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Manual Details
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Coverage Areas
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Systems Covered:
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Engine Mechanical, Engine Performance, Transmission, Drivetrain, Suspension, Steering, Brakes, Exhaust System, Fuel System, Cooling System, Climate Control, Electrical System (including wiring diagrams), Body and Frame, Interior, Exterior, Accessories, Diagnostic Procedures, Troubleshooting.
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Page Count
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Estimated Pages:
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1800+
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Manual Type
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Type:
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Factory Service Manual / Repair Manual
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Language
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Language:
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English
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Format
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Format:
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Digital Download (PDF)
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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete disassembly, inspection, and reassembly of all engine components including cylinder heads, blocks, pistons, crankshafts, camshafts, and timing systems.
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Engine Performance:
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Fuel injection system diagnosis and repair, ignition system testing, emissions control systems (OBD-II), idle speed control, component testing (sensors, actuators).
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Transmission:
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Diagnosis, maintenance, and repair procedures for automatic transmissions, including fluid checks, band adjustments, valve body troubleshooting, and torque converter service.
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Drivetrain:
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Front and rear axle service, CV joints, driveshafts, differential overhaul, and 4WD system diagnosis and repair.
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Suspension Steering:
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Front and rear suspension component replacement (shocks, struts, ball joints, control arms), wheel alignment procedures, steering gear diagnosis and repair, power steering system service.
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Brakes:
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Brake system diagnosis, disc brake component replacement (pads, rotors, calipers), drum brake service, parking brake adjustments, ABS system diagnostics and component testing.
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Electrical System:
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Comprehensive wiring diagrams, component testing for starters, alternators, batteries, lighting systems, power windows, door locks, and comfort features. Includes diagnostic procedures for electrical faults.
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Body And Frame:
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Body panel repair and replacement, door and window installation, interior trim removal and installation, rust repair techniques, frame inspection and straightening where applicable.
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Procedures Included
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Maintenance Tasks:
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Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, differential fluid changes, fuel filter replacement, battery testing and replacement.
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Troubleshooting Guidance:
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Systematic diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. Includes symptom-based troubleshooting.
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Repair Procedures:
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Step-by-step instructions for component removal, installation, and adjustment for virtually all vehicle systems. Torque specifications for all critical fasteners.
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Diagnostic Tools:
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Information on using OBD-II scanners, multimeters, and other specialized tools for diagnosing vehicle issues.
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Technical Depth
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Depth Of Coverage:
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Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 5,000-7,500 miles or 6 months (depending on driving conditions and oil used). Consult manual for specific recommendations.
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Engine Air Filter:
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Replace every 15,000-30,000 miles or as needed based on inspection.
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Spark Plugs 4.7L:
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Replace every 100,000 miles (use Champion Copper Plus or equivalent).
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Spark Plugs 3.9L:
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Replace every 30,000 miles (use Champion copper or platinum plugs).
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Coolant Flush:
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Every 5 years or 100,000 miles.
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Transmission Fluid Change:
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Every 30,000-60,000 miles, depending on driving conditions. Consult manual.
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Fluid Specifications
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Engine Oil Type 4.7L:
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SAE 5W-30 Synthetic Blend or Full Synthetic (API SN or newer).
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Engine Oil Type 3.9L:
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SAE 5W-30 (API SN or newer).
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Coolant Type:
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Mopar OAT (Organic Additive Technology) 50/50 Antifreeze/Coolant (or equivalent HOAT).
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Brake Fluid Type:
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DOT 3
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Known Issues
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Common Problems:
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Eccentric camshaft pulley failure (4.7L V8), occasional transmission shudder (45RFE), rear axle seal leaks, cooling fan clutch issues, plenum gasket leaks (4.7L V8).
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Common Problems Electrical:
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Window regulator failures, interior lighting issues, instrument cluster intermittent problems.
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Recommended Parts
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Oil Filter 4.7L:
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Mopar P/N 04540000 or equivalent (e.g., Wix 57899, Fram PH16).
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Air Filter 4.7L:
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Mopar P/N 04591210AB or equivalent (e.g., Wix 49367).
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Vehicle History
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Brand Heritage
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Parent Company:
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Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles, now Stellantis)
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Model Evolution
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Generation:
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Second Generation (DN, 2001-2003)
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Redesign Notes:
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Significant redesign from the first generation, featuring a new chassis, updated styling, and improved powertrains. Introduced optional third-row seating.
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Production
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Manufacturing Plant:
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Jefferson North Assembly, Detroit, Michigan
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Production Years Global:
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1997-2003 (First Gen), 2001-2003 (Second Gen - North America)
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