Repair manual
Dodge Pickup R1500 Repair Manual
Step-by-step repair and maintenance instructions for the Dodge Pickup R1500 (1997–2012): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
94sections
1113articles
ENManual language
- DESCRIPTION
- DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION
- DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE
- DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
- STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
- STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
- MOPAR® ENGINE RTV GEN II
- MOPAR® ATF RTV
- MOPAR® GASKET MAKER
- MOPAR® GASKET SEALANT
- FORM-IN-PLACE GASKET AND SEALER APPLICATION
- STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
- REMOVAL
- INSTALLATION
- SPECIFICATIONS - 3.7L ENGINE
- TORQUE SPECIFICATIONS
- Filter Element Only
- DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET
- CYLINDER-TO-CYLINDER LEAKAGE TEST
- CYLINDER-TO-WATER JACKET LEAKAGE TEST
- VISUAL TEST METHOD
- COOLING SYSTEM TESTER METHOD
- CHEMICAL TEST METHOD
- STANDARD PROCEDURE - REFACING
- TESTING VALVE SPRINGS
- DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER
- STANDARD PROCEDURE - CYLINDER BORE HONING
- CLEANING
- INSPECTION
- SELECT FIT IDENTIFICATION
- MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)
- CONNECTING ROD BEARING FITTING
- STANDARD PROCEDURE - PISTON RING FITTING
- OPERATION
- 2WD
- 4WD
- DIAGNOSIS AND TESTING - ENGINE OIL LEAK
- Air Leak Detection Test Method
- INSPECTION FOR REAR SEAL AREA LEAKS
- DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS
- DISASSEMBLY
- ASSEMBLY
- STANDARD PROCEDURE - ENGINE OIL SERVICE
- CRANKCASE OIL LEVEL INSPECTION
- ENGINE OIL CHANGE
- DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
- RIGHT EXHAUST MANIFOLD
- LEFT EXHAUST MANIFOLD
- MEASURING TIMING CHAIN WEAR
- SERVICE PROCEDURE - TIMING VERIFICATION
- TIMING - SINGLE CAMSHAFT
- DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
- DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
- DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE
- DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
- CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
- DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS-INTRODUCTION
- STANDARD PROCEDURE -REPAIR DAMAGED OR WORN THREADS
- STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
- MOPAR® ENGINE RTV GEN II
- MOPAR® ATF RTV
- MOPAR® GASKET MAKER
- MOPAR® GASKET SEALANT
- FORM-IN-PLACE GASKET AND SEALER APPLICATION
- REMOVAL
- GENERAL DESCRIPTION
- CYLINDER BLOCK
- PISTONS
- PISTON PINS
- PISTON RINGS
- CONNECTING RODS
- CRANKSHAFT
- CAMSHAFT
- VALVE TIMING
- VALVES
- VALVE SPRING
- CYLINDER HEAD
- OIL PUMP
- OIL PRESSURE
- TORQUE
- Filter Element Only
- Housing Assembly
- DESCRIPTION - CYLINDER HEAD
- DESCRIPTION - VALVE GUIDES
- CLEANING
- INSPECTION
- INSTALLATION - LEFT CYLINDER HEAD
- INSTALLATION - RIGHT CYLINDER HEAD
- DESCRIPTION
- REMOVAL - RIGHT SIDE
- REMOVAL-LEFT SIDE
- INSTALLATION - RIGHT SIDE
- INSTALLATION - LEFT SIDE
- TESTING VALVE SPRINGS
- DIAGNOSIS AND TESTING -HYDRAULIC LASH ADJUSTER
- INSTALLATION
- STANDARD PROCEDURE - CYLINDER BORE HONING
- STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING
- MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)
- CRANKSHAFT MAIN BEARING SELECTION
- MAIN BEARING SELECTION CHART - 4.7L
- DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS
- STANDARD PROCEDURE - PISTON RING FITTING
- OPERATION
- 2WD
- 4WD
- ENGINE LUBRICATION FLOW CHART-BLOCK: TABLE 1
- ENGINE LUBRICATION FLOW CHART-CYLINDER HEADS: TABLE 2
- DIAGNOSIS AND TESTING - ENGINE OIL LEAK
- Air Leak Detection Test Method
- INSPECTION FOR REAR SEAL AREA LEAKS
- STANDARD PROCEDURE - ENGINE OIL SERVICE
- CRANKCASE OIL LEVEL INSPECTION
- ENGINE OIL CHANGE
- DISASSEMBLY
- ASSEMBLY
- DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE
- RIGHT EXHAUST MANIFOLD
- DESCRIPTION-TIMING DRIVE SYSTEM
- OPERATION - TIMING DRIVE SYSTEM
- STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR
- STANDARD PROCEDURE - ENGINE TIMING -VERIFICATION
- SINGLE CAMSHAFT TIMING
- DESCRIPTION
- DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
- DIAGNOSIS AND TESTING - SMOKE DIAGNOSIS CHARTS
- CYLINDER COMPRESSION PRESSURE
- CYLINDER COMBUSTION PRESSURE LEAKAGE
- STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
- MOPAR® ENGINE RTV GEN II
- MOPAR® ATF RTV
- MOPAR® GASKET MAKER
- MOPAR® GASKET SEALANT
- FORM-IN-PLACE GASKET AND SEALER APPLICATION
- STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
- STANDARD PROCEDURE-HYDROSTATIC LOCK
- INSTALLATION - ENGINE
- INSTALLATION-CRANKCASE BREATHER
- GENERAL DESCRIPTION
- PISTONS
- PISTON PINS
- PISTON RINGS
- CONNECTING RODS
- CYLINDER HEAD
- OIL PRESSURE
- TORQUE CHART 5.9L DIESEL ENGINE
- Testing Air Cleaner Element using Filter Minder™
- Filter Removal
- INSTALLATION
- CLEANING-CYLINDER HEAD
- CLEANING-CROSSHEADS
- CLEANING-PUSHRODS
- INSPECTION - CYLINDER HEAD
- INSPECTION-CROSSHEADS
- INSPECTION-PUSHRODS
- REMOVAL-ROCKER HOUSING
- CLEANING
- INSPECTION
- INSTALLATION - CYLINDER HEAD COVER
- VALVE GUIDE BORE SPECIFICATIONS
- STANDARD PROCEDURE - VALVE LASH ADJUSTMENT AND VERIFICATION
- Rocker Arms
- Push Rods
- Crossheads
- STANDARD PROCEDURE-CYLINDER BORE REPAIR
- METHOD 1-OVERSIZE BORE
- CYLINDER BORE DIMENSION CHART
- METHOD 2-REPAIR SLEEVE
- REPAIR SLEEVE BLOCK REBORE DIMENSIONS CHART
- SLEEVE DRIVER CONSTRUCTION SPECIFICATION CHART
- SLEEVE MACHINING DIMENSIONS CHART
- STANDARD PROCEDURE-CAM BORE REPAIR
- BORE SPECIFICATIONS
- REMOVAL-CAMSHAFT BEARINGS
- Camshaft
- CAMSHAFT DIMENSIONS
- Camshaft Bushing/Bores
- Camshaft Gear
- Thrust Plate
- CAMSHAFT THRUST PLATE THICKNESS CHART
- INSTALLATION - CAMSHAFT BEARINGS
- STANDARD PROCEDURE - CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE
- CONNECTING ROD JOURNAL DIAMETER LIMITS CHART
- REMOVAL - GEAR
- STANDARD PROCEDURE - MAIN BEARING CLEARANCE
- REMOVAL
- PISTON
- STANDARD PROCEDURE -HEAD GASKET SELECTION
- CLEANING-PISTON AND CONNECTING ROD
- CONNECTING ROD
- INSPECTION - PISTONS
- INSPECTION-CONNECTING ROD
- OPERATION
- DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE
- STANDARD PROCEDURE - ENGINE OIL LEVEL
- STANDARD PROCEDURE - ENGINE OIL SERVICE
- USED ENGINE OIL DISPOSAL
- CLEANING AND INSPECTION
- STANDARD PROCEDURE - TIMING VERIFICATION
- DESCRIPTION
- Vehicle Identification Number
- Engine Serial Number
- ENGINE DIAGNOSIS - INTRODUCTION
- ENGINE DIAGNOSIS - PERFORMANCE
- ENGINE DIAGNOSIS - MECHANICAL
- DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
- CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
- CYLINDER HEAD GASKET FAILURE DIAGNOSIS
- CYLINDER-TO-CYLINDER LEAKAGE TEST
- CYLINDER-TO-WATER JACKET LEAKAGE TEST
- VISUAL TEST METHOD
- COOLING SYSTEM TESTER METHOD
- CHEMICAL TEST METHOD
- DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
- PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS
- OIL LEVEL TOO HIGH
- OIL LEVEL TOO LOW
- VALVE TRAIN NOISE DIAGNOSIS
- DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION
- INSPECTION FOR REAR SEAL AREA LEAKS
- STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS
- STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
- MOPAR® ENGINE RTV GEN II
- MOPAR® ATF RTV
- MOPAR® GASKET MAKER
- MOPAR® BED PLATE SEALANT
- MOPAR® GASKET SEALANT
- FORM-IN-PLACE GASKET AND SEALER APPLICATION
- STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
- STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE
- REMOVAL - ENGINE ASSEMBLY
- GENERAL SPECIFICATIONS
- CYLINDER BLOCK
- CRANKSHAFT
- MAIN BEARING JOURNALS
- CONNECTING RODS
- PISTONS
- PISTON PINS
- PISTON RING
- CAMSHAFT
- HYDRAULIC TAPPETS
- CYLINDER HEAD
- CYLINDER HEAD VALVE SEAT
- VALVES
- VALVE SPRING
- LUBRICATION
- OIL PUMP
- TORQUE
- INSTALLATION
- REMOVAL
- INSPECTION
- REMOVAL - CYLINDER HEAD(S)
- INSTALLATION - CYLINDER HEAD(S)
- LEFT CYLINDER HEAD COVER
- RIGHT CYLINDER HEAD COVER
- VALVE SPRING TESTING
- VALVE AND VALVE SEAT - REFACING
- VALVE SEATS
- Valve
- VALVE GUIDE OVERSIZE CHART
- TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL
- CRANKSHAFT SPROCKET INSTALLATION
- OPERATION
- CHECKING ENGINE OIL PRESSURE
- CHECKING ENGINE OIL LEVEL
- ENGINE OIL AND FILTER CHANGE
- OIL SPECIFICATION
- OIL FILTER SPECIFICATION
- USED ENGINE OIL DISPOSAL
- DISASSEMBLY
- CLEANING
- ASSEMBLY
- CYLINDER BORE HONING
- PISTON FITTING
- CONNECTING ROD
- PISTON PIN
- PISTON
- CONNECTING ROD BEARING - FITTING
- MEASURING CONNECTING ROD BEARING CLEARANCE
- PLASTIGAGE METHOD
- PREFERRED METHOD
- MEASURING CRANKSHAFT END PLAY
- CRANKSHAFT JOURNAL MEASUREMENT
- DESCRIPTION & OPERATION
- PARKING BRAKES
- BRAKE PEDAL
- BRAKE/PARK INDICATOR
- POWER BRAKE BOOSTER
- MASTER CYLINDER
- ADJUSTABLE PEDALS SYSTEM
- BLEEDING BRAKE SYSTEM
- MASTER CYLINDER BLEEDING
- BRAKE SYSTEM BLEEDING
- Manual Bleeding
- Pressure Bleeding
- HYDRO-BOOST BRAKE BOOSTER
- PARKING BRAKE SHOES
- CABLE TENSIONER
- BRAKE LAMP SWITCH
- Switch Continuity Test
- PARK/BRAKE INDICATOR
- POWER BRAKE BOOSTER/MASTER CYLINDER FUNCTIONAL TEST
- POWER BRAKE BOOSTER VACUUM TEST
- POWER BRAKE BOOSTER CHECK VALVE TEST
- BRAKE FLUID
- Checking & Filling
- Brake Fluid Contamination
- Removal (Front)
- Installation (Front)
- Removal (Rear)
- Installation (Rear)
- Removal
- Installation
- ADJUSTABLE PEDAL MOTOR
- ADJUSTABLE PEDAL SWITCH
- Removal (Front Hose)
- Installation (Front Hose)
- Removal (Rear Hose)
- Installation (Rear Hose)
- Removal (Rear Tube/Hose Assembly)
- Installation (Rear Tube/Hose Assembly)
- CALIPER
- Removal (Rear - Except SRT-10)
- Installation (Rear - Except SRT-10)
- Removal (Rear - SRT-10)
- Installation (Rear - SRT-10)
- Removal (Front & Rear)
- Installation (Front & Rear)
- Removal (Center Cable)
- Installation (Center Cable)
- Removal (Right Rear Cable)
- Installation (Right Rear Cable)
- Removal (Left Rear Cable)
- Installation (Left Rear Cable)
- Removal (Rear - Single Rear Wheels)
- Installation (Rear - Single Rear Wheels)
- Removal (Rear - Dual Rear Wheels)
- Installation (Rear - Dual Rear Wheels)
- Disassembly
- Assembly
- DISC BRAKE SPECIFICATIONS
- TORQUE SPECIFICATIONS
- ETHYLENE-GLYCOL MIXTURES
- PROPYLENE-GLYCOL MIXTURES
- DESCRIPTION - HOAT COOLANT
- COOLANT PERFORMANCE
- COOLANT SELECTION AND ADDITIVES
- OPERATION
- DESCRIPTION
- INSTALLATION
- DESCRIPTION - SRT-10
- HYDRAULIC FAN STRATEGY
- ACTIVATING THE HYDRAULIC FAN WITH THE DRBIII®
- RADIATOR COOLING FAN HYDRAULIC FLUID PATH
- 3.7L/4.7L/5.7L ENGINE
- 5.9L DIESEL
- CLEANING
- INSPECTION
- SRT-10
- DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER
- 3.7L V-6
- 4.7L V-8
- 5.7L V-8
- 8.3L V-10
- 3.7L/4.7L ENGINE
- 5.7L ENGINE
- ON-BOARD DIAGNOSTICS - GAS ENGINES
- DIESEL ENGINE
- REMOVAL - 3.7/4.7L
- REMOVAL - 5.7L
- REMOVAL - 5.9L DIESEL
- INSTALLATION - 3.7/4.7L
- INSTALLATION - 5.9L DIESEL
- NOISE
- LEAKS
- VISCOUS DRIVE
- ELECTRONICALLY CONTROLLED VISCOUS DRIVE
- RADIATOR COOLANT FLOW
- DIAGNOSIS AND TESTING - RADIATOR CAP-TO-FILLER NECK SEAL
- RADIATOR CAP
- DESCRIPTION - WATER PUMP
- DESCRIPTION - WATER PUMP BYPASS
- OPERATION-WATER PUMP
- OPERATION - WATER PUMP BYPASS
- DIAGNOSIS AND TESTING-WATER PUMP
- TORQUE SPECIFICATIONS
- REMOVAL
- INSTALLATION
- ST/SLT/SLT+ FASCIA INSTALLATION
- SPORT FASCIA INSTALLATION
- SAFETY PRECAUTIONS AND WARNINGS
- STANDARD PROCEDURE - LIGHT DUTY FRONT FRAME RAIL TIP REPLACEMENT
- SERVICE SLEEVE ASSEMBLY
- STANDARD PROCEDURE - HYDROFORM FENDER RAIL REPAIR
- STANDARD PROCEDURE - REAR FRAME H-SECTION REPLACEMENT
- WELD PROCESS
- SPECIFICATIONS - FRAME DIMENSIONS
- VEHICLE PREPARATION
- INDEX
- GEAR NOISE
- BEARING NOISE
- LOW SPEED KNOCK
- VIBRATION
- DRIVELINE SNAP
- DIAGNOSTIC CHART
- REMOVAL
- ADJUSTMENTS
- PINION GEAR DEPTH VARIANCE
- PINION DEPTH MEASUREMENT AND ADJUSTMENT
- DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
- SHIM SELECTION
- GEAR CONTACT PATTERN
- AXLE SPECIFICATIONS
- TORQUE SPECIFICATIONS
- INSTALLATION
- DISASSEMBLY
- ASSEMBLY
- DESCRIPTION
- 3.7L V-6 ENGINE
- 4.7L V-8 ENGINE
- 5.7L V-8 ENGINE
- TORQUE
- ENGINE FIRING ORDER - 3.7L V-6
- FIRING ORDER/CABLE ROUTING - 5.7L V-8 ENGINE
- 8.3L - FIRING ORDER
- SPARK PLUG CABLE RESISTANCE
- SPARK PLUGS
- IGNITION COIL RESISTANCE - 3.7L V-6
- IGNITION COIL RESISTANCE - 4.7L V-8
- IGNITION COIL RESISTANCE - 5.7L V-8
- IGNITION COIL RESISTANCE - 8.3L
- IGNITION TIMING
- DESCRIPTION - PCM OUTPUT
- OPERATION - PCM OUTPUT
- OPERATION - ASD SENSE - PCM INPUT
- DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS
- REMOVAL
- INSTALLATION
- 3.7L V-6
- 4.7L V-8
- 5.7L V-8
- 5.9L Diesel
- 8.3L
- 8.3L - REPLACING WITH NEW SENSOR
- 8.3 L - REPLACING OLD SENSOR WITH ORIGINAL
- 8.3L - INSTALLATION - WITH NEW SENSOR
- 8.3L - REPLACING OLD SENSOR WITH ORIGINAL
- 8.3L-SRT-10
- 3.7L V-6 / 4.7L V-8 / 5.7L V-8 Engines Only
- 3.7L V-6/4.7L V-8
- 5.7L V8
- DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS
- NORMAL OPERATING
- COLD FOULING/CARBON FOULING
- WET FOULING OR GAS FOULING
- OIL OR ASH ENCRUSTED
- ELECTRODE GAP BRIDGING
- SCAVENGER DEPOSITS
- CHIPPED ELECTRODE INSULATOR
- PREIGNITION DAMAGE
- SPARK PLUG OVERHEATING
- CLEANING AND ADJUSTMENT
- OPERATION
- DESCRIPTION
- TRANSMISSION IDENTIFICATION
- GEAR RATIOS
- OPERATION
- DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION
- DIAGNOSIS AND TESTING - PRELIMINARY
- VEHICLE IS DRIVABLE
- VEHICLE IS DISABLED
- DIAGNOSIS AND TESTING - ROAD TESTING
- 45RFE CLUTCH APPLICATION CHART
- 545RFE CLUTCH APPLICATION CHART
- DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TEST
- Pressure Test Port Locations
- TEST PROCEDURE
- UPSHIFT PRESSURE
- DOWNSHIFT PRESSURE
- IN-GEAR PRESSURE
- DIAGNOSIS AND TESTING - CONVERTER HOUSING FLUID LEAK
- STANDARD PROCEDURE - ALUMINUM THREAD REPAIR
- CLEANING
- INSPECTION
- ASSEMBLY
- GENERAL
- TORQUE SPECIFICATIONS
- REMOVAL
- TRANSMISSION SHIFT INTERLOCK
- ADJUSTMENTS - BRAKE TRANSMISSION SHIFT INTERLOCK
- BTSI FUNCTION CHECK
- DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL
- DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID
- DIAGNOSIS AND TESTING - FLUID CONTAMINATION
- STANDARD PROCEDURE - FLUID LEVEL CHECK
- STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT
- INSTALLATION
- STANDARD PROCEDURE - TRANSMISSION FILL
- DIAGNOSIS AND TESTING - GEARSHIFT CABLE
- ADJUSTMENTS - GEARSHIFT CABLE
- 2C CLUTCH
- 4C CLUTCH
- LOW/REVERSE CLUTCH
- UNDERDRIVE CLUTCH
- OVERDRIVE CLUTCH
- REVERSE CLUTCH
- CONVERTER CLUTCH SWITCH VALVE
- CONVERTER CLUTCH REGULATOR VALVE
- TORQUE CONVERTER LIMIT VALVE
- STANDARD PROCEDURE - OIL PUMP VOLUME CHECK
- PRESSURE
- PRESSURE ON A CONFINED FLUID
- FORCE MULTIPLICATION
- PISTON TRAVEL
- REACTION PLANETARY GEARTRAIN
- REVERSE PLANETARY GEARTRAIN
- INPUT PLANETARY GEARTRAIN
- DISASSEMBLY
- IMPELLER
- TURBINE
- STATOR
- TORQUE CONVERTER CLUTCH (TCC)
- NO EMCC
- PARTIAL EMCC
- FULL EMCC
- GRADUAL-TO-NO EMCC
- SOLENOIDS
- PRESSURE SWITCHES
- 45RFE PRESSURE SWITCH STATES
- 545RFE PRESSURE SWITCH STATES
- Calculated Temperature
- SOLENOID SWITCH VALVE
- MANUAL VALVE
- LOW/REVERSE SWITCH VALVE
- DESCRIPTION
- IDENTIFICATION
- GEAR RATIOS
- OPERATION
- PARK POWERFLOW
- NEUTRAL POWERFLOW
- REVERSE POWERFLOW
- FIRST GEAR POWERFLOW
- SECOND GEAR POWERFLOW
- DIRECT DRIVE POWERFLOW
- FOURTH GEAR POWERFLOW
- DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION
- DIAGNOSIS AND TESTING - PRELIMINARY
- VEHICLE IS DRIVEABLE
- VEHICLE IS DISABLED
- DIAGNOSIS AND TESTING - ROAD TESTING
- DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TEST
- Pressure Test Port Locations
- Test One - Transmission In Manual Low
- Test Two - Transmission in 2 Range
- Test Three - Transmission in D Range Third Gear
- Test Four - Transmission In Reverse
- Test Five - Governor Pressure
- Test Six - Transmission in Overdrive Fourth Gear
- DIAGNOSIS AND TESTING -AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION
- Front Clutch Air Test
- Rear Clutch Air Test
- Front Servo Air Test
- Rear Servo Air Test
- DIAGNOSIS AND TESTING - CONVERTER HOUSING FLUID LEAK
- TORQUE CONVERTER LEAK POINTS
- DIAGNOSIS AND TESTING - DIAGNOSIS CHARTS
- STANDARD PROCEDURE - ALUMINUM THREAD REPAIR
- REMOVAL
- CLEANING
- INSPECTION
- ASSEMBLY
- OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE DRUM
- INPUT SHAFT END PLAY CHECK
- BAND ADJUSTMENT AND FINAL
- KICKDOWN (FRONT) BAND
- LOW/REVERSE (REAR) BAND
- FRONT BAND
- REAR BAND
- DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK
- ADJUSTMENTS - BRAKE TRANSMISSION SHIFT INTERLOCK
- BTSI FUNCTION CHECK
- GOVERNOR PRESSURE SOLENOID VALVE
- GOVERNOR PRESSURE SENSOR
- GOVERNOR BODY AND TRANSFER PLATE
- GOVERNOR PRESSURE CURVES
- LOW TRANSMISSION FLUID TEMPERATURE
- NORMAL OPERATION
- WIDE OPEN THROTTLE OPERATION
- TRANSFER CASE LOW RANGE OPERATION
- INSTALLATION
- DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL
- DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID
- DIAGNOSIS AND TESTING - FLUID CONTAMINATION
- STANDARD PROCEDURE - FLUID LEVEL CHECK
- PROCEDURE TWO
- STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT
- STANDARD PROCEDURE - TRANSMISSION FILL
- DISASSEMBLY
- DIAGNOSIS AND TESTING - GEARSHIFT CABLE
- ADJUSTMENTS - GEARSHIFT CABLE
- DIRECT CLUTCH, HUB AND SPRING
- OVERDRIVE CLUTCH
- OVERDRIVE PISTON
- PRESSURE
- PRESSURE ON A CONFINED FLUID
- FORCE MULTIPLICATION
- PISTON TRAVEL
- ADJUSTMENTS - THROTTLE VALVE CABLE
- ADJUSTMENT PROCEDURE
- IMPELLER
- TURBINE
- STATOR
- TORQUE CONVERTER CLUTCH (TCC)
- STANDARD PROCEDURE - TORQUE CONVERTER DRAINBACK VALVE
- DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS
- DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS)
- CHECK BALLS
- REGULATOR VALVE
- KICKDOWN VALVE
- KICKDOWN LIMIT VALVE
- 1-2 SHIFT VALVE
- 1-2 SHIFT CONTROL VALVE
- 2-3 SHIFT VALVE
- 3-4 SHIFT VALVE
- 3-4 TIMING VALVE
- 3-4 QUICK FILL VALVE
- THROTTLE VALVE
- SWITCH VALVE
- MANUAL VALVE
- CONVERTER CLUTCH LOCK-UP VALVE
- CONVERTER CLUTCH LOCK-UP TIMING VALVE
- SHUTTLE VALVE
- BOOST VALVE
- UPPER HOUSING VALVE AND PLUG
- GOVERNOR BODY, SENSOR AND SOLENOID
- CONTROL PRESSURE ADJUSTMENTS
- LINE PRESSURE ADJUSTMENT
- THROTTLE PRESSURE ADJUSTMENT
- DESCRIPTION
- IDENTIFICATION
- OPERATING RANGE
- SHIFT MECHANISM
- SHIFTING
- DIAGNOSIS AND TESTING - TRANSFER CASE -NV241 GENII
- DIAGNOSIS CHART
- REMOVAL
- DISASSEMBLY
- CLEANING
- MAINSHAFT/SPROCKET/HUB
- INPUT GEAR AND PLANETARY CARRIER
- SHIFT FORKS/HUBS/SLEEVES
- REAR RETAINER COMPONENTS
- DRIVE CHAIN
- LOW RANGE ANNULUS GEAR
- FRONT CASE AND REAR CASE
- OIL PUMP/OIL PICKUP
- OIL PUMP AND REAR CASE
- SEAL BOOT
- INSTALLATION
- TORQUE SPECIFICATIONS
- STANDARD PROCEDURE - FLUID DRAIN AND REFILL
- OPERATION
- OPERATING MODE VERSUS RESISTANCE
- DESCRIPTION
- OPERATING RANGES
- SHIFT MECHANISM
- IDENTIFICATION
- OPERATION
- DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
- DISASSEMBLY
- CLEANING
- MAINSHAFT/SPROCKET/HUB INSPECTION
- INPUT GEAR AND PLANETARY CARRIER
- SHIFT FORKS/HUBS/SLEEVES
- REAR EXTENSION HOUSING
- FRONT OUTPUT SHAFT AND DRIVE CHAIN
- LOW RANGE ANNULUS GEAR
- FRONT AND REAR CASES
- OIL PUMP/OIL PICKUP
- OIL PUMP AND REAR CASE
- SEAL BOOT AND SHIFT MOTOR ASSEMBLY
- INSTALLATION
- TRANSFER CASE - NV243
- REMOVAL
- STANDARD PROCEDURE - FLUID DRAIN AND REFILL
- DESCRIPTION
- OPERATING RANGES
- SHIFT MECHANISM
- IDENTIFICATION
- OPERATION
- DIAGNOSIS CHART
- DISASSEMBLY
- CLEANING
- MAINSHAFT/SPROCKET/HUB INSPECTION
- INPUT GEAR AND PLANETARY CARRIER
- SHIFT FORKS/HUBS/SLEEVES
- REAR EXTENSION HOUSING
- FRONT OUTPUT SHAFT AND DRIVE CHAIN
- LOW RANGE ANNULUS GEAR
- FRONT AND REAR CASES
- OIL PUMP/OIL PICKUP
- OIL PUMP AND REAR CASE
- INSTALLATION
- TORQUE SPECIFICATIONS
- REMOVAL
- STANDARD PROCEDURE - FLUID DRAIN AND REFILL
- SECTOR ANGLES VS. TRANSFER CASE POSITION
- MODE SENSOR CHANNEL STATES
- SELECTOR SWITCH INTERPRETATION
- DESCRIPTION
- IDENTIFICATION
- OPERATING RANGE
- SHIFT MECHANISM
- SHIFTING
- DIAGNOSIS AND TESTING - TRANSFER CASE - NV271
- REMOVAL
- DISASSEMBLY
- CLEANING
- MAINSHAFT/SPROCKET/HUB
- INPUT GEAR AND PLANETARY CARRIER
- SHIFT FORKS/HUBS/SLEEVES
- DRIVE CHAIN
- LOW RANGE ANNULUS GEAR
- FRONT CASE AND REAR CASE
- OIL PUMP/OIL PICKUP
- INSTALLATION
- TORQUE SPECIFICATIONS
- STANDARD PROCEDURE - FLUID DRAIN AND REFILL
- OPERATION
- OPERATING MODE VERSUS RESISTANCE
- DESCRIPTION
- OPERATING RANGES
- SHIFT MECHANISM
- IDENTIFICATION
- OPERATION
- DIAGNOSIS AND TESTING - TRANSFER CASE - NV273
- DISASSEMBLY
- CLEANING
- MAINSHAFT/SPROCKET/HUB INSPECTION
- INPUT GEAR AND PLANETARY CARRIER
- SHIFT FORKS/HUBS/SLEEVES
- REAR EXTENSION HOUSING
- FRONT OUTPUT SHAFT AND DRIVE CHAIN
- LOW RANGE ANNULUS GEAR
- FRONT AND REAR CASES
- OIL PUMP/OIL PICKUP
- INSTALLATION
- TRANSFER CASE - NV273
- STANDARD PROCEDURE - FLUID DRAIN AND REFILL
- SECTOR ANGLES VS. TRANSFER CASE POSITION
- MODE SENSOR CHANNEL STATES
- REMOVAL
- DESCRIPTION
- OPERATION
- LOW LUBRICANT LEVEL
- HARD SHIFTING
- TRANSMISSION NOISE
- GEARTRAIN FROM FIXTURE
- OUTPUT SHAFT
- REVERSE IDLER
- CLEANING
- SHIFT LEVER ASSEMBLY
- SHIFT SHAFT AND FORKS
- FRONT/REAR HOUSINGS AND BEARING RETAINERS
- COUNTERSHAFT BEARINGS AND RACES
- REVERSE IDLER COMPONENTS
- Shift Socket
- Output Shaft And Geartrain
- ASSEMBLY
- SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS
- REAR HOUSING - 2WD
- ADAPTER HOUSING - 4WD
- INSTALLATION
- TORQUE SPECIFICATIONS
- DESCRIPTION
- OPERATION
- POWER STEERING FLOW AND PRESSURE
- REMOVAL
- INSTALLATION
- SPECIFICATIONS
- ADJUSTMENT
- TORQUE CHART
- GAS ENGINE
- DIESEL
- GAS
- OUTER TIE ROD END
- REMOVAL - OUTER TIE ROD END
- INSTALLATION - OUTER TIE ROD END
- LUBRICATION
- PUMP LEAKAGE
- POWER STEERING PUMP - INITIAL OPERATION
- DIESEL ENGINE
- POWER STEERING FLUID LEVEL CHECKING
- PRESSURE HOSE
- RETURN HOSE - RESERVOIR TO COOLER
- RETURN HOSE - GEAR TO COOLER
- DIAGNOSIS AND TESTING - HYDRAULIC FLOW AND PRESSURE
- FLOW AND PRESSURE TEST - AT POWER STEERING GEAR
- INITIAL OPERATION
- PRESSURE HOSE - PUMP TO FAN
- PRESSURE HOSE - FAN TO GEAR
- RETURN HOSE - FAN TO PUMP
- RETURN HOSE - COOLER TO PUMP
- GEAR NOISE
- BEARING NOISE
- LOW SPEED KNOCK
- VIBRATION
- DRIVELINE SNAP
- DIAGNOSTIC CHART
- REMOVAL
- ADJUSTMENTS
- PINION DEPTH MEASUREMENT AND ADJUSTMENT
- DIFFERENTIAL CASE BEARING PRELOAD AND GEAR BACKLASH
- GEAR TOOTH CONTACT PATTERN
- AXLE SPECIFICATIONS
- TORQUE SPECIFICATIONS
- INSTALLATION
- ASSEMBLY
- DESCRIPTION
- OPERATION
- DISASSEMBLY
- CLEANING
- INSPECTION
- GEAR NOISE
- BEARING NOISE
- LOW SPEED KNOCK
- VIBRATION
- DRIVELINE SNAP
- DIAGNOSTIC CHART
- REMOVAL
- PINION GEAR DEPTH VARIANCE
- PINION DEPTH MEASUREMENT AND ADJUSTMENT
- DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH
- SHIM SELECTION
- GEAR CONTACT PATTERN
- DIFFERENTIAL BEARING PRELOAD CHECK
- AXLE SPECIFICATIONS
- TORQUE SPECIFICATIONS
- INSTALLATION
- DESCRIPTION
- OPERATION
- TRAC-LOK
- DIFFERENTIAL TEST
- ASSEMBLY
- GEAR NOISE
- BEARING NOISE
- LOW SPEED KNOCK
- VIBRATION
- DRIVELINE SNAP
- DIAGNOSTIC CHART
- REMOVAL
- ADJUSTMENTS
- PINION GEAR DEPTH VARIANCE
- PINION DEPTH MEASUREMENT
- DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
- GEAR CONTACT PATTERN
- SIDE GEAR CLEARANCE
- AXLE SPECIFICATIONS
- TORQUE SPECIFICATIONS
- INSTALLATION
- ASSEMBLY
- DESCRIPTION
- OPERATION
- DIAGNOSIS AND TESTING
- DIFFERENTIAL TEST