Contents

Introduction

• Body code plate
• Fastener identification
• Fastener usage
• International vehicle control and display symbols
• Metric system
• Torque references
• Veci label
• Vehicle identification number
• Vehicle safety certification label
• Equipment identification plate

Lubrication and maintenance

• Lubrication and maintenance
• International symbols
• Parts and lubricant recommendation
• Fluid types
• Fluid capacities
• Maintenance schedules
• Jump starting
• Hoisting
• Towing

Suspension

• Wheel alignment
• Front - 2WD
• Front - 4WD
• Rear

Differential and driveline

• Propeller shaft
• Front axle - 216FBI
• Front axle - 248FBI
• Rear axle - 9 1/4
• Rear axle - 248RBI
• Rear axle - 267RBI
• Rear axle - 286RBI

Brakes

• Brakes - base
• Hydraulic / mechanical
• Brake lines
• Combination valve
• Disc brake calipers
• Fluid
• Fluid reservoir
• Pedal
• Power brake booster
• Rotors
• Brake pads / shoes
• Master cylinder
• Wheel cylinders
• Support plate
• Drum
• Parking brake
• Pedal
• Cables
• Cable tensioner

Clutch

• Clutch disc
• Clutch housing
• Clutch release bearing
• Pressure plate
• Flywheel
• Pilot bearing
• Clutch pedal
• Linkage

Cooling

• Cooling
• Accessory drive
• Engine
• Transmission

Audio

• Audio
• Antenna body and cable
• Radio choke relay
• Instrument panel antenna cable
• Radio
• Radio noise suppression components
• Radio noise suppression
• Engine-to-body ground strap
• Cab-to- bed ground strap
• Heater core ground strap
• Remote switches
• Speaker
• A-pillar tweeter speaker
• Front door speaker
• Rear cab side panel speaker
• Rear door speaker

Chime / buzzer

• Chime warning system

Electronic control modules

• Body control / central timer module
• Communication
• Controller antilock brake
• Data link connector
• Engine control module
• Powertrain control module

Engine systems

• Battery system
• Charging
• Starting

Heated systems

• Heated mirrors
• Heated seat system

Horn

• Horn switch

Ignition control

• Ignition control
• Automatic shut down relay
• Camshaft position sensor
• Distributor cap
• Distributor rotor
• Ignition coil
• Spark plug
• Spark plug cable

Instrument cluster

• Instrument cluster
• ABS indicator
• Airbag indicator
• Brake / park brake indicator
• Check gauges indicator
• Cruise indicator
• Engine temperature gauge
• Fuel gauge
• Gear selector indicator
• High beam indicator
• Low fuel indicator
• Malfunction indicator lamp (mil)
• Odometer
• Oil pressure gauge
• Overdrive off indicator
• Seatbelt indicator
• Service reminder indicator
• Shift indicator (transfer case)
• Speedometer
• Tachometer
• Transmission overtemp indicator
• Turn signal indicators
• Upshift indicator
• Voltage gauge
• Wait-to-start indicator
• Washer fluid indicator
• Water-in-fuel indicator

Lamps

• Lamps / lighting - exterior
• Turn signal and hazard warning
• Brake lamp switch
• Center high mounted stop lamp
• Center high mounted stop lamp unit
• Clearance lamp
• Combination flasher
• Daytime running lamp module
• Fog lamp
• Fog lamp unit
• Headlamp
• Headlamp relay
• Headlamp switch
• Headlamp unit
• License plate lamp
• License plate lamp unit
• Marker lamp
• Multi-function switch
• Outboard identification lamp
• Park / turn signal lamp
• Park / turn signal lamp unit
• Tail lamp
• Tail lamp unit
• Turn signal cancel cam
• Underhood lamp
• Underhood lamp unit

Message systems

• Overhead console
• Compass / mini-trip computer
• Ambient temp sensor

Power systems

• Power locks
• Power mirrors
• Power seat system
• Power windows

Restraints

• Restraints
• Service after an airbag
• Airbag control module
• Child tether
• Clockspring
• Driver airbag
• Front seat belt and retractor
• Front seat belt buckle
• Passenger airbag
• Passenger airbag on/off switch
• Rear seat belt and retractor
• Rear seat belt buckle
• Seat belt switch
• Seat belt turning loop adjuster
• Turning loop height adjuster knob

Speed control

• Speed control
• Cable
• Speed control servo
• Switch
• Vacuum reservoir

Vehicle theft security

• Vehicle theft security
• Vtss indicator

Wipers / washers

• Wipers / washers
• Washer fluid level switch
• Washer hoses / tubes
• Washer nozzle
• Washer pump / motor
• Washer reservoir
• Wiper arm
• Wiper blade
• Wiper module
• Wiper relay

Wiring

• Wiring diagram information
• Component index
• Power distribution
• Junction block
• Ground distribution
• Bus communications
• Charging system
• Starting system
• Fuel / ignition system
• Transmission control system
• Vehicle speed control
• Rear wheel antilock brakes
• All wheel antilock brakes
• Vehicle theft security system
• Instrument cluster
• Horn/cigar lighter / power outlet
• Air conditioning-heater
• Airbag system
• Interior lighting
• Central timer module
• Audio system
• Overhead console
• Front lighting
• Rear lighting
• Turn signals
• Wipers
• Trailer tow
• Power windows
• Power door locks
• Power mirrors
• Power seats
• Splice information
• Connector pin-outs
• Connector / ground locations
• Splice locations
• Power distribution

Engine

• Engine 5.2l
• Engine 5.9l
• Engine 8.0l
• Engine 5.9l diesel

Exhaust system

• Exhaust system
• Catalytic converter - 3.9l / 5.2l / 5.9l
• Catalytic converter - 5.9l heavy
• Exhaust pipe - 3.9l / 5.2l / 5.9l
• Exhaust pipe - 5.9l heavy duty / 8.0l
• Exhaust pipe - 5.9l diesel
• Heat shields
• Muffler - 3.9l / 5.2l / 5.9l / 8.0l
• Muffler - 5.9l diesel
• Tailpipe - 3.9l / 5.2l / 5.9l
• Tailpipe - 5.9l heavy duty / 8.0l
• Tailpipe - 5.9l diesel
• Resonator
• Turbocharger
• Charge air cooler and plumbing

Frame and bumpers

• Bumpers
• Front air dam
• Front fascia
• Front lower fascia
• Front fascia—sport
• Front bumper
• Front bumper—sport
• Rear bumper
• Frame
• Cab chassis adapter bracket
• Front tow hook
• Spare tire winch
• Trailer hitch
• Transfer case skid plate

Fuel system

• Fuel delivery - gasoline
• Fuel injection - gasoline
• Fuel delivery - diesel
• Fuel injection - diesel

Steering

• Steering
• Column
• Gear
• Pump
• Linkage - 2WD
• Linkage - 4WD

Transmission / transaxle

• Manual - NV3500
• Manual - NV4500
• Manual - NV5600
• Automatic transmission - 42RE
• Automatic transmission - 44RE
• Automatic transmission - 46RE
• Automatic transmission - 47RE
• Transfer case - NV231HD
• Transfer case - NV241LD
• Transfer case - NV241HD

Tires / wheels

• Tires/wheels
• Tires
• Spare tire
• Wheels
• Studs
• Wheel cover

Body

• Body
• Decklid / hatch / liftgate / tailgate
• Door - front
• Door - cargo
• Exterior
• Hood
• Instrument panel system
• Interior
• Paint
• Seats
• Stationary glass
• Weatherstrip / seals

Heating and air conditioning

• Heating and air conditioning
• Controls
• Distribution
• Plumbing

Emissions control systems

• Emissions control
• Air injection
• Evaporative emissions

New vehicle preparation

• Introduction
• Receiving
• Under hood
• Under vehicle
• Exterior
• Body interior
• Road test
• Pre delivery storage
• Programmable electronic features
• Appearance tips
• Final steps

Index

Service manual comment forms