Engine Mechanical:
Engine assembly, disassembly, rebuild procedures, cylinder heads, pistons, crankshaft, camshaft, timing systems (belt/chain), oil pump, lubrication, cooling system, fuel injection systems (MPI), emissions control.
Engine Electrical:
Ignition system (spark plugs, coils, timing), starting system, charging system (alternator, battery), engine control module (ECM) operation, sensors (crankshaft position, camshaft position, O2, MAP, MAF, throttle position), wiring diagrams.
Transmission Manual:
Clutch system, manual transmission (NV1500, NV3500) removal, disassembly, inspection, repair, and reassembly; gear ratios, shift linkage.
Transmission Automatic:
Automatic transmission (42RE, 45RFE) removal, disassembly, inspection, repair, and reassembly; valve body operation, torque converter, transmission control module (TCM) operation, fluid capacities and types.
Drivetrain Axles:
Rear axle assembly ( Spicer Model 44, Dana 44), front axle components (for 4x4 models), universal joints, CV joints, driveshafts, propeller shafts, differential service.
Suspension:
Front suspension (independent short-long arm - SLA), rear suspension (leaf springs), shock absorbers, ball joints, control arms, bushings, springs, sway bars, alignment specifications.
Steering:
Power steering system, steering gear (rack and pinion for some models or recirculating ball), steering column, tie rods, power steering pump, hydraulic fluid type and capacity, steering linkage.
Brakes:
Front disc brakes, rear drum brakes (standard) or rear disc brakes (optional/some trims), anti-lock braking system (ABS) components and diagnosis, master cylinder, brake lines, calipers, wheel cylinders, brake fluid specifications (DOT 3), bleeding procedures, parking brake system.
Electrical Chassis:
Headlights, taillights, interior lighting, hazard lights, turn signals, horn, wipers, washer system, power windows, power locks, mirrors, trailer wiring harness, fused circuits.
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass replacement, seals, weatherstripping, trim pieces, bed liner options, paint codes.
Body Interior:
Dashboard, instrument cluster, seating systems, upholstery, headliner, interior trim panels, heating, ventilation, and air conditioning (HVAC) controls, seat belts, airbag system components (SRS - Supplemental Restraint System) and safety precautions.
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs) and their meanings, symptom-based troubleshooting guides, diagnostic procedures for various systems, use of diagnostic scan tools.
Maintenance Scheduled:
Detailed recommendations for routine maintenance tasks including oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flush, brake fluid flush, transmission fluid service, differential fluid service, tire rotation, and inspection schedules.
Repair Engine:
Complete engine overhaul procedures, head gasket replacement, piston ring replacement, bearing replacement, timing component replacement, internal engine component diagnostics and repair.
Repair Transmission:
Transmission rebuilds for both manual and automatic transmissions, torque converter replacement, clutch replacement, shift linkage adjustment, transmission control module (TCM) programming/replacement.
Repair Brakes:
Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper/wheel cylinder rebuild or replacement, ABS component replacement (sensors, modulator), brake line repair/replacement, bleeding procedures.
Repair Suspension Steering:
Ball joint replacement, tie rod end replacement, shock absorber/strut replacement, control arm bushing replacement, power steering pump replacement, steering gear repair/replacement, wheel alignment procedure and specifications.
Repair Electrical:
Component testing and replacement for starting, charging, ignition systems, sensor replacement and calibration, wiring harness repair, fuse and relay diagnostics, lighting system repair, power accessory repair.
Diagnostics Engine Performance:
Troubleshooting drivability issues, fuel system diagnostics, ignition system diagnostics, emission system troubleshooting, use of diagnostic tools for engine performance analysis.
Diagnostics HVAC:
Refrigerant system diagnosis and repair, component testing (compressor, condenser, evaporator, expansion valve), blower motor replacement, temperature control system troubleshooting.
Body Repair:
Door panel removal, glass replacement, seal replacement, tailgate repair, bumper replacement, body panel alignment, interior trim panel removal and installation.
Safety Systems:
Airbag system diagnostics, SRS module replacement, seat belt inspection and replacement, safety precautions for working with SRS components.
Depth Level:
Comprehensive (from basic maintenance to major component overhaul and complex diagnostics).
Diagnostic Detail:
Includes detailed diagnostic flowcharts, troubleshooting trees, and specific test procedures for various systems.
Specifications Data:
Provides torque specifications, clearances, fluid capacities, electrical values, and alignment data for all covered systems.
Diagrams Illustrations:
Includes numerous diagrams, schematics, and illustrations to clarify procedures and component identification.
Oil Change Interval:
Every 5,000 to 7,500 miles or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Air Filter Replacement:
Every 15,000 to 30,000 miles or as needed based on inspection.
Spark Plug Replacement:
2.5L: 60,000 miles; 3.9L/4.7L: 100,000 miles (platinum or iridium plugs recommended).
Engine Oil:
API SN/SP or ILSAC GF-6A certified. SAE 5W-30 recommended for most conditions. (Check manual for specifics per engine and climate).
Coolant:
Mopar OAT (Orange Antifreeze/Engine Coolant), or equivalent HOAT coolant (50/50 mix with distilled water).
Transmission Fluid Auto:
ATF+4 (Mopar)
Transmission Fluid Manual:
MS-9224 (Manual Transmission Fluid, e.g., NV1500/NV3500 fluid)
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent (e.g., ATF+4 in some cases, verify with manual)
Transmission Hard Shifting:
Common with 42RE automatic transmission, often related to solenoid pack or valve body issues.
Ignition Coil Failure:
Can lead to misfires and poor engine performance, especially on V8 models.
ABS Sensor Failure:
Leads to ABS warning light and loss of ABS function.
Radiator Leaks:
Can occur due to age and material degradation.
Power Steering Pump Noise:
Often due to low fluid or worn pump/hoses.
Interior Rattles And Squeaks:
Common in trucks of this era, often from trim panels or suspension components.