ABS DODGE RAM 2002 Service Repair Manual

COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise to as high as 149ÉC
(300ÉF). This temperature is hot enough to melt plas-
tic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicle's coolant bottle to iden-
tify HOAT or Non-HOAT coolant. Non-HOAT coolant
is green in color.
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTIONÐENGINE OIL
API SERVICE GRADE CERTIFIED
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Standard engine-oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans.
In diesel engines, use an engine oil that conforms
to API Service Grade CF-4 or CG-4/SH (Fig. 3).
MOPARtprovides an engine oil that conforms to this
particular grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 15W±40 specifies a multiple
viscosity engine oil.
When choosing an engine oil, consider the range of
temperatures the vehicle will be operated in before
the next oil change. Select an engine oil that is best
suited to your area's particular ambient temperature
range and variation. For diesel engines, refer to (Fig.
4).
Fig. 3 API Service Grade Certification LabelÐDiesel
Engine Oil
0 - 4 LUBRICATION & MAINTENANCEBR/BE
FLUID TYPES (Continued)

DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid is the recommended fluid for
DaimlerChrysler automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
2500 Series Club Cab
and Quad Cab with 6.5'
Short Box129 L (34 gal.)*****
All 8' Long Box 132 L (35 gal.)*****
All Cab/Chassis Models 132 L (35 gal.)*****
ENGINE OIL WITH FILTER
5.9L 4.7 L (5.0 qts.)
8.0L 6.6 L (7.0 qts.)
5.9L DIESEL 10.4 L (11.0 qts.)
COOLING SYSTEM
5.9L 19 L (20 qts.)****
8.0L 24.5 L (26.0 qts.)****
5.9L DIESEL 22.7 L (24.0 qts.)****
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 46RE 3.8 L (4.0 qts.)
O-haul - 46RE 9-9.5L (19-20 pts.)*
Service Fill - 47RE 3.8 L (4.0 qts.)
O-haul - 47RE 14-16 L (29-33 pts.)*
0 - 6 LUBRICATION & MAINTENANCEBR/BE
FLUID TYPES (Continued)

FRONT - 2WD
TABLE OF CONTENTS
page page
FRONT - 2WD
DESCRIPTION
DESCRIPTION........................7
DESCRIPTION........................8
SPECIFICATIONS
TORQUE CHART......................8
SPECIAL TOOLS
INDEPENDENT FRONT SUSPENSION......9
HUB / BEARING
REMOVAL.............................9
INSTALLATION..........................9
KNUCKLE
REMOVAL.............................10
INSTALLATION.........................10
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................10
LOWER CONTROL ARM
REMOVAL.............................10INSTALLATION.........................10
SHOCK
DIAGNOSIS AND TESTING - SHOCK........11
REMOVAL.............................11
INSTALLATION.........................11
SPRING
REMOVAL.............................11
INSTALLATION.........................12
STABILIZER BAR
REMOVAL.............................12
INSTALLATION.........................12
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT..............................12
UPPER CONTROL ARM
REMOVAL.............................13
INSTALLATION.........................13
FRONT - 2WD
DESCRIPTION
DESCRIPTION
The independent front suspension (IFS) is com-
prised of (Fig. 1) and (Fig. 2):
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Steering Knuckles
²Jounce Bumpers
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
Fig. 1 Independent Front Suspension
1 - KNUCKLE
2 - SUSPENSION ARM
3 - COIL SPRING
4 - STABILIZER BAR
5 - SUSPENSION ARM
6 - LINK
BR/BEFRONT - 2WD 2 - 7

CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DESCRIPTION
The upper suspension arm bolts on frame brackets
through the arm pivot shaft. The frame brackets
have slotted holes which allow the arms to be
adjusted for caster and camber. Pivot shaft bushings
are not replaceable.
The lower suspension arms bolt to the lower frame
brackets and pivot through bushings, these bushings
are not replaceable.
The suspension arms have lube for life riveted ball
studs.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut54 40 Ð
Shock Absorber
Lower Bolt142 105 Ð
Lower Suspension Arm
Frame Nuts169 125 Ð
Lower Suspension Arm
Ball Joint Nut149 110 Ð
Upper Suspension Arm
Pivot Bar Nuts169 125 Ð
Upper Suspension Arm
Ball Joint Nut81 60 Ð
Stabilizer Bar
Clamp Bolt54 40 Ð
Stabilizer Bar
Link Nuts37 27 Ð
Hub Bearing
2500/3500 Nut380 280 Ð
Fig. 2 Independent Front Suspension
1 - SHOCK
2 - JOUNCE BUMPER
2 - 8 FRONT - 2WDBR/BE
FRONT - 2WD (Continued)

SPECIAL TOOLS
INDEPENDENT FRONT SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the caliper adapter bolts from the
steering knuckle and remove caliper adapter assem-
bly (Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/DISC BRAKE CALIPERS - REMOVAL).
NOTE: Do not allow brake hose to support caliper
adapter assembly.
(4) Remove the rotor from the hub/bearing wheel
studs.
(5) Remove the hub/bearing nut (Fig. 3) and slide
the hub/bearing off the spindle.On 3500 HD models
the hub spindle shaft must removed (Fig. 4).
CAUTION: The hub/bearing nut can not be re-used.
INSTALLATION
(1) On models with all-wheel antilock system
(ABS), check condition of tone wheel on hub/bearing.
If teeth on wheel are damaged, hub/bearing assembly
will have to be replaced (tone wheel is not serviced
separately).
(2) Slide the hub/bearing onto the spindle.On 3500
HD slide the spindle stub shaft into the hub/bearing
and tighten.(3) Install thenewhub/bearing nut and tighten
to:
²2500/3500: 380 N´m (280 ft lbs.)
(4) Install the rotor onto hub/bearing wheel studs.
(5) Install the caliper adapter assembly (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION), and tighten
adapter bolts to:
²2500/3500: 285 N´m (210 ft lbs.)
(6) Install the wheel and tire assembly and lower
the vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS
- STANDARD PROCEDURE).
(7) Apply brakes several times to seat brake shoes.
Be sure to obtain firm pedal before moving vehicle.
Remover, Tie Rod End MB-990635
Puller Tie Rod C-3894-A
Fig. 3 Caliper Adapter Assembly
1 - HUB/BEARING
2 - SPINDLE
Fig. 4 SPINDLE STUB SHAFT
1 - Hub/Bearing
2 - Knuckle
3 - Spindle Stub Shaft
BR/BEFRONT - 2WD 2 - 9
FRONT - 2WD (Continued)

²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(6) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(7) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(8) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(9) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(10) Remove the support and lower the vehicle.
(11) Tighten the suspension arm crossmember
nuts to 169 N´m (125 ft. lbs.).
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
(1) Raise and support vehicle.
(2) Remove shock upper nut and remove retainer
and grommet.
(3) Remove lower mounting bolt from suspension
arm and remove shock (Fig. 5).
INSTALLATION
(1) Extend shock fully, install retainer and grom-
met on top of shock absorber. Check grommets and
retainer for wear.(2) Guide shock up through upper suspension arm
bracket. Install top grommet, retainer and nut.
Tighten nut to 54 N´m (40 ft. lbs.).
(3) Align bottom end of shock into lower suspen-
sion arm and install mounting bolt. Tighten bolt to
142 N´m (105 ft. lbs.).
(4) Remove support and lower vehicle.
SPRING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from the lower
suspension arm.
(6) Support the lower suspension arm outboard
end with a jack. Place a jack under the arm in front
of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
Fig. 5 Shock
1 - SHOCK
2 - JOUNCE BUMPER
BR/BEFRONT - 2WD 2 - 11
LOWER CONTROL ARM (Continued)

FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD
DESCRIPTION
DESCRIPTION........................14
DESCRIPTION........................15
SPECIFICATIONS
TORQUE CHART......................15
SPECIAL TOOLS
LINK/COIL SUSPENSION...............16
HUB / BEARING
REMOVAL.............................16
INSTALLATION.........................17
KNUCKLE
REMOVAL.............................19
INSTALLATION.........................19
UPPER CONTROL ARM
REMOVAL.............................19
INSTALLATION.........................19
UPPER BALL JOINT
REMOVAL - DANA 44 & 60................19
INSTALLATION
INSTALLATION - DANA 44 AXLE..........20
INSTALLATION - DANA 60 AXLE..........20
LOWER CONTROL ARM
REMOVAL.............................20INSTALLATION.........................20
LOWER BALL JOINT
REMOVAL
REMOVAL - DANA 44 AXLE..............21
REMOVAL - DANA 60 AXLE..............21
INSTALLATION
INSTALLATION - DANA 44 AXLE..........21
INSTALLATION - DANA 60 AXLE..........22
SHOCK
DIAGNOSIS AND TESTING - SHOCK........22
REMOVAL.............................22
INSTALLATION.........................22
SPRING
REMOVAL.............................23
INSTALLATION.........................23
STABILIZER BAR
REMOVAL.............................23
INSTALLATION.........................23
TRACK BAR
DIAGNOSIS AND TESTING - TRACK BAR....24
REMOVAL.............................24
INSTALLATION.........................24
FRONT - 4WD
DESCRIPTION
DESCRIPTION
The link/coil suspension allows each wheel to adapt
to different road surfaces. The suspension is com-
prised of (Fig. 1) :
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Track bar
²Steering Knuckles
²Jounce Bumper
Fig. 1 Link/Coil Suspension
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
2 - 14 FRONT - 4WDBR/BE

CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
CAUTION: Suspension components with rubber
bushings (except stabilizer bar) should be tightened
with the vehicle at normal height. It is important to
have the springs supporting the weight of the vehi-
cle when the fasteners are torqued. If springs arenot at their normal ride position, vehicle ride com-
fort could be affected and premature bushing wear
may occur.
DESCRIPTION
The upper and lower suspension arms use bush-
ings to isolate road noise. The suspension arms are
bolted to the frame and axle through the rubber
bushings. The lower suspension arm uses cam bolts
at the axle to allow for caster and pinion angle
adjustment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut47 35 Ð
Shock Absorber
Lower Bolt135 100 Ð
Shock Absorber
Bracket75 55 Ð
Suspension Arm Lower
Axle Nut190 140 Ð
Suspension Arm Lower
Frame Nut190 140 Ð
Suspension Arm Upper
Axle Nut163 120 Ð
Suspension Arm Upper
Frame Nut163 120 Ð
Stabilizer Bar
Clamp Bolt54 40 Ð
Stabilizer Bar
Link Upper Nut37 27 Ð
Stabilizer Bar
Link Lower Nut47 35 Ð
Track Bar
Ball Stud Nut95 70 Ð
Track Bar
Axle Bracket Bolt176 130 Ð
Hub/Bearing
Nut245 180 Ð
Hub/Bearing
Bolts166 122 Ð
BR/BEFRONT - 4WD 2 - 15
FRONT - 4WD (Continued)

SPECIAL TOOLS
LINK/COIL SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
remove the extension from the rotor if equipped (Fig.
2).(4) Remove the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(5) Remove the cotter pin and the hub nut from
the axle shaft (Fig. 3).
(6) Disconnect the ABS wheel speed sensor wire
from under the hood. Remove the sensor wire from
the frame and steering knuckle if equipped.
(7) Back off the hub/bearing mounting bolts 1/4
inch each (Fig. 4). Then tap the bolts with a hammer
to loosen the hub/bearing from the steering knuckle.
(8) Remove the hub/bearing mounting bolts and
remove the hub/bearing.
Puller C-3894±A
Remover, Wheel Stud C-4150A
Fig. 2 Hub Extension
1 - HUB EXTENSION
2 - HUB
Fig. 3 Hub Nut Cotter Pin
1 - HUB NUT
2 - COTTER PIN
Fig. 4 Hub/Bearing Mounting Bolts
1 - SOCKET AND EXTENSION
2 - ROTOR AND HUB
3 - STEERING KNUCKLE
2 - 16 FRONT - 4WDBR/BE
FRONT - 4WD (Continued)

(4) Apply a liberal quantity of anti-seize compound
to the splines of the front drive shaft.
(5) Insert the two rearmost, top and bottom rotor
hub bolts in the steering knuckle. Insert the bolts
through the back side of the knuckle so they extend
out the front face as shown.
(6) Position the hub spacer (Fig. 9) and brake
shield (Fig. 10) on bolts just installed in knuckle.
NOTE: If the vehicle is equipped with a wheel speed
sensor the brake shield must be positioned on the
hub bearing (Fig. 11).
(7) Align the rotor hub with the drive shaft and
start the shaft into the rotor hub splines.
NOTE: Position wheel speed sensor wire at the top
of the knuckle if equipped.
(8) Align the bolt holes in the hub bearing flange
with the bolts installed in the knuckle. Then thread
the bolts into the bearing flange far enough to hold
the assembly in place.
(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 166 N´m (122 ft. labs.
(10) Install the washer and hub nut and tighten to
245 N´m (180 ft. lbs.).
(11) Install a new cotter pin in the hub nut.
Tighten the nut as needed to align the cotter pin hole
in the shaft with the opening in nut.
(12) Install the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(13) Install the sensor wire to the steering knuckle
and frame and if equipped. Connect the wheel speed
sensor wire under the hood.(14) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(15) Remove the support and lower the vehicle.
(16) Apply the brakes several times to seat the
brake shoes and caliper piston. Do not move the vehi-
cle until a firm brake pedal is obtained.
Fig. 9 Hub Spacer
1 - ROTOR HUB BOLTS
2 - HUB SPACER (POSITION FLAT TO REAR)
3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
Fig. 10 Brake Shield
1 - BRAKE SHIELD
2 - HUB BEARING BOLTS
3 - STEERING KNUCKLE
Fig. 11 Brake Shield With Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
2 - HUB BEARING
3 - SHIELD
2 - 18 FRONT - 4WDBR/BE
HUB / BEARING (Continued)