Engine Mechanical:
Engine assembly, cylinder heads, valvetrain, pistons, connecting rods, crankshaft, lubrication system, cooling system, engine diagnostics.
Engine Fuel And Emissions:
Fuel delivery, injection system, evaporative emission control (EVAP), exhaust system, catalytic converter, oxygen sensors, emissions diagnostics.
Transmission Automatic:
42RLE (4-speed) and 545RFE (5-speed) automatic transmissions: disassembly, assembly, torque converter, valve body, internal components, troubleshooting, fluid service.
Transmission Manual:
NV3500 (5-speed) manual transmission: disassembly, assembly, clutch system, driveshafts, troubleshooting, fluid service.
Driveline And Axles:
Front and rear axles, differentials, CV joints, universal joints, transfer case (NV241HD, NV243), driveshaft balancing, repair, and replacement.
Suspension:
Front independent suspension (SLA - Short/Long Arm), rear solid axle, leaf springs, shocks, struts, control arms, ball joints, bushings, alignment specifications.
Steering:
Power steering system, steering gear (rack and pinion for 2WD, recirculating ball for 4WD), power steering pump, steering column, linkage, tie rods, alignment.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake booster, master cylinder, calipers, pads, rotors, lines, parking brake system, bleeding procedures, diagnostic codes.
Electrical System Charging:
Alternator, battery, voltage regulator, charging circuit diagnostics.
Electrical System Starting:
Starter motor, starter circuit, ignition switch, battery, solenoid, troubleshooting.
Lighting:
Headlights, taillights, interior lighting, fog lamps, turn signals, bulb replacement, wiring diagrams.
Instrument Panel And Gauges:
Speedometer, tachometer, fuel gauge, temperature gauge, warning lamps, instrument cluster removal and installation, diagnostics.
Body And Chassis:
Frame construction, body panels, doors, hood, tailgate, bumpers, interior trim, sound deadening, rust prevention, collision repair basics.
HVAC:
Heating, ventilation, and air conditioning system: components, refrigerant charging, leak detection, blower motor, climate control modules, troubleshooting.
Infotainment And Audio:
Radio, speakers, amplifier (if equipped), navigation system (if equipped), antenna, troubleshooting.
Safety Systems:
Airbag system, seat belts, SRS module, occupant restraint system diagnostics.
Routine Maintenance:
Oil changes, filter replacements, tire rotation, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common fault identification, electrical system diagnosis.
Component Removal And Installation:
Step-by-step guides for removing and installing major components (e.g., engine, transmission, suspension parts, brake calipers).
Rebuilding And Overhaul:
Detailed instructions for rebuilding engines, transmissions, and other major mechanical assemblies.
Diagnostic Procedures:
Use of scan tools, interpretation of diagnostic trouble codes (DTCs), sensor testing, actuator testing.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems, including power distribution, grounds, and signal paths.
Specifications And Tolerances:
Torque specifications, clearances, fluid capacities, engine measurements, alignment settings.
Body And Paint Repair:
Basic guidelines for bodywork, panel alignment, and minor paint repair.
Depth Of Coverage:
Comprehensive - covers everything from basic fluid changes to full engine and transmission rebuilds, including advanced diagnostics.
Oil Change Interval:
Every 5,000 to 7,500 miles or 6 months, whichever comes first (depending on oil type and driving conditions).
Air Filter Replacement:
Every 15,000 to 30,000 miles, or as needed based on inspection.
Spark Plug Replacement V6:
Approximately 100,000 miles (if using original equipment iridium plugs).
Spark Plug Replacement V8:
Approximately 100,000 miles (if using original equipment iridium plugs).
Transmission Fluid Change Auto:
Every 30,000 to 60,000 miles (check manual for specific recommendations, especially for severe use).
Transmission Fluid Change Manual:
Every 60,000 to 100,000 miles.
Engine Oil Type V6:
SAE 5W-20, API Certified.
Engine Oil Type V8:
SAE 5W-20 (or 5W-30 for some applications), API Certified.
Engine Coolant:
Mopar OAT (Orange) or HOAT (Yellow/Orange) coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Auto 42Rle:
ATF+4 (Chrysler Specification MS-9602).
Transmission Fluid Auto 545Rfe:
ATF+4 (Chrysler Specification MS-9602).
Transmission Fluid Manual Nv3500:
Dexron III or equivalent, or specific manual transmission fluid meeting GM spec.
Power Steering Fluid:
ATF+4 (Chrysler Specification MS-9602) or Mopar Power Steering Fluid.
Rust And Corrosion:
Common issues with frame rust, especially in areas with road salt, and rust on rocker panels and wheel wells.
Powertrain Control Module Failures:
Some reports of PCM/ECM failures, leading to various drivability issues.
Brake Wear:
Premature brake pad and rotor wear can be an issue on some models due to vehicle weight and braking demands.
Suspension Component Wear:
Ball joints, tie rod ends, and control arm bushings can wear prematurely, leading to steering looseness and noise.
ABS And Speed Sensor Issues:
Faulty ABS wheel speed sensors can trigger ABS warning lights and affect traction control.
Interior Rattles And Squeaks:
Common in many trucks of this era, requiring diagnosis and tightening of trim panels.