wheelbase DODGE TRUCK 1993 Service Repair Manual

INTRODUCTION

INTRODUCTION

DESIGNATIONS,
LABELS/PLATES/DECALS,
CODES
AND DIMENSIONS/WEIGHTS .
CONTENTS

page
MEASUREMENT
AND TORQUE
... 1 SPECIFICATIONS
page

. 11

DESIGNATIONS, LABELS/PLATES/DECALS, CODES
AND
DIMENSIONS/WEIGHTS
INDEX

page

Engine
and
Transmission/Transfer
Case
Identification
2

Engine/Transmission/GVWR
4

Equipment
Identification
Plate
3
International
Vehicle Control
and
Display
Symbols
10

Major Component
Identification 3
VEHICLE DESIGNATIONS The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes are used to identify vehicle types in charts, captions
and in service procedures. The vehicle codes are
dif­

ferent than the Vehicle Identification Number (VIN) or the wheelbase/model code.
VEHICLE SAFETY CERTIFICATION
LABEL
A certification label is attached to the left side
B-pillar. The label certifies that the vehicle conforms
to Federal Motor Vehicle Safety Standards (FMVSS).
The label also lists the: • Month and year of vehicle manufacture
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number (VIN)
Type of vehicle
Type of rear wheels (single or dual) Bar code
Month, Day and Hour (MDH) of final assembly
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
page

Trailer
Towing Specifications
4

Vehicle Code Plate
2

Vehicle Designations
1

Vehicle Dimension
4

Vehicle
Identification
Number (VIN) Plate
1

Vehicle Safety
Certification
Label
............. 1

Vehicle Weights
4
VEHICLE CODE
DESIGNATIONS
VEHICLE CODE
= AD
(DODGE
RAM

PICKUP
&
CHASSIS
CAB)

VEHICLE
FAMILY LINE DESCRIPTION
AD1
D150

AD2
D250

AD3
D350
PICKUP

4x2

AD5
W150
AD6
W250

AD7
W350
PICKUP

4x4

AD2
D250
AD3
D350
CHASSIS
CAB

4x2

AD6
W250
AD7
W350
CHASSIS
CAB

4x4

AD4
AD100

AD4
AD150
SPORT
UTILITY
4x2

AD8
AD100

AD8 AD
150
SPORT
UTILITY
4x4
J90IN-32

INTRODUCTION

PRIMARY SECONDARY
PAINT PAINT VINYL ROOF

CODE VEHICLE
ORDER-
NUMBER
PAINT- PI
PROCEDURE
(2)

(1)
XXX
)
XXXXX)
X
XXX xxxxxx
X)0C xxxx xxxx xxxx xxx XXX x xxxxxxxxxxxxxxxxx

TRANSMISSION
I
VEHICLE IDENTIFICATION CODE
J
NUMBER
MARKET
U-C-B-M
CODE 90IN-3

Fig. 2 Vehicle Code Plate
VEHICLE CODE DECODING
VEHICLE
MODEL
•NUMBER
ENGINE
-CODE
-INTERIOR TRIM CODE

Line #1 Digit
1-3 Transmission Sales Code
Digit 4 Open Space
Digit
5
Market Code - U-C-B-M
Digit 6 Open Space
Digit 7-23 Vehicle Identification No.
Line #2 Digit
1-3 Paint Procedure
Digit 4 Open Space
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint
Digit 14 Open Space
Digit 15-18 Trim Code
Digit 19 Open Space
Digit
20-22
Engine Sales Code
Digit 23 Open Space
Line #3 Digit 1-12 Vehicle Order Number
Digit 13 Open Space
Digit 14-16 Vinyl Roof Code (Door Combo
Digit
Code - Pillette)
Digit 17 Open Space
Digit 18-23 Model

J901N-20 MAJOR COMPONENT IDENTIFICATION

Refer to the applicable group for identification
data.
EQUIPMENT IDENTIFICATION PLATE

The Equipment Identification Plate is located at
the right, front corner of the inner hood panel. The
plate lists information concerning the vehicle as fol­
lows:
The model
The wheelbase
The VIN (Vehicle Identification Number)
The
T.O.N,
(order number)
The optional and special equipment installed on
the vehicle
Refer to the information listed on the plate when
ordering replacement parts.

r§Wll
EQUIPMENT
IDENTIFICATION
mmm

MODELS
V.I.N. T.O.N.

CODE
NO.
DESCRIPTION
CODE
NO.
DESCRIPTION

. ^

Fig.
3 Equipment
Identification
Plate

4 INTRODUCTION
• VEHICLE DIMENSIONS

VEHICLE

FAMILY
WHEELBASE

AVAILABLE
CAB
TO

AXLE BODY

TYPE
SfANDAID
SODIES
AVAILABLE
VEHICLE
FAMILY
WHEELBASE

AVAILABLE
CAB
TO

AXLE BODY

TYPE
NOMINAL

LENGTH
(LOAD
SPACE
D

MENSIONS
(2)

VEHICLE
FAMILY
WHEELBASE

AVAILABLE
CAB
TO

AXLE BODY

TYPE
NOMINAL

LENGTH LENGTH MAX.

WIDTH
HEIGHT
VOLUME
AD-1
AD-5
2921
mm

(115
in) —

Sweptline

1981
mm

(6.5
ft)
1981
mm

(78
in)
1778 mm
(70
in)
485 mm
19.1
in) 1.71 m3

(60.35
ft3)

AD-1
AD-2

AD-3
AD-5

AD-6
AD-7
3327
mm
(131
in) —

Sweptline

2438 mm
(8
ft)
2489 mm
(98
in)
1778 mm
(70
in)
485 mm
(19.1
in)
2.15
m3

(75.8
ft3)

AD-2
AD-3
AD-7
3327
mm
(131
in)
1422 mm
(56
in)
Chassis

Cab
2438 mm
(8
ft)
—
— — —

AD-3
AD-7
3249 mm
(135
in)
1524 mm
(60
in)
Chassis

Cab
2896 mm

(9.5
ft) —
— — —

AD-3
4039 mm
(159
in)
2134 mm
(84
in)
Chassis

Cab
3810 mm

(12.5
ft)
—
— —

AD-4
2692
mm
(106
in)
Sport

Utility

4x2
—

1778 mm 1588 mm
(62.5
in)
1062 mm
(41.8
in)
2.99
m3

(105.8
ft3)

AD-8
2692
mm
(106
in)
Sport

Utility

4x4
—

1778 mm 1588 mm
(62.5
in)
1062 mm
(41.8
in)
2.99
m3

(105.8
ft3)

AD-1
3378 mm
(133
in) —

Sweptline

1981
mm

(6.5
ft)
1984 mm
(78.1
in)
1778 mm
(70
in)
485 mm
(19.1
in) 1.71 m3

(60.4
ft3)

AD-1
AD-2

AD-5
AD-6
3785 mm
(149
in) —

Sweptline

Club
Cab 2438 mm
(8
ft)
2489 mm
(98
in)
1778 mm
(70
in)
485 mm
(19.1
in)
2.15
M3

(75.8
ft3)

®
Driver seat
to
tailgate.
(2)
Based
on
S.A.E.
procedure
Jl
100. J901N-34
VEHICLE
WEIGHTS

The Vehicle Weights chart provides:
• The Gross Vehicle Weight Rating (GVWR),
• The payload
• The curb weight
for
each vehicle type/wheelbase

TRAILER
TOWING
SPECIFICATIONS
The Trailer Towing Specifications chart provides:
• The maximum trailer tongue weight
• The maximum trailer weight
• The maximum combined weight of the trailer/load/
towing vehicle with
a
specific engine/transmission/ axle combination.

VEHICLE
DIMENSION

The Vehicle Dimension chart provides
the
dimen­
sions
for
each type
of
Ram Truck, Ram Chassis Cab
and Ramcharger vehicle.

ENGINE/TRANSMISSION/GVWR
The Engine/Transmission/GVWR chart provides
the maximum load data
for
each vehicle combina­ tion.

•
INTRODUCTION
5
ENGINE/TRANSMISSION/QVWR

RAM PICKUP VEHICLE
LINE
WHEELBASE

GVWR ENGINE
&
SALES
CODE

TRANSMISSION

VEHICLE LINE
WHEELBASE

GVWR 3.9L
EFI

EHB
5.2L
EFI

ELG
5.9L
EFI

EMG
5.9L
EFI
EMJ 5.9L

DIESEL
ETA 5-SP

MAN.
O.D. 4-SP

MAN.
O.D. 4-SP

MAN.
3-SP

AUTO
4-SP

AUTO
O.D.
D150
4x2
2921 mm

(115
in)

3327
mm (131 in)
2495
kg

(5500
lbs)
S
S

O
o
D150
4x2
2921 mm

(115
in)

3327
mm (131 in)
2495
kg

(5500
lbs)
O
S

o o o
D150
4x2
2921 mm

(115
in)

3327
mm (131 in)
2495
kg

(5500
lbs)

O
s

o
D150
4x2

3327
mm (131 in)
2722
kg

(6000
lbs)
S

s
o o
D150
4x2

3327
mm (131 in)
2722
kg

(6000
lbs)

o
s
o o o
D150
4x2

3327
mm (131 in)
2722
kg

(6000
lbs)

o
s
o
D150
4x2

3378 mm (±33 in)

3785
mm (149 in)
2722
kg

(6000
lbs)
s
s

o
D150
4x2

3378 mm (±33 in)

3785
mm (149 in)
2722
kg

(6000
lbs)

o
s

o

D250

4x2
3327
mm
(131 in)
3357
kg

(7400
lbs)
s

s© o

D250

4x2
3327
mm
(131 in)
3357
kg

(7400
lbs)
o s© o o

D250

4x2
3327
mm
(131 in)
3357
kg

(7400
lbs)

o
s
o

D250

4x2

3785
mm (149 in)
3357
kg

(7400
lbs)
s
s
o

D250

4x2

3785
mm (149 in)
3357
kg

(7400
lbs)

o
s
o

D250

4x2

3327
mm (131 in)

3785
mm (149 in)
3860
kg
(8510
lbs)
s
s
o

D250

4x2

3327
mm (131 in)

3785
mm (149 in)
3860
kg
(8510
lbs)
O
s

o

D350

4x2
3327
mm
(131 in) 3946 kg

(8700
lbs)
s
s
o

D350

4x2
3327
mm
(131 in) 3946 kg

(8700
lbs)
O

s
o

D350

4x2

3327
mm
(131 in)
4581
kg

(10,100
lbs)
S

s
o

D350

4x2

3327
mm
(131 in)
4581
kg

(10,100
lbs)
o
s
o
W150 4x4
2921 mm

(115
in)

3327
mm (131 in) 2858 kg

(6300
lbs)

2903
kg

(6400
lbs)
s®

s
o
W150
4x4
2921 mm

(115
in)

3327
mm (131 in) 2858 kg

(6300
lbs)

2903
kg

(6400
lbs)
o
s© o
W150
4x4
2921 mm

(115
in)

3327
mm (131 in) 2858 kg

(6300
lbs)

2903
kg

(6400
lbs)
o
s
o
W150
4x4

3785
mm (149 in)
2903
kg

(6400
lbs)
s

s© o
W150
4x4

3785
mm (149 in)
2903
kg

(6400
lbs)

o
s
o

W250
4x4
3327
mm

Q31
in)
3/85 mm (149 in)
3402
kg

(7500
lbs)
s

s© o

W250

4x4
3327
mm

Q31
in)
3/85 mm (149 in)
3402
kg

(7500
lbs)

o
s
o

W250

4x4

3327
mm (131 in)

3785
mm (149 in)
3860
kg
(8510
lbs)
s
s
o

W250

4x4

3327
mm (131 in)

3785
mm (149 in)
3860
kg
(8510
lbs)
o
s
o

W350
4x4
3327
mm
(131 in) 3946 kg

(8700
lbs)
s
s
o

W350

4x4
3327
mm
(131 in) 3946 kg

(8700
lbs)
o
s
o

W350

4x4
3327
mm
(131 in)
4581
kg

(10,100
lbs)
s
s
o

W350

4x4
3327
mm
(131 in)
4581
kg

(10,100
lbs)
o
s
o

S
=
STANDARD
O =
OPTIONAL
©= Not
available
in
California
J90IN-39

6 INTRODUCTION
•
ENGINE/TRANSMISSION/GVWR
(CONT'D)

RAM CHASSIS
CAB
ENGINE
&
SALES CODE TRANSMISSION
VEHICLE LINE WHEELBASE
GVWR 3.9L
EFI
EHB 5.2L
EFI
ELG 5.9L
EFI
EMG 5.9L
EFI
EMJ 5.9L

DIESEL
ETA 5-SP
MAN. O.D. 4-SP
MAN. O.D. 4-SP
MAN. 3-SP

AUTO
4-SP

AUTO
O.D.

D250

4x2
3327
mm
(131 in)
3357
kg

(7400
lbs)
S

s

3860
kg
(8510 lbs)
s©

S
o

3860
kg
(8510 lbs)
s©
s
o
O
S
o

D350

4x2
3327
mm
(131 in) 3946 kg

(8700
lbs)
s©

s
o

D350

4x2
3327
mm
(131 in) 3946 kg

(8700
lbs)
s©
s

o

3429 mm
(135
in)
4039 mm (159 in) 4581 kg

(10,100
lbs)
s
s
o

3429 mm

(135
in)
4039 mm (159 in)
4763
kg

(10,500
lbs)
o

s
o

W250
4x4
3327
mm
(131 in)
3860
kg
(8510 lbs)
s©

s

o

W250

4x4
3327
mm
(131 in)
3860
kg
(8510 lbs)
s©
s
o
o
s
o

W350
4x4
3327
mm
(131 in) 3946 kg

(8700
lbs)
s©

s

o

W350

4x4
3327
mm
(131 in) 3946 kg

(8700
lbs)
s®
s

o
o
s
o

3429 mm
(135
in)
4581
kg

(10,100
lbs)
s
s
o

4989 kg

(11,000
lbs)
o

s
o
RAMCHARGER SPORT
UTILITY
D100
4x2
2692
mm
(106 in)
2540
kg

(5600
lbs)
S
S

D150
4x2
2692
mm
(106 in)
2540
kg

(5600
lbs)
S
S

W100 4x4
2692
mm
(106 in)
2722
kg

(6000
lbs)
S
S

O
W150 4x4
2692
mm
(106 in)
2722
kg

(6000
lbs)
S
S
o
W150
4x4
2692
mm
(106 in)

2903
kg

(6400
lbs)
S

S® o
W150
4x4
2692
mm
(106 in)

2903
kg

(6400
lbs)
S S
o

S
=
STANDARD
O
=
OPTIONAL ®
= Not
available
in
California.

=
California
Only.
J901N-35

11
- 6
EXHAUST
SYSTEM
AID
INTAKE MANIFOLD

•

HOLE LOCATION FOR SUPPORT (4 WHEEL DRIVE)

REAR
CONVERTER PIPE

(115"
WHEELBASE1
(131"
WHEELBASE)

5.9L
ENGINES
HANGER

ASSEMBLY

CONVERTER PIPE
INSULATOR
MUFFLER
3.9L
AND
5.2L
ENGINES

J9211-16

Fig.
1
Single
Exhaust System—Light Duty Trucks (1 of 3)

•

EXHAUST
SYSTEM AND INTAKE MANIFOLD 11-9

RETAINER
135" & 159" WHEELBASE

BRAKE
LINE
FRONT

SUSPENSION

CROSSMEMBER
BRAKE
LINE

SHIELD

(2 WHEEL DRIVE) 12.7 ± 4.8 MM
(0.50 ± 0.19 INCH)

TYPICAL
SLIP
JOINT

(MUST BE FULLY ENGAGED) TIGHTENING TORQUE

26
N-m
(19
FT. LBS.)
43
N-m
(32 FT. LBS.)
23
N-m (200
IN.
LBS.)

14
N-m
(125
IN. LBS.)

54
N-m (40
FT. LBS.)

J9211-19

Fig. 4 Dual Exhaust System (5.9L Engines)—Heavy Duty Trucks (1 of 2)

11
- 10
EXHAUST SYSTEM
AND
INTAKE MANIFOLD
EXHAUST
PIPE

BRACE

MANUAL
TRANS. EXHAUST

PIPE

BRACE

AUTO
TRANS.

BRACKET
ISOLATORS

MUFFLER
PIPE
FRAMERAIL

131
"
WHEELBASE
135"
WHEELBASE
FRAMERAIL


135"
WHEELBASE

131"
WHEELBASE
ISOLATORS

159"
WHEELBASE
MUFFLER

PIPE
131
"
& 135"
WHEELBASE
FRAMERAIL
BRACKET
CONVERTER PIPE
FRAMERAIL
TIGHTENING
TORQUE

23 N-m (200 IN.
LBS.)

14 N-m (125 IN.
LBS.)

28
N-m (250 IN.
LBS.)
J9211-20

Fig. 5 Dual Exhaust System (5.9L Engines)—Heavy Duty Trucks (2 of 2)

•
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 17 8ERY1CE PROCEDURES
(DIESEL ENGINES)

INDEX

page

Charge
Air
Cooler
(Intercooler)
25
Engine
Exhaust
Manifold
18

Exhaust
Pipe
17

Exhaust
Tailpipe
18
EXHAUST PIPE

REMOVAL

(1) Remove the clamp that holds the front exhaust
pipe clamp to the turbocharger (Fig. 1).

Fig.
1
Exhaust
Pipe to Turbocharger
Clamp

(2)
Raise and support the vehicle on a hoist.
(3)
Remove the bolt from the exhaust pipe support
strap (Fig. 2).

(4)
Remove the clamp nuts (Fig. 2).

(5)
Separate the exhaust pipe from the front ex­
haust extension pipe (Fig. 2).
TURBOCHARGER WELD
FRONT
EXHAUST
CLAMP
JOINT
PIPE
SUPPORT STRAP
PIPE
J911M

Fig.
2 Front
Exhaust
Pipe
Mounting
and
Clamps
page

Intake
Manifold
Cover
/ Air
Intake
Heater
19

Muffler
and
Extension
Pipes
17

Turbocharger
21

INSTALLATION
(1)
Align the front exhaust pipe with the front ex­
haust extension pipe and the turbocharger exhaust outlet.

(2)
Install the exhaust pipe support strap. Tighten
the nut to 41 Nun (30 ft. lbs.) torque.

(3)
Install the exhaust pipe support clamps and

nuts.
Tighten the nuts to 54 Nun (40 ft. lbs.) torque.
(4)
Lower the vehicle.

(5)
Install the turbocharger clamp and tighten the
screw to 8 Nun (74 in. lbs.) torque (Fig. 2). (6) Start the engine and check for leaks.
MUFFLER AND EXTENSION PIPES Rear extension pipes are used on the 135 inch, 149
inch and 159 inch wheelbase vehicles.

REMOVAL
(1)
Raise and support the vehicle.

(2)
Remove the clamps and nuts from the front ex­
tension pipe. Remove the clamps and nuts from the rear extension pipe or from the muffler rear exten­sion pipe (Fig. 3).
Fig.
3 Muffler and Extension Pipe(s)

21-144
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

TRANSMISSION
ADAPTER
BOLT AND

;
WASHER
(2)

INSULATOR
SPACER
(2)

UPPER

INSULATOR
(2)

INSULATOR
MOUNTING PLATE

WITH
7"
RAIL
(135
"
WHEELBASE) LOWER
INSULATOR
(2)

J9121-532

Fig.
4
Transmission-To-Crossmember
Attachment (Except 46RH)
(29)
Secure converter in place with small C-clamp
attached to edge of converter housing.

(30)
Lower transmission and remove assembly
from under vehicle.

(31)
Remove C-clamp securing converter in hous­
ing.

(32)
Carefully slide converter out of pump and re­
move it from transmission. Place converter on bench and cover converter hub with tape, cardboard, or pa­
per to prevent dirt entry.

TORQUE CONVERTER
AND
DRIVE PLATE SERVICE
After the transmission has been removed, the drive
plate and torque converter can be replaced or re­
moved for service access.
The torque converter is not a serviceable part. If
the converter is contaminated by a transmission mal­
function, or damaged in any way, it must be replaced as an assembly. Do not attempt to flush a con­
verter contaminated by metal or clutch facing
particles. Flushing will not remove these con­
taminants.
A new torque converter and oil pump are used
in 1993, 42RH transmissions. The new converter
has a different style drive hub. The hub was changed to accept the new design drive flats on
the oil pump inner gear. The drive flats replace
the square lugs used previously. If converter re­ placement should become necessary, be sure to
use the new style converter. The new converter and oil pump are not interchangeable with pre­
vious style parts.

STARTER
RING GEAR
REPLACEMENT

CAUTION:
The
starter
ring
gear
on
standard
torque

converters
can be
replaced when necessary. How­
ever,
the
ring gear
on
torque converters with
a
modulated converter clutch, cannot
be
replaced.
The heat from
welding
will
damage
the
converter
clutch friction material. Converters with
a
clutch
must
be
replaced
as an
assembly
if the
ring gear
is

damaged.

RING GEAR REMOWAL
(1) Cut through weld material at rear side of ring
gear with a hack saw or grinding wheel. Be careful
to avoid cutting or grinding into front cover. (2) Scribe heavy line on front cover next to front
face of ring gear. Line is needed to properly locate new gear on converter. (3) Support torque converter on front cover with
blocks of wood (Fig. 6) Position blocks adjacent to converter lugs to avoid altering lug position. The
torque converter must not rest on the front cover hub during this operation.