Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of engine components, including short block, long block, cylinder heads, valvetrain, pistons, connecting rods, crankshaft, and timing systems.
Engine Management:
Engine control module (ECM) operation, sensor diagnostics, fuel injection system, ignition system, emissions control systems (EVAP, EGR), idle speed control, and diagnostic trouble codes (DTCs).
Transmission Automatic:
Service and repair procedures for the 42RE and 45RFE automatic transmissions, including torque converter, valve body, planetary gear sets, clutches, bands, hydraulic control systems, and electronic controls.
Transmission Manual:
Details for the NV3550 manual transmission, including clutch system, gearbox components, shift linkage, and related maintenance.
Drivetrain 4Wd:
Service for the NV242 (Selec-Trac) and NV247 (Quadra-Drive) transfer cases, including operation, disassembling, assembly, fluid specifications, and common issues. Also covers front and rear axle assemblies, differentials, drive shafts, and CV joints.
Brakes:
Front and rear brake system diagnostics and repair, including disc brake calipers, rotors, pads, wheel cylinders, brake lines, master cylinder, power booster, and ABS system components.
Suspension Steering:
Front and rear suspension component service: control arms, ball joints, tie rod ends, sway bar links, shock absorbers, springs, bushings, steering gear box, power steering pump, and steering column.
Electrical System:
Wiring diagrams, component locations, fuse and relay identification, charging system (alternator, battery), starting system (starter motor), lighting systems, horn, wipers, power accessories (windows, locks, mirrors), and trailer wiring.
Climate Control:
HVAC system diagnosis and repair, including blower motor, evaporator, condenser, refrigerant lines, refrigerant recovery and recharging, heater core, and air conditioning controls.
Body Interior:
Body panel removal and installation, door mechanisms, interior trim panels, seat removal, headliner, exterior lighting, bumpers, and glass replacement.
Scheduled Maintenance:
Detailed maintenance schedules and procedures for oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, coolant flushes, brake fluid flushes, and belt inspections.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for identifying and resolving common and uncommon vehicle issues, utilizing diagnostic trouble codes (DTCs), oscilloscope usage, and symptom-based troubleshooting guides.
Component Replacement:
Instructions for replacing virtually all major and minor components, including engine, transmission, drivetrain, brakes, suspension, steering, electrical, and HVAC parts.
Rebuilding Overhauling:
Procedures for rebuilding or overhauling key components such as engines, transmissions, and transfer cases, including specifications for clearances and torque values.
Specifications Data:
Extensive technical specifications, torque values, fluid capacities, electrical specifications, alignment data, and diagnostic parameters for all vehicle systems.
Depth:
Expert-level, suitable for professional technicians and advanced DIY mechanics.
Troubleshooting Guides:
Includes specific troubleshooting flowcharts and guides for various system malfunctions.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all vehicle systems.
Length:
181.5 inches (4610 mm)
Width:
71.5 inches (1816 mm)
Height:
66.1 inches (1679 mm)
Wheelbase:
104.0 inches (2642 mm)
Front Track:
60.6 inches (1539 mm)
Rear Track:
60.7 inches (1542 mm)
Curb Weight 4.0L:
approx. 4,150 lbs (1882 kg)
Curb Weight 4.7L:
approx. 4,300 lbs (1950 kg)
Towing Capacity:
Up to 5,000 lbs (2268 kg)
Payload Capacity:
approx. 1,100 lbs (499 kg)
Gross Vehicle Weight Rating Gvwr:
approx. 5,250 - 5,400 lbs (2381 - 2449 kg) depending on configuration
Passenger Volume:
approx. 100.7 cu ft (2851 L)
Cargo Volume Behind Rear Seat:
approx. 37.5 cu ft (1062 L)
Cargo Volume With Rear Seat Folded:
approx. 71.1 cu ft (2013 L)
Engine Oil Change Interval:
Every 3,000 - 7,500 miles (5,000 - 12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specifics).
Engine Oil Filter Replacement:
With every oil change.
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km).
Engine Coolant Flush:
Every 30,000 - 60,000 miles (48,000 - 96,000 km).
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) for automatic transmissions, depending on driving conditions. Manual transmission fluid inspection and potential change at similar intervals.
Spark Plug Replacement:
4.0L I6: ~100,000 miles (160,000 km) with platinum plugs. 4.7L V8: ~30,000 miles (48,000 km) with standard plugs.
Transfer Case Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km).
Engine Oil Type 4.0L:
SAE 10W-30 (API SG/SH or higher)
Engine Oil Type 4.7L:
SAE 5W-30 (API SG/SH or higher)
Engine Coolant Type:
Chrysler OAT (Organic Additive Technology) coolant, typically Mopar HOAT or equivalent (e.g., Peak Global Lifetime)
Power Steering Fluid:
ATF+4 (MS-9602) or Mopar Power Steering Fluid
Common Problems:
Cracked cylinder heads (especially 4.7L early models), radiator leaks, heater core issues, death wobble (front suspension/steering issues), alternator failure, rear main seal leaks, transfer case chain stretch (NV247 Quadra-Drive), PCM failures, O2 sensor failures.