90K Service

Complete 90,000 mile scheduled maintenance service including engine oil and filter change, transmission fluid service, differential fluid service, coolant flush, brake fluid flush, spark plugs, ignition components, filters, belts, hoses, and full inspection of chassis and drivetrain components.

Warnings

Tools required

Parts

• Engine oil filter × 1 — FL-1A or equivalent
• Spark plugs × 8 — Autolite 25 or equivalent
• Distributor cap × 1 — Use OEM specification
• Distributor rotor × 1 — Use OEM specification
• Ignition points × 1 — Use OEM specification
• Condenser × 1 — Use OEM specification
• Air filter × 1 — Use OEM specification
• Fuel filter (inline) × 1 — Use OEM specification
• PCV valve × 1 — Use OEM specification
• Drive belts × 2 — Use OEM specification
• Automatic transmission pan gasket × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• Multi-purpose chassis grease × 1 — NLGI Grade 2

Fluids

• 10W-30 or 10W-40 conventional engine oil — 5 qt
• Type F ATF (automatic transmission) — 5 qt
• Ethylene glycol green 50/50 coolant — 15 qt
• DOT 3 brake fluid — 0.75 qt
• 80W-90 GL-5 rear differential — 3.5 qt
• Type F ATF (power steering) — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure engine is completely cold before beginning work
3. Gather all fluids, filters, and parts before starting
4. Chock rear wheels securely
5. Raise front of vehicle and support on jack stands at frame rails
6. Place drain pans under vehicle in accessible location

Procedure

1. 1

   Engine oil and filter change
   Place drain pan under engine oil pan. Remove drain plug from rear passenger side of oil pan using 9/16" socket. Allow oil to drain completely (approximately 10 minutes). Remove oil filter using oil filter wrench (located on driver side of engine block). Clean oil pan drain plug and inspect threads. Install new oil filter after lubricating gasket with fresh oil, tighten hand-tight plus 3/4 turn. Reinstall drain plug. Fill engine with 5 quarts of 10W-30 or 10W-40 conventional oil through valve cover filler cap. Start engine, check for leaks, shut off and verify oil level on dipstick after 2 minutes.
2. 2

   Automatic transmission fluid service
   Place drain pan under transmission pan. Remove all transmission pan bolts except two at front corners (16 bolts total). Loosen front bolts gradually to allow pan to tilt and drain fluid. Once drained, remove front bolts and lower pan. Remove old gasket material from pan and transmission housing using scraper. Clean pan thoroughly with solvent, inspect magnet for excessive debris. Install new gasket on transmission pan (use light coat of gasket sealer if desired). Reinstall pan and torque bolts in crisscross pattern to 12-15 ft-lbs. Add approximately 3 to 4 quarts Type F ATF through dipstick tube, then check level (a pan-drop service does not drain the torque converter). Start engine, shift through all gears, and check level with engine at operating temperature in Park. Add fluid to bring to full mark.
3. 3

   Rear differential fluid service
   Place drain pan under rear differential. Remove differential cover bolts (10 bolts) and carefully pry cover loose, allowing fluid to drain. Clean cover and housing mating surfaces thoroughly, removing all old gasket material. Inspect gear teeth and bearing condition through opening for abnormal wear or debris. Install new gasket on differential cover. Reinstall cover and torque bolts in crisscross pattern to 20-25 ft-lbs. Remove fill plug on driver side of differential housing (1/2" square drive). Using fluid pump or squeeze bottle, fill differential with 80W-90 GL-5 gear oil until fluid reaches bottom of fill hole (approximately 2.5 to 3 quarts). Reinstall fill plug and torque to 15-20 ft-lbs.
4. 4

   Cooling system flush and refill
   Ensure engine is completely cold. Place drain pan under radiator. Open radiator drain petcock at bottom driver side of radiator or remove lower radiator hose at radiator. Drain coolant completely. Remove radiator cap. Flush system with water from garden hose through radiator filler neck until water runs clear from drain. Close drain petcock or reinstall lower hose with new clamp. Mix ethylene glycol concentrate with distilled water for a 50/50 mixture (system capacity approximately 14-15 quarts total; less will be needed for a partial drain-and-refill). Add coolant until full. Fill radiator to neck. Start engine with heater on high and allow to reach operating temperature. Add coolant as level drops during burping process. Once thermostat opens and upper hose becomes hot, top off radiator and install cap. Check coolant recovery tank level and fill to cold line.
5. 5

   Brake fluid flush
   Remove master cylinder reservoir cap. Using turkey baster or fluid transfer pump, remove as much old brake fluid as possible from reservoir. Refill with fresh DOT 3 brake fluid. Starting at right rear wheel, attach clear hose to bleeder screw and place other end in container. Have assistant pump brake pedal 3-4 times and hold. Open bleeder screw 1/2 turn while pedal is held. Close bleeder before pedal reaches floor. Repeat until fluid runs clear. Repeat process at left rear, right front, then left front. Keep master cylinder reservoir full throughout process. Once all corners are completed, top off reservoir to MAX line and install cap. Verify firm brake pedal before driving.
6. 6

   Spark plug replacement
   Remove spark plug wires from plugs one at a time (mark position if needed). Clean debris around spark plug bases with compressed air. Using 5/8" spark plug socket, remove all 8 spark plugs. Inspect old plugs for wear, fouling, or abnormal deposits. Gap new spark plugs to 0.030 inches using gap tool (verify specification on emissions decal under hood). Install new plugs hand-tight, then torque to 10-15 ft-lbs. Reconnect spark plug wires firmly to correct plugs in firing order 1-5-4-2-6-3-7-8 (passenger side front to rear: 1-2-3-4, driver side front to rear: 5-6-7-8).
7. 7

   Distributor cap, rotor, points, and condenser service
   Remove distributor cap by releasing two spring clips. Inspect cap for cracks, carbon tracking, and terminal corrosion. Replace if damaged. Remove rotor from distributor shaft (pull straight up). Remove two screws securing points to breaker plate. Disconnect wire from points and condenser. Remove condenser mounting screw. Install new condenser and secure wire. Install new points set and secure with screws. Rotate engine using crankshaft pulley bolt until points are at maximum opening (rubbing block on high point of distributor cam lobe). Using feeler gauge, adjust points gap to 0.021 inches by loosening adjustment screw and moving points. Tighten screws and verify gap. Apply small amount of distributor cam lube to rubbing block. Install new rotor and distributor cap. Verify all plug wires are firmly seated.
8. 8

   Air filter and PCV valve replacement
   Remove wing nut or clips securing air cleaner lid. Remove lid and old air filter element. Wipe out air cleaner housing with clean rag. Install new air filter element and replace lid, securing with wing nut or clips. Locate PCV valve in driver side valve cover or in grommet connected to intake manifold via hose. Remove PCV valve from grommet. Shake valve to verify it rattles (old valve). Install new PCV valve into grommet, ensuring tight seal. Verify all PCV hoses are connected and not cracked.
9. 9

   Fuel filter replacement
   Locate inline fuel filter between fuel pump and carburetor (usually along frame rail or at carburetor inlet). Place rag under filter connections to catch fuel spillage. Using two wrenches, loosen hose clamps or flare fittings on both sides of filter. Remove old filter, noting direction of flow arrow. Install new filter with arrow pointing toward carburetor. Secure connections with new hose clamps, tightening snugly to prevent leaks (do not overtighten). Start engine and inspect for fuel leaks. Tighten connections if seepage occurs.
10. 10

    Drive belt inspection and replacement
    Inspect fan belt and alternator/power steering belt for cracks, glazing, fraying, or excessive wear. If worn, replace both belts. To remove fan belt, loosen alternator adjustment bolt and pivot bolt, push alternator toward engine, and slip belt off pulleys. To remove power steering belt (if equipped), loosen power steering pump mounting and adjustment bolts, push pump toward engine, and remove belt. Install new belts over pulleys in correct routing. Adjust fan belt tension to 1/2 inch deflection at longest span between pulleys using firm thumb pressure. Adjust power steering belt to same deflection. Tighten all mounting and adjustment bolts securely. Start engine and verify belts run smoothly without squealing or slipping.
11. 11

    Ignition timing adjustment
    Connect timing light to number one spark plug wire (driver side front). Locate timing marks on harmonic balancer and timing tab at front of engine. Disconnect and plug vacuum advance hose at distributor. Start engine and allow to reach operating temperature at idle (approximately 600 RPM). Aim timing light at timing marks. Initial timing should be approximately 6 degrees BTDC (verify specification on emissions decal under hood). If adjustment needed, loosen distributor hold-down clamp bolt. Rotate distributor body slightly to adjust timing (rotate against the direction of rotor rotation to advance, with rotation to retard); verify direction on this engine before final tightening. Tighten hold-down bolt when correct timing achieved. Reconnect vacuum advance hose. Rev engine and verify timing advances smoothly.
12. 12

    Carburetor idle adjustment
    With engine at full operating temperature, locate idle speed screw and idle mixture screw(s) on carburetor. Connect tachometer to engine. Set parking brake and block wheels. Adjust idle speed screw to achieve 600 RPM in Park (automatic) or neutral (manual). Turn idle mixture screw(s) in slowly until engine begins to stumble, then back out 1/4 to 1/2 turn until engine runs smoothly at highest RPM. Readjust idle speed screw if needed to return to 600 RPM. If equipped with two idle mixture screws, adjust both equally for best idle quality.
13. 13

    Chassis lubrication and inspection
    Using grease gun with chassis grease, lubricate all grease fittings: both upper and lower ball joints (4 total), tie rod ends (2 outer, 2 inner if equipped with fittings), steering linkage connections (idler arm, pitman arm), and driveshaft universal joints (2-3 fittings depending on configuration). Pump grease until clean grease appears at seals. Inspect all grease fittings for damage and replace if broken. While underneath vehicle, inspect all suspension bushings, shock absorbers, steering components, brake lines, and fuel lines for wear, damage, or leaks. Check exhaust system for leaks or loose hangers. Inspect driveshaft for runout or damaged boots. Torque lug nuts to 90-100 ft-lbs in star pattern.
14. 14

    Final fluid level verification
    With engine at operating temperature and on level ground, verify all fluid levels: engine oil (dipstick should read full), transmission fluid (full mark in Park with engine running and hot), power steering fluid (full mark on reservoir), brake fluid (MAX line on master cylinder), coolant (radiator full and recovery tank at cold line), and windshield washer fluid (fill reservoir with 2 quarts washer fluid). Top off any fluids as needed.

Reassembly

1. Lower vehicle from jack stands carefully
2. Remove wheel chocks
3. Perform final walk-around inspection for tools or drain pans left under vehicle
4. Verify all filler caps, drain plugs, and bleeder screws are securely installed
5. Start engine and allow to idle for 5 minutes, monitoring for leaks or unusual noises
6. Test drive vehicle to verify proper operation of all systems serviced

Verification

• Check for oil, transmission, differential, coolant, brake, or power steering fluid leaks under vehicle after test drive
• Verify engine idles smoothly at approximately 600 RPM with no misfires
• Verify ignition timing holds steady at specified setting under timing light
• Verify transmission shifts smoothly through all gears without slipping
• Verify brake pedal is firm with no sponginess and brakes operate effectively
• Verify engine reaches and maintains normal operating temperature without overheating
• Verify no belt squealing during acceleration or when power steering is turned
• Verify all dash warning lights remain off during operation
• Record mileage and date of service for future maintenance scheduling

More procedures for this vehicle