2001 DODGE RAM battery replacement

ENGINE COOLANT
THERMOSTAT - 3.9L/5.2L/5.9L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on the 3.9L, 5.2L and 5.9L gas
powered engines is located beneath the thermostat
housing at the front of the intake manifold (Fig. 15).
The thermostat is a wax pellet driven, reverse pop-
pet choke type.
Coolant leakage into the pellet container will cause
the thermostat to fail in the open position. Thermo-
stats very rarely stick. Do not attempt to free a ther-
mostat with a prying device.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance,
increased exhaust emissions and crankcase condensa-
tion that can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTINGÐTHERMOSTAT
ON-BOARD DIAGNOSTICS
Allgasoline powered modelsare equipped with
On-Board Diagnostics for certain cooling system com-
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor-
mation. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM mem-
ory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer to
the Diagnosis section of this group for other probable
causes. For other DTC numbers, (Refer to 25 - EMIS-
SIONS CONTROL - DESCRIPTION).
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures information for diagnostic informa-
tion and operation of the DRB scan tool.
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
Factory installed thermostat housings on 3.9L,
5.2L and 5.9L engines are installed on a gasket with
an anti-stick coating. This will aid in gasket removal
and clean-up.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(3) Air Conditioned vehicles: Remove support
bracket (generator mounting bracket-to-intake mani-
fold) located near rear of generator (Fig. 16).
NOTE: On air conditioning equipped vehicles, the
generator must be partially removed.
Fig. 15 ThermostatÐ5.2L and 5.9L Gas Powered
Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
BR/BEENGINE 7 - 49

ENGINE COOLANT
THERMOSTAT - 8.0L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on all gas powered engines is
located beneath the thermostat housing at the front
of the intake manifold (Fig. 22).
The thermostat is a moveable sleeve type.
Coolant leakage into the pellet container will cause
the thermostat to fail in the open position. Thermo-
stats very rarely stick. Do not attempt to free a ther-
mostat with a prying device.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance,
increased exhaust emissions and crankcase condensa-
tion that can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTINGÐTHERMOSTAT
ON-BOARD DIAGNOSTICS
Allgasoline powered modelsare equipped with
On-Board Diagnostics for certain cooling system com-
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor-
mation. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM mem-
ory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer to
the Diagnosis section of this group for other probable
causes. For other DTC numbers, (Refer to 25 - EMIS-
SIONS CONTROL - DESCRIPTION).
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures information for diagnostic informa-
tion and operation of the DRB scan tool.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
A rubber lip-type seal with a metal shoulder is
pressed into the intake manifold beneath the thermo-
stat (Fig. 23).
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
Fig. 22 ThermostatÐ8.0L V-10 Engine
1 - COOLANT TEMP. SENSOR (FOR PCM)
2 - HEATER SUPPLY FITTING
3 - BOLTS (6)
4 - HOUSING WITH INTEGRAL SEAL
5 - THERMOSTAT
6 - RUBBER LIP SEAL
7 - TEMP. GAUGE SENDING UNIT
7 - 52 ENGINEBR/BE

to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result.Refer to the litera-
ture supplied with the cover for additional informa-
tion.
(1) To determine if the thermostat is defective, it
must be removed from the vehicle (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT THERMO-
STAT - REMOVAL).
(2) After the thermostat has been removed, exam-
ine the thermostat and inside of thermostat housing
for contaminants. If contaminants are found, the
thermostat may already be in a ªstuck openº position.
Flush the cooling system before replacing thermostat
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(3) Place the thermostat into a container filled
with water.
(4) Place the container on a hot plate or other suit-
able heating device.
(5) Place a commercially available radiator ther-
mometer into the water.
(6) Apply heat to the water while observing the
thermostat and thermometer.
(7) When the water temperature reaches 83ÉC
(181ÉF) the thermostat should start to open (valve
will start to move). If the valve starts to move before
this temperature is reached, it is opening too early.
Replace thermostat. The thermostat should be fully
open (valve will stop moving) at 95ÉC (203ÉF). If the
valve is still moving when the water temperature
reaches 203É, it is opening too late. Replace thermo-
stat. If the valve refuses to move at any time, replace
thermostat.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Disconnect the battery negative cables.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYSWEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove radiator hose clamp and hose from
thermostat housing.
(4) Remove the three (3) water outlet-to-cylinder
head bolts and remove the water outlet connector
(Fig. 27).
(5) Clean the mating surfaces of the water outlet
connector and clean the thermostat seat groove at
the top of the thermostat housing (Fig. 27).
INSTALLATION
(1) Install the thermostat into the groove in the
top of the thermostat housing (Fig. 27).
(2) Install the water outlet connector and bolts.
Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(3) Install the radiator upper hose and clamp.
(4) Fill the cooling system with coolant (Refer to 7
- COOLING - STANDARD PROCEDURE).
(5) Connect the battery negative cables.
(6) Start the engine and check for coolant leaks.
Run engine to check for proper thermostat operation.
Fig. 27 Thermostat Removal/Installation
1 - WATER OUTLET CONNECTOR
2 - THERMOSTAT HOUSING
3 - THERMOSTAT
BR/BEENGINE 7 - 55
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)

REMOVAL
(1) Disconnect battery negative cables.
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 7 - COOL-
ING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove hose clamps and hoses from radiator.
(4) Remove coolant reserve/overflow tank hose
from radiator filler neck nipple.
(5) The coolant recovery/reservoir does not require
removal. Disconnect the overflow hose from the radi-
ator.
(6) Disconnect electrical connectors at windshield
washer reservoir tank and remove tank.
(7) Remove the four fan shroud mounting bolts
(Fig. 37). Position shroud rearward over the fan
blades towards engine.
(8) Remove the two radiator upper mounting bolts
(Fig. 38).
(9) Lift radiator straight up and out of engine com-
partment. The bottom of the radiator is equipped
with two alignment dowels that fit into holes in the
lower radiator support panel (Fig. 38). Rubber bis-
cuits (insulators) are installed to these dowels. Take
care not to damage cooling fins or tubes on the radi-
ator and air conditioning condenser when removing.
CLEANING
Clean radiator fins are necessary for good heat
transfer. The radiator and air conditioning fins
should be cleaned when an accumulation of debris
has occurred. With the engine cold, apply cold water
and compressed air to the back (engine side) of the
radiator to flush the radiator and/or A/C condenser of
debris.
INSPECTION
Inspect the radiator side tanks for cracks, broken
or missing fittings also inspect the joint where the
tanks seam up to the radiator core for signs of leak-
age and/or deteriorating seals.
Fig. 37 Fan Shroud MountingÐ8.0L Engine
1 - RADIATOR SUPPORT
2 - RADIATOR
3 - BOLTS (4)
4 - FAN SHROUD
Fig. 38 Typical Radiator Mounting
1 - MOUNTING BOLTS
2 - RADIATOR
3 - ALIGNMENT DOWELS (2)
4 - RADIATOR SUPPORT
7 - 62 ENGINEBR/BE
RADIATOR - 8.0L (Continued)

ket has swollen and prevents vent valve from open-
ing, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket,
replace cap.Do not use a replacement cap that
has a spring to hold vent shut.A replacement cap
must be the type designed for a coolant reserve/over-
flow system with a completely sealed diaphragm
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.
WATER PUMP - 3.9L/5.2L/5.9L
DESCRIPTION
The water pump is located on the engine front
cover, and has an integral pulley attached (Fig. 46).
The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ven-
tilation. The water pump seals are lubricated by
antifreeze in the coolant mixture. Additional lubrica-
tion is not necessary.
OPERATION
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
DIAGNOSIS AND TESTINGÐWATER PUMP
A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
REMOVAL
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover.
On all 3.9L/5.2L/5.9L gas powered engines, a gas-
ket is used as a seal between the water pump and
timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for
fatigue cracks, loose blades or loose rivets that could
have resulted from excessive vibration. Replace fan if
any of these conditions are found. Also check condi-
tion of the thermal viscous fan drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - DIAGNOSIS AND TESTING).
(1) Disconnect negative cable from battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) Remove windshield washer reservoir tank from
radiator fan shroud.
Fig. 45 Radiator Pressure Cap
1 - STAINLESS-STEEL SWIVEL TOP
2 - RUBBER SEALS
3 - VENT VALVE
4 - RADIATOR TANK
5 - FILLER NECK
6 - OVERFLOW NIPPLE
7 - MAIN SPRING
8 - GASKET RETAINER
Fig. 46 Water Pump LocationÐTypical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
BR/BEENGINE 7 - 67
RADIATOR PRESSURE CAP (Continued)

WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906-B.(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
STANDARD PROCEDURE - FLUSHING COOLER
AND TUBES - WITHOUT RADIATOR IN-TANK
TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
(1) Remove cover plate filler plug on Tool 6906B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
Fig. 1 Automatic Transmission Oil
1 - UPPER RADIATOR SUPPORT BRACKET BOLT
2 - MOUNTING STRAPS (2)
3 - TRANS. OIL COOLER UPPER MOUNTING BOLTS (2)
4 - TRANS. OIL COOLER LOWER MOUNTING BOLT
5 - LOWER RADIATOR SUPPORT BRACKET BOLTS (2)
6 - TRANSMISSION OIL COOLER
7 - RADIATOR SUPPORT BRACKET
7 - 80 TRANSMISSIONBR/BE
TRANS COOLER - 3.9L/5.2L/5.9L (Continued)

(2) Reinstall filler plug on Tool 6906B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Remove the transmission oil cooler from the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - REMOVAL)
(8) Remove the transmission oil cooler thermostat.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - DISASSEMBLY)
(9) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(10) Re-connect the oil cooler to the transmission
cooler lines.
(11) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oil
cooler.
(14) Install Special Tool Cooler Plug 8414 into the
transmission oil cooler.
(15) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(16) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the main oil cooler core pas-
sages only.
(17) Turn pump OFF.
(18) Remove the thermostat cover from the oil
cooler.
(19) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.(20) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - ASSEMBLY)
(21) Install the transmission oil cooler onto the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION)
(22) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(23) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(24) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission fluid.
(25) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(26) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
REMOVAL
(1) Disconnect battery negative cable.
(2) Place a drain pan under the oil cooler lines.
(3) Disconnect the transmission oil cooler line
quick-connect fitting at the cooler outlet using the
quick connect release tool 6935. Loosen clamp from
inlet connection and slide hose off of nipple. Plug
cooler lines to prevent oil leakage.
(4) Remove the oil cooler lower mounting bolt (oil
cooler-to-vehicle body) (Fig. 2).
(5) Remove three bolts (radiator support bracket-
to-body) . Remove this A-shaped support bracket and
the transmission oil cooler as an assembly from the
vehicle. Take care not to damage the radiator core or
A/C condenser fins with the cooling lines when
removing.
(6) Remove oil cooler from A-shaped support
bracket by removing two upper mounting strap bolts
and mounting straps at support bracket (Fig. 2).
(7) Remove oil cooler from the A-shaped radiator
support bracket.
DISASSEMBLY
NOTE: The transmission oil cooler uses an internal
thermostat to control transmission oil flow through
the cooler. This thermostat is servicable.
(1) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(2) Remove the snap ring retaining the thermostat
end plug (Fig. 3).
BR/BETRANSMISSION 7 - 81
TRANS COOLER - 3.9L/5.2L/5.9L (Continued)

STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES - WITH RADIATOR
IN-TANK TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
The only recommended procedure for flushing cool-
ers and lines is to use Tool 6906-B Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.(2) Reinstall filler plug on Tool 6906-B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
STANDARD PROCEDURE - FLUSHING COOLER
AND TUBES - WITHOUT RADIATOR IN-TANK
TRANSMISSION OIL COOLER
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
(1) Remove cover plate filler plug on Tool 6906B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
Fig. 4 Automatic Transmission Oil CoolerÐ8.0L
Engine
1 - RADIATOR SUPPORT
2 - OIL COOLER MOUNTING BOLTS
3 - TRANSMISSION OIL COOLER
4 - TRANSMISSION OIL COOLER LINES
BR/BETRANSMISSION 7 - 83
TRANS COOLER - 8.0L (Continued)