clockspring DODGE RAM 2002 Service Owner's Guide

CENTRAL TIMER MODULE C2 - 18 WAY
CAV CIRCUIT FUNCTION
1 P33 22OR/BK DOOR LOCK DRIVER
2 M11 22PK/LB COURTESY LAMP SWITCH OUTPUT
3 Z3 18BK/OR GROUND
4 P30 22OR/DG PASSENGER DOOR LOCK SWITCH OUTPUT
5 F12 22DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 G50 22RD/DB SECURITY RELAY CONTROL
7 P132 16OR/BK HEATED SEAT RELAY CONTROL
8 G69 22BK VTSS INDICATOR DRIVER
9 P34 22PK/BK DOOR UNLOCK DRIVER
10 G73 22LG/OR CYLINDER LOCK SWITCH MUX
11 M22 22WT DOME LAMP SWITCH SENSE
12 - -
13 P31 22PK/DG PASSENGER DOOR UNLOCK SWITCH OUTPUT
14 X20 22RD/BK RADIO CONTROL MUX
15 - -
16 D1 20VT/BR CCD BUS (+)
17 D2 20WT/BK CCD BUS (-)
18 X3 20BK/RD HORN RELAY CONTROL
CIGAR LIGHTER - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1 F30 18RD/OR FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2- -
3 Z3 18BK/OR GROUND
CLOCKSPRING C1-5WAY
CAV CIRCUIT FUNCTION
1 V37 22RD/LG SPEED CONTROL SWITCH SIGNAL
2 Z9 20BK/VT (HIGHLINE (REMOTE
RADIO))GROUND
3 K4 22BK/LB SENSOR GROUND
4 X20 22RD/BK (EXCEPT BASE)) RADIO CONTROL MUX
5 X3 20BK/RD HORN RELAY CONTROL
CLOCKSPRING C2 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R43 18BK/LB DRIVER AIRBAG LINE 2
2 R45 18DG/LB DRIVER AIRBAG LINE 1
8W - 80 - 34 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

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Clockspring C1 Steering Column 32
Clockspring C2 Steering Column 32
Clockspring C3 Steering Column 32
Clutch Pedal Position Switch
(M/T)BK Top of Clutch Pedal 35
Controller Anti-Lock Brake C1 BK Left Fender Side Shield 18
Controller Anti-Lock Brake C2
(ABS)BK Left Fender Side Shield 18
Crankshaft Position Sensor
(V8)BK Rear of Engine Block 5
Crankshaft Position Sensor
(V10GY Right Side of Engine Block 8
Cummins Bus (-) Left Front of Engine 13
Cup Holder Lamp BK Center of Instrument Panel 30, 34
Data Link Connector BK Left Bottom of Instrument Panel 30, 32
Day/Night Mirror BK Day/Night Mirror N/S
Daytime Running Lamp
ModuleBK Left Fender Side Shield 18
Dome Lamp BK Rear of Cab 23
Driver Airbag YL Steering Wheel N/S
Driver Cylinder Lock Switch BK In Door 24
Driver Door Ajar Switch NAT Door Jamb N/S
Driver Door Lock Motor BK In Door 24
Driver Door Window/Lock
SwitchBL In Door 24
Driver Heated Seat Cushion BL Under Seat N/S
Driver Heated Seat Switch RD Center of Instrument Panel N/S
Driver Lumbar Motor Under Seat N/S
Driver Power Seat Front
Vertical MotorBK Under Seat N/S
Driver Power Seat Horizontal
MotorBK Under Seat N/S
Driver Power Seat Rear
Vertical MotorBK Under Seat N/S
Driver Power Seat Switch At Seat N/S
Driver Power Window Motor In Door 24
EVAP/Purge Solenoid BK Right Fender Side Shield 22
Electric Brake Provision Bottom Left of Instrument Panel N/S
Engine Control Module
(Diesel)Left Side Engine 15
Engine Coolant Temperature
Sensor (Diesel)BK Left Front of Cylinder Head (Diesel) 13
Engine Coolant Temperature
Sensor (Gas)BK On Thermostat Housing 5, 8
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(8) Remove the PRNDL cable on column shift vehi-
cles. Put the shift lever inParkposition. Pull the
cable and twist to remove from the position arm.
Push the tab up on bottom of the cable retainer, then
squeeze sides to remove retainer from the column
(Fig. 5).
(9) Remove the tilt lever (if equipped) from the col-
umn.
(10) Remove the upper and lower lock housing
shroud and remove the lower fixed shroud.
(11) Remove the turn signal multi-function switch
connector with a 7mm socket (Fig. 6).(12) Loosen the upper Support Bracket nuts to
allow some slack. This will aid in removal of the
upper fixed shroud.
(13) Remove the electrical connections from Key-in
light, Ignition Switch, Horn, Overdrive Switch and
Clock Spring (Speed Control) (Fig. 7).
(14) Remove the wiring harness from the column
by prying out the plastic retainer buttons.
(15) Remove the toe plate fasteners.
(16) Remove the column from vehicle.
(17) Remove the Ignition and Multi-Function
Switch, then remove the Clock Spring and tape the
Clock Spring to prevent it from turning, (Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
(1) Install the clock spring and switches, (Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
NOTE: Turn the Ignition Switch to the on position
and verify the gear shifter moves. If the shifter does
not move ensure the Ignition Switch is installed
properly.
(2) Column shift vehicles, install a new grommet.
Use multi-purpose lubricant, or equivalent, to aid
installation of the grommet.
NOTE: A new grommet should be used when ever
the rod is disconnected from the lever.
Fig. 5 PRNDL Drive
1 - PRNDL LEVER
2 - THUMB SCREW
3 - CABLE RETAINER
4 - PRNDL CABLE
Fig. 6 Multi-function Switch
1 - STEERING COLUMN ASSY.
2 - MULTI-FUNCTION SWITCH CONNECTOR
3 - TURN SIGNAL SWITCH AND LEVER
Fig. 7 Steering Column Wiring
1 - KEY-IN SWITCH & HALO LIGHT
2 - MULTI-FUNCTION SWITCH
3 - TURN SIGNAL SWITCH & LEVER
4 - IGNITION SWITCH
5 - SPEED CONTROL
19 - 8 COLUMNBR/BE
COLUMN (Continued)

INSTALLATION
(1) Install the gear shift lever into the steering col-
umn assembly. Align the pin holes in the gear shift
lever and the steering column assembly.
CAUTION: The pin must be installed in the original
direction.
(2) Carefully Install the pin into the steering col-
umn assembly and through the shift lever. If the pin
binds check the alignment on the holes. Be sure pin
is fully installed into the steering column assembly.
(3) Connect over drive switch wiring.
(4) Lower the steering column to install the sec-
ondary shrouds.
(5) Install the steering column mounting nuts.
Tighten the nuts to 12 N´m (105 in. lbs.).
(6) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-ING COLUMN OPENING COVER - INSTALLA-
TION).
(7) Install the upper and lower shrouds.
(8) Install the tilt lever.
STEERING WHEEL
REMOVAL
For steering wheel removal procedure,(Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
For steering wheel installation procedure,(Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
BR/BECOLUMN 19 - 15
GEAR SHIFT LEVER (Continued)

instrument panel just inboard of the glove box. Vehi-
cles equipped with a manual transmission have a
lighted storage bin installed on the instrument panel
in place of the fold-down cup holder.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the storage bin unit onto the instru-
ment panel (Fig. 10).
(2) Engage the illumination lamp and hood
retainer clip to the back of the instrument panel stor-
age bin unit.
(3) Raise and position the top of the storage bin to
the instrument panel.
(4) Install and tighten the two screws that secure
the top of the storage bin unit to the instrument
panel. Tighten the screws to 2.2 N´m (20 in. lbs.).
(5) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(6) Reconnect the battery negative cable.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT BELT TENSIONER, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG
SYSTEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1)
Disconnect and isolate the battery negative cable.
(2) Remove the Airbag Control Module (ACM) and
bracket from the floor panel transmission tunnel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/AIRBAG
CONTROL MODULE - REMOVAL).
(3) Remove the trim from the left and right cowl
side inner panels. (Refer to 23 - BODY/INTERIOR/
COWL TRIM COVER - REMOVAL).
(4) Remove the steering column opening cover
from the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(5)
Remove the two screws that secure the inside
hood latch release handle to the instrument panel lower
reinforcement and lower the release handle to the floor.
(6)Disconnect the clockspring pigtail wire connector
from the instrument panel wire harness connector
located on the instrument panel lower reinforcement.
(7) If the vehicle is so equipped, disconnect the
overdrive lockout switch pigtail wire connector from
the instrument panel wire harness connector near
the instrument panel lower reinforcement.
(8) Remove the steering column from the vehicle,
but do not remove the driver airbag, the steering
wheel, or the switches from the column. Be certain
that the steering wheel is locked and secured from
rotation to prevent the loss of clockspring centering.
(Refer to 19 - STEERING/COLUMN - REMOVAL).
(9) From under the driver side of the instrument
panel, perform the following:
(a) Disengage the park brake release handle
linkage rod from the park brake mechanism on the
Fig. 10 Instrument Panel Storage Bin Remove/Install
1 - SCREWS
2 - STORAGE BIN (RAISED)
3 - STORAGE BIN (LOWERED)
BR/BEINSTRUMENT PANEL SYSTEM 23 - 115
STORAGE BIN (Continued)

wire harness connectors from the heater-A/C housing
wire harness connectors.
(15) With the aid of an assistant, remove the tem-
porary hook and lift the instrument panel assembly
off of the roll-down bracket screws and remove it
from the vehicle.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT BELT TENSIONER, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG
SYSTEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
(1)With the aid of an assistant, load the instrument
panel assembly onto the roll-down bracket screws on
the cowl side inner panels in the vehicle (Fig. 11).
Install a temporary hook in the center hole on top of the
instrument panel. Secure the other end of the hook to
the center hole in the top of the dash panel. The hook
should support the instrument panel in its rolled down
position about 46 cm (18 inches) from the dash panel.
(2) With the instrument panel supported in the
roll-down position, reconnect the instrument panel
wire harness connectors to the heater-A/C housing
wire harness connectors.
(3) Remove the temporary hook from the instru-
ment panel and roll the instrument panel up to its
installed position against the dash panel.
(4) Install and tighten the five screws that secure
the top of the instrument panel to the top of the dash
panel. Tighten the screws to 3.2 N´m (28 in. lbs.).
(5) Tighten the right and left instrument panel
cowl side roll-down bracket screws. Tighten the
screws to 11.9 N´m (105 in. lbs.).
(6) From under the passenger side of the instru-
ment panel, reconnect the two halves of the radio
antenna coaxial cable connector.
(7) From under the driver side of the instrument
panel, perform the following:
(a) Engage the park brake release handle link-
age rod with the park brake mechanism on the left
cowl side inner panel. (Refer to 5 - BRAKES/PARK-
ING BRAKE/RELEASE - INSTALLATION).
(b) Reconnect the instrument panel wire harness
connector to the park brake switch on the park
brake mechanism.(c) Reconnect the three connectors (one from the
body wire harness, and two from the headlamp and
dash wire harness) to the three connector recepta-
cles located closest to the dash panel on the back of
the Junction Block (JB).
(d)
Reconnect the headlamp and dash wire harness
to instrument panel wire harness bulkhead connector
and tighten the screw in the center of the connector.
Tighten the screw to 3.5 N´m (31 in. lbs.).
(e) Reconnect the instrument panel wire harness
to door wire harness connector located directly
below the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(f) If the vehicle is equipped with the Infinity
sound system option, reconnect the Infinity wire
harness connector to the instrument panel wire
harness connector that is secured to the outboard
side of the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(g) Reconnect the instrument panel wire harness
connector to the stop lamp switch.
(h) Reconnect the heater-A/C housing vacuum
harness connector to the heater-A/C control vac-
uum harness connector located near the left end of
the heater-A/C housing.
(8) Reinstall the steering column into the vehicle.
Be certain that the steering wheel was locked and
secured from rotation to prevent the loss of clock-
spring centering. (Refer to 19 - STEERING/COL-
UMN - INSTALLATION).
(9) If the vehicle is so equipped, reconnect the
overdrive lockout switch pigtail wire connector to the
instrument panel wire harness connector near the
instrument panel lower reinforcement.
(10) Reconnect the clockspring pigtail wire connec-
tor to the instrument panel wire harness connector
at the instrument panel lower reinforcement.
(11) Position the inside hood latch release handle
to the instrument panel lower reinforcement.
(12) Install and tighten the two screws that secure
the inside hood latch release handle to the instru-
ment panel lower reinforcement. Tighten the screws
to 2.8 N´m (25 in. lbs.).
(13) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(14) Reinstall the trim onto the left and right cowl
side inner panels. (Refer to 23 - BODY/INTERIOR/
COWL TRIM COVER - INSTALLATION).
(15) Reinstall the Airbag Control Module (ACM)
and bracket onto the floor panel transmission tunnel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/AIRBAG
CONTROL MODULE - INSTALLATION).
(16) Reconnect the battery negative cable.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 117
INSTRUMENT PANEL ASSEMBLY (Continued)

CAB SIDE PANEL SPEAKER - REMOVAL,
REAR..............................8A-20
CABLE - ADJUSTMENTS,
TRANSMISSION THROTTLE
VALVE ......................21-210,21-382
CABLE - DESCRIPTION.................8P-4
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-4
CABLE - DESCRIPTION, BATTERY........8F-18
CABLE - DESCRIPTION, SPARK PLUG.....8I-20
CABLE - DESCRIPTION, THROTTLE
VALVE ......................21-209,21-381
CABLE - INSTALLATION, ANTENNA BODY . . 8A-6
CABLE - INSTALLATION, CHECK.........23-67
CABLE - INSTALLATION, FRONT
PARKING BRAKE......................5-30
CABLE - INSTALLATION, INSTRUMENT
PANEL ANTENNA......................8A-9
CABLE - INSTALLATION, LATCH RELEASE . 23-103
CABLE - INSTALLATION, REAR PARK
BRAKE..............................5-30
CABLE - INSTALLATION, RELEASE.......23-82
CABLE - INSTALLATION, SPARK PLUG....8I-21
CABLE - INSTALLATION, THROTTLE
CONTROL....................14-110,14-50
CABLE - OPERATION...................8P-4
CABLE - OPERATION, ANTENNA BODY.....8A-4
CABLE - OPERATION, BATTERY..........8F-18
CABLE - OPERATION, SPARK PLUG.......8I-20
CABLE - REMOVAL, ANTENNA BODY......8A-6
CABLE - REMOVAL, CHECK.............23-67
CABLE - REMOVAL, FRONT PARKING
BRAKE..............................5-29
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA...........................8A-9
CABLE - REMOVAL, LATCH RELEASE....23-103
CABLE - REMOVAL, REAR PARK BRAKE . . . 5-29
CABLE - REMOVAL, RELEASE...........23-82
CABLE - REMOVAL, SPARK PLUG........8I-21
CABLE - REMOVAL, THROTTLE
CONTROL....................14-109,14-49
CABLE INSTALLATION, GASOLINE
ENGINE - NEGATIVE..................8F-22
CABLE INSTALLATION, GASOLINE
ENGINE - POSITIVE...................8F-22
CABLE ORDER, 8.0L V-10 ENGINE -
SPARK PLUG.........................8I-3
CABLE REMOVAL, GASOLINE ENGINE -
NEGATIVE..........................8F-22
CABLE REMOVAL, GASOLINE ENGINE -
POSITIVE...........................8F-21
CABLE RESISTANCE, SPECIFICATIONS -
SPARK PLUG.........................8I-3
CABLES - DIAGNOSIS AND TESTING,
BATTERY...........................8F-19
CABLES - DIAGNOSIS AND TESTING,
SPARK PLUG........................8I-20
CAB-TO-BED GROUND STRAP -
INSTALLATION.......................8A-14
CAB-TO-BED GROUND STRAP -
REMOVAL..........................8A-13
CALIBRATION - STANDARD PROCEDURE,
COMPASS...........................8M-4
CALIPERS - DESCRIPTION, DISC BRAKE . . . 5-10
CALIPERS - OPERATION, DISC BRAKE.....5-10
CAM - DESCRIPTION, TURN SIGNAL
CANCEL............................8L-31
CAM - OPERATION, TURN SIGNAL
CANCEL............................8L-31
CAM BORE REPAIR - STANDARD
PROCEDURE........................9-151
CAM/OVERDRIVE PISTON RETAINER -
ASSEMBLY, OVERRUNNING
CLUTCH.....................21-193,21-364
CAM/OVERDRIVE PISTON RETAINER -
CLEANING, OVERRUNNING
CLUTCH
.....................21-192,21-364
CAM/OVERDRIVE PISTON RETAINER -
DESCRIPTION, OVERRUNNING
CLUTCH
.....................21-192,21-363
CAM/OVERDRIVE PISTON RETAINER -
DISASSEMBLY, OVERRUNNING
CLUTCH
.....................21-192,21-364
CAM/OVERDRIVE PISTON RETAINER -
INSPECTION, OVERRUNNING
CLUTCH
.....................21-193,21-364
CAM/OVERDRIVE PISTON RETAINER -
OPERATION, OVERRUNNING
CLUTCH
.....................21-192,21-363CAMSHAFT - INSTALLATION....9-157,9-29,9-86
CAMSHAFT - REMOVAL.......9-152,9-28,9-85
CAMSHAFT BEARINGS - I
NSTALLATION...............9-157,9-28,9-86
CAMSHAFT BEARINGS -
REMOVAL..................9-152,9-27,9-85
CANCEL CAM - DESCRIPTION, TURN
SIGNAL............................8L-31
CANCEL CAM - OPERATION, TURN
SIGNAL............................8L-31
CANISTER - DESCRIPTION, VAPOR......25-37
CANISTER - INSTALLATION, CRANKCASE
BREATHER VAPOR...................9-126
CANISTER - INSTALLATION, VAPOR......25-38
CANISTER - OPERATION, VAPOR........25-37
CANISTER - REMOVAL, CRANKCASE
BREATHER VAPOR...................9-125
CANISTER - REMOVAL, VAPOR..........25-38
CAP - DESCRIPTION, FUEL FILLER.......25-34
CAP - DESCRIPTION, RADIATOR
PRESSURE..........................7-64
CAP - DIAGNOSIS AND TESTING,
DISTRIBUTOR.......................8I-14
CAP - DIAGNOSIS AND TESTING,
RADIATOR...........................7-65
CAP - OPERATION, FUEL FILLER........25-34
CAP - OPERATION, RADIATOR
PRESSURE..........................7-64
CAP - REMOVAL/INSTALLATION, FUEL
FILLER.............................25-34
CAPACITIES, SPECIFICATIONS - FLUID.......0-6
CAPACITY TEST - DIAGNOSIS AND
TESTING, FUEL PUMP..................14-9
CARDAN UNIVERSAL JOINTS -
ASSEMBLY, DOUBLE...................3-11
CARDAN UNIVERSAL JOINTS -
ASSEMBLY, SINGLE.....................3-9
CARDAN UNIVERSAL JOINTS -
DISASSEMBLY, DOUBLE................3-10
CARDAN UNIVERSAL JOINTS -
DISASSEMBLY, SINGLE..................3-8
CARDAN UNIVERSAL JOINTS -
INSTALLATION, SINGLE.................3-35
CARDAN UNIVERSAL JOINTS -
REMOVAL, SINGLE....................3-34
CARGO BOX - INSTALLATION...........23-97
CARGO BOX - REMOVAL...............23-97
CARGO DOOR - ADJUSTMENT..........23-78
CARPETS AND FLOOR MATS -
INSTALLATION......................23-123
CARPETS AND FLOOR MATS - REMOVAL . 23-123
CARTRIDGE FUSE - DESCRIPTION,
GENERATOR......................8W-97-4
CARTRIDGE FUSE - INSTALLATION,
GENERATOR......................8W-97-4
CARTRIDGE FUSE - OPERATION,
GENERATOR......................8W-97-4
CARTRIDGE FUSE - REMOVAL,
GENERATOR......................8W-97-4
CASE - DIAGNOSIS AND TESTING,
TRANSFER...................21-431,21-467
CASE - NV241 - DESCRIPTION,
TRANSFER
............................0-5
CASE - NV241HD - ASSEMBLY,
TRANSFER
.........................21-480
CASE - NV241HD - CLEANING,
TRANSFER
.........................21-476
CASE - NV241HD - DESCRIPTION,
TRANSFER
.........................21-465
CASE - NV241HD - DISASSEMBLY,
TRANSFER
.........................21-469
CASE - NV241HD - INSPECTION,
TRANSFER
.........................21-476
CASE - NV241HD - INSTALLATION,
TRANSFER
.........................21-494
CASE - NV241HD - OPERATION,
TRANSFER
.........................21-467
CASE - NV241HD - REMOVAL,
TRANSFER
.........................21-469
CASE - NV241LD - ASSEMBLY,
TRANSFER
.........................21-445
CASE - NV241LD - CLEANING,
TRANSFER
.........................21-441
CASE - NV241LD - DESCRIPTION,
TRANSFER
.........................21-430
CASE - NV241LD - DISASSEMBLY,
TRANSFER
.........................21-432CASE - NV241LD - INSPECTION,
TRANSFER.........................21-442
CASE - NV241LD - INSTALLATION,
TRANSFER.........................21-458
CASE - NV241LD - OPERATION,
TRANSFER.........................21-430
CASE - NV241LD - REMOVAL,
TRANSFER.........................21-432
CASE BEARINGS - INSTALLATION,
DIFFERENTIAL..........3-102,3-129,3-41,3-72
CASE BEARINGS - REMOVAL,
DIFFERENTIAL..........3-102,3-129,3-40,3-72
CASE, NV241HD - TRANSFER..........21-495
CASE, NV241LD - TRANSFER..........21-459
CASE SKID PLATE - INSTALLATION,
TRANSFER..........................13-11
CASE SKID PLATE - REMOVAL,
TRANSFER..........................13-11
CASE, SPECIFICATIONS -
TRANSFER...................21-458,21-495
CASTER CORRECTION MEASUREMENT -
STANDARD PROCEDURE.................2-3
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- DESCRIPTION.......................11-5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- INSPECTION........................11-6
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- INSTALLATION......................11-6
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- OPERATION.........................11-5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- REMOVAL..........................11-5
CATALYTIC CONVERTER - 5.9L HD/8.0L -
DESCRIPTION........................11-6
CATALYTIC CONVERTER - 5.9L HD/8.0L -
INSPECTION.........................11-6
CATALYTIC CONVERTER - 5.9L HD/8.0L -
INSTALLATION........................11-7
CATALYTIC CONVERTER - 5.9L HD/8.0L -
OPERATION..........................11-6
CATALYTIC CONVERTER - 5.9L HD/8.0L -
REMOVAL...........................11-6
CAUSES OF BURNT FLUID - DIAGNOSIS
AND TESTING................21-157,21-327
CCD DATA BUS - DESCRIPTION..........8E-6
CCD DATA BUS - DIAGNOSIS AND
TESTING...........................8E-11
CCD DATA BUS - OPERATION............8E-7
CENTER - DESCRIPTION, POWER
DISTRIBUTION....................8W-97-8
CENTER - INSTALLATION, POWER
DISTRIBUTION...................8W-97-10
CENTER - OPERATION, POWER
DISTRIBUTION....................8W-97-8
CENTER - REMOVAL, POWER
DISTRIBUTION....................8W-97-8
CENTER BEARING - ADJUSTMENT.........3-8
CENTER BEARING - INSTALLATION........3-8
CENTER BEARING - REMOVAL............3-8
CENTER CONSOLE - INSTALLATION.....23-122
CENTER CONSOLE - REMOVAL.........23-122
CENTER CONSOLE LID - INSTALLATION . . 23-132
CENTER CONSOLE LID - REMOVAL.....23-131
CENTER HIGH MOUNTED STOP LAMP -
INSTALLATION........................8L-6
CENTER HIGH MOUNTED STOP LAMP -
REMOVAL...........................8L-6
CENTER HIGH MOUNTED STOP LAMP
UNIT - INSTALLATION..................8L-6
CENTER HIGH MOUNTED STOP LAMP
UNIT - REMOVAL.....................8L-6
CENTER SEAT ARMREST/CONSOLE -
INSTALLATION......................23-132
CENTER SEAT ARMREST/CONSOLE -
REMOVAL.........................23-132
CENTER SEAT ARMREST/LATCH COVER -
INSTALLATION......................23-132
CENTER SEAT ARMREST/LATCH COVER -
REMOVAL.........................23-132
CENTERING - STANDARD PROCEDURE,
CLOCKSPRING
......................8O-11
CENTRAL TIMER MODULE -
DESCRIPTION
........................8E-1
CENTRAL TIMER MODULE - DIAGNOSIS
AND TESTING
........................8E-4
CENTRAL TIMER MODULE -
INSTALLATION
........................8E-6
CENTRAL TIMER MODULE - OPERATION
. . . 8E-3
BR/BEINDEX 5
Description Group-Page Description Group-Page Description Group-Page

CENTRAL TIMER MODULE - REMOVAL....8E-5
CERTIFICATION LABEL - DESCRIPTION,
VEHICLE SAFETY...................Intro.-1
CHAIN COVER(S) - INSTALLATION,
TIMING BELT....................9-110,9-54
CHAIN COVER(S) - REMOVAL, TIMING
BELT ..........................9-110,9-53
CHAIN STRETCH - INSPECTION,
MEASURING TIMING..............9-111,9-54
CHANNEL - INSTALLATION, GLASS RUN . . 23-71
CHANNEL - REMOVAL, GLASS RUN......23-71
CHARGE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM...............24-46
CHARGE AIR COOLER AND PLUMBING -
CLEANING..........................11-19
CHARGE AIR COOLER AND PLUMBING -
DESCRIPTION.......................11-18
CHARGE AIR COOLER AND PLUMBING -
INSPECTION........................11-19
CHARGE AIR COOLER AND PLUMBING -
INSTALLATION.......................11-20
CHARGE AIR COOLER AND PLUMBING -
OPERATION.........................11-18
CHARGE AIR COOLER AND PLUMBING -
REMOVAL..........................11-18
CHARGE AIR COOLER SYSTEM - LEAKS
- DIAGNOSIS AND TESTING............11-18
CHARGING - DESCRIPTION.............8F-25
CHARGING - OPERATION..............8F-25
CHARGING - STANDARD PROCEDURE,
BATTERY............................8F-8
CHARGING SYSTEM - DIAGNOSIS AND
TESTING...........................8F-25
CHART, SPECIFICATIONS - TORQUE....5-3,5-37
CHART, SPECIFICATIONS -
TORQUE.............19-21,19-41,19-43,19-9
CHART, SPECIFICATIONS -
TORQUE.....................2-15,2-26,2-8
CHART, SPECIFICATIONS - TORQUE......22-11
CHARTS - DIAGNOSIS AND TESTING,
DIAGNOSIS..................21-102,21-274
CHARTS - DIAGNOSIS AND TESTING,
SMOKE DIAGNOSIS...................9-118
CHASSIS ADAPTER BRACKET -
INSTALLATION, CAB..................13-10
CHASSIS ADAPTER BRACKET -
REMOVAL, CAB......................13-10
CHECK - INSTALLATION...............23-78
CHECK - REMOVAL...................23-78
CHECK - STANDARD PROCEDURE,
COOLANT LEVEL......................7-16
CHECK - STANDARD PROCEDURE, FLUID
LEVEL......................21-157,21-328
CHECK - STANDARD PROCEDURE, OIL
PUMP VOLUME...............21-166,21-336
CHECK CABLE - INSTALLATION.........23-67
CHECK CABLE - REMOVAL.............23-67
CHECK GAUGES INDICATOR -
DESCRIPTION.......................8J-17
CHECK GAUGES INDICATOR -
OPERATION.........................8J-17
CHECK VALVE - DESCRIPTION, FUEL
TANK ..............................14-21
CHECK VALVE - DESCRIPTION, ONE WAY . 25-31
CHECK VALVE - DESCRIPTION, VACUUM . . 24-28
CHECK VALVE - DIAGNOSIS AND
TESTING, ONE-WAY..................25-31
CHECK VALVE - INSTALLATION, FUEL
TANK ..............................14-23
CHECK VALVE - INSTALLATION, ONE
WAY...............................25-31
CHECK VALVE - INSTALLATION, VACUUM
. 24-29
CHECK VALVE - OPERATION, ONE WAY
. . . 25-31
CHECK VALVE - OPERATION, VACUUM
....24-28
CHECK VALVE - REMOVAL, FUEL TANK
. . . 14-22
CHECK VALVE - REMOVAL, ONE WAY
....25-31
CHECK VALVE - REMOVAL, VACUUM
.....24-29
CHECKS - DIAGNOSIS AND TESTING,
PRELIMINARY
.........................7-4
CHILD TETHER - INSTALLATION
..........8O-9
CHILD TETHER - REMOVAL
.............8O-9
CHIME WARNING SYSTEM -
DESCRIPTION
........................8B-1
CHIME WARNING SYSTEM - DIAGNOSIS
AND TESTING
........................8B-2
CHIME WARNING SYSTEM - OPERATION
. . . 8B-1
CHOKE RELAY - DESCRIPTION, RADIO
....8A-7CHOKE RELAY - DIAGNOSIS AND
TESTING, RADIO......................8A-8
CHOKE RELAY - INSTALLATION, RADIO....8A-9
CHOKE RELAY - OPERATION, RADIO......8A-8
CHOKE RELAY - REMOVAL, RADIO.......8A-8
CIGAR LIGHTER OUTLET - DESCRIPTION . 8W-97-2
CIGAR LIGHTER OUTLET - DIAGNOSIS
AND TESTING.....................8W-97-2
CIGAR LIGHTER OUTLET -
INSTALLATION....................8W-97-4
CIGAR LIGHTER OUTLET - OPERATION . 8W-97-2
CIGAR LIGHTER OUTLET - REMOVAL . . 8W-97-3
CIRCUIT ACTUATION TEST MODE -
DESCRIPTION........................25-2
CIRCUIT BREAKER - DESCRIPTION....8W-97-4
CIRCUIT BREAKER - DIAGNOSIS AND
TESTING.........................8W-97-4
CIRCUIT FUNCTIONS - DESCRIPTION . . 8W-01-4
CIRCUIT INFORMATION - DESCRIPTION . 8W-01-4
CIRCUIT SENSE - DESCRIPTION,
IGNITION...........................8E-17
CIRCUIT SENSE - OPERATION, IGNITION . . 8E-19
CIRCUITS - DIESEL - OPERATION,
NON-MONITORED....................25-24
CIRCUITS - GAS ENGINES - OPERATION,
NON-MONITORED....................25-24
CLAMPS - DESCRIPTION, HOSE...........7-4
CLAMPS - OPERATION, HOSE.............7-4
CLASSIFICATION OF LUBRICANTS -
STANDARD PROCEDURE..................0-1
CLEANER ELEMENT - INSTALLATION,
AIR ...............................9-130
CLEANER ELEMENT - REMOVAL, AIR.....9-129
CLEANING AND INSPECTION, OIL
COOLER & LINES....................9-179
CLEANING, BATTERY SYSTEM...........8F-5
CLEANING, CHARGE AIR COOLER AND
PLUMBING.........................11-19
CLEANING, CROSSHEADS..............9-134
CLEANING, CYLINDER HEAD.......9-134,9-77
CLEANING, CYLINDER HEAD
COVER(S)..................9-137,9-23,9-79
CLEANING, ENGINE BLOCK..........9-27,9-85
CLEANING, EXHAUST
MANIFOLD.................9-109,9-185,9-53
CLEANING, FRONT SERVO......21-164,21-334
CLEANING FUEL SYSTEM PARTS -
STANDARD PROCEDURES..............14-61
CLEANING, HYDRAULIC LIFTERS.....9-37,9-92
CLEANING, INTAKE MANIFOLD . 9-107,9-184,9-51
CLEANING, INTAKE/EXHAUST VALVES &
SEATS ..............................9-26
CLEANING, MANUAL - NV4500..........21-20
CLEANING, MANUAL - NV5600..........21-63
CLEANING, OIL PAN.........9-103,9-179,9-46
CLEANING, OIL PRESSURE RELIEF
VALVE .............................9-180
CLEANING, OIL PUMP............9-104,9-181
CLEANING, OIL PUMP..........21-168,21-338
CLEANING, OPERATION.................9-22
CLEANING, OVERDRIVE UNIT....21-179,21-353
CLEANING, OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER...................21-192,21-364
CLEANING, PISTON & CONNECTING
ROD.......................9-169,9-39,9-94
CLEANING, PUSHRODS................9-134
CLEANING, RADIATOR - 5.9L............7-59
CLEANING, RADIATOR - 5.9L DIESEL......7-64
CLEANING, RADIATOR - 8.0L............7-61
CLEANING, RADIATOR FAN - 5.9L
DIESEL.............................7-43
CLEANING, RADIATOR FAN - 5.9L/8.0L....7-42
CLEANING, REAR CLUTCH
......21-204,21-377
CLEANING, REAR SERVO
.......21-207,21-379
CLEANING, ROCKER ARM / ADJUSTER
ASSY
..............................9-146
CLEANING, SOLID LIFTERS/TAPPETS
.....9-164
CLEANING, SPARK PLUG
...............8I-20
CLEANING, TRANSFER CASE - NV241HD
. 21-476
CLEANING, TRANSFER CASE - NV241LD
. 21-441
CLEANING, TURBOCHARGER
...........11-16
CLEANING, VALVE BODY
........21-244,21-418
CLEANING, WATER PUMP - 5.9L
.........7-68
CLEANING, WATER PUMP - 5.9L DIESEL
. . . 7-72
CLEANING, WATER PUMP - 8.0L
.........7-71
CLEANING, WIPER & WASHER SYSTEM
. . . 8R-6CLEANING/REVERSE FLUSHING -
STANDARD PROCEDURE, COOLING
SYSTEM............................7-17
CLEARANCE - STANDARD PROCEDURE,
CONNECTING ROD BEARING AND
CRANKSHAFT JOURNAL...............9-158
CLEARANCE - STANDARD PROCEDURE,
MAIN BEARING......................9-159
CLEARANCE LAMP - INSTALLATION.......8L-7
CLEARANCE LAMP - REMOVAL..........8L-7
CLOCKSPRING - DESCRIPTION.........8O-10
CLOCKSPRING - INSTALLATION.........8O-13
CLOCKSPRING - OPERATION...........8O-10
CLOCKSPRING - REMOVAL............8O-12
CLOCKSPRING CENTERING - STANDARD
PROCEDURE........................8O-11
CLOSURE PANEL TRIM - INSTALLATION,
REAR.............................23-121
CLOSURE PANEL TRIM - REMOVAL,
REAR.............................23-120
CLUB/QUAD CAB - INSTALLATION.......8O-20
CLUB/QUAD CAB - REMOVAL...........8O-19
CLUSTER - ASSEMBLY, INSTRUMENT....8J-12
CLUSTER - DESCRIPTION, INSTRUMENT . . . 8J-2
CLUSTER - DIAGNOSIS AND TESTING,
INSTRUMENT........................8J-6
CLUSTER - DISASSEMBLY, INSTRUMENT . . 8J-10
CLUSTER - INSTALLATION, INSTRUMENT . 8J-13
CLUSTER - OPERATION, INSTRUMENT.....8J-3
CLUSTER - REMOVAL, INSTRUMENT......8J-10
CLUSTER BEZEL - INSTALLATION.......23-108
CLUSTER BEZEL - REMOVAL..........23-108
CLUTCH - 5.9L DIESEL - DESCRIPTION,
FAN DRIVE VISCOUS...................7-56
CLUTCH - 5.9L DIESEL - OPERATION,
FAN DRIVE VISCOUS...................7-56
CLUTCH - 5.9L/8.0L - DESCRIPTION,
FAN DRIVE VISCOUS...................7-55
CLUTCH - 5.9L/8.0L - OPERATION, FAN
DRIVE VISCOUS......................7-55
CLUTCH - ASSEMBLY, FRONT....21-162,21-333
CLUTCH - ASSEMBLY, REAR.....21-205,21-377
CLUTCH - CLEANING, REAR.....21-204,21-377
CLUTCH - DESCRIPTION.................6-1
CLUTCH - DESCRIPTION, A/C
COMPRESSOR.......................24-11
CLUTCH - DESCRIPTION, FRONT . 21-160,21-330
CLUTCH - DESCRIPTION, OVERDRIVE . . . 21-172,
21-343
CLUTCH - DESCRIPTION, REAR . . 21-203,21-375
CLUTCH - DIAGNOSIS AND TESTING
.......6-2
CLUTCH - DISASSEMBLY, FRONT
. 21-161,21-331
CLUTCH - DISASSEMBLY, REAR
. . 21-204,21-376
CLUTCH - INSPECTION, A/C
COMPRESSOR
.......................24-15
CLUTCH - INSPECTION, FRONT
. . 21-162,21-332
CLUTCH - INSPECTION, REAR
. . . 21-204,21-377
CLUTCH - INSTALLATION, A/C
COMPRESSOR
.......................24-15
CLUTCH - OPERATION
..................6-2
CLUTCH - OPERATION, A/C
COMPRESSOR
.......................24-13
CLUTCH - OPERATION, FRONT
. . . 21-160,21-330
CLUTCH - OPERATION, OVERDRIVE
....21-172,
21-343
CLUTCH - OPERATION, REAR
....21-203,21-375
CLUTCH - REMOVAL, A/C COMPRESSOR
. . 24-13
CLUTCH - SPECIFICATIONS
...............6-7
CLUTCH - WARNING
....................6-2
CLUTCH AND BAND OPERATION -
DIAGNOSIS AND TESTING, AIR
TESTING TRANSMISSION
.......21-100,21-272
CLUTCH BREAK-IN - STANDARD
PROCEDURE, A/C COMPRESSOR
........24-13
CLUTCH CAM/OVERDRIVE PISTON
RETAINER - ASSEMBLY,
OVERRUNNING
...............21-193,21-364
CLUTCH CAM/OVERDRIVE PISTON
RETAINER - CLEANING, OVERRUNNING
. 21-192,
21-364
CLUTCH CAM/OVERDRIVE PISTON
RETAINER - DESCRIPTION,
OVERRUNNING
...............21-192,21-363
CLUTCH CAM/OVERDRIVE PISTON
RETAINER - DISASSEMBLY,
OVERRUNNING
...............21-192,21-364
6 INDEXBR/BE
Description Group-Page Description Group-Page Description Group-Page