1993 DODGE TRUCK brake

0
- 22
LUBRICATION
AND
MAINTENANCE

DRIVETRAIN

INDEX

page

Axles
25
Clutch
and
Brake Pedal
Bushings
............ 22

Clutch Master Cylinder
22

Drive Shafts
26
page

Front Axle U-Joint
and
Pivot Bearings
......... 26

Transfer
Case
(4WD
Vehicles)
. . ........ 24

Transmissions
. 22

CLUTCH
AND
BRAKE PEDAL
If the clutch and brake pedal mechanism squeaks,
the pivot bushings should be lubricated (Fig. 1). Use
MOPAR®Multi-Purpose Lubricant, or an equivalent.

CLUTCH
MASTER CYLINDER
HYDRAULIC FLUID LEVEL The clutch master cylinder fluid level should be in­
spected at the same time as underhood maintenance
is conducted. The fluid level should be at indicating
line (Fig. 1). If the fluid level is low, locate and cor­
rect any possible leaks. Fill the reservoir with clean,
moisture-free brake fluid.
FLUID SPECIFICATION The only fluid recommended for use is
MOPAR®Brake Fluid, or an equivalent product. The
SLAVE

CYLINDER
CLUTCH
HOUSING
23
N«m
(200 IN.
LBS.)
product is identified as SAE J-1703 or DOT 3 flu­
id.Do not use any other type of
fluid.

CAUTION:
Never
use
reclaimed brake fluid
or
fluid
from
an
unsealed container.
Do not use
fluid that
has
been opened
and
allowed
to
stand
for an ex­

tended length
of
time.
TRANSMISSIONS

SPECIAL ADDITIVES Chrysler Motors does not recommend the addition
of any special additives to a transmission. Black
light detection dye can be used as an aid in detecting
fluid leaks.
RESERVOIR

STUD
VIEW
IN
DIRECTION
GtAKBQWZ

LUBRICATE
CLUTCH
PEDAL
23 N#m
(200 IN. LBS.)
5
N«m
(40 IN.
LBS

MASTER

CYLINDER
COTTER
PIN

NUT
23 N*m (200 IN.
LBS.) WAVE WASHER RETAINING RING

BRAKE
PEDAL VIEW
IN
DIRECTION FLAT WASHER
OF ARROW
Y
RR06F1

Fig.
1
Clutch
& Brake
Pedal
Mechanism

•

LUBRICATION
AND
MAINTENANCE
0 - 23 GEAR SHIFTER BOOTS
Inspect the shifter boots periodically for stone and
heat damage. Replace, if necessary.
SEVERE DRIVING CONDITIONS The interval between the transmission drain and
refill maintenance should be decreased to:
• NV4500 manual transmission—every 29 000 km (18,000 miles)
• Automatic transmission—every 19 000 km (12,000
miles)
A severe driving condition includes:
• Extended operation with heavy cargo loads
• Driving in deep mud or snow
• Off-road operation (4WD)
• Trailer towing
• Operation as a commercial vehicle
• Snow plowing
MANUAL TRANSMISSIONS

INSPECTION/LUBE
OIL
LEVEL
The transmission should be checked for leaks when
other service is necessary under the vehicle. To check
the lube oil level, remove the fill hole plug (Fig. 2 ). If the level is below the bottom of the fill hole, raise
the level to the bottom of the fill hole with:
• Castrol Syntorq for NV4500 transmissions
• SAE 5W-30 engine oil (API Service SG, SG/CD or
SG/CE) for Getrag 360 transmissions.

Fig.
2 NV4500 Manual
Transmission

DRAIN
AND
FILL
The NV4500 transmission fluid should be changed
according to the intervals listed in the Manual
Transmission—Drain & Refill Intervals chart below.

Also,
refer to the Fluid Capacities chart.
AUTOMATIC TRANSMISSIONS

FLUID
LEWEL
It is recommended that the fluid (ATF) level in au­
tomatic transmissions be checked while involved
with other underhood maintenance.
Vehicle operation with an incorrect ATF level
will greatly reduce the life of the transmission.
Fig.
3 Getrag 360 Manual
Transmission

MANUAL TRANSMISSION-DRAIN & REFILL INTERVALS
Normal

Service
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

58 000
km
36,000
miles

Severe
Service
29 000
km
18,000
miles

J9000-43

The condition of the ATF also should be deter­
mined. If the ATF is dark in color and has a strong odor, the fluid should be changed. Also the filter should be replaced and the bands adjusted.
The following procedure must be used to check the
automatic transmission fluid (ATF) level.
(1) Position the vehicle on level ground.
(2) Operate the engine at idle speed.
(3) Apply the parking brake.
(4) Place the gear selector in N (neutral).
(5) Remove the dipstick from the tube. Wipe it
clean and determine if the ATF is hot or warm.
Hot ATF has a temperature of approximately
82°C (180°F). Warm ATF is when its temperature
is between 29-52°C (85-125°F). (6) Wipe the dipstick clean and completely insert it
into the tube. Remove the dipstick from the tube and
observe the ATF level.
(7) If the ATF is hot, the level should be in the
crosshatched area that is marked OK.
(8) If the ATF is warm, the level should be be­
tween the two dimples.

0
- 28
LUBRICATION
AND
MAINTENANCE

•
CHASSIS AND BODY

page

Body
Component Mechanisms
32
Front
Suspension
Ball
Joints
28

Front
Wheel Bearings
29

Headlamps
32

Lower
and
Upper Suspension
Arm
Bushings
.... 30

Manual
Steering Gear
28

STEERING
LINKAGE

INSPECTION When
a
vehicle
is
raised
for
maintenance under
the vehicle,
all
steering components should
be
checked.
LUBRICATION SCHEDULE The steering linkage
is
lubricated with
a
chassis
lubricant. However,
it is
recommended that
the
link­
age
be
inspected
and
lubricated after each:
•
24 000 km
(15,000 miles) interval
or
every
6

months,
for 2WD
vehicles subject
to the
LIGHT
DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
2WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule
•
12 000 km
(7,500 miles) interval
or
every
6

months,
for 4WD
vehicles subject
to the
LIGHT DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
4WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
LUBRICATION (1) Inspect
the
steering linkage
for
looseness
and

excessive wear. (2) Replace,
all
ruptured seals
and
damaged steer­
ing linkage components. Damaged seals should
be re­

placed
to
prevent leakage
and
contamination
of the
lubricant.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
steering linkage:
• Clean
the
Zerk type lubrication fittings
on the tie-

rod
and
center link ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile- age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints
page

Power
Brake System
30
Power
Steering System
. . 29

Rear
Wheel Bearings
30

Speedometer Cable
33

Steering Linkage
28

Tires
32

FRONT
SUSPENSION
BALL JOINTS

INSPECTION When
a
vehicle
is
raised
for
lubrication/general
maintenance,
the
ball joints should
be
inspected.
LUBRICATION SCHEDULE The front suspension ball joints
are
lubricated dur­
ing manufacture with
a
long-life chassis lubricant.
However,
it is
recommended that
the
ball joints
be

inspected
and the
studs lubricated:
•
At
each
36 000 km
(22,500 miles) interval
or
every
2 years,
for
vehicles subject
to the
LIGHT DUTY
CY­
CLE Maintenance Schedule
•
At
each
9 600 km
(6,000 miles) interval
or
every
2

years,
for
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
4WD vehicles that
are
frequently driven
off-

road should
be
lubricated
at
every engine
oil
change.
LUBRICATION (1) Inspect
the
front suspension. Examine
the
ball
studs
for
looseness
and
excessive wear. (2) Replace
all
torn ball-stud seals
and
damaged
ball joints. Damaged seals should
be
replaced
to
pre­ vent leakage
and
contamination.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
ball studs:
• Clean
the
Zerk type lubrication fittings
on the

ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile-age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints

MANUAL
STEERING
GEAR

LUBRICATION Manual steering gears
are
permanently lubricated
during manufacture. Periodic lubrication
is not
nec­
essary.

•

LUBRICATION
AND
MAINTENANCE
0 - 29
POWER STEERING SYSTEM

SERVICE SCHEDULE

FLUID
LEWEL

WARNING.
THE
POWER
STEERING
FLUID LEVEL
SHOULD
ALWAYS
BE
CHECKED
WITH THE EN­

GINE
OFF TO
PREVENT
PERSONAL
INJURY.

The power steering fluid should be checked when­
ever the engine is being serviced for other reasons. Clean the outside of the cap before removing. The
fluid should be at the proper level indicated on cap dipstick (Fig. 1).

Fig.
1
Power
Steering Reservoir & Cap—Typical
The reservoir fluid level can be determined with
the fluid either hot or cold. If the fluid level is below
the FULL HOT or FULL COLD marks on the dip­ stick, add power steering fluid. The dipstick is at­
tached to the reservoir cap (Fig. 1).
FLUID SPECIFICATION MOPAR03)Power Steering Fluid is highly recom­
mended.

FRONT
WHEEL BEARINGS
INSPECTION/LUBRICATION SCHEDULE

2WD
VEHICLES
It is recommended that 2WD front wheel bearings
be inspected for proper lubrication whenever the
brake rotors are removed or at least: • At each 39 000 km (24,000 miles) interval for ve­
hicles subject to the LIGHT DUTY CYCLE Mainte­ nance Schedule • At each 36 000 km (22,500 miles) interval for ve­
hicles subject to the HEAVY DUTY CYCLE Mainte­ nance Schedule The bearings should be cleaned and re-packed
with a high temperature, multi-purpose EP lu­
bricant.
4WD
VEHICLES

It is recommended that 4WD front wheel bearings
be inspected for proper lubrication whenever the
brake rotors are removed or at least:
• At each 24 000 km (15,000 miles) interval for ve­
hicles subject to the LIGHT DUTY CYCLE Mainte­ nance Schedule
• At each 19 000 km (12,000 miles) interval for ve­
hicles subject to the HEAVY DUTY CYCLE Mainte­ nance Schedule
For vehicles used for extensive off-road, 4WD
operation, the front wheel bearings should be in­ spected every 1 600 km (1,000 miles).
The bearings should be cleaned and re-packed
with a high temperature, multi-purpose EP lu­
bricant whenever the disc brake rotors are re­ surfaced.
INSPECTION If the lubricant:
• Is not sufficient
• Contaminated with foreign particles
• Appears dry or has been contaminated with water
to produce a milky appearance, the bearings should
be cleaned and re-packed with lubricant.

CAUTION:
Do not add
lubricant
to the
wheel
bear­
ings.
Re-pack completely. Mixing
of
different
types
of lubricants
in
wheel
bearings should
be
avoided.
This could possibly result
in
excessive thinning
and
leakage
of the
lubricant.

LUBRICATION (1) Discard the original seal.
(2) Clean the original lubricant from the bearings
and from the hub cavity (Figs. 2 and 3).
(3) Inspect the bearing rollers for indications of
pitting. Light bearing roller discoloration is consid­ ered normal. A wheel bearing must be replaced if any serious damage exists.
(4) Re-pack the bearings with a high temperature,
multi-purpose NLGI GC-LB lubricant. The use of a
bearing packer is recommended. A small amount of fresh lubricant also should be added to the hub cav­ ity.
BEARING INSTALLA TION/ADJUSTMENT (1) Install the hub/rotor (with inner bearing and
seal) on steering knuckle spindle.
(2) Install the outer bearing, the thrust washer
and the nut.
(3) Tighten wheel bearing nut to 27-34 N^m (240-
300 in. lbs.) torque while rotating hub/rotor. This
will seat the bearings.
(4) Loosen the nut 1/4 of-a-turn (90°), then tighten
it finger-tight.

0 - 30
LUBRICATION
AND
MAINTENANCE
— - •

Fig.
2 Front
Wheel
Bearing—2WD Vehicles
Fig.
3 Front
Wheel
&
Spindle
Bearings—4WD

Vehicles

(5) Position nut lock on the nut with one pair of
slots aligned with the cotter pin hole. Install the cot­
ter pin.
(6) Install the dust cap and wheel/tire. Tighten the
wheel lug nuts to 115 N*m (85 ft. lbs.) torque. Install
the wheel cover.

LUBRICANT SPECIFICATION
Use a high temperature, multi-purpose NLGI
GC-LB lubricant (MOPAR®Wheel Bearing Lubricant,
or an equivalent lubricant).
REAR
WHEEL BEARINGS
LUBRICATION
DANA
60
AND
70
AXLES
The rear wheel bearings for vehicles equipped with
a Dana 60 or 70 axle should be cleaned and re­
packed whenever the rear brakes are serviced. Refer
to Group 3—Rear Axles for the service procedure.

CHRYSLER
AXLES
, Vehicles equipped with 8 3/8-inch and 9
1/4-inch

axles have axle shaft bearings instead of wheel bear­

ings.
These bearings are lubricated by the axle hous­
ing sump.

LOWER
AND UPPER
SUSPENSION
ARM

BUSHINGS

INSPECTION
SCHEDULE
The lower and upper suspension arm bushings
should be inspected each time the underside of the
vehicle is serviced.

INSPECTION
The lower suspension arm bushings can be visually
inspected by raising the vehicle on a hoist and in­ specting from underneath. The upper suspension arm
bushings can be inspected after removing the front wheels. If failure exists, replace the bushing (refer to Group 2—Front Suspension for the proper proce­

dures).

The suspension arm bushings never should be
lubricated.

GUIDELINES
(1) Faulty bushings are detected by the bushing
being off-center in relation to the outer sleeve.
(2) Total failure is evident by excessive movement
within the bushing.

(3)
Small cracks in the outer, non-confined rubber
does not indicate failure of the rubber. '

POWER BRAKE SYSTEM
Vehicles are equipped with power disc brakes at
the front wheels and drum brakes at the rear wheels.

MASTER CYLINDER

FLUID
LEVEL INSPECTION
The brake fluid level should be inspected at the
same time as other underhood service is done (Fig.

4).
If necessary, add fluid to raise the level to the
bottom of the split rings. With disc-brakes, the fluid level can be expected to lower as the brake pads
wear. However, a low fluid level can also be caused
by a leak, and repair will then be necessary.

•

LUBRICATION
AND
MAINTENANCE
0 - 31
Fig. 4 Master Cylinder Fluid Level
FLUID
SPECIFICATION

Power brake systems require MOP AR®Heavy-D uty
Brake Fluid, or an equivalent product identified with
FMVSS No. 116, DOT-3 and SAE J-1703 Standard designations. Use fresh brake fluid only when adding fluid to the
reservoir. Never use reclaimed fluid, fluid that does not conform to the DOT/SAE Standards, or fluid from a container that has been left open.

CAUTION:
Use of a
brake fluid that
has a
lower ini­

tial
boiling point then specified
by
FMVSS
No. 116
or
DOT 3
could result
in
sudden brake failure dur­
ing
hard, prolonged braking.

CAUTION:
Do not
allow petroleum base
fluids
to

contaminate
the
brake fluid. Seal damage
will
re­

sult.
BRAKE SYSTEM INSPECTION (1) Inspect the brake pads and linings for excessive
wear, cracks and broken rivets.
(2) Inspect brake pads and linings for contamina­
tion with brake fluid, axle lubricant and/or other flu­
ids.

(3) Replace the front brake pads and the rear
brake linings if they are worn to within 0.78 mm (1/32 in) of a rivet head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for ease of movement. (5) Inspect the self-adjuster components for frayed
cables, loose or overheated springs, and a binding
condition.
(6) Inspect the caliper dust boots for damage/tears
and indications of brake fluid leakage. Inspect the
bushings and pins for corrosion, tears and a binding condition.
(7) Inspect the rear wheel cylinder dust boots for
fluid leaks. Inspect the pistons and cylinder bores for
proper appearance. (8) Inspect the brake differential warning valve
and housing for indications of leakage, kinked hoses and loose fittings.

BRAKE
FLUID
HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
• Correct length
• Severe surface cracking
• Swelling
• Pulling
• Scuffing
• Excessively worn areas If the hose fabric casing is exposed either by
cracks or abrasions in the rubber cover, the
hose should be replaced.
Faulty brake fluid hose installation can cause
twisting, and wheel/tire or chassis interference.
(1) Inspect all the hoses for kinks, a distorted con­
dition and fluid leakage. (2) Inspect the hose and tubing routing under the
vehicle. Verify that no hose/tubing is rubbing against any exhaust system or other underbody components.

PARKING
BRAKE
LUBRICATION
The pivot and sliding contact areas of the parking
brake ratio lever should be lubricated to maintain ease of operation (Fig. 5).
(1) Apply MOPAR®Spray White Lube or equiva­
lent to the sliding contact areas.
(2) Lubricate the control lever pivot areas with en­
gine oil.

PARKING
BRAKE
FUNCTIONAL
TEST
AND
INSPECTION
(1) Engage the parking brake pedal and then re­
lease it. (2) Test it for smooth operation and vehicle-hold­
ing capability.
(3) Inspect the parking brake cables for kinks,
fraying and a binding condition. (4) With the parking brake released, the rear
wheels should rotate without restriction. Adjust the
parking brake cable tension, if necessary.
(5) Repair any parking brake malfunctions.
BRAKE OPERATIONAL TEST (1) Drive the vehicle and test for proper brake ac­
tion.

0
- 32
LUBRICATION
AND
MAINTENANCE

•

Fig.
5 Parking Brake Ratio Lever Lubrication (2) Note any indication of brake overheating,
wheel dragging or the vehicle pulling to one side.
(3) Evaluate any performance complaints received
from the owner/operator. (4) Repair the brake system as necessary (refer to
Group 5—Brakes for additional information and ser­
vice procedures).

BODY
COMPONENT
MECHANISMS
LUBRICATION REQUIREMENTS
All operating mechanisms and linkages should be
lubricated when necessary. This will maintain ease of operation and provide protection against rust and
excessive wear. The door weatherstrip seals should
be lubricated to prolong their life as well as to im­ prove door sealing.

LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operat­
ing mechanisms should be:
• Inspected • Cleaned
• All the pivoting/sliding contact areas on the mech­ anisms should then be lubricated.
MOPAR®Multi-Mileage Lubricant or an equiva­
lent, should be used to lubricate the mechanisms.
The door weatherstrip seals should be lubricated
with silicone lubricant spray. Refer to the Body Lu­
bricant Specifications chart below for additional lu­
bricant applications.

LUBRICATION
(1) When necessary, lubricate the cab and cargo
box operating mechanisms with the specified lubri­
cants.

(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas­
senger clothing. (3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker and safety latch should be lubricated periodi­
cally.
(5) The door lock cylinders should be lubricated 2
times each year (preferably autumn and spring): • Spray a small amount of lock cylinder lubricant di­
rectly into the lock cylinder
• Apply a small amount to the key and insert it into
the lock cylinder • Rotate it to the locked position and then back to
the unlocked position several times
• Remove the key. Wipe the lubricant from it with a
clean cloth to avoid soiling of clothing.

TIRES
RECOMMENDED MAINTENANCE
The condition of the tires should be inspected. The
inflation pressures tested/corrected at the same time as the engine oil is changed and the oil filter is re­
placed.
The tires/wheels should be rotated periodically to
ensure even tread wear. The tires/wheels should be
rotated at the first 12 000 km (7,500-miles) interval.
Thereafter, at each 24 000 km (15,000-miles) inter­
val.
INSPECTION
Inspect the tires for excessive wear, damage. Test
the tires for the recommended inflation pressure and adjust the pressure accordingly. Refer to the tire in­
flation pressure decal located on the left door face. Also to Group 22—Tires And Wheels for tire pres­sure charts, tire replacement, and treadwear indica­

tors.

ROTATION
Tires/wheels should be rotated according to the rec­
ommended interval. The first tire/wheel rotation is
the most important for establishing the prevention of uneven tread wear. After rotation, adjust the tire in­
flation pressure to the air pressure recommended on
the decal located on the left door face.
Refer to Group 22—Tires And Wheels for the rec­
ommended method of tire/wheel rotation.

HEADLAMPS

MAINTENANCE SCHEDULE
Every six months check the headlamp beams to en­
sure that the headlamp beams are correctly posi­
tioned.

AIM
ADJUSTMENT
Refer to Group 8L—Lamps for headlamp aim ad­
justment procedures.

•

LUBRICATION
AND
MAINTENANCE
0 - 33 BODY LUBRICANT SPECIFICATIONS

COMPONENT
SERVICE
INTERVAL
LUBRICANT

Door
Hinges
As
Required
Engine
Oil

Door
Latches
As
Required Multi-Purpose Grease
NLGI
GC-LB

(Water
Resistant)
(1)

Hood
Latch Release Mechanism
&
Safety Latch
As
Required
(When Performing Other Underhood Services) Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Hood
Hinges
As
Required
Engine
Oil

Seat Regulator
&
Track Release Mechanism
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Tailgate Hinge
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Tailgate Support Arms
As
Required

Engine
Oil

Tailgate Latches
As
Required
White
Spray Lubricant
(3)

Tailgate Release Handle (Pivot & Slide Contact Surfaces)
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Window System Components (Regulators, Tracks,
Rods

&
Channel Areas — Except
Glass
Run Weatherstrips
and
Felt
Lubricator,
if
Equipped)
As
Required

White
Spray Lubricant
(3)

Lock
Cylinders Twice/Year
Lock
Cylinder Lubricant
(4)

Parking Brake Mechanism
As
Required Multi-Purpose Grease
NLGI
GC-LB
(1)

1.
Mopar
Wheel
Bearing Grease (High
Temperature)

2. Mopar Multi-Mileage Lubricant 3. Mopar Spray
White
Lube
4. Mopar Lock Cylinder Lubricant

J9200-58

SPEEDOMETER
CABLE

SERVICE INFORMATION Speedometer cable lubrication is not necessary. For
service information involving noisy or erratic cables,
refer to Group 8E—Instrument Panel and Gauges.