Dodge Dakota 2001 Service Repair Manual FREE PDF DOWNLOAD
Dodge Dakota 2001 Service Repair Manual FREE PDF DOWNLOAD
Dodge Dakota 2001 Service Repair Manual FREE PDF DOWNLOAD
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Introduction
2 Suspension
5 Brakes
6 Clutch
7 Cooling
8A Audio
8B Chime/Buzzer
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
22 Tires/Wheels
23 Body
25 Emissions Control
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel
(Fig. 2). The VIN contains 17 characters that provide
data concerning the vehicle. Refer to the decoding
chart to determine the identification of a vehicle.
VECI LABEL tion reads from left to right, starting with line 4 in
the center of the plate to line 1 at the bottom of the
plate (Fig. 4).
DESCRIPTION
The last code imprinted on a vehicle code plate will
All vehicles are equipped with a combined VECI
be followed by the imprinted word END. When two
label. This label is located in the engine compart-
vehicle code plates are required, the last available
ment (Fig. 3).
spaces on the first plate will be imprinted with the
letters CTD (for continued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because
of the plate overlap.
DIGITS 20 AND 21
BODY CODE PLATE Body Type
• 31 = Dakota Club Cab (130.9 in. Wheel Base)
DESCRIPTION • 61 = Dakota (111.9 in. Wheel Base)
• 62 = Dakota (123.9 in. Wheel Base)
LOCATION AND DECODING
A metal body code plate is attached to the floor pan BODY CODE PLATE—LINE 3
under the passenger seat. Remove the passenger
seat, door sill scuff plate and pull back the carpet to DIGITS 1,2, AND 3
access the body code plate. There are seven lines of Paint Procedure
information on the body code plate. Lines 5, 6, and 7
are not used to define service information. Informa-
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4 INTRODUCTION AN
BODY CODE PLATE (Continued)
DIGIT 4 BODY CODE PLATE—LINE 1
Open Space
DIGITS 1 THROUGH 6 Body-in-white assembly sequence.
DIGITS 5 THROUGH 8
Primary Paint DIGITS 7 THROUGH 9
Refer to Group 23, Body for color codes. Open Space
DIGIT 14
Open Space EQUIPMENT IDENTIFICATION
DIGITS 15 THROUGH 18
PLATE
Interior Trim Code
DESCRIPTION
DIGIT 19 The Equipment Identification Plate (Fig. 5) is
located at the left, front of the inner hood panel. The
Open Space
plate lists information concerning the vehicle as fol-
DIGITS 20, 21, AND 22 lows:
• The model.
Engine Code
• The wheelbase.
• EPE = 2.5 L 4 cyl. MPI Gasoline
• EHC = 3.9 L 6 cyl. MPI Gasoline • The VIN (Vehicle Identification Number).
• The T.O.N. (order number).
• ELF = 5.2 L 8 cyl. MPI Gasoline
• The optional and special equipment installed on
• ELM = 5.9 L 8 cyl. MPI Gasoline
the vehicle.
BODY CODE PLATE—LINE 2 Refer to the information listed on the plate when
ordering replacement parts.
DIGITS 1, 2, AND 3
Transmission Codes
• DDK = 5–Speed Manual (NVG 1500)
• DDQ = 5–Speed Manual (AX15)
• DDC = 5–Speed Manual (NVG 3500)
• DGK = 4–Speed Automatic (42RE)
• DGW = 4–Speed Automatic (44RE)
• DGT = 4–Speed Automatic (46RE)
DIGIT 4
Open Space
TORQUE REFERENCES cations Chart for torque references not listed in the
individual torque charts (Fig. 10).
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
page page
LUBRICATION &
MAINTENANCE
SPECIFICATIONS
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis- Fig. 3 NLGI Symbol
cosity grade which indicates the cold-to-hot tempera- 1 - WHEEL BEARINGS
ture viscosity range. 2 - CHASSIS LUBRICATION
• SAE 30 = single grade engine oil. 3 - CHASSIS AND WHEEL BEARINGS
• SAE 10W-30 = multiple grade engine oil.
DaimlerChrysler Corporation only recommends
multiple grade engine oils. SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
AN LUBRICATION & MAINTENANCE 0-3
PARTS & LUBRICANT (Continued)
RECOMMENDATIONS CAUTION: DO NOT use gasoline containing METH-
When service is required, DaimlerChrysler Corpo- ANOL. Gasoline containing methanol may damage
ration recommends that only Mopart brand parts, critical fuel system components.
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing Daimler-
Chrysler Corporation vehicles. MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
FLUID TYPES Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
DESCRIPTION - FUEL REQUIREMENTS ber without MMT. Gasoline blended with MMT
Your engine is designed to meet all emissions reg- reduce spark plug life and reduce emission system
ulations and provide excellent fuel economy and per- performance in some vehicles. We recommend that
formance when using high quality unleaded “regular” gasolines free of MMT be used in your vehicle. The
gasoline having an octane rating of 87. The routine MMT content of gasoline may not be indicated on the
use of premium gasoline is not recommended. Under gasoline pump; therefore, you should ask your gaso-
normal conditions the use of premium fuel will not line retailer whether or not his/her gasoline contains
provide a benefit over high quality regular gasolines MMT.
and in some circumstances may result in poorer per- It is even more important to look for gasoline with-
formance. out MMT in Canada because MMT can be used at
Light spark knock at low engine speeds is not levels higher than allowed in the United States.
harmful to your engine. However, continued heavy MMT is prohibited in Federal and California refor-
spark knock at high speeds can cause damage and mulated gasoline.
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may SULFUR IN GASOLINE
not be covered by the new vehicle warranty. If you live in the northeast United States, your
Poor quality gasoline can cause problems such as vehicle may have been designed to meet California
hard starting, stalling and hesitations. If you experi- low emission standards with Cleaner-Burning Cali-
ence these symptoms, try another brand of gasoline fornia reformulated gasoline with low sulfur. If such
before considering service for the vehicle. fuels are not available in states adopting California
Over 40 auto manufacturers world-wide have emission standards, your vehicles will operate satis-
issued and endorsed consistent gasoline specifications factorily on fuels meeting federal specifications, but
(the Worldwide Fuel Charter, WWFC) to define fuel emission control system performance may be
properties necessary to deliver enhanced emissions, adversely affected. Gasoline sold outside of California
performance and durability for your vehicle. We rec- is permitted to have higher sulfur levels which may
ommend the use of gasolines that meet the WWFC affect the performance of the vehicle’s catalytic con-
specifications if they are available. verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
REFORMULATED GASOLINE light to illuminate. We recommend that you try a dif-
Many areas of the country require the use of ferent brand of unleaded gasoline having lower sulfur
cleaner burning gasoline referred to as “reformulat- to determine if the problem is fuel related prior to
ed” gasoline. Reformulated gasoline contain oxygen- returning your vehicle to an authorized dealer for
ates, and are specifically blended to reduce vehicle service.
emissions and improve air quality.
CAUTION: If the Malfunction Indicator Lamp (MIL),
We strongly support the use of reformulated gaso-
Check Engine or Service Engine Soon light is flash-
line. Properly blended reformulated gasoline will pro-
ing, immediate service is required; see on-board
vide excellent performance and durability for the
diagnostics system section.
engine and fuel system components.
COOLANT PERFORMANCE
DESCRIPTION - ENGINE COOLANT The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL conditions. The coolant performance of various mix-
BASE COOLANT AND IS HARMFUL IF SWAL- tures follows:
LOWED OR INHALED. IF SWALLOWED, DRINK Pure Water-Water can absorb more heat than a
TWO GLASSES OF WATER AND INDUCE VOMIT- mixture of water and ethylene-glycol. This is for pur-
ING. IF INHALED, MOVE TO FRESH AIR AREA. pose of heat transfer only. Water also freezes at a
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT higher temperature and allows corrosion.
STORE IN OPEN OR UNMARKED CONTAINERS. 100 percent Ethylene-Glycol-The corrosion
WASH SKIN AND CLOTHING THOROUGHLY AFTER inhibiting additives in ethylene-glycol need the pres-
COMING IN CONTACT WITH ETHYLENE GLYCOL. ence of water to dissolve. Without water, additives
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF form deposits in system. These act as insulation
GLYCOL BASE COOLANT PROPERLY, CONTACT causing temperature to rise to as high as 149°C
YOUR DEALER OR GOVERNMENT AGENCY FOR (300°F). This temperature is hot enough to melt plas-
LOCATION OF COLLECTION CENTER IN YOUR tic and soften solder. The increased temperature can
AREA. DO NOT OPEN A COOLING SYSTEM WHEN result in engine detonation. In addition, 100 percent
THE ENGINE IS AT OPERATING TEMPERATURE OR ethylene-glycol freezes at -22°C (-8°F).
HOT UNDER PRESSURE, PERSONAL INJURY CAN 50/50 Ethylene-Glycol and Water-Is the recom-
RESULT. AVOID RADIATOR COOLING FAN WHEN mended mixture, it provides protection against freez-
ENGINE COMPARTMENT RELATED SERVICE IS ing to -37°C (-34°F). The antifreeze concentration
PERFORMED, PERSONAL INJURY CAN RESULT. must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
AN LUBRICATION & MAINTENANCE 0-5
FLUID TYPES (Continued)
tion against freezing is provided with a 68 percent SAE VISCOSITY
antifreeze concentration, which prevents freezing An SAE viscosity grade is used to specify the vis-
down to -67.7°C (-90°F). A higher percentage will cosity of engine oil. Use only engine oils with multi-
freeze at a warmer temperature. Also, a higher per- ple viscosities such as 5W-30 or 10W-30. These are
centage of antifreeze can cause the engine to over- specified with a dual SAE viscosity grade which indi-
heat because specific heat of antifreeze is lower than cates the cold-to-hot temperature viscosity range.
that of water. Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 4) and
CAUTION: Richer antifreeze mixtures cannot be (Fig. 5).
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
37,500 Miles (60 000 km) or at 30 months 82,500 Miles (132 000 km) or at 66 months
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Drain and refill transfer case fluid. • Flush and replace engine coolant if it has been
• Drain and refill automatic transmission fluid. 30,000 miles (48 000 km) or 24 months since last
Replace filter and adjust bands (3.9L, and 5.9L only). change.
45,000 Miles (72 000 km) or at 36 months 90,000 Miles (144 000 km) or at 72 months
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Lubricate front suspension ball joints if • Replace engine air cleaner element.
required. • Inspect PCV valve, replace as necessary.
• Inspect front wheel bearings. (3.9L, 4.7L, and 5.9L)*
• Inspect brake linings. • Replace spark plugs.
• Flush and replace engine coolant at 36 months, • Lubricate front suspension ball joints if
regardless of mileage. required.
• Inspect front wheel bearings.
52,500 Miles (84 000 km) or at 42 months • Inspect brake linings.
• Change engine oil. • Inspect auto tension drive belt and replace if
• Replace engine oil filter. required (3.9L, 4.7L, & 5.9L).D
• Flush and replace engine coolant if not done at
36 months. 97,500 Miles (156 000 km) or at 78 months
• Change engine oil.
60,000 Miles (96 000 km) or at 48 months • Replace engine oil filter.
• Change engine oil.
• Replace engine oil filter. 105,000 Miles (168 000 km) or at 84 months
• Replace engine air cleaner element. • Change engine oil.
• Replace ignition cables (2.5L, 3.9L, 5.9L). • Replace engine oil filter.
• Inspect PCV valve, replace as necessary. • Flush and replace engine coolant if it has been
(3.9L, 4.7L, and 5.9L)* 30,000 Miles (48 000km) or 24 months since last
• Replace spark plugs. change.
• Inspect auto tension drive belt and replace if • Inspect auto tension drive belt and replace if
required (3.9L, & 5.9L). required (3.9L, 4.7L, & 5.9L).D
• Inspect and adjust tension on drive belt (2.5L).
• Drain and refill automatic transmission fluid 112,500 Miles (181 000 km) or at 90 months
and change filter (4.7L only). • Change engine oil.
• Replace engine oil filter.
67,500 Miles (108 000 km) or at 54 months • Drain and refill automatic transmission fluid.
• Change engine oil. Replace filter and adjust bands (3.9L & 5.9L only).
• Replace engine oil filter. • Drain and refill transfer case fluid.
• Lubricate front suspension ball joints if • Lubricate front suspension ball joints if
required. required.
• Inspect front wheel bearings. • Inspect front wheel bearings.
• Inspect brake linings. • Inspect brake linings.
• Flush and replace engine coolant if it has been
75,000 Miles (120 000 km) or at 60 months 30,000 Miles (48 000km) or 24 months since last
• Change engine oil. change.
• Replace engine oil filter.
• Drain and refill automatic transmission fluid. 120,000 Miles (192 000 km) or at 96 months
Replace filter and adjust bands (3.9L & 5.9L). • Change engine oil.
• Drain and refill transfer case. • Replace engine oil filter.
• Flush and replace engine coolant if it has been • Replace engine air cleaner element.
30,000 miles (48 000 km) or 24 months since last • Replace ignition cables (2.5L, 3.9L & 5.9L).
change.
AN LUBRICATION & MAINTENANCE 0-9
MAINTENANCE SCHEDULES (Continued)
• Inspect PCV valve, replace as necessary. 18,000 Miles (29 000 km)
(3.9L, 4.7L, and 5.9L)* • Change engine oil.
• Replace spark plugs. • Replace engine oil filter.
• Inspect auto tension drive belt and replace if • Drain and refill manual transmission fluid (3.9L
required (3.9L, 4.7L, & 5.9L).D only).
• Drain and refill automatic transmission fluid
and change filter (4.7L only). 21,000 Miles (34 000 km)
*This maintenance is recommended by Daimler- • Change engine oil.
Chrysler Corporation to the owner but is not • Replace engine oil filter.
required to maintain the warranty on the PCV valve. • Inspect front wheel bearings.
DThis maintenance is not required if the belt was
previously replaced. 24,000 Miles (38 000 km)
Important: Inspection and service should also be • Change engine oil.
performed any time a malfunction is observed or sus- • Replace engine oil filter.
pected. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands (3.9L & 5.9L).‡
SCHEDULE “B” • Drain and refill automatic transmission fluid
Use schedule “B” if the vehicle is usually operated and change filter (4.7L only).
under the following conditions: • Lubricate front suspension ball joints if
• Frequent short trip driving less than 5 miles (8 required.
km) • Change rear axle fluid.
• Frequent driving in dusty conditions • Change front axle fluid (4x4).
• Trailer towing • Inspect brake linings.
• Extensive idling
• More than 50% of the driving is at sustained 27,000 miles (43 000 km)
high speeds during hot weather, above 90°F (32°C) • Change engine oil.
• Replace engine oil filter.
3,000 Miles (5 000 km)
• Change engine oil. 30,000 Miles (48 000 km)
• Replace engine oil filter. • Change engine oil.
• Replace engine oil filter.
6,000 Miles (10 000 km) • Replace engine air cleaner element.
• Change engine oil. • Replace spark plugs.
• Replace engine oil filter. • Inspect PCV valve, replace as necessary.
(3.9L, 4.7L and 5.9L)*
9,000 Miles (14 000 km) • Inspect and adjust drive tension on drive belt
• Change engine oil. (2.5L).
• Replace engine oil filter.
33,000 Miles (53,000 km)
12,000 Miles (19 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter.
• Drain and refill automatic transmission fluid. 36,000 Miles (58 000 km)
Replace filter and adjust bands (3.9L & 5.9L).‡ • Change engine oil.
• Drain and refill automatic transmission fluid • Replace engine oil filter.
and change filter (4.7L only). • Lubricate front suspension ball joints if
• Lubricate front suspension ball joints if required.
required. • Drain and refill automatic transmission fluid.
• Change rear axle fluid. Replace filter and adjust bands (3.9L & 5.9L).‡
• Change front axle fluid (4x4). • Drain and refill automatic transmission fluid
• Inspect brake linings. and change filter (4.7L only).
• Drain and refill transfer case fluid.
15,000 Miles (24 000 km) • Change rear axle fluid.
• Change engine oil. • Change front axle fluid (4x4).
• Replace engine oil filter. • Inspect brake linings.
• Inspect engine air cleaner element, replace
as necessary.
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0 - 10 LUBRICATION & MAINTENANCE AN
MAINTENANCE SCHEDULES (Continued)
39,000 Miles (62 000 km) • Change rear axle fluid.
• Change engine oil. • Change front axle fluid (4x4).
• Replace engine oil filter. • Inspect brake linings.
• Inspect auto tension drive belt and replace if
42,000 Miles (67 000 km) required (3.9L & 5.9L).
• Change engine oil.
• Replace engine oil filter. 63,000 Miles (101 000 km)
• Inspect front wheel bearings. • Change engine oil.
• Replace engine oil filter.
45,000 Miles (72 000 km) • Inspect front wheel bearings.
• Change engine oil.
• Replace engine oil filter. 66,000 Miles (106,000 km)
• Inspect engine air cleaner element, replace • Change engine oil.
as necessary. • Replace engine oil filter.
48,000 Miles (77 000 km) 69,000 Miles (110 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Lubricate front suspension ball joints if
required. 72,000 Miles (115 000 km)
• Drain and refill automatic transmission fluid. • Change engine oil.
Replace filter and adjust bands (3.9L & 5.9L).‡ • Replace engine oil filter.
• Drain and refill automatic transmission fluid • Lubricate front suspension ball joints if
and change filter (4.7L only). required.
• Change rear axle fluid. • Drain and refill automatic transmission fluid.
• Change front axle fluid (4x4). Replace filter and adjust bands (3.9L & 5.9L).‡
• Inspect brake linings. • Drain and refill automatic transmission fluid
and change filter (4.7L only).
51,000 Miles (82 000 km) • Drain and refill transfer case fluid.
• Change engine oil. • Change rear axle fluid.
• Replace engine oil filter. • Change front axle fluid (4x4).
• Flush and replace engine coolant. • Inspect brake linings.
54,000 Miles (86 000 km) 75,000 Miles (120 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Drain and refill manual transmission fluid (3.9L • Inspect engine air cleaner element, replace
only). as necessary.
• Inspect auto tension drive belt and replace if
57,000 Miles (91 000 km) required (3.9L, 4.7L & 5.9L).D
• Change engine oil.
• Replace engine oil filter. 78,000 Miles (125 000 km)
• Change engine oil.
60,000 Miles (96 000 km) • Replace engine oil filter.
• Change engine oil.
• Replace engine oil filter. 81,000 Miles (130 000 km)
• Replace engine air cleaner element. • Change engine oil.
• Replace ignition cables. • Replace engine oil filter.
• Inspect PCV valve, replace as necessary. • Flush and replace engine coolant if it has been
(3.9L, 4.7L, and 5.9L)* 30,000 miles (48 000 km) since last change.
• Replace spark plugs.
• Drain and refill automatic transmission fluid. 84,000 Miles (134 000 km)
Replace filter and adjust bands (3.9L & 5.9L).‡ • Change engine oil.
• Drain and refill automatic transmission fluid • Replace engine oil filter.
and change filter (4.7L only). • Inspect front wheel bearings.
• Lubricate front suspension ball joints if • Lubricate front suspension ball joints if
required. required.
AN LUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES (Continued)
• Drain and refill automatic transmission fluid. 108,000 Miles (173 000 km)
Replace filter and adjust bands (3.9L & 5.9L).‡ • Change engine oil.
• Drain and refill automatic transmission fluid • Replace engine oil filter.
and change filter (4.7L only). • Lubricate front suspension ball joints if
• Change rear axle fluid. required.
• Change front axle fluid (4x4). • Drain and refill automatic transmission fluid.
• Inspect brake linings. Replace filter and adjust bands (3.9L & 5.9L).‡
• Drain and refill automatic transmission fluid
87,000 Miles (139 000 km) and change filter (4.7L only).
• Change engine oil. • Drain and refill transfer case fluid.
• Replace engine oil filter. • Change rear axle fluid.
• Change front axle fluid (4x4).
90,000 Miles (144 000 km) • Inspect brake linings.
• Change engine oil.
• Replace engine oil filter. 111,000 Miles (178 000 km)
• Replace engine air cleaner element. • Change engine oil.
• Replace spark plugs. • Replace engine oil filter.
• Inspect PCV valve, replace as necessary. • Flush and replace engine coolant if it has been
(3.9L, 4.7L, and 5.9L)* 30,000 miles (48 000 km) since last change.
• Inspect auto tension drive belt and replace if
required (3.9L, 4.7L, & 5.9L).D 114,000 Miles (182 000 km)
• Inspect and adjust tension on drive belt (2.5L). • Change engine oil.
• Replace engine oil filter.
93,000 Miles (149 000 km)
• Change engine oil. 117,000 Miles (187 000 km)
• Replace engine oil filter. • Change engine oil.
• Replace engine oil filter.
96,000 Miles (154 000 km)
• Change engine oil. 120,000 Miles (192 000 km)
• Replace engine oil filter. • Change engine oil.
• Lubricate front suspension ball joints if • Replace engine oil filter.
required. • Replace engine air cleaner element.
• Drain and refill automatic transmission fluid. • Replace ignition cables.
Replace filter and adjust bands (3.9L & 5.9L).‡ • Inspect PCV valve, replace as necessary.
• Drain and refill automatic transmission fluid (3.9L, 4.7L, and 5.9L)*
and change filter (4.7L only). • Replace spark plugs.
• Change rear axle fluid. • Lubricate front suspension ball joints if
• Change front axle fluid (4x4). required.
• Inspect brake linings. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands (3.9L & 5.9L).‡
99,000 Miles (158 000 km) • Drain and refill automatic transmission fluid
• Change engine oil and change filter (4.7L only).
• Replace engine oil filter. • Change rear axle fluid.
• Change front axle fluid (4x4).
102,000 Miles (163 000 km) • Inspect brake linings.
• Change engine oil. • Inspect auto tension drive belt and replace if
• Replace engine oil filter. required (3.9L, 4.7L, & 5.9L).D
• Inspect and adjust tension on drive belt (2.5L).
105,000 Miles (168 000 km) *This maintenance is recommended by Chrysler
• Change engine oil. Corporation to the customer but is not required to
• Replace engine oil filter. maintain warranty on the PCV valve.
• Inspect engine air cleaner element, replace DThis maintenance is not required if the belt was
as necessary. previously replaced.
• Inspect front wheel bearings. ‡Prolonged operation with heavy loading, espe-
• Inspect auto tension drive belt and replace if cially in hot weather, use of vehicle for off-the-high-
required (3.9L, 4.7L, & 5.9L).D way operation, and trailer towing require the more
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0 - 12 LUBRICATION & MAINTENANCE AN
MAINTENANCE SCHEDULES (Continued)
frequent transmission service indicated with a ‡ in HOIST
Schedule “B”. Perform these services if the vehicle is
usually operated under these conditions. WARNING: THE HOISTING AND JACK LIFTING
Important: Inspection and service should also be POINTS PROVIDED ARE FOR A COMPLETE VEHI-
performed any time a malfunction is observed or sus- CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
pected. NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
HOISTING SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
STANDARD PROCEDURE—HOISTING
RECOMMENDATIONS CAUTION: DO NOT LET THE REAR WHEELS/AXLE
HANG UNSUPPORTED WHEN THE VEHICLE IS
FLOOR JACK LIFTED WITH THE PARKING BRAKE APPLIED.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under: NOTE: When a frame-contact type hoist is used,
• An axle tube. verify that the lifting pads are positioned properly
• Aluminum differential. (Fig. 7).
• A body side sill.
• A steering linkage component. A vehicle can be lifted with:
• A drive shaft. • A single-post, frame-contact hoist.
• The engine or transmission oil pan. • A twin-post, chassis hoist.
• The fuel tank. • A ramp-type, drive-on hoist.
• A front suspension arm.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehicle should be raised until lifted wheels Fig. 11 Long Bed Vehicle Towing—Typical
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo- 2WD vehicles can be towed with the front wheels
site end of the vehicle, especially when towing over on the surface for extended distances at speeds not
rough terrain or steep rises in the road. If necessary, exceeding 48 km/h (30 mph).
remove the wheels from the lifted end of the vehicle (1) Attach wheel lift device to rear wheels.
and lower the vehicle closer to the ground, to (2) Attach safety chains to frame rails. Route
increase the ground clearance at the opposite end of chains so not to interfere with tail pipe when vehicle
the vehicle. Install lug nuts on wheel attaching studs is lifted.
to retain brake drums. (3) Turn the ignition switch to the OFF position to
unlock the steering wheel.
RAMP ANGLE
CAUTION: Do not use steering column lock to
If a vehicle with flat bed towing equipment is used,
secure steering wheel during towing operation.
the approach ramp angle should not exceed 15
degrees. (4) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
TOWING WHEN KEYS ARE NOT AVAILABLE (5) Verify that steering components are in good
When the vehicle is locked and keys are not avail- condition.
able, use a flat bed hauler. A Sling-type device can be (6) Shift the transmission to NEUTRAL.
used on 4WD vehicles provided all the wheels are
lifted off the ground using tow dollies. TOWING-FRONT END LIFTED
When lifting from the front end, all vehicles must
be towed with a Wheel-lift device or transported on a
flat bed.
(1) Attach Wheel-lift device to front wheels.
AN LUBRICATION & MAINTENANCE 0 - 15
TOWING (Continued)
(2) Attach the safety chains to the disabled vehicle (2) Attach wheel lift device to rear wheels.
at the frame rails. (3) Attach safety chains to frame rails. Route
chains so not to interfere with tail pipe when vehicle
CAUTION: Do not use steering column lock to is lifted.
secure steering wheel during towing operation. (4) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(3) Turn the ignition switch to the OFF position to
unlock the steering wheel. CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
TWO WHEEL DRIVE—MANUAL AND AUTOMATIC
TRANSMISSION (5) Secure steering wheel in straight ahead posi-
Provided the transmission is operable, tow only in tion with a clamp device designed for towing.
NEUTRAL at speeds not to exceed 30 mph (50 (6) Shift the transfer case to NEUTRAL.
km/h) and distances less than 15 miles (25km/h).
If the vehicle is to be towed more than 15 miles, FOUR WHEEL DRIVE TOWING—FRONT END
the propeller shaft should be disconnected or place LIFTED
tow dollies under rear wheels. When lifting from the front end, all vehicles must
be towed with a wheel-lift device or transported on a
STANDARD PROCEDURE—FOUR WHEEL flat bed.
DRIVE VEHICLE TOWING (1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
FOUR WHEEL DRIVE TOWING—REAR END LIFTED (2) Attach wheel lift device to front wheels.
(3) Attach the safety chains to the disabled vehicle
CAUTION: at the frame rails.
Short bed vehicles must be towed with a Wheel-lift
device (Fig. 10) or transported on a flat bed. Long CAUTION: Do not use steering column lock to
bed vehicles must be transported on a flat bed (Fig. secure steering wheel during towing operation.
11). When using a Wheel-lift device, all wheels must
(4) Turn the ignition switch to the OFF position to
be lifted off the ground using tow dollies.
unlock the steering wheel.
(1) Raise the front of the vehicle off the ground (5) Shift the transfer case to NEUTRAL.
and install tow dollies under front wheels.
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AN SUSPENSION 2-1
SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe (Fig. 1).
NOTE: Periodic lubrication of the front suspension/ Fig. 1 Wheel Alignment Measurements
steering system components may be required. Rub- 1 - FRONT OF VEHICLE
ber bushings must never be lubricated. Refer to 2 - STEERING AXIS INCLINATION
Lubrication And Maintenance for the recommended 3 - PIVOT POINT
4 - TOE-IN
maintenance schedule.
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Column coupler binding. 2. Replace coupler.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
Fig. 5 Toe
1 - JAM NUT
2 - TIE ROD
3 - TIE ROD END
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
DESCRIPTION SPECIFICATION
TOTAL TOE (6
VEHICLE WHEEL BASE CASTER (6 0.50°) CAMBER (6 0.50°)
0.06°)
111.9 2.99° −0.25° 0.10°
4x2
130.9 3.13° −0.25° 0.10°
111.9 3.16° −0.25° 0.10°
4x4
130.9 3.27° −0.25° 0.10°
MAXIMUM RT to LT DIFFERENCE 0.50° 0.50° 0.06
DAKOTA RT
DESCRIPTION SPECIFICATION
VEHICLE WHEEL BASE CASTER (6 0.50°) CAMBER (6 0.50°) TOTAL TOE (6 0.06°)
111.9 3.67° −0.34° 0.10°
4x2
130.9 3.81° −0.34° 0.10°
MAXIMUM RT to LT DIFFERENCE 0.50° 0.50° 0.06
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2-6 FRONT - 2WD AN
FRONT - 2WD
TABLE OF CONTENTS
page page
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Shock Absorber 26 19 —
Upper Nut
Shock Absorber 28 21 —
Lower Bolts
Lower Suspension Arm 175 130 —
Front Nut
Lower Suspension Arm 108 80 —
Rear Nut
Lower Suspension Arm 127 94 —
Ball Joint Nut
Upper Suspension Arm 167 130 —
Pivot Shaft Nuts
Upper Suspension Arm 210 155 —
Pivot Shaft to Frame Nuts
Upper Suspension Arm 81 60 —
Ball Joint Nut
Stabilizer Bar 37 27 —
Link Upper Nut
Stabilizer Bar 47 35 —
Link Ball Stud Nut
Stabilizer Bar 60 45 —
Retainer Bolts
Hub/Bearing 251 185 —
Spindle Nut
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2-8 FRONT - 2WD AN
SPECIAL TOOLS
FRONT SUSPENSION
HUB / BEARING has machined mounting locations for the front brake
calipers and hub bearing.
REMOVAL
(1) Raise and support vehicle.
OPERATION
The steering knuckle pivot between the upper and
(2) Remove wheel and tire assembly.
lower ball joint. Steering linkage attached to the
(3) Remove brake caliper, rotor, and ABS wheel
knuckle allows the vehicle to be steered.
speed sensor if equipped, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(4) Remove hub/bearing spindle nut and discard REMOVAL
nut (Fig. 4). (1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
CAUTION: The hub/bearing spindle nut can not be (3) Remove disc brake caliper, rotor, shield and
re-used. ABS speed sensor, (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/ROTORS - REMOVAL).
(5) Slide hub/bearing off spindle. (4) Remove tie-rod from steering knuckle arm,
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
REMOVAL).
(5) Remove the hub/bearing. (Refer to 2 - SUS-
PENSION/FRONT/HUB / BEARING - REMOVAL).
(6) Remove the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - REMOVAL).
(7) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and upper
shock mounting hole (Fig. 9).
(8) Tighten the tool lower nut to compress the coil
spring.
(9) Remove the lower ball joint nut and separate
the ball joint from the knuckle with Remover
C-4150A (Fig. 10).
(10) Remove the upper ball joint nut and separate
the ball joint from the knuckle with Remover
Fig. 4 Hub/Bearing MB-991113 (Fig. 5).
1 - KNUCKLE
2 - HUB/BEARING CAUTION: When install Remover MB-991113 to sep-
3 - SPINDLE NUT arate the ball joint, be careful not to damage the
ball joint seal.
SPRING
DESCRIPTION
The springs mount between the lower suspension
arms and frame rail spring seats. A rubber isolator
seats on top off the spring to help prevent noise.
OPERATION
The coil springs control ride quality and maintain
proper ride height.
INSTALLATION
NOTE: The ramped or open end of the coil spring is
the bottom of the spring.
FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD
DESCRIPTION - 4WD
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub/bearings
units bolted to cast steering knuckle. The double-row
hub bearings are sealed and lubricated for life. The
steering knuckles turn (pivot) on ball joints. The
upper ball joint is riveted to the outboard portion of
the suspension arm and lubricated for life. The lower
ball joint is pressed into the lower suspension arm
and requires lubrication.
The 4x4 front suspension is comprised of (Fig. 1):
• Shock absorbers
• Torsion-bar springs
• Suspension arms
• Steering knuckles Fig. 1 Front Suspension - 4x4
• Stabilizer bar 1 - UPPER SUSPENSION ARM
• Jounce/Rebound bumpers 2 - SHOCK ABSORBER
• Hub/Bearing 3 - STABILIZER BAR
• Ball Joints 4 - LOWER SUSPENSION ARM
5 - TORSION BAR
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2 - 16 FRONT - 4WD AN
FRONT - 4WD (Continued)
CAUTION: Components attached with a nut and cot- DESCRIPTION - SUSPENSION ARMS
ter pin must be torqued to specification. Then if the The upper suspension arm bolts on frame brackets
slot in the nut does not line up with the cotter pin through the arm pivot shaft. The frame brackets
hole, tighten nut until it is aligned. Never loosen the have slotted holes which allow the arms to be
nut to align the cotter pin hole. adjusted for caster and camber. Pivot shaft bushings
are not replaceable.
The lower suspension arms bolt to the lower frame
CAUTION: Suspension components with rubber/ure-
brackets and pivot through bushings, these bushings
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is are not replaceable.
The suspension arms have lube for life riveted ball
important to have the springs supporting the weight
studs. The suspension arm travel (jounce) is limited
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle through the use of urethane bumpers. Rebound
ride comfort could be affected and premature bush- travel is limited by the shock absorber.
ing wear may occur.
STANDARD PROCEDURE - LUBRICATION
Periodic lubrication of the suspension system may
be required. Refer to Lubrication And Maintenance
for the recommended maintenance schedule.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
SPECIAL TOOLS
FRONT SUSPENSION
Remover MB-991113
Remover C-4150A
KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
OPERATION
The stabilizer bar is used to minimize vehicle front
sway during turns. The bar helps to maintain a flat
attitude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle must
be on a drive on hoist. The vehicle suspension
must be at curb height for stabilizer bar installation.
(1) Remove the stabilizer bar retainer bolts from
Fig. 6 Lower Ball Joint the lower suspension arms (Fig. 7) and remove the
1 - REMOVER retainers.
2 - LOWER BALL STUD (2) Remove the stabilizer bar retainer nuts, bolts
and retainers from the frame crossmember (Fig. 7)
and remove the bar.
CAUTION: The ball joint stud tapers must be
(3) If necessary, remove the bushings from the sta-
CLEAN and DRY before installing the knuckle.
bilizer bar.
Clean the stud tapers with mineral spirits to remove
dirt and grease.
INSTALLATION
(2) Install the knuckle onto the upper and lower
NOTE: To service the stabilizer bar the vehicle must
ball joint.
be on a drive on hoist. The vehicle suspension
(3) Install the upper and lower ball joint nuts.
must be at curb height for stabilizer bar installation.
Tighten the upper ball joint nut to 81 N·m (60 ft.
(1) If removed, install the bushings on the stabi-
lbs.) and the lower ball joint nut to 183 N·m (135 ft.
lizer bar.
lbs.) then install cotter pins. Grease the lower ball
(2) Position the stabilizer bar on the frame cross-
joint.
member brackets and install the retainers and nuts
(4) Remove the hydraulic jack from the lower sus-
and bolts finger-tight (Fig. 7).
pension arm.
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2 - 20 FRONT - 4WD AN
STABILIZER BAR (Continued)
Fig. 8 Hub/Bearing
1 - HUB BEARING
Fig. 7 Stabilizer Bar 2 - STEERING KNUCKLE
1 - LOWER SUSPENSION ARM
2 - FLAG NUT
3 - STABILIZER BAR INSTALLATION
4 - RETAINER (1) Install the hub/bearing into the steering
knuckle and tighten the bolts to 166 N·m (123 ft.
lbs.).
NOTE: Check the alignment of the bar to ensure
(2) Install the brake rotor and caliper. (Refer to 5 -
there is no interference with the either frame rail or
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
chassis component. Spacing should be equal on
INSTALLATION).
both sides.
(3) Install the ABS wheel speed sensor if equipped.
(3) Install the stabilizer bar to the lower suspen- (Refer to 5 - BRAKES/ELECTRICAL/FRONT
sion arm. WHEEL SPEED SENSOR - INSTALLATION).
(4) Install the retainers and bolts to the lower sus- (4) Install the halfshaft nut and tighten to 235
pension arm and tighten to 34 N·m (25 ft. lbs.). N·m (173 ft. lbs.).
(5) Tighten the frame retainer nuts to 190 N·m (5) Install the wheel and tire assembly. (Refer to
(140 ft. lbs.). 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
(6) Tighten the frame retainer bolts to 108 N·m CEDURE).
(80 ft. lbs.). (6) Remove the support and lower vehicle.
SHOCK
DESCRIPTION
The top of the low-pressure gas charged shock are
bolted to the frame. The bottom of the shock are
bolted to the lower suspension arm.
REMOVAL
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
INSTALLATION
NOTE: Upper shock nut must be replaced or use
Mopar Lock ’N Seal or LoctiteT 242 on existing nut.
(1) Install the lower retainer (lower retainer is
stamped with a L) and grommet on the shock
absorber stud. Insert the shock absorber through the
frame bracket hole.
(2) Install the lower bolt and tighten the bolt to
108 N·m (80 ft. lbs.).
(3) Install the upper grommet, retainer (upper
retainer is stamped with a U) and new nut or use
Mopar Lock ’N Seal or Loctitet 242 on existing nut,
on the shock absorber stud. Tighten nut to 26 N·m
(19 ft. lbs.).
Fig. 14 Torsion Bar
1 - SWIVEL
TORSION BAR 2 - ANCHOR
3 - BEARING
DESCRIPTION 4 - ADJUSTMENT BOLT
5 - TORSION BAR
The front of the bar mounts to the back side of the
6 - LOWER SUSPENSION ARM
lower suspension arm. The rear end of the bar is
mounted in a anchor that rests in the frame cross-
member.
OPERATION
The torsion bars are used to control ride height
and ride quality. The vehicle height is adjusted
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2 - 24 FRONT - 4WD AN
TORSION BAR (Continued)
REAR
TABLE OF CONTENTS
page page
REAR SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 25 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPRING AND SHOCK. . . . . . . . . . . . . . . . . . . . 25 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SHOCK STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
SHOCK OPERATION
Ride control is accomplished through the use of
DESCRIPTION dual-action shock absorbers. The shocks dampen the
The top of the shock absorbers are bolted to the jounce and rebound as the vehicle travels over vari-
body crossmember. The bottom of the shocks are ous road conditions.
bolted to the axle brackets. The axle brackets are
staggered one ahead of the axle and one befind.
AN REAR 2 - 27
SHOCK (Continued)
REMOVAL OPERATION
(1) Raise vehicle and support rear axle. The springs control ride quality and maintain vehi-
(2) Remove shock absorber lower nut and bolt from cle ride height. The shackles allow the springs to
the axle bracket (Fig. 1). change their length as the vehicle moves over various
(3) Remove shock absorber upper nut and bolt road conditions.
from the frame bracket and remove the shock
absorber. REMOVAL
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of the
rear axle. Use care to avoid bending the side rail
flange.
INSTALLATION
(1) Install shock absorber and upper mounting bolt
and nut. Tighten nut to 95 N·m (70 ft. lbs.).
(2) Install shock absorber into the axle bracket.
Install the bolt and nut and tighten nut to 95 N·m
(70 ft. lbs.).
(3) Remove axle support and lower vehicle.
SPRING
DESCRIPTION Fig. 2 Leaf Spring - 4x2
The 4x2 rear suspension system uses a 4-leaf two
1 - JOUNCE BUMPER
stage or 5-leaf single stage springs and a solid drive
2 - SHACKLE
axle. The 4x4 rear suspension system uses only a 3 - PLATE
4-leaf two stage spring and solid drive axle. The for- 4 - LEAF SPRING
ward end of the springs are mounted to the body rail
hangers through rubber bushings. The rearward end
of the springs are attached to the body by the use of
shackles. The spring and shackles use rubber bush-
ings. The bushing help to isolate road noise.
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2 - 28 REAR AN
SPRING (Continued)
STABILIZER BAR
DESCRIPTION
The stabilizer bar (optional) extends across the
underside of the vehicle and is bolted to the top of
the axle. Links at the end of the bar are bolted to
frame brackets.
OPERATION
The stabilizer bar is used to minimize vehicle body
roll. The spring steel bar helps to control the vehicle
body in relationship to the suspension.
REMOVAL
(1) Raise and support vehicle.
(2) Remove nuts and bolts from the links at the
stabilizer bar.
(3) Remove stabilizer bar retainer bolts and retain-
ers (Fig. 4).
(4) Remove stabilizer bar and replace worn,
Fig. 3 Leaf Spring - 4x4 cracked or distorted bushings.
1 - SHACKLE (5) Remove links upper mounting nuts and bolts
2 - JOUNCE BUMPER and remove links.
3 - SEAT
4 - PLATE
5 - LEAF SPRING
INSTALLATION
CAUTION: The rear of the vehicle must be lifted only
with a jack or hoist. The lift must be placed under the
frame rail crossmember located aft of the rear axle.
Use care to avoid bending the side rail flange.
page page
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DESCRIPTION
A propeller shaft (Fig. 1), (Fig. 2), and (Fig. 3) is
the shaft which connects the transmission/transfer
case to the axle differential. This is the link through
which the engine power is transmitted to the axle.
The propeller shaft is designed and built with the
yoke lugs in line with each other which is called zero
phasing. This design produces the smoothest running
condition, an out-of-phase shaft can cause a vibra-
tion.
Tubular propeller shafts are balanced by the man-
ufacturer with weights spot welded to the tube.
Use the exact replacement parts when installing
the propeller shafts. The use of the correct replace- Fig. 1 FRONT PROPELLER SHAFT
ment parts helps to ensure safe operation. All fasten- 1 - PROPELLER SHAFT
ers must be torqued to the specified values for safe 2 - CONSTANT VILOCITY JOINT
operation. 3 - COMPANION FLANGE
4 - BOLT
5 - COMPANION FLANGE
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3-2 PROPELLER SHAFT AN
PROPELLER SHAFT (Continued)
Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash
material on shaft. with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws and
tighten to proper torque.
3) Loose or bent U-joint yoke or 3) Install new yoke.
excessive runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of 7) Installl new propeller shaft.
balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test, and
condition. evaluate.
10) Excessive drive pinion gear shaft 10) Re-index propeller shaft and
runout. evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as necessary.
RUNOUT
(1) Remove dirt, rust, paint and undercoating from
the propeller shaft surface where the dial indicator
will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180°,
and re-install the propeller shaft. Measure shaft
Fig. 5 Clamp Screw At Position 1 runout again.
1 - CLAMP
(6) If the propeller shaft runout is now within
2 - SCREWDRIVER specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
STANDARD PROCEDURES
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn.
(1) Remove any external bearing snap rings, if
equipped, from universal joint so protractor base sits
flat.
(2) Rotate the shaft until transmission/transfer
case output yoke bearing is facing downward.
SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS
SPECIAL TOOLS (2) Mark a line across the transfer case flange and
C/V for installation reference.
PROPELLER SHAFT (3) Mark a line across the propeller shaft flange
yoke and front axle companion flange for installation
reference.
(4) Remove companion flange bolts (Fig. 13).
(5) Remove transfer case flange bolts and remove
propeller shaft.
Inclinometer 7663
INSTALLATION
(1) Install propeller shaft with with all reference
marks aligned.
Installer Bearing 6052
(2) Loosely install bolts to C/V and transfer case
PROPELLER SHAFT - FRONT companion flange.
(3) Install bolts to companion flange and flange
REMOVAL yoke and tighten to 108 N·m (80 ft. lbs.).
(4) Tighten bolts to transfer case companion flange
(1) Position transmission and transfer case to their
to 30.5 N·m (22.5 ft. lbs.).
neutral positions. Raise and support vehicle. Remove
(5) Install skid plate, if equipped.
skid plate, if equipped.
(6) Lower vehicle and road test to verify repair.
AN PROPELLER SHAFT 3-9
INSTALLATION
Fig. 14 Propeller Shaft (1) Install new slinger on shaft and drive into posi-
1 - COMPANION FLANGE tion with appropriate installer tool.
2 - FLANGE YOKE (2) Install new center bearing on shaft with Bear-
3 - REAR PROPELLER SHAFT ing Installer Tool 6052. Drive on shaft with hammer
until bearing is seated.
(3) Clean shaft splines and apply a coat of multi–
INSTALLATION purpose grease.
(1) Slide the slip yoke onto the transmission, or (4) Align master splines and slide front and rear
transfer case, output shaft. half-shafts together. Reposition slip yoke boot and
(2) Align and install the center bearing and heat install new clamp.
shield to the support bracket, if necessary. Install the (5) Install propeller shaft in vehicle.
bolts and tighten to 68 N·m (50 ft. lbs.).
(3) Align companion flange reference mark with
flange yoke mark.
(4) Install companion flange bolts and tighten to
108 N·m (80 ft. lbs.).
(5) Lower the vehicle.
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3 - 10 PROPELLER SHAFT AN
CENTER BEARING (Continued)
ASSEMBLY
NOTE: The following procedure is described for a
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
HALF SHAFT
TABLE OF CONTENTS
page page
SPECIFICATIONS
HALF SHAFT
TORQUE SPECIFICATIONS
Remover/Installer C-4124
(5) Remove the hub nut and washer from the stub
Fig. 5 Front
shaft (Fig. 4).
(6) Remove the wheel and tire. 1 - DRIVESHAFT
2 - FRONT AXLE
3 - STEERING KNUCKLE
INSTALLATION
(1) Insert the C/V drive shaft stub into the hub
bearing bore of the steering knuckle.
(2) Apply a light coating of wheel bearing grease
on the axle shaft splines.
(3) Install the inner C/V joint onto the axle shaft
flange. Push firmly on the shaft until the axle shaft
snap-ring engages with the groove on the inside of
the joint housing.
(4) Clean hub bearing bore, axle driveshaft splines,
and hub bearing mating surface of all foreign mate-
rials. Apply light coating of grease to all mating sur-
Fig. 4 Hub Nut & Washer
faces.
1 - DRIVE SHAFT
(5) Install the hub bearing to the axle driveshaft
2 - HUB WASHER
and the steering knuckle.
3 - HUB NUT
(6) Install the bolts to hold the hub bearing to the
steering knuckle. Refer to Group 2, Suspension, for
(7) Remove the brake caliper and rotor, refer to the proper torque.
Group 5 Brakes for procedures. (7) Clean all foreign material from the stub shaft
(8) Remove the ABS wheel speed sensor if threads. Install the hub nut and washer.
equipped. Refer to Group 5 Brakes for procedures. (8) Install the ABS wheel speed sensor, if
(9) Remove the bolts holding the hub bearing to equipped. Refer to Group 5, Brakes, for proper proce-
the knuckle. dures.
(10) Remove hub bearing from axle driveshaft and (9) Install the brake caliper and rotor. Refer to
steering knuckle. Group 5, Brakes, for proper procedures.
(11) Support the drive shaft at the C/V joint hous- (10) Apply the brakes and tighten hub nut to 244
ings. N·m (180 ft. lbs.) torque.
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3 - 16 HALF SHAFT AN
AXLE SHAFT (Continued)
(11) Install the spring washer, nut lock and cotter Apply only the specified lubricant amount to each
pin on the stub shaft (Fig. 6) . C/V joint.
(1) Clean the C/V joints and shaft of all old grease
and foreign matter.
(2) Slide the inner C/V joint boot up the shaft and
insert the lip located within the small-diameter end
of the boot into the shaft groove (Fig. 7).
(3) Retain the small–diameter of the boot on the
shaft with a ladder-type clamp in the boot groove
(Fig. 7). Verify that the boot and lip are properly
positioned on the intermediate shaft. Position the
clamp locating tabs in the slots and tighten the
clamp.
(4) Compress the clamp bridge with Remover/In-
staller C-4124. Squeeze the tool handles to complete
Fig. 6 Cotter Pin Installation the tightening of the clamp (Fig. 8). Care must be
1 - COTTER PIN exercised when using the tool to avoid cutting
2 - NUT LOCK through the clamp bridge or damaging the
boot.
(12) Install the skid plate, if equipped.
(13) Install the wheel and tire.
CV BOOT
REMOVAL
(1) Remove axle driveshaft from vehicle.
(2) Remove outer C/V joint.
(3) Remove outer C/V joint small clamp and
remove boot (Fig. 7).
(4) Remove inner C/V joint boot clamps and
remove boot.
CV JOINT - OUTER
REMOVAL
(1) Clamp shaft in a vise (with soft jaws) and sup- Fig. 10 Ball Access
port C/V joint. 1 - ALIGNMENT MARKS
(2) Remove clamps from the C/V joint and discard. 2 - BEARING HUB
(3) Slide the boot off the outer joint and down the 3 - BEARING CAGE
shaft. 4 - HOUSING
(4) Remove lubricant to expose the C/V joint snap
ring. (9) Press down one side of the bearing cage/hub to
(5) Open snap ring and slide the joint off the shaft gain access to a ball at the opposite. If joint is tight,
(Fig. 9). use a hammer and brass drift to loosen the bearing
hub. Do not contact the bearing cage with the
drift.
(10) Remove ball from the bearing cage (Fig. 11). If
necessary, a small pry bar can be used to pry the ball
loose from the cage.
CAUTION: Prevent damage to the slinger after (8) Position the small-diameter end of the replace-
installation or a when a replacement outer C/V joint ment boot on the interconnecting shaft. Retain the
is installed. boot with a replacement clamp.
(9) Apply the required amount of lubricant to the
outer C/V joint and boot.
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3 - 20 HALF SHAFT AN
CV JOINT - OUTER (Continued)
(10) Align the shaft splines to the outer C/V joint
splines. Push the outer C/V joint until the snap ring
seats in the groove (Fig. 20).
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
CV JOINT - INNER
REMOVAL Fig. 22 Tripod C-Clip
(1) Remove the axle driveshaft.
1 - SNAP RING
(2) Place the C/V joint housing in a vise. 2 - CHAMFERED EDGE
(3) Remove the inner boot retaining clamps. Pull 3 - GROOVE
the inner boot back onto the interconnecting shaft. 4 - C-CLIP
Discard the retaining clamps. 5 - TRIPOD
(4) Pull tripod and shaft straight out from the
inner C/V joint housing.
(5) Remove snap ring from behind the tripod and
slide tripod toward the center of the shaft (Fig. 21).
(6) Remove C-clip from the end of the shaft (Fig.
22).