oil DODGE TRUCK 1993 Service User Guide

0 - 14
LUBRICATION
AND
MAINTENANCE

•
ENGINE
MAINTENANCE

INDEX

page
Air
Injection
Systems/Air Pump
. 17

Air-Conditioner
Compressor
21
Battery
19

Cooling System
15

Crankcase
Ventilation
System
17
Diesel Engine
Air Filter
Canister
17

Drive Belts
20
Engine
Air
Cleaner
Filter
Element
16

Engine Break-In
14

Engine
Oil 14

Engine
Oil
Change
and Filter
Replacement
15

Exhaust Gas
Recirculation
(EGR) System
...... 19
page
Exhaust
Manifold
Heat
Control
Valve
. 17
Exhaust System
, 21

Fuel System
18

Hoses
and
Fittings
16
Ignition
Cables,
Distributor
Cap and
Rotor
...... 19

Ignition
Timing
. 19

Oxygen
(02)
Sensor
19
Rubber/Plastic Components
20

Spark Plugs
. 19

Throttle
Control
Linkage
18

Vacuum Operated, Emission
Control
Components
19

ENGINE BREAK-IN
After first starting a new engine, allow it to idle
for 15 seconds before shifting into a drive gear. Also:
• Drive the vehicle at varying speeds less than 88
km/h (55 mph) for the first 480 km (300 miles).
• Avoid fast acceleration and sudden stops.
• Do not drive at full-throttle for extended periods of
time
• Do not drive at constant speeds
• Do not idle the engine excessively A special break-in engine oil is not required. The
original engine oil installed is a high quality lubri­
cant. New engines tend to consume more fuel and oil un­
til after the break-in period has ended.

ENGINE
OIL SPECIFICATIONS

API SERWICE
GRADE
Use an engine oil that conforms to API Service
Grade S5 SG/CD or SG/CE. MOPAR®provides engine
oils that conform to all of these service grades.

SULFATED ASH—DIESEL ENGINES
Oils that contain an excessive amount of sulfated
ash can cause deposits to develop on Diesel engine
valves. These deposits can result in valve wear.

SAE
WISC0SITY
An SAE viscosity grade is used to specify the vis­
cosity of engine oil. SAE 30 specifies a single viscos­
ity engine oil.
Engine oils also have multiple viscosities. 10W-30

<
5W-30

1
1 1

F
-20 0 10 20 32 60 80 100

C
-29 -18 -12 -7 0 16 27 38
ANTICIPATED
TEMPERATURE RANGE BEFORE
NEXT
OIL
CHANGE
J9000-39

Fig.
1 Temperature/Engine Oil Viscosity—Gasoline
Engines

-12°C
-18°C 10°F
0°F- 15W-40

-23°c(^-10eF

I
10W-30
WITH
WITHOUT
BLOCK HEATER
BLOCK
SYNTHETIC
OIL

HEATER
10W-30 5W-30

J9100-29

Fig.
2 Temperature/Engine Oil Viscosity—Diesel
Engines

ENERGY
G0NSERWING
OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either EN­
ERGY CONSERVING or ENERGY CONSERVING

II.
OIL
LEVEL
INDICATOR (DIPSTICK)

GASOLINE ENGINES
The engine oil indicator is located at the right
front of the engine.

•

LUBRICATION
AND
MAINTENANCE
0 - 15
DIESEL
ENGINES

The Diesel engine oil level indicator is located at
the left center of the engine, above the
fuel
injection

pump (Fig. 3).

Fig.
3
Diesel
Engine
Oil
Dipstick

ACCEPTABLE
OIL
LEVEL
To maintain proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
For gasoline engines, the acceptable levels are indi­ cated between the ADD and
FULL
marks on oil
dip­
stick. For Diesel engines, the acceptable levels are
indicated between the L (low) and H
(high) marks
on
oil dipstick. The oil level should be checked periodically. The
vehicle should be on a level surface. Wait for
five
minutes after stopping the engine. For gasoline en­
gines,
add oil only when the level indicated on the
dipstick is at or below the ADD mark. For Diesel en­
gines,
add oil only when the level indicated on the
dipstick is between the L and H marks.
Never oper­
ate a Diesel
engine when
the oil
level
is below
the L mark. The distance between the L and H
marks represents 1.9L (2 Qts) engine oil.

CAUTION:
Do not
overfill
an
engine crankcase
with

oil. This
will
cause
oil
aeration
and
result
in a de­

crease
in the
engine
oil
pressure.
ENGINE
OIL
CHANGE AND FILTER REPLACEMENT

WARNING: PROTECTIVE CLOTHING
AND
GLOVES SHOULD
BE
WORN. EXPOSED SKIN SHOULD
BE

WASHED
WITH
SOAP
AND
WATER
TO
REMOVE
USED
ENGINE
OIL.
DO NOT
USE
GASOLINE, THIN­
NER,
OR
SOLVENTS
TO
REMOVE ENGINE
OIL

FROM
SKIN.
DO NOT
POLLUTE. DISPOSE
OF
USED
ENGINE
OIL
PROPERLY.
ENGINE
OIL
FILTER

All engines are equipped with a throw-away type
oil filter. The same type of filter is recommended
when the filter is changed.

OIL CHANGE
AND
FILTER
REPLACEMENT
Bring engine up to normal operating temperature.
A more complete drainage of oil will result.
(1) Remove the drain hole plug and drain the en­
gine oil from the crankcase.
(2) Install the drain hole plug with a replacement
gasket. For gasoline engines, the oil filter should be
replaced during every second engine oil change.
For Diesel engines, the oil filter should be re­
placed during every engine oil change.
(3) Rotate the oil filter counterclockwise to remove
it.
(4) Clean the engine cylinder block oil filter boss. (5) Apply a light coat of new engine oil to the rub­
ber seal on the oil filter.
(6) Install and hand tighten the oil filter 1/2 to 3/4
of a turn clockwise. (7) Add new engine oil at the fill hole location on
top of the engine cylinder head cover. Wipe off any spilled oil.
(8) Observe the oil level on the dipstick.

CAUTION:
Do not
overfill
the
engine crankcase
with

oil.
(9)
Start the engine. Observe the oil pressure
gauge or warning lamp (as applicable). If the oil
pressure does not increase, stop the engine immedi­ ately. Check oil level.

COOLING SYSTEM

WARNING:
USE
EXTREME CAUTION WHEN
THE
ENGINE
IS
OPERATING.
DO NOT PUT
YOUR
HANDS NEAR
THE
DRIVE BELT(S), PULLEYS
OR
FAN BLADE.
DO NOT
STAND
IN A
DIRECT LINE
WITH
THE FAN
BLADE.

INSPECTION SCHEDULE
Determine the coolant level. Inspect the cooling
system hoses/clamps after each service interval has
elapsed.

COOLANT LEVEL
It is recommended that the engine coolant level be
inspected at least once a month during periods of hot
weather.
With the engine at normal operating temperature,
check the coolant level in the coolant reserve tank.
The coolant level must be at least above the ADD mark. Add coolant to the coolant reserve tank only.

0-18
LUBRICATION
AND
MAINTENANCE

•
COOLANT FREEZE PROTECTION

Cooling systems contain a 50/50 mixture of anti­
freeze (ethylene glycol) and distilled water. This is
the recommended coolant mixture.
It is recommended that the degree of coolant pro­
tection be tested every 12 months. If the coolant is
contaminated or rusty, the cooling system should be
drained, flushed. Refill with a 50/50 mixture of fresh
coolant. Refer to Group 7—Cooling Systems for addi­
tional information.

SYSTEM
INSPECTION

WARNING:
IF THE
ENGINE
HAS
BEEN RECENTLY
OPERATED,
DO NOT
REMOVE
THE
RADIATOR

CAP.
THIS WILL AVOID
YOU
BEING SCALDED

WITH
HOT, PRESSURIZED COOLANT.

(1) Test the radiator cap for proper sealing and op­
eration. Use caution when removing the radiator cap
to avoid contact with hot coolant. Place a heavy rag
or towel over the cap and turn to the first stop. Do
not press down. Pause to allow the pressure to re­
lease through the overflow tube. Then press down
and turn counterclockwise to remove the cap.
(2) Inspect the coolant overflow tubing and the
connections at the coolant reserve tank and at the
radiator.
(3) Inspect the entire cooling system for leaks. A
black-light detector can be used as an aid in detect­ ing the source of coolant leaks.
(4) Inspect the radiator and air conditioner con­
denser fins for debris, etc. (5) If necessary, refer to Group 7—Cooling Systems
for additional information and service procedures.

RADIATOR CAP
The radiator cap must be completely tightened to
provide proper pressure. Inspect and test radiator cap
when cooling system service is performed.

MAIN,
FLUSH
AND
FILL

WARNING: ANTI-FREEZE (ETHYLENE GLYCOL)
IS
POISONOUS.
KEEP
OUT OF THE
REACH
OF
CHIL­

DREN.

Drain, flush, and fill the cooling system at the in­
terval specified in maintenance schedule. For proper service instructions see Group 7, Cooling System.

HOSES AND
FITTINGS
It is recommended that rubber hoses be periodi­
cally inspected. Inspect all hose fittings for looseness and corrosion.
ENGINE
AIR
CLEANER
FILTER
ELEMENT

MAINTENANCE
SCHEDULE
With normal driving conditions, the engine air
cleaner filter element should be replaced:
• Light-Duty Cycle-after each 48 000 km (30,000
miles) interval has elapsed
• Heavy-Duty Cycle-after
each
38 000 km (24,000
miles) interval has elapsed
When the vehicle is operated in dusty areas, the
filter element should be replaced more often.
For Diesel engines, the air filter canister should be
cleaned at the same time the filter is replaced.

SERVICE/REPLACEMENT
(1) Remove the air cleaner cover.
(2) Remove the air cleaner filter (Fig. 4).

CAUTION:
Do not tap the filter or immerse the filter medium in liquid to remove trapped debris.
(3) Clean filter by blowing the trapped debris from
the filter with compressed air (Fig. 5). Direct the air in the opposite direction of normal intake air flow.
Keep the air nozzle at least two inches away from
the filter.
(4) If the filter has become partially saturated with

oil,
replace the filter. Inspect the crankcase ventilat­
ing system for proper operation.
(5) Wash the air cleaner cover and body with
cleaning solvent. Wipe it dry.
(6) Install the air cleaner filter element. Attach
the cover to the body (Fig. 4).
Fig,
4
Engine
Air Oeaner—
Typical

•

Fig.
5
Cleaning
Filter
Element—Typical

DIESEL
ENGINE
AIR
FILTER CANISTER MAINTENANCE SCHEDULE

The Diesel engine air filter should be cleaned after
each interval specified in the Diesel engine mainte­
nance schedule.
When the vehicle is operated in dusty areas, the
canister should be cleaned more frequently.

EXHAUST
MANIFOLD HEAT CONTROL VALVE
MAINTENANCE SCHEDULE
The exhaust manifold heat valve should be ser­
viced after the interval specified in the maintenance schedule has elapsed.
SERVICE The exhaust manifold heat valve is located at the
left manifold (Fig. 6). Test the valve for non-re­ stricted movement.
Fig.
6 Manifold Heat Control
Valve
LUBRICATION
AND
MAINTENANCE
0 - 17

Fig.
7 Positive
Crankcase
Ventilation

System—Typical

SYSTEM OPERATION
Each PCV system is comprised of an air inlet filter,
a flow-control (PCV) valve, and the associated hoses.
The air inlet filter is located at the cylinder head cover (Fig. 7).
WARNING:
USE
EXTREME CAUTION WHEN
THE

ENGINE
IS
OPERATING.
DO NOT PUT
YOUR
HANDS NEAR
THE
DRIVE BELT(S), PULLEYS
OR

FAN BLADE.
DO NOT
STAND
IN A
DIRECT LINE

WITH
THE FAN
BLADE.

(1) With the engine idling, accelerate momen­
tarily. The valve shaft counterweight should move CLOCKWISE.
(2) If no movement is observed, either the shaft is
binding or the thermostat spring is weak or broken. (3) If the thermostat spring is weak or broken, re­
place the spring.
(4) Verify the manifold is COOL. Apply
MOPAR®Rust Penetrant (or an equivalent product)
to each end of the valve shaft at the bearings (Fig.
6).

(5) Allow the solvent to penetrate for a few min­

utes.
Then, rotate the valve shaft back and forth un­
til it turns without restriction.

AIR INJECTION SYSTEMS/AIR PUMP
Air injection system/air pump valves and switches
should be periodically tested for proper operation. In­
spect the check valve tubing for corrosion. Replace it
if excessive corrosion exists.

CRANKCASE
VENTILATION
SYSTEM
All gasoline engines are equipped with a positive
crankcase ventilation (PCV) system. The PCV sys­
tem prevents emission of residual engine oil vapor
from the crankcase (Fig. 7).

0-18
LUBRICATION
AND
MAINTENANCE

• MAINTENANCE SCHEDULE
A crankcase ventilation system must be clean to
provide good operation and durability. Periodic main­
tenance is necessary. Replace the PCV valve. Re­
move residual combustion deposits from the hoses and throttle body/intake manifold passages.
The PCV valve should be replaced and the system
should be serviced at the interval specified in main­
tenance schedule. If a vehicle is routinely used for short trips, the crankcase ventilation system could
possibly require more maintenance.
CRANKCASE AIR INLET FILTER
MAINTENANCE SCHEDULE Replace or clean, the air inlet filter at the interval
specified in maintenance schedule.
More frequent PCV system maintenance could be
required for:
• Vehicles routinely used for short trips
• Vehicles routinely involved in stop and go traffic
operation
• Vehicles routinely involved in extended periods of
engine idle
MAINTENANCE Clean and lubricate the crankcase air inlet filter
according to the following procedure. (1) Disconnect the fresh air hose from the port on
the crankcase air inlet filter housing (Fig. 8).
(2) Remove the air filter housing from the cylinder
head cover (Fig. 8). Clean the filter in kerosene or a similar solvent.
(3) Lubricate the filter by inverting the housing
and filling it with SAE 30 viscosity engine oil.
(4) Insert the air filter housing nipple in the cylin­
der head cover grommet. Connect the fresh air hose
to the upper port (Fig. 8).
J9000-52

Fig.
8
Crankcase
Air Inlet
Filter
THROTTLE CONTROL LINKAGE

Transmission linkage pivot pin areas (Fig. 9),
should be serviced. The areas lubricated every second
oil change with a multi-purpose lubricant (NLGI GC-
LB).

PIVOT
AREAS
Fig.
9
Transmission
Linkage
Pivot Areas

FUEL
SYSTEM

INSPECTION The fuel system filler cap, nozzle, tubes, hoses, and
connections should be inspected periodically.
FUEL FILTER The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag­
nosis and service procedures refer to Group 14, Fuel
System.
GASOLINE ENGINE FUEL REQUIREMENTS All gasoline engines require fuel that has a mini­
mum octane rating of 87 determined by the (R +
M)/2 calculation method.
The use of a brand of unleaded gasoline that con­
tains additives is recommended. Gasoline with addi­
tives will improve fuel economy and reduce emissions.

ALCOHOL/GASOLINE
BLENDS
Many brands of blended unleaded gasoline am now
available. Unleaded gasoline is blended with oxygenated-type
fuels to produce a clean air gasoline in many areas.
The use of this type of blended fuel is recommended.
ETH ANOL—Unleaded gasoline and ethanol
blended fuels are a mixture of 10 percent ethanol and 90 percent unleaded gasoline. This is an accept­
able blend of fuel.
MTBE— MTBE blended fuels are a mixture of un­
leaded gasoline and up to 15 percent MTBE (Methyl
Tertiary Butyl Ether). Unleaded gasoline blended
with MTBE is acceptable.

•

LUBRICATION
AND
MAINTENANCE
0 - 21 ROUTINE INSPECTION
It is recommended that the drive belt(s) be rou­
tinely inspected for cracks, fraying and excessive
wear. Replace as necessary.

EXHAUST SYSTEM
An exhaust system must be properly aligned to
prevent stress, leakage, and vehicle body contact.
MAINTENANCE SCHEDULE Inspect the exhaust system at the interval specified
in maintenance schedule.
INSPECTION Inspect for cracked or loose joints, corrosion dam­

age,
and worn or broken hangers. Replace all compo­
nents that are damaged. Do not attempt repair. Also,
inspect for the following conditions and correct as
necessary:
• Exhaust system leaks, misalignment • Contact with body panels or the frame
• Catalytic converter bulging or excessive heat dam­
age

CAUTION:
A
catalytic converter
will
become
con­

taminated
if
leaded gasoline
is
burned
in the en­

gine.
If
this
occurs,
the
complete converter must
be
replaced.

AIR-CONDITIONER COMPRESSOR LUBRICANT
AND
REFRIGERANT
The lubricant level in the compressor should be
checked if there are indications that oil was lost.
Loss of lubricating oil usually accompanies a loss of
refrigerant. The presence of bubbles in sight glass in­ dicates that loss of refrigerant has occurred. For additional information involving the A/C sys­
tem, refer to Group 24—Heater And Air Condition­ ing.

•

LUBRICATION
AND
MAINTENANCE
0 - 23 GEAR SHIFTER BOOTS
Inspect the shifter boots periodically for stone and
heat damage. Replace, if necessary.
SEVERE DRIVING CONDITIONS The interval between the transmission drain and
refill maintenance should be decreased to:
• NV4500 manual transmission—every 29 000 km (18,000 miles)
• Automatic transmission—every 19 000 km (12,000
miles)
A severe driving condition includes:
• Extended operation with heavy cargo loads
• Driving in deep mud or snow
• Off-road operation (4WD)
• Trailer towing
• Operation as a commercial vehicle
• Snow plowing
MANUAL TRANSMISSIONS

INSPECTION/LUBE
OIL
LEVEL
The transmission should be checked for leaks when
other service is necessary under the vehicle. To check
the lube oil level, remove the fill hole plug (Fig. 2 ). If the level is below the bottom of the fill hole, raise
the level to the bottom of the fill hole with:
• Castrol Syntorq for NV4500 transmissions
• SAE 5W-30 engine oil (API Service SG, SG/CD or
SG/CE) for Getrag 360 transmissions.

Fig.
2 NV4500 Manual
Transmission

DRAIN
AND
FILL
The NV4500 transmission fluid should be changed
according to the intervals listed in the Manual
Transmission—Drain & Refill Intervals chart below.

Also,
refer to the Fluid Capacities chart.
AUTOMATIC TRANSMISSIONS

FLUID
LEWEL
It is recommended that the fluid (ATF) level in au­
tomatic transmissions be checked while involved
with other underhood maintenance.
Vehicle operation with an incorrect ATF level
will greatly reduce the life of the transmission.
Fig.
3 Getrag 360 Manual
Transmission

MANUAL TRANSMISSION-DRAIN & REFILL INTERVALS
Normal

Service
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

58 000
km
36,000
miles

Severe
Service
29 000
km
18,000
miles

J9000-43

The condition of the ATF also should be deter­
mined. If the ATF is dark in color and has a strong odor, the fluid should be changed. Also the filter should be replaced and the bands adjusted.
The following procedure must be used to check the
automatic transmission fluid (ATF) level.
(1) Position the vehicle on level ground.
(2) Operate the engine at idle speed.
(3) Apply the parking brake.
(4) Place the gear selector in N (neutral).
(5) Remove the dipstick from the tube. Wipe it
clean and determine if the ATF is hot or warm.
Hot ATF has a temperature of approximately
82°C (180°F). Warm ATF is when its temperature
is between 29-52°C (85-125°F). (6) Wipe the dipstick clean and completely insert it
into the tube. Remove the dipstick from the tube and
observe the ATF level.
(7) If the ATF is hot, the level should be in the
crosshatched area that is marked OK.
(8) If the ATF is warm, the level should be be­
tween the two dimples.

0
- 24
LUBRICATION
AND
MAINTENANCE

•
CAUTION:
Do not
overfill
the
transmission.
(9) Adjust
the
level
of the ATF
accordingly.
It
is
important
to use the
correct fluid
in an

automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used. Dexron®
II

ATF
can be
used
if the
recommended fluid
is not
available,
(10) Insert
the
dipstick into
the
tube.

DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL
The chart below lists
the
intervals
at
which
the

transmission should
be
serviced. Also, refer
to the

Fluid Capacities chart
for
fill capacity.
AUTOMATIC TRANSMISSION SERVICE
IN-
TERVALS

Normal

Usage
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

38
000 km 24,000
miles

Severe
Usage
19 000 km 12,000
miles

J9100-19

It
is
very important
to use the
correct fluid
in

an automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used.
An
equivalent
Dexron®
II ATF
could
be
used only
if the
recom­
mended fluid
is not
available.
The torque converter does
not
have
a
drain plug.
No attempt should
be
made
to
drain
the
converter.
Refer
to
Group
21
—Transmissions
for
transmission
drain
and
refill procedures.

TRANSFER
CASE
(4WD
VEHICLES)
INSPECTION The NP205
and
NP241 transfer cases fluid level
should
be
checked whenever maintenance
is
neces­
sary under
the
vehicle.

FLUID
LEVEL
The vehicle must
be
level when
the
fluid level
is checked.
The transfer case drain fill hole plugs
are
located
at
the
rear
of the
housing (Figs.
4 and 5).

Determine
the
transfer case fluid level according
to

the following procedure.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case.
The
fluid level should
be at the

bottom edge
of the
fill hole.
The
level
can be
slightly
below
the
bottom edge
of the
fill hole
if the
fluid
is
cold.
(3)
If the
level
is not
acceptable, raise
the
fluid
level
to the
bottom edge
of the
fill hole with: • MOPAR®ATF PLUS
or an
equivalent Dexron
II®

ATF
for
NP241 transfer case
• Multi-purpose gear
oil (API GL-5) or
engine
oil

(API
SG,
SG/CD
OR
SG/CE)
for
NP205 transfer

cases.

Add fluid
in
small amounts
to
raise
the
level. (4) Install
the
fill hole plug (Figs.
4 and 5).

Tighten
the
fill hole plug
to 27 N-m (20
ft-lbs) torque.
(5) Remove
the
support
and
lower
the
vehicle.

Fig.
4
HP241 Transfer
Case
Fig.
5
NP205 Transfer
Case

FLUID DRAIN
AND
REFILL The transfer case fluid should
be
changed every
60

000
km
(37,500 miles).
For
vehicles subject
to the

HEAVY DUTY CYCLE Maintenance Schedule,
a 58

000
km
(36,000 miles) interval
is
recommended.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case. (3) Place
an
appropriate container under
the
trans­
fer case drain hole plug (Figs.
4 and 5).
(4) Remove
the
drain hole plug. Drain
the
fluid
from
the
transfer case into
the
container.

•

LUBRICATION
AND
MAINTENANCE
0 - 25
CAUTION:
Do not
over-tighten
the
drain
and fill
hole

plugs.
Over-tightening
can strip the
hole
threads

and/or crack
the
aluminum housing.

(5) Install the drain hole plug (Figs. 4 and 5) in
the transfer case. Tighten the drain hole plug to 27 N*m (20 ft-lbs) torque. (6) Fill the transfer case to the bottom edge of the
fill hole (Figs. 4 and 5) with: • MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases
• Multi-purpose gear oil (API GL-5) or engine oil (API SG, SG/CD or SG/CE) for NP205 transfer cases. (7) Install the fill hole plug (Figs. 4 and 5) in the
transfer case. Tighten the plug to 27 N«m (20 ft-lbs) torque.
(8) Remove the support and lower the vehicle.
FLUID SPECIFICATION
• MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases • Multi-purpose gear oil (API GL-5) or engine oil (API SG, SG/CD or SG/CE) for NP205 transfer cases
NP20I
MULTI-PURPOSE GEAR OIL/ENGINE
OIL
SELECTION

MULTI-PURPOSE GEAR OIL-if the anticipated
minimum temperature will: • Be above 32°C (90°F)-use SAE 140, API GL-5;
• Decrease to as low as -23°C (-10°F)-use SAE 90,
API GL-5; and • Be below -23°C (-10°F)-use SAE 80, API GL-5. ENGINE OIL—if the anticipated minimum tem­
perature will be: ® Above 0°C (32°F)-use SAE 50, API SG, SG/CD or
SG/CE;
• Below 0°C (32°F)-use SAE 30, API SG, SG/CD or SG/CE.
SHIFT MECHANISM-NP241 AND NP205 The transfer case shift mechanism should be
cleaned and lubricated as necessary.
Lubricate the pivot, the sliding contact areas and
the shift linkage pivot ends with light-weight engine oil (Figs. 6 and 7).

AXLES
INSPECTION/LUBRICANT LEVEL For normal vehicle operation, periodic axle lubri­
cant level checks are not necessary. The exterior of
the axle housing should be inspected for leakage. Check the lubricant level to confirm the leakage.

LUBRICANT LEVEL
(1) Raise the vehicle with an axle or wheel type
hoist. Support the vehicle.
(2) The rear axle differential housings have a rub­
ber, PRESS-IN type fill plug (Fig. 8). Pry the fill
TRANSMISSION

ASSEMBLY
GEARSHIFT
MECHANISM TRANSFER CASE

SCREWS
(2)
50
FT. LBS.
(68 N*m)
CLAMP
SHIFT
ROD

SCREW

80 IN.
LBS.

(9 N*m)
RP1091
Fig.
6 Shift
Mechanism
Lubrication—NP241 Transfer
Case

Fig.
RY682
7 Shift
Mechanism
Lubrication—NP205 Transfer

Case

plug from the differential housing. The front axle (4WD vehicles)*differential housings have a thread­
ed-type fill plug (Fig. 9). Un-thread the fill plug from
the differential housing.
(3) The lubricant level should be within 12 mm
(1/2 in) of the fill hole for the 8.25 and 9.25 rear ax­

les.
The lubricant level should be between 12mm (1/2
in) and 24mm (1 in.) of the fill hole for the Dana ax­

les.

(4) If necessary, add lubricant to raise the level to
the acceptable position.
(5) Install the fill hole plug in the differential
housing (Figs. 8 and 9).

DRAIN
AND
REFILL
Periodic axle lubricant change for normal vehicle
operation is not necessary. Refer to the chart below-

0
- 28
LUBRICATION
AND
MAINTENANCE

•
CHASSIS AND BODY

page

Body
Component Mechanisms
32
Front
Suspension
Ball
Joints
28

Front
Wheel Bearings
29

Headlamps
32

Lower
and
Upper Suspension
Arm
Bushings
.... 30

Manual
Steering Gear
28

STEERING
LINKAGE

INSPECTION When
a
vehicle
is
raised
for
maintenance under
the vehicle,
all
steering components should
be
checked.
LUBRICATION SCHEDULE The steering linkage
is
lubricated with
a
chassis
lubricant. However,
it is
recommended that
the
link­
age
be
inspected
and
lubricated after each:
•
24 000 km
(15,000 miles) interval
or
every
6

months,
for 2WD
vehicles subject
to the
LIGHT
DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
2WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule
•
12 000 km
(7,500 miles) interval
or
every
6

months,
for 4WD
vehicles subject
to the
LIGHT DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
4WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
LUBRICATION (1) Inspect
the
steering linkage
for
looseness
and

excessive wear. (2) Replace,
all
ruptured seals
and
damaged steer­
ing linkage components. Damaged seals should
be re­

placed
to
prevent leakage
and
contamination
of the
lubricant.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
steering linkage:
• Clean
the
Zerk type lubrication fittings
on the tie-

rod
and
center link ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile- age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints
page

Power
Brake System
30
Power
Steering System
. . 29

Rear
Wheel Bearings
30

Speedometer Cable
33

Steering Linkage
28

Tires
32

FRONT
SUSPENSION
BALL JOINTS

INSPECTION When
a
vehicle
is
raised
for
lubrication/general
maintenance,
the
ball joints should
be
inspected.
LUBRICATION SCHEDULE The front suspension ball joints
are
lubricated dur­
ing manufacture with
a
long-life chassis lubricant.
However,
it is
recommended that
the
ball joints
be

inspected
and the
studs lubricated:
•
At
each
36 000 km
(22,500 miles) interval
or
every
2 years,
for
vehicles subject
to the
LIGHT DUTY
CY­
CLE Maintenance Schedule
•
At
each
9 600 km
(6,000 miles) interval
or
every
2

years,
for
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
4WD vehicles that
are
frequently driven
off-

road should
be
lubricated
at
every engine
oil
change.
LUBRICATION (1) Inspect
the
front suspension. Examine
the
ball
studs
for
looseness
and
excessive wear. (2) Replace
all
torn ball-stud seals
and
damaged
ball joints. Damaged seals should
be
replaced
to
pre­ vent leakage
and
contamination.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
ball studs:
• Clean
the
Zerk type lubrication fittings
on the

ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile-age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints

MANUAL
STEERING
GEAR

LUBRICATION Manual steering gears
are
permanently lubricated
during manufacture. Periodic lubrication
is not
nec­
essary.