1993 DODGE TRUCK transmission fluid

6
- 14
CLUTCH

(9) Install transmission. Also install transfer case
on 4-wheel drive models.
Fig.
10
Clutch
Release
Fork
And Bearing

PILOT BEARING REPLACEMENT
(1) Remove transmission and clutch housing.
(2) Remove clutch cover and disc.
(3) Remove pilot bearing. Use blind hole puller
tools such as those included in Snap-On set CG40CB
to remove bearing. (4) Clean bearing bore with solvent and wipe dry
with shop towel. (5) Install new bearing with clutch alignment tool
(Fig. 11). Keep bearing straight during installation.
Do not allow bearing to become cocked. Tap bearing
into place until flush with edge of bearing bore. Do
not recess bearing.

BEARING SEAL
MUST
FACE

J9206-8

Fig.
11 Typical Method Of Installing Pilot Bearing (6) Lubricate bearing with Mopar high tempera­
ture grease, or an equivalent quality grease.
(7) Install clutch cover and disc.
(8) Install clutch housing, transmission and trans­
fer case on 4-wheel drive models.

CLUTCH LINKAGE SERVICE
The clutch master cylinder, remote reservoir,
slave cylinder and connecting lines are all ser­
viced as an assembly. These components cannot
be serviced separately. The linkage cylinders and connecting lines are sealed units. They are
prefilled with fluid during manufacture and
must not be disassembled nor disconnected.

LINKAGE REMOVAL
(1) Raise vehicle.
(2) On diesel models, remove slave cylinder shield
from clutch housing (Fig. 12).
Fig.
12
Slave
Cylinder
Shield—Diesel
Models

(3) Remove nuts attaching slave cylinder to studs
on clutch housing flange.
(4) Remove slave cylinder from clutch housing
(Fig. 13). (5) Disengage slave cylinder fluid line from under-
vehicle retainer clips. (6) Lower vehicle.
(7) On diesel models, disconnect clutch pedal inter­
lock switch wires.
(8) Carefully remove locating clip from clutch mas­
ter cylinder mounting bracket (Fig. 14). (9) Remove retaining ring, flat washer and wave
washer that attach clutch master cylinder push rod
to clutch pedal (Fig. 14).

COOLING SYSTEM

CONTENTS page

DIAGNOSIS
... 4

ENGINE
ACCESSORY
DRIVE BELTS
40

ENGINE
BLOCK HEATERS
48

GENERAL
INFORMATION
Throughout this group, references are made to partic­
ular vehicle models by alphabetical designation or by
the particular vehicle nameplate. A chart showing a
breakdown of alphabetical designations is included in
the Introduction section at the beginning of this man­
ual.
5.9L gas powered engines will be' referred to as ei­
ther: LDC (Light Duty Cycle) or HDC (Heavy Duty
Cycle).

COOLING
SYSTEM
The cooling system regulates engine operating tem­
perature. It allows the engine to reach normal oper-
page

SERVICE
PROCEDURES
15

SPECIFICATIONS
; 49
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre­
vents overheating.
The cooling system also provides a means of heat­
ing the passenger compartment and cooling the auto­
matic transmission fluid (if equipped). The cooling system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed maximum duty cool­
ing package is available on most models. This pack­ age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.
NOTE: HEATER
COOLANT FLOW
CIRCUIT
IS
ALWAYS

OPEN
EXCEPT
WHEN
IN MAX. A/C
OR
OFF
MODES
HEATER
INTAKE MANIFOLD
COOLANT FLOW "METERED" FROM REAR
TO

FRONT
AND
BELOW EXHAUST
HEAT
CROSSOVER
SHUT
OFF
VALVE

A/C
ONLY COOLANT FLOW
-
PUMP
TO

CYLINDER BLOCK,
UP
THROUGH CYLINDER HEADS
TO
INTAKE MANIFOLD WATER
BOX TO
RADIATOR-TO PUMP

•BYPASS
THERMOSTAT CLOSED-HIGH FLOW
THERMOSTAT OPEN
- LOW
FLOW
J9207-18

Fig.
1
Cooling
System
Routing—3.9U5.2L Engine—Typical

7 - 26
COOLING
SYSTEM
————
Fig. 33 Generator
Mounting
Bolts—5.9L
Diesel (7) Remove thermostat housing mounting bolts.
(8) Remove thermostat housing, lifting bracket and
thermostat (Fig. 34).

Fig.
34 Thermostat Removal—5.9L
Diesel

(9) Clean the mating surfaces of the thermostat
housing and the cylinder head.
INSTALLA TION—DIESEL (1) Install the thermostat in the housing.
(2) Position the thermostat seal with the shoulder
towards the housing (Fig. 35).
(3) Install thermostat, lifting bracket, seal and
housing. Tighten the mounting bolts to 24 N°m (18 ft. lbs.) torque. (4) Position generator in place. Tighten mounting
bolt to 24 N*m torque. Tighten pivot bolt to 43 N*m (32 ft. lbs.) torque.
(5) Install accessory drive belt. Refer to Belt Re­
moval/Installation in the Engine Accessory Drive
Belt section of this group.
(6) Connect battery cable to battery. •

Fig.
35 Thermostat Seai—5.9L Diesel—Typical (7) Fill cooling system. Refer to Refilling Cooling
System in this group.

COOLANT
The cooling system is designed around the coolant.
Coolant flows through the engine water jacket ab­ sorbing heat produced during engine operation. The
coolant carries the heat to radiator and heater core.
Here it is transferred to the ambient air passing
through the radiator and heater core fins. The cool­ ant also removes heat from the automatic transmis­sion fluid in vehicles equipped with an automatic
transmission.
COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating conditions. The coolant performance of various mix­
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur­
pose of heat transfer only. Water also freezes at a higher temperature and allows corrosion.

100%
Ethylene-Glycol-The corrosion inhibiting
additives in ethylene-glycol need the presence of wa­
ter to dissolve. Without water, additives form depos­ its in system. These act as insulation causing
temperature to rise to as high as 149°C (300°F). This
temperature is hot enough to melt plastic and soften solder. The increased temperature can result in en­
gine detonation. In addition, 100 percent ethylene-
glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water-Is the recom­
mended mixture, it provides protection against freez­
ing to -37°C (-35°F). The antifreeze concentration
must always be a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec­
tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing (6) Remove generator mounting bolt (Fig. 33).

7 - 30
COOLING
SYSTEM

•

COOLING
SYSTEM

Fig.
39
Pressure
Testing
Cooling
System—Typical bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys­
tem according to following criteria:
Holds Steady: If pointer remains steady for two
minutes, serious coolant leaks are not present in sys­
tem. However, there could be an internal leak that does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can­
not be detected, inspect for interior leakage or per­
form Internal Leakage Test.
Drops Slowly: Indicates a small leak or seepage is
occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,

hoses,
gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure ap­
plied.
Drops Quickly: Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil.
An alternative method is to operate engine for a
short period to churn the oil. After this is done, re­
move engine dipstick and inspect for water globules.
Also inspect transmission dipstick for water globules and transmission fluid cooler for leakage.

WARNING:
WITH
PRESSURE TESTER TOOL
7700
INSTALLED
ON
RADIATOR,
DO
NOT ALLOW
PRES­

SURE
TO
EXCEED
110 KPA (20
PSI). PRESSURE

WILL
BUILD
UP
QUICKLY
IF A
COMBUSTION LEAK

IS
PRESENT.
TO
RELEASE
PRESSURE,
ROCK

TESTER
FROM SIDE
TO
SIDE. WHEN REMOVING

TESTER,
DO NOT
TURN TESTER MORE THAN
1/2

TURN
IF
SYSTEM
IS
UNDER
PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a combustion leak exists. This is usually the result of
a cylinder head gasket leak or crack in engine. Re­
pair as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi). Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter, do not remove spark plug cables or short
out cylinders (non-diesel engines) to isolate compres­
sion leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an ab­ normal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head
gasket, cracked engine cylinder block or cylinder
head. A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail­ able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST-WITHOUT
PRESSURE TESTER DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.

WARNING:
DO NOT
REMOVE CYLINDER BLOCK DRAIN PLUGS
OR
LOOSEN RADIATOR DRAIN-

COCK
WITH
SYSTEM
HOT AND
UNDER PRES­

SURE.
SERIOUS BURNS FROM COOLANT
CAN

OCCUR.

Drain sufficient coolant to allow thermostat re­
moval. Refer to Thermostat Replacement. Disconnect
water pump drive belt. Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.

CAUTION:
Avoid
overheating.
Do not
operate
en­

gine
for an
excessive
period
of
time.
Open
drain-

cock
immediately
after
test
to
eliminate
boil
over.

Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases% are leaking into
cooling system, bubbles will appear in coolant. If
bubbles do not appear, internal combustion gas leak­ age is not present.

COOLANT
RESERVE/0WERFL0W
SYSTEM
The coolant reserve/overflow system (Fig. 40 or 41)
works in conjunction with the radiator pressure cap.

•

COOLING
SYSTEM
7 - 33 The radiator supplies sufficient heat transfer to
cool the engine and automatic transmission (if equipped).

RADIATOR COOLANT FLOW CHECK
Use the following procedure to determine if coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. If the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow­ ing to the radiator.

WARNING:
HOT,
PRESSURIZED COOLANT
CAN
CAUSE
INJURY
BY
SCALDING. USING
A
RAG
TO

COVER
THE
RADIATOR
PRESSURE
CAP,
OPEN RADIATOR
CAP
SLOWLY
TO THE
FIRST STOP.
THIS
WILL
ALLOW
ANY
BUILT-UP
PRESSURE
TO
VENT
TO
THE
RESERVE/OVERFLOW TANK. AFTER
PRESSURE
BUILD-UP
HAS
BEEN RELEASED,
RE­

MOVE
CAP
FROM FILLER NECK.

(2) Drain a small amount of coolant from the radi­
ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal op­
erating temperature. If coolant is flowing past the
exposed tubes, the coolant is circulating.

RADIATOR REMOVAL-EXCEPT DIESEL
(1) Disconnect negative battery cable from battery.

WARNING;
DO NOT
REMOVE
THE
CYLINDER BLOCK DRAIN PLUGS
OR
LOOSEN
THE
RADIATOR
DRAINCOCK
WITH
THE
SYSTEM
HOT AND
UNDER
PRESSURE.
SERIOUS BURNS FROM COOLANT
CAN OCCUR.

(2) Drain the cooling system. Refer to Draining
Cooling System.
(3) Disconnect throttle cable from clip at radiator
fan shroud. (4) Remove hose clamps and hoses from radiator.
Special Clamp Tool number 6094 (Fig. 44) may be
used to remove the constant tension clamps.
(5) Remove coolant reserve/overflow tank hose
from radiator filler neck nipple.
(6) If equipped with an automatic transmission
(except diesel), disconnect oil cooler hoses at radiator
lower tank.
(7) Remove fan shroud mounting bolts/clips and
position shroud rearward on engine (Fig. 45). (8) Loosen radiator lower mounting bolts. Remove
the upper mounting bolts. Lift radiator straight up and out of engine compartment. Take care not to
damage radiator cooling fins or tubes.

INSTALLATION
(1) Position shroud rearward on engine.
(2) Slide radiator into position. Place behind radi­
ator support with lower mounting holes (slots) rest-
HOSE
CLAMP
TOOL
6094
HOSE

CLAMP

J9207-36

Fig.
44
Hose
Clamp
Tool
RADIATOR SHROUD
MOUNTING MOUNTING
BOLTS
CUPS
RADIATOR
V1

FAN SHROUD^
J9207-44
Fig.
45 Radiator and Fan
Shroud—Gas Engines

ing on loosened bottom mounting bolts. Install upper
mounting bolts. Tighten all mounting bolts to 11
N*m (95 in. lbs.) torque.
(3) Connect radiator hoses.
(4) Connect transmission oil cooler lines to bottom
tank. Tighten hose clamps to 4 N#m (35 in. lbs.)
torque.
(5) Position fan shroud on radiator flange. Install
mounting clips (Fig. 45).
(6) Connect throttle cable to fan shroud.
(7) Position heater controls to full heat position.
(8) Fill cooling system with coolant. Refer to Refill­
ing Cooling System in this group.
(9) Operate engine until it reaches normal temper­
ature. Check cooling system and automatic transmis­
sion (if equipped) fluid levels.

RADIATOR REMOVAL-DIESEL
(1) Disconnect negative battery cable from battery.

•

COOLING
SYSTEM
7 - 35

HOSE
CLAMP TOOL
6094
HOSE

CLAMP

J9207-36
Fig.
48
Hose
damp Tool

TRANSMISSION
OIL
COOLER—EXCEPT DIESEL
The automatic transmission oil is cooled when it
passes through a cooler in the radiator lower tank (Fig. 49 and 50).

h*-TRANSMISSION

- OIL
COOLER

FRONT
OF
VEHICLE
AUTOMATIC

TRANSMISSION
PRESSURE
LINE
6 AND
8
CYLINDER ENGINE

RETURN
LINE
RY402

Fig.
49 Top View of
Transmission
Oil
Cooling
Circuit—Except Diesel—Typical

COOLING
TUBE (CUT-A-WAY)

DRAIN
COCK
HOSE

CLAMP
HOSE
TO

COOLER
LINE
HOSE
TO

COOLER
LINE

RY401

Fig.
50 Automatic
Transmission
Oil Cooler—Except
Diesel—
Typical

In case of a leak in the transmission oil cooler, en­
gine coolant may become mixed with transmission
fluid or transmission fluid may enter engine cooling system. Both cooling system and transmission should
be drained and inspected in the event cooler is leak­ ing.
REPLACING
OIL
COOLER
IN
BOTTOM
TANK

Remove radiator. Refer to Radiator removal in this
group. The servicing should be performed by a qual­
ified repair facility.
Once the repaired or replacement radiator has been
installed, fill the cooling system and inspect for

leaks.
Refer to Refilling Cooling System and Testing Cooling System For Leaks sections in this group. If
the transmission operates properly after repairing
the leak, drain the transmission and remove the
transmission oil pan. Inspect for sludge and/or rust. Inspect for a dirty or plugged inlet filter. If none of
these conditions are found, the transmission and
torque convertor may not require reconditioning. Re­
fer to Group 21 for automatic transmission servicing.

1RANSMISSI0N
OIL
COOLER-DIESEL
The transmission oil cooler is mounted to a bracket
on the turbocharger side of the engine (Fig. 51).

TRANSMISSION
OIL
COOLER
Fig.
51 Automatic
Transmission
Oil Cooler—5.9L

Diesel
REMOVAL

In case of a leak in the transmission oil cooler, en­
gine coolant may become mixed with transmission
fluid or transmission fluid may enter engine cooling system. Both cooling system and transmission should
be drained and inspected in the event cooler is leak­ ing. (1) Disconnect negative battery cable at battery.
(2) Drain cooling system. Refer to Draining Cool­
ing System. (3) Disconnect coolant lines from cooler.
(4) Disconnect transmission oil lines from cooler.
Plug cooler lines to prevent oil leakage. (5) Remove oil cooler mounting straps.
(6) Lift oil cooler off of mounting bracket.

INSTALLATION
(1) Position oil cooler on bracket.
(2) Install mounting straps.
(3) Connect transmission oil lines to cooler.

7 - 36
COOLING
SYSTEM

• (4) Connect coolant hoses to cooler.

(5)
Connect battery cable to battery.

(6)
Fill cooling system. Refer to Refilling Cooling
System in this section. (7) Check transmission oil level and fill as neces­
sary.

TRANSMISSION
OIL/TO-AIR
COOLER
Oil to air transmission coolers are mounted ahead
of the radiator and operate in conjunction with the
main cooler (Figs, 52 or 53). The transmission oil is
routed through the main cooler first, then the auxil­ iary cooler, before returning to the transmission.
FRONT
OIL-TO-AIR
COOLER

RADIATOR
RADIATOR GRILL SUPPORT RETURN JO

_
TRANSMISSION

*
PRESSURE

(FROM BOTTOM COOLER)
VIEW
IN
CIRCLE J9007-75 Fig.
52
Transmission
Oil-to-Air Cooler—Except

Diesel—
Typical

AUXILIARY
OIL TO AIR
COOLER
J9107-73
Fig.
53
Transmission
Oil-to-Air
Cooler—Diesel

Engine—Typical
COOLING
SYSTEM FAN—GAS ENGINES

Also refer to Viscous Fan Drive in this group for
additional information.
REMOVAL (1) Disconnect negative battery cable from battery.
(2) Remove throttle cable at top of fan shroud.
(3) Unsnap coolant reserve/overflow tank from fan
shroud and lay aside. The tank is held to shroud
with T-shaped slots. Do not disconnect hose or drain
coolant from tank.
(4) The thermal Viscous Fan Drive/Fan Blade As­
sembly is attached (threaded) to water pump hub
shaft (Fig. 54). Remove fan blade/viscous fan drive
assembly from water pump by turning mounting nut
counterclockwise as viewed from front. Threads on
viscous fan drive are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be
used. Place a bar or screwdriver between water pump
pulley bolts (Fig. 54) to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive as­
sembly from vehicle at this time.
FAN BLADE

ASSEMBLY

THREADED NUT WATER
PUMP

PULLEY
PULLEY
BOLTS
WATER PUMP
THREADED SHAFT
(WATER PUMP HUB)
VISCOUS
FAN DRIVE CRANKSHAFT
PULLEY
J9307-32

Fig.
54 Fan
Blade/Viscous
Fan
Drive—Gas
Engines
Do not unbolt fan blade assembly (Fig. 54) from
viscous fan drive at this time.
(5) Remove fan shroud attaching hardware (two
bolts at bottom-two clips at top). (6) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete unit from vehicle.
After removing fan blade/viscous fan drive assem­
bly, do not place viscous fan drive in horizontal po­ sition. If stored horizontally, silicone fluid in the
viscous fan drive could drain into its bearing assem­
bly and contaminate lubricant.

13
- 32
FRAME
AND
BUMPERS

• r INSTALLATION
(1) Verify the insulators and spacers are positioned
on the frame holddown brackets (Figs. 4 and 5). (2) Position the cab on the frame.
(3) Install the cab holddown nuts and bolts (Figs. 4
and 5). Tighten the nuts to 68 N-m (50 ft. lbs.)
torque. Tighten the bolts to 81 Nnn (60 ft. lbs.)
torque. (4) Position the restraint cable ends on the cab
rear seat belt anchor bolts. Install the retaining nuts.
Tighten the nuts to 45 N-m. (33 ft. lbs.) torque.
(5) Connect the steering shaft to the steering gear.
(6) Connect the tubing to the clutch master cylin­
der (if equipped).
(7) Connect the transmission and transfer case (if
equipped) shift linkage. (8) Connect the cable to the starter motor.
(9) Connect the heater and A/C hoses.
(10) Connect the engine controls.
(11) Connect the parking brake cable and the
brake lines.
(12) Connect the wire harness connectors to the
engine components and to the frame. (13) Connect all remaining items between the cab
and the frame components. (14) Install the battery in the tray. Connect the ca­
bles to the terminals. (15) Inspect the installation of the cab on the
frame and verify that:
• All connecting hardware is tightened
• All fluids and lubricants are full
• All electrical, engine, drivetrain and chassis com­
ponents are operational.

CARGO
BOX REMOVAL The cargo box is attached to the rear frame struc­
ture with holddown bolts (Fig. 6). The box can be re­ moved for repair or service access. Refer to the
associated component procedures when necessary.
(1) Disconnect the battery cables from the termi­

nals.

(2) Disconnect the rear lamp wire harness connec­

tors.
(3) Support the exhaust pipe. Disconnect the sup­
port hanger from the cargo box. (4) Loosen the clamps. Disconnect the fuel and
vent hoses from the nozzle tubes (Fig. 7). (5) Remove the cargo box holddown bolts (Fig. 6).
The bolts are accessible from the underside of the cargo box. (6) Identify, mark and retain the spacers (if used)
for installation reference. (7) Remove the cargo box from the frame (Fig. 6).

CARGO CARGO
BOX

FWD HOSE CLAMP
J9123-551
Fig.
7
Fuel
& Vent
Hoses
INSTALLATION
(1) Position cargo box on the frame (Fig. 6).
(2) Insert the spacers. Install the holddown bolts
(Fig. 6). Tighten the bolts to 47 Nnn (35 ft. lbs.)
torque.
(3) Connect the fuel and vent hoses to the nozzle
tubes (Fig. 7). Tighten the fuel hose clamp screw to 3
Nnn (20 in. lbs.) torque. Tighten the vent hose clamp screw to 2 Nnn (14 in. lbs.) torque.
(4) Connect the tail pipe to the hanger on the
cargo box. Remove the support. (5) Connect rear lamp wire harness connectors.
(6) Connect the battery cables to the terminals.
(7) Inspect the installation of the cargo box on the
frame and verify that:
• All connecting hardware is tightened • All electrical system components are operational