table of contents DODGE RAM 1500 1998 2.G Repair Manual

ENGINE - 5.7L
TABLE OF CONTENTS
page page
ENGINE - 5.7L
DESCRIPTION........................182
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION..........183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE..........183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............185
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE............186
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.....186
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION............187
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............188
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........190
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................190
REMOVAL............................190
INSTALLATION........................191
SPECIFICATIONS
5.7L ENGINE........................192
TORQUE...........................195
SPECIAL TOOLS
5.7L ENGINE........................196
AIR INTAKE SYSTEM
REMOVAL............................199
INSTALLATION........................199
CYLINDER HEAD
OPERATIONÐCYLINDER HEAD...........199
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE....................199
REMOVAL............................200
CLEANING...........................200
INSPECTION.........................200
INSTALLATION........................200
CYLINDER HEAD COVER(S)
REMOVAL............................201
INSTALLATION........................201
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES.........202
DESCRIPTION.......................202
STANDARD PROCEDURE - REFACING.....202
REMOVAL............................203INSTALLATION........................203
ROCKER ARM / ADJUSTER ASSY
REMOVAL............................203
INSTALLATION........................203
VALVE STEM SEALS
DESCRIPTION........................203
VALVE SPRINGS
REMOVAL............................204
INSTALLATION........................204
ENGINE BLOCK
CLEANING...........................205
INSPECTION.........................205
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG. 205
REMOVAL - CAMSHAFT...............205
INSPECTION.........................206
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG..............................206
INSTALLATION - CAMSHAFT............206
CRANKSHAFT
REMOVAL............................206
INSTALLATION........................207
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING..............207
INSPECTION.........................208
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................208
INSTALLATION........................208
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS........................209
REMOVAL............................209
INSTALLATION........................209
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................209
INSTALLATION........................210
FLEX PLATE
REMOVAL............................210
INSTALLATION........................210
HYDRAULIC TAPPETS
DIAGNOSIS AND TESTING - HYDRAULIC
TAPPETS...........................210
REMOVAL............................211
INSTALLATION........................211
PISTON & CONNECTING ROD
DESCRIPTION........................211
9 - 180 ENGINE - 5.7LDR

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................232
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............233
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS.................236
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION/LEAKAGE TESTS.......239
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........239
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........240
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................240
REMOVAL
REMOVAL - ENGINE..................241
REMOVALÐCRANKCASE BREATHER....242
INSTALLATION
INSTALLATION - ENGINE..............242
INSTALLATIONÐCRANKCASE BREATHER . 243
SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL.........244
TORQUE...........................245
SPECIAL TOOLS
5.9L DIESEL ENGINE.................246
ENGINE DATA PLATE
DESCRIPTION........................248
AIR CLEANER ELEMENT
REMOVAL............................248
INSTALLATION........................249
CYLINDER HEAD
DESCRIPTION........................249
REMOVAL............................249
CLEANING
CLEANINGÐCYLINDER HEAD..........251
CLEANINGÐCROSSHEADS............251
CLEANINGÐPUSHRODS..............252
INSPECTION
INSPECTION - CYLINDER HEAD.........252
INSPECTIONÐCROSSHEADS..........252
INSPECTIONÐPUSHRODS.............253
INSTALLATION........................253
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER....255
REMOVALÐROCKER HOUSING.........255
CLEANING...........................255INSPECTION.........................255
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER . 255
INSTALLATION - ROCKER HOUSING.....255
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................256
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS................256
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION.......259
REMOVAL - VALVE SPRINGS AND SEALS . . . 260
INSTALLATION........................261
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION........................261
REMOVAL............................261
CLEANING...........................262
INSPECTION.........................262
INSTALLATION........................263
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING...................264
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE...................264
STANDARD PROCEDUREÐCYLINDER
BORE REPAIR.......................265
STANDARD PROCEDUREÐCAM BORE
REPAIR ............................267
INSPECTION.........................267
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......268
REMOVAL - CAMSHAFT...............268
INSPECTION.........................270
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 271
INSTALLATION - CAMSHAFT............271
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................272
CRANKSHAFT AND GEAR
DESCRIPTION........................273
REMOVAL - GEAR.....................273
INSTALLATION - GEAR..................273
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE........................274
9 - 230 ENGINE 5.9L DIESELDR

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION........................1
DESCRIPTION - 5.9L DIESEL.............3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE . . . 4
DIAGNOSIS AND TESTING - DIESEL
ENGINE..............................5
SPECIFICATIONS - TORQUE...............5
SPECIAL TOOLS........................6
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER.....6
OPERATION............................6
REMOVAL
REMOVAL............................6
REMOVAL............................6
INSPECTION...........................6
INSTALLATION
INSTALLATION........................6
INSTALLATION........................7
EXHAUST PIPE
REMOVAL - 3.7L/4.7L/5.7L.................7
INSPECTION...........................7
INSTALLATION - 3.7L/4.7L/5.7L..............7
EXHAUST PIPE
REMOVAL - DIESEL......................7
INSPECTION...........................8
INSTALLATION - DIESEL..................8
HEAT SHIELDS
DESCRIPTION..........................8
REMOVAL.............................8
INSTALLATION..........................8
MUFFLER
REMOVAL.............................9INSTALLATION..........................9
MUFFLER - 5.9L DIESEL
REMOVAL.............................10
INSTALLATION.........................10
TAILPIPE - 5.9L DIESEL
REMOVAL.............................10
INSPECTION..........................10
INSTALLATION.........................11
TAILPIPE
REMOVAL.............................11
INSPECTION..........................11
INSTALLATION.........................11
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING -
TURBOCHARGER BOOST PRESSURE.....11
TURBOCHARGER
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................14
CLEANING............................15
INSPECTION..........................15
INSTALLATION.........................15
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION.........................16
OPERATION...........................16
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS..............16
REMOVAL.............................17
CLEANING............................17
INSPECTION..........................17
INSTALLATION.........................17
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.The federal gasoline engine exhaust system con-
sists of engine exhaust manifolds, exhaust pipes, cat-
alytic converter(s), extension pipe (if needed),
exhaust heat shields, muffler and exhaust tailpipe
(Fig. 1), (Fig. 2), (Fig. 3)
The California emission vehicles exhaust system
also contains the above components as well as mini
catalytic converters added to the exhaust pipe.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. Minimum
clearance between any exhaust component and the
body or frame is 25.4 mm (1.0 in.). If the system con-
tacts any body panel, it may amplify objectionable
noises from the engine or body.
DREXHAUST SYSTEM 11 - 1

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

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS....................1
FUEL INJECTION - GAS...................21FUEL DELIVERY - DIESEL.................44
FUEL INJECTION - DIESEL................68
FUEL DELIVERY - GAS
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS
DESCRIPTION..........................1
OPERATION............................2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE...................2
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............3
TORQUE - FUEL SYSTEM - EXCEPT
DIESEL..............................3
SPECIAL TOOLS
FUEL SYSTEM........................5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION..........................5
OPERATION............................6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................7
INSTALLATION..........................7
FUEL LINES
DESCRIPTION..........................7
QUICK CONNECT FITTING
DESCRIPTION..........................8STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS............................8
FUEL PUMP
DESCRIPTION.........................11
OPERATION...........................11
FUEL PUMP MODULE
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................12
FUEL RAIL
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................13
INSTALLATION.........................15
FUEL TANK
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL- EXCEPT DIESEL..............17
INSTALLATION - EXCEPT DIESEL..........19
INLET FILTER
REMOVAL.............................20
INSTALLATION.........................20
FUEL DELIVERY - GAS
DESCRIPTION
The fuel delivery system consists of:
²a fuel pump module containing the electric fuel
pump, fuel filter/fuel pressure regulator, fuel gauge
sending unit (fuel level sensor) and a secondary fuel
filter located at the bottom of the pump module
²fuel tubes/lines/hoses
²a combination fuel filter/fuel pressure regulator
²quick-connect fittings²fuel injector rail
²fuel tank
²fuel tank filler/vent tube assembly
²fuel tank filler tube cap
²accelerator pedal
²throttle cable
Certain fuel delivery components can be found in
(Fig. 1).
DRFUEL SYSTEM 14 - 1

FUEL INJECTION - GAS
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL
REMOVAL.............................21
INSTALLATION.........................21
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................22
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................24
INSTALLATION.........................25
FUEL INJECTOR
DESCRIPTION.........................26
OPERATION
OPERATION - FUEL INJECTOR..........26
OPERATION - PCM OUTPUT............27
REMOVAL.............................27
INSTALLATION.........................27
FUEL PUMP RELAY
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................28
INSTALLATION.........................28
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................29
INSTALLATION.........................29INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................31
MAP SENSOR
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................33
INSTALLATION.........................34
OXYGEN SENSOR
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................36
PTO SWITCH
DESCRIPTION.........................36
OPERATION...........................36
THROTTLE BODY
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL.............................36
INSTALLATION.........................37
THROTTLE CONTROL CABLE
REMOVAL.............................38
INSTALLATION.........................40
THROTTLE POSITION SENSOR
DESCRIPTION.........................41
OPERATION...........................41
REMOVAL.............................41
INSTALLATION.........................43
ACCELERATOR PEDAL
REMOVAL
The following procedure applies only to vehicles
without the Adjustable Pedal Package (code XAP).
The accelerator pedal is serviced as a complete
assembly including the bracket.
The accelerator cable is connected to the upper
part of the accelerator pedal arm by a plastic
retainer (clip) (Fig. 1). This plastic retainer snaps
into the top of the accelerator pedal arm.
(1) From inside the vehicle, hold up accelerator
pedal. Remove plastic cable retainer (clip) and throt-
tle cable core wire from upper end of accelerator
pedal arm (Fig. 1). Plastic cable retainer (clip) snaps
into pedal arm.(2) Remove 2 accelerator pedal mounting bracket
nuts. Remove accelerator pedal assembly.INSTALLATION
(1) Place accelerator pedal assembly over 2 studs.
(2) Install and tighten 2 mounting nuts. Refer to
Torque Specifications.
(3) Slide throttle cable into opening slot in top of
pedal arm.
(4) Push plastic cable retainer (clip) into accelera-
tor pedal arm opening until it snaps into place.
(5) Before starting engine, operate accelerator
pedal to check for any binding.
DRFUEL INJECTION - GAS 14 - 21

FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page page
FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM.....45
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER
DRAINING AT FUEL FILTER..............47
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM PARTS.................47
STANDARD PROCEDURE - FUEL SYSTEM
PRIMING............................47
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL . 48
TORQUE - FUEL SYSTEM - DIESEL
ENGINE.............................48
SPECIAL TOOLS
DIESEL FUEL SYSTEM.................49
FUEL FILTER / WATER SEPARATOR
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL.............................50
INSTALLATION.........................50
FUEL HEATER
DESCRIPTION.........................51
OPERATION...........................51
DIAGNOSIS AND TESTING - FUEL HEATER . . . 52
REMOVAL
REMOVAL/INSTALLATION...............52
FUEL HEATER RELAY
DESCRIPTION.........................52
OPERATION...........................52
REMOVAL.............................52
INSTALLATION.........................53
FUEL INJECTION PUMP
DESCRIPTION.........................53
OPERATION...........................53
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING........................53
REMOVAL.............................54
INSTALLATION.........................55
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION.........................57
OPERATION...........................57
REMOVAL
REMOVAL/INSTALLATION...............57FUEL LINES
DESCRIPTION.........................57
OPERATION...........................57
DIAGNOSIS AND TESTING - HIGH-
PRESSURE FUEL LINE LEAKS...........58
REMOVAL.............................58
INSTALLATION.........................60
FUEL PRESSURE SENSOR
DESCRIPTION.........................60
OPERATION...........................60
REMOVAL.............................60
INSTALLATION.........................61
FUEL PRESSURE LIMITING VALVE
DESCRIPTION.........................61
OPERATION...........................61
REMOVAL.............................61
INSTALLATION.........................61
FUEL TANK
DESCRIPTION - DIESEL..................62
REMOVAL - DIESEL.....................62
INSTALLATION - DIESEL.................62
FUEL TANK MODULE
DESCRIPTION.........................63
OPERATION...........................63
REMOVAL.............................63
INSTALLATION.........................64
FUEL TRANSFER PUMP
DESCRIPTION.........................64
OPERATION...........................64
REMOVAL.............................64
INSTALLATION.........................65
CASCADE OVERFLOW VALVE
DESCRIPTION.........................66
OPERATION...........................66
REMOVAL
REMOVAL/INSTALLATION...............66
WATER IN FUEL SENSOR
DESCRIPTION.........................66
OPERATION...........................66
REMOVAL.............................66
FUEL DRAIN CIRCUIT
OPERATION...........................67
14 - 44 FUEL DELIVERY - DIESELDR

FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................68
OPERATION...........................68
REMOVAL.............................68
INSTALLATION.........................71
CAMSHAFT POSITION SENSOR
DESCRIPTION.........................71
OPERATION...........................71
REMOVAL.............................72
INSTALLATION.........................72
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................72
OPERATION...........................72
REMOVAL.............................73
INSTALLATION.........................73
FUEL CONTROL ACTUATOR
DESCRIPTION.........................74
OPERATION...........................74
REMOVAL.............................74
FUEL INJECTOR
DESCRIPTION.........................74
OPERATION...........................74
REMOVAL.............................75
INSTALLATION.........................77
FUEL INJECTOR RAIL
DESCRIPTION.........................78
OPERATION...........................78
REMOVAL.............................78
INSTALLATION.........................78INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR
DESCRIPTION.........................79
OPERATION...........................79
REMOVAL.............................79
INSTALLATION.........................79
INTAKE AIR HEATER
DESCRIPTION.........................80
OPERATION...........................80
REMOVAL.............................80
INSTALLATION.........................80
INTAKE AIR HEATER RELAY
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................82
INSTALLATION.........................82
INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................82
INSTALLATION.........................82
MAP SENSOR
DESCRIPTION.........................83
THROTTLE CONTROL CABLE
REMOVAL.............................83
INSTALLATION.........................84
PTO SWITCH
DESCRIPTION.........................85
OPERATION...........................85
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
Engine Mounted Sensor:The APPS assembly is
located at the top-left-front of the engine. A plastic
cover is used to cover the assembly. The actual sen-
sor is located behind its mounting bracket.
Battery Tray Mounted Sensor:The Accelerator
Pedal Position Sensor (APPS) assembly is located
under the vehicle battery tray. A cable connects the
assembly to the accelerator pedal. A plastic cover
with a movable door is used to cover the assembly.
OPERATION
Engine Mounted Sensor:The Accelerator Pedal
Position Sensor (APPS) is a linear potentiometer. Itprovides the Engine Control Module (ECM) with a
DC voltage signal proportional to the angle, or posi-
tion of the accelerator pedal.
Battery Tray Mounted Sensor:The APPS pro-
vides the ECM with two DC voltage signals which
change as the position of the accelerator changes.
One of the DC voltage signals will be half the voltage
of the other signal.
REMOVAL
Engine Mounted Sensor :
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assem-
bly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 1).
14 - 68 FUEL INJECTION - DIESELDR

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

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
DIAGNOSIS AND TESTING - STEERING
COLUMN.............................7
REMOVAL.............................7
INSTALLATION..........................9
IGNITION SWITCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................9
REMOVAL.............................10
INSTALLATION.........................11
KEY-IN IGNITION SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......11
KEY CYLINDER
REMOVAL.............................12
INSTALLATION.........................12GEAR SHIFT LEVER
REMOVAL.............................12
INSTALLATION.........................12
UPPER STEERING COUPLING
REMOVAL.............................13
INSTALLATION.........................13
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD...................14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD.................................14
INSTALLATION - 4X4 HD................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
TILT LEVER KNOB RELEASE
REMOVAL.............................16
INSTALLATION.........................16
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT INACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
19 - 6 COLUMNDR