maintenance DODGE RAM 2003 Service Owner's Manual

(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13)
Tighten pinion gear side adjuster an additional:
²New Bearings6 Adjuster Holes
²Original Bearings4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 281 N´m (207 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 37).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shaft gasket and install axle
shafts.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).
DIFFERENTIAL TRAC-RITE
DESCRIPTION
The Trac-RiteŸ differential is a helical gear differ-
ential. The differential has two side gears, six pinion
gears and six pinion brake shoes.
NOTE: The differential is seviced as an assembly
only if damaged, but can be disassembled for
cleaning. The assembly should be cleaned every
time a bearing is changed due to damage.
OPERATION
When one wheel begins to spin the pinion gears on
that side are forced toward the pinion brake shoes.
The pinion brake shoes then cause frictional drag on
the opposite pinion gears and the side gear. These
friction forces transfer the power to the opposite
wheel. Once the frictional forces are overcome, differ-
entiation will occur. The torque will be continually
biased by the frictional forces to the high traction
wheel.
DISASSEMBLY
(1) Remove differential ring gear bolts.
(2) Remove differential case cover locating screws
(Fig. 38).
(3) Remove differential case cover.
(4) Remove side gear and thrust washer (Fig. 39).
Fig. 37 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 38 LOCATION SCREWS
1 - DIFFERENTIAL COVER
2 - LOCATION SCREWS
DRREAR AXLE - 11 1/2 AA 3 - 145
DIFFERENTIAL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS HIGH OR THE
COOLANT WARNING LAMP
ILLUMINATES. COOLANT MAY
OR MAY NOT BE LOST OR
LEAKING FROM THE COOLING
SYSTEM1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic,
or engine is being idled with
very high ambient (outside)
temperatures and the air
conditioning is on. Higher
altitudes could aggravate these
conditions.1. This may be a temporary condition and
repair is not necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to the
normal range. If the gauge does not return
to the normal range, determine the cause
for overheating and repair. Refer to
Possible Causes (2-18).
2. Is the temperature gauge
reading correctly?2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL). Repair as
necessary.
3. Is the temperature warning
illuminating unnecessarily?3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - SCHEMATIC -
ELECTRICAL).
4. Coolant low in coolant
reserve/overflow tank and
radiator?4. Check for coolant leaks and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
5. Pressure cap not installed
tightly. If cap is loose, boiling
point of coolant will be lowered.
Also refer to the following Step
6.5. Tighten cap
6. Poor seals at the radiator
cap.6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace cap
if necessary.
(b) Check condition of radiator filler neck.
If neck is bent or damaged, replace
radiator (5.9L) or degas bottle (3.7L, 4.7L).
7. Coolant level low in radiator
but not in coolant reserve/
overflow tank. This means the
radiator is not drawing coolant
from the coolant reserve/
overflow tank as the engine
cools (5.9L).7. (a) Check condition of radiator cap and
cap seals. Refer to Radiator Cap in this
Group. Replace cap if necessary.
(b) Check condition of radiator filler neck.
If neck is bent or damaged, replace
radiator.
(c) Check condition of the hose from the
radiator to the coolant tank. It should fit
tight at both ends without any kinks or
tears. Replace hose if necessary.
(d) Check coolant reserve/overflow tank
and tanks hoses for blockage. Repair as
necessary.
8. Incorrect coolant
concentration8. Check coolant. (Refer to LUBRICATION
& MAINTENANCE/FLUID TYPES -
DESCRIPTION).
9. Coolant not flowing through
system9. Check for coolant flow at radiator filler
neck with some coolant removed, engine
warm and thermostat open. Coolant
should be observed flowing through
radiator. If flow is not observed, determine
area of obstruction and repair as
necessary.
7 - 12 COOLINGDR
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-
IGNITION (NOT CAUSED BY
IGNITION SYSTEM). GAUGE
MAY OR MAY NOT BE
READING HIGH1. Engine overheating. 1. Check reason for overheating and
repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.2. Check coolant concentration. (Refer to
LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION).
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING1. Vacuum created in cooling
system on engine cool-down is
not being relieved through
coolant reserve/overflow system.1. (a) Radiator cap relief valve stuck.
(Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP -
DIAGNOSIS AND TESTING). Replace if
necessary
(b) Hose between coolant
reserve/overflow tank and
radiator is kinked. Repair as
necessary.
(c) Vent at coolant reserve/
overflow tank is plugged. Clean
vent and repair as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for blockage
and repair as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly. (Refer to 7
- COOLING/ENGINE/RADIATOR FAN -
REMOVAL)
2. Fan blades striking a
surrounding object.2. Locate point of fan blade contact and
repair as necessary.
3. Air obstructions at radiator or
air conditioning condenser.3. Remove obstructions and/or clean
debris or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has
defective bearing.4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL).
5. A certain amount of fan noise
may be evident on models
equipped with a thermal viscous
fan drive. Some of this noise is
normal.5. (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH -
DESCRIPTION) for an explanation of
normal fan noise.
DRCOOLING 7 - 15
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE HEATER
PERFORMANCE.
THERMOSTAT FAILED IN
OPEN POSITION1. Has a Diagnostic trouble
Code (DTC) been set?1. (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for correct procedures
and replace thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
3. Obstructions in heater
hose/fittings3. Remove heater hoses at both ends and
check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of
the hoses is hot, the water
pump may not be operating
correctly or the heater core may
be plugged. Accessory drive belt
may be slipping causing poor
water pump operation.5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - REMOVAL). If a slipping
belt is detected, (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS -
DIAGNOSIS AND TESTING). If heater
core obstruction is detected, (Refer to 24 -
HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE - REMOVAL).
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR
THE GRILL AREA WHEN
WEATHER IS WET, ENGINE IS
WARMED UP AND RUNNING,
AND VEHICLE IS STATIONARY.
TEMPERATURE GAUGE IS IN
NORMAL RANGE1. During wet weather, moisture
(snow, ice or rain condensation)
on the radiator will evaporate
when the thermostat opens. This
opening allows heated water
into the radiator. When the
moisture contacts the hot
radiator, steam may be emitted.
This usually occurs in cold
weather with no fan or airflow to
blow it away.1. Occasional steam emitting from this
area is normal. No repair is necessary.
COOLANT COLOR 1. Coolant color is not
necessarily an indication of
adequate corrosion or
temperature protection. Do not
rely on coolant color for
determining condition of coolant.1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION). Adjust coolant mixture as
necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/
OVERFLOW TANK.
TEMPERATURE GAUGE IS IN
NORMAL RANGE1. Level changes are to be
expected as coolant volume
fluctuates with engine
temperature. If the level in the
tank was between the FULL and
ADD marks at normal operating
temperature, the level should
return to within that range after
operation at elevated
temperatures.1. A normal condition. No repair is
necessary.
7 - 16 COOLINGDR
COOLING (Continued)

(5) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) Install tensioner assembly to mounting
bracket. An indexing tab is located on back of ten-
sioner. Align this tab to slot in mounting bracket.
Tighten nut to 67 N´m (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.
(4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 N´m
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
N´m (50 in. lbs.) torque.
(5) Install drive belt. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
(6) Check belt indexing marks (Fig. 4).
BELT TENSIONERS - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 5). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
Fig. 4 Tensioner Indexing Marks And Mounting Nut
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
Fig. 5 Belt
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - AUTOMATIC TENSIONER
6 - A/C COMPRESSOR
7 - 24 ACCESSORY DRIVEDR
BELT TENSIONERS - 5.9L (Continued)

For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to the Lubri-
cation and Maintenance section of this manual for
the proper battery jump starting procedure. While
battery charging can be considered a maintenance
procedure, the battery charging procedure and
related information are located later in this section of
the service manual. This was done because the bat-
tery must be fully-charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important thatthe battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester), a 12-volt test lamp and/or special service
tools may be required. All OBD-sensed systems are
monitored by the PCM. Each monitored circuit is
assigned a Diagnostic Trouble Code (DTC). The PCM
will store a DTC in electronic memory for any failure
it detects. Always check the PCM for stored trouble
codes before returning the vehicle to service. Refer to
Charging System for the proper charging system test
procedures. Refer to Starting System for the proper
starting system test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technician diagnose a
defective battery. Follow the instruction manual sup-
plied with the tester to properly diagnose a battery.
If the instruction manual is not available, refer to
the standard procedure in this section, which
includes the directions for using the Micro 420 bat-
tery tester.
8F - 2 BATTERY SYSTEMDR
BATTERY SYSTEM (Continued)

ponents. In addition to the maintenance schedules
found in this service manual and the owner's man-
ual, it is recommended that these procedures be per-
formed any time the battery or related components
must be removed for vehicle service.
(1) Clean the battery cable terminal clamps of all
corrosion. Remove any corrosion using a wire brush
or a post and terminal cleaning tool, and a sodium
bicarbonate (baking soda) and warm water cleaning
solution (Fig. 1).
(2) Clean the battery tray and battery holddown
hardware of all corrosion. Remove any corrosion
using a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal.
(3) If the removed battery is to be reinstalled,
clean the outside of the battery case and the top
cover with a sodium bicarbonate (baking soda) and
warm water cleaning solution using a stiff bristle
parts cleaning brush to remove any acid film (Fig. 2).
Rinse the battery with clean water. Ensure that the
cleaning solution does not enter the battery cells
through the vent holes. If the battery is being
replaced, refer to Battery System Specifications for
the factory-installed battery specifications. Confirm
that the replacement battery is the correct size and
has the correct ratings for the vehicle.
(4) Clean the battery thermal guard with a sodium
bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.(5) Clean any corrosion from the battery terminal
posts with a wire brush or a post and terminal
cleaner, and a sodium bicarbonate (baking soda) and
warm water cleaning solution (Fig. 3).
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
DRBATTERY SYSTEM 8F - 5
BATTERY SYSTEM (Continued)

INSPECTION
The following information details the recommended
inspection procedures for the battery and related
components. In addition to the maintenance sched-
ules found in this service manual and the owner's
manual, it is recommended that these procedures be
performed any time the battery or related compo-
nents must be removed for vehicle service.
(1) Inspect the battery cable terminal clamps for
damage. Replace any battery cable that has a dam-
aged or deformed terminal clamp.
(2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case
(if equipped). Inspect the battery case for cracks or
other damage that could result in electrolyte leaks.
Also, check the battery terminal posts for looseness.
Batteries with damaged cases or loose terminal posts
must be replaced.
(4) Inspect the battery thermal guard (if equipped)
for tears, cracks, deformation or other damage.
Replace any battery thermal guard that has been
damaged.
(5) Inspect the battery built-in test indicator sight
glass (if equipped) for an indication of the battery
condition. If the battery is discharged, charge as
required. Refer to Standard Procedures for the
proper battery built-in indicator test procedures. Also
refer to Standard Procedures for the proper battery
charging procedures.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can befound on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
²Group Size- The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment.
²Cold Cranking Amperage- The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
²Reserve Capacity- The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load.
²Ampere-Hours- The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
Part NumberBCI Group Size
ClassificationCold Cranking
AmperageReserve
CapacityAmpere -
HoursLoad Test
Amperage
56029449AB 65 600 120 Minutes 66 300
56029451AB 65 750 150 Minutes 75 375
56028450AA 65 600 120 Minutes 66 300
56028452AA 65 750 150 Minutes 75 375
56028452AB 65 700 130 Minutes 70 350
56029396AA 65 700 130 Minutes 70 350
56029382AA 65 700 130 Minutes 70 350
8F - 6 BATTERY SYSTEMDR
BATTERY SYSTEM (Continued)

SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
A large capacity, low-maintenance storage battery
(Fig. 4) is standard factory-installed equipment on
this model. Models equipped with a diesel engine
must utilize two 12-volt batteries connected in paral-
lel. Male post type terminals made of a soft lead
material protrude from the top of the molded plastic
battery case to provide the means for connecting the
battery to the vehicle electrical system. The battery
positive terminal post is physically larger in diameter
than the negative terminal post to ensure proper bat-
tery connection. The lettersPOSandNEGare also
molded into the top of the battery case adjacent to
their respective positive and negative terminal posts
for identification confirmation. Refer to Battery
Cables for more information on the battery cables
that connect the battery to the vehicle electrical sys-
tem.
The battery is made up of six individual cells that
are connected in series. Each cell contains positively
charged plate groups that are connected with lead
straps to the positive terminal post, and negatively
charged plate groups that are connected with lead
straps to the negative terminal post. Each plate con-
sists of a stiff mesh framework or grid coated with
lead dioxide (positive plate) or sponge lead (negative
plate). Insulators or plate separators made of a non-
conductive material are inserted between the positive
and negative plates to prevent them from contacting
or shorting against one another. These dissimilar
metal plates are submerged in a sulfuric acid and
water solution called an electrolyte.
The factory-installed battery has a built-in test
indicator (hydrometer). The color visible in the sight
glass of the indicator will reveal the battery condi-
tion. Refer to Standard Procedures for the proper
built-in indicator test procedures.The factory-in-
stalled low-maintenance battery has non-re-
movable battery cell caps.Water cannot be added
to this battery. The battery is not sealed and has
vent holes in the cell caps. The chemical composition
of the metal coated plates within the low-mainte-
nance battery reduces battery gassing and water
loss, at normal charge and discharge rates. There-
fore, the battery should not require additional water
in normal service. Rapid loss of electrolyte can be
caused by an overcharging condition.
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the
terminals should be properly cleaned and inspected
before diagnostic procedures are performed. Refer to
Battery System Cleaning for the proper cleaning pro-
cedures, and Battery System Inspection for the
proper battery inspection procedures. Refer to Stan-
dard Procedures for the proper battery charging pro-
cedures.
Micro 420 Battery Tester
Fig. 4 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - TEST INDICATOR (IF EQUIPPED)
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
DRBATTERY SYSTEM 8F - 7
BATTERY SYSTEM (Continued)

BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps10
Amps20 Amps
Open Circuit
VoltageHours Charging @ 21É C
(70É F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
If equipped, an indicator (hydrometer) built into
the top of the battery case provides visual informa-
tion for battery testing (Fig. 6). Like a hydrometer,
the built-in indicator measures the specific gravity of
the battery electrolyte. The specific gravity of the
electrolyte reveals the battery state-of-charge; how-
ever, it will not reveal the cranking capacity of the
battery. A load test must be performed to determine
the battery cranking capacity. Refer to Standard Pro-
cedures for the proper battery load test procedures.
Before testing, visually inspect the battery for any
damage (a cracked case or cover, loose posts, etc.)
that would cause the battery to be faulty. In order to
obtain correct indications from the built-in indicator,
it is important that the battery be level and have a
clean sight glass. Additional light may be required to
view the indicator.Do not use open flame as a
source of additional light.
To read the built-in indicator, look into the sight
glass and note the color of the indication (Fig. 7). Thebattery condition that each color indicates is
described in the following list:
²Green- Indicates 75% to 100% battery state-of-
charge. The battery is adequately charged for further
testing or return to service. If the starter will not
crank for a minimum of fifteen seconds with a fully-
charged battery, the battery must be load tested.
Refer to Standard Procedures for the proper battery
load test procedures.
²Black or Dark- Indicates 0% to 75% battery
state-of-charge. The battery is inadequately charged
and must be charged until a green indication is visi-
ble in the sight glass (12.4 volts or more), before the
battery is tested further or returned to service. Refer
to Standard Procedures for the proper battery charg-
ing procedures. Also refer to Diagnosis and Testing
for more information on the possible causes of the
discharged battery condition.
²Clear or Bright- Indicates a low battery elec-
trolyte level. The electrolyte level in the battery is
below the built-in indicator. A maintenance-free bat-
tery with non-removable cell caps must be replaced if
the electrolyte level is low. Water must be added to a
low-maintenance battery with removable cell caps
before it is charged. Refer to Standard Procedures for
the proper battery filling procedures. A low electro-
lyte level may be caused by an overcharging condi-
tion. Refer to Charging System for the proper
charging system diagnosis and testing procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used in place of the hydrometer test
when a hydrometer is not available, or for mainte-
nance-free batteries with non-removable cell caps.
Before proceeding with this test, completely charge
the battery (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
(1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Fig. 6 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC RODFig. 7 Built-In Indicator Sight Glass Chart
8F - 10 BATTERY SYSTEMDR
BATTERY (Continued)