9) Check and record freeze frame data to determine conditions
which set code. Turn ignition off. Disconnect transmission solenoid
harness connector. Disconnect PCM harness connectors. Inspect
connectors and terminals for damage. Repair as necessary. If connector
and terminals are okay, measure resistance of governor pressure sensor
ground circuit between transmission solenoid harness connector and
Black PCM harness connector C1. If resistance is greater than 5 ohms,
repair open governor pressure sensor ground circuit. If resistance is
5 ohms or less, go to next step.
10) Measure resistance of governor pressure sensor signal
circuit between White PCM harness connector C2 and governor pressure
sensor harness connector. If resistance is greater than 5 ohms, repair
open governor pressure sensor signal circuit. If resistance is 5 ohms
or less, go to next step.
11) Connect a fused jumper wire between fused B+ circuit and
transmission control relay output circuit at transmission relay
connector. Turn ignition on. Measure voltage between ground and
governor pressure signal circuit at White PCM harness connector C2. If
voltage is greater than one volt, repair governor pressure signal
circuit for short to voltage. If voltage is one volt or less, go to
next step.
12) Drain transmission fluid and remove oil pan. Disconnect
pressure/temperature sensor harness connector. Inspect connector and
terminals for damage. Repair as necessary. If connector and terminals
are okay, reconnect transmission solenoid harness connector. Carefully
connect a fused jumper wire between ground circuit and governor
pressure signal circuit at governor pressure sensor harness connector.
Turn ignition on. Using scan tool, read governor pressure sensor
voltage. If voltage is .1 volt or less, replace pressure/temperature
sensor. If voltage is greater than .1 volt, go to next step.
13) Measure resistance of governor pressure sensor signal
circuit between White PCM harness connector C2 and governor pressure
sensor harness connector. If resistance is greater than 5 ohms, repair
or replace transmission solenoid and harness assembly. If resistance
is 5 ohms or less, go to next step.
14) Measure resistance of governor pressure sensor ground
circuit between Black PCM harness connector C1 and governor pressure
sensor harness connector. If resistance is greater than 5 ohms, repair
or replace transmission solenoid and harness assembly. If resistance
is 5 ohms or less, go to next step.
15) Turn ignition on. Measure voltage between ground and
governor pressure signal circuit at governor pressure sensor harness
connector. If voltage is greater than one volt, repair or replace
transmission solenoid and harness assembly. If voltage is one volt or
less, replace PCM.
16) Turn ignition off. Disconnect PCM harness connectors.
Disconnect transmission solenoid harness connector. Inspect connector
and terminals for damage. Repair as necessary. If connector and
terminals are okay, measure resistance of sensor ground circuit
between Black PCM harness connector C1 and solenoid harness connector.
If resistance is less than 5 ohms, go to next step. If resistance is 5
ohms or greater, repair open in governor pressure sensor ground
circuit.
17) Turn ignition on. Measure voltage between ground and
governor pressure signal circuit at governor pressure sensor harness
connector. If voltage is greater than one volt, repair governor
pressure signal circuit for short to voltage. If voltage is one volt
or less, go to next step.
18) Turn ignition off. Measure resistance of governor
pressure sensor signal circuit between White PCM harness connector C2
and solenoid harness connector. If resistance is greater than 5 ohms,
repair open governor pressure sensor signal circuit. If resistance is
5 ohms or less, go to next step.
19) Turn ignition on. Using scan tool, read governor pressure
sensor voltage. If voltage is 4.65 volts or less, replace PCM. If
resistance is greater than 4.65 volts, go to next step.
20) Turn ignition off. Drain transmission fluid and remove
oil pan. Disconnect pressure/temperature sensor harness connector.
Inspect connector and terminals for damage. Repair as necessary. If
connector and terminals are okay, reconnect transmission solenoid
harness connector. Measure resistance of governor pressure sensor
signal circuit between White PCM harness connector C2 and governor
pressure sensor harness connector. If resistance is greater than 5
ohms, repair or replace transmission solenoid and harness assembly. If
resistance is 5 ohms or less, go to next step.
21) Measure resistance of governor pressure sensor ground
circuit between Black PCM harness connector C1 and governor pressure
sensor harness connector. If resistance is greater than 5 ohms, repair
or replace transmission solenoid and harness assembly. If resistance
is 5 ohms or less, go to next step.
22) Turn ignition on. Measure voltage between ground and
governor pressure signal circuit at governor pressure sensor harness
connector. If voltage is greater than one volt, repair or replace
transmission solenoid and harness assembly. If voltage is one volt or
less, replace pressure/temperature sensor.
23) Check and record freeze frame data to determine
conditions which set code. Conditions required to set DTC P1764 are
not present at this time. Using wiring diagram as a guide, inspect
wiring and connectors. Repair wiring harness as necessary. If wiring
and connectors are okay, go to next step.
24) Using scan tool, clear DTCs. While reading DTCs, wiggle
wiring harness between PCM and governor pressure sensor. If DTC P1764
resets while wiggling wiring harness, repair wiring harness as
necessary. If DTC P1764 does not reset, go next step.
25) DTC P1764 sets if governor pressure sensor input is less
than .1 volt for 8.36 seconds. Possible causes are: PCM internally
shorted or open, incorrectly wired, dirty or corroded connectors or
open or shorted wiring. See INACTIVE DTC CONDITION under SELF-
DIAGNOSTIC SYSTEM. Testing is complete.
DTC P1765: TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT
Circuit Description
Circuit is monitored continuously while key is on. Code sets
if voltage on transmission control relay circuit at PCM is different
than expected voltage for 3 seconds.
Possible Causes
* Generator source circuit open.
* Transmission relay control circuit open.
* Transmission relay control circuit short to ground.
* Transmission control relay wiring harness defective.
* PCM defective.
* Transmission control relay defective.
Diagnostic Procedures
1) Using scan tool, read DTCs. On AN and DN bodies, go to
next step. On all except AN and DN bodies, if DTC SPECIFIC GOOD TRIPS
counter is not displayed or displayed count is not "0", go to step 9).
If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed count is
"0", go to next step.
2) Using scan tool, actuate transmission control relay. If
transmission control relay does not click, go to step 5). If
transmission control relay clicks, go to next step.
3) Wiggle wiring harness between transmission control relay
TRIP COUNTER displays "0", return to appropriate test(s). If DTC
SPECIFIC GOOD TRIP COUNTER displays one or more, repair is complete.
Go to step 9).
3) If coming to this test from a mis-fire DTC test, go step
7). If coming to this test from other than a mis-fire DTC test, use
scan tool to monitor pretest enabling conditions until all conditions
have been met. Once all enabling conditions are met, observe
appropriate monitor for DTC on scan tool and go to next step.
4) Using scan tool, monitor SIMILAR CONDITIONS to attempt to
duplicate conditions that vehicle was operating at when DTC was set.
If conditions can be duplicated, GOOD TRIP COUNTER will change to one
or more. Monitor operation may be observed on scan tool. All specified
enabling conditions for specified DTC must be met before PCM will
operate monitor. Go to next step.
5) Turn ignition off for 10 seconds. Start engine and allow
it to idle for 2 minutes while monitoring scan tool. If STARTS SINCE
SET and DTC SPECIFIC GOOD TRIP COUNTER change to one or more, repair
is complete. Go to step 9). If STARTS SINCE SET and DTC SPECIFIC GOOD
TRIP COUNTER do not change to one or more, go to next step.
6) Using scan tool, read DTCs. If any DTC exists, return to
appropriate test(s). If no other DTC exists, go to next step.
7) Using scan tool, monitor SIMILAR CONDITIONS to attempt to
duplicate conditions that vehicle was operating at when DTC was set.
If conditions can be duplicated, MISFIRE GOOD TRIP COUNTER will change
to one or more. If MISFIRE GOOD TRIP COUNTER changes to one or more,
test is complete. Go to step 9). If MISFIRE GOOD TRIP COUNTER does not
change to one or more, go to next step.
8) Using scan tool, read DTCs. If any DTC exists, return to
appropriate test(s). If no other DTC exists, go to next step.
9) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
REMOVAL & INSTALLATION
GOVERNOR PRESSURE SENSOR, GOVERNOR PRESSURE SOLENOID &
TRANSMISSION FLUID TEMPERATURE SENSOR
NOTE: Transmission fluid temperature sensor is integral with
governor pressure sensor.
Removal
1) Raise and support vehicle. Drain transmission fluid.
Remove transmission oil pan and filter. Disconnect harness connectors
from governor pressure solenoid and sensor.
2) Remove pressure solenoid retainer-to-governor body screws.
Separate solenoid retainer from governor and pull solenoid from
governor body.
3) Remove governor body-to-valve body bolts. Separate
governor body from valve body. Remove governor body and gasket. Remove
retainer clip holding pressure sensor to governor body and remove
pressure sensor.
Installation
1) Clean all gasket surfaces. Lubricate NEW "O" ring with ATF
and install on pressure sensor. Push pressure sensor into governor
body and install retainer clip. Position governor body on valve body
with NEW gasket and install governor body-to-valve body bolts.
2) Lubricate NEW "O" ring with ATF and install on pressure
solenoid. Push solenoid into governor body. Install solenoid retainer.
Reconnect harness connectors to pressure solenoid and sensor. To
complete installation, reverse removal procedure.
1) Start engine, and check booster vacuum hose connections. A
hissing noise indicates a vacuum leak. Repair any vacuum leaks before
proceeding. Stop engine, and shift transmission into Neutral. Pump
brake pedal until all vacuum reserve in booster is depleted.
2) Hold brake pedal under light pressure. If pedal does not
hold firm and falls away, master cylinder may be faulty. Bleed system
using appropriate method, and repeat step 1). See BLEEDING PROCEDURES
under BLEEDING BRAKE SYSTEM.
3) If pedal still does not hold firm, master cylinder is
faulty. If pedal holds firm, start engine and observe pedal height. If
pedal height change is not apparent, power booster or vacuum check
valve is faulty. Install good check valve, and repeat steps 1) and 2).\
If pedal falls away slightly under light pressure and then holds firm,
go to next step .
4) Start engine. Release brake pedal. Increase engine speed
to 1500 RPM. Close throttle and immediately turn off ignition. Wait at
least 90 seconds, and try brake action again. Booster should provide 2
or more vacuum assisted pedal applications. If vacuum assist is not
provided, perform booster and check valve vacuum tests.
POWER BRAKE BOOSTER VACUUM TEST
Connect vacuum gauge to booster check valve using "T"
fitting. Start engine, and run at idle speed for one minute. Clamp
hose shut between vacuum source and check valve. Stop engine, and
observe vacuum gauge. If vacuum drops more than one in. Hg within 15
seconds, booster diaphragm or check valve is faulty.
POWER BRAKE BOOSTER CHECK VALVE TEST
Disconnect vacuum hose from check valve. Remove check valve
and valve seal from booster. Use a hand-operated vacuum pump for
testing. Apply 15-20 in. Hg at large end of check valve. Vacuum should
hold steady. If gauge on pump indicates vacuum loss, check valve is
faulty and should be replaced.
COMBINATION VALVE METERING VALVE TEST
Metering valve operation can be checked visually with aid of
an assistant. While an assistant applies and releases brake pedal,
observe metering valve stem. If valve is operating correctly, stem
will extend slightly when brakes are applied, and contract when brakes
are released. If valve is faulty, replace combination valve assembly.
COMBINATION VALVE PRESSURE DIFFERENTIAL SWITCH TEST
1) Using an assistant, apply brake pedal. Observe brake
warning light. Raise and support vehicle, and connect a bleed hose to
one rear wheel cylinder. Submerge other end of hose into container
partially filled with brake fluid. Have assistant press and hold brake
pedal down while observing brake warning light. Open bleeder screw. If
warning light glows, switch is operating properly.
2) If warning light fails to glow, check circuit fuse, bulb
and wiring. Repair as necessary. Repeat step 1). If warning light
fails to glow, check brakelight, parking brake switches and related
wiring. Repair as necessary. Repeat step 1). If warning light fails to
glow, pressure differential switch is faulty. Replace combination
valve assembly, and bleed brake system. Verify proper valve operation.
REMOVAL & INSTALLATION
Removal (AX15 & NV1500)
1) Shift gear selector into 1st or 3rd gear. Raise and
support vehicle. Disconnect necessary exhaust system components.
Remove "Y" pipe and position remaining pipes for working clearance.
Support transmission adjustable jackstand. Disconnect rear cushion and
mounting bracket from transmission or transfer case.
2) Remove rear crossmember. If transmission will be
disassembled for repair, drain transmission fluid. Disconnect
transmission shift linkage, speedometer cable, transfer case vacuum
lines and clutch hydraulic lines. Lower transmission/transfer case
assembly no more than 3" (76 mm). Reaching around transmission case,
unseat and lift shift lever dust boot. Press shift lever retainer
downward, turn retainer counterclockwise, and lift lever and retainer
out of shift tower.
3) Mark front and rear drive shaft and "U" joint for
reassembly reference. Disconnect and remove both drive shafts. Remove
crankshaft position sensor (AX15). Disconnect transmission/transfer
case assembly vent hoses. Remove slave cylinder from clutch housing.
Remove wire harness from clips on transmission case and transfer case.
4) Support transmission/transfer case assembly with
transmission jack. Secure assembly to jack with safety chains.
Reposition adjustable jackstand under engine. Remove clutch housing
brace rod. Remove clutch housing nuts and bolts. Remove
transmission/transfer case assembly.
Installation
To install, reverse removal procedure. Apply high-temperature
grease to release fork, lever, pivot ball stud and pilot bushing
located in end of crankshaft. Fill transmission with appropriate
fluid, if necessary. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS table.
Removal (NV 3500)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Open console lid and remove bolts attaching console to floor
pan. Lift cup holder bin and remove bolt attaching console to floor
pan. Lift rear of console and pull console rearward to separate from
shift bezel. Remove console from vehicle. Remove screws attaching
shift boot to floor pan and slide boot upward on lever extension.
2) Remove shift lever extension. Raise and support vehicle.
On 4WD models, remove skid plate, if equipped. Mark drive shaft and
axle yoke for alignment reference. Remove drive shaft. Remove exhaust
"Y" pipe. On 4WD models, disconnect and lower remaining exhaust pipes
for clearance as necessary. Disconnect speed sensor harness connector
and back-up light harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine attaching bolts. Slide
NOTE: Clutch release bearing is packed with grease. DO NOT use
cleaning solvent to clean release bearing.
Removal
1) Remove transmission and clutch housing. See TRANSMISSION
(DAKOTA) or TRANSMISSION (RAM PICKUP). Disconnect release bearing fr\
om
fork, and remove bearing. See Fig. 11. Remove release fork.
2) Inspect bearing. Bearing should turn smoothly under a
light thrust load. Inspect release fork and fork ball pivot for
distortion and wear.
Installation
1) Lubricate crankshaft pilot bearing, input shaft splines,
bearing retainer slide surface, fork pivot and release fork pivot
surface with high-temperature bearing grease.
2) Install release fork and release bearing. Ensure fork and
bearing are properly secured. Install transmission and clutch housing.
Fig. 11: Exploded View Of RWD Clutch Release Bearing Assembly
Courtesy of Chrysler Corp.
CLUTCH MASTER CYLINDER
Removal
1) Disconnect clutch pedal interlock switch wires. Remove
locating clip from clutch master cylinder mounting bracket. Remove
retaining clip, flat washer and wave washer that attach clutch master
cylinder push rod to clutch pedal. Slide clutch master cylinder push
rod off pedal pin. Ensure cap on clutch master cylinder reservoir is
tight.
2) Remove clutch fluid reservoir. Rotate clutch master
cylinder 45 degrees counterclockwise to unlock it. Remove cylinder
from dash panel. Remove clutch master cylinder rubber seal from dash
panel.
Installation
Lubricate cylinder seal with liquid soap to ease
installation. Seat seal in dash and around cylinder. To install,
reverse removal procedure.
FLUID TYPE
Use SAE 80W-90 or 90W hypoid gear lubricant with MIL-L-2105-C
and API GL-5 ratings.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
AXLE SHAFT & HUB BEARING
Removal
1) Raise and support vehicle. Remove wheel. Remove brake
caliper with hose attached, and secure aside. DO NOT allow brake
caliper to hang by brake hose. Remove brake rotor. Remove ABS wheel
speed sensor (if equipped). Remove grease cap from center of front
hub. Remove cotter pin from end of axle shaft. Remove axle nut and
washer.
2) Remove hub/bearing assembly-to-knuckle bolts. Remove
hub/bearing assembly from steering knuckle and axle shaft. Remove
brake dust shield. To remove right (passenger-side) axle shaft,
carefully pull axle shaft from axle housing.
NOTE: Left axle shaft will disengage from collar located on
intermediate axle shaft.
3) To remove left (driver's side) axle shaft, disconnect
electrical connector and vacuum hoses at vacuum shift motor. Remove
bolts, vacuum shift motor and gasket. Carefully pull axle shaft from
axle housing and collar on intermediate axle shaft.
Installation
1) Install NEW oil seal on axle shaft with seal lip facing
toward splines on differential end of axle shaft. Coat seal lip with
wheel bearing grease.
2) Install right axle shaft into axle housing. Ensure axle
shaft engages with side gears in differential.
3) To install left axle shaft, ensure collar is engaged with
splines on intermediate axle shaft. Install left axle shaft into axle
housing. Ensure axle shaft engages with splines on collar. Install
vacuum shift motor, ensuring fork on vacuum shift motor engages groove
on collar. Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS table.
4) To complete installation, reverse removal procedure. Apply
silicone rubber sealant to edge of grease cap before installing.
Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer selector levers case are in Neutral. Reference mark drive
shaft and pinion flange for reassembly reference.
2) Remove bolts and "U" joint straps at pinion flange. Remove
center carrier bearing bolts (if equipped). Remove drive shaft.
CAUTION: The "U" joint components are not serviceable. Replace
complete assembly. DO NOT reuse.
(1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add container of Mopar Gear Oil Friction Modifier when
refilling.
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FLUID TYPE
Use SAE 80W-90 or SAE 90W hypoid gear lubricant with MIL-L-
2105-B and API GL-5 ratings. Also add a container of Mopar Gear Oil
Friction Modifier when refilling.
FLUID DRAIN & REFILL
1) With lubricant of rear axle assembly at normal operating
temperature, raise and support vehicle so rear wheels are free to
rotate. Clean around axle housing cover. Loosen axle housing cover
bolts. Drain lubricant from axle housing. Remove bolts and axle
housing cover.
2) Position differential so hole in differential case faces
down. Wipe all accessible areas of axle housing. Ensure sealing
surfaces on axle housing and cover are clean. Apply a 1/4" thick bead
of silicone sealant on inside of bolt holes and along sealing surfaces
on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to 30 ft. lbs. (41 N.m). Remove oil
filler plug. Add a container of Mopar Gear Oil Friction Modifier. Fill
axle with gear lube. Install oil filler plug. Lower vehicle.
TROUBLE SHOOTING
DIFFERENTIAL NOISE
1) Ensure differential lubricant is at normal operating
temperature. Road test vehicle. Note if differential noise exists in
turns, but not during straight-ahead driving. Probable cause is
incorrect or insufficient rear axle lubricant or additive.
2) Drain and refill rear axle. See FLUID DRAIN & REFILL under
LUBRICATION. Road test vehicle and note if noise still exists, it may
be necessary to disassemble rear axle so differential can be repaired.
See RBI FULL-FLOATING AXLES article for removal of differential case.
TESTING
NOTE: Power-Lok differential can be tested without removing
differential carrier from axle housing. Either test can be
used to check drive axle.
TEST I
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs, and tighten securely.
2) Using torque wrench on adapter, rotate axle, and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(41 N.m) or greater than 200 ft. lbs. (271 N.m), Power-Lok unit must\
be replaced or repaired.