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ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection.
Fig.4NLGISYMBOL
1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS
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.
DESCRIPTION - POWER STEERING FLUID
Mopart ATF +4, Automatic Transmission Fluid is required in the power steering system. Substitute fluids can induce power steering system failure.
Mopart ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF 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.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWAL- LOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMIT- ING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.
Mopart
Antifreeze/Coolant,
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Year/100,000 Mile Formula (MS-9769), or the equiva- lent ethylene glycol base coolant with organic corro- sion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solu- tion.
MoparT
Antifreeze/Coolant,
CAUTION: Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mix- tures follows:
Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for pur- pose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The
corrosion inhibiting additives in ethylene-glycol need the pres- ence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plas- tic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recom- mended mixture, it provides protection against freez- ing to -37°C (-34°F). The antifreeze concentration
LUBRICATION & MAINTENANCE
0 - 4
FLUID TYPES (Continued)must always be a minimum of 44 percent, year- round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec- tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher per- centage of antifreeze can cause the engine to over- heat because specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyl- ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicle’s coolant bottle to iden- tify HOAT or Non-HOAT coolant. Non-HOAT coolant is green in color.
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.
-37°C (-35°F). If
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE - NV241
GENIIRecommended lubricant
for the NV241 GENII transfer case is Mopart ATF +4, Automatic Trans- mission Fluid.
DESCRIPTION - TRANSFER CASE - NV271
Recommended lubricant for the NV271 transfer case is Mopart ATF +4, Automatic Transmission Fluid.
DESCRIPTION - TRANSFER CASE - NV243
Recommended lubricant for the NV243 transfer case
is Mopart ATF +4, Automatic Transmission Fluid.
DESCRIPTION - TRANSFER CASE - NV273
Recommended lubricant for the NV273 transfer case
is Mopart ATF +4, Automatic Transmission Fluid.
DR
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality.
FRONTAXLE
† C205F - Mopart Gear Lubricant 75W-90
† 9 1/4 AA - Mopart Synthetic Gear Lubricant75W-90
REARAXLE
† 9 1/4 - Mopart Synthetic Gear Lubricant 75W-140
† 10 1/2 AA - Mopart Synthetic Gear Lubricant † 11 1/2 AA - Mopart Synthetic Gear Lubricant75W-90
75W-90
NOTE: Trac-LokT differentials require Limited Slip Additive in the lubricant. Trac-Rite™ differentials DO NOT require Limited Slip Additive.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality.
† NV3500 - Mopart Manual Transmission Lubricant † NV4500 - Mopart Synthetic 75W85 Manual † NV5600 - Mopart Manual Transmission Lubri-
Transmission Lubricant
cant
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID
NOTE: Refer to Service Procedures in this group for fluid level checking procedures.
Mopart ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler auto- matic transmissions.
Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid.
Mopart ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF 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.
DR FLUID TYPES (Continued) FLUID ADDITIVES
DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks.
Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been sup- ported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of trans- mission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.
OPERATION - AUTOMATIC TRANSMISSION FLUID
The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays con- stant through the temperature range of operation, transmission operation and shift feel will remain con- sistent. Transmission fluid must also be a good con- ductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
2DESCRIPTION
SPECIFICATION
FUEL TANK
Short Box (Lt. Duty)
Long Box (Lt. Duty)
98 L (26 gal.)*
132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L
4.7L
5.7L
5.9L
8.0L
4.7 L (5.0 qts.)
5.6 L (6.0 qts.)
6.6 L (7.0 qts.)
4.7 L (5.0 qts.)
6.6 L (7.0 qts.)
5.9L DIESEL
10.4 L (11.0 qts.)
LUBRICATION & MAINTENANCE
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2DESCRIPTION
SPECIFICATION
COOLING SYSTEM
3.7L
4.7L
5.7L
5.9L
8.0L
5.9L Diesel Engine
15.4 L (16.2 qts.)**
15.4 L (16.2 qts.)**
15.4L (16.2 qts.)**
15.5 L (16.3 qts.)**
24L (24.3 qts.)**
28L (29.5 qts.)**
POWER STEERING
Power steering fluid capacities are dependent on engine/ chassis options as well as steering gear/cooler options. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these capacities may vary. Refer to 19, Steering for proper fill and bleed procedures.
AUTOMATIC TRANSMISSION
Service Fill - 46RE
O-haul - 46RE
Service Fill - 45RFE/
545RFE
3.8 L (4.0 qts.)
9-9.5L (19-20 pts.) L 4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.) 14-16 L (29-33 pts.) L
O-haul - 45RFE/545RFE L Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC/FLUID -
STANDARD PROCEDURE) MANUAL TRANSMISSION
NV3500 4X2
NV3500 4X4NV4500
NV56002.3 L (4.8 pts.) 2.0 L (4.2 pts.) 3.8 L (8.0 pts.) 4.5 L (9.5 pts.)
TRANSFER CASE
NV241 GENII
NV243
NV271
NV273
1.6 L (3.4 pts.)
1.6 L (3.4 pts.)
1.89 L (4.0 pts.)
1.89 L (4.0 pts.)
FRONT AXLE ± .03 L (1 oz)
C205F 9 1/4 AA
1.66 L (3.5 pts.) 2.25 L (4.75 pts.)
REAR AXLE ± .03 L (1 oz)
9 1/4
10 1/2 AA 11 1/2 AA
2.32 L (4.9 pts.)*** 2.25 L (4.75 pts.) 3.62 L (7.65 pts)
*** With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive.
** Includes 0.9L (1.0 qts.) for coolant reservoir.
*Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
0 - 6
LUBRICATION & MAINTENANCE
DR
MAINTENANCE SCHEDULES DESCRIPTION
Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual.
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. † Day or night temperatures are below 0° C (32° F).† Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 16 km (10 miles). † More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F). † Trailer towing. † Taxi, police, or delivery service (commercial ser- vice).† Off-road or desert operation. † If equipped for and operating with E-85
(ethanol) fuel.NOTE: Most vehicles are operated under the condi- tions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9.
Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.
CAUTION: Failure to perform the required mainte- nance items may result in damage to the vehicle.
AtEachStopforFuel
† Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.† Check the windshield washer solvent and add if required.
OnceaMonth
or damage.
terminals as required.
† Check tire pressure and look for unusual wear † Inspect the battery and clean and tighten the † Check the fluid levels of coolant reservoir, brake master cylinder, power steering and transmission and add as needed. † Check all lights and all other electrical items for
correct operation.
AtEachOilChange
pension components.
† Change the engine oil filter. † Inspect the exhaust system. † Inspect the brake hoses. † Inspect the CV joints (if equipped) and front sus- † Check the automatic transmission fluid level. † Check the manual transmission fluid level. † Check the coolant level, hoses, and clamps. † Rotate the tires at each oil change interval shown on Schedule “A” 10 000 km (6,000 miles) or every other interval shown on Schedule “B” 10 000
km (6,000 miles).Schedule “B”
Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. † Day or night temperatures are below 0° C (32° F).† Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 16 km (10 miles). † More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F). † Trailer towing. † Taxi, police, or delivery service (commercial ser- vice).† Off-road or desert operation. † If equipped for and operating with E-85
(ethanol) fuel.DR MAINTENANCE SCHEDULES (Continued)
LUBRICATION & MAINTENANCE
0 - 7
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary.Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Inspect PCV valve, replace as necessary. Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/ 48RE).‡ Drain and refill automatic tranmission fluid and change main sump filter (45RFE/ 545RFE only).‡Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary.3,000
(5 000)6,000
(10 000)
9,000
(14 000)
21,000
(34 000)18,000
(29 000)24,000
(38 000)12,000
(19 000)15,000
(24 000)27,000
(43 000)30,000
(48 000)X*
33,000
(53 000)39, 000
(62 000)36,000
(58 000)42,000
(67 000)45,000
(72 000)LUBRICATION & MAINTENANCE
0 - 8
MAINTENANCE SCHEDULES (Continued)Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Replace ignition cables (5.7L/5.9L/8.0L). Inspect PCV valve, replace as necessary. Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/ 48RE). Drain and refill automatic tranmission fluid and change main sump filter (45RFE/ 545RFE only).Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Inspect engine air cleaner filter. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L).51,000
(82 000)54,000
(86 000)57,000
(91 000)48,000
(77 000)DR
60,000
(96 000)X*
63,000
66,000
69,000
72,000
75,000
(101 000)
(106 000)
(110 000)
(115 000)
(120 000)
DR MAINTENANCE SCHEDULES (Continued)
LUBRICATION & MAINTENANCE
0 - 9
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Inspect PCV valve, replace as necessary. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L). Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/ 48RE). Drain and refill automatic tranmission fluid and change main sump and spin-on cooler return filter (if equipped) [45RFE/545RFE only].Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Flush and replace engine coolant. Flush and replace Power Steering Fluid. Inspect brake linings.78,000
81,000
84,000
87,000
90,000
(125 000)
(130 000)
(134 000)
(139 000)
(144 000)
X* X‡
93,000
96,000
99,000
(149 000)
(154 000)
(158 000)
100,000
(160 000)102,000
(163 000)LUBRICATION & MAINTENANCE
0 - 10
MAINTENANCE SCHEDULES (Continued)DR
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Replace ignition cables (5.7L/5.9L/8.0L). Inspect PCV valve, replace as necessary. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L). Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/ 47RE/48RE). Drain and refill automatic tranmission fluid and change main sump filter (45RFE/ 545RFE only).
105,000
(168 000)108,000
(173 000)111,000
(178 000)114,000
(182 000)117,000
(187 000)120,000
(192 000)X‡
X*
X‡
* This maintenance is recommended by the manu- facture to the owner but is not required to maintain the emissions warranty.
‡ This maintenance is not required if previously
replaced.
Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.
DR MAINTENANCE SCHEDULES (Continued) Schedule “A”
LUBRICATION & MAINTENANCE
0 - 11
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Check transfer case fluid level. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Inspect brake linings. Replace engine air cleaner filter. Replace spark plugs.6,000
(10 000)
12,000
(19 000)18,000
(29 000)24,000
(38 000)30,000
(48 000)[6]
[12]
[24]
[18]
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Check transfer case fluid level. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Flush and replace engine coolant at 60 months, regardless of mileage. Inspect brake linings. Replace engine air cleaner filter. Replace spark plugs. Inspect PCV valve, replace as necessary. Replace ignition cables (5.7L/5.9L/8.0L).
36,000
(58 000)42,000
(67 000)48,000
(77 000)54,000
(84 000)60,000
(96 000)[36]
[42]
[48]
[54]
[60]
X*
[30]
66,000
(106 000)
[66]
LUBRICATION & MAINTENANCE
0 - 12
MAINTENANCE SCHEDULES (Continued)DR
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Drain and refill transfer case fluid. Flush and replace engine coolant, if not done at 60 mos. Flush and replace Power Steering Fluid. Inspect brake linings. Replace engine air cleaner filter. Replace spark plugs. Replace ignition cables (5.7L/5.9L/ 8.0L). Inspect PCV valve, replace as necessary. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/ 8.0L). Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/48RE). Drain and refill automatic tranmission fluid and change main sump filter and spin-on cooler return filter (if equipped) [45RFE/545RFE only].72,000
78,000
84,000
90,000
96,000
(115 000)
(125 000)
(134 000)
(144 000)
(154 000)
100,000
(160 000)[78]
[84]
[72]
[96]
[90]
X*
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Check transfer case fluid level. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Inspect brake linings. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L). Replace engine air cleaner filter. Replace spark plugs.
102,000
(163 000)108,000
(173 000)114,000
(182 000)120,000
(192 000)[102]
[108]
[114]
[120]
X‡
X‡
* This maintenance is recommended by the manu- facture to the owner but is not required to maintain the emissions warranty.
‡ This maintenance is not required if previously
replaced.
Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.
WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the right equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.
DR
LUBRICATION & MAINTENANCE
0 - 13
JUMP STARTING STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN THE BATTERY SYSTEM SEC- TION OF THE SERVICE MANUAL. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN- DARD PROCEDURE) † DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. † IF EQUIPPED, DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. † DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. † DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. † DO NOT USE OPEN FLAME NEAR BATTERY. † REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCI- DENTAL ARCING OF BATTERY CURRENT. † WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
inspect engine compartment for:
(1) Raise hood on disabled vehicle and visually † Battery cable clamp condition, clean if necessary. † Frozen battery. † Yellow or bright color test indicator, if equipped. † Low battery fluid level. † Generator drive belt condition and tension. † Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis- abled vehicle is severe, damage to booster vehicle charging system can result.
(2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF.
(3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accesso- ries.
(4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to neg- ative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible.
(6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the dis- charged battery.
CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will over- heat and could fail.
(7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 sec- onds, stop cranking engine and allow starter to cool (15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
ground on disabled vehicle.
† Disconnect BLACK cable clamp from engine † When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. † Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
0 - 14
LUBRICATION & MAINTENANCE
DR
HOISTING STANDARD PROCEDURE - HOISTING
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHI- CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO- NENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT (Fig. 5) OR SECURE VEHICLE TO HOIST- ING DEVICE WHEN THESE CONDITIONS EXIST.
† A drive shaft. † The engine or transmission oil pan. † The fuel tank. † A front suspension arm.
NOTE: Use the correct frame rail only (Fig. 7) and (Fig. 8).
lifting locations
HOIST
A vehicle can be lifted with: † A single-post, frame-contact hoist. † A twin-post, chassis hoist. † A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 6). The forward lifting pads should be posi- tioned against the forward flange of the transmis- sion crossmember brackets at the bottom of the frame rail (Fig. 7). The real lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail (Fig. 8). Safety stands should be placed under the frame rails at the front and rear ends (Fig. 5).
Fig.5SafetyStands
1 - SAFETY STANDS
FLOOR JACK
When properly positioned, a floor jack can be used to lift a vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails (Fig. 5).
CAUTION: Do not lift vehicle with a floor jack posi- tioned under: † An axle tube. † A body side sill. † A steering linkage component.
Fig.6VehicleLiftingLocations
DR HOISTING (Continued)
LUBRICATION & MAINTENANCE
0 - 15
Fig.7FRONTLIFTPADLOCATION
1 - BODY MOUNT BRACKET 2 - FRONT LIFT PAD 3 - TRANSMISSION CROSSMEMBER BRACKET 4 - FRAME RAIL
Fig.9TowVehiclesWithApprovedEquipment
1 - SLING TYPE 2 - WHEEL LIFT 3 - FLAT BED
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be observed when towing a vehicle:
being towed.
disabled vehicle’s fuel tank.
while it is lifted by the towing device.
pendent of the lifting and towing equipment.
† Secure loose and protruding parts. † Always use a safety chain system that is inde- † Do not allow towing equipment to contact the † Do not allow anyone under the disabled vehicle † Do not allow passengers to ride in a vehicle † Always observe state and local laws regarding † Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. † Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. † Do not tow a heavily loaded vehicle. Damage to the cab, cargo box or frame may result. Use a flatbed device to transport a loaded vehicle.
towing regulations.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors.
Fig.8REARLIFTPADLOCATION
1 - FRAME RAIL 2 - REAR LIFT PAD 3 - LEAF SPRING MOUNTING BRACKET 4 - BOX MOUNTING BRACKET
TOWING STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved sling-type towing equipment can be used to tow all vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flat-bed device can also be used to transport a disabled vehicle (Fig. 9).
A wooden crossbeam may be required for proper connection when using the sling-type, front-end tow- ing method.
LUBRICATION & MAINTENANCE
0 - 16
TOWING (Continued)A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the oppo- site end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15
degrees.TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail- able, use a flat bed hauler. A Wheel-lift or Sling-type device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dol- lies.
DR
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be transported on a flat-bed device. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dol- lies.
WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION (AUTO- MATIC TRANSMISSION) OR A FORWARD DRIVE GEAR (MANUAL TRANSMISSION).
CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehi- cle or a flat-bed hauling vehicle is recommended.
DR
SUSPENSION
2 - 1
SUSPENSION
TABLE OF CONTENTS
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
FRONT - INDEPENDENT FRONT SUSPENSION . . 8FRONT - LINK/COIL REAR
. . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38page
page
WHEEL ALIGNMENT
TABLE OF CONTENTS
page
page
WHEEL ALIGNMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - PRE-ALIGNMENTINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT
STANDARD PROCEDURE - TOE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - CAMBER,
CASTER AND TOE ADJUSTMENT . . . . . . . . . . 4
STANDARD PROCEDURE - ALIGNMENT
LINK/COIL SUSPENSION. . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
MEASUREMENT - 4WD (LD) . . . . . . . . . . . . . . 3
ALIGNMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - HEIGHT
SPECIAL TOOLS
ADJUSTMENT - 4WD (LD) . . . . . . . . . . . . . . . . 3
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT . . . . . . . . . . . . . . . . . . 4
WHEEL ALIGNMENT DESCRIPTION
NOTE: Suspension components with rubber/ure- thane bushings should be tightened with the vehi- cle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.
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).
CAUTION: Never attempt to modify suspension or steering components by heating or bending.
Fig.1WheelAlignmentMeasurements
1 - FRONT OF VEHICLE 2 - STEERING AXIS INCLINATION 3 - PIVOT POINT 4 - TOE-IN
2 - 2 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) OPERATION † CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more posi- tive caster. Positive caster promotes directional sta- bility. This angle enables the front wheels to return to a straight ahead position after turns (Fig. 1) † CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire (Fig. 1) † TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause’s unsta- ble steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment (Fig. 1) † THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and exces-
DR
sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle (Fig. 1)
DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION
Before starting wheel alignment,
the following inspection and necessary corrections must be com- pleted. Refer to Suspension and Steering System Diagnosis Chart below for additional information.
(1) Inspect tires for size, air pressure and tread
(2) Inspect front wheel bearings for wear. (3) Inspect front wheels for excessive radial or lat-
eral runout and balance. (4) Inspect ball studs,
steering gear for looseness, roughness or binding.
(5) Inspect suspension components for wear and
linkage pivot points and
(6) On 4x4 vehicles check suspension height (LD
wear.
noise.
only).
(7) Road test the vehicle.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
FRONT END NOISE
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
EXCESSIVE PLAY IN STEERING
2. Loose or worn steering or suspension components. 3. Loose or worn steering or suspension components.
2. Tighten or replace components as necessary. 3. Tighten or replace components as necessary.
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
2. Loose or worn steering or suspension components. 3. Loose or worn steering gear.
2. Tighten or replace components as necessary. 3. Replace steering gear.
FRONT WHEELS SHIMMY
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
2. Loose or worn steering or suspension components. 3. Tires worn or out of balance. 4. Alignment.
2. Tighten or replace components as necessary. 3. Replace or balance tires. 4. Align vehicle to specifications.
VEHICLE INSTABILITY
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
2. Loose or worn steering or suspension components. 3. Tire pressure. 4. Alignment.
2. Tighten or replace components as necessary. 3. Adjust tire pressure. 4. Align vehicle to specifications.
DR WHEEL ALIGNMENT (Continued)
WHEEL ALIGNMENT
2 - 3
CONDITION
POSSIBLE CAUSES
CORRECTION
EXCESSIVE STEERING EFFORT
VEHICLE PULLS TO ONE SIDE
1. Loose or worn steering gear.
1. Replace steering gear.
2. Column coupler binding. 3. Tire pressure. 4. Alignment.
1. Tire pressure. 2. Tire. 3. Alignment. 4. Loose or worn steering or suspension components. 5. Radial tire lead. 6. Brake pull. 7. Weak or broken spring. 8. Ride height (LD) 4WD only.
2. Replace coupler. 3. Adjust tire pressure. 4. Align vehicle to specifications.
1. Adjust tire pressure. 2. Criss-Cross Front Tires. 3. Align vehicle to specifications. 4. Tighten or replace components as necessary. 5. Rotate or replace tire as necessary. 6. Repair brake as necessary. 7. Replace spring. 8. Measure and adjust ride height. (LD only)
STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT MEASUREMENT - 4WD (LD)
The vehicle suspension height MUST be measured and adjusted before performing wheel alignment pro- cedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it’s own weight and taken on both sides of the vehicle.
(1) Inspect tires and set to correct pressure. (2) Jounce the front of the vehicle. (3) Measure and record the height from the ground at the centerline of the rear lower control arm bolt front tip (Fig. 2).
(4) Measure and record the height from the ground at the front spindle centerline (Static Load Radius) (Fig. 2).
(5) Subtract the first measurement from the sec- ond measurement. The difference between the two measurement should be 58 mm (2.3 inches) ± 3 mm (0.12 inches).
(6) If value is greater than 61 mm (2.4 inches), tighten the torsion bar bolt until the specification is achieved (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(7) If value is less than 55 mm (2.1 inches), loosen the torsion bar bolt until the specification is achieve- d,(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(8) Repeat the previous steps until the ride height
is within specifications.
Fig.2HEIGHTMESUREMENT
1 - HEIGHT FROM THE GROUND AT THE FRONT SPINDLE CENTERLINE (STATIC LOAD RADIUS) 2 - CENTERLINE OF THE REAR LOWER CONTROL ARM BOLT FRONT TIP 3 - GROUND LINE
STANDARD PROCEDURE - HEIGHT ADJUSTMENT - 4WD (LD)
The vehicle suspension height MUST be measured and adjusted before performing wheel alignment pro- cedure (Refer to 2 - SUSPENSION/WHEEL ALIGN- MENT - STANDARD PROCEDURE). Also when front suspension components have been replaced. This measurement must be performed with the vehi- cle supporting it’s own weight and taken on both sides of the vehicle.
2 - 4 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued)
To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle.
CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehi- cle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height.
NOTE: If a height adjustment has been made, per- form height measurement again on both sides of the vehicle.
STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE- MENT MUST BE PERFORMED BEFORE AN ALIGN- MENT.
NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle.
Camber and caster angle adjustments involve changing the position of the upper control arm incon- junction with the slotted holes in the frame brackets, Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876
between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height (Fig. 3).STANDARD PROCEDURE - TOE ADJUSTMENT
4X4 SUSPENSION HEIGHT MESUREMENT MUST BE PERFORMED BEFORE AN ALIGN- MENT.
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position.
(2) Loosen the tie rod jam nuts.
DR
Fig.3CASTER&CAMBERADJUSTMENT
1 - FRONT PIVOT BOLT 2 - REAR PIVOT BOLT 3 - SLOTTED HOLES FOR ADJUSTMENT OF CASTER & CAMBER 4 - UPPER CONTROL ARM
NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the
inner tie rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.).
(5) Verify the specifications (6) Turn off engine.
STANDARD PROCEDURE - CAMBER, CASTER AND TOE ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE- MENT MUST BE PERFORMED BEFORE AN ALIGN- MENT.
Camber and caster angle adjustments involve changing the position of the upper control arm with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. (Fig. 3)
NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle.
CASTER
Moving the front or rear position of the upper con- trol arm in or out, will change the caster angle and camber angle significantly. To maintain the camber
DR WHEEL ALIGNMENT (Continued)
angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height (Fig. 3).
To increase positive caster angle, move the rear position of the upper control arm inward (toward the engine). Move the front of the upper control arm out- ward (away from the engine) slightly until the origi- nal camber angle is obtained using special tool 8876
to move the upper control arm for proper adjustment. (Fig. 3)CAMBER
Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm for proper adjustment. (Fig. 3)
After adjustment is made tighten the upper control
arm nuts to proper torque specification.
TOE ADJUSTMENT
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position.
(2) Loosen the tie rod jam nuts.
WHEEL ALIGNMENT
2 - 5
Fig.4TIERODEND
1 - JAM NUT 2 - TIE ROD - INNER 3 - TIE ROD END - OUTER
the down position. Set the front end alignment to specifications while the vehicle is in its NOR- MALLY LOADED CONDITION.
CAMBER: The wheel camber angle is preset and
is not adjustable.
CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnabil- ity.
Caster can be adjusted by rotating the cams on the
lower suspension arm (Fig. 5).
NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the
inner tie rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.).
(5) Verify the specifications (6) Turn off engine.
STANDARD PROCEDURE - ALIGNMENT LINK/COIL SUSPENSION
Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in
Fig.5ALIGNMENTADJUSTMENTCAM
1 - BRACKET REINFORCEMENT 2 - ADJUSTING BOLT 3 - ADJUSTMENT CAM
TOE POSITION: The wheel toe position adjust-
ment should be the final adjustment.
2 - 6 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued)
(1) Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine.
(2) Loosen the adjustment sleeve clamp bolts. (3) Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change dur- ing clamp tightening.
(4) Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change dur- ing clamp tightening.
(5) Verify the right toe setting and a straight steer-
ing wheel.
(6) Road test the vehicle.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
SPECIFICATIONS
DESCRIP-
TION
VEHICLE
1500
WHEEL BASE
4X2
4X2
4X2
120.5
in
140.5
in
160.5
in
VEHICLE
1500
WHEEL BASE
4X4
4X4
4X4
120.5
in
140.5
in
160.5
in
SPECIFICATION
CASTER
(3.0° Max, +.75° Target)
4.0°
4.2°
4.4°
CASTER
(3.0° Max, +.75° Target)
4.2°
4.4°
4.6°
CAMBER (± .50°)
TOTAL TOE-IN (± .10°)
.0°
.0°
.0°
.10°
.10°
.10°
CAMBER (±.50°)
TOTAL TOE-IN (±.10°)
.0°
.0°
.0°
.10°
.10°
.10°
DR
SPECIFICATION
—
.40°
