Engine Mechanical:
Detailed overhaul procedures, component testing, torque specifications, timing belt/chain service, piston and ring installation, cylinder head reconditioning.
Fuel System:
Fuel pump testing, injector service, fuel pressure regulator diagnosis, evaporative emission control (EVAP) system troubleshooting.
Cooling System:
Radiator service, water pump replacement, thermostat testing, coolant specifications, fan clutch diagnosis.
Exhaust System:
Muffler and catalytic converter replacement, exhaust manifold repair, oxygen sensor testing and replacement.
Transmission Manual:
NV3550 (AX-15 successor) overhaul, clutch service, shift linkage adjustment, component diagnostics.
Transmission Automatic:
42RLE (optional) overhaul, torque converter replacement, valve body diagnosis, shift solenoid testing, fluid specifications.
Drivetrain 4X4:
NV241OR (242OR) transfer case service, Dana 30 front axle, Dana 35c rear axle overhaul, axle spline counts, differential fluid specifications, U-joint replacement, driveshaft service.
Brakes:
Front disc brake service (caliper, rotor, pad replacement), rear drum brake service (shoes, drum, wheel cylinder replacement), ABS system diagnostics, brake fluid specifications, bleeding procedures.
Steering:
Power steering system diagnosis, pump replacement, steering gear (steering box) adjustment and overhaul, tie rod end replacement, alignment specifications.
Suspension:
Front and rear suspension component replacement (shocks, springs, control arms, bushings), sway bar link replacement, lift kit installation considerations.
Electrical System:
Wiring diagrams for all circuits, fuse box locations, relay identification, battery charging system diagnosis, starter motor service, alternator testing.
Lighting System:
Headlight, taillight, turn signal, and interior lighting bulb replacement and troubleshooting, connector diagnostics.
Instrument Panel:
Gauge cluster removal and installation, warning light diagnosis, odometer troubleshooting.
HVAC System:
Air conditioning system service (refrigerant recharge, leak detection, compressor replacement), heater core replacement, blower motor testing, climate control system diagnosis.
Body Exterior:
Door panel removal, fender replacement, hood adjustment, bumper fascia repair, hardtop and soft top service, tailgate and door hinge repair.
Body Interior:
Seat removal and installation, dashboard disassembly, carpet replacement, sound deadening installation, trim panel repair.
Routine Maintenance:
Oil change, filter replacement, tire rotation, brake inspection, fluid level checks, spark plug replacement, air filter replacement.
Troubleshooting Diagnostics:
Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, OBD-II diagnostic trouble codes (DTCs) explained.
Component Replacement:
Step-by-step instructions for replacing major and minor components across all systems.
Engine Rebuild:
Complete engine overhaul instructions, including disassembly, cleaning, inspection, machining specifications, and reassembly.
Transmission Rebuild:
Detailed procedures for rebuilding both manual and automatic transmissions.
Electrical Diagnostics:
Troubleshooting electrical circuits using wiring diagrams, multimeter usage, testing relays and switches, power and ground checks.
Body Repair:
Panel alignment, rust repair techniques, door and window glass replacement, soft top and hardtop maintenance.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Depth Level:
Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, depending on driving conditions (severe duty recommended for off-road use).
Transmission Fluid Change Manual:
Every 50,000-60,000 miles.
Transmission Fluid Change Automatic:
Every 30,000-40,000 miles for normal use, sooner for severe use.
Coolant Flush:
Every 2 years or 30,000 miles.
Engine Oil:
SAE 10W-30 (API SN or higher recommended)
Engine Coolant:
Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water.
Transmission Fluid Manual:
SAE 75W-90 Synthetic Gear Lubricant (API GL-5)
Transmission Fluid Automatic:
ATF+4 (MS-9602)
Transfer Case Fluid:
ATF+4 (MS-9602)
Rear Axle Fluid:
SAE 75W-140 Synthetic Hypoid Gear Lubricant (API GL-5, with friction modifier for LSD if equipped)
Front Axle Fluid:
SAE 75W-90 Synthetic Gear Lubricant (API GL-5)
Common Issues:
Cracked exhaust manifolds, oil filter adapter leaks, death wobble (suspension/steering component wear), rear axle pinion seal leaks, heater core leaks, manual transmission bearing noise (some NV3550 models).
