I have a 2002 Dodge Ram 5.9 motor and it’s in theft mode. The red light under the gas gauge is a solid red. It will not crank it’ll turn over have no dash cluster gauges or fire to the fuel pump or the coils. How do I correct it? I’ve tried everything. Google and other people have said to try. I have no wiring going to my key switch in the doors. I’m lost. What do I do?

Summary of Contents for Dodge 2001 Ram 1500

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Cooling Audio Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame &...
Page 2 INTRODUCTION BR/BE INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATE TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 3 INTRODUCTION BR/BE BODY CODE PLATE (Continued) • BE6 = 1500 4 X 4 DIGIT 19 • BR2 = 2500 4 X 2 Open Space • BE2 = 2500 4 X 2 • BR7 = 2500 4 X 4 DIGITS 20, 21, AND 22 •...
Page 4 BR/BE INTRODUCTION BODY CODE PLATE (Continued) DIGITS 14 THROUGH 16 Tailgate code line marks on the top of each bolt head. The actual • MWD = Plain Tailgate bolt strength grade corresponds to the number of line • MPB = Tailgate Applique (Black) marks plus 2.
Page 5 INTRODUCTION BR/BE FASTENER IDENTIFICATION (Continued) Fastener Identification...
Page 6 BR/BE INTRODUCTION FASTENER IDENTIFICATION (Continued) Fastener Strength...
Page 7 INTRODUCTION BR/BE FASTENER USAGE INTERNATIONAL VEHICLE CONTROL & DISPLAY DESCRIPTION - FASTENER USAGE SYMBOLS WARNING: USE OF AN INCORRECT FASTENER DESCRIPTION - INTERNATIONAL SYMBOLS MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. The graphic symbols illustrated in the following International Control and Display Symbols Chart are Figure art, specifications and torque references in used to identify various instrument controls.
Page 8 BR/BE INTRODUCTION METRIC SYSTEM (Continued) CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg x 3.377 = Kilopascals (kPa)
Page 9 INTRODUCTION BR/BE METRIC SYSTEM (Continued) Metric Conversion Chart...
Page 10 BR/BE INTRODUCTION cations Chart for torque references not listed in the TORQUE REFERENCES individual torque charts. DESCRIPTION Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifi- Torque Specifications...
Page 11 INTRODUCTION BR/BE is attached to a riveted metal plate located to the VECI LABEL right side of the generator (Fig. 3). DESCRIPTION Vehicles equipped with 3.9L V-6 or 5.2L/5.9L V-8 LDC-gas powered engines have a VECI label. The label combines both emission control informa- tion and vacuum hose routing.
Page 12 Z = 5.9L 8 cyl. MPI-LDC 5 = 5.9L 8cyl. MPI-HDC Check Digit 0 through 9 or X Model Year 1=2001 Plant Location J = St. Louis North S = Dodge City M = Lago Alberto Assembly 12 thru 17 Vehicle Build Sequence...
Page 13 INTRODUCTION BR/BE VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety certification label (Fig. 5) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all appli- cable Federal Motor Vehicle Safety Standards. The label also lists: •...
Page 14 LUBRICATION & MAINTENANCE 0 - 1 BR/BE LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION ......1 DESCRIPTION .
Page 15 Check Engine or Service Engine Soon light is flash- with diesel fuel. ing, immediate service is required; see on-board Use good quality diesel fuel from a reputable sup- diagnostics system section. plier in your Dodge truck. For most year-round ser- vice, number diesel fuel...
Page 16 BR/BE LUBRICATION & MAINTENANCE 0 - 3 INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1). Fig. 2 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS FLUID TYPES DESCRIPTION - ENGINE OIL...
Page 17 0 - 4 LUBRICATION & MAINTENANCE BR/BE FLUID TYPES (Continued) Standard engine-oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans.
Page 18 BR/BE LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) DESCRIPTION Mopar ATF +4, type 9602, Automatic Transmis- sion Fluid when new is red in color. The ATF is dyed A multi-purpose, hypoid gear lubricant which con- red so it can be identified from other fluids used in forms to the following specifications should be used.
Page 19 0 - 6 LUBRICATION & MAINTENANCE BR/BE FLUID CAPACITIES DESCRIPTION SPECIFICATION Dry fill capacity Depending on type and size of internal SPECIFICATIONS cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Refer FLUID CAPACITIES to 21, Transmission for proper fluid fill procedure.
Page 20 BR/BE LUBRICATION & MAINTENANCE 0 - 7 conditions such as dusty areas and very short trip MAINTENANCE SCHEDULES driving. LIGHT DUTY ENGINE (1500 AND 2500 FLUID FILL LOCATIONS AND LUBRICATION MODELS EXCEPT 8.0L) MAINTENANCE POINTS SCHEDULES The fluid check/fill locations and lubrication points There are two maintenance schedules that show are located in each applicable group.
Page 21 0 - 8 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Inspect brake hoses. 75,000 Miles (120 000 km) or at 60 months • Lubricate the steering linkages. • Inspect auto tension drive belt and replace if • Inspect manual transmission fluid level. required.** •...
Page 22 BR/BE LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) • More than 50 percent of the driving is at sus- 105,000 Miles (168 000 km) or at 84 months • Inspect auto tension drive belt and replace if tained high speeds during hot weather, above 90°F (32°C).
Page 23 0 - 10 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Inspect exhaust system. 33,000 Miles (53 000 km) • Change engine oil. 18,000 Miles (29 000 km) • Replace engine oil filter. • Change engine oil. • Inspect engine coolant level, hoses, and clamps. •...
Page 24 BR/BE LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) • Inspect brake linings. 63,000 Miles (101 000 km) • Lubricate the steering linkages. • Change engine oil. • Check manual transmission fluid level. • Replace engine oil filter. • Change rear axle fluid. •...
Page 25 0 - 12 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Inspect brake hoses. • Lubricate the steering linkages. • Lubricate the steering linkages. • Check manual transmission fluid level. • Check manual transmission fluid level. • Inspect exhaust system. •...
Page 26 BR/BE LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) • Change front axle fluid (4x4). DESCRIPTION - MEDIUM DUTY TRUCK • Inspect exhaust system. MAINTENANCE SCHEDULE (8.0L 2500 & 3500 MODELS — CALIFORNIA ONLY) 111,000 Miles (178 000 km) •...
Page 27 0 - 14 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) FLUID FILL LOCATIONS AND LUBRICATION 60,000 Miles (96 000 km) or at 60 months • Replace engine oil and filter. POINTS • Replace engine air cleaner element. The fluid fill/check locations and lubrication points •...
Page 28 BR/BE LUBRICATION & MAINTENANCE 0 - 15 MAINTENANCE SCHEDULES (Continued) • Inspect front wheel bearings. Clean and repack, • Inspect front wheel bearings. Clean and repack, if required (4x2). if required (4x2). • Change rear axle fluid. • Change front axle fluid (4x4). 114,000 Miles (183 000 km) or at 116 months •...
Page 29 0 - 16 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) 57,000 Miles (91 000 km) 90,000 Miles (144 000 km) • Replace engine oil and filter. • Replace engine oil and filter. • Replace engine air cleaner element. 60,000 Miles (96 000 km) •...
Page 30 BR/BE LUBRICATION & MAINTENANCE 0 - 17 MAINTENANCE SCHEDULES (Continued) • Inspect brake linings. EMISSION CONTROL SYSTEM MAINTENANCE ‡Off-the-highway operation, trailer towing snow The scheduled emission maintenance listed in bold plowing, prolonged operation with heavy loading, type on the Maintenance Schedules, must be done at especially in hot weather require the more frequent the mileage specified to assure the continued proper transmission service indicated with an ‡...
Page 31 0 - 18 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Drain and refill transfer case fluid. • Drain and refill automatic transmission fluid. • Inspect brake linings. Replace filter and adjust bands. • Flush and replace engine coolant at 36 months, •...
Page 32 BR/BE LUBRICATION & MAINTENANCE 0 - 19 MAINTENANCE SCHEDULES (Continued) • Flush and replace engine coolant if it has been 15,000 Miles (24 000 km) • Change engine oil. 30,000 miles (48 000 km) or 24 months since last • Replace engine oil filter. change.
Page 33 0 - 20 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Inspect brake linings. 33,000 Miles (53 000 km) • Flush and replace engine coolant. • Change engine oil. • Lubricate tie rod ends every 3,000 miles (5 000 • Replace engine oil filter. •...
Page 34 BR/BE LUBRICATION & MAINTENANCE 0 - 21 MAINTENANCE SCHEDULES (Continued) 66,000 Miles (106 000 km) 84,000 Miles (134 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate tie rod ends every 3,000 miles (5 000 •...
Page 35 0 - 22 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) 99,000 Miles (156 000 km) First is Schedule “A.” It lists all the scheduled • Change engine oil. maintenance to be performed under “normal” operat- • Replace engine oil filter. ing conditions.
Page 36 BR/BE LUBRICATION & MAINTENANCE 0 - 23 MAINTENANCE SCHEDULES (Continued) FLUID FILL LOCATIONS AND LUBRICATION 52,500 Miles (84 000 km) or at 42 months • Change engine oil and filter. POINTS • Drain crankcase breather canister (if equipped). The fluid fill/check locations and lubrication points are located in each applicable group.
Page 37 0 - 24 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Flush and replace engine coolant if it has been • Inspect front wheel bearings. Clean and repack, 30,000 miles (48 000 km) or 24 months since last if required (4x2). •...
Page 38 BR/BE LUBRICATION & MAINTENANCE 0 - 25 MAINTENANCE SCHEDULES (Continued) 26,250 Miles (42 000 km) 56,250 Miles (90 000 km) • Change engine oil and filter. • Change engine oil and filter. • Drain crankcase breather canister (if equipped). • Drain crankcase breather canister (if equipped). 30,000 Miles (48 000 km) 60,000 Miles (96 000 km) •...
Page 39 0 - 26 LUBRICATION & MAINTENANCE BR/BE MAINTENANCE SCHEDULES (Continued) • Replace fuel filter and clean water in fuel sensor. 86,250 Miles (138 000 km) • Change engine oil and filter. 116,250 Miles (186 000 km) • Drain crankcase breather canister (if equipped). •...
Page 40 BR/BE LUBRICATION & MAINTENANCE 0 - 27 (3) On disabled vehicle, place gear selector in park JUMP STARTING or neutral and set park brake. Turn off all accesso- ries. STANDARD PROCEDURE (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to neg- WARNING: REVIEW ALL SAFETY PRECAUTIONS ative terminal (-).
Page 41 0 - 28 LUBRICATION & MAINTENANCE BR/BE JUMP STARTING (Continued) Fig. 8 Jumper Cable Clamp Connections—Diesel Engine 1 - POSITIVE CABLE CONNECTION 2 - BATTERY 3 - NEGATIVE OR GROUND CABLE CONNECTION DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle.
Page 42 BR/BE LUBRICATION & MAINTENANCE 0 - 29 HOISTING (Continued) NOTE: When a frame-contact type hoist is used, TOWING verify that the lifting pads are positioned properly (Fig. 10). The forward lifting pads should be posi- STANDARD PROCEDURE tioned a minimum of 5 inches forward of the cross- A vehicle equipped with SAE approved sling-type member bolt access holes (Fig.
Page 43 0 - 30 LUBRICATION & MAINTENANCE BR/BE TOWING (Continued) • Do not tow a vehicle in a manner that could TOWING WHEN KEYS ARE NOT AVAILABLE jeopardize the safety of the operator, pedestrians or When the vehicle is locked and keys are not avail- other motorists.
Page 44 SUSPENSION 2 - 1 BR/BE SUSPENSION TABLE OF CONTENTS page page WHEEL ALIGNMENT ..... . . 1 FRONT - 4WD .
Page 45 2 - 2 WHEEL ALIGNMENT BR/BE WHEEL ALIGNMENT (Continued) Fig. 2 Alignment Angles - Link/Coil 1 - WHEEL CENTERLINE 6 - KING PIN 2 - NEGATIVE CAMBER ANGLE 7 - VERTICAL 3 - PIVOT CENTERLINE 8 - POSITIVE CASTER 4 - SCRUB RADIUS 5 - TRUE VERTICAL OPERATION DIAGNOSIS AND TESTING - PRE-ALIGNMENT...
Page 46 BR/BE WHEEL ALIGNMENT 2 - 3 WHEEL ALIGNMENT (Continued) down several times. Always release the bumper in CAMBER: Move the forward position of the pivot the down position. Set the front end alignment to bar in or out. This will change the camber angle sig- specifications while the vehicle is in its NOR- nificantly and caster angle only slightly.
Page 47 2 - 4 WHEEL ALIGNMENT BR/BE WHEEL ALIGNMENT (Continued) Fig. 4 Chassis Measurement 1 - GAUGE HOLE 3 - HANGER BOLT 2 - HANGER BOLT 4 - GAUGE HOLE...
Page 48 BR/BE WHEEL ALIGNMENT 2 - 5 WHEEL ALIGNMENT (Continued) CORRECTED CASTER CHART-CAB CHASSIS 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- Caster 4x2 8800 4x4 8800 4x2 &...
Page 49 2 - 6 WHEEL ALIGNMENT BR/BE WHEEL ALIGNMENT (Continued) SPECIFICATIONS ALIGNMENT NOTE: *4 x 2 11,000 GVW has a solid front axle with link/coil suspension system. DESCRIPTION SPECIFICATION GROSS VEHICLE WHEEL BASE PREFERRED PREFERRED 4 x 2 & 4 x 4 WEIGHT lbs.
Page 50 BR/BE FRONT - 2WD 2 - 7 FRONT - 2WD TABLE OF CONTENTS page page FRONT - 2WD OPERATION......11 DESCRIPTION .
Page 51 2 - 8 FRONT - 2WD BR/BE FRONT - 2WD (Continued) tightened with the vehicle 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 bush- ing wear may occur.
Page 52 BR/BE FRONT - 2WD 2 - 9 FRONT - 2WD (Continued) SPECIAL TOOLS INDEPENDENT FRONT SUSPENSION Remover, Tie Rod End MB-990635 Fig. 3 Caliper Adapter Assembly 1 - HUB/BEARING 2 - SPINDLE (4) Install the rotor onto hub/bearing wheel studs. (5) Install the caliper adapter assembly (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/DISC Puller Tie Rod C-3894-A...
Page 53 2 - 10 FRONT - 2WD BR/BE KNUCKLE (Continued) OPERATION (4) Position indicator plunger against the bottom of the steering knuckle lower ball joint boss. The steering knuckles pivots between the upper and lower ball joints. The steering linkage is NOTE: The dial Indicator plunger must be perpen- attached to the knuckles controls vehicle steering.
Page 54 BR/BE FRONT - 2WD 2 - 11 LOWER CONTROL ARM (Continued) (5) Install the steering knuckle on the lower ball REMOVAL joint. Install the lower ball joint nut and tighten to: (1) Raise and support vehicle. • LD: 129 N·m (95 ft. lbs.) (2) Remove shock upper nut and remove retainer •...
Page 55 2 - 12 FRONT - 2WD BR/BE SPRING (Continued) (3) Remove the brake caliper assembly and rotor, (6) Install the tie rod end on the steering knuckle (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ and tighten nut to 108 N·m (80 ft. lbs.). Install cotter ROTORS - REMOVAL).
Page 56 BR/BE FRONT - 2WD 2 - 13 UPPER BALL JOINT (Continued) (4) Remove upper ball joint cotter pin and nut. (5) Separate ball joint from knuckle with remover MB-990635. (6) Remove pivot bar bolts from upper suspension arm bracket and remove arm from vehicle (Fig. 7). Fig.
Page 57 2 - 14 FRONT - 4WD BR/BE FRONT - 4WD TABLE OF CONTENTS page page FRONT - 4WD OPERATION......22 DESCRIPTION .
Page 58 BR/BE FRONT - 4WD 2 - 15 FRONT - 4WD (Continued) Fig. 1 Link/Coil Suspension 1 - STABILIZER BAR 2 - SHOCK ABSORBER 3 - COIL SPRING 4 - UPPER SUSPENSION ARM 5 - LOWER SUSPENSION ARM 6 - TRACK BAR SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS...
Page 59 2 - 16 FRONT - 4WD BR/BE FRONT - 4WD (Continued) (4) Remove the brake caliper, (Refer to 5 - SPECIAL TOOLS BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). LINK/COIL SUSPENSION (5) Remove the cotter pin and the hub nut from the axle shaft (Fig. 3). Puller C-3894–A Fig.
Page 60 BR/BE FRONT - 4WD 2 - 17 HUB / BEARING (Continued) Fig. 5 Rotor Hub/Bearing Assembly Fig. 7 Wheel Speed Sensor 1 - ROTOR AND HUB 1 - HUB BEARING 2 - UNIT BEARING ASSEMBLY 2 - WHEEL SPEED SENSOR 3 - SEAL (6) Back off the hub/bearing mounting bolts 1/4 inch each (Fig.
Page 61 2 - 18 FRONT - 4WD BR/BE HUB / BEARING (Continued) INSTALLATION - 2500/3500 (1) Install the wheel speed sensor in the hub bear- ing if equipped. (2) Position the rotor on the hub/bearing. (3) Press the wheel studs/hub extension studs through the back side of the rotor and through the hub bearing flange (Fig.
Page 62 BR/BE FRONT - 4WD 2 - 19 HUB / BEARING (Continued) Fig. 12 Brake Shield With Wheel Speed Sensor 1 - WHEEL SPEED SENSOR 2 - HUB BEARING 3 - SHIELD (11) Install a new cotter pin in the hub nut. Fig.
Page 63 2 - 20 FRONT - 4WD BR/BE HUB / BEARING (Continued) (8) Install a new cotter pin in hub nut. Tighten the INSTALLATION nut as needed to align cotter pin hole in shaft with (1) Position the steering knuckle on the ball studs. the opening in the nut.
Page 64 BR/BE FRONT - 4WD 2 - 21 LOWER CONTROL ARM (Continued) must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even.
Page 65 2 - 22 FRONT - 4WD BR/BE SHOCK (Continued) (8) Lower the axle until the spring is free from the upper mount. Remove the coil spring. INSTALLATION (1) Position the coil spring on the axle pad. (2) Raise the axle into position until the spring seats in the upper mount.
Page 66 BR/BE FRONT - 4WD 2 - 23 STABILIZER BAR (Continued) (4) Turn the front wheel 180° to the right and record the dial indicator reading. Repeat this step three times and record all readings. (5) If any of the readings exceed 2.03 mm (0.080 in) replace the track bar.
Page 67 2 - 24 FRONT - 4WD BR/BE UPPER CONTROL ARM (Continued) Fig. 20 Track Bar Fig. 22 Upper and Lower Suspension Arm 1 - AXLE BRACKET 2 - FRAME BRACKET 1 - STABILIZER BAR 3 - TRACK BAR 2 - SHOCK ABSORBER 4 - FLAG NUT 3 - COIL SPRING 4 - UPPER SUSPENSION ARM...
Page 68 BR/BE FRONT - 4WD 2 - 25 LOWER BALL JOINT (Continued) (2) Position tools as shown to remove lower ball UPPER BALL JOINT stud (Fig. 24). REMOVAL - (1) Position tools as shown to remove upper ball stud (Fig. 26). Fig.
Page 69 2 - 26 REAR BR/BE REAR TABLE OF CONTENTS page page REAR OPERATION......28 DESCRIPTION .
Page 70 BR/BE REAR 2 - 27 REAR (Continued) SPRING AND SHOCK ABSORBER CONDITION POSSIBLE CAUSES CORRECTION SPRING SAGS 1. Broken leaf. 1. Replace spring. 2. Spring fatigue. 2. Replace spring. SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification. 2.
Page 71 2 - 28 REAR BR/BE REAR (Continued) (4) Remove the rear shock absorber from the vehi- SPECIAL TOOLS cle. SUSPENSION-REAR Puller C-3894-A BUSHINGS REMOVAL (1) Remove the spring from the vehicle. (2) Position the spring eye in a press. (3) Press the bushing out with an appropriate size driver.
Page 72 BR/BE REAR 2 - 29 SPRING (Continued) (2) Remove the nuts and spring clamp bolts that attach the spring to the axle (Fig. 2) and (Fig. 3)and (Fig. 4). (3) Remove the nuts and bolts from the spring front and rear shackle eyes. Note: To remove front eye bolt on left side spring fuel tank must be removed, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL).
Page 73 2 - 30 REAR BR/BE STABILIZER BAR DESCRIPTION The stabilizer bar extends across the underside of the vehicle and is bolted to the axle. Links at the end of the bar are bolted to the frame. OPERATION The stabilizer bar is used to minimize vehicle body roll.
Page 74 DIFFERENTIAL & DRIVELINE 3 - 1 BR/BE DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . . 1 REAR AXLE - 248RBI .
Page 75 3 - 2 PROPELLER SHAFT BR/BE PROPELLER SHAFT (Continued) Fig. 1 Front Propeller Shaft 1 - TRANSFER CASE 3 - FRONT AXLE 2 - FRONT PROPELLER SHAFT 4 - UNIVERSAL JOINT CLAMP Fig. 2 Rear Propeller Shaft with Center Bearing 1 - CENTER BEARING 3 - TRANSMISSION TRANSFER 2 - REAR AXLE...
Page 76 BR/BE PROPELLER SHAFT 3 - 3 PROPELLER SHAFT (Continued) Fig. 5 Propeller Shaft And Yoke 1 - REFERENCE MARKS Before undercoating a vehicle, the propeller Fig. 3 Rear Propeller Shaft - Dana Axles shaft and the U-joints should be covered to pre- 1 - SLIDING YOKE vent an out-of-balance condition and driveline 2 - PROPELLER SHAFT...
Page 77 3 - 4 PROPELLER SHAFT BR/BE PROPELLER SHAFT (Continued) DRIVELINE VIBRATION Drive Condition Possible Cause Correction Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash material on shaft. with solvent. 2) Loose U-joint clamp screws. 2) Install new clamps and screws and tighten to proper torque.
Page 78 BR/BE PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) (15) If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. (16) Install the wheel and tires. Lower the vehicle. RUNOUT (1) Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft.
Page 79 3 - 6 PROPELLER SHAFT BR/BE PROPELLER SHAFT (Continued) (3) Place Inclinometer 7663 (J-23498A) on yoke bearing (A) parallel to the shaft (Fig. 9). Center bub- ble in sight glass and record measurement. This measurement will give you the transmis- sion or Output Yoke Angle (A).
Page 80 BR/BE PROPELLER SHAFT 3 - 7 PROPELLER SHAFT (Continued) Fig. 12 Universal Joint Angle Example 1 - 4.9° Angle (C) 4 - 3.0° Angle (A) 2 - 3.2° Angle (B) 5 - Output Yoke 3 - Input Yoke Fig. 13 Universal Joint Angle Two-Piece Shaft 1 - YOKES MUST BE IN SAME PLANE...
Page 81 3 - 8 PROPELLER SHAFT BR/BE PROPELLER SHAFT (Continued) SPECIFICATIONS PROPELLER SHAFT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Center Bearing Bolts Front Shaft Flange Yoke Front Shaft Axle Yoke Rear Shaft 9 1/4 Axle Rear Shaft Dana Axle SPECIAL TOOLS PROPELLER SHAFT - FRONT PROPELLER SHAFT...
Page 82 BR/BE PROPELLER SHAFT 3 - 9 PROPELLER SHAFT - FRONT (Continued) Fig. 15 Center Bearing 1 - SUPPORT BRACKET 2 - CENTER BEARING ASSEMBLY 3 - CENTER BEARING ASSEMBLY 4 - SUPPORT BRACKET Fig. 14 Front Propeller Shaft 1 - TRANSFER CASE 2 - FRONT AXLE 3 - AXLE YOKE 4 - SLIP YOKE BOOT...
Page 83 3 - 10 PROPELLER SHAFT BR/BE PROPELLER SHAFT - REAR (Continued) Fig. 18 Center Bearing Fig. 17 Rear Propeller Shaft—Corporate Axles 1 - SUPPORT BRACKET 1 - COMPANION FLANGE 2 - CENTER BEARING ASSEMBLY 2 - FLANGE YOKE 3 - CENTER BEARING ASSEMBLY 3 - REAR PROPELLER SHAFT 4 - SUPPORT BRACKET (5) Position universal joint into pinion yoke for...
Page 84 BR/BE PROPELLER SHAFT 3 - 11 CENTER BEARING (Continued) to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY Individual components of cardan universal joints are not serviceable.
Page 85 3 - 12 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI TABLE OF CONTENTS page page FRONT AXLE - 216FBI VACUUM MOTOR..... . . 31 DESCRIPTION .
Page 86 BR/BE FRONT AXLE - 216FBI 3 - 13 FRONT AXLE - 216FBI (Continued) When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns.
Page 87 3 - 14 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) • Missing drive shaft balance weight(s). cle turns. A worn pinion mate shaft can also cause a • Worn or out of balance wheels. snapping or a knocking noise. •...
Page 88 BR/BE FRONT AXLE - 216FBI 3 - 15 FRONT AXLE - 216FBI (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1.
Page 89 3 - 16 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) Condition Possible Causes Correction Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level. 2. Worn axle shaft seals. 2. Replace seals. 3.
Page 90 BR/BE FRONT AXLE - 216FBI 3 - 17 FRONT AXLE - 216FBI (Continued) (8) Disconnect the stabilizer bar links at the axle (15) Install front propeller shaft. brackets. (16) Check and add differential lubricant, if neces- (9) Disconnect the shock absorbers from axle sary.
Page 91 3 - 18 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) If a new gear set is being installed, note the depth variance etched into both the original and replace- ment pinion. Add or subtract this number from the thickness of the original depth shim/oil slinger to compensate for the difference in the depth variances.
Page 92 BR/BE FRONT AXLE - 216FBI 3 - 19 FRONT AXLE - 216FBI (Continued) (5) Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 108 N·m (80 ft. lbs.). Fig. 8 Gauge Tools In Housing 1 - ARBOR DISC 2 - PINION BLOCK Fig.
Page 93 3 - 20 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) Fig. 9 Pinion Gear Depth Measurement 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR DIFFERENTIAL SIDE BEARING PRELOAD AND Fig. 10 Adjustment Shim Loactions GEAR BACKLASH 1 - PINION GEAR DEPTH SHIM/OIL BAFFLE Differential side bearing preload and gear backlash...
Page 94 BR/BE FRONT AXLE - 216FBI 3 - 21 FRONT AXLE - 216FBI (Continued) (7) Using a dead-blow hammer, seat the differen- tial dummy bearings to each side of the housing (Fig. 12) and (Fig. 13). Fig. 12 Seat Pinion Gear Side Dummy Bearing 1 - DEAD-BLOW HAMMER 2 - DIFFERENTIAL HOUSING Fig.
Page 95 3 - 22 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) Fig. 16 Differential Case To Ring Gear Side Fig. 17 Differential Case To Pinion Gear Side 1 - DIAL INDICATOR 1 - DIAL INDICATOR FACE 2 - DIFFERENTIAL CASE TO PINION GEAR SIDE 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - PINION GEAR 3 - DIFFERENTIAL HOUSING...
Page 96 BR/BE FRONT AXLE - 216FBI 3 - 23 FRONT AXLE - 216FBI (Continued) (31) Rotate the differential case several times to seat the side bearings. (32) Position the indicator plunger against a ring gear tooth (Fig. 19). (33) Push and hold ring gear upward while not allowing the pinion gear to rotate.
Page 97 3 - 24 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) Fig. 21 Gear Tooth Contact Patterns...
Page 98 BR/BE FRONT AXLE - 216FBI 3 - 25 FRONT AXLE - 216FBI (Continued) SPECIFICATIONS FRONT AXLE - 216FBI AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 3.92, 4.10 Ring Gear Diameter 216 mm (8.50 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Pinion Gear Standard Depth 109.5 mm (4.312 in.) Pinion Bearing Preload - Original Bearing...
Page 99 3 - 26 FRONT AXLE - 216FBI BR/BE FRONT AXLE - 216FBI (Continued) FLANGE WRENCH - C-3281 HANDLE, DRIVE - C-4171 PILOTS - C-3288-B INSTALLER, CUP - D-144 DIAL INDICATOR - C-3339 REMOVER, CUP - D-147 INSTALLER, BEARING - C-3716-A REMOVER, CUP - D-149 INSTALLER, CUP - D-146 INSTALLER, BEARING - D-156...
Page 100 BR/BE FRONT AXLE - 216FBI 3 - 27 FRONT AXLE - 216FBI (Continued) REMOVER/INSTALLER BEARING D-354 BLOCK, ADAPTERS - C-293-40 INSTALLER, YOKE - W-162-D BLOCK, ADAPTER - C-293-18 INSTALLER, BEARING - W-262 ADAPTER PLUG - C-293-3 INSTALLER, SEAL - 5041 HOLDER YOKE - 6719A PULLER/PRESS - C-293-PA PINION DEPTH SET - 6730...
Page 101 3 - 28 FRONT AXLE - 216FBI BR/BE AXLE SHAFTS AXLE SHAFTS - INTERMEDIATE REMOVAL (1) Raise and support the vehicle. REMOVAL (2) Remove wheel and tire assembly. (1) Remove vacuum shift motor housing. (3) Remove brake caliper and rotor. Refer to (2) Remove outer axle shaft.
Page 102 BR/BE FRONT AXLE - 216FBI 3 - 29 AXLE SHAFTS - INTERMEDIATE (Continued) AXLE SHAFT SEALS REMOVAL (1) Remove hub bearings and axle shafts. (2) Remove axle shaft seal from the differential housing with a long drift or punch. Be careful not to damage housing.
Page 103 3 - 30 FRONT AXLE - 216FBI BR/BE AXLE VACUUM MOTOR (Continued) OPERATION The shift motor receives a vacuum signal from the switch mounted on the transfer case when the vehi- cle operator wants to switch from two wheel drive mode to four wheel drive mode, or vice versa.
Page 104 BR/BE FRONT AXLE - 216FBI 3 - 31 AXLE VACUUM MOTOR (Continued) DIAGNOSIS AND TESTING - VACUUM MOTOR AXLE VACUUM SHIFT MOTOR...
Page 105 3 - 32 FRONT AXLE - 216FBI BR/BE AXLE VACUUM MOTOR (Continued) AXLE VACUUM SHIFT MOTOR (CONT’D)
Page 106 BR/BE FRONT AXLE - 216FBI 3 - 33 AXLE VACUUM MOTOR (Continued) REMOVAL (1) Disconnect the vacuum and wiring connector from the shift housing. (2) Remove indicator switch. (3) Remove shift motor housing cover, gasket and shield from the housing (Fig. 28). Fig.
Page 107 3 - 34 FRONT AXLE - 216FBI BR/BE SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 31 Yoke Bearing Cap Fig. 30 Axle Shaft U-Joint 1 - LARGE-DIAMETER SOCKET WRENCH 1 - SHAFT YOKE 2 - VISE 2 - BEARING CAP 3 - SMALL-DIAMETER SOCKET WRENCH 3 - SNAP RINGS 4 - BEARING CAP 5 - SPINDLE YOKE...
Page 108 BR/BE FRONT AXLE - 216FBI 3 - 35 PINION SEAL (Continued) Fig. 34 Pinion Yoke Installer Fig. 32 Pinion Yoke 1 - PINION FLANGE 1 - YOKE HOLDER 2 - DIFFERENTIAL HOUSING 2 - YOKE 3 - YOKE PULLER Fig. 33 Pinion Seal Installer 1 - HANDLE 2 - INSTALLER (3) Install a new nut on the pinion gear.
Page 109 3 - 36 FRONT AXLE - 216FBI BR/BE PINION SEAL (Continued) Fig. 36 Pinion Shaft Nut Fig. 37 Bearing Cap Reference 1 - PINION FLANGE 1 - REFERENCE LETTERS 2 - HOLDING TOOL 6719 2 - REFERENCE LETTERS 3 - AXLE HOUSING DIFFERENTIAL REMOVAL (1) Raise and support vehicle.
Page 110 BR/BE FRONT AXLE - 216FBI 3 - 37 DIFFERENTIAL (Continued) Fig. 41 Pinion Mate/Side Gear Fig. 39 Differential Removal 1 - THRUST WASHER 1 - DIFFERENTIAL 2 - SIDE GEAR 2 - PRY BAR 3 - PINION MATE GEAR (3) Rotate the differential side gears and remove ASSEMBLY the pinion mate gears and thrust washers (Fig.
Page 111 3 - 38 FRONT AXLE - 216FBI BR/BE DIFFERENTIAL (Continued) Fig. 43 Differential Case Fig. 42 Pinion Mate Shaft Roll-Pin 1 - RAWHIDE HAMMER 1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN (2) Install a Pilot Stud C-3288-B at the left side of the differential housing and attach dial indicator to the pilot stud.
Page 112 BR/BE FRONT AXLE - 216FBI 3 - 39 DIFFERENTIAL (Continued) Fig. 45 Differential Cover 1 - SEALANT SURFACE 2 - SEALANT 3 - SEALANT THICKNESS Fig. 46 Differential Bearing Puller 1 - ADAPTERS DIFFERENTIAL CASE 2 - BEARING BEARINGS 3 - DIFFERENTIAL 4 - PLUG 5 - PULLER REMOVAL...
Page 113 3 - 40 FRONT AXLE - 216FBI BR/BE DIFFERENTIAL CASE BEARINGS (Continued) Fig. 48 Ring Gear 1 - CASE 2 - RING GEAR 3- HAMMER Fig. 47 Differential Bearing Installer 1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER PINION GEAR/RING GEAR REMOVAL NOTE: The ring and pinion gears are serviced as a...
Page 114 BR/BE FRONT AXLE - 216FBI 3 - 41 PINION GEAR/RING GEAR (Continued) Fig. 52 Rear Pinion Bearing Cup 1 - DRIVER Fig. 50 Pinion Gear 2 - HANDLE 1 - RAWHIDE HAMMER Fig. 53 Collapsible Spacer Fig. 51 Front Pinion Bearing Cup 1 - COLLAPSIBLE SPACER 1 - REMOVER 2 - SHOULDER...
Page 115 3 - 42 FRONT AXLE - 216FBI BR/BE PINION GEAR/RING GEAR (Continued) Fig. 54 Rear Pinion Bearing Fig. 55 Rear Pinion Bearing Cup 1 - PULLER 2 - VISE 1 - INSTALLER 3 - ADAPTERS 2 - HANDLE 4 - PINION SHAFT INSTALLATION NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve...
Page 116 BR/BE FRONT AXLE - 216FBI 3 - 43 PINION GEAR/RING GEAR (Continued) (5) Install pinion seal with an appropriate installer (Fig. 57). Fig. 57 Pinion Seal Installer 1 - HANDLE 2 - INSTALLER (6) Install proper thickness depth shim on the pin- ion gear.
Page 117 3 - 44 FRONT AXLE - 216FBI BR/BE PINION GEAR/RING GEAR (Continued) (11) Install yoke washer and a new nut on the pinion gear. Tighten the nut to 258 N·m (190 ft. lbs.) minimum. Do not over-tighten. Maximum torque is 393 N·m (290 ft.
Page 118 BR/BE FRONT AXLE - 248FBI 3 - 45 FRONT AXLE - 248FBI TABLE OF CONTENTS page page FRONT AXLE - 248FBI VACUUM MOTOR..... . . 63 DESCRIPTION .
Page 119 3 - 46 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns.
Page 120 BR/BE FRONT AXLE - 248FBI 3 - 47 FRONT AXLE - 248FBI (Continued) • Missing drive shaft balance weight(s). cle turns. A worn pinion mate shaft can also cause a • Worn or out of balance wheels. snapping or a knocking noise. •...
Page 121 3 - 48 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1.
Page 122 BR/BE FRONT AXLE - 248FBI 3 - 49 FRONT AXLE - 248FBI (Continued) Condition Possible Causes Correction Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level. 2. Worn axle shaft seals. 2. Replace seals. 3.
Page 123 3 - 50 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) REMOVAL (9) Install the stabilizer bar link to the axle bracket. Tighten the nut to 37 N·m (27 ft. lbs.) (1) Raise and support the vehicle. torque. (2) Remove the wheels and tires.
Page 124 BR/BE FRONT AXLE - 248FBI 3 - 51 FRONT AXLE - 248FBI (Continued) Fig. 4 Pinion Gear ID Numbers 1 - PRODUCTION NUMBERS 2 - PINION GEAR DEPTH VARIANCE 3 - GEAR MATCHING NUMBER Note where Old and New Pinion Marking columns Fig.
Page 125 3 - 52 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) (5) Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 108 N·m (80 ft. lbs.). Fig. 8 Gauge Tools In Housing 1 - ARBOR DISC 2 - PINION BLOCK Fig.
Page 126 BR/BE FRONT AXLE - 248FBI 3 - 53 FRONT AXLE - 248FBI (Continued) Fig. 9 Pinion Gear Depth Measurement 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR DIFFERENTIAL SIDE BEARING PRELOAD AND Fig. 10 Adjustment Shim Loactions GEAR BACKLASH 1 - PINION GEAR DEPTH SHIM/OIL BAFFLE Differential side bearing preload and gear backlash...
Page 127 3 - 54 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) (7) Using a dead-blow hammer, seat the differen- tial dummy bearings to each side of the housing (Fig. 12) and (Fig. 13). Fig. 12 Seat Pinion Gear Side Dummy Bearing 1 - DEAD-BLOW HAMMER 2 - DIFFERENTIAL HOUSING Fig.
Page 128 BR/BE FRONT AXLE - 248FBI 3 - 55 FRONT AXLE - 248FBI (Continued) Fig. 16 Differential Case To Ring Gear Side Fig. 17 Differential Case To Pinion Gear Side 1 - DIAL INDICATOR 1 - DIAL INDICATOR FACE 2 - DIFFERENTIAL CASE TO PINION GEAR SIDE 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - PINION GEAR 3 - DIFFERENTIAL HOUSING...
Page 129 3 - 56 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) (31) Rotate the differential case several times to seat the side bearings. (32) Position the indicator plunger against a ring gear tooth (Fig. 19). (33) Push and hold ring gear upward while not allowing the pinion gear to rotate.
Page 130 BR/BE FRONT AXLE - 248FBI 3 - 57 FRONT AXLE - 248FBI (Continued) Fig. 21 Gear Tooth Contact Patterns...
Page 131 3 - 58 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) SPECIFICATIONS FRONT AXLE - 248FBI AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 4.10 Ring Gear Diameter 248 mm (9.75 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Pinion Gear Standard Depth 127 mm (5.000 in.) Pinion Bearing Preload - Original Bearing...
Page 132 BR/BE FRONT AXLE - 248FBI 3 - 59 FRONT AXLE - 248FBI (Continued) PILOTS, STUDS - C-3288-B INSTALLER, CUP - C-111 DIAL INDICATOR, SET - C-3339 INSTALLER, CUP - C-146 INSTALLER, FLANGE - C-3718 REMOVER, CUP - D-158 REMOVER, CUP - D-162 HANDLE, DRIVE - C-4171 PULLER/PRESS - C-293-PA INSTALLER, BEARING - C-4190...
Page 133 3 - 60 FRONT AXLE - 248FBI BR/BE FRONT AXLE - 248FBI (Continued) BLOCK, ADAPTER – C-239-37 Fig. 22 Hub and Knuckle 1 - KNUCKLE 2 - HUB BEARING (8) Remove axle shaft from the housing. Avoid BLOCK, ADAPTER – C-239-62 damaging the axle shaft oil seal.
Page 134 BR/BE FRONT AXLE - 248FBI 3 - 61 AXLE SHAFTS - INTERMEDIATE (Continued) (4) Install the inner axle seal (Fig. 25). Fig. 23 Bushing Removal 1 - BUSHING Fig. 25 Seal Installation 2 - SHIFT MOTOR HOUSING OPENING 1 - SHIFT MOTOR HOUSING OPENING 3 - AXLE TUBE 2 - SEAL 4 - LOCATION FOR OPEN-END WRENCH...
Page 135 3 - 62 FRONT AXLE - 248FBI BR/BE AXLE SHAFT SEALS (Continued) Fig. 26 Seal Installation 1 - DIFFERENTIAL HOUSING 2 - POSITION FOR OPEN-END WRENCH 3 - SPECIAL TOOL 5041-2 4 - SPECIAL TOOL 8417 5 - SEAL 6 - SPECIAL TOOL 8411 Fig.
Page 136 BR/BE FRONT AXLE - 248FBI 3 - 63 AXLE VACUUM MOTOR (Continued) DIAGNOSIS AND TESTING - VACUUM MOTOR AXLE VACUUM SHIFT MOTOR...
Page 137 3 - 64 FRONT AXLE - 248FBI BR/BE AXLE VACUUM MOTOR (Continued) AXLE VACUUM SHIFT MOTOR (CONT’D)
Page 138 BR/BE FRONT AXLE - 248FBI 3 - 65 AXLE VACUUM MOTOR (Continued) REMOVAL (1) Disconnect the vacuum and wiring connector from the shift housing. (2) Remove indicator switch. (3) Remove shift motor housing cover, gasket and shield from the housing (Fig. 28). Fig.
Page 139 3 - 66 FRONT AXLE - 248FBI BR/BE SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 31 Yoke Bearing Cap Fig. 30 Axle Shaft Outer U—Joint 1 - LARGE-DIAMETER SOCKET WRENCH 1 - SHAFT YOKE 2 - VISE 2 - BEARING CAP 3 - SMALL-DIAMETER SOCKET WRENCH 3 - SNAP RINGS 4 - BEARING CAP...
Page 140 BR/BE FRONT AXLE - 248FBI 3 - 67 PINION SEAL (Continued) Fig. 32 Pinion 1 - YOKE HOLDER 2 - YOKE 3 - YOKE PULLER Fig. 34 Install Pinion Yoke 1 - YOKE INSTALLER 2 - YOKE HOLDER Fig. 33 Pinion Seal Installation 1 - SPECIAL TOOL C—4171 2 - SPECIAL TOOL C—8108 (3) Install a new nut on the pinion gear.
Page 141 3 - 68 FRONT AXLE - 248FBI BR/BE PINION SEAL (Continued) Fig. 36 Tightening Pinion Shaft Nut Fig. 37 Bearing Cap Reference 1 - PINION FLANGE 1 - REFERENCE LETTERS 2 - HOLDING TOOL 6719 2 - REFERENCE LETTERS 3 - AXLE HOUSING DIFFERENTIAL REMOVAL (1) Raise and support vehicle.
Page 142 BR/BE FRONT AXLE - 248FBI 3 - 69 DIFFERENTIAL (Continued) Fig. 41 Pinion Mate/Side Gear Fig. 39 Differential Removal 1 - THRUST WASHER 1 - DIFFERENTIAL 2 - SIDE GEAR 2 - PRY BAR 3 - PINION MATE GEAR (3) Rotate the differential side gears and remove ASSEMBLY the pinion mate gears and thrust washers (Fig.
Page 143 3 - 70 FRONT AXLE - 248FBI BR/BE DIFFERENTIAL (Continued) Fig. 43 Differential Case Fig. 42 Pinion Mate Shaft Roll-Pin 1 - RAWHIDE HAMMER 1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN (2) Install a Pilot Stud C-3288-B at the left side of the differential housing and attach dial indicator to the pilot stud.
Page 144 BR/BE FRONT AXLE - 248FBI 3 - 71 DIFFERENTIAL (Continued) Fig. 45 Differential Cover 1 - SEALANT SURFACE 2 - SEALANT 3 - SEALANT THICKNESS Fig. 46 Differential Bearing Removal DIFFERENTIAL CASE 1 - SPECIAL TOOL C-293-PA 2 - SPECIAL TOOL C-293-62 BEARINGS 3 - SPECIAL TOOL C-4487-1 4 - BEARING...
Page 145 3 - 72 FRONT AXLE - 248FBI BR/BE DIFFERENTIAL CASE BEARINGS (Continued) Fig. 48 Ring Gear 1 - CASE 2 - RING GEAR 3 - HAMMER Fig. 47 Install Differential Side Bearings 1 - HANDLE C-4171 2 - DIFFERENTIAL CASE 3 - BEARING 4 - TOOL C-4190 PINION GEAR/RING GEAR...
Page 146 BR/BE FRONT AXLE - 248FBI 3 - 73 PINION GEAR/RING GEAR (Continued) Fig. 52 Rear Pinion Bearing Cup 1 - DRIVER Fig. 50 Remove Pinion 2 - HANDLE 1 - RAWHIDE HAMMER Fig. 53 Collapsible Spacer Fig. 51 Front Pinion Bearing Cup 1 - COLLAPSIBLE SPACER 1 - REMOVER 2 - SHOULDER...
Page 147 3 - 74 FRONT AXLE - 248FBI BR/BE PINION GEAR/RING GEAR (Continued) Fig. 54 Rear Bearing Fig. 55 Rear Pinion Bearing Cup 1 - PULLER 2 - VISE 1 - INSTALLER 3 - ADAPTERS 2 - HANDLE 4 - PINION SHAFT INSTALLATION NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve...
Page 148 BR/BE FRONT AXLE - 248FBI 3 - 75 PINION GEAR/RING GEAR (Continued) (5) Install pinion seal with an appropriate installer (Fig. 57). Fig. 57 Pinion Seal Installer 1 - HANDLE 2 - INSTALLER (6) Install proper thickness depth shim on the pin- ion gear.
Page 149 3 - 76 FRONT AXLE - 248FBI BR/BE PINION GEAR/RING GEAR (Continued) (11) Install yoke washer and a new nut on the pinion gear. Tighten the nut to 291 N·m (215 ft. lbs.) minimum. Do not over–tighten. Maximum torque is 380 N·m (280 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing preload torque and never exceed specified preload torque.
Page 150 BR/BE REAR AXLE - 9 1/4 3 - 77 REAR AXLE - 9 1/4 TABLE OF CONTENTS page page REAR AXLE - 9 1/4 PINION SEAL DESCRIPTION ......77 REMOVAL .
Page 151 3 - 78 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) Fig. 1 9 1/4 Axle...
Page 152 BR/BE REAR AXLE - 9 1/4 3 - 79 REAR AXLE - 9 1/4 (Continued) 1 - HUB 30 - COVER BOLT 2 - AXLE SHAFT 31 - WASHER 3 - VENT FITTING 32 - CLIP 4 - DIFFERENTIAL HOUSING 33 - SIDE GEAR 5 - CUP 34 - THRUST WASHER...
Page 153 3 - 80 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns.
Page 154 BR/BE REAR AXLE - 9 1/4 3 - 81 REAR AXLE - 9 1/4 (Continued) When road testing, first warm-up the axle fluid by VIBRATION driving the vehicle at least 5 miles and then acceler- Vibration at the rear of the vehicle is usually ate the vehicle to the speed range where the noise is caused by a: the greatest.
Page 155 3 - 82 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1.
Page 156 BR/BE REAR AXLE - 9 1/4 3 - 83 REAR AXLE - 9 1/4 (Continued) Condition Possible Causes Correction Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level. 2. Improper grade of lubricant. 2. Fill differential with the correct fluid type and quantity.
Page 157 3 - 84 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) INSTALLATION (1) Raise the axle with lifting device and align to the leaf spring centering bolts. (2) Install the spring clamps and spring brackets. Refer to 2 Suspension for procedures. (3) Install shock absorbers and tighten nuts to 82 N·m (60 ft.
Page 158 BR/BE REAR AXLE - 9 1/4 3 - 85 REAR AXLE - 9 1/4 (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006...
Page 159 3 - 86 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) Fig. 10 Pinion Depth Tools Fig. 11 Pinion Gear Depth Measurement 1 - ARBOR DISC 1 - ARBOR 2 - PINION BLOCK 2 - SCOOTER BLOCK 3 - ARBOR 3 - DIAL INDICATOR 4 - PINION HEIGHT BLOCK...
Page 160 BR/BE REAR AXLE - 9 1/4 3 - 87 REAR AXLE - 9 1/4 (Continued) right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft. lbs.) (7) Measure the ring gear backlash. The range of backlash is 0.13 to 0.203 mm (0.005 to 0.008 inch).
Page 161 3 - 88 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) Fig. 14 Gear Tooth Contact Patterns...
Page 162 BR/BE REAR AXLE - 9 1/4 3 - 89 REAR AXLE - 9 1/4 (Continued) and differential housing on opposite sides of the hub its thickness with a micrometer. Add the washer (Fig. 15) . thickness to the recorded side gear clearance. The sum of gear clearance and washer thickness will determine required thickness of replacement thrust washer (Fig.
Page 163 3 - 90 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) SPECIFICATIONS REAR AXLE - 9 1/4 AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.21, 3.55, 3.92 Differential Case Flange Runout 0.076 mm (0.003 in.) Differential Case Clearance 0.12 mm (0.005 in.) Ring Gear Diameter 235 mm (9.25 in.)
Page 164 BR/BE REAR AXLE - 9 1/4 3 - 91 REAR AXLE - 9 1/4 (Continued) Puller C-452 Handle C-4171 Installer C-3860-A Installer—C-4076-B Installer C-3718 Handle C-4735-1 Wrench C-4164 Remover C-4828 Puller/Press C-293-PA...
Page 165 3 - 92 REAR AXLE - 9 1/4 BR/BE REAR AXLE - 9 1/4 (Continued) Adapters C-293-47 Adapters C-293-37 Installer C-4310 Plug C-293-3 Installer D-129 Installer C-4213 Installer C-3095 Fixture 8136 Remover C-4309 Trac-lok Tools C-4487...
Page 166 BR/BE REAR AXLE - 9 1/4 3 - 93 REAR AXLE - 9 1/4 (Continued) Trac-lok Tools 8139 Fig. 17 Pinion Shaft Lock Screw 1 - LOCK SCREW 2 - PINION MATE SHAFT Height Block 8542 Arbor Discs 8541 AXLE SHAFTS REMOVAL (1) Place the transmission in NEUTRAL and raise and support vehicle.
Page 167 3 - 94 REAR AXLE - 9 1/4 BR/BE AXLE SHAFTS (Continued) (5) Install cover and fill with gear lubricant. (6) Install brake drum (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DRUM - INSTALLATION). (7) Install wheel and tire assemblies. (8) Remove support and lower vehicle. AXLE SHAFT SEALS REMOVAL (1) Remove axle shaft.
Page 168 BR/BE REAR AXLE - 9 1/4 3 - 95 AXLE BEARINGS (Continued) INSTALLATION (1) Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. (2) Install the axle shaft bearing with Installer C-4198 and Handle C-4171 . Ensure that the bearing part number is against the installer.
Page 169 3 - 96 REAR AXLE - 9 1/4 BR/BE PINION SEAL (Continued) (10) If the rotating torque is low, use Holder 6719 to hold the companion flange (Fig. 23) and tighten the pinion nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved.
Page 170 BR/BE REAR AXLE - 9 1/4 3 - 97 DIFFERENTIAL (Continued) Fig. 27 Pinion Shaft Lock Screw Fig. 25 Reference Mark 1 - LOCK SCREW 1 - REFERENCE MARKS 2 - PINION SHAFT 2 - REFERENCE MARK 3 - BEARING CAPS Fig.
Page 171 3 - 98 REAR AXLE - 9 1/4 BR/BE DIFFERENTIAL (Continued) ASSEMBLY (1) Install differential side gears and thrust wash- ers. (2) Install differential pinion and thrust washers. (3) Install the pinion shaft. (4) Align the hole in the pinion shaft with the hole in the differential case and install the pinion shaft lock screw.
Page 172 BR/BE REAR AXLE - 9 1/4 3 - 99 DIFFERENTIAL - TRAC-LOK (Continued) (2) Raise one rear wheel until it is completely off the ground. (3) Engine off, transmission in neutral, and park- ing brake off. (4) Remove wheel and bolt Special Tool 6790 or equivalent tool to studs.
Page 173 3 - 100 REAR AXLE - 9 1/4 BR/BE DIFFERENTIAL - TRAC-LOK (Continued) Fig. 34 Step Plate Fig. 35 Threaded Adapter Disc 1 - LOWER SIDE GEAR 1 - SOCKET 2 - DIFFERENTIAL CASE 2 - SLOT IN ADAPTER 3 - STEP PLATE 3 - SCREWDRIVER 4 - DISC (7) Position a small screw driver in slot of...
Page 174 BR/BE REAR AXLE - 9 1/4 3 - 101 DIFFERENTIAL - TRAC-LOK (Continued) Fig. 39 Side Gear & Clutch Pack Fig. 37 Pinion Gear Thrust Washer 1 - DIFFERENTIAL CASE 1 - THRUST WASHER 2 - RETAINER 2 - FEELER GAUGE 3 - SIDE GEAR AND CLUTCH DISC PACK Lubricate each component with gear lubricant before assembly.
Page 175 3 - 102 REAR AXLE - 9 1/4 BR/BE DIFFERENTIAL - TRAC-LOK (Continued) Fig. 40 Clutch Disc Pack Fig. 42 Clutch Pack and Upper Side Gear 1 - CLUTCH PACK 1 - SIDE GEAR AND CLUTCH PACK 2 - RETAINER 2 - DIFFERENTIAL CASE 3 - SIDE GEAR 3 - STEP PLATE - C-6960-3...
Page 176 BR/BE REAR AXLE - 9 1/4 3 - 103 DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential case from axle housing. (2) Remove bearings from the differential case with Puller C-293-PA, Adapters C-293-47 and Plug SP-293-3 (Fig. 43). Fig. 44 Differential Side Bearings 1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING...
Page 177 3 - 104 REAR AXLE - 9 1/4 BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 45 Ring Gear 1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER Fig. 47 Pinion Gear (10) Install bolts into two of the threaded holes in 1 - RAWHIDE HAMMER the companion flange 180°...
Page 178 BR/BE REAR AXLE - 9 1/4 3 - 105 PINION GEAR/RING GEAR/TONE RING (Continued) (18) Remove the rear bearing cup from housing (20) Remove rear bearing from the pinion (Fig. 51) (Fig. 49) with Remover C-4307 and Handle C–4171. with Puller/Press C-293-PA and Adapters C-293-47. Fig.
Page 179 3 - 106 REAR AXLE - 9 1/4 BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 54 Pinion Seal 1 - HANDLE 2 - DIFFERENTIAL HOUSING 3 - INSTALLER Fig. 52 Rear Pinion Bearing Cup 1 - INSTALLER 2 - HANDLE Fig.
Page 180 BR/BE REAR AXLE - 9 1/4 3 - 107 PINION GEAR/RING GEAR/TONE RING (Continued) (9) Install a new collapsible preload spacer on pin- CAUTION: Never loosen pinion nut to decrease pin- ion shaft and install the pinion into the housing (Fig. ion bearing rotating torque and never exceed spec- 56).
Page 181 3 - 108 REAR AXLE - 9 1/4 BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 58 Pinion Fig. 59 Ring Gear Bolts 1 - COMPANION FLANGE 2 - TORQUE WRENCH 1 - TORQUE WRENCH 2 - RING GEAR BOLTS 3 - RING GEAR (19) Position ring gear on the differential case and 4 - DIFFERENTIAL CASE start two ring gear bolts.
Page 182 BR/BE REAR AXLE - 248RBI 3 - 109 REAR AXLE - 248RBI TABLE OF CONTENTS page page REAR AXLE - 248RBI INSTALLATION ......125 DESCRIPTION .
Page 183 3 - 110 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) gears. As a result, the pinion gears revolve with the TRAC-LOK DIFFERENTIAL pinion mate shaft but do not rotate around it (Fig. 1). The Trac-lok clutches are engaged by two concur- rent forces.
Page 184 BR/BE REAR AXLE - 248RBI 3 - 111 REAR AXLE - 248RBI (Continued) of traction, the wheel with the least traction may Turn the vehicle sharply to the left and to the right. spin. This will load the bearings and change the noise level.
Page 185 3 - 112 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1.
Page 186 BR/BE REAR AXLE - 248RBI 3 - 113 REAR AXLE - 248RBI (Continued) Condition Possible Causes Correction Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level. 2. Improper grade of lubricant. 2. Fill differential with the correct fluid type and quantity.
Page 187 3 - 114 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) INSTALLATION (1) Raise axle with lifting device and align to the leaf spring centering bolts. (2) Install spring clamps and spring brackets. Refer to 2 Suspension for procedures. (3) Install shock absorbers and tighten nuts to 82 N·m (60 ft.
Page 188 BR/BE REAR AXLE - 248RBI 3 - 115 REAR AXLE - 248RBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004...
Page 189 3 - 116 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) (5) Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 108 N·m (80 ft. lbs.). Fig. 9 Pinion Gear Depth Measurement 1 - ARBOR 2 - SCOOTER BLOCK Fig.
Page 190 BR/BE REAR AXLE - 248RBI 3 - 117 REAR AXLE - 248RBI (Continued) (7) Using a dead-blow hammer, seat the differen- tial dummy bearings to each side of the housing (Fig. 12) and (Fig. 13). Fig. 12 Seat Pinion Gear Side Dummy Bearing 1 - DEAD-BLOW HAMMER 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE...
Page 191 3 - 118 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) Fig. 16 Differential Case To Ring Gear Side 1 - DIAL INDICATOR 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING (14) Remove differential case and dummy bearings from the housing.
Page 192 BR/BE REAR AXLE - 248RBI 3 - 119 REAR AXLE - 248RBI (Continued) (20) Push and hold differential case to ring gear (29) Install differential case into the housing. side of the housing and record dial indicator reading (30) Remove spreader from the housing. (Fig.
Page 193 3 - 120 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) GEAR CONTACT PATTERN The ring and pinion gear contact patterns will show if the pinion depth is correct. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.
Page 194 BR/BE REAR AXLE - 248RBI 3 - 121 REAR AXLE - 248RBI (Continued) Fig. 21 Gear Tooth Contact Patterns...
Page 195 3 - 122 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) SPECIFICATIONS REAR AXLE - 248RBI AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 4.10 Ring Gear Diameter 248 mm (9.75 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Pinion Gear Standard Depth 127.0 mm (5.000 in.) Pinion Bearing Preload - Original Bearings...
Page 196 BR/BE REAR AXLE - 248RBI 3 - 123 REAR AXLE - 248RBI (Continued) Dial Indicator C-3339 Installer 8149 Puller/Press C-293-PA Holder 6719A Adapters C-293-37 Puller C-452 Installer C-4190 Installer 8108 Spreader W-129-B Handle C-4171 Pilot Studs C-3288-B...
Page 197 3 - 124 REAR AXLE - 248RBI BR/BE REAR AXLE - 248RBI (Continued) Fixture 6963-A Installer C-3095-A Remover D-158 Installer C-3718 Remover D-162 Trac-lok Tools 8139 Adapters C-293-37 Trac-lok Tools C-4487 Installer D-111 Gauge Set 6730 Installer D-146...
Page 198 BR/BE REAR AXLE - 248RBI 3 - 125 REAR AXLE - 248RBI (Continued) (7) Inspect bearing and seal contact surfaces on the axle tube for burrs/roughness. Remove all the rough contact surfaces from the axle tube. (8) Carefully slide the hub onto the axle. CAUTION: Do not let grease seal contact axle tube threads during installtion.
Page 199 3 - 126 REAR AXLE - 248RBI BR/BE PINION SEAL (Continued) (6) Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 291.5 N·m (215 ft. lbs.) (Fig. 24). Rotate pinion shaft several revolutions to ensure the bearing rollers are seated. Fig.
Page 200 BR/BE REAR AXLE - 248RBI 3 - 127 PINION SEAL (Continued) Fig. 26 Bearing Cap Identification 1 - REFERENCE LETTERS 2 - REFERENCE LETTERS Fig. 25 Check Pinion Rotation Torque 1 - PINION YOKE 2 - INCH POUND TORQUE WRENCH (11) Install the brake drums.
Page 201 3 - 128 REAR AXLE - 248RBI BR/BE DIFFERENTIAL (Continued) (12) Remove the dial indicator. (13) Pry the differential case loose from the hous- ing. To prevent damage, pivot on housing with the end of the pry bar against spreader (Fig. 28). Fig.
Page 202 BR/BE REAR AXLE - 248RBI 3 - 129 DIFFERENTIAL (Continued) (5) Install differential into the housing. Tap the differential case with a rawhide/rubber hammer to ensure the bearings are seated in housing (Fig. 32). (6) Remove the spreader. Fig. 31 Pinion Mate Shaft Roll-Pin 1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN...
Page 203 3 - 130 REAR AXLE - 248RBI BR/BE DIFFERENTIAL (Continued) (10) Apply a bead of Mopar Silicone Rubber Seal- will correct the condition in most instances. If the ant or equivalent to the housing cover (Fig. 34). chatter persists, clutch damage could have occurred. DIFFERENTIAL TEST The differential can be tested without removing the differential case by measuring rotating torque.
Page 204 BR/BE REAR AXLE - 248RBI 3 - 131 DIFFERENTIAL - TRAC-LOK (Continued) Fig. 38 Step Plate 1 - LOWER SIDE GEAR Fig. 36 Differential Case Holding Fixture 2 - DIFFERENTIAL CASE 1 - HOLDING FIXTURE 3 - STEP PLATE 2 - VISE 3 - DIFFERENTIAL Fig.
Page 205 3 - 132 REAR AXLE - 248RBI BR/BE DIFFERENTIAL - TRAC-LOK (Continued) (8) Install Forcing Screw C-6960-4 and tighten (11) Loosen the Forcing Screw in small increments screw to 122 N·m (90 ft. lbs.) maximum to compress until the clutch pack tension is relieved and the dif- Belleville springs in clutch packs (Fig.
Page 206 BR/BE REAR AXLE - 248RBI 3 - 133 DIFFERENTIAL - TRAC-LOK (Continued) (3) Install clutch pack and side gear in the ring gear side of the differential case (Fig. 45). Be sure clutch pack retaining clips remain in position and are seated in the case pockets. Fig.
Page 207 3 - 134 REAR AXLE - 248RBI BR/BE DIFFERENTIAL - TRAC-LOK (Continued) Fig. 46 Clutch Pack and Upper Side Gear 1 - SIDE GEAR AND CLUTCH PACK 2 - DIFFERENTIAL CASE 3 - STEP PLATE - C-6960-3 (15) Install and seat pinion shaft roll pin in differ- Fig.
Page 208 BR/BE REAR AXLE - 248RBI 3 - 135 DIFFERENTIAL CASE BEARINGS (Continued) Fig. 49 Ring Gear Removal 1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER Fig. 48 Install Differential Side Bearings 1 - HANDLE C-4171 2 - DIFFERENTIAL CASE 3 - BEARING 4 - TOOL C-4190 PINION GEAR/RING GEAR/...
Page 209 3 - 136 REAR AXLE - 248RBI BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 53 Rear Bearing Cup Removal 1 - DRIVER Fig. 51 Remove Pinion Gear 2 - HANDLE 1 - RAWHIDE HAMMER Fig. 54 Collapsible Spacer Fig. 52 Front Bearing Cup Removal 1 - COLLAPSIBLE SPACER 1 - REMOVER 2 - SHOULDER...
Page 210 BR/BE REAR AXLE - 248RBI 3 - 137 PINION GEAR/RING GEAR/TONE RING (Continued) (16) Remove the rear bearing from the pinion with Puller/Press C–293-PA and Adapters C–293–37 (Fig. 55). Place 4 adapter blocks so they do not damage the bearing cage. Fig.
Page 211 3 - 138 REAR AXLE - 248RBI BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) (4) Install new pinion seal with an appropriate installer (Fig. 58). Fig. 58 Pinion Seal 1 - SPECIAL TOOL C—4171 2 - SPECIAL TOOL C—8108 NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh.
Page 212 BR/BE REAR AXLE - 248RBI 3 - 139 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 61 Pinion Yoke Fig. 62 Check Pinion Gear Rotation Torque 1 - YOKE INSTALLER 1 - PINION YOKE 2 - YOKE HOLDER 2 - INCH POUND TORQUE WRENCH Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig.
Page 213 3 - 140 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI TABLE OF CONTENTS page page REAR AXLE - 267RBI INSTALLATION ......157 DESCRIPTION .
Page 214 BR/BE REAR AXLE - 267RBI 3 - 141 REAR AXLE - 267RBI (Continued) through the pinion mate and side gears. The side gears are splined to the axle shafts. During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears.
Page 215 3 - 142 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) ally utilizes a ramping action supplied by the cross Axle shaft bearings produce noise and vibration shafts to increase the force applied to the clutch when worn or damaged. The noise generally changes packs to increase the torque supplied to the non-slip- when the bearings are loaded.
Page 216 BR/BE REAR AXLE - 267RBI 3 - 143 REAR AXLE - 267RBI (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1.
Page 217 3 - 144 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) Condition Possible Causes Correction Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level. 2. Improper grade of lubricant. 2. Fill differential with the correct fluid type and quantity.
Page 218 BR/BE REAR AXLE - 267RBI 3 - 145 REAR AXLE - 267RBI (Continued) INSTALLATION (1) Raise axle with lifting device and align to the leaf spring centering bolts. (2) Install spring clamps and spring brackets. Refer to 2 Suspension for procedures. (3) Install shock absorbers and tighten nuts to 82 N·m (60 ft.
Page 219 3 - 146 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004...
Page 220 BR/BE REAR AXLE - 267RBI 3 - 147 REAR AXLE - 267RBI (Continued) (5) Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 108 N·m (80 ft. lbs.). Fig. 9 Pinion Gear Depth Measurement 1 - ARBOR 2 - SCOOTER BLOCK Fig.
Page 221 3 - 148 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) (7) Using a dead-blow hammer, seat the differen- tial dummy bearings to each side of the housing (Fig. 12) and (Fig. 13). Fig. 12 Seat Pinion Gear Side Dummy Bearing 1 - DEAD-BLOW HAMMER 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE...
Page 222 BR/BE REAR AXLE - 267RBI 3 - 149 REAR AXLE - 267RBI (Continued) Fig. 16 Differential Case To Ring Gear Side 1 - DIAL INDICATOR 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING (14) Remove differential case and dummy bearings from the housing.
Page 223 3 - 150 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) (20) Push and hold differential case to ring gear (29) Install differential case into the housing. side of the housing and record dial indicator reading (30) Remove spreader from the housing. (Fig.
Page 224 BR/BE REAR AXLE - 267RBI 3 - 151 REAR AXLE - 267RBI (Continued) GEAR CONTACT PATTERN The ring and pinion gear contact patterns will show if the pinion depth is correct. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.
Page 225 3 - 152 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) Fig. 21 Gear Tooth Contact Patterns...
Page 226 BR/BE REAR AXLE - 267RBI 3 - 153 REAR AXLE - 267RBI (Continued) SPECIFICATIONS REAR AXLE - 267RBI AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 4.10 Ring Gear Diameter 267 mm (10.50 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Pinion Gear Standard.
Page 227 3 - 154 REAR AXLE - 267RBI BR/BE REAR AXLE - 267RBI (Continued) Holder 6719A Puller/Press C-293-PA Puller C-452 Adapters C-293-62 Installer 8108 Installer C-4190 Spreader W-129-B Handle C-4171 Pilot Studs C-3288-B Fixture 6963-A Dial Indicator C-3339...
Page 228 BR/BE REAR AXLE - 267RBI 3 - 155 REAR AXLE - 267RBI (Continued) Remover D-158 Installer C-3718 Remover D-162 Trac-lok Tools 8139 Adapters C-293-62 Trac-lok Tools C-4487 Installer D-111 Gauge Set 6730 Installer D-146 Arbor Discs 6732 Installer C-3095-A...
Page 229 3 - 156 REAR AXLE - 267RBI BR/BE (11) Tighten adjustment nut to 163-190 N·m (120- AXLE SHAFTS 140 ft. lbs.) while rotating the wheel. Then loosen adjustment nut 1/8 to 1/3 of-a-turn to provide 0.025- REMOVAL 0.250mm (0.001-0.009 in.) wheel bearing end play. (1) Remove the axle shaft flange bolts.
Page 230 BR/BE REAR AXLE - 267RBI 3 - 157 PINION SEAL (Continued) (10) Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. INSTALLATION (1) Clean the seal contact surface in the housing bore. (2) Examine the splines on the pinion shaft for burrs or wear.
Page 231 3 - 158 REAR AXLE - 267RBI BR/BE PINION SEAL (Continued) NOTE: The bearing rotating torque should be con- (9) Install the hold down clamps and tighten the stant during a complete revolution of the pinion. If tool turnbuckle finger-tight. the rotating torque varies, this indicates a binding condition.
Page 232 BR/BE REAR AXLE - 267RBI 3 - 159 DIFFERENTIAL (Continued) Fig. 30 Pinion Mate/Side Gear Fig. 28 Differential Removal 1 - THRUST WASHER 1 - DIFFERENTIAL 2 - SIDE GEAR 2 - PRY BAR 3 - PINION MATE GEAR (4) Align the hole in the pinion gear mate shaft with the hole in the differential case.
Page 233 3 - 160 REAR AXLE - 267RBI BR/BE DIFFERENTIAL (Continued) Fig. 32 Differential Case Fig. 31 Pinion Mate Shaft Roll-Pin 1 - RAWHIDE HAMMER 1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN (3) Spread the housing enough to install the case in the housing.
Page 234 BR/BE REAR AXLE - 267RBI 3 - 161 DIFFERENTIAL (Continued) (4) Remove wheel and bolt Special Tool 6790 to studs. (5) Use torque wrench on special tool to rotate wheel and read rotating torque (Fig. 35). Fig. 35 Powr-lok Test -Typical 1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE Fig.
Page 235 3 - 162 REAR AXLE - 267RBI BR/BE DIFFERENTIAL - POWR-LOK (Continued) Fig. 37 Cover Half Removal Fig. 36 Case Marked 1 - CLUTCH PLATES 1 - REFERENCE MARKS 2 - BUTTON HALF 3 - FLANGE HALF Fig. 38 Powr-Lok Components 1 - FLANGE HALF 7 - PINION MATE CROSS SHAFT...
Page 236 BR/BE REAR AXLE - 267RBI 3 - 163 DIFFERENTIAL - POWR-LOK (Continued) ASSEMBLY The Powr-Lok differential has a two-piece cross shaft and uses 2 disc and 3 plates for each clutch pack. One plate and one disc in each clutch pack is dished.
Page 237 3 - 164 REAR AXLE - 267RBI BR/BE DIFFERENTIAL - POWR-LOK (Continued) If bolt heads have 7 radial lines or the number 180 stamped on the head, tighten these bolts to 122-136 N·m (90-100 ft. lbs.) torque. Fig. 42 Case Half Installation Fig.
Page 238 BR/BE REAR AXLE - 267RBI 3 - 165 DIFFERENTIAL CASE BEARINGS (Continued) Fig. 45 Ring Gear Removal 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER Fig. 44 Install Differential Side Bearings 1 - HANDLE C-4171 2 - DIFFERENTIAL CASE 3 - BEARING 4 - TOOL C-4190 PINION GEAR/RING GEAR/...
Page 239 3 - 166 REAR AXLE - 267RBI BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 49 Rear Bearing Cup Removal 1 - REMOVER Fig. 47 Remove Pinion Gear 2 - HANDLE 1 - RAWHIDE HAMMER Fig. 50 Rear Pinion Bearing Removal 1 - PULLER 2 - VISE Fig.
Page 240 BR/BE REAR AXLE - 267RBI 3 - 167 PINION GEAR/RING GEAR/TONE RING (Continued) NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If ring and pinion gears are reused, the pinion depth shim should not require replacement.
Page 241 3 - 168 REAR AXLE - 267RBI BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) (7) Install original solid shims on pinion gears. (8) Install yoke with Installer C-3718 and Yoke Holder 6719 (Fig. 55). Fig. 56 Pinion Gear Rotation Torque 1 - PINION YOKE 2 - TORQUE WRENCH Fig.
Page 242 BR/BE REAR AXLE - 286RBI 3 - 169 REAR AXLE - 286RBI TABLE OF CONTENTS page page REAR AXLE - 286RBI INSTALLATION ......185 DESCRIPTION .
Page 243 3 - 170 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) through the pinion mate and side gears. The side gears are splined to the axle shafts. During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears.
Page 244 BR/BE REAR AXLE - 286RBI 3 - 171 REAR AXLE - 286RBI (Continued) on bumpy roads and provide more pulling power when when the bearings are loaded. Road test the vehicle. one wheel looses traction. Pulling power is provided Turn the vehicle sharply to the left and to the right. continuously until both wheels loose traction.
Page 245 3 - 172 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1.
Page 246 BR/BE REAR AXLE - 286RBI 3 - 173 REAR AXLE - 286RBI (Continued) Condition Possible Causes Correction Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level. 2. Improper grade of lubricant. 2. Fill differential with the correct fluid type and quantity.
Page 247 3 - 174 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) INSTALLATION (1) Raise the axle with lifting device and align to the leaf spring centering bolts. (2) Install the spring clamps and spring brackets. Refer to 2 Suspension for procedures. (3) Install shock absorbers and tighten nuts to 82 N·m (60 ft.
Page 248 BR/BE REAR AXLE - 286RBI 3 - 175 REAR AXLE - 286RBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004...
Page 249 3 - 176 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) Fig. 8 Gauge Tools In Housing Fig. 9 Pinion Gear Depth Measurement 1 - ARBOR DISC 1 - ARBOR 2 - PINION BLOCK 2 - SCOOTER BLOCK 3 - ARBOR 3 - DIAL INDICATOR 4 - PINION HEIGHT BLOCK...
Page 250 BR/BE REAR AXLE - 286RBI 3 - 177 REAR AXLE - 286RBI (Continued) (7) Using a dead-blow hammer, seat the differen- tial dummy bearings to each side of the housing (Fig. 12) and (Fig. 13). Fig. 12 Seat Pinion Gear Side Dummy Bearing 1 - DEAD-BLOW HAMMER 2 - DIFFERENTIAL HOUSING Fig.
Page 251 3 - 178 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) Fig. 16 Differential Case and Dial Indicator 1 - DIAL INDICATOR 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING (14) Remove differential case and dummy bearings from the housing.
Page 252 BR/BE REAR AXLE - 286RBI 3 - 179 REAR AXLE - 286RBI (Continued) (21) Push and hold differential case to ring gear (29) Install differential case in the housing. side of the housing and record dial indicator reading (30) Remove spreader from the housing. (Fig.
Page 253 3 - 180 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) GEAR CONTACT PATTERN ANALYSIS The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the axle housing. It will also show if the ring gear backlash has been adjusted correctly.
Page 254 BR/BE REAR AXLE - 286RBI 3 - 181 REAR AXLE - 286RBI (Continued) Fig. 21 Gear Tooth Contact Pattern...
Page 255 3 - 182 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) SPECIFICATIONS REAR AXLE - 286RBI AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 4.10 Ring Gear Diameter 286 mm (11.25 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Pinion Gear Standard Depth 147.625 mm (5.812 in.) Pinion Bearing Preload - Original Bearings...
Page 256 BR/BE REAR AXLE - 286RBI 3 - 183 REAR AXLE - 286RBI (Continued) Puller C-452 Installer, Seal 8152 Wrench C-3281 Bridge 938 Dial Indicator Set C-3339 Splitter, Bearing 1130 Holder, Yoke 6719 Handle C-4171 Installer C-4190 Gauge, Pinion Depth Seting 6730...
Page 257 3 - 184 REAR AXLE - 286RBI BR/BE REAR AXLE - 286RBI (Continued) Installer C-4308 Installer D-191 Installer C-4204 Installer D-389 Remover C-4307 Spreader W-129-B Remover D-159 Pilot Studs C-3288-B Installer D-187-B...
Page 258 BR/BE REAR AXLE - 286RBI 3 - 185 (9) Install the hub bearing adjustment nut. Use AXLE SHAFTS Socket DD-1241–JD to install the adjustment nut. (10) Tighten the adjustment nut to 163-190 N·m REMOVAL (120-140 ft. lbs.) while rotating the wheel. (1) Remove the axle shaft flange bolts.
Page 259 3 - 186 REAR AXLE - 286RBI BR/BE PINION SEAL (Continued) Fig. 22 Yoke Removal 1 - PINION YOKE 2 - REMOVER C452 NOTE: The seal is correctly installed when the seal Fig. 23 Yoke Installation flange contacts the face of the differential housing flange.
Page 260 BR/BE REAR AXLE - 286RBI 3 - 187 PINION SEAL (Continued) Fig. 26 Bearing Cap Identification 1 - REFERENCE LETTERS 2 - REFERENCE LETTERS Fig. 25 Check Pinion Rotation Torque 1 - PINION YOKE 2 - INCH POUND TORQUE WRENCH DIFFERENTIAL REMOVAL (1) Raise and support the vehicle.
Page 261 3 - 188 REAR AXLE - 286RBI BR/BE DIFFERENTIAL (Continued) Fig. 30 Pinion Mate/Side Gear Fig. 28 Differential Removal 1 - THRUST WASHER 1 - DIFFERENTIAL 2 - SIDE GEAR 2 - PRY BAR 3 - PINION MATE GEAR DISASSEMBLY (4) Remove the differential side gears and thrust washers.
Page 262 BR/BE REAR AXLE - 286RBI 3 - 189 DIFFERENTIAL (Continued) Fig. 32 Differential Case Fig. 31 Pinion Mate Shaft Roll-Pin 1 - RAWHIDE HAMMER 1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN (1) Position Spreader W-129-B with the tool dowel pins seated in the locating holes.
Page 263 3 - 190 REAR AXLE - 286RBI BR/BE DIFFERENTIAL (Continued) (4) Remove wheel and bolt Special Tool 6790 or equivalent tool to studs. (5) Use torque wrench on special tool to rotate wheel and read rotating torque (Fig. 35). Fig. 35 Trac-lok Test - Typical (6) If rotating torque is less than 22 N·m (30 ft.
Page 264 BR/BE REAR AXLE - 286RBI 3 - 191 DIFFERENTIAL - TRAC-LOK (Continued) (1) Saturate the clutch plates with Mopar Hypoid Gear Lubricant or Additive. (2) Assembly the discs and plates on the side gear (Fig. 38) in the following order. (a) Install dished disc on side gear.
Page 265 3 - 192 REAR AXLE - 286RBI BR/BE DIFFERENTIAL - TRAC-LOK (Continued) Fig. 41 Case Halfs Fig. 39 Clutch Pack 1 - FIXTURE 1 - LUGS 2 - CASE BOLTS 2 - FLANGE HALF 3 - TORQUE WRENCH 3 - SIDE GEAR DIFFERENTIAL CASE BEARINGS REMOVAL...
Page 266 BR/BE REAR AXLE - 286RBI 3 - 193 DIFFERENTIAL CASE BEARINGS (Continued) PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring and pinion gears are service in a matched set. Do not replace the ring gear without replacing the matched pinion gear. (1) Remove differential from axle housing.
Page 267 3 - 194 REAR AXLE - 286RBI BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 45 Pinion Yoke Removal 1 - WRENCH 2 - YOKE 3 - REMOVER Fig. 47 Front Bearing Cup Removal 1 - REMOVER 2 - HANDLE Fig. 46 Remove Pinion Gear 1 - RAWHIDE HAMMER (13) Remove front...
Page 268 BR/BE REAR AXLE - 286RBI 3 - 195 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 49 Rear Pinion Bearing Removal Fig. 50 Pinion Rear Bearing Cup 1 - PULLER 2 - VISE 1 - INSTALLER 3 - PINION SHAFT 2 - HANDLE 4 - ADAPTER BLOCKS INSTALLATION (1) Apply Mopar Door Ease stick lubricant to out-...
Page 269 3 - 196 REAR AXLE - 286RBI BR/BE PINION GEAR/RING GEAR/TONE RING (Continued) (7) Install original solid shims on pinion gears. (8) Install yoke with Installer C-3718 and Yoke Holder 6719 (Fig. 54). Fig. 52 Pinion Seal 1 - HANDLE 2 - INSTALLER (6) Install rear bearing and oil slinger, if equipped, on the pinion gear with Installer D-389 and a press...
Page 270 BR/BE REAR AXLE - 286RBI 3 - 197 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 55 Pinion Gear Rotation Torque Fig. 56 Ring Gear Bolt 1 - PINION YOKE 1 - TORQUE WRENCH 2 - TORQUE WRENCH 2 - RING GEAR BOLT 3 - RING GEAR 4 - CASE (16) Invert the differential case in the vise.
Page 272 BRAKES 5 - 1 BR/BE BRAKES TABLE OF CONTENTS page page BRAKES - BASE INSTALLATION......20 SPECIFICATIONS .
Page 273 5 - 2 BRAKES BR/BE RELEASE SHOES REMOVAL ......40 REMOVAL ......41 INSTALLATION.
Page 274 BR/BE BRAKES 5 - 3 BRAKES - BASE (Continued) TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Booster Mounting Nuts Booster Mounting Nuts to the Dashpanel Diesel Hydraulic Booster Mounting Bolts Diesel Hydraulic Booster Booster Lines Diesel Hydraulic Booster Booster Hoses Master Cylinder Mounting Nuts...
Page 275 5 - 4 BRAKES BR/BE BRAKES - BASE (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Park Brake Pedal Assembly Mounting Bolts/Nuts Hub/Bearing — LD 4x2 Spindle Nut Hub/Bearing — HD 4x2 Spindle Nut Hub/Bearing — 4x4 Hub/Bearing Bolts SPECIAL TOOLS BASE BRAKES Cap, Master Cylinder Pressure Bleed 6921 HYDRAULIC/MECHANICAL...
Page 276 BR/BE BRAKES 5 - 5 HYDRAULIC/MECHANICAL (Continued) WARNING DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM WARNING: DUST AND DIRT ACCUMULATING ON Base brake components consist of the brake shoes, BRAKE PARTS DURING NORMAL USE MAY CON- calipers, wheel cylinders, brake drums, rotors, brake TAIN ASBESTOS FIBERS FROM PRODUCTION OR lines, master cylinder, booster, and parking brake AFTERMARKET LININGS.
Page 277 5 - 6 BRAKES BR/BE HYDRAULIC/MECHANICAL (Continued) (3) During road test, make normal and firm brake BRAKE DRAG stops in 25-40 mph range. Note faulty brake opera- Brake drag occurs when the lining is in constant tion such as low pedal, hard pedal, fade, pedal pulsa- contact with the rotor or drum.
Page 278 BR/BE BRAKES 5 - 7 HYDRAULIC/MECHANICAL (Continued) front tire (bruised, ply separation) can also cause BRAKE NOISES pull. Some brake noise is common with rear drum A common and frequently misdiagnosed pull condi- brakes and on some disc brakes during the first few tion is where direction of pull changes after a few stops after a vehicle has been parked overnight or stops.
Page 279 5 - 8 BRAKES BR/BE HYDRAULIC/MECHANICAL (Continued) filled with brake fluid (Fig. 1). Be sure end of bleed adapter provided with the equipment or Adapter hose is immersed in fluid. 6921. BRAKE LINES STANDARD PROCEDURE - DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs.
Page 280 BR/BE BRAKES 5 - 9 BRAKE LINES (Continued) tube can be used for emergency repair when factory The pressure differential switch is connected to the replacement parts are not readily available. brake warning lamp. To make a ISO flare use an ISO flaring tool kit. The metering valve on the 1500 and early (1) Cut off damaged tube with Tubing Cutter.
Page 281 5 - 10 BRAKES BR/BE COMBINATION VALVE (Continued) (4) Have helper press and hold brake pedal to floor (4) Bleed base brake system, (Refer to 5 - and observe warning light. BRAKES/HYDRAULIC/MECHANICAL STAN- (a) If warning light illuminates, switch is operat- DARD PROCEDURE).
Page 282 BR/BE BRAKES 5 - 11 DISC BRAKE CALIPERS (Continued) Fig. 6 Caliper Fig. 8 Protect Caliper Piston 1 - WASHERS 1 - CALIPER 2 - MOUNTING BOLTS 2 - PADDED BLOCK OF WOOD 3 - HOSE BOLT 3 - C-CLAMP DISASSEMBLY (4) To remove the caliper piston direct short (1) Drain the brake fluid from caliper.
Page 283 5 - 12 BRAKES BR/BE DISC BRAKE CALIPERS (Continued) Fig. 11 Bushings And Boot Seals Fig. 9 Piston Dust Boot Removal 1 - CALIPER 1 - CALIPER 2 - BUSHING 2 - DUST BOOT 3 - BOOT SEAL (10) Push caliper mounting bolt bushings out of INSPECTION the boot seals and remove the boot seals from the caliper (Fig.
Page 284 BR/BE BRAKES 5 - 13 DISC BRAKE CALIPERS (Continued) Fig. 12 Polishing Piston Bore Fig. 14 Caliper Piston Installation 1 - HONE 1 - CALIPER 2 - CALIPER 2 - DUST BOOT 3 - PISTON BORE 3 - PISTON Fig. 13 Piston Seal Fig.
Page 285 5 - 14 BRAKES BR/BE DISC BRAKE CALIPERS (Continued) (1) Install the rear disc brake caliper (Fig. 16). (7) Install the wheel and tire assemblies, (Refer to (2) Install the banjo bolt with new copper washers 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- to the caliper .tighten to 38 N·m (28 ft.
Page 286 BR/BE BRAKES 5 - 15 FLUID (Continued) SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
Page 287 5 - 16 BRAKES BR/BE FLUID RESERVOIR (Continued) PEDAL DESCRIPTION The brake booster is operated by a suspended type brake pedal. The pedal pivots on a shaft located in a mounting bracket attached to the dash panel. The pedal shaft is supported by bushings in the pedal and mounting bracket.
Page 288 BR/BE BRAKES 5 - 17 PEDAL (Continued) (8) Push pedal shaft back and out of passenger EXTERIOR/BRAKE LAMP SWITCH - INSTALLA- side of bracket (Fig. 24). TION). (9) Remove pedal shaft, brake pedal, wave washer (10) Install knee bolster, (Refer to 23 - BODY/IN- and bushings from vehicle.
Page 289 5 - 18 BRAKES BR/BE POWER BRAKE BOOSTER (Continued) (2) With the engine off depress the brake pedal several times to discharge the accumulator. Grasp the accumulator and see if it wobbles or turns. If it does the accumulator has lost a gas charge and the booster must be replaced.
Page 290 BR/BE BRAKES 5 - 19 POWER BRAKE BOOSTER (Continued) STANDARD PROCEDURE - BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. (1) Fill power steering pump reservoir.
Page 291 5 - 20 BRAKES BR/BE POWER BRAKE BOOSTER (Continued) (12) Bleed the hydraulic booster. ROTORS DIAGNOSIS AND TESTING—DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs.
Page 292 BR/BE BRAKES 5 - 21 ROTORS (Continued) (6) Remove the hub and rotor assembly (C3500 only) (Fig. 31). Fig. 29 Checking Rotor Runout And Thickness Fig. 31 ROTOR / HUB REMOVAL Variation REMOVAL - 1500/2500 FRONT 1 - DIAL INDICATOR (1) Raise and support the vehicle.
Page 293 5 - 22 BRAKES BR/BE ROTORS (Continued) (4) Remove the rotor from the hub/bearing wheel studs. REMOVAL - 3500 FRONT (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the hub extension mounting nuts and remove the extension from the rotor if equipped.
Page 294 BR/BE BRAKES 5 - 23 BRAKE PADS/SHOES REMOVAL - REAR (1) Raise and support the vehicle. (2) Remove the rear wheel and tire assemblies. (3) Compress the caliper. (4) Remove caliper mounting bolts NOTE: Do not allow brake hose to support caliper assembly.
Page 295 5 - 24 BRAKES BR/BE BRAKE PADS/SHOES (Continued) REMOVAL - FRONT Fig. 38 Top Anti-Rattle Spring 1 - CALIPER ADAPTER Fig. 40 Caliper 2 - ANTI-RATTLE SPRING 1 - CALIPER 2 - CALIPER ADAPTER Fig. 39 Bottom Anti-Rattle Spring 1 - ANTI-RATTLE SPRING 2 - CALIPER ADAPTER (1) Raise and support vehicle.
Page 296 BR/BE BRAKES 5 - 25 BRAKE PADS/SHOES (Continued) Fig. 44 Bottom Anti-Rattle Spring 1 - ANTI-RATTLE SPRING 2 - CALIPER ADAPTER tool into brake adjusting hole rotate adjuster star wheel to retract brake shoes. Fig. 42 Outboard Brake Shoe (5) Vacuum brake components to remove brake lin- 1 - OUTBOARD SHOE ing dust.
Page 297 5 - 26 BRAKES BR/BE BRAKE PADS/SHOES (Continued) (7) Remove adjuster cable. Slide cable eye off (3) Remove clip nuts securing brake drum to wheel anchor pin. Then unhook and remove cable from studs. adjuster lever. (4) Remove brake drum. (8) Remove cable guide from secondary shoe and (5) Vacuum brake components to remove brake lin- anchor plate from anchor pin.
Page 298 BR/BE BRAKES 5 - 27 BRAKE PADS/SHOES (Continued) (10) Top off master cylinder fluid level. INSTALLATION - FRONT (1) Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and cal- iper piston. (2) Clean caliper mounting adapter and anti-rattle springs.
Page 299 5 - 28 BRAKES BR/BE BRAKE PADS/SHOES (Continued) (3) Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. (4) Install parking brake lever to the secondary shoe and install retaining clip. (5) Install primary shoe on support plate. Secure shoe with new spring retainers and pin.
Page 300 BR/BE BRAKES 5 - 29 BRAKE PADS/SHOES (Continued) OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER (1) Start engine and check booster vacuum hose connections.
Page 301 5 - 30 BRAKES BR/BE MASTER CYLINDER (Continued) STANDARD PROCEDURE—MASTER CYLINDER BLEEDING A new master cylinder should be bled before instal- lation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. (1) Mount master cylinder in vise.
Page 302 BR/BE BRAKES 5 - 31 MASTER CYLINDER (Continued) Fig. 58 Wheel Cylinder Components–Typical 1 - SPRING 2 - CYLINDER 3 - PISTON CLIP 4 - BOOT Fig. 57 Master Cylinder 5 - PUSH ROD 1 - MOUNTING NUT 6 - PISTON 2 - MOUNTING NUT 7 - BLEED SCREW 3 - BRAKE LINES...
Page 303 5 - 32 BRAKES BR/BE WHEEL CYLINDERS (Continued) INSTALLATION (6) Disconnect brake line at wheel cylinder and remove cylinder. (1) Apply thin coat of silicone sealer to wheel cyl- (7) Remove bolts attaching support plate to axle inder mounting surface of support plate (Fig. 59). and remove support plate.
Page 304 BR/BE BRAKES 5 - 33 DRUM (Continued) The drum forces both brake shoes to move in the BRAKE DRUM RUNOUT same direction of rotation. Servo action begins with Measure drum diameter and runout with an accu- the primary brake shoe which begins to wedge (or rate gauge.
Page 305 5 - 34 BRAKES BR/BE DRUM (Continued) Discard the brake springs and retainer components if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Over- heating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate, replace the support plate if any of the pads are worn or rusted through.
Page 306 BR/BE BRAKES 5 - 35 DRUM (Continued) ADJUSTMENT WITH ADJUSTING TOOL PARKING BRAKE (1) Be sure parking brake lever is fully released. (2) Raise vehicle so rear wheels can be rotated DESCRIPTION – 2500/3500 WITH REAR DISC freely. BRAKES (3) Remove plug from each access hole in brake The parking brakes are operated by a system of support plates.
Page 307 5 - 36 BRAKES BR/BE PARKING BRAKE (Continued) OPERATION - 2500/3500 WITH REAR DISC (3) Loosen the cable tensioner nut at the equalizer to create slack in the front cable. BRAKES (4) Lower the vehicle. To apply the parking brake the pedal is depressed. (5) Remove the knee bolster, (Refer to 23 - BODY/ This creates tension in the cable which pulls forward INSTRUMENT...
Page 308 BR/BE BRAKES 5 - 37 (7) Compress cable tabs on each cable end fitting CABLES at the brake cable support plate. (8) Remove the cables from the brake cable sup- REMOVAL - REAR PARK BRAKE CABLE - port plates. 2500/3500 WITH REAR DISC BRAKES (1) Raise and support the vehicle.
Page 309 5 - 38 BRAKES BR/BE CABLES (Continued) (4) Remove the rear cables from the cable connec- (7) Pull the right rear cable through the brake tors. hose bracket and remove the cable retainers from the (5) Compress tabs on cable end fitting on the right axle.
Page 310 BR/BE BRAKES 5 - 39 CABLES (Continued) INSTALLATION - FRONT PARKING BRAKE (7) Lock the left cable end fitting tabs into the frame bracket lower hole. CABLE (8) Install the right rear cable into the tensioner (1) From inside the vehicle, insert the cable end cable bracket and lock the cable end fitting tabs into fitting into the hole in the pedal assembly.
Page 311 5 - 40 BRAKES BR/BE CABLE TENSIONER ADJUSTMENT NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is nec- essary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation.
Page 312 BR/BE BRAKES 5 - 41 RELEASE (Continued) Using a trim stick or another suitable wide (4) Lift the park brake release handle to access flat-bladed tool, gently pry each of the park brake and snap the plastic retainer clip that secures the release handle mounting bracket latch tabs away park brake release linkage rod to the lever on the from the retaining notches in the instrument panel...
Page 313 5 - 42 BRAKES BR/BE SHOES (Continued) (6) Disengage the park brake cable from behind the rotor assembly to allow easier disassembly of the park brake shoes (Fig. 74). Fig. 75 SHOES REMOVAL 1 - PARK BRAKE SHOES 2 - ADJUSTER 3 - RETURN SPRINGS Fig.
Page 314 CLUTCH 6 - 1 BR/BE CLUTCH TABLE OF CONTENTS page page CLUTCH OPERATION......16 DESCRIPTION .
Page 315 6 - 2 CLUTCH BR/BE CLUTCH (Continued) WARNING WARNING:: EXERCISE CARE WHEN SERVICING CLUTCH COMPONENTS. FACTORY INSTALLED CLUTCH DISCS DO NOT CONTAIN ASBESTOS FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY CONTAIN ASBESTOS FIBERS FROM AFTERMAR- KET COMPONENTS. BREATHING EXCESSIVE CON- CENTRATIONS OF THESE FIBERS CAN CAUSE SERIOUS BODILY HARM.
Page 316 BR/BE CLUTCH 6 - 3 CLUTCH (Continued) Fig. 3 Clutch Components And Inspection...
Page 317 6 - 4 CLUTCH BR/BE CLUTCH (Continued) Oil contamination indicates a leak at either the Check condition of the clutch before installation. A rear main seal or transmission input shaft. Oil leak- warped cover or diaphragm spring will cause grab age produces a residue of oil on the housing interior and incomplete release or engagement.
Page 318 BR/BE CLUTCH 6 - 5 CLUTCH (Continued) DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1. Normal wear. 1. Replace cover and disc. 2. Driver frequently rides (slips) the 2. Replace cover and disc. clutch. Results in rapid overheating and wear.
Page 319 6 - 6 CLUTCH BR/BE CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc binds on input shaft 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub splines. during installation. splines if possible. Replace disc if necessary. 2. Input shaft splines rough, 2.
Page 320 BR/BE CLUTCH 6 - 7 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Contact surface of release bearing 1. Clutch cover incorrect or release 1. Replace clutch cover and release damaged. fingers bent or distorted. bearing. 2. Release bearing defective or 2. Replace the release bearing. damaged.
Page 321 6 - 8 CLUTCH BR/BE CLUTCH DISC (Continued) Fig. 4 Clutch Disc-V6 Engine Fig. 6 Clutch Disc-V10/Diesel Engines 1 - FACING MATERIAL 1 - FACING MATERIAL 2 - DAMPER SPRINGS (4) 2 - DAMPER SPRINGS (9) 3 - 281 mm (11 in.) 3 - 312.5 mm (12.3 IN) 4 - HUB 4 - HUB...
Page 322 BR/BE CLUTCH 6 - 9 CLUTCH DISC (Continued) Fig. 7 Supporting Engine With Jack Stand And Wood Block—Diesel Model Shown 1 - WOOD BLOCK 2 - ADJUSTABLE JACK STAND Fig. 9 Clutch Cover Bolt Loosening/Tightening Pattern Fig. 10 Clutch Disc And Cover Alignment/ Installation Fig.
Page 323 6 - 10 CLUTCH BR/BE CLUTCH DISC (Continued) (9) Remove release lever and release bearing from clutch housing. Apply Mopar high temperature bearing grease to bore of release bearing, release lever contact surfaces and release lever pivot stud (Fig. 11). Fig.
Page 324 BR/BE CLUTCH 6 - 11 (4) Remove the release fork from the clutch hous- CLUTCH HOUSING ing. (5) Reinstall the clutch housing. Tighten the hous- DIAGNOSIS AND TESTING - CLUTCH HOUSING ing bolts nearest the alignment dowels first. Clutch housing alignment is important to proper (6) Mount the dial indicator on the threaded rod clutch operation.
Page 325 6 - 12 CLUTCH BR/BE CLUTCH HOUSING (Continued) On gas engines, the acceptable maximum TIR for housing bore runout is 0.010 inch. If measured TIR is more than 0.010 in. (as in the example), bore runout will have to be corrected with offset dowels. Offset dowels are available in 0.007, 0.014 and 0.021 in.
Page 326 BR/BE CLUTCH 6 - 13 CLUTCH HOUSING (Continued) 0.009 in. (at the 0.000 corner), 0.012 in. (at the –0.003 corner) and 0.013 in. (at the –0.004 corner). After installing the clutch assembly and housing, tighten the housing bolts nearest the alignment dow- els first.
Page 327 6 - 14 CLUTCH BR/BE CLUTCH HOUSING (Continued) (4) Lubricate release fork and pivot contact sur- faces with Mopar High Temperature wheel bearing grease before installation. (5) Align and install clutch housing on transmis- sion (Fig. 23). Tighten housing bolts closest to align- ment dowels first and to the following torque values: •...
Page 328 BR/BE CLUTCH 6 - 15 CLUTCH RELEASE BEARING (Continued) (2) Inspect release lever and pivot stud. Be sure stud is secure and in good condition. Be sure fork is not distorted or worn. Replace fork spring clips if bent or damaged. (3) Lubricate input shaft splines, bearing retainer slide surface, lever pivot ball stud, and release lever pivot surface with Mopar high temperature bearing...
Page 329 6 - 16 CLUTCH BR/BE PRESSURE PLATE (Continued) Two clutch covers are used for all applications. The 281 mm cover (Fig. 27) is used for 3.9L, 5.2L and 5.9L gas engine applications. Fig. 28 Pressure Plate - V10/Diesel Engine 1 - COVER 2 - RELEASE FINGERS 3 - PRESSURE PLATE 4 - 312.5 mm (12.3 in.)
Page 330 BR/BE CLUTCH 6 - 17 FLYWHEEL (Continued) shaft speeds and releasing the energy back into the ASSEMBLY system when the crankshaft slows down. NOTE: The ring gear is a shrink fit on the flywheel. DIAGNOSIS AND TESTING - FLYWHEEL This means the gear must be expanded by heating Check flywheel runout whenever misalignment is in order to install it.
Page 331 6 - 18 CLUTCH BR/BE PILOT BEARING (Continued) OPERATION The pilot bearing supports the transmission input shaft, maintains proper clutch assembly alignment and allows the transmission input shaft to rotate at a different speed (RPM) than the engine mounted crankshaft. When the clutch pedal is depressed (with vehicle in drive mode) the clutch disc slows and stops therefore, the transmission input shaft slows and stops as well.
Page 332 BR/BE CLUTCH 6 - 19 CLUTCH PEDAL (Continued) (2) Lubricate pedal shaft, pedal shaft bore (Fig. 33) and all bushings with Mopar Multi Mileage, or high temperature bearing grease. (3) Position clutch pedal in support. Align pedal with pivot shaft and slide shaft through pedal bush- ings.
Page 333 6 - 20 CLUTCH BR/BE LINKAGE (Continued) The clutch fluid reservoir, master cylinder, slave cylinder and fluid lines are pre-filled with fluid at the factory during assembly operations. The hydraulic system should not require additional fluid under normal circumstances. The reservoir fluid level will actually increase as normal clutch wear occurs.
Page 334 BR/BE CLUTCH 6 - 21 LINKAGE (Continued) (7) Position clutch fluid reservoir on dash panel and install reservoir screws. Tighten screws to 5 N·m (40 in. lbs.) torque. (8) Install the plastic clip securing the hydraulic line to the dash panel into the lower dash panel flange.
Page 335 6 - 22 CLUTCH BR/BE CLUTCH PEDAL POSITION SWITCH DESCRIPTION A clutch pedal position (interlock) switch is in the starter relay circuit and is mounted on the clutch master cylinder push rod (Fig. 38). The switch is actuated by clutch pedal movement. OPERATION The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully...
Page 336 COOLING 7 - 1 BR/BE COOLING TABLE OF CONTENTS page page COOLING REFILLING COOLING SYSTEM - 3.9L/5.2L/ DESCRIPTION ......1 5.9L/8.0L ENGINES .
Page 337 7 - 2 COOLING BR/BE COOLING (Continued) Fig. 1 Engine Cooling System Flow 1 - HEATER 3 - CROSSFLOW RADIATOR 2 - BYPASS* Coolant flow circuits for the 5.9L diesel engine are shown in (Fig. 3). DESCRIPTION—HOSE CLAMPS The cooling system utilizes both worm drive and spring type hose clamps.
Page 338 BR/BE COOLING 7 - 3 COOLING (Continued) Fig. 3 Cooling System Circulation—Diesel Engine...
Page 339 7 - 4 COOLING BR/BE COOLING (Continued) • Increasing engine speed for more air flow is rec- ommended. TRAILER TOWING: Consult Trailer Towing section of owners manual. Do not exceed limits. AIR CONDITIONING; ADD-ON OR AFTER MARKET: A maximum cooling package should have been ordered with vehicle if add-on or after market A/C is installed.
Page 340 BR/BE COOLING 7 - 5 COOLING (Continued) ACCESSING DIAGNOSTIC TROUBLE CODES PRESSURE TESTER METHOD To read DTC’s and to obtain cooling system data, The engine should be at normal operating temper- (Refer to 25 - EMISSIONS CONTROL - DESCRIP- ature. Recheck the system cold if cause of coolant TION).
Page 341 7 - 6 COOLING BR/BE COOLING (Continued) hoses, gasket edges and heater. Seal small leak holes If the needle on dial of pressure tester does not with a Sealer Lubricant (or equivalent). Repair leak fluctuate, race engine a few times to check for an holes and inspect system again with pressure abnormal amount of coolant or steam.
Page 342 BR/BE COOLING 7 - 7 COOLING (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM GAS ENGINE COOLING SYSTEM DIAGNOSIS—GASOLINE ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE 1. Has a Diagnostic Trouble Code (DTC) 1. (Refer to 25 - EMISSIONS CONTROL - GAUGE READS LOW been set indicating a stuck open DESCRIPTION) for On-Board Diagnostics thermostat?
Page 343 7 - 8 COOLING BR/BE COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 5. Pressure cap not installed tightly. If cap 5. Tighten cap is loose, boiling point of coolant will be lowered. Also refer to the following Step 6. Poor seals at the radiator cap. 6.
Page 344 BR/BE COOLING 7 - 9 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 16. Thermostat partially or completely 16. Check thermostat operation and shut. replace as necessary. (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL) . 17. Viscous fan drive not operating 17.
Page 345 7 - 10 COOLING BR/BE COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION PRESSURE CAP IS 1. Pressure relief valve in radiator cap is 1. Check condition of radiator cap and BLOWING OFF STEAM defective. cap seals. (Refer to 7 - COOLING/ AND/OR COOLANT TO ENGINE/RADIATOR PRESSURE CAP - COOLANT TANK.
Page 346 BR/BE COOLING 7 - 11 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISY VISCOUS 1. Fan blades loose. 1. Replace fan blade assembly. (Refer to FAN/DRIVE 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) 2. Fan blades striking a surrounding 2. Locate point of fan blade contact and object.
Page 347 7 - 12 COOLING BR/BE COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT COLOR 1. Coolant color is not necessarily an 1. (Refer to LUBRICATION & indication of adequate corrosion or MAINTENANCE/FLUID TYPES - temperature protection. Do not rely on DESCRIPTION). Adjust coolant mixture coolant color for determining condition of as necessary.
Page 348 BR/BE COOLING 7 - 13 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE) refill with correct mixture (Refer to 7 - COOLING - STANDARD PROCEDURE). 7. Thermostat stuck shut. 7.
Page 349 7 - 14 COOLING BR/BE COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. Replace radiator cap, check vent WHEN ENGINE IS COOLING. system on engine cool-down is not hose between radiator and reservoir being relieved through coolant bottle for blockage also check reservior/overflow system.
Page 350 BR/BE COOLING 7 - 15 COOLING (Continued) STANDARD PROCEDURE—DRAINING ING). The coolant need not be removed from tank unless the system is being refilled with fresh mix- COOLING SYSTEM 3.9L/5.2L/5.9L/8.0L ture. ENGINES (4) Remove radiator pressure cap. WARNING: DO NOT REMOVE CYLINDER BLOCK STANDARD PROCEDURE—REFILLING DRAIN PLUGS OR LOOSEN RADIATOR DRAIN- COOLING SYSTEM 3.9L/5.2L/5.9L/8.0L...
Page 351 7 - 16 COOLING BR/BE COOLING (Continued) (3) Fill coolant reserve/overflow tank to the FULL mark. (4) Start and operate engine until thermostat opens. Upper radiator hose should be warm to touch. (5) If necessary, add 50/50 water and antifreeze mixture to the coolant reserve/overflow tank to main- tain coolant level.
Page 352 BR/BE COOLING 7 - 17 COOLING (Continued) REVERSE FLUSHING ENGINE SPECIFICATIONS Drain cooling system. Remove thermostat housing TORQUE and thermostat. Install thermostat housing. Discon- nect radiator upper hose from radiator and attach flushing gun to hose. Disconnect radiator lower hose DESCRIPTION N·m from water pump and attach a lead-away hose to...
Page 353 7 - 18 COOLING BR/BE COOLING (Continued) SPECIAL TOOLS COOLING Pliers 6094 Spanner Wrench 6958 Pressure Tester 7700–A Adapter Pins 8346...
Page 354 BR/BE ACCESSORY DRIVE 7 - 19 ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONERS - 3.9L/5.2L/5.9L INSTALLATION......27 DESCRIPTION .
Page 355 7 - 20 ACCESSORY DRIVE BR/BE BELT TENSIONERS - 3.9L/5.2L/5.9L (Continued) REMOVAL (5) Remove pulley bolt. Remove pulley from ten- sioner. WARNING: BECAUSE OF HIGH SPRING PRES- INSTALLATION SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO- (1) Install pulley and pulley bolt to tensioner. MATIC TENSIONER.
Page 356 BR/BE ACCESSORY DRIVE 7 - 21 BELT TENSIONERS - 8.0L (Continued) Fig. 3 Belt Tensioner—8.0L V-10 Engines 1 - PULLEY BOLT 2 - IDLER PULLEY 3 - TENSIONER PULLEY 4 - TENSIONER 5 - TENSIONER MOUNTING BOLT Fig. 4 Indexing Marks—8.0L Engines Typical 1 - TENSIONER ASSEMBLY If a new belt is being installed, the arrow must be 2 - TENSIONER MOUNTING NUT...
Page 357 7 - 22 ACCESSORY DRIVE BR/BE BELT TENSIONERS - 8.0L (Continued) Fig. 6 Belt Tensioner 1 - PULLEY BOLT 2 - IDLER PULLEY 3 - TENSIONER PULLEY 4 - TENSIONER 5 - TENSIONER MOUNTING BOLT Fig. 5 Indexing Marks—8.0L Engines Typical 1 - TENSIONER ASSEMBLY 2 - TENSIONER MOUNTING NUT 3 - INDEXING ARROW...
Page 358 BR/BE ACCESSORY DRIVE 7 - 23 BELT TENSIONERS - 8.0L (Continued) OPERATION WARNING: THE AUTOMATIC BELT TENSIONER ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT TO DISASSEMBLE THE TENSIONER ASSEMBLY. The automatic belt tensioner maintains correct belt tension using a coiled spring within the tensioner housing.
Page 359 7 - 24 ACCESSORY DRIVE BR/BE BELT TENSIONERS - 5.9L DIESEL (Continued) be replaced (Fig. 11). Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. Fig.
Page 360 BR/BE ACCESSORY DRIVE 7 - 25 DRIVE BELTS - 3.9L/5.2L/5.9L (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from has separated from belt body) pulley grooves.
Page 361 7 - 26 ACCESSORY DRIVE BR/BE DRIVE BELTS - 3.9L/5.2L/5.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE 1. Incorrect belt tension 1. Inspect/Replace tensioner if (Objectionable squeal, squeak, or necessary rumble is heard or felt while drive 2. Bearing noise 2. Locate and repair belt is in operation) 3.
Page 362 BR/BE ACCESSORY DRIVE 7 - 27 DRIVE BELTS - 3.9L/5.2L/5.9L (Continued) INSTALLATION CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 13) (Fig. 14) for correct engine belt routing.
Page 363 7 - 28 ACCESSORY DRIVE BR/BE DRIVE BELTS - 8.0L (Continued) NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play.
Page 364 BR/BE ACCESSORY DRIVE 7 - 29 DRIVE BELTS - 8.0L (Continued) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt groove 2. Pulley groove tip has worn away 2. Replace belt rubber to tensile member GROOVE JUMPING 1.
Page 365 7 - 30 ACCESSORY DRIVE BR/BE DRIVE BELTS - 8.0L (Continued) REMOVAL INSTALLATION Drive belts are equipped with a spring loaded auto- CAUTION: When installing the accessory drive belt, matic belt tensioner (Fig. 16). This belt tensioner will the belt must be routed correctly. If not, engine may be used on all belt configurations, such as with or overheat due to water pump rotating in wrong without power steering or air conditioning.
Page 366 BR/BE ACCESSORY DRIVE 7 - 31 DRIVE BELTS - 8.0L (Continued) These are not a reason to replace the belt. However, cracks running along a rib (not across) are not nor- mal. Any belt with cracks running along a rib must be replaced (Fig.
Page 367 7 - 32 ACCESSORY DRIVE BR/BE DRIVE BELTS - 5.9L DIESEL (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from has separated from belt body) pulley grooves.
Page 368 BR/BE ACCESSORY DRIVE 7 - 33 DRIVE BELTS - 5.9L DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE (Objectional squeal, spueak, 1. Incorrect belt tension 1. Inspect/Replace tensioner if or rumble is heard or felt while drive necessary belt is in operation) 2.
Page 369 7 - 34 ACCESSORY DRIVE BR/BE DRIVE BELTS - 5.9L DIESEL (Continued) INSTALLATION CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 21) (Fig. 22) for correct engine belt routing.
Page 370 BR/BE ACCESSORY DRIVE 7 - 35 VACUUM PUMP - 5.9L DIESEL (Continued) The complete assembly must be removed in order DIAGNOSIS AND TESTING—VACUUM PUMP to service either pump. However, the power steering OUTPUT pump can be removed and serviced separately when The vacuum pump supplies necessary vacuum to necessary.
Page 371 7 - 36 ACCESSORY DRIVE BR/BE VACUUM PUMP - 5.9L DIESEL (Continued) (6) Remove bottom, inboard nut that attaches adapter to steering pump. This nut secures a small bracket to engine block. Nut and bracket must be removed before pump assembly can be removed from block.
Page 372 BR/BE ACCESSORY DRIVE 7 - 37 VACUUM PUMP - 5.9L DIESEL (Continued) Fig. 28 Steering Pump, Vacuum Pump and Adapter Fig. 27 Adapter to Power Steering Pump Nuts 1 - PUMP SHAFT 1 - VACUUM PUMP 2 - VACUUM FITTING 2 - ATTACHING NUTS 3 - VACUUM PUMP DRIVE 3 - STEERING PUMP...
Page 373 7 - 38 ACCESSORY DRIVE BR/BE VACUUM PUMP - 5.9L DIESEL (Continued) (6) Working from under vehicle, install pump assembly lower attaching bolt. Then tighten upper and lower bolt to 77 N·m (57 ft. lbs.). (7) Position bracket on steering pump inboard stud.
Page 374 BR/BE ENGINE 7 - 39 ENGINE TABLE OF CONTENTS page page COOLANT REMOVAL ......49 DESCRIPTION .
Page 375 7 - 40 ENGINE BR/BE DIAGNOSIS AND TESTING ....63 INSPECTION ......69 RADIATOR COOLANT FLOW .
Page 376 BR/BE ENGINE 7 - 41 cap. The system also provides some reserve coolant COOLANT RECOVERY to the radiator to cover minor leaks and evaporation CONTAINER - 3.9L/5.2L/5.9L/ or boiling losses. 5.9L DIESEL As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine.
Page 377 7 - 42 ENGINE BR/BE COOLANT RECOVERY CONTAINER - 3.9L/5.2L/5.9L/5.9L DIESEL (Continued) Fig. 4 Coolant Reserve/Overflow Tank—8.0L V-10 Engine 1 - COOLANT RESERVE/OVERFLOW TANK 2 - TANK MOUNTING BOLTS (3) 3 - ICM MOUNTING BOLTS (2) 4 - IGNITION CONTROL MODULE (ICM) Fig.
Page 378 BR/BE ENGINE 7 - 43 RADIATOR FAN - 3.9L/5.2L/5.9L/8.0L (Continued) (9) After removing fan blade/viscous fan drive assembly, do not place viscous fan drive in horizon- tal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant.
Page 379 7 - 44 ENGINE BR/BE RADIATOR FAN - 3.9L/5.2L/5.9L/8.0L (Continued) (4) Install fan blade/viscous fan drive assembly to water pump shaft (Fig. 6). (5) Except 8.0L V-10 Engine: Install coolant reserve/overflow tank to fan shroud. Snaps into posi- tion. (6) Install throttle cable to fan shroud. (7) Connect negative battery cable.
Page 380 BR/BE ENGINE 7 - 45 RADIATOR FAN - 5.9L DIESEL (Continued) (3) Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. INSTALLATION (1) Install fan blade assembly to viscous fan drive. Tighten mounting bolts to 23 N·m (17 ft.
Page 381 7 - 46 ENGINE BR/BE ENGINE BLOCK HEATER - 3.9L/5.2L/5.9L (Continued) Fig. 10 Engine Block Heater—8.0L V-10 Engine Fig. 9 Engine Block Heater 1 - FREEZE PLUG HOLE 1 - FREEZE PLUG HOLE 2 - SCREW 2 - BLOCK HEATER 3 - POWER CORD (120V AC) 3 - SCREW 4 - BLOCK HEATER...
Page 382 BR/BE ENGINE 7 - 47 ENGINE BLOCK HEATER - 8.0L (Continued) The 5.9L diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (Fig. 12). Fig. 12 Engine Block Heater—5.9L Diesel Engine 1 - BLOCK HEATER Fig.
Page 383 7 - 48 ENGINE BR/BE ENGINE BLOCK HEATER - 5.9L DIESEL (Continued) • Radiator fan relay on/off times (if equipped) • Target idle speed REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV- COOLANT TEMPERATURE SENSOR.
Page 384 BR/BE ENGINE 7 - 49 OPERATION ENGINE COOLANT The wax pellet is located in a sealed container at THERMOSTAT - 3.9L/5.2L/5.9L the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension DESCRIPTION and water pump pressure to force the valve to open. CAUTION: Do not operate an engine without a ther- DIAGNOSIS AND TESTING—THERMOSTAT mostat, except for servicing or testing.
Page 385 7 - 50 ENGINE BR/BE ENGINE COOLANT THERMOSTAT - 3.9L/5.2L/5.9L (Continued) Fig. 16 Generator Support Bracket—3.9L and 5.9L Engine 1 - IDLER PULLEY BUSHING 2 - A/C AND/OR GENERATOR MOUNTING BRACKET 3 - IDLER PULLEY 4 - SCREW AND WASHER (4) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) (Fig.
Page 386 BR/BE ENGINE 7 - 51 ENGINE COOLANT THERMOSTAT - 3.9L/5.2L/5.9L (Continued) Fig. 19 Thermostat—3.9L and 5.9L Engines Fig. 20 Thermostat Position—5.2L and 5.9L Engines 1 - THERMOSTAT HOUSING 2 - GASKET 3 - INTAKE MANIFOLD 4 - THERMOSTAT 5 - MACHINED GROOVE (4) Position thermostat housing to intake manifold.
Page 387 7 - 52 ENGINE BR/BE ENGINE COOLANT THERMOSTAT - 8.0L DESCRIPTION CAUTION: Do not operate an engine without a ther- mostat, except for servicing or testing. The thermostat on all gas powered engines is located beneath the thermostat housing at the front of the intake manifold (Fig.
Page 388 BR/BE ENGINE 7 - 53 ENGINE COOLANT THERMOSTAT - 8.0L (Continued) CAUTION: A number or letter is stamped into the tongue of constant tension clamps . If replacement is necessary, use only an original equipment clamp with a matching number or letter. (4) Remove upper radiator hose clamp.
Page 389 7 - 54 ENGINE BR/BE ENGINE COOLANT THERMOSTAT - 8.0L (Continued) cial Seal Tool number C-3995-A with handle tool number C-4171. (4) Install thermostat into recessed machined groove on intake manifold (Fig. 25). (5) Install thermostat housing (Fig. 25). (6) Install housing-to-intake manifold bolts.
Page 390 BR/BE ENGINE 7 - 55 ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued) to be used with cool or cold temperatures only. WEAR SAFETY GLASSES WHEN SERVICING CON- If used with high outside temperatures, serious STANT TENSION CLAMPS. engine damage could result. Refer to the litera- ture supplied with the cover for additional informa- CAUTION: A number or letter is stamped into the tion.
Page 391 7 - 56 ENGINE BR/BE FAN DRIVE VISCOUS CLUTCH - 3.9L/5.2L/5.9L/8.0L DESCRIPTION The thermal viscous fan drive (Fig. 28) is a sili- cone-fluid- filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds.
Page 392 BR/BE ENGINE 7 - 57 FAN DRIVE VISCOUS CLUTCH - 3.9L/5.2L/5.9L/8.0L (Continued) WARNING: BE SURE THAT THERE IS ADEQUATE cracks, loose blades, or loose rivets that could FAN BLADE CLEARANCE BEFORE DRILLING. have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are (1) Drill a 3.18-mm (1/8-in) diameter hole in the found.
Page 393 7 - 58 ENGINE BR/BE FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued) Only when sufficient heat is present, will the vis- VISCOUS DRIVE cous fan drive engage. This is when the air flowing If the fan assembly free-wheels without drag (the through the radiator core causes a reaction to the fan blades will revolve more than five turns when bimetallic coil.
Page 394 BR/BE ENGINE 7 - 59 FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued) CAUTION: Some engines equipped with serpentine OPERATION drive belts have reverse rotating fans and viscous The radiator supplies sufficient heat transfer using fan drives. They are marked with the word the cooling fins interlaced between the horizontal REVERSE to designate their usage.
Page 395 7 - 60 ENGINE BR/BE RADIATOR - 3.9L/5.2L/5.9L (Continued) CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. (3) Remove hose clamps and hoses from radiator. (4) Remove coolant reserve/overflow tank hose from radiator filler neck nipple.
Page 396 BR/BE ENGINE 7 - 61 RADIATOR - 3.9L/5.2L/5.9L (Continued) and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris. INSPECTION Inspect the radiator side tanks for cracks, broken or missing fittings also inspect the joint where the tanks seam up to the radiator core for signs of leak- age and/or deteriorating seals.
Page 397 7 - 62 ENGINE BR/BE RADIATOR - 8.0L (Continued) REMOVAL (1) Disconnect battery negative cables. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
Page 398 BR/BE ENGINE 7 - 63 RADIATOR - 8.0L (Continued) Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. INSTALLATION (1) Position fan shroud over the fan blades rear- ward towards engine. (2) Install rubber insulators to alignment dowels at lower part of radiator.
Page 399 7 - 64 ENGINE BR/BE RADIATOR - 5.9L DIESEL (Continued) WARNING: CONSTANT TENSION HOSE CLAMPS (8) Remove the four fan shroud mounting bolts ARE USED ON MOST COOLING SYSTEM HOSES. (Fig. 41). Position shroud rearward over the fan blades towards engine. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER...
Page 400 BR/BE ENGINE 7 - 65 RADIATOR - 5.9L DIESEL (Continued) (10) Lift radiator straight up and out of engine (15) Fill cooling system with coolant (Refer to 7 - compartment. The bottom of the radiator is equipped COOLING - STANDARD PROCEDURE). with two alignment dowels that fit into holes in the (16) Operate engine until it reaches normal tem- lower radiator support panel (Fig.
Page 401 7 - 66 ENGINE BR/BE RADIATOR PRESSURE CAP (Continued) tracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow tank to be drawn through its connecting hose into radiator. If the vacuum valve is stuck shut, the radiator hoses will collapse on cool- down.
Page 402 BR/BE ENGINE 7 - 67 RADIATOR PRESSURE CAP (Continued) ket has swollen and prevents vent valve from open- ing, replace cap. Fig. 46 Water Pump Location—Typical Fig. 45 Radiator Pressure Cap 1 - WATER PUMP BYPASS HOSE 1 - STAINLESS-STEEL SWIVEL TOP 2 - FAN BLADE ASSEMBLY 2 - RUBBER SEALS 3 - VISCOUS FAN DRIVE...
Page 403 7 - 68 ENGINE BR/BE WATER PUMP - 3.9L/5.2L/5.9L (Continued) (4) Disconnect the coolant reserve/overflow tank- to-radiator hose at the tank. (5) Remove the four fan shroud mounting bolts at the radiator (Fig. 47). Do not attempt to remove shroud from vehicle at this time. Fig.
Page 404 BR/BE ENGINE 7 - 69 WATER PUMP - 3.9L/5.2L/5.9L (Continued) Fig. 49 Fan Blade and Viscous Fan Drive—Typical 1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY Fig.
Page 405 7 - 70 ENGINE BR/BE WATER PUMP - 3.9L/5.2L/5.9L (Continued) INSTALLATION If water pump is replaced because of bearing/shaft damage or leaking shaft seal, the mechanical cooling (1) Clean gasket mating surfaces. fan assembly should also be inspected. Inspect for (2) Using a new gasket, install water pump to fatigue cracks, loose blades or loose rivets that could engine as follows: Guide water pump nipple into...
Page 406 BR/BE ENGINE 7 - 71 WATER PUMP - 8.0L (Continued) CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. (5) Remove radiator upper hose at radiator.
Page 407 7 - 72 ENGINE BR/BE WATER PUMP - 8.0L (Continued) (11) Remove heater hose at water pump fitting. (15) Remove the heater hose fitting from water (12) Remove the seven water pump mounting bolts pump if pump replacement is necessary. Note posi- (Fig.
Page 408 BR/BE ENGINE 7 - 73 WATER PUMP - 8.0L (Continued) Fig. 60 Water Pump—5.9L Diesel—Typical (non-A/C shown) 1 - WATER PUMP Fig. 59 Heater Hose Fitting Position—8.0L V-10 2 - ACCESSORY DRIVE BELT 3 - AUTOMATIC BELT TENSIONER 1 - HEATER HOSE FITTING 4 - MOUNT BOLT 2 - WATER PUMP 5 - 3/8 SQUARE HOLE...
Page 409 7 - 74 ENGINE BR/BE WATER PUMP - 5.9L DIESEL (Continued) (3) Install accessory drive belt. Refer to procedure in this group. (4) Install the bolt retaining the wiring harness near top of water pump. (5) Fill cooling system. Refer to Refilling Cooling System in this section.
Page 410 BR/BE ENGINE 7 - 75 WATER PUMP INLET TUBE - 3.9L/5.2L/5.9L (Continued) (2) Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. (3) Remove upper radiator hose clamp at radiator. A special clamp tool must be used to remove the con- stant tension clamps.
Page 411 7 - 76 ENGINE BR/BE WATER PUMP INLET TUBE - 3.9L/5.2L/5.9L (Continued) Fig. 66 Coolant Return Fig. 68 Bracket Bolts—3.9L V-6 or 5.2/5.9L V-8 1 - COOLANT RETURN TUBE LDC-Gas 2 - WATER PUMP 1 - COOLANT TUBE MOUNTING BOLT 3 - TUBE MOUNTING BOLT 2 - BRACKET MOUNTING BOLTS 4 - O-RING...
Page 412 BR/BE ENGINE 7 - 77 WATER PUMP INLET TUBE - 3.9L/5.2L/5.9L (Continued) REMOVAL—WATER PUMP BYPASS HOSE INSTALLATION—WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING WITH AIR CONDITIONING A water pump bypass hose (Fig. 70) is used (1) Position bypass hose clamps to the center of between the intake manifold and water pump on all hose.
Page 413 7 - 78 ENGINE BR/BE WATER PUMP INLET TUBE - 3.9L/5.2L/5.9L (Continued) (12) Install air cleaner assembly. (13) Install upper radiator hose to radiator. (14) Connect throttle cable to clip at radiator fan shroud. (15) Connect wiring harness to A/C compressor. (16) Fill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
Page 414 BR/BE TRANSMISSION 7 - 79 TRANSMISSION TABLE OF CONTENTS page page TRANS COOLER - 3.9L/5.2L/5.9L FLUSHING COOLER AND TUBES - DESCRIPTION ......79 WITHOUT RADIATOR IN-TANK OPERATION.
Page 415 7 - 80 TRANSMISSION BR/BE TRANS COOLER - 3.9L/5.2L/5.9L (Continued) (3) Verify pump power switch is turned OFF. Con- nect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. (4) Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush.
Page 416 BR/BE TRANSMISSION 7 - 81 TRANS COOLER - 3.9L/5.2L/5.9L (Continued) (2) Reinstall filler plug on Tool 6906B. (20) Install a new thermostat spring, thermostat, (3) Verify pump power switch is turned OFF. Con- cover, and snap-ring into the transmission oil cooler. nect red alligator clip to positive (+) battery post.
Page 417 7 - 82 TRANSMISSION BR/BE TRANS COOLER - 3.9L/5.2L/5.9L (Continued) ASSEMBLY (1) Throughly clean the thermostat bore on the transmission oil cooler. (2) Install new spring, thermostat, end plug and snap ring. (3) Install transmission oil cooler (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER INSTALLATION).
Page 418 BR/BE TRANSMISSION 7 - 83 TRANS COOLER - 8.0L (Continued) (2) Reinstall filler plug on Tool 6906-B. (3) Verify pump power switch is turned OFF. Con- nect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. (4) Disconnect the cooler lines at the transmission.
Page 419 7 - 84 TRANSMISSION BR/BE TRANS COOLER - 8.0L (Continued) erally used to clean automatic transmission compo- (19) Remove Special Tool Cooler Plug 8414 from nents. DO NOT use solvents containing acids, water, the transmission oil cooler. gasoline, or any other corrosive liquids. (20) Install a new thermostat spring, thermostat, (2) Reinstall filler plug on Tool 6906B.
Page 420 BR/BE TRANSMISSION 7 - 85 TRANS COOLER - 8.0L (Continued) INSTALLATION (1) Install the oil cooler and cooler line assembly to the vehicle. (2) Install three mounting bolts and tighten to 6 N·m (50 in. lbs.) torque. (3) Connect the transmission cooling lines to the oil cooler by pushing the rubber hoses onto the oil cooler tubes.
Page 421 7 - 86 TRANSMISSION BR/BE TRANS COOLER - 5.9L DIESEL (Continued) WARNING: WEAR PROTECTIVE EYEWEAR THAT (11) Place CLEAR suction line into a one quart MEETS THE REQUIREMENTS OF OSHA AND ANSI container of Mopar ATF +4, type 9602, Automatic Transmission Fluid.
Page 422 BR/BE TRANSMISSION 7 - 87 TRANS COOLER - 5.9L DIESEL (Continued) (9) Re-install the thermostat cover onto the oil (5) Remove the charge air cooler-to-oil cooler bolt cooler and install the snap-ring. (Fig. 8). (10) Re-connect the oil cooler to the transmission cooler lines.
Page 423 7 - 88 TRANSMISSION BR/BE TRANS COOLER - 5.9L DIESEL (Continued) (7) Lift oil cooler off of mounting bracket. INSTALLATION—AIR TO OIL COOLER (8) If replacing cooler, make sure to transfer con- (1) Carefully position the oil cooler assembly to the verter drain back valve to new cooler.
Page 424 AUDIO 8A - 1 BR/BE AUDIO TABLE OF CONTENTS page page AUDIO ENGINE-TO-BODY GROUND STRAP DESCRIPTION ......1 REMOVAL .
Page 425 8A - 2 AUDIO BR/BE AUDIO (Continued) Refer to Electrical, Restraints for more information The RAZ radio receiver with a remote radio switch on the clockspring. Refer to Electrical, Body Control/ option is one of the features that the CTM controls. Central Control Module for more information on the The CTM is programmed to send switch status mes- Central Timer Module.
Page 426 BR/BE AUDIO 8A - 3 AUDIO (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO AUDIO 1. Fuse faulty. 1. Check radio fuses in junction block. Replace faulty fuses, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connections. Repair, if required.
Page 427 8A - 4 AUDIO BR/BE AUDIO (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO/POOR TAPE 1. Faulty tape. 1. Insert known good tape and test operation. OPERATION 2. Foreign objects behind 2. Remove foreign objects and test operation. tape door. 3.
Page 428 BR/BE AUDIO 8A - 5 ANTENNA BODY & CABLE (Continued) commercial radio stations in both the Amplitude the instrument panel (secondary) antenna coaxial Modulating (AM) and Frequency Modulating (FM) cable. The primary coaxial cable includes a grommet frequency ranges. These electromagnetic radio fre- that seals the cable to an entry hole in the right cowl quency signals induce small electrical modulations side outer panel where the cable passes into the pas-...
Page 429 8A - 6 AUDIO BR/BE ANTENNA BODY & CABLE (Continued) (1) Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery negative terminal post. (2) The resistance should be less than one ohm. (3) If the resistance is more than one ohm, check the braided ground strap(s) connected to the engine and the vehicle body for being loose, corroded, or...
Page 430 BR/BE AUDIO 8A - 7 ANTENNA BODY & CABLE (Continued) (3) Remove the foam tape to access the coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. (4) Securely tie a suitable length of cord or twine to the antenna half of the coaxial cable connector.
Page 431 8A - 8 AUDIO BR/BE ANTENNA BODY & CABLE (Continued) securely to the connector on the end of the antenna location views for the various wire harness connec- tors, splices and grounds. cable being installed into the instrument panel. This cord will be used to pull or “fish”...
Page 432 BR/BE AUDIO 8A - 9 RADIO CHOKE RELAY (Continued) There should now be battery voltage. If OK, repair (2) Install and tighten the two screws that secure the open amplified speaker (+) circuits to the speak- the filter, choke, and speaker relay mounting bracket er-mounted amplifiers as required.
Page 433 8A - 10 AUDIO BR/BE INSTRUMENT PANEL ANTENNA CABLE (Continued) (7) Remove the radio receiver from the instrument These radio receivers can only be serviced by an panel. Refer to Audio, Radio for the procedures. authorized radio repair station. See the latest War- (8) Pull the antenna cable out through the radio ranty Policies and Procedures manual for a current receiver opening in the instrument panel.
Page 434 BR/BE AUDIO 8A - 11 RADIO (Continued) • Radio memory presets not working properly (6) Connect the battery negative cable. Turn the • Volume changes with no remote radio switch ignition switch to the On position. Check for battery input voltage at the fused ignition switch output (acc/run) •...
Page 435 8A - 12 AUDIO BR/BE RADIO (Continued) RADIO NOISE SUPPRESSION COMPONENTS DESCRIPTION Radio Frequency Interference (RFI) and Electro- Magnetic Interference (EMI) noise suppression is accomplished primarily through circuitry internal to the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are used on this vehicle to control RFI or EMI noise include the fol- lowing:...
Page 436 BR/BE AUDIO 8A - 13 RADIO NOISE SUPPRESSION COMPONENTS (Continued) • Wiper motor. If the source of RFI or EMI noise is identified as a component on the vehicle (i.e., generator, blower motor, etc.), the ground path for that component should be checked.
Page 437 8A - 14 AUDIO BR/BE ENGINE-TO-BODY GROUND STRAP (Continued) Fig. 12 Engine-To-Body Ground Strap Remove/ Install - V10 Engine Fig. 13 Cab-To-Bed Ground Strap Remove/Install 1 - GROUND STRAP 1 - BED CROSSMEMBER 2 - GROUND STRAP 2 - GROUND STRAP 3 - SCREW 3 - CAB FLOOR PANEL 4 - SCREW...
Page 438 BR/BE AUDIO 8A - 15 HEATER CORE GROUND STRAP (Continued) wheel trim cover. The switch on the left side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions.
Page 439 8A - 16 AUDIO BR/BE REMOTE SWITCHES (Continued) manual in the vehicle glove box. For complete circuit (2) Use an ohmmeter to check the switch resis- diagrams, refer to the appropriate wiring informa- tances as shown in the Remote Radio Switch Test tion.
Page 440 BR/BE AUDIO 8A - 17 REMOTE SWITCHES (Continued) (5) Install the driver side airbag module onto the steering wheel. Refer to Electrical, Restraints for the procedures. (6) Reconnect the battery negative cable. SPEAKER DESCRIPTION STANDARD The standard equipment speaker system includes speakers in four locations.
Page 441 8A - 18 AUDIO BR/BE SPEAKER (Continued) PREMIUM circuit and return (–) circuit cavities for the inopera- tive speaker location(s) in the radio receiver wire The Infinity speakers used in the premium speaker harness connectors for continuity to ground. In each system are driven by dual amplifiers that are inte- case, there should be no continuity.
Page 442 BR/BE AUDIO 8A - 19 SPEAKER (Continued) (8) Turn the radio receiver off. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the Infinity-amplified front door- mounted speaker on the same side of the vehicle as the inoperative speaker.
Page 443 8A - 20 AUDIO BR/BE A-PILLAR TWEETER SPEAKER (Continued) (5) Reconnect the body wire harness connector to INSTALLATION the A-pillar tweeter wire harness connector. (1) Position the speaker to the front door inner (6) Engage the trim onto the A-pillar. Refer to panel.
Page 444 BR/BE AUDIO 8A - 21 REAR CAB SIDE PANEL SPEAKER (Continued) (3) Remove the two screws that secure the speaker to the rear door inner panel (Fig. 22). Fig. 21 Rear Speaker Remove/Install - Club Cab 1 - WIRE HARNESS CONNECTOR 2 - CAB SIDE INNER PANEL Fig.
Page 446 CHIME/BUZZER 8B - 1 BR/BE CHIME/BUZZER TABLE OF CONTENTS page page CHIME WARNING SYSTEM DIAGNOSIS AND TESTING ....2 DESCRIPTION ......1 CHIME WARNING SYSTEM .
Page 447 8B - 2 CHIME/BUZZER BR/BE CHIME WARNING SYSTEM (Continued) • Head/Park Lights-On Warning - The CTM • The vehicle is over a programmed speed value chime tone generator will generate repetitive chime (Middle East Gulf Coast Country (GCC) only). The tones at a fast rate to announce that hard wired CTM chime tone generator will generate repetitive inputs from the driver door ajar switch, headlamp...
Page 448 BR/BE CHIME/BUZZER 8B - 3 CHIME WARNING SYSTEM (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- TEM CAPACITOR TO DISCHARGE BEFORE PER- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE FORMING FURTHER DIAGNOSIS OR SERVICE. THIS ATTEMPTING ANY STEERING WHEEL, STEERING IS THE ONLY SURE WAY TO DISABLE THE AIRBAG COLUMN, OR INSTRUMENT PANEL COMPONENT SYSTEM.
Page 449 8B - 4 CHIME/BUZZER BR/BE CHIME WARNING SYSTEM (Continued) CHIME WARNING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO KEY-IN IGNITION 1. Driver door ajar switch 1. Check for continuity between the driver door WARNING CHIME, BUT sense circuit open. ajar switch sense circuit cavities of the connector OTHER CHIME FEATURES for the driver side front door ajar switch and the instrument panel wire harness connector...
Page 450 BR/BE CHIME/BUZZER 8B - 5 CHIME WARNING SYSTEM (Continued) CHIME WARNING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO CHIMES AND OTHER 1. CTM ground circuit(s) 1. Check for continuity between the ground circuit CTM FEATURES ERRATIC open. cavities of the instrument panel wire harness OR DISABLED connector(s) for the CTM and a good ground.
Page 452 ELECTRONIC CONTROL MODULES 8E - 1 BR/BE ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page BODY CONTROL/CENTRAL TIMER MODULE REMOVAL ......12 DESCRIPTION .
Page 453 8E - 2 ELECTRONIC CONTROL MODULES BR/BE BODY CONTROL/CENTRAL TIMER MODULE (Continued) • Intermittent Wipe Control - All versions of external connector receptacles that connect it to the vehicle electrical system through one (base) or two the CTM provide control of the intermittent wipe (high-line/premium) take outs with connectors from delay, and wipe-after-wash features.
Page 454 BR/BE ELECTRONIC CONTROL MODULES 8E - 3 BODY CONTROL/CENTRAL TIMER MODULE (Continued) base version of the CTM and the hard wired inputs armature above the inboard side of the instrument or outputs of all CTM versions can be diagnosed panel steering column opening. using conventional diagnostic tools and methods;...
Page 455 8E - 4 ELECTRONIC CONTROL MODULES BR/BE BODY CONTROL/CENTRAL TIMER MODULE (Continued) • Horn relay control - high-line/premium version ing with the proper hard wired outputs needed to only perform its many functions. • VTSS indicator driver - high-line/premium ver- WARNING: ON VEHICLES EQUIPPED WITH AIR- sion only •...
Page 456 BR/BE ELECTRONIC CONTROL MODULES 8E - 5 BODY CONTROL/CENTRAL TIMER MODULE (Continued) CTM from the CTM connector receptacle(s). Check CTM using the DRBIII scan tool before returning the wire harness connectors and the CTM receptacles the vehicle to service. for loose, corroded, or damaged terminals and pins. If (1) Disconnect and isolate the battery negative OK, go to Step 6.
Page 457 8E - 6 ELECTRONIC CONTROL MODULES BR/BE BODY CONTROL/CENTRAL TIMER MODULE (Continued) (1) Position the CTM to the inboard side of the instrument panel steering column opening. (2) Reconnect the instrument panel wire harness connector(s) for the CTM (one connector for the base version CTM, two connectors for the high-line/pre- mium version) to the CTM connector receptacle(s) (Fig.
Page 458 BR/BE ELECTRONIC CONTROL MODULES 8E - 7 COMMUNICATION (Continued) In addition to reducing wire harness complexity, The two data bus wires are twisted together in component sensor current loads and controller hard- order to shield the wires from the effects of any Elec- ware, multiplexing offers a diagnostic advantage.
Page 459 8E - 8 ELECTRONIC CONTROL MODULES BR/BE COMMUNICATION (Continued) Once a message is broadcast over the CCD data bus, all electronic control modules on the data bus have the ability to receive it through their CCD chip. Reception of CCD messages is also carried out by the transceiver in the CCD chip.
Page 460 BR/BE ELECTRONIC CONTROL MODULES 8E - 9 COMMUNICATION (Continued) Fig. 7 Bus Termination When the microprocessor signals the transceiver in PRIORITY the CCD chip to broadcast a message, the transceiver Messages can be broadcast almost simultaneously turns the current drivers On and Off, which cycles by modules over the CCD data bus.
Page 461 8E - 10 ELECTRONIC CONTROL MODULES BR/BE COMMUNICATION (Continued) Fig. 8 Voltage Cycling to Correspond to Message zeros have a higher priority. For example: of the two MESSAGE IDENTIFICATION messages below, Message #2 loses arbitration at the Because messages are broadcast over the data bus, second bit, where Message #1 has a zero and Mes- all modules can receive them, yet not all modules sage #2 has a one (Fig.
Page 462 BR/BE ELECTRONIC CONTROL MODULES 8E - 11 COMMUNICATION (Continued) the module attempts to have the CCD chip re-send the message. DIAGNOSIS AND TESTING - CCD DATA BUS CCD BUS FAILURE The CCD data bus can be monitored using the DRBIII scan tool.
Page 463 8E - 12 ELECTRONIC CONTROL MODULES BR/BE CONTROLLER ANTILOCK BRAKE (Continued) • ABS Warning Lamp • Brake Warning Lamp REMOVAL (1) Disconnect battery negative cable. (2) Push the harness connector locks to release the locks, (Fig. 11) then remove the connectors from the CAB.
Page 464 BR/BE ELECTRONIC CONTROL MODULES 8E - 13 ENGINE CONTROL MODULE DESCRIPTION - ECM The ECM is bolted to the left side of the engine behind the fuel filter (Fig. 14). It is a separate com- ponent and can be serviced. The FPCM is internal to the fuel injection pump (Fig.
Page 465 8E - 14 ELECTRONIC CONTROL MODULES BR/BE ENGINE CONTROL MODULE (Continued) NOTE: ECM Outputs: To avoid possible voltage spike damage to either the Powertrain Control Module (PCM) or ECM, igni- After inputs are received by the ECM, certain sen- tion key must be off, and negative battery cables sors, switches and components are controlled or reg- must be disconnected before unplugging ECM con- ulated by the ECM.
Page 466 BR/BE ELECTRONIC CONTROL MODULES 8E - 15 POWERTRAIN CONTROL MODULE (Continued) • The PCM pre-positions the idle air control (IAC) motor. • The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. • The PCM monitors the engine coolant tempera- ture sensor input.
Page 467 8E - 16 ELECTRONIC CONTROL MODULES BR/BE POWERTRAIN CONTROL MODULE (Continued) • Manifold absolute pressure (MAP) sensor • The PCM operates the A/C compressor clutch • Throttle position sensor (TPS) through the clutch relay. This happens if A/C has • Camshaft position sensor signal (in the distribu- been selected by the vehicle operator and requested tor) by the A/C thermostat.
Page 468 BR/BE ELECTRONIC CONTROL MODULES 8E - 17 POWERTRAIN CONTROL MODULE (Continued) • Camshaft position sensor signal (in the distribu- DESCRIPTION - POWER GROUNDS tor) The Powertrain Control Module (PCM) has 2 main • Park/neutral switch (gear indicator signal—auto. grounds. Both of these grounds are referred to as trans.
Page 469 8E - 18 ELECTRONIC CONTROL MODULES BR/BE POWERTRAIN CONTROL MODULE (Continued) • Idle air control (IAC) motor Based on inputs that it receives, the PCM adjusts • Ignition coil ignition coil dwell. The PCM also adjusts the gener- • Leak detection pump (if equipped) ator charge rate through control of the generator •...
Page 470 BR/BE ELECTRONIC CONTROL MODULES 8E - 19 POWERTRAIN CONTROL MODULE (Continued) • Power ground OPERATION - IGNITION CIRCUIT SENSE • Sensor return The ignition circuit sense input tells the PCM the • Signal ground ignition switch has energized the ignition circuit. •...
Page 471 8E - 20 ELECTRONIC CONTROL MODULES BR/BE POWERTRAIN CONTROL MODULE (Continued) (4) Remove three PCM mounting bolts and remove (3) Check pin connectors in the PCM and the three PCM from vehicle. 32–way connectors for corrosion or damage. Repair as necessary. INSTALLATION (4) Install three 32–way connectors.
Page 472 ENGINE SYSTEMS 8F - 1 BR/BE ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 473 8F - 2 BATTERY SYSTEM BR/BE BATTERY SYSTEM (Continued) For battery system maintenance schedules and DIAGNOSIS AND TESTING - BATTERY SYSTEM jump starting procedures, see the owner’s manual in The battery, starting, and charging systems in the the vehicle glove box. Optionally, refer to Lubrication vehicle operate with one another and must be tested and Maintenance for the recommended battery main- as a single complete system.
Page 474 BR/BE BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The battery has an 1. Refer to Battery Specifications for the proper WEAK OR DEAD WHEN incorrect size or rating for size and rating.
Page 475 8F - 4 BATTERY SYSTEM BR/BE BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery Specifications for the proper CHARGE CANNOT BE incorrect size or rating for specifications.
Page 476 BR/BE BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) • A faulty or incorrect starting system component. parts cleaning brush to remove any acid film (Fig. 2). Refer to Starting System for the proper starting sys- Rinse the battery with clean water. Ensure that the tem diagnosis and testing procedures.
Page 477 8F - 6 BATTERY SYSTEM BR/BE BATTERY SYSTEM (Continued) (2) Inspect the battery tray and battery holddown hardware for damage. Replace any damaged parts. (3) Slide the thermal guard off of the battery case, if equipped. Inspect the battery case for cracks or other damage that could result in electrolyte leaks.
Page 478 BR/BE BATTERY SYSTEM 8F - 7 BATTERY (Continued) OPERATION The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reac- tion occurs. This reaction causes the battery to dis- charge electrical current from its terminals.
Page 479 8F - 8 BATTERY SYSTEM BR/BE BATTERY (Continued) • The battery open-circuit voltage is less than 12.4 WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT volts. A battery that will not accept a charge is faulty, TEST, ASSIST-BOOST, OR CHARGE.
Page 480 BR/BE BATTERY SYSTEM 8F - 9 BATTERY (Continued) (2) Look through the battery cap holes to deter- WARNING: IF THE BATTERY SHOWS SIGNS OF mine the level of the electrolyte in the battery (Fig. FREEZING, LEAKING OR LOOSE POSTS, DO NOT 6).
Page 481 8F - 10 BATTERY SYSTEM BR/BE BATTERY (Continued) NOTE: Models equipped with the diesel engine option are equipped with two 12-volt batteries, con- nected in parallel (positive-to-positive and negative- to-negative). In order to ensure proper charging of each battery, these batteries MUST be disconnected from each other, as well as from the vehicle electri- cal system, while being charged.
Page 482 BR/BE BATTERY SYSTEM 8F - 11 BATTERY (Continued) in a completely discharged battery. At first, the WARNING: IF THE BATTERY SHOWS SIGNS OF charging current (amperage) will be low. As the bat- FREEZING, LEAKING OR LOOSE POSTS, DO NOT tery charges, the specific gravity of the electrolyte TEST, ASSIST-BOOST, OR CHARGE.
Page 483 8F - 12 BATTERY SYSTEM BR/BE BATTERY (Continued) • Clear or Bright - Indicates a low battery elec- WARNING: THE BATTERY CONTAINS SULFURIC trolyte level. The electrolyte level in the battery is ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID below the built-in indicator. A maintenance-free bat- CONTACT WITH THE SKIN, EYES, OR CLOTHING.
Page 484 BR/BE BATTERY SYSTEM 8F - 13 BATTERY (Continued) STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery. This test can be used in place of the hydrometer test when a hydrometer is not available, or for mainte- nance-free batteries with non-removable cell caps.
Page 485 8F - 14 BATTERY SYSTEM BR/BE BATTERY (Continued) WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN.
Page 486 BR/BE BATTERY SYSTEM 8F - 15 BATTERY (Continued) Fig. 13 Volt-Ammeter-Load Fig. 15 Load 50% CCA Rating - Note Voltage - Typical 1 - INDUCTION AMMETER CLAMP 2 - NEGATIVE CLAMP LOAD TEST TEMPERATURE TABLE 3 - POSITIVE CLAMP Temperature Minimum Voltage °F °C...
Page 487 8F - 16 BATTERY SYSTEM BR/BE BATTERY (Continued) A vehicle that has not been operated for approxi- If the IOD is over thirty-five milliamperes, the mately twenty days, may discharge the battery to an problem must be found and corrected before replac- inadequate level.
Page 488 BR/BE BATTERY SYSTEM 8F - 17 BATTERY (Continued) place process to identify and correct all sources of WARNING: WEAR A SUITABLE PAIR OF RUBBER excessive IOD. It is now safe to select the lowest mil- GLOVES (NOT THE HOUSEHOLD TYPE) WHEN liampere scale of the multi-meter to check the low- REMOVING BATTERY...
Page 489 8F - 18 BATTERY SYSTEM BR/BE BATTERY (Continued) (4) Clean the battery cable terminal clamps and side battery is mirror image of the hold down hard- ware used for the left side battery. the battery terminal posts. Refer to Battery System When installing a battery into the battery tray, be in this group for the location of the proper battery certain that the hold down hardware is properly...
Page 490 BR/BE BATTERY SYSTEM 8F - 19 BATTERY HOLDDOWN (Continued) Fig. 20 Battery Cables - Typical 1 - EYELET 2 - NUT 3 - POWER DISTRIBUTION CENTER 4 - POSITIVE CABLE 5 - SCREW Fig. 19 Left Battery Hold Downs Remove/Install - 6 - NEGATIVE CABLE Typical for Right Battery 7 - EYELET...
Page 491 8F - 20 BATTERY SYSTEM BR/BE BATTERY CABLE (Continued) DIESEL ENGINE the other eyelet terminal is secured with a ground screw to the outer surface of the left frame rail, Diesel engine models feature a clamping type below the battery. female battery terminal made of soft lead die cast onto one end of the battery cable wire.
Page 492 BR/BE BATTERY SYSTEM 8F - 21 BATTERY CABLE (Continued) rosion foreign material, then reassembled. THE ASD RELAY MAY NOT PREVENT THE DIESEL Following reassembly, check the voltage drop for the ENGINE FROM STARTING. BE CERTAIN TO ALSO battery cable connection and the battery cable again DISCONNECT THE FUEL SHUTDOWN SOLENOID to confirm repair.
Page 493 8F - 22 BATTERY SYSTEM BR/BE BATTERY CABLE (Continued) Fig. 23 Test Battery Positive Connection Resistance - Typical 1 - VOLTMETER 2 - BATTERY (3) Connect the voltmeter to measure between the Fig. 21 Fuel Shutdown Solenoid Connector - Diesel battery positive cable terminal clamp and the starter Engine solenoid B(+) terminal stud (Fig.
Page 494 BR/BE BATTERY SYSTEM 8F - 23 BATTERY CABLE (Continued) (4) Connect the voltmeter to measure between the NEGATIVE CABLE REMOVAL - GASOLINE battery negative cable terminal clamp and a good Both the battery negative cable and the battery clean ground on the engine block (Fig. 25). Rotate positive cable are serviced in the battery wire har- and hold the ignition switch in the Start position.
Page 495 8F - 24 BATTERY SYSTEM BR/BE BATTERY CABLE (Continued) NEGATIVE CABLE INSTALLATION - GASOLINE (1) Position the battery wire harness into the engine compartment and under the compressor mounting bracket, if equipped. (2) Install and tighten the nut that secures the battery negative cable ground eyelet terminal to the stud on the power steering pump pivot bolt.
Page 496 BR/BE BATTERY SYSTEM 8F - 25 BATTERY TRAY (Continued) OPERATION (4) From the engine compartment, remove the two nuts with washers that secure the rear of the battery The battery tray provides a secure mounting loca- tray support to the two studs that extend through tion and supports the battery.
Page 497 8F - 26 BATTERY SYSTEM BR/BE BATTERY TRAY (Continued) (8) Install and tighten the two screws with wash- (10) If the left battery tray is being installed, ers that secure the outboard side of the battery tray install the battery temperature sensor onto the left to the inner fender shield.
Page 498 BR/BE CHARGING 8F - 27 CHARGING TABLE OF CONTENTS page page CHARGING INSTALLATION......29 DESCRIPTION .
Page 499 8F - 28 CHARGING BR/BE CHARGING (Continued) INSPECTION (2) Inspect condition of battery cable terminals, battery posts, connections at engine block, starter The Powertrain Control Module (PCM) monitors solenoid and relay. They should be clean and tight. critical input and output circuits of the charging sys- Repair as required.
Page 500 BR/BE CHARGING 8F - 29 BATTERY TEMPERATURE SENSOR DESCRIPTION The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. OPERATION The BTS is used to determine the battery temper- ature and control battery charging rate. This temper- ature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate.
Page 501 8F - 30 CHARGING BR/BE GENERATOR (Continued) Although the generators appear the same exter- nally, different generators with different output rat- ings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Gen- erator Ratings in the Specifications section at the back of this group for amperage ratings and part numbers.
Page 502 BR/BE CHARGING 8F - 31 GENERATOR (Continued) Fig. 6 Generator Connectors—Typical Denso Fig. 4 Remove/Install Generator—Diesel Engine 1 - FIELD WIRES 1 - UPPER MOUNTING BOLT 2 - B+ (OUTPUT TERMINAL) 2 - BRACKET-TO-ENGINE BOLT 3 - FIELD WIRE CONNECTOR 3 - LOWER MOUNTING BOLT/NUT 4 - GENERATOR (5) Install negative battery cable(s) to battery(s).
Page 503 8F - 32 STARTING BR/BE STARTING TABLE OF CONTENTS page page STARTING STARTER MOTOR ..... . 39 DESCRIPTION ......32 REMOVAL .
Page 504 BR/BE STARTING 8F - 33 STARTING (Continued) When the starter relay coil is energized, the nor- shaft. When the driver releases the ignition switch to mally open relay contacts close. The relay contacts the On position, the starter relay coil is de-energized. connect the relay common feed terminal to the relay This causes the relay contacts to open.
Page 505 8F - 34 STARTING BR/BE STARTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER ENGAGES, 1. Starter ring gear faulty. 1. Refer to Starter Motor in Removal and Installation. SPINS OUT BEFORE Remove starter motor to inspect starter ring gear. ENGINE STARTS.
Page 506 BR/BE STARTING 8F - 35 STARTING (Continued) FEED CIRCUIT TEST The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit. For complete starter wir- ing circuit diagrams, refer 8, Wiring Diagrams. When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter...
Page 507 8F - 36 STARTING BR/BE STARTING (Continued) Fig. 4 Test Battery Positive Cable Fig. 2 Test 1 - BATTERY 1 - VOLTMETER 2 - VOLTMETER 2 - BATTERY 3 - STARTER MOTOR (4) Connect voltmeter to measure between battery negative terminal post and a good clean ground on engine block (Fig.
Page 508 BR/BE STARTING 8F - 37 STARTING (Continued) (5) Connect positive lead of voltmeter to starter (6) If equipped with dual battery system (diesel), housing. Connect negative lead of voltmeter to bat- connect positive lead of voltmeter to driver side bat- tery negative terminal post (Fig.
Page 509 8F - 38 STARTING BR/BE STARTING (Continued) SPECIFICATIONS STARTING SYSTEM Starter Motor and Solenoid Manufacturer Nippon Denso Nippon Denso Nippon Denso Part Number 56027702AB 56027703AB 4741012 3.9L, 5.2L, 5.9L Engine Application 8.0L (Gasoline) 5.9L (Diesel) (Gasoline) 1.4 Kilowatt 1.4 Kilowatt 2.7 Kilowatt Power Rating 1.9 Horsepower...
Page 510 BR/BE STARTING 8F - 39 All starter motors use an overrunning clutch and ENGINE STARTER MOTOR starter pinion gear unit to engage and drive a starter ring gear that is integral to the flywheel (manual DESCRIPTION transmission), torque converter or torque converter The starter motors used for the 5.9L diesel engine drive plate (automatic transmission) mounted on the and the 8.0L gasoline engine available in this model...
Page 511 8F - 40 STARTING BR/BE ENGINE STARTER MOTOR (Continued) Fig. 7 Continuity Test Between Solenoid Terminal and Field Coil Terminal - Typical 1 - OHMMETER 2 - SOLENOID TERMINAL 3 - FIELD COIL TERMINAL Fig. 9 Starter Motor Remove/Install - 3.9L/5.2L/5.9L Gasoline Engine 1 - ENGINE 2 - STARTER MOUNTING FLANGE...
Page 512 BR/BE STARTING 8F - 41 ENGINE STARTER MOTOR (Continued) Fig. 11 Starter Motor Remove/Install - 5.9L Diesel Engine Fig. 10 Starter Motor Wire Harness Remove/Install - 5.9L Diesel Engine 1 - MOUNTING BOLT 1 - SOLENOID WIRE 2 - MOUNTING BOLTS (3) (6) Support starter motor and remove two bolts 3 - BATTERY TERMINAL securing starter motor to engine.
Page 513 8F - 42 STARTING BR/BE ENGINE STARTER MOTOR (Continued) ENGINE STARTER MOTOR RELAY DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine com- partment.
Page 514 BR/BE STARTING 8F - 43 ENGINE STARTER MOTOR RELAY (Continued) (5) The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selec- tor lever is in Park or Neutral positions.
Page 516 HEATED SYSTEMS 8G - 1 BR/BE HEATED SYSTEMS TABLE OF CONTENTS page page HEATED MIRRORS ......1 HEATED SEAT SYSTEM .
Page 517 8G - 2 HEATED MIRRORS BR/BE HEATED MIRRORS (Continued) OPERATION - HEATED MIRROR SYSTEM The operation of the heated mirror system can be confirmed in one of the following manners: The solid state electronic control logic and timer • Turn the ignition switch to the On position. circuitry for the heated mirror system receives bat- While monitoring the instrument panel voltmeter, tery current from a fuse in the Junction Block (JB)
Page 518 BR/BE HEATED MIRRORS 8G - 3 is turned On or Off. The electronic control logic and MIRROR SWITCH timer circuitry also energizes or de-energizes the heated mirror relay, which controls the feed of elec- DESCRIPTION trical current to the outside mirror heating grids. The heated mirror system electronic control logic and timer circuitry is programmed to turn the heated mirror system Off automatically after about fifteen...
Page 519 8G - 4 HEATED MIRRORS BR/BE MIRROR SWITCH (Continued) (3) Disconnect and isolate the battery negative molded plastic mirror glass case and the mirror cable. Disconnect the 3-way instrument panel wire glass, where it remains in direct contact with the harness connector for the heated mirror switch from back of the mirror glass at all times.
Page 520 BR/BE HEATED SEAT SYSTEM 8G - 5 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM HEATED SEAT ELEMENT & SENSOR ..11 DESCRIPTION ......5 HEATED SEAT RELAY OPERATION .
Page 521 8G - 6 HEATED SEAT SYSTEM BR/BE HEATED SEAT SYSTEM (Continued) OPERATION the switch for the faulty heated seat is depressed in either the Low or High direction. This process will The heated seat module receives fused battery cur- repeat every time the faulty heated seat switch is rent through the energized heated seat relay in the actuated until the problem has been corrected.
Page 522 BR/BE HEATED SEAT SYSTEM 8G - 7 HEATED SEAT SYSTEM (Continued) • If both indicator lamps for a heated seat switch cubby bin located in the lower right corner of the operate, but the heated seat elements do not heat, instrument cluster bezel next to the radio receiver.
Page 523 8G - 8 HEATED SEAT SYSTEM BR/BE DRIVER SEAT HEATER SWITCH (Continued) The indicator lamps in the heated seat switches minated after the heated seat has been turned Off, receive battery current through a fused ignition refer to Heated Seat Module in Electronic Control switch output (run) circuit when the ignition switch Modules for the location of the proper heated seat is in the On position.
Page 524 BR/BE HEATED SEAT SYSTEM 8G - 9 DRIVER SEAT HEATER SWITCH (Continued) Manual for additional diagnosis and testing proce- dures. If not OK, replace the faulty heated seat switch. Fig. 4 Heated Seat Switch and Bezel Remove/Install Fig. 3 Heated Seat Switch 1 - INSTRUMENT PANEL Heated Seat Switch Continuity 2 - SCREW (3)
Page 525 8G - 10 HEATED SEAT SYSTEM BR/BE DRIVER SEAT HEATER SWITCH (Continued) (3) Reconnect the two instrument panel wire har- each seating position to each other in series with the ness connectors to the connector receptacles on the heated seat module through the seat wire harness. backs of the heated seat switches.
Page 526 BR/BE HEATED SEAT SYSTEM 8G - 11 HEATED SEAT ELEMENT (Continued) DIAGNOSIS & TESTING - HEATED SEAT seat cushion cover half of the 4-way heated seat wire harness connector. The heated seat sensor resistance ELEMENT AND SENSOR should be between 1 kilohm and 200 kilohms. If OK, The heated seat module will self-diagnose shorted go to Step 2.
Page 527 8G - 12 HEATED SEAT SYSTEM BR/BE HEATED SEAT RELAY (Continued) ifications have common physical dimensions, current FORMING FURTHER DIAGNOSIS OR SERVICE. THIS capacities, terminal patterns, and terminal functions. IS THE ONLY SURE WAY TO DISABLE THE AIRBAG The ISO micro-relay terminal functions are the same SYSTEM.
Page 528 BR/BE HEATED SEAT SYSTEM 8G - 13 HEATED SEAT RELAY (Continued) (3) The relay normally open terminal (87) is con- nected to the common feed terminal (30) in the ener- gized position. This terminal supplies battery voltage to the heated seat module. There should be continu- ity between the cavity for relay terminal 87 and the B(+) to heated seat module circuit cavity of the heated seat module wire harness connector at all...
Page 529 8G - 14 HEATED SEAT SYSTEM BR/BE PASSENGER SEAT HEATER SWITCH (Continued) temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a...
Page 530 BR/BE HEATED SEAT SYSTEM 8G - 15 PASSENGER SEAT HEATER SWITCH (Continued) Cluster in the index of this service manual for the harness connector for the heated seat switch. If OK, proper cluster illumination lamps diagnosis and test- go to Step 7. If not OK, repair the open fused ignition ing procedures.
Page 531 8G - 16 HEATED SEAT SYSTEM BR/BE PASSENGER SEAT HEATER SWITCH (Continued) (2) Remove the cluster bezel from the instrument (6) From the back of the heated seat switch bezel, panel. Refer to Cluster Bezel in the index of this gently push the heated seat switch out through the service manual for the location of the proper cluster front of the bezel.
Page 532 HORN 8H - 1 BR/BE HORN TABLE OF CONTENTS page page HORN OPERATION ......3 DESCRIPTION .
Page 533 8H - 2 HORN BR/BE HORN (Continued) tion on the high-line or premium CTM. (Refer to 8 - location views for the various wire harness connec- ELECTRICAL/VEHICLE THEFT SECURITY - GEN- tors, splices and grounds. ERAL INFORMATION) for more information on the (1) Disconnect the wire harness connector(s) from VTSS.
Page 534 BR/BE HORN 8H - 3 HORN (Continued) INSTALLATION DIAGNOSIS AND TESTING (1) Position the horn and mounting bracket unit(s) DIAGNOSIS AND TESTING - HORN RELAY onto the right fender wheel house front extension. (2) Install and tighten the screw that secures the The horn relay (Fig.
Page 535 8H - 4 HORN BR/BE HORN RELAY (Continued) Fig. 2 Horn Relay TERMINAL LEGEND NUMBER IDENTIFICATION Fig. 3 Power Distribution Center COMMON FEED 1 - COVER COIL GROUND 2 - POWER DISTRIBUTION CENTER COIL BATTERY NORMALLY OPEN (3) See the fuse and relay layout label affixed to NORMALLY CLOSED the underside of the PDC cover for horn relay iden- tification and location.
Page 536 BR/BE HORN 8H - 5 HORN SWITCH (Continued) location views for the various wire harness connec- tors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 538 IGNITION CONTROL 8I - 1 BR/BE IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL DISTRIBUTOR ROTOR DESCRIPTION ......1 DIAGNOSIS AND TESTING .
Page 539 8I - 2 IGNITION CONTROL BR/BE IGNITION CONTROL (Continued) SPECIFICATIONS SPECIFICATIONS - TORQUE - IGNITION DESCRIPTION N·m Ft. Lbs. In. Lbs. Camshaft Position Sensor—8.0L Engine Crankshaft Position Sensor—All Engines Distributor Hold Down Bolt Ignition Coil Mounting—3.9L/5.2L/5.9L Engines—if tapped bolts are used Ignition Coil Mounting—3.9L/5.2L/5.9L Engines—if nuts/bolts are used Ignition Coil Mounting—8.0L Engine...
Page 540 BR/BE IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 3.9L V-6 RC12LC4 1.01 mm (.040 in.) 5.2L/5.9L V-8...
Page 541 8I - 4 IGNITION CONTROL BR/BE AUTOMATIC SHUT DOWN RELAY (Continued) • When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays.
Page 542 BR/BE IGNITION CONTROL 8I - 5 AUTOMATIC SHUT DOWN RELAY (Continued) Fig. 3 Power Distribution Center (PDC) 1 - POWER DISTRIBUTION CENTER (PDC) INSTALLATION The ASD relay is located in the Power Distribution Center (PDC) (Fig. 3). Refer to label on PDC cover Fig.
Page 543 8I - 6 IGNITION CONTROL BR/BE CAMSHAFT POSITION SENSOR (Continued) The CMP also detects an area on the camshaft drive gear that has no notch (Fig. 7). When the sen- sor passes this area, it tells the Engine Control Mod- ule (ECM) that Top Dead Center (TDC) of the number 1 cylinder is occurring.
Page 544 BR/BE IGNITION CONTROL 8I - 7 CAMSHAFT POSITION SENSOR (Continued) Fig. 8 CMP Sensor Operation—8.0L V-10 Engine Fig. 9 CMP Location - Diesel 1 - CAM DRIVE GEAR 1 - CAMSHAFT POSITION SENSOR (CMP) 2 - LOW MACHINED AREA 2 - BOTTOM OF FUEL INJECTION PUMP 3 - HIGH MACHINED AREA 4 - CAMSHAFT POSITION SENSOR 5 - AIR GAP...
Page 545 8I - 8 IGNITION CONTROL BR/BE CAMSHAFT POSITION SENSOR (Continued) Fig. 13 Sensor Depth Positioning Rib—8.0L V-10 Fig. 11 Camshaft Position Sensor—Typical Engine 1 - SYNC SIGNAL GENERATOR 2 - CAMSHAFT POSITION SENSOR 1 - CAMSHAFT POSITION SENSOR 3 - PULSE RING 2 - PAPER SPACER 4 - DISTRIBUTOR ASSEMBLY 3 - RIB MATERIAL (FOR SENSOR DEPTH POSITIONING)
Page 546 BR/BE IGNITION CONTROL 8I - 9 CAMSHAFT POSITION SENSOR (Continued) (2) From the parts department, obtain a peel-and- stick paper spacer (Fig. 13). These special paper spacers are of a certain thickness and are to be used as a tool to set sensor depth. (3) Clean the face of sensor and apply paper spacer (Fig.
Page 547 8I - 10 IGNITION CONTROL BR/BE CAMSHAFT POSITION SENSOR (Continued) (15) Install sensor mounting bolt and tighten to 6 N·m (50 in. lbs.) torque. (16) Connect engine wiring harness to sensor. Replacing With a New Sensor (1) Apply a small amount of engine oil to the sen- sor o-ring (Fig.
Page 548 BR/BE IGNITION CONTROL 8I - 11 DISTRIBUTOR (Continued) (5) Before distributor is removed, the number one cylinder must be brought to the Top Dead Center (TDC) firing position. (6) Attach a socket to the Crankshaft Vibration Damper mounting bolt. (7) Slowly rotate engine clockwise, as viewed from front, until indicating mark on crankshaft vibration damper is aligned to 0 degree (TDC) mark on timing chain cover (Fig.
Page 549 8I - 12 IGNITION CONTROL BR/BE DISTRIBUTOR (Continued) (6) Rotate the distributor housing until rotor is aligned to CYL. NO. 1 alignment mark on the cam- shaft position sensor (Fig. 19) . (7) Tighten clamp holddown bolt (Fig. 20) to 22.5 N·m (200 in.
Page 550 BR/BE IGNITION CONTROL 8I - 13 DISTRIBUTOR CAP (Continued) rotor button (Fig. 21) or (Fig. 22). Also check for DISTRIBUTOR ROTOR white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap DIAGNOSIS AND TESTING - DISTRIBUTOR that displays charred or eroded terminals.
Page 551 8I - 14 IGNITION CONTROL BR/BE IGNITION COIL (Continued) filled coils. The rear coil pack contains two indepen- but the engine is not running), it will shut down the dent epoxy filled coils. ASD circuit. Base ignition timing is not adjustable on the 8.0L V-10 engine.
Page 552 BR/BE IGNITION CONTROL 8I - 15 IGNITION COIL (Continued) Fig. 26 Ignition Coil—5.9L V-8 HDC-Gas Engine Fig. 27 Ignition Coil Packs—8.0L V-10 Engine 1 - COIL MOUNTING BOLTS (3) Remove the four (4) coil pack-to-coil mounting 2 - IGNITION COIL bracket bolts for the coil pack being serviced (Fig.
Page 553 8I - 16 IGNITION CONTROL BR/BE IGNITION COIL (Continued) gle plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Group O, Lubrication and Maintenance Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled.
Page 554 BR/BE IGNITION CONTROL 8I - 17 SPARK PLUG (Continued) COLD FOULING/CARBON FOULING This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard Cold fouling is sometimes referred to as carbon procedures. fouling. The deposits that cause cold fouling are basi- cally carbon (Fig.
Page 555 8I - 18 IGNITION CONTROL BR/BE SPARK PLUG (Continued) CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode (Fig.
Page 556 BR/BE IGNITION CONTROL 8I - 19 SPARK PLUG (Continued) SPARK PLUG CABLE DESCRIPTION Spark plug cables are sometimes referred to as sec- ondary ignition wires. OPERATION The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individ- ual spark plugs at each cylinder.
Page 557 8I - 20 IGNITION CONTROL BR/BE SPARK PLUG CABLE (Continued) SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cable, do not remove the cable from the cap.
Page 558 BR/BE IGNITION CONTROL 8I - 21 SPARK PLUG CABLE (Continued) Fig. 39 Engine Firing Order—3.9L V-6 Engine Fig. 41 Spark Plug Cable Order—8.0L V-10 Engine When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and Fig.
Page 560 INSTRUMENT CLUSTER 8J - 1 BR/BE INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER OIL PRESSURE GAUGE DESCRIPTION ......2 DESCRIPTION .
Page 561 8J - 2 INSTRUMENT CLUSTER BR/BE through a dedicated hole in the lens. The remainder INSTRUMENT CLUSTER of the EMIC, including the mounts and the electrical connections, are concealed behind the cluster bezel. DESCRIPTION The molded plastic EMIC housing has four integral mounting tabs, two each on the upper and lower edges of the housing.
Page 562 BR/BE INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) • Check Gauges Indicator grams, proper wire and connector repair procedures, • Cruise Indicator (Odometer VFD) further details on wire harness routing and reten- • Four-Wheel Drive Indicator tion, as well as pin-out and location views for the •...
Page 563 8J - 4 INSTRUMENT CLUSTER BR/BE INSTRUMENT CLUSTER (Continued) The EMIC circuitry operates on battery current strength. Current flow through the second coil received through a fused B(+) fuse in the Junction changes, which causes changes in its magnetic field Block (JB) on a non-switched fused B(+) circuit, and strength.
Page 564 BR/BE INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) The VFD is diagnosed using the EMIC self-diag- The hard wired indicators are diagnosed using con- nostic actuator test. (Refer to 8 - ELECTRICAL/IN- ventional diagnostic methods. The EMIC and CCD STRUMENT CLUSTER DIAGNOSIS...
Page 565 8J - 6 INSTRUMENT CLUSTER BR/BE INSTRUMENT CLUSTER (Continued) CHIME WARNING REQUESTS PRELIMINARY DIAGNOSIS The EMIC is programmed to request chime service WARNING: ON VEHICLES EQUIPPED WITH AIR- from the Central Timer Module (CTM) when certain BAGS, DISABLE THE AIRBAG SYSTEM BEFORE indicator lamps are illuminated.
Page 566 BR/BE INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER (Continued) (7) Turn the ignition switch to the Off position. CAUTIONS COULD RESULT IN ACCIDENTAL AIR- Disconnect and isolate the battery negative cable. BAG DEPLOYMENT AND POSSIBLE PERSONAL Reinstall the instrument cluster. Reconnect the bat- INJURY.
Page 567 8J - 8 INSTRUMENT CLUSTER BR/BE INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER FAILURE MESSAGE Message Description Correction A failure has been identified in the cluster 1. Replace the faulty cluster. CPU, RAM, or EEPROM. The CCD data bus is not operational. 1.
Page 568 BR/BE INSTRUMENT CLUSTER 8J - 9 INSTRUMENT CLUSTER (Continued) completion of the test, if the ignition switch is turned connector (Connector C2) for the instrument cluster to the Off position during the test, or if a vehicle and the instrument panel wire harness connector speed message indicating that the vehicle is moving (Connector C1) for the CTM.
Page 569 8J - 10 INSTRUMENT CLUSTER BR/BE INSTRUMENT CLUSTER (Continued) (2) Turn the exterior lamps On with the headlamp (1) Disconnect and isolate the battery negative switch. Rotate the headlamp switch panel lamps dim- cable. mer thumbwheel upward to just before the interior (2) Remove the cluster bezel from the instrument lamps detent.
Page 570 BR/BE INSTRUMENT CLUSTER 8J - 11 INSTRUMENT CLUSTER (Continued) GEAR SELECTOR INDICATOR (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument cluster from the instru- ment panel. (Refer to 8 - ELECTRICAL/INSTRU- MENT CLUSTER - REMOVAL). (3) Remove the steering column opening cover from the instrument panel.
Page 571 8J - 12 INSTRUMENT CLUSTER BR/BE INSTRUMENT CLUSTER (Continued) (3) Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board (Fig. 5). Fig. 6 Instrument Cluster Components 1 - COVER 2 - HOUSING 3 - OVERLAY AND GAUGES 4 - HOOD 5 - LENS Fig.
Page 572 BR/BE INSTRUMENT CLUSTER 8J - 13 INSTRUMENT CLUSTER (Continued) ASSEMBLY (1) Insert the bulb and bulb holder unit straight into the correct bulb mounting hole in the cluster electronic circuit board (Fig. 5). WARNING: ON VEHICLES EQUIPPED WITH AIR- (2) With the bulb holder fully seated against the BAGS, DISABLE THE AIRBAG SYSTEM BEFORE cluster electronic circuit board, turn the bulb holder ATTEMPTING ANY STEERING WHEEL, STEERING...
Page 573 8J - 14 INSTRUMENT CLUSTER BR/BE INSTRUMENT CLUSTER (Continued) INSTALLATION the instrument cluster with the proper vehicle equipment option setting to enable and/or disable the upshift indicator lamp. Refer to the appropriate WARNING: ON VEHICLES EQUIPPED WITH AIR- diagnostic information. BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT...
Page 574 BR/BE INSTRUMENT CLUSTER 8J - 15 ABS INDICATOR (Continued) ABS indicator will be illuminated. The indicator through the translucent outer layer of the overlay remains illuminated until the cluster receives a when it is illuminated from behind by a Light Emit- lamp-off message from the CAB, or until the ignition ting Diode (LED) soldered onto the instrument clus- switch is turned to the Off position, whichever occurs...
Page 575 8J - 16 INSTRUMENT CLUSTER BR/BE AIRBAG INDICATOR (Continued) • Bulb Test - Each time the ignition switch is Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due turned to the On position the brake indicator is illu- to an open or short in the cluster airbag indicator cir- minated by the instrument cluster for about four sec- cuit, the cluster sends a message notifying the ACM...
Page 576 BR/BE INSTRUMENT CLUSTER 8J - 17 BRAKE/PARK BRAKE INDICATOR (Continued) (Refer to 5 - BRAKES - DIAGNOSIS AND TEST- CHECK GAUGES INDICATOR ING). If no brake system problem is found, the fol- lowing procedure will help locate a faulty park brake DESCRIPTION switch or park brake switch sense circuit.
Page 577 8J - 18 INSTRUMENT CLUSTER BR/BE CHECK GAUGES INDICATOR (Continued) • Engine Oil Pressure Low Message - Each equipped with the optional speed control system, this time the cluster receives a message from the PCM indicator is electronically disabled. The cruise indica- indicating the engine oil pressure of a gasoline tor consists of the word “CRUISE”, which appears in engine is about 3.45 kPa (0.5 psi) or lower, or a diesel...
Page 578 BR/BE INSTRUMENT CLUSTER 8J - 19 CRUISE INDICATOR (Continued) the instrument cluster. For further diagnosis of the run) circuit whenever the ignition switch is in the On cruise indicator or the instrument cluster circuitry or Start positions. The cluster is programmed to that controls the indicator, (Refer to 8 - ELECTRI- move the gauge needle back to the low end of the CAL/INSTRUMENT CLUSTER - DIAGNOSIS AND...
Page 579 8J - 20 INSTRUMENT CLUSTER BR/BE ENGINE TEMPERATURE GAUGE (Continued) swept to several calibration points on the gauge scale OPERATION in a prescribed sequence in order to confirm the func- The fuel gauge gives an indication to the vehicle tionality of the gauge and the cluster control cir- operator of the level of fuel in the fuel tank.
Page 580 BR/BE INSTRUMENT CLUSTER 8J - 21 FUEL GAUGE (Continued) • More Than Full Percent Tank Full Message is a small, rectangular window, and behind these - Each time the cluster receives a message from the windows is a single, movable red pointer. PCM indicating the percent tank full is more than The gear selector indicator graphics are white full, the gauge needle is moved to the far left (low)
Page 581 8J - 22 INSTRUMENT CLUSTER BR/BE HIGH BEAM INDICATOR (Continued) bol icon for “High Beam” in the opaque layer of the DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- instrument cluster overlay. The dark outer layer of LATE THE BATTERY NEGATIVE (GROUND) CABLE, the overlay prevents the indicator from being clearly THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- visible when it is not illuminated.
Page 582 BR/BE INSTRUMENT CLUSTER 8J - 23 HIGH BEAM INDICATOR (Continued) ing wheel, then inspecting the headlamps at the transistor. The instrument cluster will turn on the front of the vehicle. Once the headlamp low beams low fuel indicator for the following reasons: •...
Page 583 8J - 24 INSTRUMENT CLUSTER BR/BE require that a fault be repaired and the PCM or MALFUNCTION INDICATOR ECM be reset before a lamp-off message will be sent. LAMP (MIL) For more information on the PCM, the ECM, and the DTC set and reset parameters, (Refer to 25 - EMIS- DESCRIPTION SIONS CONTROL - OPERATION).
Page 584 BR/BE INSTRUMENT CLUSTER 8J - 25 ODOMETER (Continued) The odometer can display values up to 499,999 ing the trip odometer information in order for the kilometers (499,999 miles). The odometer latches at trip odometer information to be reset. • Message Failure - If the cluster fails to receive these values, and will not roll over to zero.
Page 585 8J - 26 INSTRUMENT CLUSTER BR/BE OIL PRESSURE GAUGE (Continued) orange gauge needle is internally illuminated. Gauge nated, and a single chime tone is generated. The illumination is provided by replaceable incandescent gauge needle remains at the low end of the scale and bulb and bulb holder units located on the instrument the check gauges indicator remains illuminated until cluster electronic circuit board.
Page 586 BR/BE INSTRUMENT CLUSTER 8J - 27 • Actuator Test - Each time the cluster is put OVERDRIVE OFF INDICATOR through the actuator test, the indicator will be turned on during the bulb check portion of the test to DESCRIPTION confirm the functionality of the LED and the cluster An overdrive off indicator is standard equipment control circuitry.
Page 587 8J - 28 INSTRUMENT CLUSTER BR/BE SEATBELT INDICATOR (Continued) turn on the seatbelt indicator for the following rea- The SRI is serviced as a unit with the instrument sons: cluster. • Seatbelt Reminder Function - Each time the OPERATION cluster receives a battery current input on the fused ignition switch output (st-run) circuit, the indicator The Service Reminder Indicator (SRI) gives an will be illuminated as a seatbelt reminder for about...
Page 588 BR/BE INSTRUMENT CLUSTER 8J - 29 nosed using conventional diagnostic tools and meth- SHIFT INDICATOR (TRANSFER ods. CASE) DIAGNOSIS AND TESTING - FOUR-WHEEL DESCRIPTION DRIVE INDICATOR A four-wheel drive indicator is standard equipment The diagnosis found here addresses an inoperative on all instrument clusters.
Page 589 8J - 30 INSTRUMENT CLUSTER BR/BE SHIFT INDICATOR (TRANSFER CASE) (Continued) (3) Turn the ignition switch to the Off position. provided by replaceable incandescent bulb and bulb Disconnect and isolate the battery negative cable. holder units located on the instrument cluster elec- Remove the instrument cluster from the instrument tronic circuit board.
Page 590 BR/BE INSTRUMENT CLUSTER 8J - 31 TACHOMETER (Continued) ment cluster. The tachometer consists of a movable in a prescribed sequence in order to confirm the func- gauge needle or pointer controlled by the instrument tionality of the gauge and the cluster control cir- cluster circuitry and a fixed 210 degree scale on the cuitry.
Page 591 8J - 32 INSTRUMENT CLUSTER BR/BE TRANSMISSION OVERTEMP INDICATOR (Continued) (st-run) circuit whenever the ignition switch is in the are located near the upper edge of the instrument On or Start positions; therefore, the LED will always cluster overlay, between the speedometer and the be off when the ignition switch is in any position tachometer.
Page 592 BR/BE INSTRUMENT CLUSTER 8J - 33 TURN SIGNAL INDICATORS (Continued) problems are found, the following procedure will help receives battery current on the instrument cluster locate a short or open in the left or right turn signal electronic circuit board through the fused ignition indicator circuit.
Page 593 8J - 34 INSTRUMENT CLUSTER BR/BE VOLTAGE GAUGE (Continued) above the temperature gauge. The voltage gauge con- until ten seconds after the engine intake manifold air sists of a movable gauge needle or pointer controlled heater has completed its cycle. •...
Page 594 BR/BE INSTRUMENT CLUSTER 8J - 35 WAIT-TO-START INDICATOR (Continued) behind the cutout causes the “WAIT TO START” text the cutout in the opaque layer of the overlay causes to appear in red through the translucent outer layer the “LOW WASHER” text to appear in amber of the overlay when the indicator is illuminated from through the translucent outer layer of the overlay behind by a Light Emitting Diode (LED) that is sol-...
Page 595 8J - 36 INSTRUMENT CLUSTER BR/BE WASHER FLUID INDICATOR (Continued) cluster circuitry that controls the indicator, (Refer to OK, repair the open ground circuit to ground (G100) 8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAG- as required. NOSIS AND TESTING). The washer fluid level (2) Remove the instrument cluster from the instru- switch input to the cluster can be diagnosed using ment panel.
Page 596 BR/BE INSTRUMENT CLUSTER 8J - 37 WATER-IN-FUEL INDICATOR (Continued) OPERATION from the ECM, the indicator will be illuminated. The indicator remains illuminated until the cluster The water-in-fuel indicator gives an indication to receives a water-in-fuel lamp-off message from the the vehicle operator when the water accumulated in ECM or until the ignition switch is turned to the Off the diesel engine fuel filter/separator filter bowl position, whichever occurs first.
Page 598 LAMPS 8L - 1 BR/BE LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....33 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 599 8L - 2 LAMPS/LIGHTING - EXTERIOR BR/BE MARKER LAMP INSTALLATION......29 REMOVAL ......22 TAIL LAMP INSTALLATION.
Page 600 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) regardless of the ignition switch position. When the (1) Turn the ignition switch to the On position. turn signal (multi-function) switch control stalk is Actuate the turn signal switch or the hazard warning moved up (right turn) or down (left turn), the turn switch.
Page 601 8L - 4 LAMPS/LIGHTING - EXTERIOR BR/BE LAMPS/LIGHTING - EXTERIOR (Continued) (9) Disconnect the instrument panel wire harness SPECIAL TOOLS connector for the multi-function switch from the switch connector receptacle. Check for continuity HEADLAMP ALIGNMENT between the hazard flasher signal circuit cavities in the JB receptacle for the combination flasher and the instrument panel wire harness connector for the multi-function switch.
Page 602 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 5 BRAKE LAMP SWITCH (Continued) causing the PCM’s output brake signal to go high, With switch plunger retracted, attach test leads to disengaging the speed control, cutting off PCM power pins 3 and 4. Replace switch if meter indicates no to the speed control solenoids.
Page 603 8L - 6 LAMPS/LIGHTING - EXTERIOR BR/BE BRAKE LAMP SWITCH (Continued) Fig. 3 Brake Lamp Switch 1 - TAB NOTCH (IN BRACKET) 2 - SWITCH PLUNGER 3 - SWITCH TAB CENTER HIGH MOUNTED Fig. 4 Center High Mounted Stop Lamp STOP LAMP 1 - CHMSL CARGO LAMP HOUSING 2 - CHMSL...
Page 604 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 7 CLEARANCE LAMP (Continued) OPERATION The combination flasher has five blade-type termi- nals intended for the following inputs and outputs: fused B(+), fused ignition switch output, ground, turn signal circuit, and hazard warning circuit. Constant battery voltage and ground are supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is...
Page 605 8L - 8 LAMPS/LIGHTING - EXTERIOR BR/BE COMBINATION FLASHER (Continued) will become high and the IC signals the PNP transis- tor to de-energize the circuit. This cycling will con- tinue until the right or left turn signal switch is turned off. A special design feature of the combination flasher allows it to sense that a turn signal circuit or bulb is not operating, and provide the driver an indication...
Page 606 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 9 DAYTIME RUNNING LAMP MODULE DESCRIPTION The Daytime Running Lights (Headlamps) System is installed on vehicles manufactured for sale in Can- ada only. A separate module, mounted on the cowl, controls the DRL. OPERATION The headlamps are illuminated when the ignition switch is turned to the ON position.
Page 607 8L - 10 LAMPS/LIGHTING - EXTERIOR BR/BE FOG LAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. WITH ENGINE RUNNING 2. Poor lighting circuit Z33-ground. 2. Test for voltage drop across Z33-ground ABOVE IDLE locations.
Page 608 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 11 FOG LAMP (Continued) Additional fog lamp diagnostic procedures listed are for vehicles equipped with quad headlamps and the DRL option. CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE INOPERATIVE 1 Fog lamp/DRL* feed shorted to 1.
Page 609 8L - 12 LAMPS/LIGHTING - EXTERIOR BR/BE FOG LAMP UNIT (Continued) SPORT INSTALLATION The fog lamps are serviced from the rearward side of the front bumper. (1) Disconnect and isolate the battery negative (1) Position fog lamp in bumper. cable. (2) Install fog lamp to bumper attaching nuts.
Page 610 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 13 FOG LAMP UNIT (Continued) Fig. 12 Fog Lamp Alignment 1 - VEHICLE CENTERLINE 5 - 100 mm (4 in.) 2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 6 - 7.62 METERS (25 FEET) 3 - HIGH-INTENSITY AREA 7 - FRONT OF FOG LAMP 4 - FLOOR TO CENTER OF FOG LAMP LENS...
Page 611 8L - 14 LAMPS/LIGHTING - EXTERIOR BR/BE HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING and posts. OR IGNITION TURNED 2. Loose or worn generator drive 2.
Page 612 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION 6. Broken connector terminal or wire 6. Repair connector terminal or wire splice. splice in headlamp circuit. HEADLAMPS (LOW 1. No ground for low beam circuit. 1. Ground should be present according to BEAM) DO NOT Multifunction switch position.
Page 613 8L - 16 LAMPS/LIGHTING - EXTERIOR BR/BE HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMP SWITCH ON 1. Headlamp feed circuit shorted to 1. Check wiring circuit from right headlamp (HIGH BEAMS ON), ONE ground. fuse to headlamp. Repeat for left side. HIGH BEAM ON AND Trace short circuit in wiring and repair.
Page 614 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP RELAY (Continued) interference that can be generated as the electromag- netic field of the relay coil collapses. The headlamp relay terminals are connected to the vehicle electrical system through a connector recepta- cle in the Power Distribution Center (PDC).
Page 615 8L - 18 LAMPS/LIGHTING - EXTERIOR BR/BE HEADLAMP RELAY (Continued) (4) Connect a battery to terminals 85 and 86. (4) Remove the headlamp relay by grasping it There should now be continuity between terminals firmly and pulling it straight out from the receptacle 30 and 87, and no continuity between terminals 87A in the PDC.
Page 616 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 19 HEADLAMP SWITCH (Continued) (1) Disconnect and isolate the battery negative BAG DEPLOYMENT AND POSSIBLE PERSONAL cable. Remove the headlamp switch from the instru- INJURY. ment panel. (Refer to 8 - ELECTRICAL/LAMPS/ (1) Disconnect and isolate the battery negative LIGHTING - EXTERIOR/HEADLAMP SWITCH - cable.
Page 617 8L - 20 LAMPS/LIGHTING - EXTERIOR BR/BE HEADLAMP SWITCH (Continued) INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 618 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 21 HEADLAMP UNIT (Continued) (5) From behind the bumper, tighten the bumper (6) Measure the distance from the center of head- mounting nuts. lamp lens to the floor. Transfer measurement to the (6) Install the screws attaching top of headlamp alignment screen (with tape).
Page 619 8L - 22 LAMPS/LIGHTING - EXTERIOR BR/BE HEADLAMP UNIT (Continued) HEADLAMP ADJUSTMENT LICENSE PLATE LAMP UNIT Headlamps can be aligned using the screen method provided or alignment tool C-4466–A or equivalent REMOVAL can be used. refer to the instructions provided with (1) Disconnect and isolate the battery negative the tool for proper procedures.
Page 620 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 23 MARKER LAMP (Continued) (1) Disconnect and isolate the battery negative cable. (2) Remove four screws attaching rear ID lamps to tailgate (Fig. 23). (3) Separate ID lamps from tailgate. (4) Disengage ID lamp wire connector from body wire harness.
Page 621 8L - 24 LAMPS/LIGHTING - EXTERIOR BR/BE MULTI-FUNCTION SWITCH (Continued) includes momentary switching of the headlamp high be in a raised position. The multi-function switch beam circuits to provide an optical horn feature hazard warning circuitry simultaneously provides a (sometimes referred to as flash-to-pass), which allows signal to the hazard warning sense of the combina- the vehicle operator to momentarily flash the head- tion flasher to activate or deactivate the flasher out-...
Page 622 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 25 MULTI-FUNCTION SWITCH (Continued) spring mechanism rotates with the steering wheel DIAGNOSIS AND TESTING - MULTI-FUNCTION and the cam lobes contact the cancel actuator when SWITCH it is extended from the multi-function switch. When Refer to the appropriate wiring information.
Page 623 8L - 26 LAMPS/LIGHTING - EXTERIOR BR/BE MULTI-FUNCTION SWITCH (Continued) Fig. 25 Multi-Function Switch Tests MULTI-FUNCTION SWITCH TESTS SWITCH POSITIONS CONTINUITY BETWEEN TURN SIGNAL HAZARD WARNING Neutral Pins 12, 14, & 15 Left Pins 15, 16, & 17 Left Pins 12 & 14 Left *Pins 22 &...
Page 624 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 27 MULTI-FUNCTION SWITCH (Continued) (3) If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 625 8L - 28 LAMPS/LIGHTING - EXTERIOR BR/BE MULTI-FUNCTION SWITCH (Continued) (5) Carefully lift the upper inner shroud upward far enough to access the multi-function switch mounting screws. (6) Install and tighten the two tamper proof screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-func- tion switch to the steering column housing.
Page 626 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 29 OUTBOARD IDENTIFICATION LAMP (Continued) PARK/TURN SIGNAL LAMP UNIT REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove screw attaching the park lamp to headlamp module. (3) Grasp lamp and pull forward to disengage clip attaching park/turn lamp to headlamp module.
Page 627 8L - 30 LAMPS/LIGHTING - EXTERIOR BR/BE TAIL LAMP (Continued) (3) Separate lens from lamp. (4) Grasp bulb, push in slightly and rotate 1/2 turn counter-clockwise. PICKUP (1) Disconnect and isolate the battery negative cable. (2) Remove screws from tail lamp. (3) Grasp lamp, firmly pull lamp rearward to dis- engage retaining studs.
Page 628 BR/BE LAMPS/LIGHTING - EXTERIOR 8L - 31 TURN SIGNAL CANCEL CAM (Continued) turn signal cancel cam. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn sig- nal cancel actuator.
Page 629 8L - 32 LAMPS/LIGHTING - EXTERIOR BR/BE UNDERHOOD LAMP (Continued) Fig. 33 Underhood Lamp 1 - UNDER HOOD LAMP Fig. 32 Underhood Lamp Bulb 2 - HOOD 1 - BULB 3 - CONNECTOR 2 - DEPRESS TERMINAL INWARD 3 - BULB WIRE LOOP INSTALLATION 4 - LAMP BASE (1) Install bulb.
Page 630 BR/BE LAMPS/LIGHTING - INTERIOR 8L - 33 LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR GLOVE BOX LAMP AND SWITCH SPECIFICATIONS ......33 REMOVAL .
Page 631 8L - 34 LAMPS/LIGHTING - INTERIOR BR/BE DOME LAMP (Continued) tion includes wiring diagrams, proper wire and con- nector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness con- nectors, splices and grounds.
Page 632 BR/BE LAMPS/LIGHTING - INTERIOR 8L - 35 DOOR AJAR SWITCH (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Grasp the body of the door ajar switch with a pair of pliers and move the switch gently back-and- forth while pulling it out of the door hinge pillar mounting hole.
Page 633 8L - 36 LAMPS/LIGHTING - INTERIOR BR/BE GLOVE BOX LAMP AND SWITCH (Continued) (5) Install the glove box onto the instrument panel. REMOVAL (Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE (1) Disconnect and isolate the battery negative BOX - INSTALLATION) for the procedures. cable.
Page 634 BR/BE LAMPS/LIGHTING - INTERIOR 8L - 37 READING LAMP (Continued) (5) Reconnect the battery negative cable. (4) Remove bulb from lamp terminals. INSTALLATION VANITY LAMP (1) Install bulb into lamp terminals. (2) Place one side of lens into housing. REMOVAL (3) Insure dim control is in place, and snap lens (1) Insert a flat blade into the slot at front of lens.
Page 636 MESSAGE SYSTEMS 8M - 1 BR/BE MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE OPERATION ......9 DESCRIPTION .
Page 637 8M - 2 MESSAGE SYSTEMS BR/BE OVERHEAD CONSOLE (Continued) Fig. 1 Overhead Console...
Page 638 BR/BE MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) 1 - SUNGLASSES STORAGE BIN 11 - WIRE HARNESS 2 - GARAGE DOOR OPENER STORAGE BIN DOOR 12 - SPRINGS (2) 3 - COMPUTER LENS OR COVER PLUG 13 - READING AND COURTESY LAMP HOUSING 4 - HOOK AND LOOP FASTENER 14 - REFLECTORS 5 - SECURITY INDICATOR LAMP...
Page 639 8M - 4 MESSAGE SYSTEMS BR/BE OVERHEAD CONSOLE (Continued) while maintaining a speed of 48 kilometers-per-hour NOTE: If the wrong direction is still indicated in the (30 miles-per-hour) or higher. compass display, the area selected for calibration The thermometer function is supported by an may be too close to a strong magnetic field.
Page 640 BR/BE MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) Fig. 2 Variance Settings (3) Depress both the U.S./Metric and the Step (1) Be certain that the ignition switch is in the Off push buttons at the same time and hold them down position, before you begin the demagnetizing proce- for more than 100 milliseconds, but not more than dure.
Page 641 8M - 6 MESSAGE SYSTEMS BR/BE OVERHEAD CONSOLE (Continued) Fig. 4 Overhead Console Latch Tabs 1 - PUSH BUTTON 2 - GARAGE DOOR OPENER STORAGE BIN DOOR 3 - LATCH TABS (4) Slide the overhead console rearward far enough to disengage the two mounting hooks on the rear of the housing from the mounting holes in the inner roof panel (Fig.
Page 642 BR/BE MESSAGE SYSTEMS 8M - 7 OVERHEAD CONSOLE (Continued) (7) Remove the overhead console from the vehicle. aside as needed for access to the pivot latches that are integral to the overhead console housing for the OVERHEAD CONSOLE DISASSEMBLY sunglasses storage bin pivot pins. (3) Open the sunglasses storage bin.
Page 643 8M - 8 MESSAGE SYSTEMS BR/BE OVERHEAD CONSOLE (Continued) the latch. Repeat this step to engage the second pivot snap features of the cover plug are fully engaged in pin with its pivot latch. the overhead console housing. (3) Close the garage door opener storage bin door. (5) If the vehicle is so equipped, install the com- (4) If the vehicle is so equipped, position the com- pass mini-trip computer module onto the overhead...
Page 644 BR/BE MESSAGE SYSTEMS 8M - 9 COMPASS/MINI-TRIP COMPUTER (Continued) Compass mini-trip computer units for vehicles nostic tests as described in this group. If these tests equipped with the VTSS include a red Light-Emit- prove inconclusive, the use of a DRBIII scan tool ting Diode (LED) on their electronic circuit board.
Page 645 8M - 10 MESSAGE SYSTEMS BR/BE COMPASS/MINI-TRIP COMPUTER (Continued) DIAGNOSIS & TESTING - COMPASS MINI-TRIP (7) Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch COMPUTER output (run/start) circuit cavity of the roof wire har- If the problem with the compass mini-trip com- ness connector for the overhead console.
Page 646 BR/BE MESSAGE SYSTEMS 8M - 11 COMPASS/MINI-TRIP COMPUTER (Continued) NOTE: If the compass functions, but accuracy is INSTALLATION suspect, it may be necessary to perform a variation (1) Position the compass mini-trip computer mod- adjustment. This procedure allows the compass ule onto the overhead console housing.
Page 647 8M - 12 MESSAGE SYSTEMS BR/BE AMBIENT TEMP SENSOR (Continued) DIAGNOSIS & TESTING - AMBIENT (4) Remove the jumper wire from the body half of the ambient temperature sensor wire harness con- TEMPERATURE SENSOR nector. Check for continuity between the sensor The thermometer function is supported by the return circuit cavity of the roof wire harness over- ambient temperature sensor, a wiring circuit, and a...
Page 648 BR/BE MESSAGE SYSTEMS 8M - 13 AMBIENT TEMP SENSOR (Continued) INSTALLATION (3) Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. (1) Position the ambient temperature sensor onto (4) Reconnect the battery negative cable. the inner hood reinforcement. (2) Install and tighten the one screw that secures the ambient temperature sensor bracket to the inner hood reinforcement.
Page 650 POWER SYSTEMS 8N - 1 BR/BE POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEAT SYSTEM.
Page 651 8N - 2 POWER LOCKS BR/BE POWER LOCKS (Continued) On those models equipped with the optional RKE hardware components are damaged or faulty, the system, the power lock system also includes the fol- entire CTM unit must be replaced. The power lock lowing components, which are described in further system components and the hard wired inputs or out- detail elsewhere in this service manual:...
Page 652 BR/BE POWER LOCKS 8N - 3 POWER LOCKS (Continued) OPERATION - POWER LOCK SYSTEM speed messages from the PCM in order to provide this feature. If the airbag has been deployed and the All versions of the power lock system allow both vehicle has stopped moving, the CTM will automati- doors to be locked or unlocked electrically by operat- cally unlock the doors, prevent the doors from being...
Page 653 8N - 4 POWER LOCKS BR/BE POWER LOCKS (Continued) • Horn Chirp - If this feature is enabled, the appropriate wiring information. The wiring informa- CTM provides a horn chirp by internally pulling the tion includes wiring diagrams, proper wire and con- control coil of the horn relay to ground through a nector repair procedures, details of wire harness hard wired circuit output.
Page 654 BR/BE POWER LOCKS 8N - 5 POWER LOCKS (Continued) and receiving the proper messages on the CCD data DOOR CYLINDER LOCK bus, that the CTM is receiving the proper hard wired SWITCH inputs, and that the power lock motors are being sent the proper hard wired outputs by the CTM.
Page 655 8N - 6 POWER LOCKS BR/BE DOOR CYLINDER LOCK SWITCH (Continued) (6) Disengage the retainers that secure the door DOOR CYLINDER LOCK SWITCH cylinder lock switch pigtail wire harness to the inner Switch Position door panel. Resistance Driver Side Passenger Side (7) Remove the door cylinder lock switch from the door.
Page 656 BR/BE POWER LOCKS 8N - 7 POWER LOCK MOTOR (Continued) DIAGNOSIS AND TESTING - POWER LOCK REMOTE KEYLESS ENTRY MOTOR TRANSMITTER On models with a base version of the Central Timer Module (CTM), confirm proper power lock DESCRIPTION switch operation before you proceed with this diagno- The Remote Keyless Entry (RKE) system Radio sis.
Page 657 8N - 8 POWER LOCKS BR/BE REMOTE KEYLESS ENTRY TRANSMITTER (Continued) the suspect transmitter does not, replace the faulty OPERATION RKE transmitter. On models with a base version of the Central Timer Module (CTM), the power lock switches are NOTE: Be certain to perform the RKE Transmitter hard-wired to the power lock motors.
Page 658 BR/BE POWER LOCKS 8N - 9 POWER LOCK SWITCH (Continued) (5) Test the power lock switch continuity. See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Neutral, Lock, and Unlock switch positions (Fig. 2) or (Fig. 3). If OK, repair the door lock switch output (lock and/or unlock) circuit(s) between the power window and lock switch unit and the power lock motors (base Central...
Page 659 8N - 10 POWER MIRRORS BR/BE POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS OPERATION......12 DESCRIPTION .
Page 660 BR/BE POWER MIRRORS 8N - 11 AUTOMATIC DAY / NIGHT MIRROR (Continued) OPERATION The ambient photocell sensor is located on the for- ward-facing (windshield side) of the rear view mirror housing, and detects the ambient light levels outside of the vehicle. The headlamp photocell sensor is located inside the rear view mirror housing behind the mirror glass and faces rearward, to detect the level of the light being received at the rear window...
Page 661 8N - 12 POWER MIRRORS BR/BE AUTOMATIC DAY / NIGHT MIRROR (Continued) REMOVAL POWER MIRROR SWITCH (1) Disconnect and isolate the battery negative DESCRIPTION cable. (2) Unplug the wire harness connector from the Both the right and left power outside mirrors are automatic day/night mirror (Fig.
Page 662 BR/BE POWER MIRRORS 8N - 13 POWER MIRROR SWITCH (Continued) (3) Remove the nut that secures the power mirror OPERATION switch to the driver side front door trim panel. The power mirrors in vehicles equipped with the (4) Remove the trim panel from the inside of the available heated mirror system option also include an driver side front door.
Page 663 8N - 14 POWER MIRRORS BR/BE SIDEVIEW MIRROR (Continued) (4) Disconnect and isolate the battery negative (6) Unplug the wire harness connector at the inop- cable. Check for continuity between the ground cir- erative power mirror. Use two jumper wires, one con- cuit cavity in the door wire harness half of the power nected to a 12-volt battery feed, and the other mirror switch wire harness connector and a good...
Page 664 BR/BE POWER SEAT SYSTEM 8N - 15 POWER SEAT SYSTEM TABLE OF CONTENTS page page POWER SEAT SYSTEM POWER LUMBAR ADJUSTER ... . . 18 DESCRIPTION ......15 PASSENGER POWER SEAT SWITCH OPERATION.
Page 665 8N - 16 POWER SEAT SYSTEM BR/BE DIAGNOSIS & TESTING - DRIVER POWER DRIVER POWER SEAT SWITCH SEAT SWITCH DESCRIPTION For circuit descriptions and diagrams, refer to Wir- ing Diagrams. (1) Disconnect and isolate the battery negative cable. (2) Remove the power seat switch from the power seat.
Page 666 BR/BE POWER SEAT SYSTEM 8N - 17 DRIVER POWER SEAT SWITCH (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) If equipped with a 6-way power seat, remove the two screws that secure the power seat switch and bezel unit to the seat cushion frame (Fig.
Page 667 8N - 18 POWER SEAT SYSTEM BR/BE LUMBAR CONTROL SWITCH (Continued) OPERATION this grid is compressed, the more the slats bow out- ward against the center of the seat back padding, When the power lumbar switch paddle is actuated, providing additional lumbar support. a battery feed and a ground path are applied through the switch contacts to the power lumbar adjuster DIAGNOSIS &...
Page 668 BR/BE POWER SEAT SYSTEM 8N - 19 of the circuit breaker must not be allowed to con- PASSENGER POWER SEAT tinue, or the motor may be damaged. SWITCH DIAGNOSIS & TESTING - PASSENGER POWER DESCRIPTION SEAT SWITCH For circuit descriptions and diagrams, refer to Wir- ing Diagrams.
Page 669 8N - 20 POWER SEAT SYSTEM BR/BE PASSENGER POWER SEAT SWITCH (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) If equipped with a 6-way power seat, remove the two screws that secure the power seat switch and bezel unit to the seat cushion frame (Fig.
Page 670 BR/BE POWER SEAT SYSTEM 8N - 21 RECLINER MOTOR (Continued) the motor and drive unit of the power seat recliner (5) Test the power seat switch. Refer to Power mechanism is secured with two screws to the seat Seat Switch in the Diagnosis and Testing section of cushion frame, and is concealed by the outboard seat this group.
Page 671 8N - 22 POWER SEAT SYSTEM BR/BE POWER SEAT TRACK (Continued) Operate the power seat switch to move all three (2) Remove the seat, power seat track from the seat motors in each direction. The seat should move vehicle as a unit. Refer to Body for the procedure. in each of the selected directions.
Page 672 BR/BE POWER WINDOWS 8N - 23 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS POWER WINDOW SWITCH ....24 DESCRIPTION ......23 REMOVAL .
Page 673 8N - 24 POWER WINDOWS BR/BE POWER WINDOWS (Continued) vehicle with the inoperative window. Unplug the wire (LED) in the paddle of each switch is illuminated harness connector from the switch and bezel unit. whenever the ignition switch is in the On position. (2) Connect the battery negative cable.
Page 674 BR/BE POWER WINDOWS 8N - 25 POWER WINDOW SWITCH (Continued) (1) Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty cir- cuit breaker. (2) Turn the ignition switch to the On position. Check for battery voltage at the circuit breaker in the junction block.
Page 675 8N - 26 POWER WINDOWS BR/BE POWER WINDOW SWITCH (Continued) INSTALLATION this diagnosis, confirm proper switch operation. (Refer to 8 - ELECTRICAL/POWER WINDOWS/ (1) Connect the power window switch to the har- POWER WINDOW SWITCH - DIAGNOSIS AND ness connector. TESTING).
Page 676 RESTRAINTS 8O - 1 BR/BE RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS FRONT SEAT BELT & RETRACTOR DESCRIPTION ......1 REMOVAL .
Page 677 8O - 2 RESTRAINTS BR/BE RESTRAINTS (Continued) and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds.
Page 678 BR/BE RESTRAINTS 8O - 3 RESTRAINTS (Continued) Deployment of the airbags depends upon the angle STEERING COLUMN, OR INSTRUMENT PANEL and severity of the impact. The airbag system is COMPONENTS YOU MUST FIRST DISCONNECT designed to deploy upon a frontal impact within a AND ISOLATE THE BATTERY NEGATIVE (GROUND) thirty degree angle from either side of the vehicle CABLE.
Page 679 8O - 4 RESTRAINTS BR/BE RESTRAINTS (Continued) DIAGNOSIS AND TESTING - AIRBAG SYSTEM energy. Always place or store any airbag on a surface with its trim cover or airbag cushion side facing up, Proper diagnosis and testing of the airbag system to minimize movement in case of an accidental components, the PCI data bus, the data bus message deployment.
Page 680 BR/BE RESTRAINTS 8O - 5 RESTRAINTS (Continued) WARNING: IF YOU EXPERIENCE SKIN IRRITATION SYSTEM. FAILURE TO TAKE THE PROPER PRECAU- DURING CLEANUP, RUN COOL WATER OVER THE TIONS COULD RESULT IN ACCIDENTAL AIRBAG AFFECTED AREA. ALSO, IF YOU EXPERIENCE DEPLOYMENT AND POSSIBLE PERSONAL INJURY. IRRITATION OF THE NOSE OR THROAT, EXIT THE (1) During the following test, the battery negative VEHICLE FOR FRESH AIR UNTIL THE IRRITATION...
Page 681 8O - 6 RESTRAINTS BR/BE RESTRAINTS (Continued) (9) Turn the ignition switch to the Off position for Cluster (EMIC) and for airbag system diagnosis and about fifteen seconds, and then back to the On posi- testing through the 16-way data link connector tion.
Page 682 BR/BE RESTRAINTS 8O - 7 AIRBAG CONTROL MODULE (Continued) the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags to deploy. The impact sensor and saf- ing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM.
Page 683 8O - 8 RESTRAINTS BR/BE AIRBAG CONTROL MODULE (Continued) (6) Disengage the retainer on the instrument OBSERVE THIS WARNING COULD RESULT IN ACCI- panel wire harness take out to the ACM from the DENTAL, INCOMPLETE, OR IMPROPER AIRBAG retainer hole in the left side of the instrument panel DEPLOYMENT AND POSSIBLE OCCUPANT INJU- center support bracket.
Page 684 BR/BE RESTRAINTS 8O - 9 (2) Remove the screw that secures the child tether CHILD TETHER anchor (standard cab) or child tether (club/quad cab) to the cab back panel (Fig. 7). REMOVAL (3) Remove the child tether anchor (standard cab) Standard cab models have two child tether anchors or child tether (club/quad cab) from the cab back secured near the top of the cab back panel.
Page 685 8O - 10 RESTRAINTS BR/BE CHILD TETHER (Continued) (1) Position the child tether anchor (standard cab) on or in the rotating steering wheel. On this model or child tether (club/quad cab) onto the cab back the rotating electrical components include the driver panel (Fig.
Page 686 BR/BE RESTRAINTS 8O - 11 CLOCKSPRING (Continued) STANDARD PROCEDURE - CLOCKSPRING (3) Depress the two plastic clockspring auto-lock- ing tabs (Fig. 8). CENTERING The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop.
Page 687 8O - 12 RESTRAINTS BR/BE CLOCKSPRING (Continued) WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE.
Page 688 BR/BE RESTRAINTS 8O - 13 CLOCKSPRING (Continued) INSTALLATION on the lower inner shroud and apply hand pressure to snap them together. The clockspring cannot be repaired. It must be (6) From below the steering column, install and replaced if faulty or damaged, or if the driver airbag tighten the two screws that secure the lower inner has been deployed.
Page 689 8O - 14 RESTRAINTS BR/BE out lines, then fold back out of the way along with DRIVER AIRBAG the horn switch. Following an airbag deployment, the airbag cushion quickly deflates by venting the nitro- DESCRIPTION gen gas towards the instrument panel through the The driver airbag protective trim cover is the most porous fabric material used on the steering wheel visible part of the driver airbag.
Page 690 BR/BE RESTRAINTS 8O - 15 DRIVER AIRBAG (Continued) Fig. 10 Driver Airbag Remove/Install 1 - DRIVER AIRBAG 3 - CLOCKSPRING PIGTAIL WIRE CONNECTOR 2 - HORN SWITCH FEED PIGTAIL WIRE CONNECTOR 4 - SCREW (2) (3) Pull the driver airbag away from the steering DISASSEMBLY wheel far enough to access the two wire harness con- The horn switch is integral to the driver airbag...
Page 691 8O - 16 RESTRAINTS BR/BE DRIVER AIRBAG (Continued) WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLER- CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCI- DENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJU-...
Page 692 BR/BE RESTRAINTS 8O - 17 DRIVER AIRBAG (Continued) ASSEMBLY engage the locking blocks on each side of the trim cover with the lip of the housing. Be certain that The horn switch is integral to the driver airbag each of the locking blocks is fully engaged on the lip trim cover.
Page 693 8O - 18 RESTRAINTS BR/BE DRIVER AIRBAG (Continued) INSTALLATION (4) Carefully position the driver airbag in the steering wheel. Be certain that the clockspring pig- The following procedure is for replacement of a tail wires in the steering wheel hub area are not faulty or damaged driver airbag.
Page 694 BR/BE RESTRAINTS 8O - 19 FRONT SEAT BELT & RETRACTOR (Continued) (3) Remove the retractor cover from the seat back frame. (4) Remove the two screws that secure the seat belt retractor to the seat back frame (Fig. 16). (5) Remove the front shoulder belt and retractor from the seat back frame.
Page 695 8O - 20 RESTRAINTS BR/BE FRONT SEAT BELT & RETRACTOR (Continued) (4) Reinstall the trim onto the B-pillar. (Refer to FRONT SEAT BELT BUCKLE 23 - BODY/INTERIOR/B-PILLAR TRIM - INSTAL- LATION). REMOVAL (5) Position the shoulder belt turning loop onto the height adjuster.
Page 696 BR/BE RESTRAINTS 8O - 21 FRONT SEAT BELT BUCKLE (Continued) (2) On the driver’s side only, reconnect the body OPERATION wire harness connector for the seat belt switch to the The passenger airbag is deployed by an electrical seat belt switch pigtail wire connector on the seat signal generated by the Airbag Control Module belt buckle.
Page 697 8O - 22 RESTRAINTS BR/BE PASSENGER AIRBAG (Continued) WARNING: WHEN REMOVING A DEPLOYED AIR- BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.
Page 698 BR/BE RESTRAINTS 8O - 23 PASSENGER AIRBAG (Continued) INSTALLATION ment panel. New replacement passenger airbags come with new airbag door snap retainers installed. (3) Carefully position the passenger airbag onto WARNING: DISABLE AIRBAG SYSTEM the instrument panel. BEFORE ATTEMPTING ANY STEERING WHEEL, (4) Align the five tabs and retainers on the upper STEERING COLUMN, OR INSTRUMENT PANEL edge and sides of the passenger airbag door with the...
Page 699 8O - 24 RESTRAINTS BR/BE PASSENGER AIRBAG ON/OFF SWITCH (Continued) switch is in its installed position, the only compo- will be extinguished and the passenger airbag is nents visible through the dedicated opening of the enabled. cluster bezel are the switch face plate and nomencla- The passenger airbag switch is connected in series ture, the key cylinder actuator, and a small round between the Airbag Control Module (ACM) and the...
Page 700 BR/BE RESTRAINTS 8O - 25 PASSENGER AIRBAG ON/OFF SWITCH (Continued) Fig. 22 Passenger Airbag On/Off Switch Face Plate Remove/Install 1 - PASSENGER SIDE AIRBAG ON/OFF SWITCH 2 - SCREW (3) 3 - FACE PLATE Fig. 20 Passenger Airbag On/Off Switch Connectors (8) Remove the passenger airbag on/off switch from the face plate.
Page 701 8O - 26 RESTRAINTS BR/BE PASSENGER AIRBAG ON/OFF SWITCH (Continued) (5) Position the passenger airbag on/off switch and face plate unit to the opening in the instrument panel (Fig. 21). (6) Install and tighten the three screws that secure the passenger airbag on/off switch face plate to the instrument panel.
Page 702 BR/BE RESTRAINTS 8O - 27 REAR SEAT BELT & RETRACTOR (Continued) (2) Install and tighten the screw that secures the (2) Fold the rear seat unit up and back against the retractor to the quarter inner panel. Tighten the cab back panel (stowed position) for access to the screw to 40 N·m (29 ft.
Page 703 8O - 28 RESTRAINTS BR/BE REAR SEAT BELT BUCKLE (Continued) (1) Reach through the opening between the rear The seat belt switch receives ground through its seat back and the floor panel to position the rear seat pigtail wire connection to the body wire harness from belt buckle/buckle unit (right side) or lap belt/buckle another take out of the body wire harness.
Page 704 BR/BE RESTRAINTS 8O - 29 SEAT BELT SWITCH (Continued) (3) Remove the instrument cluster from the instru- (3) Remove the trim from the B-pillar. (Refer to 23 ment panel. Check for continuity between the seat - BODY/INTERIOR/B-PILLAR TRIM - REMOVAL). belt switch sense circuit cavity in the instrument (4) Remove the screw that secures the upper end panel wire harness connector (Connector C2) for the...
Page 705 8O - 30 RESTRAINTS BR/BE TURNING LOOP HEIGHT ADJUSTER KNOB REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
Page 706 ON/OFF, RES/ACCEL, SET, The Vehicle Speed Sensor (VSS) is no longer used COAST, and CANCEL. for any Dodge Truck. The system is designed to operate at speeds above Vehicle speed and distance covered are measured by 30 mph (50 km/h).
Page 707 8P - 2 SPEED CONTROL BR/BE SPEED CONTROL (Continued) OPERATION - SPEED CONTROL SYSTEM trol. To store a set speed, depress the SET switch while the vehicle is moving at a speed between 35 and 85 mph. In order for the speed control to engage, Gas Engines and/or Diesel With Automatic Trans.
Page 708 BR/BE SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) (3) If vacuum is less than ten inches of mercury, (a) Locate one-way check valve. The valve is determine source of leak. Check vacuum line to located in vacuum line between speed control servo engine for leaks.
Page 709 8P - 4 SPEED CONTROL BR/BE SPEED CONTROL (Continued) SPECIFICATIONS TORQUE - SPEED CONTROL SYSTEM DESCRIPTION Ft. Lbs. In. Lbs. Servo Mounting Bracket Nuts Switch Module Mounting Screws Vacuum Reservoir Mounting Screws REMOVAL - DIESEL WITH AUTO. TRANS. CABLE (1) Disconnect both negative battery cables at both DESCRIPTION batteries.
Page 710 BR/BE SPEED CONTROL 8P - 5 CABLE (Continued) Fig. 2 Servo Cable at Throttle Body—V-10 Engine 1 - THROTTLE CABLE 2 - THROTTLE VALVE CABLE 3 - SPEED CONTROL SERVO CABLE (5) Before starting engine, operate accelerator OPERATION pedal to check for any binding. A speed control servo is not used if equipped (6) Install cable/lever cover.
Page 711 8P - 6 SPEED CONTROL BR/BE SPEED CONTROL SERVO (Continued) Fig. 3 Servo Cable at Throttle Lever 1 - PINCH (2) TABS 2 - CABLE MOUNTING BRACKET 3 - PINCH TABS (2) 4 - OFF 5 - THROTTLE CABLE 6 - THROTTLE LEVER 7 - THROTTLE LEVER PIN 8 - OFF 9 - CONNECTOR...
Page 712 BR/BE SPEED CONTROL 8P - 7 SPEED CONTROL SERVO (Continued) Fig. 7 Battery Holddown 1 - REMOVE 2 BOLTS 2 - BATTERY HOLDDOWN STRAP Fig. 5 Servo Mounting at Battery Tray 1 - BATTERY TRAY 2 - SPEED CONTROL SERVO 3 - SERVO MOUNTING NUTS (2) Fig.
Page 713 8P - 8 SPEED CONTROL BR/BE SPEED CONTROL SERVO (Continued) (13) Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retain- ing clip (Fig. 6) and remove clip. Note: The servo mounting bracket displayed in (Fig. 6) is a typical bracket and may/may not be applicable to this model vehicle.
Page 714 BR/BE SPEED CONTROL 8P - 9 SPEED CONTROL SERVO (Continued) Fig. 12 Battery Heat Shield Fig. 14 Battery Tray Upper Mounting Bolts/Nuts 1 - BATTERY HEAT SHIELD 1 - BATTERY TRAY 2 - REMOVE 2 BOLTS 3 - REMOVE 2 NUTS Fig.
Page 715 8P - 10 SPEED CONTROL BR/BE SPEED CONTROL SERVO (Continued) Fig. 16 Servo Cable at Throttle Lever 1 - PINCH (2) TABS 2 - CABLE MOUNTING BRACKET 3 - PINCH TABS (2) 4 - OFF 5 - THROTTLE CABLE 6 - THROTTLE LEVER 7 - THROTTLE LEVER PIN 8 - OFF 9 - CONNECTOR...
Page 716 BR/BE SPEED CONTROL 8P - 11 SPEED CONTROL SERVO (Continued) 8.0L V-10 ENGINE (1) Position servo to mounting bracket. (2) Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. (3) Insert servo studs through holes in servo mounting bracket.
Page 717 8P - 12 SPEED CONTROL BR/BE • The vehicle speed signal decreases at a rate of SWITCH 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) DESCRIPTION • If the actual speed is not within 20 mph of the set speedThe previous disengagement conditions are Gas Engines and Diesel With Auto.
Page 718 BR/BE SPEED CONTROL 8P - 13 SWITCH (Continued) • If the actual speed is not within 20 mph of the set speedThe previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the ECM’s RAM.
Page 719 8P - 14 SPEED CONTROL BR/BE VACUUM RESERVOIR (Continued) (1) Disconnect and isolate battery negative cable. (2) Remove both windshield wiper arm/blade assemblies. Refer to 8, Wiper and Washer Systems. (3) Remove rubber weather-strip at front edge of cowel grill (Fig. 21). Fig.
Page 720 VEHICLE THEFT SECURITY 8Q - 1 BR/BE VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY VTSS INDICATOR DESCRIPTION ......1 DESCRIPTION .
Page 721 8Q - 2 VEHICLE THEFT SECURITY BR/BE VEHICLE THEFT SECURITY (Continued) tem of the vehicle. These hard wired circuits are VTSS engine no-run feature enable logic will apply integral to several wire harnesses, which are routed anytime the PCM is replaced with a new unit. throughout the vehicle and retained by many differ- ARMING ent methods.
Page 722 BR/BE VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) er-up mode will also apply if the battery goes dead LATE THE BATTERY NEGATIVE (GROUND) CABLE, while the system is armed, and battery jump-starting THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- is attempted.
Page 723 8Q - 4 VEHICLE THEFT SECURITY BR/BE VTSS INDICATOR (Continued) TESTING). If no VTSS problem is found, the follow- the JB and the Power Distribution Center (PDC) as ing procedure will help to locate a short or open in required. the VTSS indicator control circuit.
Page 724 WIPERS/WASHERS 8R - 1 BR/BE WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS OPERATION......10 DESCRIPTION .
Page 725 8R - 2 WIPERS/WASHERS BR/BE WIPERS/WASHERS (Continued) contains all of the switches for both the wiper and nozzles for as long as the washer pump/motor is washer systems. energized. • Washer Fluid Level Switch - The washer fluid • Wipe-After-Wash Mode - The internal circuitry level switch is located in a dedicated hole on the of the CTM provides a wipe-after-wash feature lower rear side of the washer reservoir, above the...
Page 726 BR/BE WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) activates the washer pump/motor, which dispenses when the Off position is selected, the park switch washer fluid onto the windshield glass through the that is integral to the wiper motor is closed to ground washer nozzles.
Page 727 8R - 4 WIPERS/WASHERS BR/BE WIPERS/WASHERS (Continued) However, these tests may not prove conclusive in the open fused ignition switch output circuit between the diagnosis of this system on models equipped with a multi-function switch and the JB as required. high-line or premium Central Timer Module (CTM).
Page 728 BR/BE WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) (10) Disconnect the headlamp and dash wire har- routing and retention, connector pin-out information ness connector for the wiper module from the wiper and location views for the various wire harness con- motor pigtail wire connector. Reconnect the battery nectors, splices and grounds.
Page 729 8R - 6 WIPERS/WASHERS BR/BE WIPERS/WASHERS (Continued) (CTM) from the CTM connector receptacle. Reconnect CAUTION: Never use compressed air to flush the the battery negative cable. Turn the ignition switch washer system plumbing. Compressed air pres- to the On position. With the washer button sures are too great for the washer system plumbing depressed, check for battery voltage at the washer components and will result in further system dam-...
Page 730 BR/BE WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) the wiper blade with a new unit. Do not attempt to sharp bends that might pinch the washer hose must repair a wiper blade that is damaged. be avoided. WASHER FLUID LEVEL SWITCH DESCRIPTION The washer fluid level switch is a single pole, sin- gle throw reed-type switch mounted on the rear of...
Page 731 8R - 8 WIPERS/WASHERS BR/BE WASHER FLUID LEVEL SWITCH (Continued) REMOVAL INSTALLATION The washer fluid level switch can be removed from (1) Install a new rubber grommet seal into the the washer reservoir without removing the reservoir washer fluid level switch mounting hole in the front from the vehicle.
Page 732 BR/BE WIPERS/WASHERS 8R - 9 WASHER HOSES/TUBES (Continued) be routed away from hot, sharp, or moving parts; tures of the nozzle are fully engaged with the under- and, sharp bends that might pinch the hose must be side of the cowl plenum cover/grille panel. avoided.
Page 733 8R - 10 WIPERS/WASHERS BR/BE WASHER PUMP/MOTOR (Continued) REMOVAL (5) Reconnect the headlamp and dash wire harness connector for the washer pump/motor unit to the (1) Disconnect and isolate the battery negative motor connector receptacle (Fig. 3). cable. (6) Refill the washer reservoir with the washer (2) Disconnect the headlamp and dash wire har- fluid drained from the reservoir during the removal ness connector for the washer pump/motor from the...
Page 734 BR/BE WIPERS/WASHERS 8R - 11 WASHER RESERVOIR (Continued) COOLING - STANDARD PROCEDURE - DRAIN/ (3) Reconnect the washer hose to the barbed outlet DIESEL ENGINE). nipple of the washer pump. (3) Disconnect the upper radiator hose from the (4) Reconnect the headlamp and dash wire harness radiator.
Page 735 8R - 12 WIPERS/WASHERS BR/BE WIPER ARM (Continued) OPERATION Turn the ignition switch to the On position and move the wiper control knob on the end of the The wiper arms are designed to mechanically multi-function switch control stalk to its Off posi- transmit the motion from the wiper pivots to the tion.
Page 736 BR/BE WIPERS/WASHERS 8R - 13 WIPER BLADE (Continued) • Element - The wiper element or squeegee is the towards the pivot end of the arm far enough to dis- resilient rubber member of the wiper blade that con- engage the pivot block from the hook (Fig. 7). tacts the glass.
Page 737 8R - 14 WIPERS/WASHERS BR/BE OPERATION WIPER MODULE The wiper module operation is controlled by the DESCRIPTION vehicle operator through battery current inputs received by the wiper motor from the multi-function The wiper module is secured with screws to the switch on the steering column.
Page 738 BR/BE WIPERS/WASHERS 8R - 15 WIPER MODULE (Continued) WIPER RELAY DESCRIPTION The wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for wiper relay identification and loca- tion.
Page 739 8R - 16 WIPERS/WASHERS BR/BE WIPER MOTOR RELAY (Continued) The wiper relay terminals are connected to the wiring information. The wiring information includes vehicle electrical system through a connector recepta- wiring diagrams, proper wire and connector repair cle in the Power Distribution Center (PDC). The procedures, details of wire harness routing and inputs and outputs of the wiper relay include: retention, connector pin-out information and location...
Page 740 BR/BE WIPERS/WASHERS 8R - 17 WIPER MOTOR RELAY (Continued) should be continuity between the receptacle for ter- (2) Remove the cover from the Power Distribution minal 87A of the wiper relay in the PDC and the Center (PDC) (Fig. 11). wiper motor park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times.
Page 742 WIRING 8W - 1 BR/BE WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 INTERIOR LIGHTING....8W-44-1 COMPONENT INDEX .
Page 744 BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION CONNECTOR - MOLEX DESCRIPTION ......1 REMOVAL .
Page 745 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION BR/BE WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 746 BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 747 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION BR/BE WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 748 BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WARNING: DO NOT ALLOW FLAME OR SPARKS NEAR BATTERY. GASES ALWAYS This is a list of terms and definitions used in the PRESENT IN AND AROUND THE BATTERY. wiring diagrams.
Page 749 8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION BR/BE WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 5). (2) Connect the other lead of the voltmeter to the selected test point.
Page 750 BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 7). (2) Connect the other lead of the voltmeter to the other side of the switch or component.
Page 751 8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION BR/BE WIRING DIAGRAM INFORMATION (Continued) SPECIAL TOOLS CONNECTOR - AUGAT SPECIAL TOOLS - WIRING/TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector from its mating half/ component. (3) Push down on the yellow connector locking tab to release the terminals (Fig.
Page 752 BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 CONNECTOR - AUGAT (Continued) (2) Insert the removed wire in the same cavity on the repair connector. (3) Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities.
Page 753 8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION BR/BE CONNECTOR - THOMAS AND BETTS (Continued) (4) Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). Fig. 14 SINGLE LOCK TAB 1 - SINGLE LOCK TAB Fig.
Page 754 BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half/component. (3) Remove connector locking wedge, required (Fig. 16). Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL 1 - FROM SPECIAL TOOL KIT 6680 2 - CONNECTOR (5) Cut the wire 6 inches from the back of the con-...
Page 755 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION BR/BE WIRE STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams. (1) Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.
Page 756 BR/BE 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 4WD Switch ......8W-31 Electric Brake Provision .
Page 757 BR/BE 8W-02 COMPONENT INDEX 8W - 02 - 1 Component Page Component Page Map Lamps ......8W-49 Radio .
Page 758 BR/BE 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch Relay ..8W-10-27 Fuse 14 (JB) ..... . . 8W-10-10 A/C Compressor Clutch .
Page 786 BR/BE 8W-12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ..8W-12-13 Fuse 15 (JB) ..... 8W-12-6, 16 A/C-Heater Control .
Page 808 BR/BE 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-10, 8 Intake Air Heater Relay No. 2 ... . . 8W-15-9 A/C-Heater Control .
Page 826 BR/BE 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Cummins Bus ..... . . 8W-18-4 G200 .
Page 830 BR/BE 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auxiliary Battery ....8W-20-3 G116 ......8W-20-2 Battery Temperature Sensor .
Page 834 BR/BE 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Auxiliary Battery ....8W-21-2 Fuse 9 (PDC) ..... . . 8W-21-2 Battery .
Page 838 BR/BE 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-14, 38, 39 G107 ......8W-30-34, 36 A/C-Heater Control .
Page 880 BR/BE 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Controller Antilock Brake ....8W-31-5 Joint Connector No. 4 ....8W-31-5 Fuse I (PDC) .
Page 886 BR/BE 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-2 Joint Connector No.
Page 890 BR/BE 8W-34 REAR WHEEL ANTILOCK BRAKES 8W - 34 - 1 8W-34 REAR WHEEL ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-34-3 Instrument Cluster .
Page 894 BR/BE 8W-35 ALL WHEEL ANTILOCK BRAKES 8W - 35 - 1 8W-35 ALL WHEEL ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-35-4 Joint Connector No.
Page 898 BR/BE 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Central Timer Module C1 ....8W-39-4 Horn Switch ......8W-39-3 Central Timer Module C2 .
Page 902 BR/BE 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Data Link Connector ....8W-40-4 Joint Connector No. 3 ....8W-40-6 Daytime Running Lamp Module .
Page 910 BR/BE 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Central Timer Module ....8W-41-2 Horn Relay ......8W-41-2 Cigar Lighter .
Page 914 BR/BE 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-5 Fuse J (PDC) ..... . . 8W-42-5 A/C Compressor Clutch Relay .
Page 920 BR/BE 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ....8W-43-2, 3 Instrument Cluster ....8W-43-3 Clockspring .
Page 924 BR/BE 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Ash Receiver Lamp ....8W-44-6 Headlamp Switch ....8W-44-4, 5, 6 Cargo Lamp No.
Page 930 BR/BE 8W-45 CENTRAL TIMER MODULE 8W - 45 - 1 8W-45 CENTRAL TIMER MODULE Component Page Component Page Central Timer Module C1 ..8W-45-8, 9, 10 Instrument Cluster ....8W-45-8 Central Timer Module C2 .
Page 940 BR/BE 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Central Timer Module C2 ....8W-47-4 Joint Connector No. 8 ....8W-47-3 Clockspring .
Page 950 BR/BE 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temperature Sensor ... 8W-49-5 Joint Connector No. 1 ....8W-49-3 Automatic Day/Night Mirror .
Page 956 BR/BE 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Cargo Lamp No. 1 ....8W-50-2 Joint Connector No.
Page 970 BR/BE 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Aftermarket Center High Mounted Left Back-Up Lamp ....8W-51-2 Stop Lamp .
Page 976 BR/BE 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Aftermarket Trailer Tow Connector ..8W-52-4 Joint Connector No. 4 ....8W-52-3 Brake Lamp Switch .
Page 980 BR/BE 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Fuse 6 (JB) ......8W-53-3 Joint Connector No.
Page 984 BR/BE 8W-54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Aftermarket Trailer Tow Connector . . 8W-54-2, 3, 4 Headlamp Switch ....8W-54-2 Back-Up Lamp Switch .
Page 988 BR/BE 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker 1 8W-Cb ....8W-60-2 Junction Block ..... . 8W-60-2 Driver Door Window/Lock Switch .
Page 990 BR/BE 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Central Timer Module C2 ....8W-61-4 G301 ......8W-61-2 Driver Door Lock Motor .
Page 994 BR/BE 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page G201 ......8W-62-3 Joint Connector No.
Page 998 BR/BE 8W-63 POWER SEATS 8W - 63 - 1 8W-63 POWER SEATS Component Page Component Page Circuit Breaker 2 ....8W-63-2, 3 Heated Seat Relay ....8W-63-5, 7 Driver Heated Seat Cushion .
Page 1006 BR/BE 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-10-19 S202 .
Page 1014 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page 4WD Switch 8W-80-4 C329 (Standard Cab) ....8W-80-22 A/C Compressor Clutch ....8W-80-4 C333 (Club Cab) .
Page 1015 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS BR/BE Component Page Component Page Crankshaft Position Sensor G300 ......8W-80-44 (Gas Except 8.0L) .
Page 1016 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Left Speed Control Switch ... . 8W-80-58 Passenger Power Seat Switch Left Tail/Stop/Turn Signal Lamp ..8W-80-58 (Club Cab) .
Page 1017 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS BR/BE 4WD SWITCH - BLACK 2 CIRCUIT FUNCTION G107 18BK/GY 4WD SWITCH SENSE Z1 18BK GROUND A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z11 18BK/WT GROUND A/C HEATER CONTROL - BLACK 7 WAY...
Page 1018 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C LOW PRESSURE SWITCH - 2 WAY CIRCUIT FUNCTION C20 18BR A/C SWITCH SENSE C22 18DB A/C SWITCH SENSE ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - 6 WAY CIRCUIT FUNCTION K104 18BK/LB SENSOR GROUND H105 18LG/DB IDLE VALIDATION SWITCH NO.
Page 1019 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS BR/BE AMBIENT TEMPERATURE SENSOR - 2 WAY CIRCUIT FUNCTION G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL G32 20BK/VT SENSOR GROUND ASH RECEIVER LAMP - BLACK 2 WAY CIRCUIT FUNCTION E2 22OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL Z3 20BK/OR GROUND AUTOMATIC DAY/NIGHT MIRROR - BLACK 3 WAY...
Page 1020 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 BLOWER MOTOR - 2 WAY CIRCUIT FUNCTION C1 12DG BLOWER MOTOR FEED C7 12BK/TN HIGH SPEED BLOWER MOTOR BLOWER MOTOR RESISTOR BLOCK - BLACK 4 WAY CIRCUIT FUNCTION C7 12BK/TN HIGH SPEED BLOWER MOTOR C6 14LB M2 SPEED BLOWER MOTOR C5 16LG...
Page 1021 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS BR/BE C105 - (HEADLAMP AND DASH SIDE) CIRCUIT L34 20RD/OR L39 20LB C106 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT G107 20GY Z1 20BK C106 - BLACK (4X4 INDICATOR SIDE) CIRCUIT G107 18BK/GY Z1 18BK C114 - BLACK (AMBIENT TEMPERATURE SEN- SOR SIDE)
Page 1022 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 C125 (DIESEL) - (ENGINE SIDE) CIRCUIT F18 18LG/BK G113 18OR A14 12RD/WT C3 18DB/BK C90 18LG/WT K22 18OR/DB A40 14RD/LG K131 18BR/WT A93 12RD/BK K104 18BK/LB G7 18WT/OR C126 (DIESEL) - GRAY (TRANSMISSION SIDE) CIRCUIT K20 18DG V37 18RD/LG (A/T)
Page 1023 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BR/BE C129 - (HEADLAMP AND DASH SIDE) CIRCUIT B113 20RD/VT B114 20WT/VT Z13 12BK B40 12LB K4 20BK/LB K226 20DB/WT L7 16BK/YL L50 18WT/TN L76 12BK/OR L63 16DG/RD L1 18VT/BK A6 12RD/OR L62 16BR/RD A61 16DG/BK (GAS) C129 - (CHASSIS HARNESS SIDE)
Page 1024 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 C130 (DIESEL) - (TRANSMISSION SIDE) CIRCUIT V35 18LG/RD V32 18YL/RD A14 14RD/WT A142 14DG/OR A40 14RD/LG A93 12RD/BK K118 18PK/YL L1 18VT/BK K131 18BR/WT G85 18OR/BK V40 18WT/PK L10 18BR/LG D1 18VT/BR K51 18DB/YL C13 18DB/OR D20 18DG...
Page 1025 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BR/BE C130 (DIESEL) (IN PDC) - (HEADLAMP AND DASH SIDE) CIRCUIT V35 20LG/RD V32 20YL/RD A14 16RD/WT A142 14DG/OR A40 14RD/LG A93 12RD/BK K118 20PK/YL L1 18VT/BK K131 20BR/WT G85 22OR/BK V40 22WT/PK L10 18BR/LG D1 20VT/BR K51 20DB/YL...
Page 1026 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C130 (GAS) - (ENGINE HARNESS SIDE) CIRCUIT V35 18LG/RD V32 18YL/RD A14 16RD/WT A142 14DG/OR K118 18PK/YL L1 18VT/BK V40 18WT/PK L10 18BR/LG D1 18VT/BR K51 18DB/YL C13 18DB/OR D20 18DG D2 18WT/BK K4 20BK/LB C90 18LG/WT...
Page 1027 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BR/BE C130 (GAS) (IN PDC) - (HEADLAMP AND DASH SIDE) CIRCUIT V35 20LG/RD V32 20YL/RD A14 16RD/WT A142 14DG/OR A93 12RD/BK K118 20PK/YL L1 18VT/BK V40 22WT/PK L10 18BR/LG D1 20VT/BR K51 20DB/YL C13 22DB/OR D20 20DG D2 20WT/BK...
Page 1028 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C134 - (HEADLAMP AND DASH SIDE) CIRCUIT D220 20WT/VT (DIESEL) L3 18RD/OR Z12 18BK/TN D2 20WT/BK D1 20VT/BR D20 20DG D21 20PK/DB D1 20VT/BR D2 20WT/BK L7 18BK/YL A12 16RD/TN T6 22OR/WT L39 20LB (HIGHLINE) F15 22DB F32 16PK/DB...
Page 1029 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS BR/BE C134 - (HEADLAMP AND DASH SIDE) CIRCUIT V32 20YL/RD V18 22YL/DG V40 22WT/PK L62 16BR/RD G85 22OR/BK (DIESEL) G107 20GY G29 18BK/WT G34 20RD/GY L63 16DG/RD L50 18WT/TN F12 20DB/WT L10 18BR/LG Z3 18BK/OR V10 16BR C134 - (I/P HARNESS SIDE)
Page 1030 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C134 - (I/P HARNESS SIDE) CIRCUIT L35 22BR/YL L35 20BR/YL V37 22RD/LG G11 22WT/LG Z9 16BK/VT (EXCEPT BASE/SLT) X3 20BK/RD Z5 18BK/DB F33 16PK/RD L4 14VT/WT V4 16RD/YL V49 16RD/BK V3 16BR/WT V5 16DG Z2 16BK/LG Z6 18BK/PK...
Page 1031 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS BR/BE C203 - (I/P HARNESS SIDE) CIRCUIT X58 18DB/OR X57 18BR/LB F37 16RD/LB F21 14TN M1 22PK X51 18BR/YL X52 18DB/WT M2 22YL G10 22LG/RD M22 22WT (BASE) P30 22OR/RD (HIGHLINE/PREMIUM) L50 18WT/TN X13 16BK/RD (PREMIUM RADIO) M3 22PK/DB C16 22LB/YL...
Page 1032 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C203 - (BODY HARNESS SIDE) CIRCUIT X56 18DB/RD X53 18DG X55 18BR/RD P31 22PK/DG (HIGHLINE/PREMIUM) P34 20PK/BK (POWER LOCK/WINDOW (HIGHLINE/PREMIUM)) C205 - NATURAL (I/P SIDE) CIRCUIT E2 22OR Z3 22BK/OR C205 - NATURAL (ASH RECEIVER LAMP SIDE) CIRCUIT E2 22OR Z3 20BK/OR...
Page 1033 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS BR/BE C237 - (I/P SIDE) CIRCUIT C5 16LG Z2 22BK/LG C82 22YL/OR C7 12BK/TN C4 16TN F15 22DB C6 14LB C237 - (RESISTOR BLOCK SIDE) CIRCUIT C5 16LG Z2 20BK/LG C82 20YL/OR C7 12BK/TN C4 16TN F15 20DB...
Page 1034 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C308 - (BODY HARNESS SIDE) CIRCUIT L50 18WT/TN Z2 20BK/LG M1 20PK M3 20PK/DB C308 - (CHMSL HARNESS SIDE) CIRCUIT L50 18WT/TN L50 18WT/TN Z3 18BK/OR Z3 18BK/OR M1 18PK M1 18PK M3 18PK/DB M3 18PK/DB C329 (CLUB CAB) - BLACK (RIGHT BACK-UP...
Page 1035 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS BR/BE C329 (STANDARD CAB) - BLACK (TAIL LAMP SIDE) CIRCUIT L7 18BK/YL Z13 16BK L62 18DG/BR L1 18VT/BK C329 (STANDARD CAB) - BLACK (CHASSIS SIDE) CIRCUIT L7 16BK/YL Z13 16BK L62 16BR/RD L1 18VT/BK C333 (CLUB CAB) - BLACK (LEFT BACK-UP LAMP SIDE)
Page 1036 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C333 (STANDARD CAB) - BLACK (CHASSIS SIDE) CIRCUIT L7 16BK/YL Z13 16BK L63 16DG/BR L1 18VT/BK C342 - GRAY (VALANCE LICENSE LAMP JUMPER SIDE) CIRCUIT Z13 18BK L7 18BK/YL C342 - BLACK (CHASSIS HARNESS SIDE) CIRCUIT Z13 18BK L7 16BK/YL...
Page 1037 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS BR/BE C344 (DUAL REAR WHEELS) - BLACK (FENDER LAMPS SIDE) CIRCUIT Z13 18BK L7 18BK/YL C345 - (BODY HARNESS SIDE) CIRCUIT C16 20LB/YL P70 22WT P72 22YL/BK X54 18VT X56 18DB/RD P74 22DB F21 14TN (POWER LOCKS/ WINDOWS) Z2 14BK/LG Z9 16BK/VT (PREMIUM RADIO)
Page 1038 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C346 - (BODY HARNESS SIDE) CIRCUIT F35 18RD (POWER LOCKS/WINDOWS) Q16 14BR/WT Q26 14VT/WT P33 18OR/BK (POWER LOCKS/WIN- DOWS) X82 20LB/RD P35 18OR/VT P36 19PK/VT G73 20LG/OR (HIGHLINE/PREMIUM) P33 18OR/BK (BASE, POWER LOCKS/ WINDOWS) P30 22OR/DG (HIGHLINE/PREMIUM) P34 18PK/BK (POWER LOCKS/WIN-...
Page 1039 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS BR/BE C347 - (LEFT DOOR HARNESS SIDE) CIRCUIT C16 20LB/YL P70 22WT P72 22YL/BK X53 20DG (STANDARD RADIO) X53 18DG (PREMIUM RADIO) X55 20BR/RD (STANDARD RADIO) X55 18BR/RD (PREMIUM RADIO) P74 22DB F21 14TN (EXCEPT BASE) Z2 14BK/LG (EXCEPT BASE) M1 22PK...
Page 1040 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C352 - WHITE (VISOR MIRROR SIDE) CIRCUIT M1 20PK Z4 20BK C352 - WHITE (OVERHEAD CONSOLE SIDE) CIRCUIT M1 20PK Z3 20BK C353 - WHITE (VISOR MIRROR SIDE) CIRCUIT M1 20PK Z4 20BK C353 - WHITE (OVERHEAD CONSOLE SIDE) CIRCUIT...
Page 1041 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS BR/BE C359 (HEATED SEATS) - (BODY SIDE) CIRCUIT P7 20LB/BK P137 20DG P8 20LB/WT F235 16RD P139 20WT P138 20VT/LG Z2 16BK/LG F37 16RD/LB G10 20LG/RD P140 20VT/BK C359 (HEATED SEATS) - (POWER SEAT SIDE) CIRCUIT P7 20LB/BK P137 20DG...
Page 1042 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C361 - (BODY HARNESS SIDE) CIRCUIT X91 18WT/DG (PREMIUM RADIO) X57 18BR/LB (STANDARD RADIO) X93 18WT/VT (PREMIUM RADIO) X51 18BR/YL (STANDARD RADIO) C361 - (REAR DOOR HARNESS SIDE) CIRCUIT X57 18BR/LB X51 18BR/YL C364 - (BODY HARNESS SIDE) CIRCUIT...
Page 1043 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS BR/BE C365 (HEATED SEAT) - (DRIVER SEAT SIDE) CIRCUIT Z2 16BK/LG P130 16TN F37 16RD/LB P142 22DB P144 20BK/WT C365 (HEATED SEAT) - (PASSENGER SEAT SIDE) CIRCUIT Z2 16BK/LG P130 16TN F37 16RD/LB P142 20DB P144 20BK/WT CAMSHAFT POSITION SENSOR (DIESEL) - 3 WAY...
Page 1044 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 CARGO LAMP NO. 1 - BLACK 2 WAY CIRCUIT FUNCTION M1 18PK FUSED B(+) M3 18PK/DB CARGO LAMP DRIVER CARGO LAMP NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION M1 18PK FUSED B(+) M3 18PK/DB CARGO LAMP DRIVER...
Page 1045 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS BR/BE CENTRAL TIMER MODULE C1 - GREEN 14 WAY CIRCUIT FUNCTION G75 22TN DRIVER DOOR AJAR SWITCH SENSE G13 22DB/RD CHIME REQUEST SIGNAL V8 16VT WIPER SWITCH MODE SENSE V18 22YL/DG WIPER MOTOR RELAY CONTROL G16 22BK/LB PASSENGER DOOR AJAR SWITCH SENSE Z2 22BK/LG...
Page 1046 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 CLOCKSPRING C1 - 5 WAY CIRCUIT FUNCTION V37 22RD/LG SPEED CONTROL SWITCH SIGNAL Z9 20BK/VT (SLT/HIGHLINE (REMOTE GROUND RADIO)) K4 22BK/LB SENSOR GROUND X20 22RD/BK (BASE) RADIO CONTROL MUX X3 20BK/RD HORN RELAY CONTROL CLOCKSPRING C2 - YELLOW 2 WAY CIRCUIT...
Page 1047 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS BR/BE CONTROLLER ANTILOCK BRAKE C2 (ABS) - BLACK 4 WAY CIRCUIT FUNCTION B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+) B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-) B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-) B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+) CRANKSHAFT POSITION SENSOR (GAS 8.0L) - GRAY 3 WAY...
Page 1048 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D1 18VT/BR CCD BUS (+) Z2 20BK/LG GROUND Z12 18BK/TN GROUND D20 20DG SCI RECEIVE D21 20PK/DB SCI TRANSMIT D2 18WT/BK CCD BUS (-) D220 20WT/VT (DIESEL) SCI RECEIVE (PCM, DSL) M1 20PK...
Page 1049 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS BR/BE DRIVER CYLINDER LOCK SWITCH - BLACK 2 WAY CIRCUIT FUNCTION Z2 20BK/LG GROUND G73 20LG/OR CYLINDER LOCK SWITCH MUX DRIVER DOOR AJAR SWITCH (CTM) - NATURAL 2 WAY CIRCUIT FUNCTION Z2 18BK/LG GROUND G75 18TN DRIVER DOOR AJAR SWITCH SENSE...
Page 1050 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 DRIVER HEATED SEAT CUSHION - BLUE 4 WAY CIRCUIT FUNCTION P131 16RD/DG LEFT SEAT HEATER B(+) DRIVER Z2 18BK/LG GROUND P144 20BK/WT SEAT TEMPERATURE 5V SUPPLY P141 20TN/LB LEFT SEAT TEMPERATURE SENSOR INPUT DRIVER HEATED SEAT SWITCH - RED 6 WAY CIRCUIT FUNCTION...
Page 1051 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS BR/BE DRIVER POWER SEAT HORIZONTAL MOTOR (CLUB CAB) - BLACK - 2 WAY CIRCUIT FUNCTION P17 16RD/LB LEFT SEAT HORIZONTAL REARWARD P15 16YL/LB LEFT SEAT HORIZONTAL FORWARD DRIVER POWER SEAT HORIZONTAL MOTOR (STANDARD CAB) - 2 WAY CIRCUIT FUNCTION P17 14DB/RD...
Page 1052 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 DRIVER POWER SEAT SWITCH (STANDARD CAB) - 14 WAY CIRCUIT FUNCTION F37 14RD/LB FUSED B(+) Z3 14BK/OR GROUND P11 14YL/WT LEFT SEAT REAR UP P13 14RD/WT LEFT SEAT REAR DOWN P17 14DB/RD LEFT SEAT HORIZONTAL REARWARD P15 14YL/LB LEFT SEAT HORIZONTAL FORWARD...
Page 1053 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS BR/BE ENGINE CONTROL MODULE (DIESEL) - 50 WAY CIRCUIT FUNCTION H104 18BR/OR IDLE VALIDATION SWITCH NO. 1 K244 20YL/DB CUMMINS BUS (+) K6 18VT/WT 5V SUPPLY K14 18BK/DB SENSOR GROUND F18 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) G60 18GY/BK ENGINE OIL PRESSURE SENSOR SIGNAL...
Page 1054 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K104 18BK/LB SENSOR GROUND ENGINE COOLANT TEMPERATURE SENSOR (GAS) - 2 WAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND K2 18TN/BK...
Page 1055 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS BR/BE FUEL HEATER (DIESEL) - 2 WAY CIRCUIT FUNCTION Z11 14BK/TN GROUND A93 12RD/BK FUEL HEATER RELAY OUTPUT FUEL INJECTION PUMP (DIESEL) - 9 WAY CIRCUIT FUNCTION K240 20BK DATA LINK (-) FUEL INJECTION PUMP K242 20WT DATA LINK (+) FUEL INJECTION PUMP K44 18VT/OR...
Page 1056 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 FUEL INJECTOR NO. 4 - BLACK 2 WAY CIRCUIT FUNCTION K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 5 - BLACK 2 WAY CIRCUIT FUNCTION K38 18GY...
Page 1057 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS BR/BE FUEL INJECTOR NO. 10 (8.0L) - BLACK 2 WAY CIRCUIT FUNCTION K116 18WT FUEL INJECTOR NO. 10 DRIVER A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL PUMP MODULE (GAS) - LT GRAY 4 WAY CIRCUIT FUNCTION Z13 16BK...
Page 1058 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION K20 18DG GENERATOR FIELD T125 18DB GENERATOR SOURCE GLOVE BOX LAMP AND SWITCH - 2 WAY CIRCUIT FUNCTION M1 22PK FUSED B(+) Z3 22BK/OR GROUND HEADLAMP SWITCH C1 - BLACK 14 WAY CIRCUIT...
Page 1059 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS BR/BE HIGH NOTE HORN - BLACK 2 WAY CIRCUIT FUNCTION X2 18DG/RD HORN RELAY OUTPUT Z1 18BK GROUND IDLE AIR CONTROL MOTOR - BLACK 4 WAY CIRCUIT FUNCTION K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER K60 18YL/BK IDLE AIR CONTROL NO.
Page 1060 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 IGNITION SWITCH C1 - BLACK 7 WAY CIRCUIT FUNCTION A41 14YL IGNITION SWITCH OUTPUT (START) A21 12DB IGNITION SWITCH OUTPUT (RUN-START) A2 14PK/BK FUSED B(+) A22 14BK/OR IGNITION SWITCH OUTPUT (RUN) A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC) A1 10RD...
Page 1061 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS BR/BE INTAKE AIR TEMPERATURE SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K104 18BK/LB SENSOR GROUND K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL INTAKE AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND...
Page 1062 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 JOINT CONNECTOR NO. 2 (IN PDC) - 18 WAY CIRCUIT FUNCTION A16 14RD/LB FUSED B(+) A16 14RD/LB FUSED B(+) A16 14RD/LB FUSED B(+) V5 16DG WIPER PARK SWITCH SENSE V5 16DG WIPER PARK SWITCH SENSE V5 16DG WIPER PARK SWITCH SENSE...
Page 1063 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS BR/BE JOINT CONNECTOR NO. 5 - NATURAL 22 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) M1 22PK FUSED B(+) M1 22PK FUSED B(+) Z3 20BK/OR GROUND Z3 18BK/OR GROUND Z3 22BK/OR GROUND Z3 18BK/OR GROUND E2 22OR...
Page 1064 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 JOINT CONNECTOR NO. 7 - NATURAL 22 WAY CIRCUIT FUNCTION D1 18VT/BR CCD BUS (+) D1 18VT/BR CCD BUS (+) D1 20VT/BR CCD BUS (+) D2 18WT/BK CCD BUS (-) D2 18WT/BK CCD BUS (-) D2 20WT/BK CCD BUS (-)
Page 1065 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS BR/BE JUNCTION BLOCK C1 - BLUE 15 WAY CIRCUIT FUNCTION G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL A20 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN) L61 18LG LEFT TURN SIGNAL V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L7 18BK/YL PARK LAMP RELAY OUTPUT F18 20LG/BK...
Page 1066 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 JUNCTION BLOCK C4 - BROWN 11 WAY CIRCUIT FUNCTION F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN) X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L61 18LG LEFT TURN SIGNAL F12 22DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
Page 1067 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS BR/BE JUNCTION BLOCK C8 - ORANGE 8 WAY CIRCUIT FUNCTION F30 18RD/OR FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F73 20YL FUSED B(+) F37 16RD/LB (HIGHLINE/PREMIUM) FUSED B(+) F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) JUNCTION BLOCK C9 - NATURAL 4 WAY CIRCUIT FUNCTION...
Page 1068 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 LEFT FRONT DOOR SPEAKER (PREMIUM) - 10 WAY CIRCUIT FUNCTION X83 20YL/RD AMPLIFIED HIGH LEFT FRONT SPEAKER (+) X81 20YL/BK AMPLIFIED HIGH LEFT FRONT SPEAKER (-) X53 18DG LEFT FRONT SPEAKER (+) X55 18BR/RD LEFT FRONT SPEAKER (-) X91 18WT/DG...
Page 1069 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS BR/BE LEFT LICENSE LAMP - BLACK 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z13 18BK GROUND LEFT OUTBOARD CLEARANCE LAMP - 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z4 18BK GROUND LEFT OUTBOARD HEADLAMP - BLUE 3 WAY...
Page 1070 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 LEFT REAR FENDER LAMP (DUAL REAR WHEELS) - BLACK 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z13 18BK GROUND LEFT REAR SPEAKER (PREMIUM 2 DOOR) - BLACK 2 WAY CIRCUIT FUNCTION X91 18WT/DG...
Page 1071 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS BR/BE LEFT SPEED CONTROL SWITCH - 2 WAY CIRCUIT FUNCTION K4 22WT SENSOR GROUND K4 22WT SENSOR GROUND V37 22DG/RD SPEED CONTROL SWITCH SIGNAL V37 22DG/RD SPEED CONTROL SWITCH SIGNAL LEFT TAIL/STOP/TURN SIGNAL LAMP - BLACK 3 WAY CIRCUIT FUNCTION Z13 18BK...
Page 1072 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 BR/BE MANIFOLD ABSOLUTE PRESSURE SENSOR (8.0L) - 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5V SUPPLY K4 20BK/LB SENSOR GROUND K1 18DG/RD MAP SENSOR SIGNAL MANIFOLD AIR PRESSURE SENSOR (DIESEL) - 3 WAY CIRCUIT FUNCTION K7 18OR...
Page 1073 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS BR/BE OVERDRIVE SWITCH - 2 WAY CIRCUIT FUNCTION T6 22OR/WT OVERDRIVE OFF SWITCH SENSE Z2 22BK/LG GROUND OVERHEAD CONSOLE (BASE) - 3 WAY CIRCUIT FUNCTION M2 22YL COURTESY LAMPS DRIVER M1 22PK FUSED B(+) Z2 20BK/LG GROUND...
Page 1074 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 OXYGEN SENSOR 1/1 UPSTREAM (A/T EXCEPT 8.0L) - 4 WAY CIRCUIT FUNCTION A141 18DG/WT AUTOMATIC SHUT DOWN RELAY OUTPUT K199 18BR/WT OXYGEN SENSOR 1/1 HEATER CONTROL K4 18BK/LB SENSOR GROUND K141 18LG/RD OXYGEN SENSOR 1/1 SIGNAL OXYGEN SENSOR 1/1 UPSTREAM (M/T EXCEPT 8.0L) - 4 WAY CIRCUIT...
Page 1075 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS BR/BE OXYGEN SENSOR 1/3 POST CATALYST (8.0L) - 4 WAY CIRCUIT FUNCTION A341 18DG/YL AUTOMATIC SHUT DOWN RELAY OUTPUT Z11 18BK/WT GROUND K4 18BK/LB SENSOR GROUND K341 18OR/BK OXYGEN SENSOR 1/3 SIGNAL OXYGEN SENSOR 2/1 RIGHT BANK UP (5.9L HD) (5.2L/5.9L/8.0L CALIFORNIA) CIRCUIT FUNCTION...
Page 1076 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 PASSENGER AIRBAG - 2 WAY CIRCUIT FUNCTION R42 18BK/YL PASSENGER AIRBAG LINE 1 R44 18DG/YL PASSENGER AIRBAG LINE 2 PASSENGER AIRBAG ON/OFF SWITCH C1 - 2 WAY CIRCUIT FUNCTION F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) Z6 18BK/PK GROUND...
Page 1077 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS BR/BE PASSENGER DOOR WINDOW/LOCK SWITCH - 11 WAY CIRCUIT FUNCTION Q16 14BR/WT MASTER WINDOW SWITCH RIGHT FRONT (UP) Q26 14VT/WT MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q22 14VT RIGHT FRONT WINDOW DRIVER (DOWN) Q12 14BR RF WINDOW DRIVER (UP) F35 18RD...
Page 1078 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 PASSENGER POWER SEAT HORIZONTAL MOTOR (CLUB CAB) - 2 WAY CIRCUIT FUNCTION P16 16LB RIGHT SEAT HORIZONTAL REARWARD P14 16YL/LB RIGHT SEAT HORIZONTAL FORWARD PASSENGER POWER SEAT REAR VERTICAL MOTOR (CLUB CAB) - 2 WAY CIRCUIT FUNCTION P10 16YL/WT...
Page 1079 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS BR/BE POWER OUTLET - 3 WAY CIRCUIT FUNCTION A12 16RD/TN OUTLET FEED Z3 16BK/OR GROUND POWERTRAIN CONTROL MODULE C1 (DIESEL) - BLACK 32 WAY CIRCUIT FUNCTION F18 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) K4 18BK/LB SENSOR GROUND T41 18BK/WT (A/T)
Page 1080 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 POWERTRAIN CONTROL MODULE C1 (GAS) - BLACK 32 WAY CIRCUIT FUNCTION K32 18YL/GY (8.0L) IGNITION COIL NO. 4 DRIVER F18 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) K18 18RD/BK (8.0L) IGNITION COIL NO. 3 DRIVER K4 18BK/LB SENSOR GROUND K43 18DG/GY (8.0L)
Page 1081 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS BR/BE POWERTRAIN CONTROL MODULE C2 (DIESEL) - BLACK 32 WAY CIRCUIT FUNCTION K20 18DG GENERATOR FIELD K54 18OR/BK (A/T) TORQUE CONVERTER CLUTCH SOLENOID CONTROL T60 18BR (A/T) 3-4 SHIFT SOLENOID CONTROL T13 18DB/BK OUTPUT SPEED SENSOR GROUND G7 18WT/OR (A/T) VEHICLE SPEED SENSOR SIGNAL...
Page 1082 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 POWERTRAIN CONTROL MODULE C2 (GAS) - BLACK 32 WAY CIRCUIT FUNCTION T13 18DB/BK (A/T) OUTPUT SPEED SENSOR GROUND G7 18WT/OR (A/T) VEHICLE SPEED SENSOR SIGNAL T14 18LG/BK (A/T) OUTPUT SPEED SENSOR SIGNAL T25 18LG/WT (A/T) GOVERNOR PRESSURE SENSOR SIGNAL K30 18PK (A/T)
Page 1083 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS BR/BE POWERTRAIN CONTROL MODULE C3 (GAS) - BLACK 32 WAY CIRCUIT FUNCTION C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL K199 18BR/VT (CALIFORNIA)
Page 1084 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 RADIO C2 - BLACK 7 WAY CIRCUIT FUNCTION X16 22LG ANTENNA RELAY OUTPUT X51 18BR/YL LEFT REAR SPEAKER (+) X52 18DB/WT RIGHT REAR SPEAKER (+) X53 18DG LEFT FRONT DOOR SPEAKER (+) X54 18VT RIGHT FRONT DOOR SPEAKER (+) X57 18BR/LB...
Page 1085 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS BR/BE RIGHT FOG LAMP - WHITE 2 WAY CIRCUIT FUNCTION L34 20RD/OR FUSED B(+) L39 20LB FOG LAMP SWITCH OUTPUT RIGHT FRONT DOOR SPEAKER (PREMIUM) - 10 WAY CIRCUIT FUNCTION X82 20LB/RD AMPLIFIED HIGH RIGHT FRONT DOOR SPEAKER (+) X80 20LB/BK AMPLIFIED HIGH RIGHT FRONT DOOR SPEAKER (-)
Page 1086 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 RIGHT HEADLAMP - BLACK 3 WAY CIRCUIT FUNCTION L45 18PK/RD FUSED B(+) L33 18LG/BR HIGH BEAM HEADLAMP DRIVER RIGHT LICENSE LAMP - BLACK 2 WAY CIRCUIT FUNCTION L7 18BK/YL PARK LAMP RELAY OUTPUT Z13 18BK GROUND RIGHT OUTBOARD CLEARANCE LAMP - 2 WAY...
Page 1087 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS BR/BE RIGHT POWER MIRROR - 6 WAY CIRCUIT FUNCTION P72 20YL/BK RIGHT MIRROR UP DRIVER P74 20DB RIGHT MIRROR LEFT DRIVER P70 20WT RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) C16 20LB/YL HEATED MIRROR Z2 20BK/LG GROUND RIGHT REAR FENDER LAMP (DUAL REAR WHEELS) - BLACK 2 WAY...
Page 1088 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 RIGHT REMOTE RADIO SWITCH - 2 WAY CIRCUIT FUNCTION Z2 22BK/LG GROUND X20 22RD/BK RADIO CONTROL MUX RIGHT SPEED CONTROL SWITCH - 2 WAY CIRCUIT FUNCTION K4 22WT SENSOR GROUND V37 22DG/RD SPEED CONTROL SWITCH SIGNAL RIGHT TAIL/STOP/TURN SIGNAL LAMP - BLACK 3 WAY CIRCUIT...
Page 1089 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS BR/BE SEAT BELT SWITCH (STANDARD CAB) - BLACK 2 WAY CIRCUIT FUNCTION G10 20LG/RD SEAT BELT SWITCH SENSE Z2 20BK/LG GROUND SEAT HEAT INTERFACE MODULE - 14 WAY CIRCUIT FUNCTION P7 20LB/BK DRIVER HEATED SEAT SWITCH P144 20BK/WT SEAT TEMPERATURE 5V SUPPLY...
Page 1090 BR/BE 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 TRAILER TOW CONNECTOR - 10 WAY CIRCUIT FUNCTION L62 16BR/RD RIGHT TURN SIGNAL L1 18VT/BK BACK-UP LAMP FEED A6 14RD/OR FUSED B(+) L76 14BK/OR TRAILER TOW RELAY OUTPUT B40 14LB TRAILER TOW BRAKE B(+) Z13 14BK GROUND Z13 14BK...
Page 1091 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS BR/BE WATER IN FUEL SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K104 18BK/LB SENSOR GROUND K1 18DG/RD WATER IN FUEL SENSOR SIGNAL WIPER MOTOR - 4 WAY CIRCUIT FUNCTION V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT V5 16DG WIPER PARK SWITCH SENSE V6 16DB...
Page 1092 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS TABLE OF CONTENTS page CONNECTOR/GROUND LOCATIONS DESCRIPTION ......1 tor and ground index is provided.
Page 1093 8W - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. C203 Left Cowl 23,25 C204 Left Cowl C205 Instrument Panel Center Support C206 Left Cowl 23,25 C237 Bottom Right of Instrument Panel 23,26 C303 Below Driver’s Seat C308...
Page 1094 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Cummins Bus (-) Left Front of Engine Cup Holder Lamp Center of Instrument Panel 23, 26 Data Link Connector Left Bottom of Instrument Panel 23,24 Day/Night Mirror Day/Night Mirror...
Page 1095 8W - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. G100 Left Fender Side Shield G101 Left Fender Side Shield G102 Left Fender Side Shield (RWAL Ground) G103 Near T/O for Wiper Motor G105 Front of Engine (Engine Ground) 4,5,6,9...
Page 1096 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Joint Connector No. 7 Left Side of Instrument Pane Joint Connector No. 8 Center of Instrument Panel Junction Block C1 Left Cowl Junction Block C2 Left Cowl Junction Block C3 Left Cowl...
Page 1097 8W - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Oxygen Sensor 1/1 Left Bank Up Left Exhaust Manifold Downpipe Oxygen Sensor 1/1 Upstream Catalytic Converter Inlet Side Oxygen Sensor 1/2 Downstream Catalytic Converter Outlet Side Oxygen Sensor 1/2 Left Bank Down Catalytic Converter Outlet Side Oxygen Sensor 1/2 Pre-catalyst...
Page 1098 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Right Front Wheel Speed Sensor Right Fender Side Shield Right Headlamp At Headlamp Right License Lamp At Rear Bumper Right Outboard Clearance Lamp Behind Front of Headliner Right Outboard Headlamp At Headlamp...
Page 1099 8W - 90 - 8 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Fig. 1 ENGINE COMPARTMENT (GAS ) Fig. 2 ENGINE COMPARTMENT (DIESEL ENGINE)
Page 1100 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 3 3.9-5.2-5.9 LITER ENGINE...
Page 1101 8W - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1102 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1103 8W - 90 - 12 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1104 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 7 GENERATOR (GAS ENGINE) Fig. 8 GENERATOR (DIESEL ENGINE)
Page 1105 8W - 90 - 14 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1106 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1107 8W - 90 - 16 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Fig. 11 ACCELERATOR PEDAL POSITION SENSOR Fig. 12 ENGINE CONTROL MODULE...
Page 1108 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1109 8W - 90 - 18 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1110 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 15 UNDER HOOD...
Page 1111 8W - 90 - 20 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1112 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1113 8W - 90 - 22 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1114 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1115 8W - 90 - 24 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Fig. 20 OVERHEAD CONSOLE...
Page 1116 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 21 TAIL LAMPS...
Page 1117 8W - 90 - 26 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued) Fig. 22 FRAME RAIL...
Page 1118 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 27 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1119 8W - 90 - 28 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1120 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 29 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1121 8W - 90 - 30 8W-90 CONNECTOR/GROUND LOCATIONS BR/BE CONNECTOR/GROUND LOCATIONS (Continued)
Page 1122 BR/BE 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 31 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1124 BR/BE 8W-95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS TABLE OF CONTENTS page SPLICE LOCATIONS DESCRIPTION ......1 index is provided.
Page 1125 8W - 95 - 2 8W-95 SPLICE LOCATIONS BR/BE SPLICE LOCATIONS (Continued) Splice Number Location Fig. S123 (V10) Engine Harness, Near T/O to Fuel Injector No. 3 S124 (V6, V8) Engine Harness, Top of Transmission S124 (V10) Engine Harness, In T/O to Transmission S126 (V6, V8) Engine Harness, Near T/O to Fuel Injector No.
Page 1126 BR/BE 8W-95 SPLICE LOCATIONS 8W - 95 - 3 SPLICE LOCATIONS (Continued) Splice Number Location Fig. S301 Body Harness, Left Side Instrument Panel S302 Body Harness, Left Side Instrument Panel S303 Body Harness, Left Side Instrument Panel S304 Body Harness, Left Side Instrument Panel S305 Body Harness, Right Side Instrument Panel S306...
Page 1127 8W - 95 - 4 8W-95 SPLICE LOCATIONS BR/BE SPLICE LOCATIONS (Continued) Fig. 1 DASH PANEL (GAS ENGINES) Fig. 2 DASH PANEL (DIESEL ENGINE)
Page 1128 BR/BE 8W-95 SPLICE LOCATIONS 8W - 95 - 5 SPLICE LOCATIONS (Continued)
Page 1129 8W - 95 - 6 8W-95 SPLICE LOCATIONS BR/BE SPLICE LOCATIONS (Continued)
Page 1130 BR/BE 8W-95 SPLICE LOCATIONS 8W - 95 - 7 SPLICE LOCATIONS (Continued) Fig. 5 5.2-5.9 LITER ENGINE...
Page 1131 8W - 95 - 8 8W-95 SPLICE LOCATIONS BR/BE SPLICE LOCATIONS (Continued)
Page 1132 BR/BE 8W-95 SPLICE LOCATIONS 8W - 95 - 9 SPLICE LOCATIONS (Continued)
Page 1133 8W - 95 - 10 8W-95 SPLICE LOCATIONS BR/BE SPLICE LOCATIONS (Continued) Fig. 8 RIGHT FENDER SIDE SHIELD Fig. 9 OVERHEAD CONSOLE...
Page 1134 BR/BE 8W-95 SPLICE LOCATIONS 8W - 95 - 11 SPLICE LOCATIONS (Continued) Fig. 10 LEFT COWL PANEL Fig. 11 CHASSIS...
Page 1135 8W - 95 - 12 8W-95 SPLICE LOCATIONS BR/BE SPLICE LOCATIONS (Continued)
Page 1136 BR/BE 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......5 DESCRIPTION .
Page 1137 8W - 97 - 2 8W-97 POWER DISTRIBUTION BR/BE of the receptacle shell. These clips engage and hold SPECIAL TOOLS the heating element against the insulated contact long enough for the resistor coil to heat up. When the POWER DISTRIBUTION SYSTEMS heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat.
Page 1138 BR/BE 8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER OUTLET (Continued) tor. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6.
Page 1139 8W - 97 - 4 8W-97 POWER DISTRIBUTION BR/BE CIGAR LIGHTER OUTLET (Continued) (5) Install the cigar lighter knob and element into levels resulting from a faulty generator or faulty the cigar lighter receptacle base, or the protective cap charging system control circuits. If the current rating into the power outlet receptacle base.
Page 1140 BR/BE 8W-97 POWER DISTRIBUTION 8W - 97 - 5 IOD FUSE (Continued) that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant.
Page 1141 8W - 97 - 6 8W-97 POWER DISTRIBUTION BR/BE IOD FUSE (Continued) Fig. 5 Junction Block Location Fig. 4 Ignition-Off Draw Fuse 1 - JUNCTION BLOCK 1 - JUNCTION BLOCK 2 - FUSE ACCESS PANEL 2 - IGNITION-OFF DRAW FUSE AND HOLDER 3 - LEFT INSTRUMENT PANEL END BRACKET The molded plastic JB housing has integral mount- ing brackets that are secured with two screws to the...
Page 1142 BR/BE 8W-97 POWER DISTRIBUTION 8W - 97 - 7 JUNCTION BLOCK (Continued) (2) Roll down the instrument panel from the dash (1) Reach through the outboard side of the instru- panel, but do not remove it from the vehicle. Refer to ment panel steering column opening to position the Instrument Panel Assembly in the index of this JB onto the left instrument panel end bracket.
Page 1143 8W - 97 - 8 8W-97 POWER DISTRIBUTION BR/BE POWER DISTRIBUTION CENTER (Continued) which replace all in-line fusible links. The PDC also manual for the location of more information on the houses up to thirteen blade-type fuses (two standard- ground eyelet locations. type and eleven mini-type), up to seventeen Interna- (4) Disengage each of the retainers that secure the tional Standards Organization (ISO) relays (five...
Page 1144 BR/BE 8W-97 POWER DISTRIBUTION 8W - 97 - 9 POWER DISTRIBUTION CENTER (Continued) (1) Position the PDC and the headlamp and dash wire harness unit in the engine compartment. (2) Install and tighten the two screws that secure the PDC housing to the left front fender inner shield. Tighten the screws to 8.4 N·m (75 in.
Page 1145 8W - 97 - 10 8W-97 POWER DISTRIBUTION BR/BE POWER OUTLET (Continued) the instrument panel, below the radio. The power continuity between the ground circuit cavity of the outlet base is secured by a snap fit within the instru- power outlet wire harness connector and a good ment panel.
Page 1146 BR/BE 8W-97 POWER DISTRIBUTION 8W - 97 - 11 POWER OUTLET (Continued) (6) Pull the receptacle base away from the instru- ment panel far enough to access the instrument panel wire harness connector. (7) Disconnect the instrument panel wire harness connector from the cigar lighter or power outlet receptacle base connector receptacle.
Page 1148 ENGINE 9 - 1 BR/BE ENGINE TABLE OF CONTENTS page page ENGINE 3.9L......1 ENGINE 8.0L.
Page 1149 9 - 2 ENGINE 3.9L BR/BE INSTALLATION......34 OIL FILTER CRANKSHAFT OIL SEAL - REAR REMOVAL .
Page 1150 BR/BE ENGINE 3.9L 9 - 3 ENGINE 3.9L (Continued) ENGINE 3.9L DESCRIPTION The 3.9 Liter (238 CID) six-cylinder engine is a V-Type, lightweight, single cam, overhead valve engine with hydraulic roller tappets. This engine is designed to use unleaded fuel. The engine lubrication system consists of a rotor type oil pump and a full-flow oil filter.
Page 1151 9 - 4 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING—PERFORMANCE PERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to 8 - CRANK ELECTRICAL/BATTERY SYSTEM/ BATTERY - STANDARD PROCEDURE). Check charging system.
Page 1152 BR/BE ENGINE 3.9L 9 - 5 ENGINE 3.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 11. Faulty ignition cables 11. Replace any cracked or shorted cables 12. Faulty ignition coil 12. Test and replace, as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL). ENGINE STALLS OR 1.
Page 1153 9 - 6 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING— MECHANICAL ENGINE MECHANICAL DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust oil level by draining or adding as needed 2.
Page 1154 BR/BE ENGINE 3.9L 9 - 7 ENGINE 3.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Excessive main bearing clearance 4. Measure bearings for correct clearance. Repair as necessary 5. Excessive end play 5. Check crankshaft thrust bearing for excessive wear on flanges 6.
Page 1155 9 - 8 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING—LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1156 BR/BE ENGINE 3.9L 9 - 9 ENGINE 3.9L (Continued) • Any causes for combustion/compression pressure DIAGNOSIS AND TESTING—CYLINDER loss COMPRESSION PRESSURE The results of a cylinder compression pressure test WARNING: DO NOT REMOVE THE RADIATOR CAP can be utilized to diagnose several engine malfunc- WITH THE SYSTEM HOT AND UNDER PRESSURE.
Page 1157 9 - 10 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING—REAR SEAL AREA STANDARD PROCEDURE—CYLINDER BORE LEAKS HONING Since it is sometimes difficult to determine the Before honing, stuff plenty of clean shop towels source of an oil leak in the rear seal area of the under the bores and over the crankshaft to keep engine, a more involved inspection is necessary.
Page 1158 BR/BE ENGINE 3.9L 9 - 11 ENGINE 3.9L (Continued) (4) A controlled hone motor speed between 200 and STANDARD PROCEDURE—REPAIR DAMAGED 300 RPM is necessary to obtain the proper cross- OR WORN THREADS hatch angle. The number of up and down strokes per minute can be regulated to get the desired 50°...
Page 1159 9 - 12 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) material is for use between two machined surfaces. (5) Discharge the air conditioning system, if Do not use on flexible metal flanges. equipped (Refer to 24 - HEATING & AIR CONDI- MOPAR GASKET SEALANT TIONING/PLUMBING - STANDARD PROCEDURE).
Page 1160 BR/BE ENGINE 3.9L 9 - 13 ENGINE 3.9L (Continued) (31) Remove engine from vehicle and install (18) Using a new gasket, install throttle body engine assembly on a repair stand. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ THROTTLE BODY - INSTALLATION). INSTALLATION (19) Connect the throttle linkage.
Page 1161 9 - 14 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION 3.9L ENGINE End Play 0.051 - 0.254 mm GENERAL DESCRIPTION (0.002 - 0.010 in.) CONNECTING RODS DESCRIPTION SPECIFICATION Piston Pin Bore Diameter 24.940 - 24.978 mm Engine Type 90°...
Page 1162 BR/BE ENGINE 3.9L 9 - 15 ENGINE 3.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Main Journal Beraing (0.040 - 0.060 in.) Clearance Exhaust 1.524 - 2.032 mm No. 1 0.013 - 0.038 mm (0.040 - 0.060 in.) (0.0005 - 0.0015 in.) Valve Face Angle 43.25°...
Page 1163 9 - 16 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Number of Coils Outer Rotor Clearance Installed Height 41.66 mm (Max) 0.3556 mm (1.64 in.) (0.014 in.) Wire Diameter 4.50 mm Outer Rotor Diameter (0.177 in.) (Min) 62.7126 mm (2.469 in.) HYDRAULIC TAPPETS...
Page 1164 BR/BE ENGINE 3.9L 9 - 17 ENGINE 3.9L (Continued) OVERSIZE AND UNDERSIZE ENGINE DESCRIPTION SPECIFICATION COMPONENT MARKINGS CHART End Play None OS-US Item Identification Location of Length 75.946 - 76.454 mm Identification (2.990 - 3.010 in.) Crankshaft R or M M-2-3 Milled flat on PISTON RINGS ect.
Page 1165 9 - 18 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) TORQUE DESCRIPTION N·m TORQUE CHART 3.9L ENGINE Lbs. Lbs. Through-Bolt (2WD) DESCRIPTION N·m Rear Insulator to — Lbs. Lbs. Crossmember Camshaft Sprocket—Bolt — Support Bracket—Nut Camshaft Thrust — (2WD) Plate—Bolts Rear Insulator to —...
Page 1166 BR/BE ENGINE 3.9L 9 - 19 ENGINE 3.9L (Continued) SPECIAL TOOLS ENGINE—3.9L Valve Guide Sleeve C-3973 Oil Pressure Gauge C-3292 Dial Indicator C-3339 Engine Support Fixture C-3487–A Puller C-3688 Valve Spring Compressor MD-998772–A Front Oil Seal Installer 6635 Adapter 6633 Camshaft Holder C-3509 Adapter 6716A...
Page 1167 9 - 20 ENGINE 3.9L BR/BE ENGINE 3.9L (Continued) Pressure Tester Kit 7700 Distributor Bushing Puller C-3052 Bloc–Chek–Kit C-3685–A Distributor Bushing Driver/Burnisher C-3053 Piston Ring Compressor C-385 Crankshaft Main Bearing Remover C-3059 Cylinder Bore Gauge C-119...
Page 1168 BR/BE ENGINE 3.9L 9 - 21 (2) A band-type screw clamp secures the air AIR CLEANER ELEMENT cleaner housing to throttle body. Loosen, but do not remove, this screw clamp (Fig. 4). Note clamp posi- REMOVAL - 3.9L/5.2L/5.9L tioning tabs on air cleaner housing. For air cleaner element required maintenance (3) All Engines: Disconnect breather hose at rear schedules (listed in time or mileage intervals), refer...
Page 1169 9 - 22 ENGINE 3.9L BR/BE OPERATION—CYLINDER HEAD CYLINDER HEAD The cylinder head closes the combustion chamber DESCRIPTION—CYLINDER HEAD allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the The cast iron cylinder heads (Fig. 5) are mounted cylinder head open and close to either allow clean air to the cylinder block using eight bolts.
Page 1170 BR/BE ENGINE 3.9L 9 - 23 CYLINDER HEAD (Continued) COOLING SYSTEM TESTER METHOD (17) Remove intake manifold and throttle body as an assembly. Discard the flange side gaskets and the WARNING: WITH COOLING SYSTEM TESTER IN front and rear cross-over gaskets. PLACE, PRESSURE WILL BUILD UP FAST.
Page 1171 9 - 24 ENGINE 3.9L BR/BE CYLINDER HEAD (Continued) CYLINDER HEAD COVER(S) REMOVAL A steel-backed silicone gasket is used with the cyl- inder head cover (Fig. 8). This gasket can be used again. Fig. 7 Cylinder Head Bolt -Tightening Sequence (5) Install the intake manifold (Refer to 9 - Fig.
Page 1172 BR/BE ENGINE 3.9L 9 - 25 (2) Attach dial indicator Tool C-3339 to cylinder INTAKE/EXHAUST VALVES & head and set it at right angles to valve stem being SEATS measured (Fig. 10). DESCRIPTION Both the intake and exhaust valves are made of steel.
Page 1173 9 - 26 ENGINE 3.9L BR/BE INTAKE/EXHAUST VALVES & SEATS (Continued) REFACING VALVES AND VALVE SEATS VALVES The intake and exhaust valves have a 43-1/4° to Inspect the remaining margin after the valves are 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle refaced (Fig.
Page 1174 BR/BE ENGINE 3.9L 9 - 27 INTAKE/EXHAUST VALVES & SEATS (Continued) (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- ing stones. A true and complete surface must be obtained. (2) Measure the concentricity of valve seat using a dial indicator.
Page 1175 9 - 28 ENGINE 3.9L BR/BE INTAKE/EXHAUST VALVES & SEATS (Continued) INSPECTION Examine block for cracks or fractures. The cylinder walls should be checked for out-of- round and taper. Refer to Honing Cylinder Bores in the Service Procedures portion of this Section. Inspect the oil line plug, the oil line plug is located in the vertical passage at the rear of the block between the oil-to-filter and oil-from-filter passages...
Page 1176 BR/BE ENGINE 3.9L 9 - 29 ENGINE BLOCK (Continued) Bearing Mount Adhesive. Plug should be 54.0 to 57.7 (11) Install a long bolt into front of camshaft to aid mm (2-1/8 to 2-5/16 in.) from bottom of the block. in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.
Page 1177 9 - 30 ENGINE 3.9L BR/BE CAMSHAFT & BEARINGS (IN BLOCK) (Continued) Fig. 20 Camshaft Holding Tool C-3509 (Installed Position) 1 - SPECIAL TOOL C-3509 2 - DRIVE GEAR 3 - DISTRIBUTOR LOCK BOLT Fig. 22 Alignment of Timing Marks 1 - TIMING MARKS Fig.
Page 1178 BR/BE ENGINE 3.9L 9 - 31 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (8) Turn crankshaft and camshaft to line up with The bearing shells must be installed so that the keyway location in crankshaft sprocket and in cam- tangs are in the machined grooves in the rods and shaft sprocket.
Page 1179 9 - 32 ENGINE 3.9L BR/BE CRANKSHAFT (Continued) (5) Remove and discard the crankshaft rear oil Apply enough sealant so that a small amount is seals. squeezed out. Withdraw nozzle and wipe excess seal- (6) Remove and discard the front crankshaft oil ant off the oil pan seal groove.
Page 1180 BR/BE ENGINE 3.9L 9 - 33 CRANKSHAFT MAIN BEARINGS (Continued) CRANKSHAFT IDENTIFICATION LOCATION CHART ITEM MEASUREMENT IDENTIFICATION ROD U/S 0.025 mm R1-R2-R3 ect. (0.001 in.) indicates rod journal No. 1, 2 and 3. MAIN U/S 0.025 mm M1-M2-M3 or M4 (0.001 in.) indicates main journal...
Page 1181 9 - 34 ENGINE 3.9L BR/BE CRANKSHAFT MAIN BEARINGS (Continued) INSTALLATION INSTALLATION Only one main bearing should be selectively fitted (1) Place the smaller diameter of the oil seal over while all other main bearing caps are properly tight- Front Oil Seal Installation Tool 6635 (Fig. 30). Seat ened.
Page 1182 BR/BE ENGINE 3.9L 9 - 35 CRANKSHAFT OIL SEAL - REAR (Continued) removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed. UPPER SEAL —CRANKSHAFT REMOVED (1) Remove the crankshaft (Refer to 9 - ENGINE/ ENGINE BLOCK/CRANKSHAFT - REMOVAL).
Page 1183 9 - 36 ENGINE 3.9L BR/BE CRANKSHAFT OIL SEAL - REAR (Continued) ble bearing cap to cylinder block immediately after sealant application. Fig. 34 Apply Sealant to Bearing Cap-to-Block Joint 1 - MOPAR GEN II SILICONE RUBBER ADHESIVE SEALANT NOZZLE TIP 2 - SEALANT APPLIED Fig.
Page 1184 BR/BE ENGINE 3.9L 9 - 37 CRANKSHAFT OIL SEAL - REAR (Continued) LOWER SEAL (1) Clean the rear main cap mating surfaces including the oil pan gasket groove. (2) Carefully install a new upper seal. Refer to UPPER SEAL—CRANKSHAFT INSTALLED. (3) Lightly oil the new lower seal lips with engine oil.
Page 1185 9 - 38 ENGINE 3.9L BR/BE tappet. Inspect the rocker arm push rod sockets HYDRAULIC LIFTERS (CAM IN and push rod ends for wear. BLOCK) (3) Valve tappet noise ranges from light noise to a DIAGNOSIS AND TESTING—HYDRAULIC heavy click. A light noise is usually caused by exces- sive leak-down around the unit plunger, or by the TAPPETS plunger partially sticking in the tappet body cylinder.
Page 1186 BR/BE ENGINE 3.9L 9 - 39 HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued) 20-110 seconds to leak-down. Discard tappets with (5) Remove yoke retainer and aligning yokes. leak-down time interval not within this specification. (6) Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet.
Page 1187 9 - 40 ENGINE 3.9L BR/BE PISTON MEASUREMENTS CHART PISTON & CONNECTING ROD DESCRIPTION PISTON A DIA = PISTON BORE The pistons are made of aluminum and have three SIZE DIAMETER DIAMETER ring grooves, the top two grooves are for the compres- MIN.
Page 1188 BR/BE ENGINE 3.9L 9 - 41 PISTON & CONNECTING ROD (Continued) the connecting rod is centered in cylinder bore and at (3) Immerse the piston head and rings in clean BDC. Be careful not to nick crankshaft journals. engine oil. Slide Piston Ring Compressor Tool C-385 (7) After removal, install bearing cap on the mat- over the piston and tighten with the special wrench ing rod.
Page 1189 9 - 42 ENGINE 3.9L BR/BE PISTON RINGS (Continued) lower rails. Insert oil rail spacer first, then side rails. (b) Install the second compression rings using Installation Tool C-4184. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down.
Page 1190 BR/BE ENGINE 3.9L 9 - 43 VIBRATION DAMPER (Continued) (5) Install the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION). (6) Install viscous fan drive and fan (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION). (7) Install the fan shroud.
Page 1191 9 - 44 ENGINE 3.9L BR/BE FRONT MOUNT (Continued) (3) Lower engine with support/lifting fixture while (4) Install through-bolt nuts and tighten the nuts guiding the engine bracket/cushion and through-bolt to 102 N·m (75 ft. lbs.) torque. into support cushion brackets (Fig. 48). (5) Lower the vehicle.
Page 1192 BR/BE ENGINE 3.9L 9 - 45 REAR MOUNT (Continued) (3) Using the transmission jack, lower the trans- mission and support cushion onto the crossmember (Fig. 49). (4) Install the support cushion bolts and tighten to 41 N·m (30 ft. lbs.) torque. (5) Remove the transmission jack.
Page 1193 9 - 46 ENGINE 3.9L BR/BE LUBRICATION (Continued) Fig. 51 Oil Lubrication System 1 - OIL DEFLECTOR TAB 14 - OIL PUMP 2 - BOLT 15 - OIL FILTER 3 - ROCKER ARM PIVOT 16 - CRANKSHAFT 4 - ROCKER ARM 17 - FROM OIL PUMP 5 - DRIP OILING FOR VALVE TIP 18 - OIL TO FILTER...
Page 1194 BR/BE ENGINE 3.9L 9 - 47 LUBRICATION (Continued) DIAGNOSIS AND TESTING—ENGINE OIL (12) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various PRESSURE speeds approximately 24 km (15 miles). Inspect the (1) Remove oil pressure sending unit.
Page 1195 9 - 48 ENGINE 3.9L BR/BE OIL (Continued) (6) Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE: Change engine oil at mileage and time intervals described in the Maintenance Schedule. This infor- mation can be found in the owner’s manual. TO CHANGE ENGINE OIL Run engine until achieving normal operating tem- perature.
Page 1196 BR/BE ENGINE 3.9L 9 - 49 OIL PAN (Continued) CLEANING Clean the block and pan gasket surfaces. Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots. If present, trim excess sealant from inside the engine.
Page 1197 9 - 50 ENGINE 3.9L BR/BE OIL PUMP REMOVAL (1) Remove the oil pan (Refer to 9 - ENGINE/LU- BRICATION/OIL PAN - REMOVAL). (2) Remove the oil pump from rear main bearing cap. DISASSEMBLE (1) Remove the relief valve as follows: (a) Remove cotter pin.
Page 1198 BR/BE ENGINE 3.9L 9 - 51 OIL PUMP (Continued) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 20.9 mm (0.825 in.) or less, or if the diameter is 62.7 mm (2.469 in.) or less, replace outer rotor (Fig. 60). Fig.
Page 1199 9 - 52 ENGINE 3.9L BR/BE OIL PUMP (Continued) (2) Hold the oil pump base flush against mating surface on No. 4 main bearing cap. Finger-tighten pump attaching bolts. Tighten attaching bolts to 41 N·m (30 ft. lbs.) torque. (3) Install the oil pan (Refer to 9 - ENGINE/LU- BRICATION/OIL PAN - INSTALLATION).
Page 1200 BR/BE ENGINE 3.9L 9 - 53 INTAKE MANIFOLD (Continued) DIAGNOSIS AND TESTING—INTAKE (18) Remove the throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - MANIFOLD LEAKAGE REMOVAL). An intake manifold air leak is characterized by (19) If required, remove the plenum pan and gas- lower than normal manifold vacuum.
Page 1201 9 - 54 ENGINE 3.9L BR/BE INTAKE MANIFOLD (Continued) (3) Apply Mopar GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket and cross—over gaskets (Fig.
Page 1202 BR/BE ENGINE 3.9L 9 - 55 INTAKE MANIFOLD (Continued) (8) Install closed crankcase ventilation and evapo- OPERATION ration control systems. The exhaust manifolds collect the engine exhaust (9) Connect the coil wires. exiting the combustion chambers, then channels the (10) Connect the heat indicator sending unit wire. exhaust gases to the exhaust pipes attached to the (11) Connect the heater hoses and bypass hose.
Page 1203 9 - 56 ENGINE 3.9L BR/BE EXHAUST MANIFOLD (Continued) (5) Assemble exhaust pipe to manifold and secure INSTALLATION with bolts, nuts and retainers. Tighten the bolts and (1) Be sure mating surfaces of chain case cover nuts to 34 N·m (25 ft. lbs.) torque. and cylinder block are clean and free from burrs.
Page 1204 BR/BE ENGINE 3.9L 9 - 57 TIMING BELT / CHAIN COVER(S) (Continued) (8) Install water pump (Refer to 7 - COOLING/EN- (7) If tensioner assembly is to be replaced, remove GINE/WATER PUMP - INSTALLATION). the three tensioner to block bolts and remove ten- (9) Install power steering pump (Refer to 19 - sioner assembly.
Page 1205 9 - 58 ENGINE 3.9L BR/BE TIMING BELT/CHAIN AND SPROCKETS (Continued) INSPECTION—MEASURING TIMING CHAIN (5) Slide both sprockets evenly over their respec- tive shafts and verify alignment of timing marks STRETCH (Fig. 77) with a straight-edge if necessary. NOTE: Timing chain tensioner must be removed for this operation.
Page 1206 BR/BE ENGINE 5.2L 9 - 59 ENGINE 5.2L TABLE OF CONTENTS page page ENGINE 5.2L INSTALLATION......87 DESCRIPTION .
Page 1207 9 - 60 ENGINE 5.2L BR/BE FRONT MOUNT INSPECTION ......107 REMOVAL ......100 ASSEMBLY .
Page 1208 BR/BE ENGINE 5.2L 9 - 61 ENGINE 5.2L (Continued) DIAGNOSIS AND TESTING-ENGINE DIAGNOSIS Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- - INTRODUCTION not be isolated with the Service Diagnosis charts. Engine diagnosis is helpful in determining the Information concerning additional tests and diagno- causes of malfunctions not detected and remedied by sis is provided within the following:...
Page 1209 9 - 62 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Worn or incorrect gapped spark 3. Clean plugs and set gap. (Refer to 8 plugs - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING). 4. Dirt or water in fuel system 4.
Page 1210 BR/BE ENGINE 5.2L 9 - 63 ENGINE 5.2L (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE MISSES ON 1. Worn or incorrectly gapped spark 1. Replace spark plugs or clean and ACCELERATION plugs set gap. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING) 2.
Page 1211 9 - 64 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) CONDITION POSSIBLE CAUSES CORRECTION CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. 2. Low oil pressure 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) engine oil pressure test/specifications...
Page 1212 BR/BE ENGINE 5.2L 9 - 65 ENGINE 5.2L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket gaskets 2. Loose fastener, broken or porous 2. Tighten, repair or replace the part metal part 3. Front or rear crankshaft oil seal 3.
Page 1213 9 - 66 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) DIAGNOSIS AND TESTING—LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1214 BR/BE ENGINE 5.2L 9 - 67 ENGINE 5.2L (Continued) • Any causes for combustion/compression pressure DIAGNOSIS AND TESTING—CYLINDER loss COMPRESSION PRESSURE The results of a cylinder compression pressure test WARNING: DO NOT REMOVE THE RADIATOR CAP can be utilized to diagnose several engine malfunc- WITH THE SYSTEM HOT AND UNDER PRESSURE.
Page 1215 9 - 68 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) STANDARD PROCEDURE—FORM-IN-PLACE FORM-IN-PLACE GASKET AND SEALER APPLICATION GASKETS & SEALERS Assembling parts using a form-in-place gasket There are numerous places where form-in-place requires care but it’s easier then using precut gas- gaskets are used on the engine.
Page 1216 BR/BE ENGINE 5.2L 9 - 69 ENGINE 5.2L (Continued) (1) Perform the Fuel Pressure Release Procedure strokes, depending on the bore condition, will be suf- (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - ficient to provide a satisfactory surface. Using honing STANDARD PROCEDURE).
Page 1217 9 - 70 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) (5) Remove the transmission oil cooler (Refer to 7 - (30) Remove transmission bell housing to engine COOLING/TRANSMISSION/TRANS COOLER block bolts. REMOVAL). (31) Lower the vehicle. (6) Remove the washer bottle from the fan shroud. (32) Install an engine lifting fixture.
Page 1218 BR/BE ENGINE 5.2L 9 - 71 ENGINE 5.2L (Continued) (21) Using a new gasket, install throttle body (32) Install the fan (Refer to 7 - COOLING/EN- (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ GINE/RADIATOR FAN - INSTALLATION). THROTTLE BODY - INSTALLATION). (33) Connect the radiator upper hose.
Page 1219 9 - 72 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION 5.2L ENGINE No. 5 39.688 – 39.713 mm ENGINE SPECIFICATIONS (1.5625 – 1.5635 in.) Bearing Journal Diameter DESCRIPTION SPECIFICATION No. 1 50.749 – 50.775 mm GENERAL SPECIFICATIONS (1.998 – 1.999 in.) No.
Page 1220 BR/BE ENGINE 5.2L 9 - 73 ENGINE 5.2L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Main Bearing Journal CYLINDER HEAD Diameter 63.487 – 63.513 mm Valve Seat (2.4995 – 2.5005in.) Angle 44.25° – 44.75° Out of Round (Max.) 0.127 mm Runout (Max.) 0.0762 mm (0.001 in.) (0.003 in.)
Page 1221 9 - 74 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION valve closed 378 N @ 41.66 mm Inner Rotor Thickness 20.955 mm (Min.) (85 lbs. @ 1.64 in.) (0.825 in.) valve open 890 N @ 30.89 mm (200 lbs.
Page 1222 BR/BE ENGINE 5.2L 9 - 75 ENGINE 5.2L (Continued) OVERSIZE AND UNDERSIZE ENGINE DESCRIPTION SPECIFICATION COMPONENT MARKINGS CHART PISTON RINGS U/S-O/S Item Identification Identification Ring Gap Location Compression Rings 0.254 – 0.508 mm Rod/ R or M R-1-4 Milled flat on (0.010 –...
Page 1223 9 - 76 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) TORQUE DESCRIPTION N·m TORQUE CHART 5.2L ENGINE Lbs. Lbs. Rear Insulator to — DESCRIPTION N·m Transmission— Lbs. Lbs. Bolts (4WD) Camshaft Sprocket—Bolt — Rear Insulator Bracket—Bolts — Camshaft Thrust Plate—Bolts — (4WD Automatic) Chain Case Cover—Bolts —...
Page 1224 BR/BE ENGINE 5.2L 9 - 77 ENGINE 5.2L (Continued) SPECIAL TOOLS 5.2L ENGINE Valve Guide Sleeve C-3973 Oil Pressure Gauge C-3292 Dial Indicator C-3339 Engine Support Fixture C-3487–A Puller C-3688 Valve Spring Compressor MD-998772–A Puller 1026 Adaptor 6633 Adaptor 6716A Crankshaft Damper Removal Insert 8513...
Page 1225 9 - 78 ENGINE 5.2L BR/BE ENGINE 5.2L (Continued) Front Oil Seal Installer 6635 Piston Ring Compressor C-385 Cam Bearing Remover/Installer C3132–A Crankshaft Main Bearing Remover C-3059 Camshaft Holder C-3509 Cylinder Bore Gauge C-119 Distributor Bushing Puller C-3052 Pressure Tester Kit 7700 Distributor Bushing Driver/Burnisher C-3053 Bloc–Check–Kit C-3685–A...
Page 1226 BR/BE ENGINE 5.2L 9 - 79 exhaust gases out, depending on the stroke of the CYLINDER HEAD engine. DESCRIPTION—CYLINDER HEAD OPERATION The cast iron cylinder heads (Fig. 4) are mounted The steel-backed silicone gasket is designed to seal to the cylinder block using ten bolts. The spark plugs the cylinder head cover for long periods of time are located in the peak of the wedge between the through extensive heat and cold, without failure.
Page 1227 9 - 80 ENGINE 5.2L BR/BE CYLINDER HEAD (Continued) COOLING SYSTEM TESTER METHOD (17) Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylin- WARNING: WITH COOLING SYSTEM TESTER IN der head gasket. PLACE, PRESSURE WILL BUILD UP FAST. EXCES- (18) Remove spark plugs.
Page 1228 BR/BE ENGINE 5.2L 9 - 81 CYLINDER HEAD (Continued) CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur. (6) Install push rods and rocker arm assemblies in their original position.
Page 1229 9 - 82 ENGINE 5.2L BR/BE INTAKE/EXHAUST VALVES & SEATS (Continued) STANDARD PROCEDURE—VALVES, GUIDES AND SPRINGS VALVE CLEANING Clean valves thoroughly. Discard burned, warped, or cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. VALVE GUIDES Measure valve stems for wear.
Page 1230 BR/BE ENGINE 5.2L 9 - 83 INTAKE/EXHAUST VALVES & SEATS (Continued) REFACING VALVES AND VALVE SEATS VALVES The intake and exhaust valves have a 43-1/4° to Inspect the remaining margin after the valves are 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle refaced (Fig.
Page 1231 9 - 84 ENGINE 5.2L BR/BE INTAKE/EXHAUST VALVES & SEATS (Continued) (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- ing stones. A true and complete surface must be obtained. (2) Measure the concentricity of valve seat using a dial indicator.
Page 1232 BR/BE ENGINE 5.2L 9 - 85 INTAKE/EXHAUST VALVES & SEATS (Continued) ROCKER ARM / ADJUSTER ASSEMBLY REMOVAL (1) Remove cylinder head cover and gasket (Refer ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (2) Remove the rocker arm bolts and pivots (Fig. 16).
Page 1233 9 - 86 ENGINE 5.2L BR/BE (4) If plug is too low, remove oil pan and No. 4 main ENGINE BLOCK bearing cap. Use suitable flat dowel to position properly. CLEANING Coat outside diameter of plug with Mopar Stud and Bearing Mount Adhesive.
Page 1234 BR/BE ENGINE 5.2L 9 - 87 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (1) Remove the radiator (Refer to 7 - COOLING/ INSTALLATION—CAMSHAFT BEARINGS ENGINE/RADIATOR - REMOVAL). (1) Install new camshaft bearings with Camshaft (2) Remove the A/C Condenser (if equipped) Bearing Remover/Installer Tool C-3132-A by sliding (3) Remove the engine cover.
Page 1235 9 - 88 ENGINE 5.2L BR/BE CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (7) Each tappet reused must be installed in the CRANKSHAFT same position from which it was removed. When camshaft is replaced, all of the tappets must be DESCRIPTION replaced.
Page 1236 BR/BE ENGINE 5.2L 9 - 89 CRANKSHAFT (Continued) CAUTION: Support crankshaft before removing material after assembly. DO NOT strike rear cap main bearing caps. failure to do so will allow the more than 2 times for proper engagement. (9) Clean and oil all cap bolts. Install all main crankshaft to fall damaging the crankshaft.
Page 1237 9 - 90 ENGINE 5.2L BR/BE Main Bearing Undersize Availability List CRANKSHAFT MAIN • 0.25 mm (0.001 inch) BEARINGS • 0.051 mm (0.002 inch) • 0.076 mm (0.003 inch) DESCRIPTION • 0.254 mm (0.010 inch) Main bearings (Fig. 25) are located in the cylinder •...
Page 1238 BR/BE ENGINE 5.2L 9 - 91 CRANKSHAFT MAIN BEARINGS (Continued) tion/alignment Tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly. (4) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward.
Page 1239 9 - 92 ENGINE 5.2L BR/BE CRANKSHAFT OIL SEAL - REAR (Continued) OPERATION The crankshaft seals prevent oil from leaking from around the crankshaft, either from the rear of the engine or from the engine front cover. REMOVAL The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed.

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