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POLARIS RANGER XP 700 EFI 4X4 , RANGER 6X6 2005 2006 2007 SERVICE MANUAL DIY FACTORY REPAIR MAINTENANCE SHOP MANUAL

POLARIS RANGER XP 700 EFI 4X4 , RANGER 6X6 2005 2006 2007 SERVICE MANUAL DIY FACTORY REPAIR MAINTENANCE SHOP MANUAL Download!
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POLARIS RANGER XP 700 EFI 4X4 , RANGER 6X6 2005 2006 2007 SERVICE MANUAL DIY FACTORY REPAIR MAINTENANCE SHOP MANUAL for sale
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POLARIS RANGER XP 700 EFI 4X4 , RANGER 6X6 2005 2006 2007 SERVICE MANUAL DIY FACTORY REPAIR MAINTENANCE SHOP MANUAL
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Original POLARIS RANGER XP 700 EFI 4X4 , RANGER 6X6 2005 2006 2007 SERVICE MANUAL DIY FACTORY REPAIR MAINTENANCE SHOP MANUAL instant download.
Pages: 330 + CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION 1.2 MODEL IDENTIFICATION 1.2 ENGINE DESIGNATION NUMBER. 1.2 VIN IDENTIFICATION . 1.2 ENGINE SERIAL NUMBER LOCATION . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION. 1.3 TRANSMISSION I.D. NUMBER LOCATION1.3 VEHICLE DIMENSIONS 1.4 VEHICLE DIMENSIONS RANGER 4X4, 6X6 1.5 GENERAL SPECIFICATIONS 1.6 MODEL: RANGER XP 4X4 . 1.6 MODEL: RANGER XP 6X6 . 1.6 MODEL: RANGER XP 4X4 . 1.7 MODEL: RANGER XP 6X6 . 1.8 VEHICLE INFORMATION . 1.9 PUBLICATION NUMBERS1.9 PAINT CODES . 1.9 REPLACEMENT KEYS 1.9 SPECIAL TOOLS . 1.9 MISC. SPECIFICATIONS AND CHARTS 1.10 CONVERSION TABLE 1.10 STANDARD TORQUE SPECIFICATIONS . 1.11 SAE TAP / DRILL SIZES 1.12 METRIC TAP / DRILL SIZES . 1.12 DECIMAL EQUIVALENTS. 1.12 GLOSSARY OF TERMS. 1.13 MAINTENANCE PERIODIC MAINTENANCE CHART . 2.3 PERIODIC MAINTENANCE OVERVIEW. 2.3 MAINTENANCE CHART KEY . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL2.4 50 - 100 HOUR MAINTENANCE INTERVAL2.5 100 - 300 HOUR MAINTENANCE INTERVAL . 2.6 GENERAL COMPONENT LOCATIONS 2.7 RH SIDE AND DASH VIEW (4X4) 2.7 LH SIDE AND REAR VIEW (4X4) 2.8 LH SIDE AND RH SIDE VIEWS (6X6) . 2.9 SERVICE PRODUCTS AND LUBES 2.10 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS. 2.10 MAINTENANCE REFERENCES . 2.11 MAINTENANCE REFERENCES, CONTINUED. 2.12 GENERAL VEHICLE INSPECTION AND MAINTENANCE . 2.13 PRE-RIDE / DAILY INSPECTION. 2.13 FRAME, NUTS, BOLTS, AND FASTENERS . 2.13 SHIFT LINKAGE INSPECTION / ADJUSTMENT2.13 FUEL SYSTEM AND AIR INTAKE. 2.14 FUEL SYSTEM 2.14 FUEL LINES2.14 FUEL FILTER . 2.14 VENT LINES 2.14 THROTTLE PEDAL INSPECTION. 2.14 THROTTLE FREEPLAY ADJUSTMENT 2.15 AIR FILTER SERVICE 2.15 AIR INTAKE INSPECTION . 2.16 ENGINE 2.17 COMPRESSION AND LEAKDOWN TEST . 2.17 BREATHER HOSE INSPECTION. 2.17 ENGINE OIL LEVEL2.17 ENGINE OIL AND FILTER CHANGE . 2.18 EXHAUST PIPE . 2.19 TRANSMISSION AND GEARCASES . 2.20 TRANSMISSION LUBRICATION. 2.20 FRONT GEARCASE LUBRICATION (4X4)2.21 MIDDLE GEARCASE LUBRICATION (6X6) . 2.22 REAR GEARCASE LUBRICATION (4X4). 2.23 REAR GEARCASE LUBRICATION (6X6). 2.24 COOLING SYSTEM . 2.25 LIQUID COOLING SYSTEM OVERVIEW. 2.25 COOLANT LEVEL INSPECTION 2.25 RADIATOR COOLANT LEVEL INSPECTION 2.26 COOLANT STRENGTH / TYPE . 2.26 COOLING SYSTEM PRESSURE TEST. 2.26 COOLING SYSTEM HOSES . 2.26 RADIATOR. 2.27 COOLANT DRAIN / RADIATOR REMOVAL . 2.27 2.2 GENERAL INFORMATION FINAL DRIVE / WHEEL AND TIRE . 2.27 WHEEL, HUB, AND SPINDLE TORQUE TABLE2.27 CV SHAFT BOOT INSPECTION 2.28 WHEEL REMOVAL2.28 WHEEL INSTALLATION 2.28 TIRE INSPECTION . 2.28 TIRE PRESSURE2.29 ELECTRICAL AND IGNITION SYSTEM . 2.29 BATTERY MAINTENANCE2.29 BATTERY FLUID LEVEL (CONVENTIONAL BATTERY). 2.29 BATTERY REMOVAL . 2.29 BATTERY INSTALLATION . 2.30 BATTERY STORAGE . 2.30 BATTERY CHARGING 2.30 SPARK PLUG SERVICE 2.30 ENGINE TO FRAME GROUND . 2.31 STEERING AND SUSPENSION . 2.31 STEERING. 2.31 TIE ROD END / STEERING INSPECTION2.31 CAMBER AND CASTER 2.31 WHEEL TOE ALIGNMENT INSPECTION. 2.32 TOE ADJUSTMENT2.32 FRONT SUSPENSION 2.33 REAR SUSPENSION . 2.33 REAR SUSPENSION ADJUSTMENT (4X4) . 2.33 REAR SPRING ADJUSTMENT . 2.34 BRAKE SYSTEM. 2.34 BRAKE SYSTEM INSPECTION. 2.34 BRAKE PAD INSPECTION2.34 PARKING BRAKE PAD INSPECTION 2.35 BRAKE HOSE AND FITTING INSPECTION . 2.35 CHAPTER 3 ENGINE 3 ENGINE ENGINE SPECIFICATIONS. 3.2 CRANKCASE EXPLODED VIEWS. 3.2 ENGINE FASTENER TORQUE PATTERNS3.9 TORQUE SPECIFICATIONS . 3.10 700 EFI ENGINE SERVICE SPECIFICATIONS. 3.11 SPECIAL TOOLS 3.13 GENERAL ENGINE SERVICE 3.13 ACCESSIBLE COMPONENTS 3.13 PISTON IDENTIFICATION . 3.13 COOLING SYSTEM SPECIFICATIONS. 3.13 COOLING SYSTEM PRESSURE TEST. 3.14 COOLING SYSTEM EXPLODED VIEW. 3.15 COOLING SYSTEM BLEEDING PROCEDURE 3.15 VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) 3.17 ENGINE REMOVAL3.18 ENGINE INSTALLATION NOTES. 3.19 CYLINDER HONE SELECTION AND HONING PROCEDURE. 3.20 HONING TO DEGLAZE . 3.20 CLEANING THE CYLINDER AFTER HONING . 3.21 ENGINE LUBRICATION SPECIFICATIONS . 3.21 OIL PRESSURE TEST 3.21 OIL FLOW CHART. 3.22 ENGINE DISASSEMBLY AND INSPECTION . 3.23 CYLINDER HEAD ASSEMBLY EXPLODED VIEW3.23 ROCKER ARMS / PUSH RODS. 3.24 CYLINDER HEAD REMOVAL 3.24 CYLINDER HEAD INSPECTION 3.25 CYLINDER HEAD WARP3.25 VALVE SEAL / SPRING SERVICE (ON ENGINE) . 3.25 CYLINDER HEAD DISASSEMBLY3.26 VALVE INSPECTION . 3.27 COMBUSTION CHAMBER . 3.28 VALVE SEAT RECONDITIONING. 3.28 CYLINDER HEAD REASSEMBLY. 3.30 VALVE SEALING TEST . 3.31 CYLINDER REMOVAL 3.31 VALVE LIFTER REMOVAL / INSPECTION3.31 PISTON REMOVAL3.32 CYLINDER INSPECTION3.33 PISTON-TO-CYLINDER CLEARANCE . 3.34 PISTON / ROD INSPECTION . 3.34 PISTON RING INSTALLED GAP 3.35 STARTER DRIVE BENDIX REMOVAL / INSPECTION . 3.35 FLYWHEEL / STATOR REMOVAL / INSPECTION3.36 ENGINE CRANKCASE DISASSEMBLY / INSPECTION 3.36 CAMSHAFT INSPECTION . 3.44 ENGINE REASSEMBLY . 3.45 CRANKCASE REASSEMBLY 3.45 FLYWHEEL / STATOR INSTALLATION 3.54 CYLINDER HEAD REASSEMBLY. 3.54 OIL PUMP PRIMING . 3.57 TROUBLESHOOTING CHAPTER 4 FUEL INJECTION 4 GENERAL INFORMATION 4.2 SPECIAL TOOLS . 4.2 SERVICE NOTES. 4.4 EFI SYSTEM EXPLODED VIEW . 4.5 EFI SYSTEM COMPONENT LOCATIONS. 4.6 FUEL TANK 4.8 EXPLODED VIEW 4.8 FUEL LINES - QUICK CONNECT 4.9 ELECTRONIC FUEL INJECTION . 4.9 PRINCIPAL COMPONENTS4.9 EFI OPERATION OVERVIEW . 4.9 INITIAL PRIMING / STARTING PROCEDURE . 4.10 ELECTRONIC CONTROL UNIT (ECU) 4.10 OPERATION OVERVIEW. 4.10 ECU SERVICE 4.11 ECU REPLACEMENT 4.11 FUEL PUMP4.11 OPERATION OVERVIEW. 4.11 FUEL PUMP TEST. 4.12 FUEL PUMP / TANK ASSEMBLY REPLACEMENT . 4.12 FUEL PRESSURE REGULATOR 4.14 OPERATION OVERVIEW. 4.14 FUEL PRESSURE REGULATOR TEST 4.14 FUEL PRESSURE REGULATOR REPLACEMENT 4.14 FUEL INJECTORS. 4.14 OPERATION OVERVIEW. 4.14 FUEL INJECTOR SERVICE 4.15 FUEL INJECTOR REPLACEMENT4.15 CRANKSHAFT POSITION SENSOR (CPS)4.15 OPERATION OVERVIEW. 4.15 CPS TEST. 4.16 CPS REPLACEMENT . 4.16 TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP). 4.16 OPERATION OVERVIEW. 4.16 T-BAP TEST4.16 T-BAP REPLACEMENT . 4.16 THROTTLE POSITION SENSOR (TPS) . 4.17 OPERATION OVERVIEW. 4.17 TPS TEST4.17 TPS INITIALIZATION . 4.18 TPS REPLACEMENT . 4.19 ENGINE COOLANT TEMPERATURE SENSOR (ECT) . 4.19 OPERATION OVERVIEW. 4.19 ECT SENSOR TEST . 4.20 ECT SENSOR REPLACEMENT. 4.20 GENERAL TROUBLESHOOTING4.21 DIAGNOSTIC �BLINK CODES� . 4.21 EFI TROUBLESHOOTING. 4.22 BODY / STEERING / SUSPENSION 5 TORQUE SPECIFICATIONS . 5.2 SPECIAL TOOLS . 5.2 BODY COMPONENT REMOVAL . 5.3 REMOVAL PROCEDURES. 5.3 LOWER BODY COMPONENTS 5.4 HOOD / DASH COMPONENTS 5.5 DASH INSTRUMENTS AND CONTROLS 5.6 CAB FRAME. 5.7 ASSEMBLY / REMOVAL . 5.7 CHASSIS / MAIN FRAME (4X4) 5.8 EXPLODED VIEW 5.8 CHASSIS / MAIN FRAME (6X6) 5.9 EXPLODED VIEW 5.9 SEAT / HEAD REST5.10 SEAT BASE / SEAT BACK / HEAD REST ASSEMBLY. 5.10 STEERING ASSEMBLY . 5.11 EXPLODED VIEW. 5.11 STEERING AND SUSPENSION . 5.12 EXPLODED VIEW. 5.12 FRONT A-ARM 5.13 REPLACEMENT. 5.13 FRONT STRUT 5.14 EXPLODED VIEW. 5.14 FRONT STRUT CARTRIDGE REPLACEMENT 5.15 BALL JOINT REPLACEMENT 5.15 MID AXLE A-ARM (6X6) . 5.16 REPLACEMENT. 5.16 REAR A-ARM (4X4) . 5.17 REPLACEMENT. 5.17 REAR STABILIZER BAR (4X4) 5.19 REMOVAL / INSTALLATION . 5.19 SWING ARM (6X6). 5.20 REMOVAL. 5.20 INSTALLATION . 5.20 REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6). 5.21 REAR CARGO BOX5.22 CARGO BOX - PANELS. 5.22 CARGO BOX - TAILGATE / BOX SUPPORT . 5.23 BOX REMOVAL . 5.24 BOX INSTALLATION . 5.24 STORAGE BOX 5.25 REMOVAL. 5.25 INSTALLATION . 5.25 DECAL REPLACEMENT. 5.25 CHAPTER 6 CLUTCHING 6 SPECIAL TOOLS AND SUPPLIES 6.2 TORQUE SPECIFICATIONS . 6.2 PVT SYSTEM FASTENER TORQUES 6.2 PVT SYSTEM OVERVIEW 6.2 GENERAL OPERATION 6.2 DRIVE CLUTCH OPERATION . 6.2 DRIVEN CLUTCH OPERATION 6.3 MAINTENANCE / INSPECTION 6.3 OVERHEATING / DIAGNOSIS . 6.4 PVT SYSTEM SERVICE 6.5 PVT SEALING, GUARD, AND DUCTING COMPONENTS. 6.5 DISASSEMBLY . 6.5 ASSEMBLY. 6.6 DRIVE BELT. 6.7 BELT DEFLECTION (TENSION) . 6.7 BELT REMOVAL . 6.7 BELT INSPECTION. 6.8 BELT INSTALLATION . 6.9 CLUTCH ALIGNMENT / OFFSET . 6.9 CLUTCH ALIGNMENT . 6.9 CLUTCH OFFSET. 6.10 DRIVE CLUTCH SERVICE. 6.11 SPRING SPECIFICATIONS6.11 SHIFT WEIGHTS 6.12 EXPLODED VIEW. 6.13 CLUTCH INSPECTION . 6.13 CLUTCH DISASSEMBLY6.14 SPIDER REMOVAL6.15 ROLLER, PIN, AND THRUST WASHER INSPECTION. 6.15 BUSHING SERVICE 6.16 MOVEABLE SHEAVE - BUSHING REMOVAL . 6.16 MOVEABLE SHEAVE - BUSHING INSTALLATION . 6.16 CLUTCH COVER - BUSHING REMOVAL. 6.17 CLUTCH COVER - BUSHING INSTALLATION . 6.17 CLUTCH ASSEMBLY . 6.18 DRIVEN CLUTCH SERVICE 6.19 EXPLODED VIEW. 6.19 CLUTCH DISASSEMBLY / INSPECTION. 6.19 CLUTCH ASSEMBLY . 6.21 TROUBLESHOOTING . 6.22 CHAPTER 7 FINAL DRIVE 7 SPECIAL TOOLS . 7.3 TORQUE SPECIFICATIONS . 7.3 WHEEL, HUB, AND SPINDLE TORQUE TABLE. 7.3 FRONT HUB. 7.3 HUB REMOVAL / INSPECTION 7.3 HUBSTRUT BEARING REPLACEMENT . 7.4 HUB INSTALLATION7.5 FRONT HUB EXPLODED VIEW . 7.6 DRIVE SHAFT / PROPSHAFT . 7.7 EXPLODED VIEW 7.7 DRIVESHAFT / CV JOINT HANDLING TIPS7.8 FRONT DRIVE SHAFT . 7.8 REMOVAL 7.8 CV JOINT / BOOT REPLACEMENT7.9 INSTALLATION . 7.11 FRONT PROPSHAFT REMOVAL7.11 PROPSHAFT U-JOINT SERVICE7.12 DISASSEMBLY 7.12 ASSEMBLY7.13 FRONT GEARCASE CENTRALIZED HILLIARD 7.14 AWD OPERATION. 7.14 CENTRALIZED HILLIARD EXPLODED VIEW 7.15 AWD DIAGNOSIS7.16 GEARCASE REMOVAL . 7.17 GEARCASE DISASSEMBLY / INSPECTION . 7.18 GEARCASE REASSEMBLY / INSPECTION . 7.20 BACKLASH PAD (THRUST PAD) ADJUSTMENT . 7.22 GEARCASE INSTALLATION . 7.23 MID DRIVE HUB / BEARING CARRIER (6X6) 7.23 REMOVAL. 7.23 HUB DISASSEMBLY . 7.24 HUB ASSEMBLY 7.24 HUB INSTALLATION . 7.25 MID DRIVE EXPLODED VIEW 7.26 MID DRIVE SHAFT (6X6) 7.27 REMOVAL. 7.27 DISASSEMBLY / ASSEMBLY 7.27 INSTALLATION . 7.27 MID PROP SHAFT (6X6). 7.28 REMOVAL. 7.28 MID DRIVE GEARCASE (6X6) 7.28 GEARCASE REMOVAL . 7.28 GEARCASE DISASSEMBLY . 7.29 GEARCASE ASSEMBLY 7.32 GEARCASE INSTALLATION . 7.34 MID GEARCASE EXPLODED 7.35 REAR DRIVE (4X4). 7.36 EXPLODED VIEW. 7.36 7.2 FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) 7.36 HUB INSPECTION. 7.36 HUB REMOVAL . 7.36 HUB DISASSEMBLY . 7.37 HUB ASSEMBLY 7.38 HUB INSTALLATION . 7.38 REAR DRIVE SHAFT (4X4)7.39 REMOVAL. 7.39 CV JOINT / BOOT REPLACEMENT . 7.40 INSTALLATION . 7.42 REAR PROPSHAFT (4X4). 7.43 REMOVAL. 7.43 INSTALLATION . 7.43 REAR GEARCASE (4X4) 7.44 GENERAL OPERATION 7.44 OPERATION MODES 7.45 DIFFERENTIAL REMOVAL7.46 DIFFERENTIAL DISASSEMBLY 7.46 DIFFERENTIAL ASSEMBLY . 7.49 DIFFERENTIAL INSTALLATION 7.51 DIFFERENTIAL EXPLODED VIEW7.52 REAR AXLE / GEARCASE SERVICE (6X6)7.53 REAR AXLE REMOVAL. 7.53 AXLE TUBE REMOVAL . 7.54 AXLE TUBE BEARING REPLACEMENT7.55 GEARCASE DISASSEMBLY / INSPECTION 7.55 GEARCASE ASSEMBLY 7.56 GEARCASE / AXLE INSTALLATION . 7.57 GEARCASE EXPLODED VIEW. 7.60 CHAPTER 8 TRANSMISSION 8 TORQUE SPECIFICATIONS . 8.2 SHIFT LEVER8.2 REMOVAL 8.2 INSTALLATION 8.2 SHIFT LINKAGE 8.2 INSPECTION8.2 ADJUSTMENT . 8.3 TRANSMISSION SERVICE8.3 TRANSMISSION REMOVAL8.3 TRANSMISSION DISASSEMBLY 8.5 TRANSMISSION ASSEMBLY 8.10 TRANSMISSION INSTALLATION. 8.14 TROUBLESHOOTING . 8.15 TROUBLESHOOTING CHECKLIST 8.15 TRANSMISSION EXPLODED VIEW 8.16 EXPLODED VIEW (4X4, 6X6) 8.16 CHAPTER 9 BRAKES 9 GENERAL SPECIFICATIONS / TORQUE SPECIFICATIONS / SPECIAL TOOLS. 9.2 BRAKE SYSTEM SERVICE NOTES . 9.3 BRAKE NOISE TROUBLESHOOTING . 9.3 HYDRAULIC BRAKE SYSTEM OPERATION 9.4 BRAKE SYSTEM EXPLODED VIEW9.5 MASTER CYLINDER . 9.6 REMOVAL / INSTALLATION9.6 FOOT BRAKE PEDAL 9.6 PEDAL REMOVAL / INSTALLATION 9.6 BRAKE BLEEDING / FLUID CHANGE . 9.7 PARKING BRAKE . 9.8 EXPLODED VIEW 9.8 INSPECTION / ADJUSTMENT . 9.9 PARKING BRAKE CALIPER SERVICE . 9.10 EXPLODED VIEW. 9.10 CALIPER REMOVAL . 9.10 CALIPER DISASSEMBLY / INSPECTION. 9.11 NEW BRAKE PAD INSTALLATION9.12 CALIPER INSTALLATION. 9.12 PARKING BRAKE DISC SERVICE. 9.12 DISC REMOVAL / INSPECTION 9.12 FRONT BRAKE PADS . 9.13 PAD REMOVAL / DISASSEMBLY / INSPECTION . 9.13 PAD ASSEMBLY / INSTALLATION / ADJUSTMENT 9.14 FRONT CALIPER 9.15 FRONT CALIPER EXPLODED VIEW 9.15 CALIPER REMOVAL / DISASSEMBLY . 9.15 CALIPER INSPECTION / ASSEMBLY 9.16 CALIPER INSTALLATION. 9.17 FRONT BRAKE DISC . 9.18 DISC INSPECTION / REMOVAL / REPLACEMENT . 9.18 REAR BRAKE PAD (4X4) 9.18 PAD REMOVAL . 9.18 PAD INSPECTION / INSTALLATION . 9.19 REAR BRAKE PAD (6X6) 9.20 PAD REMOVAL . 9.20 PAD INSPECTION / INSTALLATION . 9.21 REAR CALIPER 9.22 REAR CALIPER EXPLODED VIEW 9.22 CALIPER REMOVAL (4X4)9.22 CALIPER REMOVAL (6X6)9.23 CALIPER DISASSEMBLY. 9.23 CALIPER INSPECTION / ASSEMBLY 9.24 CALIPER INSTALLATION (4X4, 6X6) 9.25 REAR BRAKE DISC9.25 TROUBLESHOOTING . 9.26 BRAKES SQUEAL / POOR BRAKE PERFORMANCE . 9.26 PEDAL VIBRATION9.26 CALIPER OVERHEATS (BRAKES DRAG)9.26 BRAKES LOCK 9.26 CHAPTER 10 ELECTRICAL 10 GENERAL INFORMATION. 10.3 SPECIAL TOOLS 10.3 ELECTRICAL SERVICE NOTES 10.3 UNDER-HOOD COMPONENTS 10.3 SWITCHES / CONTROLS. 10.4 HEADLAMP SWITCH . 10.4 AWD / REAR DIFFERENTIAL SWITCH (4X4) 10.4 DIFFERENTIAL SOLENOID (4X4). 10.4 BRAKE LIGHT SWITCH. 10.5 PARKING BRAKE SWITCH10.6 INSTRUMENT CLUSTER 10.7 OVERVIEW . 10.7 RIDER INFORMATION DISPLAY. 10.7 STANDARD DISPLAY MODES . 10.8 DIAGNOSTIC DISPLAY MODE . 10.8 VIEWING DIAGNOSTIC CODES. 10.10 INSTRUMENT CLUSTER REMOVAL . 10.11 INSTRUMENT CLUSTER INSTALLATION . 10.11 INSTRUMENT CLUSTER TROUBLESHOOTING TESTS10.12 TEST 1 - NO ALL WHEEL DRIVE10.12 TEST 2 - NO DISPLAY. 10.13 TEST 3 - WHEEL SPEED SENSOR 10.13 TEST 4 - NO AWD HUB SAFETY LIMITER . 10.14 TEST 5 - FUEL GAUGE DISPLAY NOT WORKING 10.15 TEST 6 - SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) . 10.15 ALL WHEEL DRIVE (AWD) COIL. 10.16 OPERATION OVERVIEW10.16 DIAGNOSING SYSTEM FAILURES . 10.16 GEAR POSITION INDICATOR SWITCH10.16 TEST DIAGRAM10.16 HEAD LIGHTS 10.17 HIGH BEAM HEADLIGHT ADJUSTMENT 10.17 HEADLAMP BULB REPLACEMENT 10.17 HEADLAMP HOUSING REMOVAL . 10.17 HEADLAMP HOUSING INSTALLATION. 10.18 TAIL LIGHT / BRAKE LIGHT . 10.18 LAMP REPLACEMENT 10.18 COOLING SYSTEM 10.19 COOLING SYSTEM BREAK-OUT DIAGRAM . 10.19 FAN CONTROL CIRCUIT OPERATION / TESTING 10.20 FAN CONTROL CIRCUIT BYPASS TEST 10.20 COOLANT TEMPERATURE SENSOR 10.20 EFI DIAGNOSTICS10.20 EFI COMPONENT TESTING 10.20 FUEL SENDER pecno1. 10.20 TESTING. 10.20 RELAYS. 10.21 OPERATION . 10.21 FUSES / CIRCUIT BREAKER 10.22 OPERATION . 10.22 10.2 ELECTRICAL CHARGING SYSTEM 10.22 CURRENT DRAW - KEY OFF . 10.22 CHARGING SYSTEM �BREAK EVEN� TEST . 10.23 CHARGING SYSTEM ALTERNATOR TESTS. 10.23 CHARGING SYSTEM TESTING FLOW CHART. 10.25 BATTERY TERMINAL BLOCK . 10.26 BATTERY SERVICE . 10.26 BATTERY TERMINALS / BOLTS . 10.26 BATTERY IDENTIFICATION 10.26 CONVENTIONAL BATTERY . 10.27 BATTERY ACTIVATION10.27 BATTERY INSPECTION. 10.27 BATTERY REMOVAL 10.28 BATTERY INSTALLATION 10.28 CONVENTIONAL BATTERY TESTING10.28 OCV - OPEN CIRCUIT VOLTAGE TEST . 10.28 SPECIFIC GRAVITY TEST . 10.28 LOAD TEST . 10.29 OFF SEASON STORAGE10.29 CHARGING PROCEDURE . 10.29 LOW MAINTENANCE BATTERY. 10.30 BATTERY CHECK10.30 BATTERY INSPECTION. 10.30 BATTERY REMOVAL 10.30 BATTERY INSTALLATION 10.31 BATTERY TESTING . 10.31 OCV - OPEN CIRCUIT VOLTAGE TEST . 10.31 LOAD TEST . 10.31 OFF-SEASON STORAGE10.32 BATTERY CHARGING. 10.32 STARTER SYSTEM . 10.33 TROUBLESHOOTING . 10.33 VOLTAGE DROP TEST 10.33 STARTER MOTOR REMOVAL / DISASSEMBLY10.33 BRUSH INSPECTION / REPLACEMENT10.34 ARMATURE TESTING. 10.35 STARTER REASSEMBLY / INSTALLATION 10.35 STARTER SOLENOID BENCH TEST . 10.36 STARTER DRIVE . 10.36 STARTER EXPLODED VIEW . 10.37 STARTER SYSTEM TESTING FLOW CHART. 10.38 ELECTRIC BOX LIFT ACTUATOR10.39 --- DETAILED INDEX: === Air Filter Service 2.15 Air Intake Inspection . 2.16 All Wheel Drive (AWD) Coil . 10.16 AWD Diagnostics 10.9 AWD, Diagnosis . 7.16 AWD, Operation . 7.14 B Balance Shaft Gear, Removal . 3.40 Ball Joint, Replacement . 5.15 Battery Charging . 2.30 Battery Fluid Level. 2.29 Battery Installation. 2.30 Battery Maintenance2.29 Battery Removal . 2.29 Battery Service . 10.26 Battery Storage 2.30 Battery Terminal Block 10.26 Battery, Conventional 10.27 Battery, Sealed Low Maintenance10.30 Body Removal . 5.3 Brake Disc, Front 9.18 Brake Disc, Rear . 9.25 Brake Hose and Fitting Inspection. 2.35 Brake Pad Inspection . 2.34 Brake Pad, Rear . 9.18 Brake Pad, Rear (6x6) 9.20 Brake Pads, Front 9.13 Brake Pedal, Installation 9.6 Brake Pedal, Removal . 9.6 Brake System Inspection 2.34 Brake System, Bleeding 9.7 Brake System, Exploded View . 9.5 Brake System, Operation . 9.4 Breather Hose Inspection 2.17 C Cab Frame, Assembly / Removal . 5.7 Caliper, Front . 9.15 Caliper, Rear9.22 Cam Gear, Reassembly 3.39 Cam Gear, Removal3.38 Cargo Box, Installation 5.24 Cargo Box, Removal . 5.24 Centralized Hilliard, Exploded View . 7.15 Charging System 10.22 Circuit Breaker . 10.22 Clock, Setting . 10.8 Clutch Alignment . 6.9 Clutch Offset6.10 Combustion Chamber . 3.28 Compression Test 2.17 Conversion Chart 1.10 Coolant Level Inspection 2.25 Coolant Strength and Type. 2.26 Cooling System Bleeding Procedure 3.15 Cooling System Hoses 2.26 Cooling System Pressure Test .2.26 Cooling System Specifications 3.13 Cooling System, Pressure Test 3.14 Crankshaft Gear, Removal.3.40 Crankshaft Position Sensor (CPS)4.15 CV Shaft Boot Inspection2.28 Cylinder Head Assembly3.30 Cylinder Head Assembly Exploded View.3.23 Cylinder Head Disassembly 3.26 Cylinder Honing To De-glaze .3.20 Cylinder Inspection.3.33 D Decal Replacement.5.25 Decimal Equivalent Chart1.12 Diagnostic Codes, Instrument Cluster 10.10 Diagnostics, AWD.10.9 Diagnostics, Gear Circuit10.9 Drive Belt, Deflection 6.7 Drive Belt, Inspection 6.8 Drive Belt, Installation .6.9 Drive Belt, Removal.6.7 Drive Clutch, Assembly .6.18 Drive Clutch, Bushing Service 6.16 Drive Clutch, Disassembly.6.14 Drive Clutch, Exploded View .6.13 Drive Clutch, Inspection .6.13 Drive Clutch, Operation 6.2 Drive Clutch, Service .6.11 Drive Clutch, Shift Weights 6.12 Drive Clutch, Spider Removal 6.15 Drive Clutch, Spring 6.11 Driven Clutch, Assembly6.21 Driven Clutch, Disassembly / Inspection6.19 Driven Clutch, Exploded View 6.19 Driven Clutch, Operation .6.3 Driven Clutch, Service 6.19 Driveshaft / CV Joint, Handling Tips 7.8 Driveshaft / Propshaft, Exploded View .7.7 Driveshaft, Mid Drive (6x6) 7.27 E EFI Operation Overview 4.9 EFI Priming / Starting Procedure4.10 EFI Troubleshooting 4.22 Electric Box Lift Actuator.10.39 Electrical, Cooling System Breakout Diagram .10.19 Electronic Control Unit (ECU) 4.10 Engine Balance Shaft Removal 3.44 Engine Camshaft Inspection 3.44 Engine Camshaft Installation .3.46 Engine Cooling System . 3.13, 3.14 Engine Cooling System Troubleshooting3.59 Engine Crankcase Assembly 3.45 Engine Crankshaft Gear Removal3.41 IX.2 Engine Crankshaft Installation 3.46 Engine Cylinder Head Assembly3.30 Engine Cylinder Head Inspection3.25 Engine Cylinder Head Removal .3.24 Engine Cylinder Head Warp 3.25 Engine Cylinder Honing .3.20 Engine Cylinder Inspection.3.33 Engine Cylinder Installation 3.47 Engine Cylinder Removal3.31 Engine Designation Number.1.2 Engine Diagnostic Codes4.21 Engine Exploded Views . 3.2, 3.3, 3.4, 3.5, 3.7, 3.8 Engine Fastener Torques 3.9 Engine Flywheel / Stator Installation .3.54 Engine Flywheel / Stator Removal.3.36 Engine Flywheel Removal.3.37 Engine Gear(s) Removal .3.37 Engine Gears, Installation3.49 Engine Head Assembly 3.54 Engine Installation Notes3.19 Engine Lubrication.3.21 Engine Oil and Filter Change .2.18 Engine Oil Flow Chart 3.22 Engine Oil Level .2.17 Engine Oil Pressure Test .3.21 Engine Oil Priming.3.57 Engine Oil Pump Installation .3.48 Engine Oil Pump Removal.3.41 Engine Piston Identification 3.13 Engine Piston Installation3.47 Engine Piston Removal, Inspection 3.32 Engine Piston Ring Installed Gap3.35 Engine Piston to Cylinder Clearance .3.34 Engine Piston to Rod Clearance .3.34 Engine Pushrod Inspection.3.24 Engine Removal / Install Procedure 3.18 Engine Rocker Arm Inspection 3.24 Engine Serial Number Location 1.2 Engine Service Specifications .3.11 Engine Speed Display .10.8 Engine Starter Drive Removal 3.35 Engine Starter Removal .3.37 Engine Stator Gear Cover Seal(s) Installation 3.51 Engine Stator Installation3.54 Engine Temperature Sensor 4.19 Engine Temperature Sensor Replacement.4.20 Engine Temperature Sensor Test4.20 Engine Torque Table 3.10 Engine Troubleshooting .3.58 Engine Valve Inspection .3.27 Engine Valve Lifter Removal, Inspection3.31 Engine Valve Seal/Spring Service.3.25 Engine Valve Sealing Test.3.31 Engine Valve Seat Reconditioning.3.28 Engine, Accessible Components .3.13 Exhaust Pipe2.19 F Fan Control Circuit Bypass Test. 10.20 Fan Control Circuit Operation . 10.20 Flywheel / Stator Removal. 3.36 Flywheel, Removal3.36 Front A-arm, Replacement. 5.13 Front Driveshaft, CV Joint / Boot Replacement . 7.9 Front Driveshaft, Installation . 7.11 Front Driveshaft, Removal 7.8 Front Gearcase Lubrication2.21 Front Gearcase, Assembly. 7.20 Front Gearcase, Backlash Pad Adjustment7.22 Front Gearcase, Centralized Hilliard . 7.14 Front Gearcase, Disassembly / Inspection. 7.18 Front Gearcase, Installation7.23 Front Gearcase, Removal 7.17 Front Hub . 7.3 Front Propshaft, Removal. 7.11 Front Propshaft, U-Joint Service 7.12 Front Strut, Cartridge Replacement5.15 Front Strut, Exploded View5.14 Front Suspension 2.33 Fuel Filter 2.14 Fuel Injection, Component Locations . 4.6 Fuel Injection, Exploded View 4.5 Fuel Injection, Service Notes4.4 Fuel Injection, Special Tools4.2 Fuel Injector4.14 Fuel Lines 2.14 Fuel Pressure Regulator . 4.14 Fuel Pump / Tank Assembly . 4.11 Fuel Sender Test 10.20 Fuel System2.14 Fuel Tank Location. 4.8 Fuses . 10.22 G Gear / Stator Housing Seal Replacement 3.51 Gear Circuit Diagnostics 10.9 Gear Position Indicator Switch Test 10.16 General Specifications, Brakes 9.2 H Head Lights . 10.17 Hour Meter. 10.8 Hub / Bearing Carrier, Mid Drive (6x6) 7.23 Hub / Bearing Carrier, Rear (4x4). 7.36 I Indicator, Service Interval. 10.9 Instrument Cluster. 10.7 K Keys, Replacement 1.9 Kilometers to Miles Toggle . 10.10 IX.3 IX M Maintenance, Brake System2.34 Maintenance, Cooling System 2.25 Maintenance, Electrical and Ignition . 2.29 Maintenance, Engine . 2.17 Maintenance, Final Drive 2.27 Maintenance, Fuel System. 2.14 Maintenance, General Vehicle Inspection. 2.13 Maintenance, References 2.11 Maintenance, Service Products and Lubricants . 2.10 Maintenance, Steering and Suspension . 2.31 Maintenance, Transmission and Gearcases2.20 Master Cylinder, Installation9.6 Master Cylinder, Removal 9.6 Mid Axle A-arm, Replacement . 5.16 Mid Drive Gearcase (6x6). 7.28 Middle Gearcase Lubrication . 2.22 Miles to Kilometers Toggle . 10.10 Model Identification. 1.2 O Odometer 10.8 Oil Pump, Disassembly . 3.41 Oil Pump, Reassembly 3.42 Oil Pump, Removal3.41 P Paint Codes 1.9 Parking Brake Caliper Service 9.10 Parking Brake Disc. 9.12 Parking Brake Pad Inspection . 2.35 Parking Brake, Adjustment 9.9 Parking Brake, Exploded View 9.8 Parking Brake, Inspection . 9.9 Periodic Maintenance Chart. 2.3 Piston Ring Installed Gap 3.35 Piston to Cylinder Clearance . 3.34 Piston to Rod Inspection . 3.34 Pre-Ride / Daily Inspection2.13 Programmable Service Interval . 10.9 Propshaft, Mid Drive (6x6)7.28 Publication Numbers1.9 PVT System, Assembly 6.6 PVT System, Disassembly 6.5 PVT System, Maintenance 6.3 PVT System, Overview 6.2 PVT System, Service6.5 PVT Troubleshooting . 6.23 R Radiator . 2.27 Radiator Coolant Level Inspection. 2.26 Rear A-arm, Replacement. 5.17 Rear Axle Service (6x6) . 7.53 Rear Axle, Exploded View. 5.21 Rear Cargo Box . 5.22 Rear Driveshaft (4x4), CV Joint / Boot Replacement 7.40 Rear Driveshaft (4x4), Installation.7.42 Rear Driveshaft (4x4), Removal .7.39 Rear Gearcase (4x4) 7.44 Rear Gearcase Lubrication (4x4)2.23 Rear Gearcase Lubrication (6x6)2.24 Rear Propshaft Service 7.43 Rear Spring Adjustment .2.34 Rear Stabilizer Bar.5.19 Rear Suspension .2.33 Rear Suspension Adjustment (4x4).2.34 Relays 10.21 S Service Interval Indicator10.9 Shift Lever, Removal 8.2 Shift Lever,Installation .8.2 Shift Linkage Inspection and Adjustment2.13 Shift Linkage, Adjustment8.3 Shift Linkage, Inspection .8.2 Solenoid, Differential .10.4 Spark Plug Service.2.30 Special Tool, Cam Gear Installation Kit .3.39 Special Tools.1.9 Special Tools, Body/Steering/Suspension .5.2 Special Tools, Brakes 9.2 Special Tools, Clutching 6.2 Special Tools, Electrical .10.3 Special Tools, Engine .3.13 Special Tools, Final Drive .7.3 Specification, Balance Shaft Gear Bolt Torque .3.50 Specification, Cam Lobe Height .3.44 Specification, Cam Thrust Plate Fastener Torque3.48 Specification, Camshaft Gear Bolt Torque.3.50 Specification, Coolant Sensor Resistance.10.20 Specification, Cylinder Head Warp 3.25 Specification, Cylinder Taper Limit 3.33 Specification, Cylinder Warp Limit 3.33 Specification, Oil Pump Bolt Torque .3.49 Specification, Oil Pump Rotor Clearance3.41 Specification, Timing Gear Alignment 3.37 Specification, Valve Seat Contact Width3.29 Specification, Valve Spring Free Length3.26 Specification, Valve Stem Diameter 3.27 Specification, Valve Stem Guide I.D 3.27 Specification, Wheel Toe-Out .2.32 Specifications, Cam Shaft3.44 Specifications, Cooling System 3.13 Specifications, Crankcase Fastener Torque 3.46 Specifications, Engine 3.2 Specifications, Engine Lubrication.3.21 Specifications, Engine Oil Pressure 3.21 Specifications, General .1.6 Specifications, Oil Baffle Bolt Torque 3.45 Specifications, Oil Pick-up Bolt Torque .3.45 Speedometer 10.7 Speedometer Installation10.11 IX.4 Speedometer Removal 10.11 Speedometer Troubleshooting Tests .10.12 Starter Armature Testing10.35 Starter Assembly Exploded View.10.37 Starter Brush Inspection / Replacement10.34 Starter Drive .10.36 Starter Drive Removal .3.35 Starter Motor, Removal .10.33 Starter Reassembly / Installation10.35 Starter System Flow Chart 10.38 Starter System, Troubleshooting10.33 Stator, Removal 3.36 Steering 2.31 Steering, Exploded View .5.11 Storage Box, Installation .5.25 Storage Box, Removal .5.25 Swing Arm, Exploded View 5.21 Swing Arm, Installation .5.20 Swing Arm, Removal .5.20 Switch, AWD / Rear Differential (4x4) .10.4 Switch, Brake Light.10.5 Switch, Headlamp10.4 Switch, Parking Brake .10.6 T Tachometer.10.8 Tail Lights.10.18 Tap/Drill Sizes .1.12 Temperature / Barometric Air Pressure Sensor (T-Bap) .4.16 Throttle Freeplay Adjustment .2.15 Throttle Pedal Inspection2.14 Throttle Position Sensor .4.17 Throttle Position Sensor Initialization .4.18 Throttle Position Sensor Replacement 4.19 Tie Rod End Inspection 2.31 Timing Gear Mark Alignment .3.37 Tire Inspection .2.28 Tire Pressure 2.29 Toe Adjustment 2.32 Torque Chart 1.11 Torque Specifications, Body/Steering/Suspension5.2 Torque Specifications, Brakes 9.2 Torque Specifications, Clutching .6.2 Torque Specifications, Final Drive7.3 Torque Specifications, Transmission 8.2 Torque Specifications, Wheel, Hub, and Spindle2.27 Torque Specs - Engine 3.10 Transmission I.D. Number Location.1.3 Transmission Lubrication2.20 Transmission, Assembly .8.10 Transmission, Disassembly8.5 Transmission, Exploded View 8.16 Transmission, Installation8.14 Transmission, Removal .8.3 Trip Meter10.8 Troubleshooting, Brake Noise 9.3 Troubleshooting, Brake System . 9.26 Troubleshooting, Clutching6.22 Troubleshooting, No AWD . 10.12 Troubleshooting, No AWD Hub Safety Limiter. 10.14 Troubleshooting, No Fuel Gauge Display10.15 Troubleshooting, No Gear Indicator Display 10.15 Troubleshooting, No Instrument Display. 10.13 Troubleshooting, Transmission . 8.15 Troubleshooting, Wheel Speed Sensor 10.13 V Valve Seal/Spring Service. 3.25 Valve Sealing Test. 3.31 Valve Seat Reconditioning. 3.28 Vehicle Dimensions. 1.4 Vent Lines. 2.14 VIN Identification 1.2 VIN Location1.3 Voltage Drop Test10.33 W Wheel Alignment 2.32 Wheel, Installation. 2.28 Wheel, Removal . 2.28
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