2002 DODGE RAM wheel torque

(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 64).
(8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes.(9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool.
(10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on the axleshaft (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION) .
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum.
(13) Install disc brake caliper on caliper adapter
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - INSTALLATION).
(14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 129 N´m (95 ft. lbs.).
(16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
Fig. 64 Setting Gauge To Park Brake Shoe
Measurement
5 - 34 BRAKES - BASEBR/BE
SHOES (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................35
OPERATION...........................36
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES............................36
STANDARD PROCEDURE
STANDARD PROCEDURE - RWAL SERVICE
PRECAUTIONS.......................36
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM......................36
SPECIFICATIONS
TORQUE CHART......................37
FRONT WHEEL SPEED SENSOR
DESCRIPTION.........................38
OPERATION...........................38
REMOVAL
REMOVAL - 4X2......................39REMOVAL - 4X4......................39
INSTALLATION
INSTALLATION - 4X2...................39
INSTALLATION - 4X4...................39
REAR WHEEL SPEED SENSOR
DIAGNOSIS AND TESTING - REAR WHEEL
SPEED SENSOR......................40
REMOVAL.............................40
INSTALLATION.........................40
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................41
INSTALLATION.........................41
BRAKES - ABS
DESCRIPTION
The antilock brake system (ABS) is an electroni-
cally operated, all wheel brake control system. 2500
and 3500 vehicles have Electronic Brake Distribution
(EBD) designed into the systen which eliminates the
combination/proportioning valve.
The system is designed to prevent wheel lockup
and maintain steering control during periods of high
wheel slip when braking. Preventing lockup is accom-
plished by modulating fluid pressure to the wheel
brake units.
The hydraulic system is a three channel design.
The front wheel brakes are controlled individually
and the rear wheel brakes in tandem (Fig. 1). The
ABS electrical system is separate from other electri-
cal circuits in the vehicle. A specially programmed
controller antilock brake unit operates the system
components.
ABS system major components include:
²Controller Antilock Brakes (CAB)
²Hydraulic Control Unit (HCU)
²Wheel Speed Sensors (WSS)²ABS Warning Light
Fig. 1 Antilock Brake System
1 - MASTER CYLINDER AND RESERVOIR
2 - POWER BRAKE BOOSTER
3 - WIRES TO WHEEL SPEED SENSORS
4 - RIGHT REAR WHEEL
5 - LEFT REAR WHEEL
6 - HYDRAULIC BRAKE LINES TO WHEELS
7 - COMBINATION VALVE
8 - HARNESS
9 - RIGHT FRONT WHEEL
10 - LEFT FRONT WHEEL
11 - CAB/HCU
BR/BEBRAKES - ABS 5 - 35

HCU pump and solenoids. A second base brake bleed-
ing procedure is then required to remove any air
remaining in the system.
(1) Perform the base brake bleeding, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(2) Connect the scan tool to the Data Link Connec-
tor.(3) Select ANTILOCK BRAKES, followed by MIS-
CELLANEOUS, then ABS BRAKES. Follow the
instructions displayed. When scan tool displays TEST
COMPLETE, disconnect scan tool and proceed.
(4) Perform base brake bleeding a second time,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL -
STANDARD PROCEDURE).
(5) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
ABS Assembly
Bracket Bolts13 10 120
ABS Assembly
Mounting Nuts13 10 102
ABS Assembly
CAB Screws4335
ABS Assembly
Brake Lines21 15 190
Wheel Speed Sensor
Frt. Bolts (4x2)23 17 200
Wheel Speed Sensor
Frt. Bolts (4x4)14 10 120
Wheel Speed Sensor
Rear Bolt24 18 210
BR/BEBRAKES - ABS 5 - 37
BRAKES - ABS (Continued)

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

SPECIFICATIONS - CLUTCH
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut, slave cylinder 19-26 14-19 170-230
Bolt, clutch cover-5/16 in. 23 17 -
Bolt, clutch cover-3/8 in. 41 30 -
Pivot, release bearing 23 17 -
Screw, fluid reservoir 5 - 40
CLUTCH DISC
REMOVAL
(1) Raise and support vehicle.
(2) Support engine with wood block and adjustable
jack stand, so engine mounts are not strained (Fig.
4).
(3) Remove transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case for procedures.(4) If pressure plate will be reused, mark position
of cover on flywheel with paint or scriber (Fig. 5).
(5) Insert clutch alignment tool through clutch disc
and into pilot bushing, to hold disc in place.
Fig. 4 Supporting Engine -Diesel Model Shown
1 - WOOD BLOCK
2 - ADJUSTABLE JACK STAND
Fig. 5 Marking Pressure Plate Position
1 - FLYWHEEL
2 - ALIGNMENT MARKS
3 - PRESSURE PLATE
BR/BECLUTCH 6 - 7
CLUTCH (Continued)

(3) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
(4) Lubricate release fork and pivot contact sur-
faces with Mopar High Temperature wheel bearing
grease or equivalent before installation.
(5) Align and install clutch housing on transmis-
sion (Fig. 19). Tighten housing bolts closest to align-
ment dowels first and to the following torque values:
²1/4in. diameter ªAº bolts - 4.5 N´m (40 in.lb.).
²3/8in. diameter ªAº bolts - 47.5 N´m (35 ft.lb.).
²7/16in. diameter ªAº bolts - 68 N´m (50 ft.lb.).
²ªBº bolts for 5.2L/5.9L applications - 41 N´m (30
ft.lb.).
²ªBº bolts for 5.9L TD/8.0L applications - 47.5
N´m (35 ft.lb.).
²ªCº bolts for 5.2/5.9L applications - 68 N´m (50
ft.lb.).
²ªCº bolts for 5.9L TD applications - 47.5 N´m (35
ft.lb.).
²ªCº bolts for 8.0L applications - 74.5 N´m (55
ft.lb.).
(6) Install transmission-to-engine strut after
installing clutch housing. Tighten bolt attaching
strut to clutch housing first and engine bolt last.
(7) Install the starter to the clutch housing.
(8) Install the clutch housing dust shield to the
clutch housing. Tighten the bolts to
(9) Install transmission and transfer case, if
equipped. Refer to 21Transmission and Transfer Case
for proper procedures.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case forprocedures.
(2) Remove clutch housing, for NV4500 equipped
vehicles.
(3) Disconnect release bearing from release fork
and remove bearing (Fig. 20).
INSTALLATION
NOTE: Inspect bearing slide surface on transmis-
sion front bearing retainer. Replace retainer if slide
surface is scored, worn or cracked. Inspect release
lever and pivot stud. Be sure stud is secure and in
good condition. Be sure fork is not distorted or
worn. Replace fork spring clips if bent or damaged.
(1) Lubricate input shaft splines, bearing retainer
slide surface, lever pivot ball stud and release lever
pivot surface with Mopar high temperature bearing
grease or equilvalent.
Fig. 18 Transmission/Clutch Housing - NV4500
1 - CLUTCH HOUSING
2 - TRANSMISSION
Fig. 19 Clutch Housing Installation - NV4500
1 - ENGINE BLOCK
2 - CLUTCH DISC AND COVER
3 - CLUTCH HOUSING
4 - DUST COVER
6 - 12 CLUTCHBR/BE
CLUTCH HOUSING (Continued)

(2) Install release fork and release bearing (Fig.
21) and verify fork and bearing are secured by spring
clips. Also be sure that the release fork is installed
properly.
NOTE: The rear side of the release lever has one
end with a raised area. This raised area goes
toward the slave cylinder side of the transmission.
(3) Install clutch housing, if removed.(4) Install transmission and transfer case, if
equipped. Refer to 21 Transmission and Transfer
Case for procedures.
FLYWHEEL
DIAGNOSIS AND TESTING - FLYWHEEL
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can also
weaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DISASSEMBLY
NOTE: If the teeth are worn or damaged, the fly-
wheel should be replaced as an assembly. This is
the recommended repair. In cases where a new fly-
wheel is not readily available, (V10/Diesel Engine
only) a replacement ring gear can be installed. The
following procedure must be observed to avoid
damaging the flywheel and replacement gear.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES WHILE CUTTING RING GEAR.
Fig. 20 Clutch Release Components
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 N´m (200 IN. LBS.)
6 - SPRING
Fig. 21 Clutch Release Fork
1 - PIVOT BALL
2 - FORK
3 - SLAVE CYLINDER OPENING
4 - BEARING
BR/BECLUTCH 6 - 13
CLUTCH RELEASE BEARING (Continued)

STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................31
OPERATION...........................31
DIAGNOSIS AND TESTING - STARTING
SYSTEM............................32
SPECIFICATIONS
STARTING SYSTEM...................36
SPECIFICATIONS - TORQUE - STARTING
SYSTEM............................37
STARTER MOTOR
DESCRIPTION.........................37OPERATION...........................37
DIAGNOSIS AND TESTING - STARTER
MOTOR .............................38
REMOVAL.............................38
INSTALLATION.........................40
STARTER MOTOR RELAY
DESCRIPTION.........................41
OPERATION...........................41
DIAGNOSIS AND TESTING - STARTER RELAY . 41
REMOVAL.............................42
INSTALLATION.........................42
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
²Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
²Battery
²Battery cables
²Ignition switch and key lock cylinder
²Clutch pedal position switch (manual transmis-
sion)
²Park/neutral position switch (automatic trans-
mission)
²Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind.
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (PCM). Use of an induction-type milliampere
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12-volt test lamp may be
required.
Certain starting system components are monitored
by the PCM and may produce a Diagnostic Trouble
Code (DTC). Refer to Emission Control. See Diagnos-tic Trouble Codes for additional information and a
list of codes.OPERATION
The starting system components form two separate
circuits. A high-amperage feed circuit that feeds the
starter motor between 150 and 350 amperes (700
amperes - diesel engine), and a low-amperage control
circuit that operates on less than 20 amperes. The
high-amperage feed circuit components include the
battery, the battery cables, the contact disc portion of
the starter solenoid, and the starter motor. The low-
amperage control circuit components include the igni-
tion switch, the clutch pedal position switch (manual
transmission), the park/neutral position switch (auto-
matic transmission), the starter relay, the electro-
magnetic windings of the starter solenoid, and the
connecting wire harness components.
If the vehicle is equipped with a manual transmis-
sion, it has a clutch pedal position switch installed in
series between the ignition switch and the coil bat-
tery terminal of the starter relay. This normally open
switch prevents the starter relay from being ener-
gized when the ignition switch is turned to the
momentary Start position, unless the clutch pedal is
depressed. This feature prevents starter motor oper-
ation while the clutch disc and the flywheel are
engaged. The starter relay coil ground terminal is
always grounded on vehicles with a manual trans-
mission.
If the vehicle is equipped with an automatic trans-
mission, battery voltage is supplied through the low-
amperage control circuit to the coil battery terminal
of the starter relay when the ignition switch is
turned to the momentary Start position. The park/
neutral position switch is installed in series between
the starter relay coil ground terminal and ground.
BR/BESTARTING 8F - 31