power steering fluid DODGE RAM 2002 Service Repair Manual

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)

CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consist of the brake shoes,
calipers, wheel cylinders, brake drums, rotors, brake
lines, master cylinder, booster, and parking brake
components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering
components.
(3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear.Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake
lines, and master cylinder.
(b) If fluid appears contaminated, drain out a
sample to examine. System will have to be flushed
if fluid is separated into layers, or contains a sub-
stance other than brake fluid. The system seals
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system.
(4) Check parking brake operation. Verify free
movement and full release of cables and pedal. Also
note if vehicle was being operated with parking
brake partially applied.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for
being loose or for bind condition. Do not road test
until condition is corrected.
(6) Check booster vacuum check valve and hose.
(7) If components checked appear OK, road test
the vehicle.
ROAD TESTING
(1) If complaint involved low brake pedal, pump
pedal and note if it comes back up to normal height.
(2) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
firm under constant foot pressure.
(3) During road test, make normal and firm brake
stops in 25-40 mph range. Note faulty brake opera-
tion such as low pedal, hard pedal, fade, pedal pulsa-
tion, pull, grab, drag, noise, etc.
(4) Attempt to stop the vehicle with the parking
brake only and note grab, drag, noise, etc.
PEDAL FALLS AWAY
A brake pedal that falls away under steady foot
pressure is generally the result of a system leak. The
leak point could be at a brake line, fitting, hose, or
caliper/wheel cylinder. If leakage is severe, fluid will
be evident at or around the leaking component.
Internal leakage (seal by-pass) in the master cylin-
der caused by worn or damaged piston cups, may
also be the problem cause.
An internal leak in the ABS or RWAL system may
also be the problem with no physical evidence.
LOW PEDAL
If a low pedal is experienced, pump the pedal sev-
eral times. If the pedal comes back up, worn linings,
rotors, drums, or rear brakes out of adjustment are
the most likely causes. The proper course of action is
to inspect and replace all worn component and make
the proper adjustments.
BR/BEBRAKES - BASE 5 - 5
HYDRAULIC/MECHANICAL (Continued)

(8) Remove the supports and lower the vehicle.
(9) Verify a firm pedal before moving the vehicle.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Always clean the master cylinder reservoir and
caps before checking fluid level. If not cleaned, dirt
could enter the fluid.
The fluid fill level is indicated on the side of the
master cylinder reservoir (Fig. 19).
The correct fluid level is to the FULL indicator on
the side of the reservoir. If necessary, add fluid to the
proper level.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoir cap and empty fluid into
drain container.
(2) Clamp cylinder body in vise with brass protec-
tive jaws.
(3) Remove pins that retain reservoir to master
cylinder. Use hammer and pin punch to remove pins
(Fig. 20).
(4) Loosen reservoir from grommets with pry tool
(Fig. 21).
(5) Remove reservoir by rocking it to one side and
pulling free of grommets (Fig. 22).
(6) Remove old grommets from cylinder body (Fig.
23).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate new grommets with clean brake fluid
and Install new grommets in cylinder body (Fig. 24).
Use finger pressure to install and seat grommets.
(2) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
Fig. 19 Master Cylinder Fluid Level - Typical
1 - INDICATOR
2 - RESERVOIR
BR/BEBRAKES - BASE 5 - 15
DISC BRAKE CALIPERS (Continued)

EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION).
(10) Install knee bolster, (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
POWER BRAKE BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER
The hydraulic booster uses hydraulic pressure from
the power steering pump. Before diagnosing a
booster problem, first verify the power steering pump
is operating properly. Perform the following checks.
²Check the power steering fluid level.
²Check the brake fluid level.
²Check all power steering hoses and lines for
leaks and restrictions.
²Check power steering pump pressure.
NOISES
The hydraulic booster unit will produce certain
characteristic booster noises. The noises may occur
when the brake pedal is used in a manner not asso-
ciated with normal braking or driving habits.
HISSING
A hissing noise may be noticed when above normal
brake pedal pressure is applied, 40 lbs. or above. The
noise will be more noticeable if the vehicle is not
moving. The noise will increase with the brake pedal
pressure and an increase of system operating temper-
ature.
CLUNK-CHATTER-CLICKING
A clunk-chatter-clicking may be noticed when the
brake pedal is released quickly, after above normal
brake pedal pressure is applied 50-100 lbs..
BOOSTER FUNCTION TEST
With the engine off depress the brake pedal several
times to discharge the accumulator. Then depress the
brake pedal using 40 lbs. of force and start the
engine. The brake pedal should fall and then push
back against your foot. This indicates the booster is
operating properly.
ACCUMULATOR LEAKDOWN
(1) Start the engine, apply the brakes and turn the
steering wheel from lock to lock. This will ensure the
accumulator is charged. Turn off the engine and let
the vehicle sit for one hour. After one hour there
should be at least two power assisted brake applica-
tion with the engine off. If the system does not retain
a charge the booster must be replaced.(2) With the engine off depress the brake pedal
several times to discharge the accumulator. Grasp
the accumulator and see if it wobbles or turns. If it
does the accumulator has lost a gas charge and the
booster must be replaced.
SEAL LEAKAGE
If the booster leaks from any of the seals the
booster assembly must be replaced (Fig. 27).
²INPUT ROD SEAL:Fluid leakage from rear
end of the booster.
²PISTON SEAL:Fluid leakage from vent at
front of booster.
²HOUSING SEAL:Fluid leakage between hous-
ing and housing cover.
²SPOOL VALVE SEAL:Fluid leakage near
spool plug.
²RETURN PORT FITTING SEAL:Fluid leak-
age from port fitting.
Fig. 27 Hydraulic Booster Seals
1 - PUMP
2 - GEAR
3 - INPUT SEAL
4 - HOUSING SEAL
5 - ACCUMULATOR SEAL
6 - PISTON SEAL
7 - SPOOL PLUG SEAL
8 - RETURN
5 - 18 BRAKES - BASEBR/BE
PEDAL (Continued)

HYDRAULIC BOOSTER DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster.
2. Faulty spool valve action. 2. Replace booster.
3. Restriction in booster return hose. 3. Replace hose.
4. Damaged input rod. 4. Replace booster.
Excessive Brake Pedal
Effort.1. Internal or external seal leakage. 1. Replace booster.
2. Faulty steering pump. 2. Replace pump.
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 28).
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal. (Fig. 29).
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster (Fig. 30).
INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N´m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N´m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N´m (17 ft. lbs.).
BR/BEBRAKES - BASE 5 - 19
POWER BRAKE BOOSTER (Continued)

(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N´m (30 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) Install the return hose to the booster.(10) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(11) Fill the power steering pump with fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
CAUTION: Use only MOPAR power steering fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
(12) Bleed the hydraulic booster.
ROTORS
DIAGNOSIS AND TESTING
DISC BRAKE ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining with a disc
brake lathe if surface scoring and wear are light.
Replace the rotor for the following conditions:
²Severely Scored
²Tapered
²Hard Spots
²Cracked
²Below Minimum Thickness
Fig. 28 Master Cylinder And Booster
1 - MASTER CYLINDER
2 - RETURN LINE
3 - LINE FROM PUMP
4 - HYDRAULIC BOOSTER
5 - LINE TO GEAR
Fig. 29 Booster Push Rod
1 - BOOSTER PUSH ROD
2 - WASHER
3 - CLIP
4 - PEDAL
Fig. 30 Booster Mounting
1 - STEERING COLUMN
2 - MOUNTING NUTS
3 - BOOSTER PEDAL ROD
4 - MOUNTING NUTS
5 - 20 BRAKES - BASEBR/BE
POWER BRAKE BOOSTER (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................35
OPERATION...........................36
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES............................36
STANDARD PROCEDURE
STANDARD PROCEDURE - RWAL SERVICE
PRECAUTIONS.......................36
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM......................36
SPECIFICATIONS
TORQUE CHART......................37
FRONT WHEEL SPEED SENSOR
DESCRIPTION.........................38
OPERATION...........................38
REMOVAL
REMOVAL - 4X2......................39REMOVAL - 4X4......................39
INSTALLATION
INSTALLATION - 4X2...................39
INSTALLATION - 4X4...................39
REAR WHEEL SPEED SENSOR
DIAGNOSIS AND TESTING - REAR WHEEL
SPEED SENSOR......................40
REMOVAL.............................40
INSTALLATION.........................40
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................41
INSTALLATION.........................41
BRAKES - ABS
DESCRIPTION
The antilock brake system (ABS) is an electroni-
cally operated, all wheel brake control system. 2500
and 3500 vehicles have Electronic Brake Distribution
(EBD) designed into the systen which eliminates the
combination/proportioning valve.
The system is designed to prevent wheel lockup
and maintain steering control during periods of high
wheel slip when braking. Preventing lockup is accom-
plished by modulating fluid pressure to the wheel
brake units.
The hydraulic system is a three channel design.
The front wheel brakes are controlled individually
and the rear wheel brakes in tandem (Fig. 1). The
ABS electrical system is separate from other electri-
cal circuits in the vehicle. A specially programmed
controller antilock brake unit operates the system
components.
ABS system major components include:
²Controller Antilock Brakes (CAB)
²Hydraulic Control Unit (HCU)
²Wheel Speed Sensors (WSS)²ABS Warning Light
Fig. 1 Antilock Brake System
1 - MASTER CYLINDER AND RESERVOIR
2 - POWER BRAKE BOOSTER
3 - WIRES TO WHEEL SPEED SENSORS
4 - RIGHT REAR WHEEL
5 - LEFT REAR WHEEL
6 - HYDRAULIC BRAKE LINES TO WHEELS
7 - COMBINATION VALVE
8 - HARNESS
9 - RIGHT FRONT WHEEL
10 - LEFT FRONT WHEEL
11 - CAB/HCU
BR/BEBRAKES - ABS 5 - 35

OPERATION
Battery voltage is supplied to the CAB when a
speed of 15 miles per hour is reached. The CAB per-
forms a system initialization procedure at this point.
Initialization consists of a static and dynamic self
check of system electrical components.
The static and dynamic checks occurs at ignition
start up. During the dynamic check, the CAB briefly
cycles the pump and solenoids to verify operation. An
audible noise may be heard during this self check.
This noise should be considered normal.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
The CAB monitors wheel speed sensor inputs con-
tinuously while the vehicle is in motion. However,
the CAB will not activate any ABS components as
long as sensor inputs indicate normal braking.
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The antilock CAB activates the system whenever
sensor signals indicate periods of wheel slip. Periods
of wheel slip occur when brake stops involve high
pedal pressure and rate of vehicle deceleration.
The antilock system prevents lockup during a
wheel slip condition by modulating fluid apply pres-
sure to the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. Sensors at each front wheel convert wheel speed
into electrical signals. These signals are transmitted
to the CAB for processing and determination of
wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem. A speed sensor input
signal indicating a wheel slip condition activates the
CAB antilock program.
There are Two solenoid valves (Isolation and Dump
valve) which are used in each antilock control chan-
nel. The valves are all located within the HCU valve
body and work in pairs to either increase, hold, or
decrease apply pressure as needed in the individual
control channels.
During an ABS stop the ISO valve actuates, Stop-
ping anymore pressure build Ðup to the calipers.
Then the Dump valve dumps off pressure until the
wheel unlocks. This will continue until the wheels
quit slipping altogether.
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several self-tests
every time the ignition switch is turned on and the
vehicle is driven. The CAB monitors the systems
input and output circuits to verify the system is oper-
ating correctly. If the on board diagnostic system
senses that a circuit is malfunctioning the system
will set a trouble code in its memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
STANDARD PROCEDURE
STANDARD PROCEDURE - RWAL SERVICE
PRECAUTIONS
The RWAL uses an electronic control module, the
CAB. This module is designed to withstand normal
current draws associated with vehicle operation.
Care must be taken to avoid overloading the CAB
circuits.In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure.These circuits should only be tested
using a high impedance multi-meter or the DRB
tester as described in this section. Power should
never be removed or applied to any control module
with the ignition in the ON position. Before removing
or connecting battery cables, fuses, or connectors,
always turn the ignition to the OFF position.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM
ABS system bleeding requires conventional bleed-
ing methods plus use of the DRB scan tool. The pro-
cedure involves performing a base brake bleeding,
followed by use of the scan tool to cycle and bleed the
5 - 36 BRAKES - ABSBR/BE
BRAKES - ABS (Continued)

contains all of the switches for both the wiper and
washer systems.
²Washer Fluid Level Switch- The washer fluid
level switch is located in a dedicated hole on the
lower rear side of the washer reservoir, above the
washer pump/motor unit near the left front corner of
the engine compartment.
²Washer Nozzles- The dual fluidic washer noz-
zles are secured with integral snap features to dedi-
cated openings in the cowl plenum cover/grille panel
located near the base of the windshield. The washer
plumbing fittings for the washer nozzles are con-
cealed beneath the cowl plenum cover/grille panel.
²Washer Pump/Motor- The washer pump/mo-
tor unit is located in a dedicated hole on the lower
rear side of the washer reservoir near the left front
corner of the engine compartment.
²Washer Reservoir- The washer reservoir is
secured to the left side of the radiator fan shroud in
the left front corner of the engine compartment.
²Wiper Arms- The two wiper arms are secured
to the two wiper pivots, which extend through the
cowl plenum cover/grille panel located near the base
of the windshield.
²Wiper Blades- The two wiper blades are
secured to the two wiper arms, and are parked on
the glass near the bottom of the windshield when the
wiper system is not in operation.
²Wiper Module- The wiper pivots are the only
visible components of the wiper module. The remain-
der of the module is concealed within the cowl ple-
num beneath the cowl plenum cover/grille panel. The
wiper module includes the module bracket, the single
wiper motor, the wiper linkage, and the two wiper
pivots.
²Wiper Relay- The wiper relay is located in the
Power Distribution Center (PDC) in the engine com-
partment near the battery.
Features of the wiper and washer system include
the following:
²Continuous Wipe Modes- The two-speed
wiper motor and the internal circuitry of the multi-
function switch work in concert to provide two con-
tinuous wipe cycles, low speed or high speed.
²Intermittent Wipe Mode- The internal cir-
cuitry of the multi-function switch, the CTM, and the
wiper relay work in concert to provide an intermit-
tent wipe mode with multiple delay interval selec-
tions. On models with a high-line or premium CTM,
the CTM also automatically adjusts each manually
selected delay interval to compensate for vehicle
speed.
²Washer Mode- When the washer system is
activated with the multi-function switch while the
wiper system is operating, washer fluid will be dis-
pensed onto the windshield glass through the washernozzles for as long as the washer pump/motor is
energized.
²Wipe-After-Wash Mode- The internal circuitry
of the CTM provides a wipe-after-wash feature
which, if the wipers are turned Off, will operate the
washer pump/motor and the wipers for as long as the
washer system is activated, then provide several
additional wipe cycles after the washer system is
deactivated before parking the wiper blades near the
base of the windshield.
Hard wired circuitry connects the wiper and
washer system components to the electrical system of
the vehicle. These hard wired circuits are integral to
several wire harnesses, which are routed throughout
the vehicle and retained by many different methods.
These circuits may be connected to each other, to the
vehicle electrical system and to the wiper and washer
system components through the use of a combination
of soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
OPERATION
The wiper and washer system is intended to pro-
vide the vehicle operator with a convenient, safe, and
reliable means of maintaining visibility through the
windshield glass. The various components of this sys-
tem are designed to convert electrical energy pro-
duced by the vehicle electrical system into the
mechanical action of the wiper blades to wipe the
outside surface of the glass, as well as into the
hydraulic action of the washer system to apply
washer fluid stored in an on-board reservoir to the
area of the glass to be wiped. When combined, these
components provide the means to effectively main-
tain clear visibility for the vehicle operator by remov-
ing excess accumulations of rain, snow, bugs, mud, or
other minor debris from the outside windshield glass
surface that might be encountered while driving the
vehicle under numerous types of inclement operating
conditions. The vehicle operator initiates all wiper
and washer system functions with the multi-function
switch control stalk that extends from the left side of
the steering column, just below the steering wheel.
Rotating the knob on the end of the multi-function
switch control stalk selects the desired wiper system
operating mode. The wiper system allows the vehicle
operator to select from two continuous wiper speeds,
Hi or Lo, or one of several intermittent wipe Delay
mode intervals. Pushing the button on the end of the
control stalk downwards towards the steering column
8R - 2 WIPERS/WASHERSBR/BE
WIPERS/WASHERS (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Right Park/Turn Signal Lamp BK At Lamp N/S
Right Power Mirror BK In Door N/S
Right Rear Fender Lamp BK On Fender 27
Right Rear Speaker BK Bottom of Right B Pillar 23
Right Remote Radio Switch Steering Wheel N/S
Right Speed Control Switch Steering Wheel N/S
Right Tail/Stop Turn Signal
LampBK At Rear Bumper 27
Right Tweeter (Premium) Right A Pillar N/S
Right Visor/Vanity Lamp BK Right A-Pillar N/S
Seat Belt Switch BK Above Left Rear Speaker 23
Seat Heat Interface Module BK Under Seat N/S
Tailgate Lamp On Tailgate 27
Throttle Position Sensor
(Gas)Throttle Body 7, 12
Trailer Tow Connector BK On Trailer Hitch 27
Transmission Range Sensor BK Left side of Transmission N/S
Transmission Solenoid
AssemblyBK Side of Transmission 16
Under Hood Lamp BK Underside of Hood 20
Vehicle Speed Control Servo BK Below Battery 21
Washer Fluid Level Switch BK At Reservoir 21
Water In Fuel Sensor (Diesel) BK Bottom of Fuel Filter/Water Separator 13
Windshield Washer Pump BK Bottom of Washer Fluid Reservior 21
Wiper Motor BK Center Rear Engine Compartment 18
GROUNDS
GROUND
NUMBERLOCATION FIG.
G100 Left Fender Side Shield 21
G101 Left Fender Side Shield 21
G102 Left Fender Side Shield (RWAL Ground) N/S
G103 Near T/O for Wiper Motor 18
G105 Front of Engine (Engine Ground) 7, 8, 12
G107 (Diesel) Left Rear of Engine 13
G113 (Diesel) Primary Battery Engine Ground N/S
G114 Battery Engine Ground N/S
G115 (Diesel) Primary Battery Body Ground N/S
G116 Battery Frame Ground N/S
G117 (Diesel) Auxilary Battery Engine Ground N/S
G118 (Diesel) Primary Frame Ground N/S
G120 (Diesel) Auxilary Battery Body Ground N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
CONNECTOR/GROUND/SPLICE LOCATION (Continued)