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remove.
(12) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752. (Fig. 5).
INSTALLATION
INSTALLATION - GAS ENGINE
NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring.
(1) Coat the oil seal and washer with high temp
grease.
NOTE: Install the oil seal with the lip facing inward. Flat side of the washer.
the oil seal should be against
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7). (3) Install backup washer. (4) Install the retainer ring with snap ring pliers.
DR PITMAN SHAFT SEAL (Continued)
Fig.7SEALINSTALLATION
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8989
3 - STEERING GEAR(5) Coat the dust seal with high temp grease. (6) Install the dust seal with a driver and handle
(7) Install protective seal protector 8993 over the
(Fig. 7).
shaft (Fig. 8).
GEAR - LINK/COIL
19 - 25
INSTALLATION - DIESEL
NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring.
(1) Coat the oil seal and washer with high temp
grease.
NOTE: Install the oil seal with the lip facing inward. Flat side of the washer.
the oil seal should be against
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7). (3) Install backup washer. (4) Install the retainer ring with snap ring pliers. (5) Coat the dust seal with high temp grease. (6) Install the dust seal with special tool 8989
driver and C-4171 handle (Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(10) Install
the steering gear
(Refer
to 19 -
STEERING/GEAR - INSTALLATION).
(11) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(12) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
STEERING GEAR INPUT SHAFT SEAL REMOVAL
(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment
(2) Mount the steering gear upside down over a
drain pan in a soft jawed vise.
(3) Place a drain pan under the gear and rotate the input shaft back and forth several times lock-to- lock to discharge the fluid from the steering gear (4) Drain all the remaining fluid from the gear. (5) Rotate the input shaft from stop to stop and count the number of turns using a 12 point socket (Fig. 9).
Fig.8PITMANSHAFTSEALPROTECTOR
1 - STEERING GEAR 2 - SPECIAL TOOL 8993
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(10) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
GEAR - LINK/COIL
19 - 26
STEERING GEAR INPUT SHAFT SEAL (Continued)DR
NOTE: The pitman shaft will not clear the housing if it is not centered.
(6) Center the input shaft by rotating it from the stop back 1 1/2 turns to achieve center position (Fig. 9).
(10) Remove the valve housing and wormshaft assembly from the steering gear housing and place the valve housing in a soft jawed vise (Fig. 11).
Fig.9CENTERINGSTEERINGGEAR
1 - VALVE HOUSING 2 - SET SCREW 3 - RETAINER RING
Fig.11VALVEHOUSINGANDWORMSHAFT
1 - STEERING GEAR 2 - 12 POINT SOCKET 3 - RATCHET 4 - INPUT SHAFT
(11) Remove the retainer ring set screw from the
valve housing (Fig. 12).
(7) Remove the pitman shaft
(Refer
to 19 -
STEERING/GEAR/PITMAN SHAFT - REMOVAL).
(8) Remove the four bolts securing the valve hous-
(9) Remove the valve housing from the steering
ing.
gear (Fig. 10).
Fig.12SETSCREWFORTHERETAINERRING
1 - SET SCREW 2 - 3/32 ALLEN HEAD SOCKET 3 - RETAINER RING
Fig.10VALVEASSEMBLY
1 - VALVE HOUSING 2 - WORMSHAFT BALLS 3 - STEERING GEAR HOUSING
DR STEERING GEAR INPUT SHAFT SEAL (Continued)
GEAR - LINK/COIL
19 - 27
(12) Using special tool reatainer ring wrench to remove the steering gear worm thrust bearing reatainer ring (Fig. 13).
(14) Remove the dust seal with a pick (Fig. 15).
Fig.13REATINERRINGREMOVAL
1 - SPECIAL TOOL 8988
2 - RATCHET(13) Separate the wormshaft assembly from the valve housing, Then remove the wormshaft assembly from the vise (Fig. 14).
Fig.15DUSTSEALREMOVAL
1 - PICK 2 - VALVE HOUSING 3 - SEAL
CAUTION: Use care not to score the housing bore when removing seals.
(15) Remove the snap ring with snap ring pliers
(Fig. 16).
Fig.14WORMSHAFTANDVALVEASSEMBLY
Fig.16SNAPRINGREMOVAL
1 - PISTON TEFLON SEALS 2 - RETAINER RING
1 - SNAP RING PLIERS 2 - SNAP RING 3 - VALVE HOUSING
GEAR - LINK/COIL
19 - 28
STEERING GEAR INPUT SHAFT SEAL (Continued)(16) Using special tool slide hammer C-3752 with
adapter 8990 remove the oil seal (Fig. 17).
DR
Fig.17OILSEALREMOVAL
1 - VALVE HOUSING 2 - SPECIAL TOOL 3 - TORQUE WRENCH
Fig.18RETAINERRINGINSTALLATION
1 - SPECIAL TOOL 8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSINGINSTALLATION
(1) Inspect the piston teflon seals for damage.
Replace if needed.
NOTE: To replace the teflon seals, use a pick to remove the teflon o-ring and the rubber o-ring underneath. Install a new rubber o-ring in the piston seal grove and a new teflon o-ring over the top of it.
(2) Install the valve into the valve housing. (3) Thread the retainer ring into the valve housing
(Fig. 18). Tighten to 97 N·m (72 ft. lbs.)
NOTE: It is very important to make sure to compen- sate for the added length of the torque wrench when torquing to proper specifications.
(4) Install the retainer ring set screw. Tighten to
2.26 N·m (20 in. lbs.)
(5) Clean the steering gear housing.
CAUTION: Valve assembly must be centered to the housing (Fig. 19).
(6) Install the valve assembly into the steering gear (Fig. 19). Tighten the new bolts to 54 N·m (40 ft. lbs.)
(7) Install the input shaft seal protector 8986 (Fig.
20).
(8) Coat the new seal in high temp grease and Install the new oil seal using special tool 8987 driver and C-4171 handle (Fig. 21).
Fig.19CENTEREDGEARTEETH
1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN HOLE 2 - VALVE HOUSING
NOTE: Drive the oil seal into the housing until the outer edge does not quite clear the snap ring groove.
(9) Insert the snap ring into the housing. Using special tool 8987 driver and C-4171 handle push the snap ring and oil seal together until the snap ring seats in the groove.
NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring.
DR STEERING GEAR INPUT SHAFT SEAL (Continued)
GEAR - LINK/COIL
19 - 29
(14) Install the steering gear to the vehicle (Refer
to 19 - STEERING/GEAR - INSTALLATION).
(15) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
PITMAN SHAFT
REMOVAL
REMOVAL - GAS
Fig.20INPUTSHAFTSEALPROTECTOR
1 - INPUT SHAFT 2 - SPECIAL TOOL 8986
Fig.21INPUTSHAFTSEALINSTALLATION
1 - VALVE HOUSING 2 - SPECIAL TOOL 8987
3 - SPECIAL TOOL C-4171(10) Install the new dust seal using high temp grease, special tool C-4171 (driver) and 8987 (han- dle).
(11) Check to make sure the gear is centered in the middle tooth before installing the pitman shaft (Fig. 19).
(12) Install the pitman shaft into the steering gear (Refer to 19 - STEERING/GEAR/PITMAN SHAFT - INSTALLATION).
(13) Perform over-center meshload adjustment (Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(1) Separate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the steering wheel from stop to stop and
count the number of turns.
(4) Center the steering wheel by rotating it from the stop back 1 1/2 turns to achieve center position.
(5) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if it is not centered.
(6) Remove the pitman shaft from the gear (Fig.
22).
Fig.22PITMANSHAFT
1 - PITMAN SHAFT 2 - O-RING SEAL 3 - COVER 4 - ADJUSTING NUT
(7) Remove the cover if needed by loosing the adjuster nut, Then removing the cover from the pit- man shaft.
GEAR - LINK/COIL
19 - 30
PITMAN SHAFT (Continued) REMOVAL - DIESELDR
(1) Separate the pitman arm from the gear box (Refer to 19 - STEERING/LINKAGE/PITMAN ARM - REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
with a wire brush.
(4) Clean exposed end of pitman shaft and housing
(5) Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns (Fig. 23).
(6) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 23).
Fig.24PITMANSHAFT
1 - PITMAN SHAFT 2 - O-RING SEAL 3 - COVER 4 - ADJUSTING NUT
INSTALLATION
INSTALLATION - GAS
(1) Coat the seal with power steering fluid. (2) Install pitman shaft into the steering gear until
it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(4) Perform over-center meshload
adjustment, (Refer to 19 - STEERING/GEAR - ADJUSTMENTS). (5) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(6) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - DIESEL
(1) Coat the seal with power steering fluid. (2) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N·m (50 ft. lbs.).
(4) Perform over-center meshload
adjustment (Refer to 19 - STEERING/GEAR - ADJUSTMENTS). (5) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(6) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(7) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
Fig.23CENTERINGSTEERINGGEAR
1 - STEERING GEAR 2 - 12 POINT SOCKET 3 - RATCHET 4 - INPUT SHAFT
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if it is not centered.
(8) Remove the pitman shaft from the gear (Fig.
24).
(9) Remove the cover if needed by loosing the adjuster nut, Then removing the cover from the pit- man shaft.
DR
LINKAGE - INDEPENDENT FRONT SUSPENSION
19 - 31
LINKAGE - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page
page
LINKAGE - INDEPENDENT FRONT
TIE ROD END
SUSPENSION DIAGNOSIS AND TESTING - OUTER TIE ROD
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LINKAGE - INDEPENDENT FRONT SUSPENSION DIAGNOSIS AND TESTING - OUTER TIE ROD END
NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
(2) Remove the front tires. (3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.
(4) Position indicator plunger on the topside of the
outer tie rod end.
NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the outer tie rod end.
(5) Position a pry bar in order to pry downwards
on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace the outer tie rod end (Refer to 19 - STEERING/ LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall tires (Refer to 22 - TIRES/WHEELS/
the front WHEELS - STANDARD PROCEDURE).
REMOVAL - OUTER TIE ROD END . . . . . . . . . . 31
INSTALLATION - OUTER TIE ROD END . . . . . . 32TIE ROD END REMOVAL - OUTER TIE ROD END
NOTE: Do not twist removal or installation.
the boot anytime during
(1) Loosen the jam nut. (2) Remove the outer tie rod end nut from the ball
(3) Separate the tie rod ball stud from the knuckle
with Remover 8677 (Fig. 1).
(4) Unthread the outer tie rod end from the inner
stud.
tie rod.
Fig.1TIERODSEPARATION
1 - TIE ROD END 2 - SPECIAL TOOL 8677
LINKAGE - INDEPENDENT FRONT SUSPENSION
19 - 32
TIE ROD END (Continued) INSTALLATION - OUTER TIE ROD ENDDR
NOTE: Do not removal or installation.
twist
the boot at anytime during
(1) Thread the outer tie rod end onto the inner tie
rod, to it’s original position (Fig. 2).
(2) Install the outer tie rod end into the steering
knuckle (Fig. 2).
(3) Tighten the ball stud nut on the ball stud to 61
N·m (45 ft. lbs.) then an additional 90°.
(4) Set wheel toe pattern, (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- DURE).
(5) Tighten jam nut to 75 N·m (55 ft. lbs.) (Fig. 2).
Fig.2TIERODEND
1 - JAM NUT 2 - TIE ROD - INNER 3 - TIE ROD END - OUTER
DR
LINKAGE - LINK/COIL
19 - 33
LINKAGE - LINK/COIL
TABLE OF CONTENTS
page
page
LINKAGE - LINK/COIL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
STANDARD PROCEDURE - LUBRICATION . . . . 34
SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 34
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . 35
DAMPER
PITMAN ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36TIE ROD END
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37TRACK BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37DRAG LINK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LINKAGE - LINK/COIL DESCRIPTION
The steering linkage is comprised of a tie rod end, tie rod, drag link, steering damper and pitman arm (Fig. 1).
CAUTION: If any steering components are replaced or serviced an alignment must be performed.
NOTE: To avoid damaging ball stud seals, use Puller C-3894–A or an appropriate puller to remove tie rod ends (Fig. 2).
Fig.1LINK/COILFRONTSUSPENSION
1 - STABILIZER BAR 2 - PITMAN ARM 3 - STEERING GEAR 4 - STABILIZER LINK 5 - TIE ROD ENDS 6 - LOWER SUSPENSION ARMS 7 - DRAG LINK 8 - TRACK BAR 9 - DAMPER 10 - UPPER SUSPENSION ARM
LINKAGE - LINK/COIL
19 - 34
LINKAGE - LINK/COIL (Continued)DR
STANDARD PROCEDURE - LUBRICATION
Periodic lubrication of the steering system compo- nents is required. Refer to Lubrication And Mainte- nance for the recommended maintenance schedule.
The following components must be lubricated: † Tie rod † Tie rod end † Drag link
Fig.2BallStudPuller
1 - CLAMP 2 - ADJUSTMENT SLEEVE 3 - PULLER TOOL C-3894–A 4 - SEAL 5 - TIE-ROD END
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
Pitman Arm
Gear Shaft Nut
Drag Link Pitman Arm Drag Link Tie Rod Drag Link
Adjuster Clamp
Tie Rod End
Knuckle
Tie Rod End
Adjuster Clamp
Stabilizer Bar Link to Axle
Steering Damper
Axle
Steering Damper
Tie Rod
TORQUE SPECIFICATIONS
N·m 300
88
108
61
108
61
68
9581
Ft. Lbs.
225
65
80
45
80
45
50
7060
In. Lbs.
—
—
—
—
—
—
— —
—
LINKAGE - LINK/COIL
19 - 35
(2) Remove the drag link nut from the knuckle
side.
(3) Remove the drag link from the right knuckle
and pitman arm with Puller C-3894A (Fig. 3).
DR LINKAGE - LINK/COIL (Continued) SPECIAL TOOLS
STEERING LINKAGE
RemoverBallStudMB-991113
PullerTieRodC-3894-A
Fig.3DRAGLINKREMOVAL
1 - PITMAN ARM 2 - DRAGLINK 3 - C -3894-A PULLER
INSTALLATION
(1) Install the drag link to the pitman arm. Install
the nut and tighten to 88 N·m (65 ft. lbs.).
(2) Install
the drag link to the right steering knuckle. Install the nut and tighten to 108 N·m (80
ft. lbs.).(3) Install tie rod to the left steering knuckle and drag link. Install the nuts and tighten to 108 N·m (80 ft. lbs.).
(4) Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain- ing bolt is located on the bottom side of the sleeve.
PITMAN ARM REMOVAL
(1) Remove the drag link from the right knuckle
and pitman arm with Puller C-4150A (Fig. 4).
(2) Mark the pitman arm and shaft positions for installation reference. Remove the nut and washer from the pitman arm (Fig. 5). Remove the pitman arm with Puller C-4150A.
RemoverBallJointC-4150A
DAMPER REMOVAL
(1) Remove the steering damper mounting nuts
and bolts.
(2) Slide the damper from the isolation bushing. (3) Remove the damper.
INSTALLATION
(1) Install the steering damper on the axle and iso-
lation bushing. Tighten nut to 95 N·m (75 ft. lbs.).
(2) Install the steering damper on the tie rod.
Tighten nut to 81 N·m (60 ft. lbs.).
DRAG LINK REMOVAL
(1) Remove the draglink nut from the pitman arm
side.
19 - 36
LINKAGE - LINK/COIL PITMAN ARM (Continued)DR
Fig.4PITMANARMREMOVAL
Fig.6PITMANARMINSTALLED
1 - PITMAN ARM 2 - C-4150A PULLER
1 - DRAGLINK 2 - STEERING GEAR 3 - SWAYBAR 4 - NUT/WASHER 5 - PITMAN ARM
NOTE: Position the clamp on the sleeve so retain- ing bolt is located on the bottom side of the sleeve.
TIE ROD END REMOVAL
(1) Remove tie rod nuts (Fig. 7). (2) Remove tie rod from drag link and left knuckle
with Puller C-4150A.
Fig.5PITMANARMREMOVAL/INSTALLATION
1 - STEERING GEAR 2 - PITMAN ARM 3 - NUT 4 - WASHER
INSTALLATION
(1) Align reference marks and install pitman arm. (2) Install the lock washer and retaining nut on the pitman shaft and tighten nut to 251 N·m (185 ft. lbs.).
(3) Install the drag link to the pitman arm (Fig. 6). Install the nut and tighten to 108 N·m (80 ft. lbs.). (4) Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).
Fig.7TIERODENDS
1 - NUT 2 - TIE ROD ENDS
DR TIE ROD END (Continued) INSTALLATION
LINKAGE - LINK/COIL
19 - 37
(1) Install tie rod to the left steering knuckle and drag link. Install the nuts and tighten to 108 N·m (80 ft. lbs.).
(2) Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(3) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N·m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain- ing bolt is located on the bottom side of the sleeve.
TRACK BAR REMOVAL
(1) Raise and support the axle. (2) Remove the track bar bolts and nuts (Fig. 8). (3) Remove the track bar (Fig. 8).
INSTALLATION
(1) Install the track bar. (2) Install the new bolts and nuts. Tighten to 203
N·m (150 ft lbs.).
Fig.8TRACKBARREMOVAL/INSTALLATION
1 - TRACK BAR 2 - BOLT 3 - NUT
(3) Remove the supports under the axle and lower
the vehicle to the ground.
19 - 38
PUMP
PUMP
TABLE OF CONTENTS
page
DR
page
PUMP
INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 39
STANDARD PROCEDURESTANDARD PROCEDURE - POWER
INSTALLATION - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . 43INSTALLATION - PRESSURE HOSE INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER . . . . . . . . . . . . . . . 43
STEERING PUMP - INITIAL OPERATION . . . . 39
HOSES - LINK/COIL
STANDARD PROCEDURE - FLUSHING
REMOVAL
POWER STEERING SYSTEM . . . . . . . . . . . . 39
REMOVAL - RETURN HOSE - GEAR TO
REMOVAL
REMOVAL - GAS . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . 40INSTALLATION
INSTALLATION - GAS INSTALLATION - DIESEL
. . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . 41SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 41
FLUID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
STANDARD PROCEDURE - POWERSTEERING FLUID LEVEL CHECKING . . . . . . 42
FLUID COOLER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 43
REMOVAL - RETURN HOSE - RESERVOIRTO COOLER . . . . . . . . . . . . . . . . . . . . . . . . . 43
PUMP DESCRIPTION
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley.
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 44
REMOVAL - RETURN HOSE - RESERVOIRTO COOLER . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . 44INSTALLATION - PRESSURE HOSE INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER . . . . . . . . . . . . . . . 44
POWER STEERING PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL - 3.7L, 4.7L & 5.7L . . . . . . . . . . . . . . 45
. . . . . . . . . . 45
INSTALLATION - 3.7L, 4.7L & 5.7LPULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange- able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer- ing gear by the belt driven power steering pump (Fig. 1). The power steering pumps are constant flow rate and displacement, vane-type pumps.
DR PUMP (Continued)
PUMP
19 - 39
(1) Turn steering wheel all the way to the left (2) Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground. (4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid level.NOTE: For vehicles with long return lines or oil coolers turn wheel 40 times.
Fig.1POWERSTEERINGPUMP
1 - 3.7L & 4.7L (6 GROOVE) PHENOLIC (PLASTIC TYPE) PULLEY 1 - 5.7L,5.9L & 8.0L (7 GROOVE) PHENOLIC (PLASTIC TYPE) PULLEY 1 - 5.9L DIESEL (8 GROOVE) STEEL PULLEY 2 - PUMP ASSEMBLY 3 - RESERVOIR 4 - CAP
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir o-rings can be replaced. Check for leaks in the following areas: † Pump shaft seal behind the pulley † Pump to reservoir O-ring † Reservoir cap † Pressure and return lines † Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION
THE FLUID LEVEL SHOULD BE WARNING: CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS.
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature.
(5) Start the engine. With the engine idling main-
tain the fluid level.
for two minutes.
(6) Lower the front wheels and let the engine idle
(7) Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER STEERING SYSTEM
Flushing is required when the power steering/hy- draulic booster system fluid has become contami- nated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steer- ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: booster remove both return lines from the pump.
If vehicle is equipped with a hydraulic
(3) Plug the return line port/ports at the pump. (4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
(6) With the engine running at idle turn the wheel
start the engine.
back and forth.
NOTE: Do not contact or hold the wheel against the steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering Pump Initial Operation, (Refer to 19 - STEERING/ PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
PUMP
19 - 40
PUMP (Continued)(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again.
(12) Install
Steering Pump Initial Operation, STEERING/PUMP - STANDARD PROCEDURE).
the return line/lines and perform (Refer to 19 -
REMOVAL
REMOVAL - GAS
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67Nm, 40 - 50 lbft) If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled prop- erly. If this occurs the pump needs to be replaced with a new pump.
(3) Disconnect the return hose. (Fig. 2) (4) Disconnect the pressure hose. (Fig. 2) (5) Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes. (Fig. 2)
DR
REMOVAL - DIESEL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67Nm, 40 - 50 lbft) If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled prop- erly. If this occurs the pump needs to be replaced with a new pump.
(3) Disconnect the return hose. (4) Disconnect the pressure hose. (5) Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes.
(6) Loosen the pump bracket to the block. (7) Remove the 6 intake plenum bolts (Fig. 3). (8) loosen the inner cooler tube clamp at intake plenum and remove the intake plenum.
the
(9) Loosen the inner cooler tube clamp at the radi- ator support side and remove the tube from the vehi- cle.
(10) Remove the power steering pump from the top of the engine compartment where the intake plenum was (Fig. 3).
Fig.2POWERSTEERINGPUMP
1 - INTAKE PLENUM MOUNTING 2 - POWER STEERING PUMP
Fig.3POWERSTEERINGPUMPACCESS
1 - POWER STEERING PULLEY 2 - POWER STEERING RESERVOIR 3 - RETURN HOSE 4 - HIGH PRESSURE HOSE
DR PUMP (Continued) INSTALLATION
INSTALLATION - GAS
left cylinder head.
(1) Align the pump with the mounting holes in the
(2) Install 3 pump mounting bolts through the pul- ley access holes. Tighten the bolts to 28 N·m (21 ft. lbs.).
(3) Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 37 N·m (27 ft. lbs.).
(4) Install the serpentine drive belt, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
PUMP
19 - 41
INSTALLATION - DIESEL
(1) Set the power steering pump in place in the
engine compartment from the top (Fig. 3).
(2) Install the inner cooler tube. (3) Tighten the inner cooler tube clamp at the
radiator support side.
(4) Install the 6 intake plenum bolts (Fig. 3). (5) Tighten the inner cooler tube clamp at the
intake plenum.
(6) Install 3 pump mounting bolts through the pul- ley access holes. Tighten the bolts to 28 N·m (21 ft. lbs.).
(7) Tighten the pump bracket to the block. (8) Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 37 N·m (27 ft. lbs.).
(9) Install the serpentine drive belt, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(10) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
Power Steering Pressure
Switch
Power Steering Line
Pressure Line
Power Steering Line
Return Line
Power Steering Line
Pressure Line To Pump Power Steering Pump
Mounting Bolts
Power Steering Pump
Reservoir Bolts
Power Steering Pump
Bracket Bolts
TORQUE SPECIFICATIONS
N·m 10
32
71
37
28
Ft. Lbs.
In. Lbs.
—
23
52
27
27
80
—
—
—
—
—
—
19 - 42
PUMP
FLUID DESCRIPTION
DR
(3) Remove the mounting bracket bolts securing
the fluid cooler to the brace. (Fig. 4)& (Fig. 5) (4) Remove the fluid cooler from the vehicle.
The recommended fluid for the power steering sys-
tem is Mopart ATF +4.
Mopart ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or anti- freeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.
STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS.
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
Fig.4V6&V8P/SFLUIDCOOLER
1 - POWER STEERING FLUID COOLER 2 - MOUNTING BOLTS
The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold.
Use only Mopart ATF+4 Do not overfill the
power steering system.
FLUID COOLER REMOVAL
(1) Drain and siphon the power steering fluid. (2) Disconnect the return and supply hoses con-
nected to the power steering fluid cooler.
Fig.5V10&DIESELP/SFLUIDCOOLER
1 - RADIATOR 2 - POWER STEERING HOSES 3 - MOUNTING BOLTS 4 - P/S FLUID COOLER
INSTALLATION
(1) Install the fluid cooler to the vehicle. (2) Install the mounting bracket bolts securing the
fluid cooler to the brace (Fig. 4)& (Fig. 5).
(3) Reclamp the return and supply hoses to the
power steering fluid cooler.
(4) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
DR
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO COOLER
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the return hose at the cooler. (4) Disconnect the return hose at the gear (Fig. 6). (5) Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle.
Fig.6HOSECONNECTIONS
1 - RETURN HOSE 2 - PRESSURE HOSE
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the pressure hose at the pump. (4) Disconnect the pressure hose at the gear (Fig.
6).
PUMP
19 - 43
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reconnect the return hose at the gear. Tighten
the hose to 71 N·m (52 ft. lbs.) (Fig. 6).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle. (2) Reconnect
the pressure hose at
the gear.
Tighten the hose to 32 N·m (23 ft. lbs.) (Fig. 6).
(3) Reconnect
the pressure hose at Tighten the hose to 36 N·m (27 ft. lbs.).
the pump.
(4) Remove the support and lower the vehicle. (5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle. (5) Reconnect the return hose at the reservoir. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(5) Remove the pressure hose from the vehicle.
HOSES - LINK/COIL
REMOVAL - RETURN HOSE - RESERVOIR TO COOLER
REMOVAL
(1) Drain and siphon the power steering system. (2) Disconnect the return hose at the reservoir. (3) Raise and support the vehicle. (4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler. (6) Remove the hose from the vehicle.
REMOVAL - RETURN HOSE - GEAR TO COOLER
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the return hose at the cooler. (4) Disconnect the return hose at the gear (Fig. 7). (5) Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle.
PUMP
19 - 44
HOSES - LINK/COIL (Continued)DR
REMOVAL - RETURN HOSE - RESERVOIR TO COOLER
(1) Drain and siphon the power steering system. (2) Disconnect the return hose at the reservoir. (3) Raise and support the vehicle. (4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler. (6) Remove the hose from the vehicle.
Fig.7POWERSTEERINGHOSESTOSTEERING
GEAR
1 - HIGH PRESSURE HOSE 2 - RETURN HOSE 3 - STEERING GEAR
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the pressure hose at the pump. (4) Disconnect the pressure hose at the gear (Fig.
8).
Fig.8HOSESINSTALLED
1 - LOWER COUPLING BOLT 2 - HIGH PRESSURE HOSE 3 - RETURN HOSE 4 - STEERING GEAR 5 - PITMAN ARM
(5) Remove the pressure hose from the vehicle.
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reconnect the return hose at the gear. Tighten
the hose to 71 N·m (52 ft. lbs.) (Fig. 7).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle. (2) Reconnect
the pressure hose at
the gear.
Tighten the hose to 32 N·m (23 ft. lbs.) (Fig. 8).
(3) Reconnect
the pressure hose at Tighten the hose to 36 N·m (27 ft. lbs.).
the pump.
(4) Remove the support and lower the vehicle. (5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle. (5) Reconnect the return hose at the reservoir. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
DR
PUMP
19 - 45
POWER STEERING PRESSURE SWITCH DESCRIPTION
A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose (Fig. 9). This switch will be used with both 3.7L, 4.7L and 5.7L engines. There is no pres- sure switch used for the 5.9L pump.
OPERATION
The switch is used on the 3.7L V-6, 4.7L & 5.7L
V-8 engines.
The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during park- ing maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load.
When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting.REMOVAL - 3.7L, 4.7L & 5.7L
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Disconnect electrical
connector
from power
steering pressure switch.
(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 3.7L, 4.7L & 5.7L
This switch is used only with the 3.7L V–6 and the
4.7L, 5.7L V-8 engines.
(1) Install power steering switch into power steer-
ing line.
sary.
(2) Tighten to 8–11 N·m (70–100 in. lbs.) torque. (3) Connect electrical connector to switch. (4) Check power steering fluid and add as neces-
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
Fig.9PRESSURESWITCH
1 - POWER STEERING PULLEY 2 - POWER STEERING PUMP HOUSING 3 - POWER STEERING FLUID RESERVOIR 4 - RETURN HOSE 5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
PULLEY REMOVAL
CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pul- ley must be installed if removed.
(1) Remove the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - REMOVAL).
(2) Remove the pulley from the pump with an appropriate power steering pulley removal tool (Fig. 10).
Fig.10PULLEYREMOVAL
1 - POWER STEERING PUMP 2 - PULLEY 3 - POWER STEERING PULLEY REMOVAL TOOL
PUMP
19 - 46
PULLEY (Continued) INSTALLATIONCAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pul- ley must be installed if removed.
(1) Replace the pulley if it’s bent, cracked, or loose. (2) Install the pulley on the pump with an appro- priate power steering pulley installation tool (Fig. 11) making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft.
Fig.11PULLEYINSTALLATION
1 - POWER STEERING PUMP 2 - PULLEY 3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL
(3) Install
the power steering pump assembly, (Refer to 19 - STEERING/PUMP - INSTALLATION). (4) Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward
DR
approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts.
RESERVOIR REMOVAL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt. (3) Remove the power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove the reservoir mounting bolts. (5) Remove the reservoir. (6) Remove the rear bracket to the pump mounting
bolts.
INSTALLATION
(1) Install the reservoir bracket to the pump hous- ing. Do not reuse the o-rings (install new o-rings). Tighten bolts to 7 N·m (5 ft. lbs.).
NOTE: Ensure the reservoir is fully seated onto the pump.
(2) Install the reservoir to the bracket/pump body. (3) Install the reservoir mounting bolts. Tighten
bolts to 7 N·m (5 ft. lbs.).
(4) Install the power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(5) Install the serpentine drive belt, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(6) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
DR
TRANSMISSION AND TRANSFER CASE
21 - 1
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV5600
AUTOMATIC TRANSMISSION - 46RE AUTOMATIC TRANSMISSION - 48RE. . . . . . . . . . 1
. . . . . . . . . . 42
. . . . . . . . . . 87
. . . . . . . . 129
. . . . . . . . 310AUTOMATIC TRANSMISSION - 45RFE/545RFE TRANSFER CASE - NV241 GENII TRANSFER CASE - NV271
TRANSFER CASE - NV243
TRANSFER CASE - NV273. . 488
. . . . . . . . . . . 591
. . . . . . . . . . . . . . . . 623
. . . . . . . . . . . . . . . . 658
. . . . . . . . . . . . . . . . 687MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NV3500
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 4CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . 40
SPECIAL TOOLSMANUAL TRANSMISSION - NV3500
DESCRIPTIONThe transmission is a medium-duty 5-speed, con- stant mesh fully synchronized manual transmission with fifth gear overdrive range. The transmission is available in two and four-wheel drive configurations. The transmission gear case consists of two aluminum housings (Fig. 1). The clutch housing is an integral part of the transmission front housing.
A combination of roller and ball bearings are used to support the transmission shafts in the two hous- ings. The transmission gears all rotate on caged type needle bearings. A roller bearing is used between the input and output shaft.
The transmission has a single shaft shift mecha- nism with three shift forks all mounted on the shaft. The shaft is supported in the front and rear housings by bushings and one linear ball bearing. Internal shift components consist of the forks, shaft, shift lever socket and detent components
OPERATION
The manual transmission receives power through the clutch assembly from the engine. The clutch disc is
splined to the transmission input shaft and is turned at engine speed at all times that the clutch is engaged. The input shaft is connected to the transmission coun- tershaft through the mesh of fourth speed gear on the input shaft and the fourth countershaft gear. At this point, all the transmission gears are spinning.
The driver selects a particular gear by moving the shift lever to the desired gear position. This move- ment moves the internal transmission shift compo- nents to begin the shift sequence. As the shift lever moves the selected shift rail, the shift fork attached to that rail begins to move. The fork is positioned in a groove in the outer circumference of the synchro- nizer sleeve. As the shift fork moves the synchronizer sleeve, the synchronizer begins to speed-up or slow down the selected gear (depending on whether we are up-shifting or down-shifting). The synchronizer does this by having the synchronizer hub splined to the mainshaft and moving the blocker ring into contact with the gear’s friction cone. As the blocker ring and friction cone come together, the gear speed is brought up or down to the speed of the synchronizer. As the two speeds match, the splines on the inside of the synchronizer sleeve become aligned with the teeth on the blocker ring and the friction cone and eventually will slide over the teeth, locking the gear to the mainshaft, or countershaft, through the synchronizer.
21 - 2 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
Fig.1NV3500TRANSMISSION
DR MANUAL TRANSMISSION - NV3500 (Continued) DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or an incor- rect lubricant level check. Leaks can occur at the mating surfaces of the gear case, adaptor or exten- sion housing, or from the front/rear seals. A sus- pected leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous- ing will be from the housing oil seals. Leaks at com- ponent mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening or use of a non-recommended sealer.
A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the clutch disc caus- ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a minute or so before checking. These rec- ommendations will ensure an accurate check and avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant level, improper or contaminated lubricants. The con- sequence of using non-recommended lubricants is noise, excessive wear, internal bind and hard shift- ing. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indi- cations of component damage are usually hard shift- ing and noise.
Shift component damage or damaged clutch pres- sure plate or disc are additional probable causes of increased shift effort. Worn/damaged pressure plate or disc can cause incorrect release. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur- ing normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds.
MANUAL TRANSMISSION - NV3500
21 - 3
Severe highly audible transmission noise is gener- ally the initial indicator of a lubricant problem. Insufficient, improper or contaminated lubricant will promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.
REMOVAL
(1) Disconnect battery negative cable. (2) Shift transmission into Neutral. (3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Raise vehicle on hoist. (6) Remove skid plate, if equipped. (7) Drain lubricant if transmission will be disas-
sembled for service.
(8) Mark propeller shaft/shafts and companion installation reference and
for
flange yoke/yokes remove propeller shaft/shafts.
(9) Disconnect harness from clips on transmission
housing.
(10) Remove transfer case linkage if equipped. (11) Remove transfer case mounting nuts and
remove transfer case if equipped.
(12) Remove slave cylinder mounting nut and
remove cylinder (Fig. 2).
Fig.2SLAVECYLINDER
1 - MOUNTING NUTS 2 - SLAVE CYLINDER
21 - 4 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(13) Remove starter motor, structural dust cover,
dust shield and suspension crossmember (Fig. 3).
Fig.3DUSTCOVER
1 - DUST SHIELD 2 - STARTER MOTOR 3 - DUST COVER 4 - CROSSMEMBER
(14) Remove exhaust pipe from the exhaust mani-
folds.
and wood block.
(15) Support engine with adjustable jack stand
(16) Support and secure transmission to a trans-
mission jack with safety chains.
(17) Remove bolts from the rear transmission
mount.
sion mount (Fig. 4).
(18) Remove the rear crossmember and transmis-
(19) Remove bolts attaching transmission to the
engine.
(20) Move transmission rearward until input shaft is clear of clutch disc and pressure plate. Then lower jack and remove transmission from under vehicle.
DISASSEMBLY
FRONT HOUSING
(1) Shift transmission into Neutral. (2) If lubricant was not drained out of transmis- sion during removal, remove drain plug and drain lubricant.
(3) Inspect drain plug magnet for debris. (4) Remove backup light switch located on passen-
ger side of rear housing (Fig. 5).
Fig.5BACKUPLIGHTSWITCH
1 - BACKUP LIGHT SWITCH
(5) Remove shift tower bolts and remove tower and
lever assembly (Fig. 6).
Fig.4CROSSMEMBER
1 - TRANSMISSION MOUNT 2 - CROSSMEMBER
1 - SHIFT TOWER 2 - SHIFT SOCKET 3 - SEAL
Fig.6SHIFTTOWER
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 5
(6) Remove shift shaft lock bolt (Fig. 7) from the top of front housing. The bolt secures the shift shaft bushing and lever.
NOTE: This is a special bolt and can not be substi- tuted with any other bolt.
(8) Remove bearing retainer from input shaft (Fig.
9).
Fig.9INPUTSHAFTBEARINGRETAINER
1 - SHAFT BEARING 2 - BEARING RETAINER 3 - INPUT SHAFT
Fig.7SHAFTLOCKBOLT
(9) Remove input shaft snap ring (Fig. 10).
1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET
