Dodge D150 1990 User manual

199 0
SERVICE
MANUAL
REAR WHEEL DRIVE
RAM TRUCK
^CHRYSLER
WMOTORS

CHRYSLER
MOTORS
1990
SERVICE MANUAL
DODGETRUCKS
^CHRYSLER
WMOTORS
No part of this publication maybe reproduced,
stored ina retrievalsystem or transmitted in
anyform, orbyany means,electronic,mechan-
ical, photocopying,recording, or otherwise with-
out the prior written permission of Chrysler
Motors.
To order the special service toolsused and illus-
trated, please refer tothe instructions on inside
back cover.
ChryslerMotors reservesthe right tochange
testing procedures,specifications,diagnosis, or
repair methods atany timewithoutpriornotice
or incurring obligation.
Litho inU.S.A. Copyright ©1989 ChryslerMotors20M1189

COMPONENT ANDSYSTEM INDEX
Name Group-page
ACCESSORIES 1-1
SNOW PLOW 1-1
SPECIFICATIONS.1-17
ALTERNATORSERVICE8C-1
SPECIFICATIONS8C-2
BATTERY/STARTERSERVICE8B-1
BATTERYSERVICEPROCEDURES ...... 8B-1
SPECIFICATIONS8B-6
STARTERSERVICEPROCEDURES8B-4
BODY 23-1
CORPORATE IDENTITY CODE 23-38
DOOR SYSTEMS 23-20
EXTERIOR PAINT 23-38
FIXEDGLASS 23-27
GLASS SYSTEMS. 23-24
INTERIOR TRIM 23-1
INTERIOR TRIM COLOR 23-38
LATCHANDLOCKSYSTEMS 23-20
REFilMISHING PROCEDURES 23-32
SHEET METAL 23-10
BRAKES 5-42
11- INCH DRUM BRAKE'*. 5-42
12- INCH DRUM BRAKE5-46
BENDIX DISCBRAKE5-32
CHRYSLER DISCBRAKE5-22
COMPONENT SERVICE. 5-61
GENERAL INFORMATION 5-1
MASTER CYLINDER-COMBINATION
VALVE-BRAKELINES5-10
PARKING BRAKESV 5-52
POWER BRAKEBOOSTER-BRAKEPEDAL5-20
REARWHEEL ANTI-LOCK BRAKESYSTEM (RWAL) . 5-55
RWAL SERVICE DIAGNOSIS 5-59
SERVICE ADJUSTMENTS 5-6
SERVICE DIAGNOSIS 5-2
CLUTCH6-1
CLUTCHSERVICE6-11
GENERAL INFORMATION 6-1
SERVICE DIAGNOSIS 6-2
COOLING SYSTEM. . . . 7-1
ACCESSORY DRIVE BELTS7-21
COOLING SYSTEM DIAGNOSIS : 7-4
DIAGNOSIS 7-3
ENGINE BLOCKHEATERS. . . 7-24
SERVICE PROCEDURES7-8
SPECIFICATIONS7-25
DRIVE SHAFTSAND UNIVERSAL JOINTS . . 16-1
GENERAL INFORMATION 16-1
SERVICE PROCEDURES16-10
SPECIFICATIONS. 16-27
ELECTRICAL WIRING DIAGRAMS 8W-1
COMPONENT IDENTIFICATION 8W-7
ELECTRICAL WIRING DIAGRAMS
WIRE ROUTING AND COMPONENT LOCATION. . 8W-37
SPLICE LOCATION 8W-27
WIRING DIAGRAMS 8W-1
Name Group-page
ELECTRICAL 8A-1
ALTERNATORTESTPROCEDURESONVEHICLE.. . 8A-14
BATTERYTESTPROCEDURESONVEHICLE8A-2
BATTERY/STARTING/CHARGING SYSTEMS
DIAGNOSTICS 8A-1
DIAGNOSTIC INFORMATION 8A-1
GROUP INDEX ......"8A-1
SPECIFICATIONS8A-19
STARTERTESTPROCEDURESONVEHICLE8A-9
EMISSION CONTROL SYSTEMS25-1
AIR INJECTION SYSTEM25-17
EVAPORATIVE EMISSION CONTROLS25-2
EXHAUST EMISSION CONTROLS25-9
SERVICE PROCEDURES 25-22
ENGINE . . . 9-1
3.9L ENGINE SERVICEPROCEDURES9-10
5.2L75.9L ENGINE SERVICEPROCEDURES9-39
ENGINE DIAGNOSIS 9-7
GENERAL INFORMATION 9-1
STANDARD SERVICEPROCEDURES9-4
EXHAUST SYSTEMAND INTAKE MANIFOLD 11-1
EXHAUST DIAGNOSIS 11-3
GENERAL INFORMATION 11-1
SERVICE PROCEDURES11-3
FRAME STRUCTURES13-1
INSPECTION PROCEDURES13-6
LIGHT DUTY MODELS 13-12
SERVICE PROCEDURES13-11
SPECIFICATIONS13-12
TIGHTENING REFERENCE13-12
FRONT SUSPENSION2-1
FRONT SUSPENSION COMPONENT
SERVICE—2WDVEHICLES2-7
FRONT WHEEL ALIGNMENT 2-3
GENERAL INFORMATION 2-1
MODEL 44 FRONT AXLESERVICE—4WDVEHICLES. . 2-15
MODEL 60 FRONT AXLESERVICE—4WDVEHICLES. . 2-51
SPECIFICATIONS2-80
FUEL SYSTEM14-1
ACCELERATORPEDALANDTHROTTLECABLE...14-15
DUAL POINT FUEL INJECTION 14-17
FUEL DELIVERYSYSTEM14-3
FUEL TANKS 14-9
GENERAL DIAGNOSIS 14-31
SERVICE PROCEDURES14-47
HEATING AND AIR-CONDITIONING .24-1
AIR-CONDITIONING 24-8
COMPRESSORSERVICE 24-29
DIAGNOSING AIR-CONDITIONING 24-11
EVAPORATORHEATERASSEMBLY 24-36
HEATER24-1
PERFORMANCETEMPERATURE CHART 24-18
REFRIGERANTSYSTEMSERVICEPROCEDURES. . 24-22
SERVICE PROCEDURES24-6
SERVICE PROCEDURES 24-26
TEST PROCEDURES24-11
k

HORNS 8G-1
SERVICE PROCEDURES8G-2
TEST PROCEDURES8G-1
IGNITION SYSTEMS8D-1
COMPONENT IDENTIFICATION 8D-1
DIAGNOSTIC PROCEDURES8D-9
SERVICE PROCEDURES8D-11
SPECIFICATIONS8D-15
INSTRUMENT PANELANDGAUGES8E-1
CLUSTER ANDGAUGESERVICEANDTESTING....8E-4
GENERAL INFORMATION 8E-1
SWITCH ANDPANEL COMPONENT SERVICE8E-15
INTRODUCTION . . lntro.-2
CONVERSION TABLES lntro.-12
CONVERSION TABLES (CONT.) lntro.-13
INTRODUCTION lntro.-2
POWER TEAM AVAILABILITY lntro.-5
STANDARD TRUCK BODY DIMENSIONS ....... -Intro.-9
TORQUEREFERENCES Intro.-10
TRUCK MODEL LINE-UP AND WEIGHTS lntro.-7
VEHICLEAND COMPONENT IDENTIFICATION. . . . lntro.-2
LAMPS 8L-1
EXTERIOR LAMPS . 8L-1
EXTERIOR LAMPS SERVICEPROCEDURES...8L-3
INTERIOR LAMPS 8L-10
SPECIFICATIONS8L-11
LUBRICATION AND MAINTENANCE 0-1
CHASSISAND BODY .0-28
DRIVETRAIN . 0-22
ENGINE . ...0-14
GENERAL INFORMATION 0-1
POWER LOCKS8P-1
SERVICE PROCEDURES8P-2
TEST PROCEDURES8P-1
POWER MIRRORS 8T-1
SERVICE PROCEDURES8T-2
TEST PROCEDURES8T-1
POWER WINDOWS 8S-1
SERVICE PROCEDURES8S-4
TEST PROCEDURES8S-1
RADIO, ANTENNA ANDSPEAKERS• 8F-1
SERVICE PROCEDURES8F-6
TEST PROCEDURES8F-4
REARAXLES3-1
83/8-AND9 1/4-INCH DIAMETER RING GEAR
AXLESERVICE3-9
GENERAL INFORMATION 3-1
MODEL 60,60MAND70AXLESSERVICE3-33
NOISE DIAGNOSIS 3-2
REARAXLE ALIGNMENT 3-8
SPECIFICATIONS3-56
TIRE/WHEELBALANCE3-8
REAR WINDOW DEFOGGER8N-1
REPAIRPROCEDURES (GRID LINES, TERMINALS,
ANDPIGTAILS)8N-3
SERVICE PROCEDURES8N-4
TEST PROCEDURES8N-1
SPEED CONTROL SYSTEM8H-1
SERVICE PROCEDURES8H-9
TEST PROCEDURES8H-5
SPRINGS/SHOCKABSORBERS17-1
GENERAL INFORMATION '. 17-1
SERVICE PROCEDURES17-3
SPECIFICATIONS17-12
STEERING19-1
GENERAL INFORMATION 19-1
MANUAL STEERINGGEARSERVICE19-6
POWER STEERINGGEARSERVICE19-16
POWER STEERING PUMP SERVICE19-39
SPECIFICATIONS19-70
STEERING COLUMN SERVICE19-54
STEERINGLINKAGESERVICE19-4
TIRESANDWHEELS22-1
GENERAL INFORMATION 22-1
SPECIFICATIONS22-19
TIRESERVICE22-8
WHEELSERVICE22-16
TRANSMISSION-TRANSFER CASE21-1
A833 MANUAL TRANSMISSION 21-1
NP2500 MANUAL TRANSMISSION 21-16
NP435 MANUAL TRANSMISSION .21-36
SERVICE INVEHICLE21-3
SERVICE INVEHICLE21-17
SERVICE OUTOFVEHICLE21-5
SERVICE OUTOFVEHICLE21-20
A-500/A-518 AUTOMATIC TRANSMISSION 21-111
GENERAL INFORMATION 21-111
A-998/999/727 AUTOMATIC TRANSMISSION 21-43
GENERAL INFORMATION 21-43
DIAGNOSIS ANDTESTPROCEDURES21-49
IN-VEHICLE SERVICE21-75
MAINTENANCE AND ADJUSTMENTS 21-71
SUBASSEMBLY OVERHAUL 21-93
TRANSMISSION ANDTORQUECONVERTER
REMOVAL/INSTALLATION 21-87
TRANSMISSION OVERHAUL 21-91
IN-VEHICLE SERVICE 21-140
NP205 TRANSFERCASE 21-130
NP241 TRANSFERCASE 21-138
OUT-OF VEHICLESERVICE 21-142
TURN SIGNALSAND HAZARD WARNING FLASHER. . . 8J-1
SERVICE PROCEDURES: 8J-4
TESTINGPROCEDURES8J-2
WARNING BUZZER/CHIME MODULE 8M-1
SERVICE PROCEDURES8M-3
TEST PROCEDURES8M-1
WINDSHIELD WIPER AND WASHER SYSTEMS8K-1
INTERMITTENT WINDSHIELD WIPER FUNCTION
AND SWITCH TESTINGPROCEDURES.8K-5
TWOSPEED WINDSHIELD WIPER MOTOR AND
SWITCH TESTINGPROCEDURES8K-1
WINDSHIELD WASHERS8K-15
WINDSHIELD WIPER SYSTEMSERVICEPROCEDURES.. 8K-7
II

FOREWORD
Theinformationcontained in this service manual
has been prepared forthe professionalautomotive
technician involved in dailyrepairoperations.Infor-
mation in this manual is dividedintogroups.Each
group covers a generalvehiclesystem(brakes, steer-
ing, body,etc.).Eachgroup is further divided to ad-
dress individual components or systems within the
group.
TheComponentandSystemIndex will assistyou
in locating the correctgroup forthe component or
systemyourequire.
These groupscontaingeneralinformation,diagno-
sis, testing,adjustment,removaland installation, as-
sembly and disassemblyprocedures forthe
components.
Thediagnosischarts are designed to helpyou lo-
cate and correctproblems with a systematic ap-
proach. Thetablocator at the right side of this page
will helpyou to quicklylocatethe first page of each
group. The first page of eachgroupcontains an al-
phabetical index to assistinthelocation of thecom-
ponent or system.
Theinformation,descriptions,testingprocedures,
and specifications were in effect atthe time this
manual was released for printing.
Information describing the operation anduseof
standard andoptionalequipment is included inthe
Owner'sManuallocatedinthe glove box.
GROUPTITLE
— Introduction
0Lubricationand Maintenance
1 Accessories
2FrontSuspension
3 RearAxle
5 Brakes
6Clutch
7 CoolingSystem
8Electrical
9Engine
11ExhaustSystem/Intake Manifold
13Frame
14FuelSystem
16PropellerShaft—UniversalJoints
17 Springs—ShockAbsorbers
19Steering
21Transmission
22WheelsandTires
23Body
24 Heati ngandAirConditioning
25 Em issions ControlSystems

2 INTRODUCTION
•
INTRODUCTION
VEHICLEAND COMPONENT IDENTIFICATION
VEHICLECODE
The Dodge Ram Pickup,Chassis Cab and Sport
Utility Vehicle Code Chart is described below (Fig.
1):
VEHICLECODE = AD (DODGE RAM
PICKUP & CHASSISCAB)
VEHICLE
FAMILY LINE
DESCRIPTION
ADl D150
AD2D250
AD3D350
PICKUP
4x2
AD5 W150
AD6W250
AD7W350
PICKUP
4x4
AD2D250
AD3D350
CHASSIS CAB
4x2
AD6W250
AD7W350
CHASSIS CAB
4x4
AD4AD100
AD4AD150
SPORT UTILITY
4x2
AD8AD100
AD8AD150
SPORT UTILITY
4x4
J90IN-32
Fig. 1 Vehicle Code Chart
VEHICLE IDENTIFICATIONNUMBER (V.I.N.)
TheVehicleIdentificationNumber (V.I.N.) islo-
cated onthe upperleftcorner of the instrument
panel,near the windshield. All VIN's consist of17
characters ina combination of letters and numbers
that providespecificinformationabout the vehicle
(Fig. 2).
TheV.I.N. is also located onthe EquipmentIden-
tification Plate, the Vehicle Safety Certification La-
beland onthe frame rail.
EQUIPMENT IDENTIFICATION PLATE
Theequipmentidentificationplate,containsinfor-
mation regarding the vehicle:model,wheel base,
V.I.N. (Vehicle IdentificationNumber), T.O.N. (Or-
derNumber), andall production or specialequip-
ment on the vehiclewhen it was shippedfrom the
factory(Fig. 3). Alwaysrefer to thisplatewhen or-
deringparts.
TheEquipmentIdentification Plate is located on
theunderhoodpanel inthe rightfrontcorner.
VEHICLESAFETY CERTIFICATION LABEL
Avehiclesafetycertificationlabel (Fig. 4)isat-
tached to therearfacing of thedriver'sdoor.Thisla-
belreflects the date of manufacture(month and
year), Gross VehicleWeightRating (GVWR), Gross
Axle WeightRating (GAWR) front, Gross Axle
WeightRating (GAWR) rearand the VehicleIdenti-
fication Number (VIN). The Month, Day andHour of
manufacture is also included on thislabel.
All communications or inquiriesregarding the ve-
hicleshouldinclude the Month-Day-HourandVehi-
cleIdentificationNumber.
BODY CODEPLATE
Thisplate is riveted to the innerpanelunder the
cowl onthe passenger side.
There are seven (7) lines of information on this
plate.Information reads fromleft to right, starting
with line 1 at thebottom of theplate to line 7 at the
top(Fig. 5).

•
INTRODUCTION3
COUNTRY
1 = UnitedStates
2 = Canada
3 = Mexico
VehicleType
4= Multipurpose
Passenger
5 = Bus
6 = Incomplete
7 = Truck
E =
M m
TruckLine
Ramcharger
RamChassisCab
RamPickup4x2
Ramcharger
RamChassisCab
RamPickup4x4
X-
Y =
Z .
5 =
8 =
Engines
3.9L(EFI
5.2L EFI
5.9L EFP
.9L (EFI
Sequential
SerialNumber
SixDigitNumbers
Make
B = Dodge
GVWR
Hydraulic
D
E
F
G
H
J
K
L
M
W
= 0001
= 3001
= 4001
= 5001
= 6001
= 7001
= 8001
= 9001
=10,001
=Bus or
-3000
-4000
-5000
-6000
-7000
-8000
-9000
-10,000
-14,000
Inc.
Series
0 = 150SJobRated
1 = 150 JobRated
2 = 250 JobRated
3 = 350 JobRated
CheckDiait
Number or Letter
Body
3 = ClubCab
6 = ConventionalCab
7 = Sport Utility 2 DR
PlantLocation
S as Dodge City
M = Lago Alberto
J90IN-33
Fig. 2 Vehicle Identification Number (VIN)
'OOBBMBEQUIPMENTIDENTIFICATION 42is»e
MODELSV.I.N.T.O.N.
CODE NO. DESCRIPTION
CODE NO. DESCRIPTION
PRIMARY
PAINT
VEHICLE
ORDER-
NUMBER
PAINT-(3)
PROCEDURE (2)
0)
SECONDARY
PAINT
I
VINYL ROOF
CODE
XXX >XXXXX)X XXXXXXXXX
XXXXXXXXXXXXXXXXXX
XXXX XXXXXXXXXXXXXXXXX
Fig. 3 Equipment Identification Label
CHRYSLER ,
UAit ur MruK. |
GVWR
GAWRFRONT 1 WITHTIRES i RIMS AT |PSI COLD
VEHICLENUMBER
I VEHICLETYPE
TRANSMISSIONI VEHICLE IDENTIFICATION
CODE I NUMBER
MARKET U-C-B-M
CODE 90IN-3
Fig. 5 Body Code Plate
a line to punch the full 6 digits, the balance of that
line will be leftblank and theSEC code will be
punched onthe nextline.
Thelastninepositions of line #7 will contain a
twodigit species, whenapplicable, and a six digit
gateline sequence number (the last six numbers of
theVIN).
Thelast code shown on eitherplate will be fol-
lowed by END.When two plates are required, the
last code space onthe first plate will show CTD (for
continued).
When a secondplate is required, the first four
spaces of eachline will not be useddue to overlap of
theplates.
VEHICLE
MODEL
•NUMBER
ENGINE
-CODE
-INTERIOR
TRIM CODE
J901N-17
Fig. 4 Vehicle Safety Certification Label
Refer to the body code platechart(lines 1 thru 3)
fordetailedinformation(Fig. 6).
Lines 4 thru 7,of the body code plate, arese-
quenced onthe plate as follows:
• 3 digit sales codes
• 3 digitnumeric codes
• 6 digit SEC codes
Whenthere isan SEC code tobe punched on the
body code plateandthere is notenoughroomleft on

INTRODUCTION
Line
#1
Digit 1-3
Transmission Sales Code
Digit 4 Open Space
Digit 5 Market Code- U-C-B-M
Digit 6 Open Space
Digit 7-23 VehicleIdentification No.
Line #2
Digit 1-3
Paint Procedure
Digit 4 Open Space
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint
Digit 14 Open Space
Digit 15-18 Trim Code
Digit 19 Open Space
Digit 20-22 Engine Sales Code
Digit 23 Open Space
Line #3
Digit 1-12
Vehicle Order Number
Digit 13 Open Space
Digit 14-16 Vinyl Roof CodeCDoor Combo Digit
Code - Pillette)
Digit 17 Open Space
Digit 18-23 Model
J901N-20
Fig. 6 Body Code Plate Information
ENGINE SERIAL NUMBER (PARTS REPLACEMENT
INFORMATION)
On the 238C.I.D. (3.9 Liter) 6 cylinderengine, the
engineserialnumber ison a padlocated on the right
side of theblock.
On the318 C.I.D. (5.2 Liter) andthe360 C.I.D.
(5.9Liter) 8 cylinderengines,theengineserial num-
ber is located on theleft front corner of theblock, be-
low the cylinderhead(Fig. 7).
TRANSMISSION IDENTIFICATION
Specific light andmedium duty vehiclesreferred to
in this manual can be identified by part number,
model and built datesupplied on the Transmission
Identification Tag.
Operation requirementsare, in someinstances,dif-
ferent for eachvehicle and enginecombination and
some internal parts will also be different.Therefore,
when replacing parts, refer to the numberstamped
on leftside of the transmission oil panflange.
MANUALTRANSMISSION: An aluminum Identi-
fication Tag is secured to the powertake-offcover.
Do not discard this tagif the transmission power
take-off cover is removed. On other transmission
models, a bluemetal identification tagis perma-
nently attached to the left top of transmission case
near the case cover.
AUTOMATICTRANSMISSION: A surfacepad has
beenprovided onthe right of the transmission case
to supply identification.
SeeGroup21,Transmissions for additional infor-
mation.
Fig. 7 Engine Serial Number 5.2L and 5.9L

•
INTRODUCTION5
POWER TEAM AVAILABILITY
RAM PICKUP
VEHICLE
LINE
WHEELBASE
GVWR
ENGINI
E&SAI
LES CODE
TRANSMISSION
VEHICLE
LINE
WHEELBASE
GVWR
3.9L
EFI
EHB
5.2L
EFI
ELG
5.9L
EFI
EMG
5.9L
EFI
EMJ
5.9L
DIESEL
ETA
5-SP
MAN.
O.D.
4-SP
MAN.
O.D. 4-SP
MAN. 3-SP AUTO
4-SP
AUTO
O.D.
D150
4x2
2921 mm
(115in)
3327 mm
(131in)
2495 kg
(5500 lbs) S S O
o
D150
4x2
2921 mm
(115in)
3327 mm
(131in)
2495 kg
(5500 lbs)
O
s o o o
D150
4x2
2921 mm
(115in)
3327 mm
(131in)
2495 kg
(5500 lbs)
O
s o
D150
4x2
3327 mm
(131 in)
2722 kg
(6000 lbs) s s
o o
D150
4x2
3327 mm
(131 in)
2722 kg
(6000 lbs)
o
s o o o
D150
4x2
3327 mm
(131 in)
2722 kg
(6000 lbs)
O
s o
D150
4x2
3378 mm
(133in)
3785 mm
(149in)
2722 kg
(6000 lbs) s s
o
D150
4x2
3378 mm
(133in)
3785 mm
(149in)
2722 kg
(6000 lbs)
o
s o
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs) s s©
o
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs)
o
s© o o
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs)
o
s o
D250
4x2
3785 mm
(149in)
3357 kg
(7400 lbs) s s
o
D250
4x2
3785 mm
(149in)
3357 kg
(7400 lbs)
o
s o
D250
4x2
3327 mm
(131 in)
3/85mm
(149in)
3860 kg
(8510lbs) s s
o
D250
4x2
3327 mm
(131 in)
3/85mm
(149in)
3860 kg
(8510lbs)
O s
o
D350
4x2
3327 mm
(131 in)
3946 kg
(8700 lbs) s s
o
D350
4x2
3327 mm
(131 in)
3946 kg
(8700 lbs) O s
o
D350
4x2
3327 mm
(131 in)
4581 kg
(10,100 lbs) S s
o
D350
4x2
3327 mm
(131 in)
4581 kg
(10,100 lbs)
o
s o
W150
4x4
2921 mm
(115in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
s© s o
W150
4x4
2921 mm
(115in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
o
s©
o
W150
4x4
2921 mm
(115in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
o
s o
W150
4x4
3785 mm
(149in)
2903 kg
(6400 lbs) s s©
o
W150
4x4
3785 mm
(149in)
2903 kg
(6400 lbs)
o
s o
W250
4x4
3327 mm
(131 in)
3785 mm
(149in)
3402 kg
(7500 lbs) s s©
o
W250
4x4
3327 mm
(131 in)
3785 mm
(149in)
3402 kg
(7500 lbs)
o
s o
W250
4x4
3327 mm
(131 in)
3785 mm
(149in)
3860 kg
(8510lbs) s s
o
W250
4x4
3327 mm
(131 in)
3785 mm
(149in)
3860 kg
(8510lbs)
o s
o
W350
4x4
3327 mm
(131 in)
3946 kg
IQ7AA \WA s s
o
W350
4x4
3327 mm
(131 in)
(O/UUIDS]
o
s o
W350
4x4
3327 mm
(131 in)
4581 kg
HA 1 noiu«.\ S s
o
W350
4x4
3327 mm
(131 in)
(IU,lUUIDS}
o s
o
S = STANDARD O = OPTIONAL ©= Not available inCalifornia J90IN-39

6INTRODUCTION
•
POWER TEAM AVAILABILITY (CONT.)
RAMCHASSISCAB
VEHICLE
LINE
WHEELBASE
GVWR
ENGINE & SALES CODE
TRANSMISSION
VEHICLE
LINE
WHEELBASE
GVWR
3.9L
EFI
EHB
5.2L
EFI
ELG
5.9L
EFI
EMG
5.9L
EFI
EMJ
5.9L
DIESEL
ETA
5-SP
MAN.
O.D.
4-SP
MAN.
O.D.
4-SP
MAN.
3-SP
AUTO
4-SP
AUTO
O.D.
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs)
S s
D250
4x2
3327 mm
(131 in)
3860 kg
(8510lbs) s© S
o
D250
4x2
3327 mm
(131 in)
3860 kg
(8510lbs) s© s
o
D250
4x2
3327 mm
(131 in)
3860 kg
(8510lbs)
O S o
D350
4x2
3327 mm
(131 in)
3946 kg
(8700 lbs)
s© s
o
D350
4x2
3327 mm
(131 in)
3946 kg
(8700 lbs)
s® s o
D350
4x2
3429 mm
(135 in)
4039 mm
(159in)
4581 kg
(10,100 lbs)
s s
o
D350
4x2
3429 mm
(135 in)
4039 mm
(159in)
4763 kg
(10,500 lbs)
o s o
W250
4x4
3327 mm
(131 in)
3860 kg
(8510lbs) s® s
o
W250
4x4
3327 mm
(131 in)
3860 kg
(8510lbs) s® s
o
W250
4x4
3327 mm
(131 in)
3860 kg
(8510lbs)
o s o
W350
4x4
3327 mm
(131 in)
3946 kg
(8700 lbs)
s© s o
W350
4x4
3327 mm
(131 in)
3946 kg
(8700 lbs)
s® s o
W350
4x4
3327 mm
(131 in)
3946 kg
(8700 lbs)
o s o
W350
4x4
3429 mm
(135 in)
4581 kg
(10,100 lbs)
s s o
W350
4x4
3429 mm
(135 in)
4989 kg
(11,000 IBs)
o s o
RAMCHARGER SPORT UTILITY
DlOO
4x2
2692 mm
(106in)
2540 kg
(5600 lbs)
S s
D150
4x2
2692 mm
(106 in)
2540 kg
(5600 lbs)
S s
W100
4x4
2692 mm
(106in)
2722 kg
(6000 lbs)
S S
o
W150
4x4
2692 mm
(106 in)
2722 kg
(6000 lbs)
S S .... o
W150
4x4
2692 mm
(106 in)
2903 kg
(6400 lbs)
S s©
o
W150
4x4
2692 mm
(106 in)
2903 kg
(6400 lbs)
S s
o
S = STANDARD
O = OPTIONAL
© = Not availablein California.
© = CaliforniaOnly.
J901N-35

•
INTRODUCTION 7
TRUCK MODEL LINE-UP AND WEIGHTS
RAM PICKUP
MODEL/
FAMILY
BODY(3)
STYLE
GVWR
PAYLOAD
ALLOWANCE (1)
CURB
WEIGHT (2)
D150 ADl
4x2
2495 kg
5500 lbs 853kg 1880lb 1642kg
3620 lbs
D150 ADl
4x2
62 2495 kg
2722 kg
5500 lbs
6000 lbs 804kg
1021 kg 1772lbs 2252 lbs
1691 kg
1700kg
3728 lbs
3748 lbs
D150 ADl
4x2
31
2722 kg
6000 lbs 852kg 1878lbs 1870kg 4122lbs
D150 ADl
4x2
32 2722 kg
6000 lbs 787kg 1736lbs 1934kg
4264 lbs
D250 AD2
4x2 62
3357 kg
3860 kg
7400 lbs
8510lbs 1527kg 1952kg 3366lbs
4304 lbs 1830kg 1908kg
4034 lbs
4206lbs
D250 AD2
4x2
32 3357 kg
3860 kg
7400 lbs
8510lbs 1369kg 1846kg 3019lbs
4070 lbs 1987kg
2014kg
4381 lbs
4440 lbs
D350 AD3
4x2 62(4) 3946kg 4581 kg
8700 lbs
10,100 lbs
2001 kg
2485 kg
4411 lbs
5478 lbs 1945kg
2097 kg
4289 lbs
4622 lbs
W150 AD5
4x4
61 2858 kg
6300 lbs 978kg 2156lbs 1880kg 4144lbsW150
AD5
4x4
62
2903 kg 6400 lbs 966kg
2131 lbs 1936kg
4269 lbs
W150 AD5
4x4
32 2903 kg
6400 lbs 789kg 1740lbs 2114kg
4660 lbs
W250 AD6
4x4 62
3402 kg
3860 kg
7500 lbs
8510lbs 1364kg
1769kg
3007 lbs
3899 lbs
2038 kg
2092 kg
4493 lbs
4611 lbs
W250 AD6
4x4
32
3402 kg
3860 kg
7500 lbs
8510lbs 1259kg 1664kg
2775 lbs
3668 lbs 2143kg
2196kg
4725 lbs
4842 lbs
W350 AD7
4x4 62 3946kg
8700 lbs 1749kg
3855 lbs 2198kg
4845 lbs
(1) Payload includesmaximum weight ofdriver, passengers, cargo andoptional equipment notincludedin payload orGVW package
- Payload allowance for Chassis Cabs isnotsuppfieddueto large variations or body equipment installed.
2) Includes base engine
3) Body Style Cab Bed Length
61 Std. 1981mm(6.5ft
62 Std. 2438 mm8.0ft
31 Club1981mm6.5ft
32Club 2438 mm(8.0ft
63 Std.N.A.
64 Std.N.A.
71 Sport Utility N.A.
(4) Dual Rear Wheels
J90IN-36

8INTRODUCTION•
TRUCK MODEL LINE-UP AND WEIGHTS (CONT.)
RAMCHASSISCAB
MODEL/
FAMILY
BODY(3)
STYLE
GVWR
PAYLOAD
ALLOWANCE (1)
CURB
WEIGHT (2)
D250 AD2
4x2 62
3357 kg
3860 kg
7400 lbs
8510lbs (1)
1721 kg
1740kg
3794 lbs
3835 lbs
D350 AD3
4x2 62 3946
kg
8700 lbs
(1) 1794kg
3954 lbs
D350 AD3
4x2
"lit
4581 kg
4763 kg
10,100 lbs
10,500 lbs
(1) 1963
kg
1972 kg
4327 lbs
4347 lbs
D350 AD3
4x2
"12!
4581 kg
4763 kg
10,100 lbs
10,500 lbs
(1)
2032 kg
2043 kg
4479 lbs
4505 lbs
W250 AD6
4x4 62
3860 kg
8510 lbs
(1) 1886kg 4158
lbs
W350 AD7
4x4 62 3946
kg
8700 lbs
(1)
2038 kg 4494 lbs
W350 AD7
4x4
63$
4581 kg
4990 kg
10,100 lbs
11,000 lbs
(1) 2136kg
2145 kg
4709 lbs
4729 lbs
RAMCHARGER - SPORTUTILITY
MODEL/
FAMILY
BODY(3)
STYLE
GVWR
PAYLOAD
ALLOWANCES)
CURB
WEIGHT(2)
D100 AD4
4x2
71
2540 kg
5600 lbs
603 kg
1330lbs 1937kg 4270 lbs
D150 AD4
4x2
71
2540 kg 5600 lbs
606kg 1336lbs 1934kg
4264 lbs
W100 AD8
4x4
71
2722 kg 6000 lbs
618 kg
1363 lbs
2103 kg 4637 lbs
W150 AD8
4x4
71 2722 kg
2903 kg
6000 lbs
6400 lbs
621 kg
796kg 1369lbs
1755 lbs
2102 kg
2107kg
4631 lbs
4645 lbs
(1) Payload includes maximum weight of driver, passengers, cargo andoptional equipment notincludedin payload orGVW package
(4)
Includes base
Body Style
engine
Cab Bed
Length
61
Std.
1981 mm [6.5
ft)
62
Std.
2438 mm 8.0ft
31
Club 1981 mm 6.5
ft
32
Club 2438 mm 8.0 ft
63
Std.
N.A.
64 Std. N.A.
71 Sport Utility N.A.
Dual Rear Wheels
J90IN-38

•
INTRODUCTION 9
STANDARD TRUCK BODY DIMENSIONS
VEHICLE
FAMILY
WHEELBASE
AVAILABLE CAB
TO
AXLE
BODY
TYPE
STANDARD BODIES AVAILABLE
VEHICLE
FAMILY
WHEELBASE
AVAILABLE CAB
TO
AXLE
BODY
TYPE
NOMINAL
LENGTH
LOADSPACE D
IMENSIONS (2)
VEHICLE
FAMILY
WHEELBASE
AVAILABLE CAB
TO
AXLE
BODY
TYPE
NOMINAL
LENGTH LENGTH
MAX.
WIDTH
HEIGHT VOLUME
AD-1 AD-5
2921 mm
(115 in)
— Sweptline
1981 mm
(6.5 ft)
1981 mm
(78 in)
1778mm
(70 in)
485mm
19.1 in)
1.71 m3
(60.35 ft3)
AD-1 AD-2
AD-3 AD-5
AD-6 AD-7
3327mm
(131 in)
— Sweptline 2438mm
(8 ft)
2489mm
(98 in)
1778mm
(70 in)
485mm
(19.1 in)
2.15 m3
(75.8 ft3)
AD-2 AD-3
AD-7 3327mm
(131 in)
1422mm
(56 in)
Chassis
Cab 2438mm (8 ft)
— — — —.
AD-3 AD-7
3249mm
(135 in)
1524mm
(60 in)
Chassis
Cab 2896mm (9.5 ft)
— — — —
AD-3 4039mm
(159 in)
2134mm
(84 in)
Chassis
Cab 3810mm (12.5 ft)
— — — —
AD-4 2692mm
(106 in)
Sport
Utility
4x2
— 1778mm 1588mm
(62.5 in)
1062mm
(41.8 in)
2.99 m3
(105.8 ft3)
AD-8 2692mm
(106 in)
— Sport
Utility
4x4
— 1778mm 1588mm
(62.5 in)
1062mm
(41.8 in)
2.99 m3
(105.8 ft3)
AD-1 3378mm
(133 in)
— Sweptline
1981 mm
(6.5 ft)
1984mm
(78.1 in)
1778mm
(70 in)
485mm
(19.1 in)
1.71 m3
(60.4 ft3)
AD-1 AD-2
AD-5 AD-6
3785mm
(149 in)
Sweptline
Club Cab
2438mm
(8 ft)
2489mm
(98 in)
1778mm
(70 in)
485mm
(19.1 in)
2.15 M3
(75.8 ft3)
®Driver seat to tailgate.
© Based on S.A.E. procedureJ1100.J901N-34

10 INTRODUCTION
•
TORQUE REFERENCES
Individual TorqueChartsappear attheendof
manyGroups. Refer to theStandardTorqueSpecifi-
cationsandBoltIdentificationChart in thisGroup
fortorquesnotlisted in theindividualtorquecharts
(Fig. 1).
BOLT TORQUE
INCH
BOLT
GRAM 5
GRADE 8
SIZE
N-rn
ft-lbs
N'ffti
ft-lbs
(in-lbs)
(in-lbs)
1/4-20
11 (95) 14 (125)
1/4-28 11 (95) 17 (150)
5/16-18
23 (200) 31 (270)
5/16-24
27 20 34 25
3/8-16
41 30 54 40
3/8-24
48
35 61 45
7/16-14
68 50... 88 65
7/16-20 75 55 95 70
1/2-13
102 75 136 100
1/2-20
115 85 149
no
9/16-12
142 105 183 135
9/16-18
156 115 203 150
5/8-11
203 150 264 195
5/8-18
217 160 285
, 210
3/4-16
237 175 305 225
J89IN-9
Fig. 1 Grade 5 and 8 Standard Torque
Specifications
Note that the torquespecificationsgiven inthe
chart are based ontheuse of cleananddrythreads.
Reduce thetorqueby10%whenthethreadsare lubri-
cated with engine oiland by 20% if newplatedbolts
areused.
Various sizes of internalandexternalhex-lob-
ular (Torx) headfasteners are used as attaching
hardware on numerouscomponentsand assem-
blies.Due to theever-changing usage andappli-
cation of automotivefasteners,Torx-head
fastenersmaynot be identified as suchthrough-
out thismanual.
METRICTHREADANDGRADE IDENTIFICATION
Metric andSAE threadnotationsdifferslightly.
Thedifference is illustratedinFig. 2.
Commonmetricfastenerstrengthproperty classes
are 9.8and 12.9 with the class identification em-
bossed onthehead of eachbolt(Fig.3). Some metric
nuts will be marked with singledigitstrengthiden-
tification numbers on thenut face.
SAEstrength classes rangefrom grade 2 to8 with
line identification embossed oneachbolthead.Mark-
ingscorresponding to twolines less thantheactual
grade (Fig. 4).FOR EXAMPLE-Grade 7 bolt will
exhibit 5 embossed lines on thebolthead.
5/16-18
METRIC
M8X 1.25
THREAD
MAJOR
DIAMETER
ININCHES
NUMBER
OF
THREADS
PER INCH
THREADDISTANCE
MAJORBETWEEN
DIAMETERINTHREADSIN
MILLIMETERSMILLIMETERS
PR606B
Fig. 2 Thread Notation (Metric and SAE)
METRICBOLTS—IDENTIFICATION CLASS NUMBERS
CORRESPOND TOBOLTSTRENGTH—INCREASINGNUMBERS
REPRESENT INCREASING STRENGTH. J89IN-10
Fig. 3 Metric Bolt Identification
SAE CLASSIFICATION
GRADE 5
GRADE 8
MARKINGS FOUND
ONTOPOFBOLT
HEADINDICATE
GRADE
120° 60°
GRADE 2
GRADES GRADE 8
(SAE) BOLTS—IDENTIFICATIONMARKSCORRESPOND
TO BOLT STRENGTH—INCREASINGNUMBERS
REPRESENT INCREASINGSTRENGTH.
J89IN-11
Fig. 4 SAE Bolt Identification

•
INTRODUCTION11
INTERNATIONALSYMBOLS hide. These symbolsareapplicable to thosecontrols
which are displayed onthe instrumentpanel orin
Some ofthe InternationalSymbolsshownbelow
the immediatevicinity
of thedriver(Fig. 5).
areused to identifycontrolsanddisplaysin this ve-
INTERNATIONAL SYMBOLS
D
UPPER BEAM
LOWER BEAM TURNSIGNAL HAZARD
WARNING
WINDHIELD
WIPER
CP
WINDSHIELD
WASHER
Ir \
WINDSHIELDWIPER
ANDWASHER VENTILATINGFAN PARKINGLIGHTS FRONT
HOOD
REAR HOOD
(TRUNK)
CHOKE (COLD
STARTINGAID)
HORN FUEL
1
ENGINECOOLANT
TEMPERATURE
BATTERY CHARGING
CONDITION
ENGINEOIL
4
SEAT BELT
LIGHTER
REAR WINDOW
WIPER
REAR WINDOW
WASHER PARKING
BRAKE
(©)
BRAKE FAILURE WINDSCREEN
DEMISTING
ANDDEFROSTING
Fig. 5 International Symbols
RK230
METRICSYSTEM
Artwork, specifications,andtighteningreferences
in this Service Manual are identified inthe metric
systemand in the SAE system.
During anymaintenance or repairprocedures, itis
important to salvage metricfasteners(nuts,bolts,
etc.) for reassembly. If thefastener isnot salvage-
able, a fastener of equivalentspecificationshould be
used.
WARNING: USEOFANINCORRECTFASTENER
MAY RESULT INCOMPONENTDAMAGEOR PER-
SONALINJURY.
Mega
(M) Million
Deci (D)
Tenth
Kilo (K)Thousand Centi (C)
Hundreth
Milli - (m)
Thousandth
J901N-2
Fig. 6 Metric Prefixes
Themetricsystem is based on quantities of one,
ten, one hundred, one thousand, andone million
(Fig. 6).
ThefollowingTables will assistyou in conversion
procedures.

12INTRODUCTION
•
CONVERSION TABLES
in-lbs to N*m
N#m to in-lbs
in- lb
N»m
in-lb
N»m
in-lb
N«m in-lb in-lb
N»m
2
.2260
42
4.7453
82
9.2646
122
13.7839
162 18.3032
4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552
3 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811
10 1.12% 50 5.6492 90 10.1685 130 14.6878 170 19.2071
12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331
14
1.5818
54 6.ton 94 10.6204 134 15.1397 174 19.6590
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850
18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369
22 2.4856 62 . 7.0049 102 11.5243 142 16.0436 182 20.5629
24 2.7116 64 7.2309 104 11.7502 144 16.2696 184 20.7889
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148
28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2408
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966
N»m in-lb
N*m in-lb
N*m in-lb
N*m in-lb
.2
.4
.6
.8
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
3.2
3.4
3.6
3.8
4
1.7702
3.5404
5.3107
7.0809
8.8511
10.6213
12.3916
14.1618
15.9320
17.7022
19.4725
21.2427
23.0129
24.7831
26.5534
28.3236
30.0938
31.8640
33.6342
35.4045
4.2
4.4
4.6
4.8
5
5.2
5.4
5.6
5.8
6
6.2
6.4
6.6
6.8
7
7.2
7.4
7.6
7.8
8
37.1747
38.9449
40.7152
42.4854
44.2556
46.0258
47.7961
49.5663
51.3365
53.1067
54.8770
56.6472
58.4174
60.1876
61.9579
63.7281
65.4983
67.2685
69.038
70.8090
8.2
8.4
8.6
8.8
9
9.2
9.4
9.6
9.8
10
10.2
10.4
10.6
10.8
11
11.2
11.4
11.6
11.8
12
72.5792
74.3494
76.1197
77.8899
79.6601
81.4303
83.2006
84.9708
86.7410
88.5112
90.2815
92.0517
93.8219
95.5921
97.3624
99.1326
100.9028
102.6730
104.4433
106.2135
12.2
12.4
12.6
12.8
13
13.2
13.4
13.6
13.8
14
14.2
14.4
14.6
14.8
15
15.2
15.4
15.6
15.8
16
107.9837
109.7539
111.5242
113.2944
115.0646
116.8348
118.6051
120.3753
122.1455
123.9157
125.6860
127.4562
129.2264
130.9966
132.7669
134.5371
136.3073
138.0775
139.8478
141.6180
16.2
16.4
16.6
16.8
17
17.2
17.4
17.6
17.8
18
18.5
19
19.5
20
20.5
21
22
23
24
25
ft-lbs to N*m
N*m to ft-lbs
ft-lb N»m
ft-lb
N»m
ft-lb
N«m
ft-lb
N«m ft-lb
N«m
N»m
ft-lb
N«m
ft-lb
N»m
ft-lb
N«m
ft-lb
N«m
ft-lb
1
1.3558
21 28.4722
41
55.5885
61 82.7049
81 109.8212
1
.7376
21
15.9888
41
30.2400
61 44.9913
81 59.7425
2
2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770
2
1.4751
22
16.2264 42
30.9776
62 45.739 82 60.4801
3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4
2.9502
24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.128] 85 115.2446 5 3.6878 25 18.4391 45 3.1903 65 47.9415 85 62.693
6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46
33.9279
66 48.6791 86 63.4303
7 9.4907 27 36.6071 47 63.7234 67 90.83% 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956
88
119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893
49
36.1405 69 50.8918 89 65.6430
10 13.5582 3 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756
30
22.1269
90
36.8781 70 51.6293 90 66.306
11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72
97.6m
92 124.7352 12 8.8507 32 23.6020 52 3.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73
98.9747
93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.843 93 68.593
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.573 94 69.3308
15 20.3373 35 47.4536 55 74.5700 75 101.6862
95
128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.9258 76 103.0422
96
130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547
96
70.8060
17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.398 57 42.0410 77 56.7923
97
71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.753 98 132.8702 18 13.2761 38 3.0274 58 42.7786 78 57.5298
98
72.311
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 3.7649 59 43.5162 79 58.2674
99
73.0187
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537
80
59.0050 100 73.7562
in. to mmmm toin.
in.
mm
in.
mm
in. mm
in.
mm
in.
mm mm
in. mm
in.
mm in. mm
in.
mm
in.
.01
.254
.21 5.334
.41
10.414
.61
15.494 .81
3.574
.01 .00039
.21
.0327
.41
.01614 .61 .02402
.81
.3189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 3.83 .02 .0379 .22 .00866 .42 .01654 .62 .02441 .82 .0323
.03 .762 .23 5.842 .43 10.922 .63 16.002
.83
21.32 .3 .3118 .23 .00906 .43 .01693 .63 .0243 .3 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .3157 .24 .00945 .44 .01732 .64 .0253 .84 .0337
.05 1.270 .25 6.350 .45 11.43 .65 16.510 .85 21.590 .05 .3197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .0253 .86 .03386
.07 1.778 .27 6.858 .47 11.93 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .0263 .87 .03425
.OS 2.032 .28 7.112 .48 12.192 .68 17.272 .3 22.352 .3 .00315 .3 .01102 .48 .01890 .68 .02677 .3 .03465
.09 2.286 .29 7.366 .49 12.446 .69 17.526
.89
22.606 .09 .0354 .29 .01142 .49 .01929 .69 .02717 .89 .3504
.10 2.540 .3 7.63 .50 12.700 .70 17.73 .90 22.860 .10 .00394 .3 .01181 .3 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .0043 .31 .0123 .51 .0203 .71 .02795 .91 .0353
.12 3.048 .32 8.13 .52 13.208 .72 18.23
.92
23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.32 .33 8.32 .53 13.462 .73 18.542 .93 23.622 .13 .3512
.33
.01299 .53 .0237 .73 .02874
.93
.03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 3.876 .14 .00551
.34
.01339 .54 .02126 .74 .02913 .94 .3701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.13 .15 .3591 .35 .01378 .55 .02165 .75 .02953 .95
.3740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .0235 .76 .02992 .96 .373
.17 3.318 .37 9.3% .57 14.478 .77 19.558 .97 24.63 .17 .00669 .37 .01457 .57 .02244 .77 .0332 .97 .0319
.18 4.572 .3 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .3709 .3 .01496 .3 .0223 .78 .0371 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 3.066 .99 25.146 .19 .3748 .39 .01535 .59 .02323 .79 .3110 .99 .03898
.20 5.080 .40 10.160 .60 15.240
.80
3.33 1.3 25.400 .3 .3787 .40 .01575 .60 .02362 .3 .313 1.3 .03937
J901N-10

•
INTRODUCTION13
CONVERSION TABLES (CONT.)
Multiply By
To Get Multiply
By
To Get
in.-lbs. x 0.11298 = Newton-Metres (N»m) (N*m) x8.851
=
in.-lbs.
ft.-lbs. x
1.3558
= Newton-Metres (N«m)
(NTH)
x 0.7376
=
ft.-lbs.
inches Hg. (60°F)
x 3.377
= Kiiopascals (kPa) (kPa) x
0.2961
Inches Hg.
Pounds/Sq. In. x
6.895
= Kiiopascals (kPa) (kPa) x0.145
Pounds/Sq. In.
Inches x25.4
= Millimetres(mm) (mm) x
0.03937
=
Inches
Feet
x 0.3048 5 = Metres(M) (M) x3.281
=
Feet
Yards
x 0.9144
*=Metres(M) (M) x
1.0936
Yards
Miles x
1.6093
= Kilometres(Km) (Km) x
0.6214
=
Miles
Miles/Hr. x
1.6093 = Kilometres/Hr.(Km/h) (Km/h) x
0.6214
Miles/Hr.
Feet/Sec.
x 0.3048 = Metres/Sec.(M/S) (M/S) x3.281
Feet/Sec.
Kilometres/Hr. x
0.27778
= Metres/Sec.(M/S) (M/S) x
3.600
Kilometres/Hr.
Miles/Hr. x
0.4470 = Metres/Sec.(M/S) (M/S) x
2.237 Miles/Hr.
COMMON METRICEQUIVALENTS
1Inch= 25Millimeters1 Cubic Inch= 16 Cubic Centimeters
1Foot= 0.3 Meter 1 Cubic Foot= 0.03 Cubic Meter
1Yard= 0.9 Meter 1 Cubic Yard= 0.8 Cubic Meter
1 Mile = 1.6Kilometers
J901N-11

#LUBRICATIONANDMAINTENANCE0 - 1
LUBRICATIONAND MAINTENANCE
CONTENTS
PagePage
CHASSIS ANDBODY. . 28ENGINE14
DRIVETRAIN ............................ 22 GENERAL INFORMATION .................. 1
GENERAL INFORMATION
INDEX
Page
Assist (Jump)Starting8
Chassis Lubrication ........................ 6
Classification ofLubricants2
FluidCapacities8
Fuel Usage2
HoistingRecommendations9
Introduction . . . . 1
Page
Maintenance Schedule—Heavy Duty Cycle5
Maintenance Schedule—Light Duty Cycle ........ 4
Parts andLubricationRecommendations3
Parts RequiringNoLubrication2
NoiseControlSystems1
Severe Service. . 1
TowingRecommendations10
VehicleStorage12
INTRODUCTION
Maintenance and lubrication servicerecommenda-
tions havebeencompiled to providemaximumpro-
tection forthe owner'sinvestmentagainst all
reasonabletypes of driving conditions.
Sincetheseconditionsvary with the individual op-
erator's driving habits, theareain which thevehicle
is operatedandthetype of service to which the ve-
hicle is subjected, itis necessary to prescribe lubrica-
tion andmaintenanceservice ona timeschedule as
well asa mileage interval basis.
Vehicles with a GrossVehicleWeightRating
(GVWR) of3 855 kg (8,500lbs.) or less must meet
light duty emissionstandards (see LIGHTDUTY
CYCLEMaintenancecharts).Vehicles with a Gross
VehicleWeightRating of (GVWR) 3 856 kg (8,501
lbs.) or more must conform to theheavy duty emis-
sion standards (see HEAVYDUTYCYCLEMainte-
nancecharts).
The GVWR for eachvehicleappearsontheSafety
Certification label,affixed to thelock pillar onthe
drivers door(Fig. 1).
Additional information canbe found intheOwner's
Manual provided with thevehicle.
SEVERE SERVICE
Vehiclesoperatingunderone or moreofthefollow-
ing conditions will requiremorefrequentservice (see
the Lubrication andMaintenanceSchedules—Heavy
Duty Cycle).
(a) In extremelydustyareas.
PU625
Fig. 1 Safety Certification Label
(b)50% or more ofthe vehicleoperation in
heavy city traffic in high temperatures (32°C or
90°F or higher).
(c)Prolonged idling.
(d)Extremelyshortrunoperation.
(e)Commercialtypeoperation.
(f)Operatedinwater.
After extendedoperation in mud,sand,water,
or similar dirty conditions,haveyourbrake drums,
brake linings, andaxle joints inspectedandcleaned
assoon as possible.This will preventanyabrasive
wear or unpredictable braking action.
It isthe owner'sresponsibility to determine
driving conditions(normal or severe serviceopera-
tion), to havethevehicleservicedaccording to the
Maintenance Scheduleand to payforthenecessary
parts andlabor.
NOISE CONTROL SYSTEMS
All vehicles built over 4 535 kg (10,000lbs.)Gross
VehicleWeightRating (GVWR) andmanufactured
for saleanduseintheUnitedStatesarerequired to