2002 DODGE RAM ECU

(5) Vacuum leak ? Check condition of banjo fit-
tings, banjo bolts, and sealing washers. If leaks are
not present, a leak exists within VP-44 pump.
Replacement of VP-44 requires authorization.DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM
Air will enter the fuel system whenever fuel supply
lines, separator filters, injection pump, high-pressure
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start-
ing, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from the system
before starting the engine.
Inspect the fuel system from the fuel transfer
pump to the injectors for loose connections. Leaking
fuel is an indicator of loose connections or defective
seals. Air can also enter the fuel system between the
fuel tank and the transfer pump. Inspect the fuel
tank and fuel lines for damage that might allow air
into the system.
For air bleeding, refer to the Air Bleed Procedure.
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS
LOW-PRESSURE LINES
Fuel supply line restrictions or a defective fuel
transfer pump can cause starting problems and pre-
vent engine from accelerating. The starting problems
include; low power and/or white fog like exhaust.
Test all fuel supply lines for restrictions or block-
age. Flush or replace as necessary. Bleed fuel system
of air once a fuel supply line has been replaced. Refer
to Air Bleed Procedure for procedures.
To test for fuel line restrictions, a vacuum restric-
tion test may be performed. Refer to Fuel Transfer
Pump Pressure Test.
HIGH-PRESSURE LINES
Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance,
engine mis-fire and white smoke from exhaust.
Examine all high-pressure lines for any damage.
Each radius on each high-pressure line must be
smooth and free of any bends or kinks.
Replace damaged, restricted or leaking high-pres-
sure fuel lines with correct replacement line.
CAUTION: All high-pressure fuel lines must be
clamped securely in place in holders. Lines cannot
contact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. If line is kinked or bent, it
must be replaced. Use only recommended lines
when replacement of high-pressure fuel line is nec-
essary.
Fig. 9(T(FITTING - FRONT DISCONNECTED
1 - FUEL DRAIN LINE (TO VP-44 PUMP)
2 - RUBBER SEAL/GASKET
3 - RUBBER CAP
4 - FUEL DRAIN LINE
5-9T9FITTING
Fig. 10 VACUUM PUMP AT VP-44 PUMP
1 - VP-44 DRAIN LINE
2 - VP-44 INJECTION PUMP
3 - HAND-OPERATED PUMP
14 - 60 FUEL DELIVERY - DIESELBR/BE
FUEL DELIVERY - DIESEL (Continued)

DESCRIPTIONÐHIGH PRESSURE FUEL LINES
The high-pressure fuel lines are the 6 lines located
between the fuel injection pump and the fuel injector
connector tubes (Fig. 45). All other fuel lines are con-
sidered low-pressure lines.
OPERATIONÐHIGH PRESSURE FUEL LINES
CAUTION: The high-pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. If lines are ever
kinked or bent, they must be replaced. Use only the
recommended lines when replacement of high-pres-
sure fuel line is necessary.
High-pressure fuel lines deliver fuel under pres-
sure of up to approximately 120,000 kPa (17,405 PSI)
from the injection pump to the fuel injectors. The
lines expand and contract from the high-pressure
fuel pulses generated during the injection process. All
high-pressure fuel lines are of the same length and
inside diameter. Correct high-pressure fuel line usage
and installation is critical to smooth engine opera-
tion.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE
FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 120,000 kPa (17,400 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND
NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-
PRESSURE FUEL LEAKS WITH A SHEET OF CARD-
BOARD. HIGH FUEL INJECTION PRESSURE CAN
CAUSE PERSONAL INJURY IF CONTACT IS MADE
WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 46). If a high-pressure line con-
nection is leaking, bleed the system and tighten the
connection. Refer to the Air Bleed Procedure in this
group for procedures. Replace damaged, restricted or
leaking high-pressure fuel lines with the correct
replacement line.
Fig. 45 High-Pressure Fuel Lines
Fig. 46 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
14 - 78 FUEL DELIVERY - DIESELBR/BE
FUEL LINES (Continued)

CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
REMOVAL
High-pressure lines are used between the fuel
injection pump and the fuel injectors only. All high-
pressure fuel lines are of the same length and inside
diameter. Correct high-pressure fuel line usage and
installation is critical to smooth engine operation.
CAUTION: Refer to Cleaning Fuel System Parts.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at cylinder head
and injection pump ends.
(3) Remove cable cover (Fig. 47). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 47). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.Do not
remove any cables at lever.(4) Disconnect wiring harness (clip) at bottom of
Accelerator Pedal Position Sensor (APPS) mounting
bracket (Fig. 48).
(5) Using 2 small screwdrivers, pry front wiring
clip (Fig. 49) from cable bracket housing. Position
wiring harness towards front of engine.
(6) Remove electrical connector from APPS by
pushing connector tab rearward while pulling down
on connector (Fig. 50).
(7) Disconnect 2 electrical cables from cable
mounting studs (Fig. 51) at intake air heater on top
of intake manifold.
(8) Remove engine oil dipstick from engine.
(9) Remove engine oil dipstick tube support
mounting bolt (Fig. 51) and position tube to side.
(10) Disconnect clamps and remove air tube
(intake manifold-to-intercooler) (Fig. 49).
(11) Remove 4 air intake housing mounting bolts
and remove housing (Fig. 52) and (Fig. 51). Position
ground cable at top of air intake housing to front of
engine.
(12) Remove intake manifold air heater element
block from engine (Fig. 53). Discard old upper and
lower gaskets
(13) Remove 3 cable bracket housing mounting
bolts (Fig. 52). Carefully position cable bracket and
cable assembly to side of engine.Leave cables con-
nected to lever.
Fig. 47 Cable/Lever/Throttle Linkage Cover
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 48 Wiring Clip at APPS
1 - LEVER
2 - MOUNTING BOLTS (6)
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
BR/BEFUEL DELIVERY - DIESEL 14 - 79
FUEL LINES (Continued)

(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable cover (Fig. 6). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 6). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(3) Using finger pressure only, disconnect end of
speed control servo cable from throttle lever pin by
pulling forward on connector while holding lever
rearward (Fig. 7).DO NOT try to pull connector
off perpendicular to lever pin. Connector will
be broken.
(4) Using two small screwdrivers, pry throttle
cable connector socket from throttle lever ball (Fig.
7).Be very careful not to bend throttle lever
arm.
(5) Disconnect transmission control cable at lever
arm (if equipped). Refer to 21, Transmission.
(6) Squeeze pinch tabs on speed control cable (Fig.
7) and pull cable rearward to remove from cable
mounting bracket.
(7) Squeeze pinch tabs on throttle cable (Fig. 7)
and pull cable rearward to remove from cable mount-
ing bracket.
(8) If equipped with an automatic transmission,
refer to 21, Transmission for transmission control
cable removal procedures.
(9) Disconnect wiring harness clip (Fig. 8) at bot-
tom of bracket.
(10) Remove 6 mounting bolts (Fig. 8) and par-
tially remove APPS assembly from engine. After
assembly is partially removed, disconnect electrical
connector from bottom of sensor by pushing on con-
nector tab (Fig. 9).
(11) Remove APPS assembly from engine.
INSTALLATION
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assem-
bly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 6) .
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(3) Connect wiring harness clip (Fig. 8) at bottom
of bracket.
(4) If equipped with an automatic transmission,
refer to Group 21, Transmission for transmission con-
trol cable installation procedures.
(5) Install speed control cable into mounting
bracket. Be sure pinch tabs (Fig. 7) have secured
cable.(6) Install throttle cable into mounting bracket. Be
sure pinch tabs (Fig. 7) have secured cable.
(7) Connect throttle cable at lever (snaps on).
(8) Connect speed control cable to lever by pushing
cable connector rearward onto lever pin while hold-
ing lever forward.
(9) Install cable cover.
(10) Connect both negative battery cables to both
batteries.
(11)ECM Calibration:Turn key to ON position.
Without starting engine, slowly press throttle pedal
to floor and then slowly release. This step must be
done (one time) to ensure accelerator pedal position
sensor calibration has been learned by ECM. If not
done, possible DTC's may be set.
(12) Use DRB scan tool to erase any DTC's from
ECM/PCM.
FUEL INJECTOR
DESCRIPTION
Six individual, high-pressure fuel injectors are
used. The injectors are vertically mounted (Fig. 10)
into a bored hole in the top of the cylinder head. This
bored hole is located between the intake/exhaust
valves.
Fig. 10 Fuel Injector Location
1 - CLAMP
2 - FUEL INJECTOR
3 - BORED HOLE
4 - SHIM
5 - BOLTS
BR/BEFUEL INJECTION - DIESEL 14 - 97
ACCELERATOR PEDAL POSITION SENSOR (Continued)

INSTALLATION
(1) Install cable through mounting hole on cable
mounting bracket (Fig. 37). Cable snaps into bracket.
Be sure 2 pinch tabs are secure.
(2) Using large pliers, connect cable end socket to
throttle lever ball (snaps on).
(3) Install remaining cable housing end into and
through dash panel opening (snaps into position).
The two plastic pinch tabs should lock cable to dash
panel.
(4) From inside vehicle, hold up accelerator pedal.
Install throttle cable core wire and plastic cable
retainer into and through upper end of pedal arm
(the plastic retainer is snapped into pedal arm).
When installing plastic retainer to accelerator pedal
arm, note index tab on pedal arm (Fig. 39). Align
index slot on plastic cable retainer to this index tab.
(5) Connect negative battery cables to both batter-
ies.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) Install cable/lever cover.
Fig. 39 Cable Removal/Installation at Pedal
1 - PINCH TWO TABS FOR CABLE REMOVAL
2 - DASH PANEL
3 - CABLE CORE WIRE
4 - THROTTLE PEDAL ARM
5 - INDEX TAB
6 - CABLE RETAINER
7 - CABLE STOP
14 - 110 FUEL INJECTION - DIESELBR/BE
THROTTLE CONTROL CABLE (Continued)

HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds. Severe highly audible transmission noise is
generally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant
will promote rapid wear of gears, synchros, shift
rails, forks and bearings. The overheating caused by
a lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.
(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(9) Remove rear crossmember.
(10) Remove clutch slave cylinder splash shield, if
equipped.
Fig. 4 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
21 - 4 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(4) Install splined Socket 6993 4X2 Socket 6984
4X4 to retain mainshaft while removing the fifth
gear nut.
(5) Install breaker bar in socket wrench (Fig. 9)
NOTE: Wedge breaker bar handle against work-
bench. Purpose of socket wrench and breaker bar
is to prevent mainshaft from turning while nut is
loosened.
(6) Remove fifth gear nut, then remove belleville
washer from mainshaft.FIFTH GEAR
(1) Remove roll pins that secure countershaft fifth
gear shift fork to shift rail with pin punch (Fig. 10).
Drive roll pins are out from the bottom of fork.
(2) Remove fifth gear clutch hub and gear snap
ring on countershaft (Fig. 11).
(3) Remove countershaft fifth gear clutch gear and
stop ring.
(4) Remove fifth gear shift fork and gear assembly.
Remove assembly by tapping fork off rail with plastic
mallet.
(5) Remove fifth gear shift fork from sleeve.
(6) Remove sleeve, struts and strut springs from
countershaft fifth gear hub, if necessary.
Fig. 8 Mainshaft Spline Seal
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 9 Fifth Gear Nut
1 - WRENCH 6443 OR 6743
2 - FIFTH GEAR NUT
3 - SPLINE SOCKET 6993 OR 6984
Fig. 10 Fifth Gear Shift Fork Roll Pins
1 - FORK ROLL PINS
2 - FIFTH GEAR SHIFT FORK
Fig. 11 Countershaft Fifth Gear Clutch Gear Snap
Ring
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
21 - 6 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(7) Remove countershaft fifth gear needle bearing
assembly (Fig. 12).
(8) Remove cone shaped rear bearing thrust
washer from end of countershaft (Fig. 13). Note posi-
tion of washer and washer bore notch for locating pin
for assembly reference.
(9) Remove and retain thrust washer locating pin
from countershaft.
(10) Remove mainshaft overdrive fifth gear with
Puller Tool Set 6444.
(11) Position first Puller Jaw 6459 or 6820 on gear
(Fig. 14).
(12) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 4X2 or 6444-4 4X4 vehicles (Fig. 15).(13) Slide assembled puller flange and rods onto
output shaft. Then seat flange in notch of puller jaw
(Fig. 15).
(14) Position second puller jaw on gear and in
notch of puller flange (Fig. 16).
(15) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place (Fig. 16).
(16) Install Puller and Bolt 6444 on puller rods.
Then secure puller to rods with retaining nuts (Fig.
17).
(17) Tighten puller bolt to remove gear from shaft
splines (Fig. 17).
Fig. 12 Countershaft Fifth Gear Needle Bearing
1 - FIFTH GEAR NEEDLE BEARING
2 - COUNTERSHAFT
Fig. 13 Countershaft Rear Bearing Thrust Washer
1 - THRUST WASHER
(CONE SHAPED)
2 - THRUST WASHER PIN
Fig. 14 First Puller Jaw On Mainshaft Fifth
(Overdrive) Gear
1 - MAINSHAFT FIFTH GEAR
2 - JAWS 6459 OR 6820
3 - MAINSHAFT
Fig. 15 Seating Puller Flange In First Puller
1 - JAWS 6459 or 6820
2 - PULLER FLANGE 6444-1
BR/BEMANUAL - NV4500 21 - 7
MANUAL - NV4500 (Continued)