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FASTENERIDENTIFICATION

DESCRIPTION

TheSAEboltstrengthgradesrangefromgrade2 tograde8.Thehigherthegradenumber,thegreater theboltstrength.Identificationisdeterminedbythe linemarksonthetopofeachbolthead.Theactual boltstrengthgradecorrespondstothenumberofline

marksplus2.Themostcommonlyusedmetricbolt strengthclassesare9.8and10.9.Themetric strengthclassidentificationnumberisimprintedon theheadofthebolt.Thehighertheclassnumber, thegreatertheboltstrength.Somemetricnutsare imprintedwithasingle-digitstrengthclassonthe nutface.RefertotheFastenerIdentificationand FastenerStrengthCharts(Fig.1).

FASTENERUSAGE

DESCRIPTION

WARNING:Useofanincorrectfastenermayresult incomponentdamageorpersonalinjury.

Fastenersandtorquespecificationsreferencesin thisServiceManualareidentifiedinmetricandSAE format.

Duringanymaintenanceorrepairprocedures,itis importanttosalvageallfasteners(nuts,bolts,etc.) forreassembly.Ifthefastenerisnotsalvageable,a fastenerofequivalentspecificationmustbeused.

DESCRIPTION

Moststrippedthreadedholescanberepairedusing aHelicoil .FollowthevehicleorHelicoil recommendationsforapplicationandrepairprocedures.

INTERNATIONALSYMBOLS

DESCRIPTION

Thegraphicsymbolsillustratedin(Fig.2)andthe followingInternationalControlandDisplaySymbols Chartareusedtoidentifyvariousinstrumentcontrols.Thesymbolscorrespondtothecontrolsanddisplaysthatarelocatedontheinstrumentpanel.

METRICSYSTEM

DESCRIPTION

Themetricsystemisbasedonquantitiesofone, ten,onehundred,onethousandandonemillion.

Thefollowingchart(Fig.3)willassistinconvertingmetricunitstoequivalentEnglishandSAE units,orviseversa.

Fig.2INTERNATIONALCONTROLANDDISPLAYSYMBOLS

1HighBeam13RearWindowWasher 2FogLamps14Fuel 3Headlamp,ParkingLamps,PanelLamps15EngineCoolantTemperature 4TurnWarning16BatteryChargingCondition 5HazardWarning17EngineOil 6WindshieldWasher18SeatBelt 7WindshieldWiper19BrakeFailure 8WindshieldWiperandWasher20ParkingBrake 9WindscreenDemistingandDefrosting21FrontHood 10VentilatingFan22Rearhood(Decklid) 11RearWindowDefogger23Horn 12RearWindowWiper24Lighter

Fig.3METRICCONVERSIONCHART

CONVERSIONFORMULASANDEQUIVALENTVALUES

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)

COMMONMETRICEQUIVALENTS

1inch=25Millimeters1CubicInch=16CubicCentimeters

1Foot=0.3Meter1CubicFoot=0.03CubicMeter

1Yard=0.9Meter1CubicYard=0.8CubicMeter

1Mile=1.6Kilometers

RefertotheMetricConversionChart(Fig.3)to converttorquevalueslistedinmetricNewtonmeters(N·m).Also,usethecharttoconvertbetween millimeters(mm)andinches(in.).

TORQUEREFERENCES

DESCRIPTION

IndividualTorqueChartsappearwithinmanyor theGroups.RefertotheStandardTorqueSpecificationsChart(Fig.4)fortorquereferencesnotlistedin theindividualtorquecharts.

TORQUEREFERENCES(Continued)

Fig.4TORQUESPECIFICATIONS

VEHICLEEMISSIONCONTROL INFORMATION(VECI)LABEL

DESCRIPTION

AllmodelshaveaVehicleEmissionControlInformation(VECI)Label.DaimlerChryslerpermanently attachesthelabelintheenginecompartment(Fig. 5).Thelabelcannotberemovedwithoutdefacing labelinformationanddestroyinglabel.

Thelabelcontainsthevehicle’semissionspecificationsandvacuumhoseroutings.Allhosesmustbe connectedandroutedaccordingtothelabel.

Thelabelalsocontainsanenginevacuumschematic.Thereareuniquelabelsforvehiclesbuiltfor saleinthestateofCaliforniaandthecountryof Canada.Canadianlabelsarewritteninboththe EnglishandFrenchlanguages.

TheVECIlabelcontainsthefollowing:

• Enginefamilyanddisplacement

• Evaporativefamily

• Emissioncontrolsystemschematic

• Certificationapplication

• Enginetimingspecifications(ifadjustable)

• Idlespeeds(ifadjustable)

• Sparkplugandgap

Fig.5VECILABELLOCATION

1-RADIATORSUPPORT

2-VECILABEL

VEHICLEIDENTIFICATION NUMBER

DESCRIPTION

TheVehicleIdentificationNumber(VIN)plateis locatedonthelowerleftA-pillarandisvisible throughthewindshield(Fig.6).TheVINcontains17 charactersthatprovidedataconcerningthevehicle. RefertotheVINdecodingcharttodeterminethe identificationofavehicle.

Fig.6VINNUMBERLOCATION

1-A-PILLAR

2-VINCODEPLATE

TheVehicleIdentificationNumberisalso imprintedonthe:

• VehicleSafetyCertificationLabel.

• Framerail.

Toprotecttheconsumerfromtheftandpossible fraudthemanufacturerisrequiredtoincludea CheckDigitattheninthpositionoftheVehicleIdentificationNumber.Thecheckdigitisusedbythe manufacturerandgovernmentagenciestoverifythe authenticityofthevehicleandofficialdocumentation.Theformulatousethecheckdigitisnot releasedtothegeneralpublic.

VEHICLEIDENTIFICATIONNUMBER(Continued)

VEHICLEIDENTIFICATIONNUMBERDECODINGCHART

POSITIONINTERPRETATIONCODE=DESCRIPTION

1CountryofOrigin1=ManufacturedbyDaimlerChrysler Corporation

2MakeJ=Jeep

3VehicleType4=MPVW/OSideAirbags. 8=MPVWithSideAirbags.

4GrossVehicleWeightRatingF=4001-5000lbs. G=5001-6000lbs.

5VehicleLineK=Liberty4X2(LHD)

L=Liberty4X4(LHD)wihtoutABB M=Cherokee4X4(RHD)

6=Cherokee(LHD)withABB

6Series3=Liberty/Renegade

4=LibertySport/CherokeeSport

5=LibertyLimited/CherokeeLimited

7BodyStyle8=SportUtility-4Door

8EngineK=3.7L6cylMPIGasoline 1=2.4L4cylMPIGasoline 5=2.8L4cylDiesel

9CheckDigit0through9orX

10ModelYear5=2005

11AssemblyPlantW=ToledoNorthAssemblyPlant 12thru17VehicleBuildSequence

VEHICLECERTIFICATION

LABEL

DESCRIPTION

Avehiclecertificationlabel(Fig.7)isattachedto everyDaimlerChryslerCorporationvehicle.Thelabel certifiesthatthevehicleconformstoallapplicable FederalMotorVehicleStandards.Thelabelalsolists:

• Monthandyearofvehiclemanufacture.

• GrossVehicleWeightRating(GVWR).Thegross frontandrearaxleweightratings(GAWR’s)are basedonaminimumrimsizeandmaximumcoldtire inflationpressure.

• VehicleIdentificationNumber(VIN).

• Typeofvehicle.

• Typeofrearwheels.

• Barcode.

• Month,DayandHour(MDH)offinalassembly.

• PaintandTrimcodes.

• Countryoforigin.

Fig.7VEHICLECERTIFICATIONLABEL-TYPICAL

Thelabelislocatedonthedriver-sidedoor shut-face.

LUBRICATION&MAINTENANCE

INTERNATIONALSYMBOLS

DESCRIPTION

Fig.1INTERNATIONALSYMBOLS

DaimlerChryslerCorporationusesinternational symbols(Fig.1)toidentifyenginecompartment lubricantandfluidinspectionandfilllocations.

PARTS&LUBRICANT RECOMMENDATION

DESCRIPTION

LUBRICANTRECOMMENDATIONS

Chassis

ComponentFluid,Lubricant,orGenuinePart SteeringGear &Linkage, BallJoints, PropShafts& Yokes,Wheel Bearings Mopar Multi-PurposeLubricant NLGIGrade2EP,GC-LB

Body

ComponentFluid,Lubricant,andGenuine Part

Hinges:

Door&HoodMopar EngineOil

SwingGateMopar Multi-PurposeLubeNLGI

Latches:Door, Hood/Safety Catch,Swing Gate

SeatRegulator &Track

Grade2EP,GC-LB

Mopar Multi-PurposeLubeNLGI

Grade2EP,GC-LB

Mopar Multi-PurposeLubeNLGI

Grade2EP,GC-LB

LockCylindersMopar LockCylinderLube

FLUIDTYPES

Whenserviceisrequired,DaimlerChryslerCorporationrecommendsthatonlyMopar brandparts, lubricantsandchemicalsbeused.Mopar provides thebestengineeredproductsforservicing DaimlerChryslerCorporationvehicles.

Onlylubricantsbearingdesignationsdefinedby thefollowingorganizationshouldbeusedtoservicea ChryslerCorporationvehicle.

• SocietyofAutomotiveEngineers(SAE)

• AmericanPetroleumInstitute(API)(Fig.2)

• NationalLubricatingGreaseInstitute(NLGI)

APIQUALITYCLASSIFICATION

FLUIDTYPES

DESCRIPTION

ENGINEOIL

WARNING:NEWORUSEDENGINEOILCANBE IRRITATINGTOTHESKIN.AVOIDPROLONGEDOR REPEATEDSKINCONTACTWITHENGINEOIL. CONTAMINANTSINUSEDENGINEOIL,CAUSEDBY INTERNALCOMBUSTION,CANBEHAZARDOUSTO YOURHEALTH.THOROUGHLYWASHEXPOSED SKINWITHSOAPANDWATER.DONOTWASH SKINWITHGASOLINE,DIESELFUEL,THINNER,OR SOLVENTS,HEALTHPROBLEMSCANRESULT.DO NOTPOLLUTE,DISPOSEOFUSEDENGINEOIL PROPERLY.CONTACTYOURDEALERORGOVERNMENTAGENCYFORLOCATIONOFCOLLECTION CENTERINYOURAREA.

Onlylubricantsbearingdesignationsdefinedby thefollowingorganizationshouldbeused.

• SocietyofAutomotiveEngineers(SAE)

• AmericanPetroleumInstitute(API)

• NationalLubricatingGreaseInstitute(NLGI)

• AssociationdesConstructeursEuropéensd’ Automobiles(EuropeanAutomobileManufacturers Association)(ACEA)

APISERVICEGRADECERTIFIED

UseanengineoilthatisAPICertified.MOPAR providesengineoils,thatmeetorexceedthis requirement.

SAEVISCOSITY

AnSAEviscositygradeisusedtospecifytheviscosityofengineoil.Useonlyengineoilswithmultipleviscositiessuchas5W-30or10W-30.Theseare specifiedwithadualSAEviscositygradewhichindicatesthecold-to-hottemperatureviscosityrange. Selectanengineoilthatisbestsuitedtoyourparticulartemperaturerangeandvariation(Fig.3).

ACEACategories

Thissymbolonthefrontofanoilcontainermeans thattheoilhasbeencertifiedbytheAmericanPetroleumInstitute(API)tomeetallthelubrication requirementsspecifiedbyDaimlerChryslerCorporation.

GEARLUBRICANTS

SAEratingsalsoapplytomultigradegearlubricants.Inaddition,APIclassificationdefinesthe lubricantsusage.SuchasAPIGL-5andSAE75W90.

ForcountriesthatusetheACEAEuropeanOil CategoriesforServiceFillOils,useengineoilsthat meettherequirementsofACEAA1/B1,A2/B2,or A3/B3.

ENERGYCONSERVINGOIL

AnEnergyConservingtypeoilisrecommendedfor gasolineengines.ThedesignationofENERGYCONSERVINGislocatedonthelabelofanengineoilcontainer.

CONTAINERIDENTIFICATION

Standardengineoilidentificationnotationshave beenadoptedtoaidintheproperselectionofengine oil.Theidentifyingnotationsarelocatedonthefront labelofengineoilplasticbottlesandthetopof engineoilcans(Fig.4).

Thissymbolmeansthattheoilhasbeencertified bytheAmericanPetroleumInstitute(API). DaimlerChrysleronlyrecommendAPICertified engineoils.UseMopar engineoilorequivalent.

SAEVISCOSITYGRADE

CAUTION:Lowviscosityoilsmusthavetheproper APIqualityortheCCMCG5designation.

Toassureofproperlyformulatedengineoils,itis recommendedthatSAEGrade10W-40engineoils thatmeetChryslermaterialstandardMS-6395,be usedinaccordancetoACEAB3,B4specification. EuropeanGrade10W-40oilsarealsoacceptable.

OilsoftheSAE5W-40gradenumberarepreferred whenminimumtemperaturesconsistentlyfallbelow -15°C.

AXLE

NOTE:DaimlerChryslerrecommendsusingMopar lubricantsorlubricantsofequalquality.

FRONTAXLE

• 186FIA(Model30)-Mopar Lubricant80W-90

REARAXLE

• 81/4-Mopar GearLubricant75W-90(Trailer Towing-Mopar SynthenticGearLubricant75W-140

NOTE:Trac-lok equippedaxlesrequire118ml(4 ounces)ofLimitedSlipAdditivebeaddedtothe lubricant.

MANUALTRANSMISSION

NOTE:DaimlerChryslerrecommendsusingMopar lubricantsorlubricantsofequalquality.

ENGINEOIL-DIESELENGINES

OnlyusesyntheticengineoilsmeetingtheAPI CategoriesSL/CFandChryslerMaterialStandard MS-10725.ThoseengineoilsnotmeetingtheviscosityandAPIQualityandMS-10725requirements shouldnotbeused.

SAEVISCOSITYGRADE

ThepreferredengineoilisSAE0W-40Mobil One Synthetic.IfyoucannotlocateSAE0W-40Mobil OneSynthetic,thenSAE5W-40Mobil OneSyntheticwouldbeacceptable.

ENGINEOIL-DIESELENGINES-EXPORT

UseonlyDieselEngineOilmeetingstandard MIL2104C orAPIClassification CDorhigher or CCML D4,D5

• NSG370-Mopar ManualTransmissionLubricantMS-9224

AUTOMATICTRANSMISSIONFLUID

NOTE:RefertoServiceProceduresinthisgroupfor fluidlevelcheckingprocedures.

Mopar ATF+4,AutomaticTransmissionFluidis therecommendedfluidforDaimlerChryslerautomatictransmissions.

DexronIIfluidISNOTrecommended.Clutch chattercanresultfromtheuseofimproper fluid.

Fig.3Temperature/EngineOilViscosity

Fig.4APICertificationMark

Thisisnormal. ATF+4alsohasauniqueodorthat maychangewithage.Consequently,odorandcolor cannotbeusedtoindicatethefluidconditionorthe needforafluidchange.

FLUIDADDITIVES

DaimlerChryslerstronglyrecommendsagainstthe additionofanyfluidstothetransmission,otherthan thoseautomatictransmissionfluidslistedabove. Exceptionstothispolicyaretheuseofspecialdyes toaidindetectingfluidleaks.

Various“special”additivesandsupplementsexist thatclaimtoimproveshiftfeeland/orquality.These additivesandothersalsoclaimtoimproveconverter clutchoperationandinhibitoverheating,oxidation, varnish,andsludge.TheseclaimshavenotbeensupportedtothesatisfactionofDaimlerChryslerand theseadditives mustnotbeused. Theuseoftransmission“sealers”shouldalsobeavoided,sincethey mayadverselyaffecttheintegrityoftransmission seals.

TRANSFERCASE-NV231

RecommendedlubricantfortheNV231transfer caseisMopar ATF+4,AutomaticTransmission Fluid.

TRANSFERCASE-NV241GENII

RecommendedlubricantfortheNV2421GENII transfercaseisMopar ATF+4,AutomaticTransmissionFluid.

TRANSFERCASE-NV242

RecommendedlubricantfortheNV242transfer caseisMopar ATF+4,AutomaticTransmission Fluid.

ENGINECOOLANT

WARNING:ANTIFREEZEISANETHYLENEGLYCOL BASECOOLANTANDISHARMFULIFSWALLOWEDORINHALED.IFSWALLOWED,DRINK TWOGLASSESOFWATERANDINDUCEVOMITING.IFINHALED,MOVETOFRESHAIRAREA. SEEKMEDICALATTENTIONIMMEDIATELY.DONOT STOREINOPENORUNMARKEDCONTAINERS. WASHSKINANDCLOTHINGTHOROUGHLYAFTER COMINGINCONTACTWITHETHYLENEGLYCOL. KEEPOUTOFREACHOFCHILDREN.DISPOSEOF GLYCOLBASECOOLANTPROPERLY,CONTACT YOURDEALERORGOVERNMENTAGENCYFOR LOCATIONOFCOLLECTIONCENTERINYOUR AREA.DONOTOPENACOOLINGSYSTEMWHEN THEENGINEISATOPERATINGTEMPERATUREOR HOTUNDERPRESSURE,PERSONALINJURYCAN RESULT.AVOIDRADIATORCOOLINGFANWHEN

ENGINECOMPARTMENTRELATEDSERVICEIS PERFORMED,PERSONALINJURYCANRESULT.

CAUTION:UseofPropyleneGlycolbasedcoolants isnotrecommended,astheyprovidelessfreeze protectionandlesscorrosionprotection.

Thecoolingsystemisdesignedaroundthecoolant. Thecoolantmustacceptheatfromenginemetal,in thecylinderheadareaneartheexhaustvalvesand engineblock.Thencoolantcarriestheheattothe radiatorwherethetube/finradiatorcantransferthe heattotheair.

Theuseofaluminumcylinderblocks,cylinder heads,andwaterpumpsrequiresspecialcorrosion protection.Mopar Antifreeze/Coolant,5 Year/100,000MileFormula(MS-9769),ortheequivalentethyleneglycolbasecoolantwithorganiccorrosioninhibitors(calledHOAT,forHybridOrganic AdditiveTechnology)isrecommended.Thiscoolant offersthebestenginecoolingwithoutcorrosionwhen mixedwith50%EthyleneGlycoland50%distilled watertoobtainafreezepointof-37°C(-35°F).Ifit losescolororbecomescontaminated,drain,flush, andreplacewithfreshproperlymixedcoolantsolution.

CAUTION:Mopar Antifreeze/Coolant,5 Year/100,000MileFormula(MS-9769)maynotbe mixedwithanyothertypeofantifreeze.Mixingof coolantsotherthanspecified(non-HOATorother HOAT),mayresultinenginedamagethatmaynot becoveredunderthenewvehiclewarranty,and decreasedcorrosionprotection.

COOLANTPERFORMANCE

Therequiredethylene-glycol(antifreeze)andwater mixturedependsuponclimateandvehicleoperating conditions.Thecoolantperformanceofvariousmixturesfollows:

PureWater-Watercanabsorbmoreheatthana mixtureofwaterandethylene-glycol.Thisisforpurposeofheattransferonly.Wateralsofreezesata highertemperatureandallowscorrosion.

100percentEthylene-Glycol-Thecorrosion inhibitingadditivesinethylene-glycolneedthepresenceofwatertodissolve.Withoutwater,additives formdepositsinsystem.Theseactasinsulation causingtemperaturetorisetoashighas149°C (300°F).Thistemperatureishotenoughtomeltplasticandsoftensolder.Theincreasedtemperaturecan resultinenginedetonation.Inaddition,100percent ethylene-glycolfreezesat-22°C(-8°F).

50/50Ethylene-GlycolandWater-Istherecommendedmixture,itprovidesprotectionagainstfreezingto-37°C(-34°F).Theantifreezeconcentration

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mustalways beaminimumof44percent,yearroundinallclimates.Ifpercentageislower,engine partsmaybeerodedbycavitation.Maximumprotectionagainstfreezingisprovidedwitha68percent antifreezeconcentration,whichpreventsfreezing downto-67.7°C(-90°F).Ahigherpercentagewill freezeatawarmertemperature.Also,ahigherpercentageofantifreezecancausetheenginetooverheatbecausespecificheatofantifreezeislowerthan thatofwater.

CAUTION:Richerantifreezemixturescannotbe measuredwithnormalfieldequipmentandcan causeproblemsassociatedwith100percentethylene-glycol.

CAUTION:Donotusecoolantadditivesthatare claimedtoimproveenginecooling.

POWERSTEERINGFLUID

Mopar ATF+4,AutomaticTransmissionFluidis requiredinthepowersteeringsystem.Substitute fluidscaninducepowersteeringsystemfailure.

Mopar ATF+4,AutomaticTransmissionFluid whennewisredincolor.TheATFisdyedredsoit canbeidentifiedfromotherfluidsusedinthevehicle suchasengineoilorantifreeze.Theredcolorisnot permanentandisnotanindicatoroffluidcondition. Asthevehicleisdriven,theATFwillbegintolook darkerincolorandmayeventuallybecomebrown. Thisisnormal. ATF+4alsohasauniqueodorthat maychangewithage.Consequently,odorandcolor cannotbeusedtoindicatethefluidconditionorthe needforafluidchange.

OPERATION-AUTOMATICTRANSMISSION FLUID

Theautomatictransmissionfluidisselectedbased uponseveralqualities.Thefluidmustprovideahigh levelofprotectionfortheinternalcomponentsby providingalubricatingfilmbetweenadjacentmetal components.Thefluidmustalsobethermallystable sothatitcanmaintainaconsistentviscositythrough alargetemperaturerange.Iftheviscositystaysconstantthroughthetemperaturerangeofoperation, transmissionoperationandshiftfeelwillremainconsistent.Transmissionfluidmustalsobeagoodconductorofheat.Thefluidmustabsorbheatfromthe internaltransmissioncomponentsandtransferthat heattothetransmissioncase.

FLUIDCAPACITIES

SPECIFICATIONS-FLUIDCAPACITIES

DESCRIPTIONSPECIFICATION

FUELTANK–Gasoline& Diesel 19.5U.S.Gallons (74L)*

ENGINEOIL

2.4LwithFilter4.7L(5.0qts.)

3.7LwithFilter4.7L(5.0qts.)

2.8LDieselwithFilter6.1L(6.4qts.)

ENGINECOOLANT

CoolingSystem-2.4L9.5L(10.0qts.)

CoolingSystem-3.7L13.2L(14.0qts.)

CoolingSystem-2.8LDiesel12.5L(11.8qts.)

POWERSTEERINGSYSTEM

Powersteeringfluidcapacitiesaredependenton engine/chassisoptionsaswellassteeringgear/ cooleroptions.Dependingontypeandsizeofinternalcooler,lengthandinsidediameterofcooler lines,oruseofanauxiliarycooler,thesecapacities mayvary.Referto19,Steeringforproperfilland bleedprocedures.

AUTOMATICTRANSMISSION

ServiceFill-545RFE4.73L(10.0pts) O-haulFill-545RFE13.33L(28.0pts) ServiceFill-42RLE3.8L(8.0pts) O-haulFill-42RLE8.3L(17.6pts)

Dryfillcapacitydependingontypeandsizeofinternalcooler,lengthandinsidediameterofcooler lines,oruseofanauxiliarycooler,thesefigures mayvary.(Referto21-TRANSMISSION/AUTOMATIC/FLUID-STANDARDPROCEDURE) TRANSFERCASE

NV2311.4L(2.95pts.)

NV241GENII2.0L(4.2pts.)

NV2421.6L(3.4pts.)

MANUALTRANSMISSION

NSG370(Approximatedry fillorfilltobottomedgeof thefillplughole.)

FRONTAXLE

1.5L(3.17pts.)

186FIA(Model30)1.24L(2.6pts.) REARAXLE

81/42.08L(4.4pts.)**

*Nominalrefillcapacitiesareshown.Avariationmay beobservedfromvehicletovehicleduetomanufacturingtoleranceandrefillprocedure.

**WhenequippedwithTrac-lok,include118ml(4.0 ounces)ofLimitedSlipAdditive.

MAINTENANCESCHEDULES

DESCRIPTION

MAINTENANCESCHEDULES-GASOLINE

ENGINES

Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.

FirstisSchedule B .Itisforvehiclesthatare operatedundertheconditionsthatarelistedbelow andatthebeginningoftheschedule.

• Dayornighttemperaturesarebelow32°F(0°C).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan10miles(16.2km).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above90°F(32°C).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

• Off-roadordesertdriving.

• IfequippedforandoperatedwithE-85(ethanol) fuel.

NOTE:IfANYoftheseapplytoyouthenchange yourengineoilevery3,000miles(5000km)or3 months,whichevercomesfirstandfollow“ScheduleB”ofthe“MaintenanceSchedules”sectionof thismanual.

NOTE:IfANYoftheseapplytoyouthenflushand replaceyourenginecoolant/anti-freezeevery 102,000miles(163000km)or60months,whichever comesfirst,andfollow“ScheduleB”ofthe“MaintenanceSchedules”sectionofthismanual.

NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule“B.”

SecondisSchedule “A”.Itisforvehiclesthatare notoperatedunderanyoftheconditionslistedunder Schedule“B.”

Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.

CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.

AtEachStopforFuel

• Checktheengineoillevelabout5minutesafter afullywarmedengineisshutoff.Checkingtheoil levelwhilethevehicleisonlevelgroundwill improvetheaccuracyoftheoillevelreading.Addoil

onlywhenthelevelisatorbelowtheADDorMIN mark.

• Checkthewindshieldwashersolvent,addas required.

OnceaMonth

• Checkthetirepressureandlookforunusual wearordamage.

• Inspectthebattery,andcleanandtightenthe terminalsasrequired.

• Checkthefluidlevelsoftheenginecoolant/antifreezereservoir,brakemastercylinder,andtransmission,andaddasneeded.

• Checkalllightsandallotherelectricalitemsfor correctoperation.

AtEachOilChange

• Changetheengineoilfilter.

• Inspecttheexhaustsystem.

• Inspectbrakehoses.

• Checktheenginecoolant/anti-freezelevel,hoses, andclamps.

• Inspectmanualtransmissionfluidlevel—if equipped.

• Aftercompletionofoff-roadoperation,the undersideofthevehicleshouldbethoroughly inspected.Examinethreadedfastenersforlooseness.

Schedule“B”

Followschedule“B”ifyouusuallyoperateyour vehicleunderoneormoreofthefollowingconditions.

• Dayornighttemperaturesarebelow32°F(0°C).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan10miles(16.2km).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above90°F(32°C).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

• Off-roadordesertdriving.

• IfequippedforandoperatedwithE-85(ethanol) fuel.

NOTE:IfANYoftheseapplytoyouthenchange yourengineoilevery3,000miles(5000km)or3 months,whichevercomesfirstandfollow“ScheduleB”ofthe“MaintenanceSchedules”sectionof thismanual.

Miles3,0006,0009,00012,00015,000 (Kilometers)(5000)(10000)(14000)(19000)(24000)

Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX

Rotatethetires.XX

Inspecttheengineairfilterelement,replaceif necessary. X

Inspectthebrakelinings. X

Drainandrefillthefrontandrearaxlefluid‡X

Miles18,00021,00024,00027,00030,000 (Kilometers)(29000)(34000)(38000)(43000)(48000)

Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX

Rotatethetires.XXX

Inspecttheengineairfilterelement,replaceif necessary. X

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary. X

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthetransfercasefluid,addifnecessary.X

Miles33,00036,00039,00042,00045,000 (Kilometers)(53000)(58000)(62000)(67000)(72000)

Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX

Rotatethetires.XX

Inspecttheengineairfilterelement,replaceif necessary. X

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded.X

Miles48,00051,00054,00057,00060,000 (Kilometers)(77000)(82000)(86000)(91000)(96000)

Changetheengineoilandengineoilfilter,ifnot replacedat3months. XXXXX

Rotatethetires.XXX

Inspecttheengineairfilterelement,replaceif necessary. X

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary. X

MAINTENANCESCHEDULES(Continued)

Miles48,00051,00054,00057,00060,000 (Kilometers)(77000)(82000)(86000)(91000)(96000)

Replacetheignitioncables(2.4LOnly). X

Inspectthebrakelinings.XX

Drainandrefillthefrontandrearaxlefluid‡XX

Drainandrefilltheautomatictransmissionfluid,and replacemainsumpfilter.

Inspectthedrivebeltandreplaceasneeded.Not requiredifbeltwaspreviously

Drainandrefillthetransfercasefluid.X

Flushandreplacetheenginecoolant/anti-freezeat 60months,ifnotdoneat102,000miles(163000 km).

Miles63,00066,00069,00072,00075,000 (Kilometers)(101000)(106000)(110000)(115000)(120000)

Changetheengineoilandengineoilfilter,if notreplacedat3months.

Rotatethetires.XX

Inspecttheengineairfilterelement,replace ifnecessary.

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded. Notrequiredifbeltwaspreviouslyreplaced.

Miles78,00081,00084,00087,00090,000 (Kilometers)(125000)(130000)(134000)(139000)(144000)

Changetheengineoilandengineoilfilter,if notreplacedat3months.

Rotatethetires.XXX

Inspecttheengineairfilterelement,replace ifnecessary.

Replacethesparkplugs.

InspectandreplacethePCVvalve,ifnecessary.

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded. Notrequiredifbeltwaspreviouslyreplaced.

Replacethetimingbelt(2.4LOnly). X

Inspectthetransfercasefluid,addifnecessary.X

Miles93,00096,00099,000102,000105,000 (Kilometers)(149000)(154000)(158000)(163000)(168000)

Changetheengineoilandengineoilfilter,if notreplacedat3months.

Rotatethetires.XX

Inspecttheengineairfilterelement,replace ifnecessary.

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded. Notrequiredifbeltwaspreviouslyreplaced.

Flushandreplacetheenginecoolant/antifreeze,ifnotdoneat60months.

Miles108,000111,000114,000117,000120,000 (Kilometers)(173000)(178000)(182000)(187000)(192000)

Changetheengineoilandengineoilfilter,if notreplacedat3months.

Rotatethetires.XXX

Inspecttheengineairfilterelement,replace ifnecessary.

Replacethesparkplugs.

InspectandreplacethePCVvalve,ifnecessary.

Replacetheignitioncables(2.4LOnly). X

Inspectthebrakelinings.XX

Drainandrefillthefrontandrearaxlefluid‡XX

Drainandrefilltheautomatictransmissionfluid, andreplacemainsumpfilter.

Inspectthedrivebeltandreplaceasneeded. Notrequiredifbeltwaspreviouslyreplaced.

Drainandrefillthetransfercasefluid.X

Flushandreplacetheenginecoolant/anti-freeze at120months,ifnotreplacedat102,000miles (163000km).

Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.

Thismaintenanceisrecommendedbythemanufacturertotheowner,butitisnotrequiredtomaintainemissionswarranty.

‡Off-highwayoperation,trailertowing,taxi,limousine,bus,snowplowing,orothertypesofcommercial serviceorprolongedoperationwithheavyloading, especiallyinhotweather,requirefrontandrearaxle serviceindicatedwitha‡in Schedule“B”.Perform theseservicesifthevehicleisusuallyoperatedunder theseconditions.

MAINTENANCESCHEDULES(Continued)

Schedule“A”

Miles6,00012,00018,00024,00030,000 (Kilometers)(10000)(19000)(29000)(38000)(48000) [Months][6][12][18][24][30]

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XXXXX

Inspecttheengineairfilterelement,andreplace ifnecessary. X

Replacethesparkplugs. X

Inspectthebrakelinings.X

Inspectthetransfercasefluid. X

Miles36,00042,00048,00054,000 (Kilometers)(58000)(67000)(77000)(86000) [Months][36][42][48][54]

Changetheengineoilandengineoilfilter.XXXX

Rotatethetires.XXXX

Inspectthebrakelinings.XX

Miles60,00066,00072,00078,000 (Kilometers)(96000)(106000)(115000)(125000) [Months][60][66][72][78]

Changetheengineoilandengineoilfilter.XXXX

Rotatethetires.XXXX

Inspecttheengineairfilterelement,andreplaceif necessary. X

Replacethesparkplugs. X

Inspecttheignitioncables,andreplaceifnecessary (2.4LOnly). X

InspectandreplacethePCVvalve,ifnecessary. X

Inspectthebrakelinings.X

Inspectthedrivebeltandreplace,ifneeded.X

Inspectthedrivebeltandreplaceasneeded.Not requiredifpreviouslyreplaced. X

Flushandreplacetheenginecoolant/anti-freezeat60 months,ifnotdoneat102,000miles(163000km). X

Inspectthetransfercasefluid.X

Miles84,00090,00096,000102,000 (Kilometers)(134000)(144000)(154000)(163000) [Months][84][90][96][102]

Changetheengineoilandengineoilfilter.XXXX Rotatethetires.XXXX

Inspecttheengineairfilterelement,andreplaceif necessary.

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary. X

Inspectthebrakelinings.X

Inspectthedrivebeltandreplaceasneeded.Notrequired ifpreviouslyreplaced.

Flushandreplacetheenginecoolant/anti-freezeifnot doneat60months. X

Inspectthetransfercasefluid.X

Miles108,000114,000120,000 (Kilometers)(173000)(182000)(192000) [Months][108][114][120]

Changetheengineoilandengineoilfilter.XXX Rotatethetires.XXX

Inspecttheengineairfilterelement,andreplaceifnecessary.

Replacethesparkplugs.

InspectandreplacethePCVvalve,ifnecessary.

Inspecttheignitioncables,andreplaceifnecessary(2.4L Only).

Inspectthebrakelinings.X

Inspectthedrivebeltandreplaceasneeded.Notrequiredifpreviouslyreplaced.

Flushandreplacetheenginecoolant/anti-freezeifnotdoneat 102,000miles(163000km).

Replacethetimingbelt(2.4LOnly). X

Drainandrefillthetransfercasefluid.X

Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.

Thismaintenanceisrecommendedbythemanufacturertotheowner,butitisnotrequiredtomaintainemissionswarranty.

MAINTENANCESCHEDULES-DIESELENGINE

Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.

FirstisSchedule B .Itisforvehiclesthatare operatedundertheconditionsthatarelistedbelow andatthebeginningoftheschedule.

• Dayornighttemperaturesarebelow32°F(0°C).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan10miles(16.2km).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above90°F(32°C).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

• Off-roadordesertdriving.

NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule“B.”

SecondisSchedule “A”.Itisforvehiclesthatare notoperatedunderanyoftheconditionslistedunder Schedule“B.”

Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.

CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.

AtEachStopforFuel

• Checktheengineoillevelabout5minutesafter afullywarmedengineisshutoff.Checkingtheoil levelwhilethevehicleisonlevelgroundwill improvetheaccuracyoftheoillevelreading.Addoil onlywhenthelevelisatorbelowtheADDorMIN mark.

• Checkthewindshieldwashersolvent,addas required.

OnceaMonth

• Checkthetirepressureandlookforunusual wearordamage.

• Inspectthebattery,cleanandtightentheterminalsasrequired.

• Checkthefluidlevelsofenginecoolant/antifreezedeaerationbottle,brakemastercylinder,and transmission,andaddasneeded.

• Checkalllightsandallotherelectricalitemsfor correctoperation.

AtEachOilChange

• Changetheengineoilfilter.

• Inspecttheexhaustsystem.

• Inspectbrakehoses.

• Checktheenginecoolant/anti-freezelevel,hoses, andclamps.

• Inspectengineaccessorydrivebelts.Replaceas necessary.

• Inspectforthepresenceofwaterinthefuelfilter/waterseparatorunit.

TireRotation

• Rotatethetiresevery6,000miles(10000km).

Schedule“B”

Followschedule“B”ifyouusuallyoperateyour vehicleunderoneormoreofthefollowingconditions.

• Dayornighttemperaturesarebelow32°F(0°C).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan10miles(16.2km).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above90°F(32°C).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

• Off-roadordesertdriving.

Miles6,25012,50018,75025,00031,250 (Kilometers)(10000)(20000)(30000)(40000)(50000)

Changetheengineoilandengineoilfilter.XXXXX

Inspecttheengineairfilterelement.Replaceas necessary. XXXXX

Replacetheengineairfilterelement. XX Replacethefuelfilter/waterseparatorunit.X Inspectthebrakelinings.XX Drainandrefillthefrontandrearaxlefluid.XX

MAINTENANCESCHEDULES(Continued)

Miles37,50043,75050,00056,25062,500 (Kilometers)(60000)(70000)(80000)(90000)(100000)

Changetheengineoilandengineoilfilter.XXXXX

Inspecttheengineairfilterelement. Replaceasnecessary. XXXXX

Replacetheengineairfilterelement. XXX

Replacethefuelfilter/waterseparatorunit.X

Replacetheengineaccessorydrivebelt.X

Inspectthebrakelinings.XXX

Drainandrefillthefrontandrearaxlefluid.XXX

Drainandrefillthetransfercasefluid.X

Drainandrefilltheautomatictransmission fluid,andreplacesumpfilter. X

Miles68,75075,00081,25087,50093,750100,000 (Kilometers)(110000)(120000)(130000)(140000)(150000)(160000)

Changetheengineoilandengineoil filter. XXXXXX

Inspecttheengineairfilterelement.Replaceasnecessary.

Replacetheengineairfilterelement. XXX

Replacetheengineaccessorydrive belt. X

Replacetheenginetimingbeltand idlerpulleys. X

Inspecttheenginetimingbelttensioner,replaceifnecessary.†

Replacethefuelfilter/waterseparatorunit.

Flushandreplacetheenginecoolant/anti-freeze.

Inspectthebrakelinings.XX

Drainandrefillthefrontandrear axlefluid.

Appliesonlyifvehicleisusedforfrequent trailertowing,orfleet/commercialservice.

†Thereplacementofsuchcomponentisrequested ifthereissuperficialwear,bearingclearance,orevidentgreaseleak.

Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.

Schedule“A”

Miles12,50025,00037,50050,000 (Kilometers)(20000)(40000)(60000)(80000)

Changetheengineoilandengineoilfilter.XXXX

Inspecttheengineairfilterelement.Replaceasnecessary. XXXX

Replacetheengineairfilterelement. XX

Replacethefuelfilter/waterseparatorunit.XX

Inspectthebrakelinings.XX

Inspectthetransfercasefluid.X

Miles62,50075,00087,500100,000 (Kilometers)(100000)(120000)(140000)(160000)

Changetheengineoilandengineoilfilter.XXXX

Inspecttheengineairfilterelement.Replaceasnecessary. XXXX

Replacetheengineairfilterelement. XX

Replacethefuelfilter/waterseparatorunit.XX

Replacetheenginetimingbelt,andidlerpulleys.X

Inspecttheenginetimingbelttensioner,replaceifnecessary.† X

Flushandreplacetheenginecoolant.X

Replacetheengineaccessorydrivebelt.X

Inspectthebrakelinings.XX

Inspectthetransfercasefluid.X

†Thereplacementofsuchcomponentisrequested ifthereissuperficialwear,bearingclearance,orevidentgreaseleak.

Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.

MAINTENANCESCHEDULES-GASOLINE ENGINES-EXPORT

Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.

FirstisSchedule “A”.Itisforvehiclesthatarenot operatedunderanyoftheconditionslistedunder Schedule“B.”

SecondisSchedule B .Itisforvehiclesthatare operatedundertheconditionsthatarelistedbelow andatthebeginningoftheschedule.

• Dayornighttemperaturesarebelow0°C(32°F).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan16.2km(10miles).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C(90°F).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

• Off-roadordesertdriving.

Mostvehiclesareoperatedundertheconditions listedforSchedule“B.”

Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.

CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.

AtEachStopforFuel

• Checktheengineoillevelabout5minutesaftera fullywarmedengineisshutoff.Checkingtheoillevel whilethevehicleisonlevelgroundwillimprovethe accuracyoftheoillevelreading.Addoilonlywhen thelevelisatorbelowtheADDorMINmark.

• Checkthewindshieldwashersolvent,addas required.

OnceaMonth

• Checkthetirepressureandlookforunusual wearordamage.

• Inspectthebattery,andcleanandtightenthe terminalsasrequired.

• Checkthefluidlevelsofthecoolantreservoir, brakemastercylinder,andtransmission,andaddas needed.

• Checkalllightsandallotherelectricalitemsfor correctoperation.

Schedule“A”

AtEachOilChange

• Changetheengineoilfilter.

• Inspecttheexhaustsystem.

• Inspectbrakehoses.

• Checkthecoolantlevel,hoses,andclamps.

• Inspectmanualtransmissionfluidlevel—if equipped.

• Aftercompletionofoff-roadoperation,the undersideofthevehicleshouldbethoroughly inspected.Examinethreadedfastenersforlooseness.

Kilometers1200024000360004800060000 (Miles)(7,500)(15,000)(22,500)(30,000)(37,500) [Months][6][12][18][24][30]

Changetheengineoilandengineoilfilter.XXXXX

Inspecttheengineairfilterelement,replaceif necessary. X

Replacethesparkplugs. X Inspectthebrakelinings.X

Inspectthetransfercasefluid.X

Kilometers720008400096000108000 (Miles)(45,000)(52,500)(60,000)(67,500) [Months][36][42][48][54]

Changetheengineoilandengineoilfilter.XXXX Rotatethetires.XXXX

Inspecttheengineairfilterelement,replaceifnecessary. X

InspectandreplacethePCVvalve,ifnecessary . X

Inspecttheignitioncables,andreplaceifnecessary (2.4LOnly). X

Replacethesparkplugs. X

Inspectthebrakelinings.XX

InspectandreplacetheAutoTensionDriveBelt,as needed. X

Inspectthetransfercasefluid.X

Kilometers120000132000144000156000 (Miles)(75,000)(82,500)(90,000)(97,500) [Months][60][66][72][78]

Changetheengineoilandengineoilfilter.XXXX Rotatethetires.XXXX

Inspecttheengineairfilterelement,replaceifnecessary. X

MAINTENANCESCHEDULES(Continued)

Kilometers120000132000144000156000 (Miles)(75,000)(82,500)(90,000)(97,500) [Months][60][66][72][78]

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary. X

Inspectthebrakelinings.X

Inspectthedrivebeltandreplaceasneeded.Not requiredifpreviouslyreplaced.

Flushandreplacetheenginecoolantat60months, regardlessofmileage. X

Inspectthetransfercasefluid.X

Kilometers160000168000180000192000 (Miles)(100,000)(105,000)(112,500)(120,000) [Months] [84][90][96]

Inspecttheengineairfilterelement,replaceifnecessary. X

Replacethesparkplugs. X

Inspecttheignitioncables,replaceifnecessary(2.4L Only). X

InspectandreplacethePCVvalve,ifnecessary. X

Inspectthebrakelinings.X

Inspectthedrivebeltandreplaceasneeded.Notrequired ifpreviouslyreplaced.

Flushandreplacetheenginecoolantifnotdoneat60 months. X

Replacethetimingbelt(2.4LOnly). X Drainthetransfercase,andrefill. X

Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.

Thismaintenanceisrecommendedbythemanufacturertotheowner,butitisnotrequiredtomaintainemissionswarranty.

MAINTENANCESCHEDULES(Continued)

Schedule“B”

Followschedule“B”ifyouusuallyoperateyour vehicleunderoneormoreofthefollowingconditions.

• Dayornighttemperaturesarebelow0°C(32°F).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan16.2km(10miles).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C(90°F).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

• Off-roadordesertdriving.

Kilometers500010000140001900024000 (Miles)(3,000)(6,000)(9,000)(12,000)(15,000)

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XX

Inspecttheengineairfilterelement,replaceif necessary. X

Inspectthebrakelinings. X

Drainandrefillthefrontandrearaxlefluid‡X

Kilometers2900034000380004300048000 (Miles)(18,000)(21,000)(24,000)(27,000)(30,000)

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XXX

Inspecttheengineairfilterelement,replaceif necessary. X

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary. X

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X Inspectthetransfercasefluid,addifnecessary.X

Kilometers5300058000620006700072000 (Miles)(33,000)(36,000)(39,000)(42,000)(45,000)

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XX

Inspecttheengineairfilterelement,replaceif necessary. X

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded.X

Kilometers7700082000860009100096000 (Miles)(48,000)(51,000)(54,000)(57,000)(60,000)

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XXX

Inspecttheengineairfilterelement,replaceif necessary. X

MAINTENANCESCHEDULES(Continued)

Kilometers7700082000860009100096000

(Miles)(48,000)(51,000)(54,000)(57,000)(60,000)

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary. X

Replacetheignitioncables(2.4LOnly). X

Inspectthebrakelinings.XX

Drainandrefillthefrontandrearaxlefluid‡XX

Drainandrefilltheautomatictransmissionfluid,and replacemainsumpfilter. X

Inspectthedrivebeltandreplaceasneeded.Not requiredifbeltwaspreviouslyreplaced. X

Drainandrefillthetransfercasefluid.X

Flushandreplacetheenginecoolant/anti-freezeat 60months,ifnotdoneat102,000miles(163000 km).

Kilometers101000106000110000115000120000

(Miles)(63,000)(66,000)(69,000)(72,000)(75,000)

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XX

Inspecttheengineairfilterelement,replaceif necessary. X

Inspectthebrakelinings. X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded.Not requiredifbeltwaspreviouslyreplaced.

Kilometers125000130000134000139000144000

(Miles)(78,000)(81,000)(84,000)(87,000)(90,000)

Changetheengineoilandengineoilfilter.XXXXX

Rotatethetires.XXX

Inspecttheengineairfilterelement,replaceif necessary. X

Replacethesparkplugs. X

InspectandreplacethePCVvalve,ifnecessary.

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded.Not requiredifbeltwaspreviouslyreplaced. X

Replacethetimingbelt(2.4LOnly). X

Inspectthetransfercasefluid,addifnecessary.X

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Kilometers149000154000158000163000168000

(Miles)(93,000)(96,000)(99,000)(102,000)(105,000)

Changetheengineoilandengineoilfilter.XXXXX Rotatethetires.XX

Inspecttheengineairfilterelement,replaceif necessary. X

Inspectthebrakelinings.X

Drainandrefillthefrontandrearaxlefluid‡X

Inspectthedrivebeltandreplaceasneeded.Not requiredifbeltwaspreviouslyreplaced.

Flushandreplacetheenginecoolant/anti-freeze,if notdoneat60months.

Kilometers173000178000182000187000192000

(Miles)(108,000)(111,000)(114,000)(117,000)(120,000)

Changetheengineoilandengineoilfilter.XXXXX

Inspecttheengineairfilterelement,replaceif necessary. X

Replacethesparkplugs.

InspectandreplacethePCVvalve,ifnecessary.

Replacetheignitioncables(2.4LOnly). X

Inspectthebrakelinings.XX

Drainandrefillthefrontandrearaxlefluid‡XX

Drainandrefilltheautomatictransmissionfluid,and replacemainsumpfilter.

Inspectthedrivebeltandreplaceasneeded.Not requiredifbeltwaspreviouslyreplaced.

Drainandrefillthetransfercasefluid.X

Flushandreplacetheenginecoolant/anti-freezeat 120months,ifnotreplacedat102,000miles(163 000km).

Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.

Thismaintenanceisrecommendedbythemanufacturertotheowner,butitisnotrequiredtomaintainemissionswarranty.

DESCRIPTION–DIESELENGINES–EXPORT SCHEDULES

Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.

FirstisSchedule “A”.Itisforvehiclesthatarenot operatedunderanyoftheconditionslistedunder Schedule B .

SecondisSchedule “B”.Itisforvehiclesthatare operatedundertheconditionsthatarelistedbelow andatthebeginningoftheschedule.

• Extensiveengineidling.

• Drivingindustyconditions.

MAINTENANCESCHEDULES(Continued)

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C(90°F).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

Mostvehiclesareoperatedundertheconditions listedforSchedule B . Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.

CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.

AtEachStopforFuel

• Checkthewindshieldwashersolventandaddif required.

Schedule“A”

OnceaMonth

• Checkthetirepressureandlookforunusual wearordamage.

• Inspectthebatteryandcleanandtightenthe terminalsasrequired.

• Checkthefluidlevelsofcoolantreservoir,brake mastercylinder,powersteeringandtransmission andaddasneeded.

• Checkalllightsandallotherelectricalitemsfor correctoperation.

AtEachOilChange

• Changetheengineoilfilter.

• Inspecttheexhaustsystem.

• Inspectthebrakehoses.

• Checkthemanualtransmissionfluidlevel—if equipped.

• Checkthecoolantlevel,hoses,andclamps.

• Inspectengineaccessorydrivebelts.Replaceas necessary.

• Inspectforthepresenceofwaterinthefuelfilter/waterseparatorunit.

• Rotatethetires.

Kilometers20000km40000km60000km80000km100000km

Changetheengineoilandengineoilfilter. XXXXX

Inspecttheengineairfilterelement. Replaceasnecessary. XXX

Replacetheengineairfilterelement.XX

Replacethefuelfilter/waterseparator unit. XXXXX

Replacetheenginetimingbelt,andidler pulleys. X

Inspecttimingbelttensioner,andreplace ifnecessary.‡ X

Inspecttheengineaccessorydrivebelt.XXXX

Replacetheengineaccessorydrivebelt.X

Inspecttheballjoints.XXXXX

Inspectthebrakelinings.XX

Inspectthetransfercasefluid.X

Kilometers120000km140000km160000km180000km

Changetheengineoilandengineoilfilter.XXXX

Inspecttheengineaccessorydrivebelts,and replaceifnecessary. XXXX

Inspecttheengineairfilterelement.Replaceas necessary. XX

MAINTENANCESCHEDULES(Continued)

Kilometers120000km140000km160000km180000km

Replacetheengineairfilterelement.XX

Replacethefuelfilter/waterseparatorunit.XXXX

Flushandreplacetheenginecoolant.X

Inspecttheballjoints.XXXX

Inspectthebrakelinings.XX

Drainandrefilltheautomatictransmissionfluid, changesumpfilter,andcoolerreturnfilter(if equipped). X

Inspectthetransfercasefluid.X

Drainandrefillthetransfercasefluid.X

Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected.

‡Replaceifthereissuperficialwear,bearingclearance,orevidentgreaseleak.

WARNING:Youcanbebadlyinjuredworkingonor aroundamotorvehicle.Doonlythatservicework forwhichyouhavetheknowledgeandtheright equipment.Ifyouhaveanydoubtaboutyourability toperformaservicejob,takeyourvehicletoa competentmechanic.

Schedule“B”

Followschedule“B”ifyouusuallyoperateyour vehicleunderoneormoreofthefollowingconditions.

• Extensiveengineidling.

• Drivingindustyconditions.

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C(90°F).

• Trailertowing.

• Taxi,police,ordeliveryservice(commercialservice).

Kilometers10000km20000km30000km40000km50000km

Changetheengineoilandengineoilfilter. XXXXX

Inspecttheengineairfilterelement. Replaceasnecessary. XXX

Replacetheengineairfilterelement.XX

Replacethefuelfilter/waterseparatorunit.XX

Inspecttheengineaccessorydrivebelt. XXXX

Replacetheengineaccessorydrivebelt.X

Replacetheenginetimingbeltandidler pulleys. X

Inspectthetimingbelttensioner.‡ X

Inspecttheballjoints. XXXXX

Inspectthebrakelinings.XX

Drainandrefillthefrontandrearaxle fluid. XX

Drainandrefilltheautomatictransmission fluid,andreplacesumpfilter. X

MAINTENANCESCHEDULES(Continued)

Kilometers60000

Changetheengineoilandengineoilfilter.XXXXX

Inspecttheengineairfilterelement.Replace asnecessary. XX

Replacetheengineairfilterelement.XXX

Replacethefuelfilter/waterseparatorunit.XXX

Inspecttheengineaccessorydrivebelt.XXXX

Replacetheengineaccessorydrivebelt.X

Replacetheenginetimingbelt,idlerpulleys, andtensioner. X

Inspecttheballjoints.XXXXX

Inspectthebrakelinings.XXX

Drainandrefillthefrontandrearaxlefluid.XXX

Drainandrefillthetransfercasefluid.X

Drainandrefilltheautomatictransmission fluid,andreplacesumpfilter. X

Kilometers110000

Changetheengineoilandengineoilfilter. XXXXXX

Inspecttheengineairfilterelement. Replaceasnecessary. XXX

Replacetheengineairfilterelement.XXX

Inspecttheengineaccessorydrivebelts, andreplaceifnecessary. XXXXX

Replacetheengineaccessorydrivebelt.X

Inspectthetimingbelttensioner.‡X

Replacetheenginetimingbeltandidler pulleys. X

Replacethefuelfilter/waterseparatorunit.XXX

Flushandreplacetheenginecoolant.X

Inspecttheballjoints. XXXXXX

Inspectthebrakelinings.XXX

Drainandrefillthefrontandrearaxle fluid. XXX

Drainandrefilltheautomatictransmission fluid,andreplacesumpfilter. X

Replacethetransmissioncoolerreturnfilter(ifequipped). X

Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected. ‡Replaceifthereissuperficialwear,bearingclearance,orevidentgreaseleak.

FLUIDFILL/CHECK LOCATIONS

DESCRIPTION

Thefluidcheck/fillpointlocationsarelocatedin eachapplicableservicemanualsection.

HOISTING

STANDARDPROCEDURE-HOISTING RECOMMENDATIONS

RefertotheOwner’sManualforemergencyvehicle liftingprocedures.

Whenproperlypositioned,afloorjackcanbeused toliftaJeepvehicle(Fig.5).Supportthevehiclein theraisedpositionwithjackstandsatthefrontand rearendsoftheframerails.

NOTE:Usethecorrectsub-framerailorframerail liftinglocationsonly.

HOIST

RefertotheOwner’sManualforemergencyvehicle liftingprocedures.

Avehiclecanbeliftedwith:

• Asingle-post,frame-contacthoist.

• Atwin-post,chassishoist.

• Aramp-type,drive-onhoist.

NOTE:Whenaframe-contacttypehoistisused, verifythattheliftingpadsarepositionedproperly.

WARNING:THEHOISTINGANDJACKLIFTING POINTSPROVIDEDAREFORACOMPLETEVEHICLE.WHENACHASSISORDRIVETRAINCOMPONENTISREMOVEDFROMAVEHICLE,THE CENTEROFGRAVITYISALTEREDMAKINGSOME HOISTINGCONDITIONSUNSTABLE.PROPERLY SUPPORTORSECUREVEHICLETOHOISTING DEVICEWHENTHESECONDITIONSEXIST.

JUMPSTARTING

STANDARDPROCEDURE-JUMPSTARTING PROCEDURE

WARNING:REVIEWALLSAFETYPRECAUTIONS ANDWARNINGSINTHEBATTERYSYSTEMSECTIONOFTHESERVICEMANUAL.(Referto8ELECTRICAL/BATTERYSYSTEM/BATTERY-STANDARDPROCEDURE)

• DONOTJUMPSTARTAFROZENBATTERY, PERSONALINJURYCANRESULT.

• IFEQUIPPED,DONOTJUMPSTARTWHEN MAINTENANCEFREEBATTERYINDICATORDOTIS YELLOWORBRIGHTCOLOR.

Fig.5CorrectVehicleLiftingLocations

1-FrameContactLift(SinglePost) ChassisLift(Non-AxleDualPost) OutboardLift(DualPost) FloorJack

2-FloorJack

CAUTION:DonotattempttoliftaJeepvehiclewith afloorjackpositionedunder:

• Abodysidesill.

• Asteeringlinkagecomponent.

• Adriveshaft.

• Theengineortransmissionoilpan.

• Thefueltank.

• Afrontsuspensionarm.

• Transfercase.

• DONOTJUMPSTARTAVEHICLEWHENTHE BATTERYFLUIDISBELOWTHETOPOFLEAD PLATES.

• DONOTALLOWJUMPERCABLECLAMPSTO TOUCHEACHOTHERWHENCONNECTEDTOA BOOSTERSOURCE.

• DONOTUSEOPENFLAMENEARBATTERY.

• REMOVEMETALLICJEWELRYWORNON HANDSORWRISTSTOAVOIDINJURYBYACCIDENTALARCINGOFBATTERYCURRENT.

• WHENUSINGAHIGHOUTPUTBOOSTING DEVICE,DONOTALLOWBATTERYVOLTAGETO EXCEED16VOLTS.REFERTOINSTRUCTIONS PROVIDEDWITHDEVICEBEINGUSED. FAILURETOFOLLOWTHESEINSTRUCTIONSMAY RESULTINPERSONALINJURY.

JUMPSTARTING(Continued)

CAUTION:Whenusinganothervehicleasa booster,donotallowvehiclestotouch.Electrical systemscanbedamagedoneithervehicle.

TOJUMPSTARTADISABLEDVEHICLE:

(1)Raisehoodondisabledvehicleandvisually inspectenginecompartmentfor:

• Generatordrivebeltconditionandtension.

• Fuelfumesorleakage,correctifnecessary.

• Frozenbattery.

• Yelloworbrightcolortestindicator,ifequipped.

• Lowbatteryfluidlevel.

CAUTION:Ifthecauseofstartingproblemondisabledvehicleissevere,damagetoboostervehicle chargingsystemcanresult.

(2)Whenusinganothervehicleasabooster source,turnoffallaccessories,placegearselectorin parkorneutral,setparkbrakeorequivalentand operateengineat1200rpm.

(3)Ondisabledvehicle,placegearselectorinpark orneutralandsetparkbrakeorequivalent.Turn OFFallaccessories.

(4)Connectjumpercablestoboosterbattery.RED clamptopositiveterminal(+).BLACKclamptonegativeterminal(-).DONOTallowclampsatopposite endofcablestotouch,electricalarcwillresult(Fig. 6).Reviewallwarningsinthisprocedure.

(5)Ondisabledvehicle,connectREDjumpercable clamptobatterypositive(+)terminal.Connect BLACKjumpercableclamptotheengineascloseto thegroundcableconnectionaspossible(Fig.6).

CAUTION:Donotcrankstartermotorondisabled vehicleformorethan15seconds,starterwilloverheatandcouldfail.

(6)Allowbatteryindisabledvehicletochargeto atleast12.4volts(75%charge)beforeattemptingto startengine.Ifenginedoesnotstartwithin15seconds,stopcrankingengineandallowstartertocool (15min.),beforecrankingagain.

DISCONNECTCABLECLAMPSASFOLLOWS:

• DisconnectBLACKcableclampfromengine groundondisabledvehicle.

• WhenusingaBoostervehicle,disconnect BLACKcableclampfrombatterynegativeterminal. DisconnectREDcableclampfrombatterypositive terminal.

• DisconnectREDcableclampfrombatterypositiveterminalondisabledvehicle.

Fig.6JumperCableClampConnections 1-ENGINEGROUND 2-NEGATIVEJUMPERCABLE 3-BATTERYNEGATIVECABLE 4-POSITIVEJUMPERCABLE 5-BATTERYPOSITIVECABLE 6-BATTERY 7-TESTINDICATOR(IFEQUIPPED)

TOWING

STANDARDPROCEDURE-TOWING

AvehicleequippedwithSAEapprovedwheellifttypetowingequipmentcanbeusedtotowJeepvehicles.Whentowinga4WDvehicleusingawheel-lift towingdevice,usetowdolliesundertheoppositeend ofthevehicle.Avehiclewithflatbeddevicecanalso beusedtotransportadisabledvehicle(Fig.7).

Fig.7TowVehiclesWithApprovedEquipment

TOWING(Continued)

SAFETYPRECAUTIONS

CAUTION:Thefollowingsafetyprecautionsmustbe observedwhentowingavehicle:

• Securelooseandprotrudingparts.

• Alwaysuseasafetychainsystemthatisindependentoftheliftingandtowingequipment.

• Donotallowtowingequipmenttocontactthe disabledvehicle’sfueltank.

• Donotallowanyoneunderthedisabledvehicle whileitisliftedbythetowingdevice.

• Donotallowpassengerstorideinavehicle beingtowed.

• Alwaysobservestateandlocallawsregarding towingregulations.

• Donottowavehicleinamannerthatcould jeopardizethesafetyoftheoperator,pedestriansor othermotorists.

• Donotattachtowchains,T-hooks,orJ-hooksto abumper,steeringlinkage,driveshaftsoranon-reinforcedframehole.

• Donottowaheavilyloadedvehicle.Useaflatbeddevicetotransportaloadedvehicle.

TWO-WHEEL-DRIVEVEHICLETOWING

DaimlerChryslerCorporationrecommendsthata vehiclebetowedwiththerearendlifted,whenever possible.

WARNING:WHENTOWINGADISABLEDVEHICLE ANDTHEDRIVEWHEELSARESECUREDINA WHEELLIFTORTOWDOLLIES,ENSURETHE TRANSMISSIONISINTHEPARKPOSITION(AUTOMATICTRANSMISSION)ORAFORWARDDRIVE GEAR(MANUALTRANSMISSION).

WARNING:ENSUREVEHICLEISONALEVELSURFACEORTHEWHEELSAREBLOCKEDTOPREVENTVEHICLEFROMROLLING.

TWOWHEELDRIVETOWING-REARENDLIFTED

CAUTION:Donotusesteeringcolumnlockto securesteeringwheelduringtowingoperation.

2WDvehiclescanbetowedwiththefrontwheels onthesurfaceforextendeddistancesatspeedsnot exceeding48km/h(30mph).

(1)Attachwheelliftdevicetorearwheels.

(2)Placethetransmissioninneutral.

(3)Raisevehicletotowingposition.

(4)Attachsafetychains.Routechainssonotto interferewithtailpipewhenvehicleislifted.

(5)TurntheignitionswitchtotheOFFpositionto unlockthesteeringwheel.

CAUTION:Donotusesteeringcolumnlockto securesteeringwheelduringtowingoperation.

(6)Securesteeringwheelinstraightaheadpositionwithaclampdevicedesignedfortowing.

(7)Placetransmissioninpark.

TWOWHEELDRIVETOWING-FRONTENDLIFTED

CAUTION:Manyvehiclesareequippedwithair dams,spoilers,and/orgroundeffectpanels.To avoidcomponentdamage,awheel-lifttowingvehicleoraflat-bedhaulingvehicleisrecommended.

(1)Attachwheelliftdevicetorearwheels.

(2)Placethetransmissioninneutral.

(3)Raisetherearofthevehicleoffthegroundand installtowdolliesunderrearwheels.

(4)Attachwheelliftdevicetofrontwheelsand raisevehicletotowingposition.

(5)Attachthesafetychains.

CAUTION:Donotusesteeringcolumnlockto securesteeringwheelduringtowingoperation.

(6)TurntheignitionswitchtotheOFFpositionto unlockthesteeringwheel.

(7)Securesteeringwheelinstraightaheadpositionwithaclampdevicedesignedfortowing.

(8)Placetransmissioninpark.

FOUR-WHEEL-DRIVEVEHICLETOWING

DaimlerChryslerCorporationrecommendsthata 4WDvehiclebetransportedonaflat-beddevice.A Wheel-liftdevicecanbeusedprovided thetrailing wheelsareoffthegroundandpositionedin towdollies.

WARNING:WHENTOWINGADISABLEDVEHICLE ANDTHEDRIVEWHEELSARESECUREDINA WHEELLIFTORTOWDOLLIES,ENSURETHE TRANSMISSIONISINTHEPARKPOSITION.

CAUTION:Manyvehiclesareequippedwithair dams,spoilers,and/orgroundeffectpanels.To avoidcomponentdamage,awheel-lifttowingvehicleoraflat-bedhaulingvehicleisrecommended.

FOURWHEELDRIVETOWING—REARENDLIFTED

WARNING:ENSUREVEHICLEISONALEVELSURFACEORTHEWHEELSAREBLOCKEDTOPREVENTVEHICLEFROMROLLING.

(1)Attachwheelliftdevicetofrontwheels. (2)Placethetransmissioninneutral.

TOWING(Continued)

(3)Raisethefrontofthevehicleofftheground andinstalltowdolliesunderfrontwheels.

(4)Attachwheelliftdevicetorearwheelsand raisevehicletotowingposition.

(5)Attachsafetychains.Routechainssonotto interferewithtailpipewhenvehicleislifted.

(6)TurntheignitionswitchtotheOFFpositionto unlockthesteeringwheel.

CAUTION:Donotusesteeringcolumnlockto securesteeringwheelduringtowingoperation.

(7)Securesteeringwheelinstraightaheadpositionwithaclampdevicedesignedfortowing.

(8)Placetransmissioninpark.

FOURWHEELDRIVETOWING—FRONTEND LIFTED

WARNING:ENSUREVEHICLEISONALEVELSURFACEORTHEWHEELSAREBLOCKEDTOPREVENTVEHICLEFROMROLLING.

(1)Attachwheelliftdevicetorearwheels.

(2)Placethetransmissioninneutral.

(3)Raisetherearofthevehicleoffthegroundand installtowdolliesunderrearwheels.

(4)Attachwheelliftdevicetofrontwheelsand raisevehicletotowingposition.

(5)Attachthesafetychains.

CAUTION:Donotusesteeringcolumnlockto securesteeringwheelduringtowingoperation.

(6)TurntheignitionswitchtotheOFFpositionto unlockthesteeringwheel.

(7)Securesteeringwheelinstraightaheadpositionwithaclampdevicedesignedfortowing.

(8)Placetransmissioninpark.

SUSPENSION

TABLEOFCONTENTS

DIAGNOSISANDTESTING-SUSPENSION ANDSTEERINGSYSTEM ................1

SUSPENSION

DIAGNOSISANDTESTING-SUSPENSIONAND STEERINGSYSTEM

CONDITIONPOSSIBLECAUSESCORRECTION

FRONTENDNOISE1.Looseorwornwheelbearings.1.Replacewheelbearings.

2.Looseorwornsteeringor suspensioncomponents.

2.Tightenorreplacecomponentsas necessary.

EXCESSIVEPLAYIN STEERING

1.Looseorwornwheelbearings.1.Replacewheelbearings.

2.Looseorwornsteeringor suspensioncomponents.

2.Tightenorreplacecomponentsas necessary.

3.Looseorwornsteeringgear.3.Adjustorreplacesteeringgear.

FRONTWHEELSSHIMMY1.Looseorwornwheelbearings.1.Replacewheelbearings.

2.Looseorwornsteeringor suspensioncomponents. 2.Tightenorreplacecomponentsas necessary.

3.Tireswornoroutofbalance.3.Replaceorbalancetires. 4.Alignment.4.Alignvehicletospecifications.

VEHICLEINSTABILITY1.Looseorwornwheelbearings.1.Replacewheelbearings.

2.Looseorwornsteeringor suspensioncomponents. 2.Tightenorreplacecomponentsas necessary.

3.Tirepressure.3.Adjusttirepressure. 4.Alignment.4.Alignvehicletospecifications.

EXCESSIVESTEERING EFFORT

VEHICLEPULLSTOONE SIDEDURINGBRAKING

1.Looseorwornsteeringgear.1.Adjustorreplacesteeringgear.

2.Powersteeringfluidlow.2.Addfluidandrepairleak. 3.Columncouplerbinding.3.Replacecoupler. 4.Tirepressure.4.Adjusttirepressure. 5.Alignment.5.Alignvehicletospecifications.

1.Uneventirepressure.1.Adjusttirepressure. 2.Wornbrakecomponents.2.Repairbrakesasnecessary. 3.Airinbrakeline.3.Repairasnecessary.

SUSPENSION(Continued)

CONDITIONPOSSIBLECAUSESCORRECTION

VEHICLELEADSOR DRIFTSFROMSTRAIGHT AHEADDIRECTIONON UNCROWNEDROAD

KNOCKING,RATTLING ORSQUEAKING

1.Radialtirelead.1.Crossfronttires.

2.Brakesdragging.2.Repairbrakeasnecessary.

3.Weakorbrokenspring.3.Replacespring.

4.Uneventirepressure.4.Adjusttirepressure.

5.WheelAlignment.5.Alignvehicle.

6.Looseorwornsteeringor suspensioncomponents.

6.Repairasnecessary.

7.Crosscasteroutofspec.7.Alignvehicle.

1.Wornshockbushings.1.Replaceshock.

2.Loose,wornorbentsteering/ suspensioncomponents.

3.Shockvalve.3.Replaceshock.

IMPROPERTRACKINGLoose,wornorbentsteering/ suspensioncomponents.

2.Inspect,tightenorreplacecomponents asnecessary.

Inspect,tightenorreplacecomponentsas necessary. 2-2SUSPENSION

WHEELALIGNMENT

DESCRIPTION

NOTE:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethe springssupportingtheweightofthevehiclewhen thefastenersaretorqued.Ifspringsarenotattheir normalrideposition,vehicleridecomfortcouldbe affectedandprematurebushingwearmayoccur.

Wheelalignmentinvolvesthecorrectpositioningof thewheelsinrelationtothevehicle.Thepositioning isaccomplishedthroughsuspensionandsteering linkageadjustments.Analignmentisconsidered essentialforefficientsteering,gooddirectionalstabilityandtominimizetirewear.Themostimportant measurementsofanalignmentarecaster,camber andtoe(Fig.1).

CAUTION:Neverattempttomodifysuspensionor steeringcomponentsbyheatingorbending.

NOTE:Periodiclubricationofthefrontsuspension/ steeringsystemcomponentsmayberequired.Rubberbushingsmustneverbelubricated.Referto LubricationAndMaintenancefortherecommended maintenanceschedule.

OPERATION

• CASTER istheforwardorrearwardtiltofthe steeringknucklefromvertical.Tiltingthetopofthe knuckleforwardprovidesnegativecaster.Tiltingthe topoftheknucklerearwardprovidespositivecaster. Positivecasterpromotesdirectionalstability.This

Fig.1WheelAlignmentMeasurements

1-FRONTOFVEHICLE

2-STEERINGAXISINCLINATION

3-PIVOTPOINT

4-TOE-IN

angleenablesthefrontwheelstoreturntoastraight aheadpositionafterturns(Fig.1)

• CAMBER istheinwardoroutwardtiltofthe wheelrelativetothecenterofthevehicle.Tiltingthe topofthewheelinwardprovidesnegativecamber. Tiltingthetopofthewheeloutwardprovidespositive camber.Incorrectcamberwillcausewearonthe insideoroutsideedgeofthetire(Fig.1)

• TOE isthedifferencebetweentheleadinginside edgesandtrailinginsideedgesofthefronttires. Wheeltoepositionoutofspecificationcause’sunstablesteering,uneventirewearandsteeringwheeloffcenter.Thewheeltoepositionisthe final front wheelalignmentadjustment(Fig.1)

• THRUSTANGLE istheangleoftherearaxle relativetothecenterlineofthevehicle.Incorrect thrustanglecancauseoff-centersteeringandexces-

sivetirewear.Thisangleisnotadjustable,damaged component(s)mustbereplacedtocorrectthethrust angle(Fig.1)

STANDARDPROCEDURE

STANDARDPROCEDURE-HEIGHT MEASUREMENT

RIDEHEIGHT

NOTE:Thesuspensionisnon-adjustable.

Thevehiclesuspensionheightshouldbemeasured beforeperformingwheelalignmentprocedure.Also whenfrontsuspensioncomponentshavebeen replaced.Thismeasuremustbeperformedwiththe vehiclesupportingit’sownweightandtakenonboth sidesofthevehicle.

Frontandrearrideheightsarenotadjustable.The springselectionsatassemblydeterminerideheight foracceptableappearanceofthevehicle.Rideheight dimensionsassumefullfluids(includingfuel)and zeropassengers.Refertothetablebelowforfront rideheightdimensions.

Vehiclerideheightauditsshouldbeperformedutilizingthefollowingprocedure:

(1)Drivethevehiclestraightandforwardona non-tackysurfaceforaminimumof20feettoneutralizetrackwidth.

(2)Bouncethefrontofthevehiclefivetimes.

(3)Measureandrecordthedimensions

FRONTRIDEHEIGHTFrontrideheightis definedbytherelativeverticaldistancebetweenthe spindlecenterlineandtherearpivotpointofthe frontlowercontrolarmtocradleattachment.The spindlecenterlineistobemeasuredattheouter wheelface(pointA).Therearpivotpointistobe measuredatthecenterofthecam/pivotbolt(point B)atitsrearwardmostend(nutend).(Fig.2)

REARRIDEHEIGHTRearrideheightisdefined bytherelativeverticaldistancebetweenthetopof thelowerspringseatstrikesurfaceandthebottom ofthejouncecup(truemetaltometaljouncetravel). Thisistobemeasuredverticallyinsidethecoilfrom thepointintersectingtheinboardedgeandthefor/ aftcenterofthejouncecup(pointC)downtothe strikesurface(pointD).(Fig.3)

Fig.2FRONTRIDEHEIGHTMESUREMENT

1-POINT-A

2-POINT-B

Fig.3REARRIDEHEIGHTMESUREMENT

1-POINT-C

2-POINT-D

WHEELALIGNMENT(Continued)

STANDARDPROCEDURE-CAMBERAND CASTERADJUSTMENT

Camberandcasterangleadjustmentsinvolve changingthepositionofthelowercontrolarmcam bolts.(Fig.4)

(2)Loosenthetierodjamnuts.

NOTE:Eachfrontwheelshouldbeadjustedfor one-halfofthetotaltoepositionspecification.This willensurethesteeringwheelwillbecentered whenthewheelsarepositionedstraight-ahead.

(3)Adjustthewheeltoepositionbyturningthetie rodasnecessary(Fig.5).

Fig.4LOWERCONTROLARM

1-FRONTCAMBOLT

2-OUTERTIERODEND

3-LOWERBALLJOINTNUT

4-LOWERCONTROLARM

5-REARCAMBOLT

STANDARDPROCEDURE-TOEADJUSTMENT

4X4SUSPENSIONHEIGHTMESUREMENT MUSTBEPERFORMEDBEFOREANALIGNMENT.

Thewheeltoepositionadjustmentisthefinal adjustment.

(1)Starttheengineandturnwheelsbothways beforestraighteningthewheels.Securethesteering wheelwiththefrontwheelsinthestraight-ahead position.

Fig.5TIERODEND

1-JAMNUT

2-TIEROD-INNER

3-TIERODEND-OUTER

(4)Tightenthetierodjamnutto75N·m(55ft. lbs.).

(5)Verifythespecifications (6)Turnoffengine.

STANDARDPROCEDURE-CAMBER,CASTER ANDTOEADJUSTMENT

Camberandcasterangleadjustmentsinvolve changingthepositionofthelowersuspensionarm cambolts.(Fig.4)

CASTER

Movingtherearpositionofthecamboltinorout, willchangethecasteranglesignificantlyandcamber angleonlyslightly.Tomaintainthecamberangle whileadjustingcaster,movetherearofthecambolt inorout.Thenmovethefrontofthecambolt slightlyintheoppositedirection.(Fig.4)

Toincreasepositivecasterangle,movetherear positionofthecamboltoutward(fromtheengine). Movethefrontofcamboltinward(towardthe engine)slightlyuntiltheoriginalcamberangleis obtained.(Fig.4)

WHEELALIGNMENT(Continued)

CAMBER

Movebothofthecamboltstogetherinorout.This willchangethecamberanglesignificantlyandcaster angleslightly.(Fig.4)

Afteradjustmentismadetightenthecamboltnuts topropertorquespecification.

TOEADJUSTMENT

Thewheeltoepositionadjustmentisthefinal adjustment.

(1)Starttheengineandturnwheelsbothways beforestraighteningthewheels.Securethesteering wheelwiththefrontwheelsinthestraight-ahead position.

(2)Loosenthetierodjamnuts.

NOTE:Eachfrontwheelshouldbeadjustedfor one-halfofthetotaltoepositionspecification.This willensurethesteeringwheelwillbecentered whenthewheelsarepositionedstraight-ahead.

(3)Adjustthewheeltoepositionbyturningthetie rodasnecessary(Fig.5).

(4)Tightenthetierodjamnutto75N·m(55ft. lbs.).

(5)Verifythespecifications (6)Turnoffengine.

SPECIFICATIONS

ALIGNMENT

NOTE:Specificationsareindegrees.

FRONT

REAR

SPECIFICATIONS

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FRONT

DESCRIPTION

Thefrontsuspensionisdesignedtoalloweach wheeltoadapttodifferentroadsurfacesindependently.Thewheelsaremountedtohubbearingson thesteeringknucklespindles.Thedouble-rowhub bearingsaresealedandlubricatedforlife.Thesteeringknucklesturn(pivot)onballjointsintegraltothe outboardportionoftheuppercontrolarmsand pressedintothelowersteeringknuckle.Theball jointsarelubricatedforlife.(Fig.1)

FRONT(Continued)

1-SWAYBAR

Fig.1FRONTSUSPENSION

2-SWAYBARBUSHING/BRACKET

3-UPPERCONTROLARM

4-SPRING/SHOCKASSEMBLY

5-STEERINGKNUCKLE

6-OUTERTIERODEND

7-LOWERCONTROLARM

8-SWAYBARLINK

9-CLEVISBRACKET 2-8FRONT

SPECIFICATIONS

TORQUECHART

WARNING

WARNING:Suspensioncomponentswithrubber bushingsmustbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethesprings supportingtheweightofthevehiclewhenthefastenersaretorqued.Ifspringsarenotattheirnormal rideposition,vehicleridecomfortwillbeaffected andcauseprematurebushingwear.

TORQUESPECIFICATIONS

DESCRIPTIONN·mFt.Lbs.In.Lbs.

FrontShockAbsorber

ClevisBracketUpperNut

FrontShockAbsorber

ClevisBracketLowerNut

FrontShockAbsorberTop (4)MountingNuts

FrontShocktoSpringand InsulatorNut

UpperSuspensionArm FrontNut

UpperSuspensionArm RearNut

LowerSuspensionArm FrontNut

LowerSuspensionArm RearNut

StabilizerBarClampNut149110—

FRONT(Continued)

StabilizerBarLinkUpper Nut 136100—

StabilizerBarLinkLower Nut 11585—

SPECIALTOOLS FRONTSUSPENSION

BALLJOINTPRESS-C-4212F

FRONTLOWERCONTROLARM&CLEVIS BUSHINGREMOVER/INSTALLER-8858

RemoverC-4150A

REMOVER/INSTALLERFRONTLOWERBALL JOINT-8859

FRONTLOWERCONTROLBUSHINGREMOVER/ INSTALLER-8830

BUSHINGS

REMOVAL

REMOVAL-STABILIZERBARBUSHINGS

(1)Raisevehicleonhoist.

(2)Removethestabilizerbushingclamps.

(3)Removethestabilizerbushingsfromthestabilizerbar.

REMOVAL-LOWERCONTROLARMBUSHING

(1)Removethelowercontrolarm(Referto2SUSPENSION/FRONT/LOWERCONTROLARMREMOVAL).

(2)Securethecontrolarminavise.

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(3)Pressthebushingoutusingspecialtools 8858-5(Receiver),8858-6(Driver)and8839withthe threadedrodandthebearingasshown(Fig.2)

NOTE:Extremepressurelubricationmustbeusedon thethreadedportionsofthetool.Thiswillincrease thelongevityofthetoolandinsureproperoperation duringtheremovalandinstallationprocess.

(2)Pressthebushingoutusingspecialtools 8858-1(receiver),8858-3(driver)and8839withthe threadedrod8839andthebearingasshown(Fig.3)

Fig.2LOWERCONTROLARMBUSHINGREMOVAL

1-8858-5RECEIVER

2-8858-6DRIVER

3-8839THREADEDROD

REMOVAL-CLEVISBRACKETBUSHING

(1)Removetheclevisbracketfromtheshock (Referto2-SUSPENSION/FRONT/CLEVIS BRACKET-REMOVAL).

Fig.3CLEVISBRACKETBUSHING

1-8839THREADEDROD 2-8858-1RECEIVER 3-8858-3DRIVER

REMOVAL-UPPERCONTROLARMBUSHINGS

(1)Removetheuppercontrolarm(Referto2SUSPENSION/FRONT/UPPERCONTROLARMREMOVAL).

(2)Securethecontrolarminavise.

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(3)Installbushingremovertools8830-3(Adapter), 8830-2(Receiver)and8830–4(Driver)withthe threadedrod8838andthebearingasshown(Fig.4) (4)Pressoutthebushing.

INSTALLATION

INSTALLATION-STABILIZERBARBUSHINGS

(1)Installthestabilizerbushingstothestabilizer bar.

(2)Installthestabilizerbushingclamps.Tighten thenutsto149N·m(110ft.lbs.).

(3)Lowerthevehicle.

BUSHINGS(Continued)

Fig.4UPPERCONTROLARMBUSHINGREMOVAL

1-8830-3(ADAPTER)

2-8830-2(RECIEVER)

3-8830-4(DRIVER)

4-8838(THREADEDROD)

INSTALLATION-LOWERCONTROLARM BUSHING

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(1)Installthenewlowercontrolarmbushingsinto thelowercontrolarmusingtools8858-5(driver), 8858-6(receiver)andthebearingwiththethreaded rod8839(Fig.5)makingsuretoproperlyorientthe bushinginthecontrol.

(2)Removethecontrolarmfromthevise.

(3)Installthelowercontrolarm(Referto2-SUSPENSION/FRONT/LOWERCONTROLARMINSTALLATION).

(4)Resetthevehiclerideheight(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

(5)Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

INSTALLATION-CLEVISBRACKETBUSHING

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

Fig.5LOWERCONTROLARMBUSHINGINSTALLATION

1-8858-5DRIVER 2-8858-6RECEIVER 3-8839THREADEDROD

(1)Installthenewclevisbracketbushingintothe lowercontrolarmusingtools8858-2(driver),8858-1 (receiver)andthebearingwiththethreadedrod 8839(Fig.6)makingsuretoproperlyorientthe bushinginthecontrol.

Fig.6CLEVISBRACKETBUSHING

1-8839THREADEDROD 2-8858-2DRIVER 3-8858-1RECEIVER

(2)Installtheclevisbracket(Referto2-SUSPENSION/FRONT/CLEVISBRACKET-INSTALLATION).

INSTALLATION-UPPERCONTROLARM BUSHINGS

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(1)Installthenewuppercontrolarmbushings intotheuppercontrolarmusingtools8830-3 (Adapter),8830-1(Driver)and8830-2(Receiver)the bearingwiththethreadedrod8838(Fig.7)making suretoproperlyorientthebushinginthecontrol arm.

(2)Removethecontrolarmfromthevise.

(3)Installtheuppercontrolarm(Referto2-SUSPENSION/FRONT/UPPERCONTROLARMINSTALLATION).

(4)Resetthevehiclerideheight(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

(5)Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

(3)Removethecaliperadapter(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERS-REMOVAL).

CAUTION:Neverallowthediscbrakecaliperto hangfromthebrakehose.Damagetothebrake hosewillresult.Provideasuitablesupporttohang thecalipersecurely.

(4)Removethediscbrakerotor(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSREMOVAL).

(5)Removethewheelspeedsensor(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-REMOVAL).

(6)Removethebracketsecuringthewheelspeed sensorwire.

(7)Removetheaxleshaftnut.(ifequippedwith fourwheeldrive)

(8)Removethethreemountingboltsforthehub/ bearingassembly.

(9)Removethehub/bearing.

INSTALLATION

(1)Installthehub/bearingassemblytothevehicle.

(2)Installthethreemountingboltsforthehub/ bearing.Tightentheboltto130N·m(96ft.lbs.).

(3)Installtheaxleshaftnut.Tightenthenutto 135N·m(100ft.lbs.).(ifequippedwithfourwheel drive)

(4)Installthebrackettothewheelspeedsensor wire.

(5)Installthewheelspeedsensortothehub. Tightentheboltto13.5N·m(10ft.lbs.)(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-INSTALLATION).

(6)Installthediscbrakerotor(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSINSTALLATION).

(7)Installthediscbrakecaliperadapter.Tighten thenutto135N·m(100ft.lbs.)(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSINSTALLATION).

(8)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

HUB/BEARING

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethetireandwheelassembly.

KNUCKLE

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethetireandwheelassembly.

(3)Removethecaliperadapter.(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERADAPTER-REMOVAL).

CAUTION:Neverallowthediscbrakecaliperto hangfromthebrakehose.Damagetothebrake hosewillresult.Provideasuitablesupporttohang thecalipersecurely.

(4)Removethediscbrakerotor.(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSREMOVAL).

(5)Removethewheelspeedsensor.(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-REMOVAL).

(6)Removetheaxleshaftnut.(ifequippedwith fourwheeldrive)

(7)Removethehub/bearing.(Referto2-SUSPENSION/FRONT/HUB/BEARING-REMOVAL).

(8)Seperatetheoutertierodendfromthesteeringknuckle.(Referto19-STEERING/LINKAGE/ TIERODEND-REMOVAL).

(9)Removethelowerballjointnut.

(10)SeperatethelowerballjointfromthesuspensionarmusingtoolC–4150A.

(11)Removetheupperballjointnut.

(12)Seperatetheupperballjointfromtheknuckle usingtoolC–4150A.

(13)Removetheknucklefromthevehicle.

INSTALLATION

(1)Installtheknuckletothevehicle.

(2)Installtheupperballjointnut.Tightenthenut to81N·m(60ft.lbs.).

(3)Installthelowerballjointnut.Tightenthenut to81N·m(60ft.lbs.).

(4)Installtheoutertierodendtothesteering knuckle.(Referto19-STEERING/LINKAGE/TIE RODEND-INSTALLATION).

(5)Installthehub/bearing.(Referto2-SUSPENSION/FRONT/HUB/BEARING-INSTALLATION).

(6)Installtheaxleshaftnut.Tightenthenutto 135N·m(96ft.lbs.).(ifequippedwithfourwheel drive).

(7)Installthewheelspeedsensor.(Referto5BRAKES/ELECTRICAL/FRONTWHEELSPEED SENSOR-INSTALLATION).

(8)Installthediscbrakerotor.(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSINSTALLATION).

(9)Installthecaliperadapter.(Referto5BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKECALIPERADAPTER-INSTALLATION).

(10)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(11)Performthesettoeprocedure(Referto2SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

LOWERBALLJOINT

DIAGNOSISANDTESTING-LOWERBALL JOINT

(1)Raisethevehicleonadrive-onhoist.

NOTE:Ifadrive-onhoistisnotavailable,use woodenblockswithjackstandstosupportthe lowercontrolarmintheballjointarea.Placethe jackstandsappropriatelyandlowerthehoistplacingweightonthelowercontrolarm.Thelowercontrolarmsshouldnowbesupportingthevehicle weight.

(2)Withtheuseofjackstands,liftthefrontend offthehoistandpositionwoodenblocksunderneath bothlowercontrolarmssupportingthevehicles weight.

(3)Removethetireandwheelassembly.

(4)Attachadialindicatortothebaseofthelower controlarmandalignthedialindicator’scontact pointwiththedirectionofthestudaxis,touchthe machinedflatontheknuckleandzerothedialindicator.(Fig.8)

NOTE:Usecarewhenapplyingtheloadtothe knuckle,sothepartsarenotdamagedusingcare nottoteartheboot.

(5)Fromthefrontofthevehicle,insertaprybar togetitrestedonthelowercontrolarmanduse leverprincipletopushtheknuckleupuntilthearm ofthedialindicatornolongermoves.

(6)Recordtheballjointmovementoneachsideof thevehicle.Theendplayisacceptablewithnomore than1.5mmofendplaybacktoback.

REMOVAL

(1)Removethetireandwheelassembly.

(2)Removethebrakecaliperandrotor(Referto5 -BRAKES/HYDRAULIC/MECHANICAL/ROTORSREMOVAL).

(3)Disconnectthetierodfromthesteering knuckle(Referto19-STEERING/LINKAGE/TIE RODEND-REMOVAL).

(4)Removethesteeringknuckle(Referto2-SUSPENSION/FRONT/KNUCKLE-REMOVAL).

(5)Movethehalfshafttothesideandsupportthe halfshaftoutoftheway(IfEquipped).

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(6)Securethesteeringknuckleinavise.

Fig.8SUSPENSIONINTHECURBPOSITION

1-PRYBAR

2-BALLJOINT

3-DIALINDICATOR

4-WOODENBLOCKORSUPPORT

5-CLAMP

(7)Removetheballjointboot.

(8)Presstheballjointfromthesteeringknuckle usingspecialtoolsC-4212–F(PRESS),8859-2 (RECEIVER)and8859-1(DRIVER)(Fig.9).

(1)Installtheballjointintothesteeringknuckle andpressinusingspecialtoolsC-4212–F(press), 8859-3(driver)and6761(receiver)(Fig.10).

Fig.9LOWERBALLJOINT

1-8859-1DRIVER

2-C-4212FPRESS

3-8859-2RECEIVER

INSTALLATION

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

Fig.10LOWERBALLJOINT

1-6761RECEIVER

2-8859-3DRIVER

3-C-4212FPRESS

(2)Installtheballjointboot.

(3)Removethesupportforthehalfshaftand installintoposition(IfEquipped).

(4)Installthesteeringknuckle(Referto2-SUSPENSION/FRONT/KNUCKLE-INSTALLATION).

(5)Installthetierodendintothesteeringknuckle (Referto19-STEERING/LINKAGE/TIERODENDINSTALLATION).

(6)Installandtightenthehalfshaftnutto136 N·m(100ft.lbs.).

(7)Installthebrakecaliperandrotor(Referto5BRAKES/HYDRAULIC/MECHANICAL/ROTORSINSTALLATION).

(8)Installthetireandwheelassembly(Referto22 -TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(9)Checkthevehiclerideheight(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

(10)Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

LOWERCONTROLARM

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethetireandwheelassembly.

(3)Removethelowerclevisbracketboltatthe lowercontrolarm.

(4)Removethestabilizerlinkboltatthelower controlarm.

(5)Removethelowerballjointnut.

(6)Separatethelowerballjointfromthelower controlarmusingtoolC-4150A.

NOTE:Markingthelowercontrolarmpivotbolts frontandrearwillaidintheassemblyprocedure.

(7)Markthelowercontrolarmpivotboltsfront andrear.

(8)Removethefrontcam/pivotbolt.(Fig.11)

(9)Removetherearcam/pivotbolt.(Fig.11)

(10)Removethelowercontrolarmfromthevehicle.

(9)Performafullwheelalignment(Referto2SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).

SHOCK REMOVAL

REMOVAL-LEFTSIDE

(1)Disconnectthebattery.

(2)Removethebattery(Referto8-ELECTRICAL/BATTERYSYSTEM/BATTERY-REMOVAL).

(3)Unclipthepowercenterandmoveittotheside outoftheway.

(4)Removethebatterytray(Referto8-ELECTRICAL/BATTERYSYSTEM/TRAY-REMOVAL).

(5)Disconnectthebatterytemperaturesensor fromthebatterytray.

(6)Removethefouruppershockmountingnuts.

(7)Raiseandsupportthevehicle.

(8)Removethelefttireandwheelassembly.

(9)Removethelowerboltatthelowercontrol securingtheclevisbracket.

(10)Removethestabilizerlink(Referto2-SUSPENSION/FRONT/STABILIZERLINK-REMOVAL).

(11)Removethelowerballjointnut.

(12)Seperatethelowerballjointfromthelower controlarmusingtoolC-4150A.

(13)Rotatethelowercontrolarmdownwardto allowaccess.

Fig.11LOWERCONTROLARM

1-FRONTCAMBOLT

2-OUTERTIERODEND

3-LOWERBALLJOINTNUT

4-LOWERCONTROLARM

5-REARCAMBOLT

INSTALLATION

(1)Installthelowercontrolarmtothevehicle.

(2)Installtherearcam/pivotbolt.

(3)Installthefrontcam/pivotbolt.

(4)Installthelowerballjointnut.Tightenthenut to81N·m(60ft.lbs.)

(5)Alignthemarksfrontandrearatthecam/ pivotboltsandtightenthenuts.Tightenthenutsto 170N·m(125ft.lbs.)

(6)Installthestabilizerlinkboltatthelowercontrolarm.Tightenthenutto136N·m(100ft.lbs.)

(7)Installthelowerclevisbracketboltatthe lowercontrolarm.Tightenthenutto150N·m(110 ft.lbs.)

(8)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(14)Removetheclevisbracketattheshock. (15)Removetheshockassemblyfromthevehicle. (Fig.12)

(16)Removethespringfromtheshock(ifneeded).

REMOVAL-RIGHTSIDE

(1)Removetheairbox(Referto9-ENGINE/AIR INTAKESYSTEM/AIRCLEANERELEMENTREMOVAL).

(2)Removethetwocruisecontrolservomounting nuts.

(3)Removetheuppershockmountingnuts.

(4)Raiseandsupportthevehicle.

(5)Removetherightsidetireassembly.

(6)Removethelowerboltatthelowercontrol securingtheclevisbracket.

(7)Removethestabilizerlink(Referto2-SUSPENSION/FRONT/STABILIZERLINK-REMOVAL).

(8)Removethelowerballjointnut.

(9)Seperatethelowerballjointfromthelower controlarmusingtoolC-4150A.

(10)Rotatethelowercontrolarmdownwardto allowaccess.

(11)Removetheclevisbracketattheshock.(Fig. 13)

Fig.12SHOCKASSEMBLY

(12)Removetheshockassemblyfromthevehicle. (Fig.13)

(13)Removethespringfromtheshock(ifneeded). (Referto2-SUSPENSION/FRONT/SPRINGREMOVAL).

INSTALLATION

INSTALLATION-LEFTSIDE

(1)Installthespringtotheshock(ifremoved). (2)Installtheshockassemblytothevehicle. (3)Installthefouruppershockmountingnuts. Tightenthenutsto108N·m(80ft.lbs.).

(4)Installtheclevisbracketattheshock.(Referto 2-SUSPENSION/FRONT/CLEVISBRACKETINSTALLATION).Tightentheboltto88N·m(65 ft.lbs.).

(5)Raisethelowercontrolintoplaceandreconnectthelowerballjointnut.Tightenthenutto81 N·m(60ft.lbs.).

(6)Installtheclevisbracketatthelowercontrol arm.(Referto2-SUSPENSION/FRONT/CLEVIS BRACKET-INSTALLATION).Tightentheboltto 150N·m(110ft.lbs.).

(7)Installthelowerstabilizerlinkatthelower controlarm.Tightentheboltto136N·m(100ft.lbs.) (Referto2-SUSPENSION/FRONT/STABILIZER LINK-INSTALLATION).

(8)Installthelefttireandwheelassembly.(Refer to22-TIRES/WHEELS/WHEELS-STANDARD PROCEDURE).

(9)Lowerthevehicle.

(10)Reconnectthebatterytemperaturesensor.

(11)Installthebatterytray(Referto8-ELECTRICAL/BATTERYSYSTEM/TRAY-INSTALLATION).

(12)Installthebattery(Referto8-ELECTRICAL/BATTERYSYSTEM/BATTERY-INSTALLATION).

(13)Reconnectthebatterycables.

INSTALLATION-RIGHTSIDE

(1)Installthespringtotheshock(ifremoved). (Referto2-SUSPENSION/FRONT/SPRINGINSTALLATION).

(2)Installtheshockassemblytothevehicle.

(3)Installthefouruppershockmountingnuts. Tightenthenutsto108N·m(80ft.lbs.).

(4)Installtheclevisbracketattheshock.(Referto 2-SUSPENSION/FRONT/CLEVISBRACKETINSTALLATION).Tightentheboltto88N·m(65 ft.lbs.).

Fig.13SHOCK&CLEVISASSEMBLY

1-FRONTCRADLE

2-SPRING&SHOCKASSEMBLY

3-STEERINGKNUCKLE

4-CLEVISBRACKET

5-LOWERCONTROLARM

(5)Raisethelowercontrolintoplaceandreconnectthelowerballjointnut.Tightenthenutto81 N·m(60ft.lbs.).

(6)Installtheclevisbracketatthelowercontrol arm.(Referto2-SUSPENSION/FRONT/CLEVIS BRACKET-INSTALLATION).Tightentheboltto 150N·m(110ft.lbs.).

(7)Installthelowerstabilizerlinkatthelower controlarm.Tightentheboltto136N·m(100ft.lbs.)

(Referto2-SUSPENSION/FRONT/STABILIZER LINK-INSTALLATION).

(8)Installtherighttireandwheelassembly. (Referto22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(9)Lowerthevehicle.

(10)Installthecruisecontrolservomountingnuts.

(11)Installtheairbox(Referto9-ENGINE/AIR INTAKESYSTEM/AIRCLEANERELEMENTINSTALLATION).

SPRING

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethetireandwheelassembly.

(3)Removetheshock.Refertotheproperside shockremovalprocedurebeingworkedon.(Referto2 -SUSPENSION/FRONT/SHOCK-REMOVAL).

(4)SecuretheshockassemblyintoaPentastar ServiceEquipmentW-7200Springcompressor.(Fig. 14)

(5)Compressthespring.

Fig.14SPRINGCOMPRESSOR

1-SPRINGCOMPRESSOR

2-SPRING

(6)Removetheshockmountnut.

(7)Removetheshockfromthespringcompressor.

(8)Transferthenecessarypartstothetypeof repairbeingdone(Insulator,Spring,shockand mount).

INSTALLATION

(1)Installtheshocktothespringandspringcompressor,Afterthetransferofthenecessarypartsto thetypeofrepairbeingdone(Insulator,Spring, shockandmount).

(2)Installtheshockmountingnut.Tightenthe boltto41N·m(30ft.lbs.).

(3)Loosenthecompressedspring.

(4)Removetheshockassemblyfromthespring compressor.

(5)Installtheshocktothevehicle.(Referto2SUSPENSION/FRONT/SHOCK-INSTALLATION).

(6)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(7)Removethesupportandlowerthevehicle.

CLEVISBRACKET

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethetireandwheelassembly.

(3)Removethelowerclevisboltatthelowercontrolarm.(Fig.15)

(4)Removetheupperclevisboltattheshock.(Fig. 15)

Fig.15CLEVISBRACKET

1-UPPERBOLT

2-CLEVISBRACKET

3-LOWERBOLT

(5)Removethelowerstabilizerlinkboltatthe lowercontrolarm.

(6)Removethelowerballjointnut.

(7)Seperatethelowerballjointfromthelower controlarmusingtoolC-4150A.

(8)Swingthelowercontrolarmdownwardto allowclearencetoremovetheclevisbraket.

(9)Removetheclevisbracketfromthevehicle.

INSTALLATION

(1)Installtheclevisbrackettotheshock Seatthe clevisagainstthestopontheshock.Tightenthe boltto136N·m(100ft.lbs.)(Fig.15).

(2)Raisethelowercontrolarmtothelowerball joint.

(3)Installthenuttothelowerballjoint.Tighten thenutto81N·m(60ft.lbs.).

(4)Installtheclevisbrackettothelowercontrol arm.Tightentheboltto150N·m(110ft.lbs.).

(5)Installthelowerstabilizerlinkboltatthe lowercontrolarm.Tightentheboltto115N·m(85 ft.lbs.).

(6)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(7)Lowerthevehicle.

STABILIZERBAR

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethetireandwheelassembly.

(3)Removetheupperstabilizerlinkboltsatthe stabilizerbar.

(4)Removethestabilizerbarbushingclampsfrom theframe(Fig.16).

(5)Removethestabilizerbarfromthevehicle.

STABILIZERLINK

REMOVAL

(1)Raiseandsupportthevehicle. (2)Removethetireandwheelassembly.

(3)Removethelowerstabilizerlinkboltatthe lowercontrolarm.

(4)Removetheupperstabilizerlinkboltatthe stabilizerbar.

(5)Removethestabilizerlink.(Fig.17)

Fig.16SWAYBAR

1-SWAYBAR

2-SWAYBARBUSHINGS

INSTALLATION

(1)Installthestabilizerbartothevehicle.

(2)Installthestabilizerbarbushingclamps(Fig. 16).Tightenthenutsto149N·m(110ft.lbs.).

(3)Installtheupperstabilizerlinkboltsand washeratthestabilizerbar.Tightentheboltto136 N·m(100ft.lbs.).

(4)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(5)Lowerthevehicle.

Fig.17STABILIZERBARLINK

1-STABILIZERBAR

2-STABILIZERBARLINK

INSTALLATION

(1)Installthestabilizerlink(Fig.17).

(2)Installtheupperstabilizerlinkboltand washeratthestabilizerbar.Tightentheboltto136 N·m(100ft.lbs.).

(3)Installthelowerstabilizerlinkboltand washeratthelowercontrolarm.Tightenthenutto 115N·m(85ft.lbs.).

(4)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

UPPERCONTROLARM REMOVAL

REMOVAL-RIGHTSIDE

(1)Raiseandsupportthevehicle.

(2)Removetherightsidetireandwheelassembly.

(3)Removetheupperballjointnut.

(4)Separatetheupperballjointfromthesteering knuckleusingtoolC-4150A.

(5)Lowerthevehicle.

(6)Removetheairbox(Referto9-ENGINE/AIR INTAKESYSTEM/AIRCLEANERELEMENTREMOVAL).

UPPERCONTROLARM(Continued)

(7)Removethecruisecontrolservomountingnuts.

(8)Removetheuppercontrolarmrearbolt.

(9)Removetheuppercontrolarmfrontbolt.

(10) Removetheuppercontrolarmfromthevehicle.

REMOVAL-LEFTSIDE

(1)Raiseandsupportthevehicle.

(2)Removetheleftsidetireandwheelassembly.

(3)Removetheupperballjointnut.

(4)Separatetheupperballjointfromthesteering knuckleusingtoolC-4150A.

(5)Lowerthevehicle.

(6)Removethebattery(Referto8-ELECTRICAL/BATTERYSYSTEM/BATTERY-REMOVAL).

(7)Unclipthepowercenterandmoveittotheside outoftheway.

(8)Removethebatterytray(Referto8-ELECTRICAL/BATTERYSYSTEM/TRAY-REMOVAL).

(9)Disconnectthebatterytemperaturesensor fromthebatterytray.

(10)Removetheuppercontrolarmrearboltby usingaratchetandextensionunderthesteering shaftandpositionedbythepowersteeringreservoir. (Fig.18)

(5)Installtheairbox(Referto9-ENGINE/AIR INTAKESYSTEM/AIRCLEANERELEMENTINSTALLATION).

(6)Installtheupperballjointnut.Tightenthenut to81N·m(60ft.lbs.).

(7)Installtherightsidetireandwheelassembly. (Referto22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(8)Lowerthevehicle.

(9)Setthetoeandcenterthesteeringwheel (Referto2-SUSPENSION/WHEELALIGNMENTSTANDARDPROCEDURE).

INSTALLATION-LEFTSIDE

(1)Installtheuppercontrolarmtothevehicle.

(2)Installtheuppercontrolarmfrontbolt(Fig. 19).Tightentheboltto122N·m(90ft.lbs.).

(3)Installtheuppercontrolarmrearbolt(Fig. 19).Tightentheboltto122N·m(90ft.lbs.).

(4)Reconnectthebatterytemperaturesensorto thebatterytray.

(5)Installthebatterytray(Referto8-ELECTRICAL/BATTERYSYSTEM/TRAY-INSTALLATION).

(6)Installthebattery(Referto8-ELECTRICAL/ BATTERYSYSTEM/BATTERY-INSTALLATION).

(7)Reclipandmountthepowercenter.

(8)Installtheupperballjointnut(Fig.19). Tightenthenutto81N·m(60ft.lbs.).

Fig.18REARBOLT

(11)Removetheuppercontrolarmfrontbolt.

(12) Removetheuppercontrolarmfromthevehicle.

INSTALLATION

INSTALLATION-RIGHTSIDE

(1)Installtheuppercontrolarmtothevehicle.

(2)Installtheuppercontrolarmfrontbolt. Tightentheboltto122N·m(90ft.lbs.).

(3)Installtheuppercontrolarmrearbolt.Tighten theboltto122N·m(90ft.lbs.).

(4)Installthecruisecontrolservomountingnuts.

Fig.19UPPERCONTROLARM

1-FRONTPIVOTBOLT 2-REARPIVOTBOLT 3-RATCHETTOOL 4-STEERINGKNUCKLE

(9)Installtheleftsidetireandwheelassembly. (Referto22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).

(10)Lowerthevehicle.

(11)Setthetoeandcenterthesteeringwheel (Referto2-SUSPENSION/WHEELALIGNMENTSTANDARDPROCEDURE).

REAR

DESCRIPTION

Therearsuspension(Fig.1)iscomprisedof:

• Driveaxle

• Shockabsorbers

• Coilsprings

• Lowersuspensionarms

• Uppersuspensionarm

• Stabilizerbar

CAUTION:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethe springssupportingtheweightofthevehiclewhen thefastenersaretorqued.Thiswillmaintainvehicle ridecomfortandpreventprematurebushingwear.

1-COILSPRING

2-UPPERSUSPENSIONARM

3-STABILIZERBAR 4-LOWERSUSPENSIONARM 5-SHOCK

Fig.1REARSUSPENSION

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REAR(Continued)

WARNING

WARNING:Suspensioncomponentswithrubber bushingsmustbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethesprings

DIAGNOSISANDTESTING-REARSUSPENSION

supportingtheweightofthevehiclewhenthefastenersaretorqued.Ifspringsarenotattheirnormal rideposition,vehicleridecomfortwillbeaffected andcauseprematurebushingwear.

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.Looseupperballjoint.4.Replaceballjoint.

5.Loose,wornorbentsuspension components.

IMPROPERTRACKING1.Loose,wornorbentsuspension components.

SPECIFICATIONS

TORQUECHART

5.Inspect,tightenorreplacecomponents asnecessary.

1.Inspect,tightenorreplacecomponents asnecessary.

2.Bentaxle.2.Replaceaxle.

TORQUESPECIFICATIONS

DESCRIPTIONN·mFt.Lbs.In.Lbs.

ShockAbsorberUpper Nut 10880—

ShockAbsorberLower Nut 11585—

SuspensionArmUpper BallJointNut 9570—

SuspensionArmUpper FrameBolts 10074— ControlArmFrameBolts10074—

RearUpperBallJoint BracketBolts 136100—

SuspensionArmsLower Body/AxleBracketNut 163120—

ControlArmstoControl ArmBracket 10175—

SuspensionArmsLower FrameBracketNut 163120—

ControlArmBracketto RearDifferential 135100—

RearDifferentialDamper toRearDifferential 6145—

StabilizerBarBolts9973—

SPECIALTOOLS

REARSUSPENSION

BALLJOINTPRESS-C-4212F

REMOVAL/INSTALLATIONREARUPPER CONTROLARMBUSHINGS-8860

REMOVER/INSTALLERREARUPPERBALLJOINT -8861

SHOCK

REMOVAL

(1)Raiseandsupportthevehicle.Positiona hydraulicjackundertheaxletosupporttheaxle.

CAUTION:Donotallowtheaxletohangfromthe uppersuspensionarmballjoint.

(2)Removetheuppernutandboltfromtheframe bracket(Fig.2).

REARLOWERCONTROLARMBUSHING REMOVER/INSTALLER-8862

(3)Removethelowernutandboltfromtheaxle bracket.Removetheshockabsorber.

INSTALLATION

(1)Installtheshockabsorberintheframebracket andinstalltheboltandnut(Fig.2).

(2)Installtheshockabsorberintheaxlebracket andinstalltheboltandnut(Fig.2).

(3)Removethesupportsandlowerthevehicle.

Fig.2SHOCKABSORBER

1-UPPERMOUNTINGBOLT

2-LOWERMOUNTINGBOLT

(4)Tightentheuppermountingnutsto108N·m (80ft.lbs.).Tightenthelowermountingnutsto115 N·m(85ft.lbs.).

SPRING

REMOVAL

(1)Raiseandsupportthevehicle.Positiona hydraulicjackundertheaxletosupporttheaxle.

(2)Removetheshockabsorberlowerboltfromthe axlebracket.

(3)Lowerthehydraulicjackandtilttheaxleand removethecoilspring(Fig.3).

(4)Removeandinspecttheupperandlower springisolators(Fig.3).

INSTALLATION

(1)Installtheupperisolator(Fig.3).

(2)Installthelowerisolator(Fig.3).

(3)Pulldownontheaxleandpositionthecoil springinthelowerisolator.

CAUTION:Ensurethespringispositionedonthe lowerisolator.

(4)Raisetheaxlewiththehydraulicjack.

(5)Installtheshockabsorbertotheaxlebracket andtightento115N·m(85ft.lbs.).

(6)Removethesupportsandlowerthevehicle.

(7)Tightenthestabilizerbarlinksto99N·m(73 ft.lbs.).

JOUNCEBUMPER

REMOVAL

(1)Removetheshock(Referto2-SUSPENSION/ REAR/SHOCK-REMOVAL).

(2)Removethecoilspring(Referto2-SUSPENSION/REAR/SPRING-REMOVAL).

(3)Pullthejouncebumperdownwardstoremove. (Fig.4)

INSTALLATION

(1)Installthejouncebumperintothemountby twistingthebumperintoplace(Fig.4).

(2)Installthecoilspring(Referto2-SUSPENSION/REAR/SPRING-INSTALLATION).

(3)Installtheshock(Referto2-SUSPENSION/ REAR/SHOCK-INSTALLATION).

Fig.3COILSPRING

1-UPPERINSULATOR

Fig.4JOUNCEBUMPER

STABILIZERBAR

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Removethestabilizerbarboltsfromthelower suspensionarm.(Fig.5).

(3)Removethestabilizerbar.

UPPERBALLJOINT

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Supporttherearaxlewithahydraulicjack.

(3)Removetheballjointpinchboltfromthetopof theaxle.(Fig.7)

(4)Separatetheballjointarmassemblyfromthe differentialhousingbypryingupwards.

Fig.5REARSTABILIZERBAR

1-MOUNTINGHOLES

2-STABILIZERBAR

INSTALLATION

(1)Positionthestabilizerbarovertheaxleand installtheboltstothelowersuspensionarm(Fig.6). Ensurethebariscenteredwithequalspacingon bothsides.Tightentheboltsto99N·m(73ft.lbs.).

(2)Removesupportandlowerthevehicle.

Fig.7BALLJOINTPINCHBOLT

1-UPPERBALLJOINT 2-PINCHBOLT

(5)Removetheuppersuspensionarmfromthe vehicle(Referto2-SUSPENSION/REAR/UPPER CONTROLARM-REMOVAL).

(6)Securethesuspensionarminavise.

(7)InstallspecialtoolsC-4212F(press),8861-3 (driver)and8861-2(receiver)(Fig.8)

Fig.6STABILIZERBARMOUNTS

1-STABILIZERBARMOUNTINGBOLTS

2-LOWERSUSPENSIONARM

Fig.8UPPERBALLJOINT-REMOVAL 1-C-4212FPRESS 2-8861-3DRIVER 3-8861-2RECEIVER

(8)Pressouttheoldballjoint.

UPPERBALLJOINT(Continued)

INSTALLATION

(1)InstallspecialtoolsC-4212F(press),8861-1 (receiver)and8861-2(driver)withtheballjointin place(Fig.9).

OPERATION-UPPERSUSPENSIONARM, BUSHINGS,ANDBALLJOINT

Theuppersuspensionarmprovidesfore/aftand laterallocationoftherearaxle.Thesuspensionarm travelislimitedthroughtheuseofjouncebumpers incompressionandshockabsorbersinrebound.

REMOVAL

(1)Raiseandsupportthevehicle.

(2)Supporttherearaxlewithahydraulicjack.

(3)Removetheballjointpinchboltfromthetopof thedifferentialhousingbracket(Fig.7).

(4)Removepartialnutsfromtheheatshieldin ordertolowertheshielddownenoughtogetthe properclearencetoremovetherightsideboltfrom thebody.

(5)Removetheuppersuspensionarmmounting boltsfromthebodyandremovethearm(Fig.10).

Fig.9UPPERBALLJOINT-INSTALLATION

1-C-4212FPRESS

2-8861-1RECEIVER

3-8861-2DRIVER

(2)Presstheballjointintheuppersuspension arm.

(3)Removetheuppersuspensionarmfromthe vise.

(4)Reinstalltheuppersuspensionarm(Referto2 -SUSPENSION/REAR/UPPERCONTROLARMINSTALLATION).

(5)Raisetherearaxlewithahydraulicjackto aligntheballjointwiththedifferentialhousing bracket.

(6)Inserttheballjointintothedifferentialhousingbracket.

(7)Installtheballjointpinchboltandtightento 95N·m(70ft.lbs.).(Fig.7).

(8)Removethesupportsandlowerthevehicle.

UPPERCONTROLARM

DESCRIPTION-UPPERSUSPENSIONARM, BUSHINGS,ANDBALLJOINT

Thesuspensionarmusesverticalspoolbushingsto isolateroadnoise.Thesuspensionarmisbolted throughbushingstocagenutsinthebodyandaball jointtothetopofthedifferentialhousing.

Fig.10UPPERCONTROLARM

1-BODYMOUNTS

2-UPPERBALLJOINT

3-STABILIZERBAR

4-UPPERCONTROLARM

5-LOWERCONTROLARM

(6)Removethesupportbracketmountingboltsif needed.(Fig.11)

INSTALLATION

(1)Positiontheuppersuspensionarminthe framerailbrackets(Fig.10).

(2)Installthemountingboltsandtightento100 N·m(74ft.lbs.).

(3)Retightentheheatshieldbackintoplace.

(4)Pullthearmdownonthedifferentialhousing bracketandinstallthepinchboltandnut.Tighten thenutto95N·m(70ft.lbs.)(Fig.7).

2-26REAR

UPPERCONTROLARM(Continued)

Fig.11BALLJOINTBRACKET

1-UPPERBALLJOINT

2-SUPPORTBRACKETBOLTS

(5)Removethesupportsandlowerthevehicle.

LOWERCONTROLARM

DESCRIPTION

Thelowersuspensionarmsarestampedsteeland weldedandusevoidedroundbushingsattheaxle endandsolidrubberatthebodyendofthearm.

OPERATION

Thebushingsprovideisolationfromtheaxle.The armsmounttotheunibodyframerailbracketand theaxlebrackets.Thearmandbushingsprovide locationandreacttoloads.

REMOVAL

(1)Raisethevehicleandsupporttherearaxle.

(2)Removethestabilizerbarretainingboltsfrom thesuspensionarm.

(3)Removethelowersuspensionarmnutandbolt fromtheaxlebracket(Fig.12).

NOTE:Whenremovingtherightsidesuspension armfromtheframerailitwillbenecessarytopry theexhaustoverslightlytoallowenoughclearance toremovethebolt.

(4)Removethenutandbolt(Fig.12)fromthe framerailandremovethelowersuspensionarm.

INSTALLATION

(1)Positionthelowersuspensionarmintheaxle bracketandframerailbracket.

NOTE:Theendofthearmwiththevoidedround bushingattachestotheaxlebracket.

Fig.12LOWERSUSPENSIONARM

1-AXLEBRACKETBOLT

2-LOWERCONTROLARM

3-BODYBRACKETBOLT

(2)Installtheaxlebracketboltandnutfinger tight(Fig.12).

NOTE:Wheninstallingtherightsidesuspension armtotheframerailitwillbenecessarytoprythe exhaustoverslightlytoallowenoughclearanceto installthebolt.

(3)Installtheframerailbracketboltandnutfingertight.

(4)Installthestabilizerbarretainingboltstothe suspensionarm.

(5)Removethesupportsandlowerthevehicle.

(6)Withthevehicleonthegroundtightenthenut attheframeto163N·m(120ft.lbs.).Tightenthe nutattheaxlebracketto163N·m(120ft.lbs.).

BUSHINGS

REMOVAL

REMOVAL-LOWERSUSPENSIONARM BUSHING

(1)Removethelowersuspensionarm(Referto2SUSPENSION/REAR/LOWERCONTROLARMREMOVAL).

(2)Securethesuspensionarminavise.

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(3)Installspecialtools8862-4(receiver),8862-5 (spacer)and8862-1or8862-2(driver)withthe threadedrod8839andthebearingasshown(Fig.13)

Fig.13LOWERSUSPENSIONARMBUSHING REMOVAL

1-8839THREADEDROD

2-8862-4RECEIVER 3-8862-5SPACER 4-8862-1OR8862-2DRIVERS

(4)Pressoutthebushing.

REMOVAL-UPPERSUSPENSIONARM BUSHING

(1)Removetheuppersuspensionarm(Referto2SUSPENSION/REAR/UPPERCONTROLARMREMOVAL).

(2)Securethesuspensionarminavise.

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(3)Installspecialtools8853-3(driver),8860-1 (receiver)andwiththethreadedrod8838andthe bearingasshown(Fig.14)

(4)Pressoutthebushing.

INSTALLATION

INSTALLATION-LOWERSUSPENSIONARM BUSHING

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

Fig.14UPPERSUSPENSIONARMBUSHINGREMOVAL

1-8853-3DRIVER 2-8860-1RECEIVER 3-8838THREADEDROD

(1)Installthenewlowersuspensionarmbushings intothelowersuspensionarmusingtools8862-3 (driver),8862-4(receiver),8862-5(spacer)andthe bearingwiththethreadedrod8839(Fig.15)making suretoproperlyorientthebushinginthesuspension arm.

Fig.15LOWERSUSPENSIONARMBUSHING INSTALLATION

1-8862-3DRIVER 2-8862-5SPACER 3-8862-4RECEIVER 4-8839THREADEDROD

(2)Removethesuspensionarmfromthevise.

(3)Installthelowersuspensionarm(Referto2SUSPENSION/REAR/LOWERCONTROLARMINSTALLATION).

BUSHINGS(Continued)

INSTALLATION-UPPERSUSPENSIONARM BUSHING

NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.

(1)Installthenewuppersuspensionarmbushings intotheuppersuspensionarmusingtools8835-3 (receiver),8860-2(driver)andthebearingwiththe threadedrod8838(Fig.16)makingsuretoproperly orientthebushinginthesuspensionarm.

(2)Removethesuspensionarmfromthevise.

(3)Installtheuppersuspensionarm(Referto2SUSPENSION/REAR/UPPERCONTROLARMINSTALLATION).

Fig.16UPPERSUSPENSIONARMBUSHINGINSTALLATION

1-8838THREADEDROD 2-8835-3RECEIVER 3-8860-2DRIVER

DIFFERENTIAL&DRIVELINE

PROPELLERSHAFT

DIAGNOSISANDTESTING

PROPELLERSHAFT

PROPELLERSHAFTVIBRATION

Out-of-roundtireorwheelsthatareoutofbalance, willcausealowfrequencyvibration.

Brakerotorsthatareunbalancedwillcausea harsh,lowfrequencyvibration.

Drivelinevibrationcanbecausedbylooseordamagedenginemounts.

Propellershaftvibrationincreaseswithvehicle speed.Avibrationthatoccursataspecificspeedis notusuallycausedbyaoutofbalancepropeller shaft.Wornuniversaljointsoranincorrectpropeller shaftangle,cancausesuchavibration.

DRIVELINEVIBRATION

DriveConditionPossibleCauseCorrection

PropellerShaftNoise1.Undercoatingorotherforeign materialonshaft. 1.Cleanexteriorofshaftandwash withsolvent.

2.LooseU-jointclampscrews.2.Installnewclampsandscrews andtightentopropertorque.

3.LooseorbentU-jointyokeor excessiverunout. 3.Installnewyoke.

4.Incorrectdrivelineangularity.4.Measureandcorrectdriveline angles.

5.Wornjoint.5.Installnewjoint.

6.Propellershaftdamagedorout ofbalance. 6.Installlnewpropellershaft.

7.Brokenrearspring.7.Installnewrearspring.

8.Excessiverunoutorunbalanced condition.

8.Re-indexpropellershaft,test,and evaluate.

9.Excessivedrivepiniongearshaft runout. 9.Re-indexpropellershaftand evaluate.

10.Excessiveaxleyokedeflection.10.Inspectandreplaceyokeif necessary.

11.Excessivetransfercaserunout.11.Inspectandrepairasnecessary.

U-JointNoise1.LooseU-jointclampscrews.1.Installnewclampsandscrews andtightentopropertorque.

2.Lackoflubrication.2.Replacejointsasnecessary.

BALANCE

NOTE:Indexingthepropellershaft180°relativeto theyokemayeliminatesomevibrations.

(1)Raisethevehicle.

(2)Cleanalltheforeignmaterialfromthepropellershaftanduniversaljoints.

(3)Inspectpropellershaftformissingbalance weights,brokenwelds,andbentareas.

NOTE:Ifthepropellershaftisbent,itmustbe replaced.

(4)Inspectuniversaljointsforwear,properly installationandcorrectalignmentwiththeshaft.

(5)Removewheelsandtiresandinstallwheellug nutstoretainbrakedrums/rotors.

(6)Markandnumbertheshaftsixinchesfromthe pinionyokeendatfourpositions90°apart.

(7)Runandacceleratethevehicleuntilvibration occurs.Notetheintensityandspeedthevibration occurred.Stoptheengine.

(8)Positiononescrewclamp(1)(Fig.1)onthepropellershaftwithwsascrewdriver(2).

(9)Starttheengineandcheckforvibration.If thereislittleornochangeinvibration,movethe clamptothenextpositions.Repeatthevibration test.Ifthereisnodifferenceinvibrationattheother

positions,thesourceofthevibrationmaynotbepropellershaft.

RUNOUT

RUNOUTSPECIFICATIONS

FrontofShaft0.020in.(0.50mm) CenterofShaft0.025in.(0.63mm) RearofShaft0.020in.(0.50mm) note:

Measurefront/rearrunoutapproximately3inches(76 mm)fromtheweldseamateachendoftheshaft tubefortubelengthsover30inches.Fortubelengths under30inches,themaximumallowedrunoutis 0.020in.(0.50mm)forthefulllengthofthetube.

(1)Cleanpropellershaftsurfacewherethedial indicatorwillcontacttheshaft.

(2)Thedialindicatormustbeinstalledperpendiculartotheshaftsurface.

(10)Ifvibrationdecreased,installasecondclamp (Fig.2)andrepeatthetest.

(11)Iftheadditionalclampcausesanadditional vibration,separatetheclamps(1)(Fig.3)(1/4inch aboveandbelowthemark).Repeatthevibration test.

(12)Increasedistancebetweentheclampsand repeatthetestuntiltheamountofvibrationisatthe lowestlevel.Bendtheslackendoftheclampssothe screwswillnotloosen.

(13)Ifvibrationremainsunacceptable,repeatthe proceduretothefrontendofthepropellershaft.

(14)Installwheelandtires,andlowervehicle.

(3)Measurerunoutatthecenterandendsofthe shaftawayfromweldareastoensureanaccurate measurements.

(4)RefertoRunoutSpecificationschart.

(5)Ifpropellershaftrunoutisoutofspecification, removepropellershaft.Indextheshaft180°and measureshaftrunoutagain.

(6)Ifpropellershaftrunoutisnowwithinspecifications,marktheshaftandyokesforproperorientation.

(7)Ifpropellershaftrunoutisnotwithinspecifications,checkrunoutofthetransmission/transfercase andaxle.Correctasnecessaryandrepeatpropeller shaftrunoutmeasurement.

(8)Replacepropellershaftiftherunoutstill exceedsthelimits.

STANDARDPROCEDURE

PROPELLERSHAFTANGLE

Thisprocedureappliestothefrontandrearpropellershaft.Toobtainfront(output)angleontheC/V frontpropellershaft,placeInclinometer7663onthe machinedringofthepinionflange.ToobtainpropellershaftanglemeasurementontheC/Vfrontpropellershaft,placeinclinometeronthepropellershaft tube.

(1)Raiseandsupportthevehicleattheaxlesas levelaspossible.Allowthewheelsandpropeller shafttoturn.

(2)Removeuniversaljointsnapringsifequipped, soinclinometerbasesitsflat.

(3)Rotateshaftuntiltransmission/transfercase outputyokebearingcapisfacingdownward.

Fig.2TWOCLAMPSATSAMEPOSITION

Fig.4OUTPUTYOKEANGLE(A)

1-SLIPYOKEBEARINGCAP

2-INCLINOMETER

NOTE:Alwaysmakemeasurementsfromfrontto rearandfromthesamesideofthevehicle.

(4)Placeinclinometer(1)(Fig.4)onyokebearing cap(2)orpinionflangeringparalleltotheshaft. Centerbubbleinsightglassandrecordmeasurement.ThismeasurementwillgiveyouthetransmissionorOutputYokeAngle(A).

1-PINIONYOKEBEARINGCAP 2-INCLINOMETER 3-4PROPELLERSHAFT

(5)Rotatepropellershaft90degreesandplace inclinometer(2)(Fig.5)onyokebearingcap(1)or propellershafttubeonC/Vpropellershaft,parallel totheshaft.Centerbubbleinsightglassandrecord measurement.Thismeasurementcanalsobetaken attherearendoftheshaft.Thismeasurementwill giveyouthepropellershaftangle(C)

(6)Subtractsmallerfigurefromlarger(Cminus A)toobtaintransmissionoutputoperatingangle.

Fig.6INPUTYOKEANGLE(B)

(7)Rotatepropellershaft90degreesandplace inclinometer(2)(Fig.6)onpinionyokebearingcap (1)paralleltotheshaft.Centerbubbleinsightglass andrecordmeasurement.Thismeasurementwill giveyouthepinionshaftorinputyokeangle(B).

(8)Subtractsmallerfigurefromlarger(Cminus B)toobtainaxleInputOperatingAngle.

RULES

GoodcancellationofU-jointoperatinganglesis within1degree.

Operatingangleslessthan3degrees.

Operatingangleslessthan10degreesfordouble cardanU-joint.

Atleast1/2ofonedegreecontinuousoperating (propellershaft)angle.

Fig.5PROPELLERSHAFTANGLE(C)

1-SHAFTYOKEBEARINGCAP 2-INCLINOMETER

PROPELLERSHAFT(Continued)

SPECIFICATIONS

TORQUESPECIFICATIONS

DESCRIPTIONN·mFt.Lbs.In.Lbs.

FrontShaft-Companion FlangeBolts

RearShaft-Companion FlangeBolts

SPECIALTOOLS

INCLINOMETER7663

SHAFT-PROPELLERFRONT REMOVAL

2.8LDIESEL

Fig.7LEFTEXHAUSTFLANGE

1-EXHAUSTFLANGE

2-FRONTPROPELLERSHAFT

3-COMPANIONFLANGE

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)Removeleftsideexhaustflange(1)(Fig.7) bolts.

(3)Markcompanionflanges(3)andC/Vjointsat thefront(2)andrearofthepropellershaftforinstallationreference.

Fig.8TRANSFERCASECOMPANIONFLANGE

1-FLANGEBOLT

2-COMPANIONFLANGE

(4)Removebolts(1)(Fig.8)fromthefrontand rearC/Vjoints.

(5)Pushpropellershaftforwardtocleartransfer casecompanionflange(2).

(6)Removeshaftfromthefrontaxlecompanion flange.

(7)Pulldownontheexhaustandtiltthefrontof theshaftdownandpullshaftforwardandremove fromthevehicle.

3-6PROPELLERSHAFT

GASENGINES

Fig.9TRANSFERCASECOMPANIONFLANGE

1-FLANGEBOLT

2-COMPANIONFLANGE

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)MarkcompanionflangesandC/Vjointsatthe frontandrearofthepropellershaftforinstallation reference.

(3)Removebolts(1)(Fig.9)fromthefrontand rearC/Vjoints(2).

(4)Pushpropellershaftforwardtocleartransfer casecompanionflange.

(5)Removeshaftfromthefrontaxlecompanion flange.

(6)Tiltthefrontoftheshaftdownandpullshaft forwardandremovefromthevehicle.

INSTALLATION

2.8LDIESEL

(1)Installpropellershaftbetweencompanion flanges.

(2)Alignmarksonthecompanionflangeswiththe marksontheC/Vjoints.

(3)InstallfrontC/Vjointboltsandtightento30 N·m(22ft.lbs.).

(4)InstallrearC/Vjointboltsandtightento30 N·m(22ft.lbs.).

(5)Installexhaustflangeandbolts.

GASENGINES

(1)Installpropellershaftbetweencompanion flanges.

(2)Alignmarksonthecompanionflangeswiththe marksontheC/Vjoints.

(3)InstallfrontC/Vjointboltsandtightento30 N·m(22ft.lbs.).

Fig.10TRANSFERCASECOMPANIONFLANGE

1-FLANGEBOLT 2-COMPANIONFLANGE

(4)InstallrearC/Vjointbolts(1)(Fig.10)and tightento30N·m(22ft.lbs.).

SHAFT-PROPELLERREAR REMOVAL

Fig.11COMPANIONFLANGE

1-PROPELLERSHAFT

2-PINIONCOMPANIONFLANGE

3-REFERENCEMARK

4-PROPELLERSHAFTCOMPANIONFLANGE

(1)Withvehicleinneutral,positionvehicleon hoist.

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SHAFT-PROPELLERREAR(Continued)

(2)Markareferenceline(3)(Fig.11)acrosscompanionflanges(2)(4)andpropellershaft(1)for installation.

INSTALLATION

Fig.12DUSTBOOTCLAMP

1-SLINGER

2-BOOT

3-AWL

4-TRANSFERCASE

(3)Pryopenclampholdingthedustboot(2)(Fig. 12)topropellershaftyoke,ifequipped.

Fig.14COMPANIONFLANGE

1-PROPELLERSHAFT

2-PINIONCOMPANIONFLANGE

3-REFERENCEMARK

4-PROPELLERSHAFTCOMPANIONFLANGE

(1)Slideslipyokeonthetransmission/transfer caseoutputshaft.On4x2vehicleswithamanual transmissioninstalltransmissionflangeboltsand tightento115N·m(85ft.lbs.).

(2)Alignreferencemarks(3)(Fig.14)oncompanionflanges(2)(4)andpropellershaft(1).

Fig.13MANUALTRANSMISSION

1-FLANGE

2-FLANGEBOLT

(4)On4x2vehicleswithmanualtransmission removertransmissioncompanionflange(1)bolts(2) (Fig.13).

(5)Removepinioncompanionflangebolts. (6)Removepropellershaft.

Fig.15CRIMPINGBOOTCLAMP

1-CLAMPTOOL 2-SLINGER 3-BOOT 4-CLAMPS

(3)Installcompanionflangeboltsandtightento 115N·m(85ft.lbs.).

(4)Tightendustboot(3)(Fig.15)clamp(4)if equippedwithClampC-4975A(1).

UNIVERSALJOINT-SINGLE CARDAN

DISASSEMBLY-WITHSNAPRINGS

Fig.17PRESSOUTBEARING 1-PRESS 2-SOCKET

Fig.16REMOVESNAPRING 1-SNAP-RING

NOTE:Thisproceduredescribesapropellershaft equippedwithacardanjointinthetubeyoke.For propellershaftsequippedwithacompanion/slip yoke,repeatthestepstoremovetheremainingcardanjoint.

(1)Tapoutsideofbearingcapwithadriftto loosensnapring.

(2)Removesnaprings(1)(Fig.16)frombothsides ofyoke.

(3)Positionyokewiththegreasefittingif equipped,pointingup.

(4)Positionasocket(2)(Fig.17)withainside diameterlargeenoughtoreceivethebearingcap, beneaththeyokeonapress.

(5)Placeanothersocket(2)withanoutsidediametersmallerthanbearingcapontheupperbearing capandpress(1)thelowercapthroughtheyoke.

NOTE:Ifthebearingcapwillnotpulloutofthe yokebyhandafterpressing,taptheyokeearnear thebearingcaptodislodgethecap.

(6)Pullbearingcapoftheyoke.

Fig.18PRESSOUTREMAININGBEARING 1-CROSS 2-BEARINGCAP

(7)Turnyokeoverinthepressandstraightenthe cross(1)(Fig.18).Pressthecrossuntiltheremainingbearingcap(2)canberemoved.

UNIVERSALJOINT-SINGLECARDAN(Continued)

CAUTION:Ifcrossorbearingcaparenotstraight duringremoval,thebearingcapwillscorethewalls oftheyokeboreanddamagecanoccur.

ASSEMBLY-WITHSNAPRINGS

Fig.19CROSSINYOKE

1-CROSS 2-YOKE

NOTE:Thisproceduredescribesapropellershaft equippedacardanjointinthetubeyoke.Forpropellershaftsequippedwithacompanion/slipyoke, repeatthestepstoremovetheremainingcardan joint.

(1)Apply(EP)N.L.G.I.Grade1or2greaseto insideofyokebores.

(2)Positioncross(1)(Fig.19)inyoke(2)withlube fittingpointingup,ifequipped.

Fig.20BEARINGONCROSS

1-BEARINGCAP

2-CROSSEND

(3)Placeabearingcap(1)(Fig.20)overthecross end(2)andaligncapwithyokebore.

(4)Pressbearingcapintotheyokeboreenoughto clearsnapringgroove.

(5)RepeatStep3andStep4toinstalltheoppositebearingcap.

NOTE:Ifjointisstifforbinding,striketheyokewith asofthammertoseattheneedlebearings.

(6)Addgreasetolubefitting,ifequipped.

HALFSHAFT

CAUTION

CAUTION::Nevergrasphalfshaftassemblybythe boots.Thismaycausetheboottopuckerorcrease andreducetheservicelifeoftheboot. AvoidoverangulatingorstrokingtheC/Vjoints whenhandlingthehalfshaft.

Halfshaftsexposedtobatteryacid,transmission fluid,brakefluid,differentialfluidorgasolinemay causethebootstodeteriorate.Failuretofollow theseinstructionwillresultindamage.

DIAGNOSISANDTESTING

HALFSHAFT

CheckinboardandoutboardC/Vjointforleaking grease.Thisisasignofbootorbootclampdamage.

NOISE/VIBRATIONINTURNS

Aclickingnoiseorvibrationinturnscouldbe causedbyadamagedouterC/Vorinnertripodjoint sealbootorsealbootclamps.Thiswillresultinthe loss/contaminationofthejointgrease,resultingin inadequatelubricationofthejoint.Noisecouldalso becausedbyanothercomponentofthevehiclecomingincontactwiththehalfshafts.

CLUNKINGNOISEDURINGACCELERATION

ThisnoisemaybeadamagedorwornC/Vjoint.A tornbootorloose/missingclampontheinner/outer jointwhichhasallowedthegreasetobelostwill damagetheC/Vjoint.

SHUDDER/VIBRATIONDURINGACCELERATION

Thiscouldbeaworn/damagedinnertripodjointor astickingtripodjoint.Improperwheelalignment mayalsocauseashudderorvibration.

VIBRATIONATHIGHWAYSPEEDS

Thisproblemcouldbearesultofoutofbalance fronttiresortire/wheelrunout.Foreignmaterial (mud,etc.)packedonthebacksideofthewheel(s) willalsocauseavibration.

REMOVAL

Fig.1STABILIZERBARLINK

1-STABILIZERBAR

2-STABILIZERBARLINK

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)Removehalfshafthubnut.

HALFSHAFT(Continued)

(3)Removestabilizerlink(2)(Fig.1)fromstabilizerbar(1).

(6)Pulloutonthesteeringknuckleandpushthe halfshaftoutoftheknuckle.

(7)Withaprybarremovethehalfshaftfromthe axle.

NOTE:Rightsidehalfshafthasanaxleshaftthat maycomeoutoftheaxle.

INSTALLATION

Fig.2CLEVISBRACKET

1-UPPERBOLT

2-CLEVISBRACKET

3-LOWERBOLT

(4)Removeclevisbracket(2)lowerbolt(3)(Fig.2).

Fig.3LOWERCONTROLARM

1-FRONTCAMBOLT

2-OUTERTIERODEND

3-LOWERBALLJOINTNUT

4-LOWERCONTROLARM

5-REARCAMBOLT

(5)Removerlowerballjointnut(3)andseparate lowerballjointfromthelowercontrolarm(4)(Fig. 3).

Fig.4LOWERCONTROLARM

1-FRONTCAMBOLT

2-OUTERTIERODEND

3-LOWERBALLJOINTNUT

4-LOWERCONTROLARM

5-REARCAMBOLT

NOTE:Seperaterighthalfshaftfromaxleshaftina viseifnecessaryandinstallaxleshaftintheaxle.

(1)Applyalightcoatofwheelbearinggreaseon thefemalesplinesoftheinnerC/Vjoint.

(2)Installhalfshaftontheaxleshaftsplineand pushfirmlytoengagethesnapring.Pullonthehalf shafttoverifysnaphasengaged.

(3)Cleanhubbearingboreandapplyalightcoat ofwheelbearinggrease.

(4)Pulloutonthesteeringknuckleandpushthe halfshaftthroughtheknuckle.

(5)Installlowerballjoint(3)intothelowercontrol arm(4)andtightenpinchbolt(Fig.4).

(6)Alignclevis(2)withknuckle.Installand tightenlowerclevisbolt(3)tospecifications(Fig.5).

Fig.6STABILIZERBARLINK

1-STABILIZERBAR 2-STABILIZERBARLINK

(7)Installstabilizerbarlink(2)onstabilizerbar (1)(Fig.6).

(8)Installhalfshafthubnutandtightentospecifications.

Fig.5CLEVISBRACKET

1-UPPERBOLT

2-CLEVISBRACKET

3-LOWERBOLT

SPECIFICATIONS

JOINT/BOOT-C/VOUTER

REMOVAL

Fig.7BOOTCLAMPLOCATIONS

1-C/VHOUSING

2-CLAMP

3-HALFSHAFT

4-CLAMP

5-C/VBOOT

(1)Placeshaftinvisewithsoftjawsandsupport C/Vjoint.

CAUTION:DonotdamageC/Vhousingorhalf shaft.

(2)Removeclamps(2)(4)withacut-offwheelor grinder(Fig.7).

(5)Spreadsnapring(1)andslidethejointoffthe shaft(Fig.8).

1-SNAPRING

Fig.8OUTERC/VJOINT

2-SNAPRINGGROVE

3-SNAPRINGPLIERS

(3)Slidethebootdowntheshaft. (4)RemovelubricanttoexposetheC/Vjointsnap ring.

Fig.9BEARINGACCESS

1-ALIGNMENTMARKS 2-BEARINGHUB 3-BEARINGCAGE 4-HOUSING

(6)Slidebootofftheshaftanddiscardoldboot. (7)Markalignmentmarks(1)ontheinnerrace/ hub(2),bearingcage(3)andhousingwithdabsof paint(Fig.9).

Fig.10BEARING

1-HOUSING 2-INNERRACE/HUB 3-BEARINGCAGE 4-BALL

(8)ClampC/Vjointinaverticalpositioninasoft jawedvise.

(9)Pressdownonesideofthebearingcage(3)to gainaccesstotheballattheoppositeside.

NOTE:Ifjointistight,useahammerandbrassdrift toloosenthebearinghub.Donotcontactthebearingcagewiththedrift.

3-14HALFSHAFT

JOINT/BOOT-C/VOUTER(Continued)

(10)Removeball(4)fromthebearingcage(3)(Fig. 10).

(13)Turninnerrace90°inthecageandrotatethe innerrace/huboutofthecage(Fig.12).

INSTALLATION

1-HOUSING

2-INNERRACE

3-CAGEWINDOW

(11)Repeatstepaboveuntilallsixballsare removedfromthebearingcage.

(12)Liftcageandinnerrace(2)upwardandout fromthehousing(1)(Fig.11).

Fig.13INNERRACE/HUB

1-INNERRACE/HUB 2-BEARINGCAGE

(1)ApplyalightcoatofgreasetotheC/Vjoint componentsbeforeassemblingthem.

(2)Aligninnerrace,cageandhousingaccordingto thealignmentreferencemarks.

(3)Insertinnerrace(1)intothecage(2)(Fig.13) androtateraceintothecage.

Fig.14CAGEANDINNERRACE/HUB 1-CAGEWINDOWS 2-SNAPRING

Fig.11CAGEANDINNERRACE/HUB

Fig.12INNERRACE/HUB

JOINT/BOOT-C/VOUTER(Continued)

(4)Rotateinnerrace/hubinthecage(1)(Fig.14).

(6)Rotatecage90°intothehousing(1)(Fig.16).

(7)Applylubricantincludedwithreplacement boot/jointtotheballraces.Spreadlubricantequally betweenalltheraces.

Fig.15BEARINGCAGEANDHOUSING

1-OUTERRACE

2-BEARINGCAGEWINDOW

3-CVJOINTHOUSING

(5)Insertcageintothehousing(3)(Fig.15).

Fig.17BALLBEARING

1-C/VHOUSING

2-INNERRACE/HUB 3-BEARINGCAGE 4-BEARING

(8)Tiltinnerrace/hub(2)andcage(3)andinstall theballs(4)(Fig.17).

(9)Placenewclampsontonewbootandslideboot ontotheshafttoit’soriginalposition.

(10)ApplytherestoflubricanttotheC/Vjoint andboot.

Fig.16CAGEANDINNERRACE/HUB

1-C/VHOUSING

2-BEARINGHUBLARGECOUNTERBOREOUTWARD

3-BOOTRETAININGSHOULDER

4-BEARINGHUBSMALLCOUNTERBOREINWARD 5-SLINGER

1-SNAPRING

Fig.18OUTERC/VJOINT

2-SHAFTTAPER

3-SNAPRINGGROVE 4-BEARINGHUB

3-16HALFSHAFT

JOINT/BOOT-C/VOUTER(Continued)

(11)Pushthejointontotheshaftuntilthesnap ring(1)seatsinthegroove(3)(Fig.18).Pullonthe jointtoverifythespanringhasengaged.

(12)Positionbootonthejointinit’soriginalposition.Ensurebootisnottwistedandremoveany excessair.

Fig.20INNERC/VBOOT

Fig.19BOOTCLAMPLOCATIONS

1-C/VHOUSING

2-CLAMP

3-HALFSHAFT

4-CLAMP

5-C/VBOOT

(13)Securebothbootclamps(2)(4)(Fig.19)with ClampInstallerC-4975A.Placetoolonclampbridge andtightentooluntilthejawsofthetoolareclosed.

JOINT/BOOT-C/VINNER

REMOVAL

(1)Clampshaftinavise(withsoftjaws)andsupportC/Vjoint(1).

(2)Removeclampswithacut-offwheelorgrinder. (3)Slidebootdown(2)theshaft(Fig.20).

1-HOUSING

2-BOOT

3-HOUSINGSNAPRING

Fig.21HOUSINGSNAPRING

1-HOUSING

2-SNAPRING

3-CAGE/INNERRACE

(4)Removelubricantfromhousing(1)toexpose theC/Vsnapring(2)andremovesnapring(Fig.21).

(7)Removespreadinnerrace(1)snapring(4)and removerace(1)fromtheshaft(3)(Fig.23).

(8)Removebootfromtheshaftanddiscard.

Fig.22C/VBEARINGS

1-CAGE

2-INNERRACE

3-SHAFT

4-BEARING

(5)Removebearings(4)fromthecage(1).

(6)Rotatecage(1)30°andslidecageofftheinner race(2)anddowntheshaft(3)(Fig.22).

Fig.24INNERC/VJOINT

1-HOUSING

2-CAGE

3-BEARINGS

4-HOUSINGSNAPRING

5-INNERRACESNAPRING

6-INNERRACE

(9)Cleanandinspecthousing(1),cage(2),bearings(3),housingsnap-ring(4),innerracesnap-ring (5)andinnerrace(6)forwearordamage(Fig.24).

Fig.23INNERRACE

1-INNERRACE

2-PLIERS

3-SHAFT

4-SNAPRINGACCESS

INSTALLATION

Fig.25BEARINGCAGE

1-SHAFT

2-CAGE

3-SMALLDIAMETER 4-SNAPRINGGROOVE

(1)Applyacoatofgreasesuppliedwiththejoint/ boottotheC/Vjointcomponentsbeforeassembling them.

(2)Placenewclampsonthenewbootandslide bootdowntheshaft.

(3)Slidecage(2)(Fig.25)ontotheshaft(1)with thesmalldiameter(3)endtowardstheboot.

(4)Installtheinnerrace(1)(Fig.26)ontothe shaft(3).Pullontheracetoverifysnapringhas engaged.

Fig.26INNERRACE

1-INNERRACE

2-CAGE

3-SHAFT

Fig.27CAGE/INNERRACE

1-CAGE 2-INNERRACE 3-SHAFT 4-CAGEWINDOW

(5)Aligncage(1)(Fig.27)withtheinnerrace(2) andslideovertherace.

(6)Turnthecage30°toalignthecagewindows(4) withtherace(2).

Fig.28C/VCOMPONENTS

1-HOUSING 2-BEARINGASSEMBLY 3-HOUSINGSNAPRING 4-HOUSINGBORE

(7)Applygreasetotheinnerraceandbearings andinstallthebearings.

(8)Applygreasetothehousingbore(4)(Fig.28) theninstallthebearingassembly(2)intothehousing(1).

(9)Installthehousingsnapring(3)andverifyitis seatedinthegroove.

(10)Fillthehousingandbootwiththeremaining grease.

(11)SlidethebootontotheC/Vhousingintoit’s originalposition.Ensurebootisnottwistedand removeanyexcessair.

(12)SecurebothbootclampswithClampInstaller C-4975A.Placetoolonclampbridgeandtightentool untilthejawsofthetoolareclosed.

FRONTAXLE-186FIA

DIAGNOSISANDTESTING

FRONTAXLE-186FIA

GEARNOISE

Axlegearnoisecanbecausedbyinsufficientlubricant,incorrectbacklash,toothcontact,worn/damaged gearsorthecarrierhousingnothavingtheproper offsetandsquareness.

Gearnoiseusuallyhappensataspecificspeed range.Thenoisecanalsooccurduringaspecifictype ofdrivingcondition.Theseconditionsareacceleration,deceleration,coast,orconstantload.

Whenroadtesting,firstwarm-uptheaxlefluidby drivingthevehicleatleast5milesandthenacceleratethevehicletothespeedrangewherethenoiseis thegreatest.Shiftout-of-gearandcoastthroughthe peak-noiserange.Ifthenoisestopsorchanges greatlycheckfor:

• Insufficientlubricant.

• Incorrectringgearbacklash.

• Geardamage.

Differentialsideandpinionsgears,usuallydonot causenoiseduringstraight-aheaddriving,whenthe gearsareunloaded.Thesidegearsareloadedduring turns.Awornpinionmateshaftcanalsocausea snappingoraknockingnoise.

BEARINGNOISE

Bearingnoisecanbeeitherawhiningoragrowlingsound.

Pinionbearings haveaconstanthighpitchnoise, becauseitrotatesatafasterrate.Thisnoisechanges withvehiclespeed.Ifnoiseisheardunderaload,the rearpinionbearingisthesource.Ifnoiseisheard duringacoast,thefrontpinionbearingisthesource.

Differentialbearings usuallyproducealowpitch noise.Thedifferentialbearingnoiseisconstantand variesonlywithvehiclespeed.

Axleshaftbearing noisegenerallychangeswhen thebearingsareloaded.Turnvehiclesharplytothe leftandtherightduringaroadtest.Thiswillload andunloadthebearingsandchangethenoiselevel. Ifaxlebearingdamageisslight,thenoiseisusually notnoticeableatspeedsabove30m.p.h.

LOWSPEEDKNOCK

Lowspeedknockisgenerallycausedby:

• WornU-joints/CVjoint.

• Wornside-gearthrustwashers.

• Wornpinionshaftbore.

VIBRATION

Vibrationattherearofthevehicleisusually causedby:

• Damageddriveshaft.

• Missingdriveshaftbalanceweight(s).

• Wornorout-of-balancewheels.

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• Loosewheellugnuts.

• WornU-joints/CVjoint.

• Loose/brokensprings.

• Damagedaxleshaftbearing(s).

• Loosepiniongearnut.

• Excessivepinionyokerunout.

• Bentaxleshaft(s).

Checkforlooseordamagedfront-endcomponents orengine/transmissionmounts.Thesecomponents cancontributetowhatappearstobeanaxlevibration.Alsolookatengineaccessories,bracketsand drivebelts.

NOTE:Alldrivelinecomponentsshouldbeexaminedbeforestartinganyrepair.

DRIVELINESNAP

Asnaporclunknoisewhenthevehicleisshifted intogearortheclutchengaged,canbecausedby:

• Highengineidlespeed.

• Transmissionshiftoperation.

• Looseengine/transmission/transfercasemounts.

• WornU-joints/CVjoint.

• Loosespringmounts.

• Loosepiniongearnutandyoke.

• Excessiveringgearbacklash.

• Excessivesidegeartocaseclearance. Todeterminedthesourceofasnap/clunknoise, raisevehicleonahoistwiththewheelsfreeto rotate.Haveahelpershiftthetransmissionintogear andlistenforthenoise.

DIAGNOSTICCHART

ConditionPossibleCausesCorrection

WheelNoise1.Wheelloose.1.Tightenloosenuts.

2.Faulty,brinelledwheelbearing.2.Replacebearing.

AxleShaftNoise1.Misalignedaxletube.1.Inspectaxletubealignment. Correctasnecessary.

2.Bentorsprungaxleshaft.2.Inspectandcorrectasnecessary.

3.End-playinpinionbearings.3.Refertopinionpre-load informationandcorrectas necessary.

4.Excessivegearbacklash betweentheringgearandpinion.

4.Checkadjustmentofthering gearandpinionbacklash.Correct asnecessary.

5.Improperadjustmentofpinion gearbearings. 5.Adjustthepinionbearings pre-load.

6.Loosepinionyokenut.6.Tightenthepinionyokenut.

7.Scuffedgeartoothcontact surfaces. 7.Inspectandreplaceas necessary.

AxleShaftBroke1.Misalignedaxletube.1.Replacethebrokenshaftafter correctingtubemis-alignment.

2Vehicleoverloaded.2.Replacebrokenshaftandavoid excessiveweightonvehicle.

3.Erraticclutchoperation.3.Replacebrokenshaftandavoid orcorrecterraticclutchoperation.

4.Grabbingclutch.4.Replacebrokenshaftandinspect andrepairclutchasnecessary.

ConditionPossibleCausesCorrection

DifferentialCracked1.Improperadjustmentofthe differentialbearings.

1.Replacecaseandinspectgears andbearingsforfurtherdamage. Setdifferentialbearingpre-load properly.

2.Excessiveringgearbacklash.2.Replacecaseandinspectgears andbearingsforfurtherdamage. Setringgearbacklashproperly.

3.Vehicleoverloaded.3.Replacecaseandinspectgears andbearingsforfurtherdamage. Avoidexcessivevehicleweight.

4.Erraticclutchoperation.4.Replacecaseandinspectgears andbearingsforfurtherdamage. Avoiderraticuseofclutch.

DifferentialGearsScored1.Insufficientlubrication.1.Replacescoredgears.Fill differentialwiththecorrectfluidtype andquantity.

2.Impropergradeoflubricant.2.Replacescoredgears.Fill differentialwiththecorrectfluidtype andquantity.

3.Excessivespinningofone wheel/tire.

3.Replacescoredgears.Inspectall gears,pinionbores,andshaftfor damage.Serviceasnecessary.

LossOfLubricant1.Lubricantleveltoohigh.1.Drainlubricanttothecorrect level.

2.Wornaxleshaftseals.2.Replaceseals.

3.Crackeddifferentialhousing.3.Repairasnecessary.

4.Wornpinionseal.4.Replaceseal.

5.Worn/scoredyoke.5.Replaceyokeandseal.

6.Axlecovernotproperlysealed.6.Remove,clean,andre-seal cover.

AxleOverheating1.Lubricantlevellow.1.Filldifferentialtocorrectlevel.

2.Impropergradeoflubricant.2.Filldifferentialwiththecorrect fluidtypeandquantity.

3.Bearingpre-loadstoohigh.3.Re-adjustbearingpre-loads.

4.Insufficientringgearbacklash.4.Re-adjustringgearbacklash.

ConditionPossibleCausesCorrection

GearTeethBroke1.Overloading.1.Replacegears.Examineother gearsandbearingsforpossible damage.

2.Erraticclutchoperation.2.Replacegearsandexaminethe remainingpartsfordamage.Avoid erraticclutchoperation.

3.Ice-spottedpavement.3.Replacegearsandexamine remainingpartsfordamage.

4.Improperadjustments.4.Replacegearsandexamine remainingpartsfordamage.Ensure ringgearbacklashiscorrect.

AxleNoise1.Insufficientlubricant.1.Filldifferentialwiththecorrect fluidtypeandquantity.

2.Improperringgearandpinion adjustment.

2.Checkringgearandpinion contactpattern.

3.Unmatchedringgearandpinion.3.Replacegearswithamatched ringgearandpinion.

4.Wornteethonringgearand/or pinion.

4.Replaceringgearandpinion.

5.Loosepinionbearings.5.Adjustpinionbearingpre-load.

6.Loosedifferentialbearings.6.Adjustdifferentialbearing pre-load.

7.Mis-alignedorsprungringgear.7.Measureringgearrun-out. Replacecomponentsasnecessary.

8.Loosedifferentialbearingcap bolts.

8.Inspectdifferentialcomponents andreplaceasnecessary.Ensure thatthebearingcapsaretorqued totheproperspecification.

9.Housingnotmachinedproperly.9.Replacehousing.

3-24FRONTAXLE-186FIA

FRONTAXLE-186FIA(Continued)

REMOVAL

Fig.1DRAINPLUG

1-LEFTFRONTAXLEBRACKET

2-DRAINPLUG

3-DIFFERENTIALHOUSING

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)Removeskidplate.

(3)Removedifferentialhousing(3)drainplug(2) anddrainfluid(Fig.1).

(6)Removestabilizerbar(1)links(2)fromthe lowercontrolarms(Fig.2).

Fig.2STABILIZERBARLINK

1-STABILIZERBAR

2-STABILIZERBARLINK

(4)Markfrontpropellershaftandpinionflange. Removepropellershaftfrompinionflange.

(5)Removehalfshafthubnuts.

Fig.3LOWERCONTROLARM

1-FRONTCAMBOLT 2-OUTERTIERODEND 3-LOWERBALLJOINTNUT 4-LOWERCONTROLARM 5-REARCAMBOLT

(7)Removetierodend(2)nutsandseparateends fromtheknuckles(Fig.3).

(8)Removelowerballjointnuts(3)andseparate balljointsfromthelowercontrolarms(4)(Fig.3).

Fig.4CLEVISBRACKET

1-UPPERBOLT 2-CLEVISBRACKET 3-LOWERBOLT

(9)Removeshockclevis(2)lowerbolts(3)(Fig.4). (10)Pulloutonthesteeringknucklesandpush thehalfshaftoutoftheknuckles.

(11)Withaprybarremovethehalfshaftsfrom theaxle.

Fig.5DRAINTROUGH 1-TROUGH 2-MOUNTINGNUT

NOTE:Righthalfshafthasasplinedaxlethatmay comeoutwiththehalfshaft.

(12)Removedifferentialventhosefromcoverand removedraintrough(1)nut(2)(Fig.5).

Fig.7RIGHTAXLEBRACKET

1-RIGHTAXLEBRACKET 2-FRONTBRACKETBOLT 3-REARBRACKETBOLT

(17)Removefrontbolt(2)andrearbolt(3)from rightaxlebracket(1)framemounts(Fig.7).

Fig.6LEFTFRONTAXLEBRACKET

1-LEFTFRONTAXLEBRACKET 2-CRADLEBRACKETBOLT

(13)Supportaxlewithalift/jack. (14)Removeboltsfromleftfrontaxlebracket(1) andcradlebracketbolt(Fig.6).

(15)Removeoilfilterdriptray. (16)Markandremoverightcontrolarmcambolt.

Fig.8LEFTREARAXLEBRACKET 1-LEFTREARAXLEBRACKET 2-BRACKETBOLT

3-26FRONTAXLE-186FIA

(18)Removebolt(2)fromleftrearaxlebracket(1) framemount(Fig.8).

(19)Loweraxleandfromvehicle.

INSTALLATION

Fig.10LEFTAXLEBRACKET

1-LEFTREARAXLEBRACKET 2-BRACKETBOLT

Fig.9RIGHTAXLEBRACKET

1-RIGHTAXLEBRACKET

2-FRONTBRACKETBOLT

3-REARBRACKETBOLT

NOTE:Separaterightaxleshaftfromthehalfshaft ifnecessaryandinstallaxleshaftintheaxle.

(1)Installrightbracket(1)(Fig.9)toaxleand tightento88N·m(65ft.lbs.).

(2)Installleftrearbracket(1)(Fig.10)toaxleand tightento61N·m(45ft.lbs.).

(3)Installleftfrontbracket(1)(Fig.11)toaxle andtightento61N·m(45ft.lbs.).

(4)Raiseaxleupandalignbracketswithframe mounts.

(5)Installframemountboltsandtightento88 N·m(65ft.lbs.).

(6)Installhalfshafts.

Fig.11FRONTAXLEBRACKET

1-LEFTFRONTAXLEBRACKET 2-CRADLEBRACKETBOLT

Fig.12LOWERCONTROLARM

1-FRONTCAMBOLT

2-OUTERTIERODEND

3-LOWERBALLJOINTNUT

4-LOWERCONTROLARM

5-REARCAMBOLT

(7)Installrightfrontcontrolarmcambolt(1)(Fig. 12)withmarksaligned.

(8)Installlowerballjointintolowercontrolarms (4)andtightennuts(3).

(9)Aligncleviswithknucklesandinstallclevis bolts.

(16)Installskidplate.

(17)Tightenclevisandstabilizerlinksboltsto specifications.

(18)Checkvehiclealignment.

ADJUSTMENTS

Fig.13STABILIZERBARLINK

1-STABILIZERBAR

2-STABILIZERBARLINK

(10)Installstabilizerbar(1)(Fig.13)links(2)to lowercontrolarmsandinstallbolts.

(11)Installoilfiltertrough.

(12)Installnewhalfshafthubnutsandtightento 136N·m(100ft.lbs.).

(13)Installpropellershaft.

(14)Installaxleventhose.

(15)Filldifferentialwithgearlubricant.

Fig.14PINIONGEARIDNUMBERS 1-PRODUCTIONNUMBERS 2-DRIVEPINIONGEARDEPTHVARIANCE 3-GEARMATCHINGNUMBER

Ringandpiniongearsaresuppliedasmatched sets.Gearmatchnumbers(3)(Fig.14)forthering andpiniongearareetchedontoeachgear.Aplus(+) number,minus(–)numberorzero(0)isetchedinto thefaceofthepiniongear(2).Thisnumberisthe amount(inthousandthsofaninch)thedepthvaries fromthestandarddepthsettingofapinionetched witha(0).

Compensationforpiniondepthvarianceis achievedwithaselectshim/oilslinger.Theshimsare placedbetweentherearpinionbearingandthepiniongearhead.

Ifinstallinganewgear,notethedepthvariance numberoftheoriginalandreplacementpinion.Add orsubtractthisnumberfromtheoriginaldepth shim/oilslingertocompensateforthedifferencein thedepthvariances.Thenumbersrepresentthousandsofaninchdeviationfromthestandard.Ifthe numberisnegative,addthatvaluetotherequired thicknessofthedepthshims.Ifthenumberispositive,subtractthatvaluefromthethicknessofthe depthshim.

PinionGearDepthVarianceChart:Notewhere OldandNewPinionMarkingcolumnsintersect. Intersectingfigurerepresentsplusorminusthe amountneeded.

3-28FRONTAXLE-186FIA

PINIONGEARDEPTHVARIANCE

PINIONDEPTHMEASUREMENT

Fig.15PINIONGEARDEPTHTOOLS

1-DIALINDICATOR

Measurementsaretakenwithpinionbearingcups andpinionbearingsinstalledinthehousing.Take measurementswithPinionGaugeSetandDialIndicatorC-3339(1)(Fig.15).

(1)AssemblePinionHeightBlock6739(3),Pinion Block8804(6)andrearpinionbearingontoScrew 6741(5).

(2)Insertheightgaugecomponentsintothehousingthroughpinionbearingcups.

(3)InstallfrontpinionbearingandCone-nut6740 (4)ontothescrew.TightenCone-NutuntilTorqueTo Rotatescrewis1.7N·m(15in.lbs.).

Fig.16DEPTHTOOLSINHOUSING 1-PINIONHEIGHTBLOCK 2-ARBORDISC 3-ARBOR 4-PINIONBLOCK

(4)PositionArborDisc6732(2)(Fig.16)andArbor D-115-3(3)intothehousingbearingcradles.Install differentialbearingcapsonArborDiscsandtighten boltsto41N·m(30ft.lbs.).

NOTE:ArborDiscs6732hasdifferentstepdiameterstofitotheraxles.Chooseproperstepforaxle beingserviced.

(5)AssembleDialIndicatorC-3339intoScooter BlockD-115-2andsecuresetscrew.

DIFFERENTIALSIDEBEARINGPRELOADAND GEARBACKLASH

Fig.17PINIONDEPTHMEASUREMENT

1-SCOOTERBLOCK

2-ARBOR

3-DIALINDICATOR

(6)PositionScooterBlock(1)(Fig.17)withDial Indicator(3)flushonthepinionheightblock.Hold thescooterblockandzerothedialindicator.

(7)Slowlyslidethescooterblockacrossthepinion heightblockovertothearbor(2).Movethescooter blocktillthedialindicatorprobecreststhearbor(2) andrecordthehighestreading.

(8)Selectashim/oilslingerequaltothedialindicatorreadingplusthepiniondepthvariancenumber etchedinthefaceofthepinion.Forexample,ifthe depthvarianceis–2,add+0.002in.tothedialindicatorreading.

Fig.18SHIMLOCATIONS

1-PINIONGEARDEPTHSHIM/OILSLINGER

2-DIFFERENTIALBEARINGSHIM

3-RINGGEAR

4-DIFFERENTIALBEARINGSHIM

5-COLLAPSIBLESPACER

Differentialbearingpreloadandgearbacklashis achievedwithselectiveshims(2)(4)(Fig.18)located betweenthedifferentialbearingcupsanddifferential housing.Thepropershimthicknesscanbedeterminedusingslip-fitDummyBearingsD-348inplace ofthedifferentialsidebearingsandaDialIndicator C-3339.Beforemeasuringdifferentialbearingpreloadandgearbacklash,measurepiniongeardepth andpreparepinionforinstallation.Piniongeardepth isessentialtoestablishinggearbacklashandtooth contactpatterns.Aftermeasuringshimthicknessto takeupdifferentialsideplay,installpinionandmeasuregearbacklashshimthickness.Overallshim thicknessisthedialindicatorreadingandpreload specificationaddedtogether.Thegearbacklashmeasurementdeterminestheshimthicknessusedonthe ringgearsideofthedifferentialcase.Subtractgear backlashshimthicknessfromoverallshimthickness todetermineshimthicknessforpiniongearsideof thedifferential.Differentialshimmeasurementsare performedwithspreaderW-129-Bremoved.

3-30FRONTAXLE-186FIA

Fig.20BEARINGCAPBOLTS

1-BEARINGCAPS 2-HOUSING 3-BOLTS

Fig.19DUMMYSHIMS

1-DUMMYSHIM

2-DIFFERENTIALHOUSING

3-DIFFERENTIALCASE

4-DUMMYBEARINGS

NOTE:Itisdifficulttosalvagethedifferentialside bearingsduringtheremovalprocedure.Install replacementbearingsifnecessary.

(1)Removedifferentialsidebearingsfromdifferentialcase.

(2)Installringgearondifferentialcaseand tightenboltstospecification.

(3)InstallDummyBearingsD-348(4)(Fig.19)on differentialcase(3).

(4)Installdifferentialcaseinthehousing.

(5)RecordthethicknessofDummyShims8107 (1).Inserttheshimsbetweenthedummybearings andthedifferentialhousing(2).

(6)Installthebearingcaps(1)(Fig.20)intheir correctpositionsandsnugthebolts(3).

(7)Withadead-blowhammer(1)(Fig.21),seat thedifferentialdummybearingstopinionsideofthe housing(2).

Fig.21SEATDUMMYBEARINGSPINIONSIDE 1-HAMMER 2-DIFFERENTIALHOUSING 3-DIFFERENTIAL

Fig.22SEATDUMMYBEARINGRINGGEARSIDE 1-DIFFERENTAILHOUSING 2-HAMMER 3-RINGGEAR

(8)Withadead-blowhammer(2)(Fig.22),seat thedifferentialdummybearingstotheringgear(3) sideofthehousing(1).

(12)Pushandholddifferentialcasetoringgear sideofthehousing(2)(Fig.24)andrecorddialindicator(1)reading.

(13)Add0.152mm(0.006in.)tothezeroendplay total.Thisnewtotalrepresentsthethicknessof shimstocompressorpreloadthenewbearingswhen thedifferentialisinstalled.

(14)Rotatedialindicatoroutofthewayonthe pilotstud.

(15)Removedifferentialcaseanddummybearings fromthehousing.

(16)Installthepiniongearinthehousing.Install thepinionyokeandestablishthecorrectpinion rotatingtorque.

(17)InstalldifferentialcaseandDummyBearings D-348inthehousing.

(18)Installasingledummyshimintheringgear side.Installbearingcapsandtightenboltssnug.

Fig.23DIFFERENTIALPINIONGEARSIDE

1-PINIONSIDE

2-PILOTSTUD

3-DIALINDICATOR

(9)ThreadPilotStudC-3288-B(2)(Fig.23)into rearcoverboltholebelowringgear.

(10)AttachaDialIndicatorC-3339(3)tothePilot Stud.Positionthedialindicatorplungeronflatsurfacebetweentheringgearbolts.

(11)Pushandholddifferentialcasetopiniongear side(1)ofthehousingandzerodialindicator.

Fig.24DIFFERENTIALRINGGEARSIDE

1-DIALINDICATOR

2-DIFFERENTIALHOUSING

Fig.25DIFFERENTIALPINIONGEARSIDE

1-DIALINDICATOR

2-PINIONGEAR

3-RINGGEAR

(19)Seatringgearsidedummybearing.

(20)Positionthedialindicator(1)(Fig.25) plungeronaflatsurfacebetweentheringgear(3) boltheads.

(21)Pushandholddifferentialcasetowardpinion gear(2)andzerodialindicator.

(22)Pushandholddifferentialcasetoringgear side(3)(Fig.26)ofthehousingandrecorddialindicator(1)reading.Adddummyshimthicknesstothis reading.Thiswillbethetotalshimthicknessto achievezerobacklash.

(23)Subtract0.076mm(0.003in.)fromthedial indicatorreadingtocompensateforbacklashbetween ringandpiniongears.Thistotalisthethickness shimrequiredtoachieveproperbacklash.

(24)Subtractthebacklashshimthicknessfrom thetotalpreloadshimthickness.Theremainderis

3-32FRONTAXLE-186FIA

Fig.26DIFFERENTIALRINGGEARSIDE

1-DIALINDICATOR

2-PINIONGEAR

3-RINGGEAR

theshimthicknessrequiredonthepinionsideofthe axlehousing.

(25)Rotatedialindicatoroutofthewayonpilot stud.

(26)Removedifferentialcaseanddummybearings fromthehousing.

(27)Installsidebearingsandcupsondifferential case.

(28)InstallspreaderW-129-BwithAdapterSet 6987onthehousingandspreadaxleopeningenough toreceivedifferentialcase.

CAUTION:Neverspreadthedifferentialhousing over0.34mm(0.013in.).Ifthehousingisoverspread,itcouldbedistortedordamaged.

(29)Placethebearingpreloadshimsintheaxle housing,againsttheaxletubes.

(30)Installdifferentialcaseintothehousing.

(31)Removespreaderfromthehousing.

GEARBACKLASH

(1)Rotatethedifferentialcaseseveraltimesto seatthesidebearings.

(2)Positiontheindicatorplunger(1)(Fig.27) againstaringgeartooth(2).

(3)Pushandholdringgearupwardwhilenot allowingthepiniongeartorotate.

(4)Zerodialindicatorfacetopointer.

(5)Pushandholdringgeardownwardwhilenot allowingthepiniongeartorotate.Dialindicator readingshouldbebetween0.12mm(0.005in.)and 0.20mm(0.008in.).Ifbacklashisnotwithinspecificationstransferthenecessaryamountofshimthicknessfromonesideofthehousingtotheother.

Fig.27RINGGEARBACKLASH

1-DIALINDICATOR

2-RINGGEAR

(6)Verifydifferentialcaseandringgearrunoutby measuringringtopiniongearbacklashateightlocationsaroundtheringgear.Readingsshouldnotvary morethan0.05mm(0.002in.).Ifreadingsvarymore thanspecified,theringgearorthedifferentialcase isdefective.

Fig.28BACKLASHSHIMS

Aftertheproperbacklash(Fig.28)isachieved,performGearContactPatternAnalysisprocedure.

Fig.29GEARDESCRIPTION

1-TOPLAND

2-PROFILE

3-TOE

4-HEEL

5-ROOT

Theringgearandpinionteethcontactpatterns willshowifthepiniondepthiscorrectinthehousing.Itwillalsoshowiftheringgearbacklashhas beenadjustedcorrectly.Thebacklashcanbeadjusted withinspecificationstoachievedesiredtoothcontact patterns.

TheTOPLAND(1)(Fig.29)ofthegeartoothis thetopsurfaceofthetooth.ThePROFILE(2)ofthe geartoothisthedepthofthetooth.TheTOE(3)of thegearistheportionofthetoothsurfaceattheend towardsthecenter.TheHEEL(4)ofthegearisthe portionofthetoothattheouter-end.TheROOT(5) ofthegeartoothisthelowestportionofthetooth.

SPECIFICATIONS

NOTE:IfthePROFILEacrossthetoothisthesame itisa3Axiscutgear.IfthePROFILEacrossthe toothistapereditisa2Axiscutgear.

(1)Applyathincoatofhydratedferricoxideor equivalenttothedriveandcoastsideoftheringgear teeth.

(2)Wrap,twistandholdashoptowelaroundthe pinionyoketoincreasetheturningresistanceofthe pinion.Thiswillprovideamoredistinctcontactpattern.

(3)Withaboxedendwrenchonaringgearbolt, rotatethedifferentialcaseonecompleterevolutionin bothdirectionswhilealoadisbeingappliedfrom shoptowel.

Theareasontheringgearteethwiththegreatest degreeofcontactagainstthepinionteethwillsqueegeethecompoundtotheareaswiththeleastamount ofcontact.Noteandcomparepatternsonthering gearteethtoGearToothContactPatternschart(Fig. 30)andadjustpiniondepthandgearbacklashas necessary.

DIFFERENTIALBEARINGPRELOADCHECK

Thefinalcheckonthedifferentialassemblybefore installingtheaxles,istorquetorotatepinion(1) (Fig.31)anddifferentialcombinedwithaninch poundtorquewrench(2).Thiswillverifythecorrect differentialbearingpreload.

Torquetorotatethedifferentialandpinionisthe torquetorotatethepinionplus:

• GearRatio3.55-0.48-0.78N·m(4.2-6.9in.lbs.)

• GearRatio3.73-0.45-0.75N·m(3.9-6.6in.lbs.)

• GearRatio4.10-0.41-0.69N·m(3.6-6.0in.lbs.)

AXLESPECIFICATIONS

DESCRIPTIONSPECIFICATION

AxleRatio3.55,3.73,4.10

RingGearDiameter186mm(7.33in.)

RingGearBacklash0.12-0.20mm(0.005-0.008in.)

PinionBearingPreload1.69-2.82N·m(15-25in.lbs.)

DifferentialBearingPreload

AddedToPinionTorqueToRotate

GearRatio3.550.48-0.78N·m(4.2-6.9in.lbs.)

GearRatio3.730.45-0.75N·m(3.9-6.6in.lbs.)

GearRatio4.100.41-0.69N·m(3.6-6.0in.lbs.)

3-34FRONTAXLE-186FIA

FRONTAXLE-186FIA(Continued)

Fig.30PATTERNINTERPRETATION(GEARCUT2AXIS)

Fig.31PINIONROTATINGTORQUE

1-PINIONCOMPANIONFLANGE

2-TORQUEWRENCH

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TORQUESPECIFICATIONS

DESCRIPTIONN·mFt.Lbs.In.Lbs. RingGearBolts95-12270-90DifferentialBearingCap Bolts 54-6739-50DifferentialCoverBolts19-2614-19PinionNut217-352160-260LeftAxleBracketBolts6145FrontAxleBracketBolts6145RightAxleBracketBolts8865AxleBracketsToFrame Bolts 8865-

SPECIALTOOLS

DIALINDICATORC-3339

PULLERC-293-PA

INSTALLERC-3716-A

ADAPTERC-293-39

ADAPTERC-293-42

PILOTSTUDC-3288-B

HANDLEC-4171

DUMMYBEARINGSD-348

REMOVERC-4307

PLUGSP-3289

INSTALLERC-4308

PULLERC-452

INSTALLERD-146

SPREADERW-129-B

INSTALLERW-162-D

REMOVERD-149

INSTALLER6448

DUMMYSHIMS8107

PINIONDEPTHSET6774

CUP8109

SPANNERWRENCH6958

REMOVER8420A

ADAPTERKIT6987B

INSTALLER8681

REMOVER7794-A

PINIONBLOCK8804

COVER-DIFFERENTIAL

REMOVAL

INSTALLER8805 INSTALLER8806

Fig.32DRAINPLUG

1-LEFTFRONTAXLEBRACKET 2-DRAINPLUG 3-DIFFERENTIALHOUSING

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)Removeskidplate.

(3)Removedrainplug(2)(Fig.32)fromhousing (3)anddrainfluid.

(4)Removeoiltrough(1)(Fig.33)boltfromaxle bracket.

(5)Removeoiltroughnut(2)fromdifferential cover.

(6)Loosenleftfrontaxlebracketbolt(2)(Fig.34) atcradle.

(7)Removeleftfrontaxlebracket(1)boltsfrom theaxleandletbrackethangforwardoftheaxle.

(8)Removeventhosefromcoverandremoveoil trough.

(9)Removedifferentialcoverboltsandremove cover.

INSTALLATION

(1)Cleancoverandmatingsurface.

(2)ApplyabeadofMoparAxleRTVsealant(1) (Fig.35)orequivalenttothedifferentialcover(2).

COVER-DIFFERENTIAL(Continued)

Fig.35APPLYSEALANT

1-SEALANT 2-DIFFERNTIALCOVER

Fig.33DRAINTROUGH 1-TROUGH 2-MOUNTINGNUT

Fig.34LEFTFRONTAXLEBRACKET

1-LEFTFRONTAXLEBRACKET 2-CRADLEBRACKETBOLT

CAUTION:Ifcoverisnotinstalledwithin3to5minutes,thecovermustbecleanedandnewRTV applied.Failuretofollowtheseinstructionswill resultinaleak.

(3)Installdifferentialhousingcover(1)(Fig.36) andtightenboltsinacriss-crosspatternto19-26 N·m(14-19ft.lbs.).

(4)Installdraintroughandtightennutto23N·m (200in.lbs.).

Fig.36DIFFERENTIALCOVER

1-COVER 2-VENTTUBE

(5)Installventhose(2)ondifferentialcoverwith newclamp.

(6)Installaxlebrackettoaxleandtightento61 N·m(45ft.lbs.).

(7)Installdraintroughbolttoaxlebracketand tightento12N·m(110in.lbs.).

(8)Tightenleftfrontaxlebracketcradlenutto61 N·m(45ft.lbs.).

(9)Installskidplate.

3-40FRONTAXLE-186FIA

SHAFT-AXLE

REMOVAL

Fig.37AXLESHAFTPULLER

1-SNAPRINGGROVE

2-SLIDHAMMERTHREADS

3-REMOVERBLOCKS

4-REMOVERCOLLAR

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)Removerighthalfshaftfromvehicle.

(3)Removesnapringando-ringfromaxleshaft.

(4)AssembleRemover8420Ablocks(3)(Fig.37) withhammerthreads(2)onsnapringgroove(1)on theshaft.Slidecollar(4)overblocksandthreadslid hammerintoremoverandremoveshaft.

(5)Slideaxleshaftoutoftheaxletube.

INSTALLATION

(1)Lubricatebearing(1)(Fig.38)boreandseal(2) lipwithgearlubricant.Insertaxleshaftthrough seal,bearingandengageitintosidegearsplines.

NOTE:Usecaretopreventshaftsplinesfromdamagingaxleshaftseal.

(2)Installhalfshaftsnap-ringando-ring.

(3)Pushtheaxleshaftuntiltheaxleshaftsnapringpassesthroughthesidegear.

(4)Installrighthalfshaft.

(5)Checkdifferentialfluidlevel.

Fig.38AXLESHAFTSEAL 1-BEARING 2-SEAL

SEAL-AXLESHAFT REMOVAL

Fig.39SHAFTSEALREMOVER 1-SHAFTSEAL 2-REMOVER

(1)Removehalfshaft. (2)Removeaxleshaftforrightsidesealremoval.

(3)Removeshaftseal(1)(Fig.39)withRemover 7794-A(2)andaslidehammer.

INSTALLATION

Fig.40SEALINSTALLER

1-INSTALLER8806

2-HANDLEC-4171

(1)Applyalightcoatoflubricantonthelipofthe shaftseal.

(2)Install new shaftsealwithInstaller8806(2) (Fig.40)andHandleC-4171(1).

(3)Installrightaxleshaftifremoved.

(4)Installhalfshaft.

BEARING-AXLE

REMOVAL

(1)Removehalfshaft.

(2)Removeaxleshaftforrightsidesealremoval.

(3)RemoveshaftsealwithRemover7794-Aanda slidehammer.

(4)Removeshaftbearing(1)(Fig.41)with Remover7794-A(2)andaslidehammer.

INSTALLATION

(1)Install new shaftbearingwithInstaller8805 andHandleC-4171.

(2)Applyalightcoatoflubricantonthelipofthe shaftseal.

Fig.41SHAFTBEARINGREMOVER

1-SHAFTBEARING 2-REMOVER

Fig.42SEALINSTALLER

1-INSTALLER8806 2-HANDLEC-4171

(3)Install new shaftsealwithInstaller8806(1) (Fig.42)andHandleC-4171(2). (4)Installrightaxleshaftifremoved. (5)Installhalfshaft.

SEAL-PINION REMOVAL

Fig.43PINIONROTATINGTORQUE

1-PINIONCOMPANIONFLANGE 2-TORQUEWRENCH

(1)Withvehicleinneutral,positionvehicleon hoist.

(2)Removebrakecalipersandrotors.

(3)Removepropellershaft.

(4)Rotatepiniongearaminimumoftentimesand verifythepinionrotatessmoothly.

(5)Recordtorquetorotatethepiniongear(1)(Fig. 43)withainchpoundtorquewrench(2).

Fig.45PINIONFLANGEREMOVER 1-SPANNERWRENCH 2-REMOVER

(8)Prypinionsealoutwithasealpick.

INSTALLATION

Fig.44PINIONFLANGENUT

1-SPANNERWRENCH

2-PINIONCOMPANIONFLANGE

(6)UsingashortpieceofpipeandSpanner Wrench6958(1)(Fig.44)toholdthepinioncompanionflange(2)andremovethepinionnut.

(7)RemovepinioncompanionflangewithRemover C-452(2)(Fig.45)andSpannerWrench6958(1).

Fig.46PINIONROTATINGTORQUE

1-PINIONCOMPANIONFLANGE 2-TORQUEWRENCH

(1)Applyalightcoatingofgearlubricantonthe lipofpinionseal.InstallsealwithInstaller8681.

(2)Installpinioncompanionflangeonthepinion gearwithInstallerW-162-D,Cup8109andWrench 6958.

CAUTION:Donotexceedtheminimumtightening torque216N·m(160ft.lbs.)whileinstallingpinion nutatthispoint.Failuretofollowtheseinstructions willresultindamage.

(3)Installa new nutonthepiniongear. Tighten thenutonlyenoughtoremovetheshaftend play.

SEAL-PINION(Continued)

CAUTION:Neverloosenpinionnuttodecreasepinionrotatingtorqueandneverexceedspecifiedpreloadtorque.Failuretofollowtheseinstructionswill resultindamage.

(4)Rotatepinionaminimumoftentimeandverifypinionrotatessmoothly.Rotatethepinionshaft (1)(Fig.46)withaninchpoundtorquewrench(2). Rotatingtorqueshouldbeequaltothereading recordedduringremovalplus0.56N·m(5in.lbs.).

(5)Ifrotatingtorqueislow,useSpannerWrench 6958toholdthepinioncompanionflangeandtighten thepinionnutin6.8N·m(5ft.lbs.)incrementsuntil properrotatingtorqueisachieved.

CAUTION:Ifmaximumtighteningtorqueisreached priortoreachingtherequiredrotatingtorque,the collapsiblespacermayhavebeendamaged.Failure tofollowtheseinstructionswillresultindamage.

(6)Installpropellershaft.

(7)Filldifferentialwithgearlubricant.

DIFFERENTIAL

Fig.47DIFFERENTIALCOVER

(1)Removedifferentialhousingcover(1)(Fig.47).

(2)Pushrightaxleshaft(1)(Fig.48)outofside gear(3)withascrewdriver(2)andremoveshaft.

Fig.48RIGHTSHAFTINSIDEGEAR

1-AXLESHAFT

2-SCREWDRIVER 3-SIDEGEAR

Fig.49DIFFERENTIALSPREADER

1-DIFFERENTIALHOUSING 2-SAFETYCLAMPS

3-SPREADER 4-TURNBUCKLE

(3)Markdifferentialbearingcapsforinstallation reference.

(4)Loosenbearingcapbolts.

3-44FRONTAXLE-186FIA

DIFFERENTIAL(Continued)

(5)PositionSpreaderW-129-B(3)(Fig.49)onto differentiallocatingholesandinstallthesafetyholddownclamps(2).Tightenspreaderturnbuckle(4)finger-tight.

Fig.51DIFFERENTIALCASE 1-DIFFERENTIALHOUSING 2-DIFFERENTIALCASE 3-DIFFERENTIALBEARINGS

DISASSEMBLY

Fig.50SPREADDIFFERENTIALCASE

1-PILOTSTUD

2-DIALINDICATOR

3-SPREADER

(6)InstallaPilotStudC-3288-B(1)(Fig.50)at theleftsideofthedifferentialhousing.AttachDial IndicatorC-3339(2)topilotstud.Loadindicator plungeragainsttheoppositesideofthehousingand zerotheindicator.

(7)Spreaddifferentialcasewhilemeasuringthe distancewiththedialindicator.

CAUTION:Neverspreadthedifferentialhousing over0.34mm(0.013in).Failuretoheedcaution mayresultindamage.

(8)Removedialindicator.

(9)Holddifferentialcase(2)(Fig.51)andremove bearingcaps.

(10)Removedifferentialfromthehousing(1).

(11)Tagdifferentialbearing(3)cupsandshimsto indicatelocation.

(12)Removespreaderfromhousing.

Fig.52PINIONMATEGEAR

1-THRUSTWASHER 2-SIDEGEAR 3-PINIONMATEGEAR

(1)Removeringgear. (2)Removeroll-pinholdingmateshaftinhousing.

DIFFERENTIAL(Continued)

(3)Removepiniongearmateshaft.

(4)Rotatedifferentialsidegears(2)(Fig.52)and removepiniongears(3)andthrustwashers(1).

(5)Removedifferentialsidegearsandthrust washers.

ASSEMBLY

Fig.53PINIONMATEGEAR

1-THRUSTWASHER

2-SIDEGEAR

3-PINIONMATEGEAR

(1)Installdifferentialsidegears(2)(Fig.53)and thrustwashers.

(2)Installpinionmategears(3)andthrustwashers(1).

(3)Installpiniongearmateshaft.

(4)Alignholeinthepiniongearmateshaft(2) (Fig.54)withtheholeinthedifferentialcase.

(5)Installtheroll-pin(3)inthedifferentialcase withahammerandpunch(1).Peentheedgeofthe roll-pinholeinthedifferentialcaseintwoplaces 180°apart.

(6)Lubricatealldifferentialcomponentswith hypoidgearlubricant.

(7)Installringgear.

INSTALLATION

NOTE:Ifdifferentialbearingsordifferentialcaseare replaced,RefertoadjustmentsforeDifferential BearingPreloadandGearBacklashprocedures.

Fig.54PINIONMATESHAFTROLL-PIN 1-PUNCH 2-PINIONMATESHAFT 3-MATESHAFTLOCKPIN

Fig.55VARI-LOK 1-ANTI-ROTATIONTAB 2-OILFEEDTUBE

(1)PositionSpreaderW-129-Bondifferentiallocationholesandinstallsafetyholddownclamps. Tightenspreaderturnbucklefinger-tight.

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