Dodge Dakota 2005 Service-Repair-Manual-FREE-PDF-DOWNLOAD
Dodge Dakota 2005 Service-Repair-Manual-FREE-PDF-DOWNLOAD
Dodge Dakota 2005 Service-Repair-Manual-FREE-PDF-DOWNLOAD
com
Introduction
2 Suspension
5 Brakes
6 Clutch
7 Cooling
8A Audio/Video
8B Chime/Buzzer
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8R Wipers/Washers
8T Navigation/Telecommunication
8W Wiring
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
22 Tires/Wheels
23 Body
25 Emissions Control
DTC Index
INTRODUCTION
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify
various instrument controls. The symbols correspond to the controls and displays that are located on the instrument
panel.
Download Complete manual for FREE @ https://www.heydownloads.com
4 INTRODUCTION ND
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt
strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade
corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and
10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class
number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut
face. Refer to the Fastener Identification and Fastener Strength Charts.
Bolt Markings and Torques - Metric
FASTENER USAGE
DESCRIPTION
FASTENER USAGE
WARNING: Use of an incorrect fastener may result in component damage or personal injury.
Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem-
bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
METRIC SYSTEM
DESCRIPTION
Download Complete manual for FREE @ https://www.heydownloads.com
8 INTRODUCTION ND
The metric system is based on quantities of one, ten, one hundred, one thousand and one million.
The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifications Chart for
torque references not listed in the individual torque charts.
Download Complete manual for FREE @ https://www.heydownloads.com
ND LUBRICATION & MAINTENANCE 0-1
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international sym-
bols to identify engine compartment lubricant and fluid
inspection and fill locations.
Download Complete manual for FREE @ https://www.heydownloads.com
0-2 LUBRICATION & MAINTENANCE ND
Body
FLUID TYPES
When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi-
cles.
Only lubricants bearing designations defined by the following organization should be used to service a Chrysler
Corporation vehicle.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI)
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage.
Such as API GL-5 and SAE 75W-90.
ND LUBRICATION & MAINTENANCE 0-3
FLUID TYPES
DESCRIPTION
FUEL REQUIREMENTS
Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance
when using high quality unleaded “regular” gasoline having an octane rating of 87. The routine use of premium
gasoline is not recommended. Under normal conditions the use of premium fuel will not provide a benefit over high
quality regular gasolines and in some circumstances may result in poorer performance.
Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at
high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a
heavy spark knock may not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these
symptoms, try another brand of gasoline before considering service for the vehicle.
Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide
Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability
for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of cleaner burning gasoline referred to as “reformulated” gasoline. Refor-
mulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air
quality.
We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent
performance and durability for the engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates
are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels
blended with these oxygenates may be used in your vehicle.
CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical
fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline
blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT.
Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We
recommend that gasolines free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated
on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher
than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your vehicle may have been designed to meet California low emission
standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in
states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal spec-
ifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is
permitted to have higher sulfur levels which may affect the performance of the vehicle’s catalytic converter. This may
cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recom-
mend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel
related prior to returning your vehicle to an authorized dealer for service.
Download Complete manual for FREE @ https://www.heydownloads.com
0-4 LUBRICATION & MAINTENANCE ND
CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing,
immediate service is required; see on-board diagnostics system section.
• The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance,
damage the emission control system, and could result in loss of warranty coverage.
• An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If
you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and
may require immediate service. Contact your dealer for service assistance.
• When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is
high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or
engine piston damage may result.
• The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these
products contain high concentrations of methanol. Fuel system damage or vehicle performance problems
resulting from the use of such fuels or additives is not the responsibility of DaimlerChrysler Corporation and
may not be covered under the new vehicle warranty.
NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed
against you.
ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE
TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED
CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE
GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CON-
TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
WARNING: DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze pro-
tection and less corrosion protection.
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder
head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/
fin radiator can transfer the heat to the air.
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection.
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant
with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This cool-
ant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water
to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
ND LUBRICATION & MAINTENANCE 0-5
CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any
other type of antifreeze. Mixing of coolants other than specified non-HOAT or other HOAT coolant, may
result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion
protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and distilled water mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mixtures follows:
Pure Distilled Water - Distilled water can absorb more heat than a mixture of water and ethylene-glycol. This is for
purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion.
100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of distilled
water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to
rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased
temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Distilled Water - Is the recommended mixture, it provides protection against freezing to
-37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If
percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage
will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat
because specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob-
lems associated with 100 percent ethylene-glycol.
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 INTER-
NAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH
SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS,
HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CON-
TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi-
cles.
Only lubricants bearing designations defined by the following organization should be used.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI)
• Association des Constructeurs Européens d’ Automobiles (European Automobile Manufacturers Association)
(ACEA)
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity
of engine oil. Use only engine oils with multiple viscos-
ities such as 5W-30 or 10W-30. These are specified
with a dual SAE viscosity grade which indicates the
cold-to-hot temperature viscosity range. Select an
engine oil that is best suited to your particular temper-
ature range and variation.
ACEA Categories
For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the require-
ments of ACEA A1/B1, A2/B2, or A3/B3.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been
adopted to aid in the proper selection of engine oil.
The identifying notations are located on the front label
of engine oil plastic bottles and the top of engine oil
cans.
This symbol means that the oil has been certified by
the American Petroleum Institute (API). Diamler-
Chrysler only recommend API Certified engine oils.
Use MoparT engine oil or equivalent.
AXLE
NOTE: DaimlerChrysler recommends MoparT lubricants or lubricants of equal quality.
FRONT AXLE
• C205F - MoparT Gear Lubricant 75W-90
REAR AXLE
• 8 1/4 - MoparT Synthetic Gear Lubricant 75W-140
• 9 1/4 - MoparT Synthetic Gear Lubricant 75W-140
ND LUBRICATION & MAINTENANCE 0-7
MoparT ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmis-
sions.
Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid.
MoparT ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an
indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually
become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and
color cannot be used to indicate the fluid condition or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those auto-
matic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid
leaks.
Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and
others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge.
These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be
used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of
transmission seals.
MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends MoparT lubricants or lubricants of equal quality.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 25 U.S. Gallons (95 Liters)****
ENGINE OIL
3.7L - with Filter 4.7L (5.0 qts.)
4.7L - with Filter 5.6L (6.0 qts.)
COOLING SYSTEM
3.7L 15.4L (16.2 qts.)***
4.7L 15.4L (16.2 qts.)***
AUTOMATIC TRANSMISSION
Service Fill - 42RLE 3.8L (4.0 qts.)
O-haul Fill - 42RLE 8.3L (17.6 pts.)
2WD - 5.2 L (11 pts.)
Service Fill - 545RFE
4WD - 6.2 L (13 pts.)
O-haul Fill - 545RFE 13.33L (28.0 pts.)
Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of
an auxiliary cooler, these figures may vary. (Refer to 21 - TRANSMISSION/AUTOMATIC/FLUID - STANDARD
PROCEDURE)
MANUAL TRANSMISSION
G238 2.2L (4.65 pts.)
TRANSFER CASE
NV233 1.18L (2.5 pts.)
NV244 1.35L (2.85 pts.)
FRONT AXLE
C205F 1.66L (56 oz.)
REAR AXLE
8 1/4 in. 2.07L (70 oz.)
9 1/4 in. 2.13L (72 oz.)
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
Power Steering
Power steering fluid capacities are dependent on engine/chassis options as well as steering gear/cooler options.
Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary
cooler, these capacities may vary.
MAINTENANCE SCHEDULES
DESCRIPTION
MAINTENANCE SCHEDULES
There are two maintenance schedules that show the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the
beginning of the schedule.
• Day or night temperatures are below 32° F (0° C).
• Stop and go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 10 miles (16 km).
• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).
• Trailer towing.
• Taxi, police, or delivery service (commercial service).
• Off-road or desert operation.
• If equipped for and operating with E-85 (ethanol) fuel.
NOTE: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.
NOTE: If ANY of these apply to you then change your coolant every 102,000 miles (163 000 km) or 60
months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this
manual.
NOTE: Most vehicles are operated under the conditions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule
9B9.
Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval
that occurs first.
NOTE: Under no circumstances should oil change intervals exceed 6000 miles (10 000 km) or 6 months
whichever comes first.
CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.
Once a Month
• Check tire pressure and look for unusual wear or damage.
• Inspect the battery and clean and tighten the terminals as required.
• Check the fluid levels of coolant reservoir, brake master cylinder, and transmission and add as needed.
• Check all lights and all other electrical items for correct operation.
Download Complete manual for FREE @ https://www.heydownloads.com
0 - 10 LUBRICATION & MAINTENANCE ND
Schedule “B”
Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions.
• Day or night temperatures are below 32° F (0° C).
• Stop and go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 10 miles (16 km).
• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).
• Trailer towing.
• Taxi, police, or delivery service (commercial service).
• Off-road or desert operation.
• If equipped for and operating with E-85 (ethanol) fuel.
NOTE: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.
NOTE: If ANY of these apply to you then change your coolant every 102,000 miles (163 000 km) or 60
months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this
manual.
Schedule “A”
WARNING:
You can be badly injured working on or around a motor vehicle. Do only that service work for which you
have the knowledge and the right equipment. If you have any doubt about your ability to perform a service
job, take your vehicle to a competent mechanic.
JUMP STARTING
STANDARD PROCEDURE
JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN THE BATTERY SYSTEM SECTION OF
THE SERVICE MANUAL. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE)
• DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.
• IF EQUIPPED, DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW
OR BRIGHT COLOR.
• DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES.
• DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
• DO NOT USE OPEN FLAME NEAR BATTERY.
• REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARC-
ING OF BATTERY CURRENT.
• WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can
be damaged on either vehicle.
Download Complete manual for FREE @ https://www.heydownloads.com
0 - 16 LUBRICATION & MAINTENANCE ND
CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat
and could fail.
7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine.
If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before crank-
ing again.
TOWING
STANDARD PROCEDURE
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved wheel lift-type towing equipment can be used to tow all vehicles. When
towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A
vehicle with flatbed device can also be used to transport a disabled vehicle.
NOTE: Towing the vehicle at more than 30 mph (50 km/h) or for more than 15 miles (25 km ) can cause
severe transmission damage.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must
be observed when towing a vehicle:
CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there
is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep
rises in the road.
RAMP ANGLE
If a vehicle with flatbed towing equipment is used, the approach ramp angle should not exceed 15 degrees.
Download Complete manual for FREE @ https://www.heydownloads.com
0 - 18 LUBRICATION & MAINTENANCE ND
WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL
LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid com-
ponent damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.
CAUTION: Do not use steering column lock to secure steering wheel during towing operation.
7. Secure steering wheel in straight ahead position with a clamp device designed for towing.
8. Place the transmission in park.
CAUTION: Do not use steering column lock to secure steering wheel during towing operation.
6. Turn the ignition switch to the OFF position to unlock the steering wheel.
7. Secure steering wheel in straight ahead position with a clamp device designed for towing.
8. Place the transmission in park.
ND LUBRICATION & MAINTENANCE 0 - 19
CAUTION: Internal damage to the transfer case will occur if a front or rear wheel lift is used when recre-
ational towing.
NOTE: Because of the design of the transfer cases only vehicles equipped with a NV 244 Generation II
transfer case should be used for recreational towing.
NOTE: The NV 244 Generation II transfer case must be shifted into Neutral (N) for recreational towing. The
Neutral (N) selection button is located on the lower left hand corner of the 4WD Control Switch. Shifts into
and out of transfer case Neutral (N) can take place with the selector switch in any mode position.
NOTE: If the vehicle is to be towed for multiple days or one day for an eight hour or above duration, dis-
connect and isolate the battery to prevent discharge do to the illumination of the odometer and PRNDL
light. After the battery negative cable is reinstalled the radio clock and stations will need to be reset.
CAUTION: It is necessary to follow these steps to be certain that the transfer case is fully in Neutral (N)
before recreational towing to prevent damage to internal parts.
NOTE: Items 1 through 5 are requirements that must be met prior to depressing the Neutral (N) selection
button, and must continue to be met until the 4 seconds elaspes and the shift has been completed. If any
of these requirements (with the exception of 3 - Key ON) are not met prior to depressing the Neutral (N)
button or are no longer met during the 4 second timer, then the Neutral (N) indicator light will flash con-
tinuously until all requirements are met or until the Neutral (N) button is released.
NOTE: The ignition key must be ON for a shift to take place and for the position indicator lights to be oper-
able. If the key in not ON, the shift will not take place and no position indicator lights will be on or flashing.
Download Complete manual for FREE @ https://www.heydownloads.com
0 - 20 LUBRICATION & MAINTENANCE ND
NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met.
CAUTION: Damage to the transmission may occur if the transmission is shifted into Park (P) with the trans-
fer case in Neutral (N) and the engine RUNNING. With the transfer case in Neutral (N) ensure that the engine
is OFF prior to shifting the transmission into Park (P).
NOTE: Items 1 through 5 are requirements that must be met prior to depressing the Neutral (N) selection
button, and must continue to be met until 1 second elapses and the shift has been completed. If any of
these requirements (with the exception of 3 - key ON) are not met prior to depressing the Neutral (N) button
or are no longer met during the 1 second time, then all of the mode position indicator lights will flash con-
tinuously until all requirements are met or until the Neutral (N) button is released.
NOTE: The ignition key must be ON for a shift to take place and for the position indicator lights to be oper-
able. If the key is not ON, the shift will not take place and no position indicator lights will be on or flashing.
NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met.
CAUTION:
• Do not use a bumper mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged.
• Do not disconnect the rear driveshaft because fluid will leak from the transfer case and damage internal
parts.
ND SUSPENSION 2-1
SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION
NOTE: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have
the springs supporting the weight of the vehicle
when the fasteners are torqued. If springs are not
at their normal ride position, vehicle ride comfort
could be affected and premature bushing wear
may occur.
OPERATION
• CASTER (1) is the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of
the knuckle forward provides less positive caster.
Tilting the top of the knuckle rearward provides
more positive caster. Positive caster promotes
directional stability. This angle enables the front
wheels to return to a straight ahead position after
turns.
• CAMBER (2) is the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting
the top of the wheel inward provides negative
camber. Tilting the top of the wheel outward pro-
vides positive camber. Incorrect camber will
cause wear on the inside or outside edge of the
tire.
• TOE (4) is the difference between the leading
inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause’s unstable
steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel align-
ment adjustment.
• THRUST ANGLE (3) is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle
can cause off-center steering and excessive tire wear. Off-center steering, lead or pull and Minimal adjustment
(clearance between spring seat hole and leaf spring pin) can be made by loosening the U-Bolts and moving
one side forward and the other rearward. All damaged component(s) must be replaced to correct the thrust
angle.
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
STANDARD PROCEDURE
HEIGHT MEASUREMENT
The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure.
Also when front suspension components have been replaced. This measure must be performed with the vehicle
supporting it’s own weight and taken on both sides of the vehicle.
TOE ADJUSTMENT
SUSPENSION HEIGHT MESUREMENT MUST BE
PERFORMED BEFORE AN ALIGNMENT.
The wheel toe position adjustment is the final adjust-
ment.
1. Start the engine and turn wheels both ways before
straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
2. Loosen the tie rod jam nuts (3).
3. Adjust the wheel toe position by turning the inner tie rod (4) as necessary.
4. Tighten the tie rod jam nut (3) to 75 N·m (55 ft. lbs.).
5. Verify the specifications.
6. Turn off engine.
ND WHEEL ALIGNMENT 2-5
NOTE: Both front and rear lower control arm cam bolts are adjustable.
NOTE: Camber and caster adjustments must be made at the lower control arm The upper control arm is not
adjustable.
NOTE: When the lower control arm cam bolts are loosened the lower control arm will normally go outwards
automatically with the weight of the vehicle.
CASTER
Moving the rear position of the lower control arm at the frame in or out, will change the caster angle significantly
and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the lower
control arm in or out. Then move the front of the lower control arm slightly in the opposite direction.
CAMBER
Move both the front and rear of the lower control arm together in or out. This will change the camber angle signif-
icantly and caster angle slightly.
After adjustment is made tighten the lower control arm bolt & nuts to 203 N·m (150 ft. lbs.).
TOE ADJUSTMENT
The wheel toe position adjustment is the final adjust-
ment.
1. Start the engine and turn wheels both ways before
straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
2. Loosen the tie rod jam nuts (3).
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
SPECIFICATIONS
DESCRIPTION SPECIFICATION
VEHICLE WHEEL BASE CASTER CAMBER TOTAL TOE-IN
ALL 131 in 3.5 ± .05° .25° ± .50° .20° ± .05°
MAX RT/LT — -.20° ± .50° 0° ± .50° 0.05° ± 0.05°
DIFFERENCE
DESCRIPTION REAR SPECIFICATION
CAMBER TOTAL TOE-IN
(-.10° ± 0.35°) (0.30° ± 0.35°)
THRUST ANGLE 0° ± 0.4°
ND FRONT 2-7
FRONT
TABLE OF CONTENTS
page page
FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DESCRIPTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 7 LOWER CONTROL ARM
CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 8 SHOCK
SPECIAL TOOLS DIAGNOSIS AND TESTING
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 9 SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL SPRING
LOWER CONTROL ARM BUSHING . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
UPPER CONTROL ARM BUSHING . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
LOWER CONTROL ARM SHOCK BUSHING . 13 STABILIZER BAR
INSTALLATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
LOWER CONTROL ARM BUSHING . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
UPPER CONTROL ARM BUSHING . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LOWER CONTROL ARM SHOCK BUSHING . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
HUB / BEARING STABILIZER LINK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
KNUCKLE UPPER BALL JOINT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 DIAGNOSIS AND TESTING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 UPPER CONTROL ARM
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LOWER BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . 21
FRONT
DESCRIPTION
SUSPENSION
The front suspension is designed to allow each wheel to adapt to different road surfaces independently. The wheels
are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and
lubricated for life. The steering knuckles turn (pivot) on ball joints.
The front suspension is comprised of :
• Shock absorbers
• Control arms
• Steering knuckles
• Stabilizer bar
• Stabilizer link
• Tie Rod Ends
• Hub/Bearing
• Rack & Pinion
• Ball Joints
Download Complete manual for FREE @ https://www.heydownloads.com
2-8 FRONT ND
NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at nor-
mal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners
are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and pre-
mature bushing wear may occur.
CONTROL ARMS
The lower control arms bolt to the lower frame brackets and pivots through bushings. The frame brackets have
slotted holes which allow the arms to be adjusted for caster and camber.
The control arms have lube for life ball studs. The control arm travel (jounce) is limited through the use of rubber/
urethane bumpers. Rebound travel is limited by the shock absorber.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
SPECIAL TOOLS
FRONT SUSPENSION
PULLER - 8677
BUSHING - 9334
BUSHINGS - 9601
ND FRONT 2 - 11
BUSHINGS
DESCRIPTION
Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height.
It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are
not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.
REMOVAL
LOWER CONTROL ARM BUSHING
1. Remove the lower control arm (6) (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
2. Secure the control arm in a vise.
INSTALLATION
LOWER CONTROL ARM BUSHING
1. Install the new bushing (4) into the lower control
arm (3) using tools C-4212-F (Press) (1), 9603–2
(Depth Gauge) (2), 9603–1 (Driver) (5).
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 14 FRONT ND
HUB / BEARING
REMOVAL
1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the brake caliper and rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL).
4. Remove the ABS wheel speed sensor if equipped, (Refer to 5 - BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - REMOVAL).
5. Remove the halfshaft nut 4X4 only.
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 16 FRONT ND
NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the
steering knuckle will occur.
INSTALLATION
1. Install the brake dust shield (5).
2. Install the hub/bearing (1) into the steering knuckle
(4) and tighten the bolts (3) to 163 N·m (120 ft.
lbs.).
3. Install the brake rotor and caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
4. Install the ABS wheel speed sensor (4) if equipped
(Refer to 5 - BRAKES/ELECTRICAL/FRONT
WHEEL SPEED SENSOR - INSTALLATION).
5. Install the halfshaft nut and tighten to 251 N·m (185 ft. lbs.) 4X4 only.
6. Install the wheel and tire assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
7. Remove the support and lower vehicle.
KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has
machined mounting locations for the front brake calipers and hub bearing.
ND FRONT 2 - 17
OPERATION
The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows
the vehicle to be steered.
REMOVAL
1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the brake caliper, rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL),
shield and ABS wheel speed sensor if equipped (Refer to 5 - BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - REMOVAL).
4. Remove the front halfshaft nut 4X4 only.
5. Remove the tie rod end nut (1).
8. Separate the ball joint (1) from the knuckle (3) with
Remover 8677 (2).
9. Install an hydraulic jack to support the lower control
arm.
11. Separate the ball joint (3) from the knuckle (1)
with Remover 8677 (2) and remove the knuckle
(1).
INSTALLATION
CAUTION: The ball joint stud tapers must be
CLEAN and DRY before installing the knuckle.
Clean the stud tapers with mineral spirits to
remove dirt and grease.
2. Install the knuckle (7) onto the upper (2) and lower
ball joints (5).
3. Install the upper (1) and lower ball joint nuts (6).
Tighten the nut to 75 N·m (55 ft. lbs.).
4. Remove the hydraulic jack from the lower control
arm (4).
5. Install the tie rod end (2) and tighten the nut (1) to
75 N·m (55 ft. lbs.).
1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as pos-
sible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
2. Mount a dial indicator solidly to the topside of the lower control arm and then zero the dial indicator.
3. Position the indicator plunger against the bottom surface of the steering knuckle.
NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle.
4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly.
5. If the travel exceeds 0.5 mm (0.020 in.), replace the lower ball joint (Refer to 2 - SUSPENSION/FRONT/LOWER
BALL JOINT - REMOVAL).
REMOVAL
1. Remove the tire and wheel assembly.
2. Remove the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
3. Remove the outer tie rod retaining nut (1) from the
knuckle (5).
8. Move the halfshaft to the side and support the halfshaft out of the way 4X4 only.
9. Remove the snap ring (3) from the ball joint flange
(2).
10. Press the ball joint (3) from the lower control arm
(4) using special tools C-4212-F (PRESS) (1),
8445–3 (Driver) (2) and 9604 (Receiver) (5).
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 24 FRONT ND
INSTALLATION
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa-
tion process.
1. Install the ball joint (3) into the control arm and
press in using special tools C-4212-F (press) (1),
8441–4 (Receiver) (2) and 9654–1 (Driver) (4).
2. Install the snap ring (3) around the ball joint flange
(2).
3. Remove the support for the halfshaft and install into position 4X4 only.
4. Install the steering knuckle (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION).
ND FRONT 2 - 25
5. Install the tie rod end (2) into the steering knuckle
(5), then install the retaining nut (1) and tighten to
75 N·m (55 ft. lbs.) (Refer to 19 - STEERING/LINK-
AGE/TIE ROD END - INSTALLATION).
6. Install and tighten the halfshaft nut to 251 N·m (185
ft. lbs.). (If Equipped).
7. Install the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
8. Install the tire and wheel assembly (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
9. Check the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
10. Perform a wheel alignment (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
10. Remove the lower ball joint nut (3). Separate the
lower ball joint (3) from the steering knuckle (1)
with Remover 8677 (2).
14. Remove the lower control arm bolts (3) ,nuts (5)
and washers(4).
15. Remove the lower control arm (6) from the
vehicle.
INSTALLATION
NOTE: All suspension components should be tighten with the weight of the vehicle on them (curb height).
7. Install the stabilizer bar link (Refer to 2 - SUSPENSION/FRONT/STABILIZER LINK - INSTALLATION) and tighten
to 169 N·m (125 ft. lbs.).
8. Tighten the lower control arm pivot nut (5) and
bolts (3) (to 244 N·m (180 ft. lbs.).
9. Insert the outer tie rod end (2) into the steering
knuckle (5). Install and tighten the retaining nut (1)
to 75 N·m (55 ft. lbs.).
SHOCK
DIAGNOSIS AND TESTING
SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and
metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If
the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any
of these conditions exist.
ND FRONT 2 - 31
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This
condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced.
To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five
times. The action throughout each stroke should be smooth and even.
The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubri-
cating them. Grease and mineral oil-base lubricants will deteriorate the bushing.
REMOVAL
1. Raise and support the vehicle.
2. Remove the tire and wheel assembly.
3. Support the lower control arm outboard end.
4. Remove the upper shock nuts (1).
INSTALLATION
NOTE: All suspension components should be tighten with the weight of the vehicle on them (curb height).
3. Install the lower part of the shock (2) into the lower
control arm shock bushing.
4. Position shock module clevis (2) to lower control
(6). Install bolt (4) so head of bolt is facing rear of
vehicle and hand start nut (3). Tighten the bolt (4)
& nut (5) to 81 N·m (60 ft. lbs.).
5. Install the stabilizer link lower nut (5) to the lower
control arm (6) (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - INSTALLATION).
6. Remove the support from the lower control arm outboard end.
7. Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
8. Remove the support and lower the vehicle.
ND FRONT 2 - 33
SPRING
REMOVAL
1. Remove the shock (Refer to 2 - SUSPENSION/
FRONT/SHOCK - REMOVAL).
2. Install the shock assembly in the Branick 7200T
spring removal/installation tool or equivalent (1).
3. Compress the spring (2).
INSTALLATION
1. Install the lower isolator.
2. Install the upper isolator.
3. Position the shock into the coil spring.
4. Install the upper shock mounting plate.
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 34 FRONT ND
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the chassis and connects to the frame crossmember. The ends of the
bar mount to the lower suspension arm. All mounting points of the stabilizer bar are isolated by bushings.
OPERATION
The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the
road surface.
ND FRONT 2 - 35
REMOVAL
1. Remove the stabilizer link (1) upper nut and
remove the retainers and grommets (Refer to 2 -
SUSPENSION/FRONT/STABILIZER LINK -
REMOVAL).
2. Remove the stabilizer bar retainer bolts (2) also
remove the retainers from the frame sway bar and
remove the bar (3).
3. If necessary, remove the bushings from the stabi-
lizer bar.
INSTALLATION
1. If removed, install the bushings on the stabilizer
bar.
2. Position the stabilizer bar (1) on the frame cross-
member brackets and install the bracket (3) and
bolts (2) finger-tight.
STABILIZER LINK
REMOVAL
1. Raise and support the vehicle.
2. Remove the lower nut (5).
3. Remove the upper nut, retainers and grommets
from the stabilizer bar (3).
4. Remove the stabilizer link (1) from the vehicle.
INSTALLATION
1. Install the stabilizer link (1) to the vehicle.
2. Install the retainers, grommets and upper nut to the
stabilizer bar (3) and Tighten to 37 N·m (27 ft. lbs.).
3. Install the lower nut (5) and Tighten to 169 N·m
(125 ft. lbs.).
4. Remove the support and lower the vehicle.
ND FRONT 2 - 37
5. Position a pry bar (3) between the steering knuckle (4) and the upper control arm (2). Pry upwards on the upper
control arm.
6. If the travel exceeds 0.5 mm (0.020 in.), replace the upper control arm since the upper ball joint is integral to the
arm (Refer to 2 - SUSPENSION/FRONT/UPPER CONTROL ARM - REMOVAL).
7. If the upper ball joint is within specs reinstall the front tires (Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
INSTALLATION
NOTE: All suspension components should be tighten with the weight of the vehicle on them (curb height).
4. Install the wheel and tire assembly, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
5. Remove the support and lower vehicle.
6. Perform a wheel alignment, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
ND REAR 2 - 39
REAR
TABLE OF CONTENTS
page page
REAR SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIAGNOSIS AND TESTING - REAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . 40 STABILIZER LINK
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
JOUNCE BUMPER STABILIZER BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REAR
DESCRIPTION
The rear suspension is comprised of:
• Shock Absorbers (6)
• Jounce Bumpers
• Stabilizer Bar
• Stabilizer links
• Leaf Springs (1)
• Drive Axle
CAUTION: Suspension components with rubber/urethane bushings (except stabilizer bar) should be tight-
ened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the
vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort
could be affected and premature bushing wear may occur.
IMPROPER TRACKING 1. Loose, worn or bent suspension 1. Inspect, tighten or replace components
components. as necessary.
2. Bent axle. 2.Replace axle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
JOUNCE BUMPER
REMOVAL
1. Raise and support the vehicle.
2. Remove the bolts (2) securing the jounce bumper
(1).
3. Remove the jounce bumper (1).
INSTALLATION
1. Install the jounce bumper (1) and bolts (2). Tighten
to 41 N·m (30 ft.lbs.).
2. Remove the support and lower the vehicle.
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 42 REAR ND
SHOCK
REMOVAL
1. Raise vehicle and support the axle.
2. Remove the upper shock bolt (1) and nut (2).
INSTALLATION
1. Position the shock absorber (6) to the vehicle.
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 44 REAR ND
3. Install the bolt (1) through the axle bracket and the
shock (3). Install the nut (2) to the bolt (1). Tighten
to 102 N.m (75 ft. lbs.)
4. Remove the support and lower the vehicle.
ND REAR 2 - 45
SPRING
REMOVAL
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of
the rear axle. Use care to avoid bending the side
rail flange.
INSTALLATION
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of
the rear axle. Use care to avoid bending the side
rail flange.
3. Align front spring eye (2) with the bolt hole in the
front frame bracket. Install the spring eye bolt (1)
and flag nut through the access hole in the frame
(3) and tighten the bolt (1) finger-tight.
5. Install the U-bolts (1), spring plate (4) and nuts (2).
6. Tighten the U-bolt nuts (2) to 149 N·m (110 ft. lbs.).
7. Install the wheel and tire assemblies. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
Download Complete manual for FREE @ https://www.heydownloads.com
2 - 48 REAR ND
8. Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the
weight of the vehicle.
9. Tighten the spring eye pivot bolt (1) and flagnut to
163 N·m (120 ft. lbs.).
10. Tighten the upper shackle bolt and nut (2) and the
lower shackle bolt (3) and nut to 163 N·m (120 ft.
lbs.).
ND REAR 2 - 49
STABILIZER LINK
REMOVAL
1. Raise and support the vehicle.
2. Remove the rear tire.
3. Support the rear axle with a jack.
4. Remove the lower link nut (4) at the stabilizer bar
(6).
5. Remove the upper link nut (1) and bolt (2) at the
frame. On the left side stabilizer link (7), upper
bolt pull the bolt (2) back after the nut (1) is
removed and then pull the link (7) downward
with the bolt (2) still in the link (7) to allow
clearance from the fuel tank (3).
6. Remove stabilizer link (7).