Transmission and transfer case DODGE RAM 1500 1998 2.G Owner's Guide

8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Switch (Manual Transfer Case)..... 8W-80-5
A/C Compressor Clutch (Diesel)......... 8W-80-5
A/C Compressor Clutch (Gas)........... 8W-80-5
A/C Heater Control C1................ 8W-80-5
A/C Heater Control C2................ 8W-80-6
A/C Pressure Transducer (Diesel)........ 8W-80-6
A/C Pressure Transducer (NGC)......... 8W-80-6
Accelerator Pedal Position Sensor (5.7L) . . 8W-80-6
Accelerator Pedal Position Sensor
(Diesel M/T)...................... 8W-80-7
Accelerator Pedel Position Sensor
(Diesel A/T)....................... 8W-80-7
Adjustable Pedal Motor (Except Memory) . 8W-80-7
Adjustable Pedal Switch (Except Memory) . 8W-80-8
Airbag Control Module C1............. 8W-80-8
Airbag Control Module C2............. 8W-80-9
Airbag-Left Curtain.................. 8W-80-9
Airbag-Passenger On/Off Switch....... 8W-80-10
Airbag-Passenger Squib.............. 8W-80-10
Airbag-Right Curtain................ 8W-80-10
Ambient Temperature Sensor.......... 8W-80-10
Amplifier Audio C1 (Premium)......... 8W-80-11
Amplifier Audio C2 (Premium)......... 8W-80-11
Ashtray Lamp...................... 8W-80-11
Automatic Day/Night Mirror C1 (Except
Base).......................... 8W-80-12
Automatic Day/Night Mirror C2
(Telematics)..................... 8W-80-12
Back-Up Lamp Switch............... 8W-80-12
Battery Temperature Sensor........... 8W-80-12
Blend Door Actuator (Single Zone)...... 8W-80-13
Blower Motor...................... 8W-80-13
Blower Motor Resistor Block.......... 8W-80-13
Brake Fluid Level Switch............. 8W-80-13
Brake Lamp Switch................. 8W-80-13
Brake Transmission Shift Interlock
Solenoid........................ 8W-80-14
C102 (NGC)....................... 8W-80-14
C103............................. 8W-80-14
C106 (5.7L A/T).................... 8W-80-14
C106 (5.7L A/T).................... 8W-80-15
C107 (5.7L)........................ 8W-80-15
C107 (5.7L)........................ 8W-80-16
C108 (Diesel)...................... 8W-80-16
C108 (Diesel)...................... 8W-80-16
C109 (Diesel)...................... 8W-80-17
C109 (Diesel)...................... 8W-80-17
C110 (Diesel)...................... 8W-80-17
C110 (Diesel)...................... 8W-80-18
C112 (Diesel M/T)................... 8W-80-18
C112 (Diesel M/T)................... 8W-80-18
C112 (Diesel A/T)................... 8W-80-18Component Page
C112 (Diesel A/T)................... 8W-80-19
C130 (Diesel)...................... 8W-80-19
C131 (4.7L Electronic Transfer Case).... 8W-80-20
C131 (4.7L Electronic Transfer Case).... 8W-80-20
C131 (5.7L/Diesel).................. 8W-80-20
C131 (5.7L/Diesel).................. 8W-80-21
C131 (3.7L/4.7L Except Electronic
Transfer Case)................... 8W-80-21
C131 (3.7L/4.7L Except Electronic
Transfer Case)................... 8W-80-22
C200............................. 8W-80-22
C200............................. 8W-80-23
C201............................. 8W-80-23
C201............................. 8W-80-23
C202............................. 8W-80-24
C202............................. 8W-80-24
C206............................. 8W-80-24
C206............................. 8W-80-24
C207............................. 8W-80-24
C207............................. 8W-80-25
C216............................. 8W-80-25
C216............................. 8W-80-25
C217............................. 8W-80-26
C217............................. 8W-80-26
C218............................. 8W-80-26
C218............................. 8W-80-27
C219............................. 8W-80-27
C219............................. 8W-80-29
C220............................. 8W-80-30
C220............................. 8W-80-31
C250 (Hands Free).................. 8W-80-31
C250 (Hands Free).................. 8W-80-32
C301............................. 8W-80-32
C301............................. 8W-80-32
C301............................. 8W-80-33
C302............................. 8W-80-33
C302 (SLT)........................ 8W-80-34
C304............................. 8W-80-34
C304............................. 8W-80-34
C305 (SLT)........................ 8W-80-35
C305 (SLT)........................ 8W-80-35
C306............................. 8W-80-36
C306............................. 8W-80-36
C308............................. 8W-80-36
C308............................. 8W-80-37
C309............................. 8W-80-37
C309............................. 8W-80-37
C311 ............................. 8W-80-38
C311 ............................. 8W-80-38
C313............................. 8W-80-38
C313............................. 8W-80-39
C315............................. 8W-80-39
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.
Connector, ground, and splice indexes are provided.Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
index for the proper figure number. For items that
are not shown in this section N/S is placed in the
Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
4WD Switch (Manual Transfer
Case)BK Near T/O for Backup Lamp Switch 16, 17, 19
A/C Compressor Clutch BK At A/C Compressor 3, 6, 7, 10
A/C Pressure Transducer BK Left Side of A/C Compressor 6, 7, 10
A/C-Heater Control C1 BK Center of Instrument Panel 34, 35, 36
A/C-Heater Control C2 BK Center of Instrument Panel 34, 35
Accelerator Pedal Position Sensor Under Battery Tray 22, 27
Adjustable Pedal Motor WT Left of Instrument Panel 31
Adjustable Pedal Switch BL Left of Instrument Panel 35, 38
Airbag Control Module C1 YL Lower Center of Instrument Panel 35, 36
Airbag Control Module C2 YL Lower Center of Instrument Panel 44, 46
Airbag Control Module-Left Side
ImpactYL Left B-Pillar 44, 46
Airbag Control Module-Right Side
ImpactYL Right B-Pillar 45, 47
Airbag-Driver Squib 1 YL On Steering Wheel N/S
Airbag-Left Curtain YL Top Left B-Pillar 44, 46
Airbag-Passenger YL Right Front of Instrument Panel 35, 39
Airbag-Right Curtain YL Top Right B-Pillar 45, 47
Ambient Temperature Sensor BK Left Rear of Hood 23, 29
Amplifier Audio C1 GY Top Center of Instrument Panel 35, 39
Amplifier Audio C2 GY Top Center of Instrument Panel 35, 39
Ashtray Lamp Center Stack 35
Automatic Day/Night Mirror (Except
Base)BK Top Center of Windshield N/S
Backup Lamp Switch BK Left Rear of Transmission 12, 13, 17, 19
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

DESCRIPTION N´m Ft. In.
Lbs. Lbs.
GeneratorÐMounting Bolt 55 40 Ð
Intake ManifoldÐBolts Refer to Procedure
Lifter Guide Holder 12 Ð 106
Oil Pan Bolts 12 - 105
Oil Dipstick Tube 12 Ð 105
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐAttaching Bolts 28 Ð 250
Oil Pump Pickup Tube ± Bolt
and Nut28 Ð 250
Rear Seal Retainer Attaching
Bolts15 Ð 132
Rear Insulator to BracketÐ 68 50 Ð
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Bracket to 41 30 Ð
Crossmember FlangeÐNuts
Rear Support Plate to
Transfer41 30 Ð
CaseÐBolts
Rocker ArmÐBolts 22 Ð 195
Spark Plugs Ð Ð Ð
Thermostat HousingÐBolts 28 Ð 250
Throttle BodyÐBolts 12 Ð 105
Transfer Case to Insulator 204 105 Ð
Mounting PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 176 129 Ð
Water Pump to Timing Chain 28 Ð 250
Case CoverÐBoltsSPECIAL TOOLS
5.7L ENGINE
CRANKSHAFT DAMPER REMOVER INSERT - 8513-A
Bloc±Chek±Kit C-3685±A
Bore Size Indicator C-119
Puller 8454
Crankshaft Damper Installer 8512
9 - 196 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

(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
REMOVAL - ENGINE
(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) Reinstall drain plug. Tighten to 50N´m (37 ft.
lbs.) torque.
(9) Lower the vehicle.
(10) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(11) Remove radiator upper hose.
(12) Remove upper fan shroud mounting bolts.
(13) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(14) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(15) Remove cooling fan and shroud together.
(16) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(17) Raise vehicle on a hoist.
(18) Remove transmission and transfer case (if
equipped).
(19) Disconnect exhaust pipe from turbocharger
extension pipe.
(20) Disconnect engine harness to vehicle harness
connectors.
(21) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).(22) Remove flywheel/flexplate.
(23) Remove transmission adapter
(24) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(25) Lower vehicle.
(26) Disconnect lower radiator hose from radiator
outlet.
(27) Automatic transmission models:
(28) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(29) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(30) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(31) Disconnect charge air cooler piping.
(32) Remove charge air cooler mounting bolts.
(33) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(34) Remove damper and speed indicator ring from
front of engine.
(35) Disconnect engine block heater connector.
(36) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
(37) Remove the passenger battery ground cable
from the engine block. Remove the driver side bat-
tery ground cable from the engine block.
(38) Remove power steering pump from engine by
removing 3 bolts.
(39) Remove accelerator linkage cover.
(40) Disconnect cables from on-engine APPS.
(41) Disconnect the ECM power connector.
(42) Disconnect the ECM ground wire from the
hydroform screw.
(43) Disconnect the fuel supply and return hoses.
(44) Remove the cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(45) Disconnect the 3 injector harness connectors
at the rocker housing. Disconnect the wire harnesses
from the injectors.
(46) Remove the rear engine lift bracket.
(47) Remove cylinder #4, #5, and #6 intake and
exhaust rocker arms, pedestals, and push tubes. Note
the original location for re-assembly.
(48) Loosen #6 fuel line shield bolts and rotate
shield out of the way.
(49) Remove cylinder #5 and #6 high pressure fuel
lines. Remove the fuel connector tube nut and fuel
connector tube. Remove cylinder #5 and #6 fuel injec-
tor.
(50) Remove rocker housing.
DRENGINE 5.9L DIESEL 9 - 241
ENGINE 5.9L DIESEL (Continued)

(8) Replace injector o-ring and sealing washer on
injectors #5 and #6. Install injectors and torque using
the following steps:
²Step 1ÐInstall injector hold-down capscrews
and torque to 5 N´m (44 in. lbs.) torque.
²Step 2ÐLoosen injector hold-down capscrews.
²Step 3ÐInstall HPC connector tube and nut.
Torque nut to 15 N´m (11 ft. lbs.) torque.
²Step 4ÐTorque injector hold-down capscrews to
10 N´m (89 in. lbs.) torque.
²Step 5ÐTorque HPC connector tube nut to 50
N´m (37 ft. lbs.) torque.
(9) Install #5 and #6 high pressure fuel lines. Fol-
low correct torque sequence per section 14. Torque
fuel line fittings to 30 N-m (22 ft-lb). Torque brace
capscrew to 24 N-m (18 ft-lb).
(10) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(11) Install push tubes, rocker arms, and pedestals
for cylinders #4, #5, and #6. Torque the mounting
bolts to 36 N-m (27 ft-lbs).
(12) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(13) Install cylinder head cover. Torque to 24 N-m
(18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD -
INSTALLATION).
(14) Connect breather tube and lube oil drain tube
to breather housing cover. Install breather housing.
Torque capscrews to 24 N-m (18 ft-lbs)
(15) Connect fuel supply and return hoses.
(16) Connect ECM ground to hydroform screw.
Connect ECM power connector.
(17) Install the APPS cable(s) to the APPS. Install
the throttle linkage cover.
(18) Install the power steering pump.
(19) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(20) Connect the engine block heater connection.
(21) Connect the A/C compressor and pressure sen-
sor connectors
(22) Install the charge air cooler and a/c condenser
(if equipped). Install and tighten the charge air
cooler mounting bolts to 2 N-m (17 in-lbs).
(23) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(24) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(25) Install the radiator upper support panel.
(26) Install radiator.
(27) Connect the transmission quick-connect oil
cooler lines.(28) Raise vehicle.
(29) Connect a/c compressor suction/discharge hose
(if equipped).
(30) Install the radiator lower hose and clamps.
(31) Install the battery negative cables to the
engine block on the driver and passenger side.
(32) Install the transmission adapter with a new
camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).
(33) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(34) Install the starter motor. Torque to 43 N-m
(32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(35) Connect engine to vehicle harness connectors.
(36) Install transmission and transfer case (if
equipped).
(37) Connect the exhaust pipe to the turbocharger
elbow.
(38) Connect the transmission auxiliary oil cooler
lines (if equipped).
(39) Lower the vehicle.
(40) Connect the heater core supply and return
hoses.
(41) Install the cooling fan and upper fan shroud
at the same time. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION).
(42) Install the coolant recovery bottle.
(43) Install the windshield washer bottle.
(44) Install the upper radiator hose and clamps.
(45) Raise vehicle.
(46) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(47) Change oil filter and install new engine oil.
(48) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(49) Connect grid heater harness at grid heater
relays.
(50) Connect electrical connections to rear of alter-
nator.
(51) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
(1) Install a new o-ring onto the breather element.
(2) Lubricate o-ring and install into cylinder head
cover. Torque capscrews to 10 N´m (89 in. lbs.).
(3) Connect breather tube and lube oil drain tube.
(4) Install breather cover (Fig. 4). Torque to 24
N´m (18 ft. lbs.)
(5) Install oil fill cap.
DRENGINE 5.9L DIESEL 9 - 243
ENGINE 5.9L DIESEL (Continued)

(6) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(7) Install the cover to the gear housing, aligning
the seal pilot with the nose of the crankshaft (Fig.
70).
(8) Install the cover bolts and tighten to 24 N´m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install dust shield over nose of crankshaft.
(10) Install the crankshaft damper and speed indi-
cator ring. Torque the bolts to 40 N´m (30 ft. lbs.).
Then rotate an additional 60É. Use the engine bar-
ring tool to keep the engine from rotating during
tightening operation.
(11) Install the fan support/hub assembly and
torque bolts to 32 N´m (24 ft. lbs.).
(12) Install power steering pump.
(13) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (32 ft.lbs.).
(14) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(15) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(16) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Connect battery negative cables.
(18) Start engine and check for oil leaks.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the transmission and transfer case (if
equipped).(3) Remove the clutch cover and disc (if manual
transmission equipped) (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate.
(5) Drill holes 180É apart into the seal. Be careful
not to contact the drill against the crankshaft.
(6) Install #10 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 71).
INSTALLATION
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(1) Clean the crankshaft journal with a suitable
solvent and dry with a clean shop towel or com-
pressed air. Wipe the inside bore of the crankshaft
seal retainer with a clean shop towel.
(2) Inspect the crankshaft journal for gouges,
nicks, or other imperfections. If the seal groove in the
crankshaft is excessively deep, install the new seal
1/8º deeper into the retainer bore, or obtain a crank-
shaft wear sleeve that is available in the aftermar-
ket.
(3) Install the seal pilot and new seal, provided in
the replacement kit, onto the crankshaft.
(4) Remove the seal pilot.
(5) Install the installation tool over crankshaft.
(6) Using a ball peen hammer, strike the tool at
the 12, 3, 6, and 9 o'clock positions until the align-
ment tool bottoms out on the retainer (Fig. 72).
Fig. 70 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
Fig. 71 Crankshaft Rear Seal Removal
1 - NO. 10 SCREW
2 - REAR SEAL
3 - CRANKSHAFT
4 - SLIDE HAMMER
9 - 276 ENGINE 5.9L DIESELDR
CRANKSHAFT OIL SEAL - FRONT (Continued)

(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N´m (101 ft. lbs.) torque.
(8) Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
(11) Connect battery negative cables.
(12) Check engine oil level and adjust, if necessary.
(13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan drain plug and drain the
engine oil. Re-install plug and torque to 50 N´m (44
ft. lbs.) torque.
(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5)
Remove flywheel or torque converter drive plate.
(6) Disconnect starter cables from starter motor.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(8) Remove four (4) oil pan rear bolts. Slide a
feeler gauge between the seal retainer and oil pan
gasket to break the seal.(9) Remove the six (6) retainer-to-block bolts (Fig.
73).
(10) Remove the rear seal retainer and gasket
(Fig. 73).
(11) Support the seal retainer and drive out the
crankshaft seal with a hammer and suitable punch.
INSTALLATION
(1) If using the old seal retainer, the crankshaft
seal must be replaced.
(2) Inspect oil pan gasket for nickes or cuts. If gas-
ket is damaged, the oil pan must be removed and
gasket must be replaced. Wipe oil pan gasket dry and
apply light coating of RTV.
(3) Using the retainer alignment/seal installation
tool provided in the seal service kit, install the align-
ment tool into the retainer and install to the cylinder
block (Fig. 74), using a new gasket. Tighten the six
(6) mounting bolts by hand.
(4) The seal alignment tool is used to align rear
cover properly. Starting with the center two bolts,
tighten the retainer in a circular pattern to 10 N´m
(89 in. lbs.). Remove the alignment tool.
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
Fig. 72 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 73 Crankshaft Rear Seal Retainer and Gasket
1 - RETAINER
2 - GASKET
3 - BOLT
DRENGINE 5.9L DIESEL 9 - 277
CRANKSHAFT OIL SEAL - REAR (Continued)

(5) Make sure the provided seal pilot is installed
into the new crankshaft seal. Use the alignment/in-
stallation tool and press the seal onto the crankshaft
(Fig. 75). Alternately drive the seal at the 12, 3, 6
and 9 o'clock positions.
(6) Remove the alignment tool and trim the
retainer gasket even with the oil pan mounting sur-
face (Fig. 76).
(7) Remove the seal pilot.
(8) Apply a small amount of MopartSilicone Rub-
ber Adhesive Sealant to the oil pan rail T-joints.
(9) Install the four (4) oil pan rear mounting bolts
and torque to 28 N´m (21 ft. lbs.).
(10) Install new rectangular ring seal for cam bore.
(11) Install the flywheel housing and bolts. Torque
bolts to 77 N´m (57 ft. lbs.).
(12) Install the flywheel or converter drive plate.
Tighten bolts to 137 N´m (101 ft. lbs.).
(13) Install the starter motor Refer to (Refer to 8 -
ELECTRICAL/STARTING/STARTER MOTOR -
INSTALLATION).
(14) Install the transmission and transfer case (if
equipped).
(15) Lower vehicle.(16) Fill the crankcase with new engine oil.
(17) Connect the battery negative cables.
(18) Start engine and check for oil leaks.
Fig. 74 Aligning Seal Retainer with Alignment/
Installation Tool
1 - ALIGNMENT / INSTALLATION TOOL
2 - SEAL RETAINER
Fig. 75 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 76 Trimming Excess Gasket Material
1 - GASKET
9 - 278 ENGINE 5.9L DIESELDR
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter from below using a cap-style filter
wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional
1¤2turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Install engine support fixture # 8534.
(3) Raise vehicle on hoist.
(4) Disconnect starter cables from starter motor.
(5) Remove transmission and transfer case (if
equipped).
(6) Remove flywheel or flexplate.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(8) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).(9) Install the oil pan drain plug if sealing surface
is not damaged and tighten to 50 N´m (37 ft. lbs.)
torque.
(10) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(11) Remove oil pan and suction tube.
CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Place suction tube in oil pan and guide them
into place. Using a new tube to block gasket, install
and tighten the suction tube bolts by hand. Starting
with the oil pump inlet bolts, tighten the bolts to 24
N´m (18 ft. lbs.) torque. Tighten the remaining tube
brace bolts to 43 N´m (32 ft. lbs.) torque.
(3) Starting in the center and working outward,
tighten the oil pan bolts to 28 N´m (21 ft. lbs.)
torque.
(4) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 77 N´m
(57 ft. lbs.) torque.
(5) Connect starter motor cables.
(6) Install the flywheel or flexplate. Torque to 137
N´m (101 ft. lbs.).
(7) Install transmission and transfer case (if
equipped).
(8) Lower vehicle.
(9) Remove the engine support fixture # 8534.
(10) Install battery negative cables.
(11) Fill the crankcase with new engine oil.
(12) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
DRENGINE 5.9L DIESEL 9 - 293

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT BUMPER
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................3
REAR BUMPER
REMOVAL.............................3
INSTALLATION..........................4
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT....4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR.................11
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT.............13SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS......15
SPECIFICATIONS - FRAME DIMENSIONS . . . 16
SPECIFICATIONS - TORQUE............22
FRONT CROSSMEMBER
REMOVAL.............................22
INSTALLATION.........................22
FRONT SKID PLATE
REMOVAL.............................23
INSTALLATION.........................23
FRONT TOW HOOK ASSEMBLY
REMOVAL.............................23
INSTALLATION.........................23
TRANSMISSION CROSSMEMBER
REMOVAL.............................24
INSTALLATION.........................24
TRAILER HITCH
REMOVAL.............................25
INSTALLATION.........................25
TRANSFER CASE SKID PLATE
REMOVAL.............................26
INSTALLATION.........................26
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper center bracket nuts 95 70 Ð
Front bumper stud plate nuts 95 70 Ð
License plate hitch reinforcement bolts 54 40 Ð
Rear bumper support bracket stud plate nuts 54 40 Ð
Rear bumper support bracket to hitch bolts 54 40 Ð
Rear bumper to hitch bolts 54 40 Ð
DRFRAMES & BUMPERS 13 - 1