Bedford CF Van Workshop Service Repair Manual

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GROUP TAB LOCATOR
Introduction
0 Lubrication & Maintenance
2 Suspension
3 Differential & Driveline
5 Brakes
6 Clutch
7 Cooling
8A Audio
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission and Transfer Case
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
30 New Vehicle Preparation
Component and System Index
Service Manual Comment Forms (Rear of Manual)

AN INTRODUCTION 1
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE SAFETY CERTIFICATION LABEL INTERNATIONAL SYMBOLS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VEHICLE IDENTIFICATION NUMBER FASTENER IDENTIFICATION
VECI LABEL FASTENER USAGE
BODY CODE PLATE METRIC SYSTEM
EQUIPMENT IDENTIFICATION PLATE TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VEHICLE SAFETY The label is located on the driver-side door shut-

face (Fig. 1).
CERTIFICATION LABEL All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
DESCRIPTION Vehicle Identification Number.
A vehicle safety certification label is attached to
every DaimlerChrysler Corporation vehicle. The label
certifies that the vehicle conforms to all applicable
Federal Motor Vehicle Safety Standards. The label
also lists:
• Month and year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR’s) are
based on a minimum rim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
• Bar code.
• Month, Day and Hour (MDH) of final assembly.
• Paint and Trim codes.
• Country of origin. Fig. 1 Vehicle Safety Certification Label
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2 INTRODUCTION AN
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel
(Fig. 2). The VIN contains 17 characters that provide
data concerning the vehicle. Refer to the decoding
chart to determine the identification of a vehicle.
Fig. 2 Vehicle Identification Number (VIN)

1 - VIN
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1= USA
2 Make B = Dodge
3 Vehicle Type 7 = Truck
F = 4001-5000 lbs.
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
H = 6001-7000 lbs.
G = Dakota
Dakota Sport
Dakota 4x4
5 Vehicle Line
L = Dakota
Dakota Sport
Dakota 4x2
2 = Dakota
6 Series Dakota Sport
Dakota SLT
2 = Club Cab
7 Body Style A = Quad Cab
6 = Conventional Cab
P = 2.5L
X = 3.9L
8 Engine N=4.7L
Y = 5.2L
Z = 5.9L
9 Check Digit
10 Model Year 1=2001
11 Assembly Plant S = Warren Truck Assembly
12 Thru 17 Vehicle Build Sequence Assembly Sequence
AN INTRODUCTION 3
VECI LABEL tion reads from left to right, starting with line 4 in
the center of the plate to line 1 at the bottom of the
plate (Fig. 4).
DESCRIPTION
The last code imprinted on a vehicle code plate will
All vehicles are equipped with a combined VECI
be followed by the imprinted word END. When two
label. This label is located in the engine compart-
vehicle code plates are required, the last available
ment (Fig. 3).
spaces on the first plate will be imprinted with the
letters CTD (for continued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because
of the plate overlap.
Fig. 3 VECI Label Location

1 - VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL Fig. 4 Body Code
BODY CODE PLATE—LINE 4
The VECI label contains the following:
• Engine family and displacement DIGITS 1 THROUGH 12
• Evaporative family Vehicle Order Number
• Emission control system schematic
• Certification application DIGITS 13, 14, AND 15
• Engine timing specifications (if adjustable) Open Space
• Idle speeds (if adjustable)
• Spark plug and gap DIGITS 16, 17, AND 18
The label also contains an engine vacuum sche- Car Line Shell
matic. There are unique labels for vehicles built for • AN1 = Dakota 4 X 2
sale in the state of California and the country of • AN5 = Dakota 4 X 4
Canada. Canadian labels are written in both the
English and French languages. These labels are per- DIGIT 19
manently attached and cannot be removed without Price Class
defacing information and destroying label. • L = Dakota (All)
DIGITS 20 AND 21
BODY CODE PLATE Body Type
• 31 = Dakota Club Cab (130.9 in. Wheel Base)
DESCRIPTION • 61 = Dakota (111.9 in. Wheel Base)
• 62 = Dakota (123.9 in. Wheel Base)
LOCATION AND DECODING
A metal body code plate is attached to the floor pan BODY CODE PLATE—LINE 3
under the passenger seat. Remove the passenger
seat, door sill scuff plate and pull back the carpet to DIGITS 1,2, AND 3
access the body code plate. There are seven lines of Paint Procedure
information on the body code plate. Lines 5, 6, and 7
are not used to define service information. Informa-
4 INTRODUCTION AN
BODY CODE PLATE (Continued)
DIGIT 4 BODY CODE PLATE—LINE 1
Open Space
DIGITS 1 THROUGH 6 Body-in-white assembly sequence.
DIGITS 5 THROUGH 8
Primary Paint DIGITS 7 THROUGH 9
Refer to Group 23, Body for color codes. Open Space
DIGIT 9 DIGITS 10 THROUGH 12 Cargo box code

Open Space • XBS = Sweptline
DIGITS 10 THROUGH 13 DIGITS 13 THROUGH 16

Secondary Paint Open Space
DIGIT 14
Open Space EQUIPMENT IDENTIFICATION
DIGITS 15 THROUGH 18
PLATE
Interior Trim Code
DESCRIPTION
DIGIT 19 The Equipment Identification Plate (Fig. 5) is
located at the left, front of the inner hood panel. The
Open Space
plate lists information concerning the vehicle as fol-
DIGITS 20, 21, AND 22 lows:
• The model.
Engine Code
• The wheelbase.
• EPE = 2.5 L 4 cyl. MPI Gasoline
• EHC = 3.9 L 6 cyl. MPI Gasoline • The VIN (Vehicle Identification Number).
• The T.O.N. (order number).
• ELF = 5.2 L 8 cyl. MPI Gasoline
• The optional and special equipment installed on
• ELM = 5.9 L 8 cyl. MPI Gasoline
the vehicle.
BODY CODE PLATE—LINE 2 Refer to the information listed on the plate when
ordering replacement parts.
DIGITS 1, 2, AND 3
Transmission Codes
• DDK = 5–Speed Manual (NVG 1500)
• DDQ = 5–Speed Manual (AX15)
• DDC = 5–Speed Manual (NVG 3500)
• DGK = 4–Speed Automatic (42RE)
• DGW = 4–Speed Automatic (44RE)
• DGT = 4–Speed Automatic (46RE)
DIGIT 4
Open Space
DIGIT 5 Fig. 5 Equipment Identification Plate—Typical

Market Code
• B = International
INTERNATIONAL SYMBOLS
• C = Canada
• M = Mexico DESCRIPTION
• U = United States The graphic symbols illustrated in the following
International Control and Display Symbols Chart
DIGIT 6 (Fig. 6) are used to identify various instrument con-
Open Space trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
DIGITS 7 THROUGH 23
Vehicle Identification Number (VIN)
Refer to Vehicle Identification Number (VIN) para-
graph for proper breakdown of VIN code.
AN INTRODUCTION 5
INTERNATIONAL SYMBOLS (Continued)
Fig. 6 INTERNATIONAL SYMBOLS

1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
FASTENER IDENTIFICATION FASTENER USAGE

GRADE/CLASS IDENTIFICATION DESCRIPTION
DESCRIPTION WARNING: USE OF AN INCORRECT FASTENER
The SAE bolt strength grades range from grade 2 MAY RESULT IN COMPONENT DAMAGE OR PER-
to grade 8. The higher the grade number, the greater SONAL INJURY.
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual Figure art, specifications and tightening torque ref-
bolt strength grade corresponds to the number of line erences in this manual are identified in metric and
marks plus 2. The most commonly used metric bolt SAE format.
strength classes are 9.8 and 10.9. The metric During any maintenance or repair procedures, it is
strength class identification number is imprinted on important to salvage all fasteners (nuts, bolts, etc.)
the head of the bolt. The higher the class number, for reassembly. If the fastener is not salvageable, a
the greater the bolt strength. Some metric nuts are fastener of equivalent specification must be use.
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification (Fig. 7) DESCRIPTION
and Fastener Strength Charts (Fig. 8). Most stripped threaded holes can be repaired using
a Helicoil t. Follow the manufacture recommendation
for application and repair procedures.
6 INTRODUCTION AN
FASTENER USAGE (Continued)
Fig. 7 FASTENER IDENTIFICATION

AN INTRODUCTION 7
FASTENER USAGE (Continued)
Fig. 8 FASTENER STRENGTH

8 INTRODUCTION AN
METRIC SYSTEM Refer to the Metric Conversion Chart (Fig. 9) to

convert torque values listed in metric Newton-
meters (N·m). Also, use the chart to convert between
DESCRIPTION
millimeters (mm) and inches (in.)
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY 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) kPa x 0.2961 = Inches Hg
(60° F)
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/ x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
Hr. (Km/h) (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
AN INTRODUCTION 9
METRIC SYSTEM (Continued)
Fig. 9 METRIC CONVERSION CHART

10 INTRODUCTION AN
TORQUE REFERENCES cations Chart for torque references not listed in the
individual torque charts (Fig. 10).
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
Fig. 10 TORQUE SPECIFICATIONS

AN LUBRICATION & MAINTENANCE 0-1
LUBRICATION & MAINTENANCE

TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE HOISTING

SPECIFICATIONS . . . . . . . . . . . . . . . . .........1 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12
INTERNATIONAL SYMBOLS HOISTING RECOMMENDATIONS. . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . .........2 JUMP STARTING
PARTS & LUBRICANT STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE . . . . . . . . . . .........2 JUMP STARTING PROCEDURE . . . . . . . . . . . . 12
CLASSIFICATION OF LUBRICANTS . .........2 TOWING
FLUID TYPES STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 13
DESCRIPTION . . . . . . . . . . . . . . . . . . . .........3 TOWING RECOMMENDATIONS . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . .........6 TWO WHEEL DRIVE VEHICLE TOWING . . . . . 14
FLUID FILL/CHECK LOCATIONS FOUR WHEEL DRIVE VEHICLE TOWING. . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . .........7
MAINTENANCE SCHEDULES
DESCRIPTION . . . . . . . . . . . . . . . . . . . .........7
LUBRICATION &
MAINTENANCE
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

FUEL TANK 2-Door: 83L (22 U.S. Service Fill - 46RE 3.8L (4.0 qts)
Gallons)**** O-haul Fill - 46RE 9.1-9.5L (19-20 pts)
4-Door: 91L (24 U.S. O-haul Fill - 45RFE 13.33L (28.0 pts)
Gallons)****
MANUAL TRANSMISSION
ENGINE OIL - WITH FILTER
NV3500 2.28L (4.8 pts.)
2.5L Engine 4.3L (4.5 qts.)
TRANSFER CASE
NV233 1.18L (2.5 pts.)
NV244 1.35L (2.85 pts.)
FRONT AXLE
COOLING SYSTEM
C205F 1.66L (3.5 pts.)
2.5L Engine 9.3L (9.8 qts.)***
REAR AXLE
3.9L Engine 13.3L (14.0 qts.)***
9 1/4 2.32L (4.9 pts.)**
4.7L Engine 12.3L (13.0 qts.)***
8 1/4 2.22L (4.7 pts.)**
5.9L Engine 13.7L (14.6 qts.)***
** When equipped with Trac-lok, include 148 ml (5
AUTOMATIC TRANSMISSION oz.) of Friction Modifier.
Service Fill - 42RE 3.8L (4.0 qts) *** Includes 0.9L (1.0 qts.) for coolant reservoir.
O-haul Fill - 42RE 9.1-9.5L (19-20 pts) ****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
0-2 LUBRICATION & MAINTENANCE AN
INTERNATIONAL SYMBOLS API QUALITY CLASSIFICATION This symbol (Fig. 2) on the

front of an oil container means that the oil has been
certified by the American Petroleum Institute (API) to meet
DESCRIPTION all the lubrication requirements specified by
DaimlerChrysler Corporation uses international DailmlerChrysler Corporation.
symbols to identify engine compartment lubricant Refer to Group 9, Engine for gasoline engine oil
and fluid inspection and fill locations (Fig. 1). specification.
Fig. 2 API Symbol

GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
Fig. 1 International Symbols LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
PARTS & LUBRICANT by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
STANDARD PROCEDURE—CLASSIFICATION OF symbol is the usage and quality identification letters.
LUBRICANTS Wheel bearing lubricant is identified by the letter
Only lubricants bearing designations defined by “G”. Chassis lubricant is identified by the latter “L”.
the following organization should be used to service a The letter following the usage letter indicates the
DaimlerChrysler Corporation vehicle. quality of the lubricant. The following symbols indi-
• Society of Automotive Engineers (SAE) cate the highest quality.
• American Petroleum Institute (API) (Fig. 2)
• National Lubricating Grease Institute (NLGI)
(Fig. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis- Fig. 3 NLGI Symbol
cosity grade which indicates the cold-to-hot tempera- 1 - WHEEL BEARINGS
ture viscosity range. 2 - CHASSIS LUBRICATION
• SAE 30 = single grade engine oil. 3 - CHASSIS AND WHEEL BEARINGS
• SAE 10W-30 = multiple grade engine oil.
DaimlerChrysler Corporation only recommends
multiple grade engine oils. SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
PARTS & LUBRICANT (Continued)
RECOMMENDATIONS CAUTION: DO NOT use gasoline containing METH-
When service is required, DaimlerChrysler Corpo- ANOL. Gasoline containing methanol may damage
ration recommends that only Mopart brand parts, critical fuel system components.
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing Daimler-
Chrysler Corporation vehicles. MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
FLUID TYPES Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
DESCRIPTION - FUEL REQUIREMENTS ber without MMT. Gasoline blended with MMT
Your engine is designed to meet all emissions reg- reduce spark plug life and reduce emission system
ulations and provide excellent fuel economy and per- performance in some vehicles. We recommend that
formance when using high quality unleaded “regular” gasolines free of MMT be used in your vehicle. The
gasoline having an octane rating of 87. The routine MMT content of gasoline may not be indicated on the
use of premium gasoline is not recommended. Under gasoline pump; therefore, you should ask your gaso-
normal conditions the use of premium fuel will not line retailer whether or not his/her gasoline contains
provide a benefit over high quality regular gasolines MMT.
and in some circumstances may result in poorer per- It is even more important to look for gasoline with-
formance. out MMT in Canada because MMT can be used at
Light spark knock at low engine speeds is not levels higher than allowed in the United States.
harmful to your engine. However, continued heavy MMT is prohibited in Federal and California refor-
spark knock at high speeds can cause damage and mulated gasoline.
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may SULFUR IN GASOLINE
not be covered by the new vehicle warranty. If you live in the northeast United States, your
Poor quality gasoline can cause problems such as vehicle may have been designed to meet California
hard starting, stalling and hesitations. If you experi- low emission standards with Cleaner-Burning Cali-
ence these symptoms, try another brand of gasoline fornia reformulated gasoline with low sulfur. If such
before considering service for the vehicle. fuels are not available in states adopting California
Over 40 auto manufacturers world-wide have emission standards, your vehicles will operate satis-
issued and endorsed consistent gasoline specifications factorily on fuels meeting federal specifications, but
(the Worldwide Fuel Charter, WWFC) to define fuel emission control system performance may be
properties necessary to deliver enhanced emissions, adversely affected. Gasoline sold outside of California
performance and durability for your vehicle. We rec- is permitted to have higher sulfur levels which may
ommend the use of gasolines that meet the WWFC affect the performance of the vehicle’s catalytic con-
specifications if they are available. verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
REFORMULATED GASOLINE light to illuminate. We recommend that you try a dif-
Many areas of the country require the use of ferent brand of unleaded gasoline having lower sulfur
cleaner burning gasoline referred to as “reformulat- to determine if the problem is fuel related prior to
ed” gasoline. Reformulated gasoline contain oxygen- returning your vehicle to an authorized dealer for
ates, and are specifically blended to reduce vehicle service.
emissions and improve air quality.
CAUTION: If the Malfunction Indicator Lamp (MIL),
We strongly support the use of reformulated gaso-
Check Engine or Service Engine Soon light is flash-
line. Properly blended reformulated gasoline will pro-
ing, immediate service is required; see on-board
vide excellent performance and durability for the
diagnostics system section.
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS MATERIALS ADDED TO FUEL

Some fuel suppliers blend unleaded gasoline with All gasoline sold in the United States and Canada
oxygenates such as 10% ethanol, MTBE, and ETBE. are required to contain effective detergent additives.
Oxygenates are required in some areas of the country Use of additional detergents or other additives is not
during the winter months to reduce carbon monoxide needed under normal conditions.
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
FLUID TYPES (Continued)
FUEL SYSTEM CAUTIONS CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
CAUTION: Follow these guidelines to maintain your protection and less corrosion protection.
vehicle’s performance:
The cooling system is designed around the coolant.
• The use of leaded gas is prohibited by Federal The coolant must accept heat from engine metal, in
law. Using leaded gasoline can impair engine perfor- the cylinder head area near the exhaust valves and
mance, damage the emission control system, and engine block. Then coolant carries the heat to the
could result in loss of warranty coverage. radiator where the tube/fin radiator can transfer the
• An out-of-tune engine, or certain fuel or ignition heat to the air.
malfunctions, can cause the catalytic converter to The use of aluminum cylinder blocks, cylinder
overheat. If you notice a pungent burning odor or heads, and water pumps requires special corrosion
some light smoke, your engine may be out of tune or protection. Mopart Antifreeze/Coolant, 5
malfunctioning and may require immediate service. Year/100,000 Mile Formula (MS-9769), or the equiva-
Contact your dealer for service assistance. lent ethylene glycol base coolant with organic corro-
• When pulling a heavy load or driving a fully sion inhibitors (called HOAT, for Hybrid Organic
loaded vehicle when the humidity is low and the tem- Additive Technology) is recommended. This coolant
perature is high, use a premium unleaded fuel to offers the best engine cooling without corrosion when
help prevent spark knock. If spark knock persists, mixed with 50% Ethylene Glycol and 50% distilled
lighten the load, or engine piston damage may result. water to obtain a freeze point of -37°C (-35°F). If it
• The use of fuel additives which are now being loses color or becomes contaminated, drain, flush,
sold as octane enhancers is not recommended. Most and replace with fresh properly mixed coolant solu-
of these products contain high concentrations of tion.
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels CAUTION: MoparT Antifreeze/Coolant, 5
or additives is not the responsibility of Daimler- Year/100,000 Mile Formula (MS-9769) may not be
Chrysler Corporation and may not be covered under mixed with any other type of antifreeze. Mixing of
the new vehicle warranty. coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
NOTE: Intentional tampering with emissions control be covered under the new vehicle warranty, and
systems can result in civil penalties being assessed decreased corrosion protection.
against you.
COOLANT PERFORMANCE
DESCRIPTION - ENGINE COOLANT The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL conditions. The coolant performance of various mix-
BASE COOLANT AND IS HARMFUL IF SWAL- tures follows:
LOWED OR INHALED. IF SWALLOWED, DRINK Pure Water-Water can absorb more heat than a
TWO GLASSES OF WATER AND INDUCE VOMIT- mixture of water and ethylene-glycol. This is for pur-
ING. IF INHALED, MOVE TO FRESH AIR AREA. pose of heat transfer only. Water also freezes at a
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT higher temperature and allows corrosion.
STORE IN OPEN OR UNMARKED CONTAINERS. 100 percent Ethylene-Glycol-The corrosion
WASH SKIN AND CLOTHING THOROUGHLY AFTER inhibiting additives in ethylene-glycol need the pres-
COMING IN CONTACT WITH ETHYLENE GLYCOL. ence of water to dissolve. Without water, additives
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF form deposits in system. These act as insulation
GLYCOL BASE COOLANT PROPERLY, CONTACT causing temperature to rise to as high as 149°C
YOUR DEALER OR GOVERNMENT AGENCY FOR (300°F). This temperature is hot enough to melt plas-
LOCATION OF COLLECTION CENTER IN YOUR tic and soften solder. The increased temperature can
AREA. DO NOT OPEN A COOLING SYSTEM WHEN result in engine detonation. In addition, 100 percent
THE ENGINE IS AT OPERATING TEMPERATURE OR ethylene-glycol freezes at -22°C (-8°F).
HOT UNDER PRESSURE, PERSONAL INJURY CAN 50/50 Ethylene-Glycol and Water-Is the recom-
RESULT. AVOID RADIATOR COOLING FAN WHEN mended mixture, it provides protection against freez-
ENGINE COMPARTMENT RELATED SERVICE IS ing to -37°C (-34°F). The antifreeze concentration
PERFORMED, PERSONAL INJURY CAN RESULT. must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent SAE VISCOSITY
antifreeze concentration, which prevents freezing An SAE viscosity grade is used to specify the vis-
down to -67.7°C (-90°F). A higher percentage will cosity of engine oil. Use only engine oils with multi-
freeze at a warmer temperature. Also, a higher per- ple viscosities such as 5W-30 or 10W-30. These are
centage of antifreeze can cause the engine to over- specified with a dual SAE viscosity grade which indi-
heat because specific heat of antifreeze is lower than cates the cold-to-hot temperature viscosity range.
that of water. Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 4) and
CAUTION: Richer antifreeze mixtures cannot be (Fig. 5).
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES

NOTE: Refer to the vehicle’s coolant bottle cap to
identify HOAT or Non-HOAT coolant. Non-HOAT
coolant is green in color.
The use of aluminum cylinder blocks, cylinder

heads and water pumps requires special corrosion
protection. Only Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with Fig. 4 Temperature/Engine Oil Viscosity
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37°C (-35°F). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are

claimed to improve engine cooling.
DESCRIPTION - ENGINE OIL

WARNING: NEW OR USED ENGINE OIL CAN BE Fig. 5 Temperature/Engine Oil Viscosity
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL. ENERGY CONSERVING OIL
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY An Energy Conserving type oil is recommended for
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO gasoline engines. The designation of ENERGY CON-
YOUR HEALTH. THOROUGHLY WASH EXPOSED SERVING is located on the label of an engine oil con-
SKIN WITH SOAP AND WATER. DO NOT WASH tainer.
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO CONTAINER IDENTIFICATION
NOT POLLUTE, DISPOSE OF USED ENGINE OIL Standard engine oil identification notations have
PROPERLY. CONTACT YOUR DEALER OR GOVERN- been adopted to aid in the proper selection of engine
MENT AGENCY FOR LOCATION OF COLLECTION oil. The identifying notations are located on the label
CENTER IN YOUR AREA. of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
This symbol on the front of an oil container means
API SERVICE GRADE CERTIFIED that the oil has been certified by the American Petro-
Use an engine oil that is API Service Grade Certi- leum Institute (API) to meet all the lubrication
fied. MOPARt provides engine oils that conform to requirements specified by DaimlerChrysler.
this service grade.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopart ATF +4, type 9602, Automatic Transmis-

sion Fluid is the recommended fluid for Daimler-
Chrysler automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopart ATF +4, type 9602, Automatic Transmis-
Fig. 6 Engine Oil Container Standard Notations sion Fluid when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
DESCRIPTION - TRANSFER CASE - NV233 the vehicle such as engine oil or antifreeze. The red
Recommended lubricant for the NV233 transfer color is not permanent and is not an indicator of fluid
case is Mopart ATF +4, type 9602, Automatic Trans- condition. As the vehicle is driven, the ATF will begin
mission Fluid. to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
DESCRIPTION - TRANSFER CASE - NV244 accompanied with a burnt odor and/or deterioration
Recommended lubricant for the NV244 transfer in shift quality may indicate fluid deterioration or
case is Mopart ATF +4, type 9602, Automatic Trans- transmission component failure.
mission Fluid.
FLUID ADDITIVES
DESCRIPTION - AXLE DaimlerChrysler strongly recommends against the
A multi-purpose, hypoid gear lubricant which con- addition of any fluids to the transmission, other than
forms to the following specifications should be used. those automatic transmission fluids listed above.
Mopar Hypoid Gear Lubricant conforms to all of Exceptions to this policy are the use of special dyes
these specifications. to aid in detecting fluid leaks.
Various “special” additives and supplements exist
FRONT AXLE that claim to improve shift feel and/or quality. These
• The lubricant should have MIL-L-2105C and additives and others also claim to improve converter
API GL 5 quality specifications. clutch operation and inhibit overheating, oxidation,
• Lubricant is a thermally stable SAE 80W-90 varnish, and sludge. These claims have not been sup-
gear lubricant. ported to the satisfaction of DaimlerChrysler and
these additives must not be used. The use of trans-
REAR AXLE mission “sealers” should also be avoided, since they
• The lubricant should have MIL-L-2105C and may adversely affect the integrity of transmission
API GL 5 quality specifications. seals.
• 8 1/4 axle lubricant is a thermally stable SAE
80W-90 gear lubricant. OPERATION - AUTOMATIC TRANSMISSION
• 9 1/4 axle lubricant is a thermally stable SAE
FLUID
75W-90 gear lubricant.
The automatic transmission fluid is selected based
NOTE: Trac-lok™ equipped axles require a friction upon several qualities. The fluid must provide a high
modifier be added to the lubricant. level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
DESCRIPTION - MANUAL TRANSMISSION so that it can maintain a consistent viscosity through
Mopart Manual Transmission Lubricant is the a large temperature range. If the viscosity stays con-
only lubricant recommended for use in the manual stant through the temperature range of operation,
transmissions. transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
DESCRIPTION - AUTOMATIC TRANSMISSION ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
FLUID heat to the transmission case.
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
FLUID FILL/CHECK • Check fluid levels of coolant reservoir, power

steering and transmission and add as needed.
LOCATIONS • Check all lights and all other electrical items for
correct operation.
DESCRIPTION • Inspect and clean wiper blades. Replace if
The fluid check/fill points and lubrication locations required.
are located in each applicable Sections.
At Each Oil Change
• Inspect exhaust system.
MAINTENANCE SCHEDULES • Inspect brake hoses.
• Rotate the tires at each oil change interval
DESCRIPTION shown on Schedule “A”: (7,500 miles) or every other
Service and maintenance procedures for compo- interval shown on Schedule “B” (6,000 miles).
nents and systems listed in Schedule “A” or “B” can • Check engine coolant level, hoses, and clamps.
be found by using the Group Tab Locator index at
the front of this manual. If it is not clear which EMISSION CONTROL SYSTEM MAINTENANCE
group contains the information needed, refer to the The scheduled emission maintenance listed in bold
index at the back of this manual. type on the Maintenance Schedules, must be done at
There are two maintenance schedules that show the mileage specified to assure the continued proper
proper service based on the conditions that the vehi- functioning of the emission control system. These,
cle is subjected to. and all other maintenance services included in this
Schedule “A”, lists scheduled maintenance to be manual, should be done to provide the best vehicle
performed when the vehicle is used for general trans- performance and reliability. More frequent mainte-
portation. nance may be needed for vehicles in severe operating
Schedule “B”, lists maintenance intervals for vehi- conditions such as dusty areas and very short trip
cles that are operated under the conditions listed at driving.
the beginning of that schedule section.
Use the schedule that best describes the driving FLUID FILL LOCATIONS AND LUBRICATION
conditions. POINTS
Where time and mileage are listed, follow the The fluid fill/check locations and lubrication points
interval that occurs first. are located in each applicable group.
MAINTENANCE SCHEDULES SCHEDULE “A”

There are two maintenance schedules that show
proper service for the Dakota. 7,500 Miles (12 000 km) or at 6 months
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.
Second is Schedule “B”. It is a schedule for vehi- 15,000 Miles (24 000 km) or at 12 months
cles that are operated under the conditions listed at • Change engine oil.
the beginning of that schedule. • Replace engine oil filter.
Use the schedule that best describes the driving
conditions. 22,500 Miles (36 000 km) or at 18 months
Where time and mileage are listed, follow the • Change engine oil.
interval that occurs first. • Replace engine oil filter.
• Lubricate front suspension ball joints if
At Each Stop For Gasoline required.
• Check engine oil level, add as required. • Inspect front wheel bearings.
• Check windshield washer solvent and add if • Inspect brake linings.
required.
• Clean windshield and wiper blades as required. 30,000 Miles (48 000 km) or at 24 months
• Change engine oil.
Once A Month • Replace engine oil filter.
• Check tire pressure and look for unusual wear • Replace engine air cleaner element.
or damage. • Replace spark plugs.
• Inspect battery and clean and tighten terminals
as required.
MAINTENANCE SCHEDULES (Continued)
• Drain and refill automatic transmission fluid • Inspect auto tension drive belt and replace if
and change filter (4.7L only). required (3.9L, & 5.9L).
37,500 Miles (60 000 km) or at 30 months 82,500 Miles (132 000 km) or at 66 months
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Drain and refill transfer case fluid. • Flush and replace engine coolant if it has been
• Drain and refill automatic transmission fluid. 30,000 miles (48 000 km) or 24 months since last
Replace filter and adjust bands (3.9L, and 5.9L only). change.
45,000 Miles (72 000 km) or at 36 months 90,000 Miles (144 000 km) or at 72 months
• Lubricate front suspension ball joints if • Replace engine air cleaner element.
required. • Inspect PCV valve, replace as necessary.
• Inspect front wheel bearings. (3.9L, 4.7L, and 5.9L)*
• Inspect brake linings. • Replace spark plugs.
• Flush and replace engine coolant at 36 months, • Lubricate front suspension ball joints if
regardless of mileage. required.
• Inspect front wheel bearings.
52,500 Miles (84 000 km) or at 42 months • Inspect brake linings.
• Change engine oil. • Inspect auto tension drive belt and replace if
• Replace engine oil filter. required (3.9L, 4.7L, & 5.9L).D
• Flush and replace engine coolant if not done at
36 months. 97,500 Miles (156 000 km) or at 78 months
60,000 Miles (96 000 km) or at 48 months • Replace engine oil filter.
• Replace engine oil filter. 105,000 Miles (168 000 km) or at 84 months
• Replace engine air cleaner element. • Change engine oil.
• Replace ignition cables (2.5L, 3.9L, 5.9L). • Replace engine oil filter.
• Inspect PCV valve, replace as necessary. • Flush and replace engine coolant if it has been
(3.9L, 4.7L, and 5.9L)* 30,000 Miles (48 000km) or 24 months since last
• Replace spark plugs. change.
• Inspect auto tension drive belt and replace if • Inspect auto tension drive belt and replace if
required (3.9L, & 5.9L). required (3.9L, 4.7L, & 5.9L).D
• Inspect and adjust tension on drive belt (2.5L).
• Drain and refill automatic transmission fluid 112,500 Miles (181 000 km) or at 90 months
and change filter (4.7L only). • Change engine oil.
• Replace engine oil filter.
67,500 Miles (108 000 km) or at 54 months • Drain and refill automatic transmission fluid.
• Change engine oil. Replace filter and adjust bands (3.9L & 5.9L only).
• Replace engine oil filter. • Drain and refill transfer case fluid.
• Lubricate front suspension ball joints if • Lubricate front suspension ball joints if
required. required.
• Inspect front wheel bearings. • Inspect front wheel bearings.
• Inspect brake linings. • Inspect brake linings.
• Flush and replace engine coolant if it has been
75,000 Miles (120 000 km) or at 60 months 30,000 Miles (48 000km) or 24 months since last
• Change engine oil. change.
• Drain and refill automatic transmission fluid. 120,000 Miles (192 000 km) or at 96 months
Replace filter and adjust bands (3.9L & 5.9L). • Change engine oil.
• Drain and refill transfer case. • Replace engine oil filter.
• Flush and replace engine coolant if it has been • Replace engine air cleaner element.
30,000 miles (48 000 km) or 24 months since last • Replace ignition cables (2.5L, 3.9L & 5.9L).
change.
• Inspect PCV valve, replace as necessary. 18,000 Miles (29 000 km)
(3.9L, 4.7L, and 5.9L)* • Change engine oil.
• Replace spark plugs. • Replace engine oil filter.
• Inspect auto tension drive belt and replace if • Drain and refill manual transmission fluid (3.9L
required (3.9L, 4.7L, & 5.9L).D only).
• Drain and refill automatic transmission fluid
and change filter (4.7L only). 21,000 Miles (34 000 km)
*This maintenance is recommended by Daimler- • Change engine oil.
Chrysler Corporation to the owner but is not • Replace engine oil filter.
required to maintain the warranty on the PCV valve. • Inspect front wheel bearings.
DThis maintenance is not required if the belt was
previously replaced. 24,000 Miles (38 000 km)
Important: Inspection and service should also be • Change engine oil.
performed any time a malfunction is observed or sus- • Replace engine oil filter.
pected. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands (3.9L & 5.9L).‡
SCHEDULE “B” • Drain and refill automatic transmission fluid
Use schedule “B” if the vehicle is usually operated and change filter (4.7L only).
under the following conditions: • Lubricate front suspension ball joints if
• Frequent short trip driving less than 5 miles (8 required.
km) • Change rear axle fluid.
• Frequent driving in dusty conditions • Change front axle fluid (4x4).
• Trailer towing • Inspect brake linings.
• Extensive idling
• More than 50% of the driving is at sustained 27,000 miles (43 000 km)
high speeds during hot weather, above 90°F (32°C) • Change engine oil.
3,000 Miles (5 000 km)
• Change engine oil. 30,000 Miles (48 000 km)
• Replace engine oil filter. • Change engine oil.
6,000 Miles (10 000 km) • Replace engine air cleaner element.
• Change engine oil. • Replace spark plugs.
• Replace engine oil filter. • Inspect PCV valve, replace as necessary.
(3.9L, 4.7L and 5.9L)*
9,000 Miles (14 000 km) • Inspect and adjust drive tension on drive belt
• Change engine oil. (2.5L).
33,000 Miles (53,000 km)
12,000 Miles (19 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Drain and refill automatic transmission fluid. 36,000 Miles (58 000 km)
Replace filter and adjust bands (3.9L & 5.9L).‡ • Change engine oil.
• Drain and refill automatic transmission fluid • Replace engine oil filter.
and change filter (4.7L only). • Lubricate front suspension ball joints if
• Lubricate front suspension ball joints if required.
required. • Drain and refill automatic transmission fluid.
• Change rear axle fluid. Replace filter and adjust bands (3.9L & 5.9L).‡
• Change front axle fluid (4x4). • Drain and refill automatic transmission fluid
• Inspect brake linings. and change filter (4.7L only).
• Drain and refill transfer case fluid.
15,000 Miles (24 000 km) • Change rear axle fluid.
• Change engine oil. • Change front axle fluid (4x4).
• Replace engine oil filter. • Inspect brake linings.
• Inspect engine air cleaner element, replace
as necessary.
0 - 10 LUBRICATION & MAINTENANCE AN
39,000 Miles (62 000 km) • Change rear axle fluid.
• Change engine oil. • Change front axle fluid (4x4).
• Replace engine oil filter. • Inspect brake linings.
• Inspect auto tension drive belt and replace if
42,000 Miles (67 000 km) required (3.9L & 5.9L).
• Replace engine oil filter. 63,000 Miles (101 000 km)
• Inspect front wheel bearings. • Change engine oil.
45,000 Miles (72 000 km) • Inspect front wheel bearings.
• Replace engine oil filter. 66,000 Miles (106,000 km)
• Inspect engine air cleaner element, replace • Change engine oil.
as necessary. • Replace engine oil filter.
48,000 Miles (77 000 km) 69,000 Miles (110 000 km)
• Lubricate front suspension ball joints if
required. 72,000 Miles (115 000 km)
• Drain and refill automatic transmission fluid. • Change engine oil.
Replace filter and adjust bands (3.9L & 5.9L).‡ • Replace engine oil filter.
• Drain and refill automatic transmission fluid • Lubricate front suspension ball joints if
and change filter (4.7L only). required.
• Change rear axle fluid. • Drain and refill automatic transmission fluid.
• Change front axle fluid (4x4). Replace filter and adjust bands (3.9L & 5.9L).‡
• Inspect brake linings. • Drain and refill automatic transmission fluid
and change filter (4.7L only).
51,000 Miles (82 000 km) • Drain and refill transfer case fluid.
• Change engine oil. • Change rear axle fluid.
• Replace engine oil filter. • Change front axle fluid (4x4).
• Flush and replace engine coolant. • Inspect brake linings.
54,000 Miles (86 000 km) 75,000 Miles (120 000 km)
• Drain and refill manual transmission fluid (3.9L • Inspect engine air cleaner element, replace
only). as necessary.
57,000 Miles (91 000 km) required (3.9L, 4.7L & 5.9L).D
60,000 Miles (96 000 km) • Replace engine oil filter.
• Replace ignition cables. • Replace engine oil filter.
(3.9L, 4.7L, and 5.9L)* 30,000 miles (48 000 km) since last change.
• Replace spark plugs.
and change filter (4.7L only). • Inspect front wheel bearings.
• Lubricate front suspension ball joints if • Lubricate front suspension ball joints if
required. required.
AN LUBRICATION & MAINTENANCE 0 - 11
and change filter (4.7L only). • Lubricate front suspension ball joints if
• Change rear axle fluid. required.
• Change front axle fluid (4x4). • Drain and refill automatic transmission fluid.
• Inspect brake linings. Replace filter and adjust bands (3.9L & 5.9L).‡
• Drain and refill automatic transmission fluid
87,000 Miles (139 000 km) and change filter (4.7L only).
• Change engine oil. • Drain and refill transfer case fluid.
• Replace engine oil filter. • Change rear axle fluid.
• Change front axle fluid (4x4).
90,000 Miles (144 000 km) • Inspect brake linings.
• Replace spark plugs. • Replace engine oil filter.
(3.9L, 4.7L, and 5.9L)* 30,000 miles (48 000 km) since last change.
required (3.9L, 4.7L, & 5.9L).D 114,000 Miles (182 000 km)
• Inspect and adjust tension on drive belt (2.5L). • Change engine oil.
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
• Lubricate front suspension ball joints if • Replace engine oil filter.
required. • Replace engine air cleaner element.
• Drain and refill automatic transmission fluid. • Replace ignition cables.
Replace filter and adjust bands (3.9L & 5.9L).‡ • Inspect PCV valve, replace as necessary.
• Drain and refill automatic transmission fluid (3.9L, 4.7L, and 5.9L)*
and change filter (4.7L only). • Replace spark plugs.
• Change rear axle fluid. • Lubricate front suspension ball joints if
• Change front axle fluid (4x4). required.
• Inspect brake linings. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands (3.9L & 5.9L).‡
99,000 Miles (158 000 km) • Drain and refill automatic transmission fluid
• Change engine oil and change filter (4.7L only).
• Replace engine oil filter. • Change rear axle fluid.
• Change front axle fluid (4x4).
102,000 Miles (163 000 km) • Inspect brake linings.
• Change engine oil. • Inspect auto tension drive belt and replace if
• Replace engine oil filter. required (3.9L, 4.7L, & 5.9L).D
• Inspect and adjust tension on drive belt (2.5L).
105,000 Miles (168 000 km) *This maintenance is recommended by Chrysler
• Change engine oil. Corporation to the customer but is not required to
• Replace engine oil filter. maintain warranty on the PCV valve.
• Inspect engine air cleaner element, replace DThis maintenance is not required if the belt was
as necessary. previously replaced.
• Inspect front wheel bearings. ‡Prolonged operation with heavy loading, espe-
• Inspect auto tension drive belt and replace if cially in hot weather, use of vehicle for off-the-high-
required (3.9L, 4.7L, & 5.9L).D way operation, and trailer towing require the more
frequent transmission service indicated with a ‡ in HOIST
Schedule “B”. Perform these services if the vehicle is
usually operated under these conditions. WARNING: THE HOISTING AND JACK LIFTING
Important: Inspection and service should also be POINTS PROVIDED ARE FOR A COMPLETE VEHI-
performed any time a malfunction is observed or sus- CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
pected. NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
HOISTING SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
STANDARD PROCEDURE—HOISTING
RECOMMENDATIONS CAUTION: DO NOT LET THE REAR WHEELS/AXLE
HANG UNSUPPORTED WHEN THE VEHICLE IS
FLOOR JACK LIFTED WITH THE PARKING BRAKE APPLIED.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under: NOTE: When a frame-contact type hoist is used,
• An axle tube. verify that the lifting pads are positioned properly
• Aluminum differential. (Fig. 7).
• A body side sill.
• A steering linkage component. A vehicle can be lifted with:
• A drive shaft. • A single-post, frame-contact hoist.
• The engine or transmission oil pan. • A twin-post, chassis hoist.
• The fuel tank. • A ramp-type, drive-on hoist.
• A front suspension arm.
When properly positioned, a floor jack can be used JUMP STARTING

to lift a Dakota vehicle (Fig. 7). Support the vehicle
in the raised position with jack stands at the front STANDARD PROCEDURE—JUMP STARTING
and rear ends of the frame rails.
PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a

booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
Fig. 7 Correct Vehicle Lifting Locations—Typical
JUMP STARTING (Continued)
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-

abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster

source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition Fig. 8 Jumper Cable Clamp Connections
OFF. 1 - ENGINE GROUND
(3) On disabled vehicle, place gear selector in park 2 - NEGATIVE JUMPER CABLE
or neutral and set park brake. Turn off all accesso- 3 - BATTERY NEGATIVE CABLE
ries. 4 - POSITIVE JUMPER CABLE
(4) Connect jumper cables to booster battery. RED 5 - BATTERY POSITIVE CABLE
clamp to positive terminal (+). BLACK clamp to neg- 6 - BATTERY
ative terminal (-). DO NOT allow clamps at opposite 7 - TEST INDICATOR
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable TOWING
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the STANDARD PROCEDURE—TOWING
ground cable attaching point as possible (Fig. 8). RECOMMENDATIONS
(6) Start the engine in the vehicle which has the A vehicle equipped with an SAE approved Wheel-
booster battery, let the engine idle a few minutes, lift towing device can be used to tow all Short Bed
then start the engine in the vehicle with the dis- DAKOTA vehicles. Long Bed vehicles must be towed
charged battery. with a Flat-bed device (Fig. 9). When towing a 4WD
vehicle, use tow dollies under the opposite end of the
CAUTION: Do not crank starter motor on disabled vehicle.
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to

at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:

• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
• When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
• Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle. Fig. 9 Tow Vehicles With Approved Equipment
TOWING (Continued)
SAFETY PRECAUTIONS STANDARD PROCEDURE—TWO WHEEL DRIVE
VEHICLE TOWING
NOTE: The following safety precautions must be
observed when towing a vehicle.
TOWING-REAR END LIFTED
• Secure loose and protruding parts.
CAUTION:
• Always use a safety chain system that is inde-
Short bed vehicles must be towed with a Wheel-lift
pendent of the lifting and towing equipment.
device (Fig. 10) or transported on a flat bed (Fig.
• Do not allow towing equipment to contact the
11). Long bed vehicles must be transported on a
disabled vehicle’s fuel tank.
flat bed.
• Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
• Do not allow passengers to ride in a vehicle
being towed.
• Always observe state and local laws regarding
towing regulations.
• Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists. Fig. 10 Short Bed Vehicle Towing—Typical
• Do not attach tow chains, T-hooks, or J-hooks to
a bumper, steering linkage, drive shafts or a non-re-
inforced frame hole.
• Do not tow a heavily loaded vehicle. Damage to
the cab, cargo box or frame may result. Use a flat
bed device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehicle should be raised until lifted wheels Fig. 11 Long Bed Vehicle Towing—Typical
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo- 2WD vehicles can be towed with the front wheels
site end of the vehicle, especially when towing over on the surface for extended distances at speeds not
rough terrain or steep rises in the road. If necessary, exceeding 48 km/h (30 mph).
remove the wheels from the lifted end of the vehicle (1) Attach wheel lift device to rear wheels.
and lower the vehicle closer to the ground, to (2) Attach safety chains to frame rails. Route
increase the ground clearance at the opposite end of chains so not to interfere with tail pipe when vehicle
the vehicle. Install lug nuts on wheel attaching studs is lifted.
to retain brake drums. (3) Turn the ignition switch to the OFF position to
unlock the steering wheel.
RAMP ANGLE
CAUTION: Do not use steering column lock to
If a vehicle with flat bed towing equipment is used,
secure steering wheel during towing operation.
the approach ramp angle should not exceed 15
degrees. (4) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
TOWING WHEN KEYS ARE NOT AVAILABLE (5) Verify that steering components are in good
When the vehicle is locked and keys are not avail- condition.
able, use a flat bed hauler. A Sling-type device can be (6) Shift the transmission to NEUTRAL.
used on 4WD vehicles provided all the wheels are
lifted off the ground using tow dollies. TOWING-FRONT END LIFTED
When lifting from the front end, all vehicles must
be towed with a Wheel-lift device or transported on a
flat bed.
(1) Attach Wheel-lift device to front wheels.
TOWING (Continued)
(2) Attach the safety chains to the disabled vehicle (2) Attach wheel lift device to rear wheels.
at the frame rails. (3) Attach safety chains to frame rails. Route
chains so not to interfere with tail pipe when vehicle
CAUTION: Do not use steering column lock to is lifted.
secure steering wheel during towing operation. (4) Turn the ignition switch to the OFF position to
(3) Turn the ignition switch to the OFF position to
unlock the steering wheel. CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
TWO WHEEL DRIVE—MANUAL AND AUTOMATIC
TRANSMISSION (5) Secure steering wheel in straight ahead posi-
Provided the transmission is operable, tow only in tion with a clamp device designed for towing.
NEUTRAL at speeds not to exceed 30 mph (50 (6) Shift the transfer case to NEUTRAL.
km/h) and distances less than 15 miles (25km/h).
If the vehicle is to be towed more than 15 miles, FOUR WHEEL DRIVE TOWING—FRONT END
the propeller shaft should be disconnected or place LIFTED
tow dollies under rear wheels. When lifting from the front end, all vehicles must
be towed with a wheel-lift device or transported on a
STANDARD PROCEDURE—FOUR WHEEL flat bed.
DRIVE VEHICLE TOWING (1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
FOUR WHEEL DRIVE TOWING—REAR END LIFTED (2) Attach wheel lift device to front wheels.
(3) Attach the safety chains to the disabled vehicle
CAUTION: at the frame rails.
Short bed vehicles must be towed with a Wheel-lift
device (Fig. 10) or transported on a flat bed. Long CAUTION: Do not use steering column lock to
bed vehicles must be transported on a flat bed (Fig. secure steering wheel during towing operation.
11). When using a Wheel-lift device, all wheels must
(4) Turn the ignition switch to the OFF position to
be lifted off the ground using tow dollies.
(1) Raise the front of the vehicle off the ground (5) Shift the transfer case to NEUTRAL.
and install tow dollies under front wheels.
AN SUSPENSION 2-1
SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1 FRONT - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

FRONT - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT HEIGHT ADJUSTMENT 4WD . . . . . . . . . . . . . . .3

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 CAMBER AND CASTER ADJUSTMENT . . . . . . .4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .2 CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . .2 TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .4
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .5
HEIGHT MEASUREMENT 4WD . . . . . . . . . . . . .3
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe (Fig. 1).
CAUTION: Never attempt to modify suspension or

steering components by heating or bending.
NOTE: Periodic lubrication of the front suspension/ Fig. 1 Wheel Alignment Measurements
steering system components may be required. Rub- 1 - FRONT OF VEHICLE
ber bushings must never be lubricated. Refer to 2 - STEERING AXIS INCLINATION
Lubrication And Maintenance for the recommended 3 - PIVOT POINT
4 - TOE-IN
maintenance schedule.
Positive caster promotes directional stability. This

OPERATION angle enables the front wheels to return to a straight
• CASTER is the forward or rearward tilt of the ahead position after turns (Fig. 2).
steering knuckle from vertical. Tilting the top of the • CAMBER is the inward or outward tilt of the
knuckle forward provides negative caster. Tilting the wheel relative to the center of the vehicle. Tilting the
top of the knuckle rearward provides positive caster. top of the wheel inward provides negative camber.
2-2 WHEEL ALIGNMENT AN
WHEEL ALIGNMENT (Continued)
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire (Fig. 2).
• TOE is the difference between the leading inside
edges and trailing inside edges of the front tires.
Wheel toe position out of specification cause’s unsta-
ble steering, uneven tire wear and steering wheel off-
center. The wheel toe position is the final front
wheel alignment adjustment (Fig. 2).
• THRUST ANGLE is the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle (Fig. 2).
DIAGNOSIS AND TESTING - PRE-ALIGNMENT Fig. 2 Wheel Alignment

1 - FRONT OF VEHICLE
INSPECTION 2 - STEERING AXIS INCLINATION
Before starting wheel alignment, the following 3 - PIVOT POINT
inspection and necessary corrections must be com- 4 - TOE-IN
pleted. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size, air pressure and tread (5) Inspect suspension components for wear and
wear. noise.
(2) Inspect front wheel bearings for wear. (6) On 4x4 vehicles check suspension height.
(3) Inspect front wheels for excessive radial or lat- (7) Road test the vehicle.
eral runout and balance.
(4) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Lower ball joint (4x4). 3. Gease joint and perform diagnosis and
testing.
EXCESSIVE PLAY IN 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

STEERING
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
AN WHEEL ALIGNMENT 2-3
VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Column coupler binding. 2. Replace coupler.
3. Tire pressure. 3. Adjust tire pressure.
VEHICLE PULLS TO ONE 1. Tire pressure. 1. Adjust tire pressure.

SIDE 2. Alignment. 2. Align vehicle to specifications.
4. Radial tire lead. 4. Rotate or replace tire as necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
7. Ride height 4WD only. 7. Measure and adjust ride height.
STANDARD PROCEDURE - HEIGHT

MEASUREMENT 4WD
The vehicle suspension height must be measured
and adjusted if necessary before performing wheel
alignment on a 4x4 vehicle. Also when front suspen-
sion components have be replaced. This measure
must be performed with the vehicle supporting it’s
own weight and taken on both sides of the vehicle.
(1) Inspect tires for the correct size and air pres-
sure.
(2) Jounce the front of the vehicle.
(3) Measure and record the distance between the
ground and the center of the lower suspension arm
rear mounting bolt head (Fig. 3).
(4) Measure and record the distance between the
ground and the center of the front wheel (Fig. 3).
(5) Subtract the first measurement from the sec-
ond measurement. The difference between the two
measurement should be 47 mm (1.85 inches) 6 3.25
mm (0.125 inches).
STANDARD PROCEDURE - HEIGHT Fig. 3 Height

ADJUSTMENT 4WD To adjust the vehicle height turn the torsion bar
The vehicle suspension height must be measured adjustment bolt CLOCKWISE to raise the vehicle
and adjusted if necessary before performing wheel and COUNTER CLOCKWISE to lower the vehicle.
alignment on a 4x4 vehicle. Also when front suspen-
sion components have be replaced. This measure
must be performed with the vehicle supporting it’s
own weight and taken on both sides of the vehicle.
2-4 WHEEL ALIGNMENT AN
CAUTION: ALWAYS raise the vehicle to the correct STANDARD PROCEDURE - CASTER
suspension height, NEVER lower the vehicle to
obtain the correct suspension height. If the vehicle NOTE: 4x4 suspension height measurement must
suspension height is too high, lower the vehicle be performed before alignment.
below the height specification. Then raise the vehi-
cle to the correct suspension height specification. Moving the rear position of the pivot bar in or out,
This will insure the vehicle maintains the proper will change the caster angle significantly and camber
suspension height. angle only slightly. To maintain the camber angle
while adjusting caster, move the rear of the pivot bar
in or out. Then move the front of the pivot bar
NOTE: If a height adjustment has been made, per- slightly in the opposite direction.
form height measurement again on both sides of For example, to increase a positive caster angle,
the vehicle. move the rear position of the pivot bar inward
(toward the engine). Move the front of pivot bar out-
ward (away from the engine) slightly until the origi-
STANDARD PROCEDURE - CAMBER AND nal camber angle is obtained.
CASTER ADJUSTMENT
STANDARD PROCEDURE - CAMBER
NOTE: 4x4 suspension height measurement must
be performed before alignment. NOTE: 4x4 suspension height measurement must
be performed before alignment.
Camber and caster angle adjustments involve
changing the position of the upper suspension arm Move the front of the pivot bar in or out. This will
pivot bar (Fig. 4). change the camber angle significantly and caster
angle slightly.
After adjustment is made tighten the pivot bar
nuts to proper torque specification.
STANDARD PROCEDURE - TOE ADJUSTMENT

NOTE: 4x4 suspension height measurement must
be performed before alignment.
The wheel toe position adjustment is the final

adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.
Fig. 4 Caster & Camber Adjustment-Typical
NOTE: Each front wheel should be adjusted for
1 - PIVOT BAR
2 - + CASTER
one-half of the total toe position specification. This
3 - + CAMBER will ensure the steering wheel will be centered
4 - UPPER ARM SUSPENSION when the wheels are positioned straight-ahead.
NOTE: On 4x2 vehicles use Alignment Tool 8393 for

alignment. The tool attaches to the pivot bar on the
upper control arm.
AN WHEEL ALIGNMENT 2-5
(3) Adjust the wheel toe position by turning the tie (4) Tighten the tie rod jam nut to 75 N·m (55 ft.
rod as necessary (Fig. 5). lbs.).
(5) Verify the specifications.
(6) Turn off engine.
Fig. 5 Toe
1 - JAM NUT
2 - TIE ROD
3 - TIE ROD END
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
DESCRIPTION SPECIFICATION
TOTAL TOE (6
VEHICLE WHEEL BASE CASTER (6 0.50°) CAMBER (6 0.50°)
0.06°)
111.9 2.99° −0.25° 0.10°
4x2
130.9 3.13° −0.25° 0.10°
111.9 3.16° −0.25° 0.10°
4x4
130.9 3.27° −0.25° 0.10°
MAXIMUM RT to LT DIFFERENCE 0.50° 0.50° 0.06
DAKOTA RT
DESCRIPTION SPECIFICATION
VEHICLE WHEEL BASE CASTER (6 0.50°) CAMBER (6 0.50°) TOTAL TOE (6 0.06°)
111.9 3.67° −0.34° 0.10°
4x2
130.9 3.81° −0.34° 0.10°
MAXIMUM RT to LT DIFFERENCE 0.50° 0.50° 0.06
2-6 FRONT - 2WD AN
FRONT - 2WD
TABLE OF CONTENTS
page page
FRONT - 2WD OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7 SHOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BUSHINGS - CONTROL ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPRING
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HUB / BEARING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
KNUCKLE STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOWER BALL JOINT UPPER BALL JOINT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 13
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 10 UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . 13
LOWER CONTROL ARM UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT - 2WD CAUTION: Suspension components with rubber/ure-

thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
DESCRIPTION - 2WD
important to have the springs supporting the weight
The front suspension is designed to allow each
of the vehicle when the fasteners are torqued. If
wheel to adapt to different road surfaces indepen-
springs are not at their normal ride position, vehicle
dently. The wheels are mounted to hub bearings on
ride comfort could be affected and premature bush-
the cast iron steering knuckle spindles. The double-
ing wear may occur.
row hub bearings are sealed and lubricated for life.
The steering knuckles turn (pivot) on ball joints riv- • Shock absorbers
eted to the outboard portion of the suspension arms. • Coil springs
The ball joints are lubricated for life. • Suspension arms
The 4x2 front suspension is comprised of (Fig. 1): • Stabilizer bar
• Jounce/Rebound Bumpers
CAUTION: Components attached with a nut and cot-
• Steering Knuckle
ter pin must be torqued to specification. Then if the
• Hub/Bearing
slot in the nut does not line up with the cotter pin
• Ball Joints
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
AN FRONT - 2WD 2-7
FRONT - 2WD (Continued)
DESCRIPTION - SUSPENSION ARMS

The upper suspension arm bolts on frame brackets
through the arm pivot shaft. The frame brackets
have slotted holes which allow the arms to be
adjusted for caster and camber. Pivot shaft bushings
are not replaceable.
The lower suspension arms bolt to the lower frame
brackets and pivot through bushings, these bushings
The suspension arms have lube for life riveted ball
studs. The suspension arm travel (jounce) is limited
through the use of urethane bumpers. Rebound
travel is limited by the shock absorber.
Fig. 1 Front Suspension - 4X2

1 - UPPER SUSPENSION ARM
2 - STEERING KNUCKLE
3 - COIL SPRING
4 - LOWER SUSPENSION ARM
5 - STABILIZER BAR
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Shock Absorber 26 19 —
Upper Nut
Lower Bolts
Lower Suspension Arm 175 130 —
Front Nut
Rear Nut
Ball Joint Nut
Upper Suspension Arm 167 130 —
Pivot Shaft Nuts
Pivot Shaft to Frame Nuts
Ball Joint Nut
Stabilizer Bar 37 27 —
Link Upper Nut
Link Ball Stud Nut
Retainer Bolts
Hub/Bearing 251 185 —
Spindle Nut
2-8 FRONT - 2WD AN
SPECIAL TOOLS
FRONT SUSPENSION
Compressor, Coil Spring DD-1278
Fig. 2 BUSHING REMOVAL

1 - 8441-1
2 - 8441-2
3 - 8441-3
Remover Ball Joint MB-991113 INSTALLATION

(1) Install the bushing in the control arm and
inserted over the shaft.
(2) Install the bushing tool (Fig. 3).
Remover Ball Joint C-4150A
Puller Tie Rod C-3894-A Fig. 3 BUSHING INSTALLATION

1 - 8441-1
BUSHINGS - CONTROL ARM 2 - 8441-4
REMOVAL (3) Press the bushing into the control arm.

(1) Remove the control arm from the vehicle,(Refer (4) Install the washer and nut to the control arm
to 2 - SUSPENSION/FRONT/UPPER CONTROL shaft. Tighten the nut to 167 N·m (130 ft. lbs.).
ARM - REMOVAL). (5) Remove the control arm from the vise.
(2) Mount the control arm securely in a vise. (6) Install the control arm in the vehicle, (Refer to
(3) Remove the nut and washer from the control 2 - SUSPENSION/FRONT/UPPER CONTROL ARM -
arm shaft. INSTALLATION).
(4) Install the bushing tool (Fig. 2).
(5) Press out the old bushings.
AN FRONT - 2WD 2-9
HUB / BEARING has machined mounting locations for the front brake
calipers and hub bearing.
REMOVAL
(1) Raise and support vehicle.
OPERATION
The steering knuckle pivot between the upper and
(2) Remove wheel and tire assembly.
lower ball joint. Steering linkage attached to the
(3) Remove brake caliper, rotor, and ABS wheel
knuckle allows the vehicle to be steered.
speed sensor if equipped, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(4) Remove hub/bearing spindle nut and discard REMOVAL
nut (Fig. 4). (1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
CAUTION: The hub/bearing spindle nut can not be (3) Remove disc brake caliper, rotor, shield and
re-used. ABS speed sensor, (Refer to 5 - BRAKES/HYDRAU-
LIC/MECHANICAL/ROTORS - REMOVAL).
(5) Slide hub/bearing off spindle. (4) Remove tie-rod from steering knuckle arm,
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
REMOVAL).
(5) Remove the hub/bearing. (Refer to 2 - SUS-
PENSION/FRONT/HUB / BEARING - REMOVAL).
(6) Remove the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - REMOVAL).
(7) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and upper
shock mounting hole (Fig. 9).
(8) Tighten the tool lower nut to compress the coil
spring.
(9) Remove the lower ball joint nut and separate
the ball joint from the knuckle with Remover
C-4150A (Fig. 10).
(10) Remove the upper ball joint nut and separate
Fig. 4 Hub/Bearing MB-991113 (Fig. 5).
1 - KNUCKLE
2 - HUB/BEARING CAUTION: When install Remover MB-991113 to sep-
3 - SPINDLE NUT arate the ball joint, be careful not to damage the
ball joint seal.
INSTALLATION (11) Remove steering knuckle.

(1) Slide hub/bearing on spindle.
(2) Install new spindle nut and tighten to 251 INSTALLATION
N·m (185 ft. lbs.). (1) Position steering knuckle on upper and lower
(3) Install brake rotor, caliper, and ABS wheel ball joints and install nuts. Tighten lower nut to 127
speed sensor if equipped, (Refer to 5 - BRAKES/HY- N·m (94 ft. lbs.). Tighten upper nut to 81 N·m (60 ft.
DRAULIC/MECHANICAL/ROTORS - INSTALLA- lbs.) and install new cotter pins.
TION). (2) Remove the spring compressor.
(4) Install wheel and tire assembly. (Refer to 22 - (3) Install the shock absorber. (Refer to 2 - SUS-
TIRES/WHEELS/WHEELS - STANDARD PROCE- PENSION/FRONT/SHOCK - INSTALLATION).
DURE). (4) Install the hub/bearing. (Refer to 2 - SUSPEN-
(5) Remove support and lower vehicle. SION/FRONT/HUB / BEARING - INSTALLATION).
(5) Install ABS speed sensor, brake dust shield,
rotor and caliper, (Refer to 5 - BRAKES/HYDRAU-
KNUCKLE LIC/MECHANICAL/ROTORS - INSTALLATION).
(6) Install tie rod to steering knuckle arm, (Refer
DESCRIPTION to 19 - STEERING/LINKAGE/TIE ROD END -
The knuckle is a single casting with legs machined INSTALLATION).
for the upper and lower ball joints. The knuckle also
2 - 10 FRONT - 2WD AN
KNUCKLE (Continued)
Fig. 5 Upper Ball Joint

1 - UPPER BALL JOINT
2 - REMOVER
3 - KNUCKLE Fig. 6 Lower Ball Joint Boss
1 - BALL JOINT BOSS
(7) Install the wheel and tire assembly. (Refer to 3 - DIAL INDICATOR
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(8) Remove support and lower the vehicle upper suspension arm and record the dial indicator
reading.
(7) If the travel exceeds 1.52 mm (0.060 in.),
LOWER BALL JOINT replace the lower suspension arm.
DIAGNOSIS AND TESTING - LOWER BALL

LOWER CONTROL ARM
JOINT
(1) Raise the front of the vehicle. Place safety floor REMOVAL
stands under both lower suspension arms as far out-
board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.
(3) Remove disc brake caliper and rotor from steer-
NOTE: The upper suspension arms must not con- ing knuckle, (Refer to 5 - BRAKES/HYDRAULIC/
tact the rebound bumpers. MECHANICAL/ROTORS - REMOVAL).
(4) Remove shock absorber. (Refer to 2 - SUSPEN-
(2) Remove the tire and wheel assemblies. SION/FRONT/SHOCK - REMOVAL).
(3) Mount a dial indicator solidly under the lower (5) Remove stabilizer bar link from the lower sus-
suspension arm. pension arm. (Refer to 2 - SUSPENSION/FRONT/
(4) Position indicator plunger against the bottom STABILIZER BAR - REMOVAL).
of the steering knuckle lower ball joint boss. (6) Remove the coil spring.
(7) Remove lower suspension arm mounting bolts
NOTE: The dial indicator plunger must be perpen- (Fig. 7)from the frame mounts and remove the arm.
dicular to the machined surface of the steering
knuckle lower ball joint boss (Fig. 6). INSTALLATION
(5) Position a pry bar over the top of the upper CAUTION: Frame mounting bolts must be installed
suspension arm and under the pivot bar of the upper to their original location and orientation to avoid
suspension arm. Pry down on the upper suspension damaging the steering rack boots.
arm and then zero the dial indicator.
(6) Reposition the pry bar under the upper suspen- (1) Loosely attach suspension arm to frame
sion arm and on top of the frame rail. Pry up on the mounts.
(2) Install the coil spring.
AN FRONT - 2WD 2 - 11
LOWER CONTROL ARM (Continued)
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
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.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
Fig. 7 Lower Suspension Arm base lubricants will deteriorate the bushing.
2 - FRAME MOUNTS REMOVAL
(1) Remove the upper shock nut, retainer and
(3) Install the shock absorber. (Refer to 2 - SUS- grommet from the shock absorber stud (Fig. 8) .
PENSION/FRONT/SHOCK - INSTALLATION).
(4) Install stabilizer bar link to the lower suspen-
sion arm and tighten nut to 47 N·m (35 ft. lbs.)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
BAR - INSTALLATION).
(5) Install brake rotor and caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(6) Install wheel and tire assembly. (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove support and lower the vehicle.
(8) Tighten the front suspension arm mounting
nut to 175 N·m (130 ft. lbs.) and the rear nut to 108
N·m (80 ft. lbs.).
Fig. 8 Front Shock Absorber

SHOCK 1 - RETAINER
2 - GROMMET
DESCRIPTION 3 - SHOCK ABSORBER
The top of the low-pressure gas charged shock are
bolted to the frame. The bottom of the shock are (2) Raise and support the vehicle.
bolted to the lower suspension arm. (3) Remove the lower mounting bolts and remove
shock absorber through the lower suspension arm
OPERATION (Fig. 8) .
The shock absorbers dampen jounce and rebound
of the vehicle over various road conditions. INSTALLATION
DIAGNOSIS AND TESTING - SHOCK NOTE: Upper shock nut must be replaced or use
A knocking or rattling noise from a shock absorber Mopar Lock ’N Seal or LoctiteT 242 on existing nut.
may be caused by movement between mounting (1) Install the lower retainer (lower retainer is
bushings and metal brackets or attaching compo- stamped with a L) and grommet on the shock
nents. These noises can usually be stopped by tight- absorber stud and extend the shock. Insert the shock
ening the attaching nuts. If the noise persists, absorber through the lower suspension arm and
inspect for damaged and worn bushings, and attach- upper mounting hole.
SHOCK (Continued)
(2) Install the lower mounting bolts and tighten to
28 N·m (21 ft. lbs.).
(4) Install the upper grommet and retainer (upper
retainer is stamped with a U) on the shock
absorber stud. Install a new nut or use Mopar Lock
’N Seal or Loctitet 242 on existing nut and tighten to
26 N·m (19 ft. lbs.).
SPRING
DESCRIPTION
The springs mount between the lower suspension
arms and frame rail spring seats. A rubber isolator
seats on top off the spring to help prevent noise.
OPERATION
The coil springs control ride quality and maintain
proper ride height.
REMOVAL Fig. 9 Spring Compressor

(1) Raise and support the vehicle.
1 - COIL SPRING
(3) Remove the stabilizer bar link from the lower
3 - SPRING COMPRESSOR
suspension arm. (Refer to 2 - SUSPENSION/FRONT/
STABILIZER BAR - REMOVAL).
(4) Remove the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and upper
shock mounting hole (Fig. 9).
(6) Tighten the tool lower nut to compress the coil
spring.
(7) Remove the lower ball joint nut and separate
C-4150A (Fig. 10).
(8) Loosen the spring compressor lower nut to
relieve spring tension.
(9) Remove the tool and pull down on the lower
suspension arm to remove the spring.
INSTALLATION
NOTE: The ramped or open end of the coil spring is
the bottom of the spring.
(1) Tape the isolator pad to the top of the coil

spring. Position the spring in the lower suspension
arm pocket. Be sure that the coil spring is seated in Fig. 10 Lower Ball Joint
the pocket. 1 - LOWER BALL JOINT
(2) Install Spring Compressor DD-1278 up through 2 - REMOVER
the lower suspension arm, coil spring upper shock 3 - STEERING KNUCKLE
mounting hole.
(3) Tighten the tool nut to compress the coil
spring.
SPRING (Continued)
(4) Install the lower ball joint into the knuckle and
tighten the nut to 127 N·m (94 ft. lbs.). Install cotter
pin.
(5) Remove the spring compressor tool.
(6) Install the stabilizer bar link to the lower sus-
pension arm and tighten nut to 47 N·m (35 ft. lbs.).
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
BAR - INSTALLATION).
(7) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(8) Install the wheel and tire assembly. (Refer to
CEDURE).
STABILIZER BAR Fig. 11 Stabilizer Bar

1 - RETAINER
2 - GROMMET
DESCRIPTION
3 - STABILIZER LINK
The bar extends across the front underside of the
4 - STABILIZER BAR
chassis and mounts on the frame rails. Links con-
nected the bar to the lower suspension arms. Stabi-
lizer bar mounts are isolated by rubber bushings. (6) Install the lower link mounting nut and tighten
Links are isolated with rubber grommets. to 47 N·m (35 ft. lbs.).
OPERATION NOTE: Ensure both link end caps are facing

straight forward.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con- (7) Install the upper link grommet, retainer and
trol the vehicle body in relationship to the suspen- nut and tighten to 37 N·m (27 ft. lbs.).
sion. (8) Remove support and lower vehicle.
REMOVAL
(1) Raise and support the vehicle. UPPER BALL JOINT
(2) Remove the upper link nut, retainer and grom-
met from each link. DIAGNOSIS AND TESTING - UPPER BALL
(3) Remove the lower link nut from the lower sus-
pension arm on each side (Fig. 11).
JOINT
(1) Position a floor jack under the lower suspen-
(4) Remove the stabilizer bar retainer bolts and
sion arm. Raise the wheel and allow the tire to
remove the retainers and stabilizer bar from the
lightly contact the floor (vehicle weight relieved from
vehicle.
the tire).
(5) Remove the bushings from the stabilizer bar.
(2) Mount a dial indicator solidly on the upper sus-
pension arm.
INSTALLATION (3) Position the indicator plunger against the
(1) Install the bushings on the stabilizer bar.
upper ball joint boss of the steering knuckle.
(2) Install the stabilizer bar on the frame and
(4) Grasp the top of the tire and apply force in and
install the retainers and the bolts.
out. Look for movement at the ball joint between the
(3) Tighten the bolts to 60 N·m (45 ft. lbs.).
upper suspension arm and steering knuckle.
NOTE: Ensure the bar is center with equal spacing (5) If lateral movement is greater than 1.52 mm
on both sides. (0.060 in.), replace upper suspension arm.
(4) Install the link lower retainer and grommet on

the links. UPPER CONTROL ARM
(5) Install the links into the stabilizer bar and
lower suspension arm on each side. REMOVAL
(1) Raise and support the vehicle.
UPPER CONTROL ARM (Continued)
(3) Remove brake hose bracket from the arm. INSTALLATION
(4) Position a hydraulic jack under the arm and
raise the jack to unload the rebound bumper. NOTE: Before installation, insure pivot bar adjust-
(5) Remove cotter pin and nut from upper ball joint. ment bolts are in their original location (Fig. 12).
(6) Separate upper ball joint from steering knuckle
with Remover MB-991113 (Fig. 5). (1) Position suspension arm pivot bar on adjust-
ment bolts. Install nuts and tighten to 210 N·m (155
CAUTION: When installing Remover MB-991113 to ft. lbs.).
separate the ball joint, be careful not to damage the (2) Position steering knuckle on upper ball joint.
ball joint seal. Tighten the upper ball joint nut to 81 N·m (60 ft.
lbs.) and install a new cotter pin.
(7) Remove suspension arm pivot bar mounting (3) Install the wheel and tire assembly. (Refer to
nuts and remove suspension arm (Fig. 12). 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(4) Remove support and lower vehicle.
(5) Align front end to specifications. (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 12 Upper Suspension Arm

1 - UPPER SUSPENSION ARM
FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 20

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 UPPER BALL JOINT
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 16 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 21
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 16 UPPER CONTROL ARM
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
LOWER CONTROL ARM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SHOCK
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
KNUCKLE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 22
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SHOCK ABSORBERS. . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STABILIZER BAR TORSION BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HUB / BEARING BUSHINGS - CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LOWER BALL JOINT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 20
FRONT - 4WD
DESCRIPTION - 4WD
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub/bearings
units bolted to cast steering knuckle. The double-row
hub bearings are sealed and lubricated for life. The
steering knuckles turn (pivot) on ball joints. The
upper ball joint is riveted to the outboard portion of
the suspension arm and lubricated for life. The lower
ball joint is pressed into the lower suspension arm
and requires lubrication.
The 4x4 front suspension is comprised of (Fig. 1):
• Shock absorbers
• Torsion-bar springs
• Suspension arms
• Steering knuckles Fig. 1 Front Suspension - 4x4
• Stabilizer bar 1 - UPPER SUSPENSION ARM
• Jounce/Rebound bumpers 2 - SHOCK ABSORBER
• Hub/Bearing 3 - STABILIZER BAR
• Ball Joints 4 - LOWER SUSPENSION ARM
5 - TORSION BAR
FRONT - 4WD (Continued)
CAUTION: Components attached with a nut and cot- DESCRIPTION - SUSPENSION ARMS
ter pin must be torqued to specification. Then if the The upper suspension arm bolts on frame brackets
slot in the nut does not line up with the cotter pin through the arm pivot shaft. The frame brackets
hole, tighten nut until it is aligned. Never loosen the have slotted holes which allow the arms to be
nut to align the cotter pin hole. adjusted for caster and camber. Pivot shaft bushings
The lower suspension arms bolt to the lower frame
CAUTION: Suspension components with rubber/ure-
brackets and pivot through bushings, these bushings
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is are not replaceable.
The suspension arms have lube for life riveted ball
important to have the springs supporting the weight
studs. The suspension arm travel (jounce) is limited
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle through the use of urethane bumpers. Rebound
ride comfort could be affected and premature bush- travel is limited by the shock absorber.
ing wear may occur.
STANDARD PROCEDURE - LUBRICATION
Periodic lubrication of the suspension system may
be required. Refer to Lubrication And Maintenance
for the recommended maintenance schedule.
SPECIFICATIONS
TORQUE CHART

Upper Nut
Lower Bolts
Front Bolt
Rear Bolt
Ball Joint Nut
Pivot Shaft Nuts
Pivot Shaft to Frame Nuts
Ball Joint Nut
Frame Retainer Bolt
Frame Retainer Nut
Control Arm Retainer Bolts
Hub/Bearing 166 123 —
olts
SPECIAL TOOLS
FRONT SUSPENSION
Puller Tie Rod C-3894-A
Fig. 2 Lower Ball Joint

1 - REMOVER
2 - LOWER BALL STUD
Remover MB-991113
Remover C-4150A
LOWER CONTROL ARM

Fig. 3 Lower Suspension Arm
REMOVAL 1 - PIVOT BOLTS
(1) Raise and support the vehicle. 2 - LOWER SUSPENSION ARM
(3) Remove the front halfshaft, (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/HALF SHAFT/AXLE INSTALLATION
SHAFT - REMOVAL). (1) Position the lower suspension arm at the frame
(4) Remove the torsion bar. (Refer to 2 - SUSPEN- rail brackets. Install the pivot bolts and nuts.
SION/FRONT/TRACK BAR - REMOVAL). Tighten the nuts finger-tight.
(5) Remove the outer tie rod from the steering
knuckle. (Refer to 19 - STEERING/LINKAGE/TIE CAUTION: The ball joint stud taper must be CLEAN
ROD END - REMOVAL). and DRY before installing the knuckle. Clean the
(6) Remove the shock absorber lower bolt. stud taper with mineral spirits to remove dirt and
(7) Remove the stabilizer bar. (Refer to 2 - SUS- grease.
PENSION/FRONT/STABILIZER BAR - REMOVAL).
(2) Insert the ball joint into steering knuckle.
(8) Remove the cotter pin and nut from lower ball
Install and tighten the retaining nut to 183 N·m (135
joint. Separate ball joint from the steering knuckle
ft. lbs.) and install a new cotter pin.
with Remover C-4150A (Fig. 2).
(3) Install the torsion bar. (Refer to 2 - SUSPEN-
(9) Remove the suspension arm pivot bolts and
SION/FRONT/TRACK BAR - INSTALLATION).
suspension arm from frame rail brackets (Fig. 3).
LOWER CONTROL ARM (Continued)
(4) Install shock absorber lower bolt and tighten to CAUTION: When installing Remover MB-991113 to
108 N·m (80 ft. lbs.). separate the ball joint, be careful not to damage the
(5) Install the front halfshaft. (Refer to 3 - DIF- ball joint seal.
FERENTIAL & DRIVELINE/HALF SHAFT/AXLE
SHAFT - INSTALLATION). (7) Remove the upper ball joint cotter pin and nut.
(6) Install the stabilizer bar. (Refer to 2 - SUS- Separate the ball joint from the knuckle with
PENSION/FRONT/STABILIZER BAR - INSTALLA- Remover MB-991113 (Fig. 5).
TION). (8) Remove the lower ball joint cotter pin and nut.
(7) Install the outer tie rod to the knuckle. (Refer Separate the ball joint from the knuckle with
to 19 - STEERING/LINKAGE/TIE ROD END - Remover C-4150A (Fig. 6) and remove the knuckle.
INSTALLATION). (9) Remove the hub/bearing from the steering
(8) Tighten the lower suspension front pivot nut to knuckle. (Refer to 2 - SUSPENSION/FRONT/HUB /
108 N·m (80 ft. lbs.). Tighten rear pivot bolt to 190 BEARING - REMOVAL).
N·m (140 ft. lbs.).
CEDURE).
(10) Remove the support and lower the vehicle.
(11) Adjust the front suspension height and align
if necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE).
KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
REMOVAL Fig. 4 Tie Rod End Puller

(1) Raise and support the vehicle. 1 - TOOL C-3894-A
(2) Remove the wheel and tire assembly. 2 - BALL STUD
3 - SEAL
(3) Remove the brake caliper, rotor, shield and
4 - TIE-ROD END
ABS wheel speed sensor if equipped. (Refer to 22 -
5 - LOCKNUT
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(4) Remove the front halfshaft, (Refer to 3 - DIF- INSTALLATION
SHAFT - REMOVAL). NOTE: When installing hub/bearing with ABS
(5) Remove the tie rod end nut (Fig. 4). Separate brakes, position the speed sensor opening towards
the tie rod from the knuckle with Remover C-3894A. the front of the vehicle.
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
REMOVAL). (1) Install the hub/bearing to the steering knuckle
(6) Support the lower suspension arm with a and tighten the bolts to 166 N·m (123 ft. lbs.).
hydraulic jack and raise the jack to unload the
rebound bumper.
KNUCKLE (Continued)
(5) Install the tie rod end and tighten the nut to
88 N·m (65 ft. lbs.). (Refer to 19 - STEERING/LINK-
AGE/TIE ROD END - INSTALLATION).
(6) Install the front halfshaft, (Refer to 3 - DIF-
SHAFT - INSTALLATION).
(7) Install the ABS wheel speed sensor if equipped
and brake shield, rotor and caliper. (Refer to 5 -
INSTALLATION).
CEDURE).
(9) Remove the support and lower the vehicle.
Fig. 5 Upper Ball Joint STABILIZER BAR

1 - UPPER BALL STUD
2 - REMOVER DESCRIPTION
The bar extends across the front underside of the
chassis and connects to the frame crossmember. The
ends of the bar mount to the lower suspension arm.
All mounting points of the stabilizer bar are isolated
by bushings.
OPERATION
The stabilizer bar is used to minimize vehicle front
sway during turns. The bar helps to maintain a flat
attitude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle must
be on a drive on hoist. The vehicle suspension
must be at curb height for stabilizer bar installation.
(1) Remove the stabilizer bar retainer bolts from
Fig. 6 Lower Ball Joint the lower suspension arms (Fig. 7) and remove the
1 - REMOVER retainers.
2 - LOWER BALL STUD (2) Remove the stabilizer bar retainer nuts, bolts
and retainers from the frame crossmember (Fig. 7)
and remove the bar.
CAUTION: The ball joint stud tapers must be
(3) If necessary, remove the bushings from the sta-
CLEAN and DRY before installing the knuckle.
bilizer bar.
Clean the stud tapers with mineral spirits to remove
dirt and grease.
INSTALLATION
(2) Install the knuckle onto the upper and lower
NOTE: To service the stabilizer bar the vehicle must
ball joint.
be on a drive on hoist. The vehicle suspension
(3) Install the upper and lower ball joint nuts.
must be at curb height for stabilizer bar installation.
Tighten the upper ball joint nut to 81 N·m (60 ft.
(1) If removed, install the bushings on the stabi-
lbs.) and the lower ball joint nut to 183 N·m (135 ft.
lizer bar.
lbs.) then install cotter pins. Grease the lower ball
(2) Position the stabilizer bar on the frame cross-
joint.
member brackets and install the retainers and nuts
(4) Remove the hydraulic jack from the lower sus-
and bolts finger-tight (Fig. 7).
pension arm.
STABILIZER BAR (Continued)
Fig. 8 Hub/Bearing
1 - HUB BEARING
Fig. 7 Stabilizer Bar 2 - STEERING KNUCKLE
2 - FLAG NUT
3 - STABILIZER BAR INSTALLATION
4 - RETAINER (1) Install the hub/bearing into the steering
knuckle and tighten the bolts to 166 N·m (123 ft.
lbs.).
NOTE: Check the alignment of the bar to ensure
(2) Install the brake rotor and caliper. (Refer to 5 -
there is no interference with the either frame rail or
chassis component. Spacing should be equal on
INSTALLATION).
both sides.
(3) Install the ABS wheel speed sensor if equipped.
(3) Install the stabilizer bar to the lower suspen- (Refer to 5 - BRAKES/ELECTRICAL/FRONT
sion arm. WHEEL SPEED SENSOR - INSTALLATION).
(4) Install the retainers and bolts to the lower sus- (4) Install the halfshaft nut and tighten to 235
pension arm and tighten to 34 N·m (25 ft. lbs.). N·m (173 ft. lbs.).
(5) Tighten the frame retainer nuts to 190 N·m (5) Install the wheel and tire assembly. (Refer to
(140 ft. lbs.). 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
(6) Tighten the frame retainer bolts to 108 N·m CEDURE).
(80 ft. lbs.). (6) Remove the support and lower vehicle.
HUB / BEARING LOWER BALL JOINT

REMOVAL DIAGNOSIS AND TESTING - LOWER BALL
(1) Raise and support the vehicle. JOINT
(3) Remove the halfshaft nut. NOTE: If the ball joint is equipped with a lubrication
(4) Remove the ABS wheel speed sensor if fitting, grease the joint then road test the vehicle
equipped, (Refer to 5 - BRAKES/ELECTRICAL/ before performing test.
FRONT WHEEL SPEED SENSOR - REMOVAL).
(5) Remove the brake caliper and rotor, (Refer to 5 (1) Raise the front of the vehicle. Place safety floor
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS - stands under both lower suspension arms as far out-
REMOVAL). board as possible. Lower the vehicle to allow the
(6) Remove the hub/bearing mounting bolts from stands to support some or all of the vehicle weight.
the steering knuckle (Fig. 8).
NOTE: The upper suspension arms must not con-
(7) Slid the hub/bearing out of the steering
tact the rebound bumpers.
knuckle and off the halfshaft.
(2) Remove the tire and wheel assemblies.
(3) Mount a dial indicator solidly to the underside
of the lower suspension arm.
LOWER BALL JOINT (Continued)
(4) Position indicator plunger against the bottom
surface of the steering knuckle lower ball joint boss.
NOTE: The dial indicator plunger must be perpen-

dicular to the machined surface of the steering
knuckle lower ball joint boss (Fig. 9).
Fig. 10 Upper Ball Joint Boss

1 - DIAL INDICATOR
2 - BALL JOINT BOSS
(4) Grasp the top of the tire and pull outward,

Fig. 9 Lower Ball Joint Boss then zero the dial indicator.
(5) Grasp the top of the tire and push inward and
1 - BALL JOINT BOSS
record the dial indicator reading.
3 - DIAL INDICATOR
(6) If lateral movement is greater than 1.52 mm
(0.060 in.), replace upper suspension arm.
(5) Position a pry bar over the top of the upper

suspension arm and under the pivot bar of the upper UPPER CONTROL ARM
suspension arm. Pry down on the upper suspension
arm and then zero the dial indicator. REMOVAL
(6) Reposition the pry bar under the upper suspen- (1) Raise and support vehicle.
sion arm and on top of the jounce/rebound bracket. (2) Remove wheel and tire assembly.
Pry up on the upper suspension arm and record the (3) Remove brake hose brackets from suspension
dial indicator reading. arm.
(7) If the travel exceeds 1.52 mm (0.060 in.), (4) Position hydraulic jack under lower suspension
replace the lower control arm. arm and raise jack to unload rebound bumper.
(5) Remove shock absorber. (Refer to 2 - SUSPEN-
SION/FRONT/SHOCK - REMOVAL).
UPPER BALL JOINT (6) Remove the cotter pin and nut from upper ball
joint.
DIAGNOSIS AND TESTING - UPPER BALL (7) Separate upper ball joint from the steering
JOINT knuckle with Remover MB-991113 (Fig. 11).
(1) Position a floor jack under the lower suspen-
sion arm. Raise the wheel and allow the tire to CAUTION: When installing Remover MB-991113 to
lightly contact the floor (vehicle weight relieved from separate the ball joint, be careful not to damage the
the tire). ball joint seal.
(2) Mount a dial indicator solidly on the upper sus-
pension arm. (8) Remove suspension arm pivot bar bolts and
(3) Position the indicator plunger against the back remove suspension arm (Fig. 12).
side of the upper ball joint boss of the steering
knuckle (Fig. 10).
UPPER CONTROL ARM (Continued)
CEDURE).
(9) Align front suspension. (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
SHOCK
DESCRIPTION
The top of the low-pressure gas charged shock are
bolted to the frame. The bottom of the shock are
bolted to the lower suspension arm.
Fig. 11 Separate Upper Ball Joint OPERATION

1 - UPPER BALL STUD The shock absorbers dampen jounce and rebound
2 - REMOVER of the vehicle over various road conditions.
DIAGNOSIS AND TESTING - SHOCK

A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
Fig. 12 Upper Suspension Arm an upright position and force the piston in and out of
1 - PIVOT BAR BOLT the cylinder four or five times. The action throughout
2 - UPPER SUSPENSION ARM each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
INSTALLATION noise by lubricating them. Grease and mineral oil-
(1) Position suspension arm pivot bar on mounting base lubricants will deteriorate the bushing.
bracket. Install bolts and tighten (temporarily) to 136
N·m (100 ft. lbs.). REMOVAL
(2) Insert ball joint in steering knuckle and (1) Raise and support vehicle.
tighten ball joint nut to 81 N·m (60 ft. lbs.) then (2) Remove the upper shock absorber nut, retainer
install a new cotter pin. and grommet (Fig. 13) .
(3) Install shock absorber. (Refer to 2 - SUSPEN- (3) Remove the lower bolt and remove the shock
SION/FRONT/SHOCK - INSTALLATION). absorber.
NOTE: Upper shock nut must be replaced or use
Mopar Lock ’N Seal or Loctite T 242 on existing nut.
(4) Remove hydraulic jack.
(5) Attach brake hose brackets to suspension arm.
(6) Tighten upper suspension arm pivot bolts to
224 N·m (165 ft. lbs.).
SHOCK (Continued)
through an anchor adjustment bolt that increases or
decreases the angle of the torsion bar. Increasing or
decreasing the bar angle changes the angle of the
suspension arms.
REMOVAL
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) Raise and support the vehicle with the front

suspension hanging.
(2) Turn the adjustment bolt counterclockwise to
release spring load (Fig. 14).
NOTE: Count and record the number of turns for

installation reference.
(3) Remove the adjustment bolt from swivel.

(4) Remove torsion bar and anchor. Remove anchor
Fig. 13 Shock Absorber
from torsion bar.
1 - NUT (5) Remove all foreign material from torsion bar
2 - RETAINER
mounting in anchor and suspension arm.
3 - GROMMET
(6) Inspect adjustment bolt, bearing and swivel for
4 - SHOCK
damage.
INSTALLATION
NOTE: Upper shock nut must be replaced or use
Mopar Lock ’N Seal or LoctiteT 242 on existing nut.
(1) Install the lower retainer (lower retainer is
stamped with a L) and grommet on the shock
absorber stud. Insert the shock absorber through the
frame bracket hole.
(2) Install the lower bolt and tighten the bolt to
108 N·m (80 ft. lbs.).
(3) Install the upper grommet, retainer (upper
retainer is stamped with a U) and new nut or use
Mopar Lock ’N Seal or Loctitet 242 on existing nut,
on the shock absorber stud. Tighten nut to 26 N·m
(19 ft. lbs.).
Fig. 14 Torsion Bar
1 - SWIVEL
TORSION BAR 2 - ANCHOR
3 - BEARING
DESCRIPTION 4 - ADJUSTMENT BOLT
5 - TORSION BAR
The front of the bar mounts to the back side of the
lower suspension arm. The rear end of the bar is
mounted in a anchor that rests in the frame cross-
member.
OPERATION
The torsion bars are used to control ride height
and ride quality. The vehicle height is adjusted
TORSION BAR (Continued)
INSTALLATION BUSHINGS - CONTROL ARM

CAUTION: The left and right side torsion bars are REMOVAL
NOT interchangeable. The bars are identified and
(1) Remove the control arm from the vehicle.
stamped R or L, for right or left. The bars do not
(Refer to 2 - SUSPENSION/FRONT/UPPER CON-
have a front or rear end and can be installed with
TROL ARM - REMOVAL),(Refer to 2 - SUSPEN-
either end facing forward.
SION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(1) Insert torsion bar ends into anchor and suspen-
sion arm. (2) Mount the control arm securely in a vise.
(3) Remove the nut and washer from the control
(2) Position anchor and bearing in frame cross-
member. Install adjustment bolt through bearing, arm shaft.
anchor and into the swivel. (4) Install the bushing tool.
(5) Press out the old bushings.
(3) Turn adjustment bolt clockwise the recorded
amount of turns.
(4) Lower vehicle and adjust the front suspension INSTALLATION
height. (Refer to 2 - SUSPENSION/WHEEL ALIGN- (1) Install the bushing in the control arm and
MENT - STANDARD PROCEDURE). inserted over the shaft.
(2) Install the bushing tool.
(3) Press the bushing into the control arm.
(4) Install the washer and nut to the control arm
shaft. Torque the nut to 167 N·m (130 ft. lbs.) speci-
fication.
(5) Remove the control arm from the vise.
(6) Install the control arm in the vehicle. (Refer to
2 - SUSPENSION/FRONT/UPPER CONTROL ARM -
INSTALLATION), (Refer to 2 - SUSPENSION/
FRONT/LOWER CONTROL ARM - INSTALLA-
TION).
AN REAR 2 - 25
REAR
TABLE OF CONTENTS
page page
REAR SPRING
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 25 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPRING AND SHOCK. . . . . . . . . . . . . . . . . . . . 25 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SHOCK STABILIZER BAR
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR DIAGNOSIS AND TESTING - SPRING AND

SHOCK
DESCRIPTION A knocking or rattling noise from a shock absorber
The rear suspension is comprised of: may be caused by movement between mounting
• Drive Axle bushings and metal brackets or attaching compo-
• Shock Absorbers nents. These noises can usually be stopped by tight-
• Stabilizer Bar (optional) ening the attaching nuts. If the noise persists,
• Leaf Springs inspect for damaged and worn bushings, and attach-
CAUTION: A vehicle should always be loaded so conditions exist.
the vehicle weight center-line is located immedi- A squeaking noise from the shock absorber may be
ately forward of the rear axle. Correct vehicle load- caused by the hydraulic valving and may be intermit-
ing provides proper front tire-to-road contact. This tent. This condition is not repairable and the shock
results in maximum vehicle handling stability and absorber must be replaced.
safety. Incorrect vehicle weight distribution can The shock absorbers are not refillable or adjust-
cause excessive tire tread wear, spring fatigue or able. If a malfunction occurs, the shock absorber
failure, and erratic steering. 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
CAUTION: Suspension components with rubber/ure-
each stroke should be smooth and even.
thane bushings should be tightened with the vehi-
The spring eye and shock absorber bushings do not
cle at normal ride height. It is important to have the
require any type of lubrication. Do not attempt to
springs supporting the weight of the vehicle when
stop spring bushing noise by lubricating them.
the fasteners are torqued. This will maintain vehicle
Grease and mineral oil-base lubricants will deterio-
ride comfort and prevent premature bushing wear.
rate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart below for additional infor-
mation.
2 - 26 REAR AN
REAR (Continued)
SPRING AND SHOCK ABSORBER
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. Worn bushings. 2. Replace bushings.

3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.

2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SPECIFICATIONS
TORQUE CHART

Lower Bolt
Upper Bolt
Frame Bracket Nuts
Link Nuts
Retainer Bolts
Spring U-Bolt Nuts 149 110 —
2WD
Spring U-Bolt Nuts 149 110 —
4WD
Spring 163 120 —
Eye Nut
Spring 163 120 —
Shackle Nuts
Jounce Bumper 61 45 —
Bolts
SHOCK OPERATION
Ride control is accomplished through the use of
DESCRIPTION dual-action shock absorbers. The shocks dampen the
The top of the shock absorbers are bolted to the jounce and rebound as the vehicle travels over vari-
body crossmember. The bottom of the shocks are ous road conditions.
bolted to the axle brackets. The axle brackets are
staggered one ahead of the axle and one befind.
AN REAR 2 - 27
SHOCK (Continued)
REMOVAL OPERATION
(1) Raise vehicle and support rear axle. The springs control ride quality and maintain vehi-
(2) Remove shock absorber lower nut and bolt from cle ride height. The shackles allow the springs to
the axle bracket (Fig. 1). change their length as the vehicle moves over various
(3) Remove shock absorber upper nut and bolt road conditions.
from the frame bracket and remove the shock
absorber. REMOVAL
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of the
rear axle. Use care to avoid bending the side rail
flange.
(1) Raise the vehicle at the frame.

(2) Use a hydraulic jack to relieve the axle weight.
(3) Remove the wheel and tire assemblies.
(4) Remove the nuts, the U-bolts and spring plate
from the axle (Fig. 2) and (Fig. 3) .
(5) Remove the nut and bolt from the spring front
eye.
(6) Remove the nut and bolt that attaches the
spring shackle to the rear frame bracket.
(7) Remove the spring from the vehicle.
(8) Remove the shackle from the spring.
Fig. 1 Shock Absorber

1 - SHOCK ABSORBER
2 - MOUNTING BOLT
3 - MOUNTING BOLT
INSTALLATION
(1) Install shock absorber and upper mounting bolt
and nut. Tighten nut to 95 N·m (70 ft. lbs.).
(2) Install shock absorber into the axle bracket.
Install the bolt and nut and tighten nut to 95 N·m
(70 ft. lbs.).
(3) Remove axle support and lower vehicle.
SPRING
DESCRIPTION Fig. 2 Leaf Spring - 4x2
The 4x2 rear suspension system uses a 4-leaf two
1 - JOUNCE BUMPER
stage or 5-leaf single stage springs and a solid drive
2 - SHACKLE
axle. The 4x4 rear suspension system uses only a 3 - PLATE
4-leaf two stage spring and solid drive axle. The for- 4 - LEAF SPRING
ward end of the springs are mounted to the body rail
hangers through rubber bushings. The rearward end
of the springs are attached to the body by the use of
shackles. The spring and shackles use rubber bush-
ings. The bushing help to isolate road noise.
2 - 28 REAR AN
SPRING (Continued)
STABILIZER BAR
DESCRIPTION
The stabilizer bar (optional) extends across the
underside of the vehicle and is bolted to the top of
the axle. Links at the end of the bar are bolted to
frame brackets.
OPERATION
The stabilizer bar is used to minimize vehicle body
roll. The spring steel bar helps to control the vehicle
body in relationship to the suspension.
REMOVAL
(2) Remove nuts and bolts from the links at the
stabilizer bar.
(3) Remove stabilizer bar retainer bolts and retain-
ers (Fig. 4).
(4) Remove stabilizer bar and replace worn,
Fig. 3 Leaf Spring - 4x4 cracked or distorted bushings.
1 - SHACKLE (5) Remove links upper mounting nuts and bolts
2 - JOUNCE BUMPER and remove links.
3 - SEAT
4 - PLATE
5 - LEAF SPRING
INSTALLATION
CAUTION: The rear of the vehicle must be lifted only
with a jack or hoist. The lift must be placed under the
frame rail crossmember located aft of the rear axle.
Use care to avoid bending the side rail flange.
(1) Install the spring shackle on the spring finger

tight.
(2) Position the spring on the rear axle pad. Make sure
the spring center bolt is inserted in the pad locating hole.
(3) Align front spring eye with the bolt hole in the
front frame bracket. Install the spring eye bolt and Fig. 4 Stabilizer Bar Mounting
nut and tighten the spring eye nut finger-tight. 1 - STABILIZER BAR
(4) Align spring shackle eye with the bolt hole in 2 - LINK
3 - RETAINER
the rear frame bracket. Install the bolt and nut and
tighten the spring shackle eye nut finger-tight.
(5) Install the spring seat (4x4 only), U-bolts, INSTALLATION
spring plate and nuts.
(1) Install the stabilizer bar and center it with
(6) Tighten the U-bolt nuts to 149 N·m (110 ft. lbs.).
equal spacing on both sides. Install stabilizer bar
(7) Install the wheel and tire assemblies. (Refer to
retainers and tighten bolts to 54 N·m (40 ft. lbs.).
(2) Install link into frame brackets and the stabi-
CEDURE).
lizer bar. Install mounting nuts and bolts.
(8) Remove the support stands from under the
frame rails. Lower the vehicle until the springs are
(4) Tighten stabilizer link nuts to 54 N·m (40 ft. lbs.).
supporting the weight of the vehicle.
(9) Tighten the spring eye pivot bolt nut and all
shackle nuts to 163 N·m (120 ft. lbs.).
AN DIFFERENTIAL & DRIVELINE 3-1
DIFFERENTIAL & DRIVELINE

TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1 REAR AXLE - 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . 47

HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REAR AXLE - 9 1/4 . . . . . . . . . . . . . . . . . . . . . . . 78
FRONT AXLE - C205F . . . . . . . . . . . . . . . . . . . . . 22
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT PROPELLER SHAFT - REAR

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .3 CENTER BEARING
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . .3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . .8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROPELLER SHAFT - FRONT ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . ................8 SINGLE CARDAN UNIVERSAL JOINTS
INSTALLATION. . . . . . . . . . . . ................8 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PROPELLER SHAFT
DESCRIPTION
A propeller shaft (Fig. 1), (Fig. 2), and (Fig. 3) is
the shaft which connects the transmission/transfer
case to the axle differential. This is the link through
which the engine power is transmitted to the axle.
The propeller shaft is designed and built with the
yoke lugs in line with each other which is called zero
phasing. This design produces the smoothest running
condition, an out-of-phase shaft can cause a vibra-
tion.
Tubular propeller shafts are balanced by the man-
ufacturer with weights spot welded to the tube.
Use the exact replacement parts when installing
the propeller shafts. The use of the correct replace- Fig. 1 FRONT PROPELLER SHAFT
ment parts helps to ensure safe operation. All fasten- 1 - PROPELLER SHAFT
ers must be torqued to the specified values for safe 2 - CONSTANT VILOCITY JOINT
operation. 3 - COMPANION FLANGE
4 - BOLT
5 - COMPANION FLANGE
3-2 PROPELLER SHAFT AN
PROPELLER SHAFT (Continued)
Fig. 2 Rear Propeller Shaft with Center Bearing

1 - REAR AXLE 3 - TRANSMISSION EXTENSION HOUSING
2 - REAR PROPELLER SHAFT 4 - CENTER BEARING
Fig. 3 Rear Propeller Shaft

1 - REAR AXLE 3 - TRANSMISSION EXTENSION HOUSING
2 - REAR PROPELLER SHAFT
AN PROPELLER SHAFT 3-3
Also make alignment reference marks (Fig. 4)on pended by springs in a floating motion. The propeller
the propeller shaft yoke and axle, or transmission, shaft must be able to change operating angles when
yoke prior to servicing. This helps to eliminate possi- going over various road surfaces. This is accom-
ble vibration. plished through universal joints/constant vilocity
joint, which permit the propeller shaft to operate at
different angles. The slip joints (or yokes) permit con-
traction or expansion.
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.
CAUTION: Use original equipment replacement

parts for attaching the propeller shafts. The speci-
fied torque must always be applied when tightening
the fasteners.
DIAGNOSIS AND TESTING - PROPELLER

SHAFT
Fig. 4 Reference Marks on Yokes
VIBRATION
1 - REFERENCE MARKS
Tires that are out-of-round, or wheels that are
unbalanced, will cause a low frequency vibration.
CAUTION: Do not allow the propeller shaft to drop (Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
or hang from any propeller shaft joint during TESTING)
removal. Attach the propeller shaft to the vehicle Brake drums that are unbalanced will cause a
underside with wire to prevent damage to the joints. harsh, low frequency vibration. (Refer to 5 - BRAKES
- DIAGNOSIS AND TESTING)
OPERATION Driveline vibration can also result from loose or
The propeller shaft must operate through con- damaged engine mounts.
stantly changing relative angles between the trans- Propeller shaft vibration increases as the vehicle
mission and axle. It must also be capable of changing speed is increased. A vibration that occurs within a
length while transmitting torque. The axle rides sus- specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective universal
joints, or an incorrect propeller shaft angle, are usu-
ally the cause of such a vibration.
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.
3) Loose or bent U-joint yoke or 3) Install new yoke.
excessive runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of 7) Installl new propeller shaft.
balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test, and
condition. evaluate.
10) Excessive drive pinion gear shaft 10) Re-index propeller shaft and
runout. evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as necessary.
BALANCE (8) Run and accelerate the vehicle until vibration

occurs. Note the intensity and speed the vibration
NOTE: Removing and re-indexing the propeller occurred. Stop the engine.
shaft 180° relative to the yoke may eliminate some (9) Install a screw clamp at position 1 (Fig. 5).
vibrations. (10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
If propeller shaft is suspected of being unbalanced, clamp to one of the other three positions. Repeat the
it can be verified with the following procedure: vibration test.
(1) Raise the vehicle. (11) If there is no difference in vibration at the
(2) Clean all the foreign material from the propel- other positions, the source of the vibration may not
ler shaft and the universal joints. be propeller shaft.
(3) Inspect the propeller shaft for missing balance (12) If the vibration decreased, install a second
weights, broken welds, and bent areas. If the pro- clamp (Fig. 6) and repeat the test.
peller shaft is bent, it must be replaced. (13) If the additional clamp causes an additional
(4) Inspect the universal joints to ensure that they vibration, separate the clamps (1/2 inch above and
are not worn, are properly installed, and are cor- below the mark). Repeat the vibration test (Fig. 7).
rectly aligned with the shaft. (14) Increase distance between the clamp screws
(5) Check the universal joint clamp screws torque. and repeat the test until the amount of vibration is
(6) Remove the wheels and tires. Install the wheel at the lowest level. Bend the slack end of the clamps
lug nuts to retain the brake drums or rotors. so the screws will not loosen.
(7) Mark and number the shaft six inches from the (15) If the vibration remains unacceptable, apply
yoke end at four positions 90° apart. 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.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180°,
and re-install the propeller shaft. Measure shaft
Fig. 5 Clamp Screw At Position 1 runout again.
1 - CLAMP
(6) If the propeller shaft runout is now within
2 - SCREWDRIVER specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)

Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the
Fig. 6 Two Clamp Screws At The Same Position shaft tube for tube lengths over 30 inches. For
tube lengths under 30 inches, the maximum
allowed runout is 0.020 in. (0.50 mm) for the full
length of the tube.
STANDARD PROCEDURES
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn.
(1) Remove any external bearing snap rings, if
equipped, from universal joint so protractor base sits
flat.
(2) Rotate the shaft until transmission/transfer
case output yoke bearing is facing downward.
NOTE: Always make measurements from front to

Fig. 7 Clamp Screws Separated rear and from the same side of the vehicle.
1 - 1⁄2 INCH
(3) Place Inclinometer 7663 (J-23498A) on yoke
bearing (A) parallel to the shaft (Fig. 8). Center bub-
ble in sight glass and record measurement.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
Fig. 9 Propeller Shaft Angle Measurement (C)

1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
Fig. 8 Front (Output) Angle Measurement (A)

1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
(4) Rotate propeller shaft 90 degrees and place

Inclinometer on yoke bearing parallel to the shaft
(Fig. 9). Center bubble in sight glass and record mea-
surement. This measurement can also be taken at
the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(5) Subtract smaller figure from larger (C minus
A) to obtain Transmission Output Operating Angle.
(6) Rotate propeller shaft 90 degrees and place
Inclinometer on pinion yoke bearing parallel to the
shaft (Fig. 10). Center bubble in sight glass and
record measurement.
This measurement will give you the pinion
shaft or Input Yoke Angle (B). Fig. 10 Rear (Input) Angle Measurement (B)
(7) Subtract smaller figure from larger (C minus 1 - PINION YOKE BEARING CAP
B) to obtain axle Input Operating Angle. 2 - INCLINOMETER
Refer to rules given below and the example in (Fig.
11)for additional information.
TWO-PIECE PROPELLER SHAFT
• Good cancellation of U–joint operating angles
The procedure to measure the propeller shaft
(within 1°).
angles involved with a two-piece (Fig. 12) propeller
• Operating angles less than 3°.
shaft is the same as those for a one-piece propeller
• At least 1/2 of one degree continuous operating
shaft.
(propeller shaft) angle.
Fig. 11 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. 12 Universal Joint Angle Two-Piece Shaft

1 - YOKES MUST BE IN SAME PLANE
SPECIFICATIONS
PROPELLER SHAFT

Center Bearing Bolts 68 50 -
Transfer Case Flange
30.5 22.5 -
Bolts
Companion Flange Bolts 108 80 -
SPECIAL TOOLS (2) Mark a line across the transfer case flange and
C/V for installation reference.
PROPELLER SHAFT (3) Mark a line across the propeller shaft flange
yoke and front axle companion flange for installation
reference.
(4) Remove companion flange bolts (Fig. 13).
(5) Remove transfer case flange bolts and remove
propeller shaft.
Inclinometer 7663
Bearing Splitter 1130

Fig. 13 Front Propeller Shaft
1 - PROPELLER SHAFT
2 - CONSTANT VILOCITY JOINT
4 - BOLT
INSTALLATION
(1) Install propeller shaft with with all reference
marks aligned.
Installer Bearing 6052
(2) Loosely install bolts to C/V and transfer case
PROPELLER SHAFT - FRONT companion flange.
(3) Install bolts to companion flange and flange
REMOVAL yoke and tighten to 108 N·m (80 ft. lbs.).
(4) Tighten bolts to transfer case companion flange
(1) Position transmission and transfer case to their
to 30.5 N·m (22.5 ft. lbs.).
neutral positions. Raise and support vehicle. Remove
(5) Install skid plate, if equipped.
skid plate, if equipped.
(6) Lower vehicle and road test to verify repair.
PROPELLER SHAFT - REAR CENTER BEARING

REMOVAL DESCRIPTION
(1) Place the transmission into the Neutral posi- The two-piece propeller shaft uses a center bearing
tion. to support the shafts. The bearing is used to support
(2) Raise and support vehicle on safety stands. the shafts where they are joined together. The bear-
(3) Mark a line across the axle companion flange ing is insulated in rubber and is mounted to the
and flange yoke for installation reference. frame crossmember.
(4) Mark an outline of the center bearing on the
support bracket for installation reference, if OPERATION
equipped. The propeller shaft center bearing serves to divide
(5) Mark an outline of the heat shield on the cen- the required propeller shaft length into two smaller
ter bearing for installation reference, if equipped. shafts, which has several inherent advantages. Hav-
(6) Remove center bearing and heat shield bolts, if ing two short propeller shafts instead of one long
equipped. shaft decreases the chance of unwanted noise and
(7) Remove companion flange bolts. vibrations. The shorter shafts are easier to balance
(8) Slide slip yoke off of the transmission, or trans- and serve to increase ground clearance while main-
fer case, output shaft and remove the propeller shaft taining acceptable driveline angles.
(Fig. 14).
REMOVAL
(1) Remove rear propeller shaft.
(2) Remove slip joint boot clamp and separate the
two half-shafts.
(3) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(4) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during

removal of center bearing.
(5) Set shaft in press and press bearing off the

shaft.
INSTALLATION
Fig. 14 Propeller Shaft (1) Install new slinger on shaft and drive into posi-
1 - COMPANION FLANGE tion with appropriate installer tool.
2 - FLANGE YOKE (2) Install new center bearing on shaft with Bear-
3 - REAR PROPELLER SHAFT ing Installer Tool 6052. Drive on shaft with hammer
until bearing is seated.
(3) Clean shaft splines and apply a coat of multi–
INSTALLATION purpose grease.
(1) Slide the slip yoke onto the transmission, or (4) Align master splines and slide front and rear
transfer case, output shaft. half-shafts together. Reposition slip yoke boot and
(2) Align and install the center bearing and heat install new clamp.
shield to the support bracket, if necessary. Install the (5) Install propeller shaft in vehicle.
bolts and tighten to 68 N·m (50 ft. lbs.).
(3) Align companion flange reference mark with
flange yoke mark.
(4) Install companion flange bolts and tighten to
108 N·m (80 ft. lbs.).
(5) Lower the vehicle.
3 - 10 PROPELLER SHAFT AN
CENTER BEARING (Continued)
CENTER BEARING ADJUSTMENT

Drive away shudder is a vibration that occurs at
first acceleration from a stop. Shudder vibration usu-
ally peaks at the engines highest torque output.
Shudder is a symptom associated with vehicles using
a two-piece propeller shaft. To decrease shudder,
lower the center bearing in 1/8 inch increments. Use
shim stock or fabricated plates. Plate stock must be
used 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
Fig. 15 Snap Ring
NOTE: The following procedure is described for a 1 - SNAP RING
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
Individual components of cardan universal joints

are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 15).
(4) Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the yoke.
(5) Position the yoke with the grease fitting, if
equipped, pointing up.
(6) Place a socket with an outside diameter
smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 16). Fig. 16 Press Out Bearing
(7) If the bearing cap will not pull out of the yoke
1 - PRESS
by hand after pressing, tap the yoke ear near the 2 - SOCKET
bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the
yoke over and straighten the cross in the open hole.
Then, carefully press the end of the cross until the
remaining bearing cap can be removed (Fig. 17).
CAUTION: If the cross or bearing cap are not

straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
AN PROPELLER SHAFT 3 - 11
SINGLE CARDAN UNIVERSAL JOINTS (Continued)
Fig. 17 Press Out Remaining Bearing Fig. 18 Cross In Yoke

1 - CROSS 1 - CROSS
2 - BEARING CAP 2 - YOKE
ASSEMBLY
NOTE: The following procedure is described for a
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1

or 2 grease to inside of yoke bores to aid in installa-
tion.
(2) Position the cross in the yoke with its lube fit-
ting, if equipped, pointing up (Fig. 18).
(3) Place a bearing cap over the trunnion and
align the cap with the yoke bore (Fig. 19). Keep the
needle bearings upright in the bearing assembly. A
needle bearing lying at the bottom of the cap will
prevent proper assembly.
(4) Press the bearing cap into the yoke bore
Fig. 19 Install Bearing On Trunnion
enough to install a snap ring.
1 - BEARING CAP
(5) Install a snap ring.
2 - TRUNNION
(6) Repeat Step 3 and Step 4to install the opposite
bearing cap. If the joint is stiff or binding, strike the
yoke with a soft hammer to seat the needle bearings.
(7) Add grease to lube fitting, if equipped.
(8) Install the propeller shaft.
3 - 12 HALF SHAFT AN
HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT CV BOOT

DESCRIPTION . . . . . . . . ... . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . ... . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING .. . . . . . . . . . . . . . . 12 CV JOINT - OUTER
HALF SHAFT . . . . . . . . ... . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS . . . . . . ... . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . ... . . . . . . . . . . . . . . 14 CV JOINT - INNER
AXLE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
HALF SHAFT DIAGNOSIS AND TESTING - HALF SHAFT

Check for grease in the vicinity of the inboard tri-
DESCRIPTION pod joint and outboard C/V joint; this is a sign of
The two constant velocity (C/V) drive shafts are inner or outer joint seal boot or seal boot clamp dam-
identical and interchangeable. They are comprised of age. A light film of grease may appear on the right
three major components (Fig. 1): inner tripod joint seal boot; this is considered normal
• An inner, tripod C/V joint and should not require replacement of the seal boot.
• A short, solid interconnecting shaft
• An outer, Rzeppa C/V joint with stub shaft NOISE AND/OR VIBRATION IN TURNS
The inner tripod-joints are attached to the axle A clicking noise and/or a vibration in turns could
shaft splines (Fig. 1). The outer joint is splined and be caused by one of the following conditions:
mates with the hub bearing on the knuckle. • Damaged outer C/V or inner tripod joint seal
The lubricant amounts included with replacement boot or seal boot clamps. This will result in the loss
rubber boots are different for inner and outer C/V and/or contamination of the joint grease, resulting in
joints. Apply only the specified lubricant amount to inadequate lubrication of the joint.
each C/V joint. • Noise may also be caused by another component
of the vehicle coming in contact with the driveshafts.
CAUTION: Proper C/V joint boot sealing is critical
for retaining the special lubricant. Prevent foreign CLUNKING NOISE DURING ACCELERATION
material from entering and contaminating the C/V This noise may be a result of one of the following
joints. Mishandling a C/V drive shaft can cause a conditions:
boot to be punctured or damage within the joints. • A torn seal boot on the inner or outer joint of the
Always support both ends of the C/V drive shaft driveshaft assembly which has allowed the C/V joint
during removal and installation to avoid damage. to become damaged.
• A loose or missing clamp on the inner or outer
When replacing C/V drive shaft components, joint of the driveshaft assembly which has allowed
ensure that only exact replacements parts are the C/V joint to become damaged.
installed. • A damaged or worn driveshaft C/V joint.
OPERATION SHUDDER OR VIBRATION DURING ACCELERATION

The axle driveshafts are located on either side of This problem could be a result of:
the differential and transmits power to the drive • A worn or damaged driveshaft inner tripod joint.
wheels, while allowing for vertical movement in the • A sticking tripod joint spider assembly (inner tri-
vehicle’s suspension. pod joint only).
• Improper wheel alignment.
AN HALF SHAFT 3 - 13
HALF SHAFT (Continued)
Fig. 1 C/V Drive Shaft Components

HALF SHAFT (Continued)
1 - RETAINER & HOUSING ASM 11 - RACE RETAINING RING
2 - C-CLIP 12 - SEAL RETAINING CLAMP
3 - TRIPOD JOINT SPIDER 13 - DRIVE AXLE OUTBOARD SEAL
4 - SEAL RETAINING CLAMP 14 - SEAL RETAINING CLAMP
5 - INNER BOOT 15 - AXLE SHAFT
6 - SEAL RETAINING CLAMP 16 - RETAINING RING
7 - C/V JOINT OUTER RACE 17 - BALL & ROLLER RETAINER
8 - C/V JOINT CAGE 18 - TRIPOD JOINT BALL
9 - C/V JOINT INNER RACE 19 - NEEDLE ROLLER
10 - CHROME ALLOY BALL
VIBRATION AT HIGHWAY SPEEDS • Out of balance front tires or wheels.

This problem could be a result of: • Improper tire and/or wheel runout.
• Foreign material (mud, etc.) packed on the back-
side of the wheel(s).
SPECIFICATIONS
HALF SHAFT

Axle Flange Bolts 90 65 -
Axle Nut 244 180 -
SPECIAL TOOLS AXLE SHAFT

SPECTIAL TOOLS REMOVAL
(1) Loosen the lug nuts and hub nut while the
vehicle is on the surface with the brakes applied (Fig.
2).
Remover Cup L-4518
Remover/Installer C-4124
Fig. 2 Wheel Hub Nut

(2) Raise the vehicle.
(3) Remove the skid plate, if equipped.
AXLE SHAFT (Continued)
(4) Remove the cotter pin, nut lock, and spring (12) Disengage the inner C/V joint from the axle
washer from the stub shaft (Fig. 3). shaft (Fig. 5). Position two pry bars between the
inner C/V housing and the axle housing. Apply pres-
sure away from the differential housing. This will
disengage the axle shaft snap-ring from the groove
on the inside of the C/V housing.
Fig. 3 Cotter Pin, Nut Lock & Spring

1 - SPRING WASHER
2 - HUB NUT
3 - NUT LOCK
4 - COTTER PIN
(5) Remove the hub nut and washer from the stub
Fig. 5 Front
shaft (Fig. 4).
(6) Remove the wheel and tire. 1 - DRIVESHAFT
2 - FRONT AXLE
(13) Remove the driveshaft from the vehicle.
INSTALLATION
(1) Insert the C/V drive shaft stub into the hub
bearing bore of the steering knuckle.
(2) Apply a light coating of wheel bearing grease
on the axle shaft splines.
(3) Install the inner C/V joint onto the axle shaft
flange. Push firmly on the shaft until the axle shaft
snap-ring engages with the groove on the inside of
the joint housing.
(4) Clean hub bearing bore, axle driveshaft splines,
and hub bearing mating surface of all foreign mate-
rials. Apply light coating of grease to all mating sur-
Fig. 4 Hub Nut & Washer
faces.
1 - DRIVE SHAFT
(5) Install the hub bearing to the axle driveshaft
2 - HUB WASHER
and the steering knuckle.
3 - HUB NUT
(6) Install the bolts to hold the hub bearing to the
steering knuckle. Refer to Group 2, Suspension, for
(7) Remove the brake caliper and rotor, refer to the proper torque.
Group 5 Brakes for procedures. (7) Clean all foreign material from the stub shaft
(8) Remove the ABS wheel speed sensor if threads. Install the hub nut and washer.
equipped. Refer to Group 5 Brakes for procedures. (8) Install the ABS wheel speed sensor, if
(9) Remove the bolts holding the hub bearing to equipped. Refer to Group 5, Brakes, for proper proce-
the knuckle. dures.
(10) Remove hub bearing from axle driveshaft and (9) Install the brake caliper and rotor. Refer to
steering knuckle. Group 5, Brakes, for proper procedures.
(11) Support the drive shaft at the C/V joint hous- (10) Apply the brakes and tighten hub nut to 244
ings. N·m (180 ft. lbs.) torque.
AXLE SHAFT (Continued)
(11) Install the spring washer, nut lock and cotter Apply only the specified lubricant amount to each
pin on the stub shaft (Fig. 6) . C/V joint.
(1) Clean the C/V joints and shaft of all old grease
and foreign matter.
(2) Slide the inner C/V joint boot up the shaft and
insert the lip located within the small-diameter end
of the boot into the shaft groove (Fig. 7).
(3) Retain the small–diameter of the boot on the
shaft with a ladder-type clamp in the boot groove
(Fig. 7). Verify that the boot and lip are properly
positioned on the intermediate shaft. Position the
clamp locating tabs in the slots and tighten the
clamp.
(4) Compress the clamp bridge with Remover/In-
staller C-4124. Squeeze the tool handles to complete
Fig. 6 Cotter Pin Installation the tightening of the clamp (Fig. 8). Care must be
1 - COTTER PIN exercised when using the tool to avoid cutting
2 - NUT LOCK through the clamp bridge or damaging the
boot.
(12) Install the skid plate, if equipped.
(13) Install the wheel and tire.
CV BOOT
REMOVAL
(1) Remove axle driveshaft from vehicle.
(2) Remove outer C/V joint.
(3) Remove outer C/V joint small clamp and
remove boot (Fig. 7).
(4) Remove inner C/V joint boot clamps and
remove boot.
Fig. 8 Compressing Clamp Bridge

1 - BOOT CLAMP PLIERS
2 - SLINGER
(5) Position the large-diameter end of the boot on

the C/V joint housing.
(6) After the inner joint boot small clamp is
installed, the inboard hub must be set to a service
build length.
(a) Compress the inner hub down the connector
shaft.
(b) Use a small blunt drift between the large
Fig. 7 Boot Retaining end and the boot seal to relieve the pressure.
1 - LOCATING SHOULDERS (c) The distance edge of the lip to the edge of the
2 - CLAMPS flange should be 181.00 mm (7.13 in.). This will
eliminate excess air that can cause a ballooning
affect and possibly cause damage to the boot.
INSTALLATION (7) Verify that the boot is not twisted and that it is
The lubricant amounts included with replacement correctly positioned on the housing.
boots are different for inner and outer C/V joints.
CV BOOT (Continued)
(8) Install the large ladder clamp on the boot and
secure as done with the small ladder clamps (Fig. 8).
(9) Slide the outer C/V joint boot small clamp onto
shaft.
(10) Slide outer C/V joint boot onto shaft and into
position on shaft.
(11) Install small clamp to boot as done above.
(12) Install large boot clamp over outer C/V joint.
(13) Install outer C/V joint to shaft.
(14) Install large boot clamp to boot and C/V joint.
(15) Install the C/V driveshaft.
CV JOINT - OUTER
REMOVAL
(1) Clamp shaft in a vise (with soft jaws) and sup- Fig. 10 Ball Access
port C/V joint. 1 - ALIGNMENT MARKS
(2) Remove clamps from the C/V joint and discard. 2 - BEARING HUB
(3) Slide the boot off the outer joint and down the 3 - BEARING CAGE
shaft. 4 - HOUSING
(4) Remove lubricant to expose the C/V joint snap
ring. (9) Press down one side of the bearing cage/hub to
(5) Open snap ring and slide the joint off the shaft gain access to a ball at the opposite. If joint is tight,
(Fig. 9). use a hammer and brass drift to loosen the bearing
hub. Do not contact the bearing cage with the
drift.
(10) Remove ball from the bearing cage (Fig. 11). If
necessary, a small pry bar can be used to pry the ball
loose from the cage.
Fig. 9 Outer C/V Joint

1 - SNAP RING
2 - SNAP RING GROVE
3 - SNAP RING PLIERS
Fig. 11 Ball Removal

(6) Remove slinger from the joint if damaged. Use
1 - HOUSING
a brass drift and a hammer and tap slinger ring off 2 - BEARING HUB
the joint. 3 - BEARING CAGE
(7) Mark alignment marks on the bearing hub, 4 - BALL
bearing cage and housing with dabs of paint (Fig.
10).
(11) Repeat step above until all six balls are
(8) Clamp C/V joint in a vertical position in a in
removed from the bearing cage.
soft jawed vise.
CV JOINT - OUTER (Continued)
(12) Move bearing cage and hub to a vertical posi- (3) Insert one of the bearing hub lands into a bear-
tion. Pull cage upward and out from the housing ing cage window. Roll the hub into the cage (Fig. 14).
(Fig. 12). Rotate the bearing hub 90° to complete the installa-
tion (Fig. 15).
Fig. 12 Bearing Cage & Hub

1 - HOUSING
Fig. 14 Bearing Hub
2 - BALL RACE 1 - BEARING HUB
3 - BALL CAGE WINDOW 2 - BEARING CAGE
(13) Turn bearing hub 90° in the bearing cage.

Align one pair of the hub lands with the cage win-
dows. Raise and insert one of the lands into the adja-
cent cage window. Remove bearing hub by rolling it
out of the cage (Fig. 13).
Fig. 15 Bearing Cage & Hub

1 - CAGE WINDOWS
2 - SNAP RING
(4) Insert bearing cage/hub into the housing (Fig.

16). Rotate the cage/hub 90° to complete the installa-
tion (Fig. 17).
Fig. 13 Bearing Hub (5) Apply the lubricant included with the replace-
ment boot to the ball raceways. Spread the lubricant
INSTALLATION equally between all the raceways. One packet of
If the outer C/V joint is excessively worn, replace lubricant is sufficient to lubricate the joint.
the entire C/V joint and boot. (6) Tilt bearing hub and cage and install the balls
(1) Lightly apply lubricating oil to all the outer in the raceways (Fig. 18).
C/V joint components before assembling them.
(2) Align the bearing hub, cage and housing
according to the alignment reference marks.
Fig. 16 Bearing Cage & Hub Installation Fig. 18 Ball

1 - BALL RACE 1 - CV JOINT HOUSING
2 - BEARING CAGE WINDOW 2 - BEARING HUB
3 - CV JOINT HOUSING 3 - BEARING CAGE
4 - BALL
Fig. 17 Bearing Cage & Hub Installed In Housing

1 - CV JOINT HOUSING
2 - BEARING HUB LARGE COUNTERBORE OUTWARD
3 - BOOT RETAINING SHOULDER
4 - BEARING HUB SMALL COUNTERBORE INWARD
5 - SLINGER
(7) Apply a small amount of lubricant to inner Fig. 19 Slinger Installation

diameter of slinger. Place slinger squarely on the 1 - HAMMER
outer C/V joint. Use installer tool L-4518-1 from tool 2 - OUTER CV JOINT
3 - SLINGER
set L-4518 and hammer slinger onto joint until it
4 - INSTALLER
seats (Fig. 19).
CAUTION: Prevent damage to the slinger after (8) Position the small-diameter end of the replace-
installation or a when a replacement outer C/V joint ment boot on the interconnecting shaft. Retain the
is installed. boot with a replacement clamp.
(9) Apply the required amount of lubricant to the
outer C/V joint and boot.
(10) Align the shaft splines to the outer C/V joint
splines. Push the outer C/V joint until the snap ring
seats in the groove (Fig. 20).
Fig. 21 Snap Retaining Ring

1 - SNAP RING
2 - TRIPOD JOINT
Fig. 20 Outer C/V 3 - SNAP RING PLIERS
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
(11) Ensure that the snap ring is properly seated

in the housing. Pull the outer C/V joint from the
interconnecting shaft to test.
(12) Place the large-diameter end of the replace-
ment boot over the edge of the C/V joint housing.
Ensure that the boot is not twisted.
(13) Retain the boot on the housing with a replace-
ment retaining clamps.
CV JOINT - INNER
REMOVAL Fig. 22 Tripod C-Clip
(1) Remove the axle driveshaft.
1 - SNAP RING
(2) Place the C/V joint housing in a vise. 2 - CHAMFERED EDGE
(3) Remove the inner boot retaining clamps. Pull 3 - GROOVE
the inner boot back onto the interconnecting shaft. 4 - C-CLIP
Discard the retaining clamps. 5 - TRIPOD
(4) Pull tripod and shaft straight out from the
inner C/V joint housing.
(5) Remove snap ring from behind the tripod and
slide tripod toward the center of the shaft (Fig. 21).
(6) Remove C-clip from the end of the shaft (Fig.
22).

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GROUP TAB LOCATOR

0 Lubrication & Maintenance

3 Differential & Driveline

8E Electronic Control Modules

8Q Vehicle Theft Security

13 Frame & Bumpers

21 Transmission and Transfer Case

24 Heating & Air Conditioning

30 New Vehicle Preparation

Component and System Index

Service Manual Comment Forms (Rear of Manual)

VEHICLE SAFETY CERTIFICATION LABEL INTERNATIONAL SYMBOLS

VEHICLE SAFETY The label is located on the driver-side door shut-

Fig. 2 Vehicle Identification Number (VIN)

VIN DECODING INFORMATION

POSITION INTERPRETATION CODE = DESCRIPTION

Fig. 3 VECI Label Location

DIGIT 9 DIGITS 10 THROUGH 12 Cargo box code

DIGITS 10 THROUGH 13 DIGITS 13 THROUGH 16

DIGIT 5 Fig. 5 Equipment Identification Plate—Typical

Fig. 6 INTERNATIONAL SYMBOLS

FASTENER IDENTIFICATION FASTENER USAGE

Fig. 7 FASTENER IDENTIFICATION

Fig. 8 FASTENER STRENGTH

METRIC SYSTEM Refer to the Metric Conversion Chart (Fig. 9) to

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

Fig. 9 METRIC CONVERSION CHART

Fig. 10 TORQUE SPECIFICATIONS

LUBRICATION & MAINTENANCE

LUBRICATION & MAINTENANCE HOISTING

SPECIFICATIONS - FLUID CAPACITIES

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

INTERNATIONAL SYMBOLS API QUALITY CLASSIFICATION This symbol (Fig. 2) on the

Fig. 2 API Symbol

GASOLINE/OXYGENATE BLENDS MATERIALS ADDED TO FUEL

COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder

CAUTION: Do not use coolant additives that are

DESCRIPTION - ENGINE OIL

Mopart ATF +4, type 9602, Automatic Transmis-

FLUID FILL/CHECK • Check fluid levels of coolant reservoir, power

MAINTENANCE SCHEDULES SCHEDULE “A”

When properly positioned, a floor jack can be used JUMP STARTING

CAUTION: When using another vehicle as a

CAUTION: If the cause of starting problem on dis-

(2) When using another vehicle as a booster

(7) Allow battery in disabled vehicle to charge to

DISCONNECT CABLE CLAMPS AS FOLLOWS:

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1 FRONT - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

WHEEL ALIGNMENT HEIGHT ADJUSTMENT 4WD . . . . . . . . . . . . . . .3

CAUTION: Never attempt to modify suspension or

Positive caster promotes directional stability. This

DIAGNOSIS AND TESTING - PRE-ALIGNMENT Fig. 2 Wheel Alignment

SUSPENSION AND STEERING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

2. Loose or worn steering or 2. Tighten or replace components as

EXCESSIVE PLAY IN 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or 2. Tighten or replace components as

CONDITION POSSIBLE CAUSES CORRECTION