Haynes Ford Explorer, Mazda Navajo & Mercury Mountaineer Automotive Repair Manual 1563923548, 9781563923548

Citation preview

36024

Ford Explorer 1991 thru 1999 Includes

ah models

Mazda Navajo and

Mercury Mountaineer

Haynes Repair Manual and Every manual based on a complete teardown

rebuild

m

v Includes essential information for today's

more complex

vehicles

Boston Public Library

Ford Explorer Mazda Navajo & Mercury Mountaineer

Automotive Repair

Manual by Jay Storer

and John H Haynes Member

of the Guild of Motoring Writers

Models covered: Ford Explorer, Mazda Navajo and Mercury Mountaineer models

All

1991 through 1999

(8B1

-

36024) (2021)

AUTOMOTIVE

nuns &

ACCISSSCKISS

ASSOC gfigg

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes North America, 861 Lawrence Drive Newbury Park California

91320 USA

Inc

MEMBER

ABCDE FGHU

KLMNO PQRS

About Its

this

manual must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

purpose The purpose

of this

manual

is

to help

you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you to have it done by a dealer service department or a repair shop; it provides infor-

Using the manual

choose

The manual

divided into Chapters.

Each Chapter is divided into numbered Secwhich are headed in bold type between horizontal lines. Each Section consists of

mation and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble

tions,

Procedures, once described are not normally repeated.

hope you use the manual

the work yourself. For

At the beginning of each

to tackle

numbered Sec-

you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration

many

simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a

shop and making the trips to leave it and pick up. More importantly, a lot of money can be saved by avoiding the expense the shop it

References to the left or right side of the assume you are sitting in the dnver's

vehicle

seat, facing forward.

Even though we have prepared this manual with extreme care, neither the publisher

Section 3 and Step

the illustration refers to (or

neces-

Chapter.

for

means

the text,

it's

number. Cross references given without use word "Chapter" apply to Sections and/or paragraphs in the same Chapter. For example, "see Section 8" means in the same

and the Step within that Section. That illustration 3.2

in

of the

tion captions pinpoint the pertinent Section is,

When

sary to refer to another Chapter, the reference will be given as Chapter and Section

consecutively numbered paragraphs.

occurs.

We

is

that Section.

nor the author can accept responsibility

any errors mation given.

in,

or omissions from, the infor-

paragraph) 2 within

NOTE A Note provides information necessary to make the procedure easier to understand.

properly complete a procedure or information which

will

CAUTION A Caution

provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly

BR BR

being worked on.

TL230.5

WARNING

.E95 S76 I999x

A Warning

provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Acknowledgements We are grateful to the Ford writers

©

who

Motor Company

for assistance with technical information

and

certain illustrations. Technical

contributed to this project include Alan Ahlstrand and Jeff Kibler.

Haynes North America, With permission from J.H. Haynes

Inc.

& Co.

1991, 1992, 1993, 1998, 1999

Ltd.

A book

in

the Haynes Automotive Repair Manual Series

Printed

in

the U.S.A.

reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

All rights

ISBN

1

56392 354 8

Library of

Congress Catalog Card Number 99-66572

While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

99-384

1

0-3

Contents Introductory pages About this manual

0-2

Introduction to the Ford Explorer,

Mazda Navajo

and Mercury Mountaineer numbers

Vehicle identification Buying parts

Maintenance techniques, tools and working Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Safety first! Troubleshooting

Chapter

facilities

0-4 0-5 0-6 0-6 0-12 0-13 0-14 0-15 0-16 0-17

1

Tune-up and routine maintenance

Chapter 2

Part

1-1

A

4.0L (pushrod) V6 engine

Part B SOHC V6 engine

2A-1

2A

2B-1

2B

2C-1

2C

2D-1

2D

Chapter 2 4.0L

Chapter 2

Part

C

5.0L V8 engine

Chapter 2

Part

D

General engine overhaul procedures

Chapter 3 Cooling, heating and

air

conditioning systems

3-1

3

4-1

4

5-1

5

6-1

6

Chapter 4 Fuel and exhaust systems

Chapter 5 Engine

electrical

systems

Chapter 6 Emissions control systems

Part A Manual transmission

Chapter 7

Chapter 7

Part

Chapter 7

Part

7A-1

7A

7B-1

7B

7C-1

7C

B

Automatic transmission

C

Transfer case

Chapter 8 Clutch and driveaxles

8-1

8

9-1

9

Chapter 9 Brakes

Chapter 10 Suspension and steering systems

Chapter

10-1

10

11-1

11

12-1

12

1

Body

Chapter 12 Chassis

electrical

system

1

Wiring diagrams

12-20

Index

IND-1

IND

0-4

Haynes photographer, mechanic and author with 1991 Explorer

Introduction to the Ford Explorer, Mazda Navajo, and Mercury Mountaineer The models covered by available

this

manual are

a variety of trim options.

in

In

the

1991 through 1994 model years, a Mazda Navajo model was available, which was mechanically identical to the Ford Explorer. Beginning with 1997 models, the LincolnMercury Division of Ford Motor Company offered the Mercury Mountaineer model, which was mechanically identical to the Ford Explorer models for 1997 and 1998. The 4.0L pushrod V6 engine has been available for all the years covered by this manual, with the optional

becoming models.

SOHC V6 becom-

1997, and the 5.0L V8 engine an option beginning with 1996

ing available

in

Chassis layout is conventional, with the engine mounted at the front and the power being transmitted through either a manual or automatic transmission to a driveshaft and solid rear axle on 2WD models. On 4WD models a transfer case transmits power to the front axle by

way

of a driveshaft. Trans-

missions used are a five-speed overdrive manual transmission and both four-speed and five-speed overdrive automatic transmissions. The V8 engine is available only with an automatic transmission. 1994 and earlier vehicles use twin Ibeam front suspension with coil springs and radius arms. 1995 and later models use upper and lower control arms and torsion

bars.

All

models use

semi-elliptical

leaf

springs at the rear. Some models have an optional Automatic Ride Control system that controls ride height and firmness with a computer,

sensors

and

air-powered

shock

absorbers. All

models are equipped with power

assisted front disc brakes, and most models

have drum rear brakes. Some models have rear disc brakes. 1994 and earlier models are equipped with a rear-wheel anti-lock brake system, while 1995 and later models are equipped with a four-wheel anti-lock brake system.

0-5

Vehicle identification numbers

Vehicle identification Modifications

are

unpublicized process

in

a

and

continuing

vehicle manufactur-

Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are necessary to correctly ing.

identify the

component

required.

month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and the certification statement. The VC label also contains the VIN number, which is used for warranty identification of the vehicle,

and provides such information

as manufacturer, type of restraint system, body type, engine, transmission, model year and vehicle serial number.

Number

Vehicle Identification

numbers

(VIN) This very important identification

number

is located on a plate attached to the left side dashboard just inside the windshield (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when

the vehicle

was manufactured, engine

type,

the model year and the body style.

Vehicle Certification Label The Vehicle

12/90

CMK: Z540L8

H

....

52K6

26

/

I

.RE

N

Vehicle Emissions Control

Information (VECI) label Chapter

is

found under the hood (see

6).

cali-

and serial numbers, as well as plant name, can be found on the valve cover, as well as stamped on the engine itself (see illustration). The engine code is also found as the eighth digit of the VIN code. The letter X indicates the 4.0L pushrod V6, the letter E indicates the 4.0L SOHC V6, and the letter P bration

^

Manual transmission numbers The manual transmission identification number and serial numbers can be found on a tag on the

left

or right side of the transmis-

sion main case (see illustration).

The VIN number is visible through the windshield on the driver's side

2950LB. u

1338KG P235/75Rl5Su

IS

15X7. OJJ psi it ?£

15X7.0JJ PS

II)

'

DATE:

attached with a bolt, usually at the extension housing (see illustration).

tion are

Certification label

LU, FORD MOIUR EVW

-RON!

Tags with the automatic transmission number, build date and other informa-

serial

indicates the 5.0L V8.

(VC label, also referred to as the Truck Safety Compliance Certification label) is attached to the front of the left (driver's side) door pillar (see illustration). The upper half of the label contains the name of the manufacturer, the

IfM?

numbers

This label

Engine numbers Labels containing the engine code,

Automatic transmission

r

COLD

ShU

ABOVE

A - FORD MOTOR COMPANY PART NUMBER B - SERIAL NUMBER

F0BO9 T0026

1FMDU34X6MUC26861

C - BAR CODE (INVENTORY PURPOSES)

TYPE:MPV

The engine The vehicle

certification label, also

known

identification label is usually

The manual transmission

affixed to the valve cover

as the Truck Safety Compliance Certification label, is located

on the

identification

label is affixed to the side of the

transmission case left

front door pillar

TRANSMISSION MODEL

L|NE SH|FT

17

1—

C0DE

o

t-

YEAR

MONTH

BUILD DAY

DAY

CODE

The automatic transmission

identification

label is attached with a bolt, usually to the

extension housing

The transfer case

identification tag is retained by a bolt at the rear of the transfer case

The

differential identification tag is bolted

to the differential cover

i

0-6

Buying parts Replacement parts are available from sources, which generally fall into one of

many

two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed

parts

components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned

parts on an

exchange

basis,

amount

unique to the vehicle and not generally

which can save

money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and a considerable

general accessories, have convenient hours,

charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are

avail-

able elsewhere (such as major engine part*.

of

transmission parts, tnm pieces,

Warranty information:

If

etc.)

the vehicle

is

covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers still

available and.

if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

this task,

as well as other repair procedures,

such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always

*%

Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged comers on the hex head where the wrench fits. Develop the habit of replacing

all

damaged

Grade

J^ Grade 5

or 2

Bolt strength marking (standard/SAE/USS;

Grade

Identification

Hex Nut

.

Grades

i

^^_

TJf

k

Grade Hex Nut Property Class 9

quite well. After applying the rust penetrant,

work

3 Dots

a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners it

for

may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores.

a bolt or stud breaks off in an assemcan be drilled and removed with a spe-

If

bly,

plastic.

-^3 Grade 8

nuts and bolts

and must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works let

as aluminum), thin sheet metal or

new

ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability with

1

be replaced exactly as removed. Replace any with new ones. Never use a lockwasher on any soft metal surface (such

damaged washers

it

cial tool

commonly

available for this purpose.

Most automotive machine shops can perform

W^ Hex Nut

Grades

^,i i.f r

^_^ 6 Dots

Standard hex nut strength markings

bottom

-

metric)

Identification

O Arabic 9

^_~> Hex Nut Property Class 10

Hand-operated vacuum

Dial caliper

Compression gauge with spark plug

pump

Timing

light

Damper/steering wheel puller

General purpose puller

Valve spring compressor

Valve spring compressor

Piston ring groove cleaning tool

Ring removal/installation tool

hole adapter

Hydraulic

lifter

,;3l t -

[W

^i

j

removal tool

WH f$ t

*

*

Ridge reamer

Maintenance techniques, tools and working

0-10

Brake hold-down spring tool

Ring compressor

Cylinder hone

Brake cylinder hone

Clutch plate alignment tool

should start

off

minor repair

tool

with the maintenance

and

Tap and

Standard screwdriver (5/16-inch x 6 inch)

which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period kit,

Phillips

screwdriver (No.

Combination

pliers

-

ity,

especially

when

2x6 inch)

various extensions and

6 inch

the larger drive

can

Socket

assemble a tool set complete enough for most repair and overhaul procedures and will add tools from the special category when is felt that the expense is justified by the frequency of use.

Wire brush

Reversible ratchet

Jackstands Drain

tools

should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (box-end and openend combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench. in this list

Combination wrench set (1/4-inch to 1 inch or 6 to 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Brake bleeder wrench

size)

Torque wrench (same size dhve as sockets) Ball

pan be part of be necessary to

basic tune-ups are going to it

will

vehicles properly.

Repair and overhaul tool set These tools are essential

for

anyone

in

in

8 ounce

Standard screwdriver (1/4-inch x 6 inch) Standard screwdriver (stubby 5/16-inch)

3x8 inch)

Phillips

screwdhver (No.

Phillips

screwdriver (stubby

Pliers

-

vise grip

Pliers

-

lineman's

Pliers

-

needle nose

Pliers

-

snap-ring (internal -

-

No.

and

2)

external)

1/2-inch

Scribe

Scraper (made from flattened copper

the maintenance and

minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatil-

-

hammer (plastic/rubber)

Cold chisel

plans to perform major repairs and are

addition to those

peen hammer

Soft-face

purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most

who

10 inch

-

Universal joint

(2)

routine maintenance,

mm

Feeler gauge set

If

set(s)

Extension

Safety goggles

Note:

The

tool

Oil filter

Maintenance and minor repair tool kit

and cable cleaning

wrench Funnel (medium

more expensive,

bulky and

is

has the capacity of accepting a very wide range of large sockets. Ideally, however, the mechanic should have a 3/8-inch drive set and a 1/2-inch drive set. it

Fine emery cloth Battery post

the 1/2-

inch drive over the 3/8-inch drive. Although

of time, the experienced do-it-yourselfer will

it

die set

We recommend

drives are available.

Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil

facilities

tubing)

Centerpunch Pin

punches

(1/16, 1/8, 3/16-inch)

Steel rule/straightedge

-

12 inch

Maintenance techniques, tools and working Allen

A

wrench set

mm to

4

10

selection of

Wire bnjsh

A set can usua substantial savings over the individual tool prices, and they often come with a tool box. As additional tools are of the large retail chain stores.

(1/8 to 3/8-inch or

mm)

files

(large)

Note: Another tool which

and a

drill

is

often useful

is

an

with a chuck capacity of 3/8-inch

set of good quality

drill bits.

Special tools The

tools

include those which

in this list

are not used regularly, are expensive to buy,

need to be used in accordance with manufacturer's instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on a temor which

their

list

primarily contains only those

and instruments widely available to the public, and not those special tools produced by the vehicle manufacturer for distribution to dealer service departments. Occasionally, tools

references to the manufacturer's special in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. Howtools are included

ever,

sometimes there is no alternative to Where this is the case, and the tool

their use.

cannot be purchased or borrowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor

Piston ring groove cleaning tool

over a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be used. Tool stores will often be the only source of some of the special tools that are needed, but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools.

Care and maintenance of tools makes Keep them clean and in usable condition and store them properly when not in use. Always wipe off any sense to

tools are expensive, so

treat

them

grease or metal chips before putting

dirt,

them away. Never leave tools lying around in the work area. Upon completion of a job, always check closely under the hood for tools that may have been left there so they won't get lost during a test drive.

Some tools, such as screwdrivers, pliwrenches and sockets, can be hung on a panel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or ers,

Cylinder compression gauge Cylinder ridge reamer Cylinder surfacing hone

tools

Cylinder bore gauge

tool

Micrometers and/or dial calipers Hydraulic lifter removal tool

sequent jobs if you do.

Piston ring installation tool

Balljoint

used frequently. When a worn out, replace it. Subbe safer and more enjoyable

wear out

damaged

if

will

Stroboscopic timing

or bolt hole can

pick-up)

Hand operated vacuum/pressure pump Tachometer/dwell meter Universal electrical multimeter Cable hoist Brake spring removal and installation tools

Floor jack

For the do-it-yourselfer

who

ing to get involved in vehicle

is

number

when purchasing

just start-

maintenance

from overtightening. Stripping threads is an all-too-common occurrence, especially when working with aluminum parts, because aluminum is so soft that it easily strips out. Usually, external or internal threads are only partially stripped. After they've been cleaned up with a tap or die, they'll still work.

maintethe extent of the tools.

choices: 1)

of options If

nance and minor repair is work to be done, the purchase of individual tools is satisfactory. If, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one

Drill

and

oversize bolt,

2)

tap the hole to the next suitable

and

install

repair

damaged

Heli-Coil or Slimsert. kits

are designed to

threads

in

straight-

through holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole, then tap it with the special included tap. Install the Heli-Coil and the hole is back to its original diameter and thread pitch.

Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin your whole day's work and cost you a bundle if you wreck an expensive part.

Working

facilities

Not to be overlooked when discussing tools is the workshop. If anything more than routine maintenance is to be carried out, some sort of suitable work area is essential. It is understood, and appreciated, that many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof.

A clean,

flat

workbench or

fortable working height

table of

com-

an absolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four is

inches.

As mentioned dry storage space

previously, is

some

clean,

also required for tools,

as well as the lubricants,

fluids,

cleaning sol-

disposal site or recycling center. Plastic jugs,

internal

become

Sometimes, however, threads are badly damaged. When this happens, you've got three

Buying tools

repair, there are a

Sometimes, the

light (inductive

like

These easy-to-use

threads of a nut

threads

Dial indicator set

thread repair kit

stripped, usually

How to repair damaged

Impact screwdriver

remove the jam nut and bolt. The third method uses a patented

soon become necessary. Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour the used fluids into large containers, seal them with caps and take them to an authorized

or

separator

Universal-type puller

available

will

is

3)

it

with respect.

impact from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though,

Piston ring compressor

and

allows the cost of the tools to be spread

Good

porary basis.

This

the tool selection. Building a tool set gradually

the specified size, then run the threaded plug into the hole with a bolt and jam nut. Once the plug is fully seated,

at

needed, add-on sets, individual tools and a larger tool box can be purchased to expand

Jackstands (second set) Jack (scissor or hydraulic type) electric

be bought

ally

0-11

facilities

a larger diameter

screw or stud.

and tap the hole to accept a threaded plug, then drill and tap the plug

Drill

to the original screw size. You can also buy a plug already threaded to the original size. Then you simply drill a hole to

vents, etc. which

such as old antifreeze containers, are for this

ideal

purpose.

Always keep a supply of old newspapers and clean rags available. Old towels are for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted surface, such as when leaning over a fender to service something under the hood, always cover it with an old blanket or bedspread to protect the finish. Vinyl covered pads, made

excellent

especially for this purpose, are available at

auto parts stores.

0-12

Jacking and towing Warning: On models equipped with Automatic Ride Control, the system service switch must be turned OFF (see Chapter 10) before jacking or towing.

Jacking When

the vehicle with either the

diagonally opposite the one being to prevent the vehicle from moving.

is

lifted

equipped with an under-chassis mounted spare tire, remove the tire or tire carrier from the rack before the vehicle is raised in order to a void sudden weight Warning:

If

release from the chassis.

When using the vehicle jack, the manufacturer recommends positioning the jack under the axles, shock absorber or jacking bracket, as close to the wheel to be removed as possible. Caution: When raising the rear axle, don't place the jack under the differential, this could cause the rear cover to leak. Place the jack under the axle tubes.

When

Equipment

raising the vehicle for service,

always place jackstands under the frame rails. NEVER work under the vehicle when it is supported only by a jack!

specifically

designed

for

towing should be used. It should be attached to the frame members of the vehicle, not the bumpers or brackets. Safety is a major con-

when towing and

sideration lifting

supplied jack or a floor jack, block the wheel that

Towing

and

state

local

all applicable laws must be obeyed. A

safety chain system times.

Remember

power brakes

will

must be used at all power steering and not work with the engine that

off. It

is

recommended 2WD

towed from the the ground.

If

vehicles be

rear, with the rear

it's

wheels

absolutely necessary,

off

2WD

towed from the front with the wheels off the ground, provided that speeds do not exceed 35 mph and the distance is less than 50 miles; the transmission may be damaged if the speed/mileage limitations are exceeded. Four-wheel drive vehicles must not be towed with all four wheels on the ground. They must be towed with the front wheels raised and the rear wheels on a towing dolly or placed on a flat bed trailer or vehicles can be

front

truck.

When the vehicle is towed with the rear wheels raised, the steering wheel must be

Front axle jacking location under the axle

arm

clamped

in

(1991 to 1994 models)

the straight ahead position with a

special device designed for use during towing. Warning: Don't use the steering lock to keep the front wheels pointed straight ahead. It's

not strong enough for

this

purpose.

REAR AXLE TUBE JACK Front suspension jacking point, under the lower control

and

later

models)

arm (1995

Rear jacking locations - Position the jack under the rear frame rail or under the U-bolts on the rear axle, not under the differential

0-13

Booster battery (jump) starting Observe these precautions when using a booster battery

to start

a vehicle:

f)

g)

one in the vehicle. The two vehicles MUST NOT

Make

TOUCH each

sure the transaxle

the booster battery

Booster battery

2

o1&!

o i5xf

module (two door model shown; four door model similar)

5

Installation

DELETE'

'

5

the reverse of removal.

9

BALL BEARING

2

to the

system com-

10).

Drain the transfer case lubricant (see

Chapter

1).

Refer to Chapter 8 and remove the front or rear driveshaft for access to the yoke and 3

be replaced. early models, remove the output shaft nut, washer, rubber seal and front yoke seal to

4

On

or rear flange (see illustration). Note: Before

removing the rear flange, make indexing marks on the flange, nut and shaft, to align

NEEDLE BEARING

1

the battery. 6.4 Front output shaft

1991 through 1994 models Refer to

illustration

seal

FRONT OUTPUT

5.2

Working inside the vehicle, remove the above the left rear wheel well to gain access to the module. Remove the two bolts securing the control module and the

2

SHAFT

trim panel

bracket (see illustration). 3

Pull the control

module

part

way

out and

disconnect the electrical connectors from the module. Remove the control module. Installation is the reverse of removal. 4

FRONT OUTPUT YOKE

STEEL

WASHER

SEAL

components

oil

r

Chapter 7 Part C

6.7 Pry out the seal with a seal removal tool (rear seal

shown, front seal

Use a large socket

6.10

seal in (rear seal

similar)

7C-5

Transfer case

to drive the

shown, front

new

Some models

7.3

removed

S®

*

Lp ^^—^

are equipped with a

damper - this must be remove the transfer case

transfer case

similar)

to

^ j

% >

7.5

Disconnect the

shift

motor connector

7.6

(electronic shift models)

Disconnect the vent hose from its bracket (electronic shift models)

Disconnect the speed sensor connector (if equipped) and

7.8

speedometer cable them on reassembly.

On

to the

models, remove the snap-ring holding the front driveshaft yoke on the trans-

5

later

fer case.

Remove the dust seal from the yoke opening of the transfer case. 7 Carefully pry out the oil seal with a seal removal tool (see illustration). 6

Installation Refer to

illustration 6.

10

8 Inspect the oil seal contact surface on the housing for scoring or burrs that may damage the new oil seal. If found, remove them with emery cloth or medium grit wetand-dry sandpaper. Use a clean cloth dipped in solvent and remove any sanding residue

from the bore. 9 Apply multipurpose grease to the oil seal lip. Position the seal into the output shaft housing bore and make sure the oil seal is not cocked

in

the bore.

10 Drive the oil seal into the output housing bore using a seal driver (available at most auto parts stores), or carefully drive the seal into the bore with a hammer and a large socket or section of pipe of the appropriate size (see illustration). 11 Clean the transfer case output female

OFF

position before the vehicle

damage

is

system com-

splines and apply multi-purpose grease to

raised to prevent

them. Insert the driveshaft splined shaft into the female splines. 12 Install the front yoke or rear flange onto the splines, then install the rubber seal, steel washer and nut (snap-ring on the front yoke on later models). Tighten the nut to the torque listed in this Chapter's Specifications. 13 Connect the front or rear driveshaft to

ponents (see Chapter 10). On models so equipped, remove the 2 bolts securing the skid plate to the frame and

the front or rear axle input yoke (see Chap-

case (see Chapter

ter 8).

5

14 Refill the transfer case lubricant (see Chapter 1). 15 Remove the jackstands and lower the

squeeze the locking tabs

vehicle.

7

Transfer case

-

removal and

installation

Removal Refer to

illustrations 7.3, 7.5, 7.6, 7.8

and

remove

it.

On models so equipped, remove

3

damper from

7C

tion).

Drain the lubricant from the transfer

4

On

1).

electronically-controlled

PUSH) toward each

tion).

Disconnect both driveshafts (see Chap-

7

make sure

bracket (electronic

turned

other, then pull the elec-

connector apart. This may take some effort, but it shouldn't be necessary to use tools to separate the connector halves. Disconnect the electrical connector from the transfer case motor and from the connector mounting bracket (see illustration). Disconnect the speed sensor electrical 6 connector (if equipped) and speedometer cable from the transfer case (see illustra-

ter 8).

is

models,

(the part labeled

trical

Raise the vehicle and support it securely on jackstands. Caution: If the vehicle is equipped with Automatic Ride Control (ARC), the air suspension switch

the

the transfer case (see illustra-

7.12 1

to the

8

Disconnect the vent hose from the

lever bracket (manual

shift)

shift)

or

shift

mounting

(see illustration).

7C-6

Chapter

7

Part

C Transfer case c)

Install

the five bolts Securing the transfer

case and tighten this

7.12

case

The transfer secured by

is

d)

five bolts

TRANSFER CASE RETAINING BOLTS (SI

e)

Warning: The catalytic converter is next to the vent hose and is extremely hot after the engine has been njn. Be careful when working around the converter and if possible allow the converter to cool down several hours phor to working around it. 9 On manually-controlled models, remove the nut from the shift lever and remove the shift lever

10

On

(see illustration 3.4)

manually-controlled models, remove

the large bolt and the small bolt retaining the shifter to the

extension housing. Pull on the

control lever unit until the bushing slides off

the transfer case

shift lever pin.

Place a transmission jack beneath the transfer case and apply jack pressure to slightly raise the transfer case. Use safety chains to secure the transfer case to the jack. 12 Remove the five bolts holding the trans11

fer

case

to the transmission extension

hous-

ing (see illustration).

13

to the torque listed in Chapter's Specifications and in the

torque sequence shown (see illustration) Note: On manually controlled models, always tighten the large bolt securing the shifter to the extension housing before tightening the small bolt Install the vent assembly so the white marking on the hose is positioned in the notch in the shift lever bracket (manual shift) or mounting bracket (electronic shift) Note: The upper end of the vent hose should be 3/4 inch above the top of the shifter on manually controlled models. Connect the rear dnveshaft to the transfer case output flange. Tighten the bolts to the torque listed in the Chapter 8 Specifications.

Slide the transfer case rearward

and

off

the transmission output shaft, then lower the

f)

Refill

the transfer case with the proper

type of lubhcant (see Chapter

1).

case from the vehicle. Remove and discard the gasket between the transfer case and the extension housing.

transfer

Installation Refer to 14

illustration

7.

14

removal Steps with the following additions: a) Install a new gasket between the transfer case and the extension housing. b) Slide the transfer case onto the transmission output shaft, making sure the Installation is the reverse of the

splines align,

until

CASE TO EXTENSION BOLT TORQUE SEQUENCE

the transfer case

seats over the dowel pin.

7.14 Tighten the transfer case mounting bolts in the

sequence shown

8-1

Chapter 8 Clutch and drivetrain Contents Section Axleshafts

and

bearings and

(rear),

seals

-

removal

-

19 -

removal, inspection and installation

description and check

Clutch hydraulic fittings

-

line

-

Front axle assembly

removal and

Clutch release bearing

-

-

removal and

installation....

9 11

installation

removal, inspection and installation

removal and installation Clutch/starter interlock switch - removal and installation Double cardan type U-joint - overhaul Double cardan type U-joint - overhaul Clutch release cylinder

-

inspection

replacement and

7

10

bleeding

Clutch master cylinder and reservoir -

Flywheel

2

(4WD models)

Front axleshaft and joint assembly

general information

Clutch pedal

3

quick-disconnect

Clutch hydraulic system

Section

and universal joints - description and check Driveshafts - removal and installation Driveshaft

installation

Clutch components Clutch

oil

-

5 8 12

16 16

removal and

-

removal,

installation

21

installation

-

20

component

General information Pilot bearing - inspection and replacement Rear axle assembly - removal and installation Rear axle - description and check Right stub shaft assembly, carrier oil seals and bearings (1 994 and earlier models) - removal and installation Single cardan type U-joint

13 14 4

overhaul

1

6 18 17

22 15

Specifications

Clutch Fluid type

See Chapter

Type

Single dry plate, diaphragm spring

Actuation

Hydraulic

1

Rear axle Type

Integral carrier

Ring gear size

8.8-inch

Lubricant type

See Chapter

Driveshaft type

One-piece with single or double cardan type

1

joints

Front axle Type Hubs (1994 and

Dana Model 35 IFS

Lubricant type

Manual and automatic locking type See Chapter 1

Torque specifications

Ft-lbs (unless otherwise indicated)

earlier)

Clutch Pressure plate-to-flywheel bolts Clutch master cylinder-to-firewall bolts

1

7 to 23

15 to 20 16-23 in-lbs 13 to 19

Clutch master cylinder reservoir bolts

Release cylinder-to-clutch housing bolts

Rear driveshaft Driveshaft-to-transfer case bolts

(4WD models

only)

12 to 16

Driveshaft-to-rear axle bolts

1991 through 1996 With double-cardan U-joint With single-cardan U-joint

70 to 95 8 to 15

1997 and later 4WD models 2WD models

70 to 95 64 to 87

Front driveshaft Driveshaft-to-transfer case flange bolts

1991 through 1996

1997 and

later

Driveshaft-to-differential

yoke bolts

70 to 95 22 120 to 180

in-lbs

8

8-2

Ch.ipter 8

Clutch and dnvetrain

Torque specifications (continue

f

I

lb

Rear axle

Pmon

See Chapter 1 15 to 30 See Chapter 10 See Chapter 10 See Chapter 9

—

Cover txyts shaft took bort

Leaf spring U-bort nuts Rear shock abeorber-to-axie bracket bou or nut

Brake backing plate nuts

Front axle 1991 through 1994 P.vot

bo

120 to 150 70 to 92 190 to 230 95 to 110

•

Pivot bracket -to-frame nut

Axle stud

Lower Upper

Camer

balljoint nut

85 to 100 35 to 53 75 to 95 See Chapter 10 See Chapter 10 See Chapter 10

ball|Oint nut

to axle

arm

bolts

Carrier shear bolt

Front shock absorber-to-radius

arm nut

Front spring seat nut Front radius arm bracket bolts

1995 and

later

45 to 59 45 to 59 See Chapter 10 See Chapter 1 See Chapter 10

Axle to frame bolts Axle retainer throughbolts

A-arm

bolts

Balljoint

nuts

Wheel hub

bolts

and fluid reservoir, the hydraulic line, an internal release cylinder and the clutch

leaks.

release (or throwout) bearing.

in

cylinder 1

General information The information components

Chapter deals power to the wheels, except for the transmission and transfer case, which are dealt with in Chapter 7 For the purposes of this Chapter, these components are grouped into three categories; clutch, driveshaft and axles. Separate Sections within this Chapter offer general descriptions and checking procedures for components in each of the three groups. with the

Since nearly

all

in this

that transmit

the procedures covered

The

3

internal release cylinder,

concentrically on

Chapter

10).

2

Clutch

Refer to

the system

components

(see

description and check

lem

ing

is

sometimes

the engine at nomnal idle

is

sometimes

called the

speed

"

run

with the

in Neutral (clutch pedal up engaged). Disengage the clutch (pedal

transmission -

the transmission into Reverse.

ing noise should

noise would

called a throwout bearing,

in

most

No

shift

grind-

be heard. A grinding likely

indicate a prob-

the pressure plate or the clutch

disc. c)

To check for complete clutch release,

operating or slave cylinder.

run the engine (with the parking brake

Other than to replace components with 5 obvious damage, some preliminary checks should be performed to diagnose clutch

applied to prevent movement) and hold the clutch pedal approximately 1/2-inch

from the

floor.

problems.

between

1st

a)

The

first

check should be of the

level in the clutch

master

add

cylinder.

fluid If

the

as necessary inspect the hydraulic system for

fluid level is low,

fluid

times.

If

Shift the transmission

gear and Reverse several the shift is hard or the transmis-

component failure is indiCheck the release bearing travel

sion grinds, cated.

(see illustration). With the clutch pedal

BLEED SCREW PORT

illustration 2.5

models with a manual transmission use a single dry plate, diaphragm spring type clutch. The clutch disc has a splined hub which allows it to slide along the splines of the transmission input shaft. The clutch and 1

To check "clutch spin-down time,

clutch plate or disc, the clutch release bear-

and

-

ation.

b)

directly

matic Ride Control (ARC), make sure the air suspension switch is turned to the OFF position before the vehicle is raised to prevent to

descnbed

Section 10 and retest the clutch oper-

down), wait several seconds and

pushes

the release cylinder

damage

input

the master cylinder reservoir has

on the release bearing. This eliminates the need for a release lever. 4 Terminology can be a problem when discussing the clutch components because common names are in some cases different from those used by the manufacturer. For example, the driven plate is also called the shaft,

Chapter involve working under the vehicle, make sure it's securely supported on sturdy jackstands or on a hoist where the vehicle can be easily raised and lowered. Caution: If the vehicle is equipped with Autoin this

mounted

the transmission

If

run dry, bleed the system as

2.5 Release cylinder

All

FRONT OF

contact by spring pressure exerted by the diaphragm in the

pressure plate are held

in

pressure plate.

The clutch release system is operated by hydraulic pressure. The hydraulic release

2

system consists

of the clutch pedal, a

master

and

bearing travel can be checked through the inspection port

VEHICLE

RELEASE BEARING TRAVEL INSPECTION PORT (RUBBER PLUG

REMOVED)

Chapter 8

Clutch and drivetrain

8-3

FLYWHEEL

3.5b Clutch assembly and related components

TRANSMISSION

PILOT

BEARING

Loosen the pressure plate bolts (arrows) one turn at a time in rotation until they can be removed by hand

3.5a

BOLT

CLUTCH PLATE AND COVER

depressed completely, the release cylinder should extend substantially. If it doesn't,

check the

fluid level in

clutch master cylinder (see Chapter d)

3

the 1).

Bleed the system (see Section 10). Visually inspect the pivot bushing at the top of the clutch pedal to make sure there is no binding or excessive play.

Clutch components - removal, inspection and installation

Warning: Dust produced by clutch wear and deposited on clutch components may contain asbestos, which is hazardous to your health. DO NOT blow it out with compressed air and DO NOT inhale it. DO NOT use gasoline or petroleum-based solvents to remove the dust. Brake system cleaner should be used to flush the dust into a drain pan. After the clutch components are wiped clean with a rag, dispose of the contaminated rags and cleaner

in

CLUTCH SLAVE CYLINDER ASSEMBLY

a covered, marked container.

Removal illustrations 3.5a and 3.5b Access to the clutch components is normally accomplished by removing the transmission (and transfer case on 4WD models),

Refer to

used underneath the engine, make block is positioned between the jack and oil pan to spread the load. Caution: The pick-up for the oil pump is very close to the bottom of the oil pan. If the pan is bent or distorted in any way, engine oil starvation jack

is

sure a

wood

could occur. 3 To support the clutch disc during removal, install a clutch alignment tool through the clutch disc hub (see illustration 3.13).

4

and presThe marks are

Carefully inspect the flywheel

sure plate for indexing marks.

usually an X, an O or a white letter. If they cannot be found, scribe marks yourself so the pressure plate and the flywheel will be in

the

same alignment

during installation.

Turning each bolt only 1/4-turn at a time, loosen the pressure plate-to-flywheel bolts. Work in a criss-cross pattern until all spring pressure is relieved evenly. Then hold the pressure plate securely and completely remove the bolts, followed by the pressure plate and clutch disc (see illustrations). 5

Inspection Refer to 6

illustrations 3.9, 3.

when

Ordinarily,

1

and 3. 1 1b

1a

a problem occurs

in

the

can be attributed to wear of the clutch driven plate assembly (clutch disc). However, all components should be clutch,

it

inspected at this time. 7 Inspect the flywheel for cracks, heat checking, grooves and other obvious defects. If the imperfections are slight, a machine shop can machine the surface flat

and smooth, which

is

highly

recommended

regardless of the surface appearance. Refer to

Chapter 2

for the flywheel

removal and

procedure. 8 Inspect the pilot bearing (see Section 6). 9 Inspect the lining on the clutch disc. There should be at least 1/16-inch of lining installation

above the

heads. Check for loose rivets, broken springs and other

rivet

distortion, cracks,

obvious

damage

(see illustration). As men-

tioned above, ordinarily the clutch disc tinely replaced, dition,

replace

it

so

if

in

with a

is

rou-

doubt about the con-

new

one.

1

leaving the engine

in

the vehicle.

If,

being removed for major overcheck the clutch for wear and replace worn components as necessary.

the engine

is

haul, then

However, the

relatively

low cost of the clutch

components compared to the time and trouble spent gaining access to them warrants their replacement anytime the engine or transmission is removed, unless they are new or in near perfect condition. The following procedures are based on the assumption the

engine

will

stay

in

8

of course,

place.

Referring to Chapter 7 Part A and Part C, remove the transmission from the vehicle.

2

Support the engine while the transmission is out. Preferably, an engine hoist should be used to support it from above. However, if a

3.9 Typical clutch

disc

components

Lining

down

-

in

Rivets

-

this will

these secure

the lining

damage

wear

use

and

will

the flywheel or

pressure plate if allowed to contact the surfaces

Marks

-

"Flywheel

side" or similar

Chapter 8

8-4

Clutch and drivetrain

NORMAL FINGER WEAR

EXCESSIVE

WEAR 1a Examine the pressure plate friction surface for score

3.1

marks, cracks and evidence of overheating (bluing)

EXCESSIVE FINGER WEAR

BROKEN OR BENT FINGERS clutch alignment tool (available at most auto parts stores) required to center the clutch disc in the pressure plate

A

3.13

is

3.11b Replace the pressure plate if any of these conditions are noted

10 The release bearing should also be replaced along with the clutch disc (see Sec-

bolts only finger tight, working around the

ing noise.

tion 5).

pressure plate.

2

Center the clutch disc by ensuring the alignment tool extends through the splined hub and into the pilot bearing in the crankshaft. Wiggle the tool up, down or sideto-side as needed to bottom the tool in the pilot bearing. Tighten the pressure plate-toflywheel bolts a little at a time, working in a

cracking, warpage, scoring or heat checking.

Check the machined surfaces and the

11

diaphragm spring fingers plate (see illustrations).

of the pressure If

the surface

is

grooved or otherwise damaged, replace the pressure plate. Also check for obvious damage, distortion, cracking, etc. Light glazing can be removed with medium grit emery cloth.

and

If

a

new pressure

plate

is

required,

new

factory-rebuilt units are available.

14

Tighten the pressure plate-to-flywheel

15

12

Before installation, clean the flywheel plate machined surfaces with

and pressure

lacquer thinner or acetone.

no

oil

lining of

It's

important that

on these surfaces or the the clutch disc. Handle the parts only

or grease

is

with clean hands.

13

to the torque listed

Specifications.

16

If

Remove

removed,

install

bearing as described

17

Install

in this

Chapter's

the alignment tool.

the clutch release

Section 5. the transmission and all in

compo-

nents removed previously. Tighten all fasteners to the torque values listed in this Chapter's Specifications.

Position the clutch disc and pressure

plate against the flywheel with the clutch held in

place with an alignment tool (see illustraMake sure it's installed properly (most

4

Flywheel

-

inspection

Visually inspect the flywheel for signs of

If any of these conditions exist, the flywheel must be removed and resurfaced at an automotive machine shop (see Chapter 2).

5

criss-cross pattern to prevent distorting the cover. After all of the bolts are snug, tighten

them

Installation

slippage, pilot bearing noise or release bear-

Clutch release bearing - removal, inspection and installation

Warning: Dust produced by clutch wear and deposited on clutch components may contain asbestos, which is hazardous to your health. DO NOT blow it out with compressed air and DO NOT inhale it. DO NOT use gasoline or petroleum-based solvents to remove the dust. Brake system cleaner should be used to flush the dust into a drain pan. After the clutch components are wiped clean with a rag, dispose of the contaminated rags and cleaner

in

a covered,

marked

container.

tion).

replacement clutch plates will be marked "flywheel side" or something similar - if not marked, install the clutch disc with the flat side of the hub toward the flywheel).

Inspect the flywheel when the vehicle 1 suffers from excessive transmission gear wear, transmission jumping out of gear, driveline vibration, clutch pedal vibration, clutch

Removal and inspection Refer to 1

illustration

Remove

Part A).

5.2

the transmission (see Chapter 7

Chapter 8 Clutch and drivetrain SLAVE CYLINDER

8-5

PRELOAD SPRING

FRONT OF VEHICLE

RELEASE BEARING/ CARRIER ASSEMBLY

TRANSMISSION INPUT SHAFT

INSTALLATION

REMOVAL 5.2 Release bearing removal

Within the clutch housing, twist the

2

release bearing and carrier assembly

6

bly

installation details

Push the release bearing and carrier until it bottoms out

onto the slave cylinder

until

feel resistance. Keep turning the assemand the preload spring will push the

you

and

(see illustration 7

release bearing off the release cylinder (see

5.2).

the transmission (see Chapter 7

Install

Hold the center of the bearing and

rotate the outer portion while applying pressure.

If

6

the bearing doesn't turn smoothly or

Pilot

bearing

inspection and

-

replacement

noisy, replace it with a new one. Wipe the bearing with a clean rag and inspect it for damage, wear and cracks. Don't immerse the bearing in solvent - it's sealed for life and to ruin

Apply a

Refer to

it.

pilot

1

and

bearing

6.5

flashlight will

lubrication. Its primary

purpose

to support

is

the front of the transmission input shaft.

The

bearing should be inspected whenever the clutch components are removed from the pilot

engine.

Lubricate the inner bore of the bearing

Due

doubt as to

bearing carrier with a synthetic long-life

new

grease. Don't use petroleum-based grease.

one.

to

its

its

inaccessibility,

if

you are

condition, replace

Note:

If

Removal requires a special

5

is

light

sure plate diaphragm fingers.

and

illustrations 6.

The clutch

a needle roller type bearing which is pressed into the rear of the crankshaft (see illustration). It is prelubricated and does not require additional 1

coat of high-temperature lithium based grease to the face of the release bearing, where it contacts the pres-

5

be replaced. A

be

helpful to direct light into the recess.

Installation 4

fol-

ter 7 Part A).

ing should

it's

do so would

the vehicle, disregard the

lowing steps which do not apply. 2 Remove the transmission (refer to Chap-

3 Remove the clutch components (see Section 3). 4 Inspect for any excessive wear, scoring, lack of grease, dryness or obvious damage. If any of these conditions are noted, the bear-

Part A).

illustration).

3

removed from

it

in

with a

puller

and

(see illustration). Remove the bearing and clean the crankshaft recess.

slide

hammer

6 To install the new bearing, lightly lubricate the outside surface with lithium-based grease, then drive it into the recess with a soft-face hammer. The seal must face out (see illustration 6.1). 7 Install the clutch components, transmission and

all

other

viously, tightening

components removed all

pre-

fasteners properly.

the engine has been

NEEDLE HOLLER BEARING

RECESS FOR

REMOVAL

8

TOOL

SEAL

IRON COLLAR NOTE: IRON COLLAR AND NEEDLE

ROLLER BEARING ARE ONE ASSEMBLY AND CANNOT BE REPLACED INDIVIDUALLY. 6.1

The

pilot

transmission)

bearing seal must face out (towards the the bearing is installed in the crankshaft

when

6.5

Removing the

pilot

bearing requires an internal puller

connected to a

slide

hammer

)

8-6

Clutch and drivetrain

Chapter 8

THANSMISSION BtU HOUSING

Clutch hydraulic line quickdisconnect fittings - general information

7

Refer to

nrOAAUUC BLEED SCREW

illustration 7.2

The hydraulic

1

TRANSMISSION INPUT SHAFT

quick-disconnect (available

equipped with and a special tool

lines are

fittings

most auto parts stores)

at

is

required for separation.

2 Depress the white retainer within the quick-disconnect fitting with the special tool while pulling on the hydraulic line, then disconnect the male connector (see illustration) To install, push the male connector into the female connector until it locks into place There should be no loss of hydraulic 3 fluid

WONT Of VEM»CIE

BOLT

during separation of the fittings so there

no need to bleed the system after a fitting has been disconnected unless shifting is hard is

8.4 Clutch release cylinder

or there's a lack of clutch reserve travel.

Clutch release cylinder

8

and

-

installation details

DISCONNECT TOOL

removal

Installation

installation 7.2

A

special tool

is

Refer to

clutch pedal.

7).

Remove

the pedal's pivot pin.

pedal.

9

Attach the master cylinder to the firewall

Remove the clutch/starter interlock 3 switch from the pushrod (see Section 12).

and

install

4

Disconnect the hydraulic

slave cylinder (see Section

5

line

from the

Within the engine compartment, remove

careful not to

Working

the bolts securing the release cylinder to the transmission and slide the

release cylinder assembly off the transmis-

in

any

the

same

area,

remove the

Be

spill any of the fluid. the clutch master cylinder and reservoir from the engine compartment.

7

Specifications.

Attach the master cylinder reservoir to

the firewall and install the mounting bolts,

them securely. Connect the hydraulic

tightening 11

cylinder (see Section

of the fluid.

bolts securing the clutch master cylinder to the firewall.

Remove

spill

Be

the mounting bolts. Tighten the

bolts to the torque listed in this Chapter's

10

7).

reservoir to the firewall (see illustration).

6 the transmission (see Chapter 7

Part A).

4

nect the pushrod from the top of the clutch

the bolts securing the clutch master cylinder

Disconnect the hydraulic quick-disconnect fitting from the slave cylinder (see Sec-

2

3

line fitting

illustration 8.4

Note: Pnor to removing the release cylinder, disconnect the master cylinder pushrod from the clutch pedal. If not disconnected, permanent damage to the master cylinder will occur if the clutch pedal is depressed while the release cylinder is disconnected. 1 Pry off the retainer bushing and disconnect the master cylinder pushrod from the

tion

Install 8 the clutch master cylinder through the firewall and make sure the pushrod is positioned on the correct side of the clutch pedal so it can be installed onto

required to

disconnect the hydraulic

careful not to

Remove

line to

the slave

7).

12 Working inside the vehicle, connect the pushrod to the clutch pedal and install the clip or retainer

13

Install

bushing.

the clutch/starter interlock switch

(see Section 12).

sion input shaft (see illustration) Installation is the reverse of the removal 5 Steps with the following additions: a)

Install the

shaft

with

toward the b)

Install

9

the left

hydraulic

line

master cylinder

facing

installation details

side of the transmission.

the release cylinder mounting tighten them to the torque

2)

Clutch pedal Master cylinder

listed in this Chapter's Specifications.

3)

Reservoir bolt

necessary, bleed the clutch hydraulic system (see Section 10).

4)

Clip

bolts

c)

9.5 Typical clutch

release cylinder onto the input

1

and

If

Clutch master cylinder and reservoir

-

removal and

installation

Removal Refer 1

to illustration 9.5

Disconnect the negative cable from the

battery.

Working inside the vehicle, remove the spring clip or retainer bushing and discon2

FRONT OF VEHICLE

-

Chapter 8 BOX END

has been inside an open container for an extended period of time. Raise the vehicle and place it securely 3 on jackstands to gain access to the bleeder valve, which is located on the left side of the clutch housing. Caution: If the vehicle is equipped with Automatic Ride Control (ARC), make sure the air suspension switch is turned

BLEED

WRENCH

Clutch and drivetrain

SCREW

to the

OFF

position before the vehicle

raised to prevent

damage

ponents (see Chapter

The bleeder valve is accessible through a port on the left side of the clutch housing

Connect the negative cable

to the bat-

tery.

15

Fill

the clutch master cylinder reservoir

DOT

3 specifications and bleed the clutch system (see Section 10).

10

Clutch hydraulic system bleeding

Refer to

illustration 10.5

The hydraulic system should be bled to remove all air whenever air enters the system. This occurs if the fluid level has been allowed to fall so low that air has been drawn into the master cylinder. Under normal circumstances, air should not enter the system when the 1

quick-disconnect hydraulic line fittings are disconnected. The procedure is very similar to bleeding a brake system, but depends mainly on gravity, rather than the pumping action of the pedal, for the bleeding effect.

2

from the master cylinder,

down

line, into

the hydraulic

Fill

the master cylinder reservoir to the

conforming to DOT 3 Do not re-use any of the fluid coming from the system during the bleeding operation and don't use fluid which top with

new brake

fluid

specifications. Caution:

the release cylin-

der and out through the clear plastic tube. Let the fluid run out until it is free of bubbles. let

the fluid level drop too low in

the master cylinder, or air

the hydraulic line

have

to

be started

and

1 1

Clutch pedal

will

be drawn

the whole process

into will

over.

Refer to

Disconnect the barbed

the

of

clutch

pedal.

Remove

clutch pedal.

Remove

3

the

lockpin

and

cylinder pushrod from the

Remove

the plastic bushing.

the trim panel from the driver's

sidewall.

Unbolt the parking brake and

4

move

it

aside.

Pry the retainer from the clip on the pedal support bracket (see illustration). 6 Slide the pedal out of the bracket. 5

7

sive

Inspect the pedal bushings for exceswear (sloppy fit on the pedal shafts).

Replace the bushings

if

necessary. Always

oil

the bushings (new or old) with clean engine before reassembly. 8 Installation is the reverse of the removal Steps. oil

1

released.

the fluid reservoir to the step.

The clutch should now be completely

bled. If it isn't (indicated by failure to disengage completely), repeat Steps 5 through 9. 11 Continue this process until all air is evacuated from the system, indicated by a

stream of fluid being ejected from the bleeder valve each time with no air bubbles in the hose or container. 12 Install the dust cap and lower the vehicle. Check carefully for proper operation before placing the vehicle in normal service. solid

Check the

end

clutch/starter interlock switch rod from the

Refer to

Fill

illustration 11.5

battery.

2

pedal

9 10

removal and

Disconnect the negative cable from the

1

Close the bleeder valve. 7 Have an assistant slowly depress the clutch pedal and hold it. Open the bleeder valve on the release cylinder, allowing fluid to flow through the clear plastic hose. Close the bleeder valve when the flow stops. Once closed, have the assistant release the pedal. 8 Slowly press and release the pedal five times, waiting for two seconds each time the 6

is

-

installation

remove the master

tion). Fluid will run

Note: Don't

with brake fluid conforming to

system com-

10).

4 Remove the dust cap which fits over the bleeder valve and push a length of clear plastic hose over the valve. Place the other end of the hose into a clear container. Open the bleeder valve (see illustra5

10.5

14

to the

is

8-7

fluid level.

12

Clutch/starter interlock switch

removal and

-

installation

illustration 12.2

Disconnect the negative cable from the

battery.

2 Disconnect the electrical connector from the clutch/starter interlock switch, also called a clutch pedal position switch (see illustration).

Rotate the switch so the plastic retainer Squeeze the retainer tabs together and slide the retainer rearward off the switch. 4 Detach the switch from the master cylinder pushrod and take it out. Installation is the reverse of the removal 5 Steps. Be sure the switch is securely seated on the master cylinder pushrod.

3

is

visible.

TABS

BUSHING

BUSHING

8 •%.

ORIENTATION

'CUP

PUSH

ROD

BUSHING 12.2 Typical clutch/starter

BUSHING

SPRING

WASHER

BRAKE PEDAL

11.5 Typical clutch pedal installation details

WIRING

HARNESS

interlock switch installation details

Dnveshaft and universal joints

13

Clutch and drivetr.nn

Chapter 8

8-8

-

description and check

The dnveshaft

1

is

mi

a tube running between

the transfer case or transmission

and the

rear

axle or front axle. Universal |omts are located at either end of the dnveshaft(s) and permit

power

4WD

be transmitted

to

models, the

to the rear (and

front)

wheels

on

at varying

angles 2

Some

yoke

at

dnveshafts feature a splined

one end. which

fits

slip

into the transmis-

sion extension housing Others incorporate a

yoke as part of the dnveshaft. This arrangement allows the length of the driveshaft to change, which compensates for suspension movement. On models with a slip yoke at the front 3 of the dnveshaft, an oil seal is used to prevent leakage of fluid and to keep dirt and contaminants from entenng the transmission. slip

If

leakage

14.3 The rear driveshaft may have come from the factory with yellow paint marks that indicate the correct alignment of the

companion flange make new paint marks

driveshaft with the not,

oil

DOUBLE CARDAN

seal, referring to the pro-

cedures in Chapter 7. The driveshaft assembly requires very 4 little service. The universal joints on models not equipped with grease fittings are lubricated for life and must be replaced if problems develop. The driveshaft(s) must be removed from the vehicle for this procedure. Since the driveshaft is a balanced unit, 5 it's important that no undercoating, mud, etc. be allowed to stay on it. When the vehicle is

same

DOUBLE

CARDAN DRIVESHAFT

vehicle slowly until the transmission

these aren't

relative position to

allowing the vehicle to coast, then accel-

the driveshaft and the differential flange in line with each other. This is to make sure the

erate.

A

clunking or knocking noise

will

worn universal joints. Drive the vehicle at a speed of about 10

indicate b)

mph and

driveshaft

reinstalled in the

is

same

end

5

Remove

noises.

the driveshaft.

Raise the vehicle and support it securely on jackstands. With the transmission in

fer

noted, drive the vehicle again,

Neutral, manually turn the driveshaft(s),

out of the transmission.

time manually keeping the transmis-

watching the universal joints for exces-

6

sive play.

Steps with the following additions:

to 15

road, free of

and note

With

this

first,

traffic,

drive the

speed (rpm) most evident.

c)

the engine

problem

is

then second, then third gear

ranges and running the engine up to the engine speed noted. If the noise or vibration decreased or was eliminated, visually inspect the

then place the transmis-

bolts

a)

14

Driveshafts

-

removal and

b)

installation

ing

Rear driveshaft

joints.

Refer to

not at

fault

To check

for

On an open

worn

universal joints:

road, free of

traffic,

drive the

the bolts and lower the rear of On 4WD models, remove the

and detach the

case.

On

repeat Step 3 for the

front

On 2WD models,

2WD

is

end from the transslide the front end

the reverse of the removal

models, slide the front of the

driveshaft into the transmission.

damage, material on the would effect balance, miss-

weights and damaged universal Another possibility for this condition would be tires which are out-of-balance or a bent or damaged wheel(s). d) If the noise or vibration occurs at the same engine speed regardless of which gear the transmission is in, the driveshaft

position

of the driveshaft (see illustration).

Installation

driveshaft(s) for

shaft which

marks on

to preserve the balance.

On 4WD models,

sion in

a)

to place

front

vehicle

7

scribe, white paint

or a

4

On an open

is

use a

visible,

hammer and punch

High gear. Let off on the accelerator,

sion in Neutral, allowing the vehicle to coast. Listen for abnormal driveline

at which the

c)

is in

it

component:

this

case flanges, then unbolt the driveshaft from the transfer case (doublecardan model shown)

BOLTS

preserve the balance. Problems with the driveshaft(s) are usu6 ally indicated by a noise or vibration while driving the vehicle. A road test should verify if the problem is the driveshaft(s) or another

b)

Make alignment

marks on the front driveshaft and transfer

it's a good idea to clean the and inspect it for any obvious damage. Also check that the small weights used to originally balance the driveshaft(s) are in place and securely attached. Whenever a driveshaft is removed it's important that

reinstalled in the

4x4 INSTALLATION

14.9

raised for service

a)

transfer

case flanges

- if

TRANSFER CASE FLANGE

driveshaft(s)

vehicle

On 4WD models, make alignment

marks on the driveshaft and

evident at the front of the drive-

is

shaft, replace the

be

14.4

1

illustrations 14.3

c)

and

14.4

On 4WD models, position the front end of the driveshaft on the transfer case with the alignment marks aligned. Raise the rear of the driveshaft into position, checking to be sure the marks are in

Disconnect the negative cable from the

alignment.

mission

If

battery.

rear wheels to

Raise the vehicle and support it securely on jackstands. Place the transmission in

and the

2

Neutral with the parking brake off. Look for the yellow paint marks made at 3 the factory on the axle companion flange and

the driveshaft flange (see illustration).

If

not,

is still in

make

sure the trans-

Neutral, then turn the

match the pinion flange

driveshaft.

Front driveshaft

(4WD models)

Refer to illustrations 14.9 and

14.

10

Using a scribe, white paint or a hammer and punch, place marks on the driveshaft 7

1

Chapter 8 Clutch and drivetrain

8-9

STRAP

14.10

Make alignment marks on

the front driveshaft and

yoke

differential

-

wrap the

universal joint with tape after it so the bearings won't fall off

unbolting

AXLE YOKE

BOLTS (4

and

differential flanges in line with

(see illustration 14.3). This the driveshaft

is

is

to

reinstalled in the

REQ'D)

each other

make sure same posi-

tion to preserve the balance.

the driveshaft

before

it

comes completely

and transfer case flanges.

Use the

Unbolt the flange that secures the driveshaft double-cardan joint to the transfer case

the rest of the

9

vise or large pliers to

way

work the cup

at the transfer case, instead of a double-car-

6

dan.

lift

the bolts and straps that secure

5

After the bearings

have been removed,

the spider from the yoke and thoroughly

clean

all dirt

and debris from the yokes on

the front end of the driveshaft to the differen-

both ends of the driveshaft.

yoke (see illustration). 11 Wrap tape around the universal joint bearings at the axle end of the driveshaft so

7

for lubrication will

they won't

versal joint servicing

tial

fall off.

12 Installation is the reverse of the removal Steps with the following additions: a)

Raise the front of the driveshaft into be sure the marks are in alignment. If not, make sure the

position, checking to

transmission b)

is still in

Neutral, then turn

lowed

and

bolts.

Tighten the bolts to the torque listed this

Single cardan type U-joint overhaul

Refer to

in

Chapter's Specifications.

illustrations 15.2, 15.4a

-

in

the yoke and par-

one bearing cup

in

the yoke.

Start the spider into the bearing

9

then partially

install

cup and

the other cup. Align the

spider and press the bearing cups into posiseals.

straps

carefully.

tially install

Remove

install the

bearings

be included with the unikit and should be fol-

Position the spider

tion,

the tape securing the bearing

joint

with grease. Ordinarily, specific instructions

the front wheels to align the marks.

cups and

15

Pack the new universal

8

the universal joint snap-

out (see illustration).

(see illustration). Note: On 1997 and later models, there is a consiant-velocity (CV) joint

Remove

Remove

rings with small pliers

out of the yoke.

Transfer the sockets to the other side and press the opposite bearing cup out in the same manner.

1

15.2

(inside the pipe or large socket), stopping just

Make alignment marks on

8

diameter than the cup on the opposite bearing cup (see illustration) and use the vise or press to force the cup out slightly smaller

being careful not to

damage

the dust

10 install the snap-rings. If difficulty is encountered in seating the snap-rings, strike the driveshaft yoke sharply with a hammer. This will spring the yoke ears slightly and allow the snap-rings to seat in the groove. This should also be done if the joint feels tight after assembly. 1 Install the driveshaft (see Section 1 4).

Double-cardan type U-joint

16

-

overhaul Note: A press or large vise will be required for procedure. It may be a good idea to take the driveshaft to a driveline repair shop or this

machine shop where the universal joints can be replaced for you, normally at a reasonable charge. Note: On 1997 and later 4WD models,

the front driveshaft

CV joint is not service-

defective replace the driveshaft.

able,

if

1

Remove

the driveshaft (see Section 14).

Use paint or small punch and hammer and mark the positions of the spiders, the center yoke and the centering socket as related to the stud yoke which is welded to the front of the driveshaft tube. The spiders must be assembled with the bosses in their 2

original position to provide proper clearance. 3 Use a small screwdriver and pry out the snap-rings that attach the bearings in the front of the center yoke. 4 Supporting the driveshaft, place it in position on either an arbor press or on a workbench equipped with a vise. 5 Place a piece of pipe or a large socket with the same inside diameter over one of the

and 15.4b

Note: A press or large vise will be required for this procedure. It may be a good idea to take the driveshaft to a driveline repair shop or

8

machine shop where the universal joints can be replaced for you, normally at a reasonable charge.

Remove

the driveshaft (see Section 14). Place the driveshaft in a sturdy vise and remove the snap-rings from the spider (see illustration). Caution: Never place the tube 1

2

of the driveshaft in a vise. The tube can distorted or a fracture could will

3

be started

be

that

eventually ruin the shaft.

Supporting the driveshaft, place

it

in

position on either an arbor press or on a

workbench equipped with a

vise.

Place a piece of pipe or a large socket with the same inside diameter over one of the bearing cups Position a socket which is of

4

The universal joint bearing cups can be pressed out with a vise and sockets

15.4a

15.4b The bearing cup can be extracted with locking pliers

1

Chapter 8

8-10

cover

Clutch and drivetrain

*.^».«»

THRUST WASHER

OBEDIENTIAL BEARING

DIFFERENTIAL SHIMS

DIFFERENTIAL

BEARING CUP RATIO TAG

PINION

NUT

SPRING

PUSH-ON NUT 17.1

bearing cups. Position a socket which is of slightly smaller diameter than the cup on the opposite bearing cup and use the vise or press to force the cup out (inside the pipe or

comes

An exploded view

of a typical rear axle

and press the opposite bearing cup out

assembly

in

the

same manner. 7

1

Repeat Steps 6 and 7 and remove

bearings from the universal

all

joints.

completely out of the yoke (see illustration 15.4a). Use the vise or large pliers to work the cup the rest of the way out (see illustra-

With the front bearing cups removed, remove the spider from the center yoke. Pull the centering socket yoke off the 9 center stud and remove the rubber seal from

tion 15.4b).

the centering ball stud.

large socket), stopping just before

6

it

Transfer the sockets to the other side

8

10

Remove

yoke and from the driveshaft yoke.

the snap-rings from the center

Press or drive the bearing out as previ-

ously described.

12

With the bearing cups removed, remove

the center yoke from the spider.

13

Remove

the spider from the driveshaft

yoke. After the bearings have been removed, the spider from the yoke and thoroughly clean all dirt and debris from the yokes on

14

lift

Chapter 8 Clutch and drivetrain both ends of the driveshaft. If using a repair kit, install all of the parts supplied. 15 Pack the new universal joint bearings with grease. Ordinarily, specific instructions

be included with the servicing kit and should be

Rear axle check

17

mission noises, make a note of the engine speed at which the noise is most pronounced. Stop the vehicle and place

description and

the transmission in Neutral

for lubrication will

uni-

Refer to

versal joint

fol-

a hypoid (the centerline of the pinion gear is below the centerline of the ring gear) semi-floating type (see illustration). The differential carrier is a

lowed carefully. 16 Remove the clamps on the driveshaft dust boot seal and discard the clamps. 17 Note the orientation of the slip yoke to the driveshaft tube for installation during assembly. Mark the relationship of the slip yoke to the driveshaft tube. 18 Carefully pull the slip joint from the driveshaft, be careful not to damage the boot seal.

19

Inspect the spline area and thoroughly all

foreign matter from the splines with

solvent.

Lubricate the splines with multi-purpose

grease. 21

Install

driveshaft

the dust boot seal loosely on the

in

its

yoke

into the

original position. Refer to

marks made prior to removal. 22 Install new clamps on the dust boot seal and tighten securely. 23 To assemble the double cardan joints, position the spider

Make

in

the driveshaft yoke.

sure the spider bosses

plugs) are

in

(or lubricating

their original positions.

Start the spider into the bearing

then partially

tubes are

install

cup and

the other cup. Align the

being careful not to

tion,

2

An

axle

is

The axle pressed and welded

made

of steel,

optional Traction-Lok limited slip rear

also available. This differential allows

normal operation

the

damage

allow the snap-rings to seat

In

Overhaul and general repair of the rear 6 axle is beyond the scope of the home to the many special tools and measurements required. Thus, the

mechanic due critical

procedures listed here will involve axleshaft removal and installation, axleshaft oil seal replacement, axleshaft bearing replacement and removal of the entire unit for repair or replacement.

the dust

Repeat Step 25 and 26

in

the groove.

for the

Pack the socket

relief

replacement of the axleshafts, it's important to know the axle identification number. It's located on a small metal tag near one of the cover bolts. 4 Many times a problem is suspected in the rear axle area when, in fact, it lies elsewhere. For this reason, a thorough check should be performed before assuming a rear axle problem. The following noises are those com5 monly associated with rear axle diagnosis procedures: a)

ball

Road noise b)

will

show whether

the

the cause of the noise.

remain the same

if

the

is

susceptible to emitting vibrations will remain about the same during varying driving situations, where rear axle noise will change

larly

with

and

bearing.

Install

is

under power or coasting. Tire noise is sometimes mistaken for mechanical problems. Tires which are worn or low on air pressure are particuvehicle

multi-purpose grease, then position the cenyoke over the spider ends and press in the

new snap-rings. a new seal on the

noise is often mistaken for mechanical faults. Driving the vehicle on

road surface

ter

Install

Road

different surfaces will

remaining

and the

noises. Tire noise

during coasting, acceleration, etc. centering ball

stud and position the centering socket yoke on the stud.

18

Rear axle assembly and installation

-

removal

order to undertake certain operations,

particularly

bearings.

c)

Engine and transmission noise can be deceiving because it will travel along the driveline. To isolate engine and trans-

Removal Refer to

illustrations 18.6, 18.8, 18.9, 18.11

and 18.13 Loosen the

lug nuts on the rear wheels. Raise the rear of the vehicle, support it securely on jackstands and remove the rear wheels. Also remove the rear spare wheel/tire 1

2

for

cle

more working room. Caution: If the vehiis equipped with Automatic Ride Control

(ARC),

make sure

the air suspension switch

is

raised to

components 3

(see Chapter

10).

Remove

the axleshafts (see Section 19), and disconnect the rear of the driveshaft from the axle (see Section 14).

4

Unbolt the brake

line junction

block from

the axle housing and detach the brake lines

from the clips on the axle housing. Disconnect the rear anti-lock electrical connector from the sensor on the axle housing (see Chapter 9). On models with Automatic Ride Control (ARC), disconnect the rear height sensor (see Chapter 10). 5 Remove the rear brake drums or discs/calipers (see Chapter 9). Remove the nuts and bolts that secure 6 the brake backing plate, or disc brake adapter and dust shield) to the axle (see

8

ing plugs) are in their original positions.

31 Start the spider into the bearing cup and then partially install the other cup. Align the spider and press the bearing cups into position, being careful not to damage the dust

18.6

seals.

that secure the brake

32 Install new snap-rings. If difficulty is encountered in seating the snap-rings, strike the driveshaft yoke sharply with a hammer.

axle housing (arrows)

will

spring the yoke ears slightly and

allow the snap-rings to seat in the groove. This should also be done if the joint feels tight

assembly. 33 If so equipped, lubricate the U-joints through the grease fittings with multi-purpose

after

grease.

34

Install

the driveshaft (see Section

1 4).

is

OFF position before the vehicle prevent damage to the system

turned to the

30 Place the front spider in the center yoke and make sure the spider bosses (or lubricat-

This

is

both wheels.

25 Install new snap-rings. If difficulty is encountered in seating the snap-rings, strike the driveshaft yoke sharply with a hammer. This will spring the yoke ears slightly and

28 29

is

until one wheel loses The unit utilizes multi-disc clutch packs and a speed-sensitive engagement mechanism which locks both axleshafts together, applying equal rotational power to

for

seals.

27

assembly

into the carrier.

spider and press the bearing cups into posi-

26

rear axle

casting with a pressed-steel cover.

3

driveshaft tube, then install the

24

The

1

and run

engine to the same speed. If the noise the same, the rear axle is not at fault.

illustration 17.1

traction.

clean

20

8-11

Remove

the nuts

backing plate to the

Clutch and drivetram

Chapter 8

8-12

18.8 Place the axle housing on a transmission jack firmly

-

the axle housing

is

heavy and can cause

and secure

injury

it

18.9 if it

falls

Remove

the four nuts that secure the spring/shock mounting bracket to the axle AXLE

LEAF SPAING

HOUSING

(LH SIDE)

AXLE HOUSING END FLANGE (LH SIDE)

Tilt the axle housing as shown to clear the spring, then lower the jack and take the axle out from under the vehicle

18.13 18.1

1

Unbolt the stabilizer bar brackets from the axle housing

Separate the backing plate from them up out of the way. Caution; Be careful not to bend or kink the brake lines as you reposition the backing plate. 7 Detach the vent hose from the axle housing. The vent hose is secured to the axle by a crimp-type clamp - you'll need to replace it with a screw-type clamp. Refer to Chapter 9 and release the front parking brake cable from the rear cables. Place a transmission jack beneath the 8 axle housing. Secure the axle housing to the jack with a safety strap or chain (see illustration). Note: You'll need to tilt the axle housing on the jack to remove it. Secure the axle so it can't fall off the jack, but position the strap or chain so the axle can be tilted. Remove the U-bolt nuts that secure the 9 spring/shock mounting bracket to the axle (see illustration). Detach the shock absorber from the bracket. 1 Lower the bracket away from the spring, illustration).

the axle and

tie

then remove the U-bolts. 11 Unbolt the stabilizer bar bracket bolts

from the axle housing (see

Move

illustration).

the stabilizer bar out of the way.

On

models equipped with the 5.0L V8, remove the right-side anti-windup bar (see Chapter 10).

12

Raise the axle up

off

the spring.

Move

it

toward the passenger side of the vehicle

until

the driver's side end of the axleshaft clears the spring.

13

the driver's side of the axle housing (see illustration). Lower the axle, it toward the driver's side and remove it from beneath the vehicle. Tilt

down move

prevent damage to the system components (see Chapter 10). 3 Remove the rear brake drums or calipers and discs (see Chapter 9). 4 Clean all dirt from the area surrounding the carrier cover.

Remove

5

the cover and drain the differ-

ential lubricant (see

Installation; 14

Installation

Steps.

Be sure

is

the reverse of the removal

to tighten the fasteners to the

torque values listed

in this

Chapter

1).

6

Remove

and

differential pinion shaft

tions).

On

the differential shaft lock-bolt

(see illustraTraction-Lok differentials, it isn't

Chapter's Specifi-

cations. Tighten the wheel lug nuts to the torque listed in the Chapter 1 Specifications.

19

Axleshafts (rear), bearings and oil seals - removal and installation

Axleshaft removal Refer to

illustrations 19.6a, 19.6b, 19.6c,

19.7a, 19.7b

and 19.8

Loosen the

lug nuts on the rear wheels. Raise the rear of the vehicle, support it securely on jackstands and remove the rear wheels. Caution: If the vehicle is equipped with Automatic Ride Control (ARC), make 1

2

sure the air suspension switch is turned to the OFF position before the vehicle is raised to

19.6a

The pinion shaft lock-bolt

recess

in

fits in

the differential housing

a

1

.

8-13

Chapter 8 Clutch and drivetrain

19.6b

Remove

the bolt with a

thinwall socket

.

19.6c

.

.

.

then

pull

the pinion shaft out

Remove

the C-lock from the end of - the differential lubricant is very slippery and makes the C-locks hard to hold with pliers, so be careful not to drop them

19.7a

each axieshaft

on Traction-Lok models, the spacer spring (arrow) need not be removed

.

Using the slide hammer, withdraw the bearand oil seal as a unit (see illustration). 10 Thoroughly clean the rear axle housing bore with a rag and solvent.

ing

Lubricate the

1

lubricant

and

new

install

bearing with rear axle

the bearing into the

housing bore. Use a bearing/seal driver

tool,

matches the outer bearing race (see illustration). Tap the bearing in until it's into the full depth of its recess. Caution: Do not tap on the inner bearing race while installing the bearing, as it will be damor large socket that

19.7b There's a rubber O-ring in the Clock groove in the end of each axieshaft

19.8

Lift

and

pull

axle housing

-

the axieshaft out of the

be careful not to damage the

necessary to remove the preload spring (see illustration). Caution; If the axleshafts orpinion

is

rotated while the pinion shaft

pinion gears could

fall

is out,

the

out and possibly be

damaged. Reinsert the pinion shaft and

8

Carefully

remove the axleshafts from the

oil

seal at the

the rubber O-ring

fits in the axle shaft groove under the C-lock (see illustration).

cocked during installation it will be damaged, component failure and an oil leak.

leading to

Axieshaft installation

and bearing

replacement

which

the

end of the housing.

Push the axleshafts toward the center of the vehicle and remove the C-locks from the button end of the axleshafts (see illustra-

damage

damage

lock-

7

axle tube seal installation tool or a large

socket that matches the seal diameter. CauIf the seal is installed incorrectly or gets

housing (see illustration). Don't

Oil seal

Don't lose or

seal

tion:

bolt while the axleshafts are being removed.

tion).

oil

aged. 12 Apply multi-purpose grease between the lips of the axieshaft seal. 13 Install a new axieshaft seal using the

Refer to

14

illustrations 19. 14

Make sure

and

19.

15

the rubber O-ring

is in

the

Refer to illustrations 19.9 and 19.11 9

Insert a rear axle bearing

slide

hammer

position

it

remover and

bore of the bearing and behind the bearing outer race. into the

8

WHEEL BEARING AND SEAL REMOVER

Remove the wheel bearing and seal with a

19.9

puller

and

slide

hammer

The wheel bearing and

seal can be socket or piece of pipe of the correct diameter if the special 19.11

installed with a large

tool isn't available

Clutch and drivetrain

Chapter 8

8-14

19.15 Align the lock-bolt hole in

the pinion lock shaft with the hole in

the differential

housing

The O-ring in the C-lock groove goes toward the wheel end of

19.14

the axleshaft

UPPER SPRING

SEATRH

BOLT AND RETAINER

RETAINER

JOUNCE BUMPER

INSULATOR SPACER

SPRING

INSULATOR

SEAT

BOLT AND WASHER

COTTER AXLE PIVOT BRACKET RH

PIN

PITMAN ARM

CROSSMEMBER LEFT AXLE PIVOT BRACKET

/.NUT INSULATOR

RIVET

RETAINER

RADIUS

ARM

.NUT

SPLASH SHIELD

FHONT OF VEHICLE

LH SIDE SHOWN RH SIDE SAME EXCEPT AS

BOLT-611171

SHOWN SHOWING RH AXLE INSTALLATION VIEWY

VIEW V

20.7

The

front axle

assembly (1991 through 1994

4WD

models)

-

exploded view

7

7

1

8-15

Chapter 8 Clutch and drivetrain

Use a

20.21

large screwdriver or prybar

(arrow) to carefully pry the

groove

CV joint out

the C-lock on the button end of the

Push the shaft out

axleshaft splines.

C-lock seats

the

until

the counterbore of the differ-

in

ential side gear.

15 Position the differential pinion shaft through the case and pinion gears, aligning the hole in the shaft with the lock-bolt hole (see illustration).

Apply thread-locking com-

pound

to the lock-bolt, install the bolt

tighten

it

and

to the torque listed in this Chapter's

Specifications.

16

Clean the gasket mounting surface on

the rear axle housing and cover of

all

old gas-

wire to

keep any

strain off the flexible

brake

Remove

and

slightly

Remove

compress the

front coil spring.

the nut securing the lower portion of

the spring to the axle beam.

7

Carefully lower the jack

spacer, seat and stud (see illusCaution: The axle arm assembly must be supported on the jack throughout spring removal and installation. Do not let the arm assembly hang suspended by the brake coil spring,

tration).

Detach the shock absorber from the arm bracket. 9 Detach the radius arm and bracket from the axle arm and remove them from the vehi-

in

a criss-cross pattern

8

radius

to the torque listed in this Chapter's Specifi-

cle.

cations.

10

Refill

and grade

the axle with the correct quantity of lubricant (see

19 Install Chapter 9).

brake

the

Chapter

1).

components

(see

Install

21

Lower the vehicle and tighten the lug in the Chapter 1

nuts to the torque listed Specifications.

20

the pivot bolt securing the right

arm assembly to the frame crossmember. Remove the clamps securing the axleshaft boot to the axleshaft slip yoke and axle-

axle

shaft. Slide the

the wheels and lug nuts.

20

Front axle assembly

models)

-

(4WD

removal and

rubber boot over the stub

shaft.

Once

is disconnected yoke, lower the floor jack and remove the right axle arm assembly. 12 Position the jack under the differential housing and remove the bolt securing the left 1

from the

the right driveaxle

slip

arm to the frame crossmember. Lower and remove the left axle arm assembly. axle

Installation 13

1991 through 1994 models Removal Refer to

Installation

is

the reverse of the removal

procedure. 14 Tighten

all fasteners to the torque listed Chapter's Specifications and related Chapters.

in this

illustration 20.

Raise the front of the vehicle and install jackstands under the radius arm brackets. 2 Disconnect the driveshaft from the front

is

axle

3

yoke (see Section

Remove

Chapter

9).

1 4).

the front brake calipers (see

Caution: Tie the calipers up with

1995 and later models Removal Refer to 15

illustrations 20.21,

Loosen the wheel

20.22 and 20.23

lug nuts, raise the

sure the

If

the vehicle

air

suspension switch

is

OFF position before the vehicle prevent damage to the system

raised to

components

(see Chapter

10).

Remove

16

in

the caliper and brake disc as Chapter 9, then disconnect the

ABS

sensor and secure the sensor and wire harness aside. 17 Remove the hub driveaxle/nut. Place a prybar between two of the wheel studs to prevent the hub from turning while loosening the nut. Warning: Discard the wheel hub nut and washer assembly and replace it with a new one, this nut is designed for a single torque sequence and cannot be re-used. 18 Remove the brake hose support bracket-to-strut bolt.

Support the lower control arm with a

floor jack,

remove the lower and separate the

balljoint nut

control control

arm arm

from the steering knuckle (see Chapter 10). Warning: The jack must remain in this position throughout the entire procedure. 20 Remove the stabilizer bar (see Chapter 10).

joint adapter, pry the inner

hammer with CV CV joint assembly

from the front

differential

(see illustration).

damage

the front differen-

Using a prybar or slide

21

Be

careful not to

Suspend the

tial.

don't

let

may

it

axle with a piece of wire

hang, or

damage

to the outer

-

CV

occur.

22 Press the driveaxle out of the hub with a two-jaw puller, using a prybar or large screwdriver to keep the hub from turning (see illustration). Caution: Never use a hammer to remove the driveaxle from the hub or damage

end of the driveaxle will occur. Once the driveaxle is loose from

to the

23

1

securely on jackstands.

turned to the

joint

installation

make

(ARC),

19

Remove

it

the wheel(s). Caution:

equipped with Automatic Ride Control

is

outlined

and remove the

hose.

Tighten the bolts

and support

vehicle

Detach the tie-rod ends from the steering linkage (see Chapter 10). Remove the stabilizer bar and its con5 necting links (see Chapter 10). 6 Position a floor jack under the axle arm

4

gasket remover. Apply a continuous bead of silicone sealant. Run the bead to the inside of the bolt holes and install the cover and bolts.

18

strut/knuckle assembly and remove the stub shaft from the hub

lines.

ket material residue with lacquer thinner or

1

20.23 After the driveaxle has been pull out on the

separated from the hub,

the end of the axleshaft. Push the

in

O-ring toward the outer end of the groove (toward the wheel) (see illustration). Carefully insert the axle into the housing and install

20.22 A two jaw puller can be used to press the driveaxle from the hub - do not hammer on the axle

splines, pull out

bly

the hub on the strut/knuckle assem-

and guide the outer

hub.

Remove

CV

joint

out of the

the support wire and carefully

detach the driveaxle from the vehicle (see illustration).

8

8-16

Chapter 8 24

ClACLI*

Clutch and drivetrain

Refer to Section 14 and disconnect the

from the front differential Disconnect the front axle vent hose. You

front dnveshaft

25

may have install

to cut off the original

clamp and

a screw-type clamp during reinstalla-

tion

Support the differential with a floonack. strapping or chaining the differential to the

26

jack

SHAFT

IS PI

SIDE

20.30 The inner CV joint stub shaft is completely seated when the circlip on the shaft snaps into the groove in the differential side gear

circlip

Pull out

insert the outer

rail,

Installation illustration

20.30

on the strut/knuckle assembly

CV

joint

stub shaft into

hub (make sure the splines are aligned). Push the shaft as far into the hub as possible

the

by hand. Support the outer CV joint housing and 32 carefully tap on the hub, using a soft-faced hammer, until enough threads on the stub shaft are exposed to thread the old driveaxle/hub nut on. Caution: Don'f allow any force to

housing is the reverse of the disassembly procedure. Installation of the differential

on the inner stub

30 Coat the differential seal lips with multipurpose grease and insert the stub shaft into the differential side gear until the shaft is seated and the circlip snaps into place (see

and

Refer to

28

new

illustration)

one mounts the left side of the difand the top bolt (just above the pinion and facing the engine) secures the top of the differential to the crossmember.

GEAR

a

31

ferential to the frame,

TO SEAT IN THE DIFFERENTIAL

Install

shaft splines.

Remove

frame

INSTALLED.'. CIRCLIP IS FELT

29

head

the three mounting bolts and remove the axle from the vehicle with the lack. One bolt holds the right axle tube to the

27

Tighten the carrier mounting bolts to the in this Chapter's Specifications

torque listed

the

33

be transmitted

to the inner portion of

CV joint. Tighten the nut

until

the stub shaft

LEFT SHAFT AND JOINT ASSEMBLY

BEARING INNER LOCKNUT

MANUAL LOCKING HUB

RIGHT SHAFT AND JOINT ASSEMBLY

21.4

An exploded view

of the

4WD front axle

(1991 through 1994 models)

is

1

8-17

Chapter 8 Clutch and drivetrain

Remove

21.5

the spindle securing nuts

21.6

Remove

21.7a Withdraw the

the spindle seat

(arrows), then tap the spindle loose with a soft face

hammer and remove

joint

left

shaft

and

assembly

it

securely on jackstands and remove the front pulled completely into the hub, then

the nut and discard

remove

the driveaxle/hub washer and a

34

Install

nut. Tighten the nut to the torque listed

Chapter's Specifications while pre-

venting the hub from turning by placing a screwdriver between two wheel studs.

35

Insert the balljoint stud into the steering

knuckle.

Install

torque listed

Remove the front brake calipers (see Chapter 9). Hang the calipers out of the way with pieces of wire. Don't disconnect the brake hoses. 4 Remove the locking hubs, wheel bearings and locknuts (see illustration). Refer to Chapter 1 Section 28, for the hub/brake disc and wheel bearing removal procedure. 3

it.

new

in this

wheels.

a new nut and tighten it to the the Chapter 10 Specifica-

in

,

Remove

5

the nuts securing the spindle to

tions.

the steering knuckle.

Tap the spindle

36

plastic or soft faced

hammer

Install

the stabilizer bar (see Chap-

then remove

ter 10).

37 Install the brake disc and caliper (see Chapter 9). 38 Install the brake hose support bracket bolt and ABS sensor. 39 Install the wheel and lug nuts and lower the vehicle. Tighten the lug nuts to the torque listed in

the Chapter

40

Check the

level

and add,

21

if

1

Specifications.

front differential lubricant

necessary (see Chapter

1).

Front axleshaft and joint assembly - removal, component replacement and installation

1991 through 1994 models Removal

1

2

lug nuts on the front wheels. Raise the front of the vehicle, support it

Loosen the

STUB SHAFT

7

On

the

and

left

side of the vehicle, pull the

assembly out

of the carrier necessary, tap the slinger off the shaft with a hammer (see illustration). Note: Don't remove the slinger unless necessary. You'll need a press to

shaft

joint

(see illustration).

If

it.

hammer -

reinstall

Clean

it

and grease from the spinsure there are no nicks or

all dirt

Make

in the bearing bore. 12 Install the new bearing in the bore with the manufacturer's mark out. Install the bearing with a bearing/seal installer (see illustra-

burrs

tion).

shaft (see illustration).

Spindle bearing and

oil

seal

DRIVER

HANDLE

replacement 9

illustrations 21.

Place the spindle

12 and 21. 13 in

a padded vise so

the vise grips the spindle's second step. 10 Remove the bearing and oil seal with a slide

hammer and

-Q

8 SPINDLE

BEARING REPLACER

puller attachment.

SOOT

and

ASSEMBLY

If

with a

dle bore.

8 Working on the right side, remove the metal clamps from the shaft and joint assembly and the stub shaft. Slide the rubber boot onto the stub shaft and pull the shaft and joint assembly from the splines of the stub

necessary, tap the slinger off a press is needed to

21 .7b

1

install

21.8

RIGHT SHAFT-AND-JOINT

free,

(see illustration). the spindle seat (see illustra-

tion).

Refer to

Refer to illustrations 21.4, 21.5, 21.6, 21.7a, 21.7b and 21.8

with a it

it

Remove

6

to jar

The

right axleshaft

U-joint

assembly

21.12 Drive the spindle bearing out with a bearing driver

7 1

8-18

Clutch and drivetram

Chapter 8

S*NDit BEAWNO

21.13 Drive

in

a

new

seal with

its lip

toward the driver

21.14a Mark the shaft and yoke so they can be reassembled in the same

21.14b

Remove

the snap-rings from the

joint with a

screwdriver

relative position

Axleshaft assembly universal joint 13

Use the same

tools to install the seal

(see illustration) The

lip

of the seal

installer. After installation,

coat the

faces the lip

of the

seal with high-temperature lubricant.

replacement Refer to illustrations 21.14a, 21.14b and 21.15

14

Mark the orientation

and

of the shaft

FRONT OF VEHICLE

FRONT WHEEL HUB AND SPINDLE

FRONT WHEEL HALFSHAFT AND JOINT

21.15 Position the joint and sockets in a - the small socket is smaller than the bearing cup, the large socket is large enough to receive the bearing cup

NUT AND

WASHER

vise to press the bearings out

ASSEMBLY

21.24 1995 and later driveaxle assembly -

exploded view 1

2 3 4 5

6 7

8 9 10 1

Nut and washer assembly Front wheel hub Excluder seal Driveaxle

and outer joint

assembly Boof clamp Boot Boot clamp Driveshaft

Stop

ring

Circlip

Spider assembly

12

Tri -lobe insert

13

Housing

14

Inner

15

Boot clamp

16

Inner

1

Circlip

18

Housing Front wheel hub

19

CV joint CV joint

Front Wheel Halfshaft and Joint Assembly,

GKN Design

7

.

Chapter 8

8-19

Clutch and drivetrain

TRIPOD

OUTER RACE

ASSY

TABS 21.28 Bend the retaining tabs

down

slightly

.

21.29

.

.

.

.

yoke, then remove the internal snap-rings from the U-joint with a screwdriver (see illus-

23 in

and remove the outer race from the tripod assembly

Tighten the lug nuts to the torque listed

Chapter

1

.

trations).

same as is

of the

procedure

for driveshaft universal joints,

described

in

is

the

which

Section 15 (see illustration).

1995 and later models

If

the slinger

spindle, have

was removed from

the

pressed on by a machine

it

shop.

On

1

the right side of the carrier,

rubber boot and

install

new metal clamps on

the

the

no blind spline to ensure correct alignment, so pay special attention to the yoke ears and make sure they are in phase. Be sure the assembly is fully seated and crimp the metal clamp. stub shaft

On

18

slip

the

yoke. There

left

is

side of the carrier, slide the

assembly through the knuckle and engage the splines on the shaft in the shaft

and

joint

carrier.

19 dle

down

the

Move the inner (exposed) stop ring down the shaft about 1/2-inch (see illustra30

Inner

31

Install

the splash shield.

Install

on the steering knuckle, then

the spin-

install

and

tighten the spindle nuts to the torque listed

in

Move

the tripod

the inner snap-ring

CV joint and boot

down

until

the shaft towards

the circlip

is

visible

replacement

on the end of the driveaxle. Remove the circlip and remove the tripod assembly from the

Disassembly

driveaxle (see illustration).

Installation 16

the stop ring axle shaft

tion).

The remainder

15

Move

21.30

32

Refer to illustrations 21.24, 21.28, 21.29, 21.30 and 21.31

1995 and with Constant 24

later

models are equipped

Velocity

(CV)

joint

driveaxle assemblies (see illustration).

inboard tripod design

CV

joint

type

The

and driveaxle

boot are serviceable units. The outer CV joint is not serviceable and must be replaced as an assembly. However, the outer driveaxle

boot is serviceable with a similar procedure as the inner boot. 25 Remove the driveaxle from the vehicle (see Section 20). 26 Mount the driveaxle in a vise. The jaws of the vise should be lined with wood or rags to prevent

damage

to the axleshaft.

Chapter 10. 20 Install the front wheel bearings and locking hubs (see Chapter 1). 21 Install the brake caliper (see Chapter 9). 22 Install the front wheels and lower the

Cut the boot clamps from the boot and discard them. 28 Bend the retaining tabs slightly to allow for tripod removal (see illustration). 29 Remove tripod assembly from outer

vehicle.

race (see illustration).

27

No

further disassembly of the tripod

is

possible. Inspect the tripod rollers, roller

bearings and races carefully for worn spots and smooth operation. or worn tripods cannot be rebuilt be replaced. 33 Remove the inner stop ring axleshaft and remove the old boot.

damage,

Damaged and must from the

Reassembly Refer to 21.40

illustrations 21.38a,

21.38b and

Slide a new clamp and the inner CV joint boot on the axleshaft. Install a new inner stop ring past the 35 second ring groove about 1/2-inch. 36 Install the tripod assembly on the

34

driveaxle with the chamfered side inward.

Push the tripod assembly down the axle enough to allow circlip installation. Install the new circlip and push the tripod assembly towards the axle end until the tripod seats on 37

far

8 CIRCLIP

STOP RING

21.31

Remove

the circlip and pull the tripod

assembly off t he axleshaft

CIRCLIP 31.38a

Install

the Tri-pod circlip

8-20

Clutch and drivetrain

Chapter 8

IW RMG QA

«Onam> -^llMlISh-

KM

LEFT-HAND DRIVEAXLE 508.3MM (20.0 IN)

RIGHT HAND DRIVEAXLE 438.3MM(17.3IN)

21.40 Driveaxle assembly length specifications

21.38b Push the tripod assembly toward the axle end and move the stop ring into the groove

the circhp and the inner stop ring groove

is

exposed. 38 Move the inner stop ring to its groove to secure the tripod assembly (see illustrations)

39 Fill the outer race with CV joint grease and spread some on the inside of the boot as well. The left axle tripods use about 6.5 ounces of grease and the right axles use about 7 ounces. Push the tripod assembly

47

Detach the boot from the

slide

it

off

CV

joint

and

the axleshaft.

Check the grease for contamination by rubbing a small amount between your fingers. If the grease feels gritty, the CV joint is contaminated and must be replaced. 49 If the grease is not contaminated, remove all traces of grease from the CV joint using solvent and a soft bristle brush. Thoroughly dry the CV joint using compressed air, if available. All traces of solvent must be

removed

or

damage

to the

CV

joint

Wear eye protection using compressed air! occur. Warning:

may when

into outer race and bend the six retaining tabs back to their original shape.

score marks, cracks and other signs of

Wipe any excess grease from the axle boot groove on the outer race. Seat the small diameter of the boot in the recessed area on the axleshaft and install the clamp. Push the other end of the boot onto the outer race and move the race in-or-out to adjust the axle to the proper length (see illustration). This applies only to 1995 and 1996 models. The

spots are normal and will not CV joint performance. 52 Install the new outer boot and clamps onto the driveaxle shaft. Completely pack the CV joint with the grease provided in the boot kit. Force the grease into the joint and around the balls and races. Spread the remaining grease evenly inside the boot. Total grease fill is approximately 6.0 ounces. 53 Position the outer boot on the CV joint and using the appropriate boot clamp pliers, tighten the clamps.

models have grooves

in

the

axleshafts that locate the boot clamps.

With the axle set to the proper length, equalize the pressure in the boot by inserting a dull screwdriver between the boot and the outer race. Don't damage the boot with the

41

CV

joint

and boot

wear or damage (see

Right stub shaft assembly, oil seals and bearings

22

pit-

illustration). Shiny,

polished

adversely affect

(1994 and earlier models)

-

removal and installation

Removal Refer to illustrations 22.

Loosen the

7,

22.9 and 22. 10

on the

lug nuts

front wheels.

Raise the front of the vehicle, support it securely on jackstands and remove the front wheels. front driveshaft

yoke (see Section

14).

from the axle

Secure the driveshaft

f

ass* •ustr

aside.

Remove

4 joint

the spindles and the shaft and assemblies from both sides (see Sec-

Place a transmission jack under the car-

5 rier

bsli

'•:

tion 19).

and unbolt the

from the left axle from the arm. After

carrier

arm. Separate the carrier

remove the carrier. a vise or on a work-

the lubricant has drained,

6 Place the carrier bench.

in

II

C

':$ bearin

factor

Turn the shaft assembly so the open is exposed, then push the C-clip off with a pair of screwdrivers (see AXl

illustration).

tion 20.

Outer CV joint and boot replacement illustration

21.50

Note: The outer CV joint is a non-serviceable item and is permanently retained to the driveaxle.

If

any damage or excessive wear

to the axle or the

outer

CV joint,

the

and outer CV joint assembly must be replaced. Complete rebuilt driveaxle assemblies are be available at most auto parts stores. If after disassembly and inspecdriveaxle

tion the CV joint is deemed serviceable, replace the boot as described below. 45 Remove the inner CV joint and boot.

46

rcc rtfto

1C

Detach the

3

r:s

side of the C-clip

42 Install the boot clamp. A pair of special clamp-crimping pliers are required. 43 Install a new clip on the stub axle. 44 Install the driveaxle as described in Sec-

occurs

: i

7

tool.

Refer to

219

carrier

2

50

later

54 Assemble the inner and install the driveaxle.

1

ting,

1997 and

1995 and 1996 models

48

Inspect the cage, balls and races for

40

-

•

Cut the boot clamps and remove them from the outer CV joint.

21.50 After the old grease has been completely removed and the solvent has dried, rotate the outer joint housing through its full range of motion and inspect the bearing surfaces for wear or damage - if the balls, race or cage appear damaged, replace the driveaxle shaft and outer joint assembly

22.7

Push the C-clip

off

the shaft with a

pair of screwdrivers

8 7

1

.

8-21

Chapter 8 Clutch and drivetrain BENCH MOUNTED HOLDING FIXTURE

BENCH HOLDING FIXTURE

AXLE BEARING

REMOVER SEAL PULLER

22.9

8

the passenger side oil seal with a slide hammer and a puller that hooks to the inside of the seal

Remove

Pull the slip

yoke and shaft assembly

out of the carrier.

9

Remove

mer and

the

oil

seals with a slide

puller (see illustration).

The

ham-

driver's

removed with an attachment that grips the outer edge of the seal. A hammer and chisel can also be used, being careful not to gouge the housing or the seal bore. 10 Remove the caged needle bearings with a slide hammer and a puller attachment (see side can be

illustration).

Installation Refer to

illustrations 22.

1 1

and 22. 14

Clean and inspect the bearing bore for nicks and burrs before installing a new caged 1

bearing. Position the bearing with the

facturer's

marks facing

manu-

out, then drive the

bearing

in until

it

22.10

is fully

seated

Remove

in

the caged needle bearings with a slide

the bore

(see illustration). 12 Coat the oil seal with high-temperature lubricant

13

and drive

Install

into the carrier

shaft

14

it

into the carrier housing.

the slip yoke and shaft assembly

so the C-clip groove

in

the

is visible.

Push the C-clip

into the

screwdriver (see illustration).

groove with a

Make

sure

it

is

completely seated in the groove. Caution: Don't push on the center of the C-clip with the screwdriver, as it may be damaged. Push in the notches of the clip. 15 Clean all traces of gasket sealant from the mating surfaces with lacquer thinner or gasket remover. Apply RTV sealant in an unbroken 1/4-inch wide bead, inboard of the bolt holes, and install the differential cover. 16 Position the carrier on the transmission

and

puller

jack and

install

it

in

hammer

position on the support

arm. Use the guide pins for alignment. Install and tighten the bolts in a clockwise or coun-

terclockwise pattern to the torque listed in this Chapter's Specifications. 1 Install the shear bolt securing the carrier to the axle arm and tighten to the torque listed in this Chapter's Specifications. 1 Install the shaft and joint assemblies and spindles.

Connect the driveshaft

19

to the

yoke (see

Section

14).

20

the carrier with lubricant (see Chap-

Fill

ter

21

1).

the front wheels and lower the

Install

vehicle.

22 in

Tighten the lug nuts to the torque listed

Chapter

1

AXLE BEARING AND SEAL INSTALLER

DRIVER

HANDLE

8

NEEDLE BEARING

22.1

1

Drive the bearings

in with the manufacturer's marking facing out

22.14 Push the C-clip into the groove with a screwdriver - don't press on the center of the C-clip or it may be damaged

8-22

Chapter 8

Clutch and drivetrain

Notes

9-1

Chapter 9

Brakes

Contents Section

System (ABS) - general information caliper - removal and installation disc - inspection, removal and installation fluid level check hoses and lines - inspection and replacement hydraulic system - bleeding light switch - removal and installation pads - replacement shoes (rear) - replacement system check

Anti-lock Brake

2

Brake Brake Brake Brake Brake Brake Brake Brake Brake

4 5

See Chapter

1

9 10 15 3 6

See Chapter

Section General information Master cylinder - removal and Parking brake - adjustment

1

installation

replacement Parking brake shoes (rear disc brakes only) - inspection and replacement Power brake booster - check, removal, installation and adjustment Wheel cylinder - removal and installation Parking brake cables

-

8 11

12

13 14 7

1

Specifications

Brake

fluid

DOT 3

type

brake

fluid

Drum brakes Drum wear limit Minimum lining thickness

Specified on

drum

1/16 inch above

rivet

heads

Disc brakes Pad

lining

minimum thickness

1/8 inch

Front brake disc

Minimum

thickness*

1994 and earlier 1995 and 1996

0.810 inch

2WD 4WD

0.964 inch

0.810 inch

1997 and later Runout limit 1996 and earlier 1997 and later Thickness variation

1996 and 1997 and

1

.023 inch

0.003 inch 0.0005 inch limit (parallelism)

0.002 inch 0.0002 inch

earlier later

Rear brake disc

Minimum

thickness*

0.409 inch

Runout limit 1996 and earlier 1997 and later Thickness variation (parallelism) *Refer to

minimum

thickness cast into the disc

0.003 inch 0.0002 inch 0.0005 inch (it

supersedes the information printed here)

Torque specifications

Ft-lbs (unless otherwise indicated)

Backing plate-to-axle housing nuts Brake booster-to-firewall nuts Brake hose -to-caliper banjo bolt Caliper mounting bolts 1996 and earlier

25

Front

Rear 1 997 and

to

35

15 to 20

23

to

29

38 20

to

48

later

Front

Rear Caliper mounting bracket-to-spindle bolts Caliper adapter-to-rear axle flange nuts

Master cylinder-to-brake booster nuts RABS valve mounting screw RABS sensor mounting bolt

21 to 26

20 73 to 97 80 13 to 25 11 to 14 25 to 30

9

Brakes

Chapter 9

9-2

VACUUM

General information

1

VALVE

MECHANICAL STOP LIGHT SWITCH

jstratior

General description All

models covered by

Typical dual matter

1.3 this

manual are

cylinder brake system

equipped with hydraulically-operated. powerassisted brake systems All tront brake systems are disc type, while the rear brakes are

(non-ABS models)

drum type Some models are equipped with an Anti-lock Brake System (ABS), which is descnbed in Section 2. All brakes are self-adjusting. The front and rear disc brakes automatically compensate for pad wear, while the rear drum brakes incorporate an adjustment mechanism which either disc or

is

RABS VALVE

clean

activated as the brakes are applied.

The hydraulic system is a split design, meaning there are separate circuits for the front and rear brakes (see illustration). If one circuit fails, the

other circuit

will

become proved c)

remain func-

and a warning indicator will light up on the dashboard, showing that a failure has tional

parts

Do

filtering

all

clearances and

Master cylinder The master cylinder is located under the hood, mounted to the power brake booster, and is best recognized by the large fluid reservoir on top. The removable plastic reser-

completion of any brake system work,

cedure, seek professional advice.

partitioned to prevent total fluid loss

in

the event of a front or rear brake hydraulic

system

test the

brakes carefully

in

cause personal

this

procedure

injury. a"

If

a problem

is

suspected

system, don't drive the vehicle

cylinder

Upon

2

in

the brake

r

i

"n

l

until it's fixed.

Anti-lock Brake

System (ABS)

-

general information

a controlled

d)

mal service. Warning: Some models covered by this manual are equipped with an air suspen-

designed for the "split system" mentioned earlier and has separate primary and secondary piston assemblies,

perform

may result in unexpected shifting or movement of the vehicle, which could

3

area before putting the vehicle into nor-

failure.

The master

suspension sys-

or towing (see Chap-

torque specifications are adhered to. If at all unsure about a certain pro-

you are

is

to the

lifting

ter 10). Failure to

mask.

that

power

tem before

ers which are not in perfect condition,

occurred.

voir

electrical

Safety should be paramount whenever any servicing of the brake components is performed. Do not use parts or fasten-

and be sure

Always disconnect the

sion system.

with brake system not allow the fine dust to airborne. Also, wear an ap-

all

cleaner.

1

Some models

Anti-lock Brake

ea

are equipped with an

System (ABS).

Early

models

are equipped with rear wheel anti-lock brake

I

i

t

e*

is

ton).

the piston nearest the firewall being the

primary piston, which applies hydraulic pres-

3

sure to the front brakes.

battel

RAB

Power brake booster



removal and

installation

Warning: On models equipped with airbags, always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chapter 12).

GRILLE 25

24.2a Grille installation details - Explorer models

1

Open

i

AIR

DEFLECTOR RIVET

RADIATOR AIR UPPER DEFLECTOR

24.2a and 24.2b

illustrations

LOWER

(1991 through 1996)

1996 and earlier models Refer to

air

RETAINERS

the hood.

Remove

the screws and detach the from the vehicle (see illustrations). Installation is the reverse of the removal 3 procedure. Be careful not to overtighten the screws.

2

grille

1997 and later models Refer to

illustrations 24.4,

4

Open

and

plastic rivets holding the plastic shield

the hood and

r

24.6a and 24.6b

remove the screws

GRILLE

over the top of the radiator (see illustration). Refer to Chapter 12 and remove the 5 headlights.

Remove the grille mounting screws, and disengage the grille from the four clips along the bottom of the grille opening (see illustra6

tions). Installation is the reverse of the removal procedure. Note: Make sure the grille locating tabs are aligned before installing the screws.

7

24.2b Grille installation details

Navajo models

I

SCREWS

Chapter

11

24.6a Grille mounting screws on 1997 and later models - on each side there is one screw at the top (A) and one in the marker light area (B)

25.2a Remove the plastic rivets and the deflector (arrow indicates one) on each

25.2b

air

support brackets

where the deflectors are shown here)

25

Front fender

removal and

11-17

24.6b Release the grille from the clips (arrows) on each side and along the bottom - grille removed for clarity

Remove the

grille

side of the radiator on 1997 and later models (Explorer shown, Mountaineer similar, but with bolted

Body

25.2c Remove the grille opening reinforcement panel by removing the nut (arrow) from underneath

bolt (arrow) holding the reinforcement panel to the hood latch support

impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chapter 12).

.

2 grille

.

On 1997 and

later models, remove the opening reinforcement panel (see illus-

trations).

3

Open

the front door and

remove the

sin-

gle cowl-to-fender bolt (see illustration).

installation

Removal

4

illustrations 25.2a, 25.2b, 25.2c,

Warning: On models equipped with airbags,

Refer to

always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the

25.2d, 25.2e, 25.3

and

Remove

grille

1

the

25.

(see Section 24) and

the headlight trim and housing.

Open

the hood and remove the four

bolts across the top of the fender. Note:

On

models with speed control, unbolt the speed control from the fender when removing the right-side fender.

i

jj 25.2d and the bolt (arrow) on the front side retaining the panel to the fenders .

.

.

25.2e Remove the support bracket bolts (arrows) on each side of the radiator and remove the panel

25.3

Remove

the front fender bolt (arrow) through the door opening

11

Chapter

11-18 Raise the vehicle and support

5

it

Body

11

securely

on jackstands.

Remove the screws or plastic nvets and 6 detach the inner fender panel. Removing the makes

front wheel/tire

Remove

7

*NO ASMftMlV

mow •oov

WA»*R

ASSfMB.

the job easier.

the bolt at the lower front

edge

of the fender (see illustration).

Remove the two bolts attaching the 8 fender to the rocker panel. Carefully detach the fender from the vehicle. Note: On models so equipped, remove the running board or front section of the lower rocker panel trim to access the two lower-rear fender

U NUT

bolts.

Installation Installation is the reverse of the removal 9 procedure, but don't fully tighten the bolts. 1 Check the alignment of the fender to the door edge and the hood (close the hood to

check

for

an even gap), then tighten the bolts

securely.

SM

26

Front

bumper and valance

-

SC«EW AND WASHER ASSEMBLY

INSULATOR

removal and installation

ASSEMBLY

Warning: On models equipped with airbags, always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could

cause personal injury (see Chapter 12). Note: The bumper is heavy and somewhat awkwhrd to remove and install; at least two people should perform this procedure.

Remove

On 1997 and

4

securing the valance to the bumper,

pull

the

valance back and remove it. 2 Installation is the reverse of removal.

Front

bumper

Refer to

illustrations

and set the parking brake.

with optional fog

lights, disconnect the electrical connectors from the fog lights, then unbolt and remove

a)

assistant hold onto the

you're installing a

fer the license plate

r applicable,

remove the

air

indicate bolts

and

plastic rivet)

-

removal and

bumper

new bumper,

trans-

holder and any addi-

items to the

new bumper.

Note: The

awkward

to

is heavy and somewhat remove and install - at least two

bumper

people should perform

this

procedure.

Removal Refer to

illustration

Remove

27.2

light socket from the bumper (see Chapter 12). 2 Have an assistant hold onto the bumper assembly and remove the nuts and retainer on 1

the license plate

K

Remove the two nuts (arrows) on each side to remove the front bumper from the frame

26.6

Rear bumper installation

assembly, then remove the bolts/nuts on each side securing the bumper to the frame (see illustration). On some models, there are studs on the bumper and nuts to hold them

If

27

lights.

Have an

The bumper can be adjusted by repositioning the fasteners in the brackets.

Tighten the fastener nuts securely.

On models equipped

5

tional trim

deflector panel below the radiator (arrows

b)

(see illustration).

7 Installation is the reverse of the removal steps with the following additions:

26.4 and 26.6

Raise the front of the vehicle, support it securely on jackstands, block the rear wheels

Where

models, remove the below the radiator

to the chassis.

3

26.4

later

plastic air deflector panel

6 the screws and plastic rivets

Ins

(1995 and earlier model shown)

the fog

Valance 1

25.7 Remove the bolts along the top of the fender, the lower front, and the bottom rear

bumper mounting bolts are welded to a strap (arrow) - remove the two nuts on the opposite side and pull the bolts/strap out

27.2 Rear

seitn

Chapter

29.5 Pry off the plastic covers (A indicates one

remove the rear

bolts (B indicates

one

in

each side securing the bumper to the frame (see illustration). Note: If there were any spacers between the bumper brackets and the frame, save them for use on reassembly. If necessary, remove the bumper brack3 ets, stone deflector and step plate.

and removed)

place)

bolt with cover

Body

11

29.6

11-19

Remove

the plastic cover

1997 and

later

Refer to

29.6 and 29. power seats, position the way up and disconnect the

left

to a dealer service

department or a shop specializing tive glass

in

automo-

work.

If

is

the reverse of removal with

new bumper,

you're installing a

fer the brackets,

When

trans-

stone deflector and any

additional items to the b)

installing the

new bumper.

step pad, start at the

locator hole at the center of the bumper. c)

Loosely

bumper fasteners, bumper position so there

install the

then adjust the is

a 3/4-inch horizontal gap between the

bumper and body. d)

28

4

On models

the seat

models

illustrations 29.5,

all

with

battery (see Chapter

Seats

-

removal and installation

5

1).

At the rear of the seat, remove the seat-

to-floor bolts (see illustration).

the following additions: a)

bo't (B) at the slider bar

operations should be

29 Installation

and the

specialized tools and techniques. These

Installation 4

(A)

Tighten the fasteners securely after adjustment.

Windshield glass Replacement

-

of the

replacement windshield and

fixed glass requires the use of special fast-

setting adhesive/caulk materials

and some

Warning: On models equipped with airbags, always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chapter 12).

6

Remove

the bolt from the slider bar (see

illustration).

7

Remove

the front seat-to-floor bolts and

remove the seat (see

illustration).

the vehicle.

Rear seat cushion Front seat

-

60/40

split

seat

1996 and earlier models 1 Remove the pin securing

the insulators

8

at the front of the seat track,

then remove

9

Refer to

cover.

vehicle.

tion).

Installation is the reverse of the

removal

steps. Tighten the retaining bolts securely.

1

illustrations 29.

10

and

29.

1

Remove the rear seat latch handle. Remove the outboard cushion latch

both seat track insulators. 2 Remove the four bolts securing the seat track to the floorpan and lift the seat from the

3

On power

models, disconnect the electrical connectors underneath before removing the seat from

Remove

the Torx screws that secure the

seat back to the cushion frame (see illustra-

Separate the cushion from the seat back by pulling it forward while holding the seat back in place.

11

i 29.7 Front seat-to-floor bolts (arrows)

29.10 The seat cushion frame is secured to the seat back frame with Torx screws

3 7

11-20

Chapter

Body

11

r

i 29.1

1

The seat cushion frame

is

29.14 Remove the Torx bolt (A) on each side of the seat - if necessary, remove the floor bolt (B) and seat belt bolt/nut (C)

secured to the floor

with nuts (arrows) 11 Remove the nuts that secure the seat cushion and frame (see illustration). Take the seat cushion and frame out. 12 Installation is the reverse of removal. Tighten the nuts and Torx screws securely.

Rear seat back

-

60/40

split

19

Refer to

Remove

1

14

the seat latch handle and cush-

Remove

14

the Torx screws that secure the

steps

-

50/50

split

seat 20

Remove

30

the nut and detach the cushion

Tilt

remove the

the cushion forward, it

to the floor

and take

it

' (

out.

plates

22 Installation is the reverse of removal. Tighten the cushion pivot and link arm nuts

ands 2

securely.

15 ion

16

Pull the seat

Remove

back away from the cush-

the nut and bolt that secure the

back toward the side of the vehicle to detach it from the center pivot Pull the seat

bracket, then

lift it

out.

necessary, remove the nut and bolt that secure the buckle and seat back pivot bracket (see illustration 29.14).

18

-

50/50

split

seat

it.

seat back and seat belt to the floor (on the side nearest the door). 1

iheRi

Rear seat back

and remove

23

durini

Remove

the nut and detach the cushion

31.2a Push

arm from the seat cushion. 24 Remove the nut and bolt that secure the seat back latch and seat belt to the floor (on the side nearest the door). Note: A special seat-belt bit, available at your auto parts store, is required to

25

Tilt

remove seat

belt bolts.

the seat back forward, pull

the door to disengage

31 .2b Disconnect the electrical connector from the cigarette

it

it

toward

from the center pivot

31.3a

down on

the ash tray retainer and pull the ash tray out

link

If

lighter

(

come

seat back to the cushion frame (see illustration).

!

arm from the seat cushion.

nuts that secure

ion latch cover.

the reverse of removal.

secun

21 illustration 29.

is

Rear seat cushion

link

seat

Installation

Tighten the nuts and Torx screws securely.

tan that

tf

chest

when

and take out of the vehicle. 26 If necessary, remove the link arm cover (if equipped) and link arm from the seat back. 27 If necessary, remove the pivot bracket and seat buckle from the floor.

Remove

4

I

it

the ash tray bracket screws

lems as ne availa

foren

Chapter

11

Body

31.4a Pull back sharply on the edge of the instrument cluster bezel

31.3b Pull the bracket out, disconnect the electrical connector and remove the bracket

28

Installation is the reverse of the

11-21

.

connect the

removal

steps. Tighten the retaining bolts and nuts

31

securely.

Instrument cluster bezel removal and installation

-

Seat belt check

1

Check the seat

plates

belts,

and guide loops

and signs

for

buckles, latch

obvious

damage

of wear.

Check that the seat belt reminder light comes on when the ignition key is turned to the Run or Start position. 3 The seat belts are designed to lock up during a sudden stop or impact, yet allow free movement during normal driving. Check 2

that the retractors return the belt against your

chest while driving and rewind the belt fully when the buckle is unlatched. 4 If any of the above checks reveal problems with the seat belt system, replace parts as necessary. Note:

A

special seat-belt

available at your auto parts store, to

remove seat

belt bolts.

is

bit,

required

always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chapter 12).

Refer to

at the rear of

it.

column to provide additional clearance, disconnect the 4WD electronic shift electrical connector (if equipped) and remove steering

the bezel. Installation

is

the reverse of the removal

procedure.

illustrations 31.2a, 31.2b, 31.3a,

1995 and later models

and 31.4b

Disconnect the negative battery cable 1 from the battery. Squeeze the ash tray retaining clip and 2 pull the ash tray out. Disconnect the cigarette lighter electrical connector and remove the ash tray (see illustrations). 3 Remove the ashtray bracket screws and pull

connector

4 Carefully pull back the edge of the instrument cluster bezel near the ashtray and disengage the clips from the instrument panel (see illustrations). Work around the perimeter of the bezel, detaching each clip. Depress the hazard warning switch on the

5

1994 and earlier models 31.3b, 31.4a

electrical

the bracket and remove

Warning: On models equipped with airbags,

30

.

the bracket out (see illustrations). Dis-

Refer to illustrations 31.7, 31.8a, 31.8b, 31.9a and 31.9b

Disconnect the negative battery cable, 6 then the positive battery cable and wait two minutes before proceeding any further. 7 Unbolt both the parking brake release handle bracket from the dash, and the hood release handle bracket (see illustration).

11

31.4b ... to disengage the clips from the instrument panel

31.7

Remove

the bolts from the parking brake release hood release (B)

(A)

and the

1

1

Chapter

11-22

11

Body

the screws (arrows) at the bottom of the lower cover and pull the clips out at the top to remove the lower instrument panel cover

Remove

the lower instrument panel cover below the steering column, then remove the four screws and the steel rein8

forcement panel (see illustrations). Remove the bezel retaining screws (see 9 illustrations). Tilt

1

the steering wheel

down

to the lowest

position. Pull the top of the instrument cluster

bezel outward while disengaging the lower half.

Remove

the bezel from the vehicle.

Installation

1

is

the reverse of removal.

Remove

31.8b

Remove

31.8a

the screws retaining the instrument panel to

1994 and earlier models Refer to 1

illustration

the cowl top (see illustration)

32.9

Disconnect the cable from the negative

battery terminal.

2

Remove

hood

Remove

the screws at the bottom of the lower cover and unsnap the top of the cover from the instrument panel. Remove the cover.

Remove the lower instrument panel cover reinforcement brace. 4 Remove the ash tray and the ashtray

Instrument panel

removal and

installation

antenna from the radio and the vacuum lines and control cables from the heater/air conditioning control assembly. Carefully remove the instrument panel 10 from the vehicle.

Remove

the steering column covers

(see Section 33).

Remove

Warning: On models equipped with airbags,

6

always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chapter 12). Note: The instrument panel is heavy and

(see Section 31) and the instrument cluster

least

to

remove and

two people should perform

dure.

31.9a

Remove

install - at

this

proce-

1

Installation is the reverse of removal.

1 995

and later models

retainer.

5

somewhat awkward

switches, radio and heater/air condi-

tioning control assembly. Disconnect the

3

32

Carefully pull

the instrument panel back slightly and disconnect all the electrical connectors from the lights,

the screws retaining the

release cable to the lower instrument panel cover.

the screws (arrows) and the steel

reinforcement panel

the instrument cluster bezel

(see Chapter 12). 7

Remove

the inside A-pillar moldings and

the kick-panels from each side.

Remove

the

passenger-side lower insulation panel. 8 Remove the nut retaining the instrument panel to the brake pedal support bracket and disconnect the wiring harness from the steering

column.

9 Remove the bolts retaining each side of the instrument panel to the cowl sides and

the screws (arrows) at the top of the bezel

31 .9b

.

.

.

Refer to

illustrations 32. 16, 32. 19, 32.20,

32.21, 32.23, 32.27a, 32.27b, 32.27c

and

32.27d

Disconnect the negative battery cable, 12 then the positive battery cable and wait two minutes before proceeding any further. 13 Position the steering wheel in the lock position. Note:

remains

in

Make

sure the steering wheel

the lock position

procedure or damage

duhng

the entire

to the airbag sliding

contact will occur. 14 Remove the center console, if equipped (see Section 36). 15 Remove the lower instrument panel

and the two below the bezel (arrows) and remove the instrument cluster bezel

Chapter

11

Body

11-23

32.9 Instrument panel installation details

•

1994 and earlier models Instrument panel-to-cowl top screws

Nut

inserts

Cowl top U-nut

Cowl side Instrument panel mounting bolt (nght side) Instrument panel mounting bolt (left side)

U-nut Parking brake release bracket

Lower instrument panel cover reinforcement Lower instrument panel cover Screw Instrument panel

the reinforcement panel and the instrument cluster bezel (see Section 31). Remove the instrument cluster (see Chapter

cover,

12).

16

Remove

the lower insulation panel on

the passenger side, by removing the plastic

pushpins and rivets (see illustration). 17 Remove the A-pillar moldings from both sides. Remove both kick panels by removing the plastic rivets.

32.16 Instrument panel installation details

1995 and

later

1

Defroster

2 3 4 5 6

Passenger airbag cover

7

8 9 10

grille

Screw Screw Instrument panel

Glove box Pushpin Rivet

Sound Screw

insulator

1

Center bracket

12

Screw

13

Nut Brace

14 15

16 1

18 19

20 21

22 23 24 25 26 27 28 29

-

models

Screw Ash tray Screw Center trim panel Radio opening panel Access cover Lower cover Reinforcement panel Nut Steering column reinforcement

Screw Shift indicator

Instrument cluster Fuse panel cover

Instrument cluster bezel

11

11-24

Chapter

Remove the two bolts (arrows) inside the glove box area, out the passenger air bag enough to disconnect its electrical connector, then remove the airbag

32.19 pull

32.21

Remove

the bolts (arrows) and the instrument panel brace

11

Body

32.20 After removing the lighter and the knob for the rear washer switch, remove the center trim panel screws (arrows)

32.23 Remove the two mounting bolts (arrows) behind the fuse panel cover at the

left

of the instrument panel

32.27a Disconnect the instrument panel connectors (A) and ground wires (B) in the right kick-panel area

electrical

^& fcjL

fe

/ A

=5^ •

&

-

...

32.27b With the distribution box pulled aside, loosen the bolts (arrows) enough to disconnect the electrical connectors at the firewall on the engine side the bolts do not come out

32.27c Pull back on the bulkhead connector on the driver's side of the lower firewall

32.27d With the instrument panel pulled away, remove the bolt (arrow) in the center of the main electrical connector

Chapter

Body

11

11-25

t

Use a small wrench

33.3

wheel lever

Open

18

(if

to

remove the

tilt

33.4 Detach the screws

- then separate the steering column cover halves to remove them from the column

equipped)

the glove box, press the release

the screws securing the upper edge of the

and lower the glove box. Remove the hinge retaining screws and remove the glove

26

box.

slightly

tabs

19

in

Remove

the two mounting screws for away from

instrument panel.

and disconnect nectors and wiring

all

harness

attached to the instrument panel.

the instrument panel and disconnect the electrical connector (see illustration). Warning: Handle the airbag module with care!

27

the two screws and carefully pull the center trim panel off the instrument panel (see illustration). Remove the radio 1 2) and the heater/air conditionassembly (see Chapter 3). 21 At the right of the throttle pedal, remove the bolts and the lower instrument panel

ing control

tration).

Remove

the screws from the lower column cover (see illustration). Separate the cover halves and detach

a)

Disconnect the electrical connector at the brake pedal position switch (on the

6

Installation is the reverse of removal.

b)

At the lower right side of the cowl, disconnect all the electrical harness connectors and ground wires routed to the

34

Sideview mirrors

c)

later

and move it aside enough to loosen the bolts on the bulkhead connectors (see illustration). Disconnect

Remove

the steering column mounting lower and support the steering column. Pry off the fuse panel cover at the left

23 edge of the instrument panel and remove the two bolts (see illustration). 24 Remove the one bolt on the lower right grilles

its

clips

the connectors. d)

Use the handle to pull out the electrical connector on the driver's side (see illustration).

e)

side of the instrument panel.

Pry out the defroster

instrument panel (see illustration). In the left side of the engine compartment pull the power distribution box out of

illustration).

bolts,

25

retainers

4

(see Chapter

22

Disconnect the negative battery cable. Remove the key lock cylinder (see Chapter 12). Note: This is only necessary for removal of the upper column cover. Remove the tilt wheel lever (see illus3 1

steering

5

them from the

and remove

the instrument panel back and loosen the bolt at the large bulkhead Pull

connector

until the

disconnected (see

28

connector can be

Installation is the reverse of the

1

tery until

connections have been

not connect the bat-

Steering column cover

and

plastic watershield (see Section 16).

Disconnect the electrical connector from the mirror. On most models, this will require removal of the radio speaker for that door to access the mirror connector (see Chapter 12 for speaker removal). 3 Peel back the insulator pad, then

remove the three mirror retaining nuts and detach the mirror from the vehicle (see illustration).

4

Installation is the reverse of removal.

35

Cowl cover

-

removal

1

2

illustration

Remove

Chapter

installation

illustrations

33.3 and 33.4

Warning: On models equipped

Remove

pry up the

left

the center screw, then and right cowl panels,

held by clips

with airbags,

always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could

cause personal

injury (see

Chapter

12).

removal and

installation

35.2

the windshield wiper arms (see

12).

Remove

hand and

Refer to

34.3

the door trim panel and the

2

Refer to

33

illustration

Remove

removal

Do

electrical

Refer to

illustration).

procedure. Warning: all

removal and

installation

secured, especially the passenger airbag.

35.2

steering column.

brake pedal).

Remove

brace (see

the three nuts (arrows)

and detach the mirror

models, it is possible to leave the harness attached to the instrument panel. Disconnect the wiring harness from the following connectors:

facing up.

20

back

the electrical con-

the passenger airbag, pull the unit

Always carry the module with the trim side facing away from your body and place the module in a secure location with the trim side

Remove

2

Carefully pull the instrument panel

On 1997 and

34.3

the screw securing the

left

hand cowl covers (see illustration), then pull up both cowl panels, which are held to the body with clips. right

panels are being removed for If the replacement (not just for access to something under the covers), disconnect the windshield washer hoses from the nozzles on the 3

panels.

4

Installation

is

the reverse of removal.

11

11-26

36.2

Chapter

Body

11

Base model console

7

5 6 7

Bolts

8 9

Cover

4

the front trim

Floor console

assembly Screws Screws Armrest Mounting bracket Mounting bracket

2 3

Remove

36.6

panel/message center from the console

installation details

Cup

console and remove the console. 5

Installation

High

line

is

the reverse of removal.

model

Refer to illustrations 36.6, 36. 7 and 36.8

6 of

holder

Using your hands, press the

front

trim

in

on the sides

panel/message center

unsnapping the retaining clips (see illustraDisconnect the electrical connectors and remove the panel. 7 Using the same procedure, remove the rear trim panel/cup holder from the console tion).

then the positive battery cable and wait two

36

Center console

removal and

minutes before proceeding any

further.

installation

Base model Warning: On models equipped with airbags,

Refer to

always disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the impact sensors, steering column or instrument panel to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chapter 12). 1 Disconnect the negative battery cable,

2

36.7

Remove

illustration

Remove

each side

36.2

the two plastic screw covers on

of the

console (see illustration).

Remove the four bolts and Remove the screw in 3

Remove

the two console mounting bolts (see

illustration).

the armrest open-

9

At the center of the console, below the

cup

holder,

the screws retaining the cup holder and remove the cup holder. Remove the two screws securing the front half of the

the trim panel/cup holder

Remove

the armrest.

ing.

4

(see illustration). 8 At the front of the console, loosen the bolt in the center of the main electrical connector, and separate the connector halves.

remove the two mounting

then slide the console rearward to free

bolts, it

from

the rear floor mount.

10

Installation

is

the reverse of removal.

36.8 Loosen the bolt (A) and disconnect the electrical connector at the front of the console, then remove the two console mounting bolts (B)

12-1

Chapter 12 Chassis electrical system Contents Section Airbag

Brake light switch - replacement Bulb replacement Circuit breakers - general information Connectors - general information Electrical troubleshooting

Fuses

-

-

3

general information

2

4 5

general information

-

Gauges and speedometer cable

-

removal and

25

installation

General information Headlight switch - replacement Headlights

-

1

15

19 17 18

adjusting

replacement - removal and installation Heated rear window and rear wiper switch - removal Headlight bulb

-

Headlight housing

and

16

installation

Ignition lock cylinder-

Ignition switch

6

general information

Fusible links

Section

check and replacement Instrument cluster - removal and installation Multi-function switch - check and replacement Power door lock system - general information Power window system - general information Power mirrors - removal and installation Radio antenna - removal and installation Radio - removal and installation Relays - general information and testing Speakers - removal and installation Turn signal/hazard flasher relays - replacement Windshield washer reservoir and pump assembly - removal and installation Windshield wiper arm - removal and installation Windshield wiper motor - removal and installation Wiring diagrams - general information

30 26 20

general information

-

replacement

end

lem, wiring diagrams are included at the

Warning: To prevent electrical shorts, fires and injury, always disconnect the cable from the negative terminal of the battery before checking, repairing or replacing electrical

supplied by a lead/acid-type battery charged by the alternator. This chapter covers repair and service procedures for various chassis (non-engine related) electrical components. For information regarding the engine electrical system (battery, alternator, distributor

see Chapter 5. should be noted that when portions of the electrical system are serviced, the negative battery cable should be disconnected from the battery to prevent electrical shorts

and

starter motor), It

and/or

9 14 13 12 31

fires.

nector and the battery

is

problem

what makes up

that point

that individual circuit. Trouble

spots, for instance, can often be isolated by if

other

components

related to that cir-

through the

same

fuse

and ground connections. Electrical problems usually stem from simple causes such as loose or corroded connectors, a blown fuse, a melted fusible link or a bad relay. Visually inspect the condition of all fuses, wires and connectors in a problem circuit before troubleshooting it.

The basic

tools

needed

for electrical

troubleshooting include a circuit tester, a high impedance (10 M-ohm) digital voltmeter, a

and a jumper wire with an breaker for bypassing electrical components. Before attempting to locate or continuity tester inline circuit

define a problem with electrical test instruments, use the wiring diagrams to decide where to make the necessary connections.

Con-

free.

same

noting

components

7

23

Before tackling any troublesome electrical circuit, first study the appropriate wiring diagrams to get a complete understanding of

cuit are often routed

is

21

tinue checking the rest of the circuit

The chassis electrical system of this vehicle is a 12-volt, negative ground type. Power for the lights and all electrical accesis

8

29 27 28 22

of this manual.

components.

sories

24

11

General information

which

10

-

in

the

fashion.

When you voltage

is

reach a point

present, the problem

and the

last test point

at

which no between

lies

with voltage.

problem can be traced to a loose connection. Note: Keep in mind

Most

that

of the time the

some

circuits receive voltage only

the ignition key

is in

when Run

the Accessory or

position.

Finding a short circuit is

to

One method of finding shorts in a circuit remove the fuse and connect a test light

or voltmeter

in its

voltage present

in

place. There should be no

the circuit.

Move

the elec-

connectors from side-to-side while watching the test light. If the bulb goes on, there is a short to ground somewhere in that area, probably where the insulation has been rubbed through. The same test can be performed on each component in a circuit, even trical

a switch.

Ground check 2

Electrical troubleshooting

Voltage checks

-

Perform a voltage check

general information

first

cuit is not functioning properly.

A

typical electrical circuit consists of

electrical

component, any switches,

an

relays,

breakmotors, ers, etc. related to that component and the wiring and connectors that link the compofuses, fusible links or circuit

nents to both the battery

and the chassis. To

help you pinpoint an electrical circuit prob-

when a

cir-

Connect one

lead of a circuit tester to either the negative battery terminal or a

known good ground.

Connect the other lead

to a connector

in

the circuit being tested, preferably nearest to the battery or fuse. If the bulb of the tester

which means between the con-

lights up, voltage is present,

that the part of the circuit

Perform a ground test to check whether a component is properly grounded. Disconnect the battery and connect one lead of a self-powered test light, known as a continuity tester, to a known good ground. Connect the other lead to the wire or ground connection being tested. If the bulb goes on, the ground is

good. If

the bulb does not go on, the ground

not good.

is

12

12-2

Chapter 12

Chassis electrical system

Continuity check A

check determines

continuity

are any breaks

in

a circuit

the

in

if

it

if

there

conducting

is

With the circuit off (no a self-powered continu-

electricity properly.

power

-

circuit),

ity tester can be used to check the circuit. Connect the test leads to both ends of the the test light comes on the circircuit, and if

passing current properly. If the light doesn't come on, there is a break somewhere in the circuit. The same procedure can be used to test a switch, by connecting the con-

cuit

is

tinuity tester to the

power

in

and power out

sides of the switch. With the switch turned on, the test light should come on.

Finding an open circuit When cuits

it

is

diagnosing for possible open often difficult to locate

cir-

them by

because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the electrical connector may correct the open circuit condition. Remember this if an open cir-

3.3 To backprobe a connector, insert a small, sharp probe (such as a straight pin) into the

cuit is indicated

when

Intermittent

cuit.

troubleshooting a

cir-

problems may also be

caused by oxidized or loose connections. Electrical troubleshooting

you keep

in

mind

that

all

is

simple

if

electrical circuits are

basically electricity running from the battery, through the wires, switches, relays, fuses and

fusible links to

each

electrical

component

and then to ground, from which it is passed back to the battery. Any electrical problem is an interruption in the flow of electricity to and from the battery.

3

Connectors

-

general information

in

of the connector, along side it

The power distribution box is located the engine compartment - fuses are located under the cover

contacts the terminal

connect your meter leads to the probes to test a functioning circuit

inside;

rior

(see illustrations)

The fuse panels are equipped with

selves, not the wires,

miniaturized fuses because their compact dimensions and convenient blade-type termi-

ment).

design allow fingertip removal and instalIf an electrical component fails, always check the fuse first. The best way to check

when unplugging two connector halves (there are times, however, when this is not possible - use good judgis usually necessary to know which male or female, of the connector you're checking. Male connectors are easily distinguished from females by the shape of their It

side,

internal pins.

continuity or voltage

with a circuit tester, insertion of the test

probe

into the receptacle

connector and

may open

the

fitting

poor contact. Instead, insert the test probe from the wire harness side of the connector, known as "backprobing" (see illustration).

to the

nal

lation.

is with a test light. Check for power exposed terminal tips of each fuse. If power is present at one side of the fuse but not the other, the fuse is blown. A blown fuse can also be identified by visually inspecting

the fuses at the

it

When checking

bulb, motor, etc.)

(light

back

the wire, until

sight

4.1a

result in

(see illustration). Each fuse protects one or more circuits.

Consult your owner's manual - it will have the most accurate guide for your vehicle. The cover of the interior fuse panel contains a fuse puller tool

and spare fuses. Note:

On engine compartment and boxes, there

is

interior fuse a fuse identification guide on

the inside of the cover, either

Refer to

illustration 3.3

4

Always release the lock attempting to unplug

inline

lever(s)

Although nothing more than a finger

is

usuaily necessary to pry lock levers open, a

small pocket screwdriver

to-release levers.

Once

-

general information

effective for hardthe lock levers are

is

released, try to pull on the connectors them-

Refer to 4.7

stamped

into

on a printed sheet. To open the engine compartment fuse panel (also called a power distribution box), press on the tab above the Ford emblem, then slide the cover out of its tabs and lift it off. To open the footwell fuse panel on 1991 the plastic or

before

type connectors.

There are a variety of lock lever configurations.

Fuses

illustrations 4. 1a, 4. 1b, 4. 1c, 4.2

and

The electrical circuits are protected by a combination of fuses, cartridge-type fusible links and circuit breakers. There are two fuse panels; one on the power distribution box in the engine compartment and one in the inte-

FUSE PANEL COVER

On 1991 through 1994 models, the interior fuse panel is located above the

4.1b

driver's footwell

- lift

the

handle and let the panel swing down for access

The interior fuse panel on 1995 and models is at the left end of the instrument panel (shown with plastic cover removed)

4.1c

later

FUSE PANEL

Chapter 12

Chassis electrical system

Fuse Value

12-3

Amps

Color Code

4

Pink

5

Tan

10

Red

15

light Blue

20

Yellow

25

Natural

30

Each fuse amp value has a corresponding color code

4.7

4.2

The fuses can easily be checked visually to see blown (the fuse on the left is blown)

if

they are

On

5.2b

later

models the power

distribution

fusible links

5.2a Conventional type fusible links (arrow) can be found exiting the power distribution box in the engine compartment

through 1994 models, lift the handle and let the fuse panel swing down. On 1995 and later models, pry open the plastic cover at the left end of the instrument panel (access with the driver's door open). Use the plastic twist the fuses during removal or installation. Twisting could force the terminal open too far, resulting in a bad connection. Be sure to replace blown fuses with the correct type and amp rating. Fuses of different ratings are physically interchangeable, but replacing a fuse with one of a higher or lower value than specified is not recom-

mended. Each

electrical circuit

needs a spe-

Cartridge-type fusible links (maxi-fuses)

Some links.

e)

f)

links are

used

in

are not ordinarily fused, such as the ignition circuit. In

fusible

link

(described

below)

which

tion) their

turn off all electrical

is

usually

components and the

igni-

switch before replacing a fuse. Never bypass a fuse with pieces of metal or foil. Serious damage to the electrical system could result. If the replacement fuse immediately fails, do not replace it again until the cause of the tion

problem

is

cases, this

isolated will

and corrected.

be a short

In

be repaired, a new should be installed dure is as follows: a)

caused by a broken or deteriorated

wire.

6

into place.

to obtain

Connect the battery ground

cable. Test

Circuit breakers

-

general

information

link of in its

the

same

place.

size wire

The proce-

Disconnect the cable from the negative

Refer to

b)

illustration 6.3

Circuit

breakers protect accessories

such as the windshield wipers, windshield washer pump, interval wiper, low washer breakers are located in the box or interior fuse box. Refer to the cover of your fuse box or the fuse panel guide in your owner's manual for the location of the circuit breakers used in fluid, etc. Circuit

power

distribution

your vehicle.

Because a

battery terminal.

most

the wiring

it

rosin core solder at

after

c)

circuit in

connector on the new

and crimp

the circuit for proper operation.

is

removing the link. Conventional type fusible links cannot

value of each fuse

The amperage molded into the

the

in

shows common amperage values and corresponding colors. Caution: Always

of protection.

h)

addition to the conventional type of

the wiring harness (see illustration), there is also cartridge type fusible links located in the engine compartment fuse

located

Use

new link

by fusible circuits which

fuse body. Different colors are also used to denote fuses of different amperage types. The accompanying color code (see illustra-

amount

Position

each end of the a good solder joint. g) Use plenty of electrical tape around the soldered joint. No wires should be exposed.

and 5.2b

circuits are protected

These

back approximately

1/2-inch.

block that are similar to a large fuses and, disconnecting the negative battery cable, are simply unplugged and replaced by a unit of the same amperage (see illustration). Some fusible links are held in place by a screw which must be loosened before

cific

Strip the insulation

fusible link

fuse puller to remove and insert fuses. Don't

relays,

Relays

d)

illustrations 5.2a

box contains

and fuses

Mini- fuses

general

Fusible links information Refer to

Green

Light

circuit

breaker resets

Disconnect the fusible link from the

automatically, an electrical overload

wiring harness.

cuit

Cut the damaged fusible link out of the wiring just behind the connector.

circuit to

in

itself

a

cir-

breaker protected system will cause the fail momentarily, then come back on. If the circuit does not come back on, check it immediately.

12

12-4

Chapter 12

Chassis electrical system Power

Control circuts

circuts

7.4

Most

relays are

marked on

the outside to easily identify the control and power circuits

6.3 Perform a continuity test with an

ohmmeter to check infinite

a circuit breaker resistance indicates a bad circuit

-

breaker defective, that

a)

Remove

the circuit breaker from the fuse

panel. Note: The circuit breaker for the is mounted behind the glove compartment. Using an ohmmeter, verify that there is continuity between both terminals of the

rear wiper

b)

circuit is

no

breaker (see continuity,

illustration).

If

there

replace the circuit

breaker. c)

Install the

old or

new

circuit breaker.

component

will

not operate

5

The various relays are mounted in engine compartment (see illustration 5.2b) and several locations throughout the vehicle (see Chapter

5).

If

a faulty relay

between the relay power example illustrated here, there should be no continuity between terminal 30 and 87. Connect a fused jumper wire between 6 one of the two control circuit terminals and the positive battery terminal. Connect another jumper wire between the other control circuit terminal and ground. When the connections are made, the relay should click. On some relays, polarity may be critical, so, if the relay doesn't click, try swapping the jumper wires on the control circuit terminals. 7 With the jumper wires connected, check for continuity between the power circuit terminals. Now, there should be continuity between terminals 30 and 87. If the relay fails any of the above tests, 8

can be removed and tested using the procedure below or by a dealer service department or other repair shop. Defective relays must be replaced as a unit. it

Testing If it

continues to cut out, a short circuit is indicated. Troubleshoot the appropriate

diagrams at the book) or have the system

Refer to 2

illustration 7.4

It's

best to refer to the wiring diagram determine the proper hook-

circuit (see the wiring

for the circuit to

back of this checked by a professional mechanic.

ups for the relay you're testing. However, if you're not able to determine the correct hook-up from the wiring diagrams, you may be able to determine the test hook-ups from

7

Relays

general information and

the information that follows.

On most relays, two of the terminals are 3 the relay's control circuit (they connect to the

testing

relay coil which,

General information Several electrical accessories in the vehicle, such as the fuel injection system, horns, starter, and fog lamps use relays to transmit the electrical signal to the component. Relays use a low-current circuit (the control circuit) to open and close a high-cur-

power

circuit).

replace

If

the relay

is

control circuit coil

4

The

is

relays are

it.

energized, closes the

complete the circuit). The other terminals are the power circuit (they are connected together within the relay when the large contacts to

1

rent circuit (the

when

the relay from the vehicle and

for continuity

circuit terminals. In the

suspected,

is

Remove

check

properly.

energized).

marked as an

check and

Multi-function switch

replacement Warning: On models equipped with airbags, disconnect the negative battery cable, then the positive battery cable and wait two minutes before working in the vicinity of the

aid to help

you determine which terminals are the control circuit and which are the power circuit (see illustration).

Switch positions

Hazard warning

Continuity between

Neutral

OFF

1 and 6; 1 and 8 3 and S; 3 and 8 3 and 2; 3 and 6

ON OFF OFF

Left

Right

4 and 4 and

6; 8;

4 and 2 4 and 5

8.2b Turn signal and hazard switch continuity chart

Switch positions

Continuity between

Flash to Pass hold lever in this position

12 and 11 9 and 10

beam Low beam

9 and 10

High

8.2a Multi-function switch terminal identification guide

8.2c Headlight

9

dimmer switch

and 11

continuity chart

Chapter 12

12-5

Chassis electrical system

Ohmmeter readings

(

Switch positions

Test terminals

Wiper OFF

13 and 14

47.6

Wash OFF

14 and 15

103.3 K

Intermltent

13

and 13 and 13 and 14 and

11.3K-ohms 4.08 K-ohma 0-ohms 0-ohms

Low High

Wash ON Wiper OFF Delay control knob

14 14 14

16

or

- 10%)

K -ohms

14 and 15

103.3

14 and 16

3.3

ohms

K-ohms

@ maximum position Delay control knob

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Chapter 12

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12-23

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12-24

Chassis electrical system

Chapter 12

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12-26

Chapter 12

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Chapter 12

Chassis electrical system

12-27

MULTIPLEX AIR

COMMUNICATION

CONDITIONER HEATER

NETWOHK

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•

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-

4.0L

SOHC V6 engine

(6 of 7)

12-28

Chapter 12

Chassis electrical system

HOI

MAUI

IN

C131

|

|

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RUNNING LAMPS (DRL) MODULE

Typical headlight system

—cm tdayjjme I

BH HEADLAMP

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DB/LG DB/LG

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12

12-36

Chapter 12

Chassis electrical system

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(1

of 2)

OVERHEAD CONSOLE

Chapter 12

Chassis electrical system

12-37

FROM C2 It DIMMER MODULI

T

S3

OK IB

J

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53 []

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Chapter 12

Chassis electrical system

12-39

AUTO LAMPS

BR

cut RM FROWT AUTOMATIC DAY /NIGHT

MIRRORS

I

I

PARK/TUBM

|

|

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L__J BEMQIE

m

ANTI-THEFT PERSONALITY

MODULE

(RAP)

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FROM

(1

of 2)

S244

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W/O LAMP OUT WARNING 14

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&2Q4

12

12-40

Chapter 12

Chassis electrical system

TRANSMISSION

CONTROLS

P/O .

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I

f

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CONTROLS

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oil

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1

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REAR

\

power window system

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|

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-

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BOX

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(2 of 2)

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power window system

-

1995 and

later

(1

of 3)

—

.

12-42

Chassis electrical system

Chapter 12

T

INSTRUMENT ILLUMINATION

400 DO I LB BK

JT

C245F

C245M

R BK 235

400 R LB BK C5Q1 12

5

to

T MASTtB

window

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CONTROL

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RIGHT

/ /_-

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WINDOW SWITCH PAGE 100-2

-

:

-

1995 and

}

later (2 of 3)

n

H

FROM

power window system

PQWEB WINDOW MQIQB

|

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|

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S409

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CONTROL

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£221

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LIFTGATE

WASHER PUMP Ihqiqb

cb^smcH C438 Y— -

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£41i

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57 I |

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washer system

57

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later

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of 2)

0302

p

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Chapter 12

Chassis electrical system

12-47

FROM BATTERY SAVER RELAY "

•

POWtH

|

D1STRJ0U1IQH

m \«* ii 1M

C2B1

V

SS7 Q

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•

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Typical liftgate wiper and washer system

-

1995 and

later (2 of 2)

BJBHBCB r-i r—'T

"

|

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\

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511

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|

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|

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lLL. j C2B9Y

(cpp)

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306(1 T/LB

AUTOMATIC TRANSMISSION W CENTER CONSOLE

LG

511

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r*7*"> CJLUICH I

BRAKE ON/OFF (BOO) SWITCH

AC2Q9 r,TTCLUICH I*

|

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I •

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306 B T/LB

306 I H T/LB

306

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switch

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INPUT

I

12

12-48

Chapter 12

Chassis electrical system

CMM

MtTWUMtNT

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nJL

tML. If

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2)

Cruise control circuit

I

INTERIOR

UBR/O Q

364 Q

C21Z 181

UBR/O

CI 79

'I *

J

BLOWER HELAY

I

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defrost switch

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C2il

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(1

of 2)

df

C2J1

aim

Chapter 12

Chassis electrical system

12-49

miTf-H r vr.uN Q PRESSURE SWITCH

NORMALLY OPEN AT OR BELOW IH CLOSED AT OR ABOVE 2*J kP« (41 I

kP»

(24 S p«i)

pil)

0202

AiC.

COMPREaSOB CLUTCH SOLENOID

Typical heating and air conditioning system (2 of

2)

m FRONT SPEAKER

12

*

Q2B2

Typical base model audio system

12-50

Notes

IND-1

Index About

this manual, 0-2 Accelerator cable, removal, installation and adjustment, 4-11 Acknowledgements, 0-2

Air cleaner housing,

removal and

installation,

4-10

Air conditioning

accumulator/drier, removal and installation, 3-16

and heating system, check and maintenance, 3-12 compressor, removal and installation, 3-14 condenser, removal and installation, 3-15 evaporator and expansion valve, removal and installation, 3-16 expansion (orifice) tube, removal and installation, 3-17 Air filter replacement, 1-22

Body, 11-1 through 11-26 bumper (front) and valance, removal and installation, 11-18 bumper (rear), removal and installation, 11-18 center console, removal and installation, 1 1-26 cowl cover, removal and installation, 1 1-25 door hinge, removal and installation, 1 1-7 latch striker, removal, installation and adjustment, 11-7 lock cylinder, removal and installation, 11-9 removal, installation and alignment, 11-7 trim panel and watershield, removal and installation, 11-9 door window glass, front, replacement and adjustment, 11-11 door window regulator, front, replacement, 11-11 fender (front) removal and installation, 11-17

Airbag, general information, 12-19

general information, 11-1

Alignment, general information, 10-25 Alternator, removal and installation, 5-10 Antifreeze, general information, 3-2

hinges and locks, maintenance, 11-3

Anti-lock Brake System (ABS), general information, 9-2 Automatic Ride Control system, general information, 10-17 Automatic transmission, 7B-1 through 7B-8 brake/transmission shift interlock system (1995 and later models), description, check and solenoid replacement, 7B-4 diagnosis, general, 7B-2

check/change, 1-13 general information, 7B-1 neutral-start switch (1994 and

fluid

earlier models), removal,

and adjustment, 7B-4 removal and installation, 7B-6 cable

adjustment, 7B-2

removal and

installation,

7B-3

replacement and adjustment, 7B-3 lever assembly, removal and installation, 7B-3 linkage lubrication, 1-19

shift indicator cable, shift shift

latch control cable, removal and installation, 1 1-6 hood, removal, installation and adjustment, 11-3 inner door handle and latch assembly, removal and installation, 11-8

instrument cluster bezel, removal and installation,

1

1-21

instrument panel, removal and installation, 11-22 liftgate

glass and hinge, removal and installation, 11-15

and latches, removal and installation, 11-13 removal and installation, 11-13 maintenance, 11-1 outer door handle, removal and installation, 1 1 -9 radiator grille, removal and installation, 11-16 rear door window glass, replacement, 11-13 rear door window regulator, replacement, 11-13 panel, lock cylinder

installation

shift

hood

transmission control switch (1996 and later models), check and

replacement, 7B-4 transmission range sensor (1995 and later models), check and

replacement, 7B-5

vacuum diaphragm (1994 and

earlier models), removal and 7B-6 Automotive chemicals and lubricants, 0-14 Axle arm (front) (1991 through 1994 2WD models), removal and installation,

installation, 10-11 Axle assembly, removal and installation 4WD models, front, 8-15 rear, 8-1

Axle pivot bracket (1991 through 1994 models), removal and installation, 10-11 Axle pivot bushing (1991 through 1994 models), removal and installation, 10-11 Axle, rear, description and check, 8-11 Axleshafts (rear), bearings and oil seals, removal and installation, 8-12

repair

major damage, 11-3 minor damage, 11-2 seat belt check, 11-21 seats, removal and installation, 11-19 sideview mirrors, removal and installation, 1 1-25 steering column cover, removal and installation, 11-25 upholstery and carpets, maintenance, 11-2 vinyl trim, maintenance, 11-2 windshield glass, removal and installation, 11-19 Booster battery (jump) starting, 0-13 Brake light switch, replacement, 12-18 Brake On-Off (BOO) switch, check, 6-22 Brakes, 9-1 through 9-22 Anti-lock Brake System (ABS), general information, 9-2 brake disc, inspection, removal and installation, 9-8 brake light switch, removal and installation, 9-21 caliper, removal and installation, 9-8 check, 1-28 general information, 9-2 hoses and lines, inspection and replacement, 9-14 hydraulic system, bleeding, 9-14 master cylinder, removal and installation, 9-13 pads, replacement, 9-5 parking brake

B

adjustment, 9-15 cables, replacement, 9-15

Balljoints,

removal and

installation, 10-7

Battery

and replacement, 5-3 and charging, 1-16 maintenance check, emergency jump starting, 0-13 removal and installation, 5-2

cables, check

shoes

(rear disc

brakes

only),

inspection and replacement, 9-19

power brake booster, check, removal,

installation

and

adjustment, 9-20

shoes wheel

(rear),

replacement, 9-9 removal and installation, 9-12

cylinder,

IND

3

IND-2

1

Index

Brake/transmission shift interlock system (1995 and later models), description, check and solenoid replacement, 7B-4 Bulb replacement, 12-12 Bumper (front) and valance, removal and installation, 11-18 Bumper (rear), removal and installation, 11-18

Buying parts, 0-6

Coil spring (1991 through 1994 models),

removal and

installation, 10-9

Connectors, general information, 12-2 Conversion factors, 0-15 Coolant reservoir, removal and installation, 3-5 Coolant temperature sending unit, removal and installation, 3-6 Cooling fan and viscous clutch, inspection, removal and installation, 3-4

Cooling system

Camshaft position (CMP) sensor, check and replacement, 6-18 Camshaft, removal, inspection and installation 4.0L (pushrod) V6 engine, 2A-14 4.0L SOHC V6 engine, 2B-12 5.0L V8 engine, 2C-11

check, 1-24

air

conditioning

and installation, 3-16 and heating system, check and maintenance, 3-12 compressor, removal and installation, 3-14 condenser, removal and installation, 3-15 evaporator and expansion valve, removal and installation, 3-16 expansion (orifice) tube, removal and installation, 3-17

Center console, removal and installation, 11-26 Charging system general information and precautions, 5-9

antifreeze, general information, 3-2

Chassis electrical system, 12-1 through 12-20

coolant reservoir, removal and installation, 3-5

airbag, general information, 12-19

coolant temperature sending

brake light switch, replacement, 12-18 bulb replacement, 12-12 circuit breakers, general information, 12-3 connectors, general information, 12-2

unit,

removal and

installation,

3-6

cooling fan and viscous clutch, inspection, removal and

3-4

installation,

cooler (5.0L V8 only), removal and installation, 3-6 general information, 3-2

engine

door lock system, power, general information, 12-19

oil

heater and

electrical troubleshooting, general information, 12-1

air

conditioning blower motor

check, 3-9 replacement, 3-10

and

fuses, general information, 12-2 fusible links, general information, 12-3

gauges and speedometer cable, removal and

air

accumulator/drier, removal

Catalytic converter, 6-28

general operating check, 5-9

and refilling), 1-35 conditioning systems, 3-1 through 3-18

servicing (draining, flushing

Cooling, heating and

circuit,

heater installation,

12-17

and

general information, 12-1 headlight bulb, replacement, 12-11

headlights, adjusting, 12-11

heated rear window and rear wiper switch, removal and installation, 12-10 ignition lock cylinder, replacement, 12-7 ignition switch, check and replacement, 12-6 instrument cluster, removal and installation, 12-16 mirrors, power, removal and installation, 12-18 multi-function switch, check and replacement, 12-4 power window system, general information, 12-18 radio antenna, removal and installation, 12-16 radio, removal and installation, 12-15 relays, general information and testing, 12-4 speakers, removal and installation, 12-16 turn signal/hazard flasher relay, check and replacement, 12-6 windshield washer reservoir and pump assembly, removal and installation, 12-8 windshield wiper

arm, removal and installation, 12-8 motor, removal and installation, 12-7 wiring diagrams, general information, 12-19

Chassis lubrication, 1-19 Circuit breakers, general information, 12-3

Clutch components, removal, inspection and installation, 8-3 description and check, 8-2 hydraulic line quick-disconnect fittings, general information, 8-6 hydraulic system, bleeding, 8-7 master cylinder and reservoir, removal and installation, 8-6 pedal, removal and installation, 8-7

conditioning control assembly, removal and

control cables,

headlight housing, removal and installation, 12-11 headlight switch, replacement, 12-9

air

installation,

3-7

check and adjustment, 3-8

core, replacement, 3-11 radiator,

removal and

installation,

3-3

thermostat, check and replacement, 3-2 water pump, check and replacement, 3-6

Cowl cover, removal and

installation,

11-25

Crankshaft

2D-19 and main bearing oil clearance check, 2D-22 removal, 2D-15 Crankshaft front oil seal, replacement 4.0L (pushrod) V6 engine, 2A-17 4.0L SOHC V6 engine, 2B-10 5.0L V8 engine, 2C-7 Crankshaft position (CKP) sensor, check and replacement, 6-17 Crankshaft rear main oil seal, replacement 4.0L (pushrod) V6 engine, 2A-18 4.0L SOHC V6 engine, 2A-18 5.0LV8 engine, 2C-1 Cylinder compression check, 2D-6 inspection, installation

Cylinder head cleaning and inspection, 2D-1

disassembly, 2D-10 reassembly, 2D-13

Cylinder head, removal and installation 4.0L (pushrod) V6 engine, 2A-9 4.0L SOHC V6 engine, 2B-7 5.0L V8 engine, 2C-6 Cylinder honing, 2D-17

release bearing, removal, inspection and installation, 8-4 release cylinder, removal and installation, 8-6 Clutch and drivetrain, 8-1 through 8-22

Clutch/starter interlock switch, removal and installation, 8-7

Differential lubricant level

check and change, 1-20

Door hinge, removal

and

installation,

11-7

Index latch striker, removal, installation

lock cylinder, removal

and

and adjustment,

installation,

1 1

-7

ignition timing,

11-9

trim panel and watershield, removal and installation, 11-9 Double-cardan type U-joint, overhaul, 8-9 Drag link (1991 through 1994 models), removal and installation,

10-19 Driveplate, removal

and

and replacement, 1-15

5.0L V8 engine, 2C-1 and driveaxle yoke lubrication (4WD models), 1 -36 Driveshaft and universal joints, description and check, 8-8 Dri veshaft

and

installation, 8-8

Electrical troubleshooting, general information, 12-1

Electronic shift control module, removal and installation, 7C-4 Electronic shift controls, removal and installation, 7C-3

Emissions and engine control systems, 6-1 through 6-28 Brake On-Off (BOO) switch, check, 6-22 camshaft position (CMP) sensor, check and replacement, 6-18 catalytic converter,

6-28

crankshaft position (CKP) sensor, check and replacement, 6-17

Engine Coolant Temperature (ECT) sensor, check and replacement, 6-16 Evaporative Emissions Control System (EVAP), 6-27 Exhaust Gas Recirculation (EGR) system, 6-24 general information, 6-1 Idle Air Control (IAC) valve,

check and replacement, 6-23

information sensors, 6-5 inlet air

temperature control system (1994 and

Intake Air Temperature (IAT) sensor,

earlier models),

6-24

check and replacement, 6-16

knock sensor, general information, 6-21 Mass Airflow (MAF) sensor, check and replacement, 6-15 OBD-I Trouble Codes, 6-7 OBD-II Trouble Codes, 6-12 On Board Diagnosis (OBD) system and trouble codes, 6-4 oxygen sensor (02S), check and replacement, 6-20 Positive Crankcase Ventilation (PCV) system, 6-23 Power Steering Pressure (PSP) switch, check and replacement, 6-20 Powertrain Control Module (PCM), replacement, 6-13 Throttle Position Sensor (TPS), check and replacement, 6-14 Transmission Range (TR) sensor, general information, 6-22 Vehicle Speed Sensor (VSS), check and replacement, 6-22 Engine Coolant Temperature (ECT) sensor, check and replacement, 6-16 Engine electrical systems, 5-1 through 5-12 alternator, removal and installation, 5-10 battery

cables, check and replacement, 5-3

emergency jump starting, 0-13 removal and installation, 5-2 charging system general information and precautions, 5-9 general operating check, 5-9 general information, 5-2 ignition coil, check and replacement, 5-6 Ignition Control

Module (ICM) (1991-1995 models), check and

replacement, 5-8 ignition

system

general information, 5-4 general operating check, 5-5

starter solenoid, replacement,

5-12

and precautions, 5-1 voltage regulator/alternator brushes, removal and installation, 5starting system, general information

10

installation

4.0L (pushrod) V6 engine, 2A-18 4.0L SOHC V6 engine, 2B-15

Driveshafts, removal

check, 5-9

motor removal and installation, 5-12 and circuit, in-vehicle check, 5-1 starter relay, removal and installation, 5-12 starter

lock system, power, general information, 12-19 removal, installation and alignment, 11-7

Drivebelt check, adjustment

IND-3

Engine oil and filter change, 1-11 Engine oil cooler (5.0L V8 only), removal and installation, 3-6 Engines 4.0L (pushrod) V6 engine, 2A-1 through 2A-20 camshaft, removal, inspection and installation, 2A-14 crankshaft oil seals, replacement, 2A-17 crankshaft pulley, front oil seal and timing chain cover, removal and installation, 2A-1 cylinder heads, removal and installation, 2A-9 exhaust manifolds, removal and installation, 2A-9 flywheel/driveplate, removal and installation, 2A-18 general information, 2A-3 intake manifold, removal and installation, 2A-8 mounts, check and replacement, 2A-19 oil pan and baffle, removal and installation, 2A-16 oil pump, removal and installation, 2A-17 repair operations possible with the engine in the vehicle, 2A-3 rocker arms and pushrods, removal, inspection and installation, 2A-6 timing chain and sprockets, inspection, removal and installation, 2A-12 Top Dead Center (TDC) for number one piston, locating, 2A-3 valve covers, removal and installation, 2A-4 valve lifters, removal, inspection and installation, 2A-14 valve springs, retainers and seals, replacement, 2A-7 4.0L SOHC V6 engine, 2B-1 through 2B-16 camshafts, removal, inspection and installation, 2B-12 crankshaft pulley and front oil seal, removal and installation, 2B-10 cylinder heads, removal and installation, 2B-7 exhaust manifolds, removal and installation, 2B-6 flywheel/driveplate, removal and installation, 2B-15 general information, 2B-2 intake manifold (lower), removal and installation, 2B-6 mounts, check and replacement, 2B-15 oil pan, removal and installation, 2B-13 oil pump, removal and installation, 2B-14 rear main oil seal, replacement, 2B-15 repair operations possible with the engine in the vehicle, 2B-2 rocker arms and lash adjusters, removal, inspection and installation, 2B-4 timing chain and sprockets, inspection, removal and installation, 2B-10 Top Dead Center (TDC) for number one piston, locating, 2B-3 valve covers, removal and installation, 2B-3 valve springs, retainers and seals, replacement, 2B-5 5.0L V8 engine, 2C-1 through 2C-14 camshaft, removal, inspection and installation, 2C-11 crankshaft front oil seal, replacement, 2C-7 crankshaft rear main seal, replacement, 2C-13 cylinder head(s), removal and installation, 2C-6 driveplate, removal and installation, 2C-13 exhaust manifold(s), removal and installation, 2C-6 general information, 2C-2 intake manifold, removal and installation, 2C-5 mounts, check and replacement, 2C-13 oil pan, removal and installation, 2C-12 oil pump, removal and installation, 2C-12 repair operations possible with the engine in the vehicle, 2C-2

IND

7

1

IND-4

Index

rocker arms and pushrods, removal, inspection and

2C-3 timing chain and sprockets, inspection, removal and installation, 2C-9 timing chain cover, removal and installation, 2C-8 Top Dead Center (TDC) for number one piston, locating, 2C-2 valve covers, removal and installation, 2C-3 valve lifters, removal, inspection and installation, 2C-10 valve springs, retainers and seals, replacement, 2C-4 installation,

general engine overhaul procedures

crankshaft

2D-19 and main bearing oil clearance check, 2D-22 removal, 2D-15 cylinder compression check, 2D-6 cylinder head cleaning and inspection, 2D-11 reassembly, 2D-13 disassembly, 2D-10 inspection, installation

Front axleshaft and joint assembly, removal, replacement and installation, 8-17 Front door

window glass, replacement and adjustment, 11-11 window regulator, replacement. 11-11 Front hub lock, spindle bearing and wheel bearing maintenance (1994 and earlier 4WD models), 1-31 automatic locking hubs, 1-33 manual locking hubs. 1-32 Fuel and exhaust systems, 4-1 through 4-18 accelerator cable, removal, installation and adjustment. 4-1 air cleaner housing, removal and installation. 4-10 exhaust system servicing, general information. 4-17 fuel injection

system

check. 4-12 general information, 4-12

fuel

sending unit, check and replacement, 4-9 pressure regulator, removal and installation, 4-15

fuel

rail

fuel level

and

injectors,

removal and

cylinder honing, 2D-1

general information, 4-3

engine block

lines

and

pressure

engine overhaul disassembly sequence, 2D-9 reassembly sequence, 2D-20 engine rebuilding alternatives, 2D-9 engine removal, methods and precautions, 2D-7 engine, removal and installation, 2D-8 general information, engine overhaul, 2D-5

and break-in after overhaul, 2D-25 and balance shaft (4.0L SOHC V6 only), installation, 2D-24 jackshaft, balance shaft and bearings (4.0L SOHC V6 removal and inspection, 2D-14 main and connecting rod bearings, inspection, 2D-19 oil pressure check, 2D-5 piston rings, installation, 2D-21

installation,

4-16

general information, 4-5 procedure, 4-3 pump, removal and installation, 4-8 pump/fuel pressure, check, 4-4

2D-16 inspection, 2D-17

cleaning,

initial

component

fittings,

relief

Sequential Electronic Fuel Injection (SEFI), 4-12

tank cleaning and repair, 4-8

removal and throttle

installation,

body and upper

installation,

and

4-13

Variable Induction (VIS)

start-up

4-7

intake manifold, removal

System (1997 and

later

4.0L

SOHC

engine), 4-17

jackshaft

Fuel only),

filter

replacement, 1-24

Fuel system check, 1 -24 Fuses, general information, 12-2 Fusible links, general information, 12-3

pistons/connecting rods

2D-18 and rod bearing oil clearance check, 2D-23 removal, 2D-14 vacuum gauge diagnostic checks, 2D-6 valves, servicing, 2D-13 Evaporative Emissions Control System (EVAP), 6-27 Exhaust Gas Recirculation (EGR) system, 6-24 Exhaust manifold(s), removal and installation 4.0L (pushrod) V6 engine, 2A-9 4.0L SOHC V6 engine, 2B-6 5.0L V8 engine, 2C-6 Exhaust system inspection, installation

check, 1-25 servicing, general information, 4-17

Extension housing

oil

seal

Gauges and speedometer

cable, removal and installation, 12-17 General engine overhaul procedures, 2D-1 through 2D-26 crankshaft

2D-19 and main bearing oil clearance check, 2D-22 removal, 2D- 15 cylinder compression check, 2D-6 cylinder head cleaning and inspection, 2D-11 disassembly, 2D-10 reassembly, 2D-13 cylinder honing, 2D-17 inspection, installation

engine block

(2WD models), replacement, 7A-4

cleaning,

2D-16 2D-17

inspection,

Fender

(front),

removal and

installation,

11-17

Fluid level checks, 1-7

brake and clutch fluid, 1-8 engine coolant, 1-8 engine oil, 1-7 windshield washer fluid, 1-9 Flywheel, inspection, 8-4 Flywheel/driveplate, removal and installation 4.0L (pushrod) V6 engine, 2A-18

4.0L

SOHC V6

engine, 2B-15

engine overhaul disassembly sequence, 2D-9 reassembly sequence, 2D-20 engine rebuilding alternatives, 2D-9 engine removal, methods and precautions, 2D-7 engine, removal and installation, 2D-8

and break-in after overhaul, 2D-25 and balance shaft (4.0L SOHC V6 only), installation, 2D-24 jackshaft, balance shaft and bearings (4.0L SOHC V6 removal and inspection, 2D-14 main and connecting rod bearings, inspection, 2D-19 oil pressure check, 2D-5 initial

start-up

jackshaft

only),

Index piston rings, installation, 2D-21

IND-5

Jackshaft, balance shaft and bearings (4.0L removal and inspection, 2D-14

pistons/connecting rods

2D-18 and rod bearing oil clearance check, 2D-23 removal, 2D-14 vacuum gauge diagnostic checks, 2D-6 valves, servicing, 2D-13

SOHC

V6

only),

inspection, installation

K Knock sensor, general

information, 6-21

H Headlight bulb, replacement, 12-11 housing, removal and installation, 12-11 switch, replacement, 12-9 Headlights, adjusting, 12-11

Heated rear window and rear wiper switch, removal and installation, 12-10 Heater and air conditioning blower motor and circuit, check, 3-9 replacement, 3-10 Heater and air conditioning control assembly, removal and installation,

control cables,

3-7

check and adjustment, 3-8

Leaf spring, rear, removal and installation, 10-15 Liftgate

glass and hinge, removal and installation, 11-15 panel, lock cylinder and latches, removal and installation, 11-13 removal and installation, 11-13 Linkage adjustment, manual-shift transfer case, 7C-2 Lower control arm (1995 and later models), removal, inspection and installation, 10-12

M Main and connecting rod bearings, inspection, 2D-19 Maintenance

core, replacement, 3-1

schedule, 1-6

Hinges and locks, maintenance, 11-3 Hood latch control cable, removal and installation, 11-6 Hood, removal, installation and adjustment, 11-3 Hub and bearing assembly, front (1995 and later 4WD models), removal and installation, 10-6

Control (IAC) valve, check and replacement, 6-23 check and replacement, 5-6 Ignition Control Module (ICM) (1991 -1995 models), check and replacement, 5-8 Ignition lock cylinder, replacement, 12-7 Ignition switch, check and replacement, 12-6 Idle Air

Ignition coil,

Ignition

system

general information, 5-4 general operating check, 5-5 Ignition timing, check, 5-9

Information sensors, 6-5 Initial start-up and break-in after overhaul, 2D-25 Inlet air temperature control system (1994 and earlier models), 6-24 Inner door handle and latch assembly, removal and installation, 11-8

Instrument cluster bezel, removal and installation, 11-21 removal and installation, 12-16 Instrument panel, removal and installation, 11-22 Intake Air Temperature (IAT) sensor, check and replacement, 6-16 Intake manifold, removal and installation 4.0L (pushrod) V6 engine, 2A-8 4.0L SOHC V6 engine, 2B-6 5.0L V8 engine, 2C-5 Introduction to the Ford Explorer, Mountaineer, 0-4

Jacking and towing, 0-12 Jackshaft and balance shaft (4.0L installation,

2D-24

Mazda Navajo, and Mercury

SOHC V6 only),

techniques, tools and working

facilities,

0-6

Manual transmission, 7A-1 through 7A-4 extension housing oil seal (2WD models), replacement, 7A-4 general information, 7A-2

check and change, 1-20 mount, check and replacement, 7A-2 overhaul, general information, 7A-4 removal and installation, 7A-3 Shift lever, removal and installation, 7A-2 speedometerA/SS pinion gear and seal, removal and installation, 7A-4 Mass Airflow (MAF) sensor, check and replacement, 6-15 Master cylinder (brake), removal and installation, 9-13 Mirrors, power, removal and installation, 12-18 Mount, transmission, check and replacement, 7A-2 lubricant level

Mounts, check and replacement 4.0L (pushrod) V6 engine, 2A-19 4.0L SOHC V6 engine, 2B-15 5.0L V8 engine, 2C-1 Multi-function switch,

check and replacement, 12-4

N and earlier models), removal, and adjustment, 7B-4

Neutral-start switch (1994 installation

OBD-I Trouble Codes, 6-7 OBD-II Trouble Codes, 6-12 Oil pan, removal and installation 4.0L (pushrod) V6 engine, 2A-16 4.0L SOHC V6 engine, 2B-13 5.0LV8 engine, 2C-1 Oil pressure check, 2D-5 Oil pump, removal and installation 4.0L (pushrod) V6 engine, 2A-17 4.0L SOHC V6 engine, 2B-14 5.0L V8 engine, 2C-1 On Board Diagnosis (OBD) system and trouble codes, 6-4 Outer door handle, removal and installation, 11-9

IND

IND-6

Index

Output shaft

Owner

seals, front

oil

installation,

and

rear,

removal and

removal and

safety checks, 1-11

Oxygen sensor

(02S),

Shift cable (automatic transmission)

adjustment. 7B-2

7C-4

check and replacement, 6-20

7B-3 replacement and adjustment, 7B-3 Shift lever assembly, removal and installation, 7B-3 Shift lever, removal and installation, 7A-2, 7C-2 Shock absorbers, inspection, removal and installation front,

rear,

Parking brake adjustment, 9-15 cables, replacement, 9-15

shoes

(rear disc

brakes

Pilot bearing, inspection

only), inspection

and replacement, 9-19

and replacement, 8-5

Piston rings, installation, 2D-21

Pistons/connecting rods

2D-18 and rod bearing removal, 2D-14 inspection, installation

oil

clearance check, 2D-23

Crankcase Ventilation (PCV) system, 6-23 Positive Crankcase Ventilation (PCV) valve check and replacement, 1-23 Power brake booster, check, removal, installation and adjustment, 9-20

Power

steering

fluid level

check, 1-12

10-24 pump, removal and installation, 10-22 system bleeding, 10-25 line

quick-disconnect

fittings,

Power Steering Pressure (PSP) switch, check and replacement, 6-20 Powertrain Control Module (PCM), replacement, 6-13

10-4 10-15

Sideview mirrors, removal and installation, 11-25 Single cardan type U-joint, overhaul, 8-9 Spark plug and wire check and replacement, 1-17 Speakers, removal and installation, 12-16 SpeedometerA/SS pinion gear and seal, removal and installation, 7A-4 Stabilizer bar, removal and installation front,

rear,

Positive

installation.

Shift indicator cable,

motor

Starter

and

10-14 10-16

circuit, in-vehicle

removal and

check, 5-11 5-12

installation,

Starter relay, removal and installation, 5-12 Starter solenoid, replacement, 5-12 Starting system, general information and precautions, 5-11

Steering and suspension check, 1-26 Steering column cover, removal and installation, 11-25 Steering system drag link (1991 through 1994 models), removal and installation, 10-19 gear, removal and installation, 10-20 general information, 10-3, 10-17

power line

steering

quick-disconnect

pump, removal and

fittings,

10-24 10-22

installation,

system bleeding, 10-25 Radiator

grille,

removal and

installation,

11-16

Radiator, removal and installation, 3-3

Radio antenna, removal and installation, 12-16 Radio, removal and installation, 12-15 Radius arm (1991 through 1994 models), removal and installation,

10-10

Radius arm insulators (1991 through 1994 models), replacement, 10-10 Rear anti-windup bar (5.0L V8 models only), removal and installation,

Rear door window

10-16

steering connecting rod (1991 through 1994 models), removal

and

installation,

10-20

and installation, 10-18 and installation, 10-20

steering wheel, removal tie-rod ends, removal

wheel alignment, general information, 10-25 wheels and tires, general information, 10-26 Suspension and steering systems, 10-1 through 10-26

Suspension system Automatic Ride Control system, general information, 10-17 axle pivot bracket (1991 through 1994 models), removal and installation,

10-11

11-13 window regulator, replacement, 11-13 Rear main oil seal, replacement, 4.0L SOHC V6 engine, 2B-15 Relays, general information and testing, 12-4 Repair operations possible with the engine in the vehicle 4.0L (pushrod) V6 engine, 2A-3 4.0L SOHC V6 engine, 2B-2

axle pivot bushing (1991 through 1994 models), removal

5.0L V8 engine, 2C-2 Right stub shaft assembly, carrier oil seals and bearings (1994 and earlier models), removal and installation, 8-20 Rocker arms and lash adjusters, removal, inspection and installation, 4.0L SOHC V6 engine, 2B-4 Rocker arms and pushrods, removal, inspection and installation 4.0L (pushrod) V6 engine, 2A-6

front

glass, replacement,

5.0LV8 engine, 2C-3

installation, balljoints, coil

removal and

installation,

10-7

spring (1991 through 1994 models), removal and installation,

front axle

10-9

arm (1991 through 1994

installation,

2WD

models), removal and

10-11

wheel spindle, removal and

installation,

10-5

general information, 10-3

hub and bearing assembly, front (1995 and later 4WD models), removal and installation, 10-6 lower control arm (1995 and later models), removal, inspection and installation, 10-12 radius arm (1991 through 1994 models), removal and installation,

radius

arm

10-10

insulators (1991 through

1994 models),

replacement, 10-10 rear anti-windup bar (5.0L V8 models

10-16 spring, removal and

only),

removal and

installation, first!, 0-16 Seat belt check, 11-21 Seats, removal and installation, 11-19

Safety

and

10-11

rear leaf

installation,

10-15

shock absorbers, inspection, removal and front,

10-4

installation

Index rear,

10-15

overhaul, general information, 7A-4

removal and front, 10-14 rear, 10-16

stabilizer bar,

torsion bar (1995 installation,

IND-7

and

later

installation

models), removal and

10-14

upper control arm (1995 and and installation, 10-13

later

models), removal, inspection

removal and installation. 7A-3 shift lever, removal and installation, 7A-2 speedometerA/SS pinion gear and seal, removal and installation, 7A-4 Trouble Codes OBD-I, 6-7

OBD-11,6-12 Troubleshooting, 0-17

Thermostat, check and replacement, 3-2 Throttle body and upper intake manifold, removal and installation, 4-13 Throttle Position Sensor (TPS), check and replacement, 6-14 Tie-rod ends, removal and installation, 10-20 Timing chain and sprockets, inspection, removal and installation 4.0L (pushrod) V6 engine, 2A-12 4.0L SOHC V6 engine, 2B-10 5.0L V8 engine, 2C-9 Tire and tire pressure checks, 1-9 Tire rotation, 1-14 Tools, 0-8 Top Dead Center (TDC) for number one piston, locating 4.0L (pushrod) V6 engine, 2A-3 4.0L SOHC V6 engine, 2B-3 5.0LV8 engine, 2C-2 Torsion bar (1995 and later models), removal and installation, 10-14 Transfer case, 7C-1 through 7C-6 electronic shift control module, removal and installation, 7C-4 electronic shift controls, removal and installation, 7C-3 general information, 7C-1 linkage adjustment, manual-shift transfer case, 7C-2 lubricant level check and change, 1-22 output shaft oil seals, front and rear, removal and installation, 7C-4 removal and installation, 7C-5 shift lever, removal and installation, 7C-2 Transmission Range (TR) sensor, general information, 6-22 Transmission, automatic, 7B-1 through 7B-8 brake/transmission shift interlock system (1995 and later models), description, check and solenoid replacement, 7B-4 diagnosis, general, 7B-2 fluid check/change, 1-13 general information, 7B-1

and earlier models), removal, and adjustment, 7B-4 removal and installation, 7B-6

Tune-up and routine maintenance, 1-1 through 1-36 Tune-up general information, 1-7 Turn signal/hazard flasher relay, check and replacement, 12-6

U Underhood hose check and replacement, 1-14 Upholstery and carpets, maintenance, 11-2 Upper control arm (1995 and later models), removal, inspection and installation, 10-13

Vacuum diaphragm installation,

(1994 and earlier models), removal and

7B-6

Vacuum gauge

diagnostic checks, 2D-6 Valve covers, removal and installation 4.0L (pushrod) V6 engine, 2A-4 4.0L SOHC V6 engine, 2B-3 5.0L V8 engine, 2C-3 lifters, removal, inspection and installation 4.0L (pushrod) V6 engine, 2A-14

Valve

5.0L V8 engine, 2C-10

Valve springs, retainers and seals, replacement 4.0L (pushrod) V6 engine, 2A-7 4.0L SOHC V6 engine, 2B-5 5.0L V8 engine, 2C-4 Valves, servicing, 2D-13 Variable Induction (VIS) System (1997 and later 4.0L SOHC engine), 4-17 Vehicle identification numbers, 0-5 Vehicle Speed Sensor (VSS), check and replacement, 6-22 Vinyl trim, maintenance, 11-2

Voltage regulator/alternator brushes, removal and installation, 10-10

neutral-start switch (1994 installation

shift

cable

Water pump, check and replacement, 3-6 Wheel bearing (front) check, repack and adjustment (2WD

adjustment, 7B-2

removal and

installation,

7B-3

replacement and adjustment, 7B-3 lever assembly, removal and installation, 7B-3 linkage lubrication, 1-19

shift indicator cable, shift

shift

transmission control switch (1996 and later models), check and replacement, 7B-4 transmission range sensor (1995 and later models), check and

replacement, 7B-5

vacuum diaphragm (1994 and

earlier models),

W

removal and

installation, 7B-6 Transmission, manual, 7A-1 through 7A-4 extension housing oil seal (2WD models), replacement, 7A-4 general information, 7A-2 lubricant level check and change, 1-20 mount, check and replacement, 7A-2

models),

1

-29

Wheel cylinder, removal and installation, 9-12 Wheel spindle, removal and installation, 10-5 Wheels and tires, general information, 10-26 general information, 12-18 Windshield glass, removal and installation, 11-19 Windshield washer reservoir and pump assembly, removal and

Window system, power,

installation, 12-8

Windshield wiper arm, removal and installation, 12-8 blade check and replacement, 1-34 motor, removal and installation, 12-7 Wiring diagrams, general information, 12-19

Working

facilities,

0-11

IND

Haynes Automotive Manuals NOTE New manuals

are

added

list on a periodic basis If you do not see a listing Haynes dealer for the latest product information

to this

consult your local

DOOM

ACURA -12020

Integra 86 thru 89

4 Legend 86

thru

90

30008 30010

MM

Jhp CJ sm JEEP 150020) 4020 Concord/Honwt/Gramkn/SfWn 70 thru 4025 (Renault) Alliance 4 Encore '83 thru -

1 1

'

'83

3001 1 300 1 2

'87

'30020

5020 4000 1 5025 5000 1 5026 5000 1

models 80 models '77 models '84

all all all

GMC 400 4 000 see CHRYSLER (25030) Aria* 4 Plymouth Reliant 81 thru 89 Caravan 4 Ply. Voyager '84 thru '95 Caravan 4 Pry. Voyaoar 96 thru '98 Challenger /Plymouth Saporro 78 thru 83 Challenger '67-70 SM DART (30025) Colt/Ptymouth Champ 78 thru 87 Dakota Pick-ups all models 87 thru 96 -

30010

AUDI thru 87

30025

thru 83 thru 88

-30030

Dart, Challenger/Plymouth Barracuda 4 Valiant 6 cyl models '67 thru 76

Daytona 4 Chrysler Laser Intrepid

'30034 '30035

AUSTIN Healey Sprite

see

MG

Midget (66015)

8020 802 1 8025 1 8035 1 8050

'

1

•

1

1

BUCK -19020

19025

375 Series 82 thru '92 3 Series except 325iX models '92 thru '97 3201 all 4 cyl models '75 thru '83 528I & 530i all models 78 thru '80 1 500 thru 2002 except Turbo '59 thru '77

Century (FWD) - see GM (38005.) Buick. Oldsmobile & Pontlac Full-size (Front wheel drive) 85 thru 98 Buick Electra. LeSabre and Park Avenue: Oldsmobile Delta 88 Royale. Ninety Eight and Regency; Pontlac Bonneville Buick Oldsmobile 4 Pontlac Full-size (Rear wheel drive) Buick Estate

70 thru

90.

Bectra70 thru

'84,

'30041 -30045

30050 '30055 '30060 •30065

Mid-size Regal 4 Century 74 Regal - see GENERAL MOTORS (38010) Skyhawk - see GM (38030) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (38025) thru '87

CADILLAC

3401

34025

'24032

Sedans Caprice, Impala, Biscayne, Bel Air & Wagons '69 thru '90

Full-size

36062 36066 •36070 •36071

•36074 •36075 '36078

Eagle Vision, '93 thru '97 Chrysler/Plym. Mid-size '82 thru '95 Rear-wheel Drive - see DODGE (30050)

•25030

200SX

'380 1 6

38025

Calais 4 Pontiac Grand Am '85 thru '95 38030 Cadillac Eldorado 4 Oldsmobile Toronado 71 thru '85, Seville '80 thru '85, Buick Riviera 79 thru '85 '38035 Chevrolet Lumina APV, Oldsmobile Silhouette 4 Pontiac Trans Sport '90 thru '95

models '80 thru '83 B-210 all models 73 thru 78 210 all models 78 thru '82 240Z, 260Z 4 280Z Coupe 70 thru 78 280ZX Coupe & 2+2 79 thru '83 all

300ZX - see NISSAN (72010) 310 all models 78 thru '82 510 4 PL521 Pick-up '68 thru 73 510 all models 78 thru '81 620 Series Pick-up all models 73 thru 79 720 Series Pick-up - NISSAN (72030) 28025 81 0/Maxima all gas models, 77 thru '84

Listings

shown

with

updated

an asterisk

'97 '91

GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Olds Cutlass Ciera 4 Pontiac 6000 all models '82 thru '96 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme 4 Pontiac Grand Prix front wheel drive '88 thru '95 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza Pontlac J-2000 4 Sunbird '82 thru '94 Chevrolet Cavalier 4 Pontiac Sunfire '95 thru '98 Buick Skylark, Chevrolet Citation, Olds Omega, Pontiac Phoenix '80 thru '85 Buick Skylark 4 Somerset, Olds Achieva,

'38015

(')

to include later

General Motors Full-size Rear-wheel Drive - see BUICK (19025)

GEO Metro - see CHEVROLET Sprint (24075) Prizm - see CHEVROLET (24060) or

TOYOTA '40030

Storm

•47020

Trooper

'84 thru '91

'81 thru '93

Pick-up

.

JAGUAR XJ6 all 6 cyl models 68 thru 86 XJ6 all models 88 thru 94 XJ12 4 XJS all 12 cyl models 72

50020

-

see

FORD Pick-up (36059) all

models 70 thru 96

63020 63025 63030

See FORD

Listing

MGB Roadster & GT Coupe 62 thru '80 MG Midget 4 Austin Healey Sprite '58 thru '80

MITSUBISHI Cordis, Tredla, Galant, Precis Mirage '83 thru 93 Eclipse, Eagle Talon 4

Plymouth Laser '68040

Pick-up 83 thru

4

'90 thru '94

Montero

'96.

'83 thru

93

NISSAN 72010 300ZX all models •72015 '72020 •72030

Altima

incl.

Turbo

'84 thru '89

models '93 thru '97 Maxima all models '85 thru '91 all

Pick-ups '80 thru

'96,

Pathfinder

'87 thru '95

72040 Pulsar all models '83 thru '86 72050 Sentra all models 82 thru '94 '72051 Sentra 4 200SX all models '95 '72060

Inc.,

fVe

Land Cruiser Sena* FJ60 62 SO 4 FZJ80 68 thru 82

-92008

MR2

92070 92075

a* model* 85 thru 87

models 09 thru 78 model* 79 thru 95 95 thru 98. 4Runner 96 thru 96. T100 93 thru 90 Previa all models -91 thru 95 Tercel all models '87 thru 94 Pick-up Pick-up

all

all

Tacoma

'92070 '92080

92085 94007 94010

Stanza

all

97010 97015

thru '98

'82 thru '90

models

97025 '97040

Spitfire

TR7

all

ail models 62 thru models 75 thru 81

'81

Hermann Ghla 54 thru 79 ail gasoline models 74 thru '81 Rabbit, Jetta, Sclrocco, 4 Pick-up gas models 74 thru 91 4 Convert*** 80 thru V2 Golf 4 Jetta 93 thru 97 Rabbit, Jetta, Pick-up dieset 77 thru 84 Transporter 1000 all models 68 thru '79 Transporter 1700, 1800,2000 72 thru 79 Type 3 1 800 4 1000 63 thru 73 Vanagon air-cooled models 80 thru 83 Beetle 4

Dasher

4 1800 Sports HI thru 73 models '66 thru 74 models 78 thru '93 all models 75 thru 82 4 700 Series ail models 82 thru '88

120, 130 Series

140 240 200 740

Series Series Series

all

all

TECHBOOK MANUALS 10205 10210 10215 10220 10225 10230 10240 10305 10310 10320 10330 10340 10345 1 0355 10360 10405 10410 10415 10420 10425 10430 10435 10440 10445 10450

Automotive Computer Code* Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1996 Holley Carburetor Manual Rochester Carburetor Manual Weber/Zenlth/Stromberg/SU Carburetor Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repelr Small Engine Repair Manual Suspension, Steering 4 Drivellne Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair 4 Painting Automotive Brake Manual Automotive Detaiing Manual Automotive Eelectrlcal Manual Automotive Heating 4 Air Conditioning Automotive Reference Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual A TV Basics

OLDSMOBILE '73015

Cutlass 74 thru '88 For other OLDSMOBILE BUICK, CHEVROLET or

GENERAL MOTORS

titles,

SPANISH MANUALS

see

Hating.

PLYMOUTH For PLYMOUTH

titles,

see DODGE.

PONTIAC 79008 79018 7901 9

Flero all models '84 thru '88 Firebird V8 models except Turbo Firebird all models '82 thru 92

70 thru

For other PONTIAC titles, see BUICK, CHEVROLET or

GENERAL MOTORS

listing.

PORSCHE '80020

91

1

80025 914 80030 924 '80035 944

Coupe & Targa models incl. incl.

Turbo

4 cyl models '69 thru

all

models models

all

'65 thru '89

76 Turbo 76 thru

all

'82

'81

98903 98905 98910 98915 99040 99041 99042 99055 99075 99077 99083 99088 99091 99095 99100 991

1

Reparac!6n de Carroceria 4 Plntura Codigos Automotrfces da la Computadors Frenos Automotrlz Inyeccl6n de Combustible 1986 al 1994 Chevrolet 4 GMC Camionetas 67 al '87 Chevrolet 4 GMC Camionetas 88 al 95 Chevrolet Camionetas Cerradas '68 al '95 Dodge Caravan/Ply. Voyager '84 al '95 Ford Camionetas y Bronco 80 al '94 Ford Camionetas Cerradas '69 al '91 Ford Modelos de Tamano Grande 75 al 87 Ford Modelos de Tamano Medlano 75 al '86 Ford Taurus 4 Mercury Sable 75 al '86 GM Modelos de Tamano Grande 70 al '90 GM Modelos de Tamano Mediano 70 al '88 Nissan Camionetas '80 al '96, Pathfinder 87

991 1 8 991 25

al

95

Nissan Sentra '82 al '94 Toyota Camionetas y 4-Runner 79

al '95

'83 thru '89

-

models '90 thru '93 see SUZUKI Samurai (90010)

RENAULT Alliance,

Encore

-

see

AMC (14020)

indicate model coverage as of this printing. These titles will be periodically model years - consult your Haynes dealer for more information.

Haynes North America,

a*

-92050

•97020

MG

'68020

Tm n* ar

VOLVO 91

MERCURY

'68030

7*

M M

96020 96030 96035 96040 96045

123 Series Diesel 76 thru '85 190 Series 4-cyl gas models, '84 thru '88 230, 250 4 280 6 cyl sohc 68 thru 72 280 123 Series gas models 77 thru 81 350 4 450 all models 71 thru '80

63012

thru

Camry a» modal* S3 thru 91 Camry a* mod*** 92 thru 92016 CeHce Mear WHeal Drive 71 ffwu *» 92020 Caiica Front Wheel Drive eVu tj 92025 Celtca tupra al modes* 79 thru tt 92030 Corolla a» model* 75 thru 79 92032 Coroaa rear wheal dnve modal* at) tvu t7 92035 Coroaa front wheal dm* models WtruV -92O30 Coroaa 4 Oeo Priam -93 tvu -97 92040 Corolla Tercel a* modal* SO thru 42 92045 Corona all modal* 74 thru '82 92050 CreaaMa aH model* 78 thru 82 920S5 Land Crulaer Sena* F J40. 43. 48 4 84

'9601 7

MERCEDES-BENZ '63015

aarrajrafiaslUiiU'O i

90008

models '89 thru '94 Navajo - see FORD Explorer (36024) Pick-ups 72 thru 93 Pick-ups '94 on - see Ford (36071) RX-7 all models 79 thru '85 RX-7 all models '86 thru '91 626 (rear wheel dnve) 79 thru '82 626 4 MX-6 (front wheel drive) 83 thru

61035

•0010

960 1 2 '96016

MPV all

61 040 '61041

'•

•uftvxj'M

vw

61010 GLC (rear wheel drive) 77 thru 83 61011 GLC (front wheel drive) 81 thru 85 •61015 323 4 Protege 90 thru 97 •61016 MX-5 Miata '90 thru 97

•61036

4WO

TRIUMPH

MAZDA

61030

4

08 thru 82

LINCOLN

'61020

7W0

SUZUKI

thru 85

Cherokee, Comanche 4 Wagonaar Limited all models 84 thru 96 CJ all models '49 thai 86 Grand Cherokee all models 93 thru 98 Grand Wagoneer 4 Pick-up 72 thru '91 Wrangler all models '87 thru 95

•50025 '50029 '50030

1»00 4 1e«0

(92036)

all

Tracker

'86 thru '94

-

Roadster

Ranger/Bronco II gas models '83 thru '92 Ford Ranger '93 thru '97 & Mazda Pick-ups '94 thru '97 Taurus 4 Mercury Sable '86 thru '95 Taurus 4 Mercury Sable '96 thru '98

GENERAL MOTORS '10360 '38005

model*

Hombre see CHEVHOLfT S- 10 f2*07i; Rodeo 91 thru '97. Amlgo 89 thru 94. Honda Passport 95 thru '97

'80

Thunderbird/Mercury Cougar '89 and 36090 Vans all V8 Econoline models '69 thru •36094 Vans full size '92 thru '95 •36097 Windstar Mini-van '95 thru '98

38020

28016 28018 28020 28022

'

4 Mercury Bobcat 75 thru Probe all models '89 thru '92 Pinto

all

'47017

-4901 '49011 •49015

1100. 11O0. 1400 4 lettO

••002 ••003

920O5 -92000

Excel

7» Bvu a*

SUBARU

Pasaport see ISUZU Rodeo (47017) Prelude CVCC all models 79 thru 89

ISUZU

vKsudsnaj Turbo

•7010

TOYOTA

HYUNDAI '4301 5

•4010 fMW

SATURN

Civic 4 del Sol '92 thru 95 -

-42040

66010 66015

Pick-ups, Expedition 4 Lincoln Navigator '97 thru '98

•36086

Intrepid,

DATSUN 28005 28007 28009 28012 28014

thru '82);

Tempo 4 Mercury Topaz '84 thru '94 36082 Thunderbird/Mercury Cougar '83 thru '88

'38010

Plymouth Breeze, 95 thru '98 Full-size Front-Wheel Drive '88 thru '93 K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde 4 New Yorker,

Dodge

thru '80

36048 36049 36050 Mustang 4 Mercury Capri incl. Turbo Mustang, 79 thru '93; Capri, 79 thru '86 •36051 Mustang all models '94 thru '97 36054 Pick-ups and Bronco 73 thru 79 •36058 Pick-ups and Bronco '80 thru '96

'25015

25025

4 Mazda Navajo '91 thru '95 Fairmont 4 Mercury Zephyr 78 thru '83 Festiva 4 Aspire '88 thru '97 Fiesta all models 77 thru '80 Ford 4 Mercury Full-size, Explorer

pick-up, LTD II, Mercury Montego, Comet. XR-7 & Lincoln Versailles (75 thru '86) Mustang V8 all models '64-1/2 thru 73 Mustang II 4 cyl, V6 & V8 74 thru 78

CHRYSLER 10310 Chrysler Engine Overhaul Manual Chrysler Cirrus, Dodge Stratus,

Accord CVCC ail modal* 70 thru '83 Accord an models 84 thru S9 Accord all models BO thru 93 Accord all models '94 thru 94 Civic 1200 all models 73 thru 79 Civic 1300 4 1500 CVCC 80 thru S3 Civic 1SOO CVCC all models 75 thru TV Civic all models '84 thru 91

42010 42011 42012 •42013 42020 42021 42022 42023 42024

Navigator

Ford LTD & Mercury Marquis {75 thru '82); Ford Custom 500, Country Squire, Crown Victoria & Mercury Colony Park (75 thru '87); Ford LTD Crown Victoria & Mercury Gran Marquis ('83 thru '87)

'36059

CHEVROLf T ASTRO (24010) see CHEVROLET

59010 Rear Wheel Orive

'90

36020 Escort/Mercury Tracer '91 thru '96 Expedition - see FORD Pick-up (36059)

(38020)

see

JEEP

Ford LTD & Mercury Marquis ('83 thru '86); Ford Torino, Gran Tonno, Elite, Ranchero

24046 Impala SS 4 Caprice and Buick Roadmaster '91 thru '96 Lumina '90 thru '94 - see GM (38010) 24048 Lumina 4 Monte Carlo '95 thru '98 Lumina APV - see GM (38038) 24050 Luv Pick-up all 2WD & 4WD 72 thru '82 24055 Monte Carlo all models 70 thru '88 Monte Carlo '95 thru '98 - see LUMINA 24059 Nova all V8 models '69 thru 79 '24060 Nova/Geo Prizm '85 thru '92 24064 Pick-ups '67 thru '87 - Chevrolet & GMC, all V8 & in-line 6 cyl, 2WD & 4WD '67 thru '87; Suburbans, Blazers & Jimmys '67 thru '91 '24065 Pick-ups '88 thru '98 - Chevrolet & GMC, all lull-size models '88 thru '98; Blazer & Jimmy '92 thru '94; Suburban '92 thru '98; Tahoe & Yukon '95 thru '98 '24070 S-10 4 GMC S-15 Pick-ups '82 thru '93 24071 S-10, Gmc S-15 4 Jimmy '94 thru '96 '24075 Sprint 4 Geo Metro '85 thru '94 '24080 Vans - Chevrolet 4 GMC 68 thru '96

'25020

78

Aerostar Mini-vans '86 thru '96 Aspire - see FORD Festiva (36030) Contour/Mercury Mystique 95 thru 98 Courier Pick-up all models 72 thru '82

Cougar (75

Corsica/Beretta all models '87 thru '96 all V8 models '68 thru '82 Corvette all models '84 thru '96

24045

'68 thru

36040 Granada 4 Mercury Monarch 75 36044 Ford 4 Mercury Mid-size, Ford Thunderbird & Mercury

24040 Corvette '24041

24 Sport Coupe 4 Spider X1/9 all models 74 thru '80

36008 36012 Crown Victoria 4 Mercury Grand Marquis 88 thru '96 36016 Escort/Mercury Lynx '81 thru

24017 Camaro 4 Firebird '93 thru '97 24020 Chevelle, Malibu, El Camino '69 thru '87 24024 Chevette 4 Pontiac T1000 76 thru '87 see GENERAL MOTORS

-

Safari

Vans 4 Pick up*

HONDA

'50010

'93

Cavalier - see GM (38015) Celebrity - see GM (38005)

-

full-size

FORD

CHEVROLET

Citation

lull-size

all

1

36028 36030 36032 36036

'93

10305 Chevrolet Engine Overhaul Manual Astro 4 GMC Safari Mini-vans '85 thru 24015 Camaro V8 all models 70 thru '81 24016 Camaro all models '82 thru '92

all

FIAT

•36024

•2401

models 74 thru '93 models '94 thru '96 Ram 50/D50 Pick-ups 4 Raider and Plymouth Arrow Pick-ups 79 thru 93 Dodge/Ply./Chrysler RWD 71 thru '89 Shadow/Plymouth Sundance '87 thru '94 Spirit 4 Plymouth Acclaim 89 thru '95 Vans - Dodge 4 Plymouth 71 thru '96 Pick-ups

see MITSUBISHI Eclipse (68030) Vision - see CHRYSLER (25025)

•36006

,

Cadillac Rear Wheel Orive 70 thru Cimarron, Eldorado 4 Seville - see GM(380T5. 38030J

Dodge 4 Plymouth Neon '95 thru '97 Omni 4 Plymouth Horizon 78 thru '90

Talon

•36004

70 thru

'85,Ninety-eight 70 thru '84 70 thru '81, Catalina 70 thru '81 Grandville 70 thru 75, Parisienne '83 thru '86

'21030

89

EAGLE

Pontiac Bonneville

19030

'84 thru

see Chrysler (25025)

10355 Ford Automatic Transmission Overhaul 10320 Ford Engine Overhaul Manual

LeSabre 70 thru '85. Limited 74 thru 79 Oldsmobile Custom Cruiser 70 thru '90. Delta 88

-

30040 Pick-ups

BMW

your

for

861 Lawrence Drive,

Newbury

Park,

Nearly 100 Haynes motorcycle manuals also available

CA

91320

•

(805) 498-6703

5-98

Common

spark plug conditions NORMAL

I

3 9999 03786 075

Symptoms:

Brown to grayish-tan color and electrode wear. Correct heat range for engine operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range. ;

TOO HOT

WORN

Symptoms:

Symptoms:

Rounded electrodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in weather and poor

damp fuel

Recommendation:

or

cold

economy. Plugs have

been left in the engine too long. Replace with new plugs of the

same

heat range. Follow the recschedule.

ommended maintenance

.•.

N&

and

shortened plug

Recommendation: correct

advanced mixture, leaks,

the

i

ignit

lean fuel

intake

rrv

sticking valv
absence of depos lator.

hesitation.

Recommendation: Make

sure the plug has the correct heat range. Check for a clogged air filter or problem in the fuel system or engine management system. Also check for ignition system problems.

Symptoms:

Melted electrodes

Insulators are white, but may be dirty due to misfiring or flying

debris in the combustion chamber. Can lead to engine damage. Recommendation: Check for the correct plug heat range, over-

advanced

ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

ASH DEPOSITS

HIGH SPEED GLAZING

Symptoms:

Symptoms:

Light

brown deposits

encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation

Insulator

has yellow-

during acceleration.

glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high speeds.

Recommendation:

Recommendation:

If excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gaso-

line

brands.

ish,

if

OIL DEPOSITS by poor

oil

Oily coating control. Oil

is

caused leaking

past worn valve guides or piston rings into the combustion chamber. Causes hard starting, misfiring and hesitation.

Recommendation:

Correct the mechanical condition with necessary repairs and

install

new

new

driving habits warrant.

DETONATION Symptoms:

Symptoms:

Install

plugs. Consider using a colder plug

Insulators

may be

cracked or chipped. Improper gap setting techniques can also result in a fractured insulator tip. Can lead to piston

damage.

Recommendation: Make

sure the anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine. fuel

plugs.

MECHANICAL DAMAGE Symptoms: May be caused by

GAP BRIDGING Symptoms: Combustion deposits between the electrodes. Heavy deposits accumulate and bridge the electrode gap. The plug ceases to fire, resulting in a dead lodge

a

foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston

damage.

Recommendation:

Recommendation:

Repair the mechanical damage. Remove the foreign object from the engine and/or install the correct reach

faulty plug

plug.

cylinder.

Locate the and remove the deposits from between the electrodes.

Inside this manual: Routine maintenance

Tune-up procedures Engine repair Cooling and heating Air conditioning

Fuel

and exhaust

Emissions control

Brakes

Suspension and steering Electrical

systems

Wiring diagrams

Chapter 2 Part B

Engine

W%l 9 5b

An exploded view

adapter

•

Step-by-step procedures linked to hundreds of easy-to-follow photos and illustrations

•

Complete troubleshooting section

ss»mbty

DISTRIBUTOR DRIVE

'*& $i

ADAPTOR

9.5a To remove th« distributor drive adapter, remove the distributor hold-down

identify specific ice

and remove the three adapter

retaining

bolts (arrows)

a

the

good

on

seal

the

Iront

idea lo replace the O-

nng between the distributor drive adapter and the cylinder head Remove the distributor (see Chapter S) and the adapter (see Illustrations) Note: If you remove rfie adapter, slop fhe following Steps describing or) vehicle seal

.I

prevent damaging the pin If you replaced the Front 8

cam

the inner timing belt cover

stall

When you

9

install

tach the adapter, tighten the bolts securely, and install the distributor

tighten the bolt to the torque in this Chapter's

It

you're replacing a rear seal or you

a couple of small holes

do

into the holes,

m** (see

then care'ully

illustration)

• Written

Use your sprocket holding

10

tool

tt

Specifications Installation of Ihe

11

nents drill

from hands-on experience based on a vehicle teardown using commonly available tools

the sprocket

sure the R or F mark Faces outt The 01 the pulley with the deep recess must face th( engine, which means the shallow feces;

must face oul

adapter,

is

remaining

compo

the reverse ot removal

11

fl

OH

Rocker arm and hydraulic valve

10

lash adjusters - check, removal, inspection, and installation

Don't

•

the camshaft in the process

There are several ways t seal Fabricate a described in Section 6 or use a very large socket with an inside diameter targe enough to clear the nose of the camshaft and carefully drive the seal into place (see illustrations) Remove Ihe sprocket positioning pin ie cam, if necessary, lo 7

:

9.6 To extract a camshaft seal, couple ot small holes in the old thread a pair of sheetmetal screv the holes and pry the seal out v