SERVICEMANUAL 2003 CHEROKEE NOPARTOFTHISPUBLICATIONMAYBE REPRODUCED,STOREDINARETRIEVAL SYSTEM,ORTRANSMITTED,INANYFORMOR BYANYMEANS,ELECTRONIC,MECHANICAL, PHOTOCOPYING,RECORDING,OROTHERWISE, WITHOUTTHEPRIORWRITTENPERMISSION OFDAIMLERCHRYSLERCORPORATION.
DaimlerChryslerCorporationreservestherighttomakechangesindesignor tomakeadditionstoorimprovementsinitsproductswithoutimposingany obligationsuponitselftoinstallthemonitsproductspreviouslymanufactured.
Copyright©DaimlerChryslerCorporation
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FOREWORD Theinformationcontainedinthisservicemanualhasbeenpreparedfortheprofessionalautomotivetechnicianinvolvedindailyrepairoperations.Informationdescribingtheoperationanduseofstandardand optionalequipmentisincludedintheOwner’sManualprovidedwiththevehicle.
Informationinthismanualisdividedintogroups.Thesegroupscontaindescription,operation,diagnosis, testing,adjustments,removal,installation,disassembly,andassemblyproceduresforthesystemsandcomponents.Toassistinlocatingagrouptitlepage,usetheGroupTabLocatorbyclickingtothefollowingpage.The firstpageofthegrouphasacontentssectionthatlistsmajortopicswithinthegroup.
AServiceManualCommentformisincludedattherearofthismanual.Usetheformtoprovide DaimlerChryslerCorporationwithyourcommentsandsuggestions.
Tighteningtorquesareprovidedasaspecificvaluethroughoutthismanual.Thisvaluerepresentsthe midpointoftheacceptableengineeringtorquerangeforagivenfastenerapplication.Thesetorquevaluesare intendedforuseinserviceassemblyandinstallationproceduresusingthecorrectOEMfasteners.When replacingfasteners,alwaysusethesametype(partnumber)fastenerasremoved.
DaimlerChryslerCorporationreservestherighttochangetestingprocedures,specifications,diagnosis, repairmethods,orvehiclewiringatanytimewithoutpriornoticeorincurringobligation.
GROUPTABLOCATOR 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)and(Fig.2).
FASTENERUSAGE DESCRIPTION
DESCRIPTION-FASTENERUSAGE
WARNING:USEOFANINCORRECTFASTENER MAYRESULTINCOMPONENTDAMAGEORPERSONALINJURY.
Fastenersandtorquespecificationsreferencesin thisServiceManualareidentifiedinmetricandSAE format.
Duringanymaintenanceorrepairprocedures,itis importanttosalvageallfasteners(nuts,bolts,etc.) forreassembly.Ifthefastenerisnotsalvageable,a fastenerofequivalentspecificationmustbeused.
DESCRIPTION-THREADEDHOLEREPAIR
Moststrippedthreadedholescanberepairedusing aHelicoil .FollowthevehicleorHelicoil recommendationsforapplicationandrepairprocedures.
INTERNATIONALSYMBOLS DESCRIPTION
Thegraphicsymbolsillustratedinthefollowing InternationalControlandDisplaySymbolsChart (Fig.3)areusedtoidentifyvariousinstrumentcontrols.Thesymbolscorrespondtothecontrolsanddisplaysthatarelocatedontheinstrumentpanel.
Fig.3INTERNATIONALCONTROLANDDISPLAYSYMBOLS
1HighBeam13RearWindowWasher 2FogLamps14Fuel 3Headlamp,ParkingLamps,PanelLamps15EngineCoolantTemperature 4TurnWarning16BatteryChargingCondition 5HazardWarning17EngineOil 6WindshieldWasher18SeatBelt 7WindshieldWiper19BrakeFailure 8WindshieldWiperandWasher20ParkingBrake 9WindscreenDemistingandDefrosting21FrontHood 10VentilatingFan22Rearhood(Decklid) 11RearWindowDefogger23Horn 12RearWindowWiper24Lighter
METRICSYSTEM DESCRIPTION
Themetricsystemisbasedonquantitiesofone, ten,onehundred,onethousandandonemillion. Thefollowingchartwillassistinconvertingmetric unitstoequivalentEnglishandSAEunits,orvise versa.
CONVERSIONFORMULASANDEQUIVALENTVALUES MULTIPLYBYTOGETMULTIPLYBYTOGET
in-lbsx0.11298=NewtonMeters (N·m) N·mx8.851=in-lbs
ft-lbsx1.3558=NewtonMeters (N·m) N·mx0.7376=ft-lbs
InchesHg(60°F)x3.377=Kilopascals(kPa)kPax0.2961=InchesHg psix6.895=Kilopascals(kPa)kPax0.145=psi
Inchesx25.4=Millimeters(mm)mmx0.03937=Inches Feetx0.3048=Meters(M)Mx3.281=Feet Yardsx0.9144=MetersMx1.0936=Yards mphx1.6093=Kilometers/Hr. (Km/h)
Km/hx0.6214=mph
Feet/Secx0.3048=Meters/Sec(M/S)M/Sx3.281=Feet/Sec mphx0.4470=Meters/Sec(M/S)M/Sx2.237=mph Kilometers/Hr.(Km/h)x0.27778=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
RefertotheMetricConversionCharttoconvert torquevalueslistedinmetricNewton-meters(N·m). Also,usethecharttoconvertbetweenmillimeters (mm)andinches(in.)(Fig.4).
Fig.4METRICCONVERSIONCHART
TORQUEREFERENCES DESCRIPTION
IndividualTorqueChartsappearwithinmanyor theGroups.RefertotheStandardTorqueSpecifica-
tionsChartfortorquereferencesnotlistedinthe individualtorquecharts(Fig.5). Fig.5TORQUESPECIFICATIONS
VEHICLEEMISSIONCONTROL INFORMATION(VECI)LABEL DESCRIPTION
AllmodelshaveaVehicleEmissionControlInformation(VECI)Label.DaimlerChryslerpermanently attachesthelabelintheenginecompartment(Fig. 6).Thelabelcannotberemovedwithoutdefacing labelinformationanddestroyinglabel.
Thelabelcontainsthevehicle’semissionspecificationsandvacuumhoseroutings.Allhosesmustbe connectedandroutedaccordingtothelabel.
Thelabelalsocontainsanenginevacuumschematic.Thereareuniquelabelsforvehiclesbuiltfor saleinthestateofCaliforniaandthecountryof Canada.Canadianlabelsarewritteninboththe EnglishandFrenchlanguages.
TheVECIlabelcontainsthefollowing:
• Enginefamilyanddisplacement
• Evaporativefamily
• Emissioncontrolsystemschematic
• Certificationapplication
• Enginetimingspecifications(ifadjustable)
• Idlespeeds(ifadjustable)
• Sparkplugandgap
Fig.6VECILABELLOCATION
1-RADIATORSUPPORT
2-VECILABEL
VEHICLEIDENTIFICATION NUMBER DESCRIPTION
TheVehicleIdentificationNumber(VIN)plateis locatedonthelowerleftA-pillarandisvisible throughthewindshield(Fig.7).TheVINcontains17 charactersthatprovidedataconcerningthevehicle. RefertotheVINdecodingcharttodeterminethe identificationofavehicle.
Fig.7VINNUMBERLOCATION
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) M=Cherokee4X4(RHD)
6Series3=LibertyRenegade 4=LibertySport/CherokeeSport 5=LibertyLimited/CherokeeLimited
7BodyStyle8=SportUtility-4Door 8EngineK=3.7L6cylMPIGasoline 1=2.4L4cylMPIGasoline 7=2.5L4cylDiesel
9CheckDigit0through9orX
10ModelYear3=2003
11AssemblyPlantW=ToledoNorthAssemblyPlant 12thru17VehicleBuildSequence
VEHICLESAFETY CERTIFICATIONLABEL
DESCRIPTION
Avehiclesafetycertificationlabel(Fig.8)is attachedtoeveryDaimlerChryslerCorporationvehicle.Thelabelcertifiesthatthevehicleconformstoall applicableFederalMotorVehicleSafetyStandards. Thelabelalsolists:
• Monthandyearofvehiclemanufacture.
• GrossVehicleWeightRating(GVWR).Thegross frontandrearaxleweightratings(GAWR’s)are basedonaminimumrimsizeandmaximumcoldtire inflationpressure.
• VehicleIdentificationNumber(VIN).
• Typeofvehicle.
• Typeofrearwheels.
• Barcode.
• Month,DayandHour(MDH)offinalassembly.
• PaintandTrimcodes.
• Countryoforigin.
Thelabelislocatedonthedriver-sidedoor shut-face.
Fig.8VEHICLESAFETYCERTIFICATIONLABELTYPICAL
LUBRICATION&MAINTENANCE INTERNATIONALSYMBOLS DESCRIPTION
DaimlerChryslerCorporationusesinternational symbolstoidentifyenginecompartmentlubricant andfluidinspectionandfilllocations(Fig.1).
PARTS&LUBRICANT RECOMMENDATION DESCRIPTION
DESCRIPTION-FLUIDTYPES
Whenserviceisrequired,DaimlerChryslerCorporationrecommendsthatonlyMopar brandparts, lubricantsandchemicalsbeused.Mopar provides thebestengineeredproductsforservicing DaimlerChryslerCorporationvehicles.
Onlylubricantsbearingdesignationsdefinedby thefollowingorganizationshouldbeusedtoservicea ChryslerCorporationvehicle.
• SocietyofAutomotiveEngineers(SAE)
• AmericanPetroleumInstitute(API)(Fig.2)
• NationalLubricatingGreaseInstitute(NLGI) (Fig.3)
Fig.1INTERNATIONALSYMBOLS
SAEVISCOSITYRATING AnSAEviscositygradeisusedtospecifytheviscosityofengineoil.Thesearespecifiedwithadual SAEviscositygradewhichindicatesthecold-to-hot temperatureviscosityrange.ExampleSAE5W-30= multigradeengineoil.
DaimlerChryslerCorporationonlyrecommends multigradeengineoils.
PARTS&LUBRICANTRECOMMENDATION(Continued)
APIQUALITYCLASSIFICATION Thissymbol(Fig.2)onthefrontofanoilcontainer meansthattheoilhasbeencertifiedbytheAmericanPetroleumInstitute(API)tomeetallthelubricationrequirementsspecifiedbyDaimlerChrysler Corporation.
SPECIALIZEDLUBRICANTSANDOILS Somemaintenanceorrepairproceduresmay requiretheuseofspecializedlubricantsoroils.Consulttheappropriatesectionsinthismanualforthe correctapplicationoftheselubricants.
DESCRIPTION-LUBRICANT RECOMMENDATIONS Chassis
ComponentFluid,Lubricant,orGenuinePart
Fig.2APISymbol
GEARLUBRICANTS SAEratingsalsoapplytomultigradegearlubricants.Inaddition,APIclassificationdefinesthe lubricantsusage.SuchasAPIGL-5andSAE75W90.
LUBRICANTSANDGREASES Lubricatinggreaseisratedforqualityandusage bytheNLGI.AllapprovedproductshavetheNLGI symbol(Fig.3)onthelabel.AtthebottomNLGI symbolistheusageandqualityidentificationletters. Wheelbearinglubricantisidentifiedbytheletter “G”.Chassislubricantisidentifiedbythelatter“L”. Theletterfollowingtheusageletterindicatesthe qualityofthelubricant.Thefollowingsymbolsindicatethehighestquality.
SteeringGear &Linkage,Ball Joints,Prop Shafts& Yokes,Wheel Bearings
Body
Mopar Multi-PurposeLubricant NLGIGrade2EP,GC-LB
Component Fluid,Lubricant,andGenuine Part
Hinges:
Door&HoodMopar EngineOil
SwingGateMopar Multi-PurposeLubeNLGI Grade2EP,GC-LB
Latches:Door, Hood/Safety Catch,Swing Gate
Mopar Multi-PurposeLubeNLGI Grade2EP,GC-LB
SeatRegulator &Track Mopar Multi-PurposeLubeNLGI Grade2EP,GC-LB
LockCylindersMopar LockCylinderLube
Fig.3NLGISymbol
1-WHEELBEARINGS
2-CHASSISLUBRICATION
3-CHASSISANDWHEELBEARINGS
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FLUIDTYPES DESCRIPTION DESCRIPTION-FLUIDTYPES
Whenserviceisrequired,DaimlerChryslerCorporationrecommendsthatonlyMopar brandparts, lubricantsandchemicalsbeused.Mopar provides thebestengineeredproductsforservicing DaimlerChryslerCorporationvehicles.
Onlylubricantsbearingdesignationsdefinedby thefollowingorganizationshouldbeusedtoservicea ChryslerCorporationvehicle.
• SocietyofAutomotiveEngineers(SAE)
• AmericanPetroleumInstitute(API)(Fig.4)
• NationalLubricatingGreaseInstitute(NLGI) (Fig.5)
SAEVISCOSITYRATING
AnSAEviscositygradeisusedtospecifytheviscosityofengineoil.Thesearespecifiedwithadual SAEviscositygradewhichindicatesthecold-to-hot temperatureviscosityrange.ExampleSAE5W-30= multigradeengineoil.
DaimlerChryslerCorporationonlyrecommends multigradeengineoils.
APIQUALITYCLASSIFICATION
Thissymbol(Fig.4)onthefrontofanoilcontainer meansthattheoilhasbeencertifiedbytheAmericanPetroleumInstitute(API)tomeetallthelubricationrequirementsspecifiedbyDaimlerChrysler Corporation.
LUBRICANTSANDGREASES Lubricatinggreaseisratedforqualityandusage bytheNLGI.AllapprovedproductshavetheNLGI symbol(Fig.5)onthelabel.AtthebottomNLGI symbolistheusageandqualityidentificationletters. Wheelbearinglubricantisidentifiedbytheletter “G”.Chassislubricantisidentifiedbythelatter“L”. Theletterfollowingtheusageletterindicatesthe qualityofthelubricant.Thefollowingsymbolsindicatethehighestquality.
GEARLUBRICANTS SAEratingsalsoapplytomultigradegearlubricants.Inaddition,APIclassificationdefinesthe lubricantsusage.SuchasAPIGL-5andSAE75W90.
Fig.5NLGISymbol
1-WHEELBEARINGS
2-CHASSISLUBRICATION
3-CHASSISANDWHEELBEARINGS
SPECIALIZEDLUBRICANTSANDOILS Somemaintenanceorrepairproceduresmay requiretheuseofspecializedlubricantsoroils.Consulttheappropriatesectionsinthismanualforthe correctapplicationoftheselubricants.
DESCRIPTION-AXLE NOTE:DaimlerChryslerrecommendsusingMopar lubricantsorlubricantsofequalquality.
FRONTAXLE • 186FIA(Model30)-Mopar SynthenticGear Lubricant75W-140
REARAXLE • 81/4-Mopar GearLubricant75W-90(Trailer Towing-Mopar SynthenticGearLubricant75W-140
NOTE:Trac-lok equippedaxlesrequire118ml(4 ounces)ofLimitedSlipAdditivebeaddedtothe lubricant.
Fig.4APISymbol
DESCRIPTION-MANUALTRANSMISSION
NOTE:DaimlerChryslerrecommendsusingMopar lubricantsorlubricantsofequalquality.
• NV1500-Mopar ManualTransmissionLubricant
• NV3550-Mopar ManualTransmissionLubricant
DESCRIPTION-AUTOMATICTRANSMISSION FLUID
NOTE:RefertoServiceProceduresinthisgroupfor fluidlevelcheckingprocedures.
Mopar ATF+4,AutomaticTransmissionFluidis therecommendedfluidforDaimlerChryslerautomatictransmissions.
DexronIIfluidISNOTrecommended.Clutch chattercanresultfromtheuseofimproper fluid.
Mopar ATF+4,AutomaticTransmissionFluid whennewisredincolor.TheATFisdyedredsoit canbeidentifiedfromotherfluidsusedinthevehicle suchasengineoilorantifreeze.Theredcolorisnot permanentandisnotanindicatoroffluidcondition. Asthevehicleisdriven,theATFwillbegintolook darkerincolorandmayeventuallybecomebrown. 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.
DESCRIPTION-TRANSFERCASE-NV231 RecommendedlubricantfortheNV231transfer caseisMopar ATF+4,AutomaticTransmission Fluid.
DESCRIPTION-TRANSFERCASE-NV242
RecommendedlubricantfortheNV242transfer caseisMopar ATF+4,AutomaticTransmission Fluid.
DESCRIPTION-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 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.
DESCRIPTION-ENGINEOIL-DIESEL ENGINES UseonlyDieselEngineOilmeetingstandard MIL2104C orAPIClassification CDorhigher or CCML D4,D5.
SAEVISCOSITYGRADE CAUTION:Lowviscosityoilsmusthavetheproper APIqualityortheCCMCG5designation.
Toassureofproperlyformulatedengineoils,itis recommendedthatSAEGrade10W-40engineoils thatmeetChryslermaterialstandardMS-6395,be used.EuropeanGrade10W-40oilsarealsoacceptable.
OilsoftheSAE5W-40or5W-30gradenumberare preferredwhenminimumtemperaturesconsistently fallbelow-12°C.
DESCRIPTION-POWERSTEERINGFLUID TherecommendedfluidforthepowersteeringsystemisMOPAR PowerSteeringFluidorequivalent. Donotuseautomatictransmissionfluidanddonot overfill.
OPERATION-AUTOMATICTRANSMISSION FLUID Theautomatictransmissionfluidisselectedbased uponseveralqualities.Thefluidmustprovideahigh levelofprotectionfortheinternalcomponentsby providingalubricatingfilmbetweenadjacentmetal components.Thefluidmustalsobethermallystable sothatitcanmaintainaconsistentviscositythrough alargetemperaturerange.Iftheviscositystaysconstantthroughthetemperaturerangeofoperation, transmissionoperationandshiftfeelwillremainconsistent.Transmissionfluidmustalsobeagoodconductorofheat.Thefluidmustabsorbheatfromthe internaltransmissioncomponentsandtransferthat heattothetransmissioncase.
FLUIDCAPACITIES SPECIFICATIONS-FLUIDCAPACITIES
DESCRIPTIONSPECIFICATION
FUELTANK18.5U.S.Gallons(70 Liters)****
ENGINEOIL
EngineOil-withFilter2.4L
4.7L(5.0qts.)
EngineOil-withFilter3.7L 4.7L(5.0qts.)
EngineOil-WithFilter2.5LDiesel
DESCRIPTIONSPECIFICATION
FRONTAXLE
186FIA(Model30)1.24L(2.6pts.) REARAXLE
81/42.08L(4.4pts.)*
*WhenequippedwithTrac-lok,include118ml(4.0 ounces)ofLimitedSlipAdditive.
****Nominalrefillcapacitiesareshown.Avariation maybeobservedfromvehicletovehicledueto manufacturingtoleranceandrefillprocedure.
6.5L(6.9qts.)
ENGINECOOLANT
CoolingSystem-2.4L9.5L(10.0qts.)
CoolingSystem-3.7L13.2L(14.0qts.)
CoolingSystem-2.5L Diesel 12.5L(13.2qts.)
POWERSTEERINGSYSTEM
Powersteeringfluidcapacitiesaredependenton engine/chassisoptionsaswellassteeringgear/cooler options.Dependingontypeandsizeofinternal cooler,lengthandinsidediameterofcoolerlines,or useofanauxiliarycooler,thesecapacitiesmayvary. Referto19,Steeringforproperfillandbleed procedures.
AUTOMATICTRANSMISSION
ServiceFill-45RFE4.73L(10.0pts)
O-haulFill-45RFE13.33L(28.0pts)
ServiceFill-42RLE3.8L(8.0pts)
O-haulFill-42RLE8.3L(17.6pts)
DryfillcapacityDependingontypeandsizeof internalcooler,lengthandinsidediameterofcooler lines,oruseofanauxiliarycooler,thesefiguresmay vary.(Referto21-TRANSMISSION/AUTOMATIC/ FLUID-STANDARDPROCEDURE)
TRANSFERCASE
NV2311.4L(2.95pts.)
NV2421.6L(3.4pts.)
MANUALTRANSMISSION
NV1500(Approximatedry fillorfilltobottomedgeof thefillplughole.)
NV3550(Approximatedry fillorfilltobottomedgeof fillplughole.)
2.3L(4.8pts.)
4X4-1.98L(4.2pts.)
4X2-2.28L(4.8pts.)
FLUIDFILL/CHECK LOCATIONS DESCRIPTION
Thefluidcheck/fillpointlocationsarelocatedin eachapplicableservicemanualsection.
MAINTENANCESCHEDULES DESCRIPTION MaintenanceScheduleInformationnotincludedin thissection,islocatedintheappropriateOwner’s Manual.
Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.
FirstisSchedule 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.
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.
• Checkthefluidlevelsofthecoolantreservoir, brakemastercylinder,powersteering,andtransmission,andaddasneeded.
• Checkalllightsandallotherelectricalitemsfor correctoperation.
AtEachOilChange • Changetheengineoilfilter.
• Inspecttheexhaustsystem.
• Inspectbrakehoses.
• Checkthecoolantlevel,hoses,andclamps.
• Rotatethetires.
• Inspectmanualtransmissionfluidlevel—if equipped.
• Aftercompletionofoff-roadoperation,the undersideofthevehicleshouldbethoroughly inspected.Examinethreadedfastenersforlooseness.
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.
Miles3,0006,0009,00012,00015,000 (Kilometers)(5000)(10000)(14000)(19000)(24000)
Changetheengineoilandengineoilfilter.
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineaircleaner element(2.4LOnly).
Replacetheengineaircleanerelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Miles18,00021,00024,00027,00030,000 (Kilometers)(29000)(34000)(38000)(43000)(48000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly). X
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary. X
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Drainandrefilltheautomatictransmission fluid,andreplacemainsumpfilter. X
Miles33,00036,00039,00042,00045,000 (Kilometers)(53000)(58000)(62000)(67000)(72000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly). X
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxle fluid‡ X
Inspectthedrivebeltandreplaceas needed. X
MAINTENANCESCHEDULES(Continued)
Miles48,00051,00054,00057,00060,000 (Kilometers)(77000)(82000)(86000)(91000)(96000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary.
Replacetheignitioncables(2.4LOnly). X
Inspectthebrakelinings.XX
Drainandrefillthefrontandrearaxlefluid‡XX
Drainandrefilltheautomatictransmission fluid,andreplacemainsumpfilter. X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously
Drainandrefillthetransfercasefluid.X
Miles63,00066,00069,00072,00075,000 (Kilometers)(101000)(106000)(110000)(115000)(120000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
MAINTENANCESCHEDULES(Continued)
Miles78,00081,00084,00087,00090,000 (Kilometers)(125000)(130000)(134000)(139000)(144000)
Changetheengineoilandengineoilfilter.XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly). X
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement(2.4L Only). X
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary. X
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Drainandrefilltheautomatictransmission fluid,andreplacetransmissionfilter(s). X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced. X
Replacethetimingbelt(2.4LOnly). X
Miles93,00096,00099,000102,000105,000 (Kilometers)(149000)(154000)(158000)(163000)(168000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly). X
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
Flushandreplacetheenginecoolant.X
Miles108,000111,000114,000117,000120,000 (Kilometers)(173000)(178000)(182000)(187000)(192000)
Changetheengineoilandengineoilfilter.XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly). X
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement(2.4L Only). X
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary.
Replacetheignitioncables(2.4LOnly). X Inspectthebrakelinings.XX
Drainandrefillthefrontandrearaxlefluid‡XX
Drainandrefilltheautomatictransmission fluid,andreplacemainsumpfilter. X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
Drainandrefillthetransfercasefluid.X
Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.
‡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
Replacetheengineairfilterelement. X
Replacethesparkplugs. X
Inspectthebrakelinings.X
Inspectthetransfercasefluid. X
Miles36,00042,00048,00054,000 (Kilometers)(58000)(67000)(77000)(86000) [Months][36][42][48][54]
Changetheengineoilandengineoilfilter.XXXX
Inspectthebrakelinings.XX
Miles60,00066,00072,00078,000 (Kilometers)(96000)(106000)(115000)(125000) [Months][60][66][72][78]
Changetheengineoilandengineoilfilter.XXXX
Inspectthebrakelinings.X
Replacetheengineairfilterelement. X
Replacethesparkplugs. X
Replacetheignitioncables(2.4LOnly). X
InspectandreplacethePCVvalve,ifnecessary. X
Inspectthedrivebeltandreplace,ifneeded.X
Inspectthedrivebeltandreplaceasneeded.Not requiredifpreviouslyreplaced. X
Flushandreplacetheenginecoolantat60months, regardlessofmileage. X
Inspectthetransfercasefluid.X
MAINTENANCESCHEDULES(Continued)
Miles84,00090,00096,000102,000 (Kilometers)(134000)(144000)(154000)(163000) [Months][84][90][96][102]
Changetheengineoilandengineoilfilter.XXXX
Inspectthebrakelinings.X
Replacetheengineairfilterelement. X Replacethesparkplugs. X
InspectandreplacethePCVvalve,ifnecessary. X
Inspectthedrivebeltandreplaceasneeded.Not requiredifpreviouslyreplaced. XX
Flushandreplacetheenginecoolantifnotdoneat60 months. X
Drainandrefilltheautomatictransmissionfluid,and replacetransmissionfilter(s). X
Inspectthetransfercasefluid.X
Miles108,000114,000120,000 (Kilometers)(173000)(182000)(192000) [Months][108][114][120] Changetheengineoilandengineoilfilter.XXX
Inspectthebrakelinings.X
Replacetheengineairfilterelement. X Replacethesparkplugs. X
InspectandreplacethePCVvalve,ifnecessary. X Replacetheignitioncables(2.4LOnly). X
Inspectthedrivebeltandreplaceasneeded.Notrequiredifpreviously replaced. XX
Flushandreplacetheenginecoolantifnotdoneat163000km (102,000miles). X
Replacethetimingbelt(2.4LOnly). X
Drainandrefillthetransfercasefluid.X
Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.
HOISTING STANDARDPROCEDURE-HOISTING RECOMMENDATIONS RefertotheOwner’sManualforemergencyvehicle liftingprocedures.
Whenproperlypositioned,afloorjackcanbeused toliftaJeepvehicle(Fig.6).Supportthevehiclein theraisedpositionwithjackstandsatthefrontand rearendsoftheframerails.
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)
Fig.6CorrectVehicleLiftingLocations
1-FrameContactLift(SinglePost) ChassisLift(Non-AxleDualPost) OutboardLift(DualPost) FloorJack
2-FloorJack
CAUTION:DonotattempttoliftaJeepvehiclewith afloorjackpositionedunder:
• Abodysidesill.
• Asteeringlinkagecomponent.
• Adriveshaft.
• Theengineortransmissionoilpan.
• Thefueltank.
• Afrontsuspensionarm.
• Transfercase.
NOTE:Usethecorrectsub-framerailorframerail liftinglocationsonly.
• DONOTJUMPSTARTAFROZENBATTERY, PERSONALINJURYCANRESULT.
• IFEQUIPPED,DONOTJUMPSTARTWHEN MAINTENANCEFREEBATTERYINDICATORDOTIS YELLOWORBRIGHTCOLOR.
• 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. 7).Reviewallwarningsinthisprocedure.
(5)Ondisabledvehicle,connectREDjumpercable clamptobatterypositive(+)terminal.Connect BLACKjumpercableclamptotheengineascloseto thegroundcableconnectionaspossible(Fig.7).
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.7JumperCableClampConnections
1-BOOSTERBATTERY 2-NEGATIVEJUMPERCABLE 3-ENGINEGROUND 4-DONOTALLOWVEHICLESTOTOUCH 5-BATTERYNEGATIVECABLE 6-DISCHARGEDBATTERY 7-POSITIVEJUMPERCABLE
TOWING STANDARDPROCEDURE-TOWING AvehicleequippedwithSAEapprovedwheellifttypetowingequipmentcanbeusedtotowJeepvehicles.Whentowinga4WDvehicleusingawheel-lift towingdevice,usetowdolliesundertheoppositeend ofthevehicle.Avehiclewithflatbeddevicecanalso beusedtotransportadisabledvehicle(Fig.8).
Fig.8TowVehiclesWithApprovedEquipment
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.
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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.
MAINTENANCESCHEDULES MAINTENANCESCHEDULESFORALL MARKETSEXCEPTU.S.,CANADAand MEXICO
DESCRIPTION
DESCRIPTION
MaintenanceScheduleInformationnotincludedinthis section,islocatedintheappropriateOwner’sManual. Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.
FirstisSchedule 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.
NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule“B.”
SecondisSchedule “A”.Itisforvehiclesthatare notoperatedunderanyoftheconditionslistedunder Schedule“B.”
Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.
CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.
AtEachStopforFuel • Checktheengineoillevelabout5minutesaftera fullywarmedengineisshutoff.Checkingtheoillevel
whilethevehicleisonlevelgroundwillimprovethe accuracyoftheoillevelreading.Addoilonlywhenthe levelisatorbelowtheADDorMINmark.
• Checkthewindshieldwashersolvent,addas required.
OnceaMonth • Checkthetirepressureandlookforunusual wearordamage.
• Inspectthebattery,andcleanandtightenthe terminalsasrequired.
• Checkthefluidlevelsofthecoolantreservoir, brakemastercylinder,powersteering,andtransmission,andaddasneeded.
• Checkalllightsandallotherelectricalitemsfor correctoperation.
AtEachOilChange • Changetheengineoilfilter.
• Inspecttheexhaustsystem.
• Inspectbrakehoses.
• Checkthecoolantlevel,hoses,andclamps.
• Rotatethetires.
• Inspectmanualtransmissionfluidlevel—if equipped.
• Aftercompletionofoff-roadoperation,the undersideofthevehicleshouldbethoroughly inspected.Examinethreadedfastenersforlooseness.
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
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineaircleaner element(2.4LOnly).
Replacetheengineaircleanerelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Kilometers2900034000380004300048000
(Miles)(18,000)(21,000)(24,000)(27,000)(30,000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly). X
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary. X
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Drainandrefilltheautomatictransmission fluid,andreplacemainsumpfilter. X
Kilometers5300058000620006700072000
(Miles)(33,000)(36,000)(39,000)(42,000)(45,000)
Changetheengineoilandengineoilfilter.XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement(2.4L Only).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Inspectthedrivebeltandreplaceas needed. X
Kilometers7700082000860009100096000 (Miles)(48,000)(51,000)(54,000)(57,000)(60,000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly). X
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary.
Replacetheignitioncables(2.4LOnly). X
Inspectthebrakelinings.XX
Drainandrefillthefrontandrearaxlefluid‡XX
Drainandrefilltheautomatictransmission fluid,andreplacemainsumpfilter. X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously
Drainandrefillthetransfercasefluid.X
Kilometers101000106000110000115000120000 (Miles)(63,000)(66,000)(69,000)(72,000)(75,000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly). X
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
Kilometers125000130000134000139000144000
(Miles)(78,000)(81,000)(84,000)(87,000)(90,000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary.
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Drainandrefilltheautomatictransmission fluid,andreplacetransmissionfilter(s).
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
Replacethetimingbelt(2.4LOnly). X
Kilometers149000154000158000163000168000
(Miles)(93,000)(96,000)(99,000)(102,000)(105,000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly). X
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Inspectthebrakelinings.X
Drainandrefillthefrontandrearaxlefluid‡X
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
Flushandreplacetheenginecoolant.X
Kilometers173000178000182000187000192000 (Miles)(108,000)(111,000)(114,000)(117,000)(120,000)
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheengineairfilterelement, replaceifnecessary(3.7LOnly).
Cleananddrytheengineairfilter element(2.4LOnly).
Replacetheengineairfilterelement (2.4LOnly).
Replacethesparkplugs. X
InspectandreplacethePCVvalve,if necessary.
Replacetheignitioncables(2.4LOnly). X Inspectthebrakelinings.XX
Drainandrefillthefrontandrearaxlefluid‡XX Drainandrefilltheautomatictransmission fluid,andreplacemainsumpfilter.
Inspectthedrivebeltandreplaceas needed.Notrequiredifbeltwaspreviously replaced.
Drainandrefillthetransfercasefluid.X
Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.
Thismaintenanceisrecommendedbythemanufacturertotheowner,butitisnotrequiredtomaintainemissionswarranty.
‡Off-highwayoperation,trailertowing,taxi,limousine,bus,snowplowing,orothertypesofcommercial serviceorprolongedoperationwithheavyloading, especiallyinhotweather,requirefrontandrearaxle serviceindicatedwitha‡in Schedule“B”.Perform theseservicesifthevehicleisusuallyoperatedunder theseconditions.
MAINTENANCESCHEDULESFORALLMARKETSEXCEPTU.S.,CANADAandMEXICO(Continued)
Schedule“A” Kilometers1200024000360004800060000
(Miles)(7,500)(15,000)(22,500)(30,000)(37,500) [Months][6][12][18][24][30]
Changetheengineoilandengineoilfilter. XXXXX
Replacetheengineairfilterelement. X
Replacethesparkplugs. X
Inspectthebrakelinings.X
Inspectthetransfercasefluid.X
Kilometers720008400096000108000
(Miles)(45,000)(52,500)(60,000)(67,500) [Months][36][42][48][54]
Changetheengineoilandengineoilfilter.XXXX
Replacetheengineairfilterelement. X
CheckandreplacethePCVValve,ifnecessary . X
Replacetheignitioncables(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
Inspectthebrakelinings.X
Replacetheengineairfilterelement. X
Replacethesparkplugs. X
InspectandreplacethePCVvalve,ifnecessary. X
Inspectthedrivebeltandreplaceasneeded.Not requiredifpreviouslyreplaced. XX
Flushandreplacetheenginecoolantat60months, regardlessofmileage. X
Inspectthetransfercasefluid.X
MAINTENANCESCHEDULESFORALLMARKETSEXCEPTU.S.,CANADAandMEXICO(Continued)
Kilometers160000168000180000192000
(Miles)(100,000)(105,000)(112,500)(120,000) [Months][84][90][96]
Changetheengineoilandengineoilfilter.XXX
Inspectthebrakelinings.X
Replacetheengineairfilterelement. X
Replacethesparkplugs. X
Replacetheignitioncables(2.4LOnly). X
InspectandreplacethePCVvalve,ifnecessary. X
Inspectthedrivebeltandreplaceasneeded.Not requiredifpreviouslyreplaced.
Flushandreplacetheenginecoolantifnotdoneat60 months.
Drainandrefilltheautomatictransmissionfluid,and replacetransmissionfilter(s). X
Replacethetimingbelt(2.4LOnly). X
Drainthetransfercase,andrefill. X
Inspectionandserviceshouldbeperformedanytimeamalfunctionisobservedorsuspected.Retain allreceipts.
Thismaintenanceisrecommendedbythemanufacturertotheowner,butitisnotrequiredtomaintainemissionswarranty.
DESCRIPTION—DIESELENGINES MaintenanceScheduleInformationnotincludedin thissection,islocatedintheappropriateOwner’s Manual.
Therearetwomaintenanceschedulesthatshow the required serviceforyourvehicle.
FirstisSchedule “B”.Itisforvehiclesthatare operatedundertheconditionsthatarelistedbelow andatthebeginningoftheschedule.
• Extensiveengineidling.
• Drivingindustyconditions.
• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C(90°F).
• Trailertowing.
• Taxi,police,ordeliveryservice(commercialservice).
NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule B .
SecondisSchedule “A”.Itisforvehiclesthatare notoperatedunderanyoftheconditionslistedunder Schedule B
Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.
CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.
AtEachStopforFuel • Checktheengineoillevelabout5minutesaftera fullywarmedengineisshutoff.Checkingtheoillevel whilethevehicleisonlevelgroundwillimprovethe accuracyoftheoillevelreading.Addoilonlywhenthe levelisatorbelowtheADDorMINmark.
• Checkthewindshieldwashersolventandaddif required.
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.
Schedule“B” Followschedule“B”ifyouusuallyoperateyour vehicleunderoneormoreofthefollowingconditions.
• Extensiveengineidling.
• Drivingindustyconditions.
• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C(90°F).
• Trailertowing.
• Taxi,police,ordeliveryservice(commercialservice).
Kilometers10000km20000km30000km40000km50000km
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheballjoints. XXXXX
Inspectengineaccessorydrivebelt. XXXX
Replaceengineaccessorydrivebelt.X
Inspecttheengineairfilterelement. Replaceasnecessary. XXX
Replacetheengineairfilterelement.XX
Replacetheenginetimingbelt. X
Inspectidlerpulleysandtimingbelt tensioner‡. X
Replacefuelfilter/waterseparatorunit.XX
Inspectthebrakelinings. XXXXX
Drainandrefillthefrontandrearaxlefluid.XX
Drainandrefillautomatictransmissionfluid andreplacetransmissionmainsumpfilter. X
Kilometers60000km70000km80000km90000km100000km
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheballjoints. XXXXX
Inspectengineaccessorydrivebelt. XXXXX
Replaceengineaccessorydrivebelt.X
Inspecttheengineairfilterelement. Replaceasnecessary. XX
Replacetheengineairfilterelement.XXX
Inspectidlerpulleysandtimingbelt tensioner‡. X
Replacetheenginetimingbelt. X
Inspectthebrakelinings. XXXXX
Drainandrefillthefrontandrearaxlefluid.XXX
Replacethefuelfilter/waterseparatorunit.XXX
Drainandrefillthetransfercasefluid.X
Drainandrefilltheautomatictransmission fluidandreplacetransmissionmainsump filter. X
Kilometers110000km120000km130000km140000km150000km160000km
Changetheengineoiland engineoilfilter. XXXXXX
Inspecttheballjoints. XXXXXX
Inspecttheengineairfilter element.Replaceas necessary.
Replacetheengineairfilter element.
Inspectengineaccessory drivebelt.
Replaceengineaccessory drivebelt.
Inspecttheidlerpulleysand timingbelttensioner‡.
Replacetheenginetiming belt.
Inspectthebrakelinings. XXXXXX
Drainandrefillthefrontand rearaxlefluid.
Replacethefuelfilter/water separatorunit.
Flushandreplacetheengine coolant.
Drainandrefillautomatic transmissionfluidandreplace transmissionfilter(s).
Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected. Retainallreceipts.
‡Replaceifthereissuperficialwear,bearingclearance,orevidentgreaseleak.
Schedule“A” Kilometers20000km40000km60000km80000km100000km
Changetheengineoilandengineoilfilter. XXXXX
Inspecttheballjoints. XXXXX
Inspectthebrakelinings.XX
Inspecttheengineairfilterelement. Replaceasnecessary. XXX
Replacetheengineairfilterelement.XX
Inspecttheengineaccessorydrivebelt. XXXXX
Replacetheengineaccessorydrivebelt.X
Replacethefuelfilter/waterseparatorunit. XXXXX
Inspectidlerpulleys,andtimingbelt tensioner‡. X
Replacetheenginetimingbelt. X
Inspectthetransfercasefluid.X
Kilometers120000km140000km160000km180000km
Changetheengineoilandengineoilfilter.XXXX
Inspecttheballjoints.XXXX
Inspectthebrakelinings.XX
Inspecttheengineaccessorydrivebelt.XXXX
Inspecttheengineairfilterelement.Replaceas necessary. XX
Replacetheengineairfilterelement.XX
Replacethefuelfilter/waterseparatorunit.XXXX
Flushandreplacetheenginecoolant.X
Inspectthetransfercasefluid.X
Drainandrefillthetransfercasefluid.X
Drainandrefillautomatictransmissionfluidand replacetransmissionfilter(s). X
Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected. Retainallreceipts.
‡Replaceifthereissuperficialwear,bearingclearance,orevidentgreaseleak.
WARNING:Youcanbebadlyinjuredworkingonor aroundamotorvehicle.Doonlythatservicework forwhichyouhavetheknowledgeandtheright equipment.Ifyouhaveanydoubtaboutyourability toperformaservicejob,takeyourvehicletoa competentmechanic.
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SUSPENSION TABLEOFCONTENTS pagepage
SUSPENSION
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 WHEELALIGNMENT DESCRIPTION NOTE:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethe springssupportingtheweightofthevehiclewhen thefastenersaretorqued.Ifspringsarenotattheir normalrideposition,vehicleridecomfortcouldbe affectedandprematurebushingwearmayoccur.
Wheelalignmentinvolvesthecorrectpositioningof thewheelsinrelationtothevehicle.Thepositioningis accomplishedthroughsuspensionandsteeringlinkage adjustments.Analignmentisconsideredessentialfor efficientsteering,gooddirectionalstabilityandtominimizetirewear.Themostimportantmeasurementsof analignmentarecaster,camberandtoe(Fig.1).
CAUTION:Neverattempttomodifysuspensionor steeringcomponentsbyheatingorbending.
NOTE:Periodiclubricationofthefrontsuspension/ steeringsystemcomponentsmayberequired.Rubberbushingsmustneverbelubricated.Referto LubricationAndMaintenancefortherecommended maintenanceschedule.
OPERATION • CASTER istheforwardorrearwardtiltofthe steeringknucklefromvertical.Tiltingthetopofthe knuckleforwardprovidesnegativecaster.Tiltingthe topoftheknucklerearwardprovidespositivecaster. Positivecasterpromotesdirectionalstability.This angleenablesthefrontwheelstoreturntoastraight aheadpositionafterturns(Fig.1)
Fig.1WheelAlignmentMeasurements
1-FRONTOFVEHICLE
2-STEERINGAXISINCLINATION
3-PIVOTPOINT
4-TOE-IN
• CAMBER istheinwardoroutwardtiltofthe wheelrelativetothecenterofthevehicle.Tiltingthe topofthewheelinwardprovidesnegativecamber. Tiltingthetopofthewheeloutwardprovidespositive camber.Incorrectcamberwillcausewearonthe insideoroutsideedgeofthetire(Fig.1)
• TOE isthedifferencebetweentheleadinginside edgesandtrailinginsideedgesofthefronttires. Wheeltoepositionoutofspecificationcause’sunstablesteering,uneventirewearandsteeringwheeloffcenter.Thewheeltoepositionisthe final front wheelalignmentadjustment(Fig.1)
• THRUSTANGLE istheangleoftherearaxlerelativetothecenterlineofthevehicle.Incorrectthrust anglecancauseoff-centersteeringandexcessivetire wear.Thisangleisnotadjustable,damagedcomponent(s) mustbereplacedtocorrectthethrustangle(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
MeasurementTargetMinimumMaximum FrontRide
FrontCross
RideHeight
Left-Right 0.0mm-10.0mm10.0mm
RearRide Height
DistanceCD 97.1mm87.1mm107.1mm
RearCross
RideHeight
Left-Right 0.0mm-10.0mm10.0mm
STANDARDPROCEDURE-CAMBERAND CASTERADJUSTMENT
Camberandcasterangleadjustmentsinvolve changingthepositionofthelowercontrolarmcam bolts.(Fig.4)
Fig.4LOWERCONTROLARM
1-FRONTCAMBOLT
2-OUTERTIERODEND
3-LOWERBALLJOINTNUT
4-LOWERCONTROLARM
5-REARCAMBOLT
STANDARDPROCEDURE-TOEADJUSTMENT
4X4SUSPENSIONHEIGHTMESUREMENTMUSTBE PERFORMEDBEFOREANALIGNMENT.
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.
STANDARDPROCEDURE-CAMBER,CASTER ANDTOEADJUSTMENT
Camberandcasterangleadjustmentsinvolve changingthepositionofthelowersuspensionarm cambolts.(Fig.4)
1-JAMNUT
Fig.5TIERODEND 2-TIEROD-INNER
3-TIERODEND-OUTER
CASTER Movingtherearpositionofthecamboltinorout, willchangethecasteranglesignificantlyandcamber angleonlyslightly.Tomaintainthecamberangle whileadjustingcaster,movetherearofthecambolt inorout.Thenmovethefrontofthecambolt slightlyintheoppositedirection.(Fig.4)
Toincreasepositivecasterangle,movetherearpositionofthecamboltoutward(fromtheengine).Move thefrontofcamboltinward(towardtheengine)slightly untiltheoriginalcamberangleisobtained.(Fig.4)
CAMBER Movebothofthecamboltstogetherinorout.This willchangethecamberanglesignificantlyandcaster angleslightly.(Fig.4)
Afteradjustmentismadetightenthecamboltnuts topropertorquespecification.
TOEADJUSTMENT Thewheeltoepositionadjustmentisthefinal adjustment.
(1) Starttheengineandturnwheelsbothwaysbefore straighteningthewheels.Securethesteeringwheelwith thefrontwheelsinthestraight-aheadposition.
(2)Loosenthetierodjamnuts.
NOTE:Eachfrontwheelshouldbeadjustedfor one-halfofthetotaltoepositionspecification.This willensurethesteeringwheelwillbecentered whenthewheelsarepositionedstraight-ahead.
(3)Adjustthewheeltoepositionbyturningthetie rodasnecessary(Fig.5).
(4) Tightenthetierodjamnutto75N·m(55ft.lbs.).
(5)Verifythespecifications
(6)Turnoffengine.
WHEELALIGNMENT(Continued)
SPECIFICATIONS
ALIGNMENT
NOTE:Specificationsareindegrees.
FRONT DESCRIPTIONSPECIFICATION
REAR DESCRIPTIONSPECIFICATION
FRONT DESCRIPTION NOTE:Suspensioncomponentswithrubber/urethanebushingsshouldbetightenedwiththevehicleatnormalrideheight.Itisimportanttohavethe springssupportingtheweightofthevehiclewhen thefastenersaretorqued.Ifspringsarenotattheir normalrideposition,vehicleridecomfortcouldbe affectedandprematurebushingwearmayoccur.
Thefrontsuspensionisdesignedtoalloweach wheeltoadapttodifferentroadsurfacesindependently.Thewheelsaremountedtohubbearingson thesteeringknucklespindles.Thedouble-rowhub bearingsaresealedandlubricatedforlife.Thesteeringknucklesturn(pivot)onballjointsintegraltothe outboardportionoftheuppercontrolarmsand pressedintothelowersteeringknuckle.Theball jointsarelubricatedforlife.(Fig.1)
2-8FRONT KJ
FRONT(Continued)
WARNING WARNING:SUSPENSIONCOMPONENTSWITH RUBBERBUSHINGSMUSTBETIGHTENEDWITH THEVEHICLEATNORMALRIDEHEIGHT.ITIS IMPORTANTTOHAVETHESPRINGSSUPPORTING THEWEIGHTOFTHEVEHICLEWHENTHEFASTENERSARETORQUED.IFSPRINGSARENOTAT THEIRNORMALRIDEPOSITION,VEHICLERIDE COMFORTWILLBEAFFECTEDANDCAUSEPREMATUREBUSHINGWEAR.
Fig.1FRONTSUSPENSION 1-SWAYBAR
2-SWAYBARBUSHING/BRACKET
3-UPPERCONTROLARM
4-SPRING/SHOCKASSEMBLY
5-STEERINGKNUCKLE
6-OUTERTIERODEND
7-LOWERCONTROLARM
8-SWAYBARLINK
9-CLEVISBRACKET
SPECIFICATIONS TORQUECHART
TORQUESPECIFICATIONS
DESCRIPTIONN·mFt.Lbs.In.Lbs. FrontShockAbsorberClevisBracketUpperNut136100— FrontShockAbsorberClevisBracketLowerNut150110— FrontShockAbsorberTop(4)MountingNuts10880— FrontShocktoSpringandInsulatorNut4130— UpperSuspensionArmFrontNut12290— UpperSuspensionArmRearNut12290— LowerSuspensionArmFrontNut170125— LowerSuspensionArmRearNut170125— StabilizerBarClampNut149110— StabilizerBarLinkUpperNut136100— StabilizerBarLinkLowerNut11585— Hub/Bearing Bolt 13096— Hub/Bearing HalfshaftNut 135100— UpperBallJointNut8160— LowerBallJointNut8160— WheelSpeedSensor13.510—
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)
(2)Pressthebushingoutusingspecialtools 8858-1(receiver),8858-3(driver)and8839withthe threadedrod8839andthebearingasshown(Fig.3)
Fig.2LOWERCONTROLARMBUSHING-REMOVAL
1-8858-5RECEIVER 2-8858-6DRIVER 3-8839THREADEDROD
REMOVAL-CLEVISBRACKETBUSHING (1)Removetheclevisbracketfromtheshock (Referto2-SUSPENSION/FRONT/CLEVIS BRACKET-REMOVAL).
NOTE:Extremepressurelubricationmustbeusedon thethreadedportionsofthetool.Thiswillincreasethe longevityofthetoolandinsureproperoperationduringtheremovalandinstallationprocess.
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)thebearing withthethreadedrod8838(Fig.7)makingsureto properlyorientthebushinginthecontrolarm.
(2)Removethecontrolarmfromthevise.
(3)Installtheuppercontrolarm(Referto2-SUSPENSION/FRONT/UPPERCONTROLARMINSTALLATION).
(4)Resetthevehiclerideheight(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).
(5)Performawheelalignment(Referto2-SUSPENSION/WHEELALIGNMENT-STANDARD PROCEDURE).
HUB/BEARING REMOVAL (1)Raiseandsupportthevehicle.
(2)Removethetireandwheelassembly.
(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).
1-8830-3(ADAPTER)
2-8830-1(DRIVER)
3-BUSHING
4-8830-2(RECEIVER)
5-8838(THREADEDROD)
(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).
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.
Fig.9LOWERBALLJOINT 1-8859-1DRIVER
2-C-4212FPRESS
3-8859-2RECEIVER
Fig.8SUSPENSIONINTHECURBPOSITION 1-PRYBAR
2-BALLJOINT
3-DIALINDICATOR
4-WOODENBLOCKORSUPPORT
5-CLAMP
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.
(7)Presstheballjointfromthesteeringknuckle usingspecialtoolsC-4212–F(PRESS),8859-2 (RECEIVER)and8859-1(DRIVER)(Fig.9).
INSTALLATION NOTE:Extremepressurelubricationmustbeused onthethreadedportionsofthetool.Thiswill increasethelongevityofthetoolandinsureproper operationduringtheremovalandinstallationprocess.
(1)Installtheballjointintothesteeringknuckle andpressinusingspecialtoolsC-4212–F(press), 8859-3(driver)and6761(receiver)(Fig.10).
Fig.10LOWERBALLJOINT
1-6761RECEIVER
2-8859-3DRIVER
3-C-4212FPRESS
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(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.
INSTALLATION (1)Installthelowercontrolarmtothevehicle.
(2)Installtherearcam/pivotbolt.
(3)Installthefrontcam/pivotbolt.
(4)Installthelowerballjointnut.Tightenthenut to81N·m(60ft.lbs.)
(5)Alignthemarksfrontandrearatthecam/ pivotboltsandtightenthenuts.Tightenthenutsto 170N·m(125ft.lbs.)
Fig.11LOWERCONTROLARM
1-FRONTCAMBOLT
2-OUTERTIERODEND
3-LOWERBALLJOINTNUT
4-LOWERCONTROLARM
5-REARCAMBOLT
(6)Installthestabilizerlinkboltatthelowercontrolarm.Tightenthenutto136N·m(100ft.lbs.)
(7)Installthelowerclevisbracketboltatthe lowercontrolarm.Tightenthenutto150N·m(110 ft.lbs.)
(8)Installthetireandwheelassembly.(Referto 22-TIRES/WHEELS/WHEELS-STANDARDPROCEDURE).
(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.
2-16FRONT
(10)Removethestabilizerlink(Referto2-SUSPENSION/FRONT/STABILIZERLINK-REMOVAL).
(11)Removethelowerballjointnut.
(12)Seperatethelowerballjointfromthelower controlarmusingtoolC-4150A.
(13)Rotatethelowercontrolarmdownwardto allowaccess.
(14)Removetheclevisbracketattheshock.
(15)Removetheshockassemblyfromthevehicle. (Fig.12)
(16)Removethespringfromtheshock(ifneeded).
(13)Removethespringfromtheshock(ifneeded). (Referto2-SUSPENSION/FRONT/SPRINGREMOVAL).
Fig.12SHOCKASSEMBLY
1-SPRING
2-JOUNCEBUMPER
3-SHOCK
4-UPPERCONTROLARM
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)
(12)Removetheshockassemblyfromthevehicle. (Fig.13)
Fig.13SHOCK&CLEVISASSEMBLY 1-FRONTCRADLE 2-SPRING&SHOCKASSEMBLY 3-STEERINGKNUCKLE 4-CLEVISBRACKET 5-LOWERCONTROLARM
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.).
(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)
STABILIZERBAR REMOVAL (1)Raiseandsupportthevehicle.
(2)Removethetireandwheelassembly.
(3)Removetheupperstabilizerlinkboltsatthe stabilizerbar.
(4)Removethestabilizerbarbushingclampsfrom theframe(Fig.16).
(5)Removethestabilizerbarfromthevehicle.
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.Tighten theboltto136N·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.
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.
STABILIZERLINK REMOVAL (1)Raiseandsupportthevehicle.
(2)Removethetireandwheelassembly.
(3)Removethelowerstabilizerlinkboltatthe lowercontrolarm.
(4)Removetheupperstabilizerlinkboltatthe stabilizerbar.
(5)Removethestabilizerlink.(Fig.17)
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).
(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)
Fig.18REARBOLT
1-STEERINGSHAFT
2-REARBOLT
3-RATCHETWITHANEXTENSION
(11)Removetheuppercontrolarmfrontbolt. (12)Removetheuppercontrolarmfromthevehicle.
INSTALLATION INSTALLATION-RIGHTSIDE (1)Installtheuppercontrolarmtothevehicle.
(2)Installtheuppercontrolarmfrontbolt. Tightentheboltto122N·m(90ft.lbs.).
(3)Installtheuppercontrolarmrearbolt.Tighten theboltto122N·m(90ft.lbs.).
(4)Installthecruisecontrolservomountingnuts.
(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.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.
Fig.1REARSUSPENSION
1-COILSPRING
2-UPPERSUSPENSIONARM
REAR(Continued)
WARNING
WARNING:SUSPENSIONCOMPONENTSWITH RUBBERBUSHINGSMUSTBETIGHTENEDWITH THEVEHICLEATNORMALRIDEHEIGHT.ITIS IMPORTANTTOHAVETHESPRINGSSUPPORTING
DIAGNOSISANDTESTING-REARSUSPENSION
THEWEIGHTOFTHEVEHICLEWHENTHEFASTENERSARETORQUED.IFSPRINGSARENOTAT THEIRNORMALRIDEPOSITION,VEHICLERIDE COMFORTWILLBEAFFECTEDANDCAUSEPREMATUREBUSHINGWEAR.
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.
ShockAbsorberUpperNut10880— ShockAbsorberLowerNut11585— SuspensionArmUpperBallJointNut9570— SuspensionArmUpperFrameBolts10074— RearUpperBallJointBracketBolts136100— SuspensionArmsLowerBody/AxleBracketNut163120— SuspensionArmsLowerFrameBracketNut163120— StabilizerBarBolts9973—
SPECIALTOOLS SHOCK REMOVAL (1)Raiseandsupportthevehicle.Positiona hydraulicjackundertheaxletosupporttheaxle.
CAUTION:Donotallowtheaxletohangfromthe uppersuspensionarmballjoint.
(2)Removetheuppernutandboltfromtheframe bracket(Fig.2).
(3)Removethelowernutandboltfromtheaxle bracket.Removetheshockabsorber.
Fig.2SHOCKABSORBER
INSTALLATION (1)Installtheshockabsorberintheframebracket andinstalltheboltandnut(Fig.2).
(2)Installtheshockabsorberintheaxlebracket andinstalltheboltandnut(Fig.2).
(3)Removethesupportsandlowerthevehicle.
(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).
(3)Pullthejouncebumperdownwardstoremove. (Fig.4)
Fig.3COILSPRING
1-UPPERINSULATOR
2-JOUNCEBUMPER
3-COILSPRING
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).
Fig.4JOUNCEBUMPER
INSTALLATION (1)Installthejouncebumperintothemountby twistingthebumperintoplace(Fig.4).
(2)Installthecoilspring(Referto2-SUSPENSION/REAR/SPRING-INSTALLATION).
(3)Installtheshock(Referto2-SUSPENSION/ REAR/SHOCK-INSTALLATION).
STABILIZERBAR REMOVAL (1)Raiseandsupportthevehicle.
(2)Removethestabilizerbarboltsfromthelower suspensionarm.(Fig.5).
(3)Removethestabilizerbar.
Fig.5REARSTABILIZERBAR
1-MOUNTINGHOLES 2-STABILIZERBAR
INSTALLATION (1)Positionthestabilizerbarovertheaxleand installtheboltstothelowersuspensionarm(Fig.6). Ensurethebariscenteredwithequalspacingon bothsides.Tightentheboltsto99N·m(73ft.lbs.).
(2)Removesupportandlowerthevehicle.
(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
UPPERBALLJOINT REMOVAL (1)Raiseandsupportthevehicle.
(2)Supporttherearaxlewithahydraulicjack.
(3)Removetheballjointpinchboltfromthetopof theaxle.(Fig.7)
(4)Separatetheballjointarmassemblyfromthe differentialhousingbypryingupwards.
Fig.8UPPERBALLJOINT-REMOVAL 1-C-4212FPRESS 2-8861-3DRIVER 3-8861-2RECEIVER
(8)Pressouttheoldballjoint.
INSTALLATION
(1)InstallspecialtoolsC-4212F(press),8861-1 (receiver)and8861-2(driver)withtheballjointin place(Fig.9).
Fig.7BALLJOINTPINCHBOLT
1-UPPERBALLJOINT
2-PINCHBOLT
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.
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).
(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).
(5)Removethesupportsandlowerthevehicle.
Fig.10UPPERCONTROLARM
1-BODYMOUNTS 2-UPPERBALLJOINT 3-STABILIZERBAR 4-UPPERCONTROLARM 5-LOWERCONTROLARM
Fig.11BALLJOINTBRACKET
1-UPPERBALLJOINT 2-SUPPORTBRACKETBOLTS
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.
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:Extremepressurelubricationmustbeusedon thethreadedportionsofthetool.Thiswillincreasethe longevityofthetoolandinsureproperoperationduringtheremovalandinstallationprocess.
(3)Installspecialtools8862-4(receiver),8862-5 (spacer)and8862-1or8862-2(driver)withthe threadedrod8839andthebearingasshown(Fig.13)
Fig.12LOWERSUSPENSIONARM
INSTALLATION (1)Positionthelowersuspensionarmintheaxle bracketandframerailbracket.
NOTE:Theendofthearmwiththevoidedround bushingattachestotheaxlebracket.
(2)Installtheaxlebracketboltandnutfinger tight(Fig.12).
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:Extremepressurelubricationmustbeusedon thethreadedportionsofthetool.Thiswillincreasethe longevityofthetoolandinsureproperoperationduringtheremovalandinstallationprocess.
(3)Installspecialtools8853-3(driver),8860-1 (receiver)andwiththethreadedrod8838andthe bearingasshown(Fig.14) (4)Pressoutthebushing.
INSTALLATION INSTALLATION-LOWERSUSPENSIONARM BUSHING
NOTE:Extremepressurelubricationmustbeusedon thethreadedportionsofthetool.Thiswillincreasethe longevityofthetoolandinsureproperoperationduringtheremovalandinstallationprocess.
(1) Installthenewlowersuspensionarmbushings intothelowersuspensionarmusingtools8862-3(driver),8862-4(receiver),8862-5(spacer)andthebearing withthethreadedrod8839(Fig.15)makingsureto properlyorientthebushinginthesuspensionarm.
Fig.14UPPERSUSPENSIONARMBUSHINGREMOVAL
1-8853-3DRIVER
2-8860-1RECEIVER
3-8838THREADEDROD
Fig.15LOWERSUSPENSIONARMBUSHING INSTALLATION
1-8862-3DRIVER
2-8862-5SPACER
3-8862-4RECEIVER 4-8839THREADEDROD
(2)Removethesuspensionarmfromthevise.
(3)Installthelowersuspensionarm(Referto2SUSPENSION/REAR/LOWERCONTROLARMINSTALLATION).
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INSTALLATION-UPPERSUSPENSIONARM BUSHING NOTE:Extremepressurelubricationmustbeusedon thethreadedportionsofthetool.Thiswillincreasethe longevityofthetoolandinsureproperoperationduringtheremovalandinstallationprocess.
(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 TABLEOFCONTENTS PROPELLERSHAFT DIAGNOSISANDTESTING
VIBRATION
Tiresthatareout-of-round,orwheelsthatare unbalanced,willcausealowfrequencyvibration.
Brakerotorsthatareunbalancedwillcausea harsh,lowfrequencyvibration.
Drivelinevibrationcanalsoresultfromlooseor damagedenginemounts.
Propellershaftvibrationincreasesasthevehicle speedisincreased.Avibrationthatoccurswithina specificspeedrangeisnotusuallycausedbyapropellershaftbeingunbalanced.Defectivejointsoran incorrectpropellershaftangle,areusuallythecause ofsuchavibration.
DRIVELINEVIBRATION
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.
DriveConditionPossibleCauseCorrection
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.
JointNoise1.LooseU-jointclampscrews.1.Installnewclampsandscrews andtightentopropertorque.
2.Lackoflubrication.2.Replacejointsasnecessary.
BALANCE NOTE:Removingandre-indexingthepropeller shaft180°relativetotheyokemayeliminatesome vibrations.
Ifpropellershaftissuspectedofbeingunbalanced, itcanbeverifiedwiththefollowingprocedure:
(1)Raisethevehicle.
(2)Cleanalltheforeignmaterialfromthepropellershaftandtheuniversaljoints.
(3)Inspectthepropellershaftformissingbalance weights,brokenwelds,andbentareas. Ifthepropellershaftisbent,itmustbereplaced.
(4)Inspecttheuniversaljointstoensurethatthey arenotworn,areproperlyinstalled,andarecorrectlyalignedwiththeshaft.
(5)Checktheuniversaljointclampscrewstorque.
(6)Removethewheelsandtires.Installthewheel lugnutstoretainthebrakedrumsorrotors.
(7)Markandnumbertheshaftsixinchesfromthe yokeendatfourpositions90°apart.
(8)Runandacceleratethevehicleuntilvibration occurs.Notetheintensityandspeedthevibration occurred.Stoptheengine.
(9)Installascrewclampatposition1(Fig.1).
(10)Starttheengineandre-checkforvibration.If thereislittleornochangeinvibration,movethe clamptooneoftheotherthreepositions.Repeatthe vibrationtest.
(11)Ifthereisnodifferenceinvibrationatthe otherpositions,thesourceofthevibrationmaynot bepropellershaft.
(12)Ifthevibrationdecreased,installasecond clamp(Fig.2)andrepeatthetest.
Fig.1CLAMPATPOSITION1 1-CLAMP 2-SCREWDRIVER
Fig.2TWOCLAMPSATSAMEPOSITION
(13)Iftheadditionalclampcausesanadditional vibration,separatetheclamps(1/4inchaboveand belowthemark).Repeatthevibrationtest(Fig.3).
(14)Increasedistancebetweentheclampscrews andrepeatthetestuntiltheamountofvibrationis atthelowestlevel.Bendtheslackendoftheclamps sothescrewswillnotloosen.
(15)Ifthevibrationremainsunacceptable,apply thesamestepstothefrontendofthepropellershaft.
(16)Installthewheelandtires.Lowerthevehicle.
RUNOUT (1)Removedirt,rust,paintandundercoatingfrom thepropellershaftsurfacewherethedialindicator willcontacttheshaft.
(2)Thedialindicatormustbeinstalledperpendiculartotheshaftsurface.
(3)Measurerunoutatthecenterandendsofthe shaftsufficientlyfarawayfromweldareastoensure thattheeffectsoftheweldprocesswillnotenterinto themeasurements.
(4)RefertoRunoutSpecificationschart.
(5)Ifthepropellershaftrunoutisoutofspecification,removethepropellershaft,indextheshaft180°, andre-installthepropellershaft.Measureshaft runoutagain.
(6)Ifthepropellershaftrunoutisnowwithin specifications,marktheshaftandyokesforproper orientation.
(7)Ifthepropellershaftrunoutisnotwithinspecifications,verifythattherunoutofthetransmission/ transfercaseandaxlearewithinspecifications. Correctasnecessaryandre-measurepropellershaft runout.
(8)Replacethepropellershaftiftherunoutstill exceedsthelimits.
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.
STANDARDPROCEDURE STANDARDPROCEDURES Thisprocedureappliestoboththefrontpropeller shaftsandtherearpropellershaft.Toobtainthe front(output)angleontheC/Vfrontpropellershaft, theinclinometerisplacedonthemachinedringof thepinionflange.Toobtainthepropellershaftangle measurementontheC/Vfrontpropellershaft,the inclinometerisplacedonthepropellershafttube.
PROPELLERSHAFTANGLE (1)Raiseandsupportthevehicleattheaxlesas levelaspossible.Allowthewheelsandpropeller shafttoturn.
(2)Removeanyexternalbearingsnapringsfrom universaljointifequipped,sotheinclinometerbase willsitsflat.
(3)Rotatetheshaftuntiltransmission/transfer caseoutputyokebearingcapisfacingdownward,if necessary.
NOTE:Alwaysmakemeasurementsfromfrontto rear.
(4)PlaceInclinometeronyokebearingcap,orthe pinionflangering,(A)paralleltotheshaft(Fig.4). Centerbubbleinsightglassandrecordmeasurement.
NOTE:ThismeasurementwillgiveyouthetransmissionorOutputYokeAngle(A).
Fig.4OUTPUTYOKEANGLE(A)
1-SLIPYOKEBEARINGCAP 2-INCLINOMETER
(5)Rotatepropellershaft90degreesandplace Inclinometeronyokebearingcap,orpropellershaft tubeonC/Vpropellershaft,paralleltotheshaft(Fig. 5).Centerbubbleinsightglassandrecordmeasurement.Thismeasurementcanalsobetakenatthe rearendoftheshaft.
NOTE:Thismeasurementwillgiveyouthepropeller shaftangle(C).
(6)Subtractsmallerfigurefromlarger(Cminus A)toobtaintransmissionoutputoperatingangle.
(7)Rotatepropellershaft90degreesandplace Inclinometeronpinionyokebearingcapparallelto theshaft(Fig.6).Centerbubbleinsightglassand recordmeasurement.
NOTE:Thismeasurementwillgiveyouthepinion shaftorinputyokeangle(B).
(8)Subtractsmallerfigurefromlarger(Cminus B)toobtainaxleInputOperatingAngle.
Fig.5PROPELLERSHAFTANGLE(C)
1-SHAFTYOKEBEARINGCAP 2-INCLINOMETER
Fig.6INPUTYOKEANGLE(B)
1-PINIONYOKEBEARINGCAP 2-INCLINOMETER
Refertorulesgivenbelowandtheexamplein(Fig. 7)foradditionalinformation.
• GoodcancellationofU-jointoperatingangles (within1°).
• Operatingangleslessthan3°.
• Operatingangleslessthan10°fordoublecardan U-joint.
• Atleast1/2ofonedegreecontinuousoperating (propellershaft)angle.
PROPELLERSHAFT(Continued)
1-4.9°Angle(C)
2-3.2°Angle(B) 3-InputYoke
SPECIFICATIONS
Fig.7U-JOINTANGLEEXAMPLE 4-3.0°Angle(A) 5-OutputYoke
TORQUESPECIFICATIONS
DESCRIPTIONN·mFt.Lbs.In.Lbs.
FrontShaft-Companion FlangeBolts 3022-
RearShaft-YokeNuts1813-
SPECIALTOOLS INCLINOMETER7663 PROPELLERSHAFT-FRONT REMOVAL REMOVAL-2.5LDIESEL (1)ShifttransmissionandtransfercaseintoNeutral.
(2)Raiseandsupportthevehicle.
(3)Removeleftsideexhaustflangebolts(Fig.8).
Fig.9TRANSFERCASECOMPANIONFLANGE 1-FLANGEBOLT 2-COMPANIONFLANGE
REMOVAL (1)ShifttransmissionandtransfercaseintoNeutral.
(2)Raiseandsupportthevehicle.
(3)MarkcompanionflangesandC/Vjointsatthe frontandrearofthepropellershaftforinstallation reference.
(4)RemoveboltsfromthefrontandrearC/V joints.
(5)Pushpropellershaftforwardtocleartransfer casecompanionflange(Fig.10).
Fig.8LEFTEXHAUSTFLANGE
1-EXHAUSTFLANGE
2-FRONTPROPELLERSHAFT
3-COMPANIONFLANGE
(4)MarkcompanionflangesandC/Vjointsatthe frontandrearofthepropellershaftforinstallation reference.
(5)RemoveboltsfromthefrontandrearC/V joints.
(6)Pushpropellershaftforwardtocleartransfer casecompanionflange(Fig.9).
(7)Removetheshaftfromthefrontaxlecompanionflange.
(8)Pulldownontheexhaustandtiltthefrontof theshaftdownandpullshaftforwardandremove fromthevehicle.
Fig.10TRANSFERCASECOMPANIONFLANGE 1-FLANGEBOLT 2-COMPANIONFLANGE
(6)Removetheshaftfromthefrontaxlecompanionflange.
(7)Tiltthefrontoftheshaftdownandpullshaft forwardandremovefromthevehicle.
PROPELLERSHAFT-FRONT(Continued)
INSTALLATION INSTALLATION-2.5LDIESEL (1)Installpropellershaftbetweencompanion flanges.
(2)Alignmarksonthecompanionflangeswiththe marksontheC/Vjoints.
(3)InstallfrontC/Vjointboltsandtightento30 N·m(22ft.lbs.).
(4)InstallrearC/Vjointboltsandtightento30 N·m(22ft.lbs.).
(5)Installexhaustflangeandbolts.
(6)Lowervehicle.
INSTALLATION (1)Installpropellershaftbetweencompanion flanges.
(2)Alignmarksonthecompanionflangeswiththe marksontheC/Vjoints.
(3)InstallfrontC/Vjointboltsandtightento30 N·m(22ft.lbs.).
(4)InstallrearC/Vjointboltsandtightento30 N·m(22ft.lbs.).
(5)Lowervehicle.
PROPELLERSHAFT-REAR REMOVAL (1)Shiftthetransmission/transfercaseintoNeutral.
(2)Raiseandsupportvehicle.
(3)Markareferencelineacrossthepinionyoke andpropellershaftforinstallation.
(4)RemoveU-jointstrapboltsatthepinionshaft yoke.
(5)Pryopenclampholdingthedustboottopropellershaftyoke(Fig.11),ifequipped.
(6)Slideslipyokeoffofthetransmission/transfer caseoutputshaftandremovethepropellershaft (Fig.12).
INSTALLATION (1)Slideslipyokeonthetransmission/transfer caseoutputshaft.
(2)Alignreferencemarksonthepinionyokeand propellershaft.
(3)InstallU-jointstrapsandtightenstrapboltsto 18N·m(13ft.lbs.).
1-SLINGER 2-BOOT
3-AWL
4-TRANSFERCASE
Fig.12REARPROPELLERSHAFT
1-CLAMP 2-YOKE
3-PROPELLERSHAFT
4-AXLEYOKE
5-CLAMP
6-OUTPUTSHAFT
7-BOOT
(4)Tightendustbootclampifequippedwith ClampC-4975A(Fig.13).
(5)Removesupportandlowerthevehicle.
Fig.11DUSTBOOTCLAMP
Fig.13CRIMPINGBOOTCLAMP
1-CLAMPTOOL
2-SLINGER
3-BOOT
4-CLAMPS
SINGLECARDANUNIVERSAL JOINTS DISASSEMBLY NOTE:Individualcomponentsofcardanuniversal jointsarenotserviceable.Ifwornorleaking,they mustbereplacedasanassembly.
(1)Removethepropellershaft.
(2)Taptheoutsideofthebearingcapassembly withadrifttoloosensnapring.
(3)Removesnapringsfrombothsidesofyoke (Fig.14).
(4)Settheyokeinanarborpressorvisewitha socketwhoseinsidediameterislargeenoughto receivethebearingcappositionedbeneaththeyoke.
(5)Positiontheyokewiththegreasefitting,if equipped,pointingup.
(6)Placeasocketwithanoutsidediameter smallerthantheupperbearingcapontheupper bearingcapandpressthecapthroughtheyoketo releasethelowerbearingcap(Fig.15).
(7)Ifthebearingcapwillnotpulloutoftheyoke byhandafterpressing,taptheyokeearnearthe bearingcaptodislodgethecap.
Fig.14REMOVESNAPRING 1-SNAPRING
Fig.15PRESSOUTBEARING 1-PRESS 2-SOCKET 3-8PROPELLERSHAFT
SINGLECARDANUNIVERSALJOINTS(Continued) (8)Toremovetheoppositebearingcap,turnthe yokeoverandstraightenthecrossintheopenhole. Then,carefullypresstheendofthecrossuntilthe remainingbearingcapcanberemoved(Fig.16).
CAUTION:Ifthecrossorbearingcaparenot straightduringinstallation,thebearingcapwill scorethewallsoftheyokeboreanddamagecan occur.
1-CROSS 2-YOKE
Fig.16PRESSOUTREMAININGBEARING 1-CROSS 2-BEARINGCAP
ASSEMBLY (1)Applyextremepressure(EP)N.L.G.I.Grade1 or2greasetoinsideofyokebores.
(2)Positionthecrossintheyokewithitslubefitting,ifequipped,pointingup(Fig.17).
(3)Placeabearingcapoverthetrunnionand alignthecapwiththeyokebore(Fig.18).Keepthe needlebearingsuprightinthebearingcap.
(4)Pressthebearingcapintotheyokebore enoughtoclearsnapringgroove.
(5)Installasnapring.
(6)RepeatStep3andStep4toinstalltheoppositebearingcap.
NOTE:Ifthejointisstifforbinding,striketheyoke withasofthammertoseattheneedlebearings.
(7)Addgreasetolubefitting,ifequipped.
(8)Installthepropellershaft.
Fig.18INSTALLBEARINGONTRUNNION 1-BEARINGCAP 2-TRUNNION
Fig.17CROSSINYOKE
HALFSHAFT HALFSHAFT CAUTION CAUTION:Nevergrasphalfshaftassemblybythe boots.Thismaycausetheboottopuckerorcrease andreducetheservicelifeoftheboot. AvoidoverangulatingorstrokingtheC/Vjoints whenhandlingthehalfshaft.
Halfshaftsexposedtobatteryacid,transmission fluid,brakefluid,differentialfluidorgasolinemay causethebootstodeteriorate.
DIAGNOSISANDTESTING
CheckforgreaseattheinboardandoutboardC/V joint.Thisisasignofbootorbootclampdamage.
NOISE/VIBRATIONINTURNS
Aclickingnoiseoravibrationinturnscouldbe causedbyadamagedouterC/Vorinnertripodjoint sealbootorsealbootclamps.Thiswillresultinthe loss/contaminationofthejointgrease,resultingin inadequatelubricationofthejoint.Noisecouldalso becausedbyanothercomponentofthevehiclecomingincontactwiththehalfshafts.
CLUNKINGNOISEDURINGACCELERATION
Thisnoisemaybearesultofadamagedorworn C/Vjoint.Atornbootorloose/missingclamponthe inner/outerjointwhichhasallowedthegreasetobe lostwilldamagetheC/Vjoint.
SHUDDER/VIBRATIONDURINGACCELERATION Thisproblemcouldbearesultofaworn/damaged innertripodjointorastickingtripodjoint.Improper wheelalignmentmayalsocauseashudderorvibration.
VIBRATIONATHIGHWAYSPEEDS Thisproblemcouldbearesultofoutofbalance fronttiresortire/wheelrunout.Foreignmaterial (mud,etc.)packedonthebacksideofthewheel(s) willalsocauseavibration.
REMOVAL (1)Raiseandsupportvehicle. (2)Removewheelandtireassembly. (3)Removehalfshafthubnut. (4)Removestabilizerlink(Fig.1).
Fig.1STABILIZERBARLINK
1-STABILIZERBAR 2-STABILIZERBARLINK
(5)Removelowerclevisbolt(Fig.2). (6)Seperatelowerballjointfromthelowercontrol arm(Fig.3).
(7)Pulloutonthesteeringknuckleandpushthe halfshaftoutoftheknuckle. (8)Withaprybarremovethehalfshaftfromthe axle.
HALFSHAFT(Continued)
Fig.2CLEVISBRACKET
1-UPPERBOLT
2-CLEVISBRACKET
3-LOWERBOLT
NOTE:Rightsidehalfshafthasanaxleshaftthat maycomeoutoftheaxle.
INSTALLATION NOTE:Seperaterighthalfshaftfromaxleshaftina viseifnecessaryandinstalaxleshaftintheaxle.
(1)Applyalightcoatofwheelbearinggreaseon thefemalesplinesoftheinnerC/Vjoint.
(2)Installhalfshaftontheaxleshaftsplineand pushfirmlytoengagethesnapring.Pullonthehalf shafttoverifysnaphasengaged.
SPECIFICATIONS Fig.3LOWERCONTROLARM
1-FRONTCAMBOLT 2-OUTERTIERODEND 3-LOWERBALLJOINTNUT 4-LOWERCONTROLARM 5-REARCAMBOLT
(3)Cleanhubbearingboreandapplyalightcoat ofwheelbearinggrease.
(4)Pulloutonthesteeringknuckleandpushthe halfshaftthroughtheknuckle.
(5)Installlowerballjointintothelowercontrol armandtightenpinchbolt.
(6)Aligncleviswithknuckle.Installandtighten lowerclevisbolt.
(7)Installstabilizerlink.
(8)Installhalfshafthubnut.
(9)Installwheelandtireassembly.
(10)Removesupportandlowervehicle.
TORQUESPECIFICATIONS
SPECIALTOOLS CLAMPINSTALLERC-4975A CVJOINT/BOOT-OUTER REMOVAL (1)Clampshaftinavise(withsoftjaws)andsupportC/Vjoint.
(2)Removeclampswithacut-offwheelorgrinder (Fig.4).
CAUTION:DonotdamageC/Vhousingorhalf shaft.
1-SNAPRING
Fig.5OUTERC/VJOINT
2-SNAPRINGGROVE
3-SNAPRINGPLIERS
Fig.4BOOTCLAMPLOCATIONS
1-C/VHOUSING
2-CLAMP
3-HALFSHAFT
4-CLAMP
5-C/VBOOT
(3)Slidethebootdowntheshaft.
(4)RemovelubricanttoexposetheC/Vjointsnap ring.
(5)Spreadsnapringandslidethejointoffthe shaft(Fig.5).
(6)Slidebootofftheshaftanddiscardoldboot.
(7)Markalignmentmarksontheinnerrace/hub, bearingcageandhousingwithdabsofpaint(Fig.6).
(8)ClampC/Vjointinaverticalpositioninasoft jawedvise.
(9)Pressdownonesideofthebearingcagetogain accesstotheballattheoppositeside.
Fig.6BEARINGACCESS 1-ALIGNMENTMARKS
2-BEARINGHUB
3-BEARINGCAGE
4-HOUSING
NOTE:Ifjointistight,useahammerandbrassdrift toloosenthebearinghub.Donotcontactthebearingcagewiththedrift.
(10)Removeballfromthebearingcage(Fig.7).
(11)Repeatstepaboveuntilallsixballsare removedfromthebearingcage.
(12)Liftcageandinnerraceupwardandoutfrom thehousing(Fig.8).
(13)Turninnerrace90°inthecageandrotatethe innerrace/huboutofthecage(Fig.9).
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CVJOINT/BOOT-OUTER(Continued)
Fig.7BEARING
1-HOUSING
2-INNERRACE/HUB
3-BEARINGCAGE
4-BALL
Fig.10INNERRACE/HUB
1-INNERRACE/HUB 2-BEARINGCAGE
Fig.8CAGEANDINNERRACE/HUB
1-HOUSING
2-INNERRACE
3-CAGEWINDOW
INSTALLATION NOTE:IfC/Vjointisworn,replaceentireC/Vjoint andboot.
(1)ApplyalightcoatofgreasetotheC/Vjoint componentsbeforeassemblingthem.
(2)Aligntheinnerrace,cageandhousingaccordingtothealignmentreferencemarks.
(3)Inserttheinnerraceintothecage(Fig.10)and rotateraceintothecage.
(4)Rotatetheinnerrace/hubinthecage(Fig.11).
(5)Insertcageintothehousing(Fig.12).Rotate thecage90°intothehousing(Fig.13).
Fig.11CAGEANDINNERRACE/HUB 1-CAGEWINDOWS 2-SNAPRING
Fig.9INNERRACE/HUB
3-14HALFSHAFT
CVJOINT/BOOT-OUTER(Continued)
Fig.12BEARINGCAGEANDHOUSING
1-OUTERRACE
2-BEARINGCAGEWINDOW
3-CVJOINTHOUSING
Fig.13CAGEANDINNERRACE/HUB
1-C/VHOUSING
2-BEARINGHUBLARGECOUNTERBOREOUTWARD
3-BOOTRETAININGSHOULDER
4-BEARINGHUBSMALLCOUNTERBOREINWARD
5-SLINGER
(6)Applythelubricantincludedwiththereplacementboottotheballraces.Spreadthelubricant equallybetweenalltheraces.
(7)Tiltinnerrace/hubandcageandinstallthe balls(Fig.14).
(8)Placenewclampsontonewbootandslideboot ontotheshafttoit’soriginalposition.
(9)ApplytherestoflubricanttotheC/Vjointand boot.
1-C/VHOUSING
Fig.14BALLBEARING 2-INNERRACE/HUB 3-BEARINGCAGE 4-BEARING
(10)Installthejointontotheshaft.Pushthejoint ontotheshaftuntilthesnapringseatsinthegroove (Fig.15).Pullonthejointtoverifythespanringhas engaged.
Fig.15OUTERC/VJOINT
1-SNAPRING 2-SHAFTTAPER 3-SNAPRINGGROVE 4-BEARINGHUB
(11)Positionthebootonthejointinit’soriginal position.Ensurethatthebootisnottwistedand removeanyexcessair.
(12)Securebothbootclamps(Fig.16)withClamp InstallerC-4975A.Placetoolonclampbridgeand tightentooluntilthejawsofthetollareclosed.
CVJOINT/BOOT-OUTER(Continued)
(4)RemovelubricanttoexposetheC/Vhousing snapringandremovesnapring(Fig.18).
Fig.16BOOTCLAMPLOCATIONS
1-C/VHOUSING
2-CLAMP
3-HALFSHAFT
4-CLAMP
5-C/VBOOT
CVJOINT/BOOT-INNER REMOVAL
(1)Clampshaftinavise(withsoftjaws)andsupportC/Vjoint.
(2)Removeclampswithacut-offwheelorgrinder.
CAUTION:DonotdamageC/Vhousingorhalf shaft.
(3)Slidethebootdowntheshaft(Fig.17).
Fig.18HOUSINGSNAPRING
1-HOUSING
2-SNAPRING
3-CAGE/INNERRACE
(5)Removebearingsfromthecage(Fig.19).
Fig.17INNERC/VBOOT
1-HOUSING
2-BOOT
3-HOUSINGSNAPRING
Fig.19C/VBEARINGS
1-CAGE
2-INNERRACE
3-SHAFT
4-BEARING
(6)Rotatecage30°andslidecageofftheinner raceanddowntheshaft.
(7)Removespreadinnerracesnapring(Fig.20) andremoveracefromtheshaft.
(8)Removebootfromtheshaftanddiscard.
3-16HALFSHAFT
CVJOINT/BOOT-INNER(Continued)
Fig.20INNERRACE
1-INNERRACE
2-PLIERS
3-SHAFT
4-SNAPRINGACCESS
(9)Cleanandinspectallcomponentsforwearor damage(Fig.21).
(2)Placenewclampsonthenewbootandslide bootdowntheshaft.
(3)Slidecageontotheshaft(Fig.22)withthe smalldiameterendtowardstheboot.
Fig.21INNERC/VJOINT
1-HOUSING
2-CAGE
3-BEARINGS
4-HOUSINGSNAPRING
5-INNERRACESNAPRING
6-INNERRACE
INSTALLATION (1)Applyacoatofgreasesuppliedwiththejoint/ boottotheC/Vjointcomponentsbeforeassembling them.
Fig.22BEARINGCAGE 1-SHAFT 2-CAGE 3-SMALLDIAMETER 4-SNAPRINGGROOVE
(4)Installtheinnerraceontotheshaft(Fig.23). Pullontheracetoverifysnapringhasengaged.
Fig.23INNERRACE
1-INNERRACE 2-CAGE 3-SHAFT
(5)Aligncagewiththeinnerraceandslideover therace.
CVJOINT/BOOT-INNER(Continued)
(6)Turnthecage30°toalignthecagewindows withtherace(Fig.24).
Fig.25C/VCOMPONENTS
Fig.24CAGE/INNERRACE
1-CAGE
2-INNERRACE
3-SHAFT
4-CAGEWINDOW
(7)Applygreasetotheinnerraceandbearings andinstallthebearings.
(8)Applygreasetothehousingbore(Fig.25)then installthebearingassmblyintothehousing.
(9)Installthehousingsnapringandverifyitis seatedinthegroove.
1-HOUSING
2-BEARINGASSEMBLY
3-HOUSINGSNAPRING 4-HOUSINGBORE
(10)Fillthehousingandbootwiththeremaining grease.
(11)SlidethebootontotheC/Vhousingintoit’s originalposition.Ensurebootisnottwistedand removeanyexcessair.
(12)SecurebothbootclampswithClampInstaller C-4975A.Placetoolonclampbridgeandtightentool untilthejawsofthetoolareclosed.
FRONTAXLE-186FIA FRONTAXLE-186FIA DESCRIPTION
The186FIA(Model30)axleconsistsofanalumunumcentersectionwithanaxletubeextendingfrom oneside.Thetubeispressedintothedifferential housing.Theintegraltypehousing,hypoidgear designhasthecenterlineofthepinionsetbelowthe centerlineoftheringgear.
Thedifferentialcaseisaone-piecedesign.Thedifferentialpinionmateshaftisretainedwitharollpin.Differentialbearingpreloadandringgear backlashisadjustedbytheuseofshims(selectthickness).Theshimsarelocatedbetweenthedifferential bearingcupsandtheaxlehousing.Pinionbearing preloadissetandmaintainedbytheuseofacollapsiblespacer.
Thepoweristransferredfromtheaxlethrough twoconstantvelocity(C/V)driveshaftstothewheel hubs.
Thedifferentialcoverprovidesameansforinspectionandservicewithoutremovingtheaxlefromthe vehicle.Thecoverhasaventtubeusedtorelieve internalpressurecausedbyvaporizationandinternalexpansion.
OPERATION Theaxlereceivespowerfromthetransfercase throughthefrontpropellershaft.Thefrontpropeller shaftisconnectedtothepiniongearwhichrotates
thedifferentialthroughthegearmeshwiththering gearboltedtothedifferentialcase.Theenginepower istransmittedtotheaxleshaftsthroughthepinion mateandsidegears.Thesidegearsaresplinedto theaxleshafts.
Duringstraight-aheaddriving,thedifferentialpiniongearsdonotrotateonthepinionmateshaft.This occursbecauseinputtorqueappliedtothegearsis dividedanddistributedequallybetweenthetwoside gears.Asaresult,thepiniongearsrevolvewiththe pinionmateshaftbutdonotrotatearoundit(Fig.1).
Whenturningcorners,theoutsidewheelmust travelagreaterdistancethantheinsidewheelto completeaturn.Thedifferencemustbecompensated fortopreventthetiresfromscuffingandskidding throughturns.Toaccomplishthis,thedifferential allowstheaxleshaftstoturnatunequalspeeds(Fig. 2).Inthisinstance,theinputtorqueappliedtothe piniongearsisnotdividedequally.Thepiniongears nowrotatearoundthepinionmateshaftinopposite directions.Thisallowsthesidegearandaxleshaft attachedtotheoutsidewheeltorotateatafaster speed.
BEARINGNOISE Theaxleshaft,differentialandpinionbearingscan allproducenoisewhenwornordamaged.Bearing noisecanbeeitherawhining,oragrowlingsound. Pinionbearingshaveaconstant-pitchnoise.This noisechangesonlywithvehiclespeed.Pinionbearing noisewillbehigherpitchedbecauseitrotatesata fasterrate.Drivethevehicleandloadthedifferential.Ifbearingnoiseoccurs,therearpinionbearing isthesourceofthenoise.Ifthebearingnoiseis heardduringacoast,thefrontpinionbearingisthe source.
Wornordamageddifferentialbearingsusuallyproducealowpitchnoise.Differentialbearingnoiseis similartopinionbearingnoise.Thepitchofdifferentialbearingnoiseisalsoconstantandvariesonly withvehiclespeed.
Axleshaftbearingsproducenoiseandvibration whenwornordamaged.Thenoisegenerallychanges whenthebearingsareloaded.Roadtestthevehicle. Turnthevehiclesharplytotheleftandtotheright. Thiswillloadthebearingsandchangethenoise level.Whereaxlebearingdamageisslight,thenoise isusuallynotnoticeableatspeedsabove30mph.
LOWSPEEDKNOCK Fig.2DIFFERENTIAL-ONTURNS
1-PINIONGEARSROTATEONPINIONSHAFT
DIAGNOSISANDTESTING 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 greatly:
• Checkforinsufficientlubricant.
• Incorrectringgearbacklash.
• Geardamage.
Differentialsidegearsandpinionscanbechecked byturningthevehicle.Theyusuallydonotcause noiseduringstraight-aheaddrivingwhenthegears areunloaded.Thesidegearsareloadedduringvehicleturns.Awornpinionmateshaftcanalsocausea snappingoraknockingnoise.
Lowspeedknockisgenerallycausedbyaworn U-jointorbywornside-gearthrustwashers.Aworn pinionshaftborewillalsocauselowspeedknock.
VIBRATION Vibrationattherearofthevehicleisusually causedby:
• Damageddriveshaft.
• Missingdriveshaftbalanceweight(s).
• Wornoroutofbalancewheels.
• Loosewheellugnuts.
• WornU-joint(s).
• Loose/brokensprings.
• Damagedaxleshaftbearing(s).
• Loosepiniongearnut.
• Excessivepinionyokerunout.
• Bentaxleshaft(s).
Checkforlooseordamagedfrontendcomponents orengine/transmissionmounts.Thesecomponents cancontributetowhatappearstobearearend vibration.Donotoverlookengineaccessories,bracketsanddrivebelts.
Alldrivelinecomponentsshouldbeexamined beforestartinganyrepair.
DRIVELINESNAP Asnaporclunknoisewhenthevehicleisshifted intogear(ortheclutchengaged)canbecausedby:
• Highengineidlespeed.
• Transmissionshiftoperation.
• Looseengine/transmission/transfercasemounts.
• WornU-joints.
• Loosespringmounts.
• Loosepiniongearnutandyoke.
• Excessiveringgearbacklash.
• Excessivesidegeartocaseclearance.
Thesourceofasnaporaclunknoisecanbedeterminedwiththeassistanceofahelper.Raisethevehicleonahoistwiththewheelsfreetorotate.Instruct thehelpertoshiftthetransmissionintogear.Listen forthenoise,amechanicsstethoscopeishelpfulin isolatingthesourceofanoise.
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.
5.Improperadjustmentofpinion gearbearings.
4.Checkadjustmentofthering gearandpinionbacklash.Correct asnecessary.
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.
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.
ConditionPossibleCausesCorrection
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.
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.
ConditionPossibleCausesCorrection
AxleNoise1.Insufficientlubricant.1.Filldifferentialwiththecorrect fluidtypeandquantity.
REMOVAL (1)Raiseandsupportvehicle.
(3)Removeskidplate.
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.
(2)Removewheelandtireassemblies.
(4)Removedifferentialdrainplug(Fig.3)and drainfluid.
(5)Removehalfshafthubnuts.
(6)Removestablizerbarlinksfromthelowercontrolarms.
(7)Removetierodendnutsandseperateends fromtheknuckles.
(8)Removelowerballjointnutsandseperateball jointsfromthelowercontrolarms.
(9)Removelowershockclevisbolts.
(10)Pulloutonthesteeringknucklesandpush thehalfshaftoutoftheknuckles.
(11)Withaprybarremovethehalfshaftsfrom theaxle.
NOTE:Righthalfshafthasasplinedaxlethatmay comeoutwiththehalfshaft.
(12)Removedifferentialventhose(Fig.4)from cover.
3-DIFFERENTIALHOUSING 3-22FRONTAXLE-186FIA
8.Inspectdifferentialcomponents andreplaceasnecessary.Ensure thatthebearingcapsaretorqued totheproperspecification.
9.Housingnotmachinedproperly.9.Replacehousing.
(13)Markfrontpropellershaftandpinionflange. Removepropellershaftfrompinionflange.
(14)Supportaxlewithalift/jack.
Fig.3DRAINPLUG
1-LEFTFRONTAXLEBRACKET
2-DRAINPLUG
Fig.4DIFFERENTIALCOVER 1-COVER 2-VENTTUBE
(15)Removeboltsfromleftfrontaxlebracket(Fig. 5).
Fig.6RIGHTAXLEBRACKET 1-RIGHTAXLEBRACKET 2-FRONTBRACKETBOLT 3-REARBRACKETBOLT
Fig.5LEFTFRONTAXLEBRACKET
1-LEFTFRONTAXLEBRACKET 2-BRACKETBOLT
(16)Removeoilfilterdriptray.
(17)Markandremoverightcontrolarmcambolt.
(18)Removeboltsfromrightaxlebracketframe mounts(Fig.6).
(19)Removeboltfromleftrearaxlebracketframe mount(Fig.7).
(20)Loweraxleandfromvehicle.
Fig.7LEFTREARAXLEBRACKET
1-LEFTREARAXLEBRACKET 2-BRACKETBOLT
INSTALLATION NOTE:Seperaterightaxleshaftfromthehalfshaft ifnecessaryandinstallaxleshaftintheaxle.
(1)Installleftrearbrackettoaxleandtightento 61N·m(45ft.lbs.).
(2)Installrightbrackettoaxleandtightento88 N·m(65ft.lbs.).
(3)Installleftfrontbrackettoaxleandtightento 61N·m(45ft.lbs.).
(4)Raiseaxleupandalignbracketswithframe mounts.
(5)Installframemountboltsandtightento88 N·m(65ft.lbs.).
(6)Installhalfshafts.
(7)Installrightfrontcontrolarmcamboltwith marksaligned.
(8)Installlowerballjointintolowercontrolarms andtightenpinchbolts.
(9)Aligncleviswithknucklesandinstallclevis bolts.
(10)Installstabilizerlinkstolowercontrolarms andinstallbolts.
(11)Installoilfilterdriptray.
(12)Installnewhalfshafthubnutsandtightento 136N·m(100ft.lbs.).
(13)Installpropellershaft.
(14)Installaxleventhose.
(15)Filldifferentialwithgearlubricant.
(16)Installskidplate.
(17)Installwheelandtireassemblies.
(18)Removesupportandlowervehicle.
(19)Tightenclevisandstabilizerlinksboltsto specifications.
(20)Checkvehiclealignment.
ADJUSTMENTS Ringandpiniongearsaresuppliedasmatched setsonly.Theidentifyingnumbersfortheringand piniongearareetchedontoeachgear(Fig.8).Aplus (+)number,minus(–)numberorzero(0)isetched intothefaceofthepiniongear.Thisnumberisthe amount(inthousandthsofaninch)thedepthvaries fromthestandarddepthsettingofapinionetched witha(0).RefertoBacklashandContactPattern Analysisparagraphinthissectionforadditional information.
Compensationforpiniondepthvarianceis achievedwithaselectshim/oilslinger.Theshimsare placedbetweentherearpinionbearingandthepiniongearhead(Fig.9).
Fig.8PINIONGEARIDNUMBERS
1-PRODUCTIONNUMBERS
2-DRIVEPINIONGEARDEPTHVARIANCE
3-GEARMATCHINGNUMBER
Fig.9SHIMLOCATIONS
1-PINIONGEARDEPTHSHIM/OILSLINGER
2-DIFFERENTIALBEARINGSHIM
3-RINGGEAR
4-DIFFERENTIALBEARINGSHIM
5-COLLAPSIBLESPACER
Ifanewgearsetisbeinginstalled,notethedepth varianceetchedintoboththeoriginalandreplacementpinion.Addorsubtractthisnumberfromthe thicknessoftheoriginaldepthshim/oilslingerto compensateforthedifferenceinthedepthvariances. RefertothePinionGearDepthVariancechart. NotewhereOldandNewPinionMarkingcolumns intersect.Intersectingfigurerepresentsplusor minustheamountneeded.
Notetheetchednumberonthefaceofthepinion gearhead(–1,–2,0,+1,+2,etc.).Thenumbersrepresentthousandsofaninchdeviationfromthestandard.Ifthenumberisnegative,addthatvaluetothe requiredthicknessofthedepthshims.Ifthenumber ispositive,subtractthatvaluefromthethicknessof thedepthshim.Ifthenumberis0nochangeisnecessary.
PINIONGEARDEPTHVARIANCE PINIONDEPTHMEASUREMENT Measurementsaretakenwithpinionbearingcups andpinionbearingsinstalledinthehousing.Take measurementswithPinionGaugeSetandDialIndicatorC-3339(Fig.10).
Fig.10PINIONGEARDEPTHTOOLS
(1)AssemblePinionHeightBlock6739,Pinion Block8804andrearpinionbearingontoScrew6741 (Fig.10).
(2)Insertheightgaugecomponentsintothehousingthroughpinionbearingcups.
(3)Installfrontpinionbearingandhandtight Cone-nut6740ontothescrew.
(4)PositionArborDisc6732andArborD-115-3 intothehousingbearingcradles.Installdifferential bearingcapsonArborDiscsandtightenboltsto41 N·m(30ft.lbs.)(Fig.11).
Fig.11DEPTHTOOLSINHOUSING
3-26FRONTAXLE-186FIA
FRONTAXLE-186FIA(Continued)
NOTE:ArborDiscs6732hasdifferentstepdiameterstofitotheraxles.Chooseproperstepforaxle beingserviced.
(5)AssembleDialIndicatorC-3339intoScooter BlockD-115-2andsecuresetscrew.
(6)PositionScooterBlock/DialIndicatorflushon thepinionheightblock.Holdthescooterblockand zerothedialindicator.
(7)Slowlyslidethescooterblockacrossthepinion heightblockovertothearbor(Fig.12).Movethe scooterblocktillthedialindicatorprobecreststhe arborandrecordthehighestreading.
entialbearingpreloadandgearbacklashmeasurements,measurethepiniongeardepthandprepare thepinionforinstallation.Establishingproperpinion geardepthisessentialtoestablishinggearbacklash andtoothcontactpatterns.Aftertheoverallshim thicknesstotakeupdifferentialsideplayismeasured,thepinionisinstalled,andthegearbacklash shimthicknessismeasured.Theoverallshimthicknessisthetotalofthedialindicatorreadingandthe preloadspecificationaddedtogether.Thegearbacklashmeasurementdeterminesthethicknessofthe shimusedontheringgearsideofthedifferential case.Subtractthegearbacklashshimthicknessfrom thetotaloverallshimthicknessandselectthat amountforthepiniongearsideofthedifferential (Fig.13).DifferentialshimmeasurementsareperformedwithspreaderW-129-Bremoved.
Fig.12PINIONDEPTHMEASUREMENT
1-SCOOTERBLOCK
2-ARBOR
3-DIALINDICATOR
(8)Selectashim/oilslingerequaltothedialindicatorreadingplusthepiniondepthvariancenumber etchedinthefaceofthepinion(Fig.8).Forexample, ifthedepthvarianceis–2,add+0.002in.tothedial indicatorreading.
DIFFERENTIAL Differentialbearingpreloadandgearbacklashis adjustedbytheuseofselectiveshims.Theshimsare locatedbetweenthedifferentialbearingcupsandthe differentialhousing.Thepropershimthicknesscan bedeterminedusingslip-fitDummyBearingsD-348 inplaceofthedifferentialsidebearingsandaDial IndicatorC-3339.Beforeproceedingwiththediffer-
Fig.13SHIMLOCATIONS
1-PINIONGEARDEPTHSHIM/OILSLINGER
2-DIFFERENTIALBEARINGSHIM
3-RINGGEAR
4-DIFFERENTIALBEARINGSHIM
5-COLLAPSIBLESPACER
SHIMSELECTION NOTE:Itisdifficulttosalvagethedifferentialside bearingsduringtheremovalprocedure.Install replacementbearingsifnecessary.
(1)Removedifferentialsidebearingsfromdifferentialcase.
(2)Installringgearondifferentialcaseand tightenboltstospecification.
(3)InstallDummyBearingsD-348ondifferential case.
(4)Installdifferentialcaseinthehousing.
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(5)RecordthethicknessofDummyShims8107. Inserttheshimsbetweenthedummybearingsand thedifferentialhousing(Fig.14).
(7)Withadead-blowhammer,seatthedifferential dummybearingstoeachsideoftheaxlehousing (Fig.16)and(Fig.17).
1-DUMMYSHIM
Fig.14DUMMYSHIMS
2-DIFFERENTIALHOUSING
3-DIFFERENTIALCASE
4-DUMMYBEARINGS
(6)Installthebearingcapsintheircorrectpositionsandsnugthebolts(Fig.15).
Fig.16SEATDUMMYBEARINGSPINIONSIDE 1-HAMMER 2-DIFFERENTIALHOUSING 3-DIFFERENTIAL
Fig.15BEARINGCAPBOLTS Fig.17SEATDUMMYBEARINGRINGGEARSIDE 1-DIFFERENTAILHOUSING 2-HAMMER 3-RINGGEAR
(8)ThreadPilotStudC-3288-Bintorearcoverbolt holebelowringgear.
(9)AttachaDialIndicatorC-3339tothePilot Stud.Positionthedialindicatorplungeronflatsurfacebetweentheringgearbolts.
(10)Pushandholddifferentialcasetopiniongear sideofthehousingandzerodialindicator(Fig.18).
(11)Pushandholddifferentialcasetoringgear sideofthehousingandrecorddialindicatorreading (Fig.19).
(12)Add0.152mm(0.006in.)tothezeroendplay total.Thisnewtotalrepresentsthethicknessof
3-28FRONTAXLE-186FIA
Fig.18DIFFERENTIALPINIONGEARSIDE
1-PINIONSIDE
2-PILOTSTUD
3-DIALINDICATOR
Fig.19DIFFERENTIALRINGGEARSIDE
1-DIALINDICATOR 2-DIFFERENTIALHOUSING
shimstocompressorpreloadthenewbearingswhen thedifferentialisinstalled.
(13)Rotatedialindicatoroutofthewayonthe pilotstud.
(14)Removedifferentialcaseanddummybearings fromthehousing.
(15)Installthepiniongearinthehousing.Install thepinionyokeandestablishthecorrectpinion rotatingtorque.
(16)InstalldifferentialcaseandDummyBearings D-348inthehousing.
(17)Installasingledummyshimintheringgear side.Installbearingcapsandtightenboltssnug. (18)Seatringgearsidedummybearing(Fig.17).
(19)Positionthedialindicatorplungeronaflat surfacebetweentheringgearboltheads.
(20)Pushandholddifferentialcasetowardpinion gearandzerodialindicator(Fig.20).
Fig.20DIFFERENTIALPINIONGEARSIDE 1-DIALINDICATOR 2-PINIONGEAR 3-RINGGEAR
(21)Pushandholddifferentialcasetoringgear sideofthehousingandrecorddialindicatorreading (Fig.21).Adddummyshimthicknesstothisreading. Thiswillbethetotalshimthicknesstoachievezero backlash.
Fig.21DIFFERENTIALRINGGEARSIDE 1-DIALINDICATOR 2-PINIONGEAR 3-RINGGEAR
(22)Subtract0.076mm(0.003in.)fromthedial indicatorreadingtocompensateforbacklashbetween ringandpiniongears.Thistotalisthethickness shimrequiredtoachieveproperbacklash.
(23)Subtractthebacklashshimthicknessfrom thetotalpreloadshimthickness.Theremainderis theshimthicknessrequiredonthepinionsideofthe axlehousing.
(24)Rotatedialindicatoroutofthewayonpilot stud.
(25)Removedifferentialcaseanddummybearings fromthehousing.
(26)Installsidebearingsandcupsondifferential case.
(27)InstallspreaderW-129-BwithAdapterSet 6987onthehousingandspreadaxleopeningenough toreceivedifferentialcase.
CAUTION:Neverspreadthedifferentialhousing over0.34mm(0.013in.).Ifthehousingisoverspread,itcouldbedistortedordamaged.
(28)Placethebearingpreloadshimsintheaxle housing,againsttheaxletubes.
(29)Installdifferentialcaseintothehousing.
(30)Removespreaderfromthehousing.
(31)Rotatethedifferentialcaseseveraltimesto seatthesidebearings.
(32)Positiontheindicatorplungeragainstaring geartooth(Fig.22).
(36)Verifydifferentialcaseandringgearrunout bymeasuringringtopiniongearbacklashateight locationsaroundtheringgear.Readingsshouldnot varymorethan0.05mm(0.002in.).Ifreadingsvary morethanspecified,theringgearorthedifferential caseisdefective.
Aftertheproperbacklashisachieved,perform GearContactPatternAnalysisprocedure.
(33)Pushandholdringgearupwardwhilenot allowingthepiniongeartorotate.
(34)Zerodialindicatorfacetopointer.
(35)Pushandholdringgeardownwardwhilenot allowingthepiniongeartorotate.Dialindicator readingshouldbebetween0.12mm(0.005in.)and 0.20mm(0.008in.).Ifbacklashisnotwithinspecificationstransferthenecessaryamountofshimthicknessfromonesideofthehousingtotheother(Fig. 23).
GEARCONTACTPATTERN Theringgearandpinionteethcontactpatternswill showifthepiniondepthiscorrectinthehousing.It willalsoshowiftheringgearbacklashhasbeen adjustedcorrectly.Thebacklashcanbeadjustedwithin specificationstoachievedesiredtoothcontactpatterns.
(1)Applyathincoatofhydratedferricoxideor equivalenttothedriveandcoastsideoftheringgear teeth.
(2)Wrap,twistandholdashoptowelaroundthe pinionyoketoincreasetheturningresistanceofthe pinion.Thiswillprovideamoredistinctcontactpattern.
(3)Withaboxedendwrenchonaringgearbolt, rotatethedifferentialcaseonecompleterevolutionin bothdirectionswhilealoadisbeingappliedfrom shoptowel.
Theareasontheringgearteethwiththegreatest degreeofcontactagainstthepinionteethwillsqueegeethecompoundtotheareaswiththeleastamount ofcontact.Noteandcomparepatternsonthering gearteethtoGearToothContactPatternschart(Fig. 24)andadjustpiniondepthandgearbacklashasnecessary.
Fig.23BACKLASHSHIMS
DIFFERENTIALBEARINGPRELOADCHECK Thefinalcheckonthedifferentialassemblybefore installingtheaxles,istorquetorotatepinionand differentialcombined.Thiswillverifythecorrectdifferentialbearingpreload.
SPECIFICATIONS
Torquetorotatethedifferentialandpinionisthe torquetorotatethepinionplus:
GearRatio3.73 0.45-0.75N·m(3.9-6.6in.lbs.)
GearRatio4.10 .... 0.41-0.69N·m(3.6-6.0in.lbs.)
SPECIFICATIONS
DESCRIPTIONSPECIFICATION
AxleRatio3.73,4.10
RingGearDiameter186mm(7.33in.)
RingGearBacklash0.12-0.20mm(0.005-0.008in.)
PinionBearingPreload1.69-2.82N·m(15-25in.lbs.)
DifferentialBearingPreload
AddedToPinionTorqueToRotate
GearRatio3.730.45-0.75N·m(3.9-6.6in.lbs.)
GearRatio4.100.41-0.69N·m(3.6-6.0in.lbs.)
TORQUESPECIFICATIONS
DESCRIPTIONN·mFt.Lbs.In.Lbs.
RingGearBolts95-12270-90DifferentialBearingCap Bolts 54-6739-50-
DifferentialCoverBolts19-2614-19PinionNut217-352160-260LeftAxleBracketBolts6145FrontAxleBracketBolts6145RightAxleBracketBolts8865AxleBracketsToFrame Bolts 8865-
SPECIALTOOLS
ADAPTERC-293-39
INSTALLERD-146
PULLERC-452
DIALINDICATORC-3339
REMOVERD-149
INSTALLERW-162-D
INSTALLERC-3716-A
CUP8109
PINIONDEPTHSET6774
HANDLEC-4171
REMOVERC-4307
PINIONBLOCK8804
INSTALLERC-4308
SPANNERWRENCH6958
INSTALLER6448
SPREADERW-129-B
ADAPTERC-293-42
ADAPTERKIT6987B
PILOTSTUDC-3288-B
INSTALLER8805
AXLESHAFTS REMOVAL (1)PlacethetransmissioninNeutral. (2)Raiseandsupportvehicle.
(3)Removerightwheelandtireandassembly.
(4)Removerighthalfshaftfromvehicle.
(5)Removesnapringfromaxleshaft.
(6)AssembleRemover8420Aontotheshaft(Fig. 25).Threadslidhammerintoremoverandremove shaft.
Fig.25AXLESHAFTPULLER
1-SNAPRINGGROVE 2-SLIDHAMMERTHREADS 3-REMOVERBLOCKS 4-REMOVERCOLLAR
(7)Slideaxleshaftoutoftheaxletube.
NOTE:Usecaretopreventdamagetoaxleshaft bearingandseal,whichwillremaininaxleshaft tube.
INSTALLATION (1)Lubricatebearingboreandseallipwithgear lubricant.Insertaxleshaftthroughseal,bearing (Fig.26)andengageitintosidegearsplines.
NOTE:Usecaretopreventshaftsplinesfromdamagingaxleshaftseal.
(2)Pushontheaxleshaftuntiltheaxleshaft snap-ringpassesthroughthesidegear.
(3)Installrighthalfshaft.
(4)Installrightwheelandtireassembly.
(5)Checkdifferentialfluidlevel.
(6)Lowervehicle.
AXLESHAFTS(Continued)
Fig.26AXLESHAFTSEAL
1-BEARING 2-SEAL
AXLESHAFTSEALS REMOVAL
(1)Removehalfshaft.
(2)Removeaxleshaftforrightsidesealremoval.
(3)RemoveshaftsealwithRemover7794-Aanda slidehammer(Fig.27).
(2)Install new shaftsealwithInstaller8806and HandleC-4171(Fig.28).
Fig.27SHAFTSEALREMOVER
1-SHAFTSEAL 2-REMOVER
INSTALLATION (1)Applyalightcoatoflubricantonthelipofthe shaftseal.
Fig.28SEALINSTALLER 1-SEALBORE 2-INSTALLER
(3)Installrightaxleshaftifremoved. (4)Installhalfshaft.
AXLEBEARINGS REMOVAL
(1)Removehalfshaft.
(2)Removeaxleshaftforrightsidesealremoval. (3)RemoveshaftsealwithRemover7794-Aanda slidehammer.
(4)RemoveshaftbearingwithRemover7794-A andaslidehammer(Fig.29).
Fig.29SHAFTBEARINGREMOVER 1-SHAFTBEARING 2-REMOVER
3-36FRONTAXLE-186FIA
INSTALLATION (1)Install new shaftbearingwithInstaller8805 andHandleC-4171.
(2)Applyalightcoatoflubricantonthelipofthe shaftseal.
(3)Install new shaftsealwithanappropriate installer.
(4)Installrightaxleshaftifremoved.
(5)Installhalfshaft.
PINIONSEAL REMOVAL (1)Raiseandsupportthevehicle.
(2)Removewheelandtireassemblies.
(3)Removebrakecalipersandrotors,referto5 Brakesforprocedures.
(4)Markpropellershaftandpinioncompanion flangeforinstallationreference.
(5)Removepropellershaftfromthepinioncompanionflange.
(6)Rotatepiniongearaminimumoftentimesand verifythepinionrotatessmoothly.
(7)Recordthetorquetorotatethepiniongear (Fig.30)withainchpoundtorquewrench.
Fig.31PINIONFLANGENUT
1-SPANNERWRENCH
2-PINIONCOMPANIONFLANGE
Fig.30PINIONROTATINGTORQUE
1-PINIONCOMPANIONFLANGE
2-TORQUEWRENCH
(8)UsingashortpieceofpipeandSpanner Wrench6958toholdthepinioncompanionflange (Fig.31)andremovethepinionnut.
(9)Removepinioncompanionflange(Fig.32)with RemoverC-452andSpannerWrench6958.
(10)RemovepinionsealwithRemover7794-Aand aslidehammer(Fig.33).
Fig.32PINIONFLANGEREMOVER
1-SPANNERWRENCH 2-REMOVER
INSTALLATION (1)Applyalightcoatingofgearlubricantonthe lipofpinionseal.InstallsealwithInstaller8681.
(2)Installpinioncompanionflangeonthepinion gearwithInstallerW-162-D,Cup8109andWrench 6958.
CAUTION:Donotexceedtheminimumtightening torque216N·m(160ft.lbs.)whileinstallingpinion nutatthispoint.Damagetocollapsiblespaceror bearingsmayresult.
(3)Installa new nutonthepiniongear. Tighten thenutonlyenoughtoremovetheshaftend play.
PINIONSEAL(Continued)
Fig.33PINIONSEAL
1-REMOVER
2-SLIDEHAMMER
3-PINIONSEAL
CAUTION:Neverloosenpinionnuttodecreasepinionrotatingtorqueandneverexceedspecifiedpreloadtorque.Ifpreloadtorqueorrotatingtorqueis exceededanewcollapsiblespacermustbe installed.
(4)Rotatepinionaminimumoftentimeandverifypinionrotatessmoothly.Rotatethepinionshaft withaninchpoundtorquewrench.Rotatingtorque shouldbeequaltothereadingrecordedduring removalplus0.56N·m(5in.lbs.)(Fig.34).
CAUTION:Ifmaximumtighteningtorqueisreached priortoreachingtherequiredrotatingtorque,the collapsiblespacermayhavebeendamaged. Replacethecollapsiblespacer.
(6)Installpropellershaftwithinstallationreferencemarksaligned.
(7)Filldifferentialwithgearlubricant.
(8)Installbrakerotorsandcalipers.
(9)Installwheelandtireassemblies.
(10)Lowerthevehicle.
DIFFERENTIAL REMOVAL (1)Removeaxlefromthevehicle.
(2)Removedifferentialhousingcover(Fig.35).
Fig.34PINIONROTATINGTORQUE
1-PINIONCOMPANIONFLANGE 2-TORQUEWRENCH
(5)Iftherotatingtorqueislow,useSpanner Wrench6958toholdthepinioncompanionflange andtightenthepinionshaftnutin6.8N·m(5ft. lbs.)incrementsuntilproperrotatingtorqueis achieved.
Fig.35DIFFERENTIALCOVER
1-COVER 2-VENTTUBE
(3)Pushrightaxleshaftoutofsidegear(Fig.36) andremovetheshaft.
(4)Markdifferentialbearingcapsforinstallation reference.
(5)Loosenthebearingcapbolts.
(6)PositionSpreaderW-129-Bontothedifferential locatingholesandinstallthesafetyholddownclamps (Fig.37).Tightenthetoolturnbucklefinger-tight.
(7)InstallaPilotStudC-3288-Battheleftsideof thedifferentialhousing.AttachDialIndicatorC-3339 topilotstud.Loadindicatorplungeragainstthe oppositesideofthehousingandzerotheindicator.
3-38FRONTAXLE-186FIA
DIFFERENTIAL(Continued)
Fig.36RIGHTSHAFTINSIDEGEAR
1-AXLESHAFT
2-SCREWDRIVER
3-SIDEGEAR
Fig.37DIFFERENTIALSPREADER
1-DIFFERENTIALHOUSING
2-SAFETYCLAMPS
3-SPREADER
4-TURNBUCKLE
(8)Spreadthehousingtoremovethedifferential casefromthehousing.Measurethedistancewiththe dialindicator(Fig.38).
CAUTION:Neverspreadthedifferentialhousing over0.34mm(0.013in).Ifhousingisover-spread,it couldbedistortedordamaged.
Fig.38SPREADDIFFERENTIALCASE
1-PILOTSTUD
2-DIALINDICATOR
3-SPREADER
(9)Removethedialindicator.
(10)Holdingthedifferentialcaseinposition,and removebearingcapboltsandcaps.
(11)Removethedifferentialfromthehousing(Fig. 39).Ensuredifferentialbearingcupsandshims remaininpositiononthedifferentialbearings.
(12)Tagdifferentialbearingcupsandshimsto indicatetheirlocation.
(13)Removespreaderfromhousing.
DISASSEMBLY (1)Removeringgear.
(2)Removeroll-pinholdingmateshaftinhousing.
(3)Removepiniongearmateshaft.
(4)Rotatedifferentialsidegearsandremovethe pinionmategearsandthrustwashers(Fig.40).
(5)Removedifferentialsidegearsandthrust washers.
DIFFERENTIAL(Continued)
Fig.39DIFFERENTIALCASE
1-DIFFERENTIALHOUSING
2-DIFFERENTIALCASE
3-DIFFERENTIALBEARINGS
Fig.40PINIONMATEGEAR
1-THRUSTWASHER
2-SIDEGEAR
3-PINIONMATEGEAR
ASSEMBLY
(1)Installdifferentialsidegearsandthrustwashers.
(2)Installpinionmategearsandthrustwashers.
(3)Installpiniongearmateshaft.
(4)Alignholeinthepiniongearmateshaftwith theholeinthedifferentialcase.
(5)Installtheroll-pininthedifferentialcasewith ahammerandpunch(Fig.41).Peentheedgeofthe roll-pinholeinthedifferentialcaseintwoplaces 180°apart.
Fig.41PINIONMATESHAFTROLL-PIN 1-PUNCH 2-PINIONMATESHAFT 3-MATESHAFTLOCKPIN
(6)Lubricatealldifferentialcomponentswith hypoidgearlubricant.
(7)Installringgear.
INSTALLATION NOTE:Ifdifferentialbearingsordifferentialcaseare replaced,RefertoadjustmentsforeDifferential BearingPreloadandGearBacklashprocedures.
(1)PositionSpreaderW-129-Bondifferentiallocationholesandinstallsafetyholddownclamps. Tightenthetoolturnbucklefinger-tight.
(2)InstallPilotStudC-3288-Btotheleftsideof thedifferentialhousing.AttachDialIndicatorC-3339 topilotstud.Loadtheindicatorplungeragainstthe oppositesideofthehousingandzerotheindicator.
(3)Spreadthehousingtoinstallthedifferential caseandpreloadshimsinthehousing.Measurethe distancewiththedialindicator.
DIFFERENTIAL(Continued)
CAUTION:Neverspreadthedifferentialhousing over0.34mm(0.013in).Ifhousingisover-spread,it couldbedistortedordamaged.
(4)Removethedialindicator.
(5)Installdifferentialcaseinthehousing.Ensure differentialbearingcupsremainonthebearingsand preloadshimsareseatedinthehousing.Tapdifferentialcasetoensurebearingscupsareseatedinthe housing.
(6)Installbearingcapstotheiroriginallocations andlooselyinstallcapbolts.
(7)Removedifferentialhousingspreader(Fig.42).
Fig.42DIFFERENTIALSPREADER
1-DIFFERENTIALHOUSING
2-SAFETYCLAMPS
3-SPREADER
4-TURNBUCKLE
(8)Tightenthebearingcapboltsinacriss-cross patternto54-68N·m(39-50ft.lbs.).
5-PLUG 3-40FRONTAXLE-186FIA
(9)Installtherightaxleshaft.
(10)Applya6.38mm(1/4in.)beadofredMopar SiliconeSealerorequivalenttothehousingcover.
CAUTION:Ifcoverisnotinstalledwithin3to5minutes,thecovermustbecleanedandnewRTV appliedoradhesionqualitywillbecompromised.
(11)Installdifferentialhousingcoverandtighten boltsinacriss-crosspatternto19-26N·m(14-19ft. lbs.).
(12)Installaxleassemblyinvehicle.
(13)Filldifferentialwithlubricantandinstallfill plug.
DIFFERENTIALCASE BEARINGS REMOVAL (1)Removedifferentialfromthehousing.
(2)Removebearingsfromthedifferentialcase withPuller/PressC-293-PA,AdaptersC-293-39and PlugSP-3289(Fig.43).
Fig.43DIFFERENTIALBEARINGPULLER
1-PULLER
2-ADAPTERS
3-BEARING
4-DIFFERENTIAL
INSTALLATION (1)InstalldifferentialcasebearingswithInstaller C-3716-AandHandleC-4171(Fig.44).
(2)Installdifferentialintothehousing.
DIFFERENTIALCASEBEARINGS(Continued)
Fig.45RINGGEAR
1-DIFFERENTIALCASE 2-RINGGEAR 3-HAMMER
Fig.44DIFFERENTIALCASEBEARINGS
1-HANDLE
2-DIFFERENTIAL
3-BEARING
4-INSTALLER
PINIONGEAR/RINGGEAR REMOVAL NOTE:Theringgearandpinionareservicedasa matchedset.Neverreplaceringgearwithout replacingthematchedpiniongear.
(1)Raiseandsupportvehicle
(2)Markpinioncompanionflangeandpropeller shaftforinstallationalignment.
(3)Removepropellershaftfrompinioncompanion flangeandtiepropellershafttounderbody.
(4)Removeaxleassemblyfromthevehicle.
(5)Removedifferentialfromaxlehousing.
(6)Placedifferentialcaseinavisewithsoftmetal jaw(Fig.45).
(7)Removeboltsholdingringgeartodifferential case.
(8)Driverringgearoffthedifferentialcasewitha rawhidehammer(Fig.45).
(9)WithSpannerWrench6958andashortlength of1in.pipe,holdpinioncompanionflangeand removepinionnut(Fig.46).
Fig.46PINIONCOMPANIONFLANGE
1-SPANNERWRENCH 2-PINIONCOMPANIONFLANGE
(10)Removepinioncompanionflangefrompinion shaftwithRemoverC-452andFlangeWrench C-3281(Fig.47).
(11)Removepiniongearandcollapsiblespacer fromhousing(Fig.48).
(12)Removefrontpinionbearingcup,bearing,oil slingerandpinionsealwithRemoverC-149and HandleC-4171(Fig.49).
(13)Removerearpinionbearingcup(Fig.50)with RemoverC-4307andHandleC-4171.
3-42FRONTAXLE-186FIA
PINIONGEAR/RINGGEAR(Continued)
Fig.47PINIONFLANGEREMOVER 1-SPANNERWRENCH 2-REMOVER
Fig.48PINIONGEAR 1-RAWHIDEHAMMER
(14)Removecollapsiblepreloadspacerfrompinion gear(Fig.51).
(15)Removerearpinionbearingfromthepinion withPuller/PressC-293-PAandAdaptersC-293-39 (Fig.52).Removeoilslinger/piniondepthshimfrom thepinionshaftandrecordthickness.
Fig.49FRONTBPINIONBEARINGCUP 1-REMOVER 2-HANDLE
Fig.50REARPINIONBEARINGCUP 1-REMOVER 2-HANDLE
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