tow bar DODGE RAM 2003 Service User Guide

8W-10 POWER DISTRIBUTION
Component PageA/C Compressor Clutch....................8W-10-16, 43, 44
A/C Compressor Clutch Relay.................8W-10-16, 43, 44
A/C-Heater Control......................8W-10-46, 47, 58
Adjustable Pedal Relay......................8W-10-14, 34
Adjustable Pedal Switch.................8W-10-14, 34, 46, 58
Airbag Control Module......................8W-10-46, 48
Airbag Control Module-Left Side Impact...............8W-10-46
Airbag Control Module-Right Side Impact..............8W-10-46
Ambient Temperature Sensor...................8W-10-52, 54
Amplifier Audio...........................8W-10-33
Auto Shut Down Relay......................8W-10-11, 18
Automatic Day/Night Mirror...................8W-10-45, 52
Auxiliary Battery...........................8W-10-11
Backup Lamp Switch.......................8W-10-48, 53
Battery..............................8W-10-11, 18
Blower Motor.............................8W-10-56
Brake Lamp Switch....................8W-10-13, 32, 43, 44
Capacitor.............................8W-10-21, 23
Center High Mounted Stop Lamp/Cargo Lamp............8W-10-42
Cigar Lighter Outlet.........................8W-10-50
Circuit Breaker............................8W-10-56
Clearance Lamp No. 1........................8W-10-37
Clearance Lamp No. 2........................8W-10-37
Clearance Lamp No. 3........................8W-10-37
Clearance Lamp No. 4........................8W-10-37
Clearance Lamp No. 5........................8W-10-37
Clutch Interlock Brake Switch....................8W-10-39
Coil On Plug No. 1........................8W-10-19, 22
Coil On Plug No. 2........................8W-10-20, 21
Coil On Plug No. 3........................8W-10-19, 22
Coil On Plug No. 4........................8W-10-20, 21
Coil On Plug No. 5........................8W-10-19, 22
Coil On Plug No. 6........................8W-10-20, 21
Coil On Plug No. 7........................8W-10-19, 22
Coil On Plug No. 8........................8W-10-20, 21
Compass/Mini-Trip Computer...................8W-10-42, 45
Condenser Fan..........................8W-10-17, 49
Condenser Fan Relay.......................8W-10-17, 49
Controller Antilock Brake...................8W-10-13, 30, 48
Data Link Connector.......................8W-10-32, 54
Dome Lamp.............................8W-10-42
Door Lock Switch-Passenger.....................8W-10-45
Driver Door Module.......................8W-10-42, 56
Electric Brake Provision.......................8W-10-18
Engine Control Module........................8W-10-43
EVAP/Purge Solenoid.........................8W-10-45
Fender Lamp-Front Left.......................8W-10-37
Fender Lamp-Front Right......................8W-10-37
Fender Lamp-Rear Left.......................8W-10-37
Fender Lamp-Rear Right.......................8W-10-37
Fog Lamp Relay.........................8W-10-15, 38
Fog Lamp-Left............................8W-10-38
Fog Lamp-Right...........................8W-10-38
Front Control Module....8W-10-12, 31, 32, 34, 35, 36, 48, 45, 51, 52, 54 , 55
Fuel Heater.............................8W-10-57
Fuel Heater Relay........................8W-10-17, 57
Fuel Injector No. 1........................8W-10-22, 24
Fuel Injector No. 2....................8W-10-20, 21, 23, 24
Fuel Injector No. 3........................8W-10-22, 24
Fuel Injector No. 4....................8W-10-20, 21, 23, 24
Fuel Injector No. 5........................8W-10-22, 24
Fuel Injector No. 6....................8W-10-20, 21, 23, 24
Fuel Injector No. 7........................8W-10-22, 24
Fuel Injector No. 8....................8W-10-20, 21, 23, 24
Fuel Injector No. 9..........................8W-10-24
Fuel Injector No. 10.........................8W-10-23
Fuel Pump Module........................8W-10-16, 42
Fuel Pump Relay.....................8W-10-16, 42, 43, 44
Fuse 1..............................8W-10-11, 18
Fuse 2............................8W-10-11, 12, 18
Fuse 3..............................8W-10-12, 26
Fuse 4..............................8W-10-12, 26
Fuse 5.......................8W-10-11, 12, 13, 27, 28, 29
Fuse 6............................8W-10-12, 13, 30
Fuse 7..............................8W-10-13, 30
Fuse 8..............................8W-10-14, 31
Fuse 9..............................8W-10-12, 26
Fuse 10..............................8W-10-12, 26
Fuse 11............................8W-10-12, 13, 32
Fuse 12............................8W-10-17, 49, 57
Fuse 13..............................8W-10-12, 32
Fuse 14..............................8W-10-14, 39
Fuse 15............................8W-10-15, 16, 36
Fuse 16............................8W-10-16, 43, 44
Fuse 17............................8W-10-16, 17, 42
Fuse 18..............................8W-10-13, 32
Fuse 19..............................8W-10-13, 33
Fuse 20..............................8W-10-12, 26
Fuse 21..............................8W-10-13, 33
Fuse 22..............................8W-10-13, 33
Fuse 24..............................8W-10-13, 32
Fuse 25..............................8W-10-13, 33
Fuse 27............................8W-10-16, 17, 47
Fuse 28............................8W-10-43, 44, 45
Fuse 32..............................8W-10-16, 36
Fuse 33..............................8W-10-16, 36Component PageFuse 34..............................8W-10-16, 36
Fuse 35...............................8W-10-48
Fuse 36..............................8W-10-47, 58
Fuse 37...............................8W-10-48
Fuse 38..............................8W-10-47, 48
Fuse 40............................8W-10-14, 15, 34
Fuse 41..............................8W-10-15, 38
Fuse 42..............................8W-10-13, 34
Fuse 43..............................8W-10-13, 34
Fuse 45............................8W-10-15, 16, 38
Fuse 46............................8W-10-14, 15, 35
Fuse 47..............................8W-10-15, 35
Fuse 48..............................8W-10-14, 34
Fuse 49..............................8W-10-11, 18
Fuse 50...............................8W-10-45
Fuse 51............................8W-10-13, 14, 32
Fuse 52..............................8W-10-47, 48
Fuse 53...............................8W-10-45
Fusible Link.............................8W-10-11
G103...............................8W-10-51, 52
G106...........................8W-10-31, 51, 55, 57
G107...............................8W-10-27, 29
G201.................................8W-10-26
Generator.............................8W-10-11, 28
Glove Box Lamp And Switch.....................8W-10-42
Headlamp Switch..........................8W-10-38
Headlamp-Left............................8W-10-55
Headlamp-Right...........................8W-10-55
Heated Mirror Relay.......................8W-10-17, 47
Horn Relay............................8W-10-15, 38
Horn-High Note...........................8W-10-38
Horn-Low Note............................8W-10-38
Ignition Coil.............................8W-10-24
Ignition Coil-Left...........................8W-10-23
Ignition Coil-Right..........................8W-10-23
Ignition Switch................8W-10-12, 26, 39, 45, 48, 50, 56
Instrument Cluster................8W-10-13, 26, 32, 33, 45, 50
Integrated Power Module . 8W-10-2, 3, 5, 11, 12, 13,, 14, 15, 16, 17, 18, 26, 27,
28, 29, 30, 31, 32, 33, 34, 35, 36, 38, 39, 42, 43, 44, 45, 46, 47, 48, 49, 50, 52,
54, 55, 57, 58
Leak Detection Pump........................8W-10-28
License Lamp-Left..........................8W-10-36
License Lamp-Right.........................8W-10-37
Overhead Map/Reading Lamp....................8W-10-42
Oxygen Sensor 1/1 Upstream.....................8W-10-25
Oxygen Sensor 1/2 Downstream...................8W-10-25
Oxygen Sensor 2/1 Upstream.....................8W-10-25
Oxygen Sensor 2/2 Downstream...................8W-10-25
Oxygen Sensor Downstream Relay................8W-10-11, 18
Park Lamp Relay.........................8W-10-16, 36
Park/Turn Signal Lamp-Left Front................8W-10-36, 51
Park/Turn Signal Lamp-Right Front...............8W-10-36, 51
Passenger Airbag On/Off Switch...................8W-10-46
Passenger Lumbar Switch......................8W-10-30
Power Mirror-Left..........................8W-10-47
Power Mirror-Right.........................8W-10-47
Power Outlet...........................8W-10-13, 33
Power Outlet-Console........................8W-10-34
Power Seat Switch-Driver......................8W-10-30
Power Seat Switch-Passenger....................8W-10-30
Power Window Circuit Breaker....................8W-10-56
Powertrain Control Module . 8W-10-17, 18, 19, 21, 23, 24, 28, 29, 33, 39, 40, 41,
42, 43, 44, 49, 57
PTCNo.1.........................8W-10-42, 43, 44, 45
PTCNo.2 ..............................8W-10-50
PTCNo.5 ..............................8W-10-35
Radio...............................8W-10-32, 50
Seat Belt Tensioner Reducer.....................8W-10-50
Seat Heater Interface Module....................8W-10-34
Sentry Key Immobilizer Module...............8W-10-33, 43, 44
Spare Relay.............................8W-10-58
Starter Motor...........................8W-10-14, 39
Starter Motor Relay.......................8W-10-14, 39
Tail/Stop/Turn Signal Lamp-Left.............8W-10-36, 51, 52, 54
Tail/Stop/Turn Signal Lamp-Right.............8W-10-37, 51, 52, 54
Tailgate Lamp Assembly.....................8W-10-36, 41
Trailer Tow Connector...................8W-10-15, 16, 35, 36
Trailer Tow Connector-Add On..............8W-10-18, 35, 36, 52
Trailer Tow Left Turn Relay...................8W-10-15, 35
Trailer Tow Right Turn Relay...................8W-10-15, 35
Transfer Case Control Module................8W-10-13, 34, 39
Transmission Control Module...............8W-10-12, 27, 41, 56
Transmission Control Relay................8W-10-12, 27, 28, 29
Transmission Range Sensor..................8W-10-40, 48, 53
Transmission Solenoid Assembly.................8W-10-12, 28
Transmission Solenoid/TRS Assembly.........8W-10-27, 29, 40, 48, 53
Underhood Lamp...........................8W-10-32
Vacuum Pump............................8W-10-43
Vistronic Fan Drive.........................8W-10-58
Washer Fluid Level Switch....................8W-10-52, 54
Washer Pump Motor-Front......................8W-10-52
Wiper High/Low Relay......................8W-10-14, 31
Wiper Motor-Front........................8W-10-31, 52
Wiper On/Off Relay........................8W-10-14, 31
DR8W-10 POWER DISTRIBUTION 8W - 10 - 1

STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the air cleaner resonator and duct
work as an assembly.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(7) Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for
engine removal.
(8) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(9) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(10) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(11) Remove the intake manifold and IAFM as an
assembly(Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - REMOVAL).
(12) Disconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses
from pump, for P/S pump removal.
(13) Remove the power steering pump and set
aside.
(14) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(15) Raise and support the vehicle on a hoist and
drain the engine oil.
(16) Remove engine front mount thru-bolt nuts.
(17) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(18) Disconnect exhaust pipe at manifolds.
(19) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
9 - 186 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 40É to 60É
for proper seating of rings (Fig. 3).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
DRENGINE - 5.9L 9 - 233
ENGINE - 5.9L (Continued)

²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using the crankshaft barring tool (PN 7471±B).
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install fuel injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVAL
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Disconnect engine grid heater harness at grid
heater relays.(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(5) Raise vehicle on a hoist.
(6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
oil.
(8) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(9) Remove radiator upper hose.
(10) Remove upper fan shroud mounting bolts.
(11) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(12) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(13) Remove cooling fan and shroud together.
(14) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(15) Raise vehicle on a hoist.
(16) Remove transmission and transfer case (if
equipped).
(17) Disconnect exhaust pipe from turbocharger
extension pipe.
(18) Disconnect engine harness to vehicle harness
connectors.
(19) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(20) Remove flywheel/flexplate.
(21) Remove transmission adapter
(22) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(23) Lower vehicle.
(24) Disconnect lower radiator hose from radiator
outlet.
(25) Automatic transmission models:
(26) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(27) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(28) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(29) Disconnect charge air cooler piping.
(30) Remove charge air cooler mounting bolts.
(31) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(32) Remove damper and speed indicator ring from
front of engine.
(33) Disconnect engine block heater connector.
(34) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
9 - 290 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

Inspect the piston pin for nicks, gouges and exces-
sive wear. Measure the pin diameter (Fig. 93). The
minimum diameter is 39.990 mm (1.5744 inch), max-
imum 40.003 mm (1.5749 inch). If the diameter is out
of limits, replace the pin.
INSPECTIONÐCONNECTING ROD
Inspect the connecting rod for damage and wear.
The I-Beam section of the connecting rod cannot have
dents or other damage. Damage to this part can
cause stress risers which will progress to breakage.
Measure the connecting rod pin bore (Fig. 94). The
maximum diameter is 40.042 mm (1.5765 inch), min-
imum diameter is 40.019 mm (1.5756 inch). If out of
limits, replace the connecting rod.
INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.(3) Compress the rings using a piston ring com-
pressor tool (Fig. 95). If using a strap-type ring com-
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen-
ter) - (Fig. 96).
(5) Make sure the front of the piston is oriented
properly according to the marking on the top of the
piston and the numbers on the rod and cap are ori-
ented as illustrated.
(6) Position the piston and rod assembly into the
cylinder bore with the front of the piston oriented
properly according to the stamping in the top of the
piston. In this position the numbers on the connect-
ing rod should be facing the intake or camshaft side
of the engine, and the rod bolt hex heads toward the
oil cooler. Use care when you install the piston and
connecting rod so the cylinder bore is not damaged. If
a fractured split connecting rod is being installed, the
long side of the connecting rod must be installed on
the intake side of the engine.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
Fig. 93 Piston Pin Diameter
1 - PISTON PIN
Fig. 94 Connecting Rod Pin Bore
1 - CONNECTING ROD
Fig. 95 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
Fig. 96 Piston/Rod Assembly at BDC
9 - 332 ENGINE 5.9L DIESELDR
PISTON & CONNECTING ROD (Continued)

MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier than using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
REMOVAL
(1) Remove the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
DRENGINE 8.0L 9 - 361
ENGINE 8.0L (Continued)

(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171, if necessary. The
oil feed hole must be at the 12 o'clock position when
installed.
(2) On 4X2 vehicles, install extension housing seal
with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 93).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.(12)
The difference between the two measurements is
the end-play for the reverse countershaft gear assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.006-
0.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
Fig. 91 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 92 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
Fig. 93 MEASURE DEPTH OF REVERSE
COUNTERSHAFT GEAR BEARING RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
DRMANUAL TRANSMISSION - NV5600 21 - 119
MANUAL TRANSMISSION - NV5600 (Continued)

(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then partially press
input shaft into retainer (Fig. 237). Use a suitably
sized press tool to support retainer as close to input
shaft as possible.
(4) Install input shaft retaining ring.
(5) Press the input shaft the remainder of the way
into the clutch retainer.
(6) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(7) Lubricate lip of piston seals with generous
quantity of MopartDoor Ease. Then lubricate
retainer hub and bore with light coat of transmission
fluid.
(8) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.0209thick), can be used to
guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) Install piston spring in retainer and on top of
piston. Concave side of spring faces downward
(toward piston).
(10) Install the spacer ring and wave spring into
the retainer. Be sure spring is completely seated in
retainer groove.
(11) Install pressure plate (Fig. 236). Ridged side
of plate faces downward (toward piston) and flat side
toward clutch pack.
(12) Install first clutch disc in retainer on top of
pressure plate. Then install a clutch plate followed
by a clutch disc until entire clutch pack is installed
(4 discs and 3 plates are required) (Fig. 236).
(13) Install the reaction plate.
(14) Install selective snap-ring. Be sure snap-ring
is fully seated in retainer groove.
(15) Using a suitable gauge bar and dial indicator,
measure clutch pack clearance (Fig. 238).
(a) Position gauge bar across the clutch drum
with the dial indicator pointer on the pressure
plate (Fig. 238).
(b) Using two small screw drivers, lift the pres-
sure plate and release it.
(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the
snap-ring and record the dial indicator reading.
Clearance should be 0.635 - 0.914 mm (0.025 -
0.036 in.). If clearance is incorrect, steel plates, discs,
selective snap ring and pressure plates may have to
be changed.
The selective snap ring thicknesses are:
²0.107 - 0.109 in.²0.098 - 0.100 in.
²0.095 - 0.097 in.
²0.083 - 0.085 in.
²0.076 - 0.078 in.
²0.071 - 0.073 in.
²0.060 - 0.062 in.
Fig. 237 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM
Fig. 238 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4-STAND
5 - REAR CLUTCH
6 - GAUGE BAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 251
REAR CLUTCH (Continued)

TIRE REVOLUTIONS PER MILE,
SPECIFICATIONS.....................22-10
TIRE ROTATION - STANDARD
PROCEDURE.........................22-2
TIRE WEAR PATTERNS - DIAGNOSIS
AND TESTING........................22-8
TIRES - DESCRIPTION.................22-5
TIRES - DESCRIPTION, RADIAL - PLY.....22-6
TIRES - DESCRIPTION, REPLACEMENT....22-6
TIRE/VEHICLE LEAD - DIAGNOSIS AND
TESTING............................22-8
TO COOLER - INSTALLATION, RETURN
HOSE - GEAR..................19-43,19-44
TO COOLER - INSTALLATION, RETURN
HOSE - RESERVOIR.............19-43,19-44
TO COOLER - REMOVAL, RETURN HOSE
- GEAR............................19-43
TO COOLER - REMOVAL, RETURN HOSE
- RESERVOIR..................19-43,19-44
TO GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT.............8W-01-9
TO GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT . 8W-01-10
TO OIL COOLER - INSTALLATION, AIR.....7-75
TO OIL COOLER - REMOVAL, AIR.........7-74
TO OIL COOLER - REMOVAL, WATER......7-74
TO USE WIRING DIAGRAMS -
DESCRIPTION, HOW................8W-01-1
TOE ADJUSTMENT - STANDARD
PROCEDURE..........................2-4
TOE ADJUSTMENT - STANDARD
PROCEDURE, CAMBER, CASTER..........2-4
TOOL - ADJUSTMENT, WITH ADJUSTING . . . 5-36
TOOLS - 4.7L ENGINE, SPECIAL.........9-102
TOOLS - 5.7L ENGINE, SPECIAL.........9-192
TOOLS - 5.9L DIESEL ENGINE, SPECIAL . . 9-294
TOOLS - 5.9L ENGINE, SPECIAL.........9-240
TOOLS - 8.0L ENGINE, SPECIAL.........9-367
TOOLS - 9 1/4 AA, SPECIAL.............2-29
TOOLS - BASE BRAKES, SPECIAL.........5-5
TOOLS - BATTERY SYSTEM SPECIAL
TOOLS, SPECIAL......................8F-7
TOOLS - BODY, SPECIAL...............23-14
TOOLS - COOLING, SPECIAL.............7-20
TOOLS - DIESEL FUEL SYSTEM,
SPECIAL...........................14-60
TOOLS - FRONT SUSPENSION, SPECIAL . . . 2-11
TOOLS - FUEL SYSTEM, SPECIAL........14-5
TOOLS - OVERHEAD CONSOLE, SPECIAL . . 8M-6
TOOLS - POWER DISTRIBUTION
SYSTEMS, SPECIAL................8W-97-2
TOOLS - POWER STEERING GEAR,
SPECIAL...........................19-22
TOOLS - RE TRANSMISSION, SPECIAL . . 21-189,
21-370
TOOLS - RFE TRANSMISSION, SPECIAL . . 21-535
TOOLS - STEERING LINKAGE, SPECIAL . . . 19-35
TOOLS - STEERING, SPECIAL............19-5
TOOLS - TRANSFER CASE NV271/NV273,
SPECIAL....................21-650,21-714
TOOLS - WHEEL ALIGNMENT, SPECIAL.....2-7
TOOLS - WIRING/TERMINAL, SPECIAL . 8W-01-10
TOOLS, DIAGNOSIS AND TESTING -
SPECIAL............................11-4
TOOLS, FRONT AXLE - 9 1/4 AA -
SPECIAL............................3-53
TOOLS, FRONT AXLE - C205F - SPECIAL . . . 3-30
TOOLS, HALF SHAFT - SPECIAL..........3-12
TOOLS, HEADLAMP ALIGNMENT -
SPECIAL............................8L-7
TOOLS, MANUAL TRANSMISSION -
NV3500 - SPECIAL...................21-40
TOOLS, MANUAL TRANSMISSION -
NV4500 - SPECIAL...................21-79
TOOLS, MANUAL TRANSMISSION -
NV5600 - SPECIAL..................21-122
TOOLS, PROPELLER SHAFT - SPECIAL.....3-6
TOOLS, REAR AXLE - 10 1/2 AA -
SPECIAL...........................3-108
TOOLS, REAR AXLE - 11 1/2 AA -
SPECIAL
...........................3-135
TOOLS, REAR AXLE - 9 1/4 - SPECIAL
.....3-80
TOOLS, SPECIAL TOOLS - BATTERY
SYSTEM SPECIAL
.....................8F-7
TOOLS, SPECIFICATIONS - SPECIAL
.......9-16
TOP COVER - INSTALLATION,
INSTRUMENT PANEL
..................23-60TOP COVER - REMOVAL, INSTRUMENT
PANEL.............................23-59
TORSION BAR - DESCRIPTION...........2-25
TORSION BAR - INSTALLATION..........2-26
TORSION BAR - OPERATION.............2-25
TORSION BAR - REMOVAL..............2-25
TORSION BAR CROSS MEMBER
BUSHING - INSTALLATION..............2-14
TORSION BAR CROSSMEMBER
BUSHING - REMOVAL..................2-12
TOUCH-UP - DESCRIPTION, PAINT.......23-75
TOUCH-UP - STANDARD PROCEDURE,
PAINT.............................23-75
TOW HOOK ASSEMBLY - INSTALLATION,
FRONT.............................13-26
TOW HOOK ASSEMBLY - REMOVAL,
FRONT.............................13-26
TOW WIRING - DESCRIPTION, TRAILER . . 8L-22
TOWING - STANDARD PROCEDURE.......0-15
TRACK - DESCRIPTION, POWER SEAT....8N-18
TRACK - DIAGNOSIS AND TESTING,
POWER SEAT.......................8N-18
TRACK - INSTALLATION, POWER SEAT . . . 8N-19
TRACK - INSTALLATION, SEAT..........23-83
TRACK - OPERATION, POWER SEAT.....8N-18
TRACK - REMOVAL, POWER SEAT.......8N-19
TRACK - REMOVAL, SEAT..............23-83
TRACK BAR - INSTALLATION...........19-37
TRACK BAR - REMOVAL................19-37
TRAC-RITE - ASSEMBLY, DIFFERENTIAL . . 3-120,
3-147
TRAC-RITE - CLEANING, DIFFERENTIAL . . 3-119,
3-146
TRAC-RITE - DESCRIPTION,
DIFFERENTIAL..................3-118,3-145
TRAC-RITE - DISASSEMBLY,
DIFFERENTIAL..................3-118,3-145
TRAC-RITE - INSPECTION, DIFFERENTIAL . 3-119,
3-146
TRAC-RITE - OPERATION, DIFFERENTIAL . 3-118,
3-145
TRAILER HITCH - INSTALLATION........13-25
TRAILER HITCH - REMOVAL............13-25
TRAILER TOW WIRING - DESCRIPTION . . . 8L-22
TRANS COOLER - 5.9L DIESEL -
DESCRIPTION........................7-73
TRANS COOLER - 5.9L DIESEL -
OPERATION..........................7-74
TRANS TEMP INDICATOR -
DESCRIPTION.......................8J-38
TRANS TEMP INDICATOR - OPERATION . . . 8J-38
TRANSDUCER - DESCRIPTION, A/C
PRESSURE.........................24-15
TRANSDUCER - DIAGNOSIS AND
TESTING, A/C PRESSURE..............24-15
TRANSDUCER - INSTALLATION, A/C
PRESSURE.........................24-16
TRANSDUCER - OPERATION, A/C
PRESSURE.........................24-15
TRANSDUCER - REMOVAL, A/C
PRESSURE.........................24-16
TRANSFER CASE - NV241 GENII -
ASSEMBLY.........................21-604
TRANSFER CASE - NV241 GENII -
CLEANING
.........................21-602
TRANSFER CASE - NV241 GENII -
DESCRIPTION
.........................0-4
TRANSFER CASE - NV241 GENII -
DESCRIPTION
......................21-591
TRANSFER CASE - NV241 GENII -
DIAGNOSIS AND TESTING
............21-592
TRANSFER CASE - NV241 GENII -
DISASSEMBLY
......................21-593
TRANSFER CASE - NV241 GENII -
INSPECTION
.......................21-602
TRANSFER CASE - NV241 GENII -
INSTALLATION
......................21-614
TRANSFER CASE - NV241 GENII -
OPERATION
........................21-591
TRANSFER CASE - NV241 GENII -
REMOVAL
.........................21-593
TRANSFER CASE - NV243 - ASSEMBLY
. . 21-670
TRANSFER CASE - NV243 - CLEANING
. . 21-668
TRANSFER CASE - NV243 -
DESCRIPTION
.........................0-4
TRANSFER CASE - NV243 -
DESCRIPTION
......................21-658TRANSFER CASE - NV243 - DIAGNOSIS
AND TESTING......................21-659
TRANSFER CASE - NV243 -
DISASSEMBLY......................21-660
TRANSFER CASE - NV243 - INSPECTION . 21-668
TRANSFER CASE - NV243 -
INSTALLATION......................21-679
TRANSFER CASE - NV243 - OPERATION . 21-659
TRANSFER CASE - NV243 - REMOVAL . . . 21-660
TRANSFER CASE - NV271 - ASSEMBLY . . 21-637
TRANSFER CASE - NV271 - CLEANING . . 21-635
TRANSFER CASE - NV271 -
DESCRIPTION.........................0-4
TRANSFER CASE - NV271 -
DESCRIPTION......................21-623
TRANSFER CASE - NV271 - DIAGNOSIS
AND TESTING......................21-624
TRANSFER CASE - NV271 -
DISASSEMBLY......................21-625
TRANSFER CASE - NV271 - INSPECTION . 21-635
TRANSFER CASE - NV271 -
INSTALLATION......................21-649
TRANSFER CASE - NV271 - OPERATION . 21-623
TRANSFER CASE - NV271 - REMOVAL . . . 21-625
TRANSFER CASE - NV273 - ASSEMBLY . . 21-701
TRANSFER CASE - NV273 - CLEANING . . 21-698
TRANSFER CASE - NV273 -
DESCRIPTION.........................0-4
TRANSFER CASE - NV273 -
DESCRIPTION......................21-687
TRANSFER CASE - NV273 - DIAGNOSIS
AND TESTING......................21-688
TRANSFER CASE - NV273 -
DISASSEMBLY......................21-689
TRANSFER CASE - NV273 - INSPECTION . 21-699
TRANSFER CASE - NV273 -
INSTALLATION......................21-713
TRANSFER CASE - NV273 - OPERATION . 21-688
TRANSFER CASE - NV273 - REMOVAL . . . 21-689
TRANSFER CASE CONTROL MODULE -
DESCRIPTION.......................8E-15
TRANSFER CASE CONTROL MODULE -
OPERATION.........................8E-15
TRANSFER CASE, NV241 GENII........21-614
TRANSFER CASE, NV241/NV243 . . 21-615,21-680
TRANSFER CASE, NV243.............21-680
TRANSFER CASE, NV271.............21-649
TRANSFER CASE NV271/NV273, SPECIAL
TOOLS......................21-650,21-714
TRANSFER CASE, NV273.............21-713
TRANSFER CASE SKID PLATE -
INSTALLATION.......................13-26
TRANSFER CASE SKID PLATE -
REMOVAL..........................13-26
TRANSFER PUMP - DESCRIPTION, FUEL . . 14-75
TRANSFER PUMP - INSTALLATION, FUEL . 14-76
TRANSFER PUMP - OPERATION, FUEL....14-76
TRANSFER PUMP - REMOVAL, FUEL.....14-76
TRANSMISSION - 45RFE/545RFE -
DESCRIPTION, AUTOMATIC............21-489
TRANSMISSION - 45RFE/545RFE -
OPERATION, AUTOMATIC.............21-490
TRANSMISSION - 46RE - DESCRIPTION,
AUTOMATIC
........................21-131
TRANSMISSION - 46RE - OPERATION,
AUTOMATIC
........................21-133
TRANSMISSION - 48RE - DESCRIPTION,
AUTOMATIC
........................21-312
TRANSMISSION - 48RE - OPERATION,
AUTOMATIC
........................21-314
TRANSMISSION - CLEANING
..........21-104
TRANSMISSION - DESCRIPTION,
MANUAL
.............................0-4
TRANSMISSION - DIAGNOSIS AND
TESTING, AUTOMATIC
....21-139,21-320,21-491
TRANSMISSION - NV3500 - ASSEMBLY,
MANUAL
...........................21-17
TRANSMISSION - NV3500 - CLEANING,
MANUAL
...........................21-15
TRANSMISSION - NV3500 -
DESCRIPTION, MANUAL
................21-1
TRANSMISSION - NV3500 - DIAGNOSIS
AND TESTING, MANUAL
................21-3
TRANSMISSION - NV3500 -
DISASSEMBLY, MANUAL
................21-4
TRANSMISSION - NV3500 -
INSPECTION, MANUAL
................21-15
DRINDEX 35
Description Group-Page Description Group-Page Description Group-Page