weight DODGE TRUCK 1993 Service Repair Manual

INTRODUCTION

INTRODUCTION

DESIGNATIONS,
LABELS/PLATES/DECALS,
CODES
AND DIMENSIONS/WEIGHTS .
CONTENTS

page
MEASUREMENT
AND TORQUE
... 1 SPECIFICATIONS
page

. 11

DESIGNATIONS, LABELS/PLATES/DECALS, CODES
AND
DIMENSIONS/WEIGHTS
INDEX

page

Engine
and
Transmission/Transfer
Case
Identification
2

Engine/Transmission/GVWR
4

Equipment
Identification
Plate
3
International
Vehicle Control
and
Display
Symbols
10

Major Component
Identification 3
VEHICLE DESIGNATIONS The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes are used to identify vehicle types in charts, captions
and in service procedures. The vehicle codes are
dif­

ferent than the Vehicle Identification Number (VIN) or the wheelbase/model code.
VEHICLE SAFETY CERTIFICATION
LABEL
A certification label is attached to the left side
B-pillar. The label certifies that the vehicle conforms
to Federal Motor Vehicle Safety Standards (FMVSS).
The label also lists the: • Month and year of vehicle manufacture
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number (VIN)
Type of vehicle
Type of rear wheels (single or dual) Bar code
Month, Day and Hour (MDH) of final assembly
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
page

Trailer
Towing Specifications
4

Vehicle Code Plate
2

Vehicle Designations
1

Vehicle Dimension
4

Vehicle
Identification
Number (VIN) Plate
1

Vehicle Safety
Certification
Label
............. 1

Vehicle Weights
4
VEHICLE CODE
DESIGNATIONS
VEHICLE CODE
= AD
(DODGE
RAM

PICKUP
&
CHASSIS
CAB)

VEHICLE
FAMILY LINE DESCRIPTION
AD1
D150

AD2
D250

AD3
D350
PICKUP

4x2

AD5
W150
AD6
W250

AD7
W350
PICKUP

4x4

AD2
D250
AD3
D350
CHASSIS
CAB

4x2

AD6
W250
AD7
W350
CHASSIS
CAB

4x4

AD4
AD100

AD4
AD150
SPORT
UTILITY
4x2

AD8
AD100

AD8 AD
150
SPORT
UTILITY
4x4
J90IN-32

4 INTRODUCTION
• VEHICLE DIMENSIONS

VEHICLE

FAMILY
WHEELBASE

AVAILABLE
CAB
TO

AXLE BODY

TYPE
SfANDAID
SODIES
AVAILABLE
VEHICLE
FAMILY
WHEELBASE

AVAILABLE
CAB
TO

AXLE BODY

TYPE
NOMINAL

LENGTH
(LOAD
SPACE
D

MENSIONS
(2)

VEHICLE
FAMILY
WHEELBASE

AVAILABLE
CAB
TO

AXLE BODY

TYPE
NOMINAL

LENGTH LENGTH MAX.

WIDTH
HEIGHT
VOLUME
AD-1
AD-5
2921
mm

(115
in) —

Sweptline

1981
mm

(6.5
ft)
1981
mm

(78
in)
1778 mm
(70
in)
485 mm
19.1
in) 1.71 m3

(60.35
ft3)

AD-1
AD-2

AD-3
AD-5

AD-6
AD-7
3327
mm
(131
in) —

Sweptline

2438 mm
(8
ft)
2489 mm
(98
in)
1778 mm
(70
in)
485 mm
(19.1
in)
2.15
m3

(75.8
ft3)

AD-2
AD-3
AD-7
3327
mm
(131
in)
1422 mm
(56
in)
Chassis

Cab
2438 mm
(8
ft)
—
— — —

AD-3
AD-7
3249 mm
(135
in)
1524 mm
(60
in)
Chassis

Cab
2896 mm

(9.5
ft) —
— — —

AD-3
4039 mm
(159
in)
2134 mm
(84
in)
Chassis

Cab
3810 mm

(12.5
ft)
—
— —

AD-4
2692
mm
(106
in)
Sport

Utility

4x2
—

1778 mm 1588 mm
(62.5
in)
1062 mm
(41.8
in)
2.99
m3

(105.8
ft3)

AD-8
2692
mm
(106
in)
Sport

Utility

4x4
—

1778 mm 1588 mm
(62.5
in)
1062 mm
(41.8
in)
2.99
m3

(105.8
ft3)

AD-1
3378 mm
(133
in) —

Sweptline

1981
mm

(6.5
ft)
1984 mm
(78.1
in)
1778 mm
(70
in)
485 mm
(19.1
in) 1.71 m3

(60.4
ft3)

AD-1
AD-2

AD-5
AD-6
3785 mm
(149
in) —

Sweptline

Club
Cab 2438 mm
(8
ft)
2489 mm
(98
in)
1778 mm
(70
in)
485 mm
(19.1
in)
2.15
M3

(75.8
ft3)

®
Driver seat
to
tailgate.
(2)
Based
on
S.A.E.
procedure
Jl
100. J901N-34
VEHICLE
WEIGHTS

The Vehicle Weights chart provides:
• The Gross Vehicle Weight Rating (GVWR),
• The payload
• The curb weight
for
each vehicle type/wheelbase

TRAILER
TOWING
SPECIFICATIONS
The Trailer Towing Specifications chart provides:
• The maximum trailer tongue weight
• The maximum trailer weight
• The maximum combined weight of the trailer/load/
towing vehicle with
a
specific engine/transmission/ axle combination.

VEHICLE
DIMENSION

The Vehicle Dimension chart provides
the
dimen­
sions
for
each type
of
Ram Truck, Ram Chassis Cab
and Ramcharger vehicle.

ENGINE/TRANSMISSION/GVWR
The Engine/Transmission/GVWR chart provides
the maximum load data
for
each vehicle combina­ tion.

•

INTRODUCTION
7
VEHICLE
WEIGHTS

RAM
PICKUP

MODEL/
FAMILY
BODY
(3)

STYLE
GVWR
PAYLOAD

ALLOWANCE
(1)
CURB

WEIGHT
(2)

D150
AD1
4x2
61

2495
kg
5500
lbs
853
kg 1880 lb
1642 kg
3620
lbs

D150
AD1

4x2

62
2495
kg

2722
kg
5500
lbs

6000
lbs 804 kg
1021 kg 1772 lbs

2252
lbs 1691 kg
1700 kg
3728 lbs
3748 lbs

D150
AD1

4x2

31
2722
kg
6000
lbs 852 kg
1878 lbs 1870 kg
4122 lbs

D150
AD1

4x2

32
2722
kg
6000
lbs
787 kg 1736 lbs 1934 kg
4264 lbs

D250
AD2
4x2
62

3357
kg

3860
kg
7400
lbs
8510 lbs 1527 kg
1952 kg
3366 lbs
4304 lbs 1830 kg
1908 kg
4034 lbs
4206 lbs

D250
AD2

4x2

32
3357
kg

3860
kg
7400
lbs
8510 lbs 1369 kg
1846 kg
3019 lbs

4070
lbs 1987 kg
2014 kg 4381 lbs

4440
lbs

D350
AD3
4x2
62(4)
3946 kg
4581 kg
8700
lbs

10,100
lbs 2001 kg

2485
kg 4411 lbs
5478 lbs

1945
kg

2097
kg 4289 lbs

4622
lbs

W150
AD5
4x4
61

2858 kg
6300
lbs
978
kg
2156
lbs
1880 kg
4144 lbs

W150
AD5

4x4

62
2903
kg

6400
lbs
966
kg
2131 lbs
1936 kg 4269 lbs

W150
AD5

4x4

32
2903
kg

6400
lbs 789 kg
1740 lbs 2114 kg

4660
lbs

W250
AD6
4x4
62

3402
kg

3860
kg
7500
lbs
8510 lbs 1364 kg
1769 kg
3007
lbs
3899 lbs 2038 kg

2092
kg
4493
lbs
4611 lbs

W250
AD6

4x4

32
3402
kg

3860
kg
7500
lbs
8510 lbs 1259 kg
1664 kg
2775
lbs
3668 lbs
2143
kg
2196 kg
4725
lbs

4842
lbs

W350
AD7
4x4
62
3946 kg
8700
lbs 1749 kg

3855
lbs 2198 kg

4845
lbs
(1)
Payload
includes
maximum
weight
of
driver,
passengers,
cargo
and
optional
equipment
not
included
in
pavload
or
GVW
package
-
rayload
allowance
for
Chassis
Cabs
is
not supplied due to
large
variations
or
body
equipment
installed.

(2)
Includes
base
engine

(3)
Body
Style
Cab
Bed
Length

61
Std. 1981
mm
(6.5 ft
62 Std. 2438
mm
8.0 ft
31
Club
1981 mm 6.5 ft
32
Club
2438
mm
8.0 ft

63
Std. N.A

64
Std. N.A.

71
Sport
Utility N.A.
(4)
Dual
Rear
Wheels
J90IN-36

8 INTRODUCTION
•
VEHICLE
WEIGHTS
(CONT'D)

RAM
CHASSIS
CAB

MODEL/
FAMILY
BODY(3)

STYLE
GVWR
PAYLOAD

ALLOWANCE
(1)
CURB

WEIGHT
(2)

D250
AD2
4x2
62

3357
kg

3860
kg
7400
lbs
8510 lbs 1721 kg
1740 kg
3794 lbs

3835
lbs

D350
AD3
4x2
62
3946 kg
8700
lbs

ID
1794 kg
3954 lbs

D350
AD3

4x2

4581 kg

4763
kg
10,100
lbs

10,500
lbs

..,
1963
kg
1972 kg
4327
lbs

4347
lbs

D350
AD3

4x2

"111 4581 kg

4763
kg
10,100
lbs

10,500
lbs
1.1

2032
kg

2043
kg 4479 lbs

4505
lbs

W250
AD6
4x4
62

3860
kg
8510 lbs
1.) 1886 kg
4158 lbs

W350
AD7
4x4
62
3946 kg
8700
lbs

ID
2038 kg
4494 lbs

W350
AD7

4x4

4581 kg

4990
kg
10,100
lbs

11,000
lbs

ID

2136 kg

2145
kg 4709 lbs
4729 lbs

RAMCHARGER
-
SPORT
UTILITY
MODEL/
FAMILY
BODY(3)

STYLE
GVWR
PAYLOAD

ALLOWANCES)
CURB

WEIGHT(2)
D100
AD4
4x2 71

2540
kg
5600
lbs
603
kg 1330 lbs
1937
kg

4270
lbs

D150
AD4
4x2 71

2540
kg
5600
lbs
606
kg
1336
lbs
1934
kg

4264
lbs

W100
AD8
4x4 71

2722
kg
6000
lbs
618
kg

1363
lbs
2103
kg
4637
lbs

W150
AD8
4x4 71

2722
kg

2903
kg
6000
lbs

6400
lbs 621 kg

796
kg
1369
lbs

1755
lbs

2102
kg

2107
kg

4631
lbs

4645
lbs
(1)
Payload includes maximum weight
of
driver,
passengers,
cargo and optional equipment not included in payload
or
GVW package - Payload allowance
for
Chassis
Cabs
is
not
supplied
due to
large variations
of
body equipment installed.

!
2)
Includes base engine

3)
Body Style
Cab
Bed Length
6V
Std.
1981

mm
[6.5 ft)
62
Std.
2438
mm
8.0 ft

31
Club
1981
mm
6.5 ft
32
Club
2438
mm
8.0 ft

63
Std.
N.A
64
Std.
N.A.
71 Sport
Utility N.A.

(4) Dual Rear Wheels
J90IN-38

TRAILER TOWING
SPECIFICATIONS

ALLOWABLE
TONGUE WEIGHTS Max. Tongue
Model
GVWR
Weight

D/W150/150S
Ramcharger All
800

D/W250
All
900

D/W350
Single
Rear Wheels All
1000

Dual Rear Wheels All
1200

GCWR
-
GROSS
COMBINED
WEIGHT RATING

(Total
truck,
trailer,
cargo,
people
&
fluids)
AXLE
RATIOS

ENGINE
TRANSMISSION
3.54
3.90 4.10
4.56

D-150 3.9L Man. 5-spd.
8,000 8,000

Auto. 3-spd.
8,800
9,200

Auto. 4-spd.
O/D
8,800
9,200

5.2L Auto. 3-spd.
11,500
12,500

Auto. 4-spd.
O/D
10,500
10,500

Auto. 4-spd.
H.D.
11,500
12,500

5.9L Auto. 4-spd
H.D.
12,000
13,000 13,500
14,000

D-250
3.9L Auto. 3-spd.
8,800

9,200

5.2L Auto. 4-spd.
O/D
10,500 10,500

Auto. 4-spd.
H.D.
11,500
12,500

5.9L Auto. 4-spd.
H.D.
12,000
13,000 13,500
14,000

D-350
5.9L Auto. 4-spd.
H.D.
12,000
13,000 13,500 14,000

W-150 3.9L Auto. 4-spd.
H.D.
8,800
9,200

5.2L Auto. 4-spd.
H.D.
11,500
12,500

5.9L Auto. 4-spd.
H.D.
12,000
13,000 13,500
14,000

W-250
5.9L Auto. 3-spd.
12,000
13,000 13,500 14,000

W-350
5.9L Auto. 3-spd.
12,000 13,000 13,500 14,000

Auto. 4-spd.
H.D.
12,000
13,000 13,500 14,000

Ramcharger
4x2
5.2L Auto. 4-spd.
H.D.
11,500 12,500

5.9L Auto. 4-spd.
H.D.
12,000 13,000 13,500 14,000

Ramcharger
4x4
5.2L Auto. 4-spd.
H.D.
11,500 12,500

5.9L Auto. 4-spd.
H.D.
12,000
13,000 13,500 14,000

•
• —
LUiRICATlON
AND
MAINTENANCE
0 - 1
CONTENTS

page
page

CHASSIS
AND
BODY
28
ENGINE MAINTENANCE
14
DRIVETRAIN
.,,, 22
GENERAL INFORMATION
1

GENERAL
INFORMATION INDEl

page

Classification
of
Lubricants
. 3

Components
Requiring
No
Lubrication
4

Fuel Requirements
. 2
Introduction
1

Lubrication
and
Replacement Parts Recommendation
3
page

Routine Maintenance
2

Starting
Assistance (Jump Starting)
9

Vehicle
Lifting
Recommendations
............ 10

Vehicle Noise
Control
2

Vehicle Towing Recommendations
11

INTRODUCTION
Lubrication and maintenance is divided into re­
quired and recommended service tasks. The required service tasks must be completed to verify the emis­
sion controls function correctly. The recommended
service tasks should be completed to maintain safety
and durability. This information will assist the service personnel
in providing maximum protection for each owner's
vehicle. Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time in­
terval as well as a distance interval. It is the owner's responsibility to determine the ap­
plicable driving condition. Also to have the vehicle serviced according to the maintenance schedule, and
to pay for the necessary parts and labor. Vehicles with a Gross Vehicle Weight Rating
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform
to light duty emission standards. Vehicles with a Gross Vehicle Weight Rating (GVWR) of 3 856 kg
(8,501 lbs.) or more must conform to heavy duty
emission standards. The GVWR for each vehicle is listed on the Safety
Certification Label. This label is affixed to the driver
side door pillar (Fig. 1).
Additional maintenance and lubrication informa­
tion is listed in the Owner's Manual.
Mm
rv
CHRYSLER
DATE
OF MFR
MFD BY CORPORATION
GVWR
GAWR FRONT
GAWR REAR
WITH
TIRES

WITH
TIRES
RIMS
AT

RIMS
AT

PSI
COLD

PSI
COLD THIS VEHICLE CONFORMS
TO
ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

STANDARDS
IN
EFFECT ON
THE
DATE
OF
MANUFACTURE SHOWN ABOVE.

SINGLE
DUAL

BAR
CODE

VEHICLE MADE
IN

4648503
J9UN-25

Fig. 1 Vehicle Safety
Certification
Label

SEVERE DRIVING
CONDITIONS
Vehicles subjected to severe driving conditions
should decrease the interval between component
maintenance. Severe driving conditions are defined
as:

• Frequent short trip driving less than 24 km (15
miles)
• Frequent driving in dusty conditions
• Trailer towing
• Extensive engine idling
• Sustained high speed operation
• Desert operation
• Frequent starting and stopping
• Cold climate operation

LUBRICATION
AND
MAINTENANCE

LUBRICATION
AND
MAINTENANCE
0-11

J
DRIVE-ON
HOIST

I
FRAME
CONTACT
HOIST
TWIN
POST
CHASSIS
HOIST

FLOOR
JACK
RROOD30
Fig.
8 Correct Vehicle Lifting
Locations
An axle tube
A body side sill
A steering linkage component
A drive shaft
The engine or transmission oil pan
The fuel tank
• A front suspension arm Use the correct frame rail lifting locations only
(Fig. 8).
HOIST A vehicle can be lifted with:
• A single-post, frame-contact hoist
• A twin-post, chassis hoist
• A ramp-type, drive-on hoist
When a frame-contact type hoist is used, verify
that the lifting pads are positioned properly (Fig. 8).

WARNING:
WHEN
A
SERVICE
PROCEDURE
RE­
QUIRES
THE
REMOVAL
OF
THE
REAR
AXLE,
FUEL

TANK,
OR
SPARE
TIRE,
EITHER:

• PLACE ADDITIONAL WEIGHT ON THE REAR
END OF THE VEHICLE
« ATTACH THE VEHICLE TO THE HOIST
« PLACE JACK STANDS UNDER THE VEHICLE
FOR SUPPORT TO PREVENT TIPPING WHEN
THE CENTER OF BALANCE CHANGES
4WD VEHICLES A standard hoist can be used to lift a 4WD vehicle.
The hoist should be inspected for adequate clearance. The lift arms, pads or ramps should be adjusted to
ensure that there is adequate clearance (Fig. 9).
ADJUSTMENT
PAD

ii 7
MAINTAIN
CLEARANCE
HOIST
ARM

RK44

Fig.
9 Lifting 4WD Vehicle
With
Single-Post
Hoist—
Typical
When a twin-post hoist is used, a 4 x 4 x 12-inch
wood spacer also could be required. Place the wood spacer under the front axle (opposite the differential
housing). This will maintain balance and level lift­ ing.

CAUTION:
The
block
that
is
used must
be
secured in
a
safe manner. This
will
ensure
that
it
will
not un­

balance
the
vehicle.
VEHICLE
TOWING
RECOMMENDATIONS
When it is necessary to tow a Ram Truck, the rec­
ommended method is either:
• the sling-type, rear-end raised towing method; or
• the wheel-lift towing method with a tow dolly lo­
cated under the front wheels. A vehicle with flat-bed hauling equipment can also
be used to transport a disabled vehicle.

SLING-TYPE
FLAT
BED
RR0OD29
Fig.
10 Tow Vehicles
With
Approved
Equipment

•

Fig.
5
Cleaning
Filter
Element—Typical

DIESEL
ENGINE
AIR
FILTER CANISTER MAINTENANCE SCHEDULE

The Diesel engine air filter should be cleaned after
each interval specified in the Diesel engine mainte­
nance schedule.
When the vehicle is operated in dusty areas, the
canister should be cleaned more frequently.

EXHAUST
MANIFOLD HEAT CONTROL VALVE
MAINTENANCE SCHEDULE
The exhaust manifold heat valve should be ser­
viced after the interval specified in the maintenance schedule has elapsed.
SERVICE The exhaust manifold heat valve is located at the
left manifold (Fig. 6). Test the valve for non-re­ stricted movement.
Fig.
6 Manifold Heat Control
Valve
LUBRICATION
AND
MAINTENANCE
0 - 17

Fig.
7 Positive
Crankcase
Ventilation

System—Typical

SYSTEM OPERATION
Each PCV system is comprised of an air inlet filter,
a flow-control (PCV) valve, and the associated hoses.
The air inlet filter is located at the cylinder head cover (Fig. 7).
WARNING:
USE
EXTREME CAUTION WHEN
THE

ENGINE
IS
OPERATING.
DO NOT PUT
YOUR
HANDS NEAR
THE
DRIVE BELT(S), PULLEYS
OR

FAN BLADE.
DO NOT
STAND
IN A
DIRECT LINE

WITH
THE FAN
BLADE.

(1) With the engine idling, accelerate momen­
tarily. The valve shaft counterweight should move CLOCKWISE.
(2) If no movement is observed, either the shaft is
binding or the thermostat spring is weak or broken. (3) If the thermostat spring is weak or broken, re­
place the spring.
(4) Verify the manifold is COOL. Apply
MOPAR®Rust Penetrant (or an equivalent product)
to each end of the valve shaft at the bearings (Fig.
6).

(5) Allow the solvent to penetrate for a few min­

utes.
Then, rotate the valve shaft back and forth un­
til it turns without restriction.

AIR INJECTION SYSTEMS/AIR PUMP
Air injection system/air pump valves and switches
should be periodically tested for proper operation. In­
spect the check valve tubing for corrosion. Replace it
if excessive corrosion exists.

CRANKCASE
VENTILATION
SYSTEM
All gasoline engines are equipped with a positive
crankcase ventilation (PCV) system. The PCV sys­
tem prevents emission of residual engine oil vapor
from the crankcase (Fig. 7).

•

LUBRICATION
AND
MAINTENANCE
0 - 25
CAUTION:
Do not
over-tighten
the
drain
and fill
hole

plugs.
Over-tightening
can strip the
hole
threads

and/or crack
the
aluminum housing.

(5) Install the drain hole plug (Figs. 4 and 5) in
the transfer case. Tighten the drain hole plug to 27 N*m (20 ft-lbs) torque. (6) Fill the transfer case to the bottom edge of the
fill hole (Figs. 4 and 5) with: • MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases
• Multi-purpose gear oil (API GL-5) or engine oil (API SG, SG/CD or SG/CE) for NP205 transfer cases. (7) Install the fill hole plug (Figs. 4 and 5) in the
transfer case. Tighten the plug to 27 N«m (20 ft-lbs) torque.
(8) Remove the support and lower the vehicle.
FLUID SPECIFICATION
• MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases • Multi-purpose gear oil (API GL-5) or engine oil (API SG, SG/CD or SG/CE) for NP205 transfer cases
NP20I
MULTI-PURPOSE GEAR OIL/ENGINE
OIL
SELECTION

MULTI-PURPOSE GEAR OIL-if the anticipated
minimum temperature will: • Be above 32°C (90°F)-use SAE 140, API GL-5;
• Decrease to as low as -23°C (-10°F)-use SAE 90,
API GL-5; and • Be below -23°C (-10°F)-use SAE 80, API GL-5. ENGINE OIL—if the anticipated minimum tem­
perature will be: ® Above 0°C (32°F)-use SAE 50, API SG, SG/CD or
SG/CE;
• Below 0°C (32°F)-use SAE 30, API SG, SG/CD or SG/CE.
SHIFT MECHANISM-NP241 AND NP205 The transfer case shift mechanism should be
cleaned and lubricated as necessary.
Lubricate the pivot, the sliding contact areas and
the shift linkage pivot ends with light-weight engine oil (Figs. 6 and 7).

AXLES
INSPECTION/LUBRICANT LEVEL For normal vehicle operation, periodic axle lubri­
cant level checks are not necessary. The exterior of
the axle housing should be inspected for leakage. Check the lubricant level to confirm the leakage.

LUBRICANT LEVEL
(1) Raise the vehicle with an axle or wheel type
hoist. Support the vehicle.
(2) The rear axle differential housings have a rub­
ber, PRESS-IN type fill plug (Fig. 8). Pry the fill
TRANSMISSION

ASSEMBLY
GEARSHIFT
MECHANISM TRANSFER CASE

SCREWS
(2)
50
FT. LBS.
(68 N*m)
CLAMP
SHIFT
ROD

SCREW

80 IN.
LBS.

(9 N*m)
RP1091
Fig.
6 Shift
Mechanism
Lubrication—NP241 Transfer
Case

Fig.
RY682
7 Shift
Mechanism
Lubrication—NP205 Transfer

Case

plug from the differential housing. The front axle (4WD vehicles)*differential housings have a thread­
ed-type fill plug (Fig. 9). Un-thread the fill plug from
the differential housing.
(3) The lubricant level should be within 12 mm
(1/2 in) of the fill hole for the 8.25 and 9.25 rear ax­

les.
The lubricant level should be between 12mm (1/2
in) and 24mm (1 in.) of the fill hole for the Dana ax­

les.

(4) If necessary, add lubricant to raise the level to
the acceptable position.
(5) Install the fill hole plug in the differential
housing (Figs. 8 and 9).

DRAIN
AND
REFILL
Periodic axle lubricant change for normal vehicle
operation is not necessary. Refer to the chart below-

2
- 10
FRONT SUSPENSION
AND
AXLE

• INSTALLATION
(1) Position the spring and isolation pad on the
suspension arm. Install the spring compressor tool.
Compress the spring until the lower suspension arm
can be properly positioned in the steering knuckle.
(2) Install the nuts on the ball studs. Tighten the
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
the lower nut.
* 11/16-16 bolt, to 183 Nnn (135 ft. lbs.) torque
• 3/4-16 bolt, to 237 Nnn (175 ft. lbs.) torque Install replacement cotter pins.
(3) Install the strut.
(4) Connect the stabilizer bar.
(5) Install the shock absorber.
(6) Install the brake splash shield on the steering
knuckle. Tighten the screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install the hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle. (10) Test the vehicle brakes and the suspension for
proper operation.

LOWER SUSPENSION
ARM
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove hex-head mounting bolt from the cross-
member. (3) Remove the lower suspension arm from vehicle.
INSTALLATION (1) Position lower suspension arm on vehicle.
(2) Install mounting bolt, tighten finger-tight.
(3) Follow procedure under Coil Spring Installa­
tion.
(4) Lower the vehicle to the surface with the
wheels/tires supporting the vehicle weight. Tighten
the lower suspension arm mounting bolt to 305 Nnn (225 ft. lbs.) torque.

LOWER
BALL
STUD

INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms
must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to
the lower suspension arm. (3) Position indicator plunger against knuckle arm
and zero indicator. (4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) If the travel of the suspension arm is 0.020
inch (0.51 mm) or more, replace the ball joint. REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove ball joint seal. Use assembled Remov­
er/Installer C-4212 to force the ball stud out of the
lower suspension arm bore (Fig. 6).

Fig.
6
Lower
Bail
Stud
Removal

INSTALLATION (1) Force the replacement ball stud into the lower
suspension arm bore with assembled Remover/In­
staller C-4212 (Fig. 7).
Fig.
7
Lower
Ball
Stud
Installation