tire type DODGE RAM 2003 Service Owner's Manual

Impact Airbag Control Modules (SIACM). An airbag
indicator in the ElectroMechanical Instrument Clus-
ter (EMIC) illuminates for about six seconds as a
bulb test each time the ignition switch is turned to
the On or Start positions. Following the bulb test,
the airbag indicator is turned on or off by the ACM
to indicate the status of the supplemental restraint
system. If the airbag indicator comes on at any time
other than during the bulb test, it indicates that
there is a problem in the supplemental restraint sys-
tem electrical circuits. Such a problem may cause air-
bags not to deploy when required, or to deploy when
not required.
Deployment of the supplemental restraints
depends upon the angle and severity of an impact.
Deployment is not based upon vehicle speed; rather,
deployment is based upon the rate of deceleration as
measured by the forces of gravity (G force) upon the
impact sensors. When an impact is severe enough,
the microprocessor in the ACM or the SIACM signals
the inflator of the appropriate airbag units to deploy
their airbag cushions. The outboard front seat belt
tensioners are provided with a deployment signal by
the ACM in conjunction with the driver and passen-
ger airbags. During a frontal vehicle impact, the
knee blockers work in concert with properly fastened
and adjusted seat belts to restrain both the driver
and the front seat passenger in the proper position
for an airbag deployment. The knee blockers also
absorb and distribute the crash energy from the
driver and the front seat passenger to the structure
of the instrument panel. The seat belt tensioner
removes the slack from the outboard front seat belts
to provide further assurance that the driver and
front seat passenger are properly positioned and
restrained for an airbag deployment.
Typically, the vehicle occupants recall more about
the events preceding and following a collision than
they do of an airbag deployment itself. This is
because the airbag deployment and deflation occur so
rapidly. In a typical 48 kilometer-per-hour (30 mile-
per-hour) barrier impact, from the moment of impact
until the airbags are fully inflated takes about 40
milliseconds. Within one to two seconds from the
moment of impact, the airbags are almost entirely
deflated. The times cited for these events are approx-
imations, which apply only to a barrier impact at the
given speed. Actual times will vary somewhat,
depending upon the vehicle speed, impact angle,
severity of the impact, and the type of collision.When the ACM monitors a problem in any of the
dual front airbag system circuits or components,
including the seat belt tensioners, it stores a fault
code or Diagnostic Trouble Code (DTC) in its memory
circuit and sends an electronic message to the EMIC
to turn on the airbag indicator. When the SIACM
monitors a problem in any of the side curtain airbag
system circuits or component, it stores a fault code or
DTC in its memory circuit and sends an electronic
message to the ACM, and the ACM sends an elec-
tronic message to the EMIC to turn on the airbag
indicator. Proper testing of the supplemental
restraint system components, the Programmable
Communications Interface (PCI) data bus, the elec-
tronic message inputs to and outputs from the EMIC,
the SIACM, or the ACM, as well as the retrieval or
erasure of a DTC from the ACM, SIACM, or EMIC
requires the use of a DRBIIItscan tool. Refer to the
appropriate diagnostic information.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the factory-installed passive restraints.
WARNING
WARNINGS - RESTRAINT SYSTEM
WARNING: DURING AND FOLLOWING ANY SEAT
BELT OR CHILD RESTRAINT ANCHOR SERVICE,
CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
DRRESTRAINTS 8O - 5
RESTRAINTS (Continued)

the locating pins on the bottom of the ACM mounting
flanges into the locating holes in the bracket.
(3) Still working from the left side of the floor
panel transmission tunnel, install and tighten the
two screws that secure the left ACM mounting
flanges to the bracket that is welded onto the floor
panel transmission tunnel. Tighten the screws to 14
N´m (10 ft. lbs.).
(4) From the right side of the floor panel transmis-
sion tunnel, tighten each of the two screws that
secure the right side of the ACM to the bracket on
the floor panel transmission tunnel. Tighten the
screws to 14 N´m (10 ft. lbs.).
(5) Reach through the rearward facing opening
below the instrument panel center stack support
bracket on the top of the floor panel transmission
tunnel to access and reconnect the instrument panel
wire harness connector for the ACM to the ACM con-
nector receptacle located on the rearward facing side
of the module. Be certain that the latch and the red
Connector Position Assurance (CPA) lock on the con-
nector are each fully engaged.
(6) On models with an automatic transmission,
reinstall the ACM cover onto the instrument panel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/ACM
COVER - INSTALLATION).
(7) On models with a manual transmission, rein-
stall the floor console onto the top of the floor panel
transmission tunnel. (Refer to 23 - BODY/INTERI-
OR/FLOOR CONSOLE - INSTALLATION).
(8) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).AUTOMATIC LOCKING
RETRACTOR
DESCRIPTION
The seat belt retractors used in all seating posi-
tions include an inertia-type, emergency locking
mechanism as standard equipment (Fig. 9). However,
the retractor locking mechanism for the passenger
side front seating position is mechanically switchable
from an emergency locking retractor to an automatic
locking retractor. The primary function of this fea-
ture is to securely accommodate a child seat in the
passenger side front seating position of the vehicle
without the need for a self-cinching seat belt tip half
latch plate unit or another supplemental device that
would be required to prevent the seat belt webbing
from unwinding freely from the retractor spool of an
inertia-type emergency locking retractor mechanism.
The automatic locking mechanism is integral to the
passenger side front seat belt and retractor unit and
is concealed beneath a molded plastic cover located
on the same side of the retractor spool as the seat
belt tensioner housing. The retractor is secured to
the inner B-pillar on the right side of the vehicle and
is concealed beneath the molded plastic inner B-pil-
lar trim. The automatic locking mechanism cannot be
adjusted or repaired and, if faulty or damaged, the
entire passenger side front seat belt and retractor
unit must be replaced.
Fig. 9 Automatic Locking Retractor
1 - TENSIONER HOUSING OR CHAMBER
2 - GAS GENERATOR
3 - TENSIONER PIGTAIL WIRE
4 - SPOOL
5 - TENSION REDUCER (DRIVER SIDE ON STANDARD CAB
ONLY)
6 - REDUCER CONNECTOR RECEPTACLE
7 - RETRACTOR LOCKING MECHANISM COVER
DRRESTRAINTS 8O - 13
AIRBAG CONTROL MODULE (Continued)

(8) Connect servo cable to throttle body. Refer to
servo Cable Removal/Installation.
(9) Install left-front wheel-well liner.
(10) Connect negative battery cable to battery
(connect both cables if diesel).
(11) Before starting engine, operate accelerator
pedal to check for any binding.
SWITCH
DESCRIPTION
Two separate switch pods operate the speed control
system. The steering-wheel-mounted switches use
multiplexed circuits to provide inputs to the PCM (to
the ECM for diesel) for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owner's manual for more information on speed
control switch functions and setting procedures.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
Depending on engine control computer (JTEC
having a 3± plug connector or NGC having a 4±
plug connector), 2 types of switches are used.
Both types of switches are internally and exter-
nally different. The switch used with the NGC
system has an attached pigtail lead. The switch
used with the JTEC system does not have an
attached pigtail lead.
OPERATION
When speed control is selected by depressing the
ON, OFF switch, the PCM (ECM for diesel) allows a
set speed to be stored in its RAM for speed control.
To store a set speed, depress the SET switch while
the vehicle is moving at a speed between approxi-
mately 35 and 85 mph. In order for the speed control
to engage, the brakes cannot be applied, nor can the
gear selector be indicating the transmission is in
Park or Neutral.
The speed control can be disengaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
The speed control can be disengaged also by any of
the following conditions:
²An indication of Park or Neutral
²The VSS signal increases at a rate of 10 mph
per second (indicates that the co-efficient of friction
between the road surface and tires is extremely low)
²Depressing the clutch pedal.
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear)
²The VSS signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate)
²If the actual speed is not within 20 mph of the
set speed
The previous disengagement conditions are pro-
grammed for added safety.
Once the speed control has been disengaged,
depressing the ACCEL switch restores the vehicle to
the target speed that was stored in the PCM's RAM
(ECM for diesel).
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCM's RAM.
If, while the speed control is engaged, the driver
wishes to increase vehicle speed, the PCM (ECM for
diesel) is programmed for an acceleration feature.
With the ACCEL switch held closed, the vehicle
accelerates slowly to the desired speed. The new tar-
get speed is stored in the PCM's RAM when the
ACCEL switch is released. The PCM also has a9tap-
up9feature in which vehicle speed increases at a rate
of approximately 2 mph for each momentary switch
activation of the ACCEL switch.
The PCM also provides a means to decelerate with-
out disengaging speed control. To decelerate from an
existing recorded target speed, depress and hold the
COAST switch until the desired speed is reached.
Then release the switch. The ON, OFF switch oper-
ates two components: the PCM's ON, OFF input, and
the battery voltage to the brake switch.
Fig. 9 SERVO CABLE CLIP REMOVE/INSTALL Ð
TYPICAL
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
8P - 8 SPEED CONTROLDR
SERVO (Continued)

(4) Reinstall the washer hose for the washer noz-
zle into its routing clips on the underside of the cowl
plenum cover/grille panel.
(5) Reinstall the cowl plenum cover/grille panel
over the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - INSTALLATION).
(6) Close and latch the hood.
(7) Reinstall both wiper arms onto the wiper piv-
ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - INSTALLATION).
WASHER PUMP/MOTOR
DESCRIPTION
The washer pump/motor unit (Fig. 12) is located on
the rearward facing surface of the washer reservoir,
in the right (except V-10 or diesel engine) or left
(V-10 and diesel engine only) front corner of the
engine compartment. A small permanently lubricated
and sealed electric motor is coupled to the rotor-type
washer pump. A seal flange with a barbed inlet nip-
ple on the pump housing passes through a rubber
grommet seal installed in a dedicated mounting hole
of the washer reservoir. When the pump is installed
in the reservoir a barbed outlet nipple on the pumphousing connects the unit to the washer system
through a short washer reservoir hose.
The washer pump/motor unit is retained on the
reservoir by the interference fit between the barbed
pump inlet nipple and the grommet seal, which is a
light press fit. The top of the washer pump is also
secured to the washer reservoir by the use of a snap
post on the motor housing and a snap post receptacle
molded into the reservoir that allows for mounting of
the washer pump without the use of fasteners. An
integral connector receptacle on the top of the motor
housing connects the unit to the vehicle electrical
system. The washer pump/motor unit cannot be
repaired. If faulty or damaged, the entire washer
pump/motor unit must be replaced.
OPERATION
The washer pump/motor unit features a small
Direct Current (DC) electric motor. The motor is con-
nected to the vehicle electrical system through a sin-
gle take out and two-cavity connector of the right
(except V-10 or diesel engine) or left (V-10 or diesel
engine only) headlamp and dash wire harness. The
motor is grounded at all times through another take
out of the right (except V-10 or diesel engine) or left
(V-10 or diesel engine only) headlamp and dash wire
harness. On models without the V-10 or diesel engine
a single eyelet terminal connector is secured by a nut
to a ground stud located on the right front fender
inner shield in the engine compartment. On models
with a V-10 or diesel engine an eyelet terminal con-
nector is secured by a ground screw to the left front
fender inner shield in the engine compartment. The
motor receives battery current on a washer pump/
motor control circuit.
The washer pump/motor control circuit is energized
through a high side driver within the Front Control
Module (FCM) whenever the FCM receives an elec-
tronic message requesting washer system operation
from the instrument cluster over the Programmable
Communications Interface (PCI) data bus. The
instrument cluster monitors a resistor multiplexed
hard wired input from the momentary washer switch
contacts within the multi-function switch on the
steering column to determine when it should issue
the electronic message requesting washer system
operation.
Washer fluid is gravity-fed from the washer reser-
voir to the inlet side of the washer pump. When the
pump motor is energized, the motor spins the rotor
within the washer pump. The spinning pump rotor
pressurizes the washer fluid and forces it through
the pump outlet nipple, the washer plumbing, and
the washer nozzles onto the windshield glass.
The washer pump/motor unit may be diagnosed
using conventional diagnostic tools and methods.
Fig. 12 Washer Pump/Motor
1 - MOTOR
2 - SNAP POST
3 - CONNECTOR RECEPTACLE
4 - PUMP
5 - OUTLET NIPPLE
6 - INLET NIPPLE
7 - FILTER SCREEN
DRWIPERS/WASHERS 8R - 13
WASHER NOZZLE (Continued)

WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 14).
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 15).(5) Solder the connection together using rosin core
type solder only (Fig. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
DR8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15

(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to
the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N´m (45 ft.lbs.) torque.
(3) Lower the transmission so the transmission
mount rests on the crossmember, and the studs of
the transmission mount are aligned in the slots in
the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot.
(5) Torque the nuts to 54N´m (40 ft. lbs.).
LUBRICATION
DESCRIPTION
A gear-type positive displacement pump (Fig. 51) is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan (Fig. 52).
Fig. 51 Positive Displacement Oil PumpÐTypical
1 - INNER ROTOR AND SHAFT
2 - BODY
3 - DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
8 - LARGE CHAMFERED EDGE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
DRENGINE - 5.9L 9 - 267
REAR MOUNT (Continued)

CONNECTING RODS
The connecting rods are a split angle design (Fig.
89). They have a pressed-in-place wrist pin bushing
that is lubricated by piston cooling nozzle oil spray.
There are two different types of connecting rods:
machined and fractured split. The main different
between the two styles is the surface finish on the
connecting rod split face.
Machined connecting rods can be identified by a
machined surface at the connecting rod and cap split
face. Machined connecting rods have numbers
stamped on the rod cap and connecting rod near the
parting line. The number stamped on the connecting
rod must match the number stamped on the rod cap
and be installed on the camshaft or intake side of the
engine.
Fractured split connecting rods are first manufac-
tured as a single piece and then fractured into two
pieces. Fractured split connecting rods can be identi-
fied by a rough and irregular surface at the connect-
ing rod split face. To properly assemble the rod cap to
the connecting rod, the bearing tangs on the connect-
ing rod and cap must be located on the same side of
the rod. The long end of the connecting rod must be
assembled on the intake or camshaft side of the
engine.
Measuring methods and specifications are common
between fractured split and machined connecting
rods.
Both fractures split and machined connecting rods
and caps are machined as an assembly and are not
interchangeable. If a connecting rod or cap is dam-
aged, the entire assembly must be replaced.
Machined and fractured split connecting rods cannot
be used in the same engine.
STANDARD PROCEDURE - HEAD GASKET
SELECTION
(1) Measure piston protrusion for all six pistons.
(2) Calculate the average piston protrusion. Maxi-
mum allowable protrusion is 0.516 mm (0.020 inch).
NOTE: There are two different head gaskets avail-
able. One gasket is for Average piston protrusion
less than 0.30 mm (0.011 inch). The other gasket is
for Average piston protrusion greater than 0.30 mm
(0.011 inch)
REMOVAL
(1) Disconnect the battery cables.
(2) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Remove bolts and the block stiffener.(5) Using Miller Tool 7471-B crankshaft barring
tool, rotate the crankshaft so all of the pistons are
below TDC.
(6) Before removing the piston(s) from the bore(s):
(a) Remove any carbon ridge formations or
deposits at the top of the bore with a dull scraper
or soft wire brush.
(b) If cylinder bore wear ridges are found, use a
ridge reamer to cut the ridge from the bore. DO
NOT remove more metal than necessary to remove
the ridge.
(7) Remove the J-jet cooling nozzels, if equipped.
NOTE: If cylinders have ridges, the cylinders are
oversize and will more than likely need boring.
(8) Using a hammer and steel stamp, stamp the
cylinder number in the top of each piston. The front
of the piston is identified by a stamping on the top of
the piston. DO NOT stamp in the outside 5 mm (.197
in.) of the piston diameter. DO NOT stamp over the
piston pin.
(9) Mark the connecting rod and cap with the cor-
responding cylinder numbers.
(10) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
Fig. 89 Connecting Rod
9 - 330 ENGINE 5.9L DIESELDR
PISTON & CONNECTING ROD (Continued)

from the center outlet of the filter through an oil gal-
lery that channels the oil up to the tappet galleries,
which extends the entire length of block.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, cylinder walls, and piston pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan (Fig. 49).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS
Begin with a through 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
be sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light source.
(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 24km (15 miles), and
repeat previous step.
(5) If the oil leak source is not positively identified
at this time, proceed with the air leak detection test
method as follows:
(6) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) 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.
(9) 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.
(10) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(11) If no leaks are detected, turn off the air sup-
ply and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed
to next step.
(12) 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.
Fig. 48 Pressure Feed Type (Gerotor) Oil PumpÐ
Typical
1 - OUTER ROTOR
2 - INNER ROTOR
3 - OIL PUMP COVER
4 - TIMING CHAIN COVER
9 - 394 ENGINE 8.0LDR
LUBRICATION (Continued)

(9) Remove the bolts and remove the spare tire
winch. (Fig. 23)
(10) Position the wire harness forward of the work
area.
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(11) Carefully remove the H-section welds using a
grinder or equivalent tool.
(12) Remove the H-section and clean any remain-
ing welds from the frame.
(13) Trial fit the replacement part.
(14) Remove all e-coat from within 25 mm (1.0 in.)
of the weld area.
(15) Using the appropriate measuring equipment,
position the replacement part and verify correct posi-
tioning in all three (X,Y, and Z) planes of space.(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - FRAME DIMENSIONS)
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(16) Weld the replacement H-section into position.
The welding should be performed in a skip (stitch)
type method to minimize the heat buildup following
I-CAR or the American Welding Society welding pro-
cedures and utilizing the process specifications at the
end of this section. Refer to the Weld Process Speci-
fications welding schedule below.
(17) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
mating face between the frame and replacement
H-section.
(b) Apply a durable top coat to the outside of the
repair area.
(18) Position the wiring harness back.
(19) Install the spare tire winch and install the
bolts. (Fig. 23)
(20) Tighten the bolts to 41 N´m (30 ft. lbs.).
(21) Install the spare tire winch tube and install
the clip. (Fig. 22)
(22) Install the spare tire.
(23) Lift the axle into position and install the rear
shackle bolts. (Fig. 21)
(24) Tighten the bolts to 163 N´m (120 ft. lbs.).
(25) Install the lower shock absorber bolts. (Refer
to 2 - SUSPENSION/REAR/SHOCK - INSTALLA-
TION)
(26) Install the trailer hitch. (Refer to 13 - FRAME
& BUMPERS/FRAME/TRAILER HITCH - INSTAL-
LATION)
(27) Install the cargo box. (Refer to 23 - BODY/EX-
TERIOR/CARGO BOX - INSTALLATION)
(28) Reconnect the battery ground.
Fig. 23 SPARE TIRE WINCH ASSEMBLY
1 - SPARE TIRE WINCH ASSEMBLY
2 - BOLTS
3 - RETAINER BRACKET
4 - H-SECTION/SPARE WHEEL SUPPORT
13 - 16 FRAMES & BUMPERSDR
FRAME (Continued)

(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then partially press
input shaft into retainer (Fig. 237). Use a suitably
sized press tool to support retainer as close to input
shaft as possible.
(4) Install input shaft retaining ring.
(5) Press the input shaft the remainder of the way
into the clutch retainer.
(6) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(7) Lubricate lip of piston seals with generous
quantity of MopartDoor Ease. Then lubricate
retainer hub and bore with light coat of transmission
fluid.
(8) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.0209thick), can be used to
guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) Install piston spring in retainer and on top of
piston. Concave side of spring faces downward
(toward piston).
(10) Install the spacer ring and wave spring into
the retainer. Be sure spring is completely seated in
retainer groove.
(11) Install pressure plate (Fig. 236). Ridged side
of plate faces downward (toward piston) and flat side
toward clutch pack.
(12) Install first clutch disc in retainer on top of
pressure plate. Then install a clutch plate followed
by a clutch disc until entire clutch pack is installed
(4 discs and 3 plates are required) (Fig. 236).
(13) Install the reaction plate.
(14) Install selective snap-ring. Be sure snap-ring
is fully seated in retainer groove.
(15) Using a suitable gauge bar and dial indicator,
measure clutch pack clearance (Fig. 238).
(a) Position gauge bar across the clutch drum
with the dial indicator pointer on the pressure
plate (Fig. 238).
(b) Using two small screw drivers, lift the pres-
sure plate and release it.
(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the
snap-ring and record the dial indicator reading.
Clearance should be 0.635 - 0.914 mm (0.025 -
0.036 in.). If clearance is incorrect, steel plates, discs,
selective snap ring and pressure plates may have to
be changed.
The selective snap ring thicknesses are:
²0.107 - 0.109 in.²0.098 - 0.100 in.
²0.095 - 0.097 in.
²0.083 - 0.085 in.
²0.076 - 0.078 in.
²0.071 - 0.073 in.
²0.060 - 0.062 in.
Fig. 237 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM
Fig. 238 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4-STAND
5 - REAR CLUTCH
6 - GAUGE BAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 251
REAR CLUTCH (Continued)