Chrysler Full-Size Trucks 1989-1996 Repair Guide

Intermediate Shaft

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REMOVAL & INSTALLATION



2.5L Engine

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Use a special tool as shown to extract the intermediate shaft



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Fig. Fig. 2: Install the crankshaft and intermediate shaft oil seal as shown2.5L engine



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Fig. Fig. 3: Use this reference as a guide to correctly install the timing belt and sprockets

  1. Disconnect the negative battery cable.
  2.  
  3. Crank the engine around until the No. 1 piston is at TDC. Remove the timing belt covers to confirm that all timing marks are lined up.
  4.  
  5. Remove the fuel pump, if equipped. Remove the distributor. Looking down at the oil pump, the slot in the shaft must be paralleled with the center line of the crankshaft. Remove the oil pump.
  6.  
  7. Remove the timing belt and the intermediate shaft sprocket.
  8.  
  9. Remove the shaft retainer bolts and remove the retainer from the block.
  10.  
  11. Remove the intermediate shaft from the engine.
  12.  
  13. If necessary, remove the front bushing using tool C-4697-2 and the rear bushing using tool C-4686-2, or their equivalents.
  14.  



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Fig. Fig. 4: Align the crankshaft and intermediate shaft timing marks as shown-2.5L engine

To install:
  1. Install the front bushing using tool C4697-1 until the tool is flush with the block. Install the rear bushing using tool C-4686-1 until the tool is flush with the block.
  2.  
  3. Lubricate the distributor drive gear and install the intermediate shaft.
  4.  
  5. Replace the seal in the retainer and apply silicone sealer to the mating surface of the retainer. Install the retainer to the block and tighten the bolts to 10 ft. lbs. (12 Nm).
  6.  
  7. Install the intermediate shaft sprocket and the timing belt.
  8.  
  9. With the timing belt properly installed, install the oil pump so the slot is parallel to the center line of the crankshaft.
  10.  
  11. Install the distributor so the rotor is aligned with the No. 1 spark plug wire tower on the cap.
  12.  
  13. Install the fuel pump, if equipped.
  14.  
  15. Connect the negative battery cable and road test the vehicle.
  16.