transmission fluid DODGE RAM 1500 1998 2.G Service Manual

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

Component Page
Speaker-Right Instrument Panel....... 8W-80-96
Speaker-Right Rear................. 8W-80-96
Speed Control Servo (Diesel A/T/NGC) . . . 8W-80-97
Speed Control Switch-Left (ETC)....... 8W-80-97
Speed Control Switch-Left
(Except ETC).................... 8W-80-97
Speed Control Switch-Right (ETC)...... 8W-80-97
Speed Control Switch-Right (Except
ETC)........................... 8W-80-97
Tail/Stop/Turn Signal Lamp-Left....... 8W-80-98
Tail/Stop/Turn Signal Lamp-Right...... 8W-80-98
Tailgate Lamp..................... 8W-80-98
Throttle Position Sensor (3.7L)......... 8W-80-98
Throttle Position Sensor (4.7L)......... 8W-80-99
Tow/haul Overdrive Switch............ 8W-80-99
Trailer Tow Connector............... 8W-80-99
Trailer Tow Connector-Add On......... 8W-80-99
Transfer Case Control Module C1 (Electric
4x4).......................... 8W-80-100
Transfer Case Control Module C2 (Electric
4x4).......................... 8W-80-100Component Page
Transfer Case Control Module C3
(Electric 4x4)................... 8W-80-101
Transfer Case Mode Sensor.......... 8W-80-101
Transfer Case Selector Switch........ 8W-80-101
Transfer Case Shift Motor........... 8W-80-101
Transmission Range Sensor.......... 8W-80-102
Transmission Solenoid Assembly
(48RE)........................ 8W-80-102
Transmission Solenoid/TRS Assembly
(NGC)......................... 8W-80-102
Vacuum Pump (Diesel).............. 8W-80-103
Vistronic Fan Drive (Diesel).......... 8W-80-103
Washer Fluid Level Switch........... 8W-80-103
Washer Pump Motor-Front........... 8W-80-103
Water In Fuel Sensor............... 8W-80-103
Wheel Speed Sensor-Left Front....... 8W-80-104
Wheel Speed Sensor-Rear............ 8W-80-104
Wheel Speed Sensor-Right Front...... 8W-80-104
Wiper Motor...................... 8W-80-104
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTSDR

INTEGRATED POWER MODULE C4 - 10 WAY
CAV CIRCUIT FUNCTION
1 Z116 18BK/VT GROUND
2 L54 18WT/LG RIGHT STOP LAMP FEED
3 W1 20BR/TN WASHER FLUID SWITCH SENSE
4- -
5- -
6 F941 20PK/LG (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
7 W7 20BR/GY WIPER PARK SWITCH SENSE
8- -
9- -
10 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
INTEGRATED POWER MODULE C5 - 26 WAY
CAV CIRCUIT FUNCTION
1 F922 16PK/YL FUSED IGNITION SWITCH OUTPUT (RUN)
2 F941 20PK/LG (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z912 20BK (GAS) GROUND
3- -
4 L10 18WT/GY FUSED IGNITION SWITCH OUTPUT (RUN)
5- -
6- -
7- -
8 Z920 12BK GROUND
9 C110 20DB/LB DEFOGGER RELAY CONTROL
10 - -
11 C13 20LB/OR A/C CLUTCH RELAY CONTROL
12 - -
13 - -
14 Z114 20BK/LG (DIESEL) GROUND
14 K173 18BR/VT (NGC) CONDENSER FAN RELAY CONTROL
15 F202 20PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
15 A16 16RD/BR (NGC) FUSED B(+)
16 T515 20YL/DB TRANSMISSION CONTROL RELAY CONTROL
17 C16 16DB/GY HEATED MIRROR RELAY OUTPUT
18 C3 20DB/YL A/C CLUTCH RELAY OUTPUT
19 - -
20 - -
21 C110 20DB/LB DEFOGGER RELAY CONTROL
22 W4 16BR/OR WIPER RELAY HIGH SPEED OUTPUT
23 F100 18PK/VT FUSED IGNITION SWITCH OUTPUT (RUN)
24 F201 18PK/OR FUSED IGNITION SWITCH OUTPUT (RUN)
25 - -
26 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Speed Control Switch-Right (ETC) WT At Steering Wheel N/S
Starter Solenoid Left Engine 23
Tail/Stop/Turn Signal Lamp-Left BK At Lamp 50, 51
Tail/Stop/Turn Signal Lamp-Right BK At Lamp 50, 51
Throttle Position Sensor NAT Throttle Body 6
Trailer Tow Connector BK At Trailer Hitch 51
Trailer Tow Connector-Add On BK At Trailer Hitch 51, 53
Transfer Case Control Module C1 BK Left Side of Instrument Panel 35, 38
Transfer Case Control Module C2 GY Left Side of Instrument Panel 35, 38
Transfer Case Control Module C3 BK Left Side of Instrument Panel 35, 38
Transfer Case Mode Sensor BK Left Front Side of Transfer Case 13, 14, 16, 20
Transfer Case Position Sensor BK Front Middle of Transfer Case 20
Transfer Case Selector Switch BK Center of Instrument Panel 11, 12, 33, 35, 36
Transfer Case Shift Motor BK Left Rear of Transmission 13, 14, 20
Transmission Range Sensor BK Left side of Transmission 11, 14
Transmission Solenoid Assembly BK Left Side of Transmission 14, 11
Transmission Solenoid/TRS
Assembly (3.7L/4.7L)BK Left Side of Transmission 15, 16
Underhood Lamp BK Underside of Hood 29
Vacuum Pump (Diesel) Right Rear Engine Compartment 21
Vistronic Fan Drive Front Engine Compartment 28
Washer Fluid Level Switch BK At Reservoir 21, 23, 26, 28
Washer Pump Motor-Front BK At Washer Fluid Reservoir 21, 23, 26, 28
Water In Fuel Sensor (Diesel) BK Right Side Engine 10
Wheel Speed Sensor-Left Front BK Left Rear Lower Side of Engine
Compartment22, 29
Wheel Speed Sensor-Rear BK Right Rear of Body 51
Wheel Speed Sensor-Right Front GY Right Rear Lower Side of Engine
Compartment21
Wiper Motor-Front BK Left Side of Cowl 22, 25
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
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 PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and MopartGasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
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
DRENGINE - 3.7L 9 - 9
ENGINE - 3.7L (Continued)

DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or
mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING) - PERFORMANCE and (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)ÐMECHANICAL for
possible causes and corrections of malfunctions.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING) and (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS
AND TESTING) for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following diagnosis:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING).
²Engine Cylinder Head Gasket Failure Diagnosis
(Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO-
SIS AND TESTING).
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
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 PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
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
9 - 94 ENGINE - 4.7LDR
ENGINE - 4.7L (Continued)

material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
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) 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).
9 - 240 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (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)

(6) Remove the wooden dowel rods and rubber
bands from the tappets.
(7) Lubricate the push rods with engine oil and
install in their original location.Verify that they
are seated in the tappets.
(8) Lubricate the valve tips with engine oil and
install the crossheads in their original locations.
(9) Lubricate the crossheads and push rod sockets
with engine oil and install the rocker arms and ped-
estals in their original locations. Tighten bolts to 36
N´m (27 ft. lbs.) torque.
(10)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(11) Install the cylinder head cover and reusable
gasket (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(12) Install gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION). Install front crankshaft dust
seal.
(13) Install the crankshaft damper with the speed
indicator ring (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - INSTALLATION).
(14) Install the fan support/hub assembly Refer to
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(15) Install the power steering pump.
(16) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (32 ft. lbs.).
(17) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(18) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(19) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 11 N´m (95 in. lbs.) torque.
(20) Install the radiator upper support panel.
(21) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(22) Raise vehicle on hoist.
(23) Connect radiator lower hose and install
clamp.
(24) Connect transmission auxiliary oil cooler lines
(if equipped).
(25) Lower vehicle.
(26) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(27) Install the electronically controlled viscous
fan/drive assembly. Connect harness connector.(Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).(28) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(29) Connect the coolant recovery hose to the radi-
ator filler neck.
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
(1) Measure the connecting rod bore with bearings
removedand the bolts tightened to 100 N´m (73 ft.
lbs.) torque..
(2) Measure the connecting rod bore with the bear-
ingsinstalledand the bolts tightened to 100 N´m
(73 ft. lbs.) torque.
Measure within 20É arc from each side of the part-
ing line. Also measure 90É from parting line.
Record the smallest and largest diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 63). Calculate the average diam-
eter for each side of the journal.
Determine minimum bearing clearance by calculat-
ing the differance between the smallest connecting
rod bore diameter with the bearing installed and the
average diameter for each side of the crankshaft jour-
nal.
Determine the maximum bearing clearance by cal-
culating the difference between the largest connect-
ing rod bore diameter and the average diameter with
the bearing installed for each side of the crankshaft
journal.
DESCRIPTION MEASUREMENT
CONNECTING ROD
BORE, BEARINGS
REMOVEDMIN. 72.99 mm (2.874
in.)
MAX. 73.01 mm (2.875
in.)
CONNECTING ROD
BORE, BEARINGS
INSTALLEDMIN. 69.05 mm (2.719
in.)
MAX. 69.10 mm (2.720
in.)
9 - 272 ENGINE 5.9L DIESELDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................2
DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE........4
SPECIAL TOOLS
STEERING...........................5COLUMN...............................6
GEAR - INDEPENDENT FRONT SUSPENSION..17
GEAR - LINK/COIL.......................20
LINKAGE - INDEPENDENT FRONT
SUSPENSION...........................32
LINKAGE - LINK/COIL....................34
PUMP.................................39
STEERING
DESCRIPTION
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
Power steering systems consist of:
²Steering column
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure and return hoses
²Oil Cooler
OPERATION
The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
DRSTEERING 19 - 1