2003 DODGE RAM Trans cooler diesel

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
2DESCRIPTIONSPECIFICATION
FUEL TANK
Short Box (Lt. Duty) 98 L (26 gal.)*
Long Box (Lt. Duty) 132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L 4.7 L (5.0 qts.)
4.7L 5.6 L (6.0 qts.)
5.7L 6.6 L (7.0 qts.)
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.)
2DESCRIPTION SPECIFICATION
COOLING SYSTEM
3.7L 15.4 L (16.2 qts.)**
4.7L 15.4 L (16.2 qts.)**
5.7L 15.4L (16.2 qts.)**
5.9L 15.5 L (16.3 qts.)**
8.0L 24L (24.3 qts.)**
5.9L Diesel Engine 28L (29.5 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.)L
Service Fill - 45RFE/
545RFE4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.)
O-haul - 45RFE/545RFE 14-16 L (29-33 pts.)L
LDry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or use of
an auxiliary cooler, these figures may vary. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC/FLUID -
STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV3500 4X2 2.3 L (4.8 pts.)
NV3500 4X4 2.0 L (4.2 pts.)
NV4500 3.8 L (8.0 pts.)
NV5600 4.5 L (9.5 pts.)
TRANSFER CASE
NV241 GENII 1.6 L (3.4 pts.)
NV243 1.6 L (3.4 pts.)
NV271 1.89 L (4.0 pts.)
NV273 1.89 L (4.0 pts.)
FRONT AXLE   .03 L (1 oz)
C205F 1.66 L (3.5 pts.)
9 1/4 AA 2.25 L (4.75 pts.)
REAR AXLE   .03 L (1 oz)
9 1/4 2.32 L (4.9 pts.)***
10 1/2 AA 2.25 L (4.75 pts.)
11 1/2 AA 3.62 L (7.65 pts)
*** With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive.
** Includes 0.9L (1.0 qts.) for coolant reservoir.
*Nominal refill capacities are shown. A variation may be
observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
DRLUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)

DESCRIPTIONÐCOOLING SYSTEM FLOW -
5.9L DIESEL
The diesel engine cooling system consists of :
²Cross-flow radiator
²Belt driven water pump
²Belt driven mechanical cooling fan
²Electronic viscous fan drive
²Fan shroud
²Radiator pressure cap²Vertically mounted thermostat
²Coolant reserve/recovery system
²Transmission oil cooler
²Coolant
Coolant flow circuits for the 5.9L diesel engine are
shown in (Fig. 3).
Fig. 1 Engine Cooling System Flow - 3.7L/4.7L
1 - LH CYL. HEAD
2 - BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD
5 - RH BANK CYL. BLOCK6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
8 - FROM HEATER CORE
9 - TO HEATER CORE
7 - 2 COOLINGDR
COOLING (Continued)

WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOT
AND UNDER PRESSURE. SERIOUS BURNS FROM
THE COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
For 3.7L / 4.7L/5.9L engines, remove the radiator
cap from the coolant degas bottle to add coolant.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
BlockÐBolts 41 30 Ð
Automatic Belt Tensioner
PulleyÐBolt 61 45 Ð
Block HeaterÐBolt 2 Ð 17
Generator/Compressor
Mounting BracketÐBolts
# 1 and 2 54 40 Ð
# 3 40 30 Ð
Fan Shroud to Radiator
MountingÐBolts6Ð55
Radiator to Support - Bolts 8.5 Ð 75
Fan Blade to Viscous Fan
DriveÐBolts24 18 Ð
Idler PulleyÐBolt 54 40 Ð
Thermostat HousingÐBolts
- All Except 5.9L13 Ð 112
Thermostat HousingÐBolts
- 5.9L23 16 Ð
Power Steering Oil Cooler
Ð Bolts6Ð55
Transmission Auxiliary Oil
CoolerÐBolts 6 Ð 55
Transmission Oil Cooler
Tube Nuts31.5 24 Ð
Coolant Bottle Ð Bolts 8.5 Ð 75
Transmission Oil Cooler to
Transmission - 5.9L/46RE -
Tube Nuts 31.5 24 Ð
Transmission Oil Cooler to
Transmission - 3.7L/4.7L/
45RFE - Tube Nuts20 18 Ð
Water PumpÐBolts 24 18 Ð
Water Pump Ð Bolts - 4.7L 58 43 Ð
SPECIFICATIONS -
SPECIFICATIONS
DESCRIPTION SPECIFICATION
3.7/4.7L Engine 15.4L (16.2 qts.)- to the
middle of the cold fill
range
5.7L Engine 15.4L (16.2 qts.)- to the
middle of the cold fill
range
5.9L Engine 15.5L (16.3 qts.)- to the
MIN mark after 3 warm
up, cool down cycles
8.0L Engine 24L (25.3 qts.)
5.9L Diesel Engine 28L (29.5 qts.)
SPECIAL TOOLS
COOLING
Pliers Constant Pressure Hose Clamp - 6094
3/8º Quick Connect Release Tool - 6935
SPANNER WRENCHÐ6958
7 - 20 COOLINGDR
COOLING (Continued)

Fan speed is monitored by the ECM. A lack of fan
speed will set a DTC. Circuit concerns will also set
fan clutch DTC's.
Fan speed and duty cycle percent can be monitored
with the DRB III..
DIAGNOSIS AND TESTING - ELECTRONICLY
CONTOLLED VISCOUS FAN DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
²Fan duty cycle high. This may occur when ambi-
ent (outside air temperature) is very high.
²Engine loads and temperatures are high such as
when towing a trailer.
²Cool silicone fluid within the fan drive unit is
being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
ELECTRONICALLY CONTROLLED VISCOUS DRIVE
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against exces-
sively high coolant temperature.
The Electronic Viscous Fan drive can be tested
using the DRB III scan tool.
(1) Set the parking brake and verify the transmis-
sion is in park or neutral.
(2) Stat and allow engine to reach normal operat-
ing termeratures.
(3) With engine idling, connect the DRB III and
select appropraite model year and engine option.
(4) Lacate and select actuator tests, then select
PWM Viscous Fan.
(5) Monitor fan speed and duty cycle; verify that
the fan speed increments are proportional to the duty
cycle precentage during the actuation event.
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found.
RADIATOR
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and verti-
cal plastic side tanks (Fig. 32).
This radiator does not contain an internal trans-
mission oil cooler
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radiator core to cool the engine.
Fig. 31 Fan Blade/Viscous Fan Drive
1 - ELECTRICAL CONNECTOR
2 - VISCOUS FAN DRIVE
3 - FAN BLADE
4 - BOLT
5 - FAN DRIVE
7 - 56 ENGINEDR
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued)

(12) Install coolant reserve/overflow container or
degas container to fan shroud and tighten the bolts
to 8.5 N´m (75 in. lbs.).
(13) Connect upper radiator hose and install
clamp.
(14) Install battery negative cable.
(15) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(16) Operate the engine until it reaches normal
operating temperature. Check cooling system fluid
levels.
RADIATOR - 5.9L DIESEL
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and verti-
cal plastic side tanks (Fig. 35).
This radiator does not contain an internal trans-
mission oil cooler
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radiator core to cool the engine.
DIAGNOSIS AND TESTINGÐRADIATOR
COOLANT FLOW
Use the following procedure to determine if coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. If the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow-
ing to the radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES-
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
(2) Drain a small amount of coolant from the radi-
ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal
operating temperature. If coolant is flowing past the
exposed tubes, the coolant is circulating.
REMOVAL
(1) Disconnect both battery negative cables.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove air box and turbocharger inlet tube.
(4) Remove coolant tank hose, washer bottle hose
and the positive battery cable from the fastening
clips located on top of the radiator.
(5) Remove hose clamps and hoses from radiator.
Fig. 35 Radiator Ð Typical
1 - SCREW
2 - SCREW
3 - LOWER MOUNT
4 - RADIATOR
5 - DRAINCOCK
6 -LOWER MOUNT
DRENGINE 7 - 59
RADIATOR (Continued)

(6) Remove the power steering cooler mounting
bolts and position the power steering cooler out of
the way.
(7) Disconnect the transmission cooler lines at the
transmission. The transmission cooler will remain on
the radiator and can be removed as an assembly.
(8) Remove the lower shroud assembly and the
electronic viscous fan wiring from the upper shroud
assembly.
(9) Remove the two radiator upper mounting bolts
(Fig. 36).
(10) Lift radiator straight up and out of engine
compartment. The bottom of the radiator is equipped
with two alignment dowels that fit into holes in the
lower radiator support panel. Rubber biscuits (insu-
lators) are installed to these dowels. Take care not to
damage cooling fins or tubes on the radiator and air
conditioning condenser when removing.
CLEANING
Clean radiator fins are necessary for good heat
transfer. The radiator and oil cooler fins should be
cleaned when an accumulation of debris has
occurred. With the engine cold, apply cold water and
compressed air to the back (engine side) of the radi-
ator to flush the radiator and/or oil coolers of debris.
INSPECTION
Inspect the radiator side tanks for cracks, broken
or missing fittings also inspect the joint where the
tanks seam up to the radiator core for signs of leak-
age and/or deteriorating seals.
Inspect radiator core for corroded, bent or missing
cooling fins. Inspect the core for bent or damaged
cooling tubes.
INSTALLATION
(1) Install rubber insulators to alignment dowels
at lower part of radiator.
(2) Lower the radiator into position while guiding
the two alignment dowels into lower radiator sup-
port. Different alignment holes are provided in the
lower radiator support for each engine application.
(3) Install two upper radiator mounting bolts.
Tighten bolts to 11 N´m (95 in. lbs.) torque.
(4) Connect both radiator hoses and install hose
clamps.
(5) Connect transmission cooler lines to radiator
tank. Inspect quick connect fittings for debris and
install until an audible ªclickº is heard. Pull apart to
verify connection.
(6) Position power steering cooler on the radiator
and tighten nuts to 8.5M´N (75 in. lbs.)
(7) Attach electronic viscous fan wiring to upper
shroud ands install lower shroud.
(8) Position coolant recover tank hose, washer bot-
tle hose and the positive battery cable into the clips
located on the top of the radiator.
(9) Install air box and turbocharger inlet hose.
Tighten clamps to 4 N´M (35 in. lbs.).
(10) Position heater controls tofull heatposition.
(11) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(12) Operate engine until it reaches normal tem-
perature. Check cooling system and automatic trans-
mission (if equipped) fluid levels.
RADIATOR PRESSURE CAP
DESCRIPTION
All cooling systems are equipped with a pressure
cap (Fig. 37). For 5.9L engines, the pressure cap is
located on top of the radiator outlet tank. For the
3.7L/4.7L engines, the pressure cap is located on top
of the coolant degas container. The cap releases pres-
sure at some point within a range of 97-to-124 kPa
(14-to-18 psi). The pressure relief point (in pounds) is
engraved on top of the cap
The cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi-
ator cooling capacity. The cap contains a spring-
Fig. 36 Fan Shroud MountingÐ5.9L Diesel Engine
1 - RADIATOR SUPPORT
2 - UPPER FAN SHROUD
3 - BOLTS (2)
4 - LOWER FAN SHROUD
5 - RADIATOR
7 - 60 ENGINEDR
RADIATOR - 5.9L DIESEL (Continued)

TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION
DESCRIPTION........................72
DESCRIPTION........................72
OPERATION...........................72
REMOVAL.............................72
DISASSEMBLY - 5.9L ONLY...............73
ASSEMBLY - 5.9L ONLY..................73
INSTALLATION.........................73TRANS COOLER - 5.9L DIESEL
DESCRIPTION.........................73
OPERATION...........................74
REMOVAL
REMOVALÐAIR TO OIL COOLER.........74
REMOVALÐWATER TO OIL COOLER......74
INSTALLATION
INSTALLATIONÐAIR TO OIL COOLER.....75
INSTALLATION.......................75
TRANS COOLER
DESCRIPTION
DESCRIPTION
An air-to-oil transmission oil cooler is standard on
all engine packages. The transmission oil cooler is
mounted to the front of the radiator above the power
steering cooler (Fig. 1).
DESCRIPTION
An air-to-oil transmission oil cooler is standard on
all engine packages. The transmission oil cooler is
mounted to the front of the radiator above the power
steering cooler (Fig. 2).
OPERATION
Transmission oil is routed through the cooler
where heat is removed from the transmission oil
before returning to the transmission. Vehicles
equipped with the 5.9L engine have an internal ther-
mostat that controls fluid flow through the cooler-
.When the transmission fluid is cold ( less than
operating temperature) the fluid is routed through
the cooler bypass. when the transmission fluid
reaches operating temperatures and above, the ther-
mostat closes off the bypass allowing fluid flow
through the cooler. The thermostat is serviceable.
NOTE: Vehicles with the 3.7L/4.7L engines are not
equipped with the oil cooler thermostat.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Place a drain pan under the oil cooler lines.(3) Disconnect the transmission oil cooler line
quick-connect fitting at the cooler outlet using the
quick connect release tool 6935. Plug the cooler lines
to prevent oil leakage.
(4) Unsnap the transmission cooler tubes from the
radiator tank clips.
Fig. 1 Cooling Module Ð 5.9L Gas
1 - TRANS OIL COOLER BYPASS (5.9L only)
2 - OIL COOLER THERMOSTATIC BYPASS VALVE (5.9L only)
3 -TRANS OIL COOLER
4 - OIL COOLER MOUNTING BOLT (4)
5 - POWER STEERING COOLER
6 - POWER STEERING COOLER MOUNTING BOLT(2)
7 - TRANS OIL COOLER OUTLET
8 - TRANS OIL COOLER INLET
9 - COOLER LINE CLIP
10 - COOLER LINE CLIP
11 - RADIATOR
7 - 72 TRANSMISSIONDR

(5) Remove the bolts attaching the transmission
cooler to the radiator.
(6) Remove oil cooler from the vehicle. Take care
not to damage the radiator core or transmission
cooler tubes.
DISASSEMBLY - 5.9L ONLY
NOTE: The transmission oil cooler uses an internal
thermostat to control transmission oil flow through
the cooler. This thermostat is servicable.
(1) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(2) Remove the snap ring retaining the thermostat
end plug (Fig. 3).
(3) Remove the end plug, thermostat and spring
from transmission oil cooler (Fig. 3).
ASSEMBLY - 5.9L ONLY
(1) Throughly clean the thermostat bore on the
transmission oil cooler.
(2) Install the new spring, thermostat, end plug
and snap ring.(3) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
INSTALLATION
(1) Position the transmission cooler tubes to the
front of the radiator.
(2) Snap the transmission cooler tubes into the
clips on the side of the radiator tank.
(3) Install the transmission cooler attaching bolts.
Tighten the bolts to 16 N´m (140 in. lbs.).
(4) inspect the quick connect fittings for debris and
install the quick connect fitting on the cooler tube
until an audible ªclickº is heard. Pull apart the con-
nection to verify proper installation and install the
secondary latches.
(5) Connect the battery negative cable.
(6) Start the engine and check all fittings for
leaks.
(7) Check the fluid level in the automatic trans-
mission. Refer to the appropriate transmission sec-
tion(Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 45RFE/545RFE/FLUID - STANDARD
PROCEDURE) or(Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 46RE/FLUID - STAN-
DARD PROCEDURE).
TRANS COOLER - 5.9L DIESEL
DESCRIPTION
All diesel models equipped with an automatic
transmission are equipped with both a main water-
to-oil cooler and a separate air-to-oil cooler. Both cool-
Fig. 2 Cooling Module - 3.7L/4.7L/5.7L
1 - TRANS OIL COOLER
2 - TRANS OIL COOLER MOUNTING BOLT (3)
3 - POWER STEERING OIL COOLER
4 - POWER STEERING OIL COOLER MOUNTING BOLT
5 - TRANS OIL COOLER OUTLET
6 - TRANS OIL COOLER INLET
7 - COOLER LINE CLIP
8 - COOLER LINE CLIP
9 - RADIATOR
Fig. 3 Transmission Oil Cooler Thermostat
Removal/Installation
1 - THERMOSTAT HOUSING
2 - SPRING
3 - END PLUG
4 - SNAP RING
5 - THERMOSTAT
DRTRANSMISSION 7 - 73
TRANS COOLER (Continued)