2005 CHRYSLER CARAVAN brake fluid

TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE..............141TE AUTOMATIC TRANSAXLE............146
40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE
DESCRIPTION..........................2
OPERATION............................4
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE
TRANSAXLE GENERAL DIAGNOSIS........5
DIAGNOSIS AND TESTING - ROAD TEST....5
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS.....................6
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS.....................8
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE....9
REMOVAL.............................9
DISASSEMBLY.........................12
ASSEMBLY............................29
INSTALLATION.........................51
SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC
SCHEMATICS........................54
SPECIFICATIONS - 41TE TRANSAXLE.......66
SPECIAL TOOLS.......................68
ACCUMULATOR
DESCRIPTION.........................73
OPERATION...........................73
DRIVING CLUTCHES
DESCRIPTION.........................74
OPERATION...........................74
FINAL DRIVE
DESCRIPTION.........................74
OPERATION...........................75
DISASSEMBLY.........................75
ASSEMBLY............................78
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD
MEASUREMENT AND ADJUSTMENT......79FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK....82
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE......................82
GEAR SHIFT CABLE
REMOVAL.............................84
HOLDING CLUTCHES
DESCRIPTION.........................86
OPERATION...........................86
INPUT CLUTCH ASSEMBLY
DISASSEMBLY.........................86
ASSEMBLY............................95
OIL PUMP
DESCRIPTION........................110
OPERATION..........................110
DISASSEMBLY........................110
ASSEMBLY...........................112
PLANETARY GEARTRAIN
DESCRIPTION........................112
OPERATION..........................112
SEAL - OIL PUMP
REMOVAL............................113
INSTALLATION........................113
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................113
OPERATION..........................114
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................115
REMOVAL............................115
INSTALLATION........................116
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................117
OPERATION..........................118
REMOVAL............................118
INSTALLATION........................119
RSTRANSMISSION/TRANSAXLE21-1

FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid)
should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground.At normal operating temperature 82É C
(180É F), the fluid level is correct if it is in the HOT
region on the oil level indicator (Fig. 187). The fluid
level should be within the COLD region of the dip-
stick at 27É C (80É F) fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 188).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
Fig. 187 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 82 40TE AUTOMATIC TRANSAXLERS

(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way.
(5) Disconnect gear shift cable at manual valve
lever (Fig. 191).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 191).
Fig. 190 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
Fig. 191 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 84 40TE AUTOMATIC TRANSAXLERS
FLUID (Continued)

41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE
DESCRIPTION........................147
OPERATION..........................149
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE
TRANSAXLE GENERAL DIAGNOSIS......149
DIAGNOSIS AND TESTING - ROAD TEST . . 150
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS...................150
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS...................153
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 154
REMOVAL............................154
DISASSEMBLY........................157
ASSEMBLY...........................174
INSTALLATION........................196
SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC
SCHEMATICS.......................199
SPECIFICATIONS - 41TE TRANSAXLE......211
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE.........213
ACCUMULATOR
DESCRIPTION........................218
OPERATION..........................218
DRIVING CLUTCHES
DESCRIPTION........................219
OPERATION..........................219
FINAL DRIVE
DESCRIPTION........................219
OPERATION..........................220
DISASSEMBLY........................220
ASSEMBLY...........................224
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD..........................228
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK . . . 230
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE.....................231
GEAR SHIFT CABLE
REMOVAL............................233
INSTALLATION........................234
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT.......235
HOLDING CLUTCHES
DESCRIPTION........................236
OPERATION..........................236INPUT CLUTCH ASSEMBLY
DISASSEMBLY........................237
ASSEMBLY...........................246
OIL PUMP
DESCRIPTION........................261
OPERATION..........................261
DISASSEMBLY........................261
ASSEMBLY...........................263
PLANETARY GEARTRAIN
DESCRIPTION........................263
OPERATION..........................263
SEAL - OIL PUMP
REMOVAL............................264
INSTALLATION........................264
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................264
OPERATION..........................265
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................266
REMOVAL............................266
INSTALLATION........................267
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................268
OPERATION..........................268
REMOVAL............................269
INSTALLATION........................270
SPEED SENSOR - INPUT
DESCRIPTION........................271
OPERATION..........................271
REMOVAL............................272
INSTALLATION........................272
SPEED SENSOR - OUTPUT
DESCRIPTION........................273
OPERATION..........................273
REMOVAL............................274
INSTALLATION........................274
TORQUE CONVERTER
DESCRIPTION........................275
OPERATION..........................278
REMOVAL............................280
INSTALLATION........................280
TRANSMISSION CONTROL RELAY
DESCRIPTION........................281
OPERATION..........................281
TRANSMISSION RANGE SENSOR
DESCRIPTION........................281
OPERATION..........................282
REMOVAL............................282
INSTALLATION........................282
21 - 146 41TE AUTOMATIC TRANSAXLERS

CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.
(9) Using the end play measurement that was
determined, add 0.18mm (0.007 inch). This should
give you between 5-18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with MopartSilicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 204). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a 0.05mm
(0.002 inch) thicker shim. If the turning torque is too
low, install a 0.05mm (0.002 inch) thinner shim.
Repeat until 5-18 inch-pounds of turning torque is
obtained.
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid)
should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground.At normal operating temperature 82É C
(180É F), the fluid level is correct if it is in the HOT
region on the oil level indicator (Fig. 205). The fluid
level should be within the COLD region of the dip-
stick at 27É C (80É F) fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.
(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 206).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
Fig. 205 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 230 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 207).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 208).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.
(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 208).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
Fig. 207 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 208 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 232 41TE AUTOMATIC TRANSAXLERS
FLUID (Continued)

AJAR SWITCH - EXPORT -INSTALLATION, HOOD .................8Q-3
AJAR SWITCH - EXPORT - REMOVAL, HOOD .............................. 8Q-3
ALIGNMENT - DESCRIPTION, WHEEL ......2-47
ALIGNMENT - EXPORT - STANDARD PROCEDURE, FRONT FOG LAMP UNIT .....8L-9
ALIGNMENT - EXPORT - STANDARD PROCEDURE, HEADLAMP UNIT .........8L-15
ALIGNMENT - STANDARD PROCEDURE, FRONT FOG LAMP UNIT ................8L-9
ALIGNMENT - STANDARD PROCEDURE, FRONT WIPER ARM ................... 8R-9
ALIGNMENT - STANDARD PROCEDURE, HEADLAMP UNIT ..................... 8L-14
ALIGNMENT - STANDARD PROCEDURE, WHEEL ............................. 2-52
ALIGNMENT, SPECIFICATIONS - WHEEL ....2-56
AMBIENT TEMP SENSOR - DESCRIPTION . 8M-12
AMBIENT TEMP SENSOR - OPERATION . . 8M-12
AMBIENT TEMPERATURE SENSOR CIRCUIT, DIAGNOSIS AND TESTING .....8M-12
AMBIENT TEMPERATURE SENSOR, DIAGNOSIS AND TESTING .............8M-12
AMPLIFIER - INSTALLATION .............8A-7
AMPLIFIER - REMOVAL ................8A-7
AN AIRBAG DEPLOYMENT - STANDARD PROCEDURE, SERVICE AFTER ...........8O-7
ANCHOR - DESCRIPTION, CHILD RESTRAINT .......................... 8O-9
ANCHOR - OPERATION, CHILD RESTRAINT .......................... 8O-10
ANTENNA - EXPORT - DESCRIPTION, QUARTER GLASS INTEGRAL ............8A-13
ANTENNA - EXPORT - OPERATION, QUARTER GLASS INTEGRAL ............8A-13
ANTENNA - NAVIGATION RADIO - INSTALLATION ....................... 8A-11
ANTENNA - NAVIGATION RADIO - REMOVAL .......................... 8A-11
ANTENNA BODY AND CABLE - DESCRIPTION ........................ 8A-7
ANTENNA BODY AND CABLE - OPERATION .......................... 8A-7
ANTENNA BODY AND CABLE, DIAGNOSIS AND TESTING ..............8A-8
ANTENNA CABLE - INSTALLATION, INSTRUMENT PANEL .................8A-12
ANTENNA CABLE - REMOVAL, INSTRUMENT PANEL .................8A-12
ANTENNA, EXPORT - QUARTER GLASS INTEGRAL .......................... 8A-13
ANTENNA MODULE - EXPORT - DESCRIPTION ....................... 8A-10
ANTENNA MODULE - EXPORT - OPERATION ......................... 8A-10
ANTENNA MODULE, EXPORT ...........8A-10
ANTILOCK BRAKE - DESCRIPTION, CONTROLLER ........................ 8E-4
ANTILOCK BRAKE - INSTALLATION, CONTROLLER ........................ 8E-6
ANTILOCK BRAKE - OPERATION, CONTROLLER ........................ 8E-5
ANTILOCK BRAKE - REMOVAL, CONTROLLER ........................ 8E-5
ANTILOCK BRAKE SYSTEM - DESCRIPTION ........................ 5-87
ANTILOCK BRAKE SYSTEM - OPERATION . . 5-88
ANTILOCK BRAKE SYSTEM BLEEDING - STANDARD PROCEDURE ................5-90
ANTILOCK BRAKE SYSTEM (EXPORT) - DESCRIPTION ........................ 5-87
A-PILLAR LOWER EXTENSION TRIM - INSTALLATION ....................... 23-79
A-PILLAR LOWER EXTENSION TRIM - REMOVAL .......................... 23-79
A-PILLAR TRIM - INSTALLATION ........23-79
A-PILLAR TRIM - REMOVAL ............23-79
A-PILLAR-HEADER, OR B-PILLAR - INSTALLATION ....................... 23-17
A-PILLAR-HEADER, OR B-PILLAR - REMOVAL .......................... 23-17
APPLIQUE - INSTALLATION .............23-14
APPLIQUE - REMOVAL ................23-14
ARM - DESCRIPTION, LOWER CONTROL . . . 2-12
ARM - INSPECTION, LOWER CONTROL ....2-14
ARM - INSTALLATION, LOWER CONTROL . . 2-15
ARM - INSTALLATION, REAR WIPER .....8R-10 ARM - OPERATION, LOWER CONTROL
.....2-12
ARM - REMOVAL, LOWER CONTROL ......2-12
ARM - REMOVAL, REAR WIPER .........8R-10
ARM ALIGNMENT - STANDARD PROCEDURE, FRONT WIPER ............8R-9
ARM (REAR BUSHING - HYDRO) - ASSEMBLY, LOWER CONTROL ...........2-15
ARM (REAR BUSHING - HYDRO) - DISASSEMBLY, LOWER CONTROL ........2-13
ARM (REAR BUSHING - STANDARD) - ASSEMBLY, LOWER CONTROL ...........2-14
ARM (REAR BUSHING - STANDARD) - DISASSEMBLY, LOWER CONTROL ........2-13
ARMREST - INSTALLATION ............23-108
ARMREST - REMOVAL ...............23-108
ARMREST - SECOND ROW - FOLD-IN- FLOOR - INSTALLATION ..............23-130
ARMREST - SECOND ROW - FOLD-IN- FLOOR - REMOVAL .................. 23-130
ARMREST ROTATING ASSEMBLY - SECOND ROW - FOLD-IN-FLOOR -
INSTALLATION ...................... 23-130
ARMREST ROTATING ASSEMBLY - SECOND ROW - FOLD-IN-FLOOR -
REMOVAL ......................... 23-130
ARMS - DESCRIPTION, ROCKER ........9-112
ARMS - INSPECTION, ROCKER ...........9-35
ARMS - INSTALLATION, FRONT WIPER ....8R-9
ARMS - INSTALLATION, ROCKER .........9-35
ARMS - OPERATION, ROCKER ..........9-112
ARMS - REMOVAL, FRONT WIPER .........8R-9
ARMS - REMOVAL, ROCKER .............9-35
ARMS AND SHAFT - ASSEMBLY, ROCKER ............................ 9-113
ARMS AND SHAFT - DISASSEMBLY, ROCKER ............................ 9-113
ARMS AND SHAFT - INSTALLATION, ROCKER ............................ 9-113
ARMS AND SHAFT - REMOVAL, ROCKER . . 9-112
ASSIST DISPLAY - DESCRIPTION, PARK . . . 8B-3
ASSIST DISPLAY - INSTALLATION, PARK . . . 8B-4
ASSIST DISPLAY - OPERATION, PARK .....8B-3
ASSIST DISPLAY - REMOVAL, PARK ......8B-4
ASSIST HANDLE - INSTALLATION ........23-79
ASSIST HANDLE - REMOVAL ...........23-79
ASSIST MODULE - DESCRIPTION, PARK . . . 8B-4
ASSIST MODULE - INSTALLATION, PARK . . 8B-6
ASSIST MODULE - OPERATION, PARK .....8B-5
ASSIST MODULE - REMOVAL, PARK ......8B-5
ASSIST SENSOR - DESCRIPTION, PARK . . . 8B-6
ASSIST SENSOR - INSTALLATION, PARK . . . 8B-6
ASSIST SENSOR - OPERATION, PARK .....8B-6
ASSIST SENSOR - REMOVAL, PARK ......8B-6
ASSIST STRAP - INSTALLATION, FRONT SEAT BACK ........................ 23-112
ASSIST STRAP - REMOVAL, FRONT SEAT BACK ........................ 23-112
ATTACHED - INSTALLATION, EXTERIOR NAME PLATES - ADHESIVE .............23-51
ATTACHED - INSTALLATION, EXTERIOR NAME PLATES - TAPE .................23-51
ATTACHED - REMOVAL, EXTERIOR NAME PLATES - ADHESIVE .................. 23-51
ATTACHED - REMOVAL, EXTERIOR NAME PLATES - TAPE ...................... 23-51
AUDIO/VIDEO - DESCRIPTION ...........8A-1
AUDIO/VIDEO, DIAGNOSIS AND TESTING . . 8A-2
AUTO SHUT DOWN RELAY - DESCRIPTION ......................... 8I-3
AUTO SHUT DOWN RELAY - OPERATION . . . 8I-3
AUTOMATIC ADJUSTER - DIAGNOSIS AND TESTING, DRUM BRAKE ............5-14
AUTOMATIC ADJUSTER TENSION RELEASE - STANDARD PROCEDURE,
PARKING BRAKE ...................... 5-63
AUTOMATIC ADJUSTER TENSION RESET - STANDARD PROCEDURE, PARKING
BRAKE .............................. 5-64
AUTOMATIC DAY / NIGHT MIRROR - DESCRIPTION ....................... 8N-28
AUTOMATIC DAY / NIGHT MIRROR - OPERATION ......................... 8N-28
AUTOMATIC DAY / NIGHT MIRROR, DIAGNOSIS AND TESTING .............8N-28
AUTOMATIC TEMPERATURE CONTROL, DESCRIPTION ........................ 24-3
AUTOMATIC TEMPERATURE CONTROL, OPERATION .......................... 24-5AUTOMATIC TEMPERATURE CONTROL
SYSTEM, OPERATION ................24-114
AUTOMATIC TRANSAXLE - DESCRIPTION, 40TE ................... 21-2
AUTOMATIC TRANSAXLE - DESCRIPTION, 41TE .................21-147
AUTOMATIC TRANSAXLE - OPERATION, 40TE ............................... 21-4
AUTOMATIC TRANSAXLE - OPERATION, 41TE ............................. 21-149
AUTOMATIC TRANSAXLE, SPECIAL TOOLS - 41TE ...................... 21-213
AUTOMATIC/MANUAL TRANSAXLE FLUID - DESCRIPTION ........................0-4
AWD - INSTALLATION ..................2-45
AWD - INSTALLATION, REAR WHEEL SPEED SENSOR ....................... 5-92
AWD - INSTALLATION, SPRING ..........2-39
AWD - REMOVAL ..................... 2-44
AWD - REMOVAL, REAR WHEEL SPEED SENSOR ............................ 5-92
AWD - REMOVAL, SPRING ..............2-38
AWD, HEAVY DUTY, CARGO - INSTALLATION ........................ 2-36
AWD, HEAVY DUTY, CARGO - REMOVAL . . . 2-36
AWD POWER TRANSFER UNIT FLUID - DESCRIPTION .........................0-6
AWD REAR DRIVELINE MODULE FLUIDS - DESCRIPTION ........................0-6
B OR C-PILLAR - INSTALLATION, SEAT BELT HEIGHT ADJUSTER ..............8O-38
B OR C-PILLAR - REMOVAL, SEAT BELT HEIGHT ADJUSTER ................... 8O-38
BACK - INSTALLATION, BENCH SEAT ....23-147
BACK - INSTALLATION, FRONT SEAT ....23-111
BACK - QUAD BUCKET - INSTALLATION, BUCKET SEAT ...................... 23-141
BACK - QUAD BUCKET - REMOVAL, BUCKET SEAT ...................... 23-140
BACK - REMOVAL, BENCH SEAT ........23-147
BACK - REMOVAL, FRONT SEAT ........23-111
BACK ASSIST STRAP - INSTALLATION, FRONT SEAT ....................... 23-112
BACK ASSIST STRAP - REMOVAL, FRONT SEAT ....................... 23-112
BACK COVER - INSTALLATION, BENCH SEAT ............................. 23-148
BACK COVER - INSTALLATION, FRONT SEAT ............................. 23-116
BACK COVER - REMOVAL, BENCH SEAT . . 23-148
BACK COVER - REMOVAL, FRONT SEAT . . 23-113
BACK COVER/FOAM - SECOND ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-133
BACK COVER/FOAM - SECOND ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-133
BACK COVER/FOAM - THIRD ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-156
BACK COVER/FOAM - THIRD ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-155
BACK FRAME - SECOND ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-134
BACK FRAME - SECOND ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-134
BACK FRAME - THIRD ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-157
BACK FRAME - THIRD ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-156
BACK HINGE - REMOVAL, BENCH SEAT . . 23-146
BACK HINGE COVERS - QUAD BUCKET, 50/50 SPLIT, BENCH - INSTALLATION,
SEAT ............................. 23-146
BACK HINGE COVERS - QUAD BUCKET, 50/50 SPLIT, BENCH - REMOVAL, SEAT . . 23-146
BACK PANEL - INSTALLATION, BENCH SEAT ............................. 23-144
BACK PANEL - INSTALLATION, FRONT SEAT ............................. 23-113
BACK PANEL - REMOVAL, BENCH SEAT . . 23-143
BACK PANEL - REMOVAL, FRONT SEAT . . 23-112
BACK PANEL - SECOND ROW -FOLD-IN-FLOOR - INSTALLATION,
SEAT ............................. 23-134
BACK PANEL - SECOND ROW -FOLD-IN-FLOOR - REMOVAL, SEAT .....23-134
BACK PANEL - THIRD ROW -FOLD-IN- FLOOR - INSTALLATION, SEAT .........23-158
BACK PANEL - THIRD ROW -FOLD-IN- FLOOR - REMOVAL, SEAT .............23-158
2 INDEXRS
Description Group-Page Description Group-Page Description Group-Page

BRAKE CABLES - ADJUSTMENT,PARKING ............................ 5-65
BRAKE CALIPER - INSTALLATION, REAR DISC ............................... 5-30
BRAKE CALIPER - REMOVAL, REAR DISC ............................... 5-28
BRAKE CALIPER ADAPTER - INSTALLATION, FRONT DISC .............5-31
BRAKE CALIPER ADAPTER - REMOVAL, FRONT DISC ......................... 5-31
BRAKE CALIPER (CONTINENTAL TEVES BRAKES) - INSTALLATION, FRONT
DISC ............................... 5-27
BRAKE CALIPER (CONTINENTAL TEVES BRAKES) - REMOVAL, FRONT DISC .......5-24
BRAKE CALIPER GUIDE PINS (TRW BRAKES) - INSTALLATION, DISC .........5-32
BRAKE CALIPER GUIDE PINS (TRW BRAKES) - REMOVAL, DISC .............5-31
BRAKE CALIPER (TRW BRAKES) - INSTALLATION, FRONT DISC .............5-27
BRAKE CALIPER (TRW BRAKES) - REMOVAL, FRONT DISC ................5-24
BRAKE FASTENER TORQUE, SPECIFICATIONS .......................5-9
BRAKE FLUID CONTAMINATION - DIAGNOSIS AND TESTING ..............5-33
BRAKE FLUID LEVEL CHECKING - STANDARD PROCEDURE ................5-33
BRAKE FLUID LEVEL SWITCH - DESCRIPTION ........................ 5-10
BRAKE FLUID LEVEL SWITCH - INSTALLATION ........................ 5-11
BRAKE FLUID LEVEL SWITCH - OPERATION .......................... 5-10
BRAKE FLUID LEVEL SWITCH - REMOVAL ........................... 5-11
BRAKE FLUID, SPECIFICATIONS ..........5-33
BRAKE INTERMEDIATE - INSTALLATION, CABLE - PARKING ..................... 5-69
BRAKE INTERMEDIATE - REMOVAL, CABLE - PARKING ..................... 5-69
BRAKE LAMP SWITCH - DESCRIPTION ....8L-4
BRAKE LAMP SWITCH - DIAGNOSIS AND TESTING ........................ 8L-4
BRAKE LAMP SWITCH - INSTALLATION ....8L-5
BRAKE LAMP SWITCH - OPERATION ......8L-4
BRAKE LAMP SWITCH - REMOVAL .......8L-5
BRAKE LEVER AND FRONT CABLE - INSTALLATION, PARKING ...............5-77
BRAKE LEVER AND FRONT CABLE - REMOVAL, PARKING ................... 5-77
BRAKE PROPORTIONING - DESCRIPTION, ELECTRONIC VARIABLE ....5-88
BRAKE PROPORTIONING - OPERATION, ELECTRONIC VARIABLE ................5-89
BRAKE ROTOR - DIAGNOSIS AND TESTING ............................ 5-55
BRAKE ROTOR - INSTALLATION, FRONT . . . 5-59
BRAKE ROTOR - REMOVAL, FRONT .......5-59
BRAKE ROTOR, EXPORT ................5-60
BRAKE ROTOR MACHINING - STANDARD PROCEDURE ......................... 5-58
BRAKE ROTOR, SPECIFICATIONS .........5-60
BRAKE SHOE LINING - INSPECTION, REAR DRUM ......................... 5-22
BRAKE SHOES - ADJUSTMENT, PARKING . . 5-85
BRAKE SHOES - ADJUSTMENT, REAR DRUM .............................. 5-23
BRAKE SHOES - CLEANING, DISC ....5-16,5-18
BRAKE SHOES - INSPECTION, DISC . . . 5-16,5-18
BRAKE SHOES - INSTALLATION, REAR DISC ............................... 5-19
BRAKE SHOES - INSTALLATION, REAR DRUM .............................. 5-22
BRAKE SHOES - REMOVAL, REAR DISC ....5-17
BRAKE SHOES - REMOVAL, REAR DRUM . . 5-19
BRAKE SHOES (CONTINENTAL TEVES BRAKES) - INSTALLATION, FRONT
DISC ............................... 5-16
BRAKE SHOES (CONTINENTAL TEVES BRAKES) - REMOVAL, FRONT DISC .......5-15
BRAKE SHOES (TRW BRAKES) - INSTALLATION, FRONT DISC .............5-17
BRAKE SHOES (TRW BRAKES) - REMOVAL, FRONT DISC ................5-15
BRAKE SYSTEM - DESCRIPTION, ANTILOCK ........................... 5-87BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE ........................5-4
BRAKE SYSTEM - OPERATION, ANTILOCK ........................... 5-88
BRAKE SYSTEM BLEEDING - STANDARD PROCEDURE, ANTILOCK ................5-90
BRAKE SYSTEM (EXPORT) - DESCRIPTION, ANTILOCK ...............5-87
BRAKE SYSTEM, SPECIAL TOOLS - BASE . . 5-10
BRAKE TUBES AND HOSES - DESCRIPTION ........................ 5-14
BRAKE TUBES AND HOSES - INSPECTION ......................... 5-14
BRAKE TUBES AND HOSES - OPERATION . . 5-14
BRAKES - DESCRIPTION, BASE ...........5-3
BRAKES - OPERATION, BASE .............5-3
BRAKES (EXPORT) - DESCRIPTION, BASE ................................5-3
BRAKES (EXPORT) - DESCRIPTION, DISC . . 5-13
BRAKES (FRONT) - DESCRIPTION, DISC . . . 5-11
BRAKES (FRONT) - OPERATION, DISC .....5-13
BRAKES (REAR) - DESCRIPTION, DISC ....5-13
BRAKES (REAR) - DESCRIPTION, DRUM . . . 5-13
BRAKES (REAR) - OPERATION, DISC ......5-14
BRAKE/TRANSMISSION SHIFT INTERLOCK SOLENOID - DIAGNOSIS
AND TESTING ................ 21-115,21-266
BREAK-IN, STANDARD PROCEDURE - A/C CLUTCH ........................ 24-15
BUCKET - INSTALLATION, BUCKET SEAT BACK - QUAD ........................ 23-141
BUCKET - INSTALLATION, SEAT BELT BUCKLE - FIRST ROW INBOARD -
QUAD ............................. 8O-36
BUCKET - REMOVAL, BUCKET SEAT BACK - QUAD ...................... 23-140
BUCKET - REMOVAL, SEAT BELT BUCKLE - FIRST ROW INBOARD - QUAD .........8O-35
BUCKET, 50/50 SPLIT, BENCH - INSTALLATION, SEAT BACK HINGE
COVERS - QUAD .................... 23-146
BUCKET, 50/50 SPLIT, BENCH - INSTALLATION, SEAT CUSHION COVER
- QUAD ........................... 23-144
BUCKET, 50/50 SPLIT, BENCH - REMOVAL, SEAT BACK HINGE COVERS
- QUAD ........................... 23-146
BUCKET, 50/50 SPLIT, BENCH - REMOVAL, SEAT CUSHION COVER -
QUAD ............................. 23-144
BUCKET SEAT BACK - QUAD BUCKET - INSTALLATION ...................... 23-141
BUCKET SEAT BACK - QUAD BUCKET - REMOVAL ......................... 23-140
BUCKET SEAT RISER - INSTALLATION, QUAD ............................. 23-143
BUCKET SEAT RISER - REMOVAL, QUAD . 23-143
BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - INSTALLATION, QUAD .......23-143
BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - REMOVAL, QUAD ...........23-143
BUCKET SEAT SIDE SHIELD/CUP HOLDER - FLAP AND SPRING
ASSEMBLY - INSTALLATION, QUAD .....23-151
BUCKET SEAT SIDE SHIELD/CUP HOLDER - FLAP AND SPRING
ASSEMBLY - REMOVAL, QUAD .........23-151
BUCKET SEAT SIDE SHIELD/CUP HOLDER - INSTALLATION, QUAD .......23-142
BUCKET SEAT SIDE SHIELD/CUP HOLDER - REMOVAL, QUAD ...........23-141
BUCKLE - FIRST ROW - BENCH - INSTALLATION, SEAT BELT .............8O-37
BUCKLE - FIRST ROW - BENCH - REMOVAL, SEAT BELT ................8O-36
BUCKLE - FIRST ROW INBOARD - QUAD BUCKET - INSTALLATION, SEAT BELT ....8O-36
BUCKLE - FIRST ROW INBOARD - QUAD BUCKET - REMOVAL, SEAT BELT ........8O-35
BUCKLE - FRONT INBOARD - INSTALLATION, SEAT BELT .............8O-35
BUCKLE - FRONT INBOARD - REMOVAL, SEAT BELT ......................... 8O-35
BUCKLE - SECOND ROW - THREE PASSENGER BENCH - INSTALLATION,
SEAT BELT ......................... 8O-40BUCKLE - SECOND ROW - THREE
PASSENGER BENCH - REMOVAL, SEAT
BELT .............................. 8O-40
BUCKLE - SECOND ROW INBOARD - 50/50 BENCH - INSTALLATION, SEAT
BELT .............................. 8O-38
BUCKLE - SECOND ROW INBOARD - 50/50 BENCH - REMOVAL, SEAT BELT ....8O-37
BUMPER - DESCRIPTION, JOUNCE ........2-35
BUMPER - INSTALLATION, STOP ........23-25
BUMPER - OPERATION, JOUNCE .........2-35
BUMPER - REMOVAL, STOP ............23-25
BUMPER BEZEL - INSTALLATION, SLIDING DOOR STOP .................23-25
BUMPER BEZEL - REMOVAL, SLIDING DOOR STOP ........................ 23-25
BUMPER REINFORCEMENT - INSTALLATION, FRONT .................13-3
BUMPER REINFORCEMENT - INSTALLATION, REAR .................. 13-5
BUMPER REINFORCEMENT - REMOVAL, FRONT .............................. 13-3
BUMPER REINFORCEMENT - REMOVAL, REAR ............................... 13-5
BUS COMMUNICATION RECEIVE - PCM INPUT - OPERATION, DATA .............8E-14
BUS, OPERATION - PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) .....14-25
BUSHING - LEAF SPRING FRONT - INSTALLATION ........................ 2-30
BUSHING - LEAF SPRING FRONT - REMOVAL ........................... 2-29
BUSHINGS - INSTALLATION, FRONT CROSSMEMBER MOUNT ...............13-17
BUSHINGS - REMOVAL, FRONT CROSSMEMBER MOUNT ...............13-17
BUSHINGS (CONTINENTAL TEVES BRAKES) - ASSEMBLY, CALIPER GUIDE
PIN ................................ 5-25
BUSHINGS (CONTINENTAL TEVES BRAKES) - DISASSEMBLY, CALIPER
GUIDE PIN ........................... 5-24
CABIN HEATER - DESCRIPTION ........24-113
CABIN HEATER, DIAGNOSIS AND TESTING - SUPPLEMENTAL ...........24-114
CABLE - DESCRIPTION .................8P-4
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-7
CABLE - DESCRIPTION, SPARK PLUG .....8I-10
CABLE - INSTALLATION ................8P-4
CABLE - INSTALLATION, GEAR SHIFT ....21-234
CABLE - INSTALLATION, HOLD OPEN LATCH ............................. 23-38
CABLE - INSTALLATION, INSIDE HANDLE . . 23-38
CABLE - INSTALLATION, INSTRUMENT PANEL ANTENNA ..................... 8A-12
CABLE - INSTALLATION, LATCH RELEASE . 23-64
CABLE - INSTALLATION, OUTSIDE HANDLE ............................ 23-37
CABLE - INSTALLATION, PARKING BRAKE LEVER AND FRONT ..............5-77
CABLE - INSTALLATION, THROTTLE CONTROL .......................... 14-40
CABLE - OPERATION ................... 8P-4
CABLE - OPERATION, ANTENNA BODY .....8A-7
CABLE - PARKING BRAKE INTERMEDIATE - INSTALLATION ..........5-69
CABLE - PARKING BRAKE INTERMEDIATE - REMOVAL .............5-69
CABLE - REMOVAL .................... 8P-4
CABLE - REMOVAL, GEAR SHIFT . . 21-233,21-84
CABLE - REMOVAL, HOLD OPEN LATCH . . . 23-38
CABLE - REMOVAL, INSIDE HANDLE .....23-37
CABLE - REMOVAL, INSTRUMENT PANEL ANTENNA .......................... 8A-12
CABLE - REMOVAL, LATCH RELEASE .....23-63
CABLE - REMOVAL, OUTSIDE HANDLE ....23-37
CABLE - REMOVAL, PARKING BRAKE LEVER AND FRONT .................... 5-77
CABLE - REMOVAL, THROTTLE CONTROL .......................... 14-40
CABLE ADJUSTMENT, ADJUSTMENTS - GEARSHIFT ........................ 21-235
CABLE ADJUSTMENT, INSTALLATION - SYNCHRONIZING ..............23-105,23-147
CABLE, DIAGNOSIS AND TESTING - ANTENNA BODY ...................... 8A-8
RS INDEX5
Description Group-Page Description Group-Page Description Group-Page