automatic transmission fluid type DODGE RAM 1500 1998 2.G Workshop Manual

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................1
DESCRIPTION - ENGINE OIL AND
LUBRICANTS.........................1
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................2
DESCRIPTION - POWER STEERING FLUID . . 3
DESCRIPTION - ENGINE COOLANT........3
DESCRIPTION - TRANSFER CASE.........4
DESCRIPTION - AXLE...................4
DESCRIPTION - MANUAL TRANSMISSION . . . 4
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID..................4
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES.....................5
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION........................6
MAINTENANCE SCHEDULES Ð 24±VALVE
CUMMINS TURBO DIESEL..............12
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 19
HOISTING
STANDARD PROCEDURE - HOISTING.......20
TOWING
STANDARD PROCEDURE - TOWING........21
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
DESCRIPTION
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use good quality diesel fuel from a reputable sup-
plier in your Dodge truck. For most year-round ser-
vice, number 2 diesel fuel meeting ASTM
specification D-975 will provide good performance. If
the vehicle is exposed to extreme cold (below 0ÉF/-
18ÉC), or is required to operate at colder-than-normal
conditions for prolonged periods, use climatized No. 2
diesel fuel or dilute the No. 2 diesel fuel with 50%
No. 1 diesel fuel. This will provide better protection
from fuel gelling or wax-plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good-quality fuel and fol-low the cold-weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm-up perfor-
mance.
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
DRLUBRICATION & MAINTENANCE 0 - 1

Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC. (Fig. 5)
DESCRIPTION - POWER STEERING FLUID
MopartATF +4, Automatic Transmission Fluid is
required in the power steering system. Substitute
fluids can induce power steering system failure.
MopartATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACTYOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with organic corro-
sion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise to as high as 149ÉC
(300ÉF). This temperature is hot enough to melt plas-
Fig. 4 API RATING WRAP FIGURE
Fig. 5 DIESEL OIL VISCOSITY CHART
DRLUBRICATION & MAINTENANCE 0 - 3
FLUID TYPES (Continued)

tic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicle's coolant bottle to iden-
tify HOAT or Non-HOAT coolant. Non-HOAT coolant
is green in color.
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 to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE
Recommended lubricant for the NV241 GENII,
NV271, NV243, NV244 GENII, and NV273 transfer
cases is MopartATF +4, Automatic Transmission
Fluid.
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
FRONT AXLE
²C205F - MopartGear Lubricant 75W-90
²9 1/4 AA - MopartSynthetic Gear Lubricant
75W-90
REAR AXLE
²9 1/4 - MopartSynthetic Gear Lubricant 75W-
140
²10 1/2 AA - MopartSynthetic Gear Lubricant
75W-90
²11 1/2 AA - MopartSynthetic Gear Lubricant
75W-90
NOTE: Trac-LokTdifferentials require Limited Slip
Additive in the lubricant. Trac-RiteŸ differentials
DO NOT require Limited Slip Additive.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
²NV3500 - MopartManual Transmission Lubri-
cant
²NV4500 - MopartSynthetic 75W85 Manual
Transmission Lubricant
²NV5600 - MopartManual Transmission Lubri-
cant
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, Automatic Transmission Fluid is
the recommended fluid for DaimlerChrysler auto-
matic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.
0 - 4 LUBRICATION & MAINTENANCEDR
FLUID TYPES (Continued)

FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
Short Box (Lt. Duty) 98 L (26 gal.)*
Long Box (Lt. Duty) 132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L 4.7 L (5.0 qts.)
4.7L 5.6 L (6.0 qts.)
5.7L 6.6 L (7.0 qts.)
5.9L DIESEL 11.4 L (12.0 qts.)
DESCRIPTION SPECIFICATION
COOLING SYSTEM
3.7L 15.4 L (16.2 qts.)**
4.7L 15.4 L (16.2 qts.)**
5.7L 15.4L (16.2 qts.)**
5.9L Diesel Engine 28L (29.5 qts.)**
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 48RE 3.8 L (4.0 qts.)
O-haul - 48RE 14-16L (29-33 pts.)L
Service Fill - 45RFE/
545RFE4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.)
O-haul - 45RFE/545RFE 14-16 L (29-33 pts.)L
LDry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/AUTOMATIC/
FLUID - STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV3500 4X2 2.27 L (4.8 pts.)
NV3500 4X4 1.99 L (4.2 pts.)
NV4500 3.79 L (8.0 pts.)
NV5600 4.50 L (9.5 pts.)
TRANSFER CASE
NV241 GENII 1.6 L (3.4 pts.)
NV243 1.6 L (3.4 pts.)
NV244 GENII 1.6 L (3.4 pts.)
NV271 1.89 L (4.0 pts.)
NV273 1.89 L (4.0 pts.)
FRONT AXLE   .03 L (1 oz)
C205F 1.66 L (3.5 pts.)
9 1/4 AA 2.25 L (4.75 pts.)
DRLUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)

Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the batteries and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and transfer case (if equipped), add as needed.
²Check Filter MinderŸ. Replace air cleaner
filter element if necessary.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints (if equipped) and front sus-
pension components.
²Check the automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
Tire Rotation
²Rotate the tires every 7,500 miles (12 000 km).
Engine Oil Change Chart Notes
²LTier 1 EPA (250 hp or 305 hp) Engines Only
(see engine data label for your engine type)
²² California LEV (235 hp) Engines Only (see
engine data label for your engine type)
Schedule ªBº
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
Miles 3,750 7,500 11,250 15,000 18,750
(Kilometers) (6 000) (12 000) (18 000) (24 000) (30 000)
Change engine oil and engine oil filter. X² XL²X²XL²X²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Inspect water pump weep hole for
blockage.X
Replace fuel filter element. Clean the water
in fuel sensor.X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Inspect brake linings.X
Inspect and adjust parking brake if
necessary.X
DRLUBRICATION & MAINTENANCE 0 - 13
MAINTENANCE SCHEDULES (Continued)

Miles 112,500 120,000 127,500 135,000 142,500 150,000
(Kilometers) (181 000) (193 000) (205 000) (217 000) (229 000) (241 000)
[Months] [90] [96] [102] [108] [114] [150]
Inspect front wheel bearings. X X
Inspect brake linings. X X
Inspect and adjust parking
brake if necessary.XX
Adjust valve lash clearance.X
²LTier 1 EPA (250 hp or 305 hp) Engines Only
(see engine data label for your engine type)
²² California LEV (235 hp) Engines Only (see
engine data label for your engine type)
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
DRLUBRICATION & MAINTENANCE 0 - 19
MAINTENANCE SCHEDULES (Continued)

for more than about 1.6 kilometers (one mile) and
the vehicle speed remains greater than about twenty-
four kilometers-per-hour (fifteen miles-per-hour).
²Vacuum Fluorescent Display Synchroniza-
tion- The EMIC transmits electronic panel lamp
dimming level messages which allows all other elec-
tronic modules on the PCI data bus with Vacuum
Fluorescent Display (VFD) units to coordinate their
illumination intensity with that of the EMIC VFD
units.
²Vehicle Theft Security System- The EMIC
monitors inputs from the door cylinder lock
switch(es), the door ajar switches, the ignition
switch, and the Remote Keyless Entry (RKE) receiver
module, then provides electronic horn and lighting
request messages to the Front Control Module (FCM)
located on the Integrated Power Module (IPM) for
the appropriate VTSS alarm output features.
²Wiper/Washer System Control- The EMIC
provides electronic wiper and/or washer request mes-
sages to the Front Control Module (FCM) located on
the Integrated Power Module (IPM) for the appropri-
ate wiper and washer system features. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS - DESCRIP-
TION).
The EMIC houses six analog gauges and has pro-
visions for up to twenty-three indicators (Fig. 3) or
(Fig. 4). The EMIC includes the following analog
gauges:
²Coolant Temperature Gauge
²Fuel Gauge
²Oil Pressure Gauge
²Speedometer
²Tachometer
²Voltage Gauge
Some of the EMIC indicators are automatically
configured when the EMIC is connected to the vehi-
cle electrical system for compatibility with certain
optional equipment or equipment required for regula-
tory purposes in certain markets. While each EMIC
may have provisions for indicators to support every
available option, the configurable indicators will not
be functional in a vehicle that does not have the
equipment that an indicator supports. The EMIC
includes provisions for the following indicators (Fig.
3) or (Fig. 4):
²Airbag Indicator (with Airbag System only)
²Antilock Brake System (ABS) Indicator
(with ABS or Rear Wheel Anti-Lock [RWAL]
brakes only)
²Brake Indicator
²Cargo Lamp Indicator
²Check Gauges Indicator
²Cruise Indicator (with Speed Control only)
²Door Ajar Indicator²Electronic Throttle Control (ETC) Indicator
(with 5.7L Gasoline Engine only)
²Gear Selector Indicator (with Automatic
Transmission only)
²High Beam Indicator
²Lamp Out Indicator
²Low Fuel Indicator
²Malfunction Indicator Lamp (MIL)
²Seatbelt Indicator
²Security Indicator (with Sentry Key Immo-
bilizer & Vehicle Theft Security Systems only)
²Service Four-Wheel Drive Indicator (with
Four-Wheel Drive only)
²Tow/Haul Indicator (with Automatic Trans-
mission only)
²Transmission Overtemp Indicator (with
Automatic Transmission only)
²Turn Signal (Right and Left) Indicators
²Upshift Indicator (with Manual Transmis-
sion only)
²Washer Fluid Indicator
²Wait-To-Start Indicator (with Diesel Engine
only)
²Water-In-Fuel Indicator (with Diesel Engine
only)
Each indicator in the EMIC, except those located
within one of the VFD units, is illuminated by a ded-
icated LED that is soldered onto the EMIC electronic
circuit board. The LED units are not available for
service replacement and, if damaged or faulty, the
entire EMIC must be replaced. Cluster illumination
is accomplished by dimmable incandescent back
lighting, which illuminates the gauges for visibility
when the exterior lighting is turned on. Each of the
incandescent bulbs is secured by an integral bulb
holder to the electronic circuit board from the back of
the cluster housing.
Hard wired circuitry connects the EMIC to the
electrical system of the vehicle. These hard wired cir-
cuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the EMIC through the use of a combination of
soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
The EMIC modules for this model are serviced only
as complete units. The EMIC module cannot be
adjusted or repaired. If a gauge, an LED indicator, a
VFD unit, the electronic circuit board, the circuit
DRINSTRUMENT CLUSTER 8J - 5
INSTRUMENT CLUSTER (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)

GEAR - LINK/COIL
TABLE OF CONTENTS
page page
GEAR - LINK/COIL
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................21
ADJUSTMENTS
ADJUSTMENT........................21
SPECIFICATIONS
POWER STEERING GEAR..............22
TORQUE CHART......................23
SPECIAL TOOLS
POWER STEERING GEAR..............23
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE...............25REMOVAL - DIESEL...................25
INSTALLATION
INSTALLATION - GAS ENGINE...........26
INSTALLATION - DIESEL................26
STEERING GEAR INPUT SHAFT SEAL
REMOVAL.............................27
INSTALLATION.........................29
PITMAN SHAFT
REMOVAL
REMOVAL - GAS......................30
REMOVAL - DIESEL...................30
INSTALLATION
INSTALLATION - GAS..................31
INSTALLATION - DIESEL................31
GEAR - LINK/COIL
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 12.5:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
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.
(2) Lock the steering wheel.
(3) Siphon out as much power steering fluid as
possible.
Fig. 1 STEERING GEAR
1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT
19 - 20 GEAR - LINK/COILDR

OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump (Fig.
1). The power steering pumps are constant flow rate
and displacement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
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 steeringpump and system if any other fluid is used, and do
not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
Fig. 1 POWER STEERING PUMP
1 - 3.7L & 4.7L (6 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.7L,5.9L & 8.0L (7 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.9L DIESEL (8 GROOVE)
STEEL PULLEY
2 - PUMP ASSEMBLY
3 - RESERVOIR
4 - CAP
19 - 40 PUMPDR
PUMP (Continued)