cooling DODGE RAM 2002 Service Manual PDF

(4) Install the bolt retaining the wiring harness
near top of water pump.
(5) Fill cooling system. Refer to Refilling Cooling
System in this section.
(6) Connect both battery cables.
(7) Start and warm the engine. Check for leaks.
WATER PUMP INLET TUBE -
5.9L
REMOVAL
REMOVAL - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING
If equipped with A/C, the generator and A/C com-
pressor along with their common mounting bracket
(Fig. 63) must be partially removed. Removing the
generator or A/C compressor from their mounting
bracket is not necessary. Also, discharging the A/C
system is not necessary.Do notremove any refriger-
ant lines from A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN 24 - HEATING AND AIR CON-
DITIONING.
Fig. 61 Water Pump Removal/Installation
1 - O-RING SEAL (SQUARE)
2 - WATER PUMP
3 - BOLT (2)
Fig. 62 Pump O-ring Seal
1 - O-RING SEAL
2 - GROOVE
3 - WATER PUMP
Fig. 63 Generator - A/C Compressor Mounting
Bracket - Typical
BR/BEENGINE 7 - 73
WATER PUMP - 5.9L DIESEL (Continued)

(1) Disconnect negative battery cable from battery.
(2) Partially drain cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).Do not
waste reusable coolant. If the solution is clean, drain
the coolant into a clean container for reuse.
(3) Remove upper radiator hose clamp at radiator.
A special clamp tool must be used to remove the con-
stant tension clamps. Remove hose at radiator.
(4) Disconnect throttle cable from clip at radiator
fan shroud.
(5) Unplug wiring harness from A/C compressor.
(6) Remove the air cleaner assembly.
(7) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(8)5.9L V-8 LDC-Gas:The drive belt idler pulley
must be removed to gain access to one of the A/C
compressor/generator bracket mounting bolts.
Remove the idler pulley bolt and remove idler pulley
(Fig. 64).(9)5.9L HDC-Gas:The automatic belt tensioner/
pulley assembly must be removed to gain access to
one of the A/C compressor/generator bracket mount-
ing bolts. Remove the tensioner mounting bolt (Fig.
65) and remove tensioner.
(10) Remove the engine oil dipstick tube mounting
bolt at the side of the A/C-generator mounting
bracket.
(11) Disconnect throttle body control cables.
(12) Remove heater hose coolant return tube
mounting bolt (Fig. 66) (Fig. 67) and remove tube
from engine. Discard the old tube O-ring.
(13) Remove bracket-to-intake manifold bolts
(number 1 and 2 (Fig. 63).
(14) Remove remaining bracket-to-engine bolts
(Fig. 68) (Fig. 69).
Fig. 64 Idler Pulley - 5.9L V-8 LDC-Gas Engine
Fig. 65 Belt Tensioner - 5.9L HDC-Gas Engine
1 - PULLEY BOLT
2 - IDLER PULLEY
3 - TENSIONER PULLEY
4 - TENSIONER
5 - TENSIONER MOUNTING BOLT
7 - 74 ENGINEBR/BE
WATER PUMP INLET TUBE - 5.9L (Continued)

(15) Lift and position generator and A/C compres-
sor (along with their common mounting bracket) to
gain access to bypass hose. A block of wood may be
used to hold assembly in position.
(16) Loosen and position both hose clamps to the
center of bypass hose. A special clamp tool must be
used to remove the constant tension clamps. Remove
hose from vehicle.
REMOVAL - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
A water pump bypass hose (Fig. 70) is used
between the intake manifold and water pump on all
gas powered engines. To test for leaks, (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
(1) Partially drain cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE). Do not
waste reusable coolant. If the solution is clean, drain
the coolant into a clean container for reuse.WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(2) Loosen both bypass hose clamps and position to
the center of hose.
(3) Remove hose from vehicle.
INSTALLATION
INSTALLATION - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING
(1) Position bypass hose clamps to the center of
hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Install generator-A/C mounting bracket assem-
bly to engine. Tighten bolt number 1 (Fig. 63) to 41
N´m (30 ft. lbs.) torque. Tighten bolt number 2 (Fig.
63) to 28 N´m (20 ft. lbs.) torque. Tighten bracket
mounting bolts (Fig. 68) (Fig. 69) to 40 N´m (30 ft.
lbs.) torque.
(5) Install a new O-ring to the heater hose coolant
return tube (Fig. 66) (Fig. 67). Coat the new O-ring
with antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Fig. 66) (Fig. 67).
(7) Connect throttle body control cables.
(8) Install oil dipstick mounting bolt.
(9)/5.9L V-8 LDC-Gas Engine:Install idler pul-
ley. Tighten bolt to 41 N´m (30 ft. lbs.) torque.
Fig. 70 Water Pump Bypass Hose - Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
7 - 76 ENGINEBR/BE
WATER PUMP INLET TUBE - 5.9L (Continued)

(10)5.9L HDC-Gas:Install automatic belt ten-
sioner assembly to mounting bracket. A dowel pin is
located on back of tensioner (Fig. 71). Align this to
dowel hole (Fig. 72) in tensioner mounting bracket.
Tighten bolt to 41 N´m (30 ft. lbs.) torque.(11) Install drive belt (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
CAUTION: When installing the serpentine accessory
drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION). The correct belt with the correct length must
be used.
(12) Install air cleaner assembly.
(13) Install upper radiator hose to radiator.
(14) Connect throttle cable to clip at radiator fan
shroud.
(15) Connect wiring harness to A/C compressor.
(16) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Start and warm the engine. Check for leaks.
INSTALLATION - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
(1) Position bypass hose clamps to the center of
hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Start and warm the engine. Check for leaks.
Fig. 71 Tensioner Dowel Pin - 5.9L HDC-Gas Engine
1 - BELT TENSIONER
2 - DOWEL PIN
Fig. 72 Tensioner Mounting
1 - DOWEL PIN HOLE
2 - TENSIONER MOUNTING BRACKET
BR/BEENGINE 7 - 77
WATER PUMP INLET TUBE - 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)

(3) Remove the end plug, thermostat and spring
from transmission oil cooler (Fig. 3).
ASSEMBLY
(1) Throughly clean the thermostat bore on the
transmission oil cooler.
(2) Install new spring, thermostat, end plug and
snap ring.
(3) Install transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
INSTALLATION
(1) Install the oil cooler assembly to the A-shaped
radiator support bracket using the two upper mount-
ing bolts and mounting straps. Install the bolts but
do not tighten at this time.
(2) Install the radiator support bracket and oil
cooler (as an assembly) to the vehicle.
(3) Install the two lower radiator A-shaped support
bracket bolts. Do not tighten bolts at this time.
(4) Slide and position the oil cooler on the
A-shaped bracket until its lower mounting hole lines
up with the bolt hole on the vehicle body. Tighten the
oil cooler mounting strap bolts to 6 N´m (50 in. lbs.)
torque.
(5) Install the upper radiator A-shaped support
bracket bolt. Tighten all three radiator support
bracket mounting bolts to 11 N´m (95 in. lbs.) torque.
(6) Inspect quick connect fitting for debris and
install the quick-connect fitting on the cooler outler
tube until an audible ªclickº is heard. Pull apart to
verify connection.
(7) Connect battery negative cable.
(8) Start the engine and check all fittings for
leaks.
(9) Check the fluid level in the automatic trans-
mission (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 42RE/FLUID - STANDARD
PROCEDURE), (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 44RE/FLUID - STAN-
DARD PROCEDURE) or (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
46RE/FLUID - STANDARD PROCEDURE).
TRANS COOLER - 8.0L
DESCRIPTION
The air-to-oil cooler is located in front of and to the
left side of the radiator (Fig. 4). This cooler is sup-
plied as standard equipment on all models equipped
with an automatic transmission.
OPERATION
The transmission oil is routed through the cooler
where the cooler removes heat from the transmission
fluid, before returning to the transmission.
Fig. 2 Transmission Oil Cooler - 5.9L Engine
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
Fig. 3 Transmission Oil Cooler Thermostat
Removal/Installation
1 - THERMOSTAT HOUSING
2 - SPRING
3 - END PLUG
4 - SNAP RING
5 - THERMOSTAT
BR/BETRANSMISSION 7 - 81
TRANS COOLER - 5.9L (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)

(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
REMOVALÐAIR TO OIL COOLER
(1) Remove front bumper.
(2) Place a drain pan under the oil cooler.
(3) Raise the vehicle.
(4) Disconnect the oil cooler quick-connect fittings
from the transmission lines.
(5) Remove the charge air cooler-to-oil cooler bolt
(Fig. 8).
(6) Remove two mounting nuts.
(7) Remove the oil cooler and line assembly
towards the front of vehicle. Cooler must be rotated
and tilted into position while removing.
REMOVALÐWATER TO OIL COOLER
CAUTION: If a leak should occur in the water-to-oil
cooler mounted to the side of the engine block,
engine coolant may become mixed with transmis-
sion fluid. Transmission fluid may also enter engine
cooling system. Both cooling system and transmis-
sion should be drained and inspected in case of oil
cooler leakage.
Fig. 8 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 - 86 TRANSMISSIONBR/BE
TRANS COOLER - 5.9L DIESEL (Continued)