1993 DODGE TRUCK Service Repair Manual

19 9 3

SERVICE
MANUAL

D&
W150-350

RAMCHARGER

REAR
WHEEL DRIVE TRUCK

CHRYSLER
CORPORATION

SERVICE
MANUAL

1993
DODGE TRUCKS

To order the special service tools used and
illustrated, please refer to the instructions on inside back cover.

CHRYSLER

W
CORPORATION

NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME­
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER CORPORATION.

Chrysler
Corporation
reserves
the
right
to make
changes
in
design
or to make
additions to or improvements in its products
without
imposing any obliga­
tions upon
itself
to
install
them
on its products previously manufactured.

Litho
in
U.S.A.
Copyright ©
1992
Chrysler Corporation
15M0992

FOREWORD

The information contained in this service manual has been prepared for the professional automotive tech­
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
The Component and System Index of this manual identifies the correct group for the component or system
to be serviced. In addition, a Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler Corporation with your comments and suggestions.
To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re­
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993 California Air Research Board (CARB) requirements.

GROUP TAB LOCATOR

Introduction

0
Lubrication
and
Maintenance
2
Front Suspension
and
Axle

3
Rear Suspension
and
Axles

5
Brakes

6
Clutch
7
Cooling System

8
Electrical

9
Engines
11
Exhaust System
and
Intake
Manifold

13
Frame
and Bumpers

14
Fuel
System

16
Propeller Shafts

19
Steering

21
Transmission
and
Transfer Case

22
Wheels and Tires

23
Body Components

24
Heating
and Air
Conditioning

25
Emission Control Systems Component and System Index
Service Manual Comment Forms (Rear
of
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

2 INTRODUCTION

•
MFD
BY
GAWR
FRONT
GAWR REAR
CHRYSLER

CORPORATION

DATE
OF MFR

GVWR

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
MDH:
BAR
CODE
VEHICLE MADE
IN

4648503
J9HN-25

Fig. 1 Vehicle Safety Certification Label
The Vehicle Identification Number is also im­
printed on the:
• Body Code Plate
• Equipment Identification Plate
• Vehicle Safety Certification Label
• And on a frame rail.

VEHICLE CODE PLATE
A metal vehicle code plate (Fig. 2) is attached to

top,
right side of cowl below cowl grille. There can be a maximum of seven rows of vehicle information im­
printed on the plate. The information should be read
from left to right, starting with line 1 at the bottom
of the plate up to line 7 (as applicable) at the top of
the code plate. Refer to the decoding chart to decode lines 1
through 3.
Lines 4 through 7 on the plate are imprinted in se­
quence according to the following descriptions:
• 3-character sales code • 3-digit numerical code
• 6-digit SEC code If there is not enough space left in the row for all
of the 6-digit SEC code:
• The unused space will remain blank
• The code will be listed in the next row.
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number.
The last code on a vehicle code plate will be fol­
lowed by the imprinted word END. When two plates
are required, the last available spaces on the first
plate will be imprinted with the letters CTD (for con­ tinued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because of the plate overlap.
To retrieve information from a vehicle code plate:
• Illuminate the plate with a shop light
• View the plate via the cowl grille slots
• Record the needed coded information.

ENGINE AND TRANSMISSION/TRANSFER CASE

IDENTIFICATION
Refer to Group 9—Engines for all engine identifi­
cation data. Refer to Group 21—Transmissions for all transmis­
sion/transfer case identification data.
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country

1
=
United States
2
=
Canada

3
=
Mexico Vehicle Type
4
=
Multipurpose
Passenger

5
=
Bus
6
=
Incomplete
7
=
Truck
GVWR
and

Hydraulic Brakes
0001 3001
4001
5001 6001
7001 8001
9001

10,001

Bus
or I
3000
4000
5000 6000
7000 8000
9000

10,000
14,000

nc.
Truck Line

E
=
Ramcharger
4x2
Chassis
Cab
4x2

Pickup
4x2

M
=
Ramcharger
4x4
Chassis
Cab
4x2
Pickup
4x4
Engines

X
=
3.9L
(MPI)

Y = 5.2L
(MPI)

Z
=
5.9L
(EFI)

5
=
5.9L HDC

8
=
5.9L Turbo Diesel Sequential
Serial Number

Six
Digit Numbers

Series

0 =
150S Job Rated
1
= 150
Job Rated
2
= 250
Job Rated

3
= 350
Job Rated
Body

3
=
Club Cab 6
=
Conventional Cab
9
=
Sport
Utility
2 DR
Plant Location

S
=
Dodge City
M
=
Lago
Alberto J931N-18

INTRODUCTION

PRIMARY SECONDARY
PAINT PAINT VINYL ROOF

CODE VEHICLE
ORDER-
NUMBER
PAINT- PI
PROCEDURE
(2)

(1)
XXX
)
XXXXX)
X
XXX xxxxxx
X)0C xxxx xxxx xxxx xxx XXX x xxxxxxxxxxxxxxxxx

TRANSMISSION
I
VEHICLE IDENTIFICATION CODE
J
NUMBER
MARKET
U-C-B-M
CODE 90IN-3

Fig. 2 Vehicle Code Plate
VEHICLE CODE DECODING
VEHICLE
MODEL
•NUMBER
ENGINE
-CODE
-INTERIOR TRIM CODE

Line #1 Digit
1-3 Transmission Sales Code
Digit 4 Open Space
Digit
5
Market Code - U-C-B-M
Digit 6 Open Space
Digit 7-23 Vehicle Identification No.
Line #2 Digit
1-3 Paint Procedure
Digit 4 Open Space
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint
Digit 14 Open Space
Digit 15-18 Trim Code
Digit 19 Open Space
Digit
20-22
Engine Sales Code
Digit 23 Open Space
Line #3 Digit 1-12 Vehicle Order Number
Digit 13 Open Space
Digit 14-16 Vinyl Roof Code (Door Combo
Digit
Code - Pillette)
Digit 17 Open Space
Digit 18-23 Model

J901N-20 MAJOR COMPONENT IDENTIFICATION

Refer to the applicable group for identification
data.
EQUIPMENT IDENTIFICATION PLATE

The Equipment Identification Plate is located at
the right, front corner of the inner hood panel. The
plate lists information concerning the vehicle as fol­
lows:
The model
The wheelbase
The VIN (Vehicle Identification Number)
The
T.O.N,
(order number)
The optional and special equipment installed on
the vehicle
Refer to the information listed on the plate when
ordering replacement parts.

r§Wll
EQUIPMENT
IDENTIFICATION
mmm

MODELS
V.I.N. T.O.N.

CODE
NO.
DESCRIPTION
CODE
NO.
DESCRIPTION

. ^

Fig.
3 Equipment
Identification
Plate