2002 DODGE RAM bleed power steering

DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid is the recommended fluid for
DaimlerChrysler automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
2500 Series Club Cab
and Quad Cab with 6.5'
Short Box129 L (34 gal.)*****
All 8' Long Box 132 L (35 gal.)*****
All Cab/Chassis Models 132 L (35 gal.)*****
ENGINE OIL WITH FILTER
5.9L 4.7 L (5.0 qts.)
8.0L 6.6 L (7.0 qts.)
5.9L DIESEL 10.4 L (11.0 qts.)
COOLING SYSTEM
5.9L 19 L (20 qts.)****
8.0L 24.5 L (26.0 qts.)****
5.9L DIESEL 22.7 L (24.0 qts.)****
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 46RE 3.8 L (4.0 qts.)
O-haul - 46RE 9-9.5L (19-20 pts.)*
Service Fill - 47RE 3.8 L (4.0 qts.)
O-haul - 47RE 14-16 L (29-33 pts.)*
0 - 6 LUBRICATION & MAINTENANCEBR/BE
FLUID TYPES (Continued)

HYDRAULIC BOOSTER DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster.
2. Faulty spool valve action. 2. Replace booster.
3. Restriction in booster return hose. 3. Replace hose.
4. Damaged input rod. 4. Replace booster.
Excessive Brake Pedal
Effort.1. Internal or external seal leakage. 1. Replace booster.
2. Faulty steering pump. 2. Replace pump.
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 28).
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal. (Fig. 29).
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster (Fig. 30).
INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N´m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N´m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N´m (17 ft. lbs.).
BR/BEBRAKES - BASE 5 - 19
POWER BRAKE BOOSTER (Continued)

(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N´m (30 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) Install the return hose to the booster.(10) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(11) Fill the power steering pump with fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
CAUTION: Use only MOPAR power steering fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
(12) Bleed the hydraulic booster.
ROTORS
DIAGNOSIS AND TESTING
DISC BRAKE ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining with a disc
brake lathe if surface scoring and wear are light.
Replace the rotor for the following conditions:
²Severely Scored
²Tapered
²Hard Spots
²Cracked
²Below Minimum Thickness
Fig. 28 Master Cylinder And Booster
1 - MASTER CYLINDER
2 - RETURN LINE
3 - LINE FROM PUMP
4 - HYDRAULIC BOOSTER
5 - LINE TO GEAR
Fig. 29 Booster Push Rod
1 - BOOSTER PUSH ROD
2 - WASHER
3 - CLIP
4 - PEDAL
Fig. 30 Booster Mounting
1 - STEERING COLUMN
2 - MOUNTING NUTS
3 - BOOSTER PEDAL ROD
4 - MOUNTING NUTS
5 - 20 BRAKES - BASEBR/BE
POWER BRAKE BOOSTER (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

OPERATION
Battery voltage is supplied to the CAB when a
speed of 15 miles per hour is reached. The CAB per-
forms a system initialization procedure at this point.
Initialization consists of a static and dynamic self
check of system electrical components.
The static and dynamic checks occurs at ignition
start up. During the dynamic check, the CAB briefly
cycles the pump and solenoids to verify operation. An
audible noise may be heard during this self check.
This noise should be considered normal.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
The CAB monitors wheel speed sensor inputs con-
tinuously while the vehicle is in motion. However,
the CAB will not activate any ABS components as
long as sensor inputs indicate normal braking.
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The antilock CAB activates the system whenever
sensor signals indicate periods of wheel slip. Periods
of wheel slip occur when brake stops involve high
pedal pressure and rate of vehicle deceleration.
The antilock system prevents lockup during a
wheel slip condition by modulating fluid apply pres-
sure to the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. Sensors at each front wheel convert wheel speed
into electrical signals. These signals are transmitted
to the CAB for processing and determination of
wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem. A speed sensor input
signal indicating a wheel slip condition activates the
CAB antilock program.
There are Two solenoid valves (Isolation and Dump
valve) which are used in each antilock control chan-
nel. The valves are all located within the HCU valve
body and work in pairs to either increase, hold, or
decrease apply pressure as needed in the individual
control channels.
During an ABS stop the ISO valve actuates, Stop-
ping anymore pressure build Ðup to the calipers.
Then the Dump valve dumps off pressure until the
wheel unlocks. This will continue until the wheels
quit slipping altogether.
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several self-tests
every time the ignition switch is turned on and the
vehicle is driven. The CAB monitors the systems
input and output circuits to verify the system is oper-
ating correctly. If the on board diagnostic system
senses that a circuit is malfunctioning the system
will set a trouble code in its memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
STANDARD PROCEDURE
STANDARD PROCEDURE - RWAL SERVICE
PRECAUTIONS
The RWAL uses an electronic control module, the
CAB. This module is designed to withstand normal
current draws associated with vehicle operation.
Care must be taken to avoid overloading the CAB
circuits.In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure.These circuits should only be tested
using a high impedance multi-meter or the DRB
tester as described in this section. Power should
never be removed or applied to any control module
with the ignition in the ON position. Before removing
or connecting battery cables, fuses, or connectors,
always turn the ignition to the OFF position.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM
ABS system bleeding requires conventional bleed-
ing methods plus use of the DRB scan tool. The pro-
cedure involves performing a base brake bleeding,
followed by use of the scan tool to cycle and bleed the
5 - 36 BRAKES - ABSBR/BE
BRAKES - ABS (Continued)

(8) Connect the engine harness connector and
ground cable to the PDC.
(9) Connect the vacuum pump supply hose.
(10) Connect the APPS connector (Fig. 5).
(11) Install the APPS assembly bracket to the cyl-
inder head bracket.
(12) Install the throttle linkage cover.
(13) Connect the power steering pressure and
return lines.
(14) Connect the passenger battery ground cable to
the engine block. Tighten the bolt to 77 N´m (57 ft.
lbs.) torque.
(15) Connect the engine block heater connector.
(16) Connect the a/c compressor electrical connec-
tors.
(17) Install the charge air cooler and a/c condenser
(if a/c equipped). Install and tighten the charge air
cooler mounting bolts to 2 N´m (17 in. lbs.) torque.
(18) Connect the charge air cooler piping. Torque
all clamps to 8 N´m (72 in. lbs.) torque.
(19) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(20) Install the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).(21) Install the radiator upper support panel.
(22) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(23) Connect the transmission quick-connect oil
cooler lines to the radiator. Push together until an
audible ªclickº is heard. Verify connection by pulling
apart.
(24) Raise vehicle.
(25) Connect a/c compressor suction/discharge hose
(if a/c equipped).
(26) Install the radiator lower hose and clamps.
(27) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(28) Install the transmission and transfer case (if
equipped).
(29) Connect the exhaust pipe to the turbocharger
elbow (Fig. 3). Torque the bolts to 34 N´m (25 ft. lbs.)
torque.
(30) Connect the transmission auxiliary oil cooler
lines (if equipped).
(31) Lower the vehicle
(32) Connect the heater core supply and return
hoses.
(33) Install the cooling fan and shroud at the same
time (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(34) Install the coolant recovery bottle to the fan
shroud (Fig. 2) and connect the hose to the radiator
filler neck.
(35) Install the windshield washer bottle to the fan
shroud and connect the pump supply hose and elec-
trical connections.
(36) Install the radiator upper hose and clamps.
(37) Change oil filter and install new engine oil.
(38) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(39) Connect battery negative cables.
(40) Perform the fuel line air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(41) Start engine and inspect for engine oil, cool-
ant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
VAPOR CANISTER
(1) Position vapor canister with strap over stud on
engine front cover. Install retaining nut. Tighten nut
10 N´m ( 89 in. lbs.).
(2) If removed, position hose onto crankcase
breather, then position clamp.
(3) Position lower portion of hose into vapor canis-
ter, then install and tighten cap.
Fig. 9 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
9 - 126 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

LINE COUPLERS - OPERATION, A/C......24-41
LINE COUPLERS - STANDARD
PROCEDURE, A/C....................24-44
LINE LEAKS - DIAGNOSIS AND TESTING,
HIGH-PRESSURE FUEL................14-78
LINER - INSTALLATION, REAR
WHEELHOUSE.......................23-96
LINER - REMOVAL, REAR WHEELHOUSE . . 23-96
LINES - CLEANING AND INSPECTION,
OIL COOLER........................9-179
LINES - DESCRIPTION, FUEL............14-8
LINES - DESCRIPTION, HIGH PRESSURE
FUEL..............................14-78
LINES - DESCRIPTION, REFRIGERANT....24-40
LINES - DESCRIPTION, VACUUM........25-37
LINES - OPERATION, HIGH PRESSURE
FUEL..............................14-78
LINES - OPERATION, REFRIGERANT......24-41
LINK CONNECTOR - DESCRIPTION, DATA . 8E-12
LINK CONNECTOR - OPERATION, DATA . . . 8E-12
LINKAGE - 2WD - DESCRIPTION........19-40
LINKAGE - 2WD - INSTALLATION........19-41
LINKAGE - 2WD - REMOVAL............19-40
LINKAGE - 4WD - DESCRIPTION........19-42
LINKAGE - 4WD - INSTALLATION........19-43
LINKAGE - 4WD - REMOVAL............19-42
LINKAGE - INSTALLATION...............6-16
LINKAGE - REMOVAL..................6-15
LINKAGE, SPECIAL TOOLS - STEERING . . . 19-41,
19-44
LINK/COIL SUSPENSION - STANDARD
PROCEDURE, ALIGNMENT...............2-5
LINK/COIL SUSPENSION, SPECIAL
TOOLS..............................2-16
LIQUID LINE - INSTALLATION...........24-52
LIQUID LINE - REMOVAL..............24-52
LOAD TEST - STANDARD PROCEDURE....8F-12
LOADS - STANDARD PROCEDURE,
TESTING FOR A SHORT TO GROUND
ON FUSES POWERING SEVERAL......8W-01-9
LOCATION - DESCRIPTION, CONNECTOR/
GROUND/SPLICE...................8W-91-1
LOCATIONS, SPECIFICATIONS - BODY
SEALER............................23-47
LOCATIONS, SPECIFICATIONS -
STRUCTURAL ADHESIVE...............23-44
LOCATIONS, SPECIFICATIONS - WELD.....23-4
LOCK & REMOTE KEYLESS ENTRY
SYSTEM - DIAGNOSIS AND TESTING,
POWER.............................8N-5
LOCK - STANDARD PROCEDURE,
HYDROSTATIC...............9-11,9-122,9-66
LOCK CYLINDER - DIAGNOSIS AND
TESTING, IGNITION SWITCH AND KEY.....19-9
LOCK CYLINDER - INSTALLATION.......23-74
LOCK CYLINDER - INSTALLATION.......19-10
LOCK CYLINDER - REMOVAL...........23-74
LOCK CYLINDER - REMOVAL...........19-10
LOCK MOTOR - DESCRIPTION, POWER....8N-7
LOCK MOTOR - DIAGNOSIS AND
TESTING, POWER.....................8N-7
LOCK MOTOR - OPERATION, POWER.....8N-7
LOCK SWITCH - DESCRIPTION, DOOR
CYLINDER...........................8N-5
LOCK SWITCH - DESCRIPTION, POWER . . . 8N-8
LOCK SWITCH - DIAGNOSIS AND
TESTING, DOOR CYLINDER.............8N-6
LOCK SWITCH - DIAGNOSIS AND
TESTING, POWER.....................8N-9
LOCK SWITCH - INSTALLATION, DOOR
CYLINDER...........................8N-6
LOCK SWITCH - OPERATION, DOOR
CYLINDER...........................8N-5
LOCK SWITCH - OPERATION, POWER.....8N-8
LOCK SWITCH - REMOVAL, DOOR
CYLINDER...........................8N-6
LOCKS - DESCRIPTION, POWER.........8N-1
LOCKS - DIAGNOSIS AND TESTING,
POWER.............................8N-4
LOCKS - OPERATION, POWER
...........8N-3
LOOP ADJUSTER - INSTALLATION, SEAT
BELT TURNING
......................8O-29
LOOP ADJUSTER - REMOVAL, SEAT
BELT TURNING
......................8O-29
LOOP HGT ADJUSTER KNOB -
INSTALLATION, TURNING
..............8O-30
LOOP HGT ADJUSTER KNOB -
REMOVAL, TURNING
.................8O-30LOW FUEL INDICATOR - DESCRIPTION . . . 8J-22
LOW FUEL INDICATOR - OPERATION.....8J-22
LOW MOUNTED - INSTALLATION, SIDE
VIEW MIRROR.......................23-98
LOW MOUNTED - REMOVAL, SIDE VIEW
MIRROR...........................23-98
LOW PRESSURE SWITCH -
DESCRIPTION, A/C...................24-21
LOW PRESSURE SWITCH - DIAGNOSIS
AND TESTING, A/C...................24-21
LOW PRESSURE SWITCH -
INSTALLATION, A/C...................24-21
LOW PRESSURE SWITCH - OPERATION,
A/C................................24-21
LOW PRESSURE SWITCH - REMOVAL,
A/C................................24-21
LOWER - INSTALLATION, LATCH........23-80
LOWER - INSTALLATION, LATCH
STRIKER...........................23-82
LOWER - REMOVAL, LATCH............23-80
LOWER - REMOVAL, LATCH STRIKER....23-82
LOWER BALL JOINT - DIAGNOSIS AND
TESTING............................2-10
LOWER CONTROL ARM - INSTALLATION . . 2-10,
2-20
LOWER CONTROL ARM - REMOVAL . . 2-10,2-20
LOWER FASCIA - INSTALLATION, FRONT . . . 13-3
LOWER FASCIA - REMOVAL, FRONT......13-3
LUBRICANTS - STANDARD PROCEDURE,
CLASSIFICATION OF....................0-1
LUBRICATION - DESCRIPTION....9-174,9-42,9-98
LUBRICATION - DESCRIPTION, AXLE.......0-5
LUBRICATION - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS........9-63,9-8
LUBRICATION - OPERATION....9-174,9-42,9-98
LUBRICATION - STANDARD PROCEDURE . 19-40,
19-42
LUMBAR CONTROL SWITCH -
DESCRIPTION.......................8N-18
LUMBAR CONTROL SWITCH -
OPERATION.........................8N-19
LUMBAR CONTROL SWITCH - REMOVAL . 8N-19
LUMBAR MOTOR - DESCRIPTION.......8N-19
LUMBAR MOTOR - DIAGNOSIS AND
TESTING...........................8N-19
LUMBAR MOTOR - OPERATION.........8N-19
LUMBAR SUPPORT - INSTALLATION....23-133
LUMBAR SUPPORT - REMOVAL........23-132
MAIN BEARING CLEARANCE -
STANDARD PROCEDURE...............9-159
MAIN BEARING FITTING - STANDARD
PROCEDURE, CRANKSHAFT.............9-31
MAIN BEARINGS - DESCRIPTION,
CRANKSHAFT........................9-31
MAIN BEARINGS - INSTALLATION,
CRANKSHAFT....................9-32,9-88
MAIN BEARINGS - OPERATION,
CRANKSHAFT........................9-31
MAIN BEARINGS - REMOVAL,
CRANKSHAFT....................9-31,9-88
MAIN BEARINGS - STANDARD
PROCEDURE, FITTING CRANKSHAFT......9-88
MAINTENANCE SCHEDULES -
DESCRIPTION.........................0-7
MALFUNCTION INDICATOR LAMP MIL -
DESCRIPTION.......................8J-23
MALFUNCTION INDICATOR LAMP MIL -
OPERATION.........................8J-23
MANAGER - DESCRIPTION, TASK........25-17
MANAGER - OPERATION, TASK.........25-21
MANIFOLD - CLEANING, EXHAUST . 9-109,9-185,
9-53
MANIFOLD - CLEANING, INTAKE . . . 9-107,9-184,
9-51
MANIFOLD - DESCRIPTION, EXHAUST . . . 9-109,
9-53
MANIFOLD - DESCRIPTION, FUEL DRAIN . . 14-89
MANIFOLD - DESCRIPTION, INTAKE . . 9-106,9-50
MANIFOLD - INSPECTION, EXHAUST
.....9-109,
9-186,9-53
MANIFOLD - INSPECTION, INTAKE
. 9-108,9-184,
9-51
MANIFOLD - INSTALLATION, EXHAUST
. . . 9-109,
9-186,9-53
MANIFOLD - INSTALLATION, FUEL
DRAIN
.............................14-90
MANIFOLD - INSTALLATION, INTAKE
.....9-108,
9-184,9-51MANIFOLD - OPERATION, EXHAUST . . 9-109,9-53
MANIFOLD - OPERATION, FUEL DRAIN . . . 14-89
MANIFOLD - OPERATION, INTAKE........9-50
MANIFOLD - REMOVAL, EXHAUST . . 9-109,9-185,
9-53
MANIFOLD - REMOVAL, FUEL DRAIN.....14-90
MANIFOLD - REMOVAL, INTAKE . . . 9-107,9-184,
9-50
MANIFOLD LEAKAGE - DIAGNOSIS AND
TESTING, INTAKE................9-106,9-50
MANUAL - NV4500 - ASSEMBLY........21-21
MANUAL - NV4500 - CLEANING.........21-20
MANUAL - NV4500 - DESCRIPTION.......21-1
MANUAL - NV4500 - DIAGNOSIS AND
TESTING............................21-3
MANUAL - NV4500 - DISASSEMBLY.......21-5
MANUAL - NV4500 - INSPECTION.......21-20
MANUAL - NV4500 - INSTALLATION......21-37
MANUAL - NV4500 - OPERATION.........21-3
MANUAL - NV4500 - REMOVAL..........21-4
MANUAL - NV4500 - SPECIFICATIONS....21-38
MANUAL - NV5600 - ASSEMBLY........21-64
MANUAL - NV5600 - CLEANING.........21-63
MANUAL - NV5600 - DESCRIPTION......21-46
MANUAL - NV5600 - DIAGNOSIS AND
TESTING...........................21-48
MANUAL - NV5600 - DISASSEMBLY......21-49
MANUAL - NV5600 - INSPECTION.........21-63
MANUAL - NV5600 - INSTALLATION......21-78
MANUAL - NV5600 - OPERATION........21-48
MANUAL - NV5600 - REMOVAL.........21-49
MANUAL - NV5600 - SPECIFICATIONS....21-79
MANUAL BLEEDING - STANDARD
PROCEDURE..........................5-7
MANUAL TRANSMISSION -
DESCRIPTION.........................0-5
MANUAL TRANSMISSION -
INSTALLATION, SHIFT BOOT...........23-122
MANUAL TRANSMISSION - REMOVAL,
SHIFT BOOT........................23-122
MAP SENSOR - INSTALLATION.........14-108
MARKER LAMP - INSTALLATION........8L-23
MARKER LAMP - REMOVAL............8L-23
MASTER CYLINDER - DESCRIPTION......5-26
MASTER CYLINDER - INSTALLATION......5-28
MASTER CYLINDER - OPERATION........5-26
MASTER CYLINDER - REMOVAL..........5-27
MASTER CYLINDER BLEEDING -
STANDARD PROCEDURE................5-27
MASTER CYLINDER/POWER BOOSTER -
DIAGNOSIS AND TESTING..............5-26
MATCH MOUNTING - STANDARD
PROCEDURE.........................22-3
MATS - INSTALLATION, CARPETS AND
FLOOR............................23-123
MATS - REMOVAL, CARPETS AND
FLOOR............................23-123
MEASUREMENT - STANDARD
PROCEDURE, CASTER CORRECTION.......2-3
MEASUREMENTS, SPECIFICATIONS -
BODY GAP AND FLUSH................23-56
MEASURING TIMING CHAIN STRETCH -
INSPECTION....................9-111,9-54
MECHANICAL - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS . . . 9-116,9-6,9-61
MECHANISM - DESCRIPTION, SHIFT....21-208,
21-379
MECHANISM - NV4500 - INSTALLATION,
SHIFT..............................21-44
MECHANISM - NV4500 - REMOVAL,
SHIFT..............................21-43
MECHANISM - OPERATION, SHIFT......21-208,
21-379
METRIC SYSTEM - DESCRIPTION......Intro.-9
MICRO-RELAY - DESCRIPTION.......8W-97-13
MICRO-RELAY - DIAGNOSIS AND
TESTING........................8W-97-14
MICRO-RELAY - INSTALLATION......8W-97-14
MICRO-RELAY - OPERATION........8W-97-14
MICRO-RELAY - REMOVAL
..........8W-97-14
MIDTRONICS ELECTRICAL TESTER -
STANDARD PROCEDURE, USING
........8F-15
MIL - DESCRIPTION, MALFUNCTION
INDICATOR LAMP
....................8J-23
MIL - OPERATION, MALFUNCTION
INDICATOR LAMP
....................8J-23
MILE, SPECIFICATIONS - TIRE
REVOLUTIONS PER
....................22-9
BR/BEINDEX 19
Description Group-Page Description Group-Page Description Group-Page

PLATE - INSTALLATION, TRANSFER
CASE SKID.........................13-11
PLATE - REMOVAL, TRANSFER CASE
SKID..............................13-11
PLATE LAMP - INSTALLATION, LICENSE . . 8L-22
PLATE LAMP - REMOVAL, LICENSE......8L-22
PLATE LAMP UNIT - INSTALLATION,
LICENSE...........................8L-22
PLATE LAMP UNIT - REMOVAL, LICENSE . . 8L-22
PLATE, SPECIFICATIONS - FUEL
INJECTION PUMP DATA...............14-77
PLATES - INSTALLATION, EXTERIOR
NAME.............................23-89
PLATES - REMOVAL, EXTERIOR NAME....23-89
PLUG - CLEANING, SPARK.............8I-20
PLUG - DESCRIPTION, SPARK...........8I-16
PLUG - INSTALLATION, SPARK..........8I-20
PLUG - INSTALLATION, STEERING GEAR
HOUSING...........................19-30
PLUG - OPERATION, SPARK............8I-16
PLUG - REMOVAL, SPARK..............8I-19
PLUG - REMOVAL, STEERING GEAR
HOUSING...........................19-29
PLUG CABLE - DESCRIPTION, SPARK.....8I-20
PLUG CABLE - INSTALLATION, SPARK....8I-21
PLUG CABLE - OPERATION, SPARK.......8I-20
PLUG CABLE - REMOVAL, SPARK........8I-21
PLUG CABLE ORDER, 8.0L V-10 ENGINE
- SPARK .............................8I-3
PLUG CABLE RESISTANCE,
SPECIFICATIONS - SPARK...............8I-3
PLUG CABLES - DIAGNOSIS AND
TESTING, SPARK.....................8I-20
PLUG CONDITIONS - DIAGNOSIS AND
TESTING, SPARK.....................8I-17
PLUGS, SPECIFICATIONS - SPARK........8I-3
PLUMBING - CLEANING, CHARGE AIR
COOLER............................11-19
PLUMBING - DESCRIPTION, CHARGE
AIR COOLER........................11-18
PLUMBING - INSPECTION, CHARGE AIR
COOLER............................11-19
PLUMBING - INSTALLATION, CHARGE
AIR COOLER........................11-20
PLUMBING - OPERATION, CHARGE AIR
COOLER............................11-18
PLUMBING - REMOVAL, CHARGE AIR
COOLER............................11-18
PLUMBING - SERVICE CAUTIONS........24-42
PLUMBING - SERVICE WARNINGS.......24-42
POLISHING - DESCRIPTION, WET
SANDING/BUFFING..................23-130
PORT - DESCRIPTION, REFRIGERANT
SYSTEM SERVICE.....................24-1
PORT - OPERATION, REFRIGERANT
SYSTEM SERVICE.....................24-2
POSITION SENSOR - DESCRIPTION,
ACCELERATOR PEDAL.................14-95
POSITION SENSOR - DESCRIPTION,
THROTTLE..........................14-50
POSITION SENSOR - INSTALLATION,
ACCELERATOR PEDAL.................14-97
POSITION SENSOR - OPERATION,
ACCELERATOR PEDAL.................14-95
POSITION SENSOR - OPERATION,
THROTTLE..........................14-50
POSITION SENSOR - REMOVAL,
ACCELERATOR PEDAL.................14-95
POSITION SWITCH - DESCRIPTION,
CLUTCH PEDAL.......................6-17
POSITION SWITCH - DIAGNOSIS AND
TESTING, PARK/NEUTRAL.......21-195,21-367
POSITION SWITCH - INSTALLATION,
PARK/NEUTRAL...............21-195,21-367
POSITION SWITCH - OPERATION,
CLUTCH PEDAL.......................6-17
POSITION SWITCH - REMOVAL,
PARK/NEUTRAL...............21-195,21-367
POSITIVE CABLE INSTALLATION,
GASOLINE ENGINE...................8F-22
POSITIVE CABLE REMOVAL, GASOLINE
ENGINE
............................8F-21
POTENTIAL - STANDARD PROCEDURE,
TESTING OF VOLTAGE
..............8W-01-8
POWER BRAKE BOOSTER -
INSTALLATION
........................5-19
POWER BRAKE BOOSTER - REMOVAL
.....5-19
POWER DISTRIBUTION - DESCRIPTION
. 8W-97-1POWER DISTRIBUTION - OPERATION . . 8W-97-1
POWER DISTRIBUTION CENTER -
DESCRIPTION.....................8W-97-8
POWER DISTRIBUTION CENTER -
INSTALLATION...................8W-97-10
POWER DISTRIBUTION CENTER -
OPERATION.......................8W-97-8
POWER DISTRIBUTION CENTER -
REMOVAL........................8W-97-8
POWER DISTRIBUTION SYSTEMS,
SPECIAL TOOLS...................8W-97-2
POWER GROUNDS - DESCRIPTION......8E-17
POWER LOCK & REMOTE KEYLESS
ENTRY SYSTEM - DIAGNOSIS AND
TESTING............................8N-5
POWER LOCK MOTOR - DESCRIPTION....8N-7
POWER LOCK MOTOR - DIAGNOSIS AND
TESTING............................8N-7
POWER LOCK MOTOR - OPERATION......8N-7
POWER LOCK SWITCH - DESCRIPTION....8N-8
POWER LOCK SWITCH - DIAGNOSIS
AND TESTING........................8N-9
POWER LOCK SWITCH - OPERATION......8N-8
POWER LOCKS - DESCRIPTION..........8N-1
POWER LOCKS - DIAGNOSIS AND
TESTING............................8N-4
POWER LOCKS - OPERATION............8N-3
POWER MIRROR SWITCH -
DESCRIPTION.......................8N-13
POWER MIRROR SWITCH -
INSTALLATION......................8N-14
POWER MIRROR SWITCH - OPERATION . . 8N-13
POWER MIRROR SWITCH - REMOVAL . . . 8N-13
POWER MIRRORS - DESCRIPTION......8N-11
POWER MIRRORS - OPERATION........8N-11
POWER OUTLET - DESCRIPTION.....8W-97-10
POWER OUTLET - DIAGNOSIS AND
TESTING........................8W-97-10
POWER OUTLET - INSTALLATION....8W-97-11
POWER OUTLET - OPERATION.......8W-97-10
POWER OUTLET - REMOVAL........8W-97-11
POWER SEAT SWITCH - DESCRIPTION,
DRIVER............................8N-17
POWER SEAT SWITCH - DESCRIPTION,
PASSENGER........................8N-20
POWER SEAT SWITCH - DIAGNOSIS
AND TESTING, DRIVER................8N-17
POWER SEAT SWITCH - DIAGNOSIS
AND TESTING, PASSENGER............8N-20
POWER SEAT SWITCH - INSTALLATION,
DRIVER............................8N-18
POWER SEAT SWITCH - INSTALLATION,
PASSENGER........................8N-21
POWER SEAT SWITCH - OPERATION,
DRIVER............................8N-17
POWER SEAT SWITCH - OPERATION,
PASSENGER........................8N-20
POWER SEAT SWITCH - REMOVAL,
DRIVER............................8N-18
POWER SEAT SWITCH - REMOVAL,
PASSENGER........................8N-21
POWER SEAT SYSTEM - DESCRIPTION . . . 8N-16
POWER SEAT SYSTEM - DIAGNOSIS
AND TESTING.......................8N-16
POWER SEAT SYSTEM - OPERATION.....8N-16
POWER SEAT TRACK - DESCRIPTION....8N-21
POWER SEAT TRACK - DIAGNOSIS AND
TESTING...........................8N-22
POWER SEAT TRACK - INSTALLATION....8N-22
POWER SEAT TRACK - OPERATION......8N-22
POWER SEAT TRACK - REMOVAL.......8N-22
POWER STEERING FLOW AND
PRESSURE - DIAGNOSIS AND
TESTING............................19-4
POWER STEERING GEAR LEAKAGE -
DIAGNOSIS AND TESTING.............19-16
POWER STEERING GEAR, SPECIAL
TOOLS.............................19-22
POWER STEERING GEAR,
SPECIFICATIONS
.....................19-21
POWER STEERING PUMP - INITIAL
OPERATION - STANDARD PROCEDURE
. . . 19-33
POWER STEERING PUMP, SPECIAL
TOOLS
.............................19-38
POWER STEERING SYSTEM -
DIAGNOSIS AND TESTING
..............19-2
POWER STEERING SYSTEM -
STANDARD PROCEDURE, FLUSHING
.....19-34POWER WINDOW SWITCH -
DESCRIPTION.......................8N-24
POWER WINDOW SWITCH - DIAGNOSIS
AND TESTING.......................8N-24
POWER WINDOW SWITCH -
INSTALLATION......................8N-26
POWER WINDOW SWITCH - OPERATION . . 8N-24
POWER WINDOW SWITCH - REMOVAL . . . 8N-25
POWER WINDOWS - DESCRIPTION......8N-23
POWER WINDOWS - DIAGNOSIS AND
TESTING...........................8N-23
POWER WINDOWS - OPERATION........8N-23
POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON FUSES . 8W-01-9
POWR-LOK - ASSEMBLY, DIFFERENTIAL . . . 3-99
POWR-LOK - DISASSEMBLY,
DIFFERENTIAL........................3-99
POWR-LOK - DIAGNOSIS AND TESTING . . . 3-99
PRELIMINARY CHECKS - DIAGNOSIS
AND TESTING.........................7-4
PRESSURE - DESCRIPTION, HOSES......19-39
PRESSURE - DIAGNOSIS AND TESTING,
BOOST.............................14-93
PRESSURE - DIAGNOSIS AND TESTING,
CYLINDER COMPRESSION...........9-64,9-9
PRESSURE - DIAGNOSIS AND TESTING,
ENGINE OIL................9-101,9-178,9-45
PRESSURE - DIAGNOSIS AND TESTING,
FUEL TRANSFER PUMP...............14-84
PRESSURE - DIAGNOSIS AND TESTING,
POWER STEERING FLOW.................19-4
PRESSURE - DIAGNOSIS AND TESTING,
TURBOCHARGER BOOST...............11-13
PRESSURE - GAS ENGINES -
SPECIFICATIONS, FUEL SYSTEM.........14-3
PRESSURE - OPERATION, HOSES........19-39
PRESSURE BLEEDING - STANDARD
PROCEDURE..........................5-8
PRESSURE CAP - DESCRIPTION,
RADIATOR...........................7-64
PRESSURE CAP - OPERATION,
RADIATOR...........................7-64
PRESSURE FOR HIGH SPEEDS -
DESCRIPTION, TIRE...................22-7
PRESSURE FUEL LINES - DESCRIPTION,
HIGH..............................14-78
PRESSURE FUEL LINES - OPERATION,
HIGH..............................14-78
PRESSURE GAUGE - DESCRIPTION, OIL . . 8J-25
PRESSURE GAUGE - OPERATION, OIL....8J-25
PRESSURE GAUGES - DIAGNOSIS AND
TESTING............................22-8
PRESSURE LEAK DOWN TEST -
DIAGNOSIS AND TESTING, FUEL.........14-2
PRESSURE LEAKAGE - DIAGNOSIS AND
TESTING, CYLINDER COMBUSTION....9-64,9-9
PRESSURE RELEASE - STANDARD
PROCEDURE, FUEL SYSTEM.............14-3
PRESSURE RELIEF VALVE - CLEANING,
OIL................................9-180
PRESSURE RELIEF VALVE -
DESCRIPTION, HIGH
..................24-46
PRESSURE RELIEF VALVE - INSPECTION,
OIL
................................9-180
PRESSURE RELIEF VALVE -
INSTALLATION, OIL
...................9-180
PRESSURE RELIEF VALVE - OPERATION,
HIGH
..............................24-47
PRESSURE RELIEF VALVE - REMOVAL,
OIL
................................9-180
PRESSURE SENSOR/SWITCH -
INSTALLATION, OIL
...................9-181
PRESSURE SENSOR/SWITCH -
REMOVAL, OIL
......................9-181
PRESSURE SWITCH - DESCRIPTION, A/C
HIGH
..............................24-20
PRESSURE SWITCH - DESCRIPTION, A/C
LOW
..............................24-21
PRESSURE SWITCH - DIAGNOSIS AND
TESTING, A/C HIGH
...................24-20
PRESSURE SWITCH - DIAGNOSIS AND
TESTING, A/C LOW
...................24-21
PRESSURE SWITCH - INSTALLATION,
A/C HIGH
...........................24-20
PRESSURE SWITCH - INSTALLATION,
A/C LOW
...........................24-21
BR/BEINDEX 23
Description Group-Page Description Group-Page Description Group-Page