power DODGE RAM 2002 Service Workshop Manual

WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906-B.(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES - WITHOUT RADIATOR
IN-TANK TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
(1) Remove cover plate filler plug on Tool 6906B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
Fig. 1 Automatic Transmission Oil
1 - UPPER RADIATOR SUPPORT BRACKET BOLT
2 - MOUNTING STRAPS (2)
3 - TRANS. OIL COOLER UPPER MOUNTING BOLT (2)
4 - TRANS. OIL COOLER LOWER MOUNTING BOLT (2)
5 - LOWER RADIATOR SUPPORT BRACKET BOLT (2)
6 - TRANSMISSION OIL COOLER
7 - RADIATOR SUPPORT BRACKET
BR/BETRANSMISSION 7 - 79
TRANS COOLER - 5.9L (Continued)

(2) Reinstall filler plug on Tool 6906B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Remove the transmission oil cooler from the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - REMOVAL)
(8) Remove the transmission oil cooler thermostat.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - DISASSEMBLY)
(9) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(10) Re-connect the oil cooler to the transmission
cooler lines.
(11) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oil
cooler.
(14) Install Special Tool Cooler Plug 8414 into the
transmission oil cooler.
(15) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(16) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the main oil cooler core pas-
sages only.
(17) Turn pump OFF.
(18) Remove the thermostat cover from the oil
cooler.
(19) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.(20) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - ASSEMBLY)
(21) Install the transmission oil cooler onto the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION)
(22) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(23) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(24) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission fluid.
(25) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(26) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
REMOVAL
(1) Disconnect battery negative cable.
(2) Place a drain pan under the oil cooler lines.
(3) Disconnect the transmission oil cooler line
quick-connect fitting at the cooler outlet using the
quick connect release tool 6935. Loosen clamp from
inlet connection and slide hose off of nipple. Plug
cooler lines to prevent oil leakage.
(4) Remove the oil cooler lower mounting bolt (oil
cooler-to-vehicle body) (Fig. 2).
(5) Remove three bolts (radiator support bracket-
to-body). Remove this A-shaped support bracket and
the transmission oil cooler as an assembly from the
vehicle. Take care not to damage the radiator core or
A/C condenser fins with the cooling lines when
removing.
(6) Remove oil cooler from A-shaped support
bracket by removing two upper mounting strap bolts
and mounting straps at support bracket (Fig. 2).
(7) Remove oil cooler from the A-shaped radiator
support bracket.
DISASSEMBLY
NOTE: The transmission oil cooler uses an internal
thermostat to control transmission oil flow through
the cooler. This thermostat is servicable.
(1) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(2) Remove the snap ring retaining the thermostat
end plug (Fig. 3).
7 - 80 TRANSMISSIONBR/BE
TRANS COOLER - 5.9L (Continued)

STANDARD PROCEDURE
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES - WITH RADIATOR
IN-TANK TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
The only recommended procedure for flushing cool-
ers and lines is to use Tool 6906-B Cooler Flusher.
WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906-B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES - WITHOUT RADIATOR
IN-TANK TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
(1) Remove cover plate filler plug on Tool 6906B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
Fig. 4 Automatic Transmission Oil CoolerÐ8.0L
Engine
1 - RADIATOR SUPPORT
2 - OIL COOLER MOUNTING BOLTS
3 - TRANSMISSION OIL COOLER
4 - TRANSMISSION OIL COOLER LINES
7 - 82 TRANSMISSIONBR/BE
TRANS COOLER - 8.0L (Continued)

erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Remove the transmission oil cooler from the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - REMOVAL)
(8) Remove the transmission oil cooler thermostat.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - DISASSEMBLY)
(9) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(10) Re-connect the oil cooler to the transmission
cooler lines.
(11) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oil
cooler.
(14) Install Special Tool Cooler Plug 8414 into the
transmission oil cooler.
(15) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(16) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the main oil cooler core pas-
sages only.
(17) Turn pump OFF.
(18) Remove the thermostat cover from the oil
cooler.(19) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.
(20) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - ASSEMBLY)
(21) Install the transmission oil cooler onto the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION)
(22) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(23) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(24) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission fluid.
(25) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(26) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
REMOVAL
(1) Place a drain pan under the oil cooler lines.
(2) Disconnect the two transmission lines from the
oil cooler by loosening the two worm gear clamps and
pulling the rubber hoses off of the oil cooler tubes
(Fig. 5). Plug all oil cooler lines to prevent oil leak-
age.
(3) Remove three oil cooler-to-radiator support
mounting bolts (Fig. 5).
(4) Remove the oil cooler and line assembly from
the vehicle.
Fig. 5 Transmission Oil CoolerÐ8.0L Engine
1 - RADIATOR SUPPORT
2 - OIL COOLER MOUNTING BOLTS
3 - TRANSMISSION OIL COOLER
4 - TRANSMISSION OIL COOLER LINES
BR/BETRANSMISSION 7 - 83
TRANS COOLER - 8.0L (Continued)

INSTALLATION
(1) Install the oil cooler and cooler line assembly to
the vehicle.
(2) Install three mounting bolts and tighten to 6
N´m (50 in. lbs.) torque.
(3) Connect the transmission cooling lines to the
oil cooler by pushing the rubber hoses onto the oil
cooler tubes. Tighten the worm gear clomps to 2 N´m
(18 in. lbs.)
(4) Start the engine and check all fittings for
leaks.
(5) Check the fluid level in the automatic trans-
mission (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 47RE/FLUID - STANDARD
PROCEDURE).
TRANS COOLER - 5.9L DIESEL
DESCRIPTION
All diesel models equipped with an automatic
transmission are equipped with both a main water-
to-oil cooler and a separate air-to-oil cooler. Both cool-
ers are supplied as standard equipment on diesel
engine powered models when equipped with an auto-
matic transmission.
The main water-to-oil transmission oil cooler is
mounted to a bracket on the turbocharger side of the
engine (Fig. 6).
The air-to-oil cooler is located in front of and to the
left side of the radiator (Fig. 7).
OPERATION
The transmission oil is routed through the main
cooler first, then the auxiliary cooler where addi-
tional heat is removed from the transmission oil
before returning to the transmission.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES - WITH RADIATOR
IN-TANK TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
The only recommended procedure for flushing cool-
ers and lines is to use Tool 6906-B Cooler Flusher.
Fig. 6 Transmission Water-To-Oil CoolerÐDiesel
EngineÐTypical
1 - TRANSMISSION WATER-TO-OIL COOLER
Fig. 7 Auxiliary Transmission Oil CoolerÐDiesel
Engine
1 - CHARGE AIR COOLER (INTERCOOLER)
2 - QUICK-CONNECT FITTINGS (2)
3 - MOUNTING NUTS (2)
4 - MOUNTING BOLT
5 - TRANSMISSION OIL COOLER
7 - 84 TRANSMISSIONBR/BE
TRANS COOLER - 8.0L (Continued)

WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906-B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES - WITHOUT RADIATOR
IN-TANK TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
(1) Remove cover plate filler plug on Tool 6906B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Remove the transmission oil cooler from the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - REMOVAL)
(8) Remove the transmission oil cooler thermostat.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - DISASSEMBLY)
BR/BETRANSMISSION 7 - 85
TRANS COOLER - 5.9L DIESEL (Continued)

assembly. Replace the faulty or damaged antenna
base and cable, if required.
TEST 3
Test 3 checks the condition of the vehicle body
ground connection. This test should be performed
with the battery positive cable removed from the bat-
tery. Disconnect both battery cables, the negative
cable first. Reconnect the battery negative cable and
perform the test as follows:
(1) Connect one ohmmeter test lead to the vehicle
fender. Connect the other test lead to the battery
negative terminal post.
(2) The resistance should be less than one ohm.
(3) If the resistance is more than one ohm, check
the braided ground strap(s) connected to the engine
and the vehicle body for being loose, corroded, or
damaged. Repair the ground strap connections, if
required.
TEST 4
Test 4 checks the condition of the ground between
the antenna base and the vehicle body as follows:
(1) Connect one ohmmeter test lead to the vehicle
fender. Connect the other test lead to the outer crimp
on the antenna coaxial cable connector.
(2) The resistance should be less then one ohm.
(3) If the resistance is more then one ohm, clean
and/or tighten the antenna base to fender mounting
hardware.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Reach under the passenger side of the instru-
ment panel near the right cowl side inner panel to
disengage the coaxial cable connector from the
retainer clip located on the bottom of the heater-A/C
housing (Fig. 2).
(3) Remove the foam tape to access the coaxial
cable connector. Disconnect the connector by pulling
it apart while twisting the metal connector halves.
Do not pull on the cable.
(4) Securely tie a suitable length of cord or twine
to the antenna half of the coaxial cable connector.
This cord will be used to pull or ªfishº the cable back
into position during installation.
(5) Reach above the Powertrain Control Module
(PCM) on the right side of the dash panel in the
engine compartment to disengage the antenna coax-
ial cable grommet from the hole in the dash panel
(Fig. 3).
(6) Pull the antenna coaxial cable out of the pas-
senger compartment and into the engine compart-
ment through the hole in the dash panel.(7) Raise the sleeve on the antenna mast far
enough to access and unscrew the antenna mast from
the antenna body (Fig. 4).
(8) Remove the antenna cap nut using an antenna
nut wrench (Special Tool C-4816) (Fig. 5).
(9) Remove the antenna adapter from the top of
the fender.
(10) Lower the antenna body and cable assembly
through the top of the fender.
(11) Pull the antenna body and cable out through
the opening between the right cowl side outer panel
and the top of the fender, while feeding the antenna
coaxial cable out of the engine compartment through
the hole in the right cowl side reinforcement.
(12) Untie the cord or twine from the antenna
body and cable coaxial cable connector, leaving the
cord or twine in the place of the cable through the
vehicle.
(13) Remove the antenna body and cable from the
vehicle.
INSTALLATION
(1) Tie the end of the cord or twine that was used
during instrument panel antenna cable removal
securely to the connector on the end of the antenna
cable being installed into the instrument panel. This
cord will be used to pull or ªfishº the cable back into
position.
Fig. 2 Antenna Coaxial Cable Connector
1 - RETAINER CLIP
2 - TO RADIO
3 - TO ANTENNA
4 - FOAM TAPE
8A - 6 AUDIOBR/BE
ANTENNA BODY & CABLE (Continued)

OPERATION
The filter, choke, and speaker relay unit is used to
control the supply of fused battery current to the
front door speaker-mounted dual amplifiers. The
speaker relay is energized by a fused 12 volt output
from the radio receiver whenever the radio is turned
on. For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
DIAGNOSIS AND TESTING - RADIO CHOKE
RELAY
The filter, choke and speaker relay is used to
switch power to the individual speaker amplifiers
used with the Infinity premium speaker package.
The choke and relay are serviced only as a unit. If all
of the speakers are inoperative the filter, choke and
speaker relay unit should be considered suspect.
However, before replacement make the following
checks of the filter, choke and speaker relay circuits.
For complete circuit diagrams, refer to the appropri-
ate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
(1) Check the fused B(+) fuse in the junction block.
If OK, go to Step 2. If not OK, replace the faulty
fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the junction block. If OK, go to Step 3. If not OK,
repair the open fused B(+) circuit to the battery as
required.
(3) Disconnect the instrument panel wire harness
connector from the filter, choke and speaker relay
unit. Check for battery voltage at the fused B(+) cir-
cuit cavity of the instrument panel wire harness con-
nector for the filter, choke and speaker relay unit. If
OK, go to Step 4. If not OK, repair the open fused
B(+) circuit to the junction block fuse as required.
(4) Probe the ground circuit cavity of the instru-
ment panel wire harness connector for the filter,
choke and speaker relay unit. Check for continuity to
a good ground. There should be continuity. If OK, go
to Step 5. If not OK, repair the open ground circuit to
ground as required.
(5) Turn the ignition switch to the On position and
turn the radio on. Check for battery voltage at the
radio 12-volt output circuit cavity of the instrument
panel wire harness connector for the filter, choke and
speaker relay unit. If OK, go to Step 6. If not OK,repair the open radio 12-volt output circuit to the
radio as required.
(6) Turn the radio and ignition switches to the Off
position. Reconnect the instrument panel wire har-
ness connector to the filter, choke and speaker relay
unit. Check for battery voltage at the amplified
speaker (+) circuit cavity of the instrument panel
wire harness connector for the filter, choke and
speaker relay unit. There should be zero volts. Turn
the ignition and radio switches to the On position.
There should now be battery voltage. If OK, repair
the open amplified speaker (+) circuits to the speak-
er-mounted amplifiers as required. If not OK, replace
the faulty filter, choke and speaker relay unit.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Reach under the driver side of the instrument
panel near the 16-way data link connector and
inboard of the ash receiver to access the filter, choke,
and speaker relay (Fig. 6) .
(3) Disconnect the instrument panel wire harness
connector from the filter, choke and speaker relay
wire harness connector.
Fig. 6 Filter, Choke, and Speaker Relay Remove/
Install
1 - ASH RECEIVER HOUSING
2 - DATA LINK CONNECTOR
3 - CENTER BRACE
4 - SCREW
5 - CHOKE AND RELAY
6 - WIRE HARNESS CONNECTORS
8A - 8 AUDIOBR/BE
RADIO CHOKE RELAY (Continued)

RADIO
DESCRIPTION
Available factory-installed radio receivers for this
model include an AM/FM/cassette (RAS sales code),
an AM/FM/CD/3-band graphic equalizer (RBR sales
code), or an AM/FM/CD/cassette/3-band graphic
equalizer (RAZ sales code). The factory-installed RAZ
sales code radio receivers can also communicate on
the Chrysler Collision Detection (CCD) data bus net-
work through a separate two-way wire harness con-
nector. All factory-installed receivers are stereo
Electronically Tuned Radios (ETR) and include an
electronic digital clock function.
These radio receivers can only be serviced by an
authorized radio repair station. See the latest War-
ranty Policies and Procedures manual for a current
listing of authorized radio repair stations.
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed when the vehicle is
shipped from the factory. This fuse feeds various
accessories that require battery current when the
ignition switch is in the Off position, including the
clock. The IOD fuse is removed to prevent battery
discharge during vehicle storage.
When removing or installing the IOD fuse, it is
important that the ignition switch be in the Off posi-
tion. Failure to place the ignition switch in the Off
position can cause the radio display to become scram-
bled when the IOD fuse is removed and replaced.
Removing and replacing the IOD fuse again, with the
ignition switch in the Off position, will correct the
scrambled display condition.
The IOD fuse should be checked if the radio or
clock displays are inoperative. The IOD fuse is
located in the junction block. Refer to the fuse layout
label on the back of the instrument panel fuse access
panel for IOD fuse identification and location.
OPERATION
The radio receiver operates on fused battery cur-
rent that is available only when the ignition switch is
in the On or Accessory positions. The electronic digi-
tal clock function of the radio operates on fused bat-
tery current supplied through the IOD fuse,
regardless of the ignition switch position.
For more information on the features, setting pro-
cedures, and control functions for each of the avail-
able factory-installed radio receivers, see the owner's
manual in the vehicle glove box. For complete circuit
diagrams, refer to the appropriate wiring informa-
tion. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
details of wire harness routing and retention, connec-
tor pin-out information and location views for the
various wire harness connectors, splices and grounds.
DIAGNOSIS AND TESTING - RADIO
If the vehicle is equipped with the optional remote
radio switches located on the steering wheel and the
problem being diagnosed is related to one of the
symptoms listed below, be certain to check the
remote radio switches and circuits. Refer to Audio,
Remote Radio Switch prior to attempting radio diag-
nosis or repair.
²Stations changing with no remote radio switch
input
²Radio memory presets not working properly
²Volume changes with no remote radio switch
input
²Remote radio switch buttons taking on other
functions
²CD player skipping tracks
²Remote radio switch inoperative.
For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
CAUTION: The speaker output of the radio receiver
is a ªfloating groundº system. Do not allow any
speaker lead to short to ground, as damage to the
radio receiver may result.
(1) Check the fused B(+) fuse in the junction block.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the junction block. If OK, go to Step 3. If not OK,
repair the open fused B(+) circuit to the Power Dis-
tribution Center (PDC) as required.
(3) Check the fused ignition switch output (acc/
run) fuse in the junction block. If OK, go to Step 4. If
not OK, repair the shorted circuit or component as
required and replace the faulty fuse(s).
(4) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (acc/run) fuse in the junction block. If OK, go
to Step 5. If not OK, repair the open fused ignition
8A - 10 AUDIOBR/BE

RADIO NOISE SUPPRESSION
COMPONENTS
DESCRIPTION
Radio Frequency Interference (RFI) and Electro-
Magnetic Interference (EMI) noise suppression is
accomplished primarily through circuitry internal to
the radio receivers. These internal suppression
devices are only serviced as part of the radio receiver.
External suppression devices that are used on this
vehicle to control RFI or EMI noise include the fol-
lowing:
²Radio antenna base ground
²Radio receiver chassis ground wire or strap
²Engine-to-body ground straps
²Cab-to-bed ground strap
²Heater core ground strap
²Resistor-type spark plugs
²Radio suppression-type secondary ignition wir-
ing.
For more information on the spark plugs and sec-
ondary ignition components, refer to Electrical, Igni-
tion Control.
DIAGNOSIS AND TESTING - RADIO NOISE
SUPPRESSION COMPONENTS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds. Inspect the ground paths
and connections at the following locations:
²Blower motor
²Cab-to-bed ground strap
²Electric fuel pump
²Engine-to-body ground straps
²Generator
²Ignition module
²Heater core ground strap
²Radio antenna base ground
²Radio receiver chassis ground wire or strap
²Wiper motor.If the source of RFI or EMI noise is identified as a
component on the vehicle (i.e., generator, blower
motor, etc.), the ground path for that component
should be checked. If excessive resistance is found in
any ground circuit, clean, tighten, or repair the
ground circuits or connections to ground as required
before considering any component replacement.
For service and inspection of secondary ignition
components, refer to Electrical, Ignition Control.
Inspect the following secondary ignition system com-
ponents:
²Distributor cap and rotor
²Ignition coil
²Spark plugs
²Spark plug wire routing and condition.
Reroute the spark plug wires or replace the faulty
components as required.
If the source of the RFI or EMI noise is identified
as two-way mobile radio or telephone equipment,
check the equipment installation for the following:
²Power connections should be made directly to
the battery, and fused as closely to the battery as
possible.
²The antenna should be mounted on the roof or
toward the rear of the vehicle. Remember that mag-
netic antenna mounts on the roof panel can adversely
affect the operation of an overhead console compass,
if the vehicle is so equipped.
²The antenna cable should be fully shielded coax-
ial cable, should be as short as is practical, and
should be routed away from the factory-installed
vehicle wire harnesses whenever possible.
²The antenna and cable must be carefully
matched to ensure a low Standing Wave Ratio
(SWR).
Fleet vehicles are available with an extra-cost RFI-
suppressed Powertrain Control Module (PCM). This
unit reduces interference generated by the PCM on
some radio frequencies used in two-way radio com-
munications. However, this unit will not resolve com-
plaints of RFI in the commercial AM or FM radio
frequency ranges.
ENGINE-TO-BODY GROUND
STRAP
REMOVAL
(1) Remove the screw that secures the engine-to-
body ground strap eyelet to the dash panel (Fig. 10).
(2) Remove the screw that secures the engine-to-
body ground strap eyelet to the back of the engine
cylinder head (Fig. 11) or (Fig. 12).
8A - 12 AUDIOBR/BE