oil DODGE RAM 1500 1998 2.G Repair Manual

CONDITION POSSIBLE CAUSES CORRECTION
Clutch disc facing contaminated with
oil, grease, or clutch fluid.1. Leak at rear main engine seal or
transmission input shaft seal.1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.1. Release bearing sticking or
binding and does not return to the
normal running position.1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.1. Rough handling. Impact bent
cover, spring, or disc.1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.2. Tighten clutch cover using proper
procedure.
Facing on flywheel side of disc torn,
gouged, or worn.1. Flywheel surface scored or
nicked.1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.1. Frequent operation under high
loads or hard acceleration
conditions.1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.1. Clutch disc hub splines damaged
during installation.1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
DRCLUTCH 6 - 3
CLUTCH (Continued)

DESCRIPTION - COOLING SYSTEM FLOW -
5.9L DIESEL
The diesel engine cooling system consists of :
²Cross-flow radiator
²Belt driven water pump
²Cooling fan (attached to the electronic viscous
fan drive)
²Belt driven Electronic viscous fan drive
²Two piece fan shroud
²Radiator pressure cap
²Vertically mounted thermostat
²Coolant reserve/recovery system
²Transmission oil cooler
²Coolant
Coolant flow circuits for the 5.9L diesel engine are
shown in (Fig. 3).
DESCRIPTION - HOSE CLAMPS
The cooling system utilizes spring type hose
clamps. If a spring type clamp replacement is neces-
sary, replace with the original Mopartequipment
spring type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter and ensure the
clamp has the same size width (Fig. 4).
Fig. 2 5.7L Engine Coolant System Flow
1 - LH CYLINDER HEAD
2 - TO RADIATOR3 - FROM RADIATOR
4 - TO RH CYLINDER HEAD
DRCOOLING 7 - 3
COOLING (Continued)

PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if the cause of coolant
loss is not located during the warm engine examina-
tion.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove the radiator pressure cap from
the filler neck and check the coolant level. Push
down on the cap to disengage it from the stop tabs.
Wipe the inside of the filler neck and examine the
lower inside sealing seat for nicks, cracks, paint, dirt
and solder residue. Inspect the radiator-to- reserve/
overflow tank hose for internal obstructions. Insert a
wire through the hose to be sure it is not obstructed.
Inspect the cams on the outside of the filler neck.
If the cams are damaged, seating of the pressure cap
valve and tester seal will be affected.
Attach pressure tester (7700 or an equivalent) to
radiator filler neck.
Operate the tester pump to apply 103.4 kPa (15
psi) pressure to the system. If the hoses enlarge
excessively or bulges while testing, replace as neces-
sary. Observe the gauge pointer and determine the
condition of the cooling system according to following
criteria:
Holds Steady:If the pointer remains steady for
two minutes, serious coolant leaks are not present in
system. However, there could be an internal leakthat does not appear with normal system test pres-
sure. If it is certain that coolant is being lost and
leaks cannot be detected, inspect for interior leakage
or perform Internal Leakage Test. Refer to INTER-
NAL LEAKAGE INSPECTION.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all of the connections for seep-
age or slight leakage with a flashlight. Inspect the
radiator, hoses, gasket edges and heater. Seal the
small leak holes with a Sealer Lubricant (or equiva-
lent). Repair the leak holes and inspect the system
again with pressure applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine the system for external leakage.
If leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove the engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove the engine dipstick and inspect for water
globules. Also inspect the transmission dipstick for
water globules and transmission fluid cooler for leak-
age.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 145 kPa (21 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate the engine without the pressure cap on
the radiator until the thermostat opens. Attach a
Pressure Tester to the filler neck. If pressure builds
up quickly it indicates a combustion leak exists. This
is usually the result of a cylinder head gasket leak or
crack in engine. Repair as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of the gauge pointer indicates compres-
sion or combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notshort out cylinders to isolate com-
pression leak.
If the needle on dial of the pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
Fig. 5 Leak Detection Using Black Light - Typical
1 - TYPICAL BLACK LIGHT TOOL
7 - 6 COOLINGDR
COOLING (Continued)

exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINECOOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of the top of the thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
DIAGNOSIS AND TESTING - COOLING SYSTEM DIESEL ENGINE
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW1. Vehicle is equipped with a heavy
duty cooling system.1. None. System operating normally.
NOTE: Information on dash cluster
is displayed based on broadcast
datd from ECM. DTC will be set for
engine sensore circuit concern.2. Thermostat stuck open 2. Inspect and test thermostat.
3. Coolant level low. 3. Fill cooling system. (Refer to 7 -
COOLING - STANDARD
PROCEDURE)
4. Temperature gauge not
functioning correctly.4. Check cluster (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
5. Engine sensor stuck in range 5. Monitor sensor with DRB III to
verify sensor reading changes with
increasing temperature.
6. Engine sensor failed out of
range.A DTC will be set.
7. Electronically Controlled Vicsous
Fan Drive not operating properly.7. Check Electronically Controlled
Viscous Fan Drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
DRCOOLING 7 - 7
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
3. Is the temperature warning
illuminating unnecessarily?3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL).
4. Coolant low in coolant reserve/
overflow tank and radiator?4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator Cap.
Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator (5.9L) or degas
bottle (3.7L, 4.7L).
7. Coolant level low in radiator but
not in coolant reserve/overflow
tank. This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools (5.9L).7. (a) Check condition of radiator
cap and cap seals. Refer to
Radiator Cap in this Group. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to
LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
9. Coolant not flowing through
system9. Check for coolant flow at radiator
filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine area
of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.10. Remove insects and debris.
(Refer to 7 - COOLING -
STANDARD PROCEDURE).
7 - 12 COOLINGDR
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Temperature gauge reading is
inconsistent (fluctuates, cycles or is
erratic)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and
repair if necessary. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING).
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
REMOVAL).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in radiator
cap is defective.1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
7 - 14 COOLINGDR
COOLING (Continued)

STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 5.9L DIESEL ENGINE
Clean cooling system prior to refilling (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(1) Close radiator drain plug.
CAUTION: Due to the use of the one-way check
valve, the engine must not be operating when refill-
ing the cooling system.
NOTE: The diesel engine is equipped with two one-
way check valves (jiggle pins). The check valves
are used as a servicing feature and will vent air
when the system is being filled. Water pressure (or
flow) will hold the valves closed.
(2) Fill the cooling system with a 50/50 mixture of
water and antifreeze.
(3) Fill coolant reserve/overflow tank to the FULL
mark.
(4) Start and operate engine until thermostat
opens. Upper radiator hose should be warm to touch.
(5) If necessary, add 50/50 water and antifreeze
mixture to the coolant reserve/overflow tank to main-
tain coolant level. This level should be between the
ADD and FULL marks. The level in the reserve/over-
flow tank may drop below the ADD mark after three
or four warm-up and cool-down cycles.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain a freeze
point of -37ÉC (-35ÉF). If it loses color or becomes con-
taminated, drain, flush, and replace with fresh prop-
erly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
Do not remove the radiator cap to add coolant to
the system. When adding coolant to maintain the cor-
rect level, do so only at the reserve/overflow bottle.
Remove the radiator cap only for testing or when
refilling the system after service. Removing the cap
unnecessarily can cause loss of coolant and allow air
to enter the system, which produces corrosion.
WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOTAND UNDER PRESSURE. SERIOUS BURNS FROM
THE COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Bolt - Automatic Belt
Tensioner to Block41 30 -
Bolt - Automatic Belt
Tensioner Pulley61 45 -
Bolt - Automatic Belt
Tensioner Pulley - Diesel43 32 -
Bolt - Block Heater 2 - 17
Bolts - Generator/
Compressor Mounting
Bracket
# 1 and 2 54 40 -
# 3 40 30 -
Bolts - Generator/
Compressor Mounting
Bracket - Diesel24 18 -
Bolts - Fan Shroud to
Radiator Mounting - All
Except 5.9L Diesel6-55
5.9L Diesel 11.8 - 105
Bolts - Radiator to Support 8.5 - 75
Bolts - Fan Blade to
Viscous Fan Drive24 18 -
Fan Drive - All Except
8.0L/5.9L Diesel50 37 -
8.0L/5.9L Diesel 115 85 -
Bolt - Idler Pulley 54 40 -
Bolt - Idler Pulley - Diesel 43 32 -
Bolts - Thermostat Housing
- All Except 5.9L13 - 112
Bolts - Thermostat Housing
5.9L23 16 -
Bolts - Thermostat Housing
- Diesel10 - 89
Bolts - Power Steering Oil
Cooler8.4 - 75
Bolts - Transmission
Auxiliary Oil Cooler6-55
DRCOOLING 7 - 19
COOLING (Continued)

DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Nuts - Transmission Oil
Cooler Tube31.5 24 -
Bolts - Coolant Bottle 8.5 - 75
Tube Nuts - Transmission
Oil Cooler to Transmission
5.9L/46RE 31.5 24 -
3.7L/4.7L/5.7L/45RFE 20 18 -
Bolts - Water Pump -
Diesel24 18 -
Bolts - Water Pump - 4.7L 58 43 -
Block Heater - Diesel 55 41 -
Transmission Oil Cooler -
Diesel
M8 24 18 -
M12 77 57 -
SPECIFICATIONS -
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Metric Standard
3.7/4.7L/5.7L
Engine15.4L 16.2 qts.- to the
middle of the
cold fill range
5.9L Diesel
Engine28L 29.5 qts.
SPECIAL TOOLS
COOLING
Pliers Constant Pressure Hose Clamp - 6094
3/8º Quick Connect Release Tool - 6935
SPANNER WRENCHÐ6958
Cooling System Pressure Tester - 7700A
Adapter Pins 8346
7 - 20 COOLINGDR
COOLING (Continued)

INSTALLATION
(1) Install tensioner on to the mounting bracket.
Tighten bolt to 41 N´m (30 ft. lbs.).
(2) Install tensioner and bracket assembly
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
BELT TENSIONER - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 5) and
remove tensioner.
Fig. 4 Accessory Drive Belt - 5.9L Diesel
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
Fig. 5 AUTOMATIC BELT TENSIONER 5.9L DIESEL
ENGINE
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
DRACCESSORY DRIVE 7 - 23
BELT TENSIONER-5.7L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
BELT SLIPS 1. Belt slipping because of
insufficient tension1. Inspect/Replace tensioner if
necessary
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member2. Replace belt
9GROOVE JUMPING9
(Belt does not maintain correct
position on pulley)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Pulley(s) not within design
tolerance2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)1. Incorrect belt tension 1. Replace Inspect/Replace
tensioner if necessary
2. Tensile member damaged during
belt installation2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)1. Tension sheeting contacting
stationary object1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age2. Replace belt
3. Tension sheeting splice has
fractured3. Replace belt
DRACCESSORY DRIVE 7 - 25
DRIVE BELT - 3.7L / 4.7L (Continued)