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Jeep 2001 Wrangler TJ Service Manual

Other manuals for 2001 Wrangler TJ: Parts Catalog
Manual is about: Jeep 2001 Wrangler TJ Parts catalog Illustration and Text

Summary of 2001 Wrangler TJ

  • Page 1

    Group tab locator ins introduction 0s lubrication & maintenance 7s cooling 8as audio 8js instrument cluster 8os restraints 8wa wiring 14s fuel system 21s transmission/transaxle service manual comment forms (rear of manual).

  • Page 2: Introduction

    Introduction table of contents page page vehicle data-supplement description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 veci label description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 body code plate description . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 3

    When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap. Body code plate—line 3 digits 1 through 12 vehicle order number digits 13, 14, and 15 roof • vjn = soft top white • vju = soft top spice • vjx = soft top black • vkn = hard...

  • Page 4: Vehicle Identification

    • erh = 4.0l 6 cyl. Mpi gasoline body code plate—line 1 digits 1, 2, and 3 transmission codes • ddq = ax5 5–speed manual • ddo = ax15 5–speed manual • dgd = 30rh 3–speed automatic • dgg = 32rh 3–speed automatic digit 4 open space digit 5 market code • b = international digit 6 open space digits 7 th...

  • Page 6: Lubrication & Maintenance

    Lubrication & maintenance table of contents page page lubrication & maintenance description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2 fluid types description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 m...

  • Page 7

    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 emission standards, your v...

  • Page 8: Fluid Types

    Fluid types description - engine coolant warning: antifreeze is an ethylene glycol base coolant and is harmful if swal- lowed or inhaled. If swallowed, drink two glasses of water and induce vomit- ing. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or un...

  • Page 9: Maintenance Schedules

    Description - 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 ...

  • Page 10

    • inspect manual transmission fluid level (if equipped). • after completion of off-road operation, the underside of the vehicle should be thoroughly inspected. Examine threaded fasteners for looseness. Schedule “a” 7,500 miles (12 000 km) or at 6 months • change engine oil. • replace engine oil filt...

  • Page 11

    97,500 miles (156 000 km) or at 78 months • change engine oil. • replace engine oil filter. • lubricate steering linkage joints and outer tie rod ends. 100,000 miles (160 000 km) • drain and refill automatic transmission fluid, change filter, and adjust bands. • flush and replace engine coolant if n...

  • Page 12

    27,000 miles (43 000 km) • change engine oil. • replace engine oil filter. • lubricate steering linkage tie rod ends. 30,000 miles (48 000 km) • change engine oil. • replace engine oil filter. • inspect engine air cleaner element, replace if necessary. • replace spark plugs. • inspect drive belt, ad...

  • Page 13

    • lubricate steering linkage tie rod ends. • drain and refill front and rear axles.‡ • inspect brake linings. • lubricate steering and suspension ball joints. 75,000 miles (120 000 km) • change engine oil. • replace engine oil filter. • inspect engine air cleaner element, replace as necessary. • lub...

  • Page 14

    120,000 miles (192 000 km) • change engine oil. • replace engine oil filter. • inspect engine air cleaner element, replace as necessary. • replace ignition cables (2.5l only). • replace spark plugs. • inspect drive belt, adjust tension as necessary (2.5l only). • inspect drive belt and replace as ne...

  • Page 16: Cooling

    Cooling table of contents page page cooling description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 diagnosis and testing . . . . . . . . . . . . . . . . . . 2 on-board diagnostics (obd) . . . . . . . . . . . 2 preli...

  • Page 17

    Operation - hose clamps the worm type hose clamp uses a specified torque value to maintain proper tension on a hose connec- tion. The spring type hose clamp applies constant ten- sion on a hose connection. To remove a spring type hose clamp, use special tool 6094 or equivalent, con- stant tension cl...

  • Page 18

    Cooling system diagnosis chart condition possible causes correction temperature gauge reads low 1. Has a diagnostic trouble code (dtc) been set indicating a stuck open thermostat? 1. (refer to 25 - emissions control - description) for on-board diagnostics and dtc information. Replace thermostat if n...

  • Page 19

    Condition possible causes correction 3. Is the temperature warning illuminating unnecessarily? 3. (refer to 8 - electrical/ instrument cluster - schematic - electrical). 4. Coolant low in coolant reserve/ overflow tank and radiator? 4. Check for coolant leaks and repair as necessary. (refer to 7 - c...

  • Page 20

    Condition possible causes correction 13. Fuel or ignition system problems. 13. Refer to 14 - fuel system or 8 - electrical for diagnosis and testing procedures. 14. Dragging brakes. 14. Check and correct as necessary. (refer to 5 - brakes - diagnosis and testing) for correct procedures. 15. Bug scre...

  • Page 21

    Condition possible causes correction 6. Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing a thermostat to open late. 6. (a) check for cylinder head gasket leaks. (refer to 7 - cooling - diagnosis and testing). (b) check for coolant in the engine oil. Inspect for white...

  • Page 22

    Condition possible causes correction (c) vent at coolant reserve/overflow tank is plugged. Clean vent and repair as necessary. (d) reserve/overflow tank is internally blocked or plugged. Check for blockage and repair as necessary. Noisy viscous fan/drive 1. Fan blades loose. 1. Replace fan blade ass...

  • Page 23

    Condition possible causes correction steam is coming from the front of vehicle near the grill area when weather is wet, engine is warmed up and running, and vehicle is stationary. Temperature gauge is in normal range 1. During wet weather, moisture (snow, ice or rain condensation) on the radiator wi...

  • Page 24

    Caution: be sure that the heater control valve is closed (heat off). This is done to prevent coolant flow with scale and other deposits from entering the heater core. Connect the water supply hose and air supply hose to the flushing gun. Allow the engine to fill with water. When the engine is filled...

  • Page 25: Accessory Drive

    Accessory drive table of contents page page belt tensioners - 2.5l removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 belt tensioners - 4.0l description . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 r...

  • Page 26

    Removal on 4.0l engines, the tensioner arm has three marks. Upon installation of a new belt, the dou- ble line marks close to each other should be very close to the mark on the base. The belt should be replaced if the single line mark lines up with the mark on the base. If the above specification ca...

  • Page 27: Engine

    Engine table of contents page page coolant recovery container removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 engine coolant temp sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 op...

  • Page 28

    Removal warning: hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before remov- ing the coolant temperature sensor. The coolant temperature sensor is installed in the thermostat housing (fig. 2). (1) partially drain cooling system until coolant level is...

  • Page 29: Transmission

    Transmission table of contents page page trans cooler standard procedure . . . . . . . . . . . . . . . . . . 14 flushing coolers and tubes . . . . . . . . . 14 trans cooler standard procedure - flushing coolers and tubes when a transmission failure has contaminated the fluid, the oil cooler(s) must ...

  • Page 30: Audio

    Audio table of contents page page audio description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 amplified subwoofer description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 diagnosis and testing . . . . ...

  • Page 31: Antenna Body & Cable

    Inoperative speaker location(s) from the radio receiver wire harness connectors and to the amplified subwoofer for continuity. In each case, there should be continuity. If not ok, repair the shorted speaker feed (+) and/or return (–) circuit(s) to the speaker as required. If ok, replace the amplifie...

  • Page 32: Radio

    (1) from outside the vehicle, feed the antenna cable and base assembly through the outer cowl side panel. (2) from inside the passenger compartment, pull the cable and grommet into the hole in the inside cowl side panel until the grommet is seated. (3) install the three screws retaining the antenna ...

  • Page 33: Speaker

    (12) reach through the instrument panel glove box opening to access and remove the screw that secures the cd radio bracket and the ground strap to the back of the radio receiver chassis (fig. 4). (13) pull the radio out from the instrument panel far enough to access the wire harness connectors and t...

  • Page 34: Sound Bar

    Installation warning: on vehicles equipped with air- bags, (refer to electrical/restraints) before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible pers...

  • Page 35

    (6) unplug the sound bar wire harness connector. (7) lift each outboard end flap of the sound bar cover over the top of the sport bar far enough to access the mounting screws (fig. 8). (8) remove the two screws that secure each end of the sound bar to the sport bar. (9) lift the sound bar up off of ...

  • Page 36: Instrument Cluster

    Instrument cluster table of contents page page instrument cluster description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 diagnosis and testing . . . . . . . . . . . . . . . . . . 6 instrument cluster . . . . . . . ....

  • Page 37

    Description the instrument cluster for this model is an elec- tromechanical instrument cluster (emic) module that is located in the instrument panel above the steering column opening, directly in front of the driver (fig. 1). The emic gauges and indicators are protected by an integral clear plastic ...

  • Page 38

    The emic module incorporates a blue-green elec- tronic digital vfd for displaying odometer, trip odometer, and diagnostic information. The emic includes the following analog gauges: • coolant temperature gauge • fuel gauge • oil pressure gauge • speedometer • tachometer • voltage gauge the emic also...

  • Page 39

    Extreme position and the microprocessor turns on the check gauges indicator to provide a distinct visual indication of a problem to the vehicle operator. The instrument cluster circuitry may also generate a chime tone when it monitors certain conditions or inputs to provide the vehicle operator with...

  • Page 40

    Information for additional details on these vfd func- tions. The vfd is diagnosed using the emic self-diag- nostic actuator test. (refer to 8 - electrical/in- strument cluster - diagnosis and testing). Proper testing of the pci data bus and the data bus message inputs to the emic that con- trol some...

  • Page 41

    (refer to 8 - electrical/chime/buzzer - operation). The hard wired chime inputs to the emic are diagnosed using conventional diagnostic methods. Proper testing of the emic, its program- ming, and the pci data bus chime request message functions requires the use of a drbiii t scan tool. Refer to the ...

  • Page 42

    Of wire harness routing and retention, connector pin- out information and location views for the various wire harness connectors, splices and grounds. Note: certain indicators in this instrument cluster are automatically configured. This feature allows those indicators to be activated for compatibil...

  • Page 43

    The instrument cluster actuator test will put the instrument cluster into its self-diagnostic mode. In this mode the instrument cluster can perform a self- diagnostic test that will confirm that the instrument cluster circuitry, the gauges, the pci data bus mes- sage controlled indicator lamps, and ...

  • Page 44

    Instrument cluster failure message vfd message description correction 9 bus b0 9 pcm - mil message the cluster is not receiving a mil lamp message from the pcm. A drbiii t scan tool is required for further diagnosis. Refer to the appropriate diagnostic information. 9 bus b1 9 skim - skim message the...

  • Page 45

    (4) disconnect the floor wire harness connector from the seat belt switch pigtail wire connector. Check for continuity between the seat belt switch sense circuit cavity of the instrument panel wire har- ness connector (connector c2) for the instrument cluster and a good ground. There should be no co...

  • Page 46

    Warning: on vehicles equipped with air- bags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and iso- late the battery negative (ground) cable, then wait two minutes for the airbag sys- tem capacitor to ...

  • Page 47

    And a good ground. There should be no continuity. If ok, go to step 3. If not ok, repair the shorted panel lamp dimmer signal circuit between the instrument cluster and the left multi-function switch as required. (3) check for continuity between the panel lamp dimmer signal circuit cavities of the i...

  • Page 48

    (4) pull the bulb and bulb holder unit straight back to remove it from the bulb mounting hole in the cluster electronic circuit board. Cluster lens (1) disconnect and isolate the battery negative cable. (2) remove the instrument cluster from the instru- ment panel. (refer to 8 - electrical/instru- m...

  • Page 49

    Assembly warning: on vehicles equipped with air- bags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and iso- late the battery negative (ground) cable, then wait two minutes for the airbag sys- tem capa...

  • Page 50: Abs Indicator

    Installation warning: on vehicles equipped with air- bags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and iso- late the battery negative (ground) cable, then wait two minutes for the airbag sys- tem ...

  • Page 51: Airbag Indicator

    And retention, connector pin-out information and location views for the various wire harness connec- tors, splices and grounds. Warning: on vehicles equipped with air- bags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or se...

  • Page 52: Brake/park Brake

    Remains illuminated for about twelve seconds or until the cluster receives a single lamp-off message from the acm, whichever is longer. • actuator test - each time the cluster is put through the actuator test, the airbag indicator will be turned on, then off again during the bulb check por- tion of ...

  • Page 53

    Bulb check portion of the test to confirm the function- ality of the led and the cluster control circuitry. The park brake switch and the brake warning pressure switch are each connected in parallel between ground and the red brake warning indicator driver input to the instrument cluster so that eac...

  • Page 54: Check Gauges Indicator

    (4) check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If not ok, replace the faulty park brake switch. Check gauges indicator description a check gauges indicat...

  • Page 55: Cruise Indicator

    Cruise indicator description a cruise indicator is standard equipment on all instrument clusters, but is only functional on vehi- cles equipped with the optional speed control system. The cruise indicator is located near the upper edge of the instrument cluster overlay, in the upper left quadrant of...

  • Page 56

    Operation the engine coolant temperature gauge gives an indication to the vehicle operator of the engine cool- ant temperature. This gauge is controlled by the instrument cluster electronic circuit board based upon the cluster programming and electronic mes- sages received by the cluster from the po...

  • Page 57: Fog Lamp Indicator

    Fog lamp indicator description a fog lamp indicator is standard equipment on all instrument clusters, but is only functional on vehi- cles equipped with the optional front and/or rear fog lamps. The fog lamp indicator is located near the upper edge of the instrument cluster overlay, in the upper lef...

  • Page 58: Fuel Gauge

    Fuel gauge description a fuel gauge is standard equipment on all instru- ment clusters. The fuel gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The fuel gauge consists of a movable gauge needle or pointer controlled by the instrument cluster electroni...

  • Page 59: High Beam Indicator

    The pcm continually monitors the fuel tank send- ing unit, then sends the proper messages to the instrument cluster. For further diagnosis of the fuel gauge or the instrument cluster circuitry that con- trols the gauge, (refer to 8 - electrical/instru- ment cluster - diagnosis and testing). For prop...

  • Page 60: Low Fuel Indicator

    Replace the indicator bulb and bulb holder with a known good unit and repeat the test. If the indicator still fails to illuminate, replace the faulty instrument cluster. If the problem being diagnosed is related to inoperative headlamp high beams, be certain to repair the headlamp system circuits an...

  • Page 61: Malfunction Indicator

    • less than empty percent tank full mes- sage - each time the cluster receives a message from the pcm indicating the percent tank full is less than empty, the low fuel indicator is illuminated immedi- ately. This message would indicate that the fuel tank sender input to the pcm is a short circuit. •...

  • Page 62: Odometer

    Require service. For proper diagnosis of the fuel and emissions systems, the pcm, the pci data bus, or the message inputs to the instrument cluster that control the mil, a drbiii t scan tool is required. Refer to the appropriate diagnostic information. Odometer description an odometer and trip odome...

  • Page 63: Oil Pressure Gauge

    Vehicle speed sensor, the pcm, the pci data bus, or the message inputs to the instrument cluster that control the odometer/trip odometer, a drbiii t scan tool is required. Refer to the appropriate diagnostic information. Oil pressure gauge description an oil pressure gauge is standard equipment on a...

  • Page 64: Seatbelt Warning

    Seatbelt warning indicator description a seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the center of the instrument cluster overlay, directly below the high beam indicator and above the odometer/trip odometer vacuum fluorescent display (v...

  • Page 65

    Cil-like cutout of the words “full time” in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green lens behind the cutout in the opaque layer of the cluster overlay causes the “full...

  • Page 66

    Information on the transfer case switch. For further diagnosis of the part time indicator or the instrument cluster circuitry that controls the led, (refer to 8 - electrical/instrument cluster - diagno- sis and testing). Diagnosis and testing - part time indicator the diagnosis found here addresses ...

  • Page 67: Speedometer

    Test, confirm the functionality of the full time indica- tor light emitting diode (led) and the cluster con- trol circuitry by performing the instrument cluster actuator test. (refer to 8 - electrical/instru- ment cluster - diagnosis and testing). If the full time indicator fails to illuminate durin...

  • Page 68: Tachometer

    Equivalent opposite units from the primary scale. A label on the cluster overlay beneath the hub of the speedometer pointer abbreviates the unit of measure for the primary scale in all upper case letters (i.E.: mph or km/h), followed by the unit of measure for the secondary scale in all lower case l...

  • Page 69: Turn Signal Indicators

    Munications interface (pci) data bus. The tachome- ter is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run- start) circuit whenever the ignition switch is in the on or start positions. The cluster...

  • Page 70: Upshift Indicator

    To diagnose or repair the turn signal indicators. (refer to 8 - electrical/lamps/lighting - exterior - diagnosis and testing - turn signal & hazard warning system). If no turn signal and hazard warning system problem is found, the following procedure will help locate an open in the right or left tur...

  • Page 71: Voltage Gauge

    Accelerating and is brought back into the range of indicator operation, or until the transmission is shifted into another gear. • actuator test - each time the cluster is put through the actuator test, the upshift indicator will be turned on, then off again during the bulb check portion of the test ...

  • Page 72

    • actuator test - each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence to confirm the functionality of the gauge and the cluster control circuitry. The pcm continually monitors the system volt...

  • Page 74: Restraints

    Restraints table of contents page page restraints description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 diagnosis and testing . . . . . . . . ...

  • Page 75

    Description a dual front airbag system is standard factory-in- stalled safety equipment on this model. The airbag system is a passive, inflatable, supplemental restraint system (srs) and vehicles with this equip- ment can be readily identified by the “srs - air- bag” logo molded into the driver airb...

  • Page 76

    Chanical instrument cluster (emic) lights for about seven seconds as a bulb test each time the ignition switch is turned to the on or start positions. Follow- ing the bulb test, the airbag indicator is turned on or off by the acm to indicate the status of the airbag system. If the airbag indicator c...

  • Page 77

    Warning: replace airbag system compo- nents only with parts specified in the daimlerchrysler mopar parts catalog. Substitute parts may appear interchange- able, but internal differences may result in inferior occupant protection. Warning: the fasteners, screws, and bolts originally used for the airb...

  • Page 78

    Cleanup procedure following an airbag deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge used to initiate the propellant used to deploy the airbags. However, this residue may also contai...

  • Page 79: Airbag Control Module

    (9) turn the ignition switch to the off position for about fifteen seconds, and then back to the on posi- tion. Observe the airbag indicator in the instrument cluster. It should light for six to eight seconds, and then go out. This indicates that the airbag system is functioning normally and that th...

  • Page 80

    Operation). The acm microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the acm detects a monitored system fault, it sets an active diagnostic trouble code (dtc) and sends messages to the emic over the pci data bus to turn on the ai...

  • Page 81

    Enough to access the airbag control module (acm), which is forward of the floor console. (3) if the vehicle is equipped with the optional anti-lock brake system (abs), remove the accelera- tion switch from the left side of the mounting bracket on the floor panel transmission tunnel. (refer to 5 - br...

  • Page 82: Clockspring

    Warning: the airbag control module con- tains the impact sensor, which enables the system to deploy the airbags. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag con- trol module is accidentally dropped dur- ing service, the m...

  • Page 83

    Dard procedure - clockspring centering). The clockspring cannot be repaired. If the clock- spring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. Operation the clockspring is a mechanical electrical circuit component that is used to provide continuous...

  • Page 84

    (4) from the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise, until the rotor flats are horizontal. If the clockspring pigtail wires are not oriented towards the bottom of the clockspring, rotate the rotor another one-half turn in the counterclockwise dire...

  • Page 85

    (11) using a small screwdriver, gently pry both plastic latches of the clockspring assembly to release them from the steering column upper housing. Note: if the clockspring plastic latches are broken, be certain to remove the broken pieces from the steering column upper housing. (12) remove the cloc...

  • Page 86: Driver Airbag

    Note: before starting this procedure, be certain that the front wheels are still in the straight-ahead position. (1) if the removed clockspring is being reinstalled, remove the wire from the index hole that is locking the clockspring rotor to the clockspring case to main- tain clockspring centering....

  • Page 87

    That is captured on the upper left inflator mounting stud between the inflator and the upper trim cover retainer. The other horn switch pigtail wire is routed between the upper right inflator stud and the infla- tor, then secured with a small nylon retainer that is pressed onto the inflator stud. Th...

  • Page 88

    Caution: do not pull on the clockspring wire har- ness to disengage the connector from the driver airbag inflator connector receptacle. (5) the clockspring driver airbag pigtail wire con- nector is a tight snap fit into the airbag inflator con- nector receptacle, which is located on the back of the ...

  • Page 89

    (6) remove the horn switch ground pigtail wire eyelet terminal connector from the upper left airbag housing stud. (7) disengage the four trim cover locking blocks from the lip around the outside edge of the driver airbag housing and remove the housing from the cover (fig. 16). Assembly the horn swit...

  • Page 90

    Installation the following procedure is for replacement of a faulty or damaged driver airbag. If the driver airbag has been deployed, the clockspring must also be replaced. (refer to 8 - electrical/restraints/ clockspring - installation). Warning: disable the airbag system before attempting any stee...

  • Page 91: Front Seat Belt &

    Front seat belt & retractor removal warning: during and following any seat belt service, carefully inspect all seat belts, buckles, mounting hardware, and retractors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tig...

  • Page 92: Front Seat Belt Buckle

    (3) position the support/guide washer and the shoulder belt turning loop onto the height adjuster near the top of the sport bar (fig. 18). (4) install and tighten the screw that secures the shoulder belt turning loop to the adjuster. Tighten the screw to 43 n·m (32 ft. Lbs.). (5) fold and snap the s...

  • Page 93

    And sealed within the stamped metal airbag housing along with the folded airbag cushion. A yellow con- nector on the end of a short, two-wire pigtail harness connects the passenger airbag inflator to the vehicle electrical system. The molded plastic passenger airbag door also serves as a trim cover ...

  • Page 94

    Warning: when removing a deployed air- bag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. (1) disconnect and isolate the battery n...

  • Page 95: Switch

    Passenger airbag on / off switch description the passenger airbag on-off switch is standard equipment on all versions of this model (fig. 23). This switch is a two-position, resistor multiplexed switch with a single integral red light-emitting diode (led), and a non-coded key cylinder-type actuator....

  • Page 96

    Driver circuit, which energizes the light-emitting diode (led) that illuminates the off indicator of the switch. The acm will also illuminate the off indica- tor of the switch for about seven seconds each time the ignition switch is turned to the on position as a bulb test. The acm will store a diag...

  • Page 97: Rear Seat Belt &

    Rear seat belt & retractor removal warning: during and following any seat belt service, carefully inspect all seat belts, buckles, mounting hardware, and retractors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tigh...

  • Page 98: Rear Seat Belt Buckle

    Installation warning: during and following any seat belt service, carefully inspect all seat belts, buckles, mounting hardware, and retractors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fastener...

  • Page 99: Seat Belt Switch

    Installation warning: during and following any seat belt service, carefully inspect all seat belts, buckles, mounting hardware, and retractors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fastener...

  • Page 100: Seat Belt Turning Loop

    Warning: on vehicles equipped with air- bags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and iso- late the battery negative (ground) cable, then wait two minutes for the airbag sys- tem capacitor to ...

  • Page 101

    (1) position the turning loop adjuster onto the sport bar (fig. 29). Be certain that the word “up” stamped on the adjuster is properly oriented. (2) install and tighten the two screws that secure the turning loop adjuster to the sport bar. Tighten the screws to 43 n·m (32 ft. Lbs.). (3) align the tr...

  • Page 102: Wiring

    Wiring table of contents page page wiring diagram information. . . . . . 8wa-01-1 component index . . . . . . . . . . . . . . . . . 8wa-02-1 power distribution . . . . . . . . . . . . . . 8wa-10-1 fuse block. . . . . . . . . . . . . . . . . . . . . . . 8wa-11-1 ground distribution . . . . . . . . . ...

  • Page 104: Wiring Diagram

    8w-01 wiring diagram information table of contents page page wiring diagram information description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 diagnosis and testing . . . . . . . . . . . . . . . . . . 5 wiring har...

  • Page 105

    Fig. 1 wiring diagram example 1 8wa - 01 - 2 8w-01 wiring diagram information tj wiring diagram information (continued).

  • Page 106

    Fig. 2 wiring diagram example 2 tj 8w-01 wiring diagram information 8wa - 01 - 3 wiring diagram information (continued).

  • Page 107

    Fig. 3 wiring diagram symbols 8wa - 01 - 4 8w-01 wiring diagram information tj wiring diagram information (continued).

  • Page 108

    Terminology this is a list of terms and definitions used in the wiring diagrams. Lhd . . . . . . . . . . . . . . . . . Left hand drive vehicles rhd . . . . . . . . . . . . . . . . Right hand drive vehicles atx . . Automatic transmissions-front wheel drive mtx . . . . Manual transmissions-front wheel...

  • Page 109

    • probing tools - these tools are used for probing terminals in connectors (fig. 4)select the proper size tool from special tool package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Intermittent and poor connections most intermittent el...

  • Page 110

    Standard procedure - testing for continuity (1) remove the fuse for the circuit being checked or, disconnect the battery. (2) connect one lead of the ohmmeter to one side of the circuit being tested (fig. 6) (3) connect the other lead to the other end of the circuit being tested. Low or no resistanc...

  • Page 111: Connector - Augat

    Special tools special tools - wiring/terminal connector - augat removal (1) disconnect battery. (2) disconnect the connector from its mating half/ component. (3) push down on the yellow connector locking tab to release the terminals (fig. 8). (4) using special tool 6932, push the terminal to remove ...

  • Page 112: Connector - Molex

    Installation (1) reset the terminal locking tang. (2) insert the removed wire in the same cavity on the repair connector. (3) repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identifica- tion, refer to the ...

  • Page 113: Diode

    (4) insert the probe end of special tool 6934 into the back of the connector cavity (fig. 13). (5) grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. (6) repair or replace the terminal as necessary. Installation (1) reset the terminal locking tang. (2) insert ...

  • Page 114: Terminal

    Terminal removal (1) disconnect battery. (2) disconnect the connector being repaired from its mating half/component. (3) remove the connector locking wedge, if required (fig. 16). (4) position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull ...

  • Page 115: Wire

    Wire standard procedure standard procedure - wire splicing when splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams. (1) remove one-half (1/2) inch of insulation from each wire that needs to be spliced. (2) place a piece of adhesive lined heat shrink tub-...

  • Page 116

    8w-02 component index component page 4wd indicator . . . . . . . . . . . . . . . . . . . . . . . 8wa-31 a/c compressor clutch relay . . . . . . . . . . . 8wa-42 a/c compressor clutch . . . . . . . . . . . . . . . . 8wa-42 a/c-heater control . . . . . . . . . . . . . . . . . . . 8wa-42 a/c high press...

  • Page 117

    Component page speed control servo . . . . . . . . . . . . . . . . . . . 8wa-30 speed control switch pod . . . . . . . . . . . . . . 8wa-30 subwoofer . . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-47 throttle position sensor . . . . . . . . . . . . . . . . 8wa-30 torque converter clutch sol...

  • Page 118

    8w-10 power distribution component page a/c compressor clutch . . . . . . . . . . . . . . 8wa-10-16 a/c compressor clutch relay . . . . . . . 8wa-10-8, 16 automatic shut down relay . . . . . 8wa-10-7, 13, 14 battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-10-7 blower motor relay . ...

  • Page 136

    8w-11 fuse block component page a/c compressor clutch relay . . . . . . . . . . 8wa-11-8 a/c-heater control . . . . . . . . . . . . . . . . . . 8wa-11-6 airbag control module . . . . . . . . . . . . . 8wa-11-5, 7 antilock brake relay . . . . . . . . . . . . . . . . 8wa-11-6 automatic shut down relay...

  • Page 146

    8w-15 ground distribution component page a/c compressor clutch . . . . . . . . 8wa-15-11, 12, 13 a/c-heater control . . . . . . . . . . . . . . . . 8wa-15-6, 7 airbag control module . . . . . . . . . . . . . . . 8wa-15-9 antilock brake relay . . . . . . . . . . . . . . . . 8wa-15-2 battery . . . . ....

  • Page 160

    8w-18 bus communication component page airbag control module . . . . . . . . . . . . . . . 8wa-18-2 controller antilock brake . . . . . . . . . . . . . 8wa-18-2 data link connector . . . . . . . . . . . . . . . . . 8wa-18-2 fuse 24 (pdc) . . . . . . . . . . . . . . . . . . . . . . 8wa-18-2 g105 . . ...

  • Page 162

    8w-20 charging system component page automatic shut down relay . . . . . . . . . . . 8wa-20-2 battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-20-2 battery temperature sensor . . . . . . . . . . . 8wa-20-3 engine starter motor . . . . . . . . . . . . . . . . 8wa-20-2 fuel pump relay...

  • Page 166

    8w-21 starting system component page battery . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-21-2, 3 clutch pedal position switch . . . . . . . . . . 8wa-21-2 clutch pedal position switch connector . . 8wa-21-2 engine starter motor . . . . . . . . . . . . . . 8wa-21-2, 3 engine starter motor r...

  • Page 170

    8w-30 fuel/ignition system component page a/c compressor clutch relay . . . . . . . . . . 8wa-30-3 a/c high pressure switch . . . . . . . . . . . . 8wa-30-16 a/c low pressure switch . . . . . . . . . . . . 8wa-30-16 a/c-heater control . . . . . . . . . . . . . . . . . 8wa-30-16 airbag control module...

  • Page 190

    8w-31 transmission control system component page brake lamp switch . . . . . . . . . . . . . . . . . 8wa-31-2 brake transmission shift interlock solenoid . . . . . . . . . . . . . . . . . 8wa-31-2 fuse 10 (fb) . . . . . . . . . . . . . . . . . . . . . . . 8wa-31-2 fuse 11 (fb) . . . . . . . . . . . ...

  • Page 192

    8w-35 antilock brakes component page antilock brake relay . . . . . . . . . . . . . . . . 8wa-35-2 brake lamp switch . . . . . . . . . . . . . . . . . 8wa-35-3 brake transmission shift interlock solenoid . . . . . . . . . . . . . . . . . . . . . . . . 8wa-35-2 center high mounted stop lamp . . . . ....

  • Page 196

    8w-40 instrument cluster component page airbag control module . . . . . . . . . . . . . . . 8wa-40-4 antilock brake relay . . . . . . . . . . . . . . . . 8wa-40-6 brake warning indicator switch . . . . . . . . 8wa-40-6 data link connector . . . . . . . . . . . . . . . 8wa-40-3, 4 daytime running lam...

  • Page 206

    8w-41 horn/cigar lighter/power outlet component page cigar lighter/power outlet . . . . . . . . . . . . 8wa-41-2 clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8wa-41-3 fuse 19 (fb) . . . . . . . . . . . . . . . . . . . . . . . 8wa-41-2 fuse 13 (pdc) . . . . . . . . . . . . . . . . . . ...

  • Page 210

    8w-42 air conditioning-heater component page a/c compressor clutch . . . . . . . . . . . . . . . 8wa-42-4 a/c compressor clutch relay . . . . . . . . . . 8wa-42-4 a/c high pressure switch . . . . . . . . . . . . . 8wa-42-4 a/c low pressure switch . . . . . . . . . . . . . 8wa-42-4 a/c-heater control...

  • Page 214

    8w-43 airbag system component page airbag control module . . . . . . . . . . . . . 8wa-43-2, 3 brake transmission shift interlock solenoid . . . . . . . . . . . . . . . . . . . . . . . . 8wa-43-3 clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8wa-43-2 data link connector . . . . . . . ....

  • Page 218

    8w-44 interior lighting component page a/c-heater control . . . . . . . . . . . . . . . . . . 8wa-44-7 dome lamp . . . . . . . . . . . . . . . . . . . . . . 8wa-44-2, 3 driver door ajar switch . . . . . . . . . . . . . . 8wa-44-6 fuse 4 (fb) . . . . . . . . . . . . . . . . . . . . . . . . 8wa-44-6 f...

  • Page 226

    8w-47 audio system component page brake lamp switch . . . . . . . . . . . . . . . . . 8wa-47-2 fuse 3 (fb) . . . . . . . . . . . . . . . . . . . . . . . . 8wa-47-2 fuse 15 (fb) . . . . . . . . . . . . . . . . . . . . . . . 8wa-47-2 fuse 24 (pdc) . . . . . . . . . . . . . . . . . . . . . . 8wa-47-2 f...

  • Page 230

    8w-48 rear window defogger component page fuse 7 (fb) . . . . . . . . . . . . . . . . . . . . . . . . 8wa-48-2 fuse 17 (fb) . . . . . . . . . . . . . . . . . . . . . . . 8wa-48-2 fuse 2 (pdc) . . . . . . . . . . . . . . . . . . . . . . . 8wa-48-2 fuse block . . . . . . . . . . . . . . . . . . . . . ...

  • Page 232

    8w-50 front lighting component page beam select switch . . . . . . . . . . . . . . . . . . 8wa-50-2 circuit breaker . . . . . . . . . . . . . . . . . . . . . 8wa-50-2 daytime running lamp module . . 8wa-50-2, 3, 8, 9 fog lamp relay . . . . . . . . . . . . . . . . . . 8wa-50-7, 8 fuse 1 (fb) . . . . ...

  • Page 242

    8w-51 rear lighting component page back-up lamp switch . . . . . . . . . . . . . . 8wa-51-2, 4 brake lamp switch . . . . . . . . . . . . . . . . 8wa-51-5, 7 brake transmission shift interlock solenoid . . . . . . . . . . . . . . . . . . . . . . . . 8wa-51-7 center high mounted stop lamp . . . . . 8w...

  • Page 252

    8w-52 turn signals component page brake lamp switch . . . . . . . . . . . . . . . . 8wa-52-2, 3 fuse 13 (fb) . . . . . . . . . . . . . . . . . . . . . 8wa-52-2, 3 fuse 7 (pdc) . . . . . . . . . . . . . . . . . . . . . 8wa-52-2, 3 fuse block . . . . . . . . . . . . . . . . . . . . . . . 8wa-52-2, 3 g...

  • Page 258

    8w-53 wipers component page front washer pump . . . . . . . . . . . . . . . . . 8wa-53-2 front wiper motor . . . . . . . . . . . . . . . . . . 8wa-53-2 fuse 14 (fb) . . . . . . . . . . . . . . . . . . . . . . . 8wa-53-2 fuse 6 (fb) . . . . . . . . . . . . . . . . . . . . . . . . 8wa-53-3 fuse block ...

  • Page 262

    8w-70 splice information component page s101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-10-14 s102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-11-8 s103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8wa-42-4 s105 . . . . . . . . . . . . . . . . . . . . ...

  • Page 270

    8w-80 connector pinouts component page a/c compressor clutch . . . . . . . . . . . . . . . 8wa-80-3 a/c-heater control c1 . . . . . . . . . . . . . . . 8wa-80-3 a/c-heater control c2 . . . . . . . . . . . . . . . 8wa-80-3 a/c-heater control c3 . . . . . . . . . . . . . . . 8wa-80-3 a/c high pressure...

  • Page 271

    Component page intake air temperature sensor . . . . . . . . 8wa-80-30 leak detection pump (lhd) . . . . . . . . . . 8wa-80-30 left courtesy lamp . . . . . . . . . . . . . . . . 8wa-80-30 left fog lamp (except built-up-export) . 8wa-80-30 left front park/ turn signal lamp (except built-up-export) . ...

  • Page 272

    A/c compressor clutch - black 2 way cav circuit function 1 c3 20db/bk a/c compressor clutch relay output 2 z1 20bk ground a/c-heater control c1 - 5 way cav circuit function a c7 12br/tn blower motor high speed b c6 14lb blower motor m2 speed c c5 16lg/lb blower motor m1 speed d c4 18tn blower motor ...

  • Page 273

    A/c low pressure switch - 2 way cav circuit function 1 c22 20db/wt (4 cyl) a/c low pressure switch sense 1 c21 20db/or (4 cyl) a/c switch sense 2 c21 20db/or (6 cyl) a/c switch sense 2 c22 20db/wt (6 cyl) a/c low pressure switch sense airbag control module - yellow 22 way cav circuit function 1 r45 ...

  • Page 274

    Blend door actuator - 6 way cav circuit function 5 - - 6 - - 7 z11 20db/wt ground 8 c36 20yl blend door feed back signal 9 - - 10 f24 20or fused ignition switch output (run) blower motor - 2 way cav circuit function a c1 12dg blower motor relay output b c7 12bk/tn blower motor high driver blower mot...

  • Page 275

    Brake lamp switch - gray 6 way cav circuit function 5 f32 19pk/db fused b(+) 6 l50 18wt/tn brake lamp switch output brake transmission shift interlock solenoid - white 2 way cav circuit function 1 k29 20wt/pk brake lamp switch sense 2 g5 20db/wt fused ignition switch output (run-start) brake warning...

  • Page 276

    C103 - black (engine side) cav circuit 7 a141 18dg/wt 8 k4 20bk/lb 9 f12 20rd/lg 10 z12 20bk/tn 11 z12 20bk/lb 12 g7 20wt/or (drl) 13 g107 20bk/rd 14 c3 20db/bk c104 (lhd) - gray (dash side) cav circuit 1 c90 20lg 2 c21 20db/or 3 b1 18yl/db (abs) 4 b2 18yl (abs) 5 t41 20br/lb 6 b3 18lg/db (abs) 7 b4...

  • Page 277

    C104 (rhd) - black (dash side) cav circuit 1 c90 20lg 2 c21 18db/or 3 a42 18dg 4 f42 18dg/lg 5 t41 20br/lb 6 t40 20br 7 f15 18db 8 a242 18vt/or 9 l1 20vt/bk 10 f20 20vt/wt c104 (rhd) - black (engine side) cav circuit 1 c90 20lg 2 c21 20db/or (6 cyl) 2 c22 20db/wt (4 cyl) 3 a42 18dg 4 f42 18dg/lg 5 t...

  • Page 278

    C104 (rhd abs) - (engine side) cav circuit 1 c90 20lg 2 c21 20db/or 3 b1 18yl/db 4 b2 18yl 5 t41 20br/lb 6 b3 18lg/db 7 b4 18lg 8 - 9 l1 20vt/bk 10 f20 20vt/wt 11 f42 18dg/lg 12 t40 12br 13 f15 18db 14 - c106 - black (dash side) cav circuit 1 f30 12rd/pk 2 l1 20vt/bk 3 f20 20vt/wt 4 f15 20db 5 a1 14...

  • Page 279

    C107 - yellow (dash side) cav circuit 1 l7 18bk/yl 2 l60 18tn 3 l61 18gy 4 l3 14rd/or 5 l4 14vt/wt 6 z12 20bk/lb 7 x3 20rd/yl 8 v10 16br 9 z12 20bk/tn 10 f61 16wt/or 11 v30 20db/rd (rhd) 12 b43 18pk/or (abs) 13 d32 18lg 14 d21 20pk (abs) 14 d21 18pk c107 - yellow (crossbody side) cav circuit 1 l7 18...

  • Page 280

    C108 - blue (dash side) cav circuit 7 g34 14rd/gy (drl) 8 f3 14lb/or 9 l50 18wt/tn (abs) 10 v37 18rd/lg (speed control) 11 l9 18bk/wt 12 m1 20pk/wt 12 m1 20pk/wt 13 l22 20lg/dg (except canada) 14 k29 18wt/pk c108 - blue (crossbody side) cav circuit 1 v32 20yl/rd 2 b41 20yl/vt (lhd) 3 k4 20bk/lb 4 f3...

  • Page 281

    C110 - black (dash side) cav circuit 1 l7 18bk/yl 2 l60 18tn 3 l61 18gy 4 l3 14rd/or 5 l4 14vt/wt 6 x2 18wt/rd 7 - 8 v10 16br 9 l22 10lg/dg (except canada) 10 k52 18pk/bk 11 f12 20rd/lg 12 - 13 l39 16lb (front fog lamps) 14 l13 20br/yl (built-up-export) c154 - black (engine side) cav circuit 1 z1 18...

  • Page 282

    C170 - lt. Gray (dash side) cav circuit 6 c90 20lg 7 - 8 g19 20lg/or (abs) 9 l39 16lb (except built-up-export) 10 a111 12rd/lb c170 - black (i/p side) cav circuit 1 l13 20br/yl (built-up-export) 2 c81 20lb/wt (hard top) 3 g99 20gy/wt 4 - 5 g107 20bk/rd 6 c90 20lg 7 - 8 g19 20lg/or 9 l39 16lb (except...

  • Page 283

    C202 - gray (crossbody side) cav circuit a6 z12 20bk/lb a6 z12 20bk/lb a7 - a8 g34 14rd/gy a9 f38 16lb a10 g5 20db/wt a10 g5 20db/wt a11 - a12 - c203 - green (i/p side) cav circuit b1 l60 18tn b2 l61 18gy b3 g26 20lb b3 g26 20lb b4 l50 18wt/tn (lhd) b5 - b6 l7 18bk/yl b7 m1 20pk/wt b8 d32 20lg b9 v2...

  • Page 284

    C203 - green (crossbody side) cav circuit b14 d25 2ovt/yl b14 d25 18vt/yl c204 - red (i/p side) cav circuit c1 x16 20lg c2 v13 18br/lg (hard top) c3 g10 20lg/rd c4 z12 20bk/tn c5 m2 20yl c6 v23 18br/pk c7 e19 20rd c8 l50 18 wt/tn (lhd) c9 l22 20lg/dg (built-up-export) c10 x12 16pk c11 x51 18br/yl c1...

  • Page 285

    C205 - lt. Green (i/p side) cav circuit 1 z11 20bk/wt 2 c4 18tn 3 c5 16lg/lb 4 c6 14lb 5 f24 20rd/dg 5 f24 20rd/dg 6 c36 20db/rd 7 c7 12br/tn 8 a111 12rd/lb 9 f24 20rd/dg 10 z1 20bk c205 - (hvac side) cav circuit 1 z11 20db/wt 2 c4 14tn 3 c5 14lg 4 c6 14lb 5 f24 20or 6 c36 20yl 7 c7 12bk/tn 8 a111 1...

  • Page 286

    C322 (lhd) - black (crossbody side) cav circuit g1 l7 18bk/yl g2 l62 18br/rd g3 l1 20vt/bk g4 l63 18dg/rd g5 z1 12bk g6 g10 20lg/rd g7 l50 18wt/tn g7 l50 18wt/tn g8 - g9 g9 20gy/bk g10 v23 18br/pk c322 (rhd) - black (rear body side) cav circuit 1 l7 18bk/yl 2 l62 18br/rd 3 l1 20vt/bk 4 l63 18dg/rd 5...

  • Page 287

    C323 (lhd) (except 2 speaker soft top) - red (rear body side) cav circuit h1 c15 12bk/wt (hard top) h2 m1 20pk/wt h3 m2 20yl h4 v23 18br/pk (hard top) h5 v13 18br/lg (hard top) h6 v20 18vt/or (hard top) h7 x51 18br/yl (4 speaker system) h8 c57 18br/lb (4 speaker system) h9 x52 18db/wt (4 speaker sys...

  • Page 288

    C323 (rhd) (except 2 speaker soft top) - gray (crossbody side) cav circuit 1 c15 12bk/wt (hard top) 2 m1 20pk/wt 3 m2 20yl 4 v23 18br/pk (hard top) 5 v13 18br/lg (hard top) 6 v20 18vt/or (hard top) 7 x51 18br/yl (4 speaker system) 8 x57 18br/lb (4 speaker system) 9 x52 18db/wt (4speaker system) 10 x...

  • Page 289

    C326 (hard top) - (rear body side) cav circuit 9 m2 20yl 10 - c326 (hard top) - black (hard top side) cav circuit 1 c15 12bk/wt 2 - 3 v13 18br/lg 4 v23 18br/pk 5 v23 18br/pk 6 z1 12bk 7 - 8 m1 18pk/wt 9 m2 18yl 10 - cigar lighter/accessory relay - black 5 way cav circuit function 1 f30 12rd/pk fused...

  • Page 290

    C330 (4 spkr sys) - white (sound bar jumper side) cav circuit 1 x57 18br/lb 2 x51 18br/yl 3 m1 20pk/wt 4 m2 20yl 5 x58 18db/pk 6 x52 18db/wt c330 (4 spkr sys) - black (sound bar side) cav circuit 1 x57 20br/lb 2 x51 20br/yl 3 m1 20pk/wt 4 m2 20yl 5 x58 20db/pk 6 x52 20db/wt c331 (hard top) - black (...

  • Page 291

    Camshaft position sensor - 3 way cav circuit function 1 k44 18tn/yl camshaft position sensor signal 2 k4 20bk/lb sensor ground 3 k7 20or 5v supply cigar lighter/power outlet - red 3 way cav circuit function 1 f38 16lb fused cigar lighter/accessory relay output 2 - - 3 z1 16bk ground circuit breaker ...

  • Page 292

    Clutch pedal position switch (m/t) - black 2 way cav circuit function 1 t141 14yl/rd fused ignition switch output (start) 2 a41 14yl fused ignition switch output (start) controller antilock brake - 25 way cav circuit function 1 b1 18yl/db right rear wheel speed sensor (-) 2 b3 18lg/db left rear whee...

  • Page 293

    Data link connector - black 16 way cav circuit function 3 - - 4 z12 20bk/lb ground 5 z12 20bk/tn ground 6 d32 20lg sci receive 7 d21 20pk sci transmit 8 - - 9 - - 10 - - 11 - - 12 - - 13 - - 14 - - 15 - - 16 m1 20pk/wt fused b(+) daytime running lamp module (except built-up-export) - black 10 way ca...

  • Page 294

    Engine coolant temperature sensor - black 2 way cav circuit function 1 k2 18tn/bk engine coolant temperature sensor signal 2 k4 20bk/lb sensor ground front fog lamp switch - black 4 way cav circuit function 1 e2 20or fused panel lamps dimmer switch signal 2 l35 18br/wt fog lamp switch output 3 l95 1...

  • Page 295

    Fuel injector no. 1 (2.5l) - 2 way cav circuit function 1 f42 18dg/lg fused automatic shut down relay output 2 k11 18wt/db fuel injector no. 1 driver fuel injector no. 1 (4.0l) - 2 way cav circuit function 1 f42 18dg/lg fused automatic shut down relay output 2 k11 18wt/db fuel injector no. 1 driver ...

  • Page 296

    Fuel injector no. 4 (2.5l) - 2 way cav circuit function 1 f42 18dg/lg fused automatic shut down relay output 2 k14 18lb/br fuel injector no. 4 driver fuel injector no. 4 (4.0l) - 2 way cav circuit function 1 f42 18dg/lg fused automatic shut down relay output 2 k14 18lb/br fuel injector no. 4 driver ...

  • Page 297

    Generator - black 2 way cav circuit function 1 k125 18wt/db generator source 2 k20 18dg generator field headlamp leveling switch (built-up-export) - 6 way cav circuit function 1 - - 2 l22 20lg/dg fused headlamp switch output 3 - - 4 z1 20bk ground 5 l13 20br/yl headlamp adjust signal 6 - - high note...

  • Page 298

    Ignition coil pack (4.0l) - black 4 way cav circuit function 1 k19 18gy ignition coil no.1 driver 2 f42 18dg/lg fused automatic shut down relay output 3 k17 18db/tn ignition coil no.2 driver 4 k18 18rd/yl ignition coil no.3 driver ignition switch - 10 way cav circuit function 1 a1 14rd fused b(+) 2 ...

  • Page 299

    Instrument cluster c2 - 16 way cav circuit function 7 c81 20lb/wt (except lhd except built-up-export) rear window deffoger relay control 8 g19 20lg/or abs warning indicator driver 9 g99 20gy/wt brake warning indicator driver 10 - - 11 l107 20wt park lmap relay output 12 d25 20vt/yl pci bus 13 g26 20...

  • Page 300

    Left front park/ turn signal lamp (except built-up-export) - black 3 w cav circuit function 1 l61 18gy left turn signal 2 l7 18bk/yl headlamp switch output 3 z1 18bk ground left front position lamp (built-up-export) - black 2 way cav circuit function 1 l7 18bk/yl headlamp switch output 2 z1 20bk gro...

  • Page 301

    Left headlamp leveling motor (built-up-export) - black 3 way cav circuit function 1 l22 20lg/dg fused headlamp switch output 2 l13 20br/yl headlamp adjust signal 3 z1 20bk ground left license lamp (built-up-export) - gray 2 way cav circuit function 1 l7 18bk/yl headlamp switch output 2 z1 20bk groun...

  • Page 302

    Left rear wheel speed sensor - 2 way cav circuit function 1 b3 18lg/db left rear wheel speed sensor (-) 2 b4 18lg left rear wheel speed sensor (+) left side marker lamp (except built-up-export) - gray 2 way cav circuit function 1 l61 18gy left turn signal 2 z1 18bk ground left side repeater lamp (bu...

  • Page 303

    Multi-function switch - gray 20 way cav circuit function 1 l50 18wt/tn brake lamp switch output 2 l61 18gy left turn signal 3 l5 20bk/gy fused ignition switch output (run-acc) 4 l63 18dg/rd left turn/stop signal 5 l62 18br/rd right turn/stop signal 6 l60 18tn right turn signal 7 z1 18bk body ground ...

  • Page 304

    Oxygen sensor 2/1 upstream (4.0l california/european iii) - 4 way cav circuit function 1 f142 18or/dg oxygen sensor upstream heater relay out- put 2 k299 18br/wt ground 3 k4 20bk/lb sensor ground 4 k241 18lg/rd oxygen sensor 2/1 signal oxygen sensor 2/2 downstream (4.0l california/european iii) - 4 ...

  • Page 305

    Passenger door ajar switch - black 3 way cav circuit function 1 m23 20yl/bk door ajar switch output 2 - - 3 g76 20tn/yl driver door ajar switch sense power steering pressure switch (2.5l) - black 2 way cav circuit function 1 z1 20bk ground 2 k10 18db/br power steering pressure switch sense powertrai...

  • Page 306

    Powertrain control module c2 - white 32 way cav circuit function b1 - - b2 - - b3 - - b4 k11 18wt/db fuel injector no. 1 driver b5 k13 18yl/wt fuel injector no. 3 driver b6 k38 18gy (4.0l) fuel injector no. 5 driver b6 k15 18pk/bk (lhd 4.0l california) fuel injector no. 5 driver b7 - - b8 - - b9 k17...

  • Page 307

    Powertrain control module c3 - gray 32 way cav circuit function c11 v32 18yl/rd (speed control) speed control on/off switch sense c12 a142 14dg/pk automatic shut down relay output c13 - - c14 k107 18or (canada) leak detection pump switch sense c15 k118 18pk/yl battery temperature sensor signal c16 k...

  • Page 308

    Radio choke and relay - black 4 way cav circuit function 1 x60 16dg/rd fused b(+) 2 x13 16bk/rd subwoofer relay 3 x16 20lg antenna 4 z1 20bk ground rear fog lamp (built-up-export) - black 2 way cav circuit function 1 l38 18br/wt rear fog lamp feed 2 z1 20bk ground rear washer pump (hard top) - black...

  • Page 309

    Rear wiper/washer switch (hard top) - white 6 way cav circuit function 1 z1 18bk/wt ground 2 v20 18vt/or rear washer motor control 3 e2 20or fused panel lamps dimmer switch signal 4 v13 18br/lg rear wiper motor control 5 v23 18br/pk fused ignition switch output (run) 6 - - right courtesy lamp - blac...

  • Page 310

    Right front turn signal lamp (built-up-export) - black 3 way cav circuit function 1 l60 18tn right turn signal 2 - - 3 z1 18bk ground right front wheel speed sensor - black 2 way cav circuit function 1 b6 18wt/db right front wheel speed sensor (-) 2 b7 18wt right front wheel speed sensor (+) right h...

  • Page 311

    Right rear lamp assembly (built-up-export) - black 4 way cav circuit function 1 l62 18br/rd right turn/stop signal 2 l1 20br/rd back-up lamp feed 3 l50 18wt/tn brake lamp switch feed 4 l7 18bk/yl headlamp switch output right rear lamp assembly (except built-up-export) - black 6 way cav circuit funct...

  • Page 312

    Right side repeater lamp (built-up-export) - gray 2 way cav circuit function 1 l60 18tn right turn signal 2 z1 18bk ground seat belt switch (rhd built-up-export) - black 2 way cav circuit function 1 g10 20lg/rd seat belt switch sense 2 z1 20bk ground sentry key immobilizer module - black 6 way cav c...

  • Page 313

    Subwoofer - lt. Gray 6 way cav circuit function 1 x51 18br/yl left rear speaker (+) 2 x57 18br/lb left rear speaker (-) 3 x13 16bk/rd subwoofer relay power 4 x52 18db/wt right rear speaker (+) 5 x58 18db/pk right rear speaker (-) 6 z9 16bk/wt ground throttle position sensor - 3 way cav circuit funct...

  • Page 314

    Underhood lamp - black 2 way cav circuit function 1 z1 18bk ground 2 m1 20pk/wt fused b(+) vehicle speed sensor - black 3 way cav circuit function 1 k6 20vt/or 5v supply 2 k4 20bk/lb sensor ground 3 g7 20wt/or vehicle speed sensor signal windshield wiper switch - black 7 way cav circuit function 1 v...

  • Page 316: Connector/ground

    8w-90 connector/ground locations table of contents page connector/ground locations description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 connector/ground locations description this section provides illustrations identifying con- nector and ground locations in the vehicle. A connec- t...

  • Page 317

    Connector name/number color location fig. C110 bk left fender side shield 1, 3, 4 c154 bk top right side of transmission 20, 21, 22, 23, 24 c170 (lhd) lt gy left kick panel 10, 14 c170 (rhd) lt gy right kick panel 12 c202 (lhd) gy left kick panel 8, 10, 14 c202 (rhd) gy right kick panel 9, 12 c203 (...

  • Page 318

    Connector name/number color location fig. Fuel injector no.4 bk at injector 17, 18 fuel injector no.5 bk at injector 17 fuel injector no.6 bk at injector 17 fuel pump module bk above fuel tank 26 g100 rear center of engine compartment 3, 4 g101 rear center of engine compartment 3, 4 g102 left radiat...

  • Page 319

    Connector name/number color location fig. Left fog lamp (except built-up-export) bk at lamp n/s left front park/turn signal lamp (except built-up- export) bk at lamp n/s left front position lamp (built-up-export) bk at lamp 1 left front speaker bk at speaker 10, 12 left front turn signal lamp (built...

  • Page 320

    Connector name/number color location fig. Power steering pressure switch (2.5l) bk near power steering pump 18 powertrain control module - c1 (lhd) bk right rear of engine compartment 5 powertrain control module - c1 (rhd) bk left rear of engine compartment powertrain control module - c2 (lhd) wt ri...

  • Page 321

    Connector name/number color location fig. Right rear wheel speed sensor bk near vehicle speed sensor t/o 26 right side marker lamp (except built-up-export) gy at lamp n/s right side repeater lamp gy at lamp 2 seat belt switch bk near park brake switch 25 sentry key immobilizer module bk at immobiliz...

  • Page 322

    Fig. 1 left headlamp tj 8w-90 connector/ground locations 8wa - 90 - 7 connector/ground locations (continued).

  • Page 323

    Fig. 2 right headlamp 8wa - 90 - 8 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 324

    Fig. 3 engine comp ar tment rear lhd tj 8w-90 connector/ground locations 8wa - 90 - 9 connector/ground locations (continued).

  • Page 325

    Fig. 4 engine comp ar tment rear rhd 8wa - 90 - 10 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 326

    Fig. 5 powertrain control module fig. 6 front wiper motor tj 8w-90 connector/ground locations 8wa - 90 - 11 connector/ground locations (continued).

  • Page 327

    Fig. 7 speed control servo 8wa - 90 - 12 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 328

    Fig. 8 dash p anel lhd tj 8w-90 connector/ground locations 8wa - 90 - 13 connector/ground locations (continued).

  • Page 329

    Fig. 9 dash p anel rhd 8wa - 90 - 14 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 330

    Fig. 10 left side instrument p anel bux tj 8w-90 connector/ground locations 8wa - 90 - 15 connector/ground locations (continued).

  • Page 331

    Fig. 11 right side instrument panel lhd 8wa - 90 - 16 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 332

    Fig. 12 instrument p anel rhd tj 8w-90 connector/ground locations 8wa - 90 - 17 connector/ground locations (continued).

  • Page 333

    Fig. 13 left cowl manual transmission lhd 8wa - 90 - 18 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 334

    Fig. 14 left cowl panel lhd tj 8w-90 connector/ground locations 8wa - 90 - 19 connector/ground locations (continued).

  • Page 335

    Fig. 15 steering column 8wa - 90 - 20 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 336

    Fig. 16 4.0 liter engine right side tj 8w-90 connector/ground locations 8wa - 90 - 21 connector/ground locations (continued).

  • Page 337

    Fig. 17 4.0 liter engine left side 8wa - 90 - 22 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 338

    Fig. 18 2.5 liter engine left side tj 8w-90 connector/ground locations 8wa - 90 - 23 connector/ground locations (continued).

  • Page 339

    Fig. 19 transfer case fig. 20 manual transmission bux 8wa - 90 - 24 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 340

    Fig. 21 manual transmission fig. 22 automatic transmission bux tj 8w-90 connector/ground locations 8wa - 90 - 25 connector/ground locations (continued).

  • Page 341

    Fig. 23 4.0 liter engine and transmission rhd fig. 24 2.5 liter engine and transmission 8wa - 90 - 26 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 342

    Fig. 25 body connect ors tj 8w-90 connector/ground locations 8wa - 90 - 27 connector/ground locations (continued).

  • Page 343

    Fig. 26 fuel pump fig. 27 rear lamps bux 8wa - 90 - 28 8w-90 connector/ground locations tj connector/ground locations (continued).

  • Page 344: Splice Locations

    8w-95 splice locations table of contents page splice locations description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 splice locations description this section provides illustrations identifying the general location of the splices in this vehicle. A splice index is provided. Use the w...

  • Page 345

    Splice number location fig. S137 near t/o for throttle position sensor 7 s138 middle of radiator closure panel 2 s140 near t/o for c104 n/s s141 near t/o for left front turn signal lamp n/s s142 near t/o for right front turn signal lamp 1 s143 near t/o for left front park/turn signal lamp n/s s144 n...

  • Page 346

    Splice number location fig. S336 (lhd) near t/o for airbag control module 14 s336 (rhd) near t/o for 100 way connector 15 s400 near t/o for rear window defogger feed n/s s401 near t/o for rear window defogger feed n/s tj 8w-95 splice locations 8wa - 95 - 3 splice locations (continued).

  • Page 347

    Fig. 1 headlamp splices 8wa - 95 - 4 8w-95 splice locations tj splice locations (continued).

  • Page 348

    Fig. 2 right headlamp splices tj 8w-95 splice locations 8wa - 95 - 5 splice locations (continued).

  • Page 349

    Fig. 3 rear engine comp ar tment lhd 8wa - 95 - 6 8w-95 splice locations tj splice locations (continued).

  • Page 350

    Fig. 4 rear engine comp ar tment rhd tj 8w-95 splice locations 8wa - 95 - 7 splice locations (continued).

  • Page 351

    Fig. 5 2.5 liter engine rear fig. 6 4.0 liter engine rear 8wa - 95 - 8 8w-95 splice locations tj splice locations (continued).

  • Page 352

    Fig. 7 4.0 liter engine fig. 8 4.0 liter engine right side tj 8w-95 splice locations 8wa - 95 - 9 splice locations (continued).

  • Page 353

    Fig. 9 4.0 liter engine and transmission fig. 10 2.5 liter engine 8wa - 95 - 10 8w-95 splice locations tj splice locations (continued).

  • Page 354

    Fig. 11 2.5 liter engine and transmission fig. 12 instrument panel lhd tj 8w-95 splice locations 8wa - 95 - 11 splice locations (continued).

  • Page 355

    Fig. 13 instrument p anel rhd 8wa - 95 - 12 8w-95 splice locations tj splice locations (continued).

  • Page 356

    Fig. 14 dash p anel lhd tj 8w-95 splice locations 8wa - 95 - 13 splice locations (continued).

  • Page 357

    Fig. 15 dash p anel rhd 8wa - 95 - 14 8w-95 splice locations tj splice locations (continued).

  • Page 358

    Fig. 16 body wiring splices tj 8w-95 splice locations 8wa - 95 - 15 splice locations (continued).

  • Page 359

    Fig. 17 rear lamps 8wa - 95 - 16 8w-95 splice locations tj splice locations (continued).

  • Page 360: Fuel System

    Fuel system table of contents page page fuel delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 1 fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . 3 fuel delivery table of contents page page fuel delivery specifications . . . . . . . . . . . . . . . . . . . . . . . . . 1 ro...

  • Page 361: Rollover Valve

    Rollover valve description the fuel tank is equipped with 2 rollover valves. The valves are located on the top of the fuel tank (fig. 1) . Operation the rollover valves will prevent fuel flow through the fuel tank vent (evap) hoses in the event of an accidental vehicle rollover. The evap canister dr...

  • Page 362: Fuel Injection

    Fuel injection table of contents page page fuel injection specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3 crankshaft position sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 fuel i...

  • Page 363: Crankshaft Position

    Crankshaft position sensor removal the crankshaft position (ckp) sensor is mounted to the transmission bellhousing at the left/rear side of the engine block. The sensor may be mounted to the transmission with one of the following three different configura- tions: • with one bolt (fig. 1). If sensor ...

  • Page 364: Fuel Injector

    Fuel injector description an individual fuel injector (fig. 4) is used for each individual cylinder. Operation - pcm output the nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector...

  • Page 365: O2 Heater Relay

    O2 heater relay description the oxygen (o2) sensor heater relay is located in the powertrain distribution center (pdc). Operation refer to oxygen sensor for oxygen sensor relay information. Removal the oxygen sensor heater relay is located in the power distribution center (pdc). Refer to label on pd...

  • Page 366

    Downstream sensor - engine equipped with 2 sensors: the downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sen- sor, the pcm calculates how much air-fuel ratio change is required. The pcm then looks at the upstream oxy...

  • Page 368: Transmission/transaxle

    Transmission/transaxle table of contents page page transmission/transaxle description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 manual-ax5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 manual-nv3550 . . . . . . . . . . . . . . . . . . . . . . . . 34 automatic - 30rh . . ....

  • Page 369: Manual-Ax5

    Manual-ax5 disassembly adapter/extension housing (1) drain transmission lubricant, if necessary. (2) remove release bearing and lever. (3) remove clutch housing bolts and remove hous- ing (fig. 1). (4) remove vehicle speed sensor and speedometer adapter, if necessary. (5) remove shift tower bolts an...

  • Page 370

    (7) remove detent ball plug (fig. 4). (8) remove detent spring (fig. 5) and ball (fig. 6) with pencil magnet. (9) remove shift arm retainer bolt (fig. 7). Fig. 4 detent ball plug 1 - torx bit 2 - detent ball plug fig. 5 detent spring 1 - pencil magnet 2 - detent ball spring fig. 6 detent ball 1 - pe...

  • Page 371

    (10) remove shift arm restrictor pins (fig. 8). Note: restrictor pins are not interchangeable, they are color coded. Note color and location of restric- tor pins for installation reference. (11) remove shift lever shaft plug (fig. 9). (12) remove shifter shaft with large magnet (fig. 10). (13) remov...

  • Page 372

    (16) remove adapter/extension housing (fig. 12). (17) on 4x2 transmissions, remove speedometer gear retaining snap-ring from output shaft. Remove speedometer gear from output shaft and remove speedometer gear lock ball from output shaft. Remove speedometer drive gear locating snap-ring (fig. 13). (1...

  • Page 373

    (22) separate intermediate plate and transmission case by tapping them loose with rawhide/rubber hammer (fig. 16). (23) separate intermediate plate from the trans- mission case (fig. 17). Geartrain and shift mechanism (1) install suitable bolts and washers in intermedi- ate plate (fig. 18). Then cla...

  • Page 374

    (3) remove bolt holding fifth gear shift fork to shift rail (fig. 20). (4) remove fifth gear blocker ring from counter- shaft assembly with puller l-4407 (fig. 21). (5) remove fifth gear synchro ring (fig. 22). (6) remove countershaft fifth gear assembly from countershaft (fig. 23). Fig. 20 shift fo...

  • Page 375

    (7) remove fifth gear thrust ring from counter- shaft (fig. 24). (8) remove fifth gear thrust ring lock ball from countershaft (fig. 25). Caution: lock balls, check balls, interlock balls, and interlock pins are used in various places in the transmission. Pins or balls must be identified and marked ...

  • Page 376

    (12) remove bolts holding 1-2 and 3-4 shift forks to the shift rails (fig. 28) and discard bolts. (13) remove bolts holding reverse shift arm bracket to intermediate plate (fig. 29). (14) remove snap-ring holding output shaft rear bearing into the intermediate plate (fig. 30). (15) remove countersha...

  • Page 377

    (18) remove 3-4 shift fork from the 3-4 shift rail (fig. 33). (19) remove snap-ring from 1-2 shift rail to allow the removal of the 1-2 shift fork. (20) remove 1-2 shift fork from the 1-2 and the 3-4 shift rails (fig. 34). (21) remove threaded plugs from intermediate plate. Then remove lock ball and...

  • Page 378

    (22) remove intermediate plate from the vise, rotate the plate 180°, and reinstall plate in the vise using the same bolt and washer mounting set-up. Caution: interlock balls and pins are different sizes and shapes. Pins and balls must be identified and marked for installation reference. (23) remove ...

  • Page 379

    (28) remove interlock pin from reverse shift rail (fig. 40). (29) remove reverse elongated check ball (fig. 41). (30) remove snap-ring on 3-4 shift rail. (31) remove 1-2 shift rail from intermediate plate. (32) remove interlock pin from 1-2 shift rail (fig. 42). (33) remove 1-2 shift rail elongated ...

  • Page 380

    Assembly geartrain and shift mechanism refer to (fig. 44) while assembling and installing the shift rail components. Note: shift rail components must be in neutral position when installing check balls and interlock pins. Check balls and interlock pins must be installed in original location. (1) inst...

  • Page 381

    (2) install 1-2 elongated check ball into the inter- mediate plate (fig. 45). (3) install interlock pin into the 1-2 shift rail (fig. 46). (4) install 1-2 shift rail into the intermediate plate. (5) install snap-ring onto 3-4 shift rail. (6) install reverse check ball into the intermediate plate (fi...

  • Page 382

    (8) assemble reverse arm bracket to the reverse fork (fig. 49). (9) install reverse shift rail into intermediate plate and position reverse arm bracket to intermediate plate (fig. 50). (10) install snap-ring onto reverse shift rail (fig. 51). (11) install reverse shift head and rail assembly into th...

  • Page 383

    (13) install fifth gear shift rail (fig. 53). (14) remove intermediate plate from the vise, rotate plate 180° and reinstall plate in the vise using the same bolt and washer mounting set-up. (15) install shift rail detent balls in the intermedi- ate plate. (16) install shift rail detent springs in th...

  • Page 384

    (27) install new bolts to hold the shift forks to the shift rails (fig. 56). (28) position mainshaft rear bearing retainer over the output shaft and onto the intermediate plate. (29) install new bearing retainer bolts into the intermediate plate. (30) move reverse shift arm into the reverse gear pos...

  • Page 385

    (34) align pin with the alignment notch in the reverse idler gear assembly (fig. 60). Alignment notch in the reverse idler gear race/hub is a small relief cut above one of the main longitudinal slots. Verify pin is aligned with proper slot, the opposite slot has an oil drain hole which the pin will ...

  • Page 386

    (41) install fifth gear shift fork to the countershaft fifth gear assembly. (42) install countershaft fifth gear bearings into the countershaft fifth gear assembly. (43) position countershaft fifth gear assembly on the countershaft. Verify fifth gear fork is installed onto the fifth gear shift rail....

  • Page 387

    (4) install new front bearing snap rings (fig. 67). (5) install front bearing retainer gasket to front bearing retainer. (6) install front bearing retainer (fig. 68) and tighten bolts to 17 n·m (12 ft. Lbs.). (7) on 4x2 transmissions, install speedometer drive gear locating snap-ring (fig. 69). Inst...

  • Page 388

    (11) start shifter arm shaft in hole in back of adapter or extension housing. Align shift arm and shifter arm shaft. Insert shifter arm shaft through the shifter arm and into forward portion of the adapter or extension housing (fig. 72). (12) rotate shifter arm shaft until the hole in the shift arm ...

  • Page 389

    (15) install shift restrictor pins in shift tower and tighten to 27 n·m (20 ft. Lbs.) (fig. 75). Caution: restrictor pins are not interchangeable and are color coded. Verify pins are installed in the original locations. (16) install shift detent ball in detent opening of case (fig. 76). (17) install...

  • Page 390

    (19) install shift tower gasket onto shift tower. (20) install shift tower oil deflector and gasket onto the adapter or extension housing. (21) install shift tower onto transmission case (fig. 79). (22) install shift tower bolts and tighten to 18 n·m (13 ft. Lbs.). (23) install new metal o-ring onto...

  • Page 391

    Specifications specifications - manual - ax5 torque specifications description n·m ft. Lbs. In. Lbs. Plugs, access 19 14 - bolts, adapter housing 34 25 - switch, back-up light 44 32.5 - plugs, drain and fill 44 32.5 - bolts, front bearing retainer 17 12 - plugs, interlock and detent 19 14 - screws, ...

  • Page 392

    Special tools transmission dial indicator c-3339 installer c-3995-a handle c-4171 installer 8211 installer 8212 installer 8208 splitter p-334 installer 8109 tube driver l-4507 tj manual-ax5 21s - 25 manual-ax5 (continued).

  • Page 393: Bearing Retainer

    Bearing retainer removal (1) remove release bearing and lever from the transmission. (2) remove the bolts holding the front bearing retainer to the transmission case. (3) remove the front bearing retainer from the transmission case. (4) with a pry tool, remove the front bearing retainer seal. Instal...

  • Page 394

    (3) remove output shaft pilot bearing rollers from the input shaft and the output shaft. (4) remove fourth gear synchronizer ring from the input shaft (fig. 83). (5) remove select fit snap-ring holding the input shaft bearing onto the input shaft. (6) remove bearing from the input shaft with bearing...

  • Page 395: Output Shaft

    (5) install output shaft pilot bearing rollers in input shaft bore (fig. 85). Ensure to use sufficient petroleum jelly to hold rollers in position. (6) install fourth gear synchronizer ring onto the input shaft. (7) install input shaft to output shaft. Use care when mating the two shafts not to disp...

  • Page 396

    Fig. 88 fifth gear, first gear bearing and race 1 - press ram 2 - output shaft 3 - first-fifth gear-bearing assembly fig. 89 first gear bearing inner race lock ball 1 - lock ball 2 - pencil magnet fig. 90 second gear, reverse gear and 1-2 synchronizer 1 - press ram 2 - second gear 3 - 1-2 synchroniz...

  • Page 397

    (11) with bearing splitter p-334 or press plates positioned under third gear, press the 3-4 synchro- nizer and third gear from output shaft (fig. 92). (12) remove third gear needle roller bearing from output shaft or gear. Assembly note: lubricate the transmission components with mopar 75w-90 gl 3 g...

  • Page 398

    Fig. 94 synchronizer identification 1 - sleeves 2 - hubs fig. 95 select 3-4 synchronizer snap-ring i.D. Mark snap ring thickness mm (in.) c-1 1.75-1.80 (0.0689-0.0709) d 1.80-1.85 (0.0709-0.0728) d-1 1.85-1.90 (0.0728-0.0748) e 1.90-1.95 (0.0748-0.0768) e-1 1.95-2.00 (0.0768-0.0787) f 2.00-2.05 (0.0...

  • Page 399

    (18) install first gear needle bearing onto output shaft (fig. 98). (19) install first gear onto output shaft and over bearing. (20) install first gear bearing inner race onto out- put shaft and inside first gear bearing. Rotate bear- ing race until race installs over lock ball. (21) position output...

  • Page 400

    Fig. 100 select/install fifth gear snap ring i.D. Mark snap ring thickness mm (in.) a 2.67-2.72 (0.1051-0.1071) b 2.73-2.78 (0.1075-0.1094) c 2.79-2.84 (0.1098-0.1118) d 2.85-2.90 (0.1122-0.1142) e 2.91-2.96 (0.1146-0.1165) f 2.97-3.02 (0.1169-0.1189) g 3.03-3.08 (0.1193-0.1213) h 3.09-3.14 (0.1217-...

  • Page 401: Manual-Nv3550

    Manual-nv3550 table of contents page page manual-nv3550 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 36 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 installation. . . . . . . . . . . ....

  • Page 402

    (24) support engine with adjustable jack stand. Position wood block between jack and oil pan to avoid damaging pan. (25) support transmission with transmission jack. (26) secure transmission to jack with safety chains. (27) disconnect rear cushion and bracket from transmission. (28) remove rear cros...

  • Page 403

    Disassembly front housing (1) shift transmission into neutral. (2) remove drain plug and drain lubricant. (3) inspect drain plug magnet for debris. (4) remove backup light switch. Switch is located on passenger side of rear housing (fig. 5). (5) remove shift tower bolts and remove tower and lever as...

  • Page 404

    (8) remove shift shaft detent plunger and spring (fig. 10). Remove spring and plunger with a pencil magnet. (9) remove bolts attaching input shaft bearing retainer to front housing and remove retainer. Note: use pry tool to carefully lift retainer and break sealer bead (fig. 11). (10) remove bearing...

  • Page 405

    (12) remove bolts that attach front housing to rear housing (fig. 14). Three bolts at extreme rear of housing are actually for the output shaft bearing retainer. It is not necessary to remove all three bolts at this time. Leave at least one bolt in place until geartrain is ready to be removed from c...

  • Page 406

    (15) remove screw from reverse blocker and remove blocker (fig. 17) from case. (16) note position of input shaft, shift shaft and forks, and geartrain components in housing (fig. 18). Shift/fork shafts and reverse idler segment (1) unseat the roll pin that secures the shift socket to the shift shaft...

  • Page 407

    (2) with a hammer and punch drive out roll pin that secures shift bushing and lever to shift shaft (fig. 20). Note: use proper size punch to avoid bending the shift shaft. (3) pull shift shaft straight (fig. 21) out of rear housing. (4) remove shift socket from rear housing (fig. 22). (5) remove lev...

  • Page 408

    (7) remove the reverse idler shaft support bolt (front bolt) (fig. 25). (8) loosen rear reverse idler shaft bolt (rear bolt) (fig. 25). (9) remove reverse idler shaft support (fig. 26) segment by sliding it straight out of housing. (10) support geartrain and rear housing on fix- ture 6747 as follows...

  • Page 409

    Rear housing - 2wd (1) on 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (fig. 29). Bolts are rear of shift tower open- ing. (2) unseat output shaft bearing from bearing bore in rear housing. Use plastic/rawhide mallet to tap rear housing upward...

  • Page 410

    Rear adapter housing - 4wd (1) locate rear seal dimples (fig. 33). With slide hammer mounted screw, remove rear seal by insert- ing screw into one of the seal dimples (fig. 34). (2) remove rear bearing snap ring from output shaft with snap ring pliers (fig. 35). Fig. 32 countershaft rear bearing 1 -...

  • Page 411

    (3) lift rear adapter housing upward and off geartrain (fig. 36). (4) remove bearing retainer bolts and remove rear bearing retainer and rear bearing (fig. 37). If needed push or tap bearing out of the housing with a ham- mer. (5) examine condition of bearing bore, counter- shaft rear bearing race a...

  • Page 412

    (4) remove retaining ring that secures two-piece thrust washer on shaft (fig. 39). Use a small pry tool to remove retaining ring. (5) remove two-piece thrust washer (fig. 40). Note position of washer locating lugs in shaft notches for installation reference. (6) remove second gear and needle bearing...

  • Page 413

    (10) remove 1-2 synchro hub and sleeve and first gear from output shaft with press and bearing split- ter 1130 (fig. 43). Position splitter between first and reverse gears. (11) remove first gear needle bearing (fig. 44). (12) remove output shaft bearing snap ring (fig. 45). (13) on 2-wheel drive mo...

  • Page 414

    (16) remove fifth-reverse synchro hub snap ring (fig. 48). (17) remove fifth-reverse synchro hub and sleeve with a press (fig. 49). (18) remove reverse gear and needle bearing (fig. 50). Fig. 47 fifth gear needle bearing 1 - fifth gear needle bearing (spread bearing to clear shoulder on shaft) fig. ...

  • Page 415

    Reverse idler (1) remove idler gear snap rings (fig. 51). (2) remove thrust washer, wave washer, thrust plate and idler gear from shaft. (3) remove idler gear needle bearing from shaft. Assembly sealers are used at all case joints. Usa mopar gas- ket maker for all case joints and mopar silicone seal...

  • Page 416

    Output shaft lubricate shaft, gears and bearings with recom- mended lubricant during assembly. Petroleum jelly can be used to hold parts in place. Check bearing surfaces of output shaft for nicks or scratches. Smooth surfaces with 320/400 grit emery cloth if nec- essary. Apply oil to emery cloth and...

  • Page 417

    (6) install new fifth-reverse hub snap ring (fig. 57) and verify the snap ring is seated. Note: snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to 0.086 in.). Install thickest snap ring that will fit in shaft groove. (7) install fifth gear synchro ring in synchro hub and sleev...

  • Page 418

    (10) invert output shaft and set the shaft in cup 6310-1 so that fifth gear is seated on the tool (fig. 61). (11) install first gear bearing on output shaft (fig. 61). Verify bearing is seated on shaft shoulder and is properly joined. (12) install first gear on shaft and over bearing with bearing sy...

  • Page 419

    (17) install interm ring. (18) install new 1-2 synchro hub snap ring (fig. 66) and verfiy the snap ring is seated. Note: snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 in.). Install thickest snap ring that will fit in shaft groove. (19) install second gear synchro ri...

  • Page 420

    (21) install second gear needle bearing on shaft (fig. 68). (22) install second gear onto shaft and bearing (fig. 69). Verify second gear is fully seated on syn- chro components. (23) install two-piece thrust washer (fig. 70). Ensure washer halves are seated in shaft groove and that washer lugs are ...

  • Page 421

    (24) start retaining ring around two-piece thrust washer (fig. 71). Ensure locating dimple is between the thrust washer halves. (25) seat thrust washer retaining ring with plastic mallet (fig. 72). (26) install third gear needle bearing on shaft (fig. 73). (27) install third gear on shaft and bearin...

  • Page 422

    (28) install third speed synchro ring on third gear (fig. 75). (29) assemble 3-4 synchro hub, sleeve, springs, struts and detent balls. (30) start 3-4 synchro hub on output shaft splines by hand (fig. 76). Caution: the 3-4 synchro hub and sleeve can be installed backwards. One side of the sleeve has...

  • Page 423

    (33) install output shaft bearing. (34) install output shaft bearing snap ring, spread- ing it just enough to install it (fig. 79). Verify snap ring is seated in shaft groove. (35) verify position of synchro sleeves before pro- ceeding with assembly operations (fig. 80). Grooved side of 3-4 sleeve s...

  • Page 424

    Reverse idler assembly (1) lubricate idler components with gear lube. (2) slide idler gear bearing on shaft (fig. 81). Bearing fits either way on shaft. (3) slide gear onto shaft. Side of gear with recess goes to rear (fig. 81). (4) place first lock ball in dimple at rear end of idler shaft (fig. 81...

  • Page 425

    (8) attach a slide hammer or suitable puller to the bolt and remove the bearing. (9) use the short end of installer 8119 to install the new bearing. (10) the bearing is correctly installed if the bear- ing is flush with the transmission case. Detent plunger bushing inspect detent plunger bushings fo...

  • Page 426

    (4) install fourth gear synchro ring on input shaft (fig. 86). (5) adjust height of idler gear pedestal on assem- bly fixture (fig. 87). Start with a basic height of 18.4 cm (7-1/4 in.). Final adjustment can be made after gear is positioned on pedestal. (6) install assembled output shaft and geartra...

  • Page 427

    (10) position reverse idler in support cup of assem- bly fixture (fig. 90). Ensure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary. Also be sure that short end of idler shaft is facin...

  • Page 428

    Rear housing - 2wd (1) drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface (fig. 94). (2) apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race. (3) install countershaft rear bearing in bearing race (fig. 95). Fig. 9...

  • Page 429

    Caution: be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (fig. 96). (4) apply extra petroleum jelly to hold counter- shaft rear bearing in place when housing is installed. (5) apply light coat of petroleum jelly to ...

  • Page 430

    (10) start first two bolts in retainer (fig. 99). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer. (11) remove alignment pin 8120 and install last retainer bolt (fig. 99). (12) tighten all three retainer bolts to 30-35 n·m (22-26 ft. Lbs.). Adapter...

  • Page 431

    (10) lubricate lip of new rear seal (fig. 102) with mopar door ease or transmission fluid. (11) install new rear seal in adapter housing bore with installer c-3860-a. Verify seal is seated in hous- ing bore (fig. 102). Shift shaft, shaft lever and bushing and shift socket (1) verify that all synchro...

  • Page 432

    Caution: positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 180° off. If this occurs, the transmission will have to be disassem- bled again to correct shaft alignment. (9) select correct new roll pin for shift shaft lever (fi...

  • Page 433

    (11) seat shaft lever roll pin with pin punch (fig. 110). Caution: the shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush. (12) verify that lock pin slot in lever bushing is positioned as shown (fig. 110). (13)...

  • Page 434

    (6) apply 1/8 in. Wide bead of mopar gasket maker or equivalent, to mating surfaces of front and rear housings (fig. 115). (7) have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain. (8) work front housing downward onto geartrain unt...

  • Page 435

    (14) lubricate then install shift shaft detent plunger in housing bore (fig. 118). Lubricate plunger with petroleum jelly or gear lubricant. Verify plunger is fully seated in detent notch in shift shaft. (15) install detent spring inside plunger (fig. 118). (16) install plug on detent spring and com...

  • Page 436

    (19) install new oil seal in front bearing retainer with installer 6448 (fig. 121). (20) apply bead of mopar silicone sealer or equiv- alent to flange surface of front bearing retainer (fig. 122). (21) align and install front bearing retainer over input shaft and onto housing mounting surface (fig. ...

  • Page 437

    Shift tower and lever (1) apply petroleum jelly to ball end of shift lever and interior of shift socket. (2) shift the transmission into third gear. (3) align and install shift tower and lever assem- bly (fig. 125). Be sure shift ball is seated in socket and the offset in the tower is toward the pas...

  • Page 438

    (24) install and tighten propeller shaft u-joint clamp bolts to 19 n·m (170 in. Lbs.). (25) align marks on front propeller shaft, axle and transfer case yokes, if equipped. (26) install and tighten propeller shaft u-joint clamp bolts to 19 n·m (170 in. Lbs.). (27) install slave cylinder in clutch ho...

  • Page 439

    Special tools nv3550 manual transmission remover c-3985-b installer c-3972-a remover bushing 6957 installer bushing 6951 handle c-4171 remover 8117 remover/installer 6858 fixture 6747 21s - 72 manual-nv3550 tj manual-nv3550 (continued).

  • Page 440

    Adapter 6747-1a adapter 6747-2b cup 8115 splitter bearing 1130 tube 6310-1 installer 8118 remover/installer 8119 pin alignment 8120 installer c-3860-a installer 8123 installer bearing cone 6448 tj manual-nv3550 21s - 73 manual-nv3550 (continued).

  • Page 441: Vehicle Speed Sensor

    Vehicle speed sensor description the 3-wire vehicle speed sensor (vss) is located on the speedometer pinion gear adapter. If equipped with 4wd, this adapter is located on the extension housing of the transfer case (drivers side). If equipped with 2wd, this adapter is located on the left side of the ...

  • Page 442: Extension Housing

    Installation (1) clean inside of speedometer pinion gear adapter before installing speed sensor. (2) install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, ver- ify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. (3) tighten s...

  • Page 443

    Installation (1) align bushing oil hole with oil slot in rear housing. (2) tap bushing into place with installer 6951 and handle c-4171. (3) install new oil seal in housing using installer c-3972-a (fig. 133). (4) install propeller shaft with reference marks aligned. (5) remove support and lower veh...

  • Page 444: Automatic - 30Rh

    Automatic - 30rh table of contents page automatic - 30rh disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 77 automatic - 30rh disassembly (1) remove transmission from vehicle. (2) install a suitable tail shaft housing plug to avoid contaminating internal components with clean- ing so...

  • Page 445

    (d) position the dial indicator plunger against a flat spot on the oil pump and zero the dial indica- tor. (e) move input shaft in and out and record read- ing. (13) loosen front band adjusting screw lock nut (fig. 5) 4-5 turns. Then tighten band adjusting screw until band is tight around front clut...

  • Page 446

    (19) remove front and rear clutch units as an assembly. Grasp input shaft, hold clutch units together and remove them from case (fig. 8). (20) lift front clutch off rear clutch (fig. 9). Set clutch units aside for overhaul. (21) remove output shaft thrust washer from out- put shaft (or from rear clu...

  • Page 447

    (23) remove front band from case (fig. 11). (24) remove extension housing from transmission case. (25) remove governor body and park gear from output shaft. (26) remove output shaft and planetary geartrain as assembly (fig. 12). Support geartrain with both hands during removal. Do not allow machined...

  • Page 448

    (31) using snap-ring plier, pull rear band anchor pin (located on the servo side of the rear support) from transmission case. (32) remove rear band and link from transmission (fig. 17). (33) separate link from rear band (fig. 18). (34) if necessary remove front and rear band servo levers. All transm...

  • Page 449

    (37) remove compressor tools and remove front servo rod guide, spring and servo piston. (38) compress rear servo spring retainer about 1/16 in. With c-clamp and tool c-4470 or sp-5560 (fig. 24). Valve spring compressor c-3422-b can also be used to compress spring retainer. (39) remove rear servo spr...

  • Page 450: Automatic - 32Rh

    Automatic - 32rh table of contents page page automatic - 32rh description . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 diagnosis and testing . . . . . . . . . . . . . . . . . 89 preliminary . . . . . . . . . . . . . . ...

  • Page 451

    Park powerflow as the engine is running and the crankshaft is rotating, the flexplate and torque converter, which are also bolted to it, are all rotating in a clockwise direction as viewed from the front of the engine. The notched hub of the torque converter is connected to the oil pump’s internal g...

  • Page 452

    Reverse powerflow when the gear selector is moved into the reverse position (fig. 3), the front clutch and the rear band are applied. With the application of the front clutch, engine torque is applied to the sun gear, turning it in a clockwise direction. The clockwise rotation of the sun gear causes...

  • Page 453

    First gear powerflow when the gearshift lever is moved into the drive position the transmission goes into first gear (fig. 4). As soon as the transmission is shifted from park or neutral to drive, the rear clutch applies, applying the rear clutch pack to the front annulus gear. Engine torque is now ...

  • Page 454

    Second gear powerflow in drive-second (fig. 5), the same elements are applied as in manual-second. Therefore, the power flow will be the same, and both gears will be dis- cussed as one in the same. In drive-second, the trans- mission has proceeded from first gear to its shift point, and is shifting ...

  • Page 455

    Direct drive powerflow the vehicle has accelerated and reached the shift point for the 2-3 upshift into direct drive (fig. 6). When the shift takes place, the front band is released, and the front clutch is applied. The rear clutch stays applied as it has been in all the forward gears. With the fron...

  • Page 456

    Diagnosis and testing - preliminary two basic procedures are required. One procedure for vehicles that are drivable and an alternate proce- dure for disabled vehicles (will not back up or move forward). Vehicle is driveable (1) check for transmission fault codes using drb t scan tool. (2) check flui...

  • Page 457

    (11) measure input shaft end play (fig. 10). (a) attach adapter 8266-7 to handle 8266-8. (b) attach dial indicator c-3339 to handle 8266-8. (c) install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on adapter 8266-7 to secure it to the input shaft. (d) p...

  • Page 458

    (18) squeeze front band together and remove band strut (fig. 14). (19) remove front band reaction pin with pencil magnet. Pin is accessible from converter housing side of case (fig. 15). (20) remove front band lever (fig. 16). Fig. 13 oil pump/reaction shaft support 1 - oil pump and reaction shaft s...

  • Page 459

    (21) slide front band rearward and onto driving shell. Band will not be removed until after front/rear clutch removal. (22) remove front and rear clutch units as assem- bly. Grasp input shaft, hold clutch units together and remove them from case (fig. 17). (23) lift front clutch off rear clutch (fig...

  • Page 460

    (29) loosen rear band adjusting screw 4-5 turns (fig. 22). (30) remove snap-ring that secures low-reverse drum to rear support hub, however do not remove drum at this time (fig. 23). (31) remove rear band upper and lower reaction pins with parallel jaw snap-ring pliers (fig. 24). Spread plier jaws i...

  • Page 461

    Fig. 24 rear band pivot and reaction pins 1 - parallel jaw snap-ring pliers 2 - rear band pivot and reaction pins fig. 25 marking rear support to aid assembly 1 - rear support 2 - assembly reference marks fig. 26 rear support 1 - oil pan face 2 - transmission housing 3 - rear support fig. 27 overrun...

  • Page 462

    (36) remove low-reverse drum and overrunning clutch as assembly. Slide drum and clutch through rear band and out of case. Set drum and clutch assembly aside for cleaning and inspection. (37) remove rear band from case. (38) compress front servo rod guide about 1/8 in. With spring compressor tool c-3...

  • Page 463

    Rear band the 32rh transmission has a double wrap band, a pivot pin, and a reaction pin (fig. 32). The band lever pivots against a lug on the band. The reaction pin functions as the stop, or locating mechanism for the band lower lug. (1) install band components and low-reverse drum as follows: (2) i...

  • Page 464

    Rear support and low-reverse drum (1) hold low-reverse drum in position and install rear support (fig. 36). (2) align support with punch marks made during disassembly. (3) install and tighten rear support bolts to 17 n·m (150 in. Lbs.) torque. (4) install snap-ring that retains low-reverse drum to h...

  • Page 465

    Planetary geartrain and output shaft (1) lubricate output shaft, rear support bore and low-reverse drum hub with transmission fluid. (2) install assembled output shaft and planetary geartrain in case (fig. 38). (3) align drive lugs on rear planetary gear with slots in low-reverse drum (fig. 39). The...

  • Page 466

    Fig. 40 governor valve and output shaft spotface alignment 1 - output shaft 2 - governor body 3 - governor valve bore 4 - spotface fig. 41 governor body and park gear 1 - governor/park assembly 2 - governor valve shaft bore 3 - rear support 4 - output shaft splines 5 - seal rings fig. 42 governor va...

  • Page 467

    Front/rear clutch (1) install output shaft thrust plate on shaft hub (fig. 45). Use petroleum jelly to hold thrust plate in place. (2) check input shaft seal rings. Verify that diago- nal-cut ends of teflon seal ring are properly joined and ends of plastic ring are correctly positioned. Also be sure...

  • Page 468

    (7) raise front end of transmission upward as far as possible and support case with wood blocks. Front/ rear clutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible. (8) install front and rear clutch units as assembly (fig. 49). Align rear clu...

  • Page 469

    Fig. 50 installing front band and reaction pin 1 - front band 2 - front band reaction pin 3 - front clutch retainer fig. 51 front band linkage installation 1 - band lever 2 - band strut 3 - front band fig. 52 installing front band pivot pin access plug 1 - 1/4'' drive extension 2 - front band reacti...

  • Page 470

    (8) thread two pilot stud tools c-3288-b into bolt holes in oil pump flange (fig. 55). (9) align and install oil pump gasket (fig. 55). (10) lubricate oil pump seals with mopar t door- ease, or ru-glyde, door eze, or atf plus 4. (11) install oil pump (fig. 56). Align and position pump on pilot studs...

  • Page 471

    Valve body (1) install new manual lever shaft seal in case. Use suitable deep well socket to install seal. (2) make sure neutral switch has not been installed in case. Remove switch if necessary as it will interfere with valve body installation. (3) install new seal rings on accumulator piston (fig....

  • Page 472

    Extension housing, control lever and converter (1) install throttle valve and transmission shift levers on manual valve shaft. Tighten lever clamp screws securely. (2) position new extension housing gasket on transmission case. Use petroleum jelly to hold gasket in place. (3) install new rear seal i...

  • Page 473

    Thrust washer/spacer/snap-ring dimensions component metric inch front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in. Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in. Output shaft thrust plate (output shaft pilot hub) 1.5-1.6mm 0.060-0.063 in. Output shaft thrust was...

  • Page 474: Accumulator

    Torque specifications description n·m ft. Lbs. In. Lbs. Bolt/nut, crossmember 31 23 - bolt, driveplate to crankshaft 68 50 - plug, front band reaction 75 55 - locknut, front band adj. 34 25 - switch, park/neutral 34 25 - bolt, fluid pan 17 13 - bolt, oil pump 20 15 - bolt, overrunning clutch cam 17 ...

  • Page 475: Fluid And Filter

    Adjustments - rear band the transmission oil pan must be removed for access to the rear band adjusting screw. (1) raise vehicle. (2) remove transmission oil pan and drain fluid. (3) loosen band adjusting screw locknut 5-6 turns. Be sure adjusting screw turns freely in lever. (4) tighten adjusting sc...

  • Page 476

    Ers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contami- nants. Standard procedure - fluid level check low fluid level can cause a variety of conditions becaus...

  • Page 477

    Caution: do not overfill transmission, fluid foam- ing and shifting problems can result. (9) add fluid to bring level up to max arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Standard procedure - fluid and filter replac...

  • Page 478: Front Clutch

    Front clutch operation to apply the clutch, pressure is applied between the clutch retainer and piston. The fluid pressure is provided by the oil pump, transferred through the control valves and passageways, and enters the clutch through the hub of the reaction shaft support. With pressure applied b...

  • Page 479

    Fig. 67 front clutch components - typical 1 - snap-ring (wave) 7 - seal 2 - reaction plate 8 - piston 3 - clutch disc 9 - spring 4 - clutch plate 10 - snap-ring 5 - seal 11 - spring retainer 6 - clutch retainer 21s - 112 automatic - 32rh tj front clutch (continued).

  • Page 480: Gear Shift Cable

    (5) position spring in clutch piston (fig. 70). (6) position spring retainer on top of piston spring. Make sure retainer is properly installed (fig. 67). (7) compress piston spring and retainer with com- pressor tool c-3575-a (fig. 68). Then install new snap ring to secure spring retainer and spring...

  • Page 481: Governor And Park Gear

    (8) install any floor console components removed previously. (refer to 23 - body/interior/floor console - installation) adjustment - gearshift cable check adjustment by starting the engine in park and neutral. Adjustment is ok if the engine starts only in these positions. Adjustment is incorrect if ...

  • Page 482

    Assembly caution: exercise care when installing the seal rings. They are easily broken if overspread or twisted during installation. If it was necessary to remove the park gear, inspect the seal rings and bore in rear support. Install new seal rings on park gear hub only if orig- inal rings are dama...

  • Page 483: Park/neutral Position

    Park/neutral position switch description the park/neutral position switch (fig. 76) is threaded into the side of the transmission case, just above the transmission oil pan mounting surface. The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the groun...

  • Page 484: Shift Mechanism

    Shift mechanism description the shift mechanism is cable operated and pro- vides six shift positions. The shift indicator is located on the console next to the gear shift. The shift posi- tions are: • park (p) • reverse (r) • neutral (n) • drive (d) • manual second (2) • manual low (1) operation man...

  • Page 485

    Adjustment procedure (1) turn ignition switch to off position. (2) remove air cleaner if necessary. (3) disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. (4) verify that transmission throttle lever is in fully closed position. Then be sure lever...

  • Page 486: Transfer Case-Nv231

    Transfer case-nv231 table of contents page page transfer case-nv231 disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 119 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 speed sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 installation...

  • Page 487

    (9) tap rear retainer with rawhide or rubber mal- let to loosen sealer bead. (10) remove rear retainer from rear case half (fig. 4). (11) remove snap-ring holding oil pump in position on output shaft. (12) disengage oil pickup tube from oil pump and remove oil pump assembly. Remove oil pump by tilt-...

  • Page 488

    Yoke and range lever (1) remove transfer case indicator switch. (2) remove front yoke nut as follows: (a) move range lever to 4l position. (b) then remove nut with socket and impact wrench (fig. 7). (3) remove yoke. If yoke is difficult to remove by hand, remove it with bearing splitter, or with sta...

  • Page 489

    (5) remove oil pickup tube from rear case (fig. 12). (6) remove mode fork spring (fig. 13). (7) pull front output shaft upward and out of front output shaft bearing (fig. 14). (8) remove front output shaft and chain. Fig. 11 loosening rear case 1 - rear case 2 - pry tool (in case slot) 3 - front cas...

  • Page 490

    Shift forks and mainshaft (1) remove detent plug, o-ring, detent spring and detent plunger (fig. 15). (2) remove mainshaft from mode sleeve and input gear pilot bearing. (3) remove mode fork and sleeve as an assembly (fig. 16). Note position of sleeve for assembly refer- ence. The short side of the ...

  • Page 491

    Mainshaft (1) remove mode hub retaining ring with heavy duty snap-ring pliers (fig. 20). (2) slide mode hub off mainshaft (fig. 21). (3) slide drive sprocket off mainshaft (fig. 22). Fig. 19 sector bushing and o-ring removal 1 - seal retainer 2 - sector shaft bore 3 - o-ring seal fig. 20 mode hub re...

  • Page 492

    Input gear and low range gear (1) remove front bearing retainer attaching bolts (fig. 23). (2) remove front bearing retainer. Pry retainer loose with pry tool positioned in slots at each end of retainer (fig. 24). (3) remove front bearing retainer seal. Tap seal out with drift and hammer. (4) remove...

  • Page 493

    Input and low range gear (1) remove snap-ring that retains input gear in low range gear (fig. 27). (2) remove retainer (fig. 28). (3) remove front tabbed thrust washer (fig. 29). (4) remove input gear (fig. 30). (5) remove rear tabbed thrust washer from low range gear (fig. 31). Fig. 27 input gear s...

  • Page 494

    Assembly lubricate transfer case components with mopar t atf +4, type 9602, automatic transmission fluid or petroleum jelly (where indicated) during assembly. Bearings and seals caution: the bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do n...

  • Page 495

    (5) install output shaft front bearing retaining ring (fig. 36). Start ring into place by hand. Then use small screwdriver to work ring into case groove. Be sure ring is fully seated before proceeding. (6) install new front output seal in front case with installer tool 8143-a as follows: (a) place n...

  • Page 496

    (9) using remover c-4210 and handle c-4171, drive input shaft bearing from inside the annulus gear opening in the case (fig. 41). (10) install locating ring on new bearing. (11) position case so forward end is facing upward. (12) using remover c-4210 and handle c-4171, drive input shaft bearing into...

  • Page 497

    (13) remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (fig. 43). (14) install new pilot bearing with installer 5065 and handle c-4171 (fig. 44). (15) remove front bearing retainer seal w...

  • Page 498

    Input and low range gear (1) install first thrust washer in low range gear (fig. 48). Be sure washer tabs are properly aligned in gear notches. (2) install input gear in low range gear. Be sure input gear is fully seated. (3) install remaining thrust washer in low range gear and on top of input gear...

  • Page 499

    (3) clean gasket sealer residue from retainer and inspect retainer for cracks or other damage. (4) apply a 3 mm (1/8 in.) bead of mopar t gasket maker or silicone adhesive to sealing surface of retainer. (5) align cavity in seal retainer with fluid return hole in front of case. Caution: do not block...

  • Page 500

    (9) install assembled mode fork and sleeve (fig. 58). Be sure fork rail goes through range fork and into case bore. Also be sure sleeve is aligned and seated on mainshaft hub. (10) rotate sector to neutral position. (11) install new o-ring on detent plug (fig. 59). (12) lubricate detent plunger with...

  • Page 501

    Front output shaft and drive chain (1) lubricate front output shaft-sprocket assembly, drive chain, and drive sprocket with transmission fluid. (2) assemble drive chain and front output shaft (fig. 60). (3) start chain on mainshaft drive sprocket. (4) guide front shaft into bearing and drive sprocke...

  • Page 502

    Oil pump and rear case (1) install magnet in front case pocket (fig. 62). (2) assemble oil pickup screen, connecting hose, and tube. (3) install new pickup tube o-ring in oil pump (fig. 63). (4) insert oil pickup tube in oil pump inlet. (5) position assembled oil pump and pickup tube in rear case. B...

  • Page 503

    (3) install new seal washer on front output shaft (fig. 68). (4) lubricate yoke hub with transmission fluid and install yoke on front shaft. (5) install new seal washer on front shaft. (6) install yoke and new yoke nut on front output shaft (fig. 67). (7) tighten yoke nut to 122-176 n·m (90-130 ft. ...

  • Page 504

    Note: vehicles built with a 4.0l engine and a man- ual transmission use a damper weight on the trans- fer case output shaft. Be sure to identify the transfer case before proceeding. (7) install a new output shaft rear slinger with installer 8408, if the vehicle is not equipped with an output shaft d...

  • Page 505: Speed Sensor

    Speed sensor removal the vehicle speed sensor (vss) is located on the speedometer pinion gear adapter. If equipped with 4wd, this adapter is located on the transfer case extension (left side) (fig. 75). If equipped with 2wd, this adapter is located on the extension housing of the transmission (left ...

  • Page 506

    Installation (1) clean inside of speedometer pinion gear adapter before installing speed sensor. (2) install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, ver- ify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. (3) tighten s...

  • Page 507: Service Manual Comments

    Service manual comments what features do you find most useful? ______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ________________...

  • Page 508

    Daimlerchrysler international operations attn. Publications dept. Cims 486-02-70 800 chrysler drive auburn hills, mi 48326-2757 ✃.