1993 DODGE TRUCK Service Repair Manual

12

INTRODUCTION

STANDARD
TORQUE
SPECIFICATIONS
BOLT TORQUE
BOLT ORAM
5

GRADES

SIZE
M*fn

ft-lbs
Nfft

ft-abs

(in-lbs)
(In-lbs)

1/4-20
11
(95) 14
(125)

1/4-28
11 (95) 17 (150)

5/16-18
23 (200) 31 (270)

5/16-24
27 20 34 25

3/8-16
41
30 54
40

3/8-24
48 35 61 45

7/16-14
68
50 88 65

7/16-20
75 55 95 70

1/2-13
102
75 136 100

1/2-20
115 85 149 110

9/16-12
142
105 183 135

9/16-18
156 115 203 150

5/8-11
203 150 264 195

5/8-18
217 160 285 210

3/4-16
237 175
305 225

J89IN-9

THREAD
NOT A
TION—SAE
AND
METRIC

INCH

5/16-18
METRIC
M8
X 1.25

THREAD MAJOR
DIAMETER
IN INCHES NUMBER
OF
THREADS

PER
INCH
THREAD DISTANCE
MAJOR BETWEEN
DIAMETER IN THREADS
IN

MILLIMETERS MILLIMETERS

PR606B

•
A grade 8 bolt has 6 line marks on top of the bolt
head
The most commonly used metric bolt strength
classes are 9.8 and 12.9. The metric strength class identification number is imprinted on the head of the
bolt (Fig. 2). The higher the class number, the
SAE
CLASSIFICATION
GRADE
5

GRADE
8
MARKINGS
FOUND

ON TOP OF BOLT HEAD INDICATE
GRADE
120°
60°

GRADE
2
GRADE
5
GRADE
8

(SAE) BOLTS—IDENTIFICATION
MARKS
CORRESPOND
TO BOLT STRENGTH—INCREASING NUMBERS

REPRESENT
INCREASING STRENGTH.
J89IN-11
Fig.
1 SAE
Bolt
Grade
Identification

greater the bolt strength. Some metric nuts are im­
printed with a single-digit strength class on the nut

face.
METRIC BOLTS—IDENTIFICATION
CLASS
NUMBERS

CORRESPOND
TO BOLT STRENGTH— INCREASING NUMBERS
REPRESENT
INCREASING STRENGTH.
J89IN-10

Fig.
2
Metric
Bolt
Class
Identification

METRIC
CONVERSION
Refer to the Metric Conversion chart to convert
torque values listed in metric Newton-meters (N»m).

Also,
use the chart to convert between millimeters (mm) and inches (in.)

•

INTRODUCTION 13
METRIC
CONVERSION

in-lbs
to N«m
N*m
to
in-lbs

in-
lb
N®m

in-lb
N®m

in-lb
N»m

in-lb
N@m

in-lb
N«m
2
.2260
42 4.7453 82

9.2646
122 13.7839 162
18.3032

4
.4519 44 4.9713
84

9.4906
124
14.0099
164

18.5292

6
.6779 46
5.1972
86

9.7165
126 14.2359 166
18.7552

8
.9039
48
5.4232
88
9.9425 128
14.4618 168 18.9811
10
1.1298
50
5.6492
90
10.1685
130 14.6878 170
19.2071
12
1.3558
52
5.8751
92
10.3944
132 14.9138 172
19.4331
14
1.5818
54

6.1011
94
10.6204
134

15.1397
174
19.6590
16
1.8077

56
6.3270
96 10.8464
136
15.3657
176
19.8850
18
2.0337
58
6.5530
98
11.0723
138
15.5917
178
20.1110
20
2.2597

60
6.7790
100
11.2983
140
15.8176
180

20.3369
22 2.4856 62
7.0049
102
11.5243
142 16.0436 182

20.5629

24 2.7116 64
7.2309
104
11.7502
144
16.2696
184
20.7889

26 2.9376
66
7.4569
106
11.9762
146
16.4955
186

21.0148
28 3.1635 68
7.6828
108
12.2022
148 16.7215
188

21.2408
30 3.3895 70
7.9088
110
12.4281
150 16.9475
190

21.4668
32 3.6155 72
8.1348
112 12.6541
152 17.1734 192

21.6927

34
3.8414
74

8.3607
114
12.8801 154 17.3994 194

21.9187

36 4.0674 76
8.5867

116
13.1060
156 17.6253 196

22.1447

38 4.2934 78
8.8127
118 13.3320
158 17.8513 198
22.3706
40 4.5193 80

9.0386
120
13.5580
160 18.0773
200 22.5966
in-lb

N®m

in-lb
N®m
in-lb

N»m
in-lb

.2

.4 .6
.8

1
1.2
1.4
1.6
1.8

2

2.2 2.4
2.6 2.8

3
3.2
3.4 3.6
3.8

4
1.7702

3.5404

5.3107

7.0809
8.8511

10.6213
12.3916
14.1618
15.9320
17.7022
19.4725

21.2427

23.0129 24.7831
26.5534 28.3236
30.0938
31.8640
33.6342
35.4045 4.2
4.4
4.6
4.8

5

5.2
5.4
5.6
5.8

6

6.2
6.4
6.6
6.8
7
7.2
7.4 7.6 7.8

8
37.1747

38.9449
40.7152
42.4854

44.25%
46.0258
47.7961 49.5663
51.3365
53.1067

54.8770

56.6472

58.4174
60.1876
61.9579
63.7281
65.4983 67.2685
69.0388 70.8090 8.2
8.4
8.6
8.8

9

9.2 9.4
9.6 9.8
10 10.2
10.4
10.6
10.8
11
11.2
11.4
11.6
11.8
12 72.5792
74.3494

76.1197

77.8m

79.6601 81.4303
83.2006
84.9708
86.7410
88.5112
90.2815

92.0517

93.8219
95.5921 97.3624
99.1326
100.9028
102.6730
104.4433
106.2135 12.2
12.4
12.6
12.8

13
13.2

13.4

13.6
13.8
14 14.2
14.4
14.6 14.8

15
15.2
15.4 15.6 15.8
16
107.9837

109.7539
111.5242
113.2944
115.0646 116.8348
118.6051 120.3753
122.1455
123.9157
125.6860
127.4562
129.2264
130.9966 132.7669 134.5371
136.3073
138.0775 139.8478
141.6180 16.2
16.4 16.6
16.8

17
17.2
17.4
17.6
17.8
18
18.5

19

19.5

20
20.5

21
22

23
24

25

ft-lbs
to N*m
N»m
to
ft-lbs

ft-lb
N«m

ft-lb
N»m

ft-lb
N©m

ft-lb
N»m
ft-lb
N®m
N®m

ft-lb
N®m

ft-ib
N®m

ft-lb
N©m

ft-lb
N®m
ft-lb

1
1.3558

21 28.4722
41

55.5885
61
82.7049 81
109.8212
1

.7376 21
15.9888 41

30.240)
61
44.9913
81 59.7425

2
2.7116
22
29.8280

42

56.9444
62

84.0607
82
111.1770
2

1.4751
22
16.2264
42 30.9776 62
45.7289
82 60.4801

3
4.0675

23
31.1838

43

58.3002
63

85.4165
83

112.5328
3

2.2127
23

16.9639
43
31.7152
63

46.4664

83
61.2177

4
5.4233

24 32.5396
44

59.6560 64
86.7723 84
113.8888
4

2.9502
24
17.7015
44
32.4527
64
47.2040
84 61.9552

5
6.7791

25
33,8954

45
61.0118
65

88.1281
85

115.2446
5

3.6878
25

18.4391
45
33.1903
65

47.9415

85
62.6928

6
8.1349

26 35.2513
46
62.3676 66
89.4840 86
116.6004
6

4.4254 26
19.1766 46
33.9279 66 48.6791
86 63.4303
7
9.4907

27 36.6071
47
63.7234 67
90.8398 87
117.9562 7

5.1629
27
19.9142 47
34.6654 67

49.4167

87 64.1679

8
10.8465
28 37.9629
48 65.0793 68
92.1956 88
119.3120
8

5.9005 28

20.6517
48 35.4030 68
50.1542
88 64.9545

9
12.2024
29
39.3187

49 66.4351 69
93.5514 89
120.6678
9

6.6381
29
21.3893 49
36.1405 69
50.8918
89 65.6430
10 13.5582
30 40.6745
50 67.7909
70 94.9073 90 122.0236
10

7.3756
30 22.1269
50
36.8781 70
51.6293
90 66.3806
11 14.9140
31 42.0304
51
69.1467
71
96.2631 91
123.3794

11
8.1132
31
22.8644
51
37.6157
71
52.3669
91 67.1181
12 16.2698
32 43.3862 52
70.5025 72
97.6189 92 124.7352
12

8.8507
32
23.6020 52
38.3532 72
53.1045
92
67.8557

13
17.6256

33
44.7420

53

71.8583
73
98.9747
93

126.0910
13

9.5883
33

24.3395
53

39.0908
73

53.8420

93
68.5933
14 18.9815 34

46.0978
54
73.2142 74
100.3316 94
127.4468 14
10.3259 34
25.0771 54 39.8284 74
54.5720
94 69.3308

15
20.3373

35
47.4536

55
74.5700
75

101.6862
95

128.8026
15

11.0634
35

25.8147
55
40.5659
75

55.3172

95
70.0684
16 21.6931
36
48.8094

56
75.9258 76
103.0422
96

130.1586
16
11.8010 36
26.5522 56
41.3035 76

56.0547

96 70.8060
17 23.0489
37 50.1653 57
77.2816 77
104.3980 97

13].5144
17
12.5386
37
27.2898 57
42.0410 77
56.7923
97

71.5435

18
24.4047

38 51.5211 58
78.6374 78
105.7538 98 132.8702
18 13.2761 38
28.0274 58

42.77m
78
57.5298
98 72.2811
19 25.7605 39 52.8769
59
79.9933 79
107.1196 99 134.2260
19

14.0137
39
28.7649 59
43.5162 79
58.2674

99
73.0187

20 27.1164
40
54.2327
60
81.3491 80
108.4654 100 135.5820
20
14.7512 40
29.5025 60
44.2537
80
59.0050
100 73.7562

in.
to mm
mm
to in.

in.
mm

in.
mm

in.
mm
in.

mm
in.

mm mm
in.
mm

in.
mm

in.
mm

in.

mm
in.

.01 .254 .21

5.334
.41
10.414 .61
15.494 .81
20.574 .01 .00039 .21

.00827
.41 .01614
.61 .02402
.81 .03189
.02 .508 .22
5.588
.42
10.668 .62
15.748 .82
20.828 .02 .00079 .22
.00866 .42 .01654
.62 .02441
.82 .03228

.03
.762
.23

5.842
.43

10.922
.63

16.002
.83
21.082

.03
.00118
.23
.00906
.43
.01693

.63

.02480

.83
.03268
.04 1.016 .24

6.096
.44

11.176
.64

16.256 .84
21.336
.04
.00157
.24

.00945 .44
.01732
.64
.02520

.84
.03307

.05
1.270
.25

6.350
.45

11.430
.65

16.510
.85

21.590
.05

.00197
.25

.00984
.45
.01772
.65
.02559

.85
.03346
.06 1.524 .26
6.604

.46 11.684 .66
16.764 .86 21.844
.06 .00236 .26
.01024

.46
.01811
66 .02598
.86

.03m

.07 1.778 .27

6.858
.47
11.938 .67
17.018 .87
22.098 .07
.00276 .27
.01063 .47
.01850

.67
.02638
.87 .03425
.08
2.032
.28 7.112 .48
12.192 .68
17.272 .88
22.352
.08 .00315 .28
.01102 .48

.01890
.68

.02677

.88 .03465
.09
2.286
.29

7.366
.49
12.446 .69
17.526 .89
22.606 .09 .00354 .29
.01142 .49 .01929 .69
.02717

.89 .03504
.10
2.540
.30

7.620
.50

12.700
.70

17.780

.90
22.860

.10 .00394 .30
.01181
.50 .01969
.70 .02756
.90 .03543
.11
2.794

.31
7.874

.51 12.954 .71
18.034 .91
23.114
.11 .00433 .31

.01220
.51 .02008
.71 .02795
.91 .03583
.12
3.048

.32 8.128 .52
13.208 .72
18.288 .92
23.368
.12 .00472 .32

.01260
.52
.02047

.72 .02835
.92 .03622

.13
3.302
.33
8.382
.53

13.462
.73

18.542
.93

23.622

.13
.00512
.33

.01299
.53
.02087
.73
.02874

.93
.03661
.14
3.5%
.34

8.636
.54

13.716 .74
18.796 .94
23.876
.14 .00551 .34
.01339 .54 .02126 .74 .02913
.94 .03701

.15
3.810

.35

8.890
.55

13.970
.75

19.050
.95

24.130

.15
.00591
.35

.01378
.55
.02165

.75
.02953

.95
.03740

.16 4.064
.36 9.144 .56
14.224 .76 19.304 .96 24.384
.16
.00630
.36

.01417

.56 .02205 .76 .02992
.96
.03780

.17 3.318 .37

9.398
.57
14.478 .77
19.558 .97
24.638 .17 .00669 .37

.01457

.57 .02244 .77
.03032
.97 .03819
.18
4.572
.38
9.652

.58
14.732 .78
19.812 .98
24.892
.18 .00709 .38
.01496 .58 .02283
.78 .03071
.98 .03858
.19 4.826 .39

9.906
.59
14.986 .79

20.0%
.99 25.146
.19 .00748 .39
.01535 .59
.02323 .79

.03110

.99 .03898
.20
5.080

.40
10.160
.60

15.240
.80

20.320
1.00

25.400

.20
.00787
.40
.01575 .60
.02362 .80

.03150

1.00
.03937

J901N-10

•
• —
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

0 - 2
LUBRICATION
AND
MAINTENANCE

• Commercial service
When a vehicle is continuously subjected to severe
driving conditions, lubricate:
• Body components
• All the driveline coupling joints
• Steering linkage More often than normal driving conditions

DUSTY
AREAS
With this type of severe driving condition, special
care should be given to the:
• Engine air cleaner filter
• PCV filter
• Crankcase ventilation system
• Brake booster control valve air filter. Verify that the filters and the associated compo­
nents are clean. Also verify that they are functioning
effectively. This will minimize the amount of abra­ sive particles that enter the engine.

OFF-ROAD
(4WD)
OPERATION
After off-road (4WD) operation, inspect the under­
side of the vehicle. Inspect the:
• Tires
• Body structure
• Steering components
• Suspension components • Exhaust system
• Threaded fasteners

HARSH
SURFACE ENVIRONMENTS
After extended operation in harsh environments,
the brake drums, brake linings, and rear wheel bear­ ings should be inspected and cleaned. This will pre­
vent wear and erratic brake action.

ROUTINE MAINTENANCE
The following routine maintenance is recommended
on a monthly basis: TIRES—Inspect the tires for unusual wear/damage.
Determine if the inflation pressure is adequate for
the vehicle load. BATTERY—Inspect and clean the terminals.
Tighten the terminals if necessary. FLUIDS—Determine if the component fluid levels
are acceptable. Add fluid, if necessary. LIGHTS/ELECTRICAL—Test all the electrical sys­
tems in the vehicle for proper operation. It is also recommended that the engine oil and the
washer fluid level be determined at each fuel fill-up.

VEHICLE
NOISE CONTROL
Vehicles with a GVWR of 4 535 kg (10,000 lbs), or
more, are required to comply with Federal Exterior Noise Regulations (Fig. 2).
VEHICLE
NOISE
EMISSION
CONTROL INFORMATION

DATE
OF
VEHICLE
MANUFACTURE

THIS
VEHICLE CONFORMS
TO
U.S. EPA REGULATIONS FOR NOISE EMISSION

APPLICABLE
TO
MEDIUM
AND HEAVY
DUTY
TRUCKS. THE
FOLLOWING
ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT
OF 1972. (A) THE
REMOVAL
OR

RENDERING
INOPERATIVE, OTHER
THAN
FOR
PURPOSES
OF
MAINTENANCE,
REPAIR.
OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF
DESIGN
(LISTED
IN
THE
OWNERS
MANUAL)
INCORPORATED
INTO
THIS
VEHICLE
IN COMPLIANCE
WITH
THE NOISE CONTROL
ACT:
(B) THE
USE
OF
THIS
VEHICLE
AFTER SUCH DEVICE
OR
ELEMENT
OF
DESIGN HAS BEEN REMOVED
OR
RENDERED
INOPERATIVE.

PU626D

Fig.
2 Vehicle
Noise
Emission
Control Information
Label

UNAUTHORIZED
DEFEAT
OF
NOISE
CONTROL COMPONENTS
Federal law prohibits removal, altering or other­
wise defeating any noise control component. This in­
cludes before or after the vehicle is in use. Federal
law also prohibits the use of a vehicle after a noise
control component is defeated.

REQUIRED MAINTENANCE/SERVICE
FOR
NOISE
CONTROL

The following maintenance is required after each
6-month or 9 600 km (6,000 miles) interval. This will
ensure that the vehicle noise control components are
operating properly.

EXHAUST SYSTEM
Inspect exhaust system for exhaust leaks and dam­
aged components. The exhaust hangers, clamps and
U-bolts should be attached and in good condition.
Burned or ruptured mufflers, damaged exhaust pipes should be replaced. Refer to Group 11—Exhaust Sys­
tem/Intake Manifold for service information.

AIR
FILTER
HOUSING/CANISTER
Inspect the air filter assembly for proper fit. Verify
the cover is securely attached to the housing/canis­
ter. Inspect all the air filter housing hoses for con­ nections. The gasket between the air filter housing and throttle body must be in good condition. The air
filter element should be clean and serviced according
to the maintenance schedule.

FUEL
REQUIREMENTS
GASOLINE
ENGINES
All engines require the use of unleaded gasoline to
reduce the effects of lead to the environment. Also unleaded fuel is necessary to prevent damage to the
catalytic converter/02 sensor. The fuel must have a
minimum octane rating of 87 based on the (R + M)/2
calculation method.

•

LUBRICATION AND MAINTENANCE
0 - 3
CAUTION: UNLEADED FUEL ONLY must
be
used
in

vehicles equipped
with
a
catalyst emission
control

system.
All
vehicles have reminders
printed
on the
instrument
panel below
the
fuel
gauge
and on the

fuel
filler
door.
The
vehicles also have
fuel
filler

tubes
that
are
specially designed
to
accept only
the
small-diameter nozzles.
It is
illegal
to
bypass
the

design
of an
unleaded
fuel
filler
tube.

DIESEL ENGINES All
Ram
Truck
and Ram
Cab/Chassis Diesel
en­

gines normally
can use
number
2D
Diesel fuel
for

most year-round operations.
A
fuel conforming
to

ASTM Specification D-975
is
recommended.
For ex­

treme cold-weather, number
ID
Diesel fuel
is
recom­ mended.

CLASSIFICATION
OF
LUBRICANTS
Lubricating fluids
and
chassis lubricants
are
clas­
sified according
to
standards recommended
by the:
• Society
of
Automotive Engineers
(SAE)

• American Petroleum Institute
(API)

• National Lubricating Grease Institute (NLGI)
ENGINE
OIL

SAE
VISCOSITY
GRADE
An
SAE
viscosity grade
is
used
to
specify
the
vis­
cosity
of
engine
oil. SAE 30
specifies
a
single viscos­
ity engine
oil.

Engine oils also have multiple viscosities. These
are specified with
a
dual
SAE
viscosity grade which
indicates
the
cold-to-hot temperature viscosity range (Fig.
3).

API
SERVICE
GRADE
The
API
Service Grade specifies
the
type
of
perfor­
mance
the
engine
oil is
intended
to
provide.
The API
Service Grade specifications also apply
to
energy con­
serving engine oils
(Fig. 3).

For maximum gasoline engine protection,
use API

Service Grade
SG,
SG/CD
or
SG/CE engine
oil.

For maximum Diesel engine protection,
use

API Service
CE or
SG/CE engine
oil.

GEAR LUBRICANTS A dual grade
is
also used
to
specify
the
viscosity
of

multi-purpose gear lubricants.
The
API
grade designation identifies gear lubri­
cants
in
terms
of
recommended usage.
OIL

QUALITY

SAE

VISCOSITY
GRADE

FUEL

ECONOMY

NOTATION
J91004

Fig.
3 SAE Oil
Viscosity Grade
& API
Service
Grade
CHASSIS COMPONENT
AND
WHEEL BEARING
LUBRICANTS The chassis
and
wheel bearing lubricants
are
iden­
tified
by the
NLGI Certification Symbol.
The
symbol
contains
a
coded designation. This identifies
the us­
age
and
quality
of the
lubricant.
The letter
G
within
the
symbol designates wheel
bearing lubricant.
The
letter
L
designates chassis
lu­

bricant. When
the
letters
are
combined,
the
lubricant can
be
used
for
dual applications.
Use
only lubricants
that display
the
NLGI Certification Symbol.

NATIONAL LUBRICATING
GREASE
INSTITUTE
NLGI

AUTOMOTIVE
WHEEL BEARING
&
CHASSIS LUBRICANT
GC-LB

-CERTIFICATION

SYMBOL
—
USAGE
AND

QUALITY
DESIGNATION
J920W7

Fig.
4
NLGI
Lubricant Container
Certification/
Identification
Symbol
LUBRICATION
AND
REPLACEMENT
PARTS

RECOMMENDATION
Ram Trucks
are
engineered
to
provide many years
of dependable operation. However, lubrication service
and maintenance
are
required
for
each vehicle. When
necessary, MOPAR®brand lubricants
and
genuine
re­

placement parts
are
recommended.