Dodge Durango (DN). Manual

FASTENER USAGE

WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.

Figure art, specifications and torque references in

this Service Manual are identified in metric and SAE
format.

During any maintenance or repair procedures, it is

important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.

THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using

a Helicoil

t. Follow the manufactures recommenda-

tions for application and repair procedures.

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one,

ten, one hundred, one thousand and one million.

The following chart will assist in converting metric

units to equivalent English and SAE units, or vise
versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY

TO GET

MULTIPLY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg
(60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

x 3.281

= Feet

Yards

x 0.9144

= Meters

x 1.0936

= Yards

mph

x 1.6093

= Kilometers/Hr. (Km/h)

Km/h

x 0.6214

= mph

Feet/Sec

x 0.3048

= Meters/Sec (M/S)

M/S

x 3.281

= Feet/Sec

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/
Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr.
(Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.)

TORQUE REFERENCES

DESCRIPTION

Individual Torque Charts appear at the end of

many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.

INTRODUCTION

DESCRIPTION AND OPERATION (Continued)

ABS BRAKE SYSTEM, BLEEDING

. . . . . . . . . 5-44

ABS WARNING LAMP

. . . . . . . . . . . . . . . . . . 5-43

ABSOLUTE PRESSURE (MAP)

SENSOR—3.9/5.2/5.9L ENGINES,
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48

ABSOLUTE PRESSURE (MAP)

SENSOR—4.7L V–8 ENGINE,
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49

ABSOLUTE PRESSURE (MAP)

SENSOR—PCM INPUT, MANIFOLD . . . . . . . 14-33

ABSORBER, SHOCK

. . . . . . . . . . . . 2-16,2-24,2-8

ABSORBERS, SHOCK

. . . . . . . . . . . 2-15,2-23,2-6

A/C APPLICATION TABLE . . . . . . . . . . . . . . . 24-73
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . 24-11
A/C UNIT, REAR OVERHEAD

. . . . . . . . . . . . 24-64

ACCELERATION, CLUNKING NOISE

DURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

ACCELERATION, SHUDDER OR

VIBRATION DURING . . . . . . . . . . . . . . . . . . . 3-18

ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-22
ACCESSORY BELT REPLACEMENT—4.7L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

ACCESSORY DRIVE BELT DIAGNOSIS

. . . . . 7-19

ACCESSORY DRIVE BELT—5.2L/5.9L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

ACCUMULATOR

. . . 21-137,21-193,21-306,21-31,

21-391

ACTUATION TEST MODE, CIRCUIT

. . . . . . . . 25-2

ACTUATOR, FRONT DOOR INSIDE

HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-35

ACTUATOR, MODE DOOR VACUUM . . . . . . . . 24-62
ACTUATOR, REAR DOOR INSIDE

HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-42

ADAPTER HOUSING SEAL

. . . . . . . . . . . . . 21-365

ADDITIONAL, COOLANT—ADDING

. . . . . . . . 7-23

ADDITIVES, COOLANT SELECTION

. . . . . . . . 7-23

ADHESIVE LOCATIONS, STRUCTURAL

. . . 23-100

ADJUSTER AND MOTORS,

POWER SEAT . . . . . . . . . . . . . . . . 8R-1,8R-2,8R-3

ADJUSTER, HYDRAULIC LASH

. . . . . . . . 9-46,9-6

ADJUSTER NOISE DIAGNOSIS,

HYDRAULIC LASH . . . . . . . . . . . . . . . . . . . . . 9-14

ADJUSTMENT, CENTER BEARING

. . . . . . . . . 3-17

ADJUSTMENT, COMPASS VARIATION

. . . . . . 8V-6

ADJUSTMENT, DOOR LATCH

. . . . . . . . . . . . 23-67

ADJUSTMENT, FRONT BAND

. . . . . . . . . . . 21-310

ADJUSTMENT, REAR BAND

. . . . . . . . . . . . 21-310

ADJUSTMENT, SHIFTER

. . . . . . . . 21-440,21-471

ADJUSTMENT, TRANSMISSION

THROTTLE VALVE CABLE . . . . . . . 21-140,21-308

ADJUSTMENTS, BAND

. . . . . . . . . . . . . . . 21-141

AERATION, COOLANT—LOW LEVEL

. . . . . . . 7-22

AFTERMARKET REPAIR PRODUCTS

. . . . . . . 23-3

AIR CLEANER ELEMENT (FILTER)

. . . . . . . . 14-50

AIR CONDITIONER CONTROL, HEATER

. . . . . 24-8

AIR CONDITIONER, HEATER

. . . . . . . . . . . . . 24-7

AIR CONDITIONER, REAR OVERHEAD

. . . . . 24-9

AIR CONDITIONING/HEATER, 8W-42

. . . . . . 8W-1

AIR CONTROL (IAC) MOTOR—3.9/5.2/

5.9L ENGINES, IDLE . . . . . . . . . . . . . . . . . . 14-47

AIR CONTROL (IAC) MOTOR—4.7L V–8

ENGINE, IDLE . . . . . . . . . . . . . . . . . . . . . . . 14-48

AIR CONTROL (IAC) MOTOR—PCM

OUTPUT, IDLE . . . . . . . . . . . . . . . . . . . . . . . 14-37

AIR FLOW CHECK PROCEDURE,

THROTTLE BODY MINIMUM . . . . . . . . . . . . 14-43

AIR TEMPERATURE SENSOR—3.9/5.2/

5.9L ENGINES, INTAKE MANIFOLD . . . . . . . 14-52

AIR TEMPERATURE SENSOR—4.7L V-8

ENGINE, INTAKE MANIFOLD . . . . . . . . . . . . 14-53

AIR TEMPERATURE SENSOR—PCM

INPUT, INTAKE MANIFOLD . . . . . . . . . . . . . 14-32

AIR TESTING TRANSMISSION CLUTCH

AND BAND OPERATION . . . . . . . . . . 21-211,21-49

AIR TESTING TRANSMISSION CLUTCH

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-356

AIRBAG CONTROL MODULE

. . . . . . . 8M-12,8M-3

AIRBAG MODULE, DRIVER SIDE

. . . . 8M-2,8M-6

AIRBAG MODULE, PASSENGER SIDE

. 8M-3,8M-9

AIRBAG MODULE TRIM COVER, DRIVER

SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7

AIRBAG SYSTEM

. . . . . . . . . . . . 8M-1,8M-4,8M-5

AIRBAG SYSTEM, 8W-43

. . . . . . . . . . . . . . . 8W-1

AJAR SWITCH, DOOR

. . . . . . . . . . . . . 8Q-3,8Q-5

AJAR SWITCH, DRIVER DOOR

. . . . . . . 8U-2,8U-3

AJAR SWITCH, LIFTGATE

. . . . . . . . . . . 8Q-3,8Q-5

ALERT, TAMPER

. . . . . . . . . . . . . . . . . . . . . . 8Q-2

ALIGNMENT

. . . . . . . . . . . . . . . . . . . . . . . 2-1,2-5

ALIGNMENT, FOG LAMP

. . . . . . . . . . . . . . . . 8L-8

ALIGNMENT, HEADLAMP

. . . . . . . 8L-6,8L-7,8L-9

ALIGNMENT SCREEN PREPARATION,

LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6

ALIGNMENT, VEHICLE PREPARATION

FOR HEADLAMP . . . . . . . . . . . . . . . . . . . . . . 8L-6

ALIGNMENT, WHEEL

. . . . . . . . . . . . . . . . . 2-1,2-3

ALL-WHEEL ANTI-LOCK BRAKES, 8W-35

. . 8W-1

ALUMINUM THREAD

REPAIR . . . . . . . . . . . . . . . . 21-227,21-359,21-63

AMBIENT TEMPERATURE

SENSOR . . . . . . . . . . . . . . . . . . . 8V-13,8V-4,8V-6

AMPERAGE TEST, FUEL PUMP

. . . . . . . . . . . 14-8

AMPLIFIER, POWER

. . . . . . . . . . 8F-14,8F-3,8F-8

ANALYSIS, GEAR CONTACT PATTERN . . 3-53,3-96
ANALYZING ROAD TEST

. . . . . . . . . 21-208,21-46

ANGLE MEASUREMENT PREPARATION,

DRIVELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

ANGLE MEASUREMENT, PROPELLER

SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

ANGLE, PROPELLER SHAFT JOINT

. . . . . . . . . 3-4

ANGLE, REAR AXLE PINION INPUT

. . . . . . . 3-16

ANTENNA

. . . . . . . . . . . . . . . . . . . 8F-15,8F-4,8F-8

ANTILOCK BRAKE BLEEDING, REAR

WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

ANTILOCK BRAKE SYSTEM

. . . . . . . . . . . . . . 5-40

ANTILOCK BRAKES

. . . . . . . . . . . . . . . . . . . . 5-43

ANTI-LOCK BRAKES, 8W-34 REAR

WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1

ANTI-LOCK BRAKES, 8W-35 ALL-WHEEL

. . 8W-1

ANTILOCK BRAKES, CONTROLLER

. . . . 5-41,5-44

ANTILOCK BRAKES, CONTROLLER REAR

WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

ANTILOCK BRAKES, FOUR WHEEL

. . . . . . . . 5-40

ANTILOCK BRAKES, REAR WHEEL

. . . . . . . . 5-32

ANTILOCK CONTROL ASSEMBLY

. . . . . . . . . 5-44

ANTILOCK, REAR WHEEL

. . . . . . . . . . . 5-32,5-36

A-PILLAR GRAB HANDLE

. . . . . . . . . . . . . . 23-52

A-PILLAR TRIM

. . . . . . . . . . . . . . . . . . . . . . 23-52

APPLICATION, BULB

. . . . . . . . . . . . . . . . . . 8L-22

APPLICATION TABLE, A/C

. . . . . . . . . . . . . . 24-73

AREA LEAKS—INSPECTION, R

EAR SEAL . . . . . . . . . . . . . . . . . . . . . . 9-14,9-147

ARM AND BLADE, WIPER

. . . . . . . . . . . . . . . 8K-2

ARM, LOWER SUSPENSION

. . . . . . . . . 2-10,2-18

ARM, ROCKER . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
ARM, UPPER SUSPENSION

. . . . . . . . . 2-10,2-19

ARM, WIPER

. . . . . . . . . . . . . . . . . . . . . . . . 8K-11

ARMING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1

ARMREST/CONSOLE INERTIA LATCH

COVER, CENTER . . . . . . . . . . . . . . . . . . . . . 23-12

ARMS AND PUSH RODS, ROCKER

. . 9-107,9-166

ARMS, ROCKER

. . . . . . . . . . . . . . . . . . . . . . 9-40

ARMS, SUSPENSION

. . . . . . . . . . . . . . . 2-15,2-7

ASD AND FUEL PUMP RELAYS

. . . . . . . . . . 14-42

ASH RECEIVER, INSTRUMENT PANEL

. . . . 8E-20

ASSEMBLY, ANTILOCK CONTROL

. . . . . . . . . 5-44

ASSEMBLY, CYLINDER HEAD

. . . . . . 9-124,9-182

ASSEMBLY, ENGINE

. . . . . . . . . 9-102,9-161,9-31

ASSEMBLY, FINAL

. . . . . . . . . . . . . . . . . 3-46,3-81

ASSEMBLY, INPUT CLUTCH

. . . . . . . . . . . 21-381

ASSEMBLY, INSTRUMENT PANEL

. . . . . . . . 8E-27

ASSEMBLY, LOW/REVERSE CLUTCH

. . . . . 21-391

ASSEMBLY, PARK BRAKE PEDAL

. . . . . . . . . 5-23

ASSEMBLY, PISTON AND CONNECTING

ROD . . . . . . . . . . . . . . . . 9-116,9-124,9-175,9-182

ASSEMBLY, SOLENOID AND PRESSURE

SWITCH . . . . . . . . . . . . . . . . . . . . . 21-349,21-362

ASSIST HANDLE, OVERHEAD

. . . . . . . . . . . 23-65

AUDIO SYSTEM

. . . . . . . . . . . . . . . . . . . 8F-1,8F-4

AUDIO SYSTEM, 8W-47

. . . . . . . . . . . . . . . . 8W-1

AUDIO SYSTEMS

. . . . . . . . . . . . . . . . . . . . . 8F-20

AUGAT CONNECTORS, TERMINAL/

CONNECTOR REPAIR- . . . . . . . . . . . . . . . . 8W-11

AUTO SHUTDOWN (ASD) RELAY—PCM

OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36

AUTOMATIC BELT TENSIONER

. . . . . . . . . . . . 7-7

AUTOMATIC BELT TENSIONER—4.7L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

AUTOMATIC BELT TENSIONER—5.2L/

5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

AUTOMATIC DAY/NIGHT MIRROR

. . . . . 8T-5,8T-6

AUTOMATIC DAY/NIGHT MIRROR

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-5

AUTOMATIC SHUTDOWN (ASD) RELAY

. . . 14-44

AUTOMATIC SHUTDOWN (ASD) RELAY

SENSE—PCM INPUT . . . . . . . . . . . . . . . . . . 14-31

AUTOMATIC TRANSMISSION, 42/44RE

. . . . . 21-1

AUTOMATIC TRANSMISSION,

45RFE . . . . . . . . . . . . . . . . . . . . . . 21-330,21-331

AUTOMATIC TRANSMISSION, 46RE

. . . . . 21-161

AUTOMATIC TRANSMISSION

DIAGNOSIS . . . . . . . . . . . . . . . . . . . 21-206,21-44

AUTOMATIC TRANSMISSION GENERAL

DIAGNOSIS, 45RFE . . . . . . . . . . . . . . . . . . 21-353

AUTOMATIC TRANSMISSION OIL

COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

AXLE, 8 1/4

. . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

AXLE, 8 1/4 AND 9 1/4

. . . . . . . . . . . . . . . . . 3-59

AXLE, 8 1/4 AND 9 1/4 INCH

. . . . . . . . . . . . 3-99

AXLE, 8 1/4 INCH

. . . . . . . . . . . . . . . . . . . . . 3-98

AXLE, 9 1/4 INCH

. . . . . . . . . . . . . . . . . . . . . 3-98

AXLE, C205F

. . . . . . . . . . . . . . . . . . . . . 3-30,3-55

AXLE COMPONENTS

. . . . . . . . . . . . . . . . . . . 3-47

AXLE DRIVESHAFTS, FRONT

. . . . . . . . . . . . . 3-18

AXLE, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
AXLE PINION GEAR DEPTH, 8 1/4

. . . . . . . . 3-91

AXLE PINION GEAR DEPTH, 9 1/4

. . . . . . . . 3-92

AXLE PINION INPUT ANGLE, REAR

. . . . . . . 3-16

AXLE, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
AXLE SEAL AND BEARING, 8 1/4 AND 9

1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

AXLE SHAFT

. . . . . . . . . . . . . . . . . . . . . 3-38,3-70

AXLE SHAFT SEAL AND BEARING

. . . . . . . . 3-38

AXLE SKID PLATE, FRONT

. . . . . . . . . . . . . . 13-6

AXLES, 8 1/4 AND 9 1/4 . . . . . . . . . . . . . 3-90,3-99
AXLES, 9 1/4

. . . . . . . . . . . . . . . . . . . . . . . . . 3-60

BACK, 2ND ROW CENTER SEAT

. . . . . . . . . 23-16

BACK, 2ND ROW SEAT

. . . . . . . . . . . . . . . . 23-13

BACK, 3RD ROW SEAT

. . . . . . . . . . . . . . . . 23-17

BACK, BUCKET SEAT

. . . . . . . . . . . . . . . . . . 23-11

BACK COVER, 2ND ROW CENTER SEAT

. . . 23-16

BACK COVER, 2ND ROW SEAT

. . . . . . . . . . 23-14

BACK COVER, 3RD ROW SEAT

. . . . . . . . . . 23-17

BACK COVER/CUSHION, BUCKET SEAT . . . . 23-11
BACKLASH, DIFFERENTIAL BEARING

PRELOAD AND GEAR . . . . . . . . . . . . . . 3-50,3-95

BACKLITE, LIFTGATE

. . . . . . . . . . . . . . . . . . . 23-8

BACK-UP LAMP BULB, TAIL, BRAKE,

TURN SIGNAL . . . . . . . . . . . . . . . . . . . . . . . 8L-11

BACK-UP LAMP, TAIL, BRAKE, TURN

SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-17

BALANCE, TIRE AND WHEEL

. . . . . . . . . . . . 22-9

BALL JOINT, LOWER

. . . . . . . . . . . . . . . . 2-15,2-7

BALL JOINT, UPPER

. . . . . . . . . . . . . . . . 2-15,2-8

BAND ADJUSTMENT, FRONT

. . . . . . . . . . . 21-310

BAND ADJUSTMENT, REAR

. . . . . . . . . . . . 21-310

BAND ADJUSTMENTS

. . . . . . . . . . . . . . . . 21-141

BAND OPERATION, AIR TESTING

TRANSMISSION CLUTCH . . . . . . . . 21-211,21-49

BANDS . . . . . . . . . . . . . . . . . . . . . . . 21-200,21-38
BAR, STABILIZER

. . 2-11,2-15,2-20,2-23,2-25,2-7

BAR, TORSION

. . . . . . . . . . . . . . . . . . . . . . . 2-17

BAR, TOWEL

. . . . . . . . . . . . . . . . . . . . . . . . 23-10

BARS, TORSION

. . . . . . . . . . . . . . . . . . . . . . 2-15

BASE BRAKE BLEEDING

. . . . . . . . . . . . . . . . 5-11

BASE BRAKE SYSTEM

. . . . . . . . . . . . . . . 5-1,5-5

BASE BRAKES

. . . . . . . . . . . . . . . . . . . . . . . . 5-31

BASE COAT/CLEAR COAT FINISH

. . . . . . . . . 23-2

BATTERY

. . . . . . . . 8A-1,8A-19,8A-21,8A-22,8A-5

BATTERY CABLES

. . . . . . . . . . . . . . . . 8A-14,8A-3

BATTERY CHARGING . . . . . . . . . . . . . . . . . . 8A-16
BATTERY FEED (TCM)

. . . . . . . . . . . . . . . . 21-349

BATTERY HOLD DOWNS

. . . . . . . . . . . 8A-18,8A-4

BATTERY REPLACEMENT, REMOTE

KEYLESS ENTRY TRANSMITTER . . . . . . . . . 8P-8

BATTERY TEMPERATURE SENSOR

. . . . 8C-2,8C-4

BATTERY TRAY

. . . . . . . . . . . . . . . . . . 8A-20,8A-4

BATTERY VOLTAGE—PCM INPUT

. . . . . . . . 14-31

BEARING, 8 1/4 AND 9 1/4 AXLE SEAL

. . . . 3-71

BEARING ADJUSTMENT, CENTER

. . . . . . . . . 3-17

BEARING, AXLE SHAFT SEAL

. . . . . . . . . . . . 3-38

BEARING, CENTER

. . . . . . . . . . . . . . . . . 3-11,3-2

BEARING NOISE

. . . . . . . . . . . . . . . . . . 3-34,3-68

BEARING, OUTPUT SHAFT FRONT

. 21-237,21-73

BEARING, OUTPUT SHAFT REAR

. . 21-236,21-72

BEARING PRELOAD AND GEAR

BACKLASH, DIFFERENTIAL . . . . . . . . . . 3-50,3-95

BEARINGS, CAMSHAFT

. . . . . . . . . . . 9-113,9-172

BEARINGS, CRANKSHAFT

MAIN . . . . . . . . 9-113,9-141,9-174,9-27,9-61,9-91

BEARINGS, DIFFERENTIAL SIDE

. . . . . . 3-40,3-75

BEARINGS—FITTING, CONNECTING

ROD . . . . . . . . . . . . . . . . . . . . . . 9-100,9-157,9-25

BEARINGS—FITTING, CRANKSHAFT

MAIN . . . . . . . . . . . . . . . . . . . . . . . . . 9-100,9-157

INDEX

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Dodge Durango (DN). Manual - part 467