Table Of Contents - Dodge D150 1990 Service Manual

Table of Contents

Component And System Index4
Group Title6
Vehicle And Component Identification7
Vehicle Code7
Vehicle Identification Number7
Equipment Identification Plate7
Equipment Identification Label8
Vehicle Safety Certification Label8
Body Code Plate8
Engine Serial Number9
Transmission Identification9
Body Code Plate Information9
Engine Serial Number 5.2L And 5.9L9
Power Team Availability10
Ram Pickup10
Ram Chassis Cab11
Ramcharger Sport Utility11
Standard Truck Body Dimensions14
Torque References15
Bolt Torque15
Grade 5 And 8 Standard Torque Specifications15
Metric Bolt Identification15
International Symbols16
Metric System16
Metric Prefixes16
Conversion Tables17
Lubrication And Maintenance20
General Information20
Severe Service20
Noise Control Systems20
Required Maintenance For Noise Control Systems21
Exhaust System21
Air Cleaner Assembly21
Tampering With Noise Control System Prohibited21
Gear Lubricants22
Lubricants/Greases22
Parts And Lubrication Recommendations22
Light Duty Cycle - Gasoline Engines23
Heavy Duty Cycle - Gasoline Engines24
Fluid Capacities27
Assist (Jump) Starting27
Booster Battery27
Connecting Positive Jumper Cable27
Hoisting Recommendations28
Portable Starting Unit28
Twin Post28
Floor Jack28
Towing Recommendations29
Single Post Hoist/Outboard Twin Post29
Hoisting29
Towing Equipment29
Lifting-Ground Clearance30
Rear Towing Pickup30
Front Towing Pickup30
Towing Chains And Hooks30
Flat Towing31
Ignition Key Available31
Ignition Key Not Available31
Safety Precautions31
Storage For Less Than 1 Month32
Storage For 1 To 3 Months32
Storage For More Than 3 Months32
Engine33
During Break-In33
Viscosity33
Energy Conserving33
Checking Engine Oil Level34
Materials Added To Engine Oils34
Engine Oil Filter Selection34
Engine Oil Filter34
Cooling System35
Hoses And Fittings35
Radiator Cap35
Engine Air Cleaner35
Manifold Heat Control Valve36
Air Injection System36
Crankcase Ventilation System36
Ventilation System Operation36
Frequency Of Service37
Inspection And Service Procedure37
Crankcase Inlet Air Filter37
Check Vacuum At Pcv Valve37
Fuel System38
Gasolines Containing Alcohol38
Gasolines Containing Mtbe38
Materials Added To Fuel38
Spark Plugs39
Ignition Timing39
Battery39
Hoses39
Drive Belts40
Engine Mounts40
Ignition Wires40
Air Conditioning Compressor40
Drivetrain41
Clutch And Brake Linkage41
Clutch Master Cylinder41
Shifter Mechanism Boot41
Check Fluid Level42
Special Additives42
Drain And Fill42
Gearshift Linkage42
Automatic Transmission43
Transfer Case43
Drain, Filter Change, Band Adjustment And Fill43
Lubricant Selection44
Gear Shift Mechanism44
Conventional Differential44
Frequency Of Oil Change44
Front Axle Universal Drive Joint And Pivot Bearings45
Propeller Shaft Universal Joints45
Removing Filler Plug45
Rear Axle Fill Plugs45
Universal Joint Seal Inspection46
Universal Joint And Slip Spline With Grease Fittings (Typical)46
Constant Velocity Universal Joint Lubrication Points46
Chassis And Body47
Steering Linkage47
Front Suspension Ball Joints47
Steering Linkage Lubrication47
Manual Steering Gear48
Power Steering48
Wheel Bearings48
Front Wheel Bearings48
Upper And Lower Control Arm Bushings49
Brakes49
Master Cylinder49
Check Master Cylinder Fluid Level49
Parking Brake50
Brake Hoses50
Headlights50
Speedometer Cable50
Body Mechanisms Lubrication51
Accessories52
Snow Plow52
Snow Plow Components52
Hydraulic Cylinder And Motor53
Solenoid Valves53
Mechanical Hydraulic Valves53
Solenoid Valve "B"53
Pilot Check Valve54
Crossover Relief Valve54
Raise Blade—Voltage Application & Hydraulic Fluid Flow55
Lower & Float Blade - Voltage Application & Hydraulic Fluid Flow56
Angle Blade Right - Voltage Application & Hydraulic Fluid Flow57
Angle Blade Left— Voltage Application & Hydraulic Fluid Flow58
Snow Plow Diagnosis59
Snow Plow Wiring Diagrams60
Service Procedures60
Solenoid Valve Coil Functional Test60
Snow Plow Control Wiring Diagram61
Snow Plow Auxiliary Lighting Wiring Diagram63
Power Unit - Exploded View64
Power Unit Disassembly/Inspection65
Cylinder Components65
Power Unit Assembly66
Insert Valve66
Solenoid Valve "C"/Four-Way Valve66
Crossover Relief Valve - Disassembled66
Power Angling Cylinder Service67
Angling Cylinder - Exploded View67
Snow Plow Specifications68
Torque Specifications68
Front Suspension70
Front Wheel Alignment72
General Alignment Information72
Wheel Alignment Measurements72
Pre-Alignment Inspection73
Caster & Camber Adjustment Location73
Front Suspension Diagnosis74
Wheel Alignment Measurements/Adjustments75
Wheel "Toe" Position75
"Toe" Position Adjustment75
Front Suspension Component Service76
Lower Suspension Arm Strut Removal/Installation76
Lower Suspension Arm Removal/Installation76
Coil Spring Suspension—2Wd77
Spring Compressor & Ball Stud Loosening Tools Installed77
Lower Ball Stud Replacement78
Lower Ball Stud Removal79
Lower Ball Stud Installation79
Lower Suspension Arm Bushing Replacement80
Upper Suspension Arm Removal/Installation80
Ball Stud Loosening Tool Installed80
Upper Suspension Arm Bushing Replacement81
Upper Ball Stud Replacement81
Upper Suspension Arm Bushing Removal81
Steering Knuckle Removal/Installation82
Upper Suspension Arm Bushing Installation82
Tie-Rod End Ball Stud Removal82
Loosening Upper Ball Stud83
Model 44 Front Axle Service -4Wd Vahicles84
Rotor/Hub And Bearing Service84
Steering Knuckle, Spindle And Ball Stud Service85
Wheel Bearing Nut Lock Removal85
Wheel Bearing Adjusting Nut, Retaining Washer & Nut Lock85
Spindle Removal From Steering Knuckle86
Needle Bearing Removal (Right-Side Spindle)86
"Snap" Retaining Ring Removal/Installation86
Seal Installation On Axle Shaft Shield88
Lubricating Seal88
Right Axle Shaft Removal/Installation89
U-Joint Service89
Left Axle Shaft Service90
Bearing Cap Removal90
Bearing Cap Installation90
Bearing Cap & Spider Installation90
Left (Disconnect) Axle91
Intermediate Shaft Bearing Removal91
Right (Disconnect) Axle Housing Service Tools91
Inner Axle Shaft Removal/Installation92
Intermediate Shaft Bearing Installation92
Sealant On Housing Cover93
Wheel Lug Nut Tightening Sequence93
Disconnect Axle Vacuum Control System Service94
Axle Shift Motor Functional94
Disconnect Axle Vacuum Control System94
Axle Vacuum Shift Motor94
Disconnect Axle/Shift Motor Diagnosis95
Two-Wheel Drive Operation Diagnosis95
Four-Wheel Drive Operation Diagnosis96
Disconnect Axle Vacuum Hose Routing97
Shift Motor Service98
Steering Knuckle Arm Removal/Installation98
Shift Motor & Axle Disconnect Components98
Drag-Link Ball Stud Removal With Tool C-415098
Drag Link Removal/Installation99
Tie-Rod End Replacement99
Steering Knuckle Arm Removal99
Correct Drag Link Installation99
Stabilizer Bar Removal/Installation100
Complete Axle Removal/Installation100
Tie-Rod End Removal100
Stabilizer Bar—4Wd Vehicles100
Differential Service101
Ring Gear Runout Measurement102
Bearing Cap Identification102
Differential Housing Separation102
Differential Case Flange "Runout" Measurement103
Drive Pinion Gear Shaft Yoke Nut Removal103
Drive Pinion Gear Shaft Yoke Removal103
Model 44 Axle Differential - Exploded View104
Inner Bearing Removal104
Pinion Gear Mate Shaft Lock Pin Removal105
Differential Bearing Removal105
Master Bearing Tools On Hubs106
Drive Pinion Gear Depth Information107
Differential Case "End Play" Measurement107
Drive Pinion Gear Id Numbers107
Drive Pinion Gear Standard Depth/Distance108
Shim Locations108
Drive Pinion Gear Depth Variance109
Drive Pinion Gear Depth Measurement109
Pinion Gear Depth Gauge Tool Set D-271109
Pinion Block Tool Inserted In Shaft Bore109
Arbor Disc & Arbor Tools In Housing110
Pinion Height Block Tool Against Arbor Tool110
Shaft Front Bearing Cup Installation110
Shaft Rear Bearing Installation111
Rotating Drive Pinion Gear Shaft111
Drive Pinion Gear Shaft Seal Installation112
Ring Gear "Backlash" Adjustment114
Differential Housing, Separation115
Ring Gear "Backlash" Measurement115
Ring Gear Teeth Contact Patterns116
Differential Bearing Installation116
Differential Bearing Cap Reference Letters116
Desired Teeth Contact Patterns117
Incorrect Teeth Contact Patterns118
Lubricant119
Drain And Refill119
Model 60 Front Axle Service—4Wd120
Dualmatic Locking Hub Service120
Wheel Bearing Adjustment121
Rotor/Hub And Wheel Bearing Service121
Hex-Head Screw Removal/Installation122
Caliper Lock & Spring Removal122
Axle Shaft And U-Joint Service123
Caliper Lock & Spring Installation123
Spindle & Splash Shield Removal/Installation123
Steering Knuckle Service125
Lower Ball Socket Removal126
Seal & Lower Bearing Cup Installation126
Lower Bearing & Seal Installation126
Axle Specifications150
Rear Axles152
Noise Diagnosis153
Tire Noise154
Front Wheel Bearing Noise154
Gear Noise (Drive Pinion And Ring)154
Bearing Noise154
Pre-Disassembly Inspection155
Driveline "Snap"155
Axle Shaft Bearing Noise155
Engine And Transmission Noise155
Rear Axle Alignment159
Tire/Wheel Balance159
Sure-Grip/Trac-Lok Differentials160
Rear Axle With 8 3/8-Inch Ring Gear161
Rear Axle With 9 1/4-Inch Ring Gear162
Axle Shaft, Seal And Bearing Service163
Axle Shaft Removal163
Pinion Gear Mate Shaft Lock Screw163
Axle Shaft C-Clip Lock163
Axle Shaft Seal And Bearing Removal164
Axle Shaft Bearing And Seal Installation164
Axle Shaft Installation164
Axle Shaft Seal Installation164
Drive Pinion Gear Shaft Seal Replacement165
Tightening Drive Pinion Gear Shaft Nut166
Standard Differential Service167
Differential "Side Play" Test168
Brake Components210
Antilock Rear Wheel Brake System (Rwal)210
Brake Fluid/Lubricants/Cleaning Solvents210
Brake Safety Precautions211
Battery Service Diagnosis211
Preliminary Brake Check211
Road Testing211
Pedal Falls Away212
Low Pedal212
Brake Fade212
Spongy Pedal212
Pull213
Rear Brake Grab Or Pull213
Brake Noise213
Brakelining Contamination213
Power Booster Check Valve Test214
Power Booster Vacuum Test214
Vacuum Check Valve And Seal (Typical)214
Typical Booster Vacuum Test Connections214
Service Adjustments215
Brake Fluid And Level215
Recommended Fluid215
Rear Brake Adjustment215
Brake System Bleeding216
Adjustment With Tool C-3784216
Testing Drum Brake Adjuster Operation216
Wheel Nut Tightening217
Stop Lamp Switch Adjustment217
Metering Valve Tool C-4121217
Wheel Nut Tightening Sequence217
Without Speed Control218
With Speed Control218
Master Cylinder - Combination Valve - Brake Lines219
Two-Section Master Cylinder219
Integral Master Cylinder219
Combination Valve220
Master Cylinder Removal220
Master Cylinder Service—Two-Section Cylinder220
Reservoir Replacement - Two Section Cylinder220
Integral Cylinder Assembly221
Master Cylinder Bleeding221
Cylinder Bleeding Procedure221
Master Cylinder Installation221
Combination Valve Operation222
Combination Valve Removal/Installation222
Metering (Hold-Off) Valve222
Pressure Differential Switch And Valve222
Brake Line And Hose Replacement223
Combination Valve Mounting223
Front Brake Lines224
Rear Brake Lines And Rwal Components225
Brake Lines—Two-Wheel Drive Models226
Brake Lines—Four-Wheel Drive Models227
Brake Line Emergency Repair228
Flaring228
Brakeline Flaring Tools228
Power Brake Booster - Brake Pedal229
Booster Removal229
Power Brake Booster And Pedal Mounting229
Booster Installation230
Brake Pedal Removal/Installation230
Chrysler Disc Brake231
General Service Information231
Disc Brake Components231
Chrysler Disc Brake Caliper Mounting231
Disc Brake Operation233
Disc Brake Lining Wear Compensation233
Brakeshoes233
Hoses And Adapter233
Brake Shoe Removal234
Removing/Installing Retainer Clips And Anti-Rattle Springs234
Caliper Removal/Installation234
Removing Outboard Brakeshoe234
Brakeshoe Installation235
Removing/Installing Inboard Brakeshoe235
Outboard Brakeshoe Positioed On Caliper Finger235
Caliper Removal236
Caliper Overhaul236
Caliper Disassembly236
Seating Outboard Brakeshoe236
Removing Caliper Piston Seal237
Caliper Components237
Installing Caliper Piston Seal237
Lightly Polishing Piston Bore With Tool C-4095237
Caliper Installation238
Rotor Removal238
Rotor Inspection And Service238
Installing Caliper Piston238
Checking Rotor Minimum Thickness239
Rotor Runout239
Rotor Thickness Variation239
Rotor Refinishing239
Rotor Installation240
Rotor Refinishing Equipment240
Bendix Disc Brake241
Bendix Disc Brake Caliper241
Caliper Mounting Adapter Attachment241
Bendix Disc Brake Caliper Operation242
Rear Wheel Anti-Lock Brake System264
Intermediate Cable Replacement264
Rear Wheel Anti-Lock Brake System (Rwal)264
Anti-Lock Electronic Control Module265
Rwal Hydraulic Valve265
Speed Sensor And Exiter Ring265
Anti-Lock Indicator Lamp266
Anti-Lock System Operation266
Normal Braking Mode266
Rwal Speed Sensor266
Isolation/Dump Valve Cycle Times267
Rwal Service Diagnosis268
System Fault Codes268
Fault Code Capacity268
Fault Code Identification268
Clearing A Fault Code269
Connector Locations269
Module Connector Identification269
Module Connector Pin Position269
Component Service270
Hydraulic Valve Replacement270
Checking Speed Sensor Air Gap270
Valve Removal/Installation270
Speed Sensor Replacement271
Sensor Removal271
Sensor Installation271
Electronic Control Module Replacement271
Clutch274
Clutch Components274
Clutch Linkage Fluid274
Clutch Component Lubrication274
Service Diagnosis275
General Diagnosis Information275
Clutch Misalignment275
Clutch Problem Causes275
Measuring Clutch Housing Bore Runout276
Correcting Clutch Housing Bore Runout276
Dial Indicator Mounting Stud Or Rod276
Clutch Housing Misalignment And Runout276
Measuring Clutch Housing Face Runout277
Correcting Clutch Housing Face Runout277
Installation Methods And Parts Usage278
Inspection And Diagnosis Charts278
Clutch Inspection Points279
Clutch Slips280
Improper Clutch Release281
Clutch Grab/Chatter282
Clutch Noise283
Clutch Service284
Clutch Cover And Disc Removal284
Clutch Cover And Disc Installation284
Clutch Disc Alignment284
Release Bearing Replacement285
Clutch Housing Removal/Installation285
Clutch Housing Installation And Tightening Reference285
Clutch Release Fork And Bearing285
Pilot Bushing Replacement286
Clutch Linkage Service286
Linkage Removal286
Linkage Installation286
Clutch Linkage And Pedal Components287
Clutch Pedal Removal/Installation288
Cooling System Components290
System Coolant Routing291
Diagnosis292
Engine Cooling System Overheat Diagnosis292
Cooling System Diagnosis293
Water Pumps297
Water Pump Removal297
Radiator Fan Removal/Installation298
Water Pump Removal/Installation298
Water Pump Installation299
Engine Thermostat299
Thermostat Removal300
Thermostat Installation300
Coolant300
Coolant Performance300
Coolant Selection - Additives301
Coolant Service301
Coolant Level Check-Routine301
Low Coolant Level - Aeration301
Refilling The Cooling System302
Cooling System Cleaning, Reverse Flushing302
Reverse Flushing Radiator302
Reverse Flushing Engine302
Testing Cooling System For Leaks303
Ultraviolet Light Method303
Presser Tester Method303
Internal Leakage Inspection303
Coolant Reserve System (Crs)304
Combustion Leakage Test (Without Pressure Tester)304
Radiator Pressure Cap305
Radiator Cap To Filler Neck Seal, Pressure Relief Check305
Pressure Testing Radiator Caps305
Radiator306
Radiator Coolant Flow Check306
Radiator Removal306
Radiator And Fan Shroud306
Transmission Oil Cooler307
Radiator Draincock Service307
Cooling System Hoses307
Hose Clamps307
Transmission Oil-To-Air Cooler308
Cooling System Fan308
Thermal Control Fan Drive308
Fan Installation309
Accessory Drive Belts310
Proper Belt Tension310
Belt Tension Testing310
V-Belt Diagnosis310
Accessory Drive Belt Schematics311
Alternator And Air Conditioning Belts311
Air Pump Belt312
Power Steering Pump Belt312
Engine Block Heaters313
Cooling System Specifications314
Conversion Chart314
Tightening Reference314
Accessory Drive Belt Tension315
Electrical316
Battery/Starting/Charging Systems Diagnostics316
Diagnostic Information316
Starting System Components316
Battery Test Procedures On Vehicle317
Charging System Components317
Test Indicator318
State Of Charge Test318
Causes Of Battery Discharging318
Battery Construction And Test Indicator318
Ignition Off Draw (Iod)319
Open Circuit Voltage Test319
Ignition Off Draw Tests319
Low Amperage Iod Test319
Battery Load Test320
Battery Open Circuit Voltage320
Volt-Amps-Load Tester320
Volt-Ammeter-Load Tester Connections320
Charging Battery321
Load 50% Cold Crank Rating Note Voltage321
Charging Time Required322
Charging Completely Discharged Battery322
Battery Charging Time Table322
Voltmeter Accurate To 1/10 Volt Connected322
Battery Diagnostics Chart323
Starter Won't Crank323
Visual Inspection323
Test Indicator/Open Circuit Voltage Test323
Starter Test Procedures On Vehicle324
Starter Feed Circuit Test324
Volt-Amps Tester (Typical)324
Volt-Amps Tester Connections (Typical)324
Starter Feed Circuit Resistance Test325
Starter Draw Tests325
Test Battery Connection Resistance325
Test Ground Circuit Resistance325
Starting System Diagnostics326
Starter Control Circuit Tests327
Starter Solenoid Test327
Starter Relay Test327
Test Starter Motor Ground327
Ignition Switch Test328
Bench Testing Starter Solenoid328
Alternator Test Procedures On Vehicle329
Alternator Output Wire Resistance Test329
Current Output Test330
Alternator Output Wire Resistance Test (Typical)330
Using On-Board Diagnostic System331
Operation Of On-Board Diagnostic System331
Fault Codes331
Alternator Current Output Test331
Charging System Diagnostics332
How To Use Check Engine Lamp For Fault Codes333
Charging System Fault Codes333
Alternator Fault Code Chart333
Reduction Gear Starter334
Alternator Specifications334
Battery/Starter Service336
Battery Visual Inspection And Service336
Maintenance Free Battery336
Battery Holddown337
Battery Tray337
Cleaning Battery337
Cleaning Battery Post337
Cleaning Battery Cable Terminal338
Battery Cables Disconnected338
Starter Service Procedures339
Starting System Description339
Starter Motor Removal And Installation339
Remove Or Install Starter Wire Connector339
Remove Or Install Starter Motor340
Battery Specifications341
Alternator Service342
Alternator Removal And Installation342
Remove Or Install Alternator Mounting Bolts342
Remove Or Install Wire Connector342
Ignition Systems344
Distributor Cap344
Distributor Cap Inspection—Typical344
Distributor Rotor345
Engine Firing Order—3.9L345
Engine Firing Order—5.2L And 5.9L345
Distributor Rotor Inspection—Typical345
Spark Plug Cable Resistance346
Spark Plug Condition347
Normal Operating Conditions347
Setting Spark Plug Gap347
Electrode Gap Bridging347
Chipped Electrode Insulator348
Spark Plug Overheating348
Scavenger Deposits348
Preignition Damage348
Single Board Engine Controller349
Spark Plug Removal349
Spark Plug Gap Adjustment349
Spark Plug Installation349
Coolant Temperature Sensor350
Auto Shutdown (Asd) Relay350
Manifold Absolute Pressure (Map) Sensor350
Ignition Coil351
Asd Relay Location351
Ignition Coil Connections351
Testing For Spark At Coil352
Failure To Start Test352
Checking For Spark352
Coil Terminals352
Coolant Temperature Sensor Test353
Sbec 60-Way Connector353
Poor Performance Test353
Spark Advance (Sbec Controlled) Test353
Single Board Engine Controller (Sbec)354
Spark Plug Service355
Ignition Timing Procedure355
Idle Rpm Test355
Distributor356
Hall Effect Pick-Up Assembly Replacement357
Hall Effect Pick-Up Removal And Installation357
Ignition Rotor Removal And Installation357
Distributor Specifications358
Sensor Specifications359
Instrument Panel And Gauges360
Instrument Cluster360
Message Center - Gas Engine360
Emissions Maintenance Reminder360
Message Center361
Electronic Digital Clock361
Anti-Lock Warning Light361
Brake System Warning Light361
Temperature And Oil Indicating System362
Alternator Indicating System362
Fuel Level Indicating System362
Temperature/Oil Indicating System362
Cluster And Gauge Service And Testing363
Speedometer/Odometer System363
Distance Sensor Test363
Sending Unit Test363
Fuel Tank Sending Unit Test364
Fuel Gauge System Diagnosis364
Warning Lamp System Tests365
Low Oil Pressure Warning Lamp Circuit Test365
Combination Oil Switch And Connection365
Combination Oil Unit Test366
Seat Belt Warning System366
Brake System Warning Lamp366
Brake Warning Lamp Switch366
Cluster Bezel367
Instrument Cluster Bezel367
Cluster Mask And Lens368
Instrument Cluster Assembly368
Printed Circuit Board368
Instrument Panel Cluster And Switches368
Gauge Replacement370
Gauge And Gauge Circuit Testing370
Temperature Gauge Circuit Test370
Fuel Gauge370
Temperature/Oil/Fuel Gauge Diagnosis371
Oil Pressure Gauge Circuit Test371
Fuel Gauge Circuit Test372
Voltage Gauge Circuit Test372
Voltmeter Pins372
Speedometer Pins372
Lamp Bulbs373
Cluster Illumination Lamps373
Lamp Bulb Replacement373
Four Wheel Drive Indicator Lamp373
Switch And Panel Component Service374
Steering Column Lowering And Raising374
Lowering Steering Column374
Heater Control375
Heater A/C Control375
Switches375
Headlamp Switch375
Power Mirror Switch376
Auxiliary Headlamp Switch376
Snow Plow Toggle Switch376
Cargo Lamp Switch377
Map Lamp Switch377
Glove Box Lamp Switch377
Snow Plow Control Assembly377
Fuseblock And Flashers378
Overdrive Lockout Switch378
Message Center Module378
Hood Release378
Cigar Lighter379
Housing379
Ash Tray379
Glove Box379
Glove Box Lock380
Catch380
Illumination Bulb Replacement380
Glove Box And Bin380
Ash Tray Illumination Lamp381
Map Lamp Bulb381
Four Wheel Drive Indicator381
Heater Or Heater A/C Illumination Lamp381
Radio, Antenna And Speakers382
Radio Schematics382
Interference Elimination382
Radio Reception Mode382
Radio Connector Pins383
Radio Diagnosis384
Test Procedures385
Antenna385
Bench Test For Antenna Malfunction385
Antenna Bench Test Points385
Removing Antenna Cable386
Cap Nut And Adapter386
Removing Grommet386
Removing Or Installing Antenna Body386
Radio Replacement387
Door Mounted Speaker387
Instrument Cluster Faceplate387
Radio To Instrument Panel Mounting387
Rear Speaker - Standard Cab Pickup388
Rear Speaker - Club Cab Pickup388
Rear Speaker - Ramcharger388
Ramcharger Rear Speaker388
Horns390
Horns Will Not Sound390
Horns Sound Continuously391
Horn Switch Replacement391
Horn Replacement391
Standard Steering Wheel391
Horn Replacement - Diesel Engine393
Optional Steering Wheel393
Horn Removal And Installation393
Speed Control System394
Road Test398
Inoperative System398
Checking For Fault Code398
Speed Control System Electrical Tests398
Electrical Tests At Engine Controller399
Stop Lamp Speed Control Switch Test399
Engine Controller And Connector Location399
Vacuum Supply Test400
Speed Control Switch Continuity Chart400
Speed Control Switch400
Speed Control Cable Attachment400
Speed Control Cable Attachment - Servo401
Speed Control Cable And Mounting Bracket401
Push Cable In And Mark At Protective Sleeve401
Speed Control Cable Attachment At Servo401
Speed Control Servo402
Servo Throttle Cable Assembly402
Steering Column Cover402
Speed Control Vacuum Reservoir Replacement403
Steering Column Connectors403
Removing Steering Wheel403
Turn Signals And Hazard Warning Flasher404
Turn Signal Lever Positions404
Hazard Warning Knob404
Turn Signal And Hazard Warning Flasher Location405
Hazard Warning System Diagnosis405
Turn Signal And Hazard Warning Switch Tests405
Turn Signal System Diagnosis406
Turn Signal/Hazard Warning Switch407
Steering Column Wiring Connectors408
Removing Steering Wheel (Typical)408
Disconnecting Wires408
Turn Signal Switch408
Windshield Wiper And Washer Systems410
Standard Two Speed Wiper Motor System Test410
Voltmeter Between Terminal "L" And Ground412
Test Lamp Between Terminal "H" And Ground412
Switch Test413
Two Speed Wiper Switch Continuity Chart413
Two Speed Wiper Motor Wiring Schematic413
Intermittent Windshield Wiper Function And Switch Testing Procedures414
Intermittent Wipe Switch Test414
Intermittent Wipe Module Location414
Intermittent Wipe Switch Continuity Chart415
View From Terminal Side415
Intermittent Wipe Wiring Schematic415
Windshield Wiper System Service Procedures416
Wiper Blades416
Wiper Blade Element Change416
Wiper Arm Replacement416
Wiper Motor Replacement417
Linkage Replacement417
Drive Assembly Left Pivot Assembly417
Adjusting Wiper Arms417
Right Pivot Assembly418
Wiper Linkage418
Wiper Switch Replacement418
Wire Trough Cover419
Wiper Switch Replacement-Tilt Column419
Windshield Washers424
Windshield Washer Pump Replacement424
Windshield Washer System424
Windshield Washer Diagnosis425
Lamps426
Exterior Lamps426
Headlamp Diagnosis426
Headlamp Dimmer Switch Test427
Dimmer Switch Wiring Harness427
Dimmer Switch Test Points427
Exterior Lamps Service Procedures428
Sealed Beam Replacement428
Side Marker Lamp And Bulb428
Tail, Stop, Turn Signal, Rear Side Marker And Back-Up Lamps428
Cab Chassis429
I.d. And Clearance Lamps For Dual Wheel429
Wheel Flare Mounted And Rear Clearance Lamps429
Cargo Lamp Bulb430
Rear Clearance Lamps430
Clearance And Identification Lamps430
License Lamp431
Cargo Lamp431
License Plate Lamps431
Step Bumper431
Headlamp Dimmer Switch432
Headlamp Aiming Procedures432
Pre Aiming Instructions432
Compensating The Aimers For Floor Slope432
Testing Aimer Calibration433
Mounting Aimers433
Checking Aimer Calibration433
Checking Vertical Aim Calibration433
Horizontal Adjustment434
Vertical Adjustment434
Headlamp Adjustment Using Aiming Screen Method434
Headlamp Aimers In Position434
Underhood Retractable Lamp435
Interior Lamps435
Daytime Running Light Module435
Underhood Lamp Removal/Installation435
Dome With Headliner436
Exterior Light Bulbs437
Circuit Breaker437
Warning Buzzer/Chime Module438
Seat Belt Warning Buzzer Location438
Buzzer Module Connector Terminal Identification438
Seat Belt Buckle Switch Test439
Warning Buzzer System Schematic439
Key-In Switch440
Standard Steering Wheel Horn Pad Removal440
Remove Steering Wheel With Tool440
Remove Lock Plate Retaining Ring Using441
Hazard Warning Switch Knob442
Rear Window Defogger444
Control Switch/Timer Relay Module444
Control Switch/Timer Module Test445
Rear Window Grid Lines Test445
Systems Electrical Circuit445
Repair Procedures446
Grid Line Repair446
Heated Rear Window Control Switch Replacement447
Power Locks448
Circuit Breaker Test448
Voltage Test448
Electric Motor Test448
Door Lock Motor Replacement449
Door Trim Panel449
Power Windows450
Switch Voltage Test450
Power Window System Diagnosis451
Gear And Pinion Replacement And Lubrication453
Regulator And Motor Assembly453
Electric Window Regulator Mounting453
Bench Repair454
Power Mirrors456
Mirror Motor Test Procedure456
Mirror Test Chart456
Power Mirror And Headlamp Switches456
Mirror Switch Test Procedure457
Mirror Switch Replacement457
Mirror Assembly Replacement457
Power Mirror Replacement458
Electrical Wiring Diagrams460
Main Circuit Identification Codes461
Wire Color Code Chart461
Locating A System Or Component462
Splice Locations462
Fusible Links462
Fusible Link Replacement462
Symbols, Fuses And Connectors463
Multiple Fusible Link Replacement463
Single Fusible Link Replacement463
Fusible Link Repair463
Legend Of Symbols Used On Wiring Diagrams464
Component Identification466
Wiring Diagrams467
Clearance Lamp Wiring With Dual Rear Wheel469
Tailgate Wiring469
Roof Wiring470
Interior Wiring470
Cab Wiring471
Extended Cab Wiring472
Door Wiring473
—Cowl Panel Wiring474
—Steering Column Wiring474
Instrument Panel Wiring475
Stop Lamp And Parking Brake Switch Wiring476
A/C Heater Wiring476
Snow Plow Control Wiring477
Engine Compartment Wiring Efi Engine478
Engine Compartment Wiring Diesel Engine479
Starter Wiring480
Four-Wheel Drive Wiring480
Underhood Lamp Wiring481
Transmission Wiring482
Engine Wiring483
Snow Plow Wiring484
Wiring Diagrams - Electrical485
Splice Location486
Electrical Wiring Diagrams Wire Routing And Component Location496
Alphabetical Index496
Fuse Application Chart503
Charging System With Electronic Fuel Injection Ignition505
Starter System510
Part Throttle Unlock511
3-Speed Automatic Transmission511
Ignition Switch512
Overdrive Lockout System (Gas)513
Overdrive Lockout System (Diesel)514
Electronic Fuel515
Injection Ignition System515
Diesel Engine Wiring520
Automatic Transmission Wiring-Diesel525
Message Center (Diesel)555
Message Center (Gas)556
Cluster - Printed Circuit Board557
Printed Circuit Board Connectors558
Stereo Radio-4 Speakers559
4 Wheel Drive Indicator Lamp569
Electric Window Lift Connector And Switch Functions570
Electric Door Locks571
Left Door Switch Connector572
Right Door Switch Connector572
Power Remote Mirrors573
Single Board Engine Controller Connector579
Viewed From Wire End583
Instrument Panel To Steering Column Wiring583
Crankshaft588
Cylinder Head588
Six-Cylinder Engine588
Valve Covers589
Intake Manifold589
Engine Firing Order—3.9 Liter589
Water Cooled Intake Manifold589
Engine Description—5.2/5.9 Liter590
Standard Service Procedures591
Form-In-Place Gaskets591
Room Temperature Vulcanizing591
Engine Performance591
Honing Cylinder Bores592
Measuring With Plastigage592
Cylinder Bore Cross-Hatch Pattern592
Repair Of Damaged Or Worn Threads593
Placement Of Plastigage In Bearing Shell593
Clearance Measurement593
Altenrative Method593
Engine Diagnosis594
Service Diagnosis - Mechanical594
Service Diagnosis - Performance595
Inspection For Engine Oil Leaks596
Checking Engine Oil Pressure596
3.9L Engine597
Engine Front Mounts (Insulators)597
Engine Rear Mount (Insulator)597
Engine Front Mounts597
Engine Assembly598
Rear Engine Support598
Check Operation Of Exhaust Valve Rotators598
Rocker Arms And Shaft Assembly599
Intake And Exhaust Rocker Arm Identification599
Rocker Arm Location—Left Bank599
Cylinder Heads600
Rocker Arm Retainers And Notch Location600
Cylinder Head Assembly600
Cylinder Head Bolt Tightening Sequence600
Intake Manifold Sealing601
Intake Manifold Bolt Tightening Sequence601
Valves And Valve Springs602
Valve Inspection602
Compress Valve Springs With Tool C-3422A602
Positioning Valve With Tool C-3973602
Refacing Valves And Valve Seats603
Valve Seats603
Valves603
Testing Valve Springs603
Checking Valve Spring For Squareness604
Installing Valve, Cup Seal, Spring And Retainer604
Measuring Valve Stem Length With Tool C-396B604
Replace Valve Stem Shields Or Valve Springs605
Hydraulic Tappets605
Oil Level Too High605
Oil Level Too Low605
Valve Timing606
Hydraulic Tappet Assembly606
Timing Chain Cover, Oil Seal And Chain607
Cover Removal607
Measuring Timing Chain For Stretch607
Measuring Timing Chain Wear And Stretch607
Timing Chain Cover External Oil Seal608
Removing Oil Seal608
Installing Vibration Damper With Tool C-3688608
Installing Oil Seal608
Camshaft (Engine Removed From Vehicle)609
Camshaft And Dual Sprocket Assembly609
Location Of Cup Plugs In Oil Galleries609
Timing Chain Oil Tab Installation609
Distributor Drive Shaft Bushing610
Alignment Of Timing Marks610
Removal/Installation Camshaft Bearings610
Camshaft Bearings610
Distributor Timing611
Cylinder Block611
Installing Distributor Driveshaft Bushing611
Position Of Installed Distributor Drive Gear611
Engine Core Oil And Cam Plugs612
Cylinder Bore Inspection612
Pistons, Pins And Rings612
Finished Pistons612
Piston Pins613
Fitting Rings613
Connecting Rods613
Measuring Piston Ring Side Clearance613
Installation Of Connecting Rod Bearings614
Crankshaft Identification614
Crankshaft Main Bearings614
Crankshaft Main Journals614
Rear Main Bearing Oil Seals615
Upper Rope Seal615
Main Bearing Identification615
Installing Upper/Lower Oil Seal With Tool C-3511615
Rear Main Bearing Cap616
Oil Pan End Seal At Rear Bearing616
Oil Pan Gaskets And Seal Installation616
Oil Pump617
Oil Pressure Relief Valve617
Checking Oil Pump Cover Flatness617
Measuring Outer Rotor Thickness617
Oil Pump Assembly And Installation618
Measuring Inner Rotor Thickness618
Measuring Clearance Between Rotors618
Measuring Clearance Over Rotors618
Oil Line Plug Inspection619
Oil Filter619
Removing Oil Filter With Tool C-4065619
Engine Lubrication System619
Engine Specifications—3Jl620
Engine Rear Mounts—4-Wd627
Checking Operation Of Exhaust Valve Rotators627
Intake And Exhaust Rocker Arm629
Proper Rocker Arm Location On Shaft629
Torque Specifications-5.2L/5.9L657
Exhaust System And Intake Manifold658
Heat Shields658
Exhaust Gas Recirculation (Egr)658
Catalytic Converter658
Exhaust Diagnosis660
Frame Structures672
Frame Siderail Material672
Frame Load-Carrying Capacity672
Frame Type672
Inspection Procedures677
Horizontal Or Diagonal677
Vertical Or Sideview677
Measurements678
Frame Dimensions679
Springs/Shock Absorbers768
Steering780
Steering System Description780
Power Steering Pump Service818
Pump Leakage Diagnosis822
Pressure Test823
Pressure Test Gauge823
Flow Control Value823
Hose Removal824
Hose Installation824
Pump Removal825
Pump Installation825
Pump Repair Service825
Pulley Removal825
Pump Disassembly826
Pulley Installation826
Pump Clamped In A Vise826
Vane-Submerged Type Pump826
Pump Cleaning And Inspection827
End Plate Retaining Ring Removal827
Pump Shaft Removal827
Pump Assembly828
Pressure/Thrust Plates & Ring/Rotor Removal828
Pump Shaft Retaining Ring Removal828
Pump Seal Removal828
Pump Shaft Seal Installation829
Thrust Plate & Rotor Assembly829
Pump Housing Bore829
Rotor Retaining Ring Installation829
Pump Initial Operation830
Cam Ring Installation830
Rotor Vane Installation830
Seating Pressure Plate831
End Plate Installation831
Flow Control Valve/Spring Installation831
Pump & Reservoir Seals832
Pump Shaft Pulley Installation832
Steering Column Service833
Steering Column—Console Shift833
Steering Column - Removal/Installation834
Steering Column - Column Shift834
Link Rod Removal From Grommet835
Turn Signal Lever835
Steering Wheel (Typical)835
Replacement Grommet Installation835
Standard/Fixed Steering Column836
Ground Clip & Spacer Installation836
Wash/Wipe Switch Removal/Installation836
Steering Shaft Disassembly837
Multi-Function Control Stalk Removal/Installation837
Ignition Key Lamp837
Turn Signal & Flasher Switch Removal837
Ignition Key Buzzer/Chime Switch Removal838
Key/Lock Cylinder & Lock Levers838
Dimmer Switch838
Shift Tube Disassembly/Assembly838
Shift Tube Removal839
Shift Tube Installation839
Upper Part Of Steering Column840
Steering Column Shaft841
Lock Housing & Shift Gate841
Transmission Shift Lever Installation841
Lock Levers & Spring Assembly841
Key Lamp And Turn Signal Switch Installation842
Shaft Installation842
Tiltable Steering Column842
Lock Plate Retaining Ring Removal/Installation843
Connector & Wires Taped843
Key/Lock Cylinder Removal844
Key Buzzer/Chime Switch & Wedge Spring844
Wash/Wipe Switch Pivot Pin Removal844
Tilt Spring Retainer Removal844
Ignition Switch Removal845
Pivot Pin Removal845
Steering Column Shaft Centering Spheres845
Bearing Housing—Disassembly846
Bearing Housing-Assembly846
Shift Tube Removal From Bowl846
Sector & Bolt Spring846
Manual Steering Gear Specifications849
Power Steering Gear Specifications849
Transmission-Transfer Case852
Noisy Operation853
Slips Out Of Gear853
Clutch Problems853
Hard Shifting853
Shift Linkage Removal/Installation854
Gearshift Linkage Adjustment854
Speedometer Pinion And Adapter Service854
Adapter Oil Seal Replacement855
Adapter And Pinion Installation855
Extension Housing Yoke Seal Replacement855
Removing Yoke Seal856
Transmission Disassembly857
Gearshift Housing And Shift Mechanism Removal857
Transmission Mounted In Repair Stand857
Overdrive-4 Transmission Components858
Extension Housing/Mainshaft/Drive Pinion Removal859
Rotating Extension Housing For Access To Countershaft859
Removing/Installing Extension Housing And Mainshaft859
Mainshaft Disassembly860
Mainshaft Gear Identification860
Removing/Installing Mainshaft Geartrain Snap Ring860
Removaing/Installing Mainshaft860
Drive Pinion/Countershaft Gear Disassembly861
Reverse Gear/Shaft/Lever/Fork Removal861
Removing Reverse Idler Gear Shaft861
Transmission Case861
Transmission Assembly862
Reverse Gear/Shaft/Lever/Fork Installation862
Countershaft Gear/Drive Pinion Installation862
Gears862
Extension Housing Bushing Replacement863
Synchronizer Assembly863
Positioning Countershaft Gear In Case863
Gear, Shaft And Lever Placement863
Replacing Extension Housing Bushing864
First-Second Synchronizer Components864
Third-O/D Synchronizer864
Np2500 Manual Transmission867
Adapter And Pinion Removal868
Speedometer Adapter And Pinion Components868
Installing Adapter Oil Seal And Lock Ring868