clutch DODGE RAM 2003 Service Owners Manual

POWERTRAIN CONTROL MODULE C3 (JTEC) - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7 K73 18YL/BK (3.7L) KNOCK SENSOR NO. 1 SIGNAL
8 K199 18BR/VT OXYGEN SENSOR 1/1 HEATER CONTROL
9 K127 18DB/OR OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SWITCH SENSE
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (5.9L) OVERDRIVE OFF SWITCH SENSE
13 T10 18YL/DG (5.9L DIESEL) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SOLENOID CONTROL
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT (CALIFORNIA) OXYGEN SENSOR 2/1 HEATER CONTROL
16 K299 18BR/WT (EXCEPT CALIFORNIA) OXYGEN SENSOR 1/2 HEATER CONTROL
17 - -
18 K74 18BR/VT (3.7L) KNOCK SENSOR NO. 2 SIGNAL
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAPORATIVE EMISSION SOLENOID CONTROL
21 - -
22 - -
23 - -
24 K29 18WT/PK BRAKE SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 G8 18LB/BK FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D20 18LG SCI RECEIVE
30 D25 18VT/BR PCI BUS
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91

POWERTRAIN CONTROL MODULE C3 (NGC) - WHITE 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 K51 20DB.YL ASD RELAY CONTROL
4- -
5 V35 18LG/RD (4.7L) S/C VENT CONTROL
6 Y145 20DB/YL CONDENSER FAN RELAY CONTROL
7 V32 20YL/RD (4.7L) S/C POWER SUPPLY
8 K106 18WT/DG (4.7L) NVLD SOLENOID CONTROL
9 K199 18BR/VT O2 1/2 HEATER CONTROL
10 K399 18BR/GY (4.7L) O2 2/2 HEATER CONTROL
11 C13 20DB/OR A/C CLUTCH RELAY CONTROL
12 V36 18TN/RD (4.7L) S/C VACUUM CONTROL
13 - -
14 V32 20YL/RD (5.7L) BRAKE SWITCH NO.2 SIGNAL
15 Y215 20YL/PK (5.7L) S/C SWITCH RETURN
16 K223 18PK/DB (5.7L) APPS NO.1 RETURN
17 K981 18BR/DG (5.7L) APPS NO.2 RETURN
18 V38 20VT/OR (5.7L) S/C SWITCH NO.2 SIGNAL
19 A142 16DG/OR ASD RELAY OUTPUT
20 K108 18WT/TN EVAP PURGE SOL SIGNAL
21 T24 20BR/YL TRS T24 SENSE (P/N SENSE)
22 G113 18OR PTO SWITCH SENSE
23 K29 18WT/PK BRAKE SWITCH SIGNAL
24 - -
25 K255 18WT/DG (5.7L) APPS NO.1 SIGNAL
26 - -
27 - -
28 A142 16DG/OR ASD RELAY OUTPUT
29 K52 18PK/BK EVAP PURGE SOL CONTROL
30 S28 18YL/BK P/S SWITCH SIGNAL
31 - -
32 K118 18PK/YL BATT TEMP SIGNAL
33 G8 18LB/BK FUEL LEVEL SIGNAL
34 V37 18RD/LG S/C SWITCH NO.1 SIGNAL
35 K107 18OR NVLD SWITCH SIGNAL
36 K81 18DB/DG (5.7L) APPS NO.2 SIGNAL
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
8W - 80 - 92 8W-80 CONNECTOR PIN-OUTSDR

TRANSMISSION CONTROL MODULE - BLACK 60 WAY
CAV CIRCUIT FUNCTION
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z113 18BK GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T59 18PK UNDERDRIVE SOLENOID CONTROL
56 A61 16DG/BK FUSED B(+)
57 Z13 16BK/RD GROUND
58 - -
59 T159 18DG/WT 4C SOLENOID CONTROL
60 T60 18BR OVERDRIVE SOLENOID CONTROL
TRANSMISSION RANGE SENSOR (5.9L/DIESEL) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
2 Y193 20YL/RD TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX
3- -
4 L1 18VT/BK BACKUP LAMP FEED
5 Y128 20DG/GY TRANS RANGE SENSOR ELECTRONIC CLUSTER 5
VOLT SUPPLY
6 T24 20BR/YL PARK/NEUTRAL POSITION SWITCH SENSE (T41)
TRANSMISSION SOLENOID ASSEMBLY (5.9L/8.0L)-8WAY
CAV CIRCUIT FUNCTION
1 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
2 K6 18VT/WT 5 VOLT SUPPLY
3 K4 18BK/LB SENSOR GROUND
4 T25 18LG/RD GOVERNOR PRESSURE SENSOR SIGNAL
5 K88 18VT/WT GOVERNOR PRESSURE SOLENOID CONTROL
6 T60 18BR 3-4 SHIFT SOLENOID CONTROL
7 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 105

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.
Connector, ground, and splice indexes are provided.Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
index for the proper figure number. For items that
are not shown in this section N/S is placed in the
Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
4WD Switch (Manual Transfer
Case)BK Near T/O for Backup Lamp Switch 16
A/C Compressor Clutch BK At A/C Compressor 3, 5, 8, 9, 10
A/C Pressure Transducer BK Left Side of A/C Compressor 3, 5, 8, 9, 10
A/C-Heater Control C1 BK Center of Instrument Panel 36, 37, 38
A/C-Heater Control C2 BK Center of Instrument Panel 36, 37
Adjustable Pedal Motor WT Left of Instrument Panel 33
Adjustable Pedal Switch BL Left of Instrument Panel 37, 39
Airbag Control Module YL Lower Center of Instrument Panel 37, 38
Airbag Control Module-Left Side
ImpactYL Left B-Pillar 44, 45
Airbag Control Module-Right Side
ImpactYL Right B-Pillar N/S
Airbag-Driver Squib 1 YL On Steering Wheel 32
Airbag-Left Curtain Squib YL Top Left B-Pillar 44, 45
Airbag-Passenger Squib 1 YL Right Front of Instrument Panel 37, 40
Airbag-Right Curtain Squib YL Top Right B-Pillar N/S
Ambient Temperature Sensor BK Left Rear of Hood 31
Amplifier Audio C1 GY Top Center of Instrument Panel 37, 40
Amplifier Audio C2 GY Top Center of Instrument Panel 37, 40
Automatic Day/Night Mirror (Except
Base)BK Top Center of Windshield N/S
Backup Lamp Switch BK Left Rear of Transmission 16
Battery Temperature Sensor BK Below Battery Tray 26, 28, 29, 30
Blend Door Actuator (Single Zone) BK Behind Right Side of Instrument
PanelN/S
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C317 BK At Passenger Seat N/S
C319 BK Bottom Left of Left Door N/S
C322 DK GY Left Rear of Frame N/S
C323 BK Left Side of Instrument Panel N/S
C327 BK Right Rear Fender 48, 49
C328 BK Left Rear Fender 48, 49, 50
Camshaft Position Sensor GY Right Front Side of Engine 3, 6, 8, 9
Capacitor Left Rear of Engine Compartment N/S
Center High Mounted Stop
Lamp/Cargo LampBK Rear of Cab 47
Cigar Lighter Outlet NAT Rear of Cigar Lighter 34, 37, 38
Clearance Lamp No. 1 BK Left Roof 46
Clearance Lamp No. 2 BK Left-Center Roof 46
Clearance Lamp No. 3 BK Center Roof 46
Clearance Lamp No. 4 BK Right-Center Roof 46
Clearance Lamp No. 5 BK Right Roof 46
Clockspring C1 BK Steering Column 33
Clockspring C2 YL Steering Column 33
Clockspring C3 BK Steering Column N/S
Clockspring C4 BK Steering Column N/S
Clutch Interlock Brake Switch BK At Clutch Pedal 26, 27
Coil On Plug No.1 BK Left Top Side of Intake Manifold 4
Coil On Plug No.2 BK Right Top Side of Intake Manifold 3
Coil On Plug No.3 BK Left Top Side of Intake Manifold 4
Coil On Plug No.4 BK Right Top Side of Intake Manifold 3
Coil On Plug No.5 BK Left Top Side of Intake Manifold 4
Coil On Plug No.6 BK Right Top Side of Intake Manifold 3
Coil On Plug No.7 BK Left Top Side of Intake Manifold 4
Coil On Plug No.8 BK Right Top Side of Intake Manifold 3
Compass/Mini-Trip Computer BK In Overhead Console N/S
Condenser Fan BK Near Condenser 26, 27
Controller Anti-Lock Brake C1 BK Left Fender Side Shield 26, 27, 28
Controller Anti-Lock Brake C2
(ABS)BK Left Fender Side Shield 26, 28
Crankshaft Position Sensor BK Right Rear of Engine Block 3, 6, 8, 9
Cylinder Lock Switch-Driver
(Premium)BK In Left Front Door 42
Cylinder Lock Switch-Passenger
(Premium)LT GY In Right Front Door N/S
Data Link Connector BK Left Bottom of Instrument Panel 37, 39
Data Link Connector - Engine
(Diesel)BK Near T/O for Water In Fuel Sensor N/S
Dome Lamp BK Center of Headliner N/S
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(5) Install fan blade assembly (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).
(6) Install radiator upper shroud and tighten fas-
teners to 11 N´m (95 in. lbs.).
(7) Connect electrical connector for shroud fan.
(8) Install radiator upper hose.
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect negative cable to battery.
STRUCTURAL COVER
DESCRIPTION
The structural dust cover is made of die cast alu-
minum and joins the lower half of the transmission
bell housing to the engine bedplate.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from
exhaust manifold.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 64) in the sequence shown.
(5) Pivot the exhaust pipe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 65) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 65) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
Fig. 64 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 65 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
9 - 56 ENGINE - 3.7LDR
VIBRATION DAMPER (Continued)

FRONT MOUNT
REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising
engine. Failure to do so may cause damage to the
fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(3) Raise the vehicle.
(4) Remove the engine oil filter.
(5) Remove the oil drain trough.
(6) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(7) Support the front axle with a suitable jack.
(8) Remove the (4) bolts that attach the engine
mounts to the front axle.
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle.
(11) Remove the through bolts(12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13) Remove the (8) mount to engine attaching
bolts
(14) Remove the engine mounts.4WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising
engine. Failure to do so may cause damage to the
fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(3) Raise the vehicle.
(4) Remove the skid plate.
(5) Remove the front crossmember.
(6) Remove the engine oil filter.
(7) Remove the oil drain trough.
(8) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(9) Support the front axle with a suitable jack.
(10) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 66).
Fig. 66 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
DRENGINE - 3.7L 9 - 57

(11) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(12) Lower the front axle.
(13) Remove the (6) through bolts
(14) Raise the engine far enough to be able to
remove the left (Fig. 67) and right (Fig. 68) engine
mounts.
(15) Remove the engine mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the engine block with (8) bolts. Torque bolts to 54
N´m (40 ft. lbs.).
(2) Insert the (2) through bolts into the right and
left side engine mounts and loose assemble the two
nuts onto the through bolts.
(3) Lower the engine until the through bolts rest
onto the slots in the frame brackets.(4) Tighten the through bolt nuts to 94 N´m (70 ft.
lbs.).
(5) Install the oil drain trough.
(6) Install the engine oil filter.
(7) Lower the vehicle.
(8) Install the viscous fan (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(9) Reconnect the negative battery cable.
4WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N´m (70 ft. lbs.).
(2) Raise the front axle into the frame and install
the left and right side through bolts. Torque nuts to
94 N´m (70 ft. lbs.).
(3) Insert the two upper through bolts into the
right and left side engine mounts and loose assemble
the two nuts onto the through bolts.
(4) Lower the engine until the left and right side
engine brackets rest on the through bolts, and the
Fig. 67 ENGINE MOUNT SUPPORT BRACKET
1 - BOLT
2 - ENGINE MOUNT SUPPORT BRACKET
3 - BOLT
Fig. 68 ENGINE MOUNT SUPPORT BRACKET RH
1 - BOLT
2 - ENGINE MOUNT SUPPORT BRACKET
9 - 58 ENGINE - 3.7LDR
FRONT MOUNT (Continued)

lower engine bracket through holes align with the
engine mounts, and the left engine bracket holes
align with the front axle slots (Fig. 69).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
(6) Loose assemble the lower through bolts.
(7) Torque the nuts for the (4) through bolts to 101
N´m (75 ft. lbs.).(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N´m (75 ft. lbs.).
(9) Install the oil drain trough.
(10) Install the engine oil filter.
(11) Install the front crossmember.
(12) Install the skid plate.
(13) Lower the vehicle.
(14) Install the viscous fan (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(15) Reconnect the negative battery cable.
Fig. 69 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
DRENGINE - 3.7L 9 - 59
FRONT MOUNT (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.If the oil leak source is not pos-
itively identified at this time, proceed with the air
leak detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(2) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kPa (3 PSI) of test pressure.
(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(5) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(6) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose.(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
DRENGINE - 3.7L 9 - 63
LUBRICATION (Continued)