2002 DODGE RAM engine coolant

SPECIFICATIONS
TORQUE - DIESEL ENGINE
DESCRIPTION N m Ft. Lbs. In. Lbs.
Accelerator Pedal Position Sensor Bracket Bolts 12 9 105
Air Intake Housing Bolts 24 18 212
Banjo Fittings at top of Filter/Separator 24 18 212
Banjo Fittings at Fuel Return Lines 24 18 212
Banjo Fitting At Fuel Supply Line (Injector Pump) 24 18 212
Camshaft Position Sensor (CMP) Bolt 20 15 177
ECM Mounting Bolts 24 18 212
Engine Coolant Temperature (ECT) Sensor 14 10 124
Engine Lifting Bracket Bolts 77 57 681
Fuel Drain Manifold ªTº Fitting 12 9 106
Fuel Filter Canister Bracket Bolts 24 18 212
Fuel Filter Canister Mounting Nut 14 10 124
Fuel Filter Drain Valve Mounting Screws 3-5 2-4 30-40
Fuel Heater Screws 2-3 1-2 15-20
Fuel Injector Clamp Bolts 10 7 89
Fuel Pump Module Locknut 24-44 18-32 212-389
Fuel Tank Mounting Nuts 41 30 363
Fuel Transfer Pump Mounting Nuts 12 9 106
High-Pressure Fuel Line Fittings (at Injectors) 38 28 336
High-Pressure Fuel Line Fittings (at Pump) 24 18 212
High-Pressure Fuel Line Clamps-to-Intake Manifold 24 18 212
Hose Clamps at Intercooler Tube 8 6 72
Injection Pump-to-Injection Pump Gear Nut 170 125
Injection Pump Mounting Nuts 43 32 380
Intake Manifold Air Temperature (IAT) Sensor 14 10
Intake Manifold Air Heater Relay Bolts 4.5 40
Manifold Air Pressure (MAP) Sensor 14 10
PCM Mounting Bolts 4 35
Overflow Valve-to-Fuel Injection Pump 24 18
Water-In-Fuel (WIF) Sensor 2-3 15-20
14 - 94 FUEL INJECTION - DIESELBR/BE
FUEL INJECTION - DIESEL (Continued)

(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, disassemble and clean the steer-
ing gear and flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
REMOVAL - GASOLINE ENGINE
(1) Remove the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) OR (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - REMOVAL).
(2) Remove the hoses from the power steering
pump and cap the fittings.
(3) Remove battery ground cable and unthread
stud from cylinder head, do not remove from bracket.
(4) Loosen upper bracket bolt and remove the
lower bracket to engine block bolts.
(5) Pivot the pump assembly past the coolant tube.
(6) Remove the upper stud and remove upper bolt
from cylinder head.
(7) Remove steering pump and mounting bracket
from engine as an assembly.
(8) Remove the pump pulley with Puller C-4333, to
access pump attaching bolts, (Refer to 19 - STEER-
ING/PUMP/PULLEY - REMOVAL).
(9) Remove the front pump bracket (Fig. 3). On
8.0L engine remove rear pump bracket (Fig. 4).
Fig. 3 Pump Mounting 8.0L
1 - FRONT BRACKET
2 - REAR BRACKET
3 - STEERING PUMP
4 - PULLEY
Fig. 4 Pump Mounting 8.0L
1 - FRONT BRACKET
2 - REAR BRACKET
3 - STEERING PUMP
4 - PULLEY
BR/BEPUMP 19 - 35
PUMP (Continued)

INSTALLATION
INSTALLATION - GASOLINE ENGINE
(1) Install the front pump bracket and tighten
bolts to 47 N´m (35 ft. lbs.). On 8.0L engine install
rear pump bracket and tighten nut to 47 N´m (35 ft.
lbs.), tighten bolts to 24 N´m (18 ft. lbs.).
(2) Install the pump pulley with Installer
C-4063±B, (Refer to 19 - STEERING/PUMP/PULLEY
- INSTALLATION).
(3) Install steering pump assembly on the engine
block. Install the upper stud and bolt in bracket.
(4) Pivot the pump down past the coolant tube and
install the lower bolts in bracket.
(5) Tighten the bolts and nut to 41 N´m (30 ft.
lbs.).
(6) Connect the hoses to the pump.
(7) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION), (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION).
(8) Fill the reservoir with power steering fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
INSTALLATION - DIESEL ENGINE
(1) Install the two pump body spacers.
(2) Rotate the drive gear until the steering pump
and vacuum pump drive dogs align. Install the steer-
ing pump onto the vacuum pump bracket. Use care
to avoid damaging the oil seal in the vacuum pump
during installation.The steering pump housing
and spacers must mate completely with the
vacuum pump bracket.
(3) Install the vacuum pump bracket to steering
pump nuts and tighten to 24 N´m (18 ft. lbs.).
(4) Position new gasket on vacuum pump assem-
bly. Use sealer if necessary to retain the gasket.
(5) Align and install the pump assembly on the
engine. Ensure the steering pump stud is inserted
into the block bracket. Tighten the pump- to-engine
block attaching bolts to 77 N´m (57 ft. lbs.).
(6) Install the steering pump to attaching bracket
nut and tighten to 24 N´m (18 ft. lbs.).
(7) Remove plug and install the oil pressure send-
ing unit and electrical connector.
(8) Install the oil feed line to the vacuum pump.
Tighten the oil line connection to 7 N´m (60 in. lbs./ 5
ft. lbs.).
Fig. 8 Bracket Mounting Nuts
1 - VACUUM PUMP
2 - ATTACHING NUTS
3 - STEERING PUMP
4 - PUMP SPACERS
5 - OIL FEED FITTING
Fig. 9 Steering Pump & Vacuum Pump
1 - PUMP SHAFT
2 - VACUUM FITTING
3 - VACUUM PUMP DRIVE
4 - OIL SEAL
5 - MOUNTING BRACKET
6 - DRIVE DOG
7 - PUMP SPACERS
BR/BEPUMP 19 - 37
PUMP (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.4. Check with DRBTscan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRBTscan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRBTscan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
21 - 110 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has two primary causes.
(1) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(2) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to reverse flush cooler and lines after
repair
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.
Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary coolers
as well. The torque converter should also be replaced
whenever a failure generates sludge and debris. This is
necessary because normal converter flushing procedures
will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
Fig. 88 Installing Overdrive Housing Seal
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 157
EXTENSION HOUSING SEAL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.4. Check with DRBTscan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRBTscan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRBTscan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
21 - 282 AUTOMATIC TRANSMISSION - 47REBR/BE
AUTOMATIC TRANSMISSION - 47RE (Continued)

INSTALLATION
(1) Place seal in position on overdrive housing.
(2) Drive seal into overdrive housing with Seal
Installer C-3995-A (Fig. 82).
(3) Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks
made at removal and connect propeller shaft to rear
axle pinion yoke.
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluidexpansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has two primary causes.
(1) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(2) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to reverse flush cooler and lines after
repair
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
Fig. 81 Removing Overdrive Housing Yoke Seal
1 - SPECIAL TOOL C-3985-B
2 - SEAL
Fig. 82 Installing Overdrive Housing Seal
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
BR/BEAUTOMATIC TRANSMISSION - 47RE 21 - 327
EXTENSION HOUSING SEAL (Continued)

DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performing the following tests, refer to Cool-
ing for the procedures to check the engine coolant
level and flow, engine coolant reserve/recovery sys-
tem operation, accessory drive belt condition and ten-
sion, radiator air flow and the fan drive operation.
Also be certain that the accessory vacuum supply
line is connected at the engine vacuum source.
MAXIMUM HEATER OUTPUT
Engine coolant is delivered to the heater core
through two heater hoses. With the engine idling atnormal operating temperature, set the temperature
control knob in the full hot position, the mode control
switch knob in the floor position, and the blower
motor switch knob in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged at the HVAC housing floor
outlets. Compare the test thermometer reading to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature15.5É C
(60É F)21.1É C
(70É F)26.6É C
(80É F)32.2É C
(90É F)
Minimum Air Temperature at
Floor Outlet62.2É C
(144É F)63.8É C
(147É F)65.5É C
(150É F)67.2É C
(153É F)
If the floor outlet air temperature is too low, refer
to Cooling to check the engine coolant temperature
specifications. Both of the heater hoses should be hot
to the touch. The coolant return heater hose should
be slightly cooler than the coolant supply heater
hose. If the return hose is much cooler than the sup-
ply hose, locate and repair the engine coolant flow
obstruction in the cooling system. Refer to Cooling
for the procedures.
An alternate method of checking heater perfor-
mance is to use a DRBIIItscan tool to monitor the
engine coolant temperature. The floor outlet air tem-
perature reading should be no more than 4.5É C (40É
F) lower than the engine coolant temperature read-
ing.
OBSTRUCTED COOLANT FLOW Possible loca-
tions or causes of obstructed coolant flow:
²Faulty water pump.
²Faulty thermostat.
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²A plugged heater core.If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is still
low, a mechanical problem may exist.
MECHANICAL PROBLEMS Possible locations or
causes of insufficient heat:
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²A faulty, obstructed or improperly installed
blend door.
²A faulty blower system.
²A faulty a/c heater control.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
a/c heater control panel, the following could require
service:
²A faulty a/c heater control.
²A faulty blend door actuator.
²A faulty, obstructed or improperly installed
blend door.
²An obstructed cowl air intake.
²The engine cooling system.
Heater Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
INSUFFICIENT HEATER
OUTPUT.1. Incorrect engine
coolant level.1. Check the engine coolant level. Refer to Cooling for
the procedures.
2. Air trapped in engine
cooling system.2. Check the operation of the coolant reserve/recovery
system. Refer to Cooling for the procedures.
24 - 6 HEATING & AIR CONDITIONINGBR/BE
HEATING & AIR CONDITIONING (Continued)