1993 DODGE TRUCK tow

0-18
LUBRICATION
AND
MAINTENANCE

•
COOLANT FREEZE PROTECTION

Cooling systems contain a 50/50 mixture of anti­
freeze (ethylene glycol) and distilled water. This is
the recommended coolant mixture.
It is recommended that the degree of coolant pro­
tection be tested every 12 months. If the coolant is
contaminated or rusty, the cooling system should be
drained, flushed. Refill with a 50/50 mixture of fresh
coolant. Refer to Group 7—Cooling Systems for addi­
tional information.

SYSTEM
INSPECTION

WARNING:
IF THE
ENGINE
HAS
BEEN RECENTLY
OPERATED,
DO NOT
REMOVE
THE
RADIATOR

CAP.
THIS WILL AVOID
YOU
BEING SCALDED

WITH
HOT, PRESSURIZED COOLANT.

(1) Test the radiator cap for proper sealing and op­
eration. Use caution when removing the radiator cap
to avoid contact with hot coolant. Place a heavy rag
or towel over the cap and turn to the first stop. Do
not press down. Pause to allow the pressure to re­
lease through the overflow tube. Then press down
and turn counterclockwise to remove the cap.
(2) Inspect the coolant overflow tubing and the
connections at the coolant reserve tank and at the
radiator.
(3) Inspect the entire cooling system for leaks. A
black-light detector can be used as an aid in detect­ ing the source of coolant leaks.
(4) Inspect the radiator and air conditioner con­
denser fins for debris, etc. (5) If necessary, refer to Group 7—Cooling Systems
for additional information and service procedures.

RADIATOR CAP
The radiator cap must be completely tightened to
provide proper pressure. Inspect and test radiator cap
when cooling system service is performed.

MAIN,
FLUSH
AND
FILL

WARNING: ANTI-FREEZE (ETHYLENE GLYCOL)
IS
POISONOUS.
KEEP
OUT OF THE
REACH
OF
CHIL­

DREN.

Drain, flush, and fill the cooling system at the in­
terval specified in maintenance schedule. For proper service instructions see Group 7, Cooling System.

HOSES AND
FITTINGS
It is recommended that rubber hoses be periodi­
cally inspected. Inspect all hose fittings for looseness and corrosion.
ENGINE
AIR
CLEANER
FILTER
ELEMENT

MAINTENANCE
SCHEDULE
With normal driving conditions, the engine air
cleaner filter element should be replaced:
• Light-Duty Cycle-after each 48 000 km (30,000
miles) interval has elapsed
• Heavy-Duty Cycle-after
each
38 000 km (24,000
miles) interval has elapsed
When the vehicle is operated in dusty areas, the
filter element should be replaced more often.
For Diesel engines, the air filter canister should be
cleaned at the same time the filter is replaced.

SERVICE/REPLACEMENT
(1) Remove the air cleaner cover.
(2) Remove the air cleaner filter (Fig. 4).

CAUTION:
Do not tap the filter or immerse the filter medium in liquid to remove trapped debris.
(3) Clean filter by blowing the trapped debris from
the filter with compressed air (Fig. 5). Direct the air in the opposite direction of normal intake air flow.
Keep the air nozzle at least two inches away from
the filter.
(4) If the filter has become partially saturated with

oil,
replace the filter. Inspect the crankcase ventilat­
ing system for proper operation.
(5) Wash the air cleaner cover and body with
cleaning solvent. Wipe it dry.
(6) Install the air cleaner filter element. Attach
the cover to the body (Fig. 4).
Fig,
4
Engine
Air Oeaner—
Typical

•

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.

•

FRONT
SUSPENSION
AND
AXLE
2 - 5 (4) Front wheels for excessive radial, lateral
runout and unbalance. Refer to Group 22, Wheels and Tires for diagnosis information.
(5) Suspension components for wear and noise. Check
components for correct torque. Refer to Groups 2 and 3, Suspension and Axle for additional information.

WHEEL
ALIGNMENT
MEASUREMENTS/ADJUSTMENTS
The front wheel alignment positions must be set to
the specified limits. This will prevent abnormal tire
tread wear. The equipment manufacturer's recommenda­
tions for use of their
equipment
should always
be followed. All
damaged
front suspension sys­
tem components
should
be replaced. Do not at­ tempt to straighten any
bent
component.

CAMBER AND CASTER-2WD VEHICLES Camber and caster angle adjustments involve repo­
sitioning the upper suspension arm cam adjustment
bolts (Fig. 2). Alignment adjustments are accom­
plished by loosening the nuts and changing the posi­
tion of the cam bolt.
(1) Remove all foreign material from the adjust­
ment bolt threads.
(2) Record the camber and caster measurements
before loosening the adjustment bolt nuts.
(3) The camber angle should be adjusted as near as
possible to the preferred angle. The caster should be
the same at both sides of the vehicle. Refer to the Specifications chart.
CAMBER AND CASTER—4WD VEHICLES For 4WD vehicles, the correct wheel camber (verti­
cal tilt) angle is factory preset at zero degree (0°).
Camber cannot be altered by adjustment.
CAUTION: Do not attempt to
adjust
the
camber
an­
gle by
heating
or bending the axle or any
suspen­

sion
component. If camber angle is
incorrect,
the
component(s)
causing
an
incorrect
angle must be replaced.
(1) It is important that the camber (vertical tilt)
angle be the same for both front wheels.
(2) The camber angle should be measured with ac­
curate wheel alignment equipment. The acceptable
range is -1° to +1°. Refer to the Specifications chart.
Road test the vehicle and observe the steering
wheel return-to-center position. Before road testing,
check
and
correct
the tire
inflation pressures. Inflate
both
of the front tires
with exactly the
same
pressure.
During the road test, make vehicle turns to both
the left and right. If the steering wheel returns to­
ward the center position unassisted, the caster angle is correct. However, if the steering wheel does not re­ turn toward the center position unassisted, an incor­
rect caster angle is probable.
(1) The caster angle is factory preset at positive
two degrees
(
+
2°).
The acceptable range is +1/2° to +
3
1/2°.
(2) The caster angle should be measured with ac­
curate wheel alignment equipment.
(3) Caster angle can be adjusted by installing ta­
pered shims between the front axle pads and the spring brackets. The caster angle should be adjusted
as near as possible to the preferred angle.
(4) Record the caster measurement before remov­
ing the original shims from the spring pads.
(5) The caster should be the same at both sides of
the vehicle. Refer to the Specifications chart.
RN1030

Fig.
2 Caster &
Camber
Adjustment Location—2WD
Vehicles

WHEEL TOE POSITION The wheel toe position adjustment should be the fi­
nal front wheel alignment adjustment. In all in­ stances, follow the equipment manufacturer's
recommended procedure.
(1) Secure the steering wheel with the front wheels
in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight­ ening the wheels.
With power steering, the engine should be op­
erating during the wheel toe position adjust­
ment.
(2) Loosen the tie rod adjustment sleeve clamp
bolts (Fig. 3).
(3) Adjust the wheel toe position by rotating the
tie rod adjustment sleeve (Fig. 3). Rotate each tie-rod end in the direction of
sleeve rotation during the adjustment (Fig. 3).
This will ensure that both tie-rod ends are at the center of their travel.
(4) If applicable, turn the ignition switch off.

2
- 30
FRONT
SUSPENSION
AND
AXLE

• REMOVAUDISASSEMBL
Y

(1) Raise and support the vehicle.
(2) Disconnect the vacuum and wiring connector
from the shift housing. (3) Remove the shift motor housing cover, gasket
and shield from the housing.
(4) Remove the E-clips from the shift motor hous­
ing and shaft. Remove shift motor and shift fork
from the housing (Fig. 32).
Fig.
32
Vacuum
Shift Motor
Components

(5) Remove the O-ring seal from the shift motor
shaft. (6) Clean and inspect all the components. If any
component is excessively worn or damaged, it should
be replaced.
ASSEMBL Y/IHSTALLA TION (1) Install a replacement O-ring seal on the shift
motor shaft (Fig. 32). (2) Insert the shift motor shaft through the hole in
the housing and shift fork. The shift fork offset should be toward the differential.
(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover. Ensure the shift fork is correctly guided
into the shift collar groove.
(5) Install the shift motor housing shield and bolts.
Tighten the bolts to 14 N*m (10 ft. lbs.) torque.

INTERMEDIATE AXLE SHAFT
REMOVAL/DISASSEMBLY (1) Remove the vacuum motor housing from the

axle,
refer to Vacuum Shift Motor Removal.
(2) Remove the hub, spindle and axle shaft, refer
to the removal procedures above.
(3) Remove the shift collar from the shift motor
housing.
(4) Remove the differential housing cover and
drain the lubricant.
(5) Push the intermediate axle shaft toward the center of the vehicle. Remove the C-lock from the
shaft and side gear in the differential.
(6) Remove the intermediate axle shaft with Re­
mover/Installer D-354-4 and Adaptor D-354-3 (Fig.

33).

J9202-104
Fig.
33
intermediate
Axle Shaft Removal/Installation
(7) Remove the intermediate axle shaft bearing
with Tool D-354-4, Tool
D-354-1,
and Slide Hammer C-637 (Fig. 34, 35).
(8) Remove the needle bearing from intermediate
axle shaft with Remover/Installer D-330 (Fig. 34, 35).

RK724

Fig.
34
Intermediate
Shaft Bearing
Removal

(9) Remove the inner axle shaft seal from the shift
motor housing. Certain vehicles could also have a
seal guard; discard both components. The guard is
not used with a replacement seal.

2
- 32
FRONT
SUSPENSION
AND
AXLE

• (5) Disconnect flexible brake fluid hose fittings at
the frame crossmember. Plug the hoses at the fit­

tings.

(6) Remove the shock absorber lower nut and stud
from the axle shaft tube bracket. Remove the nuts and disconnect the stabilizer bar links from the
spring brackets.
(7) Disconnect the vacuum hoses and wiring con­
nections from the shift motor housing.
(8) Remove nuts and the washers from the spring
U-bolts. Remove the complete front axle from the ve­
hicle.

INSTALLATION
(1) Position the front axle under the front of the
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make sure the stabilizer bar link bolt holes face toward the
rear of the vehicle.
(2) Install the spring U-bolts, washers and nuts.
Refer to Front Suspension — 4WD Vehicles within
this group. (3) Install the shock absorber. Refer to Front Sus­
pension — 4WD Vehicles within this group. (4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension-4WD Vehicles
within this group.
(5) Remove plugs and connect the brake hose fit­

tings.
Refer to Group 5, Brakes. (6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering. (7) Connect the drive shaft to the pinion yoke with
the installation reference marks aligned. Install the
washers and the nuts and tighten to 19 N*m (14 ft. lbs.) torque.
(8) Connect the vacuum hoses and wiring connec­
tions to the shift motor housing. (9) Remove the supports, lower the vehicle and re­
move the block from the brake pedal.
(10) Raise the vehicle.
• Bleed and adjust the brakes
• Lubricate all the ball stud fittings
• Inspect the differential housing lubricant level. Re­
fer to Group 0, Lubrication and Maintenance. (11) Lower the vehicle and test the axle and sus­
pension operation.

DIFFERENTIAL
DISASSEMBLY

REMOVAL/DISASSEMBLY (1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 38). (2) Remove the differential bearing caps.
(3) Position Spreader W-129-A with the tool dowel
pins seated in the locating holes (Fig. 39). Install the
holddown clamps and tighten the tool turnbuckle fin­ ger-tight.
INSTALLATION

EFERENCE
LETTERS

J9003-92

Fig.
38 Bearing Cap
Identification
SPECIAL
TOOL

MODEL
44-W-129-A
MODEL
60-D-167
DIAL

INDICATOR

«ar"P—

J9202-113

Fig.
39
Differential
Housing
Separation
(4) Install a pilot stud at the left side of the differ­
ential housing. Attach Dial Indicator to housing pilot stud. Load the indicator plunger against the opposite
side of the housing (Fig. 39) and zero the indicator.

CAUTION:
Do not
spread
over the specified
dis­

tance.
If the
housing
is over-separated, it
could
be distorted or
damaged.

(5) Separate the housing enough to remove the
case from the housing. Separate housing a maxi­
mum distance of 0.38 mm (0.015 in) with the spreader tool. Measure the distance with the dial
indicator (Fig. 39).
(6) Remove the dial indicator.
(7) Pry the differential case loose from the hous­
ing. To prevent damage, pivot on housing with the end of the pry bar against case.
(8) Remove the case from housing. If they are re­
usable, retain the differential bearing cups and bear­ ings together as matched sets.

2
- 38
FRONT
SUSPENSION
AND
AXLE

•
PINION GEAR DEPTH VARIANCE

Or§@ift^i
Linton
IsptocMnwtt
HnS®n
Oior Itoplli
fflttanct

Or§@ift^i
Linton
-4
-2

-1
0

+
1

-ft
+3
+4
+4
+
0.008
+
0.007

+
0.006
+
0.005
+
0.004

+
0.003
+
0.002
+
0.001
0

+3
+
0.007
+
0.006
+
0.005
+
0.004

+
0.003
+
0.002

+
0.001
0
-0.001
+2
+
0.006
+
0.005
+
0.004

+
0.003
+
0.002
+
0.001
0
-0.001

-0.002

+
1
+
0.005
+
0.004

+
0.003
+
0.002

+
0.001
0
-0.001
-0.002

-0.003

0
+
0.004

+
0.003
+
0.002

+
0.001
0

-0.001
-0.002
-0.003

-0.004

-1
+
0.003

+
0.002
+
0.001
0
-0.001
-0.002

-0.003 -0.004
-0.005

-2
+
0.002
+
0.001
. 0
-0.001

-0.002
-0.003 -0.004
-0.005 -0.006

-3
+
0.001
0
-0.001
-0.002

-0.003 -0.004
-0.005 -0.006

-0.007

-.4
0
-0.001
-0.002

-0.003 -0.004 -0.005
-0.006
-0.007

-0.008
PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH TOOL SET D-11144
The following gear depth measurement and adjust­
ment procedure involves using Tool Set D-115-44. (1) Insert Master Pinion Block D-139 into the
dif­

ferential housing (Fig. 57).

PINION BLOCK TOOL PINION BLOCK TOOL
J8902-46

DIFFERENTIAL
HOUSING

ARBOR
DISC
TOOL
ARBOR

TOOL
J9003-103
DIFFERENTIAL

HOUSING
J9003-101
Fig.
57
Pinion
Block
In Shaft
Bore

(2) Place Disc D-115-4 on Arbor D-115-3 and posi­
tion in the bearing cradles (Fig. 58). This is the cen­
terline of the ring gear/axle shaft. (3) Place Pinion Height Block D-115-1 on top of
master pinion block tool and against arbor tool (Fig.
59).

(4) Place Gauge Block D-115-2 and Dial Indicator
D-106-5 on lowest step of block tool (Fig. 60). Zero
the dial indicator pointer.
Fig.
58
Disc
&
Arbor
In
Housing

(5) Move the gauge block toward the arbor until
the indicator plunger contacts the arbor tool (Fig.
60).
Slide the gauge block across the arbor while ob­
serving indicator. Record the longest travel distance,
whether inward (-) or outward (+•), indicated by the
pointer.
The distance indicated, plus or minus the
amount etched in the gear is the required thick­

ness.

(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
thickness with the total shim pack thickness if
required.
(7) Remove the measurement tools from the differ­
ential housing.

FRONT
SUSPENSION
AND AXLE
2 - 47

DRIVE
SIDE
OF RING

GEAR
TEETH
HEEL

TOE
COAST
SIDE
OF RING

GEAR
TEETH TOE

HEEL
DESIRABLE
CONTACT PATTERN.
PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH. PATTERN SHOULD BE CENTERED
ON

THE COAST SIDE OF TOOTH, BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE
SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP
OF

THE TOOTH.
RING GEAR
BACKLASH
CORRECT

THINNER
PINION GEAR DEPTH SHIM REQUIRED.
RING GEAR
BACKLASH
CORRECT.

THICKER
PINION GEAR DEPTH
SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT
DECREASE
RING

GEAR
BACKLASH.

PINION GEAR DEPTH SHIM

CORRECT
INCREASE
RING

GEAR
BACKLASH.

Fig.
86 Gear
Teeth
Contact Patterns
J9003-24

•

TAPERED

BUSHING

J9202-53

Fig.
32 Tapered
Bushing
Installation

J9202-52

Fig.
33
Lower
King
Pin and Retainer
Installation
(12) Install the axle shaft, refer to Axle Shaft and
U-Joint Installation.

COMPLETE
AXLE REMOVAL/INSTALLATION SERVICE
INFORMATION
It is not necessary to remove the complete front
axle from the vehicle for routine service. If the hous­
ing or axle shaft tubes are damaged, the complete axle can be removed and installed via the following
procedures.

REMOVAL
(1) Block the brake pedal in the up position. Raise
and support the vehicle at a comfortable working
height.
(2) Remove the front wheels/tires.
FRONT SUSPENSION
AND
AXLE
2 - 59
(3) Mark the front drive shaft and the pinion yoke
for installation alignment reference.
(4) Disconnect the front drive shaft from the axle
yoke. Attach the drive shaft to the frame rail with
wire.

(5) Remove the cotter pin, the nut, and disconnect
the drag link from the steering knuckle arm (left side only). Discard the cotter pin.
(6) Disconnect flexible brake fluid hose fittings at
the frame crossmember. Plug the hoses at the fit­

tings.
(7) Remove the shock absorber lower nut and stud
from the axle shaft tube bracket. Remove the nuts and disconnect the stabilizer bar links from the
spring brackets. (8) Remove nuts and the washers from the spring
U-bolts. Remove the complete front axle from the ve­
hicle.
INSTALLATION (1) Position the front axle under the front of the
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make sure the stabilizer bar link bolt holes face toward the
rear of the vehicle.
(2) Install the spring U-bolts, washers and nuts.
Refer to Front Suspension — 4WD Vehicles within
this group. (3) Install the shock absorber. Refer to Front Sus­
pension—4 WD Vehicles within this group.
(4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension—4WD Vehicles within this group.
(5) Remove plugs and connect the brake hose fit­

tings.
Refer to Group 5, Brakes. (6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering. (7) Connect the drive shaft to the pinion yoke with
the installation reference marks aligned. Install the
washers and the nuts and tighten to 19 N-m (14 ft. lbs.) torque.
(8) Remove the supports, lower the vehicle and re­
move the block from the brake pedal.
(9) Raise the vehicle.
• Bleed and adjust the brakes
• Lubricate all the ball stud fittings
• Inspect the differential housing lubricant level. Re­
fer to Group 0, Lubrication and Maintenance.
(10) Lower the vehicle and test the axle and sus­
pension operation.

DIFFERENTIAL DISASSEMBLY
REMOVAL/DISASSEMBLY
(1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 34).
(2) Remove the differential bearing caps.