2002 DODGE RAM power

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
OPERATION............................2
WARNING.............................2
DIAGNOSIS AND TESTING - CLUTCH........2
SPECIFICATIONS - CLUTCH...............7
CLUTCH DISC
REMOVAL.............................7
INSTALLATION..........................8
CLUTCH HOUSING
DIAGNOSIS AND TESTING - CLUTCH
HOUSING............................9
REMOVAL.............................11
INSTALLATION.........................11
CLUTCH RELEASE BEARING
REMOVAL.............................12
INSTALLATION.........................12FLYWHEEL
DIAGNOSIS AND TESTING - FLYWHEEL.....13
DISASSEMBLY.........................13
ASSEMBLY............................14
PILOT BEARING
REMOVAL.............................14
INSTALLATION.........................14
CLUTCH PEDAL
REMOVAL.............................15
INSTALLATION.........................15
LINKAGE
REMOVAL.............................15
INSTALLATION.........................16
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................17
OPERATION...........................17
CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, dry-
type disc, diaphragm style pressure plate (Fig. 1) and
hydraulic linkage. The flywheel is bolted to the rear
flange of the crankshaft. The clutch pressure plate is
bolted to the flywheel with the clutch disc between
these two components. The clutch system provides
the mechanical, link between the engine and the
transmission. The system is designed to transfer the
torque output of the engine, to the transmission
while isolating the transmission from the engine fir-
ing pulses to minimize concerns such as gear rattle.
Fig. 1 ENGINE POWERFLOW
BR/BECLUTCH 6 - 1

DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrain control module (PCM) has been
programmed to monitor certain cooling system com-
ponents:
²If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) can be set.
²If an open or shorted condition has developed in
the relay circuit controlling the electric radiator fan,
a Diagnostic Trouble Code (DTC) can be set.
If the problem is sensed in a monitored circuit
often enough to indicated an actual problem, a DTC
is stored. The DTC will be stored in the PCM mem-
ory for eventual display to the service technician.
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC's and to obtain cooling system data,
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRB
scan tool to erase a DTC. Refer to the appropriate
Powertrain Diagnostic Procedures service informa-
tion for operation of the DRB scan tool.
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate engine until radiator
upper hose is warm to touch. Aim the commercially
available black light tool at components to be
checked. If leaks are present, black light will cause
additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 5).
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if cause of coolant
loss is not located during the warm engine examina-
tion.WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove radiator pressure cap from filler
neck and check coolant level. Push down on cap to
disengage it from stop tabs. Wipe inside of filler neck
and examine lower inside sealing seat for nicks,
cracks, paint, dirt and solder residue. Inspect radia-
tor-to- reserve/overflow tank hose for internal
obstructions. Insert a wire through the hose to be
sure it is not obstructed.
Inspect cams on outside of filler neck. If cams are
damaged, seating of pressure cap valve and tester
seal will be affected.
Attach pressure tester (7700 or an equivalent) to
radiator filler neck (Fig. 6).
Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
Fig. 5 Leak Detection Using Black LightÐTypical
1 - TYPICAL BLACK LIGHT TOOL
BR/BECOOLING 7 - 5
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS - 5.9L
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
BELT TENSIONERS - 8.0L
DESCRIPTION.........................20
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
BELT TENSIONERS - 5.9L DIESEL
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
DRIVE BELTS - 5.9L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT.........................24
REMOVAL.............................26INSTALLATION.........................26
DRIVE BELTS - 8.0L
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT.........................27
REMOVAL.............................29
INSTALLATION.........................29
DRIVE BELTS - 5.9L DIESEL
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT.........................30
REMOVAL.............................32
INSTALLATION.........................32
VACUUM PUMP - 5.9L DIESEL
DESCRIPTION.........................33
OPERATION...........................34
DIAGNOSIS AND TESTINGÐVACUUM PUMP
OUTPUT............................34
REMOVAL.............................34
INSTALLATION.........................36
BELT TENSIONERS - 5.9L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
5.9L engines. These engines are equipped with an
automatic belt tensioner (Fig. 1). The tensioner main-
tains correct belt tension at all times. Due to use of
this belt tensioner, do not attempt to use a belt ten-
sion gauge on 5.9L engines.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).(1) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Disconnect wiring and secondary cable from
ignition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head.
Fig. 1 Automatic Belt Tensioner - 5.9L Engines
1 - AUTOMATIC TENSIONER
2 - COIL AND BRACKET
3 - SCREW AND WASHER
BR/BEACCESSORY DRIVE 7 - 19

(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 2).
(5) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) Install tensioner assembly to mounting
bracket. An indexing tab is located on back of ten-
sioner. Align this tab to slot in mounting bracket.
Tighten nut to 67 N´m (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.(4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 N´m
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
N´m (50 in. lbs.) torque.
(5) Install drive belt. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
(6) Check belt indexing marks (Fig. 2).
BELT TENSIONERS - 8.0L
DESCRIPTION
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
Drive belts on 8.0L engines are equipped with a
spring loaded automatic belt tensioner (Fig. 3) This
belt tensioner will be used with all belt configura-
tions, such as with or without power steering or air
conditioning.
The tensioner is equipped with an indexing arrow
(Fig. 4) on back of tensioner and an indexing mark
on tensioner housing.
Fig. 2 Tensioner Indexing Marks and Mounting Nut
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
Fig. 3 Belt TensionerÐ8.0L V-10 Engines
1 - PULLEY BOLT
2 - IDLER PULLEY
3 - TENSIONER PULLEY
4 - TENSIONER
5 - TENSIONER MOUNTING BOLT
7 - 20 ACCESSORY DRIVEBR/BE
BELT TENSIONERS - 5.9L (Continued)

OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
If a new belt is being installed, the arrow must be
within approximately 3 mm (1/8 in.) of indexing
mark (point B-) (Fig. 5). Belt is considered new if it
has been used 15 minutes or less. If this specification
cannot be met, check for:
²The wrong belt being installed (incorrect length/
width)
²Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, water pump, idler pul-
ley or generator)
²A pulley on an engine accessory being loose
²Misalignment of an engine accessory²Belt incorrectly routed.
A used belt should be replaced if tensioner index-
ing arrow has moved to point-A (Fig. 5). Tensioner
travel stops at point-A.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
CAUTION: If the pulley is to be removed from the
tensioner, its mounting bolt has left-hand threads.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 6) and
remove tensioner.
Fig. 4 Indexing MarksÐ8.0L Engines Typical
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
Fig. 5 Indexing MarksÐ8.0L Engines Typical
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
BR/BEACCESSORY DRIVE 7 - 21
BELT TENSIONERS - 8.0L (Continued)

BELT TENSIONERS - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 9). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
If a new belt is being installed, the arrow must be
within approximately 3 mm (1/8 in.) of indexing
mark. Belt is considered new if it has been used 15
minutes or less. If this specification cannot be met,
check for:
²The wrong belt being installed (incorrect length/
width)²Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, water pump, idler pul-
ley or generator)
²A pulley on an engine accessory being loose
²Misalignment of an engine accessory
²Belt incorrectly routed.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 10) and
remove tensioner.
INSTALLATION
(1) Install tensioner assembly to mounting
bracket. A dowel is located on back of tensioner. Align
this dowel to hole in tensioner mounting bracket.
Tighten bolt to 41 N´m (30 ft. lbs.) torque.
(2) Install drive belt (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
Fig. 9 Belt
1 - WATER PUMP
2 - ACCESSORY DRIVE BELT
3 - AUTOMATIC BELT TENSIONER
4 - 3/89SQUARE BOLT
5 - MOUNT. BOLT
Fig. 10 Automatic Belt Tensioner Diesel EngineÐ
Typical
1 - WATER PUMP
2 - ACCESSORY DRIVE BELT
3 - AUTOMATIC BELT TENSIONER
4 - 3/89SQUARE BOLT
5 - MOUNT. BOLT
BR/BEACCESSORY DRIVE 7 - 23

REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 12). This
belt tensioner will be used on all belt configurations,
such as with or without power steering or air condi-
tioning. For more information, (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/BELT TENSIONERS -
DESCRIPTION).(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 12).
(2) Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(3) Remove belt from idler pulley first.
(4) Remove belt from vehicle.
INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be routed correctly. If not, engine may
overheat due to water pump rotating in wrong
direction. Refer to (Fig. 13) (Fig. 14) for correct
engine belt routing. The correct belt with correct
length must be used.
(1) Position drive belt over all pulleysexceptidler
pulley. This pulley is located between generator and
A/C compressor.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 12).
(3) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place.
Remove wrench. Be sure belt is properly seated on
all pulleys.
(4) Check belt indexing marks.
Fig. 12 Belt Tensioner - 5.9L Gas Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
Fig. 13 Belt Routing - 5.9L Engines with A/C
1 - GENERATOR PULLEY
2 - A/C PULLEY
3 - POWER STEERING PULLEY
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - TENSIONER PULLEY
7 - IDLER PULLEY
7 - 26 ACCESSORY DRIVEBR/BE
DRIVE BELTS - 5.9L (Continued)

DRIVE BELTS - 8.0L
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 15), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) arenotnor-
mal. Any belt with cracks running along a rib mustbe replaced (Fig. 15). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory
drive pulleys for alignment, glazing, or excessive end
play.
Fig. 14 Belt Routing - 5.9L Engines Without A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PULLEY
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - TENSIONER PULLEY
Fig. 15 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
BR/BEACCESSORY DRIVE 7 - 27
DRIVE BELTS - 5.9L (Continued)