Fastener Tightening Specifications
Headlamp Bezel Replacement (Dual)
Headlamp Bezel Replacement (Single)
Radiator Grille Emblem/Nameplate Replacement (GMC)
Radiator Grille Emblem/Nameplate Replacement (Chevrolet)
Hood Emblem/Nameplate Replacement (Duramax)
Hood Emblem/Nameplate Replacement (Chevrolet, GMC, Isuzu)
Grille Replacement
Hood Air Grille Replacement
Body Side Outside Assist Handle Replacement
Eliminating Unwanted Odors in Vehicles
Floor Carpet Drying
Front Floor Mat/Carpet Replacement
Headlining Trim Panel Replacement (Crew Cab)
Headlining Trim Panel Replacement (Standard Cab)
Fastener Tightening Specifications
Instrument Panel Extension Trim Plate Replacement
Driver Knee Bolster Panel Replacement
Passenger Knee Bolster Replacement
Instrument Panel Cluster Trim Plate Bezel Replacement
Instrument Panel Storage Compartment Replacement
Instrument Panel Compartment Replacement
Instrument Panel Assist Handle Replacement
Instrument Panel Upper Trim Pad Replacement
Instrument Panel Carrier Replacement
Console Replacement
Roof Console Replacement
Fastener Tightening Specifications
Door Inside Handle Bezel Replacement
Front Door Trim Plate Replacement (Manual Windows)
Front Door Trim Plate Replacement (Power Windows)
Rear Door Trim Plate Replacement (Manual Windows)
Rear Door Trim Plate Replacement (Power Windows)
Pull Handle Replacement
Front Side Door Trim Panel Replacement
Rear Side Door Trim Panel Replacement
Front Side Door Water Deflector Replacement
Rear Side Door Water Deflector Replacement
Front Side Door Front Garnish Molding Replacement
Rear Side Door Trim Panel Cup Holder Replacement
Body Hinge Pillar Trim Panel Replacement
Engine Cover Replacement
Door Sill Plate Replacement
Front and Rear Side Door Step Stowage Compartment Replacement
Assist Handle Replacement
Coat Hook Replacement
Sunshade Replacement
Front Side Door Opening Frame Garnish Molding
Windshield Garnish Molding Replacement
Upper Pillar Garnish Molding Replacement
Lower Pillar Garnish Molding Replacement
Rear Door Opening Upper Frame Garnish Molding Replacement
Rear Window Garnish Molding Replacement (Standard Cab)
Rear Window Garnish Molding Replacement (Crew Cab)
Pressure Relief Valve Replacement
Fastener Tightening Specifications
Radiator Support Diagonal Brace Replacement
Cab Replacement
Door Hardware Lubrication
Front Side Door Adjustment
Front Side Door Replacement
Rear Side Door Adjustment
Rear Door Replacement
Hood Handle Replacement
Front Side Door Upper Hinge and Lower Hinge Replacement
Rear Side Door Upper Hinge and Lower Hinge Replacement
Hood Adjustment
Hood Replacement
Hood Primary and Secondary Latch Replacement
Hood Layer Installation
Hood Layer Removal
Front Side Door Check Link Replacement
Rear Side Door Check Link Replacement
Front Side Door Hinge Pin and Bushing Replacement
Hood Rear Seal Replacement
Front Side Door Auxiliary Sealing Strip Replacement
Rear Side Door Bottom Auxiliary Sealing Strip Replacement
Rear Door Upper Sealing Strip Replacement
Auxiliary Weatherstrip Replacement
Front Door Opening Weatherstrip Replacement
Front Side Door Upper Auxiliary Weatherstrip Replacement
Rear Door Opening Weatherstrip Replacement
Door Description
Front Bumper Replacement (Swept Back Bumper)
Front Bumper Replacement (Steel Bumper)
Front Tow Hook Replacement
Radiator Crossmember Replacement
Engine Front Crossmember Replacement
Engine Rear Crossmember Replacement
Transfer Case Crossmember Replacement
Body Front Mount Replacement
Body Rear Mount Replacement
Wheelhouse Panel Replacement
Wheelhouse Splash Shield Replacement
Step Replacement (Frame Mounted)
Step Replacement (Fuel Tank Mounted)
Transfer Case Side Member Bracket Replacement
Fastener Tightening Specifications
Auxiliary Air Compressor Schematics
Diagnostic Starting Point - Auxiliary Air Compressor
Auxiliary Air Compressor Malfunction
Auxiliary Air Compressor Replacement (6500/7500/8500)
Auxiliary Air Compressor Replacement (4500/5500)
Auxiliary Air Tank Replacement (4500/5500)
Auxiliary Air Tank Replacement (6500/7500/8500)
Auxiliary Air Compressor Filter Replacement
Auxiliary Air Compressor Description and Operation
Fastener Tightening Specifications
Moveable Window Schematics (w/o crew cab)
Moveable Window Schematics (w/crew cab)
Defogger Schematics
Diagnostic Starting Point - Fixed and Moveable Windows
Symptoms - Fixed and Moveable Windows
Rear Window Defogger Malfunction
Power Windows Malfunction (Crew Cab)
Power Windows Malfunction (Standard Cab)
Windshield Replacement
Windshield Reveal Molding Replacement
Front Side Door Window Replacement
Rear Side Door Window Replacement
Rear Window Replacement
Door Window Regulator Handle Replacement
Rear Side Door Window Channel Replacement
Stationary Window Reveal Molding Repair
Front Side Door Window Switch Replacement
Front Side Door Window Regulator Replacement
Front Side Door Window Regulator Motor Replacement
Rear Side Door Window Regulator Replacement
Rear Side Door Window Regulator Motor Replacement
Front Side Door Window Belt Outer Sealing Strip Replacement
Front Side Door Window Belt Inner Sealing Strip Replacement
Rear Side Door Window Inner Sealing Strip Replacement
Rear Side Door Window Outer Sealing Strip Replacement
Rear Side Door Window Weatherstrip Replacement
Adhesive Installation of Stationary Windows
Door Window Channel Replacement
Full-Cut Method Description
Urethane Adhesive Description
Stationary Window Description
Power Windows Description and Operation
Rear Window Defogger Description and Operation
Special Tools
Fastener Tightening Specifications
Horn Schematics
Diagnostic Starting Point - Horns
Symptoms - Horns
Horns Malfunction
Horn Replacement
Air Horn Replacement
Steering Wheel Horn Switch Replacement
Horns System Description and Operation
Fastener Tightening Specifications
Headlights/Daytime Running Lights (DRL) Schematics
Exterior Lights Schematics
Interior Lights Schematics
Interior Lights Dimming Schematics
Diagnostic Starting Point - Lighting
DTC P0504
Symptoms - Lighting Systems
Backup Lamps Malfunction (Manual Transmission)
Backup Lamps Malfunction (Automatic Transmission)
Daytime Running Lamps Malfunction
Dome Lamps Malfunction
Hazard Lamps Malfunction
Headlamps Malfunction
Interior Backlighting Malfunction
Marker Lamps Malfunction
Park Lamps Malfunction
Stop Lamps Malfunction
Turn Signal Lamps and/or Indicators Malfunction
Stop Lamp Switch Replacement
Headlamp Switch Replacement
Daytime Running Lamp (DRL) Diode Replacement
Daytime Running Lights (DRL) Control Module Replacement
Hazard and Turn Signal Flasher Replacement
Dome and Reading Lamp Bulb Replacement
Dome Lamp Replacement
Sealed Beam Headlamp Replacement (Dual)
Sealed Beam Headlamp Replacement (Single)
Headlamp Aiming
Roof Marker Lamp Bulb Replacement
Roof Marker Lamp Replacement
Parking and Turn Signal Lamp Replacement
Parking and Turn Signal Lamp Bulb Replacement
Luminescent Lamp Replacement - Outside Mirror
Tail Lamp Replacement
Tail Lamp Bulb Replacement
Exterior Lighting Systems Description and Operation
Interior Lighting Systems Description and Operation
Special Tools
Fastener Tightening Specifications
Outside Rearview Mirror Schematics (w/DB6)
Outside Rearview Mirror Schematics (w/DB8)
Diagnostic Starting Point - Mirrors
Symptoms - Mirrors
Heated Mirrors Inoperative
Power Mirrors Inoperative
Outside Rearview Mirror Opening Cover Replacement
Power Mirror Switch Replacement
Outside Rearview Mirror Replacement
Heated Outside Rearview Mirror Switch Replacement
Power Mirror Replacement
Outside Rearview Mirror Motor Replacement
Outside Rearview Mirror Glass Replacement - Lower
Outside Rearview Mirror Glass Replacement - Upper
Outside Rearview Mirror Housing Replacement
Inside Rearview Mirror Replacement
Rearview Mirror Support Installation
Outside Mirror Description and Operation (Power Mirrors)
Outside Mirror Description and Operation (Heated Mirrors)
Fastener Tightening Specifications
Door Lock/Indicator Schematics
Diagnostic Starting Point - Vehicle Access
Symptoms - Vehicle Access
Power Door Locks Malfunction
Power Door Lock Actuator Replacement
Lock Cylinder Binding
Front Side Door Lock Cylinder Replacement
Front Side Door Inside Handle Replacement
Front Side Door Outside Handle Replacement
Rear Side Door Inside Handle Replacement
Rear Side Door Outside Handle Replacement
Front Side Door Lock Replacement
Rear Door Lock Replacement
Front Side Door Lock Striker Replacement
Rear Side Door Lock Striker Replacement
Door Lock Switch Replacement
Power Door Locks Description and Operation
Fastener Tightening Specifications
Wiper/Washer Schematics
Diagnostic Starting Point - Wiper/Washer Systems
Symptoms - Wiper/Washer Systems
Windshield Wiper Washer System Malfunction
Windshield Wiper System Malfunction
Low Washer Fluid Indicator Malfunction
Wiper Arm Tip Pressure Check
Wiper Blade Element Check
Windshield Washer Solvent Container and Pump Replacement
Air Inlet Grille Panel Replacement
Windshield Wiper Arm Replacement
Windshield Wiper Blade Replacement
Wiper Blade Element Replacement
Windshield Wiper Motor Cover Replacement
Windshield Wiper Motor Replacement
Windshield Wiper Transmission Replacement
Windshield Glass Cleaning
Wiper Blade Element Cleaning
Wiper Chatter Repair
Wiper/Washer System Description and Operation
Special Tools
Fastener Tightening Specifications
Air Antilock Brake System Schematics
Status Lamps Reference Table
Status Lamp Resetting (Bendix RDU Unit)
Diagnostic Starting Point - Air Antilock Brake System
Symptoms - Air Antilock Brake System
Status Lamps Illuminated - LFT, STEERAXLE, and SEN
Status Lamps Illuminated - RHT, STEERAXLE, and SEN
Status Lamps Illuminated - LFT, DRIVEAXLE and SEN
Status Lamps Illuminated - RHT, DRIVEAXLE, and SEN
Status Lamps Illuminated - LFT, STEERAXLE, and MOD
Status Lamps Illuminated - RHT, STEERAXLE, and MOD
Status Lamps Illuminated - LFT, DRIVEAXLE, and MOD
Status Lamps Illuminated - RHT, DRIVEAXLE, and MOD
Status Lamps Illuminated - TRC and MOD
Status Lamps Illuminated - Engine Control Unit
Green VLT Status Lamp Inoperative
Status Lamps Illuminated - Invalid Combination
Air ABS Indicator Always On
Air ABS Indicator Inoperative
Air Low Traction Indicator Always On
Air Low Traction Indicator Inoperative
Air Traction Off Indicator Always On
Air Traction Off Indicator Inoperative
Trailer ABS Indicator Always On
Trailer ABS Indicator Inoperative
Air ABS Traction Control Switch Replacement
Electronic Brake Control Module Replacement
Electronic Brake Control Module Configuration (Bendix remote diagnostic unit RDU)
Rear Air Brake Relay Valve Replacement
Rear Brake Pressure Modulator Valve Replacement
Front Brake Pressure Modulator Valve Replacement
Front Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Air ABS Description and Operation
Special Tools
Fastener Tightening Specifications
Air Brake Air System Schematics
Air Brake System Schematics
Low Air Indicator Malfunction
Air Brakes Application Slow
Air Brake Safety Valve Deploys
Braking Action Uneven - Front to Rear
Braking Action Uneven - Side to Side
Air Brakes Drag
Air Brake Dryer Constantly Cycling or Purging
Air Brake Dryer Safety Valve Exhausting Air
Air Brake Dryer Purge Valve Exhausting Air
Air Brake Dryer Does Not Purge or Exhaust Air
Desiccant Being Expelled From Purge Valve Exhaust
Air Brake System Testing
Air Brake Dryer Testing
Low Air Pressure Switch Operational Check
Air Brake Park Control Valve Operational Check
Air Brake Park Control Valve Leakage Test
Parking Control Valve Operational Check
Parking Control Valve Leakage Test
Reservoir Check Valve Leakage Test
Air Brake Double Check Valve Operational Check
Air Brake Double Check Valve Leakage Test
Air Brake Application Valve Operational Check
Air Brake Application Valve Leakage Test
Rear Quick Release Double Check Valve Operational Check
Rear Quick Release Double Check Valve Leak Test
Rear Air Brake Relay Valve Operational Check
Rear Air Brake Relay Valve Leakage Test
Rear Relay Double Check Valve Operational Check
Rear Relay Double Check Valve Leakage Test
Chassis Mounted Park Control Valve Operational Check
Chassis Mounted Park Control Valve Leakage Test
Vehicle Tow Protection Valve Operational Check
Trailer Brake Control Valve Operational Check
Trailer Brake Control Valve Leakage Test
Air Dryer/Moisture Ejector System Check
Air Dryer and/or Moisture Ejector Inoperative
Air Brake Reservoir Draining
Air Brake Reservoir Filling
Air Brake Pedal Replacement
Trailer Stop Lamp Switch Replacement
Hose and Line Replacement - Nylon Push-In Type Fitting
Hose and Line Replacement - Trailer and Emergency
Hose and Line Replacement - Trailer and Bracket Gladhand
Hose and Line Replacement - Trailer Coupling Hose Bracket
Hose and Line Replacement - Trailer Coupling
Hose and Line Replacement - Trailer Dummy Couplings
Reservoir Replacement - Front Axle
Primary Air Brake Supply Reservoir Replacement
Reservoir Replacement - Rear Axle Front Unit (Non-GZK)
Reservoir Replacement - Rear Axle Front Unit (GZK)
Reservoir Replacement - Rear Axle Rear Unit
Reservoir Replacement - Rear Axle Truck Service
Reservoir Replacement - Rear Axle Tractor Service
Air Brake Reservoir Support Replacement - Front Axle
Primary Air Brake Supply Reservoir Support Replacement
Air Brake Reservoir Support Replacement - Rear Axle (GZT RQ2)
Air Brake Reservoir Support Replacement - Rear Axle (Non-GZT, RQ2 or GZK)
Air Brake Reservoir Support Replacement - Rear Axle (GZK)
Manual Air Brake Reservoir Drain Valve Replacement
Low Air Pressure Switch Replacement
Air Dryer Replacement
Air Dryer Desiccant Cartridge Replacement
Air Brake Supply Manifold Replacement
Instrument Panel Mounted Air Brake Park Control Valve Replacement
Tractor Air Brake Park Control Valve Replacement
Trailer Brake Supply Valve Replacement
Air Brake Double Check Valve Replacement
Air Brake Application Valve Replacement
Front Air Brake Limit Valve Replacement
Air Brake Quick Release Valve Replacement
Rear Air Brake Quick Release Double Check Valve Replacement - Right Side
Rear Air Brake Relay Valve Replacement
Rear Air Brake Relay Double Check Valve Replacement
Chassis Mount Air Brake Park Control Valve Replacement
Towing Vehicle Protection Valve Replacement
Trailer Brake Control Valve Replacement
Air Dryer Description and Operation
Brake Warning System Description and Operation
Air Brake System Description and Operation
Special Tools
Fastener Tightening Specifications
Air Compressor Governor Valve Specifications
Air Compressor and Governor Valve Diagnosis
Air Compressor Not Unloading
Air Supply Contaminated
Air Compressor Excessive Noise
Air Compressor Fails to Maintain Sufficient Pressure
Air Pressure Excessively Low or High
Air Compressor Maintenance
Air Compressor Replacement (RPO L18)
Air Compressor Replacement (RPO LG4, LF8)
Air Compressor Bracket Replacement - Front (Haldex Compressor)
Air Compressor Gear Replacement
Air Compressor Pulley Replacement (Haldex Compressor)
Air Compressor Air Strainer Filter Replacement
Air Compressor Governor Valve Replacement
Air Compressor Description and Operation (Wabco Compressor)
Air Compressor Description and Operation (Haldex Compressor)
Special Tools
Fastener Tightening Specifications
Air Drum Brake Component Specifications
Air Drum Brake System Diagnosis
Air Drum Brake System Inspection
Brake Drum Inspection
Brake Drum Replacement
Brake Drum Refinishing
Front Cam Brake Assembly Replacement
Rear Cam Brake Assembly Replacement
Brake Shoe Inspection
Brake Shoe Replacement
Brake Camshaft Replacement
Air Brake Automatic Slack Adjuster Replacement (Arvin-Meritor)
Front Air Brake Chamber Clevis Replacement
Rear Air Brake Chamber Clevis Replacement
Front Air Brake Chamber Replacement
Rear Air Brake Chamber Replacement
Front Air Brake Chamber Overhaul
Rear Air Brake Chamber Overhaul
Caging the Rear Air Brake Chamber
Air Drum Brake Adjustment (Arvin-Meritor)
Air Drum Brake Adjustment (Pushrod Stroke Measurement)
Air Drum Brakes Description and Operation
Fastener Tightening Specifications
Antilock Brake System Schematics
Diagnostic Starting Point - Antilock Brake System
DTC B2745
DTC C0035-C0052
DTC C0110
DTC C0220-C0229
Symptoms - Antilock Brake System
ABS Indicator Malfunction
Low Traction Indicator Malfunction
Traction Off Indicator Malfunction
Electronic Brake Control Module Replacement (4500, 5500)
Electronic Brake Control Module Replacement (6500, 7500, 8500 W/JE3)
Electronic Brake Control Module Replacement (6500, 7500, 8500, W/JE4)
Brake Pressure Modulator Valve Replacement
Front Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement (J69)
Rear Wheel Speed Sensor Replacement (Without J69)
Front Wheel Speed Sensor Reluctor Wheel Replacement
Rear Wheel Speed Sensor Ring Replacement
Electronic Traction Control Switch Replacement
ABS Description and Operation
Special Tools
Fastener Tightening Specifications
Disc Brake Component Specifications
Caliper Wear Shim Specifications
Diagnostic Starting Point - Disc Brakes
Brake Rotor Thickness Measurement
Brake Rotor Thickness Variation Measurement
Brake Rotor Surface and Wear Inspection
Brake Pad Inspection
Brake Caliper Inspection
Front Disc Brake Pads Replacement (TRW - Pin Slider)
Front Disc Brake Pads Replacement (Dayton-Walther)
Rear Disc Brake Pads Replacement (Dayton-Walther Fixed Mount)
Rear Disc Brake Pads Replacement (TRW Pin Slider)
Brake Pad and Rotor Burnishing
Front Brake Caliper Replacement (Dayton-Walther 6500,7500,8500FM6/FS7,)
Front Brake Caliper Replacement (Pin Slider)
Front Brake Caliper Replacement (4500, 5500, FRX)
Front Brake Caliper Replacement (4500, 5500, FM7/FM8)
Front Brake Caliper Replacement (6500, 7500, 8500, FM8)
Rear Brake Caliper Replacement (TRW Pin Slider)
Rear Brake Caliper Replacement (Dayton-Walther Fixed Mount)
Brake Caliper Overhaul (TRW - Pin Slider)
Brake Caliper Overhaul (Fixed Mount)
Brake Caliper/Mounting Plate Wear Adjustment (Front TRW)
Brake Caliper/Mounting Plate Wear Adjustment (Rear Dayton-Walther)
Brake Caliper/Mounting Plate Wear Adjustment (Front Dayton-Walther)
Front Brake Caliper Mounting Plate Replacement (6500, 7500, 8500, FM6/FS7)
Front Brake Caliper Mounting Plate Replacement (6500, 7500, 8500, FM8)
Front Brake Caliper Mounting Plate Replacement (Dayton-Walther 4500, 5500)
Rear Brake Caliper Mount Plate Replacement (4500, 5500, GL4/GL8/HD2-J69)
Rear Brake Caliper Mount Plate Replacement (4500, 5500, HPK)
Rear Brake Caliper Mount Plate Replacement (6500, 7500, 8500)
Front Brake Rotor Replacement (4500, 5500, Non FRX)
Front Brake Rotor Replacement (6500, 7500, 8500, FM6/FS7)
Front Brake Rotor Replacement (4500, 5500, FRX)
Front Brake Rotor Replacement (6500, 7500, 8500, FM8)
Rear Brake Rotor Replacement (6500, 7500, 8500)
Rear Brake Rotor Replacement (4500, 5500, GL4, GL8)
Rear Brake Rotor Replacement (4500, 5500, HPK/HO8)
Brake Rotor Refinishing
Disc Brake System Description and Operation
Special Tools
Fastener Tightening Specifications
Brake System Specifications
Hydraulic Brake Schematics
Diagnostic Starting Point - Hydraulic Brakes
DTC C0163 or C0164 (C4)
DTC C0163 or C0164 (C6,C7)
DTC C0267
DTC C0272
DTC C0285
DTC C0286
Symptoms - Hydraulic Brakes
Brake Warning Indicator Malfunction
Service Brake Soon Indicator Malfunction
Brake Fluid Loss
Disc Brake System Diagnosis
Hydraulic Brake System Diagnosis
Brake Assist System Diagnosis
Brake System Vehicle Road Test
Brake Pedal Travel Measurement and Inspection
Hydraulic Brake Booster Leak Inspection
Hydraulic Brake Assist System Noise Inspection
Brake System External Leak Inspection
Brake System Internal Leak Test
Hydraulic Brake Component Operation Visual Inspection
Brake Pipe and Hose Inspection
Brake Pedal Pushrod Inspection
Master Cylinder Reservoir Filling
Master Cylinder Replacement
Master Cylinder Bench Bleeding
Brake Fluid Level Indicator Switch Replacement
Brake Pedal Assembly Replacement
Brake Pipe Replacement
Front Brake Hose Replacement
Rear Brake Hose Replacement (Axle)
Rear Brake Hose Replacement (GZT/GPG)
Rear Brake Hose Replacement (Non-GZT/GPG)
Hydraulic Brake System Bleeding
Hydraulic Brake System Flushing
Power Brake Booster Replacement
Power Brake Booster Pump Replacement
Fluid Flow Switch Replacement
Brake Fluid and Brake Fluid Handling
Brake Warning System Description and Operation
Hydraulic Brake System Description and Operation
Brake Assist System Description and Operation
Special Tools
Fastener Tightening Specifications
Park Brake Hardware Inspection
Parking Brake Shoe Inspection
Park Brake Drum Inspection
Parking Brake Shoe Replacement (J69)
Parking Brake Shoe Replacement (12 x 3)
Parking Brake Shoe Replacement (9 x 3)
Parking Brake Shoe Lining Burnishing
Propeller Shaft Parking Brake Camshaft Replacement (12 x 3)
Propeller Shaft Parking Brake Camshaft Replacement (9 x 3)
Park Brake Lubrication
Parking Brake Lever Replacement
Parking Brake Indicator Switch Replacement (MWE)
Parking Brake Indicator Switch Replacement (Non MWE)
Park Brake Hardware Replacement (12 x 3)
Park Brake Hardware Replacement (9 x 3)
Parking Brake Cable Replacement
Propeller Shaft Parking Brake Drum Replacement
Parking Brake Support Replacement (12 x 3)
Parking Brake Support Replacement (9 x 3)
Instrument Panel Park Brake Switch Replacement
Parking Brake Adjustment (Wheel Park Brake)
Parking Brake Adjustment (Driveline Park Brake)
Control Module References
Electronic Brake Control Module Programming and Setup (w/Antilock Brakes)
Engine Control Module Programming and Setup (W/RPO LMM)
Glow Plug Control Module Programming and Setup
Inflatable Restraint Sensing and Diagnostic Module Programming and Setup
Instrument Cluster Programming and Setup
Powertrain Control Module Programming and Setup
Radio Programming and Setup
Remote Control Door Lock Receiver Programming and Setup
Serial Data Gateway Module Programming and Setup
Service Programming System (SPS)
Transfer Case Shift Control Module Programming and Setup
Electronic Brake Control Module Scan Tool Information
Engine Control Module Scan Tool Information (V8 Gasoline)
Engine Control Module Scan Tool Information (with RPO LMM)
Glow Plug Control Module Scan Tool Information
Inflatable Restraint Sensing and Diagnostic Module Scan Tool Information
Instrument Cluster Scan Tool Information
Multifunction Accessory Module Scan Tool Information
Radio Scan Tool Information
Transfer Case Shift Control Module Scan Tool Information
Strategy Based Diagnosis
Diagnostic Procedure Instructions
Diagnostic Starting Point - Vehicle
Diagnostic System Check - Vehicle
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Diagnostic Trouble Code (DTC) List - Vehicle
Symptoms - Vehicle
Diagnostic Repair Verification
Fastener Tightening Specifications
Axle Spacer and Shim Specifications
Axle Preload and Backlash Specifications
Adhesives, Fluids, Lubricants, and Sealers
Front Drive Axle Disassembled Views
Diagnostic Starting Point - Front Drive Axle
Symptoms - Front Drive Axle
Front Drive Axle Noises
Noisy in Drive
Noisy When Coasting
Intermittent Noise
Constant Noise
Noisy on Turns
Front Drive Axle Bearing Wear (Tapered)
Front Drive Axle Bearing Wear (Straight)
Front Axle Lubricant Leak Diagnosis
Front Axle Lubricant Replacement
Manual Locking Hub Replacement
Front Axle Shaft Replacement
Output Shaft Seal Replacement
Differential Carrier Assembly Cover and/or Gasket Replacement
Front Axle Housing Replacement
Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement
Differential Side Bearing Replacement
Front Axle Lubricant Level Inspection
Drive Pinion and Ring Gear Replacement
Drive Pinion Bearings Replacement
Differential Replacement
Front Differential Case Disassemble
Differential Carrier Assembly Housing Inspection
Differential Case Bearings Inspection
Differential Case and Gears Inspection
Pinion and Ring Gear Inspection
Thrust Washers, Shims, and Adjuster Sleeves Inspection
Shims Inspection
Front Differential Case Assemble
Pinion Depth Adjustment
Differential Carrier Bearing Preload Adjustment
Backlash Inspection and Adjustment
Gear Tooth Contact Pattern Inspection
Front Drive Axle Description and Operation
Fastener Tightening Specifications
Driveline Disassembled Views (Three Piece)
Driveline Disassembled Views (Two Piece)
Driveline Disassembled Views (One Piece)
Driveline Disassembled Views (Transfer Case)
Driveline Disassembled Views (Front)
Propeller Shaft Diagnosis
Ping, Snap, or Click Noise
Transfer Case Propeller Shaft Replacement
Front Propeller Shaft Replacement
One-Piece Rear Propeller Shaft Replacement (One Piece-FRX)
One-Piece Rear Propeller Shaft Replacement (One Piece-Rear)
Two-Piece Rear Propeller Shaft Replacement (Two Piece-FRX)
Two-Piece Rear Propeller Shaft Replacement (Two Piece-Rear)
Three-Piece Rear Propeller Shaft Replacement (Three Piece-FRX)
Three-Piece Rear Propeller Shaft Replacement (Three Piece-Rear)
Four-Piece Rear Propeller Shaft Replacement
Tandem Axle Propeller Shaft Replacement
Propeller Shaft Assembly Component Lubrication
Slip Joint Replacement
Propeller Shaft Center Support Bearing Replacement (Bolt On)
Propeller Shaft Center Support Bearing Replacement (Press On)
Yoke Replacement
Universal Joint Replacement
Universal Joint Replacement - External Snap Ring
Propeller Shaft Description and Operation
Axle Preload and Backlash Specifications
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Differential Lock Schematics
Two-Speed Rear Axle Schematics
Rear Axle Disassembled Views
Diagnostic Starting Point - Locking/Limited Slip Rear Axle
Diagnostic Starting Point - Rear Drive Axle
Symptoms - Locking/Limited Slip Rear Axle
Symptoms - Rear Drive Axle
Differential Lock Indicator Inoperative
Differential Lock On at All Times
Differential Lock Inoperative
Two Speed Rear Axle Inoperative (Electric Operated)
Two Speed Rear Axle Inoperative (Air Operated)
Rear Drive Axle Noises
Noisy in Drive
Noisy When Coasting
Intermittent Noise
Constant Noise
Noisy on Turns
Wheel Bearing Wear - Rear Drive Axle
Rear Axle Lubricant Leak Diagnosis
Two Speed Rear Axle Air Shift Control Valve Diagnosis
Two Speed Rear Axle Shift Quick Release Valve Diagnosis
Two Speed Rear Axle Pressure Protection Valve Diagnosis
Two Speed Rear Axle Shift Motor Diagnosis
Air Leakage Test
Differential Lock Control Valve Diagnosis
Differential Lock Pressure Protection Valve Diagnosis
Differential Lock Relay Valve Diagnosis
Differential Lock Shift Cylinder Diagnosis
Rear Axle Lubricant Level Inspection
Rear Axle Lubricant Replacement
Two Speed Rear Axle Air Shift Control Valve Replacement
Two Speed Rear Axle Pressure Protection Valve Replacement
Two Speed Rear Axle Shift Control Switch Replacement
Two Speed Rear Axle Shift Quick Release Valve Replacement
Two Speed Rear Axle Shift Motor Relay Replacement
Two Speed Rear Axle Shift Motor Replacement
Vent Hose Replacement
Rear Axle Housing Cover and Gasket Replacement (11 Inch Axle)
Rear Axle Shaft and/or Gasket Replacement (Dana 286 Axle)
Rear Axle Shaft and/or Gasket Replacement (Except Dana 286 Axle)
Rear Axle Hub, Bearing, Cup, and/or Seal Replacement
Drive Pinion Flange/Yoke and/or Oil Seal Replacement (Dana 286 Axle)
Drive Pinion Flange/Yoke and/or Oil Seal Replacement (Except Dana 286 Axle, Output Shaft)
Drive Pinion Flange/Yoke and/or Oil Seal Replacement (Except Dana 286 Axle, Input Shaft)
Drive Pinion and Ring Gear Replacement
Drive Pinion Bearings Replacement
Differential Replacement (Except Dana 286 Axle)
Differential Replacement (Dana 286 Axle)
Differential Side Bearings Replacement
Rear Axle Housing Replacement
Differential Lock Control Valve Replacement
Differential Lock Pressure Protection Valve Replacement
Differential Lock Shift Cylinder Replacement
Differential Lock Relay Valve Replacement
Differential Lock Switch Replacement
Inter-Axle Differential Lock Control Valve Replacement
Inter-Axle Differential Lock Switch Replacement
Differential Overhaul
Bearings Inspection
Differential Inspection
Pinion and Ring Gear Inspection
Rear Axle Housing Inspection
Shims Inspection
Pinion Depth Adjustment
Differential Carrier Bearing Preload Adjustment
Wheel Bearing Adjustment
Backlash Adjustment
Gear Tooth Contact Pattern Inspection
Locking Differential Description and Operation
Rear Drive Axle Description and Operation
Two Speed Rear Axle Shift System Description and Operation (Electric Operated)
Two Speed Rear Axle Shift System Description and Operation (Air Operated)
Fastener Tightening Specifications
Radio/Navigation System Schematics
Diagnostic Starting Point - Cellular, Entertainment, and Navigation
DTC B1025, B1035, B1045, or B1055
Symptoms - Entertainment
Radio Displays CAL or CAL ERR
Radio Displays CLN or CLEAN
Radio Displays LOC, LOCKED, or CODE
Radio Poor Reception
Speaker Replacement Reference
Speaker Malfunction
Tape Player Weak, Slow, or Garbled Output
Compact Disc Care and Cleaning
Radio Replacement
Fixed Antenna Mast Replacement
Radio Antenna Replacement
Antenna Cable Replacement
Radio Front Side Door Speaker Replacement
Radio Rear Side Door Speaker Replacement
Radio/Audio System Description and Operation
Fastener Tightening Specifications
Instrument Cluster Schematics
Driver Information System Schematics
Audible Warnings Schematics
Diagnostic Starting Point - Displays and Gages
DTC B0540
DTC B0560
DTC B1365
DTC B1372
DTC P0381
DTC P0461
DTC P0462
DTC P0463
DTC P0521, P0522, or P0523
DTC P0608
DTC P0654
DTC P2066
DTC P2067
DTC P2068
Symptoms - Displays and Gages
Change Engine Oil Indicator Malfunction
Charge Indicator Malfunction
Chime Malfunction
Diesel Particulate Filter Warning Indicator Malfunction
Engine Oil Pressure Gage Inaccurate or Inoperative
Fuel Gage Inaccurate or Inoperative (Dual Tank)
Fuel Gage Inaccurate or Inoperative (Single Tank)
Hourmeter Inaccurate or Inoperative
Instrument Cluster Inoperative
Instrument Cluster Gages Inoperative
Speedometer and/or Odometer Inaccurate or Inoperative
Tachometer Inaccurate or Inoperative
Transmission Fluid Temperature Gage Inaccurate or Inoperative
Water in Fuel Indicator Malfunction
Multifunction Alarm Module Replacement
Telltale Circuit Board Replacement
Instrument Cluster Replacement
Air Brake Pressure Gage Replacement
Air Cleaner Filter Restriction Gage Replacement
Transmission Fluid Temperature Gage Replacement
Accessory Switch Replacement (Shift Selector)
Accessory Switch Replacement (Center Stack)
Accessory Switch Replacement (Auxiliary)
Audible Warnings Description and Operation
Indicator/Warning Message Description and Operation
Instrument Cluster Description and Operation
Special Tools
Cruise Control Schematics
Diagnostic Starting Point - Cruise Control
DTC P0565
DTC P0567
DTC P0568
DTC P0571
DTC P1574
Symptoms - Cruise Control
Cruise Control Malfunction
Cruise Control Switch Replacement
Cruise Control Description and Operation
Temperature Versus Resistance (EGR Temperature Sensors)
Temperature Versus Resistance (EGT Sensors)
Temperature Versus Resistance (IAT Sensor 2)
Temperature Versus Resistance (IAT Sensor 1)
Temperature Versus Resistance (ECT Sensors)
Temperature Versus Resistance (Fuel Temperature Sensor)
Altitude Versus Barometric Pressure
Fastener Tightening Specifications
Fuel System Specifications
Fuel Injection Line Routing Diagram
Engine Controls Schematics
Diagnostic Starting Point - Engine Controls
DTC P0016
DTC P003A
DTC P0047 or P0048
DTC P0087 or P0088
DTC P0090
DTC P0097 or P0098
DTC P0101
DTC P0102 or P0103
DTC P0106
DTC P0107 or P0108
DTC P0112 or P0113
DTC P0116
DTC P0117 or P0118
DTC P0168
DTC P0181
DTC P0182 or P0183
DTC P0191
DTC P0192 or P0193
DTC P0201, P0202, P0203, P0204, P0205, P0206, P0207, or P0208
DTC P0234
DTC P0299
DTC P029D, P02A1, P02A5, P02A9, P02AD, P02B1, P02B5, or P02B9
DTC P02E0
DTC P02E7
DTC P02E8 or P02E9
DTC P0300-P0308
DTC P0335
DTC P0336
DTC P0340
DTC P0341
DTC P0401 or P0402
DTC P0403 or P046C
DTC P0405 or P0406
DTC P040C or P040D
DTC P040F
DTC P041C or P041D
DTC P0420
DTC P0502
DTC P0545 or P0546
DTC P0602, P0606, P060B, P061C, P062C, P062F, or P2610
DTC P0640
DTC P0642 or P0643
DTC P064C
DTC P0650
DTC P0652 or P0653
DTC P0671-P0678
DTC P0698 or P0699
DTC P0851 or P0852
DTC P1224, P1227, P122A, P1233, P1236, P1239, P1242, or P1247
DTC P1448
DTC P150C
DTC P154A
DTC P154B
DTC P154C
DTC P154D
DTC P160C
DTC P166B
DTC P166C
DTC P2002
DTC P2032 or P2033
DTC P20E2
DTC P2122, P2123, P2127, P2128, or P2138
DTC P2146, P2149, P2152, or P2155
DTC P2228 or P2229
DTC P2266
DTC P2269
DTC P244B
DTC P244C
DTC P2453
DTC P2454 or P2455
DTC P2459
DTC P2463
DTC P2510
DTC P2544
DTC P2563
DTC P2564 or P2565
DTC P2632
DTC P2636
DTC P268A
DTC P268C-P268F or P2690-P2693
Symptoms - Engine Controls
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Fuel Pressure Regulator Diagnosis
Fuel System Diagnosis
Fuel Return System Diagnosis
Fuel Leak Diagnosis
Fuel System Diagnosis - High Pressure Side
Fuel Injector Balance Test with Tech 2
Fuel Tank Leak Test
Contaminants-in-Fuel Diagnosis
Charge Air Cooler Diagnosis (Full System Air Leak Test)
Charge Air Cooler Diagnosis (Charge Air Cooler Air Leak Test)
Charge Air Cooler Diagnosis (Induction System Smoke Test)
Inspection/Maintenance (I/M) System Check
Inspection/Maintenance (I/M) System DTC Table
Inspection/Maintenance (I/M) Complete System Set Procedure
Fuel Heater Inoperative
Fuel Heater Always On
High Idle Switch Diagnosis
Engine Control Module Replacement
High Idle Switch Programming
Fuel Injector Flow Rate Programming
Speed Calibration Programming
Diesel Particulate Filter (DPF) Service Regeneration
Diesel Particulate Filter (DPF) Regeneration Enable
Engine Coolant Temperature Sensor Replacement
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Intake Air Temperature (IAT) Sensor 2 Replacement
Intake Air Valve Replacement
Intake Air Heater Replacement
Manifold Absolute Pressure Sensor Replacement
Accelerator Pedal Position Sensor Replacement
Metal Collar Quick Connect Fitting Service
Plastic Collar Quick Connect Fitting Service
Fuel System Priming
Fuel Filter Replacement
Fuel Heater Replacement
Water in Fuel Indicator Sensor Replacement
Water-in-Fuel Draining
Fuel Filter Assembly Replacement
Fuel Tank Draining
Fuel Tank Replacement (Side Mounted)
Fuel Tank Replacement (Mid Mounted)
Fuel Tank Replacement (Rear Mounted)
Fuel Tank Replacement (Rear Mounted - 15 Gal)
Fuel Level Sensor Replacement (Mid Mounted)
Fuel Pump Replacement (NG6)
Fuel Sender Assembly Replacement (Rear Mounted)
Fuel Sender Assembly Replacement (Rear Mounted - 15 Gal)
Fuel Sender Assembly Replacement (Mid Mounted)
Fuel Sender Assembly Replacement (Side Mounted)
Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump
Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block
Fuel Hose/Pipes Replacement - Chassis
Fuel Injection Fuel Return Pipe Replacement - Left Side
Fuel Injection Fuel Return Pipe Replacement - Right Side
Fuel Feed Pipe Replacement
Fuel Return Pipe Replacement
Fuel Injection Fuel Feed Front Pipe Replacement - Right Side
Fuel Injection Fuel Feed Front Pipe Replacement - Left Side
Fuel Injection Fuel Feed Pipe Replacement - Right Side
Fuel Injection Fuel Feed Pipe Replacement - Left Side
Fuel System Cleaning
Fuel Feed Pipe and Return Pipe Purging
Fuel Injection Fuel Rail Assembly Replacement - Bank 1
Fuel Injection Fuel Rail Assembly Replacement - Bank 2
Fuel Injection Fuel Feed Manifold Replacement
Fuel Pressure Regulator Replacement
Fuel Pressure Relief Valve Replacement
Fuel Injection Pump Replacement
Fuel Injector Replacement (Right)
Fuel Injector Replacement (Left)
Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
Fuel Temperature Sensor Replacement
Glow Plug Replacement - Bank 1
Glow Plug Replacement - Bank 2
Glow Plug Control Module Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement
Exhaust Gas Recirculation Valve Motor Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Valve Cooler Replacement
Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1
Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2
Exhaust Pressure Differential Sensor Replacement
Exhaust Pressure Differential Sensor Pipe Replacement
Exhaust Temperature Sensor Replacement - Position 1
Exhaust Temperature Sensor Replacement - Position 2
Turbocharger Control Solenoid Valve Replacement
Turbocharger Vane Position Sensor Replacement
Turbocharger Learn
Air Cleaner Element Replacement
Air Cleaner Assembly Replacement
Air Cleaner Outlet Duct Replacement
Air Intake Pipe Replacement
Charge Air Cooler Replacement
Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement
Accelerator Pedal Position System Description
Diesel Particulate Filter (DPF) System Description
Engine Control Module Description
Engine Idle Control System Description
Exhaust Gas Recirculation (EGR) System Description
Fuel System Description
Glow Plug System Description
Intake Air Heater System Description
Turbocharger System Description
Special Tools
Fastener Tightening Specifications
Engine Controls Schematics
Multiuse Module Bracket Replacement
Fuel System Cleaning
Fuel Tank Replacement
Fuel Hose/Pipes Replacement - Filter to Engine
Fuel Filter Replacement (Primary)
Fuel Hoses/Pipes Replacement - Filter to Tank
Accelerator Pedal Position Sensor Replacement
Air Cleaner Replacement
Air Cleaner Element Replacement
Fuel Tank Draining
Water-in-Fuel Draining
Air Cleaner Assembly Replacement
Air Cleaner Outlet Duct Replacement
Charge Air Cooler Replacement
Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement
Engine Controls Schematics
Multiuse Module Bracket Replacement
Water-in-Fuel Draining
Fuel System Bleeding
Fuel Sender Assembly Replacement
Fuel Tank Draining
Fuel System Cleaning
Fuel Tank Replacement
Metal Collar Quick Connect Fitting Service
Plastic Collar Quick Connect Fitting Service
Fuel Hose/Pipes Replacement - Filter to Engine
Fuel Hoses/Pipes Replacement - Filter to Tank
Fuel Filter Replacement (Primary)
Accelerator Pedal Position Sensor Replacement
Air Cleaner Replacement
Air Cleaner Element Replacement
Air Cleaner Assembly Replacement
Air Cleaner Outlet Duct Replacement
Charge Air Cooler Replacement
Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement
Temperature Versus Resistance
Ignition System Specifications
Fastener Tightening Specifications
Emission Hose Routing Diagram
Evaporative Emissions Hose Routing Diagram
Fuel Hose/Pipes Routing Diagram (Single Fuel Tank)
Engine Controls Schematics
Scan Tool Data List
Scan Tool Data Definitions
Scan Tool Output Controls
DTC P0068
DTC P0102
DTC P0103
DTC P0107
DTC P0108
DTC P0112
DTC P0113
DTC P0117
DTC P0118
DTC P0120
DTC P0131 or P0151
DTC P0132 or P0152
DTC P0134 or P0154
DTC P0200
DTC P0220
DTC P0230
DTC P0315
DTC P0325
DTC P0327 or P0332
DTC P0335
DTC P0336
DTC P0341
DTC P0342
DTC P0343
DTC P0351-P0358
DTC P0443
DTC P0506 or P0507
DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610
DTC P0641
DTC P0650
DTC P0651
DTC P1125
DTC P1516
DTC P2101
DTC P2108
DTC P2120
DTC P2121
DTC P2125
DTC P2135
DTC U0107
Symptoms - Engine Controls
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Ignition Relay Diagnosis (Ignition B)
Ignition Relay Diagnosis (Ignition A)
Fuel Pump Electrical Circuit Diagnosis
Fuel System Diagnosis
Secondary Fuel System Diagnosis
Fuel Injector Solenoid Coil Test
Fuel Injector Balance Test with Special Tool
Fuel Injector Balance Test with Tech 2
Fuel Tank Leak Test
Alcohol/Contaminants-in-Fuel Diagnosis (With Special Tool)
Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool)
Manifold Absolute Pressure Sensor Diagnosis
Electronic Ignition (EI) System Diagnosis
Poor Fuel Fill Quality
Powertrain Control Module Replacement
Speed Calibration Programming
Electronic Throttle Actuator Control Module Replacement
Multiuse Module Bracket Replacement (Reposition)
Engine Coolant Temperature Sensor Replacement
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Manifold Absolute Pressure Sensor Replacement
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1
Throttle Body Assembly Replacement
Throttle Body Cleaning
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Gage Installation and Removal
Metal Collar Quick Connect Fitting Service
Fuel Filter Replacement
Fuel Tank Draining
Fuel Tank Replacement (15 Gallon Tank)
Fuel Tank Replacement (Mid Mount)
Fuel Tank Replacement (Rear)
Fuel Pump Replacement (15 Gallon Tank)
Fuel Sender Assembly Replacement (Rear Tank)
Fuel Sender Assembly Replacement (Mid Mount Tank)
Fuel Sender Assembly Replacement (Side Tank)
Fuel Sender Assembly Replacement (15 Gallon Tank)
Fuel Hoses/Pipes Replacement - Filter to Tank
Fuel System Cleaning
Fuel Pressure Service Valve Replacement
Fuel Injection Fuel Rail Assembly Replacement
Fuel Pulse Dampener Replacement
Fuel Injector Replacement
Fuel Injector Cleaning
Evaporative Emission Canister Purge Solenoid Valve Replacement
Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (C4500 and C5500)
Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (C6500, C7500, C8500)
Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis
Evaporative Emission Canister Replacement (C6500/7500 and 8500)
Evaporative Emission Canister Replacement (C4500 and C5500)
Evaporative Emission System Cleaning
Ignition Coil Replacement
Spark Plug Wire Inspection
Spark Plug Wire Replacement
Spark Plug Inspection
Spark Plug Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement
Knock Sensor 1 Replacement
Knock Sensor 2 Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Valve Bracket Replacement
Exhaust Gas Recirculation Pipe Replacement
Exhaust Gas Recirculation (EGR) System Cleaning
Air Cleaner Replacement
Air Cleaner Element Replacement
Air Cleaner Assembly Replacement
Air Cleaner Outlet Front Duct Replacement
Powertrain Control Module Description
Throttle Actuator Control (TAC) System Description
Fuel System Description
Evaporative Emission Control System Description
Electronic Ignition (EI) System Description
Knock Sensor (KS) System Description
Air Intake System Description
Special Tools
Fastener Tightening Specifications
Engine Cooling Schematics
Diagnostic Starting Point - Engine Cooling
DTC P0480
DTC P0483 or P0493
DTC P0495
DTC P0526
Symptoms - Engine Cooling
Low Engine Coolant Indicator Always On
Engine Overheating
Loss of Coolant
Thermostat Diagnosis
Coolant Heater Inoperative (Gasoline)
Coolant Heater Inoperative (Diesel)
Engine Fails To Reach Normal Operating Temperature
Pressure Cap Testing
Cooling System Leak Testing
Fan Clutch Diagnosis
Cooling System Draining and Filling (Static Fill)
Cooling System Draining and Filling (Vac N Fill)
Flushing
Radiator Cleaning
Cooling Layer Removal
Cooling Layer Installation
Radiator Surge Tank Replacement
Radiator Surge Tank Inlet Hose/Pipe Replacement
Radiator Inlet Hose Replacement
Radiator Outlet Hose Replacement (L18, LG4)
Radiator Outlet Hose Replacement (LMM)
Radiator Outlet Hose Replacement (LG5)
Engine Oil Cooler Replacement
Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement
Engine Oil Cooler Hose/Pipe Replacement (8.1L Engine)
Fan Replacement
Fan Clutch Replacement
Cooling Fan Pulley Replacement
Turbocharger Coolant Bypass Valve Replacement (6.6L LMM)
Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LMM) Engine - Inlet Pipe)
Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LMM) Engine - Outlet Pipe)
Exhaust Gas Recirculation Valve Cooler Replacement
Exhaust Gas Recirculation Cooler Water Feed Pipe Replacement
Exhaust Gas Recirculation Cooler Water Return Pipe Replacement
Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY/LBZ)
Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LMM)
Exhaust Gas Recirculation Cooling Pipe Replacement - Lower
Exhaust Gas Recirculation Cooling Pipe Replacement - Upper
Water Outlet Tube Replacement (6.6L LMM)
Engine Coolant Thermostat Replacement (8.1L Engine)
Engine Coolant Thermostat Replacement (LG4)
Engine Coolant Thermostat Replacement (6.6L LMM)
Engine Coolant Thermostat Replacement (Caterpillar)
Thermostat Housing Crossover Replacement (6.6L LMM)
Engine Coolant Crossover Pipe Replacement (8.1L Engine)
Thermostat Bypass Pipes Replacement (6.6L LMM)
Thermostat Bypass Pipes Replacement (6.6L LLY)
Water Pump Replacement (6.6L)
Water Pump Replacement (7.8L)
Water Pump Replacement (L18)
Water Pump Replacement (Caterpillar)
Water Pump Outlet Pipe Replacement (6.6L)
Radiator Drain Cock Replacement
Engine Coolant Fan Shroud Replacement
Radiator Replacement
Radiator Support Replacement
Radiator Air Lower Baffle and Deflector Replacement (V22)
Radiator Air Lower Baffle and Deflector Replacement (GRW)
Radiator Air Side Baffle and Deflector Replacement
Radiator Air Upper Baffle and Deflector Replacement
Plug Adaptor Replacement
Coolant Heater Replacement (L18)
Coolant Heater Replacement (LG5)
Coolant Heater Replacement (6.6L (LLY) Engine)
Coolant Heater Cord Replacement (6.6L)
Coolant Heater Cord Replacement (Original)
Cooling Fan Description and Operation (with RPO LMM)
Cooling System Description and Operation
Special Tools
Fastener Tightening Specifications
Battery Usage
Generator Usage
Starting and Charging Schematics
Auxiliary Battery Schematics
Diagnostic Starting Point - Engine Electrical
DTC C0899
DTC C0900
DTC P0512
DTC P0562
DTC P0563
DTC P0615
DTC P0621 (7.2L / 7.8L)
DTC P0621 (6.6L/ 8.1L)
DTC P0622 (7.2L / 7.8L)
DTC P0622 (6.6L / 8.1L)
Symptoms - Engine Electrical
Battery Inspection/Test
Battery Charging
Battery Electrical Drain/Parasitic Load Test
Battery Common Causes of Malfunction
Charging System Test
Starter Solenoid Does Not Click (LF6 /LF8)
Starter Solenoid Does Not Click (6.6L /8.1L)
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
Starter Noise Diagnosis
Battery Isolator Malfunction
Battery Negative Cable Disconnection and Connection (C4/C5 - Gas Engine)
Battery Negative Cable Disconnection and Connection (C4/C5 - Diesel Engine)
Battery Negative Cable Disconnection and Connection (C 6/7/8)
Battery Negative Cable Replacement (LLY/LMM w/o ANC/B3D)
Battery Negative Cable Replacement (LG4 Ground Cable)
Battery Negative Cable Replacement (LG5 Starter Motor Ground Cable)
Battery Negative Cable Replacement (LLY/LMM w/ANC/B3D)
Battery Positive Cable Replacement (LLY/LMM w/o ANC/B3D)
Battery Positive Cable Replacement (LLY/LMM w/ANC/B3D)
Battery Positive Cable Replacement (7.2L (CAT))
Battery Replacement (C4/C5 - Triple Batteries)
Battery Replacement (C4/C5 - Dual Batteries)
Battery Replacement (C 6/7/8)
Battery Replacement (C4/C5 - Single Battery)
Battery Tray Replacement (C4/C5)
Battery Box Replacement
Battery Isolator Replacement (C4/C5)
Engine Ground Strap Replacement
Starter Replacement (LLY/LMM)
Starter Replacement (LG5)
Starter Replacement (LG4)
Starter Replacement (L18)
Starter Shield Replacement
Starter Solenoid Switch Replacement (LLY/LMM)
Generator Bracket Replacement (L18)
Generator Bracket Replacement (LMM)
Generator Bracket Replacement (LG5)
Auxiliary Generator Bracket Replacement (LLY/LMM)
Generator Replacement (L18)
Generator Replacement (LG5)
Generator Replacement (LG4)
Generator Replacement (LMM)
Auxiliary Generator Replacement
Battery Description and Operation
Charging System Description and Operation (6.6L / 8.1L)
Charging System Description and Operation (7.2L / 7.8L)
Starting System Description and Operation (7.2L / 7.8L)
Starting System Description and Operation (6.6L / 8.1L)
Special Tools
Fastener Tightening Specifications
Exhaust System Schematics
Diagnostic Starting Point - Engine Exhaust
Symptoms - Engine Exhaust
Restricted Exhaust
Exhaust Leakage
Exhaust Noise
Exhaust Manifold Replacement (With LF8)
Exhaust Manifold Replacement - Left Side (8.1L)
Exhaust Manifold Replacement - Left Side (LMM)
Exhaust Manifold Replacement - Right Side (8.1L)
Exhaust Manifold Replacement - Right Side (LMM)
Turbocharger Exhaust Pipe Replacement
Exhaust Manifold Pipe Replacement (7.2L CAT)
Exhaust Manifold Pipe Replacement (L18)
Exhaust Manifold Pipe Replacement (LMM)
Exhaust Pipe Replacement - Left Side
Exhaust Pipe Replacement - Right Side
Front Pipe Replacement (With LF8)
Engine Brake Switch Replacement
Clutch Engine Brake Switch Replacement
Exhaust Brake Actuator Control Solenoid Valve Replacement
Engine Brake Actuator Control Valve Replacement
Engine Brake Actuator Replacement (7.8L)
Exhaust Throttle Replacement (With LF8)
Exhaust Seal Replacement (8.1L)
Intermediate Pipe Replacement (With LF8)
Catalytic Converter Replacement (LMM)
Catalytic Converter Replacement (L18)
Exhaust Particulate Filter Cleaning (LF8 DPF Service Regeneration)
Exhaust Particulate Service Filter Replacement (With LF8)
Exhaust Particulate Filter Replacement (With LF8)
Exhaust Particulate Filter Replacement (LMM)
Exhaust System Insulator, Hanger, Bracket Replacement
Exhaust Muffler Replacement
Exhaust Particulate Filter Rear Cooler Pipe Replacement (LMM)
Exhaust Particulate Filter Rear Cooler Pipe Replacement (With LF8)
Exhaust Flexible Pipe Replacement
Exhaust Tail Intermediate Pipe Replacement (With LF8 With 2 Door)
Exhaust Tail Intermediate Pipe Replacement (With LF8 With 4 Door)
Exhaust Tail Intermediate Pipe Replacement (With LF6 With 2 Door)
Exhaust Tail Intermediate Pipe Replacement (With LF6 With 4 Door)
Tail Pipe Replacement (Horizontal)
Exhaust Tail Vertical Pipe Replacement
Exhaust Tail Vertical Upper Pipe Replacement
Exhaust System Description
Special Tools
Fastener Tightening Specifications
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers
Connecting Rod Bearings Selection Specifications
Cylinder Head Gasket Selection Specifications
Crankshaft Bearing Selection Specifications
Valve Clearance Adjustment Specifications
Thread Repair Specifications
Engine Mechanical Schematics
Disassembled Views
Engine Identification
Diagnostic Starting Point - Engine Mechanical
Symptoms - Engine Mechanical
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Coolant in Combustion Chamber
Coolant in Engine Oil
Fuel in Engine Oil
Turbocharger Whine Noise
Turbocharger Hissing Noise
Turbocharger Oil Leak From Compressor Seal
Turbocharger Oil Leak From Turbine Seal
Turbocharger Lack of Oil Supply
Engine Compression Test
Cylinder Leakage Test
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Crankcase Ventilation System Inspection/Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Drive Belt Replacement
Drive Belt Tensioner Replacement
Drive Belt Idler Pulley Replacement
Engine Mount Inspection
Engine Front Mount Replacement
Engine Mount Bracket Replacement - Left Side
Engine Mount Bracket Replacement - Right Side
Positive Crankcase Ventilation Valve Replacement (Left)
Positive Crankcase Ventilation Valve Replacement (Right)
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LMM)
Charged Air Cooler Hoses/Pipes Replacement (Right)
Charged Air Cooler Hoses/Pipes Replacement (Left)
Intake Manifold Tube Replacement
Center Intake Manifold Replacement (LMM)
Intake Manifold Replacement - Left Side (LMM)
Intake Manifold Replacement - Right Side (LMM)
Oil Filler Tube Replacement (Left Side)
Oil Filler Tube Replacement (Front)
Oil Level Indicator Tube Replacement
Valve Rocker Arm Cover Replacement - Upper Left Side
Valve Rocker Arm Cover Replacement - Upper Right Side
Valve Rocker Arm Cover Replacement - Lower Left Side
Valve Rocker Arm Cover Replacement - Lower Right Side
Valve Rocker Arm, Shaft, and Push Rod Replacement
Valve Clearance Adjustment
Turbocharger Replacement
Turbocharger Oil Feed Pipe Replacement
Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement
Cylinder Head Replacement - Left Side
Cylinder Head Replacement - Right Side
Valve Stem Oil Seal and Valve Spring Replacement
Valve Lifter Replacement
Crankshaft Balancer Replacement
Crankshaft Front Oil Seal Replacement
Engine Front Cover Replacement
Camshaft Position Sensor Exciter Ring Replacement
Crankshaft Reluctor and Oil Pump Drive Gear Replacement
Camshaft Replacement
Crankshaft Rear Oil Seal Replacement
Engine Flywheel Housing Replacement
Engine Flywheel Replacement (Manual Transmission)
Engine Flywheel Replacement (Automatic Transmission)
Lower Oil Pan Replacement
Upper Oil Pan Replacement
Oil Pump Replacement
Oil Filter Adapter and Oil Cooler Assembly Replacement
Engine Oil Pressure Sensor and/or Switch Replacement
Engine Oil Level Sensor and/or Switch Replacement
Engine Replacement
Engine Oil and Oil Filter Replacement
Starter Removal
Crankshaft Balancer Removal
Oil Pump Removal
Crankshaft Balancer Installation
Starter Installation
Draining Fluids and Oil Filter Removal
Engine Flywheel Removal (Manual Transmission)
Engine Flywheel Removal (Automatic Transmission)
Crankshaft Rear Oil Seal Removal
Exhaust Outlet Removal
Exhaust Pipe Removal - Left Side
Exhaust Pipe Removal - Right Side
Lower Oil Pan Removal
Upper Oil Pan Removal
Engine Flywheel Housing Removal
Engine Mounting to Stand
Cooling Fan Pulley Removal
Fuel Filter Assembly Removal
Generator and Drive Belt Tensioner Bracket Removal
Engine Coolant Thermostat Housing Removal
Engine Wiring Harness Assembly Removal
Exhaust Gas Recirculation Valve and Cooler Removal
Turbocharger Removal
Fuel Pipes and Fuel Rail Removal
Fuel Injector Removal
Valve Rocker Arm Cover Removal - Upper Left Side
Valve Rocker Arm Cover Removal - Upper Right Side
Valve Rocker Arm Cover Removal - Lower Left Side
Valve Rocker Arm Cover Removal - Lower Right Side
Intake Manifold Crossover Removal
Intake Manifold Removal - Right Side
Intake Manifold Removal - Left Side
Valve Rocker Arm, Shaft, and Push Rod Removal
Exhaust Manifold Removal - Left Side
Exhaust Manifold Removal - Right Side
Cylinder Head Removal - Left Side
Cylinder Head Removal - Right Side
Valve Lifter Removal
Fuel Injection Pump Removal
Water Pump Removal
Oil Filter Adapter and Oil Cooler Assembly Removal
Crankshaft Front Oil Seal Removal
Engine Front Cover Removal
Oil Pump Suction Pipe and Screen Assembly Removal
Piston Oil Cooling Nozzle Removal
Piston, Connecting Rod, and Bearing Removal
Camshaft Removal
Crankshaft and Bearing Removal
Engine Block Cleaning and Inspection
Upper Oil Pan Cleaning and Inspection
Camshaft and Bearings Cleaning and Inspection
Crankshaft and Bearing Cleaning and Inspection
Crankshaft Balancer Cleaning and Inspection
Engine Flywheel Cleaning and Inspection
Piston and Connecting Rod Disassemble
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Piston and Connecting Rod Assemble
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Valve and Seat Grinding
Cylinder Head Assemble
Valve Lifters Cleaning and Inspection
Valve Rocker Arm and Shaft Cleaning and Inspection
Piston Oil Cooling Nozzle Cleaning and Inspection
Oil Pump Cleaning and Inspection
Engine Front Cover Cleaning and Inspection
Lower Oil Pan Cleaning and Inspection
Valve Rocker Arm Cover Cleaning and Inspection - Lower
Valve Rocker Arm Cover Cleaning and Inspection - Upper
Intake Manifold Cleaning and Inspection
Oil Filter Adapter and Oil Cooler Assembly Cleaning and Inspection
Engine Coolant Thermostat Housing Cleaning and Inspection
Exhaust Manifold Cleaning and Inspection
Exhaust Pipe Cleaning and Inspection
Exhaust Outlet Cleaning and Inspection
Fuel Injection Pump Cleaning and Inspection
Fuel Injector Cleaning and Inspection
Turbocharger Cleaning and Inspection
Engine Flywheel Housing Cleaning and Inspection
Water Pump Cleaning and Inspection
Exhaust Gas Recirculation Valve Cooler Cleaning and Inspection
Thread Repair
Fuel Line Torquing
Service Prior to Assembly
Crankshaft and Bearing Installation
Camshaft Installation
Piston, Connecting Rod, and Bearing Installation
Piston Oil Cooling Nozzle Installation
Oil Pump Installation
Oil Pump Suction Pipe and Screen Assembly Installation
Engine Front Cover Installation
Crankshaft Front Oil Seal Installation
Oil Filter Adapter and Oil Cooler Assembly Installation
Water Pump Installation
Fuel Injection Pump Installation
Valve Lifter Installation
Cylinder Head Gasket Selection
Cylinder Head Installation - Left Side
Cylinder Head Installation - Right Side
Exhaust Manifold Installation - Left Side
Exhaust Manifold Installation - Right Side
Valve Rocker Arm, Shaft, and Push Rod Installation
Valve Clearance Adjustment
Intake Manifold Installation - Left Side
Intake Manifold Installation - Right Side
Intake Manifold Crossover Installation
Valve Rocker Arm Cover Installation - Lower Left Side
Valve Rocker Arm Cover Installation - Lower Right Side
Valve Rocker Arm Cover Installation - Upper Left Side
Valve Rocker Arm Cover Installation - Upper Right Side
Fuel Injector Installation
Fuel Pipes and Fuel Rail Installation
Turbocharger Installation
Exhaust Gas Recirculation Valve and Cooler Installation
Engine Wiring Harness Assembly Installation
Engine Coolant Thermostat Housing Installation
Generator and Drive Belt Tensioner Bracket Installation
Fuel Filter Assembly Installation
Power Steering Pump Mounting Bracket Installation
Cooling Fan Pulley Installation
Engine Removal from Stand
Engine Flywheel Housing Installation
Upper Oil Pan Installation
Lower Oil Pan Installation
Exhaust Pipe Installation - Left Side
Exhaust Pipe Installation - Right Side
Exhaust Outlet Installation
Crankshaft Rear Oil Seal Installation
Engine Flywheel Installation (Manual Transmission)
Engine Flywheel Installation (Automatic Transmission)
Engine Prelubing
Crankcase Ventilation System Description
Drive Belt System Description
Engine Component Description
Lubrication Description
Cleanliness and Care
Separating Parts
Replacing Engine Gaskets
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Tools and Equipment
Special Tools
Fastener Tightening Specifications
Drive Belt Replacement
Drive Belt Tensioner Replacement
Engine Front Mount Replacement
Engine Rear Mount Replacement
Engine Front Mount Bracket Replacement
Engine Rear Mount Bracket Replacement
Engine Replacement
Engine Mechanical Schematics
Drive Belt Replacement (Water Pump Belt Replacement)
Drive Belt Replacement (Drive Belt and Tensioner Replacement)
Drive Belt Tensioner Replacement
Engine Mount Inspection
Engine Front Mount Replacement
Engine Rear Mount Replacement
Engine Front Mount Bracket Replacement
Engine Rear Mount Bracket Replacement
Engine Replacement
Fastener Tightening Specifications
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers
Engine Mechanical Schematics
Disassembled Views
Engine Identification
Diagnostic Starting Point - Engine Mechanical
Symptoms - Engine Mechanical
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Coolant in Combustion Chamber
Coolant in Engine Oil
Engine Compression Test
Cylinder Leakage Test
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Crankcase Ventilation System Inspection/Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Drive Belt Replacement
Drive Belt Tensioner Replacement
Drive Belt Idler Pulley Replacement
Engine Front Mount Replacement (C6500/C7500/C8500)
Engine Front Mount Replacement (C4500/C5500)
Engine Mount Inspection
Engine Mount Bracket Replacement - Left Side (C6500/C7500/C8500)
Engine Mount Bracket Replacement - Left Side (C4500/C5500)
Engine Mount Bracket Replacement - Right Side (C6500/C7500/C8500)
Engine Mount Bracket Replacement - Right Side (C4500/C5500)
Intake Manifold Replacement
Valve Rocker Arm Cover Replacement - Left Side
Valve Rocker Arm Cover Replacement - Right Side
Valve Rocker Arm and Push Rod Replacement
Valve Stem Oil Seal and Valve Spring Replacement
Valve Lifter Replacement
Oil Level Indicator Tube Replacement
Oil Filler Tube Replacement
Cylinder Head Replacement - Left Side
Cylinder Head Replacement - Right Side
Crankshaft Balancer Replacement
Crankshaft Front Oil Seal Replacement
Engine Front Cover Replacement
Camshaft Timing Chain and Sprocket Replacement
Oil Pump Drive Replacement
Camshaft Replacement
Oil Filter Adapter and Bypass Valve Assembly Replacement
Oil Pan Replacement
Engine Oil Pressure Sensor and/or Switch Replacement
Engine Oil Level Sensor and/or Switch Replacement
Oil Pump Replacement
Crankshaft Rear Oil Seal Replacement
Engine Flywheel Replacement
Engine Replacement
Engine Oil and Oil Filter Replacement
Draining Fluids and Oil Filter Removal
Crankshaft Balancer Removal
Engine Flywheel Removal (Manual Transmission)
Engine Flywheel Removal (Automatic Transmission)
Crankshaft Rear Oil Seal Removal
Engine Flywheel Housing Removal (Manual Transmission)
Engine Flywheel Housing Removal (Automatic Transmission)
Clutch Pilot Bearing Removal
Oil Level Indicator and Tube Removal
Exhaust Manifold Removal - Left Side
Exhaust Manifold Removal - Right Side
Water Crossover Removal
Water Pump Removal
Intake Manifold Removal
Valve Rocker Arm Cover Removal - Left Side
Valve Rocker Arm Cover Removal - Right Side
Valve Rocker Arm and Push Rod Removal
Cylinder Head Removal - Left Side
Cylinder Head Removal - Right Side
Valve Lifter Removal
Oil Pump Drive Removal
Oil Pan Removal
Oil Pump, Screen and Crankshaft Oil Deflector Removal
Engine Front Cover Removal
Timing Chain and Sprocket Removal
Camshaft Removal
Piston, Connecting Rod, and Bearing Removal
Crankshaft and Bearing Removal
Oil Filter Adapter Removal
Engine Block Plug Removal
Camshaft Bearing Removal
Engine Block Cleaning and Inspection
Cylinder Boring and Honing
Crankshaft and Bearing Cleaning and Inspection
Crankshaft Balancer Cleaning and Inspection
Engine Flywheel Cleaning and Inspection (Manual Transmission)
Engine Flywheel Cleaning and Inspection (Automatic Transmission)
Piston and Connecting Rod Disassemble
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Piston and Connecting Rod Assemble
Camshaft and Bearings Cleaning and Inspection
Camshaft Bearing Installation
Camshaft Timing Chain and Sprocket Cleaning and Inspection
Valve Rocker Arm and Push Rod Cleaning and Inspection
Valve Lifter and Guide Cleaning and Inspection
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Valve Guide Reaming, and Valve and Seat Grinding
Cylinder Head Assemble
Oil Pump Disassemble
Oil Pump Cleaning and Inspection
Oil Pump Assemble
Oil Pump Drive Cleaning and Inspection
Valve Rocker Arm Cover Cleaning and Inspection
Oil Pan Cleaning and Inspection
Intake Manifold Disassemble
Intake Manifold Cleaning and Inspection
Intake Manifold Assemble
Exhaust Manifold Cleaning and Inspection
Water Crossover Cleaning and Inspection
Water Pump Cleaning and Inspection
Thread Repair
Service Prior to Assembly
Engine Block Plug Installation
Oil Filter Adapter Installation
Crankshaft and Bearing Installation
Piston, Connecting Rod, and Bearing Installation
Camshaft Installation
Timing Chain and Sprocket Installation
Engine Front Cover Installation
Oil Pump, Screen and Crankshaft Oil Deflector Installation
Oil Pan Installation
Oil Pump Drive Installation
Valve Lifter Installation
Cylinder Head Installation - Left Side
Cylinder Head Installation - Right Side
Valve Rocker Arm and Push Rod Installation
Intake Manifold Installation
Valve Rocker Arm Cover Installation - Left Side
Valve Rocker Arm Cover Installation - Right Side
Water Pump Installation
Water Crossover Installation
Exhaust Manifold Installation - Left Side
Exhaust Manifold Installation - Right Side
Oil Level Indicator and Tube Installation
Clutch Pilot Bearing Installation
Engine Flywheel Housing Installation (Manual Transmission)
Engine Flywheel Housing Installation (Automatic Transmission)
Crankshaft Rear Oil Seal Installation
Engine Flywheel Installation (Manual Transmission)
Engine Flywheel Installation (Automatic Transmission)
Crankshaft Balancer Installation
Engine Prelubing
Crankcase Ventilation System Description
Drive Belt System Description
Engine Component Description
New Product Information
Lubrication Description
Cleanliness and Care
Separating Parts
Replacing Engine Gaskets
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Tools and Equipment
Special Tools
Fastener Tightening Specifications
Refrigerant System Capacities
Leak Testing
Air Conditioning (A/C) System Performance Test
Air Conditioning (A/C) Diagnostics - Pressure Zone A
Air Conditioning (A/C) Diagnostics - Pressure Zone B
Air Conditioning (A/C) Diagnostics - Pressure Zone C
Air Conditioning (A/C) Diagnostics - Pressure Zone D
Heating Performance Diagnostic
Defrosting Insufficient
Noise Diagnosis - Auxiliary Blower Motor
Noise Diagnosis - Blower Motor
Noise Diagnosis - Air Conditioning (A/C) System (Sanden Compressor)
Noise Diagnosis - Air Conditioning (A/C) System (Delphi Compressor)
Noise Diagnosis - HVAC Module
Odor Diagnosis
Odor Correction
Refrigerant Recovery and Recharging
Air Conditioning Compressor Oil Balancing (Sanden)
Air Conditioning Compressor Oil Balancing (Delphi)
Air Conditioning Compressor Replacement (LMM)
Air Conditioning Compressor Replacement (L18)
Compressor Clutch Plate/Hub Assembly Replacement
Air Conditioning Clutch Coil Replacement
Compressor Pressure Relief Valve Replacement (HU6 Only)
Sealing Washer Replacement
O-Ring Replacement
Air Conditioning Compressor Hose Replacement
Air Conditioning Evaporator Hose Assembly Replacement
Air Conditioning Evaporator Tube Replacement - Inlet
Air Conditioning Evaporator Tube Replacement - Outlet
Air Conditioning (A/C) Coupling Assembly Replacement (Low Pressure)
Air Conditioning (A/C) Coupling Assembly Replacement (High Pressure)
Air Conditioning Evaporator Thermal Expansion Valve Screen Replacement
Air Conditioning (AC) Refrigerant Filter Replacement
Expansion (Orifice) Tube Replacement
Suction Screen Installation
Suction Screen Replacement
Compressor Relay Replacement
Air Conditioning (A/C) High Pressure Switch Replacement
Air Conditioning Cycling Switch Replacement
Air Conditioning Condenser Replacement (GRW)
Air Conditioning Condenser Replacement (V22)
Air Conditioning Accumulator Replacement
Air Conditioning (A/C) Evaporator and Blower Module Assembly Replacement
Heater Assembly Replacement
Air Conditioning Evaporator Core Replacement
Heater Inlet Hose Replacement (LMM)
Heater Inlet Hose Replacement (LG5)
Heater Inlet Hose Replacement (L18)
Heater Outlet Hose Replacement (RPO-LLY)
Heater Outlet Hose Replacement (RPO-LMM)
Heater Water Valve Replacement
Blower Motor Resistor Assembly Replacement
Blower Motor Replacement (L18, LG4, LG5)
Air Distributor Duct Replacement
Floor Air Outlet Replacement - Right Side
Floor Air Outlet Replacement - Center
Floor Air Outlet Duct Replacement - Left Side
Windshield Defroster Duct Replacement
Side Window Defogger Outlet Duct Replacement - Left Side
Side Window Defogger Outlet Duct Replacement - Right Side
Air Temperature Door Replacement
Defroster Door Replacement
Mode Door Replacement - Lower
Mode Door Replacement - Upper
Defroster Grille Replacement
Recirculation Door Replacement
Heater Core Replacement
Auxiliary Heater Assembly Replacement
Auxiliary Heater Pipe Replacement
Auxiliary Blower Motor Resistor Assembly Replacement
Auxiliary Blower Motor Replacement
Auxiliary Air Outlet Duct Replacement
Auxiliary Heater Core Replacement
Heater Water Shutoff Valve Replacement
Special Tools
Fastener Tightening Specifications
HVAC Schematics (C40)
HVAC Schematics (C60)
HVAC Schematics (C36)
DTC P0530 or P0531
DTC P0532 or P0533
DTC P0645, P0646, or P0647
DTC P1539 or P1546
Symptoms - HVAC Systems - Manual
Air Conditioning Compressor Malfunction (RPO LG4/LG5)
Air Conditioning Compressor Malfunction (RPO L18/LLY)
Blower Motor Malfunction
Auxiliary Blower Motor Malfunction
Air Temperature Malfunction
Auxiliary Air Temperature Malfunction
Air Delivery Improper
Vacuum Control System Diagnostic
Heater and Air Conditioning Control Replacement
Temperature Valve Actuator Replacement
Mode Valve Actuator Replacement (Upper)
Mode Valve Actuator Replacement (Lower)
Air Inlet Valve Actuator Replacement
Vacuum Tank Replacement
Vacuum Hose Harness Replacement
Vacuum Pump Assembly Replacement
Heater Control Blower Switch Replacement
Manual HVAC Description and Operation
Special Tools
Data Communication Schematics
Diagnostic Starting Point - Data Communications
Control Module U Code List
DTC U0010
DTC U0073
DTC U0100-U0299
DTC U0294
DTC U1000 and U1255
DTC U1001-U1254
DTC U1300, U1301, or U1305
DTC U1800, U2105, U2106, or U2108
DTC U2100
DTC U2104
Symptoms - Data Communications
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with Class 2 Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with J1939 Device
Data Link References
Data Link Connector Replacement
Serial Data Gateway Module Replacement
Data Link Communications Description and Operation
Cigar Lighter/Power Outlet Schematics
12-Volt Accessory Power Receptacle Replacement
Special Tools
Fastener Tightening Specifications
Electrical Schematic Symbols
Vehicle Zoning Strategy
Master Electrical Schematic Icons
Power Distribution Schematics
Power Moding Schematics
Ground Distribution Schematics
Upfitter Provision Schematics
Harness Routing Views
Master Electrical Component List
Front of Vehicle/Engine Compartment Component Views
Powertrain Component Views
Instrument Panel/Center Console Component Views
Passenger Compartment/Roof Component Views
Door Component Views
Luggage Compartment/Rear of Vehicle Component Views
Wheels/Vehicle Underbody Component Views
Ground Views
Electrical Center Identification Views
Component Connector End Views
Splice Pack Connector End Views
Inline Harness Connector End Views
General Electrical Diagnosis
Checking Aftermarket Accessories
Circuit Testing
Using Connector Test Adapters
Probing Electrical Connectors
Troubleshooting with a Digital Multimeter
Troubleshooting with a Test Lamp
Using Fused Jumper Wires
Measuring Voltage
Measuring Voltage Drop
Measuring Frequency
Testing for Continuity
Testing for Short to Ground
Testing for a Short to Voltage
Testing for Intermittent Conditions and Poor Connections
Inducing Intermittent Fault Conditions
Testing for Electrical Intermittents
Scan Tool Snapshot Procedure
Circuit Protection - Fuses
Circuit Protection - Circuit Breakers
Circuit Protection - Fusible Links
Wiring Repairs
Repairing Damaged Wire Insulation
Flat Wire Repairs
GMLAN Wiring Repairs
High Temperature Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Splicing Copper Wire Using Splice Sleeves
Splicing Twisted or Shielded Cable
Splicing Inline Harness Diodes
SIR/SRS Wiring Repairs
Connector Repairs
Connector Position Assurance Locks
Terminal Position Assurance Locks
AFL/EPC Connectors
Bosch Connectors (ECM)
Bosch Connectors (2.8 JPT)
Bosch Connectors (0.64)
Bosch Connectors (BSK)
Delphi Connectors (12-Way)
Delphi Connectors (Micro .64)
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Pull To Seat)
Delphi Connectors (Push To Seat)
Delphi Connectors (Weather Pack)
FCI Connectors
JST Connectors
Kostal Connectors (Transmission)
Kostal Connectors (Glow Plug Control Module)
Molex Connectors
Sumitomo Connectors
Tyco/AMP Connectors (SIR)
Tyco/AMP Connectors (Seat)
Tyco/AMP Connectors (102-Way Inline)
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (CM 42-Way)
Yazaki Connectors (16-Way)
Yazaki Connectors (2-Way)
Repairing Connector Terminals
Ignition Key Cannot Be Removed from the Ignition Lock Cylinder
Ignition Key Cannot Turn or Sticks in Any Position
Relay Replacement (Within an Electrical Center)
Relay Replacement (Attachedto Wire Harness)
Ignition Lock Cylinder Replacement
Ignition and Start Switch Replacement
Ignition Lock Cylinder Case Replacement
Special Tools
Remote Function Schematics
Diagnostic Starting Point - Remote Functions
Symptoms - Remote Functions
Keyless Entry System Inoperative
Remote Control Door Lock Receiver Replacement
Transmitter Programming
Keyless Entry System Description and Operation
Special Tools
Fastener Tightening Specifications
Operational and Functional Checks
Seat Belt Does Not Retract
Seat Belt Service Precautions
Repairs and Inspections Required After a Collision
Seat Belt Latch Stop Installation
Driver or Passenger Seat Belt Buckle Replacement
Seat Belt Buckle Replacement - Center Front
Rear Seat Belt Buckle Replacement
Front Seat Center Belt Replacement
Seat Belt Retractor Replacement - Left Front
Seat Belt Retractor Replacement - Right Front
Rear Seat Belt Retractor Replacement
Seat Belt System Description and Operation
Fastener Tightening Specifications
SIR Schematics
SIR Identification Views
Diagnostic Starting Point - SIR
DTC B0016, B0017, or B0018
DTC B0022, B0024, or B0026
DTC B0051
DTC B0053
DTC B0077, B0079, or B0080
DTC B0090
DTC B0091
DTC B1000
DTC B1001
Symptoms - SIR
Air Bag Indicator Circuit Malfunction
SIR Disabling and Enabling
SIR Service Precautions
Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Sensing and Diagnostic Module Replacement
Steering Wheel Inflatable Restraint Module Replacement
Steering Wheel Inflatable Restraint Module Coil Replacement
Inflatable Restraint Steering Wheel Module Coil Centering
Instrument Panel Inflatable Restraint Module Replacement
Instrument Panel Inflatable Restraint Module Switch Replacement
Repairs and Inspections Required After a Collision
Inflator Module Handling and Scrapping
SIR System Description and Operation
Special Tools
Seat - Air Suspension Does Not Operate
Fastener Tightening Specifications
Manual Seat Adjuster Does Not Lock
Manual Seat Adjuster Does Not Unlock
Manual Seat Adjuster Locks Between Lock Positions
Air Suspension Seat Replacement
Air Tube Replacement
Bucket Seat Replacement
Seat Riser Replacement
Front Seat Adjuster Replacement
Front Seat Storage Armrest Replacement
Front Passenger Seat Stowage Box Replacement
Front Seat Cushion Replacement
Front Seat Cushion Cover Replacement
Seat Cushion Frame Replacement
Front Seat Back Replacement
Driver or Passenger Seat Back Cushion Cover and Pad Replacement
Driver or Passenger Seat Back Cushion Frame Replacement
Front Seat Back Hinge and Recliner Mechanism Replacement
Driver or Passenger Seat Recliner Handle Replacement
Rear Seat Back Cushion Latch Cable Replacement
Rear Bench Seat Replacement
Rear Seat Riser Replacement
Rear Seat Cushion Cover and Pad Replacement
Rear Seat Cushion Frame Replacement
Rear Folding Seat Back Latch Replacement
Rear Seat Back Cushion Replacement
Rear Seat Back Cushion Cover and Pad Replacement
Rear Seat Back Cushion Hinge Replacement
Air Suspension Seat Description
Fastener Tightening Specifications
Power Steering Pump Specifications
Diagnostic Starting Point - Power Steering System (w/o Electro-Hydraulic Steering)
Symptoms - Power Steering System
Power Steering System Test
Power Steering Fluid Leaks
Rattle, Clunk, or Shudder Noise from the Power Steering System
Whine or Growl Noise from the Power Steering System
Steering Effort Too Easy in One or Both Directions
Steering Effort Hard in One or Both Directions
Power Steering System Bleeding (Manual)
Checking and Adding Power Steering Fluid
Power Steering System Flushing
Power Steering Fluid Reservoir Replacement
Power Steering Pump Pulley Replacement (L18 with C6500, C7500, C8500)
Power Steering Pump Pulley Replacement (LB7, LLY and LMM)
Power Steering Pump Pulley Replacement (L18 with C4500, C5500)
Power Steering Pump Replacement (LG5/LF6 and JE4)
Power Steering Pump Replacement (LG5/LF6 and JE3)
Power Steering Pump Replacement (LG4/LF8 and JE4)
Power Steering Pump Replacement (LG4/LF8 with JE3)
Power Steering Pump Replacement (L18 with C4500, C5500)
Power Steering Pump Replacement (LB7, LLY and LMM)
Power Steering Pump Replacement (L18 with C6500, C7500, C8500)
Steering Gear Pitman Shaft Seal Replacement
Power Steering Hose Quick Connect Fitting Replacement
Power Steering Fluid Reservoir Inlet Hose Replacement (L18, LB7, LLY and LMM)
Power Steering Fluid Reservoir Inlet Hose Replacement (LG4/LG5/LF6/LF8)
Power Steering Fluid Reservoir Outlet Hose Replacement (LG5/LF6)
Power Steering Fluid Reservoir Outlet Hose Replacement (LG4/LG8)
Power Steering Fluid Reservoir Outlet Hose Replacement (L18)
Power Steering Fluid Reservoir Outlet Hose Replacement (LB7, LLY and LMM)
Power Steering Gear Inlet Pipe/Hose Replacement (LG5/LF6)
Power Steering Gear Inlet Pipe/Hose Replacement (LB7, L18 w/Hydromax)
Power Steering Gear Inlet Pipe/Hose Replacement (LG4/LF8)
Input Shaft Bearing Protector Cap Replacement - On Vehicle
End Limiters Replacement
Pressure Relief Valve Replacement
Steering Gear Replacement (FH4)
Steering Gear Replacement (Non FH4)
Power Brake Booster Inlet Hose Replacement (L18, LLY and LMM)
Power Brake Booster Inlet Hose Replacement (LB7)
Power Brake Booster Inlet Hose Replacement (LG4/LG5/LF6 and LF8)
Power Brake Booster Outlet Hose Replacement (LG4/LG5/LF6 and LF8)
Power Brake Booster Outlet Hose Replacement (L18/LB7/LLY and LMM)
Power Steering System Description and Operation (w/o Electro-Hydraulic Steering)
Special Tools
Fastener Tightening Specifications
Steering Linkage Inspection
Tie Rod Replacement
Steering Arm Replacement (C6500/C7500/C8500)
Steering Arm Replacement (C4500/C5500)
Steering Arm Replacement (4WD)
Tie Rod Arm Replacement (10K/12K/14.6K/Axles)
Tie Rod Arm Replacement (16K Axles)
Relay Rod Replacement (4WD)
Relay Rod Replacement (2WD)
Pitman Arm Replacement (C6500/C7500/C8500)
Pitman Arm Replacement (C4500/C5500)
Pitman Arm Replacement (4WD)
Steering Linkage Description and Operation
Special Tools
Fastener Tightening Specifications
Steering Column Disassembled View (Standard Column)
Steering Column Disassembled View (Tilt Column)
Diagnostic Starting Point - Steering Column
Symptoms - Steering Wheel and Column
Steering Column Tilt Function Inoperative
Noise in Steering Column
High Shift Effort
Looseness in Steering Column
Intermediate Steering Shaft Seal Replacement
Intermediate Steering Shaft Replacement
Steering Column Accident Damage Inspection
Steering Column Trim Cover Replacement
Turn Signal Multifunction Switch Replacement
Shift Lever Replacement
Linear Shift Assembly Replacement
Tilt Lever Replacement
Steering Wheel Replacement
Steering Column Tilt Spring Replacement
Turn Signal Cancel Cam and Upper Bearing Inner Race Replacement
Turn Signal Cancel Cam and Upper Bearing Thrust Washer
Steering Column Replacement
Steering Column Seal Replacement
Steering Shaft, Lower Bearing, and Jacket Replacement (Standard Column)
Steering Shaft, Lower Bearing, and Jacket Replacement (Tilt Column)
Steering Wheel and Column Description and Operation
Special Tools
Fastener Tightening Specifications
Air Suspension Schematics
Diagnostic Starting Point - Air Suspension
Symptoms - Air Suspension
Air Suspension Malfunction
Suspension Alignment
Preventive Maintenance
Main Support Beam Replacement
Cross Channel Replacement
Air Spring Frame Hanger Replacement
Spring Hanger Bracket Insulator Replacement
Torque Rod Replacement
Torque Rod Bushing Replacement
Transverse Rod Replacement
Height Leveling Valve Replacement
Air Suspension Relief Valve Replacement
Shock Absorber Replacement
Air Spring Replacement
Air Suspension Description and Operation
Fastener Tightening Specifications
Stabilizer Shaft Replacement (Spring Mounted)
Stabilizer Shaft Replacement (Axle Mounted)
Stabilizer Shaft Link Replacement (Axle Mounted Type)
Upper Control Arm Ball Joint Replacement
Lower Control Arm Ball Joint Replacement
Wheel Bearing Adjustment (Non FH4)
Wheel Bearing Adjustment (FH4)
Steering Knuckle Replacement
Steering Knuckle and King Pin Replacement (Unitized Wheel Ends)
Steering Knuckle and King Pin Replacement (Conventional Wheel Ends)
Spring Bumper Replacement
Leaf Springs Replacement
Front Spring Hanger Replacement
Rear Spring Hanger Replacement
Front Spring Shackle Replacement
Front Wheel Hub, Bearing, and Seal Replacement
Front Wheel Bearing Lubricant Cap Replacement (Bolt-On)
Front Wheel Bearing Lubricant Cap Replacement (Press-On)
Adding Lubricant to Wheel Bearing Lubricant Caps
Shock Absorber Replacement
Shock Absorber Disposal
King Pin Bushing and Bearing Cup Replacement
Front Axle Replacement
General Description
Special Tools
Fastener Tightening Specifications (Except Haulmaxx Suspension)
Fastener Tightening Specifications (Haulmaxx Suspension)
Stabilizer Shaft Replacement (4500, 5500)
Stabilizer Shaft Replacement (6500, 7500, 8500)
Shock Absorber Replacement (4500, 5500 w/Bolt Type Shocks)
Shock Absorber Replacement (6500, 7500, 8500 w/LO-PRO)
Shock Absorber Replacement (6500, 7500, 8500)
Shock Absorber Replacement (Haulmaxx Suspension)
Shock Absorber Replacement (4500, 5500 w/Stud Type Shocks)
Rear Spring Replacement
Rear Spring Bracket Replacement
Rear Auxiliary Spring Adjustment
Rear Auxiliary Spring Replacement
Rear Spring Travel Limiting Link Replacement
Rear Auxiliary Spring Shim Replacement
Leaf Spring Replacement
Spring Hanger Replacement
Spring Bumper Replacement
Tandem Axle/Suspension Removal and Installation (Except Haulmaxx Suspension)
Tandem Axle/Suspension Removal and Installation (HaulmaxxSuspension)
Torque Rod Replacement (Transverse)
Torque Rod Replacement (Longitudinal)
Equalizing Beam Replacement (Except Haulmaxx Suspension)
Equalizing Beam Replacement (Haulmaxx Suspension)
Equalizing Beam End Bushing Replacement
Equalizing Beam Center Bushing Replacement (Off Vehicle U-340 Type)
General Description
Special Tools
Fastener Tightening Specifications
Tire Diagnosis - Irregular or Premature Wear
Tire Diagnosis - Waddle Complaint
Wheel Mounting Surface Check
Radial Tire Lead/Pull Correction
Tire and Wheel Removal and Installation (Drum Type - Single)
Tire and Wheel Removal and Installation (Disc Type - Dual)
Tire and Wheel Removal and Installation (Disc Type - Single)
Tire and Wheel Removal and Installation (Drum Type - Dual)
Tire Dismounting and Mounting (Tube-Type Tire)
Tire Dismounting and Mounting (Tubeless Tire)
Tire Rotation
Tire Matching
Tire Measuring
General Description
Tire Inflation Description
Wheel Alignment Specifications
Fastener Tightening Specifications
Steering Wheel Alignment
Wheel Alignment Measurement
Front Caster Adjustment
Front Camber Adjustment
Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment
Checking and Correcting King Pin Inclination
Stop Screw Adjustment
Caster Description
Camber Description
Toe Description
Lead/Pull Description
Fastener Tightening Specifications
Fluid Capacity Specifications
Automatic Transmission Controls Schematics
Low Main Line Pressure in All Ranges
Transmission Control Module Replacement
Shift Cable Adjustment
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Shift Cable Replacement (Steering Column)
Park/Neutral Position and Backup Lamp Switch Replacement
Park/Neutral Position and Backup Lamp Switch Adjustment
Automatic Transmission Fluid and Filter Replacement
Transmission Fluid Filler Tube and Seal Replacement
Transmission Fluid Auxiliary Cooler Inlet and Outlet Hose Replacement
Oil Cooler Hose/Pipe Replacement
Transmission Fluid Auxiliary Cooler Replacement
Transmission Fluid Temperature Sensor Replacement
Transmission Mount Replacement
Transmission Support Replacement
Transmission Mount Bracket Replacement
Transmission Replacement
Special Tools
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Starting Point - Clutch
Symptoms - Clutch
Clutch Drag Hard Shifting
Clutch Slipping
Clutch Grabbing
Clutch Rattle
Clutch Noisy
Clutch Pedal Spongy Low Pedal Effort
Clutch Pedal Hard to Push
Clutch Frequent Adjustments
Clutch Vibration
Clutch Pedal Replacement
Clutch Cable Return Spring and/or Bracket Replacement
Clutch Return Spring Replacement
Clutch Cable Replacement
Clutch Fork Assembly Replacement
Clutch Pedal Position Switch Replacement
Clutch Housing Replacement
Clutch Pilot Bearing Replacement
Clutch Assembly Replacement (Double Plate)
Clutch Assembly Replacement (Single Plate)
Release Bearing Replacement
Clutch Pedal Free Travel Adjustment (Pedal Free Travel)
Clutch Assembly Adjustment (Lubrication)
Clutch Assembly Adjustment (MPK ResettingProcedure Out of Vehicle)
Clutch Assembly Adjustment (MPK Resetting Procedure in Vehicle)
Clutch Brake Clearance Measurement
Clutch System Description and Operation
Special Tools
Fastener Tightening Specifications
Lubrication Specifications
Adhesives, Fluids, Lubricants, and Sealers
Manual Transmission Schematics
Diagnostic Starting Point - Manual Transmission
DTC P0500
DTC P0833
Symptoms - Manual Transmission
Transmission Noisy
Transmission Locked in One Gear
Transmission Jumps Out of Gear
Transmission Clunk on Acceleration or Deceleration
Transmission Fluid Leak Diagnosis
Transmission Fluid Check
Transmission Oil Changing
Control Lever and/or Boot Replacement
Rear Oil Seal Replacement
Air Shift Control Valve Replacement
Air Shift Control Lever Replacement
Transmission Range Select Control Valve Air Supply Tube Replacement (Crossmember Mounted)
Transmission Air Shift Harness Replacement
Vehicle Speed Sensor Replacement
Backup Lamp Switch Replacement
Transmission Support Replacement
Transmission Mount Bracket Replacement
Transmission Replacement
Transmission System Description and Operation
Special Tools
Power Take-Off (PTO) Schematics
Diagnostic Starting Point - Power Take-Off (PTO)
Symptoms - Power Take-Off (PTO)
Power Take-Off (PTO) Does Not Engage
Engine RPM Does Not Increase with Power Take-Off Engaged
Power Take-Off (PTO) Indicator Inoperative
Power Take-Off (PTO) Description and Operation
Approximate Fluid Capacities
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Transfer Case Control Schematics
Transfer Case Disassembled View
Diagnostic Starting Point - Transfer Case
DTC B0775
DTC B0780
DTC B0785
DTC B0790
DTC B2725
DTC C0306
DTC C0327
DTC C0359
DTC C0550
Symptoms - Transfer Case
Transfer Case Shift Control Switch Inoperative
Transfer Case Shift Control Switch Indicator Always On - Two or More
Transfer Case Shift Control Switch Indicator Flashes, then Returns to Previous Mode
Transfer Case Shift Control Switch Indicator Inoperative - One or More
Transfer Case Will Not Shift
Transfer Case Popping Noise
Transfer Case Whine or Rumble Noise
Transfer Case Growl or Grinding Noise
Transfer Case Clunk in 2HI Only
Transfer Case Clunk in 4HI
Transfer Case Clunk in 4LO
Transfer Case Shudder or Binding
Transfer Case Jumps Out of Gear
Transfer Case Leak Diagnosis
Transfer Case Shield Replacement
Transfer Case Fluid Replacement
Transfer Case Actuator Assembly Replacement
Range Selector Position Sensor Replacement
Transfer Case Actuator Assembly Control Module Replacement
Transfer Case Shift Control Switch Replacement
Transfer Case Side Mount Replacement
Transfer Case Crossmember Mount Replacement
Transfer Case Front Bracket Replacement
Transfer Case Rear Bracket Replacement
Input Shaft Seal Replacement
Front Output Shaft Seal Replacement
Rear Output Shaft Seal Replacement
Transfer Case Replacement
Transfer Case Disassemble
Transfer Case Cleaning and Inspection
Transfer Case Assemble
Transfer Case Description and Operation
Special Tools
List of Content