2001 dodge caravan service repair manual by 1636527

GROUP TAB LOCATOR IN INa 0 0a 2 2a 3 5 5a 6a 7 7a 8A 8Aa 8B 8Ba 8E 8F 8Fa 8G 8H 8I 8J 8Ja 8L 8La

Introduction Introduction Lubrication & Maintenance Lubrication & Maintenance Suspension Suspension Differential & Driveline Brakes Brakes Clutch Cooling Cooling Audio Audio Chime/Buzzer Chime/Buzzer Electronic Control Modules Engine Systems Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Instrument Cluster Lamps Lamps

8M 8N 8Na 8O 8P 8Q 8R 8Wa 9 9a 11 11a 13 14 14a 19 19a 21 21a 22 23 24 24a 25

Message Systems

25a

Emissions Control

Power Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Engine Exhaust System Exhaust System Frame & Bumpers Fuel System Fuel System Steering Steering Transmission/Transaxle Transmission/Transaxle Tires/Wheels Body Heating & Air Conditioning Heating & Air Conditioning Emissions Control

Service Manual Comment Forms

INTRODUCTION

INTRODUCTION TABLE OF CONTENTS page VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . BODY CODE PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .

......1 ......1 ......3 ......3

page FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FASTENER USAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

......4

VEHICLE SAFETY CERTIFICATION LABEL

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION

A vehicle safety certification label (Fig. 1) is located on the rearward facing of the driverâ&#x20AC;&#x2122;s door. This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour (MDH) of manufacture is also included. When it is necessary to contact the manufacturer regarding service or warranty, the information on the Vehicle Safety Certification Label would be required.

The Vehicle Identification Number (VIN) can be viewed through the windshield at the upper left corner of the instrument panel, near the left windshield pillar (Fig. 2). The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown Chart for decoding information. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

Fig. 1 Vehicle Safety Certification Label Fig. 2 Vehicle Identification Number (VIN Plate) 1 - DEFROSTER OUTLET 2 - VIN # 3 - HEATED WINDSHIELD GRID

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER (Continued) VIN CODE BREAKDOWN CHART POSITION

INTERPRETATION

CODE = DESCRIPTION

Country of Origin

1 = Built in the United States by DaimlerChrysler 2 = Built in Canada by DaimlerChrysler Canada Inc.

Make

B = Dodge C = Chrysler

Vehicle Type

4 = Multipurpose Pass. Vehicle Less Side Air Bags 8 = Multipurpose Pass. Vehicle With Side Air Bags

Gross Vehicle Weight Rating

G = 2268 - 2721 kg. (5001 - 6000 lbs.)

Car Line

P = Chrysler, Town & Country - FWD P = Dodge, Caravan/Grand Caravan - FWD T = Chrysler, Town & Country - AWD T = Dodge, Grand Caravan - AWD J = Chrysler, Voyager/Grand Voyager - FWD

Series

2 = Low Line 4 = High Line 5 = Premium 6 = Sport 7 = Special

Body Style

4 = Long Wheel Base 5 = Short Wheel Base

Engine

B = 2.4 L 4 cyl. MPI 16-VALVE DOHC G = 3.3 L 6 cyl. Ethanol Flexible Fuel MPI R = 3.3 L 6 cyl. Gas MPI L = 3.8 L 6 cyl. Gas MPI

Check Digit

See explanation in this section.

Model Year

1= 2001

Assembly Plant

B = St. Louis South

12 through 17

Sequence Number

A six digit number assigned by assembly plant.

R = Windsor

INTRODUCTION

VECI LABEL

BODY CODE PLATE – LINE 3

DESCRIPTION

DIGITS 1 THROUGH 12 Vehicle Order Number

All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label.

BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 3) is located in the engine compartment on the radiator closure panel crossmember. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.

DIGITS 13 THROUGH 17 Open space DIGITS 18 AND 19 Vehicle Shell Line • NS DIGIT 20 Carline

FWD • H = Plymouth • K = Dodge • Y = Chrysler AWD • C = Chrysler • D = Dodge • P = Plymouth DIGIT 21 Price Class • H = Highline • L = Lowline • P = Premium • S = Luxury • X = Premium DIGITS 22 AND 23 Body Type • 52 = Short Wheel Base • 53 = Long Wheel Base

BODY CODE PLATE LINE 2 Fig. 3 Body Code Plate 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN

DIGITS 1, 2 AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary paint Refer to Group 23, Body for color codes. DIGIT 8 AND 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint

INTRODUCTION

BODY CODE PLATE (Continued) DIGIT 13 AND 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • EDZ = 2.4 L 4 cyl. DOHC Gasoline • EFA = 3.0 L 6 cyl. Gasoline • EGA = 3.3 L 6 cyl. Gasoline • EGH = 3.8 L 6 cyl. Gasoline • EGM = 3.3 L 6 cyl. Ethanol Flexible Fuel DIGIT 23 Open Space

DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.

IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.

INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

INTRODUCTION

INTERNATIONAL SYMBOLS (Continued)

International Symbols 1 2 3 4 5 6 7 8 9 10 11 12

High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Windscreen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper

13 14 15 16 17 18 19 20 21 22 23 24

Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter

FASTENER IDENTIFICATION

FASTENER USAGE

DESCRIPTION

DESCRIPTION - FASTENER USAGE

The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts.

WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

INTRODUCTION

FASTENER USAGE (Continued)

FASTENER IDENTIFICATION

INTRODUCTION

RS FASTENER USAGE (Continued)

FASTENER STRENGTH

INTRODUCTION

FASTENER USAGE (Continued)

DESCRIPTION - THREADED HOLE REPAIR

METRIC SYSTEM

Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.

DESCRIPTION - METRIC SYSTEM 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 in-lbs

BY x 0.11298

TO GET = Newton Meters (N·m)

MULTIPLY N·m

BY x 8.851

TO GET = in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

x 3.281

= Feet

Yards

x 0.9144

= Meters

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/ Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (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 Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.)

INTRODUCTION

RS METRIC SYSTEM (Continued)

METRIC CONVERSION CHART

INTRODUCTION

tions Chart for torque references not listed in the individual torque charts.

TORQUE REFERENCES DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica-

TORQUE SPECIFICATIONS

INTRODUCTION

INTRODUCTION TABLE OF CONTENTS page BODY CODE PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . FASTENER USAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . THREADED HOLE REPAIR DESCRIPTION . . . . . . . . . . . . . . . . . . . . INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . .

........1 ........2 ........5 ........5

........5

page TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E-MARK LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MANUFACTURE PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

........6

BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 1) is located in the engine compartment on the radiator closure panel crossmember. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.

BODY CODE PLATE – LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13 THROUGH 17 Open space DIGITS 18 AND 19 Vehicle Shell Line • RG DIGIT 20 Carline

FWD • Y = Chrysler AWD • C = Chrysler

Fig. 1 BODY CODE PLATE 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN

INTRODUCTION

BODY CODE PLATE (Continued) DIGIT 21 Price Class • H = Highline • L = Lowline • P = Premium • S = Luxury • X = Premium DIGITS 22 AND 23 Body Type • 52 = Short Wheel Base • 53 = Long Wheel Base

BODY CODE PLATE LINE 2 DIGITS 1, 2 AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary paint(Refer to 23 - BODY/PAINT - SPECIFICATIONS). DIGIT 8 AND 9 Open Space

BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3 Transaxle Codes • DGB = 41TH 4-speed Automatic Transaxle • DGL = 41TE 4-speed Electronic Automatic Transaxle • DGM = 31TH 3-speed Automatic Transaxle DIGIT 4 Open Space DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.

IF TWO BODY CODE PLATES ARE REQUIRED DIGITS 10 THROUGH 12 Secondary Paint DIGIT 13 AND 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • ENC = 2.5 L 4 cyl. Turbo Diesel DIGIT 23 Open Space

The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.

FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 2) and (Fig. 3).

INTRODUCTION

RG FASTENER IDENTIFICATION (Continued)

Fig. 2 FASTENER IDENTIFICATION

INTRODUCTION

FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH

INTRODUCTION

FASTENER USAGE

THREADED HOLE REPAIR

DESCRIPTION

Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.

INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 4) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter

INTRODUCTION

The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY

TO GET

MULTIPLY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

x 3.281

= Feet

Yards

x 0.9144

= Meters

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/Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (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 Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.)

INTRODUCTION

RG METRIC SYSTEM (Continued)

METRIC CONVERSION CHART

INTRODUCTION

tions Chart for torque references not listed in the individual torque charts.

TORQUE REFERENCES DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica-

TORQUE SPECIFICATIONS

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) can be viewed through the windshield at the upper left corner of the instrument panel, near the left windshield pillar (Fig. 5). The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown Chart for decoding information. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

Fig. 5 Vehicle Identification Number (VIN Plate) 1 - DEFROSTER OUTLET 2 - VIN # 3 - HEATED WINDSHIELD GRID

VIN CODE BREAKDOWN CHART POSITION 1 2 3

INTERPRETATION Country of Origin Make Vehicle Type

4 5

Gross Vehicle Weight Rating Car Line

Series

Body Style

Engine

9 10 11 12 through 17

Check Digit Model Year Assembly Plant Sequence Number

CODE = DESCRIPTION 1 = Built in the Graz Austria by DaimlerChrysler C = Chrysler 4 = Multipurpose Pass. Vehicle Less Side Air Bags 8 = Multipurpose Pass. Vehicle With Side Air Bags G = 2268 - 2721 kg. (5001 - 6000 lbs.) Y = Voyager/Grand Voyager - FWD Left Hand Drive C = Voyager/Grand Voyager - AWD Left Hand Drive H = Voyager/Grand Voyager - FWD Right Hand Drive K = Voyager/Grand Voyager - AWD Right Hand Drive I = Caravan FWD 2 = Low Line 4 = High Line 5 = Premium 6 = Sport 7 = Special 4 = Long Wheel Base 5 = Short Wheel Base B = 2.4 L 4 cyl. MPI 16 - VALVE DOHC R = 3.3 L 6 cyl. Gasoline MPI M = 2.5 L 4 cyl. Turbo Diesel See explanation in this section. 1= 2001 U = Graz Austria A six digit number assigned by assembly plant.

10a

INTRODUCTION

VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety certification label (Fig. 6) is located on the rearward facing of the driver’s door. This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour (MDH) of manufacture is also included. When it is necessary to contact the manufacturer regarding service or warranty, the information on the Vehicle Safety Certification Label would be required.

Fig. 7 E-Mark Label 1 2 3 4

- Country Code - Regulation Number - Approval Number - Amendment Number

removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label.

MANUFACTURE PLATE DESCRIPTION Fig. 6 Vehicle Safety Certification Label

E-MARK LABEL DESCRIPTION An E-mark Label (Fig. 7) is located on the rear shut face of the driver’s door. The label contains the following information: • Date of Manufacture • Month-Day-Hour (MDH) • Vehicle Identification Number (VIN) • Country Codes • Regulation Number • Regulation Amendment Number • Approval Number

The Manufacturer Plate (Fig. 8) is located in the engine compartment on the passenger side strut tower. The plate contains five lines of information: • Vehicle Identification Number (VIN) • Gross Vehicle Mass (GVM) • Gross Train Mass (GTM) • Gross Front Axle Rating (GFAR) • Gross Rear Axle Rating (GRAR)

VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be

Fig. 8 Manufacturer Plate

LUBRICATION & MAINTENANCE

0-1

LUBRICATION & MAINTENANCE TABLE OF CONTENTS page LUBRICATION & MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE . . . . . . . . . . . . . LUBRICANT CLASSIFICATIONS. . . . . . . PARTS AND LUBRICANT RECOMMENDATIONS . . . . . . . . . . . . . . FLUID TYPES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .

......1 ......1 ......2 ......2 ......2 ......3 ......7

page MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HOISTING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 16 HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 JUMP STARTING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 16 JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . 16 TOWING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 17 TOWING RECOMMENDATIONS . . . . . . . . . . . . 17

......7

LUBRICATION & MAINTENANCE

DESCRIPTION

SPECIFICATION

AWD Rear Carrier

0.7 L (1.48 pts.)

*(includes oil filter)

SPECIFICATIONS

**(includes heater and recovery/reserve bottle)

SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

Fuel Tank

75 L (20 gal.)

Engine Oil* - 2.4L

4.7 L (5.0 qts.)

Engine Oil* - 3.3/3.8L

4.0 L (4.5 qts.)

Cooling System** - 2.4L

10.7 L (11.4 qts.)

Cooling System** 3.3/3.8L without Rear Heater

12.6 L (13.4 qts.)

Cooling System** 3.3/3.8L with Rear Heater

15.4 L (16.3 qts.)

Automatic Transaxle Service Fill

3.8 L (4.0 qts.)

Automatic Transaxle 31TH Overhaul Fill

8.6 L (9.1 qts.)

Automatic Transaxle 41TE Overhaul Fill

9.2 L (9.7 qts.)

AWD Power Transfer Unit

1.15 L (2.4 pts.)

Power Steering

1.2 L (2.5 pts.)

AWD Bi-directional Overrunning Clutch

0.575 L (1.22 pts.)

INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid check and fill locations (Fig. 1).

Fig. 1 International Symbols

0-2

LUBRICATION & MAINTENANCE

PARTS & LUBRICANT RECOMMENDATION

Multi-Fuel, Variable Fuel, Flexible Fuel, etc. These engine oils are preferred for use in Flexible Fuel engines.

STANDARD PROCEDURE - Classification of Lubricants

CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage may result.

Only lubricants that bear designations defined by the following organization should be used to service a DaimlerChrysler vehicle. • Society of Automotive Engineers (SAE) • 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 viscosity of engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. • SAE 30 = single grade engine oil. • SAE 10W-30 = multiple grade engine oil.DaimlerChrysler only recommends multiple grade engine oils. 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 all the lubrication requirements specified by DaimlerChrysler. Refer to Group 9, Engine for gasoline engine oil specification.

GEAR LUBRICANTS SAE ratings also apply to multiple grade gear lubricants. In addition, API classification defines the lubricants usage. LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 3)on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.

Fig. 3 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

STANDARD PROCEDURE - PARTS AND LUBRICANT RECOMMENDATIONS

Fig. 2 API Symbol FLEXIBLE FUEL ENGINE OIL – 3.3L ENGINE Engine Oil Selection for Operating on E-85 Fuel If vehicle operates on E-85 fuel either full or part-time, use only Mopart Flexible Fuel SAE 5W-30 engine oil or an equivalent that meets DaimlerChrysler Standard MS-9214. Equivalent commercial Flexible Fuel engine oils may be labeled as

When service is required, DaimlerChrysler Motor Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation vehicles.

ENGINE COOLANT The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION)

FLUID TYPES DESCRIPTION E-85 GENERAL INFORMATION The information in this section is for Flexible Fuel Vehicles (FFV) only. These vehicles can be identified by the unique Fuel Filler Door Label that states Ethanol (E-85) or Unleaded Gasoline Only. This section only covers those subjects that are unique to these vehicles. Please refer to the other sections of this manual for information on features that are common between Flexible Fuel and gasoline only powered vehicles.

ETHANOL FUEL (E-85) E-85 is a mixture of approximately 85% fuel ethanol and 15% unleaded gasoline. WARNING: Ethanol vapors are extremely flammable and could cause serious personal injury. Never have any smoking materials lit in or near the vehicle when removing the fuel filler tube cap (gas cap) or filling the tank. Do not use E-85 as a cleaning agent and never use it near an open flame.

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consumption. You can expect your MPG and your driving range to decrease by about 30% compared to gasoline operation.

ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.

SAE VISCOSITY FUEL REQUIREMENTS The vehicle will operate on both unleaded gasoline with an octane rating of 87, or E-85 fuel, or any mixture of these two. For best results, a refueling pattern that alternates between E-85 and unleaded gasoline should be avoided. When you do switch fuels, it is recommended that • you do not switch when the fuel gauge indicates less than 1/4 full • you do not add less than 5 gallons when refueling • you operate the vehicle immediately after refueling for a period of at least 5 minutes Observing these precautions will avoid possible hard starting and/or significant deterioration in driveability during warm up.

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 4).

FFV STARTING The characteristics of E-85 fuel make it unsuitable for use when ambient temperatures fall below 0°F. In the range of 0°F to 32°F, you may experience an increase in the time it takes for your engine to start, and a deterioration in driveability (sags and/or hesitations) until the engine is fully warmed up.

CRUISING RANGE Because E-85 fuel contains less energy per gallon than gasoline, you will experience an increase in fuel

Fig. 4 Temperature/Engine Oil Viscosity

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

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FLUID TYPES (Continued)

CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 5). This symbol on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler.

Fig. 5 Engine Oil Container Standard Notations

FLEXIBLE FUEL ENGINE OIL - 3.3L Engine Oil Selection for Operating on E-85 Fuel If vehicle operates on E-85 fuel either full or parttime, use only Mopart Flexible Fuel 5W-30 engine oil or an equivalent that meets DaimlerChrysler Standard MS-9214. Equivalent commercial Flexible Fuel engine oils may be labeled as Multi-Fuel, Variable Fuel, Flexible Fuel, etc. These engine oils may be satisfactory if they meet the DaimlerChrysler Standard. SAE 5W-30 engine oil is preferred for use in Flexible Fuel engines. CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage may result.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID NOTE: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: For fluid level checking procedures, (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC 31TH/FLUID - STANDARD PROCEDURE) (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE/ FLUID - STANDARD PROCEDURE)

NOTE: The 41TE transaxle has a common transmission and differential sump. Filling the transaxle accommodates the differential as well.

TRANSMISSION FLUID Mopart ATF+4 (Automatic Transmission FluidType 9602) is required in this transaxle. Substitute fluids can induce torque converter clutch shudder. Mopart ATF+4 (Automatic Transmission FluidType 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure. FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

DESCRIPTION - FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded gasoline having an octane rating of 87. The use of premium gasoline is not recommended. The use of premium gasoline will provide no benefit over high quality regular gasoline, and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle.

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FLUID TYPES (Continued) Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available.

REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as “reformulated” gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly supports the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components.

GASOLINE/OXYGENATE BLENDS

emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle’s catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board diagnostics system section.

MATERIALS ADDED TO FUEL

Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle.

All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions.

CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components.

CAUTION: Follow these guidelines to maintain your vehicle’s performance:

MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasolines free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline.

SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California

FUEL SYSTEM CAUTIONS

• The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, and could result in loss of warranty coverage. • An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. • When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. • The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of DaimlerChrysler Corporation and may not be covered under the new vehicle warranty.

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FLUID TYPES (Continued) NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you.

GEAR LUBRICATION – RATINGS SAE ratings also apply to multiple grade gear lubricants. In addition, API classification defines the lubricants usage.

DESCRIPTION - ENGINE COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/ 100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: MoparT Antifreeze/Coolant, 5 Year/ 100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible.

DESCRIPTION - LUBRICANTS AND GREASES When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopart provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used to service a Chrysler Corporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) (Fig. 6) • National Lubricating Grease Institute (NLGI) (Fig. 7)

SAE VISCOSITY RATING An SAE viscosity grade is used to specify the viscosity of engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Example SAE 5W-30 = multiple grade engine oil. DaimlerChrysler Corporation only recommends multiple grade engine oils.

API QUALITY CLASSIFICATION This symbol (Fig. 6) on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation.

Fig. 6 API Symbol

GEAR LUBRICANTS SAE ratings also apply to multiple grade gear lubricants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 80W90.

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FLUID TYPES (Continued)

LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 7) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.

FLUID FILL/CHECK LOCATIONS DESCRIPTION The fluid check/fill points and lubrication locations are located in each applicable Sections.

MAINTENANCE SCHEDULES DESCRIPTION

Fig. 7 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

OPERATION The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.

There are two maintenance schedules that show proper service for your vehicle. First is Schedule – A. It lists all the scheduled maintenance to be performed under “normal” operating conditions. Second is Schedule – B. It is a schedule for vehicles that are operated under the following conditions: • Frequent short trip driving less than 10 miles (16.2 km) • Frequent driving in dusty conditions • Frequent off-road or desert operation • Frequent trailer towing • Day and night temperatures are below freezing • Frequent long periods of engine idling • Frequent stop and go driving • More than 50% of your driving is at sustained high speeds during hot weather, above 90°F (32°C)* • Taxi, police or delivery service • If equipped for and operation with E-85 (ethanol) fuel.

DESCRIPTION At Each Stop For Fuel • Check engine oil level and add as required. • Check windshield washer solvent and add as required. Once A Month • Check tire pressure and look for unusual wear or damage. • Check fluid levels of coolant reservoir, brake master cylinder, power steering and transmission. Add fluid as required. • Check all lights and all other electrical items for correct operation. At Each Oil Change • Change oil filter • Inspect the exhaust system. • Inspect brake hoses. • Inspect the CV joints and front suspension component boots and seals. • Rotate the tires at each oil change interval shown on Schedule – A (7,500 miles - 12 000 km) or

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MAINTENANCE SCHEDULES (Continued) every other interval on Schedule – B (6,000 miles 10 000 km). • Check the engine coolant level, hoses, and clamps.

EMISSION CONTROL SYSTEM MAINTENANCE The scheduled emission maintenance listed in bold type on the Maintenance Schedules, must be done at the mileage specified to assure the continued proper functioning of the emission control system. These, and all other maintenance services included in this manual, should be done to provide the best vehicle performance and reliability. More frequent maintenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving.

DESCRIPTION - MAINTENANCE SCHEDULES SCHEDULE – A – CHRYSLER TOWN AND COUNTRY VEHICLES 7,500 Miles (12 000 km) or at 6 months • Change the engine oil. • Replace the engine oil filter. 15,000 Miles (24 000 km) or at 12 months • Change the engine oil. • Replace the engine oil filter. 22,500 Miles (36 000 km) or at 18 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 30,000 Miles (48 000 km) or at 24 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the tie rod ends and boot seals. 37,500 Miles (60 000 km) or at 30 months • Change the engine oil. • Replace the engine oil filter. 45,000 Miles (72 000 km) or at 36 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 52,500 Miles (84 000 km) or at 42 months • Change the engine oil. • Replace the engine oil filter.

60,000 Miles (96 000 km) or at 48 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check the PCV valve and replace, if necessary.* • Inspect the serpentine drive belt, replace if necessary. • Inspect the tie rod ends and boot seals. 67,500 Miles (108 000 km) or at 54 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 75,000 Miles (120 000 km) or at 60 months • Change the engine oil. • Replace the engine oil filter. • Inspect the serpentine drive belt and replace if necessary. This maintenance is not required if the belt was previously replaced. • Flush and replace engine coolant at 60 months. 82,500 Miles (132 000 km) or at 66 months • Change the engine oil. • Replace the engine oil filter. 90,000 Miles (144 000 km) or at 72 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check the PCV valve and replace, if necessary. Not required if previously changed.* • Inspect the serpentine drive belt, replace if necessary. This maintenance is not required if the belt was previously replaced. • Inspect the tie rod ends and boot seals. • Inspect the brake linings. 97,500 Miles (156 000 km) or at 78 months • Change the engine oil. • Replace the engine oil filter. 100,000 Miles (160,000 km) • Replace the spark plugs. • Replace the ignition cables. • Flush and replace engine coolant at 60 months or 100,000 miles (160,000 km). 105,000 Miles (168 000 km) or at 84 months • Change the engine oil. • Replace the engine oil filter. • Inspect the serpentine drive belt and replace if necessary. This maintenance is not required if the belt was previously replaced.

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MAINTENANCE SCHEDULES (Continued) 112,500 Miles (180 000 km) or at 90 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 120,000 Miles (192 000 km) or at 96 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check and replace the PCV valve, if necessary.* • Inspect the serpentine drive belt. Not required if replaced at 75,000, 90,000 or 105,000 miles. • Inspect the tie rod ends and boot seals. *This maintenance is recommended by DaimlerChrysler Corporation to the owner but is not required to maintain the emissions warranty. NOTE: Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

SCHEDULE – B – CHRYSLER TOWN AND COUNTRY VEHICLES Follow this schedule if the vehicle is usually operates under one or more of the following conditions. • Frequent short trip driving less than 5 miles (8 km) • Frequent driving in dusty conditions • Frequent trailer towing • Day and night temperatures are below freezing • Frequent long periods of engine idling • Frequent stop and go driving • More than 50% of your driving is at sustained high speeds during hot weather, above 90°F (32°C)* • Taxi, police or delivery service • If equipped for and operation with E-85 (ethanol) fuel.

15,000 Miles (24 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter). Replace as necessary.* • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) 18,000 Miles (29 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 21,000 Miles (34 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) 24,000 Miles (38 000 km) • Change the engine oil. • Replace the engine oil filter. 27,000 Miles (43 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 30,000 Miles (48 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the PCV valve, replace as necessary.* • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. 33,000 Miles (53 000 km) • Change the engine oil. • Replace the engine oil filter. 36,000 Miles (58 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 39,000 Miles (62 000 km) • Change the engine oil. • Replace the engine oil filter.

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MAINTENANCE SCHEDULES (Continued) 42,000 Miles (67 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) 45,000 Miles (72 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter). Replace as necessary.* • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the brake linings. 48,000 Miles (77 000 km) • Change the engine oil. • Replace the engine oil filter. • Drain and refill the automatic transmission fluid and replace the filter. (See the note at the end of Schedule – B.) 51,000 Miles (82 000 km) • Change the engine oil. 54,000 Miles (86 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 57,000 Miles (91 000 km) • Change the engine oil. • Replace the engine oil filter. 60,000 Miles (96 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the PCV valve and replace if necessary.* • Inspect the serpentine drive belt and replace if necessary. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. 63,000 Miles (101 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.)

66,000 Miles (106 000 km) • Change the engine oil. • Replace the engine oil filter. 69,000 Miles (110 000 km) • Change the engine oil. • Replace the engine oil filter. 72,000 Miles (115 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 75,000 Miles (120 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter) and replace as necessary.* • Replace the spark plugs. • Replace the ignition cables. • Inspect the serpentine drive belt and replace if necessary. This maintenance is not required if belt was previously replaced. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) 78,000 Miles (125 000 km) • Change the engine oil. • Replace the engine oil filter. 81,000 Miles (130 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 84,000 Miles (134 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) 87,000 Miles (139 000 km) • Change the engine oil. • Replace the engine oil filter. 90,000 Miles (144 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check the PCV valve and replace if necessary. Not required if previously changed.* • Inspect the serpentine drive belt and replace if necessary. This maintenance is not required if belt was previously replaced.

LUBRICATION & MAINTENANCE

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MAINTENANCE SCHEDULES (Continued) • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. • Inspect the brake linings.

93,000 Miles (149 000 km) • Change the engine oil. • Replace the engine oil filter. 96,000 Miles (154 000 km) • Change the engine oil. • Replace the engine oil filter. • Drain and refill the automatic transmission fluid and replace the filter. (See the note at the end of Schedule – B.) 99,000 Miles (158 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 100,000 Miles (160 000 km) • Flush and replace the engine coolant at 60 months or 100,000 miles (160 000 km). 102,000 Miles (163 000 km) • Change the engine oil. • Replace the engine oil filter. 105,000 Miles (168 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter) and replace as necessary.* • Inspect the serpentine drive belt and replace if necessary. This maintenance is not required if belt was previously replaced. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) 108,000 Miles (173 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings.

117,000 Miles (187 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 120,000 Miles (192 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the PCV valve and replace as necessary.* • Inspect the serpentine drive belt. Not required if replaced at 75,000, 90,000 or 105,000 miles. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. *This maintenance is recommended by DaimlerChrysler Corporation to the owner but is not required to maintain the emissions warranty. NOTE: Operating the vehicle more than 50% in heavy traffic during hot weather, above 90°F (32°C), using the vehicle for police, taxi, limousine type operation or trailer towing require the more frequent transaxle service noted in Schedule – B. Perform these services if vehicle usually operates under these conditions. NOTE: Inspection and service should also be performed anytime a malfunction is observed or suspected.

DESCRIPTION SCHEDULE – A – DODGE CARAVAN, CHRYSLER VOYAGER 7,500 Miles (12 000 km) or at 6 months • Change the engine oil. • Replace the engine oil filter. 15,000 Miles (24 000 km) or at 12 months • Change the engine oil. • Replace the engine oil filter.

111,000 Miles (178 000 km) • Change the engine oil. • Replace the engine oil filter.

22,500 Miles (36 000 km) or at 18 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings.

114,000 Miles (182 000 km) • Change the engine oil. • Replace the engine oil filter.

30,000 Miles (48 000 km) or at 24 months • Change the engine oil. • Replace the engine oil filter.

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LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) • Replace the engine air cleaner element (filter). • Replace the spark plugs on 2.4 liter engines. • Inspect and adjust the power steering pump belt tension on 2.4 liter engines. • Inspect the tie rod ends and boot seals.

37,500 Miles (60 000 km) or at 30 months • Change the engine oil. • Replace the engine oil filter. 45,000 Miles (72 000 km) or at 36 months • Change the engine oil. • Replace the engine oil filter. • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the brake linings. 52,500 Miles (84 000 km) or at 42 months • Change the engine oil. • Replace the engine oil filter. 60,000 Miles (96 000 km) or at 48 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check the PCV valve and replace, if necessary.* • Replace the spark plugs on 2.4 liter engines. • Inspect the power steering pump belt tension, and replace the belt, if necessary, on 2.4 liter engines. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, and replace if necessary. • Inspect the tie rod ends and boot seals. 67,500 Miles (108 000 km) or at 54 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 75,000 Miles (120 000 km) or at 60 months • Change the engine oil. • Replace the engine oil filter. • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, and replace if necessary. This maintenance is not required if belt was previously replaced. • Flush and replace engine coolant at 60 months. 82,500 Miles (132 000 km) or at 66 months • Change the engine oil. • Replace the engine oil filter.

90,000 Miles (144 000 km) or at 72 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check the PCV valve and replace, if necessary. Not required if previously changed.* • Replace the spark plugs on 2.4 liter engines. • Inspect and adjust the power steering pump belt tension on 2.4 liter engines. • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, and replace if necessary. This maintenance is not required if belt was previously replaced. • Inspect the tie rod ends and boot seals. • Inspect the brake linings. 97,500 Miles (156 000 km) or at 78 months • Change the engine oil. • Replace the engine oil filter. 100,000 Miles (160 000 km) • Replace the spark plugs 3.3 liter and 3.8 liter engines. • Replace the ignition cables 2.4 liter, 3.3 liter and 3.8 liter engines. • Flush and replace the engine coolant 60 months or 100,000 miles (160 000 km). 105,000 Miles (168 000 km) or at 84 months • Change the engine oil. • Replace the engine oil filter. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, and replace if necessary. This maintenance is not required if belt was previously replaced. • Inspect the generator belt on 2.4 liter engines and replace if necessary. 112,500 Miles (180 000 km) or at 90 months • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 120,000 Miles (192 000 km) or at 96 months • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Check and replace the PCV valve, if necessary.* • Replace the spark plugs 2.4 liter engines. • Inspect the power steering pump belt tension, replace belt if necessary on 2.4 liter engines.

LUBRICATION & MAINTENANCE

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MAINTENANCE SCHEDULES (Continued) • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines. Not required if replaced at 75,000, 90,000 or 105,000 miles. • Replace the engine timing belt on 2.4 liter engine only. • Inspect the tie rod ends and boot seals. * This maintenance is recommended by DaimlerChrysler Corporation to the owner but is not required to maintain the emissions warranty. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

SCHEDULE – B – DODGE VEHICLES, CHRYSLER VOYAGER Follow this schedule if the vehicle is usually operates under one or more of the following conditions. • Frequent short trips of less than 5 miles • Frequent driving in dusty conditions • Frequent trailer towing • Day and night temperatures are below freezing • Frequent stop and go driving • Extensive periods of idling • Frequent operation at sustained high speeds during hot weather, above 90°F (32°C) • Use of E-85 (ethanol) fuel in 3.3 liter engines.

3,000 Miles (5 000 km) • Change the engine oil. • Replace the engine oil filter. 6,000 Miles (10 000 km) • Change the engine oil. • Replace the engine oil filter. 9,000 Miles (14 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 12,000 Miles (19 000 km) • Change the engine oil. • Replace the engine oil filter. 15,000 Miles (24 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter). Replace as necessary.* • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the generator belt on 2.4 liter engines and replace if necessary.

18,000 Miles (29 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 21,000 Miles (34 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) 24,000 Miles (38 000 km) • Change the engine oil. • Replace the engine oil filter. 27,000 Miles (43 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 30,000 Miles (48 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the PCV valve and replace as necessary.* • Replace the spark plugs 2.4 liter engines. • Inspect and adjust the generator belt and power steering pump belt tension on 2.4 liter engines. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. 33,000 Miles (53 000 km) • Change the engine oil. • Replace the engine oil filter. 36,000 Miles (58 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 39,000 Miles (62 000 km) • Change the engine oil. • Replace the engine oil filter. 42,000 Miles (67 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.)

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LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) 45,000 Miles (72 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter). Replace as necessary.* • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Change the All Wheel Drive power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the brake linings. 48,000 Miles (77 000 km) • Change the engine oil. • Replace the engine oil filter. • Drain and replace the automatic transmission fluid and filter. • Adjust bands on 3–speed transmission. (See the note at the end of Schedule – B.) 51,000 Miles (82 000 km) • Change the engine oil. • Replace the engine oil filter. 54,000 Miles (86 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 57,000 Miles (91 000 km) • Change the engine oil. • Replace the engine oil filter. 60,000 Miles (96 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the PCV valveand replace if necessary.* • Replace the spark plugs on 2.4 liter engines. • Inspect the generator belt and power steering pump belt tension, replace belt if necessary on 2.4 liter engines. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines and replace if necessary. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. 63,000 Miles (101 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) • Inspect the brake linings.

66,000 Miles (106 000 km) • Change the engine oil. • Replace the engine oil filter. 69,000 Miles (110 000 km) • Change the engine oil. • Replace the engine oil filter. 72,000 Miles (115 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 75,000 Miles (120 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter) and replace as necessary.* • Replace the spark plugs 3.3 liter and 3.8 liter engines. • Replace the ignition cables 2.4 liter, 3.3 liter and 3.8 liter engines. • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, and replace if necessary. This maintenance is not required if belt was previously replaced. • Change the All Wheel Drive power transfer unit fluid. (See the note at the end of Schedule – B.) 78,000 Miles (125 000 km) • Change the engine oil. • Replace the engine oil filter. 81,000 Miles (130 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 84,000 Miles (134 000 km) • Change the engine oil. • Replace the engine oil filter. • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.) 87,000 Miles (139 000 km) • Change the engine oil. • Replace the engine oil filter. 90,000 Miles (144 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter).

LUBRICATION & MAINTENANCE

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MAINTENANCE SCHEDULES (Continued) • Check the PCV valve and replace if necessary. Not required if previously changed.* • Replace the spark plugs on 2.4 liter engines. • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the serpentine drive belt (3.3 liter and 3.8 liter engines) and replace if necessary. This maintenance is not required if belt was previously replaced. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. • Inspect the brake linings.

93,000 Miles (149 000 km) • Change the engine oil. • Replace the engine oil filter. 96,000 Miles (154 000 km) • Change the engine oil. • Replace the engine oil filter. • Drain and replace the automatic transmission fluid and filter. • Adjust bands on 3–speed transmission. (See the note at the end of Schedule – B.) 99,000 Miles (158 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 100,000 Miles (160 000 km) • Flush and replace engine coolant at 60 months or 100,000 miles (160 000 km). 102,000 Miles (163 000 km) • Change the engine oil. • Replace the engine oil filter. 105,000 Miles (168 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the engine air cleaner element (filter) and replace as necessary.* • Inspect the generator belt on 2.4 liter engines and replace if necessary. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines and replace if necessary. This maintenance is not required if the belt was previously replaced. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of Schedule – B.)

108,000 Miles (173 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 111,000 Miles (178 000 km) • Change the engine oil. • Replace the engine oil filter. 114,000 Miles (182 000 km) • Change the engine oil. • Replace the engine oil filter. 117,000 Miles (187 000 km) • Change the engine oil. • Replace the engine oil filter. • Inspect the brake linings. 120,000 Miles (192 000 km) • Change the engine oil. • Replace the engine oil filter. • Replace the engine air cleaner element (filter). • Inspect the PCV valve and replace as necessary.* • Replace the spark plugs on 2.4 liter engines. • Inspect the generator belt and power steering pump belt tension, replace the belt if necessary on 2.4 liter engines. • Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines. Not required if replaced at 75,000, 90,000 or 105,000 miles. • Replace the engine timing belt on 2.4 liter engines. • Change the All Wheel Drive (AWD) power transfer unit fluid. (See the note at the end of Schedule – B.) • Inspect the tie rod ends and boot seals. * This maintenance is recommended by DaimlerChrysler Corporation to the owner but is not required to maintain the emissions warranty. NOTE: Operating the vehicle more than 50% in heavy traffic during hot weather, above 90°F (32°C), using vehicle for police, taxi, limousine type operation or trailer towing require the more frequent transaxle service noted in Schedule – B. Perform these services if vehicle usually operate under these conditions. NOTE: The AWD power transfer unit fluid and the AWD overrunning clutch/rear carrier fluid must be changed at the more frequent intervals shown in schedule B if the vehicle is operated under any of the conditions noted by an asterisk at the beginning of the schedule.

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LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) Inspection and service should also be performed anytime a malfunction is observed or suspected.

HOISTING STANDARD PROCEDURE - HOISTING Refer to Owner’s Manual provided with vehicle for proper emergency jacking procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. CAUTION: Do not position hoisting device on any suspension component, including the front suspension crossmember, the rear leaf springs, and the rear axle. Do not hoist on the front and rear bumpers, the lower liftgate crossmember, the lower radiator crossmember, the down standing flanges on the sill or the front engine mount. FOR PROPER HOIST PLACEMENT REFER TO (Fig. 8). The hoisting points are identified by S.A.E. inverted triangle hoisting symbols (Fig. 8). The front hoisting points are at the bottom of the font rail below the hoisting symbol approximately 250mm behind the front suspension crossmember. When using outboard lift hoists, verify that the hoist lift pads have been properly adjusted to eliminate contact between the hoist arm and the down standing flange on the sill. The rear hoisting points are the leaf spring front mounting brackets. The hoist pad must be positioned to pick up the flanges on the bracket, not the leaf spring. When servicing the leaf springs or the leaf spring mounting brackets, special provisions are required to support the rear of the vehicle. Position the rear hoist pads under the horizontal surface on the bottom of the sill, inboard adjacent to the flange and centered fore/aft between the jacking indicator tabs on the lower flange. DO NOT HOIST ON THE FLANGE. Place a soft pad between the hoist and the painted surface on the sill to avoid scratching the finish.

Fig. 8 HOISTING AND JACKING POINTS 1 - DRIVE ON LIFT 2 - FRAME CONTACT LIFT (SINGLE POST) CHASSIS LIFT (NON-AXLE DUAL POST) OUTBOARD LIFT (DUAL POST) FLOOR JACK 3 - S.A.E. HOISTING SYMBOLS

JUMP STARTING TO JUMP START A DISABLED VEHICLE: (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 disabled 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

LUBRICATION & MAINTENANCE

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JUMP STARTING (Continued) transmission in NEUTRAL and turn the ignition OFF. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 9). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery.

Fig. 9 Jumper Cable Clamp Connections 1 2 3 4 5 6 7

BATTERY POSITIVE CABLE POSITIVE JUMPER CABLE TEST INDICATOR BATTERY NEGATIVE CABLE BATTERY NEGATIVE JUMPER CABLE ENGINE GROUND

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat 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 seconds, stop cranking engine and allow starter to cool (15 minutes), 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 positive terminal on disabled vehicle.

TOWING TOWING RECOMMENDATIONS WARNINGS AND CAUTIONS WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW VEHICLE BY FRONT OR REAR BUMPER. DO NOT GO UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE. USE A SAFETY CHAIN THAT IS INDEPENDENT FROM THE TOWING ATTACHMENT DEVICE. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers.

RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use: • FWD vehicles, use a flat bed towing device or wheel lift is recommended (Fig. 10). • AWD vehicles, a flat bed towing device or wheel lift and towing dolly is recommended (Fig. 10). When using a wheel lift towing device, be sure the disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.

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LUBRICATION & MAINTENANCE

TOWING (Continued)

FLAT BED TOWING TIE DOWNS CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result.

Fig. 10 Recommended Towing 1 - WHEEL LIFT 2 - FLAT BED

The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails, behind the front wheels. The two pair of rear slots on the bottom of the rail between the bumper extension bolts and on the bottom of the rail just rearward of the jounce bumper. Vehicles equipped with a rear sway bar have brackets at this location.

TOWING – FRONT WHEEL LIFT GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors. A towed vehicle should be raised until the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors.

LOCKED VEHICLE TOWING When a locked vehicle must be towed with the front wheels on the ground, use a towing dolly or flat bed hauler.

FLAT TOWING WITH TOW BAR • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. • AWD models should not be flat towed. For additional information, refer to RECOMMENDED TOWING EQUIPMENT in this section.

If the vehicle is being towed from the front, whenever possible ensure at lest 10 inches road clearness to the tires.

TOWING – REAR WHEEL LIFT If a vehicle cannot be towed with the front wheels lift, the rear wheels can be lifted provided the following guide lines are observed. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. • On AWD vehicles, all four wheels must be free to rotate. Use towing dollies at unlifted end of vehicle. • Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing. • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral.

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

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LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL TABLE OF CONTENTS page LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . FLUID TYPES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . .

....1 ....2 ....2 ....5

page HOISTING STANDARD PROCEDURE . . . . . . . HOISTING . . . . . . . . . . . . . . . . . JUMP STARTING STANDARD PROCEDURE . . . . . . . JUMP STARTING . . . . . . . . . . . . TOWING STANDARD PROCEDURE . . . . . . . TOWING RECOMMENDATIONS .

............7 ............7 ............8 ............8 ............8 ............8

....5

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

DESCRIPTION

SPECIFICATION

Cooling System** - 2.5 L Turbo Diesel with Auxiliary Heater

16.6 L (17.5 qts.)

SPECIFICATIONS

Automatic Transaxle Service Fill

3.8 L (4.0 qts.)

SPECIFICATIONS - FLUID CAPACITIES

Automatic Transaxle 31TH Overhaul Fill

8.6 L (9.1 qts.)

Automatic Transaxle 41TE Overhaul Fill

9.2 L (9.7 qts.)

DESCRIPTION

SPECIFICATION

Fuel Tank

75 L (20 gal.)

Fuel Tank (Diesel)

75 L (20 gal.)

Manual Transaxle (T850 5-speed)

2.4-2.7 L (2.5-2.9 qts.)

Engine Oil* - 2.4 L

4.7 L (5.0 qts.)

AWD Power Transfer Unit

1.15 L (2.4 pts.)

Engine Oil* - 3.3 L

4.0 L (4.5 qts.)

Power Steering

1.2 L (2.5 pts.)

Engine Oil* - 2.5 L

5.22 L (5.52 qts.) 10.7 L (11.4 qts.)

AWD Bi-directional Overrunning Clutch

0.575 L (1.22 pts.)

Cooling System** - 2.4 L Cooling System** - 3.3 L without Auxiliary Heater

12.6 L (13.4 qts.)

AWD Rear Carrier

0.7 L (1.48 pts.)

Cooling System** - 3.3 L with Auxiliary Heater

15.4 L (16.3 qts.)

Cooling System** - 2.5 L Turbo Diesel without Auxiliary Heater

13.8 L (14.6 qts.)

*(includes oil filter) **(includes heater and recovery/reserve bottle)

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LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid check and fill locations (Fig. 1).

SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 2).

Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY Fig. 1 International Symbols

FLUID TYPES DESCRIPTION - ENGINE OIL AND LUBRICANTS

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans (Fig. 3). This symbol means that the oil has been certified by the American Petroleum Institute (API). DiamlerChrysler only recommend API Certified engine oils that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395.

When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopart provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) • National Lubricating Grease Institute (NLGI)

Fig. 3 API Symbol

CONTAINER IDENTIFICATION

API SERVICE GRADE CERTIFIED

GEAR LUBRICANTS

Use an engine oil that is API Certified. MOPARt provides engine oils, meeting Material Standard MS-6395, that meet or exceed this requirement.

SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W-90.

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

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FLUID TYPES (Continued)

LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 4) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.

Fig. 4 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

SPECIALIZED LUBRICANTS AND OILS Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appropriate sections in this manual for the correct application of these lubricants.

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID NOTE: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: For fluid level checking procedures, (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC 31TH/FLUID - STANDARD PROCEDURE). NOTE: The 31TH transaxle has a common transmission and differential sump. Filling the transaxle accommodates the differential as well.

TRANSMISSION FLUID Mopart ATF+4 (Automatic Transmission FluidType 9602) is required in this transaxle. Substitute fluids can induce torque converter clutch shudder.

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LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

FLUID TYPES (Continued) Mopart ATF+4 (Automatic Transmission FluidType 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure. FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

DESCRIPTION - DIESEL ENGINE OIL API SERVICE GRADE CERTIFIED WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. In diesel engines, use an engine oil that conforms to API Service Grade CF-4 or CG-4/SH (Fig. 5). MOPARt provides an engine oil that conforms to this particular grade.

DESCRIPTION - FUEL REQUIREMENTS DIESEL ENGINE WARNING: DO NOT USE ALCOHOL OR GASOLINE AS A FUEL BLENDING AGENT. THEY CAN BE UNSTABLE UNDER CERTAIN CONDITIONS AND HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH DIESEL FUEL. Use good quality diesel fuel from a reputable supplier. For most year-round service, number 2 diesel fuel meeting ASTM specification D-975 will provide good performance. If the vehicle is exposed to extreme cold (below -18°C/0°F) or is required to operate at colder than normal conditions for prolonged periods, use climatize No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better protection from fuel gelling or wax plugging of the fuel filters. Diesel fuel is seldom completely free of water. To prevent fuel system trouble, including fuel line freezing in winter, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold starting and warm up performance.

Fig. 5 API Service Grade Certification Label—Diesel Engine Oil

SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 15W–40 specifies a multiple viscosity engine oil. When choosing an engine oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your area’s particular ambient temperature range and variation. For diesel engines, refer to (Fig. 6).

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

0a - 5

FLUID TYPES (Continued)

Fig. 6 Engine Oil Viscosity Recommendation – Diesel Engines

FLUID FILL/CHECK LOCATIONS

At Each Oil Change • Replace the engine oil filter at each oil change. • Inspect exhaust system. • Inspect brake hoses • Inspect the CV joints and front suspension components • Rotate the tires at each oil change interval shown on schedule “A” 20 000 km or every other interval shown on schedule “B” 20 000 km. • Check the coolant level, hoses, and clamps. • Inspect brake linings, hoses and calipers. • Inspect engine accessory drive belts. • Inspect for presence of water in fuel filter/water separator, drain if necessary.

SCHEDULE “A”

DESCRIPTION The fluid check/fill points and lubrication locations are located in each applicable service manual section.

MAINTENANCE SCHEDULES MAINTENANCE SCHEDULES - DIESEL ENGINE There are two maintenance schedules that show proper service for the vehicle. First is Schedule “A”. It lists all the scheduled maintenance to be performed under “normal” operating conditions. Second is Schedule “B”. It is a schedule for vehicles that are operated under the conditions listed at the beginning of the schedule. Use the schedule that best describes the driving conditions. Where time and mileage are listed, follow the interval that occurs first.

At Each Stop for Fuel • Check the engine oil level, add as required. • Check the windshield washer solvent and add if required. Once a Month • Check the tire pressure and look for unusual wear or damage. • Inspect the battery and clean and tighten terminals as required. • Check the fluid levels of coolant reservoir, brake master cylinder, power steering and transaxle and add as needed. • Check all lights and all other electrical items for correct operation. • Check the rubber seals on each side of the radiator for proper fit.

20 000 km (12 000 miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element. Replace as necessary. 40 000 km (24 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. 60 000 km (37 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element. Replace as necessary. 80 000 km (49 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. 100 • • •

000 km (62 000 Miles) Change engine oil. (1) Replace engine oil filter. Inspect air filter element. Replace as necessary.

120 • • • • •

000 km (75 000 Miles) Change engine oil. (1) Replace engine oil filter. Replace air filter element. Replace fuel filter/water separator element. (2) Check alignment.

140 • • •

000 km (86 000 miles) Change engine oil. (1) Replace engine oil filter. Inspect air filter element. Replace as necessary.

0a - 6

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

MAINTENANCE SCHEDULES (Continued) 160 • • • • • •

000 km (100 000 miles) Change engine oil. (1) Replace engine oil filter. Replace air filter element. Replace fuel filter/water separator element. (2) Check alignment. Flush and replace engine coolant. (3)

40 000 km (24 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. • Change manual transaxle fluid.

180 000 km (110 000 miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element. Replace as necessary. IMPORTANT: Inspection and service should also be performed any time a malfunction is observed or suspected. Retain all receipts. • Change oil every 12 months regardless of mileage. • The fuel filter/water separator element should be replaced once a year if the vehicle is driven less than 40 000 km annually or if power loss from fuel starvation is detected. • Flush and replace engine coolant every 60 months even if the vehicle is driven less than 160 000 km.

50 000 km (31 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element.

SCHEDULE “B”

80 000 km (49 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. • Change manual transaxle fluid.

Follow this schedule if the vehicle is operated under one or more of the following conditions. • Day or night temperatures are below 0° C (32° F). • Stop and go driving. • Extensive engine idling. • Driving in dusty conditions. • Short trips of less than 16.2 km (10 miles). • More than 50% of driving is at sustained high speeds during hot weather, above 32° C (90° F). • Trailer towing. • Taxi, police, or delivery service (commercial service).

10 000 km (6 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element. 20 000 km (12 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. 30 000 km (18 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element.

60 000 km (37 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. 70 000 km (43 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element.

90 000 km (55 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element. 100 • • • •

000 km (62 000 Miles) Change engine oil. (1) Replace engine oil filter. Replace air filter element. Replace fuel filter/water separator element. (2)

110 000 km (68 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Inspect air filter element. • Replace fuel filter/water separator element. (2) • Check alignment. 120 • • • •

000 km (74 000 Miles) Change engine oil. (1) Replace engine oil filter. Replace air filter element. Change manual transaxle fluid.

130 000 km (80 000 Miles) • Change engine oil. (1) • Replace engine oil filter.

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

0a - 7

MAINTENANCE SCHEDULES (Continued) • Inspect air filter element. • Replace fuel filter/water separator element. (2) • Check alignment.

140 • • •

000 km (86 000 Miles) Change engine oil. (1) Replace engine oil filter. Replace air filter element.

150 • • • • •

000 km (93 000 Miles) Change engine oil. (1) Replace engine oil filter. Inspect air filter element. Replace fuel filter/water separator element. (2) Check alignment.

160 000 km (100 000 Miles) • Change engine oil. (1) • Replace engine oil filter. • Replace air filter element. • Flush and replace engine coolant. (3) • Change oil every 12 months regardless of mileage. • The fuel filter/water separator element should be replaced once a year if the vehicle is driven less than 20 000 km annually or if power loss from fuel starvation is detected. • Flush and replace engine coolant every 60 months even if the vehicle is driven less than 160 000 km. • Change manual transaxle fluid.

The hoisting points are identified by S.A.E. inverted triangle hoisting symbols (Fig. 7). The front hoisting points are at the bottom of the font rail below the hoisting symbol approximately 250mm behind the front suspension crossmember. When using outboard lift hoists, verify that the hoist lift pads have been properly adjusted to eliminate contact between the hoist arm and the down standing flange on the sill. The rear hoisting points are the leaf spring front mounting brackets. The hoist pad must be positioned to pick up the flanges on the bracket, not the leaf spring. When servicing the leaf springs or the leaf spring mounting brackets, special provisions are required to support the rear of the vehicle. Position the rear hoist pads under the horizontal surface on the bottom of the sill, inboard adjacent to the flange and centered fore/aft between the jacking indicator tabs on the lower flange. DO NOT HOIST ON THE FLANGE. Place a soft pad between the hoist and the painted surface on the sill to avoid scratching the finish.

Fig. 7 HOISTING AND JACKING POINTS 12-

FOR PROPER HOIST PLACEMENT REFER TO (Fig. 7).

Drive On Lift Frame Contact Lift (Single Post) Chassis Lift (Non-Axle Dual Post) Outboard Lift (Dual Post) Floor Jack S.A.E. Hoisting Symbols

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LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

JUMP STARTING STANDARD PROCEDURE - JUMP STARTING (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 disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 8). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat 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 seconds, stop cranking engine and allow starter to cool (15 minutes), 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 positive terminal on disabled vehicle.

Fig. 8 Jumper Cable Clamp Connections 1 2 3 4 5 6 7

BATTERY POSITIVE CABLE POSITIVE JUMPER CABLE TEST INDICATOR BATTERY NEGATIVE CABLE BATTERY NEGATIVE JUMPER CABLE ENGINE GROUND

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL

0a - 9

TOWING (Continued)

RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use: • FWD vehicles, use a flat bed towing device or wheel lift is recommended (Fig. 9). • AWD vehicles, a flat bed towing device or wheel lift and towing dolly is recommended (Fig. 9). When using a wheel lift towing device, be sure the disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.

for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. • AWD models should not be flat towed. For additional information, refer to RECOMMENDED TOWING EQUIPMENT in this section.

FLAT BED TOWING TIE DOWNS CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result. The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails, behind the front wheels. The two pair of rear slots on the bottom of the rail between the bumper extension bolts and on the bottom of the rail just rearward of the jounce bumper. Vehicles equipped with a rear sway bar have brackets at this location.

Fig. 9 Recommended Towing 1 - WHEEL LIFT 2 - FLAT BED

TOWING – FRONT WHEEL LIFT If the vehicle is being towed from the front, whenever possible ensure at lest 10 inches road clearness to the tires.

GROUND CLEARANCE

TOWING – REAR WHEEL LIFT

CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors.

If a vehicle cannot be towed with the front wheels lift, the rear wheels can be lifted provided the following guide lines are observed.

A towed vehicle should be raised until the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors.

LOCKED VEHICLE TOWING When a locked vehicle must be towed with the front wheels on the ground, use a towing dolly or flat bed hauler.

FLAT TOWING WITH TOW BAR • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph)

CAUTION: Do not use steering column lock to secure steering wheel during towing operation. • On AWD vehicles, all four wheels must be free to rotate. Use towing dollies at unlifted end of vehicle. • Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing. • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral.

SUSPENSION

2-1

SUSPENSION TABLE OF CONTENTS page FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

page WHEEL ALIGNMENT

. . . . . . . . . . . . . . . . . . . . . . 46

FRONT TABLE OF CONTENTS page

page

FRONT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 2 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 5 HUB AND BEARING (FRONT) . . . . . . . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LOWER BALL JOINT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11

LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 11 LOWER BALL JOINT SEAL BOOT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 STABILIZER BAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STRUT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 20 STRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FRONT

OPERATION - FRONT SUSPENSION

DESCRIPTION - FRONT SUSPENSION This vehicle has a MacPherson Strut type front suspension (Fig. 1).

The front suspension allows each wheel on a vehicle to adapt to different road surfaces and conditions without greatly affecting the opposite wheel and the ability to control the vehicle. Each side of the front suspension is allowed to pivot so the vehicle can be steered in the direction preferred.

2-2

FRONT

FRONT (Continued)

Fig. 1 Front Suspension 1 2 3 4 5 6 7 8

TOWER CROSSMEMBER TAPPING PLATES LEFT STRUT ASSEMBLY LEFT STEERING KNUCKLE (WITH HUB AND BEARING) STABILIZER BAR LINK STABILIZER BAR LEFT LOWER CONTROL ARM CRADLE/CROSSMEMBER

A strut assembly is used in place of the front suspension upper control arm and upper ball joint. When a vehicle strikes a bump, the force is transferred through the hub, bearing, and knuckle, into the strut assembly to absorb the force and dampen it. The top of the strut is mounted directly to the strut tower of the vehicle. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly.

9 - CRADLE/CROSSMEMBER REINFORCEMENT 10 - BALL JOINT 11 - ISOLATOR BUSHING 12 - STEERING GEAR TIE ROD 13 - RIGHT STEERING KNUCKLE 14 - RIGHT HUB AND BEARING 15 - RIGHT STRUT ASSEMBLY

STANDARD PROCEDURE - LUBRICATION There are no serviceable lubrication points on the front suspension. The ball joints are sealed-for-life and require no maintenance. The lower ball joints have special grease fitting caps that prevent normal grease gun attachment. This has been done to eliminate the possibility of over-filling, damaging the nonvented seal. Do not attempt to remove the special grease fitting cap and replace it with a normal grease zirc fitting. CAUTION: No attempt should be made to replace the ball joint grease fitting cap with a normal zirc fitting or fill the ball joint with grease. Damage to the grease seal can result.

FRONT

RS FRONT (Continued)

SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE N·m

Ft. Lbs.

In. Lbs.

Ball Joint Nut

108

—

Cradle Crossmember Mounting Bolts

163

120

—

Disc Brake Adapter Mounting Bolts

169

125

—

Hub And Bearing Mounting Bolts

—

Hub And Bearing Axle Hub Nut

244

180

—

Lower Control Arm Pivot Bolt

183

135

—

Lower Control Arm Rear Bushing Retainer bolts

—

Stabilizer Bar Bushing Retainer Bolts

—

Stabilizer Bar Link Nuts

—

Strut Body/Tower Mounting Nuts

250

81 + 90° turn

60 + 90° turn

—

Strut Shaft Nut

100

—

Tie Rod Adjuster Jam Nut

—

Tie Rod Steering Arm Nut

—

Wheel Mounting (Lug) Nuts

135

100

—

DESCRIPTION

Strut Clevis-to-Knuckle Nuts

Press, Ball Joint C-4212F

Installer, Ball Joint 6758

Wrench, Strut Rod Nut 6864

SPECIAL TOOLS FRONT SUSPENSION REMOVER/INSTALLER, BUSHING 8460

Puller C-3894A REMOVER/INSTALLER, BALL JOINT 8490

2-3

2-4

FRONT

BUSHINGS REMOVAL - STABILIZER BAR CUSHION (1) Raise Vehicle. Refer to Hoisting in Lubrication and Maintenance. (2) Remove the 2 bolts fastening the emission leak detection pump to the cradle crossmember reinforcement. (3) Move the leak detection pump to the side allowing access to the stabilizer bar cushion retainers. (4) Remove the nut and bolt securing each stabilizer bar cushion retainer to the cradle crossmember (Fig. 2) and remove the retainers.

Fig. 3 Correctly Installed Stabilizer Bar Cushion 1 2 3 4

SLIT SQUARE CORNER STABILIZER BAR STABILIZER BAR CUSHION (BUSHING)

(4) Install each mounting bolt from rear of cradle crossmember through retainer. Install the two nuts and tighten to 68 NÂˇm (50 ft. lbs.) torque. (5) Reattach emission leak detection pump to cradle crossmember reinforcement with two mounting bolts. (6) Lower the vehicle.

Fig. 2 Front Stabilizer Bar Cushion Retainers 1 2 3 4 5

STEERING GEAR STABILIZER BAR RAISED BEAD FRONT CRADLE CROSSMEMBER RETAINERS

(5) Remove each stabilizer bar cushion from the stabilizer bar by opening the slit in the cushion and peeling it off the stabilizer bar.

INSTALLATION - STABILIZER BAR CUSHION (1) Install each new cushion on stabilizer bar by spreading cushion at slit and forcing it onto stabilizer bar. NOTE: Cushions must be installed on stabilizer bar so the square corner of the bushing will be down and slit in cushion will be facing the rear of the vehicle when the stabilizer bar is installed (Fig. 3). (2) Place stabilizer bar into mounted position with cushions properly aligned. (3) Hook each retainer into cradle crossmember mounting hole and over cushion.

HUB / BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assembly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one-piece unit. The hub and bearing is mounted to the center of the steering knuckle (Fig. 1). It is retained by four mounting bolts accessible from the rear of the steering knuckle. The hub flange has five wheel mounting studs. The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly. Otherwise, the hub and bearing is serviced only as a complete assembly.

OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft, along with the tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle.

FRONT

2-5

HUB / BEARING (Continued)

DIAGNOSIS AND TESTING - HUB AND BEARING (FRONT) The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure detailed below. The bearing contained in the Unit III front hub/ bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 48 km/h (30 mph).

Fig. 4 Hub Nut 1 2 3 4

HUB NUT NUT LOCK COTTER PIN WAVE WASHER

1 2 3 4 5 6 7

- BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP

REMOVAL - HUB AND BEARING NOTE: Replacement of the Unit III front hub/bearing assembly can be normally done without having to remove the steering knuckle from the vehicle. In the event that the hub/bearing is frozen in the steering knuckle and cannot be removed by hand, it will have to be pressed out of the steering knuckle. The steering knuckle will require removal from the vehicle to allow the hub/bearing assembly to be pressed out of the steering knuckle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL) (1) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. (2) Remove wheel lug nuts, and front tire and wheel assembly. (3) Remove the cotter pin, nut lock and spring washer from the stub axle (Fig. 4). (4) With aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut (Fig. 4). (5) Remove disc brake caliper and adapter as an assembly from knuckle as shown (Fig. 5). Hang assembly out of the way using a bungee cord or wire. Do not allow caliper hang by brake hose. (6) Remove brake rotor from hub and bearing (Fig. 5). (7) Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines.

Fig. 5 Front Brake Mounting

(8) Remove the four hub and bearing mounting bolts from the rear of steering knuckle (Fig. 6). Use care not to come in contact with and damage the ABS tone wheel on the driveshaft stub shaft upon bolt removal. (9) Remove the hub and bearing assembly from the steering knuckle.

2-6

FRONT

HUB / BEARING (Continued)

Fig. 6 Hub And Bearing Mounting Bolts 1 2 3 4

HUB STEERING KNUCKLE MOUNTING BOLTS (4) DRIVESHAFT

INSTALLATION - HUB AND BEARING CAUTION: Hub and bearing assembly mounting surfaces on the steering knuckle and stub axle (Fig. 7) must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly.

(1) Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. (2) Install the 4 hub and bearing mounting bolts from the rear of the knuckle. Equally tighten all 4 mounting bolts in a criss-cross pattern until hub/ bearing assembly is squarely seated against front of steering knuckle. Tighten mounting bolts to a torque of 65 N·m (45 ft. lbs.) (3) Install the brake rotor on the hub and bearing (Fig. 5). (4) Install brake caliper and adapter assembly back over brake rotor and align with mounting holes on steering knuckle (Fig. 5). Install the mounting bolts and tighten to 169 N·m (125 ft. lbs.) torque. (5) Install the hub nut on the end of the stub axle (Fig. 4). With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to Install the mounting bolts and tighten to 244 N·m (180 ft. lbs.) torque. (6) Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (7) Lower vehicle to the ground. (8) Check the front wheel alignment toe setting and reset if not within specifications.

KNUCKLE DESCRIPTION The steering knuckle is a single aluminum casting with legs machined for attachment of the strut assembly, steering linkage, disc brake caliper adapter, lower control arm ball joint and steering linkage (Fig. 1). The hub and bearing assembly is mounted in the center of the steering knuckle using 4 bolts. The driveshaft’s constant velocity (C/V) stub axle is splined through the center of the hub and bearing and is held in place using a nut, nut lock and cotter pin. Service replacement of the front hub and bearing assembly can be done with the steering knuckle remaining on the vehicle.

Fig. 7 Mounting Surfaces (Typical) 1 - BEARING SEAL 2 - STUB AXLE 3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS BEFORE INSTALLING BEARING ASSEMBLY 4 - STEERING KNUCKLE

CAUTION: When installing hub and bearing into steering knuckle, be careful not to damage the bearing seal (Fig. 7) on the outer C/V joint.

OPERATION The steering knuckle pivots with the strut assembly between the lower ball joint and the pivot bearing in the strut assembly. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub and bearing and axle shaft.

FRONT

2-7

KNUCKLE (Continued)

REMOVAL - STEERING KNUCKLE (1) Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Hoisting in Lubrication And Maintenance. (2) Remove the wheel and tire assembly from the vehicle. (3) Remove the cotter pin, nut lock and spring washer from the end of the stub axle and hub nut (Fig. 8).

Fig. 9 Front Brake Mounting 1 2 3 4 5 6 7

- BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP

Fig. 8 Hub Nut 1 2 3 4

HUB NUT NUT LOCK COTTER PIN WAVE WASHER

(4) Have a helper apply the vehicle’s brakes to keep hub from turning, loosen and remove the hub nut (Fig. 8). (5) Remove disc brake caliper and adapter as an assembly from knuckle as shown (Fig. 9). Hang assembly out of the way using a bungee cord or wire (Fig. 10). Do not allow caliper to hang by brake hose. (6) Remove nut attaching outer tie rod end to steering knuckle by holding the tie rod end stud while loosening and removing nut with a wrench (Fig. 11). (7) Remove tie rod end from steering knuckle using Remover, Special Tool C-3894–A (Fig. 12). (8) If equipped with antilock brakes, remove the front wheel speed sensor from the steering knuckle (Fig. 13). (9) Remove the two steering knuckle-to-strut clevis bracket attaching bolts. (10) Tip the knuckle outward and remove the driveshaft stub axle from the hub and bearing. Suspend driveshaft straight outward using a bungee cord or wire (Fig. 10). Do not allow driveshaft to hang by inner joint.

Fig. 10 CALIPER AND DRIVESHAFT SUSPENDED 1 2 3 4

HANGER SUSPENDING CALIPER HANGER SUSPENDING DRIVESHAFT DRIVESHAFT BRAKE CALIPER

2-8

FRONT

KNUCKLE (Continued)

Fig. 11 Removing Tie Rod End Attaching Nut 1 2 3 4 5

TIE ROD END STEERING KNUCKLE WRENCH SOCKET TIE ROD END STUD

Fig. 13 Front Wheel Speed Sensor 1 - MOUNTING BOLT 2 - WHEEL SPEED SENSOR 3 - STEERING KNUCKLE

(11) Remove ball joint nut by holding ball joint stud with hex wrench while loosening and removing nut with a wrench (Fig. 14).

Fig. 14 BALL JOINT NUT REMOVAL/INSTALLATION 1 - KNUCKLE 2 - BALL JOINT STUD 3 - LOWER CONTROL ARM

Fig. 12 TIE ROD REMOVAL WITH TOOL C-3894-A 1 - OUTER TIE ROD 2 - SPECIAL TOOL C-3894-A 3 - STEERING KNUCKLE

CAUTION: Do not remove ball joint stud from steering knuckle using a hammer. Damage to the Aluminum knuckle, ball joint or control arm will result. (12) Release ball joint stud from steering knuckle using Remover, Special Tool C-4150A, as shown (Fig. 15).

FRONT

2-9

KNUCKLE (Continued) the four mounting bolts and tighten them to a torque of 65 N·m (45 ft. lbs.). CAUTION: Before installing the knuckle on the ball joint stud, wipe the ball joint stud and knuckle contact area free of any grease or debris, otherwise damage to the knuckle can occur. Use a clean shop cloth with MoparT Brake Parts Cleaner applied to it for proper cleaning. (2) Place the knuckle on the ball joint stud. (3) Install a NEW steering knuckle to ball joint stud nut. Tighten the nut by holding ball joint stud with hex wrench while turning nut with a wrench (Fig. 14). Using a crowsfoot wrench on a torque wrench, tighten the nut to a torque of 108 N·m (80 ft. lbs.). (4) Slide driveshaft stub axle into hub and bearing assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle.

Fig. 15 BALL JOINT RELEASED USING C-4150A 1 - ALUMINUM KNUCKLE 2 - SPECIAL TOOL C-4150A 3 - LOWER CONTROL ARM

CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 16).

(13) Remove the steering knuckle from the vehicle. (14) If the hub and bearing needs to be transferred, remove the four bolts attaching the hub and bearing to the knuckle, then remove the hub and bearing.

INSPECTION - STEERING KNUCKLE Inspect the knuckle for the following: • Cracks or breaks • Dents or damage • Stress marks indicating a bend The front suspension knuckle is not a repairable component of the vehicles front suspension. If bent, broken or damaged in any way, do not attempt to straighten or repair the steering knuckle. It must be replaced. If inspection leads to the hub and bearing, (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING DIAGNOSIS AND TESTING)

Fig. 16 Correctly Installed Eccentric Attaching Bolt 1 2 3 4

STEERING KNUCKLE FLANGED BOLT IN TOP HOLE CAM BOLT IN BOTTOM HOLE STRUT CLEVIS BRACKET

INSTALLATION - STEERING KNUCKLE (1) If the hub and bearing needs to be installed in the knuckle, place the hub and bearing squarely into the center hole of the steering knuckle aligning the threaded mounting holes of the hub and bearing with the mounting holes in the steering knuckle. Install

NOTE: The strut clevis-to-steering knuckle bolts are installed differently on each side. Left hand side bolts are to be installed from vehicle rear to front. Right side bolts are to be installed from vehicle front to rear.

2 - 10

FRONT

KNUCKLE (Continued) (5) Install steering knuckle in clevis bracket of strut damper assembly. Install the strut clevis-tosteering knuckle attaching bolts. Tighten both bolts to a torque of 81 N·m (60 ft. lbs.) plus an additional 1/4 (90°) turn. (6) Install tie rod end into knuckle steering arm. Start nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket (Fig. 11), tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot on a torque wrench (Fig. 17), tighten the tie rod end nut to a torque of 75 N·m (55 ft. lbs.).

(15) Install wheel and tire assembly. Install and tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (16) Lower vehicle. (17) Set front wheel alignment camber and toe as necessary. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

LOWER BALL JOINT DESCRIPTION The ball joint is an integral part of the lower control arm (Fig. 1). The ball joint has a tapered stud that is pressed into the aluminum knuckle. The ball joint stud is threaded on the end for a retainer nut. The ball joint has a non-vented seal boot. The seal boot has an integrated heat shield (Fig. 18).

Fig. 17 Torquing Tie Rod End Attaching Nut (Typical) 1 2 3 4 5

STEERING KNUCKLE TIE ROD END CROWFOOT SOCKET TORQUE WRENCH

(7) If equipped with antilock brakes, install wheel speed sensor and mounting bolt on steering knuckle (Fig. 13). Tighten the speed sensor bolt to a torque of 7 N·m (60 in. lbs.). (8) Install brake rotor on hub and bearing (Fig. 9). (9) Install disc brake caliper and adapter assembly on steering knuckle. Install adapter amounting bolts and tighten to 169 N·m (125 ft. lbs.). (10) Clean any debris from the threads of the outer C/V joint stub axle. (11) Install the washer and hub nut on stub axle. (12) Have a helper apply the vehicle’s brakes to keep hub from turning, then tighten hub nut to a torque of 244 N·m (180 ft. lbs.). (13) Install the spring wave washer on the end of the stub axle. (14) Install the hub nut lock, and a new cotter pin (Fig. 8). Wrap cotter pin prongs tightly around the hub nut lock.

Fig. 18 Ball Joint Seal Boot (Typical) 1 2 3 4

BALL JOINT SEAL BOOT BALL JOINT STUD LOWER CONTROL ARM SHIELD

The ball joint used in the lower control arm of this vehicle is a sealed-for-life ball joint and requires no maintenance lubrication. The ball joint has been lubricated-for-life during the manufacturing process. A special fitting cap is installed on the fill port. This cap must not be removed and replaced with a common zirc fitting. The special cap is there to eliminate the possibility of lubrication latter during the ball joints life, thus damaging the non-vented seal boot. NOTE: The ball joint does not require any type of additional lubrication for the life of the vehicle. No attempt should be made to ever add any lubrication to the lower ball joint.

FRONT

2 - 11

LOWER BALL JOINT (Continued)

OPERATION The ball joint is a pivotal joint on the lower control arm that allows the knuckle to move up and down, and turn with ease.

DIAGNOSIS AND TESTING - LOWER BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the special fitting cap on the bottom of the ball joint and with no mechanical assistance or added force, attempt to rotate the grease fitting. If the ball joint is worn, the grease fitting will rotate easily. If movement is noted, replacement of the ball joint is recommended.

LOWER BALL JOINT SEAL BOOT REMOVAL - BALL JOINT SEAL BOOT (1) Remove steering knuckle from vehicle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE REMOVAL) (2) Using a screw driver or other suitable tool, pry the seal boot off of the ball joint (Fig. 19)

Fig. 20 Ball Joint Seal Boot Installed Position (Typical) 1 2 3 4

BALL JOINT SEAL BOOT BALL JOINT STUD LOWER CONTROL ARM SHIELD

CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. (3) Place Installer, Special Tool 6758, over seal boot and squarely align it with bottom edge of seal boot (Fig. 21). Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. (4) Wipe any grease off the ball joint stem. CAUTION: Do not attempt to install a normal grease zirc in the ball joint an lubricate the joint through the zirc fitting.

Fig. 19 Ball Joint Seal Boot Removal (Typical) 1 2 3 4 5

LOWER CONTROL ARM BALL JOINT STUD SEAL BOOT SCREW DRIVER BALL JOINT ASSEMBLY

INSTALLATION - BALL JOINT SEAL BOOT (1) Place a liberal dab of Mopart Wheel Bearing Grease around the base of the ball joint stem at the socket. (2) Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown (Fig. 20).

(5) Reinstall steering knuckle on vehicle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION)

LOWER CONTROL ARM DESCRIPTION The lower control arm is mounted to the front suspension crossmember using a pivot bolt through the center of the front pivot bushing, and the front suspension cradle crossmember reinforcement traps the rear bushing in the crossmember (Fig. 1).

2 - 12

FRONT

LOWER CONTROL ARM (Continued) (3) Remove the steering knuckle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL) (4) Remove the bolts fastening the power steering cooler to the front suspension cradle crossmember reinforcement (Fig. 22).

Fig. 21 Installing Ball Joint Seal Boot 1 2 3 4

SHIELD SPECIAL TOOL 6758 LOWER CONTROL ARM BALL JOINT SEAL BOOT

The lower control arm is an iron casting with two rubber bushings and a ball joint. The lower control arm front bushing is the spool type and is pressed into the lower control arm. The standard lower control arm rear bushing is a push-on bushing that is pushed over a stem on the rear of the lower control arm. The optional lower control arm rear bushing is a hydro-bushing that is pressed on. It has liquid filled voids that provide more effective dampening than the standard bushing. Vehicles with rear hydrobushings utilize a different lower control arm than vehicles with standard bushings. They have a straight slightly tapered round stem where the hydro-bushing is mounted whereas the standard arm has a straight stem with a squared knob on the end to retain the bushing. The lower control arm ball joint is pressed into the outer end of the arm. The ball joint has a tapered stud and retainer nut for fastening it to the steering knuckle.

OPERATION The lower control arm supports the lower end of the steering knuckle and allows for the up and down movement of the suspension during the jounce and rebound travel. The lower control arm ball joint connects the arm to the steering knuckle.

REMOVAL - LOWER CONTROL ARM (1) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. (2) Remove wheel and tire assembly.

Fig. 22 POWER STEERING COOLER 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER

(5) Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. (6) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 23). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove the reinforcement. (7) Remove the pivot bolt attaching the front bushing of the lower control arm to the front suspension cradle crossmember. (8) Remove the lower control arm.

DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) (1) Remove the lower control arm from the front suspension cradle. (Refer to 2 - SUSPENSION/ FRONT/LOWER CONTROL ARM - REMOVAL) (2) Mount the lower control arm in a vise without using excessive clamping force.

FRONT

2 - 13

LOWER CONTROL ARM (Continued)

Fig. 24 Slit Lower Control Arm Rear Bushing 1 - REAR BUSHING 2 - SLIT CUT IN BUSHING 3 - LOWER CONTROL ARM

Fig. 23 CRADLE CROSSMEMBER REINFORCEMENT ATTACHMENT 1 2 3 4 5 6 7

STEERING GEAR RIGHT LOWER CONTROL ARM LEFT LOWER CONTROL ARM CRADLE CROSSMEMBER REINFORCEMENT REAR CRADLE CROSSMEMBER ISOLATOR BUSHING STABILIZER BAR CRADLE CROSSMEMBER

(3) Using a sharp knife (such as a razor), slit the bushing lengthwise (Fig. 24) to allow its removal from the lower control arm (Fig. 24). (4) Remove the bushing from the lower control arm.

DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) (1) Remove the lower control arm from the front suspension cradle. (Refer to 2 - SUSPENSION/ FRONT/LOWER CONTROL ARM - REMOVAL) (2) Mount the lower control arm in a vise without using excessive clamping force. (3) Install Remover, Special Tool 8460, on hydrobushing as shown (Fig. 25). Removal Pin, Special Tool 8460–3, must extend though hole in center of bushing rear.

Fig. 25 HYDRO-BUSHING REMOVAL 1 2 3 4

REMOVAL PIN (8460-3) BRIDGE (8460-1) HYDRO-BUSHING LOWER CONTROL ARM

(4) Tighten forcing screw of Bridge (Special Tool 8460–1), removing bushing from lower control arm.

INSPECTION - LOWER CONTROL ARM Inspect lower control arm for signs of damage from contact with the ground or road debris. If lower control arm shows any sign of damage, inspect lower control arm for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm casting is serviced only as a complete component. Inspect both lower control arm isolator bushings for severe deterioration, and replace as required. Inspect the rear hydro-bushing for seepage. Both

2 - 14

FRONT

LOWER CONTROL ARM (Continued) type rear bushings are serviceable. If the front bushing fails, the lower control arm must be replaced. Inspect and test the ball joint per the procedure listed in Lower Ball Joint. (Refer to 2 - SUSPENSION/FRONT/LOWER BALL JOINT - DIAGNOSIS AND TESTING)

ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant specified below to the control arm bushing. (1) Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing. This will aid in the installation of the bushing on the lower control arm. (2) With the lower control arm held securely in a vise, install bushing on lower control arm. Install bushing by pushing and rocking the bushing until it is fully installed on lower control arm. Be sure that when bushing is installed it is past the upset on the end of the lower control arm (Fig. 26). (3) The rear bushing of the lower control arm, when correctly installed, is to be positioned on the lower control arm as shown (Fig. 26).

ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) CAUTION: Do not apply grease or any other type of lubricant to the arm stem where the bushing is to be mounted. Such action will reduce proper bushing adhesion to arm. (1) Secure lower control arm in a vise. NOTE: Hydro bushings and grooves on control arm stems are unique for right and left sides. Left side bushing master spline and control arm groove are on the top (when mounted on vehicle). Right side bushing master spline and control arm groove are on the bottom (when mounted on vehicle). (2) Align master spline on bushing inner sleeve with groove on lower control arm rear bushing stem (Fig. 27). Start bushing on stem by hand.

Fig. 27 BUSHING MASTER SPLINE LINED UP WITH GROOVE (RIGHT SIDE SHOWN) 1 - GROOVE 2 - HYDRO-BUSHING 3 - MASTER SPLINE

Fig. 26 Correctly Installed Lower Control Arm Bushing 1 2 3 4 5

ROUND SURFACE OF BUSHING LOWER CONTROL ARM LOWER CONTROL ARM REAR BUSHING UPSET FLAT SURFACE OF BUSHING

(4) Install lower control arm on vehicle. (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM INSTALLATION)

(3) Install Remover/Installer, Special Tool 8460, over bushing and lower control arm as shown (Fig. 28). Engage flange on lower control arm with tips of Bridge, Special Tool 8460–1 as shown (Fig. 28). The contoured side of Installer Cup, Special Tool 8460–2, should be fitted up against rear of the bushing. (4) Begin to tighten forcing screw. As bushing nears lower control arm flange, place Spacer Plate, Special Tool 8460–4 between flange and bushing inner sleeve, straddling the stem as shown (Fig. 29). (5) Install bushing up against Spacer Plate, tightening the bridge forcing screw with a torque wrench until approximately 50 N·m (37 ft. lbs.) torque is

FRONT

2 - 15

LOWER CONTROL ARM (Continued) (2) Install NEW pivot bolt attaching front bushing of lower control arm to front suspension cradle crossmember (Fig. 30). Do not tighten or torque pivot bolt at this time.

Fig. 28 HYDRO-BUSHING INSTALLATION 1 2 3 4

LOWER CONTROL ARM FLANGE INSTALLER CUP (8460-2) BRIDGE (8460-1) HYDRO-BUSHING

Fig. 30 Lower Control Arm Bushing Pivot Bolt Correctly Installed 1 - PIVOT BOLT 2 - LOWER CONTROL ARM 3 - FRONT SUSPENSION CRADLE CROSSMEMBER

Fig. 29 SPACER PLATE POSITIONED 1 2 3 4 5

SPACER PLATE (8460-4) LOWER CONTROL ARM FLANGE BRIDGE (8460-1) INSTALLER CUP (8460-2) HYDRO-BUSHING

reached. This will properly space bushing on the stem in relation to the flange. (6) Back off the forcing screw and remove tool. (7) Install lower control arm on vehicle. (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM INSTALLATION)

INSTALLATION - LOWER CONTROL ARM (1) Position lower control arm assembly into front suspension cradle crossmember guiding bushings into mounting position (Fig. 23).

(3) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 23). Tighten the M-14 size bolts to a torque of 163 N·m (120 ft. lbs.). Tighten the M-12 size bolts to a torque of 108 N·m (80 ft. lbs.). (4) Install the lower control arm rear bushing retainer bolts through reinforcement on each side of each lower control arm rear bushing. Tighten bolts to a torque of 61 N·m (45 ft. lbs.). (5) Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 23). Tighten bolts to a torque of 163 N·m (120 ft. lbs.). (6) Install the power steering cooler (Fig. 22). Tighten bolts to a torque of 11 N·m (100 in. lbs.). (7) Reinstall steering knuckle, brake rotor and caliper. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION) CAUTION: When locating jack stands under lower control arms, do not place the jack stands under the ball joints (Fig. 31). (8) Position jack stands under the lower control arms as close to the ball joints as possible (Fig. 31). Lower the vehicle onto the jack stands until the jack stands are supporting the total weight of the vehicle. (9) Tighten front lower control arm pivot bolt to a torque of 183 N·m (135 ft. lbs.).

2 - 16

FRONT

LOWER CONTROL ARM (Continued) to minimize the body roll of the vehicle during suspension movement. Connecting the stabilizer bar links to the strut assemblies helps reduce the fore-and-aft rate of the stabilizer bar from the rest of the front suspension.

REMOVAL - STABILIZER BAR (1) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. (2) Remove the bolts fastening the power steering cooler to the front suspension cradle crossmember reinforcement (Fig. 32).

Fig. 31 Jack Stands Supporting Vehicle Weight 1 2 3 4

LOWER CONTROL ARMS BALL JOINT JACK STANDS BALL JOINT

(10) Install the wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 NÂˇm (100 ft. lbs.). (11) Raise vehicle, remove jack stands and lower vehicle to the ground. (12) Perform front wheel alignment as necessary. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT STANDARD PROCEDURE)

Fig. 32 POWER STEERING COOLER

STABILIZER BAR

1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER

DESCRIPTION The stabilizer bar interconnects both front struts of the vehicle and is attached to the front crossmember (Fig. 1) . Attachment of the stabilizer bar to the front crossmember is through 2 rubber-isolator cushion bushings and retainers. A double ball jointed stabilizer bar link is used to attach each end of the stabilizer bar to the front strut assemblies. All parts of the stabilizer bar are replaceable as individual components. The stabilizer bar to front crossmember cushion bushings are split for easy removal and installation. The split in the bushings should be positioned toward the rear of the vehicle, with the square corner facing down, when the stabilizer bar is installed.

OPERATION Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel of the vehicle through the stabilizer bar. This helps

(3) Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. (4) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 33). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove the reinforcement. CAUTION: When removing the nut from the stud of the stabilizer bar link, do not allow the stud to rotate in itâ&#x20AC;&#x2122;s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 34).

FRONT

2 - 17

STABILIZER BAR (Continued)

Fig. 34 Stabilizer Bar Link To Stabilizer Bar Attachment 1 2 3 4 5 6

RATCHET WRENCH STRUT STABILIZER BAR LINK NUT STABILIZER BAR

1 2 3 4 5

STEERING GEAR STABILIZER BAR RAISED BEAD FRONT CRADLE CROSSMEMBER RETAINERS

Fig. 33 CRADLE CROSSMEMBER REINFORCEMENT ATTACHMENT 1 2 3 4 5 6 7

STEERING GEAR RIGHT LOWER CONTROL ARM LEFT LOWER CONTROL ARM CRADLE CROSSMEMBER REINFORCEMENT REAR CRADLE CROSSMEMBER ISOLATOR BUSHING STABILIZER BAR CRADLE CROSSMEMBER

(5) Remove the stabilizer bar links from each end of the stabilizer bar (Fig. 34). To do so, place an openend wrench on the flat machined into the linkâ&#x20AC;&#x2122;s mounting stud, then remove the nut while holding the wrench in place. Push each stud out of the hole in the stabilizer bar. (6) Remove the stabilizer bar bushing (cushion) retainers from the front suspension cradle crossmember (Fig. 35). (7) Remove the stabilizer bar and bushings (cushions) as an assembly from the front suspension cradle crossmember.

INSPECTION - STABILIZER BAR Inspect for broken or distorted stabilizer bar bushings (cushions), bushing retainers, and worn or damaged stabilizer bar links.

Fig. 35 Front Stabilizer Bar Retainers

INSTALLATION - STABILIZER BAR NOTE: Two different diameter stabilizer bars are available for this vehicle. Therefore, two different size bushings/cushions are also used. Use the correct bushing/cushion on the correct stabilizer bar.

2 - 18

FRONT

STABILIZER BAR (Continued) (1) If the stabilizer bar to front suspension cradle bushings require replacement at time of inspection, install new bushings before installing stabilizer bar. Bushings are replaced by opening slit on bushings and peeling them off stabilizer bar. Install new bushings on stabilizer bar by spreading bushing at slit and forcing them on the stabilizer bar. Bushings must be installed on stabilizer bar so slit in bushing will be facing toward the rear of vehicle with the square corner toward the ground, when the stabilizer bar is installed on the vehicle (Fig. 36).

Fig. 37 Stabilizer Bar Bushing Retainer Installation 1 2 3 4 5 6 7

SWAY BAR SWAY BAR BUSHING BUSHING SPLIT FRONT SUSPENSION CRADLE BUSHING CUT-OUT BUSHING RETAINER RAISED BEAD

Fig. 36 Correctly Installed Stabilizer Bar To Cradle Bushing 1 - SWAY BAR ISOLATOR BUSHING 2 - SLIT IN SWAY BAR BUSHING 3 - SWAY BAR

(2) Position stabilizer bar into front suspension cradle so stabilizer bar bushings are aligned with depressions in cradle. Install stabilizer bar bushing retainers onto crossmember aligning raised bead on retainer with cutouts in bushings (Fig. 37). Do not tighten Stabilizer bar bushing retainers bolts at this time. (3) Check position of the stabilizer bar in the front suspension cradle. The center of the curved section of the stabilizer bar must be aligned with the raised line in the center of the front suspension cradle (Fig. 38). (4) Install the stabilizer bar link mounting stud through the hole in each end of the stabilizer bar (Fig. 34). CAUTION: When installing the nut on the mounting stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 34).

Fig. 38 Stabilizer Bar Correctly Positioned In Cradle 1 - RAISED BEAD 2 - SWAY BAR 3 - WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE SUSPENSION CRADLE MUST BE IN THE CENTER OF RADIUS IN SWAY BAR 4 - FRONT SUSPENSION CRADLE

(5) Hand-thread the nut on the end of each stabilizer bar link stud. Hold the studs from turning by placing an open-end wrench on the flat machined into the link’s mounting stud, then tighten each nut while holding the wrench in place (Fig. 34). Tighten each nut to a torque of 88 N·m (65 ft. lbs.).

FRONT

2 - 19

STABILIZER BAR (Continued) (6) Tighten the stabilizer bar bushing retainer to cradle attaching bolts (Fig. 35) to 68 N·m (50 ft. lbs.) torque. (7) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 33). Tighten the M-14 size bolts to a torque of 163 N·m (120 ft. lbs.). Tighten the M-12 size bolts to a torque of 108 N·m (80 ft. lbs.). (8) Install the lower control arm rear bushing retainer bolts through reinforcement on each side of each lower control arm rear bushing. Tighten bolts to a torque of 61 N·m (45 ft. lbs.). (9) Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 33). Tighten bolts to a torque of 163 N·m (120 ft. lbs.). (10) Install the power steering cooler (Fig. 32). Tighten bolts to a torque of 11 N·m (100 in. lbs.). (11) Lower the vehicle.

STRUT DESCRIPTION - STRUT ASSEMBLY A Macpherson type strut assembly is used in place of a conventional front suspension’s upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two bolts and nuts going through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies upper mount. The strut assembly includes the components listed in the figure (Fig. 39). Each component is serviced by removing the strut assembly from the vehicle and disassembling it. The coil springs are side-oriented. Springs on the left side of the vehicle have a left-hand wind top-tobottom while springs on the right side have a righthand wind top-to-bottom. This helps provide better vehicle stability during jounce and rebound maneuvers of the front suspension. Left and right springs must not be interchanged. Coil springs are rated sep-

Fig. 39 STRUT ASSEMBLY 1 2 3 4 5 6

NUT UPPER MOUNT PIVOT BEARING UPPER SPRING SEAT UPPER SPRING ISOLATOR COIL SPRING

7 - DUST SHIELD 8 - JOUNCE BUMPER 9 - LOWER SPRING ISOLATOR 10 - STRUT (DAMPER)

2 - 20

FRONT

STRUT (Continued) arately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If the coil springs require replacement, be sure that the springs are replaced with springs meeting the correct load rating and spring rate for the vehicle and its specific options.

OPERATION - STRUT ASSEMBLY The strut assembly cushions the ride of the vehicle, controlling vibration, along with jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper seat and strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly.

DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT) (1) Inspect for damaged or broken coil springs (Fig. 39). (2) Inspect for torn or damaged strut assembly dust boots (Fig. 39). (3) Inspect the coil spring isolator on the lower spring seat for any signs of damage or deterioration. (4) Lift dust boot (Fig. 40) and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly (Fig. 40). Also inspect jounce bumpers for signs of damage or deterioration.

Fig. 40 Strut Assembly Leakage Inspection (Typical) 1 - DUST BOOT 2 - STRUT SHAFT 3 - STRUT FLUID RESERVOIR 4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID LEAKAGE

(3) If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. (4) Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets (Fig. 41).

REMOVAL - STRUT ASSEMBLY WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. (1) Raise the vehicle. See Hoisting in Lubrication and Maintenance. (2) Remove the wheel and tire assembly from location on front of vehicle requiring strut removal.

Fig. 41 Brake Hose And Speed Sensor Cable Routing 1 2 3 4 5 6

- STRUT DAMPER - WHEEL SPEED SENSOR CABLE - ROUTING BRACKET - HYDRAULIC BRAKE HOSE - ATTACHING BOLT - ROUTING BRACKET

FRONT

2 - 21

STRUT (Continued) CAUTION: When removing the nut from the stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 42). (5) Remove the stabilizer bar link from the bracket on the strut assembly (Fig. 42). To do so, place an open-end wrench on the flat machined into the link’s mounting stud, then remove the nut while holding the wrench in place. Push the stud out of the bracket.

Fig. 43 Strut Damper Attachment To Steering Knuckle 1 2 3 4 5

- STRUT CLEVIS BRACKET - ATTACHING BOLTS - TIE ROD END - ROTOR - STEERING KNUCKLE

Fig. 42 Stabilizer Bar Link To Strut Attachment 1 - NUT 2 - STRUT 3 - STABILIZER BAR LINK

CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. (6) Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Fig. 43). (7) Remove the 3 nuts attaching the strut assembly upper mount to the strut tower (Fig. 44) and remove the strut assembly from the vehicle. (8) To disassemble the strut assembly, (Refer to 2 SUSPENSION/FRONT/STRUT - DISASSEMBLY).

DISASSEMBLY - STRUT ASSEMBLY The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer’s instructions closely.

Fig. 44 Strut Assembly To Strut Tower Attaching Nuts (Typical) 1 2 3 4

WINDSHIELD WIPER MODULE STRUT TOWER STRUT MOUNT ATTACHING BOLTS UPPER STRUT MOUNT

WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED.

2 - 22

FRONT

STRUT (Continued) (1) Position the strut assembly in the strut coil spring compressor following the manufacturers instructions. Position the lower hooks on the coil spring first. The strut clevis bracket should be positioned straight outward from the compressor. (2) Turn the upper mount of the strut assembly toward the inside of the compressor as shown to allow positioning of the compressor upper hooks (Fig. 45). Position the upper hooks on top of the coil spring upper seat approximately 1 inch from outside diameter of seat (Fig. 48). Do not allow hooks to be placed closer to edge. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed.

Fig. 46 Retaining Nut Removal/Installation (Typical) 1 - UPPER MOUNT 2 - SPECIAL TOOL 6864

Fig. 45 MOUNT ROTATED AND HOOKS POSITIONED 1 - UPPER MOUNT TURNED TOWARD COMPRESSOR 2 - COMPRESSOR UPPER HOOKS 3 - UPPER SPRING SEAT

(3) Compress the coil spring until all coil spring tension is removed from the upper mount. (4) Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut (Fig. 46). Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. (5) Remove the upper mount from the strut shaft. (6) If the pivot bearing needs to be serviced, remove it from the top of the coil spring upper seat by pulling it straight up. (7) Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring. NOTE: If the coil spring or upper spring seat needs to be serviced, proceed with the next step, otherwise, proceed with step 10.

(8) Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper spring seat. (9) Remove the coil spring from the spring compressor. (10) Remove the dust shield and jounce bumper as an assembly from the strut shaft by pulling both straight up and off the strut shaft. The dust shield cannot be separated from the jounce bumper until after it is removed from strut shaft. (11) Remove the jounce bumper from the dust shield. The jounce bumper is removed from the dust shield by collapsing the dust shield until the jounce bumper can be pulled free from the dust boot. (12) Remove the spring isolator from the lower spring seat on the strut (Fig. 39). (13) Inspect the strut assembly components (Fig. 39) for the following and replace as necessary: • Inspect the strut for any condition of shaft binding over the full stroke of the shaft. • Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. • Check the upper seat for stress cracks and wear. • Check the upper spring isolator for severe deterioration. • Check for binding of the strut assembly pivot bearing. • Inspect the dust shield for rips and deterioration. • Inspect the jounce bumper for cracks and signs of deterioration.

FRONT

2 - 23

STRUT (Continued)

ASSEMBLY - STRUT ASSEMBLY For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer’s instructions closely.

(Fig. 48). This will allow proper clearance for upper mount installation without pinching the hooks in-between the two pieces. Do not allow hooks to be placed closer to edge.

NOTE: Coil Springs on this vehicle are side-oriented. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom. Left and right springs must not be interchanged. NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 5. (1) Place the coil spring in the compressor lower hooks following the manufacturers instructions. Proper orientation of the spring to the strut (once installed) is necessary. Consider the following when placing the coil spring in the compressor: From above, the compressor back is at the 12 o’clock position and you, standing in the front of the machine, are at the 6 o’clock position. Place the lower coil spring end at the 6 o’clock position for both left and right springs. (Fig. 47).

Fig. 48 HOOK PLACEMENT ON UPPER SEAT 1 - HOOKS POSITIONED 1 INCH FROM EDGE 2 - PIVOT BEARING AND UPPER SEAT

(4) Compress the coil spring far enough to allow strut installation. (5) If the pivot bearing has been removed form the upper seat, install the pivot bearing on the top of the upper spring seat (Fig. 49). The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat. Be sure the pivot bearing is sitting flat on the spring seat once mounted.

Fig. 47 SPRING POSITIONED IN COMPRESSOR (RIGHT SPRING SHOWN) 1 - COMPRESSOR LOWER HOOKS 2 - COIL SPRING END

(2) Install the upper seat and upper isolator on top of the coil spring. Position the notch in the perimeter of the upper seat toward the front of the compressor (same 6 o’clock position as in step 1). (3) Position the upper hooks on top of the coil spring upper seat so the upper hooks span approximately 1 inch past outside diameter of upper seat

Fig. 49 PIVOT BEARING INSTALLATION 1 - PIVOT BEARING 2 - UPPER SEAT

(6) Install the spring isolator on the lower spring seat of the strut (Fig. 39).

2 - 24

FRONT

STRUT (Continued) (7) Install the jounce bumper on the strut shaft (Fig. 39). The jounce bumper is to be installed with the small end pointing downward. (8) Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the jounce bumper until the dust shield snaps into the slot on the jounce bumper. The jounce bumper will be at the top of the inner dust boot. Return the dust shield to its fully extended length. (9) Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. The clevis bracket on the strut should point straight outward away from the compressor (to the 6 o’clock position). This position should be within 5° of the lower end tip of the coil spring (Fig. 50). If necessary, reposition the strut or coil spring in the compressor so both of these line up straight outward away from the compressor (to the 6 o’clock position). Install the clamp to hold the strut and coil together.

NOTE: Before releasing the tension the compressor has on the spring, using the following figure as reference (Fig. 51), make sure the upper spring seat, coil spring and strut clevis bracket are all lined up properly (within 5° of one another).

Fig. 51 COMPONENTS LINED UP 1 2 3 4

Fig. 50 COIL SPRING POSITIONING 1 2 3 4 5

FRONT OF VEHICLE END OF RIGHT COIL SPRING AT STRUT LOWER SEAT LOWER SEATS OF STRUTS STRUT CLEVIS BRACKETS END OF LEFT COIL SPRING AT STRUT LOWER SEAT

(10) Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat as shown (Fig. 45). Loosely install the retaining nut on the strut shaft. (11) Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut (Fig. 46). Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 100 N·m (75 ft. lbs.).

IMAGINARY VERTICAL LINE CLEVIS BRACKET END OF COIL SPRING NOTCH IN UPPER SPRING SEAT

(12) Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat are align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. (13) Install strut assembly on the vehicle. (Refer to 2 - SUSPENSION/FRONT/STRUT - INSTALLATION)

INSTALLATION - STRUT ASSEMBLY CAUTION: Front strut coil springs are side-oriented. When installing a strut assembly, make sure the strut being installed has the correct coil spring for that side of the vehicle. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom (Fig. 50). Do not interchange the two sides.

FRONT

2 - 25

STRUT (Continued) (1) Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in shock tower. Install the 3 upper strut mount attaching nut/washer assemblies (Fig. 44). Then using a crow foot. tighten the 3 attaching nuts to a torque of 28 N·m (250 in. lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. NOTE: The strut clevis-to-steering knuckle bolts are installed differently on each side of the vehicle. Left hand side bolts are to be installed from vehicle rear to front. Right side bolts are to be installed from vehicle front to rear. (2) Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Fig. 43). If strut assembly is attached to steering knuckle using a cam bolt, the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Tighten the strut clevis-to-steering knuckle attaching bolts to a

torque of 81 N·m (60 ft. lbs.) plus an additional 1/4 (90°) turn after specified torque is met. (3) Install the stabilizer bar link mounting stud through the bracket on the strut assembly (Fig. 42). CAUTION: When installing the nut on the mounting stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 42). (4) Hand thread the nut on the end of the stabilizer bar link stud. Hold the stud from turning by placing an open-end wrench on the flat machined into the link’s mounting stud, then tighten the nut while holding the wrench in place (Fig. 42). Tighten the nut to a torque of 88 N·m (65 ft. lbs.). (5) Install the hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets (Fig. 41). Tighten the routing bracket attaching bolts to a torque of 13 N·m (10 ft. lbs.). (6) Install the wheel/tire assembly on the vehicle. (7) Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.).

2 - 26

REAR

REAR TABLE OF CONTENTS page REAR DESCRIPTION . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . BUSHINGS REMOVAL . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . HUB / BEARING DESCRIPTION . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . DIAGNOSIS AND TESTING . . . HUB AND BEARING (REAR). REMOVAL . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . JOUNCE BUMPER DESCRIPTION . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . . SHOCK ABSORBER DESCRIPTION . . . . . . . . . . . . . OPERATION. . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . DISASSEMBLY. . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . . . .

. . . .

. 26 . 26 . 27 . 28

. . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . 29 . . . . . .

. . . . . .

. 30 . 30 . 30 . 30 . 31 . 33

. . . .

. 35 . 35 . 35 . 36

. . . . . .

. 36 . 36 . 36 . 36 . 37 . 38

REAR DESCRIPTION - REAR SUSPENSION The rear suspension design on this vehicle uses leaf springs, and a tube and casting axle (Fig. 1) (Fig. 2). The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design. There are 2 different rear suspension designs available: • Front-Wheel-Drive • All-Wheel-Drive The rear axle used on Front-Wheel-Drive applications of this vehicle is mounted to the rear leaf springs using isolator bushings at the axle mounting brackets. The rear axle used on All-Wheel-Drive applications of this vehicle is also mounted to the rear leaf

page SPRING - AWD DESCRIPTION . . . . . . . . . OPERATION. . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . . SPRING - FWD DESCRIPTION . . . . . . . . . OPERATION. . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . . SPRING MOUNTS - FRONT REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . . SPRING MOUNTS - REAR REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . . STABILIZER BAR DESCRIPTION . . . . . . . . . OPERATION. . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . . TRACK BAR DESCRIPTION . . . . . . . . . OPERATION. . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . .

. . . .

. 38 . 38 . 38 . 39

. . . .

. 40 . 40 . 40 . 41

. . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . . . . 43 . . . . . . . . . . . . . . . . . . 43 . . . .

. . . .

. 44 . 44 . 44 . 44

. . . .

. 45 . 45 . 45 . 45

springs, but does not use isolator bushings between the rear axle and the leaf springs. Each side of the rear suspension consists of these major components: • Leaf spring • Jounce bumper • Shock absorber • Hub and bearing • Track bar (one per suspension) • Stabilizer bar (one per suspension)

OPERATION - REAR SUSPENSION This rear suspension is designed to handle the various load requirements of the vehicle yet allow for a comfortable ride. The rear wheel bearings used are similar to the bearings used in the front suspension. A hub and bearing assembly is used.

REAR

2 - 27

REAR (Continued)

Fig. 1 Front-Wheel-Drive Rear Suspension 1 2 3 4 5 6

SHACKLE REAR MOUNT (HANGER) TRACK BAR SPRING PLATE ISOLATOR FRONT MOUNT (HANGER)

7 - LEAF SPRING (MONO-LEAF) 8 - ISOLATOR 9 - FWD REAR AXLE 10 - STABILIZER BAR LINKS 11 - STABILIZER BAR

SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE N·m

Ft. Lbs.

In. Lbs.

Hub And Bearing Mounting Bolts

129

—

Hub And Bearing Axle Hub Nut

244

180

—

Jounce Bumper Mounting Bolt

290

Leaf Spring Front Mount-ToBody Bolts

—

Leaf Spring Front Pivot Bolt

156

115

—

Leaf Spring Plate-To-Axle Bolts

102

—

Leaf Spring Rear Mount-ToBody Bolts

—

Leaf Spring Shackle Plate Nuts

—

Shock Absorber Mounting Bolts

102

—

DESCRIPTION

Fig. 2 All-Wheel-Drive Rear Suspension 1 2 3 4

- SHACKLE - REAR MOUNT (HANGER) - LEAF SPRING (MULTI-LEAF) - AWD REAR AXLE

2 - 28

REAR

REAR (Continued) DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Stabilizer Bar Bushing Retainer Bolts

—

Stabilizer Bar Link Nuts

—

Stabilizer Bar Link Frame Bracket Mounting Bolts

—

Track Bar Bracket-To-Body Mount Bolts

—

Track Bar Pivot Bolts

—

Wheel Mounting (Lug) Nut

135

100

—

SPECIAL TOOLS

Press, Ball Joint C-4212F

BUSHINGS REMOVAL - LEAF SPRING FRONT BUSHING (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 3). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level.

REAR SUSPENSION

REMOVER, HUB/BEARING 8458

REMOVER/INSTALLER, BUSHING 8459

Fig. 3 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6

BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK

REMOVER/INSTALLER, BUSHING 8526 (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle.

REAR

2 - 29

BUSHINGS (Continued) (3) Remove shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). (4) Remove four bolts securing leaf spring front mounting bracket to the body (Fig. 3). (5) Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower it enough to allow access to spring pivot bolt. It may be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place. (6) Remove leaf spring forward pivot bolt, then remove mounting bracket. (7) Straighten the retainer tabs on the bushing (Fig. 4).

Fig. 5 TOOL 8459 MOUNTED FOR BUSHING REMOVAL 1 2 3 4 5 6 7 8

Fig. 4 STRAIGHTENED RETAINING TABS 1 - SPRING EYE 2 - RETAINING TABS

(8) Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown (Fig. 5) and tighten Set Screw securing Remover Plate to tool threaded shaft. (9) Tighten nut (Fig. 5), removing bushing from spring eye. (10) Remove the tool from spring, then remove bushing from tool.

INSTALLATION - LEAF SPRING FRONT BUSHING (1) Install by hand NEW bushing in left side of leaf spring eye. (2) Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown (Fig. 6) and tighten

BUSHING BEARING WASHER NUT BODY (8459-1) PIN REMOVER PLATE (8459-2) SET SCREW

Set Screw securing Installer Plate (8459â&#x20AC;&#x201C;3) to tool threaded shaft. (3) Tighten nut (Fig. 6), installing bushing in spring eye. Tighten nut until bushing is fully seated and bushing flange bottoms against spring eye. Do not over-tighten causing tool and bushing to bind. (4) Remove Remover/Installer from the bushing and leaf spring. (5) Bend the retainer tabs on bushing outward against spring eye. (6) Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting. (7) Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time. (8) Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the

2 - 30

REAR

BUSHINGS (Continued) Front-Wheel-Drive vehicles with antilock brakes have an internally mounted wheel speed sensor and tone wheel. This hub and bearing can be identified by the rounded cap and molded in connector on the rear of the assembly (Fig. 7). The sensor and tone wheel cannot be serviced separately from the hub and bearing.

Fig. 6 TOOL 8459 MOUNTED FOR BUSHING INSTALLATION 1 2 3 4 5 6 7 8

NUT WASHER BEARING LEAF SPRING EYE BUSHING INSTALLER PLATE (8459-3) PIN BODY (8459-1)

body, Install the mounting bolts (Fig. 3). Tighten the four mounting bolts to 61 N·m (45 ft. lbs.) torque. (9) Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install shock absorber lower mounting bolt. Do not fully tighten bolt at this time. (10) Lower the vehicle and remove hoist arms and block of wood from under vehicle. (11) Tighten the spring front pivot bolt to 156 N·m (115 ft. lbs.) torque. (12) Tighten the lower shock absorber mounting bolt to 102 N·m (75 ft. lbs.) torque.

HUB / BEARING DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one-piece sealed unit, or hub and bearing unit type assembly. The hub and bearing is mounted to the center of the rear axle using 4 mounting bolts. It has five wheel mounting studs on the hub flange. All-Wheel-Drive vehicles have a hub and bearing unit with a splined hole in the center of the hub for rear driveshaft stub axle acceptance.

Fig. 7 HUB AND BEARING - FWD WITH ABS

OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire and wheel assembly, and disc brake rotor to the vehicle. On All-Wheel-Drive vehicles, the splined mating of the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel. Front-Wheel-Drive vehicles equipped with antilock brakes have a wheel speed sensor and tone wheel mounted to the rear of the hub and bearing. The tone wheel rotates with the hub which is sensed by the wheel speed sensor.

DIAGNOSIS AND TESTING - HUB AND BEARING (REAR) The bearing contained in the hub and bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and

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HUB / BEARING (Continued) unload the bearings and change the noise level. When bearing damage is slight, the noise is usually not noticeable at speeds above 48 km/h (30 mph).

(6) If hub and bearing cannot be removed from the axle by hand, use Remover, Special Tool 8458 (Fig. 9) and following procedure to press the hub and bearing out of the axle.

REMOVAL - HUB AND BEARING FRONT-WHEEL-DRIVE VEHICLES (1) Raise vehicle. See Hoisting in Lubrication and Maintenance. (2) Remove wheel and tire. (3) Remove brake drum or disc brake caliper and rotor from hub and bearing. Refer to Brakes. (4) If equipped with antilock brakes, perform the following: (a) Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 8). (b) Push up on metal retaining clip (Fig. 8) until it bottoms. This will release wheel speed sensor head from hub and bearing. (c) While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing.

Fig. 9 REMOVAL USING SPECIAL TOOL 8458 1 2 3 4 5 6

Fig. 8 SENSOR CONNECTOR AT HUB AND BEARING 1 - SECONDARY SENSOR RETAINING CLIP 2 - METAL SENSOR RETAINING CLIP 3 - HUB AND BEARING

(5) Remove the 4 bolts attaching the hub and bearing to the rear axle. CAUTION: Corrosion may occur between the hub and bearing, and the axle. If this occurs the hub and bearing will be difficult to remove from the axle. If the hub and bearing will not come out of the axle by pulling on it by hand, do not pound on the hub and bearing to remove it from the axle. Damage will occur. Use the following procedure.

THREADED GUIDE PINS 8458-4 HUB AND BEARING LEAF SPRING PLATE FORCING SCREW 8458-3 SCREW MOUNT 8458-2 PUSH PLATE 8458-1

(a) Thread Threaded Guide Pins into hub and bearing mounting bolt holes. (b) Remove the two outboard spring plate bolts. (c) Using the spring plate bolts, install the Screw Mount, Special Tool 8458–2, as shown (Fig. 9). (d) Place Push Plate, Special Tool 8458–1, on ends of Threaded Guide Pins (e) Place a dab of grease in dimple of Push Plate. (f) Tighten the Forcing Screw, Special Tool 8458–3, up against dimple in Push Plate and press hub and bearing out of axle by continuing to tighten screw. (g) Remove the tool. (h) Reinstall the two outboard spring plate bolts. Tighten the bolts to 102 N·m (75 ft. lbs.) torque. (7) Remove the hub/bearing from the rear axle and brake support plate.

ALL-WHEEL-DRIVE VEHICLES (1) Set the parking brake. The parking brake is set to keep the hub and bearing, and axle shaft from rotating when loosening the hub nut.

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HUB / BEARING (Continued) (2) Raise vehicle. See Hoisting in Lubrication And Maintenance. (3) Remove the wheel/tire assembly. (4) Remove the cotter pin and nut retainer (Fig. 19) from the stub shaft of the outer C/V joint. (5) Remove the spring washer (Fig. 18) from the stub shaft of the outer C/V joint. (6) Remove the hub nut and washer (Fig. 16) from the stub shaft of the outer C/V joint. (7) Remove the 6 bolts (Fig. 17) mounting the driveshaft inner joint to the output shaft of the rear drive line module. (8) Remove the rear wheel speed sensor (Fig. 20) from the rear hub/bearing. (9) Release the parking brake. (10) Remove the disc brake caliper to adapter guide pin bolts (Fig. 15). (11) Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter (Fig. 14). (12) Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 10).

(15) Remove the hub/bearing to axle mounting bolts (Fig. 13). CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle by pulling on it by hand, do not pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in noise or failure of the hub/bearing. To remove a hub/bearing which is corroded to the axle, lightly tap the disc brake caliper adapter using a soft faced hammer. This will remove both the disc brake caliper adapter and hub/bearing from the axle. The hub/bearing will then need to be removed from the caliper adapter. (16) Remove the hub/bearing from the axle. (Fig. 12). (17) If the disc brake caliper adapter and hub/ bearing were removed as an assembly from the axle and the hub/bearing cannot be removed from the adapter by hand, use the following procedure to remove it from the adapter. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of hub/bearing (Fig. 11). Do not position special tool on inner race of hub/bearing. Lightly strike Remover, Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter.

Fig. 10 Correctly Supported Caliper 1 2 3 4 5

- WIRE - CALIPER - ADAPTER - ROTOR - INNER FENDER

Fig. 11 Hub/Bearing Removal From Caliper Adapter (13) Remove the rotor from the hub/bearing. (14) Remove driveshaft from rear drive line module and hub/bearing. Driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the drive line module. Then, slide the outer joint of the driveshaft out of the hub/bearing.

1 2 3 4

SPECIAL TOOL 8214-1 PARK BRAKE CABLE DISC BRAKE CALIPER ADAPTER HUB/BEARING

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HUB / BEARING (Continued)

INSTALLATION - HUB AND BEARING FRONT-WHEEL-DRIVE VEHICLES (1) Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle. (2) Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. (3) Align the rear hub and bearing with the 4 mounting bolts and start mounting bolts into hub and bearing. Tighten the 4 bolts in a crisscross pattern until the hub nd bearing and brake support plate is fully and squarely seated onto flange of rear axle. Tighten the 4 mounting bolts to a torque of 129 N·m (95 ft. lbs.) NOTE: If equipped with antilock brakes, make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. (4) If the vehicle is equipped with antilock brakes, perform the following: (a) If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. (b) Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. (c) Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side (Fig. 8). (5) Install brake drum or disc brake rotor and brake caliper. Refer to Brakes. (6) Install wheel and tire. Tighten the wheel nuts in the proper sequence to a torque of 135 N·m (100 ft. lbs.). (7) Adjust the rear brakes as necessary. Refer to Brakes. (8) Lower vehicle. (9) Road test vehicle to ensure proper operation of brakes.

ALL-WHEEL-DRIVE VEHICLES (1) Install hub/bearing on end of axle. (Fig. 12). (2) Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 hub/ bearing mounting bolts (Fig. 13) until the disc brake caliper adapter and hub/bearing are squarely seated against the axle. Then tighten the hub/bearing mounting bolts to a torque of 129 N·m (95 ft. lbs.). (3) Install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the drive-

Fig. 12 Hub/Bearing Removal And Installation 1 - PARK BRAKE BRAKE SHOE 2 - HUB/BEARING 3 - PARK BRAKE BRAKE SHOE

Fig. 13 Hub/Bearing Mounting Bolts 1 2 3 4

- HUB/BEARING - AXLE - MOUNTING BOLTS - CALIPER ADAPTER

shaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft the drive line module. (4) Install rotor on hub/bearing. (5) Carefully lower disc brake caliper and brake shoes over rotor and onto caliper adapter by reversing the removal procedure (Fig. 14). CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts.

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HUB / BEARING (Continued)

Fig. 14 Removing / Installing Caliper 1 2 3 4 5 6 7

- LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST - DISC BRAKE CALIPER - ADAPTER ABUTMENT - OUTBOARD BRAKE SHOE HOLD DOWN CLIP - OUTBOARD BRAKE SHOE - ROTOR - ADAPTER

(6) Install the disc brake caliper guide pin bolts (Fig. 15). Tighten the guide pin bolts to a torque of 22 N·m (192 in. lbs.).

Fig. 16 Hub Nut And Washer 1 2 3 4 5

- CALIPER - HUB NUT - WASHER - ROTOR - ADAPTER

(9) Set the park brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting nuts. (10) Raise vehicle. (11) Tighten the driveshaft inner joint to drive line module output shaft mounting bolts (Fig. 17) to a torque of 61 N·m (45 ft. lbs.).

Fig. 15 Caliper Guide Pin Bolts 1 2 3 4 5

- STUD PIN BOLTS - DISC BRAKE CALIPER - DRIVESHAFT - AXLE - DISC BRAKE CALIPER ADAPTER

(7) Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut (Fig. 16) on the stub shaft of the outer C/V joint. (8) Lower vehicle.

Fig. 17 Driveshaft Attachment To Driveline Module 1 2 3 4

DRIVESHAFT BOLTS DRIVE LINE MODULE DRIVESHAFT INNER JOINT

(12) Tighten the outer C/V joint hub nut (Fig. 16) to a torque of 244 N·m (180 ft. lbs.).

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HUB / BEARING (Continued) (13) Install the spring washer (Fig. 18) on the stub shaft of the outer C/V joint.

Fig. 20 Wheel Speed Sensor Fig. 18 Spring Washer 1 2 3 4

HUB NUT STUB SHAFT ROTOR SPRING WASHER

(14) Install the nut retainer and cotter pin (Fig. 19) on the stub shaft of the outer C/V joint.

1 - MOUNTING BOLT 2 - WHEEL SPEED SENSOR

(17) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (18) Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. (19) Road test vehicle to ensure proper operation of the brake system.

JOUNCE BUMPER DESCRIPTION There are two jounce bumpers used in the rear suspension. One mounts to each frame rail above the rear axle.

OPERATION Fig. 19 Cotter Pin And Nut Retainer 1 2 3 4 5

CALIPER COTTER PIN ROTOR NUT RETAINER OUTER C/V JOINT

(15) Install the wheel speed sensor on the hub/ bearing and adapter. Install the wheel speed sensor attaching bolt (Fig. 20). Tighten the wheel speed sensor attaching bolt to a torque of 12 N·m (105 in. lbs). (16) Install wheel and tire.

The jounce bumper limits suspension travel and metal-to-metal contact of the rear axle with the frame under full jounce conditions.

REMOVAL - AWD AND HEAVY DUTY (1) Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise (Fig. 21). (2) Remove the jounce bumper from the frame rail.

REMOVAL - FRONT-WHEEL-DRIVE (1) Remove the bolt attaching the jounce bumper to frame rail (Fig. 22). (2) Remove the jounce bumper from the frame rail.

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JOUNCE BUMPER (Continued)

SHOCK ABSORBER DESCRIPTION There is one shock absorber on each side of the rear suspension. The top of each shock absorber is bolted to the frame rail. The bottom of each shock absorber is bolted to the rear axle. This vehicle is available with either standard type or load-leveling shock absorbers. On the exterior, load-leveling shock absorbers are larger in diameter than standard shock absorbers. The load-leveling shock absorbers mount the same as the standard shock absorbers.

OPERATION Fig. 21 Jounce Bumper 1 - JOUNCE BUMPER

The shock absorber dampens jounce and rebound motions of the spring and suspension. Each load-leveling shock absorber is a self-leveling, self-contained vehicle leveling system and shock absorber combined. It does not require an external compressor, hoses, or height leveling sensors. All the height leveling sensors, hydraulic pump, etc., are contained inside the shock absorber. It uses road inputs (bumps, stops, starts, turns, acceleration, deceleration, etc.) to activate pumping, which results in the extension and compression of the shock absorber.

REMOVAL - SHOCK ABSORBER (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the axle.

Fig. 22 Jounce Bumper - FWD 1 - JOUNCE BUMPER

INSTALLATION - AWD AND HEAVY DUTY (1) Install jounce bumper through bumper support plate and thread into welded nut in frame rail. (2) Tighten the jounce bumper to 33 NÂˇm (290 in. lbs.) torque.

INSTALLATION - FRONT-WHEEL-DRIVE (1) Hook the forward end of the jounce bumper bracket in the mounting hole of the frame rail, then install the mounting bolt in the opposite end, securing the bumper to the frame rail. Tighten the jounce bumper mounting bolt to 33 NÂˇm (290 in. lbs.) torque.

NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by adjusting the support jack. If the lower shock absorber bolt deflects downward during removal, lower the axle by adjusting the support jack. (3) Remove the shock absorber lower mounting bolt. (4) While holding shock absorber, remove the shock absorber upper mounting bolt and shock absorber.

DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) (1) Remove the shock absorber from the vehicle. (2) Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Driver, Special Tool 8526-2, on the tip of the Ball Joint Press screw drive as shown (Fig. 23).

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SHOCK ABSORBER (Continued)

ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) (1) Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Driver, Special Tool 8526-2, on the tip of the Ball Joint Press screw drive as shown (Fig. 25). Position the Driver this way to seat the bushing to its correct depth.

Fig. 23 Special Tools Positioned For Removal 1 - SCREW DRIVE

NOTE: It works well to place the Ball Joint Press, Special Tool C-4212F, in a bench vise as shown (Fig. 23) to perform this procedure. (3) Place the shock absorber upper mounting eye in the Receiver so the notch in the Receiver clears the shock absorber body (Fig. 24).

Fig. 25 Special Tools Positioned For Installation 1 - SCREW DRIVE

(2) Place the shock absorber upper mounting eye in the Receiver so the notch in the Receiver clears the shock absorber body (Fig. 26).

Fig. 24 Removing Bushing From Shock Absorber 1 - SCREW DRIVE 2 - SHOCK ABSORBER 3 - NOTCH

(4) Tighten the screw drive until the Driver contacts the outer circumference of the bushing evenly (Fig. 24). Continue to tighten the screw drive until the bushing is pressed completely out of the shock absorber eye and into the Receiver. (5) Back off the screw drive and remove the bushing from the Receiver.

Fig. 26 Installing Bushing In Shock Absorber 1 2 3 4

BUSHING SCREW DRIVE SHOCK ABSORBER NOTCH

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REAR

SHOCK ABSORBER (Continued) (3) Position the bushing between the shock absorber eye and the Driver (Fig. 26). Tighten the screw drive until the Driver, bushing, and shock absorber eye are touching and squarely aligned. (4) Press the bushing into the shock absorber eye until the Driver bottoms against the face of the eye. (5) Back off the Ball Joint Press screw drive and remove the shock absorber from the press. (6) Install the shock absorber on the vehicle. Refer to REMOVAL AND INSTALLATION in this section for the procedure.

INSTALLATION - SHOCK ABSORBER (1) While holding shock absorber in position against the frame rail, install the shock absorber upper mounting bolt. (2) Install the shock absorber lower mounting bolt securing the lower end of the shock absorber to the axle. (3) Remove the support jack. (4) Lower the vehicle to the ground so the full curb weight of the vehicle is supported by the suspension. (5) Tighten the upper and lower shock absorber mounting bolt to a torque of 101 NÂ·m (75 ft. lbs.).

Fig. 27 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6

BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK

SPRING - AWD DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design depending on model and options. Since the rear springs come in various designs and rates, be sure the correct spring is in use.

NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). (3) Begin removal of the shock absorber lower mounting bolt (Fig. 28).

OPERATION The leaf spring controls ride quality and maintains ride height.

REMOVAL - AWD (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 27). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing spring replacement. Jack pad should just contact axle.

Fig. 28 Rear Shock Absorber Mounting Bolt 1 - SHOCK BOLT

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SPRING - AWD (Continued) (4) Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. (5) Loosen and remove the axle plate bolts from the rear axle (Fig. 29).

Fig. 30 All-Wheel-Drive Rear Suspension 1 2 3 4

- SHACKLE - REAR MOUNT (HANGER) - LEAF SPRING (MULTI-LEAF) - AWD REAR AXLE

Fig. 29 Axle Plate Bolts 1 2 3 4

- LEAF SPRING - AXLE PLATE BOLTS (4) - AXLE PLATE - AXLE

(6) Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free. (7) Loosen and remove the 4 bolts at the front mount of the rear leaf spring (Fig. 27). (8) Loosen and remove the 2 bolts and the 2 pin nuts from the spring shackle for the rear leaf spring (Fig. 30). Then remove the inner half of the spring shackle from the outer half hanger of the spring hanger and the spring. (9) Remove the rear leaf spring from the outer half of the spring shackle. (10) Remove the leaf spring from the vehicle. (11) Loosen and remove the pivot bolt from the front mount of the rear leaf spring. (Fig. 31).

INSTALLATION - AWD CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. (1) Install the front eyelet of the rear leaf spring into the spring mount. Install the pivot bolt and nut. Do not tighten the pivot bolt at this time. (2) Position the front spring mount for the rear leaf spring against the floor pan of the vehicle. Install the 4 mounting bolts for the front spring mount (Fig. 27). Tighten the 4 mounting bolts to a torque of 61 NÂˇm (45 ft. lbs.).

Fig. 31 Leaf Spring Front Mount (Typical) 1 - LEAF SPRING 2 - SPRING MOUNT

(3) Install the rear of the leaf spring onto the outer half of the rear shackle. Install the inner half of the rear hanger. Install the pin nuts and bolts on the rear shackle, but do not tighten at this time. (4) Raise axle assembly into correct position with axle centered under spring locator post. (5) Install axle plate bolts (Fig. 29). Tighten bolts to 101 NÂˇm (75 ft. lbs.) torque. (6) Install shock absorber bolts. Do not tighten at this time. (7) Lower the vehicle and remove hoist arms and block of wood from under vehicle.

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SPRING - AWD (Continued) CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown below. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the torque specification listed below. This sequence must be followed to properly seat the bushings into the springs and to avoid bending the spring hanger. (8) Tighten the spring front pivot bolt to 156 N路m (115 ft. lbs.) torque. (9) Tighten rear spring shackle pin nuts to 61 N路m (45 ft. lbs.) torque. (10) Tighten rear spring shackle inner to outer half retaining bolts to 61 N路m (45 ft. lbs.) torque. (11) Tighten the lower shock absorber mounting bolt to 102 N路m (75 ft. lbs.) torque.

SPRING - FWD DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design depending on model and options. Since the rear springs come in various designs and rates, be sure the correct spring is in use.

Fig. 32 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6

BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK

OPERATION The leaf spring controls ride quality and maintains ride height.

REMOVAL - FWD (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 32). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing spring replacement. Jack pad should just contact axle. (3) Remove the shock absorber lower mounting bolt (Fig. 33). NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle).

Fig. 33 Rear Shock Mounting Bolt 1 - SHOCK BOLT

(4) Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. (5) Loosen and remove the spring plate bolts from the rear axle (Fig. 34). (6) Remove the spring plate from the rear axle and the leaf spring (Fig. 35). (7) Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free.

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2 - 41

SPRING - FWD (Continued)

Fig. 34 Spring Plate Bolts 1 - SPRING PLATE

Fig. 36 Rear Spring Hanger 1 - SHACKLE PLATE 2 - SPRING HANGER

(2) Raise front of spring and install four mounting bolts (Fig. 32). Tighten bolts to 61 NÂˇm (45 ft. lbs.) torque. (3) Install rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. (4) Verify lower leaf spring isolator is in position. (5) Raise axle into correct position on leaf spring with axle centered under spring locator post (Fig. 37).

Fig. 35 Spring Plate 1 - SPRING PLATE

(8) Loosen and remove the 4 bolts securing the front mount of the leaf spring to the vehicle (Fig. 32). (9) Loosen and remove the nuts from the spring hanger (Fig. 36) for the rear leaf spring. Then remove the hanger plate from the hanger and remove the spring from the spring hanger (Fig. 36). (10) Remove the leaf spring from the vehicle. (11) Loosen and remove the pivot bolt from the front mount of the rear leaf spring. Remove mount.

INSTALLATION - FWD (1) Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten at this time. CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring.

Fig. 37 Leaf Spring Locator Post 1 - LEAF SPRING ISOLATOR 2 - LEAF SPRING 3 - LOCATOR POST

(6) Verify that the leaf spring isolator is correctly positioned in the spring plate. (7) Install spring plate in position on the spring (Fig. 34).

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SPRING - FWD (Continued) (8) Install spring plate bolts (Fig. 34). Tighten bolts to 101 N·m (75 ft. lbs.) torque. (9) Install lower shock absorber bolt. Do not tighten at this time. (10) Remove jack under axle. (11) Lower the vehicle and remove hoist arms and block of wood from under vehicle. CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown below. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the torque specification listed below. This sequence must be followed to properly seat the bushings into the springs and to avoid bending the spring hanger. (12) Tighten the spring front pivot bolt to 156 N·m (115 ft. lbs.) torque. (13) Tighten rear spring shackle pin nuts to 61 N·m (45 ft. lbs.) torque. (14) Tighten rear spring shackle inner to outer half retaining bolts to 61 N·m (45 ft. lbs.) torque. (15) Tighten the lower shock absorber mounting bolt to 102 N·m (75 ft. lbs.) torque.

SPRING MOUNTS - FRONT REMOVAL (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 38). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle. (3) Remove shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). (4) Remove four bolts securing leaf spring front mounting bracket to the body (Fig. 38). (5) Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower it enough to allow access to spring pivot bolt. It may

Fig. 38 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6

BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK

be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place. (6) Remove leaf spring forward pivot bolt, then remove mounting bracket.

INSTALLATION (1) Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting. (2) Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time. (3) Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the body, Install the mounting bolts (Fig. 38). Tighten the four mounting bolts to 61 N·m (45 ft. lbs.) torque. (4) Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install

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SPRING MOUNTS - FRONT (Continued) shock absorber lower mounting bolt. Do not fully tighten bolt at this time. (5) Lower the vehicle and remove hoist arms and block of wood from under vehicle. (6) Tighten the spring front pivot bolt to 156 N路m (115 ft. lbs.) torque. (7) Tighten the lower shock absorber mounting bolt to 102 N路m (75 ft. lbs.) torque.

(2) Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand, support the weight of the axle and leaf spring. (3) Remove the lower mounting bolt from the shock absorber. (4) Remove the bolts attaching the leaf spring rear mount to the body of the vehicle (Fig. 41).

SPRING MOUNTS - REAR REMOVAL (1) Remove the attaching nuts and bolts from the leaf spring rear shackle (Fig. 39) and (Fig. 40).

Fig. 41 Rear Spring Mount 1 - LEAF SPRING MOUNT

(5) Lower the jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing.

Fig. 39 Leaf Spring Shackle Nuts (FWD) 1 - SHACKLE PLATE

INSTALLATION CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the specified torque. This sequence must be followed to avoid bending the spring hanger. (1) For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten rear spring mount bolts to 61 N路m (45 ft. lbs.). Tighten shackle nuts to 61 N路m (45 ft. lbs.).

Fig. 40 All-Wheel-Drive Rear Suspension 1 2 3 4

- SHACKLE - REAR MOUNT (HANGER) - LEAF SPRING (MULTI-LEAF) - AWD REAR AXLE

2 - 44

REAR

STABILIZER BAR DESCRIPTION (1) Front-wheel-drive models use a stabilizer bar that is mounted behind the rear axle. All-wheel-drive models use a stabilizer bar that is mounted in front of the rear axle. The stabilizer bar interconnects both sides of the rear axle and attaches to the rear frame rails using 2 rubber isolated link arms. Both type stabilizer bars have the same basic components. Attachment to the rear axle tube, and rear frame rails is through rubber-isolated bushings. The 2 rubber isolated links are connected to the rear frame rails by brackets. These brackets are bolted to the bottom of the frame rails.

OPERATION Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel to reduce body roll.

REMOVAL - AWD (1) Raise vehicle. See Hoisting in Lubrication and Maintenance. (2) Remove the bolts securing the stabilizer bar to links on each end of the bar. (3) While holding the stabilizer bar in place, remove the bolts that attach the stabilizer bar bushing retainers to the rear axle (Fig. 42). (4) Remove the stabilizer bar from the vehicle. (5) Remove the bushings from the bar utilizing the slits in the bushings. (6) If the links need to be serviced, remove the upper link arm to bracket bolt. Then remove link arm from frame rail attaching bracket.

REMOVAL - FWD (1) Raise vehicle. See Hoisting in Lubrication and Maintenance. (2) Remove the bolts securing the stabilizer bar to links on each side of bar. (3) While holding the stabilizer bar in place, remove the bolts that attach the stabilizer bar bushing retainers to the rear axle. (4) Remove the stabilizer bar from the vehicle.

INSTALLATION - AWD (1) Install bushings on stabilizer bar utilizing slits in bushings. (2) Install the stabilizer bar on the rear axle (Fig. 42).

Fig. 42 REAR STABILIZER BAR MOUNTING TO AWD AXLE 1 2 3 4

- RETAINER - BUSHING - AWD AXLE - STABILIZER BAR

(3) Install the bushing retainers over bushings and aligning bolt holes. (4) Install bushing retainers bolts. Do not tighten at this time. (5) Install bolts connecting links to stabilizer bar. Do not tighten at this time. (6) Lower the vehicle so that the full weight of the vehicle is on all four tires. With the vehicle at its curb height, tighten the following bolts to the torques listed: • Stabilizer bar bushing retainer-to-axle bracket bolts — 61 N·m (45 ft. lbs.) • Stabilizer bar-to-link bolts — 61 N·m (45 ft. lbs.)

INSTALLATION - FWD (1) Lift the stabilizer bar onto the rear axle and install the two retainer mounting bolts. DO NOT TIGHTEN. (2) Install the bolts attaching the stabilizer bar links to the stabilizer bar. DO NOT TIGHTEN. (3) Lower the vehicle so that the full weight of the vehicle is on all four tires. With the vehicle at its curb height, tighten the following bolts to the torques listed: • Stabilizer bar bushing retainer-to-axle bracket bolts — 61 N·m (45 ft. lbs.) • Stabilizer bar-to-link — 61 N·m (45 ft. lbs.)

REAR

TRACK BAR

2 - 45

with the head of the bolt facing toward the rear of the vehicle (Fig. 45) . Do not tighten.

DESCRIPTION On front-wheel-drive applications of this vehicle that are equipped with single leaf rear springs, a track bar is used on the rear axle (Fig. 1). The track bar connects the rear axle to the frame/ body of the vehicle. The track bar is isolated from the body of the vehicle by an isolator bushing located in each end of the track bar.

OPERATION The track bar prevents excessive side-to-side movement of the rear axle. The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle.

REMOVAL (1) Remove the nut and bolt mounting the track bar to the rear axle (Fig. 43) .

Fig. 44 Track Bar Installation 1 - TRACK BAR REPLACEMENT

Fig. 43 Track Bar Mounting To Axle 1 - LOWER TRACK BAR BOLT INSTALLATION

Fig. 45 Track Bar Bolt Installation 1 - TRACK BAR BOLT

(2) Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar from the track bar mount.

INSTALLATION (1) Install the track bar first into the body mount for the track bar (Fig. 44) . Install the track bar bolt

(2) Install the track bar into its mounting bracket on the rear axle (Fig. 43) . Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. (3) Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels. Tighten both track bar attaching bolts to a torque of 95 NÂˇm (70 ft. lbs.).

2 - 46

WHEEL ALIGNMENT

WHEEL ALIGNMENT TABLE OF CONTENTS page WHEEL ALIGNMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 49 SUSPENSION AND STEERING . . . . . . . . . . . . 49

page STANDARD PROCEDURE . . . . . . . WHEEL ALIGNMENT . . . . . . . . . CURB HEIGHT MEASUREMENT SPECIFICATIONS . . . . . . . . . . . . .

. . . .

. 51 . 51 . 54 . 55

WHEEL ALIGNMENT DESCRIPTION - WHEEL ALIGNMENT Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle’s front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer’s instructions should always be followed to ensure accuracy of the alignment, except when DaimlerChrysler Corporation’s wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: • Front Camber (with camber bolt package and standard procedure) • Front Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement in this section for additional information. Typical wheel alignment angles and measurements are described in the following paragraphs.

CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly (Fig. 1). Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. • Excessive negative camber will cause tread wear at the inside of the tire. • Excessive positive camber will cause tread wear on the outside of the tire.

Fig. 1 Camber 1 - WHEELS TILTED OUT AT TOP 2 - WHEELS TILTED IN AT TOP

CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is +0.3° and the right camber is 0.0°, the cross camber would be +0.3°.

WHEEL ALIGNMENT

2 - 47

WHEEL ALIGNMENT (Continued)

CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly (Fig. 2). • Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. • Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster.

Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equally distant.

Fig. 3 Toe Fig. 2 Caster

1 - TOE-IN 2 - TOE-OUT

CROSS CASTER Cross caster is the difference between left and right caster.

TOE Toe is the inward or outward angle of the wheels as viewed from above the vehicle (Fig. 3). • Toe-in is produced when the front edges of the wheels on the same axle are closer together than the rear edges. • Toe-out is produced when the front edges of the wheels on the same axle are farther apart than the rear edges.

TOE-OUT ON TURNS Toe-out on turns is the relative positioning of the front wheels while steering through a turn (Fig. 4). This compensates for each front wheel’s turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing

2 - 48

WHEEL ALIGNMENT

WHEEL ALIGNMENT (Continued) and undue tire wear when steering a vehicle through a turn.

Fig. 4 Toe-Out On Turns 1 - TOE-OUT ON TURNS

Fig. 5 S.A.I. and I.A. 1 - S.A.I. 2 - CAMBER 3 - I.A.

DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension’s jounce and rebound travel. As the vehicle’s suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged.

STEERING AXIS INCLINATION (S. A. I.) Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint (Fig. 5). S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause.

INCLUDED ANGLE (I. A.) Included angle is the sum of the S.A.I. angle plus or minus the camber angle, depending on whether or not the wheel has positive or negative camber (Fig. 5). If camber is positive, add the camber angle to the S.A.I. angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut).

THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle’s center line (Fig. 6). The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). • Negative thrust angle means the rear tires are tracking to the left of the front tires. • Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement.

WHEEL ALIGNMENT

2 - 49

WHEEL ALIGNMENT (Continued)

Fig. 6 Thrust Angle

DIAGNOSIS AND TESTING - SUSPENSION AND STEERING CONDITION Front End Whine On Turns

Front End Growl Or Grinding On Turns

Front End Clunk Or Snap On Turns

POSSIBLE CAUSES

CORRECTION

1. Defective wheel bearing

1. Replace wheel bearing

2. Incorrect wheel alignment

2. Check and reset wheel alignment

3. Worn tires

3. Replace tires

1. Defective wheel bearing

1. Replace wheel bearing

2. Engine mount grounding

2. Check for motor mount hitting frame rail and reposition engine as required

3. Worn or broken C/V joint

3. Replace C/V joint

4. Loose wheel lug nuts

4. Verify wheel lug nut torque

5. Incorrect wheel alignment

5. Check and reset wheel alignment

6. Worn tires

6. Replace tires

7. Front strut pin in upper strut mount

7. Replace the front strut upper mount and bearing

1. Loose lug nuts

1. Verify wheel lug nut torque

2. Worn or broken C/V joint

2. Replace C/V joint

3. Worn or loose tie rod

3. Tighten or replace tie rod end

4. Worn or loose ball joint

4. Tighten or replace ball joint

5. Worn/loose control arm bushing

5. Replace control arm bushing

6. Loose stabilizer bar.

6. Tighten stabilizer bar to specified torque

2 - 50

WHEEL ALIGNMENT

WHEEL ALIGNMENT (Continued) CONDITION

POSSIBLE CAUSES

CORRECTION

7. Loose strut mount to body attachment

7. Tighten strut attachment to specified torque

8. Loose crossmember bolts

8. Tighten crossmember bolts to specified torque

1. Defective wheel bearing

1. Replace wheel bearing

2. Incorrect wheel alignment

2. Check and reset wheel alignment

3. Worn tires

3. Replace tires

4. Worn or defective transaxle gears or bearings

4. Replace transaxle gears or bearings

Front End Growl Or Grinding With Vehicle Going Straight At A Constant Speed

1. Engine mount grounding 2. Worn or broken C/V joint

1. Reposition engine as required 2. Replace C/V joint

Front End Whine When Accelerating Or Decelerating

1. Worn or defective transaxle gears or bearings

1. Replace transaxle gears or bearings

Front End Clunk When Accelerating Or Decelerating

1. Worn or broken engine mount

1. Replace engine mount

2. Worn or defective transaxle gears or bearings

2. Replace transaxle gears or bearings

3. Loose lug nuts

3. Verify wheel lug nut torque

4. Worn or broken C/V joint

4. Replace C/V joint

5. Worn or loose ball joint

5. Tighten or replace ball joint

6. Worn or loose control arm bushing

6. Replace control arm bushing

7. Loose crossmember bolts

7. Tighten crossmember bolts to specified torque

8. Worn tie rod end

8. Replace tie rod end

1. Incorrect tire pressure

1. Inflate tires to recommended pressure

2. Incorrect front or rear wheel toe

2. Check and reset wheel toe

3. Worn wheel bearings

3. Replace wheel bearing

4. Worn control arm bushings

4. Replace control arm bushing

5. Excessive friction in steering gear

5. Replace steering gear

6. Excessive friction in steering shaft coupling

6. Replace steering coupler

7. Excessive friction in strut upper bearing

7. Replace strut bearing

1. Unequal tire pressure

1. Inflate all tires to recommended pressure

2. Radial tire lead

2. Perform lead correction procedure

3. Incorrect front wheel camber

3. Check and reset front wheel camber

4. Power steering gear imbalance

4. Replace power steering gear

5. Wheel braking

5. Correct braking condition causing lateral pull

Front End Whine With Vehicle Going Straight At A Constant Speed

Road Wander

Lateral Pull

WHEEL ALIGNMENT

2 - 51

WHEEL ALIGNMENT (Continued) CONDITION Excessive Steering Free Play

Excessive Steering Effort

POSSIBLE CAUSES

CORRECTION

1. Incorrect Steering Gear Adjustment

1. Adjust Or Replace Steering Gear

2. Worn or loose tie rod ends

2. Replace or tighten tie rod ends

3. Loose steering gear mounting bolts

3. Tighten steering gear bolts to specified torque

4. Loose or worn steering shaft coupler

4. Replace steering shaft coupler

1. Low tire pressure

1. Inflate all tires to recommended pressure

2. Lack of lubricant in steering gear

2. Replace steering gear

3. Low power steering fluid level

3. Fill power steering fluid reservoir to correct level

4. Loose power steering pump drive belt

4. Correctly adjust power steering pump drive belt

5. Lack of lubricant in ball joints

5. Lubricate or replace ball joints

6. Steering gear malfunction

6. Replace steering gear

7. Lack of lubricant in steering coupler

7. Replace steering coupler

STANDARD PROCEDURE - WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to ensure proper alignment. (1) Verify that the fuel tank is full of fuel. If the tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment angles. (2) The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. (3) Check the tires on the vehicle. All tires must be the same size and in good condition with approximately the same amount of tread wear. Inflate all the tires to the recommended air pressure. (4) Check the front wheel and tire assemblies for excessive radial runout. (5) Inspect lower ball joints and all steering linkage for looseness, binding, wear or damage. Repair as necessary. (6) Check suspension fasteners for proper torque and retighten as necessary. (7) Inspect all suspension component rubber bushings for signs of wear or deterioration. Replace any faulty bushings or components before aligning the vehicle. (8) Check the vehicle’s curb height to verify it is within specifications. Refer to Curb Height Measurement.

WHEEL ALIGNMENT SETUP (1) Position the vehicle on an alignment rack. (2) Install all required alignment equipment on the vehicle per the alignment equipment manufacturer’s instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle’s alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. (3) Read the vehicle’s current front and rear alignment settings. Compare the vehicle’s current alignment settings to the vehicle specifications for camber, caster and toe-in. (Refer to 2 - SUSPENSION/ WHEEL ALIGNMENT - SPECIFICATIONS) (4) If front camber and caster are not within specifications, proceed to CAMBER AND CASTER below. If caster and camber are within specifications, proceed to TOE which can be found following CAMBER AND CASTER. Rear camber, caster and toe are not adjustable. If found not to be within specifications, reinspect for damaged suspension or body components and replace as necessary.

CAMBER AND CASTER Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle’s suspension components. This is referred to as NET BUILD. The result is no

2 - 52

WHEEL ALIGNMENT

WHEEL ALIGNMENT (Continued) required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If front camber is found not to meet alignment specifications, it can be adjusted using an available camber adjustment bolt package. Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension components for any signs of damage or bending. CAUTION: Do not attempt to adjust the vehicles wheel; alignment by heating, bending or by performing any other modification to the vehicleâ&#x20AC;&#x2122;s front suspension components or body. If camber readings are not within specifications, use the following procedure to install the front camber adjustment bolt package and then adjust front camber. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains 2 flange bolts, 2 cam bolts, 2 dog bone washers, and 4 nuts. This package services both sides of the vehicle. Use the package to attach the strut clevis bracket to the steering knuckle after the strut clevis bracket has been modified. To install and adjust the camber adjustment bolt package, follow the procedure below. (1) Raise the vehicle until its tires are not supporting the weight of the vehicle. (2) Remove the front tire and wheel assemblies.

Fig. 7 Clevis Bracket To Steering Knuckle Attaching Bolts 1 2 3 4 5

- STRUT CLEVIS BRACKET - ATTACHING BOLTS - TIE ROD END - ROTOR - STEERING KNUCKLE

CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations on the sides of the strut clevis bracket (Fig. 8). (4) Using an appropriate grinder and grinding wheel, slot the bottom hole in both sides of the strut clevis bracket (Fig. 8).

CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. (3) Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts (Fig. 7)and discard. Separate the steering knuckle from the strut clevis bracket and position steering knuckle so it is out of the way of the strut.

Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area 1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE 2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON CLEVIS BRACKET 3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE 4 - STRUT CLEVIS BRACKET

WHEEL ALIGNMENT

2 - 53

WHEEL ALIGNMENT (Continued) CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog bone washers from the service package must be used to attach the steering knuckle to the strut after the mounting hole is slotted. (5) Position the knuckle back into the strut clevis bracket. Install a flanged bolt from the service package into the upper mounting hole. Install a cam bolt into the bottom mounting hole. Both bolts should point forward once installed (Fig. 9).

Fig. 10 Dog Bone Washer And Nuts Installed 1 2 3 4

- STEERING KNUCKLE - DOG BONE WASHER - STRUT CLEVIS BRACKET - ATTACHING NUTS

strut to steering knuckle attaching bolts to 81 NÂˇm (60 ft. lbs.) plus an additional 1/4 (90Â°) turn after the required torque is met.

Fig. 9 Package Bolts Correctly Installed (Left Side Shown) 1 2 3 4

STEERING KNUCKLE FLANGED BOLT IN TOP HOLE CAM BOLT IN BOTTOM HOLE STRUT CLEVIS BRACKET

(6) Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then install the nuts onto the bolts from the service package (Fig. 10). Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber, while still allowing the steering knuckle to move in clevis bracket. (7) Repeat the procedure to the other side strut clevis bracket. (8) Reinstall both front tire and wheel assemblies and tighten to specifications. (9) Lower the vehicle. Jounce the front and rear of vehicle an equal amount of times. (10) Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket (Fig. 11). When camber is set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce front and rear of vehicle an equal amount of times and verify front camber setting. Torque both front

Fig. 11 Camber Adjustment Cam Bolt 1 - STEERING KNUCKLE 2 - CLEVIS BRACKET CAM STOP AREAS 3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT

(11) If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting. Toe is adjustable using the following procedure.

TOE (1) Center the steering wheel and lock in place using a steering wheel clamp.

2 - 54

WHEEL ALIGNMENT

WHEEL ALIGNMENT (Continued) CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. (2) Loosen front inner to outer tie rod end jam nuts (Fig. 12). Grasp inner tie rods at serrations and rotate inner tie rods of steering gear (Fig. 12) to set front toe to the preferred toe specification. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICATIONS)

Fig. 12 Front Wheel Toe Adjustment 1 2 3 4 5

INNER TIE ROD SERRATION OUTER TIE ROD JAM NUT OUTER TIE ROD END INNER TIE ROD STEERING KNUCKLE

(3) Tighten tie rod jam nuts (Fig. 12) to 75 NÂ·m (55 ft. lbs.) torque.

(4) Adjust steering gear to tie rod boots at the inner tie rod. (5) Remove steering wheel clamp. (6) Remove the alignment equipment. (7) Road test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull.

STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. (1) Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. (2) When measuring, the maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). (3) Compare the measurements to the specifications listed in the following CURB HEIGHT SPECIFICATIONS chart.

CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE TM4 / 215/70 R 15 TM5 / 215/65 R 16 TTU / 215/60 R 17

FRONT

REAR

754 mm 6 10 mm

770 mm 6 10 mm

29.68 in. 6 0.39 in.

30.31 in. 6 0.39 in.

755 mm 6 10 mm

771 mm 6 10 mm

29.72 in. 6 0.39 in.

30.35 in. 6 0.39 in.

758 mm 6 10 mm

774 mm 6 10 mm

29.84 in. 6 0.39 in.

30.47 in. 6 0.39 in.

CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE TM4 / 215/70 R 15 TM5 / 215/65 R 16

FRONT

REAR

755 mm 6 10 mm

770 mm 6 10 mm

29.72 in. 6 0.39 in.

30.31 in. 6 0.39 in.

756 mm 6 10 mm

771 mm 6 10 mm

29.76 in. 6 0.39 in.

30.35 in. 6 0.39 in.

WHEEL ALIGNMENT

2 - 55

WHEEL ALIGNMENT (Continued)

SPECIFICATIONS WHEEL ALIGNMENT

NOTE: All wheel alignments are to be set at curb height. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

NOTE: All specifications are given in degrees. FRONT WHEEL ALIGNMENT

PREFERRED SETTING

ACCEPTABLE RANGE

+0.10°

-0.30° to +0.50°

0.0°

0.50°

+2.31°

+1.31° to +3.31°

0.0°

1.00°

+0.10°

−0.10° to +0.30°

0.0°

0.06°

PREFERRED SETTING

ACCEPTABLE RANGE

CAMBER*

0.0°

-0.25° to +0.25°

TOTAL TOE* **

0.0°

−0.20° to +0.20°

THRUST ANGLE*

0.0°

-0.30° to +0.30°

CAMBER Cross-Camber (Maximum side-to-side difference) CASTER* Cross-Caster (Maximum side-to-side difference) TOTAL TOE** Maximum side-to-side difference REAR WHEEL ALIGNMENT

Notes: * For reference only. These are non-adjustable angles. ** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out

SUSPENSION

2a - 1

SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION

......................1

page WHEEL ALIGNMENT

.......................3

FRONT SUSPENSION TABLE OF CONTENTS page

page

LOWER BALL JOINT SEAL BOOT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

LOWER BALL JOINT SEAL BOOT DESCRIPTION

(3) Place Installer, Special Tool 6758, over seal boot and squarely align it with bottom edge of seal boot (Fig. 1). Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm.

The lower ball joint seal boot is a two piece unit. It consists of a seal boot and a separate shield that is located in a groove at the top of the seal boot. NOTE: The seal boot should only be replaced if damaged during vehicle service. The entire lower control arm should be replaced if the joint has been contaminated.

REMOVAL (1) Remove steering knuckle from vehicle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - REMOVAL) (2) Remove shield from seal boot by gently pulling on it. (3) Using a screw driver or other suitable tool, pry seal boot off of the lower ball joint.

INSTALLATION (1) Place a liberal dab of Mopart Wheel Bearing Grease around the base of the ball joint stem at the socket. (2) Install a NEW seal boot by hand as far as possible on the ball joint. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed.

Fig. 1 Installing Ball Joint Seal Boot (Typical) 1 2 3 4

SHIELD (NOT ON RG VEHICLE) SPECIAL TOOL 6758 LOWER CONTROL ARM BALL JOINT SEAL BOOT

(4) Wipe any grease off the ball joint stem. (5) Place the shield over the top of the seal boot and stretch it into the groove at the top of the seal boot.

2a - 2

FRONT SUSPENSION

LOWER BALL JOINT SEAL BOOT (Continued) CAUTION: Do not attempt to install a normal grease zirc in the ball joint and lubricate the joint through the zirc fitting. (6) Reinstall steering knuckle on vehicle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION)

WHEEL ALIGNMENT

2a - 3

WHEEL ALIGNMENT TABLE OF CONTENTS page

page

WHEEL ALIGNMENT STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 3

CURB HEIGHT MEASUREMENT . . . . . . . . . . . . 3

WHEEL ALIGNMENT STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle

for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. (1) Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. (2) When measuring, the maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). (3) Compare the measurements to the specifications listed in the following Curb Height Specifications charts.

CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF SUSPENSION TIRE SALES CODE/TIRE SIZE TMM / 215/65 R 16

FRONT

REAR

756 mm ± 10 mm 29.76 in. ± 0.39 in.

772 mm ± 10 mm 30.39 in. ± 0.39 in.

CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF + SER SUSPENSION TIRE SALES CODE/TIRE SIZE

FRONT

REAR

TMM / 215/65 R 16

756 mm ± 10 mm 29.76 in. ± 0.39 in.

771 mm ± 10 mm 30.35 in. ± 0.39 in.

CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE

FRONT

REAR

TMM / 215/65 R 16

755 mm ± 10 mm 29.72 in. ± 0.39 in.

770 mm ± 10 mm 30.31 in. ± 0.39 in.

DIFFERENTIAL & DRIVELINE

3-1

DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page

page

HALF SHAFT - FRONT . . . . . . . . . . . . . . . . . . . . . 1 HALF SHAFT - REAR . . . . . . . . . . . . . . . . . . . . . 16

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 24 REAR DRIVELINE MODULE . . . . . . . . . . . . . . . . 26

HALF SHAFT - FRONT TABLE OF CONTENTS page HALF SHAFT - FRONT DESCRIPTION . . . . . . . . . . DIAGNOSIS AND TESTING HALF SHAFT . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION. . . . . . . . . . SPECIFICATIONS . . . . . . . CV BOOT - INNER REMOVAL . . . . . . . . . . . . .

. . . . . .

.1 .1 .1 .2 .5 .7

page INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CV BOOT - OUTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OUTER CV JOINT BEARING SHIELD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

..................7

HALF SHAFT - FRONT DESCRIPTION All vehicles use an unequal length half shaft system (Fig. 1). The left half shaft uses a tuned rubber damper weight. When replacing the left half shaft, be sure the replacement half shaft has the same damper weight as the original. All half shaft assemblies use the same type of inner and outer joints. The inner joint of both half shaft assemblies is a tripod joint, and the outer joint of both half shaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true constant velocity (CV) joint assemblies. The inner tripod joint allows for the changes in half shaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer CV joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both half shafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using

a snap ring located in the stub shaft of the tripod joint. The outer CV joint has a stub shaft that is splined into the wheel hub and retained by a steel hub nut.

DIAGNOSIS AND TESTING - HALF SHAFT VEHICLE INSPECTION (1) Check for grease in the vicinity of the inboard tripod joint and outboard CV joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. (2) A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot.

NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: â&#x20AC;¢ Damaged outer CV or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint.

3-2

HALF SHAFT - FRONT

HALF SHAFT - FRONT (Continued)

Fig. 1 Unequal Length Half Shaft System 1 2 3 4 5 6 7 8

STUB AXLE OUTER C/V JOINT OUTER C/V JOINT BOOT TUNED RUBBER DAMPER WEIGHT INTERCONNECTING SHAFT OUTER C/V JOINT BOOT STUB AXLE OUTER C/V JOINT

• Noise may also be caused by another component of the vehicle coming in contact with the half shafts.

CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: • A torn seal boot on the inner or outer joint of the half shaft assembly. • A loose or missing clamp on the inner or outer joint of the half shaft assembly. • A damaged or worn half shaft CV joint.

SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: • A worn or damaged half shaft inner tripod joint. • A sticking tripod joint spider assembly (inner tripod joint only). • Improper wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

9 - RIGHT HALFSHAFT 10 - INNER TRIPOD JOINT BOOT 11 - INNER TRIPOD JOINT 12 - INNER TRIPOD JOINT 13 - INNER TRIPOD JOINT BOOT 14 - INTERCONNECTING SHAFT & LEFT HALFSHAFT

VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: • Foreign material (mud, etc.) packed on the backside of the wheel(s). • Out of balance tires or wheels. (Refer to 22 TIRES/WHEELS - STANDARD PROCEDURE) • Improper tire and/or wheel runout. (Refer to 22 TIRES/WHEELS - DIAGNOSIS AND TESTING)

REMOVAL (1) Raise vehicle on jack stands or centered on a frame contact type hoist. (2) Remove the cotter pin and nut lock (Fig. 2) from the end of the half shaft. (3) Remove the wave washer (Fig. 3) from the end of the half shaft. (4) Remove the wheel and tire assembly from the vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL) (5) With the vehicle’s brakes applied to keep hub from turning, loosen and remove the half shaft nut. (6) Remove the two front disc brake caliper adapter to steering knuckle attaching bolts (Fig. 4).

HALF SHAFT - FRONT

3-3

HALF SHAFT - FRONT (Continued)

Fig. 2 Half Shaft Retaining Nut 1 2 3 4

HUB/BEARING NUT LOCK COTTER PIN HALF SHAFT

Fig. 4 Front Brake Mounting 1 2 3 4 5 6 7

- BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP

Fig. 3 Wave Washer 1 - HUB/BEARING ASSEMBLY 2 - WAVE WASHER 3 - HALF SHAFT

(7) Remove the disc brake caliper assembly from the steering knuckle. Caliper assembly is removed by first rotating top of caliper assembly away from steering knuckle and then removing bottom of assembly out from under machined abutment on steering knuckle. (8) Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly (Fig. 5). Do not allow the brake caliper assembly to hang by the brake flex hose. (9) Remove the brake rotor from the hub and bearing assembly.

Fig. 5 Correctly Supported Disc Brake Caliper Typical 1 2 3 4 5

STEERING KNUCKLE BRAKE FLEX HOSE CALIPER ASSEMBLY WIRE HANGER STRUT ASSEMBLY

(10) Remove nut attaching outer tie rod end to steering knuckle (Fig. 6). Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a socket while loosening and removing nut with a wrench. (11) Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113 (Fig. 7).

3-4

HALF SHAFT - FRONT

HALF SHAFT - FRONT (Continued)

Fig. 6 Removing Tie Rod End Attaching Nut 1 2 3 4 5

TIE ROD END STEERING KNUCKLE WRENCH SOCKET TIE ROD END STUD

Fig. 8 Strut To Steering Knuckle Attaching Bolts 1 - STRUT CLEVIS BRACKET 2 - NUTS AND BOLTS 3 - STEERING KNUCKLE

steering knuckle, end of half shaft must be supported. (14) Pull steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the joint out of the hub bearing. (15) Support the outer end of the half shaft assembly. Insert a pry bar between inner tripod joint and transaxle case (Fig. 9). Pry against inner tripod joint, until tripod joint retaining snap-ring is disengaged from transaxle side gear.

Fig. 7 Tie Rod End Removal From Steering Knuckle Arm 1 2 3 4

TIE ROD END SPECIAL TOOL MB-991113 STUD STEERING KNUCKLE ARM

(12) Remove the steering knuckle to strut attachment bolts (Fig. 8) from the steering knuckle. (13) Pull the steering knuckle from the strut clevis bracket. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow half shaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in

Fig. 9 Disengaging Inner Tripod Joint From Transaxle 1 - INNER TRIPOD JOINT 2 - TRANSAXLE CASE 3 - PRY BAR

HALF SHAFT - FRONT

3-5

HALF SHAFT - FRONT (Continued) (16) Hold inner tripod joint and interconnecting shaft of half shaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal (Fig. 10). When removing tripod joint, do not let spline or snap-ring drag across sealing lip of the transaxle to tripod joint oil seal.

Fig. 11 Outer CV Joint Inspection 1 - OUTER CV JOINT 2 - THIS AREA OF OUTER CV JOINT MUST BE FREE OF ALL DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO STEERING KNUCKLE.

Fig. 10 Tripod Joint Removal from Transaxle 1 2 3 4 5 6

INNER TRIPOD JOINT TRANSAXLE SPLINE OIL SEAL SNAP-RING INTERCONNECTING SHAFT

INSTALLATION (1) Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. (2) Holding half shaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand (Fig. 10). (3) Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap-ring is engaged with transaxle side gear. Test that snap-ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap-ring is fully engaged with side gear, tripod joint will not be removable by hand. (4) Clean all debris and moisture out of steering knuckle, in the area were outer CV joint will be installed into steering knuckle. (5) Ensure that front of outer CV joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV joint into hub and bearing assembly (Fig. 11).

(6) Slide half shaft back into front hub and bearing assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle. CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 12).

Fig. 12 Correctly Installed Eccentric Attaching Bolt 1 2 3 4

STEERING KNUCKLE FLANGED BOLT IN TOP HOLE CAM BOLT IN BOTTOM HOLE STRUT CLEVIS BRACKET

3-6

HALF SHAFT - FRONT

HALF SHAFT - FRONT (Continued) (7) Install steering knuckle in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both bolts to a torque of 81 N·m (60 ft. lbs.) plus an additional 1/4 turn. (8) Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket, (Fig. 6) tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket (Fig. 13), tighten the tie rod end attaching nut to a torque of 75 N·m (55 ft. lbs.).

(12) Clean all foreign matter from the threads of the outer CV joint. Install the washer and half shaft to hub/bearing assembly nut on half shaft and securely tighten nut. (13) Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (14) Lower vehicle. (15) With the vehicle’s brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) (Fig. 14).

Fig. 13 Torquing Tie Rod End Attaching Nut 1 2 3 4 5

STEERING KNUCKLE TIE ROD END CROWFOOT SOCKET TORQUE WRENCH

(9) Install braking disc on hub and bearing assembly. (10) Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper assembly under abutment on steering knuckle, and then rotating top of caliper against top abutment. (11) Install disc brake caliper adapter to steering knuckle attaching bolts (Fig. 4). Tighten the disc brake caliper adapter attaching bolts to a torque of 169 N·m (125 ft. lbs.).

Fig. 14 Torquing Front Half Shaft To Hub Nut 1 - TORQUE WRENCH

(16) Install the spring wave washer on the end of the half shaft. (17) Install the hub nut lock, and a new cotter pin (Fig. 2). Wrap cotter pin prongs tightly around the hub nut lock as shown in (Fig. 2). (18) Check for correct fluid level in transaxle assembly. (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE/FLUID - STANDARD PROCEDURE) (19) Set front toe on vehicle to required specification.

HALF SHAFT - FRONT

3-7

HALF SHAFT - FRONT (Continued)

SPECIFICATIONS SPECIFICATIONS - HALF SHAFT - FRONT TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Bolts, Caliper Adapter to Knuckle

169

125

Nut, Hub

244

180

Nuts, Front Wheel Lug

135

100

Nut, Tie Rod End to Knuckle

Nut, Strut Clevis to Knuckle

81 +90°

60 +90°

CV BOOT - INNER REMOVAL (1) Remove the half shaft requiring boot replacement from the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (2) Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard. (3) Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and discard. (4) Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider trunions to prevent the bearings from falling away. (5) Slide the tripod joint housing off the spider assembly and the interconnecting shaft (Fig. 15). (6) Remove snap-ring which retains spider assembly to interconnecting shaft (Fig. 16). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. (7) Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (Fig. 17).

Fig. 15 Spider Assembly Removal from Tripod Joint Housing 1 - TRIPOD JOINT HOUSING 2 - SPIDER ASSEMBLY 3 - SEALING BOOT

(8) Slide sealing boot off interconnecting shaft. (9) Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the half shaft assembly will require replacement. Component parts of these half shaft assemblies are not serviceable.

3-8

HALF SHAFT - FRONT

CV BOOT - INNER (Continued)

Fig. 16 Spider Assembly Retaining Snap-Ring 1 - INTERCONNECTING SHAFT 2 - SPIDER ASSEMBLY 3 - RETAINING SNAP RING

Fig. 18 Sealing Boot Installation on Interconnecting Shaft 1 2 3 4

SEALING BOOT RAISED BEAD IN THIS AREA OF SEALING BOOT GROOVE INTERCONNECTING SHAFT

(2) Install spider assembly onto interconnecting shaft (Fig. 19). Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap-ring. If the spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (Fig. 20). Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft.

Fig. 17 Spider Assembly Removal from Interconnecting Shaft 1 - SPIDER ASSEMBLY 2 - DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN REMOVING SPIDER ASSEMBLY 3 - BRASS DRIFT 4 - INTERCONNECTING SHAFT

INSTALLATION (1) Slide inner CV joint seal boot retaining clamp, onto the interconnecting shaft. Then, slide the replacement inner CV joint sealing boot onto the interconnecting shaft. Inner CV joint seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig. 18).

Fig. 19 Spider Assembly Installation on Interconnecting Shaft 1 - SPIDER ASSEMBLY 2 - INTERCONNECTING SHAFT

(3) Install the spider assembly to interconnecting shaft retaining snap-ring into groove on end of interconnecting shaft (Fig. 21). Be sure the snap-ring is fully seated into groove on interconnecting shaft.

HALF SHAFT - FRONT

3-9

CV BOOT - INNER (Continued)

Fig. 20 Installing Spider Assembly on Interconnecting Shaft 1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER ASSEMBLY 2 - SPIDER ASSEMBLY 3 - INTERCONNECTING SHAFT 4 - BRASS DRIFT

Fig. 22 Installing Tripod Housing on Spider Assembly 1 - TRIPOD JOINT HOUSING 2 - SPIDER ASSEMBLY 3 - SEALING BOOT

(6) Install inner CV joint seal boot to interconnecting shaft clamp evenly on sealing boot. (7) Place crimping tool C-4975-A over bridge of clamp (Fig. 23). (8) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 24).

Fig. 21 Spider Assembly Retaining Snap-Ring Installed 1 - INTERCONNECTING SHAFT 2 - SPIDER ASSEMBLY 3 - RETAINING SNAP RING

(4) Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. (5) Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 22).

Fig. 23 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 2 3 4

SPECIAL TOOL C-4975A INTERCONNECTING SHAFT CLAMP SEALING BOOT

3 - 10

HALF SHAFT - FRONT

CV BOOT - INNER (Continued) (11) Insert a trim stick between the CV joint housing and the sealing boot insert to vent inner CV joint assembly (Fig. 25). When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing. If this is not done damage to the sealing boot can occur.

Fig. 24 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT

CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. (9) Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. (10) Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recessâ&#x20AC;&#x2122;s of the tripod housing. CAUTION: The following positioning procedure determines the correct air pressure inside the inner CV joint assembly prior to clamping the sealing boot to inner CV joint housing. If this procedure is not done prior to clamping sealing boot to CV joint housing sealing boot durability can be adversely affected. CAUTION: When venting the inner CV joint assembly, use care so that the inner CV sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used.

Fig. 25 Trim Stick Inserted for Venting CV Joint 1 2 3 4

INNER TRIPOD JOINT SEALING BOOT SEALING BOOT CLAMP INNER TRIPOD JOINT HOUSING TRIM STICK

(12) With trim stick inserted between sealing boot insert and the CV joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot insert and the CV joint housing. This procedure will equalize the air pressure in the CV joint, preventing premature sealing boot failure. (13) Clamp CV joint sealing boot to CV joint, using required procedure for type of boot clamp application.

CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the following procedure to install the retaining clamp. (1) Place crimping tool C-4975-A over bridge of clamp (Fig. 26). (2) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 27).

HALF SHAFT - FRONT

3 - 11

CV BOOT - INNER (Continued)

Fig. 26 Crimping Tool Installed on Sealing Boot Clamp 1 2 3 4

CLAMP TRIPOD JOINT HOUSING SPECIAL TOOL C-4975A SEALING BOOT

Fig. 27 Sealing Boot Retaining Clamp Installed 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975A 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT

LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp, use the following procedure to install the retaining clamp. (1) Place prongs of clamp locking tool in the holes of the clamp (Fig. 28). (2) Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 29).

Fig. 28 Clamping Tool Installed on Sealing Boot Clamp 1 - CLAMP 2 - SPECIAL TOOL YA3050 3 - SEALING BOOT

Fig. 29 Sealing Boot Clamp Correctly Installed 1 - INNER TRIPOD JOINT HOUSING 2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT

(3) Install the half shaft back into the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)

CV BOOT - OUTER REMOVAL (1) Remove half shaft assembly requiring boot replacement from vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)

3 - 12

HALF SHAFT - FRONT

CV BOOT - OUTER (Continued) (2) Remove large boot clamp retaining CV joint sealing boot to CV joint housing (Fig. 30) and discard. (3) Remove small clamp that retains outer CV joint sealing boot to interconnecting shaft and discard. (4) Remove sealing boot from outer CV joint housing and slide it down interconnecting shaft.

Fig. 31 Outer CV Joint Removal From Interconnecting Shaft 1 - SPREAD RETAINING RING EARS AND PULL JOINT OFF SHAFT 2 - RETAINING RING 3 - RETAINING RING 4 - OUTER CV JOINT ASSEMBLY 5 - INTERCONNECTING SHAFT

Fig. 30 Outer CV Joint Seal Boot Clamps 1 2 3 4 5

SMALL CLAMP SEALING BOOT OUTER C/V JOINT HOUSING LARGE CLAMP INTERCONNECTING SHAFT

(5) Wipe away grease to expose outer CV joint to interconnecting shaft retaining ring. (6) Spread ears apart on CV joint assembly to interconnecting shaft retaining ring (Fig. 31). (7) Slide outer CV joint assembly off end of interconnecting shaft. (8) Slide sealing boot off interconnecting shaft. (9) Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the half shaft assembly will require replacement. Component parts of these half shaft assemblies are not serviceable.

INSTALLATION (1) Slide the new small diameter seal boot retaining clamp onto the interconnecting shaft. Then slide the replacement outer CV joint assembly sealing boot onto the interconnecting shaft. (2) Install the outer CV joint assembly onto the interconnecting shaft. Joint is installed on interconnecting shaft, by pushing interconnecting shaft into outer CV joint, until retaining ring is seated in groove on interconnecting shaft (Fig. 32). Verify that the retaining ring is fully seated into groove on interconnecting shaft.

Fig. 32 Outer CV Joint Installed On Interconnecting Shaft 1 - INTERCONNECTING SHAFT 2 - RETAINING RING 3 - OUTER CV JOINT ASSEMBLY

(3) Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot. (4) Install outer CV joint seal boot retaining clamp, onto interconnecting shaft. Install replacement outer CV joint sealing boot onto interconnecting shaft. Outer CV joint seal boot MUST be positioned on interconnecting shaft, so that only

HALF SHAFT - FRONT

3 - 13

CV BOOT - OUTER (Continued) the thinnest (sight) groove on interconnecting shaft is visible (Fig. 33).

Fig. 35 Sealing Boot Retaining Clamp Installed Fig. 33 Seal Boot Correctly Positioned On Interconnecting Shaft 1 2 3 4

SEALING BOOT INTERCONNECTING SHAFT THINNEST GROOVE INTERCONNECTING SHAFT BOOT CLAMP

(5) Place crimping tool C-4975-A over bridge of clamp (Fig. 34). (6) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 35).

1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT

(7) Position outer CV joint sealing boot into its retaining groove on outer CV joint housing. (8) Install sealing boot to outer CV joint retaining clamp evenly on sealing boot. (9) Place crimping tool C-4975-A over bridge of clamp (Fig. 36). (10) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 37).

Fig. 34 Crimping Tool Installed on Sealing Boot Clamp 1 2 3 4

SPECIAL TOOL C-4975A INTERCONNECTING SHAFT CLAMP SEALING BOOT

CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand.

Fig. 36 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 2 3 4

CLAMP TRIPOD JOINT HOUSING SPECIAL TOOL C-4975A SEALING BOOT

3 - 14

HALF SHAFT - FRONT

CV BOOT - OUTER (Continued)

Fig. 37 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975A 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT

Fig. 38 Removing Bearing Shield from Outer CV Joint 1 - DRIFT 2 - OUTER CV JOINT 3 - BEARING SHIELD

(11) Install the half shaft requiring boot replacement back on the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT INSTALLATION)

OUTER CV JOINT BEARING SHIELD REMOVAL (1) Clamp half shaft in a vise by the interconnecting shaft. (2) Using a drift (Fig. 38) tap around the entire edge of the bearing shield until it is removed from the outer CV joint.

INSTALLATION (1) Install bearing shield by hand on outer CV Joint so that it is installed squarely on the CV joint. (2) Position installer, Special Tool C-4698-2, and handle, Special Tool C-4698-1, on face of bearing shield (Fig. 39). CAUTION: If bearing shield is not installed flush against the face of the outer CV joint, interference with steering knuckle will occur when driveshaft is installed.

Fig. 39 Special Tools for Installing Bearing Shield 1 2 3 4

SPECIAL TOOL C-4698-2 SPECIAL TOOL C-4698-1 BEARING SHIELD OUTER CV JOINT

HALF SHAFT - FRONT

RS OUTER CV JOINT BEARING SHIELD (Continued) (3) Using a hammer, drive the bearing shield on the outer CV joint until it is flush against the front of the outer CV joint (Fig. 40).

Fig. 40 Correctly Installed Bearing Shield 1 - HAMMER 2 - SPECIAL TOOL C-4698-2 3 - BEARING SHIELD 4 - BEARING SEAL MUST BE FLUSH WITH FRONT OF OUTER CV JOINT 5 - SPECIAL TOOL C-4698-1

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3 - 16

HALF SHAFT - REAR

HALF SHAFT - REAR TABLE OF CONTENTS page HALF SHAFT - REAR DESCRIPTION . . . . . . . . . . DIAGNOSIS AND TESTING HALF SHAFT . . . . . . . . . REMOVAL . . . . . . . . . . . . .

. . . .

. 16 . 16 . 16 . 16

HALF SHAFT - REAR DESCRIPTION The inner and outer joints of both half shaft assemblies are tripod joints. The tripod joints are true constant velocity (CV) joint assemblies, which allow for the changes in half shaft length through the jounce and rebound travel of the rear suspension. On vehicles equipped with ABS brakes, the outer CV joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both half shafts is bolted rear differential assembly’s output flanges. The outer CV joint has a stub shaft that is splined into the wheel hub and retained by a steel hub nut.

NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: • Damaged outer CV or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. • Noise may also be caused by another component of the vehicle coming in contact with the half shafts.

CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions:

page INSTALLATION. . . . . . . . . SPECIFICATIONS . . . . . . CV BOOT - INNER/OUTER REMOVAL . . . . . . . . . . . . INSTALLATION. . . . . . . . .

. . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . 20

• A torn seal boot on the inner or outer joint of the half shaft assembly. • A loose or missing clamp on the inner or outer joint of the half shaft assembly. • A damaged or worn half shaft CV joint.

REMOVAL (1) Lift vehicle on hoist so that the wheels hang freely. (2) Remove rear wheel. (3) Remove cotter pin, nut lock, and wave washer (Fig. 1). (4) Remove hub nut and washer. CAUTION: The half shaft outer CV joint, when installed, acts as a bolt and secures the hub/bearing assembly. If the vehicle is to be supported or moved on its wheels, install and torque a bolt through the hub. This will ensure that the hub/bearing assembly cannot loosen. (5) Remove inner half shaft retaining bolts (Fig. 2).

HALF SHAFT - REAR

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HALF SHAFT - REAR (Continued)

Fig. 1 Cotter Pin, Nut Lock, And Wave Washer 1 2 3 4

HUB NUT NUT LOCK COTTER PIN WAVE WASHER

Fig. 2 Inner Half Shaft Bolts 1 - SHAFT 2 - FLANGE

(6) The half shaft is spring loaded. Compress inner half shaft joint slightly and pull downward to clear rear differential output flange. Then pull half shaft assembly outward to remove (Fig. 3).

INSTALLATION (1) Install the outer CV joint stub shaft through the hub bearing (Fig. 4). (2) The half shaft is spring loaded. Compress inner half shaft joint slightly and push upward until the inner CV joint flange engages the rear differential output flange.

Fig. 3 Half Shaft Removal 1 - BRAKE BACKING PLATE 2 - HALF SHAFT

Fig. 4 Half Shaft Installation 1 - BRAKE BACKING PLATE 2 - HALF SHAFT

(3) Install the inner half shaft retaining bolts (Fig. 5). Torque the bolts to 61 N·m (45 ft.lbs.). (4) Install the half shaft washer and hub nut. Torque the hub nut to 244 N·m (180 ft.lbs.). (5) Install the wave washer, nut lock, and a new cotter pin (Fig. 6). Be sure to wrap the cotter pin prongs tightly around the hub nut lock. (6) Install rear wheel. Torque the lug nuts to 135 N·m (100 ft.lbs.).

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HALF SHAFT - REAR

HALF SHAFT - REAR (Continued)

Fig. 6 Cotter Pin, Nut Lock, And Wave Washer 1 2 3 4

Fig. 5 Inner Half Shaft Bolts 1 - SHAFT 2 - FLANGE

HUB NUT NUT LOCK COTTER PIN WAVE WASHER

SPECIFICATIONS SPECIFICATIONS - HALF SHAFT - FRONT TORQUE SPECIFICATIONS DESCRIPTION

NÂ·m

Ft. Lbs.

In. Lbs.

Nut, Hub

244

180

Nuts, Rear Wheel Lug

135

100

Bolt, Half Shaft to Output Flange

CV BOOT - INNER/OUTER REMOVAL (1) Remove half shaft from vehicle. (Refer to 3 DIFFERENTIAL & DRIVELINE/HALF SHAFT REMOVAL) (2) Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft (Fig. 7). (3) Remove the large and small diameter retaining clamps holding the CV boot to the CV joint and the interconnecting shaft (Fig. 8). (4) Pull the boot back from the CV joint (Fig. 9). (5) Remove the CV housing from the interconnecting shaft and tripod assembly (Fig. 10). (6) Remove the snap-ring holding the tripod assembly onto the interconnecting shaft (Fig. 11).

Fig. 7 Clamp Shaft In Soft Jawed Vice 1 - HALF SHAFT BOOT 2 - HALF SHAFT 3 - VISE

HALF SHAFT - REAR

RS CV BOOT - INNER/OUTER (Continued)

Fig. 8 Remove Boot Clamps 1 - HALF SHAFT BOOT 2 - CLAMP

Fig. 10 Remove CV Housing 1 - HALF SHAFT JOINT HOUSING 2 - BOOT

Fig. 9 Pull Back Boot 1 - HALF SHAFT BOOT 2 - HALF SHAFT JOINT

(7) Remove the tripod assembly from the interconnecting shaft (Fig. 12). (8) Remove the CV boot from the interconnecting shaft (Fig. 13).

Fig. 11 Remove Snap-Ring 1 2 3 4

SNAP-RING HALF SHAFT BOOT TRIPOD ASSEMBLY SNAP-RING PLIERS

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HALF SHAFT - REAR

CV BOOT - INNER/OUTER (Continued)

INSTALLATION (1) Clean the interconnecting shaft and inner CV joint of any residual grease and dirt. (2) Slide the new small diameter retaining clamp onto the interconnecting shaft. (3) Install the CV boot onto the interconnecting shaft (Fig. 14).

Fig. 12 Slide Tripod Off The Shaft 1 - TRIPOD ASSEMBLY 2 - AXLE SHAFT 3 - HALF SHAFT BOOT

Fig. 14 Install CV Boot Onto Interconnecting Shaft 1 - HALF SHAFT BOOT

Fig. 13 Remove Boot 1 - HALF SHAFT BOOT

(4) Install the tripod assembly onto the interconnecting shaft (Fig. 15). (5) Install the snap-ring to hold the tripod assembly onto the interconnecting shaft (Fig. 16). (6) Install the new large diameter retaining clamp onto the CV joint housing. (7) Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. (8) Install the CV housing onto the interconnecting shaft and tripod assembly (Fig. 17). (9) Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft. (10) Position the inner CV joint boot on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig. 18).

HALF SHAFT - REAR

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CV BOOT - INNER/OUTER (Continued)

Fig. 17 Install CV Housing Fig. 15 Slide Tripod Onto The Interconnecting Shaft 1 - TRIPOD ASSEMBLY 2 - AXLE SHAFT 3 - HALF SHAFT BOOT

1 - HALF SHAFT JOINT HOUSING 2 - BOOT

Fig. 18 Sealing Boot Installation on Interconnecting Shaft 1 2 3 4

Fig. 16 Install Snap-Ring 1 2 3 4

SNAP-RING HALF SHAFT BOOT TRIPOD ASSEMBLY SNAP-RING PLIERS

SEALING BOOT RAISED BEAD IN THIS AREA OF SEALING BOOT GROOVE INTERCONNECTING SHAFT

(11) Install inner CV joint seal boot to interconnecting shaft clamp evenly on sealing boot. (12) Place crimping tool C-4975-A over bridge of clamp (Fig. 19). (13) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 20).

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HALF SHAFT - REAR

CV BOOT - INNER/OUTER (Continued)

CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the following procedure to install the retaining clamp. (1) Place crimping tool C-4975-A over bridge of clamp (Fig. 21). (2) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 22).

Fig. 19 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 2 3 4

SPECIAL TOOL C-4975A INTERCONNECTING SHAFT CLAMP SEALING BOOT

Fig. 21 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 2 3 4

CLAMP TRIPOD JOINT HOUSING SPECIAL TOOL C-4975A SEALING BOOT

Fig. 20 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT

CAUTION: The boot must not be dimpled, stretched or out of shape in any way. If boot is NOT shaped correctly, equalize pressure in boot and shape it by hand. (14) Position CV boot into the CV housing retaining groove. Install the boot large diameter retaining clamp evenly onto the boot. (15) Clamp the CV joint boot to the CV joint, using required procedure for type of boot clamp application.

Fig. 22 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975A 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT

HALF SHAFT - REAR

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CV BOOT - INNER/OUTER (Continued)

LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp, use the following procedure to install the retaining clamp. (1) Place prongs of clamp locking tool in the holes of the clamp (Fig. 23). (2) Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 24).

Fig. 24 Sealing Boot Clamp Correctly Installed 1 - INNER TRIPOD JOINT HOUSING 2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT

Fig. 23 Clamping Tool Installed on Sealing Boot Clamp 1 - CLAMP 2 - SPECIAL TOOL YA3050 3 - SEALING BOOT

(3) Install the half shaft into the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT INSTALLATION)

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PROPELLER SHAFT

PROPELLER SHAFT TABLE OF CONTENTS page

page

PROPELLER SHAFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 25

PROPELLER SHAFT DESCRIPTION WARNING: Due to propeller shaft imbalance concerns, the propeller shaft can only be serviced as an assembly. AWD models utilize a “two-piece” propeller shaft (Fig. 1) to transmit power to the rear driveline module assembly. This two-piece design consists of: • Front and rear shaft segments. • Plunging center CV joint • Center support bearing • Rubber coupler at driveline module flange The front shaft segment utilizes a CV joint at the power transfer unit connection, and a plunging CV joint at the center bearing location. The rear shaft segment utilizes a center support bearing at the forward position, and a rubber coupler at the driveline module flange.

OPERATION The propeller shaft (Fig. 1) is used to transmit torque from the transaxle power transfer unit (PTU) to the rear driveline module of AWD equipped models. The propeller shaft front half utilizes a CV joint at the PTU flange, and a plunging CV joint at the center bearing location. These joints are flexible, allowing for torsional movement of the powertrain. The propeller shaft rear half utilizes a center support bearing, which supports this two-piece assembly. The bearing also stabilizes the rear shaft segment to minimize axle wind-up. The rubber coupler at the driveline module flange dampens out propeller shaft torsional vibrations, as the driveline module it connects to is fastened to the vehicle body.

REMOVAL CAUTION: Propeller shaft removal is a two-man operation. Never allow propeller shaft to hang while

connected to power transfer unit (PTU) or rear driveline module flanges. A helper is required. (1) Make sure transaxle is in neutral (N). Using chalk, mark propeller shaft flanges at PTU and rear driveline module for installation reference. (2) Remove six propeller shaft-to-power transfer unit bolts. (3) Have helper remove three propeller shaft rubber coupler-to-driveline module bolts while he/she supports rear shaft by hand. (4) Remove center bearing support-to-crossmember bolts, while supporting front shaft with two hands. (5) Lower propeller shaft assembly to ground, using care not to damage fore and aft flanges (Fig. 1).

INSTALLATION CAUTION: Propeller shaft installation is a two-man operation. Never allow propeller shaft to hang while connected to power transfer unit (PTU) or rear driveline module flanges. A helper is required. (1) Make sure transaxle is in Neutral (N) position. (2) Obtain a helper and lift propeller shaft assembly into position (Fig. 1). (3) While helper supports front half of shaft level to underbody, align paint marks at driveline module flange and install three propeller shaft rubber coupler-to-rear driveline module bolts by hand. Do not torque at this time. (4) While helper supports front half of shaft level to underbody, align chalk marks at PTU flange. Install six propeller shaft-to-PTU flange bolts and torque to 30 N·m (22 ft. lbs.). Torque bolts alternately to ensure proper flange mating. (5) Place center bearing into position. Install and torque center bearing-to-crossmember bolts to 54 N·m (40 ft. lbs.). (6) Torque propeller shaft rubber coupler-to-rear driveline module assembly to 54 N·m (40 ft. lbs.).

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