tow DODGE RAM 1999 Service Owner's Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 283 of 1691
![DODGE RAM 1999 Service Owners Guide VISUAL INSPECTION
1) Check Water-In-Fuel (WIF) sensor electrical connector for\
corrosion, damaged terminals or wiring and tight fit on engine wiring
harness. WIF sensor is located](/img/12/56915/w960_56915-282.png "DODGE RAM 1999 Service Owners Guide VISUAL INSPECTION
1) Check Water-In-Fuel (WIF) sensor electrical connector for\
corrosion, damaged terminals or wiring and tight fit on engine wiring
harness. WIF sensor is located")
VISUAL INSPECTION
1) Check Water-In-Fuel (WIF) sensor electrical connector for\
corrosion, damaged terminals or wiring and tight fit on engine wiring
harness. WIF sensor is located in bottom of fuel filter/water
separator. See Fig. 1.
2) Check for water in fuel filter/water separator by placing
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) With engine not running, rotate handle on drain valve
forward, toward front of vehicle to OPEN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 1. Drain
water from fuel filter/water separator.
4) If no water exists and a clean flow of diesel fuel exists,
rotate handle on drain valve back to CLOSE position. Go to next step.
If water exists, allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position. Go to
next step.
5) Verify fuel filter/water separator has been serviced
according to proper service schedule. See SERVICE & ADJUSTMENT
SPECIFICATIONS - TRUCKS article.
6) Check color of Filter Minder. Filter Minder is located on
top cover on air filter housing, just above air filter. DO NOT remove
air filter from air filter housing for inspection. If Yellow disc in
Filter Minder has reached Red zone, remove and inspect air filter. See
Fig. 2 . If air filter is dirty, replace air filter and reset Filter
Minder by pressing rubber button on top of Filter Minder.
NOTE: The Yellow disc in Filter Minder may reach Red zone if air
intake is restricted or air filter has become wet during
heavy rain or snow. If air filter has become wet, allow air
filter to dry during normal engine operation and reset Filter
Minder by pressing rubber button on top of Filter Minder.
7) Ensure intercooler inlet and outlet duct clamps are tight
and front of intercooler is not restricted with dirt. See Fig. 3.
Fig. 2: Identifying Filter Minder Components
Courtesy of Chrysler Corp.
Page 289 of 1691
tachometer.
2) If WATER-IN-FUEL (WIF) warning light stays on, water
should be drained from fuel filter/water separator. To drain water
from fuel filter/water separator, ensure engine is not running. Place
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) Rotate handle on drain valve forward, toward front of
vehicle to OPEN position. Drain valve is located near top of fuel
filter/water separator. See Fig. 1.
4) Allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position.
FUEL TRANSFER PUMP
NOTE: A defective fuel transfer pump may cause low power, hard
starting and White smoke. Check fuel transfer pump output
pressure (cranking and starting), pressure drop and fuel
supply.
Fuel Transfer Pump Preliminary Inspection
1) Check for restricted or leaking fuel supply line to fuel
transfer pump or fuel return line located on driver's side of engine.
See Fig. 1 . Repair fuel supply line or fuel return line if restricted
or leaking.
2) Check for fuel leaking from fuel transfer pump. Replace
fuel transfer pump if fuel is leaking. Check fuel transfer pump output
pressure.
Fuel Transfer Pump Output Pressure
1) Clean area around filter fitting plugs, then remove plugs.
See Fig. 7 . Install Test Fittings (AVU1-2). Install Fuel Pressure Test
Gauge (6828) at inlet port. See Fig. 7. To prevent engine starting,
remove fuel injection pump relay, located in power distribution
center.
2) Turn ignition switch to START position. Inlet pressure
should be 5-7 psi. Install fuel injection pump relay. Start engine.
Inlet pressure should be 10 psi. Using a scan tool, clear FTC. FTC may
set when relay is removed. Check pressure drop.
Fig. 7: Checking Fuel Transfer Pump Output Pressure
Courtesy of Chrysler Corp.
Pressure Drop Test
Turn engine off. Move pressure gauge from inlet port to
Page 293 of 1691
![DODGE RAM 1999 Service Owners Guide Minimum Compression Pressure
Dakota
2.5L ........................................................ (1)
3.9L, 5.2L & 5.9L ............................. 100 psi (690 kPa)\
Durango .......](/img/12/56915/w960_56915-292.png "DODGE RAM 1999 Service Owners Guide Minimum Compression Pressure
Dakota
2.5L ........................................................ (1)
3.9L, 5.2L & 5.9L ............................. 100 psi (690 kPa)\
Durango .......")
Minimum Compression Pressure
Dakota
2.5L ........................................................ (1)
3.9L, 5.2L & 5.9L ............................. 100 psi (690 kPa)\
Durango ........................................ 100 psi (690 kPa)\
Ram Pickup ..................................... 100 psi (690 kPa)\
Ram Van Ram Wagon .............................. 100 psi (690 kPa)\
Maximum Variation Between Cylinders ............................ ( 1)
( 1) - Information is not available from manufacturer.
\
\
\
\
\
\
\
FUEL SYSTEM
FUEL PRESSURE RELEASE
WARNING: Fuel system is under high pressure. ALWAYS release fuel
pressure before attempting to open system for testing or
component replacement. DO NOT allow fuel to flow onto engine
or electrical parts while testing fuel system components.
Vehicles With Fuel Rail Test Port
1) Loosen fuel tank filler cap. Ensure ignition is off.
Remove protective cap from fuel rail test port.
2) Place one end of Fuel Pressure Release Hose (C-4799-1)
into an approved fuel container. Attach remaining end of hose to fuel
rail test port. Use care, as fuel system may be under pressure. Fuel
pressure will be released from fuel system. Remove hose, reinstall
protective cap, and fuel tank filler cap.
3) Wait 5 seconds. Use care when disconnecting fuel lines, as
some fuel pressure may still exist in fuel lines.
NOTE: One or more DTCs may set when fuel pump relay is removed.
Clear DTCs from PCM after fuel pressure release procedure. To
clear DTCs from PCM, see CLEARING DTCS under SELF-DIAGNOSTIC
SYSTEM in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
Vehicles Without Fuel Rail Test Port
1) Remove gas cap. Using a non-metallic tool, open flapper
valve in filler neck to relieve pressure. Remove fuel pump relay from
Power Distribution Center (PDC). Relays are identified on label under
PDC cover. Start and run engine until it stalls. Attempt to start
engine. Continue restarting engine until it will no longer run. Turn
ignition off.
CAUTION: DO NOT supply power to fuel injector for more than 4 seconds,
or fuel injector may be damaged.
2) Disconnect any fuel injector connector. Connect a jumper
wire between either fuel injector terminal and positive battery
terminal. Connect another jumper wire to other fuel injector terminal.
Momentarily touch other end of jumper wire to negative battery
terminal.
3) Place a shop towel under fuel line quick-connector at fuel
rail. Use care when disconnecting fuel lines, as some fuel pressure
may still exist in fuel lines. Disconnect fuel line quick-connector.
Reinstall fuel pump relay in PDC. Clear DTCs from PCM. To clear DTCs
from PCM, see CLEARING DTCS under SELF-DIAGNOSTIC SYSTEM in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
FUEL PRESSURE TEST
Page 320 of 1691
SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:\
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
demonstrating to their customers that they are serious about customer
satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
Page 370 of 1691
CLUTCH HOUSING (RAM PICKUP)
NOTE: Only NV4500 clutch housing can be checked using the following
bore and face runout procedures. The NV1500, NV3500 and
NV5600 clutch housings are an integral part of transmission
front case and can only be checked off vehicle.
Clutch Housing Bore Runout (NV4500)
1) Remove clutch housing. Remove clutch cover and disc. See
CLUTCH ASSEMBLY under REMOVAL & INSTALLATION. Replace one flywheel
bolt with a threaded rod. See Fig. 2. Remove release fork from clutch
housing. Reinstall clutch housing. Tighten housing bolts nearest
alignment dowels first. Mount dial indicator on threaded rod and
position indicator plunger on surface of clutch housing bore. See
Fig. 4 .
2) Rotate crankshaft until indicator plunger is at top center
of housing bore. Zero dial indicator. Rotate crankshaft and record
indicator readings at 8 points, 45 degrees apart, around bore. See
Fig. 5 .
3) Repeat measurement at least twice. Subtract each reading
from one 180 degrees opposite to determine magnitude and direction of
runout. For example: 0.000" minus (-0.007") = 0.007", 0.002" minus (-\
0.010") = 0.01", 0.004" minus (-0.005") = 0.009" or -0.001" minus (0\
.
001") = -0.002" which will be 0.002". In this example, largest
difference is 0.012" (total indicator reading). This means housing
bore is offset from crankshaft centerline by 0.006" (1/2 of 0.012").
4) On gas engines, acceptable total indicator reading is 0.
010". If measured total indicator reading is more than 0.010", bore
runout will have to be corrected using offset dowels. Offset dowels
are available in 0.007", 0.014" and 0.021". See DOWEL SELECTION table.
If total indicator reading is 0.053" or greater, replace clutch
housing. If dial indicator reads positive when plunger moves inward
(toward indicator) and negative when moves outward away from
indicator), lowest or most negative reading determines direction of
housing bore offset (runout).
5) On diesel engines, offset dowels are not available to
correct runout. If total indicator reading exceeds bore runout of 0.
015", replace either clutch housing, or transmission adapter plate. On
gas engines, if bore is offset, remove housing and original dowels,
install new offset dowels in direction need to center bore with
crankshaft centerline. Install new dowels with slotted side facing
out. Using a screwdriver, rotate dowels until total indicator reading
is less than 0.010". Ensure clutch housing face runout is within
specification.
DOWEL SELECTION
\
\
\
\
\
\
\
Application - In. (mm) Offset Dowel - In. (mm\
)
0.011-0.021 (0.2794-0.5334) ......................... 0.007 (0.1778\
)
0.022-0.035 (0.5588-0.8890) ......................... 0.014 (0.3556\
)
0.036-0.052 (0.9144-1.3208) ......................... 0.021 (0.5334\
)
\
\
\
\
\
\
\
Fig. 3: Manufactured Stud Or Threaded Rod
Courtesy of Chrysler Corp.
Page 374 of 1691
Removal (AX15 & NV1500)
1) Shift gear selector into 1st or 3rd gear. Raise and
support vehicle. Disconnect necessary exhaust system components.
Remove "Y" pipe and position remaining pipes for working clearance.
Support transmission adjustable jackstand. Disconnect rear cushion and
mounting bracket from transmission or transfer case.
2) Remove rear crossmember. If transmission will be
disassembled for repair, drain transmission fluid. Disconnect
transmission shift linkage, speedometer cable, transfer case vacuum
lines and clutch hydraulic lines. Lower transmission/transfer case
assembly no more than 3" (76 mm). Reaching around transmission case,
unseat and lift shift lever dust boot. Press shift lever retainer
downward, turn retainer counterclockwise, and lift lever and retainer
out of shift tower.
3) Mark front and rear drive shaft and "U" joint for
reassembly reference. Disconnect and remove both drive shafts. Remove
crankshaft position sensor (AX15). Disconnect transmission/transfer
case assembly vent hoses. Remove slave cylinder from clutch housing.
Remove wire harness from clips on transmission case and transfer case.
4) Support transmission/transfer case assembly with
transmission jack. Secure assembly to jack with safety chains.
Reposition adjustable jackstand under engine. Remove clutch housing
brace rod. Remove clutch housing nuts and bolts. Remove
transmission/transfer case assembly.
Installation
To install, reverse removal procedure. Apply high-temperature
grease to release fork, lever, pivot ball stud and pilot bushing
located in end of crankshaft. Fill transmission with appropriate
fluid, if necessary. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS table.
Removal (NV 3500)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Open console lid and remove bolts attaching console to floor
pan. Lift cup holder bin and remove bolt attaching console to floor
pan. Lift rear of console and pull console rearward to separate from
shift bezel. Remove console from vehicle. Remove screws attaching
shift boot to floor pan and slide boot upward on lever extension.
2) Remove shift lever extension. Raise and support vehicle.
On 4WD models, remove skid plate, if equipped. Mark drive shaft and
axle yoke for alignment reference. Remove drive shaft. Remove exhaust
"Y" pipe. On 4WD models, disconnect and lower remaining exhaust pipes
for clearance as necessary. Disconnect speed sensor harness connector
and back-up light harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine attaching bolts. Slide
Page 375 of 1691
transmission and jack rearward until input shaft clears clutch disc.
Lower transmission jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and drive shaft slip yoke. Apply sealer to threads of drain plug
before installing in case.
2) Align reference marks made on drive shaft(s) and "U"
joints during removal. After installing clutch assembly and housing,
tighten housing bolts nearest alignment dowels first. During final
transmission installation, install shims between clutch housing and
transmission at appropriate bolt location. Tighten all nuts and bolts
to specification. See TORQUE SPECIFICATIONS table.
TRANSMISSION (RAM PICKUP)
Removal (NV3500 & NV5600)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Remove shift boot bezel screws and slide boot upward on lever
extension. Remove shift tower and lever assembly. Raise and support
vehicle.
2) On 4WD models, remove skid plate, if equipped. Remove
crankshaft position sensor. Mark drive shaft and axle yoke for
alignment reference. Remove drive shaft. Remove exhaust "Y" pipe. On
4WD models, disconnect and lower remaining exhaust pipes for
clearance, as necessary. Disconnect speed sensor harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover. On
some models, it may be necessary to remove front axle struts and oil
filter for access and removal clearance.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine bolts. Slide transmission and
jack rearward until input shaft clears clutch disc. Lower transmission
jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and drive shaft slip yoke.
2) Apply sealer to threads of drain plug before installing in
case. Align reference marks made on drive shaft(s) and axle yoke(s)
during removal. After installing clutch assembly and housing, tighten
housing bolts nearest alignment dowels first. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
Removal (NV4500 & NV4500HD)
Page 376 of 1691
1) Disconnect negative battery cable. Shift transmission to
Neutral. Remove shift boot bezel screws and slide boot upward on lever
extension. Scribe mark position of extension on shank of shift lever.
2) Raise and support vehicle. On 4WD models, remove skid
plate, if equipped. Mark drive shaft and axle yoke for alignment
reference. Remove drive shaft. Remove exhaust "Y" pipe. On 4WD models,
disconnect and lower remaining exhaust pipes for clearance as
necessary. Disconnect speed sensor harness connector and back-up light
harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
See Fig. 9 . On 4WD models, disconnect transfer case shift linkage at
transfer case range lever and remove shift lever from transmission.
Remove bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and move it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder, and move aside. Remove
starter. Remove transmission splash shield. Remove transmission
harness wires from clips on transmission shift cover. On some models,
it may be necessary to remove front axle struts and oil filter for
access and removal clearance.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine bolts. Slide transmission and
jack rearward until input shaft clears clutch disc. Lower transmission
jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and propeller shift slip yoke.
2) Apply sealer to threads of drain plug before installing in
case. Align reference marks made on drive shaft(s) and axle yoke(s)
during removal. After installing clutch assembly and housing, tighten
housing bolts nearest alignment dowels first.
3) During final transmission installation, install shims
between clutch housing and transmission at appropriate bolt location.
See CLUTCH HOUSING BORE RUNOUT and CLUTCH HOUSING FACE RUNOUT under
CLUTCH HOUSING (RAM PICKUP) under TESTING. Press extension to scribe
mark made during removal. A 0.12-0.20" (3-5 mm) space should exist
between shift lever isolator, top edge of stub shaft and tool lower
jaw. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS table.
Fig. 9: Identifying Transmission Drain Bolt (NV4500 & NV4500HD)
Courtesy of Chrysler Corp.
CLUTCH ASSEMBLY
Page 379 of 1691
![DODGE RAM 1999 Service Owners Guide TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\](/img/12/56915/w960_56915-378.png "DODGE RAM 1999 Service Owners Guide TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\")
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\
Application Ft. Lbs. (N.m)\
Clutch Master Cylinder Nuts ................................ 40 (54)\
Clutch Slave Cylinder Nuts ................................. 17 (23)\
Crossmember-To-Frame Bolts
AX15 & NV3500 (Dakota) ..................................... 30 (41\
)
NV3500 (Ram Pickup) ........................................ 50 (68\
)
Crossmember-To-Transmission Insulator Nuts
2WD (NV3500 - Ram Pickup) ................................ 50 (68\
)
4WD (NV3500 - Ram Pickup) .......................... 40-45 (54-61\
)
Flywheel Bolts
Dakota 2.5L ................................................ 70 (95)\
Dakota V6 & V8 ............................................. 55 (75)\
Pressure Plate Bolts
5/16" .................................................... 17 (23)\
3/8" ..................................................... 30 (41)\
Transfer Case To Transmission Nuts
AX15 ................................................. 26 (35 N.m)\
NV3500, NV4500, NV4500HD & NV5600
5/16" ............................................. 22-30 (30-41)\
3/8" .............................................. 30-35 (41-47)\
Transmission-To-Clutch Housing Bolts
AX15 ..................................................... 27 (37)\
NV3500 (Ram Pickup) & NV5600 ....................... 40-45 (54-61\
)
NV1500, NV3500 (Dakota), NV4500 & NV 4500HD ............. 80 (108\
)
"U" Joint Clamp Bolts ...................................... 14 (19)\
INCH Lbs. (N.m)
Shift Tower Bolts (NV3500) ............................ 62-89 (7-10\
)
\
\
\
\
\
\
\
Page 408 of 1691
FLUID TYPE
Use SAE 80W-90 or 90W hypoid gear lubricant with MIL-L-2105-C
and API GL-5 ratings.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
AXLE SHAFT & HUB BEARING
Removal
1) Raise and support vehicle. Remove wheel. Remove brake
caliper with hose attached, and secure aside. DO NOT allow brake
caliper to hang by brake hose. Remove brake rotor. Remove ABS wheel
speed sensor (if equipped). Remove grease cap from center of front
hub. Remove cotter pin from end of axle shaft. Remove axle nut and
washer.
2) Remove hub/bearing assembly-to-knuckle bolts. Remove
hub/bearing assembly from steering knuckle and axle shaft. Remove
brake dust shield. To remove right (passenger-side) axle shaft,
carefully pull axle shaft from axle housing.
NOTE: Left axle shaft will disengage from collar located on
intermediate axle shaft.
3) To remove left (driver's side) axle shaft, disconnect
electrical connector and vacuum hoses at vacuum shift motor. Remove
bolts, vacuum shift motor and gasket. Carefully pull axle shaft from
axle housing and collar on intermediate axle shaft.
Installation
1) Install NEW oil seal on axle shaft with seal lip facing
toward splines on differential end of axle shaft. Coat seal lip with
wheel bearing grease.
2) Install right axle shaft into axle housing. Ensure axle
shaft engages with side gears in differential.
3) To install left axle shaft, ensure collar is engaged with
splines on intermediate axle shaft. Install left axle shaft into axle
housing. Ensure axle shaft engages with splines on collar. Install
vacuum shift motor, ensuring fork on vacuum shift motor engages groove
on collar. Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS table.
4) To complete installation, reverse removal procedure. Apply
silicone rubber sealant to edge of grease cap before installing.
Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer selector levers case are in Neutral. Reference mark drive
shaft and pinion flange for reassembly reference.
2) Remove bolts and "U" joint straps at pinion flange. Remove
center carrier bearing bolts (if equipped). Remove drive shaft.
CAUTION: The "U" joint components are not serviceable. Replace
complete assembly. DO NOT reuse.