1993 DODGE TRUCK Transfer case
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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)
Page 6 of 1502
INTRODUCTION
INTRODUCTION
DESIGNATIONS,
LABELS/PLATES/DECALS,
CODES
AND DIMENSIONS/WEIGHTS .
CONTENTS
page
MEASUREMENT
AND TORQUE
... 1 SPECIFICATIONS
page
. 11
DESIGNATIONS, LABELS/PLATES/DECALS, CODES
AND
DIMENSIONS/WEIGHTS
INDEX
page
Engine
and
Transmission/Transfer
Case
Identification
2
Engine/Transmission/GVWR
4
Equipment
Identification
Plate
3
International
Vehicle Control
and
Display
Symbols
10
Major Component
Identification 3
VEHICLE DESIGNATIONS The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes are used to identify vehicle types in charts, captions
and in service procedures. The vehicle codes are
dif
ferent than the Vehicle Identification Number (VIN) or the wheelbase/model code.
VEHICLE SAFETY CERTIFICATION
LABEL
A certification label is attached to the left side
B-pillar. The label certifies that the vehicle conforms
to Federal Motor Vehicle Safety Standards (FMVSS).
The label also lists the: • Month and year of vehicle manufacture
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number (VIN)
Type of vehicle
Type of rear wheels (single or dual) Bar code
Month, Day and Hour (MDH) of final assembly
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
page
Trailer
Towing Specifications
4
Vehicle Code Plate
2
Vehicle Designations
1
Vehicle Dimension
4
Vehicle
Identification
Number (VIN) Plate
1
Vehicle Safety
Certification
Label
............. 1
Vehicle Weights
4
VEHICLE CODE
DESIGNATIONS
VEHICLE CODE
= AD
(DODGE
RAM
PICKUP
&
CHASSIS
CAB)
VEHICLE
FAMILY LINE DESCRIPTION
AD1
D150
AD2
D250
AD3
D350
PICKUP
4x2
AD5
W150
AD6
W250
AD7
W350
PICKUP
4x4
AD2
D250
AD3
D350
CHASSIS
CAB
4x2
AD6
W250
AD7
W350
CHASSIS
CAB
4x4
AD4
AD100
AD4
AD150
SPORT
UTILITY
4x2
AD8
AD100
AD8 AD
150
SPORT
UTILITY
4x4
J90IN-32
Page 7 of 1502
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
Page 26 of 1502
CHASSIS LUBRICATION
For light
duty
cycle
vehicles
GVW resting
of
3 855 Kg (8,500 lbs ) and
below.
Component
Truck Models
Fittings
Service Interval Lubricant
Center Link
AD1
AD2
AD
4
2
36
000
km
(22,500
miles)
or 2
years Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Mileage Lubricant)
Drag
Link
Bali
joints
AW1 AW 2
AW
8
2
12
000
km
(7,500
miles)
or 6
months Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Mileage Lubricant)
Gearshift
Mechanism
Overdrive
4
AD1
1
36
000
km
(22,500
miles)
or 2
years Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Purpose Lubricant)
Parking Brake Ratio
Lever
Pivot
AD1 AD
2 AD 4
AW1 AW 8
—
36
000
km
(22,500
miles)
or 2
years
Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Purpose Lubricant)
Propeller Shaft
U-joint
AW1
AW2
AW 8
3
(1
Piece
rear
P/shaft)
12
000
km
(7,500
miles)
or 6
months
Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Purpose Lubricant)
Propeller Shaft
Slip
Spline
AD1 AD
2
(2
piece P/shaft)
1
36
000
km
(22,500
miles)
or 2
years. For severe
service,
every
4
800
km
(3,000
miles)
or 3
months. Daily,
if
vehicle is operated in
water
Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Purpose Lubricant)
Suspension
Ball Joints
AD1 AD
2
4
36
000
km
(22,500
miles) or 2 years
—
every
engine
oil change
for
off-highway operation Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Mileage Lubricant)
Tie Rod Ball Joints
AD1
AD2
AD4
AW1 AW
2
AW8 4
2
36
000
km
(22,500
miles)
or 2
years
12
000
km
(7,500
miles)
or 6
months. Daily,
if
vehicle is operated in
water
Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Mileage Lubricant)
NP-241 Transfer
Case
Shift
Lever Pivot
AW1
AW2
AW8
—
As
Required
Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Purpose Lubricant)
Wheel
Stop
AD1 AD
2
AD4
—
36
000
km
(22,500
miles)
or
as
required
Wax Type Lubricant
Constant
Velocity Joint
(Front
P/shaft)
AW1
AW2
AW8 1
12
000
km
(7,500
miles) Multi-purpose grease
-
NGLI
grade
2
EP
(Multi-Purpose Lubricant)
>
J9000-59
>
Page 27 of 1502
CHASSIS LUBRICATION
(CONT'D)
For
heavy
duty
cycle
vehicles
GVW
rating
of 3 856 Kg
(8,501
Sbs.) and
above.
Component
Truck
Models
Fittings
Service
Interval
Lubricant
Center Link
AD2-3
2
39 000 km (24,000 miles) or 2 years Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Mileage Lubricant)
Drag
Link Ball Joints
AW3
2
9
600 km (6,000 miles) or 6 months
Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Mileage Lubricant)
Constant
Velocity Joint
(Front
P/shaft)
AW3
1
9
600 km (6,000 miles) Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Purpose Lubricant)
P/shaft
U-Joints
AW3
3
9
600 km (6,000 miles) or 6 months. For severe
service,
every
1
600 km (1,000 miles). Daily, if
vehicle is
operated
in
water.
Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Purpose Lubricant)
P/shaft
Slip
Spline
AW3
(135" WB)
1
39
000 km (24,000 miles) or 2 years. For severe
service
every
4 800 km (3,000 miles) or 3 months.
Daily, if vehicle is
operated
in
water.
Multi-purpose
grease -
NGLI
grade 2 EP
(Multi-Purpose Lubricant)
Suspension
Ball Joints
AD2-3
4
39
000 km (24,000 miles) Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Mileage Lubricant)
Tie Rod
Ball
Joints
AD2-3
AW2-3
4
2
39
000 km (24,000
miles)
or 2 years
9
600 km (6,000 miles) or 6 months Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Mileage Lubricant)
NP-205
Transfer
Case
Shift
Linkage
AW2-3
—
As
required
Light
Engine Oil
NP-241
Transfer
Case
Shift
Lever
Pivot
AW2
—
As
required
Multi-purpose grease -
NGLI
grade 2 EP
(Multi-Purpose Lubricant)
J9000-60
Page 28 of 1502
•
LUBRICATION AND MAINTENANCE
0 - 9 FLUID CAPACITIES
COOLING SYSTEM
QUARTS
LITERS
POWER STEERING PINTS
LITERS
3.9L ENGINE 15.1 14.3
ALL
2.7
1.28
5.2L ENGINE
(2WD)
17.0 16.1
REAR
AXLE
PINTS
LITERS
5.2L ENGINE
(4WD)
16.5 15.6
CHRYSLER
BVa
Inch
(210
mm) 4.4
2.08
5.9L ENGINE
(2WD)
15.5 14.7
CHRYSLER
9Va
Inch
(235
mm) 4.5
2.13
5.9L ENGINE
(4WD)
15.0 14.2
DANA
60 6.0
2.84
5.9L DIESEL ENGINE (MAN.TRANS.) 15.5 14.7
DANA
70 7.0
3.31
5.9L DIESEL ENGINE
(AUTO,
TRANS)
16.5 15.6
FRONT AXLE
PINTS
LITERS
ENGINE
CRANKCASE
QUARTS
LITERS
DANA
44
FBJ 5.6
2.65
3.9L,
5.2L & 5.9
ENGINES 4.0* 3.8*
DANA
60 F
6.5
3.07
5.9L DIESEL ENGINES 12.0*
11.4**
TRANSMISSION-AUTOMATIC
QUARTS
LITERS
FUEL TANK GALLON
LITERS
A
727 (5.9L
ENGINE) 8.4
7.9
STANDARD
3.9L & 5.2L ENGINES 22.0 83.0
A
998 (3.9L
ENGINE) 8.6
8.1
OPTIONAL 3.9L & 5.2L ENGINES 30.0 113.0
A
999 (5.2L
ENGINE) 8.6
8.1
5.9L ENGINE
{G
OR
D)
30.0 113.0
A
518 (5.2L & 5.9L
ENGINES) 10.2
9.6
AD 100
&
AW 100 34.0 128.0
TRANSMISSION-MANUAL
QUARTS
LITERS
TRANSFER
CASE
PINTS
LITERS
NV
4500
4.0
3.8
NP-205
4.5 2.13
GETRAG
360 (5
Speed)
3.5
3.3
NP-241
6.0
2.84
* Add
0.5 qt. or 0.45
liter
when
the oil filter
is
changed
*
*
Add
1 qt. or 0.9
liter
with
oil filter
change STARTING ASSISTANCE (JUMP STARTING)
WARNING:
DO NOT
ATTEMPT
TO
PUSH
OR
TOW
A
VEHICLE
TO
START
THE
ENGINE. UNBURNED FUEL COULD ENTER CATALYTIC CONVERTER
AND IGNITE AFTER
THE
ENGINE
IS
STARTED.
THIS COULD CAUSE
THE
CONVERTER
TO
OVER HEAT AND RUPTURE.
BOOSTER BATTERY
WARNING:
TO
PREVENT PERSONAL INJURY
OR,
DO
NOT
ALLOW BATTERY ACID
TO
CONTACT
EYES,
SKIN
OR
CLOTHING.
DO NOT
LEAN OVER
A
BATTERY WHEN CONNECTING JUMPER
CABLES.
DO
NOT
ALLOW
THE
POSITIVE
AND
NEGATIVE
CABLE
CLAMPS
TO
CONTACT EACH OTHER.
KEEP
OPEN FLAMES
AND
SPARKS
AWAY FROM
THE BATTERY ELECTROLYTE VENT HOLES.
AL
WAYS
WEAR
EYE
PROTECTION WHEN INVOLVED
WITH
VEHICLE BATTERIES.
If it becomes necessary to use a booster battery and
jumper cables to start an engine, use the following procedure.
J9200-86
(1) Engage the parking brake. Shift the automatic
transmission to PARK (if a manual transmission, shift to NEUTRAL).
(2) Turn off all lights, and all other electrical
loads.
(3)
Observe the battery condition indicator (Fig. 5).
If the battery condition indicator is light/bright col
ored (or yellow), replace the battery. Do not attempt
to jump start an engine when the condition indi
cator is light/bright colored (or yellow). If the
condition indicator is dark in the center (but without a green dot), proceed with connecting the jumper ca
bles.
WARNING:
THE
ELECTROLYTE (ACID)
IN A
DIS
CHARGED
BATTERY
CAN
FREEZE.
DO NOT AT
TEMPT
TO
JUMP START
AN
ENGINE BEFORE DETERMINING
THE
CONDITION
OF THE
BATTERY
ELECTROLYTE.
THE
BATTERY COULD EXPLODE
AND CAUSE SEVERE PERSONAL INJURY.
CAUTION:
Do not
permit
the
metal
surfaces
on the
vehicles
to
contact.
This
could
establish
ground
(negative)
continuity
between
the
vehicle
bodies.
This
could
cause
the
on-board
computers
to be
damaged.
In
addition
it
could
reduce
the
amount
of
current
flow
through
the
starter
motor.
Page 41 of 1502
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
Page 43 of 1502
0
- 24
LUBRICATION
AND
MAINTENANCE
•
CAUTION:
Do not
overfill
the
transmission.
(9) Adjust
the
level
of the ATF
accordingly.
It
is
important
to use the
correct fluid
in an
automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used. Dexron®
II
ATF
can be
used
if the
recommended fluid
is not
available,
(10) Insert
the
dipstick into
the
tube.
DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL
The chart below lists
the
intervals
at
which
the
transmission should
be
serviced. Also, refer
to the
Fluid Capacities chart
for
fill capacity.
AUTOMATIC TRANSMISSION SERVICE
IN-
TERVALS
Normal
Usage
Light
Duty
Cycle
60 000
km
37,500
miles
Heavy
Duty
Cycle
38
000 km 24,000
miles
Severe
Usage
19 000 km 12,000
miles
J9100-19
It
is
very important
to use the
correct fluid
in
an automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used.
An
equivalent
Dexron®
II ATF
could
be
used only
if the
recom
mended fluid
is not
available.
The torque converter does
not
have
a
drain plug.
No attempt should
be
made
to
drain
the
converter.
Refer
to
Group
21
—Transmissions
for
transmission
drain
and
refill procedures.
TRANSFER
CASE
(4WD
VEHICLES)
INSPECTION The NP205
and
NP241 transfer cases fluid level
should
be
checked whenever maintenance
is
neces
sary under
the
vehicle.
FLUID
LEVEL
The vehicle must
be
level when
the
fluid level
is checked.
The transfer case drain fill hole plugs
are
located
at
the
rear
of the
housing (Figs.
4 and 5).
Determine
the
transfer case fluid level according
to
the following procedure.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case.
The
fluid level should
be at the
bottom edge
of the
fill hole.
The
level
can be
slightly
below
the
bottom edge
of the
fill hole
if the
fluid
is
cold.
(3)
If the
level
is not
acceptable, raise
the
fluid
level
to the
bottom edge
of the
fill hole with: • MOPAR®ATF PLUS
or an
equivalent Dexron
II®
ATF
for
NP241 transfer case
• Multi-purpose gear
oil (API GL-5) or
engine
oil
(API
SG,
SG/CD
OR
SG/CE)
for
NP205 transfer
cases.
Add fluid
in
small amounts
to
raise
the
level. (4) Install
the
fill hole plug (Figs.
4 and 5).
Tighten
the
fill hole plug
to 27 N-m (20
ft-lbs) torque.
(5) Remove
the
support
and
lower
the
vehicle.
Fig.
4
HP241 Transfer
Case
Fig.
5
NP205 Transfer
Case
FLUID DRAIN
AND
REFILL The transfer case fluid should
be
changed every
60
000
km
(37,500 miles).
For
vehicles subject
to the
HEAVY DUTY CYCLE Maintenance Schedule,
a 58
000
km
(36,000 miles) interval
is
recommended.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case. (3) Place
an
appropriate container under
the
trans
fer case drain hole plug (Figs.
4 and 5).
(4) Remove
the
drain hole plug. Drain
the
fluid
from
the
transfer case into
the
container.