Engine Mechanical:
Detailed diagnosis, disassembly, inspection, assembly, and repair of all engine components (e.g., pistons, rings, bearings, crankshaft, camshaft, valves, cylinder heads, blocks)
Engine Electrical:
Ignition system, fuel injection system, starting system, charging system, emissions control systems, powertrain control module (PCM) diagnostics, wiring diagrams
Transmission Automatic:
Diagnosis, maintenance, overhaul, torque converter, valve body, seals, clutch packs, planetary gears for W5A580 and 48RE transmissions
Transmission Manual:
Diagnosis, maintenance, overhaul of NV3500, NV4500, NV5600 manual transmissions
Drivetrain:
Four-wheel drive (4WD) system operation, transfer case service (e.g., NV244, NV271D, NV273D), driveshaft balancing and U-joints, propeller shafts, axle assemblies (Dana 44, Dana 60, Chrysler 9.25)
Suspension And Steering:
Front and rear suspension components (e.g., control arms, ball joints, tie rods, springs, shock absorbers), steering system (e.g., steering gear, power steering pump, hydraulic lines), alignment specifications
Brakes:
Hydraulic system, ABS components, brake fluid specifications, master cylinder, power booster, front and rear brake systems (disc/drum, caliper/rotor replacement, brake shoe adjustment), parking brake system
Electrical System Chassis:
Lighting system, horn, wipers, power windows, power locks, instrument cluster, body control module (BCM), fuse and relay locations, battery system
HVAC:
Air conditioning system (refrigerant type, charging, component replacement), heating system, ventilation, climate control module diagnosis
Body And Frame:
Body panel repair, door mechanisms, interior trim, seat removal, chassis lubrication, rust prevention, frame straightening procedures
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) system
Routine Maintenance:
Oil change intervals and procedures, filter replacements (oil, air, fuel, cabin), tire rotation, fluid checks and top-offs
Troubleshooting:
Systematic diagnostic flowcharts for common and uncommon drivability, electrical, and mechanical issues; symptom-based troubleshooting guides
Component Replacement:
Step-by-step instructions for replacing all major and minor components across all systems (e.g., alternator, starter, water pump, thermostat, brake pads, ball joints, sensors)
Diagnostic Procedures:
OBD-II diagnostic trouble codes (DTCs), sensor testing procedures, actuator testing, PCM relearn procedures, oscilloscope usage recommendations
Torque Specifications:
Comprehensive list of torque values for all critical fasteners (e.g., engine bolts, suspension components, wheel lug nuts, brake caliper bolts)
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems, including component identification and connector pinouts
Rebuilding Procedures:
Complete overhaul instructions for engines and transmissions, including inspection limits and assembly procedures
Specifications And Tolerances:
Precise measurements, clearances, and wear limits for engine parts, bearings, clutch packs, and other critical components
Depth Level:
Expert Level - Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
Engine Options:
4.7L Magnum V8, 5.7L HEMI V8, 6.7L Cummins Turbo Diesel (Heavy Duty)
4.7L V8 Horsepower:
Approx. 310 hp @ 5650 rpm
4.7L V8 Torque:
Approx. 330 lb-ft @ 3950 rpm
5.7L Hemi Horsepower:
Approx. 345 hp @ 5650 rpm
5.7L Hemi Torque:
Approx. 375 lb-ft @ 4000 rpm
6.7L Cummins Hp:
Approx. 350 hp @ 3000 rpm (later models up to 385 hp)
6.7L Cummins Torque:
Approx. 650 lb-ft @ 1500 rpm (later models up to 850 lb-ft)
Injection Type:
Sequential Multi-Port Fuel Injection (MPI) for gasoline; Common Rail Diesel Injection (CRDI) for Cummins
Fuel Type:
Unleaded gasoline (87 octane recommended); Diesel fuel (B20 compatible)
Engine Identification Codes:
EZA (4.7L), ESG (5.7L HEMI), DEO (6.7L Cummins)
Transmission Options Light Duty:
5-speed manual (NV3500), 4-speed automatic (42RLE, 45RFE)
Transmission Options Heavy Duty:
6-speed manual (NV5600), 5-speed automatic (W5A580 - Mercedes), 4-speed automatic (48RE - Cummins)
Automatic Transmission Features:
Electronically controlled, torque converter lock-up, overdrive gear
Manual Transmission Features:
Overdrive gear for fuel economy, heavy-duty clutch systems
Automatic Transmission Fluid:
Chrysler ATF+4 (MS-9602)
Manual Transmission Fluid:
Refer to manual for specific weights (e.g., SAE 75W-90, SAE 75W-140)
Oil Change Interval:
Every 3,000-6,000 miles or 3-6 months (depending on driving conditions and oil type, consult manual for specifics)
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Fuel Filter Replacement:
Every 15,000-30,000 miles (diesel); Every 30,000-60,000 miles (gasoline, often in-tank)
Transmission Fluid Change:
Every 30,000-60,000 miles (depending on usage, consult manual)
Engine Oil Specification 4.7L 5.7L:
SAE 5W-20 (API SN or newer)
Engine Oil Specification 6.7L Cummins:
SAE 15W-40 CJ-4 or CK-4 rated diesel engine oil
Coolant Type:
HOAT (Hybrid Organic Acid Technology) - Mopar OAT (Orange)
Common Problems Gasoline Engines:
Lifter tick (especially 5.7L HEMI), EGR valve issues, ignition coil failures, manifold absolute pressure (MAP) sensor issues.
Common Problems Diesel Engines:
DPF (Diesel Particulate Filter) regeneration issues, EGR cooler failures, injector problems, turbocharger issues, potential fuel injector line leaks.
Common Problems Transmissions:
W5A580 (Mercedes) can have solenoid issues; 48RE can experience torque converter shudder; worn U-joints in driveshafts.
Common Problems Suspension Steering:
Ball joint wear, tie rod end wear, steering gear play, front end shimmy.
Common Problems Electrical:
TIPM (Total Integrated Power Module) failures leading to various electrical gremlins, sensor failures (ABS, speed), HVAC blower motor issues.