4WD DODGE RAM 2002 Service Owner's Manual

8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Switch........................ 8W-80-4
A/C Compressor Clutch................ 8W-80-4
A/C Heater Control................... 8W-80-4
A/C Heater Temperature Select......... 8W-80-4
A/C High Pressure Switch............. 8W-80-4
A/C Low Pressure Switch.............. 8W-80-5
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-5
Aftermarket Trailer Tow Connector...... 8W-80-5
Airbag Control Module................ 8W-80-5
Ambient Temperature Sensor........... 8W-80-6
Ash Receiver Lamp................... 8W-80-6
Automatic Day/Night Mirror............ 8W-80-6
Back-Up Lamp Switch (M/T)........... 8W-80-6
Battery Temperature Sensor............ 8W-80-7
Blend Door Actuator.................. 8W-80-7
Blower Motor....................... 8W-80-7
Blower Motor Resistor Block............ 8W-80-7
Brake Lamp Switch.................. 8W-80-7
Brake Pressure Switch................ 8W-80-8
Bypass Jumper (A/T)................. 8W-80-8
C105.............................. 8W-80-8
C105.............................. 8W-80-8
C106.............................. 8W-80-8
C106.............................. 8W-80-8
C114 .............................. 8W-80-9
C114 .............................. 8W-80-9
C125 (Diesel)....................... 8W-80-9
C125 (Diesel)....................... 8W-80-9
C126 (Diesel)....................... 8W-80-10
C126 (Diesel)....................... 8W-80-10
C129............................. 8W-80-10
C129............................. 8W-80-11
C130 (Diesel)....................... 8W-80-11
C130 (Diesel) (In PDC)............... 8W-80-12
C130 (Gas)........................ 8W-80-13
C130 (Gas) (In PDC)................. 8W-80-14
C134............................. 8W-80-15
C134............................. 8W-80-17
C203............................. 8W-80-18
C203............................. 8W-80-19
C205............................. 8W-80-20
C205............................. 8W-80-20
C206 (Heated Seats)................. 8W-80-20
C206 (Heated Seats)................. 8W-80-21
C237............................. 8W-80-21
C237............................. 8W-80-21
C303............................. 8W-80-22
C303............................. 8W-80-22
C308............................. 8W-80-22
C308............................. 8W-80-22
C329 (Club Cab).................... 8W-80-22Component Page
C329 (Club Cab).................... 8W-80-23
C329 (Standard Cab)................ 8W-80-23
C329 (Standard Cab)................ 8W-80-23
C333 (Club Cab).................... 8W-80-23
C333 (Club Cab).................... 8W-80-23
C333 (Standard Cab)................ 8W-80-24
C333 (Standard Cab)................ 8W-80-24
C342............................. 8W-80-24
C342............................. 8W-80-24
C343............................. 8W-80-24
C343............................. 8W-80-24
C344 (Dual Rear Wheels)............. 8W-80-25
C344 (Dual Rear Wheels)............. 8W-80-25
C345............................. 8W-80-25
C345............................. 8W-80-25
C346............................. 8W-80-26
C346............................. 8W-80-26
C347............................. 8W-80-26
C347............................. 8W-80-27
C348............................. 8W-80-27
C348............................. 8W-80-28
C352............................. 8W-80-28
C352............................. 8W-80-28
C353............................. 8W-80-28
C353............................. 8W-80-28
C358............................. 8W-80-29
C358............................. 8W-80-29
C359 (Heated Seat).................. 8W-80-29
C359 (Heated Seat).................. 8W-80-29
C360 (Club Cab).................... 8W-80-30
C360 (Club Cab).................... 8W-80-30
C361............................. 8W-80-30
C361............................. 8W-80-30
C364............................. 8W-80-31
C364............................. 8W-80-31
C365 (Heated Seat).................. 8W-80-31
C365 (Heated Seat).................. 8W-80-31
Camshaft Position Sensor (8.0L Gas).... 8W-80-32
Camshaft Position Sensor (Diesel)...... 8W-80-32
Camshaft Position Sensor
(Gas Except 8.0L)................. 8W-80-32
Cargo Lamp No. 1................... 8W-80-32
Cargo Lamp No. 2................... 8W-80-32
Center High Mounted Stop Lamp No. 1 . . 8W-80-33
Center High Mounted Stop Lamp No. 2 . . 8W-80-33
Center Identification Lamp............ 8W-80-33
Central Timer Module C1............. 8W-80-33
Central Timer Module C2............. 8W-80-34
Cigar Lighter...................... 8W-80-34
Clockspring C1..................... 8W-80-34
Clockspring C2..................... 8W-80-34
Clockspring C3..................... 8W-80-35
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1

4WD SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G107 18BK/GY 4WD SWITCH SENSE
2 Z1 18BK GROUND
A/C COMPRESSOR CLUTCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z11 18BK/WT GROUND
A/C-HEATER CONTROL - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 Z3 12BK/OR GROUND
2 C7 12BK/TN HIGH SPEED BLOWER MOTOR CONTROL
3 C6 14LB M2 SPEED BLOWER MOTOR CONTROL
4 C5 16LG M1 SPEED BLOWER MOTOR CONTROL
5 C4 16TN LOW SPEED BLOWER MOTOR CONTROL
6 C90 22LG/WT A/C SELECT INPUT
7 E2 22OR PANEL LAMPS FEED
A/C HEATER TEMPERATURE SELECT-5WAY
CAV CIRCUIT FUNCTION
1- -
2 Z2 22BK/LG GROUND
3 C82 22YL/OR TEMPERATURE SELECT
4 F15 22DB FUSED IGNITION SWITCH OUTPUT (RUN)
5- -
A/C HIGH PRESSURE SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 C90 18LG/WT A/C SELECT INPUT
2 C22 18DB A/C SWITCH SENSE
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTSBR/BE

CLOCKSPRING C3-4WAY
CAV CIRCUIT FUNCTION
A V37 22DG/RD SPEED CONTROL SWITCH SIGNAL
B Z2 22BK/LG GROUND
D X20 22RD/BK RADIO CONTROL MUX
C K4 22WT SENSOR GROUND
CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 A41 14YL FUSED IGNITION SWITCH OUTPUT (START)
2 T141 14YL/RD CLUTCH PEDAL POSITION SWITCH OUTPUT
CONTROLLER ANTILOCK BRAKE C1 - BLACK 14 WAY
CAV CIRCUIT FUNCTION
1 B113 20RD/VT REAR WHEEL SPEED SENSOR (+)
2 G107 20GY 4WD SWITCH SENSE
3 D1 20VT/BR CCD BUS (+)
4 A20 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
5- -
6 Z8 14BK/VT GROUND
7 A10 14RD/DG FUSED B(+)
8 B114 20WT/VT REAR WHEEL SPEED SENSOR (-)
9 V40 20WT/PK BRAKE SWITCH SENSE
10 D2 20WT/BK CCD BUS (-)
11 G9 20GY/BK BRAKE PRESSURE SWITCH SENSE
12 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL
13 Z8 14BK/VT GROUND
14 A10 14RD/DG FUSED B(+)
CONTROLLER ANTILOCK BRAKE C2 (ABS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+)
2 B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-)
3 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
4 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+)
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35

INSTRUMENT CLUSTER C2 - 10 WAY
CAV CIRCUIT FUNCTION
1 E2 22OR PANEL LAMPS FEED
2 G29 22BK/WT WASHER FLUID SWITCH SENSE
3 G10 22LG/RD SEAT BELT SWITCH SENSE
4- -
5 E17 18YL/BK DAY BRIGHTNESS SENSE
6 L61 18LG LEFT TURN SIGNAL
7 G13 22DB/RD CHIME REQUEST SIGNAL
8 L60 18TN RIGHT TURN SIGNAL
9 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
10 G107 22GY 4WD SWITCH SENSE
INTAKE AIR HEATER RELAYS (DIESEL)-4WAY
CAV CIRCUIT FUNCTION
1 S22 18OR/BK AIR INTAKE HEATER RELAY CONTROL NO. 2
2 Z12 18BK/TN GROUND
3 S21 18YL/BK AIR INTAKE HEATER RELAY CONTROL NO. 1
4 Z12 18BK/TN GROUND
INTAKE AIR TEMPERATURE SENSOR (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
A K104 18BK/LB SENSOR GROUND
B K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
INTAKE AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
JOINT CONNECTOR NO. 1 (IN PDC) - 28 WAY
CAV CIRCUIT FUNCTION
1 V40 20WT/PK BRAKE SWITCH SENSE
2 V40 22WT/PK BRAKE SWITCH SENSE
3 V40 22WT/PK BRAKE SWITCH SENSE
4 L4 18VT/WT DIMMER SWITCH LOW BEAM OUTPUT
5 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
5 L4 16VT/WT(QUAD) DIMMER SWITCH LOW BEAM OUTPUT
8W - 80 - 50 8W-80 CONNECTOR PIN-OUTSBR/BE

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.Connector, ground, and splice indexes are provided.
Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
index for the proper figure number. For items that
are not shown in this section N/S is placed in the
Fig. column.
CONNECTORS
CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
4WD Switch BK On Front Axle N/S
A/C Compressor Clutch BK Rear of A/C Compressor 7, 8, 11
A/C Heater Control BK Center of Instrument Panel 33
A/C Heater Temperature
SelectNAT Center of Instrument Panel 33
A/C High Pressure Switch BK At A/C Compressor 7, 8, 11
A/C Low Pressure Switch BK Top of A/C Accumulator 1, 3
Accelerator Pedal Position
Sensor (Diesel)Left Front of Engine 13, 14
Aftermarket Trailer Tow
ConnectorRear of Vehicle N/S
Airbag Control Module Center of I.P. at Airbag Control Module 30
Ambient Temperature Sensor BK Radiator Left Support N/S
Ash Receiver Lamp BK Center of Instrument Panel 34
Back-up Lamp Switch (M/T) BK Top of Transmission 16
Battery Temperature Sensor BK Below Battery Tray 21
Blend Door Actuator Center of Instrument Panel N/S
Blower Motor BK Bottom Right of Instrument Panel 30
Blower Motor Resistor Block BK Bottom Right of Instrument Panel 34
Brake Lamp Switch Brake Pedal Arm 30, 32
Brake Pressure Switch BK At Master Cylinder 18
Bypass Jumper (A/T) GN Top Of Clutch Pedal 35
C105 Rear of Front Bumper N/S
C106 BK Rear of Front Bumper 22
C114 BK Radiator Left Support 20
C125 (Diesel) BK Left Rear of Engine Compartment 3
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US Item Identification Location of
Identification
U/S Crankshaft R or M M-2-3
ect.Milled flat
on
.025 MM (indicating No.
2&No. three
(.001 in.) 3 main
bearingcrankshaft
journal) and/or counterweight.
R-1-4 ect.
(indicating No.
1&
4 connecting
rod
journal)
O/S Cylinder A Following
.508 mm Bores engine
serial
(.020 in.) number.
O/S TappetsL3/89
.203 mm diamound
(.008 in.) -shaped
stamp Top
pad
Ð Front of
engine and
flat
ground on
outside
surface
of each O/S
tappet bore.
O/S Valve
StemsX Milled pad
.127 mm adjacent to
two
(.005 in.) 3/89tapped
holes on
each
end of
cylinder
head.
TORQUE
TORQUE CHART 5.9L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Timing Chain Case CoverÐ
Bolts41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
Bracket
ÐStud Nut (4WD) 41 30 Ð
ÐThrough Bolt/Nut (4WD) 102 75 Ð
Front Insulator to BlockÐ
Bolts (2WD)95 70 Ð
GeneratorÐMounting Bolt 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐAttaching Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ 68 50 Ð
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
BR/BEENGINE 5.9L 9 - 17
ENGINE 5.9L (Continued)

DESCRIPTION N´m Ft. In.
Nuts (4WD)
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Bracket to 41 30 Ð
Crossmember FlangeÐNuts
Rear Support Plate to
Transfer41 30 Ð
CaseÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting Bolts 68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator 204 105 Ð
Mounting PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 244 180 Ð
Water Pump to Timing Chain 41 30 Ð
Case CoverÐBolts
SPECIAL TOOLS
5.9L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487±A
Valve Spring Compressor MD-998772±A
Adaptor 6633
Adaptor 6716A
Valve Guide Sleeve C-3973
9 - 18 ENGINE 5.9LBR/BE
ENGINE 5.9L (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

LINKAGE - 4WD
TABLE OF CONTENTS
page page
LINKAGE - 4WD
DESCRIPTION.........................42
STANDARD PROCEDURE - LUBRICATION....42
REMOVAL.............................42
INSTALLATION.........................43SPECIFICATIONS
TORQUE CHART......................43
SPECIAL TOOLS
STEERING LINKAGE...................44
LINKAGE - 4WD
DESCRIPTION
The steering linkage is comprised of a tie rod end,
tie rod, drag link, steering damper and pitman arm
(Fig. 1).
CAUTION: If any steering components are replaced
or serviced an alignment must be performed.
NOTE: To avoid damaging ball stud seals, use
Puller C-3894±A or an appropriate puller to remove
tie rod ends (Fig. 2).
STANDARD PROCEDURE - LUBRICATION
Periodic lubrication of the steering system compo-
nents is required. Refer to Lubrication And Mainte-
nance for the recommended maintenance schedule.
The following components must be lubricated:
²Tie rod
²Tie rod end
²Drag link
REMOVAL
(1) Remove steering damper mounting nuts and
bolts and remove damper.
(2) Remove tie rod nuts.
(3) Remove tie rod from drag link and left knuckle
with Puller C-4150A.
(4) Remove drag and nuts.
(5) Remove drag link from right knuckle and pit-
man arm with Puller C-4150A.
Fig. 1 Steering Linkage
1 - DRAG LINK
2 - PITMAN ARM
3 - STEERING GEAR
4 - TIE ROD END
5 - TIE ROD
6 - DAMPER
Fig. 2 Tie Rod End
1 - CLAMP
2 - ADJUSTMENT SLEEVE
3 - PULLER TOOL C-3894±A
4 - SEAL
5 - TIE-ROD END
19 - 42 LINKAGE - 4WDBR/BE

(6) Mark the pitman arm and shaft positions for
installation reference. Remove the nut and washer
from the pitman arm. Remove the pitman arm with
Puller C-4150A.
INSTALLATION
(1) Align reference marks and install pitman arm.
(2) Install the lock washer and retaining nut on
the pitman shaft and tighten nut to 251 N´m (185 ft.
lbs.).
(3) Install drag link to the pitman arm. Install the
nut and tighten to 108 N´m (80 ft. lbs.).
(4) Install drag link to the right steering knuckle.
Install the nut and tighten to 88 N´m (65 ft. lbs.).
(5) Install tie rod to the left steering knuckle and
drag link. Install the nuts and tighten to 108 N´m
(80 ft. lbs.).(6) Install steering damper on the axle. Tighten
nut to 95 N´m (75 ft. lbs.).
(7) Install steering damper on the tie rod. Tighten
nut to 81 N´m (60 ft. lbs.).
(8) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
refer to Group 2 Suspension.
(9) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N´m (45 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain-
ing bolt is located on the bottom side of the sleeve.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Pitman Arm
Gear Shaft251 185 Ð
Drag Link
Pitman Arm108 80 Ð
Drag Link
Tie Rod88 65 Ð
Drag Link
Adjuster Clamp61 45 Ð
Tie Rod End
Knuckle108 80 Ð
Tie Rod End
Adjuster Clamp61 45 Ð
Steering Damper
Axle95 70 Ð
Steering Damper
Tie Rod81 60 Ð
BR/BELINKAGE - 4WD 19 - 43
LINKAGE - 4WD (Continued)