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9. Disconnect the wiring from the
switch and remove the switch.
10. To install, position t he switch into place and connect the wiring to the
switch.
11. Install the switch bezel (retainer).
12. Push the headlamp switch knob into the switch. (It may be necessary to
depress the knob release button.
13. Install the radio speaker bracket.
14. On models equipped with air conditioni ng, install the instrument panel
cluster bezel and the cluster.
15. Install the inst rument panel pad.
16. Install the screws which are under t he lip of the instrument panel pad.
17. Install the four screw s from inside the defroster duct (instrument panel
pad securing screws).
18. Connect the negative battery cable at the battery.
Fig. 1: Headlight switch removal
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CONSOLE MOUNTED SWITCHES
REMOVAL & INSTALLATION
1. Disconnect the negative battery cable.
The switches are secured in the consol e by simple spring clips. To remove
them, simply pull or carefully pr y them up and out of the console.
2. Unsnap the switch from the console.
3. Remove the electrical connector from the switch.
4. Installation is the reverse of removal.
Fig. 1: Console mounted accessory switches
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FUSIBLE LINKS
In addition to circuit breakers and fuses,
the wiring harness incorporates fusible
links to protect the wiring. Links are used rather than a fuse, in wiring circuits
that are not normally fused, such as th e ignition circuit. The fusible links are
color coded red in the charging and load circuits to match the color coding of
the circuits they protect. Each link is four gauges smaller than the cable it
protects, and is marked on the insulation with the gauge size because the
insulation makes it appear heavier than it really is. The engine compartment
wiring harness has several fusible links. The same size wire with a special
Hypalon insulation must be used w hen replacing a fusible link.
For more details, see the information on fusible links at the beginning of this
section.
The links are located in the following areas:
1. A molded splice at the starter solenoid Bat terminal, a 14 gauge red wire.
2. A 16 gauge red fusible link at the j unction block to protect the unfused
wiring of 12 gauge or larger wire. This link stops at the bulkhead
connector.
3. The alternator warning light and fiel d circuitry is protected by a 20 gauge
red wire fusible link used in the batte ry feed-to-voltage regulator number
3 terminal. The link is installed as a molded splice in the circuit at the
junction block.
4. The ammeter circuit is protected by two 20 gauge fusible links installed
as molded splices in the circuit at t he junction block and battery to starter
circuit.
REPLACEMENT 1. Determine the circuit that is damaged.
2. Disconnect the negative battery terminal.
3. Cut the damaged fuse link from the harness and discard it.
4. Identify and procure the proper fuse link and butt connectors.
5. Strip the wire about
1/2 in. (13mm) on each end.
6. Connect the fusible link and crimp the butt connectors making sure that the wires are secure.
7. Solder each connection with resin core solder, and wrap the connections
with plastic electrical tape.
8. Reinstall the wir e in the harness.
9. Connect the negative battery terminal and test the system for proper
operation.
CIRCUIT BREAKERS
Various circuit breakers are located under the instrument panel. In order to gain
access to these components, it may be ne cessary to first remove the under
dash padding. Most of the circuit breakers are located in the convenience
center or the fuse panel.
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members which smoothly bring gear and
shaft to the same speed before the
toothed dog clutches are engaged.
ADJUSTMENT
LINKAGE
4-SPEED TRANSMISSION
All terms used in the following procedure match those which are used in the
accompanying illustration. No linkage adjustment is possible on the 5-speed
transmissions.
1. Disconnect the negative batte ry cable at the battery.
2. Place the shift control lever (F) in Neutral.
3. Raise the vehicle and support it safely with jackstands.
4. Remove the swivel retainers (P) from the levers (E, H, and J).
5. Remove the swivels (S) from the shifter assembly (G), and loosen the
swivel locknuts (R and T).
Fig. 1: 4-speed shift linkage adjustments
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6. Make sure that levers L, M, and N
are in their Neutral positions (center
detents).
7. Align the holes of levers E, H, and J with the notch in the shifter
assembly (G). Insert an alignment gauge (J-33195) to hold the levers in
this position.
8. Insert swivel S into lever E and insta ll washer Q. Secure with retainer P.
9. Apply rearward pressure (Z) to leve r N. Tighten locknuts R and T (at the
same time) against swivel S to 25 ft. lbs. (34 Nm).
10. Repeat steps 8 and 9 for rod D and levers J and M.
11. Repeat steps 8 and 9 for rod K and levers H and L.
12. Remove the alignment gauge, lower t he vehicle, and check the operation
of the shifting mechanism.
13. Reconnect the negative battery cable.
CLUTCH SWITCH
REMOVAL & INSTALLATION 1. Disconnect the negative battery cable.
2. Remove the sound insulator on 1988- 89 vehicles or the console trim
plate on 1990-92 vehicles.
Fig. 1: Exploded view of the clutch swit ch mounting - on most models, the clutch
switch adjusts automatically
3. Unplug the clutch switch connector.
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4. Remove the switch attaching bo
lt and remove the clutch switch.
5. Installation is the reverse of t he removal procedure. The switch will
automatically adjust when depres sed for the first time.
SPEED SENSOR
REMOVAL & INSTALLATION
5-SPEED TRANSMISSION 1. Disconnect the negative battery cable.
2. Disconnect the electrical connector.
3. Remove the attaching bolt and remove the sensor.
4. Installation is the reverse of the removal procedure. The bolt torque is 89
inch lbs. (10 Nm).
SHIFT HANDLE
REMOVAL & INSTALLATION 1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Disconnect the shift rods from the control lever.
4. Lower the vehicle. Remove the shifter knob.
5. Remove the parking lever grip.
Fig. 1: Exploded view of the typi cal transmission shifter mounting
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6. Remove the console cover.
7. Remove the shifter boot.
8. Remove the shifter mounting bolt
s and remove the shifter assembly.
9. Installation is the reverse of the removal procedure. Adjust the linkage as
detailed earlier.
BACK-UP LIGHT SWITCH
REMOVAL & INSTALLATION 1. Disconnect the negative battery terminal from the battery.
2. At the left-rear of the transmission, the back-up light switch is threaded
into the transmission case. The speed sensor is held in with a separate
bracket. Disconnect the electrical co nnector from the back-up light
switch.
3. Remove the back-up light swit ch from the transmission.
4. To install, reverse the remova l procedures. Coat the threads with
Teflon® tape. Please refer to the to rque chart for specifications. Place
the gear shift lever in the revers e position and check that the back-up
lights work.
EXTENSION HOUSING SEAL
REMOVAL & INSTALLATION
This seal controls transmission oil leakage around the driveshaft. Continued
failure of this seal usually indicates a worn output shaft bushing. If so, there will
be signs of the same wear on the driveshaft where it contacts the seal and
bushing. The seal is available and is fairly simple to install, with the proper tool.
1. Raise and safely support the rear of the vehicle to minimize transmission
oil loss when the driveshaft is removed.
2. Unbolt the driveshaft fr om the differential and center support bearing, if
equipped. Wrap tape around the bearing cu ps to keep them in place on
the universal joint and slide the sh aft out of the transmission.
3. Use an small pry tool to carefully pry out the old seal. Be careful not to
insert the tool too far into the hous ing or the bushing will be damaged.
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Fig. 1: Installing the extension housing seal
4. Use an oil seal installation tool to evenly drive the new seal into the
housing. Make sure the tool only cont acts the outer metal portion of the
seal.
5. Install the driveshaft. Torque the uni versal bearing cup retainer bolts to
15 ft. lbs. (20 Nm).
TRANSMISSION
REMOVAL & INSTALLATION
On 5-speed transmissions remove the shif t lever boot and the shift lever prior to
transmission removal.
1. Disconnect the negative batte ry cable at the battery.
2. Raise the vehicle and support it safely with jackstands.
3. Drain the lubricant from the transmission.