2002 DODGE RAM torque

(3) Remove the end plug, thermostat and spring
from transmission oil cooler (Fig. 3).
ASSEMBLY
(1) Throughly clean the thermostat bore on the
transmission oil cooler.
(2) Install new spring, thermostat, end plug and
snap ring.
(3) Install transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
INSTALLATION
(1) Install the oil cooler assembly to the A-shaped
radiator support bracket using the two upper mount-
ing bolts and mounting straps. Install the bolts but
do not tighten at this time.
(2) Install the radiator support bracket and oil
cooler (as an assembly) to the vehicle.
(3) Install the two lower radiator A-shaped support
bracket bolts. Do not tighten bolts at this time.
(4) Slide and position the oil cooler on the
A-shaped bracket until its lower mounting hole lines
up with the bolt hole on the vehicle body. Tighten the
oil cooler mounting strap bolts to 6 N´m (50 in. lbs.)
torque.
(5) Install the upper radiator A-shaped support
bracket bolt. Tighten all three radiator support
bracket mounting bolts to 11 N´m (95 in. lbs.) torque.
(6) Inspect quick connect fitting for debris and
install the quick-connect fitting on the cooler outler
tube until an audible ªclickº is heard. Pull apart to
verify connection.
(7) Connect battery negative cable.
(8) Start the engine and check all fittings for
leaks.
(9) Check the fluid level in the automatic trans-
mission (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 42RE/FLUID - STANDARD
PROCEDURE), (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 44RE/FLUID - STAN-
DARD PROCEDURE) or (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
46RE/FLUID - STANDARD PROCEDURE).
TRANS COOLER - 8.0L
DESCRIPTION
The air-to-oil cooler is located in front of and to the
left side of the radiator (Fig. 4). This cooler is sup-
plied as standard equipment on all models equipped
with an automatic transmission.
OPERATION
The transmission oil is routed through the cooler
where the cooler removes heat from the transmission
fluid, before returning to the transmission.
Fig. 2 Transmission Oil Cooler - 5.9L Engine
1 - UPPER RADIATOR SUPPORT BRACKET BOLT
2 - MOUNTING STRAPS (2)
3 - TRANS. OIL COOLER UPPER MOUNTING BOLT (2)
4 - TRANS. OIL COOLER LOWER MOUNTING BOLT (2)
5 - LOWER RADIATOR SUPPORT BRACKET BOLT (2)
6 - TRANSMISSION OIL COOLER
7 - RADIATOR SUPPORT BRACKET
Fig. 3 Transmission Oil Cooler Thermostat
Removal/Installation
1 - THERMOSTAT HOUSING
2 - SPRING
3 - END PLUG
4 - SNAP RING
5 - THERMOSTAT
BR/BETRANSMISSION 7 - 81
TRANS COOLER - 5.9L (Continued)

STANDARD PROCEDURE
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 RUBBER 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
COOLERS 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
7 - 82 TRANSMISSIONBR/BE
TRANS COOLER - 8.0L (Continued)

INSTALLATION
(1) Install the oil cooler and cooler line assembly to
the vehicle.
(2) Install three mounting bolts and tighten to 6
N´m (50 in. lbs.) torque.
(3) Connect the transmission cooling lines to the
oil cooler by pushing the rubber hoses onto the oil
cooler tubes. Tighten the worm gear clomps to 2 N´m
(18 in. lbs.)
(4) Start the engine and check all fittings for
leaks.
(5) Check the fluid level in the automatic trans-
mission (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 47RE/FLUID - STANDARD
PROCEDURE).
TRANS COOLER - 5.9L DIESEL
DESCRIPTION
All diesel models equipped with an automatic
transmission are equipped with both a main water-
to-oil cooler and a separate air-to-oil cooler. Both cool-
ers are supplied as standard equipment on diesel
engine powered models when equipped with an auto-
matic transmission.
The main water-to-oil transmission oil cooler is
mounted to a bracket on the turbocharger side of the
engine (Fig. 6).
The air-to-oil cooler is located in front of and to the
left side of the radiator (Fig. 7).
OPERATION
The transmission oil is routed through the main
cooler first, then the auxiliary cooler where addi-
tional heat is removed from the transmission oil
before returning to the transmission.
STANDARD PROCEDURE
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.
Fig. 6 Transmission Water-To-Oil CoolerÐDiesel
EngineÐTypical
1 - TRANSMISSION WATER-TO-OIL COOLER
Fig. 7 Auxiliary Transmission Oil CoolerÐDiesel
Engine
1 - CHARGE AIR COOLER (INTERCOOLER)
2 - QUICK-CONNECT FITTINGS (2)
3 - MOUNTING NUTS (2)
4 - MOUNTING BOLT
5 - TRANSMISSION OIL COOLER
7 - 84 TRANSMISSIONBR/BE
TRANS COOLER - 8.0L (Continued)

WARNING:
WEAR PROTECTIVE EYEWEAR THAT MEETS THE
REQUIREMENTS OF OSHA AND ANSI Z87.1±1968.
WEAR STANDARD INDUSTRIAL RUBBER 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
COOLERS 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.
(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)
BR/BETRANSMISSION 7 - 85
TRANS COOLER - 5.9L DIESEL (Continued)

(1) Disconnect both battery negative cables.
(2) Remove air cleaner assembly and air cleaner
intake hoses.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Disconnect coolant lines from cooler.
(5) Disconnect transmission oil lines from cooler.
Plug cooler lines to prevent oil leakage.
(6) Remove oil cooler mounting straps (Fig. 9).
(7) Lift oil cooler off of mounting bracket.
(8) If replacing cooler, make sure to transfer con-
verter drain back valve to new cooler.INSTALLATION
INSTALLATIONÐAIR TO OIL COOLER
(1) Carefully position the oil cooler assembly to the
vehicle.
(2) Install two nuts and one bolt. Tighten to 11
N´m (95 in. lbs.) torque.
(3) Connect the quick-connect fittings to the trans-
mission cooler lines.
(4) Install front bumper.
(5) Start the engine and check all fittings for
leaks.
(6) Check the fluid level in the automatic trans-
mission (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 47RE/FLUID - STANDARD
PROCEDURE).
INSTALLATION
(1) Position oil cooler on bracket.
(2) Install mounting straps.
(3) Connect transmission oil lines to cooler.
(4) Connect coolant hoses to cooler.
(5) Connect battery negative cables.
(6) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Check transmission oil level and fill as neces-
sary (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 47RE/FLUID - STANDARD
PROCEDURE).
(8) Install air cleaner assembly and air cleaner
intake hoses.
Fig. 9 Transmission Water-To- Oil CoolerÐDiesel
1 - TRANSMISSION WATER-TO-OIL COOLER
BR/BETRANSMISSION 7 - 87
TRANS COOLER - 5.9L DIESEL (Continued)

CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION.........................25
OPERATION...........................25
DIAGNOSIS AND TESTING - CHARGING
SYSTEM............................25
SPECIFICATIONS
GENERATOR RATINGS.................26
SPECIFICATIONS - TORQUE -
GENERATOR/CHARGING SYSTEM........27
BATTERY TEMPERATURE SENSOR
DESCRIPTION.........................27OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................28
GENERATOR
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................28
INSTALLATION.........................30
VOLTAGE REGULATOR
DESCRIPTION.........................30
OPERATION...........................30
CHARGING
DESCRIPTION
The charging system consists of:
²Generator
²Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
²Ignition switch
²Battery (refer to 8, Battery for information)
²Battery temperature sensor
²Check Gauges Lamp (if equipped)
²Voltmeter (refer to 8, Instrument Panel and
Gauges for information)
²Wiring harness and connections (refer to 8, Wir-
ing Diagrams for information)
OPERATION
The charging system is turned on and off with the
ignition switch. The system is on when the engine is
running and the ASD relay is energized. When the
ASD relay is on, voltage is supplied to the ASD relay
sense circuit at the PCM. This voltage is connected
through the PCM and supplied to one of the genera-
tor field terminals (Gen. Source +) at the back of the
generator.
The amount of direct current produced by the gen-
erator is controlled by the EVR (field control) cir-
cuitry contained within the PCM. This circuitry is
connected in series with the second rotor field termi-
nal and ground.
A battery temperature sensor, located in the bat-
tery tray housing, is used to sense battery tempera-
ture. This temperature data, along with data from
monitored line voltage, is used by the PCM to vary
the battery charging rate. This is done by cycling theground path to control the strength of the rotor mag-
netic field. The PCM then compensates and regulates
generator current output accordingly.
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including EVR
(field control) circuitry, are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for certain failures it detects. Refer to
On-Board Diagnostics in 25, Emission Control Sys-
tem for more DTC information and a list of codes.
The Check Gauges Lamp (if equipped) monitors:
charging system voltage,engine coolant tempera-
ture and engine oil pressure. If an extreme condition
is indicated, the lamp will be illuminated. This is
done as reminder to check the three gauges. The sig-
nal to activate the lamp is sent via the CCD bus cir-
cuits. The lamp is located on the instrument panel.
Refer to 8, Instrument Panel and Gauges for addi-
tional information.
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The following procedures may be used to diagnose
the charging system if:
²the check gauges lamp (if equipped) is illumi-
nated with the engine running
²the voltmeter (if equipped) does not register
properly
²an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²accessories being left on with the engine not
running
BR/BECHARGING 8F - 25

²a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test in 8, Battery for more information.
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBtscan tool. Per-
form the following inspections before attaching the
scan tool.
(1) Inspect the battery condition. Refer to 8, Bat-
tery for procedures.(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications.
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications in 7, Cooling System.
(6) Inspect automatic belt tensioner (if equipped).
Refer to 7, Cooling System for information.
(7) Inspect generator electrical connections at gen-
erator field, battery output, and ground terminal (if
equipped). Also check generator ground wire connec-
tion at engine (if equipped). They should all be clean
and tight. Repair as required.
SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINESMINIMUM TEST
AMPS
DENSO 56028920AB 1365.9L
GAS100
DENSO 56029913AA 1175.9L
GAS90
BOSCH 56028237AB 1175.9L
GAS90
BOSCH 56028238AB 1365.9L
GAS100
DENSO 56027221AD 1365.9L
DIESEL120
BOSCH 56028239AB 1365.9L
DIESEL120
BOSCH 56028560AA 136 8.0L 100
DENSO 560289200AC 136 8.0L 100
8F - 26 CHARGINGBR/BE
CHARGING (Continued)

SPECIFICATIONS - TORQUE - GENERATOR/
CHARGING SYSTEM
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Generator Mounting Bolts
- Gas Engine41 30-
Generator Upper Mounting
Bolt - Diesel Engine54 40 -
Generator Pivot Bolt/Nut -
Diesel Engine54 40 -
Generator Mounting
Bracket-to-Engine Bolt -
Diesel Engine24 18 -
Generator B+ Cable
Eyelet Nut12 9 108
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery.
OPERATION
The BTS is used to determine the battery temper-
ature and control battery charging rate. This temper-
ature data, along with data from monitored line
voltage, is used by the PCM to vary the battery
charging rate. System voltage will be higher at colder
temperatures and is gradually reduced at warmer
temperatures.
The PCM sends 5 volts to the sensor and is
grounded through the sensor return line. As temper-
ature increases, resistance in the sensor decreases
and the detection voltage at the PCM increases.
The BTS is also used for OBD II diagnostics. Cer-
tain faults and OBD II monitors are either enabled
or disabled, depending upon BTS input (for example,
disable purge and enable Leak Detection Pump
(LDP) and O2 sensor heater tests). Most OBD II
monitors are disabled below 20ÉF.
REMOVAL
The battery temperature sensor is located under
the vehicle battery (Fig. 1) and is attached (snapped
into) a mounting hole on battery tray. On models
equipped with a diesel engine (dual batteries), only
one sensor is used. The sensor is located under the
battery on drivers side of vehicle.
(1) Remove battery. Refer to 8, Battery for proce-
dures.Fig. 1 Battery Temperature Sensor Location
1 - BATT. TEMP. SENSOR
2 - BATTERY HOLD DOWN STRAP
3 - PIGTAIL HARNESS
4 - U-NUT
5 - U-NUT
6 - ELEC. CONNEC.
BR/BECHARGING 8F - 27
CHARGING (Continued)