1993 DODGE TRUCK brake

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

10 INTRODUCTION
•
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

ID

HIGH
BEAM P
FOG UGHTS -&
HEADLIGHTS,
PARKING UGHTS, PANEL UGHTS TURN SIGNAL A
HAZARD WARNING WINDSHIELD
WASHER
WINDSHIELD WIPER WINDSHIELD WIPER
AND WASHER WINDSCREEN DEMISTING
AND DEFROSTING *

VENTILATING
FAN 8
M f

REAR
WINDOW DEFOGGER
sp

REARWINLX)W WIPER
CD
l
m

REAR
WINDOW WASHER FUEL ENGINE COOLANT
TEMPERATURE BATTERY CHARGING
CONDITION ENGINE OIL

SEAT
BELT

(©) (®) ky

11 J

LIGHTER

BRAKE
FAILURE
PARKING
BRAKE
FRONT HOOD
REAR
HOOD

(TRUNK)
HORN
11 J

LIGHTER
93IN-9

INTERNATIONAL VEHICLE CONTROL AND DISPLAY

SYMBOLS
The graphic symbols illustrated in the chart below
are used to identify various instrument controls. The
symbols correspond to the controls and displays that are located on the instrument panel.

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 - 4
LUBRICATION
AND
MAINTENANCE

COMPONENTS
REQUIRING
NO
LUBRICATION

There are many components that should not be lu­
bricated. The components that should not be lubri­ cated are: • Air pumps
• Generator bearings
• Brake booster cylinder • Clutch release bearings
• Distributors
• Drive belts • Drive belt idler pulleys • Drive shaft center bearings
• Idler arms • Rubber bushings
• Starter motor bearings • Suspension strut bearings
• Rear spring shackle bolts • Rear wheel bearings (not equipped with a Dana
or 70 axle)
• Throttle control cables
• Throttle linkage ball joints • Water pump bearings

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

>

•
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.

0 - 12
LUBRICATION
AND
MAINTENANCE

• A vehicle equipped with SAE approved sling-type
towing equipment can be used (Fig. 10). However,
many vehicles are equipped with air dams, spoilers, and/or ground effect panels. In this case a wheel-lift
towing vehicle or a flat-bed hauling vehicle is recom­ mended (Fig. 10). If a flat bed device is used, the ap­
proach angle should not exceed 15 degrees.
GROUND CLEARANCE The lifted wheels of the disabled vehicle should be
a minimum of 10 cm (4 in.) off the ground. Make
sure there is enough clearance at the opposite end.
This is critical when towing over rough terrain. If necessary, the rear ground clearance can be in­creased by removing the wheels from the lifted end
and then towing with the lifted end closer to the
ground. If the rear wheels are removed, secure the
brake drums. A 20 cm (8 in.) ground clearance must
be maintained between brake drums or rotors and the ground.
SAFETY PRECAUTIONS The following safety precautions must be consid­
ered when preparing for and during a vehicle towing operation:
• Remove exhaust pipe tips that interfere with the
tow sling and crossbar • Padding should be placed between the tow sling/
crossbar and any painted surfaces
• If the vehicle is damaged, secure the loose and pro­
truding parts
• Always use a safety chain system that is indepen­ dent of the lifting and towing equipment
• When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or
hoses
• Do not allow any of the towing equipment to con­
tact the fuel tank
• Do not tow the vehicle by connecting to the front
or rear shock absorbers
• The operator should not go under a vehicle while
it is lifted by the towing equipment. The vehicle
should first be supported by safety stands
• Do not allow passengers in a vehicle being towed
• Observe all state and local laws involving warning signals, night illumination, speed, etc.
• Do not exceed a towing speed of 48 km/h (30 mph)
• Avoid towing distances of more than 24 km (15
miles) whenever possible • Do not attach tow chains or a tow sling to a
bumper, the steering linkage, the universal joints, or a drive shaft
REAR-END RAISED TOWING It is recommended that the rear-end raised towing
method be used. Vehicles can be towed with the front
wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph) (Fig. 11). (1) Attach the J-hooks around the axle shaft tubes
outboard of the rear springs. (2) Position and center the sling under and for­
ward of the rear bumper. (3) Attach safety chains (with pads) at each end of
the rear bumper.
(4) Turn the ignition switch to the OFF position to
unlock the steering wheel. (5) Clamp the steering wheel with the front wheels
in the straight ahead position.

CAUTION:
Do not use the steering
column
lock
to

secure
front
wheel
in the straight-ahead
position.

(6) Shift the transmission to NEUTRAL.

POSITION CENTER BAR FORWARD
OF
BUMPER
-
/
J-HOOKS OUTBOARD
OF
SPRINGS
RN967A

Fig. 11 Rear-End
Raised
Towing
FRONT'END RAISED TOWING If a vehicle cannot be towed from the rear, the
front-end raised towing method normally can be
used (Fig. 12). (1) Center the sling with the bumper and position
it at the frame front crossmember.

CAUTION:
Use tow
chains
with
J-hooks
for
con­
necting
to the
disabled
vehicle's
lower
suspension
arms.
Never use
T-hooks.

(2) Route the J-hooks and tow chains over the
steering linkage outboard of the coil spring.
(3) Attach the J-hooks to the outer end of the
lower suspension arms.
(4) Raise the vehicle.
(5.) Attach the safety chains to the disabled vehicle
at the frame rails.
Vehicles equipped with a MANUAL TRANSMIS­
SION can be towed with the rear wheels on the