1993 DODGE TRUCK Group 21

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)

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

•

INTRODUCTION
11
MEASUREMENT
AND
TORQUE SPECIFICATIONS
INDEX
page

Metric
and
English/SAE
Conversion
11

Specification
Notations
11

SPECIFICATION NOTATIONS

WARNING:
THE USE OF
INCORRECT
ATTACHING
HARDWARE
CAN
RESULT
IN
COMPONENT
DAM­

AGE
AND/OR
PERSONAL
INJURY.

It is important to retain the original attaching
hardware for assembly of the components. If the at­
taching hardware is not reusable, hardware with
equivalent specifications must be used.

METRIC
AND
ENGLISH/SAE
CONVERSION
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise versa.

TORQUE SPECIFICATIONS
TORQUE
CHARTS
A torque chart for fasteners is provided at the end
of each group (of service information). Refer to the Standard Torque Specifications chart to determine
torque values not listed in the group (Figs. 1 and 2).
It is important to be aware that the torque values
listed in the chart are based on clean and dry bolt
page
Torque Specifications
11
threads. Reduce the torque value by 10 percent when the bolt threads are lubricated and by 20 percent if new.

BOLT
THREAD
AND
GRADE/CLASS
IDENTIFICATION

THREAD
IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation chart.

GRADE/CLASS
IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the line marks on the top of each bolt head (Fig. 1). The
actual bolt strength grade corresponds to the number
of line marks plus 2.
• A grade 2 bolt has no line marks on top of the bolt
head
• A grade 5 bolt has 3 line marks on top of the bolt
head • A grade 7 bolt has 5 line marks on top of the bolt
head

CONVERSION FORMULAS
AND
EQUIVALENT
VALUES
Multiply

in-lbs
ft-lbs
By

x
0.11298

x
1.3558
To
Get

=
Newton-Meters (N*m)

=
Newton-Meters (N*m) Multiply
N*m
iy

x
8.851

x
0.7376
BGef

-
in-fbs

-
ft-lbs

Inches
Hg
(60°F)

psi
x
3.377

x
6.895
=
Kilopascals
(kPa)

=
Kilopascals
(kPa)
kPa
kPa
x
0.2961

x
0.145
«
Inches
Hg

- psi

Inches
Feet

Yards
Miles
x 25.4
x
0.3048

x
0.9144

x
1.6093
« Millimeters (mm)

=
Meters (M)

-
Meters (M)

=
Kilometers (Km) mm
M
M
Km
x
0.03937

x
3.281

x
1.0936

x
0.6214
« Inches

-
Feet

=
Yards « Miles

mph

Feet/Sec.
Kilometers/Hr.

mph
x
1.6093

x
0.3048

x
0.27778

x
0.4470
=
Kilometers/Hr. (Km/h)
«
Meters/Sec.
(M/S)
«
Meters/Sec.
(M/S)

=
Meters/Sec.
(M/S)
Km/h

M/S
M/S

M/S
x
0.6214

x
3.281

x
3.600

x
2.237 - mph

=
Feet/Sec.

=
Kilometers/Hr.
» mph
COMMON
MITRIC
EQUIVALENTS

1
Inch
=
25 Millimeters
1
Cubic
Inch
»
16
Cubic
Centimeters

1
Foot
-
0.3 Meter
1
Cubic
Foot
«
0.03
Cubic
Meter
1
Yard
=
0.9 Meter
1
Cubic
Yard
=
0.8
Cubic
Meter

1
Mile =1.6 Kilometers
J91IN-1

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.

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

0-18
LUBRICATION
AND
MAINTENANCE

• MAINTENANCE SCHEDULE
A crankcase ventilation system must be clean to
provide good operation and durability. Periodic main­
tenance is necessary. Replace the PCV valve. Re­
move residual combustion deposits from the hoses and throttle body/intake manifold passages.
The PCV valve should be replaced and the system
should be serviced at the interval specified in main­
tenance schedule. If a vehicle is routinely used for short trips, the crankcase ventilation system could
possibly require more maintenance.
CRANKCASE AIR INLET FILTER
MAINTENANCE SCHEDULE Replace or clean, the air inlet filter at the interval
specified in maintenance schedule.
More frequent PCV system maintenance could be
required for:
• Vehicles routinely used for short trips
• Vehicles routinely involved in stop and go traffic
operation
• Vehicles routinely involved in extended periods of
engine idle
MAINTENANCE Clean and lubricate the crankcase air inlet filter
according to the following procedure. (1) Disconnect the fresh air hose from the port on
the crankcase air inlet filter housing (Fig. 8).
(2) Remove the air filter housing from the cylinder
head cover (Fig. 8). Clean the filter in kerosene or a similar solvent.
(3) Lubricate the filter by inverting the housing
and filling it with SAE 30 viscosity engine oil.
(4) Insert the air filter housing nipple in the cylin­
der head cover grommet. Connect the fresh air hose
to the upper port (Fig. 8).
J9000-52

Fig.
8
Crankcase
Air Inlet
Filter
THROTTLE CONTROL LINKAGE

Transmission linkage pivot pin areas (Fig. 9),
should be serviced. The areas lubricated every second
oil change with a multi-purpose lubricant (NLGI GC-
LB).

PIVOT
AREAS
Fig.
9
Transmission
Linkage
Pivot Areas

FUEL
SYSTEM

INSPECTION The fuel system filler cap, nozzle, tubes, hoses, and
connections should be inspected periodically.
FUEL FILTER The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag­
nosis and service procedures refer to Group 14, Fuel
System.
GASOLINE ENGINE FUEL REQUIREMENTS All gasoline engines require fuel that has a mini­
mum octane rating of 87 determined by the (R +
M)/2 calculation method.
The use of a brand of unleaded gasoline that con­
tains additives is recommended. Gasoline with addi­
tives will improve fuel economy and reduce emissions.

ALCOHOL/GASOLINE
BLENDS
Many brands of blended unleaded gasoline am now
available. Unleaded gasoline is blended with oxygenated-type
fuels to produce a clean air gasoline in many areas.
The use of this type of blended fuel is recommended.
ETH ANOL—Unleaded gasoline and ethanol
blended fuels are a mixture of 10 percent ethanol and 90 percent unleaded gasoline. This is an accept­
able blend of fuel.
MTBE— MTBE blended fuels are a mixture of un­
leaded gasoline and up to 15 percent MTBE (Methyl
Tertiary Butyl Ether). Unleaded gasoline blended
with MTBE is acceptable.