Engine Mechanical:
Detailed disassembly, assembly, diagnosis, and repair of all engine components, including cylinder head, block, pistons, crankshaft, camshaft, valvetrain.
Engine Fuel System:
Fuel injection systems (MPI), fuel pump, injectors, fuel pressure regulator, fuel filter replacement, diagnostic procedures.
Engine Cooling System:
Radiator, water pump, thermostat, hoses, fan operation, coolant specifications, leak detection, flushing procedures.
Engine Lubrication System:
Oil pump, oil filter replacement, oil pan, oil pressure diagnosis, oil type specifications.
Transmission Manual:
Disassembly, assembly, and repair of the manual transmission (AX-5, AX-15), clutch system, shift linkage, fluid specifications.
Transmission Automatic:
Service and repair of the automatic transmission (AW-4), torque converter, valve body, hydraulic system, fluid specifications, diagnostic procedures.
Drivetrain Transfer Case:
Service and repair of the Selec-Trac (242) and Command-Trac (231) transfer cases, operation, fluid type, and maintenance.
Drivetrain Axles:
Front and rear axle service, differential overhaul, axle shafts, U-joints, fluid specifications.
Suspension Front:
Front suspension geometry, shock absorbers, springs, control arms, ball joints, steering linkage, alignment specifications.
Suspension Rear:
Rear leaf spring suspension, shock absorbers, bushings, U-bolts, maintenance, and repair.
Steering System:
Power steering pump, steering gear box, steering column, tie rods, power steering fluid specifications, troubleshooting.
Brake System:
Front disc brakes, rear drum brakes (or disc on some models), master cylinder, brake lines, calipers, wheel cylinders, parking brake system, fluid specifications, bleeding procedures, ABS (if equipped).
Electrical System Charging:
Alternator, battery, voltage regulator, wiring diagrams, troubleshooting.
Electrical System Ignition:
Distributor, ignition coil, spark plugs, ignition timing, electronic ignition system components, diagnosis.
Electrical System Lighting:
Headlights, taillights, turn signals, interior lighting, bulb replacement, wiring diagrams.
Electrical System Accessories:
Wipers, horn, power windows, power locks, radio, HVAC blower motor, fuse box and relay identification, wiring.
HVAC System:
Air conditioning system diagnosis and repair, heater core, blower motor, controls, refrigerant type and servicing procedures.
Body Interior:
Seat removal, dashboard disassembly, trim panel removal, headliner service, interior component repair.
Body Exterior:
Door panel removal, hood and tailgate adjustment, bumper service, glass replacement, body panel repair and alignment.
Preventive Maintenance:
Detailed schedules for oil changes, filter replacements, fluid checks and changes, tire rotations, brake inspections, and tune-ups.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex problems, including symptom-based troubleshooting charts.
Component Replacement:
Step-by-step instructions for removing and installing virtually every component on the vehicle.
Engine Rebuild:
Complete instructions for engine disassembly, cleaning, inspection, machining, assembly, and break-in procedures.
Transmission Rebuild:
Detailed guides for overhauling both manual and automatic transmissions.
Electrical Diagnostics:
Comprehensive wiring diagrams for all electrical systems, testing procedures for sensors, actuators, and control modules.
Suspension Alignment:
Specifications and procedures for front and rear wheel alignment.
Depth:
Comprehensive, factory-level detail suitable for professional technicians and advanced DIYers. Includes specifications, tolerances, and torque values.
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, whichever comes first, depending on driving conditions. Use high-quality synthetic oil for extended intervals.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km) for automatic transmission, or as recommended by fluid type and usage. Manual transmission fluid every 60,000-100,000 miles.
Coolant Flush Interval:
Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. Use Mopar Antifreeze/Coolant (5/150) or equivalent HOAT (Hybrid Organic Acid Technology) coolant.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type (standard vs. platinum). Check for correct gap.
Drive Belt Inspection:
Inspect every 15,000 miles (24,000 km) for cracks and wear, replace as needed, typically around 60,000 miles.
Power Steering Fluid:
ATF+3 or Mopar Power Steering Fluid. Check level regularly.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Flush and replace every 2-3 years to prevent moisture absorption and corrosion.
Transfer Case Fluid:
For NV231/NV242: Mopar NV242 Transfer Case Lubricant or equivalent GL-4 75W-90 gear oil. Capacity is approximately 1.75 quarts.
Differential Fluid:
GL-5 80W-90 gear oil for both front and rear differentials. Capacity approx. 1.5 quarts front, 2 quarts rear. Consider limited-slip additive if equipped with a locking differential.
Common Problems:
Cracked cylinder heads (especially the 2000-2001 models, but can occur on earlier ones), aging rubber components (hoses, bushings), rust (especially in the unibody structure and rocker panels), heater core leaks, death wobble (steering shimmy), transmission cooler line leaks.