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EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 17 8ERY1CE PROCEDURES
(DIESEL ENGINES)
INDEX
page
Charge
Air
Cooler
(Intercooler)
25
Engine
Exhaust
Manifold
18
Exhaust
Pipe
17
Exhaust
Tailpipe
18
EXHAUST PIPE
REMOVAL
(1) Remove the clamp that holds the front exhaust
pipe clamp to the turbocharger (Fig. 1).
Fig.
1
Exhaust
Pipe to Turbocharger
Clamp
(2)
Raise and support the vehicle on a hoist.
(3)
Remove the bolt from the exhaust pipe support
strap (Fig. 2).
(4)
Remove the clamp nuts (Fig. 2).
(5)
Separate the exhaust pipe from the front ex
haust extension pipe (Fig. 2).
TURBOCHARGER WELD
FRONT
EXHAUST
CLAMP
JOINT
PIPE
SUPPORT STRAP
PIPE
J911M
Fig.
2 Front
Exhaust
Pipe
Mounting
and
Clamps
page
Intake
Manifold
Cover
/ Air
Intake
Heater
19
Muffler
and
Extension
Pipes
17
Turbocharger
21
INSTALLATION
(1)
Align the front exhaust pipe with the front ex
haust extension pipe and the turbocharger exhaust outlet.
(2)
Install the exhaust pipe support strap. Tighten
the nut to 41 Nun (30 ft. lbs.) torque.
(3)
Install the exhaust pipe support clamps and
nuts.
Tighten the nuts to 54 Nun (40 ft. lbs.) torque.
(4)
Lower the vehicle.
(5)
Install the turbocharger clamp and tighten the
screw to 8 Nun (74 in. lbs.) torque (Fig. 2). (6) Start the engine and check for leaks.
MUFFLER AND EXTENSION PIPES Rear extension pipes are used on the 135 inch, 149
inch and 159 inch wheelbase vehicles.
REMOVAL
(1)
Raise and support the vehicle.
(2)
Remove the clamps and nuts from the front ex
tension pipe. Remove the clamps and nuts from the rear extension pipe or from the muffler rear extension pipe (Fig. 3).
Fig.
3 Muffler and Extension Pipe(s)
21-144
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION
TRANSMISSION
ADAPTER
BOLT AND
;
WASHER
(2)
INSULATOR
SPACER
(2)
UPPER
INSULATOR
(2)
INSULATOR
MOUNTING PLATE
WITH
7"
RAIL
(135
"
WHEELBASE) LOWER
INSULATOR
(2)
J9121-532
Fig.
4
Transmission-To-Crossmember
Attachment (Except 46RH)
(29)
Secure converter in place with small C-clamp
attached to edge of converter housing.
(30)
Lower transmission and remove assembly
from under vehicle.
(31)
Remove C-clamp securing converter in hous
ing.
(32)
Carefully slide converter out of pump and re
move it from transmission. Place converter on bench and cover converter hub with tape, cardboard, or pa
per to prevent dirt entry.
TORQUE CONVERTER
AND
DRIVE PLATE SERVICE
After the transmission has been removed, the drive
plate and torque converter can be replaced or re
moved for service access.
The torque converter is not a serviceable part. If
the converter is contaminated by a transmission mal
function, or damaged in any way, it must be replaced as an assembly. Do not attempt to flush a con
verter contaminated by metal or clutch facing
particles. Flushing will not remove these con
taminants.
A new torque converter and oil pump are used
in 1993, 42RH transmissions. The new converter
has a different style drive hub. The hub was changed to accept the new design drive flats on
the oil pump inner gear. The drive flats replace
the square lugs used previously. If converter re placement should become necessary, be sure to
use the new style converter. The new converter and oil pump are not interchangeable with pre
vious style parts.
STARTER
RING GEAR
REPLACEMENT
CAUTION:
The
starter
ring
gear
on
standard
torque
converters
can be
replaced when necessary. How
ever,
the
ring gear
on
torque converters with
a
modulated converter clutch, cannot
be
replaced.
The heat from
welding
will
damage
the
converter
clutch friction material. Converters with
a
clutch
must
be
replaced
as an
assembly
if the
ring gear
is
damaged.
RING GEAR REMOWAL
(1) Cut through weld material at rear side of ring
gear with a hack saw or grinding wheel. Be careful
to avoid cutting or grinding into front cover. (2) Scribe heavy line on front cover next to front
face of ring gear. Line is needed to properly locate new gear on converter. (3) Support torque converter on front cover with
blocks of wood (Fig. 6) Position blocks adjacent to converter lugs to avoid altering lug position. The
torque converter must not rest on the front cover hub during this operation.
