DODGE RAM 2001 Service Repair Manual

OPERATION
The pilot bearing supports the transmission input
shaft, maintains proper clutch assembly alignment
and allows the transmission input shaft to rotate at a
different speed (RPM) than the engine mounted
crankshaft.
When the clutch pedal is depressed (with vehicle in
drive mode) the clutch disc slows and stops therefore,
the transmission input shaft slows and stops as well.
The pilot bearing allows the engine crankshaft to
continue to rotate even though the transmission
input shaft is stationary.
REMOVAL
(1) Remove transmission, transfer case, if
equipped, and clutch housing. Refer to Group 21,
Transmission and Transfer Case, for proper proce-
dures.
(2) Remove clutch cover and disc.
(3) Using a suitable blind hole puller, remove pilot
bearing.
INSTALLATION
(1) Clean bearing bore with solvent and wipe dry
with shop towel.
(2) Install new bearing with clutch alignment tool
(Fig. 30). Keep bearing straight during installation.
Do not allow bearing to become cocked. Tap bearing
into place until flush with edge of bearing bore. Do
not recess bearing.
(3) Install clutch cover and disc.
(4) Install clutch housing, transmission and trans-
fer case, if equipped. Refer to Group 21, Transmis-
sion and Transfer Case, for proper procedures.
CLUTCH PEDAL
REMOVAL
(1) Remove retaining clips that secure the brake
and clutch pedals to the push rods (Fig. 31).
(2) Remove the brake and clutch master cylinder
pushrods from the pedals.
(3) Remove knee bolster (Fig. 32) for access to
pedal pivot shaft.
(4) Remove brake lamp switch.
(5) Remove retainer from passenger side of pedal
pivot shaft (Fig. 33).
(6) Push pedal pivot shaft toward driver side of
support only enough to remove clutch pedal. It is not
necessary to remove shaft from pedal support
entirely.
(7) Remove clutch pedal.
Fig. 30 Typical Method Of Installing Pilot Bearing
1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - LETTER SIDE MUST FACE TRANSMISSION
Fig. 31 Clutch Cylinder Push Rod Attachment
1 - PIN
2 - CLUTCH INTERLOCK WIRE
3 - PUSH ROD
4 - CLIP
6 - 18 CLUTCHBR/BE
PILOT BEARING (Continued)

INSTALLATION
(1) Inspect bushings in clutch and brake pedals
(Fig. 33). Replace bushings if worn, cracked, or dis-
torted.(2) Lubricate pedal shaft, pedal shaft bore (Fig. 33)
and all bushings with MopartMulti Mileage, or high
temperature bearing grease.
(3) Position clutch pedal in support. Align pedal
with pivot shaft and slide shaft through pedal bush-
ings. Then repeat process for brake pedal.
(4) Slide pedal shaft through support and install
shaft retainer.
(5) Secure push rods to clutch and brake pedals.
(6) Install brake lamp switch in bracket.
(7) Install knee bolster.
LINKAGE
DESCRIPTION
The hydraulic linkage consists of a clutch master
cylinder, reservoir, a clutch slave cylinder and an
interconnecting fluid line 9 (Fig 34).
The clutch master cylinder push rod is connected
to the clutch pedal. The slave cylinder push rod is
connected to the clutch release fork. The master cyl-
inder is mounted on the driver side of the dash panel
adjacent to the brake master cylinder and booster
assembly.
The hydraulic linkage is serviced as an assembly only.
The individual components that form the linkage
assembly cannot be overhauled or serviced separately.
Fig. 32 Knee Bolster RemovalÐTypical
1 - INSTRUMENT PANEL FLANGES
2 - KNEE BOLSTER
Fig. 33 Clutch/Brake Pedal Mounting
1 - PEDAL SUPPORT
2 - SHAFT RETAINER
3 - BRAKE PEDAL
4 - CLUTCH PEDAL
5 - SHAFT RETAINER
6 - PEDAL PIVOT SHAFT
7 - BUSHINGS
Fig. 34 Clutch
1 - DASH PANEL
2 - CYLINDER RESERVOIR
3 - CLUTCH MASTER CYLINDER
4 - SLAVE CYLINDER
5 - CLUTCH HYDRAULIC LINE
BR/BECLUTCH 6 - 19
CLUTCH PEDAL (Continued)

The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are pre-filled with fluid at
the factory during assembly operations.
The hydraulic system should not require additional
fluid under normal circumstances.The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling, or remov-
ing fluid from the reservoir.
Clutch fluid level is checked at the master cylinder
reservoir. An indicator ring is provided on the outside
of the reservoir. With the cap and diaphragm
removed, fluid level should not be above indicator
ring.
To avoid contaminating the hydraulic fluid during
inspection, wipe reservoir and cover clean before
removing the cap.
OPERATION
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. Depressing the clutch pedal develops
fluid pressure in the clutch master cylinder. This
pressure is transmitted to the slave cylinder through
a connecting line. In turn, the slave cylinder operates
the clutch release lever.
The slave cylinder has an integral spring which
preloads the release bearing against the clutch dia-
phragm fingers to maintain zero free-play.
Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc.
REMOVAL
The factory installed hydraulic linkage has a quick
disconnect at the slave cylinder. This fitting should
not be disconnected or tampered with. The hydraulic
linkage is serviced as an assembly only, but it comes
as two pieces to ease installation. Once the clutch
hydraulic line is connected to the slave cylinder, it
should not be disconnected. The individual compo-
nents that form the linkage assembly cannot be over-
hauled or serviced separately.
(1) Raise and support vehicle.
(2) Remove nuts attaching slave cylinder to studs
on clutch housing (Fig. 35).
(3) Remove slave cylinder from clutch housing.
(4) Remove the plastic clip securing the hydraulic
line to the dash panel from the lower dash panel
flange.
(5) Remove the plastic clip securing the hydraulic
line to the dash panel from the upper dash panel
stud.
(6) Lower vehicle.
(7) Disconnect clutch pedal interlock switch wires.(8) Remove retaining clip (Fig. 36).
(9) Slide clutch master cylinder push rod off pedal
pin.
(10) Inspect condition of bushing in the clutch
master cylinder pushrod (Fig. 36). Replace the clutch
hydraulic linkage if bushing is worn or damaged.
(11) Verify that cap on clutch master cylinder res-
ervoir is tight. This will avoid spillage during
removal.
(12) Remove the nuts holding the clutch master
cylinder to the dash panel.
(13) Remove screws that attach clutch fluid reser-
voir to dash panel.
(14) Remove the clutch master cylinder from the
dash panel.
(15) Remove clutch cylinders, reservoir and con-
necting lines from vehicle.
INSTALLATION
The factory installed hydraulic linkage has a quick
disconnect at the slave cylinder. This fitting should
not be disconnected or tampered with. The hydraulic
linkage is serviced as an assembly only, but it comes
as two pieces to ease installation. Once the clutch
hydraulic line is connected to the slave cylinder, it
Fig. 35 Clutch Hydraulic Linkage
1 - DASH PANEL
2 - CYLINDER RESERVOIR
3 - CLUTCH MASTER CYLINDER
4 - SLAVE CYLINDER
5 - CLUTCH HYDRAULIC LINE
6 - 20 CLUTCHBR/BE
LINKAGE (Continued)

should not be disconnected. The individual compo-
nents that form the linkage assembly cannot be over-
hauled or serviced separately.
(1) Tighten cap on clutch fluid reservoir to avoid
spillage during installation.
(2) Position cylinders, connecting lines and reser-
voir in vehicle engine compartment. Locate the clutch
hydraulic line against the dash panel and behind all
engine hoses and wiring.
(3) Insert clutch master cylinder in dash panel.
Install and tighten the nuts to hold the clutch master
cylinder to the dash panel.
(4) Apply a light coating of grease to the inside
and outside diameter of the master cylinder bushing.
(5) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with retaining clip.
(6) Connect clutch pedal position (interlock) switch
wires.(7) Position clutch fluid reservoir on dash panel
and install reservoir screws. Tighten screws to 5 N´m
(40 in. lbs.) torque.
(8) Install the plastic clip securing the hydraulic
line to the dash panel into the lower dash panel
flange.
(9) Install the plastic clip securing the hydraulic
line to the dash panel onto the upper dash panel
stud.
(10) Raise vehicle.
(11) Install slave cylinder. Be sure cap at end of
cylinder rod is seated in release lever. Check this
before installing cylinder attaching nuts.
NOTE: If new linkage is being installed, do not
remove the plastic shipping strap from slave cylin-
der push rod. The shipping strap will break on its
own upon the first clutch application.
(12) Install and tighten slave cylinder attaching
nuts to 23 N´m (200 in. lbs.) torque.
(13) If a new clutch linkage is being installed, con-
nect the clutch hydraulic line (Fig. 37) to the clutch
slave cylinder.
(14) Lower vehicle.
(15) Operate linkage several times to verify proper
operation.
Fig. 36 Clutch Cylinder Push Rod Attachment
1 - PIN
2 - CLUTCH INTERLOCK WIRE
3 - PUSH ROD
4 - CLIP
Fig. 37 Clutch Slave Cylinder
1 - CLUTCH HYDRAULIC LINE
2 - CLUTCH SLAVE CYLINDER
BR/BECLUTCH 6 - 21
LINKAGE (Continued)

CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
A clutch pedal position (interlock) switch is in the
starter relay circuit and is mounted on the clutch
master cylinder push rod (Fig. 38). The switch is
actuated by clutch pedal movement.
OPERATION
The switch, which is in circuit with the starter
solenoid, requires that the clutch pedal be fully
depressed in order to start the engine. Switch cir-
cuitry and operation is provided in section 8W of
Group 8.
The position switch is an integral part of the clutch
master cylinder push rod and is not serviced
separately.
Fig. 38 Clutch Pedal Position (Interlock) Switch
1 - PIN
2 - CLUTCH INTERLOCK WIRE
3 - PUSH ROD
4 - CLIP
6 - 22 CLUTCHBR/BE

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION............................1
OPERATION.............................2
DIAGNOSIS AND TESTING..................4
PRELIMINARY CHECKS...................4
ON-BOARD DIAGNOSTICS (OBD)...........4
COOLING SYSTEM LEAKS................5
COOLING SYSTEM GAS ENGINE...........7
COOLING SYSTEM DIESEL ENGINE........12
STANDARD PROCEDURE..................15
DRAINING COOLING SYSTEM - 3.9L/5.2L/
5.9L/8.0L ENGINES......................15
DRAINING COOLING SYSTEM - 5.9L
DIESEL ENGINE........................15REFILLING COOLING SYSTEM - 3.9L/5.2L/
5.9L/8.0L ENGINES......................15
REFILLING COOLING SYSTEM - 5.9L
DIESEL ENGINE........................15
ADDING ADDITIONAL COOLANT...........16
COOLANT LEVEL CHECK................16
COOLING SYSTEM CLEANING/REVERSE
FLUSHING............................16
COOLANT SELECTION-ADDITIVES.........17
SPECIFICATIONS........................17
SPECIAL TOOLS.........................18
ACCESSORY DRIVE......................19
ENGINE................................39
TRANSMISSION.........................79
COOLING
DESCRIPTIONÐCOOLING SYSTEM FLOW -
3.9L/5.2L/5.9L ENGINE
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity forvehicles used under extreme conditions such as
trailer towing in high ambient temperatures (Fig. 1).
DESCRIPTIONÐCOOLING SYSTEM FLOW -
5.9L DIESEL
The diesel engine cooling system consists of (Fig.
2):
²Cross-flow radiator
²Belt driven water pump
²Belt driven mechanical cooling fan
²Thermal viscous fan drive
²Fan shroud
²Radiator pressure cap
²Vertically mounted thermostat
²Coolant reserve/recovery system
²Transmission oil cooler
²Coolant
BR/BECOOLING 7 - 1

Coolant flow circuits for the 5.9L diesel engine are
shown in (Fig. 3).
DESCRIPTIONÐHOSE CLAMPS
The cooling system utilizes both worm drive and
spring type hose clamps. If a spring type clamp
replacement is necessary, 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 (Fig. 4).
OPERATIONÐHOSE CLAMPS
The worm type hose clamp uses a specified torque
value to maintain proper tension on a hose connec-
tion.
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
Fig. 1 Engine Cooling System Flow
1 - HEATER
2 - BYPASS*3 - CROSSFLOW RADIATOR
Fig. 2 Cooling System Components 5.9L Diesel
Engine
1 - RADIATOR CAP
2 - AUXILIARY TRANSMISSION OIL COOLER
3 - CHARGE AIR COOLER
4 - RADIATOR LOWER HOSE
5 - OVERFLOW/RESERVOIR BOTTLE
6 - FAN SHROUD
7 - RADIATOR UPPER HOSE
8 - CONSTANT TENSION CLAMP
7 - 2 COOLINGBR/BE
COOLING (Continued)

Fig. 3 Cooling System CirculationÐDiesel Engine
BR/BECOOLING 7 - 3
COOLING (Continued)

OPERATIONÐCOOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.²Increasing engine speed for more air flow is rec-
ommended.
TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, (Refer to 7 - COOLING - DIAGNOSIS AND
TESTING)
DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrain control module (PCM) has been
programmed to monitor certain cooling system com-
ponents:
²If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) can be set.
²If an open or shorted condition has developed in
the relay circuit controlling the electric radiator fan,
a Diagnostic Trouble Code (DTC) can be set.
If the problem is sensed in a monitored circuit
often enough to indicated an actual problem, a DTC
is stored. The DTC will be stored in the PCM mem-
ory for eventual display to the service technician.
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
7 - 4 COOLINGBR/BE
COOLING (Continued)

ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC's and to obtain cooling system data,
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRB
scan tool to erase a DTC. Refer to the appropriate
Powertrain Diagnostic Procedures service informa-
tion for operation of the DRB scan tool.
DIAGNOSIS AND TESTINGÐCOOLING SYSTEM
LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate engine until radiator
upper hose is warm to touch. Aim the commercially
available black light tool at components to be
checked. If leaks are present, black light will cause
additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 5).
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if cause of coolant
loss is not located during the warm engine examina-
tion.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove radiator pressure cap from filler
neck and check coolant level. Push down on cap to
disengage it from stop tabs. Wipe inside of filler neck
and examine lower inside sealing seat for nicks,
cracks, paint, dirt and solder residue. Inspect radia-
tor-to- reserve/overflow tank hose for internal
obstructions. Insert a wire through the hose to be
sure it is not obstructed.
Inspect cams on outside of filler neck. If cams are
damaged, seating of pressure cap valve and tester
seal will be affected.
Attach pressure tester (7700 or an equivalent) to
radiator filler neck (Fig. 6).
Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
Fig. 5 Leak Detection Using Black LightÐTypical
1 - TYPICAL BLACK LIGHT TOOL
Fig. 6 Pressure Testing Cooling SystemÐTypical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
BR/BECOOLING 7 - 5
COOLING (Continued)