DRAG LINK
REMOVAL
1. Remove the drag link nut (2) from the pitman arm
side (1).
2. Remove the drag link nut from the knuckle side.
3. Remove the drag link (2) from the right knuckle
and pitman arm (1) with Puller C-3894A (3).
INSTALLATION
1. Install the drag link (2) to the pitman arm (1). Install
the nut and tighten to 88 Nꞏm (65 ft. lbs.).
2. Install the drag link to the right steering knuckle.
Install the nut and tighten to 54 Nꞏm (40 ft. lbs.).
Then an additional 90°.
3. Install tie rod to the left steering knuckle and drag
link. Install the nuts and tighten to 54 Nꞏm (40 ft.
lbs.). Then an additional 90°.
4. Remove the supports and lower the vehicle to the
surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
5. After adjustment tighten tie rod adjustment sleeve
clamp bolts to 61 Nꞏm (45 ft. lbs.).
NOTE:Positiontheclamponthesleevesoretain-
ing bolt is located on the bottom side of the sleeve.
INSTALLATION
1. Align reference marks and install pitman arm.
2. Install the lock washer and retaining nut on the pit-
man shaft and tighten nut to 251 Nꞏm (185 ft. lbs.).
3. Install the drag link (1) to the pitman arm (5). Install
thenut(4)andtightento54Nꞏm(40ft.lbs.).Then
an additional 90°.
4. Remove the supports and lower the vehicle to the
surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
5. After adjustment tighten tie rod adjustment sleeve
clamp bolts to 61 Nꞏm (45 ft. lbs.).
NOTE:Positiontheclamponthesleevesoretain-
ing bolt is located on the bottom side of the
sleeve.
TIE ROD END
REMOVAL
1. Remove tie rod nuts (1).
2. Remove tie rod from drag link and left knuckle with
remover C-4150A.
INSTALLATION
1. Install tie rod (2) to the left steering knuckle and
drag link. Install the nuts (1) and tighten to 54 Nꞏm
(40 ft. lbs.) Then an additional 90°.
2. Remove the supports and lower the vehicle to the
surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
3. After adjustment tighten tie rod adjustment sleeve
clamp bolts to 61 Nꞏm (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve.
13. Remove starter motor (2), structural dust cover (3)
bolts to clutch housing, dust shield (1) bolt and
suspension crossmember (4).
CAUTION: Do not remove structural dust cover
from engine block. If cover is removed clutch
housing and cover must be aligned with the
engine.
14. Remove exhaust pipe from the exhaust manifolds.
15. Support engine with adjustable jack stand and
wood block.
16. Support and secure transmission (1) to a trans-
mission jack (2) with safety chains.
17. Remove bolts from the rear transmission mount.
18. Remove the rear crossmember (2) and transmis-
sion mount (1).
19. Remove bolts attaching transmission to the
engine.
20. Move transmission rearward until input shaft is
clear of clutch disc and pressure plate. Then
lower jack and remove transmission from under
vehicle.
8. Install front dust shield (1) tighten bolt to 4.5 Nꞏm
(40 in. lbs.).
9. Install structural cover (3) to transmission bolts and
tighten to 54 Nꞏm (40 ft. lbs.).
10. Install starter motor (2).
11. Install suspension crossmember (4) and tighten
nuts to 102 Nꞏm (75 ft. lbs.).
12. Connect transmission harnesses to clips on case
and connect switches.
13. Install slave cylinder (2) and tighten cylinder nuts
(1)to23Nꞏm(200in.lbs.).
14. Install transfer case and transfer case linkage if
equipped.
15. Remove transmission jack.
16. Install propeller shaft/shafts with reference marks
aligned.
17. Install exhaust on the exhaust manifolds.
18. Fill transmission with lubricant. Correct fill level is
to bottom edge of fill plug hole.
SPECIFICATIONS
MANUAL TRANSMISSION - GETRAG 238
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Drain Plug 50 37 -
Fill Plug 50 37 -
Shift Tower Bolts 10 - 88
Back Up Lamp Switch Bolt 10 - 88
4x2 Output Flange Bolt200 then loosen and
tighten to 170147 then loosen and
tighten to 125-
4x4 Output Shaft Nut200 then loosen and
tighten to 170147 then loosen and
tighten to 125-
Housing Bolts 22 16 -
Interlock Plate Bolts 10 - 88
Intermediate Support Bolts 22 16 -
Intermediate Support Race
Retainer Bolt22 16 -
Countershaft Bolt 90 66 -
Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the
same recommended inflation pressures.
The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could
also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes.
The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure
should be maintained on all four tires.
TIRE PRESSURE FOR HIGH SPEEDS
For proper tire pressure specification refer to the Owners Manual.
REPLACEMENT TIRES
The original equipment tires provide a proper balance of many characteristics such as:
Ride
Noise
Handling
Durability
Tread life
Traction
Rolling resistance
Speed capability
It is recommended that tires equivalent to the original equipment tires beused when replacement is needed.
Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle.
The use of oversize tires may cause interference with vehicle components.Under extremes of suspension and
steering travel, interference with vehicle components may cause tire damage.
WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire
failure.
TIRE INFLATION PRESSURES
WARNING: Over or under inflated tires can affect
vehicle handling and tread wear. This may cause
the tire to fail suddenly, resulting in loss of vehicle
control.
Under inflation will cause rapid shoulder wear (1), tire
flexing, and possible tire failure.
Many BSR complaints such as loose trim, can be serviced using the MoparParts BSR Noise Reduction Kit. This
kit contains various tapes including foam, flock and anti-squeak used to eliminate noises caused by metal, plastic
and vinyl components. Long life lubricants and greases can also be used on avariety of components. Refer to the
Buzz, Squeak & Rattle Kit table for material contents and usage.
Buzz, Squeak & Rattle Kit
ITEM FEATURES APPLICATIONS SERVICE TEMP
Itch And Squeak
TapeAn abrasion resistant material
thin enough to conform to most
irregular surfaces. Stops most
itches and squeaks.Between metal and metal,
metal and plastic, metal and
vinyl, vinyl and plastic. Interior.
Examples: Trim panels and
bezels.-40° to 225° F
(-40° to 107° C)
Black Nylon Flock Nylon Flock with an aggressive
acrylic adhesive. Provides for
cushioning and compression fit,
also isolates components.
Water-resistant.Between metal and metal,
metal and plastic, vinyl and
plastic.
Examples: Pull cups, bezels,
clips, ducts, top cover to glass,
cowl panel.-40° to 180° F
(-40° to 82° C)
High Density
Urethane FoamTear resistant, highly resilient
and durable.Between metal and metal,
metal and plastic. Water-
resistant.
Examples: I/P, heavy metal
rattles, isolating brackets.-40° to 180° F
(-40° to 82° C)
Open Cell Foam
TapeSoft foam conforms to irregular
surfaces.Wire harness and connector
wrap.
Examples: Seals, gasket,
wiring, heat ducts.-40° to 180° F
(-40° to 82° C)
Closed Cell Low
Density Foam TapeSoft, conformable. Water-
resistant.Wherever bulk is needed.
Prevents closing flutters and
rattles when applied to door
watershield.
Examples: Door, I/P.-40° to 180° F
(-40° to 82° C)
NYE
Grease 880 Long life. Suspensions.
Examples: Strut bushings, sway
bars.-40° to 390° F
(-40° to 200° C)
Krytox
Oil Long life. Will not dry out or
harm plastics or rubber.When access is not possible, oil
will migrate to condition. Vinyl,
rubber, plastic, metal.
Examples: Convertible top
bushings, pull cups trim panel
inserts.-30° to 400° F
(-34° to 205° C)
Krytox
Grease Long life. Will not dry out or
harm plastics or rubber.Vinyl, rubber, plastic, metal,
glass.
Examples: Weather-strips,
backlite and windshield
moldings.-30° to 400° F
(-34° to 205° C)
PLASTIC BODY PANEL REPAIR
There are many different types of plastics used in today’s automotive environment. We group plastics in three dif-
ferent categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion pro-
moter for repair. These types of plastic are used extensively on DaimlerChrysler Motors vehicles. Always follow
repair material manufacturer’s plastic identification and repair procedures.
