N·m(100ft.lbs.).
4.Installthetireandwheelassembly.
5.lowerthevehicle.
UPPERBALLJOINT
1.Raisethefrontofthevehicle.Placesafetyfloor standsunderbothlowercontrolarmsasfaroutboardaspossible.Lowerthevehicletoallowthe standstosupportsomeorallofthevehicleweight.
2.Removethefronttires.
3.Mountadialindicator(1)solidlytotheframeand thenzerothedialindicator.
4.Positiondialindicatorplungeronthetopsideofthe upperballjoint(5).
NOTE:Thedialindicatorplungermustbeperpendiculartothemachinedsurfaceoftheballjoint.
NOTE:Usecarenottopryorteartheballjoint boot,whencheckingthefreeplay.
5.Positionaprybar(3)betweenthesteeringknuckle(4)andtheuppercontrolarm(2).Pryupwardsontheupper controlarm.
6.Ifthetravelexceeds0.5mm(0.020in.),replacetheupperballjoint(Referto2-SUSPENSION/FRONT/UPPER BALLJOINT-REMOVAL).
7.Iftheupperballjointiswithinspecsreinstallthefronttires(Referto22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).
1.Raisevehicleandsupporttheaxle.
2.Removethetireandwheel.
3.Removetheupperballjointretainingnut.
4.Separatetheupperballjoint(2)fromtheknuckle (3)usingspecialtool#8677(1).
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5.Removethewheelspeedsensorwirefromthe uppercontrolarm(1).
6.Movetheknuckle(3)outofthewaytoallowball jointremovaltoolaccess.
NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsure properoperationduringtheremovalandinstallationprocess.
7.Presstheballjointfromtheuppercontrolarm(1) usingspecialtoolsC-4212-F(PRESS)(2)and 9652(Driver)(3).
NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsure properoperationduringtheremovalandinstallationprocess.
1.Installtheballjoint(4)intotheuppercontrolarm (5)andpressinusingspecialtoolsC-4212-F (press)(2),9652(Driver)(1)and8975–2 (Receiver)(4).
2.Installtheupperballjoint(2)intotheknuckle(3).
3.Installtheupperballjointretainingnut(4)and tightento75N·m(55ft.lbs.).
4.Installthewheelspeedsensorwiretotheupper controlarm.
5.Installthetireandwheel.
6.Removethesupportsandlowerthevehicle.
7.Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).
DESCRIPTION
Theuppersuspensionarmsareforgedsteelanduserubberbushingsateachendofthearm.
OPERATION
Thearmsmounttotheunibodyframerailbracketandtheknuckle.Thearmandbushingsprovidelocationand reacttoloadsfromtheroad.Thebushingsprovideisolationfromtheroad.
1.Raisevehicleandsupporttheaxle.
2.Removethetireandwheel.
3.Removetheinnerfenderwell(2).
4.Removetheupperballjointretainingnut.
5.Seperatetheupperballjoint(2)fromtheknuckle (3)usingspecialtool#8677(1).
6.Removethewheelspeedsensorwirefromthe uppercontrolarm(5).
7.Removethenutandbolt(1)securingtheupper controlarm(5)tothebody.
8.Removetheuppercontrolarm(5)fromthevehicle.
1.Installtheuppercontrolarm(5)tothevehicle.
2.Installthenutandbolt(1)securingtheuppercontrolarm(5)tothebody.
3.Installthewheelspeedsensorwiretotheupper controlarm(5).
4.Installtheupperballjoint(2)intotheknuckle(3).
5.Installtheupperballjointretainingnut(4)and tightenthenutto81N·m(60ft.lbs.).
6.Installtheinnerfenderwell(2).
7.Installthetireandwheel.
8.Removethesupportsandlowerthevehicle.
9.Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).
1.Raiseandsupportthevehicle.
2.Removethetire.
3.Removethetwobrakecaliperadapterbolts(3).
4.Supportthebrakecaliperadaptorandcaliper. Do notallowthecalipertohangbythebrakehose.
5.Removethediscbrakerotor.
6.Removetheupperballjointnut(4).
7.Separatetheupperballjoint(2)fromtheknuckle (3)usingspecialtool8677.
8.Removetheclevisbolt(2)attheshock(1).
9.Removethelowerclevisbolt/nut(4)atthelower controlarm.
10.Removethelowerstabilizerlinkbolt(6).
11.Removetheclevisbracket(3).
1.Installtheclevisbracket(3)totheshock(1)and tightento122N·m(90ft.lbs.)..
2.Installthelowerstabilizerlinkbolt(6)andtightento 115N·m(85ft.lbs.)..
3.Installthelowerclevisbolt/nut(4)atthelowercontrolarmandtightento169N·m(125ft.lbs.)..
4.Installtheupperballjoint(2)intotheknuckle(3) andtightenthenutto75N·m(55ft.lbs.).
5.Installthediscbrakerotor.
6.Installthecaliperadaptormountingbolts(3)to25 N·m(18ft.lbs.).
7.Installthetireandwheelassembly.
8.Lowerthevehicle.
DESCRIPTION
Therearsuspensioniscomprisedof:
• Driveaxle
• Shockabsorbers
• Coilsprings
• Lowersuspensionarms(3)
• Uppersuspensionarm
• Stabilizerbar
CAUTION:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleat normalrideheight.Itisimportanttohavethespringssupportingtheweightofthevehiclewhenthefastenersaretorqued.Thiswillmaintainvehicleridecomfortandpreventprematurebushingwear.
WARNING
WARNING:Suspensioncomponentswithrubberbushingsmustbetightenedwiththevehicleatnormalride height.Itisimportanttohavethespringssupportingtheweightofthevehiclewhenthefastenersare torqued.Ifspringsarenotattheirnormalrideposition,vehicleridecomfortwillbeaffectedandcause prematurebushingwear.
CONDITIONPOSSIBLECAUSESCORRECTION
VEHICLEINSTABILITY1.Looseorwornwheelbearings.1.Replacewheelbearings.
2.Loose,wornorbentsuspension components.
2.Inspect,tightenorreplacecomponents asnecessary.
3.Tirepressure.3.Adjusttirepressure.
VEHICLEPULLSTOONE SIDE
KNOCKING,RATTLING ORSQUEAKING
1.Weakorbrokenspring.1.Replacespring.
2.Alignment.2.Alignvehicletospecifications. 3.Tires.3.Replacetires.
4.Brakes.4.Repairasnecassary.
1.Wornshockbushings.1.Replaceshock. 2.Looseshockmounting.2.Tightentospecifications.
3.Shockvalve.3.Replaceshock. 4.Weakorbrokenspring.4.Replacespring.
5.Loose,wornorbentsuspension components. 5.Inspect,tightenorreplacecomponents asnecessary.
IMPROPERTRACKING1.Loose,wornorbentsuspension components.
1.Inspect,tightenorreplacecomponents asnecessary.
2.Bentaxle.2.Replaceaxle.
TORQUESPECIFICATIONS
DESCRIPTIONN·mFt.Lbs.In.Lbs. ShockAbsorberUpperBolt9570— ShockAbsorberLowerBolt11585— SuspensionArmsLowerAxleBracketNut210155— SuspensionArmsLowerFrameBracketNut176130— SuspensionArmsUpperAxleBracketNut136100— SuspensionArmsUpperFrameBracketNut12995— TrackBartoAxle190140— TrackBartoRearStructure190140— StabilizerBarRetainerBolts4634— StabilizerLinkNuttoStabilizerBar8865— StabilizerLinktoBody Bolt 10275— JounceBumperBolttoBody5440—
DESCRIPTION
Thelowersuspensionarms(3)aretubularsteeland useavoidedovalbushingatthearmontheaxleside.
Thebushingsprovideisolationfromtheaxle.Thearmsmounttotheunibodyframerailbracketandtheaxlebrackets.Thearmandbushingsprovidelocationandreacttoloads.
1.Raisethevehicleandsupporttherearaxle.
2.Removethefueltank(Referto14-FUELSYSTEM/FUELDELIVERY/FUELTANK-REMOVAL).
3.Removethelowersuspensionarmnut(2)andbolt (1)fromtheaxlebracket.
4.Removethenut(1)andbolt(8)fromtheframerail andremovethelowersuspensionarm(9).
1.Raisethevehicleandsupporttherearaxle.
2.Removethelowersuspensionarmnut(2)andbolt (1)fromtheaxlebracket.
3.Removethenut(1)andbolt(8)fromtheframerail andremovethelowersuspensionarm(9).
LEFTSIDE
NOTE:Alltorquesshouldbedonewithvehicleonthegroundwithfullvehicleweight.
1.Positionthelowersuspensionarm(9)intheframe rail.
2.Installtheframerailbracketbolt(8)andnut(1) tightento176N·m(130ft.lbs.).
3.Positionthelowersuspensionarm(3)intheaxle bracket.
4.Installtheaxlebracketbolt(1)andnut(2)Tighten to210N·m(155ft.lbs.).
5.Installthefueltank(Referto14-FUELSYSTEM/ FUELDELIVERY/FUELTANK-INSTALLATION).
6.Removethesupportsandlowerthevehicle.
NOTE:Alltorquesshouldbedonewithvehicleonthegroundwithfullvehicleweight.
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1.Positionthelowersuspensionarm(9)intheframe rail.
2.Installtheframerailbracketbolt(8)andnut(1) tightento176N·m(130ft.lbs.).
3.Positionthelowersuspensionarm(3)intheaxle bracket.
4.Installtheaxlebracketbolt(1)andnut(2)Tighten to210N·m(155ft.lbs.).
5.Removethesupportsandlowerthevehicle.
DESCRIPTION
Thesuspensionarmusesbushingstoisolateroadnoise.Thesuspensionarmisboltedthroughbushingstoa bracketatthebodyandaxle.
Theuppersuspensionarmprovidesfore/aftandlaterallocationoftherearaxle.Thesuspensionarmtravelislimitedthroughtheuseofjouncebumpersincompressionandshockabsorbersinrebound.
1.Raiseandsupportthevehicle.
2.Supporttherearaxle.
3.Lowerthefueltankinordertogainaccesstothebolt(Referto14-FUELSYSTEM/FUELDELIVERY/FUEL TANK-REMOVAL).
4.Removetheuppersuspensionarmnut(2)andbolt (3)fromtheaxlebracket.
5.Removethenut(1)andbolt(5)fromtheframerail andremovetheuppersuspensionarm(2).
1.Raiseandsupportthevehicle.
2.Supporttherearaxle.
3.Removetheuppersuspensionarmnut(2)andbolt (3)fromtheaxlebracket.
4.Removethenut(1)andbolt(5)fromtheframerail andremovetheuppersuspensionarm(2).
LEFTSIDE
NOTE:Alltorquesshouldbedonewithvehicleonthegroundwithfullvehicleweight.
1.Positiontheuppersuspensionarm(2)intheframe railbracket.
2.Installthemountingbolt(5)andnut(1)tightento 129N·m(95ft.lbs.).
3.Positiontheuppersuspensionarm(4)intheaxle bracket.
4.Installthemountingbolt(3)andnut(2)tightento 136N·m(100ft.lbs.).
5.Raisethefueltankbackintoplaceandsecure (Referto14-FUELSYSTEM/FUELDELIVERY/ FUELTANK-INSTALLATION).
6.Removethesupportsandlowerthevehicle.
RIGHTSIDE
NOTE:Alltorquesshouldbedonewithvehicleonthegroundwithfullvehicleweight.
1.Positiontheuppersuspensionarm(2)intheframe railbracket.
2.Installthemountingbolt(5)andnut(1)tightento 129N·m(95ft.lbs.).
3.Positiontheuppersuspensionarm(4)intheaxle bracket.
4.Installthemountingbolt(3)andnut(2)tightento 136N·m(100ft.lbs.).
5.Removethesupportsandlowerthevehicle.
Thetopoftheshockabsorbersareboltedtothebody.Thebottomoftheshocksareboltedtotheaxlebrackets. Thestandardshockshaveconventionaltwintubeconstructionandarelowpressuregascharged.Gascharging preventscavitationduringroughroadoperation.
Theshockabsorbersdampenjounceandreboundmotionofthevehicleovervariousroadconditionsandlimitsuspensionreboundtravel.
1.Raiseandsupportthevehicle.Positionahydraulic jackundertheaxletosupporttheaxle.
2.Removetheuppernutandbolt(1)fromtheframe bracket.
3.Removethelowernutandboltfromtheaxle bracket(2).Removetheshockabsorber(1).
1.Installtheshockabsorber(2)intheframebracket andinstallthebolt(1)andnut.
2.Installtheshockabsorber(1)intheaxlebracket (2)andinstalltheboltandnut.
3.Tightentheuppermountingnutsto95N·m(70ft. lbs.).Tightenthelowermountingnutsto115N·m (85ft.lbs.).
4.Removethesupportsandlowerthevehicle.
Thecoilspringsmountupinthewheelhousewhichispartoftheunitizedbodybracket.Arubberdoughnutisolator islocatedbetweenthetopandbottomofthespring.Theisolatorsprovideroadnoiseisolation
Thecoilspringscontrolridequalityandmaintainproperrideheight.
1.Raiseandsupportthevehicle.Positionahydraulic jackundertheaxletosupporttheaxle.
2.Removethewheelandtireassemblies.
3.Removethelowershockbolt(3)fromtheaxle bracket.
4.Removethestabilizerbarlinkfromthebodyrail.
5.Lowerthehydraulicjackandtilttheaxleand removethecoilspring(4).
6.Removeandinspectthespringisolators.
1.Installtheupperisolator.
2.Installthelowerisolator(3).
3.Pulldownontheaxleandpositionthecoilspring (1)inthelowerisolator.
4.Raisetheaxlewiththehydraulicjack.
5.Installtheshockabsorber(3)totheaxlebracket andtightento115N·m(85ft.lbs.).
6.Installthestabilizerbarlinktothebodyrail,tighten to102N·m(75ft.lbs.).
7.Installthewheelandtireassemblies.
8.Removethesupportsandlowerthevehicle.
1.Raiseandsupportthevehicle.Positionahydraulic jackundertheaxletosupporttheaxle.
2.Removethewheelandtireassemblies.
3.Removethelowershockbolt(3)fromtheaxle bracket.
4.Removethestabilizerbarlinkfromthebodyrail.
5.Lowerthehydraulicjackandtilttheaxleand removethecoilspring(4).
6.Removethejouncebumper(6).
1.Installthejouncebumper,Tightento54N·m(40ft.lbs.).
2.Installtheupperisolator.
3.Installthelowerisolator(1).
4.Pulldownontheaxleandpositionthecoilspring inthelowerisolator.
5.Raisetheaxlewiththehydraulicjack.
6.Installtheshockabsorbertotheaxlebracketand tightento115N·m(85ft.lbs.)..
7.Installthestabilizerbarlinktothebodyrail,Tighten to102N·m(75ft.lbs.).
8.Installthewheelandtireassemblies.
9.Removethesupportsandlowerthevehicle.
Thestabilizerbarextendsacrossthefrontoftherearaxle.Linksareconnectedbetweenthebarandframerail.The stabilizerbarhasabushingatthebodyattachmentandaballjointatthestabilizerbarattachment.
Thestabilizerbarisusedtocontrolvehiclebodyroll,duringturns.Thebarhelpscontrolthevehiclebodyinrelationshiptothesuspension.
1.Raiseandsupportthevehicle.
2.Removebothreartireassemblies.
3.Removethestabilizerbarlinksfromstabilizerbar.
4.Removethestabilizerbarretainerboltsfromthe retainer(2).
5.Removethestabilizerbar(1)bytwistingitoutand aroundtherotorandcaliperfromtherightrearside ofthevehicle.
1.Twistandrotatetopositionthestabilizerbar(1)on theaxlefromtherightrearsideofthevehicle.
2.Installtheretainers(2)andbolts.Ensurethebaris centeredwithequalspacingonbothsides.Tighten theboltsto54N·m(40ft.lbs.).
3.Installthelinkstothestabilizerbar.
4.Tightenthenutsatthestabilizerbarto88N·m(65ft.lbs.).
5.Installthetireandwheelassemblies.
6.Removesupportandlowerthevehicle.
1.Raiseandsupportthevehicle.
2.Removethereartire.
3.Supporttherearaxlewithajack.
4.Removetheupperlinkboltattheframe.
5.Removethelowerlinknutatthestabilizerbar.
6.Removestabilizerlink.
1.Installtheupperboltforthestabilizerlinktotheframeandtightento102N·m(75ft.lbs.).
2.Installthestabilizerlinktothestabilizerbar.
3.Installthenutandtightento88N·m(65ft.lbs.).
4.Removethejackandlowerthevehicle.
1.Raiseandsupportvehicle.
2.Removethestabilizerbushingclamp.
3.Removethebushingfromthestabilizerbar.
1.Installthebushingtothestabilizerbar.
2.Installthestabilizerbarbushingclampandbolts.Tightentheboltsto46N·m(34ft.lbs.).
3.Lowerthevehicle.
1.Raiseandsupportthevehicle.Positionahydraulic jackundertheaxletosupporttheaxle.
2.Removethetrackbarbolt(3)andnut(2)fromthe framebracket.
3.Removetheleftlowershockboltattheaxle.
4.Pryinbetweenthecoilspringstoremovetrackbar bolt.
5.Removethetrackbarbolt(3)andnut(2)fromthe axlebracket.
1.Installthetrackbar(1)tothevehicle.
2.Pryinbetweenthecoilspringstoinstalltrackbar bolt(3).
3.Installthetrackbarbolt(3)andnut(2)intheframe bracket.
4.Installthetrackbar(1)intotheaxlebracket.
5.Installthetrackbarbolt(3)andnut(2)intheaxle bracket.
6.InstalltheleftlowershockbolttotheaxleTighten to115N·m(85ft.lbs.).
7.Removethesupportsandlowerthevehicle.
8.Tightentheuppermountingnutsto190N·m(140 ft.lbs.).Tightenthelowermountingnutsto190 N·m(140ft.lbs.). withfullvehicleweight.
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DIFFERENTIAL&DRIVELINE-ELECTRICAL DIAGNOSTICS ...........................1
DIFFERENTIAL&DRIVELINE-ELECTRICAL DIAGNOSTICS
DIAGNOSISANDTESTING
C1417–FRONTDIFFERENTIALCONTROL CIRCUITLOW .........................2
C1418–FRONTDIFFERENTIALCONTROL CIRCUITHIGH .........................6
C141A-FRONTDIFFERENTIALCONTROL CIRCUIT“CURRENT”PERFORMANCE ......9
C141B—FRONTDIFFERENTIALCLUTCH PERFORMANCE ......................11
C141D–REARDIFFERENTIALCONTROL CIRCUITLOW ........................14
C141E–REARDIFFERENTIALCONTROL CIRCUITHIGH ........................18
C1420—REARDIFFERENTIALCONTROL CIRCUIT“CURRENT”PERFORMANCE .....21
C1421—REARDIFFERENTIALCLUTCH PERFORMANCE ......................23
C2109–DRIVETRAINSUPPLYVOLTAGE CIRCUITLOW ........................26
DIFFERENTIAL&DRIVELINE-ELECTRICALDIAGNOSTICS
DIAGNOSISANDTESTING
C1417–FRONTDIFFERENTIALCONTROLCIRCUITLOW(CONTINUED)
Foracompletewiringdiagram RefertoSection8W
• WhenMonitored:
TheSolenoidisactive,nosolenoidsupplycircuitDTCsarepresentandbatteryvoltageisnormal.
• SetCondition:
TheFDCMdetectstheFrontDifferentialSolenoidControlisshortedlow.
FRONTDIFFERENTIALSOLENOID
(T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTOGROUND (T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITOPEN (T301)SWITCHEDBATTERYSOLENIODSUPPLYOPEN/SHORTEDTOGROUND FDCM
1. ACTIVEDTC
Ignitionon,enginenotrunning.
WiththeDRBIII ,readDTCs.
IstheDTCactiveatthistime?
Yes >> GoTo2
No >> GoTo8
2. FRONTDIFFERENTIALSOLENOIDOPERATION
Turntheignitionoff.
DisconnecttheFrontDifferentialSolenoidharnessconnector. Ignitionon,enginenotrunning.
Usinga12-volttestlight,jumpacrossfromthe(T301)SwitchBatterySolenoidSupplycircuitandthe(T306)Front DifferentialSolenoidControlcircuitintheFrontDifferentialSolenoidharnessconnector. WiththeDRBIII ,actuatetheFrontDifferentialSolenoid.
Doesthetestlightilluminatebrightlyandflashonandoff?
Yes >> InspecttheFrontDifferentialSolenoidJumperharness,repair/replaceasnecessary.IfOK,replacethe FrontDifferentialSolenoid.
PerformFDCMVERIFICATIONTEST.
No >> GoTo3
C1417–FRONTDIFFERENTIALCONTROLCIRCUITLOW(CONTINUED)
3. (T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTOGROUND Turntheignitionoff.
DisconnecttheFDCMharnessconnector.
Measuretheresistanceofthe(T306)FrontDifferentialSolenoidControlcircuitattheFDCMharnessconnectorto ground.
Istheresistancebelow100ohms?
Yes >> RepairtheshorttogroundintheFrontDifferentialSolenoidControlcircuit. PerformFDCMVERIFICATIONTEST.
No >> GoTo4
4. (T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITOPEN
Measuretheresistanceofthe(T306)FrontDifferentialSolenoidControlcircuitbetweentheFrontDifferentialSolenoidharnessconnectorandtheFDCMharnessconnector.
Istheresistancebelow5.0ohms?
Yes >> GoTo5
No >> Repairtheopeninthe(T306)FrontDifferentialSolenoidControlcircuit. PerformFDCMVERIFICATIONTEST
5. (T301)SWITCHEDBATTERYSOLENOIDSUPPLYCIRCUITSHORTEDTOGROUND
Measuretheresistanceofthe(T301)SwitchedBatterySolenoidSupplycircuitattheFDCMharnessconnectorto ground.
Istheresistancebelow100ohms?
Yes >> Repairtheshorttogroundinthe(T301)SwitchedBatterySolenoidSupplycircuit. PerformFDCMVERIFICATIONTEST.
No >> GoTo6
Measuretheresistanceofthe(T301)SwitchedBatterySolenoidSupplycircuitbetweentheFrontDifferentialSolenoidharnessconnectorandtheFDCMharnessconnector.
Istheresistancebelow5.0ohms?
Yes >> GoTo7
No >> Repairtheopeninthe(T301)SwitchedBatterySolenoidSupplycircuit. PerformFDCMVERIFICATIONTEST
GoTo7
NOTE:Beforecontinuing,checktheFDCMharnessconnectorterminalsforcorrosion,damage,orterminal pushout.Repairasnecessary.
Usingtheschematicsasaguide,inspectthewireharnessandconnectors.PayparticularattentiontoallPowerand Groundcircuits.
Werethereanyproblemsfound?
Yes >> Repairasnecessary.
PerformFDCMVERIFICATIONTEST
No >> ReplaceandprogramtheFinalDriveControlModuleinaccordancewithServiceInformation. PerformFDCMVERIFICATIONTEST.
TheconditionsnecessarytosetthisDTCarenotpresentatthistime. Usingtheschematicsasaguide,inspectthewiringandconnectorsspecifictothiscircuit. Wiggletestthewiringharnessandconnectorswhilecheckingforshortedandopencircuits.
UsingtheDRBIII ,monitorthedatarelatedtothiscircuitwhileperformingthewiggletest.Lookforthedatato changeorfortheDTCtoreset.
Werethereanyproblemsfound?
Yes >> Repairasnecessary. PerformFDCMVERIFICATIONTEST.
No >> TestComplete.
C1418–FRONTDIFFERENTIALCONTROLCIRCUITHIGH(CONTINUED)
Foracompletewiringdiagram RefertoSection8W
• WhenMonitored:
TheSolenoidisactive,nosolenoidsupplycircuitDTCsarepresentandbatteryvoltageisnormal.
• SetCondition: TheFDCMdetectstheFrontDifferentialSolenoidControlishigh.
FRONTDIFFERENTIALSOLENOID
(T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTOBATTERYVOLTAGE
(T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTO(T301)SWITCHEDBATTERY SOLENOIDSUPPLYCIRCUIT
FDCM
1. ACTIVEDTC
Ignitionon,enginenotrunning. WiththeDRBIII ,readDTCs.
IstheDTCactiveatthistime?
Yes >> GoTo2
No >> GoTo6
2. FRONTDIFFERENTIALSOLENOIDOPERATION
Turntheignitionoff.
DisconnecttheFrontDifferentialSolenoidharnessconnector. Ignitionon,enginenotrunning.
Usinga12-volttestlight,jumpacrossfromthe(T306)FrontDifferentialSolenoidControlcircuitandthe(T301) SwitchedBatterySolenoidSupplycircuitintheFrontDifferentialSolenoidharnessconnector. WithaDRBIII ,actuatetheFrontDifferentialSolenoid.
Doesthetestlightflashonandoff?
Yes >> InspecttheFrontDifferentialSolenoidJumperharnessconnector,repair/replaceasnecessary.IfOK, replacetheFrontDifferentialSolenoid. PerformFDCMVERIFICATIONTEST.
No >> GoTo3
3. (T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTOBATTERYVOLTAGE Turntheignitionoff. DisconnecttheFDCMharnessconnector. Turntheignitionon.
Measurethevoltageonthe(T306)FrontDifferentialSolenoidControlcircuitattheFDCMharnessconnector.
Doesthevoltmeterindicatevoltagepresent?
Yes >> Repairtheshorttovoltageinthe(T306)FrontDifferentialSolenoidControlcircuit. PerformFDCMVERIFICATIONTEST.
No >> GoTo4
4. (T306)FRONTDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTO(T301)SWITCHED BATTERYSOLENOIDSUPPLYCIRCUIT
Measuretheresistancebetweenthe(T306)FrontDifferentialSolenoidControlcircuitandthe(T301)SwitchedBatterySolenoidSupplycircuitintheFDCMharnessconnector.
Istheresistancebelow100ohms?
Yes >> Repairtheshortbetweenthe(T306)FrontDifferentialSolenoidControlcircuitandthe(T301)Switched BatterySolenoidSupplycircuit.
PerformFDCMVERIFICATIONTEST
No >> GoTo5
5. FDCM
NOTE:Beforecontinuing,checktheFDCMharnessconnectorterminalsforcorrosion,damage,orterminal pushout.Repairasnecessary. Usingtheschematicsasaguide,inspectthewireharnessandconnectors.PayparticularattentiontoallPowerand Groundcircuits.
Werethereanyproblemsfound?
Yes >> Repairasnecessary.
PerformFDCMVERIFICATIONTEST
No >> ReplaceandprogramtheFinalDriveControlModuleinaccordancewithServiceInformation. PerformFDCMVERIFICATIONTEST.
TheconditionsnecessarytosetthisDTCarenotpresentatthistime. Usingtheschematicsasaguide,inspectthewiringandconnectorsspecifictothiscircuit. Wiggletestthewiringharnessandconnectorswhilecheckingforshortedandopencircuits. UsingtheDRBIII ,monitorthedatarelatedtothiscircuitwhileperformingthewiggletest.Lookforthedatato changeorfortheDTCtoreset.
Werethereanyproblemsfound?
Yes >> Repairasnecessary.
PerformFDCMVERIFICATIONTEST.
No >> TestComplete.
C141A-FRONTDIFFERENTIALCONTROLCIRCUIT“CURRENT”PERFORMANCE(CONTINUED)
Foracompletewiringdiagram RefertoSection8W
• WhenMonitored: Theignitionon.NoSolenoidDTCspresent.
• SetCondition: TheFDCMdetectsacurrentfeedbackwhenthesolenoidisnotactive.
WIRINGHARNESSINSPECTION
FDCM
1. ACTIVEDTC
NOTE:YoumustdiagnoseanySolenoidcircuit(LoworHigh)DTCsfirstifsetalongwiththisDTCbefore continuing. Ignitionon,enginenotrunning. WiththeDRBIII ,readDTCs.
IstheDTCactiveatthistime?
Yes >> GoTo2 No >> GoTo3
InspectthewiringharnessfrombothsolenoidstotheFDCM.Ensurethattheharnesshasroutedcorrectly. InspecttheFDCMharnessconnectorandDifferentialSolenoidconnectors.Ensuretheterminalsarecleanandno damageispresent.
WasthewiringharnessandconnectorsOK?
Yes >> Repairasnecessary. PerformFDCMVERIFICATIONTEST. No >> ReplacetheFDCMinaccordancewiththeServiceManual. PerformFDCMVERIFICATIONTEST.
TheconditionsnecessarytosetthisDTCarenotpresentatthistime. Usingtheschematicsasaguide,inspectthewiringandconnectorsspecifictothiscircuit. Wiggletestthewiringharnessandconnectorswhilecheckingforshortedandopencircuits. UsingtheDRBIII ,monitorthedatarelatedtothiscircuitwhileperformingthewiggletest.Lookforthedatato changeorfortheDTCtoreset.
Werethereanyproblemsfound?
Yes >> Repairasnecessary. PerformFDCMVERIFICATIONTEST. No >> TestComplete.
C141B—FRONTDIFFERENTIALCLUTCHPERFORMANCE(CONTINUED)
Foracompletewiringdiagram RefertoSection8W
• WhenMonitored: Theignitionon.NoSolenoidDTCspresent.
• SetCondition: Thesolenoiddutycycleisgreaterthan95%andthewheelslippageisgreaterthan50%.
WIRINGHARNESSINSPECTION
DIFFERENTIAL(MECHANICAL)
FRONTDIFFERENTANTIALSOLENOID
1. ACTIVEDTC
NOTE:YoumustdiagnoseanySolenoidcircuit(LoworHigh)DTCsfirstifsetalongwiththisDTCbefore continuing. Ignitionon,enginenotrunning. WiththeDRBIII ,readDTCs.
IstheDTCactiveatthistime?
Yes >> GoTo2 No >> GoTo4
InspectthewiringharnessfrombothsolenoidstotheFDCM.Ensurethattheharnesshasroutedcorrectly. InspecttheFDCMharnessconnectorandDifferentialSolenoidconnectors.Ensuretheterminalsarecleanandno damageispresent.
WasthewiringharnessandconnectorsOK?
Yes >> Repairasnecessary. PerformFDCMVERIFICATIONTEST. No >> GoTo3 PerformFDCMVERIFICATIONTEST.
EnsuretheDifferentialisoperatingproperly.Referto3–Differential&DrivelineServiceInformation. InspecttheDifferentialforexternalfluidleaks.Repairasnecessary,referto3–Differential&DrivelineServiceInformation.
IstheDifferentialoperatingproperly?
Yes >> ReplacetheFrontDifferentialSolenoid. PerformFDCMVERIFICATIONTEST. No >> Repairasnecessary. PerformFDCMVERIFICATIONTEST.
TheconditionsnecessarytosetthisDTCarenotpresentatthistime. Usingtheschematicsasaguide,inspectthewiringandconnectorsspecifictothiscircuit. Wiggletestthewiringharnessandconnectorswhilecheckingforshortedandopencircuits.
UsingtheDRBIII ,monitorthedatarelatedtothiscircuitwhileperformingthewiggletest.Lookforthedatato changeorfortheDTCtoreset.
Werethereanyproblemsfound?
Yes >> Repairasnecessary. PerformFDCMVERIFICATIONTEST. No >> TestComplete.
C141D–REARDIFFERENTIALCONTROLCIRCUITLOW(CONTINUED)
Foracompletewiringdiagram RefertoSection8W
• WhenMonitored:
TheSolenoidisactive,nosolenoidsupplycircuitDTCsarepresentandbatteryvoltageisnormal.
• SetCondition: TheFDCMdetectstheRearDifferentialSolenoidControlisshortedlow.
REARDIFFERENTIALSOLENOID
(T312)REARDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTOGROUND (T312)REARDIFFERENTIALSOLENOIDCONTROLCIRCUITOPEN (T301)SWITCHEDBATTERYSOLENIODSUPPLYOPEN/SHORTEDTOGROUND FDCM
1. ACTIVEDTC
Ignitionon,enginenotrunning.
WiththeDRBIII ,readDTCs.
IstheDTCactiveatthistime?
Yes >> GoTo2
No >> GoTo8
2. REARDIFFERENTIALSOLENOIDOPERATION
Turntheignitionoff.
DisconnecttheRearDifferentialSolenoidharnessconnector. Ignitionon,enginenotrunning.
Usinga12-volttestlight,jumpacrossfromthe(T301)SwitchBatterySolenoidSupplycircuitandthe(T312)Rear DifferentialSolenoidControlcircuitintheRearDifferentialSolenoidharnessconnector.
WiththeDRBIII ,actuatetheRearDifferentialSolenoid.
Doesthetestlightilluminatebrightlyandflashonandoff?
Yes >> InspecttheRearDifferentialSolenoidJumperharness,repair/replaceasnecessary.IfOK,replacethe RearDifferentialSolenoid.
PerformFDCMVERIFICATIONTEST.
No >> GoTo3
C141D–REARDIFFERENTIALCONTROLCIRCUITLOW(CONTINUED)
3. (T312)REARDIFFERENTIALSOLENOIDCONTROLCIRCUITSHORTEDTOGROUND Turntheignitionoff. DisconnecttheFDCMharnessconnector.
Measuretheresistanceofthe(T312)RearDifferentialSolenoidControlcircuitattheFDCMharnessconnectorto ground.
Istheresistancebelow100ohms?
Yes >> RepairtheshorttogroundintheRearDifferentialSolenoidControlcircuit. PerformFDCMVERIFICATIONTEST.
No >> GoTo4
4. (T312)REARDIFFERENTIALSOLENOIDCONTROLCIRCUITOPEN
Measuretheresistanceofthe(T312)RearDifferentialSolenoidControlcircuitbetweentheRearDifferentialSolenoidharnessconnectorandtheFDCMharnessconnector.
Istheresistancebelow5.0ohms?
Yes >> GoTo5
No >> Repairtheopeninthe(T312)RearDifferentialSolenoidControlcircuit. PerformFDCMVERIFICATIONTEST
5. (T301)SWITCHEDBATTERYSOLENOIDSUPPLYCIRCUITSHORTEDTOGROUND
Measuretheresistanceofthe(T301)SwitchedBatterySolenoidSupplycircuitattheFDCMharnessconnectorto ground.
Istheresistancebelow100ohms?
Yes >> Repairtheshorttogroundinthe(T301)SwitchedBatterySolenoidSupplycircuit. PerformFDCMVERIFICATIONTEST.
No >> GoTo6
Measuretheresistanceofthe(T301)SwitchedBatterySolenoidSupplycircuitbetweentheRearDifferentialSolenoidharnessconnectorandtheFDCMharnessconnector.
Istheresistancebelow5.0ohms?
Yes >> GoTo7
No >> Repairtheopeninthe(T301)SwitchedBatterySolenoidSupplycircuit. PerformFDCMVERIFICATIONTEST
GoTo7
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