
TIE ROD END
DIAGNOSIS AND TESTING
OUTERTIERODEND
NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehi-
cle before performing test.
1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as pos-
sible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
2. Remove the front tires.
3. Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator.
4. Position indicator plunger on the topside of the outer tie rod end.
NOTE: The dial indicator plunger must be perpendicular to the machined surface of the outer tie rod end.
5. Position a pry bar in order to pry downwards on the outer tie rod end.
6. If the travel exceeds 0.5 mm (0.020 in.), replace the outer tie rod end (Refer to 19 - STEERING/LINKAGE/TIE
ROD END - REMOVAL).
7. If the outer tie rod end is within specs reinstall the front tires (Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
REMOVAL - OUTER TIE ROD END
NOTE: Do not twist the boot anytime during
removal or installation.
1. Loosen the jam nut (3).
2. Remove the outer tie rod end nut from the ball
stud.
3. Separate the tie rod ball stud (1) from the knuckle
with Remover 9360 (2).
4. Unthread the outer tie rod end (1) from the inner tie
rod.

A straight line shift pattern is used with a NEUTRAL detent. Lever range positions are imprinted in the shift knob.
SHIFTING
The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion. The vehi-
cle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual transmission,
and be moving less than 2-3 MPH when shifting into and out of the 4L operatingrange.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV241 GENII
Before beginning repair on a suspected transfer case malfunction, check all other driveline components beforehand.
The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and tires,
transmission, or clutch instead. If all other driveline components are ingood condition and operating properly, refer
to the Diagnosis Chart for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.

A straight line shift pattern is used with a NEUTRAL detent. Lever range positions are imprinted in the shift knob.
SHIFTING
The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion. The vehi-
cle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual transmission,
and be moving less than 2-3 MPH when shifting into and out of the 4L operatingrange.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV271
Before beginning repair on a suspected transfer case malfunction, check all other driveline components beforehand.
The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and tires,
transmission, or clutch instead. If all other driveline components are ingood condition and operating properly, refer
to the Diagnosis Chart for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fillhole
with Mopar
ATF +4, Automatic
Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING
TIRE AND WHEEL RUNOUT .................. 2
STANDARD PROCEDURE
MATCH MOUNTING .......................... 4
TIRE AND WHEEL BALANCE ................. 5
TIRE ROTATION ............................. 6
SPECIFICATIONS
TORQUE .................................... 7
TIRES
DESCRIPTION
TIRES ....................................... 8
SPARE / TEMPORARY TIRE .................. 8
RADIAL – PLY TIRES ......................... 8
TIRE PRESSURE FOR HIGH SPEEDS......... 9
REPLACEMENT TIRES ....................... 9
TIRE INFLATION PRESSURES ................ 9
DIAGNOSIS AND TESTING
PRESSURE GAUGES ....................... 10
TIRE NOISE OR VIBRATION ................. 10
TREAD WEAR INDICATORS ................. 10
TIRE WEAR PATTERNS ..................... 11
TIRE/VEHICLE LEAD ........................ 12
STANDARD PROCEDURE
TIRE REPAIR AREA ......................... 13
CLEANING
TIRES ..................................... 13SPECIFICATIONS
TIRE REVOLUTIONS PER MILE .............. 13
WHEELS
DESCRIPTION
DESCRIPTION .............................. 15
WHEEL DESIGN ............................ 16
DIAGNOSIS AND TESTING
WHEEL INSPECTION....................... 16
STANDARD PROCEDURE
WHEEL REPLACEMENT ..................... 16
DUAL REAR WHEEL INSTALLATION .......... 18
STUDS
REMOVAL .................................... 20
INSTALLATION ............................... 20
WHEEL COVER
REMOVAL .................................... 22
INSTALLATION
REAR ...................................... 22
FRONT .................................... 22
SPARE TIRE
DESCRIPTION
SPARE / TEMPORARY TIRE ................. 23
FULL SIZE, SPARE WHEEL WITH
MATCHING TIRE............................ 23

TIRES/WHEELS
DIAGNOSIS AND TESTING
TIRE AND WHEEL RUNOUT
Radial runout is the difference between the high and
low points on the tire or wheel.
Lateral runout is thewobbleof the tire or wheel.

2. Check the wheel radial runout.
3. Check the wheel lateral runout.
STEEL WHEELS: Radial runout 0.031 in., Lateral
runout 0.031 in. (maximum)
ALUMINUM WHEELS: Radial runout 0.02 in.,
Lateral runout 0.025 in. (maximum)
4. If point of greatest wheel lateral runout is near orig-
inal chalk mark, remount tire 180 degrees.
Recheck runout.
STANDARD PROCEDURE
MATCH MOUNTING
Wheels and tires are match mounted at the factory. This means that the high spot of the tire is matched to the low
spot on the wheel rim. Each are marked with a bright colored temporary labelon the outboard surface for alignment.
The wheel is also marked permanently on the inside of the rim in the tire well. This permanent mark may be a paint
dot or line, a permanent label or a stamped impression such as an X. An optional location mark is a small spherical
indentation on the vertical face of the outboard flange on some non styled base steel wheels. The tire must be
removed to locate the permanent mark on the inside of the wheel.
Before dismounting a tire from its wheel, a reference mark should be placedon the tire at the valve stem location.
This reference will ensure that it is remounted in the original position onthe wheel.
1. Remove the tire and wheel assembly from the
vehicle and mount on a service dynamic balance
machine.
2. Measure the total runout on the center of the tire
tread rib (3) with a dial indicator. Record the indi-
cator reading. Mark the tire to indicate the high
spot (2). Place a mark on the tire at the valve stem
(4) location (1).

For static balancing, find the location of the heavy
spot (1) causing the imbalance (5). Counter balance
wheel directly opposite the heavy spot. Determine
weight required to counter balance the area of imbal-
ance (4). Place half of this weight on theinnerrim
flange (3) and the other half on theouterrim flange
(3).
For dynamic balancing (3), the balancing equipment is
designed to locate the amount of weight to be applied
to both the inner and outer rim flange (2).
TIRE ROTATION
Tires on the front and rear axles operate at different loads and perform different steering, driving, and braking func-
tions. For these reasons, the tires wear at unequal rates. They may also develop irregular wear patterns. These
effects can be reduced by rotating the tires according to the maintenance schedule in the Owners Manual. This will
improve tread life, traction and maintain a smooth quiet ride.
The recommended method of tire rotation for single
rear wheel is. Other methods can be used, but may
not provide the same tire longevity benefits.

CAUTION: 3500 Dual rear tires have a new tire
rotation pattern. This is to accommodate the out-
lined white letter (OWL) tires. When replacing a
flat, the spare tire may have to be remounted on
the rim or installed at a different location to main-
tain the correct placement of the outlined white
letter (OWL) tires.
The recommended method of tire rotation for dual rear
wheel is. Other methods can be used, but may not
provide the same tire longevity benefits.
SPECIFICATIONS
TORQUE
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
1500 Series
Lug Nut 9/16 X 18 with
60° Cone
LD176 130 —
2500 Series
Lug Nut 9/16 X 18 with
60° Cone
HD SRW190 140 —
3500 Series
Lug Nut 9/16 X 18 with
Flat Washer
HD DRW197 145 —