tow DODGE RAM 2002 Service Repair Manual

(g) If any of these conditions occur, replace injec-
tor.
(2) Thoroughly clean fuel injector cylinder head
bore with special Cummins wire brush tool or equiv-
alent (Fig. 24). Blow out bore hole with compressed
air.
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of a
certain thickness. A new shim with correct thickness
must always be re-installed after removing injector.
Measure thickness of injector shim (Fig. 23).Shim
Thickness: 1.5 mm (.060º)
(4) Install new shim (washer) to bottom of injector
(Fig. 22). Apply light coating of clean engine oil to
washer. This will keep washer in place during instal-
lation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
(6) Note fuel inlet hole on side of fuel injector. This
hole must be positioned towards injector connector
tube. Position injector into cylinder head bore being
extremely careful not to allow injector tip to touch
sides of bore. Press fuel injector into cylinder head
with finger pressure only.Do not use any tools to
press fuel injector into position. Damage to
machined surfaces may result.
(7) Position fuel injector hold down clamp into
shouldered bolt while aligning slot in top of injector
into groove in bottom of clamp. Tighten opposite
clamp bolt (Fig. 18) to 10 N´m (89 in. lbs.) torque.
(8) Install new o-ring to fuel injector connector
tube. Apply small amount of clean engine oil to
o-ring.(9) Press injector connector tube into cylinder head
with finger pressure only.Do not use any tools to
press tube into position. Damage to machined
surfaces may result.
(10) Connect high-pressure fuel lines. Refer to
High-Pressure Fuel Lines Removal/Installation.The
fuel line fitting torque is very critical.If fitting
is under torqued, the mating surfaces will not seal
and a high-pressure fuel leak will result. If fitting is
over torqued, the connector and injector will deform
and also cause a high-pressure fuel leak. This leak
will be inside cylinder head and will not be visible
resulting in a possible fuel injector miss and low
power.
(11) Install valve cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(12) (If necessary) install intake manifold air
heater assembly. Refer to Intake Manifold Air Heater
Removal/Installation.
(13) (If necessary) install engine lifting bracket.
Tighten 2 bolts to 77 N´m (57 ft. lbs.) torque.
(14) Connect negative battery cables to both bat-
teries.
(15) Bleed air from high-pressure lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
FUEL INJECTION PUMP
RELAY
DESCRIPTION
The fuel injection pump relay is located in the
Power Distribution Center (PDC). Refer to label
under PDC cover for relay location.
OPERATION
The Engine Control Module (ECM) energizes the
electric fuel injection pump through the fuel injection
pump relay. Battery voltage is applied to the fuel
injection pump relay at all times. When the key is
turned ON, the relay is energized when a 12±volt sig-
nal is provided by the ECM. When energized,
12±volts is supplied to the Fuel Pump Control Mod-
ule. The Fuel Pump Control Module is located on the
top of the fuel injection pump and is non-servicable.
Fig. 24 Cleaning Cylinder Head Injector BoreÐ
TYPICAL BORE
1 - INJECTOR BORE
2 - WIRE BRUSH
BR/BEFUEL INJECTION - DIESEL 14 - 103
FUEL INJECTOR (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................2
DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE........4COLUMN...............................6
GEAR.................................16
PUMP.................................33
LINKAGE - 2WD.........................40
LINKAGE - 4WD.........................42
STEERING
DESCRIPTION
The power steering system consist of a steering col-
umn, steering gear and hydraulic pump. The gear is
mounted to the frame rail and attaches to the steer-
ing linkage. The pump is a constant flow rate and
displacement vane-type pump. The pump supplies
hydraulic fluid pressure to the power steering gear
(Fig. 1).
Vehicles equipped with trailer tow option have a
power steering pump oil cooler.
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.
Fig. 1 Power Steering Gear & Pump
1 - HYDRAULIC PUMP ASSEMBLY
2 - RETURN LINE HOSE ASSEMBLY
3 - FITTINGS
4 - STEERING GEAR ASSEMBLY (RECIRCULATING BALL GEAR
SHOWN)
5 - PRESSURE HOSE ASSEMBLY
BR/BESTEERING 19 - 1

(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 13).
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 14). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 15).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment, (Refer to 19 - STEERING/GEAR - DIAGNOSIS
AND TESTING).
Fig. 13 Needle Bearing Removal
1 - REMOVER
2 - SIDE COVER AREA
Fig. 14 Upper Pitman
1 - DRIVER
2 - UPPER BEARING
Fig. 15 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
BR/BEGEAR 19 - 23
PITMAN BEARING (Continued)

INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 22). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 23).Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment, (Refer to 19 - STEERING/GEAR - ADJUST-
MENTS).
SPOOL VALVE
REMOVAL
(1) Remove lock nut (Fig. 24).
(2) Remove adjuster nut with Spanner Wrench
C-4381.
Fig. 21 Needle Bearing Removal
1 - REMOVER
2 - SIDE COVER AREA
Fig. 22 Upper Pitman Shaft Bearing
1 - DRIVER
2 - UPPER BEARING
Fig. 23 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
19 - 26 GEARBR/BE
PITMAN SHAFT SEAL (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................33
OPERATION...........................33
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 33
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....33
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............34
REMOVAL
REMOVAL - GASOLINE ENGINE..........35
REMOVAL - DIESEL ENGINE............36
INSTALLATION
INSTALLATION - GASOLINE ENGINE......37INSTALLATION - DIESEL ENGINE.........37
SPECIAL TOOLS
POWER STEERING PUMP..............38
PULLEY
REMOVAL.............................38
INSTALLATION.........................39
HOSES - PRESSURE
DESCRIPTION.........................39
OPERATION...........................39
HOSES - RETURN
DESCRIPTION.........................39
OPERATION...........................39
PUMP
DESCRIPTION
The P-Series pump is used on these vehicles (Fig.
1). The pump shaft has a pressed-on pulley that is
belt driven by the crankshaft pulley on gasoline
engines. The pump is driven off the back of the vac-
uum pump on the diesel engine.
Trailer tow option vehicles are equipped with a
power steering pump oil cooler. The oil cooler is
mounted to the front crossmember.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided by the pump for the
power steering gear. The power steering pump is a
constant flow rate and displacement, vane-type
pump. The pump is connected to the steering gear
via the pressure hose and the return hose. On vehi-
cles equipped with a hydraulic booster, the pump
supplies the hydraulic pressure for the booster.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) Possible pump leakage areas. (Fig. 2).
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: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Fig. 1 P-SeriesÐPump
1 - RESERVOIR CAP AND DIPSTICK
2 - RESERVOIR
BR/BEPUMP 19 - 33

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV4500........................1
MANUAL - NV5600.......................46
AUTOMATIC TRANSMISSION - 46RE.........87AUTOMATIC TRANSMISSION - 47RE........259
TRANSFER CASE - NV241LD..............430
TRANSFER CASE - NV241HD.............465
MANUAL - NV4500
TABLE OF CONTENTS
page page
MANUAL - NV4500
DESCRIPTION..........................1
OPERATION............................3
DIAGNOSIS AND TESTING................3
REMOVAL.............................4
DISASSEMBLY..........................5
CLEANING............................20
INSPECTION..........................20
ASSEMBLY............................21
INSTALLATION.........................37
SPECIFICATIONS.......................38
SPECIAL TOOLS.......................38ADAPTER HOUSING SEAL - NV4500
REMOVAL.............................42
INSTALLATION.........................42
EXTENSION HOUSING SEAL - NV4500
REMOVAL.............................42
INSTALLATION.........................42
SHIFT MECHANISM - NV4500
REMOVAL.............................43
INSTALLATION.........................44
SHIFT COVER - NV4500
REMOVAL.............................45
INSTALLATION.........................45
MANUAL - NV4500
DESCRIPTION
The NV4500 is a five speed constant mesh manual
transmission (Fig. 1). All gear ranges including
reverse are synchronized. Fifth gear is an overdrive
range. The transmission has a cast iron gear case
and aluminum shift cover.
Two versions are used, a standard duty for 5.9L
applications and a heavy duty for V10 and Cummins
diesel applications. Main differences are the larger
diameter input shaft, output shaft and mainshaft
fifth gear in the heavy duty model.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Roller
bearings in the drive gear support the forward end ofthe mainshaft. The mainshaft gears are all supported
on caged type roller bearings. Drive gear thrust reac-
tion is controlled by a needle type thrust bearing.
The bearing is located at the forward end of the
mainshaft.
The transmission is a top loader style. The shift
lever is located in a shifter tower which is bolted to
the shift cover and operates the shift forks and rails
directly. The shift forks and rails are all located
within the aluminum cover which is bolted to the top
of the gear case.
SHIFT PATTERN
The shift pattern is in a modified H pattern (Fig.
2). Overdrive fifth and reverse gears are in line and
outboard of the first through fourth gear positions.
BR/BETRANSMISSION AND TRANSFER CASE 21 - 1

HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds. Severe highly audible transmission noise is
generally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant
will promote rapid wear of gears, synchros, shift
rails, forks and bearings. The overheating caused by
a lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.
(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(9) Remove rear crossmember.
(10) Remove clutch slave cylinder splash shield, if
equipped.
Fig. 4 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
21 - 4 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(2) Remove countershaft end play shim and rear
bearing cup (Fig. 31).
(3) Remove reverse idler shaft (Fig. 32).
(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 33).
(5) Remove idler gear (Fig. 34).
(6) Keep reverse idler gear bearings and spacer
together (Fig. 35). Insert idler shaft through gear and
bearings to keep them in place.
Fig. 31 Countershaft End Play Shim And Rear
Bearing Cup
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
Fig. 32 Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
Fig. 33 Idler Gear Moved Away From Countershaft
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT
Fig. 34 Reverse Idler Gear
1 - REVERSE IDLER GEAR
2 - DRIVE GEAR BORE
Fig. 35 Idler Gear Components
1 - BEARINGS
2 - REVERSE IDLER GEAR
21 - 12 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(10) Remove second gear clutch cone snap ring
from mainshaft synchro hub groove (Fig. 49).
(11) Remove second gear clutch cone, synchro
clutch ring and synchro stop ring (Fig. 50).
(12) Remove 1-2 synchro hub snap ring (Fig. 51).
(13) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 52). Note tapered side of
sleeve also goes toward front. Do not disassemble
synchro components unless worn or damaged.
(14) Remove first gear synchro stop ring and
clutch ring (Fig. 53).
Fig. 46 Thrust Washer Locating Pin
1 - THRUST WASHER LOCATING PIN
Fig. 47 Second Gear
1 - SECOND GEAR
Fig. 48 Second Gear Bearing
1 - SECOND GEAR NEEDLE BEARING
Fig. 49 Second Gear Clutch Cone Snap Ring
1 - 1-2 SLEEVE
2 - SNAP RING
3 - SECOND GEAR CLUTCH CONE
Fig. 50 Second Gear Clutch Cone And Ring
1 - 1-2 SLEEVE AND HUB
2 - SYNCHRO STOP RING
3 - CLUTCH RING
4 - SECOND GEAR CLUTCH CONE
21 - 16 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

CLEANING
Clean the gears, shafts, shift components and trans-
mission housings with a standard parts cleaning sol-
vent. Do not use acid or corrosive base solvents. Dry
all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Replace the gear if the teeth are chipped, cracked or
worn thin.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Replace the retainer if worn or
damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap
ring grooves and threads. Replace the shaft if any
surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or
damage.
Inspect shift forks for wear and distortion. Check
fit of the sleeve in the fork to be sure the two parts
fit and work smoothly. Replace the fork if the roll pin
holes are worn oversize or damaged. Do not attempt
to salvage a worn fork. Replace shift fork roll pins if
necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots,
pitting or other damage. Replace the bearings if nec-
essary.
Inspect the blocker rings and fiction cones. replace
either part if worn or damaged in any way. Replace if
the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the wash-
ers if worn or the locating pin notches are distorted.
Inspect the case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. Inspcet
the alignment dowels in the case top surface and in
the housing/adapter are tight and in good condition.
Replace the gear case or housing/adapter if cracked
or broken.
Fig. 61 Reverse Clutch Gear
1 - REVERSE CLUTCH GEAR
Fig. 62 First Gear
1 - FIRST GEAR
Fig. 63 First Gear Bearing
1 - MAINSHAFT
2 - FIRST GEAR BEARING
21 - 20 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)