pdftown.com_2001_dakota.pdf

GROUP TAB LOCATOR

Introduction

0 Lubrication & Maintenance2 Suspension3 Differential & Driveline5 Brakes6 Clutch7 Cooling

8A Audio8B Chime/Buzzer8E Electronic Control Modules8F Engine Systems8G Heated Systems8H Horn8I Ignition Control8J Instrument Cluster8L Lamps8M Message Systems8N Power Systems8O Restraints8P Speed Control8Q Vehicle Theft Security8R Wipers/Washers8W Wiring

9 Engine11 Exhaust System13 Frame & Bumpers14 Fuel System19 Steering21 Transmission and Transfer Case22 Tires/Wheels23 Body24 Heating & Air Conditioning25 Emissions Control30 New Vehicle Preparation

Component and System Index

Service Manual Comment Forms (Rear of Manual)

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F

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Type of vehicle. Type of rear wheels.

AN INTRODUCTION 1 Bar code. Month, Day and Hour (MDH) of final assembly. Paint and Trim codes. Country of origin. Fig. 1 Vehicle Safety Certification LabelINTROD

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EHICLE SAFETY CERTIFICATION LABELDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1EHICLE IDENTIFICATION NUMBERDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ECI LABELDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ODY CODE PLATEDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3QUIPMENT IDENTIFICATION PLATEDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EHICLE SAFETYERTIFICATION LABEL

ESCRIPTIONA vehicle safety certification label is attached to

very DaimlerChrysler Corporation vehicle. The labelertifies that the vehicle conforms to all applicableederal Motor Vehicle Safety Standards. The labellso lists: Month and year of vehicle manufacture. Gross Vehicle Weight Rating (GVWR). The gross

ront and rear axle weight ratings (GAWRs) areased on a minimum rim size and maximum cold tirenflation pressure.

Vehicle Identification Number (VIN).CTION

NTENTS

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NTERNATIONAL SYMBOLSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ASTENER IDENTIFICATIONDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ASTENER USAGEDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ETRIC SYSTEMDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ORQUE REFERENCESDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The label is located on the driver-side door shut-face (Fig. 1).

All communications or inquiries regarding thevehicle should include the Month-Day-Hour andVehicle Identification Number.

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4 Gross Vehicle Weight Rating G = 5001-6000 lbs.H = 6001-7000 lbs.

G = DakotaDakota Sport

2 INTRODUCTION AN5 Vehicle Line

6 Series

7 Body Style

8 Engine

9 Check Digit10 Model YearEHICLE IDENTIFICATIONUMBER

ESCRIPTIONThe Vehicle Identification Number (VIN) plate is

ttached to the top left side of the instrument panelFig. 2). The VIN contains 17 characters that provideata concerning the vehicle. Refer to the decodinghart to determine the identification of a vehicle.

VIN DECODING INFORMATION

POSITION INTERPRETATION CODE = DESCRIPTION1 Country of Origin 1= USA2 Make B = Dodge3 Vehicle Type 7 = Truck

F = 4001-5000 lbs.

Fig. 2 Vehicle Identification Number (VIN)1 - VIN11 Assembly Plant12 Thru 17 Vehicle Build SequencDakota 4x4L = Dakota

Dakota SportDakota 4x22 = Dakota

Dakota SportDakota SLT

2 = Club CabA = Quad Cab

6 = Conventional CabP = 2.5LX = 3.9LN=4.7L

Y = 5.2LZ = 5.9L

1=2001

S = Warren Truck Assembly

e Assembly Sequence

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AN INTRODUCTION 3ECI LABEL

ESCRIPTIONAll vehicles are equipped with a combined VECI

abel. This label is located in the engine compart-ent (Fig. 3).

The VECI label contains the following: Engine family and displacement Evaporative family Emission control system schematic Certification application Engine timing specifications (if adjustable) Idle speeds (if adjustable) Spark plug and gapThe label also contains an engine vacuum sche-atic. There are unique labels for vehicles built for

ale in the state of California and the country ofanada. Canadian labels are written in both thenglish and French languages. These labels are per-anently attached and cannot be removed without

efacing information and destroying label.

ODY CODE PLATE

ESCRIPTION

OCATION AND DECODINGA metal body code plate is attached to the floor pan

nder the passenger seat. Remove the passengereat, door sill scuff plate and pull back the carpet toccess the body code plate. There are seven lines of

Fig. 3 VECI Label Location1 - VEHICLE EMISSION CONTROL INFORMATION (VECI) LABELnformation on the body code plate. Lines 5, 6, and 7re not used to define service information. Informa-tion reads from left to right, starting with line 4 inthe center of the plate to line 1 at the bottom of theplate (Fig. 4).

The last code imprinted on a vehicle code plate willbe followed by the imprinted word END. When twovehicle code plates are required, the last availablespaces on the first plate will be imprinted with theletters CTD (for continued).

When a second vehicle code plate is necessary, thefirst four spaces on each row will not be used becauseof the plate overlap.

BODY CODE PLATELINE 4

DIGITS 1 THROUGH 12Vehicle Order Number

DIGITS 13, 14, AND 15Open Space

DIGITS 16, 17, AND 18Car Line Shell AN1 = Dakota 4 X 2 AN5 = Dakota 4 X 4

DIGIT 19Price Class L = Dakota (All)

DIGITS 20 AND 21Body Type 31 = Dakota Club Cab (130.9 in. Wheel Base) 61 = Dakota (111.9 in. Wheel Base) 62 = Dakota (123.9 in. Wheel Base)

BODY CODE PLATELINE 3

DIGITS 1,2, AND 3Paint Procedure

Fig. 4 Body Code

DD

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B

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4 INTRODUCTION AN

BIGIT 4Open Space

IGITS 5 THROUGH 8Primary PaintRefer to Group 23, Body for color codes.

IGIT 9Open Space

IGITS 10 THROUGH 13Secondary Paint

IGIT 14Open Space

IGITS 15 THROUGH 18Interior Trim Code

IGIT 19Open Space

IGITS 20, 21, AND 22Engine Code EPE = 2.5 L 4 cyl. MPI Gasoline EHC = 3.9 L 6 cyl. MPI Gasoline ELF = 5.2 L 8 cyl. MPI Gasoline ELM = 5.9 L 8 cyl. MPI Gasoline

ODY CODE PLATELINE 2

IGITS 1, 2, AND 3Transmission Codes DDK = 5Speed Manual (NVG 1500) DDQ = 5Speed Manual (AX15) DDC = 5Speed Manual (NVG 3500) DGK = 4Speed Automatic (42RE) DGW = 4Speed Automatic (44RE) DGT = 4Speed Automatic (46RE)

IGIT 4Open Space

IGIT 5Market Code B = International C = Canada M = Mexico U = United States

IGIT 6Open Space

IGITS 7 THROUGH 23

ODY CODE PLATE (Continued)Vehicle Identification Number (VIN)Refer to Vehicle Identification Number (VIN) para-

raph for proper breakdown of VIN code.BODY CODE PLATELINE 1

DIGITS 1 THROUGH 6 Body-in-white assembly sequence.

DIGITS 7 THROUGH 9Open Space

DIGITS 10 THROUGH 12 Cargo box code XBS = Sweptline

DIGITS 13 THROUGH 16Open Space

EQUIPMENT IDENTIFICATIONPLATE

DESCRIPTIONThe Equipment Identification Plate (Fig. 5) is

located at the left, front of the inner hood panel. Theplate lists information concerning the vehicle as fol-lows:

The model. The wheelbase. The VIN (Vehicle Identification Number). The T.O.N. (order number). The optional and special equipment installed on

the vehicle.Refer to the information listed on the plate when

ordering replacement parts.

INTERNATIONAL SYMBOLS

DESCRIPTIONThe graphic symbols illustrated in the following

International Control and Display Symbols Chart(Fig. 6) are used to identify various instrument con-trols. The symbols correspond to the controls and dis-plays that are located on the instrument panel.

Fig. 5 Equipment Identification PlateTypical

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AN INTRODUCTION 5

IASTENER IDENTIFICATION

RADE/CLASS IDENTIFICATION

ESCRIPTIONThe SAE bolt strength grades range from grade 2

o grade 8. The higher the grade number, the greaterhe bolt strength. Identification is determined by theine marks on the top of each bolt head. The actualolt strength grade corresponds to the number of linearks plus 2. The most commonly used metric bolt

trength classes are 9.8 and 10.9. The metrictrength class identification number is imprinted onhe head of the bolt. The higher the class number,he greater the bolt strength. Some metric nuts aremprinted with a single-digit strength class on theut face. Refer to the Fastener Identification (Fig. 7)

Fig. 6 INTERNA1 High Beam2 Fog Lamps3 Headlamp, Parking Lamps, Panel Lamps4 Turn Warning5 Hazard Warning6 Windshield Washer7 Windshield Wiper8 Windshield Wiper and Washer9 Windscreen Demisting and Defrosting10 Ventilating Fan11 Rear Window Defogger12 Rear Window Wiper

NTERNATIONAL SYMBOLS (Continued)nd Fastener Strength Charts (Fig. 8).FASTENER USAGE

DESCRIPTION

WARNING: USE OF AN INCORRECT FASTENERMAY RESULT IN COMPONENT DAMAGE OR PER-SONAL INJURY.

Figure art, specifications and tightening torque ref-erences in this manual are identified in metric andSAE format.

During any maintenance or repair procedures, it isimportant to salvage all fasteners (nuts, bolts, etc.)for reassembly. If the fastener is not salvageable, afastener of equivalent specification must be use.

DESCRIPTIONMost stripped threaded holes can be repaired using

AL SYMBOLS13 Rear Window Washer14 Fuel15 Engine Coolant Temperature16 Battery Charging Condition17 Engine Oil18 Seat Belt19 Brake Failure20 Parking Brake21 Front Hood22 Rear hood (Decklid)23 Horn24 LighterTIONa Helicoil t. Follow the manufacture recommendationfor application and repair procedures.

6 INTRODUCTION AN

FASTENER USAGE (Continued)Fig. 7 FASTENER IDENTIFICATION

AN INTRODUCTION 7

FASTENER USAGE (Continued)Fig. 8 FASTENER STRENGTH

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Refer to the Metric Conversion Chart (Fig. 9) toconvert torque values listed in metric Newton-meters (Nm). Also, use the chart to convert betweenmillimeters (mm) and inches (in.)

AND EQUIVALENT VALUES

MULTIPLY BY TO GETNm x 8.851 = in-lbs

ft-lbs x 1.3558 = Newton Meters (Nm) Nm x 0.7376 = ft-lbs

8 INTRODUCTION ANInches Hg(60 F)

x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psiInches x 25.4 = Millimeters (mm) mm x 0.03937 = InchesFeet x 0.3048 = Meters (M) M x 3.281 = FeetYards x 0.9144 = Meters M x 1.0936 = Yardsmph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mphFeet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Secmph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mphKilometers/Hr. (Km/h)

x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.(Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter1 Mile = 1.6 KilometersETRIC SYSTEM

ESCRIPTIONThe metric system is based on quantities of one,

en, one hundred, one thousand and one million.The following chart will assist in converting metric

nits to equivalent English and SAE units, or viseersa.

CONVERSION FORMULAS

MULTIPLY BY TO GETin-lbs x 0.11298 = Newton Meters (Nm)

AN INTRODUCTION 9

METRIC SYSTEM (Continued)Fig. 9 METRIC CONVERSION CHART

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10 INTRODUCTION ANFig. 10 TORQUE SPORQUE REFERENCES

ESCRIPTIONIndividual Torque Charts appear at the end ofany Groups. Refer to the Standard Torque Specifi-

cations Chart for torque references not listed in theindividual torque charts (Fig. 10).ECIFICATIONS

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LUBRICATION &MAINTENANCE

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DESCRIPTION SPECIFICATION

3.9L Engine 13.3L (14.0 qts.)***

DESCRIPTION SPECIFICATION

REAR AXLE9 1/4 2.32L (4.9 pts.)**

AN LUBRICATION & MAINTENANCE 0 - 14.7L Engine 12.3L (13.0 qts.)***5.9L Engine 13.7L (14.6 qts.)***

AUTOMATIC TRANSMISSIONService Fill - 42RE 3.8L (4.0 qts)O-haul Fill - 42RE 9.1-9.5L (19-20 pts)

8 1/4 2.22L (4.7 pts.)**** When equipped with Trac-lok, include 148 ml (5oz.) of Friction Modifier.*** Includes 0.9L (1.0 qts.) for coolant reservoir.****Nominal refill capacities are shown. A variationFUEL TANK 2-Door: 83L (22 U.S.Gallons)****

4-Door: 91L (24 U.S.Gallons)****

ENGINE OIL - WITH FILTER2.5L Engine 4.3L (4.5 qts.)3.9L Engine 3.8L (4.0 qts.)4.7L Engine 5.7L (6.0 qts.)5.9L Engine 4.7L (5.0 qts.)

COOLING SYSTEM2.5L Engine 9.3L (9.8 qts.)***Service Fill - 46RE 3.8L (4.0 qts)O-haul Fill - 46RE 9.1-9.5L (19-20 pts)

O-haul Fill - 45RFE 13.33L (28.0 pts)MANUAL TRANSMISSION

NV3500 2.28L (4.8 pts.)TRANSFER CASE

NV233 1.18L (2.5 pts.)NV244 1.35L (2.85 pts.)

FRONT AXLEC205F 1.66L (3.5 pts.)PECIFICATIONS

PECIFICATIONS - FLUID CAPACITIESLUBRICATION &

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UBRICATION & MAINTENANCESPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1

NTERNATIONAL SYMBOLSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ARTS & LUBRICANTSTANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 2

CLASSIFICATION OF LUBRICANTS. . . . . . . . . . 2LUID TYPESDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

LUID FILL/CHECK LOCATIONSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7AINTENANCE SCHEDULESDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7AINTENANCE

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OISTINGSTANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12

HOISTING RECOMMENDATIONS. . . . . . . . . . . 12UMP STARTINGSTANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 12

JUMP STARTING PROCEDURE . . . . . . . . . . . . 12OWINGSTANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 13

TOWING RECOMMENDATIONS . . . . . . . . . . . . 13TWO WHEEL DRIVE VEHICLE TOWING . . . . . 14FOUR WHEEL DRIVE VEHICLE TOWING. . . . . 15may be observed from vehicle to vehicle due tomanufacturing tolerance and refill procedure.

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0 - 2 LUBRICATION & MAINTENANCE ANNTERNATIONAL SYMBOLS

ESCRIPTIONDaimlerChrysler Corporation uses international

ymbols to identify engine compartment lubricantnd fluid inspection and fill locations (Fig. 1).

ARTS & LUBRICANT

TANDARD PROCEDURECLASSIFICATION OFUBRICANTSOnly lubricants bearing designations defined by

he following organization should be used to service aaimlerChrysler Corporation vehicle. Society of Automotive Engineers (SAE) American Petroleum Institute (API) (Fig. 2) National Lubricating Grease Institute (NLGI)

Fig. 3)

NGINE OIL

AE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITYAn SAE viscosity grade is used to specify the vis-

osity of engine oil. SAE 30 specifies a single viscos-ty engine oil. Engine oils also have multipleiscosities. These are specified with a dual SAE vis-osity grade which indicates the cold-to-hot tempera-ure viscosity range.

SAE 30 = single grade engine oil. SAE 10W-30 = multiple grade engine oil.DaimlerChrysler Corporation only recommendsultiple grade engine oils.

Fig. 1 International SymbolsAPI QUALITY CLASSIFICATION This symbol (Fig. 2) on thefront of an oil container means that the oil has beencertified by the American Petroleum Institute (API) to meetall the lubrication requirements specified byDailmlerChrysler Corporation.

Refer to Group 9, Engine for gasoline engine oilspecification.

GEAR LUBRICANTSSAE ratings also apply to multiple grade gear

lubricants. In addition, API classification defines thelubricants usage.

LUBRICANTS AND GREASESLubricating grease is rated for quality and usage

by the NLGI. All approved products have the NLGIsymbol (Fig. 3) on the label. At the bottom NLGIsymbol is the usage and quality identification letters.Wheel bearing lubricant is identified by the letterG. Chassis lubricant is identified by the latter L.The letter following the usage letter indicates thequality of the lubricant. The following symbols indi-cate the highest quality.

SPECIALIZED LUBRICANTS AND OILSSome maintenance or repair procedures may

require the use of specialized lubricants or oils. Con-sult the appropriate sections in this manual for thecorrect application of these lubricants.

Fig. 2 API Symbol

Fig. 3 NLGI Symbol1 - WHEEL BEARINGS2 - CHASSIS LUBRICATION3 - CHASSIS AND WHEEL BEARINGS

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AN LUBRICATION & MAINTENANCE 0 - 3

PECOMMENDATIONSWhen service is required, DaimlerChrysler Corpo-

ation recommends that only Mopart brand parts,ubricants and chemicals be used. Mopar provideshe best engineered products for servicing Daimler-hrysler Corporation vehicles.

LUID TYPES

ESCRIPTION - FUEL REQUIREMENTSYour engine is designed to meet all emissions reg-

lations and provide excellent fuel economy and per-ormance when using high quality unleaded regularasoline having an octane rating of 87. The routinese of premium gasoline is not recommended. Underormal conditions the use of premium fuel will notrovide a benefit over high quality regular gasolinesnd in some circumstances may result in poorer per-ormance.

Light spark knock at low engine speeds is notarmful to your engine. However, continued heavypark knock at high speeds can cause damage andmmediate service is required. Engine damage result-ng from operation with a heavy spark knock mayot be covered by the new vehicle warranty.Poor quality gasoline can cause problems such as

ard starting, stalling and hesitations. If you experi-nce these symptoms, try another brand of gasolineefore considering service for the vehicle.Over 40 auto manufacturers world-wide have

ssued and endorsed consistent gasoline specificationsthe Worldwide Fuel Charter, WWFC) to define fuelroperties necessary to deliver enhanced emissions,erformance and durability for your vehicle. We rec-mmend the use of gasolines that meet the WWFCpecifications if they are available.

EFORMULATED GASOLINEMany areas of the country require the use of

leaner burning gasoline referred to as reformulat-d gasoline. Reformulated gasoline contain oxygen-tes, and are specifically blended to reduce vehiclemissions and improve air quality.We strongly support the use of reformulated gaso-

ine. Properly blended reformulated gasoline will pro-ide excellent performance and durability for thengine and fuel system components.

ASOLINE/OXYGENATE BLENDSSome fuel suppliers blend unleaded gasoline with

xygenates such as 10% ethanol, MTBE, and ETBE.xygenates are required in some areas of the countryuring the winter months to reduce carbon monoxide

ARTS & LUBRICANT (Continued)missions. Fuels blended with these oxygenates maye used in your vehicle.CAUTION: DO NOT use gasoline containing METH-ANOL. Gasoline containing methanol may damagecritical fuel system components.

MMT IN GASOLINEMMT is a manganese-containing metallic additive

that is blended into some gasoline to increase octane.Gasoline blended with MMT provide no performanceadvantage beyond gasoline of the same octane num-ber without MMT. Gasoline blended with MMTreduce spark plug life and reduce emission systemperformance in some vehicles. We recommend thatgasolines free of MMT be used in your vehicle. TheMMT content of gasoline may not be indicated on thegasoline pump; therefore, you should ask your gaso-line retailer whether or not his/her gasoline containsMMT.

It is even more important to look for gasoline with-out MMT in Canada because MMT can be used atlevels higher than allowed in the United States.MMT is prohibited in Federal and California refor-mulated gasoline.

SULFUR IN GASOLINEIf you live in the northeast United States, your

vehicle may have been designed to meet Californialow emission standards with Cleaner-Burning Cali-fornia reformulated gasoline with low sulfur. If suchfuels are not available in states adopting Californiaemission standards, your vehicles will operate satis-factorily on fuels meeting federal specifications, butemission control system performance may beadversely affected. Gasoline sold outside of Californiais permitted to have higher sulfur levels which mayaffect the performance of the vehicles catalytic con-verter. This may cause the Malfunction IndicatorLamp (MIL), Check Engine or Service Engine Soonlight to illuminate. We recommend that you try a dif-ferent brand of unleaded gasoline having lower sulfurto determine if the problem is fuel related prior toreturning your vehicle to an authorized dealer forservice.

CAUTION: If the Malfunction Indicator Lamp (MIL),Check Engine or Service Engine Soon light is flash-ing, immediate service is required; see on-boarddiagnostics system section.

MATERIALS ADDED TO FUELAll gasoline sold in the United States and Canada

are required to contain effective detergent additives.Use of additional detergents or other additives is not

needed under normal conditions.

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0 - 4 LUBRICATION & MAINTENANCE AN

FUEL SYSTEM CAUTIONS

AUTION: Follow these guidelines to maintain yourehicles performance:

The use of leaded gas is prohibited by Federalaw. Using leaded gasoline can impair engine perfor-

ance, damage the emission control system, andould result in loss of warranty coverage. An out-of-tune engine, or certain fuel or ignitionalfunctions, can cause the catalytic converter to

verheat. If you notice a pungent burning odor orome light smoke, your engine may be out of tune oralfunctioning and may require immediate service.ontact your dealer for service assistance. When pulling a heavy load or driving a fully

oaded vehicle when the humidity is low and the tem-erature is high, use a premium unleaded fuel toelp prevent spark knock. If spark knock persists,

ighten the load, or engine piston damage may result. The use of fuel additives which are now being

old as octane enhancers is not recommended. Mostf these products contain high concentrations ofethanol. Fuel system damage or vehicle perfor-ance problems resulting from the use of such fuels

r additives is not the responsibility of Daimler-hrysler Corporation and may not be covered under

he new vehicle warranty.

OTE: Intentional tampering with emissions controlystems can result in civil penalties being assessedgainst you.

ESCRIPTION - ENGINE COOLANT

ARNING: ANTIFREEZE IS AN ETHYLENE GLYCOLASE COOLANT AND IS HARMFUL IF SWAL-OWED OR INHALED. IF SWALLOWED, DRINKWO GLASSES OF WATER AND INDUCE VOMIT-

NG. IF INHALED, MOVE TO FRESH AIR AREA.EEK MEDICAL ATTENTION IMMEDIATELY. DO NOTTORE IN OPEN OR UNMARKED CONTAINERS.ASH SKIN AND CLOTHING THOROUGHLY AFTEROMING IN CONTACT WITH ETHYLENE GLYCOL.EEP OUT OF REACH OF CHILDREN. DISPOSE OFLYCOL BASE COOLANT PROPERLY, CONTACTOUR DEALER OR GOVERNMENT AGENCY FOROCATION OF COLLECTION CENTER IN YOURREA. DO NOT OPEN A COOLING SYSTEM WHENHE ENGINE IS AT OPERATING TEMPERATURE OROT UNDER PRESSURE, PERSONAL INJURY CANESULT. AVOID RADIATOR COOLING FAN WHENNGINE COMPARTMENT RELATED SERVICE IS

LUID TYPES (Continued)ERFORMED, PERSONAL INJURY CAN RESULT.CAUTION: Use of Propylene Glycol based coolantsis not recommended, as they provide less freezeprotection and less corrosion protection.

The cooling system is designed around the coolant.The coolant must accept heat from engine metal, inthe cylinder head area near the exhaust valves andengine block. Then coolant carries the heat to theradiator where the tube/fin radiator can transfer theheat to the air.

The use of aluminum cylinder blocks, cylinderheads, and water pumps requires special corrosionprotection. Mopart Antifreeze/Coolant, 5Year/100,000 Mile Formula (MS-9769), or the equiva-lent ethylene glycol base coolant with organic corro-sion inhibitors (called HOAT, for Hybrid OrganicAdditive Technology) is recommended. This coolantoffers the best engine cooling without corrosion whenmixed with 50% Ethylene Glycol and 50% distilledwater to obtain a freeze point of -37C (-35F). If itloses color or becomes contaminated, drain, flush,and replace with fresh properly mixed coolant solu-tion.

CAUTION: MoparT Antifreeze/Coolant, 5Year/100,000 Mile Formula (MS-9769) may not bemixed with any other type of antifreeze. Mixing ofcoolants other than specified (non-HOAT or otherHOAT), may result in engine damage that may notbe covered under the new vehicle warranty, anddecreased corrosion protection.

COOLANT PERFORMANCEThe required ethylene-glycol (antifreeze) and water

mixture depends upon climate and vehicle operatingconditions. The coolant performance of various mix-tures follows:

Pure Water-Water can absorb more heat than amixture of water and ethylene-glycol. This is for pur-pose of heat transfer only. Water also freezes at ahigher temperature and allows corrosion.

100 percent Ethylene-Glycol-The corrosioninhibiting additives in ethylene-glycol need the pres-ence of water to dissolve. Without water, additivesform deposits in system. These act as insulationcausing temperature to rise to as high as 149C(300F). This temperature is hot enough to melt plas-tic and soften solder. The increased temperature canresult in engine detonation. In addition, 100 percentethylene-glycol freezes at -22C (-8F).

50/50 Ethylene-Glycol and Water-Is the recom-mended mixture, it provides protection against freez-ing to -37C (-34F). The antifreeze concentration

must alwaysbe a minimum of 44 percent, year-round in all climates. If percentage is lower, engineparts may be eroded by cavitation. Maximum protec-

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Fion against freezing is provided with a 68 percentntifreeze concentration, which prevents freezingown to -67.7C (-90F). A higher percentage willreeze at a warmer temperature. Also, a higher per-entage of antifreeze can cause the engine to over-eat because specific heat of antifreeze is lower thanhat of water.

AUTION: Richer antifreeze mixtures cannot beeasured with normal field equipment and can

ause problems associated with 100 percent ethyl-ne-glycol.

OOLANT SELECTION AND ADDITIVES

OTE: Refer to the vehicles coolant bottle cap todentify HOAT or Non-HOAT coolant. Non-HOAToolant is green in color.

The use of aluminum cylinder blocks, cylindereads and water pumps requires special corrosionrotection. Only Mopart Antifreeze/Coolant, 5ear/100,000 Mile Formula (glycol base coolant withorrosion inhibitors called HOAT, for Hybrid Organicdditive Technology) is recommended. This coolantffers the best engine cooling without corrosion whenixed with 50% distilled water to obtain to obtain a

reeze point of -37C (-35F). If it loses color orecomes contaminated, drain, flush, and replace withresh properly mixed coolant solution.

AUTION: Do not use coolant additives that arelaimed to improve engine cooling.

ESCRIPTION - ENGINE OIL

ARNING: NEW OR USED ENGINE OIL CAN BERRITATING TO THE SKIN. AVOID PROLONGED OREPEATED SKIN CONTACT WITH ENGINE OIL.ONTAMINANTS IN USED ENGINE OIL, CAUSED BY

NTERNAL COMBUSTION, CAN BE HAZARDOUS TOOUR HEALTH. THOROUGHLY WASH EXPOSEDKIN WITH SOAP AND WATER. DO NOT WASHKIN WITH GASOLINE, DIESEL FUEL, THINNER, OROLVENTS, HEALTH PROBLEMS CAN RESULT. DOOT POLLUTE, DISPOSE OF USED ENGINE OILROPERLY. CONTACT YOUR DEALER OR GOVERN-ENT AGENCY FOR LOCATION OF COLLECTIONENTER IN YOUR AREA.

PI SERVICE GRADE CERTIFIEDUse an engine oil that is API Service Grade Certi-

LUID TYPES (Continued)ied. MOPARt provides engine oils that conform tohis service grade.SAE VISCOSITYAn SAE viscosity grade is used to specify the vis-

cosity of engine oil. Use only engine oils with multi-ple viscosities such as 5W-30 or 10W-30. These arespecified with a dual SAE viscosity grade which indi-cates the cold-to-hot temperature viscosity range.Select an engine oil that is best suited to your par-ticular temperature range and variation (Fig. 4) and(Fig. 5).

ENERGY CONSERVING OILAn Energy Conserving type oil is recommended for

gasoline engines. The designation of ENERGY CON-SERVING is located on the label of an engine oil con-tainer.

CONTAINER IDENTIFICATIONStandard engine oil identification notations have

been adopted to aid in the proper selection of engineoil. The identifying notations are located on the labelof engine oil plastic bottles and the top of engine oilcans (Fig. 6).

This symbol on the front of an oil container meansthat the oil has been certified by the American Petro-leum Institute (API) to meet all the lubrication

Fig. 4 Temperature/Engine Oil Viscosity

Fig. 5 Temperature/Engine Oil Viscosityrequirements specified by DaimlerChrysler.

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FESCRIPTION - TRANSFER CASE - NV233Recommended lubricant for the NV233 transfer

ase is Mopart ATF +4, type 9602, Automatic Trans-ission Fluid.

ESCRIPTION - TRANSFER CASE - NV244Recommended lubricant for the NV244 transfer

ase is Mopart ATF +4, type 9602, Automatic Trans-ission Fluid.

ESCRIPTION - AXLEA multi-purpose, hypoid gear lubricant which con-

orms to the following specifications should be used.opar Hypoid Gear Lubricant conforms to all of

hese specifications.

RONT AXLE The lubricant should have MIL-L-2105C andPI GL 5 quality specifications. Lubricant is a thermally stable SAE 80W-90

ear lubricant.

EAR AXLE The lubricant should have MIL-L-2105C andPI GL 5 quality specifications. 8 1/4 axle lubricant is a thermally stable SAE

0W-90 gear lubricant. 9 1/4 axle lubricant is a thermally stable SAE

5W-90 gear lubricant.

OTE: Trac-lok equipped axles require a frictionodifier be added to the lubricant.

ESCRIPTION - MANUAL TRANSMISSIONMopart Manual Transmission Lubricant is the

nly lubricant recommended for use in the manualransmissions.

ESCRIPTION - AUTOMATIC TRANSMISSIONLUID

Fig. 6 Engine Oil Container Standard Notations

LUID TYPES (Continued)OTE: Refer to the maintenance schedules in thisroup for the recommended maintenance (fluid/filterhange) intervals for this transmission.NOTE: Refer to Service Procedures in this group forfluid level checking procedures.

Mopart ATF +4, type 9602, Automatic Transmis-sion Fluid is the recommended fluid for Daimler-Chrysler automatic transmissions.

Dexron II fluid IS NOT recommended. Clutchchatter can result from the use of improperfluid.

Mopart ATF +4, type 9602, Automatic Transmis-sion Fluid when new is red in color. The ATF is dyedred so it can be identified from other fluids used inthe vehicle such as engine oil or antifreeze. The redcolor is not permanent and is not an indicator of fluidcondition. As the vehicle is driven, the ATF will beginto look darker in color and may eventually becomebrown. This is normal. A dark brown/black fluidaccompanied with a burnt odor and/or deteriorationin shift quality may indicate fluid deterioration ortransmission component failure.

FLUID ADDITIVESDaimlerChrysler strongly recommends against the

addition of any fluids to the transmission, other thanthose automatic transmission fluids listed above.Exceptions to this policy are the use of special dyesto aid in detecting fluid leaks.

Various special additives and supplements existthat claim to improve shift feel and/or quality. Theseadditives and others also claim to improve converterclutch operation and inhibit overheating, oxidation,varnish, and sludge. These claims have not been sup-ported to the satisfaction of DaimlerChrysler andthese additives must not be used. The use of trans-mission sealers should also be avoided, since theymay adversely affect the integrity of transmissionseals.

OPERATION - AUTOMATIC TRANSMISSIONFLUID

The automatic transmission fluid is selected basedupon several qualities. The fluid must provide a highlevel of protection for the internal components byproviding a lubricating film between adjacent metalcomponents. The fluid must also be thermally stableso that it can maintain a consistent viscosity througha large temperature range. If the viscosity stays con-stant through the temperature range of operation,transmission operation and shift feel will remain con-sistent. Transmission fluid must also be a good con-ductor of heat. The fluid must absorb heat from theinternal transmission components and transfer thatheat to the transmission case.

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AN LUBRICATION & MAINTENANCE 0 - 7LUID FILL/CHECKOCATIONS

ESCRIPTIONThe fluid check/fill points and lubrication locations

re located in each applicable Sections.

AINTENANCE SCHEDULES

ESCRIPTIONService and maintenance procedures for compo-

ents and systems listed in Schedule A or B cane found by using the Group Tab Locator index athe front of this manual. If it is not clear whichroup contains the information needed, refer to thendex at the back of this manual.

There are two maintenance schedules that showroper service based on the conditions that the vehi-le is subjected to.Schedule A, lists scheduled maintenance to be

erformed when the vehicle is used for general trans-ortation.Schedule B, lists maintenance intervals for vehi-

les that are operated under the conditions listed athe beginning of that schedule section.

Use the schedule that best describes the drivingonditions.Where time and mileage are listed, follow the

nterval that occurs first.

AINTENANCE SCHEDULESThere are two maintenance schedules that show

roper service for the Dakota.First is Schedule A. It lists all the scheduledaintenance to be performed under normal operat-

ng conditions.Second is Schedule B. It is a schedule for vehi-

les that are operated under the conditions listed athe beginning of that schedule.

Use the schedule that best describes the drivingonditions.Where time and mileage are listed, follow the

nterval that occurs first.

t Each Stop For Gasoline Check engine oil level, add as required. Check windshield washer solvent and add if

equired. Clean windshield and wiper blades as required.nce A Month Check tire pressure and look for unusual wearr damage. Inspect battery and clean and tighten terminals

s required. Check fluid levels of coolant reservoir, powersteering and transmission and add as needed.

Check all lights and all other electrical items forcorrect operation.

Inspect and clean wiper blades. Replace ifrequired.

At Each Oil Change Inspect exhaust system. Inspect brake hoses. Rotate the tires at each oil change interval

shown on Schedule A: (7,500 miles) or every otherinterval shown on Schedule B (6,000 miles).

Check engine coolant level, hoses, and clamps.

EMISSION CONTROL SYSTEM MAINTENANCEThe scheduled emission maintenance listed in bold

type on the Maintenance Schedules, must be done atthe mileage specified to assure the continued properfunctioning of the emission control system. These,and all other maintenance services included in thismanual, should be done to provide the best vehicleperformance and reliability. More frequent mainte-nance may be needed for vehicles in severe operatingconditions such as dusty areas and very short tripdriving.

FLUID FILL LOCATIONS AND LUBRICATIONPOINTS

The fluid fill/check locations and lubrication pointsare located in each applicable group.

SCHEDULE A

7,500 Miles (12 000 km) or at 6 months Change engine oil. Replace engine oil filter.


22,500 Miles (36 000 km) or at 18 months Change engine oil. Replace engine oil filter. Lubricate front suspension ball joints if

required. Inspect front wheel bearings. Inspect brake linings.

30,000 Miles (48 000 km) or at 24 months Change engine oil. Replace engine oil filter. Replace engine air cleaner element.

Replace spark plugs.

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M Drain and refill automatic transmission fluidnd change filter (4.7L only).

7,500 Miles (60 000 km) or at 30 months Change engine oil. Replace engine oil filter. Drain and refill transfer case fluid. Drain and refill automatic transmission fluid.

eplace filter and adjust bands (3.9L, and 5.9L only).


equired. Inspect front wheel bearings. Inspect brake linings. Flush and replace engine coolant at 36 months,

egardless of mileage.

2,500 Miles (84 000 km) or at 42 months Change engine oil. Replace engine oil filter. Flush and replace engine coolant if not done at

6 months.

0,000 Miles (96 000 km) or at 48 months Change engine oil. Replace engine oil filter. Replace engine air cleaner element. Replace ignition cables (2.5L, 3.9L, 5.9L). Inspect PCV valve, replace as necessary.

3.9L, 4.7L, and 5.9L)* Replace spark plugs. Inspect auto tension drive belt and replace if

equired (3.9L, & 5.9L). Inspect and adjust tension on drive belt (2.5L). Drain and refill automatic transmission fluid

nd change filter (4.7L only).


equired. Inspect front wheel bearings. Inspect brake linings.

5,000 Miles (120 000 km) or at 60 months Change engine oil. Replace engine oil filter. Drain and refill automatic transmission fluid.

eplace filter and adjust bands (3.9L & 5.9L). Drain and refill transfer case.

AINTENANCE SCHEDULES (Continued) Flush and replace engine coolant if it has been0,000 miles (48 000 km) or 24 months since lasthange. Inspect auto tension drive belt and replace ifrequired (3.9L, & 5.9L).

82,500 Miles (132 000 km) or at 66 months Change engine oil. Replace engine oil filter. Flush and replace engine coolant if it has been

30,000 miles (48 000 km) or 24 months since lastchange.

90,000 Miles (144 000 km) or at 72 months Change engine oil. Replace engine oil filter. Replace engine air cleaner element. Inspect PCV valve, replace as necessary.

(3.9L, 4.7L, and 5.9L)* Replace spark plugs. Lubricate front suspension ball joints if

required. Inspect front wheel bearings. Inspect brake linings. Inspect auto tension drive belt and replace if

required (3.9L, 4.7L, & 5.9L).D


105,000 Miles (168 000 km) or at 84 months Change engine oil. Replace engine oil filter. Flush and replace engine coolant if it has been

30,000 Miles (48 000km) or 24 months since lastchange.

Inspect auto tension drive belt and replace ifrequired (3.9L, 4.7L, & 5.9L).D

112,500 Miles (181 000 km) or at 90 months Change engine oil. Replace engine oil filter. Drain and refill automatic transmission fluid.

Replace filter and adjust bands (3.9L & 5.9L only). Drain and refill transfer case fluid. Lubricate front suspension ball joints if

required. Inspect front wheel bearings. Inspect brake linings. Flush and replace engine coolant if it has been

30,000 Miles (48 000km) or 24 months since lastchange.


Replace engine air cleaner element. Replace ignition cables (2.5L, 3.9L & 5.9L).

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M Inspect PCV valve, replace as necessary.3.9L, 4.7L, and 5.9L)*

Replace spark plugs. Inspect auto tension drive belt and replace if

equired (3.9L, 4.7L, & 5.9L).D Drain and refill automatic transmission fluid

nd change filter (4.7L only).*This maintenance is recommended by Daimler-hrysler Corporation to the owner but is notequired to maintain the warranty on the PCV valve.DThis maintenance is not required if the belt was

reviously replaced.Important: Inspection and service should also be

erformed any time a malfunction is observed or sus-ected.

CHEDULE BUse schedule B if the vehicle is usually operated

nder the following conditions: Frequent short trip driving less than 5 miles (8

m) Frequent driving in dusty conditions Trailer towing Extensive idling More than 50% of the driving is at sustained

igh speeds during hot weather, above 90F (32C)

,000 Miles (5 000 km) Change engine oil. Replace engine oil filter.



2,000 Miles (19 000 km) Change engine oil. Replace engine oil filter. Drain and refill automatic transmission fluid.

eplace filter and adjust bands (3.9L & 5.9L). Drain and refill automatic transmission fluid

nd change filter (4.7L only). Lubricate front suspension ball joints if

equired. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings.

5,000 Miles (24 000 km) Change engine oil.

AINTENANCE SCHEDULES (Continued) Replace engine oil filter. Inspect engine air cleaner element, replace

s necessary.18,000 Miles (29 000 km) Change engine oil. Replace engine oil filter. Drain and refill manual transmission fluid (3.9L

only).

21,000 Miles (34 000 km) Change engine oil. Replace engine oil filter. Inspect front wheel bearings.

24,000 Miles (38 000 km) Change engine oil. Replace engine oil filter. Drain and refill automatic transmission fluid.

Replace filter and adjust bands (3.9L & 5.9L). Drain and refill automatic transmission fluid

and change filter (4.7L only). Lubricate front suspension ball joints if

required. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings.

27,000 miles (43 000 km) Change engine oil. Replace engine oil filter.

30,000 Miles (48 000 km) Change engine oil. Replace engine oil filter. Replace engine air cleaner element. Replace spark plugs. Inspect PCV valve, replace as necessary.

(3.9L, 4.7L and 5.9L)* Inspect and adjust drive tension on drive belt

(2.5L).

33,000 Miles (53,000 km) Change engine oil. Replace engine oil filter.

36,000 Miles (58 000 km) Change engine oil. Replace engine oil filter. Lubricate front suspension ball joints if

required. Drain and refill automatic transmission fluid.


and change filter (4.7L only). Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4x4).

Inspect brake linings.

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M9,000 Miles (62 000 km) Change engine oil. Replace engine oil filter.


5,000 Miles (72 000 km) Change engine oil. Replace engine oil filter. Inspect engine air cleaner element, replace

s necessary.


equired. Drain and refill automatic transmission fluid.eplace filter and adjust bands (3.9L & 5.9L). Drain and refill automatic transmission fluid

nd change filter (4.7L only). Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings.

1,000 Miles (82 000 km) Change engine oil. Replace engine oil filter. Flush and replace engine coolant.

4,000 Miles (86 000 km) Change engine oil. Replace engine oil filter. Drain and refill manual transmission fluid (3.9L

nly).

7,000 Miles (91 000 km) Change engine oil. Replace engine oil filter.

0,000 Miles (96 000 km) Change engine oil. Replace engine oil filter. Replace engine air cleaner element. Replace ignition cables. Inspect PCV valve, replace as necessary.

3.9L, 4.7L, and 5.9L)* Replace spark plugs. Drain and refill automatic transmission fluid.

eplace filter and adjust bands (3.9L & 5.9L). Drain and refill automatic transmission fluid

AINTENANCE SCHEDULES (Continued)nd change filter (4.7L only). Lubricate front suspension ball joints if

equired. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings. Inspect auto tension drive belt and replace if

required (3.9L & 5.9L).


66,000 Miles (106,000 km) Change engine oil. Replace engine oil filter.





and change filter (4.7L only). Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings.


as necessary. Inspect auto tension drive belt and replace if

required (3.9L, 4.7L & 5.9L).D


81,000 Miles (130 000 km) Change engine oil. Replace engine oil filter. Flush and replace engine coolant if it has been

30,000 miles (48 000 km) since last change.


Inspect front wheel bearings. Lubricate front suspension ball joints if

required.

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0,000 Miles (144 000 km) Change engine oil. Replace engine oil filter. Replace engine air cleaner element. Replace spark plugs. Inspect PCV valve, replace as necessary.

3.9L, 4.7L, and 5.9L)* Inspect auto tension drive belt and replace if

equired (3.9L, 4.7L, & 5.9L).D Inspect and adjust tension on drive belt (2.5L).



equired. Drain and refill automatic transmission fluid.eplace filter and adjust bands (3.9L & 5.9L). Drain and refill automatic transmission fluid


9,000 Miles (158 000 km) Change engine oil Replace engine oil filter.



s necessary. Inspect front wheel bearings.

AINTENANCE SCHEDULES (Continued) Inspect auto tension drive belt and replace ifequired (3.9L, 4.7L, & 5.9L).D108,000 Miles (173 000 km) Change engine oil. Replace engine oil filter. Lubricate front suspension ball joints if



and change filter (4.7L only). Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings.

111,000 Miles (178 000 km) Change engine oil. Replace engine oil filter. Flush and replace engine coolant if it has been

30,000 miles (48 000 km) since last change.



120,000 Miles (192 000 km) Change engine oil. Replace engine oil filter. Replace engine air cleaner element. Replace ignition cables. Inspect PCV valve, replace as necessary.

(3.9L, 4.7L, and 5.9L)* Replace spark plugs. Lubricate front suspension ball joints if



and change filter (4.7L only). Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings. Inspect auto tension drive belt and replace if

required (3.9L, 4.7L, & 5.9L).D Inspect and adjust tension on drive belt (2.5L).*This maintenance is recommended by Chrysler

Corporation to the customer but is not required tomaintain warranty on the PCV valve.

DThis maintenance is not required if the belt waspreviously replaced.

Prolonged operation with heavy loading, espe-

cially in hot weather, use of vehicle for off-the-high-way operation, and trailer towing require the more

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Mrequent transmission service indicated with a inchedule B. Perform these services if the vehicle issually operated under these conditions.Important: Inspection and service should also be

erformed any time a malfunction is observed or sus-ected.

OISTING

TANDARD PROCEDUREHOISTINGECOMMENDATIONS

LOOR JACK

AUTION: Do not attempt to lift a vehicle with aloor jack positioned under:

An axle tube. Aluminum differential. A body side sill. A steering linkage component. A drive shaft. The engine or transmission oil pan. The fuel tank. A front suspension arm.When properly positioned, a floor jack can be used

o lift a Dakota vehicle (Fig. 7). Support the vehiclen the raised position with jack stands at the frontnd rear ends of the frame rails.

AINTENANCE SCHEDULES (Continued)Fig. 7 Correct Vehicle Lifting LocationsTypicalHOIST

WARNING: THE HOISTING AND JACK LIFTINGPOINTS PROVIDED ARE FOR A COMPLETE VEHI-CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-NENT IS REMOVED FROM A VEHICLE, THECENTER OF GRAVITY IS ALTERED MAKING SOMEHOISTING CONDITIONS UNSTABLE. PROPERLYSUPPORT OR SECURE VEHICLE TO HOISTINGDEVICE WHEN THESE CONDITIONS EXIST.

CAUTION: DO NOT LET THE REAR WHEELS/AXLEHANG UNSUPPORTED WHEN THE VEHICLE ISLIFTED WITH THE PARKING BRAKE APPLIED.

NOTE: When a frame-contact type hoist is used,verify that the lifting pads are positioned properly(Fig. 7).

A vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist.

JUMP STARTING

STANDARD PROCEDUREJUMP STARTINGPROCEDURE

WARNING: REVIEW ALL SAFETY PRECAUTIONSAND WARNINGS IN GROUP 8A, BATTERY/START-ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOTJUMP START A FROZEN BATTERY, PERSONALINJURY CAN RESULT. DO NOT JUMP START WHENMAINTENANCE FREE BATTERY INDICATOR DOT ISYELLOW OR BRIGHT COLOR. DO NOT JUMPSTART A VEHICLE WHEN THE BATTERY FLUID ISBELOW THE TOP OF LEAD PLATES. DO NOTALLOW JUMPER CABLE CLAMPS TO TOUCHEACH OTHER WHEN CONNECTED TO A BOOSTERSOURCE. DO NOT USE OPEN FLAME NEAR BAT-TERY. REMOVE METALLIC JEWELRY WORN ONHANDS OR WRISTS TO AVOID INJURY BY ACCI-DENTAL ARCING OF BATTERY CURRENT. WHENUSING A HIGH OUTPUT BOOSTING DEVICE, DONOT ALLOW BATTERY VOLTAGE TO EXCEED 16VOLTS. REFER TO INSTRUCTIONS PROVIDEDWITH DEVICE BEING USED.

CAUTION: When using another vehicle as abooster, do not allow vehicles to touch. Electrical

systems can be damaged on either vehicle.

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J(1) Raise hood on disabled vehicle and visuallynspect engine compartment for:

Battery cable clamp condition, clean if necessary. Frozen battery. Yellow or bright color test indicator, if equipped. Low battery fluid level. Generator drive belt condition and tension. Fuel fumes or leakage, correct if necessary.

AUTION: If the cause of starting problem on dis-bled vehicle is severe, damage to booster vehicleharging system can result.

(2) When using another vehicle as a boosterource, park the booster vehicle within cable reach.urn off all accessories, set the parking brake, placehe automatic transmission in PARK or the manualransmission in NEUTRAL and turn the ignitionFF.(3) On disabled vehicle, place gear selector in park

r neutral and set park brake. Turn off all accesso-ies.(4) Connect jumper cables to booster battery. RED

lamp to positive terminal (+). BLACK clamp to neg-tive terminal (-). DO NOT allow clamps at oppositend of cables to touch, electrical arc will result.eview all warnings in this procedure.(5) On disabled vehicle, connect RED jumper cable

lamp to positive (+) terminal. Connect BLACKumper cable clamp to engine ground as close to theround cable attaching point as possible (Fig. 8).(6) Start the engine in the vehicle which has the

ooster battery, let the engine idle a few minutes,hen start the engine in the vehicle with the dis-harged battery.

AUTION: Do not crank starter motor on disabledehicle for more than 15 seconds, starter will over-eat and could fail.

(7) Allow battery in disabled vehicle to charge tot least 12.4 volts (75% charge) before attempting totart engine. If engine does not start within 15 sec-nds, stop cranking engine and allow starter to cool15 min.), before cranking again.

ISCONNECT CABLE CLAMPS AS FOLLOWS: Disconnect BLACK cable clamp from engine

round on disabled vehicle. When using a Booster vehicle, disconnectLACK cable clamp from battery negative terminal.isconnect RED cable clamp from battery positive

erminal. Disconnect RED cable clamp from battery posi-

ive terminal on disabled vehicle.

UMP STARTING (Continued)TOWING

STANDARD PROCEDURETOWINGRECOMMENDATIONS

A vehicle equipped with an SAE approved Wheel-lift towing device can be used to tow all Short BedDAKOTA vehicles. Long Bed vehicles must be towedwith a Flat-bed device (Fig. 9). When towing a 4WDvehicle, use tow dollies under the opposite end of thevehicle.

Fig. 8 Jumper Cable Clamp Connections1 - ENGINE GROUND2 - NEGATIVE JUMPER CABLE3 - BATTERY NEGATIVE CABLE4 - POSITIVE JUMPER CABLE5 - BATTERY POSITIVE CABLE6 - BATTERY7 - TEST INDICATOR

Fig. 9 Tow Vehicles With Approved Equipment

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TAFETY PRECAUTIONS

OTE: The following safety precautions must bebserved when towing a vehicle.

Secure loose and protruding parts. Always use a safety chain system that is inde-

endent of the lifting and towing equipment. Do not allow towing equipment to contact the

isabled vehicles fuel tank. Do not allow anyone under the disabled vehiclehile it is lifted by the towing device. Do not allow passengers to ride in a vehicle

eing towed. Always observe state and local laws regarding

owing regulations. Do not tow a vehicle in a manner that could

eopardize the safety of the operator, pedestrians orther motorists. Do not attach tow chains, T-hooks, or J-hooks tobumper, steering linkage, drive shafts or a non-re-

nforced frame hole. Do not tow a heavily loaded vehicle. Damage to

he cab, cargo box or frame may result. Use a flated device to transport a loaded vehicle.

ROUND CLEARANCE

AUTION: If vehicle is towed with wheels removed,nstall lug nuts to retain brake drums.

A towed vehicle should be raised until lifted wheelsre a minimum 100 mm (4 in) from the ground. Beure there is adequate ground clearance at the oppo-ite end of the vehicle, especially when towing overough terrain or steep rises in the road. If necessary,emove the wheels from the lifted end of the vehiclend lower the vehicle closer to the ground, toncrease the ground clearance at the opposite end ofhe vehicle. Install lug nuts on wheel attaching studso retain brake drums.

AMP ANGLEIf a vehicle with flat bed towing equipment is used,

he approach ramp angle should not exceed 15egrees.

OWING WHEN KEYS ARE NOT AVAILABLEWhen the vehicle is locked and keys are not avail-

ble, use a flat bed hauler. A Sling-type device can besed on 4WD vehicles provided all the wheels areifted off the ground using tow dollies.

OWING (Continued)STANDARD PROCEDURETWO WHEEL DRIVEVEHICLE TOWING

TOWING-REAR END LIFTED

CAUTION:Short bed vehicles must be towed with a Wheel-liftdevice (Fig. 10) or transported on a flat bed (Fig.11). Long bed vehicles must be transported on aflat bed.

2WD vehicles can be towed with the front wheelson the surface for extended distances at speeds notexceeding 48 km/h (30 mph).

(1) Attach wheel lift device to rear wheels.(2) Attach safety chains to frame rails. Route

chains so not to interfere with tail pipe when vehicleis lifted.

(3) Turn the ignition switch to the OFF position tounlock the steering wheel.

CAUTION: Do not use steering column lock tosecure steering wheel during towing operation.

(4) Secure steering wheel in straight ahead posi-tion with a clamp device designed for towing.

(5) Verify that steering components are in goodcondition.

(6) Shift the transmission to NEUTRAL.

TOWING-FRONT END LIFTEDWhen lifting from the front end, all vehicles must

be towed with a Wheel-lift device or transported on a

Fig. 10 Short Bed Vehicle TowingTypical

Fig. 11 Long Bed Vehicle TowingTypicalflat bed.(1) Attach Wheel-lift device to front wheels.

(2) Attach the safety chains to the disabled vehicleat the frame rails.



TWO WHEEL DRIVEMANUAL AND AUTOMATICTRANSMISSION

Provided the transmission is operable, tow only inNEUTRAL at speeds not to exceed 30 mph (50km/h) and distances less than 15 miles (25km/h).

If the vehicle is to be towed more than 15 miles,the propeller shaft should be disconnected or placetow dollies under rear wheels.

STANDARD PROCEDUREFOUR WHEELDRIVE VEHICLE TOWING

FOUR WHEEL DRIVE TOWINGREAR END LIFTED

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(2) Attach wheel lift device to rear wheels.(3) Attach safety chains to frame rails. Route

chains so not to interfere with tail pipe when vehicleis lifted.



(5) Secure steering wheel in straight ahead posi-tion with a clamp device designed for towing.

(6) Shift the transfer case to NEUTRAL.

FOUR WHEEL DRIVE TOWINGFRONT ENDLIFTED

When lifting from the front end, all vehicles mustbe towed with a wheel-lift device or transported on aflat bed.

(1) Raise the rear of the vehicle off the ground andinstall tow dollies under rear wheels.

(2) Attach wheel lift device to front wheels.(3) Attach the safety chains to the disabled vehicle


TOWING (Continued)AUTION:hort bed vehicles must be towed with a Wheel-liftevice (Fig. 10) or transported on a flat bed. Longed vehicles must be transported on a flat bed (Fig.1). When using a Wheel-lift device, all wheels muste lifted off the ground using tow dollies.

(1) Raise the front of the vehicle off the groundnd install tow dollies under front wheels.at the frame rails.



(5) Shift the transfer case to NEUTRAL.

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STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 3HEIGHT MEASUREMENT 4WD . . . . . . . . . . . . . 3

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5

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the wheels in relation to the vehicle. The positioningis accomplished through suspension and steeringleima

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2 - STEERING AXIS INCLINATION3 - PIVOT POINT

AN SUSPENSION 2 - 1ubrication And Maintenance for the recommendedaintenance schedule.

PERATION CASTER is the forward or rearward tilt of the

Positive caster promotes directional stability. Thisangle enables the front wheels to return to a straightahead position after turns (Fig. 2).

4 - TOE-INOTE: Periodic lubrication of the front suspension/teering system components may be required. Rub-teering knuckle from vertical. Tilting the top of thenuckle forward provides negative caster. Tilting theop of the knuckle rearward provides positive caster.Fig. 1 Wheel Alignment Measurements1 - FRONT OF VEHICLEinkage adjustments. An alignment is consideredssential for efficient steering, good directional stabil-ty and to minimize tire wear. The most important

easurements of an alignment are caster, cambernd toe (Fig. 1).

AUTION: Never attempt to modify suspension orteering components by heating or bending.HEEL ALIGNMENT

ESCRIPTIONWheel alignment involves the correct positioning ofSUSPE

TABLE OF

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HEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1RONT - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WHEEL AL

TABLE OF

page

HEEL ALIGNMENTDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2

PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . . 2SION

NTENTS

page

RONT - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15EAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

NMENT

NTENTS

page

HEIGHT ADJUSTMENT 4WD . . . . . . . . . . . . . . . 3CAMBER AND CASTER ADJUSTMENT . . . . . . . 4CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 4 CAMBER is the inward or outward tilt of thewheel relative to the center of the vehicle. Tilting thetop of the wheel inward provides negative camber.

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wear.(2) Inspect front wheel bearings for wear.

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noise.(6) On 4x4 vehicles check suspension height.

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2 - 2 WHEEL ALIGNMENT AN

W(3) Inspect front wheels for excessive radial or lat-ral runout and balance.(4) Inspect ball studs, linkage pivot points and

teering gear for looseness, roughness or binding.

SUSPENSION AND STEE

CONDITION POSSIBLE CAU

FRONT END NOISE 1. Loose or worn wheel b

2. Loose or worn steeringsuspension components.3. Lower ball joint (4x4).

EXCESSIVE PLAY INSTEERING

1. Loose or worn wheel b

2. Loose or worn steeringsuspension components.3. Loose or worn steering

FRONT WHEELS SHIMMY 1. Loose or worn wheel b

2. Loose or worn steeringsuspension components.3. Tires worn or out of ba4. Alignment.(7) Road test the vehicle.

G SYSTEM DIAGNOSIS

CORRECTION

ing. 1. Replace wheel bearing.

2. Tighten or replace components asnecessary.3. Gease joint and perform diagnosis andtesting.


2. Tighten or replace components asnecessary.

ar. 3. Adjust or replace steering gear.ing. 1. Replace wheel bearing.

2. Tighten or replace components asnecessary.

e. 3. Replace or balance tires.4. Align vehicle to specifications.ilting the top of the wheel outward provides positiveamber. Incorrect camber will cause wear on thenside or outside edge of the tire (Fig. 2).

TOE is the difference between the leading insidedges and trailing inside edges of the front tires.heel toe position out of specification causes unsta-

le steering, uneven tire wear and steering wheel off-enter. The wheel toe position is the final frontheel alignment adjustment (Fig. 2). THRUST ANGLE is the angle of the rear axle

elative to the centerline of the vehicle. Incorrecthrust angle can cause off-center steering and exces-ive tire wear. This angle is not adjustable, damagedomponent(s) must be replaced to correct the thrustngle (Fig. 2).

IAGNOSIS AND TESTING - PRE-ALIGNMENTNSPECTION

Before starting wheel alignment, the followingnspection and necessary corrections must be com-leted. Refer to Suspension and Steering Systemiagnosis Chart for additional information.(1) Inspect tires for size, air pressure and tread (5) Inspect suspension components for wear and

Fig. 2 Wheel Alignment1 - FRONT OF VEHICLE2 - STEERING AXIS INCLINATION3 - PIVOT POINT4 - TOE-IN

HEEL ALIGNMENT (Continued)

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SMEASUREMENT 4WD

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WThe vehicle suspension height must be measurednd adjusted if necessary before performing wheellignment on a 4x4 vehicle. Also when front suspen-ion components have be replaced. This measureust be performed with the vehicle supporting its

wn weight and taken on both sides of the vehicle.(1) Inspect tires for the correct size and air pres-

ure.(2) Jounce the front of the vehicle.(3) Measure and record the distance between the

round and the center of the lower suspension armear mounting bolt head (Fig. 3).(4) Measure and record the distance between the

round and the center of the front wheel (Fig. 3).(5) Subtract the first measurement from the sec-

nd measurement. The difference between the twoeasurement should be 47 mm (1.85 inches) 6 3.25m (0.125 inches).

TANDARD PROCEDURE - HEIGHTDJUSTMENT 4WDThe vehicle suspension height must be measured

nd adjusted if necessary before performing wheellignment on a 4x4 vehicle. Also when front suspen-

To adjust the vehicle height turn the torsion baradjustment bolt CLOCKWISE to raise the vehicleand COUNTER CLOCKWISE to lower the vehicle.

Fig. 3 HeightCONDITION POSSIBLE CAU

VEHICLE INSTABILITY 1. Loose or worn wheel b

2. Loose or worn steeringsuspension components.3. Tire pressure.4. Alignment.

EXCESSIVE STEERINGEFFORT

1. Loose or worn steering

2. Column coupler bindin3. Tire pressure.4. Alignment.

VEHICLE PULLS TO ONESIDE

1. Tire pressure.2. Alignment.3. Loose or worn steeringsuspension components.4. Radial tire lead.5. Brake pull.6. Weak or broken spring7. Ride height 4WD only.

TANDARD PROCEDURE - HEIGHT

HEEL ALIGNMENT (Continued)ion components have be replaced. This measureust be performed with the vehicle supporting its

wn weight and taken on both sides of the vehicle.CORRECTION


2. Tighten or replace components asnecessary.3. Adjust tire pressure.4. Align vehicle to specifications.

ar. 1. Adjust or replace steering gear.2. Replace coupler.3. Adjust tire pressure.4. Align vehicle to specifications.

1. Adjust tire pressure.2. Align vehicle to specifications.3. Tighten or replace components asnecessary.4. Rotate or replace tire as necessary.5. Repair brake as necessary.6. Replace spring.7. Measure and adjust ride height.

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2 - 4 WHEEL ALIGNMENT AN

WAUTION: ALWAYS raise the vehicle to the correctuspension height, NEVER lower the vehicle tobtain the correct suspension height. If the vehicleuspension height is too high, lower the vehicleelow the height specification. Then raise the vehi-le to the correct suspension height specification.his will insure the vehicle maintains the properuspension height.

OTE: If a height adjustment has been made, per-orm height measurement again on both sides ofhe vehicle.

TANDARD PROCEDURE - CAMBER ANDASTER ADJUSTMENT

OTE: 4x4 suspension height measurement muste performed before alignment.

Camber and caster angle adjustments involvehanging the position of the upper suspension armivot bar (Fig. 4).

OTE: On 4x2 vehicles use Alignment Tool 8393 forlignment. The tool attaches to the pivot bar on thepper control arm.

Fig. 4 Caster & Camber Adjustment-Typical1 - PIVOT BAR2 - + CASTER3 - + CAMBER4 - UPPER ARM SUSPENSION

HEEL ALIGNMENT (Continued)STANDARD PROCEDURE - CASTER

NOTE: 4x4 suspension height measurement mustbe performed before alignment.

Moving the rear position of the pivot bar in or out,will change the caster angle significantly and camberangle only slightly. To maintain the camber anglewhile adjusting caster, move the rear of the pivot barin or out. Then move the front of the pivot barslightly in the opposite direction.

For example, to increase a positive caster angle,move the rear position of the pivot bar inward(toward the engine). Move the front of pivot bar out-ward (away from the engine) slightly until the origi-nal camber angle is obtained.

STANDARD PROCEDURE - CAMBER


Move the front of the pivot bar in or out. This willchange the camber angle significantly and casterangle slightly.

After adjustment is made tighten the pivot barnuts to proper torque specification.

STANDARD PROCEDURE - TOE ADJUSTMENT


The wheel toe position adjustment is the finaladjustment.

(1) Start the engine and turn wheels both waysbefore straightening the wheels. Secure the steeringwheel with the front wheels in the straight-aheadposition.

(2) Loosen the tie rod jam nuts.

NOTE: Each front wheel should be adjusted forone-half of the total toe position specification. Thiswill ensure the steering wheel will be centeredwhen the wheels are positioned straight-ahead.

rod as necessary (Fig. 5).(4) Tighten the tie rod jam nut to 75 Nm (55 ft.

lbs.).(5) Verify the specifications.

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ALIGNMENT

NOTE: All alignment specifications are in degrees.

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AN WHEEL ALIGNMENT 2 - 5

WDESCRIPTION

VEHICLE WHEEL BASE CASTER (

4x2111.9 2.9130.9 3.1

4x4111.9 3.1130.9 3.2

MAXIMUM RT to LT DIFFERENCE 0.5

DAK

DESCRIPTIONVEHICLE WHEEL BASE CASTER (

4x2111.9 3.67130.9 3.81

MAXIMUM RT to LT DIFFERENCE 0.50SPECIFICATION

.50) CAMBER (6 0.50) TOTAL TOE (60.06)0.25 0.100.25 0.100.25 0.100.25 0.100.50 0.06

RT

SPECIFICATION50) CAMBER (6 0.50) TOTAL TOE (6 0.06)

0.34 0.100.34 0.100.50 0.06PECIFICATIONS(6) Turn off engine.

Fig. 5 Toe1 - JAM NUT2 - TIE ROD3 - TIE ROD END(3) Adjust the wheel toe position by turning the tie

HEEL ALIGNMENT (Continued)

FRONT - 2WD

TABLE OF CONTENTS

F

B

H

K

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9LOWER BALL JOINT

L

S

S

S

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13UPPER BALL JOINT

U

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Cter pin must be torqued to specification. Then if theslot in the nut does not line up with the cotter pinhn

Hub/Bearing

2 - 6 FRONT - 2WD ANole, tighten nut until it is aligned. Never loosen theut to align the cotter pin hole.

Ball JointsDIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 10LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 10

OWER CONTROL ARMREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10HOCKDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

RONT - 2WD

ESCRIPTION - 2WDThe front suspension is designed to allow eachheel to adapt to different road surfaces indepen-ently. The wheels are mounted to hub bearings onhe cast iron steering knuckle spindles. The double-ow hub bearings are sealed and lubricated for life.he steering knuckles turn (pivot) on ball joints riv-ted to the outboard portion of the suspension arms.he ball joints are lubricated for life.The 4x2 front suspension is comprised of (Fig. 1):

AUTION: Components attached with a nut and cot-DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 13UPPER BALL JOINT. . . . . . . . . . . . . . . . . . . . . 13

PPER CONTROL ARMREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CAUTION: Suspension components with rubber/ure-thane bushings (except stabilizer bar) should betightened with the vehicle at normal ride height. It isimportant to have the springs supporting the weightof the vehicle when the fasteners are torqued. Ifsprings are not at their normal ride position, vehicleride comfort could be affected and premature bush-ing wear may occur.

Shock absorbers Coil springs Suspension arms Stabilizer bar Jounce/Rebound Bumpers Steering Knucklepage

RONT - 2WDDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8USHINGS - CONTROL ARMREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8UB / BEARINGREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9NUCKLEDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9page

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11

SHOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PRINGDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12TABILIZER BARDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ST

DESCRIPTION Nm Ft. Lbs. In. Lbs.

AN FRONT - 2WD 2 - 7

FShock AbsorberUpper Nut

Shock AbsorberLower Bolts

Lower Suspension ArmFront Nut

Lower Suspension ArmRear Nut

Lower Suspension ArmBall Joint Nut

Upper Suspension ArmPivot Shaft Nuts

Upper Suspension ArmPivot Shaft to Frame Nuts

Upper Suspension ArmBall Joint NutStabilizer Bar

Link Upper NutStabilizer Bar

Link Ball Stud NutStabilizer BarRetainer Bolts

Hub/BearingSpindle Nut26 19

28 21

175 130

108 80

127 94

167 130

210 155

81 60

37 27

47 35

60 45 DESCRIPTION - SUSPENSION ARMSThe upper suspension arm bolts on frame brackets

through the arm pivot shaft. The frame bracketshave slotted holes which allow the arms to beadjusted for caster and camber. Pivot shaft bushingsare not replaceable.

The lower suspension arms bolt to the lower framebrackets and pivot through bushings, these bushingsare not replaceable.

The suspension arms have lube for life riveted ballstuds. The suspension arm travel (jounce) is limitedthrough the use of urethane bumpers. Reboundtravel is limited by the shock absorber.

PECIFICATIONS

ORQUE CHARTTORQUE SPECIFICATIONS

Fig. 1 Front Suspension - 4X21 - UPPER SUSPENSION ARM2 - STEERING KNUCKLE3 - COIL SPRING4 - LOWER SUSPENSION ARM5 - STABILIZER BAR

RONT - 2WD (Continued)251 185

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2 - 8 FRONT - 2WD ANPECIAL TOOLS

RONT SUSPENSION

USHINGS - CONTROL ARM

EMOVAL(1) Remove the control arm from the vehicle,(Refer

o 2 - SUSPENSION/FRONT/UPPER CONTROLRM - REMOVAL).(2) Mount the control arm securely in a vise.(3) Remove the nut and washer from the control

rm shaft.

Compressor, Coil Spring DD-1278

Remover Ball Joint MB-991113

Remover Ball Joint C-4150A

Puller Tie Rod C-3894-A(4) Install the bushing tool (Fig. 2).(5) Press out the old bushings.INSTALLATION(1) Install the bushing in the control arm and

inserted over the shaft.(2) Install the bushing tool (Fig. 3).

(3) Press the bushing into the control arm.(4) Install the washer and nut to the control arm

shaft. Tighten the nut to 167 Nm (130 ft. lbs.).(5) Remove the control arm from the vise.(6) Install the control arm in the vehicle, (Refer to

2 - SUSPENSION/FRONT/UPPER CONTROL ARM -INSTALLATION).

Fig. 2 BUSHING REMOVAL1 - 8441-1

2 - 8441-23 - 8441-3

Fig. 3 BUSHING INSTALLATION1 - 8441-12 - 8441-4

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AN FRONT - 2WD 2 - 9UB / BEARING

EMOVAL(1) Raise and support vehicle.(2) Remove wheel and tire assembly.(3) Remove brake caliper, rotor, and ABS wheel

peed sensor if equipped, (Refer to 5 - BRAKES/HY-RAULIC/MECHANICAL/ROTORS - REMOVAL).(4) Remove hub/bearing spindle nut and discard

ut (Fig. 4).

AUTION: The hub/bearing spindle nut can not bee-used.

(5) Slide hub/bearing off spindle.

NSTALLATION(1) Slide hub/bearing on spindle.(2) Install new spindle nut and tighten to 251m (185 ft. lbs.).(3) Install brake rotor, caliper, and ABS wheel

peed sensor if equipped, (Refer to 5 - BRAKES/HY-RAULIC/MECHANICAL/ROTORS - INSTALLA-ION).(4) Install wheel and tire assembly. (Refer to 22 -

IRES/WHEELS/WHEELS - STANDARD PROCE-URE).(5) Remove support and lower vehicle.

NUCKLE

ESCRIPTION

Fig. 4 Hub/Bearing1 - KNUCKLE2 - HUB/BEARING3 - SPINDLE NUTThe knuckle is a single casting with legs machinedor the upper and lower ball joints. The knuckle alsohas machined mounting locations for the front brakecalipers and hub bearing.

OPERATIONThe steering knuckle pivot between the upper and

lower ball joint. Steering linkage attached to theknuckle allows the vehicle to be steered.

REMOVAL(1) Raise and support the vehicle.(2) Remove the wheel and tire assembly.(3) Remove disc brake caliper, rotor, shield and

ABS speed sensor, (Refer to 5 - BRAKES/HYDRAU-LIC/MECHANICAL/ROTORS - REMOVAL).

(4) Remove tie-rod from steering knuckle arm,(Refer to 19 - STEERING/LINKAGE/TIE ROD END -REMOVAL).

(5) Remove the hub/bearing. (Refer to 2 - SUS-PENSION/FRONT/HUB / BEARING - REMOVAL).

(6) Remove the shock absorber. (Refer to 2 - SUS-PENSION/FRONT/SHOCK - REMOVAL).

(7) Install Spring Compressor DD-1278 up throughthe lower suspension arm, coil spring and uppershock mounting hole (Fig. 9).

(8) Tighten the tool lower nut to compress the coilspring.

(9) Remove the lower ball joint nut and separatethe ball joint from the knuckle with RemoverC-4150A (Fig. 10).

(10) Remove the upper ball joint nut and separatethe ball joint from the knuckle with RemoverMB-991113 (Fig. 5).

CAUTION: When install Remover MB-991113 to sep-arate the ball joint, be careful not to damage theball joint seal.

(11) Remove steering knuckle.

INSTALLATION(1) Position steering knuckle on upper and lower

ball joints and install nuts. Tighten lower nut to 127Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft.lbs.) and install new cotter pins.

(2) Remove the spring compressor.(3) Install the shock absorber. (Refer to 2 - SUS-

PENSION/FRONT/SHOCK - INSTALLATION).(4) Install the hub/bearing. (Refer to 2 - SUSPEN-

SION/FRONT/HUB / BEARING - INSTALLATION).(5) Install ABS speed sensor, brake dust shield,

rotor and caliper, (Refer to 5 - BRAKES/HYDRAU-LIC/MECHANICAL/ROTORS - INSTALLATION).

(6) Install tie rod to steering knuckle arm, (Referto 19 - STEERING/LINKAGE/TIE ROD END -

INSTALLATION).

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2 - 10 FRONT - 2WD AN

K(7) Install the wheel and tire assembly. (Refer to2 - TIRES/WHEELS/WHEELS - STANDARD PRO-EDURE).(8) Remove support and lower the vehicle

OWER BALL JOINT

IAGNOSIS AND TESTING - LOWER BALLOINT(1) Raise the front of the vehicle. Place safety floor

tands under both lower suspension arms as far out-oard as possible. Lower the vehicle to allow thetands to support some or all of the vehicle weight.

OTE: The upper suspension arms must not con-act the rebound bumpers.

(2) Remove the tire and wheel assemblies.(3) Mount a dial indicator solidly under the lower

uspension arm.(4) Position indicator plunger against the bottom

f the steering knuckle lower ball joint boss.

OTE: The dial indicator plunger must be perpen-icular to the machined surface of the steeringnuckle lower ball joint boss (Fig. 6).(5) Position a pry bar over the top of the upper

uspension arm and under the pivot bar of the upperuspension arm. Pry down on the upper suspensionrm and then zero the dial indicator.(6) Reposition the pry bar under the upper suspen-

Fig. 5 Upper Ball Joint1 - UPPER BALL JOINT2 - REMOVER3 - KNUCKLE

NUCKLE (Continued)ion arm and on top of the frame rail. Pry up on theupper suspension arm and record the dial indicatorreading.

(7) If the travel exceeds 1.52 mm (0.060 in.),replace the lower suspension arm.

LOWER CONTROL ARM

REMOVAL(1) Raise and support vehicle.(2) Remove wheel and tire assembly.(3) Remove disc brake caliper and rotor from steer-

ing knuckle, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL).

(4) Remove shock absorber. (Refer to 2 - SUSPEN-SION/FRONT/SHOCK - REMOVAL).

(5) Remove stabilizer bar link from the lower sus-pension arm. (Refer to 2 - SUSPENSION/FRONT/STABILIZER BAR - REMOVAL).

(6) Remove the coil spring.(7) Remove lower suspension arm mounting bolts

(Fig. 7)from the frame mounts and remove the arm.

INSTALLATION

CAUTION: Frame mounting bolts must be installedto their original location and orientation to avoiddamaging the steering rack boots.

(1) Loosely attach suspension arm to frame

Fig. 6 Lower Ball Joint Boss1 - BALL JOINT BOSS2 - STEERING KNUCKLE3 - DIAL INDICATORmounts.(2) Install the coil spring.

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L(3) Install the shock absorber. (Refer to 2 - SUS-ENSION/FRONT/SHOCK - INSTALLATION).(4) Install stabilizer bar link to the lower suspen-

ion arm and tighten nut to 47 Nm (35 ft. lbs.)Refer to 2 - SUSPENSION/FRONT/STABILIZERAR - INSTALLATION).(5) Install brake rotor and caliper, (Refer to 5 -RAKES/HYDRAULIC/MECHANICAL/ROTORS -

NSTALLATION).(6) Install wheel and tire assembly. (Refer to 22 -

IRES/WHEELS/WHEELS - STANDARD PROCE-URE).(7) Remove support and lower the vehicle.(8) Tighten the front suspension arm mounting

ut to 175 Nm (130 ft. lbs.) and the rear nut to 108m (80 ft. lbs.).

HOCK

ESCRIPTIONThe top of the low-pressure gas charged shock are

olted to the frame. The bottom of the shock areolted to the lower suspension arm.

PERATIONThe shock absorbers dampen jounce and rebound

f the vehicle over various road conditions.

IAGNOSIS AND TESTING - SHOCKA knocking or rattling noise from a shock absorberay be caused by movement between mounting

ushings and metal brackets or attaching compo-ents. These noises can usually be stopped by tight-

Fig. 7 Lower Suspension Arm1 - LOWER SUSPENSION ARM2 - FRAME MOUNTS

OWER CONTROL ARM (Continued)ning the attaching nuts. If the noise persists,nspect for damaged and worn bushings, and attach- uing components. Repair as necessary if any of theseconditions exist.

A squeaking noise from the shock absorber may becaused by the hydraulic valving and may be intermit-tent. This condition is not repairable and the shockabsorber must be replaced.

The shock absorbers are not refillable or adjust-able. If a malfunction occurs, the shock absorbermust be replaced. To test a shock absorber, hold it inan upright position and force the piston in and out ofthe cylinder four or five times. The action throughouteach stroke should be smooth and even.

The shock absorber bushings do not require anytype of lubrication. Do not attempt to stop bushingnoise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing.

REMOVAL(1) Remove the upper shock nut, retainer and

grommet from the shock absorber stud (Fig. 8) .

(2) Raise and support the vehicle.(3) Remove the lower mounting bolts and remove

shock absorber through the lower suspension arm(Fig. 8) .

INSTALLATION

NOTE: Upper shock nut must be replaced or useMopar Lock N Seal or LoctiteT 242 on existing nut.

(1) Install the lower retainer (lower retainer istamped with a L) and grommet on the shockbsorber stud and extend the shock. Insert the shockbsorber through the lower suspension arm and

Fig. 8 Front Shock Absorber1 - RETAINER2 - GROMMET3 - SHOCK ABSORBERpper mounting hole.

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2 - 12 FRONT - 2WD AN

S(2) Install the lower mounting bolts and tighten to8 Nm (21 ft. lbs.).(3) Remove support and lower the vehicle.(4) Install the upper grommet and retainer (upper

etainer is stamped with a U) on the shockbsorber stud. Install a new nut or use Mopar Lock

N Seal or Loctitet 242 on existing nut and tighten to6 Nm (19 ft. lbs.).

PRING

ESCRIPTIONThe springs mount between the lower suspension

rms and frame rail spring seats. A rubber isolatoreats on top off the spri

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